Hyundai Scoupe Full Manual

HYUNDAI1 9 9 3

CONTENTS

10

Volume 1 & 2

Shop Manual

FOREWORD

This shop manual is intended for use by service techni-cians of authorized Hyundai dealers to help them provideefficient and correct service and maintenance on Hyundaivehicle.

All the contents of this manual, including drawings andspecifications, are the latest available at the time ofpublication. However, specifications and procedures aresubject to change without any notice.As for the modifications affecting service performance,dealers shall be provided technical service bulletins orsupplementary volumes.

This book may not be reproduced or copied, as a whole oras a part, without the written permission of publisher.

JUN. 1992, Printed in Korea

NOTE : This PDF Manual contains the contents ofboth printed Volumes 1 & 2.

TITLE SECTION

GENERAL INFORMATION 00

ENGINE MECHANICAL 20

LUBRICATION AND MAINTENANCE

COOLING SYSTEM 2 5

ENGINE ELECTRICAL SYSTEM 27

INTAKE & EXHAUST SYSTEM 28

EMISSION CONTROL SYSTEM 29

FUEL SYSTEM 31

CLUTCH 41

MANUAL TRANSAXLE 4 3

AUTOMATIC TRANSAXLE 45

DRIVE SHAFT AND FRONT AXLE 49

FRONT SUSPENSION 54

REAR SUSPENSION

STEERING SYSTEM

BRAKE SYSTEM

BODY (Interior and Exterior)

BODY ELECTRICAL SYSTEM

AIR CONDITIONING SYSTEM

APPENDIX (Electrical Wiring System)

55

56

58

6 0

90

97

WS

GENERALINFORMATION

00-2 GENERAL INFORMATION

GENERAL INFORMATION

HOW TO USE THIS MANUAL

This manual is divided into 20 sections. This first page of eachsection is marked with a black tab at the edge of the page. You canquickly find the first page of each section without looking through afull table of contents.

Each section includes the essential removal, installation, adjust-ment and maintenance procedures for servicing all body styles.This information is current as of time of publication.

An INDEX is provided on the first page of each section to guide youto the item to be replaced.

TROUBLESHOOTING tables are included for each system to helpyou diagnose the system problem and find the cause. The repair foreach possible cause is referenced in the remedy column to quicklylead you to the solution.

DEFINITION OF TERMS

Standard Value

Indicates the value use as the standard for judging the quality of apart or assembly on inspection or the value to which the part orassembly is corrected and adjusted. It is given by a tolerance.

Limit

Shows the standard for judging the quality of a part or assembly oninspection and means the maximum or minimum value within whichthe part or assembly must be kept functionally or in strength. It isa value established outside the range of standard value.

NOTE, WARNING AND CAUTION

NOTEA point of information.

WARNINGInformation about an activity that could cause damage to thevehicle.

CAUTIONInformation about an activity that could cause injury ordamage to the driver, occupants or repair personnel.

ABBREVIATIONSECFI : Electronically Controlled Fuel Injection system

GENERAL INFORMATION 00-3

VEHICLE IDENTIFICATION NUMBERLOCATION

The vehicle identification number (V.I.N.) is stamped on the upperright side of the cowl top front panel.

VEHICLE IDENTIFICATION NUMBER

1. World manufacturer’s identifier codeKMH - Hyundai Motor Co., Korea2HM - Bromont Assembly Plant, Canada

2. Drive line typeV - For LHDU - For RHD

3. Body TypeF - 2 Door sedan

4. Body style & version1 - Standard2 - Deluxe (GL)3 - Super deluxe (GLS)

5. Restraint type1 - Active system2 - Passive system

6. Engine typeN - 1495 cc

7. Check digitMathematically determined to validate frame numbers

8. Model yearL- 1990M - 1991

N - 1992P - 1993 R - 1994

9. Plant codeU - Ulsan plantB - Bromont plant

10. Serial number 000001 through 999999


TRANSAXLE NUMBER IDENTIFICATIONDescription

1 2 3 4 5 6

I6

1. ModelG : A4AF1

2. Product yearM : 1991N : 1992P : 1993R : 1994

3. Final gear ratioT : 4.029

4. Classification of detailA : Scoupe

5. SpareD : Damper Spring type

6. Serial No.


ENGINE IDENTIFICATION PLATE

The engine identification plate is stamped at the right front side onthe top edge of the cylinder block.

ENGINE IDENTIFICATION NUMBER

Engine identification number consists of 11 digits.

1. Engine fuelG : Gasoline

2. Engine range4 : In line 4 cycle 4 cylinder

3. Engine development orderA-Z :

4. Engine capacityE: 1495 cc

5. Product yearL: 1990 M : 1991 N : 1992 P: 1993 R : 1994

6. Engine production sequence number000001-999999


PROTECTION OF THE VEHICLE

Always be sure to cover fenders, seats, and floor areas beforestarting work.

CAUTION:The support rod must be inserted into the hole near the edgeof the hood whenever you inspect the engine compartment toprevent the hood from falling and possibly injuring you.Assure that the support rod has been released prior to closingthe hood. Always double check to be sure the hood is firmlylatched before driving away.

A WORD ABOUT SAFETY

The following precautions must be followed when jacking up thevehicle.

1. Block wheels.2. Use only specified jacking positions.3. Support vehicle with safety stands (jack stands)

Refer to the page 00-10.4. Start the engine only after making certain the engine compart-

ment is clear of tools and people.


PREPARATION OF TOOLS AND MEASURINGEQUIPMENT

Be sure that all necessary tools and measuring equipment areavailable before starting work activity.

SPECIAL TOOLS

Use special tools when they are required.

REMOVAL OF PARTS

First find the cause of trouble and then make sure whetherremoving or disassembling is required before starting the job.

DISASSEMBLY

If the disassembly procedure is complex, requiring many parts tobe disassembled, all parts should be disassembled in a way that willnot affect their performance or external appearance and be iden-tified so that reassembly can be performed efficiently.

1. Inspection of partsEach pat-t when removed should be carefully inspected forwear, deformation, damage, and other problems.

2. Arrangement of partsAll disassembled parts should be carefully arranged forreassembly.Be sure to separate or otherwise identify the pans to bereplaced from those that will be reused.


3. Cleaning parts for reuseAll parts to be reused should be carefully and thoroughlycleaned by the appropriated method.

PARTS

When replacing parts, use HYUNDAI genuine parts.

REASSEMBLY

Standard values, such as torques and certain adjustments, mustbe strictly observed in the reassembly of all parts.If removed, these parts should be replaced with new ones.1. Oil seals2. Gaskets3. O-rings4. Lock washers5. Cotter pins (split pins)6. Nylon nuts

Depending on where they are;1. Sealant should be applied to gaskets.2. Oil should be applied to moving components of parts.3. Specified oil or grease should be applied at the prescribed

locations (oil seals, etc.) before assembly.

ADJUSTMENTS

Use gauges and testers to correct adjustments to standard values.


ELECTRICAL SYSTEM

1. Be sure to disconnect the battery cable from the negative (-)terminal of the battery.

2. Never pull on the wiring when disconnecting connectors.3. Locking connectors will click when the connector is secure.4. Handle sensors and relays carefully. Be careful not to drop

them or hit them against other parts.

RUBBER PARTS AND TUBING

Always prevent gasoline or oil from touching rubber parts or tubing.

PRECAUTIONS FOR A CATALYTIC CONVERTER

CAUTION:If large amounts of unburned gasoline flow into the converter,it may overheat and create a fire hazard. To prevent this,observe the following precautions and explain them to yourcustomer.

1. Use unleaded gasoline only.2. Avoid prolonged idling.

3.

4.

5.

6.7.

Avoid running the engine at fast idle speed for more than 10minutes and at idle speed for more than 20 minutes.Avoid spark jump test.Spark jump only when absolutely necessary. Perform this testas rapidly as possible and, while testing, never race the engine.Avoid prolonged engine compression measurement. Enginecompression tests must be made as rapidly as possible.Do not run engine when fuel tank is nearly empty. This maycause the engine to misfire and create an extra load on theconverter.Avoid coasting with ignition turned off and prolonged braking.Do not dispose of used catalyst along with parts contaminatedwith gasoline or oil.


JACK POINT

When using a single-post lift When using a free wheel type auto lift

When using double-post lift


JACK POINT

When using a floor jack

When using the jackprovided with thevehicle (for reference)

NOTEDo not support car at locations other thanthe specified support points.This will cause damage etc. to the body.


STANDARD PARTS TIGHTENING TORQUE TABLE

Bolt nominal diameter Pitch(mm) (mm)

M5

M6

M8

M10

M12

M14

M16

M18

M20

M22

M24

Torque Nm (kg.cm, Ib.ft)

Head Mark 4 Head Mark 7

0.8 3-4 (30-40, 2.2-2.9) 5-6 (50-60, 3.6-4.3)

1.0 5-6 (50-60, 3.6-4.3) 9-11 (90-110, 6.5-8.0)

1.25 12-15 (120-150, 9-11) 20-25 (200-250, 14.5-18.0)

1.25 25-30 (250-300, 18-22) 40-50 (400-500, 29-36)

1.25 35-45 (350-450, 25-32) 60-80 (600-800, 43-58)

1.5 75-85 (750-850, 55-60) 120-140 (1,200-1,400, 85-100)

1.5 110-130(1,100-1,300, 80-95) 180-210 (1,800-2,100, 130-150)

1.5 160-180 (1,600-1,800, 115-130) 260-300 (2,600-3,000, 190-215)

1.5 220-250 (2,200-2,500, 160-180) 360-420 (3,600-4,200, 260-300)

1.5 290-330 (2,900-3,300, 210-240) 480-550 (4,800-5,500, 350-400)

1.5 370-420 (3,700-4,200, 270-300) 610-700 (6,100-7,000, 440-505)

NOTES1. The torques shown in the table are standard values applicable to tightening performed under the following

conditions:1) Nuts and bolts are made of steel bar, and galvanized.2) Galvanized plain steel washers are inserted.3) All nuts, bolts, and plain washers are dry.

2. The torques shown in the table are not applicable:1) Spring washers, toothed washers and the like are inserted.2) If plastic parts are fastened.3) If self-tapping screws or self-locking nuts are used.4) If threads and surface are coated with oil.

3. It should be standard practice to reduce the torques given in the table to the percentage indicated below:1) If spring washers are used. 85%2) If threads and bearing surfaces are stained with oil 85%

LUBRICATIONANDMAINTENANCEReturn To Main Table of ContentsSCHEDULED MAINTENANCE TABLE .. . . . . . . . . . . . . . . . . . 2

RECOMMENDED LUBRICANTS AND CAPACITIES.... 6

MAINTENANCE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SCHEDULED MAINTENANCE TABLE

SCHEDULED MAINTENANCE TABLERECOMMENDED CUSTOMER MAINTENANCE (U.S.A. only)

The following maintenance services must be performed to assure good emission control and performance. Keep receiptsfor all vehicle emission services to protect your emission warranty.Where both mileage and time are shown, the frequency of service is determined by whichever occurs first.

R : REPLACEI INSPECT, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY


MAINTENANCE UNDER SEVERE USAGE CONDITIONSThe following items must be serviced more frequently on vehicles normally used under severe driving conditions.Refer to the chart below for the appropriate maintenance intervals.

I : INSPECT, CORRECT OR REPLACE IF NECESSARYR : REPLACE

SEVERE DRIVING CONDITIONSA-Repeated short distance drivingB-Extensive idlingC-Driving in dusty conditionsD-Driving in areas using salt or other corrosive materials or in very cold weatherE-Driving in sandy areasF-More than 50% driving in heavy city traffic during hot weather above 90°F (32°C)G-Driving in mountainous areasH-Towing a trailer


SCHEDULED MAINTENANCE TABLERECOMMENDED CUSTOMER MAINTENANCE (Canada only)

The following maintenance services must be performed to assure good emission control and performances. Keep receiptsfor all vehicle emission services to protect your emission warranty.Where both mileage and time are shown, the frequency of service is determined by whichever occurs first.

R : REPLACEI : INSPECT, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY

SCHEDULED MAINTENANCE TABLE 10-5

MAINTENANCE UNDER SEVERE USAGE CONDITIONSThe following items must be serviced more frequently on vehicles normally used under severe driving conditions.Refer to the chart below for the appropriate maintenance intervals.

I : INSPECT. CORRECT OR REPLACE IF NECESSARYR : REPLACE

SEVERE DRIVING CONDITIONSA-Repeated short distance drivingB-Extensive idlingC-Driving in dusty conditionsD-Driving in areas using salt or other corrosive materials or in very cold weatherE-Driving in sandy areasF-More than 50% driving in heavy city traffic during hot weather above 90°F (32°C)G-Driving in mountainous areasH-Towing a trailer

RECOMMENDED LUBRICANTS AND CAPACITIES

RECOMMENDED LUBRICANTS AND CAPACITIESRECOMMENDED LUBRICANTS

Parts

Engine oil

Specifications

API classification SG or SG/CD

Remarks

For further details, refer toSAE viscosity number

Manual transaxle API classification GL-4 or GL-5 SAE grade number:SAE 75W/85W or 75W/90

Automatic transaxle

Brake

Rear wheel bearing

Cooling system

Transaxle linkage, parkingbrake cable mechanism, hoodlock and hook, door latch, seatadjuster, trunk latch, door hinges,trunk hinges

GENUINE HYUNDAI AUTOMATICTRANSMISSION FLUID, MOPAR ATFPLUS TYPE 7176 or DIAMOND ATF SP.

MOPAR ATF PLUS TYPE7176is recommended lubricant

Conforming to DOT 3 or equivalent

Multi-purpose grease NLGIGrade #2, EP

High quality ethylene glycol Concentration level 50%

Multipurpose grease NLGIGrade #2

Power steering DEXRON II type

LUBRICANTS CAPACITIES

Description Capacities Remarks

Engine oilOil panOil filterTotal [Dry fill]

Cooling system.Manual transaxleAutomatic transaxlePower steering

2.9 lit (3.03 U.S. qts., 2.55 Imp.qts.)0.4 lit (0.42 U.S. qts., 0.35 Imp.qts.)3.3 lit (3.48 U.S. qts., 2.90 Imp.qts.)5.3 lit (5.6 U.S. qts., 5.0 Imp.qts.)2.15 lit (2.27 U.S. qts., 2.03 Imp.qts.)6.1 lit (6.4 U.S. qts., 5.4 Imp.qts.)0.9 lit (0.95 U.S. qts., 0.79 Imp.qts.)

MAINTENANCE SERVICE 10-7

MAINTENANCE SERVICEENGINE OILAlways use lubricants which conform to the requirements of the APIclassification “For Service SG or For Service SG/CD” whenavailable, and have proper SAE grade number for the expectedtemperature range.

ENGINE OIL FILTER1. Remove the oil filter with a suitable wrench.2. For installation, apply engine oil to the oil filter gasket and tighten

the oil filter fully by hand.

NOTEBe sure gasket sealing surface on engine block is clean andfree of debris.Be sure to remove old gasket from block prior to installingnew filter.

DRIVE BELT1. To check belt tension, apply moderate pressure (approximately

100 N, 22 lb) midway between the pulleys.Check the deflection and adjust if necessary.

Drive belt deflection . . . . . . . . . . . . . 9.0-10.4 mm (0.35-0.41 in.)

VALVE CLEARANCEIntake and Exhaust Valves

Adjustment conditionNormal operating temperature [Cooling temperature 80 to 95°C(176 to 205°F)]

1. Place piston of No. 1 cylinder at top dead center of compressionstroke to adjust valve clearances marked A, as shown, in thenext page.

2. Loosen nut and adjust to specification with adjusting screw.Then retighten nut.

Valve clearance (on hot engine)Intake . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.01 in.)Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 mm (0.012 in.)

10-8 MAINTENANCE SERVICE

3. After nut has been retightened, recheck to see if clearance iscorrect.

4. Place piston in No. 4 cylinder at top dead center on compressionstroke to adjust valve clearance marked B, as shown.

5. Adjust by repeating steps 2 and 3.6. Check idle speed and readjust if necessary.

REPLACEMENT OF IGNITION CABLES

The ignition cables should be replaced periodically with new ones.After replacing, make sure that the ignition cables and terminals areproperly connected and fully seated.

NOTE:When disconnecting an ignition cable, be sure to hold cablecap. If the cable is disconnected by pulling on the cable alonean open circuit might result.

REPLACEMENT OF THE AIR FILTER

The air filter will become dirty during use, which will decrease fueleconomy. Replace with a new one.1. Remove the air intake hose and air duct.2. Disconnect the connector for the air-flow sensor from the air

filter cover.3. Disconnect the air filter cover clip.4. Remove the air filter cover.

NOTEThe air filter cover should be removed carefully becauseit includes the air-flow sensor.

5. Remove the air filter element.6. Set in a new air filter element and clamp the air filter cover.


FUEL SYSTEM

Tank, Lines And Connections1. Check for damage or leakage in the fuel lines and connections.2. Inspect the surface of fuel hoses for heat and mechanical

damage. Hard and brittle rubber, cracking, checking, tears,cuts, abrasions and excessive swelling indicate deterioration ofthe rubber.

3. If the fabric casing of the rubber hose is cracked or worn, thehoses should be changed.

Fuel Filter

The fuel filter should be replaced regularly. Its performance isreduced by dirt and water collected over an extended period of use.Replace as required.

CRANKCASE EMISSION CONTROLSYSTEM (PCV valve)

The crankcase ventilation system must be kept clean to maintaingood engine performance.Periodic servicing is required to remove combustion products fromthe PCV valve.

1. Disconnect the ventilation hose from the positive crankcaseventilation (PCV) valve. Then, remove PCV valve from therocker cover and reconnect it to the ventilation hose.

2. Idle the engine and put a finger to the open end of PCV valveto make sure that intake manifold vacuum is felt on the finger.

NOTE: At this time, the plunger inside the PCV valve should moveback and forth.

3. If no vacuum is felt, replace the PCV valve and clean theventilation hose in cleaning solvent or replace if necessary.


EVAPORATIVE EMISSION CONTROLSYSTEM

1. If the fuel-vapor vent line is clogged or damaged, a fuel-vapormixture escapes into the atmosphere causing excessive emis-sion. Disconnect the line at both ends, and blow it clean withcompressed air. Remove the filler cap from the filler pipe andcheck to see that the filler cap is seating properly on the fuel fillerpipe.

2. The overfill limiter (2-way valve) installed on the vapor linebetween the fuel check valve and fuel tank outlet should bechecked for correct operation.

CANISTER (Replace)

If or when the canister filter becomes clogged, the purge air volumewill decrease and consequently, the canister capacity will bereduced.

REPLACEMENT OF OXYGEN SENSOR

The oxygen sensor is a device which controls the fuel mixture. If theoxygen sensor is damaged, the exhaust emission as well asdriveability deteriorates. Therefore, it should be replaced whenrecommended or when a failure occurs.

SPARK PLUGS

1. Spark plugs must fire properly to assure proper engine pefor-mance and emission-control. They should operate satisfacto-rily in normal vehicle service for the specified maintenanceinterval or they should be replaced.

2. The new plugs should be checked for the proper gap.

Plug gapN/A . . . . . . . . . . . . . . . . . . . . . . . 1.0-1.1 mm (0.039-0.043 in.)T/C . . . . . . . . . . . . . . . . . . . . . . . . . 0.8-0.9 mm (0.031-0.035 in.)

TIMING BELT

For disassembly and assembly procedures, refer to “ENGINEGROUP”.


TRANSAXLE OIL LEVEL INSPECTION

Inspect each component for evidence of leakage, and check the oillevel by removing the filler plug. If the oil is contaminated, it isnecessary to replace it with new oil.1. With the vehicle parked at a level place, remove the filler plug

and make sure that there is oil 5-9 mm (0.2-0.4 in.) downwardfrom the threaded lower surface.

2. Check to be sure that the transaxle oil is not noticeably dirty,and that it has a suitable viscosity.

AUTOMATIC TRANSAXLE (Change fluid)

Drain the fluid and check whether there is any evidence of contami-nation.Replenish with new fluid after the cause of any contamination hasbeen corrected.1.2.3.

4.5.

6.

7.

8.

9.

Remove drain plug to let fluid drain.Remove the oil pan.Check the oil filter for clogging and damage and replace ifnecessary.Clean both gasket surfaces of transaxle case and oil pan.Install oil pan with new gasket and tighten oil pan bolts to 10-12 Nm (100-120 kg.cm, 7.2-8.7 Ib.ft).Tighten drain plug with gasket to 30-35 Nm (300-350 kg.cm,22-25 Ib.ft).Supply 4 liters (8.5 pints) of the recommended ATF into casethrough dipstick hole. [Total quantity of ATF required is 6.1liters (12.9 pints). Actually however, approx. 4.5 liters (9.5pints) of fluid can be replaced because rest of fluid remains intorque converter.]Start engine and allow to idle for at least two minutes.Then, with parking brake on, move selector lever momentarilyto each position, ending in “N” position.Add sufficient ATF to bring fluid level to lower mark. Recheckfluid level after transaxle is at normal operating temperature.Fluid level should be between upper and lower marks of "HOT"range. lnsert dipstick fully to prevent dirt from entering transaxle.


COOLING SYSTEM

Check the cooling system for damaged hoses, loose or seepingconnections, or other possible causes of coolant loss.

Antifreeze

The engine cooling system is provided with a mixture of 50%ethylene glycol anti-freeze and 50% water at the time of manufac-ture.Since the cylinder head and water pump body are made ofaluminum alloy casting, be sure to use 30 to 60% ethylene glycolantifreeze coolant to provide corrosion protection and freezingprevention.

NOTEIf the concentration of the antifreeze is below 30%, the anti-corrosion property will be adversely affected. In addition, ifthe concentration is above 60%, both the antifreezing andengine cooling properties will decrease, adversely affectingthe engine. For these reasons, be sure to maintain the con-centration level within the specified range.

Measurement of Antifreeze Concentration

Run the engine until coolant is fully mixed. Drain some coolant(antifreeze), measure temperature and specific gravity of thecoolant. Determine concentration and safe working temperature. Ifthe coolant is short of antifreeze, add antifreeze up to a concentra-tion of 50%.

Coolant Change

WARNINGHot engine coolant can injure you.Never open the radiator cap when the engine is hot.Allow it to cool first.When removing the radiator cap, use care to avoidcontact with hot coolant or steam. Place shop towelover the cap and turn the cap counterclockwise a littleto let pressure escape through the vinyl tube. Afterrelieving the pressure, remove the cap by slowlyturning it counterclockwise.


1. Remove the radiator cap, radiator drain plug and engine drainplug to drain coolant.

2. Remove the reserve tank and drain coolant.3. After draining coolant completely, reinstall the drain plugs and

flush the engine and radiator using a radiator cleaning fluid.4. After the flushing is completed, completely drain the cleaning

fluid and install the radiator and engine drain plug.5. By referring to the section on coolant is Cooling System Group,

select an appropriate concentration for safe operating temperature within the range of 30 to 60%. Refill the system witha high quality ethylene glycol antifreeze at the selected concen-tration.A convenient mixture is 50% water and 50% antifreeze solution[Freezing point: -36°C (-32.8°F)].Reinstall the radiator cap.

6. After running the engine a while, check the coolant level andadd coolant until the specified coolant level is maintained.

7. Add coolant to the reserve tank between the “FULL” and “LOW”mark if necessary.

NOTEDo not overfill the reserve tank.

AIR CONDITIONER SYSTEM

1. To check belt tension, apply pressure (approximately 100N, 22lb) midway between the pulleys. Check the deflection andadjust if necessary.

Belt deflectionDrive belt . . . . . . . . . . . . . . . . . . . . . . . 9.0-10.4 mm (0.35-0.41 in.)Air conditioner compressor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7 mm (0.30-0.32 in.)

FRONT DISC BRAKE PADS

Check for fluid contamination and wear. Replace complete set ofpads if defective.

The pads for the right and left wheels should be replaced atthe same time. Never “split” or intermix brake pad sets. Allpads must be replaced as a complete set.

Thickness of lining “A” [Limit] . . . . . . . . . . . . . 1.0 mm (0.04 in.)

WARNING


REAR DRUM BRAKE LININGS AND REARWHEEL CYLINDERS

1. Remove the brake drum and check the thickness of brake shoelining for wear. Check the automatic brake adjusting system byhand to see if it operates smoothly. Also see if the gears are inproper mesh with each other. To assure smooth functioning,apply a very thin coat of grease to the friction surface of adjusterand link shaft.

2. Inspect the wheel cylinder boots for evidence of a brake fluidleak. Visually check the boots for cuts, tears or heat cracks. (Aslight amount of fluid on the boot may not be a leak, but may bepreservative fluid used at assembly.)1) Checking the Brake Shoes for wear.

Thickness of lining “B” [Limit] . . . . 1.0 mm (0.04 in.)

BRAKE HOSES

Inspection of brake hoses and tubing should be included in all brakeservice operations.The hoses should be checked for :1. Correct length, severe surface cracking, pulling, scuffing or

worn spots. (If the fabric casing of the hoses is exposed bycracks or abrasion in the rubber hose cover, the hoses shouldbe replaced. Eventual deterioration of hose may occur withpossible bursting failure.).

2. Faulty installation, casing twisting or interference with wheel,tire or chassis.

BRAKE FLUID (Inspect fluid level and checkfor leaks)

1. Check to make certain that the brake fluid is between the MAXand MIN markings on the fluid reservoir. Fill as required.

2. With disc brakes, the fluid level can be expected to fall as thebrake pads wear. A rapid fluid loss indicates a leak in the brakesystem which should be inspected and repaired immediately.

CAUTION:Take care in handling brake fluid as it is harmful to theeyes and may cause damage to painted surfaces andshould be cleaned immediately.


Change Fluid

1. Check the brake system for leakage before replacing brakefluid.Completely drain the brake fluid with the bleeder screwsloosened on each brake and refill the brake system with newbrake fluid.

Recommended fluid . . . . Brake Fluid conforming to DOT 3

2. The reservoir cap must be fully tightened to avoid contamina-tion from foreign matter or moisture.

WARNING:DO NOT ALLOW PETROLEUM BASE FLUID TO CON-TAMINATE THE BRAKE FLUID

BALL JOINT AND STEERING LINKAGESEALS STEERING AND DRIVE SHAFT BOOTS

1. These components, which are permanently lubricated at thefactory, do not require periodic lubrication. Damaged seals andboots should be replaced to prevent leakage or contaminationof the grease.

2. Inspect the dust cover and boots for proper sealing leakage anddamage. Replace them if defective.

POWER STEERING OIL PUMP BELT(Check and service as required)

1. Inspect the belt for evidence of cuts and cracks. Replace, ifnecessary.

2. Check belt for proper tension. If necessary, adjust the belttension as follows.1) Push the belt with a force of 100 N (22 lb) at a point halfway

between the power steering oil pump pulley and water pumppulley. The belt deflection should be 7 to 10 mm (0.28-0.39in.)

2) If belt deflection is not within specified limits, loosen oil pumpmounting bolt, and move the oil pump to obtain proper beltdeflection at 100 N (22 lb) force.


POWER STEERING FLUID LEVEL(Inspect fluid level)

1. Park the vehicle on a flat, level surface, start the engine, andthen turn the steering wheel several times to raise the tempera-ture of the fluid to approximately 50°C (122°F).

2. With the vehicle still idling, turn the wheel all the way to the leftand right several times.Check the fluid in the oil reservoir for foaming, check the fluidlevel, and replenish the fluid in the oil reservoir through the oilfilter if necessary.

POWER STEERING HOSES(Check for deterioration or leaks)

1. Check the hose connections for fluid leaks.2. The power steering hoses should be replaced if there are

severe surface cracking, pulling, scuffing or worn spots. Dete-rioration of the hoses could cause premature failure.

REAR WHEEL BEARINGS(Inspect for grease leaks)

Inspect for evidence of grease leakage round the hub cap and theback of the hub. If there is leakage of grease, remove the hub andinspect its oil seal for damage. Clean the grease off the hub andbearing and repack with specified new grease.

EXHAUST SYSTEM

1. Check for holes and gas leaks due to damage, corrosion, etc.2. Check the joints and connections for looseness and gas leaks.3. Check the hanger rubber and brackets for damage.

ENGINEMECHANICALReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18ENGINE AND TRANSAXLE ASSEMBLY . . . . . . . . . . . . . . . . . 21

TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

ROCKER ARMS AND ROCKER ARM SHAFTS . . . . . . . . . . . 30

CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . 39VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

FRONT CASE, OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . 50

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

20-2 GENERAL

GENERALSPECIFICATIONS

Description Standard Limit

GeneralTypeNumber of cylindersBoreStrokeTotal displacementCompression ratio (N/A)

(T/C)Firing orderBasic ignition timing

Valve timingIntake valve

Opens (BTDC)Closes (ABDC)

Exhaust valveOpens (BBDC)Closes (ATDC)

Compression pressure

Valve clearanceIntakeExhaust

Cylinder headWarpage of lower face of headOversize rework dimension of valve seat

Intake 0.3 mm (0.012 in.)0.6 mm (0.024 in.)

Exhaust 0.3 mm (0.012 in.)0.6 mm (0.024 in.)

Oversize rework of valve guide hole(both intake and exhaust)

0.05 mm (0.002 in.)0.25 mm (0.010 in.)0.50 mm (0.020 in.)

CamshaftHeight of cam lobe

Intake

Exhaust

In-line 12 valve OHC475.5 mm (2.97 in.)83.5 mm (3.29 in.)1,495 cc (91.17 cu.in.)107.51-3-4-2BTDC 9° ± 5°/[at 800±100 rpm]

N/A TC14° 8°42° 52°

52° 52°8° 8°13.5 kg/cm2 10.5 kg/cm2

(1.32 MPa, 192 psi) (1.03 MPa, 149 psi)

Hot Cold0.25 mm (0.01 in.) 0.18 mm (0.007 in.)0.3 mm (0.012 in.) 0.24 mm (0.009 in.)

Within 0.05 mm (0.002 in.)

28.8-28.821 mm (1.134-1.135 in.)29.1-29.121 mm (1.146-1.1465 in.)34.3-34.325 m m (1.350-1.351 in.)34.6-34.625 m m (1.362-1.363 in.)

11.05-11.058 mm11.25-11.258 mm11.50-11.508 mm

41.0837 (N/A)41.2689 (T/C)41.2698 (both N/A and T/C)

T/C: Turbo chargerN/A: Natural aspiration

GENERAL 20-3


ValveStem O.D.

Thickness of valve head (Margin)IntakeExhaust

Clearance with valve guideIntakeExhaust

Valve guideInstalled dimension O.D.Oversize

Valve seat insertWidth of seat contact

IntakeExhaust

Seat angleOversize

Valve springFree lengthLoadInstalled heightSquareness

Cylinder blockCylinder boreOut-of-roundness and taper of cylinder boreClearance with piston

PistonO.D.

Oversize

Piston ringSide clearance

No.1No.2End gap

Oversize

No. 1 and No.2Oil ring

Connecting rodBendTwistSide clearance

Connecting rod bearingOil clearanceUndersize

6 mm (both intake and exhaust)

1.1 mm(0.043in.)1.4 mm(0.055in.)

0.03-0.06 mm (0.0012-0.0024 in.)0.05-0.08 mm (0.0020-0.0031 in.)

11.0 mm (0.433 in.)0.05 mm, 0.25 mm, 0.50 mm(0.002 in., 0.010 in., 0.020 in.)

1.1-1.5 mm (0.043-0.059 in.)1.5-1.9 mm (0.059-0.075 in.)45°0.3 mm, 0.6 mm (0.012 in., 0.024 in.)

40 mm (1.575 in.)20 kg/32.0 mm32 mm1.5° or less

75.50-75.53 mmWith 0.01 mm (0.0004 in.)0.02-0.04 (0.0008-0.0016 in.) (N/A)0.025-0.045 (0.0010-0.0018 in.) (T/C)

75.470-75.500 mm (2.9713-2.9724 in.) (N/A)75.465-75.495 (2.9710-2.9722 in.) (T/C)0.25 mm, 0.50 mm, 0.75 mm, 1.00 mm(0.010 in., 0.020 in., 0.030 in., 0.039 in.)

0.04-0.08 mm (0.0016-0.0031 in.)0.04-0.08 mm (0.0016-0.0031 in.)0.30-0.50 mm (0.012-0.020 in.)0.25-1.00 mm (0.010-0.039 in.)0.25 mm, 0.50 mm, 0.75 mm, 1.00 mm(0.010 in., 0.020 in., 0.030 in., 0.039 in.)

0.05 mm (0.0020 in.) or less0.10 mm (0.004 in.) or less0.10-0.25 mm (0.04-0.010 in.)

0.032-0.056 mm (0.0013-0.0022 in.)0.25 mm, 0.50 mm, 0.75 mm(0.01 in., 0.02 in., 0.03 in.)

0.1 mm(0.004in.)0.5 mm(0.020in.)

20-4 GENERAL


CrankshaftPin O.D. 45 mm (1.7717 in.)Journal O.D. 50 mm (1.9685 in.)Bend 0.03 mm or lessOut-of-roundness, taper of journal and pin 0.01 mm (0.0004 in.) or lessEnd play 0.05-0.175 mm (0.0020-0.0069 in.)Undersize rework dimension of pin

0.25 mm (0.010 in.) 44.730-44.750 mm (1.7470-1.7618 in.)0.50 mm (0.020 in.) 44.480-44.500 mm (1.7514-1.7520 in.)0.75 mm (0.030 in.) 44.230-44.250 mm (1.7415-1.7421 in.)

Undersize rework dimension of journal0.25 mm (0.010 in.) 49.730-49.750 mm (1.9579-1.9587 in.)0.50 mm (0.020 in.) 49.480-49.500 mm (1.9480-1.9488 in.)0.75 mm (0.030 in.) 49.230-49.250 mm (1.9382-1.9390 in.)

FlywheelOut-of-roundness 0.13 mm (0.0051 in.) or less

Oil pumpClearance between outer circumferenceand front case

0.12-0.18 mm (0.0047-0.0070 in.)

Clearance between roter axial side andfront case

0.04-0.087 mm (0.0016-0.0034 in.)

Tip clearance between outer and inner roter 0.025-0.069 mm (0.0010-0.0027 in.)

Engine oil pressureAt engine idle speedRelief spring

Free heightLoad

147 KPa (1.5 kg/cm2, 21.33 psi)

46.6 mm (1.8346 in.)9.7 kg at 36.3 mm (1.4291 at 7.155 lb)

GENERAL 20-5

TIGHTENING TORQUE

N m kg.cm Ib.ft

Cylinder BlockFront engine support bracket bolt and nutFront roll stopper bracket boltRear roll stopper bracket boltLeft engine support bracket boltOil pressure switch

Cylinder headCylinder head bolt-cold engine

-hot engineIntake/manifold bolts or nutsExhaust manifold nut

N/AT/C

Rocker cover boltRocker arm shaft boltCamshaft boltRear plate bolt

Main MovingConnecting rod cap nutCrankshaft bearing cap boltFly wheel M/T boltDrive plate A/T bolt

Timing BeltCrankshaft sprocket boltCrankshaft pulley boltCamshaft sprocket boltTiming belt tensioner boltTiming belt cover boltFront case bolt

N/A: Natural AspirationT/C: Turbo ChargerM/T: Manual TransaxleA/T: Automatic Transaxle

50-7070-9070-9030-4213-15

70-7580-8515-20

15-2025-353-420-2720-278-10

35-3855-60130-140130-140

190-20013-1480-10020-2710-1212-15

500-700700-900700-900300-420130-150

700-750800-850150-200

150-200250-35030-40200-270200-27080-100

350-380550-6001300-14001300-1400

1900-2000130-140800-1000200-270100-120120-150

37-5151-6551-6522-309.4-11

51-5458-6111-14

11-1418-202.2-2.914-2014-205.8-7.2

25-27.539.8-43.494-10194-101

140-147.59.6-10.358-7214-207.2-8.78.7-11

20-6 GENERAL

Engine MountingRight mounting insulator (large) nutRight mounting insulator (small) nutRight mounting bracket to engine nuts and boltsTransaxle mount insulator nutTransaxle insulator bracket to side member boltsRear roll stopper insulator nutRear roll stopper bracket to center member boltsFront roll stopper insulator nutFront roll stopper bracket to center member boltsCenter member to body boltsOil filterOil pan boltsOil pan drain plugOil screen boltsTiming belt upper cover boltsTiming belt lower cover boltsSurge tank to inlet manifold nuts and bolts

N m kg.cm Ib.ft

90-110 900-1100 65-8050-60 450-600 32-4350-65 500-650 36-4790-110 900-1100 65-8030-40 300-400 22-2950-60 450-600 33-4345-60 500-600 36-4345-60 450-600 33-4330-40 300-400 22-2960-80 600-800 43-5812-16 120-160 8.8-11.86-8 60-80 4-635-45 350-450 25-3315-22 150-220 11-1610-12 100-120 7-910-12 100-120 7-915-20 150-200 11-14

SELECTION OF LUBRICANTS

Engine Oil

GENERAL 20-7

Recommended API classification : SG OR SG/CDRecommended SAE viscosity grades :

Temperature rangeanticipated beforenext oil change

°C °F

16 60

0 32

-23 -10

Recommended SAE viscosity numberN/A T/C

*1. Restricted by driving conditions and climate conditions.*2. Not recommended for sustained high speed vehicle operation.*3. SAE 5W-30 recommended for extremely cold area (It’s TEMP. is lower than above stated TEMP.)For best performance and for maximum protection of all engines for all types of operation, select only those lubricantswhich:1. Conform to the requirements of API classification.2. Have proper SAE grade number for expected ambient temperature range.

Lubricants which do not have both a SAE grade number and an API service classification on the container should not beused.

GENERAL

SPECIAL TOOLS

Toot(Number and name)

Crankshaft front oil seal installer09231-22000

Illustration Use

Installation of the crankshaft front oil seal(use with 09231-22100)

Crankshaft front oil seal guide09231-22100

Installation of the crank shaft front oil seal(use with 09214-21000)

Cylinder head bolt wrench09221-21000

Camshaft oil seal installer09221-21000

Removal and tightening of the cylinder

lnstallatjon of the camshaft oil seal(usewith 09221-21100)

Camshaft oil seal guide09221-21100

Used as a guide when pressing in thecamshaft oil seal (use with 09221-

Valve spring compressor09222-28000Valve spring compressor holder09222-28100

exhaust valve.

Valve stem oil seal installer09222-22000

Installation of the vale stem oil seal

GENERAL

Tool(Number and name)

Valve guide installer09221-22000 A/B

Crankshaft rear oil seal installer09231-21000

Illustration Use

Removal and installation of the valve guide

1) Installation of the engine rear oil seal2) Installation of the crankshaft rear oil

seal

Piston pin setting tool insert09235-22000Removal and installation of the pis-ton pin (use with 09234-33001)

20-10 GENERAL

TROUBLESHOOTING

Symptom

Low compression

Probable cause

Blown cylinder head gasketWorn or damaged piston ringsWorn piston or cylinder

Worn or damaged valve seat

Remedy

Replace gasketReplace ringsRepair or replace pistonand/or cylinder blockRepair or replace valveand/or seat ring

Oil pressure drop

High oil pressure

Excessive engine rolling andvibration

Noisy valves

Connecting rod and/mainbearing noise

Timing belt noise

Low engine oil level Check engine oil levelFaulty oil pressure switch ReplaceClogged oil filter ReplaceWorn oil pump gears or cover ReplaceThin or diluted engine oil Change and determine causeOil relief valve stuck (open) RepairExcessive bearing clearance Replace

Oil relief valve stuck (closed) Repair

Loose engine roll stopper (front, rear) Re-tightenLoose transaxle mount bracket Re-tightenLoose engine mount bracket Re-tightenLoose center member Re-tightenBroken transaxle mount insulator ReplaceBroken engine mount insulator ReplaceBroken engine roll stopper insulator Replace

Thin or diluted engine oil (low oil pressure) ChangeWorn or damaged valve stem or valve guide Replace

Insufficient oil supply Check engine oil levelThin or diluted engine oil Change and determine causeExcessive bearing clearance Replace

Incorrect belt tension Adjust belt tension

GENERAL 20-11

CHECKING ENGINE OIL1. Position the vehicle on a level surface.2. Warm up the engine.

NOTEIf a vehicle that has been out of service for a prolongedperiod of time, warm up the engine for approximately 20minutes.

3. Stop the engine, and wait 2 or 3 minutes, then check the oil levelafter engine oil drains to the oil pan.

4. Check that the engine oil level is within the level range indicatedon the oil dipstick. If the oil level is found to have fallen to thelower limit (the MIN mark), refill to the “MAX” mark.

NOTEWhen refilling, use the same type of engine oil as the onecurrently being used.

5. Check that the oil is not dirty or contaminated with coolant orgasoline, and that it has the proper viscosity.

REPLACING OIL FILTERFilter Selection

All Hyundai engines are equipped with a high quality, throw-awayoil filter. This filter is recommended as a replacement filter on allvehicles. The quality of replacement filters varies considerably.Only high quality filters should be used to assure the most efficientservice. Make sure that the rubber gasket from the old oil filter iscompletely removed from the mating surface on the engine block,before installing the new filter.

Replacing Oil Filter

1. Use a filter wrench to remove the oil filter.2. Before installing the new oil filter on the engine, apply clean

engine oil to the surface of the rubber gasket.3. Tighten enough the oil filter by hand.

Tightening torqueOil filter . . . . . . . . . . . . 12-16 Nm (120-160 kg.cm, 8.8-11.8 Ib.ft)

4. Run the engine to check for engine oil leaks.5. After stopping the engine, check the oil level and add oil as

necessary.

20-12 GENERAL

CHANGING ENGINE OIL

1. Run the engine until it reaches normal operating temperature.2. Stop the engine.3. Remove the oil filler cap (on rocker cover) and the drain plug (on

the oil pan). Drain the engine oil.4. Re-install and tighten the drain plug to the specified torque.

Tightening torqueDrain plug 3.5-4.5 kg.m

5. Fill the crankcase with fresh engine oil through the oil fillercap opening.

Dry fill . . . . . . . . . . . . . . . . . 3.3 lit (3.48 U.S.qts., 2.90 Imp.qts.)Drain and Refill

Without oil filter; 2.5 lit (2.85 U.S.qts., 2.37 Imp.qts.)With oil filter; 3.0 lit (3.17 U.S.qts., 2.64 Imp.qts.)

6. Install the oil filler cap.7. Start and run the engine.8. Stop the engine and then check the oil level. Add oil if

necessary.

GENERAL 20-13

CHECKING COMPRESSION PRESSURE1. Before checking compression, check the engine oil level. Make

sure the starter motor and battery are in normal operatingcondition.

2. Start the engine and wait until engine coolant temperaturereaches 80-95°C (176-205°F).

3. Stop the engine and disconnect the spark plug cables.4. Remove the spark plugs.5. Crank the engine to remove any foreign objects in the cylinders.6. Screw the compression gauge into the spark plug hole.7. Fully open the throttle.8. Crank the engine and read the gauge.

Standard valueN/A : 13.5 kg/cm2 (1.32 MPa, 192 psi) [at 250 rpm]T/C: 10.5 kg/cm2 (1.03 MPa, 149 psi) [at 250 rpm]

Limit : 12.5 kg/cm2 (1.16 MPa, 171 psi) [250-400 rpm]9.5 kg/cm2 (9.3 MPa, 135 psi) [250-400 rpm]

9. Repeat steps 6 through 8 on all cylinders, making sure that thepressure differential for each of the cylinders is within thespecified limit.

Limit : Max. 1.0 kg/cm2 (100 KPa, 14 psi) between cylinders

10. If a cylinder’s compression or pressure differential is belowthe specification, add a small amount of oil through the sparkplug hole and repeat steps 6 through 9.1) If the addition of oil brings the compression up, it is possible

that there is wear between the piston ring and cylinder wall.2) If compression remains the same, valve seizure, poor valve

seating or a compression leak from the cylinder head gasketare all possible causes.

Tightening torqueSpark plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20.4-30.6 Nm (204-306 kg.cm, 15-21 Ib.ft)

VALVE CLEARANCE ADJUSTMENT

Refer to GROUP 10 Lubrication and Maintenance.

20-14 GENERAL

TIMING BELT AND TIMING BELTTENSIONER INSTALLATION PROCEDURE1. Temporarily fasten timing belt tensioner in such position as

to place it’s pulley nearest to the water pump (pulley maytouch water pump body).

2. After installing the tensioner, the crankshaft sprocket and thecamshaft sprocket, match the timing mark of each sprocketas shown in the illustration.Rotate the crankshaft until the No.1 cylinder is at top deadcenter on the compression stroke.

CAUTION1) Be sure to install the flange in the correct direction.

(Chamfered part shows front of engine).2) When installing the camshaft sprocket, make sure that

the pin on the camshaft fits small hole in pulley.

NOTEAllow tensioner to remain in assemble state must beinstalled temporarily as follows.1) Temporarily tighten the tensioner as shown in illustra-

tion, in state that one extended end of spring tensioneris assembled to bend of tensioner bracket as imagi-nary line (wheel spring tensioner is inoperative andnot loaded).

2) Then set extended end of tensioner spring at frontcase with drive etc.

3. Install the timing belt so as not to allow slack to the tension side.Make sure that all timing marks are at their correct position withthe tension side in a strained state by applying force to thecamshaft sprocket in a counterclockwise direction.

GENERAL 20-15

TIMING BELT TENSION ADJUSTMENTPROCEDURE

The timing belt has an automatic tension adjusting mechanism.Adjustment can be made by the following procedure:

1. Turn the steering wheel fully counter-clockwise.2. Apply a wood block under the engine oil pan and carefully raise

the engine.

CAUTIONJack up only slightly to prevent engine damage.

3. Remove the engine right mount bracket.

4. Remove the water pump pulley.5. Remove the crankshaft pulley.

6. Remove the timing belt upper cover.

7. Check the belt for cracking, peeling or other damage. Besure to carefully check the entire length of the belt.

8. Rotate the crankshaft so that the No. 1 piston is at top deadcenter of the compression stroke. In other words, align thetiming mark on the camshaft sprocket with that on thecylinder head.Note that the crankshaft should be turned clockwise, notcounterclockwise. Turning the crankshaft counterclockwisewill cause the tension to become improperly adjusted.

20-16 GENERAL

9. Remove the timing belt lower cover.10. Loosen the tensioner mounting bolts 1 and 2 in that order as

shown to give the timing belt spring tension.

11. Check the belt to ensure that it is not out of position.

12. Tighten the tensioner attaching bolts 2 and 1 in that order as

13. Give the crankshaft one turn in operating direction (clockwise)

shown. If the bolt 1 is tightened first, the tensioner will move withthe bolt and cause the belt to become overtightened.

and realign crankshaft sprocket timing mark with the top deadcenter position.

CAUTION:Do not turn the crankshaft in a counterclockwise direc-tion.

14. Loosen the tensioner attaching bolts 1 and 2 in that order asshown.

15. Retighten the tensioner attaching bolts 2 and 1 in that orderas shown to the specified torque.

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-27 Nm (200-270 kg.cm, 14-20 Ib.ft)

16. Recheck the belt tension. When the tensioner and the tensionside of the timing belt are pushed in horizontally with a moderateforce [approx. 49 N (11 lb)], the timing belt cog end is approx.Half of the tensioner mounting bolt head radius (across flats)away from the bolt head center.

GENERAL

TENSION MEASURING PROCEDURE(When using a tension gauge)1. Rotate the crankshaft in a counterclockwise direction to

position of 90 degrees before top dead center as shown in theillustration.

NOTE : Make sure the valves are adjusted properly

2. Measure the belt tension in the middle of the tension sidespan using the tension gauge. (BORROUGHS BT-33-73FTYPE)

Timing belt tension (In cool condition) . . . . . . . . . . . . . . . . . . . .9.5-16.5 kg (20.9-36.4 lb)

CAUTION1) Put arm on bottom of belt teeth. And put spindle on the

middle of belt back surface.2) Keep hand off from indicating part.

20-18 ENGINE MOUNTING

ENGINE MOUNTING

COMPONENTS

Vehicle with a manual transaxle Vehicle with an automatic transaxle

TORQUE : Nm (kg.cm, Ib.ft)

ENGINE MOUNTING 20-19

REMOVAL

Attach an engine hoist to the engine hooks, and raise just enoughso that there is no pressure on the insulators.

Engine Mounting

1. Remove the engine mount insulator bolts.2. Remove the engine mount bracket from the engine.

Transaxle

1. For vehicles with a 5-speed manual transaxle, remove theselect control valve.

2. Remove the transaxle mount bolt.

3. Detach the cap from the inside of the left fender shield,remove the transaxle mounting bolts.

4. Remove the transaxle bracket.

Front Roll Stopper

Remove the front roll stopper bracket from the center member.

Rear Roll Stopper

Remove the rear roll stopper from the center member.

ENGINE MOUNTING

Center member1. Remove the under cover (R.H.).2. Remove the front roll stopper mounting bolts.3. Remove the rear roll stopper mounting bolts.4. Remove the center member from the body.

INSPECTION ITEMS

Transaxle mounting Engine mounting

Cracks, peeling anddamage

Front roll stopper Rear roll stopper

Cracks, peeling anddamage

Center member

Cracks and damage

ENGINE AND TRANSAXLE ASSEMBLY 20-21

ENGINE AND TRANSAXLE ASSEMBLYREMOVAL

1. Remove the battery.2. Detach the air cleaner.3. Disconnect the connectors for the backup lamp switch and

engine harness.4. For a vehicle with a 5-speed manual transaxle, disconnect

the select control valve connector.

5. Disconnect the connectors for the alternator harness and theoil pressure gauge wiring.

6. Drain the engine coolant.7. For vehicles with an automatic transaxle, disconnect the

transaxle oil cooler hoses.NOTEWhen disconnecting the hoses, identify their location toavoid making any errors during reassembly.

CAUTIONBe careful not to spill any oil or fluids. Also take care inpreventing the entrance of foreign material.

8. Disconnect the radiator upper and lower hoses on the engine

side, and then remove the radiator assembly.9. Disconnect the high tension cable and all wires to the distributor

from the ignition coil section.10. Disconnect the engine ground.11. Disconnect the brake booster vacuum hose.12. Remove the main fuel line, and the return and vapor hoses from

the engine side.CAUTION

To reduce the residual pressure in the hoses, refer toGroup Fuel System “Fuel filter replacement”.

13. Disconnect the heater hoses (inlet and outlet) on the engine

side.14. Disconnect the accelerator cable at the engine side.15. For vehicles with a manual transaxle, remove the clutch

cable from the transaxle.16. For vehicles with an automatic transaxle, remove the control

cable from the transaxle.17. Disconnect the speedometer cable from the transaxle.

18. Disconnect the air conditioner from the mounting bracket.19. Jack up the vehicle.

20-22 ENGINE AND TRANSAXLE ASSEMBLY

20. Drain the transaxle oil (or fluid).21. Disconnect the front exhaust pipe from the manifold or the

turbo charger discharge pipe. (for T/C)

NOTE:Use wire to suspend the exhaust pipe from the bottom ofthe vehicle.

22. For vehicles with a manual transaxle, remove the shift controlrod and extension rod.

23. Remove the lower arm ball joint bolts and the strut bar at thepoint where it is mounted to the lower arm.

24. Remove the drive shafts from the transaxle case.

CAUTION1) Plug the axle holes of the transaxle case to prevent

entry of foreign material.2) Install new circlips on the drive shafts when

reassembling.

25. Hang the lower arm and drive shaft from the body with wire.26. Attach a cable to the engine, and use a chain hoist to lift the

engine only enough to pull the cable tight.

27. Remove the front roll stopper.28. Separate the rear roll stopper.

29. Remove the engine mounting insulator bolts.30. Remove the engine mounting bracket from the engine.

32. Slowly raise the engine (to the extent that the engine andtransaxle weights are not applied to the mounting portions)and temporarily hold it in the raised condition.

CAUTIONCheck that all of the cables, hoses, harnesses, connectorsetc. are disconnected from the engine.

33. Remove the caps from inside the left fender shield andremove the transaxle mount bracket bolts.

34. Remove the engine mount insulator bolt.While directing the transaxle side downward, lift the engineand transaxle assembly up and out of the vehicles.

*T/C: Turbo charger

ENGINE AND TRANSAXLE ASSEMBLY 20-23

INSTALLATION

1. While checking the connections of the harnesses, pipes,hoses, etc., and making sure that none of them are beingcaught, damaged, etc., install the engine and transaxleassembly.

2. When the engine and transaxle assembly is installed tempo-rarily tighten the front roll stopper.

3. The front and rear center member rubber bushings andcollars are different.

4. After the weight of the engine and transaxle assembly hasbeen put on each insulator, tighten to specified torque.

5. Reassemble all of the components removed during disas-sembly. Be especially careful to properly secure all compo-nents, including fuel, electrical and fluid pipe connections.

6. Refill the coolant and check for leaks.7. Refill the transaxle fluid, test its operation, and check for

leaks.8. Check the operation of the transaxle control cable and

accelerator cable. Adjust as necessary.9. Check for proper operation of each of the various gauges.

20-24 TIMING BELT

TIMING BELT

COMPONENT

Loose side of belt Tension side of belt

Timing belt tensioner

Timing mark(Front case)

Timing mark(Crankshaft sprocket)

Crankshaft sprocket


REMOVAL1. Loosen the water pump pulley bolt.2. Loosen the alternator bolt.3. Remove the water pump pulley and belt.4. Remove the crankshaft pulley.5. Remove the timing belt cover.6. Move the timing belt tensioner fulley toward the water pump,

and temporarily secure it.7. Remove the timing belt from the camshaft sprocket.8. Remove the camshaft sprocket.9. Remove the timing belt.

NOTEIf the timing belt is reused, make an arrow mark indicatingthe turning direction (or the front of the engine) to makesure that the belt is reinstalled in the same direction asbefore.

10. Remove the crankshaft sprocket bolts. Remove the crankshaft sprocket and flange.

11. Remove the timing belt tensioner.

TIMING BELT 20-25

INSPECTION

Sprockets and Tensioner

1. Check the camshaft sprocket, crankshaft sprocket and tensionerfor abnormal wear, cracks, or damage. Replace as necessary.

2. Inspect the tensioner for easy and smooth pulley rotation andcheck for play or noise. Replace as necessary.

Timing Belt

1. Check the belt for oil or dust deposits. Replace if necessary.Small deposits should be wiped away with a dry cloth.Do not clean with solvent.

2. When the engine is overhauled or belt tension adjusted, checkthe belt in detail. If the following flaws are evident, replace thebelt with a new one.

Description Flaw conditions

1. Hardened back surface rubber

2. Cracked back surface rubber

3. Cracked or separating canvas

Back surface glossy. Non-elastic and so hard that even if a fingernail is forced into it, no mark is produced.

20-26 TIMING BELT

Description

4. Badly worn teeth (initial stage)

Flaw conditions

Canvas on load side tooth flank worn(Fluffy canvas fibers, rubber gone and color changed to white, andunclear canvas texture)

Flank worn(On load side)

5. Badly worn teeth (last stage)

6. Cracked tooth bottom

7. Missing tooth

8. Side of belt badly worn

9. Side of belt cracked

Canvas on load side tooth flank worn down and rubber exposed(tooth width reduced)

Round belt side

Abnormal wear(Fluffy canvas fiber)

NOTENormal belt should have precisely cut sides as if produced bya sharp knife.

TIMING BELT 20-27

INSTALLATION

1. Install the flange and crankshaft sprocket as shown. Pay closeattention to their mounting directions.

Tightening torqueCrankshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190-200 Nm (1900-2000 kgcm, 140-147.5 Ib.ft)

2. Install the camshaft sprocket and tighten the bolt to the specifiedtorque.

Tightening torqueCrankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-14 Nm (130-140 kg.cm, 9.6-10.3 Ib.ft)

3. Align the timing marks of the camshaft sprocket and crankshaft sprocket, with the No.1 piston placed at top deadcenter on its compression stroke.

190-200Nm(1900-2000kg.cm,137-145lb.ft)

20-28 TIMING BELT

4. To install the timing belt tensioner, first mount the tensioner,spring, and spacer. Temporarily tighten the bolts. Next, temporarily tighten the tensioner long hole side washer and bolts.Install the bottom end of the spring against the front case asshown in the illustration.

5. Secure the tensioner, positioned towards the water pump.6. Install the timing belt on the crankshaft sprocket.7. Install the timing belt on the camshaft sprocket.

When the timing belt is installed on the camshaft sprocket, makesure that the tension side is tight. Then, check to ensure thatwhen the tension side is tightened by turning the camshaftsprocket in a reverse direction, all timing marks are in line.

8. Loosen the tensioner mounting bolts 1 and 2 in that order asshown. This will apply spring tension to the timing belt only.Check the belt to ensure that it is not out of position.

9. Tighten the tensioner tightening bolts 1 and 2 in that order. if thebolt 1 is tightened first, the tensioner will move with the belt inthe direction that the belt is tightened.

10. Give the crankshaft one turn in operating direction (clock wise)and realign crankshaft sprocket timing mark with the top deadcenter position.

CAUTIONDo not turn the crankshaft in a counterclockwise direc-tion. The crankshaft should turn smoothly.

11. Loosen the tensioner attaching bolts 1 and 2 in that order.12. Tighten the tensioner attaching bolts 2 and 1 in that order to

the specified torque.

Tightening torqueTensioner attaching bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-27 Nm (200-270 kg.cm, 14-20 Ib.ft)

13. Then recheck the belt tension. Verify that when the tensionerand the tension side of the timing belt are pushed in horizontallywith a moderate force [approx. 49 N (11 lb)], the timing belt cogend is approx. ½ of the tensioner mounting bolt head radius(across flats) away from the bolt head center.

TIMING BELT

14. lnstall the timing belt cover.

Tightening torqueTiming belt cover bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-12 Nm (100-120 kg.cm, 7.2-8.7 Ib.ft)

15. Install the crankshaft pulley. In this case, make sure that thecrankshaft sprocket pin fits the small hole in the pulley.

Tightening torqueCrankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-12 Nm (100-120 kg.cm, 7.2-8.7 Ib.ft)

16. lnstall the fan belt and adjust the belt tension.17. Install the water pump pulley18. Install V-belt and adjust the belt tension.

20-30 ROCKER ARMS AND ROCKER SHAFTS

ROCKER ARMS AND ROCKER ARM SHAFTS

COMPONENTS

12-18(120-180,9-15)

Rocker shaft springValve cap

Timing belt side

Rocker arm

TORQUE : Nm (kg.cm, lb.ft)

REMOVAL

1. Remove the air intake pipe. (Turbo charger only)2. Remove the breather hose and secondary air hose.3. Remove the timing belt cover.4. Remove the rocker cover.5. Loosen the flange bolts, it holds rocker arm shafts rocker and

remove the rocker arm shaft, rocker arms and rocker arm shaftsprings as an assembly.

6. Remove the bolts, the rocker arms and rocker arm shaft springsfrom the rocker arm shaft.

INSPECTION

1. Check the rocker arm face that contacts the cam lobe. If badlyworn or damaged, replace rocker arm.

2. Check the valve cap face that contacts the valve stem. If badlyworn or damaged, replace valve cap.

3. Check the rocker arm shafts for damage. Replace as neces-sary.

ROCKER ARMS AND ROCKER SHAFTS 20-31

INSTALLATION

1. Install the rocker arms and rocker arm shaft springs to therocker arm shafts. Install the rocker arm shafts to the cylin-der head.Tighten the rocker arm shaft mounting bolts to the specifiedtorque.

Tightening torqueRocker arm shaft mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-26 Nm (200-260 kg.cm, 14-19.2 Ib.ft)

CAUTIONAdjust the valve dearence, whenever you remove therockerarms or rockerarm shafts.

2. When installing the rocker arms, shafts note the differencebetween the A and B type rockerarms, and exhaust side needsonly A type rockerarms.

3. Install the rocker cover and tighten the bolts to the specifiedtorque.

Tightening torqueRocker cover bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5-2.0 Nm (15-20 kg.cm, 1.1-1.4 Ib.ft)

CAUTION1. Sealant must be applied to top surface of cylinder head

and cam cap and area of application is shown in figure.2. The proper amount of sealant must be used to prevent the

sealant from pushing excessive amounts.3. Use sealant of specified brands or equivalent.4. Sealant (Three bond No 1212D aluminum color) or equiva-

lent) application place (4 place).

4. Install the timing belt cover.

Tightening torqueTiming belt cover bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-12 Nm (100-120 kg.cm, 7.2-8.7 Ib.ft)

5. Install the air cleaner.6. Install the breather hose.

20-32 CAMSHAFT

CAMSHAFT

COMPONENTS

80-100(800-1000,58-72)

Bolt


REMOVAL

1. Remove the air intake pipe. (Turbo charger only)2. Disconnect the breather hose and the secondary air hose.3. Remove the water pump pulley and crankshaft pulley4. Remove the timing belt cover.5. Move the timing belt tensioner pulley toward the water pump

and temporarily secure it.6. Remove the timing belt from the camshaft sprocket and the

timing belt.7. Remove the camshaft sprocket.8. Remove the distributor9. Remove the rocker cover.10. Remove the rocker arm shaft assembly. Refer to “Rocker Arms

and Rocker Arm Shafts”.11. Remove the camshaft bearing caps.12. Remove the camshaft.

CAMSHAFT 20-33

INSPECTION1. Check the camshaft journals for wear. If the journals are badly

worn, replace the camshaft.2. Check the cam lobes for damage. If the lobe is damaged or worn

excessively, replace the camshaft.

Cam height [Standard]Intake

41.0837 mm (1.5318 in.) (N/A)41.2689 mm (1.4990 in.) (T/C)

Exhaust41.2698 mm (1.5344 in.) (N/A)41.2698 mm (1.5020 in.) (T/C)

3. Check the cam surface for abnormal wear or damage, andreplace if necessary.

4. Check each bearing for damage. If the bearing surface isexcessively damaged, replace the cylinder head assembly orcamshaft bearing cap, as necessary.

5. Oil Seal (camshaft front)1) Check the lips for wear. If lip threads are worn, replace.2) Check the oil seal lip contacting surface of camshaft. If it is

worn in stages, replace the camshaft.

INSTALLATION

1. Install the camshaft after lubricating the jaurnal of camshaft withengine oil.

2. Install the camshaft bearing caps as shown in figure.

3. Install the distributor.4. Install the rocker arm and rocker arm shaft.

Refer to “Rocker Arms and Rocker Arm Shafts”.

5. Using special tools, Camshaft Oil Seal Installer (09221-21000),press fit the camshaft oil seal. Be sure to apply engine oil to theexternal surface of the oil seal.

Insert the oil seal along the camshaft front end and install bydriving the installer with a hammer until the oil seal is pulleyseated.

CAMSHAFT

6. Install the camshaft sprocket and tighten the bolts to thespecified torque.

7. Align the camshaft sprocket and crankshaft sprocket timingmarks. The piston in the No. 1 cylinder will then be at the topdead center on the compression stroke.

Tightening torqueCamshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80-100 Nm (800-1000 kg.cm, 58-72 Ib.ft)

8. Temporarily set the valve clearance to specification with theengine cold. See “Valve Clearance Adjustment Procedure”.

Valve clearance (cold engine) [Standard value]Intake valve . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)Exhaust valve . . . . . . . . . . . . . . . . . 0.24 mm (0.009 in.)

9. Install a gasket in the rocker cover groove.10. Temporarily install the rocker cover.11. Start the engine and run at idle.12. After warming the engine to normal operating temperature [80

to 95°C (176 to 205°F) coolant temperature], adjust the valveclearance to specification. See “Valve Clearance AdjustmentProcedure”.

13. lnstall the rocker cover and tighten the bolts to the specifiedtorque.

Tightening torqueRocker cover bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5-2.0 Nm (15-20 kg.cm, 1.1-1.4 Ib.ft)

14. lnstall the timing belt cover.15. lnstall the water & pump pulley and crankshaft pulley16. Install the air intake-pipe (Turbo charger only)

CYLINDER HEAD 20-35

CYLINDER HEAD

COMPONENTS

FRONT

Cylinder headgasket

TORQUE : Nm (Kg.cm, Ib.ft)

REMOVAL1. Drain the coolant and disconnect the upper radiator hose.2. Remove the breather hose (between the air cleaner and the

rocker cover).3. Remove the air intake pipe (T/C) and the air-intake hose.4. Remove the vacuum hose, fuel hose and water hose.5. Remove the cables from the spark plugs. The cables should be

removed by holding the boot portion.

20-36 CYLINDER HEAD

6. Remove the distributor.7. Remove the surge tank.8. Remove the intake manifold.9. Remove the heat protector and exhaust manifold assembly.10. Remove the water pump pulley and the crankshaft pulley.11. Remove the timing belt cover.12. Move the timing belt tensioner pulley toward the water pump

and temporarily secure it.13. Remove the timing belt.14. Remove the rocker cover.

15. Remove the cylinder head assembly. The cylinder head boltsshould be removed by using Special Tool, Cylinder Head BoltWrench (09221-11001), in the sequence as shown in theillustration.

16. Remove the gasket pieces from the cylinder block top surfaceand cylinder head bottom surface.

NOTEMake sure that the gasket pieces do not fall in the engine.

INSPECTION

1. Check the cylinder head for cracks, damage and coolantleakage.

2. Remove scale, sealing compound and carbon deposits completely. After cleaning oil passages, apply compressed air tomake certain that the passages are not clogged.

3. Check the cylinder head gasket surface for flatness by using astraight edge in the direction of A, B, . . . as shown.If flatness exceeds service limit in any direction, either replacethe cylinder head, or lightly machine the cylinder head gasketsurface.

Flatness of cylinder head gasket surface[Standard dimension] . . . . . . . . . . Less than 0.05 mm (0.002 in.)[Limit] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.004 in.)

Crankshaft pully side

CYLINDER HEAD 20-37

INSTALLATION

1. Clean all gasket surfaces of the cylinder block and the cylinderhead.

2. Install a new cylinder head gasket onto the cylinder headassembly. Do not apply sealant to the gasket and do not reusethe old cylinder head gasket.

3. Install the cylinder head bolts. Starting at top center, tighten allcylinder head bolts in sequence as shown in illustration, usingthe Cylinder Head Bolt Wrench (09221-11001). Repeat theprocedure, retightening all cylinder head bolts to the specifiedtorque.

Tightening torqueCylinder head boltWhen cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70-75 Nm (700-750 kg.cm, 51-54 Ib.ft)When hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80-85 Nm (800-850 kg.cm, 58-61 Ib.ft)

4. Move the timing belt tensioner pulley toward the water pumpand temporarily secure it.

5. Install the timing belt on the camshaft sprocket, making surethat the tension side is tight. Check to ensure that when thetension side is tightened by turning the camshaft sprocket inreverse, all timing marks are in alignment.

6. Adjust the timing according to ‘Timing Belt”.7. Install the rocker cover and tighten the bolts to the specified

torque.

Tightening torque Rocker cover bolt . . . . . . . . . . . . . . . . . . . . . . . . .1.5-2.0 Nm (15-20 kg.cm, 1.1-1.4 Ib.ft)

8. Install the timing belt cover.9. Install the new intake manifold gasket and the intake manifold.

Tighten the nuts and bolts to the specified torque.

Tightening torqueManifold nuts and bolts (both intake and exhaust) . . . . . . . . . . .

15-20 Nm (150-200 kg.cm, 11-14 Ib.ft)

10. Install the new exhaust manifold gasket and the exhaustmanifold. Tighten the exhaust manifold attaching nuts to thespecified torque.

11. Install the surge tank and tighten the nuts and bolts to thespecified torque.

Crankshaft pully side

Tightening torqueSurge tank to inlet manifold nuts and bolts . . . . . . . . . . . . . . . . . .

15-20 Nm (150-200 kg.cm, 11-14 Ib.ft)

20-38 CYLINDER HEAD

12. Install the distributor.13. Install the air intake pipe (T/C) and the air intake hose.14. Connect the vacuum hose, fuel hose and water hose.15. Install breather hose.

VALVES AND VALVE SPRINGS 20-39

VALVES AND VALVE SPRINGS

COMPONENTS

Exhaust valve seat

REMOVAL1. Using Special Tool, Valve Spring Compressor (09222-28000,

09222-28100) remove the retainer lock.Next remove the spring retainer, valve spring, spring seat andvalve.

NOTEKeep these parts in order so that they can be reinstalled intheir original positions.

2. Remove the valve stem seals with pliers, and discard.

NOTEDo not reuse the valve stem seals.

20-40 VALVES AND VALVE SPRINGS

INSPECTION

ValvesCheck each valve for wear, damage and distortion of head andstem at B. Repair or correct if necessary.If stem end A is pitted or worn, resurface as necessary. Thiscorrection must be limited to a minimum. Also resurface the valveface.Replace the valve if the margin has decreased to less than theservice limit.

Margin[Standard dimension]

Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 mm (0.051 in.)Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 m m (0.067 in.)

[Limit]Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 mm (0.043 in.)Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 m m (0.059 in.)

Valve Springs1. Check the valve spring free length and tension. If they exceed

the service limit, replace the spring.2. Using a square, test the squareness of each spring. If the spring

is excessively out of square, replace it.

Valve spring[Standard Value]

Free height . . . . . . . . . . . . . . . . . . . . . 40 mm (1.575in.)Load . . . . . . . . . 20 kg at 32 mm (53 lb at 1.075 in.)Out of square . . . . . . . . . . . . . . . . . . . . . . . . 1.5° or less

Valve GuidesCheck the valve stem-to-guide clearance. If the clearance exceedsthe service limit, replace the valve guide with next oversize part.

Valve stem-to-guide clearance[Standard dimension]

Intake . . . . . . . . . . . . . . . . 0.03-0.06 mm (0.0012-0.0024 in.)Exhaust . . . . . . . . . . . . . 0.05-0.08 mm (0.0020-0.0031 in.)

[Limit]Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.004 in.)Exhaust . . . . . . . . . . . . . . . . . . . . . . . .0.15 mm (0.006 in.)

Valve Guide Oversizes

Size mm (in.) Size markCylinder head hole sizemm (in.)

Guide inside diameter

0.05 (0.002) O.S 5 11.05-11.058(0.4350-0.4354)

0.25 (0.010) O.S 25 11.25-11.258(0.4291-0.4432)

0.50 (0.020) O.S 50 11.50-11.508(0.4528-0.4531)


Valve Seat Insert

Check the valve seat for evidence of overheating and impropercontact with the valve face. Recondition or replace the seat ifnecessary.Before reconditioning the seat, check the valve guide for wear. Ifthe valve guide is worn, replace it, then recondition the seat.Recondition the valve seat with a valve seat grinder or cutter. Thevalve seat contact width should be within specifications andcentered on the valve face.

Valve Seat Insert Replacement Procedure

1. Any valve seat insert that has been worn over the service limitshould be removed at normal temperature after cutting awaymost of the insert wall, using valve seat cutters, as shown in Fig,“A”.

1.1-1.5mm 1.5-1.7mm(0.034-0.059in.) (0.059-0.067in.)

Exhaust intake

0.15 mm A B(0.006 in.)

Valve Seat Insert Oversizes

Description Size mm (in.) Size mark Seat insert height H mm (in.) Cylinder head I.D. mm (in.)

Intake valve 0.3 (0.012) O.S 30 5.1-5.3 (0.201-0.209) 28.80-28.821 (1.134-1.135)seat insert 0.6 (0.024) O.S 60 5.4-5.6 (0.213-0.220) 29.10-29.121 (1.146-1.147)Exhaust valve 0.3 (0.012) O.S 30 5.9-6.1 (0.232-0.240) 34.30-34.325 (1.350-1.351)seat insert 0.6 (0.024) O.S 60 6.2-6.4 (0.244-0.252) 34.60-34.625 (1.362-1.363)

2. After removing the seat insert, machine the seat insert boreusing a reamer or a cutter. Cut to the size shown in the table.

3. Heat the cylinder head to about 250°C (480°F) and press in theoversize seat insert. The oversize seat insert should be atnormal room temperature for installation. After installation of anew valve seat insert, resurface the valve seat using the sameprocedure as in paragraph 1. in Valve Seat Insert.

20-42 VALVES AND VALVE SPRINGS

Valve Guide Replacement Procedures

The valve guide is installed using a press fit. Using a Valve GuideInstaller (09221-22000) or suitable tool, replace the valve guide bythe following procedure.1. Using the push rod of the Valve Guide Installer, push the valve

guide out toward the cylinder block with a press.2. Machine the valve guide insert hole in the cylinder head to the

specified oversize of the new valve guide.

3. Using the Valve Guide Installer or suitable tool, press fit thevalve guide. The use of the valve guide installer makes itpossible to press fit the valve guide to a predetermined height.The valve guide should be installed from the top of the cylinderhead. Note that the intake and exhaust valve guides aredifferent in length [42.7 mm (1.68 in.) for intake and 39.1 mm(1.54 in.) for exhaust].

4. After the valve guides have been installed, insert new valvesand check the clearance.

5. Whenever valve guides are replaced, check for valve to seatcontact and recondition the valve seats as necessary.


INSTALLATION

1.

2.

CAUTION1) Clean each part before assembly.2) Apply engine oil to sliding and rotating parts.

After installing the spring seat, fit the stem seal onto the valveguide.To install, fit the seal in by lightly tapping the Special Tool, ValveStem Oil Seal Installer (09222-22000).The seal is installed in the specified position by means of thespecial tool. Incorrect installation of the seal will adverselyaffect the lip I.D. and eccentricity, resulting in oil leakage downthe valve guides. When installing, therefore, be careful not totwist the seal. Do not reuse old stem seals.

Apply engine oil to each valve stem. Insert the valves into thevalve guides. Avoid inserting the valve into the seal with force.After insertion, check to see if the valve moves smoothly.

3. Install springs and spring retainers.Valve springs should be installed with the enamel coated sidetoward the valve spring retainer.

4. Using Special Tool, Valve Spring Compressor (09222-28000,09222-28100), compress the spring. Be careful that the valvestem seal is not distorted by the bottom of the retainer. Theninstall the retainer locks. After installation of the valves, makecertain that the retainer locks are properly installed.

5. Install the cylinder head. Refer to “Cylinder Head”.

20-44 VALVE CLEARANCE

VALVE CLEARANCE

Intake And Exhaust Valve ClearanceAdjustment Procedure

1. Warm up the engine until the temperature of the coolantrises to 80 to 95°C (176 to 205°F).

2. Turn the crankshaft clockwise until the notch on pulley islined up with the “T” mark on timing belt lower cover, toplace piston at top dead center of compression stroke.

3. Move the rocker arms marked A or B up and down by hand.Measure the valve clearance of the rocker arms that aremovable.

4. Loosen nut and adjust to specification with adjusting screw.Then retighten nut.

Valve clearance (on hot engine)Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 m m (0.006 in.)Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 mm (0.010 in.)

5. Repeat steps 2 through 4 for the clearance of other valves.

FRONT CASE, OIL PUMP 20-45

FRONT CASE, OIL PUMP

COMPONENTS

Oil pump cover

40-50(400-500,29-36)


REMOVAL

1. Remove the timing belt. Refer to “Timing Belt”.2. Remove all the oil pan bolts.3. Remove the oil pan.4. Remove the oil screen.5. Remove the front case assembly.

20-46 FRONT CASE, OIL PUMP

6. Remove the oil pump cover.7. Remove the inner and outer gears from the front case. The

mating marks on the inner and outer gears indicate the directionof installation. Make sure that the inner and outer gears areinstalled as shown.

8. Remove the plug and remove the relief spring and reliefplunger.

INSPECTION

Front Case1. Check the front case for cracks or damage. Replace as

necessary.2. Check the front oil seal for worn or damaged lips. Replace if

defective.

Oil Pan and Oil Screen

1. Check the oil pan for failure, damage or cracks.Replace if defective.

2. Check the oil screen for failure, damage and cracks and replaceif defective.

Front Case and Oil Pump Cover

Worn (especially stepped) or damaged surfaces contacting gears.

Oil Pump Gears

1. Worn or damaged gear tooth surfaces.2. Clearance between outer gear and front case.

Outer gearClearance between outer circumference and front case

0.12-0.18 mm

3. Check the tip clearance on the pump roter

Standard . . . . . . . . . . . . . . 0.025-0.069 mm (0.001-0.003 in.)

20-47

4. Check the axial clearance on the outer pump roter.

Standard . . . . . . . . . . . . . . 0.04-0.087 mm (0.0016-0.0034 in.)

Relief Valve and Spring1. Check sliding condition of the relief valve inserted in the front

case.2. Inspect for distorted or broken relief valve spring.

[Standard value]Free height . . . . . . . . . . . . . . . . . . . . . . . 46.6 mm (1.835 in.)Load . . . . . . . . . . . . . . 6.1 kg/40.1 mm (13.4 lb/1.579 in.)

20-48 FRONT CASE, OIL PUMP

INSTALLATIONOil Pump1. Install the outer and inner gears into the front case. Make sure

that the inner and outer gears are installed in the same directionas shown.

2. Install the oil pump cover and tighten the bolts to the specifiedtorque. After the bolts have been tightened, check to ensurethat the gear turns smoothly.

Tightening torqueOil pump cover bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-12 Nm (80-120 kg.cm, 6-8.8 Ib.ft)

3. Install the relief valve and spring. Tighten the plug to thespecified torque. Apply engine oil to the relief valve.

Tightening torqueRelief valve plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40-50 Nm (400-500 kg.cm, 29-36 Ib.ft)

Front CaseInstall the front case assembly with a new gasket, and tightenthe bolts to the specified torque.

Body length (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 mm (0.98 in.)(B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 mm (1.18 in.)(C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 mm (1.77 in.)(D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.36 in.)

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-15 Nm (120-150 kg.cm, 8.7-11 Ib.ft)

Oil Seal1. Inspect for worn, distorted or damaged lips.2. Check for elongated spring ring.3. Install Special Tool, Crankshaft Front Oil Seal Guide (09231-

22100), to the front end of the crankshaft. Apply engine oil to theouter surface of the oil seal guide, and install the new oil sealalong the guide by hand, until it touches front case. Always usea new oil seal when reassembling.

4. Use Special Tool, Crankshaft Front Oil Seal Installer (09231-22000), to install the oil seal.

5. Install the crankshaft sprocket, timing belt and crankshaftpulley. Refer to “Timing Belt”.

6. Install the oil screen.7. Clean both gasket surfaces of the oil pan and the cylinder block.

FRONT CASE, OIL PUMP 20-49

8. Apply sealant into the groove of the oil pan flange as shown.CAUTION1) Apply sealant approx. 4 mm (0.16 in.) in thickness.2) After application of sealant, do not exceed 15 minutes

before installing the oil pan.

9. Install the oil pan and tighten the bolts to the specifiedtorque.

Tightening torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil pan bolt 6-8 Nm (60-80 kg.cm, 4-6 Ib.ft)

20-50 PISTON AND CONNECTING ROD

PISTON AND CONNECTING ROD

COMPONENTS

Bolt

N/A

T/C


REMOVAL

Connecting Rod Cap

NOTEKeep the bearings in order with their corresponding connect-ing rods (according to cylinder numbers) for properreassembly.

1. Remove the connecting rod cap nuts and then remove the capsand the big end lower bearing.

2. Push each piston-connecting rod assembly toward the top ofthe cylinder.

Piston Pin Removal and Installation Procedures

1. Use the special tools (09234-33001) to disassemble and re-assemble the piston and connecting rod.

2. Place the proper insert in the fork (09235-22000) of the tool.Position the insert between the connecting rod and the piston.

PISTON AND CONNECTING ROD 20-51

3. insert the proper removal tool through the hole in the arch of thetool.

NOTECenter the piston, rod and pin assembly with the removalarbor.

4. Press the piston pin out of the connecting rod.

5. Install proper pin guide (refer to application chart) through pistonand into connecting rod. Hand tap pin guide into piston forproper retention. Drop piston pin into the other side of the piston.

NOTEThe pin guide centers the connecting rod in the piston.When the piston, connecting rod, piston pin and pin guideassembly are positioned on the fork of the tool, the pinguide will also center this assembly in the tool. If a pinguide that is too small is used, the piston assembly willnot be located centrally in the tool, and damage may occurto the fork and/or the insert of the tool.

6. Install piston assembly onto fork assembly of tool. Tool willsupport connecting rod at the piston pin. Be sure piston assem-bly is slid onto the fork until the pin guide contacts the fork insert.

7. Adjust the installing arbor to the proper length by turning thenumbered sleeve on the lettered shaft until the specified alpha-numeric setting from the application chart is obtained. Turnknurled nut to lock numbered sleeve on shaft.

8. Insert the installing arbor through the hole in the arch of the tool.Press piston pin into the connecting rod until the sleeve on theinstalling arbor contacts the top of the tool arch. The pin guidewill fall out of the connecting rod as the piston pin is pressed in.

CAUTIONDo not exceed 5000 pounds of force when stopping theinstalling arbor sleeve against the arch.

NOTEBowl depth

Natural AspirationTurbo Charger

0.3-0.56.1-6.3


INSPECTION

Piston and Piston Pin1. Check each piston for scuffing, scoring, wear, and other de-

fects.Replace any piston that is defective.

2. Check each piston ring for breakage, damage, and abnormalwear. Replace the defective rings. When the piston requiresreplacement, its rings also should be replaced.

3. Check the piston pin fit in the piston pin hole. Replace any pistonand pin assembly that is defective.The piston pin must push into the pin hole by hand at roomtemperature.

Piston Rings

1. Measure the piston ring side clearance. If the measured valueexceeds the service limit, insert a new ring in a ring groove tomeasure the side clearance. If the clearance still exceeds theservice limit, replace the piston and rings together. If it is lessthan the service limit, replace the piston rings only.

Piston ring side clearanceNo1. . . . . . . . . . . . . . . . . . . . 0.04-0.08 mm (0.0016-0.0031 in.)No2. . . . . . . . . . . . . . . . . . . 0.04-0.08 mm (0.0016-0.0031 in.)[Limit]No1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.004 in.)No2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.004 in.)

2. To measure the piston ring end gap, insert a piston ring into thecylinder bore. Correctly position the ring into the cylinder bygently pushing it down with a piston. Remove the piston andmeasure the end gap with a feeler gauge. If the gap is not withinthe service limit, replace the piston ring.

Piston ring end gap No.1 and No.2[Standard dimension] .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.3-0.5 mm (0.012-0.020 in.)[Limit] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 mm (0.039 in.)

Oil ring side rail end gap[Standard dimension] . . . . 0.025-1.0 mm (0.010-0.039 in.)[Limit] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 mm (0.039 in.)

When replacing the ring only, without correcting the cylinderbore, check the end gap with the ring positioned at the bottomof the ring travel.

When replacing a ring, be sure to use a ring of the same size.

Piston ring service size and markSTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None0.25 mm (0.010 in.) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250.50 mm (0.020 in.) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500.75 mm (0.030 in.) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751.00 mm (0.039 in.) O.S . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

NOTEThe mark can be found on the upper side of the ring nextto the end.

PISTON AND CONNECTING ROD 20-53

Connecting Rods

1. When reinstalling, make sure that cylinder numbers put on theconnecting rod and cap at disassembly match.When a new connecting rod is installed, make sure that thenotches for holding the bearing in place are on the same side.

2. Replace the connecting rod if it is damaged on the thrust facesat either end. Also if step wear or a severely rough surface of theinside diameter of the small end is apparent, the rod must bereplaced as well.

3. Using a connecting rod aligning tool, check the rod for bend andtwist. If the measured value is close to the repair limit, correctthe rod by a press. Any connecting rod that has been severelybent or distorted should be replaced.

Allowable bend of connecting rod . . . . . . . . . . . . . . . . . . . . . .0.05 mm/100 mm (0.0020 in./3.94 in.) or less

Allowable twist of connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . .0.1 mm/100 mm (0.0039 in./3.94 in.) or less

INSTALLATION

1. Install the spacer.

2. Install upper side rail. To install side rail, first put one end of siderail between piston ring groove and spacer, hole it down firmly,and then press down the portion which is to be inserted intogroove with a finger as illustrated.

NOTEDo not use piston ring expander when installing side rail.

3. Install lower side rail by same procedure as Step 2.

4. Using piston ring expander, install No.2 piston ring.5. Install No.1 piston ring.6. Apply engine oil around piston and piston rings.


7. Position each piston ring end gap as for apart from neighboringgaps as possible. Make sure that gaps are not positioned inthrust and pin directions.

8. Hold piston rings firmly in a piston ring compressor as they areinserted into cylinder.

9. Make sure that front mark of piston and front mark (identificationmark) of connecting rod are directed toward front of engine.

10. When connecting rod cap is installed, make sure that cylindernumbers put on rod and cap at disassembly match.

11. When new connecting rod is installed, make sure that notchesfor holding bearing in place are on same side.

12. Tighten the connecting rod cap nuts.

Tightening torqueConnecting rod cap nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35-38 Nm (350-380 kg.cm, 25-28 Ib.ft)

13. Check connecting rod side clearance.

Side clearance . . . . . . . . . . . . 0.10-0.25 mm (0.004-0.010 in.)Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 mm (0.0157 in.)

CRANKSHAFT 20-55

CRANKSHAFT

COMPONENTS

Main bearing cap


Crankshaft lowerbearing

REMOVAL

1. Remove the timing belt, front case, flywheel, cylinder headassembly and oil pan. For details refer to respective chapters.

2. Remove the rear plate and the rear oil seal.3. Remove the connecting rod caps.

NOTEMark the main bearing caps to permit reassembly in theoriginal position and direction.

4. Remove the main bearing caps and remove the crankshaft.Keep the bearings in order by cap number.

INSPECTION

Crankshaft1. Check the crankshaft journals and pins for damage, uneven

wear and cracks. Also check oil holes for clogging. Correct orreplace any defective part.

2. Inspect out-of-roundness and taper of the crankshaft journalsand pins.

[Standard dimension]Crankshaft journal O.D . . . . . . . . . . . . . . . . . 50 mm (1.8898 in.)Crank pin O.D . . . . . . . . . . . . . . . . . . . . . . . 45 mm (1.6535 in.)Crankshaft journal, pin out-of-roundness and taper . . . . . . . .

0.01 mm (0.004 in.) or less

20-56 CRANKSHAFT

Main Bearings and Connecting Rod Bearings.

Visually inspect each bearing for peeling, overheating, seizure andimproper contact. Replace the defective bearings.

Oil Clearance Measurement

To check the oil clearance, measure the outside diameter of thecrankshaft journal and the crank pin and the inside diameter of thebearing. The clearance can be obtained by calculating the differ-ence between the measured outside and inside diameters.

Journal oil clearance . . . . . . . . 0.032-0.056 mm (0.0008-0.0028 in.)Pin oil clearance . . . . . . . . . . . . 0.026-0.056 mm (0.0010-0.0022 in.)

Oil Clearance Measurement (Plastigauge Method)

Plastigauge may be used to measure the clearance.1. Remove oil and grease and any other dirt from the bearings and

journals.2. Cut the plastigauge to the same length as the width of the

crankshaft journal and place it in parallel with the journal, awayfrom oil holes.

3. Install the bearings and caps and tighten them to the specifiedtorque. During this operation, do not turn the crankshaft. Remove the caps. Measure the width of the plastigauge at thewidest part by using a scale printed on the plastigauge package.If the clearance exceeds the repair limit, the bearing should bereplaced or an undersize bearing be used.When installing a new crankshaft, be sure to use standard sizebearings.Should the standard clearance not be obtained even afterbearing replacement, the journal should be ground to a recom-mended undersize, and a bearing of the same size should beinstalled.

Oil SealCheck the front and rear oil seals for damage or worn lips.Replace any seal that is defective.

CRANKSHAFT 20-57

INSTALLATION

1. Install the upper main bearing inserts in the cylinder block.When reusing the main bearings, remember to installthem by referring to the location marks made at the timeof disassembly.

2. Install the crankshaft. Apply engine oil to the journals.

3. Install bearing caps and tighten cap bolts to the specified torquein the sequence of the center, No.2, No.4 front and rear caps.Cap bolts should be tightened evenly in 2 to 3 stages before theyare tightened to the specified torque.The caps should be installed with the arrow mark directedtoward the crank pulley side of engine. Cap numbers must becorrected.

Tightening torqueMain bearing cap bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55-60 Nm (550-560 kg.cm, 40-43.4 Ib.ft)Connecting rod cap bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35-38 Nm (350-380 kg.cm, 25-28 Ib.ft)

4. Make certain that the crankshaft turns freely and has the properclearance between the center main bearing thrust flange andthe connecting rod big end bearing.

Crankshaft end play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.05-0.175 mm (0.002-0.005 in.)

5. Install the oil seal in the crankshaft rear oil seal case. UseSpecial Tool, Crankshaft Rear Oil Seal Installer (09231-11000)as shown. Press fit the oil seal all the way in, being careful notto misalign it.

6. Install the rear oil seal case and gasket. Tighten the five bolts.Apply engine oil to the oil seal lips and crankshaft at the time ofinstallation.

7. Install the rear plate and tighten the bolts.8. Install the connecting rod caps. Refer to “Piston and Connecting

Rods”.9. Install the flywheel, front case, oil pan and timing belt. For further

details, refer to the respective chapters.

20-58 FLYWHEEL

FLYWHEEL

COMPONENTS


M/T : Manual Transaxle VehiclesA/T : Automatic Transaxle Vehicles

REMOVAL1. Remove the transaxle and clutch.2. Remove the flywheel.3. Remove the sensor wheel.4. Check the sensor wheel for damage, cracks and wear, and

replace if necessary.5. Check the clearance between sensor wheel and crank position

sensor with depth gage.

Clearance between sensor wheel and crank position sensor0.5-1.5 mm (0.020-0.059 in.)

NOTE1. Measure, the depth of the top of sensor wheel tooth and the

outside of transaxle housing.2. Measure the difference between sensor length and depth.3. Sensor length is the distance between the end of sensor

and inner point of contacting face.

INSPECTION1. Check the clutch disc contacting surface of the flywheel for

damage and wear. Replace the flywheel if excessively dam-aged or worn.

2. Check the clutch disc contacting surface of the flywheel for run-out.

Standard valueFlywheel run-out . . . . . . . . . . . . . . . . . . . . . . 0.1 m m (0.004 in.)

3. Check the ring gear for damage, cracks and wear, andreplace if necessary.

FLYWHEEL 20-59

INSTALLATION

Install the flywheel assembly and tighten the bolts to the speci-fied torque.

Tightening torqueFlywheel bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

130-140 Nm (1,300-1,400 kg.cm, 94-101 Ib.ft)Sensor wheel bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-15 Nm (120-150 kg.cm, 8.68-10.85 Ib.ft)

CYLINDER BLOCK

CYLINDER BLOCK

COMPONENTS


REMOVAL

1. Remove the cylinder head, timing belt, front case, flywheel,piston and crankshaft.

2. Using the special tool (09234-32000), remove the oil pres-sure switch.For further details, refer to the respective chapters.

3. Remove the piston cooling jet (For turbo charger)

CYLINDER BLOCK 20-61

INSPECTION

Cylinder Block

1. Visually check the cylinder block for scratches, rust and corro-sion. Also check for latent cracks or any other defects by usinga flaw detecting agent (magnafluxing). Correct or replace theblock if defective.

2. Using a straight edge and feeler gauge, check the block topsurface for warpage. Make sure that the surface is free fromgasket chips and other foreign matter.

Standard . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.0020 in.) or lessLimit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.0039 in.)

3. Measure the cylinder bore with a cylinder gauge at three levelsin the directions A and B. If the cylinder bores show more thanthe specified out-of-round or taper or if the cylinder walls arebadly scuffed or scored, the cylinder block should be reboredand honed. New oversize pistons and rings must be fitted.Measuring points are as shown.

Cylinder I.D. . . . . . . . . . . . . . . . . . . . . . . . . . 75.5 mm (2.972 in.)Cylinder I.D. . . . . . . . . . . . taper0.02 mm (0.0008 in. or less)

4. If a cylinder ridge exists, cut away with a ridge reamer.5. Oversize pistons are available in four sizes.

Piston service size and mark mm (in.)0.25 (0.010) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.250.50 (0.020) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500.75 (0.030) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751.00 (0.039) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00

6. When boring the cylinder bore to oversize, keep the specifiedclearance between the oversize piston and the bore, and makesure that all pistons used are of the same oversize.

The standard measurement of the piston outside diameter istaken at a level 12 mm (0.47 in.) above the bottom of the pistonskirt and across the thrust faces.

Piston-to-cylinder wall clearance . . . . . . . . . . . . . . . . . . . . . . . .0.02-0.04 mm (0.0008-0.0016 in.)

CYLINDER BLOCK

Piston Oil Cooling Jet (For Turbo Charger)

1. Check the cooling jet body for damage, cracks, and wear andreplace if necessary.

2. Check the oil hole, if the hole is clogged, blow it out with an airnozzle.

3. Check the check valve stuck.

Check valve springFree height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 mm (0.787 in.)Load . . . . . . . . . . . . . . . . . 0.86 kg at 15.5 mm (0.63 lb at 0.61 in.)

INSTALLATION1. Install the cooling jet

Tightening torque cooling jet bolt . . . . . . . . . . . . . . . . . . . . . . .3-3.5 kg (2.21-2.58 lb)

2. Install the following parts by referring to the respective chapters.(a) Crankshaft(b) Flywheel(c) Piston(d) Cylinder head(e) Timing belt(f) Front case

OIL PRESSURE SWITCH 20-63

OIL PRESSURE SWITCH

The oil pressure switch is located at the exhaust manifold sideof the engine. If the oil pressure in the lubricating system hasdropped below 28 KPa (4 psi) during normal operation, the oilpressure warning light is lit.

REMOVAL AND INSTALLATION

Install the oil pressure switch after applying sealant to thethreaded area.

Sealant . . . . . . . . . . . . . . . . . . . . . . Threebond 1104 or equivalent

NOTEDo not over torque the oil pressure switch.

Tightening torqueOil pressure switch adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-15 Nm (130-150 kg.cm, 9.6-11 Ib.ft)

INSPECTION

1. Check the continuity between the terminal and the body with anohmmeter.If there is noncontinuity, replace the oil pressure switch.

2. Check the continuity between the terminal and the body whenthe fine wedge is pushed. If there is continuity even when thefine wedge is pushed, replace it.

3. Or, if there is no continuity when a 50 KPa (70 psi) vacuum isapplied through the oil hole, the switch is operating properly.Check to see that air doesn’t leak. If air leaks, the diaphragm isbroken. Replace the switch.

COOLINGSYSTEMReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

COOLANT TEMPERATURE SENDER, SENSOR . . . . . 16

WATER HOSE AND PIPE. . . . . . . . . . . . . . . . . . . . . . . . 18

25-2 GENERAL


Cooling method

Cooling systemQuantity

Radiator

TypePerformance

Radiator capMain valve opening pressureVacuum valve opening pressure

Water pumpThermostat

TypeValve opening temperatureFull-opening temperatureValve lift, fully openIdentification mark

Drive belt

TypeWater temperature gauge unit

TypeResistance

Thermo switch (on radiator)Operating temperature

OFF : ONON : OFF

Water temperature sensor

TypeSwitching temperature

Automatic transaxle oil coolerPerformance

Water-cooled, pressurized,Forced circulation with electrical fan

5.5 lit (5.8 U.S.qts., 5.2 Imp.qts.)

Pressurized corrugated fin type38000 Kcal/h

81.4-108 kPa (11.8-15.6 psi, 0.83-1.7 kg/cm2)-6.86 kPa (-1.00 psi, -0.07 kg/cm2) or lessCentrifugal type impeller

Wax pellet type with jiggle valve88º (190°F)100°C (212°F)8.5 mm (0.33 in) or more at 100°C (212°F)88 (Stamped on flange)

V-ribbed belt

Thermistor type90.5-117.5 4 at 70°C (158°F)21.3-26.3 4 at 115°C (239°F)

85±3ºC (185±5.4ºF)78°C (172°F) or more

Heat-sensitive thermistor typeSwitches “ON” at 50°C (122°F) or more

1,200 Kcal/h

SERVICE STANDARD

Standard valueCoolant concentration 50%

TIGHTENING TORQUENm kg.cm Ib.ft

Alternator support bolt and nutAlternator brace boltAlternator brace mounting boltWater pump pulleyCoolant temperature sendorCollant temperature sensorWater outlet fitting boltThermostat housing bolt

20-25 200-250 14-1815-22 150-220 11-1620-28 120-150 9-118-10 80-100 6-78-10 80-100 6-715-20 150-200 9-1415-20 150-200 11-1415-20 150-200 11-14

GENERAL

TROUBLESHOOTING

Symptom

Low coolant level

Clogged radiator

Abnormally high coolanttemperature

Abnormally low coolanttemperature

Leakage from oil coolingsystem

Inoperative electricalcooling fan

Probable cause

Leakage of coolantHeater or radiator hoseFaulty radiator capThermostat housingRadiatorWater pump

Foreign material in coolant

Faulty thermostatFaulty radiator capRestriction to flow in cooling systemLoosen or missing drive beltFaulty water pumpFaulty temperature gauge or wiringFaulty electric fanFaulty thermo-switch in radiatorInsufficient coolant

Faulty thermostatFaulty temperature gauge or wiring

Loosen connectionsCracked or damaged:

HosesPipesOil cooler

Damaged:Thermo sensorElectrical motorRadiator fan relayWiring

Remedy

Repair or replace partsTighten clamps or replace’Replace gasket or housingRepair or replaceReplace parts

Replace coolant

Replace partsReplace partsClear restriction or replace partsAdjust or replaceReplaceRepair or replaceRepair or replaceReplaceRefill coolant

ReplaceRepair or replace

RetightenReplaceRepair or replaceRepair or replace

Replace or repair

25-4 GENERAL

COOLANT LEAK CHECK1. Wait until radiator is cool (less than 38°C 100°F). Loosen

radiator cap.2. Confirm that the coolant level is up to the filler neck.3. Install a radiator cap tester to the radiator filler neck and apply

139.3 KPa (19.9 psi, 1.4 kg/cm2) pressure. Maintain pressurefor two minutes, while checking for leakage from the radiator,hoses or connections.

CAUTIONRadiator coolant may be extremely hot. Do not open thesystem while hot, or scalding water could spray outcausing personal injury. Allow vehicle to cool beforeservicing this system.Be sure to completely clean away any moisture from theplaces checked.When the tester is removed, be careful not to spill anycoolant from it.Be careful, when installing and removing the tester andwhen testing, not to deform the filler neck of the radiator.

4. If there is leakage, repair or replace the appropriate part.

RADIATOR CAP PRESSURE TEST1. Use an adapter to attach the cap to the tester.2. Increase the pressure unit the gauge stops moving.

Main valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78-108 kPa (11.3-15.6 psi, 0.8-1.1 kg/cm)

3. Check that the pressure level is maintained at or above the limit.4. Replace the radiator cap if the reading does not remain at or

above the limit.

NOTEBe sure that the cap is clean before testing, since rust orother foreign material on the cap seal will cause anincorrect indication.

SPECIFIC GRAVITY TEST

1. Measure the specific gravity of the coolant with a hydrometer.2. Measure the coolant temperature, and calculate the concentra-

tion from the relation between the specific gravity and tempera-ture, using the following table for reference.

GENERAL 25-5

Relation Between Coolant Concentration and Specific Gravity

The following table is applicable only to the specified HIGH QUALITY ETHYLENE GLYCOL (ANTIFREEZE) COOLANT

ExampleThe safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant temperature of20°C (68°F).

CAUTIONIf the concentration of the coolant is below 30%, the anti-corrosion property will be adversely affected. Inaddition, if the concentration is above 60%, both the anti-freeze and engine cooling properties will decrease,affecting the engine adversely. For these reasons, be sure to maintain the concentration level within thespecified range.Do not mix different brands of antifreeze.

RECOMMENDED COOLANT

Antifreeze

ETHYLENE GLYCOLBASE FOR ALUMINUM

Mixture ratio of antifreeze in coolant

50%

25-6 GENERAL

DRIVE BELT TENSION DEFLECTIONCHECK AND ADJUSTMENT

Length of Drive BeltThere are two methods to check drive belt adjustment:

1. Apply 100 N (22 Ibs) force by either pulling or pushing thebelt at position “A” measure the deflection and compare withspecifications.

2. Use a belt tension gauge at position “A”.

New belt Used bel t

Deflection (L) 7.5-9.0 mm 9.0-10.4 mm(0.295-0.354 in.) (0.35-0.41 in.)

Tension (T) 50-70 kg 35-50 kg(110-154 lb) (77-110 lb)

GENERAL 25-7

USING A BELT TENSION GAUGEMeasuring Method

1. Press down on the tension gauge handle and insert the beltbetween the spindle and hook of the gauge.

2. Release the handle and read the measurement on the gauge.

NOTE1. Belt which has been in operation for 5 minutes or more,

must be adjusted to the used belt specifications.2. Ensure that the belt is installed correctly, as shown in the

illustration.3. A loose belt will produce a high-pitched squealing noise.4. A belt that is too tight will damage the alternator and water

pump bearing.

NIPPONDENSO

V-ribbed belt

Incorrect Correct incorrect

25-8 COOLING SYSTEM

DRIVE BELT AND PULLEY

Removal1. Loosen the water pump pulley bolts.2. Loosen the alternator support nut3. Loosen the alternator lock bolt, and remove the belt.4. Remove the water pump pulley bolts and remove the water

pump pulley.

Tightening torqueAlternator support nut A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-25 Nm (200-250 kg.cm, 14-18 Ib.ft)Alternator lock bolt B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-22 Nm (150-220 kg.cm, 10.8-15.9 Ib.ft)

InspectionCheck the following items and replace if defective.1. Check the belt surface for damage, peeling or cracks.2. Check the belt surface for oil or grease.3. Check the belt for worn or hardened areas.4. Check the surface of the pulley for cracks or damage.

Installation1. Install the water pump pulley to the water pump pulley bracket

and tighten the bolts firmly.2. After installing the belt, adjust the belt tension. See “DRIVE

BELT TENSION DEFLECTION-CHECK AND ADJUSTMENT”.

RADIATOR

RADIATOR

COMPONENTS

Oil cooler hoses(A/T vehicle only)

25-10 RADIATOR

REMOVAL1. Disconnect the radiator fan motor connector.2. Set the temperature of the heater control to the hot position.3. Loosen the radiator drain plug to drain coolant.4. Disconnect the upper and lower hose and overflow tube.5. For vehicles with automatic transaxles, disconnect the oil cooler

hoses from the automatic transaxle.

CAUTIONPlug the ends of the oil cooler hoses and the automatictransaxle fittings to prevent transaxle fluid from spillingout and foreign material from entering.

6. Remove the radiator mounting bolts.7. Remove the radiator together with the fan motor.8. Remove the fan motor from the radiator.

INSPECTION1. Check the radiator for bent, broken or plugged fins.2. Check the radiator for corrosion, damage, rust or scale.3. Check the radiator hoses for cracks, damage or deterioration.4. Check the reservoir tank for damage.5. Check the radiator cap spring for damage. Pressure test the cap

using a cooling system checker.6. Check the radiator cap seal for cracks or damage.

7. Check the radiator fan coolant temperature switch for continuitywith the switch immersed in hot water.

Continuity at 85 ± 3°C (185 ± 54°F)No continuity at 78°C (172°F) or more

NOTEImmerse the switch in hot water up to mounting threadsto check for continuity.

Radiator Fan Motor1. Check that the radiator fan rotates when battery voltage is

applied to the terminals (as shown in the figure).2. Check that abnormal noises are not produced while the

motor is turning.

RADIATOR 25-11

INSTALLATION1. Fill the radiator and reservoir tank with clean coolant mixture.2. Run the engine until the thermostat opens, and then stop the

engine3. Remove the radiator cap, and add coolant up to the filler neck

of the radiator, and then fill the reservoir tank to theupper level.

4. Check that there is no leakage from the radiator, hoses orconnections.

RADIATOR CAP

RADIATOR CAP

COMPONENTS

Radiator Cap Spring

High-pressure valve

WHEN THE PRESSURE RISES TO THE SPECIFIED WHEN THE PRESSURE IS REDUCED TO THE SPECIFIEDLEVEL [81.4-108 KPa (0.83-1.1 kg/cm, 11.8-15.6psi)] LEVEL [-6.86 KPa (-0.07 kg/cm, -1.00 psi)]

Vacuum springV e n t v a l v e

INSPECTION1. Check the radiator cap for damage, cracks and deterioration.

2. Attach a radiator cap tester to the radiator cap.3. Pump the tester until the pointer stabilizes.4. If the pointer stays constant for 10 sec. at a point exceeding the

service limit, the radiator cap is good.

WATER PUMP 25-13

WATER PUMP


REMOVAL

1. Drain the coolant and disconnect the radiator outlet hose fromthe water pump.

2. Remove the drive belt and water pump pulley.3. Remove the timing belt covers and the timing belt tensioner.4. Remove the water pump mounting bolts and remove the

alternator brace.5. Remove the water pump assembly from the cylinder block.

INSPECTION

1. Check each part for cracks, damage or wear, and replace thewater pump assembly if necessary.

2. Check the bearing for damage, abnormal noise and sluggishrotation, and replace the water pump assembly if necessary.

3. Check for water leakage. If water leaks from hole “A”, the sealis defective. Replace the water pump assembly.

25-14 WATER PUMP

INSTALLATION

1. Clean the gasket surfaces of the water pump body and cylinderblock.

2. Install the new O-ring onto the groove on the front end of thewater pipe, then wet the O-ring with water. Do not apply oil orgrease.

3. Install a new water pump gasket to the water pump and tightenthe bolts to specified torque.

Tightening torqueWater pump to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . .

12-15 Nm (120-150 kg.cm, 9-11 Ib.ft)

4. Install the timing belt tensioner and timing belt, and adjust thetiming belt tension. The engine section for procedures.

5. Install the timing belt covers.6. Install the water pump pulley and drive belt, and then adjust the

belt tension.7. Refill the system with clean coolant.8. Run the engine and check for leaks.

THERMOSTAT 25-15

THERMOSTAT

COMPONENTS


[N/A]

[T/C]

REMOVAL AND INSPECTION

1. Drain the coolant down to thermostat level or below.2. Remove the water outlet fitting and gasket.3. Remove the thermostat.4. Immerse the thermostat in hot water to check proper valve

opening temperature replace if necessary.

Valve opening temperature ....................... 88ºC (190°F)Full opening temperature . . . . . . . . . . . . . . . . . . . . . . 100ºC (212°F)

Valve lift (at full open) . . . . . . . . . . . . . . . . . . 8.5 mm (0.33 in.) or more

INSTALLATION1. Check that the flange of the thermostat is correctly seated in the

socket of the thermostat housing. If the thermostat is installedin the wrong direction, the bottom of the thermostat will touch therib inside the intake manifold, making it impossible for thethermostat to operate properly.

2. Install a new gasket and the water outlet fitting.3. Refill the system with clean coolant.

25-16 COOLANT TEMPERATURE SENDER & COOLANT TEMPERATURE SENSOR

COOLANT TEMPERATURE SENDER & COOLANT TEMPERATURE SEN-SOR

COMPONENTS

TORQUE : Nm (kg-cm, Ib.ft)

R E M O V A L

1. Drain the coolant down to sender level or below.2. Disconnect the battery ground cable and disconnect the

engine harness connector from the sender & senser.3. Remove the sender & sensor.

INSPECTIONCoolant temperature sender

1. Heat the Coolant temperature sender by submerging it in hotwater .

2. Check that the resistance is within the specified range.

Resistance . . . . . . . . . . . . . . . . . . 90.5-11 Q at 70°C (158°F)21.3-26.3 4 at 115°C (239°F)

COOLANT TEMPERATURE SENDER & COOLANT TEMPERATURE SENSOR 25-17

Coolant temperature sensor

1. Heat the sensor by submerging it in hot water.2. Check that the resistance is within the specified range.

Resistance . . . . . . . . . . . . . . 2.27-2.73 KQ at 20°C (68°F)290-354 at 80°C (176F)

INSTALLATION

1. Apply sealant to the threaded portion and tighten to the specifiedtorque.

Tightening torqueCoolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-12 Nm (100-120 kg.cm, 7.2-8.7 Ib.ft)Coolant temperature senser . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-39 Nm (200-400 kg.cm, 14-29 Ib.ft)

2. Connect the harness connector to the Coolant temperaturesender, Coolant temperature senser.

3. Connect the battery ground cable.4. Refill the system with clean coolant.

WATER HOSE AND PIPE

WATER HOSE AND PIPE

COMPONENTS

[N/A]

TORQUE : Nm (kg.cm, ib.ft)

Exc. : Except

WATER HOSE AND PIPE 25-19

INSPECTION

Check the water pipe and hoses for cracks, damage, or restrictions.Replace if necessary.

INSTALLATION1. Fit the O-ring in the groove provided at the water inlet pipe end,

wet the O-ring with water and insert the water inlet pipe.

NOTE1. Do not apply oil or grease to the water pipe O-ring.2. Keep the water pipe connections free of sand, dust, etc.3. Insert the water pipe fully into the water pump.

2. Install the T/C cooling hoses (Refer 28 Group for detail)

ENGINEELECTRICALSYSTEMReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

AUTOMATIC SPEED CONTROL (CRUISE) SYSTEM . . . . 35

GENERAL


Distributor

Type Contact pointless typeAdvance mechanism Controlled by electronic control unitFiring order 1-3-4-2

Ignition coil

TypePrimary coil resistanceSecondary coil resistanceIdentification No.

Poong SungDae Joon

Mold single-coil0.5 ± 0.05 R12.1 ± 1.8 KQ

PC91DSA-403

Spark plug N A T C

TypeNGK BKR5ES-11 BKR6ES

ChampionPlug gap

RC9YC4 RC7YC1.0-1.1 mm (0.039 ~ 0.043 in.) 0.8 -0.9 mm (0.031 -0.035 in.)

GENERAL 27-3

Starter motor

TypeRated outputRated timeNo-load characteristics

Terminal voltageAmperageMaximum speed

No. of pinion teethPinion gap

Direct drive type12V 0.9 KW30 sec

11.5V60A or less6,600 rpm or more80.0197-0.079 in. (0.52 mm)

Alternator

TypeRated outputVoltage regulator typeRegulator setting voltageTemperature compensationIdentification No.

Mando

Battery voltage sensing13.5V 75AElectronic built-in type14.4 ± 0.3V-10 ± 3 mV/ºC

AB175015

Battery

Type MF 60AH-B (Maintenance-free battery)Ampere hours (5HR) 48 Ah or more

(20HR) 60 Ah or moreCold cranking [at -17.8ºC(OºF)] 420 A or moreReserve capacity 92 min.Specific gravity [at 25ºC(77ºF)] 1.270 ± 0.01

NOTECOLD CRANK AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a terminal voltageof 7.2 or greater at a specified temperature.RESERVE CAPACITY RATING is the amount of time a battery can deliver 25A and maintain a minimum terminalvoltage of 10.5 at 26.7ºC (80°F).

27-4 IGNITION SYSTEM

IGNITION SYSTEMGENERAL INFORMATION

Ignition timing is controlled by the electronic control ignition timingsystem. The standard reference ignition timing data for the engineoperation conditions are programmed in the memory of the elec-tronic control unit (ECU).The engine conditions (rpm, load, warm-up condition, etc.) aredetected by the various sensors. Based upon these sensor signalsand the ignition timing data, signals to interrupt the primary currentare sent to the power transistor. The ignition coil is activated, andtiming is controlled this way.

TROUBLESHOOTING

Probable condition Probable cause Remedy

Engine will not start or ishard to start. (Cranks OK)

Ignition coil faulty

Power transistor faulty

Distributor faulty

Inspect ignition coil

Inspect power transistor

Inspect distributor

High tension cable faulty Inspect high tension cable

Rough idle or stalls

Spark plugs faulty Replace plugs

Ignition wiring disconnected or broken Inspect wiring


Ignition wiring faulty Inspect wiring

Ignition coil faulty Inspect ignition coil

Power transistor faulty

High tension cord faulty

Inspect power transistor

Inspect high tension cord

Engine hesitates/pooracceleration


Ignition wiring faulty Inspect wiring

Poor mileage Spark plugs faulty Replace plugs

IGNITION SYSTEM 27-5

CHECKING IGNITION COILS

1. Measurement of the primary coil resistance.Measure the resistance of the positive (+) terminal and negative (-) terminal of the ignition coil.Standard value: 0.5 ± 0.05 Q

2. Measurement of the secondary coil resistance.Measure the resistance between the ignition coil’s positive (+)terminal and the high-boltage terminal.Standard value: 12.1 ± 1.8 KQ

POWER TRANSISTOR

1. Connect the negative (-) terminal of the 3V power supply toterminal 1 of the power transistor; then check whether there iscontinuity between terminal 3 and terminal 4 when terminal 4and the positive (+) terminal are connected and disconnected.

Terminal 4 and (+) terminal Terminal 1 and terminal 3

Connected Continuity

Disconnected No continuity

2. Replace the power transistor if there is a malfunction.

CHECKING SPARK PLUG

Inspection and Cleaning

1.

2.

3.

Disconnect the spark plug cable from the spark plug.NOTEPull on the spark plug cable boot when removing the sparkplug cable, not the cable, as it may be damaged.Using a plug spark wrench, remove all of the spark plugs fromthe cylinder head.CAUTIONTake care not to allow contaminants to enter through thespark plug holes.

Check the spark plugs for the following:1) Broken insulator2) Worn electrode3) Carbon deposits4) Damaged or broken gasket5) Condition of the porcelain insulator at the tip of the spark

plug


4. Check the spark plug gap using a wire gap gauge, and adjustif necessary.Standard value: NA : 1.0 - 1.1 mm (0.039 - 0.043 in.)

TC : 0.8 - 0.9 mm (0.031 - 0.035 in.)

5. Re-insert the spark plug and tighten to the specified torque.If it is overtorqued, damage to the threaded portion of cylinderhead might result.Spark plug: 20-30 Nm (204-306 kg.cm, 15-21 Ib.ft)

Analyzing Spark PlugEngine conditions can be analyzed by the tip deposits near theelectrode.


SPARK PLUG TEST

(When engine can be cranked)

Connect the spark plug to the high tension cable. Ground the outerelectrode (main body), and crank the engine. In the atmosphere,only short sparks are produced because of the small discharge gap.If the spark plug is good, however, sparks will occur in the dischargegap (between the electrodes). In a defective spark plug, no sparkswill occur because of a leak through the insulation.

CHECKING SPARK PLUG CABLES

1. Check the cap and outer shell for cracks.2. Measure the resistance. Unit: KR

NOTEResistance should not be higher than 10,OOOQ per foot ofcable. If resistance is higher, replace the cable.

IGNITION SYSTEM

REMOVAL AND INSTALLATION OF COMPONENTS

DISTRIBUTORRemoval1. Disconnect the battery ground cable.2. Remove the two distributor cap retaining clips and move cap to

one side.3. Disconnect the lead wire connector.4. Remove the distributor mounting nut and remove the distributor

assembly.

Installation1. Turn the crankshaft so that No.1 piston cylinder is at top dead

center.2. Install the distributor to the engine while aligning the shaft slot

with distributor’s installation mark.


DISASSEMBLY AND ASSEMBLY OF DISTRIBUTOR

COMPONENTS

DISASSEMBLY1. Pull off the rotor from the rotor shaft.2. Remove the cover.3. Remove coupling lock spring.4. Place the distributor on a soft base (wooden block) so that the

spring pin can be removed.5. Remove the coupling lock pin by using pin punch.

6. Remove distribute shaft.


7. Lift off the plate and unit by removing the three mountingscrews.

INSPECTION OF CAP & ROTOR

After checking the following, repair or replace if a problem is found.1. There must be no cracking in the cap.2. There must be no damage to the cap’s electrode or the rotor’s

electrode.3. There must be no carbon tracking.4. Clean away any dirt from the cap and rotor.

REASSEMBLY

Distributor Shaft

After coating the shaft with a small amount of engine oil insert it intothe housing.CAUTIONDo not use solvent or similar products.

DiscInsert the disc into the sensor part of the pick up unit and install inalignment with the spacer.CAUTIONThe disc’s slits must not be restricted.

CHARGING SYSTEM 27-11

CHARGING SYSTEMGENERAL INFORMATION

The charging system includes a battery, an alternator with a built-in regulator, and the charging indicator light and wires. The alterna-tor has six built-in diodes (three positive and three negative), eachrectifying AC current to DC current. Therefore, DC current appearsat alternator “B” terminal.In addition, the charging voltage of this alternator is regulated by thebattery voltage detection system. The main components of thealternator are the rotor, stator, rectifier, capacitor, brushes, bear-ings and V-ribbed belt pulley. The brush holder contains a built-inelectronic voltage regulator.

TROUBLESHOOTING

Symptom I Probable cause Remedy

Charging warningindicator does notlight with ignitionswitch “ON” andengine off.

Fuse blown.

Light burned out.

Wiring connection loose.

Electronic voltage regulator faulty.

Check fuses.

Replace lamp.

Tighten loose connections.

Replace voltage regulator.

Charging warningindicator does notgo out with enginerunning.(Battery requiresfrequent recharging).

Drive belt loose or worn. Adjust tension or replace drive belt.

Battery cables loose, corroded or worn. Repair or replace cables.

Fuse blown. Check fuses.

Fusible link blown. Replace fusible link.

Electronic voltage regulator or alternator Test alternator.faulty.

Discharge battery.

Wiring faulty. Repair wiring.

Drive belt loose or worn. Adjust tension or replace drive belt.

Wiring connection loose or open circuit. Tighten loose connection or repairwiring.

Fusible link blown.

Poor grounding.

Replace fusible link.

Repair.

Electronic voltage regulator oralternator faulty.

Test alternator.

Battery life. Replace battery.

Overcharge Electronic voltage regulator faulty.

Voltage sensing wire faulty.

Replace voltage regulator.

Repair wire.

27-12 CHARGING SYSTEM

INSPECTION OF CHARGING SYSTEM

VOLTAGE DROP TEST OF ALTERNATOROUTPUT WIRE

This test determines whether or not the wiring between the alterna-tor “B” terminal and the battery (+) terminal is good by the voltagedrop method:

Preparation

1. Turn the ignition switch to “OFF”.2. Disconnect the battery ground cable.3. Disconnect the alternator output lead from the alternator “B”

terminal.4. Connect a DC ammeter (0 to 100A) in series to the “B” terminal

and disconnected the output lead. Connect the (+) lead of theammeter to the “B” terminal and the (-) lead to the disconnectedoutput wire.NOTEUse a clamp type ammeter that can measure currentwithout disconnecting the harness. The reason is thatwhen checking a vehicle that has a low output current dueto poor connection of the alternator “B” terminal, such apoor connection is corrected as the “B” terminal is loosened and a test ammeter is connected in its place. As aresult, causes for the trouble may not be determined.

5. Connect a digital voltmeter between the alternator “B” terminaland battery (+) terminal. Connect the (+) lead wire of thevoltmeter to the “B” terminal and the (-) lead wire to the battery(+) terminal.

6. Connect the battery ground cable.7. Leave the hood open.

Test

1. Start the engine.2. Turn on the headlamps and adjust the engine speed so that the

ammeter reads 20A and read the voltmeter under this condition.

Result

1. It is okay if the voltmeter indicates the standard value.Standard value: 0.2V max.

2. If the voltmeter indicates a value that is larger than the standardvalue, poor wiring is suspected. In this case check the wiringfrom the alternator “B” terminal to the fusible link to the battery(+) terminal. Check for loose connections, color change due toan overheated harness, etc. Correct them before testing again.


3. Upon completion of the test, set the engine speed at idle. Turnoff the head lamps and the ignition switch.

4. Disconnect the battery ground cable.5. Disconnect the ammeter and voltmeter that have been con

nected for testing.6. Connect the alternator output wire to the alternator “B” terminal.7. Connect the battery ground cable.

OUTPUT CURRENT TEST

This test judges whether or not the alternator gives an outputcurrent that is equivalent to the nominal output.

Preparation

1. Prior to the test, check the following items and correct asnecessary.1) Check the battery installed in the vehicle to ensure that it is

in good condition*. The battery checking method is described in “BATTERY”.NOTE*The battery that is used to test the output currentshould be one that has been partially discharged. Witha fully charged battery, the test may not be conductedcorrectly due to an insufficient load.

2) Check the tension of the alternator drive belt. The belttension check method is described in the section “COOL-ING”.

2. Turn off the ignition switch.3. Disconnect the battery ground cable.4. Disconnect the alternator output wire form the alternator “B”

terminal.5. Connect a DC ammeter (0 to 100A) in series between the “B”

terminal and the disconnected output wire. Be sure to connectthe (-) lead wire of the ammeter to the disconnected output wire.NOTETighten each connection securely, as a heavy current willflow. Do not rely on clips.

6. Connect a voltmeter (0 to 20V) between the “B” terminal andground. Connect the (+) lead wire to the alternator “B” terminaland (-) lead wire to a good ground.

7. Attach an engine tachometer and connect the battery groundcable.

8. Leave the engine hood open.


Test

1. Check to see that the voltmeter reads the same value as thebattery voltage.If the voltmeter reads 0V, and open circuit in the wire betweenthe alternator “B” terminal and battery (-) terminal, a blownfusible link or poor grounding is suspected.

2. Start the engine and turn on the headlights.3. Set the headlights to high beam and the heater blower switch to

HIGH, quickly increase the engine speed to 2,500 rpm and readthe maximum output current value indicated by the ammeter.NOTEAfter the engine startup, the charging current quicklydrops. Therefore, the above operation must be done quicklyto read the maximum current value correctly.

Result

1. The ammeter reading must be higher than the limit value. If it islower but the alternator output wire is in good condition, removethe alternator from the vehicle and test it.Limit value:52.5 A min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75A alternator

NOTE1) The nominal output current value is shown on the

nameplate affixed to the alternator body.2) The output current value changes with the electrical

load and the temperature of the alternator itself. Therefore, the nominal output current may not be obtained.If such is the case, keep the headlights on to causedischarge of the battery, or use the lights of anothervehicle to increase the electrical load.The nominal output current may not be obtained if thetemperature of the alternator itself or ambient temperature is too high.In such a case, reduce the temperature before testingagain.

2. Upon completion of the output current test, lower the enginespeed to idle and turn off the ignition switch.

3. Disconnect the battery ground cable.4. Remove the ammeter and voltmeter and the engine tachom

eter.5. Connect the alternator output wire to the alternator “B” terminal.6. Connect the battery ground cable.


REGULATED VOLTAGE TEST

The purpose of this test is to check that the electronic voltageregulator controls voltage correctly.

Preparation

1.

2.3.4.

5.

6.

7.

Prior to the test, check the following items and correct ifnecessary.1) Check the battery installed on the vehicle to see that it is

fully charged. For battery checking method, see “BATTERY”.

2) Check the alternator drive belt tension. For belt tensioncheck, see section, “COOLING”.

Turn ignition switch to “OFF”.Disconnect the battery ground cable.Connect a digital voltmeter between the “S(L)” terminal of thealternator and ground. Connect the (+) lead of the voltmeter tothe "S(L)" terminal of the alternator. Connect the (-) lead to goodground or the battery (-) terminal.Disconnect the alternator output wire from the alternator “B”terminal.Connect a DC ammeter (0 to 100A) in series between the “B”terminal and the disconnected output wire. Connect the (-) leadwire of the ammeter to the disconnected output wire.Attach the engine tachometer and connect the battery groundcable.

Test

1. Turn on the ignition switch and check to see that the voltmeterindicates the following value.Voltage: Battery voltageIf it reads 0V, there is an open circuit in the wire between thealternator “S(L)” terminal and the battery (+), or the fusible linkis blown.

2. Stan the engine. Keep all lights and accessories off.3. Run the engine at a speed of about 2,500 rpm and read the

voltmeter when the alternator output current drops to 10A orless.


Result

1. If the voltmeter reading agrees with the value listed in theRegulating Voltage Table below, the voltage regulator is functioning correctly. If the reading is other than the standard value,the voltage regulator or the alternator is faulty.

Regulating Voltage Table

2. Upon completion of the test, reduce the engine speed to idle,and turn off the ignition switch.

3. Disconnect the battery ground cable.4. Remove the voltmeter and ammeter and the engine tachom-

eter.5. Connect the alternator output wire to the alternator “B” terminal.6. Connect the battery ground cable.


ALTERNATORREMOVAL AND INSTALLATION


1. Disconnect the negative terminal from the battery.2. Loosen the belt tension and remove the belt,3. Raise the vehicle.4. Remove the mud guard-RH.5. Disconnect the alternator B+ terminal wire.6. Remove the alternator assembly.7. Installation is the reverse order of removal.


COMPONENTS (75A)

1.2.3.4.5.6.7.8.

PulleySealRotor assemblyRear bearingBearing retainerFront bearingFront bracketStatorPlate9.

10. Voltage regulator and brush holder11. Brush12. Brush spring13. Slinger14. Rectifier15. Rear bracket


DISASSEMBLY

1. Remove the three through bolts.2. Insert a fiat screwdriver between the front bracket and stator

core, and pry downward.CAUTION1) Do not insert the screwdriver too deeply, as there is a

danger of damaging the stator coil.

2) The rear cover may be hard to remove because a ringis used to lock the outer race of the rear bearing. Tofacilitate removal of rear cover, heat just the bearingbox section with a 200-watt soldering iron.Do not use a heat gun, as it may damage the diodeassembly.

3. Secure the rotor in a vise with the pulley side up.CAUTIONBe careful that the vise jaws do not damage the rotor.

4. Remove the pulley nut, then remove the spring washer, thenthe pulley, and then the spacer.

5. Remove the front bracket and two seals.6. Remove the rotor from the vise.7. Remove the brush holder screws, the rectifier screws, and the

nut from the B terminal.8. Remove the stator assembly from the rear bracket.9. Detach the slinger from the brush holder.10. When the stator is to be removed, unsolder the three stator

leads to the main diodes on the rectifier.CAUTION1) When soldering or unsoldering, use care to make sure

that heat of soldering iron is not transmitted to thediodes for a long period.

2) Use care that excessive force is not exerted on theleads of the diodes.

11. When separating the rectifier from the brush holder, unsolderthe two plates soldered to the rectifier.


INSPECTION

Rotor1. Check the rotor coil for continuity. Check to make sure that

there is continuity between the slip rings.If resistance is extremely low, it means that there is a short. Ifthere is no continuity or if there is a short circuit, replace the rotorassembly.Resistance value: Approx. 3.1 Q

2. Check the rotor coil for gound. Check to make sure that thereis no continuity between slip the ring and the core.If there is continuity, replace rotor assembly.

Stator1. Make a continuity check on the stator coil. Check to make sure

that there is continuity between the coil leads.If there is no continuity, replace stator assembly.

2. Check the coil for grounding. Check to make sure that there isno continuity between the coil and the core.If there is continuity, replace the stator assembly.

Rectifiers

Positive rectifier testCheck for continuity between the positive rectifier and stator coillead connection terminal with an ohmmeter. The ohmmeter shouldread continuity in only one direction. If there is continuity in bothdirections, a diode is shorted.Replace the rectifier assembly.


Negative rectifier testCheck for continuity between the negative rectifier and the statorcoil lead connection terminal. The ohmmeter should read continuityin only one direction. If there is continuity in both directions, a diodeis shorted, and the rectifier assembly must be replaced.

Diode trio testCheck the three diodes for continuity by connecting an ohmmeterto both ends of each diode. Each diode should have continuity inonly one direction.If continuity is present in both directions, a diode is defective and theheatsink assembly must be replaced.

BRUSH REPLACEMENTReplace the brushes if they are worn to limit line.

1. Unsolder the pigtail and remove the old brush and spring.

2. Install the brush spring and a new brush in the brush holder.3. Insert the brush to where there is a space 2 to 3 mm (0.079 to

0.118 in.) between the limit line and the end of the brush holder.4. Solder the pigtail to the brush holder.


REASSEMBLY

Perform reassembly in the reverse procedure of disassembly. Payattention to the following:Before the rotor is attached to the rear bracket, insert a wire throughthe small hole in the rear bracket to lock the brush. After the rotorhas been installed, the wire can be removed.

INSTALLATION

1. Position the alternator and insert the support bolt. (Do notattach the nut.)

2. Push the alternator forward and determine how many spacers(thickness: 0.198 mm) should be inserted between the front legof the alternator and the front case (space A in the illustration).(There should be enough spacers so that they do not fall outwhen you let go of them.)

3. Insert the spacers (space A in the illustration), attach the nut,and complete the installation.


BATTERY (MAINTENANCE FREE TYPE)

1. The maintenance-free battery is, as the name implies, totallymaintenance free and has no removable battery cell caps.

2. Water never needs to be added to the maintenance-freebattery.

3. The battery is completely sealed, except for small vent holes inthe cover.

4. The battery contains a visual inspection indicator.

BATTERY VISUAL INSPECTION (1)


SPECIFIC GRAVITY CHECK CHART

The specific gravity of battery electrolyte changes with tempera-ture. Heat thins the solution and lowers the specific gravity. Coldthickens the solution and raises the specific gravity.

A fully charged battery should have a specific gravity between1.260 and 1.280, with the electrolyte temperature at 80°F, thespecific gravity reading must be corrected by adding 4 points (.004)for each 10° above 80°F or subtracting 4 points for every 10° below80°F.

For example : The hydrometer reading is 1.280, and the electrolytetemperature reading is 10°F. By using the chart, the specific gravitymust be lowered by 0.028 points. The true corrected reading is1.252.

1.280 - 0.028 = 1.252

You should never take a hydrometer reading immediately afterwater has been added. The water and electrolyte must be mixed byeither charging for a few minutes at a low rate or by allowing thebattery to sit for an hour.CAUTIONA difference of 50 points (0.050) or more between one or morecells indicates a defective battery. It should be replaced.

BATTERY CHARGE RATE

Charge methodSpecific gravity Slow charge (5A) Fast charge (20A)

Below 1.100 14 hours 4 hours

1.100 - 1.130 12 hours 3 hours

1.130 - 1.160 10 hours 2.5 hours

1.160 - 1.190 8 hours 2.0 hours

1.190 - 1.220 6 hours 1.5 hours

Above 1.220 4 hours 1.0 hours


BATTERY VISUAL INSPECTION (2)

1.

2.3.

4.

9.

Make sure ignition switch is in the Off position and all accessories are Off.Disconnect the battery cables (negative first)Remove the battery from the vehicle.CAUTIONCare should be taken in the event the battery case iscracked or leaking, to protect your skin from the electrolyte. A suitable pair of rubber gloves (not household type)should be worn when removing the battery.

Inspect the battery carrier for damage caused by the loss of acidfrom the battery. If acid damage is present, it will be necessaryto clean the area with a solution of clean warm, water andbaking soda. Scrub the area with a stiff bristle brush and wipeoff with a cloth moistened with baking soda and water.Clean the top of the battery with the same solution as describedin Step (4).Inspect the battery case, and cover, for cracks. If cracks arepresent, the battery must be replaced.Clean the battery posts with a suitable battery post cleaner.Clean the inside surface of the terminal clamps with a suitablebattery terminal cleaning tool. Replace damaged or frayedcables and broken terminal clamps.Install the battery in the vehicle.

10. Connect the cable terminals to the battery post, making surethe top of the terminals are flush with the top of the post.

11. Tighten the terminal nut securely.12. Coat all connections with light mineral grease after tightening.

CAUTIONWhen batteries are being charged, an explosive gas formsbeneath the cover of each cell. Do not smoke near batteriesbeing charged or which have recently been charged.Do not break live circuits at the terminals of the batteriesbeing charged. A spark will occur where the circuit isbroken.Keep all open flames away from the battery.

STARTING SYSTEM 27-27

GENERAL INFORMATION

The starting system includes the battery, starter motor, solenoidswitch, ignition switch, inhibitor switch (A/T only), connection wiresand the battery cables.When the ignition key is turned to the start position, current flowsand energizes the coil of the starter motor’s solenoid. When thishappens, the solenoid plunger and the clutch shift lever areactivated, and the clutch pinion engages the ring gear. The contactsclose and the starter motor cranks.In order to prevent damage caused by excessive rotation of thestarter armature when the engine starts, the clutch pinion gearoverruns.

TROUBLESHOOTING

Probable condition

Engine will not crank.

Engine cranks slowly.

Starter keeps running.

Starter spins but enginewill not crank.

Probable cause

Battery charge low

Battery cables loose, corroded or worn

Inhibitor switch faulty(Vehicle with automatic transaxle only)

Fusible link blown

Starter motor faulty

Ignition switch faulty

Battery charge low

Battery cables loose, corroded or worn



Ignition switch faulty

Short in wiring

Pinion gear teeth broken or startermotor faulty

Ring gear teeth broken

Remedy

Charge or replace battery.

Repair or replace cables.

Adjust or replace switch.

Replace fusible link.

Repair starter motor.

Replace ignition switch.

Charge or replace battery.

Repair or replace cables.



Replace ignition switch.

Repair wiring.


Replace flywheel ring gear ortorque converter.

27-28 STARTING SYSTEM

STARTERREMOVAL AND INSTALLATION

9.8-16 (100-160, 7.3-11.7)


1. Disconnect the battery ground cable.2. Remove the speed meter cable and the shift cable.3. Disconnect the high tension cable from ignition coil to distributor.4. Disconnect the starter motor connector and terminal.5. Remove the starter motor assembly.6. Installation is the reverse order of removal.

STARTING SYSTEM

COMPONENTS

1. Front bracket2. Front bushing3. Cap4. Screw5. Solenoid6. Plunger7. Spring8. Packing9. Lever10. Holder11. Spring12. Packing13. Washer14. Stop ring15. Stopper16. O.R.C. (Overrunning clutch)17. Armature18. Washer19. Yoke ass’y20. Plate ass’y21. Rear cover22. Rear bushing23. Screw24. Bolt


INSPECTION (After removal)Pinion Gap Adjustment

1. Disconnect the wire from the M-terminal.2. Connect a 12V battery between the S-terminal and the M-

terminal.3. Set the switch to “ON”, and the the pinion will move out.

CAUTIONThis test must be performed quickly (in less than 10seconds) to prevent coil from burning.

4. Check the pinion to stopper clearance (pinion gap) with a feelergauge.If the pinion gap is out of specification, adjust by adding orremoving washers between the solenoid and the front bracket.

Pinion Gap: 052.0 mm (0.0197-0.079 in)

Solenoid Pull-in Test1. Disconnect the connector from the M-terminal.2. Connect a 12V battery between the S-terminal and M-terminal.

CAUTIONThis test must be performed quickly (in less than 10seconds) to prevent the coil from burning.

3. If the pinion moves out, the pull-in coil is good. If it doesn’t,replace the solenoid.

Solenoid Hold-in Test1. Disconnect the connector from the M-terminal.2. Connect a 12V battery between the S-terminal and the body.


3. If the pinion remains out, everything is in order. If the pinionmoves in, the hold-in circuit is open. Replace the magneticswitch.

Solenoid Return Test

1. Disconnect the connector from the M-terminal.2. Connect a 12V battery between the M-terminal and the body.


3. Pull out the pinion and then release it. If the pinion returnsquickly to its original position, everything is in order. If it doesn’treplace the solenoid.


Performance Test (No-load)1. Make the no-load circuit test as shown.2. After adjusting the rheostat until the battery voltage shown on

the voltmeter reads 11.5 volts, confirm that the maximumamperage draw is within the specifications and that the startermotor turns smoothly and freely.Current : 60A or less

DISASSEMBLYTo remove the overrunning clutch from the armature shaft, the stopring must be removed.Move the stop ring toward the pinion and remove the snap ring, nowthe stop ring can be removed from shaft.

INSPECTION (After disassembly)

Armature Coil Ground Test

Using an ohmmeter, check to make sure that there is no continuitybetween the commutator and the armature coil core. If there iscontinuity, replace armature assembly.

Armature Coil Short-Circuit Test

Test the armature coil in a growler. Replace the coil if there aresigns of a short. If the blade attached to the core vibrates while thecore is turned, the armature is shorted.

Armature Coil Open-Circuit Test

Using an ohmmeter, check for continuity between the commutatorsegments. If there is no continuity, the commutator segments areopen. Replace the armature assembly.


Field Coil Open-Circuit Test

Using an ohmmeter, check the field coil for continuity. If there is nocontinuity, the field coil is open. Replace the field coil assembly.

Field Coil Ground Test

With the field coil mounted to the yoke, check for continuity betweenthe field coil and the yoke using an ohmmeter. If there is continuity,replace the field coil.

BrushA brush worn down to the wear limit line should be replaced.

Brush Holder

Check for continuity between the (+) side brush holder and brushholder base. If there is continuity, replace the holder assembly.

Overrunning Clutch

Inspect the pinion and spline teeth for wear or damage. Replace ifdamaged. Also inspect the flywheel ring gear for damage.Rotate the pinion. It should turn freely in a clockwise direction, andlock when turned counterclockwise.


BRUSH REPLACEMENT1. Remove the worn brush while taking care not to damage the

pigtail.2. Sand the pigtail end with sandpaper to ensure a good soldering

joint.3. Solder the end of the pigtail.

REAR BRACKET BUSHING REPLACEMENT1. Before the bushing is removed, measure and record the

pressed-in position (depth) of the bushing.2. The bushing can be removed by the use of a puller as shown

in the illustration.3. Press a new bushing in, up to the position recorded under

Step. 1.

REASSEMBLY

1. Install the overrunning clutch to the front end of the armatureshaft.

2. Install the stop ring and the snap ring from the front end of thearmature shaft. Push the stop ring all the way toward the snapring.

3. When the lever is mounted to the front bracket, pay attention toits direction. If it is mounted in a reverse direction, the pinion willremain in an outward position and fail to operate properly.


INSPECTION OF CLUTCH START SYSTEM(IGNITION LOCK SYSTEM)Check clutch pedalCheck that pedal height, pedal freeplay and clutch pedal clevispin play are correct. (Refer to clutch group)

Check starter relayRemove the starter relay and check continuity between theterminals. If the continuity is not as specified, replace the relay.

Check ignition lock switch1. Check for continuity between terminals when the switch is ON

(pushed).2. Check for no continuity between terminals when the switch is

OFF (free)

AUTOMATIC SPEED CONTROL (CRUISE)

AUTOMATIC SPEED CONTROL (CRUISE)SPECIFICATIONS

Items

Speed control unitOperating voltage rangeOperating temperatureVoltage drop between unit and actuatorOperating speed range

ActuatorRated voltageOperating temperatureOperating consumptionInsulating resistance

Cruise main switchRated voltageOperating forceVoltage drop

Stop lamp switchRated voltageRated load

Stop lampCruise control

Insulating resistance

Specifications

DC 10 l 16 V-30 I +75°C (-22 I +167°F)0.4 VLow speed limit : 40±3 km/h (25±2 mph)High speed limit : 145 ± 5 km/h (90 ± 3 mph)

DC 12 V-30 ~ +90°C (-22 - +194°F)3A or less (at 12V 20°C)1 MQ or less (at 500V megger)

DC 12 V0.3 ~ 1.0 kg0.15 V or less

DC 12 V

27 x 5 W (lamp load)0.1 - 0.5 A (relay load)Min 3 MQ (by 500 V megger)

SPECIAL SERVICE TOOL


09391-33100Multi-use tester

Illustration Use

Rom PACK HMC-3

Reading diagnosis code09391-33402

Reading diagnosis code with MUT

27-36 AUTOMATIC SPEED CONTROL (CRUISE)

Engine compartment Interior

B

Name

Accelerator switch

Actuator

Clutch switch

Cruise main switch

Symbol Name Symbol

A Reed switch (Vehicle speed sensor) E

B Speed-control switch F

C Speed-control unit (cruise control unit) G

D Stop lamp switch H

AUTOMATIC SPEED CONTROL (CRUISE) 27-37


System Block Diagram

Component parts and function outline

COMPONENT PART FUNCTION

Vehicle-speed sensor

Electronic control unit (ECU)

Converts vehicle speed to pulse.

Receives signals from sensor and control switches;ECU controls all automatic speed control functions.

Actuator Regulates the throttle valve to the set opening by signalsfrom the ECU.

CRUISE main switch Switch for automatic speed control power supply.

Control switch SET switch Controls automatic speed control functions by SETRESUME switch (COAST) and RESUME (ACCEL).

CRUISE main switch indicatorIlluminates when CRUISE main switch is ON (Built intoCRUISE switch).

Piezo alarmWhen the SET or RESUME switch is switched ON, thealarm sounds to notify the driver that the control unit hasrecieved the ON signal.


COMPONENT PART FUNCTION

Cancel switch Stop lamp switch/Clutch switch (A/T)Brake switch Sends cancel signals to the ECU.

Inhibitor switch

ELC 4-speed automatic transaxle control unit Controls the overdrive ON and OFF, based on signalsfrom the ECU for the ASC.

Diagnostic connector By connecting the voltmeter or multi-use tester, controlunit diagnostic codes can be read.


CONSTRUCTION OF ACTUATORINTERNAL CONSTRUCTION

Drive gear

CIRCUIT DIAGRAM


CONTROL LOGIC BLOCK DIAGRAM


CONTROL UNIT FUNCTIONS

1. SET (Fixed-speed control)With the MAIN switch turned ON, the SET switch is switched from ON to OFF while the vehicle is being driven withinthe speed range in which speed settings are possible (approximately 40-145 km/h (25-90 mph)), the vehicle speedat the moment the SET switch was switched from ON to OFF is memorized as the “set vehicle speed”, and there afterthe actuator is controlled so that fixed-speed driving at that speed is possible. The following figure below shows thetiming charts.

1) INITIAL PULSEThe initial pulse opens the throttle valve to a degree of opening which approximately corresponds to the vehiclespeed. This pulse is output when the ASC system is set.

2) TRIM PULSEThe trim pulse is a control pulse for correcting the vehicle speed which is output response to detected speed errors.The output pulse width is determined based on the amount of deviation between the current vehicle speed andthe set vehicle speed, and on throttle position.

2. COASTDuring fixed-speed driving, while the COAST switch is ON, the actuator D.C. motor is caused to rotate to the REL(release) side. The vehicle speed when the switch is OFF as deceleration continues is entered in the memory, andis thereafter controlled as the fixed speed.

3. RESUME SPEEDWhen (after the ASC system is canceled by the cancel conditions) the RESUME switch is switched from OFF to ON,while driving at a vehicle speed which is the low-speed limit (approximately 40 km/h (25 mph)) or higher, the vehiclespeed memorized before cancellation of the ASC system will be controlled as the fixed speed.

4. ACCELERATIONDuring fixed-speed driving or above the low-speed limit, while the ACCELERATION switch is ON, the actuator’s D.Cmotor is caused to rotate to the PULL side. The vehicle speed when the switch is OFF as acceleration continues isentered in the memory, and is thereafter controlled as the fixed speed.


5. CANCELLATIONWhen the signals below are input (during fixed-speed driving), conductivity to the electromagnetic clutch is interrupted,thus canceling the ASC system.1) Stop lamp switch ON (brake pedal depressed)2) Inhibitor switch ON (selector lever at “P” or “N” position)NOTEWhen the brake pedal is depressed and the stop lamp switch is switched ON, the ASC system will be canceledeven if there is wiring damage or disconnection at the fuse for the stop lamp.

CANCEL SWITCH CIRCUIT DIAGRAM

NO : Normal openNC : Normal close

6. LOW-SPEED LIMITThere is automatic cancellation at or below the low-speed limit (approximately 40 km/h (25 mph)).


7. HIGH-SPEED LIMITThe vehicle cannot be driven at a fixed speed which is at or higher than the high-speed limit (approximately (145km/h (90 mph)).Note that the vehicle speed memorized when the SET switch is pressed while the vehicle is traveling at the high-speedlimit or higher will be the high-speed limit vehicle speed.

8. AUTOMATIC CANCELLATIONWhen, during fixed-speed driving, the signals described below are input, conductivity to the electromagnetic clutch isinterrupted, thus canceling the ASC system.1) If the vehicle speed decreases to a speed which is approximately 20 km/h (12 mph) or more below the memorized

vehicle speed.2) If there is no input of the vehicle speed signal for more than 0.5 second.3) If there is damaged or disconnected wiring of the input line (stop lamp switch load side) of the stop lamp switch.4) If the cancel switches (stop lamp switch, inhibitor switch) and command switches (SET switch or RESUME switch)

are switched on at the same time.NOTEIf the SET and RESUME switches are ON at the same time, the cruise control will operate in the COASTmode and the speed will decrease.

9. PIEZO ALARMWhen the CRUISE switch is ON, SET switch or RESUMEswitch ON signals are recieved, the alarm is activated forapproximately 0.2 second.NOTEPower is supplied from the fuse No.12 (10A) to the alarm.

10. ACCELERATOR SWITCHThe accelerator switch is a switch that functions to detect the condition of the accelerator pedal, and is one of the ELC4 A/T sensors.Because the accelerator pedal is not used during fixed-speed driving, the accelerator switch is OFF during this timeonly, so as not to adversely affect the function of the ELC 4 A/T.


11. OVERDRIVE-CANCEL FUNCTIONWhen, during fixed-speed driving, the actual vehicle speed decreases to (or below) a speed which is below thememorized vehicle speed, and the actual vehicle speed continues at that reduced speed, or during the resumeoperation described in item 3 or the acceleration operation described in item 4, etc., it becomes necessary to returnto the vehicle speed for a short time and to accelerate, the overdrive function of ELC 4 A/T-equipped models is canceledfor a certain time.


12. SELF-DIAGNOSIS FUNCTIONThe cruise control system can display trouble codes from the cruise control unit through the diagnostic connector. Thecodes can be read by using a voltmeter or the multi-use tester. Be sure to turn the main switch “ON” before trying toread the codes.NOTEThe display of the trouble codes starts if the vehicle speed decreases to less than approximately 20 km/h (12mph) after the cancellation of the ASC system function, and stops if the vehicle speed increases toapproximately 20 km/h (12 mph) or higher.

Self-diagnosis Descriptions and Displays

CODE NO. DIAGNOSIS ITEM DISPLAY PATTERNS SELF-DIAGNOSIS DESCRIPTION

11 Clutch coil 1. Open transistor2. Open brake circuit, blown fuse3. Stop lamp switch closed.4. Stop lamp circuit open.

12 Speed sensor No vehicle speed signal input for morethan 1 seconds

13 Low speed limit Vehicle speed less than 40 km/h.

14 Redundant brake Vehicle speed less than memory speedby 20 km/h

15 Control switch SET and RESUME switches on simulta-neously.

16 Cancel signal 1. Open fuse or circuit in stop lampswitch.

2. Auto transaxle inhibit switch ON(closed).

3. Open circuit in stop lamp circuit.4. Stop lamp switch ON.


13. INPUT SWITCH CHECKThis unit has a check function for the input signal switch.The display starts when the main switch is turned “ON” while the set and resume switches are turned “ON”.1) Trouble codes are stored in memory and displayed in sequential order of priority.2) Smaller code number shall be placed higher in priority.3) Even when an input of higher priority is detected among check function items, an item currently stored in memory

shall be shown on display for one cycle. (One cycle shall be an interval during which all check functions stored inmemory are shown on display.)

4) Code No.24 and 25 should be checked while a vehicle is running.

Input check table

CODE NO. DIAGNOSIS ITEM DISPLAY PATTERNS SELF-DIAGNOSIS DESCRIPTION

21 Set switch ON SET switch circuit normal

22 Resume switch ON RESUME switch circuit normal

23 Cancel switch ON Each CANCEL circuit normal

24 40 km/h over

25 40 km/h lower

When both No.24 and No.25 can beconfirmed, vehicle-speed sensor circuitno rma l


TROUBLESHOOTINGBEFORE TROUBLESHOOTING

The ASC (Automatic speed-control) system performs control func-tions for the setting or cancellation of the fixed-speed driving speedbased upon the data provided by input signals. As a result, when theASC system is canceled, the cause of the cancellation is memo-rized in a separate circuit by the ECU, regardless of whether or notthe ASC system condition is normal or abnormal, thus providing theECU with the self-diagnosis function by certain fixed patterns, aswell as the function of being able to check whether or not the ECU’sinput switches or sensor are normal. Thus, by effectively usingthese function, the time required checking and repair can beshortened.NOTEWhen the computer (ECU) power supply (ignition switch andmain switch) is switched OFF, the memorized trouble codesare erased, and so for this reason the power supply must beleft ON until the checking is completed.

SELF-DIAGNOSIS CHECKING

Self-diagnosis checking is performed when there has been anautomatic cancellation, without cancel switch operation.1. The following two methods can be used for checking the

diagnosis. Note that the diagnosis check connector is locatedin the fuse box.1) If a multi-use tester is used

Connect the multi-use tester’s socket and connector to thecigarette lighter socket and the self-diagnosis checkconnector, and set the tester.Use the tester according to its operation instructions; dis-play the diagnosis code number and then check.


2) If a voltmeter is usedConnect a voltmeter between the ground terminal and theterminal for ASC of the diagnosis check connector.It is possible to discover which circuit is the cause of thecancellation by verifying the indication shown by thevolt meter with the display patterns shown on the next page.

2. When trouble codes No. 11, 12, 15 or 16 are displayed, checkthe troubleshooting symptom applicable to that number.NOTECode No. 16 is entered in the memory as cancel switch ONsignal input if the system is canceled by depressing thebrake pedal, and code No.13 or No.14 is entered whenthere is an automatic cancellation because the vehiclespeed drops when the vehicle is driven up a steep slopewith the preset speed setting left set, etc., when however,there is a cancellation not intentionally made by the driver,the cause might be damaged or disconnected stop lampswitch input wiring, a malfunction of the stop lamp switchON, etc., even though the same code No.16 is displayed.

DISPLAY SIGNAL PATTERN (FOR EXAMPLE CODE 23)


TROUBLESHOOTING PROCEDURES

First, select the applicable malfunction symptom from the TroubleSymptom Charts. Conduct the self-diagnostic test following thedirections on the charts.Determine the condition of all function circuits.

CAUTIONBecause the computer (self-diagnosis) memory data will beerased, when the system is unintentionally canceled duringfixed-speed driving, the ignition switch and/or the cruise mainswitch of the ASC system should not be switched OFF, and thebattery should not be disconnected.

1. Make the following preliminary inspections.1) Check that the installation of the actuator, accelerator

cables are correct, and that the cables and links aresecurely connected.

2) Check that the accelerator pedal moves smoothly.3) Adjust the cable so there is no excessive tension or

excessive play on the accelerator cable.4) Check that the ECU, actuator, cruise main and control

switch and the connector of each cancel switch areconnected securely.

2. Check in the sequence indicated in the Trouble SymptomChart.

3. If these checks indicate a normal condition, replace the cruisecontrol unit.


TROUBLE SYMPTOM CHARTSTrouble Symptom 1


Trouble Symptom 2 NOTEIf, after the occurrence of the problem, the ignition switch andthe cruise main switch have not been switched OFF, it ispossible to determine (by checking the diagnosis outputcode) which circuit canceled the system’s operation.This chart is to be used, for troubleshooting if it is not possibleto use the self-diagnosis for checking.

ASC system cannot be set

Check the ECU power supply circuit No o Damaged or disconnected wiring of the ECU power supplyand SET or RESUME switch. Are circuitthey normal ? o Damaged or disconnected wiring of the SET or RESUME

switchYes

Input check items

Check results

Code 21 remains even though SETswitch is set to OFF.

Code 22 remains even though RE- RESUME switch ONSUME switch is set to OFF. malfunction

Code 23 remains even though CAN-CEL switch is set to OFF.

Code 25 does not disappear, and code24 does not appear, even though ve-hicle speed reaches approximately 40km/h (25 mph) or higher.

Normal

NOTE

Probable cause

SET switch ON mal-function

SET switch input lineshort-circuit

RESUME switch inputline short-circuit

Malfunction of the CAN-CEL circuit (ON mal-function)

Malfunction to the ve-hicle-speed sensor cir-cuit (damaged or dis-connected wiring, orshort-circuit)

Remedy

Replace the controlswitch

Repair the harness.

Replace the controlswitch.

Repair the harness.

Check or repair eachCANCEL circuit.

Check or repair thevehicle speed sensorcircuit.

Check the actuator circuit If the check results of the actuator circuit of the actuator itselfreveal a normal condition, replace the electronic control unit(ECU)


Trouble Symptom 3

Trouble symptom

o The set vehicle speed variesgreatly upward or downward

o “Surging” (repeated alternatingacceleration and deceleration)occurs after setting

Probable cause Remedy

Malfunction of the vehicle Repair the vehicle speed sensorspeed sensor circuit system, or replace the part

Malfunction of the speedometercable or speedometer drive gear

Actuator circuit poor contact Repair the actuator system, orreplace the part

Malfunction of the actuator

Malfunction of the ECU Replace the ECU

Trouble Symptom 4

Trouble symptom

The ASC system is not canceledwhen the brake pedal is depressed


Damaged or disconnected wiring of Repair the harness or replace thethe stop lamp switch stop lamp switch

Actuator drive circuit short Repair the harness or replace theactuator


Trouble Symptom 5

Trouble symptom Probable cause Remedy

The ASC system is not canceled Damaged or disconnected wiring Repair the harness or repair or re-when the shift lever is moved to the of inhibitor switch input circuit place the inhibitor switch“N” position(It is canceled, however, when the Improper adjustment of inhibitorbrake pedal is depressed) switch



Trouble Symptom 6

Trouble symptom Probable cause

Cannot decelerate (coast) by using Temporary damaged or discon-the SET switch nected wiring of SET switch input

circuit

Actuator circuit poor contact


Malfunction of the ECU

Trouble Symptom 7

Trouble symptom

Cannot accelerate or resume speedby using the RESUME switch


Damaged or disconnected wiring, orshort circuit, or RESUME switch in-put circuit

Repair the harness or replace theRESUME switch

Actuator circuit poor contact



Repair the harness or replace theactuator

Replace the ECU

Trouble Symptom 8


ASC system can be set while driving Malfunction of the vehicle-at a vehicle speed of less than 40 km/ speed sensor circuith (25 mph), or there is no automaticcancellation at that speed Malfunction of the speedometer

cable or the speedometer drive gear


Trouble Symptom 9

Trouble symptom

Remedy

Repair the harness or replace theSET switch

Repair the harness or replace theactuator

Replace the ECU

Remedy

Repair the vehicle speed sensor sys-tem, or replace the part

Replace the ECU.


The cruise main switch indicator lampdoes not illuminate(But ASC system is normal.)

Damaged or disconnected bulb ofcruise main switch indicator lamp

Harness damaged or disconnected

Repair the harness or replace thepart.


Trouble Symptom 10

Trouble Symptom 11


Malfunction of control function by Malfunction of circuit related to ac-ON/OFF switching of ELC 4 A/T accelerator switch OFF functioncelerator switch

malfunction of the ECU

Repair the harness or replace thepart

Trouble Symptom 12


Overdrive is not canceled during fixedspeed driving.

Malfunction of circuit related to over-drive cancellation, or malfunction of

No shift to overdrive during manual

Remedy

Repair the harness or replace thepart


CHECKING AUTOMATIC SPEED CONTROLSETTING

CHECKING AUTOMATIC SPEED CONTROLMAIN SWITCH

1. Switch ON the MAIN switch.2. Drive at the desired speed within the range of approximately

40-145 km/h (25-90 mph).3. Press the SET button (of the control switch).4. Check that the alarm sounds when the switch is pressed, and

that when it is released the speed is the desired speed.NOTEIf the vehicle speed decreases to approximately 20 km/h(12 mph) below the set speed, because of climbing a hill forexample, the automatic speed control will be cancelled.

CHECKING SPEED INCREASE SETTING1. Set to the desired speed.2. Press the RESUME button (of the control switch).3. Check that the alarm sounds when the switch is pressed, that

acceleration continues while the switch is pressed, and that thespeed at the time that the switch is released, becomes thedriving speed.NOTEEven if, during acceleration, the vehicle speed reaches orexceeds the high speed limit [approximately 145 km/h]acceleration will continue and when the button is released,the speed at that time (“memorized speed”) will becomesthe high limit of the vehicle speed.


CHECKING SPEED REDUCTION SETTING

1. Set to the desired speed.2. Press the COAST button (of the control switch).3. Check that the alarm sounds when the switch is pressed, that

deceleration continues while the switch is pressed, and that thespeed at the time that the switch is released becomes thedriving speed.NOTEWhen the vehicle speed reaches the low limit [approximately 40 km/h (12 mph)] during deceleration, the auto-matic speed control will be cancelled.

CHECKING AUTOMATIC SPEED CONTROLCANCELLATION1. Set the automatic speed control.2. Check that the ASC is cancelled when either of the operations

below is performed.1) The brake pedal is depressed.2) The shift lever is moved to the “N” range.3) The automatic speed control MAIN switch is switched OFF.

CHECKING RETURN TO THE SET SPEEDBEFORE CANCELLATION1. Set the automatic speed control.2. Check that the automatic speed control is cancelled when

either of the operations below is performed.1) The brake pedal is depressed.2) The shift lever is moved to the “N” range.

3. Press the RESUME button (of the control switch) while drivingat a vehicle speed of approximately 40 km/h (25 mph) or high

4. The alarm will sound when the switch is pressed. The ASC willreturn to the previously set speed before the automatic speedcontrol was cancelled.


INDIVIDUAL PARTS INSPECTIONSTOP LAMP SWITCHINSPECTION

After operating the stop lamp switch, check for continuity betweenthe terminals.

CHECKING INHIBITOR SWITCH (“N” AND “P”POSITIONS)

1. Disconnect the connector.2. Check that there is continuity between connector (M24) termi-

nals 3 and 5, 3 and 4 when the shift lever is moved to the “N”range and the “P” range.

CHECKING ACTUATOR1. Disconnect the connector.2. Measure the resistance value of the clutch coil.

Resistance of clutch coil between connector terminals (3)

and (4)

Standard value : Approx. 55 Q

INTAKE &EXHAUSTSYSTEMReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SURGE TANK AND INTAKE MANIFOLD[N/A] . . . . . . . . . . . 5

SURGE TANK AND INTAKE MANIFOLD[T/C] . . . . . . . . . . . . . .8

EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

MUFFLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

28-2 GENERAL


Air cleanerTypeElement

Exhaust pipeMufflerSuspension system

Dry typeUnwoven cloth type

Expansion resonance typeRubber hangers

TIGHTENING TORQUE N m kg.cm Ib.ft

Air cleaner mounting boltsAir cleaner mounting bracket boltsIntake manifold to cylinder head nuts and boltsSurge tank stay to cylinder block boltsThrottle body to surge tank boltsExhaust manifold to cylinder head nuts

Natural aspirationTurbo charger

Exhaust manifold cover to exhaust manifold boltsOxygen sensor to exhaust manifoldFront exhaust pipe to exhaust manifold nutsFront exhaust pipe bracket boltsFront exhaust pipe to catalytic converter boltsCatalytic converter to main muffler ass’y nutsMain muffler hanger support bracket bolts

8-10 80-100 5.8-7.215-22 150-220 11-1615-20 150-200 11-1418-25 180-250 13-1815-20 150-200 11-14

15-20 150-200 11-1425-35 250-350 18-2527-33 270-330 20-2450-60 500-600 36-4330-40 300-400 22-2930-40 300-400 22-2940-60 400-600 29-4330-40 300-400 22-2910-15 100-150 7.2-11

AIR CLEANER

AIR CLEANER

COMPONENTS

[FOR N/A]


REMOVAL1. Remove the air duct connected to the air cleaner.2. Disconnect the air flow sensor harness.3. Remove the air intake hose A at the air cleaner side and the air

intake hose B at the engine side.

28-4 AIR CLEANER

4. Remove the air cleaner cover and element.5. Remove the air cleaner mounting bolts inside of the air cleaner

and remove the air cleaner.6. Remove the air flow sensor between the air intake hose A and

B.

INSPECTION1. Check the air cleaner body, cover, or packing for distortion,

corrosion or damage.2. Check the air duct for damage.

3. Check the air cleaner element for restriction, contamination ordamage.If the element is slightly restricted, remove dust and othercontaminants by blowing air from the upper side through the ele-ment.

4. Check the air cleaner housing for restrictions, contamination ordamage.

INSTALLATIONInstall the air cleaner in the reverse order of removal.

SURGE TANK AND INTAKE MANIFOLD (N/A) 28-5

SURGE TANK AND INTAKE MANIFOLD

COMPONENTS

*N/A: Natural Aspiration


SURGE TANK AND INTAKE MANIFOLD (N/A)

REMOVAL1. Remove the idle speed actuator.

2. Remove the air intake hose connected to the throttle body.

3. Remove the accelerator cable.4. Remove the water hose and throttle body.

5. Remove the P.C.V. hose and brake booster vacuum hoses.

6. Disconnect the vacuum hose connections.

SURGE TANK AND INTAKE MANIFOLD (N/A) 28-7

7. Disconnect the high pressure fuel hose connection after reliev-ing pressure in the fuel pipe line to prevent fuel overflow. (Referto “Fuel system”).

8. Remove the surge tank stay.9. Remove the surge tank assembly and gasket.10. Disconnect the fuel injector harness connector.

11. Remove the delivery pipe with the fuel injectors and pressureregulator attached.

CAUTIONBe careful not to drop the injectors when removing thedelivery pipe.

12. Remove the insulator from the intake manifold and discon-nect the heater hose.

13. Remove the intake manifold.

INSPECTIONS u r g e T a n k

1. Check the surge tank for defects or cracks. Replace if neces-sary.

Intake Manifold1. Check for damage or cracking of any part.

INSTALLATION1. Install the delivery pipe with the fuel injectors and pressure

regulator attached.


2. Ensure that insulators are correctly inserted into the deliverypipe hole.

28-8 SURGE TANK AND INTAKE MANIFOLD (T/C)

SURGE TANK AND INTAKE MANIFOLD[T/C]

COMPONENTS

*T/C: Turbo Charger


SURGE TANK AND INTAKE MANIFOLD (T/C)

REMOVAL1. Remove the idle speed actuator.

28-9

2. Remove the air intake pipe connected to the turbo charger

3. Remove the accelerator cable.4. Remove the water hose and throttle body.

5. Remove the P.C.V. hose and brake booster vacuum hoses.

6. Disconnect the vacuum hose connections.

28-10 SURGE TANK AND INTAKE MANIFOLD (T/C)

7. Disconnect the high pressure fuel hose connection after reliev-ing pressure in the fuel pipe line to prevent fuel overflow. (Referto “Fuel system”).

8. Remove the surge tank stay.9. Remove the surge tank assembly and gasket.10. Disconnect the fuel injector harness connector.

11. Remove the delivery pipe with the fuel injectors and pressureregulator attached.


12. Remove the insulator from the intake manifold and discon-nect the heater hose.

13. Remove the intake manifold.

INSPECTIONSurge Tank

1. Check the surge tank for defects or cracks. Replace if neces-sary.

Intake Manifold1. Check for damage or cracking of any part.

INSTALLATION1. Install the delivery pipe with the fuel injectors and pressure

regulator attached.


2. Ensure that insulators are correctly inserted into the deliverypipe hole.

EXHAUST MANIFOLD 28-11

EXHAUST MANIFOLD

COMPONENTS


INSPECTIONExhaust ManifoldCheck for damage or cracking.

Exhaust Manifold GasketCheck for flaking or damage of the gasket.

TURBO CHARGER

TURBOCHARGER

Removal1. Remove the air intake pipe and the air intake hose.

2. Remove the water return and feed hose.3. Disconnect the oil feed pipe and the oil drain pipe connector

hose.

TURBO CHARGER 28-13

4. Remove the T/C discharge pipe and the T/C discharge pipebrocket.

5. Remove the T/C to exhaust manifold bolt, and remove the T/Cas an assembly.

Disassembly1. Disconnect the boost hose from the waste gate actuator2. Remove the retaining ring at waste gate valve lever.3. Remove the waste gate actuator mounting bolts to remove the

actuator.

CAUTIONMake sure that the mating mark on turbine housing andcenter housing & rotating assy. Are aligned forreassembling.

4. Remove the bolt that holds the clamp on the turbine housingthen remove the turbine housing with the waste gate valve.

CAUTIONNever attempt to adjust the waste gate valve and actuatorrod length.

5. Place the compressor cover assembly on the floor with its endsurface down and remove the snap ring with pliers.CAUTIONDuring removal, hold the snap ring so that it does not flyout.

6. Remove the center housing rotating assy.

28-14 TURBO CHARGER

INSPECTIONTurbocharger1. Inspect the cast-iron turbine housing for damage, cracks, or

evidence of contact between the turbine blades and the hous-ing.

2. Manually open and close the waste gate valve to make sure itopera tes f ree ly .

3. Inspect the turbine and compressor wheels for wear, damage,bent or broken blades.

4. Inspect the oil passage in the cartridge for signs of deposits orblockage.

5. Clean the inlet section of the compressor cover with a rag.Inspect it for signs of contact with the compressor turbine.If worn, replace it.

Waste gate actuator1. Leak-test the waste gate valve actuator with a hand pump.

Replace the actuator if leakage indicates a ruptured diaphragm.2. Check the rod to see that it is not bent or binding so as to require

replacement.Oil pipe and oil return pipe1. Inspect the oil pipe ends for evidence of coke-like deposits.

If present, replace the oil pipe.2. Inspect the oil return pipe to make sure it is clear. If blocked,

clean it out.

REASSEMBLY1. Clean the inside of turbine housing and compressor cover by

scrubbing with a bristle brush, blowing compressed air andwiping with a clean cloth.

2. Apply a thin coat of engine oil to the inside surface of the newO-ring and install it in the cartridge assembly groove.

3. Apply a thin coat of engine oil to the outer periphery of the O-ringhaving been installed on center housing & rotating assembly,then place the center housing & rotating assembly in thecompressor cover.CAUTIONUse care not to damage the vanes when installing thecenter housing & rotating assembly in compressor cover.

TURBOCHARGER 28-15

4. Place the compressor cover with center housing & rotatingassembly inside on floor with its end surface down and install theretaining ring.

5. Combine the compressor cover and center housing & rotatingassembly with the turbine housing.

CAUTIONDo not damage the center housing & rotating assemblyvanes.

6. Install the turbine housing bolt with clamps.7. Install the waste gate actuator to the compressor cover.

Tightening torqueWastgate actuator bolt . . . . . . . . . . . . . . 20-24(200-240,14-17)Turbine housing fitting bolt . . . . . . . . . . . . . . . . . 2.8-5.6(28-56,2-4)

8. Install the retaining ring to the waste gate valve lever.9. Connect the boost hose.

INSTALLATIONPerform installation in reverse procedure of removal, payingspecial attention to the following items:1. Torque all parts to specifications shown in the component

illustration.2. Before oil pipe eye joint bolt (at top of the turbocharger) installed,

pour clean engine oil into the turbocharger.3. Make sure that the oil and air hoses, etc. are property installed

and securely clamped.4. Do not reuse a heat-damaged, corroded or deformed exhaust

manifold gasket or turbocharger gasket.

28-16 MUFFLERS

MUFFLERS

COMPONENTS

5-10(50-100,4-7.2)

34-40(300-400,22-29) 40-60(460-600,22-29)


REMOVALMain MufflerCAUTIONBefore removing or inspecting the exhaust system, ensurethat the exhaust system has cooled sufficiently.

1. Disconnect the main muffler from the catalytic converter.2. Remove the rubber O-rings and take out the main muffler.

MUFFLERS 28-17

Front Exhaust Pipe1. Remove the front exhaust pipe-to-catalytic converter mounting

bolts.2. Remove the front exhaust pipe clamp bolt and remove the

exhaust manifold-to-front exhaust pipe mounting nuts.

INSPECTION1. Check the mufflers and pipes for corrosion and damage.2. Check the rubber hanger and bands for deterioration and

cracks.

INSTALLATION1. Temporarily install the front exhaust pipe, the catalytic con

verter assembly, the center exhaust pipe, and the main muffler,in that order.

2. Tighten the parts securely. Make sure there is no interferencewith any body components.

EMISSIONCONTROLSYSTEMReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

CRANKCASE EMISSION CONTROL SYSTEM . . . . . . . . . . . 7

EVAPORATIVE EMISSION CONTROL SYSTEM . . . . . . . . . . 8

EXHAUST EMISSION CONTROL SYSTEM . . . . . . . . . . . 12

GENERAL


Components

Crankcase Emission Control SystemPositive crankcase ventilation (PCV) valve

Function

HC reduction

Remarks

Variable flow rate type

Evaporative Emission Control SystemCanisterPurge control solenoid valve

Exhaust Emission Control SystemMPI system (air-fuel mixture control device)3-way catalytic converter

HC reduction

Duty control solenoid valve

CO, HC, NOx reductionCO, HC, NOx reduction

Oxygen sensor feedback typeMonolith type

SERVICE STANDARD

Purge control solenoid valveCoil resistance 4552

TIGHTENING TORQUE

Positive crankcase ventilation valve

N m

8-12

kg.cm

80-120

lb.ft

5.8-8.7

TROUBLESHOOTING

Symptom Probable cause Remedy

Engine will not start or hardto start

Vacuum hose disconnected or damagedMalfunction of the purge control solenoidvalve

Repair or replaceRepair or replace

Rough idle or engine stalls Vacuum hose disconnected or damagedMalfunction of the PCV valveMalfunction of the purge control system

Repair or replaceReplaceCheck the system; if there is a pro-blem, check its component parts

Excessive oil consumption Positive crankcase ventilation line Check positive crankcase ventila-clogged tion system

GENERAL 29-3

EMISSION CONTROLS LOCATION

N/A

T/C

A. PCV valveB. Purge control solenoid valveC. Canister

GENERAL

EMISSION CONTROL SYSTEMS

A. PCV valve

C. Canister

E. Catalytic converter

B. Purge control solenoid valve

D. 2-Way valve

GENERAL

SCHEMATIC DRAWING [ For N/A]

INPUT OUTPUT

1. AFS (Hot film)2. Coolant temperature sensor3. Throttle position sensor4 Crankshaft position sensor5. Phase sensor (in distributor)6. O2 sensor7. Knock sensor8. Vehicle speed sensor9. S/W input

- Ignition S/W- MT/AT select S/W- N/D select S/W- A/CON S/W- A/CON thermo S/W- A/CON pressure S/W- Diagnosis S/W

E C U

*1. Injector*2. Ignition coil*3. Idle speed actuator*4. Purge control solenoid valve*5. Fuel pump relay*6. Power relay*7. OBD lamp*8. Th/position sensor output

(A/T only)*9. RPM output (A/T only)

AFS: Air Flow SensorPCV : Positive Crankcase VentilationUCC : Underfloor Catalytic Converter

29-6 GENERAL

SCHEMATIC DRAWING [For T/C]

INPUT

1. AFS (Hot film)2. Coolant temperature sensor3. Throttle position sensor4. Crankshaft position sensor5. Phase sensor (in distributor)6. O2 sensor7. Knock sensor8. Map sensor (in ECU)9. Vehicle speed sensor10. S/W input

- Ignition S/W- A/CON S/W- A/CON thermo S/W- A/CON pressure S/W- Diagnosis S/W

E C U

OUTPUT

*1. Injector*2. ignition coil

(Power transistor)*3 Idle speed actuator*4. Purge control solenoid valve*5 Fuel pump relay*6. Power relay*7. Waste gate control

solenoid valve*8. OBD lamp*9. Clean burning

(Air flow sensor)

AFS: Air Flow SensorPCV : Positive Crankcase VentilationUCC : Underfloor Catalytic Converter

CRANKCASE EMISSION CONTROL SYSTEM 29-7

CRANKCASE EMISSION CONTROL SYSTEM

1.

2.

3.

Disconnect the ventilation hose from the positive crankcaseventilation (PCV) valve. Remove the PCV valve from the rockercover and reconnect it to the ventilation hose.Run the engine at idle and put a finger on the open end of thePCV valve and make sure that intake manifold vacuum is felt.NOTEThe plunger inside the PCV valve will move back and forth.

If vacuum is not felt, clean the PCV valve and ventilation hosein cleaning solvent or replace if necessary.

INSPECTION

1.2.

3.

Remove the positive crankcase ventilation valve.Insert a thin stick into the positive crankcase ventilation valvefrom the threaded side to check that the plunger moves.If the plunger does not move, the positive crankcase ventilationvalve is clogged. Clean it or replace.

INSTALLATION

Install the positive crankcase ventilation valve and tighten tospecified torque.

PCV valve tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12 Nm (80-120 kg.cm, 5.8-8.7 Ib.ft)

EVAPORATIVE EMISSION CONTROL SYSTEM


COMPONENTS

CANISTER

Inspection

1. Look for loose connections, sharp bends or damage to the fuelvapor lines.

2. Look for distortion, cracks or fuel leakage.3. After removing the charcoal canister, inspect for cracks or

damage.


PURGE CONTROL SOLENOID VALVE

Inspection

NOTEWhen disconnecting the vacuum hose, make an identificationmark on it so that it can be reconnected to its original position.

1. Disconnect the vacuum hose from the solenoid valve.2. Detach the harness connector.3. Connect a vacuum pump to the nipple to which the vacuum

hose was connected.

4. Apply vacuum and check when voltage is applied to the purgecontrol solenoid valve and when the voltage is discontinued.

Battery voltage Normal condition

When applied Vacuum is released.

When discontinued Vacuum is maintained.

5. Measure the resistance between the terminals of the solenoidvalve.

Purge control solenoid valveCoil resistance . . . . . . . . . . . . . . . . . . . . . . . 45 Q [at 20°C (68°F)]

OVERFILL LIMITER (TWO-WAY VALVE)

To inspect the overfill limiter (Two-way valve), refer to Group 31-Fuel tank.

29-10 EVAPORATIVE EMISSION CONTROL SYSTEM

FUEL FILLER CAP

The fuel filler cap is equipped with a vacuum relief valve to prevent the escape of fuel vapor into the atmosphere.

Atmospheric pressure

When pressure is in fuel tank When vacuum is in fuel tank

CHECKING PURGE CONTROL SYSTEM

EVAPORATIVE EMISSION CONTROL SYSTEM 29-11

Checking

1. Disconnect the vacuum hose from the throttle body, andconnect a vacuum pump to the vacuum hose.

2. Check the following points when the engine is cold [coolanttemperature 60°C (140°F) or below] and when it is warm[coolant temperature 70°C (158°F) or higher].

When engine is cold

Engine operatingcondition

Applying vacuum Result

I d l i n g 50 kPa (7.3 psi)3,000 rpm

Vacuum is held

When engine is warm

Engine operatingcondition

Idling

Within 3 minutesafter engine start3,000 rpm

After 3 minuteshave passed afterengine start3,000 rpm

Apply vacuum

50 kPa (7.3 psi)

Try to applyvacuum

50 kPa (7.3 psi)

Result

Vacuum is held

Vacuum is released

Vacuum will be heldmomentarily, afterwhich, it will bereleased.

29-12 EXHAUST EMISSION CONTROL SYSTEM

EXHAUST EMISSION CONTROL SYSTEM

Exhaust emissions (CO, HC, NOx) are controlled by a combinationof engine modifications and the addition of special control compo-nents.Modifications to the combustion chamber, intake manifold, cam-shaft and ignition system form the basic control system.These systems have been integrated into a highly effective systemwhich controls exhaust emissions while maintaining good driveabilityand fuel economy.

AIR/FUEL MIXTURE RATIO CONTROL SYSTEM[Multi Point Injection (MPI) System]

The MPI system is a system which employs the signals from theoxygen sensor to activate and control the injector installed in themanifold for each cylinder, thus precisely regulating the air/fuelmixture ratio and reducing emissions.This in turn allows the engine to produce exhaust gases of theproper composition to permit the use of a three-way catalyst. Thethree-way catalyst is designed to convert the three pollutants (1)hydrocarbons (HC), (2) carbon monoxide (CO), and (3) oxides ofnitrogen (NOx) into harmless substances. There are two operatingmodes in the MPI system.

1. Open-Loop air/fuel ratio is controlled by information programmedinto the ECU.

2. Closed-Loop air/fuel ratio is varied by the ECU based oninformation supplied by the oxygen sensor.

FUELSYSTEMReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SERVICE ADJUSTMENT PROCEDURES . . . . . . . . . . . . 37

MPI COMPONENTS INSPECTION . . . . . . . . . . . . . . . . . . . 42

INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

FUEL LINE AND VAPOR LINE . . . . . . . . . . . . . . . . . . . . . . 97

ENGINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

31-2 GENERAL


Fuel tankCapacity

Fuel filterType

Fuel pumpTypeDriven by

Throttle bodyThrottle position sensor (TPS)TypeResistanceOutput voltage at curb idle

Input sensorAir flow sensor (AFS)

TypeOutput voltage

Knock sensorType

Coolant temperature sensorTypeResistance

Oxygen sensorTypeOutput voltage (V)

Vehicle speed sensorType

Phase sensorTypeOutput voltage (V)

Crankshaft position sensorTypeOutput frequency (Hz)

Output actuatorInjector

TypeNumberCoil resistance (Q)

Fuel pressure regulatorRegulated pressure

Wastegate control solenoid valveTypeOutput frequency (Hz)

Idle speed actuatorTypeControl frequency (Hz)

45 lit. (11.9 U.S. gal., 9.9 Imp.gal.)

High pressure type

Electrical, in-tank typeElectrical motor

Variable resister type1.2-2.8 kQ0.25-0.5 V

Hot wire type (T/C), Hot film type (N/A)0-5 V

Piezoelectric type

Thermistor type2.27-2.73 kQ at 20°C (68°F)0.29-0.35 kQ at 80°C (176°F)

Zirconia sensor (Heated)0-1 V

Reed switch type

Hall effect sensor0.4-5 V

Magnetic typeIdle rpm : 600-900 Hz3000 rpm : 2700-3300 Hz

Electromagnetic type415.55 - 16.25 (2

300 KPa (3.06 kg/cm2, 43.3 psi)

Solenoid type20 Hz

Double coil type100 Hz

GENERAL 31-3

SERVICE STANDARD

Basic idle rpm 800±100 rpmIgnition timing (°) BTDC 9°±5°

SEALANT

Coolant temperature sensor assyCoolant temperature gauge unit

LOCTITE 962T or equivalentThree bond No.2310 or equivalent

TIGHTENING TORQUE N m Kg.cm Ib.ft

Delivery pipe installation boltsFuel pressure regulator boltsOxygen sensorCrankshaft position sensor installation boltsKnock sensor installation boltCoolant temperature sensorThrottle position sensor installation boltsHigh pressure hose and fuel filterHigh pressure hose and fuel tankThrottle body to surge tank boltsFuel tank drain plug

10-15 100-150 7-115-6 50-60 3.6-4.450-60 500-600 37-449-11 90-110 7-816-25 160-250 12-1815-20 150-200 11-153-4 30-40 2.2-2.925-35 250-350 18-2530-40 300-400 22-2915-20 150-200 11-1515-25 150-250 11-18

31-4 GENERAL

SPECIAL TOOLS


09391-330021. Multi-use tester assy

Illustration Use

(Without Adapter Ass’y)1

09391-331002. Multi-use tester sub assy

2

09391-332003. Multi-use tester main body

Diagnostic tester for MPI, automatictransaxle and cruise control systems

09391-333004. Wiring harness

09391-334025. Rom-pack (HMC-3)

39391-335006. Battery harness

39391-336007. Instruction manual

39391-337009. P/C connector

(RS-232C)

For connection to the external communi-cation device such as personal computeretc. in using Multi-use tester.

GENERAL


09391-3900011. Adapter ass’y

Illustration

11

Use

1209391-33800

12. Adapter sub ass’y

09391-33810013. Adapter body

09391-33821

14. Adapter system pack

09391-3345115. Rom-pack (HRP-A)

31-6 GENERAL


09273-24000Harness connector

Illustration Use

Engine r.p.m. check

09353-24000Fuel pressure gauge connector

Connection of fuel pressure gauge todelivery pipe for measurement of fuelpressure.

09353-24100Fuel pressure gauge & hose

GENERAL 31-7

TROUBLESHOOTINGWhen checking engine troubles, it is important to start with aninspection of the basic systems. If one of the followingconditions exists, (A) engine start failure, (B) unstable idlingor (C) poor acceleration, begin by checking the followingbasic systems.

1. Power supply1) Battery2) Fusible link3) Fuse

2. Body ground3. Fuel supply

1) Fuel line2) Fuel filter3) Fuel pump

4. Ignition system1) Spark plug2) High-tension cable3) Distributor4) Ignition coil

5. Emission control system1) PCV system2) Vacuum leak

6. Others1) Ignition timing2) Idle speed

Troubles with the MPI system are often caused by poorcontact of the harness connectors. It is important to check allharness connectors and verify that they are securely con-nected.

GENERAL

MPI TROUBLESHOOTING PROCEDURESPROBLEM1. ECU

GENERAL

PROBLEM2. ECU-KNOCK EVALUATION

31-10 GENERAL

PROBLEM3. OXYGEN SENSOR

GENERAL 31-11

PROBLEM4. AIR FLOW SENSOR (AFS)

GENERAL

PROBLEM5. COOLANT TEMPERATURE SENSOR

GENERAL 31-13

PROBLEM6. PHASE SENSOR

NOTEIf the blink code (3222) is not erased where battery (-) is resetted, it means the phase sensor fault.

31-14 GENERAL

PROBLEM7. CRANKSHAFT POSITION SENSOR

GENERAL

PROBLEM8. THROTTLE POSITION SENSOR

31-16 GENERAL

PROBLEM9. KNOCK SENSOR

GENERAL 31-17

PROBLEM10. VEHICLE SPEED SENSOR

31-18 GENERAL

PROBLEM11. BATTERY & ALTERNATOR

GENERAL 31-19

PROBLEM12. AIR CONDITIONING COMPRESSOR

GENERAL

PROBLEM13. TURBO BOOST PRESSURE HIGH

GENERAL 31-21

PROBLEM14. TURBO BOOST CONTROL DEVIATION

GENERAL

PROBLEM15. TURBO BOOST CONTROL VALVE

GENERAL

PROBLEM16. TURBO BOOST PRESSURE SENSOR

GENERAL

PROBLEM17. INJECTORS

GENERAL 31-25

PROBLEM18. PURGE CONTROL SOLENOID VALVE

31-26 GENERAL

PROBLEM19. IDLE SPEED ACTUATOR (ISA)

GENERAL 31-27

PROBLEM20. AIR-FUEL CONTROL

GENERAL

PROBLEM21. ACTUATORS (UNKNOWN)

GENERAL 31-29

FUEL TANK AND FUEL LINE

Symptom

Engine malfunctionsdue to insufficient fuelsupply

Evaporative emissioncontrol system malfunc-tions (when fuel fillercap is removed, pressureis released)


Bent or kinked fuel pipe or hose Repair or replaceClogged fuel pipe or hose Clean or replaceClogged fuel filter of in-tank fuel filter ReplaceWater in fuel filter Replace the fuel filter or clean the

Dirty or rusted fuel tank interior fuel tank and fuel lines

Malfunctioning fuel pump (Clogged filter in Clean or replace

the pump) Replace

Incorrect routing of a vapor line CorrectDisconnected vapor line CorrectFolded, bent, cracked or clogged vapor line ReplaceFaulty fuel tank cap ReplaceMalfunctioning overfill limiter (Two-way Replacevalve)

31-30 GENERAL

MPI SYSTEM INSPECTION

If the MPI system components (sensors, ECU, injector, etc.) fail,interruption or failure to supply the proper amount of fuel for variousengine operating conditions will result. The following situations canbe encountered.1. Engine is hard to start or does not start at all.2. Unstable idle3. Poor driveability

If any of the above conditions is noted, first perform an inspectionby self-diagnosis and subsequent basic engine checks (ignitionsystem malfunction, incorrect engine adjustment, etc.), and theninspect the MPI system components with the multi-use tester(MUT).

NOTES1) Before removing or installing any part, read the diagnosis

code and then disconnect the battery negative (-) terminal.2) Before disconnecting the cable from battery terminal, turn

the ignition switch to OFF. Removal or connection ofbattery cable during engine operation or while the ignitionswitch is ON could cause damage to the ECU.

3) The control harnesses between the ECU and oxygensensor are shielded wires with the shield grounded to thebody in order to prevent the influence of ignition noisesand radio interference. When the shielded wire is faultythe control harness must be replaced.

On Board Diagnostic (O.B.D.) Lamp [U.S.A. only]

A on board diagnostic lamp comes on to notify the driver of theemission control items when an irregularity is detected.However, when an irregular signal returns to normal, the on boarddiagnostic lamp will go out.Immediately after the ignition switch is turn on, the on boarddiagnostic lamp is lit for 5 seconds to indicate that the on boarddiagnostic lamp operates normally.Item Indicated by the OBDo Electronic control unito Oxygen sensoro Air flow sensoro Throttle position sensoro Coolant temperature sensoro Phase sensoro Knock sensoro Batteryo Air conditioning compressoro Bost sensor (T/C)o Purge control solenoid valveo Idle speed actuatoro Injectoro Crankshaft position sensoro Air-fuel controlo Air-fuel adaptive (California only)

GENERAL 31-31

OBD (On Board Diagnostic) Lamp Inspection

1. Check that when the ignition switch is turned on the lightilluminates for about 5 seconds and then goes out.

2. If the light does not illuminate, check for open circuit in harness,blown fuse and blown bulb.

SELF-DIAGNOSIS

The ECU monitors the input/output signals (some signals at alltimes and the others under specified conditions).When the ECU detects that an irregularity memorize the troublecode, and outputs the signal to the self-diagnosis output terminal.There are 29 diagnosis items, including the normal state, and thediagnosis results can be read out with OBD lamp or Multi-usetester.Trouble codes will remain in the ECU as long as battery power ismaintained. The trouble codes will, however, be erased when thebattery terminal or the engine control unit connector is discon-nected.

NOTEIf the sensor connector is disconnected with the ignitionswitch turned on, the diagnosis code is memorized. In thiscase, disconnect the battery negative terminal (-) for 15seconds or more, and the diagnosis memory will be erased.

31-32 GENERAL

CHECKING PROCEDURE (SELF-DIAGNOSIS)

NOTE1) When battery voltage is low, trouble codes can not be

read. Be sure to check the battery for voltage and otherconditions before starting the test.

2) Diagnosis memory is erased if the battery or the ECUconnector is disconnected. Do not disconnect the batterybefore the trouble codes are completely read.

Inspection Procedure (Using Multi-Use Tester)

1. Turn OFF the ignition switch.2. Connect the multi-use tester to the diagnosis connector in

the fuse box.3. Connect the power-source terminal of the multi-use tester to the

cigarette lighter socket.4. Turn ON the ignition switch.5. Use the multi-use tester to check the self-diagnosis codes.6. Repair the faulty part from the diagnosis chart.7. Erase the malfunction code.

NOTE1) Select 4. “SPECIAL TEST” from the function selec-

tion menu of the multi-use tester.2) Then select Item No.5 “ERASE DIAG”.3) Press the YES key when “ERASE DIAG. CODE ?” is

displayed.4) Enter ID code “39”.5) Press the CLEAR key when “FINISHED ERASING

DIAG. CODE” is displayed.6) Read the self-diagnosis output and check output of

correct code.

8. Disconnect the multi-use tester.

NOTEWhen the ignition key is in the ST position, the cigarettelighter power is OFF. If a test needs to be made duringcranking, use the battery clamp harness provided.

GENERAL 31-33

Inspection Procedure (Using OBD Lamp)

1.2.

3.

4.

5.

6.

Ignition switch ON (Do not start)Ground the L-wire (No. 10 pin) in the diagnostic terminal for 2.5second.The first output is the fault stored or the code “no fault detected”(4444)Each blink code in repeated infinitely till the next step is ord-eredRepeated until the next step is entered by grounding the L-wirefor 2.5 second. After that, the next code follows.The last output consists out of the code for “end of output”(3333). After stepping further as described above, the diagno-sis mode is left.

<Reading Method>

31-34

Actuator Control Sequence Procedure(Using OBD Lamp)

1. The L-wire (No.10 pin) in the diagnostic terminal has to begrounded before ignition ON. (Do not start).

2. Ignition switch ON (Do not start). Then the actuator control isinterrupted immediatelyIf time for grounding of L-wire is too long, the cycle starts fromthe beginning.

3. Repeated until the next step is entered by another groundingthe L-wire. After that, the next code and the next actuatorfollows.

4. The last output consists out of the code for “end of output”.After stepping further as described above, the diagnosis modeis left.

ACTUATOR TEST

No. Test item Check engine lamp Type1 No.1 Injector 1312 ACTIVATE

2 No.3 Injector 1314 ACTIVATE



5 Idle speed actuator 1321 ACTIVATE

6 Purge control solenoid valve 1322 ACTIVATE

<Reading Method>

GENERAL 31-35

Diagnosis Chart

GENERAL

SERVICE ADJUSTMENT PROCEDURES 31-37

SERVICE ADJUSTMENT PROCEDURES

Idle Speed Check Procedures

NOTE:Before adjusting check that the, spark plugs, injectors, idlespeed actuator (ISA), compression etc. are normal.

Checking conditions;oooo

1.

2.

3.

4.

Engine coolant temperature is 80 to 95°C (176 to 205°F).Lights, electric cooling fan and all accessories are off.Transaxle is in neutral [“P” or “N” range for A/T vehicles].Steering wheel is straightforward position (Vehicles with powersteering).

Install the tachometer (Disconnect the noise filter connectorsand connect the S.S.T 09273-24000 between them. Then,connect the tachometer to the S.S.T) and the timing light, orconnect the multi-use tester to the diagnostic connector in thefuse box.Start and run the engine at curb idle speed.

Run the engine for more than 5 seconds at an engine speed of2,000 to 3,00 rpm.Run the engine at idle for 2 minutes.Read the idling rpm. If the multi-use tester is used, press codeNo. 32 and read the idling rpm.

Idle speed .......................................... 800 ± 100 rpm

Throttle Valve Area Cleaning

5. Stop the engine and remove the air intake hose from the throttlebody, check the throttle valve blade and throttle body bore forcarbon deposits, rotating the valve.

6. Using a shop towel, wipe out carbon deposits from the throttlevalve blade and throttle body bore.

NOTEIf necessary, spray cleaning solvent to the throttle valvearea and leave it for about 5 minutes.

31-38 SERVICE ADJUSTMENT PROCEDURES

7. Attach the air intake hose.

8. Start the engine and check the curb idle speed under checkingconditions.

Fuel Filter Replacement

1.

2.

3.

4.

Reduce the internal pressure of the fuel pipes and hoses bycompleting the following operations.o Disconnect the fuel pump harness connector at the rear of

the fuel tank.o Start the engine and after it stalls, turn the ignition switch to

OFF.o Disconnect the battery negative (-) terminal.o Connect the fuel pump harness connector.

Remove the eye bolts while holding the fuel filter nuts securely.

CAUTIONCover with a shop towel to avoid gasoline from splashing.

Remove the fuel filter mounting bolts, then remove the fuel filterfrom the fuel filter clamp.After replacing the fuel filter, check for fuel leaks.

Overfill Limiter (Two-way Valve) Replacement

1. Disconnect the vapor hoses, and then remove the overfilllimiter.


2. Connect the overfill limiter in the correct direction.

Fuel Sender Replacement

1. Remove the fuel tank cap to lower the fuel tank’s internalpressureRemove the fuel sender installation screws, then remove thefuel sender from the fuel tank.

Fuel Pump Operating Check

1. Turn the ignition switch to the OFF positions.2. Apply battery voltage to the fuel pump drive connector to check

that the pump operates.

NOTEThe fuel pump is in-tank type and its operating sound ishard to hear without removing the fuel tank cap.

3. Pinch the hose to check that fuel pressure is felt.


Fuel Pressure Test

1. Using the fuel pressure gauge connector (09353-24000, 09353-24100), install the fuel pressure to the service valve.

2. Disconnect the vacuum hose from the pressure regulator, andplug the hose end. Measure fuel pressure at idle.

Standard value . . . . . . . . . . . . . . . . 306 kPa (3.06 kg/cm2 44.37 psi)

3. Measure the fuel pressure when the vacuum hose is connectedto the pressure regulator.

Standard value . . . . . . . Approx. 255 kPa 2.55 kg/cm2, 37 psi)

4. If the results of the measurements made in steps (2) and (3) arenot within the standard value, use the table next page todetermine the probable cause, and make the necessary re-pairs.


Condition

Fuel pressure too low

Fuel pressure too high

There is no difference infuel pressure when thevacuum hose is con-nected and when it is not.


a. Clogged fuel filter a. Replace fuel filterb. Fuel leakage to the return side, caused by b. Replace fuel pressure regulator.

poor seating of the fuel-pressure regulator.

c. Low discharge pressure of the fuel pump c. Check the in-tank fuel hose forleakage or replace the fuel pump.

a Sticking fuel-pressure regulator a. Replace fuel pressure regulatorb. Clogged or bent fuel return hose or pipe. b. Repair or replace hose or pipe.

a. Clogging, or damaged vacuum hose or the a. Repair or replace the vacuumnipple. hose or the nipple

b. Sticking or poor seating of the fuel pressure b. Repair or replace hose or pipe.regulator.

5. Stop the engine and check for a change in the fuel pressuregauge reading, which should hold for approximately 5 minutes.If the gauge indication drops, observe the rate of drop. Deter-mine and remove the causes according to the following table.

Condition Probable cause Remedy

Fuel pressure dropsslowly after engine isstopped

a. Injector leakage a. Replace injector

Fuel pressure dropsimmediately afterengine is stopped

a. The check valve within the fuel pump is a. Replace fuel pumpopen

6. Remove the fuel pressure gauge connector from the servicevalve.

31-42 MPI COMPONENTS INSPECTION

LOCATION OF MPI COMPONENTS

A. Air conditioner relayB. Air flow sensorC. Idle speed actuatorD. Throttle position sensorE. Coolant temperature sensorF. Phase sensorG. InjectorH. Oxygen sensor

I. Inhibitor switchJ. Power relayK. Diagnosis terminalL. Vehicle speed sensorM. ECUN. Purge control solenoid valveO. Crankshaft position sensor

MPI COMPONENTS INSPECTION 31-43

MPI COMPONENTS INSPECTION


MPI COMPONENTS INSPECTIONAIR FLOW SENSOR [For N/A]

The type of air flow sensor is a hot film and composed of a hot filmsensor, housing, metering duct (power transister, hybrid, sensorelement).Mass air flow rate is measured by detection of heat transfer froma hot film probe and the change of the mass air flow rate causeschange in the amount of heat being transferred from the hot wireprobe surface to the air flow.This result in the change of the temperature of the hot wire probeand in the change of resistance.

Circuit Diagram.

AFS

H Harness side connector

ground AFS signaloutput

E.C.U


Troubleshooting Hints

1. If the engine stalls occasionally, crank the engine and shake the AFS harness. If the engine stalls check the poorcontact of the AFS connector.

2. If the AFS output voltage is other than 0 when the ignition switch is turned on (do not start the engine). Check forthe faulty AFS or E.C.U.

3. If the engine can be idle even if the AFS output voltage is out of specification, check for the following conditions;1) Disturbed air flow in the AFS

Disconnected air duct, clogged air cleaner element.2) Poor combustion in the cylinder.

Faulty ignition plug, ignition coil, injector, incorrect comparison.3) Air leaks in the intake manifold

Using Multi-use Tester

Check item Data display Check conditions Engine state Test specification

Air flow sensor Intake air quantity in o Engine coolant temperature: Idle (800 rpm) 9.0-12.0 kg/h

o Service data fine step (No.35) 80 to 95° (176 to 205°F) 2000 rpm 21.0-27.0 kg/ho Item No.35 o Lamps, electric cooling fan,

accessory units : All OFF 3000 rpm 32.0-40.0 kg/h

o Transaxle : Neutral (P range Racing Quantity increase:for vehicle with A/T) with racing

o Steering wheel : Neutral

Air flow sensor Intake air quantity in o Engine coolant temperature: Idle (800 rpm) 8.0-11.2 kg/h

o Service data coarse step (No.36) 80 to 95° (176 to 205°F) 2000 rpm 20.8-25.6 kg/ho Item No.36 o Lamps, electric cooling fan,

accessory units : All OFF 3000 rpm 32.6-41.6 kg/h

o Transaxle : Neutral (P range Racing Quantity increase:for vehicle with A/T) with racing


Air flow sensor Norminal air quantity o Engine coolant temperature: Idle (800 rpm) 9.6-10.8 kg/ho Service data in idle status (No.61) 80 to 95° (176 to 205°F)o Item No.61 o Lamps, electric cooling fan,

accessory units : All OFFo Transaxle : Neutral (P range

for vehicle with A/T)o Steering wheel : Neutral

Using Voltmeter

Check item Engine state Test specification

Air flow sensor output voltage (AFS sideconnector No.4 or ECU harness sideconnector No.7)

Idle (800 rpm)

3000 rpm

0.94-0.98 V

1.76-1.79 V

NOTEWhen the vehicle is new [within initial operation of about 500 km (300 miles)], the air flow sensor air quan-tity may be about 10% higher.


Harness Inspection Procedures.


AIR FLOW SENSOR [For T/C]

The Air Flow Sensor installed between the air cleaner assemblyand the throttle body (inserted the air intake hose).The type of air flow sensor is a hot wire and composed of a hybridcircuit, hot wire element (sensor ring) which made of a platinumwire, housing, protective grid, moulding ring.Mass air flow rate is measured by detection of heat transfer froma hot wire probe and the change of the mass air flow rate causeschange in the amount of heat being transferred from the hot wireprobe surface to the air flow.This result in the change of the temperature of the hot wire probeand in the change of “Resistance”.

Circuit Diagram

Air flow sensor side connector


AFS

Sensor Signal Cleanground burning

E.C.U E.C.U


Troubleshooting HintsUsing Multi-use Tester

Check item Data display Check conditions Engine state Test specification

Air flow sensor Intake air quantity in o Engine coolant temperature: Idle (800 rpm) 9.0-12.0 kg/ho Service data fine step (No. 35) 80 to 95°C (176 to 205°F)o Item No.35 Intake air quantity in o Lamps, electric cooling fan,

2000 rpm 20.0-22.0 kg/h

o Item No.36 coarse step (No.36) accessory units: All OFF 3000 rpm 29.0-32.0 kg/ho Item No.61 Nominal air quantity o Transaxle : Neutral (P range

in idle status (No.61) for vehicle with A/T)Racing Quantity increases

with racingo Steering wheel : Neutral

Air flow sensoro Service datao Item No.36

Intake air quantity incoarse step (No.36)

o Engine coolant temperature: Idle (800 rpm) 8.0-11.2 kg/h80 to 95°C (176 to 205°F) 2000 rpm 19.2-20.8 kg/h

o Lamps, electric cooling fan,accessory units: All OFF 3000 rpm 28.9-32.0 kg/h

o Transaxle : Neutral (P range Racing Quantity increasesfor vehicle with A/T) with racing


Air flow sensoro Service datao Item No.61

Nominal air quantityin idle status (No.61)

o Engine coolant temperature: Idle (800 prm) 9.6-10.8 kg/h80 to 95°C (176 to 205°F)

o Lamps, electric cooling fan,accessory units: All OFF

o Transaxle : Neutral (P rangefor vehicle with A/T)


Using Voltmeter

Check item

Air flow sensor output voltage (AFS sideconnector No.3 or ECU harness sideconnector No.7)

Engine state

Idle (800 rpm)

3000 rpm

Test specification

2.0-2.6 V

2.6-3.3 V

Air flow sensor clean burning outputvoltage.(AFS side connector No.4 or ECUharness side connector No.25)

Clean burning state

Except clean burning state

3-5 V

0-0.5 V

NOTEWhen the vehicle is new [within initial operation of about 500 km (300 miles)], the airflow sensor air quantity maybe about 10% higher.


Harness Inspection Procedures.


COOLANT TEMPERATURE SENSOR

The coolant temperature sensor is installed in the engine coolantpassage of the cylinder head, detects engine coolant temperatureand emits signals to the E.C.U.This part employs a thermistor which is sensitive to changes intemperature. The electric resistance of a thermistor decreases inresponse to temperature rise.The E.C.U. judges engine temperature. by the sensor outputvoltage and provides optimum fuel enrichment when the engine iscold.

Circuit Diagram

Coolant temperature sensor

Coolant temperaturesensor side connector


Coolant temp.sensor output

E.C.U


If the fast idle speed is not enough or the engine gives off dark smoke during the engine warm-up operation, the coolanttemperature sensor might be the causes.



Check item

Coolant temperaturesensoro Service datao item No.24

40°C

Using Voltmeter

Data display Check conditions Coolant temperature Test specification

Sensortemperature

Ignition switch : ON When -20°C (-4°F) -20°C

or engine running When 0°C (32°F) 0°C

When 20°C (68°F) 20°C

When 40°C (104°F)

When 80°C (176°F) 80°C

Check item

Coolant temperature sensoroutput voltage(CTS side connector No.2 orECU harness side connectorNo.45)

Coolant temperature

When 0°C

When 20°C

When 40°C

When 80°C

Test specification

4.05 V

3.44 V

2.72 V

1.25 V

Harness Inspection Procedures.* : T/C

Measure the power supply voltage.o Connector: Disconnectedo Ignition switch: ONo Voltage: 4.6-4.8 V

Repair theharness(H2-45)*(H2-45)

Check for continuity of the ground circuit.o Connect: Disconnected OK E N D

Repair theharness(H1-ground)


Sensor Inspection1. Remove the coolant temperature sensor from the intake mani

fold.2. With temperature sensing portion of coolant temperature sen-

sor immersed in hot water, check resistance.

3. If the resistance deviates from the standard value greatly,replace the sensor.

INSTALLATION

1. Apply sealant LOCTITE 962T or equivalent to threaded portion.2. Install coolant temperature sensor and tighten it to specified

torque.

Tightening torqueCoolant temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-20 Nm (150-200 kg.cm, 11-15 Ib.ft)

3. Connect the harness connector securely.


THROTTLE POSITION SENSOR (TPS)

The TPS is a rotating type variable resistor that rotates with thethrottle body throttle shaft to sense the throttle valve angle. As thethrottle shaft rotates, the throttle angle of the TPS changes and theECU detects the throttle valve opening based on the change of thethrottle angle.

Circuit Diagram

Throttle position sensorside connector

Throttle position sensor


E.C.U


The TPS signal is important in the control of automatic transaxle. Shift shock and other troubles will occur if the sensoris faulty.



Using Voltmeter

Check item

Throttle position sensor outputvoltage(TPS side connector No.1 or ECUharness side connector No.53)

Check condition

At idle (800 rpm)

Wide open throttle

Test specification

0.25-0.6 V

4.25-4.6 V

Harness Inspection Procedures.* : T/C


Sensor Inspection

1. Disconnect the throttle position sensor connector.2. Measure resistance between terminal 2 (sensor power) and

terminal 3 (sensor ground).

Standard value: 1.2-2.8 kQ

3. Connect a pointer type ohmmeter between terminal 3 (sensorground) and terminal 1 (sensor output).

4. Operate the throttle valve slowly from the idle position to the fullopen position and check that the resistance changes smoothlyin proportion with the throttle valve opening angle.

5. If the resistance is out of specification, or fails to changesmoothly, replace the throttle position sensor.

Tightening torqueThrottle position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4 Nm (30-40 kg.cm, 2.2-2.9 Ib.ft)


PHASE SENSOR

Phase sensor (built in the distributor) senses the TDC point of No.1cylinder in its compression stroke, whose signals are fed to ECU tobe used to determine the sequence of fuel injection.

Circuit Diagram

Phase sensor side connector


E.C.U

Phase sensor


If the phase sensor does not operate correctly, correct sequential injection is not made so that the engine may stall orrun irregularly at idle or fail to accelerate normally.


Using Voltmeter

Check item Check condition Test specification

Phase sensor output voltage (Phase At idle (800 rpm) 0-5 V

sensor side connector No.2 or ECU 3000 rpm 0-5 Vharness side connector No.8)

Harness Inspection Procedures* : T/C


CRANKSHAFT POSITION SENSOR

The crankshaft position sensor which consist of a magnetic coil(magnetic reluctance type) is installed on the transaxle housing.The voltage signal form this crankshaft position sensor is providedto the ECU for detecting the engine RPM and position of crankshaft.

Circuit Diagram ( ): T/C

C P S



1. If unexpected shocks are felt during driving or the engine stalls suddenly, shake the crankshaft position sensor harness.If this causes the engine to stall, check for poor contact of the sensor connector.

2. If the tachometer reads 0 rpm when the engine is cranked, check for faulty crankshaft position sensor or ignition systemproblems.


Harness Inspection Procedures* : T/C

Sensor Inspection

1. Disconnect the crankshaft position sensor connector2. Measure the resistance between terminal 2 and 3.

Standard value . . . . . . . . . . . . . . . . 0.486-0.594 kQ at 20°C (68°F)

3. If the resistance deviates from the standard value, greatlyreplace the sensor

Clearance between the crank shaft position sensor and crank-shaft position sensor wheel.Standard value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5-1.5 mm

Tightening torqueCrank shaft position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-11 Nm (90-110 kg.cm, 6.6-8.1 Ib.ft)


OXYGEN SENSOR

The oxygen sensor senses the oxygen concentration in exhaustgas, converts it into a voltage which is sent to the ECU. The oxygensensor outputs about 800 mV when the air fuel ratio is richer thanthe theoretical ratio and outputs about 100 mV when the ratio isleaner (higher oxygen concentration in exhaust gas.)The ECU controls the fuel injection ratio based on this signal so thatthe air fuel ratio is maintained at the theoretical ratio.

Circuit Diagram ( ): T/C

Oxygen sensor side connector

Heater side connector

I Harness side connector


E.C.U

E.C.U


1. If the oxygen sensor is defective abnormally high emissions may occur.2. If the oxygen sensor check has resulted normal but the sensor output voltage is out of specification, check for the

following items related to air fuel ratio control system.1) Faulty injector2) Air leaks in the intake manifold.3) Faulty air flow sensor, coolant temperature sensor.


Using Voltmeter

Check item Check condition Test specification

Oxygen sensor output voltage 3000 rpm after warm-up 0.1-0.8 V(Oxygen sensor side connector toECU harness side connector No.28)

Harness Inspection Procedure ----, * : T/C


Sensor Inspection

NOTE1) Before checking, warm up the engine until the engine

coolant temperature reaches 80 to 95°C (176 to 205°F).2) Use an accurate digital voltmeter.

1. Disconnect the oxygen sensor connector, and measure theresistance between terminal 1 and terminal 2.

Standard value

Temperature °C(°F) Resistance (Q)

400 (752) 30 or more

2. Replace the oxygen sensor if there is a malfunction.

Tightening torqueOxygen sensor ..............................................................

50-60 Nm (500-600 kg.cm 37-44 Ib.ft)


INJECTORS

The injectors inject fuel according to signal coming from the ECU.The volume of fuel injected by the injector is determined by the timeduring which the solenoid valve is energized.

Circuit Diagram

Power relay

ABCD Injector side connector

ABCD Harness side connector

E.C.UE.C.U


1. If the engine is hard to start when hot, check for fuel pressure and injector leaks.2. If the injector does not operate when the engine is cranked, then check the followings:

1) Faulty power supply circuit to the ECU, faulty ground circuit2) Faulty power relay3) Faulty crankshaft position sensor, phase sensor

3. If there is any cylinder whose idle state remains unchanged when the fuel injection of injectors is cut one after anotherduring idling, check for the following items about such cylinder.1) Injector and harness2) Ignition plug and high tension cable3) Compression pressureIf the injection system is OK but the injector drive time is out of specification, check for the following itemso Poor combustion in the cylinder (faulty ignition plug, ignition coil, compression pressure, etc.)



Using Voltmeter

Check item Check condition MUT display Type

Injectoro Actuator test

IG. S/W ON(Do not start)

01. No.1 Injector

02. No.2 Injector

Activate

Activate

03. No.3 Injector Activate

04. No.4 Injector Activate

Harness Inspection Procedures. * : T/C


Injector Inspection

Operation CheckUsing a multi-use tester, check as described below.o Activate the fuel injectors in sequence.o Check the operation time of the injectors.

Operation Sound Check1. Using a stethoscope, check the injectors for a clicking sound at

idle. Check that the sound is produced at shorter intervals asthe engine speed increases.

NOTEEnsure that the sound from an adjacent injector is notbeing transmitted along the delivery pipe to an inopera-tive injector.

2. If a stethoscope is not available, check the injector operationwith your finger.If no vibrations are felt, check the wiring connector, injector, orinjection signal from ECU.

Resistance Measurement Between Terminals1. Disconnect the connector at the injector.2. Measure the resistance between terminals.

Standard value . . . . . . . . . . . . . . . . ..15.55-16.25 Q [at 20°C(68°F)]

3. Connect the connector to the injector.


IDLE SPEED ACTUATOR (ISA)

The idle speed actuator is of the double coil type and has two coil,the two coils are driven by separate driver stages in the ECU comecone coil receives the inverse signal of the other. Depending on thepulse duty factor the equilibrium of the magnetic forces of the twocoils will result in different angles of the motor. In parallel to thethrottle valve a bypass hose line is arranged, where the idle speedactuator is inserted in.

Circuit Diagram

Idle speed actuatorside connector


Idle speed actuator

To control relay

Open Closing

E.C.U E.C.U

Troubleshooting HintsUsing Multi-use Tester


Idle speed actuatoro Actuator


05. ISCV Activate


Harness Inspection Procedure * : T/C

Actuator Inspection

Resistance Measurement Between Terminals.

1. Disconnect the connector at the idle speed actuator.2. Measure the resistance between terminals.

Standard valueTerminal 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13SLTerminal 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1442

[at 20°C (68°F)]

3. Connect the connector to the idle speed actuator


VEHICLE SPEED SENSOR Vehicle speed sensor

The vehicle speed sensor is a reed switch. The vehicle speedsensor is built into the speedometer and coverts the transaxle gearrevolutions into pulse signals, which are sent to ECU.

Circuit Diagram

Vehicle speed sensor Terminal voltage (V)



Vehicle speed [km/h (mph)]

E.C.U IE.C.U


If there is an open or short circuit in the vehicle speed sensor signal circuit, the engine may stall when the vehicle isdecelerated to stop.

Harness Inspection Procedures * : T/C


* : T/C

Measure the power supply voltage ofthe vehicle speed sensoro Connector: Disconnectedo Ignition switch: ONo Voltage: 4.5-4.9V

Check for continuity of the groundcircuito Connector: Disconnected OK END !

NGRepair theharness(16-ground)


KNOCK SENSOR

The knock sensor is attached to the cylinder block and sensesengine knocking conditions.A knocking vibration from the cylinder block is applied as pressureto the piezoelectric element. This vibrational pressure is thenconverted into a voltage signal which is delivered as output. Ifengine knocking occurs, ignition timing is retarded to suppress it.

Circuit Diagram

Knock sensor

Knock sensor side connector


E.C.UE.C.U

Harness Inspection Procedures * : T/C

Check for an open-circuit, or a short-circuit to ground between the ECU andthe knock sensoro ECU connector: Disconnectedo Knock sensor connector:

Disconnected


Check for continuity of the groundcircuito Connector: Disconnected END !

Sensor Inspection

1. Disconnect the knock sensor connector2. Measure resistance between the terminal 2 and 3.

NG harness(H3-30)*(H3-30)

Repair the

Standard value . . . . . . . . . . . . . . . . . about 5MR [at 20°(68°F)]

3. If the resistance is continual, replace the knock sensor.

Tightening torque.Knock sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16-25 Nm (160-250 kg.cm, 11.8-18.4 Ib.ft)


IGNITION SWITCH-ST ANDINHIBITOR SWITCH [A/T]

When the ignition switch is set ST position, the battery voltage isapplied through the ignition switch and inhibitor switch to the ECU.If the selector lever is not P or N position, the battery voltage will notreach to the ECU.Based on this signal, the ECU determines the automatic transaxleload and drives the idle speed actuator to maintain optimum idlespeed.

Circuit Diagram

Inhibitor switch side connector


E.C.U


If the inhibitor switch harness check is normal but the inhibitor switch output is abnormal, check for the control cableadjustment.

Harness Inspection

Measure the power supply voltageof the inhibitor switcho ECU connector: Disconnected

OKo Inhibitor switch connector:

Disconnectedo Ignition switch: START and ONo Voltage (V): System voltage

circuit.

Check thepower supply


IGNITION SWITCH-ST [M/T]

The ignition switch-ST inputs a high signal to the ECU while theengine is cranking.The ECU provides fuel injection control, etc. at engine start-upbased on this signal.

Circuit Diagram

E.C.U

Harness Inspection * : T/C

Measure the input voltage to the ECUo ECU connector: Disconnectedo Ignition switch: START OKo Clutch pedal: Presso Voltage: 8V or more

NG

END !

Repair theharness(Ignition switch-27)* (Ignition

switch-27)


ELECTRONIC CONTROL UNIT (ECU)-POWER GROUND

Grounds the electronic control unit.

Circuit Diagram

E.C.U


If the ground wire of the ECU is not connected securely to ground, the unit will not operate correctly.

Harness Inspection Procedure * : T/C

Check for continuity of the groundcircuit.o ECU connector: Disconnected OK

NG

END !

Repair theharness(1 g-ground)* (1 g-ground)


AIR CONDITIONER SWITCH ANDAIR CONDITIONER RELAY

The air conditioner switch applies the battery voltage to the ECUwhen the air conditioner is turned on.When the air conditioner ON signal is input, the ECU drives the ISAand turns ON the power transistor. And then the air conditionerpower relay coil is energized to turn on the relay switch, whichactivates the air compressor magnetic clutch. Air conditioner switch

Circuit Diagram

Fusible link Ignition switch


If the air compressor magnet clutch is not activated when the air conditioner switch is turned on during idling, faultyair conditioner control system is suspected.



Check Item Data display Check condition Air conditioner switch Normal indication

Air conditioner Switch state Engine: Idling (air com- OFF OFF

switch pressor to be running when ON ONo Service data air conditioner switch iso Item No.17 ON)

Air conditioner Air conditioner Engine: Idling after OFF OFF (compressorcompressor compressor warm-up clutch non-activation)

o Service data ON ON (compressoro Item No.16 activation)

Harness Inspection

Measure the power supply voltageof the air conditioner circuito Air conditioner switch: ONo Engine control unit connector:

Disconnectedo Ignition switch: ONo Voltage: System voltage

NG

END !

Check the airconditionercircuit

Air Conditioner Inspection

Refer to GROUP-97 service adjustment procedures


PURGE CONTROL SOLENOID VALVE

The purge control solenoid valve is an duty control type, whichcontrols introduction of purge air from the canister.

Circuit DiagramControl relay

Purge control solenoidvalve side connector


E.C.U



Purge control solenoidvalveo Actuator tester


06. PURGE VALVE Activate


Harness Inspection* : T/C

Measure the power supply voltage.o Connector: Disconnectedo Ignition switch: ON OKo Voltage: System voltage

Repair theharness(Control relay-H2)

Check for an open-circuit, or a short-circuit to ground between the purge END !control solenoid valve and the engine OKcontrol unit.o Engine control unit connector:

Disconnected Repair theo Purge control solenoid valve connec- NG harness

tor: Disconnected (H1-5)* (H1-5)

Actuator InspectionRefer to GROUP 29-Evaporative Emission Control System.


ECU MAIN RELAY

When the ignition switch is on, battery power is supplied to the ECU,the injector, the air flow sensor, etc. While the ignition switch isturned on, current flows from the ignition switch through the currentrelay coil to ground.

Circuit Diagram

ECU main relayside connector


ECU main relay

E.C.U

Harness Inspection Processor : T/C

Measure the power supply voltage ofthe ECU main relayo ECU main relay connector: OK

Disconnectedo Voltage (V): system voltage

NGRepair theharness(H4, 5-Battery)


Check for open-circuit or short-circuit toground between the engine control unitand the ECU main relay OKo ECU connector: Disconnectedo ECU main relay: Disconnected

NGRepair theharness(H2-36)* (H2-36)

ECU Main Relay Inspection

1. Check continuity of relay contacts between terminal 4 (+) and2 (-).

Relay coil (between terminals 5 & 1) Continuity

No. (a Cl)

Yes (0 Cl)

When de-energized

When energized

[Relay coil (between terminals 5 & 3) Continuity

No. (a. R)

Yes (0 Cl)

When de-energized

When energized

2. If fault, replace the control relay

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........ECU main relay 7-11 Nm (70-110 kg.cm, 5.2-8.1 Ib.ft)


IGNITION COIL AND POWER TRANSISTOR[for T/C]

When the power transistor is turned ON by the signal from the ECU,primary current is shut off and a high voltage is induced in thesecondary coil.

Circuit Diagram

Ignition switch (IG1)

Ground Ignitioncoil control

E.C.U

E.C.U


FUEL PUMP

Circuit Diagram

side connectorFuel pump control relay

Battery


Fuel pump side connector


E.C.U

J Fuel pumpcheck terminal

Harness Inspection Procedures

Check the fuel pumpo Apply battery voltage to the check-

ing terminal and operate the pump.

* : T/C


WASTE GATE CONTROL SOLENOID VALVE[For T/C]

The wastegate control solenoid valve is a controller for boostpressure. integrated with the controls for spark and fuel schedulingto control the complete engine with greater stability, improvedperformance, reduced turbo charger lag, more successful sparkknock control.

Circuit Diagram

Waste gate control solenoid valve

Waste gate control solenoidvalve side connector


Waste gateoutput signal

E.C.U

E.C.U


Harness Inspection Procedure

Actuator Inspection

1. Disconnect the waste gate control solenoid valve connector.2. Measure the resistance between the terminals of the solenoid

valve.

Wastegate control solenoid valveCoil resistance . . . . . . . . . . . . . . . . . . . . about 1 M R [at 20°C (68°F)]

3. If the resistance deviates from the standard value, greatlyreplace the wastegate control solenoid valve.

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-12 Nm (100-120 kg.cm, 7.4-90 Ib.ft)

INJECTOR 31-89

INJECTOR

COMPONENTS


REMOVAL

1. Release residual pressure from the fuel line to prevent fuel fromspilling.

CAUTIONCover the hose connection with rags to prevent splash-ing of fuel that could be caused by residual pressure inthe fuel line.

31-90 INJECTOR

2. Remove the delivery pipe with the fuel injector and pressureregulator.

CAUTION2. Be careful not to drop any injectors when removing

the delivery pipe.2. Be aware that fuel may flow out when removing the

injector.

INSPECTION

1. Measure the resistance of the injectors between the terminalsusing an ohmmeter.

Resistance . . . . . . . . . . . . . . . . . . 14.55-16.25R [at 20°C (68°F)]

2. If the resistance is not within specifications, replace the injector.

INSTALLATION

1. Install a new grommet and O-ring to the injector.2. Apply a coating of solvent, spindle oil or gasoline to the O-ring

of the injector.

3. While turning the injector to the left and right, install it on to thedelivery pipe.

4. Be sure the injector turns smoothly.

NOTEIf it does not turn smoothly, the O-ring may be jammed;remove the injector and re-insert it into the delivery pipeand re-check.

THROTTLE BODY 31-91

THROTTLE BODY

COMPONENTS

Throttle valve set screw Throttle body


3-4 (30-40, 2.2-2.9)

Throttle position sensor

REMOVAL

CAUTIONThe throttle valve must not be removed.

31-92 THROTTLE BODY

1. Remove the throttle position sensor.

NOTEExcept when necessary for replacement, the throttle posi-tion sensor must not be removed.

INSPECTION

Cleaning Throttle Body

1. Clean the throttle body. The throttle body must not be cleanedby immersion in cleaning solvents.The insulation of the throttle body will be damaged if they areimmersed in cleaning solvent. They should be cleaned by usinga piece of cloth.

2. Check for restriction of the vacuum port or passage. Clean thevacuum passage by using compressed air.

FUEL TANK 31-93

FUEL TANK

COMPONENTS


REMOVAL

1. To reduce the internal pressure of the fuel lines and hoses, firststart the engine and then disconnect the electrical fuel pumpconnector.

NOTEBe sure to reduce the fuel pressure before disconnect-ing the fuel main pipe and hose otherwise fuel will spillout.

31-94 FUEL TANK

2. Disconnect the battery cable form the negative terminal of thebattery.

3. Remove the fuel tank cap.4. Remove the drain plug and drain the fuel.

5. Disconnect the return hose and vapor hose.

6. Disconnect the fuel gauge unit connector.

7. Disconnect the high pressure hose from the fuel tank.

FUEL TANK 31-95

8. Detach the fuel filler hose and leveling hose.

9. Loosen the two self-locking nuts, that hold the tank in positionand remove the two tank bands.

10. Remove the fuel vapor hose and the fuel tank.

INSPECTION

1. Check the hoses and the pipes for cracks or damage.2. Check the fuel tank cap for proper operation.3. Check the fuel tank for deformation, corrosion or cracking.4. Check the inside fuel tank for dirt or foreign material.5. Check the in-tank fuel filter for damage or restriction.

6. Test the two-way valve for proper operation.7. To check the two-way valve, lightly breathe into the inlet and

outlet. If air passes through after slight resistance, then thevalve is good.

INSTALLATION

1. Confirm that the pad is fully bonded to the fuel tank, and installthe fuel tank by tightening the self-locking nuts to the tank bandsuntil the rear end of the tank band contacts the body.

31-96 FUEL TANK

2. Connect the leveling hose to the tank and approximately 40 mm(1.6 in.) at the filler neck.

3. When connecting the filler hose, the end with the shorter straightpipe should be connected to the tank side.

4. Connect the vapor hose and return hose.When attaching the fuel hose to the line, be sure that thehose is attached as shown in the illustration.

5. To connect the high pressure hose to the fuel pump, temporarilythe flare nut by hand, and then tighten it to the specified torque.Be careful that the fuel hose does not twist.

Tightening torqueHigh pressure hose flare nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30-40 Nm (300-400 kg.cm, 22.1-29.5 Ib.ft)

CAUTIONWhen tightening the flare nut, be careful not to bend ortwist the line to prevent damage to the fuel pump con-nection.

6. Connect the electrical fuel pump and fuel gauge unit connector.

25-30mm (1.0-1.2in.)

Flare nut

Secure side

7. Tighten the drain plug to the specified torque.

Tightening torqueDrain plug . . . . . . . . . . . . . . 15-25 Nm (150-250 kg.cm, 11-18 Ib.ft)

FUEL LINE AND VAPOR LINE 31-97

FUEL LINE AND VAPOR LINE

TORQUE : Nm (kg.cm Ib.ft)

COMPONENTS

25-35 (250-350, 18-25)

REMOVAL1. Remove the upper eye bolt while holding the fuel filter nut

securely and remove the high pressure fuel hose.

CAUTION1) Be sure to reduce the fuel pressure before discon-

necting the fuel line and hose, otherwise fuel willspill out.

2) Cover the hose connection with a shop towel toprevent splashing of fuel that could be caused byresidual pressure in the fuel line.

2. Remove the lower eye bolt while holding the fuel filter nutassembly.

3. Remove the fuel filter mounting bolts, then remove the fuel filterfrom the bracket.

4. Remove the fuel return hose and line.5. Remove the fuel vapor hose and line.

31-98 FUEL LINE AND VAPOR LINE

INSPECTION

1. Check the hoses and pipes for cracking bending, deformationor restrictions.

2. Check the canister for restrictions.3. Check the fuel filter for restrictions and damage.

If a problem is found, repair or replace parts as necessary.

INSTALLATION

1. Install the fuel vapor hose and return hoses.o If the fuel line has a stepped section, connect the fuel hose

to the line securely, as shown in the illustration.o If the fuel line does not have a stepped section, connect the

fuel hose to the line securely.

2. Install the fuel filter, and tighten the fuel filter bracket.3. Insert the main line on the filter and tighten the eye bolts while

holding the fuel filter nuts.

4. Install the clips and make sure that they do not interfere withother components.

5. When installing the check valve, install it so that the valve isfacing in the direction as shown in the illustration.

ENGINE CONTROL 31-99

ENGINE CONTROL

COMPONENTS

Throttle body side inner cable


REMOVAL

1. Remove the bushing and inner cable of the accelerator armside.

2. After disconnecting the accelerator switch connector, loosenthe bolts of the accelerator arm bracket and remove.

31-100 ENGINE CONTROL

INSPECTION

1. Check the inner and outer cable for damage.2. Check the cable for smooth movement.3. Check the accelerator arm for deformation.4. Check the return spring for deterioration.5. Check the connection of the bushing to end metal fitting.6. Check the accelerator switch proper operation.

INSTALLATION

1. When installing the return spring and accelerator arm, applymulti-purpose grease around each moving point of the accel-erator arm.

2. Apply sealant to the bolt mounting hole, and tighten the accel-erator arm bracket.

Tightening torqueAccelerator arm bracket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-12 Nm (80-120 kg.cm, 5.8-7.2 Ib.ft)

3. Securely install the resin bushing of the accelerator cable on theend of the accelerator arm.

4. Apply multipurpose grease around the cable end.

CLUTCHSYSTEMReturn To Main Table of Contents

CLUTCH COVER AND DISC . . . . . . . . . . . . .

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . 8

CLUTCH CONTROL . . . . . . . . . . . . . . . . . . . . . 10

CLUTCH MASTER CYLINDER . . . . . . . . . . . . . . . 13

CLUTCH RELEASE CYLINDER . . . . . . . . . . . . . 15

17

GENERAL


Clutch operating methodClutch Disc

TypeFacing diameter (outside x inside) mm (in.)

Clutch Cover assemblyType

Clutch release cylinder*I.D. mm (in.)

Clutch Master Cylinder*I.D. mm (in.)

Hydraulic type

Single dry with diaphragm.200 x 130 (7.9 x 5.1)

Diaphragm spring strap

20.64 (0.81)

15.87 (0.62)

*I.D. : Inside Diameter

SERVICE STANDARD

Standard valueClutch disc thicknessClutch pedal heightClutch pedal free play (includes both pedal andclevis pin play)

8.7±0.4 mm (0.34±0.01 in.)178 mm (7.17 in.)6-13 mm (0.24-0.51 in.)

Clutch pedal to floor board clearance(when the clutch is disengaged)Clutch pedal stroke

90 mm (2.8 in.)

150 mm (5.7 in.)

LimitClutch disc rivet sinkDiaphragm spring end height difference

0.3 mm (0.012 in.)0.5 mm (0.02 in.)

TIGHTENING TORQUE Nm (kg.cm, Ib.ft)

Clutch pedal to pedal support member(clutch pedal bracket)Clutch pedal support memberIgnition lock switchClutch master cylinder to firewallClutch tube flare nutClutch tube bracketReservoir bandClutch release cylinderClutch release cylinder to union boltClutch cover assembly

2.5-3.5 (25-35, 14-20)

17-26 (170-260, 12-15)19-28 (190-280, 14-20)9-14 (90-140, 7-10)13-17 (130-170, 9-12)4-6 (40-60, 3-4)5-7 (50-70, 4-5)15-22 (150-220, 11-16)20-25 (200-250, 14-18)15-22 (150-220, 11-16)

GENERAL 41-3

LUBRICANTS

Items Specified lubricants Quantity

Contact surface of release bearing and fulcrum of MOLYWHITE TA NO.2 As requiredclutch release fork

Inner surface of clutch release bearing MOLYWHITE TA NO.2 As required

Inner surface of clutch release cylinder and outer Brake fluid DOT 3 As requiredcircumference of piston and cup

Inner surface of clutch disc spline MOLYWHITE TA NO.2 As required

Inner surface of clutch master cylinder and outer Brake fluid DOT 3 As requiredcircumference of piston assembly

Clutch master cylinder push rod, clevis pin and Wheel bearing grease As requiredwasher SAE J310, NLGI NO.2

Clutch pedal shaft and bushings Chassis grease SAE J310, NLGI NO.1 As required

Contact portion of release fork to release cylinder MOLYWHITE TA NO.2 As requiredpush rod

Input shaft spline MOLYWHITE TA NO.2 As required

SPECIAL TOOLS


09411-11000Clutch disc guide

Illustration Use

Installation of clutch disc

GENERAL

TROUBLESHOOTING

Symptom

Clutch slippingo Car will not respond to engine

speed during acceleration.o Insufficient car speedo Lack of power during uphill

driving

Difficult gear shifting (gear noiseduring shifting)

Probable cause

Insufficient pedal free play

Clogged hydraulic system

Excessive wear clutch disc facing

Hardened clutch disc, or oil on surface

Damaged pressure plate or flywheel

Weak or broken pressure spring

Excessive pedal free play

Hydraulic system fluid leaks, air trapping orclogging

Remedy

Adjust

Correct or replace parts

Replace

Replace

Replace

Replace

Adjust

Repair or replace parts

Unusual wear or corrosion of clutch disc spline Replace

Excessive vibration (distortion) of clutch disc Replace

Clutch When clutch is not used Insufficient free-play of clutch pedal Adjust

noisy Excessive wear clutch disc facing Replace

A noise is heard after Unusual wear and/or damage of release bearing Replaceclutch is disengaged

A noise is heard when clutch Insufficient grease on the sliding surface of Repairis disengaged bearing sleeve

Improperly installed clutch assembly or bearing Repair

A noise is heard when Damaged pilot bushing Replacethe car is moved with theclutch partially engaged

Hard pedal effort Insufficient lubrication of clutch pedal

Insufficient lubrication of spline part of clutchdisc

Repair

Repair

Insufficient lubrication of clutch release levershaft

Repair

Insufficient lubrication of front bearing retainer Repair

GENERAL

Symptom Probable cause

Hard to shift or will not shift Clutch pedal free play excessive

Clutch release cylinder faulty

Clutch disc out of true, runout is excessiveor lining broken

Remedy

Adjust

Repair or replace

Replace clutch disc

Splines on input shaft or clutch disc dirty orburred

Repair or replace

Clutch pressure plate faulty Replace

Clutch slips Clutch pedal free play insufficient

Clogged hydraulic system

Clutch disc lining oily or worn out

Adjust

Repair or replace parts

Inspect clutch disc

Pressure plate faulty

Faulty pressure plate

Replace

Replace

Clutch grabs/chatters

Release fork binding

Clutch disc lining oily or worn out

Pressure plate faulty

Worn or broken torsion spring

Engine mounts loose

Inspect release fork

Inspect clutch disc

Replace clutch cover

Replace clutch cover

Replace clutch disc

Clutch noisy Damaged clutch pedal bushing

Loose part inside housing

Replace as necessary

Replace clutch pedal bushing

Loose part inside housing

Release bearing worn or dirty

Release fork or linkage sticks

Repair as necessary

Replace release bearing

Repair as necessary

41-6 GENERAL


CLUTCH PEDAL INSPECTION ANDADJUSTMENT

1. Measure the clutch pedal height (from the face of the pedal padto the floorboard) and the clutch pedal clevis pin play (mea-sured at the face of the pedal pad).

Standard value (A) : 178 mm (7 in.)(B) : 1-3 mm (0.04-0.12 in.)

2. If either the clutch pedal height or the clutch pedal clevis pinplay are not within the standard value range, adjust as follows:1) For vehicles without auto-cruise control system, turn and

adjust the bolt so that the pedal height is the standard value,and then secure by tightening the lock nut.Vehicles with auto-cruise control system, disconnect theclutch switch connector and turn the switch for standardclutch pedal height. Then lock with lock nut.

NOTE:When the pedal height is lower than the standard value,loosen the bolt or clutch switch, and then turn the pushrod to make the adjustment. After the adjustment, tightenthe bolt or clutch switch until it reaches the pedal stopper,and then lock with the lock nut.

2) Turn the push rod to adjust the clutch pedal clevis pin playto agree with the standard value and then secure the pushrod with the lock nut.

Caution:When adjusting the clutch pedal height or the clutchpedal clevis pin play, be careful not to the push rodtoward the master cylinder.

3. After completing the adjustments, confirm that the clutch pedalfree play (measured at the face of the pedal pad) and thedistance between the clutch pedal (the face of the pedal pad)and the firewall when the clutch is disengaged, are within thestandard value ranges.

Standard value (C) : 6-13 mm (0.2-0.5 in.)(D) : 90 mm (2.8 in.)

GENERAL 41-7

4. If the clutch pedal free play and the distance between the clutchpedal and the firewall when the clutch is disengaged do notagree with the standard values, after adjusting it is probably theresult of either air in the hydraulic system or a faulty mastercylinder or clutch. Bleed the air, or disassemble and inspect themaster cylinder or clutch.

BLEEDING

Whenever the clutch tube, the clutch hose, and/or the clutchmaster cylinder have been removed, or if the clutch pedal isspongy, bleed the system.

CAUTIONUse the specified fluid. Avoid mixing different brands offluids.

Specified fluid : SAE J1703 (DOT 3)

1. Loosen the bleeder screw at the clutch release cylinder.2. Push the clutch pedal down slowly until all air is expelled.3. Hold the clutch pedal down until the bleeder is retightened.4. Refill the clutch master cylinder with the specified fluid.

CAUTIONThe rapidly-repeated operation of the clutch pedal in B-Crange may cause the release cylinder’s position to beforced out from the release cylinder body during the airbleeding, redepress the clutch pedal after it returns tothe “A” point completely

CLUTCH PEDAL

CLUTCH PEDAL

COMPONENTS


Removal

1. Remove the cotter pin, washer and clevis pin.2 . Remove the clutch pedal mounting bolt.

CLUTCH PEDAL 41-9

INSPECTION

1. Check the pedal shaft and bushing for wear.2. Check the clutch pedal for bending or twisting.3. Check the return spring for damage or deterioration.4. Check the pedal pad for damage or wear.

IGNITION LOCK SWITCH INSPECTION

1. Disconnect the connector.2. Check to be sure that there is continuity between connector

terminals.(Refer to page 27 GROUP Ignition Lock System)

INSTALLATION

1. Installation is reverse of removal.2. Apply multi-purpose grease to the bushings.

3. Apply multi-purpose grease to the clevis pin and washer.

41-10 CLUTCH CONTROL

CLUTCH CONTROL

COMPONENTS


REMOVAL

1. Drain the clutch fluid through the bleed plug.2. Remove the clevis pin, washer and cotter pin.3. Disconnect the clutch line (master cylinder side).4. Remove the master cylinder mounting bolt.

CLUTCH CONTROL 41-11

5. Remove the clutch line clips.6. Hold the nut on the clutch hose and loosen the flare nut on the

clutch line.

7. Remove the clip from the clutch hose and remove the hosefrom the bracket.

8. Remove the clutch line.

9. Disconnect the clutch line (release cylinder side).

INSPECTION

1. Check the clutch hose or lines for cracks or restrictions.

INSTALLATION

1. Connect the clutch line (release cylinder side).

41-12 CLUTCH CONTROL

2. Temporarily tighten the flare nut by hand, then tighten it to thespecified torque, being careful that the clutch hose does notbecome twisted.

3. Install the clutch line and clips.

4. Install the master cylinder.

5. Apply the specified grease to the clevis pin and washer.

Specified grease : Wheel bearing grease SAE J310,NLGI No.2

6. Install the push rod to the clutch pedal.7. Refill the clutch master cylinder with fluid.8. Bleed the system.

CLUTCH MASTER CYLINDER 41-13

CLUTCH MASTER CYLINDER

COMPONENTS

Piston stop ringI

4-6 (40-60, 3-5)


DISASSEMBLY

1. Remove the piston stop ring.2. Pull out the push rod and piston.3. Remove the reservoir band, reservoir cap and reservoir.

CAUTION1) Use care not to damage the master cylinder body

and piston assembly.2) Do not disassemble the piston assembly.

41-14 CLUTCH MASTER CYLINDER

INSPECTION

1.2.3.4.

5.

Check the inside of the cylinder body for rust pitting or scoring.Check the piston cup for wear or deformation.Check the piston for rust, pitting or scoring.Measure the master cylinder inside diameter with a cylindergauge and the piston outside diameter with a micrometer.

NOTEMeasure the inside diameter of the master cylinder at threeplaces (bottom, middle, and top), in perpendicular direc-tions.

If the master cylinder-to-piston clearance exceeds the limit,replace the master cylinder and/or piston assembly.

Limit : 0.15 mm (0.006 in.)

REASSEMBLY

1. After installing the reservoir to the master cylinder body, installthe reservoir clamp within the range shown by the arrow in theillustration.

2. Apply the specified fluid to the inner surface of the cylinderbody and to the outside of the piston assembly.

Specified fluid : SAE J1703 (DOT 3)

Flu id

CLUTCH RELEASE CYLINDER 41-15

CLUTCH RELEASE CYLINDER

COMPONENTS

I20-25 (200-250, 14-18)

Clutch tube13-17 (130-170, 7-10)


R E M O V A L

1. Disconnect the clutch line.2. Remove the release cylinder mounting.

INSPECTION

1. Check the clutch release cylinder for fluid leakage.2. Check the clutch release cylinder boots for damage.

41-16 CLUTCH RELEASE CYLINDER

DIASSEMBLY1. Remove the valve plate, spring, push rod boots.2. Remove the piston from the release cylinder using compressed

air.

CAUTION1) Cover with rags to prevent the piston from popping

out.2) Apply compressed air slowly to prevent the brake fluid

from splashing.

INSPECTION

1. Check the release cylinder bore for rust or damage.2. Measure the release cylinder bore at three locations (bottom,

middle and top) with a cylinder gauge and replace the releasecylinder assembly if the clearance to the piston outside ex-ceeds the limit.

Limit : 0.15 mm (0.006 in.)

REASSEMBLY

1. Apply the specified brake fluid to the release cylinder bodyinside and the outer surface of the piston and piston cup, andpush the piston cup assembly in the cylinder.

Specified brake fluid : DOT 3

2. Install the valve plug, spring, union.

INSTALLATION

1. Apply coating the specified grease to contact parts of therelease fork and release cylinder push rod. (KM206).

Specified grease : MOLYWHITE TA No.2

2. Install the clutch release cylinder, and the clutch line.

CLUTCH COVER AND DISC 41-17

CLUTCH COVER AND DISC

COMPONENTS

Transaxle assembly


REMOVAL

1. Remove the transaxle.2. Insert the special tool (09411-11000) at the center spline (in

order to prevent the clutch disc from falling).3. Diagonally loosen the bolts which attach the clutch cover to

flywheel. Back off bolts in succession, one or two turns at a time,to avoid bending cover flange.

NOTEDO NOT clean the clutch disc or release bearing withcleaning solvent.

41-18 CLUTCH COVER AND DISC

INSPECTION

CLUTCH COVER ASSEMBLY

1. Check the diaphragm spring end for wear and uneven height.Replace if wear is evident or height difference exceeds the limit.

Limit: 0.5 mm (0.02 in.)

2. Check the pressure plate surface for wear, cracks and colorchange.

3. Check the cover plate rivets for looseness and replace theclutch cover assembly if loose.

CLUTCH DISC

1. Check the facing for loose rivets, uneven contact, deteriorationdue to seizure, adhesion of oil or grease and replace the clutchdisc if defective.

2. Measure the rivet sink and replace the clutch disc if it is out ofspecification.

Limit: 0.3 mm (0.012 in.)

3. Check for torsion spring play and damage and if defective,replace the clutch disc.

4. Combine the clutch disc with the input shaft and check slidingcondition and check for play in the rotating direction.If it does not slide smoothly, check after cleaning andreassembling. If the play is excessive, replace the clutch discand/or the input shaft.

CLUTCH RELEASE BEARING

1. The release bearing is packed with grease, so don’t usecleaning oil, etc. to clean it.

2. Check the bearing for heat damage, abnormal noise and/orimproper rotation. Also check whether or not there is wear at thepoint of contact with the diaphragm spring.

3. If there is abnormal wear at the point of contact with the releasefork, replace the bearing.

RELEASE FORK

1. If there is abnormal wear at the point of contact with thebearing, replace the release fork.

CLUTCH COVER AND DISC 41-19

INSTALLATION

1. Apply a coating of the specified grease to the point of contactwith the fulcrum and the point of contact with the releasebearing.

Specified grease: MOLYWHITE TA No.2

CautionWhen installing the clutch, apply grease to each part, butbe careful not to apply excessive grease; excessive greasewill cause clutch slippage and shudder.

2. Apply a coating of the specified grease to the end of the releasecylinder’s push rod and to the push rod hole in the release fork.

Specified grease : MOLYWHITE TA NO.2

3. Pack the inner surface of the clutch release bearing and thegroove with the specified grease.

Specified grease: MOLYWHITE TA No.2

4. Apply a coating of the specified grease to the clutch disc spline,and then use a brush to rub it in.

Specified grease: MOLYWHITE No.2

5. Using the special tool (clutch disc guide), position the clutchdisc to the flywheel.

6. Install the clutch cover assembly. Tighten the bolts a little at atime, working in diagonal sequence, finally tightening them tothe specified torque.

7. Before installing the transaxle assembly, apply a coating of thespecified grease to the input shaft spline, and then rub in byusing a brush.

Specified grease : MOLYWHITE TA NO.2

Apply grease

MANUALTRANSAXLEReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

MANUAL TRANSAXLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 11

SHIFT LEVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

MANUAL TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

MANUAL TRANSAXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 17

INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

SHIFT FORK AND CONTROL SHAFT ASSEMBLY...... 41

DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

SPEEDOMETER DRIVEN GEAR ASSEMBLY . . . . . . . . . . . . 45

43-2 GENERAL


ModelTypeGear ratio 1st

2nd3rd4th5thReverseFinal

Speedometer gear ratio (driven/drive)

(x-T/MN/A T/C

3.4622.0531.3701.0310.838 0.8783.250 3.2503.842 3.65031/36

SERVICE STANDARD

Standard valueinput shaft bearing end playOutput shaft bearing end playDifferential bearing end play

0.00-0.050.15-0.200.25-0.30

LUBRICANTS AND GREASE

Transaxle gear oil lit(U.S. qts., Imp. qts.)

Transaxle input shaft splineTransaxle oil seal lip

Recommended lubricant Quantity

Hypoid gear oil, SAE 75W/85W, API-GL4 2.15 (2.25, 1.95)

MOLYWHITE TA NO.2 As requiredRETINAX AM, MOLYTEX GREASE EP 2 As required

SEALANTS AND ADHESIVES

Transaxle case and clutch housingalignment surfaceTransaxle case and rear coveralignment surfaceBearing retainer bolt (flush bolt only)

Recommended sealants and adhesives Quantity

THREE BOND 1216 As required



GENERAL 43-3

SNAP RING FOR ADJUSTMENT AND SPACER

Part Name Clearance of bearing side Selection thickness Identification symbols

Input bearing spacer adjusting 1.27-1.30 1.25 25layer 1.30-1.33 1.28 28(For adjustment of input shaft 1.33-1.36 1.31 31bearing end play) 1.36-1.39 1.34 34

1.39-1.42 1.37 37

1.42-1.45 1.40 401.45-1.48 1.43 431.48-1.51 1.46 461.51-1.54 1.49 491.54-1.57 1.52 52

1.57-1.60 1.55 551.60-1.63 1.58 581.63-1.66 1.61 611.66-1.69 1.64 641.69-1.72 1.67 67

1.72-1.75 1.70 701.75-1.78 1.73 731.78-1.81 1.76 761.81-1.84 1.79 791.84-1.87 1.82 82

1.87-1.90 1.85 851.90-1.93 1.88 88

1.24-1.27 1.43 43Output bearing spacer adjusting 1.27-1.30 1.46 46layer 1.30-1.33 1.49 49(For adjustment of output bearing 1.33-1.36 1.52 52end play) 1.36-1.39 1.55 55

1.39-1.42 1.58 581.42-1.45 1.61 611.45-1.48 1.64 641.48-1.51 1.67 671.51-1.54 1.70 70

1.54-1.57 1.73 731.57-1.60 1.76 761.60-1.63 1.79 791.63-1.66 1.82 821.66-1.69 1.85 85

1.69-1.72 1.88 881.72-1.75 1.91 911.75-1.78 1.94 941.78-1.81 1.97 971.81-1.84 2.00 00

1.84-1.87 2.03 031.87-1.90 2.06 061.90-1.93 2.09 091.93-1.96 2.12 12

43-4 GENERAL

Part Name

Spacer adjusting layer(For adjustment of differentialbearing end paly)

Clearance of bearing side Selection thickness Identification symbols

0.51-0.54 0.80 800.54-0.57 0.83 830.57-0.60 0.86 860.60-0.63 0.89 890.63-0.66 0.92 92

0.66-0.69 0.95 950.69-0.72 0.98 980.72-0.75 1.O1 010.75-0.78 1.04 040.78-0.81 1.07 07

0.81-0.84 1.10 100.84-0.87 1.13 130.87-0.90 1.16 160.90-0.93 1.19 190.93-0.96 1.22 22

0.96-0.99 1.25 250.99-1.02 1.28 28

TIGHTENING TORQUENm kg.cm Ib.ft

Shift cable and select cable to bodyShift lever assembly to bodyShift lever to lever (A)Lever (A) to bracket assemblyClutch release cylinder mounting boltsClutch tube flare nutShift cable and select cable to transaxleStarter motor mounting boltsTransaxle mount bracket to transaxleTransaxle mount bracket to bodyBell housing cover mounting boltsTransaxle mounting boltsRear cover boltBackup light switchPoppet spring plugSpeedometer sleeve boltInput shaft lock nutOutput gear lock nutReverse idler gear shaft boltTransaxle case tightening boltStopper bracket boltRestrict ball assemblyReverse shift lever assembly attaching boltBearing retainer boltDifferential drive gear boltInterlock plate bolt

12-15 120-150 9-1112-15 120-150 9-1119-28 190-280 13-2019-28 190-280 13-2015-22 150-220 11-1613-17 130-170 9-1215-22 150-220 11-1627-34 270-340 20-2560-80 600-800 43-5890-110 900-1100 65-808-10 80-100 6-743-55 430-550 32-398-11 80-110 6-830-35 300-350 22-2525-30 250-300 18-223-5 30-50 2-4140-160 1400-1600 102-115140-160 1400-1600 102-11543-55 430-550 32-3925-28 250-280 18-2015-22 150-220 11-1530-35 300-350 22-2515-22 150-220 11-1515-22 150-220 11-15130-140 1300-1400 94-10120-27 200-270 15-19

GENERAL

SPECIAL TOOLS

GENERAL

GENERAL 43-7

TROUBLESHOOTING

Symptom

Vibration, noise

Oil leakage

Hard shift

Jumps out of gear


Loose or damaged transaxle and engine mounts Tighten or replace mounts

Inadequate shaft end play Correct end play

Worn or damaged gears Replace gears

Worn or damaged bearings Replace bearings

Use of inferior grade of gear oil Replace with specified gear oil

Low oil level Replenish

Inadequate engine idle speed Adjust idle speed

Broken or damaged oil seal or O-ring Replace oil seal or O-ring

Faulty control cable Replace control cable

Poor contact or wear of synchronizer ring and Correct or replacegear cone

Weakened synchronizer spring Replace synchronizer spring

Use of inferior grade of gear oil Replace with specified gear oil

Worn gear shift fork or broken poppet spring Replace shift fork or poppet spring

Excessive clearance of synchronizer hub to Replace synchronizer hub andsleeve spline sleeve

Worn or damaged gears and/or bearings Replace

43-8 GENERAL


Oil Level inspection

1. Remove oil filler plug and check level with finger.2. Oil level must be up to fill hole. If it is below hole, add oil until

it runs out, then reinstall plug.3. Replace the oil that the transaxle gear oil is noticeably dirty, and

that it is not of a suitable viscosity.

OIL CHANGE

Use HP Gear Oil SAE 75W/85W (API-GL 4)

1. With the vehicle parked on a level surface, remove the drainplug and drain the transaxle oil.

2. Reinstall drain plug with new gasket, and transaxle oil totalcapacity.2.15 liters (2.27 u.s.qts., 1.89 Imp.qts.)

DRIVE SHAFT OIL SEAL REPLACEMENT

N/A Vehicle

1. Disconnect the drive shaft from the transaxle(Refer to Drive Shaft)

2. Using a flat-tip screwdriver, remove the oil seal.

3. Using the special too (09431-21200), tap the drive shaft oil sealinto the transaxle.

4. Apply a coating of gear oil to the lip of the oil seal.

Transaxle gear oil: Hypoid gear oil, SAE 75W/85W con-forming to API GL-4 or higher.

GENERAL 43-9

T/C VEHICLE

1. Disconnect the drive shaft from the transaxle.(Refer to drive shaft)

2. Remove the intermediate shaft by removing the 2 bolts.

3. Using a flat-tip screwdriver, remove the oil seal.

4. Using the special too (09431-21200), tap the drive shaft oil sealinto the transaxle.

5. Apply a coating of gear oil to the lip of the oil seal.

Transaxle gear oil: Hypoid gear oil, SAE 75W/85W con-forming to API GL-4 or higher.

43-10 GENERAL

SPEEDOMETER CABLE REPLACEMENT

1. Correctly insert the adapter into the instrument panel, andfasten the new speedometer cable.

2. Install the grommet so the cable attachment part and theprojecting part are horizontal, as shown in the illustration.

CautionThe cable should be installed so that the radius of thecable bend is 150 mm (5.9 in.) or more.

3. At the transaxle, the cable should be inserted into thetransaxle, and the nut should be securely tightened.

Caution:If the cable is not correctly and securely connected, itmay cause the speeedometer to read incorrectly or itmay produce abnormal noise.

MANUAL TRANSAXLE CONTROL 43-11

MANUAL TRANSAXLE CONTROL

COMPONENTS


REMOVAL

1. Remove the console assembly (Refer to CONSOLE)2. Remove the cotter pins and clips (shift lever side).3. Remove the shift lever assembly.

43-12 MANUAL TRANSAXLE CONTROL

4. Remove the retainer and bolts.5. Remove the cotter pins and clips (Transaxle side).6. Remove the shift cable and select cable.

INSPECTION

1. Check the select cable for proper operation and for damage.2. Check the shift cable for proper operation and for damage.3. Check the boot for damage.4. Check each bushing for wear, abrasion, sticking, restricted

movement or damage.5. Check for a weak or damaged spring.

INSTALLATION

1.2.

Install the shift lever assembly.Installation of shift lever and select cable.1) Move the transaxle select lever and shift lever to the neutral

position.2) When connecting the select cable to lever (B), adjust the

select cable’s length so that lever (B) is at the neutralposition.

3) The flange side of the resin bushing at the select cable endshould be at the lever (B) end surface.

4) The flange side of the resin bushing at the shift cable endshould be at the shift lever’s cotter pin hole.

5) After connecting the shift cable, check that the dimensions(A) and (B) shown in the illustration are equal.

6) Move the shift lever to each position and verify that theshifting is smooth.

3. Install the retainer and bolts

SHIFT LEVER ASSEMBLY 43-13

SHIFT LEVER ASSEMBLY

COMPONENTS

19-28(190-280,13-20)

Bushing

Lever (B)

Shift lever

Stopper

Bushing

Lever (A)

Bushing

Bracket assembly Return spring


INSPECTION

1. Check the bushing for wear or damage.2. Check the return spring for damage or deterioration.

ASSEMBLY

1. Apply multi-purpose grease to the sliding part of the bushings.2. Assembly is reverse of the disassembly.

43-14 MANUAL TRANSAXLE

MANUAL TRANSAXLE

COMPONENTS


MANUAL TRANSAXLE 43-15

REMOVAL

1. Remove the drain plug and drain the transaxle gear oil.2. Remove the clutch release cylinder (Refer to the CLUTCH

SECTION)3. Remove the air cleaner assembly.4. Remove the select cable and shift cable (Refer to MANUAL

TRANSAXLE CONTROL SECTION)

5. Disconnect the backup light switch connector.6. Remove the speedometer cable.7. Disconnect the clutch cable or clutch tube.

8.

9.10.11.

Remove the starter motor mounting bolts.Remove the transaxle assembly upper connecting bolts andtransaxle mounting bracket bolt.

Remove the splash shield.Remove the intermediate shaft by removing 2 bolts. (T/C only)Disconnect the tie rod end, lower the arm ball joint and driveshaft (Refer to DRIVE SHAFT AND FRONT AXLE SECTION)

12. Remove the bell housing cover.

MANUAL TRANSAXLE

13.

14.

Remove the transaxle assembly lower mounting bolts with thetransaxle assembly supported by a jack.Remove the transaxle assembly.

NOTEWhen supporting the transaxle assembly make sure thatthe lifting force is applied to a wide area, not to a smalllocalized area.

INSTALLATION

1. Installation is the reverse of removal.

MANUAL TRANSAXLE ASSEMBLY 43-17

MANUAL TRANSAXLE ASSEMBLY

43-18 MANUAL TRANSAXLE ASSEMBLY

DISASSEMBLY

1. Remove the back up light switch, gasket, mounting bracket,restrict ball assembly and mounting bracket.

2. Remove the rear cover bolt and rear cover.

3. Remove the seal bolts, spring cases, poppet springs andpoppet balls.

NOTEBe careful not to lose the springs or balls.

4. Remove the 5th speed shift fork spring pin using the special tool(09414-11000)

5. To remove the lock nuts of input shaft and output shaft, unstakethe lock nuts.


6. Shift the transaxle into 1st speed using the control lever andselect lever.

7. Shift the 5th speed synchronizer to 5th speed gear, then loosenand remove the lock nuts.

8. Remove the 5th speed synchronizer sleeve and shift fork.9. Remove the 5th synchronizer hub and ring with 5th speed gear

and needle bearing using the special tool (09451-21000)10. Remove the 5th speed gear on the output shaft using the

special tool (09455-21000)

11. Remove the select lever assembly and select lever shoe.

12. Remove the control shaft mounting bolts on the neutralposition.

13. Remove the interlock plate fixed bolt and air breather.14. Remove the control shaft assembly.


15. Remove the reverse gear shaft bolt.

16. Remove the transaxle case fixing bolts in the clutch housing.

17. Remove the bolts attaching transaxle case and detach it.

18. Remove the oil guides.

19. Remove the drive shaft bearing outer racer and spacer usingspecial tool (09455-32200).


20. Remove the output shaft bearing outer race and spacer usingthe special tool (09455-32000).

21. Remove the input shaft bearing outer race and spacer.

22. Remove the bolts on the reverse shift lever and the reverse shiftlever assembly and reverse shift lever shoe.

23. Remove the reverse idler gear and the reverse idler gearshaft.

24. Remove the spring pins of the shift fork using the special tool(09414-11000).

25. Detach the shift rail and fork assembly.


26. Remove the input shaft assembly and output shaft assembly atthe same time.

27. Remove the differential gear assembly.

28. Remove the speedometer driven gear assembly and cablesupport bracket assembly.

29. Remove the input shaft bearing outer race using (09455-32200) the special tool.

30. Remove the output shaft bearing outer race.

31. Remove the drive shaft bearing outer race using the special tool(09455-32200).


32. Remove the oil cover.

33. Remove the differential side oil seal.

34. Remove the output shaft oil guide.

35. Remove the input shaft oil seal


REASSEMBLY

Assembly procedure is the reverse of removal procedure.1. Install the drive shaft oil seal using the special tool (09431-

21000).

NOTEInsert the oil seal straightly.

2. Install the input shaft front oil seal using the special tool (09431-21000).

CautionDo not reuse the oil seal.

3. Install the output shaft oil guide in the direction illustrated.

4. Install the input shaft bearing outer race using the special tool(09455-21100).

5. Install the output shaft bearing outer race using the special tool(09532-11500).

6. Install the drive shaft bearing outer race using the special tool(09532-11500).


7.8.9.

10.

Install the oil cover.Install the differential gear assemblyInstall the input shaft assembly and the output shaft assemblyat the same time.

Reassembly the shift rail assemblies.1) Place the 1st and 2nd speed synchronizer sleeve to neutral

position.2) Place the 3rd and 4th speed synchronizer sleeve to neutral

position.3) Install the shift rail and fork assemblies.

11. Install the spring pin1) Install the spring pins using the special tool (09414-11100)

or pin punch.

2) When installing, make sure that the slit of spring pin isaligned with center line of the shift rail.

CAUTIONDo not reuse the spring pin,

12. Install the reverse idler gear and reverse idler gear shaft in thedirection illustrated.

13. Install the reverse shift lever assembly and shoe.


14. Install the drive shaft oil seal in the transaxle case using thespecial tool (09431-21200).

CautionDo not reuse the oil seal.

15. Install the input shaft roller bearing outer race and spacer usingthe special tools (09432-33400, 09500-11000).

16. Install the output shaft bearing outer race and spacer using thespecial tools (09500-11000, 09432-22100A).

17. Install the drive shaft bearing outer race and spacer using thespecial tools (09500-11000, 09532-11500)

18. Installation of spacer.1) Place two pieces of rosin-core solder with 3 mm in diameter

on the bearing outer race as illustrated.2) Install the transaxle case temporarily and tighten the bolts to

the specified torque, then remove the transaxle case.3) Detach the crushed solders.4) Measure the thickness of the crushed solder.

Select and install the proper spacers which complete follow-ing specification.

Standard value (End play)input shaft end 0-0.05 mmOutput shaft 0.15-9.20 mmDifferential case 0.25-0.30 mm

For proper spacer, refer to relevant parts catalog.


19. Install the oil guide in the transaxle case.

20. Apply the specified sealant to the clutch housing side of thetransaxle case.

Specified sealant : THREE BOND 1216

21. Install the transaxle case onto the clutch housing assemblyand tighten the bolts.

22. Center the shaft with screw driver.23. Tighten the reverse gear shaft bolt to the specified torque.

Tightening torqueReverse gear shaftbolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43-55 Nm (430-550 kg.cm 32-39 Ib.ft)

24. Install poppet balls, poppet springs, spring cases and sealbolts.

25. Install the control shaft assembly on the neutral condition andtighten the mounting bolts.

26. Install the interlock plate fixed bolt and washer and air breather.27. Apply sealant to the air breather and attach it.


28. Install the 5th speed output gear to the output shaft using thespecial tool (09432-33300)

29. Install the 5th speed sleeve, needle roller bearing, 5th speedgear with synchronizer ring.

30. Install the 5th speed synchronizer hub.

31. Install the 5th speed gear shift fork and the synchronizer sleeveat the same time.

32. Installation of locking nut.1) Shift the transaxle into 1st speed with the control lever and

select lever.2) Engage the 5th speed sleeve to the 5th speed gear.3) Tighten the locking nut to the specified torque.4) Stake the locking nut.

33. Install the spring pin using the special tool (09414-11100) or pinpunch.

NOTEThe slit of spring pin should be aligned with center line ofthe shift rail.

CautionDo not reuse the spring pin.


34. Apply the specified sealant to the rear cover and install the rearcover.

Specified sealant: THREE BOND 1216

35. Install the speedometer driven gear assembly.36. Install the shift control cable support bracket.

37. Install the back up light switch, gasket, restrict ball assembly.38. Install the mounting bracket.

39. Install the select lever assembly.

43-30 5TH SPEED SYNCHRONIZER ASSEMBLY

5TH SPEED SYNCHRONIZER ASSEMBLY

COMPONENTS

Synchronizer key

Synchronizer sleeve

Synchronizer spring

Synchronizer

Stop plateSynchronizer spring

INSPECTION

SYNCHRONIZER SLEEVE AND HUB

1. Install the synchronizer sleeve on the hub and check that theyslide smoothly.

2. Check that the sleeve is free from damage.3. Check for wear of the hub front end (surface in contact with the

5th speed gear).

CautionReplace the synchronizer hub and sleeve as a set.

SYNCHRONIZER KEY AND SPRING

1. Check for wear of the synchronizer key center protrusion.2. Check the spring for weakness, distortion and breakage.

5TH SPEED SYNCHRONIZER ASSEMBLY 43-31

2. The synchronizer sleeve has teeth missing at six places.Assemble the hub to the sleeve so that the center toothbetween the two missing teeth will touch the synchronizer key.

3. Install the synchronizer spring so that the its protrusion may beengaged in the groove of the synchronizer keys.

CautionWhen installing the synchronizer springs, make sure theyare not facing the same direction.

ASSEMBLY

1. Assemble the synchronizer hub, sleeve and key noting theirdirection.

43-32 INPUT SHAFT

INPUT SHAFT

COMPONENTS

Synchronizer ring

INPUT SHAFT 43-33

DISASSEMBLY

1. Press and remove the front taper roller bearing using-thespecial tool (09432-21400).

2. Remove the 5th speed gear sleeve, taper roller bearing, 4thspeed gear assembly, 3rd-4th synchronizer hub, sleeve andring and 3rd speed gear assembly and needle roller bearingusing the special tool (094320-33200).

INSPECTION

INPUT SHAFT

1. Check the outer surface of the input shaft where the needlebearing is mounted for damage or abnormal wear [portion (A)].

2. Check the splines for damage or wear.

NEEDLE BEARING

1. Install the needle bearing on the shaft with the bearing sleeveand gear. Check that it rotates smoothly without abnormalnoise or play.

2. Check the needle bearing cage for distortion.

SYNCHRONIZER RING

1. Check the clutch gear teeth for damage.2. Check the internal surface for damage, wear or broken grooves.

43-34 INPUT SHAFT

3. Push the synchronizer ring toward the clutch gear and checkclearance “A”. Replace if it is not within specification.

Limit: 0.5 mm (0.02 in.)


1. install the synchronizer sleeve on the hub and check that itslides smoothly.

2. Check that the sleeve is free from damage.3. Check for wear of the hub end surfaces (in contact with each

gear).

CAUTIONReplace the synchronizer hub and sleeve as a set.

SYNCHRONIZER KEY AND SPRING1. Check for wear of the synchronizer key center protrusion.2. Check the spring for weakness, distortion or damage.

GEARS

1. Check the bevel gear and clutch gear teeth for damage or wear.2. Check the gear cone for rough surfaces, damage or wear.3. Check the gear bore for damage or wear.

INPUT SHAFT 43-35

ASSEMBLY

1. Install the synchronizer hub and sleeve so that they are posi-tioned as shown in the figure.

2. Engage the synchronizer sleeve and hub.3. Install the synchronizer spring with keys

For installing, refer to the 5th speed synchronizer assemblysection.

4. Install the needle roller bearing and 3rd speed gear on the inputshaft.

5. Install the 3rd-4th gear synchronizer assembly on the inputshaft using the special tool (09432-33300).

6. Install the 4th speed gear sleeve using the special tool (09432-33300).

7. Install the needle roller bearing and 4th speed gear assembly.

CAUTION1. When installing the synchronizer assembly, make

sure that the three synchronizer keys are seated cor-rectly in their respective grooves of the synchronizerring.

2. After installing the synchronizer assembly, check that3rd gear rotates smoothly.

8. Install the taper roller bearing and 5th speed gear sleeve usingthe special tool (09432-33300).

9. Install the front bearing.

43-36 OUTPUT SHAFT

OUTPUT SHAFT

COMPONENTS

Bearing sleeveBearing sleeve

OUTPUT SHAFT 43-37

DlASSEMBLY

1. Remove the taper roller bearing, 4th output gear, spacer, 3rdoutput gear, 2nd speed gear assembly with 2nd gear sleeveand needle roller bearing, 1st and 2nd synchronizer hub andsleeve assembly, 1st speed gear assembly with needle rollerbearing and spacer and steel ball. Using the special tool(09432-33200).

2. Remove the rear taper roller bearing using the special tool(09433-21400).

INSPECTION

OUTPUT SHAFT

1. Check the outer surface of the output shaft where the needlebearing is mounted for damage or abnormal wear [portion (A)].

2. Check the splines for damage or wear.

NEEDLE BEARING

1. Install the needle bearing on the shaft with the bearing sleeveand gear. Check that it rotates smoothly without abnormalnoise or play.

2. Check the needle bearing cage for distortion.

SYNCHRONIZER RING1. Check the clutch gear teeth for damage.2. Check the internal surface for damage, wear or broken grooves.

43-38 OUTPUT SHAFT

3. Push the synchronizer ring toward the clutch gear and checkclearance “A”. Replace if it is not within specifications.

Limit : 0.5 mm (0.02 in.)


1. Install the synchronizer sleeve on the hub and check that itslides smoothly.

2. Check that the sleeve is free from damage.3. Check for wear of the hub end surfaces (in contact with each

gear).

Caution:Replace the synchronizer hub and sleeve as a set.

SYNCHRONIZER KEY AND SPRING

1. Check for wear of the synchronizer key center protrusion.2. Check the spring for weakness, distortion or damage.

GEARS

1. Check the bevel gear and clutch gear teeth for damage or wear.2. Check the gear cone for rough surfaces, damage or wear.3. Check the gear bore for damage or wear.

OUTPUT SHAFT 43-39

ASSEMBLY

1. Install the steel ball and spacer to the output shaft.2. Install the 1st speed gear assembly with needle bearing.

3. Combine the 1st-2nd gear synchronizer hub and sleeve.

4. The synchronizer sleeve has teeth missing at six places.Assemble the hub to the sleeve so that the center toothbetween the two missing teeth will touch the synchronizer key.

5. Install the synchronizer spring so that the its protrustion may beengaged in the groove of the synchronizer keys.

CAUTIONWhen installing the synchronizer springs, make sure theyare not facing the same direction.

6. Install the 1st-2nd speed gear synchronizer assembly over theoutput shaft using the special tool (09432-22000).

CAUTION1) When installing the synchronizer assembly, make

sure that the three synchronizer keys are seated correctly in their respective groove on the synchronizerring.

2) After installation of the synchronizer assembly, checkthat 1st gear rotates smoothly.

43-40 OUTPUT SHAFT

7. Install the 2nd speed gear with needle roller bearing andbearing sleeve using the special tool (09432-22000).

8. Install the 3rd speed gear and spacer.9. Install the 4th speed gear.

10. Install the taper roller bearing using the special tool (09432-22000).

11. Install the rear side taper roller bearing using the special tool(09432-22000).

SHIFT FORK AND CONTROL SHAFT ASSEMBLY 43-41

SHIFT FORK AND CONTROL SHAFT ASSEMBLY

COMPONENTS

43-42 DIFFERENTIAL

DIFFERENTIAL

COMPONENTS

DISASSEMBLY1. Clamp the differential case in a vise.2. Remove the differential drive gear retaining bolts and remove

the differential drive gear from the case.

2. Remove the ball bearings using the special (09433-21000).

CAUTIONDo not reuse the bearing removed from the shaft.

DIFFERENTIAL 43-43

4. Drive out the lock pin from the hole A using a punch.5. Drive out the pinion shaft.6. Remove the pinion gear, washers, side gears and spacers.

ASSEMBLY1. Install the spacer on the back of the side gear and then install

the gear in the differential case.

CAUTION1. When installing a new side gear, use a spacer of

medium thickness [0.93-1.00 mm (0.036-0.04 in)].2. Do not reuse the lock pin.3. The lock pin head must be sunk below the flange

surface of the differential case.

2. Set the washer on the back of each pinion and insert the twopinions to specified position while engaging them with the sidegears by turning them.

3. Insert the pinion shaft.

4. Measure the backlash between the side gears and pinions.

Standard value : 0.025-0.150 mm(0.001-0.006 in.)

5. If the backlash is out of specification, disassemble and installthe correct spacer, reassemble and remeasure.

Caution:Adjust the backlash of both side gears to the samespecification.

6. Align the pinion shaft lock pin hole with the case lock pin holeand insert the lock pin.

Caution1. Do not reuse the lock pin.2. The lock pin head must not protrude more then 3 mm

(0.118 in.).

43-44 DIFFERENTIAL

7. Install the ball bearings on both sides of the differential caseusing the special tool (09455-21100).

CautionWhen press-fitting the bearings, press on the inner raceonly.

8. Tighten to specifications using the sequence shown in theillustration.

1 through 8indicate tightening sequence

SPEEDOMETER DRIVEN GEAR ASSEMBLY 43-45

SPEEDOMETER DRIVEN GEAR ASSEMBLY

COMPONENTS

ASSEMBLY

Speedometer driven gear

1. Apply gear oil sparingly to the speedometer driven gear shaftand insert the shaft.

2. Install the spring pin in such a way that the slit does not facethe gear shaft.

AUTOMATICTRANSAXLEReturn To Main Table of ContentsGENERAL .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TRANSAXLE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

SHIFT LEVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 51

AUTOMATIC TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53AUTOMATIC TRANSAXLE ASSEMBLY . . . . . . . . . . . . . . .57

OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

FRONT CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 89

REAR CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

END CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

PLANETARY GEAR SET ASSEMBLY . . . . . . . . . . . . . . . . 98

INTERNAL GEAR AND TRANSFER DRIVEGEAR SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

TRANSFER DRIVER GEAR ASSEMBLY . . . . . . . . . . . . . . 103

TRANSFER SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 104

DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107KICKDOWN SERVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

SPEEDOMETER SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

45-2 GENERAL

GENERAL

SPECIFICATIONS

Type

Torque converterTypeEngine stall speedStall torque ratio

TransaxleType

Gear ratioFirstSecondThirdFourthReverse

Final gear ratioSpeedometer gear ratio

Automatic four speed with damper spring torque converterand integral differential

With damper clutch2,700 ± 200 rpm1.9

Electronically controlled 4-speedfull-automatic

2.8461.5811.0000.6852.1764.029Drive 36/Driven 31

GENERAL 45-3

TIGHTENING TORQUE

Items Nm kg.cm Ib.ft

Oil pan boltsTie rod end to knuckle starter motor mounting boltLower arm ball joint to knuckleTransaxle mounting bracket to transaxleSpecial boltsSelector lever assembly mounting boltsStarter motor mounting boltOil cooler hose clampHose bracketCover to selector knob Selector knob to lever assemblyBell housing cover to engineTransaxle mounting bolt [10 mm (0.40 in.) diameter bolt]Transaxle mounting bolt [8 mm (0.31 in.) diameter bolt]Torque converter to drive plateControl cable to bodyIndicator panelLever assembly to bracket assemblyDrive plate-to-convener tightening boltDrain plugPressure check plugPulse generator mounting boltBearing retainer screwLock plate boltConverter housing boltOne-way clutch outer race boltDifferential drive gear boltManual control lever nutmanual control shaft set screwInhibitor switchSprag rod support boltPump housing-to-reaction shaft support boltOil pump assembly mounting boltValve body boltValve body assembly mounting boltOil filter boltSpeedometer sleeve locking plate boltEnd clutch coverKickdown lock nut

10-12 100-120 7-927-34 270-340 17-2460-72 600-720 43-5260-80 600-800 43-5846-53 460-530 33-389-14 90-140 7-1027-34 270-340 20-254-6 40-60 3-43-5 30-50 2-42.0 or more 20 or more 1.4 or more2.0 or more 20 or more 1.4 or more8-10 80-100 6-743-53 430-530 31-3830-35 300-350 22-259-14 90-140 7-109-14 90-140 7-101.5 or more 15 or more 1.1 or more14-22 140-220 10-1446-53 460-530 34-3830-35 300-350 22-258-10 80-100 6-710-12 100-120 7-917-22 170-220 12-1548-60 480-600 35-4319-23 190-230 14-1623-35 230-350 17-25130-140 1300-1400 94-10117-21 170-210 13-158-10 80-100 6-710-12 100-120 7-920-27 200-270 15-1910-12 100-120 7-919-23 190-230 13-164-6 40-60 3-410-12 100-120 7-95-7 50-70 4-53-5 30-50 2-46-8 60-80 5-615-22 150-220 11-16

45-4 GENERAL

LUBRICANTS

Items Specified lubricant Quantity

Transaxle fluid lit. (U.S. qts., Imp.qts.) DIAMOND ATF SP, GENUINE HYUNDAI ATF 6.0 (6.4, 5.4)AUTOMATIC TRANSMISSION FLUID, OR*MOPAR ATF PLUS TYPE 7176,

Drive shaft oil seal lip Automatic transaxle fluidDEXRON D-II type

As required

Sliding part of bushing Chassis grease SAE J310, NLGI No.0 As required

Selector lever sliding portion Multipurpose grease SAE J310, NLGI No.2 As required

* : Mopar ATF PLUS TYPE 7176 is recommended lubricant.

GENERAL 45-5

SPECIAL TOOLS

GENERAL

SPECIAL TOOLS

GENERAL 45-7

SPECIAL TOOLS

45-8 GENERAL

SPECIAL TOOLS

Tool(Number and name) Illustration Use

09457-22100Transfer bearing outer raceinstaller

Installation of the transfer bearing outer race

GENERAL 45-9

TROUBLESHOOTING Based upon the use of the troubleshooting

Malfunctions of the auto transaxle can lead to other problems, suchas those described below:1. Improper maintenance and/or adjustments2. Electronic control malfunctions3. Mechanical functions4. Hydraulic control5. Engine performance malfunctions

etc.In order to properly troubleshoot the source of these malfunctions,it is first essential to methodically question the owner concerningthe problem. The driver should also be asked whether or not theproblem has occurred more than once.Tests should be conducted troubleshooting, as described at theright.

guide, the probable location of the problemshould be determined.

Checks should be made of fluid levels andthe condition of the ATF, as well as thecondition of the manual control cables;adjustments should then be made if foundto be necessary.

If a presumption has been made that thereis an abnormal condition somewhere in theelectronic-control system, the diagnosistester should be used to estimate the prob-able location by checking the malfunction-indication pattern. If the ignition key wasalready turned to OFF, however, check bymaking a road test.

When the abnormal system is discoveredduring the road test, check each element(sensors, etc.) one by one, and make re-pairs as necessary.

When the abnormal condition is presumedto be in the oil-pressure-control system,check by making oil-pressure test.

When the result of the oil-pressure testdoes not satisfy the specified pressure,check each system at places related to thevalve body, check the oil-pressure pas-sages for leakage, etc.

If the problem is unusually dirty ATF, ab-normal noises, oil leakage, or slippage ofthe clutch or brakes, or an abnormal condi-tion of the transaxle itself, disassemble andrepair the transaxle.

45-10 GENERAL

TROUBLESHOOTING GUIDE

NOTE: X indicates items of high priority during inspection.Abbreviations: TPS = Throttle Position Sensor SCSV = Shift Control Solenoid Valve

GENERAL

PCSV = Pressure control solenoid valveDCCSV = Damper clutch control solenoid valve

GENERAL

DIAGNOSIS AND TESTFLUID LEVEL AND CONDITION

1.2.

3.

4.

5.

6.

Place the vehicle on a level floor.Before removing the dipstick, wipe all dirt from the area aroundthe dipstick.With the selector lever in “P” (Park), and the parking brakesapplied, start the engine.The engine should be running at idle speed. Fluid should be atnormal operating temperature [70-80ºC (160-180ºF)].Move the selector lever sequentially to every position to fill thetorque converter and hydraulic system with fluid, then place theselector lever in “N” (Neutral) position. This operation is neces-sary to be sure that the fluid level check is accurate.Check to see if the fluid level is in “HOT” range on dipstick. Iffluid is low, add automatic transmission fluid until level reachesthe “HOT” range.Low fluid level can cause a variety of conditions because itallows the pump to take in air along with fluid. Air trapped in thehydraulic system forms bubbles, which are compressable.Therefore, the pressure will be erratic.Improper filling can also cause the fluid level to be too high.When transaxle has too much fluid, gears churn up foam andcause the same conditions which occur with low fluid level. Thisresults in accelerated deterioration of the automatic transaxlefluid. In either case, air bubbles can cause overheating, fluidoxidation, and varnishing, which can interfere with normalvalve, clutch, and servo operation. Foaming can also result influid escaping from the transaxle vent, where it may be mis-taken for a leak.Along with fluid level, it is important to check the condition of thefluid. When fluid smells burned, and is contaminated with metalparticles or friction material particles, a complete transaxleoverhaul is needed. Be sure to examine fluid on the dipstickclosely. If there is any doubt about its conditions, drain out asample for a closer check. After fluid has been checked, seatthe dipstick fully to seal out water and dirt.

GENERAL 45-13

MANUAL CONTROL CABLE

Proper manual control linkage adjustment can be determined bychecking whether inhibitor switch is performing well.1.2.3.4.

5.

6.

7.

Apply parking and service brakes securely.Place the selector lever in “R” range.Set the ignition key to “ST” position.Slowly move the selector lever upward until it clicks as it fits inthe notch of the “P” range. If the starter motor operates whenthe lever makes a click, “P” position is. correct.Then slowly move the selector lever to the “N” range by thesame procedure as in the foregoing paragraph. If starter motoroperates when the selector lever fits in “N”, the “N” position iscorrect.Also check to be sure that the vehicle doesn’t begin to moveand the lever doesn’t stop between P-R-N-D.The manual-control cable is properly adjusted if, as describedabove, the starter motor starts at both the “P” range and the “N”range.

45-14 GENERAL

OBTAINING FAULT CODES

1. Connect the voltmeter or multi-use tester to the connector fordiagnosis.

2. Read the output fault codes.Then follow the remedy procedures according to the “FAULTCODE DESCRIPTION” on the following page.

NOTE:o As many as a maximum of ten fault codes, in the

sequence of occurrence, can be stored in the RandomAccess Memory (RAM) incorporated within the controlunit.

o The same fault code can be stored as many as threetimes.

o If the number of stored fault codes or fault patternsexceeds ten, already stored fault codes will be erased,in sequence beginning with the oldest.

o Do not disconnect the battery until all fault codes orfault patterns have been read out. All stored faultcodes or fault patterns will be canceled when thebattery is disconnected.

3. If the fail-safe system is activated and the transaxle is lockedin 3rd gear, the fault code in the Fail-Safe Code Description willbe stored in the RAM.Three of these fault codes can be stored.

4. The cancellation will occur if, with the transaxle locked in 3rdgear, the ignition key is turned to the OFF position, but the faultcode is stored in the RAM.

(Multi-use tester)

GENERAL 45-15

FAULT CODE DESCRIPTION

Faultcode Fault code (for voltmeter) Cause Remedy

21 Abnormal increase of TPS output o Check the throttle position sensorconnector.

o Check the throttle position sensoritself.

o Adjust the throttle position sensor.22 Abnormal decrease of TPS output o Check the accelerator switch (No.28:

output or not).o Check the throttle position sensor

output circuit harness.

23 Incorrect adjustment of the throttle-position sensor system

24 Damaged or disconnected wiring of the o Check the oil temperature sensoroil temperature sensor system circuit harness.

o Check the oil temperature sensorconnector.

o Check the oil temperature sensoritself.

25

26

Damaged or disconnected wiring of o Check the kickdown servo switchthe kickdown servo switch system, or output circuit harness.improper contact o Check the kickdown servo switch

connector.Short circuit of the kickdown servo o Check the kickdown servo switch

switch system itself.

27 Damaged or disconnected wiring of o Check the ignition pulse signalthe ignition pulse pick-up cable system line.

28 Short circuit of the accelerator switch o Check the accelerator switchsystem or improper adjustment output circuit harness.

o Check the accelerator switchconnector.

o Check the accelerator switchitself.

o Adjust the accelerator switch.

31 Malfunction of the microprocessor o Replace the control unit.

45-16 GENERAL

Faultcode Fault code (for voltmeter) Cause Remedy

32 First gear command during high- o Replace the control unitspeed driving

33

41

42

Damaged or disconnected wiring of the o Check the pulse generator B outputpulse generator B system circuit harness.

o Check pulse generator B itself.o Check the vehicle speed reed switch

(for chattering).

Damaged or disconnected wiring of the o Check the solenoid valve connector.shift control solenoid valve A system o Check shift control solenoid valve A

itself.o Check the shift control solenoid valve

A drive circuit harnessShort circuit of the shift-control sole-noid valve A system

4 3 Damaged or disconnected wiring of o Check the solenoid valve connector.the shift control solenoid valve B o Check shift control solenoid valve Bsystem itself.

o Check the shift control solenoid valve

Short circuit of the shift control sole- B drive circuit harness.

noid valve B system44

45

46

Damaged or disconnected wiring of o Check the solenoid valve connector.the pressure control solenoid valve o Check the pressure control solenoids y s t e m valve itself.

o Check the pressure control solenoid

Short circuit of the pressure controlvalve drive circuit harness.

solenoid valve system

47 Damaged or disconnected wiring of o Check the solenoid valve connector.the damper clutchvalve system

control solenoid o Check the damper clutch controlsolenoid valve itself.

o Check the damper clutch controlsolenoid valve drive circuit harness.

48 Short circuit or the damper clutchcontrol solenoid valve system

GENERAL 45-17

Faultcode

4 9

51

52 Second gear non-synchronous

53

54 Fourth gear non-synchronous

Fault code (for voltmeter Cause

Malfunction of the damper clutchsystem

First gear non-synchronous

Third gear non-synchronous

Remedy

o Check the damper clutch controlsolenoid valve drive circuit harness.

o Check the damper clutch hydraulicpressure system

o Check the damper clutch controlsolenoid valve itself

o Replace the control unit.

o Check the pulse generator outputcircuit harness.

o Check the pulse generator connec-tor.

o Check pulse generator A and pulsegenerator B themselves.

o Kickdown brake slippage.

o Check the pulse generator A outputcircuit harness.

o Check the pulse generator A connec-tor.

o Check pulse generator A itself.o Kickdown brake slippage.


o Check the pulse generator connec-tor.

o Check pulse generator A and pulsegenerator B themselves.

o Front clutch slippage.o Rear clutch slippage.


o Check the pulse generator A con-nector.

o Check pulse generator A itself.o Kickdown brake slippage.

45-18 GENERAL

FAIL-SAFE ITEM

CodeNo.

11

12

Output code

Output pattern (for voltmeter)

NoteDescription Fail-safe (relation to

fault code)

Malfunction of the 3rd gear hold When code No. 31 ismicroprocessor generated a 4th time.

First gear command 3rd gear (D) or 2nd When code No. 32 isduring high speed gear (2, L) hold generated a 4th time.driving

13 Damaged or discon- 3rd gear (D) or 2nd When code No. 33 isnected wiring of the gear (2, L) hold generated a 4th timepulse generator Bsystem

14 Damaged or discon- 3rd gear hold When code No. 41 ornected wiring, or 42 is generated a 4thshort circuit, of shift time.control solenoid valveA

15 Damaged or discon- 3rd gear hold When code No. 43 ornected wiring, or 44 is generated a 4thshort circuit, of shift time.control solenoid valveB

16 Damaged or discon- 3rd gear (D) or 2nd When code No. 45 ornected wiring, or gear (2, L) hold 46 is generated a 4thshort circuit, of the time.pressure control sole-noid valve

17 Shift steps non-synchronous

3rd gear (D) or 2nd When code No. 51,gear (2, L) hold 52, 53 or 54 is

generated a 4th time.

GENERAL 45-19

CHECKING THE CONTROL SYSTEM (WHEN A MULTI-USE TESTER IS USED)

No. Description and display data Check conditions Standard value forjudgement

1 Pulse generator A D range (3rd) 50 km/h (31 mph) constant Upper: 1,700 ± 200 rpmo Upper No.19 speed driving Lower: 3rd

Kickdown drum rpmo Lower No.38 D range (4th) 50 km/h (31 mph) constant Upper: 0 rpm

Shift step speed driving Lower: 4th

2 Pulse generator B D range (creep), stop idle Upper: 0 rpmo Upper No.13

Transaxle output shaft rpmLower: 0 km/h (0 mph)

o Lower No.33 D range (4th) 50 km/h (31 mph) constant Upper: 1,800 ± 200 rpmVehicle speed reed switch speed driving Lower: 50 km/h (31 mph)

3 Vehicle speed reed switch P range, idle Upper: 0 km/h (0 mph)o Upper No.33

Vehicle speed reed switcho Lower, no designation D range, speedometer reading 50 km/h (31 Upper: 50 km/h (31 mph)

mph) driving

4 Throttle position sensor Accelerator fully open (engine stopped, Upper: 4.5-5.0Vo Upper No.21 ignition switch : ON) Lower: OFF

TPS outputo Lower No.28 Accelerator fully closed (engine stopped, Upper: 0.25-0.3V

Accelerator switch ignition switch : ON) Lower: ON

5 Kickdown servo switch L range, idle Upper: ONo Upper No.25

Kickdown servo switchLower: 1st

o Lower No.38 D range, idle Upper: OFFShift step Lower: C (creep)

6 Oil temperature sensor Start when transaxle cold, urban driving. Upper: temperature riseso Upper No.24

Oil temperature sensorAfter driving, stop engine and leave as it is. Upper: temperature

o Lower, no designationeventually decreases.

7 Accelerator switch Depress accelerator pedal slowly. Upper: change from ON too Upper No.28 OFF at a throttle-position

Accelerator switch sensor output of about 0.3V.o Lower No.21

TPS output

Release accelerator pedal slowly. Upper: change from OFF toON at a throttle-positionsensor output of about 0.3V.

45-20 GENERAL

No. Description and display data Check conditions Standard value forjudgement

8 Overdrive control switch Overdrive control switch ON Upper: OD-ON

o Upper No.35Overdrive control switch

o Lower, no designation Overdrive control switch OFF Upper. OD-OFF

9 Ignition signal line D range, idle Upper: 750 ± 100 rpmo Upper No.27

Ignition pulseo Lower, no designation D range, tachometer reading 2,500 rpm Upper: 2,500 rpm

10 Inhibitor switch Move shift lever in P-R-N-D-2-L sequence. Upper: changes in P-R-N-D-o Upper No.34 2-L sequence in accordance

Shift lever position with the lever position.o Lower, no designation

11 Power Economy select switch Select power pattern. Upper: ONo Upper No.36

Power Economy selectswitch Select economy pattern. Upper: OFF

o Lower, no designation

12 Air conditioner relay Switch ON the air conditioner switch Upper: ONo Upper No.37 (while idling in D range).

Air conditioner relayo Lower, no designation Switch OFF the air conditioner switch Upper: OFF

(while idling in D range).

13 Amount of damper clutch D range tachometer reading 1,500 rpm Upper: 250 ± 50 rpm

slippage TPS output approx. 0.7V Lower: 0.7Vo Upper No.47

Amount of damper clutch D range tachometer reading 2,500 rpm Upper: 0 rpm

slippage TPS output approx. 1.0V Lower: 1Vo Lower No.21

TPS output

14 Transaxle gear position D range, idle Upper: C (creep)o Upper No.38 Lower: 0.25-0.3V

Shift stepo Lower No.21 Economy pattern D range (overdrive pos- Upper: 1st-2nd-3rd-4th

TPS output sible condition) Lower: 2.5VAccelerate to 100 km/h (62 mph) with fixedthrottle position sensor output of 2.5V

GENERAL 45-21

Check conditions Standard value forjudgementNo. Description and display data

D range tachometer reading 1,500 rpmThrottle-position sensor output approx. 1.0V

15 DCCSV controlo Upper No.49DCCSV control dutyo Lower No.21TPS output

Upper: 0%

Lower: 1.0V

D range tachometer reading 2,500 rpmThrottle position sensor output approx. 1.0V

Upper: 0-60% changeaccording to load

Lower: 1.0V

ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER

45-22 GENERAL

SHIFT PATTERNS

Two shift patterns are pre-stored in the control unit of this transaxle.One is the Normal pattern (for more powerful performance), and theother is the Economy pattern (for improved fuel consumption andquieter operation).The driver can select and switch to the desired pattern by using thenormal/economy select switch on the center console.The solid lines shown in these shift patterns indicate up-shifts, andthe broken lines indicate down-shifts. The reason why there is adifference between the shift points for up-shifts and for down-shiftsis so that up-shifts and down-shifts will not occur intermittentlywhen driving at a speed close to that of the shift point.When the vehicle is stopped, there is a shift to 2nd gear in order toobtain a suitable “creeping”. Then when the accelerator pedal isdepressed, the vehicle starts off in 1st gear.

GENERAL 45-23

Normal range

VEHICLE SPEED V km/h (FINAL GEAR RATIO 4.029 TIRE RADIUS 0.279 m)

Economy range

VEHICLE SPEED V km/h (FINAL GEAR RATIO 4.029 TIRE RADIUS 0.279 m)

45-24 GENERAL

INSPECTION OF ELECTRONIC CONTROL SYSTEM COMPONENTS

GENERAL 45-25

GENERAL

GENERAL 45-31

OIL PRESSURE TESTS

1. Completely warm up the transaxle.2. Raise the front of the vehicle so that the front wheels can be

rotated.3. Connect an engine tachometer and place it in a position where

it’s easy to see.4. Attach the special oil-pressure gauge (09452-21500) and the

adapter (09452-21002) to each oil-pressure outlet port.When the reverse pressure is to be tested, the 3,000 kPa (400psi) type of gauge should be used.

5. Measure the oil pressure under various conditions. Check to besure that the measured results are within the standard valuerange shown in the “Standard oil pressure table” below.If the oil pressure is not within the specified range, check andrepair as described in the section “Preliminary Steps If OilPressure Is Not Normal” on the next page.

Standard Oil Pressure Table

NOTE:- must be 9.8 kPa (1.4 psi) or less.SW-ON : Switch ON the overdrive control switch.SW-OFF : Switch OFF the overdrive control switch.* : Hydraulic pressure is generated, but not the standard value.

45-32 GENERAL

Preliminary Steps If Oil Pressure Is Not Normal


1. ‘Line pressures are all a. Restriction on oil filter a. Visually inspect the oil filter; replace thelow (or high). oil filter if it is restricted.NOTE b. Improper adjustment of oil pressure b. Measure line pressure 2 (kickdown brake*“Line pressures” (line pressure) regulator valve pressure); if the pressure is not the stan-refers to oil pressures 2, dard value, readjust the line pressure, or3, 4 and 5 in the “Stan if necessary, replace the valve body as-dard oil pressure table” sembly.on the previous page. c. Sticking of regulator valve c. Check the operation of the regulator valve;

repair if necessary, or replace the valvebody assembly.

d. Looseness of valve body tightening part d . Tighten the valve body tightening boltand installation bolt.

e. lmproper oil pump discharge pressure e. Check the side clearance of the oil pumpgear; replace the oil pump assembly ifnecessary.

2. Improper reducingpressure

a. Improper line pressure a. Check the 2 kickdown brake pressure(line pressure); if the line pressure is notthe standard value, check as describedin item 1 above.

b. Clogging of the filter (L-shaped type) b. Disassemble the valve body assemblyof the reducing-pressure circuit and check the filter; replace the filter if it

is restricted.c. Improper adjustment of the reducing c . Measure the 1 reducing pressure; if it is

pressure not the standard value, readjust, or replace the valve body assembly.

d. Sticking of the reducing valve d. Check the operation of the reducingvalve; if necessary, repair it, or replacethe valve body assembly.

e. Looseness of valve body tightening e. Tighten the valve body tightening boltpart. and installation bolt.

3. Improper kickdownbrake pressure

a. Malfunction of the D-ring or seal ring a. Disassemble the kickdown servo andof the sleeve or kickdown servo piston. check whether the seal ring or D-ring is

damaged.If it is cut or has scratches, replace theseal ring or D-ring.

b. Looseness of valve body tightening b. Tighten the valve body tightening boltpart. and installation bolt.

c. Functional malfunction of the valve c. Replace the valve body assembly.body assembly.

GENERAL 45-33

Trouble symptom

4. Improper front clutchpressure

5. Improper end clutchpressure

6. Improper low-reverse brakepressure

7. Improper torqueconverter pressure


a. Malfunction of the D-ring or seal ring of thesleeve or kickdown servo piston.

b. Looseness of valve body tightening partc. Malfunction of the valve body assembly.d. Wear of the front clutch piston or retainer,

or malfunction of the D-ring.(Refer to the figure on the next page.)

a. Malfunction of a D-ring, seal ring of the endclutch or O-ring of the pipe (Refer to thefollowing figure.)

b. Looseness of valve body tightening part.c. Malfunction of the valve body assembly

a. O-ring between valve body and transaxledamaged or missing

b. Looseness of valve body tightening partc. Malfunction of the valve body assemblyd. Malfunction of the O-ring of the low-

reverse brake piston or the O-ring of theretainer (Refer to the following figure.)

a. Sticking of the damper clutch control sole-noid valve (DCCSV) or the damper clutchcontrol valve.

b. Clogging or leaking of the oil cooler and/orlines.

5. Damaged seal ring of the input shaft (Refer tothe following the figure)

3. Malfunction of the torque converter

a. Disassemble the kickdown servo andcheck whether the seal ring or D-ring isdamaged.If it is cut or has scratches, replace theseal ring or D-ring.

b. Tighten the valve body tightening boltand installation bolt.

c. Replace the valve body assembly.d. Disassemble the transaxle itself and

check whether or not there is wear ofthe front clutch piston and retainerinner circumference, or damage of theD-ring. If there is any wear or damagereplace the piston, retainer, D-ring andor seal ring.

a. Disassemble the end clutch and checkthe seal ring, D-ring of the piston, sealring of the retainer, etc.; replace ifthere are cuts, scars, scratches ordamage.

b . Tighten the valve body tightening boltand installation bolt.

c. Replace the valve body assembly.

a. Remove the valve body assembly andcheck to be sure that the O-ring at theupper surface of the upper valve bodyis not missing or damaged; install orreplace the O-ring if necessary.

b. Tighten the valve body tightening boltand installation bolt.

c Replace the valve body assembly.d. Disassemble the transaxle itself and

check the O-ring for damage; replaceif there are cuts, scars, scratches ordamage.

a. Check the operation of the damperclutch system and the DCCSV.

b. Repair or replace, as necessary, thecooler and/or lines.

c. Disassemble the transaxle itself andcheck for damage of the seal ring;replace the seal ring if there is dam-age.

d. Replace the torque converter.

45-34 GENERAL

Oil seal

Seal ring

GENERAL 45-35

CONVERTER STALL TEST

Stall test consist of determining maximum engine speed obtainedat full throttle in “D” and “R” positions. This test checks torqueconverter stator overrunning clutch operation, and holding ability oftransaxle clutches and low-reverse brake.

Warning:During this test, make sure that no one stand in front of orbehind vehicle.

1.

2.3.4.5.6.

7.

Check transaxle fluid level. Fluid should be at normal operatingtemperature [70-80°C (160-180°F)]. Engine coolant shouldalso be at normal operating temperature [80-95°C (176-205°F]).Apply chocks to both rear wheels.Attach an engine tachometer.Apply the parking and service brakes fully.Start the engine.With the selector lever in the “D” position, depress the accelerator pedal fully to read maximum engine rpm. Do not hold thethrottle wide open any longer than is necessary to obtainmaximum engine rpm reading, and never longer than 5 sec-onds at a time. If more than one stall test is required, operatethe engine at approximately 1,000 rpm in neutral for 2 minutesto cool the transaxle fluid between tests.

Stall speed : 2,500-2,900 rpm

Place the selector lever in the “R” position and perform the stalltest by the same procedure as previously described.

Stall Speed Above Specification in “D”If stall speed is higher than specification, rear clutch or overrunningclutch of transaxle is slipping. In this case, perform hydraulic testto locate cause of slippage.

Stall Speed Above Specification in “R”If the stall speed is higher than specification, the front clutch of thetransaxle or low-reverse brake is slipping. In this case, perform thehydraulic test to locate the cause of slippage.

Stall Speed Below Specification in “D” and “R”If the stall speed is lower than specification, insufficient engineoutput or a faulty torque converter is suspected. Check for enginemisfiring, improper ignition timing, or valve clearance etc. If theseare good, the torque converter is faulty.

45-36 GENERAL

E.L.C. 4-SPEED AUTOMATIC TRANSAXLE CONTROL COMPONENTS

D

Name Symbol Name Symbol

4 A/T control unit

M.P.I. control unit

G Pulse generator A, B AH Accelerator switch I

M.P.I. throttle position sensor B Self-diagnosis check connector EOil temperature sensor C Vehicle-speed sensor DNormal (NORM)/Economy (ECO) switch F

GENERAL 45-37

45-38 GENERAL


TRANSAXLE FLUID LEVEL INSPECTION

1. Drive the vehicle until the fluid temperature reaches normaloperating the usual temperature ]70-80ñC (160-180ñF)[.

2. Place the vehicle on a level floor.3. Move the selector lever sequentially to every position. This will

fill the torque converter and hydraulic system with fluid, thenplace lever in “N” (Neutral) position.

4. Before removing the dipstick, wipe all contaminate from areaaround the dipstick. Then take out the dipstick and check thecondition of the fluid.The transaxle should be overhauled under the following condi-tions.o If there is a “burning” odor.o If the fluid color has become noticeably blacker.o If there is a noticeably excessive amount of metal panicles

in the fluid.5. Check to see if the fluid level is in the “HOT” range on dipstick.

If fluid level is low, add automatic transaxle fluid until the levelreaches the “HOT” range.

Transaxle fluid :GENUINE HYUNDAI ATF AUTOMATIC TRANSMISSIONFLUID, MOPAR ATF PLUS TYPE 7176, OR DIAMOND ATFSP.

Low fluid level can cause a variety of abnormal conditionsbecause it allows the pump to take in air along with fluid. Airtrapped in the hydraulic system forms bubbles which arecompressable. Therefore, pressures will be erratic, causingdelayed shifting, sliping clutch and brakes, etc.Improper filling can also raise fluid level too high. When thetransaxle has too much fluid, gears churn up foam and causethe same conditions which occur with low fluid level, resultingin accelerated deterioration of automatic transaxle fluid.In either case, air bubbles can cause overheating, and fluidoxidation, which can interfere with normal valve, clutch, andservo operation. Foaming can also result in fluid escaping fromthe transaxle vent where it may be mistaken for a leak.

6. Be sure to examine the fluid on the dipstick closely.

TRANSAXLE FLUID REPLACEMENT

Refer to GROUP 10-Lubrication and Maintenance.

GENERAL 45-39

SELECTOR LEVER OPERATION CHECK

1. Shift the selector lever to each range and check to see that thelever moves smoothly and is controlled. Check to see that theposition indicator is correct.

2. Check to be sure that the selector lever can be shifted to eachposition (by button operation as shown in the illustration).

3. Start the engine and check to see if the vehicle moves forwardwhen the selector lever is shifted from “N” to “D”, and movesbackward when shifted to “R”.

4. When the shift lever malfunctions, adjust the control cable andthe selector lever sleeve. Check for worn shift lever assemblysliding parts.

INHIBITOR SWITCH ADJUSTMENT

INHIBITOR SWITCH

1. Place selector lever in “N” (Neutral) position.2. Loosen the manual control lever flange nut to free up the cable

and lever.

3. Place the manual control lever in the “N” (Neutral) position.4. Turn the inhibitor switch body until the 12 mm (.47 in.) wide end

of the manual control lever aligns with the switch body flange[12 mm (0.472 in.) wide portion].

5. Tighten the attaching bolts (2 pcs.) to the specified torque.Inhibitor Switch Attaching Bolt:10-12 Nm (100-120 kg.cm, 7-9 Ib.ft)

NOTEWhen setting up the switch body, be careful O-ring not todrop from the switch body.Tighten the attaching bolts carefully.

45-40 GENERAL

6. Make sure that the selector lever is in the “N” (Neutral) position7. Adjust the flange nut so that there is no slack in the control cable

and make sure that the selector lever operates smoothly.8. Run the vehicle and confirm that the transaxle is set in each

range when the selector lever is shifted to each position.

KICKDOWN SERVO ADJUSTMENT

1. Completely remove all dirt and other contaminating materialsadhered around the kickdown adjust screw.

2. Loosen the lock nut.

3. Loosen and tighten the adjust screw two times by torque of 5Nm (3.6 Ib.ft)

4. Again loosen the adjust screw 3 to 3-1/3 turns.

5. Tighten the lock nut to the specified torque.

Lock nut: 15-25 Nm (15-25 Nm (150-250 kg.cm, 11-18 Ib.ft)

NOTEBefore assembly, apply sealant (DC780) to center portionof the adjust screw.

LINE PRESSURE ADJUSTMENT

1. Drain out the automatic transaxle fluid.2. Remove the oil pan.3. Remove the oil filter.4. Remove the oil-temperature sensor.

GENERAL 45-41

5. Press the tab of the solenoid valve harness grommet and pushin.

6. Remove the valve body assembly. The manual valve cancome out, so be careful not to drop it.

7. Turn the adjustment screw of the regulator valve and adjust sothat the line pressure (kickdown brake pressure) reaches thestandard value.When the adjustment screw is turned clockwise, the linepressure becomes lower; when it is turned counter-clockwise,it becomes higher.

Standard value :860-900 kPa (122-129 psi, 8.77-9.18 kg/cm)Oil pressure change for each turn of adjustment screw : 38kPa (5.4 psi, 0.39 kg/cm)

8. Check to be sure that the O-ring is installed on the uppersurface of the valve body at the place shown in the figure.

9. Replace the O-ring of the solenoid valve connector with a newone.

10. Install the valve body assembly to the case and then insert thesolenoid valve connector into the case. Be sure, at this time,that the notched part of the connector faces as shown in thefigure.Also be careful that the lead wiring isn’t caught.

GENERAL

11. Tighten the ten(10) valve body assembly mounting bolts to 10-12 Nm (100-120 kg.cm, 7-9 Ib.ft).

A: 25 mm (0.709 in.) longB: 35 mm (0.984 in.) longC: 40 mm (1.575 in.) long

12. Install the oil filter.13. Install a new oil pan gasket with the oil pan.14. Pour in the specified amount of Automatic transaxle fluid.15. Make the oil pressure test. Readjust if necessary.

REDUCING PRESSURE ADJUSTMENT(If the Multi-Use Tester is not available)

1. Remove parts up to the oil filter in the same way as foradjustment of the line pressure. The valve body need not beremoved.

2. Turn the adjustment screw of the lower valve body and adjustso that the reducing pressure is the standard value.When the adjustment screw is turned to the right, the reducingpressure becomes lower; when it is turned to the left, itbecomes higher.

NOTE:When adjusting the reducing pressure, aim for the centervalue (425 kPa, 60 psi) of the standard value allowance.

Standard value :420±20 kPa (60±1 psi, 4.3±1 kg/cm)Oil pressure change for each turn of the adjustmentscrew: 22 kPa (4.3 psi, 0.3 kg.cm)

3. Install the oil filter and oil pan in the same way as for adjustmentof the line pressure.

4. Make the oil pressure test. Readjust if necessary.

(If the Multi-Use Tester is used)1. Adjust the PC solenoid so that the kickdown brake pressure is

the standard value when activated to 50% duty by the Multi-UseTester.

Standard value :320-130 kPa (39±1 psi, 2.8±1 kg/.cm)Oil pressure change for each turn of the adjustmentscrew: 30 kPa (3 psi, 0.2 kg/cm)

2. Check to be sure that the reducing pressure (after the adjust-ment is completed) is within the range of 370-490 kPa (53-70psi, 3.8-5.0 kg/cm)

GENERAL 45-43

Caution:This adjustment should be made at an oil temperature of70-80°C (160-180°F).If the adjustment is made at a temperature that is too high,the line pressure will drop during idling, with the result.that it might not be possible to make the correct adjust-ment.

THROTTLE-POSITION SENSOR ADJUSTMENT

Refer to FUEL SYSTEM-Service Adjustment Procedures.

DRIVE SHAFT OIL SEALS REPLACEMENT

1. Disconnect the drive shaft from the transaxle. (Refer toFRONT SUSPENSION-Drive Shaft)

2. Using a flat-tip (-) screwdriver, remove the oil seal.

3. Using the special tool (09431-21200), tap the drive shaft oil sealinto the transaxle.

4. Apply a coating of the transaxle fluid to the lip of the oil seal.

45-44 GENERAL

SPEEDOMETER CABLE REPLACEMENT

1. Correctly insert the adapter into the instrument panel, andfasten the new speedometer cable.

2. Install the grommet so that, as shown in the illustration, thecable attachment part and the projection part are horizontal.

Caution:The cable arrangement should be made so that the radiusof the cable bends is 150 mm (5.9 in.) or more.

3. At the transaxle end of the speedometer cable, the key jointshould be inserted into the transaxle, and the nut should besecurely tightened.

Caution:If the cable is not correctly and securely connected, it maycause an incorrect reading on the speedometer, or abnor-mal noise. Be sure to connect it correctly.

ACCELERATOR SWITCH CHECK ANDADJUSTMENT

1. After warming up the engine, make sure that the acceleratorswitch is on with the accelerator pedal in the free state.

NOTECheck to see that the accelerator switch is on or off bychecking the voltage between the G wire and the groundwire at the accelerator switch connector (2-pin)

When the accelerator switch is ON : 0VWhen the accelerator switch is OFF : 12V

2. Measure stroke B, as shown in the illustration, at the point whenthe accelerator switch goes from ON to OFF when the pedal isdepressed.

Standard value: 4-8 mm (0.16-0.31 in.)

3. If the figured stroke B deviates from the standard value, adjustit by the adjusting bolt.

GENERAL

45-46 TRANSAXLE CONTROL

T R A N S A X L E C O N T R O L

COMPONENTS


TRANSAXLE CONTROL

REMOVAL

1. Remove the console box assembly. (Refer to Body Group).2. Remove the knob installation screws.3. Disconnect the overdrive switch connector and then remove

the knob.

4. Disconnect the position indicator light connector.5. Remove the shift lever indicator assembly.

6. Remove self lock pin from the link.

7. Remove the clip, nut from the shift lever side.

8. Remove the bolt-washer assembly located on dash panel.

TRANSAXLE CONTROL

9. Remove the clip, flange nut from the transaxle side.10. Remove the transaxle control cable assembly.

INSPECTION

1. Check the control cable for function and for damage.2. Check the bushing for wear or damage.3. Check the spring for damage or deterioration.4. Check the overdrive switch for continuity.

NOTE

*Color code Color of wire *Color code Color of wire

R Red B Black

W White L Blue

5. Check the E/N switch for continuity.

Terminal1 2 3 4 5

Position

ECO

NORMAL

TRANSAXLE CONTROL 45-49

INSTALLATION

1. Apply a coating of the specified grease to the interior of thebushing.

Specified grease : Chassis grease SAE J310, NLGI No.0

2. Move the shift lever and the inhibitor switch to the “N” position,and install the control cable.

3. When connecting the control cable to the transaxle mountingbracket, install the clip until it contacts the control cable, inposition switch in the figure.

4. Install the bolt-washer assembly, nut.

5. Install the clip pin, self lock pin.(shift lever side).

45-50 TRANSAXLE CONTROL

6. Connect the position indicator light connector, the O/D switchconnector, the parking position switch connector, and the shiftlock solenoid connector.

7. Install the shift lever indicator assembly.

8. Apply the specified grease at the place shown in the figure.

Specified grease : Multipurpose grease SAE J310,NLGI No.2

9. Place the shift lever in the “N” position, and then turn the camadjusting so that the clearance between the cam adjusting andthe lever assembly end in within the standard value.

Standard value (A) : 15.2-15.9 mm (0.598-0.625 in.)

NOTEBe sure to face B of the adjusting cam to the push button(driver’s side).

10. Install the selector knob.11. Install the console box. (Refer to BODY GROUP).

ADJUSTMENT OF CONTROL CABLE

1. Eliminate slack from the control cable with the adjusting flangenut and check that the select lever operates smoothly.

2. Driving the car, check that the transaxle is set in the properrange when the select lever is shifted to each position.

SHIFT LEVER ASSEMBLY 45-51


COMPONENTS


INSPECTION

o Check the detent place for wear.o Check the bushing for wear or damage.o Check the spring for damage or deterioration.o Check the pin at the end of rod assembly for wear.

ASSEMBLY

1. Apply a coating of grease to the sliding part of the bushing.

Specified grease : Chassis grease SAE J310, NLGI No.0


2. Apply the specified grease at the places shown in the figure.

Specified grease : Multipurpose grease SAE J310,NLGI No.2

AUTOMATIC TRANSAXLE 45-53

AUTOMATIC TRANSAXLE

COMPONENTS

45-54 AUTOMATIC TRANSAXLE


1. Remove the drain plug and drain out the transaxle fluid.2. Disconnect and remove the air cleaner assembly.

3. Loosen the mounting clamps and disconnect the return andsupply hose.

NOTETo prevent to entry of dust and foreign matter, plug thedisconnected hoses and the transaxle fitting part.

4. Remove the control cable.5. Remove the speedometer cable.

6. Separate the pulse generator connector, inhibitor switch con-nector, kickdown servo switch connector, solenoid valve con-nector, and the oil temperator switch connector.

7. Remove the transaxle-to-engine bolt from the upper portion ofthe transaxle.

AUTOMATIC TRANSAXLE 45-55

8. Remove the transaxle mounting bracket

9. While supporting the lower pan of the transaxle by using a jack,remove the center member mounting bolts.

CAUTION:Support a wide area of the transaxle so that an excessiveamount of pressure is not applied to the oil pan.

10. Remove the bell housing cover.11. Remove the six special bolts connecting the converter to the

drive plate.

NOTETo remove the special bolts of torque converter, turnengine crankshaft with a box wrench to bring one of thebolts to the position appropriate for removal. After remov-ing the bolt, turn the crankshaft in the same manner asabove and remove all remaining bolts one after another.Bring the transaxle shift lever into the “N” (Neutral) posi-tion.

12. After removing the special bolts, re-install the center memberassembly.

13. Remove the lower arm ball joint (Refer to DRIVE SHAFTGROUP)

14. Remove the remaining engine connecting bolts while at thesame time supporting the transaxle with a floor jack.

INSTALLATION

1. Attach the torque converter on the transaxle side and mount thetransaxle assembly onto the engine.

CAUTIONIf the torque converter is mounted first on the engine, theoil seal on the transaxle side may be damaged. Therefore,be sure to first assemble the torque converter to thetransaxle.

45-56 AUTOMATIC TRANSAXLE

2. Install the transaxle control cable and adjust as follows.1) Move the shift lever and the inhibitor switch to the “N”

position, and install the control cable.2) When connecting the control cable to the transaxle mount-

ing bracket, install the clip until it contacts the control cable.(as shown in the illustration)

3) Remove any free-play in the control cable by adjusting nutand then check to see that the selector lever movessmoothly.

4) Check to see that the control cable has been adjustedcorrectly.

AUTOMATIC TRANSAXLE ASSEMBLY 45-57

DISASSEMBLY

Caution:Because the automatic transaxle is composed of componentparts of an especially high degree of precision, these partsshould be very carefully handled during disassembly andassembly so as not to scar or scratch them.A rubber mat should be placed on the workbench, and itshould always be kept clean.During disassembly, cloth gloves or rags should not be used.If such items must be used, use articles made of nylon, or usepaper towels.All disassembled parts must be thoroughly cleaned. Metalparts may be cleaned with ordinary detergents, but must bethoroughly air dried.Clean the clutch disc, resin thrust plate and rubber parts byusing ATF (automatic transaxle fluid), being very careful thatdust, dirt, etc. do not adhere.If the transaxle main unit is damaged, also disassemble andclean the cooler system as well.

1. Clean away any sand, mud, etc. adhered around the transaxle.2. Place the transaxle assembly on the workbench with the oil pan

down.3. Remove the torque converter.4. Measuring input shaft end play before disassembly will usually

indicate when a thrust washer change is required (except whenmajor parts are replaced).

Standard value : 0.3-0.1 mm (0.012-0.004 in.)

Thrust washers are located between the reaction shaft supportand rear clutch retainer, and between the reaction shaft supportand front clutch retainer.Mount a dial indicator to the converter housing with the dialindicator support.Make sure that the indicator plunger is seated against the endof the input shaft.When checking end play, pull out or push in the input shaft withpliers. Be careful not to scratch the input shaft. Record indicatorreading for reference when reassembling the transaxle.

5. Remove the pulse generators “A” and “B”.

6. Remove manual control lever, then remove the inhibitor switch.

45-58 AUTOMATIC TRANSAXLE ASSEMBLY

7. Remove the snap ring and kickdown servo switch

8. Remove 6 bolts, attach the special tools (09452-21100) andremove oil pump assembly

9. Remove the fiber thrust washer.

10. Pull up the input shaft, and remove the front clutch assemblyand the rear clutch assembly together.

11. Remove the thrust bearing


12. Remove the clutch hub.

13. Remove the thrust race and bearing.

14. Remove the kickdown drum.

15. Remove the kickdown band.

16. Remove the snap ring.


17. Attach the special tool (09453-21310) on the center support.Holding the handle of the tool, pull the center support straightupward.

18. Remove the reverse sun gear and the forward sun geartogether

19. Remove the planet carrier assembly and thrust bearing.

20. Remove the wave spring, return spring, reaction plate, brakedisc, and brake plate.

21. Remove the end clutch cover mounting bolts, the cover holder,and the end clutch cover.

AUTOMATIC TRANSAXLE ASSEMBLY

22. Remove the end clutch assembly.

23. Remove the thrust plate.

24. Remove the end clutch hub and thrust bearing

25. Pull out the end clutch shaft.

26. Remove the oil pan and gasket


27. Remove the oil filter from the valve body.

28. Remove the oil-temperature sensor installation bolt; then, afterremoval from the bracket, pull out from the connector.

29. Press the tab of the solenoid valve harness grommet and pushin.

30. Remove the 10 valve body bolts. Remove the valve body.

31. Using an impact driver, loosen the bolt.If an impact driver is not available, use a punch or somethingsimilar


32. Remove the bearing retainer.

33. Remove the snap ring from the bearing.

34. Loosen the rear cover mounting bolt and remove the rearcover.

35. Unstake the transafer shaft lock nut stopper.

36. Place lever in “P” position.


37. Remove the locking nut.

38. Using the special tool, remove the transfer driven gear.

39. Remove the taper roller bearing outer race.

40. Remove the snap ring

41. Remove the transfer shaft and taper roller bearing.


42. Move the manual control lever from the "P" position to “N”position

45-65

43. Remove the stopper plate.

44. Using the special tool or presser, remove the output flange anddrive gear.

45. Remove the speedometer sleeve.

46. Remove the differential cover and the gasket.


47. Before removal of the differential gear, measure the end playof the differential gear with a dial gauge.

48. Remove the 5 differential bearing retainer mounting bolts.

49. Using the special tool, remove the differential bearing retainer.

50. Loosen the mounting bolts and remove the bearing cap.

51. Remove the differential assembly.


52. Remove two bolts and the parking sprag rod.

53. Remove the set screw and the manual control shaft assembly.Remove the steel ball, the seat and the spring together at thistime.

54. Remove the kickdown servo snap ring.

55. Remove the kickdown piston assembly.


ASSEMBLY

CautionDo not reuse gaskets, oil seals and rubber parts. Replacethem with new ones at every reassembly. The O-ring of the oillevel dipstick need not be replaced.Do not use grease other than petrolatum or industrial vaseline.Apply automatic transaxle fluid to friction elements, rotatingparts, and sliding parts before installation. New clutch discsshould be immersed in automatic transaxle fluid for a mini-mum of two hours before installation.Do not apply sealer or adhesive to gaskets.When bushings must be replaced, replace their completeassembly which.Do not use shop towels during disassembly and reassemblyoperation.The oil in the cooler should also be replaced.

1. Insert manual control shaft into the transaxle case and push ittoward the manual control lever.At this time, do not install the larger one of the two O-rings onthe manual control shaft.

NOTEIf installed before inserting the shaft, the O-ring willinterfere with shaft set screw hole.

2. After installing the new O-ring on manual control shaft, drawshaft back into case. Install the set screw and gasket. Install thedetent steel ball, seat and spring at the same time.

3. Install the parking sprag rod to the detent plate (manual controlshaft).Install the sprag rod support and tighten the two bolts.

Sprag rod support bolts:20-27 Nm (200-270 kg.cm, 15-19 Ib.ft)


4. Insert the annulars gear, output flange transfer drive gear andbearing assembly into the case.

5. Before assembly of the transaxle, measure the end play of thelow-reverse brake, and select a pressure plate to be used sothat the end play will be the standard value.1) Install the brake reaction plate, brake plate and brake disc

to the transaxle case.

Caution:If new brake discs are used, be sure to immerse themin ATF for a minimum of two hours.

2) Install the appropriate pressure plate and then install thereturn spring.

Caution:Be sure that the return spring is installed so that itfaces in the correct direction.

3) Apply a coating of petroleum jelly to the wave spring andattach it to the center support.

4) Install the special tool (09453-21310) to the center support.


5) Install the snap ring.

6) Install the special tools (09454-21400, 09453-33100) and adial gauge at the transaxle case.

Caution:Install the dial gauge so that it contacts the brakereaction plate at a right angle from the transfer idlershaft hole.

7) Using a manual pump, pump air (5 kg/cm) in from theposition shown in the illustration. Read the dial indicatorgauge, and select the pressure plate that will provide thestandard value.

Standard value: 0.675-6.987 mm (0.0307-0.043 in.)

6. Install the transfer shaft, and press-fit the bearing outer race tothe transaxle case.


7. Install the transfer shaft snap ring.

8. Insert the spacer on the transfer shaft.

9. Install the bearing cage on the case.

10. Press-fit the transfer driven gear to the transfer shaft.

11. Tighten the lock nut to the specified torque.

Transfer lock nut:200-230 Nm (2000-2300 kg.cm, 146-166 Ib.ft)


12. After installing the dial gauge, measure the end play of thetransfer shaft: then select the spacer(s) needed to obtain thestandard value, and refit.

Transfer shaft end play: 0-0.06 mm (0-0.002 in.)

13. Using a punch, lock the lock nut to prevent rotation.

14. Install the transfer drive gear assembly.

15. Install the special tool at the rear side of the transaxle case.

16. Using the special tool (09452-33100), insert an assembly of theannulars gear into the transfer drive gear.


17. Install the stopper plate.

18. Apply specified sealant to the rear cover.

Specified sealant : THREE BOND 1216

19. Install the rear cover assembly.

Tightening torque :17-22 Nm (170-220 kg.cm, 12.3-15.9 Ib.ft)

20. Install snap ring.

21. Install the bearing retainer. Tighten the screws to the specifiedtorque. Apply a 5 mm (0.2 in.) width of sealant (3M Stud LockingNo. 1303). Sealant should not stick out of screw head.

Screw: 17-22 Nm (170-220 kg.cm, 13-15 Ib.ft)


identification of thrust bearings, thrust races and thrust washers Unit: mm (in.)


23. Install the planetary carrier to the case.

22. Apply a coating of petroleum jelly to thrust bearing #12 andattach to the planetary carrier.

24. Assemble the reverse sun gear and the forward sun gear in thefollowing order:1) Attach the seal ring and the snap ring to the reverse sun

gear. When attaching, squeeze the seal ring as shown inthe figure.

2) Attach thrust race #9 to the reverse sun gear.3) Attach thrust race #10 to the reverse sun gear.

4) Assemble the reverse sun gear, and then the forward sungear.

25. Install both of the previously assembled sun gears inside theplanetary carrier.


26. Install the brake disc and brake plate

27. install the selected brake pressure plate.

28. Install the return spring

29. Apply a coating of petroleum jelly to the wave spring and attachit to the center support.

30. Install the two new O-rings to the center support.


31. After applying a coating of ATF to the O-rings, install the specialtool (09453-21310) to the center support, and install into thecase.

CAUTIONBe sure that the wave spring is not out of position.

32. Install the snap ring.

CAUTION:The mating hole of the snap ring must be aligned with theinstallation hole of pulse generator A.

33. Assemble a new seal ring (large diameter) and D-ring (smalldiameter) to the kickdown servo piston, and install a new O-ringin the groove around the sleeve; then assemble the kickdownservo spring, piston and sleeve in the transaxle case.

34. Press the kickdown servo and sleeve in by using the valvespring compressor (09222-28000), install the snap ring.

35. Install the end clutch shaft. Be sure to install the longer splinetoward the front as shown.


36. Fit the thrust washer toward the return spring at the end clutchside.

37. Install the end clutch hub to end clutch.

38. Attach, using petroleum jelly, thrust bearing #13 to the endclutch hub.

39. Install the end clutch assembly.

40. Attach a new O-ring and D-ring to the end clutch cover.

CAUTION:Install so that the D-ring is not twisted.Apply a sufficient amount of automatic transaxle fluid tothe bearing.


41. Attach the end cover and fasten it with four bolts

CAUTION:When installing the end cover, be sure the screw hole iscorrectly aligned. If the end cover is turned (after it isinstalled) in order to align with the screw hole, the O-ringand/or the D-ring may be twisted as a result.

42. Install kickdown drum with its splines in mesh with the sun gear.Place the kickdown band on the kickdown drum and tighten thekickdown servo adjusting screw to keep the band in position.

43. Apply a coating of petroleum jelly to thrust bearing 8, and thenattach to the kickdown drum.

44. Apply a coating of petroleum jelly to thrust race 7, and thenattach to the rear clutch hub.

45. Install the clutch hub to the sun gear splines.


46. Attach thrust bearing #6 onto the hub using petroleum jelly.

47. Apply a coating of petroleum jelly to thrust washer #2 and thrustbearing #4. Attach to the rear clutch assembly.

48. Combine the rear clutch and the front clutch assemblies.

49. Install the entire clutch assembly.

50. If end play which was measured and recorded at disassemblyis not within standard value, adjust to specification by selectingthrust race #3.


When the thrust race is replaced with that of a differentthickness, also replace thrust washer #1 located between theoil pump and front clutch. Use a washer of proper correspond-ing thickness corresponding to thrust race.Find correct pair of thrust races (metal) and thrust washers(fiber) from following table.


Thrust race #3 (metal) Thrust race #1 (fiber)

Thickness mm (in.) Thickness mm (in.)

1.4 (0.055) 1.0 (0.039)

1.4 (0.055) 1.2 (0.047)1.8 (0.071) 1.4 (0.055)1.8 (0.071) 1.6 (0.063)2.2 (0.087) 1.8 (0.071)2.2 (0.087) 2.0 (0.079)2.6 (0.102) 2.2 (0.087)

2.6 (0.102) 2.4 (0.095)

Example:When a different thickness thick thrust race is selected, acorresponding thrust washer must be paired with it.

51. Attach the reused thrust washer #1, or the one selected in step50 to the front clutch by using petroleum jelly.

52. Install the special tool (09452-21401) to the case.

53. Attach the reused thrust race #3 or the one selected in step 50to the oil pump by using petroleum jelly.

54. Install a new oil pump gasket and the oil pump assembly.


55. Install a new O-ring in the groove of the oil pump housing andlightly apply automatic transaxle fluid to the outside surface ofthe O-ring.

56. Install the oil pump assembly by tightening the six bolts evenly.When installing this oil pump assembly, be careful that thethrust washer remains in place.

57. Check the input shaft end play. Readjust if necessary (see step51)


58. Install the O-ring at the center of the top of the valve bodyassembly (brake oil pressure passage).Install the valve body assembly to the case, fitting the detentplate (manual control shaft) pin in the slot of the manual valve.

59. Replace the O-ring of the solenoid valve connector with a newone.

60. Tighten the valve body assembly mounting bolts to 10-12 Nm(100-120 kg.cm, 7-9 Ib.ft)A : 25 mm (0.984 in.) longB : 35 mm (1.378 in.) longC : 40 mm (1.575 in.) long

61. Install the oil filter. Tighten the four oil filter mounting bolts to 5-7 Nm (50-70 kg.cm, 4-5 Ib.ft)


62. Install five magnets into the five depression provided in the oilpan.

63.

64.

Install a new oil pan gasket and oil pan. Tightening 12 bolts to10-12 Nm (100-120 kg.cm, 7-9 Ib.ft)

Install a new D-ring to the kickdown servo switch. Press into thecase and secure using the proper snap ring.

65. Install the inhibitor switch and manual lever.Adjust the inhibitor switch.

Tightening torque:10-12 Nm (100-120 kg.cm, 7-9 Ib.ft)

66. Install the pulse generator A and B


67. lnstall the differential cover assembly and gasket.

68. Install the speedmeter sleeve.

69. After applying automatic transaxle fluid to the outside surfaceof the oil pump-side cylindrical portion of the torque converter,install the torque converter carefully so as not to damage theseal lip. Make certain that the torque converter is in mesh withoil pump drive gear.

70. Measure the distance between the ring gear end and theconverter housing end. The torque converter has been properlyinstalled when measurement is approximately 12 mm (0.47 in.)

OIL PUMP ASSEMBLY 45-85

OIL PUMP ASSEMBLY

COMPONENTS Bolt (5)

O-ring

DISASSEMBLY

1. Place the oil pump body on the torque converter.2. Remove the two seal rings and O-ring.

3. Remove five volts and remove reaction shaft support fromhousing.

4. Remove the oil pump body from the torque converter.

5. Make reassembly alignment marks on drive and driven gear.6. Remove oil pump drive and driven gears from pump housing.7. Remove the steel ball from housing.

45-86 OIL PUMP ASSEMBLY

8. Remove the snap ring and the oil seal from the oil pump drivegear.

INSPECTION

1. Measure the side clearance of the oil pump gear. If theclearance exceeds the standard value, or if an inspection of thesurface area (of the oil pump housing) that contacts the oilpump gear reveals indications of interference, replace theentire oil pump assembly.

Standard value: 0.03-0.05 mm (0.0012-0.0020 in.)2. Check the surface of the reaction shaft support that contacts

the oil pump gear. If there are indications of interference,replace the entire oil pump assembly.

3. Using a dial indicator, measure the inside diameter of the oilpump body bushing.

Max inside diameter: 43.01 mm (1.69 in.)

If the inside diameter is greater than the maximum, replace theoil pump body.

4. Check oil pump drive gear rotation.

ASSEMBLY

1. Install the oil seal to the oil pump drive gear.

OIL PUMP ASSEMBLY 45-87

2. Install the snap ring.

3. After immersing the drive and driven gears in automatic transaxlefluid, install them into pump housing. When reusing gears,install with mating marks properly aligned.

4. Fit a new O-ring into the groove at the inner circumference ofthe drive gear.

5. Install the steel ball in the hole as shown in the illustration.

6. Install the two seal rings, coated with automatic transaxle fluid,to the reaction shaft support.

7. Make sure that oil pump gear turns freely.8. Install a new O-ring in the groove provided in the circumference

of the pump housing and apply petroleum jelly to the circumfer-ence of the O-ring.

9. Loosely install the reaction shaft support on the pump housing.Tighten the five bolts fingertight.

10. With the reaction shaft support properly positioned on the pumphousing, using special tools (09452-21401, 09452-21301)tighten the five bolts to 10-12 Nm (100-120 kg.cm, 7-9 Ib.ft).

OIL SEAL REPLACEMENT1. Pry off the pump housing oil seal using a screwdriver.

45-88 OIL PUMP ASSEMBLY

2. Using the special tool (09452-21200), install the oil seal to thepump housing. Apply a thin coat of automatic transaxle fluid tothe lip of the oil seal before installation.

FRONT CLUTCH ASSEMBLY 45-89

FRONT CLUTCH ASSEMBLY

COMPONENTS

Clutch reaction platethickness 3.8 mm (0.150 in.)

Clutch disc

D-ring

45-90 FRONT CLUTCH ASSEMBLY

DISASSEMBLY

1. Remove the snap ring from the clutch retainer.2. Take out the three clutch reaction plates and two clutch discs.

If the clutch reaction plates and the clutch discs are to bereused, be sure not to change the installation order or direction.

3. With return spring compressed with the special tool (09453-24000), Spring Compressor, remove snap ring, then springretainer and return spring.

4. Remove the piston from the retainer.5. Remove the D-section rings from the inner and outer circumfer-

ences of the piston.

INSPECTION

1. Check to see if the sliding surface of the disc, plate are wornor burnt, if necessary, replace then.

NOTE:If the lining of the disc is peeling off or discolored, replaceall discs.

2. Check that the check ball is free by shaking the piston.

ASSEMBLY

1. Install the D-section ring in the groove on the outside surfaceof the piston with its round side out. Install another D-sectionring to the front clutch retainer.

2. Apply automatic transaxle fluid to the outside surface of the D-section rings. Then push the piston into front clutch retainer byhand.

3. Install the return spring and spring retainer.4. Compress the return spring with the special tool (09453-24000)

and install the snap ring.

FRONT CLUTCH ASSEMBLY 45-91

5. Install the three clutch reaction plates and two clutch discs.Prior to installation, apply automatic transaxle fluid to them.

Caution:When new clutch discs are used, they should be im-mersed in automatic transaxle fluid a minimum of twohours prior to installation.

6. After installing the snap ring, check to see if there is a 0.4-0.6mm (0.0157-0.0236 in.) clearance between the snap ring andthe clutch reaction plate.To check clearance, hold the entire circumference of the clutchreaction plate down with 50 N (11 lb.) force. If clearance is outof specification, adjust the clearance by selecting the propersnap ring.

Shear drop

REAR CLUTCH ASSEMBLY

REAR CLUTCH ASSEMBLY

COMPONENTS

Clutch pressure plate

REAR CLUTCH ASSEMBLY 45-93

DISASSEMBLY

1. Remove the snap ring and thrust race.2. Remove the input shaft from the rear clutch retainer.3. Remove the snap ring from the clutch retainer.4. Remove the clutch reaction plate, three clutch plates, two

clutch discs and clutch pressure plate from the retainer.

5. Compress the return spring by using the spring compressor.6. Using a screwdriver, remove the wave spring.7. Remove the return spring and piston.8. Remove the two D-section rings from the piston.

ASSEMBLY

1.

2.

3.4.

Install the D-section rings in the grooves in the outside andinside surfaces of the piston.After applying automatic transaxle fluid to the outside surfaceof the D-section rings, push the piston into the rear clutchretainer by hand.Install the return spring on the piston.Compress the return spring with the snap ring, by pushingdown with a screwdriver and setting the snap ring in itsgroove.

5. Install clutch pressure plate, two clutch discs, clutch plate andclutch reaction plate into the rear clutch retainer.When the reaction plate, clutch plate and clutch disc areremoved, reinstall them by reversing the order of disassembly.Prior to installing, apply automatic transaxle fluid to the platesand discs.Caution:When new clutch discs are used, immerse them in auto-matic transaxle fluid for a minimum of two hours prior toinstallation

6. Install the snap ring. Check to see that the clearance betweenthe snap ring and clutch reaction plate is 0.3-0.5 mm (0.0118-0.0197 in.). To check clearance, hold the entire circumferenceof the clutch reaction plate down with 50N (11 Ibs.) force. Ifclearance is out of specification, adjust by selecting the propersnap ring. Snap rings are the same as those used for the frontclutch.

7. Insert the input shaft into the clutch retainer.

45-94 REAR CLUTCH ASSEMBLY

8. Install the thrust race, and snap ring.9. Install the three seal rings to the grooves in the input shaft.

END CLUTCH ASSEMBLY 45-95

END CLUTCH ASSEMBLY

COMPONENTS

End clutch retainer

45-96 END CLUTCH ASSEMBLY

DISASSEMBLY

1. Remove the snap ring, clutch reaction plate, clutch disc, andthe clutch plate. If the disc and plate are reused, note theinstallation order and direction when they are disassembled.

2. Remove the snap ring with snap-ring pliers, and then removethe washer and return spring.

3. Remove the piston. If it is difficult to remove, face the piston sidedownward, and, with the retainer on a base, blow air in throughthe oil passage on the rear surface.

4. Remove the seal ring from the retainer.5. Remove the two D-section rings and oil seal from the piston.

ASSEMBLY

1. Install the D-section rings and oil seal in the piston inner andouter grooves.

2. After applying a coating of automatic transaxle fluid to the D-section rings outer circumference, manually press the pistoninto the end clutch retainer.

3. Install the return spring and washer.4. After fitting a new snap ring into the guide of the special tool

(09453-33000), install the retainer. Push the snap ring as fardown on the guide as possible.Attach the installer and press until the snap ring enters thegroove. Do not press more than necessary. The places indi-cated by arrows in the illustration (center projections) are notto be supported.

5. Install the clutch plate, clutch disc and reaction plate to the endclutch retainer.If the reaction plate, clutch plate and clutch disc are reused,install them in the same order they were disassembled. Applya coating of automatic transaxle fluid.

CautionWhen a new clutch disc is used, soak it in automatictransaxle fluid for 2 hours before using it.

END CLUTCH ASSEMBLY 45-97

6. Install the snap ring. Check that the clearance between thesnap ring and the clutch reaction plate is 0.4-0.65 mm (0.016-0.026 in.).To check the clearance, hold the circumference of the clutchreaction plate down with 50N (11 lb.) force.If clearance is out of specifications, adjust the clearance byselecting the proper snap ring.

45-98 PLANETARY GEAR SET

PLANETARY GEAR SET

COMPONENTS

Thrust washer front (6)

Outer race

Overrunning clutch

B

DISASSEMBLY

1. Remove three bolts.

2. Remove the overrunning clutch outer race assembly. Removethe overrunning clutch end plate.

3. Remove the shaft of only one short pinion.4. Remove the spacer bushing and two front thrust washers.5. Remove the pinion. Do not drop the 17 roller bearings in the

pinion.

PLANETARY GEAR SET 45-99

6. Remove the thrust bearing.

7. Push the overrunning clutch out of the outer race by hand.

ASSEMBLY

1. Install the thrust bearing in the carrier. Be sure that it fitscorrectly in the carrier.

2. Apply a generous amount of petroleum jelly to the inside of theshort pinion to hold the 17 rollers bearings in place.

3. Line up the holes in the rear thrust washer and front thrustwasher with the shaft of the carrier.

4. Install the short pinion, spacer bushing and two front thrustwashers and align the holes. Use care not to allow the rollersto move out of position.

Rear thrust washer

45-100 PLANETARY GEAR SET

5. Insert the pinion shaft. Be sure that the flattened end of thepinion shaft fits properly into the hole in the rear thrust platewhen the pinion shaft is inserted

6. Install the end plate in the outer race

7. Press the overrunning clutch into the outer race. Be sure thatthe arrow on the outside circumference of the cage is pointingupward as shown in the illustration when the overrunning clutchis installed.

8. Apply petroleum jelly to the overrunning clutch end plate toretain it inside the overrunning clutch. Install the end plate in theclutch.

INTERNAL GEAR AND TRANSFER DRIVE GEAR SET ASSEMBLY 45-101

INTERNAL GEAR ASSEMBLY

COMPONENTS

1. Remove the snap ring from the rear of the output flange

INTERNAL GEAR AND TRANSFER DRIVE GEAR SET ASSEMBLY

TRANSFER DRIVE GEAR ASSEMBLY

COMPONENTS

Snap ring

Rear bearing

Front bearing

Drive gear

DISASSEMBLY

1. Using special tool (09433-21000), pull off the front bearing andthe rear bearing from transfer drive gear.

REASSEMBLY

1. Using special tool (09433-21000), press the front bearing andthe rear bearing onto the transfer drive gear.

TRANSFER DRIVEN GEAR ASSEMBLY 45-103

TRANSFER DRIVEN GEAR ASSEMBLY

COMPONENTS

Transfer ‘driven gear

Tapered roller bearing

DISASSEMBLY.

1. Using special tool (09433-21000), pull off tapered roller bearingfrom the transfer driven gear.

REASSEMBLY

1. Using special tool (09432-33800), press tapered roller bearingonto the transfer driven gear.

45-104 TRANSFER SHAFT ASSEMBLY

TRANSFER SHAFT ASSEMBLY

COMPONENTS

Transfer shaft

Outer raceTapered roller bearing

DISASSEMBLY

1. Using special tool (09433-21000), remove the bearing from thetransfer shaft.

REASSEMBLY

1. Press the bearing inner race on to the transfer shaft

DIFFERENTIAL 45-105

DIFFERENTIAL

COMPONENTS

DISASSEMBLY

1. Remove the drive gear retaining bolts and drive gear from thedifferential case.

2. Remove the bearing with the special tool (09433-21000).

3. Drive out the lock pin with a punch inserted in hole “A”.4. Remove the pinion shaft, pinion gears and washers5. Remove the side gears and spacers.

Do not mix the gears and spacers between the left and rightsides.

45-106 DIFFERENTIAL

ASSEMBLY

1. With the spacers installed on the back of the differential sidegears, install the gears into the differential case. If reusingparts, install them in their original positions noted duringdisassembly.If using new differential side gears, install medium thicknessspacers 1.0mm (0.039in.).

2. install the washers on the back of the pinion gears. Install gearsinto the differential case, then insert the pinion shaft.

3. Measure the backlash between the side gear and the piniongear.Backlash should be 0.025-0.150 mm (.0010-.0059 in) and theright and left hand gear pairs should have equal backlash. If thebacklash is out of specification, disassemble and reassembleusing different spacers for the correct backlash.

Standard value: 0.025-0.150 mm (.0010-.0059 in.)

4. Install the pinion shaft lock pin in the direction specified in theillustration. After installation, check that the projection is lessthan 3 mm (.118 in.).

CautionThe lock pin must not be reused.

5. Press the bearings onto both ends of differential case. Press onthe inner race when installing the bearings Do not apply load toouter race.

6. Install the differential drive gear onto the case.

7. Apply ATF to the bolts and tighten the bolts to the specifiedtorque in the sequence shown in the illustration.

Tightening torque:130-140 Nm (1300-1400 kg.cm, 94-101 Ib.ft)

VALVE BODY

DISASSEMBLY

1. Remove the 4 solenoid valves and the oil temperature sensorbracket.

2. Remove the manual valve.

3. Remove the valve stopper and clamp.

4. Remove the bolts (13), and then remove the lower valve body

5. Remove the separating plate

45-108 VALVE BODY

6. Remove the relief spring, two steel bails and oil filter from theintermediate plate.

7. Remove the bolts (7), and then remove the intermediate plateand upper separation plate.

8. Remove the block.

9. Remove the upper separating plate.

10. Remove, from the upper valve body, the three steel balls, theteflon ball, and the two stopper plates.

VALVE BODY 45-109

11.

12.

13.

Remove, from the upper valve body, the seven bolts; thenremove the front end cover and the adjustment screw.

CautionWhen removing the bolts, be sure to firmly press the frontend cover (as shown in the illustration) so as to prevent thespring from causing the adjustment screw to pop out.

Remove the pressue control spring and the pressure controlvalve.

Remove the torque converter control spring and the torqueconverter control valve.

14. Remove the regulator spring and the regulator valve

15. Remove the shift-control spring and shift-control plug A

VALVE BODY

16. Remove rear clutch exhaust valves A and B as well as the rearclutch exhaust spring.

17. Remove the 2-3/4-3 shift spring and the shift valve.

18. Remove, from the rear side of the upper valve body, the N-Dcontrol sleeve and the N-D control valve

19. Remove the four bolts. and then remove the rear end cover.

20. Remove the 1-2 shift spring and the 1-2 shift valve

VALVE BODY 45-111

21. Remove shift-control plug B.

22. Remove the shift-control valve.

23. Using a magnet, extract the pin from the lower valve body, andthen remove the stopper.

24. Remove the end clutch valve plug, end clutch spring, and endclutch valve.

25. Remove the three bolts from the lower valve body, and thenremove the end cover, adjustment screw, and reducing spring

45-112 VALVE BODY

26. Remove the reducing valve

27. Remove the N-R control/accumulator valve and the N-R control/accumulator spring.

28. Remove the damper clutch control sleeve, damper clutchcontrol valve, and the damper clutch control spring.

Damper clutch control sleeve

VALVE BODY 45-113

VALVE INSTALLATION POSITIONS

Upper Valve Body

45-114 VALVE BODY

Lower Valve Body

Damper clutchcontrol valve!

Damper clutchcontrol sleeve

Reducing valve

Adjustment screw

VALVE BODY 45-115

ASSEMBLY

1. Install in the lower valve body, the damper clutch control spring,damper clutch control valve, and the damper clutch controlsleeve.

2. Install the N-R control/accumulator spring and the N-R control/accumulator valve.

3. Install the reducing valve.

4. Install the reducing spring, adjustment screw, and end coverTighten the bolts to the specified torque.

Tightening torque: 4-6 Nm (40-60 kg.cm, 29-43 Ib.ft)

5. Install the end clutch valve, end clutch spring, and end clutchplug.

45-116 VALVE BODY

6. Install the stopper and secure it with the pin.

7. Install the 1-2 shift-control valve to the upper valve body.

8. Install the 1-2 shift-control plug.

9. Install the 1-2 shift valve and 1-2 shift spring

10. Install the rear end cover.

VALVE BODY 45-117

11. Install the N-D control valve and the N-D control sleeve

12. Install the 2-3/4-3 shift valve and the 2-3/4-3 shift spring.

13. Install the rear clutch exhaust spring and rear clutch exhaustvalves A and B.

14. Install the shift-control valve and shift control spring

15. Install the regulator valve and regulator spring

45-118 VALVE BODY

16. Install the torquecontrol spring.

converter control valve and torque convener

17. Install the pressure control valve and pressure control spring

18. Install the adjustment screw and front end cover. Tighten thebolts to the specified torque.

19. Install, in the upper valve body, the three steel balls, the teflonball, and the stopper plate.

20. Install the upper separating plate

VALVE BODY

21. Install the block.

22. Install the special tool (09456-21000). Then, securing theupper separating plate and the intermediate plate with the eightinstallation bolts, remove the special tool.

23. Install to the intermediate plate, the oil filter, the two steel balls,and the spring.

24. Install the special tool (09456-21000) to the intermediate plate.

25. Install the separating plate.

45-120 VALVE BODY

26. After securing the lower valve body using the 13 installationbolts, remove the special tool.

27. Install the valve stopper and clamp.

23. Install the manual valve.

29. Secure the four solenoid valves using the installation bolts.

KICKDOWN SERVO 45-121

KICKDOWN SERVO

COMPONENTS

Kickdown servo sleeve

Kickdown servo rod

ASSEMBLY

1. Install the rod and nut to the kickdown servo piston.2. Install two new D-rings (one large and one small) around the

circumference of the piston, and then apply a coating of ATFto the D-rings.

3. Install the kickdown servo piston in the sleeve.4. Install a new O-ring around the circumference of the sleeve,

and apply a coating of ATF to the O-ring.

45-122 SPEEDOMETER SLEEVE

SPEEDOMETER SLEEVE

COMPONENTS

Sleeve

Gear

DISASSEMBLY

Drive the spring pin out, and disassemble the gear and sleeve.

Caution:Do not reuse the O-rings and spring pin.

ASSEMBLY1. Install a new O-ring to the shaft part of the gear, and apply ATF

to the O-ring.2. Insert the gear into the sleeve, and align the pin hole and the

groove of the gear’s shaft.3. Tap a new spring pin into the sleeve. When tapping it in, be sure

that the slit is not at the gear side.4. Install a new O-ring into the outer groove of the sleeve, and

apply a coating of ATF to the outer circumference of the O-ring.

DRIVE SHAFT &FRONT AXLEReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

HUB AND KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

49-2 GENERAL


Drive shaftJoint type

OuterInner

Length (Joint to joint)RightLeft

Maximum permissible joint angleB.J.D.O.J

B.J. (Birfield joint)D.O.J. (Double offset joint)

N/A: 648.5 mm (25.5 in.), T/C: 355 mm (20 in.)355 mm (20 in.)

45.3° or more22° or more

TIGHTENING TORQUEN m Kg.cm Ib.ft

Drive shaft nut 200-260 2000-2600 148-192Knuckle to strut assembly 90-105 900-1050 66-77Lower arm ball joint to knuckle 60-72 600-720 44-53Tie rod end to knuckle 15-34 150-340 11-25Caliper assembly to knuckle 65-75 650-750 48-55

LUBRICANTS

Recommended lubricant Quantity

B.J. Boot grease Sunlight SW-2 95-125 gr.(Joint: 40-55 gr., Boot: 55-70 gr.)

D.O.J. Boot grease Valiant SD-R2 110±6 gr.(Joint: 60±3 gr., Boot: 40±3 gr.)

Outer surface of wheel bearing outer race Multipurpose grease As requiredWheel bearing and knuckle inside surface SAE J310, NLGI No.2 As requiredOil seal lip As required

GENERAL 49-3

SPECIAL TOOLS

Tool(Number and Name)

09500-21000Bar

Illustration Use

Installation of oil seal and bearing.

09517-21000Oil seal installer

1) Press fit for the front wheel bearing oil seal. (usewith 09500-21000).

2) Press fit for the front wheel bearing outer race.(use with 09500-21000).

09517-21100Hub bearing remover

Removal of front wheel bearing. (use with 09532-11000, 09532-11301).

09517-21200Front axle base

Press-fitting of the front wheel bearing outer race.(use with 09517-21000, 09500-21000).

09517-21400Drift

Removal of front hub bearing outer race.

09517-21500Front hub remover and installer

Removal & installation of the front hub. (use with09517-21600)

09517-21600Knuckle arm bridge

09517-21700End yoke holder

Removal of the front hub. (use with 09517-21500)

Holding of the front wheel when installing andremoving the front axle shaft.

GENERAL


09529-21000Wheel alignment gaugeattachment

09532-11000Tapered roller bearing puller

09532-11301Puller cup

09532-11600Pre-load socket

09526-11001Axle shaft puller

09568-31000Tie rod end puller

Illustration Use

Front wheel alignment for aluminum wheel.

Removal of front wheel bearing. (use with 09532-11301, 09517-21100)

Removal of front wheel bearing. (use with 09517-21100, 09532-11000)

Measuring of front wheel bearing pre-load. (usewith 09517-21500, 30mm socket and torquewrench)

Removal of the drive shaft from the front hub.

Separation of the tie rod end ball joint

GENERAL 49-5

TROUBLESHOOTING

Symptom

Vehicle pulls to one side

Vibration

Shimmy

Excessive noise

Probable cause

Galling of drive shaft ball jointWear, rattle or galling of wheel bearingDefective front suspension and steering

Wear, damage or bending of drive shaftDrive shaft rattle and hub serrationWear, rattle or sintering of wheel bearing

Improper wheel balanceDefective front suspension and steering

Wear, damage or bending of drive shaftDrive shaft rattle and hub serrationDrive shaft rattle and side gear serrationWear, rattle or galling of wheel bearingLoose hub nutDefective front suspension and steering

Remedy

ReplaceReplaceAdjust or replace

ReplaceReplaceReplace

Adjust or replaceAdjust or replace

ReplaceReplaceReplaceReplaceAdjust or replaceAdjust or replace

WHEEL BEARING TROUBLESHOOTING

Symptom

Bent cage

Galling

Cracked inner race

Etching

Brinelling

Heat discoloration Heat discoloration is dark blue resulting from overload orno lubricant (Yellow or brown color is normal)

Fatigue spalling Flaking of surface metal resulting from fatigue

Probable cause

Cage damage due to improper handling or tool usage

Metal smears on roller end due to overheating, lubricantproblem or overloading.

Race cracked due to improper fit, cocking or poor bearingseats.

Bearing surfaces appear gray or grayish black in color withrelated etching away of material usually at roller spacing

Surface indentations, on race surface caused by rollerseither under impact loading or vibration while the bearingis not rotating.

Remedy

Replace bearing

Replace bearingCheck seals, check for properlubrication

Replace bearing

Replace bearingCheck seals, check for properlubrication

Replace bearing

Replace bearingCheck seals and other parts

Replace bearingClean all related parts

49-6 DRIVE SHAFT

DRIVE SHAFT

COMPONENTS

N/AInner shaft

TORQUE: Nm (kg.cm, Ib.ft)

DRIVE SHAFT 49-7

REPAIR KITS

Kit name

Double offset joint kit

Double offset joint boot kit

Birfield joint and shaft kit

Bit-field joint boot kit

Damper kit

Illustration Contents

0 Clip (Retainer ring)o D.O.J assy0 Circlipo D.O.J boot0 Snap ringo D.O.J boot bando Boot bando Grease

0 Clip (Retainer ring)0 Circlipo D.O.J boot0 Snap ringo D.O.J boot bando Boot bando Grease

0 Clip (Retainer ring)0 Circlip0 Snap ringo D.O.J boot bando Boot bandso Damper bando B.J boot bando B.J booto B.J assyo Dust covero Grease

0 Clip (Retainer ring)0 Circlip0 Snap ringo D.O.J boot bando Boot bandso Damper bando B.J boot bando B.J booto Grease

o Clip (Retainer ring)0 Circlip0 Snap ringo D.O.J boot bando Boot bando Dynamic dampero Damper bando Grease

49-8

REPAIR KITS (TURBO CHARGER R.H.)

Kit name



Birfield joint kit

Birfield joint boot kit

Center bearing dust seal kit


D.O.J. outer raceCirclipSnap ringD.O.J. inner race, cage and ballsD.O.J. bootD.O.J. boot bandBoot bandGrease

0 Clip0 Snap ringo D.O.J booto D.O.J boot bando Boot bando Grease

0 Circlip0 Snap ringo D.O.J boot bando Boot bando B.J boot bando B.J booto B.J assemblyo Dust covero Grease

0 Circlip0 Snap ringo D.O.J boot bando Boot bandso B.J boot bando B.J booto Grease

o Inner dust sealo Center bearingo Outer dust seal

49-9

REPAIR KITS (TURBO CHARGER L.H.)

Kit name



Birfield kit

Birfield joint boot kit


o D.O.J. outer race0 Circlip0 Snap ringo D.O.J. inner race, cage and ballso D.O.J. booto D.O.J. boot bando Boot bando Grease

0 Clip0 Snap ringo D.O.J booto D.O.J boot bando Boot bando Grease

0 Circlip0 Snap ringo D.O.J boot bando Boot bando B.J boot bando B.J booto B.J assemblyo Dust covero Grease

0 Circlip0 Snap ringo D.O.J boot bando Boot bandso B.J boot bando B.J booto Grease

49-10 DRIVE SHAFT

REMOVAL

1. Remove the hub caps, and loosen the drive shaft nut.2. Lift up the vehicle and remove the tires.3. Remove the lower arm ball joint or its mounting bolts from the

lower arm.

4. Detach the tie rod end ball joint connection.5. Remove the stabilizer bar self locking nut.6. Drain the transaxle fluid.7. Insert a pry bar between the transaxle case and joint case

(D.O.J), and pry the drive shaft from the transaxle case.

CAUTION1) Be sure to apply the pry bar to the rib of the transaxle

case.2) Do not insert the pry bar too deep, as this may cause

damage to the oil seal. [max. depth : 7 mm (0.28 in.)].

8. Pull out the drive shaft from the transaxle case.

CAUTION1) Place a shop towel in the hole of the transaxle case to

prevent contamination.2) Support the drive shaft properly.3) Replace the retainer ring each time the drive shaft is

removed from the transaxle case.

9. Using special tool (09526-11001), force the drive shaft out ofthe hub.

CAUTIONWhen the drive shaft is forced out, keep the spacer fromfalling out of place.

INSPECTION

1. Check the drive shaft boot for damage and deterioration.2. Check the ball joints for wear and operating condition.3. Check the splines for wear and damage.

DRIVE SHAFT 49-11

DISASSEMBLY

CAUTION1) Do not disassemble the B.J. assembly.2 ) The drive shaft joint uses special grease. Do not substi-

tute with another type of grease.3) The boot band should be replaced with a new one.

1. Remove the D.O.J. boot bands and pull the D.O.J. boot fromthe D.O.J. outer race.

CAUTIONBe careful not to damage the boot.

2. Remove the circlip with a flat-blade screwdriver.

3. Pull out the drive shaft from the D.O.J. outer race.4. Remove the snap ring and take out the inner race, cage and

balls as an assembly.

5. Clean the inner race, cage and balls without disassembling.6. Remove the B.J. boot bands and pull out the D.O.J. boot and

B.J. boot.

CAUTIONIf the boot is to be reused, wrap tape around the drive shaftsplines to protect the boot.

Inspection after Disassembly

1. Rusted or damaged D.O.J. outer race, inner race, cage andballs.

2. Worn splines.3. Water, foreign matter or rust in B.J. boot.

CAUTIONWhen the B.J. assembly is to be reused, do not wipe awaythe grease. Check for foreign substances in the grease. Ifnecessary, clean the B.J. assembly and replace grease.

49-12 DRIVE SHAFT

ASSEMBLY

1. Wrap tape around the drive shaft splines (D.O.J. side) toprevent damage to the boots.

2. Apply grease to the drive shaft and install the boots.

Recommended lubricantB.J. Boot grease . . . . . . . . . . . . . . . . . . . . Sunlight SW-2D.O.J. Boot grease . . . . . . . . . . . . . . . . . . Valiant SD-R2

D.O.J. boot B.J. boot

3. To install the dynamic damper, keep the B.J. and shaft in astraight line and secure the dynamic damper positively in theillustrated direction and locate using small boot band.

4. Apply the specified grease to the inner race and cage. Installthe cage so that it is offset on the race as shown.

CAUTIONUse the grease included in the repair kit.

5. Apply the specified grease to the cage and fit the balls into thecage.

6. Install the chamfered side as shown, and then install the innerrace onto the drive shaft, and install the snap ring.

Dynamic damper

DRIVE SHAFT 49-13

7. Apply 40 to 50 gr. (1.4 to 1.8 oz.) of specified grease to theouter race and install the outer race onto the drive shaft.

8. Apply 20 to 40 gr. (0.7 to 1.4 oz.) of specified grease into theD.O.J boot and install the boot.

D.O.J. boot grease gr. (oz)Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110±6

In the joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ± 3In the boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ± 3

9. Tighten the D.O.J. boot bands.10. Add to the B.J. as much specified grease as was wiped away

at the time of inspection.11. Install the boots.12. Tighten the B.J. boot bands.13. To control the air in the D.O.J. boot, keep the specified distance

between the boot bands when they are tightened.

INSTALLATION

1. Tighten the following parts to the specified torque.

Nm (kg.cm, Ib.ft)

Drive shaft nut 200-260 (2000-2600, 148-192)Knuckle to strut assembly 90-105 (900-1050, 66-77)Lower arm ball joint to knuckle

60-72 (600-720, 44-53)

2 .

3 .

4 .

Install a new retainer ring each time the drive shaft is removedfrom the transaxle.Install the washer under the drive shaft nut as shown in theillustration.Install the drive shaft nut and split pin.If the holes in the nut and drive shaft are not aligned, tighten thenut to the maximum torque.

49-14 HUB AND KNUCKLE

COMPONENTS

90-105 (900-1050, 66-77)


REMOVAL

1. Remove the hub caps.2. Remove the drive shaft nut.3. Jack up the vehicle and support it with jack stands.4. Remove the wheel and tire.5. Remove the front brake assembly from the knuckle and sus-

pend it with a wire.6. Disconnect the lower arm ball joint from the knuckle using the

Special Tool (09568-31000).

7. Disconnect the tie rod end ball joint from the knuckle using theSpecial Tool (09568-31000).

Caution1. Be sure to tie the cord of the special tool to the nearby

part.2. Loose the nut but do not remove it.

HUB AND KNUCKLE 49-15

8. Disconnect the drive shaft from the hub using the special tool(09526-11001).

9. Remove the hub and knuckle as an assembly from the strut.

INSPECTION

1. Check the hub for cracks and the splines for wear.2. Check the oil seal for cracking or damage.3. Check the brake disc for scoring and damage.4. Check the steering knuckle for cracks.5. Check for a defective bearing. (Refer to “Wheel bearing

troubleshooting”.)

BEARING REPLACEMENT

1. Install the special tools as illustrated.2. Remove the hub from the knuckle by turning the special tool.

CAUTION1) Be sure to use the special tool.2) If the hub and knuckle are disassembled by striking

with a hammer, the bearing will be damaged.

3. Secure the knuckle in a vise.4. Remove the brake disc from the hub.

5. Remove the outer bearing inner race from the hub usingSpecial Tools (09532-11000, 09532-11301, 09517-21100).

49-16 FRONT AXLE

6. Remove the oil seal and inner bearing inner race from theknuckle.

7. Drive out the bearing outer races from the knuckle using theSpecial Tool (09517-21400).

CAUTIONIf either the outer or inner race needs replacement, theymust be replaced as a set.

8. Apply the specified multipurpose grease to the outside surfaceof the bearing outer race.

Recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multipurpose grease SAE J310, NLGI No.2

9. Install the bearing outer race into the knuckle with Special Tools(09500-21000, 09517-21000, 09517-21200).

10. Install the disc to the hub, and torque to specification.

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-60 Nm (500-600 kg.cm, 37-44 Ib.ft)

11. Apply the specified multipurpose grease to the bearings andinside surface of the hub.

12. Place the outside bearing inner race into the knuckle.13. Drive the oil seal (hub side) into the knuckle with the Special

Tool (09517-21000, 09500-21000).14. Apply the specified multipurpose grease to the lip of the oil seal

and to the surfaces of the oil seal which contact the hub.

Recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multipurpose grease SAE J310, NLGI No.2

15. Place the inner bearing into the knuckle.16. Tighten the hub to the knuckle to 230 Nm (2,350 kg.cm, 167

Ib.ft) with the Special Tool (09517-21500).17. Rotate the hub to seat the bearing.

FRONT AXLE 49-17

18. Measure the hub bearing starting torque.

Hub bearing starting torque [Limit] . . . . . . . . . . . . . . . . . . . . .1.3 Nm (13 kgcm, 11 Ib.in) or less

19. If the starting torque is 0 Ncm (0 in.lbs.), measure the hubbearing axial play.

20. If the hub axial play exceeds the limit while the nut is tightenedto 230 Nm (2,350 Kg.cm, 167 Ib.ft), the bearing, hub andknuckle have not been installed correctly. Repeat the disas-sembly and assembly procedure.

Hub bearing axial play [Limit] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.11 mm (0.0043 in.) or less

21. Remove the Special Tool.22. Apply the specified multipurpose grease to the bearing and to

the inside of the knuckle.

Recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multipurpose grease SAE J310, NLGI No.2

23. Drive the oil seal (drive shaft side) into the knuckle until itcontacts the bearing outer race using Special Tools.

24. Apply the specified multipurpose grease to the lip of the oilseal.

25. Install the parts to the torque specifications.

INSTALLATION

1. Lower the vehicle to the ground and tighten the knuckle to thelower arm ball joint connecting bolt.

2. Install parts to torque specifications.

FRONTSUSPENSIONReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

STRUT ASSEMBLY .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

LOWER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

CENTER MEMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

54-2 GENERAL


Suspension system Macpherson strut with coil spring

Coil springFree height and identification color

Model Free height mm (in.)

GL GL+P/S+S/R GLS+S/RGL+S/R GL+A/T GLS+P/S+S/RGL+P/S GL+A/T+P/S GLS+A/T 338.5 (13.32)GL+A/C GLS GLS+A/T+S/RGL+A/C+S/R GLS+P/S

GL+A/C+P/S GL+A/T+A/C+P/S GLS+A/C+P/S+S/RGL+A/C+P/S+S/R GLS+A/C GLS+A/T+P/SGL+A/T+A/C GLS+A/C+S/R GLS+A/T+A/C

346.1 (13.62)

GL+A/T+A/C+S/R GLS+A/C+P/S GLS+A/T+A/C+P/S+S/R

GLS+A/T+A/C+P/S+S/R GLS+AA+A/C+S/R GLS+A/T+A/C+P/SGLS+AA+A/C+P/S+S/R 353.7 (13.92)

GL, GLS: Trim level NT: With automatic transmissionA/C: With air conditioner P/S: With power steering S/R: With sun roof

NOTE : Left and right spring combination must be the same weight classification color

Shock absorberTypeMaximum lengthCompressed lengthStrokeIdentification colorStabilizer bar

Length (center to center)O.D.

Wheel and TireTire size

Temporary tireTire inflation pressure kPa (psi)

Temporary tireWheel size

Identification color

Red 1 & green 1 line

Red 1 & blue 1 line

Red 1 & pink line

Hydraulic cylindrical double-acting type490.3 mm (19.3 in.)330.6 mm159.7 mmWhite

950 mm (37.40 in.)18 mm (0.71 in.)

P175/70 R13P185/60 HR14T105/70 D14193 (28)414 (60)5J x 14 (Steel, Al wheel)4T x 14 (Temporary tire)

GENERAL 54-3

SERVICE STANDARD

Standard valueToeCamberCasterKing pin inclination angleKing pin offsetMax. camber angle difference between LH and RHSteering angle

Inside wheelOutside wheel

Wheel runoutRadial mm (in.)Axial mm (in.)

4 mm in -2 mm out-10° ± 30'1°5' ± 30' (Manual)13°14'-3.8 mm30'

1°44' ± 30' (Power)

37°24' ± 1°30'31°31'[Steel wheel] [Aluminum wheel]0.6 (0.024): Average of LH & RH 0.3 (0.012)1.0 (0.039) 0.3 (0.012)

TIGHTENING TORQUE N m kg.cm Ib.ft

Strut mounting self locking nutUpper strut installation nutKnuckle to strut assemblyLower arm ball joint to knuckleTie rod end ball joint to knuckleBall joint to lower arm assemblyLower arm mounting shaft mounting nutLower arm mounting shaft bolt (to floor)Lower arm mounting bracket bolt (to floor)Stabilizer bar lower/upper bracket mounting boltStabilizer bar to lower arm mounting bushing boltWheel hub nutWheel nut

40-5015-2090-10560-7215-3495-12095-120160-19060-8017-26

200-26090-110

400-500 29-36150-200 11-14900-1050 65-76600-720 43-52150-340 11-25950-1200 69-87950-1200 69-871600-1900 116-137600-800 43-58170-260 12-19

2000-2600900-1100

145-18865-80

LUBRICANTS

In dust cover of ball joint Listan #2, Sunlight TB-2or Morilex #2

As required

In insulator bearing of strut SAE J310A, Chassis greaseNLGI-No.0 or equivalent

As required

GENERAL

SPECIAL TOOLS


09529-21000Wheel alignment gaugeattachment

Illustration Use

Front wheel alignment for aluminum typewheel.

09532-11600Pre-load socket

Measurement of the front lower arm balljoint starting torque. (use with torquewrench)

09545-21100Ball joint dust cover installer

Installation of the front lower arm ball jointdust cover.

09432-21500Lower arm bushing arbor

09545-24000Lower arm bushing remover andinstaller ring

Removal and installation of the front lowerarm bushing (use with 09545-24000,09545-24100)

Removal & installation of the front lowerarm bushing. (use with 09545-24100,09432-21500)

09545-24100Lower arm bushing remover andinstaller base

Removal & installation of the front lowerarm bushing. (use with 09545-24000,09432-21500)

09546-11000 (J38402)Spring compressor

Compression of the front coil spring.

09546-21000Special spanner

1) Removal & installation of the front coilspring.

2) Removal & installation of the shockabsorber oil seal.

09568-31000Tie rod end puller

Separation of the tie rod end ball joint.

GENERAL 54-5

TROUBLESHOOTING

Symptom

Hard steering

Poor return of steeringwheel to center


Improper front wheel alignment CorrectExcessive turning resistance of lower arm ball ReplacejointLow tire pressure AdjustNo power assist Repair and replace

Improper front wheel alignment Correct

Poor or rough ride

Abnormal tire wear

Wandering

Improper front wheel alignment CorrectMalfunctioning shock absorber Repair or replaceBroken or worn stabilizer ReplaceBroken or worn coil spring ReplaceWorn lower arm bushing Replace the lower arm assembly

Improper front wheel alignment CorrectImproper tire pressure AdjustMalfunctioning shock absorber Replace

Improper front wheel alignment CorrectPoor turning resistance of lower arm ball joint RepairLoose or worn lower arm bushing Retighten or replace

Vehicle pulls to one side

Steering wheel shimmy

Bottoming

Improper front wheel alignment CorrectExcessive turning resistance of lower arm ball ReplacejointBroken or worn coil spring ReplaceBent lower arm Repair

Improper front wheel alignment CorrectPoor turning resistance of lower arm ball joint ReplaceBroken or worn stabilizer ReplaceWorn lower arm bushing ReplaceMalfunctioning shock absorber ReplaceBroken or worn coil spring Replace

Broken or worn coil spring ReplaceMalfunctioning shock absorber Replace

GENERAL

WHEEL AND TIRE DIAGNOSIS

GENERAL 54-7

SERVICE ADJUSTMENT PROCEDURESFRONT WHEEL ALIGNMENT

When using a wheel alignment tester to inspect front wheelalignment, always position the car on a level surface and thefront wheels in the straight ahead position. Prior to inspectionmake sure that the front suspension and steering system are innormal operating condition and that wheels and tires are free ofdeflection and tires inflated to specification.

Toe-in

Toe-in (B-A or angle 5) is adjusted by turning the tie rod turn-buckles. Toe in on the left front wheel can be reduced by turningthe tie rod toward the rear of the car. Toe change is achieved byturning the tie rods for the right and left wheels simultaneouslythe same amount as follows:

Description Toe changes mm (in.)/deg.

No. of turns of tie rod 1/2 6.5 (0.257)/39'(Same amount for rightand left)

1 13:1 (0.514)/1°18'

CAUTION1) Toe-in adjustment should be made by turning the right

and left tie rods the same amount.2) When adjusting toe-in, loosen the outer bellows clip to

prevent twisting the bellows.3) After the adjustment, firmly tighten the tie rod end lock

nuts and reinstall the bellows clip.

Toe (B-A) mm (in.) [Standard value] . . . . . . . . . . . . . . . . . . . . . . .4 in-2 out (0.157 in-0.079 out)

Tie rod end lock nuts tightening torque . . . . . . . . . . . . . . . . . . . . . . . .50-55 Nm (500-550 kg.cm, 36-40 Ib.ft)

Camber

The steering knuckle which is integral with the strut assembly ispre-adjusted to the specified camber at the factory and requiresno adjustment.

Camber [Standard value] . . . . . . . . . . . . . . . . . . . . . . . . . . . . -10° ± 30'

Caster

Caster is pre-set at the factory and can not be adjusted. Ifcaster is not within standard value, replace the bent or damagedparts.

Caster [Standard value]Manual steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1°5' ± 30'Power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1°44' ± 30'

Forward

54-8 GENERAL

NOTE1) The front suspension assembly must be free of worn,

loose or damaged parts prior to measuring front wheelalignment.

2) Measure wheel alignment by using the Special Tool(09529-21000).

3) Camber and caster are pre-set at the factory and cannotbe adjusted.

4) If camber and caster are not within specifications,replace bent or damaged parts.

Steering Angle

Steering angle, as a rule, requires no adjustment. However, ifthere is a difference in steering angle between the right and leftwheels, change the length of the right and left tie rods.

Steering angle [Standard value]Inner wheel 061 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37°24' ± 1°30'Outer wheel 002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31°31'

TIRE WEAR1. Measure the tread depth of the tires.

Tread depth of tire [Limit] . . . . . . . . . . . . . . . . . . 1.6 mm (0.06 in.)

2. If the remaining tread depth is less than the limit, replace thetire.

NOTEWhen the tread depth of the tires is reduced to 1.6 mm(0.06 in.) or less, the wear indicators will appear.

WHEEL RUNOUT

1. Jack up the vehicle and support it with jack stands.2. Measure wheel runout with a dial indicator as illustrated.3. Replace the wheel if wheel runout exceeds the limit.

Wheel runout [Limit]Steel wheel

Aluminum type wheel

Radial 0.6 mm (0.024 in.): Average of LH & RH

Axial 1.0 mm (0.039 in.)Radial 0.3 mm (0.012 in.)Axial 0.3 mm (0.012 in.)

Forward

GENERAL 54-9

WHEEL NUT TIGHTENING

1. Tightening torqueSteel and aluminium alloy wheel

Specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90-110 Nm (900-1,100 kg.cm, 65-80 Ib.ft)

CAUTIONWhen using impact-wrench, tightening torque should becontrolled certainly.

2. Tightening orderGo around the wheel tightening every other nut until they areall tight.Then double-check each nut for tightness.

STRUT ASSEMBLY

STRUT ASSEMBLY

COMPONENTS

REMOVAL

1. Raise the front of the vehicle and mount it on a jack stand.2. Remove the wheel and tire.3. Detach the brake hose and tube bracket from the strut

assembly.

NOTE.Do not pry or force the components.

STRUT ASSEMBLY 54-11

4. Remove the strut assembly from the knuckle and wheelhouse.

DISASSEMBLY

1. Using Special Tool, Spring Compressor (09546-11000), compress the coil spring.

2. Holding the upper spring seat with Special Tool, SpecialSpanner (09546-21000), loosen the nut at the top end of theshock absorber and remove the insulator.

3. Remove the spring seat, spring and rubber bumper.

INSPECTION

1. Check the bearing for wear.2. Check the rubber parts for cracks and wear.3. Check the coil spring for sagging and weakness.

54-12 STRUT ASSEMBLY

ASSEMBLY

1. Install Special Tool (09546-11000), on the coil spring andcompress the spring. After the spring is fully compressed, installit on the strut sub-assembly.

NOTEInstall the coil spring with the identification mark di-rected toward the knuckle.

2. Install the rubber bumper, upper rubber seat, upper seat assy,insulator and washer in the order.

NOTEAlign the D-shaped hole in the spring seat upper assem-bly with the indentation on the piston rod.

3. After having correctly seated the upper and lower ends of thecoil spring in the upper and lower spring seat grooves, loosenSpecial Tool (09546-11000).

4. Using Special Tool (09546-21000), hold the upper spring seatand tighten the self-locking nut to the specified torque.

Tightening of spring seat to piston rod . . . . . . . . . . . . . . . . . . . . . . . .40-50 Nm (400-500 kg.cm, 29-36 Ib.ft)

5. Pack grease in the strut upper bearing and install the cap.

CAUTIONMake sure that no grease is on the insulator rubber.

Recommended grease .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SAE J310a, Chassis grease NLGI-No.0 or equivalent

INSTALLATION

1. When installing the strut, the mating surface must be clean.2. Tighten the following parts to the specified torque.

Tightening torque Nm (kg.cm, Ib.ft)

Upper strut installation nut 15-20 (150-200, 11-14)Knuckle to strut assembly 90-105 (900-1050, 65-76)

3. Install the brake hose and bleed the brake system.

LOWER ARM

LOWER ARM

COMPONENTS


REMOVAL

1. Using Special Tool (09568-31000), disconnect the lower armball joint from the knuckle.

2. Remove the stabilizer bar mounting bolt and nut, and detachthe stabilizer bar from the lower arm.

54-14 LOWER ARM

3. Detach the lower arm bracket. Remove the lower arm mount-ing shaft bolts and separate.

4. Remove the lower arm.

INSPECTION

1. Check for cracked, deteriorated or worn bushings.2. Check for bent or cracked lower arm.3. Check for damaged boot.

INSPECTION OF BALL JOINTS

1. Remove the ball joint assembly from the lower arm.2. Inspect the ball joints for rotation condition.

1) As shown in the figure, flip the ball joint stud back andforth 5 times.

2) Using a torque gauge, measure rotation starting torqueat 0.5-2 rpm after 3° rocking and rotating torque at0.5-2 rpm after 3° rocking 30° rotation.

Rotation condition [Standard value] Nm (kg.cm, Ib.in.)

Vertical play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0Rotation starting torque .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10 (30-100, 26.0-86.8)Rotating torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6 (30-60, 26.0-52.1)

LOWER ARM 54-15

ALL JOINT AND DUST COVER REPLACEMENT

1. Remove the dust cover from the ball joint.2. Pack the specified grease or equivalent in the new dust cover.

Recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Listan #2, Sunlight TB-2 or Morilex #2

3. Press fit the dust cover to the ball joint with Special Tool (09545-21100).

LOWER ARM BUSHING REPLACEMENT

1. Install the Special Tools (09432-21500, 09545-24000, 09545-24100) on the lower arm.

2. Press out the bushing.

3. Apply soap solution to the following portions.1) Outer surface of the new bushing.2) Inner surface of the lower arm bushing mount.3) Inner surface of the Special Tools.

4. Install the Special Tools and new bushing onto the lower arm.5. Press fit the bushing into the lower arm bushing mount.

54-16 LOWER ARM

6. Center the bushing by the following procedure, if necessary.1) Reset the Special Tools and lower arm.2) Center the bushing.

NOTEAfter centering the bushing, wipe off the soap solution.

ASSEMBLY

1. Press fit the lower arm mounting shaft and tighten the shaftmounting nut.

Lower arm mounting shaft mounting nut . . . . . . . . . . . . . . . . . . . . . .95-120 Nm (950-1200 kg.cm, 69-87 lb.ft)

2. Replace the rear bushing, if necessary.When replacing, the new bushing must be within the specificdistance.

Standard value A . . . . . . . . . . . . . . . . 1.5-2.5 mm (0.059-0.098 in.)

INSTALLATION

1. Install the lower arm and lower arm mounting bracket.2. Install the lower arm mounting shaft into the floor panel holes

and tighten the bolts.

Mounting bracket bolt B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80 Nm (600-800 kg.cm, 43-58 Ib.ft)

Lower arm mounting shaft bolt A . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160-190 Nm (1600-1900 kg.cm, 116-137 Ib.ft)

3. Arrange the stabilizer bar mounting spacer, bushing and cup.Tighten the lock nut.

Dimension “A” [Standard value] . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-26 mm (0.945-1.024 in.)

LOWER ARM

4. Install the ball joint to the knuckle.

Ball joint to knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72 Nm (600-720 kg.cm, 43-52 Ib.ft)

54-18 STABILIZER BAR

STABILIZER BAR

COMPONENTS

TORQUE : Nm (Kg.cm, Ib.ft)

REMOVAL

1. Disconnect the tie rod end ball joint from the knuckle usingSpecial Tool (09568-31000).

NOTEBe sure to tie a cord to the Special Tool and to a nearby part.

2. Remove the rear roll stopper mounting bolt and rear roll bracketassembly mounting bolt.

3. Pull the rear roll bracket assembly forward.

NOTEDo not disconnect the center member assembly.

STABILIZER BAR 54-19

4. Loosen the stabilizer link bolt and nut, then separate thestabilizer bar from the lower arm.

5. Loosen the stabilizer bar mounting bolts through the steeringgear box access opening provided on the vehicle body.

6. Remove the stabilizer bar through the access opening.7. Detach the upper and lower brackets; then remove the bushing.

INSPECTION

1. Check the stabilizer bar for deterioration and damage.2. Check all bolts for condition and straightness.

INSTALLATION

1. Install the bushing onto the stabilizer bar.2. Align the upper and lower brackets with the bushing. Make sure

the projections are securely in the space between the brackets.

NOTEWhen installing, distinguish the brackets by noting theiridentification mark.Identification mark : R for R.H. side

L for L.H. side

3. Using the access opening, temporarily tighten the bushingbrackets, then position the opposite side bushing.

4. Securely tighten the stabilizer bar mounting bolts.

54-20 STABILIZER BAR

5. Fit the stabilizer link and tighten. (Refer to page 54-18).6. Reinstall the rear roil bracket assembly.7. Connect the tie rod end ball joint to the knuckle.

CENTER MEMBER 54-21

CENTER MEMBER

COMPONENTS


REMOVAL

1. Raise the vehicle and position the jack stands.2. Detach the front and rear roll stopper brackets from the engine

mounting bracket.3. Remove the center member assembly.

INSPECTION

1. Check each insulator and bushing for cracks or deterioration.2. Check each bracket for distortion or damage.

54-22 CENTER MEMBER

INSTALLATION

1. Install the front roll stopper bracket so that its round hole facesforward.

2. Fit the rear roll stopper bracket to the center member, and installthe center member assembly.

3. Temporarily tighten the front roll stopper bracket bolt. After thetotal weight of the engine has been placed on the vehicle body,securely tighten the nut.

Center member mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80 Nm (600-800 kg.cm, 43-58 Ib.ft)

Front roll stopper bracket to center member bolt . . . . . . . . . . . . . . . .30-40 Nm (300-400 kg.cm, 22-29 Ib.ft)

Rear roll stopper bracket to center member bolt . . . . . . . . . . . . . . . . . .45-60 Nm (450-600 kg.cm, 33-43 Ib.ft)

Insulator to engine mounting bracket bolts . . . . . . . . . . . . . . . . . . . . . . .45-60 Nm (450-600 kg.cm, 33-43 Ib.ft)

WHEEL AND TIRE 54-23

WHEEL AND TIREWHEEL ROTATION

1. Rotate the tires in the patterns illustrated.

CAUTIONThe temporary spare tire should not used in the wheelrotation.

Checking for pull and wander

1. If the steering pulls to one side, use the following wheel rotationprocedure.1) Switch the front right and front left tires, and perform the

road test in order to confirm vehicle stability.

2) If the steering pulls to opposite side, switch the front and reartires, and again perform the road test.

3) If the steering continues to pull to one side, switch the frontright and left tires again, and again perform the road test.

4) If the steering continues to pull to the opposite side, replacethe front wheels with new ones.

54-24 WHEEL AND TIRE

INSTRUCTIONS FOR ALUMINUM TYPE WHEELS

1. Aluminum is vulnerable to alkalies. If the vehicle has beenexposed to automobile washing detergent, or salt from seawater, or road chemicals, rinse the vehicle as soon as possible.Then apply wax to the wheels to prevent corrosion.

2. When steam cleaning the vehicle, do not direct the steam ontothe aluminum wheels.When tightening nuts for aluminum wheels, observe the follow-ing:1) Clean the hub surface.2) After finger-tightening the wheel nuts, tighten to specifica-

tions.3) Do not use an impact wrench or push the wrench by foot to

tighten the wheel nuts.4) Do not apply oil to the threaded portions.

TIRE CHAINS AND SNOW TIRES

1. Do not use tire chains on the P185/60 HR14 tires.Interference between the tire chains and the front wheel housecan occur if chains are used on the P185/60 HR14 tires.

2. When using snow tires, use them on all four wheels for menuverability and safety.

REARSUSPENSIONReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

REAR AXLE HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

55-2 GENERAL


Suspension system Trailing arm type

Coil springWire dia. x O.D. x free height mm (in.)

Identification colorShock absorber

TypeMax. lengthMin. lengthStroke

Identification color

11.0 x 118.0 x 299.4(0.43 x 4.65 x 11.78)Pink

Hydraulic, cylindrical, double acting type411 mm (16.18 in.)266 mm (10.47 in.)145 mm (5.71 in.)White

SERVICE STANDARD

Toe 6 mm in -3 mm outCamber -40'

NOTEThe rear wheel alignment is set at the factory and cannot be adjusted. If toe or camber is not within thespecification, replace the damaged parts.

TIGHTENING TORQUENm Kg.cm Ib.ft

Rear suspension arm assembly fixture mounting nuts 130-150 1300-1500 94-108Both ends of suspension arm mounting nuts 50-70 500-700 36-51Rear shock absorber mounting nuts (both) 65-80 650-800 47-58Rear spindle to backing plate bolts 50-60 500-600 36-43Wheel bearing nut 150-200 1500-2000 108-145Stopper bumper mounting nut 18-25 180-250 13-18

GENERAL 55-3

LUBRICANTS

Recommended lubricants Quantity

Inside of suspension arm (L.H.) and outerperiphery of suspension arm (R.H.)Bushing A and BWheel bearings, oil seal lip and inside.

Inside hub cap

CS-0

CS-0SAE J310a, MultipurposeNLGI No.2 or equivalentSAE J310a, MultipurposeNLGI-No.2 or equivalent

As required

As requiredAs required

As required

GENERAL

SPECIAL TOOLS


09432-21700Bearing outer race installer

09500-21000Bar

Illustration Use

Installation of rear hub outside bearing outerrace. (use with 09500-21000)

Removal & installation of oil seal and bearing(use with 09432-21700)

09517-21400Drift

Removal of rear wheel bearing outer race.

09555-21000Bar

Installation of rear suspension arm bushing.(use with 09555-21100)

09555-21100Bushing installer

Installation of rear suspension arm bushing Aand B. (use with 09555-21000)

GENERAL 55-5

TROUBLESHOOTING

Symptom

Abnormal sound


Suspension securing bolt(s) loose Tighten to specified torqueLoose wheel nuts

Faulty shock absorberWorn bushings

Replace damaged parts

Damaged or worn wheel bearingsComponents bent or distortedBroken coil spring

Wheel or tire unbalanced Balance

Poor ride control

Abnormal tire wear

Improper tire inflation

Defective tire

Improper tire inflation

Defective tire

Loose wheel nutsSuspension securing bolt(s) loose

Damaged or broken componentsWorn bushingsFaulty shock absorberSagging or broken coil spring

Improper rear wheel alignment

Improper rear wheel alignment

Bent or damaged parts

Improper inflation

Wheel or tire imbalance

Loose wheel bearings

Faulty shock absorber

Inflate to specification

Replace

Inflate to specification

Replace

Tighten to specification

Replace

Replace parts

Replace parts

Replace parts

Inflation specification

Balance

Adjust or replace

Inspect and repair

GENERAL

SERVICE ADJUSTMENT PROCEDUREREAR WHEEL ALIGNMENT

The rear suspension assembly must be free of worn, loose ordamaged parts prior to measurement of rear wheel alignment.

Standard valueToe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm in-3 mm outCamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-40'

NOTEThe rear wheel alignment is set at the factory and cannot beadjusted. If toe or camber is not within the standard value,replace the bent or damaged parts.

WHEEL BEARING STARTING FORCEINSPECTION

1. Remove the rear wheels.2. Release the parking brake.3. Measure the hub and drum starting force.

Service limit 22 N (2.2 kg, 4.9 Ibs.) or less

4. If the hub and drum starting force exceeds the limit, remove thehub cap, loosen the wheel bearing nut and retighten it, andrecheck the hub and drum starting force.

5. If the hub starting force is still beyond the limit, replace thebearings.

NOTE,There should be no axial clearance for hub and bearing.

REAR SUSPENSION 55-7

REAR SUSPENSION

COMPONENTS


REMOVAL

1. Support the side frame on a jack stand.2. Remove the rear brake assembly.3. Remove the muffler.4. Jack up the suspension arm and keep it slightly raised.5. Remove the shock absorber.

CAUTIONWhen removing parts such as fuel tank, rear suspension,etc. use a hydraulic floor jack at the front of vehicle (Referto GENERAL GROUP), to prevent the vehicle from tilting.

55-8 REAR SUSPENSION

6. Lower the jack. Remove the coil spring and temporarily installthe shock absorber to the suspension arm.

7. Disconnect the brake hose at the suspension arm and removethe rear suspension arm from the body as an assembly.

INSPECTION

1. Check the suspension arm for distortion or damage.2. Check the suspension shaft for distortion or damage.3. Check the dust cover for damage.4. Check the shock absorbers for malfunction, oil leakage or

noise.5. Check the coil springs for deterioration, cracks or damage.6. Check the spring seats and bump stoppers for damage.7. Check the stabilizer bar for damage.

DISASSEMBLY

1. Before the fixtures are removed, make alignment marks on thefixtures and suspension arms for reference during reassembly.

2. Loosen the nuts at both ends of the suspension arm to removethe fixtures and rubber bushings.

3. Before the rear suspension on cars with a rear stabilizer bar isdisassembled, put aligning marks on each end of the stabilizerbar in alignment with the punch mark on the stabilizer barbracket.Then, while the rear suspension is separated into the right andleft arms, remove the stabilizer from the bracket.

REAR SUSPENSION

4. Remove the dust cover clamp.5. Separate the suspension arm into the right and left arms. Leave

the dust cover attached to the right suspension arm to protectthe lip from damage.

6. Remove the rubber stopper from the right arm.

7. Using a flat-blade screwdriver, remove bushing A.

8. Using a hammer and drift, drive bushing B out of the leftsuspension arm.

REASSEMBLY

1. Apply the specified grease to the inside of the left suspension.

55-10 REAR SUSPENSION

2. Using special tools (09555-21100, 0955521000) drive bush-ings B and A, in that order, into the suspension arm.

CAUTION1) Apply grease to all outside surfaces of bushings B and

A.2) Drive bushing B in until the notch on the special tool

(09555-21000) reaches the end of the suspension arm.

3. When replacing the dust cover, insert a new one up to thecenter position (stopper) of the right suspension arm.

4. After applying grease to the surface of the right suspensionarm, install the rubber stopper.

5. Slowly push the right and left suspension arms together. Wipeaway the surplus grease. Align the marks on the stabilizer barand the stabilizer bar bracket.

6. Install the rubber bushings, fixtures and washers.

7. After aligning the fixtures with the suspension arms accordingto the alignment marks, loosely tighten the nuts.

CAUTION1) Install the washers and fixtures in the correct direction

and position as shown.2) Tighten the nut to specification with the vehicle low-

ered to the floor.

REAR SUSPENSION 55-11

8. Pack grease in the dust cover and lips, and secure the dustcover with the clamp.

INSTALLATION

1. Tighten the fixture attaching bolts to the specified torque.2. Install the coil springs.

3. Loosely install the shock absorbers.

CAUTIONTighten the nut to specification with the vehicle loweredto the floor.

4. Install the rear brake assembly.5. Install the wheel and tire assembly.6. Lower the vehicle and tighten the suspension arm end nuts and

shock absorber bolts to the specified torque.7. Bleed the brake system.8. Adjust the rear brake shoe clearance.

55-12 REAR AXLE HUB

REAR AXLE HUB

COMPONENTS

150-200 (1,500-2,000, 108-145)


REMOVAL

1. Jack up the rear of the vehicle and support it on jack stands.2. Remove the wheel and tire.2. Remove the brake drum.

DISASSEMBLY

1. Using a flat-blade screwdriver, remove the oil seal from thedrum.

REAR AXLE HUB 55-13

2. After removing grease from inside the hub, remove the bearingouter races, using a hammer and drift.

INSPECTION

1. Check for a damaged or worn bearing.2. Check for a worn or damaged brake drum inside surface.

ASSEMBLY

1. After applying the specified grease to the bearing surface, drivethe bearing outer races into position.

2. Install the inside bearing inner race.3. Install the grease seal and apply grease to the seal lips.

NOTEBe sure to use a new grease seal.

4. Install the outside bearing inner race.

09517-21400

55-14 REAR AXLE HUB

INSTALLATION

1. Before installing the rear hub assembly, inspect the rear wheelbearing nut using the following method to determine whether itis reusable or not.1) Screw in the rear wheel bearing nut on the spindle until the

gap shown in the illustration is achieved.2) Measure the torque required to rotate the rear wheel

bearing nut while backing it off (turning it counter-clockwise).

Limit : 5.5 Nm (48 ft.lbs.)

3) If the measured torque is less than the limit, replace the rearwheel bearing nut with a new one.

2. Install and tighten the self-locking nut to the specified torque.Check the wheel bearing for end play and starting force. (Referto Page 55-6)

3. After filling the hubcap with multipurpose grease, install the hubcap.

Grease

STEERINGSYSTEMReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

STEERING COLUMN AND SHAFT . . . . . . . . . . . . . . . . . . 14

MANUAL STEERING GEAR BOX . . . . . . . . . . . . . . . . 20

TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

POWER STEERING GEAR BOX . . . . . . . . . . . . . . . . 31

POWER STEERING OIL PUMP . . . . . . . . . . . . . . 44

POWER STEERING HOSES . . . . . . . . . . . . . . . . . . . . . . 49

56-2 GENERAL


Manual SteeringShaft and joint typeSteering gear typeRack stroke

Power SteeringShaft and joint typeSteering gear typeRack strokeOil pump typeOil pump displacementOil pump pressure switch operating pressure

Collapsible, cross joints (two joints used)Rack and pinion132 mm (lock to lock : 3.7 turns)

Collapsible, cross joints, tilt column with pop-upRack and pinion132 mm (lock to lock : 2.89 turns)Vane type9.6 cm#/rev. (0.59 in#/rev.)1.5-2.0 MPa (15-20 kg/cm2, 213-284 psi)

SERVICE STANDARD

Manual SteeringStandard valueSteering wheel free playSteering angle

inner wheelOuter wheelDifference between LH and RH

Tie rod end ball joint starting torqueTotal pinion preload

±180° or less from neutral±180° or more from neutral

Tie rod swing resistancePower Steering

Standard valueSteering wheel free playSteering angle

inner wheelOuter wheel

Difference between LH and RHStationary steering effortBelt deflection [under 98N (10 kg, 22 lb) force]Oil pump relief pressureTotal pinion preload (MANDO)Total pinion preload (TRW)Tie rod swing resistance

0-30 mm (0-1.1 in.)

37°40' ± 1°5'31°52'2° or less0.5-2.5 Nm (5-25 kg.cm, 4-22 Ib.in.)

0.4-1.1 Nm (4-11 kg.cm, 3.5-9.5 Ib.in.)0.3-1.6 Nm (3-16 kg.cm, 2.6-14 Ib.in.)2-5 Nm (20-50 kg.cm, 1.4-3.6 Ib.ft)

0-30 mm (0-1.1 in.)

37°40' ± 1°5'31°52'2° or less39.23 N (4 kg, 8.8 Ibs) or less7-10 mm6.2 MPa (65 kg/cm2, 924 psi)0.6-1.3 Nm (6-13 kg.cm, 5.2-11.3 Ib.in.)0.6-1.5 Nm (6-15 kg.cm, 5.2-13.2 Ib.in.)2-5 Nm (20-50 kg.cm, 1.4-3.6 Ib.ft)

GENERAL 56-3

TIGHTENING TORQUEN m kg.cm Ib.ft

Steering wheel lock nut 35-45 350-450 26-33Steering column and shaft assembly mounting bracket 13-18 130-180 10-13Steering shaft and joint 15-20 150-200 11-15Pinion gear and joint 15-20 150-200 11-15Dust cover mounting bolt 4-6 40-60 3-4.4Gear box mounting clamp 60-80 600-800 44-59Tie rod end lock nut 50-55 500-550 37-41Tie rod end ball joint slotted nut 15-34 150-340 11-25Rack support cover lock nut 50-70 500-700 37-52Rack support cover 7-12 70-120 5-9Tie rod to rack 80-100 800-1000 59-74[power steering only]Valve body housing to rack housing assemblyPressure and return tube mounting clipPressure and return tube to gear box (MANDO)Pressure and return tube to gear box (TRW)Pinion valve lock nut (MANDO)Pinion valve lock nut (TRW)Rack support plug lock nut (MANDO)Tie rod to rack (TRW)End plug (MANDO)End plug (TRW)Oil pump mounting bracket boltOil pump adjusting boltPressure hose mounting nut (to oil pump)Oil reservoir mounting boltReturn hose mounting clamp (to oil pump suction connector)Oil cooler tube mounting clip

20-30 200-300 15-228-12 80-120 6-912-18 120-180 9-1320-27 200-270 15-2020-30 200-300 15-2224-34 240-340 18-2550-70 500-700 37-5268-88 680-880 50-6550-70 500-700 36-5121-35 210-350 15-2620-27 200-270 15-2025-33 250-330 18-2416-24 160-240 12-188-12 80-120 6-93-5 30-50 2.2-3.68-12 80-120 6-9

LUBRICANTS

Teeth of rack and pinion

Moving parts of rack and bushings

Recommended lubricant

Multipurpose greaseSAE J310, NLGI No.2Multipurpose greaseSAE J310, NLGI No.2

Quantity

As required

As required

Moving parts of pinion and needle bearing

Lip of gear box oil seal

Tie rod side groove of bellows

Multipurpose greaseSAE J310, NLGI No.2Multipurpose greaseSAE J310, NLGI No.2Multipurpose greaseSAE J310, NLGI No.3

As required

As required

As required

Inside surface and lip of tie rod end dust cover

Power steering fluid

Multipurpose greaseSAE J310, NLGI No.2ATF DEXRONell type

As required

0.9 liter (0.95 qts.)

GENERAL

SPECIAL TOOLS

GENERAL 56-5

56-6 GENERAL

TROUBLESHOOTING (Manual Steering)


Excessive play of steeringwheel

Steering wheel operationis hard

Steering wheel does notreturn properly

Loose rack support coverLoose steering gear mounting boltsLoose or worn tie-rod end

Excessive turning resistance of tie-rod balljointExcessively tightened rack support coverRough turning of inner tie-rod and/or ball jointDistorted rackWorn steering shaft joint and/or body grommetDamaged pinion bearing

Excessive turning resistance of tie-rod ball jointExcessively tightened rack support coverRough turning of inner tie-rod and/or ball jointWorn steering shaft joint and/or body grommetDistorted rackDamaged pinion bearing

Remedy

RetightenRetightenRetighten or replace asnecessary

Replace

AdjustLubricate or replace ball jointReplaceReplaceReplace

ReplaceAdjustReplaceCorrect or replaceReplaceReplace

GENERAL 56-7

TROUBLESHOOTING (Power Steering)

Symptom

Excessive play ofsteering wheel

Probable cause

Loose rack support coverLoose steering gear mounting boltsLoose or worn tie-rod end

Steering wheel V-belt slippageoperation is heavy Damaged V-belt(Insufficient power Low fluid levelassist) Air in the fluid

The steering wheeldoes not returnproperly

Noise

Twisted or damaged hosesInsufficient oil pump pressureSticky flow control valveExcessive internal oil pump leakageExcessive oil leaks from rack and pinionin gear boxDistorted or damaged gear box or valve bodyseal ring

Excessive turning resistance of tie-rod endExcessively tightened rack support coverRough turning or inner tie-rod and/or ball jointLoose mounting of gear box to gear boxmounting bracketWorn steering shaft joint and/or body grommetDistorted rackDamaged pinion bearingTwisted or damaged hosesDamaged oil pressure control valveDamaged oil pump input shaft bearing

Hissing Noise in Steering Gear

Remedy

RetightenRetightenRetighten or replace as necessary

CheckReplaceReplenishBleed airCorrect the routing or replaceRepair or replace the oil pumpReplaceReplace damaged partsReplace damaged parts

Replace

ReplaceAdjustReplaceRetighten

Correct or replaceReplaceReplaceReroute or replaceReplaceReplace

There is some noise in all power steering systems. One of the most common is ahissing sound when the steering wheel is turned and the car is not moving. This noisewill be most evident when turning the wheel while the brakes are applied.There is no relationship between this noise and steering performance. Do not replacethe valve unless the “hissing” noise is extremely objectionable. A replacement valvewill also have a slight noise, and is not always a cure for the condition.

GENERAL

Symptom

Rattling or chuckingnoise in rack andpinion

Noise in the oil pump

Probable cause

Interference with hoses from vehicle bodyLoose gear box bracketLoose tie-rod end and/or ball jointWorn tie-rod end and/or ball joint

Low fluid levelAir in the fluidLoose pump mounting bolts

Remedy

RerouteRetightenRetightenReplace

ReplenishBleed airRetighten

NOTEA slight “grinding noise” may be heard immediately after the engine is started in extremely cold whethercondition (below -20°C): This is due to power steering fluid characteristics in extreme cold conditions and is nota malfunction.

GENERAL 56-9

SERVICE ADJUSTMENT PROCEDUREChecking Steering Wheel Free Play

1. Start the engine and with the steering wheel in the straightahead position, apply a force of 5 N (1.1 lb) while turning thesteering wheel.

2. Measure the play at the circumference of the steering wheel.

Steering wheel free play [Standard value] . . . . . . . . . . . . . . . . . . .0-30 mm (0-1.1 in.)

3. If the play exceeds the standard value, inspect the contact ofthe steering shaft and tie rod ends.

Checking Steering Angle

1. Place the front wheel on a turning radius gauge and measurethe steering angle.

Steering angle [Standard value]Inner wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37°40' ± 1°5'Outer wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31°52'

2. If the measured value is not within the standard value, adjustthe linkage.

Checking Tie Rod End Ball Joint Starting Torque1. Mount two nuts on the ball joint, and then measure the starting

torque.

Tie rod end ball joint starting torque[Standard value] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.5-2.5 Nm (5-25 kg.cm, 4.3-21.7 Ib.in.)

2. If the starting torque exceeds the standard value, replacethe tie rod end.

NOTEEven if the starting torque is below limit of the standardvalue, the ball joint may be reused unless it has drag andexcessive play.

56-10 GENERAL

Checking Stationary Steering Effort(power steering)

1. Place the vehicle on a level surface and place the steeringwheel in the straight ahead position.

2. Increase the engine speed to 1,000 rpm.

CAUTIONAfter checking, reset the engine speed to the standardvalue (idling speed).

3. Measure the turning force with a spring scale by turning thesteering wheel clockwise and countclockwise one and a halfturns.

Stationary steering effort [Standard value] . . . . . . . . . . . . . . . . .39.23 N (4 kg, 8.8 Ibs) or less

4. Check that there is no excessive force change while turning thesteering wheel.

5. If the stationary steering effort is excessive, check and adjustthe following points:1) Damage or cracks of the dust covers of the lower arm ball

joint and tie rod end.2) Pinion preload of the steering gear box and turning starting

torque of the tie rod end ball joint.3) Turning starting torque of the lower arm ball joint.

Checking Steering Wheel Return

Check the steering wheel return and confirm the following points:1. The force required to turn the steering wheel and the wheel

return should be the same for both moderate and sharp turns.2. When the steering wheel is turned 90A and held for a couple of

seconds while the vehicle is being driven at 35 km/h (22 mph),the steering wheel should return at least 70% when it isreleased.

NOTEIf the steering wheel is turned very quickly, operation maybe momentarily heavy. This is not a malfunction, espe-cially during idling, because the oil pump output will besomewhat decreased.

GENERAL 56-11

Checking Power Steering Fluid Level

1. Position the vehicle on a level surface.2. Start the engine. With the vehicle kept stationary, turn the

steering wheel several times continuously to raise the fluidtemperature from 50-60°C (122-140°F).

3. With the engine at idle, turn the steering wheel fully clockwiseand counterclockwise several times.

4. Make sure there is no foaming or cloudiness in the reservoirfluid.

5. Stop the engine to check for a difference in fluid level betweena stationary and a running engine.

NOTE1) If the fluid level varies 5 mm (0.2 in.) or more, bleed the

system again.2) If the fluid level suddenly rises after stopping the

engine, insufficient bleeding is indicated.3) Incomplete bleeding will produce a chattering sound

in the pump and a noise in the flow control valve,decreasing durability of the pump.

Replacing Power Steering Fluid

1. Jack up the front of the car and support with rigid racks.2. Disconnect the return hose from the oil reservoir and plug the

oil reservoir.3. Connect a hose to the disconnected return hose, and drain the

oil into a container.4. Disconnect the high-tension cable at the ignition coil side.

While operating the starter motor intermittently, turn the steeringwheel all the way to the left and then to the right several timesto drain the fluid.

5. Connect the return hoses, then fill the oil reservoir with thespecified fluid.

6. Bleed the system.Automatic transmission fluid DEXRONe II type:Total quantity : Approx. 0.9 liter (0.95 qts.)

Air Bleeding

1. Jack up the front wheels and support them by using a floorstand.

2. Manually turn the oil pump pulley a few times.3. Turn the steering wheel all the way to the left and to the right five

or six times.4. Disconnect the high tension cable, and then, while operating the

starter motor intermittently (for 15 to 20 seconds), turn thesteering wheel all the way to the left and then to the right five orsix times.

CAUTION1) During air bleeding, replenish the fluid supply so that

the level does not fall below the lower position of thefilter.

2) If air bleeding is done while the vehicle is idling, theair will be broken up and absorbed into the fluid. Besure to do the bleeding only while cranking.

Difference in fluid levels:Within 5 mm (0.2 in.)

While engine When engineis running is stopped

56-12 GENERAL

5.6.

7.

8.

Connect the high tension cable, and then start the engine.Turn the steering wheel to the left and then to the right, untilthere are no air bubbles in the oil reservoir.

CAUTIONDo not hold the steering wheel turned all the way to eitherstop for longer than ten seconds.

Confirm that the fluid is not milky, and that the level is up to thespecified position.Check that there is little change in the fluid level when thesteering wheel is turned left and right.

CAUTION1) If the level of the fluid changes considerably, air

bleeding should be done again.2) If the fluid level rises suddenly when the engine is

stopped, it indicates that there is still air in the system.3) If there is air in the system, a jingling noise may be

heard from the pump and the control valve. Air in thesystem will shorten the life of the pump and otherparts.

Checking Power Steering Belt Tension

1. Depress the V-belt by applying a pressure of 98 N (10 kg, 22 lb)at the specified point, and measure the deflection to confirmthat it is within the standard value.

V-belt deflection [Standard value] . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 mm (0.28-0.39 in.)

2. To adjust the belt tension, loosen the oil pump mounting bolts,move the oil pump, and then retighten the bolts.

GENERAL 56-13

Oil Pump Pressure Test

1. Disconnect the pressure hose from the oil pump. Connect thespecial tool between the oil pump and pressure hose asillustrated.

2.

3.4.

Bleed the air, and then start the engine and turn the steeringwheel several times so that the fluid temperature rises toapproximately 50°C (122°F).Increase the engine speed to 1,000 rpm.Close the shut-off valve of the special tool and measure the fluidpressure to confirm that it is within the standard value range.

Oil pump pressure [Standard value]Relief pressure . . . . . . . . . . . . . . . . . 6.2 MPa (65 kg/cm2, 924 psi)

CAUTIONDo not keep the shut-off valve on the pressure gaugeclosed for no more than ten seconds.

5. Remove the special tools, and tighten the pressure hose to thespecified torque.

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-24 Nm (160-240 kg.cm, 12-18 Ib.ft)

6. Bleed the system.

56-14 STEERING COLUMN AND SHAFT

STEERING COLUMN AND SHAFT

COMPONENTS

[NORMAL]

[TILT STEERING]


STEERING COLUMN AND SHAFT 56-15

REMOVAL

1. Remove the horn cover assembly.2. Remove the upper and lower horn plate, and disconnect the

horn button connector.

3. Remove the steering wheel lock nut.4. After making alignment marks on the steering shaft and wheel,

remove the steering wheel, using the Special Tool (09561-11002).

CAUTIONDo not hammer on the steering wheel to remove it: doingso may damage the steering column.

5. Remove the lower crash pad, and disconnect the rheostatconnector.

6. Remove the column shroud.

7. Disconnect the connectors.

8. Remove the multifunction switch.


9. Remove the bolt coupling the universal joint and pinion.

10. After removing the bolts used to secure the column bracket tothe frame, remove the steering column and shaft assembly.

DISASSEMBLY

1. Loosen the column shaft to universal joint bolt, and remove theuniversal joint.

2. If necessary to remove the steering lock, cut a slot in themounting screw heads and bracket with a hack saw. Loosen thescrews with a flat-blade screwdriver to remove the steeringwheel lock.

CAUTIONWhen the steering wheel lock is reinstalled, the steeringwheel lock assembly and screws should be replaced withnew parts.

3. If necessary, remove the tilt steering lever and mountingbracket. (Tilt steering only)

NOTEDo not disassemble the steering column and shaft.

STEERING COLUMN AND SHAFT 56-17

INSPECTION

1. Check the steering column and shaft for damage and distortion.2. Check the joints for play, damage or rough movement.3. Check the tilt bracket and spring for cracks and damage.4. Check that the steering lock mechanism operates properly.5. Check the dust cover for cracks or damage.

If necessary, replace.

ASSEMBLY

1. Assembly is reverse of the disassembly procedure.2. Align the steering lock with the column boss and insert the

ignition key to verify the steering lock operation before tighteningthe lock to specifications.

CAUTIONUse the special one way screws to install the lock.

INSTALLATION

[NORMAL]

1. Installation the universal joint to the column shaft.

NOTEMake sure that the joint is installed in the correct directionas illustrated. In securing, be sure that bolt is installedcorrectly to the gear box pinion groove and the end of boltis protruded on the opposite side of the universal jointyoke.

2. Mount the steering column shaft to the mounting frame.

CAUTIONWhen installing, be careful not to distort the steeringcolumn.

3.4.5.

Install the multifunction switch and connect the connectors.Install the column shroud.Connect the rheostat connector and install the lower crashpad.

6. Install the steering wheel.

NOTEWhen the steering wheel is installed, make sure that thealignment marks are in alignment and that the steeringwheel is in the straight ahead position.


[TILT STEERING]

1. Installation the universal joint to the gear box.

NOTEIn case of the tilt steering column, please observe thefollowing.Failure to observe these instructions could be a cause ofthe deformation of the tilt bracket which may result inheavy tilt lever operation and inoperative pop-up.

2. Before installation, make sure if a pin hole exists on thedistance bracket.1) If it does, lock the tilt around a neutral position and install a

pin stopper (P/No. : 56357-24100) to the hole.And then unlock the tilt lever.

2) If not, lock the tilt around a neutral position.

3. Install the bolt coupling the column shaft with the U-joint.

Specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-20 Nm (150-200 kg.cm, 11-15 Ib.ft)

4. Install two mounting bolts temporarily.

Neutral

STEERING COLUMN AND SHAFT

5. Install two mounting nuts.

Specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-18 Nm (130-180 kg.cm, 10-13 Ib.ft)

6. Tighten the two mounting bolts completely.

Specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-18 Nm (130-180 kg.c., 10-13 Ib.ft)

7. If the pin stopper is installed, pull it off in a low tilt position.

MANUAL STEERING GEAR BOX


COMPONENTS


REMOVAL

1. Remove the wheel and tire assembly.2. Remove the coupling bolt.

MANUAL STEERING GEAR BOX 56-21

3. Remove the tie rods from the knuckle arms, using the SpecialTool (09568-31000).

4. Remove the rack and pinion assembly from the gear boxmounting.

DISASSEMBLY

Before disassembly, measure the rack starting force and pinionstarting torque in the neutral (straight ahead) position for referenceat reassembly.

1. Clean the rack and pinion assembly and mount it in a soft-jawedvise.

CAUTIONWhen mounting the rack in the vise, wrap a cloth aroundthe rack and be careful not to damage the rack whentightening the vise.

2. Remove the tie rod assembly.3. Remove the lock nut from the yoke plug.

4. Using Special Tool (09565-21100), remove the yoke plug.

56-22 MANUAL STEERING GEAR BOX

5. Remove the yoke spring, cushion rubber and support yokefrom the gear box.

6. Remove the dust cap.7. Remove the oil seal from the gear box.

8. Remove the snap ring from the gear box. Remove the piniontogether with the bearing.

9. Remove the bearing retainer snap ring from the pinion.

10. Using Special Tool (09565-21000), remove the bearing fromthe pinion.


11.12.

13.

Remove the bellows.Using a chisel, unstake the right side rack end nut.

Move the rack all the way towards the rack housing and hold thetoothed portion of the rack in a soft-jawed vise. Loosen the tierod end and remove the tie rod assembly from the rack.


14. Remove the rack from the gear housing.

CAUTIONTo keep from damaging the bushing with the rack teeth,

remove the rack from the left side.

INSPECTION

Deterioration and damage Play in rack and bushing

Play noise or unsmoothrotation of needle bearing


ASSEMBLY

1. Prior to reassembly, clean all gear box components in asuitable solvent.

2. Press fit the bearing to the pinion with Special Tool (09565-21000).

56-25

3. Install the snap ring on the pinion.

4. Apply grease to the rack, pinion, bushing, needle roller bearingand other moving surfaces.

CAUTIONDo not seal the air passage in the housing bushing withgrease.

Recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multipurpose grease SAE J310a, NLGI grade No.2 LP

5. After inserting the rack into the gear housing, install the piniongear in mesh with the rack.

CAUTION1) Make sure that the rack is inserted into the gear

housing from the left side.2) Wipe away excessive grease.

6. Select and install the appropriate type of snap ring to minimizethe play in the axial direction on the pinion.

Thickness mm (in.) Identification color

1.590 (0.063)1.665 (0.066)1.740 (0.069)

BlueWhitYellow


7. Apply grease to the lip of the oil seal before installing the oil sealin the gear box.

NOTEBe sure to use a new oil seal.

8. Install the support yoke, cushion rubber, spring and yoke plugto the pinion gear box.

CAUTIONApply grease to the cupped portion of the support yoke.

9. Adjust the yoke plug, with Special Tool (09565-21000).Tighten the yoke plug to 11 Nm (112 kg.cm, 8 Ib.ft) and thenback off 30°-60° Secure the yoke plug with the lock nut.

CAUTION1) Adjust the yoke plug with the rack in the neutral

position.2) Apply a sealer between the lock nut and the housing.

Yoke plug lock nut tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . .50-70 Nm (500-700 kg.cm, 37-52 Ib.ft)

10. Install the tie rod end and bellows. Use a new locking plate andstake each end.

11. The combined preload of the pinion (with bellows and grease)should be measured by turning the pinion at a rate of onerevolution every 4-6 seconds with Special Tool (09565-11100).The rack starting force should also be measured.

CAUTIONThe pinion preload should be measured over the fullstroke of the rack.

Total pinion preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .± 180° or less from neutral

0.4-1.1 Nm (4-11 kg.cm, 3.5-9.5 Ib.in.)± 180° or more from neutral

0.3-1.6 Nm (3-16 kg.cm, 2.4-14 Ib.in.)Rack starting force . . . . . . . . . . . . . . 50-300 N (5-30 kg, 11-66 lb)

12. If the measured values are out of specification, replace thecushion rubber and yoke spring and readjust in accordancewith step 9.


INSTALLATION

1. Install the rubber mount on the gear box as shown.

2. Install the pinion in the coupling and install the rack and pinionassembly to the crossmember.

CAUTION1) Make sure that the rack and pinion assembly is not

tilted or twisted when installed.2) Care must be taken not to apply excessive torque, as

it distorts the rack and pinion assembly and affects thesteering effort.

3. Tighten the coupling bolt.

Joint and pinion tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-20 Nm (150-200 kg.cm, 11-15 Ib.ft)

4. Install the tie rods on the steering knuckle.

CAUTIONAlign the slot of the nut with the split pin hole of the studand tighten the nut to specifications.

Tie rod ball joint and knuckle arm tightening torque . . . . . . . . . . .15-34 Nm (150-340 kg.cm, 11-25 Ib.ft)

5. Adjust the wheel alignment.6. After confirming that the bellows are not twisted, install the clip

on the end of the bellows.

56-28 TIE ROD

TIE ROD

COMPONENTS

REMOVAL

Remove the rack and pinion and tie rods from the vehicle as anassembly.

DISASSEMBLY

1. Mount the rack and pinion assembly in a vise.

CAUTIONWhen mounting the rack in the vise, wrap a cloth aroundthe rack and be careful not to damage the rack whentightening the vise.

2. Cut the bellows mounting band and remove the bellows.

TIE ROD 56-29

3. Unstake the tie rods with a chisel.

CAUTIONIf the rack is to be removed, remove the left side tie rod endjoint from the knuckle.

4. After moving the rack fully to the right, mount the rack in a softjawed vise, and remove the left tie rod.

5. Remove the right tie rod by the same procedures described insteps (3) and (4).

INSPECTION

1. Damaged or distorted tie rods and ends.2. Damaged or distorted bellows and dust cover.3. Tie rod oscillating torque.

Tie rod oscillating torque [Standard value] . . . . . . . . . . . . . . . . . . . .2-5 Nm (20-50 kg.cm, 17-43 Ib.in.)

4. Tie rod ball joint operation and axial play.

ASSEMBLY

1. After installing the tie rods to the rack to the specified torque,secure by staking the rack keyway.

Tie rod to rack tightening torqueMANDO . . . . . . . . . . . . . . . 80-100 Nm (800-1,000 kg.cm, 59-74 Ib.ft)TRW . . . . . . . . . . . . . . . . . . . 68-88 Nm (680-880 kg.cm, 50-65 Ib.ft)

56-30 TIE ROD

2.

3.

4.

After installing the bellows on the gear housing, secure with amounting band.

CAUTIONThe bellows mounting band should be installed afteradjustment of toe-in.

Measure the rack stroke.

NOTEThe full stroke of the rack determines the maximumsteering angle.

Rack full stroke (lock to lock) . . . . . . . . . . . . . . . . . 132 mm (5.20 in.)

Adjust the length of the tie rods and tighten the lock nut.

Tie rod length [Standard value] . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174.3-176.3 mm (7.06-7.14 in.)

Tie rod lock nut tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . .50-55 Nm (500-550 kg.cm, 37-41 Ib.ft)

INSTALLATION

1. Install the rack and pinion and tie rods as an assembly to thevehicle.

POWER STEERING GEAR BOX

POWER STEERING GEAR BOX (MANDO)

COMPONENTS


POWER STEERING GEAR BOX (TRW)

COMPONENTS


POWER STEERING GEAR BOX 56-33

REMOVAL

1. Using special tool, disconnect the tie rod end from the knuckle.

2. Disconnect the shaft assembly from the gear box inside thepassenger compartment.

3. Drain the fluid.4. Disconnect the pressure and return hoses from the gear box.5. Remove the band from the steering joint cover.

6. Remove the gear box mounting bolts.7. Pull the gear box out toward the right side of the vehicle.

CAUTIONWhen the gear box is to be removed, pull it out carefullyand slowly so as not to cause damage to the boots.

INSPECTION AND ADJUSTMENT PRIORTO DISASSEMBLYMount the gear box in a soft jawed vise.

CAUTIONDo not tighten the vise on the gear housing. Use themounting section of the rack to secure it in the vise.

56-34 POWER STEERING GEAR BOX

Total Pinion Preload

1. Rotate the pinion gear for approximately 4 to 6 seconds for onerotation to confirm the total pinion preload.

Total pinion preload [Standard value] . . . . . . . . . . . . . . . . . . . . . . . . .MANDO . . . . . . . . . . 0.6-1.3 Nm (6-13 kg.cm, 5.2-11.3 Ib.in.)TRW . . . . . . . . . . . 0.6-1.5 Nm (6-15 kg.cm, 5.2-13.2 Ib.in.)

CAUTIONMeasure the pinion preload through the entire stroke ofthe rack.

2. If the measured value is out of specifications, first adjust therack support cover, then re-check the total pinion preload.

3. If the rack support cover adjustment does not obtain the totalpinion preload, check or replace the rack support cover compo-nents.

Tie Rod Swing Resistance

1. Give 10 hard swings to the tie rod.2. Measure the tie rod swing resistance with a spring scale.

Tie rod swing resistance [Standard value] . . . . . . . . . . . . . . . . . . . . . . . . .8-22 N (6-16 lb)

[2-5 Nm (20-50 kg.cm, 17-43 Ib.in.)]

3. If the measured value exceeds the standard value, replace thetie rod assembly.

NOTEEven if the measured value is below the standard value, atie rod that swings smoothly without excessive play maybe used. If the measured value is below 4.3 N (0.9 Ib)[100Ncm (8.7 Ib.in.)], replace the tie rod.

Bellows Inspection

1. Inspect the bellows for damage or deterioration.2. Make sure the bellows are secured in the correct position.3. If the bellows are defective, replace them.


DISASSEMBLY (MANDO)

CAUTIONComponents inside of the TRW power steering gear boxshould not be repaired or replaced.If necessary, they will supply a complete gear box assem-bly for you.

1. Remove the tie rod end from the tie rod.

2. Remove the dust cover from the ball joint.

3. Remove the bellows band.

4. Remove the bellows clip.5. Pull the bellows out toward the tie rod.

6.7.

NOTECheck for rust on the rack when the bellows are replaced.

Remove the feed line from the gear housing.While moving the rack slowly, drain the fluid from the gearhousing.

8. Remove the end plug.9. With the pinion turned clockwise until the rack is locked, remove

the self-locking nut.


10. Unstake the tab washer between the tie rod and rack with achisel.

11. Remove the tie rod from the rack.

CAUTIONRemove the tie rod from the rack, taking care not to twistthe rack.

12. Remove the rack support cover locking nut.

13.

14. Remove the rack support spring, rack support and bushing

Using Special Tool (09565-21100), remove the rack supportcover.

from the gear box.

15. Remove the valve body housing by loosening the two bolts.

16. Turn the rack stopper clockwise until the end of the circlipcomes out of the slot in the gear housing.

17. When the end of the circlip comes out from the notched hole ofthe housing rack cylinder, turn the rack stopper counterclockwise and remove the circlip.


18. Remove the rack stopper, rack bushing and rack from the gearhousing by moving it toward the pinion side.

CAUTIONWhen the rack has been removed, be sure to replace thehousing side oil seal.

19. Remove the O-ring from the rack bushing.

POWER STEERING GEAR BOX

20. Remove the oil seal from the rack bushing.

21. Remove the valve body from valve body housing with a softhammer.

22. Use the special tool (09565-21000) to remove the oil seal andball bearing from the valve body housing.

23. Use the special tool (09517-21400) to remove the ball bearingfrom the gear housing.

CAUTIONBe careful not to damage the pinion valve cylinder insideof the gear housing.

24. Use the special tool (09517-21400) to remove the needlebearing from the gear housing.


25. Use the special tools (09573-21200, 09555-21000) to removethe back washer and oil seal from the gear housing.

09573-21200

CAUTIONBe careful not to damage the rack cylinder inside of thegear housing.

INSPECTION

1. Rack1) Rack tooth face damage or wear2) Oil seal contact surface damage3) Rack distortion4) Oil seal ring damage or wear5) Oil seal damage or wear

2. Pinion Valve1) Pinion gear tooth face damage or wear2) Oil seal contact surface damage3) Seal ring damage or wear4) Oil seal damage or wear

3. Bearing1) Seizure or abnormal noise during bearing rotation.2) Excessive play3) Missing needle bearings

4. Others1) Damage of the gear housing cylinder bore2) Boot damage or deterioration

ASSEMBLY

1. Apply the specified oil to the entire surface of the rack oil seal.

Recommended fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specified automatic transaxle fluid

2. Install the backup washer and oil seal to the specified positionin the gear housing.

09555-21000


3.

4.

5.

6.

Apply the specified grease to the entire surface of the needlebearing.

Recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipurpose grease SAE J310, NLGI No.2

Set the scribed side of the needle bearing in the Special Tool(09432-21600) and install it into the gear housing (until thespecial tool contacts the gear housing).

CAUTIONNote the direction of the needle bearing.

Apply the specified grease to the ball bearing and install usingthe special tool (09222-21100).

Recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multipurpose grease SAE J310, NLGI No.2

CAUTIONAlways use a new bearing

Apply the specified oil to the entire surface of the rack bushingoil seal.

Recommended fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specified automatic transaxle fluid

7. Install the oil seal in the rack bushing.8. Apply the specified oil to the entire surface of the O-ring and

install it in the rack bushing.

9. Apply the specified grease to the rack teeth

Recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multipurpose grease SAE J310, NLGI No.2

CAUTIONDo not plug the vent hole in the rack with grease.


10. Insert the rack into the gear housing.Install the rack bushing and rack stopper.

11. Push in the rack stopper until the circlip groove of the rackstopper is aligned with the notched hole of the rack housing.Install the circlip while turning the rack stopper.

CAUTIONThe circlip end should not be visible through the notchedhole of the rack housing.

12. Using Special Tool (09432-21600), install the oil seal and theball bearing in the valve body.

13. Apply the specified oil and grease to the pinion valve assemblyand install in the gear housing assembly.

Recommended fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specified automatic transaxle fluid

Recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multipurpose grease SAE J310, NLGI No.2

14. Apply the specified oil and then use the Special Tool (09434-14200) to install the seal in the valve body housing.


15. Install the valve body assembly with the seal ring to the gearbox.

16. Install the tab washer and the tie rod and stake the tab washerend at two points over the tie rod.

CAUTION1) Align the tab washer pawls with the rack grooves.2) Always use a new tab washer.

17. With the pinion turned all the way clockwise, tighten the self-locking nut.

CAUTIONAlways use a new nut.

18. Apply semi-drying sealant to the threaded section of the endplug and tighten to the specified torque.

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-70 Nm (500-700 kg.cm, 37-52 Ib.ft)

19. Stake the end plug at two points on its circumference with apunch.

20. Install the bushing, rack support, rack support spring and racksupport cover in the order shown. Apply semi-drying sealant tothe threaded section of the rack support cover before installa-tion.


21. With the rack placed in the center position, attach the racksupport cover to the gear housing. Tighten the rack supportcover within the range of 20-25 Nm (200-250, kgcm, 14.5-18Ib.ft), using the Special Tool (09565-21100). Loosen the racksupport cover approximately 10°, and tighten the locking nut tothe specified torque

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-70 Nm (500-700 kg.cm, 37-52 Ib.ft)

22. Tighten the feed tube to the specified torque and install themounting rubber using adhesive.

23. Apply the specified grease to the bellows mounting position(fitting groove) of the tie rod.

Recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multipurpose grease SAE J310, NLGI No.2

24. Install the attaching band to the bellows.

CAUTIONWhen the bellows are installed, a new band must be used.

25. Install the bellows in position, taking care not to twist it.

26. Fill the dust cover inner side and lip with the specified multi-purpose grease, and place the dust cover in position with theclip ring attached in the groove of the tie rod end.

27. Install the tie rods so that the length of the left and right tie rodsare equal.

Tie rod length [Standard value] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174.3-176.3 mm (6.86-694 in.)

28. Confirm the total pinion preload.

INSTALLATION1. Install with the projection on the mounting rubber of the gear

housing aligned with the holes in the clamp and gear housingbracket.

2. Apply adhesive to the cylinder side mounting rubber so that itsslitted part will not open.

3. Check that there are no oil leaks.4. Confirm the steering wheel rotates smoothly.5. Adjust the toe-in.6. Install all parts with reference to the torque specification.

56-44 POWER STEERING OIL PUMP

POWER STEERING OIL PUMP

COMPONENTS


REMOVAL

1. Remove the pressure hose from the oil pump.2. Disconnect the suction hose from the suction connector and

drain the fluid into a container.

POWER STEERING OIL PUMP 56-45

3. Loosen the oil pump mounting bolts to remove the V-belt.4. Remove the oil pump bracket mounting bolts and disconnect

the pressure switch connector.

DISASSEMBLY

1. Remove the suction connector and the O-ring from the oilpump.

2. Remove the rear cover with the gasket and pins.3. Remove the cam ring.4. Remove the rotor and vanes.5. Remove the front side plate.

6. Remove the inner and outer O-ring.7. Remove the spring.

NOTEWhen assembling, use a new gasket and O-ring.

8. Remove the pulley nut with the spring washer.9. Pull off the pulley and the woodruff key.


10. Remove the snap ring using snap ring pliers.11. Drive out the pulley shaft with the bearing.

If necessary, use plastic hammer.

12. Remove the oil seal from the oil pump body.

NOTEWhen assembling, use a new oil seal.

13. Remove the guide bracket and nut.14. Remove the connector from the oil pump body, and take out the

flow control valve and the flow control spring.15. Remove the O-ring from the connector.

CAUTIONDo not disassemble the flow control valve.

16. Remove the oil pump switch.17. Take out the spring and the spool.18. Remove the O-ring from the oil pump switch.

INSPECTION

1. Clean all disassembled parts with suitable cleaning solvent.2. If any inside parts of the oil pump have been damaged, replace

the pump as an assembly.3. If the pulley is cracked or deformed, replace it.4. If oil leaks from around pulley shaft oil seal, replace the oil seal.5. If the serrations of the pulley or pulley shaft are deformed or

worn, replace them.

POWER STEERING OIL PUMP 56-47

ASSEMBLY

1. Install the oil pump switch.2. Install the flow control valve spring, valve and connector in the

pump body.

NOTEApply a thin coat of A.T.F. to all the replaced partsincluding the oil seal and the O-ring.

3. Install the guide bracket and nut.

4. Using special tool (09222-32100), install the oil seal into thepump body.

5. Gently insert the shaft assembly and install the snap ring.6. Install the pump pulley with woodruff key in place.

7. Install the spring and the inner and outer O-rings.8. Install the front side plate.

9. Insert the pins into the pin grooves of front housing, then installthe cam ring, paying attention to its direction.


10. Install the rotor with its punch marked side facing towards thefront side plate.

11. Install the vane plates with the round end facing outward.

12. Install the gasket and the rear cover.13. Tighten the suction connector.

INSTALLATION

1.2.3.4.

Install the oil pump to the oil pump bracket.Install the suction hose.Install the V-belt and adjust the V-belt tension.Connect the pressure hose to the oil pump, and the return hoseto the oil reservoir.

NOTEInstall the hoses so that they are not twisted and they donot come in contact with any other parts.

5. Replenish the fluid.

Recommended fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7.8.

Bleed the system.Check the oil pump pressure.Install parts by reference to the torque specification.

Specified automatic transaxle fluid

POWER STEERING HOSES 56-49

POWER STEERING HOSES

COMPONENTS


REMOVAL (Return tube)

1. Drain the fluid.2. Disconnect the return hose from the oil reservoir.3. Remove the clip which secures the return tube to the vehicle

body.4. Disconnect the return tube from the gear box.

56-50 POWER STEERING HOSES

INSPECTION

1. Inspect the hoses for damage or deterioration.2. Confirm that there is no interference between the hoses and

any other parts.

INSTALLATION

Install all parts to the torque specifications.

BRAKESYSTEMReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 15

BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

BRAKE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

FRONT DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

58-2 GENERAL

GENERALGENERAL SPECIFICATIONS

Master cylinderTypeI.D.Fluid level warning sensor

Brake boosterTypeEffective dia.Boosting ratio

Proportioning valveCut-in pressure (Split point)Decompression ratio

Front brakeTypeDisc O.D.Disc thicknessPad thicknessCylinder I.D.

Rear brakeTypeDrum I.D.Brake lining thicknessCylinder I.D.Clearance adjustment

Parking brakeTypeBraking typeCable arrangement

Brake fluid

Tandem22.22 mm (0.875 in.)Provided

Vacuum230 mm (9. in.)4.0 : 1

3.43 MPa (35 kg/cm2, 498 psi)3.7 : 1

Floating type with ventilated disc242 mm (9.53 in.)19 mm (0.75 in.)10 mm (0.394 in.)54 mm (2.126 in.)

Leading-trailing drum180 mm (7.1 in.)4.5 mm (0.177 in.)20.62 mm (0.811 in.)Automatic

Mechanical brake acting on rear wheelsLever type (cam shape)V typeDOT 3 or equivalent

GENERAL 58-3

SERVICE STANDARD

Standard valueBrake pedal height 163-168 mm (6.417-6.614 in.)Brake pedal stroke 145 mm (5.70 in.)Stop light switch outer case to pedal arm clearance 0.5-1.0 mm (0.020-0.040 in.)Brake pedal free play 4-10 mm (0.394-0.519 in.)Brake pedal to floorboard clearance 50 mm (1.969 in.) or moreBooster push rod protruding dimension 5.59-5.97 mm (0.220-0.235 in.)Parking brake lever stroke (when lever assembly is 6-7 clicks

pulled with 196 N (20 Kg, 44 lb) force)Service limit

Front disc brake pad thicknessFront disc thicknessFront disc runoutDrum brake lining thicknessBrake drum I.D.Wheel cylinder to piston clearance

1.0 mm (0.039 in.)17 mm (0.669 in.)0.15 mm (0.006 in.)0.8 mm (0.0312 in.)182 mm (7.165 in.)0.15 mm (0.006 in.)

TIGHTENING TORQUE Nm kg.cm lb.ft

Master cylinder to booster mounting nutBrake booster mounting nutBrake booster hose fitting to manifoldBleeder screw : Front

RearBrake tube flare nutProportioning valve to master cylinderCaliper guide rod boltCaliper pin boltCaliper assembly to knuckleBrake hose to front caliperBacking plate mounting bolt

8-12 80-120 6-98-12 80-120 6-98-12 80-120 6-97-13 70-130 5-107-9 70-90 5-713-17 130-170 9-128-12 80-120 6-922-32 220-320 16-2435-45 350-450 26-3365-75 650-750 48-5525-30 250-300 18-2250-60 500-600 37-44

GENERAL

SPECIAL TOOL

Tool(Number and name) Illustration Use

09581-11000Piston expander

Retraction of the front disc brake piston

GENERAL 58-5

TROUBLESHOOTING

Symptom

Noise or vibration whenbrakes are applied

Vehicle pulls to one sidewhen brakes are applied

Insufficient braking power

Probable cause

Backing plate or caliper improperly mountedLoose backing plate or caliper mounting boltsUnevenly worn or cracked brake drum or brake discForeign material in brake drumSeized pad or lining contact surfaceExcessive caliper to pad assembly clearanceUneven pad contactLack of lubrication in sliding partsLoose suspension parts

Difference in left and right tire inflation pressureImproper front wheel alignmentInadequate contact of pad or liningGrease or oil on pad or lining surfaceDrum eccentricity or uneven wearIncorrect wheel cylinder installationAuto adjuster malfunction

Low or contaminated brake fluidAir in brake systemBrake booster malfunctionInadequate contact of pad or liningGrease or oil on pad surfaceAuto adjuster malfunctionOverheated brake rotor due to dragging of pador liningRestricted brake lineProportioning valve malfunction

Remedy

CorrectRetightenReplaceCleanReplaceCorrectCorrectLubricateRetighten

AdjustAdjustCorrectReplaceReplaceCorrectCorrect

Replenish or changeBleed the systemCorrectCorrectReplaceCorrectCorrect

CorrectReplace

increased pedal stroke(Reduced pedal tofloorboard clearance)

Air in brake system Bleed the systemBrake fluid leaks CorrectAuto adjuster malfunction CorrectExcessive push rod to master cylinder clearance Adjust

58-6 GENERAL

Symptom

Brake drag

Insufficient parkingbrake function

Probable cause

Incomplete release of parking brakeIncorrect parking brake adjustmentWeak brake pedal return springRestricted master cylinder return portBroken rear drum brake shoe return springLack of lubrication in sliding partsDefective master cylinder check valve orpiston return springInsufficient push rod to master cylinder clearance

Worn brake liningGrease or oil on lining surfaceParking brake cable stickingAuto adjuster malfunctionExcessive parking brake lever stroke

Remedy

CorrectAdjustReplaceCorrectReplaceLubricateReplaceAdjustReplace

ReplaceReplaceCorrectAdjust the parkingbrake lever stroke orcheck the parkingbrake cable routing

GENERAL 58-7

SERVICE ADJUSTMENT PROCEDUREBRAKE PEDAL INSPECTION AND ADJUSTMENT

1. Pedal height

Pedal height (from top of pedal to toeboard) A . . . . . . . . . . . . . . . . . . .163-168 mm (6.417-6.614 in.)

If the pedal height is out of specification, adjust by the followingprocedure.1) Back off the stop lamp switch to a position where it does not

contact the pedal arm.2) Turn the stop lamp switch until the clearance between the stop

lamp switch outer case and the pedal arm is within the standardvalue, and tighten the lock nut.

Clearance between pedal and stop lamp switch B . . . . . . . . . . . . . . . . . .0.5 to 1.0 mm (0.02 to 0.039 in.)

2. Brake pedal free play.

Brake pedal free play C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10 mm (0.157-0.394 in.)

3. Start the engine, apply the brake pedal with approximately 50kg (110 Ibs.) of force, and measure the clearance between thebrake pedal and the floor board.

Pedal to floor board clearance Dwhen pedal is depressed 50 kg (110 Ibs.) force . . . . . . . . . . . . . .

70 mm (2.76 in.) or morewhen pedal is fully depressed without brake fluid . . . . . . . . . . . .

50 mm (1.97 in.) or more

58-8 GENERAL

BRAKE BOOSTER OPERATION TEST WITHOUTA TESTER

For a simple check of the brake booster operation, make thefollowing tests.1. Run the engine for one or two minutes, then stop it. Depress the

brake pedal several times using normal foot pressure. If thepedal goes down further the first time, but gradually rises afterthe second or third time, the brake booster is functioningproperly. Go to step 2.

2. With the engine stopped, depress the brake pedal severaltimes.Depress the brake pedal and start the engine.If the pedal goes down slightly, the booster is in good condition.Go to step 3.

3. With the engine running, depress the brake pedal and then stopthe engine.Hold the pedal depressed for 30 seconds. If the pedal heightdoes not change, the booster is in good condition.

If one of the above three tests is not okay, check the vacuum hoses,the check valve and the brake booster. Make any necessarycorrections. If all the tests are OK, then the brake booster is good.

WITH PRESSURE GAUGES

Test the following two items. If either or both of them showunsatisfactory results, a malfunction of the check valve, vacuumhose and/or brake booster is suspected.

Prior to the test, connect a vacuum gauge, pressure gauges andfoot force gauge as shown in the illustration. Bleed the system.

GENERAL

TEST 1 - Boosting function test

Start the engine

Maintain a suction pressure of approx. 68 kPa (9.8 psi, 0.7 kg/cm*)by controlling the throttle opening control

Measure the fluid pressure by depressing the brake at two levels of force

Foot force Fluid pressure

N lb. MPa psi kg/cm2

100 22 2.5 to 4.9 360 to 710 25 to 50

290 66 8.1 to 10.7 1180 to 1555 83 to 110

Good

TEST P-Non boosting function test

With engine turned off, depress brake pedal several times.

Measure the fluid pressure by depressing the brake pedal at two levels of force.

Foot force Fluid pressure

N lb. MPa psi kg/cm2

100 22 0.2 or more 29 or more 2 or more

290 60 1.9 or more 275 or more 19 or more

Good

58-10 GENERAL

BLEEDING OF BRAKE SYSTEM

1. Remove the reservoir cap and fill the brake fluid reservoir.

CAUTIONDo not allow brake fluid to remain on a painted surface.Wash it off immediately.

NOTEWhen pressure bleeding the system, do not depress thebrake pedal.

2.

3.4.

Connect a vinyl tube to the wheel cylinder bleeder screw andinsert the other end of tube in a half full container of brake fluid.Slowly pump the brake pedal several times.While depressing the brake pedal fully, loosen the bleederscrew until fluid starts to run out. Then close the bleeder screw.

5. Repeat the 3 and 4 step until there are no more bubbles in thefluid.

6. Tighten the bleeder plug screw.

Bleeder screw tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . .Front : 7-13 Nm (70-130 kg.cm, 5-10 Ib.ft)Rear : 7-9 Nm (70-90 kg.cm, 5-7 Ib.ft)

7. Repeat the above procedure for each wheel in the sequenceshown in the illustration.

PARKING BRAKE STROKE ADJUSTMENT

1. Pull the brake lever with a force of approximately 20 kg (44 Ibs.),and count the number of clicks.

Parking brake lever stroke [Standard value] . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 clicks

2. If the number of notches is not within the standard value, adjustthe cable length with the adjusting nut of the equalizer.

58-11

3. The indicator light will go out when the brake lever is fullyreleased, and will light with the lever is pulled up one notch. Ifit does not operate, replace it.

4. After the adjustment, check that the rear brakes do not dragwith the parking brake lever released.

BRAKE PEDAL

BRAKE PEDAL

COMPONENTS

[Cable type clutch]

B R A K E P E D A L 58-13

REMOVAL

1. Remove the lower crash pad assembly.2. Remove the steering column shaft mounting bolts (Refer to

Steering Group).3. Remove the clutch pedal assembly.4. Remove the console assembly (Refer to Body Group)5. Remove the glove box housing cover and RH side lower crash

pad.6. Remove the blower switch and air duct control assembly.7. Drain the coolant, disconnect the heater hose and remove the

heater unit assembly (Refer to Air Conditioning Group).8. Remove the stop lamp switch connector.9. Remove the return spring.10. Disconnect the operating rod and brake pedal from each other.

11. Remove the stopper and the washer.

12. Loosen the booster mounting nut and remove the pedalsupport member (RH).

13. Remove the pedal support (LH) and remove the pedal.

INSPECTION

1. Check the bushing for wear.2. Check the brake pedal for distortion.3. Check the brake pedal return spring for damage.4. Check the stop lamp switch.

1) With an ohmmeter connected to the stop lamp switchterminals, check for continuity.

2) If there is no continuity when the plunger is depressed andthere is continuity when the plunger is released, the stoplamp switch is normal.

BRAKE SWITCH CHECK

58-14 BRAKE PEDAL

INSTALLATION

1. Apply chassis grease to the bushing bore and flanges.

NOTEInstall the bushing in the correct position as shown in theillustration.

2. Apply chassis grease to the sliding surface of the brake pedaland operating rod clevis pin.

CAUTIONBe sure to install the split pin on the operating rod clevispin.

3. Adjust the brake pedal height and free play.4. Adjust the clutch pedal stroke and free play.5. install the steering shaft.

MASTER CYLINDER 58-15

MASTER CYLINDER

COMPONENTS

Reservoir cap


REMOVAL

1. Remove the fluid level warning device connector.2. Disconnect the brake lines from the master cylinder, and plug

the open ports.

CAUTIONDo not allow brake fluid to remain on a painted surface.Wash it off immediately.

3. Remove the master cylinder mounting nuts. Disconnect theproportioning valve mounting bracket, then lift out the mastercylinder.

DISASSEMBLY

1. Remove the reservoir cap and drain the brake fluid into asuitable container.

2. Remove the reservoir from the master cylinder.

NOTEIf necessary, support the master cylinder in a vise at itsflange not at its bore.

3. While depressing the piston, remove the snap ring.

58-16 MASTER CYLINDER

4. Remove the primary and secondary pistons from the mastercylinder body.

NOTE1) Be careful not to damage the cylinder bore.2) Do not disassemble the primary and secondary piston

assemblies.

INSPECTION

1. Check the inner surface of the master cylinder body for rust orscoring.

2. Check the primary and secondary pistons for rust, scoring,wear, damage or deterioration.

3. Check the primary and secondary piston springs for deteriora-tion.

ASSEMBLY

1. Apply the specified brake fluid to the inner surface of the mastercylinder body and to the outside of the secondary and primarypistons.

Recommended brake fluid . . . . . . . . . . . . . DOT 3 or equivalent

2. Carefully insert the spring and secondary piston assembly inthe master cylinder bore.

3. Carefully insert the primary piston assembly in the mastercylinder bore.

4. Depress the primary piston and install the retaining ring in thecylinder bore groove as illustrated.

5. Install the reservoir cap on the master cylinder.6. Lubricate the two grommets at both inside and outside with

genuine brake fluid and then insert them into the mastercylinder body.

NOTEWhenever the reservoir is replaced, the grommets mustalso be replaced.

7. Press the reservoir into the grommets with the fluid levelindicator socket facing inboard. The reservoir should snap inplace indicating that it is secure as illustrated.

8. Connect the fluid level warning connector in the socket on thereservoir.

MASTER CYLINDER 58-17

INSTALLATION

1.

2.

3.

Install the master cylinder on the brake booster with twonuts.

Nut . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Nm (80-120 kg.cm, 6-9 Ib.ft)

Connect two brake tubes and fluid level warning connector.

Brake tube flare nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-17 Nm (130-170 kg.cm, 9-12 Ib.ft)

Fill the master cylinder reservoir with brake fluid and bleed thesystem.

BRAKE BOOSTER

BRAKE BOOSTER

COMPONENTS

Clamp

Brake booster assembly


CHECK VALVE OPERATION TEST

Remove the booster hose from the check valve.

Start the engine.

Plug the check valve hole with a finger.

Check on the basis of finger touch that vacuum is present

REMOVAL

1. Remove the master cylinder.(Refer to page 58-15)

CAUTIONDo not allow brake fluid to remain on a painted surface.Wash it off immediately

BRAKE BOOSTER 58-19

2. Disconnect the vacuum hose from the booster.3. Remove the operating rod from the brake pedal.4. Loosen the booster mounting nuts.5. Lift out the booster assembly.

INSTALLATION

1.

2.

3.

4.5.6.7.8.9.

When the booster assembly is installed, replace the packing ateach end of the booster mounting holder, if necessary.Install brake booster and tighten the mounting nuts.

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12 Nm (80-120 kg.cm, 6-9 Ib.ft)

Connect clevis to brake pedal with clevis pin and install the splitpin to the clevis pin.Install master cylinder.Connect vacuum hose to brake booster.Pay attention to the direction of the check valve when installing.Fill brake reservoir with brake fluid and bleed the system.Check for fluid leakage.Check and adjust the brake pedal (Refer to page 58-7).

10. After installation, apply sufficient grease to the clevis and brakepedal contacting points.

58-20 BRAKE LINE

BRAKE LINE

COMPONENTS


INSPECTION

1. Check the brake lines for cracks, crimps and corrosion.2. Check the brake hoses for cracks, damage and leakage.3. Check the brake line flare nuts for damage and leakage.

INSTALLATION

1. Install the brake hoses without twisting them.2. The brake lines should be installed away from sharp edges,

weld beads or moving parts.3. Tighten the connections to the specified torque.

Flare nuts . . . . . . . . . . . . . . 13-17 Nm (130-170 kg.cm, 9-12 Ib.ft)Brake hose to front caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25-30 Nm (250-300 kg.cm, 18-22 Ib.ft)

FRONT DISC BRAKE 58-21

FRONT DISC BRAKE

COMPONENTS


DISC BRAKE PAD

REMOVAL

1. Remove the wheel.2. Remove brake fluid from the master cylinder reservoir

until it is approximately half full.3. Unsnap the clip and remove the retaining pin.

CAUTIONDiscard retaining pin & clip and spacer;Retaining pin & clip and spacer must be replaced whenpads are replaced.

4. Rotate the caliper assembly about the locating pin until the padassemblies are exposed for removal.

58-22 FRONT DISC BRAKE

INSPECTION

1. Check the pads for wear or oil contamination and replace, ifnecessary.

CAUTIONThe pads for the right and left wheels should be replacedat the same time. Never “split” or intermix brake pad sets.All four pads must be replaced as a complete set.

Standard value Service limit

Pad thickness mm (in.)1.0 (0.394) 1.0 (0.039)

2. Check for worn or damaged anti-rattle spring, spacer,retaining pin and clip

CAUTIONSpacer and retaining pin & clip must be replaced at thesame time pads are replaced.

3. Check for worn or damaged dust boot and locating pin seal.

INSTALLATION

1. Install the pad clips.2. Install the inner and outer pads (The inner pad has the wear

indicator and is installed on the piston side of the rotor).

3. Seat the piston in the cylinder using Special Tool (09581-11000).

4. Install the new pads.


CALIPER ASSEMBLYREMOVAL

1. Remove the wheel2. Remove brale fluid from the master cylinder reservoir until it is

approximately half full.3. Disconnect the brake tube from the hose.4. Pull off the brake hose clip and remove the brake hose from the

strut.5. Unsnap the clip and remove the retaining pin.6. Slide the caliper inboard until the locating pin seal disengages

from its groove and remove housing assembly from locatingpin.

INSPECTION

1. Inspect locating pin for wear or damage. Replace if necessaryif locating pin is not replaced, clean and protect from damageror contamination.

INSPECTION

1. Check the caliper for wear, damage, cracks and rust.2. Check the piston for rust, damage, cracks and wear on the

outer surface.3. Check the sleeve and pin for damage and rust.4. Check the pad spring and boots for damage.5. Check the carrier for damage, rust, wear and cracks.

CAUTION1) Do not use sand paper on the piston surface.2) All rubber parts must be replaced with new parts.

DISASSEMBLY

1. Remove the piston boot.2. Remove the piston using compressed air.

CAUTIONFill space between the piston and outer shoe surface of thehousing with spacers to limit the travel of the piston as itmoves outward under pressure.Use a soft material, in front of the piston when usingcompressed air.

WARNING:Do not place fingers in front of the piston when usingcompressed air.

3. Remove the piston seal care must be used to avoid scratchingor damaging the piston bore during damage.

6. Inspect the disc using a caliper and dial gauge.


Thickness of disc mm (in.) 19 (0.75) 17 (0.67)Runout of disc mm (in.) 0.15 (0.006)

58-24 FRONT DISC BRAKE

7. If necessary, replace the brake disc.1) Remove the torque plate from the knuckle and suspend it

with a wire.2) Using special tool (09526-11001), disconnect the driveshaft

from the hub, and remove the brake disc and hub.3) Install the brake disc and hub assembly to the axle shaft.4) Install the axle nut and washer, then tighten the axle nut.

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200-260 Nm (2000-2600 kg.cm, 148-192 Ib.ft)

5) Install the torque plate onto the knuckle.

ASSEMBLY

1. Clean all components with isopropyl alcohol except the padsand shim.

2. Apply rubber grease to the piston seal and install the piston sealin the cylinder.

3. Assemble the piston and piston boots according to the followingprocedure.1) Apply rubber grease to the caliper bore, outside surface of

the piston and piston boot.2) Install the piston boot on the piston as illustrated.3) Insert the piston boot in the inner groove of caliper and slide

the piston into the caliper.


4. Assemble the sliding parts according to the following proce-dure1) Apply rubber grease to the outside surface of the sleeve and

pin, pin and sleeve bore of the caliper, pin boot and sleeveboot.

2) Insert the boots into the groove of the caliper.

5. Install the pads.

NOTEDo not apply grease to the disc or pads.

6. Tighten the brake hose connecting bolt.

Tightening torque Nm (kg.cm, Ib.ft)

Sliding pin 35-45 (350-450, 26-33)Sliding bolt 22-32 (220-320, 16-24)Carrier mounting bolt 64-75 (650-750, 48-55)Brake hose mounting oil bolt 25-30 (250-300, 18-22)

NOTE1) Check that the surfaces of the pin and bolts are not

damaged before tightening.2) Bleed the system.

Depress the pedal several times and check for fluidleakage from all connecting parts.

58-26 REAR DRUM BRAKE

REAR DRUM BRAKE

COMPONENTS


REMOVAL

1. After removing the wheel, remove the brake drum.2. Remove the automatic adjuster spring and adjuster lever.

3. Spread the shoes and remove the adjusting screw, nut, socket& washer assembly.

4. Remove the shoe to shoe spring and shoe hold down spring &cup assembly.

5. Remove the parking cable at the parking lever.6. Remove the retaining ring on the parking brake cable at the

backing plate.7. Remove the brake line from the wheel cylinder.8. Remove the wheel cylinder assembly together with the backing

plate.

REAR DRUM BRAKE 58-27

INSPECTION

1.2.

3.

5.

6.

Inspect the backing plate for distortion and damage.Inspect the wheel cylinder for excessive corrosion ordamage.Inspect the brake lining and drum for proper contact.

Measure the brake drum inside diammer.Check the runout of brake drum using a dial indicator.Measure the brake shoe lining thickness.


Drum inside diameter 180 (7.1) 182 (7.165)Brake drum runout 0.015 (0.0006)Lining thickness 4.5 (0.177) 0.8 (0.0312)

INSTALLATION

1. Apply a light coating of grease to the following surfaces.o Six ledges of the backing plate.o Where shoe web contacts anchor plate.o Where automatic adjuster lever contacts adjuster socket

and automatic adjuster pin.o Where parking brake lever contacts shoe web (strut area).

2.

3.

Recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wolfracote grease per ES-2825or equivalent multipurpose grease SAE J310,NLGI No.0 to 1

Apply a thin uniform coat of multi-purpose long-life lubricant toadjuster screw threads and socket end of the adjusting screw.Install adjusting screw washer over socket end of the adjustingscrew and install socket. Turn adjusting screw into adjustingpivot nut to the limit of threads then back-off one half turn.

Assemble parking brake lever to trailing shoe and lining assem-bly by installing spring washer and a new parking brake leverpin retainer. Crimp the retainer until it retains lever to the shoesecurely

I

58-28 REAR DRUM BRAKE

4.

5.

6.

7.

8.

9.10.

Attach parking brake cable to parking brake lever and installretaining ring at the backing plate.Attach the shoe to spring to leading and trailing shoe assemblies and install to the backing plate. It will be necessary tostretch the spring as shoes are installed downward over anchorplate to the inside of shoe retaining plate.Install adjusting screw nut socket &washer assembly betweenleading shoe slot and the slot in the trailing shoe and the parkingbrake lever. The adjusting socket slot must fit into the leadingshoe, and the pivot nut must fit into the trailing shoe and parkingbrake lever.Assemble adjuster lever in the groove located in the adjusterpin and into slot of the adjuster socket that fits into the leadingshoe web.

NOTEThe adjuster pivot nut blade is marked R or L for right handand left hand brake assemblies. The pivot nut must beinstalled with the groove on the side of the blade facingoutward (facing the builder).

Attach the adjuster spring to the trailing shoe.Using an appropriate spring tool, strech the other end of thespring into the slot of the adjuster lever.install the backing plate and tighten bolts to specification.Adjust the shoe outside diameter at the horizontal diagonal tospecification by holding the automatic adjusting lever out ofengagement while rotating the adjusting screw. Ensure theadjusting screw rotates freely.

Standard dimension of shoe outside diameter . . . . . . . . . . . . . . . .179.08-179.5 mm (7.050-7.068 in.)

11. Install brake drum assembly and wheel/tire assembly.

58-29

REPLACEMENT OF WHEEL CYLINDER

Wheel cylinders should not be disassembled unless they areleaking. Carefully pull the lower edges of the wheel cylinder bootsaway from the cylinder, and note whether or not the interior is wetwith brake fluid. Excessive fluid at this point indicates leakage pastthe piston cups and a need for wheel cylinder overhaul.

DISASSEMBLY AND INSPECTION

1. Remove brake shoe assembly as outlined.2. Remove the boots and draw out the pistons, cups and the

spring and expanders assembly.3. Discard all rubber parts.4. Remove bleeder screw from the cylinder.5. Wash all parts in clean, denatured alcohol.6. Inspect pistons for scratches, scoring, or other visible damage.

Replace if necessary. Always replace rubber parts and boots.7. Inspect cylinder bore for score marks or rust. If either condition

is present, replace the entire cylinder assembly.8. Make sure bleeder hole is open.

ASSEMBLY

1. Apply light coat of brake fluid (DOT 3) to all internal parts.2. Thread bleeder screw into cylinder and tighten to specification.3. Insert return spring and cup expander assembly, cups and

pistons into their respective position in cylinder bore in thatorder. Place a boot over each end of cylinder.

4. Install brake shoe assemblies, adjuster et. as outlined above.5. Install drum assembly and wheel/tire.6. Bleed brake system.

NOTEEnsure that brake line is installed in lower wheel cylinderhole and bleed screw in upper hole. Always Bleed brakesbefore driving vehicle.

58-30 PARKING BRAKE

PARKING BRAKE

COMPONENTS


REMOVAL

1. Remove the rear console.2. Loosen the adjusting nut and detach the parking brake cable.3. Detach the parking brake switch assembly.4. Remove the parking brake lever assembly.

5. Remove the wheel and tire.6. Remove the brake drum.7. Remove the brake shoes as outlined before.8. Detach the parking brake cable from the parking lever.

PARKING BRAKE 58-31

7. Remove the parking brake cable retaining ring in the rear of thebacking plate.

8. Remove the rear seat cushion assembly and roll up the carpet.9. Loosen the parking brake cable clamp and remove the parking

brake cable assembly.

INSPECTION

1. Check the parking brake switch operation.2. Check the parking brake lever ratchet for wear.3. Check the parking brake cable for fraying or damage.

INSTALLATION

1. Check the parking brake cables for left and right identificationmarks and install accordingly.

2. Move the adjuster lever all the way back when installing theshoe-to-shoe spring.

PARKING BRAKE

3. Install the grommets in the direction shown in the illustration.

CAUTIONPay attention to grommet mounting direction

4. Apply a coating of the specified grease to the sliding parts of theratchet plate and ratchet pawl.

Specified grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multipurpose grease SAE J310, NLGI No. 2

5. After installing the cable adjuster, adjust the parking brake leverstroke.

BODY (INTERIORAND EXTERIOR)

Return To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

BODY PANELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

BODY DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

MOULDINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

REAR WINDOW GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

QUARTER FIXED GLASS . . . . . . . . . . . . . . . . . . . . . . . . 32

DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

TRUNK LID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

INTERIOR TRIM AND HEAD LINING . . . . . . . . . . . . . . . 41

CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

CRASH PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

FRONT SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

REAR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

PASSIVE SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

60-2 GENERAL


HoodType

DoorConstructionRegulator systemLocking system

Trunk lidType

Glass thicknessWindshield glassDoor glassRear window glassQuarter fixed glassDistance between door upper hinge and lower hinge

SeatFront seat travel

Seat beltFront

Rear

Rear hinged, front opening type

Front hinged, full door constructionWire drum typePin-fork system

Torsion bar type

Laminated tinted shade bandTempered tinted

341.5 mm (13.4 in.)

5 mm (0.2 in.)3.2 mm (0.13 in.)3.2 mm (0.13 in.)3.2 mm (0.13 in.)

210 mm (8.3 in.) by 15 mm (0.6 in.) steps

Passive type with lap beltW.L.R 3 point typeE.L.R 3 point type

W.L.R : Webbing Clamp Emergency Locking RetractorE.L.R : Emergency Locking Retractor

GENERAL 60-3

TIGHTENING TORQUEN m Kg.cm lb.ft

DoorDoor hinge to bodyDoor hinge to door

Trunk lid

36-42 360-420 26-3013-26 130-260 9-19

Trunk lid hinge to bodyTrunk lid hinge to trunk lid

Hood

7-9 70-90 5-6.57-9 70-90 5-6.5

Hood hinge to bodyHood hinge to hoodHood latch to body

Seat

22-27 220-270 16-19.522-27 220-270 16-19.57-9 70-90 5-6.5

Front seat to floor NutBolt

Seat belt

24-36 240-360 17.4-2635-55 350-550 25.3-40

Front seat belt buckle 40-55Front seat belt retractor to center pillar 40-55Rear seat belt upper and lower anchor to body 40-55Passive seat belt & lap belt retractor 40-55

400-550400-550400-550400-550

29-4029-4029-4029-40

GENERAL

SPECIAL TOOLS


09793-21000Door hinge adjusting wrench

09800-21000Ornament remover

09853-31000Head lining clip remover

09861-31100Sealant cut-out tool

09861-31200Sealant cutting blade

09861-31300Sealant gun

09861-31400Glass holder

09861-31000Windshield glass mouldingremover

Illustration Use

Adjustment, removal and installation ofthe door hinge

Trim removal

Removal of the head lining clips

Cutting the sealant for the windshieldglass (use with 09861-31200)

Cutting the sealant for the windshieldglass (use with 09861-31100)

Application of the sealant to thewindshield glass

Removal and installation of the wind-shield glass

Removal of the windshield glassmoulding

GENERAL 60-5

TROUBLESHOOTING

Symptom

SunroofWater leaks


Crack in roof lid glass Replace roof lid glass

Loose retainer attaching screws, Retighten screwsdeterioration of packing Replace packing

Loose frame hinge attaching screws, Retighten screwsdeterioration of packing Replace packing

Deterioration of packing on back of roof lid Replace packinglatch catch

Clogged drain pipe Clear front and rear drain pipe by applyingcompressed air

Displaced or bent drain pipe, loose or Remove headlining and pillar trim andcracked clips check pipe and flange

Dust in roof panel gutter Remove dust, taking care not to force dustinto drain pipe

Wind noise

Cracks or deterioration of roof lid inner Check weatherstrip attachment, and re-weatherstrip place if necessary

Cracks or deterioration of roof lid outer Check weatherstrip attachment, and re-weatherstrip place if necessary

Deformation or incorect attachment of air Check and replace if necessarydeflector

Noise in motor (Clutchslipping noise made inmotor when lid is fullyopened or closed is notunusual noise.)

Incorrect engagement of motor pinion with Check pinion installation and retightendrive cable motorWorn or damaged motor pinion bearing Replace motor assemblyWorn or deformed drive cable Replace drive cable

Door glass fails tooperate up and down

Door does not openor close completely

Hood does not openor close completely

Water leak throughwindshield and rearwindow

Incorrect window glass installation Adjust positionDamaged or faulty regulator arm or regulator Correct or replace

Incorrect door installation Adjust positionDefective door check Correct or replaceDoor hinge requires grease Apply grease

Striker and latch not properly aligned AdjustIncorrectly installed hood AdjustIncorrect hood bumper height Adjust

Defective seal Fill will sealantDefective body flange Correct

60-6 BODY PANELING

BODY PANELING

COMPONENTS

1. Member assy, radiator support upper2. Member assy, radiator support lower3. Panel assy, radiator support4 . Panel assy, fender apron inner front5. Panel assy, shock absorber housing6. Panel assy, fender apron upper outer7. Panel assy, cowl side inner upper8. Member assy, front side9. Panel assy, cowl top outer10. Panel assy, cowl inner lower11. Panel assy, dash12. Panel assy, front pillar13. Panel assy, side sill

14. Panel assy, front floor15. Member assy, front Seat cross16. Panel assy, door17. Rail assy, roof front18. Rail assy, roof Center19. Rail assy, roof rear20. Panel assy, rear floor21. Panel assy, quarter outer22. Panel assy, quarter inner23. Panel assy, back24. Panel, roof25. Door, fuel filler26. Panel assy, rear package tray

BODY PANELING 60-7

CROSS-SECTIONAL VIEWS

BODY PANELING

SECTION A-A

SECTION C-C

SECTION E-E

G-G

SECTION B-B

SECTION D-D

SECTION F-F

SECTION H-H

BODY PANELING 60-9

60-10 BODY PANELING

SECTION Q-Q

1. Panel assy, hood2. Panel assy, radiator support3. Panel assy, fender4. Pillar assy, front5. Panel assy, door6. Panel assy, roof7. Pillar assy, center8. Panel assy, side sill

9. Panel assy, quarter10. Panel assy, fuel filler door11. Panel assy, back12. Panel assy, cowl top13. Rail assy, roof side14. Panel assy, trunk lid15. Panel assy, rear package tray

BODY DIMENSIONS 60-11

UNDER BODY

Point symbol A-A’ B-b c-c D-d E-e F-f G-g H-h

Length (mm) 998 1031 1258 802 1122 1070 1040 1019

Point symbol A-b B-c C-d D-g’ E-f F-h A-Z B-Z

Length (mm) 1267.81 1327.89 1788.83 1603.75 1163.55 1297.26 240 572

Point symbol C-Z D-Z E-Z F-z G-Z H-Z A.Z-B.Z B.Z-D.Z

Length (mm) 634.2 1073 85 425 714 235 642.9 299.5

Point symbol B.Z-D.Z D.Z-F.Z E.Z-F.Z F.Z-H.Z F.Z-H.Z

Length (mm) 1487.1 2318.1 296 965 965

60-12 BODY DIMENSIONS

Front bumper mounting hole(Ø13)

Sun roof mounting hole(Ø6)

Front strut hole(94x109)

Trunk lid hinge mounting hole(Ø7)

Tailing arm mounting hole(Ø18)

Rear bumper mounting hole(Ø14)

Hood hinge mounting hole(Ø11)

Rear strut mounting hole(012.5)


ENGINE COMPARTMENT

Point symbol l-i

Length (mm) 744

J-j

643

K-k

1150

L-l l-j K-l K-M

912 732.52 1162.52 943.26

60-14 BODY DIMENSIONS

a/Guard mounting hole(Ø6.6)

Condenser mounting hole(Ø6.6)

Shock absorber mounting hole(Ø9)

Paint drain hole(Ø10)

Bumper mounting hole(Ø9)


Point symbol N-n N-O

Length (mm) 1070 937.03

Shock absorber mounting hole(Ø9)

Paint drain hole(Ø10)

60-16 HOOD

COMPONENTS


REMOVAL

1. Remove the hood striker assembly.

2. Remove the hood mounting bolts, and then remove the hood.

CAUTION:Protect the front body area with a cloth so as not to causedamage to the hood.

HOOD 60-17

ADJUSTMENT

Hood Hinge

1. Loosen the hood hinge mounting bolt.2. Adjust the longitudinal and lateral positions of the hood by

utilizing the oblong holes in the hinge.

Hood Striker

1. Loosen the hood striker mounting bolts.2. Adjust the alignment of the hood striker and hood latch by

adjusting the longitudinal position of the lock, and by adjustingthe height of the hood.

MOULDINGS

COMPONENTS


REMOVAL

Front Mud Guard

1. Remove the front mud guard.

Waistline Moulding

1. Beginning from either end, remove the waistline moulding fromthe fender panels, quarter panels, and doors.

MOULDINGS 60-19

Side Sill Moulding

1. After removal of the rear side sill moulding, remove the frontside sill moulding.

INSTALLATION

1. Clean the surfaces of the body to which adhesive will be appliedby using a wax and grease remover.

60-20 BUMPER

FRONT BUMPER

COMPONENTS


REMOVAL

1. Remove the front wheel guard.

BUMPER 60-21

2. Remove the reservoir tank.

3. Remove the bumper stay-to-body bolts and remove the frontbumper.

INSTALLATION

1. Installation is the reverse of the removal procedure.

BUMPER

REAR BUMPER

COMPONENTS


REMOVAL

1. Remove wheel guard.

2. Remove the bumper stay-to-body bolts.

FENDER 60-23

COMPONENTS


REMOVAL

1. Remove the mud guard and wheel guard by loosening thescrews.

2. Disconnect the side marker lamp connector.3. Remove the side marker lamp.

60-24 FENDER

4. Remove the front bumper, and then remove the side sillmoulding.

5. Remove the fender mounting bolts.

CAUTIONBe careful not to damage the paint,

INSTALLATION


NOTE:In order to prevent the fender mounting bolt area fromforming rust, apply tape sealer between the fender and thebody panel.

WINDSHIELD 60-25

COMPONENTS


REMOVAL

1. To remove the windshield, first remove the following parts;1) Front pillar trims2) Wiper arms3) Cowl top cover4) Side mouldings

2. Use the special tool to cut through the windshield sealant.

60-26 WINDSHIELD

3. Make mating marks on the glass and body if the glass is to bereinstalled.

NOTE:Use chalk or equivalent to make mating marks on theglass and body.

4. Take out the windshield glass with glass holder.

INSTALLATION

1. Using a cutter knife or the special tool, scrape the old sealantto a thickness or about 2 mm on the bonding surface around theentire windshield flange.

NOTEBe careful not to remove more adhesive than necessary,to avoid damaging the paint on the body surface.

2. Clean the body bonding surface with a sponge dampened inalcohol, wax or grease remover.

3. Install the cowl top cover mounting retainers at the locations asshown in illustration.

4. Center the new windshield in the opening.Locate by marking lines across the glass and body with agrease pencil at the four points as shown.

5. To contain the sealant during installation, glue the rubber damto the inside surface of the windshield around the entire edgeas shown.

WINDSHIELD 60-27

6. Apply a light coat of glass primer to the outside of the dam.

NOTE1) Do not apply body primer to the glass.2) Never touch the primed surfaces with your hand.

If you do, the adhesive may not bond to the glassproperly, causing a leak when the windshield is installed.

3) Keep water, dust, and abrasive materials away from theprimed surface.

7. Apply a light coat of body primer to the original sealantremaining around the window opening flange. The glass shouldbe installed 10 minutes after you apply the primer.

8. Thoroughly mix all the sealant and hardener together on a glassor metal plate with a putty knife.

NOTE:1) Clean the plate with a sponge and alcohol before

mixing.2) Follow the instructions that come with the sealant.

9. Pack adhesive into the cartridge (avoiding air pockets), toensure continuous delivery. Put the cartridge in a caulking gunor Sealant Gun, and run a bead of adhesive around the edgeof the glass as shown.

NOTEApply the adhesive within 5 minutes after applying theglass primer.

10. Using suction cups lower the glass over the opening, align itwith the marks made in step 5 and set it down on the sealant.Insert two lower spacers to prevent the windshield from movingdownward.

11. Scrape or wipe excess adhesive off with putty knife or gauze.Fill all cavities around the windshield.

WINDSHIELD

12. Perform a water-test on the windshield.Use a cold water spray, being careful not to direct a powerfulstream of water on the new adhesive material. Allow water tospill over the edges of the glass.

13. If there are leaks, apply sealant at the leak points.

14. Install the cowl top cover.

15. Install the windshield side moulding.Reinstall the front pillar trims and wiper arms.

NOTE:Make sure the sealant has set sufficiently before puttingthe vehicle back into operation.

REAR WINDOW GLASS 60-29

COMPONENTS


REMOVAL

1. Remove the defogger wire connector.

2. To remove the rear window glass, first remove the followingparts;1) Quarter inner trim2) Rear seat belt anchor bolt3) High mounted stop lamp4) Package tray trim

3. Remove the rear window glass assembly.

60-30 REAR WINDOW GLASS

INSTALLATION

1. Install the rear window glass upper and lower moulding to therear window glass.

2. To contain the sealant during installation, glue the rubber damto the inside surface of the rear window glass around the entireedge as shown.

3. Apply a light coat of glass primer to the outside of the dam.

NOTE:1) Do not apply body primer to the glass.2) Never touch the primed surfaces with your hand.

If you do, the adhesive may not bond to the glassproperly, causing a leak after the rear window isinstalled.

3) Keep water, dust, and abrasive materials away fromthe primed surface.

4. Apply a light coat of body primer to the original sealantremaining around the window opening flange. The glass shouldbe installed 10 minutes after you apply the primer.

5. Thoroughly mix all the sealant and hardener together on a glassor metal plate with a putty knife.

NOTE:1) Clean the plate with a sponge and alcohol before

mixing.2) Follow the instructions that come with the sealant.

REAR WINDOW GLASS 60-31

6. Pack adhesive into the cartridge (avoiding air pockets), toensure continuous delivery. Put the cartridge in a caulking gunor Sealant Gun, and run a bead of adhesive around the edgeof the glass as shown.

NOTE:Apply the adhesive within 5 minutes after applying theglass primer.

7. Using the special tool, install the rear window glass.

8. Use a cold water spray, being careful not to direct a powerfulstream of water on the new adhesive material. Allow water tospill over the edges of the glass.

9. Perform a water-test on the windshield.

10. Install the rear window glass side moulding.

60-32 QUARTER FIXED GLASS

COMPONENTS


INSTALLATION

1. Clean the entire circumference of the glass with isopropyl(rubbing) alcohol.

NOTE:Do not proceed with the service procedure until the glassis completely dry. Do not touch cleaned surface withfinger, dust, water, etc.

2. Apply the sealant to the entire circumference of the glass.

NOTE:Install the glass to the body within five minutes.

QUARTER FIXED GLASS

3. Install the glass to the body.Install the rear window glass moulding.

60-34 DOOR

COMPONENTS

DOOR 60-35

DOOR POSITION ADJUSTMENT

Check for a flush fit with the body, then check for an equal gapbetween the front and rear, top and bottom door edges and thebody.The door and body edges should also be parallel. Adjust at thehinge with the Special Tool (09793-21000).

CAUTION:Attach protective tape to the fender edges near the placewhere the hinge is installed.

DOOR STRIKER ADJUSTMENT

Make sure the door is not loose, and latches securely withoutslamming. If it needs adjustment;1. Draw a line around the striker plate for reference.2. Loosen the striker screws, and move the striker IN or OUT to

make the latch fit tighter or looser. Move the striker UP orDOWN to align it with the latch opening. Then lightly tighten thescrews and recheck.

NOTE:Hold the outside handle out and push the door against thebody to be sure the striker allows a flush fit.

GLASS ADJUSTMENT

If the glass does not fit evenly when closed, adjust the slant of theglass in the front-to-back direction.

INSIDE DOOR HANDLE ADJUSTMENT

Adjust the inside handle play by adjusting the mounting position inthe IN-to-OUT direction.

Full stroke [A] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.5°

REMOVAL

1. Using a screwdriver, remove the clip shown in the illustration toremove the regulator handle. (Manual type only)

DOOR

2. Remove the screws from the door trim.

3. Insert a screwdriver between the trim fasteners and door panelto pry it loose.Disconnect the connectors.

4. Remove the door trim seal.

5. Remove the quadrant inner cover.6. Remove the rear view mirror mounting screws and then

remove the rear view mirror.

7. Remove the door outside belt weatherstrip.

DOOR 60-37

8. Remove the carrier plate bolts from the regulator channel.

9. Pull the door glass out through the window slot.

10. Remove the door regulator channel mounting bolts, and thenremove the door regulator assembly.

11. Remove the inside handle mounting screws.Turn the rod holding clip and then remove the rod from the latchassembly.

12. Remove the outside door handle mounting bolts.Disconnect the outside door handle rod from the outside doorhandle at the position shown.

DOOR

13. Remove the door latch and door latch actuator.

14. Remove the door quadrant channel.

15. Remove the door rear channel.

16. Remove the door frame garnish.

17. Remove the door glass run.

DOOR 60-39

INSTALLATION

1. Installation is the reverse of removal procedure.

CAUTIONWhen installing the door trim seal, butyl tape should notbe placed over door trim fastener mounting area.

TRUNK LID

COMPONENTS


REMOVAL

1. Adjust the striker up or down, and right or left until the trunk lidis flush with the rear edge of the body.

2. Adjust the trunk hinges up or down and right or left as necessaryto equalizer the gap between the lid and body.

INTERIOR TRIM AND HEAD LINING 60-41

COMPONENTS


REMOVAL

Door Scuff Trim

1. Remove the screws from the door scuff trim2. Remove the door scuff trim.

60-42 INTERIOR TRIM AND HEAD LINING

Cowl Side Trim

1. Remove the two screws and one fastener from the cowl sidelower trim.

Quarter Inner Trim

1. Remove the door scuff trim.2. Remove the rear seat and the rear seat belt mounting bolt.3. Remove the quarter inner trim.

Center Pillar Trim

1. Loosen the screw from the center pillar.2. Remove the seat belt upper anchor cover and mounting bolt.3. Pry out the clips and remove the center pillar trim.

Front Pillar Trim

1. Using a screwdriver, remove the front pillar trim.

Rear Package Tray Trim

1. Remove the rear package tray trim mounting plugs and the rearspeaker mounting nuts.

2. Remove the rear package tray trim.

INTERIOR TRIM AND HEAD LINING 60-43

Luggage Side Trim

1. Remove the screws and plugs from the luggage side trim.

Luggage Rear Trim

1. Remove the luggage rear trim.

Rear Transverse Trim

1. Remove the transverse trim mounting fasteners and the reartransverse trim.

Head Lining

1. To remove the head lining, first remove the following parts;1) Front pillar trim.2) Center pillar trim.3) Quarter inner trim.

2. Remove the sunvisor and retainer.

INTERIOR TRIM AND HEAD LINING

3. Detach the lens from the room lamp.4. Remove the overhead console lamp.

5. Remove the roof assist handle.

6. Remove the front and rear strip from the head lining.

7. Using the special tool (09853-31000), remove the head lining.

INSTALLATION


CONSOLE 60-45

COMPONENTS


REMOVAL

1. Remove the rear console mounting screws and then pull out therear console.

CONSOLE

2. Remove the transaxle control lever.3. Remove the front console assembly and then disconnect the

connectors.

CRASH PAD 60-47

COMPONENTS

CRASH PAD

REMOVAL

1. Remove the steering wheel.2. Remove the steering column lower and upper shroud.

3. Remove the hood release cable.

4. Remove the side lower crash pad.

5. Remove the glove box.

6. Remove the front console upper cover, and then remove thelower crash pad center facia panel carefully.

CAUTIONCenter facia panel is installed firmly with clip as illus-trated.So be careful not to brake it while r&moving.

CRASH PAD 60-49

Remove the cluster facia panel.

8. Remove the cluster assembly and disconnect the connectors.

9. Remove the radio and disconnect the connectors.

10. Remove the heater control assembly.

11. Remove the main lower crash pad.

60-50 CRASH PAD

12. Detach the front speaker grille from the main crash pad.

13. Remove the main crash pad.

INSTALLATION

1. Installation is the reverse of the removal procedure.2. Connect all of the connectors securely.

FRONT SEAT 60-51

COMPONENTS

24-36 (240-360, 17.4-26)


FRONT SEAT

REMOVAL

1. Pull out the front seat mounting cover.

2. Remove the front seat assembly.

3. Remove the thigh support and shield cover.

REAR SEAT 60-53

COMPONENTS


REMOVAL

1. Pull out the rear seat cushion holder.2. Remove the rear seat cushion.

60-54 REAR SEAT

3. Remove the rear seat back mounting bolts and rear seat back.

INSTALLATION


SEAT BELT

COMPONENTS


60-56 SEAT BELT

REMOVAL

Front Seat Belt

1. Remove the door scuff trim.2. Remove the quater inner trim.

3. Remove the upper anchor plate and the lower plate.4. Remove the front seat belt retractor5. Remove the front seat belt assembly.

Rear Seat Belt

1. Remove the rear seat assembly.2. Remove the quarter inner trim.

3. Remove the rear seat belt assembly.

INSTALLATIONFront Seat belt

1. installation is the reverse of the removal procedure.

SEAT BELT 60-57

Rear Seat belt


CAUTION1. When installing the rear seat belt assembly be careful

that the lower anchor plate must be placed in directionof front of the vehicle as illustration.

2. When installing the rear seat assembly, the seat beltmust be passed through the rear seat cushion holewith untwisted state as shown in the illustration.

60-58 SUNROOF

COMPONENTS


REMOVAL

1. To remove the sunroof, first remove the following parts;1) Overhead console lamp assembly.2) Sunvisor and inside rear view mirror.3) Front pillar.4) Roof assist handle.

SUNROOF 60-59

2. Remove the sunroof glass assembly.

3. Remove the sunroof deflector.

4. Remove the sunroof handle escutcheon and the sunroofhandle base plate.

5. Remove the sunroof frame hinge.

INSTALLATION

1. Install in the reverse of the removal procedure.2. When installing the sunroof opening trim, make sure that there

is no gap between the trim and the headlining.

PASSIVE SEAT BELT

COMPONENTS

REMOVAL

Passive Seat Belt

1. Remove the passive seat belt buckle assembly from the doorframe.

2. Remove the passive seat belt retactor from the front seat.

PASSIVE SEAT BELT

Lap Belt

1. Remove the buckle assembly as shown in Figure.

2. Remove the door scuff trim.3. Remove the lap belt retractor.

INSTALLATION

1. installation is the reverse of the removal procedure.2. When installing the passive seat belt retractors, the mounting

angle is 15°.

BODYELECTRICALSYSTEMReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

FUSIBLE LINKS & FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

MULTIFUNCTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

INSTRUMENT AND WARNING SYSTEM . . . . . . . . . . . . . . 13

LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

AUDIO .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

WINDSHIELD WIPER AND WASHER ...................... 45

CLOCK .............................................................. 50

CIGARETTE LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

HORN .............................................................. 53

POWER WINDOW ............................................... 54

REMOTE CONTROL MIRROR ............................. 58

TIME AND ALARM CONTROL UNIT . . . . . . . . . . . . . . . . . . . 60

TRUNK LID OPENER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

AUTOMATIC TRANSAXLE AND KEY LOCKCONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

90-2 GENERAL

GENERALSERVICING THE ELECTRICAL SYSTEM1. Prior to servicing the electrical system, be sure to turn off the

ignition switch and disconnect the battery ground cable.

NOTE:In the course of MPI or ELC system diagnosis, when thebattery cable is removed, any diagnostic code retained bythe computer will be cleared.Therefore, if necessary, read the diagnostic codes beforeremoving the battery cable.

2. Secure the wiring harnesses by using clamps so that there is noslack. However, for any harness which passes to the engine orother vibrating parts of the vehicle, allow some slack within arange that does not allow the engine vibrations to cause theharness to come into contact with any of the surrounding parts,and then secure the harness by using a clamp.

3. If any section of a wiring harness interferes with the edge of apart or a corner, wrap the section of the harness with tape orsomething similar in order to protect it from damage.

4. When installing any of the vehicle pans, be careful not to pinchor damage any of the wiring harnesses.

5. The sensors, relays, and electrical parts, must never be subjected to strong shocks. Do not allow them to fall and do notthrow them when handling.

GENERAL 90-3

6. The electronic parts used in the computer, relays, etc. arereadily damaged by heat. If there is a need for service opera-tions that may cause the temperature to exceed 80°C (176°F),remove the electronic parts beforehand.

7. Loose connectors could be troubled. Make sure that connectors are connected securely.

8. When removing a connector, be sure to pull only the connector,not the harness.

9. Remove connectors which have catches by pressing in thedirection indicated by the arrows in the illustration.

10. Connect connectors which have catches by inserting the con-nectors until a “snap” noise is heard.

90-4 GENERAL

11. When using a circuit tester to perform continuity or voltagechecks on connector terminals, insert the test probe from theharness side.If the connector is a sealed connector, insert the test probe inthrough the hole in the rubber cap for the electrical wires, beingcareful not to damage the insulation of the wires; continue toinsert the test probe until it contacts the terminal.

12. In order to avoid overloading the wiring, take the electricalcurrent load of the optional equipment into consideration, anddetermine the appropriate wire size.

1.2.

3.

4.

5.

6.

7.8.

9.

CHECKING CABLES AND WIRES

Check the terminal for tightness.Check terminals and wires for corrosion by battery electrolyte,etc.Check terminals and wires for open circuit or impending opencircuit.Check wire insulation and coating for damage, cracks anddegrading.Check conductive parts of terminals for contact with othermetallic parts (vehicle body and other parts).Check grounding parts to verify that there is complete continuitybetween attaching bolt(s) and vehicle body.Check for incorrect wiring.Check that wirings are clamped so as to prevent contact withsharp corners of the vehicle body, etc. or hot pans (exhaustmanifold, pipe, etc.).Check that wirings are clamped firmly to secure enough clearance from the fan pulley, fan belt and other rotating or movingparts.

Test probe Connector

10. Check that the wirings between the fixed parts such as thevehicle body and the vibrating pans such as the engine aremade with adequate allowance for vibrations.

GENERAL 90-5

INSTALLATION OF RADIO EQUIPMENT

The computer for the electronic control system has been designedso that external radio waves will not interfere with their operation.However, if the antenna or cable of an amateur radio transceiveretc. is routed near the computers, it may affect the operation of thecomputers, even if the output of the transceiver is no more than25W.To protect each of the computers from interference by the transmit-ter (hum, transceiver, etc.), the following should be observed.1.2.

3.

4.

5.

Install the antenna on the roof or rear bumper.Because radio waves are emitted from the coaxial cable of theantenna, keep it 200 mm (8 in.) away from the computers andthe wiring harness, route it so that it runs at right angles to thewiring harness.The antenna and the cable should be well matched, and thestanding-wave ratio* should be kept low.A transmitter having a large output should not be installed in thevehicle.After installation of transmitter, run the engine at idle, emit radiowaves from the transmitter and make sure that the engine is notaffected.

* STANDING-WAVE RATIOIf an antenna and a cable having different impedances and con-nected, the input impedance Zi will vary in accordance with thelength of the cable and the frequency of the transmitter, and thevoltage distribution will also vary in accordance with the location.The ratio between this maximum voltage and minimum voltage iscalled the standing-wave ratio. It can also be represented by theratio between the impedances of the antenna and the cable. Theamount of radio waves emitted from the cable increases as thestanding-wave ratio increases, and this increases the possibility ofthe electronic components being adversely affected.

90-6 FUSIBLE LINKS AND FUSES

FUSIBLE LINKS & FUSESFUSIBLE LINK

Specifications

Item

Main fusible linkTypeAmpere rating

Housing color

Sub-fusible linkType

Spec i f i ca t ion

Screw-up type50A (Charging circuit)30A (Radiator fan circuit)20A (Condenser fan circuit)50A-Red30A-Pink20A-BlueLocated in engine compartment relay boxConnector type

Ampere rating & circuit, housingcolor

Ampererating

Housingcolor

BATT IGN SW

50A 30A

Red Pink

MPI

20A

Blue

H/LAMP

30A

Pink

Inspection

1. Check for a burnt fusible link with an ohmmeter (fusible linkmust be removed from holder prior to testing).

2. If a fusible link burns out, there is a short or some other problemin the circuit. Carefully determine the cause and correct itbefore replacing the fusible link.

NOTE:The fusible link will burn out within 15 seconds if a highercurrent than specified flows through the circuit.

FUSIBLE LINKS AND FUSES 90-7

FUSESInspectionWhen a fuse is blown, there are two probable causes as follows.Which of the two causes is responsible can be easily determined byvisual check after removing the fuses.1. Fuse blown due to over-current.

Prior to replacing the fuse with a new one, check the circuit fora short and the related pans for abnormal condition.Only after the correction of a short or replacement of abnormalparts, should a fuse with same ampere rating be installed.

2. Fuse blown due to repeated current on-off.Normally, this type of problem occurs after fairly long period ofuse and hence is less frequent than the above type.In this case, you may simply replace with a new fuse of the samecapacity.

CAUTION:A blade type fuse is identified by the numbered value inamperes.If the fuse is burnt-out, be sure to replace a fuse with thesame ampere rating. If a fuse of higher capacity thanspecified is used, parts may be damaged and the danger offire also exists.

Blown fuse due to overcurrent

Blown fuse due to thermal fatigue

10A 15A

IGNITION SWITCH

IGNITION SWITCH(WITH DOOR WARNING SWITCH)

INSPECTION1. Remove the connector located under the steering column.2. Check for continuity between terminals.

NOTE:indicates that there is a continuity between

terminals.RO : Round the locking bar, RE : Return the locking bar,R : Removed, I : Inserted, L : Lock, F : Free

MULTIFUNCTION SWITCH 90-9

MULTIFUNCTION SWITCH (With Auto Cruise)

COMPONENT

M37-2 M37-1

Circuit connection

MULTIFUNCTION SWITCH

MULTIFUNCTION SWITCH (Without Auto Cruise)

COMPONENT

M37-2 M37-1

Circuit connection



1. Disconnect the battery ground cable.2. Remove the steering wheel.3. Remove the steering column shroud.

4. Disconnect the harness connector.5. Remove the 3 straps.6. Remove the multifunction switch ass’y by loosening the 4

screws shown in the illustration.7. Installation is the reverse order of the removal procedure.

INSPECTION

With the multifunction switch in each position, make sure thatcontinuity exists between terminals below.

Lighting switch (Connector No.: M37-1)

Dimmer and passing switch (Connector No.: M37-1)

M37-1


Turn signal switch (Connector No.: M37-1)

L : Left positionN : Neutral positionR : Right position

Wiper switch (Connector No.: M37-2)

Washer switch (Connector No.: M37-2)

M37-2

Cruise control switch (Connector No.: M37-2)

M37-2

INSTRUMENTS AND WARNING SYSTEM 90-13

INSTRUMENTS AND WARNING SYSTEMSPECIFICATIONS

Instrument clusterTypeIllumination lampsIllumination color

Indicator and warning lampsBattery chargeOil pressureDoor ajarCheck engineBrake failureOver-drive OFFSeat beltLow fuelHigh beamTrunk lid ajarDirection indicator (LH, RH)

Package type (flexible P.C.B. with push connection)12V 3.4W x 4 EA, 1.2W x 2 EAWhite

Bulb wattage Illumination color1.2 Red1.2 Red1.2 Amber1.2 Amber1.2 Red1.2 Amber1.2 Red3.0 Amber3.0 Blue1.2 Amber1.2 Green

INSTRUMENTS AND WARNING SYSTEM

SERVICE SPECIFICATIONS

Item

SpeedometerTypeIndication tolerance

TachometerTypeIndication tolerance

Fuel gaugeTypeIndication

Temperature gaugeType

Specification

Eddy current push connection type

Speed (MPH)

Tolerance (MPH)

Speed (Km/h)

Tolerance (Km/h)

10 20 40 60 80 100 120

±1.5 ±1.5 ±1.5 ±1.5 ±1.5 ±1.5 ±1.5

20 40 60 80 100 120 140 160

+4 +3 +4 +5 +5 +5.5 +5.5 +60 0 0 0 0 +0.5 +0.5 +0.5

Electronic type

Standard (RPM) Idle 2,000 3,000 4,000 5,000 6,000 7,000

Tolerance (RPM) ±100 ±150 ±200 ±200 ±200 ±200 ±300

Air cored type (pointer remaining type)

Fuel level E (Empty)

Angle -30”

Tolerance ±2°24'

Tolerance when assem- 0°bled with fuel sender -5.36“

Resistance ( Q ) 95

1/2 F (Full)

0° +30°

±5° ±2°24'

±10° +7.06°-0°

32.5 6.5

Air cored type (pointer-zero-position returning type)

Temperature (°C)

Scale angle

Tolerance

Tolerance when assem-bled with temp. sender

70

-30”

±2.5°

_

115

14.5°

±3°

±6.5°

Red zone

24°

130

30°


TROUBLESHOOTING

Problem Probable cause Remedy

Tachometer does not operate No. 17 fuse (10A) blown Check for short and replace fuse

Tachometer faulty Check tachometer

Wiring Faulty Repair if necessary

Fuel gauge does not operate No.17 fuse (10A) blown Check for short and replace fuseFuel gauge faulty Check gaugeFuel sender faulty Check fuel senderWiring faulty Repair if necessary

Low fuel warning lamp does No.17 fuse (10A) blown Check for short and replace fusenot light Bulb burned out Replace bulb

Fuel level sensor faulty Check switchWiring or ground faulty Repair as necessary

Water temperature gauge does No. 17 (10A) fuse blown Check for short and replace fusenot operate Water temperature gauge faulty Check gauge

Water temperature sender faulty Check senderWiring or ground faulty Repair if necessary

Oil pressure warning lamp does No. 17 (10A) fuse blown Check for short and replace fusenot light Bulb burned out Replace bulb

Oil pressure sender faulty Check senderWiring or ground faulty Repair if necessary

Low brake fluid warning lamp does No. 17 (10A) fuse blown Check for short and replace fuse

not light Bulb burned out Replace bulb

Brake fluid level warning switch faulty Check switch

Parking brake switch faulty Check switchRepair if necessary

Open door warning lamp does not Wiring or ground faulty. Check for short and replace fuselight No. 5 (10A) fuse blown Replace bulb

Bulb burned out Check switchDoor switch faulty Repair if necessaryWiring or ground faulty

INSTRUMENTS AND WARNING SYSTEM

INSTRUMENT CLUSTER

COMPONENTS



1. Disconnect the battery ground cable.2. Remove the ashtray.3. Remove the low crash pad center facia panel.

4. Remove the digital clock and remote mirror switch.5. Remove screws at the cluster facia panel.

6. Remove four screws retaining cluster and connections.7. Installation is the reverse order of removal.

90-18 INSTRUMENTS AND WARNING SYSTEM

PRINTED CIRCUIT BOARD

CIRCUIT DIAGRAM

INSTRUMENTS AND WARNING SYSTEMS 90-19

SPEEDOMETER AND SPEEDOMETER CABLE

Speedometer inspection (under in-vehicle)

1. Using a speedometer tester, ensure that any indication error iswithin tolerance limits.

NOTEIt should be noted that the excessive tire wear and tire overor under-inflation will cause indication errors.

Speed (MPH) 10 20 40 60 80 100 120

Tolerance ±1.5 ±1.5 ±1.5 ±1.5 ±1.5 ±1.5 ±1.5

Speed (Km/h) 20 40 60 80 100 120 140 160

Tolerance (Km/h) +4 +3 +4 +5 +5 +5.5 +5.5 +60 0 0 0 0 +0.5 +0.5 +0.5

2. Check the speedometer for pointer fluctuation and abnormalnoise.

NOTEPointer fluctuations can be caused by a faulty speedom-eter cable.

3. Check to see if the odometer is functioning properly.

Speedometer cable inspection1. Check the cable for kinks, bents or damages in routing.

If the conditions are severe, replace cable.2. After disconnecting cable, check the core for kinks, burrs or

bent tips.

NOTEWhen installing a cable, it is necessary that extra careshould be taken to verify that the stopper of the cable isfitted properly into the speedometer groove and the cableis routed properly to eliminate any kinks.

Reed switch inspection1. Remove the instrument cluster.2. Use an ohmmeter to check circuit repeats on-off between

terminals while the speedometer drive shaft completes a turn.

Press to disconnect


TACHOMETER

On-vehicle inspection

1. Connect the multi-use tester to the diagnosis connector in thefuse box, or install a tachometer.

2. With engine started, compare the readings of the tester withthat of the tachometer.Replace tachometer if difference is excessive.

Standard (RPM) Idle 2,000 3,000 4,000 5,000 6,000 7,000

Tolerance (RPM) ±100 ±150 ±200 ±200 ±200 ±200 ±300

FUEL GAUGE AND FUEL SENDERFuel gauge operation check (in-vehicle)

1. Raise the vehicle and disconnect the fuel sender connectorfrom fuel sender.

2. Ground the harness side connector (terminal 2) via 12V, 3.4 Wbulb.

3. Turn the ignition switch to the ON position.4. Check to be sure that the test bulb flashes and that the indicator

moves gradually to the “F” position.

Fuel gauge inspection1. Remove the instrument cluster.2. Measure the resistance between terminals.

Standard resistance : 55 Q

NOTEIf the resistance value is extremely low, there may be ashort in the coil; if it is extremely high, there may a brokenwire or some other problems in the coil.

Fuel sender inspection

1. Remove the luggage covering carpet and spare tire.2. Remove the fuel tank cover retaining screws.3. Remove the fuel sender assembly.


4. Using an ohmmeter, measure the resistance between termi-nals 2 and 3 at each float level.

Float position E 1/2 F

Resistance Q 110±7 32.5±4 3±2

5. Check that resistance changes smoothly when the float ismoved to “E” or “F”.

Low fuel lebel sensor inspection1. Connect the sender with a test lamp (12V, 3.4W) to the battery

and immerse it in the water.2. The lamp should be off while thermistor is beneath the water,

and should illuminate when the sender is taken out of the water.

NOTEIf there is a malfunction, replace the fuel sender as anassembly.CAUTIONAfter completing this test, wipe the sender dry and installit in the fuel tank.

WATER TEMPERATURE GAUGE ANDSENDER

Water temperature gauge operation check (in-vehicle)

1. Remove the harness connector from water temperature senderlocated in engine compartment.

2. Ground the harness side connector via 12V, 3.4W bulb.3. Turn the ignition switch to ON position.4. Check to be sure that the test bulb flashes and that the indicator

moves.

Water temperature sender inspection

Using on ohmmeter, measure the resistance between terminal andground.If the resistance is out of specification, replace the sender.

OIL PRESSURE SWITCH AND WARNING LAMPOil pressure switch inspection1. Pull out the connector from the oil pressure switch located at the

cylinder block.2. Ensure that there is continuity between switch terminal and

ground under condition of pressure below.

Switch ON pressure .............................................0.3 ± 0.1 kg/cm2 (29.4 ± 9.8 kPa, 4.3 ± 1.4 psi)


Oil pressure warning lamp inspection1. Pull out the connector from the oil pressure switch.2. Ground the harness side connector.3. Ensure that the oil pressure warning lamp lights when the

ignition switch is turned ON.

BRAKE FLUID LEVEL WARNING SWITCHAND LAMP

Brake fluid level warning switch inspection1. Remove the connector from the switch located at brake fluid

reservoir.2. Ensure that the continuity exists between switch terminals 1

and 2 while pressing down the switch (float) with a rod.

Brake fluid level warning lamp inspection1. Start the engine.2. Release the parking brake lever to the original position.3. Disconnect the connector of the brake fluid level warning

switch.4. Ground the connector at the harness side.5. Ensure that the warning lamp lights.

Parking brake switch inspection1. Remove the rear console assembly

2. Disconnect the connector of parking brake switch.3. Check continuity between terminal and body ground.


SEAT BELT WARNING SWITCH AND LAMP

Seat belt switch inspection1. Disconnect the connector from the switch.2. Check for continuity between terminals.

Passiv Passive seat belt switch inspection1. Disconnect the connector from the switch.2. Check for continuity between terminals.

Lap belt switch inspection (with passive seat)1. Remove the connector from the switch.2. Check for continuity between terminals.

Seat belt condition Continuity

Fastened Non-conductive (-Q)

Non fastened Conductive (On)

Seat belt warning lamp inspectionWith the ignition switch turned ON, ensure that the lamp glows.

Seat belt condition Warning lamp

Fastened Off

Not fastened Glows for about six seconds

LIGHTING SYSTEM

LIGHTING SYSTEMSPECIFICATION

items

LampsExterior lamps

Head lampFront turn signal lamp (position lamp incorporated)Front side marker lampRear combination lamp

Tail and stop lampBack-up lampRear turn signal lampRear side marker lamp

Licence plate lamp

Interior lampsLuggage compartment lampHigh mounted stop lampMap lampRoom lamp

Flasher unitBlinking frequency

Turn signalHazard warning

Specifications

65/45 W28/8 W4 W

27/8 W27 W27 W4 W8 W

5 W17 W8 W10 W

85±10 C/M80±12 C/M

LIGHTING SYSTEM 90-25

TROUBLESHOOTING

Problem

One lamp does not work

Headlamps do not work

Tail, parking and licence lamp donot work

Stop lamps do not work

Stop lamps stay on

Instrument lamps do not work(taillamps light)

Turn signal does not flash on oneside

Turn signal does not operate

Hazard warning lamps do notoperate

Flasher rate too slow or too fast

Backup lamps do not work

Possible cause Remedy

Bulb burnt out Replace bulbSocket, wire or ground faulty Repair as necessary

Sub-fusible link (30A) blownHeadlamp relay faultyLighting switch faultyWiring or ground faulty

Tail fuse blownFusible link blown (30A)Taillamp relay faultyLighting switch faultyWiring or ground faulty

Stop fuse blownStop lamp switch faultyWiring or ground faulty

Stop lamp switch faulty

Lamp control rheostat faultyWiring or ground faulty

Bulb burnt-outTurn signal switch faultyWiring or ground faulty

Sub-fusible link (50A) blownTurn signal fuse blownTurn signal flasher faultyTurn signal switch faultyWiring or ground faulty

Hazard fuse blownTurn signal flasher faultyHazard switch faultyWiring or ground faulty

Lamps are of a wattage smaller orlarger than is specified for useDefective flasher unit

Back up fuse blownBack up lamp switch faultyDamaged wiring or poor grounding

Replace sub-fusible linkCheck relayCheck switchRepair as necessary

Replace fuse and check for shortReplace fusible linkCheck relayCheck switchRepair as necessary

Replace fuse and check for shortAdjust or replace switchRepair as necessary

Adjust or replace switch

Check rheostatRepair as necessary

Replace bulbCheck switchRepair as necessary

Replace fusible linkReplace fuse and check for shortCheck flasherCheck switchRepair as necessary

Replace fuse and check for shortCheck flasherCheck switchRepair as necessary

Replace lamps

Replace unit

Check for short, replace fuseCheck switchRepair as necessary

90-26 LIGHTING SYSTEM

HEADLAMP AIMINGPRE-AIMING INSTRUCTIONS1. Test dimmer switch operation.2. Observe operation of high beam indicator light mounted in the

instrument cluster.3. Inspect for badly rusted of faulty headlamp assemblies.

These conditions must be corrected before a satisfactoryadjustment can be made.

4. Place the vehicle on a level floor.5. Bounce the front suspension through three (3) oscillations by

applying body weight to bumper.6. Check and correct tire inflation pressures.7. Rock vehicle sideways to allow vehicle to assume its normal

position.8. If the fuel tank is not full, place a weight in the trunk of the vehicle

to simulate the weight of a full tank.9. There should be no other load in the vehicle other than driver

or substituted weight of approximately 70 kg (150 Ibs.) placedin driver’s position.

10. Thoroughly clean the headlamp lenses.

COMPENSATING THE AIMERS FORFLOOR SLOPE

The floor level offset dial must coincide with the floor slope foraccurate aiming. Calibration fixtures are included with the aimers.1. Attach one calibration fixture to each aimer. Fixtures will easily

snap into position on the aimer when properly positioned.2. Place aimers at the center line of each wheel on one side of

vehicle. Unit A must be placed at the rear wheel with the targetfacing forward. Unit B must be placed at the front wheel with thetarget facing rearward.

3. Adjust the thumb screw on each calibration fixture by turningeither clockwise or counter-clockwise until the level vial bubbleregisters in a centered, level position.

4. Look into the top port hole of Unit A. Turn horizontal knob untilsplit image is aligned.

5. Transfer the plus of minus reading indicated on the horizontaldial to floor level offset dial on each aimer. Press floor level dialinward to set reading.

6. Remove the calibration fixtures from both units.


TIMING AIMER CALIBRATIONThe aimer calibration may be off due to extended use.Calibration fixtures used in conjunction with the aimers can beused to check and adjust the aimer.

1. Turn the thumb adjusting screw on each calibration fixture untilit is approximately the same distance as the supporting posts.

2. Attach the calibration fixtures to each unit with level vials on top.3. Locate the true vertical plate glass window or smooth surface

and secure aimers three to five feet apart so split image targetscan be located in the viewing ports.

4. Set the floor level dial to zero.5. Rotate thumb adjusting screws on each calibration fixture until

level vials on fixtures are centered.6. With both calibration level vials centered, turn vertical dial

knobs on each aimer until aimer level vials are centered. Ifaimer vertical dial pointers read between 1/2 up and 1/2 down,aimers are within allowable vertical tolerance, Recalibrate unitsif beyond these limits.

Vertical dial pointer reading (on each aimer) 1/2 up to 1/2 down

7. Adjust horizontal dial knob on each aimer until split imagetargets align. If aimer horizontal dial pointers read between 1left and 1 right, the aimers are within allowable tolerance limits.Recalibrate units if beyond these limits.

Horizontal dial pointer reading (on each aimer) 1 left to 1 right

MOUNTING AIMERS

1. Remove the calibration fixture from the each unit.2. As shown in the figure, install the articulating vacuum cup

assembly (A), vacuum extension plate (B) and small universaladapter (C) to each unit.

3. Mark the length of the adjustable rod as shown in the figure.


4. Position the aimers on the headlamps pushing the pistonhandle forward, engaging the rubber suction cup. Immediatelypull back the piston handle until it locks in place.

NOTESteel inserts are molded into position on the adapter toinsure accuracy. These inserts must be in contact with thethree guide points on the lamps when the aimers areproperly positioned.

HORIZONTAL ADJUSTMENT1. Set the horizontal dial to zero.2. Check to see that the split image target lines are visible in the

viewing port. If necessary, rotate each aimer slightly to locatethe target.

3. Turn the horizontal screw on the side of the headlamp until thesplit image of target line appears in the mirrors as one solid line.To remove “backlash”, make the final adjustment by turningadjusting screw in a clockwise direction.

4. Repeat the last three steps on the apposite headlamp.

VERTICAL ADJUSTMENT1. The vertical dial should be set at zero. (For passenger vehicles,

“O” setting is generally required. For special settings, consultlocal state laws.

2. Turn the vertical adjusting screw until the level bubble iscentered between the lines.

3. Repeat the last two steps on the opposite headlamp.4. Re-check the target alignment on both aimers and readjust the

horizontal aim if necessary.5. Remove aimers by pressing “vacuum release” button located

on the piston handle.


AIMING WITH SCREEN

Headlamp aiming preparation

Place the vehicle on a level floor, 7.6 m (25 feet) from the aimingscreen or a light-colored wall. Four lines of adhesive tape arerequired on the screen or wall:1. Position a vertical place of tape so that it is aligned with the

vehicle center line.2. Position a horizontal tape with reference to the center line of the

headlamp.3. Position a vertical piece of tape on the screw for vertical

adjustment, adjust side screw for horizontal adjustment.

Visual headlamp adjustment1. A properly aimed low beam will appear on the aiming screen 7.6

m (25 feet) in front of the vehicle. The shaded area as shownin the illustration indicates a high intensity zone.

2. Adjust the low beam headlamps to match the low beam patternof the right and left headlamps.

NOTE:If the visual headlamp adjustment at low beam is made, theadjustment at high beam is not necessary.


RELAYInspection

1. Remove the headlamp relay and taillamp relay2. Check for continuity between the terminals.

NOTE

2. indicates power supply connection.

1. indicates that there is continuity between theterminals.

TURN SIGNAL FLASHER UNITInspection

1. Connect the positive (+) lead from the battery to terminal B andthe negative (-) lead to terminal E.

2. Connect the two turn signal lamps parallel to each other toterminal L and E, check that the bulbs turn on and off.

NOTEThe turn signal lamps should flash 75 to 95 times perminute.If one of the front or rear turn signal lamps has an opencircuit, the number of flashes will be more than 120 perminute.If operation is not as specified, replace the flasher unit.

LIGHTING SYSTEM

1.

2.

HAZARD SWITCHAfter removing the clock, disconnect the hazard switch byprying off two screws.Operate the switch and check for continuity between theterminals by using an ohmmeter.

HEADLAMPREMOVAL AND INSTALLATION1. Remove the side marker lamp by prying off the side marker

lamp mounting nut.2. Remove the headlamp mounting nuts.3. Disconnect the wiring connector.4. Installation is reverse order of the removal.

TIGHTENING TORQUE

Front combination lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 Nm (20-25 kg.cm, 1.4-1.8 Ib.ft)

Head lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Nm (30-50 kg.cm, 2.2-3.6 Ib.ft)


HIGH MOUNTED STOP LAMP

COMPONENTS

STOP LAMP SWITCHINSPECTION1. Remove the stop lamp switch connector located at brake pedal

bracket.2. Make sure that there is continuity between terminals 1 and 2

when the brake pedal is depressed.3. Be sure that no continuity exists between the terminals when

the pedal is released.

1. Remove the luggage compartment lamp switch connector.2. Check for the continuity between terminal ground.

LUGGAGE COMPARTMENT LAMP SWITCHINSPECTION

AUDIO 90-33

AM/FM RADIO WITH CASSETTEBASE AND MEDIUM GRADE

Items H-510 H-550

RadioBandTuning typeMemory (AM/FM)Frequency range

AM/FM1/FM2 AM/FM1/FM2E.T.R. E.T.R.6/12 6/12AM : 530 - 1620 KHz AM : 530 - 1710 KHzFM : 87.5 -108 MHz FM : 87.9 - 107.9 MHz

AudioPower outputVolume type

MAX. 20W x 2CHRotary

MAX. 25W x 2CHRotary

Tape playerDeck typeEject typeOperating type

Full logicKey off reverseAuto reverse

Full logicKey off reverseAuto reverse

DELUXE GRADE

Items H-565

RadioReceiving bandTuring typeMemory (AM/FM)Frequency range

Tape playerDeck typeEject typeReproducing type

Compact disc playerFrequency responseSignal to noise ratio

AM/FM1/FM2E.T.R.6/12AM : 530 - 1710 KHzFM : 87.9 - 107.9 MHz

Full logicKey-off releaseAuto reverse

5Hz-20KHz ± 1..0dB85dB (with 1HF-A)

90-34 AUDIO

SPEAKER

Items Specifications

Front speaker NOM. 20W RMSInput power MAX. 40W RMSRated impedance 4QDistortion MAX. 5%Size 10 cm (4 in.)

Rear speaker NOM. 20W RMAInput power MAX. 40W RMSRated impedance 4Q

AUDIO 90-35

TROUBLESHOOTINGThere are 5 areas where a problem can occur: the wiring harness,radio, cassette tape deck, speaker, and the antenna.Your job in troubleshooting is to isolate the problem to a particulararea.

90-36 AUDIO

CHART 1

AUDIO 90-37

CHART 2

AUDIO 90-39

CHART 4

1. RADIO

AUDIO

CHART 4 (Continued)2. TAPE

CHART 5

AUDIO 90-41

CHART 6

CHART 7

AUDIO

CHART 8

AUDIO 90-43

REMOVAL AND INSTALLATION1. After removing the ashtray, pull out the center panel by remov-

ing the mounting 2 screws.

2. Remove the radio unit from the mounting bracket by removingthe mounting 4 screws.

NOTEReplace in reverse order of the preceding steps.

SPEAKERFRONT SPEAKER

1. Remove the speaker grille.2. Remove the speaker mounting bolts.3. Remove the speaker assembly.4. Replace in reverse order of the preceding steps.

REAR SPEAKER1. Remove the speaker assembly by removing the speaker

mounting bolts.2. And then remove the speaker grille.3. Replace in reverse order of the preceding steps.


FUSE REPLACEMENT

Be sure to use the specified fuse when making a replacement.

CAUTION:Substituting with a higher capacity fuse or connection withouta fuse may result in damage to the unit.

90-44 A U D I O

TAPE HEAD AND CAPSTAN CLEANING1. To obtain optimum performance, clean the head and capstan

as often as necessary, depending upon frequency of use andtape cleanliness.

2. To clean the tape head and capstan, use a cotton swab dippedin ordinary rubbing alcohol.Wipe the head and capstan.

SPEAKER CHECKING

1. Check the speaker by using an ohmmeter.If an ohmmeter indicates the impedance of the speaker whenchecking between speaker (+) and speaker (-) of the samechannel, the speaker is ok.

2. If clicking sound is emitted from the speaker when the ohmme-ter plugs touch the speaker terminals, the speaker is ok.

Ohmmeter

WINDSHIELD WIPER AND WASHER 90-45

WINDSHIELD WIPERSPECIFICATIONS


Wiper motorRated voltageTesting voltageStarting voltageOperating voltage rangeInsulating resistanceSpeed/Current when 10 kg.cm, load test

LowHigh

Speed/Current when 40 kg.cm, load testLowHigh

Wiper arm and bladeArm spring typeArm pressure

Blade typeWiper blade length (when flat)

Wiping angle

DC 12V13.5V (terminal voltage)MAX. 8VDC 10 I 15VMIN. 1MQ

52 ± 4 rpm/MAX 3.5A71 ± 7 rpm/MAX 4.5A

44 ± 4 rpm/MAX 5.5A62 ± 6 rpm/MAX 7A

Tension typeDriver’s side : 740 ± 50 g or less (AT A=16)Passenger’s side : 650 ± 50 g or less (AT A=18)TournamentDriver’s side : 481 ± 2 mmPassenger’s side : 455 mmDriver’s side : 82.5° ± 1°Passenger’s side : 89.5° ± 1°

TROUBLESHOOTING

Problem Possible cause Remedy

Wipers do not operate or returnto off position

Wipers do not operate in INTposition

Wiper fuse blownWiper motor faultyWiper switch faultyWiring or ground faulty

Intermittent relay faultyWiper switch faultyWiper motor faultyWiring or ground faulty

Replace fuse and check for shortCheck motorCheck switchRepair as necessary

Check intermittent relayCheck switchCheck motorRepair as necessary

90-46 WINDSHIELD WIPER AND WASHER

FRONT WIPER

COMPONENTS

30 mm Moulding end line

6.9-10.8 (70-110, 5.1-8.0)


WINDSHIELD WIPER AND WASHER

REMOVAL AND INSTALLATION OF WIPERREMOVAL1. Remove the cap nuts.2. Remove the wiper arms.

3. Remove the cowl top cover by prying off the sealing caps.

4. Remove the wiper motor connector.5. Remove the wiper motor mounting bolts6. Disconnect the nut connected the wiper link assembly, then

remove the motor assembly.

NOTE:When removing the wiper motor only, it can be done bysteps 4 to 6.

7. Remove the 6 screws from the wiper link assembly.8. Take out the wiper link carefully.9. Install in reverse order of the preceding steps.

90-48 WINDSHIELD WIPER AND WASHER

INSPECTIONFRONT WIPER MOTORSpeed operation check1. Remove the connector from front wiper motor.2. Attach the positive (+) lead from the battery to terminal 1 and the

negative (-) lead to terminal 5.3. Check that the motor operates at low speed.4. Connect the positive (+) lead from the battery to terminal 1 and

the negative (-) lead to terminal 6.5. Check that the motor operates at high speed.

Automatic stop operation check1. Operate the motor at low speed.2. Stop motor operation anywhere except at the off position by

disconnecting terminal 5.3. Connect terminals 5 and 6.4. Connect the positive (+) lead from the battery to terminal 1.5. Check that the motor stops running at the off position after the

motor operates again.

WINDSHIELD WIPER AND WASHER 90-49

WINDSHIELD WASHERSPECIFICATIONS


Washer motorMotor typePump typeRated voltageCurrentDischarge pressureFlow rateOver load capacity (continuous operation)

With water

DC ferrite magnet typeCentrifugal typeDC 12VMAX. 3.8AMIN. 1.2 kg/cm2

MIN. 1,320 cc/min.

MAX. 60 sec.

INSPECTIONWASHER MOTOR

1. With the washer motor installed to the washer tank, fill thewasher tank with washer fluid.

2. Attach the positive (+) lead from the battery to terminal 2, andnegative (-) lead to the ground.

3. Check that the washer motor runs and washer fluid is ejected.4. If the motor fails to run smoothly, replace it.


1. Check the washer fluid contact point.2. Adjust the washer fluid contact point by using a metal wire to

move the washer nozzle ball.3. If the motor runs smoothly and little or no washer fluid is

pumped, check for disconnected, blocked washer hose orclogged outlet and faulty pump in the motor.

90-50 CLOCK

CLOCKSPECIFICATIONS

Items

Rated voltageOperating voltageOperating temperature rangeCurrent consumption (with DC. 13V)

Specifications

DC. 12VDC. 6 ~ 16V-30 ~ 80°C (-24 ~ +174°F)MAX. 20 mA (without display illuminated)MAX. 160 mA (with display illuminated)


1. Pull out the electronic digital clock with a trim stick.2. Grasp clock and put outward to remove.3. Disconnect clock connector.4. To install, connect clock connector and snap clock back into

place.

INSPECTION1. Disconnect clock connector.2. Inspect each terminal for applicable trouble, as shown in the

illustration.3. If there is any trouble, repair or replace clock.

CIGARETTE LIGHTER 90-51

CIGARETTE LIGHTERSPECIFICATIONS

Items Specification

Max. input 120WInsulation resistance MIN. 5M4 (at the 500V megger)Return time 13 ± 5 sec. (after pushing the lighter in)Break temperature of thermal fuse °C (°F) 138 ~ 151°C (278.4 ~ 303.4°F)


1. After removing the ashtray, remove the 5 screws and the front console.2. Then disconnect the 3-p connector from the cigarette lighter.3. Disconnect the thermo fuse case from the socket end.4. Remove the ring nut and separate the cigarette lighter socket from the thermal protector.

NOTE:When installing the cigarette lighter, align each lug on the illumination ring and cigarette lighter socket withthe groove of the hole, then position the bulb case on the thermal protect or between the stoppers of the centerpanel.

90-52 CIGARETTE LIGHTER

INSPECTION1. Take out the plug.2. Check the element spot connection for remnants of tobacco

and other materials.3. Using an ohmmeter, check for continuity of the element.

Cautions for use of the cigarette lighter socket as

auxiliary power

1. When using a “plug-in” type of accessory, do not use anythingwith a load of more than 120W.

2. It is recommended that only the lighter be inserted into theholder.

HORN 90-53

HORNSPECIFICATIONS

Items

TypeRated voltage

Power consumptionSound level

Low pitchHigh pitch

Operating voltage rangeOperating temperature rangeInsulation resistanceFundamental frequency

Low pitchHigh pitch

Specifications

FlatDC. 12VMAX. 3.5A (at DC 12V)

110 ± 5 dB (at DC 12V, 2m)110 ± 5 dB (at DC 12V, 2m)DC 10 to 14.5V-40°C ~ 80°C (-42°F ~174°F)MIN. 1 MQ (by 500V Megger)

350 ± 20 Hz415 ± 20 Hz

REMOVAL1. Disconnect the negative cable of battery.2. Remove the headlamp.3. Remove the horn attaching bolt.4. Disconnect the wires from the horn.5. Remove the horn.

ADJUSTMENTOperate the horn, and adjust the tone to a suitable level. (by turningthe adjusting screw to the right “down” or the left “up”)

CAUTION:After the adjustment, apply a small amount paint around thescrew head to avoid the possibility of loosening.

90-54 POWER WINDOW

POWER WINDOWSPECIFICATIONS

items

Power window motorTypeRated voltageRated current (at 30 kg.cm load)No-load currentLock (80 kg.cm or more) currentCircuit breaker

Trip timeTrip current

Specifications

DC motor and reduction gearDC 13.5V8A or less3A or less19A or less

3 ~ 5.5 sec17A

TROUBLESHOOTING

Symptom

All windows do not operate bymain switch

Probable cause

o Sub-fusible link (30A, for IGN)blown

o No.12 fuse (15A) blowno Poor ground (G01)

o Defective power window mainswitch

o Open circuit in wires or loose ordisconnected connector

Remedy

o Replace

o Check the circuit and replace fuseo Clean and retighten the ground

terminal mounting bolto Check the switcho Replace as necessaryo Repair or replace

Driver’s side window onlydoes not operate

o No.11 fuse (15A) blowno Defective power window main

switcho Defective LH motor or circuit

breaker

o Check the circuit and replace fuseo Check for LH switch

o Replace the motor

Passenger’s side window onlydoes not operate

o Open circuit in wires or loose or o Check the harness and the con-disconnected connector nector

o Defective power window sub- o Replace the switchswitch

o Defective motor or circuit breaker o Replace the motoro Wiring faulty or disconnected o Repair as necessary

connector

POWER WINDOW 90-55

COMPONENT

POWER WINDOW MOTORREMOVAL1. Refer to the 60 Group. (Body)2. Detach the regulator assembly.3. Remove the power window motor from the regulator assembly.

INSPECTIONConnect the motor terminals directly to the battery and check thatthe motor operates smoothly. Next, reverse the polarity and checkthat the motor operates smoothly in the reverse direction. If theoperation is abnormal, replace the motor.

90-56 POWER WINDOW

POWER WINDOW SWITCH

CIRCUIT DIAGRAM

sub switch

Power windowmain switch

Power window Tail lamp switch

POWER WINDOW

INSPECTION1. Disconnect the power window switch.2. Turn on the switch, and check the continuity between the

terminals.3. If the continuity does not exist, replace the switch.

MAIN SWITCH (D03) (DRIVER SIDE)

ILLUMINATION(D03)

No. WIRE SIZE & COLOR No. WIRE SIZE & COLOR

1 0.85 BLK 5 0.85 LT GRN I

2 0.85 BRN/BLK 6 0.85 BLK/YEL I

3 0.85 BLU 7 0.85 LT GRN/WHT

4 0 .5G GRN/WHT 8 0.85 BRN/RED

SUB SWITCH (D13) (PASSENGER SIDE)

No. WIRE SIZE & COLOR No. WIRE SIZE & COLOR

1 0.85 BLK/YEL 4 0.85 LT GRN/WHT

2 0.85 BLK/WHT 5 0.85 BLU/RED

3 0.85 BRN/BLK

REMOTE CONTROL MIRROR

REMOTE CONTROL MIRRORSPECIFICATIONS


Remote control mirror actuatorRated voltageRated currentTravel speedCurrent consumptionAdjustment angle

Remote control mirror switchRated voltageRated current

DC 12V6 0 m A3° ± 1°/sec (at DC 13.5 V)MAX. 150 mA9° (up. down. right. left)

DC 12 V0.2 A (MAX. 0.5 A)

TROUBLESHOOTING

Symptom

All mirrors do not operate


o Sub-fusible link (30A, for IGN) blown o Replace

o No.7 fuse (10A) blown o Check the circuit and replace fuse

o Poor ground (G01) o Clean and retighten the groundterminal mounting bolt

o Defective mirror switch o Check the switchReplace as necessary

One mirror do not operate

o Open circuit in wires or loose ordisconnected connector

o Defective mirror switch

o Repair or replace

o Check the switchReplace as necessary

o Defective LH (RH) mirror actuatoro Open circuit in wires or loose or

disconnected connector

o Replace the actuatoro Repair or replace

COMPONENTS

Remote control mirror switch

REMOTE CONTROL MIRROR 90-59

MIRROR SWITCHINSPECTION1. Disconnect the mirror switch connector from the wiring har-ness.2. Operate the switch and check for continuity between the

terminals. If continuity is not as specified, replace the mirrorswitch.

NOTEVL : Vertical LeftVR : Vertical RightHL : Horizontal LeftHR : Horizontal Right

REMOVAL1. Remove the outside mirror switch from the cluster facia panel.2. Remove the connector.

MIRROR ACTUATORINSPECTION

Apply battery voltage to each terminal as shown in the table andconfirm that the mirror operates properly.

90-60 TIME AND ALARM CONTROL UNIT

TIME AND ALARM CONTROL UNIT (T.A.C.U.)SPECIFICATIONS

items

Rated voltageOperating voltage rangeOperating temperature rangeInsulation resistanceRated load

Variable intermittent wiperRear defogger (heated) timerSeat belt warning

Door warning

REMOVAL1. Remove the front LH seat. (4 bolts)

2. Remove the T.A.C.U. cover. (2 tapping screws)3. Remove the T.A.C.U. from the floor. (2 bolts)4. Remove the connector.5. Installation is the reverse order of the removal.

Specifications

DC. 12VDC.9 ~ 16V-30” ~ +80°C (-22°F ~ +176°F)MIN. 100 MS2 (with 500V megger)

MAX. 5A (Inductance load)DC. 14.3V, 200W (Resistance load)DC. 12V, 1.2W (Lamp load)DC. 13.5V, 350mA (Inductance load)DC. 13.5V, 350mA (Inductance load)

INSPECTIONVARIABLE INTERMITTENT WIPER

1. Operating characteristic : Fig.12. T1 : MAX. 0.5 sec.

T2 : Time of wiper motor 1 rotation.T3 : 1.5 ± 0.7 sec. (VR=0 kR) ~ 10.5 ± 3 sec. (VR=50 kQ)

3. Variable resistance (VR) 50 ± 1okQ

TIME AND ALARM CONTROL UNIT

WASHER1. Operating characteristic : Fig.22. T1 : 0.4 ~ 1.2 sec.

T2 : 2.0 ~ 4.7 sec.3. This function should be operated preferentially even though the

variable intermittent wiper is operating.

REAR DEFOGGER (HEATED) TIMER1. Operating characteristic : Fig.32. T1 : MAX. 0.5 sec.

T2 : 10 ± 3 min.

DOOR WARNING1. Operating characteristic : Fig.42. T1, T2 : 0.3 ± 0.1 sec.

SEAT BELT WARNING (CANADA)1. Operating characteristic : Fig.52. T1 : 6 ± 1 sec.

T2 : MAX. 6 ± 1 sec.T3, T4 : 0.3 ± 0.1 sec.

PASSIVE SEAT BELT WARNING (U.S.A.)

1. Operating characteristic : Fig. 62. T1 : 6 ± 1 sec.

T2 : 60 ± F sec.T3, T4 : 0.3 ± 0.1 sec.

90-62 TIME AND ALARM CONTROL UNIT

LAP BELT WARNING (U.S.A.)

1. Operating characteristic : Fig. 72. T1 : 6 ± 1 sec.

T2 : MAX. 6 ± 1 sec.T3, T4 : 0.3 ± 0.1 sec.

3. It should be operated by the passive seat belt warning whenboth of passive seat belt warning and lap belt warning areoperating simultaneously.

CONTROL UNIT1. After tracing the problem to the control unit, replace it with a new

one. Check for proper operation.2. If system operates properly, the original control unit is faulty.

REAR HEATED (DEFOGGER) GLASSPRINTED HEATER LINE CHECK

CAUTION:Wrap tin foil around the end of the voltmeter test lead toprevent damaging the heater line. Apply finger pressure on thetin foil, moving the tin foil along the grid line to check for opencircuits.

1. Turn on the defogger switch and use a volt meter to measure thevoltage of each heater line at the glass center point. If a voltageof approximately 6V is indicated by the voltmeter, the heaterline of the rear window is considered satisfactory.

2. If a heater line is burned out between the center point and (+)terminal, voltmeter indicates 12 volts.

Printed heater line

TIME AND ALARM CONTROL UNIT 90-63

3. If a heater line is burned out between the center point and (-)terminal, the voltmeter indicates 0 volts.

4. To check for open circuits, slowly move the test lead in thedirection that the open circuit seems to exist. Try to find a pointwhere a voltage is generated or changes to 0V. The point wherethe voltage has changed is the open-circuited point.

Defogger OFF5. Use an ohmmeter to measure the resistance of each heater line

between a terminal and the center of a grid line and between thesame terminal and the center of one adjacent heater line afteranother. The section involving a broken heater line indicatesresistance twice as that in other section. In the affected section,move the test lead to a position where resistance sharplychanges.

RepairProvide the following items:1. Conductive paint2. Paint thinner3. Masking tape4. Silicone remover5. Thin brush

Wipe the glass adjacent to the broken heater line, clean withsilicone remover and attach the masking tape as shown. Shakethe conductive paint container well, and apply three coats witha brush at intervals of about 15 minutes apart. Remove the tapeand allow sufficient time for drying before applying power.For a better finish, scrape away excess deposits with a knifeafter completely dried. (allow 24 hours)

CAUTION:After repairing, clean the glass with a soft dry cloth or wipealong the grid line with a slightly moistened cloth.

Masking tape

TRUNK LID OPENER

TRUNK LID OPENERSPECIFICATIONS

items

Trunk lid openerRated voltageInsulating resistanceOperating temperature rangeRated current

Trunk lid opener switchTypeRated voltageOperating force

Specifications

DC 12VMIN. 5R (with 500V megger)-40°C ~ +80°C (-40°F ~ +176°F)11.5 ± 1A

Auto return typeDC 12V0.4 ~ 1.0 kg

COMPONENTS

TRUNK LID OPENER 90-65

INSPECTIONTRUNK LID OPENER SWITCH

Remove the trunk lid opener switch and check for continuitybetween the terminals. If continuity is not as specified, replace theswitch.

TRUNK LID OPENERRemove the trunk lid opener and check for continuity between theterminal “1” and “2”. If there is no continuity, replace the openerassembly.

90-66 AUTOMATIC TRANSAXLE AND KEY LOCK CONTROL SYSTEM

AUTOMATIC TRANSAXLE AND KEY LOCK CONTROL SYSTEMSPECIFICATION

I tems Specifications

Control unitRated voltageOperating voltage rangeOperating temperature rangeRated load

A/T solenoidRated voltageRated currentOperating voltage rangeOperating temperature rangeOperating force

Initial pull in forceSpring forceHolding force

Key lock solenoidOperating voltage rangeOperating temperature rangeExciting currentOperating force

Pull in forceHolding force

Parking position switchRated loadOperating forceOperating temperature range

DC 12VDC 9 ~ 16V-30°C ~ +80°C (-22°F ~ +176°F)MAX. 1A (A/T solenoid)MAX. 0.8A (Key lock solenoid)

DC 12V1A (MAX. 2A)DC 9 ~ 16V-30°C ~ +80°C (-22°F ~ +176°F)

0.4 kg.cm (at 12V, 20°C)0.2 kg.cm (at 12V, 20°C)1.5 kg.cm (at 12V, 20°C)

DC 9 ~ 16V-30°C ~ +80°C (-22°F ~ +176°F)MAX. 0.9A

MIN. 0.17 kg.cm (at DC 7.5 ± 0.1V)MIN. 0.25 kg.cm (at DC 6 ± 0.1V)

1A (resistance load, at DC 12V)0.8 ± 0.2 kgf-30°C ~ +80°C (-22°F ~ +176°F)

AUTOMATIC TRANSAXLE AND KEY LOCK CONTROL SYSTEM 90-67

COMPONENTS LAYOUT

A. Control unit

C. Key lock solenoid

B. A/T solenoid

D. P/position switch


SYSTEM CHECKKEY LOCK SYSTEM1. Check that the ignition key cannot be turned to “LOCK (OFF)”

position, when the position of the shift lever is not in "P" position.

2. Check that the ignition key turns to the "LOCK. (OFF)" position,when the shift lever is set to the “P” position.

SHIFT LOCK SYSTEM1. Check that under the following conditions, the shift lever cannot

be moved from the “P” position to any other position.IGNITION KEY POSITION : “ON”BRAKE PEDAL : DEPRESSEDBUTTON : PRESSED

2. Check that under the following conditions, the shift lever can bemoved from the “P” position to other position.IGNITION KEY POSITION : “ON”BRAKE PEDAL : NOT DEPRESSEDBUTTON : PRESSED

AUTOMATIC TRANSAXLE AND KEY LOCK CONTROL SYSTEM 90-69

INSPECTION

TIMING CHART


AUTOMATIC TRANSAXLE SOLENOID1. Remove the solenoid connector.2. Using an ohmmeter, measure the resistance between termi-

nals.

Standard resistance : 12-16 Q

3. Attach the positive (+) lead from the battery to terminal 1. andthe negative (-) lead to terminal 2.

4. Check that an operation noise can be heard from the solenoid.

KEY LOCK SOLENOID1. Remove the solenoid connector.2. Using an ohmmeter, measure the resistance between termi-

nals.

Standard resistance : 12.5-16.5 R

3. Attach the positive (+) lead from the battery to terminal 2. andthe negative (-) lead to terminal 1.

4. Check that an operating noise can be heard from the solenoid.

AIRCONDITIONINGSYSTEM

Return To Main Table of ContentsGENERAL .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

VENTILATORS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

HEATER CONTROL ASSEMBLY ........................... 21

HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

BLOWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

AIR CONDITIONER SYSTEM .............................. 30

AIR CONDITIONER SERVICE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

CONDENSER ................................................. 50

RECEIVER DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

EVAPORATOR UNIT .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

THERMOSTAT .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

DUAL PRESSURE SWITCH ................................. 57

REFRIGERANT LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

RELAYS ...................................................... 61

97-2 GENERAL

SPECIFICATION

GENERAL 97-3

SPECIAL TOOLS


09977-22000Pressure plate bolt remover

09977-22100Pressure plate puller

Illustration Use

Removal and installation of pressureplate

Removal of pressure plate

97-4 GENERAL

LOCATION OF COMPONENTS

A, B, C, D

A. A/CON RELAYB. CONDENSOR FAN RELAYC. RADIATOR FAN RELAY (HI)D. RADIATOR FAN RELAY (LO)

F. DUAL PRESSURE SWITCH/FUSIBLE PLUG

E. BLOWER RELAY

G. FUSE

H. THERMOSTAT I. BLOWER RESISTOR

GENERAL

VACUUM SYSTEM

V: VACUUMNV : NO VACUUMPV : PARTIAL VACUUM

MODE S/W REC & FRESH S/W

MODE CONTROL SWITCHING

MODE SWITCH BUTTON FRESH/REC-BUTTON

CONNECTION FUNCTION(VacuumHose Color)

PANEL PANEL FLOOR FLOORFLOOR

DEF RECIRC FRESHDEF

BLACK SOURCE V V V V V V V

BLUE FLOOR (PARTIAL A V V V A - -

RED FLOOR (FULL) A A V A A - -

YELLOW PANEL V V A A A - -

WHITE RECIRC * * * * V V

V=Vacuum A=Atmosphere*=Controlled by “RECIRC” or “FRESH” button.

97-6 GENERAL

SYMPTOM AND PROBABLE CAUSE IN AIR FLOW MODE CONTROL SYSTEM


On “FLOOR” position. All air through de- o Blue and/or red vacuum hose pinched or disconnected at vacuumfroster or DEF/FLOOR. motor.

o Black source hose pinched or disconnected at the connector.o Engine compartment vacuum source hose pinched or

disconnected at the vacuum manifold.o Defective vacuum motor.

On “DEF/FLOOR” position. All air through o Blue hose pinched or disconnected at vacuum motor.defroster; o Blue vacuum hoses installed improperly (reversed).



On “PANEL VENTS” position. All air through o Yellow vacuum hose pinched or disconnected at vacuum motor.defroster. o Black source hose pinched or disconnected at the connector.

o Engine compartment vacuum source hose pinched ordisconnected at the vacuum manifold.

o Defective vacuum motor.

On “PANEL/FLOOR” position. All air through o Yellow vacuum hose pinched or disconnected at vacuum motor.defroster or panel o Blue hose pinched or disconnected at vacuum motor.



On “DEF” position. (No vacuum) o White vacuum hose disconnected at the connector or recirc ductOn “RECIRC” position. All air through fresh. vacuum motor.



Engine poor idle o Engine compartment vacuum source hose disconnected.

TROUBLESHOOTING 97-7

SYMPTOM CHART

SYMPTOM REMEDY

No hot air flow Blower motor does not run at all Perform the flow chart (page 97-8)

Blower motor runs Check following :o Clogged heater ducto Clogged blower outleto Clogged heater core or hoseo Faulty air mix dooro Air mix cable adjustment

Hot air flow is low Blower speed does not change Perform flow chart (page 97-10)

Blower runs properly Check following:o Clogged heater ducto Clogged blower outleto Incorrect door position

Compressor does not come on even though the Perform the procedures in the flow chart. (page 97-11)condenser fan (or radiator-fan) run.

Compressor and condenser fan (or radiator fan) donot run.

Perform the procedures in the flow chart. (page 97-15)

Only condenser fan (or radiator fan) does not run.

Idle-up is not ok.

Perform the procedures in the flow chart. (page 97-17)

See the fuel and emissions section.

QUICK TROUBLESHOOTING HINTS

1. Check fuse No. 1 and No. 11 for blower control system.2. Check that blower relay is mounted in passenger compartment relay box.3. Check fuse No. 5 and No. 14 for A/C control system.4. Check that A/C relay is mounted in engine compartment relay box.5. Check that A/C system is properly charged.

(Refer to Air Conditioner service page 97-32)6. Checkfuse 30A (PINK) and 20A (BLUE) forcondenser and radiator fan controls, mounted in engine compartment.

TROUBLESHOOTING

SYMPTOM BLOWER MOTOR DOES NOT RUN AT ALL (Refer to circuit diagram page WS-138)


(From page 97-8)

o Remove the heater control assembly (See page 97-21)o Disconnect the M39 (6P) connector from the blower

switch

o Connect the jumper wire between the M39;6(BLU/BLK) terminal and body ground.

o Turn the ignition, blower switches ON.o Blower motor should be run.

N . GO.K

o Turn ignition switch OFF.o Remove the jumper wire.

Repair open in GRN wire between blower relayM32;3 terminal and blower switch M39;2 termi-nal.

Inspect the blower speed control switch (see page 97-23)

O.K

Repairopen BLK wire between the blower switch and bodyground or poor ground (G02).

N.GReplace the blower switch assembly

TROUBLESHOOTING

SYMPTOM BLOWER MOTOR RUNNING SPEED DOES NOT CHANGE.(Refer to circuit diagram page WS-138)

1. Ignition switch OFF.2. Remove the glove box cover.3. Disconnect the M50 connector from the blower resistor.

o Check for continuity between the 2 and 4 terminals ofthe blower resistor. (see page 97-33)

o Should show continuity.

N.GO.K

Replace the resistor.

o Disconnect the M39 (6P) connector from the blowerswitch.

o Reconnect the M50 connector to the blower resistor.o Remove the heater control assembly.

(See page 97-21)

NOTE : May be blown out the thermal limiter orresistor coil.

Turn ignition switch ON.

Measure voltage between :o M39;3 terminal and body ground.o M39;4 terminal and body ground.o M39;5 terminal and body ground.o M39;6 terminal and body ground.o Battery voltage should be read.

N.GO.K

Repair open circuit between M39;3,4,5 terminaland M50;6,1,4 terminal.

o Turn ignition switch OFF.o Check for continuity from M39;1 terminal to body ground.o Should show continuity.

N.GO.K Repair open in BLK wire between M39;1

o Replace the blower switch assembly.terminal and body ground (G02).


SYMPTOMCOMPRESSOR DOES NOT COME ON EVEN THOUGH THE CONDENSOR FAN(or Radiator fan) RUN

TROUBLESHOOTING

(FROM PAGE 97-11)

1. Measure voltage between E07;1 terminal (+) and bodyground (-).

2. Turn ON the ignition switch.l Battery voltage should be read.

N.G1.- - - - - - - - - - - Repair open on short circuit from E07;1 and/

O.K or EM03;10 terminal to No. 13 fuse.

1. Check the A/C relay operation.(see page 97-61)

O.K - - - - - - - - - -

1. Turn OFF the ignition switch.2. Reinstall the A/C relay.3. Disconnect C01 connector from the ECU.

Replace A/C relay.

1. Connect jumper wire between C01;32 terminal andbody ground.

2. Turn ON the ignition switch.* Compressor clutch should be engage.

O.KN.G Repair open circuit from C01;32 and/or MC01;1,

EM02;2 to E07;3 terminal.

1. Turn ON the blower switch and A/C switch.2. Measure voltage between C01;40 terminal (+) and

body ground (-).* Battery voltage should be read.

(GO TO PAGE 97-13)

Substitute a known-good ECU and recheck.If prescribed voltage is now available, replace the originalECU.


(FROM PAGE 97-12)

TROUBLESHOOTING

(FROM PAGE 97-13)

1. Turn the ignition switch OFF.2. Reconnect E20 connector to the dual pressure switch.

1. Disconnect M48 connector from the thermostat switch.2. Connect the jumper wire between M48;1 and M48;2

terminal.

1. Turn the blower, A/C switches ON.2. START the engine.l Compressor clutch should be engage.

N.G

O.K (Perform to page 97-13)

Replace the thermostat switch.(Refer to page 97-54)


SYMPTOM COMRPESSOR AND CONDENSER FAN (or Radiator fan) DO NOT RUN.

(Refer to circuit diagram page WS-141)

97-16 TROUBLESHOOTING

(FROM PAGE 97-15)

1. Turn the ignition switch OFF.2. Reconnect the I15 connector to the A/C switch.3. Remove the glove box from the main crush pad.4. Disconnect the M48 connector from the thermostat

switch.


SYMPTOM ONLY CONDENSER FAN (or radiator fan) DOES NOT RUN

(Refer to circuit diagram on page WS-58)

1. Inspect PINK (30A) fuse in the main fusible link box.

N.GO.K Replace the fuse.

1. Turn the ignition switch OFF.2. Disconnect E05 connector from the condenser fan

relay in the engine compartment relay box.

1. Turn the ignition, blower, A/C switches ON.2. Measure voltage between E05;1 terminal (+) and body

ground (-).* Battery voltage should be read.

N.G 1. Turn the ignition switch OFF.

O.K 2. Repair open circuit between E05;1 and/orEM03;13 to M48;1 terminal.

1. Measure voltage between E05;3 terminal (+) and bodyground (-).

* Battery voltage should be read.

N.GGO TO PAGE 97-18.O.K

1. Connect jumper wire between E05;3 terminal (+) andbody ground (-).

l Condenser fan should be run.

N.GO.K

Replace the condenser fan relay

O.K

Should show continuity.

1. Turn the ignition switch OFF.2. Measure continuity between E05;2 terminal

(+) and body ground (-).*

N.G

Repair open circuit or poor connection betweenE05;2 terminal and body ground (G03).

97-18 TROUBLESHOOTING

(FROM PAGE 97-17)

Should show battery voltage.

1. Disconnect E25 connector from the condenser fanmotor.

2. Measure voltage between E25 terminal (+) and bodyground (-).

*

O.KN.G Repair open circuit between E25;1 terminal and

BLUE (20A) fuse for condenser fan in the mainfusible link.

1. Reconnect E25 connect the to the condensor fanmotor.

2. Connect jumper wire between E25;2 terminal andbody ground by using paper clip.

l Condenser fan should be run.N.G

O.K

Repair poor connection or open circuit between E16;2 andE25;1 terminal.

Replace the condenser fan motor assembly.

VENTILATORS 97-19

VENTILATORS

COMPONENTS

Side air vent hose assembly Defroster nozzle assembly

97-20 VENTILATORS

REMOVAL AND INSTALLATION1. Remove the main crash pad assembly (Refer to BODY GROUP).2. Remove the side air vent louver duct assembly (LH/RH) after

removing the speaker.

3. Remove the heater connection assembly.4. Remove the defroster nozzle assembly.5. Remove the side defroster nozzle assembly (LH/RH).6. Remove the crash pad upper cover assembly.

7. Remove the side air vent hose assembly (LH/RH).8. Remove the side air vent louver assembly (LH/RH).

9. Remove the rear heating joint duct assembly and rear heatingside duct assembly (LH/RH).

10. Installation is the reverse of removal procedures.

HEATER CONTROL ASSEMBLY 97-21

HEATER CONTROL ASSEMBLY

COMPONENTS

Cluster facia pannel Facia panel assembly

Heater control assembly


1. Disconnect the battery ground cable.2. Remove the T.G.S (Transmission gear shift) knob.3. Using a screwdriver, pry loose two clips and remove the front

console cover after disconnect the connector for cigarettelighter.

4. Pull out the ash tray and remove two screws.

5. Using a screwdriver, pry loose 4 clips and disconnect theconnectors.NOTE : Tape the screwdriver tip before use.

6. Remove the center facia pannel.

97-22 HEATER CONTROL ASSEMBLY

7. Remove the clock assembly, using a flat blade screwdriver.NOTE : Tape the screwdriver tip before use.

8. Disconnect connector from the rheostat switch.9. Remove six screws from the cluster facia pannel as shown right

figure.10. Remove the cluster facia pannel.

11. Remove four mounting bolts of heater control assembly.12. Pull out the heater control assembly and then disconnect

connectors.

13. Disconnect the air mix control cable and vacuum connector.14. Remove the heater control assembly.15. Installation is the reverse of removal.

AIR MIX CABLE ADJUSTMENTAfter install the heatercontrol assemblythe adjust the air mix cable.1. Slide the temperature control lever to HOT.2. Turn the air mix door shaft arm to the left and connect the end

of the cable to the arm.3. Gently slide the cable outer housing back from the end enough

to take up any slack in the cable, but not enough to maketemperature control lever move, then snap the cable housinginto the clamp.

HEATER CONTROL ASSEMBLY 97-23

INSPECTIONBLOWER SWITCH1. Check for continuity between terminals as shown below.

If continuity is not as specified, replace the switch.

AIR CONDITIONER SWITCH1. Check for continuity between terminals as shown below.

If continuity is not as specified, replace the switch.

MODE CONTROL SWITCH

1. Connect the vacuum tester to black color hose of the vacuumconnector.

2. Connect the vacuum hoses to mode control switch.3. Clogged vacuum port for fresh/recirc control switch.4. Check for vacuum hiss from the mode switch and vacuum

hoses, and inspect for air flow between each hoses when themode switch is at the each positions as shown below.

NOTE :‘V’ : make airflow with blackhose.

If air flow is not as specified, replace the mode switch.

FRESH/RECIRCE BUTTON1. Connect the vacuum tester to black color hose for the fresh/

recirc control switch.2. Check for vacuum hiss and air flow as shown right figure.

97-24 HEATER UNIT

HEATER UNIT

COMPONENTS

HEATER UNIT 97-25

REMOVAL1. Disconnect the negative terminal from the battery.2. Discharge the refrigerant from the refrigeration system.

(Refer to page 97-36).3. Drain the coolant from the radiator.4. Remove the heater hoses and the evaporatorwater drain hose,5. Remove the suction and the liquid lines from the evaporator.6. Disconnect the vacuum source hose from the pipe for mode

control.

7. Remove the front and rear console assembly, cluster faciapanel and lower crash pad (LH).

8. Remove the center facia panel (Refer to page 97-21).

9. Remove the glove box assembly and lower crash pad.10. Remove the heater control assembly (Refer to page 97-21).11. Remove the center skin bracket.

12. Remove the rear heating joint duct assembly.13. Remove the evaporator assembly.14. Remove the heater unit assembly.

INSTALLATION1. Installation is the reverse of the removal procedures.2. After installation of the heater unit check that the air mix lever

slides smoothly, the full stroke right to left.If not ok, readjust the air mix cable (See page 97-22).

97-26 HEATER UNIT

DISASSEMBLY AND ASSEMBLY1. Remove the seal from the cases.2. Remove seven clips, holding the both cases.3. Separate the cases then pull out the heater core from the heater

cases.4. Assembly is the reverse of disassembly procedures.

INSPECTION

HEATER CORE1. Using a special tool, install to the heater core one side and the

other side is clogged.2. Place the heater core in water, then apply 200kpa (29psi)

pressure.3. Holding for two minutes, while checking for leakage from the

heater core.If there is leakage, repair or replace the heater core.

VACUUM MOTOR1.

2.

Connect vacuum tester to the each vacuum connectors andapply-650mmHg pressure.Check vacuum hiss from the diaphragm of the vacuum motorand smoothly return the shaft to initial position.If not ok, replace the vacuum motor.NOTE:Never manually operate any vacuum motor or vacuummotor controlled door this may cause internal damage tothe motor diaphragm.

BLOWER UNIT 97-27

BLOWER ASSEMBLY

COMPONENTS


1. Remove the glove box housing cover assembly.2. Remove the lower crash pad assembly.3. Disconnect the resistor and blower motor connector.4. Remove the three nuts from the blower unit mounting bracket.5. Pull out the blower unit and then disconnect the fresh/recirc

vacuum connector.6. Installation is the reverse of removal.

DISASSEMBLY AND ASSEMBLY

1. Disconnect the motor cooling tube.2. Remove the three screws and the blower motor assembly.

97-28 BLOWER UNIT

3. Remove the three screws and the inlet duct assembly.

4. Remove five clips, holding the upper case to the lower case.5. Remove two screws and the blower resistor.

6. Remove one screw from the cam lever of the vacuum motor.7. Remove two screws, holding the vacuum motor to the inlet

duct.8. Remove the vacuum motor assembly.9. Assembly is the reverse of disassembly procedures.

INSPECTIONBLOWER MOTOR

1. Check for bending or abnormal deflection of the rotating shaftof the blower motor assembly.

2. Check for cracking or deterioration of the packing.3. Check for damage to the fan.4. Check for damage to the blower case.5. Check the operation of the inside/outside air selection damper,

and for damage.6. Connect the blower motor terminals directly to the battery and

check that the blower motor operates smoothly.7. Next, reverse the polarity and check that the blower motor

operates smoothly in the reverse direction.

BLOWER UNIT 97-29

BLOWER RESISTOR

1. Measure terminal-to-terminal resistance of the blower resistor.If measured resistance is not within specification, the blowerresistor must be replaced.

NOTE :

O - O indicates that there is continuity between the points.

VACUUM MOTOR

1. Connect vacuum tester to the vacuum motor and apply-650mmHg pressure.

2. Check vacuum hiss from the vacuum motor and smoothlyreturn the shaft to initial position.If not ok, replace the vacuum motor.NOTE :

Never manually operate any vacuum motor or vacuummotor controlled door this may cause internal damage tothe motor diaphragm.

97-30 AIR CONDITIONER SYSTEM

AIR CONDITIONER

COMPONENTS

TORQUE : Nm (Kg-cm, Ib.ft)

AIR CONDITIONER SYSTEM

REFRIGERATION CYCLE

Low pressure andlow temperature liquid

Low pressure andlow temperature gas

97-32 AIR CONDITIONER SERVICE

GENERAL SERVICE INSTRUCTIONSWHEN HANDLING REFRIGERANT (R-l 2)1.

2.

3.

4.

5.

R-12 liquid refrigerant is highly volatile. A drop on the skin ofyour hand could result in localized frostbite, When handling therefrigerant, be sure to wear gloves.If the refrigerant splashes into your eyes, wash them with cleanwater immediately. It is standard practice to wear goggles orglasses to protect your eyes, and gloves to protect your hands.The R-12 container is highly pressurized, never leave it in a hotplace, and check that the storage temperature is below 52°C(126°F).A halide leak detector is often used to check the system forrefrigerant leakage. Bear in mind that R-12, upon coming intocontact with flame (this detector burns propane to produce asmall flame), produces phosgene a toxic gas.The discharge of R-12 refrigerant into the atmosphere depletesthe earth’s protective ozone layer. Hyundai recommends thatR-12 refrigerant should be recovered and recycled if possible.

WHEN REPLACING PARTS ON A/C SYSTEM1. Never open or loosen a connection before discharging the

system.2. Seal the open fittings with a cap or plug immediately in discon-

nected parts to prevent intrusion of moisture and dust.3. Do not remove the sealing caps from a replacement component

until it is ready to be installed.4. Before connecting an open fitting, always install a new sealing

ring. Coat the fitting and seal with refrigerant oil before makingthe connection.

WHEN INSTALL CONNECTING PARTS

Bolt/nut coupling type1. Lubricate O-ring fittings with compressor oil for easy tightening

and to prevent leaking of refrigerant gas.2. Tighten the nut using two wrenches to avoid twisting the tube.3. Tighten the O-ring fittings to the specified torque.

loosening

Over Torquing

AIR CONDITIONER SERVICE

Flange Coupling Type1. Check for missing or damaged the new O-ring (use only

specified one) and lubricate using compressor oil.2. Hand tighten the nut by pushing the one side pipe.3. Tighten the nut to the specified torque.

HOW IS THE MAGNETIC CLUTCH ENERGIZED ?The general process until the magnetic clutch is energized as shown below.

Engine run

ENGINESPEED(Crankanglesignal)

Blower relay “ON” (Blower Motor “RUN”)

A/C main power supply.

Refer to page 97-56

Refer to page 97-56

Idle up control to target rpm by controlling ISCactuator. (rpm feed back control)


ON-VEHICLE INSPECTION1. Check condenser fins for blockage or damage.

If the fins are clogged, clean them with pressurized water.NOTE:Be careful not to damage the fins.

2. Make sure that drive belt is installed correctly.Check that the drive belt fits properly in the ribbed grooves.

3. Check drive belt tension.If the proper tensions are not maintained, belt slippage willgreatly reduce air conditioning performance and drive belt life.To avoid such adverse effects, the following service procedureshould be followed:1) Any belt that has operated for a minimum of one half-hour

is considered to be a “used” belt. Adjust air conditioningdrive belt at the time of new-car preparation.

2) Check drive belt tension at regular service intervals andadjust as needed.

L(mm)

NEW BELT 5-5.5

USED BELT 6-7

4. Start Engine.5. Turn ON A/C Switch,

Check that the A/C operates at each position of the blowerswitch.

6. Check magnetic clutch operation.7. Check idle RPM increases.

When the magnetic clutch engages, idle RPM should beincreased (refer to engine section).

Pulley

Wrong

V-ribbed beltRight Wrong

AIR CONDITIONER SERVICE 97-35

8. Check condenser and radiator fan motor rotates.

9. Check amount of refrigerant1. Bring the engine speed up to 1,500 rpm.2. Operate air conditioner at maximum cooling for a few

minutes.3. Observe the sight glass on the receiver-drier and check the

amount of refrigerant in the system.

10. If no cooling or it is insufficient, inspect for leakage.Using a gas leak detector, inspect each component of therefrigeration system.


DISCHARGING THE REFRIGERANTSYSTEMCAUTIONIt has been determined that the discharge of R-12 refrigerantinto the atmosphere depletes the earth’s protective ozonelayer.Hyundai recommends that R-12 be recovered and recycledwhen possible.

When handling refrigerant (R-l 2):1) Always wear eye protection.2) Do not let refrigerant get on your skin or in your eyes. If it

does:- Do not rub your eyes or skin.- Splash large quantities of cool water in your eyes or on

your skin.- Rush to a physician or hospital for immediate treat-

ment. Do not attempt to treat it yourself.3) Keep refrigerant containers (cans of R-l 2) stored below

40°C (100°F).4) Keep away from open flames. The refrigerant, although

inflammable, will produce a poisonous gas if burned.5) Work in a well-ventilated area. Refrigerant evaporates

quickly, and can force all the air out of a small, enclosedarea.

1. Connect the refrigerant recovery system to the vehicle’s A/Csystem.

2. Operate the refrigerant recovery system according to themanufacturers instructions.

EVACUATING REFRIGERANT SYSTEM

1. When an A/C System has been opened to the atmosphere,such as during installation or repair, it must be evacuated usinga vacuum pump. (If the system has been open for several days,the receiver/dryer should be replaced).

2. Start the pump, then open both gauge valves. Turn the pumpfor about 15 minutes. Close the valves and stop the pump. Thelow gauge should indicate above 700 mm Hg (27 in-Hg) andremain steady with the valves closed.NOTE :If low pressure does not reach more than 700 mmHg (27 in-Hg) in 15 minutes, there is probably a leak in the system.Check for leaks, and repair (see Leak Test below).

3. If there are no leaks open the valves and continue pumping forat least another 15 minutes, then close both valves and stop thepump.


LEAK TEST

1. Attach an Air Conditioning Service Station.2. Open high pressure valve to charge the system to about 100

kPa (14psi), then close the supply valve.3. Check the system for leaks using a leak detector.4. If you find leaks that require the system to be opened (to repair

or replace hoses, fittings, etc.), release any charge in thesystem according to the Discharge Procedure on page 97-36.

5. After checking and repairing leaks, the system must be evacuated (see System Evacuation on page 97-36).

Electronic Leak DetectorThe leak detector is a delicate device that detects small amounts ofhalogen.In order to use the device properly, read the manuals suppliedby the manufacturer to perform the specified maintenance andinspections.

If a gas leak is detected, proceed as follows:1. Check the torque on the connection fitting and, if necessary,

tighten to the proper torque, check for leakage with the leakdetector.

2. If leakage continues even after the fitting has been retightened,discharge the refrigerant from the system, disconnect thefitting, and check the seat for damage.Replace fitting, even if the damage is slight.

3. Check compressor oil and add oil if required.4. Charge the system and recheck for leaks. If no leaks are found,

evacuate and charge the system.


CHARGING REFRIGERANT SYSTEMNOTEThis step is to charge the system through the low pressureside with refrigerant in a vapor state. When the refrigerantcontainer is placed right side up, refrigerant will enter thesystem as a vapor.

1.2.

3.

4.

5.

Attach an Air Conditioning Service Station as shown rightfigure.Open the low pressure valve. Adjust the valve so that the lowpressure gauge does not read over 412 kPa (4.2 kg/cm2, 60psi)Put the refrigerant in a pan of warm water on heat plate(maximum temperature 40°C (104°F)) to keep vapor pressurein the container slightly higher than vapor pressure in thesystem.Run the engine at fast idle, and operate the air conditioner.NOTE :Be sure to keep the container upright to prevent liquidrefrigerant from being charged into the system throughthe suction side, resulting in possible damage to thecompressor.Charge the system to the specified amount. Then, close the lowpressure valve.Specified amount: 900 ± 50 g (2.1 lb)

PERFORMANCE TESTThe performance test will help determine if the air conditioningsystem is operating within specifications.1. Connect the hoses as shown above figure.2. Insert a thermometer in the vent outlet. Determine the relative

humidity and ambient air temperature by a portable weatherstation or calling the local weather station.

3. Test conditions:o Avoid direct sunlight.o Open engine hood.o Open front doors.o Set the temperature control dial to MAX COOL and slide the

function control lever to PANEL position and recirculationcontrol lever to RECIRC position.

o Turn the fan switch to HIGH.o Run the engine at 1,500 RPM.o No driver or passengers in vehicle.

4. After running the air conditioning for 20 minutes under theabove-test conditions, read the delivery temperature from thethermometer in the dash vent and the high and low systempressure from the A/C gauges.

5. Compare with performance test chart (Refer to page 97-40).


PERFORMANCE TEMPERATURE CHART

Garage ambient temperature°C(°F)Discharge all temperature°C(°F)

Compressor discharge pressurekPa (psi)Evaporator suction pressurekPa (ps i )

21 (70) 26.5(80) 32 (90) 37.5(100) 40.6(105)

1.7-4.4 1.7-5.0 1.7-5.6 1.7-6.1 1.7-6.7(35-40) (35-41) (35-42) (35-43) (35-44)

928-1.322 1.069-1.547 1.209-1.772 1.336-1.969 1.406-2.109(132-186) (152-220) (172-252) (190-280) (200-300)

127-148 131-162 134-176 135-188 136-194(18-21) (18.6-23) (19-25) (19.2-26.8) (19.4-27.6)

NOTE :it should be noted that the gauge indications may very slightly due to garage ambient temperature conditions.

97-40 AIR CONDITIONING SERVICE

PERFORMANCE TEST DIAGNOSIS

The test gauge indicators shown on the following chapter are to be used as typical examples of common problems whichyou may need to diagnose.

AIR CONDITIONING SERVICE 97-41

97-42 AIR CONDITIONING SERVICE

8

GAUGE READINGS

Low side High sideLOW LOW

OTHER SYMPTOMS DIAGNOSIS CORRECTION

o Discharge air: o Restriction 1. Discharge system.slightly cool. in high 2. Remove and replace

o High side pipe: side of receiver-drier, liquidCool and also system pipes or other defectiveshows sweating or components.frost. 3. Evacuate system using a

vacuum pump.4. Charge system with R-125. Operate system and check

performance.

9 Low side High side o Compressor: Noisy o Compre- 1. Isolate compressor.HIGH LOW ssor 2. Remove compressor cylin-

malfunc- der head and inspecttion compressor.

3. Check compressor oil level.4. Replace receiver-drier.5. Operate system and check

performance.

Low sideHIGH

High sideHIGH

o Discharge air:Warm.

o Sight glass:Bubbles.

o High side pipe:Very hot

o Malfunc- 1. Check for loose or worntioning fan belt.condenser 2. Inspect condenser forOverch- clogged air passage.arge. 3. Inspect condenser mount-

ing for proper radiatorclearance.

4. Check for refrigerantovercharge.

5. Operate system and checkperformance.

Low sideHIGH

High sideHIGH

o Sight glass: o Large 1. Discharge refrigerantOccasional bubbles amount from system.

o Discharge air: of air and 2. Replace receiver-drierSlightly cool. moisture which may be saturated

with moisture.3. Evacuate system using

vacuum pump.4. Charge system with R-l 2.5. Operate system and check

performance.

AIR CONDITIONING SERVICE 97-43

GAUGE READINGS OTHER SYMPTOMS DIAGNOSIS CORRECTION

12 Low sideHIGH

High sideHIGH

o Discharge air:Warm.

o Evaporator:Sweating orfrost.

o Expansion 1. Discharge system.valve 2. Replace expansion valve,stuck making sure all contactsopen are clean and secure.

3. Evacuate system usingvacuum pump, then rech-arge system with R-12.

4. Operate system and checkperformance.

COMPRESSOR OIL LEVEL CHECK

The oil used to lubricate the compressor circulates in the systemwhile the compressor is operating. Whenever replacing any com-ponent of the system or when a large amount of gas leakageoccurs, add oil to maintain the original total amount of oil.

Total amount of oil in the system : 80±20cc (2.8±0.7 us fl.oz.)

Adding Oil for Replacement Component PartsWhen replacing the system’s component pans, be sure to add thefollowing amount of oil to the pans being replaced.

Component parts Amount of oilto be replaced cc (US fl.oz.)

Evaporator core 50 (1.6)Condenser 30 (1.0)Receiver-drier 10 (0.3)

97-44 COMPRESSOR

COMPRESSORON-VEHICLE INSPECTION1. Install manifold gauge set.2. Check compressor drive belt tension. (See page 97-34)3. Run engine at approx. 1,500 rpm.4. Check compressor for following :

a) Low pressure gauge reading is not lower and high pressuregauge reading is not higher than abnormal.

b) Metallic sound.c) Leakage from shaft seal.If any of the above is not satisfactory, repair the compressor.

5. Check magnetic clutch.a) Lift-up, the vehicle.b) Inspect the pressure plate and the rotor for signs of oil.c) Check the clutch bearings for noise and leaking grease.d) Using an ohmmeter, measure the resistance of the stator

coil between the clutch lead wire and ground.Standard resistance : 3.7±0.2 Q at 20°C (68°F)If resistance value is not as specified, replace the coil.

e) Connect the positive (+) lead from the battery to terminal,check that the magnetic clutch is energized.

If magnetic clutch is not energized, replace the coil.CAUTION:Do not short the positive (+) lead wire on the vehicle byapplying battery voltage.

COMPRESSOR


REMOVAL1. Run engine at idle speed with airconditioning on for 10 minutes.2. Stop the engine.3. Disconnect negative cable from battery.4. Disconnect clutch lead wire from wiring harness.5. Discharge refrigerant from refrigeration system.6. Lift up the vehicle.7. Disconnect the hose fitting for suction hose ‘A’ & ‘B’.8. Remove the suction hose ‘A’ from the compressor9. Disconnect the discharge hose from the compressor.

NOTE :Cap the open fitting immediately to keep moisture and dirtout of the system.

10. Loosen the adjusting bolt and lock nut, then remove thecompressor belt.

11. Remove the compressor mounting bolts (3) and the compres-sor, then put it down on the driveshaft.

12. Remove the compressor mounting bracket bolts (4) and thebracket with idle pulley.

13. Put off the compressor from the vehicle.

INSTALLATIONInstallation is the reverse of removal.NOTE :Prior to installing the replacement compressor, drain fluidounces (ml) of refrigerant oil from the compressor.

97-46 COMPRESSOR

DISASSEMBLY AND INSTALLATION

COMPONENT

DISASSEMBLYRemoval1. Use an S.S.T(NCon clutch holder) to assist removing the

center U-nut.

2. Remove the clutch plate. (If you can’t by hand, use a puller).

3. Remove the shim(s), taking care not to lose them.

Shim

COMPRESSOR

4. Use snap ring pliers to remove the snap ring.

5. Using a plastic hammer, tap the rotor off the shaft.NOTE:

Be careful not to damage the pulley when tapping on therotor.

6. Remove the screw and disconect the stator lead wire from thecompressor housing.

7. Using snapring pliers, remove snap ring

8. Remove the field coil by hand.

97-48 COMPRESSOR

INSPECT PRESSURE PLATE AND ROTOR1. Inspect the pressure plate and rotor surfaces for wear and

scoring. Replace if necessary.2. Check the rotor bearing for wear and leakage of grease.

Replace if necessary.

INSTALLATION1. Install the fild coil

1) The coil flange protrusion must match the hole in the fronthousing to prevent coil movement and to correctly positionthe lead wire.

2) Place the coil snap ring into position using pliers.NOTEMake sure the snap ring is firmly in place.

3) Tighten the wire clip.

2. Install the rotor pulley assembly.NOTEAfter installation, rotate the pulley assembly and check forproper installation.

COMPRESSOR

3. Install the external bearing snap ring with pliers.NOTEWhen installing the snap ring, be careful not to scratch thesurface of the bearing with pliers.

4. Install the clutch plate.1) Install the shim(s) onto the shaft.

Shim(s)Flat

2) Using S.S.T and torque wrench, install the U-nut to specifications.

Torque . . . . . . . . . . . . . 17-19 Nm (170-190 kg.cm, 12-14 lb.ft)

5. Check the clearance of magnetic clutch.1) Place a dial gauge onto the clutch front plate.2) Apply 8-12V DC to the coil and check clutch engagement.

The air gap (readings before and after the engagementshould be as follows.Air gap between the front plate and clutch rotor:0.3 - 0.6 mm (0.014 - 0.026 in.)

3) If the air gap is out of specifications, remove the U-nut andfront plate.

4) Replace the shims with ones of different thickness to adjustthe air gap.

97-50 CONDENSER

CONDENSERON-VEHICLE INSPECTION

1. Check the condenser fins for blockages or damage. The finsare clogged, clean them with compressed air. If the fins arebent, straighten them with a screwdriver or a pair of pliers.CAUTIONBe careful not to damage the fins.

2. Check the condenser fittings for leakage. Repair or replace ifnecessary.

REMOVAL1.2.3.4.

Discharge the refrigerant from the system.Disconnect the radiator upper hose as shown figure.Remove the four upper radiator mounting bolts.Lean the radiator back.

5.

6.

Disconnect the discharge tube using two wrenches to avoidtwisting the tube.Remove the liquid tube ‘A’.NOTE:Cap the open fittings immediately to keep moisture out ofthe system.

7. Remove the two condenser mounting bolts.8. Remove the condenser.

INSTALLATION1. Installation is revers of removal.2. If condenser was replaced, add refrigerant oil to the compres

sor.

Add 40-50 cc (1.4-1.7fl.oz.)

3. Evacuate, charge and test refrigeration system.

RECEIVER DRIER 97-51

RECEIVER DRIER

COMPONENTS

ON-VEHICLE INSPECTION1. Check the sight glass, fusible plug and the fittings for leakage,

using a leak detector.2. Check the receiver-drier for clogging.

a) Run the engine at fast idle with the air conditioner ON.b) Check both the inlet and outlet temperature. If difference in

temperatures between the inlet and outlet is large, replacethe receiver-drier.

REMOVAL

1. Discharge the air conditioner system.2. Disconnect the two liquid line pipes from the receiver-drier.3. Remove the receiver-drier from the bracket.

NOTEPlug the all open fittings immediately to keep moisture outof the system.

INSTALLATION1. Install the receiver-drier in the bracket.NOTEDo not remove the blind plugs until ready for connection.2. Connect the two liquid line pipes to the receiver drier at

specified torque.3. If the receiver-drier is replaced with a new unit add refrigerant

oil to the compressor.

Add 10cc (0.3 fl.oz.)


97-52 EVAPORATOR UNIT

EVAPORATOR ASSEMBLYON-VEHICLE INSPECTION1. Check quantity of refrigerant gas during refrigeration cycle.2. Install manifold gauge set.3. Run the engine at 2,000 rpm at least 5 minutes.4. Read the manifold gauge and check the gas leakage from the

evaporator by using gas leak detector.1) If the expansion valve is clogged low pressure reading will

drop to 0 kg/cm2, otherwise it is ok.2) If the expansion valve is clogged or gas leak from the

evaporator, then repair or replace as necessary.

REMOVE1. Disconnect the battery negative terminal.2. Discharge the refrigerant.3. Disconnect the liquid tube ‘B’ and suction hose from the

evaporator.NOTE:

Cap the open fittings immediately to keep moisture anddirt out of the system.

4. Remove the water drain hose from the evaporator.5. Remove the grommet cover from the dash pannel. (2 screws)

6. Remove the glove box assembly.

EVAPORATOR UNIT 97-53

7. Remove the side lower crash pad. (6 screws)8. Remove the front and rear console assembly.9. Remove the cluster facia panel assembly.

(1) Remove the digital clock assembly.(2) Remove the rheostat switch assembly.

10. Remove the lower crash pad center facia panel and disconnectthe connectors.NOTE : Using a screwdriver, pry loose one clip.l Tape the screwdriver tip before use.

11. Remove the radio and disconnect the connectors.

12. Remove 4 mounting bolts for heater control unit assembly.13. Remove the main lower crush pad assembly.14. Remove the brackets for center support lower crush pad and RH

lower crush pad.15. Disconnect the connectors for blower resistor (M63), blower

motor (M61), thermostat (I12), and the vacuum hose from therecirce/fresh vacuum motor.

16. Remove the evaporator assembly. (2 bolts and 3 nuts)

INSTALLATION1. Installation is revers of removal.2. If condenser was replaced, add refrigerant oil to the compres

sor.

Add 40-50 cc (1.4-1.7 fl.oz.)


EVAPORATOR UNIT

COMPONENTS

EXPANSION VALVE

DISASSEMBLY OF EVAPORATOR UNIT

1. Remove the seal from the cases.2. Remove 7 clips, holding the upper case to the lower case.3. Remove the pipe mounting screw.4. Remove the upper unit case with the thermostat.

NOTE :Be careful not to broken the capillary tube of the thermo-stat.

5. Disconnect the capillary tube from the outlet fitting of theevaporator.

EVAPORATOR UNIT 97-55

5. Disconnect the liquid tube and suction tube from the inlet andoutlet fittings of the expansion valve.

6. Remove the packing and heat sensing tube from suction tubeof evaporator.

7. Remove the expansion valve.

INSPECTION1. Check the evaporator fins for blockage.

If the fins are clogged, clean them with compressed air.NOTE :Never use water to clean the evaporator.

2. Check fittings for cracks or scratches.

ASSEMBLY OF EVAPORATOR UNIT

1.

2.3.

4.5.6.7.8.

Connect the expansion valve to the inlet fitting of the evapora-tor. Torque the nut.Torque : 235 kg-cm (17 ft.lb, 23 N.m)

NOTE :Be sure that the O-ring are positioned on the tube fitting.Install the holder to the suction tube with heat sensitizing tube.Connect the liquid tube to the inlet fitting of the expansion valve.Torque the nut.Torque : 135 kg-cm (10 ft-lb, 13 N.m)Install lower unit case to the evaporator.Install thermistor to the evaporator.Install upper unit case.Install one screw for the pipe clamp.Install seven clips, holding the upper case to the lower case.

97-56 THERMOSTAT

THERMOSTATON-VEHICLE INSPECTION

1. Disconnect the battery negative terminal.2. Remove glove box.3. Disconnect the M48 connector from the thermostat.4. Measure the continuity between terminals of the M48 Connec

tor.If no continuity between terminals, replace the thermostat.

REMOVAL1. Remove the evaporator assembly (Refer to page 97-56).2. Remove the thermostat from the evaporator upper cover.

NOTE :Be careful not to damage the evaporator core when re-move the capillary tube with the thermostat.

INSPECTION

1. Place the thermostat capillary tube in cold water and check forcontinuity.Cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0±1°Cut-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4±1°

2. If cut-off or cut-in temperature is too low or too high, replace thethermostat.

INSTALLATION1. Insert the capillary tube end to a depth of 50 mm (2.0 in.) at a

position 40 mm (1.6 in) from the top of the 3rd column from theleft of the evaporator.

2. Install the thermostat.3. Connect the M48 Connector to the thermostat.4. Install the glove box.5. Connect the battery negative terminal.6. Test the refrigeration system.

DUAL PRESSURE SWITCH 97-57

DUAL PRESSURE SWITCHThe dual pressure switch is a combination of the low pressureswitch (for checking the quantity of refrigerant) and the highpressure switch (for prevention of overheating). It is installed in theliquid tube ‘B’ or and when the pressure becomes approximately210 kPa (30 psi) or lower, the compressor stops, thus preventingthe compressor from being damaged by heat.When the pressure reaches 2,700 kPa (384 psi) or higher, thecompressor stops, thus preventing overheating. There is generallyno necessity for inspection; if, however, an unusual condition, suchas non-operation of the compressor is encountered, check byfollowing the procedures below.

ON-VEHICLE INSPECTION1. Disconnect connector of the dual pressure switch.2. Install the manifold gauge set.3. Observe the gauge reading.4. Check the continuity between the two terminals of the dual

pressure switch shown in the figure.If defective, replace the dual pressure switch.

REMOVAL1. Discharge the air conditioner system.2. Disconnect connector from the dual pressure switch.3. Remove the dual pressure switch using two wrenches to aboid

twisting the tube.NOTE :Cap the open fitting immediately to keep moisture out ofthe system.

INSTALLATION1. Installation is revers of removal.2. Evacuate, charge and test refrigeration system.

97-58 REFRIGERANT LINE

HANDLING TUBING AND FITTINGS

The internal parts of the refrigeration system will remain in a state of chemical stability as long as pure-moisture free R-12 and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability and cause troublesor even serious damage.

The following precautions must be observed1. When it is necessary to open the refrigeration system, have everything you will need to service the system ready so

the system will not be left open any longer than necessary.2. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture.3. All lines and components in parts stock should be capped or sealed until they are ready to be used.4. Never attempt to rebind formed lines to fit. Use the correct line for the installation you are servicing.5. All tools, including the refrigerant dispensing manifold, the gage set manifold and test hoses should be kept clean and

d r y .

1. - Clean fittings 2. - Install new o-ringuse only specified o-ring

3. - Lubricate with 4. - Assemble fittingclean refrigerant oil by using two wrench

BOLT-NUT TYPE COUPLING FLANGE COUPLING

REFRIGERANT LINE 97-59

REMOVAL AND INSTALLATIONLIQUIDE TUBE ‘B’REMOVAL1. Discharge refrigerant from the refrigeration system.2. Disconnect the connector from the dual pressure switch.3. Remove the two tube clamping bolts.

4. Disconnect the pipe fitting for liquid tube ‘B’ with receiver drierusing two wrenches to avoid twisting the tube.

5. Loosen the clamping bolt for receiver drier.

6. Lift up the vehicle.7. Remove the mud guide from the engine LH side.

8. Disconnect the liquide tube ‘B’ from the evaporator.NOTE :Cap the open fittings immediately to keeps moisture anddirt out of the system.

9. Put off the liquide tube ‘B’ from the engine under side.

INSTALLATION1. Installation is reverse of removal.2. Evacuate, charge and test refrigeration system.

97-60 REFRlGERANT LINE

DISCHARGE PIPEREMOVAL1. Discharge refrigerant from the refrigeration system.2. Remove the battery and air cleaner assembly.

3. Remove the air duct assembly.

4. Remove the two tube clamping bolts.5. Disconnect the pipe coupling for discharge pipe with discharge

hose.

6. Disconnect the pipe fitting for discharge pipe with condenserusing two wrenches to avoid twisting the tube.

7. Remove the discharge pipe.NOTECap the open fittings immediately to keeps moisture anddirt out of the system.

INSTALLATION1. Installation is reverse of removal.2. Evacuate, charge and test refrigeration system.

RELAYS

RELAYSAIR CONDITIONER RELAY AND CONDENSORFAN RELAY

1. Remove the battery ground cable.2. Remove the cover of relay box located in engine compartment.3. Remove the relays from relay box.4. Check for condituity or voltage between the terminals.

If continuity is not as specified, replace the relay

(CONDENSOR FAN RELAY-check for voltage) Condenser fan relay

If continuity is not as specified, replace the relay.

BLOWER FAN MOTOR RELAY1. Remove the battery ground cable.2. Remove the cover of relay box located behind the crash pad.3. Remove the relay and check for continuity between the termi-

nals.

If continuity is not as specified, replace the relay.

(AIR CONDITIONER RELAY-check for continuity) Air conditioner relay

Blower relay

APPENDlXReturn To Main Table of ContentsINTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6TROUBLESHOOTING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . 10FUSE AND RELAY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 15POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18DASH FUSE BOX DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22LIGHT SWITCH DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28GROUND DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30JOINT DISTRIBUTION .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42A/C COMPRESSOR CONTROLS ................................. 140A/T AND IGNITION KEY LOCK CONTROLS ..................... 144AUTOMATIC SPEED CONTROL SYSTEM .... . . . . . . . . . . . . . . . . . . 72BACK UP LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116BLOWER CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138BRAKE WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94CHARGING SYSTEM .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56CIGARETTE LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58COURTESY AND TRUNK LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118DASH, CONSOLE AND SWITCH LAMPS . . . . . . . . . . . . . . . . . . . 122DAYTIME RUNNING LlGHTS (DRL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 100DIGITAL CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132ELECTRONIC LOCK UP CONTROL SYSTEM .................. 80EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104HEAD LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96HORNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50INDICATORS/GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88/92MPI SYSTEM .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60POWER WINDOWS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146POWER DOOR MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148SOUND SYSTEM .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54STOP LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110TACU SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134TRUNK LID OPENER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126TURN/HAZARD LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78CONFIGURATION OF CONNECTORS. . . . . . . . . . . . . . . . . . . 150COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162HARNESS LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

WS-2 INTRODUCTION

INTRODUCTIONThis Group consists of five major diagnostic sections for electrical problem troubleshooting.

l Schematic diagramsl Component location indexesl Harness layoutsl Component locationl Connector configurations

The starting point of each system section is the schematic diagram, these diagrams show how all the components worktogether, such as electrical current paths from power source to ground (via electrical load), switch connections at eachpositions, and other related circuit functions.It is important to fully understand how a circuit work prior to troubleshooting and diagnosis.

An Example of Schematic Diagram

INTRODUCTION

COMPONENT LOCATION INDEXES

When you want to locate the schematic components on the vehicle, use the Component Location Index which follows eachschematic. A Component Location Index lists major components, connectors, grounds and their physical location andpagefigure reference.

ComponentsRelay with diode (C40)Alternator (E17/E18)Instrument cluster (I05-1/I17-1)

ConnectorsEM02MC02MI01

JointM01-1

Location reference-page

WS-181WS-184WS-186

WS-185WS-189WS-190

WS-17

Where connectors are listed, the number of cavities are provided. This figure indicates the total number of cavities in theconnector, regardless of how many are actually used. This information along with housing color will be useful for you toidentify connectors on the vehicle. Almost all components, connectors, grounds or splices shown on a schematic can bepinpointed visually by using the Component Location Illustrations.

WS-4 INTRODUCTION

HARNESS LAYOUTSHarness layouts show the routing of the major wiring harnesses and the in-line connectors between the major harnesses.These layouts will make electrical troubleshooting easier.

An example of Harness Layouts-Engine Harness

COMPONENT LOCATIONS

Component Locations give easy access to find the schematic components on the vehicle shown in the ComponentLocation Index. Where connectors are listed, the total number of cavities, how many are actually used, is provided to helpidentify connectors on the vehicle.

INTRODUCTION WS-5

CONNECTOR CONFIGURATIONS

This section shows the cavity or terminal locations in all the multi-pin connectors shown in the schematic diagrams. It ishelpful for you to locate check points, together with the wire colors and terminal numbers in the scematic. The configurationdrawings show the connector views as seen from a component after the harness connector has been disconnected. Whenmore than on connector is connected to a component, the connectors are all shown together. Both halves of in lineconnectors are shown together.

C01-1

C02 C03

C06

C11

C01-2

C04

C01-3

WS-6 SYMBOLS

SYMBOLSThe symbols and the abbreviations explained in this section are used throughout the manual.

SYMBOLS IN SCHEMATIC

Components Diode

A solid line means the entirecomponent is shown.

A broken line indicates onlypart of the component is shown

This means power is suppliedwith the ignition in RUN.

Connectors

This diode allows current toflow only in the direction of thearrow.

The name of the componentappears next to its upper rightcorner.

Notes about componentfunction follow its name.

Fuse and Fusible link

Each connector is numberedfor reference in the componentlocation index.

The index also lists the totalnumber of cavities and the colorthe connector. Wires may not beused in all cavities.

This means the connector con-nects directly to the component.

This indicates the connectorconnects to a lead (pigtail),wired directly to the com-ponent.

This indicates a screw terminalon the component.

HOT AT ALL TIMES

Circuit breaker

Basically a reusable fuse, a circuitbreaker will heat and open if toomuch current flows through it.Some units automatically resetwhen cool, others must be manu-ally reset.

SYMBOLS WS-7

Wires

Current path is continued anotherpage. The arrow shows the direc-tion of current flow. You shouldlook for the "P" in the Power Dis-tribution schematic to follow thewhite wire in left example.

A wavy line means thewire is broken butis to be continued.

Wire insulation is yellowwith a red strip

Where separate wires join, onlythe splice is shown: for detailson the additional wiring, referto the circuit listed.

Splices

Name of Circuit

A wire connects to anothercircuit. The wire is shownagain on that circuit whichthe arrow is pointing.

Wire choices for options or dif-ferent models are labeled andshown with a “choice” bracketlike this.

This dashed line means theRED and YEL/BLU wiresare both in connector M35.

M35

0.5BLU

0.5BLUSplices are numbered and shownas a dot with circle. The exactlocation and connection of thesesplices may vary among vehicles.

Ground-“G”

Each wire ground (G) is num-bered for reference in thecomponent location index.

This symbol means the end ofthe wire is attached to a metalpart of the vehicle.

This ground symbol (dot and 3lines overlapping the comp-nent) means the housing of thecomponent is attached to ametal part of the vehicle.

Shield Wire

This represents RFI (Radio Fre-quency interference) Shieldingaround a wire. the shielding isalways connected to ground.

SYMBOLS

Switches Joint Connectors

These switches move together:a dashed line shows a mechani-cal connection between them.

Relays

This is a relay shown with nocurrent flowing through its coilWhen a currrent flows throughcoil, contact will toggle.

normally open contact

normally closed contact

Indicator

This indicates seat belt warningindicator continues to other indi-cators within instrument cluster.

This is an indicator whichdisplays the lighted symbol.

WIRE COLOR ABBREVIATIONS

The following abbreviations are used to identify wire colors in the circuit schematics:

SYMBOLS WS-9

CONNECTOR CLASSIFICATION SYMBOLS

Electrical wiring connectors are classified according to the wiring parts in the Harness Layout.

Harness name

Engine and its extension harness

Main and its extension harness

Control (ECU) harness

T/A (TCU) and its extension harness

Floor and Rear floor, Trunk lid (Tail gate),Rear and their extension harnesses

Crash pad, Instrument and their extensionharnesses

Location

Engine compartment

Passenger compartment

Engine compartment

Engine compartment

Passenger compartment/Luggage compartment

Under crash pad

Symbol

E

M

C

T

R

I

Door and its extension harness Door D

A connector identification symbol consists of a wiring harness location classification symbol corresponding to eachother wiring harness location and number peculiar to the connector.These connector locations can be found in the WIRING HARNESS LAYOUT.

E 10 -1

Number peculiar to sub-connector (Serial Number)Number peculiar to main connector (Serial Number)Symbol indicating wiring harness (Engine wiring harness)

NOTEConnectors which connect each wiring harness are represented by the following symbols.For example:

Number peculiar to sub-connector (Serial NumberNumber peculiar to main connector (Serial Number)Rear wiring harnessMain wiring harness

WS-10 TROUBLESHOOTING INSTRUCTION

TROUBLESHOOTING INSTRUCTIONSTROUBLESHOOTING PROCEDURES

The following five-step troubleshooting procedure is recommended.

Step 1. Verify the customer complaints

Turn on all the components in the problem circuit to check the accuracy of the customer complaints. Note the symptoms.Do not begin disassembly or testing until you have narrowed down the probable causes.

Step 2. Read and analyze the schematic diagram

Locate the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current pathsfrom the power source through the system components to ground. If you do not understand how the circuit should work,read the circuit operation text. Also check other circuits that share with the problem circuit. The name of circuits that sharethe same fuse, ground, or switch, for example, are referred to on each diagrams. Try to operate any shared circuits youdid not check in step 1. If the shared circuit works, the shared wiring is okay, and the cause must be within the wiring usedonly by the problem circuit. If several circuit fails at the same time, the fuse or ground is a likely cause.

Step 3. Inspect the circuit/component with the problem isolated

Make a circuit test to check the diagnosis you made in step 2. Remember that a logical, simple procedure is the key toefficient troubleshooting. Narrow down the probable causes using the Troubleshooting Hints, System Diagnosis Charts.Test for the most likely cause of failure first. try to make tests at points that are easily accessible.

Step 4. Repair the problem

Once the problem is found, make the necessary repairs.

Step 5. Make sure the circuit works

Repeat the system check to be sure you have repaired the problem. If the problem was a blown fuse, be sure to test allof the circuits on that fuse.

TROUBLESHOOTING INSTRUCTION WS-11

TROUBLESHOOTING EQUIPMENTS

Voltmeter And Test Lamp

Use a test lamp or a voltmeter on circuits without solid-state units,use a test lamp to check for voltage. A test lamp is made up of 12-volt bulb with a pair of leads attached. After grounding one lead tovarious points along the circuit where voltage should be present.When the bulb goes on, there is voltage at the point being tested.

CAUTION:A number of circuits include solid-state modules such asElectronic Control Unit (ECU) used with computer commandcontrol injection. Voltage in these circuits should be testedonly with a 10-megohm or higher impedance digital voltmeter.Never use a test lamp on circuits that contain solid-state units.Damage to the units may result.

A voltmeter can be used in place of a test lamp. While a test lampshows whether the voltage is present or not, a voltmeter indicateshow much voltage there is.

Self-Powered Test Lamp And Ohmmeter

Use a self-powered test lamp or a ohmmeter to check for continuity.Self-powered test lamp is made of a bulb, battery and two leads andis used only on an unpowered circuit. If the leads are touchedtogether, the lamp will go on. Prior to checking the points, firstdisconnect the battery ground cable or remove the fuse which feedsthe circuit you are working on.

CAUTION:Never use a self-powered test lamp on circuits that containsolid state units. Damage to these units may result.

An ohmmeter can be used in place of a self-powered test lamp.The ohmmeter shows how much resistance there is between twopoints along a circuit. Low resistance means good continuity.Circuits which include any solid-state devices should be tested onlywith a 10-megohm or higher impedance digital multimeter. Whenmeasuring resistance with a digital multimeter, battery negativeterminal should be disconnected. Otherwise, there may incorrectreadings. Diodes and solid-state devices in a circuit can make anohmmeter give a false reading. To find out if a component isaffecting a measurement, take one reading, reverse the leads andtake a second reading. If the readings differ, the solid-state deviceis affecting the measurement.


Jumper Wire With Fuse

Use a jumper wire with fuse to by pass an open circuit.A jumper wire is made up of an in-line fuse holder connected to aset of test leads. This tool is available with small clamp connectorsproviding adaption to most connectors without damage.

CAUTION:Do not use a fuse with a higher rating then the specified fuse thatprotests the circuit being tested. Do not use this tool in any situationto substitute for input or output at the solid-state control module,such as ECU, TCU, etc.

Short Finder

Short finder is available to locate short to ground. The short findercreates a pulsing magnetic field in the shorted circuit and showsyou the location of the short through body trim or sheet metal.

TROUBLESHOOTING INSTRUCTION WS-13

TROUBLESHOOTING TEST

Testing For Voltage

This test measures voltage in a circuit. When testing for voltage ata connector, you do not have to separate the two halves of theconnector. Instead, probe the connector from the back. Alwayscheck both sides of the connector because dirt and corrosionbetween its contact surfaces can cause electrical problems.1. Connect one lead of a test lamp or voltmeter to a ground. If you

are using a voltmeter, be sure it is the voltmeter’s negative leadtest you have connected to ground.

2. Connect the other lead of the test lamp or voltmeter to aselected test point (connector or terminal).

3. If the test lamp glows, there is voltage present. If you are usinga voltmeter, note the voltage reading.A loss of more than 1 volt from specifications indicates aproblem.

Testing For Continuity

1. Disconnect the battery negative terminal.2. Connect one lead of a self-powered test lamp or ohmmeter to oneend of the part of the circuit you wish to test. If you are using anohmmeter, hold the leads together and adjust the ohmmeter to readzero ohms.3. Connect the other lead to the other end.4. If the self-powered test lamp glows, there is continuity. If you areusing an ohmmeter, low or zero resistance means good continuity.

Testing For Short To Ground

1. Remove the blown fuse and disconnect the battery and load.3. Connect one lead of a self-powered test lamp or an ohmmeter tothe fuse terminal on the load side.3. Connect the other lead to a ground.4. Beginning near the fuse block move the harness from side toside. Continue this point (about six inches apart) while watching theself powered test lamp or ohmmeter.5. When the self-powered test lamp glows, or ohmmeter registers,there is a short to ground in the wiring near that point.

Battery disconnected


Testing For A Short With A Short Finder

1. Remove the blown fuse. Leave the battery connected.2. Connect the short finder across the fuse terminals.3. Close all switches in series in the circuit you’re testing.4. Turn on the short circuit locator. It sends pulses of current to the

short.This creates a pulsing magnetic field around the wiring betweenthe fuse box and the short.

5. Beginning at the fuse box, slowly move the short finder alongthe circuit wiring. The meter will show current pulses throughsheet metal and body trim. As long as the meter is between thefuse and the short, the needle with move with each currentpulse. One you move the meter past the point of the short, theneedle will stop moving. Check around this area to locate thecause of the short circuit.

Battery disconnected

FUSE AND RELAY INFORMATION

FUSE AND RELAY INFORMATION

DASH FUSE BOXLayout

Circuit

Fuse Amperages Circuits1 30A Blower controls2 15A Turn lid opener

3 10A Hazard switch4 15A Stop lamps, A/T shift and ignition key lock solenoid

5 10A Courtesy lamps, cluster, audio, clock6 20A T A C U7 10A Audio, clock

8 15A A/T and ignition key lock control unit9

10111213

10A15A20A20A1OA

TCUWiper motor, washer motorPower windowsPower windowsHazard/cruise controls

14 10A A/C controls15 10A LH tail lamps

16 15A Not used17 10A RH tail lamps

WS-16 FUSE AND RELAY INFORMATION

ENGINE COMPARTMENT RELAY BOXLayout

FUSE

JOINT CONNECTOR

Description Amperages Circuit protected Remark

Sub-fusible linkA( Red)B(Pink)C(Blue)D(Blue)E(Green)FuseH/LAMP INDHORN

50A30A20A20A40A

10A10A

BatteryIgnition switchNot usedMPI controlHead lamp control

Head lamp indicatorHorns

FUSE AND RELAY INFORMATION WS-17

PASSENGER COMPARTMENT RELAY BOXLayout

JOINT CONNECTORS

FUSIBLE LINK BOXLayout/circuit

Main-fusible link Amperage Circuit

A (Red)

B (Blue)

50A

20A

C (Pink) 30A

Alternator

Condenser fan

Radiator fan

WS-18 POWER DISTRIBUTION

POWER DISTRlBUTlONSCHEMATIC DIAGRAM (1)

POWER DISTRIBUTION WS-19

SCHEMATIC DIAGRAM (2)

POWER DISTRIBUTION

COMPONENT LOCATION INDEX


ComponentsAlternator (E23/E24)Condenser fan motor (E25)Fuel pump control relay (E28)Headlamp relay-1 (E31)Ignition switch (M29)Inhibitor switch (M24)Radiator fan motor (E26)Taillamp relay (E06)

ConnectorsEM01EM03

WS-169WS-169WS-169WS-168WS-172WS-171WS-169WS-168

WS-169WS-169

POWER DISTRIBUTION WS-21

MEMO

WS-22 DASH FUSE BOX DETAILS

DASH FUSE BOX DETAILSSCHEMATIC DIAGRAM (1)

DASH FUSE DETAILS WS-23




HOT IN ACC OR ON

DASH FUSE BOX DETAILS WS-25


DASH FUSE BOX DETAILS WS-27


WS-28 LIGHT SWITCH DETAILS (U.S.A.)

LIGHT SWITCH DETAILS (U.S.A.)


G01

LIGHT SWITCH DETAILS (Canada) WS-29

LIGHT SWITCH DETAILS (Canada)


WS-30 GROUND DISTRIBUTION

GROUND DISTRIBUTIONSCHEMATIC DIAGRAM (G01)

HLLD H/LPSW W/SW

POWERMULTI ACCEL WINDOW

CLUSTER SWITCH SWITCH SWITCH

GROUND DISTRIBUTION WS-31

SCHEMATIC DIAGRAM (G01)



BLOWERSWITCH

BLOWERACTUA-TOR

WIPERMOTOR

BRAKE AUTOFLUIDSENSOR UNIT GL/BOX

DIODE(ForCompressor)


SCHEMATIC DIAGRAM (G06-N/A)


HALL KNOCKSENSOR ECU SENSOR

CRANK SHAFTSENSOR ECU

SCHEMATIC DIAGRAM (G06-T/C)

GROUND DISTRIBUTION

SCHEMATIC DIAGRAM (G06-T/C)

GROUND DISTRIBUTION

SCHEMATIC DIAGRAM (G08, G09)


MEMO

WS-42 JOINT DISTRIBUTION

JOINT DISTRIBUTION

SCHEMATIC DIAGRAM (E01-1 /E01-2)

JOINT DISTRIBUTION WS-43

SCHEMATIC DIAGRAM (E01-3)


SCHEMATIC DIAGRAM (E01-4)


SCHEMATIC DIAGRAM (M01-1)

WS-50 IGNITION SYSTEM

IGNITION SYSTEM

SCHEMATIC DIAGRAM (N/A)

IGNITION SYSTEM WS-51


ComponentsCluster (I05-1 ~ I05-2)Condenser (C08)Distributor (C16)ECU (C01)Ignition coil (C09)Ignition switch (M36)Noise filter (C04)

ConnectorsMC01/MC03MI01

GroundG01


WS-175WS-162WS-163WS-162WS-162WS-172WS-162

WS-174WS-174

WS-180

WS-52 IGNITION SYSTEM

SCHEMATIC DIAGRAM (T/C)

IGNITION SYSTEM WS-53



ComponentsCluster (I05-1 ~ I05-2)Condenser (C28)Distributor (C42)ECU (C21)Ignition coil (C30)Ignition switch (M36)Noise filter (C24)

WS-175WS-164WS-166WS-164WS-165WS-172WS-164

ConnectorsMC01/MC03Ml01

GroundG01

WS-174WS-174

WS-180

WS-54 STARTING SYSTEM

STARTING SYSTEM

SCHEMATIC DIAGRAM

STARTING SYSTEM WS-55


ComponentsStarter (C07/C31)Starter relay (M14)Ignition switch (M36)Ignition lock switch (M29)Inhibitor switch (M24)

ConnectorsEM01MC03

GroundG01


WS-162/165WS-170WS-172WS-172WS-171

WS-169WS-174

WS-180

CHARGING SYSTEM

CHARGING SYSTEMSCHEMATIC DIAGRAM

CHARGING SYSTEM WS-57


ComponentsAlternator (E23/E24)Instrument cluster (I05-2/I05-3)Relay with diode (M19)

ConnectorsEM03MI01


WS-169WS-175WS-171

WS-169WS-162

COOLING SYSTEM

COOLING SYSTEM


COOLING SYSTEM WS-59


ComponentsCondenser fan motor (E25)Condenser fan motor relay (E05)Radiator fan motor (E26)Radiator fan motor relay (high) (E09)Radiator fan motor relay (low) (E08)

GroundG04


WS-169WS-168WS-169WS-168WS-168

WS-180

MPI SYSTEM (N/A)

MPI SYSTEM (N/A)


3.0 WHT/BLU 3.0 WHT/BLU

MPI SYSTEM (N/A) WS-61


MPI SYSTEM (N/A)


WS-64 MPI SYSTEM (N/A)





ComponentsAir flow sensor (C11)A/C relay (E07)Cluster (I05-1 ~ I05-3)Compressor (C12)Control relay (M03)Coolant temperature (E21)Crank angle sensor (C17)Diagnostic connector (M02)ECU (C01)Fuel pump check connector (C05)Fuel pump control relay (M28)Fuel pump motor (R05)Hall sensor (C16)Ignition coil (C09)Ignition switch (M36)Inhibitor switch (M24)Injector (C14-1 ~ C14-3)ISA (Cl 5)Knock sensor (C13)Oxygen sensor (C19-1/C19-2)Pressure switch (E20)Purge control solenoid (C06)TCU (M07-1 ~ M07-2)Throttle position sensor (Cl 0)Thermo switch (M48)

WS-163WS-168WS-175WS-163WS-170WS-168WS-163WS-170WS-162WS-162WS-172WS-176WS-163WS-162WS-172WS-171WS-163WS-163WS-163WS-163WS-168WS-162WS-170WS-163WS-173

ConnectorsEM02/EM03MC01/MC02/MC03MR01

GroundG01G06G07

WS-169WS-174WS-174

WS-180WS-180WS-180

MPI SYSTEM (T/C)

MPI SYSTEM (T/C)


MPI SYSTEM (T/C) WS-67


WS-68 MPI SYSTEM (T/C)


MPI SYSTEM (T/C)




ComponentsAir flow sensor (C37)NC relay (E07)Cluster (I05-1 ~ I05-3)Control relay (M03)Compressor (C38)Coolant temperature (E21)Crank angle sensor (C33)Diagnostic connector (M02)ECU (C21)Fuel pump check connector (C27)Hall Sensor (C42)Ignition coil (C30)Ignition switch (M36)Injector (C40-1 ~ C40-3)ISA (C43)Knock sensor (C39)Oxygen sensor (C34/C35)Pressure switch (E20)Purge control solenoid (C29)Thermo switch (M48)Throttle position sensor (C41)

ConnectorsEM02/EM03MC01/MC02/MC03MR01

GroundG01G06G07

Locat ion reference-page

WS-165WS-168WS-175WS-170WS-165WS-168WS-165WS-170WS-164WS-164WS-166WS-165WS-172WS-166WS-166WS-166WS-165WS-168WS-164WS-173WS-166

WS-169WS-174WS-174

WS-180WS-180WS-180

WS-72 AUTOMATIC SPEED CONTROL SYSTEM

AUTOMATIC SPEED CONTROL SYSTEM


Dash AndConsole Lights

AUTOMATIC SPEED CONTROL SYSTEM WS-73


AUTOMATIC SPEED CONTROL SYSTEM WS-75


WS-76 AUTOMATIC SPEED CONTROL SYSTEM


ComponentsAccelerator switch (M17)Brake switch (M12)Clutch switch (M13)Combination switch (M37-:2)Cruise control actuator (M18)Cruise control module (M54)Diagnostic connector (M02)Ignition switch (M36)Inhibitor switch (M24)Main cruise switch (I16)O/D switch (M47)Piezo alarm (M30)TCU (M07-2)

ConnectorsMl02/Ml04

GroundG01G02

JointM01-5


Ws-171WS-170WS-170WS-172WS-171WS-174WS-170WS-172WS-171WS-175WS-173WS-172WS-170

WS-174

WS-180WS-180

WS-17


MEMO

WS-78 VEHICLE SPEED SENSOR

VEHICLE SPEED SENSOR

SCHEMATIC DIAGRAM

DASHFUSEBOXDiagnosticconnector

VEHICLE SPEED SENSOR WS-79


ComponentsDiagnostic connector (M02)ECU (C01/C21)Instrument cluster (I05-3/I06)TCU (M07-2)

ConnectorsMC01

GroundG01


WS-170WS-162/164WS-175WS-170

WS-174

WS-180

WS-80 ELECTRONIC LOCK UP CONTROLS

ELECTRONIC LOCK UP CONTROLS


ELECTRONIC LOCK UP CONTROLS WS-81


WS-82 ELECTRONIC LOCK UP CONTROLS


A/CCompressorControls

IgnitionSystem

VehicleSpeedSensor

ELECTRONIC LOCK UP CONTROLS WS-83


ComponentsAccelerator switch (M17)Diagnostic connector (M02)ECU (C01)ECU switch (M43)Inhibitor switch (M24)Kick down switch (M23)Over drive switch (M47)Pulse generator (M21)TCU (M07-1 ~ M07-2)Transaxle oil temperature (M22)Transaxle valve body (M26)

ConnectorsMC01

GroundG01G03


WS-171WS-170WS-162WS-172WS-171WS-171WS-173WS-171WS-170WS-171WS-171

WS-174

WS-180WS-180

WS-84 HORNS

HORNSSCHEMATIC DIAGRAM

HORNS WS-85


ComponentsHorn (E19/E33)Multifunction switch (M37-2)

ConnectorsEM02


WS-168/169WS-172

WS-169

WS-86 CIGARETTE LIGHTER

CIGARETTE LIGHTER

SCHEMATIC DIAGRAM

CIGARETTE LIGHTER WS-87


ComponentsCigarette (M42)

GroundG01


WS-172

WS-180

WS-88 INDICATORS

INDICATORS


INDICATORS WS-89


WS-90 INDICATORS


HOT AT ALL TIMES

INSTRUMENTCLUSTER

See Courtesy Lamp/Trunk Lamp.

SeeHeadlamps/DRL System.

See Dash andConsole Lights

INDICATORS WS-91



ComponentsFuel sender wiring connect (R06)Instrument cluster (I05-1 ~ I05-3/I06)Oil pressure switch (E17)

ConnectorsEM02Ml01MR02

WS-176WS-175WS-168

WS-169WS-174WS-174

GroundG01G07

WS-180WS-180

WS-92 GAUGES

GAUGES

SCHEMATIC DIAGRAM

HOT IN ON OR START

GAUGES WS-93


ComponentsCoolant temperature sensor (E22)Fuel sender wiring connector (R06)Instrument cluster (I05-1 ~ I05-2)

ConnectorsMC01Ml01/Ml02

GroundG01G06G07


WS-168WS-176WS-175

WS-174WS-174

WS-180WS-180WS-180

WS-94 BRAKE WARNING

BRAKE WARNING

SCHEMATIC DIAGRAM

BRAKE WARNING


ComponentsInstrument cluster (I05-1 ~ I05-3)Parking brake switch (R03)Brake fluid lever sensor (M20)

ConnectorsMl01MR01

GroundG01


WS-175WS-176WS-171

Ws-174WS-174

WS-180

HEAD LAMPS

HEAD LAMPS


HEAD LAMPS WS-97


WS-98 HEAD LAMPS


ComponentsCluster (I05-1/I05-3)Headlamp relay-1 (E31)

ConnectorsEM02EM03Ml01

Joint connectorE01-1


WS-175WS-169

WS-169WS-169WS-174

WS-16

HEAD LAMPS WS-99

MEMO

WS-100 DAYTIME RUNNING LIGHTS

DAYTIME RUNNING LIGHTS (DRL)


DAYTIME RUNNING LIGHTS WS-101


From F r o mpreceding page. preceding page.

WS-102 DAYTIME RUNNING LIGHTS


DAYTIME RUNNING LIGHTS WS-103


ComponentsAlternator (E23)Brake fluid level sensor (M20)Cluster (I05-1 ~ I05-3)DRL unit (E11)Headlamp relay-1/2 (E31/E31-1)Parking brake switch (R03)Taillamp relay (E06)

ConnectorsEM02EM03Ml01

Joint connectorsEO1-2EO1-3


WS-169WS-171WS-175WS-168WS-169WS-176WS-168

WS-169WS-169WS-174

WS-16WS-16

WS-104 EXTERIOR LAMPS

EXTERIOR LAMPS


EXTERIOR LAMPS WS-105


From TAILLAMP RELAYon preceding page.

To followingpage.

0.5BLK 0.5BLK

E X T E R I O R L A M P S WS-107




ComponentsLicence lamp-LH/RH (R32/R34)Taillamp relay (E06)

ConnectorsEM02RR01MR01MR02RR02

Joint connectorsE01-4M01-2


WS-177/178WS-168

WS-169WS-178WS-179WS-179WS-178

WS-16WS-17

EXTERIOR LAMPS WS-109

MEMO

WS-110 STOP LAMPS

STOP LAMPS

SCHEMATIC DIAGRAM

STOP LAMPS WS-111


ComponentsHigh mounted stop lamp (R10/R33)Stop lamp switch (M12)

ConnectorsMR01RR01RR02


WS-176/178WS-170

WS-179WS-178WS-178

WS-112 TURN/HAZARD LAMPS

TURN/HAZARD LAMPSSCHEMATIC DIAGRAM (1)

MULTISWITCH

TURN/HAZARD LAMPS WS-113


WS-114 TURN/HAZARD LAMPS


ComponentsCluster (I05-1 ~ I05-3)Flasher unit (M31)Hazard switch (113)

ConnectorsEM03Ml01Ml04MR01RR01

Joint connectorsM01-3M01-4M01-5


WS-175WS-172WS-175

WS-169WS-174WS-179WS-179WS-178

WS-17WS-17WS-17

TURN/HAZARD LAMPS WS-115

MEMO

WS-116 BACK UP LAMPS

BACK UP LAMPSSCHEMATIC DIAGRAM

BACK UP LAMPS WS-117


ComponentsBack-up switch (M25)Inhibitor switch (M24)Trunk lid opener (R35)

ConnectorsET01MR01RR02

Joint connectorM01-5


WS-171WS-171WS-172

WS-WS-179WS-178

WS-17

WS-118 COURTESY AND TRUNK LAMPS

COURTESY AND TRUNK LAMPS


COURTESY AND TRUNK LAMPS WS-119


WS-120 COURTESY AND TRUNK LAMPS


ComponentsCluster (I05-2)Courtesy lamp (M57)Front door switch LH/RH (R09/R04)TACU (M55)Trunk lamp (R11)Trunk lamp switch (R14)

ConnectorsM 5 6Ml01Ml02MR01RR01


WS-175WS-174WS-176WS-174WS-177WS-177

WS-174WS-174WS-174WS-179WS-178

COURTESY AND TRUNK LAMPS WS-121

MEMO

WS-122 DASH, CONSOLE AND SWITCH LAMPS

DASH, CONSOLE AND SWITCH LAMPS


DASH. CONSOLE AND SWITCH LAMPS WS-123


WS-124 DASH, CONSOLE AND SWITCH LAMPS


DASH, CONSOLE AND SWITCH LAMPS WS-125


ComponentsAudio (M41)A/C switch (I15)Cigar lighter (M42)Cruise switch (I16)Glove box lamp (M49-2)Glove box lamp switch (M49-1)Hazard switch (I13)Taillamp relay (E06)Rear window defogger switch (I14)Rheostat (I04)

ConnectorsEM02M49Ml01Ml04

Joint connectorsE01-4M01-1M01-2


WS-172WS-175WS-172WS-175WS-173WS-173WS-175WS-168WS-175WS-175

WS-169WS-173WS-174WS-179

WS-16WS-17WS-17

WS-126 TRUNK LID OPENER

TRUNK LID OPENER

SCHEMATIC DIAGRAM

TRUNK LID OPENER WS-127


ComponentsTrunk lid opener (R35) WS-178Trunk lid opener switch (M09) WS-170

ConnectorsMR02RR02


WS-179WS-178

WS-128 SOUND SYSTEM

SOUND SYSTEMSCHEMATIC DIAGRAM (1)

SOUND SYSTEM WS-129


WS-130 SOUND SYSTEM


ComponentsAudio (M41)Courtesy lamp (M57)Digital clock (107)Speaker-LH/RH (l01/M54)

ConnectorsM52M 5 6Ml01MI02MR02


WS-172WS-174WS-175WS-175/174

WS-173WS-174WS-174WS-174WS-179

SOUND SYSTEM WS-131

MEMO

WS-132 DIGITAL CLOCK

DIGITAL CLOCK

SCHEMATIC DIAGRAM

DIGITAL CLOCK WS-133


ComponentsAudio (M41)Cluster (I05-1/105-2)Digital clock (107)

ConnectorsMl01Ml02


WS-172WS-175WS-175

WS-174WS-174

WS-134 T.A.C.U. SYSTEM

T.A.C.U. SYSTEM


T.A.C.U. SYSTEM WS-135


WS-136 T.A.C.U. SYSTEM


T.A.C.U. SYSTEM WS-137


ComponentsAlternator (E23)Chime bell (Ml 1)Cigar lighter (M42)Door switch-LH (R09)Door warning switch (M35)Front wiper motor (C02/C23)Passive seat belt switch (D04)Rear defogger switch (I14)Seat/Lap belt switch (R02)TACU (M55)Washer motor (E03)

ConnectorsEM03EM02MC01MC02MD03Ml01Ml02Ml04MR01MR02

Joint connectorMO1-5


WS-169WS-170WS-172WS-176WS-172WS-162/164WS-167WS-175WS-176WS-174WS-168

WS-169WS-169WS-174WS-174WS-174WS-174WS-174WS-179WS-179WS-179

WS-17

WS-138 BLOWER CONTROLS

BLOWER CONTROLS


BLOWER CONTROLS WS-139



ComponentsBlower motor (M51)Blower relay (M32)Blower resistor (M50)Blower switch (M39)

WS-173WS-172WS-173WS-172

WS-140 A/C COMPRESSOR CONTROLS

A/C COMPRESSOR CONTROLS


BLOWERSWITCH

A/C COMPRESSOR CONTROLS WS-141


WS-142 A/C COMPRESSOR CONTROLS



ComponentsA/C compressor clutch (Cl 2)A/C low pressure switch (E20)A/C relay (E07)A/C switch (I15)Blower relay (M32)Blower switch (M39)ECU (C01)Thermo switch (M48)

ConnectorsEM02E M 0 3MC01MC02Ml04

WS-163WS-168WS-168WS-175WS-172WS-172WS-162WS-173

WS-169WS-169WS-174WS-174WS-179

GroundM01-5 WS-17

A/C COMPRESSOR CONTROLS WS-143

MEMO

WS-144 AUTOMATIC TRANSAXLE AND KEY LOCK CONTROLS

AUTOMATIC TRANSAXLE AND KEY LOCK CONTROLS

SCHEMATIC DIAGRAM

AUTOMATIC TRANSAXLE AND KEY LOCK CONTROLS WS-145


ComponentsA/T and key lock control unit (R16)A/T shift lock sol. (M46)Cigar lighter (M42)Ignition key lock sol. (M34)P-position switch (M45)Stop lamp switch (M12)Trunk lid opener (R35)

ConnectorsMR01MR03RR02

Joint connectorM01-5


WS-177WS-173WS-172WS-172WS-172WS-170WS-178

WS-179WS-179WS-178

WS-17

WS-146 POWER WINDOWS

POWER WINDOWS

SCHEMATIC DIAGRAM

POWER WINDOWS WS-147


ComponentsFront window motor-LH/RH (D01/D06)Power window main switch (D03)Power window switch-RH (D07)

ConnectorsMD01MD04


WS-167WS-167WS-167

WS-174WS-174

WS-148 POWER DOOR MIRRORS

POWER DOOR MIRROR

SCHEMATIC DIAGRAM

POWER DOOR MIRROR WS-149


ComponentsFlasher unit (M31)Power door mirror-LH/RH (D02/D05)Power door mirror switch (M08)

ConnectorsMD02M D 0 4Ml01


WS-172WS-167WS-170

WS-174WS-174WS-174

WS-150 CONFIGURATION OF CONNECTORS

CONFIGURATION OF CONNECTORS

CONFIGURATION OF CONNECTORS WS-151


E32 ~ I08-3


I09 ~ M11


M12 ~ M35


M36 ~ M58


MC01 ~ MR02


MR03 ~ R34


R35 ~ RR02


MEMO

WS-162

COMPONENTS (C01 ~ C09)

COMPONENT LOCATION

COMPONENT LOCATION WS-163

COMPONENTS (C10 ~ C19-2)

WS-164 COMPONENT LOCATION



COMPONENTS (D01 ~ D14)


COMPONENTS (E02 ~ E22)


COMPONENTS (E23 ~ EM03)


COMPONENTS (M02 ~ M14)

COMPONENT LOCATION W S - 1 7 1



* COMPONENTS (M28 ~ M45)


COMPONENTS (M54 ~ Ml03)


COMPONENTS (I01 ~ I16)


COMPONENTS (R02 ~ R10)


COMPONENTS (R11 ~ R32)


COMPONENTS (R33 ~ RR02)


COMPONENTS (Ml04 ~ MR04)


GROUNDS (G01 ~ G07)


GROUNDS (G08 ~ G09)

WS-182 HARNESS LAYOUT

HARNESS LAYOUT

ENGINE WIRING HARNESS

ENGINE WIRING HARNESS

E01-1 Joint connector (Head Lamp) (High) E21 Coolant temp. sensorE01-2 Joint connector (Head Lamp) (Low) E22 Coolant temp. senderE01-3 Joint connector (Head Lamp) E23 Alternator (S or L)E01-4 Joint connector (Tail Lamp) E24 Alternator (+)E03 Washer motor E25 Condenser fan motorE05 Condenser fan motor relay E26 Radiator fan motorE06 Tail lamp relay E26-1 ResistorE07 A/C relay E29 Head lamp (LH)E08 Radiator fan motor relay (Low) E30 Head lamp (RH)E09 Radiator ran motor relay (High) E31 Head lamp relayE11 Daytime running light unit (Canada) E31-1 Head lamp relayE12 Side marker lamp (RH) E33 Horn (LH)E13-1 Turn signal lamp (RH) E35-1 Turn signal lamp (LH)E16 Head lamp (RH) E36 Side marker lamp (LH)E17 Head lamp (RH) EM01 Connection with main harnessE19 Horn (RH) EM02 Connection with main harnessE20 Pressure switch EM03 Connection with main harness


CONTROL WIRING HARNESS (N/A)

C01 E C UC02 Wiper motorC04 Noise filterC05 F/P checkerC 0 6 Purge control valveC 0 7 Starter solenoidC08 CondenserC09 Ignition coilC10 Throttle position sensorC11 Air flow sensorC12 A/C compressor

C13 Knock sensorC14-1 Injector #1C14-2 Injector #2C14-3 Injector #3C14-4 Injector #4C15 Idle speed adjustC16 DistributorC17 Crank position sensorC18 Oil pressure switchC19 O2 SensorC19-1 O2 sensor heated

HARNESS LAYOUT WS-185

CONTROL WIRING HARNESS (T/C)

C21C22C23C24C25C27C28C29C30C31C32C33C34

E C UBoost sensorWiper motorNoise filterPower transistorFuel pump checkerCondenserPurge control valveIgnition coilStarter solenoidWastegateCrank angle sensor02 sensor

C35 02 sensor heatedC36 Oil pressure switchC37 Air flow sensorC38 A/C compressorC39 Knock sensorC40-1 Injector #lC40-2 Injector #2C40-3 Injector #3C40-4 Injector #4C41 Throttle position sensorC42 DistributorC43 Idle speed actuator


HARNESS LAYOUT


MAIN WIRING HARNESS

M01-1 Joint connector (IGN. 1)M01-2 Joint connector (Turn signal lamp) (RH)M01-3 Joint connector (Turn signal lamp) (LH)M01-4 Joint connector (Tail lamp)M01-5 Joint connector (Rheostat)M02 M.U.T checkerM03 E.C.U. main relayM07-1 Electronic lock up control unitM07-2 Electronic lock up control unitM08 Out side mirror switchM09 Trunk lid opener switchM11 Chime bellM12 Stop swM13 Clutch SW

M 1 4 Ignition lock switchM17 Accelerator switchM18 Cruise actuatorM19 Relay with diodeM20 Brake fluid sensorM21 Pulse generatorM22 Oil temp. sensorM23 k down switchM24 Inhibitor switchM25 Back up switchM26 T/A control solenoidM28 Fuel pump relayM29 Manual transaxle relayM30 Piezo alarmM31 Flasher unitM32 Blower relayM34 Key lock solenoidM35 Door warning switchM36 Ignition switchM37-1 Multi function switchM37-2 Multi function switchM38 Heater control illuminationM39 Blower switch

M40 Blower actuatorM41 AudioM42 Cigarette lighterM43 E.C.T switchM44 Auto transaxle shift illuminationM45 P position switchM46 Auto transaxle solenoidM 4 7 Over drive switchM48 Thermo switchM49 Glove box wiring connectorM49-1 Glove box switchM49-2 Glove box lampM50 Heater resistorM51 Blower motorM52 Speaker extension wire conn.M54 Auto cruise unitM55 TACUEM01 Connection with engine harnessEM02 Connection with engine harnessEM03 Connection with engine harnessMR01 Connection with control harnessM R 0 2 Connection with control harnessMR03 Connection with control harnessMR04 Connection with control harnessMC01 Connection with control harnessMC02 Connection with control harnessMC03 Connection with control harnessMl01 Connection with instrument harnessMl02 Connection with instrument harnessMl03 Connection with instrument harnessMl04 Connection with instrument harnessMl05 Connection with switch extension harnessMD01 Connection with drive door harnessMD02 Connection with drive door harnessMD03 Connection with drive door harnessMD04 Connection with passenger door harness


CRASH PAD WIRING HARNESS,SWITCH EXTENSION WIRING HARNESS

I01 Speaker (Front, LH)I03 Switch illuminationI04 RheostatI05-1 ClusterI05-2 ClusterI05-3 ClusterI06 Reed switchI07 Clock

I13I14I15I16Ml01Ml02Ml03Ml04

Hazard switchRear heated switchA/C switchCruise switchConnection with main harnessConnection with main harnessConnection with main harnessConnection with main harness


FLOOR WIRING HARNESS

R03 Parking brake switchR02 Lap belt switch (U.S.A.)R02 Seat belt switch (CANADA)R04 Door switch (RH)R05 Fuel pumpR06 Fuel sender extension wiringR07 Heated glass (+)R07-1 Heated glass (-)R08 Speaker (Rear, LH)R09 Door switch (LH)R10 High mounted stop lampR11 Luggage lamp

R12R16R41M56M 5 7MR01MR02MR03MR04RR01RR02

Speaker (Rear, RH)A/T and key lock control unitFuel senderRoof extension wiringRoom lampConnection with main harnessConnection with main harnessConnection with main harnessConnection with main harnessConnection with rear floor harnessConnection with trunk lid harness


REAR FLOOR WIRING HARNESS

R21 Rear combination lamp (Outside, LH)R22 Rear combination lamp (Outside, RH)R23 Trunk lid switchRR01 Connection with floor harness


TRUNK LID WIRING HARNESS

R31 Rear combination lamp (LH, Inside)R32 License plate lamp (LH)R33 High mounted stop lampR34 License plate lamp (RH)R35 Trunk lid openerR36 Rear combination lamp (RH, Inside)RR02 Connection with floor harness


DOOR WIRING HARNESS (DRIVER SIDE)

D01 Power window motor (LH)D02 Remote control mirror motor (LH)D03 Power window main switchD05 Passive seat belt switch (U.S.A.)M D 0 1 Connection with main harnessMD02 Connection with main harnessMD03 Connection with main harness


D11 Power window motorD12 Remote control mirrorD13 Power window sub. switchMD04 Connection with main harness

DOOR WIRING HARNESS (PASSENGER SIDE)

Hyundai Scoupe Full Manual

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