Mazda 323 Protege Скачать руководство пользователя страница 1

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Содержание 323 Protege

Страница 1: ...IV i I...

Страница 2: ...O 89F Vol I Europe 1204 I O 89F vol I Australia I ZM 1 o 89F vol 2 Ali information in this supplement was the latest available at the time of printing all alter nations related to modifications wili b...

Страница 3: ...VEHICLE IDENTlFlCATlUN NUMBERS VIN Europe JMZ BG8262 00 1000Uf JMZ BG8362 00 IUOOOl JMZ BG82F2 00 lOOOOl JMZ BG83F2 00 IOU001 JMZ BG83H2 00 100001 Australia JMO BGI WI 00 IO0001...

Страница 4: ...5 PREPARATION OF TOOLS AND MEASURING EQUIPMENT GI 5 SPECIAL TOOLS Gt 5 REMOVAL OF PARTS GI 5 DISASSEMBLY Gi 5 REASSEMBLY Gl 6 ADJUSTMENTS GC 7 RUBBER PARTS AND TUBING Gl 7 JACK AN5 SAFETY STAN5 POSIT...

Страница 5: ...y will be jeopardized by the use of incorrect methods or toots POSSIBLE LOSS OF WARRANTY The manufacturer s warranty on Mazda vehicles and engines can be voided if improper service or repairs are perf...

Страница 6: ...rques and symbols for oil grease and sealant are shown in the overview iItustration 3 Pages related to service procedures are shown under the illustration Refer to this information when ser vicing the...

Страница 7: ...eeded this is shown in the illustration NOTES CAUTIONS AND WARNINGS As you read through the procedures you will come across NOTES CAUTIONS and WARNINGS Each one is there for a specific purpose NOTES g...

Страница 8: ...and measuring equipment are available before starting any work SPECIAL TOOLS Use special toots when they are required REMOVAL OF PARTS White correcting a problem try also to determine its cause Begin...

Страница 9: ...and thoroughly cleaned in the appropriate method REASSEMBLY Standard values such as torques and certain adjustments must be strictly observed in the reassembly of all parts Refer to STANDARD BOLT AND...

Страница 10: ...DAMENTAL PROCEDURES GI I ADJUSTMENTS Use suitable gauges and or testers when making adjustments I 67UOGX 002 RUBBER PARTS AND TUBING Prevent gasoline or oil from getting on rubber parts or tubing 5 Gl...

Страница 11: ...ber Safety stand positions On both sides of the body frame REAR END Jack position At the center of the rear crossmember Safety stand positions On both sides of the body frame At the rear dtierential 4...

Страница 12: ...f the ground use wheel dollies With either automatic or manual transaxle 1 Set the ignition switch in the ACC position 2 Place the selector lever or shift lever in N Neutral 3 Release the parking brak...

Страница 13: ...itioner ACC Accessories ATX Automatic transaxte ATDC Afier top dead center ATF Automatic transmission ftuid BAC Bypass air control BBDC Before bottom dead center BTDC Before top dead center CPU Centra...

Страница 14: ...that the antenna and feeder are properly adjusted 4 Do not install a high powered mobile two way radio system r CAUTION GI i CRUISE CONTROL UNIT FEEDER WIRE MOBILE TWO WAY RADlO CONTROt UNlT HARNESS A...

Страница 15: ...tronic com ponents Voltmeter The DC voltmeter is used to measure of circuit voltage A volt meter with a range of 15V or more is used by connecting the positive probe red lead wire to the point where v...

Страница 16: ...f connector Never pull on the wiring harness when disconnecting con nectars Connectors can be removed by pressing or pulling the lock lever as shown Locking of connector When locking connectors make s...

Страница 17: ...wires to check that they are secured in the terminal Replacement of terminals Use the appropriate tools to remove the terminal as shown When installing the terminal be sure to insert it until it lock...

Страница 18: ...erminal i fore replacing a main fuse A 3 When replacing a pullout fuse use the in the fuse box cover disconnected be use puller supplied Wiring Harness Wiring color codes Two color wires are indicated...

Страница 19: ......

Страница 20: ...PRE DELIVERY INSPECTION AND SCHEDULED MAINTENANCE SERVICES PRE DELIVERY INSPECTION TA8LE a A 2 SCflEDULED MAiNTENANCE SERVICES Australia l l l A 3 SCHEDULED MAINTENANCE SERVICES Europe l A 5 93GOAX 7...

Страница 21: ...swrtch and steering lock III Power window if equipped 0 Door locks including child proof door locks 0 Inhibitor switch ATX only Z All lights including warning and indicator lights 0 Ignrtron key remin...

Страница 22: ...on c Driving for a prolonged period iti coid temperatures or driving only short distances regularly Replacement of the timing belt is required at every 105 000 km failure to replace the timing belt ma...

Страница 23: ...1 I I I I I I I f Evaporative emission control system Evaporative system Throttle sensor Exhaust emission contra system Dashpot Except for ATX I 1 I 1 1 I 1 1 t 1 1 1 1 1 1 1 I 1 Electrical system Ba...

Страница 24: ...the following conditions it is suggested that the engine oil and oil filter be changed more often than the recommended intervals a Driving in dusty conditions b Extended periods of idling or low speed...

Страница 25: ...1 A 1 A I A A A A I R I R R I R I 1 I t I 1 I Ignition system Initial ignition timing Spark plugs I t I I 1 I 1 I A A A A Evaporative emission control system Electrical system Ejattery electrolyte lev...

Страница 26: ...aintenance Kilometers 1 000 10 000 20 000 30 000 40 000 50 000 60 000 70 000 80 000 Miles 600 6 000 12 000 1 18 000 24 000 30 000 36 000 42 000 48 000 Chassis and body Cont d TIES lnctud ng spare tire...

Страница 27: ...of the following conditions it is suggested that the engine oil and oil filter be changed more often than the commended intervals a Driving in dusty conditions b Extended periods of idling or low spee...

Страница 28: ...R fuel 11 s and hoses 1 t 1 I I I I Ignition system lrritiai ignition timing Spark plugs Spark plugs Only for Sweden 1 I I I 1 I I 1 I I 1 I A 1 A A 1 A Adjust every 30 000 km 18 000 mils Evaporative...

Страница 29: ...sis and body Cont d Steerrng and front suspension I I 1 1 I I MTX oil A A A R A A A R Rear axle oil R A A R 1 A A A R Trabsfercarrter oil I R I A A R A A A R B s nuts on chassis and body T 1 1 T T T I...

Страница 30: ...FEATURES 1 OUTLINE Bf 3 OUTLINE OF CONSTRUCTION BI 3 SPECIFICATIONS Bf 3 lNTERGHANGEABILtP Bl 4 FLYWHEEL Bl 5 SUPPLEMENTAL SERVICE INFORMATION Bl 6 REMOVAL l I Bf 6 PROCEDURE I Bl 6 INSTALLATION I I B...

Страница 31: ...N 30 kg 22 lb mm in DRIVE BELT NEW USED AlTERNATOR 8 0 9 0 0 31 0 35 9 0 l 0 0 0 35 0 39 PIS P S AIC 1 8 0 9 O 0 31 O 35 9 0 I 0 0 0 35 0 39 ENGINE COMPRESSION STANDARD MlNlMUM kPa kglcm2 psi rpm BP...

Страница 32: ...fc Europe us 83 1 Without catalyst Gasoline 4 cvcle Cyirnder arrangement and number Combustron chamber Valve svstem In line 4 cylinders Pentroof OI IC belt driven Fi rtng order TEN terminal of diagnos...

Страница 33: ...earing 0 Thrust bearing c Connecting rod and cap 0 1 Connecting rod bearing 0 Crankshaft Piston 0 related Piston pm cl PMon ring 0 1 Crankshaft pulley 0 Rear cover 0 Flywheel X Shape different Flywhee...

Страница 34: ...OUTLINE Bl FLYWHEEL 4WD MODEL 2WD MODEL The flywheel is shaped differently to accommodate the redesigned clutch disc and cbtch cover Bl 5...

Страница 35: ...rring to Removal Note Step 1 t I ATX ONLY 1 93GOBl 706 1 Undercovers 2 Side covers 3 Resonance chamber and air cleaner assembly 4 Battery bracket cover and bafiery 5 Battery carrier and battery duct 6...

Страница 36: ...ion l Do not damage the hoses 1 Remove the AC compressor with the hoses still connected 2 Position the compressor away from the engine and secure it with wire Step 2 1 Disconnect the harness connector...

Страница 37: ...Removal Note I below Removal note Fuel hose Warning l Keep sparks and open flame away from the fuel area Caution l Cover the hose with a rag because fuel will spray out when disconnecting l Plug the...

Страница 38: ...93GOBl 708 6 Tie rod end Removal Note I below 7 Driveshaft Removal Note _ page 61 l 0 8 Propeller shaft Removal Note _ _ _ page L 5 Removal note Tie rod end 1 Remove the cotter pin and loosen the nut...

Страница 39: ...4 2 Remove the lower arm ball joint clinch bolt Caution l Do not damage the ball joint dust boot 3 Pry the lower arm downward to separate it from the knuckle 4 93G031 722 Caution l Do nut damage the o...

Страница 40: ...Water inlet pipe and gasket 7 Dynamic damper 4 Engine mount member 8 No 3 engine mount rubber Removal Note _ below 9 No 4 engine mount rubber and bracket 5 No 2 engine mount rubber and bracket f 0 En...

Страница 41: ...engine mount member Clutch release cylinder MTX f Remove the release cylinder pipe bracket from the transaxle 2 Position the release cylinder with the hose connected away from the transaxle for easie...

Страница 42: ...the figure MTX ATX 43GX3i 71 1 _ Intake manifold bracket 5 Air hose ECE without catalyst only 2 Center differential lock motor 6 Torque converter nuts TX Removal Note _ _ _ _ page 33 l 23 7 Transaxle...

Страница 43: ...ll bolts and nuts to the specified torques Step I 1 Join the engine and transaxle Toraue Snecifications 1 r MTX 37 52 3 8 5 3 27 38 37 52 3 8 5 3 27 38 ATX 64 89 6 S 9 1 4746 Nm m kg ft lb 37 52 3 8 5...

Страница 44: ...ations I Ii74 103 7 5 10 5 54 76 7 8 I N m 80 flO cm kg 69 95 in lb 55 80 5 fG 8 2 41 59 43 61 4 4 6 2 32 45 I 1 I 64 89 6 5 9 1 4746 67 93 6 8 9 5 49 69 7 37 5x 27 38 Engine and transaxle assembly Ca...

Страница 45: ...ening torque 16 23 Nm 1 6 2 3 m kg 12 47 ft lb 6 9 9 8 N m 70 100 cm kg 61 87 Mb I 93GOBl 72 J I 93GOBi 713 4 Install the No 2 engine mount rubber and bracket assembly Tightening torque 37 52 Nm 3 8 5...

Страница 46: ...ighten the No 3 engine mount nuts 0 Tightening torque 74 103 Nom 7 5 f0 5 m kg 54 76 ft lb Ii Tighten nut Tightening torque 67 93 N m 6 8 9 5 m kg 49 69 ft lb 12 Install the dynamic damper Tightening...

Страница 47: ...cIip 2 Install the driveshaft along with a new clip 3 fnstall the lower arm ball joint to the knuckle and tighten the ciinch bolt Tightening torque 43 59 Nm 4 4 6 0 m kg 31 43 ft lb 4 Install the join...

Страница 48: ...7 m kg 23 34 f lb 4 Tighten bracket nuts Tightening torque 21 27 Mm 2 1 2 8 m kg 15 20 ft Ib Select and shift cables MTX 7_ Install the select cable and the spring pin 2 Install the shift cable and t...

Страница 49: ...it Step 5 1 Connect the harness connectors shown in the figure OIL PRESSURE SWITCH Df STRlBUTdR OXYGEN SENSOR EXCEPT ECE WITHOUT CATALYST lVFFFRFh TIAI I I 4 m m I r h LOCK SENSOR DIFFERENTIAL THRO77L...

Страница 50: ...8 71 N m 80 l 10 cm k 19 25 1 9 2 6 14 5 1 1 9 69 79 9 3 N m 65 95 cm kg 56 82 h lb 79 7 8 11 N m 80 1 0 cm kg 69 95 in lb a3uar3x 839 Crossmember 1 tnstali the crossmember Tightening torque 93 107 Nm...

Страница 51: ...witch connector 4 Connect the A C cut switch connector 5 Connect the oil cooler hose ATX 6 Connect the coolant reservoir hose 7 Connect the upper and lower radiator TX Pm hoses Caution l Position the...

Страница 52: ...ter installation 1 If the engine oil was drained refill with the specified amount and type of engine oil 2 Fill the radiator with the specified amount and type of engine coolant 3 Fill the transaxle w...

Страница 53: ......

Страница 54: ...EAD BZ 6 CYLINDER BLOCK AND OIL PAN BZ 7 PISTON BZ 8 FtYWtiEEL BZ 9 CAMSHAFT BZ 10 SUPPLEMENTAL SERVICE INFORMATION BZ 11 COMPRESSION 82 I 1 INSPECTION B2 11 REMOVAL BZ 12 PROCEDURE BZ 12 ENGINE STAND...

Страница 55: ...4 300 EXHAUST MANlFOt TIGHTENING TORQUE DEFLECTION AT 98 N IO kg 22 Ib mm in DRIVE BELT 1 NEW USED ALTERNATOR 1 8 0 9 0 0 31 U 35 9 0 I 0 0 0 35 U 39 P S P S AIC 8 U 9 0 O 31 0 35 9 0 10 0 0 35 0 39 3...

Страница 56: ......

Страница 57: ...e Compression ratio cc cu In 1 839 112 2 mm in 83 0 x 85 0 3 27 x 3 35 8 2 Compression pressure kfa kg cm psi rpm 1 059 10 8 X4 300 I Vatve timing I Open i3TDC 2 IN Close ABDC 51 EX Open BBDC 59 Close...

Страница 58: ...cl Crankshaft 3 Main bearing 0 Thrust bearing 0 Connecting rod and cap 0 Connecting rod bearing I 0 Crankshaft Prston Shape different related Piston pin c Pistonring cl Crankshaft pulley 0 Rear cover...

Страница 59: ...NON TURBO BP05 The cylinder head for the BP DOHC Turbo engine is the same as for the BP DO Non Turbo engine ex cept that the intake ports are shaped differently The identification mark is cast at the...

Страница 60: ...DER BLOCK BLIND PLUG OIL RtiURN PIPE 1 93GCB2 7C The cylinder block is no different But in conjunction with the newly provided turbocharger the coolant and Mxication oil passages on the cylinder block...

Страница 61: ...B2 OUTLINE PISTON BP TURBO V J I BP NON TURBO Because of the addition of the turbocharger the piston crown recess is increased to lower the compression ratio B2 8...

Страница 62: ...OUTLfNE 82 BP NON TURBO The flywheel is shaped differently to accommodate the redesigned clutch disc and clutch cuver 82 9...

Страница 63: ...E CAMSHAFT IDENTlFlCA lON MARK EXHAUST IDENTlFlCATlON MARK INTAKE IN EX BP TURBO BP26 8P26 BP NON TURBO BP05 BP06 TDC EXHAUST OPEN The camshaft valve timing specifications are different to improve eng...

Страница 64: ...compression gauge to the No 7 spark plug hole 7 Fully depress the accelerator pedal and crank the engine 8 Record the maximum gauge reading 9 Check each cylinder in the same manner Compression 1 059...

Страница 65: ...Battery bracket 5 Battery cover 6 Battery 7 Battery carrier 8 Accelerator cable 9 Radiator hoses 10 Coolant reservoir hose f I Cooling fan connector 12 Radiator switch connector 13 Radiator bracket 14...

Страница 66: ...intercooler and air pipe downward RemovaI note P S oil pump Caution l Do not damage the hoses I _Remove the P S oil pump with the hoses still connected 2 Position the pump away from the engine and se...

Страница 67: ...harness connectors shown in the fiuure ALTERNATOR OIL PRESSURE SWITCH PRESSURE REGULATOR STARTER CObjTROL VAVLE E SPEED CONTROL CTOR KNOCK SENSOR SWITCH 03 w08X 80 Step 3 I Disconnect the hoses shown...

Страница 68: ...leakage 1 Disconnect the fuel hoses Heater hose Caution l Do not lose the heater hose joint O rings and spacer when removed 1 Depress the heater hose retainer and remove the heater hose GASKET REP OT...

Страница 69: ...the cotter pin 2 Separate the ball joint from the knuckle arm with the SST Driveshaft 1 Remove the joint shaft 2 Remove the lower arm bali joint clinch bolt Caution l Do not damage the ball joint dus...

Страница 70: ...rubber and bracket 2 No 2 engine mount rubber and bracket 7 Alternator and drive belt 3 Clutch release cylinder 8 Intercooler brat kets Removal Note _ _ _ _ _ __ page B2 18 9 Engine and transaxle asse...

Страница 71: ...nd nuts and the engine mount mem her Clutch release cylinder I Remove the release cylinder pipe bracket from the transaxle 2 Position the release cylinder with the hose connected away from the transax...

Страница 72: ...REMOVAL B2 Step 6 SeDarate the engine and transaxle in the order shown in the figure 1 Intake manifold bracket 3 Transaxie mounting bolts 2 Starter and bracket 4 Transaxle 93GOB2 7 B2 19...

Страница 73: ...UNTING PROCEDURE 1 Remove in the order shown ir the figure 1 Exhaust manifold insulator 2 Exhaust manifold and turbocharger assembly 4 Water bypass pipe 5 A C compressor bracket 3 Exhaust manifold gas...

Страница 74: ...engine 3 Install the parts shown in the figure 4 Tighten the parts to the specified torques Torque Specifications f n m kg ft lb 93GOB2 75 Water Inlet Pipe 1 Remove ail foreign material from the wate...

Страница 75: ...nifold and Turbocharger Assembly I Remove all foreign material from the exhaust manifold con tact surfaces 2 Install a new gasket 3 Instatl the exhaust manifold and turbocharger assembly Tightening to...

Страница 76: ...INSTALLATION B2 PROCEDURE 1 Tighten a b s and nuts to the specified torques Step 1 I Connect the engine and transaxie Torque Specifications 38 M 89 6 5L9 l 47 66...

Страница 77: ...ons 19 S 1 9 2 6 14 l 9 55 99 5 6 8 2 41 59 I 74 2 03 7 5 10 5 54 76 6 9 9 8 N m 16 23 T 6 2 3 12 17 19 26 1 9 2 6 14 l 9 9 6 5 9 1 4766 64 89 6 9 47 56 Engine and transaxle assembly Caution l Do not...

Страница 78: ...der and engine mount member 1 Install the No 3 engine mount rubber and loosely tighten the bott and nuts 2 Install the No 4 engine mount rubber and bracket assem bly and loosely tighten the bolts and...

Страница 79: ...the order shown Tightening torque 43 61 Nom 4 4 6 2 m kg 32 43 ft lb 9 Tighten nuts Tightening torque 67 93 N m 6 8 9 5 m kg 49 69 f b 03UOBX 828 IO Tighten the No 3 engine mount nuts 93G052 731 93GOB...

Страница 80: ...to page L 5 93GOB2 734 Drive aft I Apply grease to the end of the driveshaft Caution l When installing the driveshaft be careful not to damage the transaxle oil seal l After installation pull the fron...

Страница 81: ...pin StabiIiter I Install and adjust the stabilizer Dimension A 17 19mm 0 67 0 75 in Tightening torque f 6 23 Nm I 6 2 3 m kg 12 17 ft lb Exhaust pipe I InstaIl the exhaust pipe along with a new gaske...

Страница 82: ...Connect the hoses shown in the figure Speedometer cable I_ Connect the speedometer cable Caution l Position the hose clamp in the original location on the hose and squeeze it lightly with large plier...

Страница 83: ...CH PRESSURE REGULATOR STARTER CONTROL VAVLE GRoYD O i l tE SENSOR IDLE SPEED CONTROL KNOCK SENSOR OXYGEhENSO Step 6 Torque Specifications 03UO8X 33 7 8 11 N m 80 110 cm kg 69 11 N m 80 f IO cm kg 69 9...

Страница 84: ...que 37 52 Nm 3 8 5 3 m kg 27 38 ft lb Drive belt I Install the P S and or A C drive belt 2 Adjust the drive belt deflections Refer to page 82 2 Air pipe 1 Install a new gasket and install the air pipe...

Страница 85: ...ve assembly 1 Connect the air pipe to the turbocharger and securely tight en the hose clamp 2 Install and tighten the bolt Tightening torque 7 8 l 1 Nom 80 I 10 cm kg 69 95 in ib 3 Connect air hose an...

Страница 86: ...y carrier Tightening torque 7 8 l 1 N4m 80 I IO cm kg 69 95 in lb 2 Install the battery and the battery cover 3 Install the battery bracket Tightening torque 2 9 5 9 N m 30 60 cm kg 26 52 in lb 4 Conn...

Страница 87: ...lant 3 Fill the transaxie with the specified amount and type of transaxle oil Refer to page J3 36 4 Connect the negative battery cable 5 Start the engine and check the following I Engine oiI transaxle...

Страница 88: ...D LUBRICATION SYSTEM OUTLiNE D 2 OUTUNE OF CONSTRUCTION D 2 LUBRICATION CIRCUIT D 2 93GODX 703...

Страница 89: ...tem of the 323 4WD engine is the same as for the 2WD model The Bf DOHC turbocharged engine oil circulation path is different than that of the BP DOtiC non turbocharged engine because of the turbocharg...

Страница 90: ...E 7 ELECTRIC COOLING FAN SYSTEM E 8 SUPPLEMENTAL SERVICE INFORMATION E 9 THERMOSTAT E 9 INSPECTION E 9 ELECTRIC COOLING FAN SYSTEM E l 0 SYSTEM INSPECTlON E l 0 FAN MOTOR E If iNSPECTION E l 1 WATER...

Страница 91: ...E tNDEX INDEX ANT RESERVOlR ENGiNE COOLANT TOTAL CAPACITY MTX 5 0 liters 5 3 US qt 4 4 Imp qt ATX 6 0 liters 6 3 US qt 5 3 tmp qt 1 Fan motor Inspection _ _ _ page E 1 I E Z...

Страница 92: ...thermoswitch Inspection page E 9 inspection page E l 1 2 Electric cooling fan system 5 Radiator thermoswitch System inspection page E l 0 Removal I Inspection I 3 Fan motor Instailation page E 1 2 In...

Страница 93: ...the coolant circulation path has been changed to direct coolant to the water cooied turbocharger A two stage thermostat is used in the BP DUHC turbocharged engine to stabilize the engine coolant tem p...

Страница 94: ...5 89 5 188 l 93 Main 86 5 89 5 lSS 193 The mosta 1 Sub 83 5 86 5 182 188 Sub 83 G86 5 182 188 1 Full open temperature OC OF 95 203 100 212 i 100 212 L I Except cold area 2 Cotd area only 1 r 1 93GOEX...

Страница 95: ...tabilize the coolant temperature in the engine to improve cold weather performance and to reduce heater output temperature fluctuations as noted in the diagram Operation Stage 1 During cold weather op...

Страница 96: ...m in Hetght 390 t Depth 16 25 e Fm pnch mm in 1 3 t c Heat dissipaton capacity kcallh 38 800 43 800 C Type Double tube Transaxle oil cooler Heat dissipation capacity kcal h I 1 650 Cooling fan Number...

Страница 97: ...nnects the 2 and 2 terminals of the fan motor connector The fan mo tor turns at high speed about 2 200 rpm 3 if the vehicle is equipped with air conditioning the cooling fan motor operates whenever th...

Страница 98: ...moswitch BP DOHC Turbo only l tnspection Radiator thermoswitch BP DOHC Turbo only l Removal I Inspection I Installation Fan relay BP DOHC Turbo only l Removal Inspection 93GOEX 710 THERMOSTAT BP DOHC...

Страница 99: ...TION 1 Jump across the test fan TFA terminal and the ground GN D terminal of the diagnosis connector 2 Turn the ignition switch ON and verify that the fan operates If the fan does not operate inspect...

Страница 100: ...ttery and an ammeter to the fan motor con nectors for low speed inspection 4 Verify that the fan motor operates smoothly at the standard cu vent Current A 8 8 10 max 5 Connect the battery an ammeter a...

Страница 101: ...hermoswitch Inspection a I below Installation Note _ _ below 1NSPECTlON 1 Place the switch and a thermometer in engine oil Warning l Do not heat the engine oil above 12O C 248OF 2 Heat the engine oil...

Страница 102: ...cable 2 Remove the fan relay No 2 FAN REUY w TYPE 1 AND TYPE 2 INSPECTDN f Check continuity as shown with an ohmmeter I Terminal COMlLJlty A C No B D Yes 2 Apply 12V between terminals B and D Check fo...

Страница 103: ......

Страница 104: ...FUEL SYSTEM Fl 6 OUTLINE Fl 6 FUEL TANK AND TRANSFER PUMP Fl 7 1 SERVICE j SUPPLEMENTAL SERVICE INFORMATION Fl 9 FUEL SYSTEM I Fl 9 PRECAUTION I Fl 9 FUEL TANK I I Fl ICI TRANSFER PUMP CONTROL SYSTEM...

Страница 105: ...__ _ __ _ page Fl 12 Replacement _ _ _ _ _ ___ _ _ _ _ page Fl 12 3 Transfer pump switch Removal lnstaltation _ page Fl 13 inspection _ _ _ _ page F1 I 3 93GOFl 702 4 Transfer pump inspection _ _ _ pa...

Страница 106: ...2WD 1 BP SOHC 4WD Remark Transfer pump 0 Due to installation of propeller shaft Variable Inertra charging system 0 Two group fuel qectron Due to change of engine G slgnal Drstnbutor 0 I Due to abolis...

Страница 107: ...ONANCE CHAMBER SOLENOID VALVE PRESSURE REGULATOR CONTROL FUEL FILTER HIGH PRESSURE SIDE P j Ne S GtiAL El DlSTRlfjUTOR IDLE UP SOLENOID VALVE TO ENGINE CONTROL UNIT CHECKVALVE TWO WAY FUEL VAPOR VALVE...

Страница 108: ...ER REGULATOR SWITCH SWITCH SWITCH CONTROL lNJECTOR ELECTRICAL MAIN RELAY FAN AX SWITCH r DliiGNOSlS BLOWER Ivc CONNECTOR SWITCH RELAY ECU AIRFLOW METER Tt WATE THERMOSENSOR CLUTCH t I NEUTRAL SWITCH S...

Страница 109: ...R PUMP i WEL PUMP 1 FILTEF FUEL TANK 4x4 CONTROL UNIT FUEL PUMP CONTROL UNIT The fuel system consists of the fuel tank the transfer pump the fuel pump the fuel filters the pressure regu lator the deli...

Страница 110: ...the propeller shaft for the 4 wheel drive system A transfer pump is used to pump the fuel from the I to the right fuel pump side The transfer pump is installed in the fuel tank and is controlled by t...

Страница 111: ...nsfer pump switch is OFF and the transistor within the fuel pump control unit is ON As a result current flows to the coil the switch is switched ON and the transfer pump is activated No fuel in left t...

Страница 112: ...rom the fuel system to reduce the possibility of injury or fire 1 Start the engine 2 Push the rear seat cushion buttons and remove the cushion 3 Disconnect the fuel pump connector 4 After the engine s...

Страница 113: ...keep sparks cigarettes and open flames away from it l Before repairing the fuel tank clean it throughly with steam to remove all explosive gas 1 Remove in the order shown in the figure 2 Inspect the f...

Страница 114: ...o the fuel tank fittings at least 25mm 1 0 in 2 Push the fuel filler hose onto the fuel tank pipe and filler pipe at ieast 35mm 1 4 in TRANSFER PUMP CONTROL SYSTEM SYSTEM OPERATION 1 Turn the ignition...

Страница 115: ...rol unit terminal N is ov 3 Remove the jumper wire and verify that the voltage at the 4x4 control unit terminal N is approx WV after approx 10 sec 4 If not as specified replace 4x4 control unit No con...

Страница 116: ...position Contrnuity UD NO I Down I YES I 2 If not as specified replace the transfer pump switch TRANSFER PUMP Inspection f Remove the rear seat cushion 2 Disconnect the transfer pump connector 3 Check...

Страница 117: ...ber 6 Install in the reverse order of removal 03UOFX 626 Disassembly Assembly Caution l Prevent contaminants from entering the transfer pump I Disassemble in the order shown in the figure 2 Assemble i...

Страница 118: ...l I I GASKET REPLACE f GASKET REPLACE 7 l N m 80 l 10 cm kg 69 95 in lb I 4 1 5 6 3041 Nm m kg ft lb 1 Main silencer Inspect for deterioration and restriction 2 MiddIe pipe assembly Inspect for deteri...

Страница 119: ......

Страница 120: ...TURBO F2 23 PRESSURE REGULATOR CONTROL SYSTEM BP TURBO F2 23 A C CUT OFF SYSTEM ATX F2 24 SUPPLEMENTAL SERVICE INFORMATION F2 25 SELF DIAGNOSIS FUNCTION F2 26 OUTLINE F2 26 MALFUNCTION CODE NUMBERS F...

Страница 121: ...URBU Remark INTAKE AG 1 Resonance duct 0 0 0 SYSTEM Resonance chamber 0 0 G VICS ui Turbocharger 0 Refer to page FZ 12 Intercooler 0 Refer to page FZ 14 Air bypass valve 0 Refer to page F2 14 FUEL SYS...

Страница 122: ...URBO System operation _ _ _ page F2 56 Inspection page F2 56 4 Fuel pump control unit BP TURBO Inspection I page F2 53 Replacement page F2 53 5 Transfer pump switch Removal I InstaNation page F2 54 In...

Страница 123: ...O WAY 1 1 II d KNO II II II II VALVE VALVE THERMOSENSOR c I 31c SENSOR 1 k k FUEL FILTER TRANSFER PUMP WASTEGATE 7 II t I III TURtiOCHARGERI I SOLENOID I II i 1 WASTFGATF II I AlOCI fuAl RAlz rCD VALV...

Страница 124: ...OUTLINE F2 SYSTEM DIAGRAM BP SOHC 1 J I U a 1 93GOF2 707 m 5...

Страница 125: ...OUTLINE WtRlNG DIAGRAM BP SOHC r 93GOF2 71 FZ 8...

Страница 126: ......

Страница 127: ...DEFROSTER SWITCH HEADLIGHT SWITCH BLOWER SWITCH ELECTRICAL FAN SWITCH BATTERY A THRO77LE SENSOR NEUTRAL IDENTIFICATION CLUTCH SWITCH DIAGNOSIS CONNECTOR TEN TERMINAL INTAKE AIR THERMOSENSOR OUTPUT DEV...

Страница 128: ...ater thermosensor Resistance Airflow meter 1 20 4V 14 6 I 7 8 kf2 2o c 68OF 2 21 2 69 4OOC 104OF 1 0 I 3 8O C 176OF 0 29 0 35 E2 Vs Fully closed 200 600 Fully open 20 l 200 Resistance Ez Vc E THAA 1nt...

Страница 129: ...ake air temperature and to improve engine performance l With addition of the wastegate control system engine torque at higher rpm is increased AIR BYPASS VALVE WASTEGATE SOLENOID VALVE TURBOCHAR ACTUA...

Страница 130: ...OID VALVE OFF VALVE CLOSED ACTUATOR BOOST PRESSURE WASTEGATE SULENOlD VALVE ON VALVE OPEN Operation Engine speed below 5 300 rpm The wastegate solenoid valve is OFF Boost pressure is ap plied directly...

Страница 131: ...take aii The intercooler by cooling this high temperature air substan tially increases the charging air efficiency and engine output as well as supressing ignition knocking by reducing the com bustion...

Страница 132: ...he left to the right fuel pump side The transfer pump is mounted in the fuel tank and is controlled by the transfer pump switch and the fuel pump control unit The fuel pump control system is adopted f...

Страница 133: ...EM BP TURBO Outline l The fuel pump control system supplies electric power to the fuel pump at ail times while the engine is running The fuel pump can thus operate even though the fuel pump switch in...

Страница 134: ...nd the voltage to the fuel pump is reduced to approx WV causing the fuel pump to operate at a reduced speed to im move fuel pump longevity MAIN RELAY Engine under heavy load or cranking The ECU 1I cir...

Страница 135: ...PUMP TRANSFER PUMP SWITCH OFF NO FUEL IN LEFT TANK FUEL PUMP CONTROL UNIT TRiNSFER PUMP TRANSFER PUMP SWITCH UN 93GOF2 727 Operation 1 Whenever the ignition switch is ON and fuel is in the left trans...

Страница 136: ...FUELSYSTEM F2 Transfer Pump Switch 93GOF2 726 The fuel pump switch is a float type ON OFF switch used to operate the transfer pump It is part of the fuel gauge sender unit _...

Страница 137: ...LIGHT SWITCH CLUTCH SWITCH INJECTOR P S PRESSURE SWITCH GEN SE877 DtSTRIBUTOR PUMP CONTROL UNll CONTROL UNIT CONNECTOR P REStSTORlRELAY FUEL tNJ RELAY MAIN RELAY AIRFLOW METER SOLENOID VALVE I NEUTRAL...

Страница 138: ...The driver is thus warned to reduce engine speed DETECTtON OVERBOOST BUZZER TURBOCHARGE INDICATOR BP TURBO When the turbocharger boost pressure calcul ated by intake air amount and engine speed reach...

Страница 139: ...signal is a knocking signal If it is a knocking signal the ignition spark is retarded according to the intensity of the knock to a maximum of 4O Inhibition of spark retardation In order to improve dr...

Страница 140: ...ENOID VALVE PRESSURE REGULATOR CONTROL FUEL FROM DELIVERY PIPE1 II FUEL INJ I RELAY MAIN REU Y I II Ir __ _ VACUUM CT0 DYNAMIC Ill CHAMBER BATTERY c FUEL TO FUEL TANK nme rn a To prevent percolation o...

Страница 141: ...at high temperature condition the water thermoswitch on the radiator is switched OFF above approx II I C 232OF and stops the A C operation ECU NC OPERATION BLOWER FAN WATER THERMOSWITCH IABOVE 111 OC...

Страница 142: ...ss valve BP Turbo l Removal hstallation l 1nspection lntetcoolet BP Turbo l RemovaMnspection tnstaltation Fuel tank l Removal Inspection I Installation Fuel pump control unit BP Tubto 4x4 control unit...

Страница 143: ...S FUNCTION OUTLINE The self diagnostic function and diagnosis procedure are the same as for the 2WD model However there are some additional malfunction codes for BP Turbo models 93GOF2 737 MALFUNCTlON...

Страница 144: ...han one failure present the code numbers will be indicated in numerical or der lowest number first l After repairing a failure turn off the ignition switch disconnect the negative battery cable and de...

Страница 145: ...ntrol unit circuit for poor connectlon ACTtON Yes Repalr or replace connector Check knock control unit terminal voltage with ignition switch ON Check that voltage at ECU terminal 2J is approx 4V at id...

Страница 146: ...uity between fuel pump Yes Check for short or open circuit in wiring res stor relay terminals C W R and D L from main relay FUEL INJ relay to t resistor relay NO Replace resistor relay 93GOF2 74 1 Cir...

Страница 147: ...1 check if battery Yes Repair wiring harness voltage extsts at solenoid valve connector terminal wire NO Go to next step 3 Check if solenoid valve is OK Yes Check for short or open circuit in wiring...

Страница 148: ...C SWITCH 0 0 0 0 NEUTRAt AND CLUTCH SWfTCHES 0 0 0 STOPLIGHT SWITCH 0 0 0 0 0 ATMOSPHERIC PRESSURE SENSOR IN ECU 0 0 THROTTLE SENSOR 0 0 0 0 0 0 INTAKE AfR THERMOSENSOR 0 AlRFLOW METER 0 0 I i 0 OXYG...

Страница 149: ...system TEP INSPECTlON 1 Install pressure gauge in intake air pipe and check boost pressure at engine speed of 4 000 wm CT page F2 45 Boost pressure More than 2 0 kPa 0 02 kglcm2 0 3 psi Air Fuel mixt...

Страница 150: ...maximum pressure If OK check fuel line and filter for clogging 4 If no decrease go to next step NO Low pressure Check fuel irne pressure while pinching fuel return hose 4 If fuel line pressure quickl...

Страница 151: ...F2 II Measure resistance l O l lmm 0 039 0 043 in DAMAGE AND DETERlORATtON Resistance 16 kSI per 1 m 3 28 fi Manual I 203 I U WF turope Or 1204 l O 89F Austraha F2 34...

Страница 152: ...WIND tNG Check fur correct engine compressron Yes Go to next step Engine compression 785 kPa 8 0 kg cm2 1I4 psi 300 rpm L 1 No Check engine condition l Worn p ton piston rings or cylinder wall l Defec...

Страница 153: ...engine compression Atcohol blended fuel used TEP INSPECTION ACTION l Install pressure gauge in intake air pipe and I Yes 1 Go to Step 3 check boost pressure at engine speed of 4 000 rpm w page F2 45 B...

Страница 154: ...iring between ELECT SW A ECU and Self Diagnosis Checker 6 Check if continuity between throttle sensor termi Yes Go to next step nals IDt and E ts as shown 7 Connect System Selector to diagnosis connec...

Страница 155: ...uel pump maxi fuel line and filter for pump and pressure High pressure Check if fuel line is clogged II Measure resistance r _ es DAMAGE AND DETERIORATION Refer to 323 Workshop Manual f1203 1 O 89F Eu...

Страница 156: ...mum 785 kPa 8 0 kg cm It4 psi 300 ipm NO Check engine condition l Worn piston piston rings or cylinder wall l Defective cylinder head gasket l Distorted cylinder head l Improper valve seating Valve st...

Страница 157: ...d Check for cause Refer to specified check sequence 88 flashes Check ECU terminal 1F voltage Vottage Approx 12V Ignition switch ON 0 page FZ 60 4 If OK replace ECU W SELF TEST 4 If not OK check wiring...

Страница 158: ...ir or reptace l Thermostatl l Electric cooling fan l Radiator 5 Try known good ECU and check if condltlon Yes Replace ECU rnproves NO Change fuel to another brand or use higher octane fuel l Refer to...

Страница 159: ...aust gas visible when ventilation 1 hose or PCV hose removed 1 4 Remove turbocharger and check at oil seals of compressor and turbine shafi for oil leakage Yes NO Yes NO Yes No Check hoses for clogged...

Страница 160: ...Remove in the order shown in the figure 2 Inspect all parts and repair or replace as necessary 3 Install in the reverse order of removal referring to Installation Note TURBO I 7 8 11 N m 80 I 1Cl cm...

Страница 161: ...e and air hose 6 Accelerator cable 7 Throttle body 8 ISC valve 9 Air valve IO Dynamic chamber I 1 Intake manifold Installation Note __ _ _ _ _ below 93GOF2 751 93GOF2 75 F2 44 installation Note Intake...

Страница 162: ...Start the engine 4 Verify that the boost pressure when the engine speed is 4 000 rpm is within specification Specification More than 2 0 kPa 0 02 kg cm2 0 3 psi 5 If not within the specification chec...

Страница 163: ...moves when applying and releasing air pressure WASTEGATE SOLENOID VALVE Inspection 1 Remove the solenoid valve 2 Verify that air does nut flow from through 3 Apply IN to the solenoid valve and verify...

Страница 164: ...er materia1 from entering l Use the specified new studs when installing the turbocharger 1 Disconnect the negative battery cable 2 Lift up the vehicle 3 Remove the undercover 4 Drain the engine coolan...

Страница 165: ...Remove all gaskets and sealant 2 Install new gaskets 3 Supply 25 cc 1 5 cu in of oil through the oil passage of the turbocharger 4 Install the turbocharger to the exhaust manifold 5 Install the turboc...

Страница 166: ...pect the intercooler for crack or damage Replace it if necessary 3 Install in the reverse order of removal 19 25 1 9 2 6 80 l 10 cm kg 69 95 in lb cm kg 69 95 in lb 14 1 Air cleaner and airflow meter...

Страница 167: ...switch 5 Recpnnect the fuel pump connector and install the rear seat cushion b Use a rag as protection from fuel spray when disconnect ing the hoses Plug the hoses after removal c When inspecting the...

Страница 168: ...fuel tank keep sparks cigarettes and open flames away from it l Before repairing the fuel tank clean it throughly with steam to remove all explosive gas 1 Remove in the order shown in the figure 2 In...

Страница 169: ...2 Push the fuel filler hose onto the fuel tank pipe and filler pipe at least 35mm 1 4 in TRANSFER PUMP CONTROL SYSTEM System Operation I Turn the ignition switch ON and verify that the fuel gauge indi...

Страница 170: ...jumper wire and verify that the voltage at the fuel pump con trol unit terminal D in is OV 3 Remove the jumper wire and verify that the voltage at the fuel pump control unit terminal D L Y is approx...

Страница 171: ...Down I Yes I 2 If not as specified reptace the transfer pump switch TRANSFER PUMP Inspection 1 Remove the rear seat cushion 03UOFX 823 2 Disconnect the transfer pump connector 3 Check for continuity b...

Страница 172: ...on l Install a new seat rubber 03UOFX 826 Disassembly I Assembly Caution l Prevent contaminants from entering the transfer pump 1 Disassemble in the order shown in the figure 2 Assemble in the reverse...

Страница 173: ...tinuity between terminals A and B Terminal C 12 applied ov Continutty between A and B NO Yes 4 Measure the resistance between terminals E and F Resistance 0 62 0 66Q at 20 68OF l INJECTOR Volume Test...

Страница 174: ...cm kg 69 95 in lb 40 55 4 1 5 6 3041 N m m kg Mb 93GOF2 784 1 Main silencer Inspect for deterioration and restriction 2 Middle pipe assembly Inspect fur deterioration and restriction 3 Pre silencer In...

Страница 175: ...ssembly Inspect for deterioration and restriction 3 _Pre silencer Inspect for deterioration and restriction 4 Catalytic converter Inspect fur deterioration and restriction 5 Front pipe assembly Inspec...

Страница 176: ...pection 1 Disconnect the ECU connectors 2 Connect the SSTs Engine Signal Monitor and Adapt er to the ECU as shown 3 Place the SST Sheet 011 the Engine Signal Monitor 4 Measure the voltage at each term...

Страница 177: ...itor lamp not illumrnated Approx 12 4 lE 1F 0 Self Diagnosis Buzzer sounded for 3 sec after ignition Below 2 5V l With Self Checker switch OFF ON Diagnosis Code Number Buzzer not sounded after 3 sec A...

Страница 178: ...r terminal FEN to buzzer sounds con ECU terminal 1F tinuously Always approx 12V l Poor connection at ECU connector l ECU malfunction Always OV l Short circuit in wiring from igniter to ECU terminal tG...

Страница 179: ...tempera Betow l OV ture over 91 C t96 F or diagnosis con nector terminal TFA grounded Fan not operating Idle Approx f 2V IS 0 Blower control Blower controf switch OFF or 1st position Approx 13 Ignitio...

Страница 180: ...tch to ECU terminal 1Q l ken circuit H I winnu from A C switch to blower control switch Always below 1 W l Open or short circuit in wiring from fan relay to ECU terminal IR Electrkal cooling fan UK l...

Страница 181: ...hronle sensor Constant 4 5 5 W Airflow meter 2L I 2M 0 Throttle sensor Accelerator pedal released Approx 0 W Accelerator pedal fully depressed Approx 4 W 2N 0 20 0 2P 0 1 2Q 0 2R Oxygen sensor Airflow...

Страница 182: ...U malfunction Always approx 5V Always constant Always above f V OV after warm up Always approx IV after warm up Throttle sensor m adjustment l Open circuit in wiring from ECU terminal 2L to throttle s...

Страница 183: ...pprox 12V Monitor Green and red lamps Engrne speed above 2 000 rpm on de Approx f2V flash celeratlon Atter warm up 2v 0 Injector Nos 2 4 lgnitlon swrtch ON Approx 12V Idle Approx 12V Engine speed abov...

Страница 184: ...roubieshootlng Always OV 1 l Marn relav FUEL INJ relay malfunction l Open or shbrt circuit in wi g from injector to ECU terminal 2U or 2V Always approx 12V l ECU malfunctron Always OV or approx t2V l...

Страница 185: ...nect the SSTs to the diagnosis connector 7 Set the system selector select switch to 1 and the test switch to 02 MONITOR 8 Increase the engine speed to between 2 000 and 3 000 rpm and verify that the m...

Страница 186: ...alfunction code number 05 is indicated replace Replacement I_ Disconnect the knock sensor connector 2 Raise the vehicle and support it WI safety stands 1 93GOF2 797 3 Remove the knock sensor with usin...

Страница 187: ......

Страница 188: ...j FEATURES 1 OUTLINE I I G 3 OUTLINE OF CONSTRUCTION I G 3 SPECtFICATiONS I G 3 1 SERVICE 1 SUPPLEMENTAL SERVICE INFORMATION G 4 STARTING SYSTEM I a G 4 STARTER l I l I G 4 CHARGlNG SYSTEM G 5 PREPARA...

Страница 189: ...G INDEX 1 Starter 93GOGX 702 Removal I Instaltation _ _ _ page G 4 2 Alternator RFD Removal I Installation _ page G 5 G 2...

Страница 190: ...axicat reductron Starter Output V W 12 U 85 12 0 95 32 l 4 8rush length Standard 17 0 67 17 5 0 69 mm in Minimum 11 5 0 4531 10 0 0 39 Distributor Ignition timing BTDC FEN termrnal of diagnosis connec...

Страница 191: ...atIation 93GOGX 705 STARTING SYSTEM STARTER Removal I Installation I Remove in the order shown in the figure 2 Inspect all parts and repair or replace as necessary 3 lnstail in the reverse order of re...

Страница 192: ...3G GX 70 I Negative battery cable I Negative battery cable 7 Stabilizer Right 7 Stabilizer Right 2 Tire and wheel Right front 2 Tire and wheel Right front Installation Installation Note I page G 6 Not...

Страница 193: ...G1NG SYSTEM 93GOGX 709 1 93GOGX 710 G 6 Removal Note Tie rod end 1 Remove the right side tie rod end with the SST instailation Note Stabilizer 1 Install the stabilizer bolt Dimension A 17 19mm 0 67 0...

Страница 194: ...ABS H l 0 PREPARATION u IO REPLACEMENT H 10 CLUTCH PEDAL BP DOHC TURBO H 1 1 REMOVAL I INSPECTION INSTALLATtON H 11 CLUTCH MASTER CYLINDER BP DOHC TURBO OR WITH ABS H f 3 PREPARATION u 1 3 REMOVAL I I...

Страница 195: ...e H l 1 2 Clutch master cylinder BP DOHC Turbo or with ABS Removal I Inspection I Installation BP DOHC Turbo page H l 3 Air Ueeding with ABS _ _ page H 14 Overhaul BP DOHC Turbo _ _ page H 15 3 Ctutch...

Страница 196: ...tion page H l 1 2 Crutch master cylinder BP DUHC Turbo Overhaul page H l 5 3 Clutch cover Removal I Installation page H t 9 4 Clutch disc Removal I Installation page H 19 5 Pilot bearing Removal J Ins...

Страница 197: ...between the release fork and the release bearing 93GOHX 704 SPECIFICATIONS Hem Clutch control Engine Transaxle BP SUHC BP DOHC Turbo GSMX R Hydrautic Clutch cover Type Set load N kg lb Diaphragm sprin...

Страница 198: ...t force Fy is created and acts upon fulcrum to hold the pedal outward 11When clutch pedal depressed 1 Fukrum within range A When the pedal is depressed it moves inward centered upon fulcrum Fy which i...

Страница 199: ...clutch master cylinder push rod is applied and fy force pushing outward overcomes Fy force with the result that the clutch pedal moves out ward centered upon fulcrum 2 With fulcrum within range A When...

Страница 200: ...nder with a built in check valve is used on the BP DOHC Turbo model This is to provide smooth engagement of the clutch disc by controlling by the check valve the flow of fluid from the clutch release...

Страница 201: ...parts life a newly designed friction plate and needle roller bearings are used between the release fork and the release bearing With the kdusion of this friction plate the force required to depress th...

Страница 202: ...runout or damaged clutch disc Replace H 19 disengagement Clutch disc spiines rusted or worn Remove rust or replace H l 9 Clutch disc facing oiled Repair or replace H 19 Diaphragm spring weakened Repta...

Страница 203: ...el cylinder bleed screw 2 Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder plug 93GOHX 77 3 3 Place the other end of the vinyl hose in a clear container 4...

Страница 204: ...tion 3 Install in the reverse or y of removal p rrinQ to lnstaI ation Note _ __ _ 4 J IS 17 1 Clip 15 Bolt 2 Pin 16 Spacer 3 Spacer 17 Clutch pedal 4 Bushing 18 Bushing 5 Clip 19 Bushing 6 Assistiretu...

Страница 205: ...GOHX 716 w 12 1 Adjustment Assist return spri rtg I Measure the installation length B of the assistlreturn spring 2 Adjust the installation length B by turning nut A shown in the figure Installation l...

Страница 206: ...rface wipe it off immediately with a rag I Remove in the order shown in the figure referring to Removal Note 2 Inspect al parts and repair or replace as necessary 3 Install in the reverse order of rem...

Страница 207: ...Caution l CMch fluid will damage a painted surface ff fluid does get on a painted surface wipe it off im mediately l Do not mix different brands of clutch fluid l Do not reuse the clutch fluid that wa...

Страница 208: ...sembly Note RHD 83 t 12 8 5 f1 5 61 5 83 2 N m m kg B lb n fznuv 7 3 1 Clip 2 Hose 3 Joint 4 Bushing 5 Snap ring Disassembly Note _ _ _ page t i 1 6 Assembly Note __ _ page H l 7 6 Piston and secondar...

Страница 209: ...ton and return spring Caution l Hold a rag over the master cylinder to prevent the piston and spring from jumping out 1 Remove the piston by applying compressed air through the cylinder bore Assembly...

Страница 210: ...d contact surface of the piston t While pressing the piston install the snap ring CLUTCH RELEASE CYLINDER WITH ABS PREPARATION SST 49 0259 770B Wrench flare nut For disconnecting and connecting clutch...

Страница 211: ...l 49 1285 071 For I removal of blot Puller bearing Lj e bearing 49 0823 U72A 1 For I installation of pilot 49 E3OI 061 Body Part of 49 E301 060 49 SE01 310 Centering tool clutch disc 49 1285 073 Chuck...

Страница 212: ...OHC E l BP DOHC TURBO MORI Wl llTE TA No 2 OR B EQUIVALENT ORGANIC MOLYBDENUM GREASE 1 Clutch release cylinder 2 Transaxle Service tl I l Section J3 3 Bout 4 Release bearing 5 Clutch release fork 6 Cl...

Страница 213: ...removing the flywheel inspect for oil leakage past the crankshaft rear oil seal If necessary replace the oil seal 1 Hold the flywheel with the SST 2 Remove the flywheel Instalfation Note Flywheel 1 W...

Страница 214: ...pply organic molybdenum grease 2 Hold the clutch disc in position with the SST Clutch cover 1 Install the SST 2 Align the dowel holes with the flywheel dowels 3 Tighten the botts evenly and gradually...

Страница 215: ...I...

Страница 216: ...L LOCK SENSOR SWlTCH J3 31 IDLER GEAR SHAFI J3 33 POWERFLOW J3 34 TROUBLESHOOTING GUIDE J3 35 TRANSAXLE OIL J3 36 INSPECTlON 33 36 REPLACEMENT J3 36 TRANSFER CARRIER CM 339 36 INSPECTION J3 36 REPLACE...

Страница 217: ..._ _ _ page J3 42 Disassembly _ _ page J3 48 Inspection _ _ _ page J3 72 Assembly _ _ _ __ _ _ _ _ _ page J3 75 Installation _ _ _ _ _ _ _ _ page J3 1 I 2 4 Shift mechanism Overhaul _ _ _ _ _ page J3...

Страница 218: ...page J3 36 3 TransaxIe and transfer unit Removal I __ page J3 42 Disassembly _ page J3 48 tnspection _ I page J3 72 Assembly _ _ page J3 75 lnstaliation _ _ _ _page J3 I 12 4 Shift mechanism Overhaul...

Страница 219: ...ansaxle center differential viscous coupling and front differentia are a single compact unit l The center differential employs a planetary carrier system and a viscous coupling and functions to distri...

Страница 220: ...umber of idler gear teeth Type 011 Capacity BP DOHC turbo BP SOHC Floor shift Synchromesh Selectrve sfiding and synchromesh 3 454 3 307 1 833 I 310 1 233 0 970 Cl 91 4 0 717 3 166 L 4 214 4 388 1 oo P...

Страница 221: ...rimary 3rd gear 8 Secondary 2nd gear 13 Reverse idler gear 14 9 4 Primary 4th gear Secondary Viscous 3rd gear coupling 5 Primary 5th gear 10 Secondary 4th gear 15 Front and center differential 6 Prima...

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