Nissan - 240 SX - Service Manual - 1989 - 1989

~.,,-, '. f \ , ~\ '.~«J.. , ,,"'.,. ".' ,- \~. \ , \ , "NI5SAN h \ ) 240SX - ,'. , 1989 / .. . , . t":"', V -~ .~ SERVICE< MANUAL " " \, ~ QUICK REFERENCE INDEX NISSAN j 24DSX MODEL - S13 SERIES . GENERALINFORMATION GI MAINTENANCE MA ENGINEMECHANICAL EM ENGINELUBRICATION & COOLING SYSTEMS- LC ENGINEFUEL& EMISSIONCONTROL SYSTEM- EF ENGINECONTROL, FUEL& EXHAUST SYSTEM- FE CLUTCH CL MANUALTRANSMISSION MT AUTOMATIC TRANSMISSION AT PROPELLER SHAFT& DIFFERENTIAL CARRIER- PD FRONTAXLE& FRONTSUSPENSION FA REARAXLE& REARSUSPENSION RA BRAKESYSTEM SR STEERING SYSTEM ST BODY SF HEATER & AIRCONDITIONER HA ELECTRICAL SYSTEM EL , cg 1988 NISSAN MOTOR CO., LTD. Printed in U.S.A. Not to be reproduced in who~e or in part without the prior written permission of Ni~n .. <"" Motor Company Ltd., Tokyo, Japan. &EC FOREWORD This manual contains maintenance and repair procedures for the 1989 Nissan 240SX. In order to assure your safety and the efficient functioning of the vehicle, this manusl should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task. All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at a~y time without notice. IMPORTANT SAFETYNOTICE The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first completely satisfy himself that neither his safety nor the vehicle's safety will be jeopardiz~d by the service method selected. . NISSAN MOTORCo.,LTD. Overseas Service Department Tokyo, Japan . GENERAL INFORMATION I GI SECTION CONTENTS PRECAUTIONS GI- 2 HOW TO USE THIS MANUAL GI- 5 HOW TO READ WIRING DIAGRAMS ~ GI- 7 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES GI-10 IDENTIFICATION INFORMATION GI-13 """'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' LIFTING POINTS AND TOW TRUCK TOWING GI-17 TIGHTENING TORQUE OF STANDARD BOLTS GI-20 - PRECAUTIONS Observe the following precautions ~o ensure safe and proper servicing. These precautions are not described in each individual section. 1. Do not operate the engine for an extended period of time without proper exhaust ventilation. Keep the work area well ventilated and free of any inflammable materials. Special care should be taken when handling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials. Do not smoke while working on the vehicle. SGI285 2. Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting and towing before working on the vehicle. These operations should be done on a level surface. 3. When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder. SGI231 4. Before starting repairs which do not require battery power, always turn off the ignition switch, then disconnect the ground cable from the battery to prevent accidental short circuit. SGI232 5. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe and muffler. Do not remove the radiator cap when the engine is hot. SGI233 GI-2 PRECAUTIONS 6. Before servicing the vehicle, protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons on your person do not scratch the paint. SGI234 7. Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly. 8. Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. 9. Replace inner and outer races of tapered roller bearings and needle bearings as a set. 10. Arrange the disassembled parts in accordance with their assembled locations and sequence. 11. Do not touch the terminals of electrical components which use microcomputers (such as electronic control units). Static electricity may damage internal electronic components. 12. After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. 13. Use only the lubricants specified in MA section. 14. Use approved bonding agent, sealants or their equivalents when required. 15. Use tools and recommended special tools where specified for safe and efficient service repairs. 16. When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks. 17. Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner. Precautions for E.F.I. or E.C.C.S. Engine SGI291 1. Before connecting or disconnecting E.F.I. or E.C.C.S. harness connector to or from any E.F.I. or E.C.C.S. control unit, be sure to turn the ignition switch to the "OFF" position and disconnect the negative battery terminal. Otherwise, there may be damage to control unit. 2. Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to release fuel pressure to eliminate danger. 3. Be careful not to jar components such as control unit and air flow meter. GI-3 PRECAUTIONS Precautions for Catalyst Clean floor SG 1290 If a large amount of unburned fuel flows into the converter, the converter temperature will be excessively high. To prevent this, follow the procedure below: 1. Use unleaded gasoline only. Leaded gasoline will seriously damage the catalytic converter. 2. When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. 3. Do not run engine when the fuel tank level is low, otherwise the engine may misfire causing damage to the converter. 4. Do not place the vehicle on inflammable material. Keep inflammable material off the exhaust pipe. Precautions for Fuel Unleaded gasoline of at least 87 AKI number (RON 91) GI-4 HOW TO USE THIS MANUAL 1. A QUICK REFERENCE INDEX, a black tab (e.gJ18) is provided on the first page. You can quickly find the first page of each section by mating it to the section's black tab. 2. THE CONTENTS are listed on the first page of each section. 3. THE TITLE is indicated on the upper portion of each page and shows the part or system. 4. THE PAGE NUMBER of each section consists of two letters which designate the particular section and a number (e.g. "BR-5"). 5. THE lARGE IllUSTRATIONS are exploded views (See below) and contain tightening torques, lubrication points and other information necessary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG. "Example" Pad retainer r;~'~ Torque member ~ ~ ~ ,/I J~ ~ 5~ 641556.5.40 ~ ~. ::;:;::: / . Pin boot r- 471 Main pin IE! to sliding portion / Outer shim SBR364A 6. THE SMAll IllUSTRATIONS show the important steps such as inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustrations. Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle or transmission, etc. are presented in a step-by-step format where necessary. 7. The followings SYMBOLS AND ABBREVIATIONS are used: ~ E1I ~ rJ ~ ~ EaI~ @> : "f:l : * S.O.S. L.H., R.H. . Tightening torque Should be lubricated with grease. Unless otherwise indicated, use recommended multi-purpose grease. Should be lubricated with oil. Sealing point Checking point Always replace after every disassembly. Apply petroleum jelly. Apply A.T.F. Select with proper thickness. Adjustment is required. Service Data and Specifications Left-Hand, Right-Hand GI-5 M/T A/T Tool L.H.D. R.H.D. A.T.F. 0, 02 03 D. 0.0. 22 2, 12 1, Manual Transaxle/Transmission Automatic Transaxle/Transmission Special Service Tools Left-Hand Drive Right-Hand Drive Automatic Transmission Fluid Drive range 1st gear Drive range 2nd gear Drive range 3rd gear Drive range 4th gear Overdrive 2nd range 2nd gear 2nd range 1st gear 1st range 2nd gear 1st range 1st gear ",. HOW TO USE THIS MANUAL 8. The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. "Example" Tightening torque: 59 - 78 Nom (6.0 - 8.0 kg-m, 43 - 58 ft-Ib) 9. TROUBLE DIAGNOSES are included in sections dealing with complicated components. 10. SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of data. 11. The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle. WARNING indicates the possibility of personal injury if instructions are not followed. CAUTION indicates the possibility of component damage if instructions are not followed. . . . BOLD TYPED STATEMENTSexcept WARNING and CAUTIONgive you helpfulinformation. GI-6 HOW TO READ WIRING DIAGRAMS ""'= WIRING DIAGRAM Symbols used in WIRING DIAGRAM are shown below: Example CONNECTOR Th is shows that these con nectors white 6 terminal connectors. POWER SUPPLY -This shows the ignition switch position in which the system can be ope rated. - See POWER SUPPLY ROUTING in EL section for the detai led wiring diagram. are BRANCH M/T model n ~ . '-LAMP-! 1m lG~ . ~B~ A/T model ~ . ~ 2 ~~ ~~B-SCLG~ ~ : MfT model @ : AfT model > I I lyw IiliJ ~Whi"~ m G ~ LOCATION NUMBER This number shows where the connector is located. See HARNESS LAYOUT in EL section. The number is identical with the one in HARNESS LAYOUT. I t ABBREVIATIONS ~@! I: ~ l-l SWITCH .rn '""".~ '"" ~ --- SWITCH This shows that continuity exists between terminals CD and CID, when the switch is turned to ON position. Instrument harness g 'WIRE -b BODY D GROUN ~ COLOR CODING BR B -BI,,' OR W R G Y L P PU GY SB LG ~ ~ ~ ~~ White Red Green Blue Yellow . ~ ~ ~ ~ ~ ~ Brown Orange Pink Purple Gray Sky Blue ht Green ~ Llg . d the base is stripe, . When. the iven wire first, co orfollowe d by the stripe color as IS gshown below: Example: I L/W ~ Blue with Whtte Stripe M: Main harness S G 1543 SWITCH POSITIONS Normally open ~~ ~ Normally closed ........ = , 0--- Wiring diagram switches are shown with the vehicle in the following condition. Ignition switch "OFF", Doors, hood and trunk lid/back door closed. Pedals are not depressed and parking brake is released. .. . ~ SEL764E GI-7 HOW TO READ WIRING DIAGRAMS CONNECTOR SYMBOLS All connector symbols in wiring diagrams are shown from the terminal side. Example . ..4: Connector SG 1362 Example EE . M.~ te,m;nal . ~ Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams. G";d'-[~ Connector Connector symbol Female terminal Efj Guide Connector Connector symbol SG 1363 MULTIPLESWITCH The continuity of the multiple switch is identified in the switch chart in wiring diagrams. Example WIPER SWITCH Continuity circuit of wiper switch SWITCH POSITION -B/Y -R. -W/B -L/Y CONTINUITY CIRCUIT OFF B E C (f) 1 5 @ 2 -B. 3-4 INT 3 - 4,5 - 6 LO 3-6 HI 2.6 WASH 1 -6 -yo Example: Wiper switch in LO position Continuity circuit: Red wire - @ terminal - CID terminal - Wiperswitch (@ - @: LO) - @ terminal - CD terminal - Black wire SG 1365 GI-8 HOW TO READ WIRING DIAGRAMS SUPER MULTIPLE JUNCTION (S.M.J.) The "S.M.J." indicated in wiring diagrams is shown in a simplified form. The terminal arrangement should therefore be referred to in the foldout at the end of the Service Manual. The foldout should be spread to read the entire wiring diagram. . . Example STARTING STARTING SYSTEM Wiring Diagram W w SUPER MULTIPLE JUNCTION (S.M.J.) T..minal g rnIJ ~ SYSTEM FF Dm3 A"angament Check 0 0 [ ,=fd:0CI~ crhKk 0 - '" ~ ], ,~ r- liJ 0 j ¥ .-:: := Super Multiple Junction (S.M.J.) y--R .S.M.J. L--S 't Refer to last page ( (Foldout page). J r-R~ ~B (Main harness) DO L---1 +-+ BR~ (Instrument harness) r-B (Main harness) (Instrument harness) BR---l. SEL653F GI-9 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES m" ( INSPECTION START) ~m -=- SG I561 iii ~ lu I iii CHECK GROUND CIRCUIT. 1) Turn ignition switch "OFF". _MECT [ill rill ~ CHECK POWER SUPPLY. Check the following items. 1) Turn ignition switch "ON" .~ [ IN.G. 1) Harness continuity betWeen 2) Check voltage between crank angle sensor and battery. terminal @ and ground. 2) E.C.C.S. relay-1 (See page EF & T~Battery voltage should exist. EC-106.) 3) "BR" fusible link O.K. 2 4) Power source for E.C.U. (See page EF & EC-104.) 5) Ignition switch ~~ 00 2) Disconnect crank angle sensor harness connector. 3) Check resistance betWeen terminal @ and ground. Resistance: Approximately Check the following items. 1) Harness continu ity betWeen crank angle sensor and I N.G~ grou nd 2) Ground circuit for E.C.U. (See page EF & EC-104.) on I SG 1562 O.K. NOTICE The flow chart indicates work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. 1) Use the flow chart after locating probable causes of a problem following the "Preliminary Check" or the "Symptom Chart". 2) After repairs, re-check that the problem has been completely eliminated. 3) Refer to Component Parts Location and Harness Layout for the Systems described in each section for identification/location of components and harness connectors. 4) Refer to the Circuit Diagram for Quick Pin Point Check. If you must perform circuit continuity between harness connectors more detail, such as in case of sub harness is used, refer to Wiring Diagram and Harness Layout in EL section for identification of harness connectors. 5) When checking circuit continuity, ignition switch should be "OFF" . 6) Before checking voltage at connectors, check battery voltage. 7) After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as it was. GI-10 HOW TO FOllOW FLOW CHART IN TROUBLE DIAGNOSES HOW TO FOllOW ITJ m THIS FLOW CHART Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed blocks, as shown in the following example. I ... CHECK POWER SUPPLY. 1) Turn ignition switch "ON". 2) Check .-- Check voltage between terminal @ and ground. Battery voltage should exist. item being performed. Procedure, measurement } steps or results O.K. I2J Measurement results Required results are indicated in bold type in the corresponding block, as shown below. These have the following meanings: Battery voltage ~ 11 14V or approximately 12V Voltage: Approximately OV ~ Less than 1V - ~ Cross reference of work symbols in the text and illustrations Illustrations are provided as visual aids for work procedures. For example, symbol m indicated in the left upper portion of each illustration corresponds with the symbol in the flowchart for easy identification. More precisely, the procedure under the "CHECK POWER SUPPLY" outlined previously is indicated by an illustration m . @] Symbols used in illustrations Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol. Example View from terminal side Connector symbol ~ Direction mark ~ View from harness side Connector Connector symbol ~ [it Direction Direction mark A direction mark is shown to clarify the side of connector (terminal side or harness side). Direction marks are mainly used in the illustrations indicating terminal inspection. . . ~: View f,om lermlnel side n' r.s. All connector symbols shown from the terminal side are enclosed by a single line. ~: Viewf,omhernessside .n H.S. All connector symbols shown from the harness enclosed by a double line. mark SGI364 GI-11 side are HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES Key to symbols signifying measurements or procedures Symbol Symbol explanation ..-cT IV CONNECT £) @- 00 00 OOACC F Symbol Symbol explanation Check after disconnecting the connector to be measured. AIC switch Check after connecting the connector to be measured. AIC switch is "ON". Insert key into ignition switch. REC switch is "ON". Turn ignition switch to "OFF" position. REC switch is "OFF". Turn ignition switch to "ON" position. DEF switch is "ON". Turn ignition switch to "START" position. VENT switch is "ON". Turn ignition switch from "OFF" to "ACC" position. Fan switch is "ON". (At any position except for "OFF" position) Turn ignition switch from "ACC" to "OFF" position. Fan switch is "OFF". "cfi1234. Turn ignition switch from "OFF" to "ON" position. OOF 0 trJ Apply battery voltage directly to components. 7 Turn ignition switch from "ON" to "OFF" position. Drive vehicle. Do not start engine,or check Disconnect battery negative cable. with engine stopped. Start engine. or check is "OFF". with engine Depress running. brake pedal. Apply parking brake. Release brake pedal. Release parking brake. Depress accelerator pedal. CffH Check after engine is warmed up sufficiently. Release accelerator pedal. l!V Voltage should be measured with a voltmeter. - La) II CIUIIT foi-- Circuit resistance should be measured with an ohmmeter. € II - Le1J Currentshould be measuredwith an ammeter. GI-12 Pin terminal check for S.M.J. type E.C.U.and AIT control unit connectors. For details regarding the terminal arrangement, refer to the foldout page. ' IDENTIFICATION INFORMATION Model Variation Destination Model Body Transmission Engine Coupe HLS13FU Fastback RHLS13FU Coupe HLS13AU Fastback RHLS13AU Coupe HLS13FV Fastback RHLS13FV Coupe HLS13AV Fastback RHLS13AV Coupe HLS13FN Fastback RHLS13FN Coupe HLS13AN Fastback RHLS13AN Differential carrier FS5W71C Non-California RE4R01A FS5W71C California KA24E R200 RE4R01A FS5W71 C Canada RE4R01A Prefix and suffix designations: R 0: R : Coope Fastba~ H: KA24E engine L: L.H. drive H L S13 A N (R) L T (R) : With A.B.S. N : Canada V : California U: Non-California A : Automatic transmission F : 0 : means no indication. GI-13 5-speed manual transmission IDENTIFICATION INFORMATION Identification Number Vehicle identification plate Vehicle identification number (Chassis number) F.M.V .5.5. certification Vehicle identification label number plate SGI547 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT IN 1 H S 3 6 P X K W 000051 Manufacturer I IT IN 1: N issan passenger vehicle Engine type H: KA24E Vehicle serial number Manufacture plant W: Kyushu Model year K: 1989 year model . Vehicle line S: NISSAN 240SX Check digit (0 to 9 or XI The code for the check digit is determined by mathematical computation. Model change (0 to 91 Body type 4: Coupe 6: Fastback Restraint system S: Standard P: Automatic GI-14 IDENTIFICATION INFORMATION Identification Number (Cont'd) IDENTIFICATION PLATE NISSAN MOTORCO.,LTD. JAPAN ~:it ~i:J ill 1 2 3 4 5 6 7 8 9 CHASSIS NO NO DE CHASIS MODEL .& MOOElO 0 I &" ",-COlOR TRiM f 'Jk COlOR GUMNICION ;,.0 '/;,.0 ENGIN[ MOTOR ;; ';~: :::; ~ElE 0 ffi& && CC & & I tf; S jJt ~ ItJ :if[** :it ~ U ::::A MADEINJAPAN Type Vehicle identification number (Chassis numbed Model Body color code Trim color code Engine model Engine displacement Transmission model Axle model SGI315 ENGINE SERIAL NUMBER KA24E engine TL 1006M MANUAL TRANSMISSION NUMBER AUTOMATIC SGI274 TRANSMISSION NUMBER SGI513 GI-15 IDENTIFICATION INFORMATION Dimensions Unit: mm (in) Coupe Fastback Overall length 4,520 (178.0) 4,520 (178.0) Overall width 1,690 (66.5) 1,690 (66.5) Overall height 1,290 (50.8) 1,290 (50.8) Front tread 1,465 (57.7) 1,465 (57.7) Rear tread 1,460 (57.5) 1,460 (57.5) Wheelbase 2,475 (97.4) 2,475 (97.4) Wheels and Tires Road wheel Steel 6-JJx 15 Aluminum 6-JJx 15 Offset Tire size mm (in) 40 (1.57) Conventional 195/60R 15 86H 205/60R 15 89H * Spare T125/70D 15 *: Option GI-16 LIFTING POINTS AND TOW TRUCK TOWING Garage Jack and Safety Stand WARNING: Never get under the vehicle while it is supported only by the jack. Always use safety stands to support the frame when you have to get under the vehicle. Place wheel chocks at the front wheels when the rear wheels are raised and place wheel chocks at the rear wheels when the front wheels are raised. CAUTION: Place a wooden or rubber block between safety stand and vehicle body when the supporting body is flat. . . Garage jack points SGI552 GI-17 LIFTING POINTS AND TOW TRUCK TOWING 2-pole Lift WARNING: When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced. When setting the lift arm, do not allow the arm to contact the brake tubes and fuel lines. Sill ~ Put the sill in the slit of the lift pad to prevent the sill from deforming. If the pad does not have lift pad // the slit, prepare a suitable attachment with slit. Note: Lift-up points are the same as pantograph jack points. SGI553 Tow Truck Towing CAUTION: . . . ~ ~ All applicable state or Provincial (in Canada) laws and local laws regarding the towing operation must be obeyed. It is necessary to use proper towing equipment to avoid possible damage to the vehicle during towing operation. Towing is in accordance with Towing Procedure Manual at dealer. When towing with the rear wheels on the ground, release the parking brake and move the gearshift lever to neutral (UN" position). NISSAN recommends that vehicle be towed with the driving (rear) wheels off the ground as illustrated. 'i::ij,iiii.2ii;~1',,,';1tiii:.; -. SG 1383 GI-18 LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing (Cont'd) TOWING AN AUTOMATIC TRANSMISSION MODEL WITH FOUR WHEELS ON GROUND OR TOWING WITH FRONT WHEELS RAISED (With rear wheels on ground) Observe the following restricted towing speeds and distances. Speed: Below 50 km/h (30 MPH) Distance: Less than 65 km (40 miles) If the speed or distance must necessarily be greater, remove the propeller shaft beforehand to prevent damage to the transmission. TOWING POINT Alwayspull the cable straightout from the vehicle.Never pull on the hook at a sidewaysangle. Front Rear CE1 DD9M GI-19 TIGHTENINGTORQUE OF STANDARD BOLTS Grade Bolt size Bolt dia- meter* mm Tightening torque (Without lubricant) Pitch mm Hexagon head bolt N.m 4T M6 6.0 M8 8.0 M10 M12 12.0 M14 14.0 M6 6.0 M8 7T M10 M12 9T 10.0 8.0 10.0 12.0 6.1 0.62 4.5 5.1 1.25 13 1.3 9 15 1.5 11 1.0 13 1.3 9 16 1.6 12 1.5 25 2.5 18 29 3.0 22 1.25 25 2.6 19 30 3.1 22 1.75 42 4.3 31 51 5.2 38 1.25 46 4.7 34 56 5.7 41 1.5 74 7.5 54 88 9.0 65 1.0 8.4 0.86 6.2 10 1.0 7 1.25 21 2.1 15 25 2.5 18 1.0 22 2.2 16 26 2.7 20 1.5 41 4.2 30 48 4.9 35 1.25 43 4.4 32 51 5.2 38 1.75 71 7.2 52 84 8.6 62 1.25 77 7.9 57 92 9.4 68 14.0 1.5 127 13.0 94 147 15.0 108 M6 6.0 1.0 12 1.2 9 15 1.5 11 M8 8.0 1.25 29 3.0 22 35 3.6 1.0 31 3.2 23 37 3.8 26 27 1.5 59 6.0 43 70 7.1 51 1.25 62 46 74 7.5 54 1.75 98 6.3 10.0 72 118 12.0 87 1.25 108 11.0 80 137 14.0 101 1.5 177 18.0 130 206 21.0 152 M12 M14 10.0 12.0 14.0 1. Special parts are excluded. 2. This standard is applicable to bolts having the following marks embossed on the bolt head. 4T 7T 9T 3.8 1.0 kg-m 0.52 M14 M10 Grade ft-Ib Hexagon flange bolt N.m ft-Ib kg-m *: Nominal diameter Mark 4 7 9 M 1 GI-20 6 """"L- Nominal diameter of bolt threads (Unit: mm) Metric screw threads '..~ MAINTENANCE MA .J SECTION I CONTENTS PERIODIC MAINTENANCE ... MA- 2 GENERAL MAINTENANCE. MA- 4 RECOMMENDED LUBRICANTS AND FLUIDS MA- 6 ENGINE MAINTENANCE MA- 8 "'"'''''''''''' CHASSIS AND BODY MAINTENANCE SERVICE DATA AND SPECIFICATIONS (S.D.S.) MA-14 :" MA-20", l1li PERIODIC MAINTENANCE The following charts show the normal maintenance schedule. Under severe driving conditions, additional or more frequent maintenance will be required. Refer to "Maintenance under severe driving conditions". The periodic maintenance schedule is repeated beyond the last mileage and period shown by returning to the first 15,000 miles (24,000 km) or 12 months. EMISSION CONTROL SYSTEM MAINTENANCE MAINTENANCE. OPERATION Perform at number of miles, kilometers or months, whichever comes first. Drive belts MAINTENANCE 15 30 INTERVAL 45 60 Miles x 1,000 7.5 (km x 1,000) (12) (24) (48) (72) (96) 6 12 24 36 48 1* Months See NOTE (1). Replace every 30,000 miles (48,000 km). 1* 1* 1* 1* Air cleaner filter Vapor lines Fuel lines Fuel filter See NOTE (2)*. R Engine coolant Egnine oil R Engine oil filter (Use Nissan PREMIUM R R Then replace every 7,500 . miles (12,000 km) or 6 months. Then replace every second oil change. type or equivalent.) Ignition wires MA-8 MA-10 MA-13 MA-9 MA-10 MA-8 MA-11 MA-11 Replace every 30,000 miles (48,000 km). Inspect every 3 years. * Spark plugs Reference page MA-12 MA-12 CHASSIS AND BODY MAINTENANCE MAINTENANCE OPERATION Perform at number of miles, kilometers or months, whichever comes first. Miles x 1,000 15 (km x 1,000) (24) 12 Months Break lines & cables I I I Brake pads & discs Manual and automatic transmission & differential gear oil Steering gear & linkage, and axle & suspension parts Exhaust system MAINTENANCE INTERVAL 30 45 (48) 24 I I I I I (72) 36 I I I 60 Reference page (96) 48 I I I I I MA-16 MA-17 MA-14,15,16 MA-18, FA-4,RA-4 MA-14 NOTE: (1) After 60,000 miles (96,000 km) or 48 months, inspect every 15,000 miles (24,000 km). (2) If vehicle is operated under extremely adverse weather conditions or in arees where ambient temperatures are either extremely low or extremely high, the filters might become clogged. In such an event, replace them immediately. (3) Maintenance items and intervals with "." are recommended by NISSANfor reliable vehicle operation. The owner need not perform such maintenance in order to ~aintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required. Abbreviations: R = Replace. I = Inspect. Correct or replace if necessary. MA-2 PERIODIC MAINTENANCE MAINTENANCE UNDER SEVERE DRIVING CONDITIONS The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance is required to. be performed on the following items as shown in the table. Severe driving conditions A - Repeated short trips less than 5 miles (8 km) and outside temperatures remain below freezing B - Extensive idling and/or low speed driving for a long distance such as police, taxi or door-to-door delivery use C - Driving in dusty conditions D - Driving on rough, muddy, or salt spread roads E - Towinga trailer, usinga camper or a car-top carrier Driving condition C ABC A. . A. DE C D E . item Maintenance interval Reference More frequently' MA-10 Engine oil & oil filter R Every 3,000 miles (5,000 km) or 3 months MA-11 Every 7,500 miles (12,000 km) or 6 months MA-17 Every 30,000 miles (48,000 km) or 24 months MA-14, 15, 16 Brake pads & discs D . Steering gear & linkage, and axle & suspension parts Maintenance operations: operation R Manual and automatic transmission & differential gear oil D E Maintenance Air cleaner filter D E CD. . Maintenance R page MA-18, FA-4, RA-4 Every 7,500 miles (12,000 km) or 6 months Steering linkage ball joints & front suspension ball joints Exhaust system MA-18,FA-4 MA-14 I = Inspect. Correct or replace if necessary. R = Replace. MA-3 GENERAL MAINTENANCE General maintenance includes those items which should be checked during the normal day-to-day operation of the vehicle. They are essential if the vehicl~isto continue operating properly. The owners can perform the checks and inspectionsthemselvesor they can have their NISSANdealers do them for a nominal charge. Item Reference page OUTSIDE THE VEHICLE The ma!ntenance items listed here should be performed from time to time, unless otherwise specified. Tires Check the pressure with a gauge periodically when at a service station, including the spare, and adjust to the specified pressure if necessary. Check carefully for damage, cuts or excessivewear. Wheel nuts When checking the tires, make sure no nuts are missing,and check for any loose nuts. Tighten if necessary. Tire rotation Tires should be rotated every 12,000 km (7,500 miles.) MA-18 Wheel alignment and balance If the vehicle should pull to either side while driving on a straight and level road, or if you detect uneven or abnormal tire wear, there may be a need for wheel alignment. If the steering wheel or seat vibrates at normal highway speeds, wheel balancing may be needed. MA.17 FA-6 RA-6 Windshieldwiper blades Check for cracks or wear if they do not wipe properly. Doors and engine hood Check that all doors and the engine hood operate smoothly as well as the trunk lid and back hatch. Also ensure, that all latches lock securely. Lubricate if necessary. Make sure that the secondary latch keeps the hood from opening when the primary latch is released. When driving in areas using road salt or other corrosive materials, check lubrication frequently. INSIDE THE VEHICLE The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc. Lights Make sure that the headlights, stop lights, taillights, tUrn signal lights, and other lights are all operating properly and installed securely. Also check headlight aim. MA-19 Warning lights and buzzers/chimes Make sure that all warning lights and buzzers/chimes are operating properly. Windshield wiper and washer Check that the wipers and washer operate properly and that the wipers do not streak. Windshield defroster Check that the air comes out of the defroster outlets properly and in sufficient quantity when operating the heater or air conditioner. Steering wheel Check that it has the specified free play. Be sure to check for changes in the steering condition, such as excessivefree play, hard steering or strange noises. Free play: Lessthan 35 mm (1.38 in) Seats Check seat position controls such as seat adjusters, seatback recliner, etc. to ensure they operate smoothly and that all latches lock securely in every position. Check that the head restrains move up and down smoothly and that the locks (if so equipped) hold securely in all latched positions. Check that the latches lock securely for folding-down rear seatbacks. . Seat belts Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and retractors) operate properly and smoothly, and are installed securely. Check the belt webbing for cuts, fraying, wear or damage. MA-4 MA-19 GENERAL MAINTENANCE Item Reference page Clutch pedal Make sure the pedal operates smoothly and check that it has the proper free travel. CL-5 Brakes Check that the brake does not pull the vehicle to one side when applied. Brake pedal Check the pedal for smooth operation and make sure it has the proper distance under it when depressed fully. Check the brake booster function. BR-7 Parking brake Check that the lever has the proper travel and confirm that your vehicle is held securely on a fairly steep hill with only the parking brake applied. BR-23 Automatic transmission "Park" mechanism Check that the lock release button on the selector lever operates properly and smoothly. On a fairly steep hill check that your vehicle is held securely with the selector lever in the "P" position without applying any brakes. UNDER THE HOOD AND VEHICLE The maintenance items listed here should be checked periodically (e.g. each time you check the engine oil or refuel). Windshieldwasher fluid Check that there is adequate fluid in the tank. Engine coolant level Check the coolant levelwhen the engine is cold. MA-9 Radiator and hoses Check the front of the radiator and clean off any dirt, insects, leaves, etc., that may have accumulated. Make sure the hoses have no cracks, deformation, rot or loose connections. Brake and clutch fluid levels Makesure that the brake and clutch fluid levelsare between the "MAX" and "MIN" lines on the reservoir. MA-14,16 Engine drive belts Makesure that no belt is frayed, worn, cracked or oily. MA-8 Engine oil level Check the level on the dipstick after parking the vehicle on a level spot and turning off the engine. MA-11 Power steering fluid level and lines Check the level when the fluid is cold and the engine is turned off. Check the lines for proper attachment, leaks, cracks, etc. MA-18 Automatic transmission fluid level Check the level on the dipstick after putting the selector lever in "P" with the engine idling. MA-15 Exhaust system Make sure there are no loose supports, cracks or holes. If the sound of the exhaust seems unusual or there is a smell of exhaust fumes, immediately locate the trouble and correct it. MA-14 Underbody The underbody is frequently exposed to corrosive substances such as those used on icy roads or to control dust. It is very important to remove these substances, otherwise rust will form on the floor pan, frame, fuel lines and around the exhaust system. At the end of winter, the underbody should be thoroughly flushed with plain water, being careful to clean those areas where mud and dirt can easily accumulate. Fluid leaks Check under the vehicle for fuel, oil, water or other fluid leaks after the vehicle has been parked for a while. Water dripping from the air conditioner after use is normal. If you should notice any leaks or gasoline fumes are evident, check for the cause and correct it immediately. MA-5 RECOMMENDED LUBRICANTS AND FLUIDS Lubricants and Fluids Capacity (Approximate) Engine oil (Refill) With oil filter Without oil filter Cooling system (with reservoir tank) Reservoir tank Manual transmission Differential oil gear oil Automatic transmission fluid Power steering fluid Recommended lubricants and fluids US measure Imp measure Liter 3-3/4 qt 3-1/8 qt 3.5 3-3/8 qt 2-7/8 qt 3.2 7-1/8 qt 5-7/8 qt 6.7 3/4 qt 5/8 qt 0.7 5-1/8 pt 4-1/4 pt 2.4 API GL-4*2 2-3/4 pt 2-1/4 pt 1.3 API GL-5*2 8-3/4 qt 7-1/4 qt 8.3 1 qt 0.9 3/4 qt Genuine Nissan Motor Oil*1 or equivalent (Energy Conserving Oils of API SF or SG)*2, *3 Anti-freeze coolant (Ethylene glycol base) Genuine Nissan ATF*1 or equivalent Type DEXRON TM Type DEXRON TM Brake fluid Genuine Nissan Brake Fluid*1 or equivalent DOT 3 (US FMVSS No. 116) Multi-purpose grease NLGI No.2 (Lithium soap base) *1: Available in mainland U.S.A. through you Nissan dealer. *2: For further details, see "SAE Viscosity Number". *3: Energy Conserving Oils These oils can be identified by such labels as energy conserving, energy saving, improved fuel economy, etc. MA-6 RECOMMENDED LUBRICANTS AND FLUIDS SAE Viscosity Number Outside Temperature Anticipated ENGINE Outside Temperature Range Anticipated Before Next Oil Change GEAROIL Range Before Next Oil Change OIL 140 . °C",OF ----- +4011+104"'--+30111+86 - +16111+60--+10111 0111+32 +50 ~ -181110 -29111-20- -5W-30 T10002 T10003 10W-30 is preferable if the ambient temperature is above -18°C (0° F). 20W-40 and 20W-50 are usable if the ambient temperature is above 10°C (50° F) for all seasons. MA-7 8OW-90 is preferable if the ambient temperature is below 40°C (104°F). ENGINE MAINTENANCE Power steering oil pump IAJ Water pump lAJQ' l:~:o, I Crank pulley T : Tension checking points IAJ: Adjusting bolts lAJA;,,ood;,;oo", Checking Drive Belts 1, Inspect for cracks, fraying, wear or oil adhesion, If necessary, replace with a new one. 2. Inspect drive belt deflections by pushing on the belt midway between pulleys. Adjust if belt deflections exceed the limit. Belt deflection: Inspect drive belt deflections when engine is cold. compressor Unit: mm (in) 8MAOO2C Used belt deflection Set deflection of new belt Limit Adjusted deflection. Alternator 11 (0.43) 7-8 (0.28 - 0.31) 6-7 (0.24 - 0.28) Air conditioner compressor 12 (0.47) 7-8 (0.28 - 0.31) (0.24 Power steering oil pump 13 (0.51) 8-9 (0.31 - 0.35) 7-8 (0.28 - 0.31) Applied pushing force 6.7 - 0.28) 98 N (10 kg, 22 Ib) Changing Engine Coolant ~~~ [~O1234 m ~ ~ m .- WARNING: To avoid being scalded, never change the coolant when the engine is hot. 1. Move heater "TEMP" control lever all the way to "HOT" position. 8M AOO3C 2. Open drain cock at the bottom of radiator, and remove radiator cap. MA-8 "'. ENGINE MAINTENANCE Changing Engine Coolant (Cont'd) 3. Remove cylinder block drain plug. 4. Close drain cock and tighten drain plug securely. Apply sealant to the thread of drain plug. to;J:34 44 N.m (3.5 - 4.5 kg-m, 25 - 33 ft-Ib) L . J - 5. Open air relief plug. . 6. Fill radiator with water and close air relief plug and radiator cap. 7. Run engine and warm it up sufficiently. 8. Race engine 2 or 3 times under no-load. 9. Stop engine and wait until it cools down. 10. Repeat step 2 through step 9 until clear water begins to drain from radiator. 11. Drain water. 12. Open radiator cap and air relief plug. 13. Fill rafdiator with coolant up to specified level. Follow instructions attached to anti-freeze container for mixing ratio of anti-freeze to water. Coolant capacity. (With reservoir tank) 6.7 Q (7-1/8 US qt, 5-7/8 Imp qt) Pour coolant through coolant filler neck slowly to allow air in system to escape. MAX. MIN. 14. Close air relief plug. 15. Remove reservoir tank, drain coolant, then clean reservoir tank. 16. Install reservoir tank and fill it with coolant up to "MAX" level and then install radiator cap. 17. Run engine and warm it up sufficiently. 18. Race engine 2 or 3 times under no-load. 19. Stop engine and cool it down, then add coolant as necesary. SMA412B Checking Fuel Lines Inspect fuel lines and tank for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. If necessary, repair or replace faulty parts. MA-9 ENGINE MAINTENANCE Checking Fuel Lines CAUTION: 3 mm 10.12 in) , ~--,'-' . (Cont'd) Tightenhigh-pressurerubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end. Ensure that screw does not contact adjacent parts. , --T-+-+--J__J.-_J SMA804A Changing Fuel Filter WARNING: Before removing fuel filter, release fuel pressure from fuel line. 1. Remove fuse for fuel pump. 2. Start engine. 3. After engine stalls, crank engine two or three times to make sure that fuel pressure is released. 4. Turn. ignition switch off and install fuse for fuel pump. 5. Loosen fuel hose clamps. 6. Replace fuel filter. Be careful not to spill fuel over engine compartment. Place a shop towel to absorb fuel. Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter. . . . Whentighteningfuel hose clamps, refer to "CheckingFuel Lines". Changing Air Cleaner Filter The viscous paper type filter does not need cleaning between renewals. MA-10 ENGINE MAINTENANCE Changing Engine Oil WARNING: Be careful not to burn yourself, as the engine 011Is hot. 1. Warm up engine, and check for oil leakage from engine components. 2. Remove drain plug and oil filler cap. 3. Drain oil and refill with new engine oil. Refill oil capacity (Approximate): ~ Front SMAOO9C Unit: liter (US qt, Imp qt) With oil filter change 3.5 (3.3/4,3-1/8) Without oil filter change 3.2 (3-3/8,2-7/8) CAUTION: . Be sure to clean drain plug and Install with new washer. Drain plug: tOJ:29 - 39 N.m . . (3.0 - 4.0 kg-m, 22 - 29 ft-Ib) Use recommended engine 011. 4. Check oil level. 5. Start engine and check area around drain plug and oil filter for oil leakage. 6. Run engine for a few minutes, then turn it off. After several minutes, check oil level. SMA042C Changing Oil Filter 1. Remove oil filter with a suitable tool. WARNING: Be careful not to burn yourself, as the engine and the engine oil are hot. 2. Before installing new oil filter, clean the oil filter mounting surface on cylinder block, and coat the rubber seal of oil filter with a little engine oil. ~ SMA010 MA-11 --- ENGINE MAINTENANCE Changing Oil Filter (Cont'd) 3. Screw in the oil filter until a slight resistance is felt, then tighten additionally more than 2/3 turn. 4. Add engine oil. Refer to Changing Engine Oil. 2/3 of a turn SMA229B Changing N.G. O.K. Spark Plugs 1. Disconnect ignition wires from spark plugs at boot. Do not pull on the wire. SMA017 2. Remove spark plugs with spark plug wrench. Spark plug: Standard type ZFR5D-11 Hot type ZFR4D-11 Cold type ZFR6D-11 R 16mmV1 'o.um~ SEM294A Side electrode iii 3. Check plug gap of each new spark plug. Gap: 1.0 - 1.1 mm (0.039 - 0~043 in) 4. Install spark plugs. Reconnect ignition wires according to nos. indicated on them. Spark plug: ~:20 - 29 N.m (2.0 - 3.0 kg-m, 14 - 22 ft-Ib) SMA476 Checking Ignition Wires 1. Inspect wires for cracks, damage, burned terminals and for improper fit. 2. Measure the resistance of wires and check for intermittent breaks by shaking them. Resistance: Less than 30 kil .If it exceeds the limit, replace the ignition wire with a new one. ~ SMA015A MA-12 ENGINE MAINTENANCE Checking Vapor Lines 1. Visually inspect vapor lines for. improper attachment and for cracks, damage, loose connections, chafing and deterioration. 2. Inspect vacuum relief valve of fuel tank filler cap for clogging, sticking, etc. Refer to EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION in EF & EC section. /" " MA-13 . CHASSIS AND BODY MAINTENANCE Checking Exhaust System . Check exhaust pipes, muffler and mounting for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration. SMA211A Checking Clutch Fluid Level and Leaks . Max. If fluid level is extremely low, check clutch system for leaks. Min. SMA941B Checking M/T Oil 1. Check for oil leakage. , SMA429A 2. If leakage is found, check oil level. Never start engine while checking oil level. Filler plug: ~: 25 - 34 N.m (2.5 - 3.5 kg-m, 18 - 25 ft-Ib) K SMA103 Changing 1. Drain oil and refill with new gear oil. 2. Check oil level. Oil capacity: 2.4 Q (5-1/8 US pt, 4-1/4 Imp pt) Drain plug: ~: 25 - 34 N.m (2.5 - 3.5 kg-m, 18 - 25 ft-Ib) ~~~ .,. M/T Oil ~.;. ~"~ SMA255A MA-14 CHASSIS AND BODY MAINTENANCE Checking AIT Fluid 1. Check for fluid leakage. . . SMA430A . Front side Hot: 50 - aooc (122 - 176°F) Add" 2. If leakage is found, check fluid level. Fluid level should be checked using "HOT" range on dipstick at fluid temperatures of 50 to 80°C (122 to 176°F) after vehicle has been driven approximately 5 minutes in urban areas after engine is warmed up. But it can be checked at fluid temperatures of 30 to 50°C (86 to 122°F) using "COLD" range on dipstick for reference after engine is warmed up and before driving. However, fluid level must be rechecked using "HOT" range. 1) Park vehicle on level surface and set parking brake. 2) Start engine and then move selector lever through each gear range, ending in "P". 3) Check fluid level with engine idling. 4) Remove dipstick and wipe it clean with lint-free paper. 5) Reinsert dipstick into charging pipe as far as it will go. 6) Remove dipstick and note reading. If level is at low side of either range, add fluid to the charging pipe. Do not overfill. O.K. ~ 3. Check fluid condition. Check fluid for contamination. If fluid is very dark or smells burned, or contains frictional material (clutches, band, etc.), check operation of AlT. Refer to section AT for checking operation of AlT. Check fluid for contamination. SMA853B Changing AIT Fluid 1. Drain fluid by removing oil pan. 2. Replace gasket with new one. 3. Refill with fluid and then check fluid level. Oil capacity (With torque converter): 8.3 Q (8-3/4 US qt, 7-1/4 Imp qt) ~ SMA921B MA-15 CHASSIS AND BODY MAINTENANCE Checking Differential Gear Oil 1. Check differential carrier for oil leakage. SMA012C 2. If leakage is found, check oil level. Filler plug: ~: 59 98 N.m (6 10 kg-m, 43 - 72 ft-Ib) - - SMA257 A Changing ~~ Differential Gear Oil 1. Drain oil and refill with new gear oil. 2. Check oil level. Oil capacity: 1.3 Q (2-3/4 US pt, 2-1/4 Imp pt) Drain plug: ~: 59 98 N.m (6 10 kg-m, 43 - 72 ft-Ib) - 0,,;" PI~ - ~ SMA363A Checking Brake Fluid Level and Leaks . = If fluid level is extremely low, check brake system for leaks. MAX = MIN Checking Brake Lines and Cables . Check brake fluid lines and parking brake cables for improper attachment and for leaks, chafing, abrasions, deterioration, etc. SMA732A MA-16 CHASSIS AND BaDY MAINTENANCE Checking Disc Brake . Check condition of disc brake components. ROTOR . Check condition and thickness. Unit: mm (in) Front Rear CL22VB CL9H Standard thickness 20.0 (0.787) 9.0 (0.354) Minimum thickness 18.0 (0.709) 8.0 (0.315) Disc brake type SMA260A CALIPER . Check operationand for leakage. SMA922A PAD Check for wear or damage. . Unit: mm (in) Disc brake type Standard thickness Minimum thickness Front Rear CL22VB CL9H 10.0 (0.394) 9.5 (0.374) 2.0 (0.079) SMA847B Balancing . Wheels Adjust wheel balance using road wheel center. Wheel balance (Maximum allowable unbalance at rim flange): Refer to S.D.S. Tire balancing weight: Refer to S.D.S. MA-17 CHASSIS AND BODY MAINTENANCE Tire Rotation FRONT ! 0 . Do not include the T-type spare tire when rotating the tires. Wheel nuts: ~: 98 - 118 N.m (10.0 - 12.0 kg-m, 72 - 87 ft-Ib) A! 0 SMA650B Checking Steering Gear and Linkage STEERING GEAR Check gear housing and boots for looseness, damage or grease leakage. Check connection with steering column for looseness. STEERING LINKAGE Check ball joint, dust cover and other component parts for looseness, wear, damage or grease leakage. . . . . Q : Check grease leakage : Check tightening torque SMA851 B Checking Power Steering Fluid and Lines SMA940B . Check fluid level, when the fluid is cold. . Check lines for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. SST107B MA-18 CHASSIS AND BODY MAINTENANCE LUBRICATING LOCKS, HINGES AND HOOD LATCHES Fastback ------- lEI =~~ m m. SMA999B CHECKING SEAT BELTS, BUCKLES, RETRACTORS, ANCHORS AND ADJUSTERS CAUTION: 1. AUseat bait a..mblies, including retractors and attaching hardwares such as guida rail set, etc" should ba inspacted after any collision. Ni...n recommends that aUseet bait ...amblies in use during a collision ba replaced unless the collision was minor and the baits show no damage and continue to operete properly. Seat bait assemblies not in use during a collision should allO ba inspacted and replaced if eithar damage or improper operation is noted. 2. If tha condition of any component of a seat bait is questionable, do not have seat bait repaired, but raplaced as a bait 8118mbly. 3. If wabbing is cut, frayed, or damaged, replace bait assembly. 4. Do not spill drinks, oil, etc. on inner lap bait buckle. Never oil tongue and buckle. 5. Use a NISSAN genuine ..at bait assembly. ~ Anchor bolt 24-31 N.m (2.4 - 3.2 kg-m, 17 - 23 ft-Ib) For automatic seat bait, refer to BF section. Rear seat belt Check function of buckles and tongues when buckled and released. Front seat belt MA-19 SMAOO1C SERVICE DATA AND SPECIFICATIONS (S.D.S.) Engine Maintenance Spark plug INSPECTION AND ADJUSTMENT Drive belt deflection Unit: mm (in) Used belt deflection Adjusted deflection Limit Alternator Set deflection of new belt 11 (0.43) 7-8 6-7 (0.28 - 0.311 I (0.24 - 0.28) 6-7 7-8 (0.28 - 0.311 I (0.24 - 0.28) Air conditioner compressor 12 (0.47) Power steering oil pump 13 (0.511 1(0.31-0.35) (0.28- 0.31) 8-9 ZFR5D-11 Hot type ZFR4D-11 Cold type ZFR6D.11 Plug gap 1.0 - 1.1 mm (0.039 . 0.043 in) Ignition wire Resistance kS1 TIGHTENING 7-8 I Applied pushing force Standard type 98 N (10 kg, 22 Ib) N'm kg-m ft-Ib Spark plug 20- 29 2.0 - 3.0 14- 22 25 - 33 22.29 Oil capacity (Refill) Unit: 2 (US qt, Imp qt) 3.5 (3-3/4,3-1/8) Without 3.2 (3-3/8,2-7/8) oil filter Coolant capacity Unit: 2 (US qt, Imp qt) With reservoir tank TORQUE Unit Drain plug With oil filter Less than 30 6.7 (7-118,5-7/8) MA-20 - Engine block 34 44 3.5-4.5 Oil pan 29-39 3.0-4.0 SERVICE DATA AND SPECIFICATIONS (S.D.S.) Chassis and Body Maintenance Brake INSPECTION AND ADJUSTMENT Clutch Unit: mm (in) Unit: mm (in) - 196 (7.32.7.72) Pedal free height "H" 186 Pedal free play" A" 1.0 - 3.0 (0.039 .0.118) Disc brake Pad Standard thickness CL22VB 10.0 (0.394) CL9H 9.5 (0.374) Minimum thickness CL22VB Front axle and front suspension(Unladen)* -1°30' Camber degree Caster degree Toe-in mm (in) to 0° 2.0 (0.079) CL9H 6°00' . ~30' Rotor Standard th ickness CL22VB 0 - 2 (0 - 0.08) (Total toe-in) degree 0' - 12' Kingpin inclination degree 12°30'- 14°00' 2.0 (0.079) 20.0 (0.787) CL9H Minimum thickness CL22VB Front wheel turning angle Full turn Inside/outside d 9.0 (0.354) 39° egree -43° /33° 18.0 (0.709) CL9H *: Tankful of fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools, mats in designated position. 8.0 (0.315) Pedal Free height M/T 177 A/T Rear axle and rear suspension (Unladen)* Camber degree Toe-out mm (in) (Total toe.out) degree -1°36' 186 - 196 (7.32 - 7.72) Free play 1 - 3 (0.04 - 0.12) to -0°36' Depressed hElight [under force of 490 N (50 kg, 110 Ib) with engine running] 0 - 5 (0 . 0.20) 0' - 28' I - 187 (6.97 - 7.36) *: Tankful of fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools, mats in designated position. 100 (3.94) or more Parking brake Number of notches [at pulling force 196 N (20 kg, 44 Ib)] 6-8 Wheel bearing Wheel bearing axle end mm (in) play Wheel bearing lock nut Tightening torque N.m (kg-m, ft-Ib) Front Rear 0.03 (0.0012) or less 0.05 (0.0020) or less - - 147 216 (15 22, 235 314 (24-32, 108- 159) 174- 231) Wheel balance Wheel balance (Maximum allowable unbalance at rim flange) g (OZ) Tire balance weight MA-21 g (OZ) 10 (0.35) 5.60 (0.18 -2.12) Spacing 5 (0.18) SERVICE DATA AND SPECIFICATI'ONS(S.D.S.) Chassis and Body Maintenance (Cont'd) TIGHTENING TORQUE Unit N'm Clutch Pedal stopper lock nut Clutch switch lock nut 16 22 - 15 1.6 - 2.2 12 - 16 12 1.2 - 1.5 9 - 11 Drain and filler plugs Final drive Drain plug 25 - 34 2.5 - 3.5 18 - 25 59 -98 6 - 10 43-72 Filler plug Front axle and front 59 -98 6 - 10 43-72 37 - 46 3.8 - 4.7 27 - 34 12.6 - 14.6 91 - 106 Manual transmission suspension Tie-rod lock nut kg-m . 124 - 143 ft-Ib Camber adjusting pin Rear axle and rear suspension Toe adjusting pin 69 -88 7.0-9.0 51 - 65 Camber adjusting pin 69 -88 7.0-9.0 51 -65 7-9 Brake system Air bleed valve 0.7 - 0.9 5.1 -6.5 Brake lamp switch lock nut 12 - 15 1.2 - 1.5 9 - 11 Brake booster input rod lock nut 16 -22 1.6 - 2.2 12 - 16 10.0 - 12.0 72 -87 Wheel and tire Wheel nut 98 - 118 MA-22 ENGINEMECHANICAL EM SECTION EM CONTENTS PRECAUTION EM- 2 PREPARATION EM- 3 OUTER COMPONENT PARTS EM- 6 COMPRESSION PRESSURE EM- 7 OIL PAN EM- 8 TIMING CHAIN EM-10 OIL SEAL REPLACEMENT EM-16 CYLINDER HEAD EM-18 ENGINE REMOVAL EM-32 CYLINDER BLOCK EM-34 SERVICE DATA AND SPECIFICATIONS (S.D.S.) """'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' EM-46 PRECAUTION LIQUID GASKET APPLICATION ~~ Groove ' . . I~r Side Bolt hole SEM371C PROCEDURE a. Before applying liquid gasket, remove all traces of old liquid gasket from mating surface using a scraper. b. Apply a continuous bead of liquid gasket to mating surface. (Use Genuine Liquid Gasket or equivalent.) c. Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) wide (for oil pan). Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) wide (in areas except oil pan). d. Apply liquid gasket to inner sealing surface around hole perimeter area. (Assembly should be done within 5 minutes after coating.) e. Wait at least 30 minutes before refilling engine oil and engine coolant. EM-2 PREPARATION SPECIAL SERVICE TOOLS Tool number (Kent.Moore No.) Tool name Description ST0501S000 ( - Disassembling and assembling ) Engine stand assembly CD ST05011 000 ( ) - Engine stand @ ST05012000 ( Base - ) ~ KV10105001 ) ( Engine attachment - KV101092SO ) ( Valve spring compressor - CD Disassembling and assembling valve components CI< KV10109210 - ( ) Compressor @KV10109220 ) ( Adapter - KV109B0010 ( ) Valve oil seal drift - ~ Installing valve oil seal ~ KV10110300 ( - Disassembling and assembling piston with connecting rod ) Piston pin press stand assembly CD KV10110310 ( ) Cap @ KV10110330 ( ) Spacer @ ST13030020 ( ) Press stand @ ST13030030 ( ) Spring @ KV10110340 ( ) Drift @ KV10110320 ( ) Center shaft 3 ~ ?~~ EM-3 PREPARATION Tool number (Kent-Moore No.) Tool name Description EM03470000 (J8037 ) Piston ring compressor ~ Installing piston assembly into cylinder bore (J36467) Valveoil seal remover ~ Displacement valve oil seal KV10111100 ( - ) Seal cutter WS39930000 - ( ) Tube presser ST1661 0001 (J23907) Pilot bushing puller ~ T Removing oil pan Pressing the tube of liquid gasket ~ EM-4 PREPARATION COMMERCIAL SERVICE TOOLS Tool name Spark plug wrench Description c:Y Q 16mm (0.63 in) Pulley holder r ~ -- Valve seat cutter set ~ \ ~~.- Valve guide drift installing Holding camshaft pulley while tightening or loosening camshaft bolt Finishing valve seat dimensions .- - ~ ~ Piston ring expander Removingand spark plug Removing and installing piston ring Removing and installing valve guide Diameter: A¥:~ mm (in) ---- Intake Exhaust A 10.5 (0.413) 11.5 (0.453) B 6.6 (0.260) 7.6 (0.299) Reaming valve guide (CD) or hole for oversize valve guide (@) Valve guide reamer Diameter: ~- @ D. EM;.5 mm (in) Intake Exhaust 01 7 (0.28) 8 (0.31) Os 11.2 (0.441) 12.2'(0.480) OUTER COMPONENT PARTS KA24E ENGINE ~ ~ - 16 21 (1.6.2.1_,12 -15) 16 -21 (1.6 -21. , 12-15) B.P.T. valve . I A A umt LI-I~~ I.-L ~ rA'.. (0.5-0.6, 3.6-4.3) ,r" Adjusting bar ~ ~~ 142 10-12 (1.0-1.2,7 - 9) -152(14.5- 15.5,105- 112) ~ : N.m (kg-m, ft-Ib) rJ : Apply liquid gasket. SEM336C EM-6 COMPRESSION PRESSURE Measurement of Compression 1. 2. 3. 4. 5. Pressure Warm up engine. Turn ignition switch off. Disconnect fusible link for injectors. Remove all spark plugs. Disconnect distributor center cable. Q) 6. Attach a compression tester to NO.1 cylinder. 7. Depress accelerator pedal fully to keep throttle valve wide open. 8. Crank engine and record highest gauge indication. 9. Repeat the measurement on each cylinder as shown above. Always use a fully-charged battery to obtain specified engine revolution. Compression pressure: kPa (kg/cm2,. psi)/rpm Standard 1,324 (13.5, 192)/300 Minimum 981 (10, 142)/300 Difference limit between cylinders 98 (1.0, 14)/300 10. If cylinder compression in one or more cylinders is loyi. pour a small amount of engine oil into cylinders through spark plug holes and retest compression. . If. adding oil helps compression, piston rings may be worn or damaged. If' so, replace piston rings after checking piston. If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to S.D.S.) If valve or valve seat Is damaged excessively, replace them. If compression in any two adjacent cylinders is low and if adding oil does not help compression, there is I,akage past the gasket surface. If so, replace cylinder head gasket. . SEM 113B . . . EM-7 OIL PAN Removal 1. Raise vehicle and support it with safety stands. 2. Drain engine oil. 3. Remove front stabilizer bar securing bolts and nuts from side member. 4. Lift engine. 5. Remove oil pan bolts. @ 0 (jJ) 0 ...Q... 2- Front 0 @ @ Loosen bolts in reverse order. @ SEM337C 6. Remove oil pan. (1) Insert Tool between cylinder block and oil pan. Do not drive seal cutter into oil pump or rear oil seal retainer portion, or aluminum mating face will be damaged. Do not insert screwdriver, or oil pan flange will be deformed. . . (2) Slide Tool by tapping its side with a hammer, and remove oil pan. SEM884A 7. Pull out oil pan from front side. EM-8 OIL PAN Installation Scraper 1. Before installing oil pan, remove all traces of liquid gasket . from mating surface using a scraper. Also remove traces of liquid gasket from mating surface of cylinder block. SEM338C 2. Apply a continuous bead of liquid gasket to mating surface of oil pan. Use Genuine Liquid Gasket or equivalent. . SEM339C Cut here. ~ Liquid gasket . Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) wide. :J SLC906 7 mm 10.28 in) --Lt-. 3. Apply liquid gasket to inner sealing surface as shown in figure. Attaching should be done within 5 minutes after coating. 4. Install oil pan. Wait at least 30 minutes before refilling engine oil. . . Inner side Groove Bolt hole SEM909B EM-9 . TIMING CHAIN r ~ ~ 118. Camshaft sprocket ' ,65787 - 1161 (1:~ain'tenSioner 7-8 08 5.'-5.81 (0.7. . , ~ ~ ~ ~ rJ ~ I L--. Qj Front cover .~ ., . Crankshaft sprocket 13-1. (1.3 -1.9, 9 -141 . L. ~ : N.m (kg-m, ft-Ibl rJ : ApplV liquid gasket. SEM578C . CAUTION: \ After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. EM-10 TIMING CHAIN Removal 1. 2. 3. 4. .. . Disconnect battery terminal. Drain coolant from radiator. Remove radiator shroud and cooling fan. Remove the following belts. Power steering drive belt Compressor drive belt Alternator drive belt 5. Remove all spark plugs. 6. Set NO.1 piston,at T.D.C. on its compression stroke. Q Front SEM199C 7. Remove the following parts. Power steering pump, idler pulley and power steering pump brackets Compressor idler pulley Crankshaft pulley Oil pump with pump drive spindle . .. .. Rocker SEM200C SEM201C EM-" cover . TIMING CHAIN Removal (Cont'd) 8. Remove oil pan. (Refer to OIL PAN.) 9. Remove front cover. SEM202C 10. Remove the following parts. . Chain tensioner . Chain guides . Timing chain and sprocket . Oil thrower, oil pump drive gear and crankshaft sprocket Crank~h3ft sprocket SEM203C Inspection Check for cracks and excessivewear at roller links. Replace if necessary. Jf) ~ ,~ ' SEM204C EM-12 TIMING CHAIN crankShaft Crankshaft ~prOCket ~ ~ Installation 1. Install crankshaft sprocket, oil pump drive gear and oil thrower. . Make sure that mating marks of crankshaft sprocket face engine front. . "4~ . O;I:;:~~~'\ n ~ 0 Front. SEM205C 2. Install camshaft sprocket. 3. Confirm that NO.1 piston is set at T.D.C. on its compression stroke. 4. Install timing chain. Set timing chain by al.igning its mating marks with those of crankshaft sprocket and camshaft sprocket. ~~~ '/0 ~ (O@ . \000 ~. '~ " ~ \\ II ~ Can ,",ocke< )) " ii ~r C"ok .p-" " e: Punchmark SEM206C 5. Tighten camshaft sprocket bolt. 6. Install chain guide and chain tensioner. EM-13 TIMING CHAIN Installation (Cont'd) 7. Apply liquid'gasket to front cover. 2.0 ~ -3.0 mm 8. Apply lithium grease to sealing lip of crankshaft oil seal. (0.079 . 0.118inl die. 9. Install front cover. Be careful not to damage cylinder head gasket. Do not forget 011seal. .. SEM453C 10. Install rubber plug. (Refer to "Installation" HEAD.) 11. Install oil pan. (Refer to Oil PAN.) of CYLINDER 12. Install oil pump and distributor driving spindle with new gasket in front cover. (1) Assemble oil pump and driving spindle, aligning punchmark on driving spindle with oil hole. ~ Punchmark SEM212C EM-14 TIMING CHAIN Installation (Cont'd) (2) Make sure that driving spindle is set as shown in figure. Front Q SEM136C 13. Install distributor. 14. Make sure that NO.1 piston is set at T.D.C. and that distributor rotor is set at NO.1 cylinder spark position. Q Front SEM199C EM-15 OIL SEAL REPLACEMENT VALVE OIL SEAL 1. Remove rocker cover. 2. Remove rocker shaft assembly. 3. Remove valve spring and valve oil seal with Tool or suitable tool. Piston concerned should be set at T.D.C. to prevent valve from falling. (J36467) KV10980010 ( - 4. Apply engine oil to new valve oil seal and install it with Tool. Before installing valve oil seal, install valve spring seat. ) 15.6. 16.2 (0.614.0.638) Valve spring seat Unit: mm (in) SEM246C OIL SEAL INSTALLING DIRECTION Engine inside . Oil seal lip Engine outside Dust seal lip SEM715A FRONT OIL SEAL 1. Remove radiator shroud and crankshaft pulley. 2. Remove front oil seal. Be careful not to damage crankshaft. EM-16 9i- SEAL REPLACEMENT 3. Apply engine oil to new oil seal and install it using suitable tool. SEM115B REAR OIL SEAL 1. Remove flywheel or drive plate. 2. Remove rear oil seal retainer. 3. Remove traces of liquid gasket using scraper. 4. Remove rear oil seal from retainer. .J'I; l it 5. Apply engine oil to new oil seal and install it using suitable tool. Diameter of Iiqu id gasket: 2.0 - 3.0 mm ~ (0.079 6. Apply liquid gasket to rear oil seal retainer. - 0.118 in) EM-17 CYLINDER HEAD ~~-8 .,'0.. .0.8, 2.9' 5.8' ---Valve rocker cover- Rocker cover gasket ~ 37 - 41 (3.8 - 4.2, 27 - 30) Valve and spring Intake Spring retainer Valve '~w, ~ ,\;~ ~ ,\ ~J @ , ~~ E'M":~ Oilseal @ springseatA \\ V"Wg";..~~ Valve seat ~ . ~ ~ Cylinder head \J @<~ 'b@cg ~ Head bolt ~: N'm (kg-m, ft-Ib) SEM215C EM-18 CYLINDER HEAD CAUTION: When installing sliding parts such as rocker arms, camshaft and oil seal, be sure to apply new engine oil on their sliding surfaces. . When tightening cylinder head bolts and rocker shaft bolts, apply new engine oil to thread portions and seat surfaces of bolts. . . O.K. Hydraulic valve lifters are installed in each rocker arm. If hydraulic valve lifter is kept on its side, even when installed in rocker arm, there is a possibility of air entering it. After removal, always set rocker arm straight up, or when laying it on its side, have it soak in new engine oil. Ii SEM878B N.G. . . Do not disassemble hydraulic valve lifter. Attach tags to valve lifters so as not to mix them up. SEM868B Removal 1. Drain coolant from radiator and drain plug of block. 2. Remove the following parts. Power steering drive belt Power steering pump, idler pulley and power steering brackets Vacuum hoses of S.C.v. and pressure control solenoid valve Accelerator wire bracket 3. Disconnect E.G.R. tube from exhaust manifold. 4. Remove bolts which hold intake manifold collector to intake manifold. 5. Remove bolts which hold intake manifold to cylinder head while raising collector upwards. 6. Remove rocker cover. When removing rocker cover, do not hit rocker cover against rocker arm. . . .. EM-19 CYLINDER HEAD ~ Removal (Cont'd) 7. Set NO.1 piston at T.D.C. on its compression stroke. -5/0° 5° 10° 15° 20° Red painted / ~ Front SEM199C 8. Loosen camshaft sprocket bolt. Support timing chain by using Tool as shown in figure. . SEM218C 9. Remove camshaft sprocket. EM-20 CYLINDER HEAD Removal (Cont'd) 10. Remove front cover tightening bolts to cylinder head. SEM2106 Cam ;Urlace I I ENGINE LUBRICATION SYSTEM Oil Pressure Check WARNING: Be careful not to burn yourself, as the engine and 011may hoL / 011 pressure check should be done in "Neutral" gear position. . . 1. Check oil level. 2. Remove oil pressure switch. 3. Install pressure gauge. 4. Start engine and warm it up to normal operating temperature. 5. Check oil pressure with engine running under no-load. ST25051 001 (J25695-1) Engine rpm Idle speed 3,000 SLC926 Approximate discharge pressure kPa (kg/cm2, psi) More than 78 (0.8, 11) 412-481 (4.2-4.9,60-70) If difference is extreme, check oil passage and oil pump for oil leaks. 6. Install oil pressure switch with sealant. LC-4 ENGINE LUBRICATION SYSTEM Oil Pump \ Drive spindle ~tOJ 6. 10 (0.6 - 1.0,4.3.7.2) --.::>/pump body Gasket ~ tOJ: N.m (kg-m, ft-Ib) SLC945 . . . iT. ~~1~ Punch- . ~AU) Always replace with new oil seal and gasket. When removing oil pump, turn crankshaft so that No.1 piston is at T.D.C. on its compression stroke. When installing oil pump, align punchmark on drive spindle and oil hole on oil pump. mark Oil hole ~ Front ~~"4A REGULATOR VALVE INSPECTION 1. Visually inspect components for wear and damage. 2. Check oil pressure regulator valve sliding surface and valve spring. 3. Coat regulator valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If damaged, replace regulator valve set or oil pump assembly. . EL076 LC-5 ENGINE LUBRICATION SYSTEM Oil Pump (Cont'd) ~ OIL PRESSURE RELIEF VALVE INSPECTION Inspect oil pressure relief valve for movement, cracks and breaks by pushing the ball. If replacement is necessary, remove valve by prying it out with suitable tool. Install a new valve in place by tapping it. - OIL PUMP INSPECTION Using a feeler gauge, check the following clearance. CD Unit: mm (in) Rotor Less than 0.12 (0.0047) tip clearance CD Outer rotor to body clearance @ Side clearance (with gasket) CID 0.15 - 0.21 (0.0059 - 0.0083) 0.04 - 0.08 (0.0016 - 0.0031) If it exceeds the limit, replace gear set or entire oil pump assembly. SLC732 LC-6 ENGINE COOLING SYSTEM Cooling Circuit ~ Thermostat: Open ~ Thermostat: Closed Radiator Intake man ifold Thermostat SLC186A System Check WARNING: Never remove the radiator cap when the engine is hot; serious burns could be caused by high pressure fluid escaping from the radiator. Wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow built-up pressure to escape and then turn the cap all the way off. CHECKING COOLING SYSTEM HOSES Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. LC-7 ENGINE COOLING SYSTEM System Check (Cont'd) CHECKING COOLING SYSTEM FOR lEAKS To check for leakage. apply pressure to the cooling system with a tester. Testing pressure: 98 kPa (1.0 kg/cm2, 14 psi) CAUTION: Higher than the specified pressure may cause radiator damage. SMA990A CHECKING RADIATORCAP To check radiator cap, apply pressure to cap with a tester. Radiator cap relief pressure: 78 - 98 kPa (0.8 - 1.0 kg/cm2,11 - 14 psi) SLC613 Water Pump ~ ::~~~.~.~.m~ ~ 12'~' \ ~',P/ )!!7 . SLC187A INSPECTION Check for excessive end play and rough operation. (f SLC738 INSTAllATION Remove liquid gasket from mating surface of pump housing using a scraper. . .. Be sure liquid gasket in grooves Is also removed. , Remove liquid gasket from mating surface of cylinder block. Clean all traces of liquid gasket using white gasoline. SLC188A LC-8 ENGINE COOLING SYSTEM Water Pump (Cont'd) . . Cut off tip of nozzle of liquid gasket tube at point shown in figure. Use Genuine Liquid Gasket or equivalent. . Apply a continuous bead of liquid gasket to mating surface Cut here. ~ ] KP510-00150 SLC822 Diameter of liquid gasket: 2.0.3.0 mm 10.079.0.118 of pump housing as shown. a. Be sure diameter of liquid gasket Is within 2.0 to 3.0 mm (0.079 to 0.118 In) dla. range. b. Attach pump housing to cylinder block within five minutes of applying liquid gasket. c. After Installing pump housing, walt at least 30 minutes before starting engine. in) SLC189A Thermostat INSPECTION 1. Check for valve seating condition at ordinary temperatures. It should sea.ttightly. Water inlet SLC192A . 2. Check valve opening Upward Jiggle valve ~~ A~ ~ --~ temperature and maximum valve lift. Valve opening temperature °c (oF) 76.5 (170) Max. valve lift mmfC (infF) 8/90 (0.31/194) 3. Then check if valve closes at 5°C (9°F) below valve opening . SLC097 temperature. . After Installation, run engine for a few minutes, and check>., for leaks. SLC343 LC-9 ENGINE COOLING SYSTEM Thermostat (Cont'd) ( INSTAllATION . . . Remove liquid gasket from mating surface of thermostat using a scraper. Similarly, remove liquid gasket from mating surface of cylinder block. Clean all traces of liquid gasket using white gasoline. . . Cut off tip of nozzle of liquid gasket tube at point shown in figure. Use Genuine LiqLJidGasket or equivalent. ..~ SLC790 Cut here. ~ KP510.()0150 ] SLC822 . Apply a continuous bead of liquid gasket to mating surface of water inlet. a. Be sure diameter of liquid gasket is within 2.0 to 3.0 mm (0.079 to 0.118 in). b. Attach water inlet to cylinder block within five minutes after applying liquid gasket. c. After installing water inlet, wait at least 30 minutes before refilling coolant and starting engine. SLC824 '( .~ LC -1 0 ENGINE COOLING SYSTEM Radiator A/T model only ~3 2 -4.2 10.33-0.43, 2.4-3.1) 7~ Automatic transmission ~ @I ~ '~ ~~3.2 -4.2 . ,""lIlY 10.33-0.43,2.4 -3.1) LJ ~: Radiator shroud N-mIkg-m,ft-lb) SLC190A CAUTION: When filling radiator with coolant, refer to MA section. Cooling Fan DISASSEMBLY AND ASSEMBLY -~ '\" <1( L-.J V ~ ~: Fan N'm (lrg-m;ft-Ibl \~ ~o.~~1.0,4.3-7.2) SLC558 INSPECTION Check fan coupling for rough operation, oil leakage or bent bimetal. SLC072 LC-11 BATTERY fus Ib I e I GNI TI ON SWITCH ACC or- ON I GNITI ON SWITCH ON or- START FUSE AIR @D~ CONDI TI ON RELAY 36 r(") t'1 P P 11 !fI N 41 n a z -I ::0 a r c z .... -I I ~ THERMOSWITCH To ther-mo contro I amp. M 41 -= 36 0 !II r 0 I\,) w m » @4Ib CONDENSER FAN MOTOR CONDENSER FAN MOTOR ELECTRICAL CIRCUIT Wiring Diagram AIR = (Sub-h arness) ~ - CONNECTOR-ll CONDENSER F AN MOTOR I ~ @) ~ mIi] Ie lR;l ~ 't1H Ilnk- Ii [!t L/OR I ~::;CD ~ ~13Id ~ [!t S. M. [Refer to (Fo Idout y..>r;;;, - , CD lBIB@ [EttBr;;--, ~ (E. F. I. harness) @l@) 1i r-- >- '" '" I , '" , @ IGNITION ON or ~ ,, CD...) , , ... To thermo SWITCH START contro I amp. - '"... BODY GROUND E. ~ ~ S (Refer to CONTROL UNIT EF&EC sect Ion. ) SLC238A LC-13 SLC191A CONDENSER FAN MOTOR ELECTRICAL CIRCUIT Trouble Diagnosis m @i5 Even though air conditioner operates normally under high engine temperature conditions [above 9SoC (20SoF)] the condenser fan motor does not rotate. 00 '+ L::: m - 000 -= SLC239A m _MEeT Iu CHECK POWER SUPPLY (Motor side). 1) Disconnect condenser fan motor harness connector-H. 2) Turn ignition switch, air conditioner switch and blower switch "ON". @i5 []I] SLC241A N.G. lu SLC242A i5 0 Repair or replace harness between terminals @ and @. O.K. CHECK POWER SUPPLY (Relay side). 1) Turn ignition "OFF". 2) Disconnect air conditioner relay. 3) Turn ignition "ON". 4) Check voltage between terminals @, @ and ground. Battery voltage should exist. Check sub-harness for thermoswitch continuity. If N.G., repair or replace them. @is N.G. L--to Check the followings: 8 Harness continuity between terminal @ and battery I @is CHECK RELAY. Refer to HA section. O.K. E N.G. r Replace relay. LC-14 Check the followings: 8 Harness continuity between terminal @ and battery l. -= SLC243A EB terminal. 8 "G" fusible link If N.G. replace them. O.K. 00 00 O.K. CHECK THERMOSWITCH. Check continuity between thermoswitch terminals @ and CD. Condition ContinuitY Above Yes 92 -98°C (198 -2OS°F) Below No 92 -98°C (198 -2OS°F) iii DISCONNECT . Ii] lo.K. ' - CHECK GROUND CIRCUIT. Check harness continuity between motor harness connector-I terminal @ and ground. Continuity should exist. If N.G., repair harness. CHECK POWER SUPPLY (Motor side). 1) Turn ignition switch "OFF" 2) Disconnector fan motor harness connector-I. 3) Turn ignition switch "ON". 4) Check voltage between terminal @ and ground. Battery voltage should exist. - Ii [!] Ii SLC240A CHECK CONDENSER FAN MOTOR. 1) Turn ignition and air conditioner switch "OFF". 2) Disconnect condenser fan motor harness connector-I. 3) Check continuity between connector-H terminal @ and connector-I terminal @. Continuity should exist. If N.G. replace condenser fan motor-. O.K. N.G. iJ Ii] O.K. 3) Check voltage between fan motor harness connector-II terminal @ and ground. Battery voltage should exist. [ill [!] m 1 terminal 8 Fuse 8 Ignition switch EB I CONDENSER FAN MOTOR ELECTRICAL CIRCUIT Trouble Diagnosis (Cont'd) iii 34 ~ i5l 0 -= SLC244A [it lOK CHECK HARNESS CONTINUITY, 1) Turn ignition switch "OFF", 2) Check continuity between relay harness connector terminal @ and fan motor harness connector-I terminal @. Continuity should exist. N.G. Repair or replace harness or connectors between terminals @ and (d) . [R] ~i5@ SLC245A "- LC-15 SERVICE DATA AND SPECIFICATIONS (S.D.S.) Engine Lubrication System Oil pump Oil pressure check Unit: Engine rpm Approximate discharge pressure kPa (kg/em' , psi) Idle speed More than 78 (0.8, 11) 412.481 (4.2.4.9,60 3.000 Rotor tip clearance - 70) mm (in) Less than 0.12 (0.0047) Outer rotor to body clearance 0.15 - 0.21 (0.0059 - 0.0083) Side clearance (with gasket) 0.04 - 0.08 (0.0016.0.0031) Engine Cooling System Thermostat Radiator Valve opening temperature Max. valve lift mmfc °c (OF) 76.5 (170) (infF) 8/90 (0.31/194) Unit: kPa (kg/em' Cap relief pressure Leakage test pressure . lC-16 78 .psi) -98 (0.8 - 1.0, 11 - 14) 98 (1.0, 14) /" ENGINEFUEL& EMISSION -CONTROL SYSTEM SECTIONEF & EC CONTENTS PREPARATION ... EF & EC- 2 PRECAUTIONS """""""""""""""'"'''''''''''''''''''''''''''''''''''' EF & EC- 3 ENGINE AND EMISSION CONTROL OVERALL SYSTEM EF & EC- 4 ENGINE AND EMISSION CONTROL PARTS DESCRIPTION EF & EC- 9 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION EF & EC- 16 IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION EF & EC- 26 TROUBLE DIAGNOSES EF & EC- 31 FUEL INJECTION CONTROL SYSTEM INSPECTION EF & EC-153 EVAPORATIVE EMISSION CONTROL SYSTEM EF & EC-155 CRANKCASE EMISSION CONTROL SYSTEM EF & EC-157 SERVICE DATA AND SPECIFICATIONS (S.D.S.) EF & EC-158 When you read wiring diagrams: . Read GI section, "HOW TO READ WIRING DIAGRAIVIS". See El section, "POWER SUPPLY ROUTING" for power distribution circuit. . When you perform trouble diagnoses, read GI section, "HOW TO FOllOW FLOW CHART IN TROUBLE DIAGNOSES". E.C.C.S. Wiring Diagram - See pull-out following EL section. - / PREPARATION SPECIAL SERVICE TOOL Tool number (Kent-Moore No.) Tool name EG11160000 ( - ) Ignition coil adapter harness Description ~ EF & EC-2 Measuring engine speed PRECAUTIONS E.C.U. Do not disassemble E.C.C.S. control unit. (E.C.U.) Do not turn diagnosis mode selector forcibly. . . . . . If a batteryterminalis disconnected, the memory will return to the ROM value. The E.C.C.S.' will now start to self-control at its initial value. Engine operation can vary slightly when the terminal is disconnected. However, this is not an indication of a problem. Do not replace parts because of a slight variation. . . . Do not apply undue force to mounting bracket. Before connecting or disconnecting E.C.U. connector, make sure red and green LEOs are off after turning ignition key off. Always install the properly specified E.C.U. on car; otherwise, erroneous engine operation may result. Disconnect connector by pulling it (not the harness) straight out. Before connecting connector, make sure all pins are straight. BATTERY . Always use a 12 volt battery as a power source. . . WIRELESS EQUIPMENT When installing a C.B. ham radio or a mobile phone, be sure to observe the following, as installation location may affect the electronic control systems. 1) Keep antenna as far as possible away from electronic control units. 2) Keep antenna feeder line more than 20 cm (7.9 in) away from harness of electronic controls. Do not let them run parallel for a long distance. 3) Adjust antenna and feeder line so that standing-wave ratio can be kept smaller. 4) Be sure to ground radio to vehicle body. . INJECTOR Do not disconnect injector har~ ness connectors with engine running. Do not apply battery power directly to injectors; otherwise injectors will be damaged. . Do not disconnectbattery . cables while the engine is running. Do not reverse polarity of battery when connecting it. Otherwise, E.C.U. and/or injectors may be burned. FUEL PUMP Do not operate fuel pump when there is no fuel in lines. Do not reuse fuel hose clamps. Tighten fuel hose clamps to the specified torque. . .. E.C.C.S. PARTS HANDLING Handle air flow meter carefully to avoid damage. Do not disassemble air flow meter. Do not clean air flow meter with detergent. . Do not jolt or jar the crank angle sensor. . . . ~~ WHEN STARTING Do not depress accelerator pedal when starting. Immediately after starting, do not rev up engine unnecessarily. . Do not rev up engine just prior to shutdown. . . SEF121H EF & EC-3 E.C.C.S. HARNESS HANDLING Securely connect E.C.C.S. harness connectors. A poor connection can cause extremely high voltage to develop in the coil and condenser, resulting in damage to ICs. Keep E.C.C.S. harness at least 10 cm (3.9 in) away from adjacent harnesses, to prevent an E.C.C.S. systerri malfunction due to receiving external noise, degraded operation of ICs, etc. Keep E.C.C's' parts and harnesses dry. Before removing parts, turn off ignition switch and then disconnect battery ground cable. . . . . ENGINE AND EMISSION CONTROL OVERALL SYSTEM E.C.C.S./Component Parts Location . E.C.C.S.relay . Fuelpumprelay Fuel pump -E.G.R. control valve Exhaust gas temperature sensor (For California model) Pressure regulator ~~b Pressure regu lator control solenoid valve ~ LA.A. unit S.C.V.control ~'iWIW ~.~, Fuel filter e A'I'V' . ~ ~ " I control solenoid valve . 0 a Ignition coil and power transistor ~ ~~ G E. .R . control solenoid valve Distributor -.w~ ..f ~~;:~~ sensor . ~.,~. ~" A;,flowm.'" Exhaust gas sensor SEF122H EF & EC-4 E.G.R. control Exhaust gas temperature sensor I. (For California model) \ \ solenoid valve7 / \ "\ Ignition \ switch Throttle valve B .sensol 7 ~ : -'r---~-L- m "TI J20 m (") \ Crank angle sensor built-in distributor I C1I lFuel pressure regulator I'. !.. Engine temperatu re sensor Transmission ~ lSJ \'1' ! \.Spark C. Vehicle speed sensor ~ plug \1 '11 Carbon canister Exhaust gas sensor A.I.V. control solenoid valve A.I.V. Q: en m -'" "TI w :I ...: Intake air flow Exhaustgasflow Air flow me ENGINE AND EMISSION CONTROL OVERALL SYSTEM System Chart E.C.C.S. CONTROL SYSTEM I Crankanglesensor [ Air flow meter ! r .1 I Exhaust gas sensor [ Ignition switch 1 Starter switch [ Idle switch ! Throttle sensor . Power transistor Idle speed control Auxiliary air control (A.A.CJ valve A.I.V. control A:I.V. control solenoid valve E.G.R. control & Canister control E.G.R. control solenoid valve . . . . " Air conditioner switch Ignition timing control . ~ [ Injectors . Engine temperature sensor [ Fuel injection & mixture ratio control . E.C.C.S. control unit ," Fuel pump control - Fuel pump .~ Air regulator control Air regulator Acceleration cut control Air conditioner relay S.C.V. (Swirl control valve)control S.C.V. control solenoid valve Exhaust gas sensor monitor & self-diagnosis Inspection lamps (On the control unit) Pressu re regu lator control Pressu re regulator control solenoid valve Neutral switch (M/T) Inhibitor switch (AiT) [ Vehicle speed sensor . Power steering oil pressure switch [ Battery . Exhaust gas temperature sensor (For California model) Fail-safe function . Air flowmeter . Throttle sensor . Enginetemperaturesensor EF & EC-6 ENGINE AND EMISSION CONTROL OVERALL SYSTEM Vacuum Hose Drawing s.c. V. actuator @ -@-a @-b E.G.R. control valve ~TWI~ @ @ Air regurator tJi) @ ./"'1 Canister @ @/ 1 Vacuum tubes-1 Air duct SEF355H EF 8r. EC- 7 I GNITION SWITCH OFFACCON ST FUSIBLE LINK -c8J- CK ( Ij/] ( ( '-:::./ CHECK FUSE J-----rs} r<:::"7I 46 NJ. NlOR E. C. C. S. RELAY -- m gAUST To tachometer SENSOR ::- ." I mm- I "-------1 f20 m RESISTOR TRANSISTOR {O (") PDWER I DISTRIBUTOR rm J>r -< "U :[ c :] L.:::T AIR 108--< 3 >J >J 116 --< I en 45 6 ("") 0 43 Z -i ;0 0 r c Z .... -i CONDENSER co- co- co- co- ANGLE SENSOR SPARK PLUG ) : For tt 11 Cal ifornla M REGULATOR PUMP ::- = = -- : A/T model For @: M/T model @: For 5TH POSITION SWITCH (/) m " w 0..... :x: With : Without heaa-up display SWITCH -v<::,...FULL 'Q NEUTR ' SWITC 35 41 II ENGINE TEMPERATURE - 3D 31 18 22 4D 8 $ SENSOR EXHAUS T GAS 37 Canada 32 lIS SENSOR C TEMPERA@URE -n ------__n_--_n_n--_--_--_---- .HEAD-U DISPLA UNIT THROTTLE . f SENSOR CONT ( - MJ 1 I I r--- 28 A/T UNIT CONTR&L display head-up VALVE IDLE I : THROTTLE POWER STEERING OIL PRESSURE 33 U. S. A. A.S. C.D. -= 44 : A/T modeI wi th A.S. C.D. : A/T mode I without I NHIB RELA M ::- SWI TCH 2D : I NHI B RELAY r-= VALVE FUELL..:....J [Tl W CRANK !: ...----J SWITCH I NHI BIT 29 co- lIB; L..::..:J 21-- I ::I "U L..::J 107 13 I I L::...J A. A. C. 113 104 I GNITI ON COIL I co VALVE S. C. V. CONTROL SOLENOID VALVE 12 16 17 39 48 19 SOLENOID A. 1. V. CONTROL SOLENOID VALVE 109 METER REGULATOR E. G. R. CONTROL SOLENOID VALVE 102 4 47 PRESSURE CONTROL IDS 112 ::- LI GHT C ENGINE@ 5 24 25 106 110 No. 4r:::= L....:- I CONNECTOR = \ '-- Q SENSOR ENGINE AND EMISSION CONTROL PARTS DESCRIPTION E.C.C.S. Control Unit (E.C.U.) The EC.U. consists of a microcomputer, inspection lamps, a. diagnostic mode selector, and connectors for signal input and output and for power supply. The unit controls the engine. Crank Angle Sensor Photo diode Wave forming SEF613B circuit Rotor plate 1800 signal slit for No.1 cylinder The crank angle sensor is a basic component of the entire EC.C.S. It monitors engine speed and piston position, and sends signals to the E.C.U. to control fuel injection, ignition timing and other functions. The crank angle sensor has a rotor plate and a wave-forming circuit. The rotor plate has 360 slits for 10 signal and 4 slits for 1800 signal. Light Emitting Diodes (L.ED.) and photo diodes are built in the wave-forming circuit. When the rotor plate passes between the L.E.D. and the photo diode, the slits in the rotor plate continually cut the light being transmitted to the photo diode from the L.ED. This generates rough-shaped pulses which are converted into on-off signals by the wave-forming circuit, which are then sent to the E.C.U. SEF853B Rotor plate Air Flow Meter A Air flow meter B c Battery sou rce Output voltage Ground 16 E.C.C.S. 17 control unit 109 SEF285H Temperature compensation I resistor .. r-f The air flow meter measures the mass flow rate of intake air. Measurements are made so that the control circuit will emit an electrical output signal corresponding to the amount of heat dissipated from a hot wire placed in the stream of intake air. The airflow past the hot wire removes the heat from the hot wire. The temperature of the hot wire is very sensitive to the mass flow rate. The higher the temperature of the hot wire, the greater its resistance value. This temperature change (resistance) is determined by the mass air flow rate. The control circuit accurately regulates current (I) in relation to the varying resistance value (RH) so that VA always equals VB. The air flow meter transmits a voltage value VA to the control unit where the output is converted into an intake air signal. RH;:~-Hotwire RH RK RA. RB : Hot wire resistance : Temperature compensation resistance : Constant resistance SEF617B EF & EC-9 ENGINE AND EMISSION CONTROL PARTS DESCRIPTION Engine Temperature Sensor The engine temperature sensor detects the engine temperature, which is dependent on engine coolant temperature, and transmits a signal to the E.C.U. The temperature sensing unit employs a thermistor which is sensitive to the change in temperature. Electrical resistance of the thermistor decreases in response to the temperature rise. Throttle Sensor & Soft/Hard Idle Switch The throttle sensor responds to the accelerator pedal movement. This sensor is a kind of potentiometer which transforms the throttle valve position into output voltage, and emits the voltage signal to the E.C.U. In addition, the sensor detects the opening and closing speed of the throttle valve and feeds the voltage signal to the E.C.U. Idle position of the throttle valve is determined by the E.C.U. receiving the signal from the throttle sensor. This system is called "soft idle switch" and controls engine operation such as fuel cut. On the other hand, "hard idle switch", which is built in the throttle sensor unit, is used not for engine control but for self-diagnosis. SEF903D > ~ Not used .,---0'--- ~ ~ E (Full throttle ~:50 Idle switch Z Throttle sensor .§ 4.0 switch) 2 3 ) : Supply voltage: 5V (Applied between terminal NO.4 and 6) 6.0 Output voltage between terminal NO.4 and 5 ~ ~ '" !'" -0 6} f2.0 ~ 5 6 g ... " 9" 0 0 0 45 90 Throttle valve opening angle (deg) 135 SEF287D Fuel Injector The fuel injector is a small, elaborate solenoid valve. As the E.C.U. sends injection signals to the injector, the coil in the injector pulls the needle valve back and fuel is released ,into the intake manifold through the nozzle. The injected fuel is controlled by the E.C.U. in terms of injection pulse duration. Brass wire is used in the injector coil and thus the resistance is higher than a conventional injector. SEF359H EF &. EC-10 ENGINE AND EMISSION CONTROL PARTS DESCRIPTION Pressure Regulator 0 vacuum Intake manifold The pressure regulator maintains the fuel pressure at 299.1 kPa (3.05 kg/cm2, 43,4 psi). Since the injected fuel amount depends on injection pulse duration, it is necessary to maintain the pressure at the above value. Air chamber Q Fuel chamber Fuel return from injector To fuel tank Q SEF6058 Exhaust Gas Sensor Louver Connector Holder Isolation bushing Contact plate SEC336A ?: 1 ;; '" 0> ~0 The exhaust gas sensor, which is placed into the exhaust manifold, monitors the amount of oxygen in the exhaust gas. The sensor has a closed-end tube made of ceramic zirconia. The outer surface of the tube is exposed to exhaust gas, and the inner surface to atmosphere. The zirconia of the tube compares the oxygen density of exhaust gas with that of atmosphere, and generates electricity. In order to improve the generating power of the zirconia, its tube is coated with pratinum. The voltage is approximately 1V in a richer condition of the mixture ratio than the ideal air-fuel ratio, while approximately OV in leaner conditions. The radical change from 1V to OV occurs at around the ideal mixture ratio. In this way, the exhaust gas sensor detects the amount of oxygen in the exhaust gas and sends the signal of approximately 1V or OV to the E.C.U. > ... :J C. 8 0I Rich --- ~ I Ideal ratio --Lean Mixture ratio SEF288D Fuel Pump Outlet 0 Fuel damper The fuel pump with a fuel damper is a submergible type, and are located in the fuel tank. Motor 1) Inlet SEF043C Power Transistor The ignition signal from the E.C.U. is amplified by the power transistor, which turns the ignition coil primary circuit on and off, inducing the proper high voltage in the secondary circuit. The ignition coil is a small, molded type. SEF125H EF & EC-11 ENGINE AND EMISSION CONTROL PARTS DESCRIPTION Air Regulator - The air regulator provides an air by-pass when the engine is cold for a fast idle during warm-up. A bimetal, heater and rotary shutter are built into the air regulator. When the bimetal temperature is low, the air by-pass port opens. As the engine starts and electric current flows through a heater, the bimetal begins to turn the shutter to close the by-pass port. The air passage remains closed until the engine stops and the bimetal temperature drops. SEF636B Idle Air Adjusting (I.A.A.) Unit The I.A.A. unit is made up of the AA.C. valve, F.I.C.D. solenoid valve and idle adjust screw. It receives the signal from the E.C.U. and controls the idle speed at the preset value. The F.I.C.D. solenoid valve compensates for changes in idle speed caused by the operation of. the air compressor. A vaCl/um control valve is also installed in this unit to prevent an abnd'rmal rise in intake manifold vacuum pressure during deceleratton. Idle adjusting screw SEF126H Auxiliary Air Control (A.A. C.) Valve The E.C.U. actuates the A.A.C. valve by an ON/OFF pulse. The longer that ON pulse is received, the larger the amount- of air that will flow through the A.A.C. valve. Air SEF040E Power Steering Oil Pressure Switch The power steering oil pressure switch is attached to the power steering high-pressure tube and detects the power steering load, sending the load signal to the E.C.U. The E.C.U. then sends the idle-up signal to the I.S.C. valve. SEF286H Magnetic \ /' Vehicle Speed Sensor line Reed Reed ~SWitch N S (sS I G:0 Fieldplate N M;;Qnetic I.me I\ // \ "{ N) switch t;\ The vehicle speed sensor provides a vehicle speed signal to the E.C.U. The speed sensor consists of a reed switch, which is installed on the transmission unit and transforms vehicle speed into a pulse signal. y-/ Fieldplate SEF624B EF & EC-12 ENGINE AND EMISSION CONTROL PARTS DESCRIPTION E.G.R. Control Valve The E.G.R. control valve controls the quantity of exhaust gas to. be led to the intake manifold through vertical movement of the taper valve connected to the diaphragm, to which vacuum is applied in response to the opening of the throttle valve. SEF632B B.P.T. Valve To E.G.A. control valve Vacuum signal source Air filter ".'.1' ~~~'ff' The B.P.T. valve monitors exhaust pressure to activate' the diaphragm, controlling throttle chamber vacuum applied to the E.G.R. control valve. In other words, recirculated exhaust gas is controlled in response to positioning of the E.G.R. control valve or to engine operation. t Exhaust pressure EC344A Air Induction Valve (AJ.V.) The air induction valve sends secondary air to the exhaust manifold, using a vacuum created by exhaust pulsation in the exhaust manifold. When the exhaust pressure is below atmospheric pressure (negative pressure), secondary air is sent to the exhaust manifold. When the exhaust pressure is above atmospheric pressure, the reed valves prevent secondary air from being sent back to the air cleaner. SEF127H EF & EC-13 \. ENGINE AND EMISSION CONTROL PARTS DESCRIPTION A.I.V. Control Solenoid Valve The A. LV. control solenoid valve cuts the intake manifold vacuum signal for A.I.V. control. It responses to the ON/OFF signal from the E.C.U: When the solenoid is off, the vacuum signal from the intake manifold is cut. When the control unit sends an ON signal, the coil pulls the plunger downward and feeds the vacuum signal to the A.I.V. control valve. E.G.R. Control Solenoid Valve SEF287H The E.G.R. system is controlled only by the E.C.U. At both lowand high-speed engine revolutions, the solenoid valve turns on and accordingly the E.G.R. valve cuts the exhaust gas leading to the intake manifold. Pressure Regulator (P.R.) Control Solenoid Valve The solenoid valve responds to the ON/OFF signal from the E.C.U. When it is off, a vacuum signal from the intake manifold is fed into the pressure regulator. When the control unit sends an ON signal, the coil pulls the plunger downward and cuts the vacuum signal. S.C.V. Control Solenoid Valve The S.C.V. control solenoid valve cuts the intake manifold vacuum signal for swirl control valve. It responds to the ON/OFF signal from the E.C.U. When the solenoid is off, the vacuum signal from the intake manifold is cut. When the control unit sends an ON signal the coil pulls the plunger and feeds the vacuum signal to the swirl control valve actuator. Fuel Filter The specially designed fuel filter has a metal case in order to withstand high fuel pressure. SEF256A Carbon Canister The carbon canister is filled with active charcoal to absorb evaporative gases produc~d in Jhe fuel tank. These absorbed gases are then delivered to the intake manifold by ,manifold vacuum for combustion purposes. The vacuum in the intake passage upstream of the throttle valve increases in response to the amount of the intake air. When the vacuum of the intake passage is higher than a preset value, the 2nd purge control valve opens and the absorbed gases are sucked into the intake passage for combustion purposes. EF & EC-14 . ENGINE AND EMISSION CONTROL PARTS DESCRIPTION Check Connector for E.C.C.S. Checker Box The check connector for E.C.C.S. checker box is beside fuse box. . SEF296H Exhaust Gas Temperature Sensor (For California model) The exhaust gas temperature sensor monitors in exhaust gas temperature and transmits a signal to the E.C.U. The temperature sensing unit employs a thermistor whi~h is sensitive to the change in temperature. Electric resistance of the thermistor decreases in response to the temperature rise. SEF072G \. EF &. EC-15 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Fuel Injection Control INPUT/OUTPUT SIGNAL 'LINE Engine speed and piston position Crank angle sensor Amount of intake air Air flow meter . Engine temperature Engine temperature sensor Density of oxygen in exhaust gas Exhaust gas sensor Throttle sensor Throttle valve position Throttle valve idle position Idle switch Neutral switch (MfT) Inhibitor switch (AfT) E.C.C.S. control unit Injector Gear position Vehicle speed Vehicle speed sensor Ignition switch Start signal Battery voltage Battery BASIC FUEL INJECTION CONTROL The amount of fuel injected from the fuel injector, or the length of time the valve remains open, is determined by the E.C.U. The basic amount of fuel injected is a programmable value mapped in the E.C.U. ROM memory. In other words, the programmable value is preset by engine operating conditions determined by input signals (for engine rpm and air intake) from both the crank angle sensor and the air flow meter. ~i Low - Water temperature High SEF923C VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION In addition, the amount of fuel injection is compensated for to improve engine performan~e under various operating conditions as listed below: 1) During warm-up 2) When starting the engine 3) During acceleration 4) Hot-engine operation 1) During deceleration EF & EC-16 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Fuel Injection Control (Cont'd) CLOSED LOOP CONTROL ) FeedAgnal Exhaust ~ E.C:C.S.' control ~nit / . ection pulse e ~ InJ (gas sensor) t\ combusti~ Injector injection ~ SEF639B MIXTURE RATIO FEEDBACK CONTROL Mixture ratio feedback system is designed to precisely control the mixture ratio to the stoichiometric point so that the three-way catalyst can reduce CO, HC and NOx emissions. This system uses an exhaust gas sensor in the exhau,st manifold to check the air-fuel ratio. The control unit adjusts the injection pulse width according to the sensor voltage so the mixture ratio will be within the range of the stoichiometric air-fuel ratio. This stage refers to the closed-loop control condition. The open-loop control condition refers to that under which the E,C.U. detects any of the following conditions and feedback control stops in order to maintain stabilized fuel combustion. 1) Deceleration 2) High-load, high-speed operation 3) Engine idling 4) Malfunctioning of exhaust gas sensor or its circuit 5) Insufficient activation of exhaust gas sensor at low engine temperature 6) Engine starting MIXTURE RATIO SELF-LEARNING CONTROL The mixture ratio feedback control system monitors the mixture ratio signal transmitted from the exhaust gas sensor. This feedback signal is then sent to the E.C.U: to control the amount of fuel injection to provide a basic mixture ratio as close to the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. This is due to manufacturing errors (e.g., air flow meter hot wire) and changes during operation (injector clogging, etc.) of E.C.C.S. parts which directly affect the mixture ratio. Accordingly, a difference between the basic and theoretical mixture ratios is quantitatively monitored in this system. It is then computed in terms of "fuel injection duration" to automatically compensate for the difference between the two ratios. FUEL INJECTION TIMING No.1 CYlinder fL Injection pulse rL No.2 cylinder n No.3 cylinder n No.4 cylinder 1---1 SEF976E enginecycle--j No.1 cylinderJl n No.2 cylinder.Jl n No.3 cylinder.Jl n 1L1LfL- . No. 4 cyIInd er J1 n f"L- ~ Fuel is injected once a cycle for each cylinder in the firing order. 1 engine cycle When engine starts, fuel is injected simultaneously twice a cycle. j SEF841D EF & EC-17 into all four cylinders , ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Fuel Injection Control (Cont'd) FUEL SHUT-OFF Fuel to all cylinders is cut off during deceleration or high-speed operation. Ignition Timing Control INPUT/OUTPUT SIGNAL LINE Engine speed and piston position Crank angle sensor Amount of intake air Air flow meter Engine temperature Enginetemperature sensor Idle switch Throttle sensor Neutral switch (MfT) Inhibitor switch (AfT) Throttle valve idle position E.C.C.S. control unit Throttle valve opening angle Neutral position Start signal Ignition switch , E. EF & EC-18 Power transistor ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Ignition Timing Control (Co nt' d) SYSTEM DESCRIPTION The ignition timing is controlled by the E.C.U. in order to maintain the best air-fuel ratio in response to every running condition of the engine. The ignition timing data is stored in the ROM located in the E.C.U., in the form of the map shown below. The E.C.U. detects information such as the injection pulse width and crank angle sensor signal which varies every moment. Then responding to this information, ignition signals are transmitted to the power transistor. e.g. N: 1,800 rpm, Tp: 1.50 msec A °S.T.D.C. In addition to this, 1 At starting 2 During warm-up 3 At idle 4 At low battery voltage 5 During swirl control valve operates 6 Hot engine operation 7 At acceleration the ignition timing is revised by the E.C.U. according to the other data stored in the ROM. Tp (msec) I 1.75I A 1.50I Injection pulse width 1.25 I 1.00 I 0.75 I --- 600 - --- 1,000 -1,400 --- 1,800 N 2,200 Engine speed (rpm) SEC750A EF & EC-19 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Idle Speed Control INPUT/OUTPUT SIGNAL LINE Engine speed I I Crank angle sensor Enginetemperature sensor 1 I I Ignition switch I Engine temperature Start signal . Throttle valve idle position . I Idle switch I I .1 I I Inhibitorswitch switch(M/T) (A/T) Neutral 1 Neutral I I I A.A.C. valve F.I.C.D. solenoid valve I 1 I Air conditioner switch I Powersteeringoil pressureswitchI . Battery voltage Battery I Vehicle speed sensor E.C.C.S. control unit I 1 Air conditioner operation I I position I 1I Vehicle speed SYSTEM DESCRIPTION This system automatically controls engine idle speed to a specified level. Idle speed is controlled through fine adjustment of the amount of air which by-passes the throttle valve via AAC. valve. The A.AC. valve repeats ON/OFF operation at a rate of 100 to 200 Hz according to the signal sent from the E.C.U. The crank angle sensor detects the actual engine speed and sends a signal to the E.C.U. The E.C.U. then controls the ON/OFF time of the A.AC. valve so that engine speed coincides with the target value memorized in ROM. The target engine speed is the lowest speed at which the engine can operate steadily. The optimum value stored in the ROM is determined by taking into consideration various engine conditions, such as noise and vibration transmitted to the compartment, fuel consumption, and engine load. EF & EC-20 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Fuel Pump Control INPUT/OUTPUT SIGNAL LINE I I Crank angle sensor Ignition switch ] 1 . Engine speed E.C.C.S. control unit 1-Fuel pump relay Start signal SYSTEM DESCRIPTION Condition The E.C.U. activates the fuel pump for several seconds after the ignition switch is turned on to improve engine startability. If the E.C.U. receives a 1° signal from the crank angle sensor, it knows that the engine is rotating, and causes the pump to perform. If the 1° signal is not received when the ignition switch is on, the engine stalls. The E.C.U. stops pump operation and prevents battery discharging, thereby improving safety. The E.C.U. does not directly drive the fuel pump. It controls the ON/OFF fuel pump relay, which in turn controls the fuel pump. Ignition switch is tunred to ON. Engine running and cranking Fuel pump operation Operates for 5 seconds Operates When engine is stopped Stops in 1 second Except as shown above Stops Air Regulator Control INPUT/OUTPUT SIGNAL LINE Engine speed [ . Crank angle sensor Start signal Ignition switch E.C.C.S. control unit SYSTEM DESCRIPTION Condition The air regulator is controlled by the E.C.U. at the same time as fuel pump ON-OFF control. Ignition switch is turned to ON While engine is running and cranking EF Air regulator Air regulator operation Operates for 5 seconds Operates When engine is stopped OFF in 1 second Except as shown above OFF 8r. EC-21 I ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Air Induction Valve (A.I.V.) Control INPUT/OUTPUT SIGNAL LINE Enginetemperature Engine temperature sensor Idle switch Throttle valve idle position E.C.C.S. control unit Engine speed Crank angle sensor Vehicle speed sensor A.LV. control solenoid valve Vehicle speed SYSTEM DESCRIPTION The air induction system is designed to send secondary air to the exhaust manifold, utilizing the vacuum caused by exhaust pulsation in the exhaust manifold. The exhaust pressure in the exhaust manifold usually pulsates in response to the opening and closing of the exhaust valve and decreases below atmospheric pressure periodically. If a secondary air intake pipe is opened to the atmosphere under vacuum conditions, secondary air can be drawn into the exhaust manifold in proportion to the vacuum. The air induction valve is controlled by the E.C.C.S. control unit, corresponding to the engine temperature. When the engine is cold, the A.I.V. control system operates to reduce HC and CO. In extremely cold conditions, A.I.V. control system does not operate to reduce after-burning. This system also operates during deceleration for the purpose of blowing off water around the air induction valve. Enginecondition Water temperature °c (oF) A.LV. control solenoid valve A.LV. control system Idle or deceleration Between 28 (82) and 115 (239) ON Operates EF 8r. EC-22 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION E.G.R. (Exhaust Gas Recirculation) Control INPUT/OUTPUT SIGNAL LINE Engine speed Crank angle sensor I -. I Amount of intake air Air flow meter I 1 I . I Enginetemperature sensor Engine temperature ..,.. I Start signal . Ignition switch I I DESCRIPTION In addition, a system is provided which precisely cuts and controls port vacuum applied to the E.G.R. valve to suit engine operating conditions. This cut-and-control operation is accomplished through the E.C.U. When the E.C.U. detects any of the following conditions, current flows through the solenoid valve in the E.G.R. control vacuum line. E.C.C.S. E.G.R. control solenoid valve control unit I SYSTEM This causes the port vacuum to be discharged into the atmosphere so that the E.G.R. control valve remains closed. 1) Low engine temperature 2) Engine starting 3) High-speed engine operation 4) Engine idling E.G. R. control solenoid valve operation E.G. R. control solenoid valve Condition When starting Below 60 (140) Water temperature ON °c (oF) Above 105 (221) Idle & heavy load conditions OFF Other conditions E.G.R. system operation E.G. R. system operates under only the following conditions. B.P.T. valve Water temperature °c (oF) Above 60 (140) Below 105 (221) Exhaust gas pressure Operation High Closed Throttle position E.G.R. control solenoid valve E.G.R. system Partially open OFF Operates EF & EC-23 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Fuel Pressure Regulator Control INPUT/OUTPUT SIGNAL LINE Engine temperature Engine temperature sensor E.C.C.S. Start signal Ignition switch P.R. control solenoid valve control unit Engine speed Crank angle sensor SYSTEM DESCRIPTION above 90°C (194° F) The fuel "pressure-up" control system briefly increases fuel pressure for improved starting performance of a hot engine. Under normal operating conditions, manifold vacuum is applied to the fuel pressure regulator. When starting the engine, however, the E.C.U. allows current to flow through the ON/OFF solenoid valve in the control vacuum line, opening this line to the atmosphere. As a result, atmospheric pressure is applied, throttling the fuel passage to increase fuel pressure. START Ignition switch OFF P.R.control OFF n ON I solenoid valve ON .. Approx. 3 min r SEF741B 0<' -r, Swirl Control Valve (S.C.V.) Control INPUT/OUTPUT SIGNAL LINE Idle switch I I Idle signal . Start signal . I Ignition switch I Engine speed Crank angle sensor Enginetemperature sensor E.C.C.S. control unit S.C.V. control solenoid valve Engine temperature SYSTEM DESCRIPTION This system has a swirl control valve (S.C.V.) in the intake passage of each cylinder. While idling the S.C.V. closes. Thus the velocity of the air in the intake passage increases, promoting the vaporization of the fuel and producing a swirl in the combustion chamber. Because of this operation, this system tends to increase the burning speed of the gas mixture, improve fuel consumption, and increase the stability in running conditions. Also, except when idling, this system opens the S.C.v. In this condition, this system tends to increase power by improving intake efficiency via reduction of intake flow resistance, intake flow. The solenoid valve controls S.C.v.'s shut/open condition. This solenoid valve is operated by the E.C.U. Idle switch Water temperature Engine rpm Solenoid valve S.C.V. ON Above 35°C (95°F) Below 1,400 ON Close OFF Open Except above EF & EC-24 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Acceleration Cut Control INPUT IOUTPUT SIGNAL LINE A/C ON signal [ . Air conditioner system Throttle sensor Throttle valve opening angle E.C.C.S. control unit Air conditioner relay SYSTEM DESCRIPTION When accelerator pedal is fully depressed, air conditioner is turned off for a few seconds. This system improves acceleration when air conditioner is used. Fail-safe System AIR FLOW METER MALFUNCTION If the air flow meter output voltage is above or below the specified value, the E.C.U. senses an air flow meter malfunction. In case of a malfunction, the throttle sensor substitutes for the air flow meter. Though air flow meter is malfunctioning, it is possible to drive the vehicle and start the engine. But engine speed will not rise more than 2,400 rpm in order to inform the driver of fail-safe system operation while driving. Operation System E.G.R. control system Fixed condition ENGINE TEMPERATURE MALFUNCTION When engine temperature sensor output voltage is below or above the specified value, water temperature is fixed at the preset value as follows: Operation Condition 20°C (68°F) More than 6 minutes after ignition ON or Start 80°C (176°F) OFF A duty ratio is fixed at the preprogrammed value. Fuel is shut off above Fuel injection control system THROTTLE 2,400 rpm. (Engine speed does not exceed 2,400 rpm.) Engine temperature decided Just as ignition switch is turned ON or Start Except as shown above Idle speed control system SENSOR SENSOR 20. 80°C (68 - 176°F) (Depends on the time) MALFUNCTION When throttle sensor output voltage is below or above the specified value, throttle sensor output is fixed at the preset value. EF & EC-25 IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION PREPARATION 1. Make sure that the following good order. . . .. parts are in Battery Ignition system . Engine oil and coolant levels Fuses . E.C.U.harnessconnector . Vacuumhoses . Air intakesystem (Oil filler cap, oil level gauge, etc.) Fuel pressure .. A.I.V. hose . . Engine compression E.G.R. control valve operation . 2. On air conditioner equipped models, checks should be carried out while the air conditioner is "OFF". 3. On automatic transmission equipped models, when checking idle rpm, ignition timing and mixture ratio, checks should be carried out while shift lever is in "N" position. 4. When measuring "CO" percentage, insert probe more than 40 em (15.7 in) into tail pipe. WARNING: a. When checking or adjustment, move selector lever to "N" position, set parking brake and chock rear wheels. b. After the adjustment has been made, remove wheel chocks. Throttle valve and throttle valve switch Overall inspection sequence INSPECTION START . N.G. Perform self-diagnosis. Repair or replace. / O.K. 1 Check or adjust idle speed and ignition timing. Chec k ex haust gas sensor I N.G. function by using E.C.U. inspection lamp (Green). Check exhaust gas sensor harness. N.G. O.K. O.K. Check idle mixture ratio by using E.C.U. inspection lamps (Red and Green) [in diagnostic mode II] . N.G. I Repair or replace harness. O.K. Check base idle CO. N.G. O.K. Replace exhaust gas sensor. Check emission control parts and repair or replace if necessary. INSPECTION END EF & EC-26 N.G., Check exhaust gas sensor function. ~ IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION INSPECTION START Visually check the following: . Air cleaner clogging . Hoses and ducts for leaks . E.G.R. control valveoperation . Electrical connectors . Gaskets ~ . Throttle valveand throttle valveswitch operation ~ Start engine and warm it up until water temperature indicator points to the middle of gauge. SEF457C 3 Open engine hood and run engine at about 2,000 rpm for about 2 minutes under no-load. 4 2 ,~,,\""\""L"""): ~ "'~ 1{ 0; .1OOO,/m," ...'.«6 "!:-\ ~1 f -8 I O.K. SEF477B Check, correct or replace malfunctioning parts. Does engine run smoothly? Yes I Check and clean injectors, and replace injectors if necessary. Race engine two or three times under no-load, then run engine at idle speed. Check idle speed. M/T: 750:!:50 rpm AfT: 750:!:50 rpm (in "N" position) O.K. N.G. . Check ignition timing with a timing light. 15°:!:2° B.T.D.C. N.G. O.K. Ensure that engine speed is below 800 rpm. . O.K. Adjust idle speed to less than 800 rpm by turning idle speed adjusting screw. SMA189A @ @ EF & EC-27 c IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION A C Check ignition timing with a timing light. 1S°:t2° B.T.D.C. O.K. N.G. Adjust ignition timing by turning distributor after loosening bolt which secures distributor. 1S°:t2° B.T.D.C. Adjust idle speed by turning idle speed adjusting screw. M/T: 700:tSOrpm AfT: 70O:tSOrpm (in "N" position) 3 4 2 '*"""~"""'" 5 '~"-.(6 ~ ~ \ 1'1' 0= ,'000""';" ~7 Run engine at about 2,000 rpm for about 2 minutes under no-load. ~ 1.8I SEF477B Make sure that inspection lamp (Green) on E.C.U. goes IN.G. on and off periodically more than 5 times during 10 seconds at 2,000 rpm under no-load. O.K. ~r\ ~V~~J ~/~ SEF450H ~r\ ~V ~~/-i~/ '--'~Jf)) , @ r,' iDIY ' ~ "-'" Set the diagnosis mode of E.C.U.to mode II. Check inspection lamps (Red and Green) on E.C.U. blink at 2,000 rpm. They should blink simultaneously. Yes No INSPECTION END J~ SEF292H D' EF &. EC-28 E C' IDLE SPEED/IGNITION TIMING/IDLE MIXTURERATIO INSPECTION D @ Exhaust gas sensor ~~'! E.C.C.S. harness - . 19 nl'-'~' SEF353H ~i c Check exhaust gas sensor harness: 1) Turn off engine and disconnect battery ground cable. 2) Disconnect harness connector from E.C.U. 3) Disconnect exhaust gas sensor harness connector and connect terminal for exhaust gas sensor harness connector to ground with a jumping wire. 4) Check for continuity between terminal No. 19 of E.C.U. harness connector and ground metal on vehicle body. Continuity exists. Continuity does not exist """"""''''''''' N.G. O.K. O.K. N.G. Repair or replace E.C.C.S.harness and connect battery ground cable. Connect harness connector to E.C.U. and disconnect jumping wire from exhaust gas sensor. . Disconnect engine temperature sensor harness connector. . Connect a resistor (2.5 kil) between terminals of engine temperature sensor harness connector. . Disconnect A.I.V. hose and install a suitable plug in A.I.V. pipe. . Connect battery ground cable. Start engine and warm it up until water temperature indicator points to the middle of gauge. (Wait more than 5 minutes after starting.) Race engine two or three times under no-load then run engine at idle speed. Check "CO"% and if engine runs smoothly. Idle CO: Less than 5% After checking CO% 1) Turn off engine. 2) Disconnect the resistor from terminals of engine temperature sensor harness connector. 3) Connect engine temperature sensor harness connector to engine temperature sensor. 4) Connect A.I.V. hose. O.K. G EF & EC-29 c IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION @ G' Connect exhaust gas sensor harness to exhaust gas sensor. Replace exhaust gas sensor. N.G. Run engine at 2,000 rpm and make sure that green inspection lamp on E.C.U.goes ON and OFF more than 5 times during 10 seconds. . O.K. Check fuel pressure regulator. (See page EF & EC-124.) Check air flow meter. (See page EF & EC-88.) Check injector. (See page EF & EC-126.) Clean or replace if necessary. Check engine temperature sensor. (See page EF & EC-90.) EF & EC-30 c TROUBLE DIAGNOSES Contents How to PerformTrouble Diagnosesfor Quick and Accurate Repair EF & EC- 33 " , Diagnostic Table EF & EC- 37 1. Impossible to start - no combustion EF & EC- 38 2. Impossible to start 3. Impossible to start 4. Impossible to start - EF & EC- 39 EF & EC- 40 5. Hard to start 6. Hard to start 7. Hard to start 8. Hard to start 9. Abnormal idling 10. Abnormal idling 11. Abnormal idling 12. Unstable idling 13. Unstable idling 14. Poor driveability 15. Poor driveability 16. Poor driveability 17. Poor driveability 18. Engine stall 19. Engine stall 20. Engine stall 21. Engine stall 22. Engine" stall 23. Engine stall - 24. Backfire 25. Backfire - partial combustion partial combustion (not affected by throttle position) partial combustion (throttle position changes combustion quality) before warm-up after warm-up every time morning after a rainy day no fast idle low idle (after warm-up) high idle (after warm-up) before warm-up after warm-up stumble (while accelerating) surge (while cruising) lack of power detonation during start-up while idling while accelerating while cruising while decelerating/just after stopping " while loading (power steering, air conditioner, headlamps, etc.) through the intake through the exhaust Self-diagnosis- Description EF & EC- 60 EF & EC- 61 EF & EC- 62 ..".. Self-diagnosis -- Mode I (Exhaust gas sensor monitor) Self-diagnosis - Mode II (Mixture ratio feedback control monitor) Self-diagnosis - Mode III (Self-diagnostic system) : Self-diagnosis - Mode IV (Switches ON/OFF diagnostic system) Self-diagnosis - Mode V (Real-time diagnostic system) Diagnostic Procedure Diagnostic Procedure 1 MAIN POWER SUPPLY AND GROUND CIRCUIT Self-diagnostic item Diagnostic Procedure 2 CRANK ANGLE SENSOR Diagnostic Procedure 3 AIR FLOW METER Diagnostic Procedure 4 ENGINE TEMPERATURE SENSOR Diagnostic Procedure 5 VEHICLE SPEED SENSOR Diagnostic Procedure 6 . IGNITION SIGNAL Diagnostic Procedure 7 ENGINE CONTROL UNIT.: Diagnostic Procedure 8 EF & EC- 63 EF EF EF EF EF EF " " " & & & & & & ECECECECECEC- 67 67 68 74 76 82 EF & EC- 84 EF & EC- 86 ~ ~ , EF & EC- 88 EF & EC- 90 ~ ~ ~ E.G.R. FUNCTION Diagnostic Procedure 9 ~ EXHAUST GAS SENSOR Diagnostic Procedure 10 ~ EXHAUST GAS TEMPERATURE EF & EC- 41 EF & EC- 42 EF & EC- 43 EF & EC- 44 EF & EC- 45 EF & EC- 46 EF & EC- 47 EF & EC- 48 EF & EC- 49 EF & EC- 50 EF & EC- 51 EF & EC- 52 EF & EC- 53 EF & EC- 54 EF & EC- 55 EF & EC- 56 EF & EC- 57 EF & EC- 58 EF & EC- 59 EF & EC- 92 EF & EC- 94 EF & EC~ 98 " EF & EC-100 EF & EC-104 SENSOR EF & EC-31 EF & EC-106 TROUBLE DIAGNOSES Contents (Cont'd) Diagnostic Procedure 11 THROTTLE SENSOR ~ ~ EF & EC-110 DiagnosticProcedure12 . INJECTOR LEAK Switch ON/OFF diagnostic item Diagnostic Procedure 13 IDLE SWITCH Diagnostic Procedure 14 START SWITCH Not self-diagnostic item Diagnostic Procedure 15 FUEL PUMP Diagnostic Procedure 16 PRESSURE REGULATOR (P.R.) CONTROL SOLENOID VALVE Diagnostic Procedure 17 INJECTORS Diagnostic Procedure 18 SWIRL CONTROL VALVE (S.C.v.) CONTROL SOLENOID VALVE Diagnostic Procedure 19 AIR REGULATOR Diagnostic Procedure 20 AUXILIARY AIR CONTROL (A.A.C.) VALVE " Diagnostic Procedure 21 LA.A. CONTROL (F.LC.D. CONTROL) Diagnostic Procedure 22 AIR INDUCTION VALVE (A.LV.) CONTROL SOLENOID VALVE DiagnosticProcedure23 . NEUTRALSWITCH,INHIBITORSWITCHAND INHIBITORRELAY Electrical Components Inspection EF & EC-114 EF & EC-116 EF & EC-118 EF & EC-120 EF & EC-124 EF & EC-126 EF & EC-128 EF & EC-130 EF & EC-134 EF & EC-136 EF & EC-138 ; EF & EC-140 EF & EC-142 EF 8r. 'EC-32 TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair ~ .~.~ :A ~wol """ ~~ SEF232G INTRODUCTION The engine has an electronic control unit to control major systems such as fuel control, ignition control, idle speed control, etc. The control unit accepts input signals from sensors and instantly drives actuators. It is essential that both kinds of signals are proper and stable. At the same time, it is important that there are no conventional problems such as vacuum leaks, fouled spark plugs, or other problems with the engine. It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are caused by poor electric connections or faulty wiring. In this case, careful checking of suspicious circuits may help prevent the replacement of good parts. A visual check only may not find the cause of the problems. A road test with a circuit tester connected to a suspected circuit shou Id be performed. Before undertaking actual checks, take just a few minutes to talk with a customer who approaches with a driveability complaint. The customer is a very good supplier of information on such problems, especially intermittent ones. Through the talks with the customer, find out what sy.mptoms are present and under what conditions they occur. Start your diagnosis by looking for "conventional" problems first. This is one of the best ways to troubleshoot driveability problems on an electronically controlled engine vehicle. SE F234G EF & EC-33 TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont'd) WORK FLOW CHECK STEP 1 SERVICE MANUAL REFERENCE ITEMS& PAGES IN ------ LISTEN TO CUSTOMERCOMPLAINTS DIAGNOSTIC WORKSHEET EF & EC-35 ------ STEP 2 Can be performed Can not be performed CHECK MAIN POWER SUPPLY AND GROUND CIRCUIT <' < --- Self-diagnosis EF & EC-63 Diagnostic Procedure EF & EC-84 No DUPLICATIONOF OPERATING CONDITIONS THAT LEAD TO MALFUNCTION STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 INTERMITTENT SIMULATION EF & EC-36 < r. I I I I I I I I I I I I I I I I J I INSPECTION ON THE BASE OF EACH COMPONENT REPAIR/REPLACE :N.G. I L FINAL CHECK O.K. CHECK OUT EF & EC-34 ------- PROBLEM ~~~~~~;able Diagnostic Procedure EF & EC-86 TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont'd) KEY POINTS WHAT WHEN WHERE Vehicle & engine model Date, Frequencies Road conditions HOW Operating conditions, Weather conditions, Symptoms DIAGNOSTIC WORKSHEET There are many kinds of operating conditions that lead to malfunctions on engine components. A good grasp of such conditions can make trouble-shooting faster and more accurate. In general, feelings for a problem depend on each customer. It is important to fully understand the symptoms or under what conditions a customer complains.. Make good use of a diagnostic worksheet such as the one shown below in order to utilize all the complaints for trouble-shooting. Worksheet sample Customer name MR/MS Model & Year VIN Engine # Trans. Mileage Incident Date Manuf. Date In Service Date 0 Startability 0 No combustion 0 Partial combustion 0 Impossible to start 0 Partial combustion affected by throttle position 0 Partial combustion NOT affected by throttle position 0 Possible but hard to start 0 Othl!rs [ 0 Idling 0 No fast id Ie 0 Others [ 0 0 Driveability 0 Stumble 0 0 Intake backfire 0 Others [ 0 Detonation Surge 0 Exhaust backfire Symptoms 0 Engine stall 0 At the time of start 0 While accelerating 0 Just after stopping 0 Just after delivery 0 In the morning Frequency 0 All the time Weather conditions 0 Not effected Weather 0 Fine 0 Temperature 0 Hot 0 0 Cold 0 In town Driving conditions 0 0 0 0 Check engine light Lack of power While idling While decelerating 0 0 0 0 I 2,000 0 0 Others [ Cold 0 Highway I , I , 20 Not turned on EF & EC-35 ] Humid I 30 . I 40 . of I J 8,000 rpm 0 Off road (up/down) I . While idling 0 At racing 0 While cruising 0 While turning (RH/LH) 10 Sometimes After warm-up I I I 4,000 6,000 I In suburbs 0 0 Snowing Cool I ' In the daytime Under certain conditions During warm-up Not affected At starting 0 While accelerating While decelerating 0 Turned on 0 Low idle 0 - While loading Raining 0 Vehicle speed 0 High idle ] 0 Recently 0 0 At night Warm E. d I ngme spee 0 Road conditions 0 0 0 0 0 ] Incident occurrence Engine conditions Unstable ] 50 I 60 MPH TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont'd) INTERMITTENT PROBLEM SIMULATION In order to duplicate an intermittent problem, it is effective to create similar conditions for component parts, under which the problem might occur. Perform the activity listed under Service procedure and note the resu It. ' Variable factor 1 2 3 4 5 6 Mixture ratio Ignition timing Influential part Target condition Service procedure Made lean Remove vacuum hose and apply vacuum. Made rich Remove vacuum hose and apply pressure. Advanced Rotate distributor clockwise. Retarded Rotate distributor counterclockwise. Pressure regulator Distributor Mixture ratio feedback control Exhaust gas sensor Suspended Disconnect exhaust gas sensor harness connector. Control unit Operation check Perform self-diagnosis (Mode I/II) at 2,000 rpm. Raised Turn idle adjusting screw counterclockwise. Idle speed I.A.A. unit Lowered Turn idle adjusting screw clockwise. Poor electric connection or faulty wiring Tap or wiggle. Electric connection (Electric continuity) Temperature Harness connectors and wires Race engine rapidly. See if the torque reaction of the engine unit causes electric breaks. Cooled Cool with an icing spray or similar device. Warmed Heat with a hair drier. [WARNING: Do not overheat the unit.] Control unit Wet. [WARNING: 7 Moisture Electric parts Damp 8 Electric loads Load switches Loaded Turn on head lights, air conditioner, rear defogger, etc. 9 Idle switch condition Control unit ON-OFF switching Perform self-diagnosis (Mode IV). Ignition spark Timing light Spark power check Try to flash timing light for each cylinder. 10 EF &. EC-36 Do not directly pour water on components. Use a mist sprayer.! TROUBLE DIAGNOSES Diagnostic Table To assist with your trouble diagnoses,some typical diagnostic procedures for the following symptoms are. described. REMARKS In the following pages, the numbers such as 0, . in the above chart correspond to those in the serviceprocedure described below. Possiblecauses can be checked through the serviceprocedure shown by the mark "0". EF 8r. EC-37 TROUBLE DIAGNOSES Diagnostic Table (Cont'd) SYMPTOM & CONDITION SPECIFICATIONS 1 II mpossible to start - no combustion POSSIBLECAUSES .. 8 8 0 Mixture ratio (too lean) 0 I " 0 8 0 0 0 0 Ignition sparks (weak, missing) 0 Ignition timing FUEL SYSTEM Fuel pump (no operation) 0 Fuel pump relay (open circuited) 0 0 Injectors (no operation, clogged) IGNITION SYSTEM Ignition switch 0 0 0 0 0 Main relay 0 0 0 0 0 0 0 0 Ignition coil 0 0 Center cable (ignition leaks) 0 0 Ignition wires (ignition leaks) 0 Power transistor 0 0 Spark plugs CONTROL SYSTEM 0 Crank angle sensor 0 0 0 SERVICE PROCEDURE . LISTEN LISTEN N.G. I ---+ ~~ ../ f) Check fuel pump and/or related circuits. [See page EF & EC-120.J Fuel pump , SEF279G Listen for fuel pump operating sound. '- N.G -.: START 2l' ,,\ o-~ ' 5 \. [0 .! Timinglight . CHECK I.* @ ~ -6 /. Tachometer Ignition switch SEF283G SEF281G) Make sure tachometer needle moves when cranking. CHECK .~ ~ //11 . II ., Check flashes of timing light for weak ness. --+ ,. N.G. ignition SE Injector F280G MEASURE ~ \UyJ N.G. --+ Replace the wire. O.K. ,0 ---+ CHECK SEF315G Measure resistance of suspect wires. N.G. AdJust ' .. Ignition timing. --+ [See page EF & EC-26.J ((@S""~G Check injector circuit. [See page EF & EC-126.J Listen for injector operating sound. CHECK 8 N.G. --+Check timing. EF &. EC-38 Remove spark plugs and check their ignition sparks. TROUBLE DIAGNOSES Diagnostic SYMPTOM & CONDITION SPECI FICA nONS Table (Cont'd) 21 Impossibleto start - partial combustion POSSIBLE CAUSES 0 f) " Mixture ratio 0 0 0 0 0 Fuel pressure (too low) 0 Ignition timing FUEL SYSTEM " Fuel pump 0 Fuel pump relay (open circuited) 0 Injectors (clogged) 0 SERVICE PROCEDURE . LISTEN N.G. I Check fuel pump and/or related circuits. [See page EF & EC-120.J -.~ .1 ~ . Fuel pump sou, ~ L ~K .1 8 ~ \. :J APPL Y ,. Improved Checkinjectorcircuit. Injector SEF280G operating r. D . ~ PRESSURE , SEF291G..I MEASURE Fuel pressure gauge t 'SE".6G Remove vacuum hose from pressure regulator, and apply vacuum and/or pressure, and try to start. Connect vacuum hose to pressure regulator and measure fuel pressure. Adjust ignition timing. [See page EF & EC-26.J 1 Check mixture ratio feedback system. [See page EF & EC-26.J CHECK . ~ ~~~:ng , .. N.G. [See page EF & EC-126.J Listen for injector sound. ~.VACUUM . - //11II SEF279G L~sten for fuel ~ump operating LISTEN f) ~ - sm~G Check ignition timing. "< EF & EC-39 TROUBLE DIAGNOSES Diagnostic SYMPTOM& CONDITION 31 Impossible to start - partial combustion . . .. . . . . . 0 . POSSIBLE CAUSES SPECIFICATIONS Mixture ratio 0 Fuel pressure (too low) 0 0 0 0 0 0 Fuel filter (clogged) 0 Fuel line (clogged) 0 Injectors (clogged) 0 Pressure regulator 0 Pressure regulator vacuum hose (clogged) IGNITION SYSTEM 0 Ignition wires (ignition leaks) 0 0 Spark plugs (wet with fuel) 0 Ignition switch INTAKE SYSTEM CONTROL SYSTEM 0 Throttle chamber (with ports clogged) 0 Throttle valve (clogged) 0 Engine temperature 0 0 SERVICE PROCEDURE . LISTEN N.G. ~ Check injector circuit. [See page EF & EC-126.J //11 InJ'ector , " . , SEF280G Listen for injector operating sound. 8 0 sensor Crank angle sensor . (not affected by throttle position) 0 Ignition timing FUEL SYSTEM Table (Cont'd) CHECK N.G. --+ Throttle chamber CIean t h e ports and/or throttle valve. s~ Check throttle chamber ports and valve for clogging. . lo.K. CHECK O.K. 1---+ 'A V [ MEASURE REMOVE Pressureregulator Improved ,. . 2. Fuel pressure Connect vacuum hose to pressure regulator and measure fuel pressure. . Check mixture ratio feedback system. [See page EF & EC.26.J SEF291G Remove vacuum hose from pressure regulator, and try to start. SEF287G Check vacuum hose of pressure regulator for clogging. 1 N.G. Repair or replace the hose. 0 . . CHECK ~ CHECK MEASURE , , Timing light N.G. ~. ~ - (r@.<..~ ""'~G Ignition 1 N.G. Adjust ignition timing. [See page EF & EC-26.J resistance of '","oct;'"}~~' Replace N.G. Self-diagnosis Mode IV CHECK wire -~ PERFORM G> O.K. if?rn SEF315G Measure SEF283G Check flashes of timing light for weakness. Check ignition timing. (!) + Check starter circuit. [See page EF & EC-118.J Perform self-diagnosis Mode IV (for start signal). EF &.EC-40 the wires. Spark plug SEF282G Remove spark plugs and check their ignition sparks by cranking. TROUBLE DIAGNOSES Diagnostic SYMPTOM & CONDITION 41 Impossibleto start POSSIBLE CAUSES INTAKE SYSTEM - Table (Cont'd) partial combustion (throttle position changes combustion qu~lity) 10 Throttle chamber (with ports clogged) . 8 0 Throttle valve (clogged) 0 Air regulator (stuck closed) CONTROL SYSTEM . 0 IdIe speed control valve 0 Engine temperature sensor Idle switch 0 Neutral switch 0 0 SERVICE PROCEDURE 0 . r. CHECK N.G. Throttle chamber - Cleantheports. ~. ..~ SEF290G Check throttle valvefor clogging. Check throttle chamber ports for clogging. r. .. , - CHECK . N.G. I jj CHECK Throttle chamber Check air regulator and/or its circuit. [See page EF & EC-130.J SEF293G Make sure air regulator stays open before warm-up 8 CHECK - N.G. .,~" START , @* C.hec~ idle speed control Circuit. [See page EF & EC-134.J SEFOO6H Check terminal voltage of A.A.C. valve while cranking. EF & EC-41 N.G. Cleanthe valve. ---+ TROUBLE DIAGNOSES Diagnostic SYMPTOM & CONDITION 51 Hard to start - Table (Cont'd) before warm-up I POSSIBLE CAUSES Mixture ratio 0 f) 8 0 0 IGNITION SYSTEM Ignition switch (no start signal) 0 INTAKE SYSTEM Air regulator Engine temperature sensor Idle switch SPECIFICATIONS CONTROL SYSTEM OTHERS 0 0 0 0 0 0 Neutral switch 0 Starter (operation too slow) 0 Battery (voltage too low) 0 0 SERVICE PROCEDURE CHECK 0 N.G. START 1 + "i,. ;5 o-~ -6 " Tachometer MEASURE N.G. (less than 12V) --+Charge the battery. I.* @ ~ ~ Ignition switch SEF281G SEF296G Measure battery voltage. Make sure tachometer indicates about 300 rpm while cranking. '0 f) CHECK N.G. + Check air regulator and/or its circuit. [See page EF & EC-130.J if " CRANK g i)~ Self-diagnosis Mode IV Perform self-diagnosis Mode IV (for start signal and idle switch!. stays N.G. START ~Check * PERFORM SEF285G SEF293G Make sure air regulator open before warm-up. e I sensor circuit. [See page EF & EC-90.J ~ @ ~ . Ignition Engine tempera- switch -!ure sensor SEF292G. Start with engine temperature sensor connector disconnected. EF & .EC-42 N.G. --+ Check the malfunctioning switches and/or circuits. [See page EF & EC-118 (start signal). page EF & EC-116 (idle switch).] TROUBLE DIAGNOSES Diagnostic SYMPTOM & CONDITION 61 Hard to start - Table (Cont'd) after warm-up 0 POSSIBLE CAUSES SPECIFICATIONS FUEL SYSTEM . I . 00 Mixture ratio 0 0 Fuel pressure 0 0 Fuel line (hot fuel) 0 Pressure regulator (low fuel pressure) 0 Pressure regulator vacuum hose (clogged) 0 .. 0 0 Pressure regulator control solenoid 0 0 Pressure regulator control solenoid vacuum hose Fuel temperature sensor (open circuited) IGNITION SYSTEM CONTROL SYSTEM 0 Ignition switch (no start signal) 0 Engine temperature sensor Air flow meter OTHERS Starter (operation too slow) 0 Battery (voltage too low) 0 SERVICE PROCEDURE CHECK . MEASURE '0 N.G. f) STARTI~ ,* 2~' ~ @ ,,' o-~ SEF281G SEF296G Measure battery voltage. ' , S eIf-diagnosIs Mode IV SEF374G Cool fuel lines with wet rags, etc. and try to start. ! N.G. (less than 12V) Charge the battery. PERFORM 0 LINES Ignition switch Make sure tachometer indicates about 300 rpm while cranking. , No change ~ Proceed to other steps. CRANK FUEL I ",5 -6 /. Tachometer 0 N.G. ~ . Check starter circuit. [See page EF & EC-118.] 171~ SEF285G Perform self-diagnosis Mode IV (for start signal), . CHECK O.K. --+ SEF287G Check vacuum hose of pressure regulator for clogging. CHECK 1 N.G. Repair or replace the hose. (pressure regulator control solenoid ¥ 0\ N.G. --+ ( LISTEN Pressure regulator control solenoid 0' START i;.~ Ignition '-SEF294G switch Check terminal voltage of pressure regulator control solenoid while cranking. Listen for clicking sound from pressure regulator control solenoid when applying battery voltage. o.K. ~ N.G. Replace the solenoid. Check the solenoid circuit. [See page EF & EC-124.] l EF & EC-43 Improved + Proceed to other steps. If everything is O.K., check fuel vapor pressure. TROUBLE DIAGNOSES Diagnostic SYMPTOM & CONDITION 71 Hard to start - every time . . . o . (I). G . . . . POSSIBLE CAUSES SPECIFICATIONS Table (Cont'd) Mixture ratio 0 I 0 0 Fuel pressure 0 0 Ignition sparks (missing) FUEL SYSTEM Fuel pump (improper operation) 0 0 0 0 0 Fuel line (clogged) Canister (air leaks) 0 0 Pressure regulator (low fuel pressure) Ignition wires (ignition leaks) IGNITION SYSTEM 0 0 Ignition timing 0 Spark plugs (improper gap) CONTROL SYSTEM 0 0 Crank angle sensor Engine temperature sensor 0 Idle switch OTHERS 0 Neutral switch 0 Starter (operation too slow) 0 Battery (voltagetoo low) 0 0 SERVICE PROCEDURE 0 LISTEN N.G. ---+Check fuel pump and/or related circuits. [See page EF &I;C-120.] ~ START --+ It ,,\2i' CHECK ',5 0-~~ 8 .. ~ Charge the battery. N.G. ~* switch Check mixture . REMOVE - N.G. I .Repair or replace the hose. ratiO ;] SEF297G feedback system. Advance/retard ignition [See page EF & EC-26.] timing and try to start. Improved ~ Measurebattery voltage. ~ SEF281G Make sure tachometer indicates about 300 rpm while cranking. CHECK No change Distributor -+ Proceed to other steps. Advance ST ART ~ Retard ~ Ignition Battery rMEASUREl switch CRANK .-- @ ~ -" N.G. Tachometer Ignition , SEF279G Listen for f.uel pump operating sound. ~ /.* ro---MEASURE, +\ - Fuel pressure Connect vacuum hose to Pressure regu Iat or pressure regulator and measure fuel pressure. .. PERFORM N.G. Self-diagnosis Mode IV . Check the malfunctioning circuits. [See page EF & EC-116 (idle switch).] Replace the wires. N.G. --+ O [ tN,G. MEASURE I> MEASURE O.K. --+ Ignition wire if?rn SEF283G Check flashes of timing light for weakness. canister for air leaks. Perform self-diagnosis Mode IV (for idle switch). SEF291 G Remove vacuum hose from pressure regulator, and try to start. CHECK«3 , 1 Timing light ~";~ , SEF298G Check vacuum hose of -~ SEF315G Measure resistance of suspect ignition wires. O.K. --+ e I. CHECK S~'k'~G~ Spark plug SEF299G Remove spark plugs and measure their 9 0 0 Ignition timing (too advanced) INTAKE SYSTEM 8e 0 N.G. Check the idle switch circuit. [See page EF & EC-116.] N.G. CRANK (( i5 ;U~ ~ ~ START (l] Ignition Engine tempera- switch ture sensor SEF292G Start with engine temperature sensor connector disconnected. circuit. EF & EC-48 Check sensor circuit. [See page EF & EC-90.J TROUBLE DIAGNOSES Diagnostic Table (Cont'd) SYMPTOM & CONDITION 121 Unstableidling- before warm-up 0 POSSIBLE CAUSES 0 SYSTEM SYSTEM 0 0 0 Air regulator (not open enough) 0 Idle speed control valve (remaining OFF) CONTROL 0 0 0 0 Ignition timing INTAKE f) 8 Mixture ratio SPECIFICATIONS I Engine temperature sensor E.G.R. SYSTEM 0 E.G.R. control valve (stuck open) 0 E.G.R. solenoid (remaining OFF) 0 0 ~... SERVICE PROCEDURE .-CHECK ~ - ~~~:ng ~ ~ ""':G Check ignition . ~ -- CHECK 0 Checkmixtureratio Does not turn ON +Check its circuit. feedback system. [See page EF & EC-26.J [See page EF & EC-134.J Pressu re regu lator - SEF291G CHECK ~~ , ~ a ~ (j"E.G.R. I! control valve , SEF547A...J Check E.G.R. control valve for operation. SEFOO7H Check terminal voltage of A.A.C. valve while idling. Apply vacuum pressure to pressure regulator after disconnecting vacuum hose, and check idling. 0 air regulator and/or its circuit. [See page EF & EC-130.J SEF293G PRESSURE - iit Improved VACUUM N.G. ~Check Make sure air regulator stays open before warm-up. timing. APPLY 8 CHECK f) N.G. --+Adjust ignition timing. [See page EF & EC-26.J Stays ~rw /A CHECK '0 RUN E.G.R. solenoid " ~Ui6~ g ,l:c;\ ::: S'J ~ / N.G ST ART ~* :.Ji!J " ~"~ SEF303G Engine tem pera- SIgnition t ure sensor witch SEF292G Check terminal voltage of E.G.R. solenoid while idling. N.G. Start and run engine with engine temperature sensor connector disconnected. u 1 Check the solenoid circuit. [See page EF & EC-100.J EF & EC-49 ] ~ r Check senso [S $ p'" ' " CircUit EF & EC-90.] TROUBLE DIAGNOSES Diagnostic Table (Cont'd) SYMPTOM & CONDITION SPECIFICAnONS 131 Unstable idling - after warm-up POSSIBLE CAUSES 0 8 8 0 Mixture ratio 0 0 0 0 Ignition sparks I 0 0 8 0 0 0 0 G) 4D f) 0 Ignition timing 0 Compression pressure FUEL SYSTEM 0 Fuel line (clogged) 0 Canister (air leaks) 0 Pressure regulator control solenoid Power transistor IGNITION SYSTEM INTAKE SYSTEM 0 Ignition coil 0 Ignition wires 0 0 0 0 0 Blow-by hose (leaks) 0 Air duct (leaks) CONTROL SYSTEM 0 Idle switch 0 Load switches E.G.R. SYSTEM E.G. R. control valve 0 E.G.R. solenoid 0 SERVICE PROCEDURE , . CHECK 0 ~~ BIOW_bY hose ~ 1 N.G. leaks. Repair/replace the hose. ~";f:t SEF298G Check purge line for leaks. 1 N.G. 1 N.G. Repair/replace the hose. Repair/replace the part. CHECK Timing light CHECK N.G. --+ CHECK MEASURE 0 '. . IgOitlon wIre I , O.K. + .0 ~~ - SEF315G Check flashes of timing light for weakness. MEASURE . CHECK ~~ , COMPRESSION PRESSURE SEF309G Measure compression pressu reo N.G. ~ 6~ ~ E.G.R' control valve , SEF547A/ Check E.G.R. control valve for operation. Stays I~'" (~ CHECK E.G.R. solenoid ~fii6~ n u ~.~ SEF303G Check terminal voltage of E.G.R. solenoid while idling. 1 Check cylinder head and gasket. [See EM section.] ~ - U ~.=. SEF303G Check terminal voltage.of the solenoid while idling. + N.G. Check the solenoid circuit. [See page EF & EC-124.J CHECK SEF282G Remove spark plugs and check their ignition sparks. Measure resistance of suspect wires. ~ N.G. Replace the wire. 0 CHECK Pressure regulator control solenoid o~ ~ru SEF283G e r~ 11/"-' SEF301G Check intake system for air leaks. SEF300G Check blow-by hose for 0., Leak Engine I . . CHECK 0 ~ N.G. Check the solenoid circu it. [See page EF & EC-100.J EF & EC-50 ~"""~G Check ignition timing. ~ N.G. Adjust ignition timing. [See page EF & EC-26.J PERFORM f) Self-diagnosis Mode IV ~ SEF285G Perform self-diagnosis Mode IV (for idle switch). 1 N.G. Check the idle switch circuit. [See page EF & EC-116.J TROUBLE DIAGNOSES Diagnostic Table (Cont'd) 14 Poor driveability - stumble (while accelerating) SYMPTOM & CONDITION . f) 8 0 POSSIBLECAUSES SPECIFICATIONS Mixture ratio (;) 0 Fuel pressure FUEL SYSTEM . . 0 0 0 0 Fuel filter (clogged) 0 Fuel line (clogged) 0 Injectors (clogged) IGNITION SYSTEM 0 Ignition coil 0 Ignition wires (ignition leaks) 0 CONTROL Crank angle sensor SYSTEM 0 0 0 0 0 0 Spark plugs (ignition leaks, improper gap) Air'duct (leaks) 0 0 0 0 0 Air flow meter 0 Engine temperature sensor Exhaust gas sensor 0 Idle switch (remaining OFF) OTHERS 0 0 Power transistor INTAKE SYSTEM 0 0 Fuel (poor quality) SERVICE PROCEDURE " 0, . CHECK MEASURE -- N.G.Replacethe wires. -- N.G. Timing light Ignition wire \{I i 8 CHECK O.K. @ GJ -'} SEF315G SEF283G Measure resistance suspect wires. Check flashes of timing light for weakness. ~CHECK Leak N.G. -- Repair/replacethe part. Remove spark plugs and check their ignition sparks. ~ N.G. Self-diagnosis ModeIV ~ SEF301G Check intake system air leaks. PERFORM 0 ()III~ Eng ine .-- SEF282G of for " REMOVEPressu re regu lator Improved . I0 MEASURE Check the idle switch circuit. [See page EF & EC-116.J SEF285G Perform self-diagnosis Mode IV (for idle switch). . feedback Check mixture ratio system. Fuel pressure gauge ~. [See page EF & EC-26.J SEF291G Remove vacuum hose from pressure regulator, and try to drive. PERFORM «!) Self-diagnosis ~V U%'~ SEF285G Perform self-diagnosis Mode V (for air flow meter). N.G. Connect vacuum hose to pressure regulator and measure fuel pressure while driving. DISCONNECT 0 -.." 1:8 Improved . Replace the sensor. II! . Check the malfunctioning parts and/or circuits. [See page EF & EC.88 (air flow meter).] No change sensor ('.,~ ~; E'h,"~";~'/'>= ~~. - SEF307G Disconnect exhaust gas sensor con nector, and try to drive. EF & EC-51 . Check mixture ratio feedback system. [See page EF & EC-26.] TROUBLE DIAGNOSES Diagnostic Table (Cont'd) SYMPTOM & CONDITION 15 Poor driveability - surge (while cruising) . ... 0 f) Mixture ratio (too lean) 0 SPECI FICA TIONS POSSIBLE CAUSES . e Fuel pressure (low) SYSTEM 0 0 0 0 (missing) INTAKE SYSTEM CONTROL 0 0 Ignition timing IGNITION 0 0 8 fi) " 0 SYSTEM Air duct (leaks) 0 Throttle chamber (air leaks) 0 Intake manifold (gasket) (air leaks) 0 Crank angle sensor 0 Air flow meter 0 0 Exhaust gas sensor Idle switch E.G.R. SYSTEM 0 E.G. R. control valve (stuck open) 0 E.G.R. solenoid (remaining OFF) 0 E.G.R. vacuum hose (removed) 0 0 SERVICE PROCEDURE .~ ~p! ~CHECK CHECK leak ()11/ Engine ~ (t@s"'~a Check intake system air leaks. CHEC~ for Check l ignition timing. II , . e :::"./: control valve SEF547 A./ U REMOVE . Improved Pressure regulator ~. . 0 ~N.G. Check the solenoid circuit. [See page EF & EC-100.J MEASURE Fuel pressure gauge , t feedback system. [See page EF & EC-26.1 '",,,.,a Connect vacuum hose to pressure regulator and measure fuel pressure while driving, PERFORM DISCONNEC!.-" Self-diagnosis N.G. . Check the malfunctioning parts and/or circuits. [See page EF & EC-86 (crank angle sensor), page EF & EC-88 (air flow meter), page EF & EC-94 (ignition signa!).! PERFORM Self~ ) Check starter signal circuit. O.K. i~ ("'I riJf!jt ~--;'t\0) ~ ~'-~ SE F299H Lift the rear of the vehicle. N.G. Drive vehicle. Make sure that a green inspection lamp goes "ON" when vehicle speed is 20 km/h (12 MPH) or faster. O.K. Turn ignition switch "OFF". Reinstall the E.C.U. in place. ( DIAGNOSIS END CAUTION: . ) SE F288H N.G. Make sure that a red inspection lamp goes "ON" during turning ignition switch "ST ART"*. ~SE'29.H Mode IV Check idle switch circ~ -.----O.K. Accelerator pedal S;~~T Flashing 4 times After the inspection lamps have flashed 4 times, turn diagnostic mode selector fully counterclockwise. For safety, do not drive rear wheels at higher speed than required. EF & EC-75 I ) Check vehicle speed sensor circuit. TROUBLE DIAGNOSES - Self-diagnosis Mode V (Real-time diagnostic system) In real-time diagnosis, if the following items are judged to be working incorrectly,a malfunction willbe indicated immediately. . Crank angle sensor (180° signal & 1° signal) output signal . Ignition signal . Air flow meter Consequently, the above output signal this diagnosis systems cause very effectively determines the Compared with self-diagnosis, sitive and can detect regarded as malfunction, real-time malfunctions malfunctions during diagnosis instantly. in this diagnosis whether driving However, are test. is very not senitems stored in E.C.U. memory. SELF-DIAGNOSTIC PROCEDURE ( ) DIAGNOSIS START I Pull out E.C.U. from under the assist seat. Start engine. Turn diagnostic mode selector on E.C.U. fullyclockwise. After the inspection lamps have flashed times, turn diagnostic mode 5 selectorfully counterclockwise. ~r\ ~V ~(~~ '-~C0 ( Make ) sure that inspection flashing for 5 min. when lamps N.G. are not ) Mode V SEF288H Ifflashing,count no. of flashes. idling or racing. O.K. SE F292 H Turn ignition switch Turn "OFF". See ignition switch decoding "OFF". chart. Reinstallthe E.C.U. in place. ( Perform DIAGNOSIS END ) system real-time diagnosis inspection. If malfunction part is found, repair or replace it. CAUTION: In real-time diagnosis, and does not memorize pay attention to inspectio.n lamp flashing. E.C.U. the inspection. EF &. EC-76 displays the malfunction code only once TROUBLE DIAGNOSES Self-diagnosis - Mode V (Real-time diagnostic system) (Cont'd) DECODING CHART DISPLAY CODE MALFUNCTIONING OR PARTS CIRCUIT CONTROL UNIT SHOWS A MALFUNCTION SIGNAL WHEN THE FOLLOWING CONDITIONS ARE DETECTED. (Compare with Self-diagnosis - ModeIII.) CRANK ANGLE SENSOR . Unit: sec RED L.E.D. 3.2 3.2 The 10 or 1800 signal is momentarily missing, or, multiple, momentary noise signals enter. 3.2 '9' ON-[ Malfunction of crank angle sensor circuit 0 OFF REAL-TIME DIAGNOSTIC INSPECTION See page EF & EC-86. SEF047F AIR FLOW METER . GREEN LED .. :0: ',' 3.2 Unit: sec 3.2 3.2 Abnormal, momentary increasein air flow meter output signal ON Malfunction of air flow meter circuit 0 OFF LI1.6lnl1.61 0.4 0.60.4 V --0.6 -V 1.6 0.4 0.6 REAL-TIME DIAGNOSTIC INSPECTION See page EF & EC-88. SEF048F IGNITION SIGNAL . Unit: sec GREEN 3.2 3.2 "L.E.D. rT '9,: ON -- Signalfrom the primary ignition coil momentarily drops off. ~~ r Malfunction of ignition signal 0 OFF 1.8 0.2 REAL-TIME DIAGNOSTIC INSPECTION See page EF & EC-94. SEF049F EF & EC-77 TROUBLE DIAGNOSES Self-diagnosis- Mode V (Real:-timediagnostic system) (Cont'd) I Crank Angle Sensor . REAL-TIME DIAGNOSTIC I X : Avallab Ie -: Not available INSPECTION Check parts Check sequence 1 Check items Check conditions Tap harness connector or component during realtime diagnosis. E.C.U. harness connector If malfunction, perform the following items. Middle connectors Sensor & actuator During real-time diagnosis X X X Go to check item 2. X - - Go to check item 3. Check harness continuity Engine at connector. stopped 3 Disconnect harness connector, and then check dust adhesion to harness connector. Engine stopped X - X Clean terminal surface. 4 Check pin terminal bend. Engine stopped - - X Take out bend. 5 Reconnect harness connector and then recheck harness continuity at connector. Engine stopped X - - Replace terminal. 6 Tap harness connector or component during realtime diagnosis. During real-time diagnosis X X X If malfunction codes are displayed during real-time diagnosis, replace terminal. 2 CJ L J -E.C.U. harness connector SEF130H EF & EC-78 TROUBLE DIAGNOSES Self-diagnosis- Mode V (Real-time diagnostic system) (Cont'd) I Air Flow Meter x: Available -: Not available I Check parts Check sequence Check items Check conditions 1 Tap harness connector or. component during realtime diagnosis. 2 Middle connectors Sensor & actuator E.C.U. harness connector During real-time diagnosis X X X Go to check item 2. Check harness continuity at connector. Engine stopped X - - Go to check item 3. 3 Disconnect harness connector, and then check dust adhesion to harness connector. Engine stopped X - X Clean terminal surface. 4 Check pin terminal bend. Engine stopped - - X Take out bend. 5 Reconnect harness connector and then recheck harness continuity at connector. Engi ne stopped X - - Replace terminal. 6 Tap harness connector or component during realtime diagnosis. During real-time diagnosis X X X If malfunction codes are displayed during real-time diagnosis, replace terminal. r If malfunction, perform the following items. =-l E.C.U. harness connector Air flow meter harness connector .. I"~ ,<1/A SEF131H EF & EC-79 TROUBLE DIAGNOSES Self-diagnosis- Mode V (Real-time diagnostic system) (Cont'd) I Ignition Signal X: -: I Available Not available Check parts Check sequence Check items 1 Tap harness connector or component during realtime diagnosis. 2 Check conditions If malfunction, perform the following items. Middle connectors Sensor & actuator E.C.U. harness connector During real-time diagnosis X X X Go to check item 2. Check harness continuity at connector. Engine stopped X - - Go to check item 3. 3 Disconnect harness connector, and then check dust adhesion to harness connector. Engine stopped X - X Clean terminal surface. 4 Check pin terminal bend. Engine stopped - - X Take out bend. 5 Reconnect harness connector and then recheck harness continuity at connector. Engine stopped X - - Replace terminal. 6 Tap harness connector or component during realtime diagnosis. During real-time diagnosis X X X If malfunction codes are displayed during real-time diagnosis, replace terminal. , LE.C.U. harness connector L Ignition coil and power transistor harness con nector SEF132H EF & EC-80 TROUBLE DIAGNOSES NOTE EF &. EC-81 TROUBLE DIAGNOSES Diagnostic Procedure CAUTION: 1. Before connecting or disconnecting the E.C.U. harness connector to or from any E.C.U., be sure to turn the ignition switch to the "OFF" position and disconnect the negative battery terminal in order not to damage E.C.U. as battery voltage is applied to E.C.U. even if ignition switch is turned off. Failure to do so may damage the E.C.U. SEF289H 2. When performing E.C.U. input/output signal inspection, remove connector protector to insert tester probe into connector. SEF290H 3. When connecting or disconnecting pin connectors into or from E.C.U., take care not to damage pin terminals. 4. Make sure that there are not any bends or breaks on E.C.U. pin terminal, when connecting pin connectors. SEF291H 5. Before replacing E.C.U., perform E.C.U. input/output signal inspection and make sure whether the E.C.U. unit functions properly or not. (See page EF & EC-142.) SEF330D 6. After performing this "Diagnostic Procedure", E.C.C.S. self-diagnosis and driving test. SEF292H EF & EC-82 perform TROUBLE DIAGNOSES Diagnostic Procedure (Cont'd) 7. When measuring E.C.U. controlled components supply voltage with a circuit tester, separate one tester probe from the other. If the two tester probes accidentally make contact with each other during measurement, the circuit will be shorted, resulting in damage to the control unit power transistor. Solenoid valve SEF599D EF 8r. EC-83 ' TROUBLE DIAGNOSES Diagnostic Procedure 1 MAIN POWERSUPPLYAND GROUND CIRCUIT COMBINATION METER @ , With ~, Without head-up display head-up display CHECK ENGINE LIGHT CHECK ENGINE LIGHT I GNI T! ON SWITCH ON or START I 17o--@--<>I 6, FUSE BLOCK (Refer to "POWER SUPPL Y ROUT! NG" r-t 1:1 r.iiI ~ E. C. C S CONTR'OL' UNIT @ I Iii ~ ~ottt-O ~ tWh I te) 1""'00arness) 107-B.'--- G jI 108-B 'Fi'r;;n'\ (E. F. ~ -~ ~ CID G .. 12 I (~~strument @)eo@ 116-B 4-R/B 05 [rmef-H-iJ[gOO:!] In EL section.) @ ;; 2' 0---@ ~ ~~ ~ rness) J. harness) 6-B 13-B "II" EE ~I"I~ - @@ 24-R UTI harness) B/W~ ~~~~ine room 36-B/R 48-B '1! 1391481 @) ~~ @) E. ~ C. ~ ~@) ~ OFFACCON ST J J 1 J J 2 J 3 4 11m 5 \ link ~. EF & EC-84 ~ ~ ITiJ~ FUSIBLE LINK FUSE AND FUSI BLE LI NK (Jn RELAY BOX) S. I GNI T! ON SWITCH ~ BATTERY Component location I C. RELAY ENGINE GROUND /"BR;' fusible ~"G" fusible link ~~ .. @)lMJ 47-B/W '1: ~:~ .... 39-B "481391 Iffl :~:--,,:~:~ @@) 1111 ~.. ~ " SEF261H TROUBLE DIAGNOSES m "- INSPECTION START =' CHECK DIAGNOSTIC MODE ON THE E.C.U. Verify that diagnostic mode selector on the E.C.U. is turned "OFF". - ~ COMBINATION METER ~ GD~~ ..... >->. >- >- >- @"..QD ~ (Refer FUSE BLOCK to "POWER ~ SUPPL E. C. C. S. 8S7iROL @ Y ROUT I NG" @@ I In EL sect Ion.) 8 r-=-. @@ ~ 11 @~<§) .~o BODY GROUND G G Y/8 Y/l ".II,~. y/G (E. F. (Main) I. harness) , , ... .. >- >- harness : @D - Y/8 Y/G (jnstru nt harnes~f ~ ~ age f Y/l Y/8~ >- (Eng I Ine room harness) I 3'- Y/l ffi..ffi ". \;t!:: Y/l ' , >- ~ ->- @:D~ @ ~, , With heed-up display Without EF head-up & display EC-92 ~ SPEED SENSOR SE F224H TROUBLE DIAGNOSES INSPECTION START PI - Is speedometer working No properly? Yes CHECK VEHICLE SPEED SENSOR AND SPEEDOMETER UNIT. (See EL section.) PI SEF804F Ii] II ClUNIT ~i5 &a SEF151H §]CONNECTORII 32 [ill CHECK INPUT SIGNAL. 1) Perform switch ON/OFF diagnosis (in Mode IV). 2) Make sure green inspection lamp on E.C.U. comes "ON" when vehicle speed reaches 20 km/h (12 MPH). , N.G. O.K. ( INSPECTION END Ii] CHECK CONTINUITY BETWEEN E.C.U. AND VEHICLE SPEED SENSOR. 1) Turn ignition switch "OFF". 2) Disconnect E.C.U. harness connector. 3) Check continuity between E.C.U. terminal @ and ground by rotating rear wheel by hand. Continuity should come and go. N.G. Repair or replace harness or connectors. O.K. Reinstall any part removed. Erase the self-diagnosis memory. Make sure Code No. 55 is displayed in Mode III. 1) Perform switch ON/OFF diagnosis (in Mode IV) again. 2) Make sure green inspection lamp on E.C.U. comes "ON" when vehicle speed reaches 20 km/h (12 MPH). O.K. INSPECTION END EF & EC-93 N.G. 1) Perform self-diagnosis and find malfunction code. 2) According to displayed code No., perform diagnosis. ) TROUBLE DIAGNOSES Diagnostic Procedure 6 IGNITION SIGNAL (Code No. 21) E. C.C.S. CONTROL UNIT @ r.11;:t p:leJ ~ FUSE AND FUSI BlE LI NK I B/R~ I I I I -w ~B/R ," , I I I I I I "" "" "" " ,, :I ': I" ~ III @)L8 @)i - i@) . . ENGINE GROUND ~ 1111 ~'" "''\ FUSIBLE LINK f1 IGNITION " III ~ ~~ @I~ G ii ~ ~@ III ~~ I G cn @)g ," I ," , " i:I I I '" fJ @) LQ '" '\ ~111~ ~ ~mm[i] 1Ir!1 III ([@~ DISTRIBUTOR ~ ij . POWER TRANSISTOR CONDENSER RESISTOR BATTERY ~ - - - SPARK PLUG 111] 1 2 3 4 5 OFFACe ON ST c 0 C :J 0 I GNI TI ON SWITCH SEF225H Componentlocation l SE F34 7H EF & EC-94 TROUBLE DIAGNOSES ".. mLit~ CGIIBT 00 Battery ---. ID e SEF370H ~ ~i5 O.K. CCNECTOR II SEF444H [!] CHECK E.C.U. INPUT LINE. 1) Stop engine. 2) Disconnect harness con. nectors from power transistor and E.C.U. 3) Check continuity between terminals @ and @. Continuity should exist. If N.G., check following. 8 Resistor 8 Harness or connector Ii] [!] ~i5 ~Jur CHECK E.C.U. INPUT SIGNAL (Power transistor side). 1) Start engine. 2) Verify that pulse signal exists between power transistr harness connector terminal @ and ground with logic probe. Pulse signal should exist. N.G. [ill n ./ I ~ IE) ...., INSPECTION START CHECK E.C.U. OUTPUT SIGNAL (Power transistor side). Verify that pulse signal exists between power transistor harness connector terminal @ and ground with logic probe. Pulse signal should exist. CGIIBT N.G. CHECK E.C.U. OUTPUT SIGNAL (E.C.U. side). Verify that pulse signal exists between E.C.U. harness con- nectorterminal CD andground with logic probe. Pulse signal should exist. If N.G., check the E.C.U. pin terminals for damage or the E.C.U. harness connection. O.K. lo.K. 00 1$ 81 ID I' Repair harness, connector, or resistor between terminals @ and CD. e SEF152H Ii] ~[ ~ 00. ClUNIT 1 '8 CONNECTOR II CONIIECT tID Battery e Logic probe II CHECK POWER SUPPLY. 1) Stop engine. 2) Disconnect harness connector from ignition coil. 3) Turn ignition switch "ON". 4) Check voltage between ignition coil harness connector terminal @ and ground. Battery voltage should exist. O.K. SEF153H 00 Ii!lCoili~i5 w ~ ::E ~ SEF154H E EF & EC-95 N.G. - CHECK HARNESSCONTINUITY BETWEEN BATTERY AND IGNITION COIL. Check the following items. 8 Harness 8 "G" fusible link 8 Ignition switch TROUBLE DIAGNOSES Ii ffi cilltv~i5 Ii [ill ~i5~ SEF366H [!1 cillE>~i5~ [!1 [ill SEF156.H CHECK HARNESS CONTINUITY BETWEEN IGNITION COIL AND POWER TRANSISTOR. 1) Turn ignition switch "OF F". 2) Disconnect power transistor harness connector. 3) Che9k continuity between ignition coil harness connector terminal @ and power transistor harness connector terminal @. -=- N.G. Repair or replace harness between @ and @. O.K. CHECK GROUND CIRCUIT. Check continuity between power transistor harness connector terminal @ and ground. Continuity should exist. N.G. 1) Repair harness or connectors. I 2) Check continuity. 3) Check engine ground. O.K. CHECK COMPONENTS. Check ignition coil and power transistor. (See page EF & EC-148.) N.G. Replace ignition coil or power transistor. O.K. Reinstall any part removed. Erase the self-diagnosis memory. Perform driving test and then perform self-diagnosisagain. O.K. INSPECTION END EF & EC-96 N.G. 1) Perform E.C.U. input/output signal inspection test. 2) If N.G.. recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector. TROUBLE DIAGNOSES NOTE EF & EC-97 TROUBLE DIAGNOSES Diagnostic Procedure 7 ENGINE CONTROL UNIT (Code No. 31)Q INSPECTIONSTART 1) Turn ignition switch "ON". 2) Erasethe self-diagnosis memory. Perform self-diagnosis again. Yes Does E.C.U. display Code No. 31 again? Replace E.C.U. No ( INSPECTION END EF & EC-98 ) TROUBLE DIAGNOSES NOTE EF & EC-99 TROUBLE DIAGNOSES E.G.R. FUNCTION (CodeNo. 32) Diagnostic Procedure 8 Q [Not self-diagnosticitem (For non-California models)) E.G.R. CONTROL SOLENOID VALVE 81 E. C. C. s. CONTROL UNIT @ P ~ @)W -<> Ii] "'II:: ...I" 105- ] LG FUSE till @@) B/R (E. F. I. harness) (Eng I ne room harness) 8R-' '-B BR W G w B~ ~ .. ~ (ill) [IJI 1 2 3 4 5 J C :J ( c I GNITI ON SWITCH FUS Bt~D LI NK F~SI RELA Y BOJO Un =~~ BATTERY EF & EC-100 ~ FUSIBLE LINK @)Q OFFACC ON ST ~ ~:~ ~ ~ ~ R SE F269H TROUBLE DIAGNOSES m INSPECTION START m Responds ( CHECK E.G.R. CONTROL VALVE OPERATION. 1) Start engine and warm it up sufficiently. 2) Make sure E.G.R. control valvespring responds to your touch (use your fingers) and also when engine is raced. SEF445H Ii] INSPECTION END / Does not respond Ii] CHECK VACUUM SOURCE TO E.G.R. CONTROL VALVE. 1) Stop engine. 2) Disconnect vacuum hose connected to E.G.R. control valve and B.P.T. valve. 3) Start engine. 4) Make sure vacuum exists when racing engine. SEF157H [i ~- ~~ Clagg'og =='-- .:C\ CHECK VACUUM HOSE. 1) Stop engine. 2) Check vacuum hose for clogging, cracks, and proper connections. SEF816F N.G. Replace E.G.R. control valve. N.G. O.K. Ii] If necessary, replace vacuum hose or reconnect vacuum hose firmly. Ii] CHECK E.C.U. OUTPUT SIGNAL (Solenoid side). 1) Start engine and warm it up sufficiently. 2) Check voltage betwen E.G.R. control solenoid valve harness connector terminal @ and ground. CONNECT £) 001 trJ C.f'H 100 SEF158H Engine condition Idle (I II CONNECT C;'UNI T 105 §f CONNECTOR II tD Racing Voltage Battery voltage Temporarily drops to 0 - 1 V O.K. £) 00 (I . I ! I . Improperconnection ~ "" , CHECK COMPONENT. Check E.G.R. control valve. (See page EF & EC-148J N.G. [i ~ O.K. N.G. CHECK E.C.U. OUTPUT SIGNAL (E.C.U. side). Check voltage between E.C.U. harness connector terminal @) and ground. Engine condition Idle Raci ng Voltage Battery voltage Temporarily dropstoO-1V If N.G., check the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector. O.K. UW Repair harness or connectors between terminals @ and @. C.f'H SEF159H EF &. EC-101 ) TROUBLE DIAGNOSES Ii 1 Test condition Drive vehicle under the following conditions with a suitable shift position. . Engine speed: 3,100:1:300 3,000:1:400 . rpm (AfT) rpm (MfT) Intake manifold vacuum: -42.7:1:8.0kPa (-320:1:60 mmHg, -12.60:1:2.36 CHECK COMPONENT. 1) Stop engine. 2) Check E.G.R. control solenoid valve. (See page EF & EC-149J inHg) Driving mode Test condition 16 seconds or more @ N.G. Replace E.G.R. control solenoid valve. O.K. CHECK COMPONENT. Check E.G.R. control valveand B.P.T. valve. (See page EF & EC-148J Vehicle driving N.G. Valve spring may be stuck. Clean if necessary. If this does not correct trouble, replace E.G. R. control valve. O.K. For non-California O.K. For California INSPECTION END Idling ----. Ignition'JLj Time switch: I IC)) 0 F F -+-t----Until green and red inspection lamps go off. CD Start engine and warm it up sufficiently. @ Turn off ignition switch and keep it off until green and red inspection lamps go off. CID Start engine and make sure that air conditioner switch and rear defogger are turned "OFF" during driving test. @ Shift to suitable gear position and drive in "Test condition" for at least 16 seconds. CID Decrease engine revolution to less than 2,000 rpm. @ Repeat steps @ through CID at least 1 time. SEF037H [!1 Check resistance of exhaust gas temperature sensor. (See page EF & EC-149.) Reinstall any part removed. Erase the self-diagnosis memory. Make sure Code No. 55 is displayed in Mode III. Ii Perform driving test under the following conditions. 1) Warm up engine sufficiently. 2) Use test driving modes indicated in figure Ii. ~~E~ [!1 CHECK ENGINE LIGHT SEF924F Comes Make sure check engine light does I"ON" not come "ON" during driving test. Does not come "ON" INSPECTION END EF & EC-102 Perform self-diagnosis and find malfunction code. According to displayed code No., perform diagnosis. TROUBLE DIAGNOSES NOTE EF &. EC-103 TROUBLE DIAGNOSES Diagnostic Procedure 9 ~ EXHAUST GAS SENSOR (CodeNo. 33) E. C. c. S. CONTROL UNIT (E. F. 1harness) 19-W :~: nnn ,m ii nnnnnnnnn_nn I I I I I I I mmmm m__m m I I I I I I I 1:_' m_:::::::::~I ~ (ill) @-=<> Ii] 0 m i@ "::" EXHAUST GAS SENSOR ENGINE GROUND SEF226H Component location EF & EC-104 TROUBLE DIAGNOSES m ~ INSPECTION START ':) m ([IT)) SEF153D I;] I;] .-cT eJ II ~IT ~ = [ill connector '8 CONNECTOR II 19 Exheust ges sensor O.K. INSPECTION END CHECK INPUT SIGNAL. 1) Start engine and warm it up sufficiently. 2) Make sure green inspection lamp on E.C.U. blinks at 2,000 rpm. ~ .-cT eJ ~ SEF446H N.G. N.G. CHECK EXHAUST GAS SENSOR CIRCUIT. 1) Stop engine. 2) Disconnect E.C.U. harness connector. 3) Disconnect exhaust gas sensor harness connector. 4) Connect a jumper wire from exhaust gas sensor harness connector to ground. 5) Check continuity between E.C.U. harness connector terminal @ and ground. Continuity should exist. Repair or replace harness. O.K. Replace exhaust gas sensor. Reinstall any part removed. Erase the self-diagnosis memory. Make sure Code No. 55 is displayed in Mode III. 1) Start engine and warm it up sufficiently. 2) Set diagnosis mode to Mode I. 3) Makesure that green inspection lamp on E.C.U. goes on and off periodically more than 5 times during 10 seconds at 2,000 rpm. O.K. INSPECTION END EF & EC-105 N.G. . Perform IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATION INSPECTION. (See page EF & EC-26J TROUBLE DIAGNOSES Diagnostic Procedure 10 EXHAUST GAS TEMPERATURE SENSOR (CodeNo. 35) ~ E. C. c. S. CONTROL f'"F2I UNI T ~ (E. F. 1harness) 8-R/L @ @ (Eng I ne room R/~j t:/L 21-8 @ harness) @ (Eng I ne harness room no. 2) R/L]tiJ ~R/LI< <1881mB I:IR/~::ft) ~~/LII: @@ ..J "aiD< F7 m Ii1[!] @E)Q?~ ~ 1i1[!] 0 :A/T mode I @ :M/T model ~ EXHAUST GAS TEMPERATURE SENSOR SEF204H Component location A/T mOde; (/- /rv SEF~73H EF & EC-106 TROUBLE DIAGNOSES INSPECTION START m~~ m CONNECT £) [Y] ~ :+: ~0 I~~ H SEF201 Ii) ~~i5 CHECK INPUT SIGNAL (Exhaust gas temperature sensor side). 1) Start engine and warm it up sufficiently. 2) Keep engine speed at approximately 2,000 rpm. 3) Check voltage between exhaust gas temperature sensor harness connector terminal @ and ground under the following conditions. [ill Condition '+:. ,- 00 ~i{)u [i ~ Voltage Wh~n vacuum is not applied to E.G.R. control valve ~ CIUN!:!:8COtNECTOR When vacuum II applied control SEF202H ~i5 1.0- 2.0V is 0 - 1.0V to E.G.R. valve A sufficient vacuum applied with a hand vacuum pump may cause the engine to stall. [ill N.G. Ii) '+ 00 ~i5u O.K. EBEB , CHECK HARNESS CONTINUITY BETWEEN E.C.U. AND EXHAUST GAS TEMPERATURE SENSOR. 1) Stop engine. 2) Disconnect E.C.U. harness connector. 21 ClUNIT :EI CONNECTORII SEF203H 3) Disconnect N.G. 1) Check harness and middle harness connector connection between terminals @ and @. 2) If necessary, repair or replace harness. exhaust gas temperature sensor harness connector. 4) Check continuity between 'terminals @ and @. Continuity should exist. [i O.K. CHECK GROUND CIRCUIT. Check continuity between terminals @ and @. Continuity should exist. O.K. EB EF & EC..'07 N.G. 1) Check middle harness connector connection. 2) If necessary, repair or replace harness. TROUBLE DIAGNOSES CHECK COMPONENTS. Check exhaust gas temperature sensor. (See page EF & EC-149.) N.G. Replace exhaust gas temperature sensor. O.K. Reinstall any part removed. Erase the self-diagnosis memory. Make sure Code No. 55 is displayed in Mode III. Perform driving test, then perform self-diagnosis. .....-O.K. INSPECTION END EF & EC-108 N.G. 1) Perform E.C.U. input/output signal inspection test. 2) If N.G., recheck the E.C.U. pin terminals for damageor the connection of E.C.U. harnessconnector. TROUBLE DIAGNOSES NOTE EF & EC-109 TROUBLE DIAGNOSES THROTTLESENSOR (Code No. 43) ~ Diagnostic Procedure 11 E. C.c. S. CONTROL f- FUSE m (E. F. 1. harness) JI OR (Ma In h arness ) rnJ OR ~ , m >- @ S. M. J. ~efer to last age (FoIdout page). f @]) ~nglne room harnes~ w w : BR~ ... ~ cD >- , m ~:~ ~~ @) I , m >- 34-0R ~ ~~ ~ @)g ~ , FUSIBLE LINK FUSE AND FUS I BlE LI NK (In RElA Y BOX) 1m OFFACC ON ST c 0 I c 0 2 0 3 4 5 I GNITI ON SWITCH ~ - BATTERY SEF214H EF & EC-118 TROUBLE DIAGNOSES - m II CAJNIT lit is INSPECTION START 8 CONNECTORII Perform switch ON/OFF diagnosis (in Mode IV). 34 m 00 SEF213H INSPECTION END N.G. CHECK INPUT SIGNAL. 1) Turn ignition switch "START". 2) Check voltage between terminal @ and ground. Battery voltage should exist. If N.G., repair harness and connectors. O.K. INSPECTION END EF & EC-119 N.G. Check the following items. 1) "G" fusible link 2) Ignition switch 3) Middle harness connector TROUBLE DIAGNOSES Diagnostic Procedure 15 FUEL PUMP (Not self-diagnosticitem) FUEL PUMP E. C.C.S. CONTROL~ UNIT @~.... r=I r=I G;J ..?7 iii Inl @J){i@5) IU-8/P rffi3l~ >- BODY GROUND 107-8 .. --1 , .. I >- ,.. @ (E. F. 1. 0 harness) @@ -- (Ma I n harness) FUSE S.M.J. m, >.. 8/R (Eng I ne room harness) 8/P-ffi. .tB- 8/P 8/Y~ 8/W ~8/Y w ,.. ~ >- , .... £@) @Y~ ,~ .... ~~ @lMJ IIlnii if Ifm FUEL PUMP RELAY AIR REGULATOR III ~:~ ~ ~ \!!!I 1 2 3 4 5 SEF268H g EF & EC-120 ~ I FUSI LI NKBlE FUSE AND FUSI BlE LI NK (I n RElA Y BOX) ~ BATTERY Component location ~ [DJ~ @)Q OFFACC N ST I GNI TI ON SWITCH 8~ I' 0: ~ ~ page [Refer to 'ast (Fa I dout page).) SEF236H TROUBLE DIAGNOSES INSPECTION START m~~ ~tttill1 m i5 [Y] ~ (2J SEF264H I!J . CHECK POWER SUPPLY ~~_r IImtalV (Fuel pump side). 1) Disconnect fuel pump harness connector. 2) Turn ignition switch "ON". 3) Check voltage between terminal @ and ground. Battery voltage indication should appear for 5 seconds after turning ignition switch "ON". 00 L O.K. CHECK GROUND CIRCUIT. Check continuity between terminal @ and ground. Continuity should exist. If N.G., repair harness or connectors. [!J SEF266H [:iI .--r CHECK COMPON~NTS. 1) Turn ignition "OFF". 2) Check fuel pump. (See page EF & EC-149,) If N.G., replace fuel pump. I!J N.G. [ill [!J O.K. :filiL @"l)] 10 [Y] CHECK POWER SUPPLY (Relay side). 1) Turn ignition switch "OFF". 2.) Disconnect fuel pu,,",prelay. 3) Turn ignition switch "ON". 4) Check voltage between terminals @, @ and ground. Battery voltage should exist. N.G. CHECK HARNESSCONTINUITY BETWEEN BATTERYAND FUEL PUMP RELAY. Check following. . Harness or connectors . "BR" fusiblelink O.K. lZJOO Ii] ~ _r IV 00 = SE F377H illTI:0"'lII rnJ CHECK COMPONENTS. 1) Turn ignition "OFF". 2) Check fuel pump relay. (See page EF & EC-150,) Ii] i5[:i1~ SEF379H N.G. Replace fuel pump relay. O.K. CHECK HARNESS CONTINUITY. Check continuity between relay harnessconnectorterminal CD and fuel pump harness connector terminal @. O.K. EF & EC-121 N.G. Repair or replace harness or connectors between terminals CD and @. TROUBLE DIAGNOSES Ii CONNECT 104 If) 00 - IT B" CONNECTOR II l 0 SEF266H - Ii _r ~ ClUNrT §J CONNECTOR III/!.r:!:\ II 'liiV ~ 104 Ii CHECK E.C.U. OUTPUT SIGNAL (E.C.U.side). 1) Reconnect fuel pump harness connector and fuel pump relay. 2) Turn ignition switch "ON". 3) Check voltage between E.C.U. harness connector ~ and ground. Battery voltage indication should appear after 5 seconds. O.K. [ill 00 1211 4R3 SEF267H Ii INSPECTION END ~ _r N.G. CHECK HARNESS CONTINUITY. 1) Turn ignition switch "OFF". 2) Disconnect E.C.U. harness connector. 3) Check continuity between terminal (jQ!) and relay harness connector terminal @. Continuity should exist. If N.G., repair or replace harness and connectors between terminals ~ and @. O.K. Recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector. IV EF & EC-122 TROUBLE DIAGNOSES NOTE EF & EC-123 TROUBLE DIAGNOSES Diagnostic Procedure 16 , PRESSURE REGULATOR (P.R.) CONTROL SOLENOID VALVE (Not self-diagnostic item) PRESSURE REGULATOR CONTROL SOLENOID VALVE go~'T~;l UNIT @~ /7 [;] ~ @W~ml!J[;] LID ] I06-PU FUSE ~ 8/R @@) (E. F. 1. (Eng Ine room harness) harness) 8RJ 8R t8R (=m::~ I@l~~~~ ~ ~ ID I'\. OFFACC ON ST r 1 c ::> 2 ::> 3 4 5 I GNITI ON SWIT CH ~ FUSIBLE , LINK @)~ FUSE AND FUSI BLE LI NK -'" "CD FUSE @ @) ~nglne rnJ room harnes~ 8/R 8RJP '-BR 12-GY 8R ~. F. 1. harness) w w 8q] ~ ~:~ @) '" , ~ CD (illY~ 1m 1 2 3 4 5 OFFACC ON ST c c J J 1 GN1TI ON SWI TCH ~ @)~ I . ~ ~ [ll) FUSIBLE LINK FUSE AND FUSI BLE LI NK (1 n RELA Y BOX) ~BATTERY SEF231H Component location EF & EC-128 TROUBLE DIAGNOSES m INSPECTION START m eJ. CH ECK [Y] € L.::: - SEF227H 1!1 N.G. POWE R SOU RCE. 1) Disconnect S.C.V. control solenoid valve harness connector. 2) Turn ignition switch "ON". 3) Check voltage between terminal @ and ground. Battery voltage should exist. CHECK HARNESS CONTINUITY FOR POWER SOURCE. Check following. . "G" fusiblelink . Ignitionswitch . Harness O.K. CIIIIET £) 00 ID IJ l YJ . + CH SEF229H O.K. Ii) ~~i5 12 CAJN~ CONtECTaR II SEF230H Lass than "approx. 1,400 rpm 0.5 - 1.0V More than approx. 1,400 ';Pm Battery voltage CHECK HARNESS CONTINUITY BETWEEN SOLENOID AND E.C.U. 11 Stop engine. 2) Disconnect S.C.V. control solenoid valve harness connector and E.C.U. harness connector. 3) Check continuity between Voltage between terminal @ and grou nd Engine speed Replace S.C.V. control solenoid valve. [!J N.G. CHECK OUTPUT SIGNAL. 1) Reconnect S.C.V. control solenoid valveharness connector. 2) Start engine and warm it up sufficiently. 3) Check voltage between terminal @ and ground. [ID 00' ~i511 N.G. CHECKCOMPONENTS. 1) Turn ignition switch "OFF". 21 Check S.C.V. control solenoid valve. (See page EF & EC-149.) terminals @ and @ . Continuity should exist. If N.G., repair or replace harness or connector. O.K. 1) Perform E.C.U. input/output signal inspection test. (Terminal @) 2) If N.G., recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector. O.K. CHECK COMPONENT. Check swirl control valve actuator. (See and EF & EC-150.) page I O.K. ( INSPECTION END EF & EC-129 ) Replace swirl control valve or actuator. TROUBLE DIAGNOSES Diagnostic Procedure 19 AIR REGULATOR (Not self-diagnosticitem) FUEL PUMP E. C. C. S. CONTROL fM\ UNIT ~~~U8 ~ nil nil @D~@]) 10'-B/P ~~ 107-B BODY GROUND rffBl@) ... , .0 I (Ma I n harness) ... , .0 @ (E. F. r. harness) @iD -- GJ ... FUSE page ,.0 @@ B/P-ffi B/Y~ S. M. J. last (Fo I dout page).] ffiefer to ~ B/R (Eng I ne harness) room ffi-B/P ~B/Y B/W W BR~ I" 0: ,.. ;t [!]1]1i ... , .0.0 " S\ ".0.0 .0.0 @lMJ ...Q. @)£ d;fh m(;]1] WJ . ;1 . @i ENGINE FUEL PUMP RELAY ~~§UlA TOR GROUND ~~ ;t;t 1m OFF ACC ON ST :) :) 1 :J 2 3 4 5 I GNITI ON SWITCH 'I g EF & EC-130 ~ cn~ @)~ rru\ ~ I FUSI LI NKBlE FUSE AND FUSI BlE LI NK .J . 1!1[!J BATTERY '"a ,.J (Ma In harness) UP II: I FUSE BLOCK !Refer to 'POWER SUPPLY ROUTI NG' In EL section.) '" a I ,.J (ill) (E. F. 1. harness) G/Y~ ~G/Y L/G e:r w L/G [Refer (Fo I dout cD '" a ,.J ffi @@ ll-G/Y S. M.J. N :: to last page). r age !Eng I ne room harness) '" "", a >-"'0 ,.J '" "'.J.J @~ I. i@) AIR CONDI TI ONER RELAY ENGINE GROUND SEF270H Component location EF 8r. EC-136 TROUBLE DIAGNOSES m INSPECTION START \. m A/C .. CHECK INPUT SIGNAL. 1) Start PU engine and warm it CHECK IDLE SPEED WHEN AIR CONDITIONER SWITCH IS "ON". M/T: 1,OOO:t50rpm A/T: 1,OOO:t50rpm (at uN" range) If out of specification, adjust idle speed. (See page EF & EC-26J Yes up sufficiently. 2) Does engine revolution rise when air conditioner switch is turned "ON"? SEF129GI No r;] !f eJ I I I I Disconnect F.I.C.D. solenoid valve harness connector. 3) Turn ignition switch and air 2) 7 SEF447H -eJ , conditioner switch "ON". nal @ andground. 00 0 ClUNIT 11 8 1) Turn ignition switch "OFF". . N.G. ' I 7 I I CHECK COMPONENTS. 1) Turn ignition switc'.h .OFF" SEF448H £) HECKGROUNDCIRCUIT. Battery voltage should exist. rEIDl I II CONNECTOR II lEL JJ CHECK HARNESS CON- N.G. 2) Turn ignition switch "ON". 3) Check voltage between E.C.U. terminal (jJ) and ground. A/C switch ON Voltage 0.5 - 1.0V OFF Battery voltage INSPECTIONEND TINUITY BETWEEN BATTERYAND E.C.U. Check following. 8 Fuse 8 Ignition switch 8 Harness or connectors. I I O.K. Recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector. O.K. EF & EC-137 connectors. relay. CHECK OUTPUT SIGNAL. 1) Reconnect F.I.C.D.solenoid valveharness connector. C terminal @ andground. Continuityshouldexist. If N.G.,repairharnessor Replace air conditioner relay. O.K. I;] 2) Check continuity between I 2) Check (See HA air section.) conditioner IO.K. [i 4) Check voltage betWeentermi- 00 filii INSPECTIONEND CHECK COMPONENTS. Check F.I.C.D. solenoid valve. (See page EF & EC-151J If N.G., repair or replace F.I.C.D. solenoid valve. 1) Stop engine. [:it CONNECT O.K. CHECK POWERSOURCE. ilJ I;] ( r;] oo [i I O.K. ) TROUBLE DIAGNOSES Diagnostic Procedure 22 AIR INDUCTION VALVE (A.I.V.) CONTROL SOLENOID VALVE (Notself-diagnosticitem) E. C.c. s. CONTROLtf2) UNIT ~ ~ /' FUSE [i room harnes~ ~nglne P 102-P (E. F. 1. harness) ii @ B/R P ~ BR :req] @) G=I] G=I] [ll] (ill) FUSIBLE LINK FUSE AND FUSI BLE LI NK (1 n RELAY BOX) '" ,ID ~ '" lDo. @ (@)~ @)& 1m rims? ~ A. 1. V. CONTROL SOLENOID VALVE OFFACCON ST 1 0 C 2 c 3 4 5 IGNITION SWITCH BATTERY SEF234H Component location EF & EC-138 TROUBLE DIAGNOSES II INSPECTION START 18 II [Y] & m I;] SEF227H - N.G. CHECK POWER SOURCE. 1) Disconnect A.I.V. control solenoid valve harness connector. 2) Turn ignition switch "ON". 3) Check voltage between terminal @ and ground. Voltage: Battery voltage W CHECK HARNESSCONTINUITY BETWEENA.I.V. CONTROL SOLENOID VALVE AND BATTERY. Check harness or connector. O.K. COllECT if) ool tID , [!] @} CHECK COMPONENTS. ' N.G. 1) Turn ignition switch "OFF". 2) Check A.I.V. control solenoid valve. (See page EF & EC-149.) CYH l1t SEF229H i5 ~ ~ DlSCGltIlt:CT 102 1811 ClUNIT [!] N.G. CHECK OUTPUT SIGNAL. 1) Reconnect A.I.V. control solenoid valve harness connector. 2) Start engine and warm it up sufficiently. 3) Check voltage between terminal @ and ground. [ill ~ O.K. I;] Ef C~CTOR II Accelerator pedal position Released SEF233H Depressed Voltage 0.5 - 1.0V Battery voltage O.K. CHECK COMPONENT. Check air induction valve. (See page EF & EC-151.) , O.K. ( Replace A.I.V. control solenoid valve. INSPECTION END CHECK HARNESS CONTINUITY BETWEEN A.I.V. CONTROL SOLENOID VALVE AND E.C.U. 1) Stop engine. 2) Disconnect A.I.V. control solenoid valve harness connector. 3) Disconnect E.C.U.harness connector. 4) Check continuity between terminals @ and @. Continuity should exist. If N.G., repair harness or connector. N.G. ) 1) Perform E.C.U. input/output signal inspection test. 2) If N.G., recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector. Replace air induction valve. EF & EC-139 TROUBLE DIAGNOSES Diagnostic Procedure 23 NEUTRAL SWITCH, INHIBITOR E. C. c. S. CONTROL UNIT RELAY (Not self-diagnosticitem) I GNI T! ON SWITCH ON or START 0 @ SWITCH AND INHIBITOR @ @ @ :A/T model :M/T mode I :A/T model :A/T mode I without UP with .. A. S. C. D. FUSE BLOCK (Refer to "POWER SUPPL Y ROUT! NG" 1n EL sect Ion. ) A. S. C. D. @ I ...J ," (MaIn harness) [Refer @)@) S. M.J. to Iast (Fa I dout W-G/OR (~a~;"' I:Ss) 35- G/OR G/OR-Im j[[ ::r- 0: "ID ID m[l<==-~@) SWITCH - i5 [:it -ffi. .ffi.@83"~@3) r:=I ell B ~~~~ IJ M IDID J;!;II ~ 81 ~ B ,'" ...J room ~ no. 2) ~~ ~dP @) QJ 0 =arness G/ @) QD II 0: 0 ,"'ID lMJ@) L,WJ = I~I I NHI BI TOR I NHI BI TOR RELAY RELAY CSZJ OO(D " <> harnes~ G/OR @@) INHIBITOR f page). ," (Eng i ne A '0: 1;]81 m room --" 35 t ~ngine age I ...J -= SEF350H EF & EC-140 ft i@ -=-=-= @!@) BODY GROUND m~~ NEUTRAL SWITCH SEF246H TROUBLE DIAGNOSES INSPECTION START I;] ~[@b) IIISCOIIIlECT N.G. EO CHECK COMPONENTS. Check neutral switch (M/T) or inhibitor switch and inhibitor relay (A/T). (Seepage EF & EC-152.) [ill ~ m taEO~ [ill N.G. CHECK CONTINUITY BETWEEN SWITCH AND GROUND. I;] SEF243H M/T Check the following. . Harnesscontinuity . Fuse . S.M.J. model Check continuity between terminal @ and ground. [!J A/T model 1) Turn ignition switch "OFF". 2) Check continuity betWeen terminals @, CD and ground. Continuity should exist. (;] ~C@Th) IIISCOIIIlECT [ill EO ~ 35 r="' B Cf'UNI T CONNECTOR II SEF244H CHECK CONTINUITY BETWEEN SWITCH (M/T), RELAY (A/T) AND E.C.U. (;] M/T 131~ i5 00 131 " ~i5 NI T §T CONNECTOR For A/T model with A.S.C.D. model Check continuity between @ and @. 131A/T model Check continuity between inhibitor relay connector CDand @ @ and @. (A.S.C.D. model) Continuity should exist O.K. SEF245H II INSPECTION END ~; i5 ~ -~ n [ill ~ liI 35 SEF349H If N.G., repair or replace. N.G. Repair or replace harness or connector. O.K. i5~[[ I1Cf'U . , CHECK POWER SUPPLY FOR INHIBITOR SWITCH. 1) Turn ignition switch "ON". 2) Check voltage between terO.K. minal @ and ground. Battery voltage should exist. [!J ~~_IIECT~ O.K. (A/T) O.K. (M/T) SEF242H ~ Replace switch or relay. [ u ClUNJ T ~ CONNECTOR II IIISCOIIIlECT E0 EF &. EC-141 N.G. Repair or replace harness or connector. TROUBLE DIAGNOSES Electrical Components Inspection E.C.U. INPUTIOUTPUT SIGNAL INSPECTION E.C.U. Inspection table TERMI. NAL NO. ITEM *Dataare referencevalues. CONDITION *DATA 0.3 - 0.6V Ignition signal 1.2 - 1.5V Engine speed is 2,000 rpm 3 Ignition check 9 - 12V 0 -1V 4 Within approximately 1 second after turning ignition switch "OF F" E.C.C.S.relay (Mainrelay) BATTERY VOLTAGE (11.14V) For approximately 1 second after turning ignition switch "OFF" 8 Exhaustgastemperature I I sensor(Onlyfor California model) ,. 1.0 - 2.0V L Idle speed - - , , 0 -1.0V E.G.R. system is operating. Both A/Cswitchand blower 11 I Air conditioner relay I I 0 -1.0V switch are "ON" A/C switch is "OFF". BATTERY VOLTAGE (11.14V) 0 - 1.0V 12 S.C.V. control solenoid valve Engine speed is 2,000 rpm. EF & EC-142 BATTERY VOLTAGE (11 . 14V) TROUBLE DIAGNOSES Electrical Components Inspection (Cont'd) *Data are reference values. EF & EC-143 TROUBLE DIAGNOSES Electrical Components Inspection (Cont'd) *Data are reference values. TERMINAL NO. *DATA CONDITION ITEM OV Ignition switch "OFF" 36 Ignition switch BATTERY VOLTAGE (11 - 14V) 37 Throttle sensor power supply Approximately 38 47 Power supply for E.C.U. BATTERY VOLTAGE (11-14V) Both air conditioner switch and 41 I Air conditioner switch II u .~~o~ers~~~chlare "ON". I 5V OV I BATTERY VOLTAGE Air conditioner switch is "OFF". (11 - 14V) ne is running.1 S 43 I Power steering oil pressure switch I . 0.1 - 0.3V teenng wheel is being turned. I 11::11\:1"'1:: I~IUII'"II\:I.I . I Steenng wheel is not being turned. tch "ON" I 8-9V . I Approximately I 44 I Idle switch (EB side) Throttle valve: .idle position I I Ignnlon SWIl:cnVI'II I Throttle valve: Except idle position .. 45 15th position switch (M/T models) ~ G I ear ISIn 5th position. I I Ignl1lon SWltcn VI'll I 9 - 10V I I BATTERY VOLTAGE (11 - 14V) rOV I 6-8V Gear is except in 5th position. 46 I Power supply (Back-up) I I Ignition switch "OFF"I EF & EC-144 I BATTERY (11 - 14V) VOLTAGE TROUBLE DIAGNOSES Electrical Components Inspection (Cont' d) *Data are reference values. TERMI. NAL I CONDITION ITEM *DATA NO. Injector No.1 103 Injector No.3 BATTERY VOLTAGE (11.14V) Engine is running. 110 112 Injector No.2 I Injector No.4 0.1.0V 102 A.I.V. control solenoid valve BATTERY VOLTAGE (11.14V) Accelerator pedal is depressed. After warming up For 5 seconds after turning ignition switch "ON" 104 Fuel pump relay I Engine is running. 0.7.0.9V I " Within 5 seconds after turning ignition switch "ON" Engine is cold. Water temperature [ 0.7.0.9V is below 60°C (140°F). 105 E.G. R. control valve solenoid ] After warming up Water temperature BATTERY VOLTAGE (11.14V) BATTERY VOLTAGE (11.14V) is between 60°C (140°F) and 105°C [ (221°F). EF & EC-145 ] TROUBLE DIAGNOSES Electrical Components Inspection (Cont'd) *Data are reference values. TERMINAL NO. *DATA CONDITION ITEM 0 - 1.0V (for 3 minutes after ignition switch is turned off.) Stop and restart engine after warming it up. 106 Pressure regulator control solenoid valve Water temperature 90°C (194°F) is above BATTERY VOLTAGE (After 3 minutes) Stop and restart engine after warming it up. Water temperature 90°C (194°F) BATTERY VOLTAGE (11 - 14V) is below 7 -10V 113 A.A.C. valve Steering wheel is being turned. Air conditioner is operating. Rear defogger is "ON". Headlamps are in high position. E.C.U. PIN CONNECTOR 4-7V TERMINAL LAYOUT ~i) SEF419H EF & EC-146 TROUBLE DIAGNOSES Electrical Components Inspection (Cont'd) E.C.C.S. RELAY Check continuity between terminals = CID and CID. Condition Continuity 12V direct current supply between term inals CD and c:v Yes No supply No SEF054F CRANK ANGLE SENSOR 1. Remove distributor from engine. (crank angle sensor harness connector is connected.) 2. Turn ignition switch "ON", 3. Rotate crank angle sensor shaft slowly and check voltage between terminals @, @ and ground. SEF364H (I ~ 4. Visually check rotor plate for damage or dust. SEF176E AIR FLOW METER . Visually check hot wire air passage for dust. SEF365H ENGINE TEMPERATURE SENSOR Check engine temperature sensor resistance. Temperature °c (F) Resistance kQ 20 (68) 2.1 - 2.9 80 (176) 0.30 - 0.33 [ill SE F536H EF & EC-147 TROUBLE [ill DIAGNOSES Electrical Components Inspection IGNITION COIL Check ignition coil resistance. (Cont'd) Terminal Resistance @-@ Approximately O.7il SEF332H POWER TRANSISTOR [ill SEF333H Check continuity between power transistor terminals. Terminal No. Tester polarity @ EB @ 8 @ 8 @ EB @ EB @ 8 @ 8 @ EB Continuity No Yes No Yes E.G.R. CONTROL VALVE Apply vacuum to E.G.R.vacuum port with a hand vacuum pump. E.G.R. control valve spring should lift. SEF820F B.P.T. VALVE Plug one of two ports of B.P.T. valve. Apply a pressure above 0.490 kPa (50 mmH20, 1.97 inH2O) to check for leakage. If a leak is noted, replace valve. 13 t EC381A EF & EC~148 TROUBLE DIAGNOSES Electrical Components Inspection (Cont'd) E.G.R. CONTROL SOLENOID VALVE, A.I.V. CONTROL SOLENOID VALVE, P.R. CONTROL SOLENOID- VALVE AND S.C.V. CONTROL SOLENOID VALVE Check air passages continuity. Condition @ SEF335H 12V direct cu rrent supply between terminals CD Air passage continuity between @ and @ Air passage continuity between @ and @ Yes No No Yes and @ No supply EXHAUST GAS TEMPERATURE SENSOR Check resistance change and resistance value at 100°C (212°F). Resistance should decrease in response to temperature increase. Resistance: 100°C (212°F) 85.3 :t 8.53 k n . THROTTLE SENSOR Make sure that resistance between terminals changes when opening throttle valve manually. Resistance should change. FUEL PUMP Check continuity between terminals @ and @. Continuity should exist. EF & EC-149 @ and CD TROUBLE DIAGNOSES Electrical Components, Inspection (Cont'd) FUEL PUMP RELAY Check continuity between terminals = and @. Continuity Condition 12V direct current supply Yes betweenterminalsCID and @ No No supply - CD SEF537H INJECTORS . Check injector resistance. Resistance: Approximately 10 15n Remove injector and check nozzle for clogging. - . SWIRL CONTROL VALVE Supply vacuum to actuator and check swirl control valve operation. Condition Swirl control valve Supply vacuum to actuator Close No supply Open ------- ~ ~ SEF371H AIR REGULATOR . . Check air regulator resistance. Resistance: Approximately 75 n Check air regulator for clogging. [ill SEF339H A.A.C. VALVE Check A.A.C. valve resistance. Resistance: Approximately 10 n . SEF538H A~ve'--GV EF & EC-150 TROUBLE DIAGNOSES Electrical Components Inspection (Cont'd) Check plunger for seizure or sticking. .. Check springfor broken. SEF381H F.I.C.D. SOLENOID . VALVE Check that clicking sound is heard when applying 12V dirct current to terminals. SEF341H . Check plungerfor seizure or sticking. . L l:I"(~ Check for broken spring. ~ Plunger SEF342H AIR INDUCTION VALVE Apply vacuum to vacuum motor, suck or blow hose to make sure that air flows only towards the air induction side. IDLE SWITCH . Check continuity between moving throttle valve. terminals @ and Accelerator pedal condition Continuity Fully closed Yes Open No EF & EC-151 @ while TROUBLE DIAGNOSES Electrical Components Inspection (Co nt' d) NEUTRAL SWITCH . [:it b [ill c;JJ Check continuity between terminals @ and @. Conditions ~~ Continuity Shift to Neutral Yes Shift to other position No INHIBITOR SWITCH Check continuity between terminals @ and @. CD. Continuity between terminals @ and @ Continuity between terminals @ and CD Shift to "P" position Yes No Shift to "N" position No Yes Shift to positions other than "P" and "N" No No Conditions SEF344H INHIBITOR For A/T model without A.S.C.D. . RELAY Check continuity between terminals @ and CD (Without A.S.C.D.), @ and @ (With A.S.C.D.). Condition Battery 12V direct current supply between terminals SEF345H CD and W (WithoutA.S.C.D.), Continuity between terminals @ and @ (Without A.S.C.D.). @ and @ (With A.S.C.D.) Yes @ and CD (Without A.S.C.D.) For AlT model with A.S.C.D. [ill No supply Battery SEF348H EF & EC-152 No FUEL INJECTION CONTROL SYSTEM INSPECTION Releasing Fuel Pressure Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger. 1. Remove fuel pump fuse. 2. Start engine. 3. After engine stalls, crank it two or three times to release all fuel pressure. 4. Turn ignition switch off and reconnect fuel pump fuse. Fuel Pressure Pressure regulator Fuel pump and damper Fuel tank SEF892D SEF135H Check a. When reconnecting fuel line, always use new clamps. b. Make sure that clamp screw does not contact adjacent parts. c. Use a torque driver to tighten clamps. d. Use Pressure Gauge to check fuel pressure. e. Do not perform fuel pressure check while fuel pressure regulator control system is operating; otherwise, fuel pressure gauge might indicate incorrect readings. 1. Release fuel pressure to zero. 2. Disconnect fuel hose between fuel filter and fuel tube (engine side). 3. Install pressure gauge between fuel filter and fuel tube. 4. Start engine and check for fuel leakage. 5. Read the fuel pressure gauge indication. At idling: When fuel pressure regulator valve vacuum hose is connected. More than 226 kPa (2.3 kg/cm2, 33 psi) When fuel pressure regulator valve vacuum is disconnected. Approximately 294 kPa (3.0 kg/cm2, 43 psi) 6. Stop engine and disconnect fuel pressure regulator vacuum hose from intake manifold. 7. Plug intake manifold with a rubber cap. 8. Connect variable vacuum source to fuel pressure regulator. EF & EC-153 FUEL INJECTION CONTROL SYSTEM INSPECTION Fuel Pressure Check (Cont'd) 9. Start engine and read fuel pressure gauge indication as Vacuum Fuel pressu re . vacuum changes. Fuel pressure should decrease as vacuum increases. If results are unsatisfactory, replace fuel pressure regulator. to pressure regulator SEF718B Injector Removal and Installation 1. Release fuel pressure to zero. 2. Remove or disconnect the following: . . B.P.T. valve Fuel tube securing bolts 3. Remove injectors with. fuel tube assembly. 4. Remove injector from fuel tube. 5. Install injector as follows: 1) Clean exterior of injector tail piece. 2) Use new O-rings. CAUTION: After properly connecting injectors to fuel tube, check connection for fuel leakage. 6. Assemble injectors with fuel pipe to intake manifold. EF & EC-154 EVAPORATIVE EMISSION CONTROL SYSTEM Description Throttle chamber Vapor vent line Main purge orifice Purge control valve ~ - - Fuel tank () 0~ Carbon canister Q : Air .. : Fuelvapor SEC544A The evaporative emission control system is used to reduce hydrocarbons emitted to the atmosphere from the fuel system. This reduction of hydrocarbons is accomplished by activated charcoals in the carbon canister. The fuel vapor from the sealed fuel tank is led into the canister which contains activated carbon and the vapor is stored there when the engine is not running. The canister retains the fuel vapor until the canister is purged by the air drawn through the bottom of the canister to the intake manifold when the engine is running. When the engine runs at idle, the purge control valve is closed. Only a small amount of stored vapor flows into the intake manifold through the constant purge orifice. As the engine speed increases, and the throttle vacuum increases, the purge control valve opens and the vapor is sucked into the intake manifold through both the main purge orifice and the constant purge orifice. Q@ @c) Inspection CARBON CANISTER Check carbon canister as follows: @: Blow air and ensure that there is no leakage. @: Blow air and ensure that there is leakage. EF &. EC-155 EVAPORATIVE EMISSION Inspection CONTROL SYSTEM (Cont'd) FUELTANK VACUUM RELIEF VALVE 1. Wipe valve housing clean. 2. Inhale air through the cap. A slight resistance accompanied by valve clicks indicates that valve is in good mechanical condition. Note also that, by further inhaling air, the resistance should disappear with valve clicks. 3. If valve is clogged or if no resistance is felt, replace cap as an assembly. ~ SEC308A .. ~ Q .. Air Fuel vapor FUEL CHECK VALVE 1. Blow air through connector on fuel tank side. A considerable resistance should be felt and a portion of air flow should be directed toward the canister. 2. Blow air through connector on canister side. Air flow should be smoothly directed toward fuel tank. 3. If fuel check valve is suspected of not properly functioning in steps 1 and 2 above, replace it. SEC309A ~ - \ \ l' \ EF & EC-156 CRANKCASE EMISSION CONTROL SYSTEM Description Steel net Baffle plate - {t9t=R:/lL '--Seal u lBJ .. SEF156E C:? ~ .. type oil lever gauge : Fresh air : Blow-by gas This system returns blow-by gas to both the intake manifold and air cleaner. The positive crankcase ventilation (P.C.V.) valve is provided to conduct crankcase blow-by gas to the intake manifold. During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the P.C.V. valve. Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air. The ventilating air is then drawn from the air cleaner, through the hose connecting the air cleaner to rocker cover, into the crankcase. Under full-throttle condition, the manifold vacuum is insufficient to draw the blow-by flow through the valve, and its flow goes through the hose connection in the reverse direction. On vehicles with an excessively high blow-by some of the flow will go through the hose connection to the air cleaner under all conditions. Inspection P.C.V. (Positive Crankcase Ventilation) With engine running at idle, remove ventilation hose from P.C.V. valve; if valve is working properly, a hissing noise will be heard as air passes through it and a strong vacuum should be felt immediately when a finger is placed over valve inlet. SEC137A VENTILATION HOSE 1. Check hoses and hose connections for leaks. 2. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace. ET277 EF &. EC-157 , '1 SERVICE DATA AND SPECIFICATIONS General Specifications IGNITION TIMING IDLE SPEED °S.T.D.C. 15%2 M/T 750%50 rpm A/T 750%50 (in uNu position) Inspection and Adjustment , ENGINE TEMPERATURE SENSOR Thermistor resistance 20°C (68°F) 80°C (176°F) 2.1 -2.9 0.30 - 0.33 k11 IDLE SWITCH Engine speed when idle switch is changed from "OFF" to "ON" rpm FUEL PRESSURE at idling (Measuring point: between fuel filter and fuel pipe) Vacuum hose is connected kPa (kg/em' ,psi) Vacuum hose is disconnected kPa (kg/em' , psi) FUEL INJECTOR Coil resistance 11 AIR REGULATOR Resistance 11 M/T A/T 1,000% 150 1 ,000% 150 (in uN" position) Approximately 226 (2.3,33) Approx imately 294 (3.0,43) Approximately - 10 15 Approximately 75 EXHAUST GAS TEMPERATURE SENSOR 100°C (212°F) Therm istor resistance k11 85.3:t8.53 EF & EC-158 (S.D.S.) ENGINECONTROL, FUEL" EXHAUST SYSTEMS I FE SECTION ~~I~~~~!~ SYSTEM FE-2 FUEL SYSTEM '... EXHAUST SYSTEM FE-3 , . FE-4 - ENGINE CONTROL SYSTEM . . . .. Accelerator Control System When removing accelerator wire, make a mark to indicate lock nut's initial position. Check that throttle valve fully opens when accelerator pedal is fully depressed and that it returns to idle position when pedal is released. Adjust accelerator wire according to the following procedure. Tighten "adjusting nut" until "throttle drum" starts to move. From that position turn back "adjusting nut" 1.5 to 2 turns, and fasten it with a lock nut. Check accelerator control parts for improper contact with any adjacent parts. When connecting accelerator wire, be careful not to twist or scratch its inner wire. Lock nut tOJ 8 - 11 (0.8 -1.1,5.8 - 8.01 Adjusting nut tOJ8 -11 (0.8 -1.1,5.8 -8.01 A.S.C.D. actuator wire Adjusting nut tOJ3 -4 ~-. ,... . OA,22 -2..,\ .~.~ o:~ m Locknut - tOJ 8 12 (0.8 -1.2, 5.8 -8.7) Adjusting nut Accelerator pedal Accelerator wire bracket Throttle drum tOJ : N.m (kg-m, ft-Ibl SFE012A FE-2 FUEL SYSTEM WARNING: When replacing fuel line parts, be sure to observe the following: . Put a "CAUTION: INFLAMMABLE" sign in workshop. .. Do not smoke while servicing fuel system. Keep open flames and sparks away from work area. Be sure to disconnect battery ground cable before conducting operations. . Put drained fuel in an explosion-proof container and put licit on securely. CAUTION: . For electric fuel pump model, before disconnecting fuel hose, release fuel pressure from fuel line. Refer to "Fuel Filter Replacement" in MA section. .. Do not disconnect any fuel line unless absolutely necessary. Plug hose and pipe openings to prevent entry of dust or dirt. . Always replace O-ring and clamps with new ones. . Do not kink or twist hose and tube when they are installed. . Do not tighten hose clamps excessively to avoid damaging hoses. .. When installing fuel check valve, be careful of its designated direction. (Refer to section EF & EC.) Run engine and check for leaks at connections. tDJ 2.0 - 2.5 10.20 - 0.26' 1.4 -1.9) 7 ~ Fuel return hose U :"- l i . ~~~ I L! A ~26-36 12.7 - 3 7 20 - 27j , "-tDJ 3.2 - 4.310.33 - 0.44, 2.4 - 3.2) I ~ ! 26 -36 12.7 -3.7,20 -27) tDJ : N.m (kg-m, ft-Ib) SFE013A FE-3 EXHAUST SYSTEM CAUTION: . . . Always replace exhaust gaskets with new ones when disassembling. Check all tube connections for exhaust gas leaks, and entire system for unusual noises, with engine running. After installation, check that mounting brackets and mounting Insulator are free from undue stress. If any of above parts are not installed properly, excessive noise or vibration may be transmitted to vehicle body. Catalytic ~ conve'rter 13-16(1.3-1.6,9-121 ~ : N.m (kg.m, ft-Ib) SFE014A FE-4 CLUTCH I CL SECTION CONTENTS PRECAUTIONSAND PREPARATION , CL- 2 CLUTCH SYSTEM CL- 4 INSPECTION AND ADJUSTMENT CL- 5 HYDRAULICCLUTCH CONTROL ,. CL- 7 CLUTCH RELEASE MECHANISM CL-10 CLUTCH DISC AND CLUTCH COVER CL-12 SERVICE DATA AND SPECIFICATIONS (S.D.S.) CL-14 III PRECAUTIONS AND PREPARATION Precautions .. Recommended fluid is brake fluid "DOT 3". Never reuse drained brake fluid. Be careful not to splash brake fluid on painted areas. When removing and installing clutch piping, use Tool. . . . . ~ GG9431 0000 ( - Use new brake fluid to clean or wash all parts of master cylinder, operating cylinder and clutch damper. Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic system. ) SBR500 WARNING: After cleaning the clutch disc, wipe it with a dust collector. Do not use compressed air, Preparation SPECIAL SERVICE TOOLS Tool number (Kent-Moore No.) Tool name Description , ST20050010 ( ) Base plate ~ - . - ~"., . , ., :', ~'::.. . -,:, Inspecting diaphragm spring of clutch cover " ,.- : , , .'. :. ,',' :/. , ST20050100 ( ) Distance piece - GG9431 0000 ) ( Flare nut torque wrench - ST20600000 (J26366) Clutch aligning bar ST20050240 - ) ( Diaphragm spring adjusting wrench , = -@:j Inspecting diaphragm spring of clutch cover @~ . \!II ~m -~ Removing and installing each clutch piping t"' ==-p . Installing clutch cover and clutch disc ~ ~ ~ CL-2 Adjusting unevenness of diaphragm spring of clutch cover PRECAUTIONS AND PREPARATION Preparation (Cont'd) COMMERCIAL Tool name SERVICE TOOLS Description ~ Bearing puller Bearing drift a~ V CL-3 Removing release bearing a: 50 mm (1.97 In".mn, "I in) dia. be,,;n, r~ ~ ~f c 0 1/ , ,~ h ~ (1.6- 2.2,12- 161 ~~8-11 (0.8- 1.1,5.8-8.01 ~~ ~ ~ ~-- 16- 22 ~ Return spring ----",. Lock nut 12-15 (1.2-1.5,9-111 . Pedal stopper -~ ~ '~ 16-22(1_6-2.2,1 Clutch switch Pedalstopper 0 rI Release bearing ~ c'"";, p;" m~-// Clutch pedal EI(b) III (') r to) en I\) .A: N'm (kg-m, ft-Ib) EI Cb): Apply lithium-based grease including molybdenum disulphide. ~ . Clutch switch INSPECTION AND ADJUSTMENT Adjusting Clutch Pedal Pedal bracket Push rod Lock nut ~ 8 - 11 1/ Clutch switch or pedal stopper lock nut .- ~ . Clutch switch (0.8 -1.1, 5.8 - 8.0) 12.15 (1.2 .1.5,9.11) Pedal stopper 22 11.6.2.2,12 - 16) ).<" A \ ~ Pad 16 \ ~,"-' 1. Adjust pedal height with pedal stopper or clutch switch. Pedal height "H": 186 - 196 mm (7.32 - 7.72 in) 2. Adjust pedal free play with master cylinder push rod. Then tighten lock nut. Pedal free play "A": 1.0 - 3.0 mm (0.039 - 0.118 in) Pedal free play means the following total measured at position of pedal pad: Play due to clevis pin and clevis pin hole In clutch pedal. .. Playdue to piston and push rod. Dash lower panel Melt sheet A : N.m Ikg-m.ft-Ib) SCL323 - U.S.A. model only 3. Adjust clearance "C" between pedal stopper rubber and threaded end of clutch interlock switch while depressing clutch pedal fully. Clearance C: 1.0 - 2.0 mm (0.039 - 0.079 in) Clutch interlock switch SCL274 CL-5 INSPECTION AND ADJUSTMENT Bleeding Procedure Bleed air according to the following procedure. Clutch damper -+ Clutch operating cylinder Carefully monitor fluid level at master cylinder during bleeding operation. 1. Top up reservoir with recommended brake fluid. 2. Connect a transparent vinyl tube to air bleeder valve. 3. Fully depress clutch pedal several times. 4. With clutch pedal depressed, open bleeder valve to release air. 5. Close bleeder valve. . SCL288 6. Repeat steps 3 through 5 above until brake fluid flows from air bleeder valve without air bubbles. / SCL203 CL-6 HYDRAULIC CLUTCH CONTROL Clutch Master Cylinder Return spring Reservoir Piston assembly cap Reservoir Reservoir band Cylinder body EI @ Rubbing surface to piston assembly Dust cover lEI @ Stopper ring Packing . Apply brake fluid when assembling. Valvestopper Rubbing surface to push rod 0 ~ Push rod lEI @ Contact surface to piston assembly A 1.6 - 2.9 (0.16 - 0.3,1.1 - 2.21 . Remove this stopper, when removing piston and return spring. EI @ : Apply rubber grease. A: N.m (kg-m, ft-lbl SCL348 DISASSEMBLY AND ASSEMBLY Push piston into cylinder body with screwdriver when removing and installing valve stopper. . . . IJJJ.JJJJJJJJJj em -- -- Align groove of piston assembly and valve stopper when installing valve stopper. Check direction of piston cups. ~11J) Groove n SCL214 CL-7 HYDRAULIC CLUTCH CONTROL Clutch Master Cylinder (Cont'd) INSPECTION . . . . . Check cylinder and piston rubbing surface for uneven wear, rust or damage. Replace if necessary. Check piston with piston cup for wear or damage. Replace if necessary. Check return spring for wear or damage. Replace if necessary. Check reservoir for deformation or damage. Replace if necessary. Check dust cover for cracks, deformation or damage. Replace if necessary. Operating Cylinder ~ ~ l Piston assembly ~I Operating lEI @ cylinder Rubbing surface to piston assembly Piston spring Piston cup IEI@ lEI @ : Apply rubber grease. SCL356 INSPECTION . . . . Check rubbing surface of cylinder for wear, rust or damage. Replace if necessary. Check piston with piston cup for wear or damage. Replace if necessary. Check piston spring for wear or damage. Replace if necessary. Check dust cover for cracks, deformation or damage. Replace if necessary. CL-8 HYDRAULIC CLUTCH CONTROL Clutch Damper ~~I[';:': ~ \\ \ \ ~ L Bleeder screw ~ ..,., lEI @ Spring Piston cup EI ,.o.U-721 Rubbing surface to piston assembly @ Piston assembly Contact surface to piston assembly Damper rubber Damper EI @ cover EI @ : Apply rubber grease. ~: N.m (kg-m,ft-Ib) SCL363 INSPECTION Check cylinder and piston rubbing surface for uneven wear, rust or damage. Replace if necessary. Check damper rubber and piston cup for cracks, deformation or damage. Replace if necessary. . . CL-9 CLUTCH RELEASE MECHANISM c;7 ;6e:z . ~ :;:d'~"7 r~~~:~?~ m(Q m(Q --- ~ ~ ~ ~ ' Release sleeve Release bearing m (b): Apply lithium-based grease including molybdenum disulphide. SCL326 REMOVAL AND INSTAllATION Install retainer spring and holder spring. . ~-. -~ ~~!£) U)o///~.. -~- -. 10 (') .J SCL217 . Remove release bearing. CL145 . Install release bearing Drift SC L222 CL-10 with suitable drift. CLUTCH RELEASE MECHANISM INSPECTION . . Check release bearing to see that it rolls freely and is free from noise, cracks, pitting or wear. Replace if necessary. Check release sleeve and withdrawal lever rubbing surface for wear, rust or damage. Replace if necessary. LUBRICATION . Apply recommended grease to contact surface and rubbing surface. Too much lubricant might damage clutch disc facing. Pack this recess . IEEI(!): Apply lithium-based grease including mOlybdenum disulphide. SCL223 CL-11 CLUTCH DISC AND CLUTCH COVER m Cbi: Apply lithium-basedgreaseincluding molybdenum disulphide. SC L354 jJ . . ~ : i Clutch Disc INSPECTION Check clutch disc for wear of facing. Wear limit of facing surface to rivet head: 0.3 mm (0.012 in) sa I E ! E C') ci SCL229 . . Check clutch disc for backlash of spline and runout of facing. Maximum backlash of spline (at outer edge of disc): 0.9 mm (0.035 in) Runout limit: 1.0 mm (0.039 in) Distance of runout check point (from hub center): 107.5 mm (4.23 in) Check clutch disc for burns, discoloration or oil or grease leakage. Replace if necessary. SCL221 INSTAllATION . Apply recommended grease to contact surface of spring portion. Too much lubricant CL-12 might damage clutch disc facing. CLUTCH DISC AND CLUTCH COVER Clutch Cover and Flywheel INSPECTION . . . . AND ADJUSTMENT Set Tool and check height and unevenness of diaphragm spring. Diaphragm spring height "A": 33.0 - 35.0 mm (1.299 - 1.378 in) Check thrust rings for wear or damage by shaking cover assembly and listening for chattering noise, or lightly hammering on rivets for a slightly cracked noise. Replace clutch cover assembly if necessary. Check pressure plate and clutch disc contact surface for slight burns or discoloration. Repair pressure plate with emery paper. Check pressure plate and clutch disc contact surface for deformation or damage. Replace if necessary. A SCL219 . ST20050240 H Adjust unevenness of diaphragm spring with Tool. Uneven limit: 0.7 mm (0.028 in) FLYWHEEL INSPECTION Flywheel . . Check contact surface of flywheel for slight discoloration. Repair flywheel with emery paper. Check flywheel runout. Runout (Total indicator reading): Less than 0.15 mm (0.0059 in) burns or SCL349 INSTAllATION /(c) ~ . Insert Tool into clutch disc hub when installing clutch cover and disc. Q)J CL-13 SERVICE DATA AND SPECIFICATIONS (S.O.S.) General Specifications . CLUTCH CONTROL SYSTEM CLUTCH DISC Hydraulic Type of clutch control Model CLUTCH MASTER CYLINDER Inner diemeter mm (In) CLUTCH OPERATING . Inner diameter mm (In) 15.87 (5/8) 225 LTD Facing size (Outer dia. x inner dia. x thickness) mm (in) 225 x 150 x 3.5 (8.86 x 5.91 x 0.138) Thickness of disc assembly With loed mm (in) 7.6.8.0 (0.299 - 0.315) with 5,394 N (550 kg, 1,213 Ib) CYLINDER 17.46 CLUTCH COVER (11/16) C225S Model CLUTCH DAMPER Inner diameter mm (in) Fuilioed N (kg,lb) 4.413 (450,992) 19.05 (3/4) Inspection and Adjustment CLUTCH COVER CLUTCH PEDAL Unit: mm (in) Unit: mm (in) Pedal height "H*" 186.196 Pedal free play (8acklash at clevis) 1.0 . 3.0 (0.039 .0.118) Clearence between pedel stopper rubber and threeded end of clutch interlock Model (7.32.7.72) Diaphragm 1.0-2.0 (0.039.0.079) CLUTCH DISC Unit: mm (In) 225L TD Wear limit of facing surface to rivet heed 0.3 (0.012) Aunout limit of facing 1.0 (0.039) Distance of runout check point (from the hub center) Maximum beck lash of spline (at outer edge of disc) spring height Uneven limit of diaphragm spring toe height *: Measured from surfece of melt sheet to pedal ped Model C225S 107.5 (4.23) 0.9 (0.035) CL-14 33.0.36.0 (1299 - 1.378) 0.7 (0.028) MANUALTRANSMISSION . MT SECTION CONTENTS PREPARATION ON-VEHICLE SERVICE MT- 2 ""'"'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' MT- 4 REMOVAL AND INSTAllATION... MT- 5 MAJOR OVERHAUL MT- 6 DISASSEMBLY MT- 9 INSPECTION MT-14 ASSEMBLY MT-16 SERVICE DATA AND SPECIFICATIONS (S.O.S.) MT-26 - PREPARATION SPECIAL SERVICE TOOLS Tool number (Kent-Moore No.) Tool name Description 9 ~ ST2381 0001 ( - .. ) VW . .. Adapter setting plate KV31100401 ( - ) Transmission press stand ST23540000 (J25689-A) Pin punch ST22350000 (J25678-01 ) Drift ST23800000 (J25691-01) Drift Tightening mainshaft lock nut Removing and installing fork rod retaining pin ~ ST30031 000 (J22912-01 ) Puller ST22360002 (J25679-01 ) Drift Pressing counter gear and mainshaft w ~ ST22520000 (J26348) Wrench ST23860000 ( ) Drift Fixing adapter plate with gear assembly ~ 'Or;",~ Removing and installing 1st gear bushing Removing main drive gear bearing Measuring wear of baulk rings Installing counter drive gear mm11.50I.' do. ::: :mm (1.30 in)dia. Installing counter gear front and rear end bearings a: 29 mm (1.14 in) dia. b: 23 mm (0.91 in) dia. Installing O.D. gear bushing a: 34 mm (1.34 in) dia. b: 28 mm (1.10 in) die. Installing front cover oil seal a: 44 mm (1.73 in) dia. b: 31 mm (1.22 in) dia. MT-2 PREPARATION Tool number (Kent-Moore No.) Tool name ST33400001 (J26082) Drift ST33290001 (J25810-A) Puller Description ~ Installing rear oil seal a: 60 mm (2.36 in) dia. b: 47 mm (1.85 in) dia. Removing rear oil seal ~ ST30720000 ( ) Drift Install ing mainshaft ball bearing LS r~7mmC3'.3;")d'" ~ ST30613000 (J25742-3) Drift b: 55.5 mm (2.185 inl dia. Installing main drive gear bearing iJ a: 71.5 mm (2.815 in) dia. b: 47.5 mm (1.870 in) dia. ST33200000 (J26082) Drift a: 60 mm (2.36 in) dia. b: 44.5 mm 11.752 in) die. Installing counter rear bearing Installing 3rd & 4th synchronizer assembly COMMERCIAL SERVICE TOOL Tool name Description Puller Removing counter bearings, counter drive and O.D. gears ;!V/ MT-3 ON-VEHICLE SERVICE Replacing Rear Oil Seal REMOVAL INSTAllATION ~ST33400001 ,(J26082) SMT477A ~ ---- Check of Position Switch BACK-UPlAMP SWITCH Check continuity. . Gear position Continuity Reverse Yes Except reverse No NEUTRAL SWITCH . Check continuity. Gear position Continuity Neutral Yes Except neutral No SMT384B O.D. SWITCH . Check continuity. Gear position Continuity 5th Yes Except 5th No MT-4 REMOVAL AND INSTAllATION Removal . ~ ~ . .. . . . . Remove shift lever. Remove propeller shaft. - Refer to section PD. Insert plug into rear oil seal after removing propeller shaft. Be careful not to damage spline, sleeve yoke and rear oil seal, when removing propeller shaft. Support engine by placing a jack under oil pan. Do not place jack under oil pan drain plug. Remove transmission from engine. Support manual transmission, while removing it. Installation ~ @ SMT381 B . Tighten all transmission bolts. Bolt No. 1 2 3 4 Tightening torque N.m (kg-m,ft-Ib) 39 - 49 39 - 49 29 - 39 39 - 49 Gusset to engine MT-5 (4.0 - 5.0, 29 - 36) (4.0 - 5.0, 29 - 36) (3.0 - 4.0, 22 - 29) (4.0 - 5.0, 29 - 36) 29 - 39 (3.0 - 4.0, 22 - 29) Qmm(in) 70 60 30 25 (2.76) (2.36) (1.18) (0.98) - Neutral switch (OJ 20 29 (2.0 . 3.0, 14 22) r4 Thread - of bolts 3: -I I ~ Drain plug (OJ 25. 34 (2.5 . 3.5, 18 . 25) C/) (OJ: N'm (kg-m, s: -i w to (II to r4: ",. Apply reco genuine par equivalent. MAJOR OVERHAUL Gear Components Needle bearing --------------------- sh''''n''n~7i~-J .j " ~ \~~3ro&4Oh ~ . ~ , ~ hub-(:r - ~ :\ M // ~ "'"' r'/ ~ ~ ~ ' " " " " R) B , ~Q ;?j~) 1 ' ~~ ~ ~~ 0.0 ~~' . Snap ring Snapring* ~ " ~~MainShaftIOC~ Thrust l\\f'\'\J synchronizer N d , Shifting insert spring / ~ ~ ~ ' ,"~ b"dn. Sh,"on9i-" *"---4? , Ins~rt ""on. IU & 2n' S peedometer driveg ge I N"dI,""'''' ~ \ - ~ = ~~~' "'.JY ~ r jI ring (~)~J Mainshaft rear end bearin washe 1~.0 - 17.0, 101 - 123) no' .... (W "" n." 137.'.7 r IthoutT Countershaft I I R~I""',i... . (5th ge~r bushing WMh" * ~ Ow""w tOJ 98 . 127 0' ( ~ main gear aulk ever.ring counter gear ' ~ ;J ~ ~\1 10.0. 13.0, - 72.941 , /"< In~ ffi1a'n" / j 0.0. (5th) synchroni",,,, 'oJ' ' .-; I~ ffinn' r I W oo'ru" k" . "",,",'iw / ~~\ )j \ Coon'" .h,,, J front bearing Snap r',n, * ~"" J \\; \( r ~ .Y L , :"-- drive Counte gear'" t.. Sub -gear spring -(:r Sub-gear ub-gear bracke t S '- R R '- in. Reverse idler thrust R everse idler gear bearing r everse 'dl I er thrust washe ~,~ idl"oil .h." P y geer to geers synchronizers, .end be ,~heft., Ap * I: S e Iect with washer _mbllng. ", : Payatt ,proper thickness. WhM I'n'I : N'm (k g-m, entlonft-Ib) to"''''' its d' Irectlon. . SMT037B MT-7 Return Return spring ~ RM"';~~??\ If) - spring plug f.4 Thread ~ 20 29 (2.0 - 3.0, 14.221 of bolts - Bushing m Mating surfece to control lever Returnspring 'i Select check plunger Striking arm J Lockpin - /' <::A I ~- Striking lever I -I tDJ 9.12'°,9.'.., ~ ~ ., ( "V"@@ -25 . -101 tDJ MO"'.i 11,' " -~~.O, 1O. 131 1. . i1I ~; "2.0 ~, 1st & 2nd fork rod R...,";~ pl. ~ / @ / . ~ 2 ...8.7 i D TII,.., ofbo", CII",' boil ~-.. (1.9 - 2.5,1 "" 10 M12 bolt: 20. ~.o, 14.221 ~ ~ ~~;"';.. O SocketIE! @{ ~/ Chod< boil p'" CII"" "",.. I 00 rr@ \~ . 1 S,,'ki~ ,,'" --&../ s: r ~/ ;: ~ \ ~ ~ \ I Mating surface, to housing and control ~ I lever Spring C.."o' 110..'..--\ \ Interlock plunger Retainingpin ~/ ""; ~ ~ 3rd & 4th fork rod ~ ~ ""C' '6."",,d,..- I a.D. 3rd & 4th shift fork ~\Y/~~ II) s: -I w C» '-I C» a.D. & reverse fork rod ~ ~ ~T~ & reverse shift fork - ~ 49 59 (5 - 6, 36 - 431 ~ ~/ ~: N f.4 : Ap ge eq DISASSEMBLY Case Components 1. Remove rear extension. a. Remove control housing, check ball, return spring plug, select check plunger and return springs. SMT982 b. Remove rear extension by lightly tapping it. Soft hammer :r SMT320B 2. Remove front cover, gasket, shim of countershaft front bearing, and snap ring of main drive gear ball bearing. ') // 0~ SMT011 3. Remove transmission case by tapping lightly. TM753 4. Remove front cover oil seal. ,. ~. SMT035 MT-9 DISASSEMBLY Shift Control Components 1. Set up Tool on adapter plate. 2. Remove check ball plugs, check springs, and check balls. ST2381 0001 ( ) - TM754 3. Drive out retaining pins. Then drive out fork remove interlock balls. rods and ST23540000 (J25689-A) "" SMT984 4. Remove lever bracket securing bolt. 5. Draw out 3rd-4th fork rod. 6. Remove E-ring from 0.0. and reverse fork rod. MT -1 0 DISASSEMBLY Shift Control Components (Cont'd) 7. Draw out 0.0. and reverse fork shaft by rotating 0.0. and reverse bracket counterclockwise. . . .~ SMT792A ~ Gear Mainshaft bushing or _1 Gear Components EndPlaY 1. Before removiQg gears and shafts, measure each gear end play. Gear end play: Refer to S.D.S. If not within specification, disassemble and check contact surface of gear to hub, washer, bushing, needle bearing and shaft. ~,~ SMT025 2. Mesh 2nd and reverse gear, then draw out counter front bearing with suitable puller. 3. Remove snap ring and then remove sub-gear bracket, sub-gear spring and sub-gear. Suitable puller SMT174A 4. Draw out counter drive gear with main drive gear assembly with suitable puller. When drawing out main drive gear assembly, be careful not to drop pilot bearing and baulk ring. . 5. Remove rear side components gear. on mainshaft and counter a. Release staking on countershaft nut and mainshaft nut and loosen these nuts. Mainshaft nut: Left-hand thread MT -11 DISASSEMBLY Gear Components (Cont'd) b. Pull out 0.0. counter gear with bearing with suitable puller. c. Draw out reverse counter gear and spacer. d. Remove snap rings from reverse idler shaft and draw out reverse idler gear, thrust washers and reverse idler gear bearing. e. Remove speedometer drive gear and steel ball. Suitable puller f. g. h. i. j. k. Remove snap ring and pull out overdrive mainshaft bearing, then remove snap ring. Remove mainshaft nut. Remove steel roller and washer. Remove roller bearing and washer. Remove 0.0. main gear, needle bearing and baulk ring (0.0.). Remove 0.0. coupling sleeve, shifting inserts and shifting insert springs. SMT040B . I. Press out mainshaft and counter gear alternately. Make sure to alternate pressing of mainshaftand counter gear so as not to allow the frontsurface of one to contact the rear surface of the other. SMT751A 6. Remove front side components on mainshaft. a. Remove 1st gear washer and steel ball. b. Remove 1st main gear and 1st gear needle bearing. c. Press out 2nd main gear together with 1st gear bushing and 1st & 2nd synchronizer assembly. d. Remove mainshaft front snap ring. ST30031000 (J22912-01 ) SMT384A MT-12 DISASSEMBLY Gear Components (Cont'd) e. Press out 3rd main gear together with 3rd & 4th synchronizer assembly and 3rd gear needle bearing. SMT385A 7. Remove main drive gear bearing. a. Remove main drive gear snap ring and spacer. b. Press out main drive gear bearing. SMT420A MT -13 INSPECTION Shift Control Components Check contact surface and sliding surface for wear, scratches, projections or other damage. . ~ ~ 6 SMT137 Gear Components GEAR AND SHAFT .. Check shafts for cracks, wear or bending. Check gears for excessive wear, chips or cracks. SMT386A Counter gear SMT550A Shifting insert ~ - SYNCHRONIZERS . .. t . Check spline portion of coupling sleeves, hubs and gears for wear or cracks. Check baulk rings for cracks or deformation. Check shifting inserts for wear or deformation. Check insert springs for deformation. SMT387A MT -14 INSPECTION Gear Components . (Cont'd) Measure clearance between baulk ring and gear. Clearance between baulk ring and gear (1st, 3rd, main drive and O.D. baulk ring): Dimension Standard 1st 1.2 - 1.6 (0.047 - 0.063) 3rd and main drive 1.2 - 1.6 (0.047 - 0.063) a.D. 1.2 - 1.4 (0.047 - 0.055) Unit: mm (in) Wear limit 0.8 (0.031) SMT140 If the clearance is smaller than the wear limit, replace baulk ring. . Measure wear of 2nd baulk ring. a. Place baulk rings in position on synchronizer cone. b. While holding baulk rings against synchronizer cone as far as it will go, measure dimensions "A" and "B" bulk ring Inner\ 2nd a. Inner baulk ring. . hr onizer cone ~~r ST30031000 (J22912-01) SMT041 B ~ Unit: mm (in) ~Dial indicator ST30031OO0 (J22912-01 ) Dimension Standard A 0.6 - 1.1 (0.024 - 0.043) B 0.7 - 0.9 (0.028 - 0.035) Wear limit 0.2 (0.008) Outer baulk ring Feeler gauge ~ c. If dimension "A" or "B" replace baulk ring. is smaller than the wear limit, !5" B "" Synchronizer cone 2nd outer baulk ring SMT042B BEARINGS . Make sure bearings roll freely and are free from noise, crack, pitting or wear. SMT418A MT -1 5 ASSEMBL Y Gear Components Mainshaft ball bearing in adapter plate lJ') 1. Install bearings into case components. ST30720000 ( - ) Counter rear bearing in adapter plate ~"- ~ ~ 2. Assemble adapter plate parts. Install oil gutter on adapter plate and expand on rear side. . Upper ~ '* Front . Install bearing retainer. a.. Insert reverse shaft, then install bearing retainer. SMT028 b. Tighten each screw, then stake each at two points. MT-16 ASSEMBL Y Gear Components (Cont'd) 3. Install main drive gear bearing. a. Press main drive gear bearing. b. Install main drive gear spacer. c. Select proper main drive gear snap ring to minimize clearance of groove and install it. . Allowable clearance of groove: 0 - 0.13mm (0 - 0.0051 In) Main drive gear snap ring: Refer to S.D.S. SM T 426A 4. Assemble synchronizers. 1st & 2nd synchronizer . 1 ~Insert spring H ~ j Hub Ind coupling .leeve . Check coupling sleeve and synchronizer hub orientation. CoupJ.ing sleeve Front.id. SMT045B MT -1 7 ASSEMBL Y Gear Components (Cont'd) SMT046B SMT047B Coupling Synchronizer / ( / . 3rd & 4th synchronizer . 0.0. synchronizer sleeve hub - -, , ~ I Shi~t~g}l!sert O.D. (5th) synchronizer hub SMT095A 5. Install front side components on main shaft. a. Assemble 2nd main gear, needle bearing and 1st & 2nd synchronizer assembly, then press 1st gear bushing on mainshaft. b. Install 1st main gear. \ 1st gear thrust washer \ SMT752A MT -1 8 ASSEMBL Y Gear Components (Cont'd) c. Install steel ball and 1st gear washer. Apply multi-purpose grease to steel ball and 1st gear washer before installing. SMT403A 6. Install mainshaft and counter gear on adapter plate and main drive gear on mainshaft. a. Press mainshaft assembly to adapter plate with Tool. KV31100401 ( ) TM439 I b. Press counter gear into adapter plate with Tool. c. Install 3rd main gear and then press 3rd & 4th synchronizer assembly. ST33200000 (J26082) I KV31100401 ( ) \\ . Coupling Synchronizer / r / hub - --, ~ Pay attention to direction of 3rd & 4th synchronizer. sleeve , I Shi!ti~9_il}sert d. Install thrust washer on mainshaft and secure it with mainshaft front snap ring. Select proper snap ring to minimize clearance of groove in mainshaft. Allowable clearance of groove: 0 - 0.18mm (0 - 0.0071 in) Mainshaft front snap ring: Refer to S.D.S. e. Apply gear oil to mainshaft pilot bearing and install it on mainshaft. TM441 MT -1 9 ASSEMBLY Gear Components (Cont'd) f. Press counter drive gear with main drive gear with Tool. KV311OO401 ( ), - TM442 . Pay attention to direction of counter drive gear. Front. SMT620A g. Install sub-gear components. (1) Install sub-gear and sub-gear bracket on counter drive gear and then select proper snap ring to minimize clearance of groove in counter gear. Allowable clearance of groove: 0 - 0.18mm (0 - 0.0071 In) Counter drive gear snap ring: Refer to S.D.S. (2) Remove snap ring, sub-gear bracket and sub-gear from counter gear. (3) Reinstall sub-gear, sub-gear spring and sub-gear bracket. h. Install selected counter drive gear snap ring. TM366 i. Press counter gear front bearing onto counter gear. ST22360002 (J25679-01 ) KV311OO401 ( ) - TM443 MT-20 ASSEMBL Y Gear Components (Cont'd) 7. Install rear side components on mainshaft and counter gear. a. Install reverse idler gear to reverse idler shaft with spacers, snap rings and needle bearing. - Front I L-~ I TM451 . b. Install insert retainer and 0.0. synchronizer to mainshaft. Pay attention to direction of hub. 0.0. 15thl synchronizer hub SMT095A c. Install 0.0. gear bushing with Tool. d. Install 0.0. main gear and needle bearing. e. Install spacer, reverse counter gear and 0.0. counter gear. O.D. main gear and O.D. counter gear should be handled as a matched set. f. Install washer, roller bearing, steel roller and thrust washer. g. Tighten mainshaft lock nut temporarily. Always use new lock nut. Gear bushing . . SMT531 h. Install countershaft rear end bearing with Tool. SMT043 8. Mesh 2nd and reverse gears, then tighten mainshaft lock nut with Tool. ST22520000 IJ263481 SMTOO3A MT - 21 . ASSEMBLY Gear Components (Cont'd) . c Tool Use the left chart when deciding the reading torque. (Length of torque wrench vs. setting or reading torque) 9. Tighten countershaft lock nut. . Always use new lock nut. Torque wrench L m (ft) 0.10 m' (0.33 ft) N.m (ft-lbI ~ 157(kg-m) (16) (110) 147 (15) '" ::J c- o i '" '" a: 137 (100) f (14) 0.6 . SMTOO4A Mainshaft I (1.5) L: Length (2.0) of torque 0.7 I 0.8 m (2.5) (h) wrench 10. Stake mainshaft lock nut and countershaft punch. Countershaft lock nut with a 11. Measure gear end play. For the description, ASSEMBLY for Gear Components. refer to DIS- Shift Control Components Fork rod (1st & 2nd) Fork rod (3rd & 4th) Interlock plunger 1. Install shift rods, interlock plunger, interlock balls and check balls. Interlock ball SMT992 a. 1st-2nd shift fork SMT989 MT-22 ASSEMBL V Shift Control Components (Cont'd) b. 3rd-4th shift fork SMT990 c. a.D.-reverse shift fork or reverse shift fork. SMT991 2. Install 0.0. and reverse fork shaft by rotating 0.0. and reverse bracket clockwise. SMT791 A 3. Install E-ring on 0.0. and reverse fork rod. 4. Install lever bracket securing bolt. MT-23 ASSEMBLY Case Components 1. Install front cover oil seal. Apply multi-purpose grease to seal lip of 011seal before installing. . SMT036 2. Apply sealant to mating surface of transmission case. 3. Install gear assembly onto transmission case. SMT013 4. Install snap ring of main drive bearing. 5. Apply sealant to mating surface of adapter plate. 6. Install rear extension. MT-24 ASSEMBL Y Case Components (Cont'd) A: Distance from bearing surface to transmission @ case 7. Select counter front bearing shim. Counter front bearing shim: Refer to S.D.S. 8. Install gasket and front cover. 1 Transmission case 2 Counter gear front bearing 3 Counter gear TM371 9. Install return spring plugs, check ball, return springs and select check plunger. 10. Install control housing and gasket. SMT982 MT-25 SERVICE DATA AND SPECIFICATIONS (S.D.S) General Specifications Transmission model FS5W71C 5 Number of speeds Shift patern . Gear ratio Number of teeth Mainshaft Countershaft 5 2 I. R I 4 1st 2nd 3rd 4th O.D. Reverse 3.321 1.902 1.308 1.000 0.759 3.382 Drive 1st 2nd 3rd O.D. Reverse 22 33 27 26 21 36 Drive 1st 2nd 3rd O.D. Reverse 31 14 20 28 39 15 Reverse idler gear Remarks 3 Warner Synchromesh type Oil capacity 1 Q (US pt, Imp pt) 21 2.4 (5-1/8, 4-1/4) Sub-gear 0 Mainshaft braking mechanism 0 Double baulk ring type synchronizer 2nd synchronizer MT-26 SERVICE DATA AND SPECIFICATIONS (S.D.S) Inspection and Adjustment GEAR END PLAY Mainshaft front Gear End play Allowable clearance mm (in) 1st gear 0.31 -0.41 (0.0122 -0.0161) 2nd gear 0.11 -0.21 (0.0043 -0.0083) 3rd gear 0.11 -0.21 (0.0043 -0.0083) O.D. gear 0.24 - 0.41 (0.0094 CLEARANCE AND GEAR 0 -0.18 mm (0 -0.0071 in) Thickness mm (in) Part number 2.4 (0.094) 2.5 (0.098) 2.6 (0.102) - 0_01611 BETWEEN BAULK RING 32263-V5200 32263-V5201 32263-V5202 Mainshaft rear end bearing Allowable clearance 0 - 0.14 mm (0 - 0.0055 in) 1st, 3rd, main drive and O.D. baulk ring Thickness mm (in) Part number Unit: mm (in) Standard 1st 1.2-1.6 (0.047 - 0_063) 3rd and main drive 1.2 - 1.6 (0.047 - 0.0631 O.D. 1.2- 1.4 (0.047- 0.055) 1.1 1.2 1.3 1.4 Wear limit (0.043) (0.047) (0.0511 (0.055) 32228-20100 32228-20101 32228-20102 32228-20103 0.8 (0.031) Counter drive gear Allowable clearance 2nd baulk ring 0 -0.18 mm (0 -0.0071 in) Thickness mm (in) Unit: mm (in) Part number 1.4 (0.055) 1.5 (0.059) 1.6 (0.063) Outer baulk ring B 32215-E9000 32215-E9001 32215-E9002 AVAILABLE SHIMS Counter front bearing Inner baulk ring Synchronizer cone Dimension Standard A 0.6 - 1.1 (0.024 - 0.043) SMT0448 mm (in) CD @ Wear limit A: Distance from bearing surface to transmission case 0.2 (0.008) 1 Transmission case 2 Counter gear front bearing 3 Counter gear 0.7 - 0.9 B Unit: (0.028 - 0.035) TM371 Main drive gear bearing Allowable clearance Thickness mm (in) 1.73 1.80 1.87 1.94 2.01 2.08 (0.0681) (0.0709) (0.0736) (0.0764) (0.0791) (0.0819) Thickness of shim "A" AVAILABLE SNAP RINGS 4.52 -4.71 0 - 0.13 mm (0 - 0.0051 in) Part number 32204-78005 32204-78000 32204-78001 32204-78002 32204-78003 32204-78004 4.42 4.32 4.22 4.12 4.02 3.92 MT-27 (0.1780 -4.51 (0.1740 -4.41 (0.1701 -4.3110.1661 -4.21 (0.1622 -4.11 (0.1583 -4.01 (0.1543 -0.1854) -0.1776) -0.1736) -0.1697) -0.1657) -0.1618) - 0.1579) Part number Not necessary 0.1 0.2 0.3 0.4 0.5 0.6 (0.004) (0.008) (0.012) (0.016) (0.020) (0.024) 32218-V5000 32218-V5001 32218-V5002 32218-V5003 32218-V5004 32218-V5005 AUTOMATIC TRANSMISSION AT / SECTION / / CONTENTS PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-. . . . . . . . . . . . . . . . . . . .. ATPRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. AT- 3 AfT CONTROL DIAGRAM 4 2 AT- ON-VEHICLE SERVICE... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . AT- 7 TROUBLE DIAGNOSES REMOVAL AND INSTALLATION MAJOR OVERHAUL " AT- 11 AT- 85 AT- 86 DISASSEMBLY. . . ., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPAIR FOR COMPONENTPARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMB LY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT- SERVICE DATA AND SPECIFICATIONS (S.D.S.) AT-165 AT-101 AT -146 When you read wiring diagrams: Read GI section, "HOW TO READ WIRING DIAGRAMS". See EL section, "POWER SUPPLY ROUTING.. for power distribution circuit. When you perform trouble diagnoses, read GI section, "HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES". . . 90 - PREPARATION SPECIALSERVIC~ TOOLS Tool number (Kent-Moore No.) Tool name /f Description ST2505S001 (J25695-A) Oil pressure gauge set CD /CD CID ~ ~ ----@ ST25051001 - ( ) Oil pressure gauge @ ST25052000 ( - ' ) Hose CID Measuring line pressure ST25053000 - ( ) Joint pipe @ ST25054000 ( - ~.:. U!! " o/~~ ) Adapter CID ST25055000 - ( Adapter ) ST07870000 (J37068) Transmission case stand Disassembling and assembling AfT KV31102100 (J37065) Torque converter oneway clutch check tool Checking one-way clutch in torque converter ST25850000 (J25721-A) Sliding hammer Removing oil pump assembly ~ KV31102400 (J34285 and J34285-87) Clutch spring compressor Removing and installing clutch return springs. ~, 0 ST33200000 (J37067) Drift (J34291 ) Shim setting gauge set , a: 60 mm (2.36 in) dia. b: 44.5 mm (1.752 in) dia. ~ Ir;==:J ~T~t~~ 1?1/li ~~ AT-2 Installing oil pump housing oil seal Installing rear oil seal Selecting oil pump cover bearing race and oil pump thrust washer PRECAUTIONS . . . . . . ~ Service Notice Before proceeding with disassembly, thoroughIy clean the outside of the transmission. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter. Disassembly should be done in a clean work area. . It is very important to perform functional tests. whenever they are indicated. The valve body contains precision parts and requires extreme care when parts are removed and serviced. Place removed parts in order on a parts rack so they can be put back in the valve body in the same positions and sequences. Care . Use lint-free cloth or towels for .wiping parts will also prevent springs and small parts from clean. Common shop rags can leave fibers that could interfere with the operation of the transmission. When disassembling parts, place them in order in a parts rack so that they can be put back into the unit in their proper positions. All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or reassembly. Gaskets, seals and O-rings should be replaced. any time the transmission is disassembled. becoming scattered or lost. Properly installed valves, sleeves, plugs,~ will slide along their bores in the valve body under their own weight. Before assembly, apply a coat of recommended A.T.F. to all parts. Petroleum jelly may be applied to O-rings and seals and used to hold small bearings and washers in place during reassembly. Do not use grease. Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling. After overhaul, refill the transmission with new A.T.F. . . . ~ ) AT-3 ~ I Lock-up solenoid g , /'011 [cooler ~~~,~ L' relielvalve 9 lubrlcalion Modifier accunlulator / L~r ~ I~'ve lubrication I , II"Lr- m Pressure modifier valve m, I Ii ~ i ,' Servo changer valve converter /;;;'t "R" line pressure' check port ~~ Ii '- -- II=::II" I/) »~ ~ Co) m - 1 1 1 I I I I I I I I I I , L JlIT:Jill:JUL I=; Feedback accumulator piston ~~~~ ~:~ I J[ Pilot valve ~ Line pressure solenolo r II --'~ -J~ USh~ 1m;~~oiO A solenOIOB Z Overrun ~ -- - x n -- I I PRND21 I I "~" I J solenoid w r~ 'Manual ~~- valve AfT CONTROL DIAGRAM Electrical Control Chart - Vehicle signal ~ Speed sensor . Electrical singnal : Hydraulic pressure Vehicle signal Engine Overdrive switch Kickdown switch AfT Overdrive off indicator lamp Power supply Control signal' ---------r----I I Inhibitor switch I temperature I Fluid . sensor I I Revolution I sensor I Idle switch Full-throttle switch Throttle sensor Engine rpm signal Shift solenoid A Shift solenoid B Overrun clutch solenoid lock-up solenoid - - - - _.~ --------- L__-- AfT control unit SAT8178 Mechnical Operation Band servo Shift position Reverse clutch High clutch Forward clutch Overrun clutch 2nd apply 3rd re lease 4th apply Forward one-way clutch Low one-way clutch Low & reverse brake Lock-up p PARK N *4 2 1st 0 2nd 0 ., 0 0 0 *20 0 4th 0 0 *30 0 1st 0 2nd 0 1st 0 0 2nd 0 0 0 NEUTRAL .. . 3rd 1 * REVERSE 0 0 R D Remarks Automatic shift 1-2-3-4 . 0 . .. . 0 0 0 . Automaticshift 1-2 0 Locks (held stationary) in 1st speed 1 ..... 2 1. Operates when overdrive switch is set to "OFF". *2. Oil pressure is applied to both 2nd "apply" side and 3rd "release" side of band servo piston. However, because oil pressure area on the "release" side is greater than that on the "apply" side, brake band does not contract. *3. Oil pressure is applied to 4th "apply" side in condition *2 above, and brake band contracts. *4. A/T will not shift to 4th when overdriveswitch isset to "OFF" position. 0 . . Operates. 0 . Operates ~ . Operates during "progressive" acceleration. . Operates but does not affect power transmission. . Operates4l/llhen throttle opening is less than 1/16 but does not affect engine brake. e when throttle opening is less than 1/16. Engine brake activates. AT-5 /~ Lock-up piston Torque converter Converter housing Front planetary gear Transmission case ~ Rear planetary Forward gear clutch Brake band Forward one-way clutch Reverse clutch Low & reverse brake Overrun clutch High clutch Low one-way clu ~ I 0) \00 \0 \ 010 0 \ en :I> j I\J C1 III Input shaft Oil pumlJ Control valve Outpu ON-VEHICLE SERVICE Control Valve Assembly and Accumulators Inspection 1. Remove oil pan and gasket and drain A.T.F. 2. Remove oil strainer. I 3. Remove control valve assembly by removing fixing bolts and disconnecting harness connector. Bolt length and location Bolt symbol Length mm (in) @ 37 (1.46) @ 50 (1.97) 4. Remove solenoids and valves frbm valve body if necessary. 5. Remove terminal cord assembly if necessary. 6. Remove accumulator A, S, C and D by applying compressed air if necessary. Hold each piston with rag. 7. Reinstall any part removed. Always use new sealing parts. . . AT-7 "" ON-VEHICLE SERVICE Revolution Sensor Replacement 1. Remove rear engine mounting member from body panel while supporting AIT with jack. 2. Lower AIT assembly as much as possible. 3. Remove revolution sensor from AIT assembly. 4. Reinstall any part removed. Always use new sealing parts. . Rear Oil Seal Replacement 1. Remove propeller shaft from vehicle. 2. Remove rear oil seal. 3. Install rear oil seal. Apply A.T.F. before installing. 4. Reinstall any part removed. Refer to section PD. '\ . Parking Components Inspection 1. Remove propeller shaft from vehicle. - Refer to section PD. 2. Remove rear engine mounting member from AIT assembly. AT-8 ON-VEHICLE SERVICE Parking Components Inspection (Cont'd) 3. Remove rear extension from transmission case. 4. Replace parking components if necessary. 5. Reinstall any part removed. Always use new sealing parts. . SAT133B Inhibitor Switch Adjustment 1. Remove manual control linkage from manual shaft of AIT assembly. 2. Set manual shaft of AIT assembly in "N" position. 3. Loosen inhibitor switch fixing bolts. 4. Insert pin into adjustment holes in both inhibitor switch and manual shaft of AIT assembly as near vertical as possible. 5. Reinstall any part removed. 6. Check continuity of inhibitor switch. - Refer to "Electrical Components Inspection". ,\ --1\ SAT081B Manual Control Linkage Adjustment Move selector lever from "P" range to "1" range. Y~hould be able to feel the detents in each range. If the detents cannot be felt or the pointer indicating the range is improperly aligned, the linkage needs adjustment. 1. Place selector lever in "P" range. 2: Loosen lock nuts. 3. Tighten lock nut @ until it touches trunnion pulling selector lever toward "R" range side without pushing button. 4. Back off lock nut @ 1 turn and tighten lock nut (!) to the specified torque. Lock nut: ~: 11 - 15 N.m (1.1 - 1.5 kg-m, 8 - 11 ft-Ib) 5. Move selector lever from "P" range to "1" range. Make sure that selector lever can move smoothly. Lock nut (!) Luck nut @ SAT788B AT-9 ON-VEHICLE SERVICE NOTE AT-'O TROUBLE DIAGNOSES Contents How to Perform Trouble Diagnoses for Quick and Accurate Repair AT-13 Preliminary Check : AT-14 AfT Electrical Parts Location AT-25 Circuit Diagram for Quick Pin Point Check AT-27 Wiring Diagram AT-28 Self-diagnosis '''''''''''''' AT-30 SELF-DIAGNOSTIC PROCEDURE AT-30 JUDGEMENT OF SELF-DIAGNOSIS CODE : AT-32 REVOLUTION SENSOR CIRCUIT CHECK """'"'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' AT-36 SPEED SENSOR CIRCUIT CHECK ; AT-36 THROTTLE SENSOR CIRCUIT CHECK AT-37 SHIFT SOLENOID A CIRCUIT CHECK ( AT-38 SHIFT SOLENOID B CIRCUIT CHECK j AT-39 OVERRUN CLUTCH CIRCUIT CHECK AT-40 LOCK-UP SOLENOID CIRCUIT CHECK AT-41 FLUID TEMPERATURE SENSOR CIRCUIT AND A/T CONTROL UNIT POWER'SOURCE CIRCUIT CHECKS AT-42 ENGINE REVOLUTION SIGNAL CIRCUIT CHECK AT-43 LINE PRESSURE SOLENOID CIRCUIT CHECK ; AT-44 INHIBITOR, OVERDRIVE, KICKDOWN AND IDLE SWITCH CIRCUIT CHECKS AT-45 Diagnostic Procedure 1 (SYMPTOM: 0.0. OFF indicator lamp does not come on for about 2 seconds when turning ignition switch to "ON".) AT-47 Diagnostic Procedure 2 (SYMPTOM: Engine cannot be 'Started with selector lever in "P" or "N" range or engine .can be started with selector lever in "0", "2", "1" or "R" range.) AT-48 Diagnostic Procedure 3 (SYMPTOM: Vehicle moves when it is pushed forward or backward with selector lever in "P" range.) """"""""""'" AT-48 Diagnostic Procedure 4 (SYMPTOM: Vehicle moves forward when setting "N" range.) AT-49 Diagnostic Procedure 5 (SYMPTOM: There is large shock when changing from "N" to "R" range.) AT-50 Diagnostic Procedure 6 (SYMPTOM: vehicle does not creep backward when selecting "R" range.) AT-51 Diagnostic Procedure 7 (SYMPTOM: Vehicle does not creep forward when selecting "0" , "2" and "1" range.) AT-52 Diagnostic Procedure 8 (SYMPTOM: Vehicle cannot be started from 01 on Cruise test-Part 1.) """'''''''''''''''''''''''''''''''''' AT-53 Diagnostic Procedure 9 (SYMPTOM: A/T does not shift from 01 to 02 at specified speed. A/T does not shift from 04 to O2when depressing accelerator pedal fully at the specified speed.) . AT-54 Diagnostic Procedure 10 (SYMPTOM: A/T does not shift from 02 to 03 at the specified speed.) AT-55 Diagnostic Procedure 11 (SYMPTOM: A/T does not shift from 03 to 04 at the specified speed.) ""'"'''''''''''''''''''''''''''''''''''' AT-56 Diagnostic Procedure 12 (SYMPTOM: A/T does not perform lock-up at the specified speed.) AT-57 Diagnostic Procedure 13 (SYMPTOM: A/T does not hold lock-up condition for more than 30 seconds.) AT-58 Diagnostic Procedure 14 (SYMPTOM: Lock-up is not released when accelerator pedal is released.) ""'"'''''''''''''''''''''''''''''' AT-58 AT-11 TROUBLE DIAGNOSES Contents (Cont'd) Diagnostic Procedure 15 (SYMPTOM: Engine speed does not return to idle smoothly when AfT is shifted from D4 to D3 with accelerator pedal released. Vehicle does not decelerate by engine brake when changing overdrive switch to "OFF" position with accelerator pedal released. Vehicle does not decelerate by engine brake when changing selector lever from "D" to "2" range with accelerator pedal released.) AT-59 Diagnostic Procedure 16 (SYMPTOM: Vehicle does not start from D1 on Cruise test - Part 2.) """""""""""'"'''''''''''''''''' AT-60 Diagnostic Procedure 17 (SYMPTOM: to "OFF" Vehicle does not shift from D4 on D3 when changing position.) """"""""""" overdrive switch "'"'''''''''''''''''''''''''''' """'"'''''''''''' AT-'60 """"'" Diagnostic Procedure 18 (SYMPTOM:AfT does not shift from D3on D2when changing selector lever from" D" to "2" range.) """""""""" """'''''''' ""'''''''''''''''''''''' AT-61 """""""""" Diagnostic Procedure 19 (SYMPTOM: Vehicle does not shift from 22 on 11when changing selector lever from "2" to ",1" range.) """" Diagnostic Procedure 20 (SYMPTOM: Vehicle does not decelerate by enigne brake when shifting from 22 (12) to 1,.) Electrical Components Final Check Symptom Chart ... AT-61 AT-61 AT-62 . AT-68 Inspection """"""""""""""" """"""'" """"""""'" "" AT-72 AT-75 """""""""""""" AIT Shift Lock System ,. , SHIFT LOCK SYSTEM ELECTRICAL PARTS LOCATION CIRCUIT DIAGRAM FOR QUICK PIN POINT CHECK WIRING DIAGRAM DIAGNOSTIC PROCEDURE 1 AT-75 AT-76 AT-77 (SYMPTOM: Selector lever cannot be moved from "P" range when applying brake pedal or can be moved when releasing brake pedal.) DIAGNOSTIC PROCEDURE 2 AT-78 \ (SYMPTOM: Ignition key cannot be removed when selector lever is set to "P" position or can be CONTROL removed when lever is set to any position except "P".) SHIFT LOCK UNIT selector INSPECTION SHIFT LOCK CONTROL UNIT INSPECTION TABLE COMPONENT CHECK '"'''''''''''''''''''''''''''''''' AT-12 \ '"'''''''' AT-80 AT-82 AT-83 AT-84 TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accura,e Repair WORK FLOW CHECK IN < Reference item LISTEN TO CUSTOMER COMPLAINTS. CHECK A/T FLUID AND CONDITION. LEVEL AfT FLUID CHECK (SeepageAT-14.) Preliminary Check r-----I I I I I I I I I -- I I I I I I I I I I I I I I --~I . . PERFORM ROAD TESTING. PERFORM SELF-DIAGNOSIS. Self-diagnosis (See page AT-30.) Self-diagnosis (See page AT -30.) INSPECT MALFUNCTION ON THE BASIS OF EACH COMPONENTS CONDITION. Diagnostic Procedure (See page AT -47.) Symptom Chart (SeepageAT -72.) REPAI R/REPLACE. I L- ---------N.G. ROAD TESTING (SeepageA T-15.) FINAL CHECK AT-13 Final Check (See page AT -68.) ~ TROUBLE DIAGNOSES Preliminary ~ ~Q 81 ~~ ~ Check AIT FLUID CHECK Fluid leakage check e 1. Clean area suspected of leaking, - for example, mating surface of converter housing and transmission case. 2. Start engine, apply foot brake, place selector lever in "0" range and wait a few minutes. 3. Stop engine. SAT767B 4. Check for fresh leakage. , SAT801A Fluid condition check Fluid color Suspected problem Dark or black with burned odor Wear of frictional material Milky pink - Water contamination SA T638A Varnished fluid, light to dark brown and tacky Fluid level check Refer to section MA. AT-14 Road water entering through filler tube or breather Oxidation - Over or under filling Overheating I TROUBLE DIAGNOSES Preliminary Check (Cont'd) ROAD TESTING ROAD TEST PROCEDURE 1. Check before engine is started. 0 I 3. Cruise test. . . 2. Check at idle. 0 I Description The purpose of this road test is to determine overall performance of automatic transmission and analyze causes of problems. The road test consists of the following three parts: 1. Check before engine is started 2. Check at idle 3. Cruise test SAT786A . . Before road test, familiarize yourself with all test procedures and items to check. Conduct tests on all items. Troubleshoot items which check out No Good after road test. Refer to "Self-diagnosis" and "Diagnostic Procedure". ~ SA T639A AT-15 TROUBLE DIAGNOSES -- Preliminary Check (Cont'd) 1. Check before engine is started 0 0 Park vehicle on flat surface. SAT787A fA Move selector lever to "P" range. fA fir:) ~ .IJ SA T768B Does O.D. OFF indicator lamp. come on for about 2 seconds? Yes Does O.D. OFF indicator lamp flicker for about 8 seconds? I No a:J\ ~ SAT836B Perform self-diagnosis. - Refer to SELF-DIAGNOSIS PROCEDURE and note N.G. items. Go to "ROAD TESTING - 2. Check at idle". AT-16 Perform self-diagnosis. . - Refer to SELF-DIAGNOSIS PROCEDURE. TROUBLE DIAGNOSES, Preliminary Check (Cont'd) 2. Check at idle 0 0 Park vehicle on flat surface. 6 SA T787 A Move selector lever to "P" or "N" range. 6 Is engine started? . Yes N°I Go to Diagnostic Procedure 2.1 SAT7698 BJ BJ Moveselector lever to "D", "1", "2" or "R" range. Yes Go to Diagnostic Procedure 2. SAT7708 II II Move selector lever to "P" range. SA T7688 m m ~ Push vehicle forward or backward. Yes Does vehicle move when it is pushed forward or backward? I No SAT796A A AT-17 Go to DiagnosticProcedure 3. TROUBLE DIAGNOSES Preliminary Check (Cont'd) :A) m ~ m Move selector lever to "N" range. I ~ SAT771B ."';"";" fJ ~t,ST Brake peda I ~ ~ I SA T797 A Does vehicle move forward or backward? fJ Yes I Go to Diagnostic Procedure 4.1 [NO Appl'Y'foot brake. m m Move selector lever to "R" range. Yes Is there large shock when changing from "N" to "R" range? m Go to Diagnostic Procedure 5.1 No Release foot brake for several seconds. SAT772B m I Does vehicle creep backward when foot brake is released? Brake pedal Yes iii] Move selector lever to "D", "1" and "2" range and check if vehicle creeps forward. Does vehicle creep forward in all three ranges? No For several seconds SAT799A iii] I Go to Diagnostic.Procedure 7. SAT773B AT-18 Go to Diagnostic Procedure 6. TROUBLE DIAGNOSES t half throttle open ~ ~ AfT control~it terminal \ \Atfull Preliminary Check (Cont'd) 3. Cruise test Check all items listed in Parts 1 through 3. Throttle position can be controlled by voltage across termi-. nals (jJ)and @ of AfT control unit. .. \throttleopen ~ ~~I.J~ SAT802A Cruisetest - Part 1 0 0 Warm up engine until engine oil and A.T. F. reach operating temperature after vehicle has been driven approx. 10 minutes. A.T.F. operating temperature: 50 80°C (122 176°F) - - SAT779A Park vehicle on flat surface. II i] / II Set overdrive switch to "ON" position. -. ID Move selector lever to "P" range. SAT7748 ~ II G II Move selector lever to "D" range. m SAT7758 Accelerate vehicle by constantly depressing accelerator pedal halfway. Does vehicle start from D1 ? Yes SA T803A @ AT-19 Go to Diagnostic Procedure 8. TROUBLE DIAGNOSES Preliminary Check (Cont'd) ~ 6 m II 'll N 8/8 m ,...- 6 0/8 .. , .. m 8/811 II IU ?l ~~ 0/8 Does AfT shift from D3 to D4 at the specified speed? Specified speed when shifting from D3 to D4 : Refer to Shift schedule. ~l SAT805A . m IEm 81) 0T------------- » 0/8 If SA T806A ~ IE II] 8/8 ,.. .,..,.. ...-,.. ...(" I I I 0/8 ("-- Nb Go to Diagnostic Procedure 10. No Go to Diagnostic Procedure 11. No Go to Diagnostic Procedure 12. Does AfT hold lock-up condition for more than 30 seconds? 1 1 Go to Diagnostic Procedure 9. Yes Does AfT perform lock-up at the specified speed? Specified speed when lock-up occurs: Refer to Shift schedule. , Yes ~ No Yes m . u ~I l~ Does AfT shift from D1 to D2 at the specified speed? Specified speed when shifting from D1 to D2: Refer to Shift schedule. . Yes Does AfT shift from D2 to D3 at the specified speed? Specified speed when shifting from D2 to D3 : Refer to Shift schedule. SA T804A m ~ IE Go to Diagnostic Procedure. 13. I Yes Release accelerator pedal. 8, " ,..'" I ,..,.." ,..----- --- -- O~O 'I , m Is lock-up released when accelerator pedal is released? No Go to Diagnostic Procedure 14. _..?l 'I) ~) SA T807 A IE .I Yes I Decelerate vehicle by applying foot brake lightly. II] Does engine speed return to idle smoothly when AfT is shifted from D4 to D3 ? Yes I Stop vehicle. I I Go to "Cruise test AT-20 - Part 2". No Go to DiagnosticProcedure 15. TROUBLE DIAGNOSES Check (Cont'd) Preliminary Cruise test - Part 2 Confirm overdrive switch is in "ON" position. Confirm selector lever is in "D" range. SA T803A Hlilf-way .0 6 / Accelerate vehicle by half throttle again. 8/8 Does vehicle start from D1 ? . . . Go to Diagnostic Procedure 16. Yes 6 Accelerate vehicle to A kmfh as shown in illustration. 0/8 Accelerato~ pedal II 8/8 II I O ta O-.!.:T 21W / Depress fully Release /. .!} Does AfT shift from D4 to D2 as soon as accelerator pedal is depressed fully? / Release Go to Diagnostic Procedure 9. No Does AfT shift from D2 to D3 at the specified speed? Specified speed when shifting from D2 to 03 : Refer to Shift schedule. m No Yes m 8/81, Go to Diagnostic Procedure 10. Yes Release accelerator pedal after shifting from D2 to D3. ------ 6 Does AfT shift from D3 to D4 and does vehicle decelerate by engine brake? SAT810A Yes [;)6 II Accelerator pedal / Release accelerator pedal and then quickly depress it fully. SAT808A II No -- -- n 1W 8/8 SrI~~j_._m__C 03 Stop vehicle. ~ ~ 04 I 0/8 S~ 0» Go to "Cruise test ~s SATB11A AT-21 - Part 3". No ,+j Go to Diagnostic Procedure 11. TROUBLE DIAGNOSES Preliminary Check (Cont'd) Cruisetest - Part3 0 .0 Confirm overdrive switch is in "ON" position. Confirm selector lever is in "D" range. Accelerate vehicle using halfthrottle to D4. SAT812A fA .'- fA Release accelerator pedal. I] Set overdrive switch to "OFF" position while driving in D4 range. II I Does AfT shift from D4 to D3 ? SAT813A ~ @ m ( D3 (O.D. OFF)) 6 Engine brake "ED 6(;] @ Does AfT shift from D3 to 22 ? Does vehicle decelerate by engine brake? Yes . "1" range while ~riving in 22, II!] . Does AfT shift from 22 to 11 range? Yes IIDII ~ @ ~ I Stop vehicle. ! Perform self-diagnosis.- Refer to SELF-DIAGNOSISPROCEDURE. ~ I Go to Diagnostic Procedure 18. Go to Diagnostic Procedure 15. Go to Diagnostic Procedure 19. ... Doe's vehicle decelerate by engine brake? Yes SAT777B ~19 No Yes m Engine brake 0 ~ Yes I Move selector lever from "2" to . ,~ Yes m CD3 (0.D.OFF0 m Go to Diagnostic Procedure 15. Moveselector lever from "D" to "2" range while driving in D3. SAT776B G) Go to Diagnostic Procedure 17. Yes Does vehicle decelerate by engine brake? I] . +- No @ .... SAT778B AT-22 Go to Diagnostic Procedure 20. TROUBLE DIAGNOSES Preliminary Check (Cont'd) Vehicle speed when shifting gears Vehicle speed km/h (MPH) Throttle position D, D, --> D, D, -+ D. D. Full throttle 52 - 56 (32 - 35) 95 - 101 (59 - 63) 146 - 156 (91 - 97) 140 - 150 (87 - 93) 89 - 95 (55 - 59) 40- 44 (25- 27) 53 - 57 (33 - 35) Half throttle 38 - 42 (24 - 26) 72 -78 (45-48) 111-121 (69 -75) 55 - 65 (34-40) 33 - 39 (21 - 24) 10 - 14 (6-9) 53 - 57 (33 - 35) D, -+ -+ D, D, -+ D. D, -+ D, 1, -+ 1, Vehicle speed when performing and releasing lock-up Vehicle speed km/h (MPH) Throttle position Full throttle Half throttle O.D. switch [Shift range] Lock-up "ON" Lock-up "OFF" ON [D.] 146 - 156 (91 - 97) 140 - 150 (87 - 93) OFF [D,] 95 - 101 (59 - 63) 89 -95 (55 - 59) ON [D.] 112 - 120 (70 -75) 102-110 (63 - 68) OFF [D.] 76 - 84 (47 - 52) 71 - 79 (44-49) \ AT-23 TROUBLE DIAGNOSES Check (Cont'd) Preliminary Shift schedule (Overdrive ON) Upshift -- - - 8/8 Downshift I , Kickdown range 7/8 I I I I- 6/8 1--r-2 I I /, I / / I I / I I I I I L-.I 2/8 II I 1/81I I g> 5/8 'cCD 84/8 CD t: e 3/8 .c I- 0/8 0 10 ~ r 20 30 (10) (0) 40 I L, (20) 50 r 70 60 ~ 80 + (40) (30) (50) . 90 100 I' (60) 110 " 120 ' (70) 130 .' (80) 140 " 150 ' (90) 160 I 170 180 ',' (100) 190 ,, (110) 200 ' (120) Vehicle speed km/h (MPH) SAT804B Shift schedule (Overdrive OFF) Upshift - - - -8/8 Downshift . I 7/8 , Kickdown range I I I 6/81-- I c: 6/8 'cCD 1-;-2 "" I I 8- 4/8 / I I CD .. e .c 3/8 I- I L_I 2/8 I I I /, / Lock~p "ON" I I I I 1/8I0/8 0 I (0) 10 ' 20 , ' (10) 30 " (20) 40 I I 60 ' (30) 60 ' , (40) 70 ' 80 I (60) 90 " 100 I (60) 110 'r (70) Vehicle speed km/h (MPH) AT-24 120 I 130 I I (80) 140 160 160 170 " ' I I (90) (100) 180 I' (110) 190 200 " ' (120) SA T805B TROUBLE DIAGNOSES. AIT Electrical Parts Location Control ( valve upper body ) SAT806B AT-25 TROUBLE DIAGNOSES AfT Electrical Parts Location (Cont'd) ~ 1;Inhibitor switch ~ harness connectorrf' :. AfT solenoid ,:;?harness connector ~ ~~ 0 SAT8258 AT -26 0 [SIEE] @!j ~ lGNI TI ON SWITCH ON or START IGNITION COIL To distributor @ 0 ffiHBJ @ a@0~ @ 35213 db '2112 15 ." r c INHIBITOR SWITCH @I -i "lJ Z -0 m ::I (fI m @T 2:u I I I (fI m Z (fI r 0 ;U 26 19 20 I 2 ~(t) N A/T 6 8 ...... 9 23 7 12 29 30 28 24 @~ .:;; r.-:1t;0 m I -= r c -i m :u » ~ @crb :u m < 0 0 we POWER TRANSISTOR crb THROTTLE SENSOR <-i ;:; »:I 0. r;u ~c 1;U I I -. m-i <0 ..0 -i .~ (fir :Em :r.. -or ,Q ..0 -i- .. - -.. . 16 15 :r 17 10 4 CONTROL UNIT 35 36 22 21 34 33 s~ r- 0 ;U 0 -Z -= Cl(t) ;U m @~ 0 01 ~v.XcgONTROL S E!!3 ION @; IOFF »-I 00 -= (fI :I (") ." -i m~ @) I/) - 6 @ A -= ~ -i < m -." (fI :I -i @ -= @ (fI 0 r m Z 0 (fI 0 r m Z 0 0 0 Z 0 tD » 0 -= ;U ;U C Z "lJ ;U r C -i (") :I @ - -= -i 0 ;U m m (") (fI 0 r m - - (") :I r 0 (") A I C "lJ -rZ (fI (fI C ;U m @ (fI 0 (fI 0 Z 0 Z 0 0 r m -= - w 00 ,/ 0 r m -= :I II 27 25 31 32 "lJ "lJ O. D. OFF INDICATOR (") @ @) -= s TROUBLE DIAGNOSES Wiring Diagram COMBINATION METER IGNITION ON or 7 [Jffi@II] CONTROL SWITCH n ~t;J 12 HEAD-UP CONTROL 28 ~ ~~ll~o~~ co @ f)3\ \.!::.J co -'III III' >- co ">->- ID Vi GD II Y/G Y/8 Y/L G (J nstrument Y DI SPLA UNIT ~ ~ [J-t-W.H-t-j] ">->- >-, KICKO. D. OFF DOWN I NDI CATOR SWITCH O. D. 24 ELECTRIC SPEEDOMETER 6 SWITCH START harness) o. I co I FUSE BLOCK (Refer toP POWER ;;:~ SUPPLY ROUTINGp co", in EL section.) Effi 0EW'" @~'" @)~ .. .. .. co,co ID'co L @ Y/G. Y/8. Y/L. G MIh i te) J I~ C? IGNITION ON or co (Black) SWITCH START ~ @IIIII~I~ @ IDIII iii @fi~ - - @jj)fi@}} BODY GROUND BODY GROUND @ 11111~11IIl co ~ @ (E. F. 1. harness) L 11S-L ::::::::::::: 1-W 3- LG/R Y/W Y/G W/L 8 LG/8 L Y/R Y/R -{]II I @ :, :, 18-L/OR 21-8 28-W/L 29-8 1 ," --_n 2D-W nn _n n_n_' ' "" ", nn__nn_n 32-Y/G 33-Y/W 37-LG/R 44-Y n_nn- -, "" , ,, "" ,, ,, ,, ,, ,, , nn- . '' , ,, ,'" co ,111 ~1 co , 1 ~ I~~: co ..JID~ E. C. C. S. CONTROL UNIT (Refer to "E. C. C. S. SYSTEM" In EF&EC sect Ion. ) ~@) @)ii ENGINE GROUND 00 RESISTOR ~@) III bJ~@) ~ @ ..J>->- $.~ ~ "::> ... POWER TRANSISTOR ~c - THROTTLE To AT-28 @) distributor VALVE SWITCH ~ I I ..J~ID m THROTTLE SENSOR @ , 0 III..J ~ ~ ENGI NE TEMPERA TURE SENSOR TROUBLE DIAGNOSES Wiring Diagram (Cont'd) DROPPING RESISTOR - - REVOLUTI ON SENSOR @m :Wlth A/T CONTROL UNIT in! @)~@I~II~I b .E~~E ~ "'''' I ~ ~~'~E'" ~ 1 ! ~ a B9 B7 CB AB ClD Hll 111 @ S. E. L'~"" . a.. ~ M. ... To back-up L'E 0 braking lamp EE~ '" """"~L"'''''''~'' ..a E"''''o ~~L~~" INHIBITOR SWITCH =... - =N 5B G/R G/R R/B G/L Y/B Y/L =0 =Z I BRG/W BR G/W BR G/L G/B J. last anti-lock <;J;>@) (@) !Refer to (Fo Idout :Wlthout system J L___n_--5B -G/R -G/R -R/B -G/L -Y/B -Y/L ~ , head-up display :Wlthout head-up display :Wlth anti-lock braking system ~ ~ page page). ) '--- (ill) =0.. @) G~W ~ a:::J- I . @ (Eng Ine room 1'i"W P/L harness) OR/L B PU GY/R L/Y L/W L LG/R Y/W Y/B W/L B LB/B L I ii GY R I rJil ~~!~Dr lJU (Subharness) B W L Y G Y/R (§) " l6!B@) :;a "E ~ ~ ~ .. ~ ...... ..... ~ @)!i@) BODY GROUND ~(@) " ...... -= ..... (EngI ne ess room no. harn 2) Y/L-Lh Y/B-G" €==O SPEED SENSOR 0 n.... ::10 IZ )lUl u..J '")0 'JI -= 1: U I::I ..J < U 0 0 ... z... 0 ::10 It:Z I-Z It:W U.UI UI..J .....J >0 1:0 OU) U)U) m 0 ... 0 I-Z u.w .....J 1:0 U)U) -= UI It: ::I U) U) UlO It:... 0..0 Z UIUI Z..J ...0 It: 0 U) Z UI U) W It: 0::1 ...1::1< ..J1t: U.UI a.. 1-:1: ..JU) (@) SAT101C AT-29 TROUBLE DIAGNOSES 0 Self-diagnosis m SELF-DIAGNOSTIC PROCEDURE DIAGNOSIS START Start engine and warm it up to normal engine operating temperature. ~- fa SAT774B 0 II (g , Set overdrive switch in "ON" position. PJ Move selector lever to "P" range. fifif:j ~ Does 0.0. OFF indicator lamp come on for about 2 seconds? SAT779B Yes m m ~i .' ' ~ . fNo I ' I Go to . . I] Move selector lever to "0" range. II -CD Set overdrive switch in "OFF" SA T780B fifif:j ~ m 6 position. Wait for more than 2 seconds #~ ~~ ~ 0 after ignition switch "ON". I ..&\ OVER . \ 'ON DRIVE, OOFF m ~ve fit I." selector lever to "2" range. Set overdrive switch in "ON" position. 6 Move selector lever to "1" SAT781 B range. m m Set overdrive switch in "OF F" position. Accelerator pedal m ;;;: Depress accelerator pedal fully and release it. Depress Release SAT754A @ AT-30 Diagnostic Procedure 1.1 TROUBLE DIAGNOSES Self-diagnosis (Cont'd) A II!] II!] . Set overdrive switch in "ON" position. Check O.D. OFF indicator lamp. Refer to JUDGEMENTOF SELF-DIAGNOSISCODEon next page. ~- DIAGNOSIS END SAT782B '--- I AT-31 TROUBLE DIAGNOSES Self-diagnosis JUDGEMENT OF SELF-DIAGNOSIS (Cont'd) CODE. Damaged circuit 0.0. OFF indicator lamp: All circuits that can be confirmed by self-diagnosis are O.K. All judgement flickers are same. ,& //1\' OlD OFF Self-diagnosis start I - Start flickers-- signal 1Q-judgement - Light f-- \ - - Shade t, t,t, t, t, t, t, t, t, t, t, tl SAT723B 1st judgement flicker is longer than others. ~~ Revolution sensor circuit is short-circuited or disconnected. OlD //1\ Revolution sensor OFF --,..--- - -- Lig ht 16 r-- \ -- 15 Arr control unit Shade .. Go to REVOLUTION SENSOR CIRCUIT CHECK. SAT140B SAT724B 2nd judgement flicker is longer than others. Speed sensor circuit is short-circuited or disconnected. ~()~ OlD //1\' OFF Speed sensor - - .....--.- - - Light 24 Arr 1---1- ,-' control unit Shade .. Goto SPEEDSENSORCIRCUIT CHECK. SAT726B 3rd judgement flicker is longer than others. SAT760A Throttle sensor circuit is short-circuited or disconnected. Throttle sensor ~).l(~ OlD /)r\' OFF --- R-M-.- - - Light .",. 15 - Shade .. SA T726B tl = 2.5 seconds t2 = 2.0 seconds t3 =1.0 second AT-32 11 AfT control 10 unit Goto THROTTLESENSORCIRCUIT CHECK'sAT761A TROUBLE DIAGNOSES Self-diagnosis (Cont'd) Damaged circuit O.D. OFF indicator lamp: 4th judgement flicker is longer than others. Shift solenoid A circuit is short-circuited or disconnected. Shift solenoid A ~()~ OlD /11\' OFF Terminal cord assembly Self-diagnosis start -= - -- Light 35 . - Shade SA T727 B 5th judgement flicker is longer than others. ':()/ :;/1\' A/T control unit Go to SHIFT SOLENOID A CIRCUIT CHECK. SAT766A Shift solenoid B circuit is short-circuited or disconnected. Shift solenoid B OlD OFF -- - -- Terminal cord assembly Light 36 ' -- - Shade SAT728B 6th judgement flicker is longer than others. ,\I~ :;g, . Arr control unit Go to SHIFT SOLENOID B CIRCUIT CHECK. SAT767A Overrun clutch solenoid circuit is short-circuited or disconnected. Overrunclutch solenoid OlD OFF --- ----- Terminal assembly Light cord 21 - - \ - Shade SA T729B 7th judgement flicker is longer than others. ~~ //1\' . Arr control unit Go to OVERRUN CLUTCHSOLENOID CIRCUIT CHECK. SAT768A Lock-up solenoid circuit is short-circuited or disconnected. Look-up solenoid OlD OFF Terminal cord assembly -- -= -- Light 22 --- \ - Shade SAT730B . AT-33 Arr control unit Go to LOCK-UPSOLENOID CIRCUIT CHECK. SAT769A ----- TROUBLE DIAGNOSES Self-diagnosis (Cont'd) 0.0. OFF indicator lamp: Damaged circuit 8th judgement flicker is longer than others. \ II ..:xk Fluid temperature sensor is disconnected or AfT control unit power source circuit is damaged. OlD /11\ OFF Terminal cord assembly Self-diagnosis start -- - Light .. Shade SAT731 B CHECK. SAT143B Engine revolution signal circuit is short-circuited or disconnected. 9th judgement flicker is longer than others. ,\1// //1\' Go to FLUID TEMPERATURE SENSOR CIRCUIT AND AfT CONTROL UNIT POWER SOURCE CI RCUIT OlD OFF -0- Resistor - -....--.- - - Light 25 +- ~- AfT control Shade SAT733B 10th judgement others. flicker is longer than to ENGINE REVOLUTION .. Go CHECK. ~ solenoid Dropping resistor - Light 34 ' 4-- Shade AfT SAT732B Flickers as shown below: 33 control unit .. Go to LINE PRESSURE SOLENOID CIRCUIT CHECK. Battery power is low. Battery has been disconnected for a long time. Battery is connected conversely. (When reconnecting AfT control unit connectors. is not a problem.) ~O/D ~' OFF - Light - - Shade t. SAT734B = 1.0 SAT624B Terminal cord assembly - - ...--.- t4 SIGNAL CIRCUIT Line pressure solenoid circuit is short-circuited or disconLine p~essure nected. ..:::()~ OlD /11\' OFF I unit second AT-34 SAT776A - This TROUBLE DIAGNOSES Self-diagnosis (Cont'd) O.D. OFF indicator lamp: Dama~ed circuit Does not come on. 0 Inhibitor switch, overdrive switch, kickCtownSWltchOT idle switch circuit is disconnected or AIT control unit is damaged. 010 OFF Self-cliagnosls start - - - - - - - - - - -.- - - Light --- Shade Throttle valve switch .<: ~ .~ .. '" :§ -=- SAT157C Overdrive switch ION Kickdown switch. ) .. -= Go to INHIBITOR,.OVERDRIVE, KICKDOWN AND IDLE SWitCH CIRCUIT CHECKS. SAT736B / \ ..... '\ \ c AT-35 TROUBLE DIAGNOSES Self-diagnosis (Cont'd) . REVOLUTIONSENSORCIRCUIT CHECK Revolution sensor CHECK REVOLUTION SENSOR. Refer to "Electrical - .Components O.K. N.G. CHECK INPUT SIGNAL. 1. I 15 Arr control unit ~ f" t:;! SAT140B .'' '.-' I~ trJ ST ",:"",.,. , A/T control unit and revolution sensor (Main hamess) I! >} . Harnesscontinuitybetween revolution sensor andE.C.U. (Mainharness) . Ground circuit for E.C.U. - Refer to section EF & EC. ground while driving. . ~Measure with A.C. range.) Voltage: At Okm/h (0 MPH): OV At 30 km/h (19 MPH): 1V or more (Voltage rises gradually in response to vehicle speed) -~, .-~ Check the following .items. . Harnesscontinuitybetween 2. Check voltage between A/T control unit terminal @ and m Repair or replace revolution sensor. Inspection". PI 16 N.G. '/ O.K. Perform self-diagnosis again after driving for a while. N.G. . O;K. / 00 INSPECTION END 1. Perform A/T control unit input/output signal inspecti~n. 2. If N.G., recheck AfT control, unit pin terminals for damage or connection of A/T cORtrol unit harness connector. " -=- SAT737B SPEED SENSOR CIRCUIT PI PI Speed sensor CHECK INPUT SIGNAL. 1. -= CHECK N.G. '(,~I 24 A/T contrOl unit ~I 2.' Check voltage between A/T control unit terminal @ and ground while driving at 2 to 3 km/h (1 to 2 MPH)for 1 m (3 ft) or more. Voltage: Varies from OV , Check the following items. . Speed sensor and ground circuit for speed sensor - Refer to section El. . Harnesscontinuity between A/T control unit and speed sensor (Main harn,ss) t05V ---.-O.K. Perform self-diagnosis again after driving for a while. . O.K. INSPECTION END SA T738B AT-36 . N.G. 1. Perform A/T controlu~it input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of A/T control unit harness connector. TROUBLE DIAGNOSES Self-.diagnosis .(Cont'd) -THROTTLESENSOR CIRCUIT CHECK Throttle sensor Perform self-diagnosis(Mode III) for engine control. O.K. N.G. Check throttle sensor circuit for engine control. - Refer to section EF & EC. N.G. Check harness continuity between E.C.U. and A/T control unit regarding throttle sensor circuit. (Main harness) N.G. 1. Perform A/T control unit input/output signal inspection. 2. If N.G.. recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector. II ";" 15 11 ~ CHECK INPUT SIGNAL. 10 AfT control I unit SAT761A II 13 1.1 2. Check voltage between AlT controlunit terminals @ and @ while accelerator pedal is depressed slowly. Voltage: Fully-closed throttle: 0.2- 0.6V Fully-open throttle: 2.9- 3.9V (Voltage rises gradually in response to throttle valve opening.) [iI O.K. COllET £) Perform self-diagnosisagain after driving for a while. 'O.K. INSPECTION END SA T739B AT-37 TROUBLE DIAGNOSES Self-diagnosis (Cont'd) SHIFTSOLENblDA CIRCUITCHECK Shift solenoid A m N.G. CHECK GROUND CIRCUIT. unit SAT766A m Sub-harness connector (@)~ is 1.1 I 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal @ and ground. Resistance: 20. 30il SA T740B I!) DISCONNECT [:it 18 1 O.K. CHECK POWERSOURCE N.G. Repair or replace harness betweenA/Tcontrolunit and CIRCUIT. terminal cord assembly. (Main harness) 13 I 2. Disconnect A/T control unit 16-pin connector. 3. Check resistance between terminal @ and A/T control unit terminal @. Resistance: Approximately Oil 4. Reinstall any part removed. 1 O.K. Perform self-diagnosisafter driving for a while. lo.K. INSPECTION [ill - I!) 1.1 -=- CLE SERVICE". 2. Check the following items. 8 Shift solenoid A Referto "Electrical Components Inspection". 8 Harnesscontinuity of terminal cord assembly 13 35 AfT control 1. Remove control valve assem- bly. - Referto "ON-VEHI- Terminal cord assembly AfT control unit terminal SAT741B AT-38 END ." N.G. 1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of AfT control unit harness connector. TROUBLE DIAGNOSES Self-diagnosis (Cont'd) SHIFT SOLENOID B CIRCUIT CI:IECK Shift solenoid B m N.G. CHECK GROUND CIRCUIT. Terminal cord assembly AfT control unit SAT767A ~ lu [;] IIIKOIIIIECT l - O.K. N.G. CHECK POWERSOURCE CIRCUIT. "1 2. Disconnect A/T control unit -;:- bly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. 8 Shift solenoid B Referto "Electrical Components Inspection". 8 Harnesscontinuity of terminal cord assembly 1.1 I 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal @ and ground. Resistance: 20 - 30n 36 SAT742B 1. Remove control valve assem- I Repair or replace harness between A/T control unit and terminal cord assembly. (Main harness) 16-pin connector. 3. Check resistance between [;] terminal @ and A/T control unit terminal @. Resistance: Approximately on 4. Reinstall any part removed. _IIECT ~ IV l O.K. N.G. Perform self-diagnosis after driving for a while. lO.K. INSPECTION I 1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals END I for damage or connection of A/T control unit harness connector. / SAT743B AT-39 TROUBLE DIAGNOSES Self-diagnosis - (Cont'd) OVERRUNCLUTCH SOLENOIDCIRCUIT CHECK Overrun clutch solenoid m N.G. 1. Removecontrolvalveassembly.- Referto "ON-VEHI. CHECKGROUNDCIRCUIT. Terminal cord assembly 1.1 21 Arr control unit SA T768A m ~ IV 1 O.K. N.G. SA T744B Subharness connector Repair or replace harness betweenAlTcontrolunit and CIRCUIT. -eJ @ - I I CHECK POWERSOURCE 1.1 I!] CLE SERVICE". 2. Check the following items. 8 Overrun clutch solenoid. Refer to liElectrical Components Inspection". 8 Harnesscontinuity of terminal cord assembly 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal @ and ground. Resistance: 20 - 30n I!] ~ -= 18 18 terminal cord assembly. (Main harness) I 2. Disconnect AIT control unit 16-pin connector. 3. Check resistance between terminal @ and AIT control unit terminal @. Resistance: Approximately on 4. Reinstall any part removed. 1 O.K. Perform self-diagnosisafter driving for a while. lo.K. INSPECTION END P/L [ill SAT745B AT-40 N.G. 1. Perform AfT control unit input/output signal inspection. 2. If N.G.. recheck AfT control unit pin terminals for damage or connection of AfT control unit harness connector. TROUBLE DIAGNOSES Self-diagnosis (Cont'd) LOCK-UP SOLENOID CIRCUIT CHECK Look-up solenoid m CHECK GROUND CIRCUIT. 1. N.G. "ON-VEHICLE SERVICE". 2. Check the following items. . Lock-up solenoid - Refer to Ia 22 AfT control unit SA T769A 1. Removeoil pan.- Refer to liElectrical Components Inspection" 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal @ and ground. Resistance: 2.5 5n . . Harnesscontinuityof terminal cord assembly - m IIISQIIIIECT EO O.K. Ii) CHECK POWER SOURCE CIRCUIT. 1. N.G. Repair or replace harness between AfT control unit and terminal cord assembly. (Main harness) ~ ~ -=- SA T746B Ii] IIISCONIIECT [:iI fm'I ~ IV Sub- E1tE1harness GY/R 2. Disconnect AfT control unit 16-pin connector. 3. Check resistance between terminal @ and AfT control unit terminal @. Resistance: Approximately on 4. Reinstall any part removed. 22 J connector O.K. Perform self-diagnosis after driving for a while. . O.K. [:ill{) INSPECTION END EEfHm [ill SAT747B AT-41 N.G. 1. Perform AfT control unit input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of AfT control unit harness connector. TROUBLE DIAGNOSES Self-diagnosis (Cont'd) Fluid temperature sensor Terminal cord assembly SAT143B ~ CIINNECT £) AfT control unit terminal SAT748B I!] Subharness connector EW3 @ yo12 15~ ~ ~ IIISCOIINECT B w 18 [ill FLUID TEMPERATURE SENSOR CIRCUIT AND AIT CONTROL UNIT POWER SOURCE CIRCUIT CHECKS m CHECK AfT CONTROL UNIT POWER SOURCE. 1. I N.G. 2. Check voltage between AfT control unit terminals @ , @ and ground. Battery voltage should exist. Check the following items. . Harnesscontinuity between ignition switch and AfT con. trol unit (Mainharness) . Ignition switch and fuse - Refer to section EL. O.K. I!] N.G. CHECK FLUID TEMPERA. TURE SENSOR WITH TERMINAL CORD ASSEMBLY 1. ~ 2. Discpnnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminals @ and @ when AfT is cold. Resistance: Cold [20°C (6SoF)] Approximately 2.5 kil 4. Reinstall any part removed. O.K. SAT749B A AT-42 1. Remove oil pan. 2. Check the following items. . Fluid temperature sensor - Refer to "Electrical Com. ponents Inspection". . Harnesscontinuity of terminal cord assembly TROUBLE DIAGNOSES Self-diagnosis (Cont'd) @ [i CHECK INPUT SIGNAL OF FLUID TEMPERATURE SENSOR. '" 1.1 "'i" ' ! 13 G ' ON '} ~ CONNECT £) AfT control unit terminal lD2; :," ~.' ,)I;, , ,", N.G. Check the following items. . Harness continuity between A/T control unit and terminal cord assembly (Mainharness) II 2. Check voltage between A/T control unit terminal @ and ground while warming up A/T. Voltage: Cold [20°C (6SoF)] -+ Hot [SO°C (176°F)] : 1.56V -+ O.45V O.K. Perform self-diagnosis after driving for a while. . "::" N.G. O.K. SAT750B INSPECTION END 1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of A/T control unit harness connector. ENGINE REVOLUTION SIGNAL CIRCUIT CHECK Perform self-diagnosis (Mode III) for engine control. Check ignition signal circuit condition. Resistor N'~I Check ignition signal circuit for engine control. - Refer to section EF & EC. N.G. Check the followingitems. . Harnesscontinuity between A/T control unit and ignition coil. O.K. m CHECK INPUT SIGNAL. 25 AfT control unit SA T624B m~ 0HHm:B l1t CONNECT AfT control unit terminal £) "13 2. Check voltage between A/T control unit terminal @ and ground. Voltage: 9.5 - 12V . -=- SAT751B . Ignitioncoil- Refer to sectionEF&EC. O.K. Perform self-diagnosisagain after IN.G. driving for a while. . . Resistor O.K. INSPECTION END AT-43 1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of AfT control unit harness connector. TROUBLE DIAGNOSES Self-diagnosis (Cont'd) LINE PRESSURE SOLENOID CIRCUIT CHECK Li ne pressu re solenoid Terminal cord assembly CHECK GROUND CIRCUIT. Dropping resistor 34 1.1 33 AfT control unit SA T776A m Sub- harness connector 34\ @ID) m ~ 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal @ and ground. Resistance: 2.5- 5il 1!1 ~ IV SAT762B -.. 1. 1 2. DisconnectAfTcontrolunit 16-pinconnector. I 8 Harnesscontinuity between AfTcontrolunit @ and terminalcordassembly (Mainharness) terminal @ and AfTcontrol unit terminal@. Resistance: 11.2- 12.ail ~i5 [!] 1O.K. CHECK POWERSOURCE CIRCUIT 1.1 em - N.G. Checkthe following items. 8 Dropping resistor - Referto "ElectricalComponents Inspection". 3. Checkresistance between 1!1[!] Removecontrol valve assem- bly.- Refer to "ON-VEHICLE SERVICE". 2. Check the following items. 8 Line pressure solenoid Refer to "Electrical Components Inspection"-. 8 Harnesscontinuity of terminal cord assembly !O.K. CHECK POWERSOURCE CIRCUIT. 1.1 =- N.G. p A/T control unit terminal SA T763B 2. Check resistance between terminal @ and AfT control unit terminal @. Resistance: Approximately Oil 3. Reinstall any part removed. 1 O.K. Performself-diagnosisafter driving for a while. ! O.K. INSPECTION END AT-44 N.G. Repair or replace harness betweenAfTcontrolunit @ I N.G. and terminal cord assembly. 1. PerformAfT control unit input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of AfT control unit harness connector. TROUBLE DIAGNOSES Self-diagnosis (Cont'd) INHIBITOR, OVERDRIVE, KICKDOWN AND IDLE SWITCH CIRCUIT CHECKS m CHECK INHIBITOR SWITCH CIRCUIT. m 2. Check voltage between AfT control unit terminals CD.@. @. @, @ and ground while moving selector lever through each range. Voltage: B: Battery voltage 0: OV No. A/T control unit terminal @ @ @ CD CV P,N B 0 0 0 0 R 0 B 0 0 0 0 0 0 B 0 0 2 0 0 0 B 0 1 0 0 0 0 B O.K. 1!1 BR/W BR CHECK OVER~RIVE CIRCUIT. 1. -=SAT7838 1!1 * _caD ~ t!(g Switch position Voltage ON Battery voltage OFF 1V or less O.K. lit CIIIIIECT ~ ~10~ IV n e (t'l A/T control unit terminal SWITCH 2. Check voltage between AfT control unit terminal @ and ground when overdrive switch is in "ON" position and in "OFF" position. ~- ~G/R -=SA T7848 Refer to "Electrical Components Inspection". . Harnesscontinuity between ignition switch and inhibitor switch (Mainharness) . Harnesscontinuity between inhibitor switch and AfT control unit (Mainharness) fi/f:J.. Lever position Check the following items. . Inhibitorswitch- ~ 1. I SAT7368 N.G. A AT-45 IN.G. Check the following items. . Overdriveswitch - Refer "Electrical Components Inspection" . to . Harness continuity between AfT control unit and overdrive switch (Main harness) . Harnesscontinuity of ground circuit for overdrive switch (Main harness) TROUBLE DIAGNOSES Self-diagnosis (Cont'd) @ [!II!] [!1 CHECK KICKDOWN SWITCH CIRCUIT. 1.1 ~ 0 CONNECT t£) N.G. Check the following items. . . Kickdown switch Harnesscontinuity between AfT control unit and kick. down switch (Mainharness) . Harnesscontinuity of ground circuit for kickdown switch ~ 2. Check voltage between AfT control unit terminal (j) and ground while depressing accelerator pedal slowly. (after warming up engine) Voltage: When releasing accelerator pedal: 3 8V When depressing accelerator pedal fully: 1V or less , O.K. - I!] IN.G. CHECK IDLE SWITCH CI RCUIT. SAT754S1 I. Check voltage between AfT control unit terminal @ and ground in the same way as kickdown switch circuit. Voltage: When releasing accelerator pedal: 8 15V When depressing accelerator pedal fully: 1V or less , O.K. - Perform self-diagnosis again after drivingfor a while. . O.k. I N.G. Perform self-diagnosis (Mode IV) for engine control. Check idle switch circuit. O.K. Check harness continuity between AfT control unit and idle switch. (Main harness) AT-46 Check id Ie switch circuit for engine control. Refer to sec. tion EF & EC. 1. Perform AfT control unit input/output signal inspection. 2. If N.G., recheck AfT control - INSPECTION END N.G. unit pin terminals for damage or connection of AfT control unit harness connector. TROUBLE DIAGNOSES Diagnostic Procedure 1 SYMPTOM: 0.0. OFF indicator lamp does not come on for about 2 seconds when turning ignition switch to "ON". 0, CHECK AfT CONTROL UNIT POWER SOURCE. 1. -=- N.G. Check the following items. . t8 SAT755B 11 . 2. Check voltage between AfT control unit terminals @, ~ and ground. Battery voltage should exist. O.K. 6 I CHECK AfT CONTROL UNIT GROUND CIRCUIT. 1. -=- Fuse 0.0. OFF indicator lamp AfT control unit O.K. I] [:tI ([ill) [ill £) Check harness continuity between AfT control unit and ground. 2. Disconnect AfT control unit 16-pin connector. 3. Check resistance between AfT control unit terminals @ , @ and ground. Resistance: Approximately on Ignition switch CONNECT N.G. ~ SAT756B I] Harness continuity between ignition switch and AfT control unit (Main harness) Ignition switch and fuse - Refer to section EL. I CHECK LAMP CIRCUIT. 1. N.G. Check the following items. . 0.0. OFF indicator lamp - Refer to section EL. . Harnesscontinuity between ignition switch and 0.0. OFF indicator lamp (Main harness) . Harnesscontinuity between 0.0. OFF indicator lamp and AfT control unit ~ 2. Disconnect AfT control unit . 16-pin connector. 3. Check resistance between AfT control unit terminals @ and @. Resistance: 50 -100n 4. Reinstall any part removed. O.K. N.G. Check again. O.K. INSPECTION END AT-47 1. Perform AfT control unit input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of AfT control unit harness connector. TROUBLE DIAGNOSES D 0 Diagnostic Procedure 2 OlD OFF SYMPTOM: Enginecannot be started with selector lever in "P" or "N" range or engine can be started with selector lever in "0", "2", "1" or "R" range. Self-diagnosis start - - - - - - - - - - - - - - Light --- Shade SAT157C D Does self-diagnosis show damage to inhibitor switch circuit? Yes Check inhibitor switch circuit. - Refer to "Self-diagnosis". No fA Check continuity of inhibitor switch 2-pin connector. - Refer to "Electrical Components Inspection" . N.G. Repair or replace inhibitor switch. O.K. Check starting system. - Refer Repair or replace damaged parts. to sectionEL. O.K. SA T838B INSPECTIONEND Diagnostic Procedure 3 D SYMPTOM: Vehicle moves when it is pushed forward or backward with selector lever in "P" range. D Check parking components. Refer to "ON-VEHICLE SERVICE". SAT133B O.K. INSPECTIONEND AT-48 N.G'I Repair or replace damaged parts. I TROUBLE DIAGNOSES 0 0 Diagnostic Procedure 4 010 OFF SYMPTOM: Vehicle moves forward or backward when selecting "N" range. Self -diagnosis start 0 - - - - - - - - - - - - - - Light Does self-diagnosisshow damage to inhibitor switch after cruise test ? - - Shade No SAT157C m "P" range Yes Check manual control linkage. - Refer to "ON.VEHICLE SERVICE". Check inhibitor switch circuit. - Refer to "Self.diagnosis". f) N.G. Adjust manual control linkage. Refer to "ON.VEHICLE SERVICE". - O.K. Refill A.T.F. Check AfT fluid level again. O.K. II Lock nut 00 LCiCk nut @ SA T788B 1. Remove oil pan. 2. Check AfT fluid condition. . O.K. 11 Check again. O.K. INSPECTIONEND SA T638A II SAT171 B AT-49 N.G. 1. 2. . . . . DisassembleAfT. Check the following items. Forward clutch assembly Overrun clutch assembly Reverseclutch assembly Accumulator piston D 1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector. TROUBLE DIAGNOSES 0 Diagnostic Procedure 5 ~O /1 \ ' \1// % OFF Self-diegnosis start Throttle sensor circuit Fluid temperature sensor circuit Line pressu re solenoid circuit Light Shade ._----- SAT7588, fJ Fluid 'temperature sensor SYMPTOM: There Is large shock when changingfrom "N" to "R" range. 0 Does self-diagnosis show damage to throttle sensor, line pressure solenoid or fluid temperature sensor circuit? Yes to "Self-diagnosis". No .I) . Check throttle sensor. - Refer to section EF & EC. E.C.U. Repair or replace throttle sensor. O.K. m Check line pressure at idle with selector lever in "0" range. Refer to "PRESSURE TESTING". N.G. - Dropping resistor che~ damaged circuit. - Refer O.K. SA T0888 1. Remove control valve assembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. . Valves to control line pressure ~Pressure regulator valve, modifier valve, pilot valve and pilot filter) . Linepressuresolenoid 0 N.G. Check again. O.K. INSPECTIONEND m SA T643A AT-50 1. Perform AfT control unit input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of AfT control unit harness connector. TROUBLE DIAGNOSES Diagnostic Procedure 6 SYMPTOM:"Vehicledoes not creep backwardwhen .~~~ "R" range. 0 0 Check A/T fluid level again. SA T638A N.G'.f RefillA.T.F. : O.K. N.G. in both "1" and" R" range r fA Check stall revolution with selector lever in" 1" and" R" range. O.K. O.K. in "1" range N.G. in "R" range. II 8 Check line pressure at idle with selector lever in "R" range. - Refer to "PRESSURE TESTING". SA T642A N.G. 1. Remove oil pan. 2. Check fluid condition. N.G. IN.G., 1. Perform AfT control unit input/output signal inspection. 2. If N.G., recheck A/T control r r Check again. O.K. r 8 Reverseclutch assembly 8 High clutch assembly 8 Low & reverse brake assembly 8 Low one-way clutch O.K. SA T643A Line pressure solenoid 3. Disassemble A/T. 4. Check the following items. 8 Oil pump assembly 8 Torque converter O.K. m II 1. Remove.control valveassembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. 8 Valvesto control line pressure (Pressure regulator valve,pilot valveand pilot filter) INSPECTION END m SAT171B AT-51 I unit pin terminals for damage or connection of A/T control unit harness connector. TROUBLE DIAGNOSES Diagnostic Procedure 7 SYMPTOM:Vehicle does not creep forward when 0 selecting "D", "2" and "1" range. 0 I Check A/T fluid level again. N.G. .1 Refill A.T.F. O.K. B1 N.G. Check stall revolution with selector lever in "0" range. - Refer to "STALL TESTING". . O.K. SA T638A B1 Check line pressure at idle with selector lever in "0" range. Refer to "PR.ESSU RE TESTING". N.G. IA SA T642A . Linepressuresolenoid 3. DisassembleA/T O.K. II 1. Remove oil pan. 2. Check A/T fluid condition. N.G. 4. Check the following items. . Oil pump assembly . Forwardclutchassembly . Forwardone-wayclutch . , Lowone-wayclutch . Torqueconverter O.K. B1 N.G. Check again. O.K. INSPECTION II SAT171B AT-52 END 1. Remove control valveassembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. . Valvesto control line pressure (Pressure regulator valve, modifier valve, pilot valveand pilot filter) 1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector. TROUBLE DIAGNOSES D ~~ /11\' OlD OFF Self-diagnosis start Light --- --~Shade SA T760B ~ Diagnostic Procedure 8 Revolution sensor Speed sensor Shift solenoid A Shift solenoid B SYMPTOM: Vehicle cannot be started from D1 on Cruise test - Part 1. Go to Diagnostic Procedure 7. Is Diagnostic Procedure 7 O.K.? Yes D Does self-diagnosis show damage to revolution sensor, speed sensor, shift solenoid A or B after cruise test? Yes Check damaged circuit. - Refer to "Self-diagnosis". No 0 Check throttle sensor. section EF & EC. O.K. 7"" Refer to I N.G. Check line pressure at stall point with selector lever in "D" range. - Refer to "PRESSU RE TESTING". N.G. 1. Remove control valveassembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. O.K. II I] 1. Remove oil pan. 2. Check A/T fluid condition. N.G. O.K. O.K. O.K. SA T643A II N.G. Check again. O.K. INSPECTIONEND SAT171B AT-53 Repair or replace throttle sensor. . . . . . . Shift valveA Shift valveB Shift solenoidA ShiftsolenoidB Pilotvalve Pilotfilter 3. 4. . . . . . . DisassembleA/T. Check the following items. Forward clutch assembly Forward one-way clutch Low one-way clutch High clutch assembly Torque converter Oil pump assembly 1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of A/T control unit harness connector. TROUBLE DIAGNOSES D 0 Diagnostic Procedure 9 OlD OFF Self-diagnosis start - - - - - - - - - - - - - - Light - - Shade SA T157C m Revolution sensor SYMPTOM: AfT does not shift from D, to D2 at the specified speed. AfT does not shift from D4 to D2 when depressing accelerator pedal fully at the specified speed. Are Diagnostic 8 O.K.? Procedures 7 and Yes D Does self-diagnosis show damage to inhibitor switch after cruise test? m Speed sensor Speedometer Yes Check inhibitor switch circuit. - Refer to "Self-diagnosis". N.G. Repair or replace revolution sensor and speed sensor circuits. No Check revolution sensor and speed sensor circuit. "Self-diagnosis" SA T629B Go to Diagnostic Procedure 7 or : 8. - Refer to . O.K. iJ Check throttle sensor.- Refer to section EF & EC. 0 0 Repair or replace throttle O.K. 1. Remove oil pan. 2. Check AfT fluid condition. N.G. I O.K. O.K. O.K. m m N.G. Check again. ~ O.K. INSPECTION END 8/8 8/8 , +". Dl.:TD2" / Depress fully 6) 0/8 SAT118B I 1. Removecontrol valve.Referto "ON-VEHICLE SERVICE". 2. Checkthe following items. . Shift valveA . Shift solenoidA . Pilot valve . Pilot filter 3. 4. . . . SAT171B / D27D3 ( 0/8 ~/( Release 0 AT-54 sensor. DisassembleA/T. Check the following items. Servo piston 'assembly Brake band Oil pump assembly 1. Perform AfT control unit input/output signal inspection. .2. If N.G., recheck AfT control unit pin terminals for damage or connection of AfT control unit harnessconnector. TROUBLE DIAGNOSES D 0 Diagnostic Procedure 10 DID OFF SYMPTOM: AIT does not shift from D2to D3 at the specified speed. 5elf-diagnosis start - - - - - - - - - - - - - - Light Yes D - - Shade SAT157C Go to Diagnostic Procedure 7 or B. Are Diagnostic Procedures 7 and BO.K.? Does self-diagnosis show damage to inhibitor switch after cruise test? Yes Check inhibitor switch circuit. - Refer to "Self-diagnosis". Check throttle sensor. - Refer to section EF & EC. 0 Repair or replace throttle sensor. O.K. 1. Remove oil pan. 2. Check A/T fluid condition. N.G. .O.K. O.K. BJ O.K. I 1. Remove control valveassembly. - Refer to "ON-VEHI. CLE SERVICE". 2. Check the following items. . ShiftvalveB Shift solenoid B . . 3. 4. . . . SAT1718 II 8/8 II II N.G. Check again. Jl O.K. INSPECTION 0 0/8 l '1 SAT1198 AT-55 END Pilot valve . Pilotfilter DisassembleAlT. Check the following items. Servo piston assembly High clutch assembly Oil pump assembly 1. Perform AfT control unit input/output signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of AfT control unit harness connector. TROUBLE DIAGNOSES D \1/ /~ . Diagnostic Procedure 11 Revolution sensor OlD r:I OFF Self-diagnosis start / I SYMPTOM: AIT does not shift from D3to D4at the spee~sensor. Shift solenoid A Shift s?lerioid B Fluid specified speed. / / r .- ::;;~ature Light Are Di~gnostic Procedures 7 and 8 O.K.. I - ---_M_M_-M-M---M--uShadel . SAT761B D light I 10 - T ~ " - mUH H ~. I I No II -' Go 8. to Diagnostic Procedure 7 or Yes Does self-diagnosisshow damage to inhibitor switch, overdrive . h h. . SWltC,s Ift soIenol,d A B, revolution sensor, speed sensor or fluid temperature sensor . . f . "1 t Yes Ch~ck da~aged ~~~cUit.- Refer I to Self-diagnosIs. . ClrcUi a ter crUise test. No + Checkthrottle sensor.- Refer to section EF & EC. ~ Repair or replace throttle sensor. . O.K. 1. Remove oil pan. 2. Check AlT fluid condition. I 1:01 I!I ./ /' N.G. 11 O.K. 1. Remove control valveassembly. - Refer to "ON-VEHICLE SERVICE". . 2. . O.K. ~ . . O.K. II. . Checkthe followingitems. Shift valveB Overrunclutchcontrolvalve Shift solenoidB Pilotvalve Pilotfilter 3. DisassembleA/T. SAT171BI II. 8/8 U II I I I. I I I II Check again. I0 .K . 0/8 II U SAT120B I I INSPECTIONEND . I ~ 1. Perform AfT control unit input/output I I AT -56 4. Checkthe followingitems. . Servopistonassembly . Brakeband Torqueconverter . Oil pumpassembly signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of AfT control unit harness connector. TROUBLE DIAGNOSES D ,\1// Diagnostic Procedure 12 OlD SYMPTOM: AIT does not perform lock-up at the specified speed. :;8,'" OFF Self. .. ,-- UW fJ p b ;= - L- - j:: - II D. ==J ,J II" / . -- Forward one-way clutch to; I!. =::J l oMwdtth II - r"'\' '" -\ clutch - ..t1- .I Overrun // --:511 '>i D, 2 and 1 ranges Idle Judgement a. .. :g) 1 2 creep. ~ . 2 6 ::1::1 ::I C . 48 314 E..::I ]1!!]11 II II H 'c g ~ ] H c(c( c(!!! ~:J ...IOILc( 213 1 cI ~~ ... M 't.. i ':'NM.ct: ~ ~ 1!!5 !5!5!5,~~ '§.= &~ Engine does not start in "N", "P" ranges. No creep at all, 124 it, 1;: S ~z~ iii O.c 48 61,62 120' 126' .. i :!1 E=!5.. .ge:gi! o~ ~!i -e,~E.=!!!i h: :;! ~ ~ Excellive 101 ~ :? ~c ~e ~'6> '6>! 8~ u::8.E~et:.:i.jj:J - 90, 7 - I .c ~ 7 !5 ! Numben ere arrenged in order of probability. Perform inspections starting with number one end working up. Circled numben indicate thet the transmillion must be removed from the vehicle. ! ~ 66 7, 67 @ 3 @ 3 . .< I!! II c: 0 .:! .0 20 0. ~ u . .. 0 ~ ~ 4111 II ~it:;;i.EE ~888jn 0= ~.~ ~~ ...««««!!! ~ 0 II:: J: ...... ~-' -'III ij:;; 00 . 3 ~ @ @ 4 @I 4 4 .<§; 01 .<§; 0 @ $ 1 .. .. Gear change shock felt during deceleration by releasing accelerator pedal. 1 - Too high a change point from ~'D." to "D, ", from "D," to "D, ", from "D," to "D, ". 1 1 1 5 3 4 6 4 2 - . 2 @ICID @ .10 . . @I . 4 2 @@ 3 3 4 15 .. CIDI@ Qj)'@1@0 5 5 3 4 2 does not operate when depressing . 01 @I. @I .(j; 3 2 112 31 4 depressing pedal in "D. " beyond k ickdown vehicle speed limit. 211 31 4 - Races extremely fast or slips in changing from "D." to "D," when depressing pedal. 2 3 5 - Races extremely fast or slips in changing 1 2 3 6 pedal in "D." within kickdowII vehicle speed. operates or engine overruns when to "D," - 4 5 @. . . .0 4 when depressing pedal. - Races extremely fast or slips in changing from "D," to "D," when depressing pedal. 1 2 3 5 4 - Races extremely fast or slips in changing from "D." or "D," to "D," when depressing pedal. 1 2 3 5 4 Vehicle will not run in any range. 1 Transmission noise in "D", ranges. 1 - c: 1 to "D." - 144 .@ Failure to change gear from "D," Or from "D," to "D. ". from "D." g.!! .c ~ :J U > 1:: 1 - Kickdown 126. 1130 134 - to "D," - -~ .. 1 @@I Failure to change gear from "D," Or from "D." to "D, ". Kickdown :!! :!! i g S 1 to "D," - 126, 137 1 - Failure to change gear from "D." - 120' 124 ~ .. °.c -N :;;5505.~ ;~ -fi5.c.2!-fi' ~ ~ ! ~!~:2:!!!!S =!1~~!au ~~~~~I 80.u~ uO .:! i ."2 :2 0.c: .:J :J:J :J c: ~!~.! 1 to "D,". Almost no shock or slipping in change from i. E 0. 214 "D,"to"D.". - c: 90, 101 7 ~ 1 to "D, ". Almost no shock or slipping in change from "D," 7 ~ > :0 !~eaa~:;02 's.! t::!::!:! ,jj::;8~~::;3o ~g~=~.~ ':;C::E1~~ ii:8.E~lI::w - 7, 67 67 S -~~lIg~ I-o.';:;~ Too sharp a shock in change from "D," "D." 67 t: i & -fi ~ ~.g 11 ."'!! 51.:! - 67, 106 70 § c: - « c: ! of II:: OFF vehicle ON vehicle "2", "1" and "R" 2 3 8 @0. . . . @ 0 @0.@ 4 @"l ,. .1. @ AT-73 I OJ TROUBLE DIAGNOSES Symptom Chart (Cont'd) ON vehicle ~ ..:. ~ .. i' a. 8 c: ! of .. tr Reference 9, 14 pege (A T- 66 66 - 5 i01 ?: .Q E 61 - - Geer chenge from "I, "to Does not chenge from "1," "1," when .;! Large shock chenging from "1," range. 21 1 120' 124 1 126' 137, 126'1130 134 144 .c: ~ .: u .c:" u '" ~ ~ E 0 015 01 M E 01 c: 0 a. E 0 u '" c: 1 0 c: 01 'tI '0 M .- .. -I: a: ~ ~ c: 01 M e :J . c a)~ f! ~ ~c:a e '0~"5 ~ ~2 .. u >01 OIM a. E.!!! ~ e~ ~ ~ ~ ~ ; ~ c: ~~ ~~ (I)..J U (I) OI:J g~ .ag ..JOIL« N M .:. N 0 0 1;j 1;j '5 '5 E E :J:J ~~ ... .. ~ M.c: o.~ 1;j ~ '5 c: E 0 :J'; 8 8 g'c «««.!!! .c: ~ u 8a.~~ ~ ~~ a. 0I.c: > '" ~ 0 I~ i ~ 0' ~ "5 ~ .c: u 01 ~.. ~ > t: ~g~~i"2 'E'E c:! ~.! 2 I ~~ ILIL ~~ ~e O..J ..Ja) 6 514 3 @. 6 5 7 @.I@. 4 3 5 314 2 range. .' .. @ Transmission overheats. 3 Offensive smell et fluid charging pipe. Lock-up point is extremelv high or low. - AfT does not shift to "D. " when driving with overdrive switch "ON", - Engine is stopped at "R". "D", renges, "2" end "I" 416 5 @cvl@@[email protected]@ .I@@ @ -I Q) .. 01 Q) FUSI BLE LI NK BOX (Refer to "POWER SUPPLY ROUTING" in EL section.) BODY GROUND TROUBLE DIAGNOSES AfT Shift Lock System (Cont'd) DIAGNOSTIC PROCEDURE 1 SYMPTOM: Selector lever cannot be moved from "P" range when applying brake pedal or can be moved when releasing brak,e pedal. 0 R/W 0 N.G. CHECK POWER SOURCE. 1.1 -=- SAT818B 6 Control unit terminal ~ ~ . Fuse . Ignitionswitch 2. Check voltage between @i)[9 ~EIDJ [Y] Check the following items: . Harnesscontinuitybetween battery and control unit control unit terminals @ , @ , @ and ground. Battery voltage should exist. LIB 6 N.G. ~ Check the following items: . Detention switch - Refer to "COMPONENTCHECK". . Key switch - Refer to "COMPONENTCHECK". . Harnesscontinuity between detention switch and control unit. CHECK INPUT SIGNAL (Detention switch). -=- SAT819B 1.1 I] RIG' OJ 2. Check voltage between control unit terminal @ and ground while setting selector lever in "P" position. Control unit terminal Selector lever release butto n Voltage Not pressed -=- Battery voltage SA T820B I] CHECK INPUT SIGNAL (STOP LAMP SWITCH). 1. I ~ fI!if::j 2. Check voltage between control unit terminal @ and ground while applying brake pedal. Battery voltage should exist. O.K. @ AT-78 N.G. Check the following items: . Stop lampswitch . Harnesscontinuitybetween stop lampswitchand control unit TROUBLE DIAGNOSES AfT Shift Lock System (Cont'd) II i5~ ~ Shift lock harness I2 ~~~ \~ / ~.~,' - ~~ .tJPJ I . I .. .\ ,. ~ J .' ~' ~~ ~JJ~.) .~1~ ~ IJ ' ,~ ~ ~. ~/ / 1- . r.t\ ~. ~ :\~ ' . . . \ , \. Needle bearing m q». / m q»/ ,./.. EI ~ / Beari~grace' ~1 / Fmm "'"...' J Needle bearing \ \ Needle" . f'\~f::\ ~W~ ~ ) bilseal~~./ m onp"mp"m" ';"h" *JaI(Ij 011pump cover I R.,,;";", ~...* . '''ko~y Gasket ~ ~,~ Overrunclutch hUb Thrust washer mq» ~ Retaining plate*/ // , ./ Ealq» BearingraceElq» ~ - ~~S""';"' ~ (i B'l~\ - ~~~\ ~ ~ (with Front rear internal planetary gear carrier) Output shaft ./front snap ring \ ~~ - . I Rear sun gear ~ 7 . .X~)~ L :e ~ ~Needlebearingmq» Front planetary carrier AT-86 E.nd bearing Forward one-way clutch \ Snap ring Forward clutc h hub Thrust washer Rear internal gear I : D-ring~~. / ' Y\S";';"'~EI~ . r'\1 ~~OiIPumpcoverbearingrace*EI q» / ' Needle bearing / "" ' B q» . eanng race Eli> 'D 12 - 151 : \ ~~ ~~ q» ~o~~ ,~ ~ . "~16-21 (1'6_2'1' ,,/ ~ ~~ o.,;",~/ ~J' ~ ./ Rever~e clutch assembly (4.0-5.0,2~361 / . O-ring~EI coo,.";;::':,~ - , ~ Friction ring/ ~VaneElq»./ /' 1\ / ..~ Vanering.,/ 0 \ . I Oil pump ./ housing 0 ~ ~TOrqUeConverter 39 -49 <:\ ,J, 0 0 1 ..,( '-. Cam ring i '\.. O-ring EI Input shaft ./5 ,~ ~/./ , "":<:'i~ , / '. . ~ \\}) iP':>..~ :i~~ ~ /' 61 64 ~~.~,;~~ l~. ~~ ~~ '- . Cam nng return spnng Pivot Pin--v>~ Control pistonR o-ring~~ A ~ Side seal OiIPumPhOUSingOilseal~~ {OJ (6.2 -6.5,45 -471 \ . S pnng seat m q» MAJOR OVERHAUL D-ring ~~ '1« Oilseal ~~ _~~I ~ ~~}" . (~~'J I ~"} I ), // I ./" "" no. t:!EI~ '// .~mblv V' l t:!@>~ 9 Am.m.'"'' mblv So"," 9. I ~~ i ;::-- ~ /'. ' /l ~ 7. 9 '°.7-0.9,6., . ~ ~ /" ~ .'L Parking i ~ ~ Revolutio~ "".m" flow, aft rear snap ring ~ ." ,-. .6 -0.7, 3~0-7 6 . , 14 - 18) . .6". 20 - 2S '2.0 -2 6 .., 1"1 .. r ~ ' D Il-A""m.,"@> 0-,'''' t:! "ATF . I .': ... I."- ~1I 0.",."",,, '''10""'''' o-,~ogt:!@> ~ .nog..,EI g ge Parkin 0 ' .'-tf~: ..1;1 ,,,",," % ..CoT / Ano"".oo 00" /'. R~ -./' 0-';", ,. ,', l:;;' I EIR) t? ~~b' (1~2) Accumulator piston C SA T937 A 21. Remove manual shaft components, if necessary. a. Hold width across flats of manual shaft (outside the transmission case) and remove lock nut from shaft. AT.. 99 DISASSEMBLY Disassembly (Cont'd) b. Remove retaining pin from transmission case. Oil seal \: Transmission case SA T042 B c. While pushing detent spring down, remove manual plate and parking rod from transmission case. d. Remove manual shaft from transmission case. \ e. Remove spacer and detent spring from transmission case. f. Remove oil seal from transmission case. -In~ ~~.~ '0_L -/ ~-~j-/c ~ @~~\I I \ r ,) yj- ~ SAT044B AT -1 00 REPAIR FOR COMPONENT PARTS Oil Pump ~ EI. ~ Friction ring O-ring : N.m (kg-m, ft-Ib) Apply A.T.F. 1EaI~ : Apply petroleum jelly. ~ <@ @: Pivot pin Side seal Oil pump housing EI ~ Control Oil seal O-ring ~<@ piston Side seal ,~~ lEal~ Oil pump cover assembly Vane ring High clutch seal ring Cam ring Sp ring seat Cam ring spring .M-~EI~ SA T648A DISASSEMBLY 1. Loosen bolts in numerical order and remove oil pump cover. SAT649A Inscribe identification mark . 2. Remove rotor, vane rings and vanes. Inscribe a mark on back of rotor for Identification of fore-aft direction when reassembling rotor. Then remove rotor. . 3. While pushing on cam ring remove pivot pin. Be careful not to scratch oil pump housing. AT-101 REPAIR FOR COMPONENT PARTS Oil Pump (Cont'd) 4. While holding cam ring and spring lift out cam ring spring. Be careful not to damage oil pump housing. Hold cam ring spring to prevent it from jumping. .. 5. Remove cam ring and cam ring spring from housing. oil pump 6. Remove pivot pin from control piston and remove control piston assembly. 7. Remove oil seal from oil pump housing. Be careful not to scratch oil pump housing. . SAT655A INSPECTION Oil pump cover, rotor, vanes, control piston, side seals, cam ring and friction ring Check for wear or damage. . SA T656A AT -1 02 REPAIR FOR COMPONENT PARTS Oil Pump (Cont'd) Dial indicator Side clearances Measure side clearances between end of oil pump housing and cam ring, rotor, vanes and control piston in at least four places along their circumferences. Maximum measured values should be within specified ranges. Before measuring side clearance, check that friction rins~, O-ring, control piston side seals and cam ring sprinb are removed. Standard clearance: Cam ring 0.01 - 0.024 mm (0.0004 - 0.0009 in) Rotor, vanes, control piston 0.03 - 0.044 mm (0.0012 - 0.0017 in) If not within standard clearance, replace oil pump assembly except oil pump cover assembly. . . Vane SAT657A . Clearance lr Seal ring ~ Seal ring clearance Measure clearance between seal ring and ring groove. Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 in) Wear limit: 0.25 mm (0.0098 in) If not within wear limit, replace oil pump cover assembly. . . SA T658A ASSEMBLY 1. Drive oil seal into oil pump housing. Apply A.T.F. to outer periphery and lip surface. . 2. Install cam ring in oil pump housing by the following stops. a. Install side seal on control piston. Pay attention to its direction - Black surface goes toward control piston. Apply petroleum jelly to side seal. b. Install control piston on oil pump . . AT-1 03 REPAIR FOR COMPONENT PARTS Oil Pump (Cont'd) c. Install O-ring and friction ring on cam ring. Apply petroleum jelly to O-ring. . d. Assemble cam ring, cam ring spring and spring seat. Install spring by pushing it against pump housing. e. While pushing on cam ring install pivot pin. 3. Install rotor, vanes and vane rings. Pay attention to direction of rotor. . SAT662A 4. Install oil pump housing and oil pump cover. a. Wrap masking tape around splines of oil pump cover assembly to protect seal. Position oil pump cover assembly in oil pump housing assembly, then remove masking tape. b. Tighten bolts in a criss-cross pattern. AT -104 REPAIR FOR COMPONENT PARTS Oil Pump (Cont'd) E!!I@ Small dia. seal rings E!!I@ Large dia. seal rings j~~~ --::::~> - . ~~ . YL~ ~ ~==,/- ~--:-, £j 5. Install seal rings carefully after packing ring grooves with petroleum jelly. Press rings down into jelly to a close fit. . Sealrings come in two different diameters. Check fit carefully in each groove. Small dia. seal ring: No mark Large dia. seal ring: Yellow mark in area shown by arrow Do not spread gap of seal ring excessively while installing. It may deform ring. . SA T663A AT -1 05 REPAIR FOR COMPONENT PARTS Control Valve Assembly Harness clips Harness clips Lower body Orifice check spring Orifice check valve Reamer bolt Reamer bolt Pilot filter Lower separate gasket ~.- ~. -' ~ ~ Separator plate Upper separate gasket ~ Side plate Upper body \ '~ ~~-~. \- O-"og~ wOO'CO""" ,o'oooid -~ Q I ~ \ -;~ \ O-'og~ ~\ AT-106 . 0 . (overrun clutch solenoid and shift solenoids and B) 3-00" ,o'oooid A ,,,"mb'y ~ : N.m (kg-m, ft-Ib) SAT1938 REPAIR FOR COMPONENT PARTS Control Valve Assembly (Cont'd) DISASSEMBLY 1. Remove solenoids. a. Remove lock-up solenoid and side plate from lower body. b. Remove a-ring from solenoid. SAT194B c. Remove line pressure solenoid from upper body. d. Remove a-ring from solenoid. SA T667 A e. Remove 3-unit solenoid assembly from upper body. f. Remove a-rings from solenoids. SAT668A 2. Disassemble upper and lower bodies. a. Place upper body facedown, and remove bolts, reamer bolts and support plates. b. Remove lower body, separator plate and separate gasket as a unit from upper body. Be careful not to drop pilot filter, orifice check valve, spring and steel balls. . c. Place lower body facedown, and remove separate gasket and separator plate. d. Remove pilot filter, orifice check valve and orifice check spring. SA T670A AT-107 REPAIR FOR COMPONENT PA.RTS Control Valve Assembly (Cont'd) e. Check to see that steel balls are properly positioned in upper body and then remove them from upper body. SAT671A INSPECTION Lower and upper bodies . Check to see that there are pins and retainer plates in lower body. SAT672A . . Check to see that there are pins and retainer plates in upper body. Be careful not to lose these parts. . Check to make sure that oil circuits are clean and free from . damage. Check tube brackets and tube connectors for damage. SAT673A Tube connector 0 O'o'--.r 00 0000 ) ~ 00 o~ o~- 0 0 0 g,oooo 0 6' 00' 0 0 0 '0 0 - 0 0 C ' 00 0 '0 0 Do 0 00 0 0 a OC 0 0 '" 0 0 0",", o~ 0 00 0 0 I 0 0 ~ , 0 0 00 0' 0 ~ 0 0 0 0 0 0 0 '0 ~ ,00 0 "0 0 Co 0 0 "",,,00 0 0 D "5 °g 0 "c0 0 0 oo ~ " 00 C '0 0 'b 0 015 00 = 0, 0 c"g 0 g °c? 0 00 OC "go = ,[l = 0 0 cc" 0' 0 0 00 c DOO 0 o "0 000 o()o 0 g :sO 0 0 .0 0 ~o 0 Separator plates . Check to make sure that separator plate is free of damage and not deformed and oil holes are clean. . 0 g 0 0 0 .0. SAT675A AT - t08 REPAIR FOR COMPONENT PARTS Control Valve Assembly (Cont'd) Pilot filter . Check to make sure that filter is not clogged or damaged. SA T676A Lock-up solenoid Check that filter is not clogged or damaged. Measure resistance. - Refer to "Electrical Inspection". . . SAT091 Components B Line pressure solenoid Check that filter is not clogged or damaged. Measure resistance. - Refer to "Electrical Inspection". . . Components SAT092B 3-unit solenoid assembly (Overrun clutch solenoid and shift solenoids A and B) Measure resistance of each solenoid. - Refer to "Electrical Components Inspection". . SAT095B Fluid temperature sensor Measure resistance. Inspection" . . SAT196B AT -1 09 Refer to "Electrical Components REPAIR FOR COMPONENT PARTS Control Valve Assembly (Cont'd) ASSEMBLY 1. Install upper and lower bodies. a. Place oil circuit of upper body face up. Install steel balls in their proper positions. b. Install reamer bolts from bottom of upper body and install separate gaskets. Reamer bolt (short) SAT681A c. Place oil circuit of lower body face up. Install orifice check spring, orifice check valve and pilot filter. SAT682A d. Install lower separate gaskets and separator plates on lower body. e. Install and temporarily tighten support plates, fluid temperature sensor and tube brackets. Unit: mm (in) SAT197B AT-110 REPAIR FOR COMPONENT PARTS Control Valve Assembly (Cont'd) f. . Temporarily assemble lower and upper bodies, using reamer bolt as a guide. Be careful not to dislocate or drop steel balls, orifice check spring, orifice check valve and pilot filter. SAT198B g. Install and temporarily tighten bolts and tube brackets in their proper locations. Bolt length and location: Item Bolt length @-- mm (in) a b c d 70 (2.76) 50 (1.97) 33 (1.30) 27 (1.06) 2. Install solenoids. a. Attach a-ring and install lock-up solenoid and side plates onto lower body. Side plate SA T200B b. Attach a-rings upper body. and install 3-unit solenoids assembly onto SAT668A c. Attach a-ring and install line pressure solenoid onto upper body. 3. Tighten all bolts. SAT667A AT-111 Torque converter relief valve CD R \ / Lock-up control valve 1 1; Upper body ' ~ 0 1~ 13 Return spring , Pin \ !i @ Return spring I II PI'ot"'" II N \ \ ~ crm1rn i\ ~ Retainer Plate/ \ ' , -r ~ ~ ~ ~/ . ~fjYP 0 ~~/ ~ . . ~ .r-..,~ ;; 77 // ~~~GG/~/ \ / ) 1 / , \U - before their installation. mPlug~ 0Cf '\ 4-2 sequence valve@Returnspring\PIU9 \ p . . j@R"''''':", P'" ~ mk«co I~ crnQ ~ Shift valve B amL ~ . ~ ~ - Overrun clutch control valve =yd] Overrun clutch reducing valve P Accumulator control Plug' . eturn spnng 4-2 relay valve - ~Pi Plug Return Sho ' Retainer pl Pin /1'1"1;«(««<0 R (7) \ eeve Z @R"'" / CID spnng SI ;t fl~12L!: ~o Ar I , ~ . . ~ '«««(Cf) Pressure modifier valve --.I G1 CL.' C-L-. ~ -'i«««««O @ Return spring Apply A.T.F. to all components I '" ~ L /0~ CV Return s P",~""",~" "',, ,r-'-~ ' cV / - cJI-/ ~ // Pin-~\ !II ~ ~ CD W .... CD "W~#' \ @"'7/ ((((O #. Plug / J '\) spring e . ~/~?7 ' «~«9--' Shuttle shift valve S (j])Return .~ !~ct Sleeve e Plug ~ ) C , Shift ««[((0 @ Return spring ' «({{((((CQ". valve A ~~~~\ ~~~ ~;§p~-;.':S5(~ ~,,~ pin ~ 4-2 sequence valve and relay valve are located far back in upper body. If they are hard to remove, carefully push them out using stiff wire. Be careful not to scratch sliding surface of valve with wire. (S; ~~ SAT828A AT-114 REPAIR FOR COMPONENT PARTS Control Valve Upper Body (Cont'd) INSPECTION ~ (jj E '" i5 ~ :; 0 0 - ~ Valve springs Measure free length and outer diameter of each valve spring. Also check for damage or deformation. Numbers of each valve spring listed in table below are the same as those in the figure on AT-112. . . --r\ \\\ \ - - Q . Free length SAT829A Inspection standard Unit: mm (in) Item Part No. Parts Q D CD Torque converter relief valve spring 31742-41X18 32.3 (1.272) 9.0 (0.354) CV Pressure regulator valve spring 31742-41X16 61.5 (2.421) 8.9 (0.350) CID Pressure modifier valve spring 31742-41 X19 31.95 (1.2579) 6.8 (0.268) @ Shuttle shift valve D spring 31762-41XOO 26.5 (1.043) 6.0 (0.236) CID 4-2 sequence valve spring 31756-41 XOO 29.1 (1.146) 6.95 (0.2736) <@ Shift valve B spring 31762-41 X01 25.0 (0.984) 7.0 (0.276) m 4-2 relay valve spring 31756-41XOO 29.1 (1.146) 6.95 (0.2736) @ Shift valve A spring 31762-41 X01 25.0 (0.984) 7.0 (0.276) @ Overrun clutch control valve spring 31762-41X03 23.6 (0.929) 7.0 (0.276) @ Overrun clutch reducing valve spring 31742-41 X20 32.5 (1.280) 7.0 (0.276) ([j) Shuttle shift valve S spring 31762-41X04 51.0 (2.008) 5.65 (0.2224) @ Pilot valve spring 31742-41X13 25.7 (1.012) 9.1 (0.358) @ Lock-up control valve spring 31742-41X22 18.5 (0.728) 13.0 (0.512) . Replace valve springs if deformed or fatigued. Control valves Check sliding surfaces of valves, sleeves and plugs. . AT -11 5 REPAIR FOR COMPONENT PARTS Control Valve Upper Body (Cont'd) ASSEMBLY 1. Lubricate the control valve body and all valves with A.T.F. Install control valves by sliding them carefully into their bores. Be careful not to scratch or damage valve body. . . . ~ ' ':;'" - ~I I ~~ r I II ~. --.J:::: ~ ~ij ~ ~ 0 ~ C)J~" I I~ '\'\';! ) ~ II u71)) 7~ - - ~ p.,'h',"~ Ughtly in while turning It. ) If ! 'r' / . If pressure . cannot be inserted into bore in upper body. If this happens, use vinyl tape wrapped screwdriver center sleeve until it can be inserted. Turn sleeve slightly while installing. : regulator plug is not centered h Vin ylI ~ tape )'::--- -I \~/" I SAT832A Accumulator control plug . Align protrusion of accumulator control sleeve with notch in plug. Align parallel pin groove in plug with parallel pin, and install accumulator control valve. . Notch /" 1(0:; ~JJ ~~f~, , ----------- ) to Center plug n C-:J~/.~ ~I sleeve in spool bore ;..{ =--=--=--'--:: properly, I ""'l7<\ "- r--:-~'CZ~ II! ~_I"~) ~~ ,= "" ~II P - ~,-,='7S"S ':::-i) -:.() l '- ::,I' .J--":-'Y' -x:... ~ c \ /' '" - ~ r Pressure regulator valve Sleeve Y-'--"'; Wrap a small screwdriver with vinyl tape and use it to insert the valves into proper position. I +---rr~)~l~. ~ / SA T833A 2. Install parallel pins and retainer plates. SA T834A AT-116 REPAIR FOR COMPONENT PARTS Control Valve Upper Body (Cont'd) . Whilepushingplug,installparallelpin. ~., . . ) . :::2...y-/---uO-..:::::J u~...:::;::-u;J~~:>'''> v, ~r.:::--';:::::::::;; ~,.~~~~k/$~' ':J ~ ~ rE v/:- ,~}p!n~ - ~-'--& 4-2 sequence valve and relay valve Push 4-2 sequence valve and relay valve with wire wrapped in vinyl tape to prevent scratching valve body. Install parallel pins. . Parallel I, ~ ':> ~ I.//. '-- ~ ,:J,,&~ '::::::::::: ~-: ~(j~~~~;:;fS Cj\\C) ~ Wire \ if1-J-:G . II GG \ I SAT835A . Insert retainer plate while pushing spring. Retainer plate 00 SAT836A AT-117 Lower body Pin !i I ... ... ~ co Retainer plate 3-2 timing valve @ Return spring ~ --, CD ~-- f!!!j-- Plug RetainerPlate---\cl ~Pin Manual valve en ~ -i (I) to> " ~ Apply A.T.F. to all components before their installation. Numbers preceding valve springs correspond with t page AT-119. REPAIR FOR COMPONENT PARTS Control Valve Lower Body (Cont'd) DISASSEMBLY 1. Remove valves at parallel pins. 2. Remove valves at retainer plates. For removal procedures, refer to "DISASSEMBLY" of Control Valve Upper Body. SA T838A INSPECTION :;; Qj E as '6 :;; '5 0 0 - Valve springs Check each valve spring for damage or deformation. Also measure free length and outer diameter. Numbers of each valve spring listed in table below are the same as those in the figure on AT-118. . . ~ .~ .- \\\ \ Q : Free length SAT829A Inspection standard: Unit: mm (in) Item Part No. Parts Q D Modifier accumulator piston spring 31742-41X15 30.5 (1.201) 9.8 (0.386) 1st reducing valve spring 31756-41X05 25.4 (1.000) 6.75 (0.2657) CID 3-2 timing valve spring 31742-41 X08 20.55 (0.8091) 6.75 (0.2657) @ Servo charger valve spring 31742-41X06 23.0 (0.906) 6.7 (0.264) CD '@ . Replace valve springs if deformed or fatigued. Control valves Check sliding surfaces of control valves, sleeves and plugs for damage. . ASSEMBLY Install control valves. For installation procedures, refer to "ASSEMBLY" of Control Valve Upper Body. . SA T838A AT -11 9 REPAIR FOR COMPONENT PARTS Reverse Clutch For the number of clutch sheets (drive plate and driven platel. refer to the below cross-58ction. ~: * Apply A.T.F. : Select with proper thickness. Direction of oil seal R.~~. d"Iohd,"m~ Dish plate Retaining plate Snap ring '-- Driven plate SAT839A DISASSEMBLY 1. Remove reverse clutch assembly from clutch pack. SA T840A 2. Check operation of reverse clutch. a. Install seal ring onto oil pump cover and install reverse clutch. Apply compressed air to oil hole. b. Check to see that retaining plate moves to snap ring. c. If retaining plate does not move to snap ring, D-ring or oil seal may be damaged or fluid may be leaking at piston check ball. SAT841A AT -1 20 REPAIR' FOR COMPONENT PARTS Reverse Clutch (Cont'd) 3. Remove drive plates, driven plates, retaining plate, dish plate and snap ring. SAT842A 4. Remove snap ring from clutch drum while compressing clutch springs. Do not expand snap ring excessively. 5. Remove spring retainer and return spring. . SAT843A 6. Install seal ring onto oil pump cover and install reverse clutch drum. While holding piston, gradually apply compressed air to. oil hole until piston is removed. Do not apply compressed air abruptly. 7. Remove D-ring and oil seal from piston. . INSPECTION Reverse clutch snap ring and spring retainer Check for deformation, fatigue or damage. . SAT844A Reverse clutch return springs Check for deformation or damage. Also measure free length and outside diameter. . ... Q) Q; E ---IJ , Dish plate Overrun clutch plate ' Forwad ~lutchPlate I O"'o,~@P , If I ,~ So.."0' O"_I~""""- ' .-,it" JI-'C - 0 r J ASSEMBLY 1. Install bearing onto one-way clutch inner race. Pay attention to its direction - Black surface goes to rear side. Apply petroleum jelly to needle bearing. . . ... @ SAT112B Oil seal D-ring<:@ ~ 2. Install oil seal and D-ring onto piston. Apply A.T.F. to oil seal and D-ring. . SAT879A t 3. Install piston by rotating it slowly and evenly. Apply A.T.F. to inner surface of transmission case. . AT -1 32 REPAIR FOR COMPONENT PARTS Low & Reverse Brake (Cont'd) 4. Install return springs, spring retainer and low one-way clutch inner race onto transmission case. 5. Install dish plate, low and reverse brake drive plates, driven plates and retaining plate. 6. Install snap ring on transmission case. Driven plate Drive plate SAT812B 7. Check operation of low and reverse brake clutch piston. Refer to "DISASSEMBLY". SAT872A 8. Measure clearance between retaining plate and snap ring. If not within allowable limit, select proper retaining plate. Specified clearance: Standard 1.1 - 1.5 mm (0.043 - 0.059 in) Allowable limit 2.5 mm (0.098 in) Retaining plate: Refer to S.D.S. 9. Install low one-way clutch inner race seal ring. ~J I ' /\ - ",] ~ I\ ' I " - '\ [\ \ ( /" ~'- I \ ~r =~ , ~~ " ~- U , , ". \ r. ;;'. \ - , ~ I, " . ~ I -( - , ~= t/. ,,*'/,~. /1 f , ~ I - (;-~ .. " . .. ~, 17 ~ / '\:IC ~\ II. " \ I~N ! ( : I~ . .. Apply petroleum jelly to seal ring. Make sure seal rings are pressed held by petroleum jelly. \ r ( ( \0 SAT884A AT -1 33 firmly into place and REPAIR FOR COMPONENT PARTS Forward Clutch Drum Assembly Needle bearing Forward clutch drum assembly Snap ring Low one-way clutch Side plate Snap ring ~ ~ ~" ~ -'''''''' 0.., -. J;J-. -. '> -. -. -!. .., I ( SAT886A DISASSEMBLY 1. Remove snap ring from forward clutch drum. 2. Remove side plate from forward clutch drum. 0. SA T888A 3. Remove low one-way clutch from forward ciutci. drum. \/ SA T889A AT -1 34 REPAIR FOR COMPONENT PARTS Forward Clutch Drum Assembly (Cont'd) 4. Remove snap ring from forward clutch drum. 5. Remove needle bearing from forward clutch drum. SAT891A ~ INSPECTION Forward clutch drum Check spline portion for wear or damage. Check frictional surfaces of low one-way clutch and needle bearing for wear or damage. . . ~~ ...~ SAT892A Needle bearing and low one-way clutch Check frictional surface for wear or damage. . SAT893A ASSEMBLY 1. Install needle bearing in forward clutch drum. SAT113B AT-135 REPAIR FOR COMPONENT PARTS Forward Clutch Drum Assembly (Cont'd) 2. Install snap ring onto forward clutch drum. 3. Install low one-way clutch onto forward pushing the roller in evenly. clutch drum by SAT894A . SAT895A Install low one-way clutch with flange facing rearward. ) 4. Install side plate onto forward clutch drum. 5. Install snap ring onto forward clutch drum. AT -1 36 REPAIR FOR COMPONENT PARTS Rear Internal Gear and Forward Clutch Hub Rear internal gear (with forward one-way clutch inner race) Thrust washer lEI @ Forward clutch hub (with forward one-way clutch outer race) Snap ring Forward one-way clutch 6ri~ End bearing lEI @: Apply petroleum jelly. SA T896A DISASSEMBLY 1. Remove rear internal gear by pushing forward clutch hub forward. SA T897 A 2. Remove thrust washer from rear internal gear. f) n SAT898A 3. Remove snap ring from forward clutch hub. SAT899A AT-137 REPAIR FOR COMPONENT PARTS Rear Internal Gear and Forward Clutch Hub (Cont' d) 0 4. Remove end bearing. ~...~ ~ B/ IIT'n,,, ~ -~0'GIi)~ SAT900A 5. Remove forward one-way clutch and end bearing as a unit from forward clutch hub. ... "- 8 ~ :::=-~!) Illh I-~~,f), SAT955A 6. Remove snap ring from forward clutch hub. SAT901A INSPECTION Rear internal gear and forward clutch hub Check gear for excessive wear, chips or cracks. Check frictional surfaces of forward one-way clutch and thrust washer for wear or damage. Check spline for wear or damage. .. .. . .. .. SAT902A oc) 00 Snap ring and end bearing Check for deformation or damage. . SAT903A AT -1 38 REPAIR FOR COMPONENT PARTS Rear Internal Gear and Forward Clutch Hub (Cont'd) ASSEMBLY 1. Install snap ring onto forward clutch hub. 2. Install end bearing. SAT901A 3. Install forward one-way clutch onto clutch hub. Install forward one-way clutch with flange facing rearward. 4. Install end bearing. 5. Install snap ring onto forward clutch hub. . 6. Install thrust washer onto rear internal gear. Apply petroleum jelly to thrust washer. Securely insert pawls of thrust washer into holes in rear internal gear. . . 7. Position forward clutch hub in rear internal gear. 8. After installing, check to assure that forward clutch hub rotates clockwise. SAT905A AT-1 39 REPAIR FOR COMPONENT PARTS Band Servo Piston Assembly E-ring (large) Return spring A O-ring Return spring B ~~ Servo piston spring retainer Piston stem O-ring O-ring I ~ <&V O-ring , ~ @V ~ <&V O-ring ~ <&V Gasket ~ 0.0. servo piston retainer SAT908A DISASSEMBLY 1. Block one oil hole in 0.0. servo piston retainer and the center hole in 0.0. band servo piston. 2. Apply compressed air to the other oil hole in piston retainer to remove 0.0. band servo piston from retainer. 3. Remove O-ring from 0.0. band servo piston. a SAT909A . 4. Remove band servo piston assembly from servo piston retainer by pushing it forward. SAT910A 5. Place piston stem end on a wooden block. While pushing servo piston spring retainer down, remove E-ring. E-ring SAT911A AT-140 REPAIR FOR COMPONENT PARTS Band Servo Piston Assembly (Cont'd) 6. Remove servo piston spring retainer, return spring C and piston stem from band servo piston. "e n_@ SAT912A 7. Remove E-ring from band servo piston. SAT913A 8. Remove servo cushion spring retainer from band servo piston. 9. Remove O-rings from band servo piston. 10. Remove Q-rings from servo piston retainer. ~ SAT914A INSPECTION .. Pistons, retainers and piston stem Check frictional surfaces for abnormal wear or damage. . .... .. f Servo cushion spring retainer SAT915A Spring B Return springs . Check for deformation or damage. Measure free length and outer diameter. Inspectionstandard: Spring A SAT916A Unit: mm (in) Parts Free length Outer diameter Spring A 45.6 (1.795) 3.3 (1.350) Spring B 53.8 (2.118) 40.3 (1.587) Spring C 29.0 (1.142) 27.6 (1.087) AT-141 REPAIR FOR COMPONENT PARTS Band Servo Riston Assembly (Cont'd) ASSEMBLY 1. Install O-rings onto servo piston retainer. Apply A.T.F. to O-rings. Pay attention to position of each O-ring. . . 2. Install servo cushion spring retainer onto band servo piston. 3. Install E-ring onto servo cushion spring retainer. SAT919A 4. Install D-rings onto band servo piston. Apply A.T.F. to D-rings. . 5. Install servo piston spring retainer, return spring C and piston stem onto band servo piston. '@& ~@ SAT912A AT-142 REPAIR FOR COMPONENT PARTS Band Servo Piston Assembly (Cont'd) 6. Place piston stem end on a wooden block. While pushing servo piston spring retainer down, install E-ring. SAT921 A 7. Install band servo piston assembly onto servo piston retainer by pushing it inward. SAT922A 8. Install O-ring on 0.0. band servo piston. Apply A.T.F. to D-ring. . SAT923A 9. Install 0.0. band servo piston onto servo piston retainer by pushing it inward. SAT924A AT-143 REPAIR FOR COMPONENT PARTS Parking Pawl Components Parking rod ~ 24 - 29 N.m (2.4- 3.0 kg-m, 17 - 22 ft-Ib) Parking actuator support Parking pawl shaft Rear extension Output shaft SA T205B DISASSEMBLY 1. Slide return spring to the front of rear extension flange. 2. Remove return spring, pawl spacer and parking pawl from rear extension. 3. Remove parking pawl shaft from rear extension. SAT927A 4. Remove parking actuator support and rod guide from rear extension. AT-144 REPAIR FOR COMPONENT PARTS Parking Pawl Components (Cont'd) INSPECTION . Parking pawl and parking actuator support Check contact surface of parking rod for wear. '" SAT929A ASSEMBLY 1. Install rod guide and parking actuator support extension. 2. Insert parking pawl shaft into rear extension. onto rear 3. Install return spring, pawl spacer and parking pawl onto parking pawl shaft. SAT927A 4. Bend return spring upward and install it onto rear extension. AT-145 ASSEMBL Y Assembly 1. a. . . b. Install manual shaft components. Install oil seal onto manual shaft. Apply A.T.F. to oil seal. Wrap threads of manual shaft with masking tape. Insert manual shaft and oil seal as a unit into transmission case. c. Remove masking tape. SAT931 A d. Push oil seal evenly and install it onto transmission case. \ e. Align groove in shaft with drive pin hole, then drive pin into position as shown in figure at left. SA T933A f. Install detent spring and spacer. g. While pushing detent spring down, install manual plate onto manual shaft. AT -146 ASSEMBL Y Assembly (Cont'd) h. Install lock nuts onto manual shaft. SAT936A Front.. Accumulator piston B Accumulator 2. Install accumulator piston. a. Install O-rings onto accumulator piston. . Apply A.T.F. to O-rings. Unit: mm (in) Accumulator piston O-rings: tJ tr{'Ob AE..o, piston A Accumulator Accumulator A B C D Small diameter end 29 (1.14) 32 (1.26) 45 (1.77) 29 (1.14) Largediameter end 45 (1.77) 50 (1.97) 50 (1.97) 45 (1.77) piston C SA T937 A b. Install return spring for accumutator case. A onto transmission Unit: mm (in) Free length of return spring: Accumulator A Free length 43 (1.69) c. Install accumulator . ApplyA.T.F.to transmission case. pistons A, S, C and D. 3. Install band servo piston. a. Install return springs onto servo piston. SAT941 A AT -14 7 ASSEMBLY Assembly (Cont'd) b. Install band servo piston onto transmission case. Apply A.i.F. to O-ring of band servo piston and transmission case. . c. Install gasket for band servo onto transmission case. d. Install band servo retainer onto transmission case. 4. Install rear side clutch and gear components. a. Place transmission case in vertical position. . ST07870000 (J37068) SAT943A .;:I Forward clutch drum b. Slightly lift forward clutch drum assembly and slowly rotate it clockwise until its hub passes fully over the clutch inner race inside transmission case. SAT944A c. Check to be sure that rotation direction of forward clutch assembly is correct. ----------------- , SAT945A AT ~ 148 ASSEMBL Y Assembly (Cont'd) d. Install thrust washer onto front of overrun clutch hub. . Apply petroleum jelly to the thrust washer. Insert pawls of thrust washer securely into holes in overrun clutch hub. . Hole for pawl SAT946A e. Install overrun clutch hub onto rear internal gear assembly. SAT947A f. . Install needle bearing onto rear of overrun clutch hub. Apply petroleum jelly to needle bearing. SAT948A g. Check that overrun clutch holding forward clutch hub. hub rotates as shown while SAT949A h. Place transmission case into horizontal position. SAT950A AT-149 ASSEMBLY Assembly (Cont'd) i. Install rear internal gear, forward clutch hub and overrun clutch hub as a unit onto transmission case. j. Install needle bearing onto rear internal gear. Apply petroleum jelly to needle bearing. . k. Install bearing race onto rear of front internal gear. Apply petroleum jelly to bearing race. . Securely engage pawls of bearing race with holes in front internal gear. . I. Install front internal gear on transmission case. AT -1 50 ASSEMBL Y Adjustment When any parts listed in the following table are replaced, total end play or reverse clutch end play must be adjusted. Total end play Part name Reverse clutch end play 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 High clutch drum 8 8 Oil pump cover 8 8 - 8 Transmission case Low one-way clutch Overrun clutch Rear internal inner race hub gear Rear planetary carrier Rear sun gear Front planetary Front sun gear High clutch carrier hub Reverse clutch drum 1. Install front side clutch and gear components. a. Install rear sun gear on transmission case. Pay attention to its direction. . b. Install needle bearing on front of front planetary carrier. Apply petroleum jelly to needle bearing. c. Install needle bearing on rear of front planetary carrier. Apply petroleum jelly to bearing. Pay attention to its direction - Black side goes to front. . . . SAT967A AT -151 ASSEMBL Y Adjustment (Cont'd) d. While rotating forward clutch drum clockwise, planetary carrier on forward clutch drum. / .., SAT969A . F rant planetary , carrier Check that portion A of front planetary carrier protrudes approximately 2 mm (0.08 in) beyond portion B of forward clutch assembly. '.-= .:':.. ,..: '.. .., Portion install front A ...:::.'. Forward clutch drum Portion B SAT970A O---El~ ~~ ~f}Jj ~ r~: ""--~-L ' // e. Install bearing races on rear of clutch pack. Apply petroleum jelly to bearing races. Securely engage pawls of bearing race with hole In clutch pack. . . / SA T204B f. Place transmission case in vertical position. g. Install clutch pack into transmission case. SAT973A AT -1 52 ASSEMBLY Adjustment (Cont' d) 2. Adjust tetalend play. Total end play "T,": 0.25 - 0.55 mm (0.0098 - 0.0217 in) a. With needle bearing installed, place J34291-1 (bridge), J34291-2 (legs) and the J34291-5 (gauging cylinder) ente eil pump. The leng ends ef legs sheuld be placed firmly en machined surface ef eil pump assembly and gauging cylinder sheuld rest en tep ef the needle bearing. Leck gauging cylinder in place with set screw. b. Install J34291-23 (gauging plunger) into. gauging cylinder. c. With eriginal bearing race installed inside reverse clutch drum, place shim selecting gauge with its legs en machined surface ef transmissien case (no. gasket) and allew gauging plunger to. rest en bearing race. Leck gauging plunger in place with set screw. d. Remeve To.el and use feeler gauge to. measure gap between gauging cylinder and gauging plunger. This measurement sheuld give exact tetal end play. Total end play "T,": 0.25 - 0.55 mm (0.0098 - 0.0217 in) If end play is eut ef specificatien, decrease er increase thickness ef eil pump cever bearing race as necessary. Available oil pump cover bearing race: Refer to S.D.S. . SAT979A AT -1 53 ASSEMBL Y Adjustment (Cont'd) 3. Adjust reverse clutch drum end play. Reverse clutch drum end play "12": 0.55 - 0.90 mm (0.0217 - 0.0354 in) a. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gauging cylinder) on machined surface of transmission case (no gasket) and allow gauging cylinder to rest on front thrust surface of reverse clutch drum. Lock cylinder in place with set screw. SAT981A b. Install J34291-23 (gauging plunger) into gauging cylinder. c. With original thrust washer installed on oil pump, place shim setting gauge legs onto machined surface of oil pump assembly and allow gauging plunger to rest on thrust washer. Lock plunger in place with set screw. Lock d. Use feeler gauge to measure gap between gauging plunger and gauging cylinder. This measurement should give you exact reverse clutch drum and play. Reverse clutch drum end play "12": 0.55 - 0.90 mm (0.0217 - 0.0354 in) If end play is out of specification, decrease or increase thickness of oil pump thrust washer as necessary. Available oil pump thrust washer: Refer to S.D.S. . Feeler gauge SAT984A AT-154 ASSEMBL Y Assembly 1. Install output shaft and parking gear. a. Insert output shaft from rear of transmission case while slightly lifting front internal gear. Do not force output shaft against front of transmission case. . / ;~T216B b. Carefully push output shaft against front of transmission case. Install snap ring on front of output shaft. Check to be sure output shaft cannot be removed in rear direction. . c. Install needle bearing on transmission case. Pay attention to its direction - Black side goes to front. . Apply petroleum jelly to needle bearing. . d. Install parking gear on transmission case. ~ e. Install snap ring on rear of output shaft. Check to be sure output shaft cannot be removed in forward direciton. . SA T960A AT -1 55 ASSEMBL Y Assembly (Cont'd) 2. Install rear extension. a. Install oil seal on rear extension. Apply A.T.F. to oil seal. . SAT219B b. Install O-ring on revolution sensor. Apply A.T.F. to O-ring. c. Install revolution 'sensor on rear extension. . SAT191B d. Install rear extension gasket on transmission case. SA T963A e. Install parking rod on transmission case. f. Install rear extension on transmission case. SAT189B AT-156 ASSEMBL Y Assembly (Cont' d) 3. Install front side clutch and gear components. a. Install rear sun gear on transmission case. Pay attention to its direction. . b. Make sure needle bearing is on front of front planetary carrier. Apply petroleum jelly to needle bearing. c. Make sure needle bearing is on rear of front planetary carrier. Apply petroleum jelly to bearing. Pay attention to its direction - Black side goes to front. . . . SAT967A d. While rotating forward clutch drum clockwise, install front planetary carrier on forward clutch drum. / SAT969A ~ Front planetary . carrier Check that portion A of front planetary carrier protrudes approximately 2 mm (0.08 in) beyond po.rtion B of forward clutch assembly. Portion A Portion B SAT970A e. Make sure bearing races are on front and rear of clutch pack. Apply petroleum jelly to bearing races. Securely engage pawls of bearing races with holes in clutch pack. . . Front Rear SAT971A AT-157 ASSEMBLY Assembly (Cont'd) f. Install clutch pack into transmission case. SAT220B 4. Install brake band and band strut. a. Install band strut on brake band. Apply petroleum jelly to band strut. . SAT985A b. Place brake band on periphery of reverse clutch drum, and insert band strut into end of band servo piston stem. c. Install anchor end bolt on transmission case. Then, tighten anchor end bolt just enough so that reverse clutch drum (clutch pack) will not tilt forward. 5. Install input shaft on transmission case. Pay attention to its direction - O-ring groove side is front. 6. Install gasket on transmission case. . AT-158 ASSEMBLY Assembly (Cont'd) 7. Install oil pump assembly. a. Install needle bearing on oil pump assembly. Apply petroleum jelly to the needle bearing. b. Install selected thrust washer on oil pump assembly. Apply petroleum jelly to thrust washer. . . SA T989A c. Carefully install seal rings into grooves and press them into the petroleum jelly so that they are a tight fit. Seal ring m~ d. Install O-ring on oil pump assembly. Apply petroleum jelly to O-ring. . a-ring lEI ~ SAT991A e. Apply petroleum jelly to mating surface of transmission case and oil pump assembly. SAT992A f. . Install oil pump assembly. Install two converter housing securing bolts in bolt holes in oil pump assembly as guides. SAT993A AT-159 ASSEMBL Y Assembly (Cont'd) Transmission case Oil pump assembly . Insert oil pump assembly to the specified position in transmission, as shown at left. 8. Install O-ring on input shaft. Apply A.T.F. to O-rings. . SAT114B 9. Install converter housing. a. Install O-rings on converter housing. b. Apply recommended sealant (Nissan genuine part: KP610-00250 or equivale.nt) to outer periphery of bolt holes in converter housing. Do not apply too much sealant. . SAT997A c. Apply recommended sealant (Nissan genuine part: KP610-00250 or equivalent) to seating surfaces of bolts that secure front of converter housing. SA T998A AT -1 60 ASSEMBL Y Assembly (Cont'd) d. Install converter housing on transmission case. 10.Adjust brake band. a. Tighten anchor end bolt to specified torque. Anchor end bolt: ~: 4 - 6 N.m (0.4 - 0.6 kg-m, 2.9 - 4.3 ft-Ib) b. Back off anchor end bolt two and a half turns. c. While holding anchor end pin, tighten lock nut. 11. Install terminal cord assembly. a. Install O-ring on terminal cord assembly. Apply petroleum jelly to O-ring. b. Compress terminal cord assembly stopper and install terminal cord assembly on transmission case. . 12. Install control valve assembly. a. Install accumulator piston return springs B, C and D. Unit: mm (in) Free length of return springs: Item Free length AT-161 8 c D 66 (2.60) 45 (1.77) 58.4 (2.299) ASSEMBL Y Assembly (Cont'd) b. Install manual valve on control valve. Apply A.T.F. to manual valve. . SATOO58 c. Place control valve assembly on transmission case. Connect solenoid connector for upper body. d. Install connector clip. e. Install control valve assembly on transmission case. f. Install connector tube brackets and tighten bolts @ and @. Check that terminal assembly harness does not catch. . Bolt Length @ 37 mm (1.46 in) @ 50 mm (1.97 in) g. Install O-ring on oil strainer. Apply petroleum jelly to O-ring. h. Install oil strainer on control valve. . SAT2218 AT -1 62 ASSEMBLY Assembly (Cont'd) tI::~~1 i. Securely fasten terminal harness with clips. j. Install lock-up solenoid and fluid temperature sensor connectors. SATOO98 Connector 13. Install oil pan. a. Attach a magnet to oil pan. SAT0118 b. Install oil pan gasket on transmission case. c. Install oil pan and bracket on transmission case. Tighten four bolts In a criss-cross pattern to prevent dislocation of gasket. . SAT0128 14. Install inhibitor switch. a. Check that manual shaft is in "1" range. b. Temporarily install inhibitor switch on manual shaft. c. Move manual shaft to "N". II SAT0138 AT -163 ASSEMBL Y Assembly (Cont'd) d. Tighten bolts while inserting 4.0 mm (0.157 in) dia. pin - vertically into locating holes in inhibitor switch and manual shaft. \\ --\\ SAT014B 15. Install torque converter. a. Pour A.T.F. into torque converter. Approximately 2 liters (2-1/8 US qt, 1-3/4 Imp qt) of fluid are required for a new torque converter. When reusing old torque converter, add the same amount of fluid as was drained. . . SAT015B b. Install torque converter while aligning notches and oil pump. SAT016B c. Measure distance A to check that torque converter is in proper position. Distance "A": 26 mm (1.02 in) or more AT-164 SERVICE DATA AND SPECIFICATIONS (S.D.S.) General Specifications KA24E Engine Autorriatic transmission model RE4R01A Transmission model code number 45X06 Stall torque ratio 2.0: 1 Transmission gear ratio 1st . 2nd Top O.D. Reverse 2.785 1.545 1.000 0.694 2.272 Automatic transmission fluid Type DEXRONTM Recommended oil Oil capacity II (US qt, Imp qt) 8.3 (8-3/4,7-1/4) Specifications and Adjustment VEHICLE SPEED WHEN SHIFTING GEARS Vehiclespeed km/h (MPH) Throttle position DI -> D, D, -> D. D. -> D. D. ->D. D. -> D, D, ->DI 1,->11 Full throttle 52 -56 (32 - 35) 95 - 101 (59 - 63) 146 - 156 (91 -97) 140 - 150 (87 - 93) 89-95 (55- 59) 40-44 (25 -27) 53 - 57 (33 - 35) Half throttle 38-42 (24 - 26) 72 -78 (45-48) 111-121 (69 -75) 55-65 (34 - 40) 33 - 39 (21 - 24) 10 - 14 (6-9) 53 - 57 (33 - 35) VEHICLE SPEED WHEN PERFORMING RELEASING LOCK-UP AND STALL REVOLUTION Stall revolution Vehicle speed km/h (MPH) Throttle position O.D. switch [Shift range] Lock-up "ON" Lock-up "OFF" ON [D.] 146 - 156 (91 -97) 140 - 150 (87 -93) OFF [D.] 95 Full throttle -101 2,050 (59-63) Engine speed rpm ON [D.] 112-120 (70 -75) 102-110 (63 -68) OFF [D.] (47 - 52) 71 -79 (44 -49) 76 -84 -2,250 LINE PRESSURf; 89-95 (55-59) Half throttle rpm AT-165 line pressure kPa (kg/em' , psi) D,2 and 1 ranges R range Idle 471 .510 ' (4.8 - 5.2, 68 - 74) 657 . 696 (6.7 -7.1,95 -101) Stall 1,020 . 1,098 (10.4 -11.2,148 -159) 1.422 - 1,500 (14.5 - 15.3,206 - 218) SERVICE DATA AND SPECIFICATIONS (S.D.S.) Specifications and Adjustment (Cont'd) RETURN SPRINGS Unit: mm (in) Item Part No. Free length Outer diameter Torque converter relief valve spring 31742-41X18 32.3 (1272) 9.0 (0.354) Pressure regulator valve spring 31742-41X16 61.5 (2.4211 8.9 (0.350) Pressure modifier valve spring 31742-41 X19 31.95 (12579) 6.8 (0268) Shuttle shift valve D spring 31762-41XOO 26.5 (1.043) 6.0 (0.236) 4-2 sequence valve spring 31756-41XOO 29.1 (1.146) 6.95 (02736) Shift valve B spring 31762-41 X01 25.0 (0.984) 7.0 (0.276) 4-2 relay valve spring 31756 -41XOO 29.1 (1.146) 6.95 (0.2736) Shift valve A spring 31762-41X01 25.0 (0.984) 7.0 (0276) Overrun clutch control valve spring 31762-41X03 23.6 (0.929) 7.0 (0276) Overrun clutch reducing valve spring 31742-41X20 32.5 (1280) 7.0 (0.276) Shuttle shift valve S spring 31762-41 X04 51.0 (2.008) 5.65 (0.2224) Pilot valve spring 31742-41 X13 25.7 (1.012) 9.1 (0.358) Lock-up control valve spring 31742-41X22 18.5 (0.728) 13.0 (0.512) Modifier accumulator piston spring 31742-41X15 30.5 (1201) 9.8 (0.386) 1st reducing valve spring 31756-41X05 25.4 (1.000) 6.75 (02657) 3-2 timing valve spring 31742-41 X08 20.55 (0.8091) 6.75 (02657) Servo charger valve spring 31742-41X06 23.0 (0.906) 6.7 (0264) Parts Upper body Control valve Lower body Reverse clutch 16 pcs 30505-41 X02 19.69 (0.7752) 11.6 (0.457) High clutch 16 pes 31505-21X03 22.06 (0.8685) 11.6 (0.457) Forward clutch (Oiierrun clutch) Low & reverse brake 20 pes 31505-41X01 35.77 (1.4083) 9.7 (0.382) 18 pcs 31521-21XOO 23.7 (0.933) 11.6 (0.457) Spring A 31605-41X05 45.6 (1.795) 34.3 (1.350) Spring B 31605-41XOO 53.8 (2.118) 40.3 11.587) Spring C 31605-41X01 29.0 (1.142) 27.6 (1.087) Accumulator A 31605-41X02 43.0 (1.6931 Accumulator B 31605-41X10 66.0 (2.598) Accumulator C 31605-41X09 45.0 (1.772) Accumulator D 31605-41X06 58.0 (2283) Band servo Accumulator AT-166 ------------------- SERVICE DATA AND SPECIFICATIONS (S.O.S.) Specifications ACCUMULATOR O-RING Diameter mm (in) Accumulator and Adjustment (Cont'd) IForward A B C D Small diameter end 29 (1.14) 32 (1.26) 45 (1.77) 29 (1.14) Large diameter end 45(1.77) 50 (1.97) 50 (1.97) 45 (1.77) CLUTCHES AND BRAKES IReverse clutch/ Number of drive plates 2 Number of driven plates 2 2.0 (0.079) 1.8 (0.071) Clearance mm (in) Standard Allowable limit 0.5 - 0.8 (0.020 - 0.031) 1.2 (0.047) Number of driven plates 5 Thickness of drive plate mm(in) Standard Wear limit 2.0 (0.079) 1.8 (0.0711 Clearance mm (in) Standard Allowable limit 0.45 - 0.85 (0.0177 - 0.0335) 1.85 (0.0728) Thickness of retaining plate Thickness mm (in) 4.6 4.8 5.0 5.2 5.4 5.6 5.8 31537-21XOO 31537-21 X01 31537-21X02 31537 -21 X03 31537-21X04 31567-41X13 31567-41 X14 Number of drive plates 4 Number of driven plates 4 Thickness of drive plate mm (in) Standard Wear limit 1.6 (0.063) 1.4 (0.055) Clearance mm(in) Standard Allowable limit 1.8 - 2.2 (0.071 - 0.087) 3.0 (0.118) Thickness mm(in) 3.6 3.8 4.0 4.2 4.4 4.6 4.8 5.0 (0.142) (0.150) (0.157) (0.165) (0.173) (0.181) (0.189) (0.197) IOverrun Part number (0.181) (0.189) (0.197) (0.205) (0.213) (0.220) (0.228) IHigh clutch I Thickness of retaining plate 5 Thickness mm (in) Thickness of drive plate mm(in) Standard Wear limit Thickness of retaining plate I clutch Number of drive plates 31537.41X61 31537-41X62 31537-41X63 31537-41X64 31537-41 X65 31537-41X66 31537-41 X67 31537-41X68 AT-167 (0.315) (0.323) (0.331) (0.339) (0.346) (0.354) (0.362) 31537-41 XOO 31537-41X01 31537-41 X02 31537-41X03 31537-41 X04 31537-41X05 31537-41X06 I clutch Number of drive plates 3 Number of driven plates 5 Thickness of drive plate mm (in) Standard Wear limit 2.0 (0.079) 1.8 (0.071) Clearance mm(in) Standard Allowable limit 1.0 - 1.4 (0.039 - 0.055) 2.0 (0.079) Thickness of retaining plate Part number 8.0 8.2 8.4 8.6 8.8 9.0 9.2 Part number Thickness mm (in) Part number 4.0 (0.157) 4.2 (0.165) 4.4 (0.173) 4.6(0.181) 4.8 (0.189) 5.0 (0.197) 5.2 (0.205) 31537-41X79 31537-41 X80 31537-41X81 31537-41 X82 31537-41X83 31537-41 X84 31537-41 X20 SERVICE DATA AND SPECIFICATIONS (S.D.S.) Specifications and Adjustment (Cont'd) REVERSE CLUTCH DRUM END PLAY ILow & reverse brake I Number of drive plates 5 Number of driven plates 7 Thickness of drive plate mm (in) Standard Wear limit. I Thickness of oil pump thrust washer 8.6 8.8 9.0 9.2 9.4 9.6 I (0.339) (0.346) (0.354) (0.362) (0.370) (0.378) 31667-41X03 31667-41X04 31667-41X05 31667-41X06 31667-41X09 31667-41 X10 4.6 (0.4 - 0.6, 2.9 - 4.3) Number of returning revolutions for anchor end bolt I - Rotor, vanes and control piston - oil.pump housing Standard Seal ring clearance mm (in) Standard Allowable limit TOTAL Drive plate runout limit 0.Q1 - 0.024 (0.0004 - 0.0009) - 0.044 (0.0012 - 0.0017) 0.10 - 0.25 (0.0039 - 0.0098) 0.25 (0.0098) END PLAY 0.25 - 0.55 mm (0.0098 0.0217 in) Total e~ play "T I " - Thickness mm (in) Thickness of oil pump cover bearing race 0.8 1.0 1.2 1.4 1.6 1.8 2.0 (0.031) (0.039) (0.047) (0.0551 (0.063) (0.071) (0.079) 1 ..1 (0.043) (0.051) (0.059) (0.067) (0.075) Manual control linkage Number of returning revolutions for lock nut Distance between end of clutch housing and torque converter 2.5 0.03 31528-21 XOO' 31528-21 X01 31528-21X02 31528-21 X03 31528-21 X04 31528-21 X05 31528-21 X06 REMOVAL AND INSTAllATION Oil PUMP AND lOW ONE-WAY CLUTCH Oil pump clearance mm (in) Cam ring oil pump housing Standard Part number Part number Lock nut tightening torque Brake band Anchor end bolt tightening torque N.m (kg-m, ft-Ib) - 0.90 mm 0.7 (0.028) 0.9 (0.035) 1.3 1.5 1.7 1 .9 1.1 - 1.5 (0.043 - 0.059) 2.5 (0.098) Thickness mm (in) 0.55 (0.0217 - 0.0354 in) Thickness mm (in) 2.0 (0.079) 1.8 (0.071) Clearance mm lin) Standard Allowable limit Thickness of retaining plate Reverse clutch drum end play "Ta .. Part number 31429-21 XOO 31429-21 X01 31429-21 X02 31429-21 X03 31429-21X04 31429-21 X05 31429-21 X06 AT-168 - (1.1-1.5 11 15 N.m kg-m, 8 -11 ft-Ib) 26.0 mm (1.024 in) or more 0.5 mm (0.020 in) PROPELLER SHAFT& DIFFERENTIAL CARRIER I . PD SECTION CONTENTS PREPARATION... ." """"""""""" PROPELLER SHAFT ON-VEHICLE SERVICE "'..0 ""'''''''''''''''''''0'''''''''''''''''''' (Final drive) REMOVAL AND INSTALLATION FRONT FINAL DRIVE DISASSEMBLY INSPECTION ASSEMBLY 0 0 """'"'''''''''''''''''''' 0.. 0 0"'" 0''''' 0...0"""0" "'"'''''''''''''''''''''''''''''''''''''' """''''''0'''''''''''''0'''''''' o.0 SERVICE DATA AND SPECIFICATIONS (S.D.S.) 0 PD- 2 PD- 5 ~ PD- 9 '''''''''''''''''''''''''''''''''''''''''''''''''''''' 0 0 0" .. """"'''''''''''''''''''''''''''' ADJUSTMENT 0'"'''' PD-11 0 """""'''''''''''''...0 """"""'"'''''''''' '"'''''''''''' 0'"''''''''''''0''' ...". "'''''''''''''''''''''' 0'"'''' 0..""'''''''...0.0 PD-12 PD-13 0. PD-17 0'0'"'''''''''''''' 0 PD-18 PD-25 PD-30 - PREPARATION SPECIAL SERVICE TOOLS Tool number (Kent-Moore No.) Tool name ST38060002 (J34311) Drive pinion flange wrench KV38100800 - ( ) Equivalent tool (J25604-D 1) Differential attachment Description ~ Removing and installing propeller shaft lock nut, and drive pinion lock nut. Mounting final drive (To use, make a new hole.) ~ V a: 152 mm (5.98 in) ST309OS000 - ( Removing and installing drive pinion rear cone ) Drive pinion rear inner race puller set CD ST30031000 (J22912-D1) Puller @ ST30901000 - ( ) Equivalent tool (J26010-D1) Base ~ ~ Removing and installing differential side bearing inner cone ST3306S001 - ( ) Differential side bearing puller set CD ST33051001 ( - ) Equivalent tool (J22888) Body @ ST33061 000 (J8107-2) Equivalent tool (J26010-D1) Adapter ST30611000 (J25742-1) Drift Q}fi ~~ Installing pinion rear bearing outer race ~~ ~~\~.;II';~J..i'Hi1tlI'itr;;;'WJJ PD-2 PREPARATION Tool number (Kent-Moore No.) Tool name Description ST30613000 (J25742-3) Drift Installing pinion rear bearing outer race ~. ~ ST30701000 (J25742-2) Drift Installing pinion front bearing outer race c KV381 00200 (J26233) Gear carrier side oil seal drift KV38100500 - ( ) Gear carrier front oil seal drift KV381 00300 (J25523) Differential side bearing inner cone KV38100600 (J25267) Side bearing spacer drift ST3127S000 (See J25765-A) Preload gauge CD GG91030000 (J25765) Torque wrench @ HT62940000 - ( ) ~ roo ~ ~ CD ~ r;==~ Installing side oil seal Installing front oil seal Installing side bearing inner cone Installing side bearing spacer Measuring pinion bearing preload and total preload D ~-~ Socket adapter @ HT62900000 ( ) Socket adapter HT72400000 ( ) Slide hammer - Removing differential case assembly ~ ~ PD-3 PREPARATION Tool number (Kent-Moore No.) Tool name Description (J34309) Differential shim selector Adjusting bearing preload and gear height (J25269-4) Side bearing discs (2 Req'd) Selecting pinion height adjusting washer (J8129) Spring gauge @ ~ PD-4 Measuring carrier turning torque PROPELLER SHAFT .~ ~ 3S63A-T Washer Apply a coat of multi-purpose lithium grease containing molybdenum disulfide to the end face of the center bearing and both sides of the washer. ~ ~ Lock nut ~245 -294 125- 30, 181 - 217) 25-39 12.6- 4.0, 19 - 29) 'fh "1) 0 IX) IX) w . L'-. ? /" ' ~ Y'0 '00 rn':' Companion en ~ , R", ,.,,, ~ In' ~ )Y' . /~, // ~r Rn,-, ' ~ ' ~ ~ LockP'" t:9 ~\ G ~\J L ~~ ' P~ e,,,"'" , '"'OO-,""''"ru ~ CI p",O""". ,." . P t"J . 88. ."8(9. ' ,h,f<- LA I Inner "i"'~ Breath ' , mate nO r, J ~''''' l~O ? Pinion ", " Spe \ a """,, bea flange * : Adjustment is re * : Using locking ag : N.m (kg-m, ft-Ib ~ DISASSEMBLY Pre-inspection Before disassembling final drive, perform the following inspection. Total preload 1) Turn drive pinion in both directions several times to set bearing rollers. 2) Check total preload with Tool. Tool number: ST3127S000 (See J25765-A.) Total preload: 1.4 - 1.7 N.m (14 - 17 kg-em, 12 - 15 in-Ib) . SPD884 . Ring gear to drive pinion backlash Check ring gear-to-drive pinion backlash with a dial indicator at several points. Ring gear-to-drive pinion backlash: 0.10 - 0.15 mm (0.0039 - 0.0059in) SPD513 . . 0- Ring gear runout Check runout of ring gear with a dial indicator. Runout limit: 0.05 mm (0.0020 in) Tooth contact Check tooth contact. (Refer to Adjustment.) ../"/11 Runo~ ~m~: ~.~ m~~O.OO20in) SPD886 . Side gear to pinion mate gear backlash Measure clearance between side gear thrust washer and differential case with a feeler gauge. Clearance between side gear thrust washer and differential case: 0.1 - 0.2 mm (0.004 - 0.008 in) SPD887 Differential Carrier 1. Using two 45 mm (1.77 in) spacers, mount carrier on Tool. Tool number: PD-13 KV38100800 ( - ) DISASSEMBLY Differential Carrier (Cont'd) 2. Paint or punch match marks on one side of the side bearing cap so itcan be properly reinstalled. Bearing caps are line-board during manufacture. Replace them in their proper positions. SP D889 3. Remove side bearing caps. 4. Lift differential case assembly Tool number: HT72400000 out with ( - Tool. ) PD344 6 ? Keep the side bearing outer races together with inner cone do not mix them up. ~. SPD527 5. Loosen drive pinion nut and pull off companion SPD890 PD-14 flange. - DISASSEMBLY Differential Carrier (Cont'd) SPD891 6. Take out drive pinion (together with rear bearing inner race, bearing spacer and adjusting washer). 7. Remove oil seal. 8. Remove front bearing inner race. 9. Remove side oil seal. 10. Remove pinion bearing outer races with a brass drift. PD349 \ ""'-7 <.~. _H.. .--. . - /.'- -~ ./ 11. Remove pinion rear bearing inner race and drive pinion I height adjusting .Tool ----- - -- -PD179 PD-15 washer with suitable tool. DISASSEMBLY Differential Case 1. Remove side bearing inner cones. To prevent damage to bearing, engage puller jaws in groove. Tool number: @ ST33051001( ) Equivalent tool (J22888) @ ST33061000 (J8107-2) SPD529 Be careful not to confuse left- and right-hand parts. SPD022 2. Loosen ring gear bolts in a criss-cross fashion. 3. Tap ring gear off the differential case with a soft hammer. Tap evenly all around to keep ring gear from binding. 4. Drive out pinion mate shaft lock pin, with punch from ring gear side. Lock pin is calked at pin hole mouth on differential case. SPD025 PD-16 INSPECTION Ring Gear and Drive Pinion Check gear teeth for scoring, cracking or chipping. If any part is damaged, replace ring gear and drive pinion as a set (hypoid gear set). Differential Case Assembly Check mating surfaces of differential case, side gears, pinion mate gears, pinion mate shaft and thrust washers. SPD909 Bearing 1. Thoroughly clean bearing. 2. Check bearings for wear, scratches, pitting or flaking. Check tapered roller bearing for smooth rotation. If damaged, replace outer race and inner cone as a set. SPD715 PD-17 ADJUSTMENT For quiet and reliable final drive operation, the following five adjustments must be made correctly. 1. Side bearing preload 2. Pinion gear height 3. Pinion bearing preload 4. Ring gear-to-pinion backlash (Refer to ASSEMBLY.) 5. Ring and pinion gear tooth contact pattern ~ Side Bearing Preload A selection of carrier side bearing preload shims is required for successful completion of this procedure. 6 011 ~ ~ 1. Make sure all parts are clean and that the bearings are well lubricated with light oil or DexronTMtype automatic transmission fluid. 2. Place the differential carrier, with side bearings and bearing races installed, into the final drive housing. SPD527 3. Put the side bearing spacer in place on the ring gear end of the carrier. 4. Using the. J-25267 side bearing spacer drift, place both of the original carrier side bearing preload shims on the carrier end, opposite the ring gear. PD-18 ADJUSTMENT Side Bearing Preload (Cont'd) 5. Install the side bearing caps in their correct locations and torque the bearing cap retaining bolts. Specification: 88 - 98 N.m (9 - 10 kg-m, 65 - .72 ft-Ib) 6. Turn the carrier several times to seat the bearings. 7. Measure the turning torque of the carrier at the ring gear retaining bolts with a spring gauge, J-8129. Specification: 34.3 - 39.2 N (3.5 - 4 kg, 7.7 - 8.8 Ib) of pulling force at the ring gear bolt. 8. If the carrier turning torque is not within the specification range, increase or decrease the total thickl1ess of the side bearing adjusting washers until the turning torque is correct. If the turning torque is less than the specified range, install washers of greater thickness; if the turning torque is greater than the specification, install thinner washers. See the S.O.S. section for washer dimensions and part numbers. 9. Record the total amount of washer thickness required for the correct carrier side bearing preload. L--I I I .---i., , '-, , 10. Remove the carrier from the final drive housing, saving the selected preload washers for later use during the assembly of the final drive unit. PD344 Pinion Gear Height and Pinion Bearing Preload - iPt= I 1. Make sure all parts are clean and that the bearings are well lubricated. I- ~ 2. Assemble the pinion gear bearings into the pinion preload shim selector Tool, J-34309. I!DIiIIIIIIIIII 18 !:J SPD769 PD-19 ADJUSTMENT Pinion Gear Height and Pinion Bearing Preload (Cont'd) . . Front pinion bearing - make sure the J-34309-3 front pinion bearing seat is secured tightly against the J-34309-2 gauge anvil. Then turn the front pinion bearing pilot, J-34309-5, to secure the bearing in its proper position. Rear pinion bearing - the rear pinion bearing pilot, J-34309-8, is used to center the rear pinion bearing only. The rear pinion bearing locking seat, J-34309-4, is used to lock the bearing to the assembly. 3. Place the pinion preload shim selector Tool, J-34309-1, gauge screw assembly with the pinion rear bearing inner cone installed into the final drive housing. ~! C'/' 1\1 SPD893 4. Assemble the front, pinion bearing inner cone and the J-34309-2 gauge anvil together with the J-34309-1 gauge screw in the final drive housing. Make sure that the pinion height gauge plate, J-34309-16, will turn a full 360 degrees, and tig hten the two sections together by hand. 5. Turn the assembly several times to seat the bearings. SPD770 6. Measure the turning torque at the end of the J-34309-2 gauge anvil using torque wrench J-25765A. 'Turning torque specification: 1.0 - 1.3 N.m (10 - 13 kg-em, 8.7 - 11.3 in-Ib) PD-20 ADJUSTMENT Pinion Gear Height and Pinion Bearing Preload (Cont'd) 7. Place the J-34309-11 "R200A" pinion height adapter onto the gauge plate and tighten it by hand. CAUTION: Make sure all machined surfaces are clean. - PINION BEARING PRELOAD WASHER SELECTION - 8. Place the solid pinion bearing spacer, small end first, over the J-34309-2 gauge anvil and seat the small end squarely against the tip of the J-34309-1 gauge screw in the tool recessed portion. 9. Select the correct thickness of pinion bearing preload adjusting washer using a standard gauge of 3.5 mm (0.138 in) and your J-34309-101 feeler gauge. The exact measure you get with your gauges is the thickness of the adjusting washer required. Select the correct washer from the following chart. Drive pinion bearing preload adjusting washer: Refer to S.D:S. 10. Set your selected, correct pinion bearing preload adjusting, washer aside for use when assembling the pinion gear and bearings into the final drive. SPD774 PD-21 ADJUSTMENT Pinion Gear Height and Pinion Bearing Preload (Cont'd) - PINION HEIGHT ADJUSTING WASHER SELECTION - 11. Now, position the side bearing discs, J-25269-4, and arbor firmly into the side bearing bores. Install the side bearing caps and tighten the cap bolts to proper torque. 12. Select the correct standard pinion height adjusting washer thickness using a standard gauge of 3 mm (0.12 in) and your J-34309-101 feeler gauge. Measure the distance between the J-34309-10 pinion height adapter and the arbor. 13. Write down your exact total measurement. SPD775 14. Correct the pinion height washer size by referring to the "pinion head number." There are two numbers painted on the pinion gear. The first one refers to the pinion and ring gear as a matched set and should be the same as the number on the ring gear. The second number is the "pinion head height number," and it refers to the ideal pinion height from standard for quietest operation. Use the following chart to determine the correct pinion height washer. SPD542 PD-22 ADJUSTMENT Pinion Gear Height and Pinion Bearing Preload (Cont'd) Pinion head height number -6 -5 -4 -3 -2 -1 0 +1 +2 +3 +4 +5 +6 Add or remove from the standard pinion height washer thickness measurement Add 0.06 mm (0.0024 in) Add 0.05 mm (0.0020 in) Add 0.04 mm (0.0016 in) Add 0.03 mm (0.0012 in) Add 0.02 mm (0.0008 in) Add 0.01 mm (0.0004 in) Use the selectedwasher th ickness Subtract 0.01 mm (0.0004 in) Subtract 0.02 mm (0.0008 in) Subtract 0.03 mm (0.0012 in) Subtract 0.04 mm (0.0016 in) Subtract 0.05 mm (0.0020 in) Subtract 0.06 mm (0.0024 in) 15. Select the correct pinion height washer from the following chart. Drive pinion height adjusting washer (R200): Thickness mm (in) 3.09 3.12 3.15 3.18 3.21 3.24 3.27 3.30 (0.1217) (0.1228) (0.1240) (0.1252) (0.1264) (0.1276) (0.1287) (0.1299) 3.33 3.36 3.39 3.42 3.45 3.48 3.51 (0.1311) (0.1323) (0.1335) (0.1346) (0.1358) (0.1370) (0.1382) 3.54.(0.1394) 3.57 (0.1406) 3.60 (0.1417) 3.63 (0.1429) 3.66 (0.1441) Part No. 38164-P60 17 38154-P6Q 18 38154-P60 19 38154-P6020 381 54-P6021 38154-P6022 38154-P6023 38164-P6024 38154-P6025 38154-P6026 38154-P6027 38154-P6028 38154-P6029 38154-P6030 38154-P6031 38154-P6032 38154-P6033 38154-P6034 38154-P6035 38164-P6036 16. Remove the J-34309 pinion preload shim selector Tool from the final drive housing and disassemble to retrieve the pinion bearings. PD-23 ADJUSTMENT Tooth Contact Gear tooth contact pattern check is necessary to verify correct relationship between ring gear and drive pinion. Hypoid gear sets which are not positioned properly may be noisy, or have short life, or both. Low noise and a long life can be assured with a pattern check. 1. Thoroughly clean ring gear and drive pinion teeth. 2. Sparingly apply a mixture of powdered ferric oxide and oil or equivalent to 3 or 4 teeth of ring gear drive side. SPD357 3. Hold companion flange steady and turn the ring gear in both directions. Usually the pattern will be correct if you have calculated the shims correctly and the backlash is correct. However, in rare cases you may have to use trial-and-errorprocessas until you get a good tooth contact pattern. The tooth pattern is the best indication of how well a differential has been set up. Heel contact Face contact Toe contact ~~ ~~ To correct, increase thickness of pinion height adjusting washer in order to bring drive pinion close to ring gear. ~ To correct, reduce thickness of pinion height adjusting washer in order to make drive pinion go away from ring gear. . CM""-.. When adjustment is completed, be sure to wipe off completely the ferric oxide and oil or their equivalent. Flank contact ~ ~ PD-24 / v-t~ SPDOO7 ASSEMBLY Differential Case 1. Install side gears, pinion mate gears, thrust washers and thrust block into differential case. SPD552 2. Fit pinion mate shaft to differential case so that 'it meets lock pin holes. SPD553 3. Adjust clearance between rear face of side gear and thrust washer by selecting side gear thrust washer. Refer to S.O.S. Clearance between side gear thrust washer and differential case: 0.10 - 0.20 mm (0.0039 - 0.0079 in) SPD828 4. Install pinion mate shaft lock pin with a punch. Make sure lock pin is flush with case. SPD030 5. Apply oil to gear tooth surfaces and thrust surfaces and check that they turn properly. Gear oil SPD322 PD-25 ASSEMBLY Differential Case (Cont'd) 6. Apply locking sealant to ring gear bolts, and install them. Tighten bolts in a criss-cross fashion, lightly tapping bolt head with a hammer. 7. Press~fit side bearing inner cones on differential case with Tool. Tool number: @ KV38100300 (J25523) @ ST33061000 (J8107-2) Tool@ Tool @ PD353 Differential Carrier ~/~ if 1. Press-fit front and rear bearing outer races with Tools. Tool number: @ 5T30611000 (J25742-1) @ 5T30613000 (J25742-3) @ 5T30701000 (J25742-2) 2. Select pinion bearing adjusting washer and drive pinion bearing spacer, referring to Adjustment. Pinion front bearing outer race w~ @ SPD679 Press Adjusting washer 3. Install drive pinion height adjusting washer in drive pinion, and press-fit pinion rear bearing inner cone in it, using press and Tool. Tool number: 5T30901000 ( SPD377 PD-26 ASSEMBL Y Differential Carrier (Cont'd) 4. Place pinion front bearing inner cone in final drive housing. r-" ~ )~ E!!I ~ 0 SPD581 I J' ~ Pinion be' arlng adjDrive Pinion ust' lng spacer Pinion be' ad' arlng ~ JuH;"~~'~~ @ ~ . . Pinion fron t b earln g Inner race 5. Set drive pinion assembly (as shown in figure at left) in differential carrier and install drive pinion, with press and suitable tool. Stop when drive pinion touches bearing. Apply multi-purpose grease to pinion rear bearing inner race, pinion front bearing inner race and front pilot bearing. E: lIE! SPD897 SPD896 6. Apply multi-purpose grease to cavity at sealing lips of oil seal. Install front oil seal with Tool. Tool number: KV38100500 ( SPD557 7.: Install companion flange, and tighten pinion nut to specified torque with Tool. Ascertain that threaded portion of drive pinion and pinion nut are free from oil or grease. Tool number: ST38060002 (J34311) Tool PD416 PD-27 ASSEMBLY Differential Carrier (Cont'd) 8. Turn drive pinion in both directions several times, and measure pinion bearing preload. Pinion bearing preload: 1.1 - 1.4 N.m (11 - 14 kg-em, 9.5 - 12.2 In-Ib) When pinion bearing preload is outside the specifications, replace pinion bearing adjusting washer and spacer with a different thickness. SP D884 Q 9. Select side bearing adjusting washer. Refer to Adjustment. 10. Install differential case assembly with side bearing outer races into gear carrier. 5' SPD527 11. Insert left and right side bearing adjusting washers in place between side bearings and carrier. ~~~ , ~( ::;..;;-..f\:i{;! Tool ~ 12. Drive in side bearing spacer with Tool. Tool number: KV38100600 (J25267) bo,,'" ~~' SPD559 13. Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier. PD-28 ASSEMBL Y Differential Carrier (Cont'd) 14. Apply multi-purpose grease to cavity at sealing lips of oil seal. Install side oil seal. Tool number: KV38100200 (J26233) SP0560 15. Measure ring indicator. gear-to-drive pinion backlash with a dial Ring gear-to-drive pinion backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in) . If backlash is too small, decrease thickness of left shim and increase thickness of right shim by the same amount. If backlash is too great, reverse the above procedure. Never change the total amount of shims as it will change the bearing preload. SP0513 16. Check total preload with Tool. When checking preload, turn drive pinion in both directions several times to seat bearing rollers correctly. Total preload: Value more than 0.29 N.m (3.0 kg-em, 2.6 in-Ib) added on measured value of drive pinion preload If preload is too great, remove the same amount of shim to each side. If preload is too small, add the same amount of shim to each side. Never add or remove a different number of shims for each side as it will change ring gear-to-drive pinion backlash. 17. Recheck ring gear-to-drive pinion backlash because increase or decrease in thickness of shims will cause change of ring gear-to-pinion backlash. . . SP 0884 18. Check runout of ring gear with a dial indicator. Runout limit: 0.05 mm (0.0020 in) If backlash varies excessively in different places, foreign matter may be caught between the ring gear and the differential case. If the backlash varies greatly when the ring gear runout is within a specified range, replace the hypoid gear set or differential case. 19. Check tooth contact. Refer to Adjustment. 20. Install rear cover and gasket. . . SP0524 PD-29 SERVICE DATA AND SPECIFICATIONS (S.O.S.) Propeller Shaft GENERAL SPECIFICATIONS SPECIFICATIONS AND ADJUSTMENT Unit: mm (in) Applied model Transmission type Propeller shaft model Propeller M/T A/T 3S63A-R 3S63A-T Number of joints 3 Coupling method with transmission Sleeve type Type of journal bearings Distance between yokes Shaft length (Spider to spider) 1st 2nd Shaft outer diameter 1st 2nd Unit: mm (in) Propeller shaft runout limit Journal axial play Shell type (Non-disassembly type) 63.0 (2.480) 395.0 (15.55) 432.0 (17.011 605.0 (23.82) 605.0 (23.82) 75.0 (2.953) 75.0 (2.953) shaft model 75.0 (2.953) ... Large side 63.5 (2.500) ... Small side /~ PD-30 3S63A-R 1 3S63A- T 0.6 (0.024) 0 (0) SERVICE DATA AND SPECIFICATIONS (S.D.S.) Final Drive GENERAL SPECIFICATIONS Drive pinion preload adjustment Final drive model R200 Ring gear pitch diameter mm (in) 4.083 Number of teeth (Ring gear/Drive pinion) 49/12 Available 1.8 (3-7/8,3-1/8) 3.80 - 3.82 3.82 - 3.84 3.84-3.86 3.86 - 3.88 3.88 - 3.90 3.90 - 3.92 3.92 - 3.94 3.94-3.96 3.96 - 3.98 3.98 - 4.00 4.00-4.02 4.02 - 4.04 4.04 - 4.06 4.06 - 4.08 4.08 - 4.10 (R200) Pinion bearing adjusting washer Drive pinion to ring gear backlash mm (in) drive pinion 0.10 - 0.15 (0.0039 - 0.0059) 1.1 - 1.4 (11 - 14,9.5 -12.2) bearing preload Thickness mm (in) SPECIFICATIONS AND ADJUSTMENT Drive pinion adjustment Drive pinion bearing adjusting method preload N.m (kg-em, in-Ib) With front oil seal 205 (8.07) Gear ratio Oil capacity (approx.) Q (US pt, Imp pt) Drive pinion (0.1496 - 0.1504) (0.1504 - 0.1512) (0.1512 -0.1520) (0.1520 - 0.1528) (0.1528 - 0.1535) (0.1535 - 0.1543) (0.1543 - 0.1551) (0.1551-0.1559) (0.1559 - 0.1567) (0.1567 - 0.1575) (0.1575-0.1583) (0.1583 - 0.1591) (0.1591 - 0.1598) (0.1598 - 0.1606) (0.1606 - 0.1614) adjusting washer Part number 38125-61001 38126-61001 38127-61001 38128-61001 38129-61001 38130-61001 38131-61001 38132-61001 38133-61001 38134-61001 38135-61001 38136-61001 38137-61001 38138-61001 38139-61001 AvaUable pinion height adjusting washer Thickness mm (in) 3.09 (0.1217) 3.12 3.15 3.18 3.21 (0.1228) (0.1240) (0.1252) (0.1264) 3.24 (0.1276) 3.27 (0.1287) 3.30 3.33 3.36 3.39 3.42 3.45 3.48 3.51 3.54 3.57 3.60 3.63 3.66 (0.1299) (0.1311) (0.1323) (0.1335) (0.1346) (0.1358) (0.1370) (0.1382) (0.1394) (0.1406) (0.1417) (0.1429) (0.1441) Available drive pinion bearing preload adjusting spacer Part number Length mm (in) 38154-P6017 38154-P60 18 38154-P6019 38154-P6020 38154-P6021 38154-P6022 38154-P6023 38154-P6024 55.10 55.40 55.70 56.00 56.25 , 38154-P6025 38154-P6026 38154-P6027 38154-P6028 38154-P6029 38154-P6030 38154-P6031 38154-P6032 38154-P6033 38154-P6034 38154-P6035 38154-P6036 PD-31 (2.1693) (2.1811) (2.1929) (2.2047) (2.2146) Part number 38165-B4002 38165-B4003 38165-B4004 38165-61001 38166-61001 SERVICE DATA AND SPECIFICATIONS (S.D.S.) Final Drive (Cont'd) Total preload adjustment Total preload Side bearing adjustment Value more than 0.29 N.m 13.0 kg-cm, 2.6 in-Ibl added on measured -value of drive pinion preload Adjusting shim Side bearing adjusting method Side gear to pinion mate gear backlash IClearance betWeen side gear to differential easel mm Iinl 0.03 -0.0910.0012 - 0.00351 Available side bearing adjusting washer Thickness mm Iinl 2.00 10.07871 2.0510.08071 2.1010.0827) 2.1510.08461 2.20 10.08661 2.25 10.08861 2.30 10.09061 2.35 10.09251 2.40 10.0945) 2.45 10.09651 2.50 10.09841 2.55 10.10041 2.6010.10241 2.65 (0.10431 Available side gear thrust washer Part number 38453-N3100 38453-N3101 38453-N3102 38453-N31 03 38453-N3104 38453-N3105 38453-N3106 38453-N3107 38453-N3108 38453-N3109 38453-N3110 38453-N3111 38453-N3112 38453-N3113 Thickness mm Iinl Part number 0.80 10.03151 0.85 10.03351 0.90 10.03541 0.95 10.03741 1.00 10.03941 1.0510.04131 1.1010.0433) 1.1510.04531 1.2010.04721 1.25 10.04921 1.3010.05121 1.3510.05311 1.4010.05511 1.4510.05711 1.5010.05911 38424-40FOO 38424-40F08 38424-40F01 38424-40F09 38424-40F02 38424-40F10 38424-40F03 38424-40F 11 38424-40F04 38424-40F12 38424-40F05 38424-40F13 38424-40F06 38424-40F 14 38424-40F07 Ring gear runout Ring gear runout limit --------- PD-32 mm Iinl 0.05 10.00201 FRONTAXLE& FRONT ~USPENSION , ~ I FA SECTION CONTENTS PRECAUTIONS AND PREPARATION ... FRONT AXLE AND FRONT SUSPENSION CHECK AND ADJUSTMENT - """""'"'' FA- 2 "'"'' " FA- On-vehicle 4 FA- 5 FRONT AXLE FA- 9 FRONT AXLE - Wheel Hub and Knuckle FRONT AXLE - Baffle Plate FA-10 " FA-13 FRONT SUSPENSION FRONT SUSPENSION - FA-14 Coil Spring and Strut Assembly FRONT SUSPENSION- Tension Rod and Stabilizer Bar FRONT SUSPENSION - FA-15 ; ,' Transverse Link and Lower Ball Joint SERVICE DATA AND SPECIFICATIONS (S.O.S.) """"""V"""'"'''''''''''''''''''''''''''''''''''''''''''''''' FA-17 FA-18 FA-19 - PRECAUTIONS AND PREPARATION Precautions . . . When installing each rubber part, final tightening must be carried out under unladen condition * with tires on ground. * Fuel, radiator coolant and eRg!ne oil full. Spare tire, jack, hand tools and mats in designated positions. When removing each suspension part, check wheel alignment and adjust if necessary. Use Tool when removing or installing brake tubes. SBR500 Preparation SPECIALSERVICETOOLS Tool number (Kent-Moore No.) Tool name HT72520000 (J25730-A) Balljoint remover HT71780000 ( - ) Spring compressor ST35652000 ( - ) Strut attachment GG94310000 ( - ) Flare nut torque wrench Description ~ e5E ~~ Removing tie-rod outer end and lower ball joint Removing and installing coil spring Fixing strut assembly ~ ~ ~ Removing and installing brake piping FA-2 PRECAUTIONS AND PREPARATION Preparation (Cont'd) COMMERCIAL SERVICE TOOLS Tool name Description Wheel bearing drift OO)! Wheel bearing drift Baffle plate drift ~ ~ Removing wheel bearing ~ A: 45 mm (1.77 in) dia. B: 30 mm (1.18 in) dia. 2J Installing wheel bearing A: 68 mm (2~68 in) dia. B: 60 mm (2.36 in) dia. ~ Installing baffle plate B A: 88 mm (3.46 in) dia. B: 68 mm (2.68 in) dia. Teosion rod bushing drift Removing and installing tension rod bushing A: 75 mm (2.95 in) dia. B: 66 mm (2.60 in) dia. c: 62 mm (2.44 in) dia. D: 25.55 mm (0.98.2.17 FA-3 in) dia. FRONT AXLE AND FRONT SUSPENSION Final tightening for rubber parts requires to be carried out under unladen condition* with tires on ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. Strut mounting insulator (with strut mounting bearingl Spring upper seat Coil spring Strut assembly Front suspension member ~ - 46 52 (4.7- 5.3, 34- 38) "'.$. ~ I, ~39-49 (4.0-5.0, 29 -36) c:::? Front I ~ Transverse link assembly ~ Brake disc roter Tension rod ~ : N.m (kg-m, ft-Ib) SFA640A FA~4 CHECK AND ADJOSTMENT - On-vehicle Front Axle and Front Suspension Parts . Check front axle and front suspension parts for looseness, cracks, wear or other damage. (1) Shake each front wheel. / SMA525A (2) Retighten all nuts and bolts to the specified torque. Tightening torque: Refer to S.O.S. (3) Make sure that cotter pin is inserted. (4) Check front axle and front suspension parts for wear, cracks or other damage. SFA541A . . Check strut damage. (shock absorber) for oil leakage or other Check suspension ball joint for grease leakage and ball joint dust cover for cracks or other damage. FA'" 5 CHECK AND ADJUSTMENT - On-vehicle Front Wheel Bearing . .. . " \ SFA543A Check tightening torque of wheel bearing lock nut. tOJ: 147 216 N.m (15 22 kg-m, 108 - 159 ft-Ib) Check that wheel bearings operate smoothly. - - Check axial end play. Axial end play: 0.03 mm (0.0012 in) or less If axial end play is not within specification or wheel bearing does not turn smoothly, replace wheel bearing assembly. Refer to FRONT AXLE - Wheel Hub and Knuckle. Front Wheel Alignment Before checking front wheel alignment, be sure to make a preliminary inspection. PRELIMINARY INSPECTION Inside ~. SFA575S Make following checks. Adjust, repair or replace if necessary. Check tires for wear and improper inflation. Check front wheel bearings for looseness. Check wheel runout. . .. to S.D.S. Check front suspension for looseness. Refer .. .. Check steering linkage for looseness. Check that front shock absorbers work properly. Check vehicle posture (Unladen): "Unladen" Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. CAMBER, CASTER AND KINGPIN INCLINATION Caster and kingpin inclination are preset at factory and cannot be adjusted. . . Measure camber, caster and kingpin inclinationof both right and left wheels with a suitable alignment gauge, and adjust in accordance with the following procedures. SFA894 Kingpin inclination: 12°30' 14°00' - 90° SFA573B FA-6 CHECK AND ADJUSTMENT - On-vehicle Front Wheel Alignment Caster: 6°00' 7°30' (Cont'd) - SFA103A Camber: -1°30' to 0° Camber 90° SFA574A If camber is not within specification, adjust by turning adjusting pin as follows: (1) Remove adjusting pin Adjusting pin is installed with flat portion facing downward. SFA105A (2) Next replace adjusting pin with flat portion facing upward. (3) Turn adjusting pin to adjust. Camber changes about 5' with each graduation of adjusting pin. (4) Tighten adjusting pin to specified torque. ~: 124 - 143 N.m (12.6 - 14.6 kg-m, 91 - 106 ft-Ib) Adjusting pin SFA106A TOE-IN 1. Draw a base line on tread surface of tires. After lowering front of vehicle, move it up and down to eliminate friction, and set steering wheel in straight-ahead position. SMA123 FA-7 CHECK AND ADJUSTMENT - On-vehicle Front Wheel Alignment (Cont'd) 2. Measure toe-in. Measure distance "A" and "B" at same height as hub center. Toe-in: A - B 0.3- 2.3mm(O.012- 0.091in) 2e (Totaltoe-in) l' - 6.5' 8M~ Front t# Toe-in =A Total toe-in 9 SFA234A -B = 29 3. Adjust toe-in by varying length of steering tie-rods. (1) Loosen lock nuts. (2) Adjust toe-in by turning forward and reverse tie-rod. ~, r L -, -~ ~ Make sure both tie-rods are the same length. Standard length "L" - reference data: 174.8 mm (6.88 in) (3) Fix lock nuts, then tighten them designed torque. ~: 37 - 46 N.m (3.8- 4.7 kg-m,27 - 34 ft-Ib) SFA545A FRONT WHEEL TURNING ANGLE 1. Set wheels in straight-ahead position and then move vehicle forward until front wheels rest on turning radius gauge properly. SMA 127 2. Rotate fully steering wheel to the right or left; measure turning angle. Wheel turning angle: 't Front Inside wheel: A 39° - 43° Outside wheel: B 33° Full turns A: Inside B: Outside SFA898 FA-8 FRONT AXLE Knuckle spindle Suttle plate Snap ring Wheel hub tOJ : N.m (kg-m, tt-Ib) SFA546A FA-'9 FRONT AXLE - Wheel Hub and Knuckle Removal . Remove wheel bearing lock nut. SFA090A . ~ Remove brake caliper assembly. Brake hose need not be disconnected from brake caliper. Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted. SFA547A . Remove rotor and wheel hub from spindle. . Remove tie-rod ball joint and lower ball joint. SF,o,571 B Adjusting'pin . Remove bolts and nuts as shown at left. Make matchmarksbefore removingadjustingpin. FA-10 FRONT AXLE - Wheel Hub and Knuckle Installation .. SFA114A . Install wheel hub. Tighten wheel bearing lock nut. tOJ:147 - 216 N.m (15 - 22 kg-m, 108 - 159 ft-Ib) Check wheel bearing axial end play. Axial end play: 0.03 mm (0.0012 In) or less SFA543A Disassembly CAUTION: When removing wheel bearing from wheel hub, replace wheel bearing assembly (outer race, inner races and grease seal) with a new one. . Remove circular clip with suitable tool. SFA215A .press. . Press out wheel bearing assembly from wheel hub. Inspection WHEEL HUB . Check wheel hub for any cracks by exploration or dyeing test. CIRCULAR CLIP . Check circular clip for wear or cracks. Replace if necessary. FA-11 using a magnetic FRONT AXLE - Wheel Hub and Knuckle Assembly 1. Press new wheel bearing assembly into wheel hub from inside of rotor disc (with wheel hub). Maximum load P: 29 kN (3 t, 3.3 US ton, 3.0 Imp ton) CAUTION: .. Grease seal m Circular clip Do not press inner race of wheel bearing assembly. Do not apply oil or grease to mating surfaces of wheel bearing outer race and wheel hub. Be careful not to damage grease seal. 2. Install circular clip into groove of wheel hub. 3. Apply multi-purpose grease to sealing lip. SFA218A / FA-12 FRONT AXLE - Baffle Plate Removal .. Mark match marks on baffle plate before removing. If baffle plate raplacement requires removal of knuckle spindle. separate it equally using a screwdriver. Be careful not to scratch knuckle spindle. Matchmarks SFA548A Installation . Align matchmarks previously marked on baffle plate and install baffle plate by lightly tapping with a copper hammer and suitable tool. SFA549A FA-13 FRONT SUSPENSION cap ~~ - 59 78 (6.0 ~ - 8.0,~"( 43 - 58) ~ ~~ ~ - 39 54 (4.0 -5.5,29- 40) GaSket~ Strut mounting insulator ~~ Lock washer~ Bound bumper u""''''''~ Coil spring Strut assembly PI..,;, d;P\ Front fi suspension member I V / ~~88-108 ~ ~-J(9.0- 11.0, 65- SO) f)~ }~"""J " ~ J) link with ball joint ~ L~~46-52 (4.7-5.3, r 39 - 49 (4.0 -5.0,~ 29 - 36) ' 34-38) ~ ~88 - 108 (9.0.11.0,65- 80) If ~ Tension rod bracket 4-/r/~>\ ~\ "~:J a~~\ @ ' / ~: Transverse "-Tension rod ", l'\1~ N.m (kg-m, ft-Ib) When inStalling Stabilizer bar, tension rod and transverse link, final tightening requires to be carried out under unladen condition* with tires on the ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated position. SFA550A FA-14 FRONT SUSPENSION Strut upper portion I~ - Coil Spring and Strut Assembly Removal . .. Adjusting pin Remove strut assembly fixing bolts and nuts (to hoodledge). Do not remove piston rod lock nut on vehicle. Put match marks on strut lower bracket and camber adjusting pin. Disassembly 1. Set strut assembly on vise with Tool, then loosen piston rod lock nut. Do not remove piston rod lock nut. . Suitable bar SFA134A 2. Compress spring with a Tool so that strut mounting insulator can be turned by hand. HT71780000 ( ) SFA135A 3. Remove piston rod lock nut. ST35652000 ( ) SFA136A Inspection STRUT ASSEMBLY . . . Check for smooth operation through a full stroke, both compression and extension. Check for oil leakage occuring on welded or gland packing portion. . Check piston rod for cracks, deformation or other damage. Replace if necessary. FA-15 FRONT SUSPENSION -Coil Spring and Strut Assembly Inspection (Cont'd) STRUT MOUNTING INSULATOR Check cemented rubber-to-metal portion for separation or cracks. Check rubber parts for deterioration. . . Check thrust bearingparts for abnormalnoise or excessive rattle in axial direction. Replace if necessary. LOCK WASHER . Check for cracks, deformation or other damage. Replace if necessary. COIL SPRING . Check for cracks, deformation or other damage. Replace if necessary. Assembly . Top Bottom When installing coil spring, be careful not to reverse top and bottom direction. (Top end is flat.) SFA760 . ~ When installing coil spring on strut, it must be positioned as shown in figure at left. r=sA" \, \ Fl.. .." ~"'"d SFA'" . {} Left Front Cutout Install upper spring seat with its cutout facing the inner side of vehicle. Right " (Inner side of vehicle) Upper seat SFA576A FA-16 FRONT SUSPENSION - Tension Rod and Stabilizer Bar Removal and Installation . Remove tension rod and stabilizer bar. SFA552A Press. , SF A553A ~D"ft Front . . When removing tension rod bushing, place one drift on lower side of bushing and the other on upper side, as shown at left, and press bushing out. Place arrow mark on bushing facing tension rod before installing bushing. . Install stabilizer rear side bushings, then install front side bushings. When installing stabilizer bar clamp, make sure direction is correct (as shown at left.) ~ SFA554A . When removing and installing stanbilizer bar, fix portion A. . Install stabilizer bar with ball joint socket properly placed. SFA555A View from B mA~ ~~ O.K. ~~ N.G. SFAOO2A FA-17 FRONT SUSPENSION - Transverse Link and Lower Ball Joint Removal and Installation . . . Remove stabilizer, tension rod, ball joint and transverse link assembly. During installation, final tightening must be carried out at curb weight with tires on ground. After installation, check wheel alignment. Refer to "Front Wheel Alignment" of CHECK AND ADJUSTMENT - On-vehicle. SFA552A Inspection TRANSVERSE . . LINK Check transverse link for damage, cracks or deformation. Replace it if necessary. Check rubber bushing for damage, cracks and deformation. Replace transverse link if necessary. LOWER BALL JOINT . Measuring swing force Swing force and turning torque Before checking, turn ball joint at least 10 revolutions so that ball joint is properly broken in. Swing force: (measure point: cotter pin hole of ball stud) 7.8 - 55.9 N (0.8 - 5.7 kg, 1.8 - 12.6 Ib) Turning torque: 0.49 - 3.43 N.m (5.0 - 35 kg-em, 4.3 - 30.4 in-Ib) Cotter pin hole SFA756 Measuring turning Check ball joint for play. If ball stud is worn, play in axial direction is excessive or joint is hard to swing, replace transverse link assembly if necessary. torque SFA757 ~\( ~ lower Pry bar / Dial indicator / //:% SFA556A Vertical end play (On-vehicle) (1) Jack up front of vehicle and set the stands. (2) Clamp dial indicator onto transverse link and place indicator tip on lower edge of brake caliper. (3) Make sure front wheels are straight and brake pedal is depressed. (4) Place a pry bar between transverse link and inner rim of road wheel. (5) While pushing and releasing pry bar, observe maximum dial indicator value. Vertical end play: 0 mm (0 In) (6) If not within above specification, replace transverse link. FA-18 SERVICE DATA AND SPECIFICATIONS (S.D.S.) ... General Specifications COIL SPRING FRONT STABILIZER Bi'R Model Model Item Except Sports package Sports package Item Wire diameter mm (in) 13.3 (0.524) 13.5 (0.531) Coil diameter mm (in) 170 (6.69) 170 (6.69) Free length mm (in) 326 (12.83) 311 (12.24) 19.6 (2.0, 112) 21.6 (2.2, 123) Orange x 1, Purple x 1 Pink x 1, Purple x 1 Stabilizer diameter mm (in) Identification color Spring constant N/mm (kg/mm, Ib/in) Identification color STRUT Model Item Piston rod diameter mm (in) Stroke Sports package Except Sports package 20.0 (0.787) mm (in) 160 (6.30) Damping force [at 0.1 m (0.3 ft)/sec.] N (kg,lb) Expansion Compression Damping force [at 0.3 m (1.0 h)/sec.] N (kg,lb) Expansion Compression 412-608 (42 - 62,93 471-706 - 137) 206 - 304 (21 - 31, 46 - 68) I (48 -72,106 - 159) 235 - 353 (24 - 36, 53 - 79) 912 - 1,245 (93 - 127,205 - 280) 392 - 588 (40 - 60,88 - 132) FA-19 Except Sports package Sports package 24 (0.94) 25 10.98) White Orange SERVICE DATA AND SPECIFICATIONS (S.D.S.) . Inspection and Adjustment LOWER BALL JOINT WHEEL ALIGNMENT (Unladen*1) Camber degree -1°30' to 0° Caster degree 6° 00' - 7° 30' Swing force (Measuring point: cotter pin hole of ball stud) Toe-in (Total) N (kg, Ib) mm (in) Kingpin inclination 0.3 - 2.3 (0.012 - 0.091) degree l' - 6.5' degree 12°30' - 14°00' Turning torque N'm (kg-cm, in-Ib) 0.49 - 3.43 (5.0 - 35, 4.3 - 30.4) Vertical end play Front wheel turning angle Full turn*2 inside/outside 7.8 - 55.9 (0.8 - 5.7,1.8 - 12.6) d egree 39° mm (in) -43° /33° *1: Tankful of fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools, mats in designated position. *2: On power steering models, wheel turning force (at circumference of steering wheel) .of 98 to 147 N (10 to 15 kg, 22 to 33'lb) with engine idle. 0 (0) WHEEL RUNOUT (Radial and lateral) Wheel type Radial runout Aluminum wheel mm (in) WHEEL BEARING I lateral runout 0.3 (0.012) or less Steel wheel mm (in) Wheel bearing axial end play mm (in) 0.03 (0.0012) or less Wheel bearing lock nut Tightening tirque N'm (kg-m, ft-Ib) 147- 216 (15- 22,108 - 159) FA-20 0.5 (0.020) or less1o.8 (0.031) or less . REARAXLE & REARSUSPENSION , RA SECTION CONTENTS PRECAUTIONS AND PREPARATION "'"''.''''''''''''''''''''''''''''''' REAR AXLE AND REAR SUSPENSION CHECK AND ADJUSTMENT - RA- 2 RA- 4 On-vehicle " RA- 5 REAR 'AXLE AND REAR SUSPENSION ASSEMBLY RA- 8 REAR AXLE - Wheel Hub and Axle Housing RA- 9 REAR AXLE - Drive Shaft RA-13 REAR SUSPENSION RA-19 REAR SUSPENSION REAR SUSPENSION - Coil Spring and Shock Absorber Stabilizer Bar REAR SUSPENSION - Multi-link and Lower Ball Joint SERVICE DATA AND SPECIFICATIONS (S.D.S.) ""'"'''''''''''''''''''''''''''''''''''''''''''''' RA-20 RA-22 RA-23 RA-24 III PRECAUTIONS AND PREPARATION Precautions . ~, GG9431 0000 ( - ) . . . When installi~ each rubber part, final tightening must be carried out under unladen condition. with tires on ground. . Fuel, radiator coolant and .engine oil full. Spare tire, jack, hand tools, and mats in designated positions. Use Tool when removing or installing brake tubes. When removing each suspension part, check wheel alignment and adjust if necessarY. Do not jack up at the lower arm. SBR500 Preparation SPECIALSERVICETOOLS Tool number (Kent-Moore No.) Tool name HT71780000 ( - ) Spring compressor ST35652000 ( -. ) Strut attachment GG94310000 ( - ) Flare nut torque wrench ST30031 000 (J22912-01 ) Bearing puller ST38280000 ( - ) Arm bushing remover Description ~ ~----. ~ ~ ~ Removing and installing coil spring Fixing strut assembly Removing and installing brake piping Removing inner race of wheel bearing ~ ~ Removing and installing bushing of rear axle housing RA-2 PRECAUTIONS AND PREPARATION . Precautions (Cont'd) COMMERCIAL SERVICE TOOLS Tool name Attachment Wheelalignment Rear wheel hub drift Description ~ }aJJ} lIID) Wheel bearing drift 1:EID J Rear drive shaft plug seal drift rED RA-3 Measure rear wheel alignment A: B: e: D: E: Screw M24 x 1.5 35 (1.38) dia. 65 (2.561 dia. 56 (2.20) Unit: 12 (0.47) mm (in) Installing wheel bearing A: 41 mm (1.61 in) dia. B: 49 mm (1.93 in) dia. Removing rear wheel hub A: 26 mm (1.02 in) dia. B: 40 mm (1.57 in) dia. I nstalling rear driVe shaft plug seal A: 67 mm (2.64 in) dia. B: 85 mm (3.35 in) dia. REAR AXLE AND REAR SUSPENSION It Spring upper seat ~ Dust cover Coil spring ~-1S.'2-14) ~ Shock absorber ;:.E- 19 69 -88 (7.0 -9.0, 51 - 651 ~ Lower link 69 -88 (7.0 - 9.0, 51 -651 I~ 77 -98 (7.9 -10.0, 57 -721 Upper link rear @ ~ l L~43 -55 . (4.4 - 5.6,32 -41) ~98-118 I 110.0 - 12.0,72 - 871 ~ - 77 98 (7.9 - 10.0,57 -721 ~ 9-12 (0.9 -12,6.5 Final tightening for rubber parts requires to be carried out under unladen condition* with tires on ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. -8.71. Upper link front ~: N.m (kg-m,ft-Ib) SRA093A RA-4 v CHECK ANDADJtlSTMENT - On-vehicle Rear Axle and Rear Suspension Parts . Check axle and suspension damage. (1) Shake each rear wheel. parts for looseness, wear or SMA525A (2) Retighten all nuts and bolts to the specified torque. Tighteningtorque: Refer to S.D.S. (3) Make sure that cotter pin is inserted. (4) Check rear axle and rear suspension parts for wear, cracks or other damage. (5) Check shock absorber for oil leakage or other damage. SMA113 ! . Check suspension ball joint for grease leakage and ball joint dust cover for cracks or other damage. RA-5 CHECK AND ADJUSTMENT - On-vehicle Rear Wheel Bearing . .. SRA107A Check tightening torque of wheel bearing lock nut. ~: 235 314 N.m (24 32 kg-m, 174 - 231 ft-Ib) Check that wheel bearings op'erates smoothly. Check axial end play. Axial end play: 0.05 mm (0.0020 in) or less If axial end play is not within specification or wheel bearing does not turn smoothly, replace wheel bearing assembly. Refer to REAR AXLE - Wheel Hub and Axle Housing. - Rear Wheel Alignment Before checking rear wheel alignment, preliminary inspection. PRELIMINARY INSPECTION Inside ~. SFA575S be sure to make a Make following checks. Adjust, repair or replace if necessary. Check tires for wear and for improper inflation. Check rear wheel bearings for looseness. Check wheel runout. Refer to S.D.S. Check that rear shock absorber works properly. Check rear axle and rear suspension parts for looseness. Check vehicle posture (Unladen). ' "Unladen" : Fuel tank, radiator and engine oil full. Spare tire, jack, hand tools and mats in designated positions. .. . . . . CAMBER . Measure camber of both right and left wheels with a suitable alignment gauge and adjust in accordance with the following procedures. SRA096A Camber: -1°36' '/ SRA097A RA-6 to -0°36' CHECK AND ADJUSTMENT - On-vehicle Rear Wheel Alignment (Cont'd) If camber is not within specification, adjust by turning the adjusting pin. (1) Turn the adjusting pin to adjust. Camber changes about 5' with each graduation of the adjusting pin. (2) Tighten to the specified torque. ~:69 - 88 N.m (7.0 - 9.0 kg-m,51 - 65 ft-Ib) SRA098A TOE-IN 1. Draw a base line across the tread. After lowering rear of vehicle, move it up and down to eliminate friction. SMA123 2. Measure toe-in. Measure distance "A" center. Toe-in: A-B Lines parallel to center line of body and "B" at the same height as hub 0.5 - 4.5 mm (0.020 - 0.177 in) 2 () (Total toe-in) 1.5' - 12.5' Front ~ SFA234A Toe-in = A 6 -B Total toe-in = 26 3. Adjust toe-in by turning adjusting pins. Toe changes about 1.5 mm (0.059 in) [One side] graduation of the adjusting pin. 4. Tighten to the specified torque. ~:69 with each - 88 N.m (7.0 - 9.0 kg-m, 51 - 65 ft-Ib) Drive Shaft Check boot and drive shaft for cracks, wear, damage or grease leakage. SRA796 RA-7 REAR AXLE AND REAR SUSPENSION ASSEMBLY Removal and Installation SRA 100A . . Remove exhaust tube. Disconnect propeller shaft rear end. . Remove brake caliper assembly. Brake hose need not be disconnected from brake caliper. Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted. SFA110A . . Remove upper end nuts of shock absorber. Do not remove piston rod lock nut. Remove suspension member fixing nuts. Then draw out rear axle and rear suspension assembly. SRA101A RA-8 REAR AXLE - Wheel Hub and Axle Housing Adjusting cap I L.~ Wheel bearing withflange~ ~ : N'm(kg-m,ft-Ib) SRA102A Removal . Remove wheel bearing lock nut. . Remove brake caliper assembly and rotor. Brake hose need not be disconnected from brake caliper. Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted. SFA110A RA-9 REAR AXLE Wheel Hub and Axle Housing - Removal (Cont'd) . Separate drive shaft from axle housing by slightly tapping it. When removing drive shaft, cover boots with waste cloth to prevent them from being damaged. SFA181A . Remove axle housing. SRA104A . Remove wheel bearing with flange, and wheel hub from axle housing. SRA105A Installation .. Install axle housing with wheel hub. Tighten wheel bearing lock nut. tOJ:235 - 314N.m (24 - 32 kg-m, 174 - 231 ft-Ib) SRA106A . Check wheel bearing axial end play. Axial end play: 0.05 mm (0.0020 in) or less SRA107A RA-10 REAR AXLE - Wheel Hub and Axle Housing Disassembly SRA108A . CAUTION: Wheel bearing with flange usually does not require maintenance. If any of the following symptoms are noted, replace wheel bearing assembly (including flange, and inner and outer seals). Growling noise is emitted from wheel bearing during operation. Wheel bearing drags or turns roughly when hub is turned with your hand after bearing lock nut is tightened to specified torque. After wheel bearing is removed from hub. . . . WHEEL HUB . Remove wheel bearing (with flange) and wheel hub as one unit from axle housing before disassembling. WHEEL BEARING Using a press and drift as shown in figure at left, press wheel bearing out. Discard old wheel bearing assembly. Replace with a new wheel assembly. Press. . . SRA109A . Remove inner race from hub using a bearing replacer/puller. CAUTION: a. Do not reuse o!d inner race although it is of the same brand as the bearing assembly. b. Do not replace grease seals as single parts. ST30031 000 (J22912-01 ) SRA110A RA-11 REAR AXLE Wheel Hub and Axle Housing - Disassembly (Cont'd) AXLE HOUSING . Attach a drift on outer shell of bushing as shown in figure at left, remove bushing using arm bushing remover. When placing axle housing In a vise, use wooden blocks or copper plates as pads. Axle housing Drift SRA111A . . Ensure axle housing bore is free from scratches or deformities before pressing bushing into it. Attach bushing to chamfered bore end of axle housing and press it until it is flush with end face of axle housing. SRA112A Inspection WHEEL HUB AND AXLE HOUSING . . . Check wheel hub and axle housing for cracks by using a magnetic exploration or dyeing test. Check wheel bearing for damage, seizure, rust or rough operation. . Check rubber bushing for wear or other damage. Replace If necessary. Assembly . Place hub on a block. Attach a drift to inner race of wheel bearing and press it into hub as shown in figure at left. Be careful not to damage grease seal. Drift Block SRA113A RA-12 REAR AXLE - Drive Shaft Drive shaft ~I (24.32, ~~"'''~-~ 235.314174 - 231) Insulator ~ J @)~ I Adjusting cap : N.m (kg-m, ft-Ib) SRA114A Removal When removing drive shaft, cover boots with waste cloth to prevent damage to them. FINAL DRIVE SIDE . Remove side flange mounting bolt and separate shaft. WHEEL SIDE . Remove drive shaft by lightly tapping it with a copper hammer. To avoid damaging threads of drive shaft, install a nut while removing drive shaft. Installation . . . Insert drive shaft from wheel hub and temporarily tighten wheel bearing lock nut. Tighten side flange mounting bolts to specified torque. Tighten wheel bearing lock nut to specified torque. RA-13 REAR AXLE - Drive Shaft Snap ring "A" Final drive side Plug seal ~ Spider assembly IE! Snap ring "B" ~ Housing inner side ~ m Wheel hub side ~ ;> Boot band ~ SRA117A Disassembly Slide joint housing FINAL DRIVE SIDE 1. Remove plug seal from slide joint housing by lightly tapping around slide joint housing. 2. Remove boot bands. 3. Put match marks on slide joint housing and drive shaft before separating joint assembly. 4. Put match marks on spider assembly and drive shaft. SRA118A RA-14 REAR AXLE -Drive Shaft Disassembly (Cont'd) 5. Pry off snap ring, then remove spider assembly. CAUTION: Do not disassemble spider assembly. 6. Draw out slide joint housing. 7. Draw out boot. Cover drive shaft serration with tape to prevent damage to the boot. SRA119A WHEEL SIDE 1. Remove boot bands. 2. Put matchmarks on housing together with shaft and drive shaft before separating joint assembly. 3. Put matchmarks on spider assembly and drive shaft. SFA963 4. Pry off snap ring "A" with a screwdriver, and pull out slide joint housing. SRA120A 5. Pry off snap ring "B", then remove spider assembly. CAUTION: Do not disassemble spider assembly. 6. Draw out boot. Cover drive shaft serration with tape to prevent damage to the boot. SFA964 Inspection Thoroughly clean all parts in cleaning solvent, and dry with compressed air. Check parts for deformation or other damage. DRIVE SHAFT Replace drive shaft if it is twisted or cracked. BOOT Check boot for fatigue, cracks, or wear. Replace boot with new boot bands. RA-15 REAR AXLE - Drive Shaft Inspection (Cont'd) JOINT ASSEMBLY . . . Check spider assembly for bearing, damage. Replace spider assembly if necessary. Check housing for any damage. Replace housing set and spider assembly, if necessary. . When replacing only spider assembly, assembly from among those listed in the number stamped on sliding joint stamped on new part. Housing alone cannot be replaced. It together with spider assembly. Slide joint roller and washer select a new spider table below. Ensure is the same as that must be replaced Stamped number Part No. 00 3972010V10 01 39720 10V11 02 3972010V12 SRA121A Assembly . . After drive shaft has been assembled, make sure it moves smoothly over its entire range without binding. Use Nissan Genuine Grease or equivalent after every overhaul. FINAL DRIVE SIDE ~ 1. Install new small boot band, boot and slide joint housing to drive shaft. Cover drive shaft serration with tape to prevent damage to boot during installation. Tape SFA800 RA-16 REAR AXLE - Drive Shaft Assembly (Cont'd) 2. Install spider assembly securely, making sure marks are properly aligned. Press-fit with spider assembly serration chamfer facing shaft. 3. Install new snap ring. *"{E;= {r ~ . ~ < Su itable tool Chamfer SFA397 4. Install coil spring, spring cap and new plug seal to slide joint housing. Press plug seal. Apply sealant to mating surface of plug seal. CAUTION: a. When pressing plug seal into place, hold it horizontal so that spring inside it does not tilt or fall down. b. Move shaft in axial direction to ensure that spring is installed properly. If shaft drags or if spring is not installed properly, remove plug seal and install a new one. Discard plug seal after removal. . . SRA123A LI 5. Pack drive shaft with specified amount of grease. Specified amount of grease: 185 195 g (6.52 - 6.88 oz) 6. Set boot so that it does not swell and deform when its length is "L,". Length" L1": 110.5 - 112.5 mm (4.35 - 4.43 in) Make sure that boot is properly installed on the drive shaft groove. - I SRA124A SFA395 RA-17 REAR AXLE - Assembly Drive Shaft (Cont'd) 7. Lock new larger boot band securely with a suitable tool, then lock new smaller boot band. Suitable tool SFA472 WHEEL SIDE 1. Install new small boot band and boot on drive shaft. Cover drive shaft serration with tape to prevent damage to boot during installation. ~ Tape SFA800 ~" {I 2. Install spider assembly securely, making sure marks are properly aligned. Press-fit with spider assembly serration chamfer facing shaft. 3. Install new snap ring. 05= ~ . ~ Suitable tool Chamfer SFA397 4. Pack drive shaft with specified amount of grease. Specified amount of grease: 145 - 155 g (5.11 - 5.47 oz) 5. Install slide joint housing, then install new snap ring "A". 6. Set boot so that it does not swell and deform whe'n its length is "L2". Length "L2": 110.5 - 112.5 mm (4.35 - 4.43 in) Make sure that boot is properly installed on the drive shaft groove. 0 ~ SRA125A 7. Lock new larger and smaller boot bands securely with a suitable tool. SFA395 RA-18 REAR SUSPENSION ~~A16-19 Upper link rear ~~ 69.88 C;~ 17,.,"..".061- ~ Suspension m ember ~ 43.55 fi/ ~ Ao'I' 32 - 41) \ ~' Ii ~ ] ..@I A ~ ~ ~ 11. 98 (1.9.10,51.12) C;~ ~ 11. 77.9817.9".,'7.721 98 ~ ~ ~ (4.4 . 5,6, , '" '" .. -' (1.9. 10,51. 11.6.1.9,12.14) Gasket ~~18.24 (1.8.2.4,13.11) Upper plate Bushing Upper spring seat Upper rubber ~ 12) / 8 Mem';', - ~ ~'~~i 1' . . ~21 (2.;.2.1,16.20) ~ I" ' :j); ' c; ~ - i ' 0 21.26(2.1.2.1,16.20) Differential /~ ~ Yf0/! '\~ ) , ~ .@ @@.l 34. ~ (3.5.4.5, Stabilizer 26. 33) BUShingA ~ 43.55 (4.4.5.6,32.41) ~ (6.0 -1.0,36 - 51) ~ 71... (1.2 . 8.8, 52.64) ~~88.108 I :" , ~ - '-"""Mm (et,I h ~(~ ~. 98.118110.12,12.81) @ '", I . 69-88 (1.0.9.0,61.66) ~A49'69 , (1;9-10,51-12) "."2.72.871 ~ I ~ ...~-~"'.11 -98~ ~98.118 ~ ' K ~Dustcover -~~ ~ Plate c;~I:~"~,2.6," 8.7~ 0 <:I' vr 26 seat Bushing ~ N-->< ' - (9.0.11,86.80) Drive shaft -'---t : L 1 ! ~~ . Shock absorber ' Axle assembly - q" ~ Connecting '. rod >B~§ e @ ~~ A ~ 9.12 (0.9.1.2,6.5.8.1) CAUTION: Do not jack up at lower arm. When installing each rubber part, final tightening must be carried out under unladen condition* with tires on ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. ~ J7! I~ - 235 314 (24.32,114.231) Insulator Adjusting cap A J ~ I : N.m (kg-m, ft-Ib) SAA 132A RA-19 REAR SUSPENSION - Coil Spring and Shock Absorber Removal .. Remove shock absorber upper and lower fixing nuts. Do not remove piston rod lock nut on vehicle. Disassembly 1. Set shock absorber on vise with attachment, then loosen piston rod lock nut. . Do not remove piston rod lock nut. SRA782 2. Compress spring with Tool so that the strut upper spring seat can be turned by hand. SRA783 3. Remove piston rod lock nut. SRA784 Inspection SHOCK ABSORBER . . . ASSEMBLY Check for smooth operation through a full stroke, both compression and extension. Check for oil leakage occuring on welded or gland packing portion. Check piston rod for cracks, deformation or other damage. Replace if necessary. UPPER RUBBER SEAT AND BUSHING Check rubber parts for deterioration or cracks. Replace if necessary. . RA-20 RI;ARSUSPENSION -Coil Spring and Shock Absorber Inspection (Cont'd) COIL SPRING . Assembly . Top Bottom Check for cracks, deformation or other damage. Replace if necessary. When installing coil spring, be careful not to reverse top and bottom direction. (Top end is flat.) SFA760 . ~ When installing coil spring on strut, it must be positioned as shown in figure at left. r==A,.FI""" \ \, ~"~d Bigger inner diameter side of lower bushing ,,,.,, Vehicle front . When installing upper spring seat, make sure that it is positioned as shown. Outside of vehicle Smaller inner diameter side of lower bushing SRA126A RA-21 REAR SUSPENSION - Stabilizer Bar Removal . Remove connecting rod and clamp. Inspection . . Check stabilizer bar for deformation or cracks. Replace if necessary. Check rubber bushings for deterioration or cracks. Replace if necessary. Installation . When installing connecting rod, make sure direction is correct (as shown at left). Connecting rod Stabil izer SRA128A RA-22 REAR SUSPENSION - Multi-link and Lower Ball Joint Removal and Installation . Refer to "Removal and Installation" REAR SUSPENSION ASSEMBLY. of REAR AXLE AND Before removing, put matchmarks on adjusting pin. When installing, final tightening must be carried out at curb weight with tires on ground. After installation, check wheel alignment. Refer to "Rear Wheel Alignment" of CHECK AND ADJUSTMENT - On vehicle. . . SRA129A J; Inspection REAR SUSPENSION . MEMBER Replace suspension member assembly if cracked or deformed or if any part (insulator, for example) is damaged. UPPER AND LOWER LINKS . Replace upper or lower link as required deformed or if bushing is damaged. SUSPENSION Swing force Vertical end play SRA131A . . if cracked or LOWER BALL JOINT Measure swing force, turning torque and vertical end play in axial direction. (Use same measurement procedures as that of FA section.) If ball stud is worn, play in axial direction is excessive, or joint is hard to swing, replace lower arm. 12.7 - 90.2 N Swing force Ball joint specifications 0.5 - 3.4 N.m Turning torque Vertical end play RA-23 (1.3 - 9.2 kg, 2.9 - 20.3 Ib) (5 - 35 kg-em, 4.3 - 30.4 in-Ib) 0 mm (0 in) SERVICE DATA AND SPECIFICATIONS (S.D.S.) General Specifications SHOCKABSORBER COIL SPRING Model Except Sports package Item Wire diameter mm (in) Coil diameter mm (in) Free length mm (in) Spring constant N/mm (kg/mm, Ib/in) 11.0 (0.433) Sports package 11.3 (0.445) 90 - 100 (3.54 - 3.94) I 367.5 (14.47) 355 (13.98) Model Pink x 2 mm (in) 12.5 (0.492) Stroke 'mm (in) 155 (6.10) Damping force [at 0.1 m (0.3 ftl/sec.] N (kg, Ib) Expansion 314 - 471 (32 -48, 71 - 106) 392 . 588 (40 -60, 88 - 132). Compression 157 - 235 (16 -24, 35 -53) 196 - 294 (20 -30, 44 -66) Ught green x 2 Damping force [at 0.3 m (1.0 ftl/sec.] Expansion Compression DRIVE Sports package Piston rod diameter 119.6 (2.0, 112) 121.6 (2.2, 123) Identification color Except Sports package Item N (kg,lb) 647 - 902 (66 .92, 146 - 203) 363 - 539 (37 - 55, 82 -1211 SHAFT Final drive side Joint type Final drive side TS82F TS82C Wheel side Diameter Wheel side D I mm (in) 30 (1.18) Grease name Final drive side Nissan genuine grease or equivalent Wheel side Nissan genuine grease or equivalent SRA133A Wheel side Specified amount of grease g (oz) Final drive side 185 - 195 (6.52 - 6.88) Wheel side 145 -155 (5.11 -5.47) Boot length mm (in) Final drive side (LI) Wheelside (L2 ) REAR STABILIZER Item Identification color 110.5 -112.5 (4.35 -4.43) BAR Model Stabilizer diameter L2 SRA134A mm (in) . Except Sports package Sports package 15 (0.59) 17 (0.67) Ught green Light blue RA-24 SERVICE DATA AND SPECIFICATIONS (S.O.S.) Inspection WHEEL ALIGNMENT Camber (Unladen*) degree -1°36' to -0°36' Toe-out mm (in) (Total) degree and Adjustment WHEEL RUNOUT (Radial and lateral) Wheel type Radial runout Aluminum wheel .mm (in) Steel wheel mm (in) 0.5 - 4.5 (0.020 - 0.177) 1.5' -12.5' I Lateral runout 0.3 (0.012) 0.5 (0.020) or less I or less 0.8 (0.0311 or less * Tankful of fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools, mats in designated position. LOWER BALL JOINT Swing force (Measuring point: cotter pin hole of ball stud) N (kg, Ib) WHEEL BEARING Wheel bearing axial end play mm(in) 0.05 (0.0020) or less Turning torque N.m (kg-cm, in-Ib) Wheel bearing lock nut Tightening torque N.m (kg-m, ft-Ib) 12.7 -90.2 (1.3 - 9.2,2.9 - 20.3) I 235 -314 (24 -32, 174.231) Vertical end play RA-25 mm (in) 0.5 - 3.4 (5 - 35, 4.3 - 30.4) 0 (0) BRAKESYSTEM I BR SECTION CONTENTS PRECAUTIONS AND PREPARATION CHECK AND ADJUSTMENT BRAKE HYDRAULIC LINE BRAKE PEDAL BRACKET BRAKE BOOSTER VACUUM AND BR- 2 BR- 3 """"""".'.""'.'"''''''''''''.''''''''''''''''''' BR- 4 BR- 6 '''''''''''''''''' PIPING BR- 8 "'"'''' """"""""""""",.",.,.,.,.",,,,,,,,,,,,,..., MASTER CYLINDER BR-10 BR-12 FRONT DISC BRAKE (CL22VB, CL25VA) - Caliper BR-13 FRONT DISC BRAKE (CL22VB, CL25VA) - Rotor BR-17 REAR DISC BRAKE (CL9H) - Caliper BR-18 REAR DISC BRAKE (CL9H) PARKING BRAKE CONTROL Rotor BR-22 BR-23 : ANTI-LOCK BRAKING SYSTEM BR-25 TROUBLE DIAGNOSES BR-29 SERVICE DATA AND SPECIFICATIONS (S.D.S.) BR-54 all PRECAUTIONS AND PREPARATION Precautions . . . . . . Recommended fluid is brake fluid "DOT 3". Never reuse drained brake fluid. Be careful not to splash brake fluid on painted areas. To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid. Never use minerai oils such as gasoline or kerosene. They will ruin rubber parts of hydraulic system. Use Tool when removing and Installing brake tube. WARNING: . Clean brake pads and shoes with a waste cloth, then collect dust with a dust collector. SBR500 Preparation SPECIAL SERVICE TOOL Tool number (Kent-Moore No.) Tool name GG94310000 ( ) Flare nut torque wrench - Description Removing and ins~alling each brake piping ~ ~ Measuring brake fluid pressure KV991V0010 ( ) Brake fluid pressure gauge - KV999P1000 ( - ) A.B.S. checker 0 @ 0 @ @ Checking brake fluid pressure of A.B.S. actuator o. 0 c KV999P1010 - ) ( A.B.S. checker adapter harness Checking brake fluid pressure of A.B.S. actuator BR-2 CHECK AND ADJUSTMENT Checking Brake Fluid Level . . = MAX = Check fluid level in reservoir tank. It should be between Max. and Min. lines on reservoir tank. If fluid level is extremely low, check brake system for leaks. MIN Checking Brake System . 6/@ . *" Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts. If leakage occurs around joints, retighten or, if necessary, replace damaged parts. Check for oil leakage by fully depressing brake pedal. SMA 732A Changing Brake Fluid 1. Drain brake fluid in each air bleeder valve. 2. Refill until new brake fluid comes out of each air bleeder valve. SBR992 .. . . Use same procedure as in bleeding hydraulic system to refill brake fluid. Refer to Bleeding Procedure. Refill with recommended brake fluid "DOT 3". Never reuse drained brake fluid. Be careful not to splash brake fluid on painted areas. BR-3 BRAKE HYDRAULIC LINE Front brake (CL22VB) Proportioning valve (Do not disassemble.) ~ : N.m (kg-m, ft-Ib) 0 : Flare nut 15 -18 /1.5 -1.8, 11 -13) : Connecting bolt 17 .20/1.7 - 2.0,12.14) : Primary line . : Secondary line Bleeding SBR471A Procedure CAUTION: . . Carefully monitor brake fluid level at master cylinder during bleeding operation. Fill reservoir with r~commended brake fluid. Make sure it is full at all times while bleeding air out of system. . Place a container beneath master cylinderto avoid spillage of brake fluid. SBR995 . Bleed air according to the following procedure. Without Anti-lock Braking System: Left rear caliper ,j, Right rear caliper t Left front caliper ,j, Right front caliper SBR992 With Anti-lock Braking System: Left rear caliper ,j, Right rear caliper ,j, Left front caliper ,j, Right front caliper t Front side air bleeder on A.B.S. actuator ,j, Rear side air bleeder on A.B.S. actuator BR-4 BRAKE HYDRAULIC LINE Removal and Installation 1. To remove brake hose, first tube to hose, then withdraw 2. Cover openings to prevent connecting hydraulic line. 3. All hoses must be free from pulling. 4. After installing brake lines, depressing brake pedal. remove flare nut securing brake lock spring. entrance of dirt whenever disexcessive bending, twisting and check for oil leakage by fully SBR500 Inspection Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts. If leakage occurs around joints, retighten or, if necessary, replace damaged parts. BR-5 BRAKE PEDAL AND BRACKET Removal and. Installation ~16 S; !@j" -22 (1.6-2.2 12 ,-161 /,/< Stop lamp switch [.q]12-15 (1.2 -1.5, 9 -111 A.S.C.D. cancet switch A (1.2-1.5,9-111 12-15 . Replace clevis pin if plastic stopper. which is located at the end of clevis pin, is deformed or damaged. Brake pedal A : N.m (kg-m, ft-Ibl SBR472A Inspection Check brake pedal for following items. Brake pedal bend .. . Clevis pin deformation Crackof any weldedportion BR-6 BRAKE PEDAL AND BRACKET Adjustment Floor carpet Dash insulator Check brake pedal free height from dash reinforcement panel. Adjust if necessary. H: Free height Refer to S.D.S. D: Depressed height Refer to S.D.S. Under force of 490 N (50 kg, 110 Ib) with engine running C1: Clearance between pedal stopper and threaded end of stop lamp switch 0.3 - 1.0 mm (0.012 - 0.039 in) C2: Clearance between pedal stopper and threaded end of A.S.C.D. switch 0.3 - 1.0 mm (0.012 - 0.039 in) A: Pedal free play 1 3 mm (0.04 - 0.12 in) - Melt sheet ~: N'm (kg.m, ft.lbl SBR153A 1. Adjust pedal free height with brake booster input rod. Then tighten lock nut. Make sure that tip of input rod stays inside. SBR930 2. Adjust clearance "C1" and "C2" with stop lamp switch and A.S.C.D. switch respectively. Then tighten lock nuts. 3. Check pedal free play. Make sure that stop lamp is off when pedal is released. 4. Check brake pedal's depressed height while engine is running. If depressed height is below specified value, check brake system for leaks, accumulation of air or any damage to components (master cylinder, wheel cylinder, etc.); then make necessary repairs. BR-7 BRAKE BOOSTER Removal and Installation ( '" " I , ,) // ,""" / ,\ I \.~ ~---\ ...// / \ v..~,'"..-, \ (~'>r--- f,"\ ,~' A-:., i\'. , "" \ \ \ , ", ,:..~ / ......- \...,).-'~,\"......\' \ . \ ,...~:>\, ./ - ~;,~" , "'" ~'\. J , f,'~\ ,~ -...-- /-<:~, \;.,.........- ''! /' ~~') '" ,'r.v\\ 8 -11 (0.8-1_1,5.8- 8.0] ~: N.m (k~. ft-Ib) SBR473A Inspection OPERATING . . CHECK Depress brake pedal several times with engine off, and check that there is no change in pedal stroke. Depress brake pedal, .then start engine. If pedal goes down slightly, operation is normal. . SBROO2A AIRTIGHT O.K. N.G. ~ CHECK . Start engine, . brake pedal several times slowly. If pedal goes further down the first time and gradually rises after second or third time, booster is airtight. Depress brake pedal while engine is running, and stop engine with pedal depressed. If there is no change in pedal stroke after holding pedal down 30 seconds, brake booster is airtight. and stop it after one or two minutes. Depress SBR365A OUTPUT ROD LENGTH CHECK 1. Supply brake booster with vacuum of -66.7 kPa (-500 mmHg, -19.69 inHg) using a handy vacuum pump. 2. Check output rod length. Specified length: 10.275 - 10.525 mm (0.4045 - 0.4144 in) SBR281A BR-8 BRAKE BOOSTER Inspection (Cont'd) ~ 3. Adjust rod length if necessary. 4. If rod length is without specification, replace brake booster. BR-9 VACUlfM PIPING Removal and Installation \ Chod< ..w ~~~{a . ~ DJ Brake booster IJ. Intake manifold CAUTION: Do not apply any oil or lubricants to vacuum hose end check valve. . SBR474A Insert vacuum tube into vacuum hose more than 24 mm (0.94 in). '''_J)-=I More than 24 mm 10.94 in) SBROO4A . Install check valve, paying attention to its direction. 4 E=;=-;=:3 .. side Brake booster or Intake manifold .. vacuum pump side SBR202A Inspection HOSES AND CONNECTORS . Check vacuum lines, connections and check valve for airtightness, improper attachment chafing and deterioration. BR-'O V~CUUM PIPING Inspection (Cont'd) CHECK VALVE . When pressure is applied to brake booster side of check valve and valve does not open, replace check valve with a new one. .. Manifold side SBR475A BR-11 MASTER CYLINDER Removal and Installation Reservoir~ cap ~ 0;' fil'''~ Float~ Reservoir tank Primary ~ Seal (Do not reuse.) ~ - ~ \ *: Lubricate piston cup with brake fluid or rubber grease when assembling master cylinder. Dual proportioning valve (Do not disassemble.) Secondary ~ . piston ."; ~. I ' f!. 1 .. .. . Primary . ': \ I SBR476A .. Bend claws inwardwhen installingstopper cap. .. Pay attention to direction of piston cups in figure at left. Check parts for wear or damage. Replace if necessary. Replace stopper cap if claw is damaged or deformed. !; ) ': piston ,. ; I ,. I ... ..,. '" 'Ii 11II=II . Piston cup. );. \ SBR011A piston assembly SBR012A BR-12 FRONT DISC BRAKE (CL22VB, CL25VA) - Caliper CL22VB IEI@ Pin bolt ~ 22 Outer shim Torque member fixting bolt 72 97 ~ (7.3 - -9.9, 53 - (2.2 3.2, 16 23) - Dust seal~lEI@ lEI @ -31 - 72) A: N.m (kg-m, ft-Ib) lEI @ : P.B.C. (Poly Butyl Cuprysil)grease or silicone-based \lrease point IE! @ : Rubber grease points SBR477A @ : Brake fluid point .~ CL25V A Torque member fixing bolt Main pin bolt A 22 -31 (2.2 - 3.2, 16 - 23) A 72 -97 (7.3 - 9.9, 53 - 721 Air bleeder A7-9 (0.7.0.9, 5.1 -6.5) lEI lEI ~ ~ : : A: BR-13 Connecting bolt A17-20 (1.7 - 2.0,12 - 14) Brake hose FRONT DISC BRAKE (CL22VB, CL25VA) - Caliper Pad Replacement 1. Remove pin bolt. SBR453A 2. Swing cylinder body upward. Then remove pad retainer, and inner and outer shims. CAUTION: . When cylinder body is swung up, do not depress brake pedal because piston will pop out. Be careful not to damage dust seal or get oil on rotor. Always replace shims when replacing pads. . SBR220A Removal and Installation . Remove torque member fixing bolts and union bolt. . Install brake hose to caliper at protrusions securely. Disassembly Push out piston with dust seal using compressed air. SBR772 BR-14 FRONT DISC BRAKE (CL22VB, CL25V A) - Caliper Inspection CYLINDER . BODY Check inside surface of cylinder for scoring, rust, wear, damage or foreign materials. Replace if any such condition exists. Eliminate minor damage from rust or foreign materials by polishing surface with fine emery paper. CAUTION: Use brake fluid to clean. PISTON . . Check piston for scoring, rust, wear, damage or foreign materials. Replace if any condition exists. CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign materials are stuck to sliding surface. PIN, PIN BOLT AND PIN BOOT Check for wear, cracks condition exists. or other damage. Replace if any Assembly . . Place piston boot over rear of piston. Fit piston boot's lip properly in corresponding groove on cylinder body. Insert piston into cylinder body and fit boot's lip properly in corresponding groove on piston. SBR480A Inspection (On-vehicle) INSPECTION OF BRAKE DRAG FORCE 1. Swing cylinder body upward. 2. Make sure that wheel bearing is adjusted properly. Refer to section FA. 3. Measure rotating force (F1). SBR456A 4. 5. 6. 7. 8. Install caliper with pads to original position. Depress brake pedal for 5 seconds. Release brake pedal and rotate disc rotor 10 revolutions. Measure rotating force (F2). Calculate brake drag force by subtracting F, from F2. Maximum brake drag force (F2 F1): 59.8 N (6.1 kg, 13.5 Ib) If it is not within specification, check main pins and retainer boots in caliper. - SBR457A BR-15 FRONT DISC BRAKE (CL22VB, CL25VA) - Caliper DISC PAD Check disc pad for wear or damage. Pad standard thickness (A): 10.0 mm (0.394 in) Pad wear limit (A): 2.0 mm (0.079 in) SMA364A BR-16 FRONT DISC BRAKE (CL22VB, CL25VA) - Rotor Inspection RUBBING SURFACE Check rotor for roughness, cracks or chips. RUNOUT Adjust wheel bearing preload. Check runout using a dial indicator. Rotor repair limit: Maximum runout (Total indicator reading at center of rotor pad contact surface) 0.07 mm (0.0028 in) SBR826 THICKNESS Standard thickness: 20.0 mm (0.787 in) Minimum thickness: 18.0 mm (0.709 in) SBR827 BR-11 - REAR DISC BRAKE (CL9H) Air bleeder Copper washer ~ 7 .9 (0.7 .0.9,5.1 ~ -3.2, Pin bolt 22 31 (2.2 ~ - 6.5) - 16-23) ~ j--~ ~ } e / Cylinder body tC:J : N.m (kg-m, ft-Ib) .' B~: P.B.C.(PolyButYICuprysil) 1 b d grease or Sl Icon- ase grease point Cam grease point point ~~ ~ '~ ~\ /' I. - ,S2)'" /' ,~ ~.: - O-ring Spring ~ m@ (!, IE!I@ / / - '-..J' ~ ~ '" /'--- , ~ ,/ ~ . Piston seal fixingbolt 38 -52 (3.9 -5.3,28-38) ~ ~ m@ Inner shim 0 ~ - Adjusting nut Cup~m@ ~..oo boo' E!@ Pin ~ )) ~ ~~~ R padr;.tainerm In ~ ~ Inner' pad 0 uter pa h ' ,:.;a°@, . d . Pad "";OM EII@~ EII@ ~ '-., ~ ~"N'4) I'J@OO'OCOh'mj!?,- ~ rr-,,25.29(2.5-3.0' ~-" 18 -22) Torquemember > v &~"OO ~ - i~~RingA >-.J) A~wavewasher '~D_:-spacer Ball bearing /~ Spring washer .(/ ,~Spacer ,/~' Return spring (2.7 3.7,20 - 27) / ~~Spring <..:: -~. RlngB Lever dI Cable stay !--tC:J26 -36 m@ 1. ~ ' ! Rod Push rod Key plate RlngC Y m@ Cam bolt tC:J22-31 16-23) (2.2-3.2, ~, I J..~ . Seat Gl..// "I /'. ~ ~. (v -14) Brake hose - ":>, ,/ /' r- 0 \)' BU @ : Rubber "'@:Brakefluid - 17 20 (1.7.2.0,12 Caliper ~/' " / ~ '~~ /' ' W, I ~ ~/ Torque member saR48' A Pad Replacement CAUTION: When cylinder body is swung up, do not depress brake pedal because piston will pop out. Remove parking cable stay fixing bolt, pin bolts and lock spring. Then remove pad retainers, pads and shims. . . When installing pads, retract piston into cylinder body by turning it clockwise. Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing pads. SBR641 BR-18 REAR DISC BRAKE (CL9H) - Caliper Removal and Installation Disconnect parking brake cable and brake hose, then remove caliper assembly. . SBR482A Disassembly 1. Remove piston by turning it counterclockwise longnose pliers. with suitable SBR646 2. Pry off ring A from piston with suitable pliers and remove adjusting nut. SBR648 3. Disassemble cylinder body. Pry off rings Band C with pliers, then remove spring cover, spring and seat. / . SBR891 . Remove piston seal. Be careful not to damage cylinder body. SBR485A BR-19 REAR DISC BRAKE (CL9H) - Caliper Disassembly (Cont'd) 4. Remove return spring and lever. .. SBR877 Inspection CYLINDER . . BODY Check inside surface of cylinder for score, rust, wear or other damage. Minor damage from rust of foreign materials may be eliminated by polishing surface with a fine emery paper. Replace if necessary. CAUTION: Use brake fluid to clean. TORQUE MEMBER Check for wear, cracks or other damage. Replace if necessary. PISTON Check piston for score, rust, wear or other damage. Replace if necessary . CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign matter is stuck to sliding surface. PIN AND PIN BOOT Check for wear, cracks or other damage. Replace if necessary. Assembly Install cup securely in the specified direction. . :::::::::::::: ~f\t1t 1 I:::::::::::::: SBR849 . Convex Fit push rod into square hole in key plate. Also match convex portion of key plate with concave portion of cylinder. portion @ SBR893 BR-20 REAR DISC BRAKE (CL9H) Assembly Ring . c~ Keyplate ~.h Caliper (Cont'd) Install ring C with suitable tool. "1B'> . ,oo-j Rod fi) SB R878 . Install seat, spring, spring cover and ring B with suitable press and drift. Tool SBR492A Inspection . FI (On-vehicle) INSPECTION OF BRAKE DRAG FORCE 1. Swing cylinder body upward. 2. Make sure that wheel bearing is adjusted properly. Refer to section RA. 3. Measure rotating force (F,). SBR227A 4. 5. 6. 7. 8. Install caliper with pads to original position. Depress brake pedal for 5 seconds. Release brake pedal, rotate disc rotor 10 revolutions. Measure rotating force (F2). Calculate brake drag force by subtracting F, from F2. Maximum brake drag force (F2 F,): 86.3 N (8.8 kg, 19.4 Ib) If it is not within specification, check pins and pin boots in caliper. - DISC PAD Check disc pad for wear or damage. Standard thickness (A): 9.5 mm (0.374 in) Pad wear limit (A): 2.0 mm (0.079 in) SMA364A BR-21 REAR DISC BRAKE (CL9H) - Rotor Inspection RUBBING SURFACE Check rotor for roughness, cracks or chips. .. RUNOUT . . Check runout using a dial indicator. Make sure that axial end play is within the specifications before measuring. Refer to section RA. Rotor repair limit: Maximum runout (Total Indicator reading at center of rotor pad contact surface) 0.07 mm (0.0028 In) SBR845 THICKNESS Rotor repair limit: Minimum thickness 8.0 mm (0.315 In) SBR847 BR-22 PARKING BRAKE CONTROL Removal and Installation m . ~ ~ l. H. rear cable Ell SBR487A REMOVAL Before removing parking brake control, remove console box. Loosen cable using control lever adjuster, and separate front and rear cables. Break clinched portion of control lever using a hammer and chisel as shown in figure at left, and replace cables with new parts. Apply multi-purpose grease to areas between control lever drum and cables. . . . SBR488A INSTALLATION Be careful not to damage boot and inner cable. When installing parking brake cable at rear caliper, make sure to align matchmark on parking cable stay and cable. . Cable guide Matchmark SBR489A Inspection 1. Check control lever for wear or other damage. Replace if necessary. 2. Check parking brake cables, lamp and switch. Replace if necessary . 3. Check parts at each connecting portion for deformation or damage. If found, replace. BR-23 PARKING BRAKE CONTROL Box wrench Adjustment 1. Ensure that parking brake releases when control lever is pulled down completely. If control lever does not release parking brake, proceed as follows: Pull control lever up by 4 or 5 notches. Insert a box wrench into opening in control lever and loosen. self-lock adjusting nut to slacken cables. Completely push control lever down. 2. Forcefully depress brake pedal about five times (so that caliper is automatically set in position.). 3. Pull lever up by 4 or 5 notches. 4. Turn adjusting nut as shown in figure at left and adjust lever stroke to specified value. 5. Completely push control lever down and ensure that: Parking brake is released completely. Rear brakes are free from dragging. .. SBR490A . . 6. Pull control lever with specified amount of force. Check lever stroke and ensure smooth operation. Number of notches: Center lever type 6 8 - SBR491 A 7. Bend parking brake warning lamp switch plate so that brake warning light comes on when ratchet at parking brake lever is pulled "A" notches and goes out when fully released. Number of "A" notches: 1 SBR493A Parking brake warning lamp switch plate BR-24 ANTI-LOCK BRAKING SYSTEM System Components Warning lamp : Harness : Piping Front wheel sensor SBR516A Hydraulic Circuit Proportioning valve (Do not disassemble.) Master cylinder Front R.H. wheel ,' --Check valve (Front L.H.) Feeling valve (Front) -~ Feeling valve Check valve (Read (Read Rear R.H. wheel I SBR517 A BR-25 ~ ACTUATOR 4 6 ]0 I GNI TI ON SWI TCH ON or START 5 FRONT WHEEL SENSOR 0 I: : : ;0 0 ;01/1 0 »m - n "0 3 2 ] " ~P @~ BODY GROUND II ..~ I I I I , I , Et "'..,..... ..."', ",.. r:- .... ".. I , : : : : I I @ ~r : @ : lmum- , ... --: S. M. J. [Refer to en ~ngine room - 8R/Y R/Y L/Y -Y G/Y L/R LG/R GY/R L -W/L OR/L rnnn~ @ @ [§j :IE:IE "'.. FUSE 1 FUSIBLE FUSE AND FUSIBLE (J n RELAY BOX) m ~ .."'''' - BODY GROUND LINK rnI I I I I I I I I I i I I I I I : I I 8R/Y R/Y L/Y YG/Y L/R LG/R GY/R LW/LOR/L : (B I ack) (Ma in R/GG/L- harness) I n_nnn_~ ~mmn__nmnm 8R/Y R/YL/Y- ~- u- - - - n - - - -_h- ---n- - _n_- - - - _n_- - - - -. -- - - _u- - --- iW/R :IE ,.. Y/L Y/G I I I ~@) II , , .. rEtffi@Y :IE @£) , .. (Engine harness (§ room no. 2) ::BODY GROUND FRONT VJ CD :0 0> II) U1 :I> .. BATTERY :IE @£ - Y G/Y L/R LG/R GY/R L W/L OR/L W/R W/R .~ ~~ ,...,... c;;p 8 W 8 8 8 ,"-un_un_nnn- @ EI E2 DI DII FI 83 U G2 85 G6 H5 16 18 "1 ' I I I I I I Iast page: (FaIdout page).] <@) harnes~ I I I I I I I I I I I I ~".) , : o. OJ 3 "C R/Y~ FUSE BLOCK (Refer to "POWER SUPPLY ROUTING" in EL sect ion. ) harness) III c+ 0 "C ...'" G/L (E. F. 1- -i 0 9t@ .... " 9@ Ii l_mn @ "',...,... , < » r < m @ UP 21 9 7 .. , OJ :IJ I N . 6 ::- 0 m::o;o< »00» ;0 Z Zr -i -i< ;0 rm ;r ;r * mo rr ;o",, » 3 -< R. H. STOP LAMP SWITCH WHEEL SENSOR L. H. W/R i3J~ ALTERNATOR I I I I I I ~u_-~ "_n-n_- @ - Y/L Y/G-f ANTI-LOCK BRAKING SYSTEM Removal and Installation CAUTION: Be careful not to damage sensor edge and sensor ro,or teeth. FRONT WHEEL SENSOR ..., -_or -r-'-" I~:-- -L_,,-_!J " ~ ~ : N.m(kg-m,ft-Ib) SBR519A REAR SENSOR Rear speed seflsor tOJ18.26~(1.8 - 2.7, 13. 20) Drive pinion nut tOJ 186 (19 ~ -294 -30,137.217) tOJ : N.m (kg-m,ft-Ib) ~ Sensor rotor .-/// Companion flange . SBR520A Remove rear sensor rotor with companion propeller shaft removal. Refer to PD section. BR-27 flange after ANTI-LOCK BRAKING SYSTEM Removal and Installation (Cont'd) ACTUATOR .. . Disconnect 3 connectors and brake tubes. Remove relay bracket. Remove actuator by removing 3 nuts fixing actuator bracket. BR~28 to TROUBLE DIAGNOSES Contents How to Perform Trouble Diagnoses for Quick and Accurate Repair Symptom Chart Preliminary Check 1 BR-30 BR-33 BR-34 BR-35 ... PreliminaryCheck2 Preliminary Check 3, 4 ... Self-diagnosis Component Parts Location ... Harness Connector Location Ground Circuit Check Circuit Diagram for Quick Pinpoint Check Diagnostic Procedure 1 .. Diagnostic Procedure 2 . DiagnosticProcedure3 ...... BR-36 BR-37 ...: BR-38 BR-39 ... ""'''.' BR-40 BR-41 BR-42 BR-43 ."."."""""""""'.""""".'."""""""'.'...'..'."...' Diagnostic Procedure 4 """.. Diagnostic Procedure 5 Diagnostic Procedure 6 Diagnostic Procedure 7 Diagnostic Procedure 8 Diagnostic Procedure 9 Diagnostic Procedure 10 . Diagnostic Procedure 11 Diagnostic Procedure 12 Electrical Components Inspection , '..'...".."""""""""'.""'.""."" BR-44 ... ... BR-44 ... ... ... ... ... BR-45 ... ... ... ... BR-45 ...... BR-46 BR-47 BR-48 BR-49 ... BR-50 BR-51 ... BR-52 BR-29 TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair INTRODUCTION SEF234G The A.B.S. system has an electronic control unit to control major functions. The control unit accepts input signals from' sensors and instantly drives actuators. It is essential that both kinds of signals are proper and stable. At the same time, it is important that there are no conventional problems such as air leaks in the booster or lines, lack of brake fluid, or other problems with brake system. It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are caused by poor electric connections or faulty wiring. In this case, careful checking of suspicious circuits may help prevent the replacement of good parts. A visual check only may not find the cause of the problems, so a road test should be performed. Before undertaking actual checks, take just a few minutes to talk with a customer who approaches with a A.B.S. complaint. The customer is a very good source of information on such problems; especially intermittent ones. Through the talks with the customer, find out what symptoms are present and under what conditions they occur. Start your diagnosis by looking for "conventional" problems first. This is one of the best ways to troubleshoot brake problems on an A.B.S. controlled vehicle. BR..30 " TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont'd) WORK FLOW CHECK IN r-------------------- I I I I I I I I 1 item LISTEN TO CUSTOMER COMPLAINTS DIAGNOSTIC WORKSHEET (See page BR-32.) INVESTIGATE ITEMS YOU SHOULD CAR RY OUT RELATED TO EACH SYMPTOM AND NOTE Symptom Chart (See page BR-33.) ELIMINATE GOOD SYSTEMS ON GOOD PARTS Preliminary Check (See pages BR-34 - 36.) Not self-diagnostic item Self-diagnostic item DETERMINE MALFUNCTIONING CIRCUIT(S) OR PART(S) I I I I ,I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I OJ ~ a. 0 '" ::I ..' CD ~ 0 ... 7':' 0 » CT ::I 0 3 ~ " CD a. ~ I» n .. <5" ::I 0 0 b ::I ce '" .. ""0 5' ce a. ~. 0 ... ::I 5' ce I» n.. <' I» .. CD '" I» ::I fa "'tI CD a. ~ < CT ... I» ~, 0 ::I g;o ::I 0 iii' CD 0 0 0 -< s: "'tI -I 0 s: » G') m BR-34 "'tI Preliminary Check 2 BR-35 ~ 3 0 Preliminary Check 3 BR-36 0 0 Preliminary Check 4 BR-36 0 Diagnostic Procedure 1 BR-42 Diagnostic Procedure 2 BR-43 Diagnostic Procedure 3 BR-44 Diagnostic Procedure 4 BR-44 Diagnostic Procedure 5 BR"-45 Diagnostic Procedure 6 BR-45 LE.D. flashing1 - 4 BR-46 0 0 0 0 "'tI :IJ 0 (') m 0 C :IJ m :IJ m -n m :IJ m Z (') m "'tI 0 0 / en Preliminary Check 1 0 0 0 :E I» ::I I» ... -< (') ::I" CD n 7':' 0 iii' ce ::I 0 '" .. c)" "'tI ... 0 nCD a. c:: ... CD --.(I) 0 0 0 0 0 0 0 0 0 0 0 0 LE.D. flashing5 - 8 BR-47 0 0 0 0 0 0 L.E.D. flashing9 BR-48 0 0 0 0 0 0 LE.D. flashing 10 BR-49 0 0 0 0 0 0 LE.D. flashing 16 BR-50 0 0 0 0 0 0 L.E.D. goes off BR-51 ---- 0 Sensor shield BR-40 (')(')G') ::I"-, ... CD n 0 Motor ground BR-40 CD CD ~9. -. I» ::Ice -"'::I iiii 0 !!;-~;. 5' -. n ce 0 "'tI ::I ... Z~o ? ;:+. 2 ::I" a. r~ j"CD 0 0 b n c:: c:: 7':' .. -, a. ::I -" 0 Actuator inspection BR-52 .::.~ 1-18'1:>WOldw'l .. " a:~ Check 1. Check whether brake fluid pressuredistribution is normal. D2/D1: 52 - 56n5 77 5 -~l Perform Preliminary PR ESSU R E. --d--. :; '" .."'.. .-'" Q,Q, 'tJ ,," N.G. L~_--_--- O.K. Check whether front axles have excessive looseness. . Yes Remedy. No Perform Preliminary Check 2 and Ground Circuit Check. nn~ I I I I ~ PI kPa (kg/em'. psi) Front brake fluid pressure SBR643A I!J (\ SMA626A BR-45 TROUBLE DIAGNOSES m Diagnostic Procedure 7 Control unit connector .(§) ACTUATOR SOLENOID (L.E.D. flashing number 1 - 4) -)J_T [ill eJ ~ INSPECTIONSTART Remove battery negative terminal connector. m I SBR544A iii . CHECK SOLENOID VALVE RESISTANCE. O.K. Replace control unit. Disconnect control unit connector. Check resistance between control unit connector (vehicle side) terminals. Flashing number 1: Terminals @ and (t) Flashing number 2: Terminals @ and @ Flashing number 3 or 4: Terminals @ and @ Resistance: 0.7 - 1.60 Actuator connector @ ~ \:ill! SBR545A . iii N.G. Disconnect actuator connector. Check resistance between actuator connector (actuator side) terminals. Flashing number 1: Terminals @ and CD Flashing number 2: Terminals @ and (t) Flashing number 3 or 4: Terminals @ and @ Resistance: 0.7 - 1.60 N.G. I Replace actuator. BR-46 O.K. Repair harness between actuator connector and control unit connector. tROUBLE m DIAGNOSES Diagnostic Procedure 8 WHE~LSPEED SENSOR (L.E.D. flashing number 5 - 8) Control unit connector ~ )J INSPECTION START Remove battery negative terminal connector. [:iIi5 m SBR546A O.K. CHECK SPEED SENSOR RESISTANCE Disconnect control unit connector. Check resistance between control unit connector (vehicle side) terminals. Flashing number 5: Terminals @ and @ Flashing number 6: Terminals @ and @ Flashing number 7 or 8: Terminals (j) and @ Resistance: 0.8 - 1.2 Replace control unit. kil N.G. Refer to Preliminary Check 3 result. Check whether sensor has 0.8 1.2 kQ resistance. N.G. Re~air harness between sensor connector and control unit connector. BR-47 N.G. Replace sensor. TROUBLE DIAGNOSES m Diagnostic Procedure 9 @ Control unit connector ACTUATOR MOTOR RELAY (L.E.D. flashing number 9) I INSPECTION START Remove battery negative terminal connector. ~i5 [i] Fa SBR547 A Ii) Actuator connector @ Effij i5 ~ ~ .Ii)CHECK MOTOR [ill - SBR548A @ ~~ Replace fusible link. \:mEY [ill SBR550A ~ ~0 O.K. Repair harness between actuator and control unit. RELAY . Yes [i] N.G. ~isconnect actuator connector. Check resistance between actuator connector (actuator side) terminals @ and @. Resistance: 38 - 45n DEACTIVATION. Disconnect actuator connector. Check continuity between actuator connector (actuator side) terminals @ and @. No Check if motor's fusible link is blown. Resistance: Approximately on 0 ~ -, eJ CHECK MOTOR RELAY SOLENOID RESISTANCE. Disconnect control unit connector. Check resistance between control unit connector (vehicle side) terminals @ and @. Resistance:38 -45n ~ Motor rela; SBR688A BR-48 No II N.G. Replace motor relay. Perform Electrical Components Inspection - ACTUATOR. (See page BR-52.) N.G. .O.K. Replace actuator. TROUBLE DIAGNOSES m Control unit connector Diagnostic Procedure 10 ~ ACTUATOR SOLENOID number 10) ~~ [ _CT INSPECTION START Remove battery negative terminal connector. 18 rnJ m Actuator connector @) ~ ~) Ii CHECK SOLENOID VALVE RELAY RESISTANCE. Disconnect control unit connector. Check resistance between control unit connector (vehicle side) terminals @ and @. Resistance. 80 - 90Q SBR552A Ii) VALVE RELAY (L.E.D. flashing IVr:II~ N.G. rcheck resistance between actuator connector (actuator side) terminals (j) and 00. Resistance: 80 - 90Q O.K. Repair harness between actuator and control unit [ill I Ii) SBR553A [i N.G. Replacesolenoid valve relay. [i CHECK SOLENOID VALVE RELAY MOVEMENT. Disconnect actuator connector. Check continuity between actuator connector (actuator side) terminals @ and @. Yes r~ L~eplace solenoid valverelay. No Check if solenoid valve relay fuse is blown. Yes I Ii Replacefuse. Actuator connector -, @~eo~ [ill SBR556A BR-49 No Perform Electrical Components Inspection - ACTUATOR. (See page B R-52.) . N.G. O.K. Replace controlunit. TROUBLE DIAGNOSES Diagnostic Procedure 11 CONTROL UNIT (L.E.D. flashing number 16) INSPECTION START Control unit malfunction. Replace control unit. BR-50 TROUBLE DIAGNOSES m Control unit connector (§) )J Diagnostic Procedure 12 CONTROLUNITOR POWERSUPPLYANDGROUND CIRCUIT(Warning activates but L.E.D.comes off.) ij~ INSPECTION START PI -=SBR557A Ii) Control unit connector (§) I~ CHECK CONTROL UNIT POWER SUPPLY. Disconnect control unit connector. Check voltage between control unit connector (vehicle side) N.G. Check if control unit "10A" fuse is blown. terminal CD and body ground [Y] 1 [:iI ij Ii) SBR55BA (!J Control unit connector with ignition switch turned on. (§) SBR559A O.K. CHECK ALTERNATOR L TER~INAL VOLTAGE. Disconnect control unit connector. Check voltage between control unit connector (vehicleside) terminal @ and body ground after engine starting. Voltage: 6V or more O.K. (!J Check continuity between control unit connector (vehicle side) terminal @ and body ground with ignition switch "OFF" . O.K. Replace control unit. BR-51 N.G. Repair harness between alternator and control unit. N.G. Repair ground harness. Malfunctioning alternator. ',., TROUBLE DIAGNOSES Motor relay indicator Power supply indicator '"'$SUR' DEC "" ".' .'" 'NC~ .... ~/ in switch Electrical Components Inspection ACTUATOR (Not self-diagnostic item) INSPECTION START , mt5)." Checker~"W KV999P1000 ( - ) Harness: KV999P1010 ( Motor switch 3,4 select switch ) SBR560A Connect A.B.S. checker to actuator connector and vehicle harness with battery terminal connected and all checker switch turning off. Check that battery' voltage is at least 12 volts. Use harness for 3 channel. Set select switch to 3 channel. Turn checker power supply switch on. Check power supply indicator for coming on. No Replace battery with fully charged new one, if checker connection is correct. Yes Check checker valve relay indicator for coming on. Replace solenoid valve relay. if checker connection is correct. Yes Select one valve. Select pressure decreasing position by switch then turn motor switch on. Turn motor switch off. Select pressure increasing position. ~ CAUTION: Do not hold switch at the pressure decreasing position for more than 5 seconds. Otherwise, solenoid valve may be overheated and damaged. Repeat so that all valve will be performed. Check motor relay indicator for coming on while motor switch is turned on. No Replace motor relay. if checker connection is correct. Yes Check motor for operational sound beside the actuator in a quiet place. Yes Bring checker in the vehicle and depress the brake pedal. Repeat step ~ ~ ~.~ ~~R691A @ BR-52 No Replace actuator as assembly. if Diagnostic Procedures 7 - 12 are already performed and checker connection is correct. Valve select switch position RR is used for 4 channel checking. In the case of 3 channels, brake pedal vibration or depression will not occur in position RR. It will occur, however, in position RL. TROUBLE DIAGNOSES Electrical Components Inspection (Cont'd) Ii: N.G.: No vibration Check brake pedal for vibration while motor switch is turned on, . O.K.: Vibration . Change operating valve~,th motor switch "ON" and check for pedal vibration. I N ..: G I' . N 0 VIb ration O.K.: Vibration Replace actuator as assembly. Check brake pedal for depression when select pressure increases. O.K. Actuator works normally. BR-53 Replace actuator as assembly. SERVICE DATA AND SPECIFICATIONS (S.D.S.) General-Specifications Front brake Brake model CL22VB CL25VA Cylinder bore diameter mm (in) 54.0 (2.126) 57.2 (2.252) Pad length x width x thickness mm lin) 112.8 x 44.8 x 10.0 (4.44 x 1.764 x 0.394) 134.1 x45.3x 11.0 (5.28 x 1.783 x 0.433) 252 x 20 (9.92 x 0.79) 257 x 22 (10.12 x 0.87) Rotor outer diameter x thickness mm lin) Rear .brake Brake model CL9H Cylinder bore diameter mm lin) 33.96 (1.3370) Pad length x width x thickness mm lin) 75.0 x 40.0 x 9.5 (2.953 x 1.575 x 0.374) Rotor outer diameter x thickness 258 x 9 (10.16 x 0.35) mm (in) Master cylinder Cylinder bore diameter mm lin) Control valve Valve model 22.22 (7/8) Proportioning valve (within master cylinder) Sprit point x reducing ratio kPa (kg/em' , psi) Brake booster Booster model Diaphragm diameter 23.81 (15/16) 3,923 (40, 569) x ().4 M23 mm lin) M195T Primary Secondary 230 (9.06) Brake fluid Recommended brake fluid DOT3 Parking brake Control type Center lever BR-54 205 (8.07) 180 (7.09) SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and Adjustment BRAKE PEDAL FRONT DISC BRAKE CL25VA CL22VB Free height MfT mm (in) 177.0 - 187.0 (6.97.7.36) Item AfT Pad wear limit Minimum thickness mm(in) Rotor repair limit Minimum thickness mm (in) Maximum runout mm (in) 2.0 (0.079) 18.0 (0.709) 20.0 (0.787) 0.07 (0.0028) REAR DISC BRAKE 186.0 -196.0 (7.32 .7.72) Depressed height [under force of 490 N (50 kg, 110 Ib) with engine running) mm (in) 100 (3.94) or more Clerance between pedal stopper and threeded end of stop lamp switch mm (in) 0.3 - 1.0 (0.012 - 0.039) Clearance between pedal stopper and threaded end of A.S.C.D. switch mm (In) 0.3 . 1.0 (0.012 - 0.039) CL9H Pedal free plav at clevis mm (in) Item Pad wear limit Minimum thickness mm(in) Rotor repair limit Minimum thickness mm (in) Maximum runout mm (in) 1.3 (0.04.0.12) 2.0 (0.079) PARKING BRAKE 8.0 (0.315) Center lever Item 0.07 (0.0028) Number of notches [under force of 196 N (20 kg, 44 Ib)) Number of notches (when warning switch comes on) BR-55 6-8 STEERING SYSTEM ST SECTION CONTENTS PRECAUTIONS PREPARATION " ON-VEHICLE INSPECTION ON-VEHICLE INSPECTION STEERING WHEEL ST - 3 ST- 5 (Power steering) AND STEERING POWER STEERING GEAR POWER STEERING OIL PUMP SERVICE ST- 2 """"""'"'' AND ST- 7 COLUMN LINKAGE DATA AND SPECIFICATIONS (Model ST-10 PR24SC) ST-14 ST-27 (S.O.S.) ST-31 IDI PRECAUTIONS .. Before disassembly, thoroughly clean the outside of the unit. Disassembly should be done in a clean work area. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter. When disassembling parts, be sure to place them in order "in a parts rack so they can be reinstalled in their proper positions. Use nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might interfere with their operation. Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable solvent. Before assembly, apply a coat of recommended A.T.F.* to hydraulic parts. Vaseline may be applied to a-rings and seals. Do not use any grease. Replace all gaskets, seals and a-rings. Avoid damaging a-rings, seals and gaskets during installation. Perform functional tests whenever designated. *: Automatic transmission fluid . . . . . ST-2 PREPARATION SPECIAL SERVICE TOOLS Tool number (Kent-Moore No.) Tool name KV48100700 (J26364) Torque adapter ST27180001 (J25726-A) Steering wheel puller HT72520000 (J25730-A) Ball joint remover ST27091 000 (J26357) Pressure gauge KV48102500 - ( ) Pressure gauge adapter ST3127S000 (See J25765-A) ill GG91030000 (J25765-A) Torque wrench @ HT62940000 - ( ) Socket adapter @ HT62900000 - ( Description Measuring pinion rotating torque ~ ~n ~ Removing ball joint Measuring oil pressure Measuring oil pressure ~@ ~@ ~ Removing and installing steering wheel CJI@ Measuring turning torque CD-fJ ~ @~ @-o ) Socket adapter Reforming teflon ring KV481 04400 ( - ) Rack seal ring reformer ST-3 PREPARATION COMMERCIAL SERVICE TOOLS Tool name Description Rear oil seal drift Installing rear oil seal ~"'di' Pinion oil seal drift Installing pinion oil seal v:2.,.,dg Oil pump attachment Welding ,\1-\O.a.1\ 40 11.57) 12 .;.~fb~10.47) "". ~ ,,\~ ~o.\ ,~. qp Unit: mm lin) ST-4 SST481 A Disassembling and assembling oil pump ON-VEHICLE INSPECTION Checking Steering Wheel Play . With wheels in a straight-aheadposition,check steering wheel play. Steering wheel play: . If it is 35 mm (1.38 not in) or less within specification, check rack' and pinion assembly. Checking Neutral Position on Steering Wheel O.K. N.G. Pre-checking . Verify that the steering steering gear is centered before removing the wheel. Checking . Check that the steering wheel is in the neutral position when driving straight ahead. . If it is not in the neutral and . SST104B position, remove the steering wheel reinstall it correctly. If the tie-rod neutral lock position nut by the same compensate and is between move amount two tie-rod on for error in the serrated in the both left and neutral teeth, loosen opposite direction right sides to position. Front Wheel Turning Angle . Rotatesteeringwheel turning all the way right and left;measure angle. Turning angle of full turns: Refer to section FA forS.D.S. SMA 127 . If it is not within specification, Measured length "L": Refer to S.D.S. L SST086B ST-5 check rack stroke. ON-VEHICLE INSPECTION Checking Gear Housing Movement . Check the movement of steering gear housing during stationary steering. The maximum allowable movement is as follows: Movement of gear housing: . :t 2 mm (:t 0.08 in) (on dry paved surface) or less Apply a force of 49 N (5 kg, 11 Ib) to steering wheel to check the gear housing movement. On models equipped with power steering, turn off ignition key while checking. . If movement exceeds the limit, replace mount insulator after confirming proper installation of gear housing clamps. Adjusting Rack Retainer . Perform this driving test on a flat road. 1. Check whether vehicle moves in a straight line when steering wheel is released. 2. Check whether steering wheel returns to neutral position when steering wheel is released from a slightly turned (approx. 20°) position. If any abnormality is found, correct it by resetting adjusting screw. . ST~6 ON-VEHICLEINSPECTION (Power steering) Checking and Adjusting Drive Belts Refer to section MAfor DriveBelt Inspection. Checking Fluid Level Check the level when the fluid is cold. CAUTION: .. Do not overfill. Recommended fluid is Automatic "DEXRONTM Type". Checking Transmission Fluid Fluid Leakage Check the lines for improper attachment and for leaks, cracks, damage, loose connections, chafing or deterioration. 1. Run engine at idle speed or 1,000 rpm. Make sure temperature of fluid in oil tank rises to 60 to 80°C (140 to 176°F). 2. Turn steering wheel right-to-Ieft several times. 3. Hold steering wheel at each "lock" position for five seconds and carefully check for fluid leakage. CAUTION: SST107B Do not hold the steering wheel in a locked position for more than 15 seconds. 4. If fluid leakage at connectors is noticed, loosen flare nut and then retighten. Do not overtighten connector as this can damage O-ring, washer and connector. Bleeding Hydraulic System 1. Raise front end of vehicle until wheels clear ground. 2. Add fluid into oil tank to specified level. Meanwhile,quickly turn steering wheel fully to right and left and lightly touch steering stoppers. Repeat steering wheel operation until fluid level no longer decreases. 3. Start engine. Repeat step 2 above. . Incompleteair bleeding willcause the followingto occur. When this happens, bleed air again. ST-7 ON-VEHICLE INSPECTION (Power steering) Bleeding Hydraulic System (Cont'd) a. Generation of air bubbles in reservoir tank b. Generation of clicking noise in oil pump c. Excessive buzzing in oil pump While the vehicle is stationary or while turning the steering wheel slowly, fluid noise may occur in the valve or oil. pump. This noise is inherent in this steering system, and it will not affect performance or durability of the system. Checking Steering Wheel Turning Force 1. Park vehicle on a level, dry surface and set parking brake. 2. Start engine. 3. Warm up power steering fluid to adequate operating temperature. Temperature of fluid: Approximately 60 - 80°C (140 - 176°F). Tires need to be inflated to normal pressure. 4. Check steering wheel turning force with engine idling when steering wheel has been turned 360° from neutral position. Steering wheel turning force: 39 N (4 kg, 9 Ib) or less Checking Hydraulic System Before starting, check belt tension, driving pulley and tire pressure. 1. Set Tool. Open shut-off valve. Then bleed air. (See "Bleeding Hydraulic System".) 2. Run engine. Make sure temperature of fluid In tank rises to 60 to 80°C (140 to 176°F). ST-8 ON-VEHICLEINSPECTION (Power steering) Checking Hydraulic System (Cont'd) WARNING: Warm up engine with shut-off valve fully opened. If engine is started with shut-off valve closed, oil pressure in oil pump will increase to relief pressure, resulting in an abnormal rise in oil temperature. 3. Check pressure with steering wheel fully turned to left and right positions with engine idling at 1,000 rpm. ST27091000(J26357) ... : Direction of oil flow Low-pressure hose CAUTION: Do not hold the steering wheel in a locked position for more than 15 seconds. Oil pump maximum standard pressure: 6,865 kPa (70 kg/cm2, 995 psi) at idling 4. If oil pressure is below the standard pressure, slowly close shut-oft valve and check pressure. When pressure reaches standard pressure, gear is damaged. When pressure remains below standard pressure, pump is damaged. CAUTION: Do not close shut-off valve for more than 15 seconds. 5. If oil pressure is higher than standard pressure, pump is damaged. 6. After checking hydraulic system, remove Tool and add fluid as necessary, then completely bleed air out of system. .. SST834 ST-9 STEERING WHEEL AND STEERING COLUMN ~~~ ~ ~L"!]~:'o ~.o. 22 - 291 Steering tube assembly ~N~ \L"!] 13' - 19 (1~ - »>,9 - 13] to.) 13.1811.3.1.8,9.13) to.) : N.m (kg-m, ft-Ib) SST109B Removal STEERING . WHEEL Pull out horn pad. If it is hard to pull out horn pad, temporarily loosen fixing screw of horn pad retaining spring. SST110B SST275B . Remove steering wheel with Tool. ST -1 0 STEERING WHEEL AND STEERING COLUMN Installation Ell STEERING . WHEEL When installing steering wheel, apply multi-purpose grease to entire surface of turn signal cancel pin (both portions) and also to horn contact slip ring. SST112B STEERING . . ' Cutout port Ion COLUMN When installing steering column, fingertighten all lower bracket and clamp retaining bolts; then tighten them securely. Do not apply undue stress to steering column. When attaching coupling joint, be sure tightening bolt faces cutout portion. CAUTION: After installing steering column, turn steering wheel to make sure it moves smoothly and that the number of turns from the straight forward position to left and right locks are equal. Be sure that the steering wheel is in a neutral position when driving straight ahead. Lower joint SST800A ST -11 STEERING WHEEL AND STEERING COLUMN Disassembly and Assembly Hole cover Steering column upper shaft ~ : N.m (kg-m, ft-Ib) SST113B . . . When disassembling and assembling, unlock steering lock with key. Ensure that rounded surface of snap ring faces toward bearing when snap ring is installed. Install snap ring CD before inserting shaft into jacket tube. . Instal1 snap ring on upper shaft with box wrench. SST428A ---n Upper shaft SST770A ST -1 2 STEERING WHEEL AND STEERING COLUMN Disassembly . and Assembly (Cont'd) Tilt mechanism Tighten adjusting nut to specification. ~: 4 - 5 N.m (0.4 - 0.5 kg-m, 2.9 - 3.6 ft-Ib) SST114B . Steering lock a) Break self-shear type screws with a drill or other appropriate tool. ~~ i b) Install self-shear type screws and then cut off self-shear type screw heads. Self-shear screw SST742A Inspection . L, F~- :1 SST098B When steering wheel can not be rotated smoothly, check the steering column for the following matters and replace damaged parts. a. Check column bearings for damage or unevenness. Lubricate with recommended multi-purpose grease or replace steering column as an assembly, if ecessary. b. Check steering column lower sh ft for deformation or breakage. Replace if necessary. When the vehicle is involved in a light collision, check steering column length "L1" and steering column lower shaft length "L2". If it is not within specifications, replace steering column as an assembly. Steering column length "L1": 653.1- 654.5 mm (25.71 - 25.77 in) Steering column lower shaft length "L2": 323.7 - 325.3 mm (12.74 - 12~81 in) 1 . L2 SST115B L. . After installing steering column, check tilt mechanism operation. L1: 9.8 mm (0.386 in) L2: 19.5 mm (0.768 in) . L3:29.3 mm (1.154 in) L.: 58.2 mm (2.291 in) SST116B ST -1 3 POWER STEERING GEAR AND LINKAGE (Model PR24SC) Removal and Installation Rack mounting insulator G." hoo.'ooonO.M'OO b~,k.. tOJ 24.29 (2.4 - 3.0, ~ ~ ~I\ ~ G.." ho",'" onOOM'", "''''''.. ."P . ~ 17.22) V,",". "00' ~ ~o ~ : I ' . [qJ 29 . 39 (3 -4, 22 .29) ..,.I> 18 I Gear and linkage assembly tOJ 88 . 108 (9.0 . 11.0, 66 .80) tDJ: N.m (kg-m, ft.lb) 124B . Detach tie-rod outer sockets from knuckle arms with Tool. . Install pipe connector. SST783A CD Low-pressure side tOJ: 27 39 N.m (2.8 - 4.0 kg-m, 20 - 29 ft-Ib) - @ High-pressure side . tOJ:15 - 25 N.m (1.5 - 2.5 kg-m, 11 - 18 ft-Ib) SST080B ST -14 POWER STEERING GEAR AND LINKAGE (Model PR24SC) Removal and Installation (Cont'd) . . Observe specified tightening torque when tightening highpressure and low-pressure pipe connectors. Excessive tightening can damage threads or damaged connector O-ring. The O-ring in low-pressure pipe connector is larger than that in high-pressure connector. Take care to install the proper O-ring. . . Initially, tighten nut on tie-rod outer socket and knuckle arm to 29 to 39 N.m (3 to 4 kg-m, 22 to 29 ft-Ib). Then tighten further to align nut groove with first pin hole so that cotter pin can be installed. CAUTION: Tightening torque must not exceed 49 N.m (5 kg-m, 36 ft-Ib). arm SST824A . . Before removing lower joint from gear, set gear in neutral (wheels in straight-ahead position). After removing lower joint, put matching mark on pinion shaft and pinion housing to record neutral position of gear. To install, set left and right dust boots to equal deflection, and attach lower joint by aligning matching ~arks of pinion shaft and pinion housing. \ ST -1 5 POWER STEERING GEAR AND LINKAGE (Model PR24SC) Disassembly and Assembly The table below lists four ways to repair oil leaks in the steering gear, depending on the location of the leak. See the following figure for oil leak locations. CD Rear housing cover and rear housing Operation . .. . . @ Boot @ Boot .. .. . .. @ Cylinder tube .. Replacement . Replacement . Replacement . Replacement Rear oil seal Rack oil seal Boot clamp Rack oil seals Rack oil seal O-ring Back-up collar Cylinder tube Pinion oil seal O-ring Snap ring Copperwasher Boot clamp Remove gear from vehicle. Measure rack starting 'force and pinion rotating torque. Procedure Replace parts described above, I I Replacecylinder I I Replace rack oil seal. I I tube. I I Adjust adjusting screw. Measure rack starting force and pinion rotating torque. Service parts to be prepared . Pinion seal kit . Gear housing seal kit .. Rack oil seal Pinion seal kit . Gear housing sealkit SST117B ST -1 6 POWER STEERING GEAR AND LINKAGE (Model PR24SC) @ ~ ~r~ l ~ 0r O'@J ~@ ~16-21 ~. (1.6-2. 1 , 12-15) ~ R~ I Adjusting screw m ~ ----~:9n_U~9 ; (40-6.0, SP~;r~ng disc 29-43) 1J be rWasher Pinion assembly %@@ evli.",,," 40"""\ / So"og ~ -.! ~ Retainer CenterbUShing\ Rack oil seal~ Pinion seal ring <::::::>--O-ring I J ~Shirr:~ ~ >< Pinion oil seal ~ m "'" ~ ~ m jt;;g ~ \\\)~ m l R~kO'I_'~ '-~ '9 -74.. -7.5. rn: 43 -54' E. Tie-rod \ ~ \ :~O,~ Bro,"'d~ ~ ~~ ~JL. Bo",",m, Rack spacer \ '\-.LOCkPlate rJ . ~ socket Inner. ~Tie-rod 78 -98 (8.0 - 10"0 58 - 72) . ~37 .46 (3.8- 4 .7 , 27 - 34) Tie-rod outer Do not disassemble. ~: N.m (kg-rn,ft-Ib) ssn1SB ST -1 7 POWER STEERING GEAR AND LINKAGE (Model PR24SC) Disassembly 1. Prior to disassembling, measure pinion rotating torque. Record the pinion rotating torque as a reference. Before measuring, disconnect cylinder tube and drain fluid. Use soft jaws when holding steering gear housing. Han(lle gear housing carefully, as it is made of aluminum. Do not grip cylinder in a vise. 2. Remove pinion gear. Be careful not to damage pinion gear when removing pinion seal ring. . . . SST1198 3. Remove tie-rod outer sockets and boots. 4. Loosen tie-rod inner socket by prying up staked portion, and remove socket. 5. Remove retainer. 6. Remove pinion assembly. SST881 7. Drill staked portion of cylinder end cover with drill of 2 to 2.5 mm (0.079 to 0.098 in) diameter, until the staking is eliminated. SST450A 8. Remove gear housing end cover assembly with Tool. 9. Draw out rack assembly. . SST0818 10. Remove Using a (104°F). Remove Replace . . . Rack seal ring rack seal ring. heat gun, heat rack seal to approximately 40°C rack seal ring. Be careful not to damage rack. rack seal ring and O-ring with new ones. SST0828 ST -18 POWER STEERING GEAR AND LINKAGE (Model PR24SC) Disassembly (Cont'd) 11. Remove center bushing and rack oil seal using tape wrapped socket and extension bar. Do not scratch inner surfaces of pinion housing. +1:''''°0 "" 29mm..ok" SST472A Assembly 1. Using a heat gun, heat rack seal ring (made of Teflon) to approximately 40°C (104°F) and install it onto rack with your hand. ~R"'k ",' cO", SST083B . Using Tool, compress periphery of rack seal ring (made of Teflon) to position and secure it on rack. Always insert the tool from the rack gear side. KV481 04400 ( ) Rack teeth ~lIJIfi11lJJJ11II11IIiIJ!I. Position and secu re seal. SST084B 2. Insert rack oil seal. Place plastic film into rack oil seal to prevent damage by rack teeth. Always remove plastic film after rack oil seal is positioned properly. Make sure lips of rack oil seal face each other. . .~ ~ . . .~-- Film~~ Rack oil seal j SST201A 3. Install center bushing and rack oil seal with rack assembly. SST830A ST -1 9 POWER STEERING GEAR AND LINKAGE (Model PR24SC) Assembly (Cont'd) 4. Tighten cylinder end cover assembly with Tool. . SST081B 2-3mm CO.08- 0.12 in) 5. Fasten cylinder end cover assembly to gear housing by staking. End cover assembly SST073B 6. Set rack gear in neutral position. Measured length "L": Refer to S.D.S. L L SST086B 7. Coat seal lip of oil seal with multi-purpose grease and install new pinion oil seal to pinion housing with suitable tool. Make sure lip of oil seal faces up when installed. ... . Suitable tool Oil seal SST381 A 8. Install pinion bearing adjusting shim(s). Whenever pinion assembly, gear housing and rear housing are disassembled, replace shim(s) with new ones. Always use the same number of shim(s) when replacing. . SST074B ST -20 POWER STEERING GEAR AND LINKAGE (Model PR24SC) Assembly (Cont'd) 9. Install pinion seal ring on pinion gear assembly. Using a heat gun, heat pinion seal ring to approximately 40°C (104°F) before installing it onto pinion gear assembly. Make sure pinion seal ring is properly settled in valve groove. . . SST085B 10. Apply a coat of multi-purpose grease to needle bearing roller and oil seal lip before installing pinion assembly in gear housing. SST075B 11. Install pinion assembly to pinion housing. Be careful not to damage pinion oil seal. SST552 12. Apply a coat of multi-purpose before installing rear housing. grease to rear oil seal lip Gear housing SST121B - Protrusion 13. Install rear cover cap so that protrusion of rear housing cover is positioned as shown in figure at left. Be careful not to damage worm ring and oil seal. ST -21 POWER STEERING GEAR AND LINKAGE(Model PR24SC) Assembly (Cont'd) 14. Install diaphragm spring at retainer. Always install retainer, spring washer and diaphragm spring in that order. Make sure convex end (painted white) of diaphragm spring faces outward when installing. 15. Install retainer spring and adjusting screw temporarily. . . SST087B . Attach lock plate to side rod inner socket . Apply locking sealant to inner socket threads @. Screw inner socket into rack @ and tighten to torque. .CAUTION: Clinch two places of lock plate at rack's groove. CV ~ ~( r{ ~ @ <1;",h. @ CD. specified To prevent scratching the boot, remove burrs from lock plate. '-CD Glass portion fA SBF177 BF-13 IGNITION SWITCH ON or START POWER WINDOW REGULATOR (Driver side) BA HERY fusible (V ia I Ink-Gree~ Downward Upward @ W/R"""4..l.I L/R-;::n, ~@ r-", ~ BREAKER . I CIRCUI T I @ (Door harness @ L.H.) W/B R~B~ R/W~ @ ~ . (Main harness) W/B R~B :;!~I~:U~I R/W g, ." R/W I ~ R/B W/B ~ . .@ r- r-~~ ,,,,r-"'OI' ~ POWER WINDOW AMPLI F I ER ~~ . D (Door harness R. H. ) ~ ~ R/W R/W R/B W~B R/B L W/B ~:a~:ar-r:a0l0l~0I~ ~@ DRIVER SIDE LOCK ONESWITCH TOUCH MANUAL U N 0 U N D ON OFF a 1 a a 2 :3 0 0 a 4 POWER W (Passen PASSENGER SIDE U N 0 a <> 0 0 a MOTOR CIRCUIT BREAKER @ii(§) - BODY GROUND CJI w W I'J m @ 8 01""" 5 6 7 m "11 I GN I TI ON RELAY POWER WINDOW MAIN SWITCH Wi ope di DOOR Power Window (Cont'd) POWER WINDOW AMP. INSPECTION FRONT DRIVER SIDE POWEfI WINDOW SWITCH Connections From power window AMP From power window AMP ~~ 9 From AMP ~ power window Ground -=- IGNITION SWITCH ON or ST (Via power window relay) VOLTMETER FRONT DRIVER SIDE POWER WINDOW REGULATOR Window operating direction Upward f I Current flow Downward I\.1 direction AMP. \ 51 52 -53 54 55 - 56 57 - 58 - OPERATION Connections Operations Manual operation One-touch (Autol Operation Power source OGNI 12V 12V 12V 12V 12V 12V Ground Gmund Ground Gmund Gmund Gmund Ground ON or ST ON or ST From ignition SW(ON or STI ON or ST ON or ST ON or ST ON or ST To FR driver side power OFF OFF OFF OFF OFF ON window SW (AUTO) Q) '0; To FR driver side power OFF ON OFF OFF , OFF OFF window SW (UP) @ To FR driver side power OFF ON OFF OFF OFF ON window SW(DOWN) CV . I Regulator FR driver side regulator (Upward power source) Approx, OV Approx. over 9V Approx. OV Approx. OV Approx. OV Approx. OV FR driver side regulator (Downward power source) Approx. OV Approx. OV Appmx. over 9V Approx. OV Aprrox. over 9V Approx. over 9V Stop Upward operation Down. ward opera. tion Starting Keeping opera. tion until fully open, then "ops automatically. Operating Condition Stop Downward Carry out this operation operation check in this chart from left to right continuously, I POWERWINDOW AMP. -IFront driver sidedoor (Behind door trim) SBF789C CIRCUIT Time (sec.) BREAKER For example, when current is 30A, the circuit is broken within 8 to 20 seconds. This circuit breaker is also used in the power door lock system. 100 ' 50 20 10 8 5 1 0 SBF284E INSPECTION 10 20 30 40 50 60 70 Current (A) BF-15 . SID~ D PASSENGER BATTERY (V I a fus I b I e I Ink-Green) ORB'L ~t ([ill) @ CIRCUIT~ BREAKER~ rn::;-L/R @@D ~W/R DOOR LOCK CO Lock Between lock" un lock n a Fom I lock to un lock Fom I un lock to lock PASSENGER SIDE POSISTOR c I rcu I t operation .;;; ... SW-B 0. .= operation OFF Turns ON ON Turns OFF OFF OFF OFF OFF OFF OFF OFF Turns ON ON After SW-A Turns operation, Turns OFF immediately OFF turns ON ON (Approx. OFF 1.0 sec.) ... OFF OFF ... 0.- Test lamp OFF ...c: .2' operation 0" . . ON (Approx. OFF 1.0 sec.} -+ OFF OFF Turns ON Turns OFF ON... OFF OFF ... ON... OFF Carry out the complete inspection in this chart from left to right. Do not carry out any switch operations that are not described in the above chart so as to avoid breaking the door lock timer. Lighting period of test lamp differs according to SW-B operation. Moreover, test lamp may come on once or it may not come on at all. If this occurs, do not judge it fau Ity solely from th is step. INSPECTION CIRCUIT (This test circuit must be wired by the technician.) --- TESTLAMP BATTERY SW-B = = -=- SW-A DOOR -::- - LOCK TIMER CIRCUIT CONNECTIONS - + + - 31 Power source (BAT) 32 To/From actuators (Lock power source & Unlock ground) 33 To/From actuators (Unlock ground & Lock power source) 34 35 To lock-unlock switches (Input signal for lock) Ground 39 To lock-unlock switches (Input signal for unlock) SBF377E BF-17 INSTRUMENT PANEL f . When removing instrument panel assembly, remove defroster grille, combination meter, A/C or heater control, cluster lid C and S.M.J. first. HEAD-UP DISPLAY (H.U.D.) When removing H.U.D. finisher, be extremely careful not to scratch H.U.D.'s reflective surface. To avoid scratching, cover H.U.D.'s reflective surface or finisher with a cloth or vinyl sheet. II . Defro ster grille Super Mutiple Junction CS-M.J.) Fa ~ -~ Pewl Ii) ;;;. /~ . -~* .' * rPawl (I ~ ~ . ~ ~~ Combination meter ~~ Cluster lid C ~.Metal ~ cliPIJ '1'" I ~ * : Instrument panel assembly mounting bolts BF-18 ~/ ~P8WI Ii] INSTRUIYIENT PANEL m (j] ' / @J -- Super Multiple Junction (S.M.J.I -:- Instrument harness Fuse block Ii] Pawl (2 places each for upper and lower surface) II Pawl (4 places each for upper and lower surface) Ii [!1 1:1 0 IJ Ia II Tape H.U.D.'s reflective surface rWindshield Metalclip Pawl (To head up display assembly) Cloth or vinyl sheet SBF178E BF-19 INTERIOR AND EXTERIOR Interior SIDE, LUGGAGE AND FLOOR TRIM - Fastback ~ 0 -;?o,;', Speaker --~:. ~ ."."- fT Door corner finisher [i] Metal clip panel Ii] iii ~ U-:! Assist grip removal \I BF-20 [!I INTERIOR AND EXTERIOR Interior (Co,nt' d) m Ii] [!] (I Ii ;t=.~~~ Garnish Ii] Pawl Pawl Pawl [!I SBF179E BF-21 INTERIOR AND EXTERIOR Interior (Cont'd) SIDE TRIM - Coupe x x x ~=,1J~\ Garnish SBF180E LUGGAGE ROOM TRIM - Coupe Clip removal Ii) Ii) J-~ Removal SBF181E Bf=-22 INTERIOR AND EXTERIOR Interior (Cont'd) ROOF TRIM Fastback m Back door weatherstrip Roof rear garnish""" Coupe .~~ U ~R~f "'m ~,.". m r- /) Ii) 1ass Back door window Roof HoodnO;"' M""<"p ~l panel g ~ 7 \ r)}. 0- ~ ~ r-.~ / ~~tXL\ Roof rear garnish SBF182E BF-23 INTERIORAND EXTERIOR Exterior @ @ @ @ @> @ (j) @ SBF192E BF-24 INTERIOR AND EXTERIOR CD Windshield upper and side molding Method 1 Exterior (Cont'd) CID,@ Cowl top grilleand hood rear sealingrubber Cut off top portion of molding and clean glass and panel surfaces. . ~.q~ ~"~, <@J; Apply sealant molding. to top portion / of ~() ~ ~9 ~.,.,.,.,.,.,..: ~~;~ t . ':1:--4 SBF211E ... Cut off lower portion of new molding. CID 'r"~ SEV Hood front sealingrubber .',','.'.','. ." ':i/":::: 'J Hood front sealing rubber Finish well to give it a good appearance. Method 2 1. Cut off sealant at glass end. 2. Clean the side on which panel was mounted. 3. Set molding fastener and apply sealant & primer to body panel, and apply primer to molding. Apply primer."\ Glass~ Dam rubber ~ ~ ( -, ~ Double-faced adhesive tape SBF212E Apply sealant. 4. Install molding by aligning the molding mark located on center with vehicle center. Be sure to install tightly so that there is no gap around the corner. @ Center pillar finisher SBF519B ~ s"u"'~"h7 ~. CV Windshield lower molding It is mounted with screws. Grommet 7 ' ~ Sealing washl Grommet?' SBF213E BF-25 INTERIOR AND EXTERIOR Exterior (Cont' d) (j) , @ Body side weatherstrip and weatherstrip retainer ~ II m : Butyl tape [!) Coupe Removal ButYl tape .--; Double-faced adhesive tape Ii] Windshield pi liar garn ish Body side welt II Weatherstrip retainer Ii Body side weatherstrip Body side weatherstrip Seal SBF214E BF-26 INTERIOR AND EXTERIOR Exterior (Cont' d) @ Rear sight shield @ Door weatherstrip Apply butyl sealant where necessary while installing the weatherstrip. t""h" W,"" \ SBF215E SBF217E @ Back window upper and side molding (Coupe) Basically the same as windshield upper and side molding. @ Back door window upper and side molding (Fastback) Bonded on back door glass side. (j]) Back window lower molding (Coupe) It is mounted with screws. @ Back door window lower molding (Fastback) @ Trunk lid weatherstrip Moldingclip ~ . ~ " (9 places) Trunk lid ' weatherst . .;.. np There is a marking at vehicle center. SBF401B SBF216E BF-27 adhesive tape (When install ing fastener. heat body panel and fastener to approx. 30 to 40°C (86 to 104° F)). INTERIOR AND EXTERIOR Exterior (Cont' d) @ Back door weatherstrip (j]) Sun roof lid weatherstrip Manual sun roof Butyl seal Sealant Body panel SBF757Q @ Sun roof weatherstrip SBF424D @ Rear panel finisher (Fastback) SBF873C SBF218E @ Sun roof lid weatherstrip and sun roof frame weatherstrip (Coupe) Sun roof lid weatherstrip is bonded to lid. Apply primer before bonding it. Front // .///j Roof panel ./ Sun roof lid ' weatherstrip Sun roof rd I I SBF824D BF-28 INTERIOR AND EXTERIOR NOTE BF-29 SEAT Front Seat IRJ 43 -55 (4.4.5.6,32.41) IRJ : N.m (kg-m, ft-Ib) SBF183E BF-30 SEAT Rear Seat Striker installation m Seat back I!J adjustment I!J m ~ Bushing ~Grommet ~ '3.,.~1-::lli (1.3-1.6j 9-12)' I SBF184E ~ : N.m (kg-m. ft-Ib) BF-31 ~ - (10 .. ) AUTOMATIC SEAT BELT SYSTEM Unit Location Guide rail assembly Rear limit switch & shoulder belt buckle switch [!J Pawl Drive motor Lap belt Ii) ) (Installation ~43 -55 14.4- 5.6,32 - 411 Shoulder belt assembly (Installation m) ~~43-55 ~. 14.4- 5.6, 32 - 41) oD i~. Lap belt buckle (L.H. only) switch ~43-55 14.4 - 5.6, 32 - 411 Control unit . Control unit is located under center console box. BF-32 AUTOMATIC SEAT BELT SV;STEM Unit Location (Cont'd) m - I~ - rA 43-55 (4.4-5.6,32 -41) Ii] ~ Lapbelt retractor ~I ~~t~ A43 - 55 (4.4 - 5.6, 32 - 41) (4.4 - 5.6, 32 - 41) [!J Guide rail assembly Rear limit switch (Bottom color: Green) Guide cable ~~ J>ff Shoulder belt buckle assembly .~.~ A : N.m (kg-m. ft-Ib) SBF185E BF-33 AUTOMATIC SEAT BELT SYSTEM Wiring Diagram CIRCUIT BREAKER BATTERY (V I a fus i b I e I Ink-Green) (Eng i ne room harness) S. M.J. [Refer to (Fo Idout I ast I GNI TI ON SWITCH ON or SART page) page .J '" ~@}) m, u: '" @D WARNING CHIME E1 ~ @r7 @~~'" '" ..J , , " "'''' ..J ~ ..J I ~. j R/B (Mai n harness) @ G FUSE BLOCK (Refer to npOWER SUPPLY ROUTINGnln EL section.) I ..J 'III >- ~@ ~@ (Ma I n harness) ..J 'III >- '" , '" >- 'iii U) Q) @ EEIBHEE @ CWhi te) c '- III .c (B lack) @ Q. E III tHHHffil@ '" ,>- '" (J nstrument harness) WI) ,>- ~@ '" '" "" >- 0 [Sffi:B]@ ~QD I ~ @--<> SEAT BELT WARNING LAMP ~ 'III >- EW '" 91 o ..J E 0 0 0: 92 : I ~ 91 o @ o 92 SEAT BELT WARNING LAMP 1 [g R. H. SIDE COMBINATION FRONT LIMIT METER BF-34 SWITCH AUTOMATIC SEAT BELT SYSTEM Wiring Diagram (Cont'd) AUTOMATIC SEAT BELT CONTROL UNIT ~:With head-up ~:Without ~ ~ display head-up display ~~@V m~~~~~~ """,m ~~~~~~~ ~ m ,~~ ~ ~m ~~~~ ~~ ~~ ~~~~ ~~ ',m"~~m" R. H. SIDE CD ~ ~~~ G;R G/B j1 D ~L/W~~ ~Lr~ y w ~ Shoulder REAR LIMIT SWITCH belt buckIe condItlon ~ FR IFR and RRIRR '53 rst Shoulder buck Ie SHOULDER \ BELT Fastened BUCKLE 55 :J SWITCH 54 :J belt condl t Ion IUnfastened I I Belt ope rat In9 dl rect Ion rlFrontward Raarward L. H. SIDE @E) ~~~ LG;R LG/B jl D CD~ ~ti~R~ ~L/W J ~ L~ i-.I B "'~Rl ~ REAR LIMIT SWITCH SHOULDER BELT BUCKLE SWI TCH 55 54 Shoul der belt buckle condition Fastened Unfastened B II J ~ II 1: ~ W ~ . 0 L i=9 L Door condition ODen Close ~ ~ ~ ~ ~ ~ m' @~ @Y~ ~ ~ 171 1121 BUCKLE H. s I de dIdI B j (R.H.side door harness) B Door condition ODen Close @D R @}) BODY GROUND . 0 ~M18 fn.) DI ~ ~ m R:~ -0.. (L.H.sIde door harness) ~ 11 12 L. H. SIDE DOOR LATCH SWITCH @ ii @D(@@~ 1 LAP BELT (L. ~ FID ~ ,m 11 ~ R. H. SIDE DOOR LATCH SWITCH BODY GROUND SWITCH on I y) L. H. SI DE FRONT LI MIT SWITCH SBF784E BF-35 AUTOMATIC SEAT BELT SYSTEM Description FUNCTION Shoulder belt buckle is mainly operated while ignition switch is "ON". Condition (A): Ignition switch is "ON". When door is opened, shoulderbelt buckle is moved frontward and when pp,er i~closed, buckle is moved rearward. Condition (B): Ignition switch is "OFF". When door is opened, shoulder belt buckle is moved frontward. When the door is closed, buckle will remain in this position. IVolt- 1';;; :; 0. OFF ON ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF Door latch switch OFF ON OFF OFF OFF ON ON ON OFF OFF OFF OFF ON ON ON OFF Front OFF OFF OFF ON ON ON ON OFF OFF ON ON ON ON ON OFF OFF Rear limit switch ON ON ON ON OFF OFF ON ON ON ON OFF OFF OFF ON ON ON Drive motor power source for frontward OV OV OV OV OV 12V 12V OV OV OV OV OV 12V 12V OV OV OV OV 12V 12V OV OV OV OV 12V 12V OV OV OV OV OV OV Stop Stop Start to move Moving Stop Start to move Mov ing Stop Start to move Moving Stop Stop Start to move Moving Stop Stop Front Between Front& Rear Between Front & Front Between Front & Rear Rear Between Front & Front Front switch limit switch o!: 1 ';;; of output signal is approximate valueJ OFF Ignition operation :;0. :; 0 Drivemotor power source for rearward operation Function Shoulder buckle belt Position Front Front Rear Rear TIMER Rear Front Rear Rear Rear (Ignition switch either "ON" or "OFF") If limit switch does not operate (when accomplishing frontward operation, front limit switch can not be turned "OFF" or when accomplishing rearward operation, rear limit switch can not be turned "OFF"), control unit will continue to supply power to drive motor for 15 secondsand control unit will stop supplying power. QUICK WARNING (Ignition switch "ON") If front limit switch is not turned "OFF" after accomplishingfrontward operation, control unit will stop supplying power 15 seconds later and warning lamp will flash and chime will operate rapidly for approximately 6 seconds. REAR LOCK If quick warning functions twice successivelywhile ignition switch is "ON", shoulder belt buckle will move to rear position when the door is closed as normal but will remain in rear position even if door is opened. This function is canceledwhen ignition switch is "OFF". BF-36 AUTOMATIC SEAT BELT SYSTEM Description (Cont'd) WARNING Priority Warning item Ignition switch Shoulder anchors Indication of warning (Indicating time is approximate value.) ON are not at rear Lamp I lock position. Chime I OFF -* ON I Lamp Chime . And,", Lamp n.. R'~I - _h" Chime t:: Within 6 sec. 2 ON I Shoulder belts are not fastened. I Ancho, Lamp R'~ ON OFF Chime ON OFF Belts Unfastened I Fastened Lamp Ch ' 100 sec. I ON OFF ON .me Belts OFF Unfastened Fastened Lamp O~~ Chime Belts ON OFF Unfastened Fin 3 I Driver side lap OFF -* ON belt is not fastened. 6 sec. Fasten~~.I~ec. Lamp Chime Belts ~ Within 6 sec. r-aSIenea 4 I Normal (All belts OFF -* ON Lamp are fastened and shoulder anchors are in rear lock .. position. ) Chime ON OFF O~~ I BF-37 6 sec. AUTOMATIC SEAT BELT SYSTEM NOTE BF-38 TROUBLE DIAGNOSES Contents Symptom Chart Preliminary Check BF-40 BF-41 Main Power Supply and Ground Circuit Check , Harness Layout Circuit Diagram for Quick Pin Point Check Diagnostic Procedure 1 (Check motor circuit and stop signals.) Diagnostic Procedure 2 (Check door switch circuit) Diagnostic Procedure 3 (Check front limit switch circuit) Diagnostic Procedure 4 (Check rear limit switch circuit) Diagnostic Procedure 5 (Check shoulder belt switch circuit) Diagnostic Procedure 6 (Check lap belt switch circuit) Diagnostic Procedure 7 (Check warning chime circuit) Diagnostic Procedure 8 (Check warning lamp circuit.) Electrical Components Inspection BF-45 BF-46 BF-48 BF-49 BF-52 BF-54 BF-56 ..".. BF-58 BF-60 BF-62 BF-63 BF-64 Since left and right component parts are basically the same, harness layout and methods for electronic components inspection are shown for one side only. Although methods for checking component parts on both sides are described in the flow chart, making it easier to trouble-shoot, apply checking procedures to either side that have problems during trouble diagnoses. For those methods enclosed by double rectangulars,however,component parts on both sides must be checked as problems occurring on either side cannot be easily determined by a symptom. BF-39 TROUBLE DIAGNOSES Symptom Chart 0 Motor BF-64 0 0 BF-64 co Shoulder BF-64 :i Ii Door latch switch 0 BF-64 Rear limit switch 0 0 BF.64 Front limit switch 0 0 .. ... c: .. c: BF-65 Lap belt switch 0 E BF-64 Motor 0 Shoulder belt buckle switch 0 Door latch switch 0 BF-64 Rear limit switch 0 0 BF-64 Front limit switch 0 0 BF-65 Warning chime 0 0 Warning lamp 0 0 c: 0 of; co a 0 belt buckle switch 0 0 0 0 0 0 = R 8 BF-64 t.. iii BF-64 - " -0 0;;; :i ....i 0 . 0 0 0 0 0 0 0 0 BF-63 Procedure 8 0 BF-62 Procedure 7 0 BF-60 Procedure 6 0 BF-58 Procedure 5 0 BF-56 Procedure 4 0 0 BF.54 Procedure 3 0 0 BF-52 Procedure 2 BF-49 Procedure 1 BF-45 Procedure 2 BF-45 Procedure 1 BF-43 Procedure 2 BF-41 Procedure 1 ' f ;, iu e a. u °ji; 0c: i i5 :D"E .. "E o.>< a.;'G c: 0. -0.00 e o!::6 .>< .E 'f° a. e;, iu 0 Q: co i 0. ..u "c: j! .. a: 0 0 0 0 0 0 0 0 0 0 0 0 -8i i ..E 1ii u E .. 0co-0 0 o:;;; c: "':>< 0. 02 c: u ... 0 Ia. >CI) 1iiC ;, c: .... .0.. co co° E g- 0°-00 c: zE BF-40 0 £ .. ..c>- .!! '><-o u co ;'-0 .0.... .. a;:i .c. a: ai .. ".. ° 0 E :J:. ... 0 CI)..Jc: -.. c: :>< 0 u.. .&11_ "" !11 .. c: .. ° ...:.. :2.. f ;, 000 ... EE ij;'''- 0 .011" ... .. 11 -!.. .a..! :De g -0.." 3:: 000 EE ... g .... !.. .. . 00. '" c: of co .. u ;, ;:£... 0 .2.. -0 ° £ > '" c: .: 02 E0 ... u 05 'fROUBLE DIAGNOSES Preliminary Check PROCEDURE 1 Turn ignition switch and all other electrical switches "OFF", and close door. Disconnect negative cable from battery. Open door. Move shoulder belt buckle to center (not rear lock position and not front stop position) by wrench supplied in tool bag or equivalent. I Close door. r Connect battery cable. STEP 1 Does shoulder belt buckle move frontwards? Yes No I Open door. STEP 2 I Go to Diagnostic Procedure 2. (See page SF.52.) No Does shoulder belt buckle move frontwards? (Go to @ on next page.) Yes Close door, and turn ignition switch "ON". STEP 3 No Does shoulder belt buckle move rearwards? Yes END BF-41 Go to Diagnostic Procedure 4. (See page SF-56.) TROUBLE DIAGNOSES Preliminary Check (Cont'd) Turn ignition switch "ON". STEP 4 Does shoulder belt buckle move rearwards? Yes No Go to Diagnostic Procedure 2. (See page BF-52.) Close door. ... STEP 5 Does shoulder belt buckle move rearwards? No Go to PROCEDURE 2 of Main Power Supply and Ground Circuit Check. Yes (See page BF-45.) Then go to Diagnostic Procedure 1. (See page BF-49.) Go to Diagnostic Procedure 3. (See page BF-54.) BF-42 TROUBLE DIAGNOSES Preliminary Check (Cont'd) PROCEDURE 2 Fasten all seat belt and open both doors. Turn ignition switch "ON". STEP 1 Does warning chime sound for 6 seconds after switch is turned on? No Go to Diagnostic Procedure 7. (See page BF-62.) Yes STEP 2 No Is warning lamp flashing now? Yes Go to Diagnostic Procedure 8. (See page BF-63.) Close both doors. STEP 3 I Is warning lamp flashing although shoulder belt buckles reached rear lock position? No Yes Go to Diagnostic Procedure 4. (See page BF-56.) Unfasten L.H. shoulder belt. Does warning chime sound for 6 seconds and warning lamp glow after belt is unfastened? . . No Go to Diagnostic Procedure 5. (See page BF-58.) Yes Fasten L.H. shoulder belt. Unfasten R.H. shoulder belt. STEP 5 Does warning chime sound for 6 seconds and warning lamp glow after belt is unfastened? Yes No Fasten R.H. shoulder belt. Unfasten L.H. lap belt, and turn ignition switch "OFF". (Go to @ on next page.) Bf-43 Go to Diagnostic Procedure 5. (See page BF-58.) TROUBLE DIAGNOSES Preliminary Check (Cont'd) Turn ignition switch "ON". Does warning chime sound and warning lamp glow for 6 seconds after the switch is turned on? . No Yes END BF-44 Go to Diagnostic Procedure 6. (See page SF-60.) TROUBLE DIAGNOSES Main Power Supply and Ground Circuit Check PROCEDURE 1 Main power supply Battery voltage existence condition RIB W/L - SBF336E Terminals Ignition switch "ON" Other than ignition switch "ON" @ - Ground Yes No - Ground Yes Yes Yes Yes Yes Yes @ <@)- Ground @ - Ground Ground circuit i5~ I~I ~ Terminals l~ ~ B C.U. connectors Continuity - Ground Yes @ - Ground Yes @ - Ground Yes -=SBF337E _T IV [it Terminal L.H. side: ~ and @ R.H. side: @ and @ PROCEDURE 2 Power supply for motor drive Terminals ~ C.U. 10-pin connector Battery voltage existence L.H. side <@) - Ground Yes R.H. side @ - Ground Yes Ground circuit for motor drive - Terminals Continuity L.H. side @ - Ground Yes R.H. side @ - Ground Yes B SBF33BE -=- BF-45 TROUBLE DIAGNOSES Harness Layout m Room lamp harness m --------------------@ R.H. front limit switch @ Body ground I;] @ r. . @ ~ 18 Warning (without lamp Warning chime head-up display) Warning lamp (with head-up display) ~ [!1 @Dl.H. door latch switch J@])R.H. door latch switch- . L /~ i' \ @!I B F -46 TROUBLE DIAGNOSES Harness Layout (Cont'd) Ii \ SBF368E BF-47 TROUBLE DIAGNOSES Circuit Diagram for Quick Pin Point Check I GNI TI ON SWITCH ON or START (WIth head-up d I sp lay) @! 0~ SEAT BELT WARNING (WI thout head-up LAMP d I sp lay) ; @ BREAKER / 2] [IJ M 9 0 BELT 33 30 26 SEAT CONTROL UNIT '36 29 39 @ nlO1 44 . 4] 45 '0 HH 40 3 9 H3' 38 37 46 25 26 43 42 3] 36 32 35 I 11::0 -I I ,1/);2 I @ @ i U @ I/) O:J -m I...J .W ...Jm 0@ -:EI-- @ I/).II:: - I IO .0 -10 1/)1-- @i) @ OC @) :JO @ :...J- @I Will m.I Q... @ 5d @!D-::!:~ i I/) I0 WI-0« -...J I/) .11:: IO .0 11::0 @-::!:@Y .11:: I« .w ...JII:: I 11::0 WI-...J :JI/) 0 IW 0@ WO O:J Ei I/)...J -m I/) .1-I...J .W !r:m .> .11:: ...JO I/) I 0 I-- I-- W:E @ 0-...J I/) .11:: I« .W !r:1I:: I I 0 I-- @ .Z IO .11:: -ILL 11lIM 0- wO...J @ I/)W 0-...J W:E @ I/).1-- - (0 - I-- Ei IW WO I 0 I-- I 0 0 I-- - CD @ 51/) I @@ I 5...J : G) @ @Y @}) I 0 I- I-.> .11:: I/)W 11::0 @ I - w6 en: WARNING @ 34 \5 52 CHIME I -- S@ 51 AUTOMATIC 22 CIRCUIT @ ' @! 0~ G)@ 1/1 FUSE FUSE 0 I-- @ (0 @ I-- :E WO...J 1/)1-.Z IO .11:: II::LL @!D-::!:~ SBF7B5E BF-48 TROUBLE DIAGNOSES _T Fa @p C.U. 10-pin connector LHo"iwl ~40 IU ~ tt4~ aH°Ho"d' START Fa CHECK MOTOR CIRCUIT. 1) Disconnect 10-pin connector from control unit. 2) Check continuity. ~'Gm SBF339E m C.U. 10-pin connector IU R.H. side: @ LG/S (Go to @ on next page.) @-@ @-@ R.H. side Terminal L.H. side: @ N.G. Terminals L.H. side ~ ~ ~ @p Diagnostic Procedure 1 Continuity should exist. O.K. m Does continuity exist? Yes (Go to @ on next page.) Terminals - SBF340E [!]I~ C.U.10-pin connector "IJ i5~ Frontward operation L.H.side @ - Ground R.H. side @ - Ground No [!]I I CHECK MOTOR OPERATION. Check shoulder belt buckle movement. O.K. (Go to @ on page SF-51.) N.G. Go to DRIVE MOTOR ASSEMSLY of Electrical Components Inspection. (See page SF-64.) Rearward operation . LG/R O.K. Replace guide rail assembly. Rearward GIS operation G/R SBF341E BF-49 N.G. Replace drive motor assembly. TROUBLE DIAGNOSES Diagnostic Procedure 1 (Cont'd) 1i]@P ~motor connector Drive C.U. 10-pin connector L.H. side @ Ii] 1) Disconnect connector from drive motor assembly. 2) Check continuity. N.G. Repair harness. Terminals LG/R LG/B @-<@ @-@ @-@ @-<@ L.H. side R.H. side ~ Drive motorconnector ~c.u. 10-pin connector R.H. side ~i5 Continuity should exist. O.K. Check drive motor harness for open circuit. Repair drive motor harness. O.K. G/R Replace drive motor. SBF342E r.I_CT ellU ~ ~ -.Eer ~Drivemotor fill D 52 LG/B4~' ~ L.H. side IV ~R.H. sidelll 52 D tEJ connector G/Bhi' ~ Drivemotor connector 1) Disconnect connector from drive motor assembly. 2) Does continuity exist in at least one point? Yes Repair harness. There will be incorrect grounding. Terminals @ - Ground L.H. side SBF343E ":" <@ - Ground -=- @ - Ground R.H. side <@ - Ground No Check drive motor harness for incorrect grounding. O.K. Replace drive motor assembly. BF-50 N.G. Repair drive motor harness. TROUBLE DIAGNOSES Ii <§p _NEeT C.U. 10-pin connector Eu ~ Terminal l.H. side: @ RH. side: @ VIR Diagnostic Procedure 1 (Cont'd) @ I Ii CHECK STOP SIGNAL. 1) Moveshoulder belt buckle to center (not rear lock position and not front). 2) Check continuity. N.G. Go to Diagnostic Procedure 3 (See page BF-54.) and return to next step. Terminals -=- SBF344E l.H. side @ - Ground @ - Ground R.H. side Continuity should exist. [i'IRefer to figure [i'Ito move shoulder belt buckle. O.K. III N.G. Go to Diagnostic Procedure 4 (See page BF-56.) and return to next step. 1) Disconnect 16-pin connector from control unit. 2) Check continuity. Rearward operation LG/R Terminals RH. side l.H. side @ RH. side @ - Ground - Ground Continuity should exist. . Rearward operation O.K. Is this the second time? Yes . Replace control unit. I No SBF341 E III ~ Reinstall any part removed. IJISCOIINEeT C.U. 16-pin connector 18 Go to PROCEDURE 1 (START) of Preliminary Check. (See page BF-41.) Terminal l. H. side: @ RH. side: @ -= SBF345E BF-51 TROUBLE DIAGNOSES m ~ lu _IECT Diagnostic Procedure 2 ~ ~ C.U. 16-pin connector Terminal L.H. side: @ RH. side: @ L -= SBF346E ( START m r ) CHECK DOOR SWITCH CIRCUIT. 1) Disconnect 16-pin connector from control unit. 2) Check continuity. Ter- Ii)~ C.U. 16-pin connector ~ ~ IIISCIIIIIECT Door latch switch connectorlU I~R.H.side L rmJ Door condition & L @Ground Open Yes Close No RH. side @Ground Open Yes Close No N.G. N.G. 1) Disconnect door latch ~witch connector. 2) Check continuity. ~ L.H. side R.H. side (Go to @ on next page.) Continuity L.H. side Ii) nfFOil~ ~ minals O.K. Repair harness. Terminals @-@ @ - Ground (eM§!>,€~J§» @-@ @ - Ground (~, €J]:» Continuity should exist. 1 [;] _IECT 12J ~ ~ ~ Ug~IJ~[;] CQD)or <§9> Doorlatchswitch connectorConnector L.H. side:<@) R.H. side:@9:> Harness color L.H. side: R R.H. side: L SBF348E O.K. SBF347E -::- Yes Does continuity exist? Connector Terminals L.H. side C!ill> @ - Ground RH. side @ - Ground Go to DOOR LATCHSWITCH of Electrical Components Inspection. (See page BF-64.) . N.G. O.K. Repair harness. There will be incorrect grounding between terminals @ and (j]) or @ and (j]). Reinstall any part removed. Go to PROCEDURE 1 (START) of Preliminary Check. (See page BF-41.) Check door latch switch harness for open and short circuit. . O.K. Replace door lock assembly. BF-52 Repair door latch switch harness. TROUBLE DIAGNOSES Diagnostic Procedure 2 (Cont'd) @ 1 - Is this the second time? No Reinstall any part removed. Go to PROCEDURE 1 (START) of Preliminary Check. (See page BF-41.) SF-53 Yes Replace control unit. TROUBLE DIAGNOSES m _CT Diagnostic Procedure 3 [it ,8:~ ~C.U.10-pin connector WiV Terminal L.H. side: @ R.H. side: @ START m -= SBF344E Frontward operation Terminals L.H. side LG/R Shoulder belt .buckle position Continuity At front No Not at front Yes At front No Not at front Yes @Ground R.H. side Rearward operation @Grou nd Ii)Refer to figure Ii) to move shoulderbelt buckle. R.H. side N.G. [!] ~ -¥~~NB Rearward operation G/R UW/L \:.J <&1~vC.U. 10-pin ~ IE) SBF341E <@)Front limit switch connector' connector <&1~1). C.U. 10-pln ~m ~ Terminals L.H. side R.H. side @-G) ) Continuity should exist. O.K. ~ switch IIISQIIIIIECT assembly,£o;\ connector Wis.J I~J SBF352E [it Terminals [it 0 LlLillJ ~ = [ill fJ ~ LM tfj L (Go to @ on next page.) BF-56 Repair harness. TROUBLE DIAGNOSES DiagnosticProcedure4 (Cont'd) Ii] o m i5~ CIDor(§) ~3 Rear switch assembly connector Connector L.H. side: CID R.H. side: (§) Harness color L.H. side: L/W R.H. side: L/W 1 Ii] Does continuity ----- Connector LID Yes exist? Terminals L.H. side CID - Ground R.H. side CID - Ground Repair harness. There will be incorrect grounding between terminals @ and ~ or @ and ~. No SBF353E -=- Go to REAR LIMIT SWITCH of Electrical Components Inspection. (See page BF-64.) O.K. (Go to @ below.) ~ Check rear limit switch harness for open or short circuit. Repair rear limit switch harness. O.K. I Replace rear switch assembly. 1 Is this the second time? No Reinstall any part removed. Go to PROCEDURE 1 (STEP 3) (See page BF-41.) or PROCEDURE 2 (STEP 3) (See page BF-43.) of Preliminary Check. BF-57 Replace control unit. TROUBLE DIAGNOSES -, m IV ~ C.U. 16-pin connector rw ~ Diagnostic Procedure 5 Terminal @ l.H. si.de: R.H. side: @ 1 START Y/B m [ . , CHECK SHOULDER BELT BUCKLE SWITCH CIRCUIT. 1) Disconnect 16-pin connector from control unit. -::- SBF354E Ii1 ~:!!>j) C.U. 10-pin connector i5~ l.H. side RH. side Ter-Shoulder minals beit Continuity l.H. side @Ground Fasten Yes Unfasten No R.H. side @- Fasten Yes Ground Unfasten No belt buckle is not rear lock position, do as figure Ii1 to move it to rear. SBF355E N.G. [i 1) Disconnect connector from rear switch assembly. 2) Check continuity. ~ Repair harness. @-~ @- Ground (~, ~) @-~ @ - Ground ~, RH. side CID Rear switch assembly connector N.G. Terminals l.H. side C.U. 16-pin connector (Go to @ on next page.) 2) Check continuity when shoulder belt buckle is at rear lock position. [;) If shoulder ~ O.K. ~) Continuityshouldexist. O.K. Ii] Yes Does continuity exist? --- ConnectorTerminals l.H. side , 1I8v ~ Diagnostic Procedure 6 ~ ~C.U.16-pin connector START ( m -= SBF358E I CHECK LAP BELT BUCKLE SWITCH CIRCUIT Lap ~ c§V ~ C.U. 16-pin S8"S9' [!] ~ 1180 DISCONNECT @ - Ground ~ 18 connector belt on next page.) Continuity Lap belt Fasten No Unfasten Yes ~~~ N.G. Ii] []l] N.G. L/R ~ l..m @ connector ~ l.oIIIIB ~;..h boo". E"V ~1J' fQ;,j L/R ~ (Go to (L.H.only). ~E§) ~ O.K. 1) Disconnect 16-pin connector from control unit. 2) Check continuity. Terminals [;)i5 ) 1) Disconnect lap belt switch connector. Repair harness. 2) Check continuity. Terminals @-@ @-Ground~.~) Lap belt switch connector ~ Continuity should exist. L/R [ill O.K. [!] Does continuity exist? Yes Terminals Repair harness. There will be incorrect grounding. @ - Ground SBF360E -=- No Go to LAP SWITCH of BELT BUCKLE Electrical O.K. (Go to @ on next page.) Com- ponents Inspection. (See page BF-65.) N.G. Check lap belt buckle switch harness for open and short circuit. O.K. Replace shoulder belt buckle assembly. BF-60 N.G. Repair lap belt buckle switch harness. TROUBLE DIAGNOSES Diagnostic Procedure 6 (Cont'd) T Is this the second time? Replace control unit. No Reinstall any part removed. Go to PROCEDURE 2 (STEP 6) of Preliminary Check. (See page BF-44.) ../ BF-61 TROUBLE DIAGNOSES Diagnostic Procedure 7 m <&IT9P C.U. 16-pin connector iS~ START m I CHECK WARNING CHIME CIRCUIT. 1) Disconnect 16-pin connector from control unit. 2) Check warning chime. ~GM 1 N~" Ground intermittently. -=- SBF361E Terminals @)Warnlng chime connector I!J <&;li)pC.U.16.pin connector ijril ~ @ ij[il m GM GM (Go to @ below.) Result Ground interI Sound mittently. N.G. I!J N.G. 1) Disconnect connector from warning chime. 2) Check continuity. Repair harness. Terminals SBF362E [!] -Ground Method O.K. @-@ is [iI Continuity should exist. O.K. [!] Does continuity exist? [Q] Ves Repair harness. There will be incorrect grounding. Terminals @ -Ground SBF363E Ii] -= No Ii] Check battery voltage existence. is~ N.G.I Repairharness. For details, refer to POWER SUPPLV ROUTING in EL section. Terminals - @ Ground Battery voltage should exist. O.K. Go to WARNINGCHIMEof Electrical Components Inspection. (See page BF-65.) SBF364E -= O.K. r. Is this the second time? No Reinstall any part removed. Go to PROCEDURE2 (START) of Preliminary Check. (See page BF-43.) BF-62 N.G. Replace warning chime. r-@ Replace control unit. TROUBLE DIAGNOSES m Diagnostic Procedure 8 DISCOIINECT ~ ~ E~,° QiljQv C.U. 16-pin connector I~ Ii) ~ C.U. 16-pin connector Combination meter connector ffiJl f r CHECK WARNING LAMP CIRCUIT. 1) Disconnect 16-pin connector from control unit. 2) Check warning lamp. T'G SBF365E ) START C m Terminals Resu It @ - Ground Glow O.K. (Go to @ below.) N.G. Ii) N.G. 1) Disconnect connector from combination meter. i5 Repair harness. [ 2) Check continuity., Y/G Terminals : center SBF1 96E Spacer mounting portion (Spacer should be installed at slit portion of dam rubber.) SBF198E Fastener ,/1 ( ~ "- / Panel Double-faced adhesive tape SBF197E ~~~ Apply primer A. Install molding fastener. When installing it, heat body panel and fastener to approx. 30 to 40°C (86 to 104°F). . . upper & side molding fastener a ~ ~m rubber joint portion Unit: mm (in) i~OO vehicle center ' of glass SBF719C CAUTION: Allow primers to dry for 10 to 15 minutes before proceeding to the next step. A B BF- 70 WINDSHIELD AND WINDOWS Windshield (Cont' d) @ 1 Apply sealant evenly. Apply primer E. Morethan 12 (0.471 Glass Unit: mm (in) SBF038B SBF199E CAUTION: Windshield glass should be installed within 15 minu18sof applying 88alant 88alant starts to harden 15 minu18l at18r it is applied. CAUTION: Allow primers to dry for 10 to 15 minute, before proceeding to the next step. Set glass in position and press glass lightly and evenly. Apply sealant additionally to Io_r portion of gland make it uniform as shown below: Glass SBF720C Check for water leakage. CAUTION: For sealant drying time, refer to "Drying Time for Sealant". Apply sealant to upper & side molding fixing portion. Install moldings. (For details, refer to "Exterior".) BF-71 CAUTION: Molding must be installed securely 10 that it is in position and I88V8Ino gap. WINDSHIELD AND WINDOWS Back Window-Coupe . . . . Construction and removal/reinstallation methods of back window are basically the same as those of windshield. For details of service procedures, refer to "Windshield". The difference between windshield and back window is as follows: For sealant drying period, refer to "Drying Time for Sealant", For details of moldings, refer to "Exterior", Sealant quantity ",(/ m ~- -- " 'I : I II 1I II II I I II II 1I I I ~ III , '- ---,----------------Dam rubber and spacer m Ii) ~N_' More than riJ Install molding Vehicle ~ More than 12 (0,471 Ii] Double-faced adhesive tape I Spacer fastener, When installing it, heat body panel and fastener to approx. 30 to 40°C (86 to 104° F). 420i (16,54) 7 (0281 Unit: mm (in) Unit: mm (in) Ii] double-faced Install dam rubber and spacers with adhesive tape. (Body side) Upper and side portion Lower portion Vehicle center Lbem rubber joint portion SBF200E BF- 72 WINDSHIELD AND WINDOWS Back Door Window-Fastback . . . . Construction and removal/reinstallation method of back door window are basically the same as those of windshield. Major differences are that sealant & dam rubber are instailed to back door panel instead of glass surface. Spacer position is also changed. Moreover, there are locating pins in lower portion of glass. For details, refer to following figure. For sealant drying period, refer to "Drying Time for Sealant". For details of moldings, refer to "Exterior", Locating pin (Left and right) 1m xx: Spacer .: Locatingpin 0: Molding clip Lower molding and spacer (;J (;J 1m Back door glass Ii] Molding When panel 30 to fastener installing it, heat body & fastener to approx. 40°C (86 to 104°FI. [!) Back door upper molding Back door glass Spacer Unit: mm (in) Backdoor side ~mOlding// ~u_~ Morethan 12 (0.47) ~n 0 = Backdoor glass 7 (0,28) Welt Back door panel Unit: mm (in) Unit: mm (in) BF- 73 SBF201E WINDSHIELD AND WINDOWS Side Window Side window is a molded type. During;removal or installation, observe the following instructions. 1. Cut sealant in the same manner as that outlined under "Windshield.". 2. Be careful not to scratch molding when cutting sealant. If molding is scratched, repair. 3. Remove clips and locating pins which have been exposed from vehicle body. Wire Side window Body panel Wire SBF376E FASTBACK Sealant portion I§) Double-faced adhesive tape m More than 7 (0.28) I§) (;] Morethan '12 (0.47) Body panel Body panel More than 7 (0.28) Unit: mm (in) Unit: mm (in) BF- 74 Unit: mm (in) J SBF203E WINDSHIELD AND WINDOWS Side Window (Cont' d) COUPE " Seelent portion Clip E1 I] Ii] [I Ii] Dam rubber 30 (1.181 Clip (Bonded to glassl Unit: mm (in) Sealant quantity I] Morethen 710.281 Unit: mm (in) SBF202E BF- 75 WINDSHIELD AND WINDOWS Drying Time for Sealant \ Reference: Time required for sealant to dry to desired hardness. Unit: days 90 50 25 40 (104) 1.5 2.5 5.0 25 (77) 2.5 4.0 7.5 5 (41) 5.0 13.0 20.5 'c (oF) CAUTION: Advise the user of the fact that vehicle should not be driven on rough roads or surfaces until sealant has properly vulcanized. Repairing Water leaks for Windshield and Back Window (Coupe)/Back Door Window (Fastback) leaks can be repaired without removing and reinstalling glass. If water is leaking between caulking material and body or between glass and caulking material, determine the extent of the leak by applying water while pushing glass outward. To stop the leak, apply primer and then sealant to the leak point. .~ .-Flat stick Apply sealant. ..,. T,;m~ ,V,,: "" POlysulphide or polyurethane .. 4' 1!f!/ 4~60 /~ Work into joints. sealant SBF543B Afterwards, install molding securely. BF-76 MIRROR Door Mirror ~ (' ) Fa Mirror removal Fa Mirror SBF188E WIRING DIAGRAM I GNI TI ON SWITCH ACC or ON @ FUSE BLOCK ITIIJI]]] ~.. (Refer to "POWER SUPPLY ROUTING" In EL sect ion. ) Y/B PU/W L/B @ R. H. SIDE DOOR MIRROR @ II @ Y/B ,-PyU:: Pu/w====-.rL/B L/B (Door harness Mirror operat Ing dl rectlon ~ Leftward i ~ Rightward R. H. ) L/W (Main harness) ~ III' ...J ~'" ~, J @ _JlI>O: '" J >-> ~~ Y/L PU/W L/R ~~15~~1 MIRROR L. H. SIDE DOOR MIRROR @ II @ ~ ~ Leftward i Rightward Mirror operat Ing dl rect Ion ~ Downward i Upward SW. CHANGE OVER SW. (1)A~ ~~ 6 7 DOOR MIRROR ,- Y/L PyU:;:: PU/W===-.sL/R L/R (Ooor harness L. H. ) Mirror ope rat Ing direct Ion SWITCH BODY GROUND SBF335E BF-77 REAR COMBINATION LAMP . Rear combination lamps are installed with nuts and butyl sealant. ~ Installation Removal Butyl seal . Warmup lamp assemblyarea to a tem~ratu~ of a little below 60°C (140°F). . . Apply butyl seal evenlyas it tends to become thin in the corners. Warmup lamp assemblyarea to a tem~rature of a little below 60°C (140°F). SBF189E BF-78 FRONT AND REAR AIR SPOILER . . When installing, make sure that there are not gaps or waves at ends of air spoiler. Before installing spoiler, clean and remove oil from surface where spoiler will be mounted. / FRONT AIR SPOILER r;7~~~ '----. ~ Double-faced adhesive tape ! '-~ r;1;:;;J/ ~~~_/-o ~/~ I~J , , L . ~"'" ""' I r;-r r-.~ W~- Double-faced adhesive tape SBF190E REAR AIR SPOILER - Fastback SBF191E BF- 79 BODY ALIGNMENT . . . . . . All dimensions indicated in figures are actual ones. When a tram tracking gauge is used, adjust both pointers to equal length and check the/pointers and gauge itself to make sure there is no free play. When a measuring tape is used, check to be sure there is no elongation, twisting or bending. Measurements should be taken at the center of the mounting holes. An asterisk (*) following the value at the measuring point indicates that the measuring point on the other side is symmetrically the same value. The coordinates of the measurement points are the distances measured from the standard line of "X", "Y" and "Z". "V" "X" @) @ (:J @ Q =JQ "Z" "X" "Z" I-) ... I ... 1+1 ''V'' @: L.H.side @: R.H. side "X" : Vehicle center "V" : Center line of front axle "Z" : Imaginary base line [200 mm below datum line I"OZ" at design plan)] Engine Compartment MEASUREMENT Unit: mm SBF193E BF-80 BODY ALIGNMENT Engine Compartment (Cont' d) MEASUREMENT POINTS Unit: mm I' SBF223E Front side member Cowl top side " ' 'CID1 () <::) . CJ 7 SBF220E SBF221E Radiator core side SBF222E SF-81 ~ () ~ <) 6dia.~ <') () () SBF224E SBF225E BODY ALIGNMENT Underbody MEASUREMENT ~1J E E ... 'c :J 8 N * ~ ... cq.~ 1 ... 'It. ..., * i * * coM ... GI 'It M 1 :2 OROIL - For NVR 140S (ATSUGI make) COMPRESSOR- Model NVR 140S (ATSUGI make) " . . . .. .. . .. .. . .. . .. .. . AIC ELECTRICAL CIRCUIT HAHAHAHA- 2 5 7 9 HA-12 HA-13 HA-14 HA-15 HA-17 HA-24 HA-25 HA-28 HA-33 HA-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HA-40 AIC COMPONENT LAYOUT TROUBLE DIAGNOSES HA-42 HA-44 SERVICE DATA AND SPECIFICATIONS(S.D.S.). . . . . . . . . . . . . . . . . . . . . . . .. . . . . . HA-73 When you read wiring diagrams: Read GI section, "HOW TO READ WIRING DIAGRAMS". See EL section, "POWER SUPPLY ROUTING" for power distribution circuit. Whenyou perform trouble diagnoses,read GI section, "HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES". . . mil AIR FLOW AND COMPONENT LAYOUT Air Flow @ if @ ~ Floor and defroster ~~~ 0123~1 ~ if 10 .'"";' @ To floor CD To ventilator if Bi-Ievel 'O~~~ ~..~ if @ To defroster CD To ventilator .Ie @ ... To floor :> : Airpassedthroughheatercore <17181 MODE DOOR MOTOR f@;1 , From . I I I umInat Ion system . { -~ RHA378A This push control system operates the intake and mode door motors to activate their corresponding doors. SWITCHES AND THEIR CONTROL " FUNCTIONS I Indicator illuminates AIC I I 0 I - .. I I 0 ...... I I -fJ AIC - ... ... Q ..; I ... J ...... . ...-.. I Air outlet Intake air I I I I 0 I I I I I B/L I I I I 0 I I I I FOOT I I I I I I I I F/D I FRE DEF I FRE I I I I I I Compressor ON*1 I 0 0 I *1: Compressor is operated by thermo control amp. . I *2: It dependson modeswitchposition. HA-7 b:2: --------I. .REC I ON*1 DESCRIPTION - Push Control Intake Door Motor The intake door motor is installed on the front portion of the intake unit. Using a rod and link it opens and closes the intake door. When the REC switch is ON (OFF), the ground line of the intake door motor is switched from terminal @ to @ (@ to @). This causes the motor to start because the position switch contacts built into it are set to the current flow position. The contacts turn along with the motor. When they reach the non-current flow position, the motor will stop. The motor always turl)S in the same direction. - ~I MP---1 - ~ To push control. door llntake motor { RHA379A Mode Door Motor The mode door motor is located on the left side of the heater unit. Through the side link it opens and closes the vent, foot and defroster door. When one mode switch is pushed, the position switch built into it reads the corresponding mode to determine the direction of motor rotation. As soon as the desired mode is set, the position switch stops the motor. Mode door motor 12216151413~111><17181 *: Current flows as VENT indicated by the arrow, motor actuates as indicated by the words. 1 To push control Terminal No. Mode door motor Mode door 9peration Direction of linkage rotation (j) @ 8 8 Stop Stop 8 EB VENT--DEF Clockwise EB 8 DEF --VENT Counterclockwise RHA380A HA-8 PUSH CONTROL UNIT ~gj" fR92~1 Removal and Installation 1. Remove cluster lid C. ~ BB8 0, / , Cluster lid C \/ RHA384A 2. Push If control asse'mbly )U[f Remove audio (radio). 3. Remove four screws of push control unit. 4. Remove temperature control cable. 5. Disconnect push control unit harness connectors. 6. Remove push control unit. 7. Installation is in the reverse order of removal. Refer to Control Cable Adjustment for temperature control cable. ===1, ( Overhaul - Push control unit assembly i Co""o' "..~ Control knob 1- - ',- "- 1/'1 v' ~ ~~ ~ Control box '",,-- Finisher plate ! '/L J Coa,ro' ,,,... A ,~84 '\ L E-ring Temperature control cable L 0 Temperaturecontrollever Diode Temperature control lever assembly RHA386A HA-9 PUSH CONTROL UNIT Overhaul - Push control unit assembly(Cont'd) 1. Remove control knobs. Wrap knobs with a cloth and pull in direction indicated by arrow as shown in figure at left. Be careful not to scratch knobs during removal. 2. Disconnect illumination harness connectors. Small flat-bladed , screwdriver :J~ Illumination harness 3. Remove control base. Undo hook at each end of control box and remove control base from control box by moving it in direction indicated by arrow. 4. Remove fan switch. "- Smail flat-b 'aded"<) screwdrive!. Control base . ~ ~ AHA390A 5. Remove illumination bulb. HA-10 PUSH CONTROL UNIT Overhaul - Push control unit assembly(Cont'd) 6. Remove control knobs. Wrap finisher with a cloth and remove knobs using pliers or . similar tool. Be careful not to scratch finisher's surface. 7. Re ove control case. 8. Rem ve illumination plate. Be care ul not to scratch control amp. when removing illumination plat " . 9. Remov finisher plate. 10. Remov control amp. Be careful not to damage substrate when removing, '11. Discon -ect temperature control cable. 12. Install tion is in reverse order of removal. .. -. " \ '" , ~ HA-11 ,.,.. HEATER ELECTRICAL CIRCUIT ~ Wiring Diagram I GNIT ION SWITCH ACC or ON BLOWER MOTOR ~ @)~ L/R L/R L/OR Iii @ , 0::, ..J ..J 1J FUSE BLOCK (Refer to "POWER SUPPLY ROUTING" in EL section.) MODE DOOR MOTOR G/Y L/~ L/W L/R L/Y L/OR B li) V B/L FOOT F/D DEF 0 i @ UI Q) cc .- L alai 5.£: INTAKE DOOR MOTOR G/Y G/B L/OR j 0 @ / @) To A/C system G/Y R/Y -LG LG/B L/OR G/Y G/B R/L [ - B - G L/Y L/W - L L/B L/R L/OR ~1J0::>-II> ~~~~~II> 1J 0:: >-11> "" ..J..J..J..J @lffiJ [] RESISTOR o~J (Subharness) @)~~~ ~~~ '" OFF 4 25 26 27 23 28 21 20 1 If 1 I LLUMI 2 1314 1211 169 815 .17 7 65 43 2 I 8 19 20 21 ~ PUSH CONTROL UNIT 3 4 From illumination } system FAN SWITCH )l NA TI ON II> @)~(@) BODY GROUND RHA392A HA-12 PRECAUTIONS WARNING: . Always wear eye protection system. when working around the . Always be careful that refrigerant does not come in . . contact with your skin. Keep refrigerant containers stored below 40°C (104°F) and never drop them from high places. Work in well-ventilated area because refrigerant gas evaporates quickly and breathing may become difficult due to lack of oxygen. . Keep refrigerantaway from open flames because poisonous gas will be produced if it burns. . . . . Do not increase can temperature beyond 40°C (104°F) in charging. Do not heat refrigerant can with an open flame. There is a danger that can will explode. CAUTION: Do not use steam to clean surface of condenser or evaporator. Be sure to use cold water or compressed air. Compressed air must never be used to clean a dirty line. Clean with refrigerant gas. . Do not use manifoldgauge whose press point shape Is different from that shown. Otherwise, insufficient evacuation may occur. N.G. \3 SHA919A . . Do not over-tighten service valve cap. Do not allow refrigerant to rush out. Otherwise, compressor oil will be discharged along with refrigerant. HA-13 PRECAUTIONS FOR REFRIGERANT CONNECTION WARNING: Gradually loosen discharge side hose fitting, and remove It after remaining pressure has been released. CAUTION: When replacing or ,cleaning refrigerant observe the following. . cycle components, Do not leave compressor on its side or upside down for more than 10 minutes, as compressor pressure chamber. 011 will enter low . Whenconnectingtubes, always use a torque wrench. SHA896A . After disconnecting tubes, plug all openings Immediately to prevent entrance of dirt and moisture. Plug SHA058 . Alwaysreplace used O-rings. Apply o,rin~ not apply oom".~,oil.w.,nw, 011. N.G. . . When connecting tube, apply compressor oil to portions shown in illustration. Be careful not to apply 011 to threaded portion. O-ring must be closely attached to Inflated portion of tube. N.G. Inflated portion O.K. SHA897A . After inserting tube into union until O-ring is no longer ~ unlo@ visible, tighten nut to specified torque. . No' ~~~ ~ D After connecting line, conduct leak test and make sure that there is no leakage from connections. When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten connections of seal seat to the specified torque. & I~ ~ ~4) SHA898A HA-14 PREPARATION SPECIAL SERVICE TOOLS Tool number (Kent-Moore No.) Tool name KV998VROO1 ( - ) Clutch disc puller KV99231010 ( - ) Clutch disc wrench KV99235160 (J29751 ) Nut wrench ~ Description ~ Removing clutch disc ~ Removing shaft nut and clutch disc Removing lock nut \\Y HA-15 PREPARATION SERVICE TOOLS Tool name .0 Description Manifold gauge . Charging hose Charge valve Thermometer " Dischargingand charging refrigerant .; Discharging, evacuating and checking refrigerant Discharging and charging refrigerant Checking temperature C'- -3 Vacuum pump Electric leak detector Evacuating refrigerant Nomineillftlitivity: 1..25. '0.53."" UII Checking refrigerant leaks .. HA-16 DISCHARGING, EVACUATING, CHARGING AND CHECKING In service AIC system I *1 When it is necessary to replace pa rts When it is not necessary to replace parts + + Check the spot where malfunction occurs. Check the spot where refrigerant leaks. Point-' Repair. Discharging I i. Replace I t Add refrigerant parts. - I I I New AIC system J I Point-2 Evacuating Run pump for over 5 minutes. Point-g ! Checking airtightness O.K. *2 Once evacuating I N.G. Point-4 Repair. Twice evacuating On condition that pump operates over -98.6 kPa (-740 mmHg, -29.13 inHg) and with low humidity on a clear day. Point-5 I On condition that pump operates below -98.6 kPa (-740 mmHg, -29.13 inHg) and with high humidity on a rainy day. ! Point-6 Charging Evacuating Open high-pressure valve of manifold gauge and charge refrigerant into system. When low-pressure gauge reading is 98 kPa (1.0 kg/cm2 , 14 psi), completely close high-pressure valve of manifold gauge and stop charging. Run pump for over 20 minutes. , Point-3 N.G. Checking airtightness Point-5 1 O.K. Evacuating Run pump for over 20 minutes. I *1: Depending on the det *2: Working operation dep pump and the weather. When servicing AIC sys done under any condition. . In Point-7 Charging Checkingrefrigerantleaks l O.K. Checkoperationof AICsystem. HA-17 I N.G. I DISCHARGING, EVACUATING, CHARGING AND CHECKING To high-pressure service valve To low-pressure service valve Point-1 Discharging I \ I Slowly open the valves to discharge only refrigerant. If they are opened quickly, compressor oil will also be discharged. . SHA240B . To high-pressure service valve To low-pressure service valve . Low ~I . - Vacuum -, Elevation m (ft) pump SHA241 B Vacuum of system* kPa (mmHg, inHg) 0 (0) 101.3 (760,29.92) 300 (1,000) 98.0 (735,28.94) 600 (2,000) 94.61710,27.95) 900 (3,000) 91.3 (685,26.97) Point-21 I Evacuating the System 1. Start pump, then open both valves and run pump for over 5 minutes. 2. When low gauge has reached approx. 98.6 to 101.3 kPa (740 to 760 mmHg, 29.13 to 29.92 inHg), completely close both valves of gauge and stop vacuum pump. a. The low-pressure gauge reads lower by 3.3 kPa (25 mmHg, 0.98 inHg) per 300 m (1,000 ft) elevation. Perform evacuation according to the following table. b. The rate ascension of the low-pressure gauge should be less than 3.3 kPa (25 mmHg, 0.98 inHg) in 5 minutes. *: Values show reading of the low-pressure gauge. Point-3 Checking Airtightness I I 1. Close both low and high-pressure valves and leave them unattended for approx. 5 to 10 minutes. 2. Make sure the pointer of the low-pressure gauge does not deflect toward the "0" direction. 3. If the pointer deflects, gas leakage is present. Repair as outlined under POint-41. I I Point-4 I Repair If a problem is noticed under IPoint-31 above, locate and repair the leaking point using the following table as a guide. Leak at/around pipe connection . a-ring fouled, damaged or deformed . Oil not applied to pipe connections during installation . Pipe connections not properly tightened (too tight or too loose) HA-18 Leak at/around gauge manifold . . . . Malfunctioning charging hose Gauge improperly installed Malfunctioning valve Malfunctioning packing, etc. DISCHARGING, EVACUATING, CHARGING AND CHECKING . To low-pressure service valve To high-pressure service valve . ~I: 10 . =' I pOint-51 Evacuating the System 1. Close manifold gauge valve securely and disconnect charging hose from refrigerant can. 2. Connect center charging hose to vacuum pump. 3. Start pump, then open both valves and run pump for over 20 minutes. ) Vacuum pump SHA241B I Point-61 fU Charging ~ 1. Close manifold gauge valves securely and disconnect charging hose from vacuum pump. 2. Purge air from center charging hose. 1) Connect center charging hose to refrigerant can through charge valve. 2) Break seal of refrigerant can and purge air. Close Close SHA242B To low-pressure service valve . To high-pressure service valve 3. Charge refrigerant into system. WARNING: Ensure that engine is off. 1) Open high-pressure valve of manifold gauge and charge refrigerant into system. Open LR~ RHA278 CAUTION: To low-pressure service valve To high-pressure service valve ~ If charging liquefied refrigerant into the system with the can turned upside down to reduce charging time, charge it only through high-pressure (discharge) service valve. After charging, the compressor should always be turned several times manually. 2) When low-pressure gauge reading is 98 kPa (1.0 kg/cm2, 14 psi), completely close high-pressure valve of manifold gauge and stop charging. SHA244B HA-19 DISCHARGING, EVACUATING, CHARGING AND CHECKING Run engine at idll (Below 1,500 rpml To low-pressure service valve lI\ . Turn In or out SHA245B e IL~ n ~ #>~fr -.. Point-71 Charging I To high-pressure service valve Ii:) Close H.h II Fan lever mode and temperature dial: Maximum cold and speed 1. Open manifold gauge low-pressure valve and charge refrigerant into system. WARNING: Ensure that engine is off. 2. When refrigerant charging speed slows down, start engine air conditioning system ON, maximum cold temperature set, maximum blower speed set, can in upright position. Monitor sight glass. Charge is complete when sight glass is clear. Cycling clutch systems will produce bubbles in sight glass when clutch engages. Therefore, allow 5 seconds after clutch engages to determine if bubbles continue, and, if so, add refrigerant to clear sight glass. WARNING: Never charge refrigerant through high-pressure side (discharge side) of system since this will force refrigerant back into refrigerant can and it may explode. 3. Charge refrigerant while controlling low-pressure gauge reading at 275 kPa (2.8 kg/cm2,40 psi) or less by turning in or out low-pressure valve of manifold gauge. Be sure to purge air from charging hose when replacing can with a new one. . 4. Charge the specified amount of refrigerant into system by weighing charged refrigerant with scale. Overcharging will cause discharge pressure to rise. Refrigerant amount: 0.9 - 1.0 kg (2.0 - 2.2 Ib) RHA504 HA-20 DISCHARGING, EVACUATING, CHARGING AND CHECKING IPoint-71 Charging (Cont' d) The state of the bubbles in the sight glass can only be used for checking whether the amount of charged refrigerant is small or not. The amount of charged refrigerant should be correctly judged by means of the discharge pressure. 5. After charging, be sure to install valve cap on service valve. 6. Confirm that there are no leaks in system by checking with a leak detector. . When refrigerant charging is performed with a charging cylinder, charging station, or automatic charging equipment with engine off, charge only through high pressure side. After specified refrigerant amount has entered the system, close high-pressure valve on gauge set. Start engine, return to idle speed, operate AIC at maximum temperature setting, high blower. Observe sight glass to confirm complete charge. Overcharging will result in increased high pressures, and reduced performance. HA-21 DISCHARGING, EVACUATING, CHARGING AND CHECKING Checking Refrigerant level CONDITION Door window: A/C switch: TEMP. lever position: FAN lever position: Check sight glass after a minutes. . . . . . Almost no refrigerant Insufficient Open ON Max. COLD 4 lapse of about Suitable five Too much refrigerant Check item Temperature of highpressure and lowpressure lines. Almost no difference between high-pressure and low-pressure side temperature. High-pressure side ,is warm and low-pressure side is fairly cold. High-pressure side is hot and low-pressure side is cold. High-pressure side is abnormally hot. State in sight glass. Bubbles flow continuously. Bubbles will disappear al)d something like mist will flow when refrigerant is nearly gone. The bubbles are seen at intervals of 1 - 2 seco nd s. AImost transparent. Bubbles may appear when engine speed is raised and lowered. No bubbles can be seen. No clear difference exists between these two conditions. AC256 Pressure Repair. a. of system. High-pressure side is abnormally low. Stop compressor immediately and conduct an overall check. AC257 Both pressures on high and low-pressure sides are slightly low. AC258 Both pressures on high and low-pressu re sides are normal. Check for gas leakage, repair as required, replenish and charge system. The bubbles seen through the sight glass are influenced by the ambient temperature. Since the bubbles are hard to show up in comparatively low temperatures below 20° C (68° F), it is possible that a slightly larger amount of refrigerant would be filled, if supplied according to the sight glass. Recheck the amount when it HA-22 Both pressures on high and low-pressure sides are abnormally high. Discharge refrigerant from service valve of lowpressure side. exceeds 20°C (68° F). In higher temperature the bubbles are easy to show up. b. When the screen in the receiver drier is clogged, the bubbles will appear even if the amount or refrigerant is normal. In this case, the outlet side pipe of ,~he receiver drier becomes considerably cold. '~ DISCHARGING, EVACUATING, CHARGING AND CHECKING Checking Refrigerant Leaks ELECTRIC LEA~ DETECTOR The leak detector is a delicate device that detects small amounts of halogen. To use the device properly, read the manufacturer's manuals. Also perform the specified maintenance and inspections. SHA733A GENERAL PRECAUTIONS FOR HANDLING LEAK DETECTOR Place the probe on connection fitting and wait for 5 seconds or more. To check cooling unit, wait for 10 seconds or more. If a leak is detected, keep the probe as still as possible for one more minute. UNION TYPE RHA279 When testing single-bolt flange, place opposite side of the fitting. PLATE TYPE the probe on the ~~L RHA280 MEASUREMENT STAN.DARD If any leak is noted with a detector having a nominal sensitivity of 15 to 25 g (0.53 to 0.88 oz)/year, that leak must be repaired. The nominal sensitivity of the detector is determined under the assumption that all the leaking gas is collected by the detector. Accordingly, the quantity of gas actually leaking can. amount to five to ten times the indicated value. Generally speaking, leakage of 150 to 200 g (5.29 to 7.05 oz) of refrigerant can cause insufficient cooling. Oil deposited during assembling must be wiped off before inspection. Refrigerant easily dissolves in oil, and the presence of oil can cause an error in measurement. This precaution is important when checking a used car for refrigerant leakage. If oil is noted at or around connections, it indicates that refrigerant is leaking. . . . HA-23 DESCRIPTION OF AIR CONDITIONER Acceleration Cut System This system is controlled by the E.C.C.S. control unit. When the engine is heavily over loaded (throttle sensor judges that throttle valve is at full throttle position), the compressor is turned off for approx. 4 seconds to reduce overloading. Additionally when the temperature of engine coolant rises above approx. 113°C (235°F), the compressor is turned off. To condenser fan motor via thermo- switch ENGINE TEMPERATURE SENSOR COMPRESSOR ~ ' For U.S.A. ~ ' For Canada RHA517A HA-24 SERVICE PROCEDURES Refrigeration Cycle REFRIGERANT FLOW The refrigerant flows in the standard pattern, that is, through the compressor, the condenser, the receiver drier, through the evaporator, and back to the compressor. "The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion valve, located inside the evaporator case. FREEZE PROTECTION The compressor cycles on and off to maintain the evaporator temperature within a specified range. When the evaporator coil temperature falls below a specified point, the thermo control amplifier interrupts the compressor operation. When the evaporator coil temperature rises above the specification, the thermo control amplifier allows compressor operation. REFRIGERANT SYSTEM PROTECTION Dual-pressure switch The refrigerant system is protected against excessively high or low pressures by the dual-pressure switch, located on the receiver drier. If the system pressure rises above, or falls below the specifications, the dual-pressure switch opens to interrupt the compressor operation. Fusible plug Open at temperature above 105°C (221°F), thereby discharging refrigerant to the atmosphere. If this plug is melted and opened, check the refrigerant line and replace receiver drier. Pressure relief valve The refrigerant system is also protected by a pressure relief valve, located on the end of high flexible hose near compressor. When the pressure of refrigerant in the system increases to an abnormal level [more than 3,727 kPa (38 kg/cm2, 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere. Pressu re relief valve ~ t ' High-pressure . gas 'j High-pressu re liquid ~ I,':':':':':':':d Low-pressure liquid Low-pressu re gas lill s Outside air u Compressor t u ~ Condenser 0 Blower motor . Expansion valve Receiver drier Fusible plug Dual-pressure switch RHA393A HA-25 SERVICE PROCEDURES Refrigerant Lines ~ ~ 10.20 7.14) (1.0.2.0, 15.25 (1.5.2.5, 11 -18) rg []]J[1J Expansion valve Condenser fan motor* (U.S.A. only) Low-pressure (Suction) service valve Pressure relief valve ~7-17 (0.7 -1.7,5;1 Ie] ~~ -12.3) D (Tightening torque) 0 0 (Wrench size) *: For removal, it is necessary to remove condenser. !AJ Ie] [g 20 -29 10 -20 (1.0-2.0,7 - 14) (2.0 -3.0, 14 -22) 15 -25 (1.5-2.5,11 -18) ~: N.m (kg-m,ft-Ib) RHA394A HA-26 SERVICE PROCEDURES Compressor Mounting - 60 (4.6.6.1,33.44) co;J 45 . ~. ~- " ~~ co;J 45 - 60 (4.6-6.1,33-44) , "- co;J45.60 (4.6 - 6.1, 33 - 44) co;J: N'm (kg-m, ft-Ib) RHA395A Remove screws, which secure thermistor locating stay, from front of cool~ng unit. Replace thermo control amp. assembly with a new one. (Without removing cooling unit, thermo control amp. can be replace.) RHA396A Belt Tension . Refer to MA section. Fast Idle Control Device (F.I.C.D.) . Refer to EF & EC section. HA-27 AIC PERFORMANCE TEST Performance Chart TEST CONDITION Testing must be performed as follows: Vehicle location: Indoors or in the shade (in a well ventilated place) Doors: Closed Door window: Open Hood: Open TEMP. lever position: Max. COLD -; MODE switch: (Ventilation) set REC switch: ~(Recirculation) set FAN lever position: Max. position Engine speed: 1,500 rpm Time required before starting testing after air conditioner starts operating: More than 10 minutes For U.S.A. model, make sure that condenser fan motor does not operate during the following tests. TEST READING Recirculating-to-discharge air temperature table Inside air (Recirculating air) at blower assembly inlet Relative humidity % Dischargeair temperature at center ventilator °c tF) Air temperature °c (oF) 50 - 60 60 -70 20 (68) 1.6 - 2.7 (35 - 37) 25 (77) 4.4 - 6.0 (40 - 43) 30 (86) 9.2 - 11.3 (49 - 52) 35 (95) 14.8 - 17.0 (59 - 63) 40 (104) 18.1 - 20.3 (65 - 69) 20 (68) 2.7 -4.3 (37 - 40) 25 (77) 6.0 - 8.2 (43 - 47) 30 (86) 11.3 - 13.8 (52 - 57) 35 (95) 17.0 - 19.5 (63- 67) 40 (104) 20.3 - 22.8 (69 - 73) Ambient air temperature-to-compressor pressure table Ambient air Relative humidity % 50 -70 High-pressure (Discharge side) kPa (kg/cm2 , psi) Low-pressure (Suction side) kPa (kg/cm2 , psi) 20 (68) 1,030 - 1,255 (10.5 - 12.8, 149 - 182) 98.1 - 142.2 (1.0 - 1.45, 14.2 - 20.6) 25 (77) 1,196 - 1,471 (12.2 - 15.0, 173 - 213) 122.6 - 171.6 (1.25 - 1.75,17.8- 24.9) 30 (86) 1,402 - 1,706 (14.3 - 17.4,203 - 247) 161.8 - 210.9 (1.65 - 2.15, 23.5 - 30.6) 35 (95) 1,608 - 1,971 (16.4 - 20.1, 233 - 286) 205.9 - 259.9 (2.1 - 2.65, 29.9 - 37.7) 40 (104) 1,844 - 2,256 (18.8 - 23.0, 267 - 327) 259.9 - 318.7 (2.65 - 3.25, 37.7 - 46.2) Air temperature °c tF) HA-28 AIC PERFORMANCE TEST Performance Test Diagnoses Characteristics revealed by the manifold gauge readings for the air conditioning system are shown in the following table. For how to do the performance test, refer to the item "Performance Chart". In the following table, the portion smeared with ink on each gauge scale indicates the range showing that the air conditioning system is in good order. This range is described in Performance Chart. Condition I INSUFFICIENT 'REFRIGERANT Probable cause CHARGE Corrective action I. Insufficient cool ing. Bubbles appear in sight glass. Refrigerant is low, or leaking slightly. 1. Leak test. 2. Repair leak. 3. Charge system. Evacuate, as necessary, and recharge system. AC352A I ALMOST NO REFRIGERANT I Serious refrigerant leak. No cooling action. A lot of bubbles or something like mist appears in sight glass. Stop compressor immediately. 1. Leak test. 2. Dischargesystem. 3. Repair leak(s). 4. Replace receiver drier if necessary. 5. Check oil level. 6. Evacuate and recharge system. AC353A I MALFUNCTIONING EXPANSION VALVE I Slight cooling. Sweat or frosting on expansion valve inlet. AC354A HA-29 Expansion valve restricts refrigerant flow. . Expansion valve is clogged. . Expansion valve is inoperative. Valve stuck closed. Thermal bulb has lost charge. If valve inlet reveals sweat or frost: 1. Discharge system. 2. Remove valve and clean it. Replace it if necessary. 3. Evacuate system. 4. Charge system. If valve does not operate: 1. Discharge system. 2. Replace valve. 3. Evacuate and charge system. AIC PERFORMANCE TEST Performance Test Diagnoses Condition Insufficient cooling. Sweat on suction line. No cooling. Sweat or frosting on suction line. (Cont'd) Probable cause Corrective action Expansion valve allows too much refrigerant through evaporator. Check valve for operation. If suction side does not show a pressure decrease. replace valve. Malfunctioning expansion valve. 1. Dischargesystem. 2. Replacevalve. 3. Evacuate and charge system. Air mixed with refrigerant in system. 1. Dischargesystem. 2. Replacereceiver drier. 3. Evacuat~and charge system. Drier is saturated with moisture. Moisture has frozen in expansion valve. Refrigerant flow is restricted. 1. Discharge system. 2. Replace receiver drier (twice if necessary). 3. Evacuate system completely. (Repeat 30minutes evacuating three times.) 4. Recharge system. AC356A IAIR IN SYSTEM I Insufficient cool ing. Sight glass shows occasional bubbles. AC359A I MOISTURE IN SYSTEM I After short operation, suction side may show vacuum pressure reading. During this condition, discharge air will be warm. As a warning of this, reading vibrates around 39 kPa (0.4 kg/cm2 , 6 psi). AC360A HA-30 AIC PERFORMANCE TEST Performance MALFUNCTIONING CONDENSER Corrective action I No cooling action: engine may overheat. Bubbles appear in sight glass of drier. Suction line is very hot. Usually a malfunctioning condenser. " @ (Cont'd) Probable cause Condition I Test Diagnoses . Check fan belt and fluid coupling . Check condenser fan motor. (U.S.A. model only) . Check condenser for dirt accumulation. . Check engine cooling . system for overheating. Check for refrigerant overchargi ng. If pressure remains high in spite of all above actions taken, remove and inspect the condenser for possible oil clogging. @ AC361A I HIGH PRESSURE LINE BLOCKED I Insufficient cooling. Frosted high-pressure liquid line. Drier clogged, or restriction in high-pressure line. 1. Dischargesystem. 2. Removereceiver drier or strainer and replace it. 3. Evacuate and charge system. Interr1'al problem in compressor. or damaged gasket and valve. 1. Discharge system. 2. Remove and check compressor. 3. Repair or replace compressor. 4. Check oil level. 5. Replace receiver drier. 6. Evacuate and charge system. AC362A I MALFUNCTIONING COMPRESSOR I Insufficient cooling. AC363A HA-31 AIC PERFORMANCE TEST Performance Probable cause Condition TOO MUCH 01 L IN SYSTEM (Excessive) Test Diagnoses Too much oil circulates Insufficient cooling. with refrigerant, causing the cooling capacity of the system to be reduced. AC364A HA-32 (Cont'd,) Corrective action Refer to COMPRESSOR01L for correcting oilleve!. COMPRESSOR OIL - Checking 'I The oil used to lubricate I the compressor circulating Whenever tem or a add oil to For NVR 140S (ATSUGI make) is with the refrigerant. replacing any component of the syslarge amount of gas leakage occurs, maintain the original amount of oil. and Adjusting 4. Check the purity of the oil and then adjust oil level following the procedure below. (a) When oil is clean; Unit: mQ (US fl OZ, Imp fl oz) Amount of oil drained Above 90 (3.0, 3.2) * Oil level is right. Pour in same amount of oil as was drained out. Below 90 (3.0, 3.2) Oil levelmay be low. Pour in 90 mQ(3.0 US fl OZ, 3.2 Imp fl oz) of oil. OIL CAPACITY Unit: mQ (US fl OZ, Imp fl oz) Applied model Capacity Total in system Amount of oil which can be drained Compressor (Service parts) charging amount All models 200 (6.8, 7.0) \ Approx. 100 (3.4,3.5)* Adjusting procedure *: 200 (6.8, 7.0) If amount of oil drained is much greater than under normal circumstances, flush air conditioner system with refrigerant. Then pour in 200 mQ (6.8 US fl OZ, 7.0 Imp fl oz) of oil into air conditioner system. *: All oil cannot be drained from system. (b) When oil contains chips or other foreign material; After air conditioner system has been flushed with refrigerant, replace receiver drier. Then pour in 200 m Q (6.8 US fl oz, 7.0 Imp fl oz) of oil into air conditioner system. . OIL RETURN OPERATION Before checking and adjusting oil level, operate compressor at engine idling speed, with controls set for maximum cooling and high blower speed, for 20 to 30 minutes in order to return oil to compressor. CHECKING AND ADJUSTING FOR COMPRESSOR REPLACEMENT CHECKING AND ADJUSTING FOR USED COMPRESSOR 1. After oil return operation, stop the engine and discharge refrigerant, and then remove compressor from the vehicle. 2. Drain compressor oil from compressor discharge port and measure the amount. Oil is sometimes hard to extract when com- 200 m Q (6.8 USfl OZ, 7.0 Imp fl oz) of oil is charged in compressor (service parts). So it is necessary to drain the proper amount of oil from new compressor. Follow the procedure below. 1. After oil return operation, drain compressor oil from used compressor and measure the amount. (It is the same procedure as CHECKING AND ADJUSTING FOR USED COMPRESSOR.) pressor is cooled. Remove oil while compressor is warm [maintained to 40 to 50°C (104 to 122°F». 3. If the amount is less than 90 m Q (3.0 US fl OZ, 3.2 Imp fl oz), some refrigerant may have leaked out. Conduct leak tests on connections of each system, and if necessary, repair or replace malfunctioning parts. HA-33 COMPRESSOR OIL - For NVR 140S (ATSUGI make) CheckinSl and Adjusting (Cont'd) 2. Check the purity of the oil and then adjust oil level following the procedure below. (a) When oil is clean; Unit: mi! (US fl oz, Imp fl oz) Amount of oil drained from used compressor Above 90 (3.0, 3.2) ~ Below 90 (3.0,- 3.2) Draining amount of oil from new compressor 200 (6.8, 7.0) - [Amount of oil drained + 20 (0.7, 0.7)] 90 (3.0, 3.2) *: If amount of oil. drained is greater than under ". normal circumstances, flush air conditioner system with refrigerant. Then install new compressor. [200 mi! (6.8 US fl oz, 7.0 Imp fl oz) of oil is charged compressor service parts.] . Example: Unit: mi! (US fl OZ,Imp fl oz) Amount of oil drained from used compressor . Draining amount of oil from new compressor " 110 (3.7, 3.9) 70 (2.4,2.5) 70 (2.4, 2.5) 90 (3.0, 3.2) (b) When oil contains chips or foreign material; After air conditioner system has been flushed with refrigerant,. replace receiver drier. Then install new compressor. [200 m Q (6.8 US fl OZ, 7.0 Imp fl oz) of oil is charged in compressor service parts.] HA-34 ~ - Model NVR140S (ATSUGI make) Precautions . Plug all openings to prevent moisture and foreign matter from entering. .Do not leave compressor on its side or upside down for more than 10 minutes. When replacing or repairing compressor, check compressor oil level in system. When replacing with a new compressor, drain specified oil from new compressor. Refer to COMPRESSOR OIL. Be sure there is no oil or dirt on frictional surface of clutch disc and pulley. When replacing compressor clutch, be careful not to scratch shaft or bend pulley. When replacing compressor clutch assembly, do not forget BREAK-IN OPERATION. . . . . . . Whel\ s~ring a compressor, be sure to fill it with refrigerant \to prevent rust formation. Add refrigerant at the low-pressure side and purge air at the high-pressure side, while rotating shaft by hand. ~ COMPRESSOR HA-35 COMPRESSOR - Model NVR 1408 (ATSUGI make) Thermal protector tOJ 10. 15 11.0. 1.5, 7.111 / Key Adjusting shim 1 tOJ 29 -39 (3.0 - 4.0, 22 - 291 Center bolt tOJ 9.1 . 11.8 (0.93 - 1.2,6.7 - 8.71 tOJ: N.m (kg-m, ft-Ibl RHA283 HA-36 COMPRESSOR Model NVR 1408 (ATSUGI make) - Compressor Clutch REPLACEMENT . . When removing center bolt, hold clutch disc with clutch disc wrench. Using clutch disc puller, clutch disc can be removed. SHA052B . . ~ c::t After flattening lock washer tab, loosen lock nut. Bend down pawl of lock washer. When removing pulley, remove lock nut with nut wrench. SHA053B INSPECTION Clutch disc If the contact surface shows signs of damage due to excessive heat, the drive plate and pulley should be replaced. Pulley Clutch disc Coil ~ SHA703B Pulley Check the appearance of the pulley assembly. If the contact surface of the pulley shows signs of excessive grooving due to slippage, both the pulley and drive plate should be replaced. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation. Coil Check coil for loose connection or cracked insulation. 0.3 -0.6 Adjusting shim (0.012 -0.024) [Thickness - 0.1, 0.3, 0.5, 0.8 (0.004,0.012,0.020,0.031)] ADJUSTMENT ~ . When assembling clutch disc, adjust disc-to-pulley clearance with shims. BREAK-IN OPERATION When replacing compressor clutch assembly, do not forget break-in operation, accomplished by engaging and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque. * Spark plug gap gauge ~ ~ Unit: mm (in) RHA843 HA-37 COMPRESSOR Model NVR 140S (ATSUGI make) - Thermal Protector . . When servicing, do not allow foreign matter to get into compressor. , Check continuity between two terminals. Thermal protector SHA055B HA-38 COMPRESSOR - Model NVR140S (ATSUGI make) NOTE / HA-39 AIC ELECTRICAL CIRCUIT Wiring Diagram BATTERY fusible THERMAL I GNI TI ON SWITCH ON or START PROTEC1OR nU ~ (V I a IInk-Gree~ " THERMO- SWITCH ~ 7 " ~i h.cn.s~ ~(SUb AIR @) 0 (J ~],I ~ ~@) ~~ ci~ ~~, ~~~ CAN]"" CONDENSER FAN MOTOR @)~ to ~~ " , to ,,,,III 111 u.s.A. , .... - to '" to III " @~ @~ >- to " @) to , "" ,'" III @ ~~~/G F. I. C. D. SOLENOID VALVE l III ~ - @ ENGINE GROUND (E. F. I. li :~~~~~~~~~~~~---------------f~ ~ '" , @@ ~o: 1-0 OVJ O:Z ILU I-VJ m ~: ~ I to ""~III harness) ~ I~ ::J , IIII.... ffi£@) 0 Z ::J 0 0: (!Jill ~o: zo wO@ z~ (!J7 ~VJ (!JZ ZLU WVJ ~ @~I~~IIIFNlbb1Ii Z W III ~ I~ II~ ~ ~ ~ & (Refer to HA-40 I!!,.I'llII6MII'F!Ii CONTROLUNIT EF&EC sect Ion. ) I AIC ELECTRICAL CIRCUIT Wiring Diagram (Cont'd) IGNITION SWITCH ACC or ON BLOWER ~ L/R L/R L/OR 31' I>: '\ '\ ..J ..J ~ Iii @ @~ FUSE BLOCK (Refer to "POWER SUPPLY ROUTING" in EL sect ion. ) MODE DOOR MOTOR G/Y G V B/L FOOT F/D DfF @ INTAKE DOOR MOTOR G/Y G/B L/OR S. M. J. ffiefer to r age last (Fo I dout page). (@) @) j 0 @ THERMO CONTROL AMP. (Main harness) -L/OR 112 L/OR -LG HI2 LG - -LG/R HID LG/R L/G LG/B L/OR 0 :W ~RM'STOR @ (§) G/YR/Y- - LG 1314 1211 LG/B L/OR G/Y G/B R/L - B I'" @) - 169 815 17 87 65 43 2 1 G L/Y L/W - L L/B L/R , L/OR 31'1>:>-'" '\'\'\'\ ..J..J..J..J @~ RESISTOR @) (Subharness) ~~~ ~~~ '\. OFF 1 24 2 26 27 2 8 21 20 1 1 2 3 19 0 21 O ~3:I>:>-'" PUSH CONTROL UNIT 4 From illumination } system FAN SWITCH ( (tJ(tl-\...., I LLUMI NATI ON '" ~: @@~ (CAN): For For U. S. A. Canada BODY GROUND RHA398A HA-41 AIC COMPONENT LAYOUT Passenger compartment Resistor Inteke door motor Engine compartment \ Ther';'oswitch\ (U:S.A. onl\) \\ -'.~: :: ~ \ ...1.--\'~ Condenser fan motor (U.S.A. only) HA-42 ~/ RHA403A AIC COMPONENT LAYOUT NOTE ~ / t / HA-43 TROUBLE DIAGNOSES Contents How to Perform Trouble Diagnoses for Quick and Accurate Repair Symptom Chart Preliminary Check PRELIMINARY CHECK 1 (Intake door is not set at "FRESH" in DEF or FOOT mode.) PRELIMINARY CHECK 2 (A/C does not blow cold air.) '"'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' PRELIMINARY CHECK 3 (Magnet clutch does not engage in DEF mode.) PRELIMINARY CHECK 4 (Air outlet does not change.) PRELIMINARY CHECK 5 (Noise) Main Power Supply and Ground Circuit Check Harness Layout for AIC System Circuit Diagram for Quick Pin Point Check Diagnostic Procedure 1 (SYMPTOM: Blower motor does not rotate.) Diagnostic Procedure 2 (SYMPTOM: Air outlet does not change.) Diagnostic Pfocedure 3 (SYMPTOM: Intake door does not change in VENT, B/L or FOOT mode.) HA-45 HA-46 HA-48 HA-48 HA-49 " HA-50 HA-51 HA-52 HA-53 HA-55 HA-56 HA-57 HA-59 HA-61 Diagnostic Procedure 4 (SYMPTOM: Magnet clutch does not engage with A/C switch and fan switch are ON.) HA-62 Diagnostic Procedure 5 (SYMPTOM: Illumination or indicators of push control unit do not come on.) Electrical Components Inspection HA-66 HA-70 / HA-44 TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair WORK FLOW < Reference item LISTEN TO CUSTOMER COMPLAINTS AND CONFIRM. ----------------I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I Diagnostic procedure(s) (See page HA-57 - 69.) . Circuit diagram for quick pin point check (See page HA-56.) Symptom Chart (See page HA-46 - 47.) ELIMINATE GOOD SYSTEM(S)/ PART(S). Preliminary Check (See page HA-48 - 52.) CHECK MAIN POWER SUPPLY AND GROUND CIRCUITS. Main Powerf.;upplY and Ground Circuit Check (See page HA-53 - 54.) ELIMINATE GOOD PART(S)/ HARNESS(ES)/CONNECTOR(S) ELECTRICALLY. . Harness Layout for A/C System (See page HA-55.) . Malfunctioning harness(es)/ connector(s) Malfunctioning part(s) Electrical Components Inspection (See page HA-70- 72.) REPAIR/ REPLACE. I /1 INVESTIGATE ITEMS YOU SHOULD CARRY OUT RELATED TO EACH SYMPTOM. I I L -- -- - - ---- N.G. O.K. CHECK OUT HA-45 TROUBLE DIAGNOSES Symptom Chart DIAGNOSTIC ( TABLE Preliminary Check PROCEDURE a) It) REFERENCE It) .It) N M V It) .J:; CJ CJ II) .J:; CJ 0 a) PAGE «:I: «:I: It) SYMPTOM CJ II) .J:; CJ > IV c: N .J:; CJ > IV c: < < :I: < < :I: :I: < :I: :I: > IV c: > IV c: CJ II) .J:; CJ > IV c: E 'E E 'E E 'ii 'ii 'ii 'ii Q. 'ii Q. Q. Q. Q. .- N « « « :I: :I: :I: M II) ::::s ::::s ::::s Q, Q, 'i CJ 0 Q, CJ .+:; ... 0 c: C) IV i5 0 Blower motor does not rotate. 0 .. V e Intakedoor does not changein VENT, 0 M It) M It) < < < :I: :I: :I: II) .. ::::s ::::s Q, "II) 'i 'i 8 g g. g "II) .+:; ... 0 c: C) IV .+:; ... 0 Q, CJ .+:; ... 0 C) C) i5 i5 i5 CJ .+:; ... 0 c: C) IV CJ CJ c: IV M It) ,< :I: It) c: IV i5 0 ... 'c :I '0 ... II) ... ::::s 51 ::::s u. « It) .0 .- u. « 0 ci E IV '0 ... c: 0 CJ 0 ... c: 0 CJ E .J:; II) ... ::::s .J:; Q. 0 I- 0 0 .. 0 B/L or FOOT mode, / . <0 II) 0 Air outlet does not change. N It) II) AICdoesnot blowcold air.--- Intake door is not set at "FRESH" in DEF or FOOT mode. 0 <0 I"'It) ..- Main Power Supply and Ground Circuit Check Diagnostic Procedure 0 0 0 0 0 0 0 0 Magnet clutch does not engagewhen AIC switch and fan switch are ON. 0 .. 0 0 Magnet clutch does not engage in DEF mode. 0 .. 0 0 0 Illumination or indicators of push 0 control unit do not come on, Noise 0 0 0, ..: The numbermeanscheckingorder, 0 : Asfor checkingorder, referto eachflowchart, (It dependson malfunctioningportion.) HA-46 \\ 0 0 0 Blowermotor 0 0 Resistor 0 A/C switch 0 0 0 0 REC switch 0 0 VENTswitch 0 0 BILswitch 0 0 FOOT switch 0 0 FID switch 0 DEF switch 0 0 0 0 0 0 0 0 0 ::I: »I ~ "'-01 0 Fanswitch Modedoor motor 0 Intakedoor motor 0 0 0 A/C relay 0 0 0 Thermo control amp. 0 0 0 Dual-pressur, switch 0 0 0 Compressor (Magnetclutch) 0 0 0 Thermal protector 0 0 0 E.C.C.S.control unit 0 Illumination system 0 Knob illumination 0 0 0 0 0 Push control unit 0 0 0 Harness Compressor & R E TROUBLE DIAGNOSES Preliminary Check PRELIMINARY CHECK 1 Intake door is set at "FRESH" in DEF or F/D mode. No Is intake door in "Fresh" position when REC switch is turned from ON to OFF at VENT, B/L or FOOT mode with ignition switch at. ACe and fan speed at 4? (Can you hear air moving from the intake unit?) Go to DiagnosticProcedure 3. Yes No Go to Diagnostic Procedure 3. Is intake door in "REC" position when REC switch is turned from OFF to ON at VENT, B/L or FOOT mode with ignition switch at ACC and fan speed at 4? (Can you hear air moving from the intake unit? I Yes Is intake door in "Fresh" positionl when F/D switch or DEF switch is pushed? (Can you hear air moving from the intake unit?) Yes INSPECTION END / HA-48 No Replace control amp. built-in push control unit. TROUBLE DIAGNOSES Preliminary " PRELIMINARY CHECK 2 A/C does not blow cold air. Check (Cont'd) N.G. DOES AIR FLOW FROM VENTS? Condition . Ignition switch, AIC switch, IS BLOWER MOTOR OPERAT. ING NORMALLY? CHECK BLOWER MOTOR OPERATION. and fan switch are ON. . Modeswitch isin VENT mode and temperature lever is in full cold position. Go to Diagnostic Procedure 1. O.K. CHECK COMPRESSOR BELT TENSION. Refer to MA section. N.G. CHECK COMPRESSOR OPERATION. CHECK REFRIGERATION CYCLE PRESSURE WITH MANIFOLD GAUGE CONNECTED. Refer to Performance Chart. TN.G. Adjust or replace compressor belt CHECK REFRIGERANT. Go to Performance Test . O.K. (Does not freeze up) CHECK VENTILA. TOR DUCT FOR AIR LEAKS. CHECK THERMO CONTROL AMP. OPERATION. Refer to Electrical Components Inspection. Go to Diagnostic Procedure 4 CHECK AIR MIX DOOR ADJUSTMENT. Refer to DOOR CONTROL. N.G. (F reeze up) Diagnoses. N.G. CHECK FOR REFRIGERANT LEAKS [ evaporator freezes. O.K. N.G. Connect manifold gaugethen check system pressure. O.K. CHECK FOR EVAPORATOR I- COIL FREEZE UP. Remove intake unit. Check if O.K. O.K. No Yes I. O.K. I CHECK EVAPORATOR OUTLET AIR TEMPERATURE. Refer to Performance Chart. N.G. / CHECK THERMO CONTROL AMP. OPERATION. Refer to Electrical Components Inspection. HA-49 ,. TROUBLE DIAGNOSES Preliminary Check (Co nt' d) PRELIMINARY CHECK 3 Magnet clu,ch does not engage In DEF mode. Perform PRELIMINARYCHECK 2 before referring to the following flow chart. . With engine running, does magnet clutch engage normally when A/C switch and fan switch are ON? No Go to Diagnostic Procedure 4. Yes Push A/C switch and turn A/C system OFF. Make sure that magnet clutch is disengaged. With engine running, does magnet clutch engagenormally when DEF switch and fan switch are ON? No Replace control amp. built-in push control unit. Yes INSPECTION END ( ~ HA-50 TROUBLE DIAGNOSES Preliminary Check (Cont'd) PRELIMINARY CHECK 4 Air outlet does not change. No DOES AIR COME OUT FROM EACH DUCT NORMALLY WHEN EACH MODE SWITCH IS PUSHED WITH IGNITION SWITCH AT ACC? I Go to Diagnostic Indicator illuminates ...,1 ,.. ... ... ,1 ... "Q) 0 . ........ . ....1 Air outlet 0 VENT 0 ,.. FOOT & VENT . ....I 0 FOOT & DEF . 0 ........ FOOT & DEF 0 Air distributionratios FOOT VENT S/L F/D ... ; s.... ... .,... ' DEF DEF ... I I I I I I I I I I I VENT I I I I I I I I I I I f ''' (%) 100 I 80 ! 50 40 I 0 I I Yes / INSPECTION END HA- 51 / Procedure 2. TROUBLE DIAGNOSES , ------ Preliminary Check (Cont'd) PRELIMINARY CHECK 5 Noise Check where noise comes from. Belt Replace expansion valve. Replace compressor. The line is fixed straight to the body. The line is not fixed. Fix the line with rubber or some vibration absorbing material. ( Readjust belt tension. Refer to ENGINE MAINTENANCE in MAsection. ~ HA-52 The pully center does not match. Readjust the pully center. TROUBLE DIAGNOSES Main Power Supply and Ground Circuit Check POWER SUPPLY CIRCUIT CHECK FOR AIC SYSTEM Check power supply circuit for air conditioning system. Refer to "POWER SUPPLY ROUTING" in EL section and AIC ELECTRICAL CIRCUIT. Thermo control connector @ THERMO amp. AMP. CHECK Check power supply circuit for thermo control amp. with ignition switch ON. 1. Disconnect thermo control amp. harness connector. 2. Connect voltmeter from harness side. 3. Measure voltage across terminal No. @ and body ground. ~~ L/OR i5 Voltmeter terminal Voltage 00 ':" CONTROL RHA406A EB 8 @ Body ground Approx. 12V ~ ( ., Thermo con trol amp. ne ctor @ 'O"~ [ill -= LG/B ~ i5 .~ Continuity exists: O.K. 00 § RHA509A Check body ground circuit for thermo control amp. with ignition switch OFF, AIC switch ON and fan switch ON. 1. Disconnect thermo control amp. harness connector. 2. Connect ohmmeter from harness side. 3. Check for continuity between terminal No. @ and body ground. Ohmmeter terminal EB 8 @ Body ground / HA-53 Continuity Yes TROUBLE DIAGNOSES Main Power Supply and Ground Circuit Check (Cont'd) ..-cT lit IV 00 PUSH CONTROL Check power supply circuit switch at ACC. 1. Disconnect push control 2. Connect voltmeter from 3. Measure voltage across Push control unit connector @ ~ ~n ~! RHA431A unit harness connector. harness side. terminal No. @ and body ground. I e Ei1 Body ground Voltage Approx.12V Check body ground circuit for push control unit with ignition switch OFF. 1. Disconnect push control unit harness connector. 2. Connect ohmmeter from harness side. 3. Check for continuity between terminal No. @ and body ground. [ID Push control unit connector @ IBffiEHEI for push control unit with ignition Voltmeter terminal @ litij~ UNIT CHECK ( :: B RHAB96A \ HA-54 TROUBLE DIAGNOSES Harness Layout for A/C System Passenger compartment @ @ Engine compartment '. Condenser fan motor (U.S.A. only) :;r. ~/ Main harness Engine room harness @): @): @): @)-1: @)-2: Dual-pressure switch Condenser fan motor AIC relay Compressor (Magnet clutch) Compressor (Thermal protector) @: Mode door motor @) : Push control unit @: Fan switch @: Thermo control amp. @: Resistor @: Blower motor @: Intake door motor HA-55 RHA404A BATTERY (Via fusible IInk-Green) FUSE M 'N @ INTAKE DOOR MOTOR @€3 <8 ~ @ 10 m m I DUALPRESSURE~ SWITCH @W @ ~ O~@@ @ @ . 1][1 6~~~~gL ~ AMP, ~ 811213 I 3 5 7 1 159 1114 ~ 246 PUSH @ CONTROL _UNI T THERMISTOR I ~ r-- ::E: » 0)' ~rcr BLOWER MOTOR «ED RESI STOR I DEF. ~ ~ F/O. I U1 en 1 - VENT 8 2 ,;:~ 2 2 7 '---1'1 ~ 21 OEF;o ' (1 F/0 B/L 6~~ ~ ~ \1-1 ~ffi -1;0 m::I ~~u ILLUMINATION ~~ or. i I Ium Inat Ion system For { U. S. A. For Canada l ~ . 11>1 . . All connectors shown in this illustration "- zz ::I zo M 0' Ci\ am 6 ;0 g~ ~ ~ -::!.. :1 ~ < ~ I ~ m' -I O::Y;: ' ' ~ ~ en."." , ~ ~ ~ ~ ;0 From ~ ~ I@ m ;0 I :D :I ~ ~ 0 (,II ~ 0 en en FOOT 0 (J: ) ---1(2 (~): ~ EF '~\1 2 I E. CO UN MODE DOOR MOTOR <8 J ~: r ~ FUSE 30 I'm ~ I ~ e ~ ~~ ~ @ are unit side connectors. The unit 'side connectors with a double circle" 0 " are connected to the harness side connectors shown in the "Harness Layout for A/C System", (See page HA-55,1 . The terminal numbers in the connector coincide with the circuit numbers surrounded by a single circle" .: These switches are built in push control unit and mechanically linked to corresponding switches. TROUBLE DIAGNOSES Diagnostic Procedure 1 Flow chart No. INCIDENT 1 Fan fails to rotate. 2 Fan does not rotate at 1 peed. 3 Fan does not otate at 2peed. 4 Fan does not rotate at 3peed. 5 Fan does not rotate at 4peed. SYMPTOM: Blower motor does not rotate. ! Perform PRELIMINARY CHECK 2 befor~ referring following flow chart. . rn Check if blower motor rotates properly at each fan speed. Conduct check as per flow chart at left. L1J Fa CHECK POWER SUPPLY FOR BLOWER MOTOR. Disconnect blower motor harnessconnector. Do approx. 12 volts exist between blower motor harness terminal No. @ and body ground? \&",l1tis ~ "cfi' Check circuit continuity between blower motor harness terminal No. @ and body ground. [;J ;l1tiJ Blower4m~ 1 II L1J ~ B) ~ (Q) (g (Go to next page.) N.G. Check 15A fusesat fuse block. (Refer to "POWER SUPPLY ROUTING" in EL section and AIC ELECTRICAL CIRCUIT.) O.K. [;J 2 3 4, RHA407A ~ ~ rn Fa Blower motor connector @ to the N.G. Reconnect blower motor harness connector. ) O.K. Q CHECK BLOWER MOTOR. 00 I connector @ (Refer to Electrical Components Continuity exists: O.K. N.G. "~~ - RHA510A Inspection.) Replace blower motor. [i] Resistor@ ~m l1t i) [i] 00 ( "0' -= 23 4 . CHECK BLOWER MOTOR CIRCUIT BETWEEN BLOWER MOTOR AND RESISTOR. Do approx. 12 volts exist between resistor harnessterminal No. @ and body ground? RHA408A Ii] l1tu Blower motor connector @ O.K. [ill Disconnect blower motor and resistor harness connectors. Ii] Note Check circuit continuity between blower motor harness terminal No. @ harness terminal and resistor No. @. Resistor connector @ Y~~lfOO L/W N.G. L/W A (Go to next page.) Note: If the result is N.G. after checking circuit continuity, repair harness or connector. RHA518A HA-57 TROUBLE DIAGNOSES Diagnostic Procedure 1 (Cont'd) c B' ~ ~ RHA409A B 00 CHECK RESISTOR AFTER DISCONNECTING IT. (Refer to Electrical Components Inspection.) O.K. / II ~ ~ I CHECK FAN SWITCH CIRCUIT. Do approx. 12 volts exist between each fan switch harness terminal and body ground? AHA897 A ':" ~ ~ []J Continuity exists: O.K. Fan switch @ L/R connector L/Y LIB Flow chart No. Terminal No. [itij e @ @ ~ Body Approx. ground 12V O.K. --, Lffl 27---, L/Y Resistor connector @ -' Voltage @ @ .-. L/R ~ Reconnect resistor harness connector. ~~i5 II ~ -eft' 2 3 . ':" Fan switch connector @ iii ~ E D' II ~ ~ ~ 00 N.G. Check circuit continuity between fan switch and resistor. [2] RHA519A CHECK FAN SWITCH AFTER DISCONNECTING IT. (Refer to Electrical Components Inspection.) O.K. iii N.G. Replace fan switch. Note Check circuit continuity between fan switch harness terminal No. @and body ground. O.K. Replace blower motor. Note: If the result is N.G. after checking circuit continuity, repair harnessor connector. HA~58 Note TROUBLE DIAGNOSES Diagnostic Procedure 2 m Push control unit connector @) . _lET eJ I 00 t -= (;) Air outlet does not change. Perform PRELIMINARYCHECK 4 and M;:ttn Power Supply and Ground Circuit Check before referrir:tg to the following flow chart. SYMPTOM: RHA410A Mode door motor connector@ .-r Eu 00 RHA411 A II m CHECK MODE DOOR MOTOR POSITION SWITCH. 1. Turn VENT switch ON with ignition switch at ACC position. 2. Turn ignition switch OFF. Disconnect push control unit connector. 3. Check if continuity exists between terminal No. CD or @ of push control unit harness connector and body ground. 4. Using above procedures, check for continuity in any other mode. as indicated in chart. Mode switch 00 ,-,.-r-r , , \ ,(.., \ --- ,~\(' 'O\(..,'-,~ ,---, ,. , Q>' >, ~~~:, 654 321 Mode door motor connector @ Conti- e nuity CD or @ B/L @ or CID FOOT CIDor @ F/D @ or flow - I I = I I ::> . - - I IL' BATTERY SW 1 BATTERY BATTERY Does not flow = -1'""1 sw 1 I 0 SW 1 BATTERY Does not flow 9 I I.-J 0 SW 1 BATTERY Flows Z = I 0 SW 1 ) II . s SW 1 I' BATTERY SEL881H TYPE OF STANDARDIZED RELAYS 1M 1T 1 Make 1 Transfer 2M 1M.l B 2 Make 1 Make 1 Break 2M 1M 1M 2M ,--- r', ,. ," ( I '. ( ... ... ~ ~~), ---- " lM.1B 1T 1T I I \ , \ 'I' ' \ ?--- ... '-r, ' t 0','- \ \ I ,' ' : \ I I 1' 1B \ ~ 1\ \ " ,\ " 1M SE L882H EL-3 STANDARDIZED RELAY Circuit Outer view Type Connector symbol and connection Casecolor "J m» r-z »0 -<." tDC x~tD :;;@) r- ...", ~@ ~@ "'''' '" ~ -- BATTERY Win OR/B- t~~ ~ IBlo Head Iamp L H. Front Tur Hea Tim Rea Met crys ", (@) W~L~ GROUND Me disp Aut con L - '" ~ @ ~. I11R?1I @fIR:iJ ... 33 ~ ~1 '" '""'''' ~~~ 1>\ \SJ (!---,;w A. S G/W- lG BODY m r- G "''''1'' RELAY- \,- ~ relay -- G/Y ~~ @)~@) ] swl tCh/ Retract LAY T ) contra I u~ if" RE I GNITI ON IIIIIIi r,." '''' T !\W1@i)1WJ ~ '" r.;;;;-, ) Fue I pump. All' regulator Key '"'' '" .."', 8m CheCk relay ACCESSORY OFFACC ON ST 0 0 0 0 0 ~~ CJ RCUJ T BREAKER .. n U3 ~; @@j)~ BODY GROUND 34 SB G/R -- OR G/l - IRe Jnte ~~~ chim cont cont belt Stop unit. Haza Head Not Exter Lice Illum Head unit E. C Bac A/T cont A. B POWER SUPPLY ROUTING ----- O.K. Fuse a. If fuse Blown is blown, be sure to eliminate cause of problem before installing new fuse. b. Use fuse of specified rating. Never use fuse of more than specified rating. c. Do not install fuse in oblique direction; always insert It into fuse holder properly. d. Remove fuse for clock if vehicle is not used for a long period of time. SEL954J Fusible Link SEL387L A melted fusible link can be detected either by visual inspection or by feeling with finger tip. If its condition is questionable, use circuit tester or test lamp. CAUTION: a. If fusible link should melt, it is possible that critical circuit (power supply or large current carrying circuit) is shorted. In such a case, carefully check and eliminate cause of problem. b. Never wrap periphery of fusible link with vinyl tape. Extreme care should be taken with this link to ensure that it does not come into contact with any other wiring harness or vinyl or rubber parts. FUSIBLE LINK VARIATION Color Maximum amperage (A) 15 20 30 35 40 Brown Green Red Black Gray *Temperature condition: El-6 Less than ao°c (176°F) BATTERY CAUTION: a. If it becomes necessary to start the engine with a booster battery and jumper cables, use a 12-volt booster battery. b. After connecting battery cables, ensure that they are tightly clamped to battery terminals for good contact. c. Never add distilled water through the hole used to check specific gravity. \ How to Handle Battery Keep clean and dry. METHODS OF PREVENTING OVER-DISCHARGE The following precautions must be taken to prevent over-discharging a battery. The battery surface (particularly its top) should always be kept clean and dry. If the top surface of a battery is wet with electrolyte or water, leakage current will cause the battery to discharge. Always keep the battery clean and dry. . SEL711E . When the vehicle is not going to be used over a long period of time, disconnect the negative battery terminal. (If the vehicle has an extended storage switch, turn it off.) / SEL712E Hydrometer a . Check the charge condition of the battery. Periodically check the specific gravity of the electrolyte. Keep a close check on charge condition to prevent overdischarge. SEL442D EL-7 BATTERY How to Handle Battery CHECKING ELECTROLYTE WARNING: '\ (Cont'd) LEVEL Do not allow battery fluid to come in contact with skin, eyes, fabrics, or painted surfaces. After touching a battery, do not touch or rub your eyes until you have thoroughly washed your hands. If the acid contacts the eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention. Normally the battery does not require additional water. However, when the battery is used under severe conditions, adding distilled water may be necessary during the battery life. / . . Removethe cell plug using a suitable tool. Add distilled water up to the MAXlevel. SELOO1K Charging voltage 1 Charging current ~ "-' Normal battery Sulphated battery Charging voltage --. Charging current Duration of charge SEL709E SPECIFIC GRAVITY Read top level with scale a SULPHATION When a battery has been left unattended for a long period of time and has a specific gravity of less than 1.100, it will be completely discharged, resulting in sulphation on the cell plates. Compared with a battery discharged under normal c.onditions, the current flow in a "sulphated" battery is not as smooth although its voltage is high during the initial stage of charging, as shown in the f~gureat the left. CHECK 1. Read hydrometer and thermometer indications at eye level. SE L442D EL-8 BATTERY How to Handle Battery (Cont'd) . Hydrometer ~I~ When electrolyte level is too low, tilt battery case to raise it for easy measurement. /' 1 TI"~o-' ~ SEL710E 2. Convert into specific gravity at 20° C (68° F). Example: . When electrolyte temperatu re is 35° C (95° F) and specific gravity of electrolyte is 1.230, converted specific gravity at 20° C (68° F) is 1.240. When electrolyte temperature is 0° C (32° F) and specific gravity of electrolyte is 1.210, converted specific gravity at 20°C (68°F) is 1.196. . Converted specific gravity (5201 1.30 en 1.28 II a 1.26 II Q 1.2" I! E > 1.22 eti 1.20 ..- 1.18 II .. ?; '> .. ;;. .!:! - 'u II Q I/) 1.16 1.1" 1.12 1.10 -30 1-221 -20 1-"1 -10 11..1 0 1321 Electrolyte 10 1501 20 1681 temperature °c (0 F) SE L042D _/ EL-9 BATTERY ~ / Battery Test and Charging Chart Chart I VISUAL INSPECTION . Check battery case for cracks or bends. . Check battery terminals for damage. . If the difference between the max. and min. electrolyte level in cells is within 10 mm (0.39 in), it is O.K. N.G. O.K. Replace CHECKING SPECIFIC GRAVITY Refer to "Specific Gravity Check". . SLOW CHARGE Refer to "A: Slow Charge" . STANDARD CHARGE Refer to "B: Standard Charge" . CAPACITY TEST Refer to "Chart II". O.K. Reacty for use battery . Charge" . CAPACITY TEST Refer to "Chart II". N.G. Replace battery. Ready for use CAPACITY TEST Refer to "Chart II". ~ Ready for use . "STANDARDCHARGE" is recommended in - . N.G. Ready for use . Mount battery again and check loose ter. minals. Also, check other related circuits. CHECKING SPECIFIC GRAVITY Refer to "Specific Gravity Check". RECHARGE Refer to "C: Quick Charge". .If battery temperatUre rises above 60°C C14O"F), stop charging. Always charge battery when its temperatUre is below 60°C (140°FI. O.K. CAPACITY TEST Refer to "Chart II". QUICK CHARGE Refer to "C: Quick N.G. Replace battery. that the vehicl. is in storageafter charging. EL-10 QUICK CHARGE Refer to "C: Quick Charge" . . Time required: 45 min. CAPACITY TEST Refer to "Chart II". O.K. Ready for use N.G. Replace battery. BATTERY Battery Test and Charging Chart (Cont'd) Chart II 1// . ~ Check battery type and determine the specified current using the following table. Fig. 1 DISCHARGING (load tester) Test using battery checker. Test using load tester. Follow manufacturer's Read load tester voltage instructions when specified to check and determine if battery serviceable. O.K. Ready for use discharging current (Refer to Fig. 1.1 flows through battery for 15 seconds. is N.G. Go to next step. Ready for use CURRENT Type Current (A) 28B19R(l) 34B19R(l) 46B24R(l) 55B24R(l) 50D23R(L) 55D23R(l) 65D26R(l) 80D26R(l) 90 99 135 135 150 180 195 195 75031 R(L) 95031 R(L) 95E41 R (l) 130E41R(L) 210 240 300 330 Go to next step. ~~ .. 0 6°010 SE L697 B /" EL-11 BATTERY .~ Battery Test and Charging Chart (Cont'd) A: SLOW CHARGE Fig. 2 INITIAL CHARGING TYPE == == BATTERYT a:a: 0101 - IDID Determine initial charging current from specific gravity referring to Fig. 2. 4.0 (A) Below 1.100 . Charge battery. . Check charging voltage 30 minutes after starting the battery charge. . . CURRENT SETTING (Slow charge) :i :i:i :i:i :i:i :i a:a: :i:i a:a: a:a: a: a: a: NN 00 1n0 - " "'''' W@ ~(@) ~ ~~ " ",0: '" '" ~'" '" @)ft@) BODY (Eng i ne harness) room GROUND @)@) ~8/Y...o,.0 "O-8/Y ~8/W-'Q' @, For @), For Canada U. S. A. (Eng i ne harness room no. 2) ~ >- ,'" @)g @.?)O I FUSI BlE LINK 888 88J § cr:=::o cr:=::o §] ~M FUSE FUSE AND FUSIBLE lINK CIn RElA Y BOX) BATTERY (ill) STARTER MOTOR 7 SEl466L AfT MODEL INHIBITOR IGNITION SWITCH 1 2 3 4 5 SWITCH P N IP OFFACC ON ST :J C () WI ~@Y ~~ ~@ '" ~@) ~~ .... (Eng Ine harness) @)1f2W ~ room en ~ 8/Y-o' "O-8/Y (Eng I ne harness room no. 2) ] ~ I FUSI BlE LINK >- , '" @)Q @.?)O 888 88J § cr:=::o cr:=::o FUSE AND FUSIBLE (J n RELAY BOX) lINK §] 8/R FUSE (ill) 7 SA HERY STARTER MOTOR 7 SE L67BM EL-15 , N.G. Check Fuse and Fusible link I Does starter motor No turn? O.K. .1 Check battery for charging condition and battery terminals for connections and corrosion. VIS Replace . . N.G. Ch Re batt O.K. Check pinion rollar clutch for damage. Replace if necessery. N.G. Check wir ing of starting Repair . Ign . Clut swit . Star . Con system. O.K. Check reduction geer. armature and gear shaft for damage. Replace if necessary. Can you hear magnetic switch of starter motor operating? . Rep Ves m r- Is meshing condition gear O.K.7 I .... 0') of pinion and ring N.G. . Adju . Che retu for Cor and O.K. . Remove starter motor from engine. Does starter motor turn under no load by connecting battery (jJ terminal to M terminal of starter motor and battery terminal to starter motor body? e . Ves N.G. (Turns slowly.) Check battery for charging condition and battery terminals for connections and corrosion. N.G. ., Ch and Re Ch Re O.K. Does engine turn by replacing motor with a new one7 starter Ves Repair or replace starter motor. 1 No i I Check inside of engine. Starter motor does not stop if ignition switch is turned off. I Repair or replace ignition switch, starter relay or magnetic switch. I - .'-./, ~ hrOU9h-bOlt ..,-. ' i-- . .2.3. 2,91 Rear cover 8,",h "_bS- A : N.m Ikg-m. ft-Ib) SEL834H A2T14094 Rotor I~~ IC voltage assembly regulator A: Stator t:> N'm Ikg-m.ft-Ib) SEL695L *Rear bearing CAUTION: Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. Be careful not to lose this ringduring removal. ' EL-25 CHARGING SYSTEM - Alternator - Disassembly REAR COVER REMOVAL CAUTION: Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. To facilitate removal of rear cover, heat just bearing box section with a 200W soldering iron. Do not use a heat gun, as it can damage diode assembly. SEL628D Ohmmeter Rotor Slip Ring Check 1. Continuity test No continuity... . Ohmmeter Replace rotor. 2. Insulator test . Continuityexists. ... Replacerotor. 3. Check slip ring for wear. Slip ring minimum outer diameter: Refer to S.D.S. SE L630D Brush Check 1. Check smooth movement of brush. Not smooth ... Check brush holder and clean. . 2. Check brush for wear. Replace brush if it is worn down to the limit line. . SE L631 D 3. Check brush lead wire for damage. Damaged... Replace. 4. Check brush spring pressure. Measure brush spring pressure with brush projected proximately 2 mm (0.08 in) from brush holder. . 2 mm 10.08 inl . Spring pressure: Refer to S.D.S. Not within the specified values ... Replace. E E049 EL-26 ap- CHARGING,SYSTEM ~ Stator - AI.ternator - Check To test the stator or diode, separate them by unsoldering the connecting wires. CAUTION: Use only as much heat as required to melt solder. Otherwise, diodes will be damaged by excessive heat. SE L587 A [MITSUBISHI make] Long nose pliers used as a heat sink ~ ! [HITACHI make] 1. Continuity test . No continuity... Replace stator. [MITSUBISHI make] EL-27 CHARGING SYSTEM - Alternator Stator Check (Cont'd) 2. Groundtest . Continuity SE L384L EL-28 exists. '" Replace stator. -~ CHARGING SYSTEM - Alternator - Diode Check / MAIN DIODES . . Use an ohmmeter to check condition of diodes as indicated in chart below: If any opthe test results is not satisfactory, replace diode assembly. Ohmmeter probes Positive (fJ Continuity Negativee Positive diode plate Diode terminals Yes Diode terminals Positive diode plate No Negative diode plate Diode terminals No Diode terminals Negative diode plate Yes Diodes check (Positive side) Diodes check (Negative side) [HITACHI make] [MITSUBISHI make] Sub-diodes Negative diode plate SE L768D EL-29 Positive diode plate Diode terminals SEL385L CHARGING SYSTEM --~ Diode - Check Alternator - (Cont'd) SUB-DIODES [MITSUBISHI make] . . Attach ohmmeter's probe to each end of diode to check for continuity. Continuity is N.G. ... Replace diode assembly. SE L494H [HITACHI make] (~:1 \ !I {( ,J ~ .~ (- J / 1/) ;'//.' /.- . . ~ - (]Do ~ .4..L c-- - 0 Assembly Carefully observe the following instructions. . When soldering each stator coil lead wire to diode assembly terminal, carry out the operation as fast as possible. WHEN SOLDERING BRUSH LEAD WIRE [MITSUBISHI make] Position brush so that its wear limit line protrudes 2 mm (0.08 in) beyond end face of brush holder. . Wear limit line-, SEL386L [HITACHI make] (1) Position brush so that it extends 10.5 to 11.5 mm (0.413 to 0.453 in) from brush holder. SEL595A EL-30 CHARGING SYSTEM ~ - Alternator - Assembly (Cont'd) (2) Coil lead wire 1.5 times around terminal groove. Solder outside of terminal. When soldering, be careful not to let solder adhere to insulating tube as it will weaken the tube and cause it to break. Soldering points / After soldering. place insulating tube on terminal. 1 mm 10.04 inl SE L596A RING FITTING IN REAR BEARING . Fix ring into groove in rear bearing so that it is as close to the adjacent area as possible. REAR COVER INSTAllATION (1) Before installing front cover with pulley and rotor with rear cover, push brush up with fingers and retain brush by inserting brush lift wire into brush lift hole from outside. (2) After installing front and rear sides of alternator, pull brush lift wire by pushing toward the center. Do not pull brush lift wire by pushing toward outside of rear cover as it will damage slip ring sliding surface. SE L766D / ~ EL-31 CHARGING SYSTEM -"- Alternator - Service Data and Specifications (S.D.S.) ALTERNATOR / Type LR180-715 A2T14094 All Applied model Nominal rating V-A 12-80 Groung polaritY Negative Minimum revolution under no-load (When 13.5 volts is applied) rpm Hot output current Alrpm Less than 950 Less than 1,100 More than 22/1,300 More than 58/2,500 More than 17/5,000 More than 21/1 ,300 More than 60/2,500 Regulated output voltage V Minimum length of brush mm (in) 6.0 (0236) 8.0 (0.315) Brush spring pressure N (g, oz) 1.471 - 3.334 (150 -340, 5.29 - 11.99) 3.040 -4217 (310-430, 10.93 -15.17) Slip ring minimum outer diameter mm (in) 26.8 (1.055) 22.1 (0.870) EL-32 14.1 -14.7 COMBINATION SWITCH Check Variable intermittent wiper switch ---- TURN SIGNAL R , {[ LIGHT A WASH n:,(j " B p 2nd OFF C HI <} L ~ ~ For wiper switch LIGHTING QFF A B CA 5 0 0 6 7 8 0 0 9 10 11 12 25 26 27 I For A.S.C.D. and Horn For lighting switch INTERMITTENT WIPER VOLUME SWITCH 1 2 B C A B C 100 ~ 22 4 rq II 0 RNL OO HORN SWITCH .Q. 2 3 TURN SIGNAL SWITCH ~ b 28 SEL388L EL-33 ,~ COMBINATION SWITCH Replacement . Wiper and washer switch l .~ Each switch can be replaced without removing combination switch base. , Lighting switch SEL389L . To remove combination switch base, remove base attaching screw and turn after pushing on it. Attaching screw SE L390L EL-34 FUSE ~ I~A TTERY ~ I -0 RETRACTOR SWITCH OFFI RETRACT RELAY-4 ON I 6 I~ t <;> ... I-- @5 RETRACT RELAY-l f-- ,--- H inat RETRACT RELAY-3 .--vm=;: ~ [of ~OJ ..L- i I Ium system r1S I -=- .- To I r+- } RE TRAC T -=- I RELAY-2 m rI W (J'I -l-- - 1 cnc ::Err ~~ ~rr, nn :r~ , ~ Z G1 ~ ~~-- - l -~, 1I ~D~W~ ~P~ 4'~ 3 G1 5' ..L -=- \ ~ HEADLA~P m r MOTOR L.H. -~~ HEADLAMP MOTOR : ~! ~ R. H. - I - 4 f t1! :~f* @t, > 1- -~O~N ~ ~ ~~ [L1J IS 3 ~- --d,~~~ ~U~ 4 3 --4-- 1 --- « I < ~ < I I , L-- - C 7 - HEAD LAMP TIMER - - -~ HEADLAMP MOTOR R. H. RETRACT RELAY-] (D RETRACT RELAY-2 RETRACT RELAY-3 RETRACT RELAY-4 iii[l@~ ~@) .. ..~ ~ ~@) .. ~@) c.. rftl@ ~~ ..:~ ~~ ~~~ ". .. ..... HEADLAMP TJ MER RETRACTOR SWI TCH ~> ~~~:" ..:~ OFF ON 1 a 2 a 3 4 5 6 B 1.1 @ -~@) X ~,,~~~..~~~~ ~~ ". ~.. .. 9 jj To Illumination system @ O~ m r- HEADLAMP R. H. I W en rE~?LAMP ~ ~ HEADLAMP MOTOR L. H. BR/W PU/W OR B BR EA PU 'iff!:2 BR -mBR/WOR @) P/B ~G/l 't}: R/G @ ~G/Y @ @])@) m OR P/B P/B R/G BR/Y R/l G/R R/B OR/B 58 BR PU BR/W BR/Y P .... (Eng I ne harness) ~R/B @ room BR/Y E2 FI "' 01 A2 AS C3 Cl El 02 F2 .. B2 Bl A' C' C' C2 BR PU EA ORBR/W m OR P/B P/B R/G BR/ Y .ffi R/l G/R R/B OR/B 'B SR PU BR/W"" 8R/Y (Ma i n harness) S. M. J. ffiefer to last page (FoIdout page). ] (D1.~P:f cc ..,,"'''' ..,". ...... ~@!) Ii LIGHTING SWITCH FUSE AND FUSI BLE LI NK (J n RELA Y BOX) [§3[§ s: '" "'''' ~~@) FUSE @ en m r UI CIO UI '" ~~ ~ ~ BATTERY @ Ii @)@) BODY GROUND HEADLAMP / Description BASIC OPERATION Operation Cond ition Lighting switch Retractor switch OFF 1ST OFF 1ST 2ND OFF 2ND 1ST OFF 1ST OFF OFF Momentarily turned to PASSING OFF *: Referto / C/O* Headlamp motor No operation [A) Open Headlamps OFF ON after headlamp motor reaches fully open position. Held to open position OFF [B) Closed OFF OFF [C) Opened and closed after headlamps go off. ON [D) Open CIRCUIT OPERATION. EL-37 Momentarily ON after headlamp motor reaches fully open position, and go off. OFF HEADLAMP Description (Cont'd) CIRCUIT OPERATION [A] When lightingswitch is switched from "1ST" A-1: ~ "2ND" While operating the headlamp motor to open position FUSE ) To Illumination system RETRACT RELAY-4 RETRACT RELA Y-3 RETRACT RELAY-! RETRACT RELA Y-2 "" ..." 0" ~ I c-" .m I I --.J ~~ MEADLAMP MOTOR L. H. A-2: 7!J I ' ,,> .~" " "'" ~~ ':"> ~~ ij" "" ---~ HEADLAMP Tl MER HEADLAMP MOTOR R. H. SEL657L After the head lamp motor reaches fully open position FUSE To Illumination J system RETRACT RELA Y- 4 RETRACT RELAY-3 RETRACT RELAY-! RETRACT RELAY-2 "" ..." 0" ~ '" ...m » "" " I I ~~ HEADLAMP MOTOR L. H. / ~!J HEADLAMP TIMER HEADLAMP MOTOR R. H. SEL658L EL-38 HEADLAMP Description [B] When lightingswitch is switchedfrom "1ST" ~ (Cont'd) "OFF" (While operating the head lamp motor to closed position) FUSE To Illumination } system RETRAC RELAY-4 T LI GHT! NG SWI T CH 0 RETRACT RELAY-3 RETRACT RELAY-I RETRACT RELAY-2 ..~ I r~ .m ~» .~ . I HEADLAHP HEADLAHP MDTDR L. H. [C] C-1: TIHER _.~ +oJ » ".. "'~ ;,~ .0 r» "" r~ ~~ .. ;:~ "" .. HEADLAMP MOTOR R. H. SEL659L When lighting switch is switched to "PASSING" While operating the head lamp motor to open position FUSE To Illumination } system RETRACT RElAY-4 RETRACT RELAY-3 RETRACT RELA Y-I RETRACT RELAY-2 I . I --.J .:J HEADLAMP MDTDR L. H. HEADLAMP MOTOR R. H. r~ .m ~» .~ » ~ "'~ ;,~ .~» " ..~ r~ ~~ .. ;:~ .."" .. SEL660L EL-39 HEADLAMP Description (Cont'd) C-2: After the head lamp reaches fully open position FUSE ) To Illuolna@) '" 'III ,.. @ I L..J to HPOWER SUPPLY ROUTINGH.) ~ @Y JII @ ""'''' FUSE BLOCK (Refer "'-< II FRONT COMBI NATI ON LAMP R. H. I NA TI ON R. H. @D G/w-p~ S. M. J. ffiefer to last page (Fo Idout page). J BACK-UP B --E:J ~ LAMP L K ~~ "'''' (@) @)~ (@)~ ~~ "'''' II I~IG;I~-UP (Eng Ine harness room no. 2) ~ G/L-{}, G/W--QJ ~ I REAR COMB ~ El-48 BACK-UP LAMP SWITCH LAMP I NA TI ON L H. ~rii@ BODY GROUND SEL679M . DIODE ~@ -g9" TO '" , '", '" -< 0 H 25 ~ . c 26 ir 27 I28 R/G R/W G/L @ FOG D~ LAMP n RELAY U @D@) R/G OR/B OR/L (Eng Ine room harness) G/L OR I m ~ R/G OR/L~OR/L (MaIn harness) S. M. J. ffiefer to (Fo I dout last page page).] rI ~ CD @ FRONT FOG ~ LAMPR. H. \bL trn'I rr;;;\ CI[8::Ot/B J= ~ ~ OR~B~ FRONT FOG ~ LAMP L.H. \bL B CI[8::OR/B ~ ~ [8::ot/B (Sub-harness) ::IE Ifr Ifr "'co'" @ii@) (f) m r '" ..., r'" BODY GROUND ~~ Ifr rr rr co"'''' '" USE AND FUSIBLE LINK (I n RELAY BOX) t IGNITION SWITCH ON or START 1 C/15J CtO "U...TI "Un C 0--< 00 :J ct-. ..,- r..,C/1 -< m ct ;00tD 0 r c>o -i"Uo -0:>\ z:E [;)m .';0 0-c 3 UJ'<:J UJII> ctct COMBINATION OFF ON L TURN R. H. 2 c 3 4 5 6 7 IX B . ~ , :e @) , r TURN -@ m@ (D ~'P¥H :J ~ ~ .. .. ",,,,,,,,,, ~~~~~~~~ .. @ QD ,~, G/B~ (Main harness) m rI 0 to (Fa Idout Iast ~G/B~ .~, (J * nstrument @ S.M.J. [Refer f'i ~oW1@ page page). J @ill) GEJ ~ ~ IjIG~Y =EfI ~ ,," FRONT COMBI NATION LAMP L. H. I~@ I~@ TURN TURN r. (Eng Ine harness) -ffi room ~t:Y~ - 1m 0 LG/B G/Y G/B B J{: G/B 't::J @)ii@) - en m r @ ";1 B J{:G/Y 't::J BODY GROUND @' Fast @: @: @: @' @' Coupe With m Jj TURN SIGNAL SWITCH @IV ~ head-up 4J . ~ @ -ffi ~ ~IG:B~~ display head-up anti-lock Without ~ jIG~B=EfI Back Without With ~ ~. E!81:;?; rr ",,,,"'''' c.. FRONT COMBINATION LAMP R. H. harness) rr",,,, "''''" ~~-c.. @ii(§) c.n L. H. r ",:;; 30 '" :~3 COMBI NATI ON FLASHER UNIT HAZARD SWITCH to-. '" M display braking anti-lock system braking system 0ii@ - BODY GROUND UI (X) 01 ~ / EXTERIOR LAMP Combination Flasher Unit Check Test lamp (27W) . . Before checking, ensure that bulbs meet specifications. Connect a battery and test lamp to the combination flasher unit, as shown. Combination flasher unit is properly functioning if it blinks when power is supplied to the circuit. --- Battery ) SEL122E Bulb Specifications Item Headlamp (Sealed) Wattage (W) 65/35 Front clearance lamp 8 Front turn signal lamp 27 Front side marker lamp 3.8 Rear side marker lamp 3.8 Turn signal lamp 27 Stop/Tail lamp 27/8 Back-up lamp 27 License plate lamp 7.5 Interior lamp 10 Spot lamp 8 Trunk room lamp 3.4 Foot well lamp 3 Luggagecompartment lamp 5 High-mounted stop lamp 18 EL-51 BATTERY TIME (Refer to \ I1TIME CONTROL SYSTEMI1.) UP * @ r FUSE III~@ @ ~ BLOCK "',,'" r,c:", (Refer to "POWER'" SUPPLY ROUTI NG", ) ". ~ ~ ::u G'I ;>o;z::I: m -t m z z 1 2 3 4 ffi¥H31 ~M HEAD-UP DISPLAY CONTROL UNIT r.... c CONTROL UNIT ( -< 5 (Main harness) (Sub-harness) I 8 (J1 N I @)@ '" ii "" ~@) r", C'11 "'''' ~- GD "'., :;; (ill?) ~G/R OFF 1ST 2ND AB C AB CAB C 5 6 7 8 en m G; 01 01 ~ " r", j R/L LI GHTI NG SWITCH h.cn.s~ '" @D@@ -=- - ~ i harnes~ With ~: *1 Witho Conn : displ CASSETTE DECK S6 PU (IT) 100 g ~en ~I ~ @~, ~@ ~ IDIDL (C en ' (1Irt -< ~ '"0 ~ID n , ] iD r ~: rtO' ::I "0-' '" ,"'''''''''''' -< I~>"'c: R/y 1 lD~*1 "'" "'''' ,c: III' D @) n "'''' ILLUMINATION 1'1'~ @. ) X METER COMBINATION I LLUMINATI ON CONTROL SWITCH r-< ~ ~ rcn r::I: ~ ~~» -t BODY .... GROUND ~ EffiJ@?) ~~ r-t c ::I .... Z » -t .... 0 z '" '" '" '" "'''' @~ @~ @~ @~ @ ~~m~EI ~ HAZARD SWITCH FRONT FOG LAMP SWI TCH PER REAR AND W SHER SWITCH REAR WI NDOW DEFOGGER SWITCH SPO :l I INTERIOR LAMP INTERIOR LAMP A UP, FUSE (Refer BLOCK to "POWER :G SUPPL Y ROUT I NG". ) ~ @:@~ @:@;o;a "..'" EH (Ma In harness) R/B R/W B m r- r.ct\ ~ f'Dt\ ~ 0 ~. ~ R/B R/W w@ ,.., 9 :G " :G ., S '" .. tiS (Room I amp harness) B I (J1 W LAMP ~ . L. H. LAMP FOOT ~ . R.H. FOOT ~ @ I9I:D= R/B R/W !g)R/B-'1 R ={j [ @ I9I:D= R/B R /W R -c:IJ ~ ~ ~ @}) :gf)R/B-'1 R ={j ,'" :G ~0 ,'" :G I Q@V @~(§) @ DOOR SWI TCH (Or I ver !II m r CI CI ..... s: s I de) BODY GROUND @l) 1 @]) @ BODY-GRO~ ~ (§Y [ :~~ @: @: @: ~: ~: -=- -=- @: METER AND GAUGES Combination Meter NEEDLE TYPE = "BRAKE" or " (CD) " -~ 0 ) ) 20 11 3 17 14 16 30 6 12 24 I I I I I I I @: For- Cal i for-nia :J « ZI01/) ....>1-0:: Z 0 .... «u Ii Z ....0 1:.... Hl 1il2 :J:J -lei -I.... ""d m Z Z I (!) .... gj I- I- gj 0 I u « I- C3 0 -I U -I w :J LL 8 4 18 15 6 7 6 19 0 m I« J I 6 28 :.: u a: 6 10 6 26 1 25 W I/) i] g] ] 21 22 23 :':z U.... W(!) IZ UW ] i] 5 1 ] I] 9 27 -I I .... IZ « 6 2 SEL577M EL-54 METER AND GAUGES Combination Meter (Cont'd) DIGITAL TYPE = = CJ [ 10 0 0 03 21 10 0 0101 ] 0 8) (FUel~ (j;) (j;) 0 (j;) ~ Head-up 10 display 1, 14 unit 23 2 4 21 18 17 d-up display con *1:To Y Y Y Y Y ? ? @: I unit For Ca I Iforn Ia ? . Z 0 @) if if W :I<: u...., W(!J ) 0 *1 3 0 20 0 8 6 9 6 15 6 19 §I j 7 13 IZ uw gj 11 ...: a:: j Ij j 16 12 24 CD 5 SEL403L EL-55 METER AND GAUGES Combination Meter (Cont'd) HEAD-UP DISPLAY r---, Inn I,u,-, I ~--j HEAD-UP DISPLAY UNIT DIGITAL COMBINATION HEAD-UP ON-OFF METER Dl SPLA Y SWITCH FUSE II MPH HEAD-UP CONTROL DISPLAY UNIT 1 7 6 2 3 II km/h 5 8 9 4 To } Illumination control system To ~ ~ ~ & -= control unit SPEED SENSOR SEL480L EL-56 G L I GNITI ON SWITCH ON or START ... .~ I GNI TI ON SWI TCH ACC or ON @~~ - - BODY GROUND @ DIGITAL COMBINATION METER R/B (Re~~~E BLOCK SUPPLyt~O~POWER TING" (@Y @) FB ~ng a Ine rness) r-- III Y/B HII I " ~ @ . I @@~-<-< C1'I ..... J . . Y/L harness) km/h Y/B S. M [Refer t r'" m r- . (Main room Y/L HEAD-UP DISPLAY ON-OFF SWITCH ) " r", (FaIdout page). J Iast page 'H-< ",'" r ",...r '" @) EH£HEEB @ a:amm (81 ack) WVh (IT) EEEffiHB1 ... @~ I te) 'H-< ",,,, r ",...r :rm ED::I "1(c ::1!II::I 01 !II 01 "1 ::10 00 (Jnstrument harness) . 3 ~ -<-< " ",r w@]) ( ToE. C. C. S. control III m r OJ OJ IX) ~ 8 SPEED SENSOR To \ unit I I lumlnatlon control system [ COMBINATION I GNI TI ON SWITCH ON or START I * UP A FUEL TANK GAUGE UNIT '" -u HEAD-UP DISPLAY r I/DDI ~ !9!!9! ,'" ,... 1 HEAD-UP DISPLAY UNIT 0h~ @E)$ '" , BODY GROUND HEAD-UP DISPLAY CONTROL UNIT > C1 :I -i >m "U m' >c cm r m :J: m -i m ::u 9 IS C:J: 19 6 8 7 ~ ~@) ~~ "'\"',...'"'" \\ I GNI TI ON SWI TCH ON or START 12 -i m m 0 0 :J: m -i m ::u . @ FUSE BLOCK to "POWER SUPPLY ROUTING".) '" (Refer ME 17 @ we - \'" ::0 ~~~ \'" '" ~ ,...@ ~ ,... @ m ~I @ en @@ CO - IW (E.F. I. harness) ~rm L/B Y/R Y/G : I I n__- m__mn--:lf I I 3-Y/R [!] --nnn, ,' -< ,... ::0 ''" " @tb ~ E. C. C. S ENGI NE CONTROL' UNIT GROUND 00 ffiefer to ~ C C S m SYSTEMin' ~ Y/L L/B Y/R Y/G Y/R Y/G G/L L/B sect . . ion, ) l{j@) ,... ~"':e B ~C'D 0-.. ,... ",'" " -(11 a., 0 ",::0 \ C<+"' GROUND @)CtP 1J ;I 1»;; -:I: . 1J -I» -<-< (Q Y/LY/B' Y/RY/GG/L' L/B' 11@ @ :::::: (11 (B lack) ~: '" " ,...'" @h@TI) @: !9!!9! ~ ~ RESISTOR POWER TRANSISTOR @I ::-::-@ BODY IGNITION GROUND Y/B COIL ::SPARK PLUG I ::- - - Y/L (Eng < B "" <+0' (Q en' '" 0? "-<-< ,...'" @) t.. ~ @~ (!.<+ ENGINE GD (ID:: @'" Q~@ i te) . 0 Y/B [Q] 32-Y/G m harness) ~;u '" b; EF&EC II ~ 1 In C! C z " SEAT BELT is I' - AUTOMATIC SEAT CONTROL UNIT .JI:: III t. .c -III <. uj .JI:: C t. 0 -0 III -C III III +' III "tJ 0 .... :j t. 0 u. tJ tJ t. 0 u. t. 0 u. -. .. -. BELT ANTI-LOCK I' -I ~ a ~ C III .c. +' CONTROL UNIT CHECK ENGINE CL I' .. @@@@ ~ ~ ~ ~ CONTROL UNIT OIL I' OIL PRESSURE SWITCH FUEL II FUEL TANK GAUGE UNIT WASHER I' WASHER FLUID LEVEL SWITCH DOOR 1 I II DOOR SWI TCH COr iver s Ide) = I' UI '" :J U. DOOR SWITCH :J OIl> OI ~., 0 ~ i~~! " I> ~/ , m@ ILIJ AND FUSIBLE RELAY BOX) ~ ~.. @) LINK (Refer to -POWER SUPPLY ROUTING',) @ ~6 Y/W ~ R/L L/R f 0 ~/~ R Y/pu A @. La @) ~~ @): For @@~: For = WASHER FLUID BRAKE FLUID LEVEL SWITCH With P ;u ~: ~ (§).. f] ~ fi- @~ . d Isp Iay head-up anti-lock brak Ing system R BODY GROUND ~ I" Q~ ~ Canada Call fornla head-up @ To k d Isp Iay @!V;u W (E F h;'rn g~~~ector @ f?ri1 ;I) ~ ?i r@J l9 ".@n" 1 I W/R ~28~ND@ , WIthout @' -=- I III Y/W For U.S.A. WIth GROUND FUEL TANK GAUGE UNI T (Eng Ine room harness no.2) ~ ~~ W/R BODY CONTROL UNIT to BR sect Ion. ) c:.. ~ ~ LEVEL SWITCH 0 (III~I~II~~I~~IPI I" 'III ~ & & (Refer .. , FUSE (J n [ ~ ;U FUSIBLE LINK \ KJ DOOR SWITCH .. ~ f.ill\ rrn1 ..r 53 .. n ,.. [( 11'1~1~"J~II9~I~~1 ~ ~ ~ :R; ~ r, . R/B ~ - I> BR @ -I>en g." C<+' @ @ Y/wY/GR/WL/R CM.: R/BW/R- @)~@ " ..,.. ~rc:~~ ~ -n.. 0 ... TART Wj Y/pu -.. I~,~ ~~ S SWITCH N (!!, "0- G \0 h IGNITION en Y/w Y/G R/W illl/R R/B W/R ~ ~~ -=- GROUND roI (Me In harness) frili6I BRAKE ~ SWITCH BO~Y-=- m NG R/B '1 ~ f' .. 0 ~jJ8 -mr en ~ ~~ ;I)-=- ;I) m E.C.C.S. CONTROL UNI en m r U1 .... ID s: ~ \ \ LI GHTI NG SWITCH 5 6 7 B 9 10 11 12 2S 26 27 28 UP I lie Inl t- I I( ~-< ",r -<'" \.\. \.\. \. '" FUSE BLOCK "'~ (Refer to pPOWER \.\. SUPPL Y ROUTI NGp. ) ~'" (Eng i ne harness) room S. M. J. ffiefer to last page (Fa I dout page).] G/R ~@V I r~ '" @f $E$E ~ ~I G/R KEY SWITCH tl ~@ IDA ~R/L r- I~I A @ ~~0 m' m TIME CONTROL UNIT (Refer to pTIME CONTROL SYSTEMp.) I GNI TI ON SWITCH ON or START OFF 1ST 2ND A BCAB CA B C R/L Y/R ~~~~ 0 2 D2 H9 (Ma i n harness) G/R R/L Y/R @D@ 0) W $E @ I I I \. $E$E I II $E a::::IJ CB[EE o::::::IJ Hr '" '" FUSE f/) m ,en ..... 0 s: I .L1 I g@ I!I FUSIBLE OJ -< FUSE AND FUSIBLE (J n RELAY BOX) I $E LINK LINK ; BATTERY 0ii = DOOR SWITCH (Dr iver side) BODY GROUND WARNING LAMPS AND CHIME Diode Check w .. . Check continuity using an ohmmeter. Diode is functioning properly if test results are as shown in the figure at left. \ SEL901F . Needle type model 0 Diodes for warning la~s meter printed circuit. ~JJl Diode Digital type model =:I SEL409L Warning Chime Check EL-64 are built into the combination TIME CONTROL SYSTEM Schematic (0 u (0 C (0 U lJJ V) ::J LL L 0 LL = To rear = window defogger I :::(OQ) I')~ CE C\I~ 'e+:; --- @ L Q)'t- 1-0 REAR WINDOW I U 1-1~o:: =:~ DEFOGGER R~LAY --t V) IV) Z OL ~o I~Z ZO t!I REAR WINDOW DEFOGGER SWITCH If'I I') = I' >D 0 If'I I' SEAT BELT SWITCH DOOR SWITCH (Driver side) WARNING CHIME 0' <0 I. . I' I>0:: W lI~ Z ::J ...J aJ KEY - SWITCH >D 0 0:: Iz 0 ILLUMINATION CONTROL SWITCH U lJJ I: <0 I- I'-HTEN DARKEN I' LI GHTI NG (J LL. SWI TCH I LLUMI NA TI ON ) I NTERMI C\J TTENT WIPER VOLUME I U I~Z --t I' =:0 V) L Zo 0 ~U I-U ~~ Z t!I C\J I') FRONT WASHER SWITCH lJJ V) ::J LL = L I' FRONT WASHER MOTOR. INTERMITTENT SWITCH ~IO: ~ \ FRONT WIPER AMP. I' }TO front wiper motor I' SEL486L EL-65 a DOOR SWI TCH (Or i ver side) LI GHT I NG SWI TCH 1\ OFF 1ST 2ND ABC ABC ABC 5 6 7 8 9 10 11 12 8 25 26 DIODE imWmI ~ @J)~.... ~ , '" ~ GH "'~ ~@~ ~ M @~ ~I ~ rri z I g:~ I 1 1 \ 4 0 3'"R/l G/R BODY GROUND -. C 3 I~I OJ " ... a OJ S. M.J. ffieferto last page ine room (Fa Idout harness) ~Y/R FUSE AND FUSIBLE (j n RELAY BOX) R/l G/R Y/R PU P l/Y lG/8 8 lG R/W LINK en @) en c~~ page). J r---l 0 (Main harness) R/l G/R Y/R PU P l/Y l G/8 8 lG 02 F2 H9 812 Al1 811 AIO 810 012 @ Ii @ W en m l p--.riTl G-'::j"JJ R/W 8 lE~8 ~ ~8GRdJ 8R ~ 1 WASHER FRONT MOTOR BODY AMP. EE WIPER IIBJ "'" "'"" I [ ~ ~:R~ ~ ::j = lG/R ~ 8 FUSIBLE LINK BATTERY To front @ID-w wiper motor \G:' PU J 0 ([ill) @)Ii@) [ It FRONT WASHERW1:fR 1111~II1JJ~~D (BIackJ 1"'~"9@ ~ (jnstrument harness) ~, 19 6 T .@ ""-< AND OFFINT La HI WASH 13 TCH 14 15 ..n 16 t r 17 t 18 120 BODY GROUND ,'" ~ eft @'@ 8R (Main harness) @(§) @'@ s: ilia 3 @j)~ ~ ~~ III m r C11 OJ -.J --i TI 5 (Eng -=- @ i ~ CONTROL UNIT I~I AzI Ii KEY SWITCH ~ TIME ~ ~ ;0 OJ SWI TCH ~@ "" '" "'''' c @}) I I LLUMI NAT ION CONTROL '-!. cEtE m r- WARNI NG CHI ME T. ~ 27 28 SEA T BEL T SWI TCH "YJ - '" '" ~@ ~ 24 0---@---02 SEAT BELT 3 ' 17 o---@---o WARNING LAMP I 13 SEA T BEL T WARNING LAMP METER " ~, @ [liHE3ifI] COMBINATION _L ~ ~, @' @' TIME CONTROL SYSTEM Description FUNCTION . Time control unit has the following functions. Details of control Item 1 Intermittent 2 Washer and wiper combination 3 Illumination control Regulates brightness of illumination in 16 stages depending on the illumination control switch setting. 4 Light warning chime timer When driver's door is opened with ti9ht switch ON and ignition switch OFF, warning chime sounds. 5 Seat belt warning lamp timer Seat-belt warning lamp blinks for about 7 seconds when ignition switch is turned to "ON" 6 Seat belt warning chime timer Sounds warning chime for about 7 seconds if ignition switch is turned "ON" when seat belt switch is "ON" (seat belt is unfastened). OPERATING control Wiper is operated in cojunction with washer switch. CONDITIONS ,' Item Regulates intermittent time from approximately 3 to 12 seconds depending on the intermittent wiper volume setting. wiper control OOt/) tertrJifli31 °t ter. trJ/fli31 Intermittent wiper Power source from battery @ Ignition switch @or@ CD ON ACC or ON combination control @ ON ACC or ON Illumination control (fJ) ON Light warning chime timer @ ON OFF or ACC @ ON OFACC ON @ ON OFF or ACC ON control Washerand wiper Seat belt warning lamp timer Seat belt warning timer chime Driver's side door switch switch -----*1 Light switch Wiper switch "INT" Washer @ @ @ \@ ON Seat belt switch *2 Illumination control switch @ (j) or @ / ON ON ON ON ON ON *1 Door switch is turned ON when door is opened. *2 Seat belt switch is turned ON when driver's side seat belt is unfastened. EL-67 TIME CONTROL SYSTEM Trouble-shooting DIAGNOSTIC PROCEDURE Symptom Wiper & washer Illumination Intermittent wiper does not operate. 1 Intermittent time of wiper cannot be adjusted. 2 Wiper and washer activate individually but not in combination 3 Illumination control system does not actuate. 4 Light warning chime does not activate. 5 Seat belt warning chime does not activate. 6 Seat belt warning lamp does not go off nor come on. 7 Ignition key warning chime does not activate. 8 Rear defogger does not activate, or does not go off. 9 Warning Rear defogger [it 9 PREPARATION FOR TROUBLE-SHOOTING 1. Remove driver's side dash side cover. 2. Remove time control unit with harness connected. POWER SUPPLY CIRCUIT CHECK 1. Connect ohmmeter from harness side. 2. Check continuity between terminal @ and body ground. ~ Ohmmeter terminals Continuity - SEL689L ~ (+) (-) @ Body ground 3. Connect voltmeter from harness side. 4. Measure voltage across terminal @ and terminals @, @ or @. Voltmeter @'@~ SEL690L Yes terminals Ignition switch position (+) (-) OFF ACC ON @ @ Approx. 12V Approx. 12V Approx. 12V @ @ OV OV Approx. 12V @ @ OV Approx. 12V Approx. 12V EL-68 / TIME CONTROL SYSTEM Trouble-shooting m DIAGNOSTIC PROCEDURE-1 Intermittent wiper does not operate. T.C.U. OUTPUT FOR WIPER RELAY CIRCUIT CHECK Measure voltage across CD and @. ~ ~ 8191101 1 1181i915<1 ~ - + O.K. Needle swings from 0 to 12V every 3 to 12 seconds. [Y] SEL652L WIPER SWITCH Check continuity CIRCUIT between j TifT I w;p" ~;",h ~ "ONT" N.G. Replace wiper relay. O.K. N.G. SEL653L Measure resistance between @ and @ while turning intermittent wiper volume. ~@?] @ taJ [Q] Check harness between T.C.U. and wiper relay. Check wiper switch circuit check. Check harness between T.C.U. and wiper switch #1kn O.K. N.G. @ ~ @ Check wiper relay. Refer to "WIPER ANDWASHER". Check T.C.U. output for wiper relay circuit. Ii) CHECK @ and @. ~oo @ Check harness for T.C.U. power supply circuit. Go to "Power Supply Circuit Check". @) Wiper switch"'" "INT" 0 Ii) ~ ~ (Cont'd) ~~ DIAGNOSTIC PROCEDURE-2 Intermittent time of wiper cannot be adjusted. O.K. Check intermittent volume circuit. Intermittent wiper knob on at "S" position Approx 1kna;"L" .. position SEL654L Replace wiper switch. wiper Replace T.C.U. N.G. Check intermittent volume. wiper Replace wiper switch. O.K. Check harness between T.C.U. and intermittent wiper volume. EL-69 / TIME CONTROL SYSTEM ) Trouble-shooting (Cont'd) DIAGNOSTIC PROCEDURE-3 Wiper and washer activate individually but not in combination. N.G. Check harness betWeen T.C.U. and washer switch. Check washer switch circuit. O.K. N.G. Check T.C.U. output for wiper motor. Replace T.C.U. [ O.K. I m DIAGNOSTIC PROCEDURE-4 Illuminationcontrol system does not actuate. T.C.U. OUTPUT FOR liGHT SWITCH CIRCUIT CHECK ~oo ~ @ Light switch Replace wiper relay. m Check T.C.U. output for light switch circuit. ... ON Check harness betWeen T.C.U. and light switch. O.K. Approx.12V Check IIIumi nati on circuit. SEL648L Check for loose harness connector. O.K. [1100 [!] kJ IllUMINATION CHECK Light switch ... OFF O.K. Replace T.C.U. SEL649L CONTROL CIRCUIT 1E5L---, 0 Check illumination control circuit. III 00 @@ [aJ [ill + Ohmmeter (+1 (-I @ !J) @ @ - lIIum;nat;oncontrol .wltch OARK BRIGHT on Excep. on Except on on ISEL650L EL- 70 Check illumination control switch. TIME CONTROL SYSTEM Trouble-shooting (Co nt' d) DIAGNOSTIC PROCEDURE-5 Light warningchime does not activate. Do other warning chimes activate? O.K. N.G. Go to "PowerSupply Check". Circuit Check harness for T.C.U. power supply circuit. O.K. Check T.C.U. output for chime circuit. Check chime, and harness between T.C.U. and chime. Go to "T.C.U. output for light switch circuit check". (Refer to back page.) Check harness between T.C.U. and light switch. O.K. I T.C.U. OUTPUT FOR CHIME CIRCUIT CHECK Measure voltage across (j]) and @ when driver's door is opened and closed. ~oo @ ~ f\Tl LY'.J + - Replace T.C.U. DIAGNOSTIC Seat belt warning chime does not activate. Go to "Power Supply Circuit Check". @ .Light switch ... 1ST Approx.12Vwhen driver's side door is closed. . PROCEDURE-6 Voltmeter needle swings (0 -12V) when driver's side door is opened. SEL642L Check harness for T.C.U. power supply circuit. . O.K. Check T.C.U. output for chime circuit. Check chime, and harness between T.C.U. and chime. N.G. SEAT BELT SWITCHCIRCUIT CHECK 1. Unfasten driver's seat belt. 2. Check continuity between (j]) and @. 3. Fasten driver's seat belt. 4. Check to determine if continuity does not exist between (j]) and@. . ~oo W [ill + - Check seat belt switch circuit. O.K. Replace T.C.U. SEL643L EL-71 Check harness between T.C.U. and seat belt switch. TIME CONTROL SYSTEM Trouble-shooting (Cont'd) T.C.U. OUTPUT FOR BELT WARNING CIRCUIT CHECK LAMP switch PROCEDURE-7 Seat belt warning lamp does not go off nor comes on. Measure voltage across @ and @ when ignition DIAGNOSTIC is "ON". ~oo Go to "Power Supply Circuit Check". N.G. Check harness for T.C.U. power supply circuit. @ ~ooJ il~ 1 O.K. SEL651L Check T.C.U. oUtpUtfor belt warning lamp circuit. Voltmeter needle keeps sWinging (approx. 0 +-+ 12V) for about 7 seconds after ignition switch is turned ON. 1 O.K. Check warning lamp, and harness between T.C.U. and warning lamp. EL-72 N.G. Replace T.C.U. TIME CONTROL SYSTEM Trouble-shooting T.C.U. OUTPUT FOR CHIME CIRCUIT CHECK Measurevoltageacross@ and@ when driver's door is opened and closed. ~oo w . DIAGNOSTIC PROCEDURE-8 Ignition key warning chime does not activate. Go to "Power Supply Circuit Check". I Check harness for T.C.U. power supply circuit. I Checkkey Check key switcQ circuit~ switch or harness. I O.K. Approx. 12Vwhen Check T.C.U. output for chime circuit. SEL639L DOOR SWITCH CI RCUIT CHECK Check continuity N.G.I O.K. driver's side door is opened. DRIVER'S (Cont'd) between @ and @. Check chime and harness . O.K., between T.C.U. and chime. N.G. N.G ' .~ Check driver's door switch circuit. I Check harness between T.C.U. . and seat belt switch. O.K. ~oo LaJ Driver's side door Replace T.C.U. / ... Open SEL640L KEY SWITCH CIRCUIT CHECK Measure voltage across @ and@. [it @ @ laJ @-~ 'A SEL641L \ EL-73 TIME CONTROL SYSTEM Trouble-shooting T.C.U. OUTPUT FOR REAR DEFOGGER CIRCUIT CHECK Measure voltage across @ and @ while operating rear defogger switch. = 1 2 3 4 5 6 7 8 9 10 1819 111213141516 @ @ lNJ [Y] + - . ~ DIAGNOSTIC PROCEQURE-9 Rear defogger does not activate, or does not go off. 00 Rear defogger (Co nt' d) Go to "Power Supply Circuit Check". switch ~ Rear defoggerswitch "N": Approx. 12V ON N.G. Check harness for T.C.U. power supply circuit. O.K. . "TIMER": Reardefogger switch Approx.OV Check T.C.U. output for rear defogger circuit. SEL644L O.K. defpgger relay. N.G. DEFOGGER SWITCH CIRCUIT CHECK Check rear defogger relay, and harness between T.C.U. and rear N.G. Check defogger switch circuit. [ilOO 0 t @. ~d- j . Rear defogger switch "OFF": Except on Rear defogger switch "TIMER": on O.K. Check defogger switch, and harness between T.C.U. and defogger switch. "f' I Replace T.C.U. SEL645L -, EL-74 I WIPER ~: ~: anti-lockbraking system With Cill:@ ~ UP * ~ LG @:@I~I Without anti-lock braking system L r o",rlll 111"'"''' 111 I J / (MaIn harness) ~ S. M.J. WIPER (Eng I ne @ .r -= m r- ~ I ffiefer to last page (Fo I dout page). J room harness) LG/B LG PU PAIl B L/Y LG OR LG~B LG/R ..... UI AI0 012 BI2 BIO BII i i LG/B LG PU P B L/Y ,L @])@ WIPER ([@) MOTOR WASHER ~M BR LG/B L/Y @ ~LG ~ P I LGfR PU [] SWITCH OFFINT LO HI WASH 13 0 14 0 IS 16 17 18 19 20 111 en m r U1 OJ OJ s: @)@@) BODY GROUND AND WASHER ( ( c c 0 ,.... i' 1 0 REAR WIPER I GNI T1 ON SWITCH ACC or ON AMP. [;] UP * I IDA ,~ r- ~~ @ r-r-r-r... °"',,'" ::a~u~ FUSE BLOCK (Refer to "POWER SUPPLY ROUTING".) (Main harness) @ill) L/W ~ ~ (Back L/W harness) :[ Lg~R . l?§: 0 Lg~R (@})@) m r- L/W I (Eng I ne harness) ..... en rr-", "~... room I::"l L/W (Main harness) LG/B~LG/B S. M. J. ffiefer to last page (Fo I dout page). J B -B.3 ffi~@ L/R R/Y ' To I I I um I nat Ion contro I system, [ L @])A~@A(@) ~~ ~~ - - (/) m r a> " ~ ~ BODY REAR WASHER MOTOR @ LGB"B R/LI ~@ GROUND B door le.~ ~ 2 ~3 4 @ L~W Lg~R @@ WIPER AND WASHER Wiper Removal and Installation rP.J : N.m (kg-m, ft-Ib) SEL410L FRONT WIPER REMOVAL '; Before removing front wiper motor link, turn wiper switch OFF and disconnect motor leads at connectors. 1. Remove wiper ,arm. 2. Remove cowl cover. 3. Remove bolts which secure wiper motor. , 4. Extract wiper motor so that wiper motor link comes out of hole in front cowl top panel. Then, pull motor straight;out to disconnect ball joint which connects motor link and wiper link. Wiper motor can then be removed. SEL411L 5. Remove wiper link pivot blocks on driver and passenger sides. 6. Extract wiper link and pivot blocks (as one unit) from oblong hole on left side of cowl top. Pull straight ahead. .. ~ r FRONT WIPER INSTAllATION ,\ "" ~ l ~ .:. Wiper motor link ~ Cowltop front panel Insert securely. 1. Position wiper link and pivot blocks (as one unit) in cowl top through oblong hole. 2. Before installing pivot blocks on cowl top, hold end (motor link side) of wiper link at hole in front cowl top panel and insert motor link's ball pin into hole in wiper link. 3. Install front wiper in reverse order of above removal procedures. Apply a small amount of grease to ball joints before installation. . /' SEL412L EL- 77 WIPER AND WASHER ~ 3.7 -5.0 N.m 1 (0.38 - 0.5f kg-m, 2.7 - 3.7 ft-Ibl /~ -"-"~ / Rear wiper motor SEL413L Wiper and Washer Adjustment J INSTAllATION 1. Prior to wiper arm installation, turn on wiper switch to operate wiper motor and then turn it "OFF" (Auto Stop). 2. Lift the blade up and then set it down onto glass surface to set the blade center to clearance "L1" & "L2" immediately before tightening nut. 3. Eject washer fluid. Turn on wiper switch to operate wiper motor and then turn it "OFF". 4. Ensure that wiper blades stop within clearance "L1" & "L2". Clearance "L/': 17.5 - 32.5 mm (0.689 - 1.280 in) Clearance "L2": 25 35 mm (0.98 - 1.38 in) Tighten wiper arm nuts to specified torque. Front wiper: 17 - 23 N.m (1.7 - 2.3 kg-m, 12 - 17 ft-Ib) Rear wiper: 13 - 18 N.m (1.3 - 1.8 kg-m, 9 - 13 ft-Ib) - . *1: *2: *3: *4: *5: *6: *7: *8: 50 (1.971 28 (1.101 43 (1.691 21 (0.831 144 (5.671 155 (6.101 273 (10.751 385 (15.161 0 Clearance Unit: mm (in) * All the diameters of these circles are less than 80 (3.151. *7 "L," Clearance" rt rr~~. Glass end '8 L1" £ ~ ~ SEL425L Glass end *1: *2: *3: *4: 93 85 38 25 (3.661 (3.351 (1.501 (0.981 Nozz~e1~b Unit: mm {inl SEL414L EL- 78 WIPER AND WASHER Wiper and Washer Adjustment (Cont'd) SEL415L . Before reinstalling wiper arm, clean up the pivot area as illustrated. This will reduce possibility of wiper arm looseness. SEL024J Washer Nozzle Adjustment . UsingTool (J36126),adjust windshieldwashernozzleto correct its spray pattern. Before attempting to turn the nozzle, gently tap the end of the tool to free the nozzle. ( This will prevent "rounding out" the small female square in the center of the nozzle. SEL117K Check Valve . reservoir ':;0 F'om . To A check valve is provided in the washer fluid line. Be careful not to connect check valve to washer tube in the wrong dir~ction. ~ D";'e c~ ".I~ .. SEL411H EL- 79 WIPER AND WASHER Wiper Amplifier Check Wiper relay ~~ 1. Connect as shown in the figure at left. 2. If test lamp comes on when connected to terminal @ and battery ground, wiper relay is normal. :4; Test lamp SEL6S1 I EL-80 . CIGARETTE LlGHTER A. S. C. D. STEERING SWI TCH ~ HORN RELAY ~ ~ ~ @~ SLl P RI NG - -- ~~~~~~~ ' +t= :, : 4 . . SET/COAST 0 SWI TCH HORN 0 ~=SWITCH- - n .~ fl . (3 = 0 SWITCH I :: ~ RES~ME/ACCEL I ~ I GNI TI AC , ( @~ 2 III 0 :oJ I ~ , I @ III P0 , :E '" ,, :E'III "''''''' ,. en (Ma In harness) @: :oJ , III @: III HORN- HIGH @ rr\--.@) m r-I 00 rJoIhite) ii ~ (Eng Ine room harness) rr\--. ~@) HORN- ii @J) @~ [D- G BODY ~: ~ ~: ~ @~I III ~[D-G -= EEHHE:EJ EHffiIrn@) III ~QD:oJ (Black) , @) GROUND ::r;::: ID:J ,m :Jc+ CD, me m3 CD :J c+ LOW .~ ' '" :E , III @ '" , :E Q0 :E o=:::IJo::::IJ FUSE [§ II '" III :oJ '" '" HORN FUSIBLE SWITCH en m r 0> .... "-I s= g@) t LlNK FUSE AND FUSIBLE LINK ,... ~ ~~~:o""""'" RD @ DECK DIN 0-c UP CASSETTE RAOI 0 ,- CODE ~ I~ ~ ~@ @1Mll~@ .... "",... III"" .. ~""""III ,.. ~>,... ~ ~~~ ,...~g g co :0 ".. ,... (Main harness) m rI co c.n @: Radio @): @: Cassette Active @: Except only type deck type speaker type MJII @)ii@JJ @ BODY GROUND @ @D @) @ III""":;; -<:IE rnl @ DOOR DOOR SPEAKER en m r 01 .... ~ ~ [D=ru ~I AMP.. UNIT . 11>'1 III III"":;; :IE (Ai tl.j~L/Y1 @ 0 @ill) ' [ L/W m' L. H. SPEAKER L. H. eM: .. ..,...:;; :IE ..,...,,:;; -<:IE mBR/W~ U BR ~ ~ DOOR SPEAKER R ~ @ill) L/W L/Y i LG l';' .:1 ~ BR/W LG (Door harness L. H.) (Door harness R. H. ) BR I~ o. AMP. UNI T AUDIO AND ANTENNA Location of Antenna L ~~ Loosen~~ Main feeder cable ~2N~ (0.2 kg-m.1.4 ft-ibi J -- ~ ~,-( \\ ~1 \ \ \ \ \ \ \ \ \ \ \ \ \ \ )f/~. r[~ Radio (For AM/FM electronic tuning) SEL416L Radio Fuse Check \ ~ EL-86 AUDIO AND ANTENNA Window Antenna Repair ELEMENT CHECK 1. Attach probe circuit tester terminal on each side. (in ohm range) to antenna Ohmmeter [TI @ SEL2501 2. If an element is broken, no continuity will exist. Ohmmeter [TI @. ---' No continuity Continuity exist SEL251\ SEL2521 3. To locate broken point, move probe to left and right along element to determine point where tester needle swings abruptly. Ohmmeter [TI @ SEL2531 ELEMENT REPAIR Refer to REAR WINDOW DEFOGGER "Filament Repair". EL-87 I GNITI ON SWITCH ACC or ON I GNI TI ON SWITCH ON or START -@ FUSE FUSE A. s. C. D. OFFI A. S. C. D. STEERING SWI TCH N ON I SWITCH I I = RESUME/ACCEL SWITCH A. S. C. D. HOLD RELAY -=-=- To horn m A. S. C. D. 2 rI ~ ~ ~ ~ 7 co co 13 ::I0 mo --i::I mro ;oz 12 0 ;0 c Ct1 m » --i ~ a z ) CONTROL 3 I UNIT 10 CANCEL SWITCH 4 11 I A. S. C. @ I 5 9 8 -r-' To 8 D. CLUTCH SWITCH A. S. C. D. ACTUATOR 6 i I Iu control A/T CONTROL UNIT -=- ~ -=- SPEED SENSOR To i IlumlnatiOn control rJ) m r <.n CX) '" ~ -=- system -=[ 0, A/T @' M/T @), With @), Witho @' With syst @' Witho syst AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.) Wiring Diagram ~ 0 0 E C C1 +' C1 'v .-p P", c >- "'"' '" C COMBINATIONMETER :J C 0'.c~ .c~ +'''' P'" .- L .- L :;:D :;:D ~'" :;:.. V)>-V) Z OL ~o >-~z zo CJ ~.. Z CJ - -", ,>-", P I 0 >-->-- I 0 >-~Z :;:0 V) L ZO 0 ~O >--0 ~ E 0 V OP ~ 1_~~ @@ HEAD-UP 10 ILL 01SPLA Y CONTROL UNI ~ ' 3 3 ILL II .1 (LIQUID CRYSTAL> 20 ILL. ILL. . (LIQUID CRYSTAL> T I~I ~~~--~ @~ .", ~ CRUISE CRUISE 0~, "~~m :i ~~ m~ ~ ~0- " 0~l~~ , , '" ~bJ J J-TrT-III ~ ~ ~~- ~ ~ ~ m ~,,~ ~ - , @ m" ~ . -. ~ ~- @ '-a. I . I >'" m n I ~Til- lid U . - :J I V U .c - v v '" U U (J , , @~! bIIII ~~~~ m J U 111'4 b II E:j ~m :i:ild,,~~ ~ ~ ::; J ~~ ~ " Y/G 8 m I ~ --------- ~ . ~ r G/W -- G/R - R/G I ) " z <> W ~ I ..J >-- ti 0 . N I ~ WI..JI OI LO UJO 00 ~ ' ~~~~;::,~~ ;;:: ~ d ~ I 0 >-- UJ:;:..:;: UJ:;:0:;: , t [;!J ~ - [1] >-~ 5 ..J ' ~~! '-"''' ..~ 0O/R---o'" Z N >-:::J Ii'! U"> X-c ~~I @m """" @) @ . 0 II ~G/OR '~I' '-~I' A, . . Y/G R/G G/R S, C, 0, CLUTCH SWI T CH A, u; "' v C L '" r S, C. 0, U SWITCH CANCEL Q Q ~ffim~ u: ,{K)!j)Y/G-l3::! 'B:L '/G @ ~ ., G/W '--- O/B--o.. -NO<> " Ai: !!! @ @ ~ G/Y G/W SLI P RING O..J ~~~ O:::J ~ @ ~ ~ @ O/B---o'" @~ffi ( Ln.' , o~ LL LL <> ' ~ ' " ,: @ ,G/L--{'k Z 11 ~. "'~O~V)r~ L .~ .. I< I' r >-- ~ V) 0 0 U; . W ~ I, ., @@@@ ~111,d~IIE:j I is >-- >-- P P (Black) m V +-' ~ ~ rrr harness) 0 m (White) @~I,~II,II~ nstrument I (j I UB- (' V) V) u; < SE L590M EL-89 AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.) A.S.C.D. Wire Adjustment A.S.C.D. wire f".- .~r -- ~ SEL419L CAUTION: . . Be careful not to twist A.S.C.D. wire when removing it. Do not tense A.S.C.D. wire excessively during adjustment. After confirming that accelerator wire is properly adjusted, adjust the tension of A.S.C.D. wire in the following manner. (1) After adjusting the length of the accelerator wire, turn a securing nut by 1/2 to 1 turn from throttle open starting position to the wire loosening direction to fix. (Must be securing carried out to prevent response delay of operation of the A.S.CD.) (2) Securely tighten lock nut to hold adjusting nut in place. For A.S.C.D. stop switch and clutch switch adjustment, refer to SR and CL sections. . EL-90 AUTOMATICSPEED CONTROL DEVICE (A.S.C.D.) Trouble Diagnoses DIAGNOSTIC PROCEDURE Symptom A.S.C.D. control unit cannot be set properly. 1 Resume switch will not operate. 2 Cancel switch will not operate. 3 Engine hunts. 4 Large difference between set vehicle speed and actual speed. 5 Set speed cannot be cancelled. 6 A/T model only 8 When A.S.C.D. is set while vehicle is operating in "0.0." range, 0.0. will be cancelled and shifting to 0.0. cannot be made thereafter. 8 0.0. will not be cancelled even if actual vehicle speed is 6 km/h (4 MPH) lower than set speed. (Set speed cannot be ,maintained.) 8 0.0. will not be cancelled even if accelerator switch is turned "ON". 7 PREPARATION FOR TROUBLE-SHOOTING 1. Remove R.H. dash side cover. 2. Remove A.S.C.D. control unit with harness connected. 3. Perform check from harness side using circuit tester, with harness connector connected. A.S.C.D. control unit Q)I ~ R.H. dash side ~ SEL418L GROUND CIRCUIT CHECK . Check continuity between CID and body ground. EL-91 AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.) Trouble Diagnoses (Cont'd) DIAGNOSTICPROCEDURE-1 A.S.C.D.control unit cannot be set properly. POWER SUPPLY CIRCUIT CHECK 1. Turn A.S.C.D. main switch to "ON". 2. Check voltage between @ and CID. ~oo Turn A.S.C.D. main switch "OFF" and then "ON" to make sure indicator illuminates. Check indicator bulb, A.S.C.D.. main switch and hold relay. O.K. Approx. (4) @ 12V Check AS.C.D. power supply harness. Check power supply circuit for A.S.C.D. control unit. [Y] O.K. Voltmeter Check cut-off circuit for A.S.C.D. control unit. CUT-OFF CIRCUIT CHECK 1. Step on brake pedal. 2. Turn A.S.C.D. main switch to "ON". 3. Check voltage between (j]) and CID. O.K. N.G. Check AS.C.D. cancel switch, clutch switch (M/T model), inhibitor relay and inhibitor switch (A/T model). [ilOO :11 Approx. 12V Brake pedal Step on. Check A.S.C.D. set switch circuit for A.S.C.D. control unit. Voltmeter O.K. SEL629L Check speed sensor circuit. SET SWITCH CIRCUIT CHECK 1. Push A.S.C.D. set switch. 2. Check voltage between @ and CID. @ Approx. @ O.K. [iI@a Check actuator. Refer to "Actuator Check". l5J O.K. Voltmeter Replace A.S.C.D. control unit. SPEED SENSOR CIRCUIT CHECK 1. Disconnect speed sensor from transmission. 2. Connect a voltmeter between (j) and CID. 3. Slowly turn speed sensor by hand to make sure voltmeter pointer deflects. . Voltmeter pointer deflects twice per rotation of pinion. ~@a J~\ Lfi-J Approx.O.5V Voltmeter SEL630L EL-92 N.G. Check AS.C.D. set switch and harness betWeen control unit and set switch. Check speed sensor and harness betWeen A.S.C.D. control unit and speed sensor signal output terminal of combination meter. Replace actuator. AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.) Trouble Diagnoses (Cont'd) DIAGNOSTIC PRESUME SWITCH CI RCUI T CHECK 1. Turn resume switch to "ON". 2. Check voltage between CD and@ PROCEDURE-2 Resume switch will not operate. . N.G. Check resume switch circuit. rilOO Q) 1 Check resume switch. O.K. Replace A.S.C.D. control unit. ::~rox. @ lilJ [YJ Resume-switch - ON + Voltmeter SEL636L / DIAGNOSTIC CANCEL SWITCH CIRCUIT CHECK 1. Turn cancel switch to "ON". 2. Check voltage between @ and @ or CD and @ . PROCEDURE-3 Cancel switch will not operate. Check cancel switch circuit. riI~ Q)or@ Approx. l ~~~ Voltmeter @ Cancel switch - ON O.K. Replace A.S.C.D. control unit. j SEL637L EL-93 Check cancel switch. AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.) Trouble Diagnoses (Cont'd) DIAGNOSTIC PROCEDURE-4 Engine hunts. Check vacuum hose for Repair or replace hose. L breakage, cracks I or fracture. O.K. Does A.S.C.D.wire move smoothly? Repair or replace wire. O.K. Go to "Actuator Check". N.G. [ 4 Replace actuator. O.K. Replace A.S.C.D. control unit. DIAGNOSTIC / PROCEDURE-5 Large difference between set vehicle speed and actual speed. Check A.S.C.D. wire and actuator move smoothl y. N.G. Replace wire or actuator. O.K. Check vacuum hose for Repair or replace hose. breakage, cracks or fracture. O.K. Go to "Actuator Check". O.K. Replace A.S.C.D. control unit. EL-94 I~ I~ Replace actuator. AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.) Trouble Diagnoses (Cont'd) CUT-OFF CIRCUIT CHECK 1. Turn A.S.C.D. main switch to "ON". 2. Turn A.S.C.D. main switch to "ON" again. 3. Step on brake pedal. 4. Step on clutch pedal (M/T) or shift in "N" range (A/T). 5. Check voltagebetween CID and CID DIAGNOSTIC PROCEDURE-6 Set speed cannot be canceled. N.G. Check cut-off circuit. Check A.S.C.O. cancel switch, clutch switch (M/T model), inhibitor relay and inhibitor switch (A/T model). O.K. . \ ~ OV [JZJ + - ~oo 3 Brake pedal-> Step on. Clutch pedal (M/T)-> Step on. AfT control-> "N" range lever (A/T) CHECK Replace actuator. O.K. 1. Step on brake pedal. 2. Check voltage between @ and . CID Replace A.S.C.O. control unit ~ @ Check stop lamp switch and power supply harness. O.K. Check actuator. Refer to "Actuator Check". Voltmeter STOP LAMP CIRCUIT N.G. Check stop lamp circuit. ~ Approx. 12V [JZJ Voltmeter SEL631L O.D. CANCEL CIRCUIT CHECK FOR A.S.C.D. CONTROL UNIT 1. Turn 0.0. control switch to "ON" 2. MeasurevOltageacross @ and CID . DIAGNOSTIC PROCEDURE-7 AfT model only: . . . 0.0. control When A.S.C.D. is set while vehicle is operating in "O.D." range, O.D. will be cancelled and shifting to O.D. cannot be made thereafter. O.D. will not be cancelled even if actual vehicle speed is 6 kmfh (4 MPH) lower than set speed. (Set speed cannot be maintained.) O.D. will not be cancelled even if accelerator switch is turned "ON". switch -> ON Check 0.0. cancel circuit for A.S.C.O. control unit. O.K. Voltmeter SEL640M Replace A.S.C.O. control unit. EL-95 N.G. Check harness betWeen0.0. cancel solenoid, 0.0. control switch and A.S.C.O. control unit. AUTOMATIC SPEED CONTROL DEVICE (A.S.C.D.) Actuator Check 18 ~ '~~ [ill - DISCONNECT 1. Disconnect connector of actuator from main harness. 2. Check actuator operations as shown. + Check actuator. ~ -1'0 234 ~ '\ ~ ~ O.K. m / \ /J Release valve Air valve Vacuum valve ~ SEL423L Check to see if motor starts when 12V D.C. is applied across CD m N.G. Replace actuator. and @. O.K. ~ Ii) Check to see if A.S.C.D. wire is pulled when 12V D.C. is applied across CD. CV.:IDand @ . Check to see if A.S.C.D. wire I;) Replace actuator. O.K. (Wire is pulled.) [!) SE L691 L N.G. returns to original position 50 to 60 seconds after disconnecting lead from @ . N.G. ~ I O.K. (Wire does not return.) (;] Disconnect lead from CD to see N.G. if A.S.C.D. wire returns immediately. ~ O.K. (Wire returns.) SEL692L Replace actuator. ! Actuator is O.K. [!) ~ SEL693L (;] ~ SE L694L EL-96 Replace actuator. [ 1/ LOCATION OF ELECTRICAL UNITS Engine Compartment ~ [AJ Accessory relay-2 (Blue) A.S.C.D. hold relay (Blue) Air conditioner relay U.S.A.: FRONT [eJ BrOwn (Canada: Blue ) ( '~ ~ ~";' f?' ,/ I Fuse block Z /~ ' ~ I ~ Headlamp 11 E:~eadlamp retract relay-2 "/ (Black) Headlamp retract (Black) retract relay-3 relay-1 Horn relay (Black) SEL420L EL-97 LOCATION OF ELECTRICAL UNITS Passenger Compartment Accessory relay-1 E.C.C.S. control unit (Blue) Circuit breaker Ignition relay With power window: Brown Without power window: Blue) Bulb check relay (Blue) Rear window defogger relay (Black) S.M.J. A.S.C.D. control unit \I ( AfT control unit Door lock timer ~ / -- Combination flasher unit Chime A.S.C.D. cancel switch Stop lamp switch Headlamp timer Shift lock control unit Time control unit Automatic seat belt control unit Q SEL421L EL-98 HARNESS LAYOUT Outline Back door harness Fastback Rear wiper sub-harness Room lamp harness Doo~ harness R.H. . Instrument harness Engine room harness \ Engine room harness no. 2 E.F.I. harness. SEL496L Coupe Sun roof harness Room lamp harness. Door harness R.H. Instrument harness Engine room harness .D Door harness L.H. Engine room harness no. 2 SEL496L EL-99 HARNESS LAYOUT Main Harness / EL-100 @ @ @ @ @) @ @ @ @ @ @ @ @ @ @ @ @ @ @ @ @) @ @ @ @ @ @ @ @ @ @ @ @ @ @ @) @ @ @ @ @ @ @ @ @ m rI ~ 0 ~ en m r UI CD ~ s: : Time control unit : Headlamptimer : Check connector : Warningchime : Fuse block : Accessoryrelay-' : Circuit breaker (Modelwith power window system) : Circuit breaker (For U.S.A.I : Ignition relay (Modelwith power window system) : Ignition relay (Modelwithout power window system) : To engine room harness 0 : To engine room harness (Blue) : To engine room harness ([ill) (Black) : Bulb check relay : Rear window defoggerrelay : A.S.C.D.clutch switch (M/T model with A.S.C.D.I : To door harness L.H. @) : To door harness L.H. @ : Drillerside front limit switch (For U.S.A.) : Kickdownswitch (A/T model) : A.S.C.D.cancel switch (Modelwith A.S.C.D.I : Stop lamp switch : A.S.C.D.main switch (Modelwith A.S.C.D.I : Headlampretractor switch : Illuminationcontrol switch : Front fog lamp switch : Shift lock control unit (A/T model) : Combination flasher unit : Modedoor motor : Foot lamp L.H. : O.D. off indicator lamp (A/T model) : Rear wiper and washer switch : Rear window defoggerswitch : Hazard switch : Radio : Radio : Cassettedeck : Cassettedeck : Push control unit : Fan switch : Diode : To sub-harness @ : To main harness @ : Glovebox lamp : Glovebox lamp switch 0 @ @ @) @ @ @ @ @ @ @ @ @ @ @) @ @ : : : : : : : : : : : : : : : : Diode To instrument harness @ (Black) To instrument harness @(White) Thermo control amplifier Heater resistor Blowermotor Foot lamp R.H. To E.F.I. harness @ To door harness R.H. @ill) To door harness R.H. @ill) To room lamp harness @ Body ground Intake door motor To sub-harness @ To main harness @ Door lock timer Washerwarninglamp (Modelwith Anti-lock Brak @ Lighting switch ~ Front fog lamp switch ~ Brake warning lamp Brake fluid level switch Parking brake switch Seat belt warning lamp / r ~ I Retractor re Headlamp ti Lighting swi L- Headlamp R Bulb check Time control L- Seat belt sw Bodygro""~ \ m rI ...a 0 N ~ : : : : : : : : : : : : : : : : (§Y : (§j) : (§3) : @@) : (§9 : ~ : e : (§V : ~ : (§V : ~ : (§D : § : @9 : ~ : ~ : @ill) : ~ : (§!) : ~ : @£) : : Body ground Lap belt buckle switch (For U.S.A.) Seat belt switch (For Canada) Ash tray illumination Cigarette lighter Door mirror control switch Automatic seat belt control unit (For U.S.A.) Parking brake switch AfT device (AfT illumination and O.D. control switch) (AfT model) Shift lock solenoid (AfT model) Door switch L.H. Automatic seat belt motor assembly L.H. (For U.S.A.) Body ground (For U.s.A.) Body ground Rear speaker L.H. Rear side marker lamp L.H. Rear combination lamp L.H. ~ m rI ...a 0 Co\) ~ C/J m r- U1 II) 0 s: Rear combination lamp L.H. Back-uplamp L.H. Rear wiper amplifier Licenselamp L.H. Licenselamp R.H. Body ground Luggageroom lamp switch Back-uplamp R.H. Luggageroom lamp Rearcombination lamp R.H. Rear combination lamp R.H. Rear side marker lamp R.H. Fuel tank gaugeunit Rear speaker R.H. To back door harness @ill) To back door harness ~ To back door harness @ Automatic seat belt motor assembly R. Door switch R.H. A.B.S.control unit (For Anti-lock Brak Body ground (For Anti-lock BrakingSy Rear sensor (For Anti-lock BrakingSys m r-I ...\ 0 ~ -- @: ~ ~ @B) : ~ : @9 : @lJ : ~ : @V : ~ : @i) : @3) : @ill) : (§) : @l7) : ~ ~ : : ~ : : @ill) : (§3) : @ill) : ~ : @B) : @@) : § : : @ : ~ : @ : : Body ground Lap belt buckle switch (For U.S.A.) Seat belt switch (For Canada) Ash tray illumination Cigarette lighter Door mirror control switch Automatic seat belt control unit (For U.S.A.) Parking brake switch AfT device (AfT illumination and a.D. control switch) (AfT model) Shift lock solenoid (AfT model) Door switch L.H. Automatic seat belt motor assembly L.H. (For U.S.A) Body ground (For U.S.A.) Body ground Rear speaker L.H. ~ 0 ~ m ,... I ~ 0 U'I en m r (II 00 s: -------- Rear side marker lamp L.H. Licenselamp L.H. Licenselamp R.H. Body ground Rear side marker lamp R.H. Fuel tank gaugeunit Rear speaker R.H. Automatic seat belt motor assembly Door switch R.H. Trunk room lamp switch Trunk room lamp High-mountedstop lamp Rear window defogger Rear combination lamp L.H. Rear combination lamp R.H. Not used HARNESS LAYOUT Instrument Harness CID : To main harness @ (Black) @ : To main harness @ (White) @ : Head-updisplaycontrol unit @: @: @: Combination meter (Model with head-up display) Combination meter (Model without head-up display) Combi nation meter (Model with head-up display) QD : @ Combination meter (Model without head-up display) : Combination meter (Model without head-up display) EL-106 SE L501 L HARNESS LAYOUT NOTE ~ EL-107 HARNESS LAYOUT Engine Room Harness 'U C ::I 0 ..01 > 'U 0 ID EL-108 @ @ @ @ @ @ . : : : : : : @ : To E.F.I. harness @ (Brown) @D : @ : @ : @ : @) : @ m r-I @ @ @) @ @ @ @ @': @ @ @ @ @ @ @ @ @ @ @ Windshield wiper motor A.S.C.D. actuator (Model without Anti-lock Braking System) Rear washer motor Front washer motor Washer fluid level switch To E.F.I. harness @ (White) To engine room harness no. 2 (@D (MfT model) Inhibitor switch (AfT model) Revolution sensor (AfT model) Inhibitor switch (AfT model) (Gray) To solenoid valve sub-harness (AfT model) (Brown) : Relay box (Refer to page EL-97.J @ @ 0 @ : To engine room harness no. 2 ~ : Body ground @D @) @ @ @ @ : : : : : : @ : To engine room harness no. 2 @ : To engine room harness no. 2 Low.pressureswitch Battery .Battery Bodyground Clutch interlock relay (MfTmodel for U.S.A.) Front side marker lamp R.H. @ @ @ @ @) @ @ ~ 0 CD ~ en m r UI (XI I\) ~ : : : : : : : : : : : : : : : : : To front fog lamp sub-harness@ HeattlampR.H. Headlamp motor R.H. Front combination lamp R.H. Horn-high Condenserfan motor Horn-low Headlamp motor L.H. Headlamp L.H. Front combination lamp L.H. Front side marker lamp L.H. Body ground Relay box (Refer to page EL~7.1 Dropping resistor (AfT model.) Compressor A.I.V. control solenoidvalve Brake fluid levelswitch Windshieldwiper amplifier (Modelwithout A : To engine room harness : Front fog lamp R.H. @ : Front fog lamp L.H. : : : : : Front wheel sensor L.H.(For Anti-lock Bra Body ground (For Anti-lock BrakingSystem Actuator (For Anti-lock BrakingSystem) Windshieldwiper amplifier (Modelwith Ant A.S.C.D.actuator (Modelwith Anti-lock Br m rI ..a ..a 0 , @) "'P ~~ ~ 0 (@j) 1t.7ii'\ ~ 0 0 E112 El11 @j) : @3) : 0 0 B (fJ m : : : To main harness @ To main harness @ (Blue) To main harness @ (Black) Clutch switch (M/T model for U.S.AJ Key lock solenoid (AfT model) Key switch r- @!) : (@Y : gnition switch ~ 0: @ UI CD N ~ ombination switch : C mbination switch ([8) 0 ~ 0 @Y @ @ @ : To main : E.C.C.S : To engi (AfT mo : To engin Body ground @ (MfT mo : To engine : To engin : To engin : F.I.C.D. m r- -' -'-' I en m r UI co W ;: @) : @ : @ : @ : @) : @ : @ : @ : @ : @ : @ : @) : @) : @ : @ : @ : @) : @ : @ : @ : @ : @ : @ @ / A.A.C.va Injector n Air regula Injector n Pressurere S.C.V. con Exhaust g Injector n Injector no Enginegro Crank ang Enginetem Thermal tr Throttle v Throttle se E.G.R. con Air flow m Resistor Condenser Ignition co Power tran Front whe (For Anti-l : Body groun : Air tempera m rI ...a ...a N @D : To engine room harness @D (M/T model! ~ : To engine room harness @ ~ : To engine room harness @ @! : To engine room harness @ : Battery @) : Power steering oil pressure switch @V : Alternator : Oil pressure switch @J : Starter motor @!9 : Exhaust gas temperature sensor @ : Vehicle speed sensor : Back-up lamp switch (M/T model! ~ ~ ~ ~ en m r 01 0 .... r : Neutral switch (M/T model! @!9 : 5th position switch (M/T model! HARNESS LAYOUT Back Door Harness @D (Qlli) @ill) ~ : : : : : : @ : @D : ~ : @ill) : ~ ~ To main harness @ill) To main harness ~ To main harness @E) Rear window defogger High-mounted stop lamp To rear wiper sub-harness @D (White) (Brown) To rear wiper sub-harness To back door harness ~ (White) To back door harness @ (Brown) Rear window wiper motor ~ SEL505L EL-113 Body ground ) m r- -'-' ~ I In m r U1 0 ~ r Room @ : @) : @ : @ : (~ : @ : @ : lamp harness To main harness @ To sun roof harness @ Spot lamp (Model with sun roof) Interior lamp (Model without sun roof) Interior lamp (Fastback with sun rootl Interior lamp (Coupe with sun roof) Automatic seat belt front limit switch (For U.S.A.) Sun ro : @ : @ : @ : @ : @ : @ : @ : @ HARNESS LAYOUT Door Harness L.H. @ @ @ @ @ @ : : : : : : To main harness @ To main harness @ Door speaker (Active speaker type) Door speaker (Standard speaker type) Door mirror motor Power window regulator @) @ @ @ @ @D : : ; : : Power window main switch Power window amplifier Door lock actuator Door lock switch Door latch switch (For U.S.A.) SEL503L R.H. ~ 0 ~8 .@ill)~ @B @§) @§) 8 ~ : To main harness @ : To main harness @ : Door speaker (Active speaker type) : Door speaker (Standard speaker type) : Door mirror motor @ : : .~ : @:IV : @IV : ~ EL-115 Power window regulator Power window sub switch Door lock actuator Door lock switch Door latch switch (For U.S.A.) SEL504L HARNESS LAYOUT NOTE j l, ~ r l, , I ~ r I I EL-116 SUPER MULTIPLE JUNCTION (S.M.J.) Disconnecting and Connecting . . S.M.J. is located on left side of dash. To disconnect S.M.J., loosen fixing bolt. . To install S.M.J., tighten bolts until orange "full-tight" mark appears and then retighten to specified torque as required. ~: 3 - 5 N.m (0.3 - 0.5 kg-m, 2.2 - 3.6 ft-Ib) CAUTION: Do not overtighten bolts, otherwise, they may be damaged. S.M.J. SEL422L ~ EL-117 SUPER MULTIPLE JUNCTION (S.M.J.) Terminal Arrangement MAIN HARNESS / \ AlA2A3A4ASA6 A7A8A9AliA11A12 BIB2B3B4BsB6 CIC2C3C4CsC6 01 02 El E2 Fl F2 Gl G2G3G4GsG6 HIH21H3 H4HsH6 11121314IS16 B7B8B9BID B11B12 C7C8C9CID C11C12 LJ 011 012 Ell E12 F11 F12 G7G8G9GlDG 11612 H7H8H9HID H11H12 171819IIDI11112 ~ ~ / ENGINE ROOM HARNESS l E.C.C.S. CONTROL UNIT [11 View from harness side EL-118 INCHTO METRICCONVERSION TABLE METRICTO INCHCONVERSION TABLE ~, " Circui t Diagram Engine and Emission Control Parts Air Temperature 4 ! Diagram" ................................... 65 7 Description .........................\............ ~ Sensor Engine and Emtssion Control System Description Igni tioll Timing Control Swirl Control Valve" (S.C. V.) Control Fail-safe System Idle Speed/Ignition Timing/Idle Mixture Ratio Inspection Trouble Diagnoses Self-diagnosis - Mode III (Self-diagnostic System) Diagnostic Procedure 8 Diagnostic Procedure ~lectrical Components Inspection 9 .11 .12 13 15 16 24 .,.19 21 ~ Service Data and Specifications ..~ Please reference this Bulletin on the Contents Sections of the 1989 24USXService Manual. 8 ;... .23 pages of the ,t EM and EF&EC f' *Vehicles .modified with an Air Temperature engine. Sensor 1/23 on the air cleaner box have the I ~ COMPRESSION -It' PRESSURE Measurement 1. 2. '3. 4. 5. of Compression Pressure Warm up engine. Turn igr;1ition switch off. Disconnect fusible link for injectors. Remove all spark plugs. Disconnect distributor center cable. f g 6. Attach a compression tester to NO.1 cylinder. 7. Depress accelerator pedal fully to keep throttle valve wide open. 8. Crank engine and record highest gauge indication. 9. Repeat the measurement on each cylinder as shown above. Always use a fully-charged battery to obtain specified engine revolution. . I Compression pressure: kPa (kg/cm2, psi)/rpm Standard 1,206 (12.3, 175)/250 Minimum 1,010 (10.3, 146)/250 Difference limit between cylinders 98 (1.0, 14)/250 SEM113B 10. If cylinder compression in one or more cylinders is low, pour a small amount of engine oil into cylinders through spark plug holes and retest compression. If adding oil helps compression, piston rings may be worn . . . I or damaged. If so, replace piston rings after checking piston. If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to S.D.S.) If valve or valve seat is damaged excessively, replace them. If compression in any two adjacent cylinders is low and if adding oil does not help compression, there is leakage past the gasket surface. If so, replace cylinder head gasket. ' ",. . 2/23 SERVICE DATA AND SPECIFICATIONS (S.D.S.) General oil' Specifications ~ " KA24E Engine model 4, in-line Cylinder arrangement Displacement em' leu in) Bore x stroke mm lin) 2,3891145.78) 89 x 9613.50 x 3.78) Valve arrangement O.H.C. Firing order 1-3-4.2 Number of piston rings Compression Oil Number of main bearings I Compression ratio 2 1 5 8.6 I Unit: kPa (kg/em' , psil/rpm Compression pressure Standard Minimum Differential limit between cylinders 1,206 112.3, 175)/250 1,010 (10.3,146)/250 98 (1.0,14)/250 ~ 3/23 L v.: 0\;, ;j ENGINE AND EMISSION CONTROL OVERALL SYSTEM E.C.C.S. Component Parts Location ~ E.C.C.S.control unit . E.C.C.S.relay, . Fuel pump relay Fuelpump E.G.R. control Exhaust gas temperature sensor (For California model) valve t~ Pressure regulator Pressure solenol regUla.~Or control valve' ~ ~ s.c.v.contrOI fijif~ ~ . I.A.A. un"it ~"o, Fuel filter ~ t9 Throttle sensorl Throttle valve switch Ignition coil and power transistor Throttle chamber Air temperature ~ ) E.G.R. control solenoid valve ~ iT Engine temperatu re sensor ankangle cr ~"'o, '"~ t Jec or , ~ o;?J ~ Exhaust gas sensor 4/23 sensor 1 0 Air flow meter SEF4601 -- E.G.R. control solenoid valve Exhaust gas temperature sensor \ (For California model) \ / 7 Ignition switch r Air regulator , , , Throttle valve 8a sensoi :-)" r--L J -, Ignition coil 01 --N W S.C.V. control--solenoid valve Cran k angle sensor built-in distributor Neutral switch (M/T) Inhibitor switch (AfT) ( , Fuel pressure regulator / / valve Engine Transmission g = '\ I Swirl control""'" "- Spark plug j {} temperature sensor Carbon canister ':;. speed Vehiclesensor Exhaust gas sensor " A.I. V. control solenoid valve A.I.V. en m "~ C> , Q : Intake air flow .. : Exhaustgasflow - Air flow me ENGINE AND EMISSION CONTROL OVERALL SYSTEM E.C.C.S. CONTROLSYSTEM Crank angle sensor I Engine temperature I .1 I Air flow meter I sensor 'System Chart I I .I I I I I I I Exhaust gassensor I .1 Air temperature sensor I ~. Ignition switch J Idle switch I I I Throttle sensor I Canister control& E.G.R. control ~ control E.C.C.S. unit I switch I ~ I ~ I )1 Auxiliary air control (A.A.CJ valve )I AJ.V. control solenoidvalve ~ valve E.G.R.control solenoid AJ.V. control ~I I Idle speed control Fuel pump control Air conditioner Injectors )f Power transistor Ignition timing control I ~ I ~ ~ ~I --1 [ Starter switch I mixture ratio control I I I Fuel injection& I I - ,/1 Fuel pump I f I I Air regulator control ~ Air regulator I Neutral Inhibitor switch switch (M/T) (A/T) I Vehicle speedsensor I Power steering oil pressure I , switch [ Battery I ~I ~ I I Acceleration cut control I S.C.V.(Swirl control I valve) control I ~I I monitor Exhaust & gasself-diagnosis sensor I ~I I Pressu reregu Iator ~ ~ ~ Air conditioner relay S.C.V.control solenoid valve (On the control Inspection lampsunit) r-Exhaust gas temperature (For California model) sensor Pressure regulator control solenoid valve control Fail-safe function 8 8 Air flow meter Throttle sensor 8 8 Engine temperature sensor Air temperature sensor 6/23 ~ I ( IGNITION FUSIBLE LINK SWITCH CHECK CONNECTOR r- OFFIACCION I ST {8J- -@ CHECK ENGINE LI GHT@ FUSE f--1S} >34 382336 -0 E. C. C. s. I ...:-. iii RELAY 1 SATTERY - 46 5 24 10 I 25 INJECTOR ~ ~ ~ ~ U ffi3 PRESSURE REGULATOR CONTROL 106 SOLENOID 110 105 103 112 SOLENOID VALVE A. 1. V. CONTROL 102 SOLENOID VALVE S. C. V. CONTROL 4 -=- VALVE E. G. R. CONTROL 12 47 SOLENOID VALVE 109 16 17 I ~--_m-7 I A~~E~LOW 113 To tachometer -=- ~ n---__n_-1... '-.I -.... I\.) W m48 P 1] 6 P "'p 1 Y' 6 RESISTORm _n--nn ( $ -= -= 0 -= -= @ : For (0 : A/T model @ en m "T1 ~ C'I '" : 13 n 0 Z --i ;u 0 r @: A/T model @: ~: A/T mode With ~: Without I head-up THROTTLE VALVE SWITCH SWITCH ~LL IDLE --i 4] 11 .,!,. S ENS 0 R EXHAUST GAS TEMPERAl.URE SENSOR (g I'.tI AIR TEMPERATURE SENSOR 26 115 H --~:::::::::::::::~ 37 A. S. C. D. ENGINE TEMPERATURE 21LL 29 For U.S.A. display POWER STEERING OIL PRESSURE 35 display head-up 5TH POSITION -=- 20 wi thout 'R 44 33 I @: with ~=~ ~SWITCH 43 CONDENSER ANGLE SENSOR @: INHIBIr -=- = Ca I Iforn Ia M/T modeI PUMP 45 c z cn__m_-T CRANK SPARK PLUG n_- RELAY AIR REGULAT~ FUEL !'1 3 L INHIBITOR SWI TCH @ A.A.C. VALVE -a 107 19 ~:~ ~~ [ff:i!I:i: 104 39 EXHAUST GAS SENSOR a a a a - A/T CONTRQL UNIT ~ 0 SPEED SENSOR - ENGINE AND EMISSION CONTROL PARTS DESCRIPTION Air Temperature Sensor The air temperature sensor is used to control ignition timing when the temperature of the intake air is extremely high, in order not to cause predetonation. ~ +~I SEF1651 ~. ~ 8/23 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Ignition Timing Control ~ INPUT/OUTPUT SIGNAL LINE d E . Crank angle sensor I I Amount I 'ti on d Dist Air flow meter of intake air I Engine temperature Engine temperature Air temperature sensor Intake air temperature sensor Throttle Idle switch I E.C.C.S. control unit valve idle position Power transistor I Throttle valveopening angle I Throttle sensor I Neutral position Neutral switch (M/T) Inhibitor switch (A/T) Start signal I Ignition switch I ~ ~ 9/23 '-- / ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Ignition Timing Control (Cont'd) In addition to this, 1 At starting 2 During warm-up 3 At idle 4 At low battery voltage 5 During swirl control valve operates 6 Hot engine operation 7 At acceleration 8 When intake air temperature is extremely high the ignition timing is revised by the E.C.U. according to the other data stored in the ROM. SYSTEM DESCRIPTION The ignition timing is controlled by the E.C.U. in order to maintain the best air-fuel ratio in response to every running condition of the engine. The ignition timing data is stored in the ROM located in the E.C.U., in the form of the map shown below. The E.C.U. detects information such as the injection pulse width and crank angle sensor signal which varies every moment. Then responding to this information, ignition signals are transmitted to the power transistor. e.g. N: 1,800 rpm, Tp: 1.50 msec A °S.T.D.C. Tp (msec) 1.75i A 1.50I Injection pulse width 1.25i 1.00I 0.75 600 - - --- 1,400 1,000 1,800 - 2,200 N Engine speed (rpm) SEC750A 10/23 ~ ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Swirl Control Valve (S.C.V.) Control INPUT/OUTPUT SIGNAL LINE ~ Idle switch I Idle signal . Start signal . I Ignition I switch I Engine speed Crank angle sensor SYSTEM DESCRIPTION This system has a swirl control valve (S.C.V.) in the intake passage of each cylinder. While idling the S.C.V. closes. Thus the velocity of the air in the intake passage increases, promoting the vaporization of the fuel and producing a swirl in the combustion chamber. Because of this operation, this system tends to increase the burning speed of the gas mixture, improve fuel consumption, and increase the stability in running conditions. The solenoid valve controls S.C.V.'s shut/open condition. This solenoid valve is operated by the E.C.U. Idle switch Water temperature Engine rpm Solenoid valve S.C.V. ON Above 3SoC (9SoF) Below 1,800 ON Close OFF Open Except above . S.C.V. control solenoid valve Enginetemperature Engine temperature sensor ~ E.C.C.S. control unit This table shows the control when starting enginetemperatureis above 10°C (50°F). ~ 11/23 ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Fail-safe System ENGINE TEMPERATURE MALFUNCTION AIR FLOW METER MALFUNCTION If the air flow meter output voltage is above or below the specified value, the E.C.U. senses an air flow meter malfunction. In case of a malfunction, the throttle sensor substitutes for the air flow meter. Though air flow meter is malfunctioning, it is possible to drive the vehicle and start the engine. But engine speed will not rise more than 2,400 rpm in order to inform the driver of fail-safe system operation while driving. E.G.R. control system Operation Condition Fixed condition 20°C (68°F) More than 6 minutes after ignition ON or Start 80°C (176°F) OFF A duty ratio is fixed at the preprogrammed value. Fuel is shut off above Fuel injection control system THROTTLE 2,400 rpm. (Engine speed does not exceed 2,400 rpm.) Engine temperature decided Just as ignition switch is turned ON or Start Except as shown above Idle speed control system ~ When engine temperature sensor output voltage is below or above the specified value, water temperature is fixed at the preset value as follows: Operation System SENSOR SENSOR 20. 80°C (68. 176°F) (Depends on the time) MALFUNCTION When throttle sensor output voltage is below or above the specified value, throttle sensor output is fixed at the preset value. AIR TEMPERATURE MALFUNCTION SENSOR ~ When air temperature sensor is below or above the specified value, air temperature value is fixed at the preset value [20°C (68°F)]. ~ 12/23 .. .. - -- --~ -~~ IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION ( INSPECTION START ~ ) Visually check the following: . Air cleaner clogging . Hosesand ducts for leaks . E.G.R. control valve operation . Electricalconnectors . Gaskets . Throttle valveand throttle valveswitch operation I~~I Start engine and warm it up until water temperature indicator points to the middle of gauge. SEF457C 2 "" ~ )!' 1..! § 0:: Open engine hood and run engine at about 2,000 rpm for about 2 minutes under no-load. 3 4 ~,."..~",L../" 5 '~,.",,,,,,~,,,,,,. 5 ~ ~ ~ 1~ = 0: .""""Im;n 'v"-(6 ~~ \ ~1 ~ ~8 Run engine at about 2,000 rpm for about 2 minutes under no.load. I SEF477B ~~\ ~V Make sure that inspection lamp (Green) on E.C.U. goes IN.G. on and off periodically more than 5 times during 10 seconds at 2,000 rpm under no.load. O.K. j\.(r)J ~/~ Set the diagnosis mode of E.C.U.to mode II. Check inspection lamps (Red and Green) on E.C.U. blink at 2,000 rpm. They should blink simultaneously. Yes SEF450H ~r\ ~~ No INSPECTION END '--~(r) ) d~,/i~~ ~ SEF292H j D 14/23 @ c TROUBLE DIAGNOSES Self-diagnosis system) - Mode III (Self-diagnostic The E.C.U. constantly monitors the function of these sensors and actuators, regardless of ignition key position. If a malfunction occurs, the information is stored in the EC.U. and can be retrieved from the memory by turning on the diagnostic mode selector, located on the side of the E.C.U. When activated, the malfunction is indicated by flashing a red and a green L.ED. (Light Emitting Diode), also located on the E.C.U. Since all the self-diagnostic results are stored in the E.C.U.'s memory even intermittent malfunctions can be diagnosed. A malfunctionis indicated by the number of both red and green flashing L.ED.s. First, the red L.ED. flashes and the green flashes follow. The red L.ED. corresponds to units of ten and the green L.ED. corresponds to units of one. For example, when the red L.E.D.flashes once and the green L.ED. flashes twice, this signifies the number "12", showing that the air flow meter signal is malfunctioning. All problems are classified by code numbers in this way. . When the engine fails to start, crank it two or more seconds before beginning self-diagnosis. . Before starting self-diagnosis, do not erase the stored memory before beginning self-diagnosis. If it is erased, the self-diagnosis function for intermittent malfunctions will be lost. DISPLAY CODE TABLE Detected items Code No. I California NonCalifornia 11 Crank angle sensor circuit X X 12 Air flow meter circuit X X 13 Engine temperature sensor circuit X X 14 Vehicle speed sensor circuit X X 21 Ignition signal missing in primary coil X X 31 E.C.U. IE.C.C.S. control unit) X X 32 E.G.R. function X - 33 Exhaust gas sensor circuit X X 35 41 Exhaust gas temperature sensor circuit Air temperature sensor circuit X X 43 Throttle sensor circuit X X 45 Injector leak X - 55 No malfunction in the above circuit X X X: Available -: Not available , 15/23 X I TROUBLE DIAGNOSES E.G.R. FUNCTION (CodeNo.32) ~ Diagnostic Procedure 8 [Not self-diagnostic item (For non-Californiamodels)] E. G.R. CONTROL SOLENOID VALVE E. C. C. S. CONTROL UNI T @) Iij P ~ @)W "'''' -=<> Ii] _"XI I IDS-LG FUSE WJ B/R @)@) (E. F. I. harness) (Eng I ne harness) BR-' tBR room BR w BR~ I~ ~:~ ~ "1 2 3 4 5 ~