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Toyota Celica Supra 1986, Service And Repair Manual

The Toyota Celica Supra 1986 Service and Repair Manual is an essential resource for owners and enthusiasts looking to maintain or repair their iconic vehicle. This comprehensive manual covers all aspects of the Celica Supra, providing step-by-step instructions and diagrams. Download your free copy from manualshive.com today.

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Summary of Contents for Celica Supra 1986

Page 1: ...Toyota Service and Repair Manual 1986 Celica Supra Internal PDF links edited by MK2_Suprafan Toyota Motor Company NOT FOR SALE ...

Page 2: ...stem CH Clutch CL Manual Transmission MT Automatic Transmission AT Front Axle and Suspension FA Rear Axle and Suspension RA Brake System BR Steering System SR Body Electrical System BE Body BO Air Conditioning System AC Propeller Shaft System PR Appendix Section Page Service Specifications A Standard Bolt Torque Specifications B SST and SSM C Automatic Transmission Hydraulic Circuit D Electrical W...

Page 3: ...IS MANUAL IN 2 IDENTIFICATION INFORMATION IN 4 GENERAL REPAIR INSTRUCTIONS IN 4 PRECAUTIONS FOR VEHICLES EOUIPPEDWITH A CATALYTIC CONVERTER IN 7 VEHICLE LIFT AND SUPPORT LOCATIONS IN 8 ABBREVIATIONS USED IN THIS MANUAL IN 9 I IN 1 ...

Page 4: ...Jair task TROUBLESHOOTING tables are included for each system to help you diagnooe the system problem and find the cause The repair for each possible cause is referenced in the remedy column to quickly lead you to the solution REPAIR PROCEDURES Most repair operations begin with an overview illustration It identifies the components and shows how the parts fit together Example AOI USM I Washer Tt lr...

Page 5: ...xperienced technician with a FAST TRACK to the information needed The upper case task head ing can be read at a glance and only when necessary the text below it provides detailed information Important specifica tions end wamings always stand out in bold type REFERENCES References have been kept to a minimum However when they are required you are given the page to go to SPECIFICATIONS Specification...

Page 6: ...rforming electrical work dlsconnocc che negative from the beuery terminal b If il is necessary to disconnect the battery for inspec tion or rep1ir 1lway5 disconnect the cable from the negative 1 1 terminol which is grounded to lhe whiclebody c To p nc damage to the bottery le mir 11 pon loosen the terminal nut and raise the le straighl up without twisting It or prying it d Clean lhe bolterv termir...

Page 7: ...utor coil air filter e rburetor intake air pump and vcv from water e Never uw an impact wrench to remove or innall thermo switches or thermo sensors f When checking continuity at the wire connector insert the tester probe corefully to prevent terminals from bending g When using a vacuum fi U90 never force the hose onto a connector that is too large U 1 st down adapter inste d Once the hose has bee...

Page 8: ...hicle Lift and Support Locations VEHICLE LIFT AND SUPPORT LOCATIONS 0 Se m Notches Se am Notches JACK POSITION Front Center of crossmember Rear Center of rear axle housing PANTOGRAPH JACK POSITION 0 SUPPORT POSITION Safety stand ...

Page 9: ...Ovt Hood Com Dash Pot Double Vacuum Vel 10 Electronic ControiJed Transmission Electronic Controlled Unit Electronic Fuel Injection Exhaust Gas Recirculation Emergency Locking Retractor Evaporator Pressure Regulator Electronic Spark Advance ElectronicTuning Radio Evaporatilll Emission Control Exhaust manifold valve Except Front Left Front Right Ignition Intake manifold valve Independent Raar Suspen...

Page 10: ...LE MA 2 MAINTENANCE OPERATIONS MA 4 GENERAL MAINTENANCE MA 12 GENERAL NOTES Every se Vice item in me periodic mairmnance list must be performed F1llure to do ewn one item Cln ClUte theengineto Nnpoor1y net increase exhaust emissions ...

Page 11: ...tipped R MA 6 item 31 EVAP Charcoal canister I MA 6 litem 81 BRAKES Brtkt Iining and drums I I I I MA 6 o ttm 141 Bub pads and di5CS Front and I I I MA 7 btem 131 S th lint pipes and hoM I I I MA 7 itom 121 CHASSIS Stetringlinkage I I I MA 6 llttm 151 Boll jolntJ nd du t covtrs I I I MA 9 item 171 Automltic transmission manuel trlnlmiu ion I I 1 MA 9 ittm 181 dltferentlal eiC LSO end stetrintour h...

Page 12: ... 131 koh lint plpos I i1 I I MA 7 12 CHASSIS I I t I MA 8 itom 16 llolllolnu and dust I I I MA 9 item 11 Automatic trtnsmiu ion manual transmission MA 9 item 19 ditftuntlal and ttt tring gnr housing oil II R R R i ml Front and rcor IRS only w11eol IR MA 10 litem 211 I 8olu and nuts on I I I I II I I I I MA 11 item 22 MeinttnlnCI Mf YICU ind ieated by a star it required under the ttmu of N Eml tilo...

Page 13: ...ner ridges of the ribs Conventional typo only Check that the belt does not touch the bottom of the pulley groove If necessary replace tho drive belt b Using a belt tension gauge check the drive belt tension Belt tension gauge Nippondenso BTG 20 95506 000201or Borroughs No BT 33 73F Drive belt temion V ribbed type Conventional type Used bolt 135 20 lb New belt 170 10 lb Used bolt 80 t 20 lb New bol...

Page 14: ...1t blow from the back side thoroughly Then blow off the front side of tho oloment 5 REPLACE AIR FILTER Replace the air ciNner element with anew one 8 REPLACE ENGINE OIL AND OIL FILTER IS O pogt LU 3 Engine oil grade API grade S F or SF CC multigrade viscosity and fuel efficient oil Engino oil oopecity Drain refill with oil filter chtngo 5 1 liters 5 4 USqts 4 5 Imp qts 7 REPLACE ENGINE COOLANT a D...

Page 15: ...ated charcoal comes out If necessary replace the charcoal canister NOTE Do not attempt to wash the charcoal c Connect the hoses to the charcoal canister REPLACE GASKET IN FUEL FILLER CAP a Remove the old gasket O ring from the fuel _ fille cap Do not damage the cap i b Install the new gasket by hand j c Inspect the cap for damage or cracks i d Install the cap and check the torque limiter 10 INSPEC...

Page 16: ...lear of sharp edges moving parts end the r aust system d Cheek that the lines installed in grommets pm through the center of the grommets 13 INSPECT FRONT AND REAR BRAKE PADS A DISCS Front See BR 14 RMf S BR 20 i a Cheek m thicknns of the disc brake pads and cheek for irregular wear Minimum peel thickneu 3 0 mm 10 118 in NOTE If a squealing or scraping noise occurs from the front or rear brakes du...

Page 17: ... and dry road With the parking brake release button pushed in pull on the lever with 20 lb 9 kg 88 N of force Drive the vehicle for about 1 4 mile 400 motors in this condition Repeat this procedure 2 or 3 times Check parking brake lever travel 1 If necessary adjust the parking brake I CHASSIS 15 INSPECT STEERING LINKAGE a Check that the steering wheel freep lay Maximum steering wheel freeplay 30 m...

Page 18: ...5 mm 0 098 in If excessive play is found replace the ball joints b Inspect the dust cover for damage 18 CHECK AUTOMATIC TRANSMISSION OR MANUAL TRANSMISSION AND DIFFERENTIAL OIL Visually check the automatic transmission or manual t ran5 miaion and differential for oil leakage If leakage is found check for cause and repair 19 REPLACE MANUAL TRANSMISSION AND DIFFERENTIAL OIL a Remove the drain plug a...

Page 19: ...51iters 6 9 US qts 5 7 Imp qts d Start the engine and shift the selector into all posi tions from P through L and then shift into P e With the engine idling check the fluid level Add fluid up to the COOL level on tile dipstick CAUTION Do not overfill 21 REPACK FRONT AND REAR IRS ONLV WHEEL BEARINGS a Change tile front wheel bearing grease See pages FA 6 to 9 Groese grade Multipurpo groese NLGI No ...

Page 20: ...ood Auxiliary catch ope ltes properly Hood locks securely wtlen closed Front doors Door lod s operate properly Doors close properly Lilt back door Door lock operettt properly Seats Seat adjusts lily and locks securely at any posi tion Front sut back locks tteurely at any position Foklin9 lown rear seat b cks lock IICUrtly bl Road test Check the engine and chHils for ebnom l noltes Check that the h...

Page 21: ...rom opening when the primary latch is released INSIDE VEHICLE 7 LIGHTS a Check that the headlights stop light taillights turn signal lights and other lights areall working b Check the headlight aim 8 WARNING LIGHTS AND BUZZERS Check that all warning lights and buzzers funct ion properly 9 HORN Check that it is working 10 WINDSHIELD GLASS Check for scratches pits or abrasions 11 WINDSHIELD WIPER AN...

Page 22: ...27 BATTERY ELECTROLYTE LEVEL Check thet tho oloctrolyto level of oil batttry cells Is bttwttn the upper and lo r lwei lints on the cMe If level is low add d istilled woter only 28 BRAKE AND CLUTCH FLUID LEVELS a Check thet lht broke fluid level Is near tht upper lwei line on the through resttVOir b Chock thot the clutch fluid level is up to the top of the norrow neck of the through rttlfVoir 29 EN...

Page 23: ...er Hood CYUNOER BLOCK Components Removal of Engine Oloasoombly of CyHndor Block Inspection of Cylinder Block Dloa ombly of Ploton and Connectlng EM 1 Pego EM 2 EM 6 EM 6 EM 7 EM 7 EM 7 EM 7 EM 11 EM 13 EM 15 EM 1B EM 18 EM 18 EM 19 EM 22 EM 23 EM 29 EM 29 EM 31 EM 34 EM 36 EM 36 EM 36 EM 42 EM 48 Rod Assembly EM 48 Inspection of Piston and Connecting Rod Aaaombly EM 49 Roplacemont of Rod Bushing E...

Page 24: ...o injector Ttoubltthoot EFI ayttem Fl 8 No fu l In tank Fuel pum p not wOfking Fuet fiJttr ctoogod I fiHII clofild Of leaking EFI system problolmt R ir II ssary tSC yst problem Chock tSC avttem Fl 60 Spartt plugs feultv Inspect plugs IG 5 Low compre tlon Chock compression EM 8 Rough kUt tttUt or Vacuum Ieake Ropelr 11 necessary mluet PCV holtl EGR valve lnt kt m nitold Air lnta1 e ch ember Thtottl...

Page 25: ...system problems Repair as necesury runs after ignition switch is turned off Muffler explosion Deceleration fuel cut system always off Check EFI lfuel c utJ system Fl 79 aher fire on deceleration only Muffler explosion Air cleaner clogged Check air cleaner after fire all the time EFI system problem Repair as nee ssary lncouect igntt ion timing Reset timing IG 10 Engine backfires Voc uum loak Check ...

Page 26: ... Injector faUih y Deee redon fu cut system faulty opeedtoo Chicle tSC system fl 80 Sp uk 1J1u90 lwlty lnlptC1 pfug J IG eGR l ltl m lii WIVI on CM kEGRayatem low eompteatlon Check compression EM 8 Tire improperty Inflated lnfhne tlrea to proper pressure Clutc h slips Troubleshoot clutch Brakes dr Trouble hoot btakes U pltNint odOf lneorre t idle apeed Check ISC system fl 80 Incorrect 9 1ition timi...

Page 27: ... ftl 3 MEASURE HCI CO CONCENTRATION AT IOLE Wait at least one minute before measuring to allow the concentration to stabilize Complete the measuring within three minutes If the HC CO concentration does not conform to your regulations see the table below for possible causes TROUBLESHOOTING HC co Symptoms CeUMS H gh NOtm l Rough idlo I Faulty ignition lncouecc timing Fou d shorted or imptoperly gapp...

Page 28: ...rged battery to obtain en gine revolution of more than 250 rpm ldl Repeat steps Ia through c for each cylinder Cornpression pressure 11 5 kg em 1184 pol 1 128 kPal Minimum pressure 9 0 kg em 1 128 pel 883 kPa Dlffarence between eech cylinder l eaa than 1 0 kglcm 114 pel 98 kPa e If C l linder compression in one or more cylindeJs is lo w pour a small amount of engine oil into the cylinder through t...

Page 29: ... WOt M TIMING BELT COMPONENTS CAUTIONS Timlno Belt 1 Do not bond twlot or tum the belt inside out 2 Do not allow the l tto c orM into contact with oi welor or ateam INSPECTION AND ADJUSTMENT OF VALVE TIMING 1 DISCONNECT CABlE FROM NEGATIVE TERMINAl Of BATTERY 2 REMOVE N0 2 FAN SHROUD 3 REMOVE AIR INTAKE CONNECTOR ...

Page 30: ...g pulley one tooth be tween the matchmarks realign the matchmarks in accordance with step 7 II the matchmarks are aligned or the difference is less than one timing pulley tooth proceed to step 8 7 ADJUSTMENT OF CAMSHAFT TIMING PULLEY MARKS lal Loosen the idler pulley set bolt a little and shift the idler pulley to the alternator side with a screwdriver and wrench bl Finger tighten the idler pulley...

Page 31: ...ley marks B CHECK MATCH HOLE OF CAMSHAFT a Clean the camshaft match holes with compressed air b Align the match hole of the camshaft w ith that of the camshaft housing by turning the crankshaft pulley c After alignment make a note of the crankshaft pul ley angle on the No 1 timing belt cover NOTE Match hole alignment should be done separately for tho IN and EX sides If the crankshaft pulley angle ...

Page 32: ...ng hole find one that is nearly overlapped and rotate the crank shaft s lightty to over lap it and then insert the pin The crankshaft pulley angle can be adjust approxi mately 3 by changing the pin hole to the next one f Using SST to hold the camshaft timing pulley Install the pullay sat bolt SST 09278 54012 Tor 700 kg em 51 It lb 89 N m CAunON Do not make uae of the timing belt tontlon when tight...

Page 33: ...l Cold UHCI belt 5 7 mm 1 0 20 0 28 in I New belt 4 6 mm 0 16 0 241n l Hot IReferencel 3 5 mm 1 0 12 0 20 in l tel tf the measurement is not within specific atlon adjust with the idler pulley 11 INSTALL NO 3 TIMING BELT COVER 12 INSTALL OIL FILLER CAPANO CYLINDER HEAD COVER OF EXHAUST SlOE 13 INSTALL AIR INTAKE CONNECTOR 14 INSTALL N0 2 FAN SHROUD 15 CONNECTCABLE TO NEGATIVETERMINAL OFBATTERY REMO...

Page 34: ...rewdriver and wrench b fingertighten the set bolt and then relieve the timing belt tension 12 REMOVE TIMING BELT FROM CAMSHAFT TIMING PULLEYS 13 REMOVE CAMSHAFT TIMING PULLEYS Using SST to hold the pulley remove the pulley set bolt timing pulley and match pin SST 09278 640 12 CAUTION Do not mako uae of the timing bolt tenolon when removing end ln11alling the pulley oet bolts NOTE The exhaust and i...

Page 35: ... ing b Remove the No 1 timing belt cover c Remove the timing belt 17 REMOVE IDLER PULLEY AND TENSION SPRING 18 REMOVE CRANKSHAFT TIMING PULLEY Using SST and socket wrench remove the crankshaft tim ing pulley SST 09308 10010 19 REMOVE OIL PUMP DRIVE SHAFT PULLEY UsingSSTto holdthe pulley remove the set boltend puOey SST 09278 5401 2 INSPECTION OF COMPONENTS 1 INSPECT TIMING BELT a Premature parting...

Page 36: ...d on only one side of the belt check the belt guide and the alignment of each pulley el If there Is noticeable wear on the belt teeth check the timing belt cover gasket for damage and checlc for eoneet gasket Installation Checlc for foreign material on the pulley t h 2 INSPECT IDlER PULLEY AND TENSION SPRING lal Cheek the turning smoothness of the timing belt Idler pulley lbl Check the free length...

Page 37: ...tim ing belt during disassembly b Install the timing belt on the crankshaft timing pulley EX IN 5 INSTALL NO 1 TIMING BELT COVER 6 INSTALL BRACKET OF COOLER COMPRESSOR 7 INSTALL CRANKSHAFT PULLEY lol Install the crankshaft pulley and pulley bolt lbl Using SST to hold the crankshaft pulley torque the pulley bolt SST 09213 70010 and 09330 00021 Torque 2 200 kg em 1169 ft lb 218 N ml 8 REMOVE OIL FIL...

Page 38: ...ng propet ton sk n between the crankshaft timing pulley and the camshaft tlmlng putley on the exhaust de NOTE ln 1t1U the timing belt while the engine is cold e Loosen thtldltr pulley eet b t and stretch the timing belt Torque the idler pulley set bolt TO quo 500 kg em liM ft b 49 N ml NOTE Make aurt that tt e timing bett tension at A IseQUal to tNt at 8 H There are three pin holes on the camshaft...

Page 39: ...te the crankshaft two times clockwise lbl Check the timing marks Refer to the section of IN SPECTION AND ADJUSTMENT OF VALVE TIMING see page EM 71 11 CHECK TIMING BELT TENSION ISee ttep 10 on pogo EM 11I 12 INSTALL CYUNDER HEAD COVER AND GASKET ON EXHAUST SIDE 13 INSTALL OIL FILLER CAP 14 INSTALL NO 3 nMING BELT COVER AND GASKET 16 INSTALL FLUID COUPLING WITH FAN SHROUD 16 INSTALL RADIATOR UPPER H...

Page 40: ...ARATION FOR REMOVAL V lvt Spting Vtlvt Seem Oil Stol Val t Sorint s t 1 DISCONNECT CABLE FROM NEGATIVE TERMINAL Of BATTERY 2 DRAIN COOLANT 3 DISCONNECT EXHAUST PIPE FROM EXHAUST MANIFOLD 4 REMOVE THROTTLE CABLE BRACKET FROM CYliNDER HEAD COVER CIO AITI 6 REMOVE ACCELERATOR AND ACTUATOR CABLE BRACKET FROM CYUND 11 HEAD COVER ...

Page 41: ... 8 DISCONNECT RADIATOR UPPER HOSE FROM THER MOSTAT HOUSING 9 DISCONNECT TWO HEATER HOSES REMOVAL OF CVUNDER HEAD 1 REMOVE AIR INTAKE CONNECTOR a Disconnect the No 1 air hose from the air intakecon nector lbl Remove the two clamp bolts c Loosen the throttle body hose clamp and remove the air intake connector and the connector pipe 2 DISCONNECT FOLLOWING HOSES lal No 1 water by pass hose from ISC va...

Page 42: ...head w ith the cap end w ires REMOVE SPARK PLUGS DISCONNECT FOLlOWING WIRES a Cold start injector wire lbl Water temp sensor w ire c Start injection time switch wire d Water temp sending unit wire a Throttle position sensor w ire connector f ISC valve wire connectors DISCONNECT COLD START INJECTOR FUI L HOSE FROM DEliVERY PIPE 9 REMOVE AIR INTAKE CHAMBER at Remove the five bolts and two nuts lbl L...

Page 43: ...pump pulley wilh tho drive bell bl Remove lhe PS pump slay lcl Remove the PS pump from the bracket d Lay the PS pump to one side without disconnecting the hoses 16 REMOVE EXHAUST MANIFOLD fa Remove the five nuts and the two heat insulators b Remove seven nuts and the exhaust manifold 16 REMOVE TIMING BELT AND CAMSHA TIMING PULLEYS See steps 9 to 13 on pave EM 121 17 REMOVE OIL PRESSURE REGULATOR f...

Page 44: ...damage the cylinder heed and block aurfec on the cylinder h d gasket side 21 REMOVE EGR COOLER DISASSEMBLY OF CYLINDER HEAD See page EM 1Bl 1 REMOVE CYLINDER HEAD COVERS Remove the two cylinder head covers by loosening the screws 2 REMOVE NO 1 AND NO 2 CAMSHAFT HOUSINGS WITH CAMSHAFT Remove No 1 and No 2 camshaft housings by loosening the nuts front sidel and bolts CAUTION Looaen each cemahelt hou...

Page 45: ... bring each piston to top dead center Scrape the carbon from the piston top fbi Remove all gasketmaterial from the top of the bl k Blow carbon and oil from the bolt holes 2 CLEAN COMBUSTION CHAMBERS Using a wire brush remove all the carbon from the com bustion chambers CAUTION Be careful not to acrotctl the headgasketcon tact s face 3 CLEAN VALVE GUIDES 4 Using a valve guide brush and solvent clea...

Page 46: ... head tuf f ee w81pege 0 10 mm 10 0039 ln Maximum intake menifokt aurt ce w pege 0 10 mm 10 0039 ln Maximum ext euat manifold surface w_ o 10 mm 10 0039 ln Maximum camshaft hou ng surface warpage 0 10 mm 10 0039 ln If warpage is greator than specified value replace the head INSPECT CYLINDER HEAD FOR CRACKS Using a dye peneuant chack thecombustionchambor ln take and exhaust porta heed surface and t...

Page 47: ...980 mm 0 31 311 0 3142 ln cl Subtract the valve stem measurement Irom the valve guide measurement L 2 Standard oil clearance Intake 0 025 0 060 mm 0 0010 0 0024 ln Eol auot 0 030 0 065 mm 0 0012 0 00261n l Maximum ol d rance Intake 0 06 mm 10 0031 in Exhaust 0 10 mm 1 0 0039 ln l If the clearance is greater than following values replace the valve and guide 10 IF NECESSARY REPlACE VALVE GUIDE Cal B...

Page 48: ...guide buohlng bore dloo lion cold 13 06 13 077 mm 10 6138 0 6148 ln I Heat the cylinder head to about 90 C C 194 F g Using SST end 1 hammer drivein the new valve guide until th nap ring makes contact with the c yUnder h lad SST 0920Hl0011 h Using a sharp S mm reamer ream the valve guk Se to obtain spedfied cle rence between the guide ond new valve Stendard oil Intake 0 026 0 060 mm 0 0010 0 0024 l...

Page 49: ...e aeets b Check the valve aeating potition Apply e thin coat of pruuian blue or white lead to the valve l ace Install the valve While applying light pressure to the vetve rotate the valve agelnst the seat c Check tho valve lace and seat for the following If blue appeara 360 around the face the valve is concentric If not replace the vatve If blue IPJMitS 360 around the valve seat the guide and seat...

Page 50: ... a spring tester check the tension ofeach spring at the specified Installed height Installed height lntae elde 40 0 mm 11 575 in l Exhaust aide 43 0 mm 11 693 ln lnstaled tenelon lntalce aide 34 7 38 3 kg 178 6 84 4 lb 340 378 Nl 33 3 38 7 kg 173 4 80 9 lb 327 380 Nl If not within the Installed tension specification replace the spring 14 I_ NSPECT INTAKE EXHAUST MANIFOLDS AND AIR IN TAKE CHAMBER U...

Page 51: ...are installed in the correct order lbl Install the valve spring seats and new seals c Install springs and spring retainers on the valves d Using SST compress the valve springs and place two keepers around the valve stem SST 09202 43013 e Tap the stem lightly to assure proper fit INSPECTION OF CAMSHAFT 1 MEASURE CAMSHAFT THRUST CLEARANCE Using a dial gauge measurethe camshaft ttlrust clearance Stan...

Page 52: ...n V blocks end measure tho runout at the center journel Maximum circle runout 0 04 mm 10 0014 ln I ff the runout is greeter then maximum aftowable replace the camshaft c Uslng a micrometer measure the journal diameter S d jourNI lamot No 1 37 9 19 37 976 mm 1 4944 1 4861 ln No 2 42 959 42 976 mm 11 6913 1 69111 in No 3 43 4 19 43 476mm 11 7110 1 71161n No 4 43 969 43 975 mm 11 7307 1 73131n No 6 4...

Page 53: ...HAFT IS REMOVED FROM CAMSHAFT HOUSING Cal Remove the oil seal from the camshaft housing Using a screw driver pry out the oil seal b Install the new oil seal on the camshaft housing Apply MP grease to the oil seal Using SST install the new oil seal SST 09214 60010 2 IF CAMSHAFT HOUSING IS INSTALLED ON CYLINDER HEAD a Cut the oil seal As shown in the figure cut off the oil seal lips b Remove the oil...

Page 54: ...eck ball SST 09276 70010 cl Repeat steps a and bl when the plunger stroko Is beyond about 0 5 mm 0 020 in dl Replace the looh adjuster w ith a new one If the plun ger stroke exceeds 0 5 mm 0 020 in l evan ehcr repeating steps Ia and b several times NOTE Do not disassemble the lash adjuster 6 LASH ADJUST R LEAl DOWN T ST a Bleed the lash adjuster bl Using a leak down t11ter apply 20 kg 44 1 lb 196 ...

Page 55: ...e camshaft housing over dowels on the cylinder head lei Install and tighten the housing nuts and bolts gr du ally in three passel in the sequence shown Torque the nuts end bolts on the final pass Torque 220 kg cm 118 ft lb 22 N ml 9 INSTALL CYLINDER HEAD COVERS tal Install the gaakets to the cylinder heads lbl Piece head covers on the camshaft housing and In stall the soals ond screws ...

Page 56: ... que the bolts on the final pass SST 09043 38100 Torque 800 kg em 68 It lb 78 N ml 4 INSTALL NO 2 TIMING BELT COVER tal Position a new gasket on the cylinder head b Install the No 2 timing belt cover with three bolts and two nuts Torque 130 kiJ cm 9 ft lb 13 N m 6 INSTALL OIL PRESSURE REGULATOR a Position a new gasket on the cylinder head b Install the oll pressure regulator with three bolts c Ins...

Page 57: ...FI WIRE HARNESS TO ECU 12 INSTALL WATl A OUTLET HOUSING lal Install the w ater outlet housing w ith two bolts lbl Connect the water by pass hose and tight the clamp 13 INSTALL NO 1 FUEL PIPE AND PULSAT10N DAMPER lal Finger tighten the pulution damper end union bolt with new gaskets on tho fuel pipe bl Tighten the fuel pipe being careful not to bend it 14 INSTALL AIR INTAKE CHAMBER a1 Position 1 ne...

Page 58: ...ct the wiros to the plugs 19 INSTALL VACUUM PIPE SUBASSEMBLY Install tho vacuum pipe with bond cable and three bolts 20 CONNECT FOLLOWING HOSES tal Emiuion concrol hoses to the throttle body endair in take chamber tbl Fuel hoses to tho fuol hose support c Two PCV hoses to the cylinder head cover dl No 2 water by paso hose to throttle body e No 1 water by pass hose to ISC valve 2 1 INSTALL AIR INTA...

Page 59: ... INSTALL ACCELERATOR AND ACTUATOR BRACKET TO CYLINDER HEAD COVER CABLE 28 INSTALL THROTTLE CABlE BRACKET TO CYLINDER 29 HEAD COVER lor AJT FILL WITH COOLANT Close the radiator and engine drain cocks and fill with coolant Total capacity Dry fll MIT 8 0 litera 8 6 US qts 7 0 Imp qtsl A T 7 91itera 8 3 US qts 7 0 Imp qtsl 30 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY 31 START ENGINE Warm up the en...

Page 60: ...EMOVAL OF ENGINE I 1 000 e n 102 I 220 221 I 1 DRAIN COOLANT FROM RADIATOR AND CYLINDER BLOCK 2 REMOVE HOOD 3 REMOVE BATTERY 4 REMOVE WASHER TANK 6 REMOVE AIR CLEANERCASE AIR FLOW METER ANO AIR INTAKE CONNECTOR P1PE REMOVE THROTTLE CABLE BRACKET FROM CYLINDER HEAD COVER fo A TI 7 REMOVE ACCELERATOR AND ACTUATOR CABLE BRACKET FROM CYLINDER HEAD COVER ...

Page 61: ...ctu tor vacuum ho se from the air int1k1 chamber with cNiM control a tem c EGR valve vacuum nose 10 DISCONNECT TWO HEATER HOSES 11 DISCONNECT EA WIRE HARNESS FROM ECU tal Remove the glove box lbl Remove the computer c Disconnect the three connectors d Pull out the EFI wire harness from cowl panel 12 REMOVE FAN SHROUD AND FLUID COUPliNG tal Remove the radiator upper hose bl Remove the four shroud b...

Page 62: ... REMOVE ENGINE MOUNTING BOLTS ON EACH SIDE OF ENGINE AND GROUND STRAP 19 REMOVE SHIFT LEVER FROM INSIDE OF VEHICLE MfT only 20 RAISE VEHICLE CAUTION Be sure tho vehicle is curoly supported 21 DRAIN ENGINE OIL 22 DISCONNECT EXHAUST PIPE FROM EXHAUST MANIFOLD 23 REMOVE EXHAUST PIPE CLAMP FROM TRANSMISSION HOUSING 24 REMOVE CLUTCH RELEASE CYLINDER MfT only 26 REMOVE SPEEDOMETER CABLE 26 DISCONNECT SH...

Page 63: ...T 32 PLACE JACK UNDER TRANSMISSION Be sure to put a wooden block between the jack and the transmission pan to prevent damage 33 INSTALL A WOODEN BLOCK BETWEEN COWL PANEL AND CYUNDER HEAD REAR END TO PREVENT DAMAGE TO HEATER HOSE 34 REMOVE ENGINE REAR SUPPORT MEMBER WITH GROUND STRAP FROM BODY 35 REMOVE ENGINE WITH TRANSMISSION FROM VEHICLE Cal Attach the engine hoist chain to the lift brackets of ...

Page 64: ...1he timing belt See pages EM 11 to 13 d Remove the No 2 timing belt cover lei Remove the air Intake chamber stay If Using SST remove lhe cylinder heed bolts SST 09043 38 100 lgl Remove the cylinder head assembly 6 REMOVE Oil ALTER Using SST remove the oil filter SST 09228 44010 6 REMOVE OIL LEVEL GAUGE 7 REMOVE ALTERNATOR 8 REMOVE FUEL FILTER 9 REMOVE FUEL HOSE SUPPORT 10 REMOVE WATER BY PASS PIPE...

Page 65: ... PUMP ASSEMBLY a Remove the union bolt and nut and remove the oil pump outlet pipe b Remove bolt holding the oil pump and remove the oil pump assembly 18 MEASURE CONNECTING ROD THRUST CLEARANCE Using a dial gauge measure the thrust clearance Standard clearance 0 180 0 298 mm 10 0083 0 0117 ln Mulmum clearance 0 3 mm 0 012 ln tf clearance is greater than maximum replace the connect ing rod and or c...

Page 66: ...rip of plaatlgage across tho crankshaft pin gl Align the rod and cap marks and fit on the cap Torque the rod cap nuts Torque t50 kg em 33 ft lb 44 N ml NOTE Do not turn the crankshalt hi Remove the rod cap Iii Measure tho plestigage at Its widest pOint Standard cl enco 0 021 0 053 mm 0 0008 0 0021 ln Maximum __ 0 08 mm 0 0031 ln If thoclearance Isgreater than maximum replace the bear ings end or g...

Page 67: ... connecting rod cap end crankshaft Rod cap No 1 1 2 1 2 3 2 3 3 Crankshaft No 0 1 0 2 1 0 2 1 2 Bearing No 1 2 2 3 3 3 4 4 5 Example Rod cap No 2 Crankshaft No 1 Bearing No 3 18 PUSH OUT PISTON AND CONNECTING ROD ASSEM8lY a Remove all ttle c arbon from top of the bore to the top of the cylinder lbl Coverthe rod bolts w ith a short piece of hose to pro teet the crank pin from damage lcl Push the pi...

Page 68: ...ng cop bolla pry the bearing cap fore and aft and remove it with the lower bear ing and thrust washers No 4 journal only NOTE Keop the lower bearing inserted with the cap Arrange the c aps and lower thrust wethers In correct order c lift off tho crankshaft NOTE Keep the upper bearings and upper thrust wash 4 ers ffor theNo 4 journal only insertedin the cylinder b oe k d Clean the journals and bear...

Page 69: ...rind the main journals Unden lzed bearing U S 0 25 0 60 NOTE If replacing a standard size bearing with a stan dard oil clearance replace with one having the same num ber tf the number of the bearing cannot Le determined select a bearing from the table below according to the num bars imprinted on the cylinder block and crankshaft Cylinder Block 1 2 1 3 2 I 3 2 3 No Crankshaft No 0 0 1 0 I 2 1 2 2 B...

Page 70: ...d axial directions If any of the following meuurements are not w ithin the specification rebore the cylinder See pege EM 50l a Cylinder diameter Is greater than the maximum per missible limit On otandard sized piston Maximum diameter 83 25 mm 3 2776 ln On oversized platon 0 S 0 60 Maximum diameter 83 75 mm 3 2972 in On oversized piston 0 S 0 761 Maximum diameter 84 00 mm 3 3071 ln l On ovenlzed pi...

Page 71: ...ng needle noso pliers remove me snap rings from the piston bl Hoat thopiston in hot water to approx 60 C 140 Fl c Using a plastic l aced hammer and driver tap the pin lightly to remove the pin from the piston NOTE The piston and pin are a matched set Keep the piston piston pin and rings andconnecting rod together f eac h cylinder INSPECTION OF PISTON AND CONNECTING ROD ASSEMBLY 1 CLEAN PISTON a Sc...

Page 72: ...clearenco No 1 0 03 0 07 mm 0 0012 0 0028 ln No 2 0 02 0 08 mm 0 0008 0 0024 in If the clearance Is greater than maximum replace thepiston ring and if necessary the piston 4 MEASURE RING END GAP lei Insert the piston ring into the cylinder bore lbl Using a piston push the piston ring alittle beyond the bottom of the ring travel 100 mm 3 94 in l from top surlage of cylinder block cl Using a feeler ...

Page 73: ...icator measure the lnalde diameter of the rod bushing Using a micrometer measure the diameter of the piston pin Check that tho difference between the measure menta lo leu than the oil clearance limit Stan Mrd oil ciHronco 0 006 0 011 mm 0 0002 0 0004 ln Mulmum oUcloaranco 0 015 mm C0 00081n If the clearane e Is greater than maximum replace the rod busing REPLACEMENT OF ROD BUSHING 1 REMOVE ROD BUS...

Page 74: ...ED PISTON 0 S pistons with pins are available in the sizes listed Replace pistons in motclled sets Take the largest bore measured and select the oversized piston for that bore Bore all cylinders for the oversized piston selected 2 CALCULATE DIMENSION TO BORE CYUNDERS 3 a Using a micrometer measure the piston diameter at right engles to the piston pin center line 22 mm 0 87 in from the pist0 1 head...

Page 75: ...e ring endgaps are in the shaded area as show n CAUnON Do not olgn the end geps 3 INSTALL BEARINGS ta Install the bearings in the connecting rods and rod caps b Lubricate the face of the bearings w ith engine oil INSPECTION AND REPAIR OF CRANKSHAFT 1 MEASUR CRANKSHAR Ia Place the crankshaft on V blocks lb Using a runout gauge measure the c ircle runout at the center journal Maldmum circle runout 0...

Page 76: ...I INSPECTION AND REPAIR OF OIL PUMP DRIVE SHAFT COMPONENTS 1 INSPECT Oil PUMP DRIVE SHAFT a Using a micrometer measure the journal diameter Standercl journal caamete Front 40 969 40 976 mm 1 8128 1 8132 in l Rear 32 969 32 976 mm 1 2978 1 2982 in l lbl Using a cylinder micrometer measure the bearing bore c Subtract the joumel dl meter measurement from the bearing bore mea1urement Stonderd oU cle c...

Page 77: ...e the drive shaft thrust clear ance between the thrust ptete and eoUar Stendwd thruot cleoronco 0 08 0 13 mm 0 0024 0 00 11 ln l Moxlmum thruot cleoronco 0 3 mm 0 012 ln l If clearance is greater than maximum replece the thrust plale and or collar 4 IF NECESSARY REPlACE THRUST PlATE AND COUAR a Using SST remove the thrull plate and collar SST 09960 20016 lbl lnrtal tholhrust plate andcone in the o...

Page 78: ...nd pump drtvo ol aNII fa Using a screwdrJvor remove the oil seel lb Apply MP grooso to the oil seal lip lei Using SST install the new oil seal SST 09214 41010 and 09506 35010 2 IF REAR OIL SEAL RETAINER IS REMOVfD FROM CYLINDER BLOCK Replloeement of rear o1 seoll a Using a screwdrivet remove the oil see1 lbl Apply MP grease to the oil seal lip lei Using SST install the new oil seal SST 09223 41020...

Page 79: ... it contacts the oil lip surface for cracks Of damage dl Apply MP grease to the oil seal el Using SST install the new oil seal SST 09214 41010 6 IF REAR OIL SEALRETAINER IS INSTAUEDON CYLINDER BLOCK Replacement of rear oil seall al As shown in the figure use a knife to cut off the oil seal lip bl Using e screwdriver pry out the oil seal NOTE Be cereful not to demage the cranksheft Tape the screwdr...

Page 80: ...ith the oil grooves facing out lbl Install the bearingCall in numbered order with arTows feeing forward Tighten the bolts to the specified tor que inthe sequence thownandin two or three passeo Tor 1 040 kg em 176 ft lb 102 N ml tel Install the dial gauge and measure the crankahaft thrust clearance while l fYing the crankshaft back and forth with a screwdriver s ct d c1Mr8nee 0 06 0 25 mm 10 0020 0...

Page 81: ... pump and holding bolt Torque the bolt Torque 220 kg em 16 ft b 22 N ml c Install the oil pipe with gasket lock washer and un ion bolt Tighten the oil pipe nut and bolt Tor 360 kg em 25 ft lb 34 N ml INSTALL OIL PUMP DRIVE SHAFT While turning the drive shaft slowly insert so as not to damage the drive shaft bearing Torque tho bolt Tor 130 kg cm 9 ft b 13 N ml INSTALL REAR OIL SEAL RETAINER INSTALL...

Page 82: ... em 58 fl 78 N ml lei Install the elr intake chamber stay ldl Install the No 2 timing b lt cover lei Install tho timing belt See page EM 14 to 171 Ill Connect the PCV hose to the cylinder block g Con nec t the No 1 water by pass hose to the water by pass pipe 19 REMOVE ENGINE STANO 20 INSTALL REAR END PLATE 21 INSTALL FLYWHEEL OR DRIVE PLATEON CRANKSHAFT Install the flywheel or drive plate on cran...

Page 83: ...ng bolts on each side of the engine Ce Remove the hoist chain 3 RAISE VEHICLE CAunON Be aure tha vehicle Ia curely aupported 4 INSTALL ENGINE REAR SUPPORT MEMBER WITH GROUND STRAP TO BDOY 6 INSTALL INTERME OIATE SHAFT TO PROPELLER SHAFT 8 INSTALL POWER STEERING GEAR HOUSING a ln stall the geer housing with two brackets T 770 kg em 58 fNb 78 N ml b Connect the tut rod ends and install a new eotter ...

Page 84: ...the intake manifold b ActuatOI vacuum hose to the intake manifold with cruise control system c EGR valve vacuum hose 17 CONNECT FOLLOWING WIRES AND CABLES a Ground to the cylinder heed b Oxygen sensor wire c Oil pressure sending unit wire d ECT connectors e High tension cord from the ignition coil II Distributor connector g Water temp sending unit w ire h Temp switch wire for A Tl i Solenoid resis...

Page 85: ...4 INSTALL CLUTCH RElEASE CYLINDER MIT onlyl 211 CONNECT SHIFT LINKAGE TO SHIFT LEVER AfT only 26 CONNECT EXHAUST PIPE TO EXHAUST MANFOLD 27 INSTALL EXHAUST PIPE CLAMP TO TRANSMISSION HOUSING 28 LOWER VEHICLE 29 INSTALL POWER STE ERING PUMP ONTO BRACKET a lnttoll tha PS pump and otoy b lnttall the PS pump pulley with the drive belt lcl Pry on tha eltemotor to obtein the specified belt ten tlon See ...

Page 86: ...NSTALL HOOD 35 START ENGINE Warm up the engine end 1 1 Speet for leaks 36 PERFORM E NGINE ADJUSTMENT lei Recheck the ignition timing See page IG 10 b Retighten the cylinder head bolts See step 1B on page EM 60 37 ROAD TEST Perform a road test 36 RECHECK COOLANT AND ENGINE OIL LEVEL ...

Page 87: ...HEMATIC DRAWING EC 3 POSITIVE CRANKCASE VENTILATION IPCVI SYSTEM EC 4 FUEL EVAPORATIVE EMISSION CONTROL lEVAPI SYSTEM EC 5 DASH POT IDPI SYSTEM EC 7 EXHAUST GAS RECIRCULATION IEGRI SYSTEM EC 10 THREE WAY CATALYST ITWCI SYSTEM EC 15 NOTE TROUBLESHOOTIIIG S e page EM 2 EC 1 ...

Page 88: ... FI MI evaporative emission control EVAP Rtduc ev aporetiw HC Dun pot DP RtdUCOI HC an l CO Exhaust gas reeirculttlon EGR AtduCII NOx Three way cattlyst TWC Rt lucto HC CO an l NOx Elo tronic fuol l ction EFI ates eM engine condltioos fOf reduction of 1XhiUS1 e mis sionl Remarks for Inspection end rep1ir of the EFI system refer to Efl seetkm ...

Page 89: ... EMISSION CONTROL SYSTEMS Component layout and Schematic Drawing EC 3 ToEC J Oxvgon Son orl COMPONENT LAYOUT AND SCHEMATIC DRAWING EGR Cool1r Temp Stmor ECU ...

Page 90: ...mission cr1nkcase btow by gas HC i s routed through 1wometering oriftc s to the intake manifold for combustion in the cylinders INSPECTION OF PCV HOSES AND CONNECTIONS 1 VISUALLY INSPECT HOSES CONNECTIONS AND GASKETS Check for cracks leeks or damage 2 CLEAN TWO ORIFICES Clean off anygum depositsin theorifices with solventand blow out with compressed air ...

Page 91: ...oshJOnld aboYe purge port Cl ock Vllvt V euum Valve Cenlt t CMclt Vetv Ct ck Vo No In e _ etod Fuoi iHCI Ill 121 131 Cop HC from cank is ebl otbed In CLOSED he canister OPEH HC from C dt t ted into au intlke dllmber OPEN CLOSED CLOSED HC from t4nk is abtOfbed in the canister CLOSED OPEH OPEN lAir Is kMt into the fuol tonk INSPECTION OF FUEL VAPOR LINES FUEL TANK AND ALLER CAP 1 VISUALlY INSPECT LI...

Page 92: ...AN CANISTER FILTER Clean the filter by blowing 3 kg em 143 psi 294 kPa of compressed air into the tank pipe while holding the other upper canister pipe closed NOTE Do not attempt to wash the canister No activated carbon should come out 5 INSTALL CHARCOAL CANISTER INSPECTION OF BVSV CHECK BVSV BY BLOWING AIR INTO PIPE a Drain the coolant from the radiator into a suitable con tainer b Remove the BVS...

Page 93: ...ooensthe throttle liNt s tightty more then at idle Thtt c euses the ai fuel mhcture to burn completely Condition Dlophfogm VTV Ttwonlo Vol Idling Pushed in by return force of thfonle CLOSED Jdle speed position vatve Notmal driving Pushed out by diaphr gm apring OPEN Hlghopoodposition Oece ration Puahed in by return f orce of th ron e CLOSED Slightly_ and henllowtvcloses valve to kite potition ...

Page 94: ... Pinch the vacuum hose between OP and VTV c Release the throllle valve Cdl Check that the DP is set DP ltlng speed 2 000 rpm If notal specified speed edjust with the DP adjusting bolt 4 CHECK OPERATION OF VTV tal Set Ihe DP speed In the same procedure as above tal 10 Cl lbl Release the pinched hose and check thai the engine returns to idle speed in about 1 second IF NO PROBLEM IS FOUND WITH THIS I...

Page 95: ...V 1 CHECK AND CLEAN FILTER ON VTV 2 al Check the filter lor contamination or damage bl Using compresud air clean the filter CHECK VTV BY BlOWING AIR INTO EACH SIDE faI Check that air flows without resistance from 8 to A fbi Check that air flows with difficulty from A to B ...

Page 96: ...EC 10 EMISSION CONTROL SYSTEMS Ekhaust Gas Recirculation IEGRl System EXHAUST GAS RECIRCULATION EGR SYSTEM EGA Cooltr EFI Computtr EGR Po EGR Port Pott vsv EGR Vtc vum Moduta1or EGR Valvo EGR v Modutlta ...

Page 97: ... CLOSED Nor EGA rtcncul Polhton d be Ill Plll lfJJI c oft OPENS PHiage CLOSED Nor Above 3 c ClOSE tWHn EGA pott lOW atanlty alteJ to ttmOtDhrtre ftc ltctJa ted 114S Ft end R port 121 nat t between ClOSES ego HIGH low end high to 11mo n re OPEN Rtcireullted Po itlontd tbove 131 CLOSE pasuoe Rtehcul ttd R pon HIGH to atmojphere OPEN lntftastl Remar kt Pfessure incretlt Modult tor doses EGA varve O e...

Page 98: ...uge Vacuum Gauge at idle 4 CHECK VSV WITH COLD ENGINE at The coolant temperature should be below 57 c 135 Ft lbl Check that the vacuum gauge indicates zero at 2 500 rpm 6 CHECK VSV AND EGA VACUUM MODULATOR WITH WARM ENGINE IaI Worm up the engine lbl Check that the vacuum gauge indicate s about 70 mm Hg 12 76 in Hg 9 3 kPal at 2 500 rpm let Check that tho vacuum gauge indicates zero at idle ldl Dis...

Page 99: ... vacuum modulator lbl Block ports P and R with your finger c Slow air into port0 Check that the air passes through to tile air filter side freely dl Start the engine and maintain engine speed at 2 500 rpm tel Repeat the above test Check that there is a strong resistance to air flow lfl Disconnect the vacuum hoses to the proper locations If a problem is found replac e the EGR vacuum modulator INSPE...

Page 100: ... replace the VSV 3 CHECK FOR OPEN CIRCUIT Using an ohmmeter measure the resistance between the terminals Specified reaiatonct 38 44 0 a t 20 C 68 Ft If the res istance is Mt within specification replace the vsv INSPECTION OF EGR VALVE 1 REMOVE EGR VALVE Check the valve lor sticking and heavy carbon cleposits II a problem ia found replace it 2 INSTALL EGR VALVE WITH NEW GASKET INSPECTION OF WATER T...

Page 101: ...d weter Hl J by the catetyal h houll pon HC CO AND NO t T it J L II TWC ExMu t OM OXIDATION AND co H O REDUCTION IU INSPECTION OF EXHAUST PIPE ASSEMBLY 1 CHECK CONNECT10NS FOR LOOSBIIESS OR DAMAGE 2 CHECK CLAMPS FOR WEAKNESS CRACKS OR DAMAGE INSPECTION OF CATALYTIC CONVERTER CHECK FOR DENTS OR DAMAGE Ifany P trtof protectO ia domaged ordented to the a tent that it contacts the eatllyst repair or r...

Page 102: ...C CONVERTER 1 2 REMOVE CONVERTER IaI Jack up the vehicle lbl Check that the converter is cool C Remove the bolts at the front and rear of the con verter d Remove the converter and gaskets INSTALL CONVERTER a Place new gaskets on the converter front and rear pipes and connect the converter to the exhaust pipes lbl Tighten the bolts To Catlllyat Exhaust pipe 440 kg em 132 fHb 43 N ml lcl Reinstall t...

Page 103: ...k and Une AIR INDUCTION SYSTEM Air Flow Meter Idle SPHd Control USC Valve Throttle Body ELECTRONIC CONTROL SYSTEM Location of Electronk Control Perta Mail Relay Circuit Opening Relay Solenoid Reolotor Start Injector Time Switch W ater Temp Sensor Oxygen Sensor Electronic Controlled Unit ECUJ Fuel Cut RPM fl 1 lI i Page fl 2 Fl 4 Fl 4 Fl 8 Fl 22 Fl 28 Fl 29 fl 44 Fl 44 Fl 49 Fl 62 Fl 63 Fl 57 Fl 58...

Page 104: ... quantity of fuel into the Intake manifold in accordance with signals from the ECU Each injector injects at tho same time one hell of the fuel required for ideal combustion with each engine revolution AIR INDUCTION SYSTEM The air induction system provides sufficient olr for engine operation p rr l OUtiOn Sensor II U I Sen r w Ttmp StnlOf Oi nributOr Speed Sensor t ndit lgniti ln c w lgnittr Nouml ...

Page 105: ...conditions lcootant temperature air condition eroo off etc l Sensors transmit signals to the ECU which controls the flow ofair through the by pass of the throttle valve and adjusts idle speed to the target value See pages Fl 43 60 4 Exhaust Gas Recirculation C EGRl The ECU detects the coolant temp and con trois EGR function accordingly See page EC 101 5 Electronic Controlled Transmission CECTI t A...

Page 106: ...E al Connect the tachometer to the rvice connect lb Use tho battery aa the power source lor the tlmlf 9 light tachometer etc IN EVENT OF ENGINE MISFIRE THE CATALYTIC CONVERTER MAY OVERHEAT THEREFORE THE FOLLOWING PRECAUTIONS SHOULD BE TAKEN lal Insure correct drive belt adjustment b Insure proper connection of battery terminals etc el Handle resistor cords carefully d A fter repair w ork lnsuro th...

Page 107: ...uge oil filler cap PCV hose e tc may cause the engine to run out of tune 2 Disconnection loosenaas or cracks in the parts of the air intake system between the air flow meter cylinder head will allow elr suction end cause bad engine tune ELECTRONIC CONTROL SYSTEM 1 Beforo removing EFI wiring connectOf S terminals etc first disconnect pOwer by either tuming OFF the ignition switch or d sconnecting t...

Page 108: ...nnector with a volt ohmmeter a Carefully take out the water proofing rubber if it is a w otor proof typo connector b Insert the teste probe Into the eonnectOt from the wir ing slde when checking the continuity amperage or voltage c Do not apply unnecessary force to the terminal d After chocking install the water proofing rubber on the connector securely 10 Use SST for inspection or test of the inj...

Page 109: ...lt type 3 4 a Always use a new gukot lbl First tighten the union bolt by hand lcl Then tighten the bolt to the specified torque Torque 300 kg em 122 ft 11 29 N ml Flare nut type lal Apply e thin coat of oil to the flere and first tighten the flaro nut by hand lbl Then tighten the nut to the specified torque Torque 350 kg c m 26 fl ft 34 N ml Take the following l recautio ns when removh o and insta...

Page 110: ... are no leaks from any part of the fuel system CAUTION Alwoya pinch the hose Avoid bending 10 m v cause the hoM to crack TROUBLESHOOTING TROUBLESHOOTING HINTS 1 Engine troubles are usually not caused by the EFisystem W hen troubleshooting always first check the condition oC the other systems lal Electronic source Battery Fusible links Fuses bl Body ground lcl Fuel supply Fuel leakagl Fuel f1ller F...

Page 111: ...ctor pay particular attention to the following points fal Check to see that the terminals are not bent b Check to see that theconnectoris pushed in complete ly and locked cJ Check to see that there is no signal change when the connector is slightly tapped or wiggled 3 Sufficiently troubleshoot for other causes before replac ing the computer The computer is of high quality and it is expensive 4 Use...

Page 112: ...ROUBLESHOOTING PROCEDURES SYMPTOM DIFFICULT TO START OR NO START ENGINE WILL NOT CRANK OR CRANKS SLOWLVI BAD 1 Battery 1l Connection 1 21 Gravity Drive belt Charging system 31 Voltage 2 Fusible link BAD I Ignition switeh 2 Neutral start switch for AfT 3 Starter 4 WiringiConnection I ...

Page 113: ... B 10 mm 10 31 0 39 in I away from 4 Ignition coil igniter eng1 ne block while engine is c ranking A strong spark should be noted OK CHECK IGNITION TIMING Adjust ignition timing See page 10 91 1 Short both terminals of the NO check connector 2 Check Ignition timing STO 10 BlOC lw ohon t minab of the cheek eonnoc torl OK CHECK FUEL SUPPLY TO INJECTOR 1 Fuel line leakage deformation 1 Fuel in tank b...

Page 114: ...pluv 1 lnjectorCsl shoned or leaking Note NO 2 Injector w iringlsl betw een resistor and Chock compression pressure if necossorv All ECU shoned See page EM 61 Plugs 3 Cold start injector leakage WET See pege F1 49l 4 Start injector time switch csee page F1 71l OK CHECK EFI ELECTRONIC CIRCUIT 1 Wiring connection USING VOLT OHMMETER NO 2 Power to ECU C 1l Fusible link C 2l Fuse C3l No 1 and No 2 mai...

Page 115: ... hose 6 Fuel pressure regulator See page Fl 52 See page Fl 45 OK CHECK AIR FILTER ELEMENT I BAD r Element clean or replace OK CHECK IDLE SPEED ISC system STO 660 rpm BAD 1 Wiring connection 2 ISC valve 3 ECU test by substitution OK CHECK IGNITION TIMING Adjust ignition timing 1 Short both terminals of the NO check connector 2 Check ignition timing STO 10 BTOC w ahort terminals of the check cormect...

Page 116: ...main relay 3 Air flow meter 4 Water temp unsor 5 Injection signal circuit I1I Injector wiring 121 Resistor 3 ECU SYMPTOM ENGINE SOMETIMES STALLS CHECK DIAGNOSIS SYSTEM Diagnostic codelsl Check lor output of diagnostic code Malfunction See page Fl 251 See page F1 22l codelsi Normal code CHECK AIR FlOW METER Air flow meter See page F1 58 BAD OK CHECK WIRING CONNECTORS AND 1 Connector RElAYS BAD 2 No...

Page 117: ...0 rpm BAO C 1 Wiring connection 121 ISC valve 3 ECU test by substitution OK CHECK IGNITION TIMING Ignition system 1 Short both terminals of the NO check connector 2 Check ignition timing STO 10 BTOC lw shon tennlnals of the check connector OK CHECK SPARK PLUGS 1 Spark plug Max allowable gap 1 4 mm 1 0 055 in NO 2 Compression pres sure Precaution Never attempt to adjust gap Limit 9 0 kg em 128 psi ...

Page 118: ...EFI ELECTRONIC CIRCUIT USING VOLT OHMMETER BAD BAD BAD 1 Fuel pump ISee page Fl 441 2 Fuel filter 3 Fuel pressure regulator See page Fl 521 IInjection condition 1 Wiring connection 2 Power to ECU 11 Fusible link 21 No 1 end No 2 main relay 3 Air flow meter 4 Water temp sensor 5 Injection signal c ircuit 11 Injector wiring 21 Roslstor 31 ecu I ...

Page 119: ...Air eOf ditiotler twitch OK CHECK THROTTLE POSITION SENSOR I J Throttle body I BAD OK CHECK FUEL PRESSURE Fuel PJU sutl rogulltOt h h pteasure ISH ge Fl 451 BAD OK CHECK COLO START INJECTOR Cold start injector leakage See page Fl 491 BAD OK CHECK INJECTORS CSoe page fi S31 I ftniecto s 1eakege inie tion quantity I BAD OK CHECK EFI ELECTRONIC CIRCUIT 1 Wiring connection USING VOLT OHMMETER 2 Pow er...

Page 120: ...iming STD 10 BTDC lw ehort terminals of the cMck coi W 8Ctor OK CHECK COLD START INJECTOR 1 Cold start Injector Sea page F1 491 BAD 2 Stan injector time switch See page Fl 7 11 OK CHECK FUEL PRESSURE 1 Fuel pump tSee page F1 441 See page Fl 451 BAD 2 Fuel filter 3 Fuel pressure regulator See page F1 521 OK CHECK INJECTORS See page Fl 531 BAD InJectors clogged I OK CHECK EFI ELECTRONIC CIRCUIT 1 W ...

Page 121: ... check connectorl OK CHECK COLD START INJECTOR 1 Cold start Injector See page Fl 49 BAD 2 Start Injector time switch See pogo Fl 71 OK CHECK INJECTORS BAD InjectOr leakage OK CHECK SPARK PlUGS 1 Sperk plug M aHow tblt gep 1 4 mm 0 055 ln NO 2 Compreulon pressure Prectutlon Never attempt to adjust gap Limit 8 0 kg em 12B psi 883 kPtl on uatd platinum tipped spark plug 11 2150 rpm Note Check compres...

Page 122: ...1 Check for ootput of diagnostic code Malfunction See page F1 221 codelsi Normal code CHECK IGNITION SPARK 1 Plug wires 1 Unplug connectors of iniector resistor BAD 2 High tftnsion cords and start injection tim switch 3 Distributor 2 Check by holding spark plug wire 4 Ignition coil igniter 8 10 mm 0 31 0 39 in I away from engine block while engine cranking A strong spark should be noted OK CHECK I...

Page 123: ...ecessary See page EM 61 OK CHECK EFI ELECTRONIC CIRCUIT USING VOLT OHMMETER BAD BAD NO BAD I Fuel pump See page F1 44 2 Fuel filter 3 Fuel pressure regulator See page F1 521 Injection condition I Spark plug 2 Compression pressure Umit 9 0 kg em 128 psi B83 kPal at 260 rpm 1 W iring connection 2 Power to ECU 111 Fusible link 2 No 1 and No 2 main ralay 3 Air flow meter 4 Water temp sensor 5 Air temp...

Page 124: ... CHECK ENGINE warning llghl when lerminals T and e art short circuited CHECK ENGINE WARNING LIGHT CHECK 1 The CHECK ENGINE warning light will come on When the ignition switch it p laeed at ON and the eng1ne is not running 2 When the engine Is started the CHECK ENGINE warn ing light should go out If the light remains on the diagnosis system hasdetected a malfunction in tho systom OUTPUT OF DIAGNOST...

Page 125: ...bl In event of o malfunction the light w ill blink once ov ery 0 5 seconds The first number of blinkswill equal the first digit ofa 2 digit diagnostic code Aflora 1 5 second pause the 2nd numberof blinks will equal the 2nd number of a 2 digit diagnostic code If there ere two or more codes there w ill bea 2 5 seconds pause between each NOTE In event of a number of troubles codes indica tion will bo...

Page 126: ...s requir lng removal of the battery terminal a check must first be made to see If a diagnostic code is detected b After cancellation perform a road test if necessary confirm thot a normal code is now read on the CHECK ENGINE warning light If the same diegnostie code is still indicated It indi cates that the trouble area has not been repaired thoroughly DIAGNOSIS INDICATION Ill Including Normal tho...

Page 127: ... in 8 1 Main relay circuit 11 ECU I Bl 2 Main rol ly F1 32 ECUI 3 ECU 1 Olttt butor circuit 12 RPM SigN No Ne G sJon 10 ECU within sevet1J 2 OlllltMOI IG 7 seconds aflet engine Is crMlked 3 Stitt gnAt circuit 4 ECU 13 RPM SiOnal No Nt ion to ECU within several Satne M 12 above seconds aftM engine ruehe s 1 X rpm 1 nltlf cJrcurt 14 lgnhlon SigMI No sJ gnel from igniter t ix times in I B IGt IGfl Fl...

Page 128: ... signal 2 Throttle position Fl 35 sentor 3 ECU tAfT Signal informing ECU that vehicle 1 Vehicle tpeed sensor speed is 2 0 kmJh or less has been circuit Input ECU IO 5 ooconda w ith 2 Vehicle speed sensor eng ine running It 2 500 rpm or 3 Torque conve n er 42 Vehicle Speed more and shitt leverIa in other than aluwino Sensor Signal Nor Prange 4 ECU Mffl Stgnal infOfming ECU that veh cle speed is 2 0...

Page 129: ...ty another terminel W is grounded to the body terminal E1and body ECU ground NO IBAD Check bulb tuse and w iring between ECU end Repair or replace ignition switch IBAD Repair or replaeeJ 2 DOtts CHECK ENG warning light go OFF w hen YES System Normal engine is started INO Check wiring between ECU and CHECK ENG BAD IRepair I warning lighl joK Is there diagnosis code output when service NO ITry onoth...

Page 130: ... Name Symbol TermineINemo Eo ENGINE GROUND G6 ENGINE REVOLUTION SENSOR A C AIC MAGNET SWITCH Eo ENGINE GROUND VF CHECK CONNECTOR SPD SPEEDOMETER No 10 INJECTOR G ENGINE REVOLUTION SENSOR w WARNING LIGHT No 20 INUECTOR T CHECK CONNECTOR THA AIR TEMP SENSOR STA STARTER SWITCH VTA THROTTLE SWITCH Vs AIR FLOW METER IG1 IGNITER Ne ENGINE REVOLUTION SENSOR Vc AIR FLOW METER EGA EGA VSV Ill THROTTLE SWIT...

Page 131: ...e system the actual troubleshooting procedure may vary somewhat However please refer to these procadures and perform ac tval troubleshooting conforming to the inspectionrnothods described In this manual For example it is bettor to first make a simple check of the fuses fusible links and connecting condition of the con nectors before making your Inspection according to the procedures listed No 2 J ...

Page 132: ... 1 0 Fl 36 VTA b IG Stw ON Tlwon1e valve fully opefted 4 5 Vc E2 4 6 Fl 37 M 111uring phne fully closed 4 5 Measuring plate fulty open 0 02 0 08 Fl 38 3 Vs E2 Idling 2 4 3 000 rpm 0 3 1 0 THA E Intake lir temperature 2o c 88 FI 1 2 Fl 38 IG SfW ON 4 THW E J C t tempet ture 80 C 176 FI 0 1 0 5 F1 39 5 STA Eo IG Stw ST position 6 12 Fl 40 6 No 10 E No 20 IG Stw ON 9 14 Fl 41 7 IGt E1 Crenklng Of Idl...

Page 133: ...terminal of the wiring connector Remove the glove box Disconnect the wiring connectors from the ECU Measure the resistance between each terminal of the wir ing connectors Resistances at ECU Wiring Connectors Condition Reaistanc e 0 Throttle valve open Throttle valve fully clos ed 0 100 0 Throttle valve fully opened 3 300 10 000 Throttle va lve fvlly closed 200 800 Disconnect air flow meter connect...

Page 134: ... 10 14 No voltage Ignition switch ON 10 14 AM STOP Fuse ecu BAT IG SJW IG Cir itOpening Main Relay No 1 SJW I Fuso l Battery I Rolo a I M REL E BAT E1 D There is no YC4t606 betwMn ECU terminats BAT end E 2 Cl eck that there It vo1t1ge between ECU terminal BAT ei KI body QfOUnd NO OK L 2J J Check wiring between ECU terminal e and bodY ground Voltmtttr v ECU n Clleck fuse fusible linkt and wiring ht...

Page 135: ...al E1 and body ground Voltmeter IBAD Repair Of replace v I BAD f Rel 8ir or repf e Check fuse and wirin g harness _j OK Check NO 1 main relay BAD Replace j IG SIW E1 ecu j There is no voltage between ECU terminals IG Stw and E1 IG S W ON v Check that there I vottage between ECU terminaiiG SNV and body ground UG SIW ON NO OK Check wiring between ECU terminal E1 and body ground ECU BAD Repai r Or re...

Page 136: ...tage betwMn ECU terminals M AEL end Et CIG SIW ONI v 2 Check the t thtte is voltage between ECU ttrminet M REL end body g ound IIG SIW ONI NO OK Chec k wifil g between ECU termlnel Et onct Voltmeter body ground BAD I Repair or replace I v Check NO 1 main rtley and BAD I t wiring herneu Rtplac OK Try ono ECU ...

Page 137: ...OL Vc VTA Vc I E D tOl Ez D There is no volt ge between ECU terminals IOL end Et tO SIW ON tThrottle valve open v 2 Check that there Is voltage between ECU terminal 8 body and body ground CIG S W ONI NO OK Check wiring between ECU terminal E 11 d body ground BAD I Repair or replace I v Refer to No 1 BAD I Repair or replace O K Ohmmttll Q 00 3 CMck ttvottle po ition MnSOI BAD BAD OK Repelr or repla...

Page 138: ... BAD Repair or reJ Iace IOK 3 Check throttle position sensor I BAD I Repair 01 replace n fl 0 dol OK Check wiring between ECU and BAD throttle position sGnsor Repair or replace OK Try another ECU Vc E r ECU D There is no voltage between ECU terminals Vc and E2 IIG SIW ONI v Che k that there is voltage between ECU terminal 8 and body ground UG SJW ON OK NO Q Check throttle p osith n Refer to No 1 s...

Page 139: ...re 20 C 88 F 1 2 v Air Flow Meter ECU 8 F P Connector L_ I e I Vs Vc I 1 THA E 10 ECU i Vc E2 There is no vottag betwHtt ECU terminats Vc end b IIG S W ONI v l Check that t re is volteoo between ECU terminal Band body ground UG S W ONI NO OK 3 Check wiring betwnn ECU terminal E r end body Voltmeter ground BAD Repair 01 ropltct v Refer to No 1 L BAD I Repair or rt plect I OK Check air flow meter BA...

Page 140: ... ECU BAD Repair or replace Refer to No 1 BAD Repair or replace lOK Check air flow meter BAD Repair or replace OK Air Fk w Meter v n c u o p Check wiring between ECU BAD and air flow meter Repair or replace OK Try another ECU IIOJ D ECU D TMre is no voltage between ECU terminals THA and E2 UG SIW ONI Check thet there is voltage between ECU term al 8 and body ground UG SIW ONI OK NO i heck air temp ...

Page 141: ...6 v ON 178 F ECU Wa1er Temp S ns or 8 r I THW E _ E Q j There Is no voltage between ECU terminals THW and E2 ECU IIG SIW ONJ 2 Check that there is voltage bet wHn ECU t erminaJ 8 end body v ground 10 SIW ONI OK NO 0 Check water temp sensOr Refer to No 1 ECU BAD OK Repleee water Check wiring between ECU end temp sensor water temp sensor OK BAD v I Try another ECU I Repail Of repaee wiring ...

Page 142: ... ECU terminals STA and Et Voftm ttf ECU C IG SIW STl Check starter OK Ch ck wiring betwNn ECU and stttttr operation tetmlnat SO v BAD OK BAD Repair or replace 10111 Check wiring between ECU tetmin l E and body ground 1 IBAD I 1 Repair Of replace p CMck fusible link battery wiring BAD tTerminaf I end ignition switch Repah or replace OK Cheek that there is vottege It STA C50 terminal of stetttr IG S...

Page 143: ...s specified YOh age between resistor termiNI end body ground sro vo1t190 10 13V OK j NO Check fuse fusible link end 8AO ignition switch Repair or replace I OK Check main rel y No 2 BAO I Replace IOK Check wifing betwHn BAO re si tor and tM ttlfV Repair or replece 2 Check that thefe is specifiod vottogo between resistor tetminet end body ground STO volt190 10 13V IOK jaAO Ql Check resistance of m 1...

Page 144: ...meter lldfongl I I Check that there is voltage betw en ECU terminal IG Stw and body ground fk11ingl joK I v Check wiring b4nween ECU terminal E1 and I 1 body ground 107 1 I il jeAD Vohmettr ECU Refer to No 1 BAD Repeir or replace I I OK S W Check fuse and wiring hemeta BAD 1 Repair or repltce v OK Check wiring between ECU tnd BAD Repair or 1tplace distributor joK flO Check distributor BAD Repla ce...

Page 145: ...Fuse r 1 JlJ IG S W B Bettery M AE L l e 101 D There is no voltage between ECU te minals ISC 1 ISC and E uo srw ON a Check that there is vohage t etwee n ecu terminal 8 and body ground UG SIW ONI NO OK Check wiring between computer terminal E and body ground ECU OK BAD Try another ECU Repair or replace v Refer to No 1 I NO I Repair or replace OK Check wiring between NO 1 main BAD Repair or replace...

Page 146: ...el System FUEL SYSTEM Fuel Pump OUTLET _ CI eck Valve INLET I Fuel Pump c rwit Opening Relay Fuse 15A 8 FP ECU I No 1 Main Relay IG IG ECU STA E Fe M REL Fuel Pump Switch ECU STA Alr7r r Fuet Pump f Check Connector c e L 1 Battery 1 L L I ...

Page 147: ...ap to the check terminal e Turn off the ignition switch If there is no pressure check the following parts Fusible link Fuse IEFI 15A IGNITION 7 5A Circuit opening relay Fuel pump Wiring connections 2 CHECK FUEL PRESSURE a Check the battery voltage above 12 volts b Disconnect the battery ground cable cl Disconnect the w iring connector from the cold start Injector dl Put a suitable container or sho...

Page 148: ...s sure regulator and pinch it off p Measure the fuel pressure at idling Fuel pressure 2 3 2 7 kg em 1 33 38 psi 226 265 kPal ql Reconnect the vacuum sensing hose to the pressure regulator r Measure the fuel pressure at idling Fuel pressure 1 9 2 2 kg em 27 31 pol 186 216 kPe If not pressure check the vacuum sensing hose and pres sure regulator s Stop the engine Check that the fuel pressure remains...

Page 149: ... flame when work lng on the fuel pump 2 REMOVE FUEL TANK 3 REMOVE FUEL PUMP BRACKET FROM FUE L TANK a Remove the bolts bl Pull out the fuel pump bracket 4 REMOVE FUEL PUMP FROM FUEL PUMP BRACKET ta Remove the two nuts and disconnect the wires from the fuel pump bl Pull off the bracket from the lower side of the fuel pump lcl Remove the fuel pump from the fuel hose ...

Page 150: ...he fuel pump into the fuel hose Ib Install the rubber cushion to the lower side of the fuel pump lcl Push the lower side of the fuel pump together with the rubber cushion into the fuel pump bracket INSTALL FUEL PUMP BRACKET lal Place the bracket with a new gasket on the fuel tank b Install and tighten the screws 4 INSTALL FUEL TANK When installing the fuel tank refer to Fl 58 for the instal lation...

Page 151: ... hose from the throttle body lei Brake booster vacuum hose from the air intake chamber II Actuator vacuum hose from the air Intake chamber g Label and disconnect emissioncontrol hoses from the throttle body and air intake chamber that allow removal of vacuum pipe subassembly 4 DISCONNECT ACCELERATOR LINKAGE AND CABLE FROM THROTTLE BODY 5 DISCONNECT FOLLOWING WIRES IaI Cold start injector wire b Th...

Page 152: ...268 41045 cl Connect the SST wireI to the injector SST 09842 30050 NOTE Position the injector as far away from the battery as possible d Put a container under the injector e Turn on the ignition switch NOTE Do not start the engine fl Short both terminals of the fuel pump check connec tor with a service wire gl Connect the test probes of the SST to the battery and check that the fuel spray is as sh...

Page 153: ...ire connector b Two ISV valve connectors C Thrott le position sensor wire d Cold start lnjeCior wire B CONNECT ACCELERATOR LINKAGE AND CABLE FROM THROTTLE BODY 9 CONNECT FOLLOWING HOSES IaI Connect the emission control hoses to the throttle body and air intake chamber etc Ib Actuator vacuum hose to the air intake chamber c Brake booster vacuum hose to the air intakechamber d PCV hose to the thrott...

Page 154: ... fuel hose from the pressure regulator 3 DISCONNECT NO 2 FUEL PIPE FROM PRESSURE REGULATOR 4 REMOVE PRESSURE REGULATOR Remove the lock nut and remove the pressure regulator INSTALLATION OF PRESSURE REGULATOR 1 INSTALL PRESSURE REGULATOR Install the pressure regulator and lock nut o Torque the lock nut TO que 400 kg em 129 fHb 39 N ml 2 CONNECT NO 2 FUEL PIPE Install a new gasket pipe another gaske...

Page 155: ...ope to check that there is normal operating noise in proportion to engine rpm b If you have no sound scope you can check the injec tor transmission operation with your finger If no sound or an unusual sound i s heard check the wiring connector injector resistor or injection signal from computer 2 MEASURE RESISTANCE OF INJECTOR a Disconnect the wiring connector from the injector b Using an ohmmeter...

Page 156: ...e intake manifold INSPECTION OF INJECTOR 1 TEST INJECTION OF INJECTORS CAUT10N K p ciNr of apaot a during the teat a Connect the SST to the fuel filter outlet SST 09268 41045 lbl Connect the SST to the pressure regulatorand the In ector SST 09268 41046 lcl Hold the injector and hose with SST SST 09842 30020 dl Put the injector into the graduated cylinder NOTE Install a suitable vinyt tube onto the...

Page 157: ...T 09842 30020 Volume 40 50 cc 15 oec 2 4 3 1 cu ln Difference between each InJector Leaa than 6 cc 10 37 cu in NOTE If not w ithin specified volume clean or replace the Injector INSTALL OF INJECTORS 1 INSTALL INJECTORS INTO DELIVERY PIPE a Install the grommet and a new O ring to the Injector b Apply a thin coat of gasoline to the 0 rings and in stall the injectors into the delivery pipe 2 INSTALL ...

Page 158: ... 14 N m 3 CONNECT AND INSTALL WIRING HARNESS 4 INSTALL N0 1 FUEL PIPE a Finger tighten the pulsation damper and union bolt with new gaskets on the fuel pipe b Tighten then being careful not to bend the fuel pipe 5 INSTALL DISTRIBUTOR AND SET TIMING See pege IG 9 10 6 INSTALL AIR INTAKE CHAMBER See atepa 2 to 11 on page Fl 61 7 CHECK FOR FUEL LEAKAGE a With the ignition switch ON use a service w ir...

Page 159: ...ubber pootec tors onthe upper surfacesof the fuel tank and tank band 3 Apply the proper torque to ell tightening parts INSPECT FUEL LINES AND CONNECTIONS a Inspect the fuel lines for cracks leakage or connee dons or defo mation bl Inspect tho fuel tonk vapor vent system hoses and connections for looseness sharp bends or damage c Inspect the rue tank for deformation cracks ruelloak age or tsnk band...

Page 160: ...oMector from the air flow mete b Using an ohmmeter measure tt e resi stenee between each terminal Between Resis11nce Temperature termin als E r Va 20 400 ll E r Vc 200 400 l E2 THA 10 20k l 2o c 1 Fl 4 7k l o c 1 3 2 FJ 2 3kll 20 c I 68 Fl 0 9 1 3 kll 40 c 1104 FI 0 4 0 7 k l so c 1140 FI E1 Fe lnfWlity If not w ithin specification replace the air flow meter REMOVAL OF AIR FLOW METER 1 DISCONNECT ...

Page 161: ...ween Resistance 0 Measuring plate terminals Openiog Infinity Fully closed E1 Fe Zsro Other than closed position 20 400 Fully CIO ed Et Vs 20 1000 Fully closed to fully open position NOTE Resistance between e and Vs will change In ac cordance with the measuring plate opening INSTALLATION OF AIR FLOW METER 1 INSTALL AIR FLOW METER Install air flow meter with four nuts and one bolts 2 CONNECT AIR FLO...

Page 162: ...PERATING SOUND FROM ISC VALVE Confirm that there is a clicking sound immediately after stopping the engine REMOVAL OF ISC VALVE 1 DRAIN COOLANT 2 DISCONNECT TWO ISC VALVE CONNECTORS 3 DISCONNECT FOLLOWING HOSES FROM ISC VALVE BODY lal Two water by pass hoses bl Air hoses 4 REMOVE TWO BOLTS AND ISC VALVE BODY I ...

Page 163: ...terminals B and s and while repeatedly groundings s S S S in sequence check that the valve moves toward the closed position lbl Apply battery voltage to terminals Bo and B and while repeatedly grounding S 53 Sz s s in sequence check that the valve moves toward the open position INSTALLATION OF ISC VALVE 1 INSTALL ISC VALVE BODY AND TWO BOLTS 2 CONNECT FOLLOWING HOSES TO ISC VALVE BODY Ia Two air h...

Page 164: ...rubber cap from the 4 terminal service connector yallow and connect an EFI idle adjusting wiring harness T to it SST 09842 14010 b Connect positive testing probe to the red wire of ths SST and negative testing probe to the black wire cl Warm upthe Ox sensor with the engine at 2 500rpm for about 2 minutes d Maintain the engine speed at 2 500 rpm e Check that the needle of the voltmeter fluctuates 8...

Page 165: ... the engine Check the vacuum with your finger Pert No At idling Other than idling 8 No vacuum Vacuum No vacuum Vacuum 1 No vacuum No vecuum 6 No vacuum Vacuum 2 CHECK THROTTLE POSIT10N SENSOR taJ Check the resistance between the terminals Unplug the connector from the sensor Insert a thickness gauge betwe n the throttle stop screw and stop lever Using an ohmmeter check the resistance between each ...

Page 166: ...pass hoses b PCV hose from the throttle body c Label end di sconnect emjssion control hoses 4 DISCONNECT THROTTLE SENSOR CONNECTOR 5 REMOVE THROTTLE BODY Remove the four bolts and remove the throttle body and gasket INSPECTION OF THROTTLE BODY 1 CLEAN THROTTLE BODY BEFORE INSPECnON a Wash and clean the cast parts with a soft brush in carburetor cleaner lbl Using compressed air blow aft passages an...

Page 167: ...ws d Using e thickness gauge recheck the continuity be tween terminals IDL and E2 Cleerance between lever end stop screw Continuity IOL E2J 0 50 mm 0 0197 in Continuity 0 90 mm 10 0354 in No continuity REPLACEMENT OF THROTTLE POSITION SENSOR 1 REMOVE THROTTLE POSITION SENSOR Remove two screws and the sensor from the throttle body 2 INSTAlL THROTTLE POSITION SENSOR tal Check that the throttle valve...

Page 168: ...HROTTLE BOOY Place a new gasket and install the throttle body and foor bolts 2 CONNECT THROTTLE SENSOR CONNECTOR 3 CONNECT FOLLOWING HOSES a Emission control hoses bl PCV hose to throttle body cl No 1 and No 2 water by pass hoses 4 INSTALL AlR INTAKE CONNECTOR 5 FILL WITH COOLANT ...

Page 169: ...ktw Meter Oxygen SensOJ ECU Throttle Position Sensor Cokl Sttn Injector Fuel Pump ELECTRONIC CONTROL SYSTEM Location of Electronic Control Parts 7 Resistor 8 ISC Valve 9 InJector 10 Water Temp Sensor 11 Cok l Start Injector Time SWitch 12 Igniter w lgnition Coil ...

Page 170: ...t Fusible Link INSPECTION OF MAIN RELAYS 1 CHECK MAIN RELAYS OPERATION a Turn on the ignition switch b At this time an operation noise will occur from the I re ay 2 MEASURE RESISTANCE OF MAIN RElAYS a Remove the No 1 main relay hom the relay block Unplug the connector from the No 2 main relay b Measure the resistance between each terminal Between terminals Resistance 0 No 1 Main 1 2 40 60 Relay 3 ...

Page 171: ...NSPECTION OF CIRCUIT OPENING RELAY 1 CHECK CIRCUIT OPENING RELAY OPERATION a Remove the left kick panel b Using a voltmeter check that the meter indicates voltage at FP terminal during engine cranking and running lcl Stop the engine 2 MEASURE RESISTANCE OF CIRCUIT OPENING RELAY a Disconnect the connector b Measure the resistance between each terminal Between terminals Resistance 0 STA Eo 17 25 IG ...

Page 172: ...W r 10 No 20 Solenoid Resistor i f l Solenoid Resinor Injectoro ECU No 10 ECU No 20 INSPECTION OF SOLENOID RESISTOR MEASURE RESISTANCE OF SOLENOID RESISTOR Using an ohmmeter measure the resistance between 8 and other terminals Resistance 2 0 each ...

Page 173: ...ion Time Switch INSPECTION OF START INJECTOR TIME SWITCH ME ASURE RESISTANCE OF START INJECTOR TIME SWITCH ta Disconnect the connector b Using anohmmeter measure the resistance betwun each terminal Between terminals Resistance tm Coolant temperatur 24 40 below 30 C 186 FI STA STJ 40 60 above 40 C 104 F STA Ground 20 80 ...

Page 174: ...stem Water Temp Sensor 20 0 20 40 60 80 100 120 TEMPERATURE Cf Fl 4 321 681 104 140 1761 212 248 INSPECTION OF WATER TEMP SENSOR M EA SURE RESISTANCE OF WATER TEMP SENSOR a Disconnect the connector b Using an ohmmeter measure the resistance between both terminals Resistance Refer to chart ...

Page 175: ...er replacing the oxygen sensor Check the numbe1 of times the voh meter needle fluctuates in 10 seconds I 8 times Zero Less than 8 timee or more Warm up the Oxygen sensor with the engine at Normel 2 600 rpm for approx 90 seconds and maintain engine at 2 600 rpm Check the number of times the voltmeter 8 times or more needle fluctuates in 10 seconds Zero Le ss than 8 times Unshor1 terminals T end E o...

Page 176: ...ween terminals v and E1 CN sv Disconnect the PCV hose I IMeasure voltage between terminals o and e CN More than OV Repair Over rich Disconnect the water temp sensor connector and connect resistor w ith a resfstace of 4 8 KO or another coded water temp sensor I Short terminala T end E of the service connector I Warm up the oxygen sensor with the engine at 2 500 rpm for opprox 90 seconds And maintai...

Page 177: ...CH E ENGINE GROUND VF CHECK CONNECTOR SPO SPEEDOMETER No 10 INJECTOR G ENGINE REVOLUTION SENSOR w WARNING LIGHT No 20 INJECTOR T CHECK CONNECTOR THA AIR TEMP SENSOR STA STARTER SWITCH VTA THROTTLE SWITCH Vs AIR FLOW METER IGt IGNITER No ENGINE REVOLUTION SENSOR Vc AIR FLOW METER EGR EGR VSV IOL THROTTLE SWITCH BAT BATTERY 8 Eo ENGINE GROUND KNK KNOCK SENSOR IG S W IGNITION SWITCH NEUTRAL STAAT SWI...

Page 178: ...EJ 1 2 lnteke elr temperature 20 C 68 Fl IG SM ON THW Et 0 1 0 5 Coolant temperature 80 C Ct 76 FJ STA e 8 12 IG Stw ST position No 10 e 9 14 IG SM ON No 20 IGt Et 0 7 1 0 Cranking 01 Idling ISC 9 14 IG srw ON I e ISC 9 14 2 3 HCI eher engine off B EGR 10 13 IG SfW ON 0 Stan engine end warm up oxygen seneor 0 Shih ldon PorN r ange Cfor AfT 10 14 b P or N renge for AJTJ IG SJW ON NJC Et 0 ClutCh pe...

Page 179: ...ne Warning light outl 10 13 AJC S W ON A C Et IG S W ON 0 AJC S W OfF VF Et 0 5 Start engiM Throttle valve open 0 IG S W ON W E1 10 13 Start engine 2 3 Coolant temperature Less than 35 C 195 F TCO E 0 IG S W ON Coolant temperature 35 60 C 195 140 F 4 6 Coolant temperature More ttlan 60 C 140 F ...

Page 180: ...he glove box Unplug the wiring connectors from the ECU Measurethe resistance between each terminalof the wir ing connectors Resistances et ECU Wiring Connectou Condition Resis1 ance 0 Throttle valve open c Throttle va1 11e runv ctosed 0 Ttuottl valve fully opened 3 300 10 000 Ttvoute valve fully closed 200 800 Otsconnect lir now meter connectOr 3 000 7 000 Disconnect thronte position sensor connec...

Page 181: ...e bl Disconnect the throttle position sensor connector from the throttle position sensor c Short circuit terminals E2 and IOL on wire connector side dl Gradually raise the engine rpm and check that there is fluction between the fuel cut and fuel return points NOTE The vehicle should be stopped Fuel Cut rpm Fuel Return rpm t 800 rpm 1 200 rpm I I l ...

Page 182: ......

Page 183: ... C0 1 COOLING SYSTEM p TROUBLESHOOTING C0 2 CHECK AND REPLACE ENGINE COOLANT C0 2 WATER PUMP C0 3 THERMOSTAT CQ 6 RADIATOR C0 7 ...

Page 184: ...Aadi ator plu or cep t lty Check rtdiator C0 7 II C lindtr Mod or block a tcktd 0 plutgtd Repair as MOeSSMV I CHECK AND REPLACE ENGINE COOLANT 1 CHECK COOLANT LEVEL The coolant level should be between the LOW and FULL lines If low check for leak and add coolant up to the FULL line 2 CHECK COOLANT QUALITY There should not be any excessive deposits of rust or scales around the radiator cap or radiat...

Page 185: ...t Yater REMOVAL OF WATER PUMP 1 DRAIN COOLANT 2 LOOSEN FAN BELTS Assembly a Loosen the belt adjusting bolt and nut of the PS pump and alternator b Remove the alternator pivot nut and adjusting bar 3 REMOVE A IR CLEANER CASE 4 DISCONNECT UPPER RADIATOR HOSE 5 REMOVE FOUR FAN SHROUD BOLTS ...

Page 186: ...from the fluid coupling 7 REMOVE WATER PUMP Remove the eight bolts and one nut and remove tht water pump and gasket INSPECTION OF WATER PUMP 1 INSPECT WATER PUMP BODY AND TIMING BELT CASE Check the water pump body and timing belt case for cracks and damaged gasket surfaces Replace if necessary 2 INSPECT WATER PUMP BEARING Check that the water pump bearing operation is not rough or noisy 3 INSPECT ...

Page 187: ... pulley and position the pulley and fen belt guide on the bolts of the water pump 3 INSTALL FAN ON FLUID COUPLING 4 INSTALL FLUID COUPLING AND FAN SHROUD a Install the fan mroud together with the fluid coupling to the engir e compartment b Install the fluid coupling on the pulley with fournuts c ln nallthe four fan m roud bolts 5 INSTALL A LTERNATOR ADJUSTING BAR 6 ADJUST FAN BELT TENSION See page...

Page 188: ...pening temperature and valve lilt If the valve opening temperature and valve lift are not within the following specifications replace the ther mostat Valve opening temperature 86 oo c 1187 194 Fl Valve lift More than 8 mm 0 31 in at 100 C 212 FI c Check that valve spring is tight when the thermostat is fully closed Replace if necessary INSTALLATION OF THERMOSTAT 1 PLACE THERMOSTAT IN WATER OUTLET ...

Page 189: ...reswre tester pump the tester until tho relief valve opens Check that valve opens between 0 75 kg em 410 7 psi 74 kPa and 1 05 kg em 415 psi 103 kPa Check that the pressure gauge does not drop rapidly when pressure on cap goes below 0 6 kg em 8 5 psi 59 kPa If either check is not within limits replace cap 2 CHECK COOLING SYSTEM FOR LEAKS a Fill the radiator with coolant and attach a pressure teste...

Page 190: ...LUBRICATION SYSTEM Page TROUBLESHOOTlNG LU 2 OIL PRESSURE CHECK LU 2 REPLACEMENT OF ENGINE OIL AND OIL FllTEA LU 3 OIL PUMP LU 4 OIL PRESSURE REGULATOR For Leah Adjuster Volvel LU 9 LU 1 ...

Page 191: ...K 1 CHECK OIL QUALITY lU 4 lU 4 LU 4 lU 3 lU 3 lU 4 Check the oil for deterioration entry of water discolorq or thinning If the quality is poor chenge the oil Use API grade SF or SFICC multigrade fuel efficient ani recommended viscosity oil 1 2 CHECK OIL LEVEL The oil level should be between the L end F merl s on tho level gauge If low check forleakage and addoil up to tho F mark 3 REMOVE OIL PRES...

Page 192: ...re you feel resistance lel Then usil1gSST tighten the oil mter an e tta 3 4 tum SST 09228 44010 3 FILL WITH ENGINE OIL al Clean and install the oil drain plug with a new gasket bl Fill the engine with new oil API grade SF or SF CC multigrade fuel efficient and recommended viscosi ty oil 011 capechy Drt Ill 6 7 lton 8 0 US qts 5 0 Imp qts Drain and refill w o 011 filter change 4 8 litera 14 8 US qt...

Page 193: ...59 11 a 1 1 I Pump Shaft Rolilf vat tt oi __ f c oa Pump eo I REMOVAL AND DISASSEMBLY OF OIL PUMP 1 DRAIN ENGINE Oil 2 DRAIN COOLANT 3 REMOVE AIR ClEANER CASE 4 REMOVE AIR CONNECTOR PIP WITH NO 1 AND N0 2 AIR CLEANER HOSES 6 REMOVE OIL LEVEl GAUGE 8 DISCONNECT UPPER RADIATOR HOSE 7 l OOSEN FAN BElTS Loosen the belt edj Jstingbolts and nut of the P pump erd altern nor 8 REMOVE FOUR FAN SHROUD BOLTS...

Page 194: ... REMOVE OIL PAN e Remove the tw enty six bolts and remove the oil pan Cbl Using SST and a brass bar separate the oil pan from the cylinder block SST 09032 00100 NOTE When removir g the oil pan be careful not to damage the oil pan flange 17 REMOVE OIL PUMP ASSEMBLY Ia Remove the union bolt and nut and disconnect the oil pump outlet pipe bl Remove the oil pump mounting bolt end remove the oil pump 1...

Page 195: ...ndard cluranca 0 6 0 6mm 0 020 0 024 ln Maximum beckloah 0 9 mm 10 036 ln If the blaklash is greaterthan maximum replace the shift subassembly and or driven gear 4 MEASURE SIDE CLEARANCE Using a feeler gauge end flat block measure tile side clta ance as shown Standard clearance 0 03 0 09 mm 0 0012 0 0035 ln l Maximum clearance 0 16 mm 0 0069 ln If tho clearance Is grooter than maximum replace the ...

Page 196: ...t and nut Torque 360 kg em 26 ft lb 34 N m 2 INSTAll OIL PAN al Remove any packing material and be careful not to drop the oil on the contacting surfaces of tl e on pan A A and cylinder block Using a razor blade and gasket scraper remove all the packing FIPGl motorial from the gasket surfaces Thoroughly clean all component to remove all the loose material Clean both sealing surface w ith a non res...

Page 197: ...ogether the fluid coupling to the engine comportment b Install the fluid coupling on the pulley w ith four nuts lei Install the four fan shroud bolts B ADJUST FAN BELT TENSION See 1 811 MA 41 9 CONNECT UPPER RADIATOR HOSE 10 INSTAU AIR CONNECTOR PIPE WITH N0 1 AND N0 2 AIR CLEANER HOSES 11 INSTAU AIR CLEANER CASE 12 FILL WITH COOLANT 13 FILL WITH ENGINE OIL 14 START ENGINE AND CHECK FOR LEAKS ...

Page 198: ...ew tho relief valve plug and remove the spring and relief valve INSPECTION OF OIL PRESSURE REGULATOR Check the relief valve for scoring or wear If damaged replace the valve or regulator assembly ASSEMBLY AND INSTALLATION OF OIL PRESSURE REGULATOR 1 ASSEMBLE OIL PRESSURE REGULATOR ASSEMBLY Install the relief valve and spring in tho body and screw on the relief valve plug 2 INSTALLOILPRESSURE REGULA...

Page 199: ...r IGNITION SYSTEM PRECAUTIONS IG 2 TROUBlE SHOOTINO IG 2 ELECTRONIC SPARK ADVANCE IESA IG 3 ON VEHICLE INSP CTION IG DISTRIBUTOR IG 8 10 1 ...

Page 200: ...M edy Page Engine w ill not start lgn tion problems Perform spatk test IG 4 H1rd to lllrt Ignition c HI Inspect coil IG 7 crenk okt Ignitor Olatt butor lnapect distributor IG 7 Spark pluga feulty lnapect plugs IG 6 Rough id e or stab Spark plugt loulty lnii 8Cl plugs IG 5 Incorrect lgnitlon timing Reset timing IG t O Ignit ion problems Perform spark t est IG 4 lgn ttOn COil Inspect coil IG 7 lgn t...

Page 201: ...ogrammed with data for optimum ignition timing under any and all operating conditions Using data provided by sensors which monitor various engine functions rpm intake air volume eng temperature etc the microcomputer IECU trig gers the spark at precisely the right instant ESA SYSTEM CIRCUIT B ECU Ignition Coil w fgniter L J I 10 IGt lgnittr Assv IGf G Ne Ge e ...

Page 202: ... TEST 1 NO CHECK RESISTANCE OF HIGH TfNSION CORDS BAD Replace the cord See page IG 51 OK CHECK POWER SUPPLY TO IGNITION COIL BAD Check wiring between ignition 1 Ignition switch turn to ON switch to ignition coil 2 Check that there is battery voltage at ignition coil positive terminal brown sideI OK CHECK RESISTANCE OF IGNITION COIL BAD Replace the ignition coil Resistance lcoldl Primary 0 4 0 6 0 ...

Page 203: ...d as required Maximum realotance 26 npor cord INSPECTION OF SPARK PLUO Platinum Tipped Spark Plug CAUTION NEVER USE WIRE BRUSH FOR CLEANING NEVER ATTEMPT TO ADJUST GAP ON USED PLUG SPARK PLUGS SHOULD BE REPLACED EVERY 60 000mllee 1100 000 kml 1 INSPECT ELECTROOE Ia If using a megger insulation resistance mater Measure the insulation resistance Conact lnoulatlon raofotanca More then 10 MO If less t...

Page 204: ...Correct electrode gap of new l tg 1 1 mm 10 043 ln l If adjusting the gap of a new plug bend only the bose d the ground electrode do not touch the tip 5 ClEAN SPARK PlUGS If the elttetrode luis ttaces of wet carbon allow It to drf and then clean with a spark plug cleaner Air _ Bellow 6 kg em 85 psi 588 kPal Duration 20 seconda or Ieos NOTE If there are traces of oil clean it off withgasolint befor...

Page 205: ...sing an ohmmeter measure the resistance between the positive I I terminal brown sideI and the high tension terminal Secondary col rulotance cold 8 5 1 1 5 kll 3 CONNECT HIGH TENSION CORD ON VEHICLE INSPECTION OF DISTRIBUTOR 1 INSPECT DISTRIBUTOR CAP AHO ROTOR al Check for cracko carbon tracks burnt or CO Toded ter minals lbl Check the distributor center contact for wear If a problem is found rople...

Page 206: ...OM CYLINDER HEAD 5 REMOVE O IliNG REPLACEMENT DISTRIBUTOR DRIVE GEAR 1 GRIND DRIVE GEAR AND PIN Using a grinding wheel grind the gear and pin CAUTION Be cereful not to d I IMIII the sheft 2 REMOVE PIN AND DRIVE GEAR tal Using a punch and hammer drive out the pin lbl Remove the drive gear and d c ard it 3 INSTALL NEW DRIVE GEAR AND PIN lal Align the marks on the housing end new gear lbl Using a ham...

Page 207: ...n tho cronkshaft one full turn dl Install the new 0 ing to the distributor NOTE Alway uso a now 0 ing when installing tho dis tributor Cel Align the matchmort of the distributor the drillmark on spiral gear with that of distributor housing Cfl lnsart thodistributO aligning thocenter of flange with that of the bolt hole of cylinder head g Align the totO tooth with the pickup coil lhl Temporarily In...

Page 208: ...gine and run It at idle c Short ci euit the terminals of the check connect T and E d Using a timing light slowly turn the distributor urd the timing mark on the crankshaft pulley is alignol with the o mark Tighten the diatributor bolt Ignition timing 10 BTOCO T 8nd E Torque 140 kg cm 10 fl lb 14 N ml e Unshort the check connector ...

Page 209: ...STARTING SYSTEM Page TROUBLESHOOTING ST 2 STARTING SYSTEM CIRCUIT ST 2 STARTER ST 3 ST 1 ...

Page 210: ...ow ly Battery charge low CMdc blnefY specif te gravity C 3 Chllfi t Of repl aee banetv Battery eables loon corroded or worn Repair or repl e cables Stetter ftutty Repair starter ST 3 Slerter keeps running Starter faulty Repair aterter ST 3 H Ignition sw1tch faulty Replace Ignition Witch Short In wlr ng Repair wiring I Starter apk t engine Pinion gear teeth broken or faulty starter Repair t tart er...

Page 211: ...all St ter Housio g Retutn Spring Clutch Assemt l ST 3 t Non reu5able part REMOVAL OF STARTER 1 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2 DISCONNECT TWO WIRES FROM STARTER Remove the nut and disconnect the battery cable from the magnetic switch on the starter motor Disconnect the other wire from the terminal 3 REMOVE STARTER MOTOR Remove the two bolts and remove the starter motor from t...

Page 212: ...ND GEARS FROM MAGNETIC SWITCH ASSEMBLY 4 REMOVE STEEL BALL M191et Using a magnet remove the steel ball from theclutch shaft 110011 hole 6 REMOVE BRUSHES AND BRUSH HOLDER a Remove the end cover from the field frame b Remove the O ring c Using a screwdriver separate the brush and brush spring and remove the brush from the brush holder ldl Pull the brush holder off the armature 8 REMOVE ARMATURE FROM...

Page 213: ...the maximum correct with a lathe MEASURE DIAMETER OF COMMUTATOR Standard diemeter 30 mm 11 18 ln Minimum diameter 29 mm 1 14 1n If the diameter of the commutator is less than the mini mum replace the armature 4 CHECK SEGMENT Check that the segment is clean and free of foreign pani cles and smooth out the edge Standard undercut depth 0 6 mm 10 024 1n l Minimum undercut depth 0 2 mm 0 008 ln If the ...

Page 214: ... reading is below standard replace the bruoh spring NOTE Take the pull scale reading the instant the brush spring separates from the brush Brush Holder CHECK INSULATION OF BRUSH HOLDER Using anohmmater check for continuity between the posi tive and negative brush holders If there is continuity repair or replace the brush holder Clutch and Gears 1 INSPECT GEAR TEETH Inspect the gear teeth on the pi...

Page 215: ...g from the oppo site side SST 09286 46011 c Using SST and press tap the front bearing onto the shaft SST 09201 41020 ldl Using a press instoll the rear bearing onto the shaft Magnetic Switch 1 PERFORM PUll IN COIL OPEN CIRCUIT TEST Using an ohmmeter cheek for continuity between termi nal 50 and the terminal C If there is no continuity replace the magnetic switch 2 PERFORM HOLD IN COIL OPEN CIRCUIT...

Page 216: ... brushes NOTE Make sure that the positive lead wires are not grounded b Place the 0 ring on the field frame c Install the end cover to the field frame 3 INSTAU FIELD FRAME WITH ARMATURE IN MAGNETIC SWITCH a Place the 0 ring on the field frame b Match the protrusion of the field frame with the malt netic switch 4 INSERT STEEL BALL AND SPRING INTO CLUTCH SHAFT HOLE 6 Apply grease to t he ball and in...

Page 217: ...moves outward If theplungerdoes not move replace the magnetic sw ch 2 PERFORM HOLO IN TEST While connected as above with the plunger out discon neet the negative lead from terminal C Check that the plun ger remains out If the plunger retumsinward replace the megnetie switch 3 CHECK PlUNGER RETURN Disconnect the negative lead from the switch body Cheek that the plunger returns inward If the plunger...

Page 218: ...starter motor in the flywheel bellhousing Install the two bolts 2 CONNECT TWO WIRES TO STARTER Connect the connector to the terminal on the magnetic switch Connect the cable from the banery to the termi nal on the switch and install the nut 3 CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY Check that the car starts ...

Page 219: ...CHARGING SYSTEM Page PRECAUTIONS CH 2 TROUBLESHOOTING CH 2 ON VEHICLE INSPECTION CH 2 ALTERNATOR CH 5 CH 1 IIJ I ...

Page 220: ...ty Drive belt loose o r wom Battery cables loose corroded or worn Fuse blown Fusible link blown IC regulator or alternator faultY Wiring faulty Check CHARGE and IGN fuses Replace li t Tighten lo0 e connections Replace IC regulator Adjust or replace drive belt Repair or replace cables Check ENGINE luso Replace fusible link Check charging system Repair wiring ON VEHICLE INSPECTION 1 CHECK BATIERY SP...

Page 221: ...e Used belt refers to a belt which has been used on a running engine for 5 minutes or more After installing the drive belt check that it fits properly in the ribbed grooves Check by hand to confirm that the belt has not slipped out of the groove on the bottom of the crank pulley After installing the belt run the engine for about 5 minutes and then recheck the tension 4 CHECK FUSES FOR CONTINUITY E...

Page 222: ...ing to 2 000 rpm check the reading on the ammeter and voltmeter Standard amperage Less than lOA Standard voltage 13 5 15 1V Regulator case 25 C or 77 F If the voltage reading is greater than standard voltage replace the IC regulator If the voltage reading is less than standard voltage check the IC regulator and alternator as follows With terminal F grounded start the engine and check the voltage r...

Page 223: ...r REMOVAL OF ALTERNATOR 1 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2 DISCONNECT WIRING FROM ALTERNATOR a Disconnect the connector from the alternator b Remove the nut and wire from the alternator 3 4 REMOVE ALTERNATOR DRIVE BELT Loosen the alternator pivot adjusting lock and adjusting bolts and remove the alternator drive belt REMOVE ALTERNATOR a Remove the pivot and adjusting lock bolts...

Page 224: ...rminal insulators 4 REMOVE PULLEY a Hold SST A with a torque wrench and tighten SST 8 clockwise to the specified torque SST 09820 63010 Torque 400 kg cm 29 ft lb 39 N m b Check that SST A is secured to the rotor shaft c As shown in the figure mount SST C in a vise and then install the alternator to SST C d To loosen the pulley nut turn SST A in the direction shown in the figure CAUTION To preV nt ...

Page 225: ...K ROTOR FOR GROUND Using an ohmmeter check that there is no continuity be tween the slip ring and the rotor If there is continuity replace the rotor 3 INSPECT SLIP RINGS a Check that the slip rings are not rough or scored If rough or scored replace the rotor b Using calipers measure the slip ring diameter Standard diameter 14 4 mm 0 567 in Minimum diameter 14 0 mm 0 651 in If the diameter of the s...

Page 226: ...7 in If the exposed length is less than minimum replace the brush 2 IF NECESSARY REPLACE BRUSHES a Unsolder and remove the brush and the spring b Run the wire of the brush through the hole in the brush holder and insert the spring and brush into the brush holder c Solder the brush wire to the brush holder at the exposed length Standard exposed length 10 5 mm 0 413 in d Check that the brush moves s...

Page 227: ...ST 09608 20012 09608 00030 d Install the bearing retainer with the four screws 3 INSPECT REAR BEARING Check that the rear bearing is not rough or worn Replace if necessary 4 IF NECESSARY REPLACE REAR BEARING a Using SST remove the reer bearing with the bearing cover from the rotor shaft SST 09820 00021 CAUTION Be careful not to damoge the f1111 b Using SST and a press press in the rear bearing and...

Page 228: ...ue wrench and tighten SST B clockwise to the specified torque SST 09820 63010 Torque 400 kg em 29 ft lb 39 N ml c Check that SST A is secured to the pulley shaft d As shown in the figure mount SST C in a vise and then install the alternator to SST C e To torque the pulley nut tum SST A in the direction shown in the figure Torque 1 125 kg em 81 ft lb 110 N m fl Remove the alternator from SST C g Tu...

Page 229: ...st 1 mm 0 04 in 6 INSTALL REAR ENO COVER a Install the end cover with the three nuts b Install the terminal insulator with the nut INSTALLATION OF ATERNATOR 1 INSTALL ALTERNATOR Mount the alternator on the engine bracket with the pivot and adjusting lock bolts Do not tighten the bolts 2 INSTALL DRIVE BELT a Install the drive belt L b Using a belt tension gauge check the drive belt tension See page...

Page 230: ...CLUTCH Page TROUBLESHOOTING CL 2 CHECK AND ADJUSTMENT OF CLUTCH PEDAL Cl 3 BLEEDING OF CLUTCH SYSTEM CL 3 CLUTCH MASTER CYLINDER CL 4 CLUTCH RELEASE CYLINDER CL 5 CLUTCH UNIT CL 7 CL 1 ...

Page 231: ...h pedal freeplay insutfic ient Adjust pedal freeplay Cl 3 Clutch disc lining oily Of worn out Inspect clutch d isc CL 1 Pressure plate faulty Replace pressure plate CL 1 Release fork binding Inspect release fork CL 1 Clutch grabs chatte rs Clutch disc lining o ily or worn out Inspect clutch d isc CL l Preuure plate faulty Aepf ee pressure plate CL l Clutch diaphragm sp ring bent Align clutch d iap...

Page 232: ...ck nut c After adjusting the pedal freeplay check the pedal height 5 CHECK PEDAL OPERATION While gently depressing and releasing the pedal check that engagement and disengagement issmooth NOTE With a pedal stroke of 125 135 mm 4 92 5 31 in the pedal should return in 3 4 seconds BLEEDING OF CLUTCH SYSTEM NOTE If any work is done on the clutch svstern or if air is suspected in the clutch lines bleed...

Page 233: ...DER a Remove the mounting nut and bolt b Pull out the master cylinder DISASSEMBLY OF MASTER CYLINDER 1 REMOVE RESERVOIR TANK Remove the hold down bolt and pull off the rt iervoir tank 2 REMOVE PUSH ROD AND PISTON a PuII back the boot and using a screwdriver remove the snap ring b Pull out the push rod washer and piston ASSEMBLY OF MASTER CYLINDER 1 COAT PARTS WITH LITHIUM SOAP BASE GLYCOL I GREASE...

Page 234: ...ST connect the union SST 09751 36011 Torque 155 kg em 11 ft lb 15 N ml 3 CONNECT PUSH ROO AND INSTALL PIN Install a clip in the push rod pin 4 BLEED SYSTEM AND ADJUST CLUTCH PEDAL See page CL 31 CLUTCH RELEASE CYLINDER COMPONENTS Flexible Hose v 155 U1 15 e CVIindor 81 PIU1Jl110 II 111 I REMOVAL OF RELEASE CYLINDER 1 DISCONNECT FLEXIBLE HOSE Using SST disconnect the union SST 09751 36011 2 REMOVE ...

Page 235: ...STON AND SPRING ASSEMBLY OF RELEASE CYLINDER See page CL 5 1 COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE AS SHOWN 2 INSERT SPRING AND PISTON INTO CYLINDER 3 INSTALL BOOT AND INSERT PUSH ROD INSTALLATION OF RELEASE CYLINDER See page CL 5 1 INSTAL L RELEASE CYLINDER 2 CAREFULLY CONNECT FLEXIBLE HOSE 3 BLEED CLUTCH SYSTEM See page CL 3 ...

Page 236: ...REM OVAL OF CLUTCH UNIT 1 REMOVE TRANSMISSION S pages MT 3 4 NOTE Do not drain the transmission oil 2 REMOVE CLUTCH COVER AND DISC 3 a Loosen the set bolts one turn at a t ime until spring tension is released b Remove the set bolts and pull off the clutch assam bly REMOVE BEARING HUB AND FORK FROM TRANSMISSION a Remove the clips and pull off the bearing and hub b Remove the fork and boot ...

Page 237: ... Using a dial indlcator c heck the disc runout Maximum runout 0 8 mm 0 031 in If runout is excessive replace the disc 3 INSPECT FLVWHEEL RUNOUT Using a dial ondicator check the flywheel runout Maximum runout 0 2 mm 0 008 in If runout is excessive repair or replace the flywheel 4 INSPECT PILOT BEARING Turn the bearing by hand while applying force in the rotat ing direction 5 IF NECESSARY REPL ACE P...

Page 238: ...0 197 in 7 IF NECESSARY REPLACE PRESSURE PLATE a Drill out the rivet heads b Using a punch drive out the rivets c Install a new pressure plate with special pressure plate bolts and nuts Torque the nuts Torque 250 kg em 18 ft lb 26 N m d Stake the nuts 8 INSPECT RELEASE BEARING Turn the bearing by hand while applying force in the axial direction NOTE The bearing is permanently lubricated and re qui...

Page 239: ...der pressure INSTALLATION OF CLUTCH UNIT See page CL 7 1 INSTALL DISC ON FLYWHEEL Using SST install the disc on the flywheel SST 09301 20020 2 INSTALL CLUTCH COVER Tighten the bolts evenly and gfadually Make several passes around the cover until the cover is snug Torque the bolts Torque 185 kg em 13 ft lb 18 N m I 3 CHECK DIAPHRAGM SPRING TIP ALIGNMENT Using a feeler gauge and SST measure the gap ...

Page 240: ...N0 2 OR MP GREASE a Apply molybdenum disulphide lithium base grease to the following parts Release fork and hub contact point Release fork and push rod contact point Release fork pivot point Clutch disc spline Release bearing hub inside groove b Apply MP grease to the front of the release bearing 6 INSTALL BOOT FORK HUB AND BEARING ON TRANSMISSION 7 INSTALL TRANSMISSION See pages MT 23 241 ...

Page 241: ...SHOOTING _ _ _ MT 2 WSB TRANSMISSION MT 3 Removal of Transmission MT 3 Components MT 5 MT 1 Disassembly of Transmission MT 7 Inspection of Transmission Components MT 14 Assembly of Transmission MT 21 Installation of Transmission MT 34 ...

Page 242: ...ouit M M Remedy p Hard 10 a hih or w itt Splines on input shah dirty or burred Repeir as necessary MT 3 not shift Trensmi 5ion fautty Oiuasemble and inspeet MT 3 transmi ion Tran5mis sion jumps Transmission fautty Disassemble and inspect M T 3 out of goar transmission ...

Page 243: ...FT LEVER FROM INSIDE OF VEHICLE 6 RAISE VEHICLE AND DRAIN TRANSMISSION OIL CAUTION Be sure the vehicle is securely supported 7 REMOVE STE ERING GEAR HOUSING Remove the steering gear housing without disconnecting return and pressure tube then suspend it See page SR 27 8 REMOVE PROPELLER SHAFT Remove the propeller shaft and insert SST into the exten sion housing SST 09325 20010 9 REMOVE EXHAUST PIPE...

Page 244: ...LIGHT SWITCH CONNECTOR 12 REMOVE CLUTCH RELEASE CYLINDER 13 REMOVE STARTER 14 JACK UP TRANSMISSION SLIGHTLY Raise the transmission enough to remove the weight from the rear support 16 REMOVE ENGINE REAR MOUNTING 18 REMOVE TRANSMISSION ASSEMBLY Pull out the transmission down and toward the rear ...

Page 245: ...n l Back up Light Switch I 1 10 I IOutput Shaft _ __ _ Spring V Straight Scrtw Plug G G Shott Rewrse Idler Geer No 2Shift FO I IJ No 1 Interlock Pin 2 Shift Fork Shott ROYI W Shift Arm Lock Wash and Bolt ltt m lft lb N mll Specified tO QUt Non tt IJible part PttcOlttd part No 2 Interlock Pin No 3 lntertoc Pin No 3 Shift FO I No 3 Shift Fori Shott I Stoned Spring Pin r f No 4 Shift Fori Shaft Rever...

Page 246: ...tor COMPONENTS Cont dl pRi Counter Centtf Bearing Outer Race N tdlt Roller e riog Snap Ring l No 3 Qutd Hub Count 5th Ge1r Syn chro niz r Riog Ring Rear Searing Snapi G j0 0 0 __ __________________ ____ 0 0 2nd Gtaf Needle Roller Staring No 1 Clutch Hub Center Searing Needle RoUtt Beating lll Gear Steel 8tll WWOIIII ...

Page 247: ...ve the nine bolts C Using a plastic hammer tap the extension housing ldl Disengage the shift and select lever from the shift head e Pull out the extension housing NOTE Leave the gasket attached to the intermediate 1 plate 4 REMOVE FRONT BEARING RETAINER AND BEARING SNAP RINGS 5 SEPARATE INTERMEDIATE PLATE FROM TRANSMISSION CASE 8 Using 8 plastic hammer carefully tap the transmis sion case lbl Pull...

Page 248: ...p and the front tip surface of the nut are aligned bl Mount the intermediate plate in a vise REMOVE LOCKING BALL AND SPRING lal Using SST remove the lour plugs SST 09313 30021 lbl Using a magnetic linger remove the three springs and bans 8 REMOVE SHIFT FORKS SHIFT FORK SHAFTS AND REVERSE IDLER GEAR a Pry outthe lock washers of No 1and No 2 shift fork and remove the two set bolts b Using two screwd...

Page 249: ...ission MT 9 tel Remove the reverse idler gear stopper d Remove the reverse idler gear and shalt lel Remove No 1 shift fork end shaft f Using a magnetic finger remove No 1 and No 2 interlock pins lgl Remove No 2 shift fork and shaft ...

Page 250: ... 3 interlock pin i Using a pin punch and hammer drive out No 3 fort shaft pin ljl Pull out No 4 shift fork shaft kl Remove No 3 shift fork No 3 fork shaft and reverse shift arm with the pin 9 REMOVE SPEEDOMETER DRIVE GEAR Pry out both ends of the clip and remove the drive gear I I ...

Page 251: ... GEAR AND NEEDLE ROLL ER BEARING a Using snap ring pliers remove the snap ring lbl Using SST remove the rear bearing spacer 5th gear and bearing SST 09213 36020 CAUTION Be careful not to catch the outP t haft rear bearing roller on the counter 5th gear C Remove the spacer 12 REMOVE NO 3 HUB SLEEVE ASSEMBLY al Using two sc rewdrivers and a hammer tap out the snap ring lbl Using SST remove No 3 clut...

Page 252: ... socket wrench unscrew the torx screwsJ and remove the retainer b Using snap ring pliers remove the snap ring 16 REMOVE OUTPUT SHAFT AND COUNTER GEAR AS UNIT FROM INTERMEDIATE PLATE a Remove the output shaft input shaft and counter as a unit from the intermediate plate by pulling on the counter gear and tapping on the intermediate plate with a plastic hammer b Remove the input shaft from output sh...

Page 253: ...earing 1st gear needle roller bearing inner rece and synchronizer ring 19 REMOVE LOCKING BALL 20 REMOVE NO 1 HUB SLEEVE ASSEMBLY SECOND GEAR AND NEEDLE ROLLER BEARING Using a press remove the parts from the shaft as an as sembly 21 REMOVE NO 2 HUB SLEEVE ASSEMBLY AND THIRD GEAR a Using snap ring pliers remove the snap ring b Using a press remove No 2 hub sleeve synchroniz er ring and 3rd gear ...

Page 254: ...ing calipers measure the inner race llange thic kness M inimum thickn a 4 70 mm 10 1850 ln ct Using a micrometer measure the outer diameter of the output shaft journal Minimum diameter 2nd gear 42 85 mm 1 6870 in 3rd gear 37 80 mm 11 4882 in d Using a micrometer measure the outer diameter of the inner race Minimum diameter 42 85 mm 1 6870 in e Using a dial indicator check the shalt runout Maximum ...

Page 255: ...r 0 009 0 060 mm 0 0004 0 0024 ln 5th gear 0 009 0 062 mm 0 0004 0 0024 in Maximum clearance 0 16 mm 0 0059 ln If the clearance exceeds the limit replace the gear out put shaft and needle roller bearing CHECK OIL ClEARANCE OF THIRD GEAR Using a dial indicator measure the oil clearance between the gear and output shaft Standard clearance 0 060 0 103 mm 0 0024 0 0041 ln l Maximum clearance 0 20 mm 0...

Page 256: ...ARY REPLACE INPUT SHAFT BEARING at Using snap ring pliers remove the snap ring bl Using a press remove the bearing cl Using a press and SST install a new bearing SST 09506 35010 dl Select a snap ring that will allow minimum axial play and install it on the shaft Martt Thk kn8 S mm lin 1 2 05 2 10 10 0807 0 08271 2 2 10 2 15 10 0827 0 08461 3 2 15 2 20 10 0846 0 08661 4 2 20 2 25 10 0866 0 08861 5 ...

Page 257: ...depth 11 4 12 0 mm from retaiMr end 0 449 0 472 ln 9 IF NECESSARY REPLACE COUNTER GEAR FRONT BEARING AND SIDE RACE a Using snap ring pliers remove the snap ring bl Using a press and SST press out the bearing SST 09950 00020 c Check the side race for weer or damage d If necessarv remove the side race Using a SST and socket wrench remove tho side race SST 09950 20016 e Using a socket wrench press in...

Page 258: ...he bearing from the counter gear b Install a new bearing on the counter gear NOTE Engage tl le roller cages lei Using SST tap out the bearing outer race SST 09608 35014 109608 6020 09608 060901 NOTE The outer race wm be instaUed later as the Hans mission is assembled 11 IF NECESSARY REPLACE REVERSE RESTRICT PIN lal Using SST remove the screw plug SST 09313 30021 b Using a pin punch and hammer driv...

Page 259: ...CE REAR BEARING OUTER RACE a Remove the outer rac e from the extension housing 1 Using two screwdrivers remove the snap ring 2 Using SST tap out the outer race SST 09608 35014 109608 06020 09608 06090 b Install the bearing outer race 11 Using SST install a new outer race SST 09608 35014 09608 06020 09608 061001 2 Install the snap ring ...

Page 260: ... oil seaL SST 09201 60011 011 seal depth 26 mm 10 98 ln I 14 IF NECESSARY REPLACE OIL SEAL AND BUSHING al Using SST remove the oil seaL SST 09308 00010 or 09308 10010 w output shah installed bl Heat tho extension housing end to 80 100 C 176 212 Fl in an oil bath c Using SST remove the bushing and install a new bushing SST 09307 30010 dl Using SST drive in a new oil seal SST 09325 20010 ...

Page 261: ...l Apply gear oil to the shaft bl Place the synchronizer ring on the gear and align the ring slots with the shifting keys cl Using a press install the 3rd gear and No 2 clutch hub INSTALL SNAP RING Select a snap ring that will allow minimum axial play and install it on the shaft Mark Thickness mm in 0 1 80 1 85 1 0 0709 0 0728 11 1 86 1 91 1 0 0732 0 0752 12 1 92 1 97 10 0756 0 0776 13 1 98 2 03 10...

Page 262: ...T GEAR ASSEMBLY Ia Install the locking ball in the shaft lbl Apply gear oil to the bearing Ic Assemble the 1st gear synchronizer ring needle roller bearing and bearing inner race ld Install the assembly on the output shaft with the syn chronizer ring slots aligned with the shifting keys and turn the inner race to align it with the locking ball 7 INSTALL OUTPUT SHAFT CENTER BEARING Using SST and a ...

Page 263: ...e counter gear center bearing outer race SST 09608 35014 09608 06020 09608 060901 NOTE Install the outer race after installing the counter gear bl Install the output shaft into the intermediate plate by pulling on the output shaft and tapping on the inter mediate plate 10 INSTALL INPUT SHAFT AND COUNTER GEAR a Install the input shaft and counter gear together bl Using SST install the counter gearc...

Page 264: ... 0 0906 0 0925 18 2 67 2 72 1 0 1061 0 1071 12 2 36 2 40 0 0925 0 0945 19 2 73 2 7 10 1075 0 1 94 13 2 40 2 45 t0 094S 0 0985 20 2 79 2 84 0 1098 0 111 14 2 45 2 50 t0 096S 0 0 84 21 2 85 2 9010 22 0 114 1S 2 50 2 55 0 0984 0 1004 22 2 91 2 96 0 ll48 0 11 16 2 55 2 60 0 1004 0 1024 23 2 97 3 0210 ll69 0 11 14 INSTALL FIFTH GEAR AND OUTPUT SHAFT REAR BEARING Using SST install the 5th gear and rear ...

Page 265: ... clutch hub SST 09316 60010 09316 010 NOTE When Installing the clutch hub support the coun tershaft In front w ith a 3 5 lb hammer or equivalent 18 INSTAll SNAP RING Select a snap ring that will allow minimum axial play and install it on the shaft Mark Th ickne n mm in 2 2 06 2 11 10 0811 0 08311 3 2 12 2 17 0 0836 0 08541 4 2 18 2 23 0 0858 0 08781 6 2 24 2 29 10 0882 0 09021 19 INSTAll SPACER SY...

Page 266: ...ect a snap ring thlt will aUow minimum axial play n install it on the shaft 1 1 0 0 0748 6 2 1o 2 18 10 8 4 3 2 1 88 2 0 1 0 0772 8 2 20 2 2610 0860 3 2 02 2 07 0 0788 0 08 1 1 2 28 2 31 10 06 0 2 08 2 13 0 0818 22 INSTALL SPEEDOMETER DRIVE GEAR IaI Puta clip on the output shah and install the drive gea clip into the slot bl Slide the drive gear with clip and fit the clip Into 1ho holes 23 INSTALL...

Page 267: ... tho reverse idler gear groove Install No 3 shift fork shalt to the intermediate plate c Install No 4 shift fork shaft 111 Push the pin which was inserted Into the reverse shift arm hole into the groovaof No 3 shift fork shaft 21 Install No 4 shift fork shaft to the intennedista plate over the reverse shift arm d Using a pin punch drive in the slotted spring pin until it is flush with tho fork e A...

Page 268: ...e of No 2 hub sleeve 13 Install No 2 fork shaft to the shift fork through the intermediate plate g Install the snap ring of No 2 fork shaft h Apply MP grease to No 1 interlock pin and install the pin into the intermediate plate i Install No 1 shift fork and fork shaft I1 Install No 1 shift fork into the groove of No 1 I hub sleeve 12 Insert No 1 fori shaft to the shift fork through the intermediat...

Page 269: ...ork set bolts with lock washers Torque 125 kg em 9 ft b 12 N m I Using pliers stake the bolts w ith lock washers 24 INSTALL LOCKING BALL ANO SPRING lal Install the balls and springs Into each hole lbl Apply liquid sealer to the plugs lei Using SST tighten the four plugs SST 0931 3 30021 Torque 260 kg em 1 18 ft b 26 N m ...

Page 270: ...e bolts nuts plate washers and gasket 27 INSTALL TRANSMISSION CASE TO INTERMEDIATE PLATE a Al n each bearing outer race and each shift IO k sNII end with the case holes lbl Using a plastic hammer tap on the case to Installit 28 INSTALL BEARING SNAP RINGS Using snap ring pliers install the two snap rings 29 INSTALL FRONT BEARING RETAJNER al Install the bearing retainer with a new gasket bl Apply li...

Page 271: ...shift and t lever into the extensionhousing lei Connect the shift and select lever to the shift fori shaft ldl Install shift lever housing to shift and selectlever shalt push in the extension housing lei Install and torque the bolt Torque 400 kg m 29 ft lb 39 N ml 31 INSTALL ANO TORQUE EXTENSION HOUSING BOLTS Torque 375 kg em 27 ft b 37 N ml ...

Page 272: ...he reverse gear and Sdl gear side bl Torque the restrict pins Torque 410 kg cm 30 lt lb 40 N ml 34 INSTALL CLUTCH HOUSING C al Install the clutch housing bl Install and torque the bolts TO que 375 kg cm 27 fHb 37 N ml 35 INSTALL RELEASE FORK AND BEARING Apply molybdenum disulphide lithium base grease to tho following parts Release bearing hub inside groove Input shaft spline Release fork contact s...

Page 273: ...AR al Install tho speedometer driven gear b Install the bolt with lock plate c Torque the bolt Torque 130 kg em 1 9 It lb 13 N ml 38 INSTALL 8ACK UP LIGHT SWITCH a Install end torque the beck up light switch T _ 410 kg em 130 ft 11 40 N ml b Install the wire clamp MT 33 ...

Page 274: ...he upper transmission and torque the bolts Ta que 660 kg cm 47 ft lb 64 N m 2 INSTAll ENGINE REAR MOUNTING Install the eight bolts and torque them Torque 250 kg em 18 It lb 26 N m 3 4 5 6 INSTALL TRANSMISSION BOLTS Install and torque the bolts Torque 650 kg m 47 ft lb 64 N m INSTAll EXHAUST PIPE CLAMP BOLT Install and torque the bolt Torque 375 kg m 27 ft b 37 N m INSTALL STARTER Install the start...

Page 275: ...1 ft lb 42 N ml 10 INSTALL ST ERING GEAR HOUSING w PSl 11 FILL WITH TRANSMISSION OIL Oil grade API service GL 4 or GL 6 SAE 76W 90 or 80W 90 Capacity 2 4 litera 2 6 US qll 2 1 Imp qtal 12 INSTALL RADIATOR UPPER HOSE AND FILL COOLANT 13 CONNECT NEGATIVE BATTERY TERMINAL WIRE 14 INSTALL SHIFT LEVER 16 INSTALL CONSOLE BOX 16 PERFORM ROAD TEST Check for abnormal noise and smooth operation ...

Page 276: ...N AND ASSEMBLY Oil Pump Overdrive Input Shaft and Clutch Overdrive Case and Brake Front Clutch Rear Clutch Center Support Assembly Planetary Gear Output Shaft Transmission Case and Rear Brake Pistons Valve Body Extension Housing Torque Converter Electrical Parts ASSEMBlY OF TRANSMISSION INSTAllATION OF TRANSMISSION AT 1 Page AT 2 AT 5 AT 5 AT 6 AT 22 AT 23 AT 24 AT 25 AT 29 AT 30 AT 32 AT 42 AT 45...

Page 277: ...e page AT 81 I Preliminary Check I Stall Test See page AT 221 I jTime Lag Test See page AT 23 I Electric Control System Check See page AT 6 Measure Line Pressure See page AT 241 I Road Test I Read the diagnostic code Itrouble code from overdriveil dicator light or super monitor display and perform repairs aCCOidingly Check following Fluid level Throttle cable mark Shift linkage Neutral start switc...

Page 278: ...st linkage AT 5 incorrect Manv al valve and lever faulty Inspect valve body AT 83 Transmission faulty Disassemble af d inspect AT 45 transmission Harsh engagement Throttle cable out of adjustment Adjust throttle cable AT 5 into any drive range Valve body or primary regulator faulty Inspect valve body AT 83 Accumulator pistons faulty Inspect accumulator pistons AT 11 2 Transmission faulty Disassemb...

Page 279: ... No down shift when Valve body faulty Inspect valve body AT 83 coasting Solenoid valve faulty Inspect solenoid valve AT 19 Electric control faulty Inspect elec tric control AT 6 Oown shift occurs too Throttle cable faulty Inspect throttle cable AT 37 quickly or late while Valve body fault y Inspect valve body AT 83 coasting Transmission faulty Disassemble and inspect AT 45 Hansmission Solenoid val...

Page 280: ...orrect Distance 0 1 mm 0 0 04 in lb Tighten the adjusting nuts lc Recheck the adjustments ADJUSTMENT OF FLOOR SHIFT LINKAGE ADJUST SHIFT LINKAGE tal Loosen the nut on the shift linkage b Push the manual lever fully rearward lei Return the lever two notches to the NEUTRAL po sition Id Set the shift selector in N e While holding the selector lightly toward the R range side tighten the shift linkage ...

Page 281: ...ator Combination ter Ntutrtl Sian Switch 2 L N SP1 s 8 IG BR PwR ECT IOL ECU L L L GNO OO 001 ECU IG Fu I15AI Engint ECU C C Compute STOP Fuse 115AI COMPONENTS ECT ECU Engine ECU Throttle Posi1ton Somor No 2 S olenooid No 1 and No 2 Water Thermo __ _ Sensor 1 1 enooiod No 3 OG Tern inal Neutral Start Switch ...

Page 282: ...rdrive indicator light when OG termi nal and body ground are short circuited See page AT 8 lcl The throttle position sensor or brake signal are not in dicated but inspection can be made by checking the voltage at DG terminal ldl The signals to each gear can be checked by measur ing the voltage at OG terminal 2 The diagnostic code ltrO Jble code is retained in memory by the CPU tof ECT ECUI and due...

Page 283: ...he diagnostic code as indicated by the number ol flashes of the 00 OFF light Diagnostic Codes Indication a If the system is operating normally no malfunction the light will blink once every 0 25 seconds b In event of a malfunction the light will blink once ev ery 0 5 seconds The first number of blinks will equal the first digit of a two digit diagnostic code After a 1 5 seconds pause the 2nd numbe...

Page 284: ...rcuit NOTE If codes 62 63 or 64 appear there is an electri cal malfunction with the solenoid Causes due to mechanical failure such as a stuck switch will not appear CANCEL OUT DIAGNOSTIC CODE 1 After repair of the trouble area the diagnostic code retained in memory by the ECT ECU must be canceled out by remov ing the fuse ECU B 15A for 10 seconds or more de pending on ambient temperature the lower...

Page 285: ... sensor Of circuit 2 Inspect brake signal lal Depress the accelerator pedal to where OG termiNI indicates sv bl Depress the brake pedal and check the voltage read ing for DG terminal Brake pedal deprened OV Brake pedal roleeood SV If not as indicated there is a malfunction with either the stop light sw itch or circuit 3 Inspect each up shift position IaI b c d Warm up the engine Coolant temperetur...

Page 286: ...ge could rise anywhere between OV fN be fore the vehicle reaches 10 kmlh or 6 mph in first gear The voltage jump depends on what percent the throttle valve is opened This is a normal reading Above 10 km h or 6 mph the voltmeter indicates the cur rent gear NOTE Determine the geer position by alight shock or change In engine rpm when shifting ...

Page 287: ... event of a simultaneous malfunction of both speed sensors No 1 end No 2 no diagnostic code will appear and fail safe will not function However when driving in 0 range the transmission wl not up shift from first gear regardless of the vehicle speed Trouble No 1 Blinking overdrive indicator light while driving Output diagnosis code ISeo page AT 81 Code No 62 63 64 Disconnect ECT ECU connector end t...

Page 288: ... with changes in throttle opening1 Yes No Is voltage between ECT ECU terminals No Brake signal BR and GNO as follows faulty OV Brake pedal released 12V Brake pedal depressed Yes Computer power sourse and earth fauhy Throttle position signal faulty OG terminal wire open or short OiseonMCt ECT ECU connector and road test No Does the transmission operate in the respective gear when in the following r...

Page 289: ...rise from N 10 7V in sequence 1 0 7V_ _ Tranomi sM n faulty Solenoid faulty 0 5V IOV I0 3V Thera Is 12V between ECT ECU l GNO when 0 range NO jYes Nevtrtl start switch circuit faulty Neutral stert switch feulty Try another ECT ECU Proceed to trouble 4 AT 16 n Ia 12V between ECT ECU 2 GNO when 0 range IY jNo i I ...

Page 290: ...1esminal end body Does OG terminal voltage vary with changes in throttle opening Yes No Is voltage between ECT ECU terminals No Brake signal faulty BR and GNO as follows OV Brake pedal released 12V Brake pedal depressed Yes Computer power source and earth faulty Thronle position signal faulty DG terminal wire open or short Check voltage between ECT ECU terminals OK Faulty ECT ECU PWR and GND Fault...

Page 291: ...INo There is 12V between ECT ECU terminals l nd GNO 0 No Yes neutral start circuit neutral start switch ITry another ECT ECU Is voltage between terminals 00 and GNO as Faulty 00 switch follows I No harness 00 switch turn ON 12V Aisin or 5V Oenso Faulty 00 switch 00 turn OFF OV DO off light ooen I I Yes check 00 cutout signan Is voltage between terminals 00 and GNO as follows Approx SV IDenso or 12...

Page 292: ... trouble No 1 CAT 12 No Indicated Rold test Conn ct vottmeter to OG te rmlnat ai KK body Yes No 3solenoidstuck ground Ia tl ero 7 5 or 3V in rl e lock up range Feutty transmission white driving7 Faulty lockoUp mechanism No Is voltage between ECT ECU Faulty computer power aource BRand GNO tarminel es follows Yeo Brake pedal depre ssed 12V and earth Bra e Mdll released fauttv thronle position ajgn a...

Page 293: ...le valve fully open 5 12 Throttle valve funy closed 5 12 l GNO Throttle valve fuMy ctosed to fully open 5to0to5to0to5 12 to 0 to 12 to 0 to 12 Thton e valve fuRy open 5 12 Thtottle valve fuly cloud 0 IDl GND ThrottJe vatve opening above 1 5 12 Standing still 5 or 0 12 or 0 SPo GND 2 5 Engine running vehk le moving 6 When brake pedal i s depressed 12 BR GNO When brake pedal ia not depressed 0 2 ran...

Page 294: ...RT SWITCH Shift the lever into the L or 2 range al b IC Disconnect the connector near the staner motor Check that there is continuity between L 2 and ground 4 INSPECT THROTTLE POSITION SENSOR Using an ohmmeter check the re sistance between each Vc terminal VTA IOL e Throttle valve condition Resistance lkO IOL e Fully closed 0 Open lnfinitv Vc E t 3 7 Vu E2 Fully closed 0 2 0 8 Fully open 3 3 10 5 ...

Page 295: ...that the voltmeter needle repeatedly defects from OV to 2V B INSPECT PATTERN SELECTION SWITCH Inspect that there is continuity between 2 and eacfl terminal NOTE As there are diodes inside be careful of the teS1lr probe polarity at n 2 4 3 NORM PWR 9 INSPECT 00 SWITCH n Inspect that there is continuity between 1 and 3 t 3 c I v Terminal srr ____ t 3 poSitiOn ON OFF 10 INSPECT LOCK UP MECHANISM a Wa...

Page 296: ... ECU connector 2 INSPECT MANUAL DRIVING OPERATION a While driving check that there is respective gear change in each drive range Shift D 2 L A p position range range range range range Gear 00 J d 1st Reverse Pawl position Lock b Vehicle moves in reverse in R range C Vehicle does not move in N range d Parking pawl locks in P range If not as specified check the transmission NOTE If a problem is indi...

Page 297: ...ghest engine rpm at this time Stall speed 2 100 150 rpm g Perform the same test in R range EVALUATION IaI If the engine speed is the same for both ranges but lower than specified value Engine output is insufficient Stator one way clutch is not operating properly NOTE If more than 600rpm below the specifiOd value the torque converter could be at fault lbl If the stall speed in D range is higher tha...

Page 298: ...o aNow a one minute interval between teats fc Make three measurements and take the aver age value MEASURE TIME LAG Ill Fu11y apply the parking brake 1111 Start the engine Check idling speed A C OFF N range 650 rpm lei Shift the shift lever from N to 0 range Using e stop watch measure the time it takes from shifting the lever until the shock is felt r lag Leu than 1 2 seconds ldl Insame manner mea ...

Page 299: ...he test in R range Engl ne speed Unt preaaure kg em lpol kPol rpm 0 ranoe R range 3 7 4 1 5 1 5 7 Idling 53 58 173 81 1363 402 1500 5591 IV O 13 0 14 3 19 0 Stall 151 185 203 270 1 040 1 275 1 402 1 8631 el If the measured pressures are not up to spect lied values recheck the throttle cable adjust ment and perform a retest EVALUATION a If the measured values at all ranges are higher than specified...

Page 300: ... There is no 00 up shift or lock up when coolant is be low 63 C 145 F and speed is under 63 km h 39 mph or if there is a 10 km h 16 mph difference be tween the set cruise control speed EVALUATION 1 If there is no 1 2 up shift o No 2 solenoid is stuck 1 2 shift valve is stuck 2 If there is no 2 3 up shift o No 1 solenoid is stuck o 2 3 shift valve is stuck 3 If there is no 3 00 up shift throttle va...

Page 301: ...hock and slip at kick down f While running in 0 range 00 gear shift to 2 ani L ranges and check the engine braking eHactIt each of these ranges EVALUATION 1l If there is no engine braking effect at 2 range Brake No 1 Is defective 2 If there is no engine braking effect at L range Brake No 3 Is defective 2 2 RANGE TEST WITH NORM AND PWR PATTERNS Shift into 2 range and w hile driving with the accelor...

Page 302: ...n and for shock at up shift and down shih 3 L RANGE TEST al While running above 80 km h 50 mphI in the 0 range release your foot from the accelerator pedal and shift into L tange Then check to see that the 2 1 down shift POint conforms to 53 km h 33 mph b While running in the L range check to see that there is no up shift to 2nd gear c While running in l range release the accelerator pedal and che...

Page 303: ...Gradient 4 R RANGE TEST Snift into R range and wnile starting at full thronlt cnock for slipping 6 P RA NGE TEST Stop the vehicle on a gradient more tnan 9 II I and efur shifting into P range release the parking brake Then check to see that the parking lock pawl is functioning 10 prevent the vehicle from moving ...

Page 304: ...oid operating conditions SOLENOID NO 1 SOLENOID NO 2 BOTH SOLENOIDS NORMAL MALFUNCTIONING MALFUNCTIONING MALFUNCTIONING Solenoid valve Gear Solenoid valve Gear Solenoid valve Gear Solenoid valve Gear No 1 No 2 Position No I No 2 Position No I No 2 Position No I No 2 Position ON OFF 1st X ON IOFFI tfd 0 ON X ht X X 00 ON ON 2nd X ON 3rd OFF ONI X 00 1stl X X 00 D renge OFF ON 3rd X ON 3rd OFF X 00 ...

Page 305: ......

Page 306: ...tlo 10 20 30 40 50 60 70 80 90 100 110 120 130 4 100 kmJh 100 2 range I I 85 r z z I w 1 f 2 I 2 0 5 50 r w 3 J 2 0 15 0 1 000 2 000 3 000 4 000 5 000 Diff tntiel OUTPUT SHAFT rpm gur fltio 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 4 100 kmJh l range NORM pattern 100 PWRu pattem 1 z I 2 I z 85 I w 0 I I 65 I I I 50 I I w I t 35 I I 0 25 I I i 15 I 5 I I 0 1 000 2 000 3 000 4 000 5 000...

Page 307: ...event contamination clean the exterior of thl transmission DRAIN TRANSMISSION FLUID Remove the drain plug and drain fluid into a suitable con tainer 4 REMOVE OIL PAN FILLER TUBE AND GASKET CAUTION Some fluid w ill remain in the oil pen Be ful not to damage the filler tube end 0 flng Remove all pan bolts and carefully remove the pan assem bly Discard the gasket 6 REMOVE OIL TUBES a Remove the l our...

Page 308: ...e No 1 and 2 solenoids 1 Remove the three bolts 121 Remove the solenoid with gasket NOTE Be careful not to remove the two valve springs 8 REMOVE OIL STRAINER Remove the six bolts and the oil strainer CAUTION Be careful as some oil will come out with the oil strainer 9 REMOVE VALVE BODY a Remove the fifteen bolts bl Remove the 82 and c accumulator piston springs ...

Page 309: ...able from the cam and move the valve body DISASSEMBLY INSPECTION AND ASSEMBLY OF VALVE BODY See page AT 831 INSTALLATION OF VALVE BODY CONNECT THROTTLE CABLE TO CAM Push the cable fitting into the cam 2 REMOVE ACCUMULATOR RETAINING PLATE Remove the two pan bolts and slide out the plate 3 INSTALL VALVE BODY al Align the manual valve lever w ith the manual valve lbl Install the a and c accumulator p...

Page 310: ...EPLACING SOLENOID lal For the No 3 solenoid o Install the solenoid into the bore Tighten the two bolts Torque 55 kg em 48 in lb 6 4 N m lbl For the No 1 and 2 solenoids Make sure that the two valve spring are installed correctly Install the solenoid over the gasket and install the center of the bolt o Tighten the three bolts Torque 100 kg em 7 ft b 10 N ml 7 CONNECT TWO CONNECTORS TO EACH SOLENOID...

Page 311: ...ts are in place CAUTION Do not uae guket se Tighten the bolts evenly Torque 45 kg cm 39 in lb 4 4 N m 10 INSTALL DRAIN PlUG Torque the drain plug Torque 205 kg cm 15 fHb 20 N m 11 FILL TRANSMISSION WITH ATF Add only about four quarts of ATF CAUTION Do not overfill Fluid type ATF DEXRON n 12 CHECK FLUID LEVEL See page MA 13 REMOVAL OF THROTTLE CABLE 1 REMOVAL AIR CLEANER 2 DISCONNECT THROTTLE CABLE...

Page 312: ...EW PAINT MARK ON INNER CABLE NOTE New cables do not have a cable stopper installed Therefore to make adjustment possible paint a mark as described below al Pull the inner cablelightly until slight resistance is felt and hold it b Paint a mark as shown about 4 mm 0 16 in in width 4 CONNECT THROTTLE CABLE a Connect the cable to the throttle linkage b Connect the cable housing to the bracketon the va...

Page 313: ... bolts Torque 75 kg cm 165 in lb 7 4 N ml 4 INSTALL VALVE BODY See page AT 341 REMOVAL OF EXTENSION HOUSING 1 RAISE VEHICLE AND POSITION PAN TO CATCH ANY FLUID THAT MAY DRIP 2 REMOVE PROPELLER SHAFT 3 JACK UP TRANSMISSION SLIGHTLY Securely support the transmission on a transmission jack Lift the transmission slightly to remove weight from the rear support member 4 DISCONNECT SPEEDOMETER CABLE Loos...

Page 314: ...r or block of wood to loosen it CLEAN AND INSPECT COMPONENTS Ia Wash components in clean solvent and dry with com pressed air lb Check the case speedometer gear and output shaft for cracks wear or damage INSTALLATION OF EXTENSION HOUSING NOTE If necessary insta11 a new oil seal before insta11a tion See page AT 103 1 INSTALL NEW GASKET AND EXTENSION HOUSING ON TRANSMISSION lnsta11 the six bolts fin...

Page 315: ...k plate with a bolt and washer 6 CONNECT SPEEDOMETER CABLE 7 Place the felt dust protector and washer on the end of1toe cable Tighten the collar with pliers LOWER VEHICLE AND CHECK FLUID LEVEL See page MA 13 Start the engine shift the selector into each gear then check the fluid level with the transmission in P range Add fluid as necessary CAUTION Do not overfill Fluid type ATF DEXRON U REMOVAL OF...

Page 316: ...EHICLE AND POSITION PAN TO CATCH ANY FLUID THAT MAY DRIP 2 REMOVE PROPELLER SHAFT 3 REMOVE REAR DUST SEAL AND OIL SEAL CAUTION Clean the rear extension housing before removing the seal Using SST remove the two seals SST 09308 10010 4 INSTALL NEW OIL SEAL AND DUST SEAL Using SST drive in the oil seal as far as it will go Drive in the dust seal flush with the housing SST 09325 20010 5 INSTALL PROPEL...

Page 317: ... from the throttle linkage c Disconnect the throttle cable from the engine rear end 6 RAISE VEHICLE AND DRAIN TRANSMISSION CAUTION Be sure the vehicle Is securely supported 7 DISCONNECT THREE W IRING CONNECTORS Disconnect the three connectors located near the starter B REMOVE INTERMEDIATE PROPELLER SHAFT TOGETHBI CENTER BEARING a Disconnect the propeller shaft from the intermed te shaft bl Remove ...

Page 318: ... TRANSMISSION HOUSING AND CYl iNDER BLOCK 14 REMOVE POWER STEERING GEAR HOUSING tal Remove the sliding yoke from gear housing tbl Disconnect both tie rod ends w ith SST SST 09611 22012 c Remove the fluid line clamps ldl Remove the four bolts and remove the two brackets and rubber insulator e Remove the gear housing from the erossmembor and e J suspend it with strings Af07U 15 JACK UP TRANSMISSION ...

Page 319: ...cessary a guide pin can be made by cutting off tht head of a bolt 20 REMOVE TRANSMISSION HOUSING MOUNTING BOLTS al Remove the starter b Remove the transmission housing mounting boll 21 PRY ON END OF GUIDE PIN TO BEGIN MOVING TRANSMISSION WITH CONVERTER TOWARD REAR The guide pin helps keep the converter with the trans mission 22 REMOVE TRANSMISSION ASSEMBLY Draw out the transmission down and toward...

Page 320: ...ing connector b Remove the speed sensor 3 REMOVE SHIFT HANDLE 4 REMOVE NEUTRAL START SWITCH 5 REMOVE OIL PUMP a Remove the seven bolts lbl Position SST on the shaft in back of the spline SST 09610 20012 CAUTION Do not damage the shaft bushing surface Turn the end bolt of SST to free the pump c Grasp the front pump stator shalt and pull the pump from the case 6 WATCH FOR BEARING BEHIND OIL PUMP ...

Page 321: ...SNAP RING FROII OUTPUT SHAFT 11 REMOVE PAN AND GASKET a Remove the fourteen bolts b Remove the pan by lifting the transmission case NOTE Do not tum me transmissionover as this will con taminate the valve body with foreign materials in the bot tom of the pan 12 EXAMINE PARTICLES IN PAN Remove the magnet and use it to collect any steel chips Look carefully at the chips and particles in the pan and o...

Page 322: ...1 and 2 solenoid and the No 3 solenoid b Remove the grommet from the transmission case cl Pull the wiring out of the transmission case 15 REMOVE STRAINER 16 REMOVE VALVE BODY a Remove the fifteen bolts bl Remove the a and c accumulator piston springs cl Disconnect the throttle cable from the cam and re move the valve body 17 REMOVE THROTTLE CABLE AND RETAINER Using a 10 mm socket push the plastic ...

Page 323: ...E MOVE SPRING PIVOT PIN AND PARKING LOCK PAWl 21 IF NECESSARY REMOVE MANUAL LEVER SHAFT a Using a hammer and screwdriver pry and shift lhe collar b Using a hammer and punch drive out the pin lcl Slide the shaftout case and remove tho detent plate 22 PLACE TRANSMISSION CASE ON CYLINDER Place the transmission on a cylindrical stand for more elfi cient work CAUTION Place shop reg between the cue and ...

Page 324: ... it out from the transmission case Watch for the bearings and races on both sides of the assembly 26 MEASURE DISTANCE BETWEEN TOP OF CASE AND CLUTCH DRUM Set SST on the case as shown in the ligure SST 09350 20013 09370 12010 Make a note of the finding for reassembly 27 REMOVE FRONT CLUTCH AND BEARINGS Grasp the shaft and pull out the front clutch assembly Watch for the bearings and races on both s...

Page 325: ...REACTION PLATE RETAINING RING Using a long screwdriver compress the sna p ring and 1ft it above the groove with a wire hook 32 REMOVE REAR PARTS GROUP Grasp the intermediate shalt and pull out the rear potts group If the brake apply tube and rear thrust bearing and races do notcomeout with the assembly remove them from the case Watch for the bearing and race in the transmission case 33 BASIC DISAS...

Page 326: ...g GENERAL ASSEMBLY 1 All oil seal rings clutch discs clutch plates rotating parts and sliding surfaces should be coated with transmission fluid prior to reas sembly 3 All gaskets and rubber O rings should be replaced 5 Make sure that the ends of a snap ring are not aligned with one of the cutouts and are in stalled in the groove correctly As much as possible complete the inspection repair assembly...

Page 327: ...l Stal Ring CUlt DISASSEMBLY OF OIL PUMP 1 USE TORQUE CONVERTER AS A WORK STAND 2 REMOVE TWO OIL SEAL RINGS FROM PUMP COVER 3 REMOVE PUMP COVER 4 REMOVE O RING FROM PUMP 5 UFT PUMP OFF CONVERTER AND REMOVE Oil PUMP DRIVE GEAR AND DRIVEN GEAR Identify the top and bottom and keep in assembly order ...

Page 328: ...0 0043 0 0055 ln Maximum tip clearance 0 3 mm 10 012 ln If the tip clearance is greater than the maximum replace tho drive gear driven gear or pump body 3 CHECK SIDE CLEARANCE OF BOTH GEARS Using a steel straightedge and a feeler gauge measure the side clearance of both gears Standard aide clearance 0 02 0 05 mm 0 0008 0 0020 ln Maximum aide clearance 0 1 mm 0 004 ln If the side clearance is great...

Page 329: ...ND PUMP COVER Install the SST around the pump and cover Tighten SST to align the pump and cover SST 09350 20013 1 09363 20010 4 TIGHTEN SIX PUMP COVER BOLTS Torque 75 kg em 65 inAb 7 4 N ml 5 INSTALL TWO OIL SEAL RINGS ON PUMP COVER Spread the rings apart and slide them into the groove Hook both ends by hand W ipe off excess petroleum jelly 6 INSTALL NEW 0 RING ON PUMP COVER Make sure a new O ring...

Page 330: ... way Clutch Planetary Gear DISASSEMBLV OF OVERDRIVE INPUT SHAFT AND CLUTCH 1 REMOVE THRUST BEARINGS AND RACES FROM OVERDRIVE INPUT SHAFT 2 a Slide off the thrust bearing and race from the clutch side by hand Note the position of the races b Using a screwdriver pry off the thrust washer from the planetary gear side PULL OVERDRIVE CLUTCH ASSEMBLY FROM INPUT SHAFT CAUTION Be careful that the thNSt be...

Page 331: ...IGHTEEN SPRINGS 8 ASSEMBLE OVERDRIVE CLUTCH ON OIL PUMP AND BLOW OUT PISTON Ia Slide the overdrive clutch onto the oil pump b Apply compressed air to the oil pump to remove the piston llf the piston does not come out completety use needle nose pliers to remove it tc Remove the overdrive clutch from the oil pump 9 REMOVE CLUTCH PISTON 0 RINGS 10 REMOVE SNAP RING FROM OVERDRIVE PLANETARY GEAR ASSEMB...

Page 332: ...s not worn or burnt If the disc is worn or burnt replace disc Then check that the sliding surfaces of plate and flange are not worn or burnt If necessary replace them NOTE Do not allow the discs to dry out Prepare new discs by soaking them at least two hours in ATF ASSEMBLV OF OVERDRIVE INPUT SHAFT AND CLUTCH See pege AT 551 1 INSTALL FOUR PLUGS 2 INSTALL THRUST WASHER AND B EARING aI Coat parts w...

Page 333: ...N GROOVE tal Place SST on tho spring retainer and compress tilt springs on e shop press SST 09350 20013 109369 20040 tbl Install the snap ring with a screwdriver INSTALL CUSHION PLATE PLATE DISC AND FLANGt WITHOUT ASSEMBliNG THINNER SNAP RING ht Do not assemble the thinner snap ring yet b Using low pressure compressed air blow all OXCOS ATF from the disc CAUTION High preuure air w H I damage the e...

Page 334: ... of the snap ring are not aligned with one of the cutouts 11 INSTALL HUB AND OUTER SNAP RING Check that the ends of the snap ring are not aligned with one of the cutouts 12 ASSEMBLE OVERDRIVE CLUTCH DRUM AND OVERDRIVE PLANETARY GEAR Mesh the hub with the disc twisting and jiggling the hub as required 13 CHECK OPERATION OF ONE WAY CLUTCH Hold the clutch drum and turn the input shaft The input shaft...

Page 335: ...late Brtke Piston Rec e Piston Re1urn Spring Ring Gear Retainer Oil S ol Ring Thrust S ring R101 Thrus t Washer Snap Ring 00 Clst Thrust Staring DISASSEMBLY OF OVERDRIVE CASE AND BRAKE 1 REMOVE RACE FROM OVERDRIVE 2 REMOVE OUTER SNAP RING FROM OVERDRIVE CASE 3 REMOVE CLUTCH FLANGE DISCS PLATES AND CUSHION PLATE ...

Page 336: ...op out the brake piston If the piston does not pop out lift it out with needle nose pliers 8 REMOVE TWO OIL SEAL RINGS FROM OVERDRIVE CASE 9 REMOVE 0 RINGS FROM PISTON INSPECTION OF OVERDRIVE CASE AND BRAKE INSPECT DISC PLATE AND FLANGE Check that the sliding surface of disc is not worn or burnt If the disc is wom or burnt replace all discs Then check that the sliding surfaces of plate and flange ...

Page 337: ... THRUST BEARING AND RACES TO RING GEAJI AND SET RING GEAR IN OVERDRIVE CASE 6 7 6 NOTE Make sure that the races are installed in couect direction INSTALL CUSHION PLATE DISCS PLATES AND FLANGE Using low pressure compressed air blow all excess ATf from the discs CAUTION High pressure air will damage the discs Install in order Cushion plate rounded end down plate disc plate disc plate disc flange fla...

Page 338: ...I I I c Plate Thinner Snap Ring Disc I I _ Rear Hub Front Hub DISASSEMBLY OF FRONT CLUTCH 1 REMOVE THRUST BEARINGS AND RACES FROM BOTH SlOES OF CLUTCH Note the position of the races 2 USE EXTENSION HOUSING AS WORK STAND 3 REMOVE SNAP RING FROM FRONT CLUTCH DRUM 4 REMOVE FRONT AND REAR CLUTCH HUB Lift out the two clutch hubs together ...

Page 339: ...river SST 09350 20013 09369 20040 10 REMOVE SPRING RETAINER AND EIGHTEEN SPRINGS ASSEMBLE FRONT CLUTCH ON OVERDRIVE CASE AND BLOW OUT PISTON a Slide the front clutch onto the overdrive case b Apply compreued air to the ovardnvecesato re the piston If the piston does not come out use pi ers to remove it l c Remove the front clutch from the overdrive case 12 REMOVE O RINGS FROM PISTON INSPECTION OF ...

Page 340: ...ll down Be careful not to damage the 0 rlngs INSTALLTWENTY PISTON RETURN SPRINGS SPRING RE TAINER AND SNAP RING IN PLACE COMPRESS RETURN SPRINGSANDINSTALL SNAPRING IN GROOVE al Place SST on the spring retainer and compress the springs with a shop press SST 09350 20013 09369 20040 bl Install the snap ring w ith a screwdriver 6 INSTALL DISCS AND PlATES WITHOUT ASSEMBLING THINNER SNAP RING el Do not ...

Page 341: ...D RACES IMPORTANT Coet parta wi1h petrOleum jolyto hold U in place Install the inner race needle bearing and outer race Press them into place NOTE Face the lip of race toward the front of the clutch body 10 INSTALL FRONT CLUTCH HUB Align the disc lugs with the hub teeth Make sure the hob meshes with all discs and is tully inserted 11 INSTALL REAR CLUTCH HUB AND OUTER SNAP RING Check that the snap ...

Page 342: ...sing a screwdriver remove the snap ring SST 09350 20013 4 REMOVE SPRING RETAINER SNAP RING AND EIGHTEEN RETURN SPRINGS 5 ASSEMBLE REAR CLUTCH ON CENTER SUPPORT AND BLOW OUT PISTON at Slide rear clutch onto the center support b Apply compressed eir to center support to remove tho piston If the piston does not come out use pliers to remove lt C Remove the front clutch from the center support 6 REMOV...

Page 343: ...NGSAND INSTALL SNAP RIIIG IN GROOVE al Place SST on the spring retainer and compress the springs on shop press SST 09350 2001 3 09369 20040 b Install the snap ring with snap ring pliers 6 INSTALL DISCS PlATES AND FlANGE Using low pressure compressed air blow all excess ATF from discs CAUTION Hlgh preuure air will damage the dloco Install in order Plate disc plate disc1 1ate disc flan90 lflot end d...

Page 344: ...ap Ring Flange Snap Ring pfing Retainer Piston Return Spring Sun Gear One way Clutch AT DISASSEMBLY OF CENTER SUPPORT ASSEMBLY 1 REMOVE SNAP RING FROM END OF SUN GEAR SHAFT 2 PULL CENTER SUPPORT A SSEMBLY FROM SHAFT 3 REMOVE SNAP RING FROM FRONT OF CENTER SUPPORT ASSEMBLY NO 1 BRAKE 4 REMOVE CLUTCH FLANGE DISCS AND PlATES NO 1 BRAKE ...

Page 345: ...p out lift it out with needle nose pliers 8 REMOVE NO 1 BRAKE PISTON 0 RINGS 9 TURN CENTER SUPPORTASSEMBLY OVER AND REMOvt REAR SNAP RING NO 2 BRAKE 10 REMOVE CLUTCH FLANGE DISCS AND PLATES IND 2 BRAKEI 11 COM PRESS PISTON RETURN SPRINGS AND REMOvt SNAP RING PlaceSST on spring retainer and compress the springs with a shop press Using a screwdriver remove the snap ring SST 09360 20013 09369 20040 1...

Page 346: ...CK OPERATION OF ONE WAY CLUTCH Hold the No 2 brake hub and turn the sun gear The sun gear should turn freely counterclockwise and should lock clockwise If the one way clutch does not work properly replace it 2 IF NECESSARY REPLACE ONE WAY CLUTCH a Bend several tabs back w ith a tapered punch b Pry off the retainer with a screwdriver leave the other retainer on the hub c Remove the one way clutch d...

Page 347: ...e not worn or burnt If necessary replace them NOTE Do not allow tha discs to dry out Prepare new discs by soaking them at least two hours in ATF ASSEMBLY OF CENTER SUPPORT ASSEMBLY See AT 69 1 INSTALL TWOOIL SEALRINGS ANDONE WAYCLUTQI ASSEM BLY ON SUN GEAR 2 INSTALL THREE OIL SEAL RINGS ON CENTER SUPPORT Spread the rings apart and slip them Into the groove Hook both ends by hand 3 INSTALL NEW 0 RI...

Page 348: ...TAllSNAP RING IN GROOVE a Place SST on the spring retainer and compress the springs on a shop press SST 09350 20013 09369 200401 b Install the snap ring with a screwdriver TURN CENTER SUPPORT OVER AND INSTAll NO 1 BRAKE PISTON PLATE DISC AND FLANGE Using the low pressure compressed air blow all excess ATF from the disc CAUTION High pressure air will damage the disc Install in order Plate disc plat...

Page 349: ...th oneof the cutouts 16 CHECK PISTON STROKE OF NO 2 BRAKE With a dial indicator measure the sttoke applying llld releasing the compressed air 14 8 kg em 57 114 psi or 392 785 kPa as shown Standard piston ttroke 1 01 2 26 mm 0 0398 0 0888 ln If the stroke exceeda the limit the clutch peck is probably worn If the stroke is less than the limit parts may be mls L co o assembled or there may be excess ...

Page 350: ... Bearing Rooe Set Ring Gtar Ring Gear Race ATOMI DISASSEMBLY OF PLANETARY GEAR OUTPUT SHAFT 1 REMOVE NO 3 BRAKE DISC PLATE PACK AND FRONT PLANETARY PINION GEARS 2 3 4 Grasp the components and pull off the lront end of the out put shaft Be careful to avoid droppingthe bearing on the output shaft REMOVE THRUST WASHER FROM PLANETARY GEARS NOTE The thrust washer may have stuck to the inside of the pla...

Page 351: ...ulling up the ring gear compress the snap ring will snap ring pliers and pull out the ring gear by hand 9 REMOVE INTERMEDIATE SHAFT RING GEAR All PLANETARY GEAR FROM OUTPUT SHAFT ASSEMBlY 10 REMOVE THRUST BEARING AND RACES FROM OUTPUT SHAFT ASSEMBLY Note the position of the races 11 REMOVETHREE OIL SEAL RINGS FROM OUTPUT SHAfT 12 REMOVE STE EL THRUST WASHER AND REAR PINION GEARS FROM INTERMEDIATE ...

Page 352: ...w discs by soaking them at least two hours in ATF ASSEMBLY OF PLANETARY GEAR OUTPUT SHAFT See pege AT 751 1 INSTALL THRUST BEARING RACE AND REAR PLANETARY RING GEAR ON INTERMEDIATE SHAFT Slip the thrust bearing race and ring gear onto the shaft with the exterior spline s up as shown 2 INSTALL SET RING ON INTERMEDIATE SHAFT Push down and wind the set ring into place Check to make sure it is secure ...

Page 353: ... that the lugs interlock 10 SET IN PLACE FRONT PlANETARY RING GEAR 11 12 Slide the snap ring downward and align the lugs with tho notches Align theendsof the snap ring with the widegap betw the teeth INSTALL FRONT PLANETARY RING GEAR WITH SNAP RING While pushing down the ring gear squeeze the snap ring end with snap ring pliers and install it into the groove NOTE When the snap ring is fully seated...

Page 354: ... ON FRONT PLANETARY CARRIER Apply petroleum jelly to the washer to hold it in place dur ing later assembly Match the lugs with the planetary carrier 18 INSTALL FRONT PLANETARY GEAR ASSEMBlY TO INTERMEDIATE SHAFT 19 INSTALL PRESSURE PLATE Install the pressure plate facing the flat surface toward the intermediate shaft 20 INSTALL NO 3 BRAKE CLUTCH PACK Using low pressure compressed air blow all exce...

Page 355: ...mission Case Inner Piston DISASSEMBLY OF TRANSMISSION CASE AND REAR BRAKE PISTONS 1 COMPRfSS RETURN SPRINGS AND REM OVE SPRING RETAINER SNAP RING 2 Ia Install the SST Gradually and evenly tighten the boll tocompress the springs being careful not todamage the transmlssion caa e with SST SST 09350 20013 109369 20040 lb Using a screwdriver end hook remove the snap ring REMOVE SPRING RETAINER AND SIXT...

Page 356: ...ston and sleevedo notpop out with the compressed air c Using needle nose pliers lift out the piston from the case d Insert two long hooks behind the reaction sleeve and gradually lift it out of the case lei Using hooks lift the inner piston out of the case in the same manner 4 REMOVE O RINGS FROM OUTER AND INNER PISTONS AND REACTION SLEEVE INSPECTION OF CASE COMPONENT GROUP REPLACEMENT OF MANUAL S...

Page 357: ...e in the case 4 INSTALL SST BASE UNDER CASE SST 09350 20013 5 INSTALL SIXTEEN PISTON RETURN SPRINGS AND SET RETAINER WITH SNAP RING IN PLACE 6 7 NOTE The springs are visible through the cutout in the case which helps position them more easily COMPRESS PISTON RETURN SPRINGS TO ALLOW INSTALLATION OF SNAP RING CAUTION Do not overtighten tho bolt and bend lhe spring retainer a Carefully position the s...

Page 358: ...er BV POH ValVe Manu11 Valve t Non rtustble ptrt Valve Body Upper Ahf VII Body o Cooler Return Oleck Ball Dtl tni Spring Disassembly of Valve Body 1 UNBOLT AND REMOVE DETENT SPRING 2 REMOVE MANUAL VALVE 3 TURN ASSEMBLY OVER AND REMOVE NINE BOLTS FROM UPPER FRONT VALVE BODY AND UPPER REAR VALVE BODY ...

Page 359: ...SEMBLY OVER AND REMOVE SET BOLTS FROM LOWER VALVE BODY 5 LIFT OFF LOWER VALVE BODY AND PLATE AS SINGLE UNIT Hold valve body plate to lower valve body NOTE Be careful that the check valve and balls do 1101 fall out 6 WATCH FOR STEEL BALLS RETAINERS AND PINS 1 VALVE BODY ...

Page 360: ...Valve Body Cover Gasket 2 Solenoid No 1 and No 2 i Cooler ReturnCheck Ball it Primary Regulator Vilve lock up Relay Valve _ 8 0 J Gasket g I 0 t Non reusable p art Planger o Steeve n I n o 0 Pin 1 Retail rsl ve 0 Valve Body Cover DISASSEMBLY OF LOWER VALVE BODY 1 REMOVE LOWER VALVE BODY PLATE AND GASKETS AT BS ATI8SS 2 REMOVE DAMPING CHECK BALL COOLER RETURN CHECK BALL COOLER BY PASS VALVE AND SPR...

Page 361: ... al Remove the bolt and retainer bl Remove the spring and steel ball CAUTION Cover the spring with your hand Slowly move the bolt being c feful not to pop out the opting 5 REMOVE NO 3 SOLENOID a Remove the bolt lbl Remove tho solenoid from the bore 6 REMOVE NO 1 AND NO 2 SOLENOID al Remove the three bolts the solenoid and gasket lbl Remove the two springs from the bore ...

Page 362: ...with lock up relay valve and spring 9 REMOVE SPRING RETAINER FROM PRIMARY REGULATOR VALVE WARNING Highly compressed spring Inside keep away from face a Place a mark on the bevel when the retainer is posi tioned NOTE When reassembling position the retainer in the same position b To remove the retainer hold the valve body face down and press in on the valve sleeve The retainer will drop out Slowly r...

Page 363: ...r 1 Primary regulator valve 56 30 12 21651 Blue 21 Low coast modula tor valve 42 35 1 66731 Nooe JIIntermediate modulator valve 35 43 11 39491 Red 141 lock up relay valve 32 60 11 28351 Green fSJ Oil cooler by pass valve 33 32 11 31181 Yellow 161 Pressure relief valve 32 14 11 26541 None 171 Damping check ball 20 00 0 7874 None SEMBLY OF LOWER VALVE BODY AS See 1 page AT 861 INSERT PRIMARY REGULAT...

Page 364: ... sleeve with the plunger e Install the regulator valva sleeve retainer Ill Install the retainer on the bevel NOTE Install the retainer to the same position of the sleeve as when disassembling 2 INSTAll lOCK UP RELAY VALVE a Install the lock up relay valve into the sleeve b Install the spring into the lock up relay valve c Install the lock up relay valve assembly into the bore d lnstell the pin ...

Page 365: ...lator valve Into the bore lbl Install the intermediate modulator valve into the ben 6 INSTALL TWO VALVE SPRINGS NOTE Install the shon spring in the right bore 6 INSTALL N0 1 AND N0 2 SOLENOIDS Install the solenoid over the gasket Tighten the three bolts Torque 100 kg em 7 fHb 10 N m 7 INSTALL PRESSURE RELIEF VALVE a Place the steel ball and spring onto the bo fy b Install the retainer Torque 55 kg...

Page 366: ...at the retainers and pins ere installed correctly 10 INSTALL SPRINGS DAMPING CHECK BALL COOLER RETURN CHECK BAll AND COOLER BY PASS CHECK VALVE 11 INSTALL LOWER VALVE BODY GASKET Note that the two gaskets are not interchangeable Tho gasket must lay flat on the valve body 12 INSTALL LOWER VALVE BODY PLATE Set the plate into place Temporarily install two the short bolts finger tight tocompress the p...

Page 367: ... Front Valve Body Throttle Cam Retaintr Throttle Valve f Rtlllner k Cowr Adjunlno Ring r J I I I c r i Pln Down shift Plug Secondary Regulator VJtvt J I tr DISASSEMBLY OF UPPER FRONT VALVE BODY 1 REMOVE THROTTLE VALVE RETAINER ____ 2 REMOVE CUT BACK PLUG RETAINER ...

Page 368: ...e plate to un cover the valve WARNING Valve Is spring loaded b Remove tho valve and spring Keep the spring with the valve C Remove the other bolt and remove the cover plate 5 REMOVE THROTTLE CAM 6 REMOVE DOWN SHIFT PLUG AND SPRING 7 8 a Remove tho pin by pushing tho down shift plug bl Remove tho down shift plug with the sleeve and spring REMOVE THROTTLE VALVE AND SPRING REMOVE ADJUSTING RINGS Note...

Page 369: ...E BODY See page AT 92 1 INSERT TMROTTLE VALVE 2 Note arrangement in the figure Make sure that the vatve is inserted fully Into the bore INSTALL THROTTLE VALVE RETAINER Coat the retainer with petroleum jelly to keep It In place Note position of tabs in the figure Slip the retainer into place in the valve body 3 INSTALL ADJUSTING RINGS AND SMALL SPRING ON THROTTLE VALVE SHAFT Cal Install the seme nu...

Page 370: ... Tighten the bolt Torque 75 kg em 65 in lb 7 4 N m 7 INSTALL SECONDARY REGULATOR VALVE a Partially install the cover plate and insert the spring and secondary regulator valve bl Compress the spring and swing the cover plate into place c Install the second bolt in the cover plate and tighten both bolts Torque 66 kg em 48 ln lb 5 4 N m 8 INSERT SPRING AND CUT BACK VALVE Install the valve with smalle...

Page 371: ...AT 96 AUTOMATIC TRANSMISSION Component Grou ps Valve Body 10 INSTALL THROTTLf VALVE RETAINER 11 MAKE SURE THAT SLEEVE IS HELD BY PIN Pin ...

Page 372: ...ve Non reusable part Upper Rear Valve Body 2 3 Shift Valve Plug Retainer j Co r o o am Gasket Q Retaintr 3 4 Shift Valve Plug DISASSEMBLY OF UPPER REAR VALVE BODY 1 REMOVE SIX CHECK BALLS 2 REM OVE REAR CLUTCH SEQUENCE VALVE lal Remove the pin w ith a magnetic finger by pushing on the plug Then remove the plug ...

Page 373: ...b Remove the rear clutch sequence valve and spring 3 REMOVE 3 4 SHIFT VALVE a Push the plug remove the retainer with a magnetic finger lbl Remove the plug valve and spring 4 REMOVE COVER AND GASKET 5 REMOVE 1 2 SHIFT VALVE Remove the 1 2 shift valve and spring ...

Page 374: ...nd collapsed coils Measure the spring free height and replace if less than that shown below Spring Free height mm in Color 1 3 4 Shift valve 29 15 1 14761 2 2 3 Shift valve 29 15 1 1476 3 1 2 Shift valve 29 15 1 1476 4 Reat clutch sequence vatve 37 55 1 4783 ASSEMBLY OF UPPER REAR VALVE BODY See page AT 97 1 INSTALL 3 4 SHIFT VALVE al Install the 3 4 shift valve and spring Blue Blue Blue None b In...

Page 375: ...g em 48 ln lb 5 4 N ml 3 INSTALL 2 3 SHIFT VALVE Ia Install the 2 3 shift valve and spring b Install the plug into the bore c Coat the retainer with petroleum jelly and install it 4 INSERT REAR CLUTCH SEQUENCE VALVE a Install the valve spring and the valve b Install the plug into the bore cl Coat the pin w ith petroleum jelly and install it 5 INSTALL CHECK BALLS AS SHOWN ...

Page 376: ... GASKET ON TOP OF UPPER REAR VALVE BODY Align each bolt hole in the valve body and gasket 3 INSTALL AND FINGER TIGHTEN THREE BOLTS IN LOWER VALVE BODY TO SECURE UPPER REAR VALVE BODY NOTE Each bolt length mm is indicated in the figure 4 TURN ASSEMBLY OVER CHECK GASKET ALIGNMENT AND FINGER TIGHTEN FOUR BOLTS IN UPPER REAR VALVE BODY NOTE Each bolt length mm is indicated in the figure 5 REMOVE TEMPO...

Page 377: ... is indicated in the fig n B TURN ASSEMBLY OVER AND FINGER TIGHTEN FIVE BOLTS IN UPPER FRONT VALVE BODY NOTE Each bolt length lmml is indicated in the figute 9 TIGHTEN BOLTS IN UPPER FRONT AND REAR VAL Il BODIES Recheck the alignment of the gaskets Tighten the bolts Torque 55 kg em 148 ln lb 5 4 N ml 10 TURN ASSEMBLY OVER AND TIGHTEN BOLTS IN LOWER VALVE BODY Tighten the bolts Torque 55 kg cm 148 ...

Page 378: ...IL SEAL AND DUST SEAL a Using SST remove the oil seal SST 09308 10010 b Using SST drive In a now oil seal and dust seal SST 09325 20010 Torque Converter CLEAN TORQUE CONVERTER If the transmission is contaminated the torque converter and transmission cooler should bit thoroughly flushed us ing Toyota Transmission Cleaner INSPECTION OF TORQUE CONVERTER 1 INSERT SST IN ENO OF TORQUE CONVERTER a Inser...

Page 379: ...e the converter if the clutch still fails the test Electrical Parts 1 INSPECT SOLENOID 2 3 Check the resistance between the terminal and body Standard resistance 11 15 l INSPECT NEUTRAL START SWITCH Using an ohmmeter check the continuity of the terminal for each switch position shown in the table below If continuity between the terminals is not as specified replace the switch c R 2 l R N 2 L INSPE...

Page 380: ...omatic transmission fluid for at feast two hours S Apply automatic transmission fluid on sliding or rotating surfaces of the parts before as sembly 7 Use petroleum jelly to keep the small parts in their places Front A 8 c 0 E Before assembly make sure again that all compo nent groups are assembled correctly If something wrong is found in a certain component group dur ing assembly inspect and repai...

Page 381: ... its locking tab part AI with pan B of the case NOTE Make sure that the lips of the tube end are com pletely inserted onto the outer piston 4 PARTIALLY INSERT OUTPUT SHAFT ASSEMBLY INTO CASE Align the opening notch part A of the clutch plates with the slot part 8 of the case 5 CHECK CLUTCH PACK CLEARANCE With the case in upright position make sure that the clutch pack is lower than the ledge below...

Page 382: ...g is fully seated Make sure that the ends of the snap ring are between t he lugs 8 PUSH CENTER SUPPORT ASSEM8LY INTO CASE Align the oil hole and bolt hole of the center support with those of the body side and insert 9 INSTALL TWO CENTER SUPPORT BOLTS WITH WAVE WASHERS Align the center support with holes in the case and install the two bolls linger tight 10 INSTALL REAR CLUTCH IN CASE Rotate the cl...

Page 383: ...nt clutch hub Push the front clutch assembly into the case CAUTION Be c reful thot the thrust bearing doea not fll out 15 CHECK CORRECT INSTALLATION OF FRONT CLUTCH Set SST on the transmission case as show n in the figure Measure the distance between the top surface of tho SST and front clutch assembly If the distance corresponds to that during disassembly the front clutch is installed cor rectly ...

Page 384: ...se and the other one on the overdrive clutch NOTE The washer lugs should be inserted in the holes 21 INSTALL OVERDRIVE CLUTCH IN CASE Align the flukes of the discs in the overdrive case Align the flukes with the slots of the overdrive clutch and press the overdrive clutch into the overdrive case CAUTION Be careful that the thrust washer does not tal out 22 CHECK CORRECT INSTALLATION OF OVERDRIVE C...

Page 385: ...taldw washer side toward tho pump body together with 1ht bearing 27 INSTALl FRONT Oil PUMP a Install the oil pump gently through the two guide pin being careful that tho thrust washer does not fall out b Coat tho five set bolts w ith seal pac king and finger tighten them c Using a screwdriver remove the SST and install the two set bolts coatad with seal packing SST 09350 20013 109362 3001 11 d Tig...

Page 386: ...on Thrust play 0 3 0 9 mm 10 012 0 035 in IF NECESSARY INSTALL MANUAL VALVE LEVER SHAFT INTO CASE al Assemble a new collar to the manual valve lever NOTE Always replace the collar w ith a new one b Install the manual valve lever shaft to the transmis sion case through the manual valve lever c Drive in the roll pin with the slot at right angle to the shaft d Match the collar hole to the lever staki...

Page 387: ...g CAUTION In subsequent work be careful not to roll tht case over the cable and break the cable flttlng 37 INSTALL ACCUMULATOR PISTON AND SPRINGS 38 PLACE VALVE BODY ON TRANSMISSION Make sure the accumulator pistons are pressed fully into the bore Align the manual valve with the pin on the manual shift lever and lower valve body into place 39 LIFT SIDE OF VALVE BODY AND ATTACH THROTIU CABLE al Whi...

Page 388: ...cm 48 ln lb 5 4 N m AT 1 13 43 CONNECT SOLENOID WIRING TO EACH SOLENOID a Push the solenoid wiring through in the transmission case and connect the terminals to each solenoid b Clamp the wiring to the oil screen c Install the gromet for the wiring with the plate 44 INSTALL OIL TUBES Press the tubes by hand into the positions indicated in the figure Make sure that the oil tubes do not interfere wit...

Page 389: ...ITH NEW GASKET Torque 205 kg em 115 ft lb 20 N ml 47 INSTALL SENSOR ROTOR AND SPEEDOMETER DRIVE GEAR NOTE Install the larger diameter snap ring at the front side a Install the larger snap ring and woodruff key ontothe shaft 1 bl Install the sensor rotor lcl Install the loc k ball d Slide the speedometer gear on the shaft e Using snap ring pliers Install the outer snap ring 48 INSTAL L EXTENSION HO...

Page 390: ...shaft sleeve assembly into the housing Install the lock plate with the bolt and lock washer 52 INSTALL NEUTRAL START SWITCH a Slide the neutral start switch onto the control shaft bl Install the grommet facing the groove toward the switch body and then install the washer and nut c Move the switch sothat the slit in the switch and neu tral basic line match up Tighten the bolt and nut Torque Bolt 55...

Page 391: ...UNOUT a Temporarily mount the torque converter to the drM 1 plate Set up a dial indicator If runout exceeds 0 30 mm 0 0118 in try to correct by reorienting the installation of the converter If excessive runout cannot be corrected replace the torque converter NOTE Mark the position of the converter to ensureecr rect installation lbl Remove the torque converter 3 INSTALL ENGINE REAR MOUNT INSULATOR ...

Page 392: ......

Page 393: ... the brackets and tighten the four bolts Torque 770 kg cm 56 ft lb 76 N ml ldl Install the clamps of fluid line lei Connect the both tie rod ends to the knuckle arm Torque 600 kg cm 143 ft lb 59 N m If Install the Intermediate shaft INSTALL CONVERTER COVER EXHAUST PIPE CLAMP AND BOTH STIFFENER PlATES 17 CONNECT SPEEDOMETER CABLE Be sure the felt dust protector and washer are on the e ld of the cab...

Page 394: ...ase Torque 440 kg cm 32 ft lb 43 N ml 22 INSTALL INTERMEDIATE PROPELLER SHAFT 23 CONNECT WIRING CONNECTORS TO NEUTRAL START AND BACK UP LIGHT SWITCHES 24 CONNECT TRANSMISSION THROTTLE CABLE a Connect the cable to the throttle linkage b Connect the cable housing to the bracket 25 ADJUST TRANSMISSION THROTTLE CABLE 26 CONNECT UPPER RADIATOR HOSE AND FILL WITH COOLANT 27 CONNECT BATTERV CABLE TO NEGA...

Page 395: ...L TRANSMISSION WITH ATF Add about 4 0 liters 4 2 US qts 3 5 Imp qts Fluid type ATF DEXRON D Total capacity 6 5 litera 6 9 US qts 5 7 Imp qui 29 CHECK FlUID LEVEL See page MA 13 30 PERFORM ROAD TEST Check for abnormal noise shock slippage correct slift points and smooth operation ...

Page 396: ...PROPELLER SHAFT Page PRECAUTIONS PR 2 TROUBLESHOOTING PR 2 PROPELLER SHAFT PR 3 PR 1 ...

Page 397: ...tly in the vise as this will cause daformatK n TROUBLESHOOTING Pouible cause R medy Page Sleeve yoke spline worn Replace intermediate shaft PR 4 Center bearing worn Replace oenter bearing PR 4 Spider bearing worn or stud Replace intermediate shaft or propeller PR 4 shaft Propeller shah runout Replace propeller shaft PR 4 Propeller shah unbalance Balance prop ller shaft PR 4 Transmission extension ...

Page 398: ..._ Ptopetltr Shift REMOVAL OF PROPELLER SHAFT 1 DISCONNECT PROPELLER SHAFT FLANGE FROM FLANGE ON DIFFERENTIAL a Place matchmar1 s on the flanges b Remove the four bolts and nuts 2 REMOVE CENTER SUPPORT BEARING FROM BODY 3 REMOVE PROPELLER SHAFT a Remove the center bearing mounting bolts b Pull out the propeller shaft from the transmission c Insert SST in the transmission to prevent oil leakage SST ...

Page 399: ...ks on the flanges b Remove the four bolu and nuu 2 REMOVE CENTER SUPPORT BEARING FROM INTERMEDIATE SHAFT a Using a hammer and chisel loosen the staked port of the nut b Using SST to hold the flange remove the nut SST 09330 00021 c Place alignment marks on the flange or yoke and shaft d Clamp the flange or yoke in a vise and tap off tilt shalt ...

Page 400: ...mum runout 0 8 mm 0 031 in INSPECT SPIDER BEARINGS a Inspect the spider beari 9S for wear or damege b Check the spider beari119 axial play by turning the yoke while holding the 1tlaft tigt tly S ing exill play 0 mm 0 in If necessary replace the propeller shaft 3 INSPECT CENTER SUPPORT BEARING FOR WEAR OR DAMAGE Check that the bearing wrns freely If the baaring is damaged wom or d not turn freely r...

Page 401: ...gurt below 1 INSTALL CENTER SUPPORT BEARING ON INTERMEDIATE SHAFT NOTE Install the center support bearing with thecutOIIt toward the rear 2 INSTALL FLANGE ON INTERMEDIATE SHAFT a Coat the splines of the intermediate shaft with MP grease b Align the matchmarlcs and install the flange to the intermediate shalt c Using SST to hold the flange press the bearing into position by tightening down a new nu...

Page 402: ...ler Shaft PR 7 f Using a hammer and punch stake the nut 3 INSTALL PROPELLER SHAFT a Align the marks on the flanges and connect the flangeswith four bolts and nuts b Torque the bolts and nuts Torque 430 kg em 31 ft lb 42 N m ...

Page 403: ... the bolts and nuts Torque 430 kg em 31 ft lb 42 N m 3 CONNECT CENTER SUPPORT BEARING TO BODY a Place a height spacer between the body and center support bearing and install the two mounting bolts finger tight NOTE Some vehicles do not have a spacer In this case it is not necessary to insert one b Check that the bearing bracket is at right angle to the propeller shaft Adjust the bracket if necessa...

Page 404: ... SUSPENSION Page TROUBLESHOOTING FA 2 FRONT WHEEL ALIGNMENT FA 3 FRONT AXLE HUB FA 6 FRONT AXLE SHOCK ABSORBER FA 10 FRONT SUSPENSION FA 14 Ball Jo nts FA 14 Lower Arm FA 15 Strut Bar FA 18 Stabiliz er Bar FA 19 FA 1 ...

Page 405: ...s iml fQPefiV inflated lnflltl tires to PJoper preswrt FA 3 Stabilizer bar btnt or broken lnU tct stlbilizer bir FA 19 Shock absorber worn out Repltot hoek absorber FA II Fron t wheel shimmy Tires worn o r improperly inflated Replace tires or inflate tires to proptll FA 3 pressure Wheel out of balanct 8 llnct wheels Alignment incoucc t Ct Kk front end alignment FA 3 Wheel btatii OJ worn improperly...

Page 406: ...ess d Check the front sus nsion for looseness a Check the steering link1190 for looseness f Check that the front absorbers work properly by using the standard bounce test 2 MEASURE VEHICLE HEIGHT Vehicle he ght Tiresize Front A 225 60 HR14 223 0 18 7801 n l RwB 263 0 110 3541 It height of tho vehicle is not as specified try to level tho vehicle by shaking it down If the height isstill notcorrect1 ...

Page 407: ...N ml If the wheel angle still cannot be adjusted within limit inspect and replace any damaged or worn steering parts ADJUST CAMBER AND STEERING AXIS INCLINATION Camber lnspec1ion standard 50 45 Left right error 30 Steering a cis inclination Inspection s1llndard 10 10 45 Laft right error 30 ADJUST CASTER Caster Inspection standard 4 10 45 Adjustment standard 4 10 t 30 Left right error 30 If caster ...

Page 408: ...e level d Measure the distance between the marks on the front of the tires Inspection standerd Adjustment standerd 3 t 2 mm 0 12 0 08 in 3 t 1 mm 0 12 0 04 in e Remove the rack boot clips and loosen the clamp bolts f Adjust toe ln by turning the left and right tie rod tubes an equal amount NOTE Make wre that the tie rods are the same length g Tighten the clamp bolts and torque them Torque 175 kg c...

Page 409: ...Cap 1 050 f7S 103 DISASSEMBLY OF FRONT AXLE HUB 1 REMOVE DISC BRAKE CALIPER a Remove the caliper mounting bolts and rem01t caliper from the knuckle b Suspend the caliper with a cord NOTE Do not disconnect the brake hose 2 REMOVE AXLE HUB WITH DISC a Remove the hub grease cap cotter pin lock cap nul and axle hub b Remove the hub and disc together with the outer bearing and thrust washer NOTE Be car...

Page 410: ... FRONT AXLE HUB 1 INSPECT SPINDLE Using a magnetic flaw detector or flaw detecting penetrant check for damage or cracks 2 INSPECT BEARING Clean the bearings and outer races and inspect them for wear or damage 3 REPLACE BEARING OUTER RACE a Using a brass bar and hammer drive out the bearing outer race b Using SST carefully drive in a new bearing outer race SST 09608 30022 09608 05010 09608 06040 ...

Page 411: ...o the hub Coat the oil seal with MP grease SST 09608 30022 09608 05010 09550 00050 4 INSTALL AXLE HUB ON SPINDLE a Place the axle hub on the spindle b Install the outer bearing and thrust washer 5 ADJUST PRELOAD a Install and torque the nut Torque 300 kg em 22 ft lb 29 N m b Turn the hub right and left two or three times to allow the bearings to settle c Loosen the nut so thoro is 0 5 1 0 mm 0 020...

Page 412: ...and retighten it as tight as possible Check the preload again g Measure the hub axial play Limit 0 05 mm 0 0020 in 6 INSTALL LOCK CAP COTTER PIN AND HUB GREASE CAP NOTE If the cotter pin hole does not line up cO reet by tightening the nut by the smallest amount possible 7 INSTALL DISC BRAKE CALIPER Install brake caliper on the disc Torque the mounting bolts Torque 930 kg em 67 ft lb 91 N m ...

Page 413: ...Axle Shock Absorber FRONT AXLE SHOCK ABSORBER COMPONENTS Suspension Support Spring Seat I 1 2 7 237 lQI 41 Steering Knuckle Arm I930 c 7 ou 1 Ikg c m ft lb N mlI Spe ified torque Non feusable part Backing Plate 0 M Cotter P n Front Axle Hub ...

Page 414: ...6011 2 REMOVE THREE NUTS 3 REMOVE TWO BOLTS Remove the two bolts mounting the shock absorber assembly to the steering knuckle arm 4 REMOVE FRONT SHOCK ABSORBER FRONT AXLE HUB AND BRAKE CALIPER NOTE Collars extend into the steering knuckle bolt holes about 5 mm 0 20 in deep Push the suspension lower arm down and remove the front shock absorber front axle hub and brakecaliper 5 MOUNT FRONT SHOCK ABS...

Page 415: ...T STEERING KNUCKLE PART OF SHOCK ABSORBER Using a magnetic flaw detector or flaw detectingpenetrant inspect the steering knuckle part of the shock absorber to damage or cracks 2 INSPECT OPERATION OF SHOCK ABSORBER a Pull out the shock absorber piston rod at a constant speed and check to see that the pull feeling through out the stroke is the same b Check to see that there is no change in the pull ...

Page 416: ... suPPOrt with a new nut Torque the nut SST 09729 22031 Torque 475 kg em 34 It lb 47 N m b Pack the bearing in the suspension support with MP grease c lnrull the bearing dust cover on the suspension support 3 INSTALL BACKING PLATE AND FRONT AXLE HUB ADJUST PRELOAD See page FA S 4 INSTALL TWO BRAKE HOSES AND BRAKE CALIPER See page FA 9 5 CONNECT STEERING KNUCKLE ARM Place the shock absorber assembly...

Page 417: ...ESSIVE LOOSENESS al Jack up the front of the vehicle and place woodeol blocks with a height of 180 200 mm 7 09 7 87 in under the one front tire b Lower the jack until there is about half a load on the front coil springs Place stands under the vehicle for safety cl Make sure the front wheels are in a strai ltt forwanl position and block them with chocks d Move the lower arm up and down and check th...

Page 418: ...isconnect the knuckle arm from the tie rod SST 09611 22012 3 DISCONNECT STABILIZER BAR AND STRUT BAR FROM LOWER ARM a Remove the nut holding the stabilizer bar to the lower arm and disconnect the stabilizer bar b Remove the nuts holding the strut bar to the lower arm and disconnect the strut bar 4 REMOVE LOWER ARM AND RACK BOOT PROTECTOR Remove the bolt holding the lower arm to the cross member an...

Page 419: ...r c Wind wire twice around the dust cover and bend tt wire knot down d Remove the plug and install the grease fitting e Fill with ball joint grease Molybdenum Oisulphide Lithium Base Grease NLGI No 1 or No 2 f Remove the grease fitting and install the plug REPLACEMENT OF LOWER ARM BUSHING 1 REMOVE LOWER ARM BUSHING Using SST press out the bushing from the lower arm SST 09726 12022 09726 01030 0972...

Page 420: ...on the ball joint with a nut Torque the nut and install a new cotter pin Torque 800 kg em 58 ft lb 78 N ml b Install the knuckle arm on the tie rod with a nut Torque the nut and install a newcotter pin Torque 600 kg em 43 ft lb 59 N ml 4 CONNECT KNUCKLE ARM TO SHOCK ABSORBER Place the shock absorber assembly in position and connect the knuckle and with the two bolts Torque the bolts Torque 1 000 k...

Page 421: ... the strut bar INSTALLATION OF STRUT BAR 1 ADJUST STAKED NUT Check that the distance between the staked nut and cenl r 369 1 mm of the bolt hole is 369 1 mm 14 531 in Adjust staked nut as necessary NOTE Do not move staked nut unless required 2 CONNECT STRUT BAR TO LOWER ARM Connect the strut bar to the lower arm with a bolt Torqut the bolt Torque 670 kg em 48 ft lb 66 N m 3 CONNECT STRUT BAR TO BR...

Page 422: ...NSERT STABILIZER BAR THROUGH STRUT BAR BRACKET HOLE 2 INSTALL STRUT BAR BRACKET 3 4 Install the strut bar bracket and torque the bolts Torque 475 kg em 34 ft lb 47 N m INSTALL STRUT BAR TO LOWER ARM Install the strut bar and torque the nuts Torque 670 kg cm 48 ft lb 66 N m INSTALL STABILIZER BAR ON BRACKETS Place the stabilizer bar in position and install both stabilizer bushings and brackets on t...

Page 423: ...Page TROUBLESHOOTING RA 2 REAR WHEEL ALIGNMENT RA 3 IRS TYPE REAR AXLE SHAFT RA S REAR DRIVE SHAFT RA 12 IRS TYPE DIFFERENTIAL RA 18 LIMITED SLIP DIFFERENTIAL RA 37 IRS TYPE REAR SUSPENSION RA 44 DIFFERENTIAL SUPPORT MEMBER RA 53 IWI ...

Page 424: ... too high 0 w rong grade Drain end replace o J gear shift Oil seal worn or dlm19ed Reploeo oil seal RA 18 Side gear shah loose or damaged Tighten or replace shaft RA 18 Noi 1 In rear axle Oil level low or w rong grade Drain and replace oil Excessive backlash between pinion and Check backlash RA 23 ring or side gear Ring pinion or side gears worn or chipped Inspect gears RA 24 Pinion shaft bearing ...

Page 425: ...y the standard bounce test 2 MEASURE VEHICLE HEIGHT Vthiclt htigllt mm in Tire Front AI R r 8 223 0 283 0 225 60 HR 14 8 780 10 354 I A If height of the vehicle is not as specified try to level the vehicle by shaking it down If the height of the vehicle is still not correct check for bad springs and worn or loose suspension parts 3 INSTALL WHEEL ALIGNMENT EQUIPMENT Follow the specific in struction...

Page 426: ...e Advance the vehicle till the marks on the rear sidesof the tires come to the measuring heights of the 11 11 on the front sides NOTE Toe in should be measured at the same point011 the tire and at the same level To in lnJptc11 on standard Ot 2mm 1 0 t 0 08 in I Adju stment Stlndan l Ot 1mm 1 0 0 04 in l f If not within specification turn the left and r9l adjusting bolts an equal amount to adjust N...

Page 427: ...ide Outer Race Rear Shaft Flange Inner Boa ina Oist RotOf Bearing Ciuteo OH Seal Rear Shaft Ikg m ft lb N m I Specified torQue t Non teus able pa rt OutsKfe Bearing Outer Raoe REMOVAL OF REAR AXLE SHAFT 1 REMOVE REAR WHEEL 2 DISCONNECT DRIVE SHAFT NOTE Disconnect the rear axle shaft side only 3 REMOVE REAR BRAKE Remove the brake caliper and disc rotor RA 5 ...

Page 428: ...sconnect the axle flange and the washer SST 09557 22022 NOTE Be careful not to lose the plate washer on thotl of the flange bearing side 6 REMOVE REAR AXLE SHAFT AND SPACER Using SST pull out the rear axle shaft with the oil seal llll outer bearing SST 09520 00031 7 REMOVE INNER OIL SEAL AND BEARING a Using SST pull out the inner oil seal from rear m housing SST 0930B 00010 b Remove the inner bear...

Page 429: ...09950 00020 and 09950 00030 c Remove the oil seal from axle shaft INSPECTION AND REPLACEMENT OF REAR AXLE SHAFT COMPONENTS 1 INSPECT REAR AXLE SHAFT AND FLANGE FOR WEAR DAMAGE OR RUNOUT Maximum flange runout 0 1 mm 0 004 in If the rear axle flange is damaged or worn or if runout is greater than maximum replace the rear axle shaft 2 CLEAN AND INSPECT BEARINGS AND RACES a Clean with solvent and dry ...

Page 430: ... axle housing SST 09550 2201 1 09550 00020 09550 00040 b Install the bearing 6 INSTALL NEW INNER OIL SEAL a Using SST drive in a new oil seal to a depth of 31 mm 1 22 in l SST 09550 2201 1 09550 00020 09550 00040 b Apply MP grease No 2 to the oil seal lip 6 INSTALL OUTSIDE BEARING OUTER RACE Using SST install the bearing outside outer race in the rear axle housing SST 09550 2201 1 09550 020 09550 ...

Page 431: ...FT AND FLANGE a Install the rear a le shaft into the housing b Install the flange with plate washer NOTE Before assembly apply a thin coat of grease to the flange c When installing the axle shift and flange use SST and tighten to the point where the flange and shaft de flector tip are aligned SST 09557 22022 NOTE Do not allow grease to get on the shaft threads 2 ADJUST PRELOAD a Install the new ax...

Page 432: ... 4 kg em 0 9 3 5 in lb 0 1 0 4 N m NOTE Tum the flange one turn per 6 seconds and measure the preload If preload is less than specification retighten the nut 5 10 at a time until the specified preload is reached Maximum torque 2 000 kg em 145 ft lb 196 N m 3 IF THERE IS EXCESS PRELOAD CORRECT IN FOLLOWING PROCEDURE a Remove the axle flange b Remove the rear axle shaft and spacer c Remove the outsi...

Page 433: ...REAR AXLE AND SUSPENSION IRS Type Rear Axle Shaft RA 11 4 STAKE NUT WITH PUNCH 5 INSTALL RE AR BRAKE 8 CONNECT DRIVE SHAFT Torque 700 kg em 51 ft lb 69 N m 7 INSTALL REAR WHEEL ...

Page 434: ... kg cm ft Jb N m l Specified torque Non reusable part 1Shaft lamp Outboard Boot Outboard Joint Inner Raoe with Ball Snap Ring Outboard Be aring Outer Race REMOVAL OF REAR DRIVE SHAFT REMOVE DRIVE SHAFT NOTE Be careful not to damage the boots a Disconnect the drive shaft from the differential b Disconnec t the drive shaft from the axle shaft ...

Page 435: ...ion of the inboard joint 2 DISASSEMBLE FOUR BOOT CLAMPS OF OUTBOARD AND INBOARD JOINTS NOTE Slide the clamp toward the drive shaft and remove it 3 SLIDE BOOTS AT CENTER OF SHAFT 4 REMOVE OUTBOARD JOINT OUTER RACE a Remove the snap ring b Place matchmarks on the outer race and drive shaft NOTE Do not use a punch e Remove the outer race to the drive shaft NOTE If the end cover is damaged or worn rep...

Page 436: ...09726 00030 e Using snap ring pliers remove the snap ring 6 REMOVE OUTBOARD AND INBOARD JOINT BOOTS 7 DISASSEMBLE INBOARD JOINT a Using a screwdriver remove the end plate from tile inboard joint b Place matchmarks on the inboard joint and dri 1 shaft c Using snap ring pliers remove the snap ring d Using SST and a press remove the inbOard joint from the drive shaft SST 09726 10010 09726 00030 ...

Page 437: ...CESSARY ASSEMBLY OF REAR DRIVE SHAFT S Pl 9t RA 12 1 ASSEMBLE NEW CLAMPS ONTO DRIVE SHAFT 2 ASSEMBLE BOOT ONTO DRIVE SHAFT CAUTION Wrap the shaft wrations with vinyl upe so as to prevent dam to the boot a Place the outboard and inboard boots and new clamps on the shaft b Install a new snap ring 3 INSTALL OUTBOARD JOINT INNER RACE a Place the cagr onto shaft NOTE The larger diameter end should face...

Page 438: ...sing a press and socket wrench inboard joint cnto drive shaft c Using snap ring pliers install new snap ring d Peck 60g 0 13 Ib of grease into the flange side NOTE Use the grease supplied in the kit e Apply seal pec king THREE BOND 1344 OBm 000801 or LOCKTITE No 242 around inboard Iiiii of the end plate ttl Install it to the inboard joint NOTE Install the end plate by tapping around it 5 APPLY GRE...

Page 439: ...ermitting the follow ing shaft dimension Shaft dimension 416 5 419 5 mm 16 398 16 516 in b Lock the clamps NOTE Position the lock between the flange bolt holes e Tum both joints and stretch the boot to check that it does not deform INSTALLATION OF REAR DRIVE SHAFT See page RA 12 INSTALL DRIVE SHAFT a lnmll the drive shaft with the narrow distance between the flange and boot band at the differentia...

Page 440: ... REMOVE SIDE GEAR SHAFT OIL SEAL S le step 3 on page RA 23 6 INSTALL SIDE GEAR SHAFT OIL SEAL S le step 16 on page RA 35 7 INSTALL SIDE GEAR SHAFT See step 17 on page RA 36 8 MEASURE SIDE GEAR SHAFT RUNOUT S le step 18 on page RA 36 9 INSTALL CARRIER COVER S le step 19 on page RA 361 10 CONNECT DRIVE SHAFT See step 4 on page RA 361 11 INSTALL DRAIN PLUG AND FILL DIFFERENTIAL WITH GEAR OIL Hypoid g...

Page 441: ...l from the housing SST 09308 10010 b Remove the oil slinger 4 REMOVE FRONT BEARING AND BEARING SPACER See step 12 on page RA 25 5 INSTALL NEW BEARING SPACER AND FRONT BEARING a Install a new bearing spacer on the shaft b Install the front bearing on the shaft 6 INSTALL OIL SLINGER AND NEW OIL SEAL a Install the oil slinger facing as shown b UsingSST drive in a new oil seal SST 09316 60010 Oil seal...

Page 442: ... DRIVE PINION NUT 11 INSTALL DIFFERENTIAL See page RA 36 REMOVAL OF DIFFERENTIAL 850 61 83 860 81 831j No 1 Mounting Bolt t 1 1 83 101 t 1 Drive Shaft 1oo 101 69 1 Ikg cm fh lb N ml I Specif ied tO QU Non reusable part 500 38 49 1 2 3 4 REM OVE DRAIN PLUG AND DRAIN DIFFERENTIAL OIL DISCONNECT REAR DRIVE SHAFT DISCONNECT PROPELLER SHAFT FLANGE FROM COMPANION FLANGE REMOVE DIFFERENTIAL SUPPORT MEMBE...

Page 443: ...RS Type Differential RA 21 5 REMOVE DIFFERENTIAL t a Jack up differential and remove the carrier bolt b lower the differential carrier with a jack NOTE Wilen lowering the carrier be careful that the differential does not separate ...

Page 444: ...inion Shah PlateWasher J Side Bearing IJ i O J 0 I I Thru t Washer Side Gear Platei Washer Rear a ori n Seal Spacer Companion FIanoe Ikg c m tHb N mll Specified torque Non r sabh part Coer Differential CM e Ring Gear ide Bearing Cap 220 18 22 Oiffe enti l Carrier Gosket 410 30 401 800 58 781 Oil Seal ...

Page 445: ... from the differential carrier SST 09520 22011 3 REMOVE S IDE GEAR SHAFT OIL SEAL Using SST remove the oil seal SST 09308 10 4 CHECK RING GEAR RUNOUT If the runout is greater lhan maximum install a new ring gear Maximum runout 0 07 mm 0 0028 in 5 CHECK RING GEAR BACKLASH If the backlash is not within specification adjust the side bearing p reload or repairas necessary See page RA 32 Backlash 0 13 ...

Page 446: ...TOOTH CONTACT See RA 33 8 MEASURE DRIVE PINION PRELOAD Using a torque wrench measurethepreload of the back _ be1 111een the drive pinion and ring gear Preload starting 6 10 kg em 5 2 8 7 in lb 0 6 1 0 N ml 9 CHECK TOTAL PRELOAD Using a torque wrench measure the total preload Total preload In addition to drive pinion preload J 4 6 kg em 3 5 6 2 in lb 0 4 0 6 N ml 10 REMOVE COMPANION FLANGE a Using ...

Page 447: ...D BEARING SPACER a Using SST remove the front bearing from the hous ing SST 09556 30010 b Remove the bearing spacer If the front bearing is damaged or wom replace the bear ing 13 REMOVE DIFFERENTIAL CASE AND RING GEAR a Place matchmarks on the bearing cap and differen tial carrier b Remove the two bearing caps c Remove the two side bearing preload adjusting plate washers with SST SST 09504 22010 N...

Page 448: ...ST 09950 00020 NOTE If the drive pinion or ring gear are damaged replace them as a set b Install the washer on the drive pinion with the ch fered end facing the pinion gear cl Using SST and a pness press the roused washer rd rear bearing onto the drive pinion SST 09506 30011 REPLACE DRIVE PINION FRONT AND REAR BEARING OUTER RACE a Using a hammer and brass bar drive out the cutor race b Using SST d...

Page 449: ...all correct thrust washer and side gears Select thrust washers from the table below that will ensure the backlash is within specification Try to select washers of the same thickness for both sides Sundard backlash 0 05 0 20 mm 0 0020 0 0079 in Thrun w1sher thickness 0 96 1 04 1 06 1 14 1 16 1 24 1 26 1 34 10 0378 0 0409 10 0417 0 0449 10 0457 0 0498 0 0496 0 0528 mm in Install thrust washers and s...

Page 450: ...ear to about 100 C 212 F in and bath c Clean the contact surface of the ring gear with elm ing solvent d Then quickly Install the ring gear on the dlfferenU case e Align the marks on the ring gear and differentialcatt CAUTION Do not heat the ring gear more than IIO C 230 F f Coat the ring gear set bolts with gear oil g Install the lock plates and set bolts Tighten the 1ft bolts uniformly 1 little ...

Page 451: ...bearing NOTE Assemble the spacer oil slinger and oil seal after adjusting the gear contact pattem b Install the companion flange with SST Coat the threads of the nut with MP grease SST 09557 22022 c Adjust the drive pinion preload by tightening the companion flange nut Using SST to hold the flange tighten the nut SST 09330 00021 CAUTION As there is no r tighten a little It 1 time being careful not...

Page 452: ...n the carrier 3 ADJUST RING GEAR BACKLASH a Install only the plate washer on the ring gear bact side NOTE Insure that the ring gear has a backlash Ib Snug down the washer and bearing by tapping on me ring gear with a plastic hammer Ic Hold the side bearing boss on the teeth surface ofme ring gear and measure the backlash Backlash reference 0 10 mm 0 0039 in d Select a ring gear back plate washer u...

Page 453: ...tial case lgl Install the plate washer into the lower part of the carrier lh Place the other plate washer onto the differential case together with the outer raoe and install the dif ferential C lse with the outer race into the carrier i Using a plastic hammer snug down the washer apd bearing by tapping the ring gear lil Using a dial indicator measure the ring gear backlash Backlash 0 13 0 18 mm 0 ...

Page 454: ... Recheck the ring gear backlash Backlash 0 13 0 18 mm 0 0051 0 0071 in e If not within standard adjust by either increasingcr decreasing the washers on both sidesby eQual NOTE The backlash will change about 0 02 mm 0 001 in with 0 03 mm 0 0012 in alteration of the ad washer W3sher thitkneu Thickness 2 67 2 59 10 1012 0 1020 2 60 2 62 10 1024 0 1031 2 63 2 85 t0 1035 0 1043 2 66 2 68 C0 1047 0 1056...

Page 455: ...m 3 5 5 2 in lb 0 4 0 6 N m 7 INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION al Coat 3 or 4 teeth at three different positions on the ring gear with red lead bl Hold the companion flange firmly and rotate the ring ge ar in both directions cl Inspect the tooth pattern Face Contact Select an adjusting shim that will bring the drive pinion closer to the rin ar Pr091J Contact Toe Contact Fla...

Page 456: ...0591 2 72 10 1071 9 REMOVE FRONT BEARING AND BEARING SPACE6 See step 12 on page RA 25 1 10 INSTALL NEW BEARING SPACER AND FRONT BEARING a Install a new bearing spacer on the shaft b lnsta11 1he front bearing on the shaft 11 INSTALL OIL SLINGER AND NEW OIL SEAL a Install the oil slinger facing as shown b Using SST drive in a new oil seal SST 09316 60010 Oil seal drive in depth 1 5 mm 0 059 in c App...

Page 457: ...e maximum torque is exceeded while retightening the nut replace the bearing spacer and repeat the preload pro cedure Do not back olf the pinion nut to reduce the preload Maximum torque 2 400 kg m 174 ft lb 235 N m 14 CHECK RUNOUT OF COMPANION FLANGE Using a dial indicator measure the lateral and radial runout of the companion f nge If the runout is greater than the maximum inspect the bearings Max...

Page 458: ... 19 INSTALL DIFFERENTIAL CARRIER COVER INSTALLATION OF DIFFERENTIAL See page RA 20 1 INSTALL DIFFERENTIAL Support the differential with a jack and install the carrilr bolt Torque 850 kg em 61 ft lb 83 N m 2 INSTALL DIFFERENTIAL SUPPORT MEMBER MOUNTING BOLT NO 1 See page RA 55 Torque 850 kg cm 61 ft lb 83 N ml Lower the differential and remove the jack 3 CONNECT PROPELLER SHAFT FLANGE FROM COMPANIO...

Page 459: ... part that is to be reused must be reassembled to its former location COMPONENTS Pinion Gear Thrust Washer No 2 Thrust Washer No 3 __ Clutch Member Thrust Wallher_ Clutch MemberS i r lootch Member RH Ciootch Member LH Thrust Washer No 2 Ring Gear Clutcho 0 Mo mtoer I Thrust Washer Adjusting Washer Thrus t Washer No 3 1 soo 1 kg cm Ht lb N m Specified torque Non reusable part il Precoa1ed part 0 Nu...

Page 460: ... easier by heating the assembly to around 150 C 302 F in an o il heater or similar means 4 REMOVE FOLLOWING PARTS FROM CASE COVER a Clutch member thrust washer b Side gear c Thrust washer No 3 d Thrust washer No 2 e Adjusting washer 5 REMOVE FOLLOWING PARTS FROM DIFFERENTIAL CASE a Clutch member RH with pinion gear b Clutch member spring c Clutch member LH d Side gear and clutch member thrust wash...

Page 461: ...tial case by selecting a proper thiek ne ss adjusting washer as follows Standard clearance 0 03 0 15 mm 0 0012 0 0059 in a Clean the parts b Assemble the following parts to SST SST09411 22011 NOTE Do not assemble the adjusting washers and clutch member springs 1 Side gear thrust washer No 2 2 Side gear thrust washer No 3 31 Side gear 41 Clutch member thrust washer 5 Clutch member LH 6 Clutch membe...

Page 462: ...9543 2 95551 u I 0 75 07 75 10 2 9555 2 95671 E 75 10 75 13 2 9567 2 95791 J Loll14 If Select the adjusting washers by combining the dimen Q sion MD mark punched on case and dimension 0 0 L in the adjusting washer selection table Adi Ating wl1her lilt S MM tn Ma t Thickneu Mork Thid ntu Q rn 1 1 80 0 0709 4 1 95 0 0768 0 0 2 1 85 10 0728 5 2 00 0 0787 3 1 90 0 0748 6 2 05 0 0807 A A If c E 7091 r ...

Page 463: ...djusting washer Thrust washer No 2 Thrust washer No 3 Side gear Clutch member thrust washer i Temporarily assemble the selected thrust washers together with the other L dimension measured parts into the case NOTE Do not assemble the spring jl Tighten the bolts to specified torque Torque 650 kg em 47 ft lb 64 N ml k Tum the side gears with the side gear shaft or other means and check to see that th...

Page 464: ...h gear oil for LSD Adjusting washer NOTE Face the oil groow toward the clutch plate Thrust washer No 2 Thrust washer No 3 Side gear Clutch member thrust washer NOTE Face the oil groove toward the clutch member Clutch member LH Clutch member spring Clutch member RH with pinion gear 3 INSTALL FOLLOWING PART ONTO DIFFERENTIAL CASE COVER Adjusting washer NOTE Face the oil groove toward the clutch plat...

Page 465: ...ase threads and the bolts and install the bolts 3 Allow to stand at least 3 hours after tightening the bolts In cold weather heat to 30 so c 86 t22 F before letting stand b Tighten the bolts evenly and gradually Torque 650 kg em 47 ft lb 64 N m 6 CHECK SIDE GEAR THRUST CLEARANCE Turn the side gear with side gear shaft or other means and check to see thatthev turn smoothly 6 INSTALL SIDE BEARING Se...

Page 466: ...ear Suspension Stabm er S r 180 13 Drive Shaft Ikg m ft lb N ml I Specified tOtQue IRS TYPE REAR SUSPENSION COMPONENTS Upper Insulator Shod Absorber l Lower lnsulatOf SU peMion Arm 1 176 86 115 Outer Bushing Rear Axle Shaft Parking Brake Shoe ...

Page 467: ...ly and support the rear wspension member with stands 2 REMOVE BRAKE HOSE CLIPS 3 REMOVE STABILIZER BAR END 4 5 Disconnect the nut cushion and retainer from suspension arm REMOVE DRIVE SHAFT Remove the nut holding the rear drive shaft LEAVE A JACK UNDER SUSPENSION ARM 6 REMOVE REAR SHOCK ABSORBER a Remove the bolt holding the shock absorber to the rear suspension armanddisconnect theshock absorber ...

Page 468: ...on arm NOTE Be careful not to pull the brake line and parki brake cable b While lowering the rear suspension arm remove tilt coil spring and upper and lower insulators INSTALLATION OF COIL SPRING AND SHOCK ABSORBER 1 PUT LOWER INSULATOR ON REAR SUSPENSION ARM 2 PUT UPPER INSULATOR ON COIL SPRING 3 INSTALL COIL SPRING 4 CHECK POSITION OF LOWER INSULATOR a Jack up the rear suspension arm b Check tha...

Page 469: ...e shock absorber to the rear suspension arm with the bolt Torque the bolt Torque 375 kg em 27 ft lb 37 N m 6 CONNECT STABILIZER BAR END TO REAR SUSPENSION Connect the cushion retainer to the rear SUSPension arm Link with the nut Torque the nut Cushion Retainer Torque 180 kg cm 13 ft lb 18 N m 7 INSTALL DRIVE SHAFT Connect the drive shaft to the rear axle shaft with the nuts Torque 700 kg em 51 ft ...

Page 470: ...MOVE STABILIZER BAR BRACKETS 2 REMOVE STABILIZER BAR FROM ARM S Remove the nuts cushions and links holding both sidoo of the stabilizer bar from suspension arms and disconnect the stabilizer bar INSTALLATION OF REAR STABILIZER BAR 1 ASSEMBLE STABILIZER LINK SUBASSEMBLY AND INSTALL LINK TO ARM 2 INSTALL STABILIZER BAR TO LINK Connect the stabilizer bar on both sides of the link will bolts collars c...

Page 471: ...RIVE SHAFT 3 REMOVE REAR AXLE SHAFT FLANGE 4 REMOVE BRAKE DRUM OR DISC ROTOR 6 REMOVE REAR AXLE SHAFT 6 REMOVE BACKING PLATE OR DUST COVER 7 DISCONNECT BRAKE LINE 8 DISCONNECT SHOCK ABSORBER FROM LOWER ARM 9 REMOVE COlL SPRING 10 REMOVE REAR SUSPENSION ARM AND LOWER CONTROL BUSHING NOTE Remember where the complete mark Is when removing the suspension arm al Remove the two mounting bolts bl Remove ...

Page 472: ...CE INNER AND OUTER BUSHING a Cut off the flange tip of the bushing as shown in he figure b Bend the remaining portions inward with a cold chisel NOTE Be careful not to damage the flange c Bend in the flange tips and pull off the flange wima pair of pliers Bend the remaining flange portion so the SST can be installed to the lower arm d Using SST press out the outer bushing from theatm SST 09710 220...

Page 473: ...ngs INSTALLATION OF REAR SUSPENSION ARM 1 2 3 4 5 6 7 8 9 10 INSTALL ARM a Align the complete mark at the same position it was before removal b Provisionally tighten the suspension arm INSTALL COIL SPRING INSTALL SHOCK ABSORBER INSTALL BACKING PLATE OR OUST COVER CONNECT BRAKE LINE CONNECT PARKI NG BRAKE CABLE INSTALL REAR AXLE SHAFT INSTALL BRAKE DRUM OR DISC ROTOR CONNECT REAR DRIVE SHAFT CONNEC...

Page 474: ...nsion Sounc 11 LOWER VEHICLE Lower the vehicle and bounce it sewral times 12 TIGHTEN SUSPENSION ARM Torque Inside 1 325 k m 96 ft lb 130 N m Outside 1 175 kg em 85 ft lb 115 N m 13 CHECK AND ADJUST REAR WHEEL A LIGNMENT SeepageRA 3 14 BLEED BRAKE LINE ...

Page 475: ...pe StaPP l c I REMOVAL OF DIFFERENTIAL S UPPORT MEMBER 1 REMOVE STABILIZER BRACKET 2 REM OVE DIFFERENTIAL SUPPORT M EMBER NO 1 MOUNTING BOLT NUTS 3 DISCONNECT DRIVE SHAFT FROM DIFFERENTIAL 4 REMOVE DIFFERENTIAL CARRIER BOLTS 6 REMOVE DIFFERENTIAL SUPPORT MEMBER a Remove the No 2 mounting bolt nuts and lower stopper bl Remove the differential support member with the upper stopper ...

Page 476: ...ss the new cushion into the support member NOTE Assemble the cushion with the recesses at right angle to the support member From 3 CHECK DIFFERENTIAL SUPPORT MEMBER If the support member is damaged or worn replace it INSTALLATION OF DIFFERENTIAL SUPPORT MEMBER 1 INSTALL SUPPORT MEMBER a Put upper stopper on member b Install the support member and lower stopper will nuts NOTE Hand tighten the nuts ...

Page 477: ...R MOUNTING BOLT NO 1 RA 55 Install the No 1 mounting bolts to the support member with nuts Torque the nuts Torque 850 kg cm 61 ft lb 83 N m 4 TIGHTEN SUPPORT MEMBER NUTS Torque the nuts Torque 1 200 kg em 87 ft lb 118 N m 5 CONNECT DRIVE SHAFT 6 INSTALL STABILIZER BAR BRACKET See page RA 49 ...

Page 478: ...EM PRECAUTIONS 0 0 0 TROUBLESHOOTING CHECKS AND ADJUSTMENTS MASTER CYLINDER BRAKE BOOSTER 0 0 0 0 0 0 0 FRONT BRAKE 0 0 REAR BRAKE BRAKE HOSES AND TUBES Page BR 2 BR 2 BR 6 BR 9 BR 12 BR 14 BR 20 BR 31 BR 1 I Jij ...

Page 479: ...rake caliJ ef s BR 18 22 Parking br11t1 out of adjustment Adjust patk ing brake BR 8 30 Binding patk in g brake wire Re ptir IS MCtssary Booster pulh rod ov1 of adjvttment Adiun push rod BR 12 Return spring taulty Replace spring BR 26 Brake line resulcted Repair neQitnary Pads cracked or distorted Replace brake pads BR 14 20 C31iper pkton nicking Rtp tlr ts nece 6t BR 16 22 Adiusttt broken Rtplaoe...

Page 480: ...ledges BA 28 plate ledges wotn Orum brakes loose or mis sing hold Reptace BA 26 down spring Disc bf akes run on front edgt of Inspect lubricate replace if BA 26 inboard shOt neoessary Disc bfakeS IOO e or missing anti Replace BR 14 20 rattle spring Disc brakes loose installatio n bolt Tighten BR 14 20 I Disc br al es wear on slide bushing Replace BR 14 20 Setapjr g or grinding Worn brake linings R...

Page 481: ... BR 14 20 This ooct ion1l squeal contact with the rotor is not a functiortal ptobltm ltld da s not indicate tny 10 of blake tfftc tivtneu Squetling noin when Bent or warped backing plate causing Service or rtpltce BR 28 bfakts art not IJ pfied inte rferenca with drum __ Improper mtchining of drum causing Replace drum BR 26 interference with backing plate or shoe Mal adjustmtnt of buke pedal or boo...

Page 482: ...t4 20 f1Uie spring or pad wpport plate or Cfimping on outer pad Oi btakn tailutt of shim ln spec t rtp4tce if ntctssaty BR 14 20 Disc br a es wtw on sHOt bushing lnq kt rf1 1Ke il r tCf UIIY BR 14 20 Disc br1ka k o innalletton bolt IMP 1 tioghttn if necessarv BR 14 20 Mal adjustment of break pedal or Inspect an l cljun BR B 12 booster push rod D isc brakes POOr return of pinon IMPtC t s ervict or ...

Page 483: ...n is no more vacuum left in Ito Pedal Free Play 3 6mm booster b Push in the pedal until the beginning of resistanoe k felt Measure the distance as shown Pedal freeplay 3 6 mm 0 12 0 24 in NOTE The pedal freeplay is the amount of the strol t until the booster air valve is moved by the pedal push rod 4 IF NECESSARY ADJUST PEDAL FREEPLAY a If incorrect adjust the pedal freeplay by turning Ito pedal p...

Page 484: ...tight b Depress the brake pedal while the engine is running and stop it with the pedal depressed If there is no change in pedal reserve travel after holding the pedal for thirty secoods the booster is air tight BLEEDING OF BRAKE SYSTEM NOTE If any work is done on the brake system or if air is susp ted in the brake lines bleed the system of air CAUTION Do not let brake fluid remain on a painted sur...

Page 485: ... plug tightening torque 86 kg em 74 in lb 8 3 N m 6 REPEAT PROCEDURE FOR EACH WHEEL CHECK AND ADJUSTMENT OF PARKING BRAKE 1 CHECK THAT PARKING BRAKE LEVER TRAVEL IS CORRECT Pull the parking brake fever all the way up and oounttlw notches of lever travel Parking brake levlf travel at 20 kg 44 1 lb 196 N 5 Sdickl If incorrect adjust the parking brake 2 IF NECESSARY ADJUST PARKING BRAKE NOTE Before a...

Page 486: ...WARNING SWITCH CONNECTOR DISCONNECT TWO BRAKE TUBES Using SST disconnect two brake tubes from the master cylinder SST 09751 36011 3 REMOVE MASTER CYLINDER a Remove the lour nuts b Remove the master cylinder and gasket from the brake booster DISASSEMBLY OF MASTER CYL INDER 1 PLACE CYLINDER IN VISE 2 DISCONNECT RESERVOIR AND HOSE Remove the cap Wainer bolt and hose 3 REMOVE SNAP RING AND ELBOW 4 REM...

Page 487: ...he No 2 piston ASSEMBLY OF MASTER CYLINDER See page BR 9 1 APPLY L ITHIUM SOAP BASE GLYCOL GREASE TO RUBBER PARTS OF PISTON 2 INSTALL TWO SPRINGS AND PISTONS CAUTION Be careful not to damage the rubber Iipson the pistons a Insert two springs and pistons in the master cylindo housing as shown b Using snap ring pliers install the snap ring 3 INSTALL PISTON STOPPER BOLT Using screwdriver push the pis...

Page 488: ... CONFIRM THAT UP MARK OF MASTER CYLINDER BOOT IS IN CORRECT POSITION 3 ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD BEFORE INSTALLING MASTER CYLINDER See page BR 12 4 INSTALL MASTER CYLINDER lnttall lhe cylinder and gasket on the brake booster wilh four nuts Torque 130 kg em 9 ft lb 13 N m 5 CONNECT TWO BRAKE TUBES Using SST connect two brake tubes to the outlet plugs SST 09751 36011 Torque 155 kg em 1...

Page 489: ...VIS PIN FROM BRAKE PEDAL Remove the clip and clevis pin 3 DISCONNECT HOSE FROM BRAKE BOOSTER 4 REMOVE BRAKE BOOSTER Remove the four nuts and pull out the brake booster INSTALLATION OF BRAKE BOOSTER 1 ADJUST LENGTH OF BOOSTER PUSH ROO Adjust the length of the booster push rod to provide d t specified clearance between the push rod and the master cylinder piston Standard claaranoe 0 1 0 5 mm 0 004 0...

Page 490: ...973 0010 c Check that push rod lightly touches the pin head d Adjust the booster push rod length until the push rod lightly touches the pin head INSTALL BRAKE BOOSTER a Install the brake booster over the gasket b Tighten the four nuts Torque 130 kg em 9 ft lb 13 N ml CONNECT CLEVIS TO BRAKE PEDAL Install the clevis pin and clip INSTALL MASTER CYLINDER See steps 1 2 and 4 on 11898 BR 11l CONNECT HO...

Page 491: ...de Plate i Anti Rattl Spdng Sliding Bushing Soot Ika c m ft lb N m I Specified torque Pad Wur lndiCitOt REPLACEMENT OF BRAKE PA DS 1 2 NOTE If a squealing noise occu from the brlkM wlllo driving check the pod wear indicator If there are t _ of the indicator contacting the rotor disc the disc pill should be replaoed DRAW OUT A SMALL AMOUNT OF BRAKE FLUIO REMOV E CYLINDER INSTALLATION BOLT ...

Page 492: ... INSTALL NEW PADS AND NEW ANTI SOUEAL SHIM a Install the pads onto each spring NOTE Install the outside pad so the wear indicator is at the top side CAUTION Do not allow oil or grease to touch the rub bing face b Install the anti squeal shim toward the inside of the pad 9 LOWER CYLINDER Remove the bolt from the torque plate and lower the cylinder NOTE Insert the cylinder carefully so the boot is n...

Page 493: ...e brake fluid c Remove the clip from brake hose d Disconnect the brake hose from the cylinder 2 REMOVE CYLINDER 3 a Hold the sliding bushing and remove the cylinder installation bolt b Lift up and push out the cylinder from the torque plate pin REMOVE FOLLOWING PARTS a Anti squeal shim b Brake pads c Anti rattle springs d Pad guide plates e Pad support plate DISASSEMBLY OF CYLINDER See page BR 14 ...

Page 494: ...FROM CYLINDER REMOVE PISTON SEAL FROM CYLINDER INSPECTION OF FRONT BRAKE COMPONENTS 1 MEASURE PAO LINING THICKNESS Standard thickness 10 5 mm 0 413 in Minimum thickMIS 3 0 mm 0 118 in Replace the pad if the thickness is less than the minimum the 1 0 mm slit is no longer visible or if it shows sign of uneven wear 2 MEASURE ROTOR DISC THICKNESS Standard thickness 20 0 mm 0 787 in Minimum thickness 1...

Page 495: ... b Remove the axle hub See page FA 6 c Remove the disc from the axle hub d Install a new rotor disc Torque four bolts Torque 650 kg em 47 ft lb 64 N m e Install the axle hub and adjust the front bearingp Of load See page FA Bl f Install the torque plate onto the knuckle Torque 925 kll cm 67 ft lb 91 N m ASSEMBLY OF CYLINDER See page BR 14 1 APPLY LITHIUM SOAP BASE GLYCOL GREASE TO FOLLOWING PARTS ...

Page 496: ...i squeal shim 2 INSTALL CYLINDER a Install the cylinder onto the main pin NOTE Make sure that the boot end is installed into the groove of the main pin b Install the cylinder over the brake pads 3 INSTALL CYLINDER INSTALLATION BOLTS Install the cylinder installation bolts torque one bolt Torque 200 kg em 14 ft lb 20 N m NOTE Insert the installation bolt into the cylinder care fully so as not to we...

Page 497: ...StKket Boot Anti Squ l Shim Pad Support Plate Pad Guide Platt Anti Rottlt Spring REPLACEMENT OF BRAKE PADS NOTE If 1 squealing noise occurs from the brakes w iill driving check the pad wear indicato If there are tr of the indicato contecting the rotor disc the disc ped should be replaced 1 DRAW OUT A SMALL AMOUNT OF BRAKE FLUID 2 UNSCREW CYLINDER INSTALLATION BOLT ...

Page 498: ...ER 8 INSTALL NEW PADS AND NEW ANTI SQUEAL SHIM a Install the pads onto each spring NOTE Install the outside pad so the wear indicator is at the bonom side CAUTION Do not allow oil or grease to touch the rub bing fece b Install the anti squeal shim toward the outside of the pad 9 LOWER CYLINDER Remove the boh from the torque plate and lower the cylinder NOTE Insert the cylinder carefully so the boo...

Page 499: ...e brake fluid c Remove the clip from brake hose d Disconnect the brake hose from the cylinder 2 REMOVE CYLINDER a Hold the sliding bushing and unscrew the cylinder installation bolt b Lift up and push out the cylinder from the tor plate pin 3 REMOVE FOLLOWING PARTS a Anti squeal shim b Brake pads c Anti rattle springs d Pad guide plates e Pad support plate DISASSEMBLY OF CYLINDER See page BR 20 1 ...

Page 500: ... SET RING FROM CYLINDER 5 REMOVE PISTON SEAL FROM CYLINDER INSPECTION OF REAR BRAKE COMPONENTS 1 MEASURE PAD LINING THICKNESS Standard thickness 10 6 mm 0 413 in Minimum thickness 3 0 mm 0 118 in Replace the pad if the thicknm is less than the minimum the 1 0 mm slit is no longer visible or if it shows Si J I of uneven wear 2 MEASURE ROTOR DISC THICKNESS Standwd thickness 18 0 mm 0 709 in Minimum ...

Page 501: ...CE ROTOR DISC a Remove the torque plate from the rear axle housing b Remove the rotor disc and hub nuts c Install the rotor disc and adjust the shoe clearanct d Install the torque plate onto the rear axle housing Torque 475 kg cm 34 ft lb 47 N m ASSEMBLY OF CYLINDER See page BR 20 1 APPLY LITHIUM SOAP BASE GLYCOL GREASE TO FOLLOWING PARTS a Main pin boot b Sliding pin and boot c Piston seal and pi...

Page 502: ...es c Anti rattle springs d Brake pads e Anti squeal shim 2 INSTALL CYLINDER a ln stall the cylinder onto the main pin NOTE Make Ure that the boot end is installed into the groove of the main pin b ln rt the cylinder installation bolt into the cylinder body c Install the cylinder over the brake pads 3 TORQUE CYLINDER INSTALLATION BOLT Torque the bolt Torque 200 k cm 14 ft lb 20 N m 4 CONNECT BRAKE ...

Page 503: ...R OISC BRAKE ASSEMBLY a Remcwe two torque plate mount bolts and remooe the disc brake b Suspend the disc brake so the hose is not stretched 2 REMOVE ROTOR OISC 3 MEASURE BRAKE SHOE LINING THICKNESS See page BR 33 4 REMOVE SHOE RETURN SPRINGS 6 REMOVE SHOE STRUT WITH SPRING 6 REMOVE FRONT SHOE SHOE ADJUSTING SCRE W SET ANO TENSION SPRING a Slide out the front shoe and remove the shoe adjust ing scr...

Page 504: ... thicl ness 2 0 mm 0 079 in Minimum thickness 1 0 mm 0 039 in If the shoe lining is less than minimum replace tho parking brake shoes NOTE In order to maintain effective brakes replace all of the shoes if the thickness of any one is not within soecification 3 INSPECT REAR PARKING BRAKE LINING AND DRUM FOR PROPER CONTACT Replace the brake or lathe the brake disc as necessary 4 MEASURE CLEARANCE BET...

Page 505: ...m b Install the parking brake leverwith a new C washer c Remeasure the clearance ASSEMBLY OF PARKING BRAKE See page BR 26l 1 APPLY NON MELTING TYPE GREASE ON BACKING PLATE AS SHOWN G uso Apply non melting type grease to the sliding surfaces of the shoe 2 APPLY NON MELTING TYPE GREASE TO SHOE ADJUSTING SCREW SET CuUIIway View A ...

Page 506: ...OE ADJUSTING SCREW SET a Install the tension spring to the rear shoe b Install the front shoe to the tension spring c Install the shoe adjusting screw set between the front and rear shoes d Slide in the front shoe between the shoe hold down spring seat and the backing plate 6 INSTALL FRONT SHOE RETURN SPRING 7 INSTALL STRUT WITH SPRING 8 INSTALL REAR SHOE RETURN SPRING 9 INSTALL REAR DISC a Before...

Page 507: ...er travel Parking brake lover travel at 20 kg 44 1 lb 196 N 5 8 elides INSTALL REAR DISC BRAKE ASSEMBLY Install the disc brake an l torque two torque plate mount bolts Torque 475 kg em 34 ft lb 47 N m BED DOWN PARKING BRAKE SHOES AND DRUM a Drive the vehicle at about 50 km h 31 mph on a safe level and dry road b With the parking brake release button pushed in p_ on the lever with 9 kg 19 8 lb or 8...

Page 508: ...ECT HOSE AND TUBE a Connect the hose and tube by hand b Using a wrench to hold the hose and SST to hold the tube torque the connection SST 09751 36011 Torque 155 kg cm 11 ft lb 15 N m c Install a new hose clip INSPECTION OF BRAKE HOSES AND TUBES 1 INSPECT BRAKE HOSES a Inspect tho hose for damage cracks or swelling b Inspect the threads for damage 2 INSPECT BRAKE TUBES a Inspect the tube for damag...

Page 509: ...ING SR 2 ON VEHICLE INSPECTION SR 2 STEERING COLUMN ASSEMBLY WITH TILT STEERING SR 3 POWER STEERING SR 13 On Vehicle Inspection SR 13 BINding of Power Steering System SR 15 Oil Pressure Check SR 16 Power Steering Pump SR 18 Gear Housing SR 27 SR 1 ...

Page 510: ...and stH ring link19t Chtck front end aliiJinment Repl e lower arm ball joints 01ock power steering unit Inflate tires to ptoper preuure LubriCIUI suspension and ste ering linkage Check front end alignment Titf ttn our bolts Rtp Kt main shaft Rtpltct lower ar m ball joinu FA 3 SR 26 SR 13 FA 3 FA I5 SR 13 FA 3 FA 3 SR S FA IS ON VEHICLE INSPECTION 1 CHECK THAT STEERING WHEEL FREEPLAY IS CORRECT Wit...

Page 511: ...embly with Tilt Steering SR 3 360126 34 300 125 341 Ikg cm ft lb N ml Specified torque STEERING COLUMN ASSEMBLY WITH TILT STEERING REMOVAL OF STEERING COLUMN 360 125 34 Wheel Pad Column Cover Column and haft 130t9 13 Column Cover ...

Page 512: ... the screw at the lower portion of the steerq wheel pad and pull the pad out upward b Remove the steering wheel nut c Using SST remove the steering wheel SST 09609 20011 4 REMOVE INSTRUMENT LOWER PANEL AND AIR DUCT 5 REMOVE COLUMN COVER AND COMBINATI fj SWITCH 6 REMOVE TWO MOUNTING BOLTS FROM COLUMN HOLE COVER PLATE 0 7 REMOVE TWO COLUMN BRACKET MOUNTING NUl j B PULL OUT COLUMN TUBE AND SHAFT J Tu...

Page 513: ...th Till Steering COMPONENTS liS cu 11 pport Reinforcement Tension Spring and Cord Column Bnockolt 2110 2111 Ik m fl lb N mil Specified torque t Non rtvublt rt T tlon Spring Cottar No 1 Column TW and tnttrmediete Shift Lower Bearing d SR 6 ...

Page 514: ... TENSION SPRINGS AND CORDS a Fully tilt the main shaft upward b Pry the spring and remove the cord and spring 3 DISCONNECT INTERMEDIATE SHAFT AND MAIN SHAFT 4 a Place matchmarks on the intermediate shaft and uno versal joint b Remove the joint bolt c Remove the four bracket bolts d Separate the tilt mechanism from the oolumn tube DISCONNECT UPPER BRACKET FROM TILT STEERING SUPPORT a Remove the sup...

Page 515: ...he snap ring bl Pull out the main shaft from the bracket 6 DISASSEMBLE TILT STEERING SUPPORT AND COLUMN BRACKET a Remove the two nuts bolt and retainer b Take out the collar and release pin c Remove the tension spring and take out the tilt pawl d Remove the guide pin bolt support bolt and shim e Using a hammer r move the serration bolt and tilt lever ...

Page 516: ...09620 30010 09623 30010 b Pack MP grease into the bearing c Using SST and a hammer drive the bearing into 1he bracket SST 09620 30010 09624 30010 09631 00020 2 IF NECESSARY REPLACE LOWER BEARING a Using SST and a press remove the lower bearing Inn the main shaft SST ogS27 2001 1 b Pack MP grease into the bearing c Using SST and a press assemble the lower bea and main shaft SST 09236 00101 and 0961...

Page 517: ... all play 17 989 17 996 17 996 18 003 18 003 18 010 18 010 18 017 18 017 18 024 Outerdiametet m m inJ 0 7082 0 70851 0 7085 0 70881 0 7088 0 70911 0 709 1 0 70931 0 7093 0 70961 bl Install tilt lever and collar No 1 to the support cl Select a collar No 2 which will eliminate all play 17 982 18 000 18 000 18 0t8 Outtt d llf Mttf 0 7080 0 70871 10 7087 0 70S I dl Install collar No 2 to the support e...

Page 518: ...31 b Install the shim bolt washer and a lock nut Torque 185 kg em 13 ft lb 18 N m i 5 INSTALL TILT STEERING SUPPORT STOPPER BOLT a Install the stopper bolt bracket washer and nut b Ti llten the nut by holding the bracket with your gers as shown Torque 100 kg em 7 ft lb 10 N m 6 ASSEMBLE MAIN SHAFT AND UPPER BRACKET a Assemble the collar spring and main shaft and ill el them into the bracket b Usin...

Page 519: ...OLUMN TUBE Torque 185 k g em 13 ft lb 18 N ml 9 CONNECT MAIN SHAFT AND INTERMEDIATE SHAFT Align the marks on the joint flange and intermediate shaft and tighten the bolt Torque 250 kg em 18 ft lb 25 N m 10 INSTA LL TWO SPRINGS AND TWO CORDS a Connect the tension spring and cord and hook the spring to the hanger b Pry the spring end and hook the cord end to the suppon c Hook the cords to the cord g...

Page 520: ...NTING NUTS Torque 250 kg em 18 ft lb 25 N m 5 INSTALL COMBINATION SWITCH AND COLUMN COVER 6 INSTALL AIR DUCT AND INSTRUMENT LOWER PANEL 7 INSTALL INTERMEDIATE SHAFT a Install the column side first b Install the rack housing side c Install the two bolts and torque them Torque 350 kg em 25 ft lb 34 N m 8 CONNECT NEGATIVE CABLE TO BATTERY 9 INSTALL STEERING WHEEL Ia Position the front wheels straight...

Page 521: ...r ing wheel from lock to lock several times to boost the fluid temperature Fluid temperature 80 C 176 FI 3 CHECK FOR FOAMING OR EMULSIFICATION NOTE Foaming and emulsification indicate the existence of air in the system or that the fluid level Is too low 4 CHECK FLUID LEVEL IN RESERVOIR TANK Check the fluid level and add fluid if necessary Fluid ATF DEXRON or DEXRON n NOTE Check that the fluid leve...

Page 522: ... ENGINE IDLING TURN STEERING WHEEL FROM LOCK TO LOCK WHILE DRAINING FLUID 4 STOP ENGINE 5 FILL RESERVOIR WITH FRESH FLUID Fluid ATF DEXRON or DEXRON 0 6 START ENGINE AND RUN IT AT 1 000 RPM Blind Plug After 1 or 2 seconds fluid will begin to discharge from the return hose Stop the engine immediately at this time 7 REPEAT STEPS 5 AND 6 FOUR OR FIVE TIMES 8 CONNECT RETURN HOSE TO RESERVOIR TANK 9 BL...

Page 523: ...E OR FOUR TIMES Run the engine at 1 000 rpm or less 3 CHECK THAT FLUID IN RESERVOIR IS NOT FOAMY OR CLOUDY AND DOES NOT RISE OVER MAXIMUM WHEN ENGI NE IS STOPPED Measure the fluid level with the engine running Stop the engine and measure the fluid level Ma imum rise 5 mm 0 20 in If a problem is found repeat steps 1 and 2 Repair the PS pump if the problem pe11ists CHECK OF AIR CONTROL VALVE 1 START...

Page 524: ...rrect 2 CHECK THAT FLUIO TEMPERATURE IS AT LEAST SO C 176 F 3 START ENGINE AND RUN IT AT IDLE 4 CHECK FLUID PRESSURE READING WITH VAlllt CLOSED Close the pressure gauge valve and observe the readingon the gauge Minimum pressure 65 kg em 924 psi 6 374 kPa NOTE Oo not keep the valve closed for more than 10 seconds If pressure is low repair or replace the PS pump 5 OPEN VALVE FULLY 6 CHECK AND RECORD...

Page 525: ...f pressure is low the gear housing has an internal leak and must be repaired or replaced 9 MEASURE STEERING EFFORT Center the steering wheel and run the engine at idle Using a scale measure the steering effortin bothdirections Maximum steering effort 4 kg 8 8 lb 39 N If steering effort is excessive repair the power steering unit NOTE Be sure to consider tire type pressure and contact surface befor...

Page 526: ...OSE FROM RESERVOIR TANK 4 DISCONNECT PRESSURE TUBE FROM POWER STEERING PUMP Using SST loosen and disconnect the pressure tube SST 09631 22020 L J 5 REMOVE DRIVE BELT AND PULLEY a Push on the drive belt to hold the pulley in place and remove the pulley set nut tb Remove the drive belt adjust bolt tc Remove the PS pump rear mount bolt td Remove the drive belt te Remove the pulley and woodruff key 6 ...

Page 527: ...ap Ring Spring 0 DISASSEMBLY OF POWER STEERING PUMP 1 CLAMP POWER STEERING PUMP IN VISE CAUTION Do not tighten the vise too tight 2 REMOVE FRONT HOUSING SET BOLTS 3 REMOVE RESERVOIR TANK AND O RING Remove the two reservoir tank set bolts reservoir tank and 0 ring 4 REMOVE AIR CONTROL VALVE 5 MARK FRONT AND REAR HOUSING Mark these parts to ensure correct reassembly 6 REMOVE FRONT HOUSING Using a pl...

Page 528: ...remove the snap ring d Using a plastic hammer lightly tap the rotor shaft out of the front housing 10 REMOVE REAR PLATE AND SPRING Using a plastic hammer tap the bottom end of the mr housing and remove the rear plate and spring CAUTION Avoid gripping the rear plate with pliers thiscould de Ng it 11 REMOVE PRESSURE PORT UNION 12 REMOVE FLOW CONTROL VALVE ANO SPRING CAUTION Use 0 11 not drop scratch...

Page 529: ...that the diflerence between the rotor and cam ring measurement is tess than maximum Maximum difference 0 06 mm 0 0024 in If the diflerence Is excessive replace the cam ring with one stamped with the same letter on the rotor INSPECT AND MEASURE VANE PLATES a Check the vane plates for wear or scratches b Measure the length height and thickness of the vane plates Minimum length 14 97 mm 0 5894 in Min...

Page 530: ... 71 psi 392 or 490 kPal Into the opposite side Confirm that air does not come out from the lid hole If necessary replace the valve with one stamped with til same letter on the rear hou ing d Check that the spring is within specification Standard length 50 0 mm 1 969 in Minimum length 47 0 mm 1 850 in If the spring is not within specification replace the spring 6 IF NECESSARY REPLACE UNION SEAT a U...

Page 531: ...le bolt to the spring seat b Push in the bolt and install the snap ring with snap ring pliers c Remove the suitable bolt 4 INSTALL ROTOR SHAFT TO FRONT HOUSING Install the rotor shaft into the front housing by tapping it in with a plastic harrvner 5 INSTALL SNAP RING Using snap ring pliers install the snap ring to the front housing 6 INSTALL OIL SEAL a Apply a light coat of MP grease to a new oil ...

Page 532: ...ATES Install the vane plates with the round end facing outward 12 INSTALL REAR PLATE AND SPRING a Place the rear plate on the cam ring with the pin holes aligned with the pins b Place the spring on the rear plate 13 INSTALL REAR HOUSING a AIign the marks on the front and rear housing Nod assemble them bl Install the reservoir tank in place and tighten the reservoir tank set bolts 1 cl Finger tight...

Page 533: ...em 34 ft lb 47 N m 15 INSTALL RESERVOIR TANK Install and torque the bolts L _______ __ J Torque 130 k m 9 ft lb 13 N m 18 CHECK ROTOR SHAFT ROTATION CONDITION a Check that the rotor shaft rotates smoothly without abnormal noise b Provisionally install the pulley nut and check the rotating torque Rotating torque Less than 2 8 kg cm 2 4 in lb 0 3 N m 17 INSTALL AIR CONTROL VALVE Torque 370 kg cm 27 ...

Page 534: ...sion Now belt 125 251b Used belt 80 20 lb NOTE New belt refers to a brand new belt which has before been used Used belt refers to a belt which has been used on a running engine for 5 minutes or more e Torque the adjust bolt Torque 375 kjtcm 27 ft lb 37 N m f Push down on the drive belt to hold the pulley in place and torque the pulley set nut Torque 445 k t m 32 ft lb 44 N m g Install and torque t...

Page 535: ...ee step 2 on page SR 4 2 DISCONNECT TIE ROD END a Remove the ootter pin and nut holding the knuckle arm to the tie rod b Using SST disconnect the knuckle arm from the tie rod SST 09611 22012 3 DISCONNECT RETURN LINE AND PRESSURE LINE Using SST disconnect return and pressure lines Use a container to catch the power steering fluid SST 09631 22020 4 REMOVE GEAR HOUSING ASSEMBLY a Rer nove the gear ho...

Page 536: ...ver SnapRi VlAve Cap O Ring Cylinder End Stopper Control V lve Housing 1 l ta113 181 J Turn PtHSure Tube f Welhtr Cytinder Housing oil lngr Teflon Ring t 113 171 Rock Radc Houstno CiawW01her Rack End Ikg em ft lb N mt l Specified torque Non rtunble Plft Pr cotttd part ...

Page 537: ... Remove the union seats 3 REMOVE TIE ROD ENDS a Place matchmarks on the tie rod end and rack end b Loosen the clamp and remove the tie rod end from the rack end 4 REMOVE RACK BOOTS 5 REMOVE RACK GUIDE SPRING CAP LOCK NUT Using SST remove the rack guide spring cap lock nut SST 09612 24012 09617 24020 6 REMOVE RACK GUIDE SPRING CAP Using SST remove the rack guide spring cap SST 09612 24012 09612 100...

Page 538: ... left and right rack ends c Remove the claw washer 14 REMOVE CYLINDER END STOPPER NUT a Unnake the stoked part of cylinder housing b Using SST remove the cylinder end stopper nul SST 09630 24013 09631 24060 15 REMOVE RACK HOUSING a Remove the four bolts b Remove the rack housing c Remove the O ring 16 Rl MOVE SPACER FROM RACK HOUSING 17 REMOVE STEERING RACK WITH CYLINDER END STOPPER O RING RACK EN...

Page 539: ...CK HOUSING a Remove the oil seal with a screwdriver b Using SST install the new oil seal SST 09620 30010 109631 00020 SST 09630 24013 09631 24070 2 01L SEAL FOR CYLINDER HOUSING a Using SST drive out the oil seal b Using SST and a hammer install a new oil seal SST 09620 30010 09625 30010 09631 00020 Install the new oil seal Place the spacer on the oil seal Drive in the oil seal over the spacer unt...

Page 540: ...the teflon ring and O ring b Install a new O ring e Install a new teflon ring to SST and install it the steering reek SST 0963 24013 09631 24020 d Coat the teflon ring with power steering fluid and snug it down with your fingers e Carefully slidt the tapered end of SST over thettftot ring to seat the ring SST 0963 24013 09631 24030 NOTE Make sure the seal is uniformly spaoed around the perimeter o...

Page 541: ...oat the teflon ring with power steering fluid and snug it down with your fingers d Carefully slide the tapered end of the SST over the teflon ring to seat the ring SST 09630 24013 09631 24030 7 OIL SEAL AND BEARING FOR VALVE CAP a Using SST press out the oil seal and bearing from the valve cap SST 0962Q 30010 09631 00020 0963Q 24013 09620 24010 b Using SST press the oil seal into the valvecap SST ...

Page 542: ...0010 0963Hl0020 0963o 24013 0962o 24030 8 OIL SEAL FOR CYLINDER END STOPPER al Tap out ttle oil seal from ttle cylinder end stOPI CAUTIDN When tapping out the oil 1 be c reful to damage the inside of cylinder end stopper bl Using SST press the oil seal into the cylinder enl stopper SST 09631 20040 ...

Page 543: ...ND SPACER 3 INSTALL STEERING RACK ASSEMBLY a Insert SST into a new teflon ring of the piston SST 09630 24013 09631 24030 NOTE Protect the teflon ring from damage b Insert SST into a new oil seal of thecylinder housing Install one SST Into the other Insert two SST into the oil seal Remove one SST from the other SST 09630 24013 109631 24041 09631 24050 NOTE Protect the oil seal lip from damage ...

Page 544: ... oil seal Remove one SST from the other b Install the cylinder end stopper housing c Remove SST SST 09630 24013 09631 24041 09631 24050 6 INSTALL RACK HOUSING TO CYLINDER HOUSING NOTE Make sure that the 0 ring spacer and seal a11 installed between the rack housing and the cylinder hoo ing a Install the rack housing b Install the four bolts and torque them Torque 185 kg em 13 fl lb 18 N m 7 INSTALL...

Page 545: ...tall the three bolts and torque them Torque 185 kg em 13 ft lb 18 N m 13 ADJUST CONTROL VALVE SHAFT PRELOAD a Coat liquid sealer onto the screw surface of the bolt b Tighten the pinion adjusting screw and torque with SST SST 09612 24012 09612 10021 Torque 150 kg em 11 ft lb 15 N m c Return the pinion adjusting screw 10 d Using SST measure the preload SST 09616 00010 Preload turning 4 5 6 5 k J Cm ...

Page 546: ...lb 0 9 1 2 N m If incorrect readjust 18 INSTALL RACK GUIDE SPRING CAP LOCK NUT a Coat liquid sealer onto the lock nut and gear housi14 contact surfaces b Tighten the rack guide spring cap lock nut and torquo it with SST SST 09612 24012 109612 10021 09617 24020 Torque 700 kg em 51 ft lb 69 N m lc Recheck the total preload If incorrect readjust Preload turning 9 12 kg cm 7 8 10 4 in lb 0 9 1 2 N m 1...

Page 547: ...s NOTE Face the open ends outward as shown to avoid damage to the boots 21 INSTALL TIE ROD a Align the marks on the tie rod and rack end b Tighten the nuts and torque them Torque 175 kg m 13 ft lb 17 N m 22 INSTALL RIGHT AND LEFT TURN PRESSURE TUBES a Install the union seats b Using SST tighten the tubes and torque them SST 09631 22020 Torquor 300 kg em 22 ft lb 29 N m ...

Page 548: ...ressure line and torque it SST 09631 22020 Torque 390 kg cm 28 ft lb 38 N ml 3 CONNECT TIE ROD ENDS 4 5 6 7 8 a Install the tie rod end set nut and torque it Torque 600 kg cm 43 ft lb 59 N ml b Install the new cotter pin INSTALL INTERMEDIATE SHAFT a Install the column side first b Install the rack housing side c Install the two bolts and torque them Torque 350 kg m 25 ft l b 34 N ml FILL WITH POWE...

Page 549: ...WIPERS AND WASHERS BE 22 INSTRUMENTS AND SENDER GAUGES BE 27 REAR WINDOW DEFOGGER BE 61 HEATER BE 63 BE 1 POWER WINDOW BE 65 DOOR LOCK CONTROL SYSTEM BE 67 SUN ROOF BE 69 CRUISE CONTROL SYSTEM BE 70 REMOTE CONTROL MIRROR BE 85 MIRROR HEATER BE 86 THEFT DETERRENT SYSTEM BE 87 RADIO STEREO TAPE PLAYER AND ANTENNA BE 101 CLOCK BE 111 TRIP COMPUTER BE 113 ...

Page 550: ...tter indicates the color of the stripe CONNECTOR 1 PIN NUMBER OF FEMALE CONNECTOR Numbered in order from upper left to lower right 2 PIN NUMBER OF MALE CONNECTOR Numbered in order from upper right to lower left 3 DISTINCTION OF MALE AND FEMALE CONNECTORS Male and female connectors are distinguished by shape ol their internal pins a All connectors are shown from the open end and tht lock is on top ...

Page 551: ...IT BREAKER 1 REMOVE CIRCUIT BREAKER a Remove the kick panel b Remove the circuit breaker 2 RESET CIRCUIT BREAKER a Insert the needle into the reset hole and push it b Using an ohmmeter check that there is continuity between both terminals of the circuit breaker If there is no continuity replace the circuit breaker 3 INSTALL CIRCUIT BREAKER a Install the circuit breaker NOTE If a circuit breaker co...

Page 552: ...2 Always use a fuse puller for removing and iruerti a fuse Remove and insert straight in and out withollt twisting Twisting could force open the t8fminals too much resulting in a bad connection If a fuse continues to blow the circuit is probably shorted Have the system checked by a qualified technician Precautions TAKE CARE WHEN INSPECTING HEADLIGHT CIRCUIT WARNING With the headlight switch OFF di...

Page 553: ...r negative battery terminal and the positive lead to the connector or component terminal This check can be done with a test lamp instead of a voltmeter CONTINUITY AND RESISTANCE CHECK a Disconnect the battery terminal or wire so there is no voltage between the check points b Contact the two leads of an ohmmeter to each of the check points If the circuit has diodes reverse the two leads and check a...

Page 554: ...plaoe of the fuse c Establish conditions in which the test lamp comeson Example Ignition S W on Ignition S W and S W 1 on Ignition S W S W 1 and Relay on Connect the Relay and S W 2 off or Disconnect S W 2 d Disconnect and reconnect the connectors while watching the test lamp The short lies between the connector where the test lamp stays lit and the connector where the lampgoes out e Find the exac...

Page 555: ...M Location of Switches and Relays BE 7 LOCATION OF SWITCHES AND RELAYS ENGINE COMPARTMENT SWITCHES AND RELAYS l Water Temperature Sender Gauge Main Relay Neutral Start Switch Light Retractor Relay Ignition Coil with Igniter ...

Page 556: ...Main Switch Rtat Window Defogger Switch Heater Blower Switch Courtesv Switch IIJ C ruise Control Computet Light Corl rol Rheo tat Clutch Switch Fog Light Switcl l RearWiperSwitch Ignition Switch Turn Signal and Ha zard Switch Light Control Switch Horn Contact Headlight Dimmer Switch Wiper Washer and Cruise Control Switdl ...

Page 557: ...tc h es a n d R e l ay s B E 9 Seat BeH Warning Relay Rear Wiper Control Relay PASSENGER COMPARTMENT SWITCHES AND RELAYS Turn Sigilli fl sher Door Lock Relay lJ Power Window Relay _ lntttior Light Control Relay Front Wiper Control Relay Fog Light Relay HeeteJ Relay ...

Page 558: ...10 BODY ELECTRICAL SYSTEM Location of SwitchH and Relays PASSENGER AND LUGGAGE COMPARTMENT SWITCHES AND RELAYS Sot ct Door lode Control RtiiV OoO lock SotenoK e RearWiper 0 Co ot Courtesy Switch Fuel Geuge ...

Page 559: ... Switch 1 4 IGNITION SWITCH INSPECTION OF IGNITION SWITCH INSPECT SWITCH CONTINUITY Inspect the switch continuity between terminals 1 3 6 4 h n LOCK ACC ON START Waming Normal Push 2 If continuity is not as specified replace the switch BE 11 5 ...

Page 560: ...ty Rep iir as neeftsary Stop lighu do not STOP fuse blown Replace fuse and ctux k for short BE 4 ligllt _Stop light switct faulty Adjust or replace switch Wiring or ground faulty Repair as n ees 1ry J j Stop lights nay on Stop light switch faulty Adjust or replace switctl Instrument lights do Light control rheostat feu ltv Ch e rheostat 8E 17 not Iight Ctaillights Wiring or ground faulty Repair as...

Page 561: ...OFF UP TAIL HEAD V Headlight dimmer switch I 13 6 5 12 o HL HF on W 81 IR Gl R YI IR Wl Flosh Low 8um High Beam 1f continuity is not as specified replace the switch REPLACEMENT OF LIGHT CONTROL SWITCH AND HEADLIGHT DIMMER SWITCH REPLACE LIGHT CONTROL SWITCH AND HEADLIGHT DIMMER SWITCH a Remove the terminals from the connector See page BE 2 b Remove the light control switch c Remove the headlight d...

Page 562: ...y between terminab and 3 1 If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage across tenminals 1 and 2 b Check that there is continuity between tenminals 2 and 3 If operation is not as specified replace the relay Light Retractor Relay INSPECTION OF LIGHT RETRACTOR RELAY 1 INSPECT RELAY CONTINUITY a Check that there is continuity between terminalt ...

Page 563: ...een terminals 1 and 4 after connecting the negative 1 lead from the battery to terminal 6 After disconnecting the connection between terminal 6 and the battery check that there is continuity for 2 4 seconds between terminals 1 and 4 and continuity immediatelyfor6 14seconds between terminals 1 and 2 If operation is not as SPeCified replace the relay Light Retractor Motor INSPECTION OF LIGHT RETRACT...

Page 564: ...t the 3 4W test bulb between terminal B and pos tive lead from the battery a Disconnect the positive lead from the terminal 7 Check that the test bulb is lighting b Connect the negative lead to the terminalS Check that the test bulb does not light If operation is not as specified replace the relay 2 INSPECT TAILLIGHT CIRCUIT OPERATION Connect the positive leads from the battery to term nals 4 and ...

Page 565: ...NSPECTION OF FOG LIGHT RELAY 1 INSPECT RELAY CONTINUITY a Check that there is continuity between terminals 1 and 3 b Check that there is no continuity between terminals 2 and 4 L If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Apply battery voltage across terminals 2 and 4 b Check that there is continuity between terminals 1 and 3 If operation is not as specified re...

Page 566: ...tis 9V between terminals 1 and 3 b Gradually turn the rheostat toward the brighter sicll and check that the voltage between terminals 1and3 decreases from 9V to OV c With the brightness at minimum check that therell OV between terminals 2 and 4 and 12V when bright ness is at any other level II operation is not as specified replace the rheostat Turn Signal and Hazard Warning Switch INSPECTION OF TU...

Page 567: ...number of flashes will be more than 120 per minute If one of the side turn signal lights has an open circuit the number of flashes will increase by about 10 per minute If operation is not as specified replace the flasher Fade Out Relay INSPECTION OF FADE OUT RELAY 1 INSPECT COURTESY SWITCH CIRCUIT OPERATION Connect the positive lead from the battery to terminal 2 Connect the negative lead to termi...

Page 568: ...ECTION OF OUTSIDE HANDLE SWITCH INSPECT SWITCH CONTINUITY a Che k that there is continuity between terminals I and 2 when the switch ison b Check that there is no continuity between terminals 1 and 2 when the switch is off 1f continuity is not as specified replace the switch ...

Page 569: ...c Check that there is continuity between terminal 5 and body ground for about 0 5 seconds when the light control switch is at TAIL or HEAD and the washer switch is pushed twice in wccession If operation is not as specified replace the relay Cleaner Motor INSPECTION OF CLEANER MOTOR INSPECT MOTOR OPERATION a Connect the positive lead from the battery to terminal 1 Connect the negative lead to termi...

Page 570: ... BE 25 Wiper motor faulty Check motor BE 24 BE 25 Wiring or ground faulty Repair as neCMsary Washers do not operate Washtt hose or nozzle clogged Repair as nec e ry Washer motor faulty Replace motor Wiper switch faulty Olec k switch BE 22 BE 25 Wiring faulty Repair as necessary Front Wiper and Washer Switch INSPECTION OF FRONT WIPER AND WASHER SWITCH INSPECT FRONT WIPER AND WASHER SWITCH I ra I I ...

Page 571: ...n terminals 6 and 12 as follows Disconnect terMIR81l1 2 nd 3 Conntet termiNIS 1 2 nd 3 Ti MOOnctsJ Btt n terminals Time heeonds 8ttWHn tff mlnah 6 nd 12 6 12 Conntct tff mift fls Conne t terminal 10 iind 11 10 and11 0 3 I Continuity I 1 2 O l IContln hy I 1 2 0 2 0 2 l 4 3 t 1 I Continuity I 2 t 0 6 I Continuity I 0 1 0 4 1eon 1 0 7 i 0 4 IComlnuity I 0 5 0 6 Ieo I 1CoMinuity 1 4 3 r 1 2 l 0 6 1 1...

Page 572: ...the battery to terminal 1 Connect the negative lead to the motor body c Check that the motor operates at high speed 3 INSPECT THAT MOTOR OPERATES STOPPING AT RAISED POSITION a Connect the positive lead from the battery to terminal 2 Connect the negative lead to the motor body b Operates the motor at low speed c Stop the motor operation to disconnect the battery terminals except at the raised posit...

Page 573: ...CTION OF REAR WIPER RELAY INSPECT RELAY OPERATION 1 Connect the positive lead from the battery to terminal 1 Connect the negative lead to terminal4 a With connect the positive lead from the battery to terminal 2 check that there is no continuity between terminals 1 and 3 b With disconnect terminal 2 check that there is no continuity between terminals 1 and 3 for 9 15 seconds If operation is not as...

Page 574: ...ead from the battery to terminal 3 Connect the negative lead to the motor body Operates the motor b Stop motor o ration anywhere except stop positioo by disconnecting terminal 3 c Connect terminals 3 and 4 d Connect the positive lead from the battery to terminal 1 e Check that the motor stops running at stop position after the motor operates again If operation is not as s cified replace the motor ...

Page 575: ...faulty Chedt receiver gauge BE 30 Senck r gauge faulty Chocl oende gauge 8E 30 Wiring or ground faulty RtPIIt at necenary GAUGE fuse blown Replact fuse and check for short BE 4 Watet temperature rtetfver gauge faulty Check r ceiver gaug t 8E 31 Water temperature sendergauge f1u1tv Chock sender BE II Wiring Ot grCM tnd faulty Repair as ntcHArv GAUGE fuse blown Replace fuw and check fa _ BE 4 Oil pr...

Page 576: ... 6 7 8 1 2 3 1 2 Wiring Conntctor Sidts Ground Plr 1dng Brlke Switch Terminal 1and Flu Level W rning Switch Ttrmillll 1 Door Courte sv 1 rltctl DOME Fuse GAUGE Fuso Fuel Ltvtl W1rning Switch Terminal 1 IGN Fuso CHARGE Fuse TAIL Fuso Fuel Sender GIU91 Terminal 2 Grour d DOME Fuse CIG Fuse Light Control Rheostet Terminal 2 lgni1ionColi Turn Signal Switch Terminal 9 Turn Sicrtal SWitch Terminal 8 Dim...

Page 577: ... 100 100 105 120 120 125 5 140 140 146 160 160 187 Standerd Indication Allowable rant mpl mph 20 20 23 40 40 43 5 60 60 64 80 80 64 5 100 100 105 120 120 125 5 Tachometer ON VEHICLE INSPECTION OF TACHOMETER a Connect a tune up test tachometer and start the engine b Compare the tester and tachometer indications If the error is excessive replace the tachometer CAUTION Rovertir19 the connection of th...

Page 578: ...RESISTANCE BETWEEN TERMINALS Bttwttf l terminals Resistance Cnl IG U A pc rox 101 9 U E Approx 101 3 IG E Approx 203 2 If each resistance value is not as shown in the table above replace the receiver gauge 3 MEASURE RESISTANCE OF SENDER GAUGE a Check that the resistance changes as the float ismoved from the top to bottom position b Measure tha resistance between terminals 2 and 3 for each float po...

Page 579: ... 3 4W bulb as shown b Tum the ignition switch on Check that the bulblights up and that the receiver gauge needle rises to the upper position If indications are not as specified remove and test the receiver gauge MEASURE RESISTANCE OF RECEIVER GAUGE Using an ohmmeter measure the resistance between termi nals If each resistance value is not as shown in the table below replace the receiver gauge Betw...

Page 580: ...he number of lin should vary with engine speed If operation Is not as SPecified replace the sender gauge Brake Warning INSPECTION OF BRAKE WARNING INSPECT WARNING LIGHT OPERATION 1 2 3 a Disconnect the connector from the brake fluid lfwl warning switch Connect the switch terminal I 11 111 body ground b Turn the Ignition switch on Check that the bulb lights If operation is not correct remove and te...

Page 581: ...and Sender Gauges a 58 57 56 61 eo 59 5 7 t 11 11 2 6 8 10 12 TACHO I Combination Meter and Gauge Digital Type COMBINATION METER CIRCUIT 23 29 18 22 28 31 33 21 30 32 11 35 37 39 41 36 38 40 45 CRUISE PILOT 47 49 51 S3 55 46 605254 BE 33 ...

Page 582: ...3 Trip Computer Ttrminai6V 17 Dim Renric t tonStgnal 45 TripComl uttr Ttrminal DIM 12V 18 OoO l l 48 Trip Computer Terminal VF f12V 19 000 1 47 Trip Compuur Terminal CK 20 Oil Pressure Slndtr Gauge 48 Trip Computer Ttrmintl SET 21 Fasten Belts Relev 49 Trip Computer Terminal FUL 22 Ignition Switch 50 Trip Computer Terminal CLK 23 Battery Termintl 51 Trip ter Termintii Ml 24 Chaftg ing Rtguletor Te...

Page 583: ...ther then lhe speedometer will be slightly deleyed but this is normol 5 When the ignition switch it placed at ST all meters will go out but hit is normol 6 Do not toudl circuit components as here is danger of circuit damage due to sutic electricity Nevor battaty connections as it could result in instant dlmage to the interior of the components 7 Do not disconnect the battery while lhe engine is ru...

Page 584: ...er signal 4 puise signal Remaining fuel quantity signal Power source of fuel sender gauge Circuit ground Power souroe RPM signal Conversion signal Speed sensor signal 120 pUise Staning signal Wave form rectification signal of IG 0 TEMP signal Dim restriction signal Dim signal Power source of receiver jpuge v voo 0 TC TEM 2 IG G l ttrmlr el Con ector n r _m _ e 2 H 0 Combi hOft Mltwf Fvel w nint I ...

Page 585: ...place tachometer display at all Lights do not dim when light and rheostat SIW turned ON J No display at all K Fuel scale change display magnifier does not illuminate L Fuel warning light does not light M Fuel warning light always lit N Abnormal display No display segment or intermediate segment Replace fuel and illumination No figure or symbol indication temp gauges Defective display 0 Lights do n...

Page 586: ...ctor OK Check for short between terminal VOO and body ground of each meter Short Remove meter and connector sub harness SSTI With the ignition 5 W at ON position No No check that there is battery voltage between 1 l terminals 8 and 16 of sub harness SST OK Only speedometer display when other meters disconnected7 Yes Connect meters one by one and check when speedometer display goes out No Replace l...

Page 587: ...STEM Instruments and Sender Gaugn Gauge UA In LH cowl side Wiring Connector of Fuel Sender Gauge Fuel Sender Gauge CAUTION Newt short cirCXJit terminal FV Fuel and Ttmp GaU9h 2 4 voo l lli l S b harness CSSTl IF Ie 0 0 BE 39 ...

Page 588: ... check that there is 4 0 6 0V between tion check that there is 4 0 6 0V terminals 1 and 3 of connector for speed between terminals 1 and 3 of speed sensor total counter ometer with connector removed OK No OK IReplace speed sensor With the ignition S W at ON position does voltage between terminals 1 and 2 of SPeed sensor connector fluctuate between 0 5 0V when meter cable is turned Yes 4 0 s ov Rep...

Page 589: ...BODY ELECTRICAL SYSTEM Instruments and Sender Gauges BE 41 2 Speedomectr 3 Speedometer Spetdome1er ...

Page 590: ...With the light SIW and check that there is battery voltage between rheostat turned ON is there terminals 7 and 9 of sub harness SST battery voltage on TC termintl when rheostat turned ON of rheostat OK No Yes Does speedometer dim when other Bad wiring be meters are disconnected rheostat and mete Yes No I Replace speedometer I Check rheostat See page BE 18 I Connect other meters one by one Replace ...

Page 591: ...es volta911 between terminals 1 and 16 does voltage between terminals TR ofsub harness vary from 0 to 9V when and E of rheostat vary when rheostat is turned7 rheostat is operated Yes No Yes Is speedometer normal with other meters Bad wiring between disconnected7 rheostat and metor Yes No IReplace speedometer I LCheck rheostat See page BE 18 J Connect other meters one by one to Replace bad meter fi...

Page 592: ...t tehometer connector is more than 3V with rheostat at MAX OK No VWith the light SIW turMd ON Replace tachometer I Replace speedometer dOH voltage between tenninals 1 and 7 of sub harness vary from 0 No With the light SIW turned ON doet to 9V when rheostat is turned voltage between terminals TR and E of Yes rheostat vary when rheostat is OPerated No Yes Check rheostat Bad wiring between See page B...

Page 593: ...BODY ELECTRICAL SYSTEM Instruments and Sender Gauges BE 45 2 Sub htrness SST n I Olm oe 0 0 3 ...

Page 594: ... battery voltage on terminal 14 or con 1 t for CRUISE CONTROL nector wit h wiring meterconnector disconnected I Ye Connect sub harness SST With the ignition SIW at ON position does voltage between terminals 14 and 16 or sub harness SST change from 10 to OV when the magnet shaft is tumed about 10V about OV four times per revolution ll llffilll Wiring ConntctOt No Replace speedometer 2 Ill II lffB S...

Page 595: ...ROUBLE G Speedometer No speed unit conversion Remove meter and connect sub hamm SST j With the ignition S W at ON position is there speed unit conversion when rear terminals are short circuited7 No Yes J Replace speedometer Replace speed scale change S W 1 Speedometer I ...

Page 596: ...t suD harness SST D With the ignition S W at ON pOSition check that voltage between terminals of tachometer connector is as follows Terminals 1 6 Battery voltage Terminals 2 6 4 0 6 0V Terminals 4 6 0 1 5V OK Replace tachometer Tac hom ner TROUBLE No displlyM all Refer to section A ll i No Replace speedomeltf I i i j ...

Page 597: ...es No Bad wiring l et n voltage between terminals 16and 17 of sub igniter and meter harness fluctuate with variations in engine rpm Yes With the ignition S W at ON position does volt No i age between terminals 3 and 6 of tachometer con Replace speedometer I nectorfluctuate between 0 and 1 5V when engine speed increases from 2 000 to 3 000 rpm Yes Replace tachometer j 2 II II III I J Sul h ISSTI _ ...

Page 598: ...r I No Yes Remove meter and conne t sub harness ISSTI Q With the ignition S W at ON position light S W turned ON and rheostat turned to MAX is there 3 to 5V between terminals 4 and 6 of tachometer connector Yes Replace tachometer NOTE Conne tor dimming is performed by the dim signal Din of the speedometer Refer to section C No Replace speedometer i I I I ...

Page 599: ...peedometer and Tachometer OK Yes No IRemove meter and connect sub harneu SST I URefer to section A I With the ignition S W at ON position check the voltage No Replaoe between terminals of fuel and temp gauges conneetor speedometer is as follows D 6 5 4 0 6 0V 3 5 Ught S W turned OFF 0 2 0V OK Replace fuel and Light S W turned ON 4 0 6 0V temp gauges Y 4 5 Light S W turned ON Rheostat turned OFF 3 ...

Page 600: ...nnect sub harness ISST TROUBLE Fuel scale change display magnifier does not illumilllle j With the ignition SfW at ON position Yes does magnifier illuminate when rear i j R e p lac e F U E L S C A L E _ c H A N G E S IW terminals are short circuited I No Replace fuel and temp gauges Fueland Temp GauQe ...

Page 601: ... 1 jNo I Is terminal set nut loose No IReplace fuel and temp gauges I SECTION Yes Yes N Fuel gauge CD Is circuit plate short circuited No Replace fuel and temp gauges M i N Yes Fuel Light TROUBLE Warning light does not light Replace bulb I 1 Replace circuit plate I Retighten I TROUBLE Warning light always lit I Replace circuit plate I ...

Page 602: ...e BE 59 Yes No Remove meter and connect sub hameu SST Q With the ignition SfW at ON position and fuel and temp gauges removed is there voltage between terminals 5 and 8 of speedometer No Replace fuel and temp gauges GND TROUBLE Oefocti display Replace fuel sender gauge Yes Replace speedometer 1 I I I I _I Ill t ...

Page 603: ...im No No Only fuel and temp gauges do not dim7 Speedometer OK Yes No Remove meter and connect sub harness SST Refer to Section C Q With t he ignition SNI at ON position and connector No Replace speedometer of fuel and temp gauges disconnected check that there is voltage between terminals of the connector as follows 3 5 LightS WON 4 0 6 0V Light S W OFF 0 l OV 4 5 Light S W turned ON OK Replace fue...

Page 604: ...nd connector of water temp sender gauge Yes disconnected does top segment flash when connector is grounded No Check open circuit in wire harness between OK sensor and meter H I 9 I TROUBLE 2 Defective indication Check short circuit in wire harness OK No Bad wiring short circuiU between sensor and meter Is water temp sender gauge OK ISee page BE 55 Yes No I Replace water temp sensor Replace fuel an...

Page 605: ...d ON Light switch turned ON and rheostat turned OFF Light switch turned OFF Light switch turned ON and rheostat MIN Light switch turned ON and rheostat MAX n n n n n about 10v J U U U U L about OV 4 times revolution of magnet shaft Ignition switchON 4 0 6 0V 4 4 4 8V 3 27V 2 3 2 7V 0 3 o sv 11 13V 10 12V 1 7V Ignition switch ON F Ieveil 1 2 level 1 4 Ieveil E level Ignition switch ON Ignition swit...

Page 606: ...2 60 58 62 80 78 82 100 97 103 120 117 123 I I Starnd rd indic a1ion AUow104e r nge 20 19 21 40 J9 41 60 59 61 80 78 82 Tachometer ON VEHICLE INSPECTION OF TACHOMETER a Connect a tune up test tachometer and start lf e engine b Compare the tester and tachometer indications If the error is excessive replace the tachometer CAUTION R ing the connection of the tachometer will the transinorS and diodes ...

Page 607: ...signal voltage between terminal FR and body ground of the sender ga ge connector Voltage 4 4 4 8V at F level 3 27V at 1 2 level 2 3 2 7V at 1 4 Mltel 0 3 O SV at E level 4 INSI ECT SENDER GAUGE OPERATION Inspect the resistance between terminals FR ar d E Resistlnee 270 310n 212 mm 8 36 ln 188 226n 162 3 168 3 mm 8 390 8 826 in 140 180n 83 3 mm 3 280 in 17 33n 6 8 11 8 mm 0 228 0 466 in Water Tempe...

Page 608: ... of the sender gauge with tilt connector disconnected e Check that the top segmeter flashH with the Ignition switch at ON position 2 INSPECT SENDER GAUGE OPERATION Inspect the resistance between the terminals of the sender 9IUQe and body ground Rnis1ance 192 260 n 50 C 122 F 85 89 n 80 C 176 F ...

Page 609: ...nnect the negative I lead to terminal 6 b Connect an ohmmeter between terminals 2 end 6 c Check that there IS contonuoty between termonals for 10 20 minutes with the switch tumed on If operatloo Is not as specified replace the switch Rear Window Defogger Relay INSPECTION OF REAR WINDOW DEFOGGER RELAY 1 INSPECT RELAY CONTINUITY a Check that the there is continuity between terminals 1 and 3 b Check ...

Page 610: ...er of the wire and positive I end If there is no voltage the wire is broken betwe fl the center of the wirt and ground 2 INSPECT FOR WIRE BREAKAGE POINT a Place the voltmeter POsitive lead against tho defogger positive terminal b Place the voltmeter negative lead with the foil strip against the heat wire at the positive l terminll end and shift it toward the negative terminal end c The POint where...

Page 611: ...ptau hose Wtter valve f t lty Rtptiel vafwe Air d amper broken Repair damper Air ducts clogged RePtlr ducts Heater radiatOf leaking Of clogged Replac radiatOt Heater control unit faulty RtPiifcontrol unit Heater Blower Switch 1 INSPECTION OF HEATER BLOWER SWITCH 3 O le INSPECT SWITCH CONTINUITY Inspect heater blower switch continuity s p OFF I 11 Ill IV 10 For illumination light 4 9 5 8 8 If conti...

Page 612: ...R BLOWER RESISTOR INSPECT RESISTOR CONTINUITY Check that there is continuity between terminals 1 and 3 If there is no continuity replace the resistor Heater Control ADJUSTMENT OF HEATER CONTROL SET AIR INLET DAMPER Set the air inlet damper and control lever to FRESH SET MODE SELECTOR DAMPER Set the mode selector damperandcontrol lever to VENT SET BALANCE DAMPER Set the balance damper and control l...

Page 613: ...CK OFF UN OCK If continuity is not as specified replace the switch Power Window Master Switch INSPECTION OF POWER WINDOW MASTER SWITCH INSPECT SWITCH CONTINUITY itch left I Rlaht 2 3 7 6 2 1 UP OFF DOWN If continuity is not as specified replace the switch Power Window Door Switch INSPECTION OF POWER WINDOW DOOR SWITCH INSPECT SWITCH CONTINUITY 2 I 5 4 h n UP OFF DOWN If continuity IS not as specif...

Page 614: ...DOW MOTOR 1 INSPECT CIRCUIT BREAKER OPERATION a With the window in the full closed position hold the power window switch at UP and ciMck that there i a circult breaker operation noise within 4 to 40 seconds b With the window in the fully closed position hold the switch at DOWN and check that the window begins to descend within 60 seconds 2 INSPECT MOTOR OPERATION a Connect tho positive lead from t...

Page 615: ...there is no continuity between terminals when the switch is free If operation is not as specified replace the switch Door Lock Relay INSPECTION OF DOOR LOCK RELAY 1 INSPECT RELAY CONTINUITY a Check that there is continuity between terminals 2 3 and 4 b Check that there is no continuity between terminals 1 2 and 6 If continuity is not as specified replace the relay 2 INSPECT RELAY OPERATION a Conne...

Page 616: ...o continuity LH door lock knob pulled Continuity Continuity RH door lock knob pushed I No continuity RH door lock knob pulled Continuity Turn unlock waming switch and LH door Continuity courtesy switch off Tum unlock warning switch and o r door LH door courtesy switch off No continuity Turn RH key unloc k switch on and or door Continuity lock conttol switch to UNLOCK Turn RH key unlock switch o ff...

Page 617: ... SUN ROOF MOTOR INSPECT MOTOR OPERATION a Connect the positive lead from the battery to terminol 2 red wire and the negative lead to terminal I green wire and check that the motor turns clockwise b Connect the positive lead from the battery to terminal I green wire and the negative lead to terminal 2 red wire and check that the motor turns counterclockwise If operation is not as specified rOI Iace...

Page 618: ...Analog Meter C 6 C 7 Oioilal Mew A 10 A 1 2 S ter J Se1 Coat1 Nowal 1 1r1 SIW IA TI Battery I t AcceiiResume Control SIW For 00 Relay Parking Brake Switch Clutch Switch Stop Light Switch Cruise Control Computer Main Switch e m e 6 3 2 1 13 12 11 1 8 2 Speed Sensor Analog Meter rc o 4c C 6 0 i4o 0 ooo w o o _ J Control Switch Actuator Neutral Start Switch Speed Sensor Digital Meter r 0 0 1 lg s 2 0...

Page 619: ...e Vehicle speed does not fluctuate when set switch lnwection of actuator and c il cuit c turned on Inspection of speed sensor and circuit H Setting speed does not cancel when brake pedal Inspection of stop li t switch and circuit D deptttssed Setting speed does not cancel when parking brake lnspect n of parking brake WitCh and circuit e pulled Setting speed does not cancel when clutdl pedal Inspec...

Page 620: ...t connector from main switch No terminal 5 of main switch and body Is there continuity between terminal 5 of ground wire harness side connector and body ground Body ground faulty Yes INSPECT SWITCH OPERATION No Inspect main switch Is there battery voltage between terminal 3 and body ground with main switch tum on Yes cONTROL S W INSPECT GROUND CONNECTION Open circuit in wire harness between termin...

Page 621: ... of computer with No Open circuit in wire harness between brake pedal returned 7 terminal 1 of actuator and terminal 2 of computer Inspect stop light switch Inspect actuator Yes INSPECT STOP LIGHT SWITCH OPERATION No Inspect stop light switch Is there continuity between terminals 1 and 2 with brake pedal depressed 7 Yes cQMPUTER Disconnect computer and inspect connector on wire harness side as fol...

Page 622: ... switch turned 28 of control switch on Inspect control switch Yes Is there continuity between terminal 13 and Short circuit in wire harness between body ground with accet resume switch turned Yes terminal 13 of computer and terminal off 28 of control switch Inspect control switch No INSPECT CONTROL VALVE CIRCUIT Open or short circuit in wire harness Is resistance value about 30 n between between t...

Page 623: ...t parking brake switch Yes INSPECT SPEED SENSOR CIRCUIT Open circuit in wire harness between terminal Disconnect connector from combination meter No C 7 analog meter or A 12 digital meter of Is there continuity between terminal C 7 analog combination meter and terminal 6 of meter or A 12 digital meter of wire harness computer side connector and terminal 6 of computer Yes Disconnect connector from ...

Page 624: ...n terminal 28 and No body ground with acc l rasume switch turned on Yes Is there continuity between terminal 28 Yes Inspect control switch and body ground with accelfresume switch turned off cOMPUTER No INSPECT ACCELIRESUME SWITCH CIRCUIT Open circuit in wire harness between Is therecontinuity between terminal13and body No terminal 13 of computer and terminal 28 ground with accel resume switch tur...

Page 625: ... 39 in Yes INSPECT ACUTATOR OPERATION Replace actuator Disconnect connector from actuator No Inspect actuator operation See page BE 84 Is actuator operation normal Yes cOMPUTER INSPECT ACTUATOR CIRCUIT Open or short circuit in wire harness Isresistance value between computer terminals correct No between actuator and computer Between terminals 1 and 2 about 68 n Between terminals 2 and 3 about 30n ...

Page 626: ...s follows INSPECT RELEASE VALVE CIRCUIT Yes InSPect stop light switch Is there continuity between terminal 1 and 2 with brake pedal depressed No INSPECT STOP FUSE CIRCUIT No Open circuit in wire harness between Is there battery voltage between terminal 9 and terminal 9 of computer and STOP fuse body ground Yes INSPECT STOP LIGHT SWITCH CIRCUIT No Open or short circuit in wire harness Is there batt...

Page 627: ...ect parking brake switch Yes Replace computer IF I INSPECTION OF CLUTCH SWITCH CIRCUIT Turn ignition switch on I TCH fi X INSPECT GROUND CONNECTION No Open circuit in wire hemess between Is there continuity between terminal 3 end terminal 3 and body ground body ground Yes COMPUTER INSPECT CLUTCH SWITCH CIRCUIT Open circuit in wire hamess between Disconnect connector from computer No terminal 11 of...

Page 628: ...MPUTER INSPECT NEUTRAL START SWITCH CIRCUIT Disconnect connector from computer Is there continuity between tenninal 11 of wire harness side connector and body ground when shifted to N range 7 Yes Replace computer No Open circuit in wire harness betWMn terminal 2 and body ground No Open circuit in wire harness between terminal 11 of computer and terminal 3 of neutral start switch Inspect neutral st...

Page 629: ... or A l0 digital meter of wire harness side connector and body ground 1 No COMPUTE R INSPECT SPEED SENSOR CIRCUIT Open circuit in wire harness between Disconnect connector from combination No terminal C 7 analog meter or A 12 meter digital meter of combination meter Is there continuity between terminal C7 and terminal 6 of computer analog meter or A 1 2 digital meter of wire harness side connector...

Page 630: ...ay 6 Speed Sen sor Main Switch Voltage 7 Body Ground Turn ignition switch and main Battery voltage switch on 7 Turn ignition switch and main switch off No voltage 8 Stop Light Switch Voltage 8 Body Ground Brake pedal depressed Battery volt Brake ped11 returned No voltage 9 STOP Fuse Voltage 9 Body Ground Battery volttge 10 8ody Ground Continuity 10 Body Ground Continuity Clutch Switch Continuity 1...

Page 631: ... Clutch Switch INSPECTION OF CLUTCH SWITCH INSPECT SWITCH CONTINUITY 5 a Check that there is continuity between terminals 2 and 3 with the clutch pedal depressed b Check that there Is no continuity between terminals 2 and 3 with the clutch pedal retumed If continuity is not as specified replace the switch Neutral Start Switch See poge AT 104 Parking Brake Switch See step 3 on page BE 30 Speed Sens...

Page 632: ...easure the resistance value between terminals as follows Resistance 1 2 about 30 n 1 3 about68n If the resistance value is not as specified replace the actu ator 3 INSPECT ACTUATOR OPERATION Connect the positive lead from the banery to tenminals 2 and 3 Connect the negative lead to tenminal l a Slowly apply vacuum from 0 300 mmHg 0 11 81 in Hg 0 40 0 kPa and check that the control cable can be pul...

Page 633: ...hen reverse the polarity and check that the mirror revolution is reversed b Apply 12V to terminals 3 and 4 and check that the mirror operates Then reverse the polarity and check that the mirror revolution Is reversed If the e is no mirror operation replace the left mirror I JL L ltl213141sl IU 1 1 2 INSPECT RIGHT MIRROR OPERATION a Apply 12V to terminals 2 and 3 and check that the mirror operates ...

Page 634: ... Heater INSPECTION OF MIRROR HEATER MEASURE MIRROR HEATER RESISTANCE Measure the resistance between terminals 1 and 5 RMillllnce 5 30 n II resistance value is not correct replace the mirror NOTE The resistance value is increased according to the rise of temperature ...

Page 635: ...nt System BE 87 DOME Fust S W HAZ Fu 1 Fuse F iDiode l f Door Lock S W THEFT DETERRENT SYSTEM WIRING DIAGRAM Back Doe Coortosy S W 8tck DOC Kt y Unloelc S W I _ u 1 L 0 o r u r RH Kty Unloclc S W K2l i oo 01 1 i Door Lock RH Door Solenoid lH Door Solenoid ...

Page 636: ... Key Unlock Switch Theft Deterrent Computer 115 4 I J 3 12 11 10 9 8 2 7 Connectors Door Lock Solenoid Headlight Control Relay Taillight Control Relay Diode For RH Key Unlock Switch and Horn 1 6 Door Lock Switch Back Door Courtesy Switch Diode tFor LH Key Unlock Switch and Tailli 1 t Control ReJ ay 2 ...

Page 637: ...tem can not be set A Theft detlfftf ll system does not operate whtn LH door opened B Thtft dtterr tnt system does not opente whtn RH door opened c Theft dlttntnt svttcm does not eanet1 whtn ignition switd turned on or ACC position 0 Theft dlttrrtnt system does not canct1 whtn LH doOI unlocked with key E Theft dtttrrent system does not unotl wl tn AH door unlodced with key F Horn does not blow even...

Page 638: ...fuse and terminal 4 of computer Yes Yes jFuse faulty j BACK DOOR S W INSPECT GROUND CONNECTION No IBody ground faulty I Is there continuity between back door switch body and body ground Yes INSPECT BACK DOOR SWITCH OPERATION No Is there continuity between terminal 1 and Inspect back door switch body ground with back door switch turned on Yes BACK DOOR KEY Cfl INSPECT GROUND CONNECTION No Open circ...

Page 639: ...omputer body ground Yes INSPECT GROUND CONNECTION No Open circuit in wire hamess between Is there continuity between terminal 10 and terminal 10 of computer and body body ground ground Body ground faulty Yes INSPECT LH KEY UNLOCK SWITCH Yes Short circuit in wire hamess between CIRCUIT terminal 9 of comJ Uter and terminal 2 Is there continuity between terminal 9 and of LH key unlock switch body gro...

Page 640: ...d harness side connector and body ground with RH door unlocked Yes INSPECT LH DOOR LOCK SWITCH CIRCUIT Short circuit in wire harness between Close LH Door Yes terminal 6 of computer and terminal2 of Is there continuity between terminal 6 and LH door lock switch body ground with LH door closed No INSPECT RH DOOR LOCK SWITCH CIRCUIT Short circuit in wire harness between Close RH door Yes terminal 6 ...

Page 641: ...tinuity between terminal 6 of 1 of LH door lock switch connector side and body ground with LH door closed 7 No IRepIeee computer I Ic IINSPECTION OF RH DOOR UNLOCK CIRCUIT RH DOOR LOCK S W INSPECT DOOR LOCK SWITCH OPERATION Is RH door lock switch normal 7 No Replace RH door switch See page BE 99 Yes COMPUTER INSPECT DOOR LOCK SWITCH CIRCUIT Short circuit in wire harness between Disconnect connecto...

Page 642: ... Short circuit in wire harness Is operation normal between fuse and terminm 4 of computer Yes Yes Fuse faulty COMPUTER INSPECT IGNITION SWITCH CIRCUIT Open circuit in wire harness between fuse Disconnect connector from computer end terminal 4 of com puter Is there banery voltage between terminal 4 of No wire harness side connector and body ground7 Yes IReplace computer 1 ...

Page 643: ... of computer and terminal body ground with LH door opened with key 1 of LH key unlock switch side diode Yes IReplace computer I F INSPECTION OF RH KEY UNLOCK SWITCH CIRCUIT ITurn ignition switch off I DIODE INSPECT DIODE CONTINUITY No Replace diode Isdiode of key unlock switch normal See page BE 671 Yes OMPUTER lNSP ECT KEY UN OCK SWITCH CIRCUIT No Open circuit in wire harness between Is there con...

Page 644: ...it in wire harness between 0 isconnect connector from hom No terminal 1 of horn and fuse Is there battery voltage between terminal 1 of connector side and body ground I Yes COMPUT ER INSPECT HORN OPERATION No Replaca horn Is horn normal I See page BE 100 Yes INSPECT HORN CI RCUIT Open circuit in wire harness between Disconnect connectors from horn and No terminal 12 of computer and terminal comput...

Page 645: ...DLIGHT CONTROL RELAY Open or short circuit in wire harness CIRCUIT between terminal 12 of computer and Disconnect taillight control relay and No terminal 1 of headlight control relay theft deterrent horn Is there battery voltage between terminal 12 and body ground Yes INSPECT TAILLIGHT CONTROL RELAY Open or short circuit in wire harness CIRCUIT between terminal 12 of computer and Disconnect headli...

Page 646: ...ctor on the wire harness side as shown in the chart below Condlt10 1 Voltage or Continuity FL door lock knob unlocked Continuity FL door lock knob locked No continuity FR door lock knob unlocked Continuity FR door look knob locked No continuity Turn nition swllch to ON cw ACC Battery voltage Tum ignition switch off No voltage 81tterv voltege fL or FA door opened Conti nuirv fl and FR door clo ed N...

Page 647: ...and body ground when the switch pin is pushed If operation is not as specified replace the switch J I 2 Back Door Key Unlock Switch INSPECTION OF BACK DOOR KEY UNLOCK SWITCH INSPECT SWITCH CONTINUITY a Check that there is continuity between terminals 1 and 3 with the switch Is unlock position b Check that there is no continuity between terminals 1 and 3 with the switch Is except unlock position If...

Page 648: ...he ohmmeter to terminals 2 and 3 and check for continuity Next reverse the the test leads and check again for continuity If both of the test results are same condition replace th diode 1 Headlight Control Relay See page BE 14 Taillight Control Relay See page BE 14 Key Unlock Switch See page BE 67 Theft Deterrent Horn INSPECTION OF THEFT DETERRENT HORN INSPECT HORN OPERATION Connect the positive le...

Page 649: ...spection c Check or replace part Test by OPerating radio 1 DEAD RADIO AND TAPE PLAYER a No power to radio or tape player or power but no sound Possible causes Blown RADIO fusa Short circuit or broken wire in power source wire harness Loose connectors behind radio and tape player Loose speaker connector Defective speaker Broken wire in speaker wire harness lmpr l erly installed radio or tape player...

Page 650: ...yer connectors properly conntettd No No No Connect proper ly lnsl tet and repair power wire Properly re install Mrntss to radio and player TEST 3 Are speaker connectors connected Yes Temporarily install anothec OK Replace Speaker speaker No No Connect properly Is there continuity in speaker Ye Reptaoe radio and wite harneu tape pfayer No w o Player Inspect and repair speaker wire L Proceed to Test...

Page 651: ...Possible causes Antenna disconnected Antenna plug not properly connected Defective antenna Defective antenna booster o Defective antenna cable Defective radio or tape player Blown HAZ HORN fuse Short circuit or broken wire in wire harness for back up power source h either AM or FM okay Yes Proceed to Ten 2 No Is there back up power to connectors Yes Proceed to Test 3 behind radio No No lns t and r...

Page 652: ... f No I Does antenna have boos ter Ye _I Proceed to Teu 4 I No I OK I I Proceed to Test 5 I TEST4 Check that there is booster power OK Reinsertconnectors Yes _ Inspect to connectors behind radio Okay oonnectors No 1 there PQWer to Yes Proceed to Test 6 radio connector7 No Inspect and repair Wire ha1ne TESTS TempOfarily install another OK Inspect antenna antenna cable and antenna Okavl booster and ...

Page 653: ...tive speaker Defective radio and tape player TEST I Yes Pun out connector and OK lnwect connector Is the speaker connected reinsert No No Connect I Proceed to Test 2 I cb No I OK I TEST 2 Tempourily inttall another Yes I Replace speaker speaker Okay No Check for continuity in weaker OK Replace radio and upoe player wire harness No Inspect 1nd rep air wire speaker wire harness ...

Page 654: ...Incorrectly adjusted antenna trimmer Defective antenna cable or booster Defective speaker Defective radio Temporarily install another speaker Okay Yes__ Replac e speaker No Replace radio OK I Inspectantenna cable and booster and repair as neceS 81 y Ex Electronic search type NOTE Adjustment of antenna trimmer 1 Fully lengthen the antenna 2 With the volume and tone at maximum turn thedial to around...

Page 655: ...th station Defective antenna cable or booster Speaker imprCIPOfiY installed Vibration sound from components near aker Defective eaker Defective radio Yoo FM mul ll llth interltrenc t and txctss ively stront AM ceptton ne broadcasting st11tion cannotbt avoided In mou ceies Ytl Ttmpot ily it ll tll11nother Yes r IMf te t antetl Clblt and _na 01c avl bOOiter and repeir as ntcHarV No I Proceed to Tett...

Page 656: ...ssible causes Bad tape Dirty head Incorrectly installed speaker Vibration noise from around speaker Defective speaker Defective tape player Yes f Tape bad Yes J OK I Does vibration sound No TemPOrarily install Yos Repla ce come from around another s peaker speaker Okay speaker Yos No Repair Replace tape player I NOTE Head cleaning procedure 1 Raise the cassette door with four finger Next usinga pe...

Page 657: ...2 a Conneet the voltmeter positive lead to terminal 1 and the negative lead to terminal 4 b Connect the positive lead from the battery to terminals 7 and 8 Conne t the negative lead to terminal 3 C Check that there is battery voltage INSPECT RELAY OPERATION ANTENNA DOWN a Connect the voltmeter positive lead to terminal 4 and the negative lead to terminal 1 b Conneet the positive lead from the batt...

Page 658: ...enna Motor INSPECTION OF ANTENNA MOTOR INSPECT LIMIT SWITCH OPERATION a If the motor stops with the antenna up check mat there is no continuity between terminals 6 and 10 b If the motor stops with the antenna down check that there is no continuity between terminals 6 and 9 l ...

Page 659: ...OCK Troubleshooting CLOCK WILL NOT OPERATE Locate trouble tnd rfS Iir or Blown fuse replace fust M ntons arv Adjusti ng knob Repair if nec esury or repiXJt clock not returne d Below llV Ftecha rge or replaoe battery I Loose or rusttd Repair I Nowoltatt locate eiUH end piir I Loose or rutted Repair I CLOCK LOSES OR GAINS TIME Io ecJc amount of time 1ttedock IONS or ainsPtf day or Wft k ag ainst me ...

Page 660: ...stment of the Quartz clock reQUires a precise digilal coonter Adjustment must be mode in a shop specified by the manufacturer 3 STARTING OF CLOCK a Connect the battery terminal b Check the clock to see thet it is running and then ott it to the correct time NOTE Whenever the battery terminal is disconnected make sure to set the clock to the correct time after recon necting it ...

Page 661: ...l power batteoy otc applied directly to the component 6 In the flow chart th e is 1 high problbility that the replacement pert will solve the problem although it i not 100 guaranteed 7 Do not touch circuit components os there is danger of circuit domoge due to stotic electricity N revene botteoy connection u it could result in instant damoge to the inteoior of the components 8 Do not disconnect th...

Page 662: ...TEM Trip Computer WIRING DIAGRAM DISPLAY CLUSTER 14 terminil ConneetOf KEYBOARD 7 terminal ConntctOt COMPUTER VH N o ee I r T I fuse U 815A 8 Fu w CIG 15A ACC Fuse TAIL 15A DIM Combination Meter 4P I 8 v No n r EfI Computer E GND ...

Page 663: ...e of Kev board See page BE 114 Yes Perform input date to trip computer again Yes OK Does trip computer operate correctly for all Items No Perform each troubleshooting item Symptom Possible Cause Trouble Function keys do not operate DISPLAY CLUSTER or A Keyboard MPG displey is always zero DISPLAY CLUSTER or Trip reading dOH increase or ARRIV E mode Keyboard 8 indicate alway MPG display Is always 70...

Page 664: ... battery voltage between terminals B and GND of the wiring connector If there is no voltage repair or replace the ECV fuse con nector and wire harness b Inspect tho battery voltage between terminals DIM and GNO of the wiring connector with the light switch tumed ON NOTE The voltage is nearly equal to battery voltage c Inspect the battery voltage between terminals ACC and GN0 of the wiring connecto...

Page 665: ... between terminal and body ground of wiring coonector with the ignition switch at ON position 3 INSPECT SPEED SENSOR LINE TO CONNECTOR With the ignition switch at ON position check that there is continuity between terminals f and GND of wiring connec tor four times per each revolution of the magnet shaft ...

Page 666: ...s there continuity between the following terminalsof 8 terminal connector w hen the key is pushed Key Terminal Key Terminal DATA DATA GND MGP MGP GND FUEL FUEL GND ARRIVE ARR GND CLOCK CLK GND SET SET GND OK No Replace DISPLAY CLUSTER I Replace Keyboard I or COMPUTER 1 2 S tetminal Connector of KEYBOARD G ulrl NC E I I n u D ...

Page 667: ...onnect 14 terminal connector D With the ignition switch at ON position does voltage between terminals f and GND of the 14 terminal connector fluctuate between 0 to SV when vehicle is mOiled about 1 meter engine not running No Yes Is there continuity speed sensor and Replace DISPLAY CLUSTER wire harness Yes No Replace Keyboard I I Repair and replace speed sensor and wire harness I 14 terminal Conn ...

Page 668: ...or trip reading not change No D Does voltage change from 0 to 5V between terminals r and GND of 14 terminal connector in accordance with fuel consumption No Replace Keyboard l NOTE If tester indication can be verified this check is okay Analog Type Needle fluctuation Digital Type Number change 1 14 tem linal Connector of D ISPLAY CLUSTER _ u u I a I T Yes I Replace DISPLAY CLUSTER ...

Page 669: ...e ignition switch at ACC position and light switch tumed ON is there OV between terminals DIM and GND of the 14 terminal connector No Yes Replace Keyboard I I Replace DISPLAY CLUSTER I l4 terminal Connector of COMPUTER i i J I n u TEST TROUBLE E Inaccurate clock Replace DISPLAY CLUSTER NOTE Allowable error t5 MCOnds dav ...

Page 670: ...FRONT DOOR B0 3 BACK DOOR 80 11 MOULDING B0 12 WINDSHIELD B0 20 QUARTER WINDOW GLASS B0 26 BACK DOOR GLASS B0 31 SUN ROOF B0 35 SAFETY PAD B0 41 FRONT SEAT B0 45 REAR SEAT B0 46 SEAT BELT B0 47 BODY DIMENSIONS B0 49 B0 1 ...

Page 671: ...0 mm 0 079 0 118 in hole in the bottom of the removed damper cylinder to completely role the high pm sure gas e When drilling chips may fly out so work carefully d The gas is eolori8SS odorless and not poisonous e When working handle the damper carefully N score or scratch the exposed part of the piston rod and never allow paint or oil to get on it f Do not turn the piston rod and cylinder with th...

Page 672: ...Front Lower Frame Service Rear View Mirror Upper Front Garnish BODY Front Door FRONT DOOR COMPONENTS Trim SlJpport A Strik4tr c E f _ Giass Guide l i 1 ID tl lnslde Hondle Bezel Cover Courttly light ...

Page 673: ...emove the upper front garnish 2 REMOVE SERVICE HOLE COVER 3 REMOVE REAR VIEW MIRROR a Remove the cover b Disconnect the wiring connector tc Remove the three set screws and mirror 4 REMOVE BELT MOULDING a Remove the top of the weatherstrip near the glau on both sides of the door b Remove the two setscrews and pry loose tho retainen with a scraper to remove the belt moulding 6 REMOVE DOOR GLASS a Re...

Page 674: ...tor moonting bolts c Remove the regulator with the power window motor through the service hole DISCONNECT FOLLOWING LINKAGES a Door opening control link b Door lock control link c Door lock cylinder link d Outside control link REMOVE INSIDE HANDLE REMOVE OUTSIDE HANDLE REMOVE DOOR LOCK AND SOLENOID REPLACEMENT OF GLASS 1 REMOVE FOLLOWING PARTS a Plate b Stopper c Bolt d Stabilizer e Bracket 2 INST...

Page 675: ...5 CONNECT FOLLOWING LINKAGES a Outsidecontrol link b Door lock control link c Door lock cylinder link d Door open control link 6 ADJUST DOOR INSIDE HANDLE a Loosen the screws b Push the door handle forward until strong resistance is felt Move handle back 0 5 1 0 mm 0 020 0 039 in and tighten the mounting bolts 7 ADJUST DOOR INSIDE LOCK a Loosen the adjusting bolt b Push the door lock adjusting bol...

Page 676: ...by loosening the striker mounting screws 10 INSTALL REGULATOR MOTOR NOTE Place the wire connector through the outside of the door panel a Install the regulator motor through the service hole b Tighten the mounting bolts 11 INSTALL DOOR GLASS a Install the front lower frame b Install the glassguide into the door panel c Install the glass into the door panel d Install the glass to the lift arm brack...

Page 677: ...et screws c Install the weatherstrip on top near the glass on both sides of the door 14 INSTALL REAR VIEW MIRROR a Install the rear view mirror b Connect the wiring connector c Install the cover 15 ADJUST FRONT DOOR GLASS NOTE Before adjusting the glass check that the fitting of the door to the body is proper 1 l c b _ __ Trim Support Equalizer Arm Upper Stopper Adjusting Bolt d a I I I I I ...

Page 678: ...closed adjust the glass plate so the inner stabilizer lightly makes oantact with it After these adjustments are completed adjust the front lower frame with the lowe bolt so that there is a proper fit between the front pillar and glass 16 INSTALL SERVICE HOLE COVER a Connect the wire harness connector b Seal the service hole cover with adhesive c lnSl ft the lower edge of the service hole cover int...

Page 679: ...SST loosen the body side hinge bolts SST 09812 00010 2 ADJUST DOOR IN LEFT RIGHT AND VERTICAL DIRECTIONS Using a wrench loosen the door side hinge bolts 3 ADJUST DOOR LOCK STRIKER a Check that the door lit and door lock linkages are adjusted correctly b Adjust the striker by loosening the striker mounting screws ...

Page 680: ... drill a 2 0 3 0 mm 0 079 0 118 in hole in tho bottom of the removed damper cylinder to completely release the high pres sure gas c When drilling chips may fly out so work carefully d The gas is oolorloss odorless and not poisonous e When working handle the damper carefully Never score or scratch the exposed part of the piston rod and never alk w paint or oil to get on it f Do not tum the piston r...

Page 681: ...MPONENTS r Upper Moulding r Joint Cover J 1 Side Mooldi Wi rkm REMOVAL OF OUTSIDE MOULDING There are two types of clips for mou ding installation Locations of these clips and fasteners are as shown in the figure Carefully apply adhesive tape to protect the body ...

Page 682: ...r the side moulding b Push the side moulding down c Remove the joint cover from upper moulding REMOVE SIDE MOULDING a Insert the tip of the screwdriver between the mould ing and clip and twist it to pry loose the clips A on the window side b Pry loose the fastene and cliPS and remove the moulding 6 REMOVE UPPER MOULDING a Pry loose the fasteners and clips ...

Page 683: ...notch into the clip so it latches onto the gloss edge b Temponrily install the c lip and confirm that the clip tip is not sunk below the surface c If the tip of the clip is sunk below the surfoce replace it 3 REMOVE ANY DAMAGED FASTENER 4 CUT OLD ADHESIVE OFF AROUND FASTENER INSTALLATION AREA 5 INSTALL FASTENER INSTALLATION OF OUTSIDE MOULDING See 80 12 1 INSTALL LOWER MOULDING 2 INSTALL NEW CLIP ...

Page 684: ...dge A t the same time install the fasteners by tapping them by hand d If the moulding is not at the same level as the body insert a scraper between them and tapon the moulding while pushing on the fastener INSTALL SIDE MOULDING IN SAME MANNER AS FOR UPPER MOULDING INSTALL JOINT COVER a Slide the side moulding do1Ml b Install the joint cover to the upper moulding c Connect the side moulding into th...

Page 685: ...DING PULL OFF ROOF DRIP MOULDING a Using SST pull off the joint cover b Using SST pull off the roof drip moulding from both ends SST 09806 30010 NOTE Remove the moulding corners last INSTALLATION OF ROOF DRIP MOULDING INSTALL DRIP MOULDING BY HAND a Attach the upper edge of the moulding to tho body flange Fit the moulding by tapping it by hand b Install the joint cover ...

Page 686: ... QUARTER BELT MOULDING 1 INSTALL CLIPS ONTO STUDS Install the clips onto the studs 2 INSTALL BELT MOULDING a Attach the upper edge of the moulding to the clips b Fit the lower edge of the moulding by pushing with your hands c Connect the bolt moulding to the corner joint by slid ing it rearward REMOVAL OF QUARTER CORNER MOULDING 1 REMOVE QUARTER TRIM AND GARNISH 2 REMOVE CORNER MOULDING a Remove t...

Page 687: ...olt c Inner garnish REMOVE OUTSIDE GARNISH Remove the two set nuts and remove the garnish INSTAUATION OF CENTER PILLAR GARNISH 1 INSTALL OUTSIDE GARNISH 2 INSTALL FOLLOWING PARTS a Inner garnish b Seat belt shoulder anchor bolt c Seat belt guide REMOVAL OF DOOR BELT MOULDING 1 REMOVE FOLLOWING PARTS a Door trim panel See page 80 4 b Door weatherstrips on both ends 2 REMOVE DOOR BELT MOULDING a Rem...

Page 688: ...OF OUTSIDE MOULDING 1 BEFORE INSTALLING MOULDING REPLACE CAPS Remove the remaining eaps on the elip installation holt of the body and install _e ps 2 INSTALL MOULD NG a Install the elips to the moulding b Install the moulding onto tho panel by hand 3 INSTALL MOULDING MOUNTING NUT REMOVAL OF ROCKER PANEL MOULDING REMOVE MOULDING a Romcwe the three oerews b Pry loose the elips with t oeraper and rem...

Page 689: ...Solvent Alcohol lead free gasoline for cleaning adhering surfaces Part name Windshield glass adhesive set No 15 Windshield glau adhesive set No 35 Windshi eld glau e llesive set No 45 1 CHOOSE AN ADHESIVE SET Use a proper adhesive set depending upon the ambient temperature m 2 CHECK ADHESIVE USABLE TIME After mixing the main and hardening agents finish glass installation within the specified time ...

Page 690: ... Wiper Arm View Mhror REMOVAL Of WINDSHIELD 1 REMOVE FRONT PILLAR GARNISH a Pry out the clips with 1 ocrewdriver b Pull the garnish upward to remove it 2 REMOVE FOLLOWING PARTS a Inner rear view mirror b Roof headliner front t rim 3 REMOVE WIPER ARM 80 21 4 REMOVE WINDSHIELD MOULDING See pogo 80 12 ...

Page 691: ... interior and exterior ornaments To pr8Y8nt scretching the safety pad when removing the windshield place a plastic sheet between the piano wire and safaty pad c Cut the adhesive by pulling the piano wire around it d Remove the glass CAUTION Cut off the glass teeving as much of me urethane eyer on the body as possible INSPECTION AND CLEANING 1 CLEAN CONTACT SURFACE OF BODY a Remove any dam remainin...

Page 692: ...Place the lass in correct position onto rubbersp en c Check that all contacting parts of the glass rim ere perfectly even and do not make contact with the retaining clips d Make reference marks between the glass and body e Remove the glass CLEAN CONTACT SURFACE OF GLASS Using alcohol or similar solvent clean contact surface 15 30 mm 0 59 1 1B in wide around the entire lass rim INSTALLATION OF WIND...

Page 693: ...t installation of the gi8 S is finished within usable time See step 2 on page B0 22 Mixture should be made in 5 minutes or less al Thoroughly clean a glass plate or such and putty spatula with solvent b Thoroughly mix the main agent 500g 17 64 oz and hardening 75g 2 65 oz on the glass plate or such with a putty spatula 5 APPLY ADHESIVE a Cut off the tip of the cartridge nozzle to make a hole 5 mm ...

Page 694: ...ive at the installation area of the clips NOTE Loosely install the clip and confinm that the clip arm is not protruding above the surface c Install the clips into the moulding When installing the moulding be sure thot the clips and fasteners on the body side do not make contact d Install the outside moulding Install lower moulding Fit on the upper moulding and tap by hand to fasten the fasteners I...

Page 695: ...I ER WINDOW GLASS COMPONENTS Roof Moulding Joint Cover Belt Moulding Cushion 9 Center Pilltr Outside J Gatnis h Anchor Belt Guide Quarter Trim Moulding Setting Nut L GII1 S Retainer R or Speaker Grille Sicle Garnish Trim Lower Btc k Panel ...

Page 696: ...NISH Pry loose two clips with a screwdriver and remove the garnish 4 REMOVE LOWER BACK PANEL COVER 5 REMOVE REAR SPEAKER GRILLE o Remove the screws b Pry loose two clips with a screwdriver and remove the grille 6 REMOVE DECK SIDE TRIM AND SIDE GARNISH a Remove the deck side trim b Pry loose three clips with a screwdriver and remove the side garnish 7 REMOVE REAR SPEAKER AND BRACKET 8 REMOVE QUARTE...

Page 697: ...rom the interior d Tie both win ends to a wooden block e Separate the glass by pulling the piano wire around it Remove the glass INSTALLATION OF QUARTER WINDOW GLASS 1 PREPARE ITEMS LISTED Content of Set ButYl taPe 9 mm dia x 150 mm 0 35 x 5 91 inJ Primer 6 cc 0 17 fl oz Spon9t for applying primer Piaoo wire 1 mm dia x 600 mm 0 04 x 23 62 in fOt slicing off glass Dam Oouble stick ta for sticking o...

Page 698: ...a Using a sponge coat the glau adhering surfac with primer b Let the P ime coaling dry for 10 minutes 6 INSTALL GLASS e Attach the cushions ound the glass NOTE Install the cushions facing asshown b Coat the spacer with liquid sealer c Apply butyl tape on the glass d Tape Ver 20 mm 0 79 in of the rear area e Align the hole of rear area with the glass and body when installing the glass onto the body...

Page 699: ...w belt mouldi d Roof drip mouldi e Joint cover 7 INSTALL QUARTER TRIM 8 INSTALL REAR SPEAKER AND BRACKET 9 INSTALL SIDE GARNISH AND DECK SIDE TRIM 10 INSTALL REAR SPEAKER GRILLE 11 INSTALL LOWER BACK PANEL COVER 12 INSTALL CENTER PILLAR INNER GARNISH 13 INSTALL BELT GUIDE 14 INSTALL SEAT BELT SHOULDER BELT ANCHOR ...

Page 700: ...rip REMOVAL OF BACK DOOR GLASS 1 REMOVE REAR SPOILER a Remove the back door trim b Remove the eight nuu c Disconn t the high mount stop light wire conn tor d Lift up the rear end of the spoiler slide it toward the front and remove it e Remove the four clips from the SI Oiler ...

Page 701: ... weatherstrip Working from the vehicle outside with a screwdriV1 r loosen the weatherstrip lip from the body b If not reusing the weatherstrip From the outside cut oH the weatherstrip lip with a knife c Force the weatherstrip lip from the interior to the body flange outside Pull the glass outwards and remove it with the weatherstrip ...

Page 702: ...possible b Apply a working cord along the weatherstrip groove as shown 1 INSTALL GLASS tal Apply soapy water to the oontact face of the weatherstrip lip ond to the body flange NOTE Begin instillation in the middle of the lowe part ofthegl b Hold the glass in position on the body c Install the glass by pulling the working cord from the interior while pushing the outside of the weatherstrip with you...

Page 703: ... weatherstrip and body Pan No 08833 00030 or equivalent NOTE When adhesive is dry remove the masking tape 6 INSTALL FOLLOWING PARTS a Window defogger wire connector b Rear wiper arm 6 INSTALL REAR SPOILER a Install tho four clips to the spoiler b Install the spoiler to the back door c Connect the high mount stop light wire connector d Tighten the eight nuts e Install the back door trim ...

Page 704: ...BODY Sun Roof SUN ROOF COMPONENTS Cablt Guide Cu ln o Cable Guide Rail Front Shoe Shoo CHp r o _ Headlining Wind O fltetOJ t Guide Rail Cover siaL Guido Roll 80 36 ...

Page 705: ...ate 1 Remove the cover of the control box 2 Remove the screw inside 3 Manually operate the sun roof by inserting a large screwdriver into the hole and turning the drive shaft ADJUSTMENT OF SLIDING ROOF a Before making adjustments pull loose the clips and slide the headlining to the rear NOTE When checking adjustment reattach the head lining before sliding the roof b Vertical direction of sliding r...

Page 706: ...ng the roof forward and rearward It will adjust automatically e In event the sliding roof is tilted Difference in the left and right front clearance If the difference is about 2 mm 0 08 in Remove the drive motor and shift the cable one notch on the side with larger clearance Reinstall the motor If the difference is about 1 mm to 04 in Loosen the rear shoe bolts and re djust the sliding roof to the...

Page 707: ...otect the body b Pull the sliding roof with the guide rail upward and forward to remove DISASSEMBLY OF SUN ROOF 1 REMOVE SLIDING ROOF HEADLINING a Pry off the clip b Pull the sliding roof headlining rearward to remove 2 REMOVE GUIDE RAIL AND CABLE GUIDE CASING a Loosen the screw b Pull the guide rail rearward to remove c Pull the cableguide casing forward to remove 3 NOTE NUMBER OF SHIMS ON FRONT ...

Page 708: ... using with the screws c Use butyl tape to tOller the cut portion of the weatherstrip at the connection between the guide use and guide rail 5 ASSEMBLE SLIDING ROOF HEADLINING a Run the headlining through the guide rail b Do not clip the headlining NOTE Secure the headlining for adjustment after assembly INSTALLATION OF SUN ROOF 1 INSTALL SLIDING ROOF WITH GUIDE RAIL ONTO ROOF a Install the slidin...

Page 709: ... sliding roof and body are equal b Install the drive motor into the roof c Install the center cover of control box ADJUST SLIDING ROOF OPERATION REMOVAL OF SLIDING ROOF PANEL TO REMOVE ONLY SLIDING ROOF PANEL a Pull loose the clips and slide the headlining rearword b Remove the front and rearshoe bolts c Remove the roof panel ...

Page 710: ...Y Safety Pad SAFETY PAD COMPONENTS Duct Defroster Nont Gernish Duct Atgister Register s rlety Pod Combin1tion Meter InstrumentCluster__ Finish P nel Under Cover Con tolt Auembly 1 c t SOle Trim 8olrd 80 41 ...

Page 711: ...s disconnect the connecton and remove tho conooleassembly 6 REMOVE HOOD RELEASE LEVER BRACKET 6 REMOVE DRIVER SIDE SPEAKER PANEL Pry loose the panel with 1 screwdriver and remove it 7 REMOVE DRIVER SIDE UNDER COVER RernoV1 the three screws twO clamps and cover 8 REMOVE DRIVER SIDE FINISH LOWER PANEL Remove the six screws disconnect the four connectors and remoV1 the lower panel 9 REMOVE INSTRUMENT...

Page 712: ...L 14 REMOVE PASSENGER SIDE FINISH LOWER PANEL ASSEMBLY a Remove the glove compartment door check arm and the compartment door b Remove the door lock striker c Remove the finish lower p 1 d Disconnect the two connectors NOTE If necessary remove the speaker 15 REMOVE ECU a Disconnect the three connectors b Remove the three screws and the ECU 16 REMOVE SCREWS OF HEATER CONTROL ASSEMBLY Remove the fou...

Page 713: ...afety pad 19 REMOVE SAFETY PAD a Remove the seven screws and one bolt b Disconnect the lour connectors c Remove the Safety pad d Remove the left and right side defroster nozzle ducts e Remove the instrument panel center register from the safety pad f Remove the left and right instrument panel side reg isters from the safety pad g Remove the side defroster retainer and delrouer nozzle INSTALLATION ...

Page 714: ... Seat FRONT SEAT COMPONENTS Headren RH Upper Snt Back St1t Cushion Soat Bod LH s t Boc k 130 1 131 Soat Truck I m m I 18511S 181 378 C Z1 371 IkJ m ft lb N m J Speeitfed torque B0 45 Front Seat 8aek Board Inatzr I ...

Page 715: ...80 46 Rear Sack Lock Assembly Rear RH Seat Back t BODY Rear Seat REAR SEAT COMPONENTS Striker h Rear Seat Cushion Rear LH Seat BKI Rear Seat 8ac k Center Hinge Ikg em lft lb N mll Specified torQue ...

Page 716: ...ten the lront seat belt B0 47 b Drive the car at 10 mph 16 km h and make 1 vary hard stop c Check that the belt is locked and cannot be extended at this time NOTE Conduct this test in a safe area If the belt does not lock remove the beltmechanism assembly andconduct the following static check Also whenever installing a new belt assembly verify the proper operation before instal lation ...

Page 717: ... tilt of 15 degrees or lon and cannot be pulled out at ovor 45 degreesof tilt If a problem is found replace the assembly OUTBOARD REAR SEAT BELT Automatic locking Retractor ALR Type TESTING a Pull out the belt release it slightly and then pull it out again b Verify that tho belt cannot be extended further If a problem is found replace the assembly ...

Page 718: ...t sur pension member tear 1 io T t Center floor side member standard 1 side upper inlltlla tlon hokt hole G g Front si member bumper instal U u Rtlt floor siR mtmbtr sundard IS lation I M Jt hole H h Front side mtmbtr rur side upper ISo V v Rear floor side member tanda rd IS bumper installetion hole hole 1 1 Retractable light btac ket upper w Upper back reinforcement s tanda rd 20 inttallation nut...

Page 719: ... B C I C o C b C b c 1 335 982 1 688 946 1 220 454 152 58 138 66 165 59 13724 148 03 117 87 B I C c o e 0 F 0 8 G 9 b F 0 t 0 1 0 b 311 1 355 1 132 718 609 862 138 97 153 35 144 57 12827 123 98 133 94 I I I i 1 J i h J j I H 848 789 820 245 701 133 31 131 06 13228 9 65 27 60 ...

Page 720: ...v R r T t U u v v L l M m N n O o P p a q R r T t u v u v 818 3 2 20 1 285 50 59 789 31 06 774 30 471 1 061 42 561 740 29 13 802 31 571 1 188 45 98 821 32 3 21 860 33 981 331 13 031 803 31 61 1 105 43 50 622 24 491 1 362 53 23 1 359 63 501 1 367 53 82 1 329 52 321 1 596 62 831 1 563 62 3 21 1 072 42 201 625 24 611 971 38 23 1 109 43 681 64 2 52 93 3 661 85 3 35 85 3 351 36 1 421 37 1 461 7 0 281 7...

Page 721: ... Body Dimensions Point symbol Reference tength mm in I X y 1 242 48 901 X V 1 230 48 43 X y 1 472 57 95 X y 1 492 58 351 NOTE The luggage compartment measurement is performtrd between the two dot marked points as s hown In the figure l ...

Page 722: ...tion System _ AC 12 Evacuating and Charging of Refrigeration System AC 12 FUNCTIONAL TEST AND ADJUSTMENT _ AC 16 Vacuum Circuit AC 18 Power Serw Unit Operation _ _ AC 17 Automatic Temperature Control ___ _ ___ AC 18 Air Mix Damper Linkage _ _ AC 19 Sensor Circuit _ AC 19 Double Vacuum Valve IDVV _ _ AC 20 Water Temperature Switch AC 20 Condenrer Motor _ AC 21 SYSTEM COMPONENTS _ AC 22 COMPRESSOR A...

Page 723: ... Tighten the nut using two wrenches to avoid twisting the tube c Tighten the 0 ring fitting to the specified torque Tightening torque for O ring fittings Fittinv s i re Torque 0 31 in Tube 135 kg em 110 ft lb 13 N ml 0 50 in Tube 225 kg cm 16 h lb 2 2 N m 0 62 in Tube 325 kg m 24 ft lb 32 N ml TROUBLESHOOTING Symptom Ponjble causes Chedts and QOt rtc tlons No blower operation Blown circuit breaker...

Page 724: ...eck C t tra1ion AC 17 Oeftetiw ovv Check QPefttton AC 20 Oeftetln amplifier Chtck operftion 0ffac1ive COndenser motor Check opettdon AC 21 Defective A C rtiiV OWck opentian e g Oefec ttvt wiring connection Chect and rtPiir AC 9 Oefecti e vacuum cirwit Check for Ink and reptlr AC 16 lnttriOf ttml traturt O ftctivt water wttvt Check ot erltion doH not r1M Oeftetive te rnper ture sen C n Cheek for QC...

Page 725: ...1 5 2 0 kg em 21 28 psi 147 196 kPa L High pressure side 14 5 15 0 kg em Symptom seen in refrigilration system During operation prtmure at low pressure side some times become a vacuum and sometimes normal 206 213psi 1 422 1 471 kPal 2 MOISTURE PRESENT IN REFR IGERATION SYSTEM Condition Periodically coolsand then fails to cool Probable cause Oi gnc Si Remedy Moisture entered in refrig Drier in over...

Page 726: ...DITIONING SYSTEM Troubleshooting 3 INSUFFICIENT REFRIGERANT Condition lnsuft ocient cooling Probable cause Diagnosis AC 5 Remedy Gas leak 11 some pf ee lmufficient refrigerant in Check with luk tt1ttr and in rtfrigentlon svsttm svn n repair I Ch rge refrigerant to proper Retrivcrant leaking tmount 4 POOR CIRCULATION OF REFRIGERANT Condition Insufficient cooling ProtNblt cause Diagnosis Rmtedy Refr...

Page 727: ...heck fan motor slve reffigerant in system operation Condenser cooling Condenser cooling 3 If 1 and 2 are in insufficient insufficient conde nser normal nate check fins clogged or tan motor refrigerant amount faulty Note Vent outre frioerant through gauge manifold low presa re side by gradually open ing valve 6 EXPANSION VALVE IMPROPERLY MOUNTED HEAT SENSING TUBE DEFECTIVE OPENS TOO WIDEI Condition...

Page 728: ...rtssOt oil Insufficient v euum to see if dirty or in purging wffieient 13 Vacuum puJgt tnd charge new ttfr ttfant B REFRIGERANT DOES NOT CIRCULATE Condition Does not cool Cools from time to time in some ca P robablt ClUte Diagnosis Romody Refrigerant flow obstructed EJ p1n1jon valve orifice Allow to stand for somt time by mois ture or dirt In clogQO I and then restart operation refrigerant freezin...

Page 729: ... Condition Does not cool Probablecause Diagnosis Remedy Internal leak in oompres SO CompttMion defective Repfact compr8 0t Valves leaking or broken sliding parts lplston cylindet gasket oonnecting rod etc broken SPECIAL TOOLS AND TEST EQUIPMENT SST No u 07110 78010 To evacvate and dlarge system To check magnetic dutch 07110 77011 Includes the following 8 tools 07112 71010 To ntmcwe pressure plate ...

Page 730: ...AIR CONDITIONING SYSTEM Air Conditioning System Circuit AC 9 AIR CONDITIONING SYSTEM CIRCUIT us 0 lit ...

Page 731: ...s to a belt which has been used less than 5 minutes on a running engine Used belt refers to a belt which has been used on a running engine for 5 minutes or more 3 START ENGINE 4 TURN ON A C SWITCH Check that the AJC operates at each position of the blower switch 6 CHECK MAGNETIC CLUTCH OPERATION 6 CHECK THAT IDLE INCREASES When the magnetic clutch engages engine revolution should increase Standard...

Page 732: ... OF REFRIGERANT Observe the sight glasson the receiver Amount of Remody ln suff lcient Ctltdc fQ luk w th galnk test None suHicit nt or too much Reftt to i1t rns 3 and 4 System is emptY or n11rly Evtcuatt end c Nroe system Then empty chtck for ltl k with gesltlk thttr Proper 01 too much Atftf to items 5 and 6 Too much Oflchtroe the excess rtlrlotrant to s Ptelfltd tmount Pr oper Installation of Ma...

Page 733: ...ing system has been exposed to the at e it must be evacuated After installation of a component the system should be evacuated for eppro imatelv 15 minutes A component in service that has been opened for repair should be evae Jated for 30 minutes 1 EVACUATE SYSTEM a Connect the manifold gauge set See page AC 111 b Install the center hose of set on the vacuum pump inlet c Run the vOC lum pump and th...

Page 734: ...AKS NOTE A her evacuating the system check for leaks a Install the refrigerant container tap va lve as described in step 2 b Open the high pressure valve to charge the system with refrigerant vapor c When the low pressure gauge reads 1 kg em 14 psi 98 kPa close the high pressure valve d Using a halide gas leak detector propane torch or electric leak detector check the system for leaks If a leak is...

Page 735: ... When the re frigerant container Is placed rightside up refrigerant will enter the system as a vapor Put the refrigerant container in a pan of warm wJtet maximum temperature 40 c or 104 F to keep VIPOf pressure in the container slightly higher than viPO pressure in the system a Install refrigerant container tap valve as described in step 2 b Open the low pressure valve Adjust the valve so t t the ...

Page 736: ... hole in the sealed tap of the new container and charge the system CAUTION Be careful not to overch go tho rolrliefont as it moy causo follure of tho ings and belt WHEN SYSTEM IS FULLY CHARGED DISCONNECT MANIFOLD GAUGE SET a Close both low and high pressure valves b Close velve at refrigerant container If using one pound container of R 12 allow remaining refrigerant to _ by slowly removing the cha...

Page 737: ...rcuit ON VEHICLE INSPECTION 1 REMOVE UNDERCOVER 2 DISCONNECT FROM NORMAL CONNECTOR AND RECONNECT TO CHECK CONNECTOR OF AMPLIFIER 3 PLACE TEMPERATURE CONTROL LEVER AT 77 4 CHECK VACUUM CIRCUIT a Run the engine and observe the movement of the power servo stem visually for one minute or more The stem must be stable b If the stem moves cheek the vacuum circuit for leaks 5 REINSTALL UNDERCOVER B V euvm...

Page 738: ...NTROL LEVER AT n 5 CHECK BLOWER SPEED CONTROL BY SLIDING TEMPERATURE CONTROL LEVER tal When slidi the lever to 70 the blower speed will c hange in five steps b When sliding the lever to 85 the blower speed will change in four steps 6 CHECK WATER VALVE OPERATION BY SLIDING TEMPERATURE CONTROL LEVER a When placing the lever at the left si M fully the water valve will close b When placing the lever a...

Page 739: ...INE AT IDLING 5 CHECK AUTOMATIC TEMPERATURE CONTROL a Verify that the white line marked on the stem is posi tioned within the orange area on the po ver servo unit tb If the white line positions are not in the orange area adjust as follows 6 ADJUST AUTOMATIC TEMPERATURE CONTROL a Normally the orange adjusting terminal isconnected b If the white line on the stem is in the red area chango the connect...

Page 740: ... maximum cooling and eon nect the rod to theclamp d Using a commercial vacuum pump apply 250 mmHg 9 84 ln Hg 33 3 kPa of vacuum to the vacuum motor and verity that the damper moves to the max imum heating position 3 REINSTALL REMOVED PARTS IN REVERSE ORDER Sensor Circuit 1 IN CAR SENSOR Located In console box Check sensor resi5tance 1 7 5 6 kO 0 25 c or 32 77 FI 2 VERIFY AIR IS SUCKED IN IN CAR SE...

Page 741: ...pply 12 volts to the positive terminal and ground terminal T 1 There should be continuity be tween A and B at this time If a problem is found replace the DVV Water Temperature Switch INSPECTION OF WATER TEMPERATURE SWITCH CHECK WATER TEMPERATURE SWITCH OPERATION a Disconnect the 1 pole connector from the water temp switch lb Check continuity between the water temp switch and ground as follows Cool...

Page 742: ... page AC 9 ON VEHICLE INSPECTION 1 CHECK CONDENSER MOTOR OPERATION AC 21 NOTE When the air conditioner is on the condenser motor must rotate 2 CHECK A C RELAY OPERATION NOTE When the air conditioner is on the AfC relay must come on If a problem is found replace defective part ...

Page 743: ... 22 AIR CONDITIONING SYSTEM v1tem Components SYSTEM COMPONENTS VSV 4Sub Oemper Condenser Ambitflt Sensor 0 He l e Unit Powtr Servo e DVV tL VSV Witer Vetve kw v Compres sor Vao tum Tank 0 Blower Resis tor ...

Page 744: ...PRESSOR FOR FOLLOWING a High preuure gouge reading is not low and low pressure gauge reading is not higher than normal b Metallic sound cl Leakage from the shaft seal If defects are found repair the compressor 4 CHECK MAGNETIC CLUTCH a Inspect tho prnsuro plato and the rotor lor signs of oil b Check the clutch bearings lor noiseandgreasoleakage cl Using an ohmmeter measure the resistance of tho st...

Page 745: ...G ON FOR 10 MINUTES 2 DISCONNECT NEGATIVE CABLE FROM BATTERY 3 DISCONNECT CLUTCH LEAD WIRE FROM WIRING HARNESS 4 DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM page AC 12 5 DISCONNECT TWO FLEXIBLE HOSES FROM COMPRESSOR SERVICE VALVES Cap the OPen fining immediately to keep moisture out of the system 6 REMOVE COMPRESSOR a Loosen the drive belt b Remove the compressor mounting bolts and the compres...

Page 746: ...tnurt Plote Specified tOrQue DISASSEMBLY OF MAGNETIC CLUTCH 1 REMOVE PRESSURE PLATE a Using SST and a socket remow the shaft nut SST 07110 77011 b Using SST and a socket remove the preswre plate SST 07112 71010 cl Remove the shims from the shaft ...

Page 747: ...ot to dlmage the pul y tapping on the rotor 3 REMOVE STATOR a Disconnect the stator lead wires from the compr housing b Using SST remove the snap ring Remove the sutor SST 07114 84020 4 REMOVE ROTOR BEARINGS NOTE Press the bearings out only if they are to be r placed a Remove the bearing snap ring from the rotor lbl U ingSST press out the two bearings SST 0711077011 ...

Page 748: ...orHeus able part 6 INSPECT PRESSURE PLATE AND ROTOR a Inspect me pressure platB and rotor stJrfaces for wear and seo ing RepIeee if neceuary b Check the rotor bearings for wear and leakage of grease Replace if necen ory SuetiOft Attd Valve Val DISASSEMBLY OF COMPRESSOR 1 REMOVE FELT ...

Page 749: ...KEY Using a hammer and punch drive the key from the shaft 4 APPLY COMPRESSOR OIL TO INNER BORE Apply compressor oil to the inner bo re of the compressor 5 REMOVE SHAFT PLATE a Insert SST against the shaft Then push the holder ring downward SST 07112 15010 I Pull up the bar of the remowr and remove the shaft plate ...

Page 750: ...ST remove the bolts holding the two service valves SST 07110 61050 b Remove the 0 rings from the service valves and dis card them 8 DRAIN OIL INTO CONTAINER 9 REMOVE FRONT HOUSING a Using SST remove the six through bolts NOTE Do not reuse the six washers SST 07110 61050 b Using a hammer and punch remove the front housing by tapping on the protrusion CAUTION Be careful not to scratch the sealing su...

Page 751: ...not to scntdl the seoling surface of the housing 12 REMOVE FRONT AND REAR O RINGS FROM CYLINDER BLOCK Diseard the rings ASSEMBLY Of COMPRESSOR See AC 271 1 INSTALL REAR VALVE PLATE ON REAR CYLINDER al Install the two pins in tho rear cylinder bl Lubricate a new 0 ing with compressor oil Install the O ring in tho roar cylinder c Install the rear suction val e over the pins on tho rear cylinder NOTE...

Page 752: ...essor oil Install the O ring in the rear housing c Install the front suction valve over the pins on the front cylinder ld Install the front valve plate together with the diSo charge valve over the pins on the front cylinder NOTE The front valve plate is marked with an F e lubricate gasket with compressor oil Install the gasket on the valve plate 4 INSTALl FRONT HOUSING ON FRONT CYLINDER AND TIGHTE...

Page 753: ...T 07114 15010 6 INSTALL SHAFT PLATE a Put on the shalt plate b Preu in SST SST 07112 25010 7 INSTALL KEY IN SHAFT GROOVE Using SST and a plastic hammer tap the key lightly SST 07114 45010 Put the felt inside the bore 8 POUR COMPRESSOR OIL INTO COMPRESSOR ComP essor oil OENSOOI L 6 SUNISO No SGS 0 oquiVIIent Refill capacity 10 20 cc 0 3 0 711 oz ...

Page 754: ...e 30 kttem 26 in lb 2 9 N m or less ASSEMBLY OF MAGNETIC CLUTCH See AC 24 1 INSTALL TWO BEARINGS IN ROTOR a Using SST press a shield ring and two new bearings into the rotor boss until fully seated SST 07110 77011 b Install the bearing snap ring into the rotor groove 2 INSTALL STATOR a Install the stator on the compressor bl Using SST install the snap ring SST 07114 84020 c Connect the stator lead...

Page 755: ...bl Charge the compressor with refrigerant through the charging valve until the pressure is 3 kg em 43 psi 294 kPa c Using a gas leak detector check the compressor for leaks If leaks are found check and replace the gasket O ring or shaft seal 2 IF NECESSARY FILL COMPRESSOR WITH CLEAN COMPRESSOR OIL Remove the service valve and drain the compressor oil Fill with new oil Compressor oil DENSOOIL 6 SUN...

Page 756: ...G 20 95506 20 or Borroughs No BT 33 73F Drive belt tension N belt 125 t 251b Used belt 80 t 20 lb NOTE New belt refers to a belt which has been used less than 5 minutes on a running engine Used belt refers to a belt which has been used on a runningengine for 5 minutes or more 3 CONNECT TWO FLEXIBLE HOSES TO COMPRESSOR SERVICE VALVES Torque Dischtrllf line 226 kg em 16 ft lb 22 N ml Suction line 32...

Page 757: ...LE HOSE FROM CONDENSER INLET FITTING 4 DISCONNECT LIQUID LINE TUBE FROM CONDENSER OUTLET FITTING NOTE Cap the open fittings immediately to keep mois ture out of the system 5 REMOVE CONDENSER Remove the four bolts INSTALLATION OF CONDENSER 1 INSTALL CONDENSER Install the four bolts making sure the rubber cushions fit on the mounting flanges correctly 2 CONNECT LIQUID LINE TUBE AND DISCHARGE FLEXIBL...

Page 758: ...ugs until ready for con nection 2 CONNECT TWO LIQUID LINE TUBES TO RECEIVER Torque 135 k9 C1 1 10 ft lb 13 N ml 3 IF RECEIVER IS REPLACED ADD COMPRESSOR OIL TO COMPRESSOR Add 10 20 cc 0 3 0 7 fl oz 4 EVACUATE CHARGE AND TEST REFRIGERATION SYSTEM See AC 12 COOLING UNIT S AC 22 ON VEHICLE INSPECTION OF EXPANSION VALVE 1 CONNECT MANIFOLD GAUGE TO COMPRESSOR 2 CHECK EXPANSION VALVE OPERATION a Run the...

Page 759: ...linings immediately to keep mois ture out of the system 5 REMOVE GROMMETS FROM INLET AND OVTLET FITTINGS 6 REMOVE FOLLOWING COMPONENTS a Glove box with undercover b Side air duct 7 DISCONNECT CONNECTORS 8 REMOVE COOLING UNIT Remove the three nuts and four bolts 9 REMOVE AIC AMPLIFIER 10 REMOVE AIC WIRE HARNESS FROM COOLING UNIT m l r DISASSEMBLY OF COOLING UNIT 1 REMOVE LOWER CASE Using a screwdri...

Page 760: ...ION Never use water to cleen the evaporator 2 CHECK FITTINGS FOR CRACKS OR SCRATCHES Repair as necessary ASSEMBLY OF COOLING UNIT 1 INSTALL COMPONENTS ON EVAPORATOR a Connect the expansion valve to the inlet fitting of the evaporator Torque the nut Torque 235 kg em 17 ft b 23 N m NOTE Be sure that the O ring is positioned on tne tube fitting b Connect the liquid line tube to the inlet fitting of t...

Page 761: ...UTLET FITTINGS 5 CONNECT LIQUID LINE TUBE TO COOLING UNIT INLET FITTING 6 7 Too quo 135 kg em 10 ft lb 13 N m CONNECT SUCTION FLEXIBLE HOSE TO COOLING UNIT OUTLET FITTING Torque 325 kg em 24 ft lb 32 N m IF EVAPORATOR IS REPLACED ADD COMPRESSOR OIL TO COMPRESSOR Add 20 35 cc 0 7 1 2 fl oz 8 CONNECT NEGATIVE CABLE TO BATTERY 9 EVACUATE CHARGE AND TEST REFRIGERATION SYSTEM See page AC 12 REFRIGERANT...

Page 762: ... TEST REFRIGERATION SYSTEM See page AC 12 EXPANSION VALVE ON VEHICLE INSPECTION 1 CHECK QUANTITY OF GAS DURING REFRIGE RATION CYCLE 2 INSTALL MANIFOLD GAUGE SET a Close the high pressure and low pressurevalves b Connect the high pressure hose to the discharge service valve of the compressor c Connect the low pressure hose to the suction rvice valve of the compressor 3 RUN ENGINE Run the engine at ...

Page 763: ...ck that air comes out of pipe E c Disconnect the battery d Blow into pipe f and check thllt air comes out ol the filter G If a problem is found repair or replace the VSV 2 CHECK FOR SHORT CIRCUIT Using an ohmmeter check that there is no continuity between each terminal and the VSV body If there is continuity replace the VSV 3 CHECK FOR OPEN CIRCUIT Using an ohmmeter musure the resistance between t...

Page 764: ...EM A 10 LUBRICATION SYSTEM A 10 IGNITION SYSTEM A lO STARTING SYSTEM A 11 CHARGING SYSTEM A 11 CLUTCH A 12 MANUAL TRANSMISSION A 13 AUTOMATIC TRANSMISSION A 16 PROPELLER SHAFT A 19 FRONT AXLE AND SUSPENSION A 20 REAR AXLE AND SUSPENSION A 21 BRAKE SYSTEM A 24 STEERING A 26 BODY A 28 LUBRICANT A 29 ...

Page 765: ...nsion S lllolnt Ytrti l play limtt WllHI burlng friction preload In addition rotation friction force of the oil seat Steering wheel frttplay Chassis and body ti9htening torqut FtOnt ttlt moundi SJ bolt Front tuSC tnsion member x Body Stru1 blr bfack t x Body Relt wspens ion me mber x 8ody Front Re11 170 t 10 1b 135 t 20 lb 125 t 251b 80 t 201b 8 0 liters 8 5 us qt s 7 911ttrs 8 3 us qt s 5 1 fitt1...

Page 766: ...161 in 13 040 13 051 mm 0 5134 0 5138 ln 0 S 0 05 13 090 13 101 mm 0 5154 0 5158 ln Replacing te mperature cylinde r head side Approx 9tt C t194 F Valve Valve overall length STO Intake 107 5mm 4 232 in Exhaust 109 7 mm 4 319 in Valve face angle IN EX 44 6 Stem diameter Intake 7 970 7 985 mm 0 3138 0 3144 in Exhaust 7 965 7 980 mm 0 3136 0 3142 in Stem oil clearance STO Intake 0 025 0 060 mm 0 0010...

Page 767: ...ylinder head surf t wttl llt Limit 0 10 mm 0 0039 in Intake tnd MJnifold surfa WltCN t exhlust manifokS Limit Intake O lmm 0 01 4 in Ex hautt 0 75 mm 0 0295 in Air intakt Intake ma ifold surface wtfp ap Limit 0 1 mm 0 004 in chtmb Idler pulltv Fre e length 69mm 2 72 in tensioo f ring Pump drive Thrust eJearanee STO 0 06 0 13 mm 0 0024 0 0051 ln limit 0 3mm 0 012 in Oil cluranoe STO 0 025 0 066 mm ...

Page 768: ... 0002 0 0004 ln Limit 0 015 mm 0 0006 in Pitton pin diamtt 21 997 22 009 mm 0 8660 0 81165 ln Rod bend Limit 100mm 3 94 in 0 05mm 0 0020 in Rod twist Limit por 100mm 3 94 in 0 15mm 0 0059 in Crtnkthltt Thrust clearance STO 0 05 0 25 mm 0 0020 0 0098 ln Limit o 3mm 0 012 1n Thrust washer thickness STO 2 925 2 975 mm 0 1152 0 1171 in 0 S type 0 125 2 988 3 038 mm 0 1176 0 1196 1 n 0 S type 0 250 3 0...

Page 769: ...k 130 9 13 Timing belt case x Cylinder block 8 mm bolt Nut 186 13 18 10 mm bolt 375 27 37 Pump d rive shaft pulley x Drive shaft 220 16 22 Idler pulley x Timing belt case x Cylinder block 600 36 49 Distributor x Camshaft housing 140 10 14 Crankshaft bearing cap x Cylinder block 1 040 75 102 Conne ting rod cap x Connecting rod 450 33 44 Crank haft pulley x Crankshaft 2 200 159 216 Flywheel x Cranks...

Page 770: ...0 40011 E1 Fe oo CMtesurlng pl1te dosed 0 Measuring pl ate open E THA 10 20 kll 1 2o c 4 FI 4 1 klllo c 32 FI 2 3 kll 12o c 68 FI o 9 1 3 kll 4o c 104 F1 0 4 0 7 klli50 C 140 Fl Retistanet 81 S1 or Sl 10 3011 B S or S 10 3011 Throttle vblve fully ctosed angle e Cleetrance between stop Between termil als Resistance kill Crew Jnd lever 0 mm or 0 in VTA E 0 2 0 8 O SO mm 0 0197 in 0 100 0 90mm 0 0354...

Page 771: ...No 20 1 9 14 Ignition switch ON 1Gt E1 0 7 1 0 Cranking or idling ISC1 9 14 Ignition switch ON I E 9 14 After engine off 2 3 sees ISC I 10 13 Ignition Witch ON B EGR 0 Engine start and warm up Oxygen sensor 0 Shih position PorN range for A T 10 14 Ignition S W Except PorN range for A T NIC E 0 ON Clutch pedal not depressed for M TJ 10 14 Clutch pedal depressed for MIT 9 11 Cranking 4 6 Ignition S ...

Page 772: ...ve fuUv closed 3 000 7 000 Oisconntet air fJow mtttr conntctor Vc E 200 400 Disconnect throttle position sensor eonntetor 20 400 Meuuring plate fully closed Vs E 20 1 000 Measuring plate fuUy open THA E1 2 000 3 000 lnttkt air tempetature 20 C 88 F1 G GE Ne G8 140 180 ISC ISC ISC ISC 8 10 30 Torque Specifications Part t ghttntd kg em It II N m Fuel tank and lint Fuel link btnd x Fuel tank brtcket ...

Page 773: ... clearance STD 0 03 0 06 mm 0 0012 0 0024 in Limit 0 2mm O OOS in Side clearance STO 0 03 0 09 mm 0 0012 0 0036 n Limit 0 15 mm 0 0059 in Gear backlash STD 0 5 0 6mm 0 020 0 024 in Limit 0 9mm 0 035 in Orive shaft diameter STD 14 00 14 01 mm 0 5512 0 5516 in limit 13 9mm 0 547 in Relief valve operating pressure 4 4 5 0 kg em 63 71 psi 431 490kPa IGNITION SYSTEM Ignition timing T M in N range 10 BT...

Page 774: ...h STO 0 6mm 0 024 in Lim it 0 2 mm 0 008 in Circle runout Limit 0 05 mm 0 0020 in Spring ins talled load STO 1 785 2 415 g 3 9 5 31b 18 24 N CHARGING SYSTEM Battery specific gravity when fully Charged at 20qC 68 F 1 25 1 27 Driveb elt tension w Borroughs drive belt ttn ion gauge No 8T 33 3F New belt 170 t 10 1b Used belt 135 t 20 lb A lttrnator Rated output 12 v 60A Rotor coil resistance Len then ...

Page 775: ...IFICATIONS Clutch 154 164 mm 1 5mm 5 15 mm Non djuttable type Limit 0 3 mm Limit 0 8mm Limit 0 5 DIC th Umit 0 6 Width Limit 5 0mm Limi1 0 2mm kg em 186 Rtltut fotk aupport x Clutch housing 400 Prt l M rt p lltl x Ctutd l C OVtf 250 Muter cytinder wt bolt 250 Reservoir set bolt 250 Clutch tube union nut 155 Fltd lt hoM 235 Clutch ptdtlltttln g nut 425 6 06 6 461n 0 04 0 20 in 0 20 0 59 ln 0 012 in...

Page 776: ...tennct l imit Sy W hronizer ring to gear cte1rance STD Limit Input shaft snap ring thid ness Mttk 1 2 3 4 5 11 12 42 85 mm 37 80mm 5 60mm 0 05mm 4 70mm 42 85 mm 29 90 mm 26 85 mm 0 10 0 25 mm 0 30mm 0 10 0 41 mm 0 46 mm 0 009 0 060 mm 0 15 mm 0 060 0 103 mm 0 20mm OD09 0 052 mm 0 15 mm 1 0 mm 0 7 1 7 mm 0 5 mm 2 0S 2 10 mm 2 10 2 15 mm 2 15 2 20 mm 2 20 2 25 mm 2 25 2 30 mm 2 30 2 35 mm 2 35 2 40 ...

Page 777: ...976 in 11 2 49 2 64 mm 0 0980 0 1000 ln 12 2 55 2 60 m 0 1004 0 1024 in 13 2 61 2 56 m 0 1028 0 10471n 14 2 68 2 73 m 0 1055 0 10751n 15 2 74 2 79 m 0 1079 0 1098 in RevetW ar Matk 5 2 25 2 30mm 0 0888 0 0906 in 11 2 30 2 35 m 0 0906 0 0925 in 12 2 35 2 40 mm 0 0925 0 0945 in 13 2 40 2 45 mm 0 0945 0 0965 in 14 2 45 2 50 m 0 0965 0 0984 in 15 2 50 2 55 mm 0 0984 0 1004 in 16 2 55 2 50 mm 0 1004 0 ...

Page 778: ... 25 mm 0 0886 0 0886 n 7 2 26 2 31 mm 0 0890 0 0909 n No 3 clutch hub M8 k 2 2 06 2 11 mm 0 0811 0 0831 n 3 2 12 2 17 mm 0 0835 0 0854 n 4 2 18 2 23 mm 0 0858 0 0878 n 5 2 24 2 29 mm 0 0882 0 0902 n Torque Specifications Manual Part tightened kg cm ft lb N m transmission W58 Shift fork set bolt 125 9 12 Straight screw plug 250 18 25 Idler shaft n opper bolt 250 18 25 Reverse restrict pin 250 18 25...

Page 779: ...rpm Less than 1 2 SotCOnds Less than l S s 650rpm Between boot efWj tac eand inner cable stopper 0 lmm 0 0 04 in 0 20mm 0 0079 in Stlih point Throttle valve lui ly OPtn I Fully closed km ll mill I sd ltdult km 11 mpl l 1 2 2 3 3 QO 3 QOI 00 31 00 3 3 2 2 1 47 52 101 135 144 130 138 88 96 42 47 NOAM 111 m 57 31 84 891 81 55 0l le 291 o 52 51 105 114 152 161 2 J 28 2J 14 155 101 108 42 J Pw 32 3 1 6...

Page 780: ...body Throttle valve 19 24 0 75751 8 58 0 3378 8 0 71 0 0280 None Oown shift plug 39 55 1 5571 10 90 0 4291 9 4 1 20 0 0472 G n Secondary regulatCH 71 27 2 8059 17 43 0 6862 15 1 93 0 0760 Gr Cut back valve 23 00 0 9055 6 85 0 2697 10 5 0 65 0 0256 Grltl Clutch pinon Free length 15 1 mm 0 594 in return spring Coil outer diameter 8 0mm 0 315 in Co C1 C2 No of coils 5 5 Clutch and br1ke Free length 1...

Page 781: ...01 0 6870 0 9065 0 9075 0 9095 Oil pump body 13 46 38 1 13 38 138 38 188 0 5299 1 5005 1 5015 1 5035 00 sun gear Front 9 70 23 062 23 088 23 138 Rear 1 0 3819 0 9080 0 9090 0 9109 00 input shaft 9 00 11 200 11 221 11 271 0 3543 0 4409 0 4418 0 4437 Sun gear Front 13 50 21 501 21 527 21 577 Rear 0 53151 0 8465 0 84751 0 8495 Center support 65 69 38 386 36 411 36 461 2 58581 1 4325 1 43351 1 43551 T...

Page 782: ...ications Shaft runout Spider axial play Torque Specifications Patt tightel ed 12mm lOmm Limit Intermediate shaft x Center bearing x Joint flange 1st 2nd 3 d Center bearing flange x Universal joint flange yoke Universal joint flange yoke x Companion flange Center bearing bracket x Body kg cm 650 580 345 345 425 650 280 215 260 55 100 55 45 75 350 75 75 0 8mm Omm k l m 1 850 Looten nut 700 430 430 4...

Page 783: ... buring pre4o ad turning load It hi A in addition to rotl1ion friction force of the oil 1411 0 1 0S0g o 2 31b 0 10N Hub lXIII Pity Max limit O OSmm 0 0020 in Billll joint vertical plav Max limit 2 5 mm 0 098 in Torque Specifications Pan tightened k9 tll h lb N m Shock absorber pinon rod x SuSCMnsion wPPOrt 475 34 47 Shock ebsor btr lhtll x Ring nut 1 250 90 123 lowtr 1rm x Suspension member 1 100 ...

Page 784: ...mm 0 004 in Add oil seal rotition re11istance 1 4 kw cm 0 9 3 5 1n lb 0 1 0 4 N ml sow 0 131b sow 0 13 lb 60g 0 13 1 b 60g 0 13 lb 416 5 419 5 mm 16 398 16 516 In 12 19 kw cm 00 4 18 5 in lb 1 2 1 9 N m 6 IOkg m 5 2 8 7 in lb 0 6 1 0 N m Add dri pinion bearing preload 4 6kw cm 3 5 5 2 in lb 0 4 0 6 N ml 0 13 0 18 mm 0 0051 0 0071 in 0 05 0 20 mm 0 0020 0 00711 in 0 07 mm 0 0028 ln 0 10 mm 0 0039 i...

Page 785: ... 0 1102 1n 2 81 2 83 mm 0 1106 0 1114 on 2 84 2 66 mm 0 11 18 0 1126 2 87 2 89mm 0 1130 0 1138 in 2 90 2 92 mm 0 1142 0 1160 ln 2 83 2 95 mm 0 1154 0 1161 1 n 2 96 2 98 mm 0 1165 0 1173 1 n 2 99 3 01 mm 0 1177 0 1185 in 3 02 3 04 mm 0 1189 0 1197 1n 3 05 3 07 mm 0 1201 0 12011 in 3 08 3 10 mm 0 1213 0 1220 ln 3 11 3 13mm 0 1224 0 1232 ln 3 14 3 16mm 0 1236 0 1244 ln 3 17 3 19 mm 0 1248 0 1256 in 3...

Page 786: ...shaft 700 51 69 Compenion fl1n91 x Drive pinion t ghlen the nut 130 kg em 91 lb 151 1 100 80 108 13 N ml It 1 tJme I Nltil the speeifitd prefoad is reached Max 2 400 174 235 Ring gear x Oifftrtontial case 98S 71 i7 Side bearing CIP 800 68 78 Oifferentitl c rritr x Support 850 61 83 Carrier support x Member 850 61 83 Suspension Sheek absorber x Body 250 18 25 Shock absorbtr x Suspenston arm 375 27 ...

Page 787: ...t Disc runout Limit Pad t hickness STD Limit Parking brake Rear drum inner diameter STD Limit Lining thickness STD limit Lever travel at 20 kg 44 1 lb 196 Nl Clearan between rear shoe and levtr t64 164 mm 6 06 6 46 in 3 6mm 0 12 0 24 in More than 75 mm 2 95 in 0 1 0 Smm 0 004 0 020 n 0 60 0 65 mm 0 0236 0 0256 _ Omm 0 in 20mm 0 79 in 19mm 0 75 in 0 15mm 0 0059 in 10 5 mm 0 413 in 3 0mm 0 118 in 18...

Page 788: ... lb dun c owr x Knuddt 185 13 18 Front diloC breke cylinder inulllllion bolt 200 14 20 Fltxiblt hose 235 17 23 Brake tube flare nut 155 11 16 Slttdtr plug Front 85 74 in lb 8 3 Rear 85 74 in lb 8 3 Front disc x Front a xlt hub 650 47 64 ParkinQ btlke lt wtr x Fk or 130 9 13 Par1dng bfakt No 1 cable lock nut 55 48 in lb 6 4 P arking brtkt cable cbmp x Side member or cabt rttalntr 55 48 in lb 5 4 Rt...

Page 789: ... to vane plate gtoove cfearance Limit 0 06mm 0 0024 in Shaft to bushino eltaran STD 0 010 0 030 mm 0 0004 0 0012 ln Limit 0 07 mm 0 0028 in Flow control vatn int length STD 60 0 mm 1 969 in limit 7 0mm 1 850 in Pump rotating torque Lts1tlnn 2 8 kg em 2 4 in lb 0 3 N m s teering rack runout Limit 0 3mm 0 012 in Control valve shaft pttlold at Turning 4 5 6 5 kg cm 13 9 5 6 ln lb 0 4 0 6 N ml Total p...

Page 790: ...rack 1 50 76 103 Control va ve hou ing x Aaek housint 185 13 18 Pinion be w ing ac uu screw k ck nut x Aaek housing 700 51 69 Rad guide spring ta P lock nut x Rack housing 700 51 69 Return prtssurt right and lth tube union 300 22 29 Pressure line x Reck housing 390 28 38 Rack housing bndcet Body 770 56 76 Front housing Rear hOusing 475 34 47 Union x Re ar housing 700 51 69 PSpump x Bracket 375 27 ...

Page 791: ...8 Seat cushion x Seat truck 185 13 18 Seat adjuster x Body 375 27 37 Rear seat Se at bade center hinge x Body 80 69 in lb 7 8 Seat belt Fron t ELR Body Upper side 55 43 in lb 4 9 Lower side 440 32 43 Belt shoulder anchor x Body 440 32 43 Outer belt lower anchor x Body 440 32 43 Inner belt anchor x Body Front side 195 14 19 Rear side 440 32 43 Seat belt Rear ALR x Body 440 32 43 Belt anchor x Body ...

Page 792: ...90 Automatic t ransmission fluid ATF DEXRQN 0 Dry fill 6 5 6 9 5 7 Onin tnd refill 2 4 2 5 2 Oiffertntlal oil API GL S hypoid gl lr oil w LSD Use LSD oil only IRS type 1 2 1 3 1 1 Abo 18 C O F SAE90 Below 18 C 0 6 F SAE 80W 90 or SOW Power steering Uuld ATF DEXRON or DEXRDN ll Pump 350 oc 2 1 4 cu In Total 800oc 48 8 eu in 8 11 joint grease Molybdenum disulphide lid lium base NLGI No 1 orNo 2 Whee...

Page 793: ...STANDARD BOLT TORQUE SPECIFICATIONS Page STANDARD BOLT TORQUE SPECIFICATIONS 8 2 8 1 ...

Page 794: ...NE BOLT STRENGTH Moli et Moli CliP _ Bdl 4T Stvd boll Nom k h dboh htodNo s 5T 6 6T 7 7T 4T 0 No m1rk 4T HUtfOn 0 bolt w wtsh r No matk 4T h onbolt 6T _ hHd b011 0 Two protrucli ng ST lints _ 0 Wt4ded boll batt Two _WMr protruding 8T MxltOf bolt 4T HulfOn hud bolt 0 Th ee pr01ruding 7T lints ...

Page 795: ...3 14 1 5 760 55 75 850 61 83 16 1 5 1 150 83 113 6 1 86 58 in lb 8 4 8 1 25 160 12 16 10 1 25 330 24 32 5T 12 1 25 600 43 59 14 1 5 930 67 91 16 1 5 1 400 101 137 6 1 80 9 in lb 7 8 90 78 in lb 8 8 8 1 25 195 14 19 215 18 21 6T 10 1 25 400 29 39 440 32 43 12 1 25 730 53 72 810 59 79 14 1 6 1 250 90 123 6 1 110 8 11 120 9 12 8 1 25 260 19 25 290 21 28 10 1 25 630 38 52 590 43 58 7T 12 1 25 970 70 9...

Page 796: ...SST AND SSM Pogo SST SPECIAL SERVICE TOOLS C 2 SSM SPECIAL SERVICE MATERIALS C 12 C 1 ...

Page 797: ...I IShtft A I IU1 aellll 1 6 e w w r OP ConMCtirog Rod l Otz22 J0011 l o 11 int Rtft IO IItf a a RepiiiOtf 09223 41020 0 1 1klhlfl ReM Oil s t Replacer a 09221 44110 Oil Fill Wr A gg lllla47112 W otO _ RM Oioef a Rf Piaow a lllll 41145 lf itetkwl Tool S a IIIU 41111 uel A IIZ7f 7111t l sh Adiusttt Tool a e t 09271 64012 Ho d ng Ae a ill _ 71011 lnjtctloft Pv 0 c c c tnsn fl S nt KT Edf Colle Rf1 ae...

Page 798: ...Outch Oltc itlt n DlliZ JOI31 No 3Geugt B Ol j Gl303 35011 l pUI SNH FtOftl e no A I 01304 30011 I PUt 1 Mih FI Oftt oR lA T vnl Gllll 10 b tet tlon Hou B Metal AtOitctr OI IQI OIOIO COli St l Pulled A 3D IDOll Ool SMt l fiMt lA I I I 5 cn 0131 Z 211111 T ooO 1 _ _1 Ia I J B OIJIJ 31021 O ttl ll lltl Jlt lf So ktl lA I Outel Rtl t Gllls GIOIO e tfl t Aemcwtr 6 R p IC lA e a e 0131 10 Tf tml loft r...

Page 799: ...T001 A 2 118333 00012 Clutch C iophri W ptlng AU Mr B TOYOTA Automttlc Offt_ 013 0 20013 TraJ 111isslon Tool B 1 M V l Lt Yer 11311 380111 Shift 011 SeOI Atolt tt lllll 311111 IGIMMI ol l c 1118 1 211111 Pumo Body Setting Banes 1 Piston S pring CompressorSet 111Jlt 1211 Clu tlcl l On lm Ttwut1 Ploy CO tOil s Aepleeet1 r 8 nrt wayCiukh Te t 1113rl Tool S t 09411 221111 Side Gear Ttlron WatltW Adju ...

Page 800: ...ntillt DrM 30011 Plfl lon Re r Suring B Con Aep ecer O iffeten1 1o 36010 Pinion 8Nriroe A19l c r B 1 JUJ heft A mmn OifltrentW SlOt o r hM1 Pvl A 1 1 rr cers tJ B 1 Si w 1 1 Wo 1 cw 1 1 1 C Driw ront Nring 1 11111011 e AKieShert Oil S l AtiPIIK AUt Axle a titlf UIII tfh ttft1 T B r 9 Li1 IIUD pn 21 I no 111111 len o avu lll corl 11 DfM Pinion Front ee tneR B ...

Page 801: ...D Part No llluttnltlon Comc Nn Oft Fl roee IIIIJ ZZIZZ a Rel l c r A t 1G01Z onv PWon 8Nring B 0 TOOl S I IIII 011111 1muw FI Oftt Hub a Oriwe 111113011Z Pinion B Toot S t X eon ew 9 a 30122 fron1 Hubl ing RtOitclf S t B I IIMIIIMI 1 11111 1111 o e AaJ Huba OrNe c OIMI 31014 Inion e rifll B c o Tool S _ 0 Front HubOutet a Stlltfing W Q tm Outor ...

Page 802: ...lllu1tration 011101 o n Prion roM I 1 c II II OIIZOI onl Ov c OIIII ZIIIIZ Pitn lft A m Pulled A OII11 Z2tl2 r Aod Eoo Pwlt r A OMIZ Zte12 s o Houtiftl B r f D I ToolSet r 12 111211 IHo _W N 17 Rtc kEncl 17 zetiOI IS 0 w N r H41211 s LeO _ Wf iiiW h et e il l 311010 1 1ntO fe 8o ReP M tt S t B _____ St lngWO m a oos s s OoiSMI 1111 Jl W c I IHa nOit l ...

Page 803: ... ng Rtck 0 1 s 1 Tool S t B E _ cws e 1111131 2A02lll IP stonRinD e 1111131 2A0301 IP tonRlneTooll B Jt 1 G tJ 1 l al __ 11 Cytlndlf nd SlOPJ N tWttnel l U1 M711 IOOS O 71t Z2M1 Toot Set B e r 11872 etl Shock AtMotbf t o rht l Toot Stt B IDI72H101171t FrontShOck Abtotbtl I M Wrlf Ch we r 1 Ge7li 10110 Arm 8 uth e B RemOII t a ee bqo le 01726 12022 ion Arm B11 l f Rtmcr ff AtPitctr B ...

Page 804: ...l cs 8 091Z7 2Z03l Front I ring eomo B Dl7lf ll031 Front Spting Stat Hold B 731 00111 Bfak e Boostl l _Rod _ A Dl711 36011 Braka TutM Ur11on Nut 10x 2Wr nc A Dlt06o301110 Mou dil g c 111812 10 Ooor notS t c Bolt Wrench Set 1182 21 Ahe n IIOf 8Mwlnt B v e tlfto _ e B 0 U0 6301 0 Allt l net Pulley S t N1 1t Wrench S t B 3 0914l azl Wirlnrg C t FI lmptet Qn B ...

Page 805: ...ECIAL SERVICE TOOLS Cont d Soc tion Chmification Part Name 1 _ r _ _ 0 0 0 w g w IJ IJ 1 0 Part No Illustration IIM2 30050 G irint A EFI _ B 01111 GIOll Sptil lfT A1 n TooU A c _ ButU f R rl B 0115Nt030 A1tKtii Mnl B __ A ll llt2 G41013 Pr wr Geuve A ...

Page 806: ...AUTOMATIC TRANSMISSION HYDRAULIC CIRCUIT ...

Page 807: ...1 u a u u D 2 J z u a ...

Page 808: ...0 3 l l 1I l t I u a u a l i DO w es Iii a IL w z w P ...

Page 809: ... 0 Q g 0 a 0 a t w 0 z 0 0 w w z w t oa ctfl I l i i l i I d J l i DO ...

Page 810: ...1 1 1 1 0 g _ 0 a J a w 1 c a X w 1 z w p 0 5 J 1 ...

Page 811: ...0 6 0 CL 110 8 _ 1 0 a J I S I u 1 I fi J I l i DO h 98 J 1 I S I ...

Page 812: ...D 7 1 J J J I I J a a 1 1 0 0 Cl ea 1 a u w Cl z w l N ...

Page 813: ...0 8 u u 0 a l g 1 l 0 a 0 a t w 0 z 8 w I w z w t oa M c tr i J 6 ...

Page 814: ... a t w w z w t ca ct 0 9 ...

Page 815: ... Lock up OFF LOCK UP CIRCUIT From 1 2 Shift Valve Solenoid No 3 ON lock uP Control Valve From 1 2 Vafve Solenoid No 3 OFF From Primary Regulator Valve From Oil Pump f Ock up Control Valve From Primary Regulator Valve ...

Page 816: ...ELECTRICAL WIRING DIAGRAMS E 1 ...

Page 817: ...iuon a with H ttl Qoirtllt Lighter 5 1 Surting Clock 5 1 Stop Llghu 3 4 Comblnttion Met 2 6 Sun Roof 3 2 Crvitt Controt 3 3 Talllithtl tnd llum Mdonfiliiiiil4 2 5 3 TCCS ECT IE octronie Conuol IJ01ill e Tr n MiSiion Theft C ttt ttnt Sy 11m S 5 Fog LlghtJ Q2 1 Trip Computer Front Wiper tnd W her 3 6 Tum S Qntl tnd H111td iil J s HNdU ghu O l D Untock end SNt Btlt Wtrnlng HNdl ifht Ot ontt fJ u u lr...

Page 818: ...ECTRICAL W IRING DIAGRAM 1986 Model 1 to Page s 1 I I 2 A 8 D r l w t ni I l if i lo d J I 1 1 1 1 11I N CO lo m Ia w l I v h J l l r l J r IIlli IJATTtJIY Ll I 0 IGH1TUt L STAR I t 0 r I i a 0 I 0 w w Jf g 8 u t t L ...

Page 819: ... j n s M f_l bt c MJrVII t CCINfrro CfOII 1 J I p 0 I 5 IIII M VICI lCTOfl I 0 IJ o OflllMltfiJI 0 u 1 i a i g REMTOfl i nr OltCMICIC i Ol liNIIf C1 OR e I i G z J I icii OINl I 1 _ _ i i i i i w Oiw uutc 1 0111 _______ I t c M J t b c d f I ...

Page 820: ...t IV r IN ICAT _ y J flllf IJ t I IGRY N I v 1 I I IIC IIAI VC r y Of Q4ol Y O I Of U 1 J 0 0 0tl ll A 5 y v y 11 OIII V I 01Ul 1 u J w i t c otO ol ea J l I G 3 flo IIOltU POIRION b s flfAttJit TtiUWOI tN 0R I I a ftJ 101 111010 J _ r Cit N 1 MI MITlfiJ I ...

Page 821: ...1 7 8 D I t r _ OAUQ f m r GAW C2 S r l l _ MiKKf I l l l ll 2 ii i 1 I f i i I J l 2 i t I ...

Page 822: ...2 CELICA SUPRA Cont d A 8 j t t a l i 8 e n I i i 2 i 1 1 l lj u 8 i i I IeDt t l l 2 AI r L HEAT Vt I M 0 h l Ia Ia u I I AJe AW l l f i A lr Sl l 4 iL t b io lt I CC tllilloo ...

Page 823: ...Air ConditiOMr Cooler lind Ht ter 3 r i i 5 I i f 0 L c 1 B I M SftWO 5 l 1 f __ 0 I H V G s l I l ilt a l 4 v L E OI A1 111 co t Ill ...

Page 824: ...t v J1 IOoP IIIlllmot il lj o l_ _ ut I niUllHOlft IL t li II W WO U N J lA WAT OII T W L NtNtl fUI O IVt W V J _ wA w C t f 1 J I 0 It t r l v e uu1M i r 1 J i tccstcv I I 0 f f E OILHltalllll SiW v l 8AA Cl wou vn J t j r f AAtC O IJt t la W l r i CI IAIIQt ce tt L L c ow o 1 1 ...

Page 825: ... ea Wind wOefogoo I 8 w hI f I l I I ...

Page 826: ...et Windows I I I A B D f f G II I F w H _ 04VOI liM _ i v 0 f IWt H W llAV n a l H OIW R I OIJIII Ultfl 1 W 2 I I 6 61 s J 5 H J I L h 6 I I 0 J L D L D I P Wf Ill WINOOW loiOlOfl b d I Goo ofiiiiiii Oinl Q 011 pi I b wodlf 1 ...

Page 827: ...uhe Control I S Ughts I 3 4 I I II iu l f 0 I I r 1 1 U i l f r l CIIIUI 4 C IN T I C OMf U I Cfl 1 lou _ _ t w Nibil8ICWrUol F t a t i I I i II g I l l I j I l 1 l r l Dl trih r t l j iii f i Hl f 1 J l J t i ...

Page 828: ... I I I I IJ I r i Ui tq f 5 tUIIMs GNALANCI HAIA IIW ICOMe StWl _ t t I I TS TL Ttl t J Hom I I dJID _ l r I 6 I t ...

Page 829: ...d Washer I 7 I 8 A 8 D F D 3 J l I l I J u e J J i M J 0 I J Holo Mitlt SiW RUM WIN A NOWA5t48RSoW 1 w c 8 1 0 Io 1 o I k lok lo O 1 J J k 9 t J J J 1 0 j i 1 0 9 i rl JI J 1 g J l liM I o 0 t Wlf l ltMOtO i WIPf_Rf IOl Ofl t b d J I I I ...

Page 830: ...HI NT MAII A I IM t W O W G li 0 r Cl f 1 11114 OEJ OOCf ft SJW c HEATEROOHl flO c f IIO T SlOt _lb tlll M c w 1 lo I ICIHCI V Tt 11114 a G t W ri U IIAS l l tl L t 0 6 W O _ l l l Tt l lol CO oll r lll il o w a tO tl I ftEA 10 11tlf 8 11M Q J IU A FI lll e MAJII l lt I H l To Q tiU11M eo l24t l ...

Page 831: ... 3 4 D 8 I 3 3 I 3 3 I t t l l R I 1 o u _ 1 1 1 1 0 i ...

Page 832: ...01 i IH t U 4U ToOltx CO 1 11 To The o t U c li Ut 2 I 2 r 3 r r t l l 0 3 l D 0 s z c D 0 li o 0 0 CD z D D s i z zl 0 I 2 r I v i o i l z l l AOf OUTllfi AY AT _l I w J 2 2 rn1 2 j I J A W W I I J _ 1 lfllt 2 J f t OOOACOURlESY SI N ...

Page 833: ...I t I 7 e F f Al II I c i c c I 8 eeMt tiCVJ I I b I j ...

Page 834: ... CELICA SUPRA Cont d Auto AntiMO 5iii__T 1 2 G 4 lc A4 1 1 g u J I s 1 e hl J L j L __ l Tl lv 1 l l 4 1 IO ITLlf I __ _ b _ _ __ d M ...

Page 835: ... e 0 v I 0 I l 0 I e I I f o w s w O I 4 1 I J I I a 1 I l I ...

Page 836: ...4 i pt J Et AV t I c 0 YW i a b h t 2 I f i II 1 J I 1 1 y I t l TH4 YOltUII It HT CCIIoWVTll l i I 33 l 8 It 1 I 1 J b d 5 ...

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