ranger drifter repair manual f161!10!99a

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Ranger / Drifter RepairManual

FOREWORD This Manual has been prepared to provide information covering normal service repairs and maintenance for the RANGER / DRIFTER SERIES. As all information in this manual was the best available at the time of printing, vehicle specification and other information will be updated in Service Information. Ford/Mazda Motor Company

WARNING Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Ford/Mazda-trained technicians in mind. This manual may be useful to non-Ford/Mazda trained technicians, but a technician with our service-related training and experience will be at less risk when performing service operations. However, all users of this manual are excepted at least to know general safety procedures. This manual contains "Warnings" and "Cautions" applicable to risks not normally encountered in a general technician's experience. They should be followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that the "Warnings" and "Cautions" are not exhaustive. It is impossible to warn of all the hazardous consequences that might result from failure to follow the procedures. The procedures recommended and described in this manual are effective methods of performing service and repair. Some require tools specifically designed for a specific purpose. Persons using procedures and tools, which are not recommended by Ford/Mazda Motor Corporation, must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized. The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Ford/Mazda Motor Corporation reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation. Parts should be replaced with genuine Ford/Mazda replacement parts or with parts, which match the quality of genuine Ford/Mazda replacement parts. Persons using replacement parts of lesser quality than that of genuine Ford/Mazda replacement parts must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized. Ford/Mazda Motor Corporation is not responsible for any problems, which may arise from the use of this manual. The cause of such problems includes but is not limited to insufficient service related training, use of improper tools, use of replacement parts of lesser quality than that of genuine Ford/Mazda replacement parts, or not being aware of any revision of this manual.

CONTENTS

Ranger / DrifterRepairManual

APPLICATION:This manual is applicable to vehiclesbeginning with the Vehicle IdentificationNumbers (VIN), and related materialsshown on the following page.

Title Section

General Information GI

Engine

Lubrication System

Cooling System

Fuel and Emission Control Systems

Engine Electrical System G

Clutch H

J1

Front and Rear Axles M

Steering System N

Braking System P

Suspension R

Body S

T

U

Body Electrical System

E

D

F1

ST

TD

Special Tools

Technical Data

Manual Transmission J2

M15M–DM15MX–DR15M–DR15MX–D

LPropeller Shaft

G6

WL, WL Turbo

F2

G6

WL, WL Turbo

J3Transfer

F2

F3F2 CIS

F4F2 CARB

Heater and Air Conditioner Systems

1999 Ford/Mazda Motor CompanyAll rights reserved. Reproduction by any means, electronic or mechanical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford/Mazda Motor Company.PRINTED IN JAPAN, JAN.1999F161–10–99A

TO. MODEL .INDEXPAGES. FROM. MANUALRANG.DRFT.REPAIR MANUALBACK TO FOREWORD & ENGINE INDEX

F8/FE

ST

GI

B1

B3

B2

VEHICLE IDENTIFICATION NUMBERS (VIN) U.K. specs.

JMZ UN1B320W 100001– JMZ UN8B320W 100001– JMZ UN8F420W 100001–

European specs. JMZ UN1*620W 100001– JMZ UN1*62WW 100001– JMZ UN1*320W 100001– JMZ UN1*32WW 100001– JMZ UN8*720W 100001– JMZ UN8*72WW 100001– JMZ UN8*320W 100001– JMZ UN8*32WW 100001– General specs. (L.H.D.) MM7 UNY02100 100001– MM7 UNY021WW 100001– MM7 UNYOW100 100001– MM7 UN2*6*00 100001– MM7 UN2*6*WW 100001– MM7 UN3*6*00 100001– MM7 UN3*6*WW 100001– MM7 UN2*2*00 100001– MM7 UN2*2*WW 100001–

General specs. (R.H.D.) MM6 UNY02100 100001– MM6 UNYOW100 100001–

RELATED MATERIALS B Series Training Manual .......................................... 3333-10-99A Engine Workshop Manual WL, WL Turbo ................ 1532-10-96C Engine Workshop Manual G6 .................................... 1640-10-99A Engine Workshop Manual F2 .................................... 1641-10-99A Manual Transmission Workshop Manual M15M-D M15MX-D .............................................................. 1645-10-99A Manual Transmission Workshop Manual R15M-D R15MX-D.................................................... 1642-10-99A B Series Wiring Diagrams (European, General specs. (L.H.D.)) ..................... 5449-10-99A B Series Wiring Diagrams

(European, General specs. (R.H.D.)) .................... 5450-10-99A

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CONTINUED

MM7 UNYOW1 WW 100001–

GI–1

GENERAL INFORMATIONHOW TO USE THIS MANUAL GI-1. . . . . . . . . . . . . . .

RANGE OF TOPICS GI-1. . . . . . . . . . . . . . . . . . . . . SERVICING PROCEDURE GI-1/2. . . . . . . . . . . . . . . SYMBOLS GI-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADVISORY MESSAGES GI-3. . . . . . . . . . . . . . . . . . TROUBLESHOOTING PROCEDURE GI-3/6. . . . . .

UNITS GI-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUNDAMENTAL PROCEDURES GI-8. . . . . . . . . . . .

PROTECTION OF THE VEHICLE GI-8. . . . . . . . . . PREPARATION OF TOOLS AND

MEASURING EQUIPMENT GI-8. . . . . . . . . . . . . . SPECIAL SERVICE TOOLS GI-8. . . . . . . . . . . . . . . DISCONNECTION OF THE NEGATIVE

BATTERY CABLE GI-8. . . . . . . . . . . . . . . . . . . . . . REMOVAL OF PARTS GI-8. . . . . . . . . . . . . . . . . . . . DISASSEMBLY GI-8. . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION DURING REMOVAL,

DISASSEMBLY GI-8. . . . . . . . . . . . . . . . . . . . . . . . . ARRANGEMENT OF PARTS GI-8/9. . . . . . . . . . . . . . CLEANING OF PARTS GI-9. . . . . . . . . . . . . . . . . . . REASSEMBLY GI-9. . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENT GI-9. . . . . . . . . . . . . . . . . . . . . . . . . . RUBBER PARTS AND TUBING GI–19. . . . . . . . . . . HOSE CLAMPS GI–19. . . . . . . . . . . . . . . . . . . . . . . . . TORQUE FORMULAS GI–10. . . . . . . . . . . . . . . . . . . . VISE GI–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DYNAMOMETER GI–10. . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION OF RADIO SYSTEM GI–10. . . . . . . . ELECTRICAL SYSTEM GI–11. . . . . . . . . . . . . . . . . . . . .

ELECTRICAL PARTS GI–11. . . . . . . . . . . . . . . . . . . . CONNECTORS GI–11/13. . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL TROUBLESHOOTING

TOOLS GI–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JACKING POSITIONS GI–14. . . . . . . . . . . . . . . . . . . . . . VEHICLE LIFT (2 SUPPORTS) POSITIONS GI–14. . . SAFETY STAND POSITIONS GI–14. . . . . . . . . . . . . . . TOWING GI–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TOWING HOOKS GI–16. . . . . . . . . . . . . . . . . . . . . . . . TIEDOWN HOOKS GI–16. . . . . . . . . . . . . . . . . . . . . . .

IDENTIFICATION NUMBER LOCATIONS GI–16. . . . . VEHICLE IDENTIFICATION NUMBER GI–16. . . . . . ENGINE IDENTIFICATION NUMBER GI–16. . . . . . .

NEW STANDARDS GI–17/19. . . . . . . . . . . . . . . . . . . . . . . . ABBREVIATIONS GI–19. . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO USE THIS MANUALRANGE OF TOPICS This manual contains the procedures for performing

all of the required service operations. Theprocedures are divided into the following five basicoperations.(1) Removal/Installation(2) Disassembly/Assembly(3) Replacement(4) Inspection(5) Adjustment

Simple operations which can be performed easilyjust by looking at the vehicle, such asremoval/installation of parts, jacking, vehicle lift,cleaning of parts, and visual inspection, have beenomitted.

SERVICING PROCEDUREInspection, Adjustment The procedures for inspections and adjustments

are divided into steps. Important points in regardto the location and contents of the procedures areexplained in detail and are shown in theillustrations.

SHOWS PROCEDURE ORDERFOR SERVICE

SHOWS TIGHTENING TORQUE SPECIFICATIONS

CONTINUED

TEXT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . GI-6

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-20 PRE-DELIVERY INSPECTION TABLE . . . . . . GI-20

PRE-DELIVERY INSPECTION. . . . . . . . . . . . . .GI

HOW TO USE THIS MANUAL

GI–2

Repair procedure1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit

together, and describes visual part inspection. However, only the removal/installation procedures which need tobe performed methodically have written instructions.

2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overviewillustration. In addition, symbols indicating parts which require the use of special service tools forremoval/installation are also shown.

3. The procedures are numbered and the part that is the main point of that procedure is shown in the illustrationwith the corresponding number. Occasionally, there are important points or information concerning a procedure.Refer to this information when servicing the related part.

SHOWS SERVICEITEM (S)

SHOWS TIGHTENINGTORQUESPECIFICATIONS

SHOWS PROCEDURE ORDERFOR SERVICE

SHOWS SPECIALSERVICE TOOL (SST)FOR SERVICE OPERATION

SHOWS APPLICATIONPOINTS OF GREASE, ETC.

SHOWS EXPENDABLE PARTS

SHOWS DETAILS

SHOWS TIGHTENINGTORQUE UNITS

SHOWS THEREARE REFERRALNOTES FOR SERVICE

SHOWS REFERRALNOTES FORSERVICE

Procedure

“Removal/Installation”Portion

Indicates any relevantreferences which need to befollowed during installation.

“Inspection After Installation” Portion

Install the partsby performingSteps 1—3 inreverse order

SHOWS SPECIALSERVICE TOOL (SST)NO.

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CONTINUED

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ST


GI–3

SYMBOLS There are eight symbols indicating oil, grease,

sealant, and the use of SSTs. These symbolsshow the points of applying or using such materialsduring service.

Symbol Meaning Kind

Apply oilAppropriate newengine oil orgear oil

Apply brake fluidAppropriate newbrake fluid

Apply automatictransaxle/transmissionfluid

Appropriate newautomatictransaxle/transmission fluid

Apply greaseAppropriategrease

Apply sealantAppropriatesealant

Apply petroleumjelly

Appropriatepetroleum jelly

R Replace partO-ring, gasket,etc.

SST Use SST Appropriate SST

ADVISORY MESSAGESYou’ll find several Warnings , Cautions , Notes ,Specifications and Upper and lower limits in thismanual.

Warning A Warning indicates a situation in which

serious injury or death could result if thewarning is ignored.

Caution A Caution indicates a situation in which

damage to the vehicle could result if thecaution is ignored.

Note A Note provides added information that will

help you to complete a particular procedure.

Specification The values indicate the allowable range when

performing inspections or adjustments.

Upper and lower limits The values indicate the upper and lower limits

that must not be exceeded when performinginspections or adjustments.

TROUBLESHOOTING PROCEDUREBasic Flow of Troubleshooting

SECTION F ONLY

SECTION F ONLY

ACTUAL TROUBLESHOOTING PROCEDURES

SECTION K ONLY

IFMENTIONED

On-board diagnosis The service codes are important hints for repairing

malfunctions that are difficult to simulate. Byfollowing the service code, perform the inspectionto quickly and accurately diagnose the malfunction.

The self-diagnostic function is used duringinspection. When a service code is shown,specifying the cause of a malfunction, continue theinspection according to the items indicated by theself-diagnostic function.

Engine tune-up (Section F) Any necessary adjustments are made after starting

the engine.

Basic inspection (Section K) The basic inspection is performed to quickly

narrow down the possible causes after amalfunction occurs regardless of the symptoms.The basic inspection is performed to also locatethe region of many malfunction symptoms.

Diagnostic index The diagnostic index lists the symptoms of the

malfunctions. Select the symptoms pertaining ormost closely pertaining to the actual malfunction.

Quick diagnosis chart (If mentioned) The quick diagnosis chart lists the diagnosis and

inspection procedures to be performed specificallyrelating to the cause of the malfunction.

Symptom troubleshooting Symptom troubleshooting quickly determines the

location of the malfunction according to the type ofsymptoms.


CONTINUED



GI–4

Procedures For UseUsing the basic inspection

Perform the basic inspection before the symptom troubleshooting. Perform each step in the order shown. The reference column lists the location of the detailed procedure for each basic inspection. Although inspection and adjustment are performed as according to the procedures referred to in the reference

column, if the cause of the malfunction is discovered during the basic inspection, continue the procedures asindicated in the remarks column.

SHOWS INSPECTIONORDER

SHOWS ITEM NAMES FORTHE DETAILED PROCEDURES SHOW POINTS REQUIRING

ATTENTION IN REGARD TO INSPECTION RESULTS

Perform malfunction diagnosis according to No. 26“HOLD INDICATOR LIGHT DOES NOT ILLUMI-NATE WHEN HOLD SWITCH IS TURNED ON” orNo. 27 “HOLD INDICATOR LIGHT ILLUMINATESWHEN HOLD SWITCH IS NOT TURNED ON”

Using the diagnostic index The symptoms of the malfunctions are listed in the diagnostic index for system troubleshooting. The exact malfunction symptoms can be selected using the details.


CONTINUED


ST


GI–5

Using the quick diagnosis chart The chart lists the relation between the symptoms and cause of the malfunction. The chart is effective in quickly narrowing down the relation between the symptoms and cause of the

malfunction and specifying the region of the common cause when multiple malfunction symptoms occur. The appropriate diagnostic inspection relating to the cause of the malfunction as specified by the symptoms can

be selected by looking down the diagnostic inspection column of the chart.

PART WHICH MAY BETHE SYMPTOM

PARTS WHICH MAY BE THE CAUSE OFPROBLEMS

CHOOSE THE ACTUALSYMPTOM

ENGINE QUICK DIAGNOSTIC CHART


CONTINUED



GI–6

Using the symptom troubleshooting

Symptom troubleshooting shows diagnosis procedure, inspection method, and proper action to take for eachtrouble symptom.

TROUBLESHOOTINGHINTS describespossible point ofmalfunction.

STEP shows theorder oftroubleshooting.

INSPECTIONdescribes aninspection (method) toquickly determine thefailed part.

Reference page(s) forthe detailed procedureto performINSPECTION is shown.

ACTION describes theappropriate action totake as a result(Yes/No) ofINSPECTION.

How to perform ACTIONis described in the relativematerial shown.

TROUBLE SYMPTOM

TEXT SEQUENCE The text sequence is as indicated by the arrows shown below.

Example:


CONTINUED


ST

UNITS

GI–7

UNITSElectric current A (ampere)

Electric power W (watt)

Electric resistance (ohm)

Electric voltage V (volt)

Lengthmm (millimeter)

Lengthin (inch)

kPa (kilo pascal)

Negative pressure mmHg (millimeters of mercury)

inHg (inches of mercury)

kPa (kilo pascal)

Positive pressure kgf/cm2 (kilogram force per squarecentimeter)

psi (pounds per square inch)

Number ofrevolutions rpm (revolutions per minute)

N·m (Newton meter)

kgf·m (kilogram force per meter)

Torque kgf·cm (kilogram force per centimeter)

ft·lbf (foot pound) force

in·lbf (inch pound) force

L (liter)

US qt (U.S. quart)

Imp qt (Imperial quart)

Volume ml (milliliter)

cc (cubic centimeter)

cu in (cubic inch)

fl oz (fluid ounce)

Weightg (gram)

Weightoz (ounce)

Conversion to SI Units (Système International d’Unités) All numerical values in this manual are based on SI

units. Numbers shown in conventional units areconverted from these values.

Rounding off Converted values are rounded off to the same

number of places as the SI unit value. Forexample, if the SI unit value is 17.2 and the valueafter conversion is 37.84, the converted value willbe rounded off to 37.8.

Upper and lower limits When the data indicates upper and lower limits, the

converted values are rounded down if the SI unitvalue is an upper limit and rounded up if the SI unitvalue is a lower limit. Therefore, converted valuesfor the same SI unit value may differ afterconversion. For example, consider 2.7 kgf/cm2 inthe following specifications:

210—260 kPa 2.1—2.7 kgf/cm 2, 30—38 psi270—310 kPa 2.7—3.2 kgf/cm 2, 39—45 psi

The actual converted values for 2.7 kgf/cm2 are264 kPa and 38.4 psi. In the top specification, 2.7is used as an upper limit, so its converted valuesare rounded down to 260 and 38. In the bottomspecification, 2.7 is used as a lower limit, so itsconverted values are rounded up to 270 and 39.


CONTINUED


FUNDAMENTAL PROCEDURES

GI–8

FUNDAMENTAL PROCEDURESPROTECTION OF THE VEHICLE Always be sure to cover fenders, seats, and floor

areas before starting work.

PREPARATION OF TOOLS AND MEASURINGEQUIPMENT Be sure that all necessary tools and measuring

equipment are available before starting any work.

SPECIAL SERVICE TOOLS Use special tools when they are required.

DISCONNECTION OF THE NEGATIVE BATTERYCABLE Before beginning any work, turn the ignition switch

to LOCK, then disconnect the negative batterycable and wait for more than 1 minute to allow thebackup power supply of the SAS unit to deplete itsstored power.Disconnecting the battery cable will delete thememories of the clock, audio, and DTCs, etc.Therefore, it is neccessary to verify thosememories before disconnecting the cable.

REMOVAL OF PARTS While correcting a problem, try also to determine

its cause. Begin work only after first learning whichparts and subassemblies must be removed anddisassembled for replacement or repair. Afterremoving the part, plug all holes and ports toprevent foreign material from entering.

DISASSEMBLY If the disassembly procedure is complex, requiring

many parts to be disassembled, all parts should bemarked in a place that will not affect theirperformance or external appearance and identifiedso that reassembly can be performed easily andefficiently.

INSPECTION DURING REMOVAL, DISASSEMBLY When removed, each part should be carefully

inspected for malfunctioning, deformation,damage, and other problems.

ARRANGEMENT OF PARTS All disassembled parts should be carefully

arranged for reassembly. Be sure to separate or otherwise identify the parts

to be replaced from those that will be reused.


CONTINUED


ST


GI–9

CLEANING OF PARTS All parts to be reused should be carefully and

thoroughly cleaned using the appropriate method.

Warning Using compressed air can cause dirt and

other particles to fly out, causing injury tothe eyes. Wear protective eye wearwhenever using compressed air.

REASSEMBLY Standard values, such as torques and certain

adjustments, must be strictly observed in thereassembly of all parts.

If removed, these parts should be replaced with newones:

1 Oil seals 2 Gaskets

3 O-rings 4 Lockwashers

5 Cotter pins 6 Nylon nuts

SXU00011

Sealant, a gasket, or both should be applied to thespecified locations. When sealant is applied, partsshould be installed before sealant hardens.Hardened sealant causes leaks.

Oil should be applied to the moving components ofparts.

Specified oil or grease should be applied at theprescribed locations (such as oil seals) beforereassembly.

SXU00012

ADJUSTMENT Use suitable gauges and/or testers when making

adjustments.

SXU00013

RUBBER PARTS AND TUBING Prevent gasoline or oil from spilling on rubber parts

or tubing.

SXU00014

HOSE CLAMPS When reinstalling, position the hose clamp in the

original location on the hose, and squeeze theclamp lightly with large pliers to ensure a good fit.

SXU00015


CONTINUED


FUNDAMENTAL PROCEDURES, INSTALLATION OF RADIO SYSTEM

GI–10

TORQUE FORMULAS When using a torque wrench-SST combination, the

written torque must be recalculated due to theextra length that the SST adds to the torquewrench. Recalculate the torque using the followingformulas. Choose the formula that applies to you.

Torque Unit Formula

kgf·m kgf·m [L/(L+A) ]

kgf·cm kgf·cm [L/(L+A) ]

ft·lbf ft·lbf [L/(L+A) ]

in·lbf in·lbf [L/(L+A) ]A: The length of the SST past the torque wrench drive.L: The length of the torque wrench.

SXU00016

VISE When using a vise, put protective plates in the jaws

of the vise to prevent damage to parts.

SXU00017

DYNAMOMETERWhen test-running a vehicle on dynamometer : Place a fan, preferably a vehicle-speed

proportional type, in front of the vehicle. Connect an exhaust gas ventilation unit. Cool the exhaust pipes with a fan. Keep the area around the vehicle uncluttered. Watch the water temperature gauge.

INSTALLATION OF RADIO SYSTEMIf a radio system is installed improprerly or if a high-powered type is used, the CIS and other systems maybe affected.When the vehicle is to be equipped with a radio,observe the following precautions.

1. Install the antenna at the farthest point from controlmodules.

2. Install the antenna feeder as far as possible fromthe control modules harness, and perpendicular towiring harnesses.

3. Do not install a high-powered radio system.4. After installing the radio system, start and idle the

engine, then confirm that the engine is notinfluenced by output waves from the system.


CONTINUED


ELECTRICAL SYSTEM

GI–11

ELECTRICAL SYSTEMELECTRICAL PARTSBattery Cable Before disconnecting connectors or removing

electrical parts, disconnect the negative batterycable.

SXU00018

Wiring Harness To remove the wiring harness from the clip in the

engine room, pry up the hook of the clip using aflathead screwdriver.

CONNECTORSData Link Connector Insert the probe into the service hole when

connecting a jumper wire to the data linkconnector.

Caution Inserting a jumper wire probe into the data

link connector terminal may damage theterminal.

SXU00019

Disconnecting Connectors When disconnecting two connectors, grasp the

connectors, not the wires.

SXU00020

Connectors can be disconnected by pressing orpulling the lock lever as shown.

SXU00021

Locking Connector When locking connectors, listen for a click that will

indicate they are securely locked.

SXU00022

Inspection1. When a tester is used to check for continuity or to

measure voltage, insert the tester probe from thewiring harness side.

SXU00023

2. Check the terminals of waterproof connectors fromthe connector side, as they cannot be accessedfrom the wiring harness side.


CONTINUED


ELECTRICAL SYSTEM

GI–12

Caution To prevent damage to the terminal, wrap a

thin wire around the lead before inserting itinto the terminal.

SXU00024

TerminalsInspection Pull lightly on individual wires to check that they

are secured in the terminal.

SXU00025

Replacement Use the appropriate tools to remove a terminal as

shown. When installing a terminal, be sure to insertit until it locks securely.

Insert a thin piece of metal from the terminal sideof the connector, and then, with the terminallocking tab pressed down, pull the terminal outfrom the connector.

SXU00026

TYPE A

TYPE B

Sensors, Switches, and Relays Handle sensors, switches, and relays carefully. Do

not drop them or strike them against other objects.

SXU00027

Wiring HarnessWiring color codes Two-color wires are indicated by a two-color code

symbol. The first letter indicates the base color of the wire

and the second the color of the stripe.CODE COLOR CODE COLOR

B Black O Orange

BR Brown P Pink

G Green R Red

GY Gray V Violet

L Blue W White

LB Light Blue Y Yellow

LG Light Green

SXU00028

B/R BR/Y

BLACK

RED

BROWN

YELLOW

FuseReplacement

1. When replacing a fuse, be sure to replace it withone of the specified capacity. If a fuse again failsafter it has been replaced, the circuit probably hasa short and the wiring should be checked.

2. Be sure the negative battery terminal isdisconnected before replacing a main fuse.

SXU00029


CONTINUED


ELECTRICAL SYSTEM

GI–13

3. When replacing a pullout fuse, use the fuse puller.

SXU00030

PULLER

FUSE

ELECTRICAL TROUBLESHOOTING TOOLSJumper Wire A jumper wire is used to create a temporary circuit.

Connect the jumper wire between the terminals ofa circuit to bypass a switch.

Caution Do not connect a jumper wire from the

power source line to a body ground; thismay cause burning or other damage towiring harnesses or electronic components.

SXU00032

Voltmeter The DC voltmeter is used to measure circuit

voltage. A voltmeter with a range of 15 V or moreis used by connecting the positive (+) probe (redlead wire) to the point where voltage is to bemeasured and the negative (–) probe (black leadwire) to a body ground.

VOLTMETER POWER SOURCE LINE

BLACK LEAD

RED LEAD

GROUND

Ohmmeter The ohmmeter is used to measure the resistance

between two points in a circuit, and to check forcontinuity and short circuits.

Caution Do not connect the ohmmeter to any circuit

to which voltage is applied. This willdamage the ohmmeter.

SXU00034

POWER SOURCE LINE

GROUND LINE

OHMMETER


CONTINUED


JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) POSITIONS, SAFETY STAND POSITIONS

GI–14

JACKING POSITIONSWarning Improperly jacking a vehicle is dangerous.

The vehicle can slip off the jack and causeserious injury. Use only the correct frontand rear jacking positions and block thewheels.

Use safety stands to support the vehicle after it hasbeen lifted.

FRONT

REAR

VEHICLE LIFT (2 SUPPORTS)POSITIONSFRONT

REAR

SAFETY STAND POSITIONSFRONT

REAR


CONTINUED

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TOWING

GI–15

TOWINGProper lifting and towing are necessary to preventdamage to the vehicle.Government and local laws must be followed.

Wheel dollies

Wheel dollies

Caution Do not tow with sling-type equipment. This

could damage your vehicle. Use wheel-liftor flatbed equipment.

(With Manual Transmission)If the transmission, rear axle, and steering system arenot damaged, the vehicle may be towed on all fourwheels. If any of these components are damaged, usewheel dollies.

If all four wheels are on the ground, the vehicle may betowed only forward. Do not exceed 45 km/h (28 mph)and a distance of 15 km (9.3 miles); you could damagethe transmission.

If speed must exceed 45 km/h (28 mph) or a towingdistance of 15 km (9.3 miles), use one of thesemethods:

Place the rear wheels on dollies.

Tow with the rear wheels off the ground.

Disconnect the propeller shaft.

If the transmission or rear axle is inoperative, tow withthe rear wheels off the ground.

Caution Follow these instructions when towing the

vehicle with all wheels on the ground orwith the front wheels on the ground and therear wheels raised.

(44 Model)1. Put the transfer case in 2H.2. Set the transfer case at 2H and the hubs

at FREE.

(All Models)1. Set the transmission in neutral.2. Turn the engine switch to ACC position.3. Release the parking brake.

Remember that power assist for the brakesand steering will not be available when theengine is not running.

If your Ford/Mazda has 44, change to 2-wheel drive before having the vehicle towed. If this is not possible, tow with all four wheels raised.


CONTINUED

TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL

(With Automatic Transmission)If excessive damage or other conditions preventtowing the vehicle with the driving wheels off the ground, use wheel dollies.

PAGES. FROM. MANUAL

TOWING, IDENTIFICATION NUMBER LOCATIONS

GI–16

TOWING HOOKS

Caution The towing hooks should be used only in

an emergency (e.g. to get the vehicle out ofa ditch or a snow bank).

When using the towing hooks, always pullthe cable or chain in a straight directionwith respect to the hook. Apply nosideways force.

FRONT44

TIEDOWN HOOKS

Caution Do not use the hook loops under the front

for towing. They are designed ONLY fortying down the vehicle when it is beingtransported. Using them for towing willdamage the bumper.

FRONT42

44

IDENTIFICATION NUMBERLOCATIONSVEHICLE IDENTIFICATION NUMBER

ENGINE IDENTIFICATION NUMBERG6

WL, WL Turbo

F2 CISF2 CARB


CONTINUED


NEW STANDARDS

GI–17

NEW STANDARDS Following is a comparison of the previous standard and the new standard.

New Standard Previous Standard

Abbreviation Name NameRemark

AP Accelerator Pedal — Accelerator Pedal

ACL Air Cleaner — Air Cleaner

A/C Air Conditioning — Air Conditioning

BARO Barometric Pressure — Atmospheric Pressure

B Battery Positive Voltage VB Battery Voltage

— Brake Switch — Stoplight Switch

— Calibration Resistor — Corrected Resistance #6

CMP sensor

Camshaft Position Sensor — Crank Angle Sensor

CAC Charge Air Cooler — Intercooler

CLS Closed Loop System — Feedback System

CTP Closed Throttle Position — Fully Closed

— Closed Throttle Position Switch — Idle Switch

CPP Clutch Pedal Position — Clutch Position

CIS Continuous Fuel Injection System EGI Electronic Gasoline Injection System

CS sensor Control Sleeve SensorCSP

sensorControl Sleeve Position Sensor #6

CKP sensor

Crankshaft Position Sensor — Crank Angle Sensor 2

DLC Data Link Connector — Diagnosis Connector

DTM Diagnostic Test Mode — Test Mode #1

DTC Diagnostic Trouble Code(s) — Service Code(s)

DI Distributor Ignition — Spark Ignition

DLI Distributorless Ignition — Direct Ignition

EI Electronic Ignition — Electronic Spark Ignition #2

ECT Engine Coolant Temperature — Water Thermo

EM Engine Modification — Engine Modification

— Engine Speed Input Signal — Engine RPM Signal

EVAP Evaporative Emission — Evaporative Emission

EGR Exhaust Gas Recirculation — Exhaust Gas Recirculation

FC Fan Control — Fan Control

FF Flexible Fuel — Flexible Fuel

4GR Fourth Gear — Overdrive

— Fuel Pump Relay — Circuit Opening Relay #3

FSO solenoid

Fuel Shut Off Solenoid FCV Fuel Cut Valve #6

GEN Generator — Alternator

GND Ground — Ground/Earth

HO2S Heated Oxygen Sensor — Oxygen Sensor With heater

IAC Idle Air Control — Idle Speed Control

— Incorrect Gear Ratio — —

#1: Diagnostic trouble codes depend on the diagnostic test mode#2: Controlled by the PCM#3: In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump

relay (speed).#6: Part name of diesel engine


CONTINUED


Abbreviation

PAGES. FROM. MANUAL

NEW STANDARDS

GI–18


Name NameRemark

— Injection Pump FIP Fuel Injection Pump #6

— Input/Turbine Speed Sensor — Pulse Generator

IAT Intake Air Temperature — Intake Air Thermo

KS Knock Sensor — Knock Sensor

MIL Malfunction Indicator Lamp — Malfunction Indicator Light

MAP Manifold Absolute Pressure — Intake Air Pressure

MAF sensor

Mass Air Flow Sensor — Airflow Sensor

MFL Multiport Fuel Injection — Multiport Fuel Injection

OBD On-Board Diagnostic — Diagnosis/Self-Diagnosis

OL Open Loop — Open Loop

— Output Speed Sensor — Vehicle Speed Sensor 1

OC Oxidation Catalytic Converter — Catalytic Converter

O2S Oxygen Sensor — Oxygen Sensor

PNP Park/Neutral Position — Park/Neutral Range

— PCM Control Relay — Main Relay #6

PSP Power Steering Pressure — Power Steering Pressure

PCM Powertrain Control Module ECU Engine Control Unit #4

— Pressure Control Solenoid — Line Pressure Solenoid Valve

PAIR Pulsed Secondary Air Injection — Secondary Air Injection SystemPulsed injection

— Pump Speed Sensor — NE Sensor #6

AIR Secondary Air Injection — Secondary Air Injection SystemInjection withair pump

SAPV Secondary Air Pulse Valve — Reed Valve

SFI Sequential Multipoint Fuel Injection — Sequential Fuel Injection

— Shift Solenoid A— 1–2 Shift Solenoid Valve

— Shift Solenoid A— Shift A Solenoid Valve

Shift Solenoid B— 2–3 Shift Solenoid Valve

— Shift Solenoid B— Shift B Solenoid Valve

— Shift Solenoid C — 3–4 Shift Solenoid Valve

3GR Third Gear — 3rd Gear

TWC Three Way Catalytic Converter — Catalytic Converter

TB Throttle Body — Throttle Body

TP sensor Throttle Position Sensor — Throttle Sensor

TCV Timer Control Valve TCV Timing Control Valve #6

TCC Torque Converter Clutch — Lock-up Position

TCM Transmission (Transaxle) Control Module

— EC-AT Control Unit

— Transmission (Transaxle) FluidTemperature Sensor

— ATF Thermosensor

TR Transmission (Transaxle) Range — Inhibitor Position

TC Turbocharger — Turbocharger

VSS Vehicle Speed Sensor — Vehicle Speed Sensor

VR Voltage Regulator — IC Regulator

#4: Device that controls engine and powertrain#6: Part name of diesel engine


CONTINUED

RANG.DRFT.REPAIR MANUAL

Abbreviation Abbreviation

PAGES. FROM. MANUALTO. MODEL .INDEX

NEW STANDARDS, ABBREVIATIONS

GI–19


Name NameRemark

VAF sensor

Volume Air Flow Sensor — Air flow Sensor

WU-TWC Warm Up Three Way CatalyticConverter

— Catalytic Converter #5

WOT Wide Open Throttle — Fully Open

#5: Directly connected to exhaust manifold

ABBREVIATIONSACC Accessories. . . . . . . . . . . . . . ATDC After top dead center. . . . . . . . . . . . . ATF Automatic transmission fluid. . . . . . . . . . . . . . . BTDC Before top dead center. . . . . . . . . . . . . CARB Carburetor. . . . . . . . . . . . . ELR Emergency locking retractor. . . . . . . . . . . . . . EX Exhaust. . . . . . . . . . . . . . . FIP Fuel injection pump. . . . . . . . . . . . . . . HI High. . . . . . . . . . . . . . . . HLA Hydraulic lash adjuster. . . . . . . . . . . . . . IG Ignition. . . . . . . . . . . . . . . . IN Intake. . . . . . . . . . . . . . . . INT Intermittent. . . . . . . . . . . . . . . LH Left hand. . . . . . . . . . . . . . . . L.H.D. Left hand drive. . . . . . . . . . . . . LO Low. . . . . . . . . . . . . . . LSD Limited slip differential. . . . . . . . . . . . . . LSPV Load sensing proportioning valve. . . . . . . . . . . . . M Motor. . . . . . . . . . . . . . . . MAX Maximum. . . . . . . . . . . . . . MFW Manual freewheel. . . . . . . . . . . . . MIN Minimum. . . . . . . . . . . . . . P/S Power steering. . . . . . . . . . . . . . . RFW Remote freewheel. . . . . . . . . . . . . . RH Right hand. . . . . . . . . . . . . . . R.H.D. Right hand drive. . . . . . . . . . . . SAS Sophisticated air bag sensor. . . . . . . . . . . . . . SST Special service tool. . . . . . . . . . . . . . TNS Tail number side lights. . . . . . . . . . . . . . 2WD 2 wheel drive. . . . . . . . . . . . . . 4WD 4 wheel drive. . . . . . . . . . . . . . 42 4 wheel – 2 drive. . . . . . . . . . . . . . 44 4 wheel – 4 drive. . . . . . . . . . . . . .


CONTINUED


Abbreviation Abbreviation

PAGES. FROM. MANUAL

PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE Following items may be done at any time prior to delivery to your customer. EXTERIOR

UNDER BONNET-ENGINE RUNNING AT OPERATING TEMPERATURE

CHECK the following items: Operation of dashpot Initial ignition timing Injection timing Idle speed Operation of throttle position sensor

ON HOIST

INSPECT and ADJUST, if necessary, the following items to the specifications:

Glass, exterior bright metal and paint for damage Wheel lug nuts Tire pressures All weatherstrips for damage or detachment Operation of bonnet release and lock Door operation and alignment Headlight aiming

INSTALL the following parts: Wheel caps

UNDER BONNET-ENGINE OFF

CHECK the following items: Operation of freewheel hubs Manual transmission oil level Transfer oil level Front differential oil level Rear differential oil level Underside fuel, coolant and hydraulic lines, fittings,

connections and components for leaks Tires for cuts or bruises Steering linkage, suspension, exhaust system and

all underside hardware for looseness or damage

ROAD TEST

INSPECT and ADJUST, if necessary, the following items to the specifications:

Fuel, coolant and hydraulic lines, fittings, connections and components for leaks Engine oil level Power steering fluid level (if equipped) Brake and clutch master cylinder fluid levels Windshield washer reservoir fluid level Radiator coolant and specific gravity Tightness of water hose clamps Tightness of battery terminals, electrolyte level and

specific gravity Drive belt tensions Accelerator cable and linkage for free movement

CLEAN the spark plugs

INTERIOR

CHECK the following items: Brake operation Clutch operation Steering control Operation of meters and gauges 3 Squeaks, rattles

or unusual noise Engine general performance Emergency locking retractors Operation of transfer

AFTER ROAD TEST

INSTALL the following parts Fuse for accessories

CHECK the operation of the following items: Seat controls (sliding and reclining) and headrest Door locks Ignition switch (Engine switch) and steering lock All lights including warning and indicator lights Horn, windshield wipers and washers (if equipped) Wiper blades performance Clean the wiper blades and

windshield Antenna Cigarette lighter and clock Tilt steering (if equipped) Air conditioner at various modes (if equipped)

CHECK the following items: Presence of spare fuse Upholstery and interior finish

CHECK and ADJUST, if necessary, the following items: Operation and fit of windows Pedal height and free play of brake and clutch pedals Parking brake

REMOVE seat and floor mat protective covers CHECK for necessary owner's information material, tools and spare tire in vehicle

Gl-20

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TO. MODEL .INDEX

CONTINUED

ENGINE (G6)

DRIVE BELT ................................................................B1-1 DRIVE BELT INSPECTION ................................B1-1/2

DRIVE BELT ADJUSTMENT .............................B1-2 COMPRESSION INSPECTION ..................................B1-2 TIMING CHAIN .............................................................B1-3

TIMING CHAIN REMOVAL/ INSTALLATION....................................................B1-3/5 CYLINDER HEAD GASKET ..................................B1-6 CYLINDER HEAD GASKET REPLACEMENT .................................................B1-6/9 HYDRAULIC LASH ADJUSTER (HLA).................B1-10

HLA REMOVAL/INSTALLATION .....................B1-10/11 HLA TROUBLESHOOTING .............................B1-12 FRONT OIL SEAL.......................................................B1-13 FRONT OIL SEAL REPLACEMENT.................B1-13 REAR OIL SEAL .........................................................B1-14 REAR OIL SEAL REPLACEMENT ..................B1-14 ENGINE .......................................................................B1-15

ENGINE REMOVAL/INSTALLATION ..............B1-15/16 ENGINE DISASSEMBLY/ASSEMBLY ..............B1-17

Deflection mm inDrive belt *New Used

Generator 10.0—12.0 0.40—0.47

12.0—14.0 0.48—0.55

P/S 6.6—7.2 0.26—0.28

7.2—8.0 0.29—0.31

A/C 8.5—10.0 0.34—0.39

10.0—11.5 0.40—0.45

*: A belt that has been on a running engine for less than five minutes. 2. If the deflection is not within the specification, adjust it.

(Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) Drive Belt Tension Check 1. Belt tension can be checked in place of belt deflection.

Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has been stopped. Using the SST, check the belt tension between any two pulleys.

N kgf, Ibf

Drive belt *New Used

Generator 491-588 50-60,110-132

393-490 40-50,88-110

P/S 412—470

42-48,93—105 354—402

36-41, 80—90

A/C 557—641

56.7—65.4, 125—143

471—556 48.0—56.7, 106—124

DRIVE BELT DRIVE BELT INSPECTION Drive Belt Deflection Check 1. Check the drive belt deflection when the engine

is cold, or at least 30 minutes after the engine has been stopped. Apply pressure 98 N 10 kgf, 22 Ibf midway between the specified pulleys.

* A belt that has been on a running engine for less than five minutes.

B1-1

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CONTINUED

DRIVE BELT, COMPRESSION INSPECTION COMPRESSION INSPECTION

Warning • When the engine and the oil are hot, they

can badly burn. Be careful not to burn yourself during removal/installation of each component.

1. Verify that the battery is fully charged. Recharge it if necessary. (Refer to section G, CHARGING SYSTEM, BATTERY INSPECTION, Battery.)

2. Warm up the engine to the normal operating temperature.

3. Stop the engine and allow it to cool off for about 10 minutes.

4. Perform "Fuel Line Safety Procedure". Leave the fuel pump relay removed. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

5. Disconnect the igniter connector. (Refer to section G, IGNITION SYSTEM, IGNITION COIL REMOVAL/INSTALLATION.)

6. Remove the spark plugs. 7. Connect a compression gauge into the No.1 spark

plug hole. 8. Fully depress the accelerator pedal and crank the

engine. 9. Note the maximum gauge reading. 10. Inspect compression of each cylinder.

Compression kPa kgf/cm2, psi [rpm]Engine type Item G6

Standard 1255 12.8, 182 [270] Minimum 882.6 9.0, 128 [270] Maximum difference between 196 kPa 2.0 kgf/cm2, 28 psi

2. If the tension is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)

DRIVE BELT ADJUSTMENT 1. Loosen mounting bolts A and B, and locknut C. 2. Adjust the belt deflection or tension by turning the

adjusting bolt D. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.)

3. Tighten mounting bolts A and B and locknut C.

11. If the compression in one or more cylinders is low or the compression difference between cylinders exceeds the maximum, pour a small amount of clean engine oil into the cylinder and recheck the compression. (1) If the compression increases, the piston, the

piston rings, or cylinder wall may be worn and overhaul is required.

(2) If the compression stays low, a valve may be stuck or improperly seated and overhaul is required.

(3) If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required.

12. Disconnect the compression gauge. 13. Install the spark plugs.

Tightening torque 15—22 N.m 1.5—2.3 kgf.m, 11—l6ft.lbf

14. Connect the igniter connector. 15. Install the fuel pump relay.

B1-2


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CONTINUED

TIMING CHAIN

TIMING CHAIN TIMING CHAIN REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the generator. 3. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way.

(Refer to section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP REMOVAL/INSTALLATION.)

4. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way.

5. Remove the cylinder head. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.)

6. Remove the water pump. (Refer to section E, WATER PUMP, WATER PUMP REMOVAL/INSTALLATION.) 7. Remove the oil pan. (Refer to section D, OIL PAN, OIL PAN REMOVAL/INSTALLATION.) 8. Disconnect the oil strainer stay. 9. Remove in the order indicated in the table. 10. Install in the reverse order of removal. 11. Start the engine and check for engine oil and engine coolant leakage.

1 A/C compressor bracket 10

Balancer chain, idler sprocket, crankshaft sprocket Installation Note 2 Generator strap

3 P/S oil pump bracket 11

Timing chain, timing sprocket, camshaft sprocket Installation Note

4 Generator bracket 12

Chain adjuster Installation Note 5

Pulley lock bolt Removal/Installation Note 13 Key

6 Crankshaft pulley 7 Chain cover

14

Timing chain lever Installation Note

8 Spacer 15 Timing chain guide 9

Balancer chain guide Installation Note

B1-3


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CONTINUED

TIMING CHAIN Pulley Lock Bolt Removal/Installation Note

• Hold the crankshaft using the SST.

Timing Chain Lever Installation Note

• Install the chain lever and verify that it moves smoothly in the direction indicated.

Chain Adjuster Installation Note

• Push the chain adjuster sleeve in (toward the left) and insert the pin as shown into the lever to hold the sleeve.

Timing Chain, Timing Sprocket, Camshaft Sprocket Installation Note

1. Install the timing chain and timing sprocket so that the white link of the timing chain is aligned with the timing mark of the timing sprocket as shown.

2. Assemble the camshaft sprocket to the timing chain so that the timing mark of camshaft sprocket is aligned with the white link of timing chain as shown.

3. Secure the camshaft sprocket and the timing

chain with a wire to prevent disengagement. Balancer Chain, Idler Sprocket, Crankshaft Sprocket Installation Note 1. Install the crankshaft sprocket as shown.

2. Assemble the idler sprocket on to the idler shaft.

3. Set the balancer chain on the idler sprocket so

that the timing mark of the idler sprocket is aligned with the brown link of the balancer chain as shown.

B1-4


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CONTINUED

TIMING CHAIN 4. Install the balancer chain so that the five

alignment marks on the chain, sprocket and cylinder block align, and attach the idler sprocket to the cylinder block.

5. Hand-tighten the idler sprocket lock bolt. Balancer Chain Guide Installation Note

1. Install the chain guide A and B.

2. Install the chain guide C, and tighten the bolt D

and hand-tighten the adjusting bolt E.

3. Tighten the idler sprocket lock bolt.

4. Loosen the chain guide C by adjusting bolt E. 5. Push the chain guide C with a force of 49 N

5.0 kgf, 11 Ibf in the direction of the arrow, then pull back the chain guide 3.2—3.8 mm 0.13—0.14 in] and tighten the adjusting bolt E.

Note • The balancer chain must be replaced if chain

guide C bottoms when adjusting. 6. Measure the timing chain slack.

Specification Approx. 3.0 mm 0.12 in

B1-5


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CONTINUED

CYLINDER HEAD GASKET

CYLINDER HEAD GASKET CYLINDER HEAD GASKET REPLACEMENT

Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always

keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and

damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F1. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, COOLING SYSTEM SERVICE WARNINGS.)

(Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 4. Remove the cooling fan. 5. Remove the front pipe. 6. Remove the air intake pipe and resonance chamber. 7. Disconnect the accelerator cable and bracket. 8. S. Disconnect the vacuum hoses, water hoses, and engine harness connectors. 9. Disconnect the fuel hoses.

(Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to section F1, FUEL SYSTEM, AFTER REPAIR PROCEDURE.)

10. Remove the intake manifold bracket. 11. Remove the distributor.

(Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 12. Remove the high-tension lead.

(Refer to section G, IGNITION SYSTEM, HIGH-TENSION LEAD REMOVAL/INSTALLATION.) 13. Remove the spark plug. 14. Remove in the order indicated in the table. 15. Install in the reverse order of removal. 16. Inspect for fuel leakage. 17. Inspect the compression.

(Refer to COMPRESSION INSPECTION.) 18. Start the engine and

(1) check the pulleys and drive belt for runout and contact. (2) check the ignition timing and idle speed. (Refer to section F1, ENGINE TUNE-UP.)

B1-6


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CONTINUED


1 Upper radiator hose 2

Cylinder head cover Installation Note

5

Cylinder head Removal Note Installation Note

6

Cylinder head gasket Installation Note

3

Distributor drive gear Removal Note Installation Note

4

Camshaft sprocket Removal Note Installation Note

B1-7


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CONTINUED

CYLINDER HEAD GASKET Distributor Drive Gear Removal Note 1. Turn the crankshaft clockwise so that the No.1

piston is at TDC of the compression stroke.

2. Verify that the camshaft sprocket mark is aligned

with the horizontal surface on the cylinder head.

3. Remove the seal cover. 4. Hold the crankshaft using the SST.

5. Remove the lock bolt. Camshaft Sprocket Removal Note 1. Remove the service cover on the chain cover.

2. Push the chain adjuster sleeve in (toward the left) and insert a pin as shown into the lever hole to hold the sleeve.

3. Secure the camshaft sprocket and the chain with a

wire as shown.

4. Remove the camshaft sprocket off the camshaft

dowel pin. Cylinder Head Removal Note 1. Remove the bolts A. 2. Loosen the cylinder head bolts a few turns in the

order shown.

Cylinder Head Gasket Installation Note • Apply silicone sealant to the areas shown.

Thickness Ø3.0 mm 0.12 in

B1-8


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CONTINUED

CYLINDER HEAD GASKET Cylinder Head Installation Note

1. Tighten the cylinder head bolts a few turns in the order shown.

2. Tighten the bolts A. Camshaft Sprocket Installation Note

1. Install the camshaft sprocket onto the camshaft dowel pin.

2. Remove the wire securing the camshaft sprocket and chain.

3. Remove the retaining pin from the chain adjuster. 4. Install the service cover with a new gasket.

Tightening torque 7.9—10.7 N.m 80—110 kgf.cm, 69.5—95.4 in.lbf

Distributor Drive Gear Installation Note 1. Install the distributor drive gear with a new washer

and lock bolt. 2. Hold the camshaft with a screwdriver as shown.

3. Tighten the lock bolt. 4. Apply silicone sealant to the areas shown.

5. Install the new seal cover. Cylinder Head Cover Installation Note 1. Verify that the grooves on the cylinder head cover

are free of oil, water, and other foreign material. 2. Coat a new gasket with silicone sealant, and install

it onto the cylinder head cover. 3. Apply silicone sealant to the cylinder head as

shown.

4. Install the cylinder head cover.

B1-9


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CONTINUED

HYDRAULIC LASH ADJUSTER (HLA)

HYDRAULIC LASH ADJUSTER (HLA) HLA REMOVAL / INSTALLATION

Caution • Removal and installation of the HLA must be carried out only when the problem cannot be solved by

the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)

1. Disconnect the negative battery cable. 2. Remove the distributor.

(Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 3. Remove the cylinder head cover.

(Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Check the engine oil level,

(Refer to section D, ENGINE OIL, ENGINE OIL INSPECTION.) 7. Start the engine and

(1) check the engine oil. (2) check the idle speed, (Refer to section F1, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)

8. Check the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)

2

Rocker arm Removal Note & Installation Note

3 HLA Installation Note

1

Distributor drive gear CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Distributor Drive Gear Removal Note CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Distributor Drive Gear Installation Note

B1-10


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CONTINUED

HYDRAULIC LASH ADJUSTER (HLA) Rocker Arm Removal Note 1. Loosen the bolts a few turns in the order shown.

2. Identify the rocker arm and shaft assembly parts so that they can be reinstalled in the same locations from which they were removed.

3. Remove the rocker arm and shaft assembly together with the bolts.

HLA Installation Note 1. Place each HLA in a container filled with clean

engine oil. Caution • Do not push the pin too hard. It may damage the HLA.

2. Bleed the air from the HLA by inserting a pin into the plunger hole and pressing the plunger until it no longer moves.

3. Pour engine oil into the oil reservoir in the rocker arm.

4. Apply clean engine oil to HLA O-ring

Rocker Arm Installation Note Note

• The intake side shaft has twice as many oil holes as the exhaust side shaft.

1. Assemble the rocker arm and shaft assembly as shown in the figure according to the cap number and mark.

2. Install the rocker arm and shaft. 3. Tighten the bolts a few turns in the order shown.

B1-11


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CONTINUED


HLA TROUBLESHOOTING Problem Possible Cause Action

1. Noise when engine is started immediately after oil is changed.

2. Noise when engine is started after sitting one day or more.

Oil leakage in oil passage or in HLA

3. Noise when engine is started after new HLA is installed.

Oil leakage in HLA

Run engine at 2,000—3,000 rpm. If noise stops within 20 minutes*, HLA is normal. If not, replace HLA.

Time required for engine oil to circulate within HLA includes tolerance for engine oil condition and ambient temperature. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING, Valve Clearance Inspection.)

Insufficient oil pressure

Check oil pressure. If lower than specification, check for cause. (Refer to section D, OIL PRESSURE INSPECTION)

4. Noise continues more than 10 minutes.

Faulty HLA

Press down HLA by hand. If it does not move, HLA is normal. If it moves, replace HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.) Measure valve clearance. (Refer to HLA, HLA TROUBLESHOOTING, Valve Clearance Inspection.)

Incorrect oil amount

Check oil level. (Refer to section D, ENGINE OIL, ENGINE OIL INSPECTION.)

5. Noise during idle after high speed running.

Deteriorated oil

Replace new engine oil. (Refer to section D, ENGINE OIL, ENGINE OIL REPLACEMENT.)

Valve Clearance Inspection 1. Remove the cylinder head cover.

(Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.)

2. Measure valve clearance.

Valve clearance 0.15 mm 0.0059 in max.

3. If valve clearance is more than 0.15 mm 0.0059 in, replace the HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.)

4. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Cylinder Head Cover Installation Note.)

B1-12


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CONTINUED

FRONT OIL SEAL FRONT OIL SEAL FRONT OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Drain the engine coolant.

(Refer to section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)

3. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)

4. Remove the cooling fan and water pump pulley. 5. Remove the radiator cowling. 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal.

1

Pulley lock bolt TIMING CHAIN, TIMING CHAIN REMOVAL/INSTALLATION, Pulley Lock Bolt Removal/Installation Note

2 Crankshaft pulley 3

Front oil seal Removal Note Installation Note

Front Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected

with a rag.

Front Oil Seal Installation Note 1. Apply clean engine oil to the oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a

hammer.

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REAR OIL SEAL REAR OIL SEAL REAR OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the flywheel.

(Refer to section H, CLUTCH UNIT, CLUTCH UNIT REMOVAL/INSTALLATION.)

3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.

1

Rear oil seal Removal Note Installation Note

Rear Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver

protected with a rag.

Rear Oil Seal Installation Note 1. Apply clean engine oil to the new oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a

hammer.

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ENGINE ENGINE ENGINE REMOVAL/INSTALLATION

Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always

keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and

damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F1. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

1. Disconnect the negative battery cable. 2. Drain the engine coolant.

(Refer to section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)

3. Remove the air cleaner and fresh-air duct. 4. Remove the front pipe. 5. Disconnect the accelerator cable, bracket, heater hoses, and vacuum hoses. 6. Remove the radiator.

(Refer to section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.) 7. Remove the drive belt.

(Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 8. Disconnect the fuel hoses.

(Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to section F1, FUEL SYSTEM, AFTER REPAIR PROCEDURE.)

9. Remove the transmission. (Refer to section J2, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION.)

10. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way. (Refer to section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP REMOVAL/INSTALLATION.)

11. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way.

12. Remove in the order indicated in the table. 13. Install in the reverse order of removal. 14. Start the engine and

(1) check the engine oil, engine coolant, transmission oil, and fuel leakage. (2) check the ignition timing, idle speed and idle mixture. (Refer to section F1, ENGINE TUNE-UP.)

15. Perform a road test.

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ENGINE

1 Engine mount nut 2 Engine

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ENGINE

ENGINE DISASSEMBLY/ASSEMBLY 1. Remove the oil cooler. (Refer to section D, OIL COOLER, OIL COOLER REMOVAL/INSTALLATION.) 2. Remove the thermostat. (Refer to section E, THERMOSTAT, THERMOSTAT REMOVAL/INSTALLATION.) 3. Remove the spark plug. 4. Remove the oil pressure switch. (Refer to section D, OIL PRESSURE INSPECTION.) 5. Remove the intake-air system.

(Refer to section F1, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 6. Remove the exhaust system.

(Refer to section F1, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 7. Remove the oil filter. (Refer to section D, OIL FILTER, OIL FILTER REPLACEMENT) 8. Remove the distributor. (Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 9. Remove the generator. 10. Disassemble in the order indicated in the table. 11. Assemble in the reverse order of disassembly.

1 Water bypass pipe 6 A/C idler2 Water inlet pipe 7 P/S idler3 A/C compressor bracket 8 Oil cooler bypass pipe 4 Generator bracket 9 Generator strap5 P/S oil pump bracket

10 Engine mount

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CONTENTS

General Information GI

Engine B

Technical Data TD

Special Tools

Engine Workshop Manual F8 FE

FOREWORD This manual explains the disassembly,

inspection, repair, and reassembly procedures for the above-indicated engines. In order to do these procedures safely, quickly, and correctly, you must first read this manual and any other relevant service materials carefully.

The information in this manual is current up to April, 1997. Any changes that occur after that time will not be reflected in this particular manual. Therefore, the contents of this manual may not exactly match the mechanism that you are currently servicing.

Mazda Motor Corporation

HIROSHIMA, JAPAN

© 2001 Ford/Mazda Motor Corporation PRINTED IN JAPAN, APR. 1997 1570-10-97D

BACK.TO.MAIN.INDEX

CONTINUED

Title Section

ST

RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUALTO. MODEL .INDEX

GENERAL INFORMATION HOW TO USE THIS MANUAL .............. ................ Gl- 1

RANGE OF TOPICS .................... .................... Gl- 1 SERVICING PROCEDURE .............. ................ Gl- 1/2 SYMBOLS ............................. .......................... Gl- 3 ADVISORY MESSAGES ................. ................. Gl- 3 TEXT SEQUENCE ...................... ..................... Gl- 3

UNITS ................................................................... Gl- 4 NEW STANDARDS ............................................... Gl- 5 FUNDAMENTAL PROCEDURES ........... .............. Gl- 7

PREPARATION OF TOOLS AND MEASURING EQUIPMENT .......................... Gl- 7 SPECIAL TOOLS ............................................. Gl- 7 DISASSEMBLY ................................................ Gl- 7

INSPECTION DURING REMOVAL, DISASSEMBLY ............................................. Gl- 7 ARRANGEMENT OF PARTS ........................... Gl- 7 CLEANING OF PARTS .................................... Gl- 7 REASSEMBLY ................................................. Gl- 7 ADJUSTMENT ................................................. Gl- 8 RUBBER PARTS AND TUBING ....................... Gl- 8 HOSE CLAMPS ............................................... Gl- 8 TORQUE FORMULAS ...................................... Gl- 8 VISE ................................................................ Gl- 8

ELECTRICAL SYSTEM ........................................ Gl- 9 CONNECTORS ................................................ Gl- 9

ABBREVIATIONS.................................................. Gl- 10

HOW TO USE THIS MANUAL RANGE OF TOPICS • This manual contains the procedures for

performing all of the required service operations. The procedures are divided into the following five basic operations. (1) Removal/Installation (2) Disassembly/Assembly (3) Replacement (4) Inspection (5) Adjustment

• Simple operations which can be performed easily just by looking at the vehicle such as removal/installation of parts, jacking, vehicle lift, cleaning of parts, and visual inspection, have been omitted.

SERVICING PROCEDURE Inspection, Adjustment • The procedures .for inspections and adjustments

are divided into steps. Important points in regard to the location and contents of the procedures are explained in detail and are shown in the illustrations.

Gl-1


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PAGES. FROM. MANUAL

HOW TO USE THIS MANUAL Repair procedure 1. Most repair operations begin with an overview illustration, It identifies the components, shows how the parts fit

together, and describes visual part inspection. However, only the removal/installation procedures which need to be performed methodically have written instructions,

2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts which require the use of special service tools for removal/installation are also shown.

3. The procedures are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or information concerning a procedure. Refer to this information when servicing the related part.

Gl-2

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RANG.DRFT.REPAIR MANUAL

SYMBOLS

• There are eight symbols indicating oil, grease, sealant, and the use of SSTs. These symbols show the points of applying or using such

Symbol Meaning Kind

Apply oil New appropriate engine oil or gear oil

Apply brake fluid New appropriate brake fluid

Apply automatic transaxle / transmission fluid

New appropriate automatic transaxle/transmission fluid

Apply grease Appropriate grease

Apply sealant Appropriate sealant

Apply petroleum jelly

Appropriate petroleum jelly

Replace part O-ring, gasket, etc.

Use SST Appropriate SST

ADVISORY MESSAGES You'll find several Warnings, Cautions, Notes, Specifications and Upper and lower limits in this manual.

•

Caution • A Caution indicates a situation in which damage

to the vehicle could result if the caution is ignored.

Note • A Note provides added information that will help you

to complete a particular procedure.

Specification • The values indicates the allowable range when

performing inspections or adjustments.

Upper and lower limits • The values indicate the upper and lower limits that

must not be exceeded when performing inspections or adjustments.

TEXT SEQUENCE

• The text sequence is as indicated by the arrows shown below.

Example:


Warning A Warning indicates a situation in which serious injury or death could result if the warning is ignored.

Gl-3


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UNITS Electrical current A (ampere) Electric potential V (volt) Electric power W (watt)

mm (millimeter) Length

in (inch) kPa (kilo pascal) mmHg (millimeters of mercury) Negative pressure inHg (inches of mercury) kPa (kilo pascal) kgf/cm2 (kilogram force per square centimeter) Positive pressure

psi (pounds per square inch) Resistance Ω (ohm) Speed rpm (revolution per minute)

N•m (Newton meter) kgf•m (kilogram force per meter)

kgf•cm (kilogram force per centimeter)

ft•lbf (foot pound)

Torque

in•lbf (inch pound) L (liter) US qt (U.S. quart) Imp qt (Imperial quart) ml (milliliter) cc (cubic centimeter) cu in (cubic inch)

Volume

fl oz (fluid ounce) 9 (gram)

Weight oz (ounce)

• The actual converted values for 2.7 kgf/cm2 are 264 kPa and 38.4 psi. In the top specification, 2.7 is used as an upper limit, so its converted values are rounded down to 260 and 38. In the bottom specification, 2,7 is used as a lower limit, so its converted values are rounded up to 270 and 39.

Conversion to Sl Units (Système International d'Unités) • All numerical values in this manual are based on

81 units. Numbers shown In conventional units are converted from these values,

Rounding off • Converted values are rounded off to the same

number of places are the Sl unit value. For example, if the 81 unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.

Upper and lower limits • When the data indicates upper and lower limits,

the converted values are rounded down if the Sl unit value is an upper limit and rounded up if the Sl unit value is a lower limit. Therefore, converted values for the same Sl unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications:

210—260 kPa 2.1—2.7 kgf/cm2 , 30—38 psi 270—310 kPa 2.7—3.2 kgf/cm2 , 39—45 psi


Gl-4


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NEW STANDARDS NEW STANDARDS

• Following is a comparison of the previous standard and the new standard.

Previous Standard New Standard Abbreviation Name Abbreviation Name Remark

— Accelerator Pedal AP Accelerator Pedal — Air Cleaner ACL Air Cleaner — Air Conditioning A/C Air Conditioning — Airflow Meter VAF Volume Air Flow Sensor — Airflow Sensor MAF Mass Air Flow Sensor — Alternator GEN Generator

— ATF Thermosensor — Transmission (Transaxle) Fluid Temperature Sensor

— Atmospheric Pressure BARO Barometric Pressure VB Battery Voltage B+ Battery Positive Voltage

OC Oxidation Catalytic Converter TWC Three Way Catalytic Converter

Catalytic Converter

WU-TWC Warm Up Three Way Catalytic Converter #1

— Circuit Opening Relay FPR Fuel Pump Relay #2 — Clutch Position CPP Clutch Pedal Position — Crank Angle Sensor CMP Camshaft Position Sensor — Crank Angle Sensor 2 CKP Crankshaft Position Sensor — Diagnosis Connector DLC Data Link Connector — Diagnosis/Self-Diagnosis OBD On-Board Diagnostic — Direct Ignition DLI Distributorless Ignition

— EC-AT Control Unit TCM Transmission (Transaxle) Control Module

EGI Electronic Gasoline Injection System CIS Continuous Fuel Injection System — Electronic Spark Ignition El Electronic Ignition #3

PCM Powertrain Control Module #4 ECU Engine Control Unit

ECM Engine Control Module — Engine Modification EM Engine Modification — Engine RPM Signal — Engine Speed Input Signal — Evaporative Emission EVAP Evaporative Emission — Exhaust Gas Recirculation EGR Exhaust Gas Recirculation — Fan Control FC Fan Control — Feedback System CLS Closed Loop System — Flexible Fuel FF Flexible Fuel — Fuel Pump FP Fuel Pump — Fully Closed CTP Closed Throttle Position — Fully Open WOT Wide Open Throttle — Ground/Earth GND Ground — 1C Regulator VR Voltage Regulator

#1: Directly connected to exhaust manifold #2: In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump relay (speed). #3: Controlled by the ECM/PCM #4: Device that controls engine and powertrain

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NEW STANDARDS

Previous Standard New Standard Abbreviation Name Abbreviation Name Remark

— Idle Speed Control IAC Idle Air Control — Idle Switch — Closed Throttle Position Switch — Igniter ICM Ignition Control Module — Inhibitor Position TR Transmission (Transaxle) Range — Intake Air Pressure MAP Manifold Absolute Pressure — Intake Air Thermo IAT Intake Air Temperature — Intercooler CAC Charge Air Cooler — Knock Sensor KS Knock Sensor — Line Pressure Solenoid Valve — Pressure Control Solenoid — Lock-up Position TCC Torque Converter Clutch — Malfunction Indicator Light MIL Malfunction Indicator Lamp — Multiport Fuel Injection MFI Multiport Fuel Injection — Open Loop OL Open Loop — Overdrive 4GR Fourth Gear

HO2S Heated Oxygen Sensor With heater — Oxygen Sensor

O2S Oxygen Sensor — Park/Neutral Range PNP Park/Neutral Position — Power Steering Pressure PSP Power Steering Pressure — Pulse Generator — Input/Turbine Speed Sensor — Reed Valve SAPV Secondary Air Pulse Valve

PAIR Pulsed Secondary Air Injection Pulsed injection — Secondary Air Injection System

AIR Secondary Air Injection Inject with compressor

— Sequential Fuel Injection SFI Sequential Multipoint Fuel Injection — Service Code(s) DTC Diagnostic Trouble Code(s) — Spark Ignition Dl Distributor Ignition — Stoplight Switch — Brake Switch — Test Mode DTM Diagnostic Test Mode #5 — Throttle Body TB Throttle Body — Throttle Sensor TP Throttle Position Sensor — Turbocharger TC Turbocharger — Vehicle Speed Sensor VSS Vehicle Speed Sensor — Vehicle Speed Sensor 1 — Output Speed Sensor — Water Thermo ECT Engine Coolant Temperature

1—2 Shift Solenoid Valve Shift+A Solenoid Valve

Shift Solenoid A

2—3 Shift Solenoid Valve Shift+B Solenoid Valve

— Shift Solenoid B

— 3—4 Shift Solenoid Valve — Shift Solenoid C — 3rd Gear 3GR Third Gear — — — Incorrect Gear Ratio

#5: Diagnostic trouble codes depend on the diagnostic test mode

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FUNDAMENTAL PROCEDURES PREPARATION OF TOOLS AND MESURING EQUIPMENT • Be sure that all necessary tools and measuring

equipment are available before starting any work.

SPECIAL TOOLS • Use special tools when they are required.

DISASSEMBLY • If the disassembly procedure is complex, requiring

many parts to be disassembled, all parts should be disassembled in a way that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.

INSPECTION DURING REMOVAL, DISASSEMBLY• When removed, each part should be carefully

inspected for malfunctioning, deformation, damage, and other problems.

GI-7

ARRANGEMENT OF PARTS • All disassembled parts should be carefully

arranged for reassembly. • Be sure to separate or otherwise identify the parts

to be replaced from those that will be reused.

CLEANING OF PARTS • All parts to be reused should be carefully and

thoroughly cleaned in the appropriate method.

Warning• Using compressed air can cause dirt and

other particles to fly out, causing injury to the eyes. Wear protective eye wear " whenever using compressed air.

REASSEMBLY• Standard values, such as torques and certain

adjustments, must be strictly observed in the reassembly of all parts.

If removed, these parts should be replaced with new ones:

1 Oil seals 2 Gaskets 3 O-rings 4 Lockwashers 5 Cotter pins 6 Nylon nuts



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PAGES. FROM. MANUAL

1. Sealant, gasket, or both should be applied to the specified locations. When sealant is applied, parts should be installed before sealant hardens. Hardened sealant causes leaks.

2. Oil should be applied to the moving components of parts. 3. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly.

ADJUSTMENT• Use suitable gauges and testers when making

adjustments.

RUBBER PARTS AND TUBING • Prevent gasoline or oil from getting on rubber

parts or tubing.

HOSE CLAMPS• When reinstalling, position the hose clamp in the

original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit.

TORQUE FORMULAS• When using a torque wrench-SST combination,

the written torque must be recalculated due to the extra length that the SST adds to the torque wrench. Recalculate the torque by using the following formulas. Choose the formula that applies to you.

Torque Unit Formula N•m N•m x [L/(L+A) ]

kgf•m kgf•m x [L/(L+A) ] kgf•cm kgf•cm x [L/(L+A) ] ft•lbf ft•lbf x [L/(L+A) ] in•lbf in•lbf x [L/(L+A) ]

A: The length of the SST past the torque wrench drive.

L: The length of the torque wrench.

VISE• When using a vise, put protective plates in the

jaws of the vise to prevent damage to parts.

I

GI-8



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Locking Connector • When locking connectors, listen for a click that will

indicate they are securely locked.

2. Check the terminals of waterproof connectors from the connector side, as they cannot be accessed from the wiring harness side.

Caution • To prevent damage to the terminal, wrap a thin

wire around the lead before inserting it into the terminal.

ELECTRICAL SYSTEM CONNECTORS Disconnecting Connectors • When disconnecting two connectors, grasp the

connectors, not the wires.

• Connectors can be disconnected by pressing orpulling the lock lever as shown.

Inspection 1. When a tester is used to check for continuity or to measure voltage, insert the tester probe from the wiring

harness side.

GI-9

ELECTRICAL SYSTEM


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ABBREVIATIONS ABBREVIATIONS

EX ............................................ Exhaust HLA ......................................... Hydraulic lash adjuster IN ............................................. lntake MAX ......................................... Maximum SST ......................................... Special service tool

GI-10


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ENGINE

ENGINE OVERHAUL SERVICE WARNING .......... B- 1 ENGINE MOUNTING/DISMOUNTING ................... B- 1

MOUNTING ....................................................... B- 1/2 DISMOUNTING .................................................. B- 2

ENGINE DISASSEMBLY/ASSEMBLY .................. B- 3 TIMING BELT DISASSEMBLY/ASSEMBLY ......... B- 3/5 CYLINDER HEAD (I) DISASSEMBLY/ ASSEMBLY .................................................... B- 6/12CYLINDER HEAD (II) DISASSEMBLY/ ASSEMBLY .................................................... B-12/13 TIMING CHAIN DISASSEMBLY/ ASSEMBLY .................................................... B-14/16 CYLINDER BLOCK (I) DISASSEMBLY/ ASSEMBLY .................................................... B-17/19 CYLINDER BLOCK (II) DISASSEMBLY/ ASSEMBLY .................................................... B-20/22

ENGINE INSPECTION/REPAIR ............................ B-23 CYLINDER HEAD INSPECTION/REPAIR ........... B-23 VALVE INSPECTION ......................................... B-23/24 VALVE GUIDE INSPECTION ............................. B-24 VALVE GUIDE REPLACEMENT ......................... B-24 VALVE SEAT INSPECTION/REPAIR ................. B-25 VALVE SPRING INSPECTION ........................... B-25 CAMSHAFT INSPECTION ................................. B-26 CAMSHAFT OIL CLEARANCE INSPECTION .................................................. B-26

CAMSHAFT END PLAY INSPECTION ................... B-26 ROCKER ARM AND ROCKER ARM SHAFT

INSPECTION ..................................................... B-26/27 CYLINDER BLOCK INSPECTION/ REPAIR ............................................................. B-27 PISTON INSPECTION ........................................... B-27 PISTON CLEARANCE INSPECTION/ REPAIR ............................................................. B-28 PISTON RING CLEARANCE INSPECTION ........... B-28 PISTON PIN CLEARANCE INSPECTION .............. B-28/29 CRANKSHAFT INSPECTION ................................. B-29 CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR ........................................ B-29/30 CRANKSHAFT END PLAY INSPECTION/REPAIR ........................................ B-30 CONNECTING ROD INSPECTION ........................ B-30 CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR ........................................ B-31 CONNECTING ROD SIDE CLEARANCE INSPECTION ..................................................... B-31 PISTON AND CONNECTING ROD INSPECTION ..................................................... B-31 TENSIONER SPRING INSPECTION ..................... B-31 GEAR CLEARANCE INSPECTION ........................ B-31/32 ROTOR CLEARANCE INSPECTION ..................... B-32/33 PLUNGER SPRING INSPECTION ......................... B-33

Warning • Continuous exposure with USED engine oil

has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work.

ENGINE MOUNTING/DISMOUNTING MOUNTING 1. Install the SST (arms and attachment) to the

cylinder block holes as shown, and hand-tighten the SST (bolts).

2. Assemble the SST (bolts, nuts, and plate) to the specified positions.

ENGINE OVERHAUL SERVICE WARNING

B-1


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PAGES. FROM. MANUAL

3. Adjust the SST (bolts) so that less than 20 mm 0.79 in of thread is exposed. 4. Make the SST (plate and arms) parallel by adjusting the SST (bolts and nuts). 5. Tighten the SST (bolts and nuts) to affix the SST firmly.

Warning• The self-locking brake system of the engine

stand may not be effective when the engine is held In an unbalanced position. This could lead to sudden, rapid movement of the engine and mounting stand handle and cause serious injury. Never keep the engine in an unbalanced position, and always hold the rotating handle firmly when turning the engine.

6. Mount the engine on the SST (engine stand).

7. Drain the engine oil. 8. Install the oil drain plug.

Tightening torque 30–41 N.m 3.0–4.2 kgf.m, 22–30 ft.lbf

DISMOUNTING • Dismount in the reverse order of mounting.

B-2

ENGINE MOUNTING/DISMOUNTING


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PAGES. FROM. MANUAL

ENGINE DISASSEMBLY/ASSEMBLYTIMING BELT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.

1

Crankshaft pulley • Refer to Disassembly Note • Refer to Assembly Note

2 Upper timing belt cover 3 Lower timing belt cover 4 Guide plate 5 Spark plug

6

Timing belt • Refer to Disassembly Note • Refer to Assembly Note

7

Tensioner, tensioner spring • Refer to Assembly Note

8 Idler

B-3

ENGINE MOUNTING/DISMOUNTING


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PAGES. FROM. MANUAL

Crankshaft Pulley Disassembly Note • Hold the crankshaft by using the SST.

Timing Belt Disassembly Note 1. Turn the crankshaft clockwise and align the timing

marks as shown.

Camshaft pulley timing mark F8: 4 FE: 2

2. Remove the spark plug. Caution

• The following will damage the belt and shorten its life; forcefully twisting it. Turning it inside out, or allowing oil or grease on It.

3. Mark the timing belt rotation on the belt for proper reinstallation.

Tensioner, Tensioner Spring Assembly Note 1. Install the tensioner and tensioner spring. 2. Position the tensioner all the way to the intake

side and temporarily secure it by tightening the lock bolt.

Timing Belt Assembly Note 1. Turn the crankshaft clockwise and align the timing

marks as shown.


2. Install the timing belt.3. Turn the crankshaft clockwise twice and align the

timing marks. If they are not aligned, remove the timing belt and repeat from Timing Belt Assembly Note step 1.

4. Loosen the tensioner lock bolt to apply tension to the belt. Do not apply tension other than that of the tensioner spring.

5. Tighten the tensioner lock bolt. Be sure the tensioner does not move together with the bolt rotation.

6. Turn the crankshaft clockwise twice and check the timing belt deflection at the point indicated by applying moderate pressure 98 N 10 kgf , 22 Ibf If it is incorrect repeat from Timing Belt Disassembly Note.

B-4

Timing belt deflectionNew : 4.0―5.0 mm 0.16―0.19 In Used : 5.5―6.5 mm 0.22―0.25 in

ENGINE DISASSEMBLY/ASSEMBLY


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B-5

Crankshaft Pulley Assembly note • Hold the crankshaft by using the SST.



CONTINUED


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CYLINDER HEAD(I) DISASSEMBLY/ASSEMBLY Timing belt drive type 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.

1

Cylinder head cover • Refer to Assembly Note

2

Rocker arm • Refer to Disassembly Note • Refer to Assembly Note

3

Camshaft pulley • Refer to Disassembly Note • Refer to Assembly Note

4

Front housing • Refer to Assembly Note

5

Camshaft • Refer to Assembly Note

6

Cylinder head • Refer to Disassembly Note • Refer to Assembly Note

7 Cylinder head gasket

B-6



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PAGES. FROM. MANUAL

Rocker Arm Disassembly Note • Loosen the bolts in two or three steps in the order

shown.

Cylinder Head Assembly Note • Tighten the bolts in two or three steps in the order

shown.

Camshaft Assembly Note • Be certain that the knock pin of the camshaft faces

straight up.

Front Housing Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.

Camshaft Pulley Assembly Note • Install the camshaft pulley on the camshaft with

the knock pin fit into the hole at the timing mark.


B-7

Camshaft pulley Disassembly Note • Hold the camshaft by using a screwdriver.

Cylinder Head Disassembly Note • Loosen the cylinder head bolts in two or three

steps in the order shown.

Rocker Arm Assembly Note 1. Assemble the rocker arms, rocker arm shafts, and

camshaft bearing cap as shown in the figure.

2. Tighten the bolts in two or three steps in the ordershown.



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Cylinder Head Cover Assembly Note 1. Apply silicone sealant to the shaded areas.

B-8

Thickness ∅1.5―2.0 mm 0.060―0.078 in

2. Install the cylinder head cover and tighten the bolts in two or three steps in the order shown.

3. Tap in the seal cap by using a plastic hammer.



CONTINUED


PAGES. FROM. MANUAL

Timing chain drive type 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.

1

Cylinder head cover • Refer to Assembly Note

2

Chain adjuster • Refer to Disassembly Note • Refer to Assembly Note

3

Camshaft gear • Refer to Disassembly Note

4

Rocker arm • Refer to Disassembly Note • Refer to Assembly Note

5 Camshaft

6

Camshaft sprocket • Refer to Disassembly Note • Refer to Assembly Note

7

Cylinder head • Refer to Disassembly Note • Refer to Assembly Note

8

Cylinder head gasket • Refer to Assembly Note

B-9



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PAGES. FROM. MANUAL

Chain Adjuster Disassembly Note 1. Turn the crankshaft until the FE mark of the

camshaft pulley is at the top as shown. 2. Check that the crankshaft pulley timing mark is

aligned with the indicator pin.

Cylinder Head Disassembly Note 1. Remove the bolt A. 2. Loosen the remaining cylinder head bolts in two or

three steps in the order shown.

3. Remove the chain adjuster.

Camshaft Gear Disassembly Note 1. Pry up the washer tab.

2. Hold the camshaft with a screwdriver as shown.

Rocker Arm Disassembly Note • Loosen the rocker arm shaft bolts in two or three


2. Tighten the remaining small cylinder head bolts.

B-10

Cylinder Head Gasket Assembly Note 1. Apply silicone sealant to the shaded area.

2. Install the cylinder head gasket. 3. Apply silicone sealant to the shaded area of the

cylinder head gasket.

Cylinder Head Assembly Note 1. Tighten the cylinder head bolts in two or three




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Rocker Arm Assembly Note 1. Apply silicone sealant to the shaded area.

Camshaft Sproket Assembly Note 1. Install the camshaft sprocket to the camshaft,

aligning mark on the camshaft sprocket and timingchain.

2. Tighten the bolt in two or three steps in the order shown.

2. Hold the camshaft with a screwdriver as shown. 3. Tap in the new seal cap by using a plastic hammer.

3. Bent the washer tab to lock the locknut.Chain Adjuster Assembly Note

1. Lift the ratchet pawl and compress the chain adjuster sleeve fully, then lock it with the pin lock.

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Cylinder Head Cover Assembly Note 1. Apply silicone sealant to the seal cap as shown.

2. Apply silicone sealant to the shaded areas.

CYLINDER HEAD (II) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.

1

Valve keeper • Refer to Disassembly Note • Refer to Assembly Note

2 Upper valve spring seat 3

Valve spring (FE CIS: Single spring type)

• Refer to Assembly Note 4 Lower valve spring seat 5 Valve 6

Valve seal • Refer to Disassembly Note • Refer to Assembly Note

Valve Seal Disassembly Note • Remove the valve seal by using the SST.

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3. Install the cylinder head cover and tighten the bolts in two or three steps in the order shown.

Valve Keeper Disassembly Note • Remove the valve keeper by using the SST.



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Valve Seal Assembly Note 1. Assemble the SST so that depth L is as specified.

Depth L F8, FE CARB: 19.2―19.6 mm 0.756―0.771 in FE CIS: 21.4―22.2 mm 0.843―0.874 in

2. Press the valve seal onto the valve guide by hand. 3. Tap the SST by using a plastic hammer until its

lower end touches the cylinder head.

B-13

Valve Keeper Assembly Note • Install the valve keeper by using the SST.

Valve Spring Assembly Note • Install the valve spring with the closer pitch toward

the cylinder head.



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TIMING CHAIN DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table. 2. Assemble in the order of disassembly.

1 Water pump 2

Crankshaft pulley • Refer to Disassembly Note • Refer to Assembly Note

3

Timing chain cover • Refer to Disassembly Note • Refer to Assembly Note

4

Timing chain • Refer to Assembly Note

5 Timing gear 6 Crankshaft key 7 Timing chain lever

8 Timing chain guide 9 Oil strainer 10

Oil pan • Refer to Disassembly Note • Refer to Assembly Note

11 Oil pump cover 12 Inner rotor 13 Outer rotor 14 Spring seat 15 Pressure spring 16 Control plunger

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Timing Chain Assembly Note 1. Install the timing chain as shown in the figure.

Crankshaft Pulley Disassembly Note • Hold the crankshaft by using the SST.

Oil Pan Disassembly Note • Remove the oil pan by using the separator tool.

Thickness ∅2.5―3.5 mm 0.099―0.137 in

_

Timing Chain Cover Disassembly Note • Remove the oil seal by using a screwdriver


B-15

2. Support the timing chain by using a magnetic base.

Timing Chain Cover Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.

Tightening torqueA: 19―25 N.m 1.9―2.6 kgf.m , 14―18 ft.lbf B: 38―51 N.m 3.8―5.3 kgf.m , 28―38 ft.lbf

4. Apply silicone sealant to the mounting surface along the inside of the bolt holes as shown.

Oil Pan Assembly Note • Apply silicone sealant to the oil pan as shown.

5. Tighten the timing chain cover installation bolt.



CONTINUED


PAGES. FROM. MANUAL

Crankshaft Pulley Assembly Note • Hold the crankshaft by using the SST.

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CYLINDER BLOCK (I) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.

2

1

Oil pan (Timing belt drive type) • Refer to Disassembly Note • Refer to Assembly Note

2 Oil strainer (Timing belt drive type) 3

Oil baffle (FE CIS) • Refer to Disassembly Note • Refer to Assembly Note

4

Timing belt pulley (Timing belt drive type) • Refer to Disassembly Note • Refer to Assembly Note

5

Flywheel • Refer to Disassembly Note • Refer to Assembly Note

6 End plate 7

Oil pump (Timing belt drive type) • Refer to Disassembly Note • Refer to Assembly Note

8 Oil pump body (Timing belt drive type) 9 Outer gear (Timing belt drive type)

10 Inner gear (Timing belt drive type) 11 Oil pump cover (Timing belt drive type) 12 Spring seat (Timing belt drive type) . 13 Pressure spring (Timing belt drive type) 14 Control plunger (Timing belt drive type) 15

Rear cover • Refer to Disassembly Note • Refer to Assembly Note

16

Water pump • Refer to Assembly Note

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Oil Pan Disassembly Note Note

• Do not insert the separator tool between the oil baffle and cylinder block.

• Remove the oil pan by using the separator tool.

Oil Baffle Disassembly Note • Remove the oil baffle by using the separator tool.

Timing Belt Pulley Disassembly Note • Hold the crankshaft by using the SST.

Flywheel Disassembly Note • Hold the crankshaft by using the SST.

Oil Pump Disassembly Note • Remove the oil seal by using a screwdriver


Water Pump Assembly Note 1. Verify that the rubber seal is securely fixed onto the water pump. 2. If not, replace the rubber seal and reapply the bonding agent. 3. Install the water pump.

Rear Cover Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.

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Rear Cover Disassembly Note • Remove the oil seal by using a screwdriver




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Oil Pump Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.

Oil Pan Assembly Note• Apply Silicone sealant to the oil pan as shown.

Thickness ∅2.0―3.0 mm 0.079―0.118 in

Flywheel Assembly Note1. Hold the crankshaft by using the SST. 2. Tighten the flywheel bolt in the order shown.

Timing Belt Pulley Assembly Note • Hold the crankshaft by using the SST.

Oil Baffle Assembly Note• Apply silicone sealant to the oil baffle as shown.

Thickness ∅2.0―3.0 mm 0.079―0.118 in

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CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.

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1 Connecting rod cap 2 Lower connecting rod bearing 3

Piston and connecting rod • Refer to Disassembly Note • Refer to Assembly Note

4 Upper connecting rod bearing 5 Piston ring 6 Piston pin 7 Piston 8 Connecting rod

9

Main bearing cap • Refer to Disassembly Note • Refer to Assembly Note

10 Lower main bearing 11

Pilot bearing • Refer to Disassembly Note • Refer to Assembly Note

12 Crankshaft 13 Upper main bearing 14 Cylinder block



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Piston and Connecting Rod Disassembly Note1. Assemble the SST as shown.

2. Insert SST No.2 into the piston pin as shown andfully screw in SST No.1.

3. Set the piston and connecting rod on the SST as shown.

4. Press out the piston pin.

Main Bearing Cap Disassembly Note • Loosen the main bearing cap bolts in two or three


B-21

Pilot Bearing Disassembly Note

Pilot Bearing Assembly Note

Main Bearing Cap Assembly Note 1. Tighten the bolts in two or three steps in the order shown.

Piston and Connecting Rod Assembly Note 1. Assemble the SST as shown.

• Remove the pilot bearing by using the SST.

• Install the pilot bearing by using a suitable pipe.



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10. F mark facing the front of the engine.

2. Insert SST No.2 into the piston pin as shown and fully screw in SST No.1.

8. Verify that the second ring is installed with the scraper face downward. 9. Position the end gap of the oil ring as shown.3. Set the SST (stopper bolt) so that dimension L is

as specified.

Dimension L 60.0 mm 2.36 in

4. Apply clean engine oil to the piston pin. 5. Insert the piston pin and the SST assembled in

step 2 into the piston and connecting rod.

6. Press the piston pin into the piston and connecting rod until the SST (guide) contacts the SST (stopper bolt).

7. While inserting the piston pin, check the pressure force. If it is less than the specification, replace the piston pin or the connecting rod.

Pressure force 2.94―14.70 KN 300―1500 kgf , 660―3300 Ibf

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ENGINE INSPECTION/REPAIR CYLINDER HEAD INSPECTION/REPAIR 1. Carry out cooling flaw detection on the cylinder

head surface. Replace the cylinder head if necessary.

2. Inspect for the following and repair or replace if necessary. (1) Sunken valve seats (2) Excessive camshaft oil clearance and end

play 3. Measure the cylinder head for distortion in the six

directions as shown.

Distortion 0.15 mm 0.006 in max.

4. If the cylinder head distortion exceeds the maxi-mum, repair by grinding the height or replace the cylinder head. If the cylinder head height is not within the specification, replace it.

Standard height 91.95―92.05 mm 3.621―3.624 in

Grinding 0.20 mm 0.008 in max.

5. Measure the manifold contact surface distortion as shown.

Distortion 0.15 mm 0.006 in max.

6. If the distortion exceeds the specification, grind the surface or replace the cylinder head .


B-23

VALVE INSPECTION 1. Measure the valve head margin thickness of each valve. Replace the valve if necessary.

Margin thickness FE CIS IN: 1.80―2.20 mm 0.071―0.086 in EX: 1.30―1.70 mm 0.052―0.006 in F8, FE CARB IN: 0.8―1.2 mm 0.032―0.047 in EX: 1.3―1.7 mm 0.052―0.066 in

2. Measure the length of each valve. Replace the valve if necessary.

Standard length FE CIS IN: 115.61―116.01 mm 4.552―4.567 in EX: 116.01―116.41mm 4.568―4.583 in F8, FE CARB IN: 111.69―112.09 mm 4.398―4.412 EX: 111.49―111.89 mm 4.390―4.405 in

Minimum length FE CIS IN: 115.51 mm 4.548 in EX: 115.71 mm 4.556 in F8, FE CARB IN: 111.39 mm 4.386 in EX: 111.19 mm 4.378 in

3. Measure the stem diameter of each valve in X and Y directions at the three points (A, B, and C) shown. Replace the valve if necessary.

Standard diameter FE CIS IN: 6.970―6.985 mm 0.2745―0.2749 in EX: 6.965―6.980 mm 0.2743―0.2748 in F8, FE CARB IN: 8.030―8.045 mm 0.3162―0.3167 in EX: 8.025―8.040 mm 0.3160―0.3165 in

Minimum diameter FE CIS IN: 6.920 mm 0.2724 in EX: 6.915 mm 0.2722 in F8, FE CARB IN: 7.980 mm 0.3142 in EX: 7.975 mm 0.3140 in

ENGINE INSPECTION/REPAIR


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VALVE GUIDE INSPECTION 1. Measure the inner diameter of each valve guide in X

and Y directions at the three points (A, B, and C) shown. Replace the valve guide if necessary.

Standard inner diameter FE CIS

IN: 7.010―7.030 mm 0.2760―0.2767 in EX: 7.010―7.030 mm 0.2760―0.2767 in

F8, FE CARB IN: 8.030―8.045 mm 0.3162―0.3167 in EX: 8.025―8.040 mm 0.3160―0.3165 in

2. Measure the protrusion height (dimension A) of each valve guide without lower valve spring seat. Replace the valve guide if necessary.

VALVE GUIDE REPLACEMENTValve Guide Removal

• Remove the valve guide from the combustion chamber side by using the SST.

Valve Guide Installation1. Assemble the SSTs so that depth L is as specified.

Depth LFE CIS: 19.8―20.3 mm 0.780―0.799 in F8, FE CARB: 19.1―19.6 mm 0.752―0.771 in

2. Tap the valve guide in from the side opposite the combustion chamber until! the SST contacts the cylinder head.

3. Verify that the valve guide projection height (dimension) is within the specification.

Standard heightFE CIS: 19.8―20.3 mm 0.780―0.799 in FB, FE CARB: 19.1―19.6mm 0.752―0.771 in

B-24

Standard height FE CIS: 19.8―20.3 mm 0.780―0.799 in F8, FE CARB: 19.1―19.6mm 0.752―0.711 in



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VALVE SPRING INSPECTION 1. Apply pressing force to the pressure spring and

check the spring height. Replace the valve spring if necessary.

VALVE SEAT INSPECTION/REPAIR 1. Measure the seat contact width.

If necessary, resurface the valve seat by using a 45° valve seat cutter and/or resurface the valve face.

Standard width IN: 1.2―1.6 mm 0.048―0.062 in EX: 1.2―1.6 mm 0.048―0.062 in

2. Verify that the valve seating position is at the cen-ter of the valve face. (1) If the seating position is too high, correct the

valve seat by using a 75° (FE CIS) or 60° (F8, FE CARB) cutter, and a 45° cutter.

(2) If the seating position is too low, correct the valve seat by using a 35° (IN) or 15° (EX) cutter and a 45° cutter.

3. Check the sinking of the valve seat. Measure the protruding length (dimension L) of the valve stem. Replace the cylinder head if necessary.

Standard dimension L F8, FE CARB: 46.5 mm 1.831 in FE CIS: 49.7 mm 1.957 in

Maximum dimension L F8, FE CARB: 47.0 mm 1.850 in FE CIS: 51.2 mm 2.016 in

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Pressing forceFE CIS

IN: 203.10―229.86 N 20.71―23.44 kgf , 45.57 51.56 Ibf EX: 240.37―272.03 N 24.51―27.74 kgf , 53.93―61.02 Ibf

F8, FE CARB Inner: 117.19―136.01 N 11.95―13.87 kgf , 26.29―30.51 Ibf Outer: 243.70―267.03 N 24.85―27.23 kgf , 54.67―59.90 Ibf

Standard height FE CIS IN: 41 mm 1.614 in EX: 41 mm 1.614 in F8, FE CARB Inner: 36.5 mm 1.437 in Outer: 41.0 mm 1.614 in

2. Measure the out-of-square of the valve spring. Replace the valve spring if necessary.

Valve spring out-or-square FE CIS IN: 1.70 mm 0.067 in EX: 1.76 mm 0.069 in FB, FE CARB Inner: 1.5 mm 0.059 in Outer: 1.8 mm 0.071 in

―



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CAMSHAFT INSPECTION 1. Set the No.1 and No.5 journals on V-blocks. Measure the camshaft runout. Replace the camshaft if necessary.

Runout 0.03 mm 0.0012 in max.

2. Measure the cam lobe height at the two points as shown. Replace the camshaft if necessary.

Standard height FE CIS IN: 41.340 mm 1.6276 in EX: 41.847 mm 1.6475 in F8, FE CARB IN: 38.202 mm 1.5040 in EX: 38.202 mm 1.5040 in Fuel pump cam: 39.900 mm 1.5709 in

3. Measure the journal diameters in X and Y directions at the two points (A and B) as shown. Replace the camshaft if necessary.

Standard diameter No.1, 5: 31.940―31.965 mm

1.2575―1.2585 in No.2, 3, 4: 31.910―31.935 mm

1 .2563―1.2572 in

Minimum diameter No.1, 5: 31.910 mm 1.2563 in No.2, 3, 4: 31.880 mm 1.2551 in

CAMSHAFT OIL CLEARANCE INSPECTION 1. Position a plastigage atop the journals in the axial direction.

2. Install the camshaft cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY CYLINDER HEAD (II) Camshaft Cap Assembly Note.)

3. Remove the camshaft cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER HEAD (II) Camshaft Cap Assembly Note.)

4. Measure the oil clearance. Replace the cylinder head if necessary.

Standard clearance No.1, 5: 0.035―0.085 mm

0.00138―0.00334 in No.2, 3, 4: 0.065―0.115 mm

0.00256―0.00453 in

Maximum clearance 0.15 mm 0.006 in

CAMSHAFT END PLAY INSPECTION 1. Install the camshaft and thrust plate. 2. Measure the camshaft end play. Replace the

camshaft and/or thrust plate if necessary.

Standard end play0.08―0.16 mm 0.00315―0.00629 in

Maximum end play0.20 mm 0.008 in

ROCKER ARM AND ROCKER ARM SHAFT INSPECTION 1. Measure the rocker arm inner diameter.

Diameter FE CIS: 19.000―19.033 mm 0.7481―0.7493 in F8, FE CARB: 15.966―15.984 mm 0.6286―0.6292 in

2. Measure the rocker arm shaft diameter.

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mm in

Diameter FE CIS: 18.959―18.980 mm

0.7465―0.7472 in F8, FE CARB: 15.966―15.984 mm

0.6286―0.6292 in

3. Calculate the rocker arm-to-shaft clearance. Replace the rocker arm and/or rocker arm shaft if necessary.

Standard clearance FE CIS: 0.020―0.074 mm 0.00079―0.00291 in

F8, FE CARB: 0.016―0.061 mm 0.00063―0.00240 in

CYLINDER BLOCK INSPECTION/REPAIR 1. Measure the distortion of the cylinder block top

surface in the six directions as shown. Repair by grinding or replace if necessary.

Cylinder block distortion 0.15 mm 0.006 in max.

Cylinder block height FE: 288.93―289.07 mm 11.376―11.380 in F8: 268.43―268.57 mm 10.569―10.573 in


2. Measure the cylinder bores in X and Y directions at 65 mm 2.56 in (F8), 70 mm 2.76 in (FE) below the top surface.

3. If the cylinder bore exceeds the wear limit, replace the cylinder block or rebore the cylinder and install the oversize pistons so that the specified piston-to-cylinder clearance is obtained.

Note• Base the boring diameter on the diameter of

an oversize piston. All cylinders must be the same diameter.

Cylinder bore

Size Diameter 86.000―86.019

Standard 3.3859―3.3865 86.250―86.269

0.25 0.01 oversize 3.3957―3.3964 86.500―86.519

0.50 0.02 oversize 3.4056―3.4062

Wear limit 0.15 mm 0.006 in

PISTON INSPECTION • Measure the outer diameter of each piston at a

right angle (90°) to the piston pin, 18.0 mm 0.709 in below oil ring groove.

Piston diameter mm in Size Diameter

85.943―85.965 Standard 3.38358―3.38444

86.193―86.215 0.25 0.01 oversize 3.39342―3.39428

86.443―86.465 0.50 0.02 oversize 3.40327―3.40412

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PISTON CLEARANCE INSPECTION/REPAIR1. Calculate the piston-to-cylinder clearance.

Replace the piston or rebore the cylinders to fit an oversized piston if necessary.

Standard clearance 0.035―0.076 mm 0.0014―0.0029 in


2. If the piston is replaced, the piston rings must also be replaced.

PISTON RING CLEARANCE INSPECTION 1. Measure the piston ring-to-ring land clearance

around the entire circumference. Replace the piston and piston ring if necessary.

Standard clearance Top : 0.03―0.07 mm 0.0012―0.0027 in Second : 0.03―0.07 mm 0.0012―0.0027 in Oil : 0.03―0.07 mm 0.0012―0.0027 in


2. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel.

3. Measure each piston ring end gap by using a feeler gauge. Replace the piston ring if necessary.

Standard end gap Top : 0.20―0.35 mm 0.008―0.013 in Second : 0.15―0.30 mm 0.006―0.011 in Oil rail : 0.20―0.70 mm 0.008―0.027 in

Maximum end gap 1.0 mm 0.039 in

PISTON PIN CLEARANCE INSPECTION 1. Measure each piston pin hole diameter in X and Y directions at the four points (A, B, C, and D) as shown.

Standard diameter21.988―21.998 mm 0.8657―0.8660 in

2. Measure each connecting rod small end inner diameter in X and Y directions as shown.

Standard diameter 21.943―21.961 mm 0.8639―0.8646 in

3. Measure each piston pin diameter in X and Y directions at the four points (A, B, C, and D) as shown.

Standard diameter 21.974―21.980 mm 0.8652―0.8653 in

4. Calculate the piston pin-to-piston pin bore clearance. Replace the piston and/or piston pin if necessary.

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5. Calculate the connecting rod small end-to-piston pin clearance. Replace the connecting rod or piston pin.

Standard clearance - 0.037―0.013 mm -0.0014―0.0006 in

CRANKSHAFT INSPECTION 1. Measure the crankshaft runout. Replace the crankshaft if necessary.

Runout 0.03 mm 0.0012 in

2. Measure the journal diameter in X and Y direction at the two points (A and B) as shown. Replace the crankshaft or grind the journal and install the undersize bearing if necessary.

Main journal mm in Bearing size Diameter

Standard

No.1, 2, 4, 5 : 59.937―59.955 2.3598―2.3604 No.3 : 59.937―59.955 2.3598―2.3604

0.25 0.01 undersize

No.1, 2, 4, 5 : 59.687―59.697 2.3499―2.3502 No.3 : 59.687―59.691 2.3499―2.3500

0.50 0.02 undersize

No.1, 2, 4, 5 : 59.437―59.447 2.3401―2.3404 No.3 : 59.437―59.455 2.3401―2.3407

0.75 0.03 undersize

No.1, 2, 4, 5 : 59.187―59.197 2.3302―2.3305 No.3 : 59.187―59.205 2.3302―2.3309

Out-of-round 0.05 mm 0.002 in max.

Crank pin mm in Bearing size Diameter

Standard 50.940―50.955 2.0056―2.0060

0.25 0.01 undersize 50.690―50.705 1.9957―1.9962

0.50 0.02 undersize 50.440―50.455 1.9859―1.9864

0.75 0.03 undersize 50.190―50.205 1.9760―1.9765

Out-of-round 0.05 mm 0.002 in max.

CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR .

1. Position a plastigauge atop the journals in the axial direction. 2. Install the main bearing cap.

(Refer to ENGINE DISASSEMBLY/ASSEMBLY. CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Assembly Note.)

3. Remove the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Disassembly Note.)

4. Measure the main journal oil clearance. If the clearance exceeds the maximum, replace the main bearing or grind the main journal and install the undersize bearings so that the specified oil clearance is obtained.

Standard oil clearance No.1, 2, 4, 5: 0.025―0.074 mm 0.00099―0.00291 in No.3: 0.031―0.074 mm 0.00123―0.00291 in

Maximum oil clearance 0.10 mm 0.004 in

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mm in

mm in Bearing size Bearing thickness

Standard 2.004―2.007 0.07890―0.07901

0.25 0.01 undersize 2.129―2.139 0.08382―0.08421

0.50 0.02 undersize No.1, 2, 4, 5 : 2.254―2.264 0.08874―0.08913No.3 : 2.254―2.257 0.08874―0.08885

0.75 0.03 undersize No.1, 2, 4, 5 : 2.379―2.389 0.09367―0.09405No.3 : 2.379―2.382 0.09367―0.09377

CRANKSHAFT END PLAY INSPECTION/REPAIR1. Install the main bearing cap.

(Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Assembly Note.)

2. Measure the crankshaft end play. If the end play exceeds the maximum, replace the crankshaft bearing or grind the crankshaft and Install an undersize bearing so that the specified end play is obtained.

Standard end play 0.08―0.18 mm 0.00315―0.00708 in

Maximum end play 0.30 mm 0.012 in

Note • When replacing the No.3 crankshaft bearing

replace all of the bearing as a set.

Bearing size Bearing thickness

Standard 27.94―27.99 1.1000―1.1019

0.25 0.01 undersize 28.04―28.09 1.1 040―1.1 060

0.50 0.02 undersize 28.12―28.17 1.1071―1.1090

0.75 0.03 undersize 28.20―28.25 1.1103―1.1122

3. Remove the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Disassembly Note.)

CONNECTING ROD INSPECTION • Measure each connecting rod for bending and

distortion. Replace the connecting rod if necessary.

Bending 0.15 mm 0.006 in max. /100 mm 3.937 in

Distortion 0.180 mm 0.0071 in max. /50 mm 1.97 in

Center-to-center distance FE: 151.95―152.05 5.983―5.986 in F8: 135.95―136.05 5.353―5.356 in

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CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR 1. Position a plastigauge atop the journals in the

axial direction. 2. Install the connecting rod cap.

(Refer to ENGINE DISASSEMBLY/ASSEMBLY. CYLINDER BlOCK(II) DISASSEMBLY/ASSEMBLY,

Piston and Connecting Rod Assembly Note.) 3. Remove the connecting rod cap. 4. Measure the crankpin oil clearance. If the

clearance exceeds the maximum, replace the connecting rod bearing or grind the crankpin and use undersize bearings so that the specified clearance is obtained.

Standard oil clearance 0.027―0.067 mm 0.0011―0.0026 in

Maximum oil clearance 0.10 mm 0.004 in mm in

Bearing size Bearing thickness

Standard 1.505―1.510 0.0593―0.0594

0.25 0.01 undersize 1.630―1.635 0.0642―0.0643

0.50 0.02 undersize 1.755―1.760 0.0691―0.0692

0.75 0.03 undersize 1.880―1.885 0.0741―0.0742

CONNECTING ROD SIDE CLEARANCE INSPECTION 1. Install the connecting rod cap.

(Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY. Piston and Connecting Rod Assembly Note.)

2. Measure the connecting rod large end side clearance. Replace the connecting rod and cap if necessary.



B-31

3. Remove the connecting rod cap.

PISTON AND CONNECTING ROD INSPECTION• Check the oscillation torque as shown. If the large

end does not drop by its own weight, replace the piston or the piston pin.

TENSIONER SPRING INSPECTION • Measure the free length of the tensioner spring.

Replace the tensioner spring if necessary.

Free lengthF8: 63.0 mm 2.48 in FE CARB: 56.9 mm 2.24 in FE CIS: 53.9 mm 2.12 in

GEAR CLEARANCE INSPECTION F8, FE CARB Timing Belt Drive Type

• Measure the following clearance. Replace the gear and/or pump body if necessary.

Standard innergear tooth tip to cresent clearance

0.267―0.380 mm 0.0106―0.0149 in

Maximum innergear tooth tip to cresent crearance

0.400 mm 0.0157 in



CONTINUED


PAGES. FROM. MANUAL

Standard outer gear tooth tip to cresent clearance

0.200―0.320 mm 0.0079―0.0125 in

ROTOR CLEARANCE INSPECTION FE CIS

• Measure the following clearance. Replace the rotor and/or pump body if necessary.

Maximum Inner rotor tooth tip to outer rotor clearance

0.18 mm 0.007 in

Maximum outer gear tooth tip to cresent clearance

0.350 mm 0.0138 in

Standard side clearance 0.030―0.063 mm 0.00119―0.00248 in

Standard outer gear to pump body clearance 0.090―0.176 mm 0.0036―0.0069 in

Maximum side clearance 0.10 mm 0.004 in

Maximum outer gear to pump body clearance 0.20 mm 0.008 in

Standard outer rotor to body clearance 0.030―0.063 mm 0.00119―0.00248 in


Maximum body clearance 0.10 mm 0.004 in


B-32



CONTINUED


PAGES. FROM. MANUAL

FE CARB Timing Chain Drive Type • Measure the following clearance. Replace the

rotor and/or pump body if necessary.

Standard Inner rotor tooth tip to outer rotor clearance

0.044―0.084 mm 0.0017―0.0033 in

PLUNGER SPRING INSPECTION • Measure the free length of the plunger spring.

Replace the plunger spring if necessary.

Free length 46.4 mm 1.827 in

Maximum Inner rotor tooth tip to outer rotor clearance

0.18 mm 0.007 in

Standard outer gear to pump body clearance 0.090―0.176 mm 0.0035―0.0069 in

Maximum outer gear to pump body clearance 0.20 mm 0.008 in



B-33



CONTINUED


PAGES. FROM. MANUAL

TECHNICAL DATA TECHNICAL DATA ......................................... TD-1/4 TECHNICAL DATA

Item SpecificationCylinder head Height mm in 91.95—92.05 3.621—3.624 Distortion mm in 0.15 0.006 max. Grinding mm in 0.20 0.008 max.

IN 0.30 0.012 (Engine hot) Valve clearance (F8, FE CARB) mm in EX 0.30 0.012 (Engine hot) Valve and valve guide

IN FE CIS: 1.80—2.20 0.071—0.086 F8, FE CARB: 0.8—1.2 0.032—0.047 Margin thickness

mm in EX FE CIS: 1.30—1.70 0.052—0.066

F8, FE CARB: 1.3—1.7 0.052—0.066

Standard FE CIS: 115.61—116.01 4.552—4.567 F8, FE CARB: 111.69—112.09 4.398—4.412 IN

Minimum FE CIS: 115.51 4.548, F8, FE CARB: 111.39 4.386

Standard FE CIS: 116.01—116.41 4.568—4.583 F8, FE CARB: 111.49—111.89 4.390—4.405

Valve length mm in

EX Minimum FE CIS: 115.71 4.556, F8, FE CARB: 111.194.378

Standard FE CIS: 6.970—6.985 0.2745—0.2749 F8, FE CARB: 8.030—8.045 0.3162—0.3167 IN

Minimum FE CIS: 6.920 0.2724 F8, FE CARB: 7.980 0.3142 Standard

FE CIS: 6.965—6.980 0.2743—0.2748 F8, FE CARB: 8.025—8.040 0.3160—0.3165

Valve stem diameter mm in

EX Minimum FE CIS: 6.915 0.2722 F8, FE CARB: 7.975 0.3140 IN

FE CIS: 7.010—7.030 0.2760—0.2767 F8, FE CARB: 8.030—8.045 0.3162—0.3167

Guide inner diameter EX

FE CIS: 7.010—7.030 0.2760—0.2767 F8, FE CARB: 8.025—8.040 0.3160—0.3165

IN

FE CIS: 19.8—20.3 0.780—0.799 F8, FE CARB: 19.1—19.6 0.752—0.771 Valve guide protrusion height

mm in EX

FE CIS: 19.8—20.3 0.780—0.799 F8, FE CARB: 19.1—19.6 0.752—0.771

Valve seat IN 1.2—1.6 0.048—0.062 Seat contact width

mm in EX 1.2—1.6 0.048—0.062 IN 45°

Seat angle EX 45° Standard F8, FE CARB: 46.5 1.831 FE CIS: 49.7 1.957

IN Maximum F8, FE CARB: 47.0 1.850 FE CIS: 51.2 2.016 Standard F8, FE CARB: 46.5 1.831 FE CIS: 49.7 1.957

Seat sinking mm in (Valve protrusion height)

EX Maximum F8, FE CARB: 47.0 1.850 FE CIS: 51.2 2.016

TD-1


CONTINUED


PAGES. FROM. MANUAL

TECHNICAL DATA

Item SpecificationValve spring

H: 41.0 mm 1.614 in (FE CIS) 203.10—229.86 20.71—23.44, 45.57—51.56

IN H Inner: 36.5 mm 1.437 in Outer: 41.0 mm 1.614 in (F8, FE CARB)

Inner: 117.19—136,01 11,95—13.87, 26.29—30,51 Outer: 243.70—267.03 24.85—27.23, 54.67—59.90

H: 41.0 mm 1.614 in (FE CIS) 240.37—272.03 24.51—27.74, 53.93—61.02

Pressing force at Valve spring height H N kgf, lbf

EX H Inner: 36.5 mm 1.437 in Outer: 41.0 mm 1.614 in (F8, FE CARB)

Inner: 117.19—136.01 11.95—13.87, 26,29—30.51 Outer: 243.70—267.03 24.85—27.23, 54.67—59.90

IN FE CIS: 1.70 0.067 F8, FE CARB: Inner 1.5 0.059 outer 1.8 0.071 Out-of-square

mm in EX FE CIS: 1.76 0.069

F8, FE CARB: Inner 1.5 0.059 outer 1.8 0.071 Camshaft Camshaft runout mm in 0.03 0.0012 max.

IN FE CIS: 41,340 1.6276 F8, FE CARB: 38.202 1.5040 Lobe height mm in

EX FE CIS: 41.847 1.6475 F8, FE CARB: 38.202 1.5040 Standard 31.940—31.965 1.2575—1.2585

No.1, 5 Minimum 31.910 1.2563 Standard 31.910—31.935 1.2563—1.2572

Journal diameter mm in No.2, 3,

4 Minimum 31.880 1.2551 No.1, 5 0.035—0.085 0.00138—0,00334 No.2, 3, 4 0.065—0.115 0.00256—0.00453 Camshaft bearing oil clearance

mm in Maximum 0.15 0.006 Standard 0.08—0.16 0.00315—0.00629

Camshaft end play mm in Maximum 0.20 0.008

Rocker arm and rocker arm shaft

Rocker arm inner diameter mm in FE CIS: 19.000—19.033 0.7481—0.7493 F8, FE CARB: 15.966—15.984 0.6286—0.6292

Rocker arm shaft diameter mm in FE CIS: 18.959—18.980 0.7465—0.7472 F8, FE CARB: 15.966—15.984 0.6286—0.6292

Rocker arm to shaft clearance mm in FE CIS: 0.020—0.074 0.00079—0.00291 F8, FE CARB: 0.016—0.061 0,00063—0.00240

Cylinder block

Height mm in FE; 288.93—289.07 11.376—11.380 F8: 268.43—268.57 10.569—10.573

Distortion mm in 0.15 0.006 max. Grinding mm in 0.20 0.008 max.

Standard 86.000—86.019 3.3859—3,3865 0.25 0.01 oversize 86.250—86.269 3.3957—3.3964 Cylinder bore diameter

mm in 0.50 0.02 oversize 86.500—86.519 3.4056—3.4062

Wear limit mm in 0.15 0,006

TD-2


CONTINUED


PAGES. FROM. MANUAL

TECHNICAL DATA

Item SpecificationPiston

Standard 85.943—85.965 3.38358—3.38444

0.25 0.01 oversize 86.193—86.215 3.39342—3.39428

Piston diameter Measured at 90° to pin bore axis and 18.0 mm 0.709 in below oil ring groove mm in 0.50 0.02 oversize 86.443—86.465 3.40327—3.40412

Standard 0.035—0.076 0.0014—0.0029 Piston-to-cylinder clearance mm in

Maximum 0.15 0.006 Piston ring

Top 0.03—0.07 0.0012—0.0027 Second 0.03—0.07 0.0012—0.0027 Oil 0.03—0.07 0.0012—0.0027

Piston ring-to-ring groove clearance mm in

Maximum 0.15 0.006 Top 0.20—0.35 0.008—0.013 Second 0.15—0.30 0.006—0.011 Oil (rail) 0.20—0.70 0.008—0.027

End gap (Measured in cylinder) mm in

Maximum 1.0 0.039 Piston pin Diameter mm in 21.974—21.980 0.8652—0.8653 Connecting rod small end-to-piston pin clearance mm in - 0.037— - 0.013 -0.0014— - 0.0006 Piston-to-piston pin clearance mm in 0.008—0.024 0.00032—0.00094 Crankshaft Crankshaft runout mm in 0.03 0.0012 max.

Standard No.1, 2, 4, 5: 59.937—59.955 2.3598—2.3604 No.3: 59.937—59.955 2.3598—2.3604

0.25 0.01 undersize No.3: 59.687—59.691 2.3499—2.3500

0.50 0.02 undersize No.1, 2, 4. 5: 59.437—59.447 2.3401—2.3404 No.3: 59.437—59.455 2.3401—2.3407

Main journal diameter mm in

0.75 0.03 undersize No.1, 2, 4, 5: 59,187—59.197 2.3302—2.3305

Out-of-round mm in 0.05 0.002 max. Standard 50.940—50.955 2.0056—2.0060 0.25 0.01 undersize 50.690—50.705 1.9957—1.9962 0.50 0.02 undersize 50.440—50.455 1.9859—1.9864

Crankpin diameter mm in

0.75 0.03 undersize 50.190—50.205 1.9760—1.9765 Out-of-round mm in 0.05 0.002 max.

Standard No.1, 2, 4, 5: 0.025—0.074 0.00099—0.00291 No.3: 0.031—0.074 0.00123—0.00291 Main journal oil clearance

mm in Maximum 0.10 0.004 Standard 0.08—0.18 0.00315—0.00708

Crankshaft end play mm in Maximum 0.30 0.012

TD-3

No.1, 2, 4, 5: 59.687—59.697 2.3499—2.3502

No.3: 59.187—59.205 2.3302—2.3309


CONTINUED


PAGES. FROM. MANUAL

TECHNICAL DATA

Item SpecificationConnecting rod and connecting rod bearing

Length (Center to center) mm in F8: 135.95—136.05 5,353—5.356 FE: 151.95—152.05 5.983—5.986

Bending mm in 0.15 0.006 max./100 mm 3.937 in Distortion mm in 0.180 0.0071 max./50 mm 1.97 in

Standard 0.110—0.262 0.005—0.010 Connecting rod side clearance mm in Maximum 0.30 0.012

Standard 0.027—0.067 0.0011—0.0026 Connecting rod bearing oil clearance mm in Maximum 0.10 0.004 Tensioner spring

Free length mm in F8: 63.0 2.48, FE CARB: 56.9 2.24, FE CIS: 53.9 2.12

Oil pump

Standard FE CARB Timing chain drive type: 0.044—0.084 0.0017—0.0033 Inner rotor tooth tip to outer rotor

clearance mm in Maximum 0.18 0.007 (FE CIS, FE CARB Timing chain type)

Standard FE CIS, CARB Timing chain type: 0.090—0.176 0.0035—0.0069 Outer rotor to body clearance

mm in Maximum FE CIS, CARB Timing chain type: 0.20 0.008

Standard F8, FE CARB Timing belt drive type: 0.267—0.380 0.0106—0.0149 Inner gear tooth tip to crescent

clearance mm in Maximum F8, FE CARB Timing belt drive type:

0.400 0.0157

Standard P8, FE CARB Timing belt drive type: 0.200—0.320 0.0079—0.0125 Outer gear tooth tip to crescent

clearance mm in Maximum F8, FE CARB Timing belt drive type: 0.350 0.0138 Standard 0.030—0.063 0.00119—0.00248 Outer gear to pump body clearance

mm in Maximum 0.10 0.004

Standard F8, FE CARB Timing belt drive type:

0.030—0.063 0.00120—0.0024 FE CIS, FE CARB Timing chain drive type:

0.03—0.09 0.0012—0.0035 Side clearance mm in

Maximum 0.10 0.004 Plunger spring Free length mm in 46.4 1.827

TD-4


CONTINUED


PAGES. FROM. MANUAL

SPECIAL TOOLS SPECIAL TOOLS ........................................... ST-1 SPECIAL TOOLS 49 0107 680A Engine stand

49 L010 1A0 Engine hanger set

49 0636 100B Valve spring lifter arm

49 B012 0A2 Pivot

49 0221 251A Valve guide remover and installer

49 S120 170 Valve seal remover

49 L012 0A2 Valve seal and guide installer

49 L011 0A0B Piston pin setting tool set

49 E011 1A0 Ring gear brake set

49 1285 071 Needle bearing puller

49 P005 204 Oil seal installer

49 S011 103 Oil seal installer

ST-1


CONTINUED


PAGES. FROM. MANUAL

B2–1

ENGINE(WL, WL Turbo)

DRIVE BELT B2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE BELT INSPECTION B2–1/2. . . . . . . . . . . . . . . . DRIVE BELT ADJUSTMENT B2–2. . . . . . . . . . . . . . .

VALVE CLEARANCE B2–2. . . . . . . . . . . . . . . . . . . . . . . . VALVE CLEARANCE

INSPECTION/ADJUSTMENT B2–2. . . . . . . . . . . . . COMPRESSION INSPECTION B2–3. . . . . . . . . . . . . . . TIMING BELT B2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIMING BELT REMOVAL/INSTALLATION B2–4/5. . . . CYLINDER HEAD GASKET B2–6. . . . . . . . . . . . . . . . . .

CYLINDER HEAD GASKET REPLACEMENT B2–6/8. . . . . . . . . . . . . . . . . . . . . . . . .

ROCKER ARM B2– 9. . . . . . . . . . . . . . . . . . . . . . . . . . . ROCKER ARM REMOVAL/

INSTALLATION B2– 9/11. . . . . . . . . . . . . . . . . . . . . . . . FRONT OIL SEAL B2–11. . . . . . . . . . . . . . . . . . . . . . . . .

FRONT OIL SEAL REPLACEMENT B2–11/12. . . . . . . . REAR OIL SEAL B2–12. . . . . . . . . . . . . . . . . . . . . . . . . .

REAR OIL SEAL REPLACEMENT B2–12. . . . . . . . ENGINE B2–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE REMOVAL/INSTALLATION B2–13/14. . . . . . ENGINE DISASSEMBLY/ASSEMBLY B2–14. . . . .

DRIVE BELTDRIVE BELT INSPECTIONDrive Belt Deflection Check

1. Check the drive belt deflection when the engine iscold, or at least 30 minutes after the engine hasstopped. Apply pressure 98 N 10 kgf, 22 lbfmidway between the specified pulleys.

GENERATOR

A/C

GENERATOR

MEASURINGPOINT

WATERPUMP

CRANKSHAFTPULLEY

MEASURINGPOINT a

MEASURINGPOINT b

CRANKSHAFTPULLEY

A/C COMPRESSOR

Deflection (mm in)

Drive belt *New Used Limit

Generator7.0—9.0

0.28—0.358.0—10.0

0.32—0.3916.0

0.63

A/C

a5.0—6.2

0.20—0.246.0—6.5

0.24—0.2511.3

0.44A/C

b9.5—11.8

0.38—0.4611.0—12.5

0.44—0.4918.0

0.71

* A belt that has been on a running engine for less thanfive minutes.

2. If the deflection is not within the specification,adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)

Drive Belt Tension Check1. Belt tension can be checked in place of belt

deflection. Check the drive belt tension when theengine is cold, or at least 30 minutes after theengine has stopped. Using the SST, check the belttension between any two pulleys.

WHEN SET

WHEN MEASURED

49 9200 020A

BACK.TO.MAIN.INDEX

CONTINUED


PAGES. FROM. MANUAL

DRIVE BELT, VALVE CLEARANCE

B2–2

Tension (N kgf, lbf)

Drive belt *New Used Limit

Generator442—63745—65,99—143

383—53939—55,86—121

17718, 40

A/C403—51941—53,91—116

354—43136—44,80—96

18118.5, 41

* A belt that has been on a running engine for less thanfive minutes.

2. If the tension is not within the specification, adjustit. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)

DRIVE BELT ADJUSTMENT1. Loosen the mounting bolt and locknut A.2. Adjust the belt deflection or tension by turning

adjusting bolt B. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.)

3. Tighten the mounting bolt and locknut A.

GENERATOR

A/C

GENERATOR

WATERPUMP

CRANKSHAFTPULLEY

CRANKSHAFTPULLEY

N·m kgf·m, ft·lbf

32—463.2—4.7,24—33

A/C COMPRESSOR

B

A 19—251.9—2.6,14—18

A

B

a

A

b

38—513.8—5.3,28—38

4. Inspect the belt deflection or tension. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.)

VALVE CLEARANCEVALVE CLEARANCE INSPECTION/ADJUSTMENT

1. Remove the cylinder head cover.2. Turn the crankshaft and align the timing mark so

that the piston of the No.1 or No.4 cylinder is atTDC of compression.

3. Measure the valve clearances A with the No.1cylinder at TDC of compression, and those of Bwith the No.4 cylinder at TDC of compression.

Valve clearanceIN: 0.05—0.15 mm 0.0020—0.0059 in

[Engine cold]0.15 mm 0.0059 in

[Engine hot (Reference)]EX:0.15—0.25 mm 0.0060—0.0098 in

[Engine cold]0.25 mm 0.0098 in[Engine hot (Reference)]

ENGINEFRONT

B

A A A

B B

4. If not within the specification, adjust and recheckthe valve clearance.

5. Turn the crankshaft one full turn and measure theremaining valve clearances. Adjust if necessary.

Tightening torque (locknut)16—20 N·m 1.6—2.1 kgf·m, 12—15 ft·lbf

LOCKNUT

FEELERGAUGE

ADJUSTSCREW

6. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEADGASKET REPLACEMENT, Cylinder Head Cover Installation Note.)


CONTINUED


PAGES. FROM. MANUAL

COMPRESSION INSPECTION

B2–3

COMPRESSION INSPECTIONWarning When the engine and the oil are hot, they

can badly burn. Turn off the engine and waituntil they are cool.

1. Verify that the battery is fully charged. Recharge itif necessary.(Refer to Section G, CHARGINGSYSTEM, BATTERY INSPECTION, Battery.)

2. Warm up the engine to the normal operatingtemperature.

3. Stop the engine and allow it to cool off for about 10minutes.Warning Fuel line spills and leaks are dangerous.

Fuel can ignite and cause serious injuriesor death and damage. Fuel can also irritateskin and eyes. To prevent fuel fromspurting out of the injection nozzle hole, donot ground the FCV (fuel cut valve) terminal.

4. Disconnect the FCV (fuel cut valve) connector.5. Remove all the glow plugs.

(Refer to Section F2, INTAKE AIR SYSTEM, GLOW PLUG REMOVAL/INSTALLATION.)

6. Install the SSTs into the glow plug hole.49 S010 1A0

49 S013 102

7. Crank the engine and note the maximum gaugereading.

8. Check each cylinder as above.

Compression(kPa kgf/cm 2, psi [rpm])

ItemEngine

ItemWL, WL Turbo

Standard 2942 30, 427 [200]

Minimum 2648 27, 384 [200]

9. If the compression in one or more cylinders is low,pour a small amount of clean engine oil into thecylinder and recheck the compression.(1) If the compression increases, the piston, the

piston rings, or cylinder wall may be worn andoverhaul is required.

(2) If the compression stays low, a valve may bestuck or improperly seated and overhaul isrequired.

(3) If the compression in adjacent cylinders stayslow, the cylinder head gasket may be damagedor the cylinder head distorted and overhaul isrequired.

10. Remove the SST.11. Install the glow plug.

(Refer to Section F2, INTAKE AIR SYSTEM, GLOW PLUG REMOVAL/INSTALLATION.)

12. Connect the FCV (fuel cut valve) connector.


CONTINUED


PAGES. FROM. MANUAL

TIMING BELT

B2–4

TIMING BELTTIMING BELT REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.


7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf

38—51 3.8—5.3, 28—38

1 Timing belt cover+ Installation Note

2 Tensioner, tensioner spring

3 Timing belt+ Removal Note+ Installation Note

Timing Belt Removal Note

Caution Forcefully twisting the belt, turning it inside

out, or allowing oil or grease on it willdamage the belt and shorten its life.

FAULTY

ROTATIONARROW

25 mm 1.0 in MIN.

FAULTY FAULTY

FAULTY

1. Mark the timing belt rotation on the belt for properreinstallation.

2. Turn the crankshaft clockwise and align the timingmarks as shown.

CAMSHAFTPULLEY

TIMING MARK

TENSIONERSPRING

TENSIONER

FIP PULLEYTIMING MARK

3. Remove the tensioner and tensioner spring.

Timing Belt Installation Note1. Measure the tensioner spring free length. Replace

the tensioner spring if necessary.

Free length63.0 mm 2.48 in

FREE LENGTH

2. Turn the crankshaft clockwise and align the timingmarks as shown.

CAMSHAFTPULLEY

TIMING MARK

TENSIONERSPRING

TENSIONER

FIP PULLEYTIMING MARK

TENSIONERLOCK BOLT

Caution Overtensioning of the timing belt can cause

breakage of the belt and the camshaft.

3. Verify that the FIP attaching bolts and nuts aretightened to the specified torque. This must bedone to prevent overtensioning of the timing beltafter it has been installed.

4. Install the timing belt.5. Install the tensioner, tensioner spring, and

hand-tighten the lock bolt.6. Turn the crankshaft clockwise twice, and align the

timing marks. If they are not aligned, remove thetiming belt and repeat from Timing Belt Installation Note Step 2.

7. Loosen the tensioner lock bolt to apply tension tothe belt. Do not apply tension other than that of thetensioner spring.

8. Tighten the tensioner lock bolt. Be sure thetensioner does not move together with the boltrotation.

9. Turn the crankshaft clockwise twice, and check thetiming belt deflection as shown. If it is incorrect,repeat from Timing Belt Removal Note .


CONTINUED


PAGES. FROM. MANUAL

ST

TIMING BELT

B2–5

Timing belt deflection9.0—10.0 mm 0.36—0.39 in at

98 N 10 kgf, 22 lbf

CAMSHAFTPULLEY

TENSIONERSPRING

TENSIONER

FIP PULLEY

TENSIONERLOCK BOLT

DEFLECTIONCHECKINGPOINT

Timing Belt Cover Installation Note Tighten the timing belt cover bolts in the order

shown.


CONTINUED


PAGES. FROM. MANUAL


B2–6

CYLINDER HEAD GASKETCYLINDER HEAD GASKET REPLACEMENT

Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep

sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and

damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line SafetyProcedures”. (Refer to Section F2, FUEL SYSTEM, FUEL PRESSURE AND SERVICING FUEL SYSTEM.)

1. Disconnect the negative battery cable.2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE W

,ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)3. Remove the intake manifold, air intake pipe and breather chamber.

(Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)4. Remove the injection nozzle.

(Refer to Section F2, FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.)5. Remove the turbocharger. (WL Turbo)

(Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)6. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.)7. Remove in the order indicated in the table.8. Install in the reverse order of removal.9. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)

10. Check the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.)11. Bleed air in the fuel line. (Refer to Section F2, FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)12. Start the engine and

(1) Inspect for engine oil, engine coolant, and fuel leakage.(2) Inspect the idle speed. (Refer to Section F2, ENGINE TUNE-UP, PREPARATION, Idle Speed Adjustment.)

13. Inspect the compression. (Refer to COMPRESSION INSPECTION.)

18—19 1.8—2.0, 13.1—14.4


7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf

38—51 3.8—5.3, 28—38

7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf

29 3.0, 22 + (90°—105°) + (90°—105°)

5.0—8.8 N·m50—90 kgf·cm,44—78 in·lbf


CONTINUED

ARNINGS.) (Refer to Section E


PAGES. FROM. MANUAL

ST


B2–7

1 Drive belt

2 Cylinder head cover+ Installation Note

3 Cylinder head bolt+ Removal Note+ Installation Note

4 Cylinder head

5 Cylinder head gasket+ Installation Note

Cylinder Head Bolt Removal Note1. Remove bolts A.2. Loosen the cylinder head bolts in two or three


A

A

Cylinder Head Gasket Installation Note Apply silicone sealant to the cylinder head as

shown.

Thicknessø2.0—3.0 mm 0.08—0.11 in

ENGINEFRONT

16.0 mm0.63 in

40.5 mm1.59 in

48.5 mm1.91 in

9.0 mm0.35 in

Cylinder Head Bolt Installation Note1. Measure the length of each bolt. Replace the bolt if

necessary.

Cylinder head bolt (mm in)

Bolt head mark Standardlength

Maximumlength

W101.2—101.8

3.985—4.007102.5 4.035

N113.2—113.8

4.457—4.480114.5 4.508

LENGTH

2. Apply clean engine oil to the threads and the seatface of each bolt and install them.

3. Tighten the bolts in two or three steps in the ordershown in the figure.

Tightening torque29 N·m 3.0 kgf·m, 22 ft·lbf

A

A

4. Put a paint mark on each bolt head.5. Using the marks as a reference, tighten the bolts

by turning each 90°—105° in the sequence shown.6. Further tighten each bolt by turning another

90°—105°.

PAINT MARK

PAINT MARK

90°—105° 90°—105°

7. Tighten bolts A.

Tightening torque18—19 N·m 1.8—2.0 kgf·m, 13.1—14.4 ft·lbf


CONTINUED


PAGES. FROM. MANUAL


B2–8

Cylinder Head Cover Installation Note1. Apply silicone sealant to the cylinder head as

shown.

Thicknessø1.5—2.5 mm 0.060—0.098 in

2. Tighten cylinder head cover bolts A and B.

Tightening torque1.5—2.9 N·m 15—30 kgf·cm, 14—26 in·lbf

ENGINEFRONT

A

B

3. Tighten the cylinder head cover bolts in the ordershown.



CONTINUED


PAGES. FROM. MANUAL

ST

ROCKER ARM

B2–9

ROCKER ARMROCKER ARM REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove the air intake pipe and breather chamber.

(Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)3. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.)4. Remove in the order indicated in the table.5. Install in the reverse order of removal.

16—20 1.6—2.1, 12—15


7.9—10.7 N·m 80—110 kgf·cm, 69.5—95.4 in·lbf

30—41 3.0—4.2, 22—30

5.0—8.8 N·m50—90 kgf·cm,44—78 in·lbf

11.3—14.2 N·m 115—145 kgf·cm, 100—125 in·lbf

123—140 12.5—14.3, 91—103

R

SST

R

1 Cylinder head cover+ VALVE CLEARANCE, VALVE CLEARANCE

INSPECTION/ADJUSTMENT+ CYLINDER HEAD GASKET, CYLINDER HEAD

GASKET REPLACEMENT, Cylinder Head CoverInstallation Note

2 Camshaft pulley+ Removal Note+ Installation Note

3 Seal plate+ Installation Note

4 Camshaft+ Removal Note+ Installation Note

5 Rocker arm+ Installation Note

6 Pivot


CONTINUED


PAGES. FROM. MANUAL

ROCKER ARM

B2–10

Camshaft Pulley Removal Note Hold the camshaft by using a wrench on the cast

hexagon.

Camshaft Removal Note

Note Mark the camshaft caps so that they can be

reinstalled in the position from which they wereremoved.

Loosen the camshaft cap bolts in three or foursteps in the order shown.

ENGINEFRONT

Rocker Arm Installation Note If a new rocker arm is used, set dimension as

follows.

Dimension A0—4 mm 0—0.1 in

A

Camshaft Installation Note1. Apply silicone sealant to the front camshaft cap

mounting surfaces as shown. Prevent sealant fromgetting onto the camshaft journal, oil seal surface,and camshaft thrust surface.

2. Tighten the camshaft cap bolts gradually in three orfour steps in the order shown.

ENGINEFRONT

3. Apply clean engine oil to the new oil seal.4. Push the oil seal slightly in by hand.5. Tap the oil seal into the cylinder head by using the

SST and a hammer.6. To ensure that the oil seal is installed accurately,

measure distance between the end of the cylinderhead and the face of the oil seal.

HAMMER CYLINDERHEAD OIL SEAL

0.5—1.0 mm 0.02—0.03 in

49 S010 001

Seal Plate Installation Note Tighten the seal plate bolts in the order shown.


CONTINUED


PAGES. FROM. MANUAL

ROCKER ARM, FRONT OIL SEAL

B2–11

Camshaft Pulley Installation Note Hold the camshaft by using a wrench on the cast

hexagon and tighten the pulley lock bolt.

FRONT OIL SEALFRONT OIL SEAL REPLACEMENT

1. Disconnect the negative battery cable.2. Drain the engine coolant. (Refer to Section E,

COOLING SYSTEM SERVICE WARNINGS.)(Refer to Section E, ENGINE COOLANT, ENGINECOOLANT REPLACEMENT.)

3. Remove the upper radiator hose.4. Remove the radiator cowling and cooling fan.

(Refer to Section E, WATER PUMP, WATERPUMP REMOVAL/INSTALLATION.)

5. Remove in the order indicated in the table.6. Install in the reverse order of removal.7. Inspect the engine oil level.8. Adjust the drive belt deflection.

(Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)

R

SST

SST


350—39035—40,260—280

1 Drive belt

2 Crankshaft pulley+ Removal Note+ Installation Note

3 Front oil seal+ Removal Note+ Installation Note

Crankshaft Pulley Removal Note Hold the crankshaft by using the SST.

Caution Turning the crankshaft after the crankshaft

pulley is removed can cause the timinggear to become dislocated.

Removing the key can cause the keygroove to become misaligned.

49 S011 102A


CONTINUED


PAGES. FROM. MANUAL

FRONT OIL SEAL, REAR OIL SEAL

B2–12

Front Oil Seal Removal Note1. Cut the oil seal lip by using a razor knife.2. Remove the oil seal by using a screwdriver


RAG

Front Oil Seal Installation Note1. Apply clean engine oil to the new oil seal lip.2. Push the oil seal slightly in by hand.3. Tap the oil seal in evenly by using the SST and a

hammer.4. To ensure that the oil seal is installed accurately,

measure the distance between the end of the gearcase cover and the face of the front oil seal.

HAMMERFRONT OIL SEAL

0—0.4 mm0—0.01 in

GEAR CASE COVER

49 S010 301

Crankshaft Pulley Installation Note Hold the crankshaft by using the SST.

49 S011 102A

REAR OIL SEALREAR OIL SEAL REPLACEMENT

1. Disconnect the negative battery cable.2. Remove the flywheel.

(Refer to Section H, CLUTCH UNIT, CLUTCH UNITREMOVAL/INSTALLATION.)

3. Remove in the order indicated in the table.4. Install in the reverse order of removal.5. Inspect the engine oil level. (Refer to Section D,

ENGINE OIL, ENGINE OIL INSPECTION.)

RSST

1 Rear oil seal+ Removal Note+ Installation Note

Rear Oil Seal Removal Note1. Cut the oil seal lip by using a razor knife.2. Remove the oil seal by using a screwdriver


RAG

Rear Oil Seal Installation Note1. Apply clean engine oil to the new oil seal lip.2. Push the oil seal slightly in by hand.3. Tap the oil seal in evenly by using the SST and a

hammer.4. To ensure that the oil seal is installed accurately,

measure the distance between the end of the rearcover and the face of the rear oil seal.

HAMMERREAR OIL SEAL

REAR COVER

0—0.5 mm 0—0.01 in

49 S011 103


CONTINUED


PAGES. FROM. MANUAL

ENGINE

B2–13

ENGINEENGINE REMOVAL/INSTALLATION

Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep

sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and

damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line SafetyProcedures”. (Refer to Section F2, FUEL SYSTEM, FUEL PRESSURE AND SERVICING FUEL SYSTEM.)

1. Remove the air intake pipe. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)

2. Remove the battery. (Refer to Section G, CHARGING SYSTEM, BATTERY REMOVAL/INSTALLATION.)3. Remove the radiator. (Refer to Section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.)4. Remove the front pipe.

(Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)5. Remove the transmission.

(Refer to section J2, TRANSMISSION, TRANSMISSION REMOVAL/INSTALLATION.)6. Remove in the order indicated in the table.7. Install in the reverse order of removal.8. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)9. Bleed air in the fuel line. (Refer to Section F2, FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)

10. Start the engine and(1) Inspect the engine oil, engine coolant, and fuel leakage.(2) Inspect the idle speed.

(Refer to Section F2, ENGINE TUNE-UP, IDLE SPEED PREPARATION, Idle Speed Adjustment.)11. Perform a road test.


32—46 3.2—4.7, 24—33

7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf

20—30 2.0—3.1, 15—22

9.9—14.7 N·m100—150 kgf·cm,86.8—130 in·lbf

19—25 1.9—2.6,14—18

1 Cooling fan

2 Drive belt

3 Accelerator cable

4 A/C compressor+ Removal Note

5 P/S oil pump+ Removal Note

6 Engine mount nut

7 Engine+ Removal/Installation Note


CONTINUED


PAGES. FROM. MANUAL

ENGINE

B2–14

A/C Compressor Removal Note Remove the A/C compressor with the pipe still

connected. Position the A/C compressor so that itis out of the way.

P/S Oil Pump Removal Note Remove the P/S oil pump with the oil hose still

connected. Position the P/S oil pump so that it isout of the way.

Engine Removal/Installation Note Install the engine hanger (JE48 10 561C) to the

cylinder head by using bolt (99794 0820) or (M8 1.25, 6T, length 20 mm 0.79 in) as shown.

Tightening torque19—25 N·m 1.9—2.6 kgf·m, 14—18 ft·lbf

ENGINEFRONT

ENGINE DISASSEMBLY/ASSEMBLY1. Remove the intake-air system.

(Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)

2. Remove the exhaust system. (Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)

3. Remove the oil cooler. (Refer to Section D, OIL COOLER, OIL COOLERREMOVAL/INSTALLATION.)

4. Disassemble in the ordre indicated in the table.5. Assemble in the reverse order of disassembly.


38—513.8—5.3,28—38

38—513.8—5.3,28—38

32—463.2—4.7,24—33 19—25 1.9—2.6, 14—18

12—17 1.2—1.8, 9—13

1 Drive belt

2 Generator

3 Idler

4 A/C compressor bracket

5 Engine mount bracket

6 Oil pressure switch+ Section D, OIL PRESSURE INSPECTION

7 Water pump pulley


CONTINUED


PAGES. FROM. MANUAL

ENGINE (F2)

DRIVE BELT .................................................... B3- 1 HLA REMOVAL/INSTALLATION ................ B3-10/12 DRIVE BELT INSPECTION .......................... B3- 1 HLA TROUBLESHOOTING ........................ B3-13 DRIVE BELT ADJUSTMENT ........................ B3- 2 FRONT OIL SEAL ......................................... B3-14

TIMING BELT .................................................. B3- 4 REAR OIL SEAL ............................................. B3-15

CYLINDER HEAD GASKET ............................. B3- 7 ENGINE .......................................................... B3-16

HYDRAULIC LASH ADJUSTER (HLA) ............ B3-10

Deflection mm inDrive belt *New Used

Generator 7.0—8.0 0.28—0.31

8.0—9.0 0.32—0.35

P/S 5.0—6.0 0.20—0.23

5.5—6.5 0.22—0.25

A/C 10.0—12.0 0.40—0.47

12.0—14.0 0.48—0.55

DRIVE BELT DRIVE BELT INSPECTION Drive Belt Deflection Check 1. Check the drive belt deflection when the engine

is cold, or at least 30 minutes after the engine has stopped. Apply pressure 98 N 10 kgf, 22 Ibf midway between the specified pulleys.

* A belt that has been on a running engine for less than five minutes. 2. If the deflection is not within the specification,

adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)

Drive Belt Tension Check 1. Belt tension can be checked in place of belt

deflection. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two pulleys.

B3-1

CYLINDER HEAD GASKET ENGINE REMOVAL/INSTALLATION ......... B3-16/17

CONTINUED


PAGES. FROM. MANUALBACK.TO.MAIN.INDEX

COMPRESSION INSPECTION ........................ B3- 2/3 FRONT OIL SEAL REPLACEMENT ........... B3-14

TIMING BELT REMOVAL/INSTALLATION ... B3-4/6 REAR OIL SEAL REPLACEMENT ............. B3-15

REPLACEMENT ......................................... B3- 7/9 ENGINE DISASSEMBLY/ASSEMBLY ........ B3-18

DRIVE BELT, COMPRESSION INSPECTION Tension N kgf, Ibf

Drive belt *New Used

Generator 510—588 52—60,

115—132

432—509 44—52,

97—114

P/S 393—490 40—50, 88—110

344—441 35—45, 77—99

A/C 373—490 38—50, 84—110

275—372 28—38, 62—83

COMPRESSION INSPECTION Warning • When the engine and the oil are hot, they

can badly burn. Be careful not to burn yourself during removal/installation of each component.

• Verify that the battery is fully charged. Recharge it if necessary. (Refer to Section G, CHARGING SYSTEM, BATTERY INSPECTION, Battery.)

• Warm up the engine to the normal operating temperature.

• Stop the engine and allow it to cool off for about 10 minutes.

• Perform "Fuel Line Safety Procedure". Leave the fuel pump relay removed. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

• Disconnect the igniter connector (F2 CIS) or ignition coil primary wire connector (F2 CARB).

• Remove the spark plugs. • Connect a compression gauge into the No.1 spark

plug hole. • Fully depress the accelerator pedal and crank the

engine. • Note the maximum gauge reading. • Inspect compression of each cylinder.Compression kPa kgf/cm2, psi [rpm]

Engine type Item F2 CARB F2CIS

Standard 1196 12.2, 173 [300]

1226 12.5, 178 [300]

Minimum 837 8.54, 121 [300]

858 8.75, 124 [300]

Maximum difference between cylinders

196 kPa 2.0 kgf/cm2, 28 psi

* A belt that has been on a running engine for less than five minutes.

2. If the tension is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)

DRIVE BELT ADJUSTMENT 1. Loosen mounting bolts A and B, and locknut C. 2. Adjust the belt deflection or tension by turning the

generator or adjusting bolt D. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.)

3. Tighten mounting bolts A and B, and locknut C.

• If the compression in one or more cylinders is low or the compression difference between cylinders exceeds the maximum, pour a small amount of clean engine oil into the cylinder and recheck the compression. • If the compression increases, the piston, the

piston rings, or cylinder wall may be worn and overhaul is required.

• If the compression stays low, a valve may be stuck or improperly seated and overhaul is required.

• If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required.

• Disconnect the compression gauge. • Install the spark plugs.

Tightening torque 15—22 N-m 1.5—2.3 kgf-m, 11—16 ft-lbf

B3-2CONTINUED

BACK.TO.CHAPTER.INDEXRANG.DRFT.REPAIR MANUAL


COMPRESSION INSPECTION

• Connect the igniter connector (F2 CIS) or ignition coil primary wire connector (F2 CARB).

• Install the fuel pump relay.

B3-3

CONTINUED



TIMING BELT TIMING BELT TIMING BELT REMOVAL/INSTALLATION

1. Disconnect the negative battery cable. 2. Remove the spark plugs. 3. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 4. Remove the cooling fan and cooling fan pulley. 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Start the engine and

(1) Inspect the pulleys and drive belt for runout and contact. (2) Inspect the ignition timing.

(Refer to Section F3-F4, ENGINE TUNE-UP, IGNITION TIMING ADJUSTMENT.)

1 Generator strap 2 Cooling fan bracket

6

Timing belt Removal Note Installation Note3

Timing belt cover Installation Note 7 Tensioner, tensioner spring

Installation Note4 Crankshaft pulley 5 Guide plate

B3-4

CONTINUED



TIMING BELT Timing Belt Removal Note

1. Turn the crankshaft clockwise and align the timing marks.

Camshaft pulley timing mark 1

2. Loosen the tensioner lock bolt. 3. Push the tensioner in the direction of the ar

row to reduce tension of the timing belt and hand-tighten the tensioner lock bolt.

Caution • Forcefully twisting the belt, turning it

inside out, or allowing oil or grease on it will damage the belt and shorten its life.

Note • Mark the timing belt rotation on the belt for

proper reinstallation.

Tensioner, Tensioner Spring Installation Note

1. Measure the tensioner spring free length. If not as specified, replace the tensioner spring. Free length 63.0 mm 2.48 in

2. Install the tensioner. 3. Temporarily secure the tensioner with the spring

fully extended.

Timing Belt Installation Note 1. Verify that the timing belt pulley mark and

camshaft pulley mark are aligned with the timing marks as shown.

Camshaft pulley timing mark 1

2. Install the timing belt so that there is no

looseness at the tension side.

B3-5

CONTINUED



TIMING BELTCaution

• Applying excessive tension can break the timing belt. Be sure not to apply tension other than that of the tensioner spring.

3. Loosen the tensioner lock bolt to apply tension to the timing belt.

4. Turn the crankshaft clockwise twice and verify that the timing belt pulley mark and camshaft pulley mark are aligned with the timing marks.

5. If not, repeat from Timing Belt Removal Note. (Refer to Timing Belt Removal Note.)

Caution • Prevent the tensioner from moving with the

tensioner lock bolt as it is turned. Otherwise tension will become very high and the timing belt may break.

6. Tighten the tensioner lock bolt. 7. Inspect the timing belt deflection at the point

indicated by applying moderate pressure 98 N 10 kgf, 22 Ibf.

Timing belt deflection New : 8.0—9.0 mm 0.32—0.35 in Used : 9.0—10.0 mm 0.36—0.39 in

8. If not as specified, repeat from Timing Belt

Removal Note. (Refer to Timing Belt Removal Note.)

Timing Belt Cover Installation Note • Tighten the timing belt cover bolts in the order

shown.

B3-6

CONTINUED



CYLINDER HEAD GASKETCYLINDER HEAD GASKET CYLINDER HEAD GASKET REPLACEMENT

Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep

sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and

damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F3, F4. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.)

(Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the timing belt, (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 4. Remove the front pipe.

(Refer to Section F3-F4, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 5. Remove the air cleaner. (F2 CARB) 6. Remove the air hose. (F2 CIS) 7. Disconnect the PCV hose. 8. Disconnect the accelerator cable and bracket (F2 CIS). 9. Disconnect the vacuum hoses, and engine harness connector.

10. Disconnect the fuel hoses. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to Section F3-F4, AFTER REPAIR PROCEDURE.)

11. Remove the dynamic chamber bracket. (F2 CIS) 12. Disconnect the heater hoses. 13. Remove in the order indicated in the table. 14. Install in the reverse order of removal. 15. Inspect for fuel leakage. 16. Inspect the compression. (Refer to COMPRESSION INSPECTION.) 17. Start the engine and inspect the idle speed.

(Refer to Section F3-F4, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)

B3-7 CONTINUED




3 Cylinder head gasket 1

Cylinder head cover Installation Note

2

Cylinder head Removal Note Installation Note

B3-8

CONTINUED



CYLINDER HEAD GASKET Cylinder Head Bolt Removal Note

• Loosen the cylinder head bolts a few turns in the order shown.

Cylinder Head Bolt Installation Note • Tighten the cylinder head bolts a few turns in the

order shown.

Cylinder Head Cover Installation Note 1. Verify that the grooves on the cylinder head cover

are free of oil, water and other foreign material. 2. Apply sealant all around the cylinder head cover

side of the cylinder head cover gasket surface. 3. Install the cylinder head cover gasket into the

cylinder head cover. 4. Apply silicone sealant to the shaded area as

shown.

B3-9

CONTINUED



HYDRAULIC LASH ADJUSTER (HLA)HYDRAULIC LASH ADJUSTER (HLA) HLA REMOVAL/INSTALLATION

Caution • Removal and installation of the HLA must be carried out only when the problem cannot be solved by

the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)

1. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 2. Remove the cylinder head cover.

(Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.) 6. Start the engine and

(1) inspect the engine oil (2) inspect the idle speed. (Refer to Section F3—F4, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)

7. Inspect the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)

3 Hydraulic lash adjuster (HLA)

Installation Note1

Rocker arm component Removal Note Installation Note

2 Camshaft cap (F2 CARB) Installation Note

B3-10

CONTINUED



HYDRAULIC LASH ADJUSTER (HLA) Rocker Arm Component Removal Note

1. Loosen the bolts a few turns in the order shown.

2. Identify the rocker arm and shaft assembly parts

so that they can be reinstalled in the same locations from which they were removed.

3. Remove the rocker arm and shaft assembly together with the bolts.

Hydraulic Lash Adjuster (HLA) Installation Note

1. Place each HLA in a container filled with clean engine oil.

Caution • Do not push the pin too hard. It may

damage the HLA. 2. Bleed the air from the HLA by inserting a pin into

the plunger hole and pressing the plunger until it no longer moves.

3. Pour engine oil into the oil reservoir in the rocker

arm.

4. Apply clean engine oil to HLA 0-ring.

Camshaft Cap (F2 CARS) Installation Note

• Apply silicone sealant to the shaded areas of the cylinder head as shown.

Rocker Arm Component Installation Note Note • The intake side shaft has twice as many oil

holes as the exhaust side shaft. (F2 CARB)

1. Assemble the rocker arms and shaft assembly as shown in the figure.

B3-11

CONTINUED




2. Apply silicone sealant to the shaded areas of the

cylinder head as shown.

3. Install the rocker arm component. 4. Tighten the bolts a few turns in the order shown.

B3-12

CONTINUED



HYDRAULIC LASH ADJUSTER (HLA)HLA TROUBLESHOOTING

Problem Possible Cause Action 1. Noise when engine is started

immediately after oil is changed.

2. Noise when engine is started after sitting one day or more.

Oil leakage in oil passage or in HLA

3. Noise when engine is started after new HLA is installed.

Oil leakage in HLA

Run engine at 2,000—3,000 rpm. If noise stops within 20 minutes*, HLA is normal. If not, replace HLA. * Time required for engine oil to circulate within HLA includes tolerance for engine oil condition and ambient temperature. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING, Valve Clearance Inspection.)

Insufficient oil pressure

Check oil pressure. If lower than specification, check for cause. (Refer to section D, OIL PRESSURE INSPECTION.)

4. Noise continues more than 10 minutes.

Faulty HLA

Press down HLA by hand. If it does not move, HLA is normal. If it moves, replace HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.) Measure valve clearance. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING, Valve Clearance Inspection.)

Incorrect oil amount

Check oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.)

5. Noise during idle after high speed running.

Deteriorated oil

Replace new engine oil. (Refer to Section D, ENGINE OIL, ENGINE OIL REPLACEMENT.)

Valve Clearance Inspection 1. Remove the cylinder head cover.

(Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.)

2. Measure valve clearance.

Valve clearance 0.15 mm 0.0059 in max.

3. If valve clearance is more than 0.15 mm 0.0059 in, replace the HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.)

4. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.)

B3-13

CONTINUED



FRONT OIL SEAL FRONT OIL SEAL FRONT OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the timing belt.

(Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.)

3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the engine oil level.

(Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.)

1

Timing belt pulley Removal/Installation Note

2 Key 3

Front oil seal Removal Note Installation Note

Timing Belt Pulley Removal/Installation Note • Hold the crankshaft using the SST.

Front Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver


Front Oil Seal Installation Note

1. Apply clean engine oil to the oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a

hammer.

B3- 14

CONTINUED



REAR OIL SEALREAR OIL SEAL REAR OIL SEAL REPLACEMENT

1. Disconnect the negative battery cable. 2. Remove the flywheel.

(Refer to Section H, CLUTCH UNIT, CLUTCH UNIT REMOVAL/ INSTALLATION.)


1

Rear oil seal • Refer to Removal Note

• Refer to Installation Note Rear Oil Seal Removal Note

1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected with a

rag.

Rear Oil Seal Installation Note

1. Apply clean engine oil to the new oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a

hammer.

B3-15

CONTINUED



ENGINEENGINE ENGINE REMOVAL/INSTALLATION Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep


damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F3, F4. (Refer to section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.)

(Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the air cleaner and air hose (F2, CIS). 4. Remove the front pipe. 5. Disconnect the accelerator cable, bracket (F2 CIS), heater hoses, high-tension leads, and vacuum hoses. 6. Remove the radiator. (Refer to Section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.) 7. Remove the cooling fan and cooling fan pulley. 8. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 9. Disconnect the fuel hoses. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

(Refer to Section F3-F4, FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 10. Remove the transmission.

(Refer to Section J1-J2, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION.) 11. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way.

(Refer to Section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP REMOVAL/INSTALLATION.)

12. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way. 13. Remove in the order indicated in the table. 14. Install in the reverse order of removal. 15. Start the engine and

(1) Inspect the engine oil, engine coolant, transmission oil, and fuel leakage. (2) Inspect the ignition timing, idle speed and idle mixture. (Refer to Section F3-F4, ENGINE TUNE-UP.)

16. Perform a road test.

B3-16

CONTINUED



ENGINE

1 Engine mount nut 2 Engine

B3-17

CONTINUED



ENGINEENGINE DISASSEMBLY/ASSEMBLY

1. Remove the distributor. (Refer to Section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 2. Remove the generator. 3. Remove the thermostat. (Refer to Section E, THERMOSTAT, THERMOSTAT REMOVAL/INSTALLATION.) 4. Remove the intake-air system.

(Refer to Section F3-F4, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 5. Remove the exhaust system.

(Refer to Section F3-F4, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 6. Remove the oil filter. (Refer to Section D, OIL FILTER, OIL FILTER REPLACEMENT.) 7. Remove the oil pressure switch. (Refer to Section D, OIL PRESSURE INSPECTION.) 8. Disassemble in the order indicated in the table. 9. Assemble in the reverse order of disassembly.

1 Generator strap 6 Dipstick 2 Cooling fan bracket 7 P/S oil pump bracket 3 Generator bracket 8 Gusset plate 4 Water inlet pipe 9 Engine mount5 Water bypass pipe

B3-18

CONTINUED



D–1

LUBRICATION SYSTEMOIL PRESSURE INSPECTION D–1. . . . . . . . . . . . . . . . ENGINE OIL D–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE OIL INSPECTION D–2. . . . . . . . . . . . . . . . . . ENGINE OIL REPLACEMENT D–2. . . . . . . . . . . . . . .

OIL FILTER D–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL FILTER REPLACEMENT D–2. . . . . . . . . . . . . . . .

OIL COOLER D–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL COOLER REMOVAL/INSTALLATION D–3/4. . . . . OIL COOLER BODY INSPECTION D–4. . . . . . . . . .

OIL PAN D–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PAN REMOVAL/INSTALLATION D–4/5. . . . . . . . .

OIL PRESSURE INSPECTIONWarning Continuous exposure with USED engine oil

has caused skin cancer in laboratory mice.Protect your skin by washing with soap andwater immediately after this work.

When the engine and the oil are hot, theycan badly burn. Turn off the engine and waituntil they are cool.

1. Remove the oil pressure switch.2. Screw the SST into the oil pressure switch

installation hole.

F2, G6

49 0187 280

49 0187 280

WL, WL TURBO

3. Warm up the engine to normal operatingtemperature.

4. Run the engine at the specified speed, and notethe gauge readings.

Note The oil pressure can vary with viscosity and

temperature.

Oil pressureF2 : 295—392 kPa

3.0—4.0 kgf/cm 2, 43—56 psi [3,000 rpm]

G6 : 305—402 kPa 3.1—4.1 kgf/cm 2, 45—58 psi [3,000 rpm]

WL : 452—529 kPa 4.6—5.4 kgf/cm 2, 66—76 psi [3,000 rpm]

WL Turbo : 402—480 kPa 4.1—4.9 kgf/cm 2, 59—69 psi [3,000 rpm]

5. If the pressure is not as specified, inspect for thecause and repair or replace as necessary.

6. Stop the engine and wait until it becomes cool.7. Remove the SST.8. Apply silicone sealant to the oil pressure switch

threads as shown.1.0—2.0 mm0.040—0.078 in

4.0—6.0 mm0.16—0.23 in

9. Install the oil pressure switch before the sealanthardens.


10. Start the engine and inspect for oil leakage.

BACK.TO.MAIN.INDEX

CONTINUED


PAGES. FROM. MANUAL

ENGINE OIL, OIL FILTER

D–2

ENGINE OILENGINE OIL INSPECTION

1. Position the vehicle on level ground.2. Warm up the engine to normal operating

temperature and stop it.3. Wait for five minutes.4. Remove the dipstick and inspect for oil level and

condition. Verify that the oil level is within the F andL marks on the dipstick.

5. Add or replace oil if necessary.

ENGINE OIL REPLACEMENT

Warning When the engine and the engine oil are hot,

they can badly burn. Don’t burn yourselfwith either.

A vehicle that is lifted but not securelysupported on safety stands is dangerous. Itcan slip or fall, causing death or seriousinjury. Never work around or under a liftedvehicle if it is not securely supported onsafety stands.

Continuous exposure with USED engine oilhas caused skin cancer in laboratory mice.Protect your skin by washing with soap andwater immediately after this work.

1. Position the vehicle on level ground.2. Remove the oil filler cap and the oil pan drain plug.3. Drain the oil into a container.4. Install the drain plug by using a new washer.


5. Refill the engine oil with the specified type andamount of engine oil.

6. Refit the oil filler cap.7. Run the engine and inspect for oil leakage.8. Inspect the oil level and add oil if necessary.

(Refer to ENGINE OIL, ENGINE OIL INSPECTION.)

Note The actual oil level may vary from the specified

capacity in some cases.

Oil capacity (L US qt, Imp qt)Engine

ItemF2 G6 WL, WL

Turbo

Oil replacement3.9

4.1, 3.44.5

4.8, 4.05.6

5.9, 4.9

Oil and oil filterreplacement

4.2 4.4, 3.7

4.7 5.0, 4.4

6.3 6.7, 5.5

Total(dry engine)

4.6 4.9, 4.0

5.5 5.8, 4.8

6.7 7.1, 5.9

OIL FILTEROIL FILTER REPLACEMENT

1. Remove the oil filter by using the SST or the filterwrench.

49 9014 001

2. Use a clean rag to wipe off the mounting surfaceon the oil filter body.

3. Apply engine oil to the O-ring and tighten the filteraccording to the installation directions on the sideof the oil filter using the SST or the filter wrench.

4. Start the engine and inspect for oil leakage.5. Inspect for the oil level and add oil if necessary.

(Refer to ENGINE OIL, ENGINE OILINSPECTION.)


CONTINUED


PAGES. FROM. MANUAL

OIL COOLER

D–3

OIL COOLEROIL COOLER REMOVAL/INSTALLATIONG6, WL, WL Turbo

1. Disconnect the negative battery cable.2. Drain the engine coolant. (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)3. Remove the turbocharger.

(Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) (WL Turbo model.)4. Remove the oil filter. (Refer to OIL FILTER, OIL FILTER REPLACEMENT.)5. Remove in the order shown in the figure.6. Install in the reverse order of removal.7. Fill the radiator with the specified amount and type of engine coolant.

(Refer to section E, ENGINE COOLANT,ENGINE COOLANT REPLACEMENT.)8. Inspect the engine oil level. (Refer to ENGINE OIL, ENGINE OIL INSPECTION.)9. Start the engine and inspect for engine coolant leakage.


30—39 3.0—4.0, 22—28

G6

1 Water hose

2 Nut

3 Oil cooler


R

R

19—25 1.9—2.6, 14—18R

19—25 1.9—2.6, 14—18

R

R

30—49 3.0—5.0, 22—36

7.9—10.7 N·m80—110 kgf·cm,70—95 in·lbf

WL, WL TURBO

1 Dipstick pipe

2 Radiator hose

3 Thermostat case

4 Insulator

5 Oil cooler body+ Installation Note

6 Oil cooler


CONTINUED


PAGES. FROM. MANUAL

OIL COOLER, OIL PAN

D–4

Oil Cooler Body Installation NoteWL, WL Turbo Tighten the mounting bolts and nuts in the order

shown.

OIL COOLER BODY INSPECTIONWL, WL Turbo Measure the spring free length. Replace the spring

if necessary.

Standard free lengthBypass valve spring: 36.7 mm 1.44 inPressure control valve spring: 54.7 mm 2.15 in

BYPASS VALVE SPRING

PRESSURE CONTROL VALVE SPRING

OIL PANOIL PAN REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Drain the engine oil.

(Refer to ENGINE OIL, ENGINE OIL REPLACEMENT.)3. Remove in the order shown in the figure.4. Install in the reverse order of removal.5. Fill with the specified amount and type of engine

oil. (Refer to ENGINE OIL, ENGINE OIL REPLACEMENT.)

6. Start the engine and inspect for engine oil leakage.


7.9—10.7 N·m80—110 kgf·cm,70—95 in·lbf

F2, G6

38—513.8—5.3,28—38

38—513.8—5.3,28—38

30—413.0—4.2, 22—30

1 Gusset plate

2 Oil pan+ Removal Note+ Installation Note


CONTINUED


PAGES. FROM. MANUAL

OIL PAN

D–5


94—1159.5—11.8, 69—85

55—805.6—8.2,41—59

7.9—10.7 N·m80—110 kgf·cm,70—95 in·lbf

WL, WL TURBO

1 Crossmember (4WD)

2 Oil pan+ Removal Note+ Installation Note

Oil Pan Removal Note1. Remove the oil pan mounting bolts.

Caution Pry tools can easily scratch the cylinder

block or oil baffle and oil pan contactsurfaces. Prying off the oil pan can alsoeasily bend the oil pan flange.

2. Use a separator tool to separate the oil pan.

SEPARATOR TOOL

Oil Pan Installation Note

Caution If the bolts are reused, remove the old

sealant from the bolt threads. Tightening abolt that has old sealant on it can causebolt hole damage.

CRACKS

OLD SEALANT

1. Apply silicone sealant to the oil pan along theinside of the bolt holes and overlap the ends.

ThicknessØ2.0—3.0 mm 0.08—0.11 in

OIL PAN

2. Install the oil pan before the sealant hardens.


CONTINUED


PAGES. FROM. MANUAL

E–1

COOLING SYSTEMENGINE COOLANT E–1. . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE COOLANT LEVEL INSPECTION E–1. . . . ENGINE COOLANT REPLACEMENT E–1/2. . . . . . . . ENGINE COOLANT LEAKAGE

INSPECTION E–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR CAP E–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RADIATOR CAP INSPECTION E–3. . . . . . . . . . . . . . RADIATOR E–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RADIATOR REMOVAL/INSTALLATION E–3. . . . . . .

THERMOSTAT E–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTAT REMOVAL/INSTALLATION E–4/5. . . . THERMOSTAT INSPECTION E–5. . . . . . . . . . . . . . .

WATER PUMP E–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER PUMP REMOVAL/INSTALLATION E–6. . . .

COOLING FAN E–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING FAN REMOVAL/INSTALLATION E–7. . . COOLING FAN INSPECTION E–7. . . . . . . . . . . . . . .

ENGINE COOLANT

Warning Removing the radiator cap or loosening the

radiator drain plug while the engine isrunning, or when the engine and radiatorare hot is dangerous. Scalding coolant andsteam may shoot out and cause seriousinjury. It may also damage the engine andcooling system.

Turn off the engine and wait until it is cool.Even then, be very careful when removingthe cap. Wrap a thick cloth around it andslowly turn it counterclockwise to the firststop. Step back while the pressure escapes.

When you’re sure all the pressure is gone,press down on the cap –still using a cloth–turn it, and remove it.

When the engine and the engine coolant arehot, they can badly burn. Turn off theengine and wait until they are cool beforedraining the engine coolant.

ENGINE COOLANT LEVEL INSPECTION1. Remove the radiator cap.2. Verify that the coolant level is near the radiator filler

neck.3. Verify that the coolant level in the radiator reservoir

is between the FULL and LOW marks.4. Add coolant if necessary.

ENGINE COOLANT REPLACEMENT1. Drain the coolant in the radiator reservoir.2. Remove the radiator cap and loosen the radiator

drain plug.

DRAINPLUG

TYPE A

TYPE B

3. Drain the coolant into a container.4. Flush the cooling system with water until all traces

of color are gone.5. Let the system drain completely.6. Tighten the radiator drain plug.

Tightening torqueType A: 1.5—2.9 N·m

15—30 kgf·cm, 14—26 in·lbfType B: 0.9—1.1 N·m

9.0—12 kgf·cm, 7.9—10 in·lbf

Caution The engine has aluminum parts that can be

damaged by alcohol or methanol antifreeze.Do not use alcohol or methanol in thecooling system. Use onlyethylene-glycol-based coolant.

Use only soft (demineralized) water in thecoolant mixture. Water that containsminerals will cut down on the coolant’seffectiveness.

7. Referring to the following graph and chart, selectproper gravity of the coolant. Slowly pour thecoolant into the radiator up to the coolant filler port.

Filling pace1.0 L 1.1 US qt, 0.88 Imp qt/min. [max]

BACK.TO.MAIN.INDEX

CONTINUED


PAGES. FROM. MANUAL

ENGINE COOLANT

E–2

COOLANT TEMPERATURE °C °F

–10 14

0 32

10 50

20 68

30 86

40 104

50 122

60 140

70 158

80 176

90 194

0

1,000

1,010

1,020

1,030

1,040

1,050

1,060

1,070

1,080

1,090

1,100

COOLANT PROTECTIONSPECIFICGRAVITY

30%

40%

50%

Antifreeze solution mixture percentage

Coolant protectionVolume percentage Gravity

at 20°CCoolant protectionWater Coolant

at 20°C68°F

Above –16°C 3°F 65 35 1,054

Above –26°C –15°F 55 45 1,066

Above –40°C –40°F 45 55 1,078

8. Fill the coolant into the reservoir up to the FULLmark.

9. Fully install the radiator cap.10. Start the engine and let it idle for approx. 10

minutes. If the coolant temperature becomes toohigh, stop the engine to prevent it fromoverheating.

11. After the engine warms up, run it at approx. 2,500rpm for five minutes.

12. Increase the engine speed to approx. 3,000 rpmfor five seconds, then return to idle. Repeat severaltimes.

13. Stop the engine and wait until it is cool.14. Inspect the coolant level. If it is low, repeat Steps

7—12.15. Inspect for coolant leakage.

ENGINE COOLANT LEAKAGE INSPECTION1. Inspect the coolant level.

(Refer to ENGINE COOLANT, ENGINE COOLANT LEVEL INSPECTION.)

2. Remove the radiator cap.3. Connect a radiator cap tester and the SST to the

radiator filler neck.4. Apply pressure to the radiator.

PressureF2: 103 kPa 1.05 kgf/cm 2, 14.9 psiG6, WL, WL Turbo:

122 kPa 1.25 kgf/cm 2, 17.7 psi

Caution Applying more than 103 kPa 1.05 kgf/cm 2,

14.9 psi (F2) or 122 kPa 1.25 kgf/cm 2, 17.7psi (G6, WL, WL Turbo) can damage thehoses, fittings, and other components, andcause leakage.

49 9200 146

49 9200 147

5. Verify that the pressure is held. If not, inspect thesystem for coolant leakage.


CONTINUED


PAGES. FROM. MANUAL

ST

RADIATOR CAP, RADIATOR

E–3

RADIATOR CAPRADIATOR CAP INSPECTION

Warning Removing the radiator cap while the engine

is running, or when the engine and radiatorare hot is dangerous. Scalding coolant andsteam may shoot out and cause seriousinjury. It may also damage the engine andcooling system.

Turn off the engine and wait until it is cool.Even then, be very careful when removingthe cap. Wrap a thick cloth around it andslowly turn it counterclockwise to the firststop. Step back while the pressure escapes.

When you’re sure all the pressure is gone,press down on the cap –still using a cloth–turn it, and remove it.

1. Attach the radiator cap to a radiator cap tester withthe SST. Apply pressure gradually.

2. Verify that the pressure becomes stable within thespecification.

PressureF2: 74—102 kPa

0.75—1.05 kgf/cm 2, 10.7—14.9 psiG6, WL, WL Turbo: 94—122 kPa

0.95—1.25 kgf/cm 2, 13.5—17.7 psi

3. If the pressure is held for 10 seconds, the radiatorcap is normal.

49 9200 147

RADIATORRADIATOR REMOVAL/INSTALLATION

1. Drain the engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)

2. Remove in the order indiacted in the table.3. Install in the reverse order of removal.4. Fill the radiator with the specified amount and type

of engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)


7.9—10.7 N·m 80—110 kgf·cm, 69.5—95.4 in·lbf

18—261.8—2.7, 14—19

18—261.8—2.7,14—19

1 Radiator hose

2 Lower radiator cowling

3 Radiator cowling

4 Radiator


CONTINUED


PAGES. FROM. MANUAL

THERMOSTAT

E–4

THERMOSTATTHERMOSTAT REMOVAL/INSTALLATION

1. Drain the engine coolant. (Refer to ENGINECOOLANT, ENGINE COOLANT REPLACEMENT.)

2. Remove in the order indicated in the table.3. Install in the reverse order of removal.4. Fill the radiator with the specified amount and type

of engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)


F2

19—25 1.9—2.6, 14—18

R

1 Upper radiator hose

2 Thermostat cover

3 Thermostat+ Installation Note


G6

19—25 1.9—2.6, 14—18

19—25 1.9—2.6, 14—18

R

1 Upper radiator hose

2 Thermostat cover



7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf

R

19—25 1.9—2.6, 14—18

WL, WL TURBO

1 Dipstick pipe

2 Lower radiator hose

3 Thermostat cover


Thermostat Installation NoteF2, G6

1. Install the thermostat into the cylinder head withthe jiggle pin at the top.

2. Install a new gasket with the seal print side facingthe cylinder head.

JIGGLE PINA

AA–A

PRINT

WL, WL Turbo Install the thermostat into the thermostat cover,

aligning the projection on the gasket to thethermostat cover as shown.


CONTINUED


PAGES. FROM. MANUAL

ST

THERMOSTAT

E–5

PROJECTION

THERMOSTAT COVER

GASKET

THERMOSTAT INSPECTION

Warning During inspection, the thermostat and water

are extremely hot and they can badly burn.Do not touch the thermostat and waterdirectly.

Inspect the thermostat for the following and replace asnecessary. Open valve in room temperature Opening temperature and lift of the valve

Initial-opening temperatureF2: 83.5—89.5 °C 183—193 °FG6: 86.5—89.5 °C 188—193 °F (Main valve)

83.5—86.5 °C 183—187 °F (Sub valve)WL, WL Turbo: 80—84 °C 176—183 °F

Full open temperatureF2, G6 : 100 °C 212 °FWL, WL Turbo: 95 °C 203 °F

Full open liftG6 : 8.0 mm 0.31 in min. (Main valve)

1.5 mm 0.06 in min. (Sub valve)F2, WL, WL Turbo: 8.5 mm 0.33 in min.


CONTINUED


PAGES. FROM. MANUAL

WATER PUMP

E–6

WATER PUMPWATER PUMP REMOVAL/INSTALLATION

1. Remove the cooling fan. (Refer to COOLING FAN, COOLING FAN REMOVAL/INSTALLATION.)

2. Remove the timing belt (F2). (Refer to Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.)

3. Drain the engine coolant. (Refer to ENGINECOOLANT, ENGINE COOLANT REPLACEMENT.)

4. Remove in the order indicated in the table.5. Install in the reverse order of removal.6. Fill the radiator with the specified amount and type

of engine coolant. (Refer to ENGINE COOLANT,ENGINE COOLANT REPLACEMENT.)


F2

19—251.9—2.6, 14—18

R

38—513.8—5.3, 28—38


19—221.9—2.2, 14—16

G6

R


19—251.9—2.6, 14—18

19—221.9—2.3, 14—16

WL, WL TURBO

R

1 Water pump

2 Idler


CONTINUED


PAGES. FROM. MANUAL

COOLING FAN

E–7

COOLING FANCOOLING FAN REMOVAL/INSTALLATION

1. Remove the drive belt.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.4. Adjust the drive belt (generator) deflection.

(Refer to Section B2,DRIVE BELT, DRIVE BELT ADJUSTMENT.)


F2, G6: 7.9—10.7 N·m 80—110 kgf·cm, 69.5—95.4 in·lbfWL, WL TURBO: 19—25 1.9—2.6, 14—18

1 Cooling fan

2 Water pump pulley

COOLING FAN INSPECTION1. Rotate the cooling fan by hand and inspect for

abnormal noise and looseness. Replace thecooling fan if necessary. (Refer to COOLING FAN, COOLING FAN REMOVAL/INSTALLATION.)


CONTINUED


PAGES. FROM. MANUAL

FUEL AND EMISSION CONTROL SYSTEMS (G6)

ENGINE TUNE-UP ...............................................................F1-2 ENGINE TUNE-UP PREPARATION ............................F1-2

IGNITION TIMING ADJUSTMENT...............................F1-2/3 IDLE SPEED ADJUSTMENT .......................................F1-4 IDLE-UP SPEED INSPECTION ..................................F1-4/5 IDLE MIXTURE INSPECTION .....................................F1-5 INTAKE-AIR SYSTEM ........................................................F1-6 VACUUM HOSE ROUTING DIAGRAM .......................F1-6 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .................................F1-6/7 BYPASS AIR CONTROL (BAC) VALVE REMOVAL/INSTALLATION .................................F1-8 AIR VALVE INSPECTION ........................................... F1-8 IDLE AIR CONTROL (lAC) VALVE INSPECTION ........................................................F1-8 ACCELERATOR PEDAL REMOVAL/INSTALLATION ................................ F1-9 ACCELERATOR CABLE INSPECTION/ADJUSTMENT ..............................F1-9 FUEL SYSTEM .................................................................. F1-10 BEFORE REPAIR PROCEDURE ............................. F1-10 AFTER REPAIR PROCEDURE ................................. F1-10 FUEL TANK REMOVAL/INSTALLATION ............................... F1-11/13 NONRETURN VALVE INSPECTION ........................ F1-13 FUEL PUMP UNIT REMOVAL/INSTALLATION ............................... F1-13 FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY .............................. F1-13/14

FUEL PUMP UNIT INSPECTION .............................. F1-14/16 FUEL FILTER (HIGH-PRESSURE)

REMOVAL/INSTALLATION ............................... F1-16/17 FUEL INJECTOR REMOVAL/INSTALLATION ............................... F1-18/19 FUEL INJECTOR INSPECTION ................................ F1-19/21 PRESSURE REGULATOR REMOVAL/INSTALLATION ............................... F1-21 PRESSURE REGULATOR INSPECTION ...................................................... F1-21/22 PRESSURE REGULATOR CONTROL (PRC) SOLENOID

VALVE INSPECTION ................................................. F1-22 PULSATION DAMPER REMOVAL/INSTALLATION ............................... F1-22 PULSATION DAMPER INSPECTION ....................... F1-22 FUEL PUMP RELAY INSPECTION .......................... F1-23 EXHAUST SYSTEM .......................................................... F1-24 EXHAUST SYSTEM INSPECTION ........................... F1-24 EXHAUST SYSTEM REMOVAL/INSTALLATION ............................... F1-24 EMISSION SYSTEM .......................................................... F1-25 EMISSION SYSTEM (ENGINE COMPARTMENT SIDE) COMPONENT LOCATION .......................................................... F1-25

ROLLOVER VALVE INSPECTION ........................... F1-25 EVAPORATIVE GAS CHECK VALVE (TWO-WAY) INSPECTION ................................ F1-25

CHECK VALVE (TWO-WAY) INSPECTION ....................................................... F1-25/26 EVAPORATIVE CHAMBER INSPECTION ....................................................... F1-26 CHARCOAL CANISTER INSPECTION ................... F1-26 PURGE SOLENOID VALVE INSPECTION ....................................................... F1-26/27 POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION .............................. F1-27 CONTROL SYSTEM .......................................................... F1-28 CONTROL SYSTEM COMPONENT

LOCATION............................................................ F1-28 PCM REMOVAL/INSTALLATION .............................F1-29 PCM INSPECTION .............................................. F1-29/37 MASS AIR FLOW (MAF) SENSOR INSPECTION........................................................ F1-37 THROTTLE POSITION (TP) SENSOR

INSPECTION ....................................................... F1-37/38 THROTTLE POSITION (TP) SENSOR ADJUSTMENT .................................................... F1-38 THROTTLE POSITION (TP) SENSOR REMOVAL/INSTALLATION ................................ F1-38/39 CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION ....................................... F1-39 INTAKE AIR TEMPERATURE (IAT) SENSOR

INSPECTION ....................................................... F1-39 INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION ................................ F1-40 ENGINE COOLANT TEMPERATURE (ECT)

SENSOR REMOVAL/INSTALLATION ............... F1-40 ENGINE COOLANT TEMPERATURE (ECT)

SENSOR INSPECTION ...................................... F1-40/41 CAMSHAFT POSITION (CMP) SENSOR INSPECTION ....................................................... F1-41 OXYGEN SENSOR O2S) INSPECTION ....................................................... F1-41/42 OXYGEN SENSOR O2S) REMOVAL/INSTALLATION................................. F1-42 VARIABLE RESISTOR INSPECTION........................ F1-42 CLUTCH SWITCH INSPECTION .............................. F1-42/43 CLUTCH SWITCH REMOVAL/INSTALLATION ............................... F1-43 NEUTRAL SWITCH INSPECTION ............................ F1-43 NEUTRAL SWITCH REMOVAL/INSTALLATION ................................ F1-43/44 POWER STEERING PRESSURE

(PSP) SWITCH INSPECTION ............................ F1-44 MAIN RELAY INSPECTION ....................................... F1-44/45 MAIN RELAY REMOVAL/INSTALLATION ................ F1-45 ON-BOARD DIAGNOSTIC SYSTEM ............................... F1-45 READ/CLEAR DIAGNOSTIC TEST

RESULTS ............................................................. F1-45 PARAMETER IDENTIFICATION (PID)

ACCESS ............................................................... F1-45 DIAGNOSTIC SUPPORT PROCEDURE .................. F1-45 SIMULATION TEST..................................................... F1-45 ON-BOARD DIAGNOSTIC TEST .............................. F1-45/46 DTC READING PROCEDURE .................................. F1-46/48

F1-1


PAGES. FROM. MANUALBACK.TO.MAIN.INDEX

CONTINUED

Page 1 of 2

PID/DATA MONITOR AND RECORD PROCEDURE ......................................................F1-48

PLAYBACK OF STORED PIDS PROCEDURE ......................................................F1-48/49

DIAGNOSTIC SUPPORT PROCEDURE ..........F1-49 SIMULATION TEST PROCEDURE ........................F1-50/51

AFTER REPAIR PROCEDURE .............................F1-51 DTC INSPECTION ..................................................F1-52/69

TROUBLESHOOTING ...................................................F1-70 FOREWORD ............................................................F1-70

TROUBLESHOOTING ITEM TABLE .....................F1-70 QUICK DIAGNOSTIC CHART ...............................F1-71/74 SYMPTOM TROUBLESHOOTING .......................F1-75/114 DIAGNOSTIC INSPECTION..................................F1-115/120

ENGINE SYSTEM INSPECTION .........................F1-120/127

ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION Using the SSTs (NGS Tester) 1. Warm up the engine to normal operating

temperature. 2. Shift the transmission into neutral. 3. Turn off all electrical loads.

• A/C switch 4. Verify that the steering wheel is at straight ahead

position. 5. Connect the SSTs (NQS tester) to the DLC and

select "PID/DATA MONITOR AND RECORD". (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TEST, NGS Tester Hook-up Procedure.)

6. Access RPM PID. Press the trigger key to enter

this selection. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, PID/DATA MONITOR AND RECORD PROCEDURE.)

7. Press SETUP (Key 8) and turn the test mode on.

8. Press CANCEL. 9. Press START.

Not Using the SSTs (NGS tester) 1. Warm up the engine to normal operating

temperature. 2. Shift the transmission into neutral. 3. Turn off all electrical loads.

• A/C switch 4. Verify that the steering wheel is at straight ahead

position. Caution

• Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only.

5. Connect a dwell tachometer to the DLC terminal IG-.

IGNITION TIMING ADJUSTMENT Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION".

(Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.)

2. Verify that the RPM PID is within the specification. Specification 730—770 (750 ±20) rpm

3. If not as specified, adjust the idle speed. (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)

4. Connect the timing light to the high-tension lead of the No. 1 cylinder.

5. Verify that the timing mark on the crankshaft pulley is within the specification. Specification BTDC 4°—6°(5° ± 1°)

F1-2



CONTINUED

FUEL AND EMISSION CONTROL SYSTEMS (G6)

Page 2 of 2

ENGINE TUNE-UP

6. If not as specified, loosen the distributor lock bolts and turn the distributor to make the adjustment.

7. Tighten the distributor lock bolts to the specified torque. Tightening torque 19—25 N.m 1.9—2.6 kgf.m, 14—18 ft.lbf

8. Press SETUP (Key 8) and turn the test mode off. 9. Press CANCEL. 10. Verify that the timing mark on the crankshaft

pulley is within the specification.

Specification BTDC 1°—30°

Not Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION".


2. If using the SST (System selector) to turn on the test mode, perform the following: (1) Connect the SST to the DLC. (2) Set switch A to position 1. (3) Set the test switch to SELF TEST.

3. If using a jumper wire to turn on the test mode,

perform the following: Caution

• Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only.

• Use a jumper wire to short terminal TEN of the DLC to body GND.

4. Verify that the idle speed is within the

specification. Specification 730—770 (750 ± 20) RPM

5. If not as specified, adjust the idle speed.

(Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)

6. Connect the timing light to the high-tension lead

of the No.1 cylinder. 7. Verify that the timing mark on the crankshaft

pulley is within the specification. Specification BTDC 4°—6° (5° ± 1°)

8. If not as specified, loosen the distributor lock bolts and turn the distributor to make the adjustment.

9. Tighten the distributor lock bolts to the specified torque.

Tightening torque 19—25 N.m 1.9—2.6 kgf.m, 14—18 ft.lbf

10. Disconnect the SST or jumper wire. 11. Verify that the timing mark on the crankshaft pulley is within the specification. Specification BTDC 1°—30°

F1-3



CONTINUED

ENGINE TUNE-UP IDLE SPEED ADJUSTMENT Using the SSTs (NGS Tester)

1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.)

2. Verify that the RPM PID is within the specification. Specification 730—770 (750 ± 20) RPM

Caution • The TAS is set at the factory and must not

be adjusted. Any adjustment will negatively affect the engine performance.

3. If not as specified, verify that the ignition timing is within specification according to the "IGNITION TIMING ADJUSTMENT", then adjust the idle speed by turning the AAS.

4. Press SETUP (Key 8) to turn the test mode off. 5. Press CLEAR to clear previously selected items. 6. Disconnect the SSTs.



2. If using the SST (System selector) to turn on the test mode, perform the following: (1) Connect the SST to the DLC. (2) Set switch A to position 1. (3) Set the test switch to SELF TEST.

3. If using a jumper wire to turn on the test mode,

perform the following:

Caution • Connecting the wrong DLC terminals

may possibly cause a malfunction. Carefully connect the specified terminals only.

• Use a jumper wire to short terminal TEN of the DLC to body GND.

4. Verify that the idle speed is within the specification

using the dwell tachometer. Specification 730—770 (750 ± 20) RPM Caution • The TAS is set at the factory and must not

be adjusted. Any adjustment will negatively affect the engine performance.

5. If not as specified, verify that the ignition timing is within specification according to the "IGNITION TIMING ADJUSTMENT', then adjust the idle speed by turning the AAS.

6. Disconnect the SST or a jumper wire. 7. Disconnect the dwell tachometer. IDLE-UP SPEED INSPECTION Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION".


2. Press SETUP (Key 8) and turn the test mode off. 3. Press CANCEL. 4. Press START. 5. Verify that the idle speed is normal.

(Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)

6. Verify that the RPM PID is within the specification.

F1-4



CONTINUED

ENGINE TUNE-UP Specification

Load condition Idle-up speed (RPM)*1 P/S ON*2 A/C ON*3 700—800 (750 ± 50)

*1: Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. *2: Steering wheel is fully turned.

: A/C switch and fan switch are on. 7. If not as specified with all load conditions,

inspect the IAC valve. 8. If not as specified with some load condition,

inspect the related input switches, harnesses, and connectors.



2. Verify that the idle speed is normal. (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)

3. Verify that the idle-up speed is within the specification.

Specification Load condition Idle-up speed (rpm)*1

P/S ON*2 A/C ON*3 700—800 (750 ± 50)

*1: Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. *2: Steering wheel is fully turned. *3: A/C switch and fan switch are on. 4. If not as specified with all load conditions, inspect

the IAC valve. 5. If not as specified with some load conditions,

inspect the related input switches, harnesses, and connectors.

IDLE MIXTURE INSPECTION Vehicles With Oxygen Sensor (O2S) 1. Perform "ENGINE TUNE-UP PREPARATION".


2. Verify that the idle speed and ignition timing are within the specification. (Refer to ENGINE TUNE-UP, IGNITION TIMING INSPECTION.) (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)

3. Turn the test mode off. 4. Warm up the engine by holding the engine speed

at 2500—3000 rpm for approx. 3 minutes. 5. Insert an exhaust gas analyzer to the tailpipe. 6. Verify that the CO and HC concentrations are

within the regulation. 7. If not within the regulation, inspect the following:

• On-board diagnostic system (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TROUBLE CODE INSPECTION.)

• O2S (Refer to CONTROL SYSTEM, OXYGEN SENSOR O2S) INSPECTION.)

• Intake manifold vacuum (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Intake Manifold Vacuum Inspection.)

• Fuel line pressure (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection.)

• Ignition timing control (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Ignition Timing Control Inspection.)

• If the systems and devices are normal, replace the TWC. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)

Vehicles Without Oxygen Sensor O2S) 1. Perform "ENGINE TUNE-UP PREPARATION". 2. Verify that the idle speed and ignition timing are

within the specification. (Refer to IGNITION TIMING INSPECTION.) (Refer to IDLE SPEED ADJUSTMENT.)

3. Insert an exhaust gas analyzer to the tailpipe. 4. Verify that the CO and HC concentrations are

within the regulation. 5. If not, turn the adjust screw to adjust CO and HC

concentration using the SST.

6. If not adjusted, inspect the following:

• On-board diagnostic system (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TROUBLE CODE INSPECTION.)

• Variable resistor (Refer to CONTROL SYSTEM, VARIABLE RESISTOR INSPECTION.)

• Intake manifold vacuum (Refer to TROUBLESHOOTING, ENGINE SYSTEM, INSPECTION, Intake Manifold Vacuum Inspection.)

• Fuel line pressure (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel line Pressure Inspection.)

• Ignition timing control (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Ignition Timing Control Inspection.)

F1-5



CONTINUED

INTAKE-AIR SYSTEM

INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION

Warning • When the engine and intake-air system are hot, they can badly burn. Turn off engine and wait until

they are cool before removing the intake-air system. • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep

sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and

damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)

1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

2. Drain the engine coolant from the radiator. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)

3. Disconnect the negative battery cable. 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Complete the "AFTER REPAIR PROCEDURE".

(Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)

F1-6



CONTINUED

INTAKE-AIR SYSTEM

1 Air cleaner component 5 Throttle body component 2 Air intake hose 6 Dynamic chamber 3 MAP sensor 7

Fuel injector FUEL SYSTEM, FUEL INJECTOR REMOVAL/ INSTALLATION

4

Accelerator cable ACCELERATOR CABLE INSPECTION/ ADJUSTMENT

8 Intake manifold

F1-7



CONTINUED

INTAKE-AIR SYSTEM BYPASS AIR CONTROL (BAC) VALVE REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the IAC valve connector. 3. Drain the engine coolant from the radiator.

(Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)

4. Remove the BAC valve.

5. Install in the reverse order of removal. AIR VALVE INSPECTION Operation Inspection

Note 1. Perform the following test only when directed.

1. Carry out the "Idle Air Control (IAC) Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Idle Air Control (IAC) Inspection.)

2. Remove the BAC valve. (Refer to INTAKE-AIR SYSTEM, BAC VALVE REMOVAL/INSTALLATION.)

3. Add cold water into the engine coolant passage of the BAC valve to reduce the air valve temperature.

4. Verify that the air valve operates when hot water is added into the engine coolant passage of the BAC valve.

5. If not as specified, replace the BAC valve, 6. Install the BAC valve.

IDLE AIR CONTROL (IAC) VALVE INSPECTION Resistance Inspection

Note 2. Perform the following test only when directed,

1. Carry out the "Idle Air Control (IAC) Inspection", (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Idle Air Control (IAC) Inspection.)

2. If not as specified, perform the further inspection for the IAC valve.

3. Disconnect the negative battery cable. 4. Disconnect the IAC valve connector. 5. Measure the resistance between the IAC valve

terminals using an ohmmeter. Resistance 7.7—9.3 Ω [23 °C 73 °F]

6. If not as specified, replace the BAC valve.

(Refer to BAC VALVE REMOVAL/INSTALLATION.) If as specified, but IAC valve is failed, inspect for the following: Open circuit

• Power circuit (IAC valve connector terminal A and main relay terminal D)

• GND circuit (IAC valve connector

terminal B and PCM connector terminal 2W)

Short circuit • IAC valve connector terminal B and

PCM connector terminal 2W to GND 7. Repair or replace faulty areas. 8. Connect the IAC valve connector. 9. Connect the negative battery cable.

F1-8



CONTINUED

INTAKE-AIR SYSTEM

ACCELERATOR PEDAL REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.

1

Accelerator cable ACCELERATOR CABLE INSPECTION/ADJUSTMENT

2 Accelerator pedal

ACCELERATOR CABLE INSPECTION/ADJUSTMENT 1. Measure the free play of the accelerator cable.

Free play 1—3 mm 0.04—0.11 in

2. If not as specified, adjust by turning the locknut,

F1-9



CONTINUED

FUEL SYSTEM FUEL SYSTEM BEFORE REPAIR PROCEDURE

Warning • Fuel vapor is hazardous. It can easily

ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safety Procedures".

Note • Fuel in the fuel system is under high pressure

when the engine is not running. Fuel Line Safety Procedures 1. Remove the fuel-filler cap and release the pressure

in the fuel tank. 2. Disconnect the fuel pump relay connector located

under the passenger's side front side trim.

3. Start the engine. 4. After the engine stalls, crank the engine several

times. 5. Turn off the ignition switch. 6. Reconnect the fuel pump relay connector. AFTER REPAIR PROCEDURE

Warning • Fuel line spills and leakage are dangerous.

Fuel can ignite and cause serious injuries or death and damage. When installing the fuel hose, observe "Fuel Hose Installation" and "Fuel Leakage Inspection" described below.

Fuel Hose Installation 1. Replace damaged or deformed fuel hoses, fuel

pipes, and hose clamps. 2. When installing the fuel hose onto the fuel pipe, fit

the hose onto the pipe over 25 mm 0.98 in. When the pipe has a stopper, fit the hose until it contacts the stopper.

3. Install a hose clamp over the fuel hose within the

clamp installation range as shown, avoiding the original clamp position.

CLAMP INSTALLATION RANGE

Fuel Leakage Inspection

Warning • Fuel line spills and leakage are

dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.

Caution • Connecting the wrong DLC terminal

may possibly cause a malfunction. Carefully connect the specified terminal only.

1. Short the DLC terminal F/P to body GND using a jumper wire.

2. Turn the ignition switch on to operate the fuel pump body.

3. Pressurize the system this way for at least 5 minutes to be sure of no leakage.

4. If there is fuel leakage, inspect for damaged fuel hoses, hose clamps, and fuel pipe sealing surface and replace as necessary.

5. After repair, assemble the system and repeat Steps 1 to 3.

F1-10



CONTINUED

FUEL SYSTEM

FUEL TANK REMOVAL/INSTALLATION

Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire

may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and

damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.

1. Level the vehicle. 2. Complete the "BEFORE REPAIR PROCEDURE".

(Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Disconnect the negative battery cable. 4. Drain the fuel from the drain plug. 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Complete the "AFTER REPAIR PROCEDURE".


STRETCH CAB 2WD, DOUBLE CAB 2WD

F1-11



CONTINUED

FUEL SYSTEM

STRETCH CAB 4WD, DOUBLE CAB 4WD, REGULAR CAB

8 Fuel pump unit1

Joint hose Installation Note 9 Fuel-filler pipe

10 Dust cover 2

Breather hose Installation Note 11 Fuel inlet pipe

3 Under guard 12 Nonreturn valve

4 Fuel hose 5 Fuel tank

13

Evaporative gas check valve (two-way) Installation Note

14 Check valve (two-way) 6

Evaporative hose Installation Note

15 Evaporative chamber 7 Rollover valve

F1-12



CONTINUED

FUEL SYSTEM Evaporative Gas Check Valve (Two-way) Installation Note • Install the arrow mark of the evaporative gas

check valve (two-way) facing the charcoal canister.

Evaporative Hose Installation Note • Fit each hose onto the respective fittings within the

specification, and install clamps as shown. Length Evaporative hose: 25—30 mm 0.99—1.18 in

Breather Hose Installation Note • Fit each hose onto the respective fittings within the

specification, and install clamp as shown. Length Breather hose: 25—30 mm 0.99—1.18 in

Joint Hose Installation Note • Fit the joint hose onto the respective fittings

within the specification, and install clamps as shown. Length Joint hose: 35—40 mm 1.4—1.5 in

NONRETURN VALVE INSPECTION 1. Remove the nonreturn valve with the fuel inlet

pipe. 2. Verify that the nonreturn valve opening angle is

50—56° when pushed out from the fuel inlet pipe side, and the clearance between the nonreturn valve and the fuel inlet pipe end is within 1.5 mm 0.06 in when the nonreturn valve is returned to the closed position.

3. If not as specified, replace the nonreturn valve. FUEL PUMP UNIT REMOVAL/INSTALLATION 1. Remove the fuel pump unit.

(Refer to FUEL SYSTEM,FUEL TANK REMOVAL/INSTALLATION.)

2. Install the fuel pump unit. (Refer to FUEL SYSTEM,FUEL TANK REMOVAL/INSTALLATION.)

FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY

Warning • Fuel line spills and leakage are

dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.

1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.

F1-13



CONTINUED

FUEL SYSTEM STRETCH CAB 2WD, DOUBLE CAB 2WD


1 Rubber mount 2 Fuel filter (low-pressure) 3 Clamp 4 Fuel hose 5 Fuel pump body 6 Fuel gauge sender unit

FUEL PUMP UNIT INSPECTION Simulation Test 1. Carry out the "Fuel Pump Operation Inspection", "Fuel

Pump Control Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Operation Inspection.) (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Control Inspection.)

2. If not as specified, perform the further inspection for the fuel pump unit.

Continuity Inspection Note • Perform the following test only when directed.


2. Disconnect the negative battery cable. 3. Remove the fuel tank. (Refer to FUEL SYSTEM,

FUEL TANK REMOVAL/INSTALLATION.) 4. Inspect for continuity between fuel pump unit

connector terminals C and D.

5. If there is no continuity, replace the fuel pump

body. If as specified but the "Simulation Test" is failed, inspect the following:

Fuel pump relay malfunction Open circuit • GND circuit (fuel pump unit connector terminal D

and body GND) • Power circuit (fuel pump relay connector terminal

D and fuel pump unit connector terminal B through common connector)

Short circuit

• Fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector to GND

6. Repair or replace faulty areas. 7. Install the fuel tank.

(Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)

8. Reconnect the negative battery cable. 9. Complete the "AFTER REPAIR PROCEDURE".


F1-14



CONTINUED

FUEL SYSTEM Fuel Pump Maximum Pressure Inspection


Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.

Note • Perform the following test only when directed.


2. Disconnect the negative battery cable. 3. Connect a fuel pressure gauge to the fuel hose

between the pulsation damper and fuel main hose, then plug the opening as shown.

4. Connect the negative battery cable.

Caution • Connecting the wrong DLC terminal may

possibly cause a malfunction. Carefully connect the specified terminal only.


6. Turn the ignition switch on to operate the fuel

pump body. Measure the fuel pump maximum pressure. Fuel pump maximum pressure 500—630 kPa 5.0—6.5 kgf/cm2, 72—92 psi

7. Turn the ignition switch off and disconnect the jumper wire.

8. If not as specified, inspect the following: • Fuel pump relay • Fuel filter (low-pressure, high-pressure) for

clogging • Fuel line for clogging or leakage


10. Disconnect the negative battery cable. 11. Disconnect the fuel pressure gauge. 12. Connect the negative battery cable. 13. Complete the "AFTER REPAIR PROCEDURE".


Fuel Pump Hold Pressure Inspection Warning • Fuel line spills and leakage are dangerous.




2. Disconnect the negative battery cable. 3. Connect a fuel pressure gauge to the fuel hose

between the pulsation damper and fuel main hose, then plug the opening as shown.

4. Connect the negative battery cable. Caution • Connecting the wrong DLC terminal may



F1-15



CONTINUED

FUEL SYSTEM

1 Fuel hose 2 Protector 3

Fuel filter (high-pressure) Removal Note Installation Note

6. Turn the ignition switch on for 10 seconds to

operate the fuel pump body. 7. Turn the ignition switch off. Measure the fuel pump

hold pressure after 5 minutes. Fuel pump hold pressure More than 340 kPa 3.5 kgf/cm2, 50 psi

8. Disconnect the jumper wire. 9. Complete the "BEFORE REPAIR PROCEDURE".

(Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

10. Disconnect the negative battery cable. 11. Disconnect the fuel pressure gauge. 12. Reconnect the negative battery cable. 13. If not as specified, carry out the "PRESSURE

REGULATOR INSPECTION", "FUEL INJECTOR INSPECTION" (Refer to FUEL SYSTEM, PRESSURE REGULATOR INSPECTION.) (Refer to FUEL SYSTEM, FUEL INJECTOR INSPECTION.)

14. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)

FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION 1. Complete the "BEFORE REPAIR PROCEDURE".


2. Disconnect the negative battery cable. 3. Remove in the order indicated in the table. 4. Install in the reverse order or removal. 5. Complete the "AFTER REPAIR PROCEDURE".


Fuel Filter (High-pressure) Removal Note • Before removing the fuel filter (high-pressure),

paint marks on the fuel filter (high-pressure) and fuel filter bracket for correct reassembly.

Fuel Filter (High-pressure) Installation Note Replacing the fuel filter (high-pressure) 1. Paint a mark on the new fuel filter (high-pressure)

at the same spot as the removed fuel filter (high-pressure).

2. Align the paint marks and install the fuel filter (high-pressure) as shown.

F1-16



CONTINUED

FUEL SYSTEM

Replacing the fuel filter bracket

1. Paint a mark on the new fuel filter bracket at the same spot as the removed fuel filter bracket.

2. Align the paint marks and install the fuel filter bracket as shown.

F1-17



CONTINUED

FUEL SYSTEM

FUEL INJECTOR REMOVAL/INSTALLATION

Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and

damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

1. Complete the "BEFORE REPAIR PROCEDURE" (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Disconnect the fuel injector connectors and remove the harness from the fuel distributor. 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Complete the "AFTER REPAIR PROCEDURE." (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)

1 Dynamic chamber 6

Fuel injector Installation note2 Dynamic chamber gasket

7 Grommet 3 Fuel injector connector 8 Fuel injector insulator 4 Fuel hose

5 Fuel distributor

F1-18



CONTINUED

FUEL SYSTEM Fuel Injector Installation Note 1. Use new fuel injector O-rings. 2. Verify that the O-rings and the fuel injector sealing

surfaces are free of foreign materials. Clean with gasoline if necessary.

3. Apply a small amount of engine oil to the O-rings and into the fuel distributor.

4. Install the fuel injectors in the fuel distributor with a light twisting motion so that the O-rings will not be folded.

FUEL INJECTOR INSPECTION Simulation Test 1. Carry out the "Fuel Injector Operation Inspection".

(Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Injector Operation Inspection.)

2. If not as specified, perform the further inspection for the fuel injectors.

Resistance Inspection Note • Perform the following test only when directed.

1. Disconnect the negative battery cable. 2. Disconnect the fuel injector connectors. 3. Measure the resistance of the fuel injector using

an ohmmeter.

Resistance 12—16Ω[20°C 68°F] 4. If not as specified, replace the fuel injector.

(Refer to FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.) If as specified but "Simulation Test" is failed, inspect for the following:

Open circuit • GND circuit (No.1 cylinder fuel injector connector

terminal B and PCM connector terminal 2U) • GND circuit (No.2 cylinder fuel injector connector

terminal B and PCM connector terminal 2V) • GND circuit (No.3 cylinder fuel injector connector

terminal B and PCM connector terminal 2U) • GND circuit (No.4 cylinder fuel injector connector

terminal B and PCM connector terminal 2V) • Power circuit (No.1 cylinder fuel injector connector

terminal A and main relay connector terminal D through common connector)

• Power circuit (No.2 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector)



Short circuit • No.1 cylinder fuel injector connector terminal B

and PCM connector terminal 2U to GND • No.2 cylinder fuel injector connector terminal B

and PCM connector terminal 2V to GND • No.3 cylinder fuel injector connector terminal B

and PCM connector terminal 2U to GND • No.4 cylinder fuel injector connector terminal B

and PCM connector terminal 2V to GND 5. Repair or replace faulty areas. 6. Reconnect the fuel injector connectors. 7. Reconnect the negative battery cable. Fuel Leakage Test




F1-19



CONTINUED

FUEL SYSTEM 1. Complete the "BEFORE REPAIR PROCEDURE".


2. Disconnect the negative battery cable. 3. Remove the fuel injectors together with the fuel

distributor. (Refer to FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.)

4. Fasten the fuel injectors firmly to the fuel distributor with wire.





7. Turn the ignition switch on to operate the fuel

pump body. 8. Tilt the fuel injectors approx. 60 degrees and

verify that fuel leakage from the fuel injector nozzles is within the specification.

Fuel leakage Less than 1 drop/2 minutes

9. Turn the ignition switch off and remove the jumper wire.

10. If not as specified, replace the fuel injector. 11. Complete the "AFTER REPAIR PROCEDURE",


Volume Test Warning • Fuel line spills and leakage are dangerous.



1. Complete the "BEFORE REPAIR PROCEDURE", (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

2. Disconnect the negative battery cable. 3. Remove the fuel injectors together with the fuel

distributor. (Refer to FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.)

4. Fasten the fuel injectors firmly to the fuel distributor with wire.

5. Connect the SST as shown in the figure.





8. Turn the ignition switch on to operate the fuel pump body.

9. Measure the injection volume of each fuel injector using a graduated container.

F1-20



CONTINUED

FUEL SYSTEM

Injection volume 55—71 ml 55—71 cc, 1.9—2.3 fl oz/15 sec.

10. Turn the ignition switch off and disconnect the jumper wire.

11. If not as specified, replace the fuel injector. 12. Complete the "AFTER REPAIR PROCEDURE".


PRESSURE REGULATOR REMOVAL/INSTALLATION


Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)


2. Disconnect the negative battery cable. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Complete the "AFTER REPAIR PROCEDURE".


O 1 Vacuum hose 2 Fuel hose 3 Pressure regulator

PRESSURE REGULATOR INSPECTION Simulation Test 1. Carry out the "Fuel Line Pressure Inspection".

(Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection.)

2. If not as specified, perform the further inspection for the pressure regulator.

Operation Inspection Note • Perform the following test only when directed.

1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE".)

2. Disconnect the negative battery cable. 3. Connect a fuel pressure gauge between the

pulsation damper and fuel main hose.

4. Connect the negative battery cable. 5. Start the engine and let it idle. 6. Measure the fuel line pressure after approx. 2

minutes. Fuel line pressure 210—250 kPa 2.1—2.6 kgf/cm2, 30—36 psi

7. Disconnect the vacuum hose from the pressure regulator and measure the fuel line pressure.

Fuel line pressure 270—310 kPa 2.7—3.2 kgf/cm2, 39—45 psi 8. Turn the ignition switch off. 9. Complete the "BEFORE REPAIR PROCEDURE".

(Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.")

10. Disconnect the negative battery cable. 11. Disconnect the fuel pressure gauge. 12. Reconnect the fuel main hose to the fuel

distributor. 13. Reconnect the negative battery cable. 14. If not as specified, inspect the following:

• Fuel pump maximum pressure • Fuel pump hold pressure • Fuel filter for clogging • Fuel injector for leakage • Fuel pump relay • Fuel line for improper routing, clogging, kinks

or leakage

F1-21



CONTINUED

FUEL SYSTEM

Short circuit • PRC solenoid valve connector terminal B and

PCM connector terminal 2T through common connector to GND)

5. Repair or replace faulty areas. 6. Install the PRC solenoid valve. 7. Reconnect the negative battery cable. PULSATION DAMPER REMOVAL/INSTALLATION1. Complete the "BEFORE REPAIR PROCEDURE".


2. Disconnect the negative battery cable. 3. Remove the pulsation damper. 4. Install in the reverse order of removal. 5. Complete the "AFTER REPAIR PROCEDURE".


1 Fuel hose 2 Bolt3 Pulsation damper

If all items above are okay, replace the pressure regulator. (Refer to FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION.)

15. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)

PRESSURE REGULATOR CONTROL (PRC) SOLENOID VALVE INSPECTION Simulation Test 1. Carry out the "Pressure Regulator Control (PRC)

Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Pressure Regulator Control (PRC) Inspection.)

2. If not as specified, perform the further inspection for the PRC solenoid valve,

Airflow Inspection Note • Perform the following test only when directed.

1. Disconnect the negative battery cable. 2. Remove the PRC solenoid valve.

(Refer to INTAKE-AIR SYSTEM, VACUUM HOSE ROUTING DIAGRAM.)

3. Inspect airflow between the ports under the following conditions.

4. If not as spec tied, replace the PRC solenoid valve. If as specified but the "Simulation Test" is failed, inspect for the following: Vacuum hose improper routing, kinks or leakage Open circuit • GND circuit (PRC solenoid valve connector

terminal B and PCM connector terminal 2T through common connector)

• Power circuit (PRC solenoid valve connector terminal A and main relay connector terminal D through common connector)

PULSATION DAMPER INSPECTION 1. Remove the pulsation damper.

(Refer to FUEL SYSTEM, PULSATION DAMPER REMOVAL/INSTALLATION.)

2. Visually inspect the pulsation damper for damage and cracks. Also inspect that there is no extreme rust, which will cause fuel leakage.

3. If either is observed, replace the pulsation damper.

F1-22



CONTINUED

FUEL SYSTEM FUEL PUMP RELAY INSPECTION Simulation Test 1. Carry out the "Fuel Pump Operation Inspection",

"Fuel Pump Control Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Operation Inspection.) (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Control Inspection.)

2. If not as specified, perform the further inspection for the fuel pump relay.

Continuity Inspection Note • Perform the following test only when directed.

1. Disconnect the negative battery cable. 2. Remove the fuel pump relay located under the

passenger's side front side trim.

3. Inspect for continuity between the fuel pump relay

terminals using an ohmmeter.

4. If not as specified, replace the fuel pump relay. If as specified but the "Simulation Test" is failed, inspect for the following: Fuel pump unit malfunction Open circuit • GND circuit (fuel pump relay connector terminal

B and PCM connector terminal 1H through common connector)

• GND circuit (fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector)

• Power circuit (fuel pump relay connector terminal A or C and IG switch connector terminal IG1 through common connector)

Short circuit • Fuel pump relay connector terminal B and

PCM connector terminal 1H through common connector to GND

• Fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector to GND

5. Repair or replace faulty areas. 6. Install the fuel pump relay. 7. Reconnect the negative battery cable.

F1-23



CONTINUED

EXHAUST SYSTEM

EXHAUST SYSTEM EXHAUST SYSTEM INSPECTION 1. Start the engine and inspect the exhaust system component for exhaust gas leakage. 2. If leakage is found, repair or replace as necessary.

EXHAUST SYSTEM REMOVAL/INSTALLATION

Warning • When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait

until they are cool before removing the exhaust system.

1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.

1 After silencer 4 Front pipe2 Main silencer 5 Insulator

TWO (Europe) 6 Exhaust manifold3 Presilencer (Except Europe)

F1-24



CONTINUED

EMISSION SYSTEM

4. If not as specified, replace the rollover valve. EVAPORATIVE GAS CHECK VALVE (TWO-WAY) INSPECTION 1. Remove the evaporative gas check valve (two-

way). (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)

2. Inspect airflow of the valve under the following conditions.

Apply pressure below +2.9 kPa +22 mmHg, +0.87 inHg to port A No airflow

Apply pressure over +5.9 kPa +44 mmHg, +1.7 inHg to port A Airflow

EMISSION SYSTEM EMISSION SYSTEM (ENGINE COMPARTMENT SIDE) COMPONENT LOCATION

1 Charcoal canister Apply pressure over -0.98 kPa -7.36 mmHg, -0.29 inHg to port A Airflow

2 Purge solenoid valve 3 PCV valve

3. If not as specified, replace the evaporative gas check valve (two-way).

CHECK VALVE (TWO-WAY) INSPECTION 1. Remove the check valve (two-way).


2. Inspect airflow of the valve under the following conditions.

Apply pressure of -0.98—1-13.7 kPa -7.3—1-102 mmHg, -0.28— + 4.0 inHg to port A

No airflow

Apply pressure over +18.6 kPa +140 mmHg, +5.5 inHg to port A Airflow

ROLLOVER VALVE INSPECTION 1. Remove the rollover valve.


2. Hold the valve as shown. Blow air into port A and verify that there is airflow.

3. Turn the valve upside-down as shown. Blow

air into port A and verify that there is no airflow.

Apply pressure over -4.9 kPa -36.8 mmHg, -1.4 inHg to port B Airflow

F1-25



CONTINUED

EMISSION SYSTEM

3. If not as specified, replace the check valve (two-way).

EVAPORATIVE CHAMBER INSPECTION 1. Remove the evaporative chamber.


2. Blow air into port A and verify that air flows out from the holes B on the evaporative chamber.

3. Visually inspect that there is no damage nor crack

on the evaporative chamber. 4. If not as specified, replace the evaporative

chamber. 5. Install the evaporative chamber. CHARCOAL CANISTER INSPECTION 1. Remove the charcoal canister. 2. Plug the atmosphere side port and purge solenoid

valve side port of the charcoal canister. 3. Blow air into the charcoal canister from the fuel

tank side port and verify that there is no air leakage.

4. If there is air leakage, replace the charcoal

canister.

PURGE SOLENOID VALVE INSPECTION Simulation Test 1. Carry out the "Purge Control Inspection".

(Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Purge Control Inspection.)

2. If not as specified, perform the further inspection for the purge solenoid valve,

Airflow Inspection Note • Perform the following test only when directed.

1. Disconnect the negative battery cable. 2. Remove the purge solenoid valve. 3. Inspect airflow between the ports under the following

conditions.

4. If not as specified, replace the purge solenoid valve.

If as specified but the "Simulation Test" is failed, inspect for the following: Vacuum hose improper routing, kinks or leakage. Open circuit • GND circuit (purge solenoid valve connector

terminal B and PCM connector terminal 2X through common connector)

• Power circuit (purge solenoid valve connector terminal A and main relay connector terminal D through common connector)

F1-26



CONTINUED

EMISSION SYSTEM

Short circuit • Purge solenoid valve connector terminal B and

PCM connector terminal 2X through common connector to GND

5. Repair or replace faulty areas. 6. Install the purge solenoid valve. 7. Reconnect the negative battery cable. POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION 1. Remove the PCV valve. 2. Blow through the valve and verify that air flows as

specified.

Specification Condition Airflow

Air applied from port A Yes Air applied from port B No

3. If not as specified, replace the PCV valve.

F1-27



CONTINUED

CONTROL SYSTEM

CONTROL SYSTEM CONTROL SYSTEM COMPONENT LOCATION

1 PCM 8 O2S (Europe only)2 MAF sensor 9 Variable resistor (Except Europe) 3 TP sensor 10 Clutch switch 4 CTP switch 11 Neutral switch 5 IAT sensor 12 PSP switch 6 ECT sensor 13 Main relay 7 CMP sensor (In distributor)

F1-28



CONTINUED

CONTROL SYSTEM PCM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the cowl side panel (driver's side). 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.

1 PCM 2 PCM connector

PCM INSPECTION Using SSTs (NGS tester)

Note • PIDs for the following parts are not available

on this model. Go to the appropriate part inspection page.

1. Water temperature sender unit (Integrated with ECT sensor) (Refer to CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION.)

2. CMP sensor (Refer to CONTROL SYSTEM, CAMSHAFT POSITION (CMP) SENSOR INSPECTION.)

3. Main relay (Refer to CONTROL SYSTEM, MAIN RELAY INSPECTION.)

1. Connect the SSTs (NGS tester) to the DLC. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TEST, NGS Tester Hook-up Procedure.)

2. Turn the ignition switch on. 3. Select the "PID/DATA MONITOR AND RECORD"

function on the NGS tester display and press TRIGGER. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, PID/DATA MONITOR AND RECORD PROCEDURE.)

4. Select the appropriate PID on the NGS tester display and press START.

5. Measure the PID value. Note

• The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the PCM. Therefore, an output device malfunction is not directly indicated as a malfunction of the monitored value for the output device. If a monitored value of an output device is out of specification, inspect the monitored value of the input device related to the output control.

• For input/output signals except those of the monitoring items, use a voltmeter to measure the PCM terminal voltage.

• When measuring the following PID value, perform the following:

• TP V PID (Refer to Not Using the SSTs (NGS tester) at Constant Voltage Terminal Inspection.) (Refer to Not Using the SSTs (NGS tester) at Ground (GND) Terminal Inspection.)

6. If PID value is not within the specification, follow the instruction in action column.

Note

• Perform the SIMULATION TEST for the output device (A/C RLY, FP RLY, IACV, PRGV) after PID/DATA measurement is completed.

F1-29



CONTINUED

CONTROL SYSTEM

PID MONITOR Table Monitor item (Definition)

Unit/ Condition Condition/Specification Action PCM

terminal

A/C RLY (A/C relay) ON/OFF

Ignition switch on: OFF A/C switch on and fan switch on at idle: ON

Inspect following PIDs: RPM, TP V, ECT V, A/C SW. Inspect A/C relay. Section U

1J

A/C SW (A/C switch) ON/OFF

A/C switch and fan switch on at ignition switch on: ON A/C switch off at ignition switch on: OFF

Inspect A/C switch. Section U 1Q

B+ (Battery positive

voltage) V Constant: B+

Inspect main relay. CONTROL SYSTEM, MAIN RELAY INSPECTION Inspect battery. Section G

1B

BARO*2

(Barometric pressure)

kPa Below 400 m 0.25 mile above sea level: 100—103 kPa 1.01—1.05 kgf/cm2

DTC P1195 is indicated. Follow DTC Troubleshooting ON-BOARD DIAGNOSTIC SYSTEM, DTC INSPECTION

-

BARO V*2

(Barometric pressure signal

voltage) V Below 400 m 0.25 mile above sea

level: 3.9—4.0 V

DTC P1195 is indicated. Follow DTC Troubleshooting ON-BOARD DIAGNOSTIC SYSTEM, DTC INSPECTION

-

BRKSW (Brake switch) ON/OFF Brake pedal depressed: ON

Brake pedal released: OFF Inspect brake switch. Section P 1O

CTP SW (Idle switch) ON/OFF Accelerator depressed: OFF

Accelerator released: ON

Inspect CTP switch CONTROL SYSTEM, CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION

1N

ECT (Engine coolant

temperature) °C °F

Engine coolant temperature 20 °C 68°F: 20°C 68°F Engine coolant temperature 60 °C 140°F: 60°C 140°F

Inspect engine coolant temperature sensor. w CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION

2Q

ECT V (ECT signal

voltage)

V Engine coolant temperature 20 °C 68 °F; 2.2—2.4V After warms up: Below 1.0 V

Inspect engine coolant temperature sensor. CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION

2Q

FHO2S*1 (Oxygen sensor) V

Ignition switch on: 0,1—1.0 V After warm up: 0.1—1.0 V Acceleration (after warm up): 0.5—1.0 V Deceleration (after warm up): 0—0.5V

Inspect O2S. CONTROL SYSTEM, OXYGEN SENSOR O2S) INSPECTION

2N

FPRLY (Fuel pump relay) ON/OFF Ignition switch on: OFF

Idle: ON Cranking: ON

Inspect following PID: RPM. Inspect fuel pump relay. FUEL SYSTEM, FUEL PUMP RELAY INSPECTION

1H

IACV (Idle air control

valve) ms Idle: 2.4—2.7 ms

Inspect following PIDs: IATV, RPM, ECT V, MAF V, TP V, NL SW, CLT SW, PSP SW, A/C SW, TEN. Inspect idle air control valve. INTAKE-AIR SYSTEM, IDLE AIR CONTROL (IAC) VALVE INSPECTION

2W

1: Europe only *2: Except Europe

F1-30



CONTINUED

CONTROL SYSTEM

Monitor item (Definition)

Unit/ Condition Condition/Specification Action PCM terminal

IATDC (Intake air

temperature (Dynamic chamber))

°C

Intake air temperature 20 °C 68 °F:20°C68 °F

Inspect IAT sensor rar -CONTROL SYSTEM, INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION

2L

IATDC V (IAT signal voltage

(Dymanic chamber))

V Intake air temperature 20 °C 68 °F: 2.5—2.7 V

Inspect IAT sensor -CONTROL SYSTEM, INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION

2L

IGT (Ignition timing)

BTC Terminal TEN (DLC) short to ground: A—6 BTC Idle: 1—30 BTC

Inspect following PIDs: MAF V, IAT V, RPM, TP V, ECT V, PSP SW, NL SW, A/C SW, TEN, Inspect CMP sensor. -CONTROL SYSTEM, CAMSHAFT POSITION (CMP) SENSOR INSPECTION Inspect idle speed and ignition timing. - ENGINE TUNE-UP.

2F

INJ (Fuel injection

duration) ms

Ignition switch on: 0.0 ms Idle: 3.0—5.0 ms

Inspect following PIDs: MAF V, IAT V, RPM, TP V, ECT V, NL SW, FHO2S, PSP SW, BRK SW, A/C SW, B+. Inspect CMP sensor. - CONTROL SYSTEM, CAMSHAFT POSITION (CMP) SENSOR INSPECTION

2U 2V

MAFV (Mass air flow signal voltage)

V Ignition switch on: 1.0—2.0 V Idle: 1.9—2.8 V

Inspect mass air flow sensor. CONTROL SYSTEM, MASS AIR FLOW (MAF) SENSOR INSPECTION

20

MT/AT*1

(MT/AT distinction signal)

ON/OFF Constant: ON - 1L

NLSW (Load/no load

condition signal) ON/OFF

Neutral position and clutch pedal depressed: ON Others: OFF

Inspect neutral switch. - CONTROL SYSTEM, NEUTRAL SWITCH INSPECTION Inspect clutch switch. -CONTROL SYSTEM, CLUTCH SWITCH INSPECTION

1V

*1: Europe only

F1-31



CONTINUED

CONTROL SYSTEM

Monitor item (Definition)

Unit/ Condition Condition/Specification Action PGM

terminal

PRCV (Pressure

regulator control) ON/OFF

Ignition switch on: OFF Idle: OFF Engine start at hot condition: ON

Inspect following PIDs: ECTV, IAT V, RPM,TP V, B+. Inspect PRC solenoid valve. FUEL SYSTEM, PRC SOLENOID VALVE INSPECTION

2T

PRGV (Purge solenoid valve duty value)

% Ignition switch on: 0% Idle: 0%

Inspect following PIDs: IATV, RPM, ECT V, MAP V, TP V, FHO2S, B+. Inspect purge solenoid valve. EMISSION SYSTEM, PURGE SOLENOID VALVE INSPECTION

2X

PSP SW (PSP switch)

ON/OFF Steering wheel fully turned: ON Steering wheel straight ahead position: OFF

Inspect PSP switch. CONTROL SYSTEM, POWER STEERING PRESSURE (PSP) SWITCH INSPECTION

1P

RPM (Engine speed)

RPM Idle: 700—770 RPM Inspect CMP sensor. CONTROL SYSTEM, CRANKSHAFT POSITION SENSOR INSPECTION

2E

TEN (TEN terminal

(DLC)) ON/OFF

Terminal TEN (DLC) short to ground: ON Terminal TEN (DLC) open: OFF

Inspect wiring from DLC terminal TEN to PCM terminal 1L 1K

TP V (TP sensor signal

voltage) V

Closed throttle position: 0.4—0.6 V Wide open throttle: 3.4—4.7 V

Inspect TP sensor. CONTROL SYSTEM, THROTTLE POSITION (TP) SENSOR INSPECTION

2M

VRV*2

(Variable resistor) V

Turned fully clockwise: below 1.0 V Turned fully counterclockwise: Approx 4.0 V

Inspect variable resistor VARIABLE RESISTOR INSPECTION

2N

VS (Vehicle speed)

KPH

Vehicle speed 20 km/h mph: 20 km/h mph Vehicle speed 40 km/h mph: 40 km/h mph

Inspect vehicle speedometer sensor Section T, WARNING AND INDICATOR SYSTEM, INSTRUMENT CLUSTER INSPECTION Inspect vehicle speed sensor

1M

*2: Except Europe

F1 -32



CONTINUED

CONTROL SYSTEM

4. If there is no continuity, repair the related harnesses.

Not Using the SSTs (NGS Tester) at Power Supply Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connectors. 3. Measure the voltage between the PCM battery power

terminal connectors and body GND using an ohmmeter.

Power supply terminal 1A

Not Using the SSTs (NGS tester) at Constant Voltage Terminal Inspection

1. Turn the ignition switch on. 2. Measure the voltage between the TP sensor and

variable resistor (Except Europe) connector (vehicle side) terminal A and body GND using a voltmeter. (1) When measurement voltage is 0 V. ① Turn the ignition switch off. ② Disconnect the TP sensor and variable resistor (Except Europe) connector (applied to constant voltage).

③ Verify there is no continuity between the TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C and body GND using an ohmmeter. ④ If there is continuity, repair the related harnesses. ⑤ Using an ohmmeter, inspect for continuity between the PCM connector (vehicle side) terminal 2D and TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C which is applied to constant voltage. ⑥ If there is continuity, repair the related harness.

(2) When measurement voltage is B+. ① Turn the ignition switch off. ② Disconnect the battery positive harness, then battery negative harness. ③ Verify there is no continuity between the TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C and battery positive harness using an ohmmeter. ④ If there is continuity, repair the related harnesses.

(3) When measurement voltage is approx. 5V. • Constant voltage terminal of PCM is okay.

Not Using the SSTs (NGS tester) at Ground (GND) Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connectors. 3. Inspect for continuity between the PCM GND

terminals and body GND using an ohmmeter.

PCM GND terminal 2A 2B 2C

Power supply terminal voltage: B+

4. If not as specified, repair the related harnesses and replace the faulty fuses.

Not Using the SSTs (NGS Tester) at Serial Communication Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connectors. 3. Verify there is continuity between PCM connector

terminal 1 D and DLC KLN terminal.

4. If there is no continuity, repair the related

harnesses. Not Using the SSTs (NGS Tester) at Instrument Cluster (Engine speed signal) Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connector and instrument cluster

connector (26 pin). 3. Verify there is continuity between PCM connector

terminal 2F and instrument cluster connector (20 pin) terminal 3B.

4. If there is no continuity, repair the related harnesses.

F1-33



CONTINUED

CONTROL SYSTEM Using voltmeter

Caution • The PCM terminal voltages vary with

change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made.

1. Remove the PCM. 2. Reconnect PCM connector and battery negative

terminal.

Note • With the PCM connector connected, body

ground the voltmeter negative (-) lead and measure voltage at each PCM terminal by inserting the voltmeter positive (+) lead.

3. Measure the voltage at PCM terminal using a voltmeter.

4. If any incorrect voltage is detected, inspect related systems, wiring harnesses and connectors referring to the action column in the terminal voltage list.

PCM Terminal Voltage (Reference)

Terminal Signal Connected to Test condition Voltage (V) Action

1A Back-up power supply

Battery Constant B+ • Inspect ROOM fuse. • Inspect related harness.

Ignition switch off 0 1B Power supply Main relay

Ignition switch on B+ • Inspect related harness.

1C — — — — —

1D Serial communication

DLC (Terminal KLN)

Carry out inspection according to DTC. DTC output is a part of serial communication. Judgement by terminal voltage is not possible.

— • Inspect related harness.

No DTC stored Below 1.0 1E DTC output

DLC (Terminal FEN)

Ignition switch on and terminal TEN (in DLC) short to chassis ground DTC stored 0-B+

• Inspect related harness.

1F — — — — — 1G — —- — — —

Ignition switch on B+

Cranking Below 1.0 1H Fuel pump control

Fuel pump relay

Idle Below 1.0

• Inspect fuel pump relay. FUEL SYSTEM,FUEL PUMP INSPECTION


1I — — — — — A/C switch on B+ Ignition switch

on A/C switch off B+ A/C switch on Below 1.0

1J A/C control

A/C relay

Ignition switch off A/C switch off Below 1.0

• Inspect A/C relay. section U


Terminal TEN (DLC) open

B+

1K Diagnostic test mode

DLC (Terminal TEN)

Ignition switch on Terminal TEN

(DLC) short to ground

Below 1.0 • Inspect related harness.

1L*1 Transmission distinction

Ground Constant

0 • Inspect related harness.

*1: Europe only

F1-34

CONTINUED



CONTROL SYSTEM Terminal Signal Connected to Test condition Voltage (V) Action

Vehicle stopped 0 or Approx. 5.0 1M Vehicle speed VSS

Vehicle running Approx. 5.0

• Inspect VSS. section T • Inspect related harness.

Accelerator pedal depressed B+

1N CTP CTP switch Ignition switch on Accelerator pedal

released Below 1.0

• Inspect CTP switch. CLOSED THROTLE POSITION (CTP) SWITCH INSPECTION


Brake pedal depressed B+ 1O Brake Brake switch

Brake pedal released Below 1.0

• Inspect brake switch. section P • Inspect related harness.

Steering wheel straight ahead position

B+ 1P Power steering

pressure PSP switch Idle Steering wheel fully turned Below 1.0

• Inspect PSP switch. POWER STEERING PRESSURE (PSP) SWITCH INSPECTION


A/C switch and fan switch on Below 1.0

1Q A/C A/C switch Ignition switch on

A/C switch off B+

• Inspect A/C switch. section U

• Inspect related harness. 1R — — — — — 1S — — — — — 1T — — — — — 1U — — — — —

Transmission neutral position or clutch pedal depressed

Below 1.0

1V Load/no load distinction

Neutral/clutch switch

Ignition switch on Other than

transmission neutral or clutch pedal released

B+

• Inspect neutral switch. NEUTRAL SWITCH INSPECTION

• Inspect clutch switch. CLUTCH SWITCH INSPECTION


2A Fuel injector ground Ground Constant Below 1.0 • Inspect related harness.

2B Power ground Ground Constant Below 1.0 • Inspect related harness. 2C System ground Ground Constant Below 1.0 • Inspect related harness.

2D Analog ground

MAF sensor, IAT sensor, ECT sensor, O2S,TP sensor

Constant Below 1.0 • Inspect related harness.

Ignition switch on 5.0 2E SGT

CMP sensor (integrated into distributor) Idle 1.8—2.3

• Inspect CMP sensor. CAMSHAFT POSITION (CMP) SENSOR INSPECTION


Ignition switch on Below 1.0 2F IGT control Ignition control

module Idle 0.35—0.5

• Inspect ignition control module. section G

• Inspect related harness. 2G — — — — — 2H — — — — — 2I — — — — — 2J — — — — —

2K Constant voltage (Vref) TP sensor Ignition switch on 4.5—5.5 • Inspect related harness.

F1-35 CONTINUED




2L IAT IAT sensor Ignition switch on IAT 20° C 68°F 2.15

• Inspect IAT sensor. INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION


Accelerator pedal released 0.4—0.6

2M TP TP sensor Ignition switch on Accelerator pedal

depressed 3,4—4.7

• Inspect TP sensor. THROTTLE POSITION (TP) SENSOR INSPECTION


Ignition switch on 0.55 Engine cold 0.0—1.0

Idle 0.0—1.0

Acceleration After warm up 0.5—1.0 2N*1 O2S O2S

Deceleration 0.0—0.5

• Inspect O2S. OXYGEN SENSOR (O2S) INSPECTION


2N*2 Variable resistor Variable resistor Varies according to the variable resistor adjustment 0—4

• Inspect variable resistor. VARIABLE RESISTOR INSPECTION


Ignition switch on 1.45

Idle (after warm up) 2.15 2O Mass airflow MAP sensor Engine speed 3000 rpm (after warm up) 2.73

• Inspect MAF sensor. MASS AIR FLOW (MAF) SENSOR INSPECTION


2P — — — — —

IAT 20°C 68°F 1.02

2Q ECT ECT sensor Ignition switch on

After warm up 0.58

• Inspect ECT sensor. ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION


2R — — — — — 2S — — — — —

For 120 sec. after ignition switch on 0 ECT above

90°C 194°F (Hot condition) For 120 sec. after

engine start 0 2T Pressure regulator control

PRC solenoid valve

Others Ignition switch on B+

• Inspect PRC solenoid valve. FUEL SYSTEM, PRC SOLENOID VALVE INSPECTION


Ignition switch on B+ 2U Fuel injector

No.1,No.3 Idle B+

• Inspect fuel injector. FUEL SYSTEM,FUEL INJECTOR INSPECTION


Ignition switch on B+ 2V

Fuel injector control

Fuel injector No.2, No.4

Idle B+

• Inspect fuel injector. FUEL SYSTEM,FUEL INJECTOR INSPECTION


Ignition switch on 0.2 2W IAC IAC valve

Idle (after warm up) Approx 1.0

• Inspect IAC valve. INTAKE-AIR SYSTEM, IAC VALVE INSPECTION

• Inspect related harness. *1: Europe only *2: Except Europe

F1-36

CONTINUED




Ignition switch on B+

Idle B+ 2X Purge control Purge solenoid valve

Driving in gear

• Inspect purge solenoid valve. EMISSION SYSTEM, PURGE SOLENOID VALVE INSPECTION


2Y — — — — —

Ignition switch on B+ 2Z Engine speed output

Tachometer (integrated into instrument cluster)

Idle 4.9—7.0

• Inspect instrument cluster. FUEL SYSTEM, FUEL INJECTOR INSPECTION


MASS AIR FLOW (MAF) SENSOR INSPECTION


MAF Sensor Inspection 1. Visually inspect for the following on the MAF

sensor. • Damage • Cracks • Terminal bends • Terminal rust

2. If any of the above are found, replace the MAF sensor. If the MAF sensor PID value is out of specification, inspect as follows and repair or replace as necessary:

3. Disconnect the MAF sensor connector. Open circuit • MAF signal circuit (MAF sensor connector

terminal B and PCM connector terminal 20) • Power circuit (MAF sensor connector

terminal C and main relay terminal D through common connector) • GND circuit (MAF sensor connector terminal A and PCM connector terminal 2D through common connector)

Short circuit • MAF signal circuit (MAF sensor connector

terminal B and PCM connector terminal 20 to GND)

• Power circuit (MAF sensor connector terminal C and main relay terminal D through common connector to GND) 4. Repair or replace faulty areas.

5. Reconnect the MAF sensor connector.

THROTTLE POSITION (TP) SENSOR INSPECTIONNote • Perform the following test only when directed.

Resistance Inspection 1. Verify that the throttle valve is at closed throttle

position. 2. Inspect that the accelerator cable free play is

within the specification. (Refer to INTAKE-AIR SYSTEM, ACCELERATOR CABLE INSPECTION / ADJUSTMENT.)

3. If as specified but PID valve is out of specification, measure the resistance between TP sensor terminals A and C using an ohmmeter. Specification 4—6KΩ

4. Disconnect the TP sensor connector. 5. If not as specified, replace the TP sensor. If as

specified, inspect for the following: Open circuit • Reference voltage circuit (TP sensor

connector terminal A and PCM connector terminal 2K)

• TP signal circuit (TP sensor connector terminal B and PCM connector terminal 2M)

• GND circuit (TP sensor connector terminal C and PCM connector terminal 2D)

Short circuit • Reference voltage circuit (TP sensor


• TP signal circuit (TP sensor connector terminal B and PCM connector terminal 2M)

F1-37 CONTINUED



CONTROL SYSTEM

Specification (CTP) TP sensor terminal C

voltage (V) PCM terminal 2M voltage

TP V (NGS tester) (V) 4.5—4.9 0.4—0.6 4.9—5.1 0.4—0.6 5.1—5.5 0.4—0.6

8. Tighten the TP sensor screw. Tightening torque 1.6—2.3 N.m 16—24 kgf.cm, 14—20 in.lbf

9. Use the NGS tester ("TP V" of PID/DATA MONITOR AND RECORD function) or voltmeter to verify the TP sensor so that the voltage of PCM terminal 2M is within the specification below when the throttle valve is wide open.

Specification (WOT)

TP sensor terminal C voltage (V)

PCM terminal 2M voltage TP V (NGS tester) (V)

4.5—4.7 3.4—4.4 4.7—4.8 3.6—4.5 4.8—4.9 3.7—4.6 4.9—5.0 3.7—4.8 5.0—5.1 3.8—4.9 5.1—5.3 4.0—5.0 5.3—5.4 4.1—5.1 5.4—5.5 4.2—5.2

6. Repair or replace faulty areas. 7. Reconnect the TP sensor connector.

THROTTLE POSITION (TP) SENSOR ADJUSTMENT

Caution • Adjusting the TP sensor with the throttle

adjusting screw (TAS) can adversely affect the engine. Do not adjust the TP sensor with the TAS.

• Since the TP sensor is adjusted by the manufacturer, adjusting the TP sensor excessively can adversely affect the engine. Do not adjust the TP sensor excessively.

1. Verify that the throttle valve is at closed throttle position.

2. Disconnect the TP sensor connector. 3. Turn ignition switch on. 4. Measure and record the voltage of the

disconnected harness side connector terminal C using a voltmeter.

Specification 4.5—5.5 V

5. Reconnect the TP sensor connector. 6. Loosen the TP sensor screw.

7. Use the NGS tester ("TP V" of PID/DATA MONITOR AND RECORD function) or voltmeter to adjust the TP sensor so that the voltage of PCM terminal 2M is within the specification below when the throttle valve is at the closed throttle position.

10. If not as specified, replace the TP sensor.

(Refer to CONTROL SYSTEM, THROTTLE POSITION (TP) SENSOR REMOVAL / INSTALLATION.)

THROTTLE POSITION (TP) SENSOR REMOVAL/INSTALLATION 1. Disconnect the TP sensor connector. 2. Remove the TP sensor screws. 3. Remove the TP sensor from the throttle body.

4. Verify that the throttle valve is fully closed. 5. Install the TP sensor to the throttle body. 6. tighten the TP sensor screws.

Tightening torque 1.6—2.3 N.m 16—24 kgf.cm, 14—20 in.lbf

7. Verify that the throttle valve moves smoothly. 8. Reconnect the TP sensor connector.

F1-38 CONTINUED



CONTROL SYSTEM

Short circuit • CTP signal circuit (CTP switch connector

terminal and PCM connector terminal 1 N to GND)

4. Reconnect CTP switch connector. INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION Resistance inspection


1. Remove the IAT sensor. 2. Heat the IAT sensor using the lamp. 3. Measure the resistance of the IAT sensor using

an ohmmeter

Specification

Water temperature (°C °F) Resistance (kΩ)

9. Adjust the TP sensor. (Refer to CONTROL SYSTEM, THROTTLE POSITION (TP) SENSOR ADJUSTMENT.)

CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION

Caution • The CTP switch is set at the factory. Do not

try to adjust it. • Removing the closed throttle position

switch can negatively affect the engine. Note • Perform the following test only when directed.

1. Disconnect the CTP switch connector. 2. Inspect for continuity between the CTP switch

terminal and a GND using an ohmmeter.

Specification

20 68 2.09— 2.81

Measuring condition Continuity 80 176 0.274 —0.802

Closed throttle position Yes Others No

3. If not as specified, replace the throttle body. If the CTP switch is okay, but PI D value is out of specification, inspect as follows and repair or replace as necessary.

Open circuit • CTP signal circuit (CTP switch connector terminal

and PCM connector terminal 1N) • GND circuit (CTP switch body to GND)

4. If not as specified, replace the IAT sensor. If

IAT sensor is okay, but PID value is out of specification, inspect as follows and repair or replace as necessary.

Open circuit • IAT signal circuit (IAT sensor connector terminal

A and PCM connector terminal 2L) • GND circuit (IAT sensor connector terminal B

and PCM connector terminal 2D)

Short circuit • IAT signal circuit (IAT sensor connector terminal

A and PCM connector terminal 2Lto GND) 5. Reconnect the IAT sensor connector.

F1-39

CONTINUED



CONTROL SYSTEM ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION


ECT Sensor Resistance Inspection 1. Drain the engine coolant.

(Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)

2. Remove the ECT sensor. 3. Place the ECT sensor in water with a

thermometer, and heat the water gradually.

4. Measure the resistance between the ECT sensor

terminals A and B using an ohmmeter.

Specification Water temperature (°C °F) Resistance (kΩ)

20 68 2.2—2.8 80 176 0.29—0.4

INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the IAT sensor connector. 3. Remove the IAT sensor. 4. Install the IAT sensor.


5. Connect the IAT sensor connector. 6. Connect the negative battery cable. ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION

Warning • When the engine is hot, it can badly burn.

Turn off the engine and wait until it is cool before removing or installing the ECT sensor.

1. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)

2. Disconnect the ECT sensor connector. 3. Remove the ECT sensor.

4. Replace the gasket. 5. Install in the reverse order of removal,


6. Refill the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)

5. If not as specified, replace the ECT sensor. If the ECT sensor is okay, but PID value is out of specification, inspect for the following: Open circuit • ECT signal circuit (ECT sensor connector

terminal A and PCM connector terminal 2Q through common connector)

• GND circuit (ECT sensor connector terminal B and PCM connector terminal 2D through common connector)

Short circuit • ECT signal circuit (ECT sensor connector

terminal A and PCM connector terminal 2Q through common connector to GND)

• GND circuit (ECT sensor connector terminal B and PCM connector terminal 2D through common connector to GND)

6. Repair or replace faulty areas. F1-40 CONTINUED



CONTROL SYSTEM 7. Install the ECT sensor. 8. Refill the engine coolant.

(Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)

CAMSHAFT POSITION (CMP) SENSOR INSPECTION


Voltage Inspection 1. Remove the distributor. 2. Disconnect the fuel injector connectors. 3. Disconnect the high-tension lead. 4. Connect the distributor connector.

Warning • Turning the ignition switch on with the

fuel injector connector still connected will actuate the fuel injector.

• Turning the ignition switch on with the distributor connector still connected will generate sparks, which can cause electrical shock. Disconnect the connector and prevent it from grounding to the vehicle body.

5. Turn the ignition switch on. 6. Verify the following signal (voltage) from the PCM

2E terminal using a voltmeter when the distributor is rotated by hand.

Specification Signal Terminal Voltage SGT 2E 4 pulses/rev. (Approx. 5.0 V)

Short circuit • SGT signal circuit (Distributor harness side

connector terminal C and PCM harness side connector terminal 2E to GND)

• Power circuit (Distributor harness side connector terminal B and main relay harness side connector terminal D to GND)

9. If the harnesses are okay, replace the distributor and adjust the ignition timing. (Refer to ENGINE TUNE-UP, IGNITION TIMING ADJUSTMENT.)

OXYGEN SENSOR (O2S) INSPECTION O2S Voltage Inspection


1. Warm up the engine and run it at idle. 2. Disconnect the O2S connector. 3. Connect the voltmeter test leads to the following

O2S terminals: • (+) lead-O2S terminal A • (-) lead-O2S terminal B

4. Run the engine at 3000 rpm until the voltmeter increases 0.5—0.7 V.

5. Verify that the voltmeter needle moves when racing the engine several times.

Specification Engine condition Voltage (V)

Acceleration 0.5—1.0 Deceleration 0—0.5

7. If not as specified, inspect as follows and repair

or replace as necessary. 8. Disconnect the distributor connector.

Open circuit • SGT signal circuit (Distributor harness side

connector terminal C and PCM harness side connector terminal 2E)

• Power circuit (Distributor harness side connector terminal B and main relay harness side connector terminal D)

• GND circuit (Distributor harness side connector terminal A and engine GND)

6. If not as specified, replace the O2S. If the O2S is okay, but PID value is out of specification, inspect for following:

F1-41 CONTINUED



CONTROL SYSTEM

Variable resistor condition Resistance (kΩ)

Turned fully clockwise 4-6 Turned fully counterclockwise Below 0.1

Open circuit • O2S signal circuit (O2S connector terminal A and

PCM connector terminal 2N) • GND circuit (O2S connector terminal B and PCM

connector terminal 2D)

Short circuit • O2S signal circuit (O2S connector terminal A and

PCM connector terminal 2N to GND) 7. Repair or replace faulty areas. 8. Reconnect the O2S connector. OXYGEN SENSOR (O2S) REMOVAL/INSTALLATION 1. Disconnect the battery negative terminal. 2. Disconnect the O2S connector. 3. Remove the O2S. 4. Install in the reverse order of removal.

Tightening torque 29-49 N.m 3—5 kgf.m, 22—36 ft.lbf

VARIABLE RESISTOR INSPECTION 1. Disconnect the connector from the variable

resistor. 2. Connect an ohmmeter between the variable

resistor terminal B and C.

3. Using the SST, verify that the resistance increases in relation to the turning amount of the variable resistor.

4. If not as specified, replace the variable resistor. 5. Adjust idle mixture. 6. If the variable resistor is okay, but PCM terminal

2N or 2K voltage is out of specification, inspect for the following:

Open circuit • Reference voltage circuit (Variable resistor


• Variable resistor signal circuit (Variable resistor connector terminal B and PCM connector terminal 2N)

• GND circuit (Variable resistor connector terminal C and PCM connector terminal 2D)

Short circuit • Reference voltage circuit (Variable resistor


• Variable resistor signal circuit (Variable resistor connector terminal B and PCM connector terminal 2N)

7. If there is an open or short circuit, repair or replace wiring harness.

8. If there is no open or short circuit, replace variable resistor.

9. Reconnect the variable resistor connector. CLUTCH SWITCH INSPECTION Continuity Inspection


1. Verify that the clutch switch is installed properly. 2. Disconnect the negative battery cable. 3. Remove the clutch switch.

(Refer to CONTROL SYSTEM, CLUTCH SWITCHREMOVAL/INSTALLATION.)

4. Inspect the continuity between the clutch switch terminals A and B using an ohmmeter.

F1-42

CONTINUED



CONTROL SYSTEM

Specification Transmission Continuity

In neutral Yes Others No

Specification

5. If not as specified, replace the clutch switch. If the

clutch switch is okay, but PID value is out of specification, inspect for the following: Open circuit • Power circuit (Clutch switch connector terminal

B and PCM connector terminal 1V through common connector)

• GND circuit (Clutch switch connector terminal A and GND)

Short circuit • Power circuit (Clutch switch connector terminal

B and PCM connector terminal 1V to GND) Neutral switch

• The neutral switch operation and related harnesses continuity (Refer to NEUTRAL SWITCH INSPECTION.

6. Repair or replace faulty areas. 7. Install the clutch switch.

(Refer to CONTROL SYSTEM, CLUTCH SWITCH REMOVAL/INSTALLTION.)

8. Connect the negative battery cable. CLUTCH SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the clutch switch connector. 3. Loosen the nuts and remove the clutch switch. 4. Install the clutch switch. 5. Adjust the clutch pedal height referring to the above

and the height specification. (Refer to Section H, CLUTCH PEDAL, CLUTCH PEDAL INSPECTION/ADJUSTMENT.)

6. Connect the clutch switch connector. 7. Connect the negative battery cable. NEUTRAL SWITCH INSPECTION Continuity inspection


1. Disconnect the battery negative cable. 2. Disconnect the neutral switch connector. 3. Measure the continuity between the neutral switch

terminals A and B using an ohmmeter.

4. If not as specified, replace the neutral switch. If the

neutral switch is okay, but PID value is out of specification, inspect for the following:

Open circuit • Load/no load distinction circuit (neutral switch

connector terminal A and PCM connector terminal 1V through common connector)

• GND circuit (neutral switch connector terminal B and GND)

Short circuit • Load/no load distinction circuit (neutral switch

connector terminal A and PCM connector terminal 1V through common connector to GND) Clutch switch

• The clutch switch operation and related harness continuity. (Refer to CONTROL SYSTEM, CLUTCH SWITCH INSPECTION.)

5. Repair or replace faulty areas. 6. Reconnect the neutral switch connector. NEUTRAL SWITCH REMOVAL/INSTALLATION 1. Disconnect the battery negative cable. 2. Disconnect the neutral switch connector. 3. Remove the neutral switch. 4. Install the new washer and neutral switch.

F1-43 CONTINUED



CONTROL SYSTEM


5. Connect the neutral switch connector. 6. Connect the battery negative cable. POWER STEERING PRESSURE (PSP) SWITCH INSPECTION Continuity inspection


1. Disconnect the PSP switch connector. 2. Start the engine. 3. Inspect for continuity between the PSP switch

terminal and GND using an ohmmeter.

Specification

Condition Continuity Steering wheel in straight ahead Yes

Steering wheel fully turned No 4. If not as specified, replace the PSP switch. If the

PSP switch is okay, but PID value is out of specification, inspect for the following: Open circuit • PSP signal circuit (PSP switch connector

terminal and PCM connector terminal 1P through common connector)

• GND circuit (PSP switch body and GND)

Short circuit • PSP signal circuit (PSP switch connector terminal

and PCM connector terminal 1P through common connector to GND) Power steering fluid (Refer to Section N, engine speed sensing power steering system.)

• Fluid level • Fluid leakage • Fluid pressure 5. Repair or replace faulty areas. 6. Reconnect the PSP switch connector. MAIN RELAY INSPECTION Continuity Inspection


1. Disconnect the negative battery cable. 2. Remove the main relay connector. 3. Inspect for continuity between terminals of the

relay using an ohmmeter.

Specification

4. If not as specified, replace the main relay. If the main relay is okay, inspect for the following: Open circuit • Main relay power supply circuit (Main relay

connector terminal A and ignition switch (IG1) connector through common connector)

• PCM power supply circuit (Main relay connector terminal C and battery positive terminal through common connector)

F1-44 CONTINUED



CONTROL SYSTEM, ON-BOARD DIAGNOSTIC SYSTEM

• GND circuit (Main relay connector terminal B and GND)

Short circuit • Main relay power supply circuit (Main

relay connector terminal A and ignition switch (IG1) connector through common connector to GND)

• PCM power supply circuit (Main relay connector terminal C and battery positive terminal through common connector to GND)

5. Repair or replace faulty areas. 6. Reconnect the main relay. 7. Reconnect the negative battery cable. MAIN RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the main relay connector. 3. Remove the main relay. 4. Install the reverse order of removal.

Tightening torque 7.9—10.7 N.m 80—110 kgf.cm, 69.5—95.4 in-Ibf

ON-BOARD DIAGNOSTIC SYSTEM READ/CLEAR DIAGNOSTIC TEST RESULTS

• This retrieves all stored DTCs in the PCM and clears the DTC.

PARAMETER IDENTIFICATION (PID) ACCESS • The PID mode allows access to certain data

values, analog and digital inputs and outputs, calculated values and system status information. Since PID values for output devices are PCM internal data values, perform the Simulation Test to identify which output devices are malfunctioning.

Note • PID monitor item "PRCV" can be selected and

"ON" or "OFF' is displayed for vehicles without the PRC system, but is not used for the inspection because the corresponding part (PRC solenoid valve) is not equipped.

DIAGNOSTIC SUPPORT PROCEDURE

• These tests are the ability of the powertrain control system to detect a change in certain input devices by following the instructions on the NGS tester. There are two options: ALL TEST and SINGLE TEST. ALL TEST takes you through all diagnostic support tests. SINGLE TEST enables you to perform specific tests that relate to the particular diagnosis that you are conducting. This test MUST follow the instructions on the NGS tester. If not, a "TEST CONDITIONS NOT CORRECT' message will appear, or else the test result will be FAULTY.

SIMULATION TEST • Output devices can be turned on and off by

sending simulation command signals from the NGS tester to the PCM. The "Idling Test" and "Ignition ON Test" are available in this test. These tests will verify the PCM status, output devices, and related circuit wiring harnesses.

Note • "PRCV" of the simulation item can be selected

for vehicles without the PRC system, but is not used for the inspection because the corresponding part (PRC solenoid valve) is not equipped.

ON-BOARD DIAGNOSTIC TEST NGS Tester Hook-up Procedure

Note • Make sure the ignition switch is at LOCK

position. 1. Insert the vehicle interface module and latest

program card into the hand-held NGS control unit.

F1-45

CONTINUED



ON-BOARD DIAGNOSTIC SYSTEM

2. Plug the adapter harness connector into the

vehicle interface module and the DLC located at the engine compartment.

3. Plug the NGS tester power connector into the cigarette lighter. Alternatively, use a battery hook-up adapter.

4. Listen to the double beep. The NGS tester is now initialized. Begin the powertrain control system functional test.

DTC READING PROCEDURE Using the SSTs (NGS Tester)

Note • Start engine and keep it running. If the

engine will not start, turn the ignition switch on during the procedure.

1. Perform the necessary vehicle preparation and visual inspection. Hook the NGS tester up to the vehicle.

2. Move the cursor to VEHICLE & ENGINE

SELECTION. Press the TRIGGER key to enter this function.

3. Move the cursor to SELECT NEW VEHICLE YEAR & MODEL Press the TRIGGER key to enter this selection.

4. Move the cursor to B-SERIES (UN). Press the TRIGGER key to enter this selection.

EUROPE

F1-46

CONTINUED



ON-BOARD DIAGNOSTIC SYSTEM EXCEPT EUROPE

Note

• Make sure the selected vehicle is correct. 5. A vehicle selection screen showing the selected

vehicle will be displayed. Move the cursor to the vehicle selected. Press the TRIGGER key.

6. Move the cursor to DIAGNOSTIC DATA LINK on the main menu screen. Press the TRIGGER key to enter into menu system diagnostics.

7. Move the cursor to PCM-POWERTRAIN CONTROL MODULE. Press the TRIGGER key to enter this selection.

8. Move the cursor to DIAGNOSTIC TEST MODES.Press the TRIGGER key to enter this selection.

9. Move the cursor to READ/CLEAR DIAGNOSTIC TEST RESULTS. Press the TRIGGER key to enter this selection.

10. Press START.

11. Retrieve DTCs. Not Using the SSTs (NGS Tester) Using the SST (self-diagnosis checker) 1. Connect the SSTs to the DLC located in the

engine compartment and ground the black (negative) lead to the body.

2. Set the select switch on the SST (self-diagnosis

checker) to A. 3. Turn the dial switch on the SST (system selector)

to 1, and the test switch to SELF TEST. 4. Turn the ignition switch on. 5. Verify that the buzzer sounds for approximately 3

seconds and code "88" flashes for 5 seconds. If DTC is not detected, "00" will then be indicated. Note • If the "88" does not flash, inspect +B terminal

of the DLC, and the related harnesses and connectors.

• If the "88" flashes and the buzzer sounds more than 20 seconds, inspect the harness between the PCM terminal and the DLC. If the harness is normal, replace the PCM and inspect.

6. If any DTCs is indicated, inspect the appropriate area and repair as necessary. Note • A DTC consists of four numbers. They are

flashed one by one in the right window on the display. ("1" is always shown on the left window.)

F1-47

CONTINUED



ON-BOARD DIAGNOSTIC SYSTEM 7. After completion of repairs, erase all DTCs from

the memory. (Refer to AFTER REPAIR PROCEDURE, Not Using the SSTs (NGS tester).)

8. Remove the SSTs.

Using the Voltmeter 1. Turn the ignition switch off.

Caution • Connecting the wrong DLC terminals may

possibly cause a malfunction. Carefully connect the specified terminals only.

2. Using a jumper wire to short terminal TEN of the DLC to body GND.

3. Connect the negative battery lead of voltmeter (20V range) to the DLC terminal FEN, and the positive lead to the DLC terminal +B.

4. Turn the ignition switch on. 5. The voltmeter indicates B+ for approximately 3

seconds, then indicates 0V. 6. Read the DTCs indicated by the movement of the

voltmeter's needle. If DTC is not detected, the needle does not move.

Note • The DTC will be output as shown.

7. If any DTCs is indicated, inspect the appropriate area and repair as necessary.

8. After completion of repairs, erase all DTCs from the memory. (Refer to AFTER REPAIR PROCEDURE, Not Using the SSTs (NGS Tester).)

9. Remove the voltmeter and jumper wire PID/DATA MONITOR AND RECORD PROCEDURE 1. Perform the NGS Tester Hook-up Procedure. 2. Perform Steps 1 through 7 from the DTC

READING PROCEDURE. 3. Turn the ignition switch on or run the engine. 4. Move the cursor to PID/DATA MONITOR AND

RECORD. Press the TRIGGER key to enter this selection.

5. Move the cursor to PID values to view. Press the TRIGGER key. A star symbol will appear next to the item when it is selected. Note • Press the TRIGGER key once again to

deselect a PID. • Press the CLEAR to deselect all PIDs.

6. Press START to begin. 7. When ready to capture and store the selected

PIDs, press the TRIGGER key. 8. Press the TRIGGER key again when ready to

save information. 9. Move the cursor to STORE RECORDING AREA

1. Press the TRIGGER key.

10. Follow the instructions displayed on the NGS

tester to save the recording data. PLAYBACK OF STORED PIDS PROCEDURE

Note • Look for abnormal behavior or values that

are clearly incorrect. Inspect the signals for abrupt or unexpected changes.

F1-48 CONTINUED



ON-BOARD DIAGNOSTIC SYSTEM • Look for agreement in related signals. • Make sure signals act in proper sequence.

1. Select VIEW RECORDER AREAS.

2. Select up to four PIDs to review in the table format or two PIDs to review in the graph mode. (1) Table format: Scroll through the PID data while analyzing the information. Look for sudden drops or peaks in the values.

(2) Graph format: Scroll through the PID data while analyzing the information. Look for sudden drops or peaks in the linear lines showing the transformation of values to the line graph.

DIAGNOSTIC SUPPORT PROCEDURE 1. Perform the NGS Tester Hook-up Procedure. 2. Perform Steps 1 through 8 from the DTC

READING PROCEDURE. 3. Move the cursor to DIAGNOSTIC SUPPORT

PROCEDURE. Press the TRIGGER key to enter this selection.

4. Move the cursor to ALL TEST or SINGLE TEST.

Press the TRIGGER key. Note • ALL TEST inspects each item according to an

established programmed order. With SINGLE TEST, enable to select and inspect any test item in any order, one at a time.

5. Follow the instructions displayed on the NGS tester and press the TRIGGER key.

Note • To skip a test item, press OMIT. • Before performing the test, the basic condition

on the test vehicle must be set up in order to get exact data. Press BASIC to view the basic condition instruction screen.

• If the screen shows PASSED, the system operates correctly.

• If the screen shows FAULTY, the system operates incorrectly.

F1-49

CONTINUED



ON-BOARD DIAGNOSTIC SYSTEM SIMULATION TEST PROCEDURE Idling Test 1. Perform the NGS tester hook-up procedure. 2. Perform the Steps 1 through 7 from the DTC

READING PROCEDURE. 3. Start the engine and run it at idle. 4. Move the cursor to SIMULATION TEST. Press the

TRIGGER key to enter this selection.

5. Move the cursor to IDLING TEST. Press the TRIGGER key to enter this selection.

6. The screen will display a list of simulation items.

Select the appropriate simulation item for testing, then press the TRIGGER key.

Note • Only one simulation item can be selected at a

time.

7. Press START. Note • If the screen displays "TEST CONDITION NOT

CORRECT", inspect the following signal conditions and determine whether or not they are normal:

• NLSW: ON • RPM; above 550


9. The simulation is performed for 3 seconds, and a "SIMULATION ACTIVATED PLEASE WAIT" message is displayed during those 3 seconds.

10. To perform the simulation again, press the TRIGGER key. To exit the idling test, press the CANCEL key.

Ignition ON Test 1. Perform Steps 1 through 7 from the DTCs

READING PROCEDURE. 2. Turn the ignition switch on. Move the cursor to

SIMULATION TEST. Press the TRIGGER key to enter this selection.

3. Move the cursor to IGNITION ON TEST. Press the TRIGGER key to enter this selection.

F1-50

CONTINUED




4. The screen will display a list of simulation items.

Select the appropriate simulation item for testing, then press the TRIGGER key.

5. Press START.


7. The simulation is performed for 3 seconds, and

a "SIMULATION ACTIVATED PLEASE WAIT" message is displayed during those 3 seconds.

8. To perform the simulation again, press the

TRIGGER key. To exit the ignition on test, press the CANCEL key.

AFTER REPAIR PROCEDURE Using the SSTs (NGS Tester) 1. After repairs have been made, perform the DTCs

READING PROCEDURE. 2. Press CLEAR. 3. Press the TRIGGER key. 4. Press the CANCEL key. 5. Ensure that the customer's concern has been

resolved. Not Using the SSTs (NGS Tester) 1. After repairs, disconnect the negative battery

cable for at least 20 seconds, and depress the brake pedal. Reconnect the negative battery cable.

2. Warm up the engine to normal operating temperature. Note • If the engine will not start, continue to operate

the starter for 5-6 seconds.

3. Perform the "DTC READING PROCEDURE" again.

4. Verify that the DTC is not detected.

F1-51

CONTINUED



ON-BOARD DIAGNOSTIC SYSTEM DTC INSPECTION DTC Table

DTC No. Output pattern Display on the NGS tester Condition

P0100

MAF/VAF-CIRCUIT MALFUNCTION MAF sensor circuit malfunction

P0115

ECT-CIRCUIT MALFUNCTION ECT sensor circuit malfunction

P0120

TP-CIRCUIT MALFUNCTION TP sensor circuit malfunction

P0134

O2S 11-CIRCUITNO ACTIVITY DETECTED O2S circuit no activity detected

P0340

CAMSHAFT POS SENSOR-CKT MALFUNCTION SGT signal is not detected

P0443

EVAP SYSTEM-PURGE CTRL VALVE CKT MALF Purge solenoid valve circuit malfunction

P0505

IDLE CONTROL SYSTEM-MALFUNCTION IAC valve circuit malfunction

P1110

IATS (D/C)-OPEN OR SHORT IAT sensor circuit malfunction

P1170

HO2S 11-INVERSION O2S is stuck

P1195

EGRBS-OPEN OR SHORT Barometric pressure sensor (in PCM) malfunction

P1250

PRC-OPEN OR SHORT PRC solenoid valve circuit malfunction

P1608

PCM (CPU)-MALFUNCTION PCM internal circuit malfunction

F1-52

CONTINUED



ON-BOARD DIAGNOSTIC SYSTEM DTC Troubleshooting

DTC P0100 Mass air flow (MAP) sensor circuit malfunction DETECTION CONDITION

Input voltage from MAF sensor is below 0.7 V or above 5.4 V when ignition switch is turned on.

POSSIBLE CAUSE

• MAF sensor malfunction • Blockage at MAP sensor • Poor connection of connectors at MAF sensor and/or PCM • Leakage in intake-air system • Short to power supply circuit in wiring from MAF sensor terminal B to PCM terminal 20 • Short to ground in wiring from MAF sensor terminal B to PCM terminal 20 • Open circuit in wiring from MAF sensor terminal B to PCM terminal 20 • Open circuit in wiring from MAF sensor terminal C to main relay terminal D • Open circuit in wiring from MAF sensor terminal A to PCM terminal 2D • Open circuit in wiring from PCM terminal 2C to engine ground.

STEP INSPECTION ACTION Yes

Inspect for open circuit in following wiring harnesses, then go to Step 12. • Main relay terminal D-purge solenoid valve, PRC

solenoid valve, IAC valve CMP sensor • PCM terminal 2D-throttle position sensor, intake-air

temperature sensor, engine coolant temperature sensor, oxygen sensor

• Between PCM terminal 2C and engine ground

1

Verify stored DTC. Have DTCs P0115, P0120, P0134, P0340, P0443, P0505, P1110, P1170, and/or P1250 been stored?

No Go to next step Yes Repair or replace connector, then go to Step 12. 2

Does MAP sensor connector or PCM connector have poor connection? No Go to next step.

Yes Go to next step 3

Is intake-air system okay? No Repair or replace faulty parts, then go to Step 12.

Yes Go to next step. 4

Disconnect MAF sensor connector. Turn ignition switch on. Is there battery positive voltage at MAF sensor harness side connector terminal C?

No

Inspect for open or short circuit in wiring harness (between main relay terminal D and MAF sensor terminal C), thengo to Step 12.

Yes

Go to next step.

5

Disconnect PCM connector. MAF sensor connector is disconnected. Is there continuity between MAF sensor harness side connector terminal A and PCM harness side connector terminal 2D?

No

Repair open circuit, then go to Step 12.


Is there continuity between MAF sensor harness side connector terminal B and PCM harness side connector terminal 20 No Repair open circuit, then go to Step 12.

Yes Repair short to power circuit, then go to Step 12. 7

Is there continuity from PCM harness side connector terminals 20 to 1B? No Go to next step

Yes Repair short to ground circuit, then go to Step 12. 8

Is there continuity from PCM harness side connector terminals 20 to body ground. No Go to next step.

Yes Clean MAF sensor screen, then go to Step 12. 9

Remove MAF sensor. Is there any foreign material at MAF sensor screen?

No Go to next step. Yes

Go to next step.

10

Connect MAF sensor connector. Connect NGS tester to DLC. Turn ignition switch on. Access MAF V PID. Does MAF V PID change when air is blown into mass airflow sensor?

Note • If NGS tester is not used, measure PCM

20 terminal voltage with circuit tester.

No

Replace MAF sensor, then go to Step 12.

F1-53

CONTINUED




STEP INSPECTION ACTION Yes Go to Step 1. 11

Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?

No

Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step.

Yes Go to applicable DTC inspection. 12

Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?

No

Troubleshooting completed.

DTC P0115 Engine coolant temperature (ECT) sensor circuit malfunction

DETECTION CONDITION

Input voltage from ECT sensor is below 0.07 V or above 4.58 V when ignition switch is turned on.

POSSIBLE CAUSE

• ECT sensor malfunction • Poor connection of connectors at ECT sensor terminal and/or PCM • Short to power supply circuit in wiring from ECT sensor terminal A to PCM terminal 2Q • Short to ground in wiring from ECT sensor terminal A to PCM terminal 2Q • Open circuit in wiring from ECT sensor terminal A to PCM terminal 2Q • Open circuit in wiring from ECT sensor terminal B to PCM terminal 2D • Open circuit in wiring from PCM terminal 2C to engine ground


Inspect for open circuit in following wiring harnesses, then go to Step 9. • PCM terminal 2D-MAF sensor, O2S, IAT sensor,

and/or TP sensor • PCM terminal 2C-engine ground

1

Verify stored DTC. Have DTCs P0100, P0120, P0134, P1110, and/or P1170 been stored?


Does ECT sensor connector or PCM connector have poor connection? No Go to next step


Disconnect ECT sensor connector. Turn ignition switch on. Is there 5V at engine coolant temperature sensor harness side connector terminal A

No

Inspect for open or short circuit in wiring harness (between PCM terminal 2Q and ECT sensor terminal A), then go to Step 9.

Yes

Go to next step.

4

Disconnect PCM connector. ECT sensor connector is disconnected. Is there continuity between ECT sensor harness side connector terminal B and PCM harness side connector terminal 2D

No

Repair open circuit, then go to Step 9

Yes Repair short to power circuit, then go to Step 9 5

Is there continuity from PCM harness side connector terminals 2Q to 1B? No Go to next step.


Is there continuity from PCM harness side connector terminals 2Q to body ground? No Go to next step


Is ECT sensor okay? CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION

No

Replace ECT sensor, then go to Step 9. CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION.

F1-54 CONTINUED




STEP INSPECTION ACTION Yes Go to Step 1. 8


No

Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step.


Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"? No Troubleshooting completed.

DTC P0120 Throttle position (TP) sensor circuit malfunction DETECTION CONDITION

Input voltage from TP sensor is below 0.09 V or above 4.78 V when ignition switch is turned on.

POSSIBLE CAUSE

• TP sensor malfunction • Poor connection of connectors at TP sensor and/or PCM • Short to power supply circuit in wiring from TP sensor terminal A to PCM terminal 2K • Short to power supply circuit in wiring from TP sensor terminal C to PCM terminal 2D • Short to power supply circuit in wiring from TP sensor terminal B to PCM terminal 2M • Short to ground in wiring from TP sensor terminal B to PCM terminal 2M • Short to ground in wiring from TP sensor terminal A to PCM terminal 2K • Open circuit in wiring from TP sensor terminal A to PCM terminal 2K • Open circuit in wiring from TP sensor terminal C to PCM terminal 2D • Open circuit in wiring from TP sensor terminal B to PCM terminal 2M • Open circuit in wiring from TP sensor terminal 2C to engine ground


Inspect for open or short circuit in following wiring harnesses, then go to Step 11. • PCM terminal 2D -MAP sensor, O2S, IAT

sensor, and/or ECT sensor • Between PCM terminal 2C and engine ground

1

Verify stored DTC. Have DTC P0100, P0115, P0134, P1110 and/or P1170 been stored.

No Go to next step Yes Repair or replace connector, then go to Step 11 2

Does TP sensor connector or PCM connector have poor connection? No Go to next step.


Disconnect TP sensor connector. Turn ignition switch on. Is there 5V at TP sensor harness side connector terminal A?

No

Inspect for open or short circuit in wiring harness (between PCM terminal 2K and TP sensor terminal A), then go to Step 11

Yes

Go to next step.

4

Disconnect PCM connector. TP sensor is disconnected. Is there continuity between TP sensor harness side connector terminal C and PCM harness side connector terminal 2D.

No



Is there continuity between TP sensor harness side connector terminal B and PCM harness side connector terminal 2M. No Repair or replace wiring harness, then go to Step 11.

F1-55

CONTINUED




STEP INSPECTION ACTION Yes Repair short to power supply circuit, then

go to Step 116

Is there continuity from PCM harness side connector terminals 2D to 1B? No Go to next step.

Yes Repair short to power supply circuit, then go to Step 11.

7

Is there continuity from PCM harness side connector terminal 2M to 1B No Go to next step.


Is there continuity from PCM harness side connector terminals 2M to body ground? No Go to next step.

Yes

Go to next step.

9

Connect TP sensor and PCM connectors. Connect NGS tester to DLC. Turn ignition switch on. Access TP V PID. Does TP V increase linear according to throttle valve opening angle?

Note

• If NGS tester is not used, measure PCM 2M terminal voltage with circuit tester.

No

Verify TP sensor, then go to Step 11.

Yes Go to Step 1. 10


No


Yes Go to applicable DTC inspection 11


F1-56

CONTINUED




DTC P0134 Oxygen sensor (O2S) circuit no activity detected

DETECTION CONDITION

O2S signal does not exceed 0.45 V after the engine is started, or stays below 0.45 V for 180 seconds after the engine has reached normal operating temperature.

POSSIBLE CAUSE

• O2S malfunction • Open or short circuit in wiring harness • Open or short circuit in wiring harness • Poor connection of connector • Fuel injector malfunction • Pressure regulator malfunction • Fuel pump malfunction • Fuel delivery hose and/or fuel filter clogging or leakage • Leakage in intake-air system • Leakage in exhaust system • Ignition coil and/or igniter malfunction Insufficient compression • MAF sensor malfunction • ECT sensor malfunction • TP sensor malfunction • Vacuum hose damage or looseness Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures.Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always

keep sparks and flames away from fuel • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or

death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE

STEP INSPECTION ACTION Yes Inspect and repair DTC P0100, P0115, P0120 or

P1110 then go to Step 22. 1

Verify stored DTC. Have DTC P0100 P0120, P0115 and/or P1110 been stored? No Go to next step

Yes

Trouble is in process. Go to next step.

2

Clear DTC. Verify RPM, ECT and VS PIDs. Drive in normal mode for approx. 2 minutes under same condition. Is DTC P0134 stored?

Note • If NGS tester is not used, measure

follow PCM terminal voltages with circuit tester. ① SGT (terminal 2E) ② ECT sensor (terminal 2Q) ③ Vehicle speed (terminal 1M)

No

Go to 'TROUBLESHOOTING, ENGINE SYMPTOM TROUBLESHOOTING, Intermittent concerns".

Yes

Implement TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure" and repair or replace, then go to Step 22.

3

Implement PID/DATA MONITOR AND RECORD (ECT, RPM, TP V) from DIAGNOSTIC DATA LINK by using NGS tester. Is there any signal that is far out of specification when ignition switch is on, and engine is run at idle?


following PCM terminal voltages with circuit tester. ① ECT sensor (terminal 2Q) ② SGT (terminal 2E) ③ TP sensor (terminal 2M)

No

Go to next step.

F1-57

CONTINUED





Implement 'TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure" and repair or replace, then go to Step 22.

4

Continue monitoring items in previous step. Is there any input signal, which causes drastic changes when it is set to be in trouble condition?

No Go to next step.

Yes

Repair or replace faulty exhaust parts, then go to Step 22. EXHAUST SYSTEM, EXHAUST SYSTEM

REMOVAL/INSTALLATION.

5

Inspect exhaust system upstream from oxygen sensor. Is there any gas leakage?

No Go to next step Yes Go to next step. 6

Inspect installation of O2S. Is it okay?

No

Install O2S properly, then go to Step 22. CONTROL SYSTEM, OXYGEN SENSOR (O2S)

REMOVAL/INSTALLATION. Yes

Go to next step.

7

Implement PID/DATA MONITOR AND RECORD (O2S) from DIAGNOSTIC DATA LINK using NGS tester. Is voltage on oxygen sensor as follows while racing engine (in neutral)? • More than 0.45V when accelerator pedal is

suddenly pressed: rich condition • Less than 0.45V during fuel cut: lean condition

Note • If NGS tester is not used, measure PCM

2N terminal voltage with circuit tester.

No

Inspect and repair or replace faulty oxygen sensor harness, connector or terminal, then go to Step 22. CONTROL SYSTEM, OXYGEN SENSOR (O2S)

INSPECTION.

Yes

Repair or replace faulty harness, connector or terminal, then go to Step 22.

8

Inspect for open, poor connection, and other problems on following harnesses, connectors and terminals (for fuel injector at each cylinder): • Front main relay to fuel injector Are there any

problems? No Go to next step.

Yes

Replace faulty fuel injectors, then go to Step 22. FUEL SYSTEM, FUEL INJECTOR


9

Inspect injection amount of each fuel injector. FUEL SYSTEM, FUEL INJECTOR

INSPECTION, Fuel Injection Volume Test. Are there any fuel injectors in abnormal condition for amount or condition of injection? No Go to next step.

Yes

Repair or replace source of air suction, then go to Step 22.

10

Inspect for air suction: • From air cleaner to throttle body • From throttle body to dynamic chamber • From dynamic chamber to intake manifold Visually inspect for cracks and damage, and inspect fluctuation after spraying rust penetrating agent, then select air suction area. Can air suction be confirmed?

No

Go to next step.

Yes


11

Inspect for suction in vacuum hose which has negative pressure on intake manifold, in the same manner as previous step. Can air suction be confirmed? No Go to next step.


Inspect fuel line pressure under trouble condition. TROUBLESHOOTING, ENGINE SYSTEM

INSPECTION, Fuel Pressure Inspection. Is fuel line pressure okay?

No Go to next step.


Inspect fuel pump maximum pressure. FUEL SYSTEM, FUEL PUMP UNIT

INSPECTION, Fuel Pump Maximum Pressure Inspection.

Is it okay?

No

Replace fuel pump, then go to Step 22. FUEL SYSTEM, FUEL PUMP UNIT

REMOVAL/INSTALLATION. Yes Go to next step. 14

Inspect for clogging in fuel filter (high-pressure). Are there foreign materials on fuel side of fuel filter? No Go to Step 16.

F1-58 CONTINUED



ON-BOARD DIAGNOSTIC SYSTEM STEP INSPECTION ACTION

Yes

Replace fuel filter (high-pressure), then go to Step 22. - FUEL SYSTEM, FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION.

15

Inspect inside of fuel tank for foreign materials and stains. Is inside of fuel tank okay?

No

Clean inside of fuel tank and fuel filter (low-pressure). Replace fuel filter (high-pressure), then go to Step 22. -FUEL SYSTEM, FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION.


Inspect for leakage and clogging in fuel line from fuel distributor to fuel pump. Is it okay? No Repair or replace necessary, then go to Step 22.

Yes

Replace pressure regulator, then go to Step 22.-FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION.

17

Inspect for leakage in fuel line fuel filter (high-pressure) to fuel tank (return side). Is it okay? No Repair or replace as necessary, the go to Step 22.


Verify blinking condition on each cylinder by setting timing light on high-tension lead under trouble condition. Does it blink regularly and stably?

No Go to next step.


Inspect resistance of ignition coil. Section G, IGNITION COIL INSPECTION. Is it okay? No Replace ignition coil, then go to Step 22.

Yes

Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant passage. Repair or replace faulty parts, then go to Step 22.

20

Warning • Removing the radiator cap when the

radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury.

• When removing the radiator cap, wrap a thick cloth around and turn it slowly.

Remove radiator cap. Implement procedure to bleed air from engine coolant, then run engine at idle. Are there any small bubbles which make engine coolant white at filling opening?

Note • Large bubbles are normal since they are

remaining air coming out from engine coolant passage.

No

Go to next step.


Inspect engine compression. Section B1, COMPRESSION INSPECTION. Is it okay? No Implement engine overhaul, the go to next step.


Clear DTC. Verify DTC after running vehicle. Is there any DTC stored? No Troubleshooting completed.

F1-59

CONTINUED



ON-BOARD DIAGNOSTIC SYSTEM DTC P0340 SGT signal is not detected

DETECTION CONDITION

No SGT signal input from CMP sensor when engine is started and 2.1 seconds have passed

POSSIBLE CAUSE

• CMP sensor malfunction • CMP sensor air gap incorrect • Short to power supply circuit in wiring from CMP sensor terminal C to PCM terminal 2E • Short to ground in wiring from CMP sensor terminal C to PCM terminal 2E • Short to ground in wiring from CMP sensor terminal B to main relay terminal D • Open circuit in wiring from CMP sensor terminal C to PCM terminal 2E • Open circuit in wiring from CMP sensor terminal B to main relay terminal D • Open circuit in wiring from CMP sensor terminal A to body ground


Inspect for open circuit in following wiring harnesses, then go to Step 11. • Main relay terminal D-purg solenoid valve, PRC solenoid valve, IAC solenoid valve, MAF sensor

1

Verify stored DTC. Have DTC PP0100, P0443, P0505, and/or P1250 been stored?

No Go to next step. Yes Repair or replace connector, then go to Step 11. 2

Does CMP sensor or PCM connector have poor connection? No Go to next step


Disconnect CMP sensor connector. Turn ignition switch on. Is there battery positive voltage at CMP sensor harness side connector terminal B?

No

Inspect for open or short circuit in wiring harness (between main relay terminal D and CMP sensor terminal B), then go to Step 11.


Disconnect CMP sensor connector. Turn ignition switch on. Is there 5 V at CMP sensor harness side connector terminal C?

No

Inspect for open or short circuit in wiring harness (between PCM terminal 2E and CMP terminal C), then go to Step 11.

Yes

Go to next step.

5

Disconnect PCM connector and CMP sensor con-nector. Is there continuity between CMP sensor harness side connector terminal C and PCM harness side connector terminal 2E?

No



Is there continuity from PCM harness side connector terminal 2E to 1B? No Go to next step.


Is there continuity from PCM harness side connector terminal 2E to body ground? No Go to next step.


Is there continuity from CMP sensor harness side terminal A to body ground? No Repair open circuit, then go to Step 11.

Yes

Go to next step.

9

Connect CMP sensor connector. Connect NGS tester to DLC. Turn ignition switch on. Access RPM PID. Does RPM PID change when engine is running?

Note

• If NGS tester is not used, measure PCM 2E terminal voltage with circuit tester.

No

Replace distributor and adjust ignition timing, then go to Step 11.

Yes Go to Step 1 10


No




F1-60

CONTINUED




DTC P0443 Purge solenoid valve circuit malfunction

DETECTION CONDITION Open or short circuit is observed in purge solenoid valve system when ignition switch is turned on.

POSSIBLE CAUSE

• Purge solenoid valve malfunction • Poor connection of connectors at purge solenoid valve and/or PCM • Short to power supply circuit in wiring from purge solenoid valve B to PCM terminal 2X • Short to ground in wiring from purge solenoid valve terminal B to PCM terminal 2X • Open circuit in wiring from PCM terminal 2B and/or 2C to engine ground • Open circuit in wiring from purge solenoid valve terminal B to PCM terminal 2X • Open circuit in wiring from purge solenoid valve terminal A to main relay terminal D


Inspect for open circuit following wiring harnesses, then go to Step 9. • Main relay terminal D-PRC solenoid valve, IAC

solenoid valve, MAF sensor, CMP sensor • Between PCM terminal 2C and engine ground

1

Verify stored DTC. Have DTC P0100, P0505, P0340, and/or P1250 been stored?


Does purge solenoid valve connector or PCM connector have poor connection? No Go to next step.


Disconnect purge solenoid valve connector. Turn ignition switch on. Is there battery positive voltage at purge solenoid valve harness side connector terminal A?

No

Inspect for open or short circuit in wiring harness (between main relay terminal D and purge solenoid valve terminal A), then go to Step 9.

Yes

Go to next step.

4

Disconnect PCM connector Purge solenoid valve is disconnected. Is there continuity between purge solenoid valve harness side connector terminal B and PCM harness side connector terminal 2X?

No

Repair open circuit, then go to step 9.


5

Is there continuity from PCM harness side connector terminal 2X to 1B? No Go to next step.


Is there continuity from PCM harness side connector terminal 2X to body ground? No Go to next step.


Is purge solenoid valve okay? EMISSION SYSTEM, PURGE SOLENOID

VALVE INSPECTION No Replace purge solenoid valve, then go to Step 9.

Yes Go to Step 1. 8


No




F1-61 CONTINUED




DTC P0505 Idle air control (IAC) valve circuit malfunction

DETECTION CONDITION

Open or short circuit is observed in idle air control, system

POSSIBLE CAUSE

IAC valve malfunction Poor connection of connectors at IAC valve and/or PCM Short to ground in wiring from IAC valve terminal B to PCM terminal 2W Short to power supply circuit in wiring from IAC valve terminal B to PCM terminal 2W Short to ground in wiring from IAC valve terminal A to main relay terminal D Open circuit in wiring from PCM terminal 2B and/or 2C to engine ground Open circuit in wiring from IAC valve terminal B to PCM terminal 2W Open circuit in wiring from IAC valve terminal A to main relay terminal D


Inspect for open circuit following wiring harnesses, then go to Step 9. • Main relay terminal D-PRC solenoid valve, MAF

sensor, CMP sensor, purge solenoid valve • Between PCM terminal 2C and engine ground

1

Verify stored DTC. Have DTC P0100, P0340, P0443, and/or P1250 been stored.


Does IAC valve connector or PCM connector have poor connection? No Go to next step


Disconnect IAC valve connector. Turn ignition switch on. Is there battery positive voltage at IAC valve harness side connector terminal A?

No

Inspect for open or short circuit in wiring harness (between main relay terminal D and IAC valve ter-minal A), then go to Step 9.

Yes

Go to next step.

4

Disconnect PCM connector IAC valve is disconnected. Is there continuity between IAC valve harness side connector terminal B and PCM harness side con-nector terminal 2W?

No

Repair open circuit, then go to step 9.

Yes Repair short to power supply circuit, then go to Step 9.5

Is there continuity from PCM harness side connector terminal 2W to 1B? No Go to next step.

Yes Repair short to ground circuit, then go to Step 9, 6

Is there continuity from PCM harness side connector terminal 2W to body ground? No Go to next step

Yes

Go to next step.

7

Is resistance between IAC valve component side connector A and B as specified?

Specification 8.7—10.5 Ω [23 °C 73.4 °F]

No

Replace IAC valve, then go to Step 9.

Yes Go to Step 1 8


No


Yes Go to applicable DTC inspection 9

Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"? No Troubleshooting completed

F1-62 CONTINUED




DTC P1110 Intake air temperature (IAT) sensor circuit malfunction

DETECTION CONDITION

Input from IAT sensor is below 0.1 V or above 4.9 V when ignition switch is turned on

POSSIBLE CAUSE

• IAT sensor malfunction • Poor connection of connectors at IAT sensor terminal and/or PCM • Short to power supply circuit in wiring from IAT sensor terminal A to PCM terminal 2L • Short to GND in wiring from IAT sensor terminal A to PCM terminal 2L • Open circuit in wiring from IAT sensor terminal A to PCM terminal 2L • Open circuit in wiring from IAT sensor terminal B to PCM terminal 2D • Open circuit in wiring from PCM terminal 2C to engine GND


Inspect for open circuit in following wiring harnesses, then go to Step 7. • PCM terminal 2D-ECT sensor, MAP sensor, O2S,

CMP sensor and/or TP sensor • PCM terminal 2C-engine GND

1

Verify stored DTC. Have DTC P0100, P0115, P0120, P0134, P0335, and/or P1170 been stored?


Does IAT sensor connector or PCM connector have poor connection? No Go to next step.


Disconnect IAT sensor connector. Turn ignition switch on. Is there 5V at IAT sensor harness side connector terminal A?

No

Inspect for open or short circuit in wiring harness (between PCM terminal 2L and IAT sensor terminal A), then go to Step 9.

Yes

Go to next step.

4

Disconnect PCM connector. IAT sensor connector is disconnected. Is there continuity between IAT sensor harness side connector terminal B and PCM harness side connector terminal 2D?

No



Is there continuity from PCM harness side connector terminals 2L to 1B? No Go to next step.


Is there continuity from PCM harness side connector terminal 2D to body GND? No Go to next step.


Is IAT sensor okay? CONTROL SYSTEM, INTAKE AIR

TEMPERATURE (IAT) SENSOR INSPECTION

No

Replace IAT sensor, then go to Step 9. CONTROL SYSTEM, INTAKE AIR

TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION

Yes Go to Step 1. 8


No




F1-63

CONTINUED




DTCP1170 Oxygen sensor (O2S) is stuck

DETECTION CONDITION

When O2S signal stays above 0.45V for 20 seconds after engine has reached normal operating temperature.

POSSIBLE CAUSE

• O2S deterioration • Fuel injector malfunction • Pressure regulator malfunction • Fuel pump malfunction • Fuel delivery hose clogging or leakage • Fuel return hose and/or fuel filter clogging • Leakage in intake-air system or exhaust system PCV valve malfunction • Purge solenoid valve malfunction or purge solenoid hoses are hooked up incorrectly • Ignition coil malfunction Insufficient compression • MAF sensor malfunction • ECT sensor malfunction • TP sensor malfunction • Open or short circuit in wiring harness • Poor connection of connector • Vacuum hose damage or looseness Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Al-

ways keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious Injuries

or death and damage. Fuel can also Irritate skin and eyes. To prevent this, always com-plete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE


Inspect and repair DTC P0100, P0110, P0115, or P0120. Go to Step 26.

1

Verify stored DTC. Have DTCs P0100, P0110 P0115, and/or P0120 been stored? No Go to next step.

F1-64

CONTINUED





Trouble is in process. Go to next step.

2

Clear DTC. Verify RPM, ECT and VS PIDS. Drive vehicle approx. 1 minute under same condition. Is DTC P1170 stored?


following PCM terminal voltage with voltmeter. ① SGT (terminal 2E) ② ECT sensor (terminal 2Q) ③ Vehicle speed (terminal 1 M)

No

Go to TROUBLESHOOTING, ENGINE SYMPTOM TROUBLESHOOTING, Intermittent Concerns.

Yes

Implement TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure and repair or replace then go to Step 26.

3

Implement PID/DATA.MONITOR AND RECORD (ECT, RPM, TP V) from DIAGNOSTIC DATA LINK using NGS tester. Is there any signal that is far out of specification when ignition switch is on, and engine is run at idle?


following PCM terminal voltage with voltmeter. ① ECT sensor (terminal 2Q) ② SGT (terminal 2E) ③ TP sensor (terminal 2K)

No

Go to next step.

Yes

Implement TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure and repair or replace, then go to Step 26.

4

Continue monitoring items on previous PIDs. Is there any input signal which causes drastic changes when it is set to be in trouble condition?


Repair or replace faulty exhaust parts, then go to Step 26. EXHAUST SYSTEM, EXHAUST SYSTEM


5

Inspect exhaust system, upstream from O2S. Is there any gas leakage?

No Go to next step. Yes Go to next step. 6

Is O2S installed properly? No

Install heated oxygen sensor properly, then go to Step 26. CONTROL SYSTEM, OXYGEN SENSOR (O2S)

REMOVAL/INSTALLATION. Yes

Go to next step.

7

Implement FID/DATA MONITOR AND RECORD (O2S) from DIAGNOSTIC DATA LINK using NGS tester. Is voltage on O2S as follows while racing engine (in neutral)? • More than 0.45V when accelerator pedal is

suddenly pressed: rich condition • Less than 0.45V during fuel cut: lean

condition Note

• If NGS tester is not used, measure PCM 2N voltages with voltmeter.

No

Inspect and repair or replace faulty O2S, harnesses, connector or terminals, then go to Step 26. CONTROL SYSTEM, OXYGEN SENSOR (O2S)

INSPECTION.

Yes

Repair or replace faulty harness, connector or terminal, then go to Step 26.

8

Inspect for open, poor connection and other problems on the following harnesses, connectors, and terminals (for fuel injector at each cylinder): • From main relay to fuel injector • From fuel injector to PCM Is there any trouble? No Go to next step.

F1-65 CONTINUED





Replace faulty fuel injectors, then go to Step 26. FUEL SYSTEM, FUEL INJECTOR


9

Inspect injection amount of each injector. FUEL SYSTEM, FUEL INJECTOR

INSPECTION, Volume Test. Are there any injectors operating abnormally? (e.g. injection amount, injection condition) No Go to next step.


Inspect purge control system. TROUBLESHOOTING, ENGINE SYSTEM

INSPECTION, Purge Control Inspection. Is it okay?

No

By following system inspection, repair or replace faulty parts, then go to Step 26.

Yes

Go to next step.

11

Inspect PCV valve operation. EMISSION SYSTEM, POSITIVE CRANKCASE

VENTILATION (PCV) VALVE INSPECTION. Is it okay? No Replace PCV valve, then go to Step 26,

Yes

Inspect for leakage and injection amount. FUEL SYSTEM, FUEL INJECTOR INSPECTION.

Replace faulty fuel injector, then go to Step 26.

12


INSPECTION, Fuel Line Pressure Inspection. Is fuel line pressure okay? No Go to next step.


Inspect pressure regulator. FUEL SYSTEM, PRESSURE REGULATOR

INSPECTION. Is it okay?

No

Replace pressure regulator, then go to Step 26. FUEL SYSTEM, PRESSURE REGULATOR

REMOVAL/INSTALLATION, Yes


14

Inspect air suction: • From air cleaner to throttle body • From throttle body to dynamic chamber • From dynamic chamber to intake manifold

Visually inspect for cracks and damage, and inspect fluctuation after spraying rust penetrating agent, then select air suction area.

• Can air suction confirmed?

No

Go to next step.

Yes


15

Inspect for air suction in vacuum hose, which has negative pressure on intake manifold, in the same manner as previous step. Can air suction be confirmed? No Go to next step,



INSPECTION, Fuel Line Pressure Inspection. Is fuel line pressure okay?

No Go to next step.


Inspect fuel pump maximum pressure. FUEL SYSTEM, FUEL PUMP UNIT

INSPECTION, Fuel Pump Maximum Pressure Inspection.

Is it okay?

No

Replace fuel pump body, then go to Step 26. FUEL SYSTEM, FUEL PUMP UNIT REMOVAL/

INSTALLATION.


Inspect for clogging in fuel filter (high-pressure). Is there foreign material in fuel on fuel pump side of filter? No Go to Step 20.

Yes

Replace fuel filter (high-pressure), then go to Step 26. FUEL SYSTEM, FUEL FILTER (HIGH-

PRESSURE) REMOVAL/INSTALLATION.

19

Inspect inside of fuel tank for foreign material and stains. Is inside of fuel tank okay? No

Clean inside of fuel tank and fuel filter (low-pressure). Replace fuel filter, then go to Step 26.


Inspect for leakage and clogging in fuel line from distributor to fuel pump. Is it okay?

No Repair or replace source of fuel leakage or clogging, then go to Step 26.

F1-66 CONTINUED





Replace pressure regulator, then go to Step 26. FUEL SYSTEM, PRESSURE REGULATOR


21

Inspect for leakage in fuel line from fuel filter (high-pressure) to fuel tank (return side). Is it okay? No Repair or replace source of fuel leakage, then

go to Step 26 Yes Go to Step 24 22

Verify blinking condition on each cylinder by setting timing light on high-tension lead under trouble condition. Does it blink regularly and stably?

No Go to next step.


Inspect resistance of ignition coil. Section G, IGNITION COIL INSPECTION. Is it okay? No Replace ignition coil, then go to Step 26.

Yes

Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant passage. Repair or replace faulty parts, then go to Step 26.

24

Warning • Removing the radiator cap when the

radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury.

• When removing the radiator cap, wrap a thick cloth around and turn it slowly.

Remove radiator cap. Implement procedure to bleed air from engine coolant, then run engine at idle. Are there any small bubbles, which make engine coolant white at filling opening?

Note

• Large bubbles are normal since they are remaining air coming out from engine coolant passage.

No

Go to next step.


Inspect engine compression. Section B1, COMPRESSION INSPECTION. Is it okay? No Implement engine overhaul, then go to next step.


Clear DTC. Verify DTC after running vehicle. Is there any DTC stored? No Troubleshooting completed.

DTC P1195 Barometric pressure (BARO) sensor (in PCM) DETECTION CONDITION

Input voltage from barometric pressure sensor is below 1.5 V or above 4.5 V when ignition switch is turned on.

POSSIBLE CAUSE • Barometric pressure sensor (in PCM) malfunction. STEP INSPECTION ACTION

_ _ _ Replace PCM CONTROL SYSTEM, PCM

REMOVAL/INSTALLATION

F1-67

CONTINUED




DTC P1250 PRESSURE REGULATOR CONTROL (PRC) solenoid valve circuit malfunction

DETECTION CONDITION

Open or short circuit is observed in PRC solenoid valve when Ignition switch is turned on

POSSIBLE CAUSE

• PRC solenoid valve malfunction • Poor connection of connectors at PRC solenoid valve and/or PCM • Short to power supply circuit in wiring from PRC solenoid valve B to PCM terminal 2T • Short to GND in wiring from PRC solenoid valve terminal B to PCM terminal 2T • Short to GND in wiring from PRC solenoid valve terminal A to main relay terminal D • Open circuit in wiring from PCM terminal 2T and/or 2C to engine GND • Open circuit in wiring from PRC solenoid valve terminal B to PCM terminal 2T • Open circuit in wiring from PRC solenoid valve terminal A to man relay terminal D


Inspect for open circuit in following wiring harnesses, then go to Step 9. • Main relay terminal D-IAC valve, PRC solenoid

valve, MAF sensor, CMP sensor, purge solenoid valve

• Between PCM terminal 2C and engine ground.

1

Verify stored DTC. Have DTCs P0100, P0335, P0443 and/or P0505 been stored?


Does PRC solenoid valve connector or PCM connector have poor connection? No Go to next step.


Disconnect PRC solenoid valve connector. Turn ignition switch on. Is there battery positive voltage at harness side connector terminal A?

No

Inspect for open or short circuit in wiring harness. (between main relay terminal D and PRC solenoid valve terminal A), then go to Step 9.

Yes

Go to next step.

4

Disconnect PCM connector. PRC solenoid valve is disconnected. Is there continuity between PRC solenoid valve harness side connector terminal B and PCM harness side connector terminal 2T?

No



5

Is there continuity between PCM harness side connector terminals 2T and 1B? No Go to next step.

Yes Repair short to GND circuit, then go to Step 9. 6

Is there continuity from PCM harness side connector terminal 2T to body GND? No Go to next step.


Is PRC solenoid valve okay? FUEL SYSTEM, PRESSURE REGULATOR

CONTROL (PRC) SOLENOID VALVE INSPECTION

No Replace PRC solenoid valve, then go to Step 9.

Yes Go to Step 1. 8


No




F1-68

CONTINUED




DTCP1608 PCM internal circuit malfunction DETECTION CONDITION

PCM does not read DTC from output devices.

POSSIBLE CAUSE • PCM does not read DTC from output devices. • Short to power supply circuit in wiring from output devices (purge solenoid valve, PRC solenoid

valve, IAC solenoid valve and/or fuel injectors) to PCM


Repair short to power supply circuit. Replace PCM. CONTROL SYSTEM, PCM


1

Disconnect output devices and PCM connector. Is there continuity between the following connectors? • PCM harness side connector terminal 2X-1B • PCM harness side connector terminal 2E-1B • PCM harness side connector terminal 2W-1B • PCM harness side connector terminal 2U-1B • PCM harness side connector terminal 2V-1B

No Replace PCM CONTROL SYSTEM, PCM


F1-69

CONTINUED



TROUBLESHOOTING

TROUBLESHOOTING FOREWORD • Before proceeding with the following troubleshooting.

(1) Refer to section Gl to understand the basic troubleshooting procedure. (2) Perform the diagnostic trouble code inspection. (3) If the diagnostic trouble code is displayed, proceed with inspection steps for the code. (4) When the engine can be started, perform "ENGINE TUNE-UP".

TROUBLESHOOTING ITEM TABLE • Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart.

No. TROUBLESHOOTING ITEM DESCRIPTION 1 Melting of main or other fuses — 2 Will not crank Starter does not work.

3 Hard to start/long crank/erratic start/erratic crank

Starter cranks engine at normal speed but engine requires excessive cranking time before starting.

4 Engine stalls After start/at idle Engine stops unexpectedly at idle and/or after start. 5 Cranks normally but will not start Starter cranks engine at normal speed but engine will not run. 6 Slow return to idle Engine takes more time than normal to return to idle speed.

7 Engine runs rough/rolling idle Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively.

8 Fast idle/runs on Engine speed continues at fast idle after warm-up. Engine runs after ignition switch is turned off.

9 Low idle/stalls during deceleration Engine stops unexpectedly at beginning of deceleration or recovery from deceleration.

Engine stalls/quits Acceleration/cruise Engine stops unexpectedly at beginning of acceleration or during acceleration. Engine stops unexpectedly while cruising.

Engine runs rough Acceleration/cruise Engine speed fluctuates during acceleration or cruising. Misses Acceleration/cruise Engine misses during acceleration or cruising.

Buck/jerk Acceleration/cruise/ deceleration Vehicle bucks/jerks during acceleration, cruising, or deceleration.

Hesitation/stumble Acceleration Momentary pause at beginning of acceleration or during acceleration.

10

Surges Acceleration/cruise Momentary minor irregularity in engine output. 11 Lack/loss of power Acceleration/cruise Performance is poor under load (e.g. power down when climbing hills).

12 Knocking/pinging Acceleration/cruise Sound is produced when air/fuel mixture is ignited by something other than spark plug (e.g. hot spot in combustion chamber).

13 Poor fuel economy Fuel economy is unsatisfactory. 14 Emissions compliance Emission compliance test is failed. 15 High oil consumption/leakage Oil consumption is excessive.

16 Cooling system concerns Overheating Engine runs at higher than normal temperature/overheats.

17 Cooling system concerns Runs cold Engine takes excessive period for reaching normal operating temperature.

18 Exhaust smoke Blue, black, or white smoke from exhaust system 19 Fuel odor (in engine compartment) Gasoline fuel smell or visible leakage 20 Engine noise Engine noise from under hood 21 Vibration concerns (engine) Vibration from under hood or driveline

22 A/C does not work sufficiently A/C compressor magnetic clutch does not engage when A/C is turned on.

23 A/C is always on/A/C compressor runs continuously A/C compressor magnetic clutch does not disengage.

24 A/C is not cut off under WOT conditions A/C compressor magnetic clutch does not disengage under WOT. 25 Exhaust sulphur smell Rotten egg smell (sulphur) from exhaust. 26 Intermittent concerns Symptom occurs randomly and is difficult to diagnose. 27 Constant voltage Incorrect constant voltage.

F1-70

CONTINUED



TROUBLESHOOTING

QUICK DIAGNOSTIC CHART Possible factor

Troubleshooting item St

arte

r mot

or m

alfu

nctio

n (M

echa

nica

l or e

lect

rical

)

Star

ter c

ircui

t inc

ludi

ng ig

nitio

n sw

itch

open

Impr

oper

eng

ine

oil l

evel

Low

or d

ead

batte

ry

Cha

rgin

g sy

stem

mal

func

tion

Impr

oper

eng

ine

com

pres

sion

Impr

oper

val

ve ti

min

g

Hyd

rolo

cked

eng

ine

Impr

oper

eng

ine

oil v

isco

sity

Impr

oper

dip

stic

k

Base

eng

ine

mal

func

tion

Flyw

heel

sei

zed

Impr

oper

tens

ion

or d

amag

ed d

rive

belts

Impr

oper

eng

ine

cool

ant l

evel

Wat

er a

nd a

nti-f

reez

e m

ixed

impr

oper

ly

Coo

ling

syst

em m

alfu

nctio

n (R

adia

tor,

hose

s, o

verfl

ow

syst

em, t

herm

osta

t, et

c.)

Engi

ne o

r tra

nsm

issi

on m

ount

s im

prop

erly

inst

alle

d

1 Melting of main or other fuses 2 Will not crank x x x x x x 3 Hard to start/long crank/erratic start/erratic crank 4 Engine stalls After start/at idle X x x 5 Cranks normally but will not start X x x 6 Slow return to idle 7 Engine runs rough/rolling idle x x 8 Fast idle/runs on 9 Low idle/stalls during deceleration

Engine stalls/quits Acceleration/cruise x x Engine runs rough Acceleration/cruise x x Misses Acceleration/cruise x x

Buck/jerk Acceleration/cruise/ deceleration

x x

Hesitation/stumble Acceleration x x

10

Surges Acceleration/cruise x x 11 Lack/loss of power Acceleration/cruise x x 12 Knocking/pinging Acceleration/cruise x x 13 Poor fuel economy x x x x 14 Emissions compliance x x x x 15 High oil consumption/leakage x x x 16 Cooling system concerns Overheating x x X x 17 Cooling system concerns Runs cold x 18 Exhaust smoke x x 19 Fuel odor (in engine compartment) 20 Engine noise x x x 21 Vibration concerns (engine) x x 22 A/C does not work sufficiently.

23 A/C is always on/A/C compressor runs continuously

24 A/C is not cut off under WOT conditions 25 Exhaust sulphur smell 26 Intermittent concerns x 27 Constant voltage

F1-71 CONTINUED



TROUBLESHOOTING

Possible factor Troubleshooting item C

oolin

g fa

n se

ated

impr

oper

ly

Acce

lera

tor c

able

free

pla

y m

isad

just

men

t

Fuel

qua

lity

Engi

ne o

verh

eatin

g

Air c

lean

er e

lem

ent c

logg

ed o

r res

trict

ion

Air l

eaka

ge fr

om in

take

-air

syst

em (T

ubes

loos

enes

s,

crac

k, g

aske

ts b

roke

n)

IAC

val

ve im

prop

er o

pera

tion

Thro

ttle

body

mal

func

tion

Vacu

um le

akag

e (V

acuu

m h

ose

dam

aged

, mis

-rou

ting)

Igni

tion

coil

mal

func

tion

(e.g

. ope

n sh

ort o

r cra

cks)

Initi

al ig

nitio

n tim

ing

mis

adju

stm

ent (

CM

P &

cran

ksha

ft pu

lley

mis

adju

stm

ent

Spar

k pl

ug m

alfu

nctio

n

Hig

h-te

nsio

n le

ads

mal

func

tion

(Cra

cks

, ope

n, lo

w

resi

stan

ce)

CM

P se

nsor

dam

aged

(e.g

. ope

n or

sho

rt ci

rcui

ts)

1 Melting of main or other fuses 2 Will not crank 3 Hard to start/long crank/erratic star/erratic crank x x x x x x x 4 Engine stalls After start/at idle x x x x x x x x x x x 5 Cranks normally but will not start x x x x x x x x x x 6 Slow return to idle x 7 Engine runs rough/rolling idle x x x x x x x x x 8 Fast idle/runs on x 9 Low idle/stalls during deceleration x x

Engine stalls/quits Acceleration/cruise x x x x x x x x Engine runs rough Acceleration/cruise x x x x x x x x Misses Acceleration/cruise x x x x x x x x

Buck/jerk Acceleration/cruise/ deceleration

x x x x x x

x x

Hesitation/stumble Acceleration x x x x x x x x

10

Surges Acceleration/cruise x x x x x x x x 11 Lack/loss of power Acceleration/cruise x x x x x x x 12 Knocking/pinging Acceleration/cruise x 13 Poor fuel economy x x x x 14 Emissions compliance x x x x x 15 High oil consumption/leakage 16 Cooling system concerns Overheating 17 Cooling system concerns Runs cold 18 Exhaust smoke x x x 19 Fuel odor (in engine compartment) 20 Engine noise x x 21 Vibration concerns (engine) x 22 A/C does not work sufficiently.


24 A/C is not cut off under WOT conditions 25 Exhaust sulphur smell x 26 Intermittent concerns x x x x x x 27 Constant voltage

F1-72 CONTINUED



TROUBLESHOOTING

Fuel

pum

p bo

dy m

alfu

nctio

n (M

echa

nica

l or e

lect

rical

Pres

sure

regu

lato

r mal

func

tion

Fuel

hos

es re

stric

ted

or c

logg

ed

Inje

ctor

s m

alfu

nctio

n (L

eaka

ge o

r clo

ggin

g,

inop

erat

ive)

Fuel

leak

age

from

fuel

sys

tem

(Inc

ludi

ng in

sula

tor,

inje

ctor

O-r

ing)

Fuel

filte

rs re

stric

ted

or c

logg

ed

PRC

sol

enoi

d va

lve

impr

oper

ope

ratio

n

Impr

oper

air/

fuel

mix

ture

ratio

con

trol

Exha

ust s

yste

m re

stric

ted

or c

logg

ed

Cat

alyt

ic c

onve

rter m

alfu

nctio

n

Evap

orat

ive

emis

sion

con

trol s

yste

m m

alfu

nctio

n

PCV

valv

e m

alfu

nctio

n

V-re

fere

nce

supp

ly c

ircui

t mal

func

tion

Mai

n re

lay

mal

func

tion

(Mec

hani

cal o

r ele

ctric

al)

ECT

sens

or m

alfu

nctio

n

Possible factor Troubleshooting item

Melting of main or other fuses 1 Will not crank 2

x x x x x x x x x Hard to start/long crank/erratic start/erratic crank 3 x x x x x x x x x x After start/at idle Engine stalls 4 x x x x x x x x x x x Cranks normally but will not start 5 x Slow return to idle 6 x x x x x x x x x Engine runs rough/rolling idle 7 x Fast idle/runs on 8 x x Low idle/stalls during deceleration 9 x x x x x x x x x x x Acceleration/cruise Engine stalls/quits x x x x x x x x x x x Acceleration/cruise Engine runs rough x x x x x x x x x x x Acceleration/cruise Misses

x x x x

x x x

x x x x Acceleration/cruise/ deceleration

Buck/jerk

x x x x x x x x x x x Acceleration Hesitation/stumble x x x x x x x x x x x Acceleration/cruise Surges

10

x x x x x x x Acceleration/cruise Lack/loss of power 11x x Acceleration/cruise Knocking/pinging 12x x x x x x x Poor fuel economy 13x x x x x x x x x Emissions compliance 14 x High oil consumption/leakage 15 Overheating Cooling system concerns 16 Runs cold Cooling system concerns 17x x x x x x Exhaust smoke 18 x x x Fuel odor (in engine compartment) 19 Engine noise 20 Vibration concerns (engine) 21 A/C does not work sufficiently. 22

A/C is always on/A/C compressor runs continuously

23

A/C is not cut off under WOT conditions 24 x Exhaust sulphur smell 25x x x x x x x x Intermittent concerns 26 Constant voltage 27

F1-73 CONTINUED



TROUBLESHOOTING

Possible factor Troubleshooting item Br

ake

switc

h an

d re

late

d ci

rcui

t mal

func

tion

Neu

tral o

r clu

tch

switc

h an

d re

late

d ci

rcui

t mal

func

tion

MAF

sen

sor a

nd re

late

d ci

rcui

t mal

func

tion

TP s

enso

r and

rela

ted

circ

uit m

alfu

nctio

n

TP s

enso

r mis

adju

stm

ent (

Incl

udin

g lo

osen

ess)

Varia

ble

resi

stor

and

rela

ted

circ

uit m

alfu

nctio

n (E

xcep

t Eur

ope)

PSP

switc

h an

d re

late

d ci

rcui

t mal

func

tion

Impr

oper

refri

gera

nt c

harg

ing

amou

nt

A/C

rela

y (A

/C c

ontro

l sig

nal)

circ

uit m

alfu

nctio

n

Clu

tch

slip

page

VSS

and

rela

ted

circ

uit m

alfu

nctio

n

Impr

oper

ATF

leve

l

Brak

e dr

aggi

ng

Loos

e pa

rts

Whe

els

and

tires

impr

oper

bal

ance

Driv

e lin

e m

alfu

nctio

n

Susp

ensi

on m

alfu

nctio

n

1 Melting of main or other fuses 2 Will not crank 3 Hard to start/long crank/erratic start/erratic crank x 4 Engine stalls after start/at idle x x 5 Cranks normally but will not start 6 Slow return to idle 7 Engine runs rough/rolling idle x x x 8 Fast idle/runs on 9 Low idle/stalls during deceleration x x x x x x

Engine stalls/quits acceleration/cruise x x x x x x x Engine runs rough acceleration/cruise x x x x x x x Misses acceleration/cruise x x x x x x x

Buck/jerk acceleration/cruise/ deceleration

x x x x x x x

Hesitation/stumble acceleration x x x x x x x

10

Surges acceleration/cruise x x x x x x x 11 Lack/loss of power acceleration/cruise x x x x x 12 Knocking/pinging acceleration/cruise x 13 Poor fuel economy x x 14 Emissions compliance 15 High oil consumption/leakage 16 Cooling system concerns overheating x x 17 Cooling system concerns runs cold 18 Exhaust smoke 19 Fuel odor (in engine compartment) 20 Engine noise x 21 Vibration concerns (engine) x x x 22 A/C does not work sufficiently. x x


x

24 A/C is not cut off under WOT conditions x x 25 Exhaust sulphur smell 26 Intermittent concerns x x x x x x 27 Constant voltage x x

F1-74 CONTINUED



SYMPTOM TROUBLESHOOTING: Symptom 1-Melting of main or other fuses FI-75 Symptom 2-Will not crank FI-76 Symptom 3-Hard to start/long crank/erratic crank FI-77-78 Symptom 4-Engine stalls-after start/at idle FI-79-81 Symptom 5-Cranks normally but will not start FI-82-84 Symptom 6-Slow return to idle FI-85 Symptom 7-Engine runs rough/rolling idle FI-86-88 Symptom 8-Fast idle/runs on FI-89 Symptom 9-Low idle/stalls during deceleration FI-90 Symptom 10-Engie stalls/quits-acceleration/cruise

- Engine runs rough – acceleration/cruise - Misses-acceleration/cruise - Buck/jerk – acceleration/cruise/deceleration - Hesitation/stumble – acceleration

I-91-93 Symptom 11-Lack/loss of power-acceleration/cruise FI-94-96 Symptom 12-Knocking/pinging-acceleration/cruise FI-97 Symptom 13-Poor fuel economy FI-98-99 Symptom 14-Emission compliance FI-100-101 Symptom 15-High oil consumption/leakage FI-101 Symptom 16-Cooling system concerns-overheating FI-102-103 Symptom 17-Cooling system concerns-runs cold FI-103 Symptom 18-Exhaust smoke FI-104-105 Symptom 19-Fuel odor (in engine compartment) FI-106 Symptom 20-Engine noise FI-107 Symptom 21-Vibration concerns (engine) FI-107 Symptom 22-A/C does not work sufficiently FI-108 Symptom 23-A/C is always on (a/c compressor runs continuously FI-109 Symptom 24-A/C does not cut off under wide open throttle (wot) conditions FI-110 Symptom 25-Exhaust sulphur smell FI-111 Symptom 26-Intermittent concerns FI-112 Symptom 27-Constant voltag e FI-113-114

- Surges – acceleration/cruise F

TO. MODEL .INDEXPAGES. FROM. MANUALBACK.TO.CHAPTER.INDEX RANG.DRFT.REPAIR MANUAL

CONTINUED

TROUBLESHOOTING

SYMPTOM TROUBLESHOOTING SYMPTOM 1 MELTING OF MAIN OR OTHER FUSES

Damaged Fuse Related Wiring Harness

MAIN (80 A)

MAIN fuse Generator Ignition switch Starter Ignition coil Condenser

HEAD (30 A) HEAD fuse • Generator

A/C (10A) A/C relay • Generator

WIPER (15 A)

WIPER fuse • A/C relay • A/C switch

STOP (15 A) STOP fuse • Brake switch

FUEL INJ (30 A)

Main relay • Fuel injector • PCM • PRC solenoid valve • Purge solenoid valve • IAC valve • MAF sensor • CMP sensor

ROOM (10 A) ROOM fuse • PCM

ENGINE (15 A)

ENGINE fuse • Main relay • Fuel pump relay Fuel pump relay • Fuel pump

METER (15 A)

METER fuse • PCM

F1-75

CONTINUED



TROUBLESHOOTING

SYMPTOM 2 WILL NOT CRANK DESCRIPTION • Starter does not work.

POSSIBLE CAUSE

• Open circuit between ignition switch and starter • Starter malfunction • Seized/hydrolocked engine or flywheel

STEP INSPECTION RESULTS ACTION Yes Go to next step. 1

Inspect for following: • Battery connection • Battery condition • Fuses Are all items okay?

No

Service as necessary. Repeat Step 1.


Is clicking sound heard from starter when ignition switch is turned to START? No Go to Step 4.

Yes

Inspect for seized/hydrolocked engine or flywheel. Section H, FLYWHEEL, FLYWHEEL

INSPECTION

3

Inspect starting system. Section G, STARTING SYSTEM,

STARTER INSPECTION Is starting system okay?

No

Repair or replace components as required.


Do any other electrical accessories work? No

Inspect charging system. Section G, CHARGING SYSTEM, GENERATOR

INSPECTIONYes

No DTC is displayed: Inspect following: • START circuit in ignition switch • Open circuit between ignition switch and starter

5

Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? No

DTC is displayed: Go to appropriate DTC test. Communication error message is displayed: Inspect for following: • Open circuit between main relay and PCM

terminal 1B • Open main relay GND circuit • Main relay is stuck open. • Open or poor GND circuit at PCM • Poor connection of vehicle body GND

6 Verify test results. If okay, return to diagnostic index to service any additional symptoms.

F1-76

CONTINUED



TROUBLESHOOTING

SYMPTOM 3 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK

DESCRIPTION • Starter cranks engine at normal speed but engine requires excessive cranking time before starting. • Battery in normal condition.

POSSIBLE CAUSE

• Spark leakage from high-tension leads • Vacuum leakage Poor fuel quality • Starting system malfunction • Spark plug malfunction • Air leakage from intake-air system • Erratic signal from CMP sensor • Air cleaner restriction PCV valve malfunction • Inadequate fuel pressure • Purge solenoid valve malfunction • MAF sensor contamination • Restriction in exhaust system • Pressure regulator control (PRC) system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep


damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.

FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE

STEP INSPECTION RESULTS ACTION Yes

Go to next step.

1

Inspect for following: • Vacuum leakage • Fuel quality (e.g. proper octane, contami-

nation, winter/summer blend) • Loose bands on intake-air system • Cracks on intake-air system parts • Air cleaner restriction Are all items okay?

No

Service as necessary.

Yes

No DTC is displayed: Go to next step.

2

Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?

No

DTC is displayed: Go to appropriate DTC test.

Yes Go to symptom troubleshooting No.16 for "Cooling system concerns - Overheating".

3

Is engine overheating?

No Go to next step. Yes Repair suspected high-tension leads. 4

Inspect for cracks on high-tension leads. Are there any cracks on high-tension leads? No Go to next step.

Yes

Spark plug is wet or covered with carbon: Inspect for fuel leakage from fuel injector. Spark plug is grayish white: Inspect for clogged fuel injector.

5

Inspect spark plug conditions. Is spark plug wet, covered with carbon or grayish white?

No Install spark plugs on original cylinders. Go to next step.


Visually inspect CMP sensor. Is CMP sensor okay? No Replace malfunctioning parts.


Remove PCV valve and inspect PCV valve. Does PCV valve rattle? No Replace PCV valve.

F1-77 CONTINUED



TROUBLESHOOTING


Install fuel pressure gauge between fuel filter and fuel distributor. Connect a jumper wire between F/P terminal at DLC in engine compartment and GND. TROUBLESHOOTING, ENGINE SYSTEM

INSPECTION, Fuel Line Pressure Inspection

Turn ignition switch on. Is fuel line pressure correct? Fuel line pressure 270—310 kPa 2.7—3.2 kgf/cm2, 39—45 psi

No

Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. Inspect PRC solenoid valve and related vacuum hose and harnesses. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.


Is fuel line pressure held after ignition switch is turned off? Fuel line pressure More than 150 kPa 1.5 kgf/cm2,21 psi for 5 min.

No

Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.

Yes

Go to next step.

10

Disconnect vacuum hose from pressure regulator and plug hose. Start engine. Does fuel line pressure remain within ± 20 kPa 0.21 kgf/cm2, 3 psi while driving vehicle?

No

Inspect for clogged fuel filter.


Connect vacuum hose to pressure regulator. Install vacuum gauge to intake manifold. Start engine. Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or fuel pressure gauge reading decrease as vacuum gauge reading increases?

No

Connect vacuum hose to pressure regulator. Start engine. Verify fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator.

Yes

Inspect if purge solenoid valve sticks to open.

12

Disconnect a vacuum hose from purge solenoid valve and plug opening end of vacuum hose. Start engine. Is starting condition improved?

No

Go to next step.

Yes Replace MAP sensor. 13

Inspect for contaminated MAP sensor. Is there any contamination? No Go to next step.

Yes Inspect exhaust system. 14

Is there restriction in exhaust system? No Go to next step.

Yes Inspect for loose connectors or poor terminal contact. 15

Inspect starting system. Section G, STARTING SYSTEM,

STARTER INSPECTION Is starting system normal?

No Repair or replace components as required.


F1-78

CONTINUED



TROUBLESHOOTING SYMPTOM 4 ENGINE STALLS - AFTER START / AT IDLE DESCRIPTION • Engine stops unexpectedly at idle and/or after start.

• A/C system operation is improper. • Air leakage from intake-air system parts • Purge solenoid valve malfunction • Improper operation of IAC valve • No signal from CMP sensor due to sensor related wire or wrong installation • Vacuum leakage • Low engine compression • Spark leakage from high-tension leads • Poor fuel quality • PCV valve malfunction • Air cleaner restriction • Restriction in exhaust system • Electrical connector disconnection • Open or short circuit in fuel pump body and related harness • No battery power supply to PCM or poor GND • Inadequate fuel pressure • Fuel pump body mechanical malfunction • Fuel leakage from fuel injector • Fuel injector clogging • Pressure regulator control (PRC) system malfunction

POSSIBLE CAUSE

Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always • keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death • and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE • REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE

STEP INSPECTION RESULTS ACTION Go to next step.

Yes


1

Verify following: • Vacuum connection • Air cleaner element • No air leakage from intake-air system • No restriction of intake-air system • Proper sealing of intake manifold and

components attached to intake manifold (e.g. IAC valve)

• Ignition wiring • Fuel quality (e.g. proper octane, contami-

nation, winter/summer blend) • Electrical connections • Smooth operation of throttle valve Are all items okay?

No

Go to next step. Yes

2

Turn ignition switch on. Disconnect TP sensor connector. Measure voltage at TP sensor connector VREF terminal with ignition switch on. Voltage 4.5—5.5 V Is voltage okay?

No

Go to symptom troubleshooting No.27 "Constant voltage".

F1-79

CONTINUED



TROUBLESHOOTING



3

Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or SYSTEM PASSED" displayed?

No

DTC Is displayed: Go to appropriate DTC test. Communication error message is displayed: Inspect for following: • Open circuit between main relay and PCM terminal 1B • Open main relay GND circuit • Main relay stuck open • Open PCM GND circuit (terminal 2A, 2B or 2C) • Poor connection of vehicle body GND

Yes Inspect IAC valve and wiring harness. 4

Attempt to start engine at part throttle. Does engine run smoothly at part throttle? No Go to next step.


Connect NGS tester to DLC. Access RPM PID. Is RPM PID indicating engine speed during cranking of engine?

No

Inspect for following: • Open or short circuit In CMP sensor • Open or short circuit between CMP sensor and PCM

terminal 2E • Open or short circuit in CMP sensor harnesses If CMP

sensor and harness okay, go to next step. Yes Go to next step. 6


Yes Repair suspected high-tension lead. 7

Inspect for cracks on high-tension leads Are there any cracks on high-tension leads? No Go to next step.

Yes

Go to next step. If symptom occurs with A/C on, go to Step 14.

8

Is strong blue spark visible at each discon-nected high-tension lead while cranking engine? No

Inspect for following: • Open or short circuit in ignition coil • Open circuit in high-tension leads • Open circuit between igniter connector GND terminal

and body GND • Open circuit between ignition switch and ignition coil • Open circuit between ignition coil and condenser • Open circuit between condenser and igniter • Open circuit between ignition coil and igniter • Open circuit between igniter and PCM terminal 2F

Yes

Spark plug is wet or covered with carbon: Inspect for fuel leakage from injector. Spark plug is grayish white: Inspect for clogged fuel injector.

9

Inspect spark plug condition. Is spark plug wet, covered with carbon, or grayish white? No Install spark plugs on original cylinders.

Go to next step.Yes Go to next step. 10

Remove and shake PCV valve. Does PCV valve rattle? No Replace PCV valve.


Is there any restriction in the exhaust system? No Go to next step.

F1-80

CONTINUED



TROUBLESHOOTING


Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC and GND. Turn ignition switch on. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270—310kPa 2.7—3.2 kgf/cm2, 39—45 psi

No

Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. Inspect PRC solenoid valve, related vacuum hose and related harnesses. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.

Yes

Go to next step.

13

Visually inspect for fuel leakage at fuel injector, O-ring, and fuel line. Service as necessary. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure More than 150 kPa 1.5 kgf/cm2,21 psi for 5 min.

No


Yes

Go to next step.

14

Note • The following test is for stall concerns

with A/C on. If other symptoms exist, go to next step.

Connect pressure gauges to A/C low and high pressure side lines. Turn A/C on and measure low side and high side pressure. Section U, REFRIGERANT SYSTEM

SERVICE PROCEDURE, REFRIGER-ANT PRESSURE CHECK

Is pressure within specifications?

No

If A/C is always on, go to symptom troubleshooting No.23 "A/C is always on / A/C compressor runs continuously". For other symptoms, inspect following: • Refrigerant charging amount

Yes

Inspect if purge solenoid valve sticks to open. Inspect evaporative emission control system.

15

Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid side. Plug opening end of vacuum hose. Start engine. Is engine stall now eliminated?

No

Go to next step.

Yes Repair or replace. 16

Is air leakage felt or heard at intake-air system components while racing engine to higher speed? No Go to next step.

Yes Inspect valve timing. 17

Is engine compression correct? No Inspect for cause.


F1-81

CONTINUED



TROUBLESHOOTING

SYMPTOM 5 CRANKS NORMALLY BUT WILL NOT START

DESCRIPTION

• Starter cranks engine at normal speed but engine will not run. • Refer to "Engine stalls" if this symptom appears after engine stall. • Fuel in tank. • Battery in normal condition.

• No battery power supply to PCM • Air leakage from intake-air system • Open PCM GND or vehicle body GND • Improper operation of IAC valve • No signal from CMP sensor due to sensor related wire or incorrect installation • Low engine compression • Vacuum leakage • Spark leakage from high-tension leads • Poor fuel quality • PCV valve malfunction • Air cleaner restriction • Restriction in exhaust system • Disconnected electrical connector • Open or short circuit in fuel pump body and related harness • Inadequate fuel pressure • Fuel pump body mechanical malfunction • Fuel leakage from injector • Fuel injector is clogged. • Purge solenoid valve malfunction • Pressure regulator control (PRO) system malfunction

Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service:

POSSIBLE CAUSE

• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

• Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described In this manual.



Go to next step.

1

Verify following: • Vacuum connection • External fuel shut off or accessory (kill

switch, alarm etc.) • Fuel quality (e.g. proper octane, contami-

nation, winter/summer blend) • No air leakage from intake-air system • Proper sealing of intake manifold and


• Ignition wiring • Electrical connections • Fuses • Smooth operation of throttle valve Are all items okay?

No


F1-82

CONTINUED



TROUBLESHOOTING

STEP INSPECTION RESULTS ACTION Yes No DTC is displayed:

Go to next step. 2


No

DTC is displayed: Go to appropriate DTC test. Communication error message is displayed: Inspect for following: • Open circuit between main relay and PCM terminal

1B • Open main relay GND circuit • Main relay stuck open • Open PCM GND circuit (PCM terminal 2A, 2B or 2C) • Poor connection of vehicle body GND

Yes

Go to next step.

3

Turn ignition switch on. Disconnect TP sensor connector. Measure voltage at TP sensor connector VREF terminal with ignition switch on. Voltage 4.5—5.5 V Is voltage okay?

No

Go to symptom troubleshooting No.27 "Constant voltage",


Does engine start with throttle closed? No Go to next step.

Yes Inspect IAC valve and wiring harness. 5

Will engine start and run smoothly at part throttle? No Go to next step.


Connect NGS tester to DLC. Access RPM PID. Is RPM PID indicating engine speed when cranking engine?

No

Inspect for following: • Open or short circuit in CMP sensor • Open or short circuit between CMP sensor and PCM

terminal 2E • Open or short circuit in CMP sensor harnesses If CMP sensor and harness are okay, go to next step.



Yes Repair suspected high-tension leads. 8

Inspect for cracks on high-tension leads. Is there any cracks on high-tension leads? No Go to next step.


Is strong blue spark visible at each disconnected high-tension lead while cranking engine?

No

Inspect for following: • Open or short circuit in ignition coil • Open circuit in high-tension leads • Open circuit between igniter connector GND terminal

and body GND • Open circuit between ignition switch and ignition coil • Open circuit between ignition coil and condenser • Open circuit between condenser and igniter • Open circuit between ignition coil and igniter • Open circuit between igniter and PCM terminal 2F

Yes

If spark plug is wet or covered with carbon, inspect for fuel leakage from injector. If spark plug is grayish white, inspect for clogged fuel injector.

10

Inspect spark plug conditions. Is spark plug wet, covered with carbon, or grayish white?

No

Install spark plugs on original cylinders. Go to next step.




Is there any restriction in exhaust system? No Go to next step.

F1-83

CONTINUED



TROUBLESHOOTING


Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC in engine compartment and GND. Turn ignition switch on. Is fuel line pressure correct when ignition switch is cycled on/off five times? Fuel line pressure 270—3-10 kPa 2.7—3.2 kgf/cm2, 39—45 psi

No

Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. Inspect PRC solenoid, related vacuum hose, and har-nesses. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.

Yes

Go to next step.

14

Visually inspect for fuel leakage at fuel injector O-ring and fuel line. Service as necessary. Is fuel line pressure held after ignition switch is turned off? Fuel line pressure More than 150 kPa 1.5 kgf/cm2, 21 psi for 5 min.

No


Yes

Inspect if purge solenoid valve sticks to open mechanically. Inspect evaporative emission control system.

15

Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Start engine. Is starting condition improved?

No Go to next step.

Yes Repair or replace. 16

Is air leakage felt or heard at intake-air system components while racing engine to higher speed? No Go to next step.


Is engine compression correct? No Inspect for causes.


F1-84

CONTINUED



TROUBLESHOOTING

SYMPTOM 6 SLOW RETURN TO IDLE DESCRIPTION • Engine takes more time than normal to return to idle speed.

POSSIBLE CAUSE

• ECT sensor malfunction • Thermostat is stuck open. • Throttle body malfunction • Air leakage from intake-air system



1


No


Yes Engine coolant temperature and thermostat are okay. Go to next step.

2

Remove thermostat and inspect operation. Section E, THERMOSTAT,

THERMOSTAT INSPECTION Is thermostat okay?

No

Access ECT V PID on NGS tester. Inspect for both ECT V PID and temperature gauge on instrument cluster readings. If temperature gauge on instrument cluster indicates normal range but ECT V PID is not same as temperature gauge reading, inspect ECT sensor. If temperature gauge on instrument cluster indicates cold range but ECT V PID is normal, inspect temperature gauge and heat gauge unit.

Yes Inspect for air leakage from intake-air system components while racing engine to higher speed.

3

Is throttle body free of contamination?

No Clean or replace throttle body. 4 Verify test results. If okay, return to diagnostic index to service any additional symptoms.

F1-85

CONTINUED



TROUBLESHOOTING

SYMPTOM 7 ENGINE RUNS ROUGH/ROLLING IDLE

DESCRIPTION • Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively. • Idle speed is too slow and engine shakes excessively. • Air leakage from intake-air system parts • A/C system operation is improper. • Spark leakage from high-tension leads • Purge solenoid valve malfunction (if equipped) • Improper operation of IAC valve • Low engine compression • Erratic signal from CMP sensor • Poor fuel quality • PCV valve malfunction • Air cleaner restriction • Restriction in exhaust system • Disconnected electrical connectors • Inadequate fuel pressure • Fuel pump body mechanical malfunction • Fuel leakage from fuel injector • Fuel injector clogging • Engine overheating • Vacuum leakage • Pressure regulator control (PRC) system malfunction

POSSIBLE CAUSE

Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep





Go to next step.

1

Verify following: • External fuel shut off or accessory • Fuel quality (e.g. proper octane, contami-

nation, winter/summer blend) • No air leakage from intake-air system • Proper sealing of intake manifold and


• Ignition wiring • Electrical connections • Fuses • Smooth operation of throttle valve. Are all items okay?

No


Yes


2

Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" display? No


Yes

Go to symptom troubleshooting No.16 "Cooling system concerns - Overheating".

3

Is engine overheating? No Go to next step.

F1-86 CONTINUED



TROUBLESHOOTING


Go to next step.

4

Note • Following test is for engine running rough

idle with A/C on concerns. If other symp-toms exist, go to next step.

Connect pressure gauge to A/C low and high pressure side lines. Start engine and run it at idle. Turn A/C switch on. Measure low side and high side pressures. Section U, REFRIGERANT SYSTEM

SERVICE PROCEDURE, REFRIGER-ANT PRESSURE CHECK

Are reading pressures within specification?

No


Yes

Inspect power steering pressure switch operation and wiring harness between power steering pressure switch connector and PCM connector terminal 1P.

5

Note • Following test is for engine running rough

with P/S on. If other symptoms exist, go to next step.

Start engine and run it at idle. Access PSP SW PID. Inspect if PSP SW PID is on while turning steering wheel right to left. Is PSP SW PID okay?

No

Go to next step.



Yes Repair suspected high-tension leads. 7

Inspect for cracks on high-tension leads. Are there any cracks on high-tension leads? No Go to next step.

Yes

Spark plug is wet or covered with carbon: Inspect for fuel leakage from injector. Spark plug is grayish white: Inspect for clogged fuel injector.

8

Inspect spark plug conditions. Is spark plug wet, covered with carbon, or grayish white?



Start engine and disconnect IAC valve con-nector. Does rpm drop or engine stall? No Inspect IAC valve and wiring harness.


Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250 kPa 2.1—2.6 kgf/cm2, 30—36 psi

No

Zero or low Inspect fuel pump circuit Inspect for open fuel pump relief valve Inspect for fuel leakage inside pressure regulator Inspect for clogged main fuel line Inspect PRC solenoid valve, related vacuum hose and harnesses High • Inspect pressure regulator for high pressure cause • Inspect for clogged fuel return line

Yes

Go to next step.

11

Visually inspect for fuel leakage at fuel injector, O-ring, and fuel line. Service as necessary. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure More than 150 kPa 1.5 kgf/cm2,21 psi for 5 min.

No


F1-87

CONTINUED



TROUBLESHOOTING


Go to next step.

12

Connect NGS tester to DLC, Start the engine and run it at idle. Access FHO2S PID. Is FHO2S PID okay? • More than 0.45 V when accelerator pedal

is suddenly depressed: rich condition • Less than 0.45 V during fuel cut: lean

condition

No

Inspect and repair or replace faulty O2S, harness, connector or terminal, then go to next step.

Yes

Inspect if purge solenoid valve sticks open mechanically. Inspect evaporative emission control system.

13

Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Start engine. Does engine condition improve?

No

Go to next step.






Is engine compression correct? No Inspect for causes.


F1-88

CONTINUED



TROUBLESHOOTING

SYMPTOM 8 FAST IDLE/RUNS ON DESCRIPTION

• Engine speed continues at fast idle after warm-up. • Engine runs after ignition switch is turned off.

POSSIBLE CAUSE

• ECT malfunction • Air leakage from intake-air system • Throttle body malfunction


Connect NGS tester to DLC. Access ECT PID. Start and warm up engine to normal operating temperature. Is ECT PID reading between 112°C 234°F and 82°C 180°F?

No

ECT PID is higher than 112°C 234°F: Go to symptom troubleshooting No.16 "Cooling system concerns - Overheating". ECT PID is less than 82°C 180°F: Go to symptom troubleshooting No.17 "Cooling system concerns - Runs cold".

Yes


2


No


Yes Repair or replace parts as necessary. 3

Is there air leakage felt or heard at intake-air system components while racing engine to higher speed? No Verify accelerator cable free play.


F1-89

CONTINUED



TROUBLESHOOTING

SYMPTOM 9 LOW IDLE/STALLS DURING DECELERATION DESCRIPTION • Engine stops unexpectedly at beginning of deceleration or recovery from deceleration.

POSSIBLE CAUSE

• Vacuum leakage • IAC valve malfunction • Air leakage from intake-air system • MAF sensor or related circuit malfunction • TP sensor or related circuit malfunction • Brake switch or related circuit malfunction • Neutral/clutch switch or related circuit malfunction

STEP INSPECTION RESULTS ACTION Yes Go to symptom troubleshooting No.7 for "Engine runs

rough/Rolling idle".1

Does engine idle roughly?


Go to next step.

2

Verify following: • Proper routing and no damage of vacuum

lines • IAC valve is connected properly. • No air leakage from intake-air system Are

all items okay?

No


Yes


3


No



Does idle speed drop or stall when discon-necting IAC valve?

No

Inspect following: • Circuit from IAC valve to PCM connector terminal 2W for

open and short • IAC valve for sticking If okay, go to next step.

Yes

Inspect evaporative emission control system.

5

Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Drive vehicle. Does engine condition improve?

No

Go to next step.

Yes

Go to symptom troubleshooting No.26 for "Intermittent concerns".

6

Connect NGS tester to DLC. Access TP V, MAP V, VS, BRK SW and NL SW PIDs. Monitor each PID while driving vehicle. • TP V PID • MAF V PID • VS PID BRK • SW PID • NL SW PID Are PIDs okay? CONTROL SYSTEM, PCM INSPECTION

No

TP V PID: Inspect TP sensor. MAF V PID: Inspect MAF sensor. VS PID: Inspect VSS. BRK SW PID: Inspect brake switch. NL SW PID: Inspect neutral switch and clutch switch.


F1-90

CONTINUED



TROUBLESHOOTING

SYMPTOM 10

ENGINE STALLS/QUITS - ACCELERATION/CRUISE ENGINE RUNS ROUGH - ACCELERATION/CRUISE MISSES - ACCELERATION/CRUISE BUCK/JERK - ACCELERATION/CRUISE/DECELERATION HESITATION/STUMBLE - ACCELERATION SURGES - ACCELERATION/CRUISE

DESCRIPTION

• Engine stops unexpectedly at beginning of acceleration or during acceleration. • Engine stops unexpectedly while cruising. • Engine speed fluctuates during acceleration or cruising. • Engine misses during acceleration or cruising. • Vehicle bucks/jerks during acceleration, cruising or deceleration. • Momentary pause at beginning of acceleration or during acceleration. • Momentary minor irregularity in engine output. • A/C system operation is improper. • Air leakage from intake-air system parts • Purge solenoid valve malfunction • Improper operation of IAC valve • Erratic signal from CMP sensor • Low engine compression • Vacuum leakage • Poor fuel quality • Spark leakage from high-tension leads • Air cleaner restriction • PCV valve malfunction • Improper valve timing due to jumping out of timing belt • Restriction in exhaust system • Intermittent open or short in fuel pump circuit • Inadequate fuel pressure • Fuel pump mechanical malfunction • Fuel leakage from fuel injector • Fuel injector clogging • Intermittent open or short of MAF sensor, TP sensor and VSS • Clutch slippage Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep



POSSIBLE CAUSE



Go to next step.

1



• Ignition wiring • Fuel quality (e.g. proper octane, contami-

nation, winter/summer blend) • Electrical connections • Smooth operation of throttle valve Are all items okay?

No


F1-91 CONTINUED



TROUBLESHOOTING



2


No


Yes Go to symptom troubleshooting No.16 "Cooling system concerns - Overheating".

3

Is engine overheating?

No Go to next step. Yes Go to next step. 4

Connect NGS tester to DLC. Access RPM PID, B+ PID, TP V PID, MAF V PID, and VS PID. • RPM PID • B+PID • TP V PID • MAF V PID • VS PID Drive vehicle while monitoring PIDs. Are PIDs within specification? CONTROL SYSTEM, PCM INSPECTION

No

RPM PID: Inspect CMP sensor and related harness for vibration, intermittent open/short circuit. B+ PID: Inspect for open circuit intermittently. MAF V PID: Inspect for open circuit of MAF sensor and related wire harness intermittently. TP V PID: Inspect if output signal from TP sensor changes smoothly. VS PID: Inspect for open circuit of VSS and related wire harness intermittently.



Yes


6

Inspect spark plug condition. Is spark plug wet, covered with carbon, or grayish white?

No

Install spark plugs on original cylinders. Go to next step.




Verify that throttle lever is resting on throttle valve stop screw and/or throttle valve orifice plug. Is lever in correct position?

No Adjust as necessary.


Are there restrictions in the exhaust system? No Go to next step.


Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC in engine compartment and GND. Turn ignition switch on. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270—310kPa 2.7—3.2 kgf/cm2, 39—45 psi

No

Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.

Yes

Go to next step.

11

Visually inspect for fuel leakage at fuel injector, O-ring, and fuel line. Service as necessary. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure More than 150 kPa 1.5 kgf/cm2, 21 psi for 5 min.

No


F1-92

CONTINUED



TROUBLESHOOTING


Install vacuum gauge to intake manifold. Start engine. Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or does fuel pressure gauge reading decrease as vacuum reading increases?

No

Connect vacuum hose to pressure regulator. Start engine. Verify that fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator.

Yes

Go to next step.

13

Note • The following test is for engine stalling with

A/C on. If other symptoms exist, go to next step.

Connect a pressure gauge to A/C low and high pressure side lines. Turn A/C on and measure low side and high side pressure. Is pressure within specifications? Section U, REFRIGERANT SYSTEM

SERVICE PROCEDURES, REFRIGER-ANT PRESSURE CHECK

No


Yes


14


No Go to next step.

Yes

Inspect following: • Valve timing • Clutch

15

Is engine compression correct?

No Inspect for cause. 16 Verify test results. If okay, return to diagnostic index to service any additional symptoms.

F1-93

CONTINUED



TROUBLESHOOTING

SYMPTOM 11 LACK/LOSS OF POWER - ACCELERATION/CRUISE DESCRIPTION • Performance is poor under load e.g. power down when climbing hills).

• Improper A/C system operation • Air leakage from intake-air system parts • Purge control solenoid malfunction • Brake dragging • Erratic signal from CMP sensor • Low engine compression • Vacuum leakage • Poor fuel quality • Spark leakage from high-tension leads • Air cleaner restriction • PCV valve malfunction • Improper valve timing due to jumping out of timing belt • Restriction in exhaust system • Intermittent open or short in fuel pump circuit • Inadequate fuel pressure • Fuel pump mechanical malfunction • Fuel leakage from fuel injector • Fuel injector clogging • Intermittent open or short of MAP sensor, TP sensor and VSS • Clutch slippage

POSSIBLE CAUSE






Go to next step.

1



• Fuel quality (e.g. proper octane, contami-nation, winter/summer blend)

Are all items okay?

No


Yes No DTC Is displayed: Go to next step.

2

Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTCs. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?

No DTC is displayed: Go to appropriate DTC test.

Yes Go to symptom troubleshooting No. 16 "Cooling system concerns - Overheating".

3 Is engine overheating?

No Go to next step.

F1-94 CONTINUED



STEP INSPECTION RESULTS ACTION


Connect NGS tester to DLC. Access RPM PID, MAF V PID, TP V PID, and VS PID. • RPM PID • MAP V PID • TP V PID • VS PID Drive vehicle while monitoring PIDs. Are PIDs within specification? CONTROL SYSTEM, PCM INSPECTION

No

RPM PID: Inspect CMP sensor and related harness for vibration and/or intermittent open/short circuit. MAF V PID: Inspect for intermittent open circuit of MAF sensor and related wire harness. TP V PID: Inspect if TP sensor output increases smoothly. VS PID: Inspect for intermittent open circuit of VSS and related wire harness.



Yes


6

Inspect spark plug conditions. Is spark plug wet, covered with carbon or grayish white?







Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC in engine compartment and GND. Turn ignition switch on. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270—310 kPa 2.7—3.2 kgf/cm2, 39—45 psi

No




No

Connect vacuum hose to pressure-regulator. Start engine. Verify that fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator.

Yes

Go to next step.

11

Note • Following test is for engine stalling with

A/C on concern. If other symptoms exist, go to next step.

Connect pressure gauge to A/C low and high side pressure lines. Turn A/C on and measure low side and high side pressure. Is the pressure within specifications? Section U, REFRIGERANT SYSTEM

SERVICE PROCEDURES, REFRIGER-ANT PRESSURE CHECK

No

If A/C is always on, go to symptom troubleshooting No.23 "A/C always on/ A/C compressor runs continuously". For other symptoms, inspect following: • Refrigerant charging amount


Inspect for A/C cut off operation. Does A/C cut-off work properly? No Inspect A/C cut-off system components.

F1-95

CONTINUED



TROUBLESHOOTING

TROUBLESHOOTING



13


No

Go to next step.

Yes

Inspect following: • Valve timing • Clutch • Brake system for dragging

14

Is engine compression correct?

No Inspect for cause. 15 Verify test results. If okay, return to diagnostic index to service any additional symptoms.

F1-96

CONTINUED



TROUBLESHOOTING

SYMPTOM 12 KNOCKING/PINGING - ACCELERATION/CRUISE

DESCRIPTION • Sound is produced when air/fuel mixture is ignited by something other than spark plug (e.g. hot spot in combustion chamber).

POSSIBLE CAUSE

• Engine overheating due to cooling system malfunction • Inadequate engine compression • Inadequate fuel pressure Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep


damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE


Go to next step.

1

Connect NGS tester to DLC. Access ECT P1D. Verify ECT PID is less than 116°C 241 °F while driving. Is ECT PID less than specification?

No

Inspect cooling system for cause of overheating.

Yes


2


No





Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250kPa 2.1—2.6 kgf/cm2, 30—36 psi

No


Yes Inspect ignition timing. 5


No

Connect vacuum hose to pressure regulator. Start engine. Verify that fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator.


F1-97

CONTINUED



TROUBLESHOOTING

SYMPTOM 13 POOR FUEL ECONOMY DESCRIPTION • Fuel economy is unsatisfactory.

POSSIBLE CAUSE

• Contaminated air cleaner element • Engine cooling system malfunction • Improper automatic transmission fluid level • Weak spark • Poor fuel quality • Improper coolant level • Inadequate fuel pressure • Spark plug malfunction • PCV valve malfunction • Brake dragging • Improper valve timing due to jumping out of timing belt • Contaminated MAF sensor • Improper engine compression • Exhaust system clogging Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep




STEP INSPECTION RESULTS ACTION Yes Go to next step. 1 Inspect following:

• Air cleaner element for contamination • Automatic transmission fluid level • Fuel quality • Coolant level Are all items okay?

No Service as necessary. Repeat Step 1.

Yes No DTC is displayed: Go to next step.

2 Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTCs. Is "NO CODES RECEIVED" or "SYSTEM PASSED" display?

No


Yes Go to next step. 3 Connect NGS tester to DLC. Access ECT PID. Drive vehicle while monitoring PID. CONTROL SYSTEM, PCM INSPECTION Is PID within specification?

No Inspect for coolant leakage, cooling fan operation, or thermostat operation.

Yes Inspect for following: • Spark plug malfunction Repair or replace malfunctioning parts. If okay, go to next step.

4

Is strong blue spark visible at each discon-nected high-tension lead while cranking en-gine?

No Inspect the following: • High-tension leads • Ignition coil and connector


Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250kPa 2.1—2.6 kgf/cm2, 30—36 psi

No Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.

F1-98

CONTINUED



TROUBLESHOOTING






Is brake system functioning properly? No Inspect for cause.

Yes Replace MAP sensor. 9

Inspect for contaminated MAF sensor. Is there any contamination? No Go to next step.




F1-99

CONTINUED



TROUBLESHOOTING

SYMPTOM 14 EMISSION COMPLIANCE DESCRIPTION • Emission compliance test is failed.

POSSIBLE CAUSE

• Vacuum line leakage or blockage • Cooling system malfunction • Spark plug malfunction • Leakage from intake manifold • Inadequate fuel pressure • PCV valve malfunction or incorrect valve installation • Exhaust system clogging • Fuel tank ventilation system malfunction • Charcoal canister damage • Excessive carbon built up in combustion chamber • Improper engine compression Improper valve timing Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep




Go to next step.

1

Inspect following: • Vacuum lines for leakage or blockage • Electrical connections • Proper maintenance schedule followed • Intake-air system and air cleaner element

concerns: obstructions, leakage or dirt Are all items okay?

No


Yes


2


No


Yes Go to appropriate symptom troubleshooting. 3

Is any other drivability concern present? No Go to next step.


Connect NGS tester to DLC. Access ECT PID. Warm up engine and run it at idle. Is ECT PID correct?

No

Inspect for coolant leakage, cooling fan operation or thermostat operation.

Yes

Inspect for following: • Spark plug malfunction Repair or replace malfunctioning parts. If okay, go to next step.

5


No

Inspect following: • High-tension leads • Ignition coil and connector


Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250 kPa 2.1—2.6 kgf/cm2, 30—36 psi

No


F1-100

CONTINUED



TROUBLESHOOTING


Go to next step.

7

Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210—250kPa 2.1—2.6 kgf/cm2, 30—36 psi

No

Inspect pressure regulator for high pressure cause.




Is there restriction in the exhaust system? No Go to next step.

Yes Replace charcoal canister. 10

Inspect for fuel saturation inside charcoal canister. Is excessive amount of liquid fuel present in canister?

No Inspect fuel tank vent system.


SYMPTOM 15 HIGH OIL CONSUMPTION/LEAKAGE DESCRIPTION • Oil consumption is excessive.

POSSIBLE CAUSE

• PCV valve malfunction • Improper dipstick • Improper engine oil viscosity • Engine internal parts malfunction



Yes

Inspect internal engine parts such as valves, valve guides, valve stem seals, cylinder head drain passage, piston rings.

2

Inspect for following: • External leakage • Proper dipstick • Proper engine oil viscosity Are all items okay?

No



F1-101

CONTINUED



TROUBLESHOOTING

SYMPTOM 16 COOLING SYSTEM CONCERNS - OVERHEATING DESCRIPTION • Engine runs at higher than normal temperature/overheats.

POSSIBLE CAUSE

• Improper coolant level • Blown fuses Coolant leakage/Improper coolant level • Excessive A/C system pressure • Improper water/anti-freeze mixture • Fans reverse rotation • Poor radiator condition • Thermostat malfunction • Radiator hose damage • Improper or damaged radiator cap • Main cooling fan is inoperative. • Coolant overflow system malfunction • Improper tension of drive belt • Drive belt damage


Go to next step.

1

Inspect following: • Engine coolant level • Coolant leakage • Water and anti-freeze mixture • Radiator condition • Collapsed or restricted radiator hoses • Radiator pressure cap • Overflow system • Fan rotational direction • Fuses Are all items okay?

No


Yes


2


No


Yes Go to Step 5. 3

Start engine and run it at idle speed. Turn A/C switch on. Does A/C compressor engage?

No

Inspect for following and repair or replace as necessary: • Refrigerant charging amount • Open circuit between A/C relay and PCM terminal 1J • Seized A/C magnetic clutch • A/C magnetic clutch malfunction If all Items are okay, go to next step.


Connect NGS tester to DLC. Access A/C SW PID on NGS tester. Start engine and run it at idle speed. Turn A/C switch on. Does A/C SW PID read ON?

No

Inspect for following: • Refrigerant pressure switch operation • A/C switch stuck open • Open or short circuit between refrigerant pressure

switch and PCM terminal 1Q • Open circuit of blower motor fan switch and resistor

(if blower motor does not operate) • Evaporator temperature sensor and A/C amplifier


Is drive belt okay? No Replace drive belt.

Yes Inspect and service heater for leakage. 6

Is there any leakage around heater unit in passenger compartment? No Go to next step.

Yes Replace malfunctioning parts. 7

Is there any leakage at coolant hoses and/or radiator? No Go to next step.

F1-102

CONTINUED



TROUBLESHOOTING STEP INSPECTION RESULTS ACTION

Yes Engine coolant temperature and thermostat are okay, inspect engine block for leakage or blockage.

8

Cool down engine. Remove thermostat and inspect operation. Section E, THERMOSTAT,


No

Access ECT V PID on NGS tester. Inspect for both ECT V and temperature gauge readings. If temperature gauge on instrument cluster indicates normal range but ECT V is not same as temperature gauge reading, inspect ECT sensor. If temperature gauge on instrument cluster indicates overheating but ECT V is normal, inspect temperature gauge and heat gauge unit.


SYMPTOM 17 COOLING SYSTEM CONCERNS - RUNS COLD DESCRIPTION • Engine takes excessive period for reaching normal operating temperature.

POSSIBLE CAUSE

• Thermostat malfunction • Cooling fan system malfunction

STEP INSPECTION RESULTS ACTION Yes Inspect A/C and heater system. 1

Is customer complaint "Lack of passenger compartment heat" only? No Go to next step.

Yes Go to symptom troubleshooting No.8 "Fast idle/runs on". 2

Does engine speed continue at fast idle? No Go to next step.

Yes

Access ECT V PID on NGS tester. Inspect for both ECT V PID and temperature gauge on instrument cluster readings. If temperature gauge on instrument cluster indicates normal range but ECT V PID is not same as temperature gauge reading, inspect ECT sensor. If temperature gauge on instrument cluster indicates cold range but ECT voltage is normal, inspect temperature gauge and heat gauge unit.

3

Remove thermostat and inspect operation. Section E, THERMOSTAT,


No Replace thermostat. 4 Verify test results. If okay, return to diagnostic index to service any additional symptoms.

F1-103

CONTINUED



TROUBLESHOOTING

SYMPTOM 18 EXHAUST SMOKE DESCRIPTION • Blue, black, or white smoke from exhaust system.

Blue smoke (Burning oil): • PCV valve malfunction • Engine internal oil leakage White smoke (Water in combustion): • Cooling system (coolant loss) malfunction • Engine internal coolant leakage Black smoke (Rich fuel mixture): • Air cleaner restriction • Intake-air system is collapsed or restricted. • Fuel return line is restricted. • Excessive fuel pressure • Improper engine compression • Injector fuel leakage • Ignition system malfunction

POSSIBLE CAUSE




STEP INSPECTION RESULTS ACTION Blue Burning oil is indicated. Go to next step.

White Water in combustion is indicated. Go to Step 3. 1 What color is smoke coming from exhaust

system?

Black Rich fuel mixture is indicated. Go to Step 4. Yes

Inspect for following: • Damaged valve guide, stems or valve seals • Blocked oil drain passage in cylinder head • Piston rings are not seated, seized or worn • Damaged cylinder bore If other drivability symptoms are present, return to diagnostic index to service any additional symptoms.

2

Remove and shake PCV valve. Does PCV valve rattle?

No Replace PCV valve. Yes

Inspect for following: • Cylinder head gasket leakage • Intake manifold gasket leakage • Cracked or porous engine block If other drivability symptoms are present, return to diagnostic index to service any additional symptoms.

3

Does cooling system hold pressure?

No Inspect for cause. Yes Go to next step. 4

Inspect for following: • Air cleaner restriction • Collapsed or restricted intake-air system • Restricted fuel return line Are all items okay?

No Service as necessary, Repeat Step 4.

Yes No DTC Is displayed: Go to next step.

5 Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?

No DTC is displayed: Go to appropriate DTC test.

F1-104

CONTINUED



TROUBLESHOOTING


Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250 kPa 2.1—2.6 kgf/cm2,30—36 psi

No

Zero or low: Inspect fuel pump circuit Inspect for open fuel pump relief valve Inspect for fuel leakage inside pressure regulator Inspect for clogged main fuel line High: Inspect pressure regulator for high pressure cause Inspect for clogged fuel return line

Yes

Go to next step.

7

Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210—250kPa 2.1—2.6 kgf/cm2,30—36 psi

No


Yes Inspect spark plugs. 8


No

Inspect following: • High-tension leads • Ignition coil and connector


F1-105

CONTINUED



TROUBLESHOOTING

SYMPTOM 19 FUEL ODOR (IN ENGINE COMPARTMENT) DESCRIPTION • Gasoline fuel smell or visible leakage,

POSSIBLE CAUSE

• Excessive fuel pressure • Fuel tank vent system blockage • Charcoal canister malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep




Go to next step,

1

Visually inspect for fuel leakage at fuel injector O-ring and fuel line. Service as necessary. Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Then stop engine. Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on and off? Fuel line pressure 210—250 kPa 2.1—2.6 kgf/cm2, 30—36 psi

No


Yes

Replace vacuum hose.

2

Inspect for blockage/restriction or open be-tween engine vacuum port and charcoal canister. Inspect for blockage in fuel tank vent system. Is fault indicated?

No

Go to next step.


Inspect purge solenoid valve. EMISSION SYSTEM, PURGE SOLENOID

VALVE INSPECTION Is solenoid operating properly?

No Replace purge solenoid valve.

Yes

No DTC is displayed: Inspect charcoal canister for fuel saturation. If excessive amount of liquid fuel is present, replace charcoal canister.

4


No



F1-106

CONTINUED



POSSIBLE CAUSE

Squealing, clicking or chirping noise: • Improper engine oil level • Improper drive belt tension Rattling noise: • Loose parts Hissing sound noise: • Vacuum leakage • Loose spark plug • Air leakage from intake-air system Rumbling or grinding noise: • Improper drive belt tension Rapping or roar noise: • Exhaust system looseness Other noise: • Camshaft friction gear noise

STEP INSPECTION RESULTS ACTION Yes Inspect engine oil level or drive belts. 1

Is squealing, clicking or chirping sound present? No Go to next step.

Yes Inspect drive belt. 2

Is rumbling or grinding sound present? No Go to next step.

Yes Inspect location of rattle for loose parts. 3

Is rattling sound present? No Go to next step.

Yes

Inspect following: • Vacuum leakage • Spark plug looseness • Intake-air system leakage

4

Is hissing sound present?

No Go to next step. Yes Inspect exhaust system for loose parts. 5

Is rapping or roaring sound present? No Go to next step.

Yes Go to symptom troubleshooting No.12 "Knocking/ pinging".6

Is knocking sound present?

No If noise comes from inside engine, inspect for friction gear noise.


SYMPTOM 21 VIBRATION CONCERNS (ENGINE) DESCRIPTION • Vibration from under hood or driveline POSSIBLECAU

SE • Loose attaching bolts or worn parts • Component malfunctions such as worn parts


Inspect following systems: • Wheels • Driveline • Suspension

1

Inspect following components for loose at-taching bolts or worn parts: • Cooling fan • Drive belt and pulleys • Engine mounts

Are all items okay? No Readjust or retighten engine mount installation position. Service as necessary for other parts.


F1-107

CONTINUED



TROUBLESHOOTING

SYMPTOM 20 ENGINE NOISE DESCRIPTION • Engine noise from under hood

TROUBLESHOOTING

SYMPTOM 22 A/C DOES NOT WORK SUFFICIENTLY. DESCRIPTION • A/C compressor magnetic clutch does not engage when A/C switch is turned on.

POSSIBLE CAUSE

• Improper refrigerant charging amount • Open A/C magnetic clutch • Open circuit between A/C relay and A/C magnetic clutch • Poor GND of A/C magnetic clutch • Refrigerant pressure switch is struck open. • A/C relay is stuck open. • Seized A/C compressor • Open circuit between A/C switch and PCM through both refrigerant pressure switch and A/C amplifier



1


No

DTC is displayed: Go to appropriate DTC test,

Yes

Inspect for GND condition of magnetic clutch on A/C compressor. If GND condition is okay, inspect for open circuit of magnetic clutch coil.

2

Disconnect A/C compressor connector. Start engine and turn A/C switch on. Is there correct voltage at terminal of A/C compressor magnetic clutch connector? Specification More than 10.5V No Go to next step.

Yes

Inspect for stuck open A/C relay. Replace as necessary.

3

Connect NGS tester to DLC. Access A/C SW PID on NGS tester. Start engine. Turn A/C switch on and set blower fan at any speed. Does A/C SW PI Dread ON?

No

Go to next step.

Yes

Inspect for following: • Refrigerant charging amount • Refrigerant pressure switch operation

4

Disconnect refrigerant pressure switch con-nector. Connect a jumper wire between terminals of refrigerant pressure switch connector. Start engine and turn A/C switch on. Does A/C work?

No

Inspect for following: • A/C switch is stuck open. • Open circuit between refrigerant pressure switch and

PCM terminal 1Q • Open circuit of blower motor fan switch and resistor (if

blower motor does not operate) • Evaporator temperature sensor and A/C amplifier • Open circuit between A/C amplifier and refrigerant

pressure switch


F1-108

CONTINUED



TROUBLESHOOTING

SYMPTOM 23 A/C IS ALWAYS ON /A/C COMPRESSOR RUNS CONTINUOUSLY. DESCRIPTION • A/C compressor magnetic clutch does not disengage.

POSSIBLE CAUSE

• Stuck engagement • A/C relay is stuck closed. • Short to GND between A/C switch and PCM • Short to GND circuit between A/C relay and PCM • A/C relay to magnetic clutch circuit shorts to battery power



1


No


Yes

Inspect for following: • A/C relay is stuck closed. • Short to GND circuit between A/C relay and PCM

terminal 1J If both items okay, go to next step.

2

Start engine and run it at idle. Turn A/C switch on. Remove A/C relay. Does A/C magnetic clutch disengage?

No

Inspect if circuit between A/C relay and magnetic clutch shorts to battery power circuit. If circuit is okay, inspect magnetic clutch engagement or clearance.

Yes

Inspect for short to GND circuit between refrigerant pressure switch and PCM terminal 10.

3

Connect NGS tester to DLC. Access A/C SW PID on NGS tester. Start the engine and turn A/C switch on. Read A/C SW PID while disconnecting re-frigerant pressure switch connector. Note • A/C SW PID should read OFF when dis-

connecting connector. If A/C SW PID reading remains ON, short to GND circuit may be present.

Does A/C SW PID reading remain ON?

No

Go to next step.

Yes

Inspect for following: • Short to GND circuit between A/C switch and A/C

amplifier • Short to GND circuit between A/C amplifier and

refrigerant pressure switch

4

Reconnect refrigerant pressure switch connector. Read A/C SW PID while turning off A/C switch. Note • A/C SW PID should read OFF when turn-

ing A/C switch off. If A/C SW PID reading remains ON, short to GND circuit may be present.

Does A/C SW PID reading remain ON?

No

Inspect for stuck closed A/C switch.


F1-109

CONTINUED



TROUBLESHOOTING

SYMPTOM 24 A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE (WOT) CONDITIONS DESCRIPTION • A/C compressor magnetic clutch does not disengage under WOT.

POSSIBLE CAUSE

• TP sensor malfunction • TP sensor misadjustment • TP sensor is loosely installed.


Does A/C compressor disengage when A/C switch is turned off?

No Go to symptom troubleshooting No.23 "A/C is always on / A/C compressor runs continuously".

Yes

No DTC is displayed: Inspect TP sensor for proper adjustment.

2


No


3 Verify test results. If okay, return to diagnostic index to service any additional symptoms,

F1-110

CONTINUED



TROUBLESHOOTING

SYMPTOM 25 EXHAUST SULPHUR SMELL DESCRIPTION • Rotten egg smell (sulphur) from exhaust

POSSIBLE CAUSE

• Electrical connectors are disconnected or connected poorly • Charcoal canister malfunction • Vacuum lines are disconnected or connected improperly. • Improper fuel pressure Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep



STEP INSPECTION RESULTS ACTION Yes Go to appropriate flow chart. 1

Are any drivability or exhaust smoke concerns present? No Go to next step.


Inspect following: • Electrical connections • Vacuum lines Are all items okay?

No


Yes


3


No



Install fuel pressure gauge between fuel filter and fuel distributor. Start engine and run it at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250kPa 2.1—2.6 kgf/cm2,30—36 psi

No


Yes

Go to next step.

5

Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210—250kPa 2.1—2.6 kgf/cm2, 30—36 psi

No


Yes Replace charcoal canister. 6

Inspect charcoal canister for fuel saturation. Is excessive amount of liquid fuel present in canister?

No

Inspect fuel tank vent system. If fuel tank vent system is okay, since sulfur content can vary in different fuels, suggest trying a different brand. If fuel tank vent system is not okay, repair or replace malfunctioning parts.


F1-111

CONTINUED



TROUBLESHOOTING SYMPTOM 26 INTERMITTENT CONCERNS DESCRIPTION • Symptom occurs randomly and is difficult to diagnose.


Go to next step.

1

Talk to customer. Retrieve vehicle service history. Does vehicle have a number of previous repairs and components replaced for a certain symptom?

No

Go to Symptom Index.

Yes

Inspect each wire for corrosion, bent or loose terminal crimps.

2

Connect NGS tester to DLC. If input is switch-type component, turn on manually. Turn ignition switch on. Access PIDs for suspect component. Lightly tap on suspect component, wiggle and pull each wire/connector at suspect component or PCM. Are any PID values out of range, or do they suddenly change and go back into range?

No

Go to next step.

Yes

Inspect each wire for corrosion, bent or loose terminal crimps.

3

Start engine. Lightly tap on suspect component, wiggle and pull each wire/connector at suspect component or PCM. Are any PID values out of range, or do they suddenly change and go back into range?

No

Go to next step.

Yes

Fault occurred while spraying component: Replace part and verify repair. Fault occurred while spraying wiring: Inspect each wire for corrosion, bent or loose terminals and poor wire terminal crimps. Fault occurred while spraying vacuum line: Repair vacuum hoses.

4

Start engine. Accurately spray water on suspect component wire, component or vacuum line related to possible fault area. Are any PID values out of range, or do they suddenly change and go back into range, or was there a noticeable engine misfire/ stumble? No

Inspect wire and connector at suspect component for corrosion, bent or loose terminals, poor wire terminal crimps and high tension of wire. Repair as necessary.

F1-112

CONTINUED



TROUBLESHOOTING

SYMPTOM 27 CONSTANT VOLTAGE DESCRIPTION Incorrect constant voltage

POSSIBLE CAUSE

• Constant voltage circuit malfunction Note • TP sensor and variable resistor (Except Europe) use constant voltage.


Repair constant voltage circuit short to power in harness.

1

Disconnect TP sensor connector. Turn ignition switch on. Measure voltage between following TP sensor and variable resistor (Except Europe) connector terminals: • Constant voltage terminal - GND terminal Is constant voltage greater than 6.0 volts?

No

Go to next step.


Is voltage across battery terminals greater than 10.5 volts? No Inspect charging system.

Yes

Go to next step.

3

Turn ignition switch off. Leave TP sensor and variable resistor (Except Europe) connector disconnected. Measure voltage between battery positive terminal and GND circuit at TP sensor connector. Is voltage greater than 10.5 volts and within 1.0 volt of battery voltage?

No

Go to Step 8.

Yes

Go to Step 7.

4

Note • The purpose of this step is to determine if

NGS tester is communicating with PCM. Turn ignition switch on. Attempt to access ECT PID. Can ECT PID be accessed?

No

Go to next step.

Yes

Go to next step.

5

Turn ignition switch off. Leave TP sensor and variable resistor (Except Europe) connector disconnected. Disconnect PCM connector. Turn ignition switch on. Measure voltage between PCM connector terminals 1B and 2B. Is voltage greater than 10.5 volts?

No

Repair open circuit between PCM terminal 1B and main relay.

Yes

Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again. If constant voltage is still out of range, replace PCM.

6

Leave TP sensor, variable resistor (Except Europe) and PCM connectors disconnected. Disconnect NGS tester from DLC. Measure resistance between PCM connector terminals 2K and 2B. Is resistance greater than 10,000 ohms?

No Repair constant voltage circuit short to GND.

Yes

Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again. If constant voltage is still out of range, replace PCM.

7

Turn ignition switch off. Leave TP sensor and variable resistor (Except Europe) connector disconnected. Disconnect PCM connector. Measure resistance between PCM connector terminal 2K and constant voltage circuit at appropriate sensor connector. Is resistance less than 5.0 ohms?

No

Repair open constant voltage circuit.

Yes

Go to next step.

8

Note • The purpose of this step is to determine if

NGS tester is communicating with PCM. Reconnect TP sensor and variable resistor (Except Europe) connector. Turn ignition switch on. Attempt to access ECT PID. Can ECT PID be accessed?

No

Go to Step 10.

F1-113

CONTINUED



TROUBLESHOOTING


Reconnect sensor connector. Go to appropriate DTC test.

9

Turn ignition switch off. Disconnect NGS tester from DLC. Disconnect PCM connector. Measure resistance between GND circuit at appropriate sensor connector and PCM connector terminal 2D. Is resistance less than 5.0 ohms?

No

Repair open GND circuit.

Yes

Go to next step.

10

Turn ignition switch off. Disconnect PCM connector. Measure resistance between battery negative terminal and PCM terminals 2A, 2B and 2C. Is each resistance less than 5.0 ohms?

No

Repair open GND circuit.

Yes

GND circuits are okay. Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again.

11

Turn ignition switch off. Measure resistance between GND circuit at following sensor connector and GND: • ECT sensor • O2S • IAT sensor • MAF sensor • TP sensor • Variable resistor (Except Europe) Is each resistance less than 5.0 ohms?

No

Inspect for open GND circuit.

F1-114

CONTINUED



TROUBLESHOOTING DIAGNOSTIC INSPECTION Spark Plug Condition Inspection Purpose Inspecting spark plugs condition can determine whether problem is related to a specific cylinder or to all cylinders.

Procedure 1. Remove the spark plug. 2. Inspect spark plug condition. 3. Go to appropriate troubleshooting chart for further

information. Spark plug condition Troubleshooting chart

Specific plug is wet or covered with carbon. Symptom 1 Wet/carbon stuck on specific plug Specific plug looks grayish white. Symptom 2 Grayish white with specific plug All plugs are wet or covered with carbon. Symptom 3 Wet/carbon stuck on all plugs All plugs look grayish white. Symptom 4 Grayish white with all plugs

SYMPTOM 1 Wet/carbon stuck on specific plug

POSSIBLE CAUSE

• Spark—No spark visible or spark weak • Air/fuel mixture—Excessive fuel injection volume • Compression—No compression, low compression • Faulty spark plug Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep



STEP INSPECTION RESULTS ACTION Yes Working up and down inspect all areas related to oil. 1

Is spark plug wet/covered with carbon by engine oil? No Go to next step.

Yes

Go to next step.

2

Inspect spark plug for following: • Cracked insulator • Heating value • Air gap • Worn electrode Is spark plug okay?

No

Replace spark plug.


Inspect compression pressure at suspected faulty cylinder. Section B1, COMPRESSION INSPECTION Is compression pressure correct?

No Repair or replace malfunctioning parts.


Install all spark plugs. Carry out spark test at suspected faulty cylinder. Is strong blue spark visible? (Compare with normal cylinder)

No Repair or replace malfunctioning parts.

Yes

Inspect fuel injector for following: • Open or short in injector • Leakage • Injection volume

5

Carry out fuel line pressure inspection. TROUBLESHOOTING, ENGINE SYSTEM

INSPECTION. Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270—310 kPa 2.7—3.2 kgf/cm2, 39—45 psi

No

Zero or low: Inspect fuel pump circuit. Inspect for fuel pump relief valve open. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.

F1-115 CONTINUED



TROUBLESHOOTING

SYMPTOM 2 Grayish white with specific plug

POSSIBLE CAUSE

• Air/fuel mixture—Insufficient fuel injection volume • Faulty spark plug


Inspect spark plug for following: • Heating value • Air gap Is spark plug okay? No Replace spark plug.

Yes

Inspect for open circuit between suspected fuel injector terminal and PCM connector terminal.

2

Remove suspected fuel injector. Inspect for following: FUEL SYSTEM, FUEL INJECTOR

INSPECTION • Resistance • Fuel injection volume Are all above items

okay?

No

Replace fuel injector.

SYMPTOM 3 Wet/carbon stuck on all plugs

POSSIBLE CAUSE

• Spark—Spark weak • Air/fuel mixture—Too rich • Compression—Low compression • Clogging in intake/exhaust system Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep

sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death

and damage. Fuel can also Irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE


Is air cleaner element free of restriction? No Replace air cleaner element.


Carry out spark test. Is strong blue spark visible at each cylinder? No Repair or replace malfunctioning parts.



INSPECTION. Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270—310 kPa 2.7—3.2 kgf/cm2, 37—45 psi

No


Yes

Go to next step.

4

Inspect following PIDs: CONTROL SYSTEM, PID/DATA MONITOR

INSPECTION • MAF V • ECT • FHO2S (When engine can be started) Are PIDs okay?

No

Repair or replace malfunctioning parts.


Carry out purge control inspection. (When engine can be started) Is purge control correct? No Repair or replace malfunctioning parts.

Yes Inspect for clogging in exhaust system. 6

Carry out compression inspection. Is compression correct? No Repair or replace malfunctioning parts.

F1-116 CONTINUED



TROUBLESHOOTING

SYMPTOM 4 Grayish white with all plugs

POSSIBLE CAUSE

• Air/fuel mixture—Too lean Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep

sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious Injuries or death

and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE


Repair or replace malfunctioning parts.

1

When engine cannot be started, inspect intake-air system for air leakage. When engine can be started, carry out intake manifold vacuum inspection. Is air sucked in from intake-air system?

No

Go to next step.

Yes

Inspect following PIDs: CONTROL SYSTEM, PID/DATA MONITOR

INSPECTION • MAF V • ECT • FHO2S (When engine can be started) Inspect for PCM GND condition.

2


INSPECTION, Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270—310 kPa 2.7—3.2 kgf/cm2, 37—45 psi

No


F1-117

CONTINUED



TROUBLESHOOTING Inspection Using an Oscilloscope (Reference) Purpose Using an oscilloscope, inspection such as stuck solenoid valve is made possible without actually removing parts.

When normal Counter electromotive voltage A, generated when the three-way solenoid valve or the fuel injector is turned off from on, shows irregular convergence because induced electromotive voltage B, generated by the plunger return operation, is added to it.

When plunger is stuck When the plunger is stuck, pulse convergence is smooth because no induced electromotive voltage B is generated.

Input Signal System Investigation Procedure 1. Find an unusual signal. (Refer to procedures below) 2. Locate its source. (Refer to procedures below) 3. Repair or replace the defective part. 4. Confirm that the unusual signal has been erased.

Finding unusual signals While referring to the diagnostic trouble code inspection section of the on-board diagnostic system, use the PID/DATA MONITOR AND RECORD function to inspect the input signal system relating to the problem. 1. Turn the ignition on and run it at idle. You can assume

that any signals that are out of specifications by a wide margin are unusual.

2. When recreating the problem, any sudden change in monitor input signals that is not consciously created by the driver can be judged as unusual.

Locating the source of unusual signals

Caution: • Compare the NGS monitor voltage with the

measurement voltage using the DIGITAL MEASUREMENT SYSTEM function. If you use another tester, misreading may occur.

• When measuring voltage, attach the tester GND to the GND of the PCM that is being tested, or to the engine itself. If this is not done, the measured voltage and actual voltage may differ.

• After connecting the pin to a waterproof coupler, confirming continuity and measuring the voltage, inspect the waterproof connector for cracks. If there are any, use sealant to fix them. Failure to do this may result in deterioration of the harness or terminal from water damage, leading to problems with the vehicle.

Variable resistance type 1 (Throttle position (TP) sensor and variable resistor (Except Europe))

Investigate the input signal system 1. When you get an unusual signal, measure the #1 PCM

terminal voltage. (1) If the #1 terminal voltage and the NGS monitor voltage are the same, proceed to the next step. (2) If there is a difference of 0.5 V or more, inspect the following points concerning the PCM connector. • Female terminal opening loose • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.

2. When you get an unusual signal, measure the #2 sensor terminal voltage. (1) If there is a 0.5 V or more difference between the sensor and NGS voltages, inspect the harness for open or short circuits.

F1-118 CONTINUED



TROUBLESHOOTING

(2) If the sensor and NGS voltages are the same, inspect the following points concerning the sensor connector. If there are no problems, proceed to next investigation below.

• Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.

Investigate the standard power supply system (1) Confirm that the #3 terminal is at 5 V. (1) If the measured voltage on the #3 terminal is 5 V,

inspect the following points on the sensor connector. If there is no problem, proceed to next investigation below. (3) Female terminal opening looseness (4) Coupler (pin holder) damage (5) Pin discoloration (blackness)

(2) If the #3 terminal measures other than 5 V, inspect for the following.

• Open or short circuit in harness • Harness/pin crimp is loose or disconnected.

Investigate the GND system 1. Confirm that terminal sensor #5 is at 0 V.

(1) If it is at 0 V, inspect the sensor. If necessary, replace the sensor.

(2) If not, inspect for the following. Open or short circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected.

Variable resistance type 2 (Mass air flow (MAP) sensor)


terminal voltage. (1) If the #1 terminal voltage and the NGS monitor

voltage are the same, proceed to the next step. (2) If there is a difference of 0.5 V or more, inspect

the following points concerning the PCM connector. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.

2. When you get an unusual signal, measure the #2 sensor terminal voltage.

(1) If there is a 0.5 V or more difference between the sensor and NGS voltages, inspect the harness for open or short circuits.

(2) If the sensor and NGS voltages are the same, inspect the following points concerning the sensor connector. If there are no problems, proceed to next investigation below.


Investigate the electrical supply system 1. Confirm that the sensor #3 terminal is B+.

(1) If the measured voltage on the #3 terminal is B+, inspect the following points on the sensor connector. If there is no problem, proceed to next investigation below.

• Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness)

(2) If the #3 terminal measures other than B+, inspect for the following.

• Open or short circuit in harness • Harness/pin crimp is loose or disconnected.



(2) If not at 0 V, inspect for the following. Open circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected.

Thermistor type (Intake air temperature (IAT) and engine coolant temperature (ECT) sensors)


terminal voltage. (2) If the #1 terminal voltage and the NGS monitor

voltage are the same, proceed to the next step. (3) If there is a difference of 0.5 V or more, inspect the

following points concerning the PCM connector. (1) Female terminal opening looseness (2) Coupler (pin holder) damage (3) Pin discoloration (blackness) (4) Harness/pin crimp is loose or disconnected.

2. When you get an unusual signal, measure the #2 sensor terminal voltage. (3) If there is a 0.5 V or more difference between the

sensor and NGS voltages, inspect the harness for open or short circuits.

F1-119 CONTINUED



TROUBLESHOOTING

(2) If the sensor and NGS voltages are the same, inspect for the following points concerning the sensor connector. If there are no problems, proceed to next investigation below, • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.



(2) If not, inspect for the following. Open circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected.

Vehicle speed sensor (VSS)

1. Measure the #1 PCM terminal voltage and confirm that it

is at 0 V or 5 V when the ignition switch is on and the engine is at idle. (1) If it is at 0 V or 5 V, proceed to symptom

troubleshooting No.26 "Intermittent Concerns". (2) If not, inspect the following points concerning the

PCM connector. If there are no problem, proceed to next step.

• Female terminal opening loose • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.

2. Measure the #2 sensor terminal voltage and confirm that

it is at 0 V or 5 V when the ignition switch is on and the engine at idle. (1) If it is at 0 V or 5 V, proceed to symptom

troubleshooting No.26 "Intermittent Concerns". (2) If not, inspect the following points concerning the

sensor connector. If there are no problems, proceed to next step.


3. Confirm that the #3 terminal switch voltage is at 0 V.


(2) If not, inspect for the following. • Open circuit in harness • Female terminal opening looseness • Coupler (pin holder) damage

• Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.

ENGINE SYSTEM INSPECTION Main Relay Operation Inspection 1. Verify that the main relay clicks when the ignition switch

is turned to on and off.

2. If there is no operating sound, inspect the following. • Main relay • Harness and connector between ignition switch and

main relay Intake Manifold Vacuum Inspection 1. Verify air intake hoses are installed properly. 2. Start the engine and run it at idle. 3. Disconnect the vacuum hose between the intake

manifold and purge solenoid valve on the intake manifold side.

4. Connect a vacuum gauge to the intake manifold and measure the intake manifold vacuum.

Specification More than 60 kPa 450 mmHg, 18 inHg

5. If not as specified, inspect for the following: • Air suction at throttle body, intake manifold and

PCV valve installation points • Fuel injector insulator • Accelerator cable free play • Engine compression (Refer to section B1.) Note • Air suction can be located by engine speed change

when lubricant is sprayed on the area where suction is occurring.

F1-120

CONTINUED



TROUBLESHOOTING (3) Verify that DTC P0505 is not displayed. If DTC

P0505 is shown, carry out DTC inspection. (4) Select the SIMULATION TEST function on the

NGS display. (5) Change the duty value of the IAC valve to 100%

using the IACV PID. (6) Verify that the idle speed increases.

① If the idle speed increases, replace the PCM. ② If the idle speed does not change, inspect the following. • IAC valve air passage • Open or short circuit between IAC valve connector terminals and PCM connector terminal 2W

4. Warm up the engine to normal operating temperature and run it at idle.

5. Select the PID/DATA MONITOR AND RECORD function on the NGS display.

6. Select the following PIDs. • A/C SW • IAC V • PSP SW • RPM

7. Turn the electrical loads on and verify that the engine speed is within the specification.

Engine speed (rpm) Load condition Idle-up speed (rpm)*1

P/S ON*2 A/CON*3

700—800 (750 ± 50)

Idle Air Control (IAC) Inspection Engine coolant temperature (ECT) compensation inspection 1. Connect the SSTs (NQS tester) to DLC.


3. Select the following PIDs. • ECT • IACV • RPM

4. Verify that the engine is cold, then start the engine. 5. Verify that the engine speed decreases as the

engine warms up. 6. If the engine speed does not decrease or decreases

slowly, carry out the following. • ECT sensor inspection • IAC valve inspection

Load compensation inspection 1. Start the engine and run at idle. 2. Disconnect the IAC valve connector and verify that the

engine rotation changes.

3. If the engine condition does not change, do as follows.

(1) Connect the IAC valve connector. (2) Connect the SSTs (NGS tester) to DLC.

*1 Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. *2: Steering wheel is fully turned. *3: A/C switch and fan switch are on.

Note • Excludes temporary idle speed drop just after the electrical loads are turned on.

8. If not as specified, carry out the following. • A/C switch inspection • PSP switch inspection • IAC valve inspection

Fuel Line Pressure Inspection Warning • Fuel line spills and leakage are dangerous.

Fuel can ignite and cause serious injuries or death. Fuel can also irritate skin and eyes.

• To prevent this, always complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

1. Disconnect the negative battery cable. 2. Connect a fuel pressure gauge between the fuel

filter and fuel distributor.

CONTINUED



TROUBLESHOOTING


Caution • Connecting the wrong DLC terminals may


4. Short the DLC terminal F/P to body GND using a

jumper wire.

5. Turn the ignition switch on and measure the fuel line

pressure. Specification 270—310 kPa 2.7—3.2 kgf/cm2, 39—45 psi

6. Turn off the ignition switch and disconnect the jumper

wire. 7. If the pressure is higher than specified, inspect the fuel

pump maximum pressure. If normal, inspect fuel return hose or the pressure regulator for clogging.

8. If the pressure is lower than specified, measure the fuel line pressure while pinching the return hose.

• If the fuel line pressure quickly increases, inspect the pressure regulator and PRC solenoid valve.

• If fuel line pressure gradually increases, inspect the fuel pump maximum pressure. If the fuel pump maximum pressure is normal, inspect for clogging between fuel pump body and pressure regulator.

Fuel Pressure Hold Inspection

Warning • Fuel line spills and leakage are dangerous. Fuel

can ignite and cause serious injuries or death. Fuel can also irritate skin and eyes.


1. Disconnect the negative battery cable. 2. Connect a fuel pressure gauge between the fuel filter and

fuel distributor.

3. Connect the negative battery cable. Caution • Connecting the wrong DLC terminals may


4. Short the DLC terminal F/P to body GND using a jumper

wire.

5. Turn the ignition switch on for approx. 10 sec. to operate the fuel pump body.

6. Turn off the ignition switch and disconnect the jumper wire. 7. Observe the fuel pressure after 5 min.

Specification More than 150 kPa 1.5 kgf/cm2, 21 psi

8. If the pressure is lower than specified, measure the fuel

line pressure while pinching the return hose.

F1-122 CONTINUED



TROUBLESHOOTING

• If the fuel line pressure holds, replace the pressure

regulator. (Refer to FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION.)

• If fuel line pressure does not hold, inspect the fuel leakage from fuel line and fuel injector.

Pressure Regulator Control Inspection Warning • Fuel line spills and leakage are dangerous. Fuel

can ignite and cause serious injuries or death. Fuel can also irritate skin and eyes.


1. Disconnect the negative battery cable. 2. Connect a fuel pressure gauge between the fuel filter and

fuel distributor.

3. Connect the negative battery cable. 4. Measure the fuel line pressure under the following

conditions. Specifications

Condition Fuel pressure [kPa kgf/cm2, psi]

Idling

210—250 2.1—2.6, 30—36

During 120 sec. of hot start

270—310 2.7—3.2, 39—45

After 120 sec. of hot start

210—250 2.1—2.6, 30—36

210—250 2.1—2.6, 30—36

270—310 2.7—3.2, 3&—45

Judgment Normal Not Normal

(Perform Inspection 1)

Not Normal (Perform

Inspection 2)

Inspection 1

1. Connect the SSTs (NGS tester) to the DLC.

2. Start the engine and let it idle. 3. Select the SIMULATION TEST function on the NGS

display. 4. Select IDLING TEST mode. 5. Select PRCV PID. 6. Press START. 7. Turn the PRC solenoid valve from off to on and inspect if

the fuel pressure changes. (1) If the pressure changes, inspect the following.

• ECT, IATDC and TP V PIDs (Refer to CONTROL SYSTEM, PID/DATA MONITOR INSPECTION.)

(2) If the pressure does not change, do as follows. ① Select the SIMULATION TEST function on the NGS display. ② Select IDLING TEST mode. ③ Select PRCV PID. ④ Press START. ⑤ Turn the PRC solenoid valve from off to on and inspect if the operation sound of the valve is heard. ⑥ If the operating sound is heard, inspect the pressure regulator. ⑦ It the operating sound is not heard, inspect the PRC solenoid valve.

Inspection 2 1. Connect the SSTs (NGS tester) to the DLC.

2. Turn the ignition switch on. 3. Select the SIMULATION TEST function on the NGS

display. 4. Turn the PRC solenoid valve from off to on using the

PRCV PID and inspect if the operating sound is heard. (1) If the operating sound is heard, inspect for a loose or damaged vacuum hose. (Pressure regulator—PRC solenoid valve—intake manifold) (2) If the operating sound is not heard, inspect the

PRC solenoid valve)

F1-123 CONTINUED



TROUBLESHOOTINGFuel Injector Operation Inspection

STEP INSPECTION RESULTS ACTION Yes Fuel injector operation is okay. 1

While cranking engine, inspect for fuel injector operating sound at each cylinder using a soundscope. Is operating sound heard?

No

Not heard at all cylinders: Go to next step. Not heard at some cylinders: Go to Step 3.

Yes

Inspect following: • Fuel injector power system related wiring harnesses

and connectors • PCM connectors • Fuel injector GND and related wiring harnesses and

connectors

2

Carry out main relay operation inspection. Is main relay operation okay?

No Repair or replace malfunctioning parts. Yes Go to next step. 3

Change fuel injector connector of not operating fuel injector and operating fuel injector. Is operating sound heard? No Replace fuel injector.

Yes Inspect PCM terminal voltage of fuel injector signal. 4

Are wiring harnesses and connectors of not operating fuel injector okay? (Open or short) No Repair or replace malfunctioning parts.

Fuel Cut Control Inspection 1. Warm up engine and let it idle. 2. Turn off the electrical loads and A/C switch. 3. Connect the SSTs (NGS tester) to the DLC.


5. Select RPM and INJ PIDs. 6. Press START. 7. Monitor both PIDs while performing the following

steps. (1) Depress the accelerator pedal and increase the engine speed to 4000 rpm. (2) Release the accelerator pedal (brake pedal is not depressed) and inspect that the fuel injector duration time is 0 msec., and 2—5 msec. when the engine speed drops below 1200 rpm.

8. If not as specified, carry out the following. • ECT sensor inspection • Neutral/clutch switch inspection

Fuel Pump Operation Inspection 1. Connect the SSTs (NGS tester) to the DLC.

2. Remove the fuel-filler cap. 3. Turn the ignition switch on. 4. Select the SIMULATION TEST function on the NGS

display. 5. Turn the fuel pump relay from off to on using the FP

RLY PID and inspect if the operating sound is heard. 6. If no operating sound is heard, measure the voltage at

harness side fuel pump unit connector terminal B. Specification Battery positive voltage (Ignition switch on)

F1-124

CONTINUED



TROUBLESHOOTING 7. If the voltage is as specified, inspect the following.

• Fuel pump continuity • Fuel pump GND • Wiring harness between fuel pump relay and PCM

terminal 1 H 8. If not as specified, inspect the following.

1. Fuel pump relay 2. Wiring harness and connector (Main relay—fuel

pump relay—fuel pump unit) Fuel Pump Control Inspection 1. Connect the SSTs (NGS tester) to the DLC.

2. Turn the ignition switch on. 3. Select the SIMULATION TEST function on the NGS

display. 4. Select IG ON TEST mode. 5. Select FP RLY PID. 6. Press START. 7. Turn the fuel pump relay from off to on and inspect if

the operating sound of the fuel pump relay is heard.

8. If no operating sound is heard, inspect the fuel

pump relay. 9. If the fuel pump relay is normal, inspect the

following. • Wiring harnesses and connectors (Main

relay—fuel pump relay—PCM) Ignition Timing Control Inspection 1. Connect a timing light to the engine. 2. Crank the engine. 3. Verify that the timing mark (yellow) on the crankshaft

pulley is within the specification. Specification BTDC 9°—11°(10° ± 1°)

4. Increase the engine speed and verify the ignition timing

is advanced. 5. If the ignition timing is not advanced, carry out the

following. • CMP sensor inspection • MAP sensor inspection

F1-125

CONTINUED



TROUBLESHOOTING Spark Test

1. Remove the fuel pump relay. 2. Verify that each high-tension lead and connector is connected properly. 3. Inspect the ignition system in the following procedure.

Warning • High voltage in the ignition system can cause strong electrical shock which can result in serious injury. Avoid

direct contact to the vehicle body during the following spark test.

STEP INSPECTION RESULTS ACTION Yes Ignition system is okay. 1

Remove high-tension lead from spark plug. Hold high-tension lead with pliers installed 5—10 mm 0.20—0.39 in from GND. Crank the engine and verify that there is a strong blue spark. (Inspect each cylinder.)

No

Some cylinders do not spark: Go to next step. All cylinders do not spark: Go to Step 3.

Yes Inspect for cracks or damage of high-tension lead, distributor and Ignition coil.

2

Is high-tension lead resistance correct?

No Replace the high-tension lead. Yes Repair or replace connector. 3

Does PCM or ignition coil connector have poor connection? No Go to next step.


Is igniter okay? No Replace igniter.


Is ignition coil winding resistance okay? No Replace ignition coil.


Are distributor cap and rotor okay? No Replace distributor cap or rotor.

Yes

Inspect for open or short in wiring harness and connector of CMP sensor.

7

Are following parts okay? • CMP sensor • PCM terminal 2F voltage Specification Approx. 1.5 V

No Repair or replace malfunctioning part.

F1-126

CONTINUED



TROUBLESHOOTING Purge Control Inspection 1. Start the engine. 2. Disconnect the vacuum hose between the purge

solenoid valve and the charcoal canister. 3. Put a finger to the purge solenoid valve and verify that

there is no vacuum applied when the engine is cold. 4. If there is a vacuum, inspect the following.

• Wiring harness and connectors (Purge solenoid valve—PCM terminal 2X)

• Purge solenoid valve 5. Warm up the engine to the normal operating

temperature. 6. Stop the engine. 7. Connect the SSTs (NGS tester) to DLC.

8. Turn the ignition switch on. 9. Select the PID/DATA MONITOR AND RECORD

function on the NGS display. 10. Select ECT PID. 11. Verify that the engine coolant temperature is above

60°C 140°F. 12. If the SSTs (NGS tester) indicates below 60 °C 140 °F,

carry out the ECT sensor inspection. 13. Select the SIMULATION TEST function on the NGS

display. 14. Select PRGV PID. 15. Press START. 16. Increase the duty value of the purge solenoid valve to

50% and inspect if the operating sound of the valve is heard. (1) If the operating sound is heard, inspect the loose

or damaged vacuum hose. (Intake manifold—purge solenoid valve—charcoal canister)

(2) If the operating sound is not heard, carry out the purge solenoid valve inspection.

A/C CUT-OFF CONTROL INSPECTION 1. Start the engine. 2. Turn the A/C switch and fan switch on. 3. Verify that the A/C compressor magnetic clutch

actuates. 4. If it does not actuate, go to symptom troubleshooting

No.22 "A/C does not work sufficiently". Note • Specification of A/C cut-off control time is from 2

to 5 seconds. 5. Fully open the throttle valve in a short period and verify

that the A/C compressor magnetic clutch does not actuate.

6. If it actuates, inspect the following. (1) Connect the SSTs (NGS tester) to DLC.

(2) Turn the A/C switch off. (3) Turn the ignition switch on. (4) Select the SIMULATION TEST function on the

NGS display. (5) Select IG ON TEST mode. (6) Select A/C RLY PID (7) Press START. (8) Turn the A/C relay from off to on and inspect if the

operating sound of the relay is heard. (9) If the operating sound is heard, inspect TP V PID. (10) If the operating sound is not heard, inspect the

following. • /C relay • Open or short to GND circuit in wiring

harnesses and connectors (Main relay—A/C relay—PCM terminal 1J)

• A/C related parts

F1-127

CONTINUED



F2–1

FUEL AND EMISSIONCONTROL SYSTEMS

(WL, WL Turbo)ENGINE TUNE-UP F2–2. . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE TUNE-UP PREPARATION F2–2. . . . . . . . IDLE SPEED ADJUSTMENT F2–2. . . . . . . . . . . . . . IDLE-UP SPEED ADJUSTMENT F2–2. . . . . . . . . . . INJECTION TIMING ADJUSTMENT F2–3. . . . . . . .

INTAKE-AIR SYSTEM F2–4. . . . . . . . . . . . . . . . . . . . . . VACUUM HOSE ROUTING DIAGRAM F2–4. . . . . INTAKE-AIR SYSTEM

REMOVAL/INSTALLATION F2–5/7. . . . . . . . . . . . . . TURBOCHARGER INSPECTION F2–8/9. . . . . . . . . . GLOW PLUG REMOVAL/INSTALLATION F2–9. . . GLOW PLUG INSPECTION F2–9. . . . . . . . . . . . . . . GLOW PLUG RELAY

REMOVAL/INSTALLATION F2–9. . . . . . . . . . . . . . GLOW PLUG RELAY INSPECTION F2–10. . . . . . . . GLOW PLUG CORD INSPECTION F2–10. . . . . . . .

F2–10/11ACCELERATOR CABLE

INSPECTION/ADJUSTMENT F2–11. . . . . . . . . . . . IDLING KNOB, IDLING CABLE

INSPECTION F2–11. . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM F2–12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

BEFORE REPAIR PROCEDURE F2–12. . . . . . . . . . AFTER REPAIR PROCEDURE F2–12. . . . . . . . . . . . FUEL TANK REMOVAL/INSTALLATION F2–13/15. . . . FUEL FILTER DISASSEMBLY/

ASSEMBLY F2–15/16. . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL GAUGE SENDER UNIT

REMOVAL/INSTALLATION F2–16. . . . . . . . . . . . . . FUEL GAUGE SENDER UNIT

INSPECTION F2–16. . . . . . . . . . . . . . . . . . . . . . . . . . FUEL FILTER AIR BLEEDING F2–16. . . . . . . . . . . . . SEDIMENTOR WATER DRAINING F2–16. . . . . . . . . SEDIMENTOR SWITCH INSPECTION F2–16/17. . . . . FUEL WARMER INSPECTION F2–17. . . . . . . . . . . . FUEL INJECTION PUMP (FIP)

INSPECTION F2–17. . . . . . . . . . . . . . . . . . . . . . . . . . FUEL INJECTION PUMP (FIP)

REMOVAL/INSTALLATION F2–17/18. . . . . . . . . . . . . . INJECTION NOZZLE

REMOVAL/INSTALLATION F2–18. . . . . . . . . . . . . .

INJECTION NOZZLE DISASSEMBLY/ASSEMBLY F2–19. . . . . . . . . . . . .

INJECTION NOZZLE INSPECTION F2–19/20. . . . . . . . FUEL CUT VALVE (FCV)

REMOVAL/INSTALLATION F2–20. . . . . . . . . . . . . . FUEL CUT VALVE (FCV) INSPECTION F2–20/21. . . . . FICD SOLENOID VALVE NO.1, NO.2 INSPECTION

F2–21TIMER CONTROL VALVE (TCV)

INSPECTION F2–22. . . . . . . . . . . . . . . . . . . . . . . . . . EXHAUST SYSTEM F2–23. . . . . . . . . . . . . . . . . . . . . . . .

EXHAUST SYSTEM INSPECTION F2–23. . . . . . . . . EXHAUST SYSTEM

REMOVAL/INSTALLATION F2–23/25. . . . . . . . . . . . . . EMISSION SYSTEM F2–25. . . . . . . . . . . . . . . . . . . . . . .

ROLLOVER VALVE INSPECTION F2–25. . . . . . . . . EVAPORATIVE CHAMBER INSPECTION F2–25. . . EGR VALVE INSPECTION F2–26. . . . . . . . . . . . . . . . EGR SOLENOID VALVE INSPECTION F2–26. . . . .

F2–26CONTROL SYSTEM F2–27. . . . . . . . . . . . . . . . . . . . . . .

COMPONENT PARTS F2–27. . . . . . . . . . . . . . . . . . . . POWERTRAIN CONTROL MODULE (PCM)

REMOVAL/INSTALLATION F2–28. . . . . . . . . . . . . . POWERTRAIN CONTROL MODULE (PCM)

INSPECTION F2–28/31. . . . . . . . . . . . . . . . . . . . . . . . . . NE SENSOR INSPECTION F2–32. . . . . . . . . . . . . . . ENGINE COOLANT TEMPERATURE (ECT)

SENSOR INSPECTION F2–32/33. . . . . . . . . . . . . . . . . IDLE SWITCH INSPECTION F2–33. . . . . . . . . . . . . . CONTROL LEVER POSITION SENSOR

INSPECTION F2–33/34. . . . . . . . . . . . . . . . . . . . . . . . . . ON-BOARD DIAGNOSTIC SYSTEM F2–35. . . . . . . . .

DTC READING PROCEDURE F2–35. . . . . . . . . . . . . AFTER REPAIR PROCEDURE F2–35. . . . . . . . . . . . DTC INSPECTION F2–36/38. . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING F2–39. . . . . . . . . . . . . . . . . . . . . . FOREWORD F2–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING ITEM TABLE F2–39. . . . . . . . SYMPTOM TROUBLESHOOTING F2–40/60. . . . . . . . . SYSTEM INSPECTION F2–61/64. . . . . . . . . . . . . . . . . . .

BACK.TO.MAIN.INDEX

CONTINUED


PAGES. FROM. MANUAL

ACCELERATOR PEDAL REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . .

EGR PIPE, EGR VALVE REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . .

ENGINE TUNE-UP

F2–2

ENGINE TUNE-UPENGINE TUNE-UP PREPARATION


2. Turn the all electrical loads off.3. Connect a tachometer.

IDLE SPEED ADJUSTMENTWL

1. Perform “Engine tune-up preparation ”.2. Verify that the idle speed is within the specification.

Specification700—740 (72020) rpm

3. If not within the specification, adjust the idle speedby turning the IAS (idle adjustment screw).

LOCKNUT5.9—8.8 N·m60—90 kgf·cm,53—78 in·lbf

IAS

4. After adjusting the idle speed, tighten the locknutsecurely.

WL Turbo1. Perform “Engine tune-up preparation ”.2. Verify that the idle speed is within the specification.

SpecificationGeneral (L.H.D.) : 760—800 (78020) rpmEurope and UK : 700—740 (720 20) rpm

Caution Turning the idle switch (Europe and UK

only) with its connector connected canbreak the harness. Be sure to disconnectthe connector when turning the idle switchmore than one rotation.

3. If not as specified, loosen the idle switch locknutand adjust the idle speed by turning the idle switch.

LOCKNUT11.8—14.7 N·m120—150 kgf·cm,104—130 in·lbf

IDLE SWITCH

4. After adjusting the idle speed, tighten the locknutsecurely.

IDLE-UP SPEED ADJUSTMENT1. Perform “Engine tune-up preparation ”.2. Turn all electrical loads off in neutral shift position.3. Apply vacuum of –53.3 kPa –400 mmHg, –15.8

inHg or over to actuator B, and measure theidle-up speed.

ADJUSTINGSCREW B

LOCKNUT B

WL

ACTUATOR B

ADJUSTINGSCREW C

ACTUATOR A

WL, WL TurboADJUSTINGSCREW B

LOCKNUT B

ACTUATOR B

ADJUSTINGSCREW C

ACTUATOR A

Specification1200—1500 (1,350150) rpm

4. If not within the specification, do as follows;(1) Loosen the locknut B.(2) Adjust the idle-up speed by turning the

adjusting screw B.(3) Tighten the locknut B.


5. Release actuator B to atmosphere and applyvacuum of –53.3 kPa –400 mmHg, –15.8 inHg orover to actuator A, and measure the idle-up speed.

SpecificationWL vehicle: 805—855 (830 25) rpmWL Turbo, WL (Europe only):

825—875 (85025) rpm

6. If not as specified, adjust the idle-up speed byturning adjusting screw C.


CONTINUED


PAGES. FROM. MANUAL

ENGINE TUNE-UP

F2–3

INJECTION TIMING ADJUSTMENT

Warning Fuel vapor is hazardous. It can very easily

ignite, causing serious injury and damage.Always keep sparks and flames away fromfuel.

Fuel line spills and leaks are dangerous.Fuel can ignite and cause serious injuriesor death and damage. Fuel can also irritateskin and eyes. To prevent this, alwaysobserve the “Fuel Line Safety Procedures”,“Fuel Hose Installation”.

Caution After tightening the FIP mounting nuts and

bolt after loosening them, be sure toinspect the timing belt tension. If the belttension is not inspected, the timing belt andthe camshaft may become damaged. (Referto Section B2, TIMING BELT, TIMING BELTREMOVAL/INSTALLATION, Timing BeltInstallation Note.)

1. Remove the injection pipes (Refer to FUEL SYSTEM, FUEL INJECTION PUMP (FIP)REMOVAL/INSTALLATION.)

2. Remove the cooling fan (Refer to Section E, COOLING FAN, COOLING FANREMOVAL/INSTALLATION.)

3. Turn the crankshaft pulley at slow rotation to alignthe timing mark (BTDC 0° : yellow mark) withindicator pin.

ATDC 10 ° (WHITE MARK)

INDICATOR PINBTDC 0 °(YELLOW MARK)

4. Remove the hydraulic head plug from the injectionpump.

5. Mount the SST into the plug hole on the hydraulichead so that the dial indicator probe touches theplunger end of the pump and the dial indicatorindicates approx. 2.0 mm 0.079 in .

49 9140 074

6. Turn the crankshaft counterclockwise to approx.30° BTDC. (Align the SST installation hole on thecrankshaft pulley.)

7. Turn the crankshaft lightly right and left, and verifythat the dial gauge indicator does not move. Thenset the indicator to 0 mm 0 in.

8. Turn the crankshaft clockwise to position theindicator pin to 10° ATDC (white mark) and readthe dial indicator.

INDICATOR PIN

BTDC 0°(YELLOW MARK)

ATDC 10° (WHITE MARK)

Specification0.95—1.05 mm 0.038—0.041 in

(1.00.05 mm 0.0390.019 in)

9. If not as specified, adjust by loosening the FIPmounting nut and bolt and turn the FIP.

10. Tighten the FIP mounting nuts and then the bolt.


MOUNTING NUT

MOUNTING BOLT

11. Remove the SST.12. Install the hydraulic head plug and a new gasket.


13. Connect the injection pipes. (Refer to FUEL SYSTEM, INJECTION NOZZLEREMOVAL/INSTALLATION.)

14. Bleed the air from the fuel filter. (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)

15. Inspect for fuel leakage.16. Check the timing belt tension.

(Refer to Section B2, TIMING BELT, TIMING BELTREMOVAL/INSTALLATION, Timing Belt Installation Note.)


CONTINUED


PAGES. FROM. MANUAL

INTAKE-AIR SYSTEM

F2–4

INTAKE-AIR SYSTEMVACUUM HOSE ROUTING DIAGRAM

WL

FICD SOLENOIDVALVE No.1


FICD ACTUATOR

VACUUM PUMP

TO POWERBRAKE UNIT

WL TURBO


TO RFWACTUATOR

4WD ONLY

TO POWERBRAKE UNIT

FICD ACTUATOR

VACUUM PUMP

EGR VALVE


EGR SOLENOIDVALVE


CONTINUED


PAGES. FROM. MANUAL

INTAKE-AIR SYSTEM

F2–5

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION

Warning When the engine and intake-air system are hot, they can badly burn. Turn off the engine and wait

until they are cool before removing the intake-air system.

WL1. Disconnect the negative battery cable.2. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.)3. Remove in the order indicated in the table.4. Install in the reverse order of removal.

R

7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf

2.0—2.9 N·m20—30 kgf·cm,18—26 in·lbf

2.0—2.9 N·m 20—30 kgf·cm, 18—26 in·lbf

7.9—11.7 N·m80—120 kgf·cm,70—104 in·lbf

8.9—12.7 N·m90—130 kgf·cm,79—112 in·lbf


7.9—10.7 N·m80—110 kgf·cm,70—95 in·lbf

18.7—25.41.9—2.6,13.8—18.8

7.9—11.7 N·m80—120 kgf·cm,70—104 in·lbf

18.7—25.41.9—2.6,13.8—18.8

1 Fresh-air duct

2 Air cleaner

3 Air hose

4 Resonance chamber

5 Air intake pipe

6 FICD solenoid valve No.1


8 FICD solenoid valve bracket

9 Intake manifold


CONTINUED


PAGES. FROM. MANUAL

INTAKE-AIR SYSTEM

F2–6

WL Turbo1. Disconnect the negative battery cable.2. Drain the engine coolant from radiator.

(Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.)3. Remove the front mud guard.

(Refer to Section S, FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.)4. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.)5. Remove in the order indicated in the table.6. Install in the reverse order of removal.7. Refill the engine coolant to radiator.

(Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.)

STEP 1

4.9 N·m 50 kgf·cm, 43 in·lbf


8.9—12.7 N·m90—130 kgf·cm,79—112 in·lbf

7.9—11.7 N·m80—120 kgf·cm,70—104 in·lbf

2.0—2.9 N·m 20—30 kgf·cm, 18—26 in·lbf

7.9—11.7 N·m80—120 kgf·cm,70—104 in·lbf


7.9—11.7 N·m 80—120 kgf·cm,70—104 in·lbf

8.9—12.7 N·m90—130 kgf·cm,79—112 in·lbf

8.9—12.7 N·m90—130 kgf·cm,79—112 in·lbf

A

A

1 Fresh-air duct

2 Air cleaner

3 Air intake hose

4 Air hose

5 Air intake pipe

6 Air hose

7 Charge air cooler

8 Air hose


CONTINUED


PAGES. FROM. MANUAL

INTAKE-AIR SYSTEM

F2–7

STEP 2

7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf

19—25 1.9—2.6, 14—18

19—25 1.9—2.6, 14—18

19—25 1.9—2.6, 14—18


19—25 1.9—2.6, 14—18

R

R



3 EGR solenoid valve

4 FICD solenoid valve bracket

5 Air intake pipe

6 Intake manifold


CONTINUED


PAGES. FROM. MANUAL

INTAKE-AIR SYSTEM

F2–8

TURBOCHARGER INSPECTIONWastegate Actuator Inspection

Caution Compressed air used in the workshop is

highly pressurized and can damage theactuator. Adjust the air pressure with atransformer, and inspect the actualpressure by using an air blower beforeactual use. Stop blowing air if the rodmoved.

1. Disconnect the air hose of the wastegate actuatoron the compressor housing side.

2. Apply the compressed air using the air gun.3. Note the air pressure when the wastegate actuator

is moved.

Specification107—115 kPa

1.09—1.18 kgf/cm 2, 15.5—16.8 psiWASTEGATEACTUATOR

ROD

4. If not within the specification, replace theturbocharger. (Refer to EXHAUST SYSTEM,EXHAUST SYSTEM REMOVAL/INSTALLATION.)

Compressor Wheels Inspection1. Remove the air hose.

(Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)

2. Remove the joint pipe. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)

3. Set the small mirror as shown and inspect thecompressor wheel from view A.

Note To make work accurate, use a penlight to

inspect.

TURBOCHARGERMIRROR

A

4. Inspect all fins of compressor wheel while rotatingthe compressor wheel by hand.

5. If the compressor wheel is interfering with thehousing, it is likely that more than two fins aredamaged, cracked or bent. Replace theturbocharger.

Note If scratches are found inside the housing but

the fins are okay, the turbocharger is okay.Scratches are made in the turbocharger madeby factory.

Turbine Wheels Inspection1. Remove the air hose.

(Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)

2. Remove the joint pipe. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)

3. Set the small mirror as shown and inspect theturbine wheel from view B.

Note To make work accurate, use a penlight to

inspect.

TURBOCHARGER

MIRROR

B

4. Inspect all fins of turbine wheel while rotating theturbine wheel by hand.


CONTINUED


PAGES. FROM. MANUAL

INTAKE-AIR SYSTEM

F2–9

5. If the turbine wheel is interfering with the housing,it is likely that one or more fins are damaged,cracked or bent. Replace the turbocharger.

Note Grinding marks on the shaft are normal. This

mark is for adjusting the shaft balance at thefactory.

GRINDING MARK

GLOW PLUG REMOVAL/INSTALLATION

Caution Do not damage the heated section of the

glow plug. Do not reuse a glow plug that has been

dropped over a height of 10 cm 0.4 in. When removing the glow plug, first loosen

it over one pitch by using a tool, thenloosen by hand.


7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf

0.8—15 N·m8—15 kgf·cm,7—13 in·lbf

1 Glow plug cord

2 Glow plug

GLOW PLUG INSPECTION1. Remove the glow plug cord.2. Inspect the resistance between the glow plug

terminal and the cylinder head.

SpecificationGlow plug resistance

Approx. 0.75 Ω [20 °C 68 °F]

GLOW PLUG

3. If not as specified, replace the glow plug.

GLOW PLUG RELAY REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove glow plug relay.3. Install the glow plug relay.

8.9—12.7 N·m90—130 kgf·cm,79—112 in·lbf

GLOW PLUGRELAY



CONTINUED


123456567

INTAKE-AIR SYSTEM

F2–10

GLOW PLUG RELAY INSPECTIONSystem Inspection

1. Carry out the “Glow system inspection”. (Refer to TROUBLESHOOTING, SYSTEM INSPECTION, Glow System Inspection.)

2. If not as specified, perform the further inspectionfor the glow plug relay.

Continuity InspectionNote Perform the following test only when directed.

1. Remove the glow plug relay.2. Inspect for continuity between terminals C and D of

the glow plug relay under the following conditions.

C D

A B

C D

A B

: ContinuityStep A B C D

1 B+ GND

2

3. If there is no continuity, replace the glow plug relay.(Refer to GLOW PLUG RELAY REMOVAL/INSTALLATION.)

If as specified but theSystem Inspection is failed, inspect following:

Open circuit Power circuit (Glow plug relay connector terminal A

(1-pin: R/B) and battery) Power circuit (Glow plug relay connector terminal A

(2-pin) and PCM connector terminal O) GND circuit (Glow plug relay connector terminal A

(1-pin: R) and glow plug cord) GND circuit (Glow plug relay connector terminal B

(2-pin) and engine GND) Signal circuit (Glow plug relay connector terminal A

(1-pin: R) and PCM connector terminal I)

Short circuit Glow plug relay connector terminal A (1-pin: R/B)

and battery to GND. Glow plug relay connector terminal A (2-pin) and

PCM connector terminal O to GND. Glow plug relay connector terminal A (1-pin: R)

and PCM connector terminal I to GND.4. Repair or replace faulty areas.5. Install the glow plug relay.

GLOW PLUG CORD INSPECTION1. Remove the glow plug cord.

(Refer to GLOW PLUG REMOVAL/INSTALLATION.)2. Verify that the glow plug cord is not broken or bent.3. Verify there is continuity at both ends of the glow

plug cord.4. If there is no continuity, replace the glow plug cord.

ACCELERATOR PEDAL REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the column cover.

(Refer to Section N, MANUAL STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

3. Remove in the order indicated in the table.4. Install in the reverse order of removal.

General (R.H.D.)

5.0 N·m 50 kgf·cm, 44in·lbf

RN·m kgf·m, ft·lbf

19—25 1.9—2.6, 14—18

19—25 1.9—2.6,14—18

R

1 Idling knob

2 Idling cable

3 Brake switch connector

4 Accelerator cable+ Installation Note

5 Spring pin

6 Clevis pin

7 E clip

8 Pin

9 Bushing

10 Push rod

11 Clevis

12 Nut

13 Nut

14 Pedal component+ Installation Note


CONTINUED


INTAKE-AIR SYSTEM

F2–11

Except General (R.H.D.)

7.9—10.7 N·m 80—110 kgf·cm,69.5—95.4 in·lbf

1 Accelerator cable+ Installation Note

2 Accelerator pedal

Pedal Component Installation Note Carry out the “BRAKE PEDAL HEIGHT

INSPECTION” procedure after installing the pedalcomponent. (Refer to Section P, BRAKE PEDAL HEIGHT INSPECTION.)

Carry out the “CLUTCH PEDAL INSPECTION”procedure after installing the pedal component.(Refer to Section H, CLUTH PEDALINSPECTION/ADJUSTMENT.)

Accelerator Cable Installation Note Carry out the “ACCELERATOR CABLE

INSPECTION/ADJUSTMENT” procedure afterinstalling the accelerator cable. (Refer to ACCELERATOR CABLEINSPECTION/ADJUSTMENT.)

ACCELERATOR CABLEINSPECTION/ADJUSTMENT

1. Warm up the engine, then turn the engine switchoff.

2. Measure the free play of the accelerator cable.

LOCKNUT

Free play1—3 mm 0.04—0.11 in

3. If not as specified, adjust by turning locknut.

IDLING KNOB, IDLING CABLE INSPECTIONGeneral (R.H.D.)

1. Verify that the accelerator pedal is in the idlingposition, when the idling knob is not turned.

2. Verify that the accelerator pedal moves in thedirection that engine speed increases, when theidling knob is turned to the right.

3. Verify that the accelerator pedal returns to theidling position when the idling knob is turned to theleft.

IDLING KNOB


CONTINUED


FUEL SYSTEM

F2–12

FUEL SYSTEMBEFORE REPAIR PROCEDURE

Warning Fuel vapor is hazardous. It can very easily

ignite, causing serious injury and damage.Always keep sparks and flames away fromfuel.

Fuel in the fuel system is under high pressurewhen the engine is not running.

Warning Fuel line spills and leaks are dangerous.

Fuel can ignite and cause serious injuriesor death and damage. Fuel can also irritateskin and eyes. To prevent this, alwayscomplete the following “Fuel Line SafetyProcedures”.

Fuel Line Safety Procedures Avoid fuel line spills and leaks by completing the

following procedures.(1) Remove the fuel-filler cap and release the

pressure in the fuel tank.(2) When disconnecting a fuel hose, wrap a rag

around it to protect against fuel leakage.(3) Plug the fuel hose after removal.

AFTER REPAIR PROCEDURE

Warning Fuel line spills and leaks are dangerous.

Fuel can ignite and cause serious injuriesor death and damage. When installing thefuel hose, observe “Fuel Hose Installation”described below.

Fuel Hose Installation Verify that there is no damage or deformation on

the fuel hose and fuel pipe when installing.


CONTINUED


FUEL SYSTEM

F2–13

FUEL TANK REMOVAL/INSTALLATION

Warning Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire

may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.

1. Disconnect the negative battery cable.2. Complete the “BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)3. Remove the drain plug and drain the fuel from the fuel tank.4. Remove the rear flap.5. Remove in the order indicated in the table.6. Install in the reverse order of removal.7. Complete the “AFTER REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)

STRETCH CAB 2WD, DOUBLE CAB 2WD


7.9–10.7 N·m 80—110 kgf·cm, 69.5—95.4 in·lbf

1.1–2.1 N·m 11—22 kgf·cm, 10—19 in·lbf

1.1–2.1 N·m 11—22 kgf·cm, 10—19 in·lbf

1.1–2.1 N·m 11—22 kgf·cm, 10—19 in·lbf

2.5—3.5 N·m 25—36 kgf·cm, 22—26 in·lbf

2.5—4.6 N·m 25—47 kgf·cm, 22—40 in·lbf

11.8—16.6 N·m 120—170 kgf·cm, 105—147 in·lbf

16—22 1.6—2.3, 12—16

11.8—16.6 N·m 120—170 kgf·cm, 105—147 in·lbf

16—22 1.6—2.3, 12—16

DRAIN PLUG26—32 2.6—3.3, 19—23

32—46 3.2—4.7, 24—33

R

R

R

R R

A B

WITH BOX

32—46 3.2—4.7, 24—33WITHOUT BOX

SEAL RUBBER

EXCEPT EUROPE

EUROPE

1.1—2.1 N·m 11—22 kgf·cm, 10—19 in·lbf


CONTINUED


FUEL SYSTEM

F2–14



1.1–2.1 N·m 11—22 kgf·cm, 10—19 in·lbf

1.1–2.1 N·m 11—22 kgf·cm, 10—19 in·lbf

1.1–2.1 N·m 11—22 kgf·cm, 10—19 in·lbf

2.5—3.5 N·m 25—36 kgf·cm, 22—26 in·lbf

2.5—4.6 N·m 25—47 kgf·cm, 22—40 in·lbf

11.8—16.6 N·m 120—170 kgf·cm, 105—147 in·lbf

16—22 1.6—2.3, 12—16

11.8—16.6 N·m 120—170 kgf·cm, 105—147 in·lbf

16—22 1.6—2.3, 12—16

DRAIN HOSE26—32 2.6—3.3, 19—23 32—46 3.2—4.7, 24—33

R

R

R

R

A B

WITH BOX

7.9—10.7 N·m 80—110 kgf·cm, 69.5—95.4 in·lbf

WITHOUT BOX

32—46 3.2—4.7, 24—33

SEAL RUBBER

EUROPE

1.1—2.1 N·m 11—22 kgf·cm, 10—19 in·lbf

EXCEPT EUROPE

1 Evaporative chamber (If equipped)

2 Joint hose+ Installation Note

3 Breather hose+ Installation Note

4 Under guard

5 Fuel hose+ Installation Note

6 Fuel tank

7 Evaporative hose+ Installation Note

8 Fuel gauge sender unit

9 Rollover valve

10 Fuel-filler pipe

11 Dust cover

12 Fuel inlet pipe

13 Check valve (two–way)

14 Evaporative chamber


CONTINUED


FUEL SYSTEM

F2–15

Evaporative Hose Installation Note Fit each hose onto the respective fittings within the

specification, and install clamps as shown.

LengthEvaporative hose: 25 mm 0.98 in

10 mm 0.39 in

EVAPORATIVE HOSE

Fuel Hose Installation Note Fit each hose onto the respective fittings within the

specification, and install clamp as shown.

LengthFuel hose: 25 mm 0.98 in

10 mm 0.39 in

FUEL HOSE

Breather Hose Installation Note Fit each hose onto the respective fittings within the

specification, and install clamp as shown.

LengthBreather hose: 25 mm 0.98 in

10 mm 0.39 in

BREATHER HOSE

Joint Hose Installation Note Fit the joint hose onto the respective fittings within

the specification, and install clamps as shown.

LengthJoint hose: 35 1.4 in

9—12 mm0.36—0.47 in

VIEW A

9—12 mm0.36—0.47 in

VIEW B

FUEL FILTER DISASSEMBLY/ASSEMBLY1. Disconnect the negative battery cable.2. Complete the “BEFORE REPAIR PROCEDURE”.

(Refer to FUEL SYSTEM, BEFORE REPAIRPROCEDURE.)

3. Disassemble in the order indicated in the table.4. Assemble in the reverse order of removal.5. Complete the “AFTER REPAIR PROCEDURE”.

(Refer to FUEL SYSTEM, AFTER REPAIRPROCEDURE.)

6. Bleed air from the fuel filter. (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)

7. Start the engine and verify that fuel does not leakfrom the fuel system.

8. If fuel leaks, reassemble the fuel filter.19—25 1.9—2.6, 14—18

WITHOUT FUEL WARMER

WITH FUELWARMER


R


CONTINUED


FUEL SYSTEM

F2–16

1 Connector

2 Fuel hose

3 Priming pump

4 Fuel filter+ Assembly Note

5 Sedimentor switch+ Assembly Note

6 Drain plug

7 Fuel warmer

Sedimentor Switch Assembly Note Apply a small amount of fuel to a new O-ring.

Tighten the sedimentor switch enough to the fuelfilter by hand.

Fuel Filter Assembly Note Apply a small amount of fuel to the fuel filter

O-ring. Tighten the fuel filter approx. 3/4 by handafter the O-ring contacts the priming pump.

FUEL GAUGE SENDER UNITREMOVAL/INSTALLATION(Refer to FUEL SYSTEM, FUEL TANKREMOVAL/INSTALLATION)

FUEL GAUGE SENDER UNIT INSPECTION(Refer to Section T, WARNING AND INDICATORSYSTEM, FUEL GAUGE SENDER UNITINSPECTION.)

FUEL FILTER AIR BLEEDING

Caution Continuously cranking the engine for over

30 seconds can damage the battery and thestarter.

Repeat cranking the engine for 30 seconds andstop for 5—10 seconds until the engine starts.

SEDIMENTOR WATER DRAINING1. Disconnect the negative battery cable.2. Complete the “BEFORE REPAIR PROCEDURE”.


3. Loosen the drain plug located at the bottom of thefuel filter.

4. Pump the priming pump and drain the water.5. After all the water has been drained, tighten the

drain plug.6. Complete the “AFTER REPAIR PROCEDURE”.


7. Reconnect the negative battery cable.

SEDIMENTOR SWITCH INSPECTIONContinuity Inspection

Note Perform the following test only when directed.

1. Disconnect the negative battery cable.2. Drain fuel from the fuel filter.

(Refer to FUEL SYSTEM, SEDIMENTOR WATERDRAINING.)

3. Remove the sedimentor switch.4. Inspect continuity of the sedimentor switch by

using an ohmmeter.

Float Continuity

Up Yes

Down No

FLOAT

UP

DOWN

5. If not as specified, replace the sedimentor switch.If as specified, inspect following:Open circuit GND circuit (Sedimentor switch connector

terminal B and body GND) Power circuit (Sedimentor switch connector

terminal A and engine switch connectorterminal C)

SEDIMENTOR SWITCH

HARNESS SIDE CONNECTOR(VIEW FROM TERMINAL SIDE)

BA

ENGINE SWITCH


BA

CA

DB


CONTINUED


FUEL SYSTEM

F2–17

Short circuit GND circuit (Sedimentor switch connector

terminal B and body GND to power circuit) Power circuit (Sedimentor switch connector

terminal A and engine switch connectorterminal C to GND)

6. Repair or replace faulty areas.7. Install the sedimentor switch.8. Reconnect the negative battery cable.9. Bleed air from the fuel filter.

(Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)

FUEL WARMER INSPECTIONWith fuel warmer

1. Disconnect the negative battery cable.2. Complete the “BEFORE REPAIR PROCEDURE”.


3. Remove the fuel warmer. (Refer to FUEL SYSTEM, FUEL FILTERDISASSEMBLY/ASSEMBLY.)

4. Verify that the resistance between terminal A andthe fuel warmer body is within the specificationwhen vacuum of –26.6—–40.0 kPa–200—–300mmHg, –7.9—–11.8 inHg is appliedto port A of the fuel warmer.

SpecificationWater temperature °C °F Resistance ( Ω)

20 68 0.5—1.5

5. If not as specified, replace the fuel warmer.

FUEL INJECTION PUMP (FIP) INSPECTION

Caution FIP is sealed to maintain proper function.

Special tools and testers are required whendisassembling the FIP. Disassembling theFIP without special tools and testers willcause a malfunction.

Consult your distributor for disassembly if any FIPinternal parts are possibly malfunctioning.

FUEL INJECTION PUMP (FIP) REMOVAL/INSTALLATION

Caution After removing/installing the FIP, be sure to

inspect the timing belt tension. If the belttension is not inspected, the timing belt andthe camshaft may become damaged. (Refer to section B2, TIMING BELT, TIMING BELTREMOVAL/INSTALLATION, Timing Belt Installation Note.)



3. Remove the FICD solenoid valve bracket. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEMREMOVAL/INSTALLATION.)

4. Remove the air intake pipe. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEMREMOVAL/INSTALLATION.)

5. Set the No.1 cylinder to TDC.6. Remove in the order indicated in the table.7. Install in the reverse order of removal.8. Complete the “AFTER REPAIR PROCEDURE”.


9. Inspect injection timing. (Refer to ENGINETUNE-UP, INJECTION TIMING ADJUSTMENT.)

10. Check the timing belt tension. (Refer to Section B2,TIMING BELT, TIMING BELTREMOVAL/INSTALLATION, Timing Belt InstallationNote.)


7.9—10.7 N·m 80—110 kgf·cm, 69.5—95.4 in·lbf

2.4—3.4 N·m 25—35 kgf·cm, 22—30 in·lbf

19—25 1.9—2.6, 14—18

19—25 1.9—2.6, 14—18

59—68 6.0—7.0, 44—50

A

A

R

25—29 2.5—3.0, 19—21


CONTINUED


FUEL SYSTEM

F2–18

1 Injection pipe

2 Accelerator cable

3 Fuel hose

4 Connector

5 Vacuum hose

6 Timing belt cover+ Section B2, TIMING BELT, TIMING BELT

REMOVAL/INSTALLATION, Timing Belt CoverInstallation Note.

7 FIP mounting bolt

8 FIP mounting nut

9 FIP+ Removal Note

10 Key

FIP Removal Note1. Remove the two FIP pulley mounting bolts.2. Loosen the FIP pulley locknut.3. Remove the pulley with the SST.

FIP PULLYLOCKNUT

49 S120 215A

INJECTION NOZZLE REMOVAL/INSTALLATION

Caution Cover the outlet of the injection pipe and

fuel hose with a rag. Catch the fuel with a rag.



3. Remove the FICD solenoid valve bracket. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)

4. Remove in the order indicated in the table.5. Install in the reverse order of removal.6. Complete the “AFTER REPAIR PROCEDURE”.



R

25—29 2.5—3.0, 19—21

27—32 2.7—3.3, 20—23

59—68 6.0—7.0, 44—50

2.4—3.4 N·m 25—35 kgf·cm, 22—30 in·lbf

R

R

1 Injection pipe

2 Fuel leak pipe

3 Fuel leak washer

4 Injection nozzle+ Installation Note

5 Nozzle washer

6 Corrugated gasket+ Installation Note

Corrugated Gasket Installation Note Install the bead side facing combustion chamber.

Injection Nozzle Installation Note Install each injection nozzle onto the FIP, matching

their identification color rings as shown.

FIPINJECTION NOZZLE

COLOR RING


CONTINUED


FUEL SYSTEM

F2–19

INJECTION NOZZLE DISASSEMBLY/ASSEMBLY

Caution The injection port is very small so it must

be kept clean. Otherwise, foreign materialmay get stuck in the injection nozzle,causing damage.

1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.

29—49 3.0—5.0,22—36


1 Nozzle holder body+ Disassembly Note

2 Ring

3 Shim

4 Nozzle spring

5 Spring seat

6 Spacer

7 Needle valve+ Assembly Note

8 Nozzle body

9 Retaining nut

Nozzle Holder Body Disassembly Note Secure the retaining nut in a vise and remove the

nozzle holder body.

Needle Valve Assembly Note When the nozzle body or the needle valve is

damaged, replace them as a set.

INJECTION NOZZLE INSPECTION

Caution Fuel and fuel tank used for the nozzle tester

must be kept clean. Otherwise, foreignmaterial may get stuck between the nozzleand the nozzle tester, causing damage.

Injection Starting Pressure1. Connect the injection nozzle to a nozzle tester.2. Bleed the air by pumping the nozzle tester handle

several times.3. Slowly lower the nozzle tester handle and note the

pressure when injection starts.

Injection starting pressure11.4—12.1 MPa

116—124 kgf/cm 2, 1650—1760 psi (New)More than 10.0 MPa

102 kgf/cm 2, 1450 psi (Inspection)

4. If the injection starting pressure is not within thespecification, adjust it by installing the correct shim.

Note Adding/subtracting 0.02 mm 0.0008 in

thickness shim increases/decreases thestarting pressure approx. 470 kPa 4.8kgf/cm 2, 68 psi .

ADJUSTING SHIM

Atomization1. Connect the injection nozzle to the nozzle tester.2. Bleed the air by pumping the nozzle tester handle

several times.3. Lower the handle several times as quickly as

possible so that a pulsating whistling sound isheard, and note the atomization pattern.(1) Uniform, proper atomization(2) Incorrect injection angle and direction

(1) (2)

NORMAL FAULTYANGLE

FAULTYDIRECTION

4. If necessary, disassemble and clean or replace theinjection nozzle.


CONTINUED


FUEL SYSTEM

F2–20

Nozzle Leakage1. Connect the injection nozzle to the nozzle tester.2. Bleed the air by pumping the nozzle tester handle

several times.3. Apply 8.8 MPa 90 kgf/cm 2, 1,280 psi pressure to

the injection nozzle, and inspect for fuel leakagefrom the nozzle spray port.

CORRECT WRONG

4. If fuel leaks, disassemble and clean or replace theinjection nozzle.

Operating Inspection1. Verify that the needle valve and nozzle body are

not damaged.2. Verify that the nozzle body is not damaged. Hold

the nozzle body upright and insert approximatelytwo thirds of the needle valve; then see if theneedle valve drops to the valve seat by its ownweight when released.

NEEDLE VALVE

NOZZLEBODY

Injection Nozzle Cleaning1. Inspect the outer and inner surfaces of the injection

nozzle for carbon accumulation.2. If carbon is observed on the outer surface, remove

it by using a hard wood chip.3. If carbon is observed inside of the nozzle, remove

it by using a toothpick.

4. Remove the needle valve from the nozzle body.5. Clean the needle valve and the nozzle body with

clean light oil.6. Verify that the needle valve moves smoothly in the

nozzle body.7. If not, replace the nozzle assembly.

FUEL CUT VALVE (FCV) REMOVAL/INSTALLATIONWithout immobilizer system



3. Remove the FCV.4. Install in the reverse order of removal.

NUT2.0—2.4 N·m 20—25 kgf·cm,18—21 in·lbf


FCV15—25 1.5—2.6, 11—18

FUEL CUT VALVE (FCV) INSPECTIONWithout immobilizer systemOn-vehicle Inspection


1. With the engine idling, disconnect the FCVconnector and verify that the engine stops.

2. If the engine does not stop, carry out the followinginspection.

Off-vehicle Inspection1. Disconnect the negative battery cable.2. Remove the FCV.3. Connect the battery positive voltage to the FCV

terminal and GND the FCV body,4. Verify that the FCV stem is drawn into the FCV.


CONTINUED


123456567

FUEL SYSTEM

F2–21

5. Replace the FCV if not as specified. If as specified, inspect following:Open circuit GND circuit (FCV body and engine switch

connector terminal IG1) Power circuit (FCV connector terminal and

engine switch connector terminal IG1)

ENGINE SWITCH


BA

CA

DB

Short circuit GND circuit (FCV body and engine switch

connector terminal IG1 to GND) Power circuit (FCV connector terminal and

engine switch connector terminal IG1 to GND)

6. Repair or replace faulty areas.7. Install the FCV.8. Reconnect the negative battery cable.

FICD SOLENOID VALVE NO.1, NO.2 INSPECTIONSystem Inspection

1. Carry out the “FICD System Inspection”.(Refer to TROUBLESHOOTING, SYSTEM INSPECTION, FICD System Inspection.)

2. If not as specified, perform the further inspectionfor the FICD solenoid valve No.1, No.2.

Airflow Inspection


1. Disconnect the negative battery cable.2. Remove the FICD solenoid valve No.1, No.2.

(Refer to INTAKE-AIR SYSTEM, INTAKE-AIRSYSTEM REMOVAL/INSTALLATION.)

3. Inspect for airflow between ports of the solenoidvalve.

: Continuity : Airflow

StepTerminal Port

StepA B A B C

1

2 B+ GND

B A

B+GND

AIR FILTER

A

B

C

4. If not as specified, replace the faulty FICD solenoidvalve.If as specified but the “System Inspection” is failed,inspect following:

Vacuum hose improper routing, kinks or leakage. Open circuit GND circuit (FICD solenoid valve No.1 connector

terminal B and PCM connector terminal C) GND circuit (FICD solenoid valve No.2 connector

terminal B and PCM connector terminal P) Power circuit (FICD solenoid valve No.1 connector

terminal A and engine switch connector terminalIG1)

Power circuit (FICD solenoid valve No.2 connectorterminal A and engine switch connector terminalIG1)

ENGINE SWITCH


BA

CA

DB

Short circuit GND circuit (FICD solenoid valve No.1 connector

terminal B and PCM connector terminal IG1) GND circuit (FICD solenoid valve No.2 connector

terminal B and PCM connector terminal P) Power circuit (FICD solenoid valve No.1 connector

terminal A and engine switch connector terminalIG1 to GND)

Power circuit (FICD solenoid valve No.2 connectorterminal A and engine switch connector terminalIG1 to GND)

5. Repair or replace faulty areas.6. Install the FICD solenoid valve No.1, No.2.7. Reconnect the negative battery cable.


CONTINUED


FUEL SYSTEM

F2–22

TIMER CONTROL VALVE (TCV) INSPECTIONEurope and UK

1. Carry out the “Timer Control Valve (TCV) ControlInspection”. (Refer to TROUBLESHOOTING, SYSTEM INSPECTION, Timer Control Valve (TCV) Control Inspection.)

2. If not as specified, perform the further inspectionfor the TCV.

Continuity Inspection


1. Disconnect the negative battery cable.2. Disconnect the FIP connector (8–pin terminal).3. Verify that there is continuity between the FIP

connector terminal D and TCV body.

FIP

A

COMPONENT SIDE CONNECTOR(VIEW FROM TERMINAL SIDE)

B

C

D

E

F

G

H

4. If not as specified, send TCV to a distributor forreplacement. If the TCV is okay, but PCM terminalvoltage is out of specification, inspect as followsand repair or replace as necessary.Open circuit Power circuit (FIP connector terminal D and

PCM connector terminal H)Short circuit FIP connector terminal D and PCM connector

terminal H to GND5. Repair or replace faulty areas.6. Reconnect the FIP connector.


CONTINUED


EXHAUST SYSTEM

F2–23

EXHAUST SYSTEMEXHAUST SYSTEM INSPECTION

1. Start the engine and inspect each exhaust system component for exhaust gas leakage.2. If leakage is found, repair or replace as necessary.


Warning When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait




WL

TURKEY and GENERAL(R.H.D., L.H.D.)

EUROPE and UK

1 Tail pipe

2 Main silencer

3 Middle pipe (Turkey and General (R.H.D.,L.H.D.)

OC (Europe and UK)

4 Front pipe

5 Exhaust manifold insulator

6 Exhaust manifold


CONTINUED


EXHAUST SYSTEM

F2–24


WL TURBO

TURKEY and GENERAL(R.H.D., L.H.D.)

EUROPE and UK

1 Tail pipe

2 Main silencer

3 Middle pipe (General (L.H.D.)) OC (Europe and UK)

4 Front pipe

5 Exhaust manifold insulator

6 Joint pipe

7 Turbocharger+ Removal Note

8 Oil pipe+ Installation Note

9 Exhaust manifold


CONTINUED


EXHAUST SYSTEM, EMISSION SYSTEM

F2–25

Oil Pipe Installation Note Be sure to confirm that the turbocharger is installed

correctly, then install the oil pipe.

Water pipe Install the water pipe and tighten to the specified

torque.


OIL PIPE

WATER PIPE

Turbocharger Removal Note Do not drop the turbocharger. Do not bend the wastegate actuator mounting or

rod. Cover the intake, exhaust and oil passages to

prevent dirt or other objects from entering.

EMISSION SYSTEMROLLOVER VALVE INSPECTION

1. Remove the rollover valve.(Refer to FUEL SYSTEM, FUEL TANKREMOVAL/INSTALLATION.)

2. Blow from port A and verify that there is airflow.

A

3. Turn the valve over and blow from port A. Verifythat there is no airflow.

A

4. If not as specified, replace the rollover valve.

EVAPORATIVE CHAMBER INSPECTIONIf equipped

1. Remove the evaporative chamber.(Refer to FUEL SYSTEM, FUEL TANKREMOVAL/INSTALLATION.)

2. Blow from port A and verify that there is airflowfrom port B.

A

B

3. If not as specified, replace the evaporativechamber.


CONTINUED


123456567

EMISSION SYSTEM

F2–26

EGR VALVE INSPECTIONWL Turbo for Europe and UKAirflow Inspection


1. Remove the EGR valve.2. Inspect for airflow between 1 and 2 when vacuum

is applied using a vacuum pump as shown in thefigure.

Vacuum (kPa mmHg, inHg) Airflow

Below –21.3—–25.3–160— –190, –6.3— –7.4

Yes

Except above No

3. If not as specified, replace the EGR valve.

EGR SOLENOID VALVE INSPECTIONWL Turbo for Europe and UKAirflow Inspection


1. Disconnect the negative battery cable.2. Remove the EGR solenoid valve

(Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION, WL Turbo.)

3. Inspect for airflow between ports of the solenoidvalve.

: Continuity : Airflow

StepTerminal Port

StepA B A B C

1

2 B+ GND

B A

B+GND

AIR FILTER

A

B

C

4. If not as specified, replace the EGR solenoid valve.If the EGR solenoid valve is okay, but PCMterminal voltage is out of specification, inspect asfollows and repair or replace as necessary.

Vacuum hose improper routing, kinks or leakage.

Open circuit Power circuit (EGR solenoid valve connector

terminal A and PCM connector terminal 1R) GND circuit (EGR solenoid valve connector

terminal B and body GND through commonconnector)


A B

EGR SOLENOID VALVE

Short circuit EGR solenoid valve connector terminal A and PCM

connector terminal 1R.5. Repair or replace faulty areas.6. Install the EGR solenoid valve connector.

EGR PIPE, EGR VALVE REMOVAL/INSTALLATIONWL Turbo for Europe and UK



7.9—10.7 N·m 80—110 kgf·cm,69.5—95.4 in·lbf

19—251.9—2.6, 14—18

19—251.9—2.6, 14—18

35—403.5—4.0,25—29

1 EGR pipe

2 EGR valve


CONTINUED


CONTROL SYSTEM

F2–27

CONTROL SYSTEMCOMPONENT PARTS

WL TURBO

WL TURBO

1 Glow indicator light

2 Temperature control dial

3 Engine switch

4 PCM



7 EGR solenoid valve*1

8 ECT sensor

9 DLC

10 A/C relay

11 TCV*2

12 Control lever position sensor*2

13 Glow plug

14 NE sensor

15 Idle switch*2

16 Starter

17 Glow plug relay

*1: WL Turbo for Europe and UK*2: Europe and UK


CONTINUED


CONTROL SYSTEM

F2–28

POWERTRAIN CONTROL MODULE (PCM)REMOVAL/INSTALLATION

1. Disconnect the battery negative cable.2. Remove the driver’s side front side trim.

(Refer to Section S, TRIM, FRONT SIDE TRIMREMOVAL/INSTALLATION.)


8.9—12.7 N·m 90—130 kgf·cm, 78—112 in·lbf

1 PCM connector

2 PCM installation nut

3 PCM

POWERTRAIN CONTROL MODULE (PCM)INSPECTION

Caution The PCM terminal voltages vary with

change in measuring conditions andvehicle conditions. Always carry out a totalinspection of the input systems, outputsystems, and PCM to determine the causeof trouble. Otherwise, a wrong diagnosiswill be made.

1. Remove the driver’s side front side trim. (Refer to Section S, TRIM, FRONT SIDE TRIMREMOVAL/INSTALLATION.)

2. Remove the PCM with the connector connected.(Refer to POWERTRAIN CONTROL MODULE(PCM) REMOVAL/INSTALLATION.)

Note With the PCM connector connected, body

ground the voltmeter negative (–) lead andmeasure the voltage at each PCM terminal byinserting the voltmeter positive (+) lead.

3. Measure the voltage of each PCM terminals byusing a voltmeter.

4. If the output voltage is not normal while each inputvoltage is normal, inspect the related devicesystems. When they are normal, replace the PCM.

5. Install the PCM. (Refer to POWERTRAIN CONTROL MODULE (PCM)REMOVAL/INSTALLATION.)

6. Install the driver’s side front side trim. (Refer to Section S, TRIM, FRONT SIDE TRIMREMOVAL/INSTALLATION.)


CONTINUED


CONTROL SYSTEM

F2–29

Terminal Voltage (Reference)

O M K I G E C ABDFHJLNP

O M K I G E C A

BDFHJLNPS Q

RT

Europe and UK Turkey and General (R.H.D. ,L.H.D.)

Termi-nal

Signal Connectedto

Test condition Voltage(V)

Action

A – – – – –

A*1 Constantvoltage

Controlleverposition

Engineswitch

ON Approx.5.0

Inspect related harness.

ositionsensor

EGRvalve

OFF Below1.0

Inspect PCM. Inspect related harness.

valvepositionsensor

Idle Approx.5.0

B Systemground

Ground Constant Below1.0


C FICD control

FICD sole-noid valveNo.1

Idle ECT is below 20°C 68°F. Below1.0

Inspect FICD solenoidvalve No.1.

+ FUEL SYSTEM, FICDSOLENOID VALVE No 1

ECT is above 20°C 68°F. B+SOLENOID VALVE No.1,No.2 INSPECTION

Inspect related harness

D Start Engineswitch

Engine switch is on. Below1.0


(Starter) While cranking Approx.10

E ECT ECT sensor Engineswitch is on.

ECT is 20°C 68°F. Approx.3.1

Inspect engine coolanttemperature sensor.

+ ECT SENSORAfter warm-up Approx.

0.8

+ ECT SENSORINSPECTION


F Enginespeed

NE sensor Engine switch is on. Approx.0

Inspect NE sensor.+ NE SENSOR

(Input) Idle Approx.0.05

INSPECTION Inspect related harness

G A/C(With A/C)

Temperaturecontrol dial

Engineswitch is on.

Temperature control dial isoff and fan switch is off.

B+ Inspect microswitch.+ Section U, CONTROL

SYSTEM, HEATERCONTROL UNITINSPECTION

Temperature control dial isat position other than offand fan switch is on.

Below1.0

Inspect fan switch.+ Section U, CONTROL

SYSTEM, HEATERCONTROL UNITINSPECTION


H – – – – –

H*1 Idle (Controllever open

Idle switch Engineswitch is on.

Accelerator pedal is de-pressed.

B+ Inspect idle switch.+ IDLE SWITCH

or close) Accelerator pedal is re-leased.

Below1.0

INSPECTION Inspect related harness.

*1: Europe and UK


CONTINUED


CONTROL SYSTEM

F2–30

Termi-nal

Signal Connectedto


Action

I Glow plugvoltage

Glow plug ECT is be-low 60°C140°F.

For less than approx. 15seconds after turning engine switch on.

B+ Inspect related harness

Over approx. 15 secondsafter turning engine switchon.

Below1.0

For less than 10 minutesafter starting engine.

B+

Over 10 minutes afterstarting engine.

Below1.0

While cranking B+

ECT isabove 60°C140°F.

For less than approx. 2 seconds after turning en-gine switch on.

B+


Below1.0

While cranking B+

J Powersupply

Engineswitch

Engineswitch

OFF Below1.0

Inspect engine switch.+ Section T, POWER

SYSTEM, IGNITIONON B+

,SWITCH INSPECTION


J*1 Control le-ver position(Detection)

Control le-ver positionsensor

Engineswitch is on.

Accelerator pedal is fullyopen.

Approx.4.2

Inspect control lever posi-tion sensor.

+ CONTROL LEVER( )Accelerator pedal is fullyclosed.

Approx.0.8—1.5

POSITION SENSORINSPECTION


K Enginespeed (Out

Instrumentcluster

Engine switch is on. B+ Inspect related harness.speed (Out-put)

clusterIdle 6.9—7.1

L*1 Powersupply

Engineswitch

Engineswitch

OFF Below1.0

Inspect engine switch.+ Section T, POWER

SYSTEM, IGNITIONON B+

,SWITCH INSPECTION


L*2 A/C control(With A/C)

A/C relay Engine switch is on. B+ Inspect A/C relay.S ti U CONTROL(With A/C)

Idle A/C is not operating B++ Section U, CONTROL

SYSTEM, A/C RELAYA/C is operating Below

1.0

SYSTEM, A/C RELAYINSPECTION


M Glow indica-tor light con-

Glow indica-tor light

Engine switch is off. Below1.0

Inspect glow indicatorlightg

trolg

Engine switch is on and within approx. 4.5sec. (25 °C 77 °F).

g+ Section T, WARNING

AND INDICATORSYSTEM, WARNING

Over 4.5 seconds (25 °C 77 °F) afterturning engine switch on.

B+ AND INDICATOR LIGHTBULB REPLACEMENT


N*1 A/C control(With A/C)

A/C relay Engine switch is on. B+ Inspect A/C relay.S ti U CONTROL(With A/C)

Idle A/C is not operating B++ Section U, CONTROL

SYSTEM, A/C RELAYA/C is operating Below

1.0

SYSTEM, A/C RELAYINSPECTION


N*2 – – – – –*1: Europe and UK*2: Turkey and General (R.H.D., L.H.D.)


CONTINUED


CONTROL SYSTEM

F2–31

Termi-nal

Signal Connectedto


Action

O Glow sys-tem

Glow plugrelay

Engine cool-ant tempera-ture is below

For less than approx. 15seconds after turning en-gine switch on.

B+ Inspect glow plug relay.+ INTAKE-AIR SYSTEM,

GLOW PLUG RELAY60°C140°F.


Below1.0

INSPECTION Inspect related harness.

For less than 10 minutesafter starting engine.

B+

Over 10 minutes afterstarting engine.

Below1.0

While cranking B+

Engine cool-ant tempera-ture is

For less than approx. 2 se-conds after turning engineswitch on.

B+

above 60°C140°F.


Below1.0

While cranking B+

P FICD control

FICD sole-noid valveNo.2

Idle Temperature control dialis not at OFF

Engine coolant temper-ature is below 60°C140°F.

Below1.0

Inspect FICD solenoidvalve No.2.

+ FUEL SYSTEM, FICDSOLENOID VALVE No.1,No.2 INSPECTION

Temperature control dialis not at OFF

Engine coolant temper-ature is above 60°C140°F.

B+ Inspect related harness.

Q – – – – –

Q*1 Timer control

TCV Engine switch is on. B+ Inspect TCV.+ CONTROL SYSTEM,

Idle Below1.0

TIMER CONTROL VALVE(TCV) INSPECTION


R – – – – –

R*3 EGR valvecontrol

EGRsolenoidvalve

Engine switch is on. B+ Inspect EGR solenoidvalve.

+ EMISSION SYSTEMvalveIdle Below

1.0

+ EMISSION SYSTEM,EGR SOLENOID VALVEINSPECTION


S – – – – –

S*1 Diagnostictest mode

Data linkconnector

Engineswitch is on

Open terminal TEN B+ Inspect related harness.test mode connector

(DLC) (Ter-minal TEN)

switch is on.Short terminal TEN Below

1.0

T – – – – –

T*1 DTC output Data linkconnector(DLC) (Ter

No DTC output Below1.0


(DLC) (Ter-minal FEN) DTC output 0—B+

*1: Europe and UK*2: Turkey and General (R.H.D., L.H.D.)*3: WL Turbo for Europe and UK


CONTINUED


CONTROL SYSTEM

F2–32

NE SENSOR INSPECTION


1. Disconnect the NE sensor connector.2. Measure the resistance between the NE sensor

connector terminals A and B by using anohmmeter.

A B

Specification800—920 Ω

3. If not as specified, replace the NE sensor.

Tightening torque7.9—10.7 N·m

80—110 kgf·cm, 69.5—95.4 in·lbf

4. If NE sensor is okay, but PCM terminal F voltage isout of specification, inspect the following:Open circuit Engine speed (input) circuit (NE sensor

connector terminal A and PCM connectorterminal F)

GND circuit (NE sensor connector terminal Band PCM connector terminal B)

Short circuit NE sensor connector terminal A and PCM

connector terminal F to GND5. Repair or replace faulty areas.6. Reconnect the NE sensor connector.

ENGINE COOLANT TEMPERATURE (ECT) SENSORINSPECTION


1. Drain the engine coolant from the radiator. (Refer to Section E, ENGINE COOLANT, ENGINECOOLANT REPLACEMENT.)

2. Disconnect the ECT sensor connector.3. Remove the ECT sensor.4. Place the sensor in water with a thermometer, and

heat the water gradually.

A B

5. Measure the resistance between engine coolanttemperature sensor terminals A and B by using anohmmeter.

SpecificationWater temperature ( °C °F) Resistance (k Ω)

20 68 2.27—2.73

80 176 0.29—0.34

6. If not as specified, replace the ECT sensor.7. Refill the radiator with the specified engine coolant.

(Refer to Section E, ENGINE COOLANT, ENGINECOOLANT REPLACEMENT.)

8. Install the ECT sensor.

Tightening torque16—23 N·m 1.6—2.4 kgf·m, 12—17 in·lbf

9. If ECT sensor is okay, but PCM terminal E voltageis out of specification, inspect as follows:


CONTINUED


CONTROL SYSTEM

F2–33

Open circuit Reference voltage circuit (ECT sensor

connector terminal A and PCM connectorterminal E through common connector)

GND circuit (ECT sensor connector terminal Band PCM connector terminal B throughcommon connector)

Short circuit ECT sensor connector terminal A and PCM

connector terminal E through commonconnector to GND

10. Repair or replace faulty areas.11. Reconnect the ECT sensor connector.

IDLE SWITCH INSPECTIONEurope and UKContinuity Inspection


1. Disconnect the negative battery cable.2. Disconnect the 8-pin connector of FIP.3. Inspect for continuity between the idle switch

terminal E and ground using an ohmmeter.

COMPONENT SIDE CONNECTOR(VIEW FROM TERMINAL SIDE)

E

H

GCA

FDB

Specification: Continuity

Measuring Terminalgcondition E GND

Not accelerated

Other

Caution Turning the idle switch with its connector

connected can break the harness. Be sureto disconnect the connector when turningthe idle switch more than one rotation.

4. If not as specified, loosen the idle switch locknutand adjust the continuity by turning the idle switch.

5. If not as specified, replace the idle switch. If theidle switch is okay, but PCM terminal voltage is outof specification, inspect as follows and repair orreplace as necessary.

Open circuit Power supply circuit (Idle switch connector terminal

E and PCM connector terminal 2H throughcommon connector)

GND circuit (Idle switch connector terminal andbody GND)


C

B

AEG

DFH

Short circuit Power supply circuit (Idle switch connector terminal

E and PCM connector terminal H through commonconnector to GND)

6. Repair or replace faulty areas.7. Reconnect the 8-pin connector of FIP.

CONTROL LEVER POSITION SENSORINSPECTIONEurope and UKOutput Voltage Inspection


1. Verify that the FIP control lever is fully closed.2. Turn the engine switch on and measure the PCM

terminal J voltage.

SpecificationMeasuring condition Voltage (V)

Accelerator pedal is fullyopen.

Approx. 4.2

Accelerator pedal is fullyclosed.

Approx. 0.8—1.5

3. If not as specified, replace the control leverposition sensor. When the reading is out ofspecification, send the FIP with the control leverposition sensor to a distributor to repair. If the PCMterminal voltage is out of specification, inspect asfollows and repair or replace as necessary.

Open circuit Constant voltage circuit (Control lever position

sensor connector terminal B and PCM connectorterminal A through common connector)

Control lever position signal circuit (Control leverposition sensor connector terminal A and PCMconnector terminal J through common connector)

GND circuit (Control lever position sensorconnector terminal C and PCM connector terminalB through common connector)


CONTINUED


CONTROL SYSTEM

F2–34


C

B

AEG

DFH

Short circuit Control lever position sensor connector terminal B

and PCM connector terminal A through commonconnector to GND

Control lever position sensor connector terminal Aand PCM connector terminal J through commonconnector to GND

4. Repair or replace faulty areas.5. Reconnect the 8-pin connector of FIP.


CONTINUED



F2–35

ON-BOARD DIAGNOSTIC SYSTEMEurope and UK onlyDTC READING PROCEDUREUsing the SST (Self-Diagnosis Checker)

1. Connect the SSTs to the DLC located in the enginecompartment and GND the black (negative) lead tothe body.

49 B019 9A0

49 H018 9A1A

DLC

2. Set the select switch on the SST (self-diagnosischecker) to A.

3. Turn the dial switch on the SST (system selector)to 1, and the test switch to SELF TEST.

4. Turn the engine switch on.5. Verify that the buzzer sounds for approximately

3 seconds and code “88” flashes for 5 seconds. IfDTC is not detected, “00” will then be indicated.

Note If the “88” does not flash, inspect +B terminal of

the data link connector, and the relatedharnesses and connectors.

If the “88” flashes and the buzzer sounds morethan 20 seconds, inspect the harness betweenthe PCM terminal and the DLC. If the harnessis normal, replace the PCM and inspect.

6. If any DTCs are indicated, inspect the appropriateareas and repair as necessary.

Note A DTC consists of four numbers. They are

flashed one by one in the right window on thedisplay. (“1” is always shown on the leftwindow.)

When there are multiple malfunctions, thecodes are displayed in numerical order.

7. After completion of repairs, erase all DTCs fromthe memory. (Refer to AFTER REPAIRPROCEDURE.)

8. Remove the SSTs.

Using the Voltmeter1. Turn the engine switch off.2. Connect the DLC located in the engine

compartment terminal TEN and GND using ajumper wire.

Caution Connecting the wrong DLC terminals may

possibly cause a malfunction. Carefullyconnect the specified terminals only.

3. Connect the negative battery lead of voltmeter(20V range) to the DLC terminal FEN, and thepositive lead to the DLC terminal +B.

FEN

TENGND+B

DLC

4. turn the engine switch on.5. The voltmeter indicates the battery positive voltage

for approximately 3 seconds, then indicates 0V.6. Read the DTCs indicated by the movement of the

voltmeter’s needle. If DTC is not detected, theneedle does not move.

7. If any DTCs are indicated, inspect the appropriateareas and repair as necessary.

8. After completion of repairs, erase all DTCs fromthe memory. (Refer to AFTER REPAIRPROCEDURE.)

9. Remove the voltmeter and the jumper wire.

AFTER REPAIR PROCEDURE1. After repairs, disconnect the negative battery cable

for at least 20 seconds, and depress the brakepedal. Reconnect the negative battery cable.


Note If the engine will not start, keep the starter

operated for 5-6 seconds.

3. Perform the “DTC READING PROCEDURE”again.

4. Verify that the DTC is not detected.


CONTINUED



F2–36

DTC INSPECTIONDTC Table

DTC No. Indicator Pattern Condition

09Engine coolant temperature (ECT) sensormalfunction

12 Control lever position sensor malfunction

36 Glow plug relay malfunction

DTC 09 ENGINE COOLANT TEMPERATURE (ECT) SENSOR MALFUNCTION

DETECTIONCONDITION

Input value to PCM is excessively high or low for more than 2.0 sec.

POSSIBLECAUSE

ECT sensor malfunction Open or short circuit in wiring from ECT sensor terminal A to PCM terminal E Open or short circuit in wiring from ECT sensor terminal B to PCM terminal B

STEP INSPECTION ACTION

1 Does ECT sensor or PCM connector have Yes Repair or replace connector, then go to Step 6.poor connection? No Go to next step.

2 Disconnect ECT sensor connector. Yes Go to next step.Turn engine switch on. Is there 5 V atconnector terminal A?

No Inspect for open or short circuit in wiring harness. (PCMterminal B–ECT sensor terminal B)

3 Is there continuity between connector Yes Go to next step.terminal A and PCM terminal E? No Repair or replace wiring harness, then go to Step 6.

4 Is ECT sensor okay?+ CONTROL SYSTEM, ENGINE

Yes Go to next step.

COOLANT TEMPERATURE (ECT)SENSOR INSPECTION

No Replace ECT sensor, then go to Step 6.

5 Clear DTC from memory. Yes Go to Step 1.Is same code No. present after performing“After Repair Procedure”?

No Intermittent poor connection in harnesses or connector. Repair connectors and/or harnesses, then go to next step.

6 Clear DTC from memory.Is there any DTC present after performing

Yes Go to applicable DTC inspection.Is there any DTC present after performing“After Repair Procedure”? No Troubleshooting completed.


PCM (20 PIN)ECT SENSOR

A B

HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDE)

J BE


CONTINUED



F2–37

DTC 12 CONTROL LEVER POSITION SENSOR MALFUNCTION

DETECTIONCONDITION

Input voltage from control lever positIon sensor is below 0.1 V or above 4.75 V when continued for 1.0sec.

When idle switch is on, input voltage from control lever position sensor is below 0.35V or above 1.39V.

POSSIBLECAUSE

Control lever position sensor malfunction Idle switch malfunction Open circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal C to PCM termi-

nal B Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal A to

PCM terminal J Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal B to

PCM terminal A Open or short circuit wiring from idle switch (FIP connector: 8pin) terminal E to PCM terminal H


1 Does control lever position sensor connector Yes Repair or replace connectors, then go to Step 7.or PCM connector have poor connection? No Go to next step.

2 Disconnect control lever position sensor Yes Go to next step.connector. Turn engine switch on. Is there 5 V at connector terminal B?

No Inspect for open or short circuit in wiring harness. (PCMterminal A–control lever position sensor terminal B)

3 Is there continuity between connector Yes Go to next step.terminal A and PCM terminal J? No Repair or replace wiring harness, then go to Step 7.

4 Is there continuity between connector Yes Replace control lever position sensor, then go to Step 7.terminal C and PCM terminal B? No Repair or replace wiring harness, then go to Step 7.

5 Is there continuity between connector Yes Go to next step.terminal E and PCM terminal H? No Repair or replace wiring harness, then go to Step 7.

6 Is idle switch okay?+ CONTROL SYSTEM IDLE SWITCH

Yes Go to next step.+ CONTROL SYSTEM, IDLE SWITCH

INSPECTION No Replace idle switch.


No Intermittent poor connection in harness or connector. Repair connector and/or harness, then go to next step.





PCM (20 PIN)CONTROL LEVER POSITION SENSOR

G E C A

H F D BJ

A

B


CONTINUED



F2–38

DTC 36 GLOW PLUG RELAY MALFUNCTION

DETECTIONCONDITION

When the glow plug relay is on, current voltage signal of the relay below 1.0 V is inputted to the PCMcontinuously for more than 1.0 sec.

When the glow plug relay is off, signal of the relay current voltage above 4.0 V is inputted to the PCMcontinuously for more than 1.0 sec.

POSSIBLECAUSE

Glow plug relay malfunction Open or short circuit in wiring from PCM terminal O to glow plug relay terminal A (BR) Open or short circuit in wiring from PCM terminal I to glow plug relay terminal A (B) Open or short circuit in wiring from glow plug relay terminal A (R) to glow fuse


1 Does glow plug relay connector or PCM Yes Repair or replace connectors, then go to Step 5.connector have poor connection? No Go to next step.

2 Remove glow plug relay.Is there continuity between connectorterminal A and PCM terminal O?


terminal A and PCM terminal O? Is there continuity between connectorterminal A (B) and PCM terminal I?

No Repair or replace wiring harness.

3 Is there continuity between connector Yes Go to next step.terminal B and body GND? No Repair or replace wiring harness.

4 Is there continuity between connector Yes Go to next step.terminal A (R) and glow fuse? No Repair or replace wiring harness.

5 Is glow plug relay okay?+ INTAKE AIR SYSTEM GLOW PLUG

Yes Go to next step.+ INTAKE-AIR SYSTEM, GLOW PLUG

RELAY INSPECTION No Replace glow plug relay.


No Intermittent poor connection in harnesses or connectors. Repair connectors and/or harnesses, then go to next step.



PCM (20 PIN)


A A

A

B

HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)

GLOW PLUG RELAY

(WIRE COLOR: R)

(WIRE COLOR: B)

IO


CONTINUED


TROUBLESHOOTING

F2–39

TROUBLESHOOTINGFOREWORDBefore processing with the following troubleshooting,refer to section GI to understand the basictroubleshooting procedure.

TROUBLESHOOTING ITEM TABLE Confirm trouble symptom by using the following

diagnostic index, then go to appropriatetroubleshooting chart.

If a diagnostic trouble code is displayed, proceedwith inspection steps for the code.

No. TROUBLESHOOTING ITEMS DESCRIPTION

1 Melts main or other fuse —

2 Will not crank Starter does not work.

3 Hard start/long crank/erratic start/erratic crank Starter cranks engine at normal speed but engine requiresexcessive cranking. Battery is in normal condition.

4 Engine stalls After start Engine stops unexpectedly at idle and/or after start.

At idle

5 Cranks normally but will not start Starter cranks engine at normal speed but engine will notrun.Refer to “ENGINE STALLS” if this symptom appears afterengine stall. Fuel is in tank Battery is in normal condition.

6 Slow return to idle/fast idle Engine takes more time than normal to return to idle speed.Engine speed continues at fast idle after warm-up.

7 Engine runs rough/rolling idle Engine speed fluctuates between specified idle speed andlower speed and excessive engine shake.Idle speed is too slow and engine shakes excessively.

8 Runs on Engine runs after engine switch is turned off.

9 Engine stalls/quits Acceleration/cruise Engine stops unexpectedly at beginning of acceleration dur-ing acceleration or while cruising.

Engine runs rough Acceleration/cruise Engine speed fluctuates during acceleration or cruising.

Misses Acceleration/cruise Engine misses during acceleration or cruising.

Buck/jerk Acceleration/cruise/deceleration

Vehicle bucks/jerks during acceleration, cruising, or decel-eration.

Hesitation/stumble Acceleration Momentary pause at beginning of acceleration or during ac-celeration.

Surges Acceleration/cruise Momentary minor irregularity in engine output.

10 Lack/loss of power Acceleration/cruise Performance is poor under load (i.e. power down whenclimbing hills).

11 Poor fuel economy Fuel economy is unsatisfactory.

12 High oil consumption/leaks Oil consumption is excessive.

13 Cooling system concerns Overheating Engine runs at higher than normal temperature/overheats.

14 Cooling system concerns Runs cold Engine does not reach normal operating temperature.

15 Excessive black smoke Excessive black smoke is observed in exhaust gas.

16 Engine noise Engine noise from under hood.

17 Vibration concerns (engine) Vibration from under hood or driveline.

18 A/C does not work. A/C compressor magnetic clutch does not engage when A/Cis turned on.

19 A/C always on/A/C compressor runs continuously. A/C compressor magnetic clutch does not disengage.

20 Intermittent concerns Symptom occurs randomly and is difficult to diagnose.


CONTINUED


SYMPTOM TROUBLESHOOTING: Symptom 1-Melts main or other fuse F2-40 Symptom 2-Will not crank F2-41 Symptom 3-Hard start/long crank/erratic start/erratic crank F2-42-43 Symptom 4-Engine stalls-after start/at idle F2-43-44 Symptom 5-Cranks normally but will not start F2-45-46 Symptom 6-Slow return to idle/fast idle F2-46 Symptom 7-Engine runs rough/rolling idle F2-47-48 Symptom 8-Runs on F2-49 Symptom 9-Engie stalls/quits-acceleration/cruise

- Engine runs rough – acceleration/cruise - Misses-acceleration/cruise - Buck/jerk – acceleration/cruise/deceleration - Hesitation/stumble – acceleration

- Surges – acceleration/cruise F2-49-50 Symptom 10-Lack/loss of power-acceleration/cruise F2-51-52 Symptom 11-Poor fuel economy F2-53 Symptom 12-High oil consumption/leaks F2-54 Symptom 13-Cooling system concerns-overheating F2-55 Symptom 14-Cooling system concerns-runs cold F2-55 Symptom 15-Excessive black smoke F2-56 Symptom 16-Engine noise F2-56-58 Symptom 17-Vibration concerns (engine) F2-58 Symptom 18-A/C does not work F2-58-59 Symptom 19-A/C is always on/a/c compressor runs continuously F2-59-60 Symptom 20-Intermittent concerns F2-60


RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

CONTINUED

TROUBLESHOOTING

F2–40

SYMPTOM TROUBLESHOOTINGSYMPTOM 1 MELTS MAIN OR OTHER FUSE

TROUBLESHOOTING HINTSInspect the condition of the fuse.

Shorted harnessDeterioration

Repair shorted harness and replace fuseRepair shorted harness and replace fusefuse Replace fuse

Damaged Fuse Related Wiring Harness

MAIN (100 A) Main fuse Engine switch Generator PCM

Blower relay Blower fan motor

A/C relay Refrigerant pressure switch

HEAD (30 A) HEAD fuse Generator

GLOW (60 A) Glow plug relay Glow plugs

ENGINE (15 A) Engine fuse PCM FICD solenoid valve No.1 FICD solenoid valve No.2 FCV


CONTINUED


TROUBLESHOOTING

F2–41

SYMPTOM 2 WILL NOT CRANK

DESCRIPTION Starter does not work.

POSSIBLECAUSE

Open starter circuit between battery and starter through engine switch Starter malfunction Seized/hydrolocked engine, flywheel

STEP INSPECTION RE-SULTS

ACTION

1 Verify the following: Battery condition Battery connection


Battery connection Fuses

Are all items okay?

No Service as necessary and repeat Step 1.

2 Turn engine switch to START. Yes Go to next step.Is clicking sound heard from starter? No Go to Step 6.

3 Do any other electrical accessories work? Yes Go to next step.

No Inspect the charging system.+ Section G, CHARGING SYSTEM

4 Disconnect battery negative cable.Disconnect engine switch and starter connec-tors.Inspect for electrical connections, loose wire,bent or corroded terminals. Inspect for continuity on following circuits:


Ins ect for continuity on following circuits: Engine switch connector terminal STA and

starter terminal S Battery positive cable and starter magnet

switch terminal B.Are all circuits okay?

No Repair or replace open circuit.

5 Inspect engine switch.+ Section T, POWER SYSTEM, IGNITION


SWITCH INSPECTION.Is engine switch okay?

No Replace engine switch.

6 Inspect starting system.Is starting system okay?

Yes Inspect for seized/hydrolocked engine, flywheel.+ Section H, CLUTCH, FLYWHEEL INSPECTION

No Service as required.+ Section G, STARTING SYSTEM, STARTER

INSPECTION


CONTINUED


TROUBLESHOOTING

F2–42

SYMPTOM 3 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK

DESCRIPTION Starter cranks engine at normal speed but engine requires excessive cranking.Battery is in normal condition.

POSSIBLECAUSE

Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating Glow system malfunction

Fuel leakage Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression pressure Fuel line clogging


ACTION

1 Verify the following: Fuel quality including water contamination Loose bands on intake-air system


y Cracks on intake-air system parts Air cleaner element restriction

Are all items okay?


2 Is engine overheating? Yes Go to flowchart No.13 for “COOLING SYSTEM CONCERNS OVERHEATING”.

No Go to next step.

3 Does engine start normally after warm-up? Yes Inspect glow system operation.+ SYSTEM INSPECTION, Glow System InspectionReplace any defective parts as necessary. If quick start system is okay, go to next step.

No Go to next step.

4 Is idle speed correct? Yes Go to next step.

No Adjust idle speed.+ ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT

5 Is there any restriction in exhaust system? Yes Repair or replace as necessary.

No Go to next step.

6 Inspect for fuel leakage from fuel pipe. Yes Repair or replace as necessary.Is any fuel leakage found in fuel pipe? No Go to next step.

7 Measure engine compression. Yes Go to Step 9.Is compression okay? No Go to next step.

8 Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks

Is timing belt okay?

Yes Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket. Damaged valve seat. Worn valve stem or valve guide.

Repair or replace as necessary.

No If tension or timing of timing belt is incorrect, adjusttiming belt.If timing belt is broken, damaged or cracked, replacethe timing belt.

9 Inspect injection timing. Yes Go to next step.Is injection timing okay? No Inspect TCV (if equipped).

+ TIMER CONTROL VALVE (TCV) INSPECTIONIf TCV is okay, adjust injection timing.+ ENGINE TUNE-UP, INJECTION TIMING

ADJUSTMENT


CONTINUED


TROUBLESHOOTING

F2–43


ACTION

10 Remove and inspect injection nozzle as fol-lows: Clogged nozzle

Yes Remove FIP.Inspect FIP.If FIP okay, inspect fuel line for clogging.

Incorrect valve opening pressure Faulty nozzle gasket

Is injection nozzle okay?

No Clogged nozzle or seized needle valve:Disassemble and clean or replace the injection nozzle.Incorrect valve opening pressure:Adjust injection nozzle opening pressure.Faulty nozzle gasket:Replace nozzle gasket.

SYMPTOM 4 ENGINE STALLS – AFTER START/AT IDLE

DESCRIPTION Engine stops unexpectedly at idle and/or after start.

POSSIBLECAUSE

Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating A/C system improper operation Glow system malfunction

Fuel leakage Fuel filter clogging Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression FICD malfunction


ACTION

1 Note: The following test should be performed

on vehicles with immobilizer system.Go to next step for vehicles withoutimmobilizer system

Yes Go to “ON-BOARD DIAGNOSTIC FUNCTION” of immobilizer system.

immobilizer system.

Does immobilizer indicator light flash and indicate?

No Go to next step.



y Cracks on intake-air system parts Air cleaner element restriction

Are all items okay?


3 Is engine overheating? Yes Go to flowchart No.13 for “COOLING SYSTEM CONCERNS-OVERHEATING”.

No Go to next step.

4 Does engine run normally after warm-up? Yes Go to next step.

No Go to Step 6

5 Inspect glow system operation, Yes Go to next step.+ SYSTEM INSPECTION, Glow System

Inspection.Is quick start system operation normal?

No Repair or replace any defective part according to glowsystem operation results.+ SYSTEM INSPECTION, Glow System Inspection

6 Note: If the following test cannot be

performed due to engine stalls, go tonext step


next ste .

Connect the pressure gauge to A/C lines.Turn the fan switch on.Is pressure within specification?+ section U, REFRIGERANT SYSTEM

SERVICE PROCEDURES,REFRIGERANT PRESSURE CHECK.

No If A/C is always on, go to symptom troubleshootingNo.19 “A/C always ON/A/C compressor runs continu-ously”. For other symptoms, inspect following: Refrigerant charging amount. Cooling fan operation.


CONTINUED


TROUBLESHOOTING

F2–44


ACTION

7 Inspect FICD system operation. Yes Go to next step.+ SYSTEM INSPECTION, FICD System

InspectionIs FICD operation normal?

No Inspect the following: Engine coolant temperature sensor

+ CONTROL SYSTEM, ENGINE COOLANTTEMPERATURE SENSOR INSPECTION

Vacuum pump Vacuum leakage around vacuum pump or fittings FICD solenoid valves

+ FUEL SYSTEM, FICD SOLENOID VALVE No.1,No.2 INSPECTION

FICD actuator PCM terminal voltage, J Open circuit between FICD solenoid No.1 connector

terminal B and PCM connector terminal C Open circuit between FICD solenoid No.2 connector

terminal B and PCM connector terminal PRepair or replace any defective part as necessary.If FICD system is okay, go to next step.

8 Depress accelerator pedal slightly.Crank the engine.

Yes Inspect and adjust idle speed.+ ENGINE TUNE-UP, IDLE SPEED ADJUSTMENTIf symptom still appears, go to next step.

Does engine start now? No Go to next step.

9 Inspect fuel leakage from fuel pipe. Yes Repair or replace as necessary.Is any fuel leakage found in fuel pipe? No Go to next step.




Yes Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket. Damaged valve seat Worn valve seat or valve guide


No If tension or timing of timing belt is incorrect, adjusttiming.If timing belt is broken, damaged or cracked, replacetiming belt.

12 Inspect injection timing. Yes Go to next step.Is injection timing okay? No Adjust injection timing.

+ ENGINE TUNE-UP, INJECTION TIMINGADJUSTMENT

13 Inspect fuel filter for clogging. Yes Go to next step.Is fuel filter okay? No Replace fuel filter cartridge.

14 Remove injection nozzle. Yes Go to next step.Inspect injection nozzle for the following: Clogged nozzle Seized needle valve Incorrect valve opening pressure Faulty nozzle gasket



15 Is valve clearance correct? Yes Remove FIP.Inspect FIP.

No Adjust valve clearance.


CONTINUED


TROUBLESHOOTING

F2–45

SYMPTOM 5 CRANKS NORMALLY BUT WILL NOT START

DESCRIPTION Starter cranks engine at normal speed but engine will not run. Refer to “ENGINE STALLS” if this symptom appears after engine stall. Fuel is in tank. Battery is in normal condition.

POSSIBLECAUSE

Poor fuel quality Air cleaner restriction FCV malfunction Low engine compression Fuel leakage

Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction


ACTION


on vehicles with immobilizer system.Go to next step for vehicles withoutimmobilizer system

Yes Go to “ON-BOARD DIAGNOSTIC FUNCTION” of immobilizer system.

immobilizer system.

Does immobilizer indicator light flash and indicate?

No Go to next step.



Cracks on intake-air system parts Air cleaner element restriction Fuses

Are all items okay?

No Service as necessary.Repeat Step 2.

3 Turn engine switch to ON. Yes Go to next step.Is FCV operation sound heard? No Inspect for the following:

Stuck FCV Open circuit in FCV Open wiring harness between engine switch and

FCV. Poor ground of FCV.

4 Measure engine compression. Yes Go to step 6.Is compression okay? No Go to next step.



Yes Inspect for the following: Burnt valve Worn piston, piston ring or cylinder Damaged cylinder head gasket. Damaged valve seat Worn valve stem or valve guide

Repair or replace as necessary.No If tension or timing of timing belt is incorrect, adjust

timing.If timing belt is broken, damaged or cracked, replacetiming belt.

6 Inspect injection timing. Yes Go to next step.Is injection timing okay? No Adjust injection timing.

+ ENGINE TUNE-UP, INJECTION TIMINGADJUSTMENT






CONTINUED


TROUBLESHOOTING

F2–46


ACTION

9 Is valve clearance correct? Yes Remove FIP.Inspect FIP.


SYMPTOM 6 SLOW RETURN TO IDLE/FAST IDLE

DESCRIPTION Engine takes more time than normal to return to idle speed.Engine speed continues at fast idle after warm-up.

POSSIBLECAUSE

Malfunction of ECT sensor Thermostat stuck open FICD malfunction

Injection timing is incorrect. Accelerator cable free play incorrect adjustment Idle speed incorrect adjustment


ACTION

1 Inspect FICD system operation. Yes Go to next step.+ SYSTEM INSPECTION, FICD System

Inspection.Is FICD operation normal?

No Inspect the following: ECT sensor

+ CONTROL SYSTEM, ENGINE COOLANTTEMPERATURE (ECT) SENSOR INSPECTION

FICD solenoid valves+ FUEL SYSTEM, FICD SOLENOID VALVE No.1,

No.2 INSPECTION FICD actuators. PCM terminal voltage (J)

+ CONTROL SYSTEM, PCM INSPECTION Short to ground circuit between FICD solenoid valve

No.1 connector terminal B and PCM connector ter-minal C.

Short to ground circuit between FICD solenoid valveNo.2 connector terminal B and PCM connector ter-minal P

Repair or replace any defective part as necessary.If FICD system is okay, go to next step.

2 Inspect injection timing. Yes Go to next step.+ ENGINE TUNE-UP, INJECTION TIMING

ADJUSTMENT.Is injection timing okay?

No Adjust injection timing.+ ENGINE TUNE-UP, INJECTION TIMING

ADJUSTMENT

3 Remove thermostat and inspect operation.+ section E, THERMOSTAT, THERMOSTAT

INSPECTION.

Is thermostat okay?

Yes Inspect for free play of accelerator cable. Adjust freeplay as necessary. If free play is okay, inspect and adjust idle and/or idle-up speed.+ ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT

No Replace thermostat.


CONTINUED


TROUBLESHOOTING

F2–47

SYMPTOM 7 ENGINE RUNS ROUGH/ROLLING IDLE

DESCRIPTION Engine speed fluctuates between specified idle speed and lower speed and excessive engineshake.Idle speed is too slow and engine shakes excessively.

POSSIBLECAUSE

Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating A/C system improper operation Glow system malfunction

Fuel leakage Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression FICD malfunction


ACTION

1 Verify the following: Fuel quality including water contamination

Yes Go to next step. Fuel quality including water contamination Air cleaner element restriction No Service as necessary and repeat Step 1.

2 Is engine overheating? Yes Go to flowchart No.13 for “COOLING SYSTEM CON-CERNS-OVERHEATING”.

No Go to next step.

3 Does engine run normally after warm-up? Yes Go to next step.

No Go to Step 5.

4 Inspect glow system operation.+ SYSTEM INSPECTION Glow System

Yes Go to Step 6.+ SYSTEM INSPECTION, Glow System

Inspection.

Is glow system operation normal?


5 Note: If the following test cannot be

performed due to engine stalls, go tonext step


next ste .

Connect the pressure gauge to A/C (ifequipped) lines. Turn the blower switch on.Is the pressure within specification?+ section U, REFRIGERANT SYSTEM


No If A/C is always on, go to symptom troubleshootingNo.19 “A/C always ON/ A/C compressor runs continu-ously”. For other symptoms, inspect following: Refrigerant charging amount. Cooling fan operation.

6 Inspect for FICD system operation. Yes Go to next step.+ SYSTEM INSPECTION, FICD System In-

spectionIs FICD operation normal?

No Inspect the following: Engine coolant temperature sensor

+ CONTROL SYSTEM, ECT SENSOR INSPECTION Vacuum pump Vacuum leaks around vacuum pump or fittings FICD solenoid valves

+ FUEL SYSTEM, FICD SOLENOID VALVE No.1,No.2 INSPECTIONInspection

FICD actuators PCM terminal voltage (J)

+ CONTROL SYSTEM, PCM INSPECTION Open circuit between FICD solenoid valve No.1 con-

nector terminal B and PCM connector terminal C. Open circuit between FICD solenoid valve No.2 con-

nector terminal B and PCM connector terminal P.Repair or replace any defective part as necessary.If FICD system is okay, go to next step.


CONTINUED


TROUBLESHOOTING

F2–48


ACTION

7 Depress accelerator pedal slightly.Crank the engine.

Yes Inspect and adjust idle speed.+ ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.If symptom still appears, go to next step.

Does engine start now? No Go to next step.

8 Inspect fuel leakage from fuel pipe. Yes Repair or replace as necessary.Is any fuel leakage found on fuel pipe? No Go to next step.


on vehicles with EGR system. Go tonext step for vehicles without EGRsystem.


Carry out EGR system inspection.+ SYSTEM INSPECTION, EGR System

InspectionIs EGR system okay?

No Repair or replace as necessary.

10 Measure engine compression. Yes Go to Step12.Is compression okay? No Go to next step.



Yes Inspect follows: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket Damaged valve seat Worn valve stem or valve guide


No If tension or timing of timing belt is incorrect, adjusttiming belt.If timing belt is broken, damaged or cracked, replacetiming belt.


+ TIMER CONTROL VALVE (TCV) INSPECTIONIf TCV is okay, adjust injection timing.+ ENGINE TUNE-UP, INJECTION TIMING

ADJUSTMENT




No Clogged nozzle or seized needle valve:Disassemble and clean or replace the fuel injectionnozzle.Incorrect valve opening pressure:Adjust fuel injection nozzle opening pressure.Faulty nozzle gasket:Replace nozzle gasket.

15 Is valve clearance correct? Yes Remove fuel injection pump.Inspect fuel injection pump.



CONTINUED


TROUBLESHOOTING

F2–49

SYMPTOM 8 RUNS ON

DESCRIPTION Engine runs after engine switch is turned off.

POSSIBLECAUSE

FCV malfunction


ACTION

1 Run the engine at idle speed.Disconnect the FCV connector.Verify that the engine stops.Does the engine stop?

Yes Inspect for the following: Short to power line between engine switch and

FCV.Repair or replace wire harness.

No Inspect for FCV stuck to open.

SYMPTOM 9

ENGINE STALLS/QUITS-ACCELERATION/CRUISEENGINE RUNS ROUGH-ACCELERATION/CRUISEMISSES-ACCELERATION/ CRUISEBUCK/JERK-ACCELERATION/CRUISE/DECELERATIONHESITATION/STUMBLE-ACCELERATIONSURGES-ACCELERATION/CRUISE

DESCRIPTION Engine stops unexpectedly at beginning of acceleration, during acceleration or while cruis-ing.

Engine speed fluctuates during acceleration or cruising. Engine misses during acceleration or cruising. Vehicle bucks/jerks during acceleration, cruising, or deceleration. Momentary pause at beginning of acceleration or during acceleration. Momentary minor irregularity in engine output.

POSSIBLECAUSE

Poor fuel quality Starting system malfunction Air leaks from intake-air system Air cleaner restriction Engine overheating A/C system improper operation Fuel leakage

Glow system malfunction Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression Clutch slippage


ACTION

1 Is idle speed stable? Yes Go to next step.

No Go to flowchart No.7 “ENGINE RUNS ROUGH/ROL-LING IDLE”.

2 Is engine overheating? Yes Go to flowchart No.13 “COOLING SYSTEM CON-CERNS OVERHEATING”.

No Go to next step.

3 Does symptom disappear after warm-up? Yes Go to next step.

No Go to Step 5.

4 Inspect for glow system operation. Yes Go to next step.+ SYSTEM INSPECTION, Glow System

Inspection.Is glow system operation normal?


5 Connect the pressure gauge to A/C lines. Yes Go to next step.Turn the blower switch on.Is the pressure within specifications?+ section U, REFRIGERANT SYSTEM


No If A/C is always on, go to symptom troubleshootingNo.19 “A/C ALWAYS ON/ A/C COMPRESSOR RUNSCONTINUOUSLY”. For other symptoms, inspect fol-lowing: Refrigerant charging amount. Cooling fan operation.

6 Inspect air cleaner for clogging. Yes Go to next step.Is air cleaner okay? No Clean or replace air cleaner element.


CONTINUED


TROUBLESHOOTING

F2–50


ACTION


on turbocharger equipped model. Forother models, go to Step 9.

Inspect the hose band between the followingparts:

T b h h i d i

Yes Retighten the hose band.If the concern is resolved, complete the inspection.If the concern still exists, go to next step.

Turbocharger compressor housing and aircleaner

Turbocharger compressor housing andcharge air cooler.

Is the hose band loose?

No Go to next step.

8 Inspect for improper operation, kinks, clogs,or disconnection on the wastegate actuator.

Yes Turbocharger is okay. Go to next step.

+ INTAKE-AIR SYSTEM, WASTEGATEACTUATOR INSPECTION.

Is actuator okay?

No Repair or replace as necessary.If the concern is resolved, complete the inspection.If the concern still exists, the turbocharger is okay. Go to next step.

9 Remove injection nozzle. Yes Go to next step.Inspect injection nozzle for the following Clogged nozzle. Seized needle valve Incorrect valve opening pressure. Faulty nozzle gasket.




No Go to next step.

11 Inspect for fuel leakage from pipe. Yes Repair or replace as necessary.Is any fuel leakage found in fuel pipe? No Go to next step.

12 Inspect fuel filter for clogs. Yes Go to next step.Is fuel filter okay? No Replace fuel filter cartridge.




Yes Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket Damaged valve seat Worn valve stem and valve guide


No If tension or timing of timing belt is incorrect, adjusttiming belt. If timing belt is broken, damaged or cracked, replacetiming belt.

15 Inspect injection timing.Is injection timing okay?

Yes Inspect follows: Clutch slippage FIP


ADJUSTMENT


CONTINUED


TROUBLESHOOTING

F2–51

SYMPTOM 10 LACK/LOSS OF POWER-ACCELERATION/CRUISE

DESCRIPTION Performance is poor under load (i.e. power down when climbing hills).

POSSIBLECAUSE

Poor fuel quality Starting system malfunction Air leaks from intake-air system Air cleaner restriction Engine overheating A/C system improper operation Clutch slippage Fuel leakage

Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression pressure Turbocharger malfunction Brake system drags EGR system malfunction (WL Turbo)


ACTION

1 Is idle speed stable? Yes Go to next step.

No Go to flowchart No.7 “ENGINE RUNSROUGH/ROLLING IDLE”.

2 Is engine overheating? Yes Go to flowchart No. 13 “COOLING CONCERNSOVERHEATING”.

No Go to next step.

3 Connect the pressure gauge to A/C lines. Yes Go to next step.Turn the fan switch on.Is the pressure within specification?+ section U, REFRIGERANT SYSTEM


No If A/C is always on, go to symptom troubleshooting No.19“A/C ALWAYS ON/ A/C COMPRESSOR RUNSCONTINUOUSLY”. For other symptoms, inspect thefollowing: Refrigerant charging amount. Cooling fan operation.

4 Inspect air cleaner for clogging. Yes Go to next step.Is air cleaner okay? No Clean or replace air cleaner element.



Inspect the hose band between the followingparts:

T b h h i d i

Yes Retighten the hose band.If the concern is resolved, complete the inspection.If the concern still exists, go to next step.

Turbocharger compressor housing and aircleaner

Turbocharger compressor housing andcharge air cooler.

Is the hose band loose?

No Go to next step.

6 Inspect the wastegate actuator for improper Yes Go to next step.operation, kinks, clogs, or disconnection.+ INTAKE-AIR SYSTEM, WASTEGATE

ACTUATOR INSPECTION.Is actuator okay?

No Repair or replace as necessary.If the concern is resolved, complete the inspection.If the concern still exists, the turbocharger is okay. Go tonext step.

7 Remove the parts necessary to inspect theturbocharger. Do not remove the turbocharger.Inspect if the turbocharger primary compressorwheel is bent, damaged, or interfering with the

Yes Replace the turbocharger.

, g , ghousing on the vehicle.+ INTAKE-AIR SYSTEM, TURBOCHARGER

INSPECTION.Is there any problem?

No Go to next step.

8 Inspect if the turbocharger compressor wheellocknut is loose or has fallen down inside


turbocharger.Is there any problem?

No Go to next step.

9 Turn the turbocharger compressor wheel byhand

Yes Go to next step.hand.Does the wheel turn easily and smoothly? No Replace the turbocharger.


CONTINUED


TROUBLESHOOTING

F2–52


ACTION

10 Inspect if the turbocharger turbine wheel isdamaged, cracked, or interfering with thehousing on the vehicles.


Note: Inspect all fins on each turbine wheel.

Is there any problem?

No Go to next step.

11 Is any engine oil found inside the turbochargerturbine housing?

Yes If an excessive amount of oil is found on the vehicle,replace the turbocharger.If a small amount of oil is found, wipe the oil off thevehicle. Then, go to next step.

No Go to next step.

12 Is any engine oil found inside the turbochargercompressor housing?

Yes Wipe the oil off the vehicle and install all removed partsin Step 7. Then, go to next step.

No The turbocharger is okay. Install all removed parts inStep 7. Then, go to next step.

13 Remove injection nozzle. Yes Go to next step.Inspect injection nozzle for the following: Clogged nozzle. Seized needle valve Incorrect valve opening pressure. Faulty nozzle gasket.




No Go to next step.

15 Inspect fuel leakage from pipe. Yes Repair or replace as necessary.Is any fuel leakage found on fuel pipe? No Go to next step.



on vehicles with EGR system. Go to nextstep for vehicles without EGR system.










No If tension or timing of timing belt is incorrect, adjust timing.If timing belt is broken, damaged or cracked, replace timingbelt.


Yes Inspect follows: Brake system dragging Clutch slippage FIP

No Inspect TCV (if equipped).+ TIMER CONTROL VALVE (TCV) INSPECTIONIf TCV is okay, adjust injection timing.+ ENGINE TUNE-UP, INJECTION TIMING

ADJUSTMENT


CONTINUED


TROUBLESHOOTING

F2–53

SYMPTOM 11 POOR FUEL ECONOMYDESCRIPTION Fuel economy is unsatisfactory.

POSSIBLECAUSE

Idle speed or idle-up speedincorrect adjustment

Accelerator cable free playincorrect adjustment

Air cleaner restriction Engine cooling system malfunction Improper transmission fluid level Poor fuel quality Improper coolant level Improper engine compression

Exhaust system clogged Injection timing incorrect Injection nozzle malfunction FIP malfunction High idle speed High idle-up speed FICD malfunction Fuel leakage Brake dragging EGR system malfunction (WL Turbo)


ACTION

1 Inspect the following: Fuel quality including water contamination Air cleaner element for restriction


Transmission fluid level Coolant level

Are all items okay?


2 Inspect for idle speed and idle-up speed.+ ENGINE TUNE-UP IDLE-UP SPEED

Yes Go to next step.+ ENGINE TUNE-UP, IDLE-UP SPEED

ADJUSTMENT.Is idle-up speed within specifications?

No Go to flowchart No.6 “SLOW RETURN TO IDLE/FAST IDLE”.

3 Inspect fuel leakage from pipe.f f f ?

Yes Repair or replace as necessary.Is any fuel leakage found in fuel pipe? No Go to next step.

4 Remove injection nozzle. Yes Go to next step.Inspect injection nozzle for the following: Clogged nozzle. Seized needle valve Incorrect valve opening pressure. Faulty nozzle gasket.



5 Is there restriction in exhaust system? Yes Inspect exhaust system.

No Go to next step.

6 Is brake system functioning properly? Yes Go to next step.

No Inspect for cause.


on vehicles with EGR system. Go to nextstep for vehicles without EGR system.





8 Measure engine compression.?

Yes Go to Step 10.Is compression okay? No Go to next step.





No If tension or timing of timing belt is incorrect, adjusttiming belt . If timing belt is broken, damaged or cracked, replacetiming belt.


Yes Inspect for the following: FIP


ADJUSTMENT


CONTINUED


TROUBLESHOOTING

F2–54

SYMPTOM 12 HIGH OIL CONSUMPTION/LEAKS

DESCRIPTION Oil consumption is excessive.

POSSIBLECAUSE

Improper engine oil level Improper dipstick Improper engine oil viscosity

Engine internal part malfunction Oil leak Turbocharger malfunction


ACTION

1 Inspect the following: Proper dipstick Proper engine viscosity


Pro er engine viscosity Engine oil level

Are all items okay?




Remove the parts necessary to inspect theturbocharger. Do not remove the turbochar-


ger.Inspect if the turbocharger primary compres-sor wheel is bent, damaged, or interfering withthe housing on the vehicle.+ INTAKE-AIR SYSTEM, TURBOCHARGER

INSPECTIONIs there any problem?

No Go to next step.

3 Inspect if the turbocharger compressor wheellocknut is loose or has fallen down inside



No Go to next step.


Yes Go to next step.hand.Does the wheel turn easily and smoothly? No Replace the turbocharger.

5 Inspect if the turbocharger turbine wheel isdamaged, cracked, or interfering with thehousing on the vehicles.


Note: Inspect all fins on each turbine wheel.

Is there any problem?

No Go to next step.



No Go to next step.

7 Is any engine oil found inside the turbocharger Yes Wipe the oil off the vehicle. Then, go to next step.compressor housing? No Go to next step.

8 Is any engine oil found around oil pipes at-tached on the turbocharger center housing?

Yes If the oil leaked from the damaged pipe, replace the oilpipe. Then, go to next step.

No Go to next step.

9 Is any engine oil found inside the air intake Yes Wipe the engine oil off.pipes or Hoses? No The turbocharger is okay. Install all parts removed in

step 2. Then, go to next step.

10 Measure engine compression. Yes Inspect oil leakage from outside of engine.Is compression okay? No Inspect for the following:

Damaged valve seat. Worn valve stem and valve guide. Worn or stuck piston ring. Worn piston, piston ring, or cylinder.



CONTINUED


TROUBLESHOOTING

F2–55

SYMPTOM 13 COOLING SYSTEM CONCERNS—OVERHEATING

DESCRIPTION Engine runs at higher than normal temperature/overheats.

POSSIBLECAUSE

Cooling fan malfunction Low drive belt tension Drive belt damage Improper coolant level Thermostat malfunction Radiator clogging A/C system malfunction

Water temperature gauge or sender unit malfunc-tion

Improper or damaged radiator cap Radiator hose damage Coolant leakage (engine internal, turbocharger, ex-

ternal)


ACTION

1 Inspect the following: Engine coolant level Coolant leakage Radiator condition Collapsed or restricted radiator hoses


Collapsed or restricted radiator hoses Radiator pressure cap Drive belt tension Drive belt

Are all items okay?


2 Connect the pressure gauge to A/C lines. Yes Go to next step.Turn the blower switch on.Is the pressure within specification?+ section U, REFRIGERANT SYSTEM


No If A/C is always on, go to symptom troubleshootingNo.19 “A/C ALWAYS ON/ A/C COMPRESSOR RUNSCONTINUOUSLY”. For other symptoms, inspect thefollowing: Refrigerant charging amount Cooling fan operation

3 Inspect water temperature sender unit.Is water temperature sender unit okay?

Yes Inspect thermostat.+ section E, THERMOSTAT, THERMOSTAT

INSPECTION

No Replace water temperature sender unit.

SYMPTOM 14 COOLING SYSTEM CONCERNS—RUNS COLD

DESCRIPTION Engine does not reach normal operating temperature.

POSSIBLECAUSE

Thermostat malfunction


ACTION

1 Remove the thermostat from vehicle.Inspect thermostat.+ section E, THERMOSTAT, THERMOSTAT

INSPECTION

Yes Inspect water temperature sender unit operation.+ section T, INSTRUMENT CLUSTER, WATER TEM-

PERATURE SENDER UNIT INSPECTIONINSPECTION.

Is thermostat okay? No Replace thermostat.


CONTINUED


TROUBLESHOOTING

F2–56

SYMPTOM 15 EXCESSIVE BLACK SMOKE

DESCRIPTION Excessive black smoke is observed in exhaust gas.

POSSIBLECAUSE

Air cleaner element restriction Incorrect fuel injection timing Injection nozzle malfunction

FIP malfunction Low engine compression EGR system malfunction (WL Turbo)


ACTION

1 Does any other symptom exist? Yes Go to appropriate flow chart.

No Go to next step.

2 Inspect air cleaner element for clogging. Yes Go to next step.Is air cleaner element okay? No Repair or replace air cleaner element.


+ FUEL SYSTEM, TIMER CONTROL VALVE (TCV)INSPECTION

If TCV is okay, adjust injection timing.+ ENGINE TUNE-UP, INJECTION TIMING

ADJUSTMENT4 Remove injection nozzle. Yes Go to next step.

Inspect injection nozzle for the following: Clogged nozzle. Seized needle valve Incorrect valve opening pressure Faulty nozzle gasket




on vehicles with EGR system. Go tonext step for vehicles without EGRsystem.





6 Measure engine compression. Yes Inspect fuel injection pump.Is compression okay? No Inspect for the following:

Damaged valve seat. Worn valve stem and valve guide. Worn or stuck piston ring. Worn piston, piston ring, or cylinder.


SYMPTOM 16 ENGINE NOISE

DESCRIPTION Engine noise from under hood.

POSSIBLECAUSE

Engine internal damage Timing belt displacement Injection nozzle malfunction Loose attaching bolts or worn

parts

Improper drive belt tension Air leaks from intake-air system Turbocharger operating noise EGR system malfunction (WL Turbo)


CONTINUED


TROUBLESHOOTING

F2–57


ACTION



Remove the necessary parts to inspect the


Remove the necessary arts to ins ect theturbocharger.Inspect if the turbocharger compressor wheelis bent, damaged, or interfering with the hous-ing on the vehicle.Is there any problem?

No Go to next step.

2 Inspect if the turbocharger compressor wheellocknut is loose or has fallen down inside the



No Go to next step.


Yes Go to next step.hand.Does wheel turn easily and smoothly? No Replace the turbocharger.

4 Inspect if the turbocharger turbine wheel isdamaged, cracked, or interfering with the


housing on the vehicle.Is there any problem?

No Go to next step.



No Go to next step.

6 Is any engine oil found inside the turbocharger Yes Wipe the oil off of the vehicle. Then, go to next step.compressor housing? No Go to next step.

7 Is any exhaust gas leakage found around thelocation where the turbocharger is attached tothe exhaust manifold?

Yes Remove turbocharger. Inspect for cracks on centerhousing inlet surface.If cracks are found, replace turbocharger.If no cracks are found, DO NOT replace turbocharger.Replace gaskets, bolts, and nuts only. Then, go to nextstep.

No Go to next step.

8 Are any of the attaching bolts of center hous-ing and turbine housing loose?

Yes Retighten the loose bolts.If any bolt is missing, attach the appropriate new bolt.

No Turbocharger is okay. Install all removed parts inStep1. Go to next step.

9 Is squeal, click, or chirp sound present? Yes Inspect engine oil level or drive belt.

No Go to next step.

10 Is rumble or grind sound present? Yes Inspect drive belt.

No Go to next step.

11 Is rattle sound present? Yes Inspect location of rattle for loose parts.

No Go to next step.

12 Is hiss sound present? Yes Inspect for the following: Vacuum leaks Intake-air system leaks

No Go to next step.

13 Is rap or roar sound present? Yes Inspect exhaust system for loose parts.

No Go to next step.


CONTINUED


TROUBLESHOOTING

F2–58


ACTION

14 Inspect the injection timing. Yes Go to next step.Is injection timing okay? No Inspect TCV (if equipped)

+ FUEL SYSTEM, TIMER CONTROL VALVE (TCV)INSPECTION

If TCV is okay, adjust injection timing.+ ENGINE TUNE-UP, INJECTION TIMING

ADJUSTMENT15 Note:

The following test should be performedon vehicles with EGR system. Go tonext step for vehicles without EGRsystem.


system.Carry out EGR system inspection.+ SYSTEM INSPECTION, EGR System



16 Remove the fuel injection nozzle.Inspect for the following: Clogged nozzle. Seized needle valve

Yes Inspect for the following: Metal flow Bent connecting rod Damaged valve seat

Incorrect valve opening pressure Faulty nozzle gasket Fuel dripping (fuel leakage)


No After-leakege, clogged nozzle or seized needle valve:Disassemble and clean or replace the injection nozzle.Incorrect valve opening pressure:Adjust injection nozzle opening pressure.Faulty nozzle gasket:Replace nozzle gasket.

SYMPTOM 17 VIBRATION COCNERNS (ENGINE)

DESCRIPTION Vibration from under hood or driveline.

POSSIBLECAUSE

Loose attaching bolts or worn parts Components malfunctions such as worn parts


ACTION

1 Inspect the following components for looseattaching bolts or worn parts: Cooling fan Drive belt and pulley Engine mounts Exhaust system

Yes Inspect the following: Wheels Transmission and mounts Driveline Suspension

Service as necessary.Are all items okay? No Readjust or retighten engine mount installation posi-

tion.Service as necessary for other parts.

SYMPTOM 18 A/C DOES NOT WORK.

DESCRIPTION A/C compressor magnetic clutch does not engage when A/C is turned on.

POSSIBLECAUSE

Improper refrigerant chargingamount

Microswitch is stuck open. Open A/C magnetic clutch Open circuit in related wire har-

nesses Poor ground of A/C magnetic

clutch A/C low/high pressure switch is

stuck open.

A/C relay is stuck open. Seized A/C compressor Frost switch is stuck open. Open circuit in blower resistor Poor blower switch ground ECT sensor malfunction Improper magnet clutch clearance


CONTINUED


TROUBLESHOOTING

F2–59


ACTION

1 Turn engine switch on. Yes Go to next step.Set the fan switch to 1st, 2nd, 3rd, or 4th posi-tion.Verify the blower motor is operating.Is blower motor okay?

No Inspect for the following: Poor ground of fan switch Open circuit in blower resistor Poor contact of fan switch Blower relay is stuck open. Open circuit in blower relay coil Seized blower motor Open circuit in blower motor coil. Open circuit between blower motor and resistor Open circuit between fan switch and resistor


2 Turn the engine switch on. Yes Go to next step.Set the fan switch to 1st, 2nd, 3rd, or 4th posi-tion.Measure the voltage at PCM connector termi-nal G.+ CONTROL SYSTEM, PCM INSPECTIONSpecification:Less than 2.7 VIs voltage correct?

No Inspect for the following: Frost switch is stuck open. Poor contact of microswitch in heater control unit Open circuit between PCM connector terminal G

and frost switch connector terminal. Open circuit between frost switch connector termi-

nal and fan switch connector terminal.Repair or replace as necessary.

3 Start the engine and run it at idle speed. Yes Go to next step.Set the fan switch to 1st position.Measure the voltage at terminal of A/C relayconnector terminal C.Specification:More than 10.5 VIs voltage correct?

No Inspect for the following: Open circuit in A/C relay coil Poor contact in A/C relay A/C relay stuck open Open circuit between PCM connector terminal L

and A/C relay connector terminal. Open circuit in battery supply line Open circuit between engine switch and A/C relay

connector terminal Engine coolant temperature sensor malfunction


4 Disconnect the A/C magnetic clutch connec-tor, Measure the A/C magnetic clutch connectorterminal voltage.Specification:

Yes Inspect for the following: Poor ground of A/C magnetic is clutch Open circuit in magnet is clutch coil Refrigerant charging amount

Repair or replace as necessary.More than 10.5 VIs voltage okay?

No Inspect for the following: Open circuit between pressure switch connector

terminal and A/C magnetic clutch connector termi-nal

Refrigerant charging amount A/C pressure switch is stuck open. Magnetic clutch clearance A/C compressor is seized.


SYMPTOM 19 A/C ALWAYS ON / A/C COMPRESSOR RUNS CONTINUOUSLY.

DESCRIPTION A/C compressor magnetic clutch does not disengage.

POSSIBLECAUSE

Improper magnetic clutch clear-ance

Short to ground circuit betweenPCM and frost switch

Short to ground circuit betweenPCM and A/C relay

Short to power line between A/C relay and pressureswitch

A/C low/high pressure switch is stuck to close. A/C relay is stuck to close. Frost switch is stuck to close.


CONTINUED


TROUBLESHOOTING

F2–60


ACTION

1 Turn the engine switch on. Yes Go to next step.Turn the blower switch off.Measure the voltage at PCM connector termi-nal G.Specification:More than 2.7 VIs voltage correct?

No Inspect for the following: Short to ground circuit between PCM connector

terminal G and frost switch Short to ground circuit between frost switch and

blower switch connector terminalRepair or replace as necessary.

2 Start the engine and run it at idle speed.Turn the blower switch off.

Yes Inspect for magnetic is clutch clearance.Adjust it as necessary.

Measure the voltage at terminal of A/C relayconnector terminal C.Specification:0 VIs voltage correct?

No Inspect for the following: Short to ground circuit between PCM connector

terminal L and A/C relay terminal C A/C relay is stuck to close. Short to power line between A/C relay connector

terminal C and A/C pressure switch Short to power line between pressure switch and

A/C compressor magnetic is clutch connectorRepair or replace as necessary.

SYMPTOM 20 INTERMITTENT CONCERNS

DESCRIPTION Symptom occurs randomly and is difficult to diagnose.


ACTION

1 Talk to customer.Retrieve vehicle service history.Does vehicle have a number of previous re-


Does vehicle have a number of revious re-pairs and components replaced for a certainsymptom?

No Go to symptom index.

2 Key off.If input is switch-type component, turn onmanually.Turn engine switch off.Connect the voltmeter to the PCM terminals.Lightly tap on suspect component wiggle and

Yes Inspect each wire for corrosion, bent or loose terminalclamps.

Lightly ta on sus ect com onent, wiggle andpull each wire/connector at suspect compo-nent or PCM.Is any voltage out of range, or do they sud-denly change and go back into range?

No Go to next step.

3 Start the engine and run it at idle speed.Lightly tap on suspect component, wiggle andpull each wire/connector at suspect compo-nent or PCM

Yes Inspect each wire for corrosion, bent or loose terminalclamps.

nent or PCM.Are any voltages out of range, or do they sud-denly change and go back into range?

No Go to next step.

4 Accurately spray water on suspect componentwire, component, or vacuum line related topossible fault area.Is any voltage out of range, or suddenlychange and go back into range, or was therea noticeable engine stumble?

Yes Fault area is identified.If fault occurred while spraying on component:Replace part and verify repair.If fault occurred while spraying water:Inspect each wire for corrosion, bent, loose terminals,or poor wire terminal clamps.If fault occurred while spraying vacuum line:Repair vacuum hoses.

No Inspect wire and connector at suspect component forcorrosion, bent, loose terminals, or poor wire terminalcrimps and high tension wire. Repair as necessary.


CONTINUED


TROUBLESHOOTING

F2–61

SYSTEM INSPECTIONFICD System InspectionFast-Idle Function

1. Verify that the FICD actuator rod is not pulled.2. Verify that the engine is cold (ECT is below 20 °C

68 °F).3. Turn fan switch off.4. Start the engine.5. Verify that the FICD actuator rod is pulled.

6. If not, disconnect the vacuum hoses from the FICDactuator and inspect if there is vacuum as shown.

FICD ACTUATOR



7. If there is vacuum, consult your distributor forreplacement of the FICD actuator.

8. If there is no vacuum, inspect the following. FICD solenoid valve No.1 and No.2 Loose or damaged vacuum hoses between

FICD actuator, FICD solenoid valve No.1 andNo.2, and vacuum pump.

PCM terminal C, E and P voltages (Refer to CONTROL SYSTEM, POWERTRAINCONTROL MODULE (PCM) INSPECTION.)

Wiring harness between FICD solenoid valveNo.1 and PCM terminal C.

Wiring harness between FICD solenoid valveNo.2 and PCM terminal P.

9. Warm up the engine. (ECT above 20 °C 68 °F).10. Verify that the FICD actuator rod returns for one

notch.

11. If not, disconnect vacuum hose A from the FICDactuator and inspect if there is vacuum.

VACUUM HOSE A



12. If there is no vacuum, consult your distributor forreplacement of the FICD actuator.

13. If there is vacuum, inspect the following. FICD solenoid valve No.1 PCM terminal C, E voltages

(Refer to CONTROL SYSTEM, POWERTRAINCONTROL MODULE (PCM) INSPECTION.)

Wire harness between FICD solenoid valveNo.1 and PCM terminal C

14. Warm up the engine (ECT is above 60 °C 140°F).

15. Verify that the FICD actuator rod returnscompletely.

16. If not, disconnect vacuum hose B from the FICDactuator and inspect if there is vacuum.


CONTINUED


TROUBLESHOOTING

F2–62

VACUUM HOSE B



17. If there is no vacuum, consult your distributor forreplacement of the FICD actuator.

18. If there is vacuum, inspect the following. FICD solenoid valve No.2 PCM terminal E, G and P voltages

(Refer to CONTROL SYSTEM, POWERTRAINCONTROL MODULE (PCM) INSPECTION.)

Wiring harness between FICD solenoid valveNo.2 and PCM terminal P.

A/C Idle-up Function1. Start the engine.2. Warm up the engine to normal operating

temperature and run it at idle speed.3. Set the fan switch at 1st position.4. Verify that the FICD rod is pulled for one notch.5. If not, disconnect the vacuum hose B from the

FICD actuator and inspect if there is vacuum asshown.

VACUUM HOSE B



6. If there is vacuum, consult your distributor forreplacement of the FICD actuator.

7. If there is no vacuum, inspect the following: FICD solenoid valve No.2 PCM terminal G and P voltages

(Refer to CONTROL SYSTEM,POWERTRAIN CONTROL MODULE (PCM) INSPECTION)

Wiring harness between FICD solenoid valve No.2connector terminal B and PCM terminal P

Turbocharger Boost Pressure1. Disconnect the air hose between the intake pipe

and the boost compensator.2. Connect a pressure gauge (range of measurement

is 93.3 kPa 700 mmHg, 27.6 inHg).BOOST COMPENSATOR

PRESSURE GAUGE

TO INTAKEPIPE

3. Warm up the engine.4. With the accelerator at the wide open throttle,

increase the engine speed to 4800—5000 rpm andverify that the boost pressure is within thespecification.

Specification60.0—73.3 kPa

0.62—0.74 kgf/cm 2, 8.82—10.52 psi

5. If not as specified, inspect the exhaust system. (Refer to EXHAUST SYSTEM, EXHAUSTSYSTEM INSPECTION.)

6. If the exhaust system is normal, inspect thewastegate actuator. (Refer to INTAKE-AIRSYSTEM, TURBOCHARGER INSPECTION,Wastegate Actuator Inspection.)

7. If the wastegate actuator is normal, inspect theturbocharger. (Refer to INTAKE-AIR SYSTEM,TURBOCHARGER INSPECTION.)

TCV Control Inspection (Europe and UK)1. Crank the engine and verify that the TCV operation

sound is heard.

WL

TCV


CONTINUED


TROUBLESHOOTING

F2–63

WL Turbo

TCV

2. If no operation sound is heard, inspect the TCV (inthe FIP).

3. If the TCV is normal, inspect the following: PCM terminal Q voltage

(Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION)

Wire harness between TCV and PCM terminalQ

EGR System Inspection (if equipped)1. Make sure that all hoses are securely connected in

the proper position.2. Disconnect the vacuum hose from the EGR valve.3. Start the engine at cold condition.4. Verify that there is no vacuum at vacuum hose.5. If there is vacuum, inspect the following:

EGR solenoid valve PCM terminal R voltage

(Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.)

Wire harness between EGR solenoid valve andPCM terminal R

6. Warm up the engine to the normal operatingtemperature and run it at idle speed.

7. Verify that there is vacuum at vacuum hose.8. If there is no vacuum, inspect the following:

EGR solenoid valve PCM terminal R voltage

(Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.)

Wire harness between EGR solenoid valve andPCM terminal R

9. Connect the vacuum pump to the EGR valve.10. Apply the vacuum to the EGR valve and inspect if

the engine speed becomes unstable or the enginestalls.

11. If the engine speed does not change, stop theengine and inspect the EGR valve.


CONTINUED


TROUBLESHOOTING

F2–64

Glow System InspectionSTEP INSPECTION RE-

SULTSACTION

1 Connect NGS tester to DTC.Turn engine switch on and retrieve DTC.Are any of the following DTCs displayed? 09 (ECT sensor)

Yes Go the appropriate DTC test.After repair is completed, go to next step.

09 (ECT sensor) 12 (Control lever position sensor) 36 (Glow plug relay)

No Go to next step.

2 Turn engine switch on while engine is cold. Yes Go to next step.Does glow indicator light illuminate for approx.1—9 seconds.?

No Inspect the following according to indication conditionof glow indicator light:1. Will not go out Short circuit between glow indicator light and PCM

connector terminal M Short circuit in instrument cluster print plate

2. Illuminates for approx. 1 second (same conditionafter engine is warmed up and cold)

Extremely low resistance of engine coolant temper-ature sensor

Short circuit between engine coolant temperaturesensor and PCM connector terminal E

3. Will not illuminate Glow indicator light Open circuit between glow indicator light and PCM

connector terminal M Open circuit in instrument cluster print plate

4. Illuminates for approx. 9 seconds (same conditionafter engine is warmed up and cold)

Extremely high resistance of engine coolant temper-ature sensor

Open circuit between engine coolant temperaturesensor and PCM connector terminal E

3 Leave engine switch on while engine is cold. Yes Go to next step.Does glow plug voltage indicate B+ forapprox. 15 seconds.?

No Inspect for open or short circuit in harnesses and con-nectors between battery, glow plug relay, and glowplug.Inspect if glow plug relay is stuck open or closed.Inspect glow plug relay ground circuit.Inspect for open circuit between glow relay and PCMterminal O.

4 Does glow plug voltage indicate B+ while Yes Go to next step.cranking engine? No Inspect for open or short to ground circuit in harness

and connectors between engine switch (starter) andPCM connector terminal D.

5 Is power supplied to the glow plug for maxi- Yes Go to next step.mum 10 minutes after engine started whenengine is cold?

No Inspect for open or short circuit in harnesses and con-nectors between NE sensor and PCM connector termi-nal F.

6 Remove the glow plug wire from glow plugs.Measure resistance between glow plug andbody ground.

Yes Glow system is okay.

y gIs glow plug resistance approx. 1 Ω or less?+ INTAKE-AIR SYSTEM, GLOW PLUG

INSPECTION

No Replace glow plug.


CONTINUED


FUEL AND EMISSION CONTROL SYSTEMS

(F2 CARB) ENGINE TUNE-UP .........................................................F4-2

ENGINE TUNE-UP PREPARATION ........................F4-2 IGNITION TIMING ADJUSTMENT ...........................F4-2 IDLE SPEED ADJUSTMENT ...................................F4-2 IDLE MIXTURE ADJUSTMENT ...............................F4-2/3 DASHPOT (D/P) ADJUSTMENT ..............................F4-3 THROTTLE POSITIONER (T/P)

ADJUSTMENT ........................................................F4-3/4 A/C IDLE-UP ADJUSTMENT ...................................F4-4/5 INTAKE-AIR SYSTEM .................................................F4-6

VACUUM HOSE ROUTING DIAGRAM ...................F4-6 INTAKE-AIR SYSTEM

REMOVAL/INSTALLATION ..................................F4-7 AIR CLEANER ELEMENT

INSPECTION ..........................................................F4-8 IDLE COMPENSATOR INSPECTION ....................F4-8 AIR THERMO VALVE

INSPECTION ..........................................................F4-8 VACUUM CONTROL DIAPHRAGM

INSPECTION ..........................................................F4-8 ACCELERATOR PEDAL

REMOVAL/INSTALLATION ..................................F4-9 ACCELERATOR CABLE

INSPECTION/ADJUSTMENT .............................. F4-9 FUEL SYSTEM ..............................................................F4-10

BEFORE REPAIR PROCEDURE.............................F4-10 AFTER REPAIR PROCEDURE ...............................F4-10 FUEL TANK REMOVAL/INSTALLATION ...............F4-11/13NONRETURN VALVE INSPECTION ......................F4-13 FUEL PUMP UNIT

REMOVAL/INSTALLATION...................................F4-13 FUEL PUMP UNIT

DISASSEMBLY/ASSEMBLY ................................F4-13/14 FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION ..................................F4-14

FUEL GAUGE SENDER UNIT INSPECTION ..........................................................F4-14

FUEL PUMP INSPECTION ......................................F4-14/15 FUEL LINE PRESSURE INSPECTION ..................F4-15 FUEL LINE FLOW AMOUNT

INSPECTION ..........................................................F4-15/16 FAST IDLE SPEED ADJUSTMENT ........................F4-16 DASHPOT (D/P) INSPECTION ................................F4-16 FUEL PUMP RELAY INSPECTION ........................F4-16/17 SERVO DIAPHRAGM

REMOVAL/INSTALLATION ..................................F4-17 CARBURETOR

REMOVAL/INSTALLATION ..................................F4-17

CARBURETOR

DISASSEMBLY/ASSEMBLY ............................... F4-18/21 CARBURETOR

INSPECTION/ADJUSTMENT .............................. F4-21/24 HIGH-ALTITUDE COMPENSATOR

INSPECTION ......................................................... F4-24 PTC HEATER INSPECTION ................................... F4-24 SLOW FUEL CUT SOLENOID VALVE

INSPECTION ......................................................... F4-24 EXHAUST SYSTEM .................................................... F4-25

EXHAUST SYSTEM INSPECTION ........................ F4-25 EXHAUST SYSTEM

REMOVAL/INSTALLATION ................................. F4-25 EMISSION SYSTEM .................................................... F4-26

N0.1 PURGE CONTROL VALVE INSPECTION ......................................................... F4-26

N0.2 PURGE CONTROL VALVE INSPECTION ......................................................... F4-26

WATER THERMO VALVE INSPECTION .............. F4-26 AIR VENT SOLENOID INSPECTION ...................... F4-26 CHECK VALVE (TWO-WAY)

INSPECTION ......................................................... F4-26 CHARCOAL CANISTER INSPECTION ................. F4-26 ROLLOVER VALVE INSPECTION ......................... F4-26/27 WATER THERMO VALVE

REMOVAL/INSTALLATION ................................. F4-27 PCV VALVE INSPECTION ...................................... F4-27 CLOSED THROTTLE POSITION (CTP)

SWITCH ADJUSTMENT ...................................... F4-27 FLANGE THERMOSWITCH

INSPECTION ......................................................... F4-27 CONTROL SYSTEM .................................................... F4-28

COMPONENT LOCATION ...................................... F4-28 PCM REMOVAL/INSTALLATION ........................... F4-29 PCM INSPECTION .................................................... F4-29 PTC HEATER RELAY INSPECTION ..................... F4-30 THROTTLE POSITIONER T/P) SOLENOID

VALVE INSPECTION ........................................... F4-30 WATER THERMOSWITCH (INTAKE

MANIFOLD SIDE) INSPECTION ......................... F4-30/31 WATER THERMOSWITCH

REMOVAL/INSTALLATION ................................. F4-31 TROUBLESHOOTING ................................................ F4-32

FOREWORD ............................................................. F4-32 TROUBLESHOOTING ITEM TABLE ...................... F4-32 QUICK DIAGNOSTIC CHART ................................. F4-33

SYMPTOM TROUBLESHOOTING ......................... F4-34/47

F4-1

BACK.TO.MAIN.INDEX TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

CONTINUED

ENGINE TUNE-UP

IDLE MIXTURE ADJUSTMENT 1. Attach an exhaust gas analyzer and measure the

CO concentration.

2. Perform the "ENGINE TUNE-UP PREPARATION"

and "IDLE SPEED ADJUSTMENT." 3. Verify that CO concentration in exhaust gas at the

tail pipe during idling is as specified in the table below.

For CO concentration (%) GULF 2.0—2.5 (2.0 ) General 2.0—3.0 (2.5 ±0.5)

ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION 1. Check the condition of the engine (plugs, leaks in

hoses, etc.) 2. Make sure all accessories are OFF. 3. Connect a tacho dwell tacho tester to the engine. 4. Warm up the engine and run it for three minutes

at 2,500—3,000 rpm in neutral. IGNITION TIMING ADJUSTMENT

1. Perform the "ENGINE TUNE-UP PREPARATION.2. Disconnect the vacuum hose for vacuum spark

advance between the distributor and the carburetor at the distributor side and plug it.

3. While checking the ignition timing by using a

timing light, adjust the crankshaft pulley alignment mark position (yellow paint) by turning the distributor as specified.

Specification BTDC: 5°—7°(6°±1°)

4. Reconnect the proper vacuum hose to the port. IDLE SPEED ADJUSTMENT 1. Perform the "ENGINE TUNE-UP PREPARATION.2. Verify that the idle speed is within the

specification.

3. If not within the specification, adjust the idle

speed by turning the TAS (throttle adjust screw)

4. If not within the specification, adjust the CO concentration by turning the MAS (mixture adjust screw).

5. Remove the blind cap. (GULF)

6. Remove the spring pin.

F4-2

BACK.TO.CHAPTER.INDEX TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

CONTINUED

ENGINE TUNE-UP

7. Reconfirm that the engine speed is within the

specification. 8. If not within the specification, adjust the idle

speed by turning the TAS (throttle adjust screw).

Note GULF only

• Run the engine at idle for 3—5 seconds, then fit a blind cap to the MAS (mixture adjust screw) of the vehicles for the following markets.

• Run the engine at idle for 3—5 seconds,

then tap in the spring pin as shown.

DASHPOT (D/P) ADJUSTMENT 1. Perform the "ENGINE TUNE-UP PREPARATION"

and "IDLE SPEED ADJUSTMENT" 2. Increase the engine speed to 2,500 rpm. 3. Pull the throttle lever until the rod and arm of the

dashpot separate. 4. Slowly return the throttle lever from the position

above, then verify that the engine speed is as specified when the arm contacts the rod.

Specification 1,900—2,100 (2,000 ± 100) rpm

5. If not as specified, loosen the dashpot locknut and turn the dashpot body to adjust.

6. After adjustment, tighten the locknut.


7. Race the engine and again verify that the engine speed returns smoothly to idle speed. 8. If not, repeat the above procedure to adjust the idle speed or D/P inspect (Refer to FUEL SYSTEM, DASHPOT (D/P) INSPECTION)

THROTTLE POSITIONER (T/P) ADJUSTMENT GULF only 1. Perform the "ENGINE TUNE-UP PREPARATION"

and "IDLE SPEED ADJUSTMENT." 2. Disconnect the vacuum hose for vacuum spark

advance between the distributor and the carburetor at the distributor side and plug it.

3. Disconnect the vacuum hose from the servo diaphragm.

4. Connect the intake manifold vacuum directly to the

servo diaphragm, and verify that the engine speed is as specified.


F4-3


CONTINUED

ENGINE TUNE-UP

5. If not within the specification, adjust the engine speed by the adjust screw.

6. After adjusting the engine speed, reconnect the

vacuum hose to the proper port. Verify that the servo diaphragm operates when the engine speed is raced at 2,000 rpm or more.

7. If the servo diaphragm does not operate, inspect the T/P solenoid valve.

8. If the solenoid valve is okay, replace the servo diaphragm.

A/C IDLE-UP ADJUSTMENT GULF only with, A/C 1. Perform the "ENGINE TUNE-UP PREPARATION"

and "IDLE SPEED ADJUSTMENT." 2. Disconnect the vacuum hose from port A.

3. Connect the intake manifold vacuum directly to port A, and verify that the engine speed is as specified. Specification 1,400—1,600 (1,500 ± 100) rpm

4. If not within the specification, adjust the engine speed by the adjust screw.

5. Reconnect the proper vacuum hose to port A.

6. Disconnect the vacuum hose for vacuum spark advance between the distributor and the carburetor at the distributor side and plug it.

7. Disconnect the vacuum hose from port B.

8. Connect the intake manifold vacuum directly to

port B, and verify that the engine speed is as specified. Specification 1,050—1,250 (1,150 ±100) rpm

9. If not within the specification, adjust the engine speed by the adjust locknut on the dual servo diaphragm head.

10. Reconnect the proper vacuum hose to port B. 11. After adjusting the engine speed reconnect the

vacuum hose to the proper port. Verify that the servo diaphragm operates when the A/C is operated.

12. If the servo diaphragm does not operate, inspect the A/C idle-up solenoid valve or T/P solenoid valve.

13. If the solenoid valve is okay, replace the dual servo diaphragm.

Except GULF, with A/C 1. Perform the "ENGINE TUNE-UP PREPARATION"

and "IDLE SPEED ADJUSTMENT." 2. Disconnect the vacuum hose from the servo

diaphragm. 3. Connect the intake manifold vacuum directly to

the servo diaphragm, and verify that the engine speed is as spec tied.

F4-4


CONTINUED

ENGINE TUNE-UP


4. If not within the specification, adjust the engine speed by adjust screw.

5. Reconnect the proper vacuum hose to port. 6. After adjusting the engine speed reconnect the vacuum

hose to the proper port. Verify that the servo diaphragm operates when the A/C is operated.

7. If the servo diaphragm does not operate, inspect the A/C idle-up solenoid valve.

8. If the solenoid valve is okay, replace the servo diaphragm.

F4-5


CONTINUED

INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM

VACUUM HOSE ROUTING DIAGRAM

1 Air cleaner 12 Distributor 2 Carburetor 13 T/P solenoid valve 3 Vacuum control diaphragm 14 Servo diaphragm 4 Idle compensator 15 A/C idle-up solenoid valve 5 Air thermos sensor 16 Dual servo diaphragm 6 FICB solenoid valve 17 To intake manifold 7 High-altitude compensator 18 Fuel main line (to fuel tank) 8 FICB diaphragm 19 Fuel return line (to fuel tank) 9 Charcoal canister 20 To charcoal canister or ventilation 10 No.1 purge control valve 21 To carburetor 11 Water thermo valve

22 To check valve (two-way)

F4-6


CONTINUED

INTAKE-AIR SYSTEM INTAKE - AIR SYSTEM REMOVAL/INSTALLATION

Warning • When the engine and intake-air system are hot, they can badly bum. Turn off the engine and wait

until they are cool before removing the intake-air system. • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep

sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and

damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

1. Disconnect the negative battery cable. 2. Drain the engine coolant from the radiator. (Refer to Section E.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.

8 Intake manifold 1

Air cleaner (in idle compensator, vacuum control diaphragm, shutter valve, air thermo sensor)

2 Air cleaner element 3 Carburetor

9

Water thermoswitch CONTROL SYSTEM, WATER THERMOSWITCH REMOVAL/INSTALLATION

4 Fuel hose 10 Intake manifold gasket

5 Accelerator cable 6 PTC heater gasket

11

Water thermo valve FUEL SYSTEM, WATER THERMO VALVE REMOVAL/INSTALLATION

7 PTC heater

12 Servo diaphragm

F4-7


CONTINUED

INTAKE-AIR SYSTEM AIR CLEANER ELEMENT INSPECTION

• Visually check the air cleaner element for excessive dirt, damage or oil, replace if necessary.

IDLE COMPENSATOR INSPECTION 1. Confirm that the valve is in the closed position

when the bimetal temperature is lower than the specified temperature. Opening temperature 63—71 °C 145.4—159.8 °F

2. To check, suck air from the tube A. If excessive air leakage is found, replace the idle compensator.

3. When the bimetal temperature is more than

approx. 71 °C 159.8 °F, confirm that the valve is in the open position. If the valve is not open, replace the idle compensator as an assembly.

AIR THERMO VALVE INSPECTION Note • Perform the following test only when directed.

1. Disconnect the vacuum hose from the vacuum control diaphragm.

2. Verify that vacuum is felt at the vacuum hose when the engine is cold (below 30 °C 86 °F) and idling.

3. Warm up (above 30 °C 86 °F) the engine and verify that vacuum is not felt.

4. If vacuum condition is not as specified in Steps 2

and 3, replace the air thermo valve. VACUUM CONTROL DIAPHRAGM INSPECTION 1. Disconnect the vacuum hose from the vacuum

control diaphragm. 2. Connect a vacuum pump to the vacuum control

diaphragm. 3. Apply more than 24 KPa 180 mmHg, 7.087

inHg vacuum and verify that the shutter valve is opened to the hot position.

4. Replace the vacuum control diaphragm if not

as specified.

F4-8


CONTINUED

INTAKE-AIR SYSTEM

ACCELERATOR PEDAL REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.

1

Accelerator cable ACCELERATOR CABLE INSPECTION/ADJUSTMENT

2 Accelerator pedal ACCELERATOR CABLE INSPECTION/ADJUSTMENT

1. Verify that the throttle valve is entirely closed. 2. Measure the free play of the accelerator cable.

Free play 1—3 mm 0.04—0.11 in

3. If not as specified, adjust by turning locknut A.

F4-9


CONTINUED

FUEL SYSTEM FUEL SYSTEM BEFORE REPAIR PROCEDURE

Warning • Fuel vapor is hazardous. It can easily

ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safety Procedures".

Fuel Line Safety Procedures Note

• Fuel in the fuel system is under high pressure also when the engine is not running.

1. Remove the fuel-filler cap and release the pressure in the fuel tank.

2. Disconnect the fuel pump relay connector located under the passenger's side front side trim.

3. Start the engine. 4. After the engine stalls, crank the engine several

times. 5. Turn off the ignition switch. 6. Reconnect the fuel pump relay connector. AFTER REPAIR PROCEDURE


Fuel can ignite and cause serious injuries or death and damage. When installing the fuel hose, observe "Fuel Hose Installation" and described below.

Fuel Hose Installation 1. Replace damaged or deformed fuel hoses, fuel

pipes, and hose clamps. 2. When installing the fuel hose onto the fuel pipe, fit

the hose onto the pipe over 25 mm 0.98 in. When the pipe has a stopper, fit the hose until it contacts the stopper.

3. Install a hose clamp over the fuel hose within the clamp installation range as shown, avoiding the original clamp position.

F4-10


CONTINUED

FUEL SYSTEM

FUEL TANK REMOVAL/INSTALLATION Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous.

Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.

• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.

1. Level the vehicle. 2. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Disconnect the negative battery cable. 4. Drain the fuel from the drain plug. 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)

DOUBLE CAB

F4-11


CONTINUED

FUEL SYSTEM

REGULAR CAB

7 Rollover valve 1 Joint hose

Installation Note 8 Fuel pump unit9 Fuel-filler pipe 2 Breather hose w Installation Note

10 Dust cover 3 Under guard 11 Fuel inlet pipe

4 Fuel hose 12 Non return valve

5 Fuel tank

13 Evaporative gas check valve (two-way) Installation Note 6 Evaporative hose - Installation Note

F4-12


CONTINUED

FUEL SYSTEM Evaporative Gas Check Valve (Two-way) Installation Note • Install the arrow mark of the evaporative gas

check valve (two-way) facing the charcoal canister.

Evaporative Hose Installation Note • Fit each hose onto the respective fittings within

the specification, and install clamps as shown. Length Evaporative hose: 25 mm 0.98 in

Breather Hose Installation Note • Fit each hose onto the respective fittings within

the specification, and install clamp as shown. Length Breather hose: 25—30 mm 0.99—1.18 in

Joint Hose Installation Note • Fit the joint hose onto the respective fittings

within the specification, and install clamps as shown. Length Joint hose: 35—40 mm 1.4—1.5 in

NONRETURN VALVE INSPECTION 1. Remove the nonreturn valve with the fuel inlet

pipe. 2. Verify that the nonreturn valve opening angle is

50—56° when pushed out from the fuel inlet pipe side, and the clearance between the nonreturn valve and the fuel inlet pipe end is within 1.5 mm 0.06 in when the nonreturn valve is returned to the closed position.

3. If not as specified, replace the nonreturn valve. FUEL PUMP UNIT REMOVAUINSTALLATION 1. Remove the fuel pump unit.


2. Install the fuel pump unit. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)

FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY Warning • Fuel line spills and leakage are

dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.


F4-13


CONTINUED

FUEL SYSTEM DOUBLE CAB

REGULAR CAB

1 Fuel pump unit connector 2 Rubber mount 3 Fuel filter (low-pressure) 4 Clamp 5 Fuel hose

Assembly Note 6 Fuel pump body

Assembly Note 7 Fuel gauge sender unit

Fuel Pump Assembly Note • After installing the fuel pump body to the

bracket; pull the pump down so that it is tight against the bracket.

Fuel Hose Assembly Note 1. Do not apply excessive side force when pushing

the fuel hose onto the fuel pump nipple. 2. Install the clamps as shown.

FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) FUEL GAUGE SENDER UNIT INSPECTION (Refer to Section T, WARNING AND INDICATOR SYSTEM, FUEL GAUGE SENDER UNIT INSPECTION.) FUEL PUMP INSPECTION Continuity Inspection

Note • Perform the following test only when

directed, 1. Complete the "BEFORE REPAIR

PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

2. Disconnect the negative battery cable. 3. Remove the fuel tank.


4. Inspect for continuity between fuel pump unit connector terminals C and D.

F4-14


CONTINUED

FUEL SYSTEM

5. If there is no continuity, replace the fuel pump body. If there is continuity in the fuel pump but the fuel pump does not operate, inspect as follows and repair or replace as necessary. Open circuit • GND circuit (fuel pump unit connector

terminal C and body GND) • Power circuit (fuel pump relay connector

terminal C and fuel pump unit connector terminal D through common connector)


Short circuit • Fuel pump relay connector terminal C and

fuel pump unit connector terminal D through common connector to GND

6. Repair or replace faulty areas. If the harnesses are okay, inspect the fuel pump relay. (Refer to FUEL SYSTEM, FUEL PUMP RELAY INSPECTION.)

7. Install the fuel tank. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)

8. Reconnect the negative battery cable. 9. Complete the "AFTER REPAIR PROCEDURE".


FUEL LINE PRESSURE INSPECTION



2. Disconnect the negative battery cable. 3. Disconnect the main fuel hose (A), and connect a

fuel pressure gauge to it.

4. Connect the C and D terminals of the fuel pump relay with a jumper wire.


5. Connect the negative battery cable. 6. Turn the ignition switch ON, and verify that fuel

pressure is as specified. Specification 20—25kPa 0.20—0.25 kgf/cm2, 2.8—3.6 psi

7. If not as specified, perform the fuel pump inspection. (Refer to FUEL PUMP INSPECTION.)

FUEL LINE FLOW AMOUNT INSPECTION Note

• Perform the following test only when directed. 1. Complete the "BEFORE REPAIR

PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

2. Disconnect the negative battery cable. 3. Disconnect the main fuel hose (A), and insert the

end into a measuring beaker. 4. Connect the C and D terminals of the fuel pump

relay with a jumper wire.

F4-15


CONTINUED

FUEL SYSTEM

5. Connect the negative battery cable. 6. Turn the ignition switch on. Drive the fuel pump

for a minute and verify that the fuel flow amount is within the specification. Specification More than 1.150 cc 70.2 cu in min.

7. If not as specified, perform the fuel pump inspection. (Refer to FUEL PUMP INSPECTION.)

FAST IDLE SPEED ADJUSTMENT 1. Warm up the engine to normal operation

temperature. 2. Stop the engine. 3. Plug the hoses of the idle compensator. 4. While holding the throttle valve slightly open,

push the choke fully closed; then release the choke valve after releasing the throttle valve.

5. Start the engine, but do not touch the accelerator pedal.

6. Verify that the engine speed is 3,000—4,000 rpm. If the engine speed is not as specified, turn the adjust screw to adjust.

DASHPOT (D/P) INSPECTION 1. Open the throttle valve fully then push the dash

pot rod with a finger and make sure the rod goes into the dash pot slowly.

2. Release the finger and make sure the rod comes out quickly.

FUEL PUMP RELAY INSPECTION On-Vehicle Inspection


1. Remove the front left side trim. 2. Crank the engine while touching the fuel

pump relay by hand. 3. Verify that clicking sound is heard or vibration is

felt from the fuel pump relay white cranking the engine.

4. If there is no clicking sound or vibration, inspect the harness for the following,

Open circuit • Power circuit (fuel pump relay connector

terminal A, D and ignition switch IG1) • GND circuit (fuel pump relay connector

terminal B and PCM terminal H)

Short circuit • Fuel pump relay connector terminal A, D

and ignition switch IG1 to GND. 5. If the harnesses are okay, perform the following off-vehicle inspection.

Off-Vehicle Inspection 1. Remove the fuel pump relay. 2. Inspect for continuity between the fuel pump relay

terminals by using an ohmmeter.

F4-16


CONTINUED

FUEL SYSTEM

3. If not as specified, replace the fuel pump relay. SERVO DIAPHRAGM REMOVAL/INSTALLATION 1. Loosen the servo diaphragm installation nut.

2. Remove the servo diaphragm and the servo diaphragm bracket from the intake manifold.

3. Separate the servo diaphragm from the bracket. 4. Install the servo diaphragm onto the bracket,

then hand-tighten the installation nut. 5. Install the servo diaphragm bracket to the intake

manifold. Tightening torque 19—25N.m 1.9—2.6 kgf.m, 14—18ft.lbf

6. Tighten the installation nut to the specification.

Tightening torque 9.8—24 N.m 100—250 kgf.cm-cm, 87—216 in.lbf

CARBURETOR REMOVAL/INSTALLATION (Refer to INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)

F4-17


CONTINUED

FUEL SYSTEM

CARBURETOR DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. (Refer to Carburetor After Assembly Note.)

Caution • Replace the O-rings, gaskets, and washers when assembling the carburetor. If not, it will possibly

cause a malfunction.

F4-18


CONTINUED

FUEL SYSTEM

1 Accelerator pump connecting rod 2 Connect spring 3 Air vent solenoid valve 4 Choke rod 5 Air horn 6 Float 7 Needle valve assembly 8 Accelerator pump plunger

9

Closed throttle position (CTP) switch (GENERAL (LH.D.), high-altitude models)

10 Slow fuel cut solenoid valve 4

Air vent solenoid valve lead (separate from the connector)

11 Accelerator pump outlet check ball and spring 5 Disconnect choke rod 12 Accelerator pump inlet check ball 13 Primary slow jet 14 Secondary slow jet 15 Primary main jet 16 Secondary main jet 17 Primary venturi and nozzle 18 Secondary venturi and nozzle 19 Primary main air bleed 20 Secondary main air bleed 21 Main body 22 Vacuum diaphragm

6

Air horn and automatic choke assembly (separate from main body)

23 Throttle body 24 Mixture adjust screw

7

Air vent solenoid valve, spring, and gasket, if necessary

25 Bimetal

26 Choke breaker diaphragm 27 Power jet

Needle Valve and Float Disassembly/Assembly 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.

1 Float and pin 2 Needle valve assembly

Air Horn and Automatic Choke Disassembly/Assembly 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.

1 Vacuum hose 2 Accelerator pump connecting rod, spring, and lever 3 Connect spring

F4-19


CONTINUED

FUEL SYSTEM

1 CTP switch and spring

Air Bleeds and Jets Disassembly/Assembly 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.

2

Slow fuel cut solenoid valve, needle valve, spring, and gasket.

1 Secondary slow jet 2 Secondary slow air bleed (No.1) 3 Secondary main air bleed 4 Secondary main jet 5 Primary main air bleed 6 Slow jet and plug 7 Primary slow air bleed (No.1) 8 Primary main jet 9 Primary slow air bleed (No.2)

10 Power jet 3 Accelerator pump plunger assembly and spring 4 Retaining clip 5 Strainer and accelerator pump inlet check ball 6 Check valve plug 7 Accelerator pump outlet check ball and spring

Caution

• Note the size of all jets and air bleeds so that they will be reassembled in the correct position

11 Coasting richer air bleed (No.2) 12 Secondary slow air bleed (No.2) 13 Coasting richer air bleed (No.1)

Note • One bolt is inside the throttle body

14 Coasting richer jet 8 Disconnect vacuum diaphragm connecting rod9 Throttle body (separate from main body)

10 Vacuum diaphragm assembly and gasket Main Body Disassembly/Assembly

Caution • After installing the idle switch, be sure to adjust it.


F4-20


CONTINUED

FUEL SYSTEM

11 Diaphragm cover screws and cover 12 Spring and diaphragm 13 Accelerator cable hanger

Throttle Body Disassembly/Assembly

Caution • Do not remove the throttle valve and shaft, the Venturis, or the choke valve and shaft.

1. Disassemble in the following order. 2. Assemble in the reverse order of disassembly. (1)

When removing the mixture adjust screw, tap out the spring pin as shown in the figure.

Carburetor After Assembly Note • Install the carburetor in the reverse order of

removal. After installation, note the following. (1) Start the engine and check for leaks. (2) Make the idle adjustment. (3) After the idle adjustment is completed,

press in the spring pin.

(4) Adjust the CTP switch. (5) After the idle adjustment has been

completed, check the fast idle speed as follows.

CARBURETOR INSPECTION/ADJUSTMENT Body, Valve, Jet 1. Check for cracks on the air horn, distortion on the

installing surface attached to the main body, and wear on the contact surface of the choke valve shaft. If necessary, replace it.

2. Check for cracks and distortion on the throttle body, and wear on the contact surface of the throttle valve shaft. If necessary, replace it.

3. Check for deformity, bends, and wear on the levers, arms, and connecting rods. If necessary, replace it. Caution • Do not use a piece of wire to clean the

jets. The wire may scratch, crack, or deform the port of the jets and become the cause of malfunctions.

4. Check for clogging in jets and air bleeds. If necessary, clean with clean gasoline or kerosene and dry with compressed air.

5. Check the taper part of the MAS, solenoid valves, and needle valve (float) for cracks and dents, and wear. If necessary, replace it.

6. Check the rubber part of the accelerator pump for cracks and damage. If necessary, replace it.

F4-21


CONTINUED

FUEL SYSTEM Diaphragms 1. Push the rod fully and plug the port by hand. 2. Verify that the rod does not return when the port is

plugged.

3. If the rod returns to the original position, replace the diaphragm.

Float Level Adjusting 1. Measure the clearance H between the float and air

horn.

Clearance H 8—9 mm 0.315—0.354 in

2. If not as specified, bend the float seat lip A until the proper clearance is obtained.

3. Measure the clearance L between the bottom of

the float and air horn.

Clearance L 44—45 mm 1.732—1.772 in

4. If not as specified, bend the float stopper B until

the proper clearance is obtained.

Choke Valve 1. Use a vacuum pump to apply approximately 53

kPa 400 mmHg, 15.7 inHg vacuum to the choke diaphragm.

2. Push the choke valve lightly to close it, and check the clearance R,

Clearance R 1.72—2.22 mm 0.068—0.087 In

3. If the clearance is not as specified, adjust by bending the choke lever D.

F4-22


CONTINUED

FUEL SYSTEM Fast-idle cam

1. Set the fast-idle cam to the second highest position.

2. Adjust the throttle valve clearance G by turning the adjust screw. (The clearance becomes larger as the screw is turned clockwise.)

Clearance G 0.64—0.84 mm 0.025—0.033 in

3. Set the fast idle cam at the second highest position.

4. Check the choke valve clearance R.

Clearance R 0.60—1.20 mm 0.024—0.047 in

5. If necessary, adjust the choke valve clearance R by bending the starting arm B. If large adjustments are required, the choke rod should be bent.

Unloader system 1. Open the primary throttle valve fully. 2. Measure the choke valve clearance R.

Clearance R 2.82—3.70 mm 0.111—0.146 in

3. If the clearance is not as specified, adjust by bending tab A.

Secondary throttle valve 1. The secondary throttle valve should start to open

when the primary throttle valve opens 48 ° —52 ° and should be completely open at the same time the primary throttle valve is fully open.

2. Check the clearance between the primary throttle valve and the throttle bore when the secondary throttle valve starts to open.

3. If the clearance is not as specified, bend tab B to adjust.

F4-23


CONTINUED

FUEL SYSTEM

Clearance R 7.35—8.25 mm 0.289—0.325 in

HIGH-ALTITUDE COMPENSATOR INSPECTION 1. Disconnect each air hose from the carburetor. 2. Check the high-altitude compensator by blowing

through each hose.

500m 1,640 ft or higher (High altitude): Air passes.

Less than 500 m 1,640 ft (Low altitude): Air does not pass.

3. If not as specified, replace the high-altitude compensator.

PTC HEATER INSPECTION 1. Disconnect the PTC heater connector. 2. Connect an ohmmeter between the

connector and the intake manifold, and verify continuity.

3. If it is not correct, replace the PTC heater.

SLOW FUEL CUT SOLENOID VALVE INSPECTION Operation Inspection


1. Run the engine at idle speed. 2. Disconnect the carburetor connector (6-pin). 3. Disconnect the carburetor connector and

verify that the engine stops. 4. If the engine does not stop, replace the

slow fuel cut solenoid valve.

F4-24


CONTINUED

EXHAUST SYSTEM

EXHAUST SYSTEM

EXHAUST SYSTEM INSPECTION 1. Start the engine and inspect the exhaust system component for exhaust gas leakage. 2. If leakage is found, repair or replace as necessary.


Warning • When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait



1 After pipe 4 Front pipe 2 Main silencer 5 Exhaust manifold

3 Pre-silencer

F1-25


CONTINUED

EMISSION SYSTEM 3. Turn the ignition switch to "ON" and "OFF". If

there is a "clicking" noise, the air vent solenoid valve is working properly.

CHECK VALVE (TWO-WAY) INSPECTION 1. Remove the check valve (two-way). 2. Inspect airflow of the valve under the following

conditions. Condition Airflow

Apply pressure below +2.9 kPa +22 mmHg, +0.87 inHg to port A No

Apply pressure over +5.9 kPa +44 mmHg, +1.7 inHg to port A Yes

Apply pressure over -0.98 KPa -7.36 mmHg, -0.29 inHg to port A Yes

EMISSION SYSTEM N0.1 PURGE CONTROL VALVE INSPECTION 1. Blow through port A and verify that air does not

flow. 2. Connect a vacuum pump and apply vacuum of

-14.7 KPa -110 mmHg, -4.33 inHg or above and blow through port A again.

3. Verify that air flows from port A.

N0.2 PURGE CONTROL VALVE INSPECTION 1. Disconnect vacuum hose B from the pipe. 2. Blow into the hose and make sure air flows freely.

3. If not as specified, replace the charcoal canister. WATER THERMO VALVE INSPECTION 1. Remove the water thermo valve. 2. Put the threaded part in a water-filled container and

slowly increase the water temperature. 3. Check the airflow of the valve under the following

conditions.

Condition Port Below 50°C 122°F Above50°C 122°F

A-B No Airflow Airflow C-D Airflow No Airflow

4. If not as specified, replace the water thermo valve.

AIR VENT SOLENOID INSPECTION 1. Remove the air cleaner. 2. Touch the finger onto the air vent solenoid valve.

3. If not as specified, replace the check valve (two-way).

CHARCOAL CANISTER INSPECTION 1. Remove the charcoal canister. 2. Visually check the charcoal canister for damage

and leakage. 3. Shake the charcoal canister upside down and

verify that no pieces of charcoal falls from either nipple.

4. Replace the charcoal canister if necessary. ROLLOVER VALVE INSPECTION 1. Remove the rollover valve.

(Refer to FUEL SYSTEM,FUEL TANK REMOVAL/INSTALLATION.)

2. Hold the valve as shown. Blow air into port A and verify that there is airflow.

F4-26


CONTINUED

EMISSION SYSTEM

CLOSED THROTTLE POSITION (CTP) SWITCH ADJUSTMENT 1. Warm up the engine and run it at idle. 2. Connect a dwell tacho tester to the engine. 3. Connect a voltmeter to the CTP switch terminal. 4. Increase the engine speed to more than 2,000 rpm;

decelerate gradually and verify that the volt meter indicates as follows. Engine speed Voltage

At idle Approx. 12 V 1,000—1,200 (1,100 ±100) rpm Less than 1.5 V

5. If not as specified, turn the adjust screw to adjust.

FLANGE THERMOSWITCH INSPECTION


Continuity Inspection 1. Drain the coolant into a container.


2. Remove the flange thermoswitch from the carburetor.

3. Place the thermoswitch in water with a thermometer, and heat the water gradually.

4. Inspect the thermoswitch terminals by using

an ohmmeter. Specification

Water temperature (°C °F) Continuity

3. Turn the valve upside-down as shown. Blow air into port A and verify that there is no airflow.

4. If not as specified, replace the rollover valve. WATER THERMO VALVE REMOVAL/NSTALLATION1. Drain the engine coolant.

(Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)

2. Remove the water thermo valve from the intake manifold.

3. Wrap sealing tape two or three times around the threaded part of the valve before installing.

4. Use a new washer and install in the reverse order of removal. Tightening torque 25—39 N.m 2.5—4.0 kgf.m-m, 19—28 ft.lbf

PCV VALVE INSPECTION 1. Remove the PCV valve. 2. Check the airflow of the valve under the following

conditions.

Below 67 153 Yes

Condition Airflow

Above 67 153 No

Blow from port A Yes Blow from port B No 3. If not as specified, replace the PCV valve.

5. If not as specified, replace the flange thermoswitch.

F4-27


CONTINUED

CONTROL SYSTEM

CONTROL SYSTEM

COMPONENT LOCATION

1 Ignition coil 4 T/P solenoid valve (GULF only) 2 Water thermoswitch 5 PTC heater relay 3 PCM

6 Fuel pump relay

F4-28


CONTINUED

CONTROL SYSTEM PCM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the front left side trim. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.

PCM INSPECTION Caution • The PCM terminal voltages vary with

change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made.

1. Remove the PCM. 2. Reconnect PCM connector and battery negative

terminal. Note • With the PCM connector connected, body

ground the voltmeter negative (-) lead and measure voltage at each PCM terminal by inserting the voltmeter positive (+) lead.

3. Measure the voltage at PCM terminal using a voltmeter.

4. If any incorrect voltage is detected, inspect related systems, wiring harnesses and connectors referring to the Action column in the terminal voltage list.

PCM Terminal Voltage (Reference)

Terminal Signal Connected to Test condition Voltage (V) Action

Below 1500 rpm B+ *A Throttle

positioner control T/P solenoid valve Engine speed

Above 1500 rpm Below 1.0

• T/P solenoid valve

• Related wiring harnesses

B — GND Constant Below 1.0 • Related wiring harnesses

Coolant temperature Below 40°C 104°F

Ignition SW ON B+

C FICB control FICB solenoid valve

Other Below 1.0

• FICB solenoid valve


Idle Approx 11V D Ignition Igniter

Ignition SW ON Below 1.0

• Igniter • Related wiring

harnessesE — — — — —

ON B+ F IG1 Ignition SW Ignition SW

OFF Below 1.0

• Ignition SW • Related wiring

harnessesG — — — — —

ON B+ H

• Fuel pump control

• PTC heater control

• Fuel pump relay

• PTC heater relay

Ignition SW OFF Below 1.0

• Fuel pump relay • PTC heater

relay • Related wiring

Below 40°C 104°F B+ I Coolant

temperature Water thermoswitch

Coolant temperature

Above 40°C 104°F 0V

• Water thermoswitch


ON B+

J • Fuel pump

control • PTC heater

control

• Fuel pump relay

• PTC heater relay

Ignition SW OFF Below 1.0

• Fuel pump relay • PTC heater

relay • Related wiring

harnesses *: GULF only

F4-29


CONTINUED

CONTROL SYSTEM PTC HEATER RELAY INSPECTION 1. Remove the PTC heater relay. 2. Inspect for continuity between the PTC heater

relay terminals by using an ohmmeter.

3. If not as specified, replace the PTC heater relay. THROTTLE POSITIONER (T/P) SOLENOID VALVE INSPECTION Voltage Inspection


1. Run the engine at idle. 2. Connect a voltmeter to terminals of the T/P

solenoid valve as shown. 3. Measure the voltage as shown.

Engine speed (rpm) Voltage (V) Below 1,500 B+ Above 1,500 Below 1.0

8. If output voltage is as shown in the table above

but there is no airflow in the T/P solenoid valve, perform the following airflow inspection.

Airflow Inspection 1. Disconnect the negative battery cable. 2. Remove the T/P solenoid valve. 3. Inspect for airflow between each port under the

following condition.

4. If not as specified, replace the T/P solenoid valve.

If as specified, inspect the following: Vacuum hose improper routing, kinks or leakage.

Open circuit • Power circuit (T/P solenoid valve connector

terminal A and ignition switch IG1 through common connector.)

• GND circuit (T/P solenoid valve connector terminal B and PCM connector terminal A.) Short circuit

• T/P solenoid valve connector terminal A and ignition switch IG1 through common connector to GND

5. Repair or replace faulty areas. 6. Install the T/P solenoid valve. 7. Connect the negative battery cable. WATER THERMOSWITCH INSPECTION


Continuity Inspection 1. Drain the coolant into a container.


2. Remove the water thermoswitch from the under side of the intake manifold.

3. Place the thermoswitch in water with a thermometer, and heat the water gradually.

4. Inspect the thermoswitch terminals by using an

ohmmeter.

F4-30


CONTINUED

CONTROL SYSTEM

Specification Water temperature (°C °F) Continuity Below 40 104 Yes Above 40 104 No 5. If not as specified, replace the water

thermoswitch.

WATER THERMOSWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant.

(Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)

3. Remove the water thermoswitch from the radiator. 4. The wrap sealing tape two or three times around the

threaded part of the switch before installing.

5. Use a new washer and install in the reverse order of removal.

Tightening torque 5.9—8.8 N.m 60—90 kgf.cm-cm, 53—78 in.lbf

F4-31


CONTINUED

TROUBLESHOOTING

TROUBLESHOOTING FOREWORD

• Before proceeding with the following troubleshooting; (1) Refer to section Gl to understand the basic troubleshooting procedure. (2) Perform the diagnostic trouble code inspection. (3) If a diagnostic trouble code is displayed, proceed with inspection steps for the code. (4) When the engine can be started, perform "ENGINE TUNE-UP".

TROUBLESHOOTING ITEM TABLE • Confirm trouble symptom by using the following diagnostic index, then go to appropriate troubleshooting chart.

No. TROUBLESHOOTING ITEM DESCRIPTION 1 Cranks normally but won't start or hard start No combustion 2

Cranks normally but won't start or hard start (always)

Requires excessive cranking time (more than 5 seconds)

3

Cranks normally but won't start or hard start (engine cold)

Requires excessive cranking of longer than 5 seconds for more than 3 times for engine to start.

4

Cranks normally but won't start or hard start (engine warm)

Requires excessive cranking time (more than 5 seconds)

5 Rough idle/engine stalls at idle (always) — 6 Rough idle/engine stalls at idle (engine cold) Idling is stable when engine is warm. 7 Rough idle/engine stalls at idle (engine warm) Idling is stable when engine is cold. 8

Rough idle/engine stalls at idle when A/C or P/S ON (if equipped)

Engine runs normally at idle with no load, but stalls or vibrates excessively when load (A/C or P/S) is ON.

9 Engine suddenly stalls often — 10 High idle speed after warm-up — 11 Engine stalls at drive away — 12 Engine stalls on deceleration — 13 Hesitation — 14 Poor acceleration — 15 No power, fastest speed is low — 16 Knocking — 17 Afterburn occurs during deceleration — 18 Poor fuel economy —

F4-32


CONTINUED

TROUBLESHOOTING

QUICK DIAGNOSTIC CHART

Fuel system

No Item

Inta

ke-a

ir sy

stem

Carburetor

Cont

rol

syst

em

Engi

ne

Emis

sion

sy

stem

Engine electrical system

1

Cranks normally but won't start or hard start O O O O O O O O O O O O

2

Cranks normally but won't start or hard start (always) O O O O O O O O O O O O

3

Cranks normally but won't start or hard start (engine cold) O O O O O O O O O O O O O

4

Cranks normally but won't start or hard start (engine warm) O O O O O O O O

5

Rough idle/engine stalls at idle (always) O O O O O O O O O O O

6

Rough idle/engine stalls at idle (engine cold) O O O O

7

Rough idle/engine stalls at idle (engine warm) O O O O O O O

8

Rough idle/engine stalls at idle when A/C or P/S ON (If equipped)

9 Engine suddenly stalls often O O O 10 High idle speed after warm-up O O O 11 Engine stalls at drive away O O O O O O O 12 Engine stalls on deceleration O 13 Hesitation O O O O O O O O O O O 14 Poor acceleration O O O O O O O O O O O O O 15 No power, fastest speed is low O O O O O O O O O O O O O 16 Knocking O O O O O O O

17

Afterburn occurs during decel-eration O O

18 Poor fuel economy O O O O O O O O O O O O

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Measure compres-sion pressure

Lower than specification

O

Spark inspection No spark O O O

F4-33


CONTINUED

SYMPTOM TROUBLESHOOTING: Symptom 1-Cranks normally but will not start or hard start F4-34 Symptom 2-Cranks normally but will not start or hard start (always) F4-35 Symptom 3-Cranks normally but will not start or hard start (engine cold) F4-36-37 Symptom 4-Cranks normally but will not start or hard start (engine warm) F4-37 Symptom 5-Rough idle/engine stalls at idle (always) F4-38 Symptom 6-Rough idle/engine stalls at idle (engine cold) F4-39 Symptom 7-Rough idle/engine stalls at idle (engine warm) F4-39 Symptom 8-Rough idle/engine stalls at idle-when a/c or p/s on (if equipped) F4-40 Symptom 9-Engine suddenly stalls often F4-40 Symptom 10-High idle speed after warm-up F4-41 Symptom 11-Engine stalls at drive away F4-41-42 Symptom 12-Engine stalls on deceleration F4-42 Symptom 13-Hesitation F4-42-43 Symptom 14-Poor acceleration F4-43-44 Symptom 15-No power, fastest speed is low F4-44-45 Symptom 16-Knocking F4-46

Symptom 18-Poor fuel economy F4-47



CONTINUED

Symptom 17-After burn occurs during deceleration F4-46

TROUBLESHOOTING

SYMPTOM TROUBLESHOOTING SYMPTOM 1 CRANKS NORMALLY BUT WON'T START OR HARD START

POSSIBLE CAUSE

1. Air/Fuel mixture too lean • Air leak

2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily Ignite, causing serious injury and damage. Always keep

sparks and flames away from fuel. • Fuel line spills and teaks are dangerous. Fuel can ignite and cause serious Injuries or death and



STEP INSPECTION RESULTS ACTION Yes Repair or replace appropriate parts. 1

Check if there is any air leakage. Is there any? No Go to next step.


Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder? No Refer to section G.


Check float level. Is it okay?

No

If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank.

Yes Check each jet and air bleed for clogging. 4

Open and close throttle valve 2-3 times. Does engine start? No Go to next step.


Check each spark plug. Are they okay? No Repair or replace spark plug.

Yes Go to step 8. 6

Check ignition timing at idle. Is it okay? No Go to next step.

Yes Adjust ignition timing. 7

Perform ignition timing adjustment. Can timing be adjusted? No Check both distributor and timing belt.

Yes Go to step 10. 8

Check slow fuel cut solenoid. Is it okay? No Go to next step.

Yes Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor.

9

Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? No Repair or replace slow fuel cut solenoid valve.

Yes Go to step 12. 10

Check compression pressure. Is it okay? No Go to next step.

Yes Check pistons and cylinders for wear, 11

Add oil through plug hole. Does engine start?

No

Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket

Yes

Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)

12

Check primary main, slow system. Is it okay?

No Clean or replace each jet and air bleed.

F4-34


CONTINUED

TROUBLESHOOTING

SYMPTOM 2 CRANKS NORMALLY BUT WON'T START OR HARD START (ALWAYS)

POSSIBLE CAUSE

1. Air/Fuel mixture too lean • Air leak • Fuel level incorrect • Restricted primary main, slow system

2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression 5. Air/Fuel mixture too rich

• Float level incorrect • Loose primary main jet



damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. "





Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder? No Refer to Section G.

Yes Go to Step 8. 3






No









9




Yes Check pistons and cylinders for wear. 11


No


Yes


12



F4-35


CONTINUED

TROUBLESHOOTING

SYMPTOM 3 CRANKS NORMALLY BUT WON'T START OR HARD START (ENGINE COLD)

POSSIBLE CAUSE

1. Air/Fuel mixture too lean • Air leak

2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression 5. Air/Fuel mixture too rich

• Choke system malfunction • Loose primary main jet

Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor Is hazardous. It can easily ignite, causing serious injury and damage. Always keep







Disconnect high-tension lead at idle, then check engine speed, Does it decrease equally at each cylinder? No Refer to Section G.



No






Yes Go to Step 9. 6





Check choke system. Is it okay? No Repair or replace choke system.




10






No


F4-36


CONTINUED


Yes


13



SYMPTOM 4 CRANKS NORMALLY BUT WON'T START OR HARD START (ENGINE WARM)

POSSIBLE CAUSE

1. Percolation • Air vent solenoid valve malfunction

2. Air/Fuel mixture too rich • High float level • Choke system malfunction

Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage.

Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and



STEP INSPECTION RESULTS ACTION 1 Inspect spark plugs. Yes Repair or replace Are spark plugs wet or covered with carbon? No Go to next step.

2 Check choke system. Yes Go to next step. Is it okay? No Repair or replace choke system.

3 Check air vent solenoid valve. Yes Go to next step. Is it okay? No Replace air vent solenoid valve.

4 Check float level? Yes Check for the following: Is it okay? (float level is high.) • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) No Inspect both float and needle valve.

F4-37


CONTINUED

TROUBLESHOOTING

SYMPTOM 5 ROUGH IDLE/ENGINE STALLS AT IDLE (ALWAYS)

POSSIBLE CAUSE

1. Air/Fuel mixture too rich • High float level • Loose primary main jet • Restricted primary slow air bleed

2. Poor ignition or misfire 3. Air/Fuel mixture too lean

• Air leakage • Restricted primary main jet

4. Low engine compression Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep


damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described In this manual.





Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder? No Refer to Section G.


Check idle-up system. Is it okay? No Repair or adjust system.

Yes Go to Step 6. 4




Yes Go to Step 8. 6

Check idling speed. Is it okay? No Go to next step.

Yes Adjust idling speed. 7

Perform idling speed adjustment. Can idling speed be adjusted? No Adjust or inspect idling mixture.


Check pcv valve. Is it okay? No Repair or replace pcv valve.


Check compression pressure? Is it okay? No Go to next step.


Drive vehicle. Does engine stop at takeoff?

No


Yes


11



F4-38


CONTINUED

TROUBLESHOOTING

SYMPTOM 6 ROUGH IDLE/ENGINE STALLS AT IDLE (ENGINE COLD)

POSSIBLE CAUSE

• Choke system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep




STEP INSPECTION RESULTS ACTION 1

Check choke system (quick release). Is it okay?

Yes


No Repair or replace choke system.

SYMPTOM 7 ROUGH IDLE/ENGINE STALLS AT IDLE (ENGINE WARM)

POSSIBLE CAUSE

1. Choke system malfunction 2. Float level incorrect 3. Air vent solenoid valve malfunction






Start and warm engine. Check choke valve. Is it fully open? No Repair or replace choke system.

Yes Repair or replace spark plugs. 2

Inspect spark plugs. re spark plugs wet or covered with carbon? No Go to next step.


Check air vent solenoid valve. Is it okay? No Replace valve.


Check fuel check valve. Is it okay? No Repair or replace valve.

Yes


5

Check float level. Is it okay? (float level is high.)

No Inspect both float and needle valve.

F4-39


CONTINUED

TROUBLESHOOTING

SYMPTOM 8 ROUGH IDLE/ENGINE STALLS AT IDLE - WHEN A/C OR P/S ON (IF EQUIPPED

POSSIBLE CAUSE

1. Idle-up system malfunction • Solenoid valve malfunction

Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious Injury and damage. Always keep





Follow steps for troubleshooting item "Rough idle/engine stalls at idle (Always)".

1

Inspect idle-up system. Is it okay? No Adjust or repair system,

SYMPTOM 9 ENGINE SUDDERLY STALLS OFTEN

POSSIBLE CAUSE

1. Disconnected starter connector 2. Poor connection of starter connector Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor Is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks

and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and




Check starter connector. Is it disconnected or is it not properly con-nected?

No Properly connect connector, or repair or replace if necessary.

Yes


2

Check slow fuel cut valve. Is it okay?

No Go to next step. Yes Repair or replace wiring harness between slow fuel cut

solenoid valve and carburetor. 3


F4-40


CONTINUED

TROUBLESHOOTING

SYMPTOM 10 HIGH IDLE SPEED AFTER WARM-UP

POSSIBLE CAUSE

• Idle-up system malfunction • Choke system malfunction

Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks





Check throttle wiring. Is there sufficient slack in wiring? No Adjust or repair accelerator cable.


Check idle-up system. Is it okay? No Adjust or repair.


Check secondary throttle valve. Is it closed? No Repair or inspect secondary diaphragm link.

Yes


4


No Inspect both float and needle valve.

SYMPTOM 11 ENGINE STALLS AT DRIVE AWAY

POSSIBLE CAUSE

• Restricted primary main system • Accelerator pump malfunction • Poor ignition or misfire • Malfunctioning unloader system

Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks




STEP INSPECTION RESULTS ACTION Yes Repair or replace parts as necessary. 1

Check system for air leakage. Is there any? No Go to next step.




Check accelerator pump. Is fuel pumped out when accelerator pump is depressed? No Repair or replace accelerator pump.


Check distributor's vacuum advance. Is it correct? No Replace distributor vacuum control unit.


Check unloader system. Is it okay? No Repair or replace unloader system.

F4-41


CONTINUED

TROUBLESHOOTING



6


No Clean or replace each Jet and air bleed.

SYMPTOM 12 ENGINE STALLS ON DECELERATION

POSSIBLE CAUSE

• Slow fuel cut solenoid valve malfunction • Throttle positioner (T/P) malfunction (GULF only) Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep





Check idle-up system. Is it okay? No Repair or replace any parts as necessary.

Yes Go to Step 4. 2

Check slow fuel cut valve. Is it okay? No Go to next step.

Yes

Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor.

3


Yes


4

Check dashpot's touch speed. Is it correct?

No Adjust dashpot.

SYMPTOM 13 HESITATION

POSSIBLE CAUSE

• Spark advance control malfunction • Restricted jets • Air leakage





STEP INSPECTION RESULTS ACTION Yes Repair or replace any parts as necessary. 1

Check system for air leakage. Is there any? No Go to next step.



F4-42


CONTINUED

TROUBLESHOOTING


Check centrifugal spark advance control. Is it okay?

No

Check for the following: • Over advance (Inspect for governor spring damage.) • Under advance (Inspect governor weight, cam op eration.)


Check accelerator pump. Is fuel pumped out when accelerator pump is depressed? No Repair or replace pump.


Check secondary diaphragm. Is it okay? No Replace secondary diaphragm.


Inspect spark plugs? Are they okay? No Clean or replace spark plugs.


Is linkage of primary and secondary valve smooth? No Repair or replace any parts as necessary.

Yes


8

Inspect every jet. Are they okay?

No

Clean or replace jets. Note • Dirt and grime can be removed from jets by covering the air horn with your hand.

SYMPTOM 14 POOR ACCELERATION

POSSIBLE CAUSE

1. Spark advance control malfunction 2. Restricted intake/exhaust system 3. Air/Fuel mixture too lean

• Low float level • Restricted jets, air bleeds • Accelerator pump malfunction

4. Secondary diaphragm malfunction • RPM limiter malfunction

5. Low engine compression 6. Poor ignition Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep







Inspect intake system. Is it restricted? (especially air cleaner) No Repair or replace intake system.


Check choke valve. Is it fully open after warm-up? No Repair or replace choke system.


Check distributor, (centrifugal spark advance, vacuum spark advance) It is okay? No Repair or replace distributor.

F4-43


CONTINUED



Inspect exhaust system. Is it okay? No Repair or replace exhaust system.


Inspect accelerator pump. It is okay? No Repair or replace accelerator pump.



No



Inspect spark plugs. Are they okay? No Clean or replace spark plugs.





Yes Check pistons, rings, and cylinders for wear. 11


No

Check the following: • Cylinder heads, gaskets • Valve clearance

Yes Clean or replace each jet and air bleed. 12

Inspect all jets and air bleeds (including high speed richer) of both primary and secondary main passage. Is there blockage?

No


SYMPTOM 15 NO POWER, FASTEST SPEED IS LOW

POSSIBLE CAUSE

• Restricted primary main, slow system • Centrifugal spark advance malfunction • Restricted exhaust system • Restricted air cleaner


sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can Ignite and cause serious Injuries or death and




Check system for air leakage. Is there any No Repair or replace any part as necessary.

Yes Stop vehicle and let it idle to cool engine. Inspect coolant and engine oil.

2

Check engine. Does it seem to be overheating? No Go to next step.




Check choke valve. Is it fully open after warm-up? No Repair or replace choke valve.


Check intake system. Is it restricted? (especially air cleaner) No Repair or replace intake system.

F4-44


CONTINUED

TROUBLESHOOTING


Check exhaust system. Is it restricted? No Repair or replace exhaust system.


Check float level. Is it okay? (float level is low.)

No

If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank.


Inspect spark plugs. Are they okay? No Clean or replace spark plugs.




Check centrifugal spark advance control. Is it okay? No

Check for the following: • Over advance (Inspect for governor spring damage.) • Under advance (Inspect governor weight, cam op-

eration.)Yes Go to Step 13. 11




No



Check main (primary) system. Is it okay?

No

Check the following: • Main jet • Air bleed

Note • Dirt and grime can be removed from jets by covering the air horn with your hand.

Yes


14

Check main (secondary) system. Is it okay?

No

Check the following: • Main jet • Air bleed Note • Dirt and grime can be removed from jets by covering the air horn with your hand.

F4-45


CONTINUED

TROUBLESHOOTING

SYMPTOM 16 KNOCKING

POSSIBLE CAUSE

1. Air/Fuel mixture too lean • Restricted primary main, slow system • Poor ignition or misfire • Insufficient engine coolant


sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious Injuries or death and



STEP INSPECTION RESULTS ACTION Yes Stop vehicle and let it idle to cool engine.

Inspect coolant and engine oil, 1

Check engine Does it seem to be overheating? No Go to next step.

Yes Replace fuel, 2

Inspect spark plugs. Are spark plugs electrode free of carbon ac-cumulation? No Clean or replace spark plugs.

SYMPTOM 17 AFTERBURN OCCURS DURING DECELERATION

POSSIBLE CAUSE

• Poor ignition or misfire • Slow fuel cut solenoid valve malfunction • Throttle position (T/P) malfunction (GULF only) • Dashpot malfunction

Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage.

Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or

death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.


STEP INSPECTION RESULTS ACTION Yes Go to Step 3. 1





Inspect distributor, (centrifugal spark ad-vance, vacuum spark advance) It is okay? No Repair or replace distributor.

Yes Go to next step.4

Check thermostat. Is it okay? No Repair or replace thermostat.

Yes


5

Inspect every jet. Are they okay?

No Clean or replace jets.

F4-46


CONTINUED

TROUBLESHOOTING

SYMPTOM 18 POOR FUEL ECONOMY

POSSIBLE CAUSE

• Incorrect adjustment of main adjust screw • Incorrect adjustment of idle speed • High float level • Poor ignition or misfire


sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death

and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.



Check system for air leakage. Is there any? No Repair or replace any part as necessary.

Yes Go to Step 4. 2




Yes Go to Step 6. 4

Check idling speed. Is it correct? No Go to next step.

Yes Adjust idling speed. 5

Perform idling speed adjustment. Can it be adjusted? No Adjust or repair any part as necessary.

Yes Go to Step 8. 6

Check slow fuel cut solenoid valve. Is it okay? No Go to next step.


7



Check both CO and HC concentration. Are they okay? No Adjust CO and HC concentrations.


Check choke valve. Is it fully open after warm-up? No Repair or replace choke system.



No

Check the following: • Float • Needle valve


Check distributor, (centrifugal spark advance, vacuum spark advance) Is it okay? No Repair or replace distributor.


Check compression pressure. Is it normal? No Go to next step.



No


Yes


14

Is main jet loose?

No Clean or replace jets.

F4-47


CONTINUED

ST

G–1

ENGINE ELECTRICAL SYSTEMCHARGING SYSTEM G–1. . . . . . . . . . . . . . . . . . . . . .

BATTERY REMOVAL/INSTALLATION G–1. . . . . . BATTERY INSPECTION G–1/2. . . . . . . . . . . . . . . . . . BATTERY RECHARGING G–2. . . . . . . . . . . . . . . . . GENERATOR REMOVAL/INSTALLATION G–2/3. . . GENERATOR INSPECTION G–3/4. . . . . . . . . . . . . .

IGNITION SYSTEM G–5. . . . . . . . . . . . . . . . . . . . . . . . IGNITER INSPECTION G–5. . . . . . . . . . . . . . . . . . . IGNITION COIL REMOVAL/INSTALLATION G–5.

IGNITION COIL INSPECTION G–5/6. . . . . . . . . . . . . DISTRIBUTOR REMOVAL/INSTALLATION G–6/7. . DISTRIBUTOR DISASSEMBLY/ASSEMBLY G–8. DISTRIBUTOR INSPECTION (F2 CARB) G–9. . . HIGH-TENSION LEAD

REMOVAL/INSTALLATION G–9. . . . . . . . . . . . . . STARTING SYSTEM G–10. . . . . . . . . . . . . . . . . . . . . . .

STARTER REMOVAL/INSTALLATION G–10. . . . . . STARTER INSPECTION G–10/11. . . . . . . . . . . . . . . . . .

CHARGING SYSTEMBATTERY REMOVAL/INSTALLATION


N·m kgf·cm, in·lbf

3.5—4.935—50, 31—43

1 Negative battery cable

2 Positive battery cable

3 Battery clamp+ Installation Note (RH)

4 Battery

5 Battery tray

Battery Clamp Installation Note (RH) Install the battery clamp as shown.

FRONT

FRONT

75D26R

BATTERY INSPECTIONBattery Inspect the battery in the following procedure.Step Inspection Action

1 Measure open circuitAbove12.4 V

Go toStep 3.

1voltage of battery. Below

12.4 VGo tonext step.

2Quick charge for 30minutes and recheck

Above12.4 V

Go tonext step.

2 minutes and recheckvoltage. Below

12.4 VReplacebattery.

3

Apply test load (see testload chart) to battery usinga battery load tester and

YesBattery isokay.

3y

record battery voltage after15 seconds. Is voltagemore than specification?

NoReplacebattery.

BACK.TO.MAIN.INDEX

CONTINUED


CHARGING SYSTEM

G–2

Test load chartBattery Load (A)

34B19R 110

55D23R 180

75D26L 195

75D26R 195

80D26R 195

95D31R 250

Battery positive voltage with loadApproximatebattery temp.

Minimum voltage(V)

21 °C 70 °F 9.6

15 °C 60 °F 9.5

10 °C 50 °F 9.4

4 °C 40 °F 9.3

– 1 °C 30 °F 9.1

– 7 °C 20 °F 8.9

–12 °C 10 °F 8.7

–18 °C 0 °F 8.5

Back-up Current1. Verify that the ignition switch (engine switch) is at the

OFF position and that the key has been removed.2. Disconnect the negative battery cable.

Caution Operating electrical loads while measuring

the back-up current can damage the circuittester.

3. Measure the back-up current between the negativebattery terminal and the negative battery cable.

Back-up current20 mA max.

4. If the current exceeds the maximum, remove thefuse in the main fuse block and the fuse block oneby one while measuring the back-up current.

5. Inspect and repair harnesses and connectors ofthe fuse at which the current reduces.

BATTERY RECHARGING

Caution When disconnecting the battery, remove

the negative cable first and install it last toprevent damage to electrical componentsor the battery.

To avoid deformation or damage to thebattery, remove the battery plugs whilecharging the battery.

Do not quick charge for over 30 minutes. Itwill damage the battery.

1. Place a battery in a pan of water to prevent it fromoverheating. The water level should come up abouthalfway on the battery. Keep water off the top ofthe battery.

BATTERY

2. Connect a battery charger to the battery.3. Adjust the charging current as follows.

Battery type(5–hour rate)

Slow charge(A)

Quick charge(A)/(30 min.)

34B19R (27) 3.0—4.0 20

55D23R (48) 4.5—5.5 30

75D26L (52) 5.5—6.5 35

75D26R (52) 5.5—6.5 35

80D26R (55) 5.5—6.5 35

95D31R (64) 6.5—8.0 40

4. After the battery has been recharged, measure thebattery positive voltage and verify that the batterykeeps specified voltage for more than 1 hour.

SpecificationAbove 12.4 V

5. If not as specified, replace the battery.

GENERATOR REMOVAL/INSTALLATION

Warning When the battery cables are connected,

touching the vehicle body with generatorterminal B will generate sparks. This cancause personal injury, fire, and damage tothe electrical components. Alwaysdisconnect the battery before performingthe following operation.

1. Disconnect the negative battery cable.2. Remove the fresh-air duct, air intake pipe and air

hose. (WL, WL Turbo)3. Remove in the order indicated in the table.4. Install in the reverse order of removal.5. Inspect the drive belt deflection/tension.

(Refer to Section B2, DRIVE BELT, DRIVE BELT INSPECTION.)


CONTINUED


ST

CHARGING SYSTEM

G–3

5.0—6.8 N·m 50—70 kgf·cm, 44—60 in·lbf


38—51 3.8—5.3, 28—38

G6

19—25 1.9—2.6,14—18

5.0—6.8 N·m 50—70 kgf·cm, 44—60 in·lbf


38—51 3.8—5.3, 28—38

16—22 1.6—2.3,12—16

F2 CARB, F2 CIS

5.0—6.8 N·m 50—70 kgf·cm,44—60 in·lbf

38—51 3.8—5.3,28—38


A

B

C

38—51 3.8—5.3, 28—38

20—302.0—3.1, 15—22

A

B

C

WL, WL Turbo

1 Terminal B wire

2 Connector

3 Drive belt (generator)

4 Generator strap (G6)

5 Generator

GENERATOR INSPECTIONGenerator Warning Light

1. Verify that the battery is fully charged.2. Verify that the drive belt deflection/tension is

correct. (Refer to Section B2, DRIVE BELT,DRIVE BELT INSPECTION.)

3. Turn the ignition switch (engine switch) on andverify that the generator warning light illuminates.

4. If not, inspect the generator warning light andwiring harnesses between the battery andgenerator warning light and between the batteryand generator terminal L (G6, F2 CARB, F2 CIS), I(WL, WL Turbo).

S L

G6, F2 CARB, F2 CIS


CONTINUED


CHARGING SYSTEM

G–4

A S I

WL, WL Turbo

5. Verify that the generator warning light goes outafter engine starts.

6. If not, inspect the wiring harness between the Sterminals of the generator (WL, WL Turbo) and thegenerator.

GeneratorVoltage

1. Verify that the battery is fully charged.2. Verify that the drive belt deflection/tension is within

the specification. (Refer to Section B2, DRIVEBELT, DRIVE BELT INSPECTION.)

3. Turn off all electrical loads.4. Turn the ignition switch (engine switch) to START

position and verify that the generator turnssmoothly without any noise while the engine isrunning.

5. Measure the voltage at the terminals shown in thetable.

S L

G6, F2 CARB, F2 CIS

Standard voltage

TerminalIgnition switch ON (V) Idle [20 °C 68°F] (V)

TerminalG6, F2 CARB, F2 CIS G6, F2 CARB, F2 CIS

B B+ 14.1—14.7

L Approx. 1 13.0—14.0

S B+ 14.1—14.7

A S I

WL, WL Turbo

Standard voltage

TerminalEngine switch ON (V) Idle (V) [20 °C 68°F]

TerminalWL, WL Turbo WL, WL Turbo

B B+ 14.05—14.85

A B+ 14.05—14.85

S 0 7.025—7.425

I 2.0—4.0 13.00—14.85

6. If not as specified, disassemble and inspect thegenerator.

Current1. Verify that the battery is fully charged.2. Verify that the drive belt deflection/tension is

correct. (Refer to Section B2, DRIVE BELT,DRIVE BELT INSPECTION.)

3. Disconnect the negative battery cable.4. Connect an ammeter, capable of reading 120 A or

over, between generator terminal B and the wiringharness.

5. Connect the negative battery cable.6. Turn all electrical loads off.7. Start the engine and increase the engine speed to

2,000—2,500 rpm.8. Turn the following electrical loads on and verify that

the current reading increases. Headlights Blower motor Rear window defroster

Note Current required for generating power varies

with electrical loads applied.

Standard current (Reference)

Measuring conditionsRoom temperature: 20 °C 68 °FVoltage: 13.5 VEngine hot

Engine speedTerminal B current (A) *

Engine speed(rpm) G6, F2 CARB,

F2 CISWL, WL Turbo

1,000 Approx. 0—43 Approx. 0—58

2,000 Approx. 0—62 Approx. 0—74

*: Must not be 0 A.

9. If generator terminal B current will not increase,disassemble and inspect the generator.


CONTINUED


ST

IGNITION SYSTEM

G–5

IGNITION SYSTEMIGNITER INSPECTIONG6, F2 CIS

1. Disconnect the igniter connector.2. Turn the ignition switch on and measure the

voltage at connector terminal A using thevoltmeter.

G6, F2 CIS

SpecificationBattery positive voltage

3. Turn the ignition switch off and verify that there iscontinuity between terminal B and the bodyground.

4. While cranking the engine, measure the voltage atterminal C using the voltmeter.

SpecificationApprox. 0.5 V

5. If voltage and continuity are okay, replace theigniter. (Refer to IGNITION SYSTEM, IGNITIONCOIL REMOVAL/INSTALLATION.)

IGNITION COIL REMOVAL/INSTALLATIONG6, F2 CARB, F2 CIS


8.9—12.7 90—130, 79—112

1.5—1.9 15—20, 14—17

6.87—9.80 70—100, 60.8—86.8]


G6, F2 CIS

8.9—12.7 90—130, 79—112

2.0—2.9 20—30, 18—26

6.87—9.80 70—100, 60.8—86.8]


F2 CARB

1 Center lead

2 Connector

3 Ignition coil bracket

4 Condenser

5 Ignition coil

6 Igniter

IGNITION COIL INSPECTIONG6, F2 CARB, F2 CISPrimary Coil Winding

1. Disconnect the ignition coil connector.


CONTINUED


IGNITION SYSTEM

G–6

2. Measure the resistance at the primary coil using anohmmeter.

Specification [20 °C 68 °F]G6, F2 CIS: 0.81—0.99 ΩF2 CARB: 1.035—1.265 Ω

G6, F2 CIS

F2 CARB

3. If not as specified, replace the ignition coil. (Refer to IGNITION SYSTEM, IGNITION COILREMOVAL/INSTALLATION.)

Secondary Coil Winding1. Disconnect the ignition coil connector.2. Disconnect the center lead.3. Measure the resistance at the secondary coil using

an ohmmeter.

Specification10—16 k [20 °C 68 °F]

G6, F2 CIS

F2 CARB

(+)

4. If not as specified, replace the ignition coil. (Refer to IGNITION SYSTEM, IGNITION COILREMOVAL/INSTALLATION.)

DISTRIBUTOR REMOVAL/INSTALLATIONG6, F2 CARB, F2 CIS

1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.4. Adjust the ignition timing.

(Refer to Section F2, ENGINE TUNE-UP, IGNITION TIMING ADJUSTMENT.)

19—25 1.9—2.6, 14—18


G6


CONTINUED


ST

IGNITION SYSTEM

G–7

19—25 1.9—2.6, 14—18


F2 CARB

19—25 1.9—2.6, 14—18


F2 CIS

1 Vacuum hose

2 High-tension lead+ HIGH-TENSION LEAD


3 Connector

4 Distributor+ Installation Note

Distributor Installation Note Verify that the No.1 cylinder is at top dead center,

and align the distributor matching marks.

MATCHING MARKS


CONTINUED


IGNITION SYSTEM

G–8

DISTRIBUTOR DISASSEMBLY/ASSEMBLYG6, F2 CARB, F2 CIS


F2 CARB

F2 CISG6

R

R

R

1 Cap

2 Rotor

3 Cover

4 Signal rotor

5 Pick-up coil with igniter

6 Vacuum control unit

7 Breaker

8 Coupling set

9 Governor set

10 Oil seal

11 Bearing

12 Distributor body

13 O-ring


CONTINUED


ST

IGNITION SYSTEM

G–9

DISTRIBUTOR INSPECTION (F2 CARB)Centrifugal Spark Advance Control

1. Warm up the engine to the normal operatingtemperature.

2. Check to be sure that the idle speed and ignitiontiming are correct. (Refer to Section F2, ENGINE TUNE-UP.)

3. Turn off all electrical loads.4. Disconnect the vacuum hose to the vacuum control

unit, and plug the end of the hose.

VACUUM HOSE

5. While gradually increasing the engine speed, usethe timing light to check the advance angle oncrankshaft pulley.

ENGINE SPEED ( rpm )

19—23

9—13

ADVANCE (DEGREE)

( ° )

0 1,200 2,200 6,0000—2

(1) Excess advance weak governor spring (if . . . the governor spring is

broken, the advance will rise very high)

(2) Insufficient advance governor weight or cam .malfunction

6. If necessary, disassemble and inspect thedistributor.

Vacuum Spark Advance Control1. Warm up the engine to normal operating

temperature.2. Check to be sure that the idle speed and ignition

timing are correct.(Refer to section F2, ENGINE TUNE-UP.)

3. Turn off all electrical loads.4. Disconnect the vacuum hose to the vacuum control

unit, and plug the end of the hose.5. Attach a vacuum pump to the diaphragm A and

check using the timing light while applying vacuum.

DIAPHRAGM A

TIMING LIGHT

ADVANCE (DEGREE)

( ° )

VACUUM ( kPa mmHg , inHg )

20 150, 5.9

11—15

53.3400, 15.7

00—2

6. If necessary, disassemble and inspect thedistributor.

Pick-up Coil With Igniter Inspection1. Connect an ohmmeter to the pick-up coil.

2. Measure the resistance.

Resistance900—1,200 Ω

3. If it is not within specification, replace it.

HIGH-TENSION LEAD REMOVAL/INSTALLATION

Caution The high-tension leads must be reinstalled

to their original positions. Incorrectinstallation can damage the leads andcause power loss, and negatively affect theelectronic components.


CONTINUED


STARTING SYSTEM

G–10

STARTING SYSTEMSTARTER REMOVAL/INSTALLATION

Warning When the battery cables are connected,

touching the vehicle body with starterterminal B will generate sparks. This cancause personal injury, fire, and damage tothe electrical components. Alwaysdisconnect the battery before performingthe following operation.

1. Disconnect the negative battery cable.2. Remove the battery. (WL, WL Turbo)

(Refer to CHARGING SYSTEM, BATTERYREMOVAL/INSTALLATION.)

3. Remove the intake manifold bracket. (G6)4. Remove in the order indicated in the table.5. Install in the reverse order of removal.


9.9—11.7 N·m 100—120 kgf·cm,87—104 in·lbf

38—51 3.8—5.3, 28—38

G6, F2 CARB, F2 CIS


9.9—11.7 N·m 100—120 kgf·cm,87—104 in·lbf

38—51 3.8—5.3, 28—38

WL, WL Turbo

1 Terminal B wire

2 Terminal S wire

3 Starter

STARTER INSPECTIONOn-vehicle Inspection

1. Verify that the battery is fully charged.2. Crank the engine and verify that the starter turns

smoothly without any noise.3. If not as specified, measure the voltage at

terminals S and B when the ignition switch (engineswitch) is at START position.

SpecificationAbove 8 V

4. If the voltage is within the specification, remove thestarter and inspect the magnetic switch and thestarter.

5. If the voltage is not as specified, inspect the wiringharness, ignition switch (engine switch).

No Load Test1. Verify that the battery is fully charged.2. Connect the starter, battery, voltmeter, and

ammeter as shown.

STARTER

A

B

M

V

TERMINAL S

IGNITIONSWITCH(ENGINESWITCH)

BATTERY


CONTINUED


STARTING SYSTEM

G–11

3. Operate the starter and verify that it turnssmoothly.

4. Measure the voltage and current while the starteris operating.

SpecificationEngine type

ItemG6 F2 CARB,

F2 CISWL,

WL Turbo

Voltage (V) 11.5 11.5 11

Current (A) Below 100 Below 60 Below 130

5. If not as specified, repair or replace the inner partsas necessary.


CONTINUED


H–1

CLUTCHGENERAL PROCEDURES H–1. . . . . . . . . . . . . . . . . . . CLUTCH FLUID H–1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH FLUID INSPECTION H–1. . . . . . . . . . . . . CLUTCH FLUID REPLACEMENT/AIR

BLEEDING H–1/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH PEDAL H–2. . . . . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH PEDAL INSPECTION/ADJUSTMENT H–2/3. . . . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH PEDAL REMOVAL/INSTALLATION H–3. . . . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH PEDAL DISASSEMBLY/ASSEMBLY H–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH MASTER CYLINDER H–5. . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER

REMOVAL/INSTALLATION H–5. . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER

DISASSEMBLY/ASSEMBLY H–5/6. . . . . . . . . . . . . .

CLUTCH RELEASE CYLINDER H–7. . . . . . . . . . . . . . CLUTCH RELEASE CYLINDER

REMOVAL/INSTALLATION H–7. . . . . . . . . . . . . . . CLUTCH RELEASE CYLINDER

DISASSEMBLY/ASSEMBLY H–7. . . . . . . . . . . . . . CLUTCH UNIT H–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLUTCH COVER INSPECTION H–10. . . . . . . . . . . . CLUTCH DISC INSPECTION H–11. . . . . . . . . . . . . . . CLUTCH RELEASE COLLAR

INSPECTION H–11. . . . . . . . . . . . . . . . . . . . . . . . . . . FLYWHEEL H–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PILOT BEARING INSPECTION H–11. . . . . . . . . . . . . FLYWHEEL INSPECTION H–11. . . . . . . . . . . . . . . . .

GENERAL PROCEDURESClutch Pipe Removal/Installation

1. If any clutch pipe has been disconnected any timeduring the procedure, add brake fluid, bleed the air,and inspect for leakage after the procedure hasbeen completed.

2. If removing the clutch pipe, remove it using theSST (49 0259 770B). If installing the clutch pipe,modify the clutch pipe tightening torque to allow forthe use of a torque wrench–SST (49 0259 770B)combination, and then tighten the clutch pipe usingthe SST (49 0259 770B).

CLUTCH FLUIDCLUTCH FLUID INSPECTION

Note The fluid in the reservoir must be maintained

between the MIN/MAX level duringreplacement.

CLUTCH FLUID REPLACEMENT/AIR BLEEDING

Caution Clutch fluid will damage painted surfaces,

be careful not to spill clutch fluid on apainted surface. If this should happen,wash it off immediately.

Do not mix different brands of clutch fluid. Do not reuse the clutch fluid that was

drained out.1. Draw the fluid from the reserve tank with a suction

pump.2. Remove the bleeder cap from the clutch release

cylinder and attach a vinyl hose to the bleeder plug.3. Place the other end of the vinyl hose into a

container.4. Slowly pump the clutch pedal several times.5. With the clutch pedal depressed, loosen the

bleeder screw using the SST to let fluid escape.Close the bleeder screw using the SST.

BLEEDER SCREW

49 0259 770B

BACK.TO.MAIN.INDEX

CONTINUED


CLUTCH UNIT REMOVAL/INSTALLATION . . . H–8/10

CLUTCH FLUID, CLUTCH PEDAL

H–2

1.Repeat steps 4 and 5 until only clean fluid is seen.2.Tighten the bleeder screw.


3.Add fluid to the MAX mark.4.Check for correct clutch operation.

CLUTCH PEDALCLUTCH PEDAL INSPECTION/ADJUSTMENTClutch Pedal Height

1. Measure the distance from the upper surface of thepedal pad to the carpet.

Pedal height241.6—246.6 mm 9.52—9.70 in


PEDAL HEIGHT

A 14—171.4—1.8, 11—13

B

CARPET

2.If necessary, adjust the pedal height by turningstopper bolt A and clutch switch (or adjust bolt) B.


CONTINUED


CLUTCH PEDAL

H–3

Clutch Pedal Free Play1. Depress the clutch pedal by hand until clutch

resistance is felt, and measure the pedal free play.

Pedal free play3.0—8.0 mm 0.12—0.31 in

PEDALFREE PLAY


D

C12—161.2—1.7, 8.7—12.3

2.If necessary, adjust the pedal free play by turninglocknut C and adjusting push rod D.

Clutch Release Point Inspection1. Without depressing the clutch pedal, slowly shift

the shift lever into reverse position until the gearscontact.

2.Gradually depress the clutch pedal and measure thestroke distance from the point the gear noise stops(release point) up to the full stroke end position.

Standard distanceA: 14.6—37.5 mm 0.58—1.47 in

(reference value)

FULLSTROKEENDPOSITION

RELEASEPOINT

A

PEDAL STROKE

3.If the clutch pedal disengagement stroke is outside ofthe specification, adjust the pedal height and pedalfree play, and verify the pedal stroke.

Pedal stroke146.5—151.5 mm 5.8—5.9 in

(reference value)

CLUTCH PEDAL REMOVAL/INSTALLATION1. Disconnect the negative battery cable.

2.Remove in the order indicated in the table.3.Install in the reverse order of removal.4.After installation, adjust the clutch pedal.

(Refer to CLUTCH PEDALINSPECTION/ADJUSTMENT)

L.H.D.


19—251.9—2.6,14—18

19—251.9—2.6,14—18

6.9—9.80 N·m70—100 kgf·cm,61—86.8 in·lbf

1 Clutch switch connector (G6, F2 CIS)

2 Spring pin

3 Clevis pin

4 Nut

5 Clutch pedal component

R.H.D.G6, F2 CIS, F2 Carb Refer to section F2, INTAKE-AIR

SYSTEM, ACCELERATOR PEDALREMOVAL/INSTALLATION.

WL, WL Turbo Refer to section F2, INTAKE-AIR SYSTEM,

ACCELERATOR PEDALREMOVAL/INSTALLATION.


CONTINUED


CLUTCH PEDAL

H–4

CLUTCH PEDAL DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.

Note Apply lithium-based grease to the spring and

bush when assembling.

2. Assemble in the reverse order of disassembly.

R

12—161.2—1.7, 8.7—12.3


14—171.4—1.8, 11—13

1 Clutch switch (G6, F2 CIS)

2 Adjustment bolt (WL, WL Turbo, F2 Carb)

3 Nut

4 Stopper rubber

5 Retaining ring

6 Washer

7 Bush

8 Pin

9 Fork

10 Push rod

11 Nut

12 Pedal pad

13 Clutch pedal component


CONTINUED


CLUTCH MASTER CYLINDER

H–5

CLUTCH MASTER CYLINDERCLUTCH MASTER CYLINDER REMOVAL/INSTALLATION


* 49 0259 770B

6.9—9.8 70—100, 60.8—86.7

SST

12.8—21.5130—220, 113—190

*


R

1 Clutch pipe

2 Nut

3 Clutch master cylinder

4 Gasket

CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.

R

R

R

84—112 N·m8.5—11.5 kgf·m,61.5—83.1 ft·lbf


CONTINUED


CLUTCH MASTER CYLINDER

H–6

1 Snap ring+ Disassembly Note+ Assembly Note

2 Piston

3 Protector

4 Primary cap

5 Return spring

6 Tank cap

7 Reservoir

8 Bushing

9 Joint bolt

10 Gasket

11 One-way valve piston

12 Return spring

13 One way valve pin

14 Clutch master cylinder body

Snap Ring Disassembly Note Hold the piston down using a cloth-wrapped pin

punch.

Snap Ring Assembly Note Hold the piston down using a cloth-wrapped pin

punch.


CONTINUED


CLUTCH RELEASE CYLINDER

H–7

CLUTCH RELEASE CYLINDERCLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION



22—26 2.2—2.7, 16—19

16—22 1.6—2.3, 12—16

(LITHIUM BASED GREASE)

1 E-clip

2 Clutch hose

3 Bolt

4 Clutch release cylinder

CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.

R

5.9—8.8 N·m60—90 kgf·cm,53—78 in·lbf

G6

EXCEPTG6

1 Boot

2 Push rod

3 Piston and cap

4 Return spring

5 Bleeder cap

6 Bleeder screw

7 Steel ball

8 Clutch release cylinder body


CONTINUED


CLUTCH UNIT

H–8

CLUTCH UNITCLUTCH UNIT REMOVAL/INSTALLATION


SST

(MOLYBDENUM SULFIDE)

TRANSMISSION SIDEENGINE SIDE

18—26 1.8—2.7, 14—19

G6 :92—98 9.3—10.0, 67.3—72.3EXCEPT G6 :97—102 9.8—10.5, 70.9—75.9


SSTSST

SST

1 Transmission+ Section J1, MANUAL TRANSMISSION, MANUAL

TRANSMISSION REMOVAL/INSTALLATION

2 Clutch release collar

3 Clutch release fork

4 Clutch cover+ Removal Note+ Installation Note

5 Clutch disc+ Installation Note

6 Pilot bearing+ Removal Note+ Installation Note

7 Flywheel+ Removal Note+ Installation Note


CONTINUED


+ Section J2, MANUAL TRANSMISSION, MANUALTRANSMISSION REMOVAL/INSTALLATION

PAGES. FROM. MANUAL

CLUTCH UNIT

H–9

Clutch Cover Removal Note1. Install the SSTs.2. Loosen each bolt one turn at a time in a crisscross

pattern until spring tension is released.

49 E011 1A0

49 SE01 310A

Pilot Bearing Removal Note

Note The pilot bearing does not need to be removed

unless you are replacing it.

Use the SSTs to remove the pilot bearing.

49 1285 071

Flywheel Removal Note1. Hold the flywheel using the SST.2. Remove the bolts evenly and gradually in a

crisscross pattern.

ÇÁ

Â ÃÄ

Å

ÆÀ49 E011 1A0

G6

EXCEPT G6

49 E011 1A0

16

42

5

3

Flywheel Installation Note1. Install the flywheel to the crankshaft.2. Hand-tighten the flywheel lock bolts.3. Install the SST to the flywheel.4. Apply sealant to the bolt threads before installing

the bolt to prevent oil leakage from the bolt.5. Gradually tighten the flywheel lock bolts in a

crisscross pattern.

49 E011 1A0

G6

4

71

5

3

82

6

EXCEPT G6

49 E011 1A0

16

42

5

3

Pilot Bearing Installation NoteG6, F2 CIS, F2 Carb Install a new pilot bearing using a pipe until depth

is as follows:

Depth4.0 mm 0.16 in

PILOT BEARINGCRANKSHAFT


CONTINUED


CLUTCH UNIT

H–10

WL, WL Turbo Install a new pilot bearing using a pipe until

protrusion height is as follows:

Protrusion height0—0.2 mm 0—0.008 in

PILOT BEARINGFLY WHEEL

Clutch Disc Installation Note Hold the clutch disc in position using the SST.

49 SE01 310A

Clutch Cover Installation Note1. Install the SSTs.2. Tighten the bolts evenly and gradually in a

crisscross pattern.

49 E011 1A0

49 SE01 310A

CLUTCH COVER INSPECTION1. Measure the wear of the diaphragm spring figures.

Depth0.6 mm 0.024 in min.

DEPTH

2. Measure the flatness of the pressure plate using astraight edge and a feeler gauge.

Clearance0.5 mm 0.020 in max.

3. When checking the diaphragm spring fingers,mount a dial indicator on the cylinder block.

4. Rotate the flywheel and check for misaligneddiaphragm spring fingers.

Misalignment0.6 mm 0.030 in max.

5. Replace the clutch cover if not as specified.


CONTINUED


CLUTCH UNIT

H–11

CLUTCH DISC INSPECTION1. Using vernier calipers, measure the thickness of

the lining at a rivet head on both sides.2. If clutch disc thickness is less than the minimum,

replace the clutch disc.

Thickness0.3 mm 0.012 in min.

0.3 mm0.012 in

3. Measure the clutch disc runout using a dialindicator.

Runout0.7 mm 0.027 in max.

4. If runout is excessive, replace the clutch disc.

CLUTCH RELEASE COLLAR INSPECTION

Caution Cleaning the clutch release collar with

cleaning fluids or a steam cleaner can washthe grease out of the sealed bearing.Otherwise, clutch release collar may notoperate properly.

1. Turn the collar while applying force in the axialdirection.

2. If the collar sticks or has excessive resistance,replace the clutch release collar.

FLYWHEELPILOT BEARING INSPECTION

1. Without removing the pilot bearing from theflywheel, turn the bearing while applying force inthe axial direction.

2. If the bearing sticks or has excessive resistance,replace it.

FLYWHEEL INSPECTION1. Install a dial indicator on the cylinder block.2. Measure the flywheel runout using a dial indicator.


3. If runout is excessive, replace the flywheel.


CONTINUED


MANUAL TRANSMISSION (M15M-D, M15MX-D)

TRANSMISSION OIL INSPECTION ................ J1-1 INSPECTION .....................................................J1-2 TRANSMISSION OIL REPLACEMENT ........... J1-1/2 MANUAL TRANSMISSION OIL SEAL (M15M-D) REPLACEMENT ............. J1-2 REMOVAL/INSTALLATION ................................J1-3/7 VEHICLE SPEEDOMETER SENSOR

REMOVAL/INSTALLATION ........................ J1-2

MANUAL TRANSMISSION TRANSMISSION OIL INSPECTION 1. Remove the check plug A.

2. Verify that the oil is at the brim of the check plug hole

as shown. If it is low, add the specified oil from the check plug hole.

Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C 50 °F) Capacity: 2.0 L 2.1 US qt, 1.8 Imp qt (M15M-D) 2.5 L 2.6 US qt, 2.2 Imp qt (M15MX-D)

3. Install a new check plug A. Tightening torque A: 25—39 N.m 2.5-4.0 kgf.m, 19—28 ft.lbf

TRANSMISSION OIL REPLACEMENT 1. Remove the drain plug B with washer and the

check plug A.

2. Drain the oil into a container. 3. Clean the drain plug B. 4. Install the drain plug B with new washer.

Tightening torque B: 40—58 N.m 4.0—6.0 kgf.m, 29—43 ft.lbf

5. Add the specified oil from check plug A port until the level reaches the brim of check plug hole.

Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C 50 °F) Capacity: 2.0 L 2.1 US qt, 1.8 Imp qt (M15M-D) 2.5 L 2.6 US qt, 2.2 Imp qt (M15MX-D)

6. Install a new check plug A. Tightening torque A: 25—39 N.m 2.5—4.0 kgf.m, 19—28 ft.lbf

J1-1

BACK.TO.MAIN.INDEX TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

CONTINUED

MANUAL TRANSMISSION .............................. J1-1 VEHICLE SPEEDOMETER SENSOR

MANUAL TRANSMISSION

6. Install the vehicle speedometer sensor. Tightening torque 7.9—10.7 N.m 80—110 kgf.cm, 69.5—95.4 in.Ibf

7. Connect the vehicle speedometer sensor connector. 8. Add the specified type and amount of transmission

oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.)

9. Connect the negative battery cable. VEHICLE SPEEDOMETER SENSOR INSPECTION 1. Remove the vehicle speedometer sensor.

(Refer to MANUAL TRANSMISSION, VEHICLE SPEEDOMETER SENSOR REMOVAL/ INSTALLATION.)

2. Measure voltage between terminals of the vehicle speedometer sensor while the gear is turning.

Meter needle Action

Moves slightly under 5 V

Speedometer sensor is normal. Inspect wiring harness. (Instrument cluster-Vehicle speedometer sensor)

Does not move Replace vehicle speedometer sensor.

OIL SEAL (M15M-D) REPLACEMENT 1. Drain the transmission oil. 2. Remove the propeller shaft.

(Refer to section L, PROPELLER SHAFT (4x2),PROPELLER SHAFT REMOVAL/ INSTALLATION.)

3. Remove the oil seal using a screwdriver.

4. Apply the specified oil to new oil seal. 5. Install the oil seal until it touches the case using a

suitable piece of pipe.

6. Install the propeller shaft.

(Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/ INSTALLATION.)

7. Add the transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.)

VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the transmission oil. 3. Disconnect the vehicle speedometer sensor

connector. 4. Remove the vehicle speedometer sensor. 5. Apply transmission oil to new O-ring and install it on

new vehicle speedometer sensor.

3. Install the vehicle speedometer sensor.

(Refer to MANUAL TRANSMISSION, VEHICLE SPEEDOMETER SENSOR REMOVAL/ INSTALLATION.)

J1-2


CONTINUED

MANUAL TRANSMISSION MANUAL TRANSMISSION REMOVAL/INSTALLATION 4x2(M15M-D)

1. Disconnect the negative battery cable. 2. Drain the transmission oil into a container. 3. Remove the propeller shaft.

(Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.) 4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Add the specified type and amount of transmission oil.

(Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) 8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.

1 Shift lever knob 12 Speedometer sensor connector 2 Console 13 Back-up light switch connector 3 Dust boot 14 Neutral switch connector (F2 CIS) 4 Change boot upper plate 15 Front pipe bracket

5 Boot 16 Clutch release cylinder

6 Dust boot 7 Gasket

17

Crossmember Removal Note

18 Transmission lower mount8 Wave washer 9 Change bush 10 Change lever

19

Transmission Removal Note Installation Note

11 Change seat

J1-3


CONTINUED

MANUAL TRANSMISSION

1 Shift lever knob 12 Speedometer sensor connector 2 Console 13 Back-up light switch connector 3 Dust boot 14 Front pipe bracket 4 Change boot upper plate 15 Clutch release cylinder 5 Boot 6 Dust boot

16


7 Gasket 17 Dynamic damper 8 Wave washer 18 Transmission lower mount 9 Change bush 10 Change lever

19

Transmission Removal Note & Installation Note

11 Change seat

J1-4


CONTINUED

MANUAL TRANSMISSION

Crossmember removal note • Securely support the transmission on

a transmission jack, then remove the crossmember.

Transmission removal note • Maintain the stability of the

transmission while removing it.

Transmission installation note Warning • A transmission that is not securely

supported on a transmission jack is dangerous. It can slip or fall, causing serious injury. Never work without the transmission jack until crossmember installation is finished.

1. Place the transmission on a transmission jack.

2. Maintain the stability of the transmission while installing it.

J1-5


CONTINUED

MANUAL TRANSMISSION4x4(M15MX-D)

1. Disconnect the negative battery cable. 2. Drain the transmission and transfer oil into a container. 3. Remove the front and rear propeller shaft,

(Refer to section L, FRONT PROPELLER SHAFT (4x4), FRONT PROPELLER SHAFT REMOVAL/INSTALLATION.) (Refer to section L, REAR PROPELLER SHAFT (4x4), REAR PROPELLER SHAFT REMOVAL/INSTALLATION.)

4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Add the specified type and amount of transmission and transfer oil.

(Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) (Refer to section J3, TRANSFER, TRANSFER OIL REPLACEMENT.)

8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.

1 Shift lever knob 12 Transfer under cover2 Console 13 Speedometer sensor connector 3 Dust boot 14 Back-up light switch connector 4 Change boot upper mount 15 4x4 indicator switch connector 5 Boot 16 Front pipe bracket

6 Dust boot 17 Clutch release cylinder

7 Gasket 8 Wave washer 9 Change bush

18

Crossmember MANUAL TRANSMISSION, MANUAL TRANS-

MISSION REMOVAL/INSTALLATION, 4x2 (M15M-D), Crossmember removal Note

10 Change lever 11 Change seat

J1-6


CONTINUED

MANUAL TRANSMISSION 19 Transmission lower mount 20

Transmission and transfer Removal Note & Installation Note

Transmission and transfer removal note • Maintain the stability of the transmission and transfer while removing them.

Transmission and transfer installation note

Warning • A transmission and transfer that are not securely

supported on a transmission jack are dangerous. They can slip or fall, causing serious injury. Never work without the transmission jack until crossmember installation is finished.

1. Place the transmission and transfer on a transmission jack. 2. Maintain the stability of the transmission and transfer while

installing them.

J1-7


CONTINUED

J2–1

MANUAL TRANSMISSION (R15M–D, R15MX–D)

MANUAL TRANSMISSION J2–1. . . . . . . . . . . . . . . . . . TRANSMISSION OIL INSPECTION J2–1. . . . . . . . . TRANSMISSION OIL REPLACEMENT J2–1/2. . . . . . OIL SEAL (R15M–D) REPLACEMENT J2–2. . . . . . VEHICLE SPEEDOMETER SENSOR

REMOVAL/INSTALLATION J2–2. . . . . . . . . . . . . . .

VEHICLE SPEEDOMETER SENSOR INSPECTION...J2–2MANUAL TRANSMISSION

REMOVAL/INSTALLATION J2–3/9. . . . . . . . . . . . . . .

MANUAL TRANSMISSIONTRANSMISSION OIL INSPECTION

1. Remove the filler plug.FILLER PLUG

2. Verify that the oil is at the brim of the filler plug holeas shown. If it is low, add the specified oil from thefiller plug hole.

Specified oilGrade:

API service GL–4 or GL–5Viscosity:

SAE 75W–90 (All season) orSAE 80W–90 (Above 10° C 50°F)

FILLER PLUG HOLE

3. Install a new filler plug.


TRANSMISSION OIL REPLACEMENT1. Remove drain plugs A and B, and drain the oil into

a container.2. Clean the drain plug A.3. Install the drain plug A with new washer and a new

drain plug B.

Tightening torqueA: 40—58 N·m 4.0—6.0 kgf·m, 29—43 ft·lbfB: 21—31 N·m 2.1—3.2 kgf·m, 16—23 ft·lbf

FILLER PLUG

DRAIN PLUG ADRAIN PLUG B

4. Remove the filler plug and add the specified oilthrough the filler plug port until the level rises to thebottom of the port.

Specified oilGrade:

API service GL–4 or GL–5Viscosity:

SAE 75W–90 (All season) orSAE 80W–90 (Above 10° C 50°F)

Capacity: 2.8 L 3.0 US qt, 2.5 lmp qt (R15M–D)3.2 L 3.4 US qt, 2.8 lmp qt (R15MX–D)

FILLER PLUG HOLE

BACK.TO.MAIN.INDEX

CONTINUED


MANUAL TRANSMISSION

J2–2

1. Install a new filler plug.


OIL SEAL (R15M–D) REPLACEMENT1. Drain the transmission oil.2. Remove the propeller shaft.

(Refer to section L, PROPELLER SHAFT (4x2),PROPELLER SHAFT REMOVAL/INSTALLATION.)

3. Remove the oil seal using a screwdriver.

4. Apply the specified oil to the new oil seal.5. Install the oil seal until it touches the case using a

suitable piece of pipe.

PIPE

6. Install the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2),PROPELLER SHAFT REMOVAL/INSTALLATION.)

7. Add the transmission oil.(Refer to MANUAL TRANSMISSION,TRANSMISSION OIL REPLACEMENT.)

VEHICLE SPEEDOMETER SENSORREMOVAL/INSTALLATION(Refer to section J1, MANUAL TRANSMISSION,VEHICLE SPEEDOMETER SENSORREMOVAL/INSTALLATION.)

VEHICLE SPEEDOMETER SENSOR INSPECTION(Refer to section J1, MANUAL TRANSMISSION,VEHICLE SPEEDOMETER SENSOR INSPECTION.)


CONTINUED


ST

MANUAL TRANSMISSION

J2–3

MANUAL TRANSMISSION REMOVAL/INSTALLATION42 (R15M–D)

1. Disconnect the negative battery cable.2. Drain the transmission oil into a container.3. Remove the propeller shaft.

(Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.)4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.)5. Remove in the order indicated in the table.6. Install in the reverse order of removal.7. Add the specified amount and type of transmission oil.

(Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.)8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.

R

16—22 1.6—2.3,12—16


38—46 3.8—4.7,28—33

32—46 3.2—4.7, 24—33

22—28 2.2—2.9, 16—20

7.9—10.7 N·m 80—110 kgf·cm,69.5—95.4 in·lbf

19—25 1.9—2.6, 14—18

16—22 1.6—2.3,12—16

A

A

38—513.8—5.3,28—38

38—513.8—5.3,28—38

69—88 7.0—9.0,51—65

F2

69—88 7.0—9.0,51—65

69—88 7.0—9.0,51—65

7.9—10.7 N·m 80—110 kgf·cm, 69.5—95.4 in·lbf

38—513.8—5.3,28—38

69—88 7.0—9.0,51—65

1 Shift lever knob

2 Console

3 Dust boot

4 Change boot upper plate

5 Boot

6 Dust boot

7 Gasket

8 Wave washer

9 Change bush

10 Change lever

11 Change seat

12 Vehicle speedometer sensor connector

13 Back–up light switch connector

14 Neutral switch connector (F2 CIS)

15 Front pipe bracket


17 Crossmember+ Removal Note

18 Transmission lower mount

19 Transmission+ Removal note+ Installation note


CONTINUED


MANUAL TRANSMISSION G6

1 Shift lever knob 12 Vehicle speedometer sensor connector 2 Console 13 Back-up light switch connector 3 Dust boot 14 Neutral switch connector

4 Change boot upper plate 15 Front pipe bracket5 Boot 16 Clutch release cylinder6 Dust boot 7 Gasket

17


8 Wave washer 18 Transmission lower mount 9 Change bush 10 Change lever

19

Transmission Removal note Installation note

11 Change seat

J2-4


CONTINUED

MANUAL TRANSMISSION

J2–5

WL, WL TURBO

R

7.9—10.7 N·m 80—110 kgf·cm,69.5—95.4 in·lbf

16—22 1.6—2.3,12—16

38—46 3.8—4.7, 28—33

32—46 3.2—4.7, 24—33


38—51 3.8—5.3, 28—38

16—22 1.6—2.3,12—16

A

A

22—28 2.2—2.9, 16—20

19—25 1.9—2.6, 14—1838—51 3.8—5.3,28—38

1 Shift lever knob

2 Console

3 Dust boot

4 Change boot upper plate

5 Boot

6 Dust boot

7 Gasket

8 Wave washer

9 Change bush

10 Change lever

11 Change seat


13 Back-up light switch connector



16 Crossmember+ Removal Note


18 Transmission+ Removal note+ Installation note


CONTINUED


ST

MANUAL TRANSMISSION

J2–6

Crossmember removal note Securely support the transmission on a

transmission jack, then remove the crossmember.

Transmission removal note

Warning Do not allow the transmission to fall from

the transmission jack.

Maintain the stability of the transmission whileremoving it.

Transmission installation noteWarning A transmission that is not securely

supported on a transmission jack isdangerous. It can slip or fall, causingserious injury. Never work without thetransmission jack until crossmemberinstallation is finished.

1. Place the transmission on a transmission jack.2. Maintain the stability of the transmission while

installing them.


CONTINUED


MANUAL TRANSMISSION

J2–7

44 (R15MX–D)

1. Disconnect the negative battery cable.2. Drain the transmission and transfer oil into a container.3. Remove the front and rear propeller shaft.

(Refer to section L, FRONT PROPELLER SHAFT (4x4), FRONT PROPELLER SHAFTREMOVAL/INSTALLATION.)(Refer to section L, REAR PROPELLER SHAFT (4x4), REAR PROPELLER SHAFTREMOVAL/INSTALLATION.)

4. Remove the front pipe. (G6 engine) (Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)

5. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.)6. Remove in the order indicated in the table.7. Install in the reverse order of removal.8. Add the specified type and amount of transmission and transfer oil.

(Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) (Refer to section J3, TRANSFER, TRANSFER OIL REPLACEMENT.)

9. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.

G67.9—10.7 N·m 80—110 kgf·cm,69.5—95.4 in·lbf

R

19—251.9—2.6,14—18

38—51 3.8—5.3, 28—38


32—46 3.2—4.7, 24—33

R

44—53 4.4—5.3, 32—39

7.9—10.7 N·m 80—110 kgf·cm,69.5—95.4 in·lbf

37—503.7—5.1,27—36

38—51 3.8—5.3, 28—38

16—221.6—2.3,12—16

69—887.0—9.0,51—65

38—51 3.8—5.3, 28—38

38—51 3.8—5.3, 28—38

A

A


CONTINUED


ST

MANUAL TRANSMISSION

J2–8

1 Shift lever knob

2 Console

3 Dust boot

4 Change boot upper mount

5 Boot

6 Dust boot

7 Gasket

8 Wave washer

9 Change bush

10 Change lever

11 Change seat

12 Transfer under cover



15 Neutral switch connector

16 4x4 indicator switch connector

17 Transfer neutral switch connector (RFW model)



20 Crossmember+ MANUAL TRANSMISSION, MANUAL

TRANSMISSION REMOVAL/INSTALLATION,42 (R15M–D), Crossmember removal note


22 Transmission and transfer+ Removal note+ Installation note

WL, WL TURBO


38—51 3.8—5.3,28—38

R

7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf

R

A

38—51 3.8—5.3, 28—38

32—46 3.2—4.7, 24—33

19—25 1.9—2.6, 14—18

16—22 1.6—2.3,12—16

A 37—50 3.7—5.1,27—36

22—28 2.2—2.9, 16—20

44—53 4.4—5.3, 32—39


CONTINUED


MANUAL TRANSMISSION

J2–9

1 Shift lever knob

2 Console

3 Dust boot

4 Change boot upper mount

5 Boot

6 Dust boot

7 Gasket

8 Wave washer

9 Change bush

10 Change lever

11 Change seat

12 Transfer under cover



15 Transfer neutral switch connector (RFW model)

16 4x4 indicator switch connector



19 Crossmember+ MANUAL TRANSMISSION, MANUAL

TRANSMISSION REMOVAL/INSTALLATION,42 (R15M–D), Crossmember removal note


21 Transmission and transfer+ Removal note+ Installation note

Transmission and transfer removal note

Warning Do not allow the transmission to fall from

the transmission jack.

Maintain the stability of the transmission andtransfer while removing them.

Transmission and transfer installation note

Warning A transmission and transfer that are not

securely supported on a transmission jackare dangerous. They can slip or fall,causing serious injury. Never work withoutthe transmission jack until crossmemberinstallation is finished.

1. Place the transmission and transfer on atransmission jack.

2. Maintain the stability of the transmission andtransfer while installing them.


CONTINUED


TRANSFER TRANSFER ..................................................................J3-1 TRANSFER OIL REPLACEMENT................ J3-1

TRANSFER OIL INSPECTION ...............................J3-1

TRANSFER TRANSFER OIL INSPECTION

1. Remove the filler plug with washer.

2. Verify that the oil is at the brim of the filler plug hole

as shown. If it is low, add the specified oil from the filler plug hole. Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C 50 °F) Capacity: 2.0 L 2.1 USqt,1.8 lmp qt

3. Clean the filler plug. 4. Install the filler plug with new washer.

Tightening torque 40—58 N-m 4.0—6.0 kgf.m, 29—43 ft.lbf

TRANSFER OIL REPLACEMENT 1. Remove the filler plug with washer and drain plug

with washer.

2. Drain the oil into a container. 3. Clean the filler and drain plugs. 4. Install the drain plug with new washer.


5. Add the specified oil from filler plug port until the level reaches the brim of filler plug hole. Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C 50 °F) Capacity: 2.0 L 2.1 USqt,1.8lmpqt

6. Install the filler plug with new washer. Tightening torque 40—58 N-m 4.0-6.0 kgf.m, 29—43 ft.lbf

J3-1

CONTINUED

BACK.TO.MAIN.INDEXTO. MODEL .INDEX


ST

L–1

PROPELLER SHAFTPROPELLER SHAFT (42) L–1. . . . . . . . . . . . . . . . . .

PROPELLER SHAFT REMOVAL/INSTALLATION L–1. . . . . . . . . . . . . . . . . . . . . . . . . . .

PROPELLER SHAFT INSPECTION L–2. . . . . . . . . . FRONT PROPELLER SHAFT (44) L–2. . . . . . . . . . .

FRONT PROPELLER SHAFT REMOVAL/INSTALLATION L–2. . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT PROPELLER SHAFT INSPECTION L–3. . FRONT PROPELLER SHAFT

DISASSEMBLY/ASSEMBLY L–3/4. . . . . . . . . . . . . . . REAR PROPELLER SHAFT (44) L–5. . . . . . . . . . . .

REAR PROPELLER SHAFT REMOVAL/INSTALLATION L–5. . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR PROPELLER SHAFT INSPECTION L–5. . . .

PROPELLER SHAFT (42)PROPELLER SHAFT REMOVAL/INSTALLATION


50—58 5.0—6.0, 37—43


37—52 3.7—5.4, 27—39

SST

1 Bolt, nut

2 Nut+ Installation Note

3 Propeller shaft+ Removal Note+ Installation Note

Propeller Shaft Removal Note1. Before removing the propeller shaft, put marks on

the yoke and the companion flange on thepropeller shaft tag side for proper reinstallation.

TAGMARK

2. Remove the propeller shaft from the extensionhousing and immediately install the SST to preventoil leakage.

49 S120 440

WL, F2 CIS, F2 CARB:

WL TURBO, G6:

49 0259 440

Propeller Shaft Installation Note Align the marks made during removal, and install

the propeller shaft. If installing a new propellershaft, align the differential companion flangeprecast marking with the tag on the propeller shaft.

TAGMARK

Nut Installation Note Tighten the center bearing installation nuts with the

vehicle *unloaded.*unloaded...Fuel tank is full; engine coolant and engineoil are at specified levels; spare tire, jack and tools arein designated position.

BACK.TO.MAIN.INDEX

CONTINUED


PROPELLER SHAFT (42), FRONT PROPELLER SHAFT (44)

L–2

PROPELLER SHAFT INSPECTION1. Measure the propeller shaft runout using a dial

indicator.


2. If the runout is excessive, replace the propellershaft.

3. Move the universal joint in the direction shown, andinspect joint play.

Note Starting torque

0.3—1.1 N·m 3.0—12.0 kgf·cm, 2.7—10.4 in·lbf

4. If there is excessive play or the starting torque isnot within the specification, replace the propellershaft.

FRONT PROPELLER SHAFT (44)FRONT PROPELLER SHAFT REMOVAL/INSTALLATION


28—30 2.8—3.1, 21—22


1 Bolt, nut

2 Front propeller shaft+ Removal Note+ Installation Note

Front Propeller Shaft Removal Note Before removing the front propeller shaft, put

marks on the yoke and the companion flange onthe propeller shaft tag side for proper reinstallation.

TAGMARK

Front Propeller Shaft Installation Note Align the marks made during removal, and install

the front propeller shaft. If installing a newpropeller shaft, align the precast marking with thetag on the front propeller shaft.


CONTINUED


ST

FRONT PROPELLER SHAFT (44)

L–3

TAGMARK

FRONT PROPELLER SHAFT INSPECTION1. Measure the front propeller shaft runout using a

dial indicator.


2. If the runout is excessive, replace the frontpropeller shaft.

3. Move the universal joint in the direction shown,and inspect the joint play.


0.3—0.7 N·m 3.0—8.0 kgf·cm, 2.7—6.9 in·lbf

4. If there is excessive play or the starting torque isnot within the specification, repair the frontpropeller shaft.(Refer to FRONT PROPELLER SHAFT (44),FRONT PROPELLER SHAFTDISASSEMBLY/ASSEMBLY.)

FRONT PROPELLER SHAFTDISASSEMBLY/ASSEMBLY


R

RR

R

1 Snap ring+ Disassembly Note

2 Universal joint yoke

3 Universal joint+ Disassembly Note+ Assembly Note

4 Sliding yoke

5 Propeller shaft

Snap ring Disassembly Note1. Mark the yoke and propeller shaft for proper

reassembly.

MARK

2. Clamp the propeller shaft in a vise.3. Remove the snap ring.

Universal joint Disassembly Note1. Push one bearing cup out of the propeller shaft by

tapping the yoke with a plastic hammer.

YOKE

BEARING CUP


CONTINUED


FRONT PROPELLER SHAFT (44)

L–4

1. Remove the opposite bearing cup in the samemanner.

2. Separate the propeller shaft and yoke.3. Clamp the yoke in a vise.4. Remove the bearing cups and the spider from the

yoke in the same manner as in Steps 1 and 2.

Universal joint Assembly Note1. Verify that the inside of the bearing cup is filled with

1.15—1.45g 0.04—0.05 oz grease. Add thespecified amount of disulphide molybdem greaseas necessary.

2. Set the new spider into the yoke and tap in a newbearing cup until the snap ring groove is exposed.

SPIDER

3. Measure the snap ring clearance, then select andinstall two new snap rings of equal thickness.

Snap ring thicknessesmm in

1.22 0.0480 1.32 0.0520

1.24 0.0488 1.34 0.0528

1.26 0.0496 1.36 0.0536

1.28 0.0504 1.38 0.0543

1.30 0.0512

YOKEBEARING CUP

SNAP RINGCLEARANCE

SPIDER

4. Install the remaining bearing cups and snap ringsas in Steps 1—3.

5. Move the universal joint in the direction shown, andinspect joint play.


0.3—0.7 N·m3.0—8.0 kgf·cm, 2.7—6.9 in ·lbf

6. If there is excessive play or the starting torque isnot within the specification, replace the frontpropeller shaft.


CONTINUED


ST

REAR PROPELLER SHAFT (44)

L–5

REAR PROPELLER SHAFT (44)REAR PROPELLER SHAFTREMOVAL/INSTALLATION


50—585.0—6.0, 37—43

37—523.7—5.4, 27—39


50—585.0—6.0, 37—43

1 Bolt, nut

2 Nut+ PROPELLER SHAFT (42), PROPELLER

SHAFT REMOVAL/INSTALLATION, NutInstallation Note

3 Rear propeller shaft+ Removal Note+ Installation Note

4 Dynamic damper (WL Turbo)

Rear Propeller Shaft Removal Note1. Before removing the rear propeller shaft, put marks

on the yoke and the companion flange on the rearpropeller shaft tag side for proper reinstallation.

TAGMARK

Rear Propeller Shaft Installation Note Align the marks made during removal, and install

the rear propeller shaft. If installing a new propellershaft, align precast marking with the tag on therear propeller shaft.

TAGMARK

REAR PROPELLER SHAFT INSPECTION1. Measure the rear propeller shaft runout using a dial

indicator.


2. If the runout is excessive, replace the rearpropeller shaft.

3. Move the universal joint in the direction shown. Inspect starting torque and joint play.


0.3—1.1 N·m 3.0—12.0 kgf·cm, 2.7—10.4 in·lbf

4. If there is excessive play or the starting torque isnot within the specification, replace the rearpropeller shaft.


CONTINUED


M–1

FRONT AND REAR AXLESGENERAL PROCEDURES M– 2. . . . . . . . . . . . . . . . . . FRONT AXLE (42) M– 2. . . . . . . . . . . . . . . . . . . . . . .

WHEEL HUB, STEERING KNUCKLE INSPECTION M– 2. . . . . . . . . . . . . . . . . . . . . . . . . .

WHEEL HUB, STEERING KNUCKLEREMOVAL/INSTALLATION M– 3/5. . . . . . . . . . . . . .

FRONT AXLE (44) M– 5. . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE

INSPECTION M– 5. . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE

REMOVAL/INSTALLATION M– 6/8. . . . . . . . . . . . . . REAR AXLE M– 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR AXLE INSPECTION M– 9. . . . . . . . . . . . . . . . AXLE SHAFT REMOVAL/

INSTALLATION M– 9/11. . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SHAFT M–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE SHAFT REMOVAL/INSTALLATION M–12. . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE SHAFT DISASSEMBLY/ASSEMBLY M–13/15. . . . . . . . . . . . . . . . . . . . . . . . . . . .

OUTPUT SHAFT (MFW)REMOVAL/INSTALLATION M–16. . . . . . . . . . . . . .

OUTPUT SHAFT DISASSEMBLY/ASSEMBLY M–17/18. . . . . . . . . . . . .

REAR DIFFERENTIAL M–19. . . . . . . . . . . . . . . . . . . . . REAR DIFFERENTIAL OIL INSPECTION M–19. . . . REAR DIFFERENTIAL OIL

REPLACEMENT M–19. . . . . . . . . . . . . . . . . . . . . . . . REAR DIFFERENTIAL REMOVAL/

INSTALLATION M–20. . . . . . . . . . . . . . . . . . . . . . . . . STANDARD DIFFERENTIAL

DISASSEMBLY M–21/23. . . . . . . . . . . . . . . . . . . . . . . . . STANDARD DIFFERENTIAL ASSEMBLY M–24/27. . .

MANUAL FREEEWHEEL (MFW) MECHANISM M–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE INSPECTION M–32. . . . . . . . . . . . . . .

REMOTE FREEWHEEL (RFW) MECHANISM M–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 INDICATOR SWITCH INSPECTION M–32. . . TRANSFER NEUTRAL SWITCH

INSPECTION M–32/33. . . . . . . . . . . . . . . . . . . . . . . . . . RFW SWITCH INSPECTION M–33. . . . . . . . . . . . . . RFW MAIN SWITCH REMOVAL/

INSTALLATION M–33. . . . . . . . . . . . . . . . . . . . . . . . . RFW MAIN SWITCH INSPECTION M–33. . . . . . . . ONE-WAY CHECK VALVE INSPECTION M–34. . . LOCK AND FREE SOLENOID VALVES

INSPECTION M–34. . . . . . . . . . . . . . . . . . . . . . . . . . RFW ACTUATOR INSPECTION M–34. . . . . . . . . . . RFW CONTROL MODULE INSPECTION M–35. . . . RFW CONTROL MODULE

JOINT SHAFT COMPONENTREMOVAL/INSTALLATION M–37. . . . . . . . . . . . . .

JOINT SHAFT COMPONENT DISASSEMBLY M–38/39. . . . . . . . . . . . . . . . . . . . . . . . .

JOINT SHAFT INSPECTION M–39. . . . . . . . . . . . . . JOINT SHAFT COMPONENT ASSEMBLY M–40/42. . . CONTROL BOX REMOVAL/

INSTALLATION M–42. . . . . . . . . . . . . . . . . . . . . . . . . CONTROL BOX DISASSEMBLY/

ASSEMBLY M–43/44. . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT FORK INSPECTION M–44. . . . . . . . . . . . . . .

FRONT DIFFERENTIAL M–45. . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL

INSPECTION M–45. . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL

REPLACEMENT M–45. . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL SEAL

REPLACEMENT M–45. . . . . . . . . . . . . . . . . . . . . . . .

M–46/47FRONT DIFFERENTIAL DISASSEMBLY M–48/50. . . . FRONT DIFFERENTIAL ASSEMBLY M–51/55. . . . . . .

TROUBLESHOOTING M–56. . . . . . . . . . . . . . . . . . . . . . REMOTE FREEWHEEL (RFW) M–56/62. . . . . . . . . . . .

BACK.TO.MAIN.INDEX

CONTINUED

REMOVAL/ . . . . . . . . . . . . . . M–35/36INSPECTION


FRONT DIFFERENTIAL REMOVAL/INSTALLATION . . . . . . . . . . . . . . .

GENERAL PROCEDURES, FRONT AXLE (42)

M–2

GENERAL PROCEDURESWheel and tire removal/installation The removal and installation procedure for the

wheels and tires are not mentioned in this section.When a wheel is removed, tighten it to thespecified torque.

(Refer to section TD, SUSPENSION, Wheels and Tires.)

Suspension arm removal/installation Tighten any part of the suspension that uses

rubber bushings only after vehicle has beenlowered and unloaded.*

*Unloaded: Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire,jack, and tools are in designated position.

Brake line disconnection/connection

Caution Brake fluid will damage painted surfaces. If

brake fluid gets on a painted surface, wipeit off immediately.

Tighten the brake pipe flare nut using the SST (49 0259 770B). Be sure to modify the brakepipe fIare nut tightening torque to allow use of atorque wrench-SST combination. (Refer to section GI, FUNDAMENTAL PROCEDURES, TORQUE FORMULAS.)

If any brake line has been disconnected any timeduring the procedure, add brake fluid, bleed thebrakes, and inspect leakage after the procedurehas been completed.

Connectors disconnection/connection Disconnect the negative battery cable before doing

any work that requires the handling of connectors.Reconnect the negative battery cable only after thework is completed.

FRONT AXLE (42)WHEEL HUB, STEERING KNUCKLE INSPECTIONWheel Bearing Play Inspection After jacking up the vehicle and supporting it at the

specified places with safety stands, inspect fornoticeable bearing play by holding the top andbottom of the tire.

Wheel bearing axial play0 mm 0 in

Preload Adjustment1. Verify that the tire rotates smoothly when rotated

strongly, and that there is no rough feeling or isabnormal noise from the bearing.

2. Remove the brake caliper component and suspendit by a rope.

3. Remove the hub cap, pull out the cotter pin andremove the set cover.

4. Loosen the locknut to the extent that it can beturned by hand.

5. Attach a pull scale to a hub bolt and measure thefrictional force.

6. Tighten the locknut until the reading reaches thespecified amount.

PreloadFrictional force plus5.9—10.7 N 0.6—1.1 kgf, 1.4—2.4 lbf

7. Install the set cover, and secure with a new cotterpin.

8. Install the hub cap and brake caliper component.


CONTINUED


FRONT AXLE (42)

M–3


108—127 11—13, 80—94

54—68 5.5—7.0, 40—50

30—50 3.0—5.2, 22—50

45—58 4.5—6.0, 33—43

118—156 12—16, 87—11519—25 1.9—2.6,14—18

R

SST

R

SSTR

R

R

R

SST

SST

80—1008.1—10.2,59—73

SST SST

RR

R

R


R

1 Hub cap

2 Cotter pin

3 Set cover

4 Locknut

5 Washer

6 Brake caliper component+ Removal Note

7 Hub and disc plate component+ Installation Note

8 Dust cover

9 Tie-rod end ball joint+ section N, MANUAL STEERING, STEERING

GEAR AND LINKAGE REMOVAL/INSTALLATION, Tie-rod End Ball Joint Removal Note

10 Knuckle arm

11 Lower arm ball joint+ section R, FRONT SUSPENSION, TORSION

BAR SPRING AND LOWER ARM (42) REMOVAL/INSTALLATION, Lower Arm BallJoint/Knuckle Removal Note

12 Upper arm ball joint+ section R, FRONT SUSPENSION, UPPER

ARM REMOVAL/INSTALLATION, Upper ArmBall Joint/Knuckle Removal Note

13 Steering knuckle

14 Disc plate+ Removal Note

15 Wheel hub+ Removal Note

16 Hub bolt+ Removal Note+ Installation Note


CONTINUED


WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION

PAGES. FROM. MANUAL

FRONT AXLE (42)

M–4

17 Outer bearing inner race

18 Oil seal+ Installation Note

19 Inner bearing inner race

20 Inner bearing outer race+ Removal Note+ Installation Note

21 Outer bearing outer race+ Removal Note+ Installation Note

Brake Caliper Component Removal Note Remove the brake caliper component, and

suspend it by a rope.

Disc Plate, Wheel Hub, Hub Bolt Removal Note

Note The hub bolt does not need to be removed

unless it is being replaced.

1. After putting markings on the disc plate and thewheel hub, remove the bolt and disassemble theplate and hub.

MARK

2. Remove the hub bolt using a press as necessary.

Inner Bearing Outer Race, Outer Bearing OuterRace Removal Note

Note When the inner bearing outer race is removed,

the inner race and oil seal are removedtogether.

Remove the bearing outer race using a suitableround bar and a hammer. For the other side,reverse the wheel hub and remove the outer race.

Outer Bearing Outer Race, Inner Bearing OuterRace Installation Note Install the bearing outer race using the SSTs and a

press. For the other side, reverse the wheel huband install the outer race.

OUTSIDE BEARING

INSIDE BEARING

49 H033 101

49 B025 001

Oil Seal Installation1. After inserting the bearing in the hub, use the SST

to tap in the oil seal until it is flush with the hub endsurface.

2. Apply grease to the oil seal lip.

49 F019 001

Hub Bolt Installation Note Press new hub bolts into the wheel hub using a

press.


CONTINUED


FRONT AXLE (42), FRONT AXLE (44)

M–5

Hub and Disc Plate Component Installation Note1. Apply grease to the areas indicated in the figure.

2. Install the hub and disc plate component, thenadjust the preload. (Refer to FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE INSPECTION, Preload Adjustment.)

FRONT AXLE (44)WHEEL HUB, STEERING KNUCKLE INSPECTIONWheel Bearing Play Inspection(Refer to FRONT AXLE (42), WHEEL HUB,STEERING KNUCKLE INSPECTION, Wheel BearingPlay Inspection.)

Preload Adjustment

Caution When replacing the locknut, tighten it using

the SST and turn the wheel hub a few timesto seat the bearing. Then, perform thepreload adjustment.

1. For RFW model, remove the hub cap and driveshaft end flange. For MFW model, remove thefreewheel hub component.

2. Remove the spacer and set plate.3. Remove the brake caliper component, and

suspend it by a rope.4. Loosen the locknut to the extent that it can be

turned by hand using the SST.

49 S231 635

5. Attach a pull scale to a hub bolt and measure thefrictional force.

6. Tighten the locknut until the reading reaches thespecified amount.

PreloadFrictional force plus5.9—10.7 N 0.6—1.1 kgf, 1.4—2.4 lbf

7. Install the set plate, spacer, freewheel hub or driveshaft end flange, hub cap and brake calipercomponent.


CONTINUED


FRONT AXLE (44)

M–6

WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.


54—68 5.5—7.0

30—513.0—5.2,22—37

55—675.6—6.9,41—49

40—44 4.0—4.5, 29—32

19—25 1.9—2.6, 14—18

55—80 5.6—8.2, 41—59

SST

SST

R

SST

R

R

R

SST

R

R

RSST

R

SST

SST R

R

118—156 12—16, 87—115

45—58 4.5—6.0, 33—43

SST

R

25—29 2.5—3.0, 19—21

(MFW MODEL)

(RFW MODEL)

SSTR

1 Hub cap

2 Drive shaft end flange

3 Freewheel hub component

4 Spacer

5 Set plate

6 Locknut+ Removal Note+ Installation Note

7 Brake caliper component+ FRONT AXLE (42), WHEEL HUB, STEERING

KNUCKLE REMOVAL/INSTALLATION, BrakeCaliper Component Removal Note.

8 Hub and disc plate component

9 Dust cover

10 Tie-rod end ball joint+ Section N, MANUAL STEERING, STEERIG

GEAR AND LINKAGE REMOVAL/INSTALLATION, Tie-rod End Ball Joint Removal Note

11 Disc plate+ FRONT AXLE (42), WHEEL HUB, STEERING

KNUCKLE REMOVAL/INSTALLATION, Disc PlateRemoval Note

12 Wheel hub+ FRONT AXLE (42), WHEEL HUB, STEERING

KNUCKLE REMOVAL/INSTALLATION, WheelHub Removal Note


CONTINUED


FRONT AXLE (44)

M–7

13 Hub bolt+ FRONT AXLE (42), WHEEL HUB, STEERING

KNUCKLE REMOVAL/INSTALLATION, Hub BoltRemoval Note

+ FRONT AXLE (42), WHEEL HUB, STEERINGKNUCKLE REMOVAL/INSTALLATION, Hub BoltInstallation Note

14 Outer bearing inner race

15 Oil seal+ Installation Note

16 Inner bearing inner race

17 Inner bearing outer race+ FRONT AXLE (42) WHEEL HUB, STEERING

KNUCKLE REMOVAL/INSTALLATION, InnerBearing Outer Race, Outer Bearing Outer RaceRemoval Note

+ Installation Note

18 Outer bearing outer race+ FRONT AXLE (42) WHEEL HUB, STEERING

KNUCKLE REMOVAL/INSTALLATION, InnerBearing Outer Race, Outer Bearing Outer RaceRemoval Note

+ Installation Note

19 Nut+ Section R, FRONT SUSPENSION, TORSION

BAR SPRING AND LOWER ARM (42) REMOVAL/INSTALLATION, Nut Installation Note

20 Shock absorber bolt

21 Upper arm ball joint+ Section R, FRONT SUSPENSION, UPPER

ARM REMOVAL/INSTALLATION, Upper ArmBall Joint/Knuckle Removal Note

22 Steering knuckle component+ Removal Note

23 Lower arm ball joint

24 Oil seal+ Removal Note+ Installation Note

25 Spacer

26 Needle bearing+ Removal Note+ Installation Note

27 Steering knuckle

Locknut Removal Note Remove the locknut using the SST.

49 S231 635

Steering Knuckle Component Removal Note1. Remove the lower arm ball joint from the knuckle

using the SST. (Refer to section R, FRONTSUSPENSION, TORSION BAR SPRING ANDLOWER ARM (42) REMOVAL/INSTALLATION,Lower Arm Ball Joint/Knuckle Removal Note.)

2. Remove the lower arm installation bolt and removethe lower arm with the knuckle.

Oil Seal Removal Note Remove the oil seal using a screwdriver.

Needle Bearing Removal Note Remove the needle bearing using the SST.

49 S231 660

Needle Bearing Installation Note1. Install the needle bearing using the SST and a

press.2. Apply grease to the needle bearing.

49 S033 108


CONTINUED


FRONT AXLE (44)

M–8

Oil Seal Installation Note1. Install the new oil seal using the SST and a press.2. Apply grease to the oil seal lip.

49 S033 107

Outer Bearing Outer Race Installation Note Install the outer bearing outer race using the SST

and press.

49 F027 005

Inner Bearing Outer Race Installation Note Install the inner bearing outer race using the SST

and a press.

49 F027 007

Oil Seal Installation Note Install the new oil seal using the SST and a press.

49 S033 106

Locknut Installation Note1. Install the locknut using the SST.

49 S231 635

2. Adjust the preload. (Refer to FRONT AXLE (44) WHEEL HUB, STEERING KNUCKLE INSPECTION, Preload Adjustment)


CONTINUED


REAR AXLE

M–9

REAR AXLEREAR AXLE INSPECTIONWheel Bearing Play Inspection

1. Jack up the rear end and support it with safetystands.

2. Verify that there is no abnormal noise and that thetire rotates smoothly when forcefully rotated byhand.

3. With a hand on top of the tire, inspect the bearingplay.

Wheel bearing axial play0.05—0.25 mm 0.002—0.010 in

4. If not as specified, adjust the bearing play. (Refer to REAR AXLE, AXLE SHAFTREMOVAL/INSTALLATION, Bearing Inner Race,Bearing Locknut Installation Note, Bearing playadjustment.)

AXLE SHAFT REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.


275—313 28—32, 203—231

16—21 N·m1.6—2.2 kgf·cm,12—15 in·lbf

108—127 11—13, 80—94

RSST

SST

R

SST

R

SSTR

*SST

*49 0259 770B

SST

R

SST


CONTINUED


REAR AXLE

M–10

1 Brake drum

2 Parking brake connecting pin

3 Brake pipe

4 Nut

5 Axle shaft and back plate component

6 Shim

7 Bearing locknut+ Removal Note+ Installation Note

8 Lock washer

9 Bearing housing+ Removal Note

10 Bearing inner race+ Installation Note

11 Bearing spacer

12 Oil seal (bearing housing side)+ Installation Note

13 Bearing outer race+ Removal Note+ Installation Note

14 Back plate component

15 Axle shaft

16 Hub bolt

17 Baffle

18 Oil seal (axle casing side)+ Removal Note+ Installation Note

Bearing Locknut Removal Note

Note Be careful when removing or installing the

bearing locknuts for the left wheels becausethey are left threaded (tightened by turningcounterclockwise).

Set the SSTs as shown in the figure, and removethe bearing locknut from the rear axle shaft.

49 0603 635A

49 S120 645A

Bearing Housing Removal Note Remove the bearing and bearing housing using the

SSTs.

49 S026 204

49 S026 205

49 S026 208

Bearing Outer Race Removal Note After removing the bearing inner race and oil seal

from the rear wheel hub, tap lightly using a suitableround bar to force out the outer race.

Oil Seal (Axle Casing Side) Removal Note Remove the oil seal from the axle casing using a

screwdriver.

OIL SEAL

AXLE CASING

Oil Seal (Axle Casing Side) Installation Note1. Use the SST to tap the oil seal in until it is flush

with the end of the axle casing.2. After installation, apply grease to the oil seal lip.

OIL SEAL

AXLE CASING49 H025 001


CONTINUED


REAR AXLE

M–11

Bearing Outer Race, Oil Seal(Bearing Housing Side) Installation Note Press the bearing outer race and the oil seal using

the SSTs.

49 U027 003

49 F027 004

OIL SEAL BEARINGOUTERRACE

Bearing Inner Race, Bearing Locknut InstallationNote

Caution The torque wrench must be attached

perpendicular to the SST.

1. Set the SST and then press the bearing inner racein until 3 to 5 threads of the bearing locknutmounting screw of the axle shaft are visible abovethe top of the bearing outer race.

49 S120 748

2. Remove the SST, and then install the bearinglocknut to the axle shaft.

3. Tighten the bearing locknut using the SST to pressin the bearing inner race.

4. Remove the SST and install the lock washer sothat its tab fits into the groove of the axle shaft.

5. Tighten the bearing locknut to the specified torque.

Bearing locknut tightening torque275—313 N·m

28.0—32.0 kgf·m, 203—231 ft·lbf

49 S120 645A

49 0603 635A

Bearing play adjustment Adjust the bearing play in the axial direction (only

when the bearing is replaced).(1) First insert one side of the rear axle shaft

component and push the end of the shaft to thethrust block, then insert a shim(s) at point A sothat the clearance between the end of the shaftand the thrust block becomes 0.65—0.95 mm0.026—0.037 in .

(2) Next insert the opposite shaft component andpush the end of the shaft to the thrust block.

(3) Use a shim(s) at point A so that the clearancebetween the end of the shaft and the thrust blockbecomes 0.05—0.25 mm 0.002—0.010 in .

Bearing play in axial direction0.05—0.25 mm 0.002—0.010 in

PINION SHAFT

THRUSTBLOCK

SHIMA


CONTINUED


DRIVE SHAFT

M–12

DRIVE SHAFTDRIVE SHAFT REMOVAL/INSTALLATION


R

1 Wheel hub, steering knuckle+ FRONT AXLE (44), WHEEL HUB,

STEERING KNUCKLEREMOVAL/INSTALLATION

2 Drive shaft+ Removal Note+ Installation Note

3 Snap ring

4 Clip+ Installation Note

Drive Shaft Removal Note

Caution Do not damage the dust cover or oil seal.

Remove the drive shaft by prying with a barinserted between the differential casing and thedrive shaft.

Clip Installation NoteLeft side Install a new clip to the output shaft clip groove

with the opening facing upward.

Right side Install a new clip to the clip groove of the drive

shaft end with the opening facing upward.

OPENING

CLIP

28 mm 1.1 in

Drive Shaft Installation Note Be careful not to damage the oil seal with the shaft

spline when installing the drive shaft.


CONTINUED


DRIVE SHAFT

M–13

DRIVE SHAFT DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of removal.

R

R

R

R

R

R

LEFT SIDE

RIGHT SIDE

1 Boot band+ Disassembly Note+ Assembly Note

2 Clip

3 Outer ring+ Disassembly Note+ Assembly Note

4 Snap ring+ Assembly Note

5 Balls+ Disassembly Note+ Assembly Note

6 Inner ring+ Disassembly Note+ Assembly Note

7 Cage+ Disassembly Note+ Assembly Note

8 Boot+ Disassembly Note+ Assembly Note

9 Bell joint component

10 Drive shaft


CONTINUED


DRIVE SHAFT

M–14

Boot Band Disassembly Note

Note The wheel side boot band does not need to be

removed unless replacing it.

1. Pry up the locking clip using a screwdriver andremove the band using pliers.

2. Slide the boot along the shaft to expose the joint.

Outer Ring Disassembly Note

Caution Mark with paint; do not use a punch.

1. Mark the cage and outer ring for proper assembly.2. Remove the clip using a screwdriver.3. Remove the outer ring from the inner ring and the

balls.4. Clean the grease away.

MARKS

Balls, Inner Ring, Cage Disassembly Note

Caution Mark with paint; do not use a punch.

1. Mark the drive shaft and inner ring for properassembly.

MARKS

2. Disassemble the snap ring from the drive shaftusing a snap-ring pliers.

3. Disassemble the balls, inner ring, cage from thedrive shaft as component.

4. Turn the cage by approximately 30 degrees andpull the cage and balls away from the inner ring.

30

Boot Disassembly Note

Note The wheel side boot does not need to be

removed unless it is being replaced.

1. Wrap the shaft splines with tape.2. Remove the boot.

TAPE

Boot Assembly Note

Note The wheel side and differential side boots are

different.

100.5 mm 4.0 in

99.2 mm 3.9 in

WHEEL SIDE DIFFERENTIAL SIDE

1. With the splines of the shaft still wrapped in tapefrom disassembly, assemble the boot.

2. Temporarily assemble the wheel side boot, newboot bands, and differential side boot to the driveshaft.

3. Remove the tape.


CONTINUED


DRIVE SHAFT

M–15

Cage, Inner Ring, Balls, Snap Ring Assembly Note1. Align the marks, and install the balls and cage to

the inner ring in the direction shown in the figure.

Caution Install the cage with the offset facing the

snap ring groove. If incorrectly installed,the drive shaft may become disengaged.

2. Install a new snap ring.

CAGEBALLS

SNAP RING GROOVE

INNER RING

Outer Ring Assembly Note

Note Use the specified grease supplied in the boot

kit.

1. Apply grease to the cage, inner ring, balls, and theouter ring.

Wheel side : 110—130 g 3.8—4.6 ozDifferential side : 95—105 g 3.4—3.7 oz

2. Align the marks, and install the outer ring onto theshaft.

3. Install a new clip.

MARKS

Boot Band Assembly Note

Caution Do not damage the boot. For wheel side, apply grease only when

assembling the boot.

1. Apply grease to the inside of the boot.2. Set the drive shaft to the standard length.

LEFT SIDE

RIGHT SIDE

Standard lengthRight side : 619.0—629.0 mm 24.4—24.7 inLeft side : 551.0—561.0 mm 21.7—22.0 in

3. Release trapped air from inside the boot using ascrewdriver covered with a rag.

4. Set the new boot band to the boot groove.5. Fold the band back and use pliers to pull it tight.6. Lock the end of the band by bending the locking

clips.


CONTINUED


DRIVE SHAFT

M–16

OUTPUT SHAFT (MFW) REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.


37—57 3.7—5.5, 27—39

1 Drive shaft+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/

INSTALLATION

2 Bolt

3 Screw

4 Output shaft component+ Removal Note

Output Shaft Component Removal Note Remove the output shaft by prying with a bar

inserted between the bearing housing of the outputshaft and the differential casing.


CONTINUED


DRIVE SHAFT

M–17

OUTPUT SHAFT DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.

R

R

R

R

SST

R

1 Clip+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/

INSTALLATION, Clip Assembly Note

2 Output shaft component+ Disassembly Note+ Assembly Note

3 Oil seal+ Assembly Note

4 Bearing+ Disassembly Note+ Assembly Note

5 Output shaft

6 Bearing housing


8 O-ring

Output Shaft Component Disassembly Note Disassemble the output shaft component using a

press.


CONTINUED


DRIVE SHAFT

M–18

Bearing Disassembly Note Remove the bearing from the output shaft

component using a press.

Oil Seal Assembly Note Use the SST to assemble the new oil seal until it is

flush with the bearing housing end using the SST.

49 M005 796

Bearing Assembly Note

Caution Press the bearing center and shaft center

vertically.

Press the new bearing to the output shaft.

Oil Seal Assembly Note Assemble the new oil seal by lightly tapping it

using a plastic hammer.

Output Shaft Component Assmebly Note Press the output shaft and bearing to the bearing

housing.


CONTINUED


REAR DIFFERENTIAL

M–19

REAR DIFFERENTIALREAR DIFFERENTIAL OIL INSPECTION

Caution Position the vehicle level.

1. Remove the filler plug.2. Verify that the oil is at the brim of the filler plug

hole. If it is low, add the specified oil.

Specified oilType

Standard differential:API service GL–5, SAE 90

LSD:API service GL–6, SAE 90

Capacity42:

1.40 L 1.48 US qt, 1.23 lmp qt44:

1.85 L 1.96 US qt, 1.63 lmp qt

FILLER PLUG

WASHER

3. Install a new washer and the filler plug.


REAR DIFFERENTIAL OIL REPLACEMENT1. Remove the filler and drain plugs.2. Drain the differential oil into a container.

3. Wipe the plugs clean.4. Install a new washer and the drain plug.


5. Add the specified oil from the filler plug hole until itreaches the brim of the hole.

Specified oilType

Standard differential:API service GL–5, SAE 90

LSD:API service GL–6, SAE 90

Capacity:42:

1.40 L 1.48 US qt, 1.23 lmp qt44:

1.85 L 1.96 US qt, 1.63 lmp qt

6. Install a new washer and the filler plug.



CONTINUED


REAR DIFFERENTIAL

M–20

REAR DIFFERENTIAL REMOVAL/INSTALLATION

Caution Clean away the old sealant before applying the new sealant. Install the differential carrier within 10 minutes after applying sealant. Allow the sealant to set at least 30 minutes after installation before filling the differential with the

specified oil.

1. Drain the differential oil. (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL REPLACEMENT.)2. Remove the rear propeller shaft.

(Refer to section L, REAR PROPELLER SHAFT (44), REAR PROPELLER SHAFT REMOVAL/INSTALLATION.)3. Remove in the order indicated in the table.4. Install in the reverse order of removal.


26—28 2.6—2.9, 19—20

50—58 5.0—6.0, 37—43

1 Axle shaft and back plate component+ REAR AXLE, AXLE SHAFT REMOVAL/

INSTALLATION

2 Differential+ Removal Note

Differential Removal Note To prevent the differential from dropping, leave the

two bolts loosely tightened. Then hit the differentialcarrier using a wooden hammer.


CONTINUED


REAR DIFFERENTIAL

M–21

STANDARD DIFFERENTIAL DISASSEMBLY Disassemble in the order indicated in the table.

SST

SST

SST

SST

SST

1 Differential component+ Disassembly Note

2 Bearing cap+ Disassembly Note

3 Adjusting shim

4 Side bearing cup

5 Side bearing cone+ Disassembly Note

6 Pinion nut+ Disassembly Note

7 Companion flange+ Disassembly Note

8 Oil seal+ Disassembly Note

9 Thrust washer

10 Drive pinion+ Disassembly Note

11 Front bearing cone

12 Collapsible spacer

13 Rear bearing cone+ Disassembly Note

14 Adjusting shim

15 Front bearing cup+ Disassembly Note

16 Oil buffle

17 Rear bearing cup+ Disassembly Note

18 Carrier

19 Hex screw

20 Ring gear

21 Roll pin+ Disassembly Note

22 Pinion shaft

23 Thrust block

24 Pinion gear

25 Pinion gear thrust washer

26 Side gear

27 Side gear thrust washer

28 Case


CONTINUED


REAR DIFFERENTIAL

M–22

Differential Component Disassembly Note Mount a carrier component to the SST or

equivalent.

T57L–500–B

Bearing Cap Disassembly Note Place a mark on one of the bearing caps so that

the left and right bearing caps won’t get mixed up.Use the mark for matching at the time of assembly.

MARK

Side Bearing Cone Disassembly Note

Warning When pulling the side bearing cone, do not

allow differential component to fall. It canstrike legs or feet and may cause seriousinjury.

Caution Mark the left bearing in order to install in

the same position.

Remove the side bearing cone using a press andthe SST.

205–D064D84L–1123–A

Pinion Nut Removal Note Hold the companion frange and remove the pinion

nut.

Companion Flange Disassembly Note Remove the companion flange using universal

puller.

Oil Seal Disassembly Note Pull out the oil seal using the SST.

308–047T77F–1102–A

Drive Pinion Disassembly Note Remove the drive pinion by tapping with a plastic

hammer.


CONTINUED


REAR DIFFERENTIAL

M–23

Rear Bearing Cone Disassembly Note

Note Mark or otherwise distinguish between the front

and rear cones so that they are not mixed up atthe time of reassembly.

Remove the rear bearing cone using the SST.

205–D064D84L–1123–A

Front Bearing Cup, Rear Bearing Cup DisassemblyNote


and rear cups so that they are not mixed up atthe time of reassembly.

Remove the bearing races using the SSTs (308 047 T77F–1102A and 100 001 T50T–100–A).

100–001T50T–100–A

3308–047T77F–1102–A

Roll Pin Disassembly Note

Caution Insert the bar from the knock pin hole at the

opposite side from where the ring gear isinstalled.

Secure the gear case in a vise and remove the rollpin using a small drift.


CONTINUED


Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note

Note • Mark or otherwise distinguish between the front

and rear outer races so that they are not mixed up at the time of reassembly.

• Remove the bearing outer races by using the two grooves on the carrier and tapping the outer races alternately.

Knock Pin Disassembly Note

Caution • Insert the bar from the knock pin hole at the

opposite side from where the ring gear is installed.

• Secure the gear case in a vise and remove the knock pin by using a 4 mm 0.16 in diameter bar.

REAR DIFFERENTIAL

M–24

STANDARD DIFFERENTIAL ASSEMBLY Assemble in the order indicated in the table.


75—95 7.6—9.7, 55—70

R

SST SST

SST

R

SST

R

RR

SST

R

SST

R

SSTR

130—15013.2—15.3,96—110

298—500 30.3—50.9, 220—368

R

1 Case+ Assembly Note

2 Side gear thrust washer+ Assembly Note

3 Side gear

4 Pinion gear thrust washer

5 Pinion gear

6 Thrust block

7 Pinion shaft

8 Roll pin

9 Ring gear

10 Hex screw

11 Side bearing cone+ Assembly Note

12 Carrier

13 Oil buffle

14 Front bearing cup+ Assembly Note

15 Rear bearing cup+ Assembly Note

16 Adjusting shim+ Assembly Note

17 Rear bearing cone+ Assembly Note

18 Drive pinion+ Assembly Note


20 Front bearing cone

21 Thrust washer


23 Companion flange

24 Pinion nut

25 Side bearing cup+ Assembly Note

26 Adjusting shim+ Assembly Note

27 Bearing cap+ Assembly Note


CONTINUED


REAR DIFFERENTIAL

M–25

Adjusting Shim Assembly NotePinion height Adjustment

1. Assemble the rear bearing cone over the SST andinsert it into the rear bearing cup of the carrier.

2. Assemble the front bearing cone into the frontbearing cup and assemble the SSTs.

205–456

205–110, T76P–4020–A10

205–457

205–105, T76P–4020–A3

205–109, T76P–4020–A9

205–111, T76P–4020–A11

3. Roll the SST component back and forth a fewtimes to seat the bearings while tightening the SSTby hand.

Tightening torque27 N·m 2.8 kgf·m, 20 ft·lbf

4. Center the SST (205–456) into the side bearingbore. Install the bearing caps and tighten the bolt.


Note There should be drag on the feeler gauge

when it is inserted between the SSTs (205–110, T76P–4020–A10 and 205–456).

5. Insert the thickest feeler gauge possible betweenthe SSTs (205–110, T76P–4020–A10 and205–456).

FEELER GAUGE

205–110T76P–4020–A10

205–456

6. This measurement is the thickness needed for theselective shim if there was no marking on the drivepinion. If the drive pinion is marked with a plus (+)reading, the amount marked should be subtractedfrom the feeler gauge measurement. If the drivepinion is marked with a minus (–) reading, theamount marked should be added to the feelergauge measurement.

Rear Bearing Cone Assembly Note Assemble the selected spacer on the drive pinion

and press the rear bearing inner race until it isfirmly seated on the shaft.

205–090T75L–1165–B

Drive Pinion Assembly NoteDrive pinion preload adjustment

Caution Never loosen pinion nut to decrease drive

pinion preload torque, and never exceedspecified preload torque. If preload torqueis exceeded, a new collapsible spacer mustbe installed and the torque sequencerepeated.

1. Install the drive pinion, collapsible spacer andcompanion flange to the carrier, and tighten thepinion nut until all end play is removed.

2. Continue to tighten in small increments until thespecified preload can be obtained.

Drive pinion preload1.2—1.5 N·m

12.2—15.3 kgf·cm, 10.6—13.2 in·lbf

3. If the specified preload can’t be obtained within thespecified tightening torque range, replace thecollapsible spacer and inspect again.


CONTINUED


REAR DIFFERENTIAL

M–26

Case Assembly Note Assemble the side gears, thrust washer, thrust

block, pinion gears, pinion shaft and knock pin. After assembling the knock pin, make a crimp sothat the pin will not come out of the gear case.

Side Gear Thrust Washer Assembly Note Adjust the backlash of the side gears and pinon

gear as follows.(1) Set a dial gauge to the pinion gear as shown in

the figure.(2) Secure one of the side gears.(3) Move the pinion gear and measure the

backlash at the end of the pinion gear.

Standard backlash0—0.1 mm 0—0.004 in

(4) If the backlash exceeds the standard, use thethrust washers to adjust.

Side Bearing Cone Assembly Note

Caution Bearings should be assembled to the

original positions.

Press the side bearings into the gear case usingthe SST.

205–092T75L–1165–DA

Front Bearing Cup, Rear Bearing Cup AssemblyNote

1. Install the oil baffle in the outer bearing cup bore ofthe carrier.

2. Install the outer bearing cup and inner bearing cupusing the SST.

205–024T76P–4616–A

Oil Seal Assembly Note1. Apply a light coat of oil to the lip of a new oil seal.2. Assemble the new oil seal using the SST.

205–007T56T–4676–B

Side Bearing Cup, Adjusting Shim, Bearing CapAssembly NoteRing gear backlash adjustment

1. Install the gear case component on the carrier.2. Push the gear case component to the left side of

the carrier and measure the clearance between theside bearing and carrier. This measurement is theleft and right total shim thickness.

3. Divide the amount of shim in step 2 appropriatelybetween the right and left side, then install thebearing cap.

4. Adjust the drive pinion, ring gear backlash and theside bearing preload as follows.(1) Mark the ring gear at four points at approx. 90 °

intervals and mount a dial indicator to thecarrier so that the feeler comes in contact at a90° angle with one of the ring gear teeth.


CONTINUED


REAR DIFFERENTIAL

M–27

DIAL INDICATORWITH BRACKETRY

RINGGEAR

5. Inspect the backlash at the three other markedpoints and make sure that the minimum backlashis more than 0.12 mm 0.005 in and difference ofthe maximum and minimum backlash value is lessthan 0.08 mm 0.003 in .

6. If backlash is not as specified, correct the backlashby switching shims from one side of the differentialcase to the other.

7. Using a torque wrench, inspect the total rotatingtorque of the pinion and differential component byrotating the pinion three complete revolutions, andthen reading the rotating torque. The readingsshould not exceed 2.4 N·m 24.0 kgf·cm, 20.8 in·lbf . If the backlash is within specificationbut the rotating torque is to high, the preload maybe adjusted by removing an equal amount of shimsfrom both sides of the differential.

8. Inspect the drive pinion and ring gear toothcontact.(1) Coat both surfaces of 6—8 teeth of the ring

gear uniformly with a thin red lead coating.(2) While moving the ring gear back and forth by

hand, rotate the drive pinion several times andinspect the tooth contact.

(3) If the tooth contact is good, wipe off the redlead coating.

(4) If it is not good, adjust the pinion height, thenadjust the backlash.


CONTINUED


MANUAL FREEWHEEL (MFW) MECHANISMREMOTE FREEWHEEL (RFW) MECHANISM

M–32

MANUAL FREEWHEEL (MFW)MECHANISMON-VEHICLE INSPECTION

1. Jack up the front of the vehicle and support it onsafety stands.

2. Set the select lever in “2H” position.3. Set the freewheel hub control handle to the “FREE”

position, then turn the handle clockwise andcounterclockwise by hand, and inspect that it turnssmoothly.

4. Set the freewheel hub control handle to “LOCK”position and inspect that the wheel turns withconsiderable force applied to make it turn.

5. If not as specified, replace the freewheel hubcomponent as necessary.

REMOTE FREEWHEEL(RFW) MECHANISM44 INDICATOR SWITCH INSPECTION

1. Jack up the vehicle and support it on safety stands.2. Remove the transfer case switch

(44 indicator switch).

3. Inspect for continuity between the terminals asshown using an ohmmeter.

Continuity Switch

Yes Depressed (ON)

No Released (OFF)

4. If not correct, replace the switch.

TRANSFER NEUTRAL SWITCH INSPECTION1. Jack up the vehicle and support it on safety stands.2. Remove the transfer case switch (neutral switch).


CONTINUED


123456567

REMOTE FREEWHEEL (RFW) MECHANISM

M–33

1. Inspect for continuity at the switch using anohmmeter.

Continuity Switch

Yes Depressed (ON)

No Released (OFF)

OFF ON12 mm 0.472 in13 mm 0.512 in


RFW SWITCH INSPECTION1. Jack up the vehicle and support it on safety stands.2. Disconnect the RFW switch connector and remove

the switch.

3. Inspect for continuity at the switch using anohmmeter.

Continuity Switch

Yes Depressed (ON)

No Released (OFF)


RFW MAIN SWITCH REMOVAL/INSTALLATION1. Remove the meter hood.

(Refer to Section S, DASHBOARD ANDCONSOLE, METER HOODREMOVAL/INSTALLATION.)


À

1 RFW main switch

RFW MAIN SWITCH INSPECTION1. Remove the RFW main switch.2. Inspect for continuity between the terminals as

shown using an ohmmeter.: Continuity

SwitchTerminal

SwitchA B D F

OFF

ON



CONTINUED



M–34

ONE–WAY CHECK VALVE INSPECTION1. Remove the one–way check valve.2. Blow through A and inspect that air flows from B.3. Blow through B and inspect that air does not flow

from A.

B A

4. If not correct, replace the one–way check valve.

LOCK AND FREE SOLENOID VALVES INSPECTION1. Disconnect the vacuum hoses and the connector

from each solenoid valve.2. Blow through each valve from port B.3. Inspect that air flows from the air filter.

BA

AIR FILTER

BLOW

4. Connect 12V and a ground to the terminals of eachvalve.

5. Blow through each valve from port B.6. Inspect that air flows from port A.

B A

7. If not correct, replace the solenoid valve(s).

RFW ACTUATOR INSPECTION1. Jack up the vehicle and support it on safety stands.2. Disconnect the vacuum hoses from the actuator.3. Connect a vacuum pump tester to the actuator

(free side) as shown.4. Apply 26.66 kPa 200 mmHg, 7.87 inHg vacuum,

and verify that the rod moves toward the left(driver’s side).

5. Disconnect the vacuum pump tester.6. Connect the vacuum pump tester to the actuator

(lock side) as shown.7. Apply 26.66 kPa 200 mmHg, 7.87 inHg vacuum,

and inspect that the rod moves toward the right(passenger side).

8. If not correct, replace the actuator.


CONTINUED



M–35

RFW CONTROL MODULE INSPECTION1. Remove the scuff plate. (Refer to section S, TRIM,

SCUFF PLATE REMOVAL/INSTALLATION.)2. Remove the front side trim.

(Refer to section S, TRIM, FRONT SIDE TRIMREMOVAL/INSTALLATION.)

3. Turn the ignition switch on and inspect the RFWcontrol module terminal voltages, referring to theTerminal Voltage Chart.

RFW CONTROL MODULE

4. If not correct, replace the component(s), wiring,and/or RFW control module.

REW CONTROL MODULE REMOVAL/INSPECTION1. Remove the scuff plate. (Refer to section S, TRIM,

SCUFF PLATE REMOVAL/INSTALLATION.)2. Remove the front side trim.



1 Connector

2 Nut

3 Bolt

4 RFW control module


CONTINUED



M–36

Terminal Voltage Chart

RFW CONTROL MODULE TERMINAL

B+: Battery positive voltage

Terminal Signal name Connected to Condition Voltage Inspection point

A Lock solenoid Lock solenoidSolenoid OFF B+ Harness (Lock solenoid—RFW

CM)A Lock solenoid Lock solenoidSolenoid ON Below 0.5 V

CM) Lock solenoid

B Ground Body – Below 0.5 V Harness to ground point

C Free solenoid Free solenoidSolenoid OFF B+ Harness (Free solenoid—RFW

CM)C Free solenoid Free solenoidSolenoid ON Below 0.5 V

CM) Free solenoid

D – – – – –

E 44 indicator 44 indicator 44 indicator light OFF B+ Harness (44 indicatorlight RFW CM)E

light light 44 indicator light ON Below 0.5 Vlight—RFW CM)

44 indicator light

F Lock indicator LOCK Lock indicator light OFF B+ Harness (Lock indicatorlight RFW CM)F

light indicator light Lock indicator light ON Below 0.5 Vlight—RFW CM)

Lock indicator light

H Battery BatteryIgnition swtich ON B+ Harness, Fuse (Battery-IgnitionH Battery BatteryIgnition swtich OFF Below 0.5 V

, ( y gswitch—RFW CM)

I RFW main RFW mainRFW main switchreleased (OFF)

B+ Harness (RFW mainswitch RFW CM)I

switch switch RFW main switchdepreased (ON)

Below 0.5 Vswitch—RFW CM)

RFW main switch

J RFW switch RFW switchRFW switch OFF B+ Harness (RFW switch—RFW CM)J RFW switch RFW switchRFW switch ON Below 0.5 V

( ) RFW switch

K 44 indicator 44 indicator44 indicator switchOFF

B+ Harness (44 indicatorswitch RFW CM)K

switch switch 44 indicator switchON


44 indicator switch

L Transfer TransferTransfer neutral switchOFF

B+ Harness (Transfer neutralswitch RFW CM)L

neutral switch neutral switch Transfer neutral switchON


Transfer neutral switch


CONTINUED



M–37

JOINT SHAFT COMPONENT REMOVAL/INSTALLATION1. Drain the front differential oil. (Refer to FRONT DIFFERENTIAL, DIFFERENTIAL OIL REPLACEMENT.)2. Remove in the order indicated in the table.3. Install in the reverse order of removal.


R

23—26 2.3—2.7, 17—19

37—53 3.7—5.5, 27—39

37—53 3.7—5.5, 27—39

SST


INSTALLATION

2 Vacuum hose

3 RFW switch connector

4 Snap pin

5 Joint shaft component, control box component

6 Gear sleeve

7 Output shaft+ Removal Note

Output Shaft Removal Note Remove the output shaft using the SST.

49 0813 215A


CONTINUED



M–38

JOINT SHAFT COMPONENT DISASSEMBLY Disassemble in the order indicated in the table.

SST

SST

SST

1 Control box

2 Clip

3 Remote freewheel hub+ Disassembly Note

4 Spacer

5 Retaining ring

6 Ball bearing+ Disassembly Note

7 Adjustment shim (s)

8 Dust seal

9 Bearing+ Disassembly Note


11 Joint shaft

12 Needle bearing

13 Clip

14 Casing

15 Output shaft and gear sleeve


CONTINUED



M–39

Remote Free Wheel Hub Disassembly Note Remove the remote free wheel hub using the SST.

49 0710 520

Ball Bearing Disassembly Note1. Remove the ball bearing and the joint shaft using a

press.

2. Remove the ball bearing using a press.

Bearing Disassembly Note Remove the dust seal and bearing using the SST

and a suitable bar.

49 W027 001

Oil Seal Disassembly Note Remove the oil seal using the SST.

49 U027 004

JOINT SHAFT INSPECTION1. Measure the joint shaft runout.

Maximum runout0.03 mm 0.0012 in

2. If not correct, replace the joint shaft.


CONTINUED



M–40

JOINT SHAFT COMPONENT ASSEMBLY Assemble in the order indicated in the table.

N·m kgf·m , ft·lbf

RSST

R

R

SSTR

R

R

16—22 1.6—2.3, 12—16

SELECTIVE

SELECTIVE

SST

SST

SST

SST

SST

1 Output shaft and gear sleeve

2 Casing


4 Adjustment shim(s)+ Assembly Note

5 Ball bearing+ Assembly Note

6 Joint shaft+ Assembly Note

7 Bearing+ Assembly Note

8 Retaining ring

9 Spacer+ Assembly Note

10 Remote freewheel hub+ Assembly Note

11 Clip

12 Dust seal+ Assembly Note

13 Needle bearing

14 Clip

15 Control box


CONTINUED



M–41

Oil Seal Assembly Note1. Apply differential oil to a new oil seal.2. Install the new oil seal using the SST and a press.

49 U027 006

Ajustment Shim(s), Ball Bearing Assembly Note1. Install the removed shim(s) and the ball bearing

using the SST and a press.

49 U027 006

2. Install a new retaining ring.3. Measure the clearance between the ball bearing

and the retaining ring.

4. If not as specified, adjust by adding or removingshims. Use no more than two shims on either side.

Maximum clearance0.15 mm 0.0059 in

Available shim thickness0.15 mm 0.0059 in, 0.30 mm 0.0118 in,0.35 mm 0.0138 in, 0.40 mm 0.0157 in,0.50 mm 0.0197 in

5. Remove the retaining ring.

Joint Shaft Assembly Note Install the joint shaft using the SST and a press.

49 U027 006

Bearing Assembly Note Install the bearing using the SSTs and a press.

49 U027 006

49 U027 005

Spacer, Remote FreeWheel Hub Assembly Note1. Install the removed spacer and the remote

freewheel hub using a suitable pipe and the SSTand a press.

49 U027 005

2. Install a new clip.3. Measure the clearance between the remote

freewheel hub and the clip.


CONTINUED



M–42

4. If not as specified, adjust by adding or removingspacers. Use no more than two spacers on eitherside.


Available shim thickness0.15 mm 0.0059 in, 0.30 mm 0.0118 in,0.35 mm 0.0138 in, 0.40 mm 0.0157 in,0.50 mm 0.0197 in

Dust Seal Assembly Note1. Install the new dust seal using the SST and a press.

49 M005 796

CONTROL BOX REMOVAL/INSTALLATION1. Drain the front differential oil.

(Refer to FRONT DIFFERENTIAL, FRONT DIFFERENTIAL OIL REPLACEMENT.)


16—221.6—2.3, 12—16

23—26 2.3—2.7, 17—19

Á

Â

À


1 Vacuum hose

2 RFW switch connector

3 Control box


CONTINUED



M–43

CONTROL BOX DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.


R

R

R

R

R

R

SST

1 Snap pin

2 Washer

3 RFW actuator

4 RFW switch and washer

5 Spring cap

6 Spring and ball

7 Washer

8 Roll pin+ Disassembly Note+ Assembly Note

9 Change rod

10 Shift fork

11 Boot+ Assembly Note


13 Control box


CONTINUED



M–44

Roll Pin Disassembly Note Remove the roll pin as shown in the figure.

Oil Seal Assembly Note Install a new oil seal using the SST and a press.

49 U027 007

Boot Assembly Note Install the boot as shown in the figure.

Roll Pin Assembly Note Install a new roll pin as shown in the figure.

SHIFT FORK INSPECTION1. Measure the clearance between the gear sleeve

and the shift fork.

Standard clearance0.1—0.40 mm 0.0040—0.0157 in


2. Inspect the output shaft and gear sleeve of thesplines for damage and wear.

3. If not correct, replace the output shaft and gearsleeve as necessary.


CONTINUED


FRONT DIFFERENTIAL

M–45

FRONT DIFFERENTIALFRONT DIFFERENTIAL OIL INSPECTION(Refer to REAR DIFFERENTIAL, REARDIFFERENTIAL OIL INSPECTION.)

Specified oilType

Above –18 °C 0 °F: API GL–5, SAE 90Below –18 °C 0 °F: API GL–5, SAE 80

Capacity MFW:1.2 L 1.3 US qt, 1.1 lmp qt RFW: 1.5 L 1.6 US qt, 1.3 lmp qt

FRONT DIFFERENTIAL OIL REPLACEMENT(Refer to REAR DIFFERENTIAL, REARDIFFERENTIAL OIL REPLACEMENT.)

Specified oilType

Above –18 °C 0 °F: API GL–5, SAE 90Below –18 °C 0 °F: API GL–5, SAE 80

Capacity MFW:1.2 L 1.3 US qt, 1.1 lmp qt RFW: 1.5 L 1.6 US qt, 1.3 lmp qt

FRONT DIFFERENTIAL OIL SEAL REPLACEMENT1. Remove the drive shaft.

(Refer to DRIVE SHAFT, DRIVE SHAFTREMOVAL/INSTALLATION, Drive shaft removalNote.)

2. Drain the differential oil.(Refer to REAR DIFFERENTIAL, REARDIFFERENTIAL OIL REPLACEMENT.)

3. Remove the oil seal using a screwdriver.4. Tap in the new oil seal to the differential using the

SST.

49 G030 795

5. Install the drive shaft.(Refer to DRIVE SHAFT, DRIVE SHAFTREMOVAL/INSTALLATION, Drive Shaft InstallationNote.)

6. Add the differential oil to the specified level. (Refer to FRONT DIFFERENTIAL, FRONTDIFFERENTIAL OIL REPLACEMENT.)


CONTINUED


FRONT DIFFERENTIAL

M–46

FRONT DIFFERENTIAL REMOVAL/INSTALLATION1. Drain the differential oil. (Refer to FRONT DIFFERENTIAL, FRONT DIFFERENTIAL OIL REPLACEMENT.)2. Remove the propeller shaft.

(Refer to section L, FRONT PROPELLER SHAFT (44), FRONT PROPELLER SHAFT REMOVAL/INSTALLATION.)3. Remove in the order indicated in the table.4. Install in the reverse order of removal.

95—115 9.5—11.8, 69—85


63—93 6.4—9.5, 47—68

37—53 3.7—5.5, 27—39

55—80 5.6—8.2, 41—59

MFW

APPLY SCREW LOCK AGENT


INSTALLATION, Drive Shaft Removal Note

2 Front differential component+ Removal Note

3 Differential bracket


CONTINUED


FRONT DIFFERENTIAL

M–47

94.2—115.7 9.5—11.8, 68.8—85.3


37—53 3.7—5.5, 27—39

62.8—93.1 6.4—9.5, 46.3—68.7

23—26 2.3—2.7, 17—19

94.2—115.7 9.5—11.8, 68.8—85.3

28—30 2.8—3.1, 21—22

RFW

APPLY LOCKING COMPOUND

APPLY SCREWLOCK AGENT


INSTALLATION, Drive Shaft Removal Note

2 Vacuum hose

3 RFW switch component

4 Front differential, joint shaft component+ Removal Note

5 Joint shaft, crossmember

6 Front differential

Front Differential, Joint Shaft Component RemovalNote

1. Set the transmission jack on the differential.2. Remove the bolts and nuts indicated by arrows.

3. Remove the front differential and joint shaftcomponent from the vehicle using the transmissionjack.


CONTINUED


FRONT DIFFERENTIAL

M–48

FRONT DIFFERENTIAL DISASSEMBLY Disassemble in the order indicated in the table.

ÈSST

É

SST

ÆÇ

SST

Å

Ä

SST

À

SSTÃ

Â

Á SST

1 Bolt

2 Differential casing

3 Oil baffle

4 Differential component+ Disassembly Note

5 Lock plate

6 Bearing cap+ Disassembly Note

7 Adjusting screw

8 Side bearing outer race

9 Locknut+ Disassembly Note

10 Washer

11 Companion flange+ Disassembly Note


CONTINUED


FRONT DIFFERENTIAL

M–49


13 Drive pinion+ Disassembly Note

14 Front bearing inner race


16 Rear bearing inner race+ Disassembly Note

17 Spacer

18 Front bearing outer race+ Disassembly Note

19 Rear Bearing outer race+ Disassembly Note

20 Carrier

21 Bolt

22 Ring gear

23 Knock pin+ Disassembly Note

24 Pinion shaft

25 Pinion gear

26 Thrust washer

27 Side gear

28 Thrust washer

29 Side bearing inner race+ Disassembly Note

30 Gear case

Differential Component Disassembly Note Install the differential component on the SSTs.

49 M005 561

49 0107 680A

Bearing Cap Disassembly Note Place a mark on one of the bearing caps so that

the left and right bearing caps won’t get mixed up.Use the mark for matching at the time of assembly.

MARK

Locknut Disassembly Note Hold the companion flange using the SST and

remove the locknut.

49 S120 710

Companion Frange Disassembly Note Pull the companion flange out using the SST.

49 0839 425C

Oil Seal Disassembly Note Remove the oil seal using a screw driver.

Drive Pinion Disassembly Note Remove the drive pinion by tapping with a plastic

hammer.


CONTINUED


FRONT DIFFERENTIAL

M–50

Rear Bearing Inner Race Disassembly Note


and rear inner races so that they are not mixedup at the time of reassembly.

Remove the rear bearing inner race using the SST.

49 H027 002

Front Bearing Outer Race, Rear Bearing OuterRace Disassembly Note


and rear outer races so that they are not mixedup at the time of reassembly.

Remove the bearing outer races using the twogrooves on the carrier and tapping the outer racesalternately.

Knock Pin Disassembly Note

Caution Insert the bar from the knock pin hole at the

opposite side from where the ring gear isinstalled.

Secure the gear case in a vise and remove theknock pin using a 4 mm 0.16 in diameter bar.

Side Bearing Inner Race Disassembly Note

Caution Mark the left bearing in order to install in

the same position.

Remove the side bearing inner race from the gearcase using the SST.

49 0839 425C


CONTINUED


FRONT DIFFERENTIAL

M–51

FRONT DIFFERENTIAL ASSEMBLY

Caution Clean away the old sealant before applying the new sealant. Install the differential carrier within 10 minutes after applying sealant. Allow the sealant to set at least 30 minutes after installation before filling the differential with the

specified oll.

Assemble in the order indicated in the table.


R

SST

R

SST

69—83 7.0—8.5, 51—61 SST

SST R

SST R

R

R

SST

184—284 13—29, 95—209

R

SSTRR

SST

18—25 1.8—2.6, 14—18

23—27 2.3—2.7, 17—19

14—51 3.8—5.3, 28—38

SST

1 Gear case+ Assembly Note

2 Thrust washer+ Assembly Note

3 Side gear

4 Thrust washer

5 Pinion gear

6 Pinion shaft

7 Knock pin

8 Ring gear+ Assembly Note

9 Side bearing inner race+ Assembly Note

10 Bolt

11 Carrier

12 Front Bearing outer Race+ Assembly Note

13 Rear bearing outer race+ Assembly Note

14 Spacer+ Assembly Note

15 Rear bearing inner race+ Assembly Note


CONTINUED


FRONT DIFFERENTIAL

M–52

16 Drive pinion+ Assembly Note


18 Front bearing inner race


20 Companion flange

21 Washer

22 Locknut+ Assembly Note

23 Side bearing outer race+ Assembly Note

24 Adjusting screw+ Assembly Note

25 Bearing cap+ Assembly Note

26 Lock plate

27 Baffle plate

28 Differential casing

29 Bolt

Gear Case Assembly Note Assemble the side gears, thrust washer, pinion

gears, pinion shaft and knock pin. After assembling the knock pin, make a crimp sothat the pin will not come out of the gear case.

Thrust Washer Assembly Note1. Set a dial gauge to the pinion gear as shown in the

figure.2. Secure one of the side gears.3. Move the pinion gear and measure the backlash at

the end of the pinion gear.

Standard backlash0—0.1 mm 0—0.004 in

4. If the backlash exceeds the standard, use thethrust washers to adjust.

Ring Gear Assembly Note1. Coat the ring gear and gear case facing surfaces

with locking agent.2. Install the ring gear and tighten the bolt to the

specified torque.

Side Bearing Inner Race Assembly Note

Caution Bearings should be assembled to the

original positions.

Press the side bearings into the gear case usingthe SST.

49 G030 338

Front Bearing Outer Race Assembly Note Press the front bearing outer race into the carrier


49 F027 005

Rear Bearing Outer Race Assembly Note Press the rear bearing outer race into the carrier


49 F027 004


CONTINUED


FRONT DIFFERENTIAL

M–53

Spacer Assembly NotePinion height adjustment

Notes Use the same spacer and nut. Be careful to install collars A and B in the

correct position and facing in the correctdirection.

1. Assemble the spacer, rear bearing inner race andSST (49 8531 568) on to the SST (49 8531 565).Secure the collar with the O-ring. Then install thisto the carrier.

2. Assemble the front bearing inner race, SST (49 8531 567), companion flange, washer and nut to the SST (49 8531 565).

3. Tighten the nut to the extent that the SST (49 8531 565) can be turned by hand.

49 0350 555

49 8531 565

49 8531 568

49 8531 567

SPACER

REAR BEARING

O RING

FRONT BEARING

4. Place the SST on the surface plate and set the dialindicator to zero.

49 0727 570

5. Place the SST (49 0350 555) on top of the SST (49 8531 565), and then set the SST (49 0727 570) on top of the SST (49 0350 555).

6. Place the measuring probe of the dial indicator sothat it contacts the place where the side bearing isinstalled in the carrier. Then measure left and rightside of the lower position.

49 0727 570

49 0350 555

7. Add the two (left and right) values obtained by themeasurements taken in Step 6 and then divide thetotal by 2. From this result, subtract the resultobtained by dividing the number inscribed on theend surface of the drive pinion by 100. (If there isno figure inscribed, use 0.) This is the pinion heightadjustment value.

Note For example, the measured results obtained at

Step 6 are 0.06 mm and 0.04 mm, and thefigure inscribed on the end of the drive pinion is–2:

pinion heightadjustment value

0.06+0.042

– = 0.07 =–2100

Therefore, replace it with a spacer 0.07 mm0.003 in thicker than the currently used one.

Rear Bearing Inner Race Assembly Note

Caution Press in until the force required suddenly

increases. Install the spacer selected for the pinion

height adjustment, confirm that theinstallation direction is correct.

Press the rear bearing inner race in using theSSTs.

49 F401 331SPACER

49 G030 338


CONTINUED


FRONT DIFFERENTIAL

M–54

Drive Pinion Assembly NoteDrive pinion preload adjustment

Caution Do not install the oil seal.

1. Install the drive pinion, spacer, front bearing,collapsible spacer and companion flange to thecarrier, and temporarily tighten the locknut.

2. Adjust the preload of the drive pinon bearing asfollows.(1) Turn the companion flange by hand to seat the

bearing.(2) Use a torque wrench to tighten the locknut

temporarily tightened in Step 1, and confirmthat the specified preload can be obtainedwithin the specified tightening torque range.The torque applied at this time will be usedafter the oil seal is installed.

Locknut tightening torque128—284 N·m 13—29 kgf·m, 95—209 ff·lbf

Drive pinion preload0.9—13.4 N·m 9—14 kgf·cm, 7.9—12.1 in·lbf

49 S120 710

(3) If the specified preload can’t be obtained withinthe specified tightening torque range, replacethe collapsible spacer and inspect again.

(4) Remove the locknut, washer and companionflange.

Oil Seal Assembly Note Apply differential oil to the oil seal lip and press the

oil seal in until it touches the end of the differentialcarrier using the SST.

49 U027 003

Locknut Assembly Note1. Assemble the companion flange and washer.2. Tighten the new locknut using the SST with the

determined torque while performing drive pinionpreload adjustment.

3. Verify that the preload is within the specification.

Preload0.9—1.3 N·m 9—14 kgf·cm, 7.9—12.1 in·lbf

49 S120 710

Side Bearing Outer Race, Adjusting Screw, BearingCap Assembly NoteRing gear backlash adjustment

1. Install the differential gear component to thecarrier. After loosely tightening the bearing outerrace and bearing cap mounting bolts, completelytighten the adjustment screw by hand. Then, whileturning the ring gear, alternately tighten the left andright adjustment screws using the SST.

49 0259 720

2. Adjust the drive pinion, ring gear backlash and theside bearing preload as follows.(1) Mark the ring gear at four points at approx. 90 °

intervals and mount a dial indicator to thecarrier so that the feeler comes in contact at a90° angle with one of the ring gear teeth.

(2) Turn both bearing adjusters equally until thebacklash becomes 0.09—0.11 mm0.0035—0.0043 in using the SST.

49 0259 720


CONTINUED


FRONT DIFFERENTIAL

M–55

(3) Inspect for the backlash at the three othermarked points and make sure that theminimum backlash is more than 0.05 mm0.002 in and difference of the maximum andminimum backlash value is less than 0.07 mm0.0028 in .

(4) After adjusting the backlash, tighten theadjustment screws equally until the distancebetween both pilot sections on the bearingcaps (L) become as specified.

Bearing cap bolt tightening torque38—51 N·m 3.8—5.3 kgf·m, 28—38 ft·lbf

Standard distance185.43—185.50 mm 7.300—7.303 in

3. The inspection and adjustment procedure is asfollows:(1) Coat both surfaces of 6—8 teeth of the ring

gear uniformly with a thin red lead coating.(2) While moving the ring gear back and forth by

hand, rotate the drive pinion several times andinspect the tooth contact.

(3) If the tooth contact is good, wipe off the redlead coating.

(4) If it is not good, adjust the pinion height, thenadjust the backlash.

RED LEAD

Toe and flank contact Replace the spacer with a thinner one, and move thedrive pinion outward.

FLANK CONTACTTOE CONTACT

Heel and face contact Replace the spacer with a thicker one.Bring the drive pinion inward.

FACE CONTACTHEEL CONTACT


CONTINUED


TROUBLESHOOTING

M–56

TROUBLESHOOTINGREMOTE FREEWHEEL (RFW)Foreword Refer to section GI, HOW TO USE THIS MANUAL, TROUBLESHOOTING PROCEDURE and thoroughly read

and understand the basic flow of troubleshooting in order to properly perform the basic procedures.

Precaution This section only mentions unique symptoms of the trouble caused by RFW. Inspect and repair as necessary

for trouble caused by other sources. Inspect the connector and terminal connections when inspecting the wiring harnesses. (The cause of the

malfunction may be a poor connection in the connectors, terminals, or wiring harnesses.)

Diagnostic IndexNo TROUBLESHOOTING ITEM DESCRIPTION

1 No RFW operation from free to lock(RFW indicator light does not illuminate)

Free solenoid valve malfunction RFW indicator light bulb malfunction RFW actuator malfunction RFW switch malfunction Print plate in instrument cluster malfunction METER 15 A fuse malfunction ENGINE 15 A fuse malfunction Transfer neutral switch malfunction 44 indicator switch malfunction RFW control module malfunction Lock solenoid valve malfunction RFW control box malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harness malfunction

2 No RFW operation from lock to free(RFW indicator light does not go off)

Lock solenoid valve malfunction RFW switch malfunction RFW actuator malfunction Print plate in instrument cluster malfunction Engine 15 A fuse malfunction RFW main switch malfunction Transfer neutral switch malfunction 44 indicator switch malfunction RFW control module malfunction Free solenoid valve malfunction RFW control box malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harness malfunction

3 Noise Joint shaft bearing abrasion or damage RFW hub abrasion Joint shaft abrasion

4 Oil leakage RFW control box is poorly installed.


CONTINUED


TROUBLESHOOTING

M–57

Quick Diagnosis ChartPossible factor

Troubleshooting itemR R R Pr M EN Tr 4 R R Lo Fr R O Jo R Jo Con Va R

No RFW operation from free to lock

No RFW operation from lock to free

Noise

Oil leakage

Symptom Troubleshooting

1 NO RFW OPERATION FROM FREE TO LOCK (RFW INDICATOR LIGHT DOES NOT ILLUMINATE)

DESCRIPTION RFW does not change from free to lock.

[TROUBLESHOOTING HINTS]

Transfer neutral switch malfunction 44 indicator switch malfunction RFW control module malfunction Lock solenoid valve malfunction Free solenoid valve malfunction RFW indicator light bulb malfunction RFW control box malfunction

METER 15 A fuse and/of ENGINE 15 A fuse malfunction Print plate in instrument cluster malfunction RFW switch malfunction RFW actuator malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harnesses malfunction


1 Disconnect RFW control module connector.Turn ignition (engine) switch on.

Yes Go to Step 6.g ( g )

Measure voltage between RFW control moduleconnector terminal F and ground.Is the voltage greater than 10 V?

No Turn ignition (engine) switch off.Then go to next step.

2 Is the METER 15 A fuse okay? Yes Go to next step.

No Replace 15 A METER fuse.Then go to Step 31.

3 Inspect RFW indicator light bulb. Yes Go to next step.Is it okay? No Replace RFW indicator light bulb.

Then go to Step 31.

4 Measure voltage between instrument cluster Yes Go to next step.connector terminal 1J and ground.Is the voltage greater than 10 V?

No Repair wiring harness between METER 15 A fuseand instrument cluster.Then go to Step 31.

5 Measure voltage between instrument clusterconnector terminal 2H and ground.Is the voltage greater than 10 V?

Yes Repair wiring harness between instrument clusterand RFW control module.Then go to Step 31.

No Replace print plate in instrument cluster.Then go to Step 31.

6 Measure voltage between RFW control module Yes Go to Step 8.connector terminal H and ground.Is the voltage greater than 10 V?



CONTINUED


TROUBLESHOOTING

M–58

STEP ACTIONINSPECTION

7 Is the ENG 15 A fuse okay? Yes Repair wiring harness between ENG 15 A fuse andRFW control module.Then go to Step 31.

No Replace the ENG 15 A fuse.Then go to Step 31.

8 Disconnect free solenoid valve connector.Measure voltage between free solenoid valve

Yes Connect free solenoid valve.Then go to next step.

connector terminal A and ground.Is the voltage greater than 10 V?

No Repair wiring harness between ENG 15 A fuse andRFW control module.Then go to Step 31.

9 Measure voltage between free solenoid valve Yes Go to next step.connector terminal B and ground.Is the voltage greater than 10 V?

No Inspect free solenoid valve.Then go to Step 31.

10 Measure voltage between RFW control module Yes Go to next step.connector terminal C and ground.Is the voltage greater than 10 V?

No Repair wiring harness between free solenoid valveand RFW control module.Then go to Step 31.

11 Disconnect lock solenoid valve connector.Measure voltage between lock solenoid valve

Yes Connect lock solenoid valve.Then go to next step.



12 Measure voltage between lock solenoid valve Yes Go to next step.connector terminal B and ground.Is the voltage greater than 10 V?

No Inspect lock solenoid valve.Then go to Step 31.

13 Measure voltage between RFW control module Yes Go to next step.connector terminal A and ground.Is the voltage greater than 10 V?

No Repair wiring harness between lock solenoid valveand RFW control module.Then go to Step 31.

14 Turn ignition (engine) switch off. Yes Go to next step.Is there continuity between RFW control moduleconnector terminal B and ground?

No Repair wiring harness between RFW controlmodule and ground.Then go to Step 31.

15 Shift select lever to N position.Is there continuity between RFW control module

Yes Go to Step 19.Is there continuity between RFW control moduleconnector terminal L and ground? No Go to next step.

16 Is there continuity between transfer neutral switchconnector terminal A and ground?

Yes Repair wiring harness between RFW controlmodule and transfer neutral switch.Then go to Step 31.

No Go to next step.

17 Inspect transfer neutral switch. Yes Go to next step.Is it okay? No Replace transfer neutral switch.

Then go to Step 31.

18 Is there continuity between transfer neutral switch Yes Go to next step.connector terminal B and ground? No Repair wiring harness between transfer neutral

switch and ground.Then go to Step 31.

19 Shift select lever to 44 indicator position.Is there continuity between RFW control module

Yes Go to Step 23.Is there continuity between RFW control moduleconnector terminal K and ground? No Go to next step.

20 Is there continuity between 44 indicator switchconnector terminal A and ground?

Yes Repair wiring harness between 44 indicatorswitch and RFW control module.Then go to Step 31.

No Go to next step.


CONTINUED


TROUBLESHOOTING

M–59


21 Inspect 44 indicator switch. Yes Go to next step.Is it okay? No Replace 44 indicator switch.

Then go to Step 31.

22 Is there continuity between 44 indicator switch Yes Go to next step.connector terminal B and ground? No Repair wiring harness between 44 indicator


23 Shift select lever to 4H position.Is there continuity between RFW control module

Yes Go to Step 27Is there continuity between RFW control moduleconnector terminal J and ground? No Go to next step.

24 Is there continuity between RFW switchconnector terminal A and ground?

Yes Repair wiring harness between RFW controlmodule and RFW switch.Then go to Step 31.

No Go to next step.

25 Inspect RFW switch. Yes Go to next step.Is it okay? No Replace RFW switch.

Then go to Step 31.

26 Is there continuity between RFW switch Yes Go to next step.connector terminal B and ground? No Repair wiring harness between RFW switch and

ground.Then go to Step 31.

27 Inspect one-way check valve. Yes Go to next step.Is it okay? No Replace one-way check valve.

Then go to Step 31.

28 Inspect RFW control box. Yes Go to next step.Is it okay? No Replace RFW control box.

Then go to Step 31.

29 Inspect vacuum in vacuum hoses. Yes Go to next step.Is it okay? No Repair vacuum in vacuum hoses.

Then go to Step 31.

30 Inspect RFW control module. Yes Go to next step.Is it okay? No Repair or replace RFW control module.

Then go to next step.

31 Turn ignition (engine) switch on.Shift select lever from 2H to 4H position.

Yes Troubleshooting completed.Explain repairs to customer.

Does RFW operate from free to lock? No Inspect malfunction symptoms again, then repeatfrom Step 1 if malfunction occurs again.

2 NO RFW OPERATION FROM LOCK TO FREE (RFW INDICATOR LIGHT DOES NOT GO OFF)

DESCRIPTION RFW does not change from lock to free.


RFW main switch malfunction Transfer neutral switch malfunction 44 indicator switch malfunction RFW control module malfunction Free solenoid valve malfunction Lock solenoid valve malfunction RFW control box malfunction

ENGINE 15 A fuse malfunction RFW main switch malfunction RFW actuator malfunction RFW switch malfunction Air leakage from vacuum reservoir or actuator system One-way check valve Print plate in instrument cluster malfunction Related fuses and/or harnesses malfunction


1 Disconnect RFW control module connector.Is there continuity between RFW control module

Yes Go to next step.Is there continuity between RFW control moduleconnector terminal F and ground? No Go to Step 3.


CONTINUED


TROUBLESHOOTING

M–60


2 Disconnect instrument cluster connector No.2.Is there continuity between instrument clusterterminal 2H and ground?

Yes Repair wiring harness between RFW control moduleand instrument cluster.Then go to Step 32.

No Inspect for no continuity between Instrument clusterterminal 2H and ground.

3 Turn ignition (engine) switch off.Disconnect RFW control module connector.Turn ignition (engine) switch on

Yes Go to Step 5.

Turn ignition (engine) switch on.Measure voltage between RFW control moduleconnector terminal H and ground.Is the voltage greater than 10 V?


4 Is the ENG 15 A fuse okay? Yes Repair wiring harness between ENG 15 A fuse andRFW control module.Then go to Step 32.

No Replace the ENG 15 A fuse.Then go to Step 32.

5 Disconnect free solenoid valve connector.Measure voltage between free solenoid valve

Yes Connect free solenoid valve.Then go to next step.



6 Measure voltage between free solenoid valve Yes Go to next step.connector terminal B and ground.Is the voltage greater than 10 V?

No Inspect free solenoid valve.Then go to Step 32.

7 Measure voltage between RFW control module Yes Go to next step.connector terminal C and ground.Is the voltage greater than 10 V?

No Repair wiring harness between free solenoid valveand RFW control module.Then go to Step 32.

8 Disconnect lock solenoid valve connector.Measure voltage between lock solenoid valve

Yes Connect lock solenoid valve.Then go to next step.



9 Measure voltage between lock solenoid valve Yes Go next step.connector terminal B and ground.Is the voltage greater than 10 V?

No Inspect lock solenoid valve.Then go to Step 32.

10 Measure voltage between RFW control module Yes Go next step.connector terminal A and ground.Is the voltage greater than 10 V?

No Repair wiring harness between lock solenoid valveand RFW control module.Then go to Step 32.

11 Turn ignition (engine) switch off. Yes Go to next step.Is there continuity between RFW control moduleconnector terminal B and ground?

No Repair wiring harness between RFW control moduleand ground.Then go to Step 32.

12 Shift select lever to N position.Is there continuity between RFW control module

Yes Go to Step 16.Is there continuity between RFW control moduleconnector terminal L and ground? No Go to next step.

13 Is there continuity between transfer neutral switchconnector terminal A and ground?

Yes Repair wiring harness between RFW control moduleand transfer neutral switch.Then go to Step 32.

No Go to next step.

14 Inspect transfer neutral switch. Yes Go to next step.Is it okay? No Replace transfer neutral switch.

Then go to Step 32.


CONTINUED


TROUBLESHOOTING

M–61


15 Is there continuity between transfer neutral switch Yes Go to next step.connector terminal B and ground? No Repair wiring harness between transfer neutral



Yes Go to Step 20.Is there continuity between RFW control moduleconnector terminal K and ground? No Go to next step.

17 Is there continuity between 44 indicator switchconnector terminal A and ground?

Yes Repair wiring harness between RFW control moduleand 44 indicator switch.Then go to Step 32.

No Go to next step.

18 Inspect 44 indicator switch. Yes Go to next step.Is it okay? No Replace 44 indicator switch.

Then go to Step 32.

19 Is there continuity between 44 indicator switch Yes Go to next step.connector terminal B and ground? No Repair wiring harness between 44 indicator switch

and ground.Then go to Step 32.


Yes Go to Step 28.Is there continuity between RFW control moduleconnector terminal J and ground? No Go to next step.

21 Is there continuity between RFW switchconnector terminal A and ground?

Yes Repair wiring harness between RFW switch.Then go to Step 32.

No Go to next step.

22 Inspect RFW switch. Yes Go to next step.Is it okay? No Replace RFW switch.

Then go to Step 32.

23 Is there continuity between RFW switch Yes Go to next step.connector terminal B and ground? No Repair wiring harness between RFW switch and

ground.Then go to Step 32.

24 Push RFW main switch on.Is there continuity between RFW main switch

Yes Go to Step 28.Is there continuity between RFW main switchconnector terminal I and ground? No Go to next step.

25 Is there continuity between RFW main switchconnector terminal F and ground?

Yes Repair wiring harness between RFW main switchand RFW control module.Then go to Step 32.

No Go to next step.

26 Inspect RFW main switch. Yes Go to next step.Is it okay? No Replace RFW main switch.

27 Is there continuity between RFW main switch Yes Go to next step.connector terminal D and ground? No Repair wiring harness between RFW main switch

and ground.Then go to Step 32.

28 Inspect one-way check valve. Yes Go to next step.Is it okay? No Replace one-way check valve.

Then go to Step 32.

29 Inspect RFW actuator. Yes Go to next step.Is it okay? No Replace RFW actuator.

Then go to Step 32.

30 Inspect vacuum in vacuum hoses. Yes Go to next step.Is it okay? No Repair vacuum in vacuum hoses.

Then go to Step 32.


CONTINUED


TROUBLESHOOTING

M–62


31 Inspect RFW control module. Yes Go to next step.Is it okay? No Repair or replace RFW control module.

Then go to next step.

32 Turn ignition (engine) switch on.Move selector lever from 2H to 4H position.

Yes Troubleshooting completed.Explain repairs to customer.

Does RFW operate from free to lock? No Inspect malfunction symptoms again, then repeatfrom Step 1 if malfunction occurs again.

3 NOISE

DESCRIPTION Noise is heard from front differential.


Joint shaft bearing abrasion or damage RFW hub abrasion

Joint shaft abrasion Conventional front differential parts malfunction


1 Inspect joint shaft bearing. Yes Go to next step.Is it okay? No Replace joint shaft bearing.

2 Inspect RFW hub. Yes Go to next step.Is it okay? No Replace RFW hub.

3 Inspect joint shaft. Yes Go to next step.Is it okay? No Replace joint shaft.

4 Malfunction is caused by other than RFW.Inspect conventional front differential parts

Yes Go to next step.Inspect conventional front differential parts.Are they okay? No Replace defective part(s).

5 Has front differential noise stopped? Yes Troubleshooting completed.Explain repairs to customer.

No Inspect malfunction symptoms again, then repeatfrom Step 1 if malfunction occurs again.

4 OIL LEAKAGE

DESCRIPTION The oil leaks from front differential.


Poor installation of the RFW control box Malfunction of conventional front differential parts


1 Is RFW control box installed completely? Yes Go to next step.

No Install RFW control box securely.Then go to Step 3.

2 Malfunction is caused by something other thanRFW.


Inspect conventional front differential parts.Are they okay?

No Replace defective part(s).

3 Is there any oil leakage from front differential? Yes Inspect malfunction symptoms again, then repeatfrom Step 1 if malfunction still occurs.

No Troubleshooting completed.Explain repairs to customer.


CONTINUED


N–1

STEERING SYSTEMGENERAL PROCEDURES N–1. . . . . . . . . . . . . . . . . . . MANUAL STEERING N–1. . . . . . . . . . . . . . . . . . . . . . . .

STEERING WHEEL AND COLUMN INSPECTION N–1/2. . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING WHEEL AND COLUMNREMOVAL/INSTALLATION N–3/4. . . . . . . . . . . . . . . . . STEERING SHAFT INSPECTION N–4. . . . . . . . . . . STEERING GEAR AND LINKAGE

REMOVAL/INSTALLATION N–5/6. . . . . . . . . . . . . . . STEERING GEAR AND LINKAGE

DISASSEMBLY/ASSEMBLY N–7/9. . . . . . . . . . . . . . STEERING GEAR AND LINKAGE

INSPECTION N–9. . . . . . . . . . . . . . . . . . . . . . . . . . . POWER STEERING N–10 . . . . . . . . . . . . . . . . . . . . . . . .

AIR BLEEDING N–10. . . . . . . . . . . . . . . . . . . . . . . . . . . POWER STEERING FLUID INSPECTION N–10/12. . .

STEERING WHEEL AND COLUMN INSPECTION N–12. . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING WHEEL AND COLUMNREMOVAL/INSTALLATION N–12. . . . . . . . . . . . . . .

STEERING SHAFT INSPECTION N–12. . . . . . . . . . . STEERING GEAR AND LINKAGE

REMOVAL/INSTALLATION N–13. . . . . . . . . . . . . . . STEERING GEAR AND LINKAGE

DISASSEMBLY/ASSEMBLY N–14/15. . . . . . . . . . . . . . STEERING GEAR AND LINKAGE

INSPECTION N–15. . . . . . . . . . . . . . . . . . . . . . . . . . . POWER STEERING OIL PUMP

REMOVAL/INSTALLATION N–16/18. . . . . . . . . . . . . . . POWER STEERING OIL PUMP (F2 CIS, F2 CARB,

G6) DISASSEMBLY/ASSEMBLY N–19/20. . . . . . . . . . . POWER STEERING OIL PUMP (WL, WL TURBO)

DISASSEMBLY/ASSEMBLY N–21. . . . . . . . . . . . . .

GENERAL PROCEDURESWheels and tires removal/installation The removal and installation procedures for the

wheels and tires are not mentioned in this section.When a wheel is removed, retighten it to thespecified torque.(Refer to section TD,SUSPENSION, Wheels and Tires.)

Power steering components removal/installation If any power steering fluid line has been

disconnected anytime during the procedure, addATF M–III or equivalent (e.g. Dexron II), bleedthe fluid lines, and inspect for leakage after theprocedure has been completed.

Connectors disconnection/connection Disconnect the negative battery cable before doing

any work that requires handling of connectors.Reconnect the negative battery cable only after thework is completed.

MANUAL STEERINGSTEERING WHEEL AND COLUMN INSPECTIONSteering Wheel Play Inspection If the play exceeds specification, either the steering

joints are worn or the backlash of the steering gearis excessive. With the wheels in the straight-aheadposition, gently turn the steering wheel to the leftand right and verify that the play is withinspecification.

Steering wheel play0—30 mm 0—1.18 in

Steering Wheel Looseness Inspection Move the steering wheel as shown in the figure to

inspect for column bearing wear, steering shaftjoint play, steering wheel looseness, and columnlooseness.

BACK.TO.MAIN.INDEX

CONTINUED


MANUAL STEERING

N–2

Steering Wheel Effort Inspection1. With the vehicle on a hard, level surface, put the

wheels in the straight-ahead position.2. Remove the air bag module, if equipped.

(Refer to section T, AIR BAG SYSTEM,DRIVER-SIDE AIR BAG MODULEREMOVAL/INSTALLATION.)

3. Measure the steering wheel effort using a torquewrench.

Steering wheel effort4.5 N·m 460 kgf·cm, 399 in·lbf max.

4. If not as specified, inspect the following: rotationstarting torque of pinion, rotation torque of eachball joint, and steering joints.


CONTINUED


MANUAL STEERING

N–3

STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.


R

AIR BAG MODEL

40—50 4.0—5.0,29—36

40—50 4.0—5.0, 29—36

16—22 1.6—2.3, 12—16

16—22 1.6—2.3, 12—16

18—24 1.8—2.5, 14—18

20—26 2.0—2.7,15—19

20—26 2.0—2.7, 15—19

1 Horn cap

2 Air bag module (with air bag)+ section T, AIR BAG SYSTEM, DRIVER-SIDE

AIR BAG MODULE REMOVAL/INSTALLATION

3 Locknut

4 Steering wheel+ Removal Note+ Installation Note

5 Column cover

6 Combination switch

7 Steering shaft+ Installation Note

8 Universal joint

9 Boot

10 Intermediate shaft

11 Steering lock component+ Removal Note+ Installation Note


CONTINUED


MANUAL STEERING

N–4

Steering Wheel Removal Note

Caution Do not try to remove the steering wheel by

hitting the shaft with a hammer. The columnwill collapse.

Set the wheels in the straight-ahead position,remove the steering wheel using a suitable puller.

Steering Lock Component Removal Note Use a chisel to make a groove in the heads of the

steering lock mounting bolts. Remove the boltsusing a screwdriver. Remove the steering lockcomponent.

Steering Lock Component Installation Note Install the new steering lock mounting bolts.

Tighten the bolts until the heads break off.

Steering Shaft Installation Note1. Temporarily tighten the bolt A.2. Tighten the nut B to the specified torque.3. Tighten the bolt A to the specified torque.


A B

Steering Wheel Installation Note1. For vehicles with air bags, adjust the clock spring.

(Refer to section T, CLOCK SPRING, CLOCKSPRING ADJUSTMENT.)

2. Install the steering wheel with the vehicle in thestraight-ahead position.

STEERING SHAFT INSPECTION Inspect the following, and replace the column

component as necessary.1. Needle and ball bearing damage.2. Steering shaft length.

Length816.9—819.9 mm 32.17—32.27 in

3. Dust boot damage.


CONTINUED


MANUAL STEERING

N–5

STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION1. With the wheels in the straight-ahead position, remove in the order indicated in the table.2. Install in the reverse order of removal.

R

SST


SST

SST

SST

SST

R

R

R

R

45—584.5—6.0,33—43

37—543.7—5.5, 27—39

45—584.5—6.0,33—43

20—262.0—2.7, 15—19

69—787.0—8.0, 51—57

45—584.5—6.0, 33—43

37—543.7—5.5,27—39

45—584.5—6.0, 33—43

79—1578.0—16.0,58—115

1 Cotter pin

2 Nut

3 Ball joint+ Removal Note

4 Locknut

5 Tie rod

6 Center link

7 Idler arm+ Removal Note

8 Bushing

9 Washer

10 Bolt, nut, washer

11 Idler arm bracket


13 Bolt

14 Steering gear and pitman arm+ Removal Note

15 Dust boot+ Removal Note+ Installation Note


CONTINUED


MANUAL STEERING

N–6

Ball Joint, Idler Arm, Steering Gear and PitmanArm Removal Note Remove the ball joint from the knuckle and center

link, the idler arm from the center link, and steeringgear and pitman arm from the center link using theSST.

49 T028 3A0

Dust Boot Removal Note1. Place the chisel against the boot and hold it at the

angle shown.2. Remove the dust boot by tapping it with a hammer.

Dust Boot Installion Note1. Wipe the grease off the ball joint.2. Put a small amount of lithium-based grease into a

new dust boot.3. Install the dust boot using the SST and a press.

49 1243 785A


CONTINUED


MANUAL STEERING

N–7

STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.

R

SST


R

R

R

SST

R

197—23520.0—24.0, 145—173

128—16613.0—17.0, 95—122

15—211.5—2.2, 11—15

15—241.5—2.5, 11—18

25—342.5—3.5, 25—34

R

1 Nut

2 Pitman arm+ Disassembly Note

3 Clip

4 Dust boot+ Assembly Note

5 Locknut (side cover)+ Disassembly Note

6 Sector shaft+ Disassembly Note+ Assembly Note

7 Side cover

8 Adjusting shim

9 Adjusting screw

10 Oil seal

11 Retaining ring

12 Locknut+ Disassembly Note

13 Oil seal

14 Adjusting nut+ Disassembly Note

15 Bearing

16 Worm ball nut+ Assembly Note

17 Bearing


CONTINUED


MANUAL STEERING

N–8

Pitman Arm Disassembly Note Separate the pitman arm from the steering gear

using the SST.

49 U032 3A0

Locknut (Side Cover), Sector Shaft DisassemblyNote

1. Loosen the locknut.2. Remove the side cover attaching bolts.3. Set the sector shaft in the middle position.4. Tap the sector shaft lower end using a plastic

hammer to loosen the sector shaft.5. Lift and remove the sector shaft with the locknut

and the side cover from the gear housing.

Locknut Disassembly Note Remove the locknut using the SST.

49 U032 201

Adjusting Nut Disassembly Note Remove the adjusting nut using the SST.

49 UB39 585A

Worm Ball Nut Assembly Note1. Inspect the worm ball nut preload using the SST.

49 0180 510B

Worm ball nut preload1.0—1.3 N·m 10—14 kgf·cm, 8.7—12.1 in·lbf

[Without the sector shaft]

2. If not as specified, adjust the preload.(1) Loosen the locknut and turn the adjusting

screw using the SST.

49 U032 201


CONTINUED


MANUAL STEERING

N–9

(2) Tighten the locknut to the specified torqueusing the SST.

Tightening torque128—166 N·m 13—17 kgf·m, 95—122 ft·lbf

49 U032 201

(3) Inspect the worm ball nut preload again.

Sector Shaft Assembly Note1. Set the adjusting screw and shim, in the “T”

groove.2. Measure the clearance in the axial direction.

ADJUSTINGSHIM

3. Adjust the clearance to the specified value if theclearance is more than the specified value.

Clearance0—0.1 mm (0—0.004 in)

Adjusting shim thickness1.97 mm 0.077 in 2.00 mm 0.079 in2.03 mm 0.079 in 2.06 mm 0.081 in2.09 mm 0.082 in

Caution Be careful not to damage the oil seal and

bearing.

4. Assemble the sector shaft in such a way that theteeth of the sector shaft mesh with the center partof the teeth of the worm ball nut.

Dust Boot Assembly Note1. Wipe the grease off the ball joint.2. Put a small amount of lithium-based grease into a

new dust boot.3. Install the dust boot onto the ball joint.4. Set the SST over the boot and install a new clip.

49 U034 209

5. Wipe away excessive grease.

STEERING GEAR AND LINKAGE INSPECTIONSteering Gear Backlash Adjustment

Caution Adjust the backlash while keeping the

steering gear in the center position.Otherwise, the backlash becomesexcessively small and gears may bedamaged.

Turn the adjusting screw to adjust steering gearbacklash.

Backlash0 mm


CONTINUED


N–10

POWER STEERING

AIR BLEEDING1. Inspect the fluid level.

(Refer to POWER STEERING, POWERSTEERING FLUID INSPECTION, Fluid LevelInspection.)

2. Jack up the front of the vehicle and support it onsafety stands.

3. Turn the steering wheel fully to the left and rightseveral times with the engine not running.

4. Reinspect the fluid level. If it has dropped, addfluid.

5. Repeat Steps 3 and 4 until the fluid level stabilizes.6. Lower the vehicle.7. Start the engine and let it idle.8. Turn the steering wheel fully to the left and right

several times.9. Verify that the fluid is not foamy and that the fluid

level has not dropped.10. Add fluid as necessary and repeat Steps 8 and 9.

POWER STEERING FLUID INSPECTIONFluid Level Inspection Inspect the power steering fluid level. Add fluid to

the specified level as necessary.

Fluid specificationATF M–III or equivalent (e.g. Dexron II )

Fluid Leakage Inspection

Caution To prevent damage to the steering system,

do not keep the steering wheel in the fullyturned position for more than 5 seconds.

1. Start the engine and let it idle. Turn the steeringwheel fully to the left and right to apply fluidpressure.

Note The points where fluid leakage may occur are

indicated in the figure.

2. Inspect for fluid leakage.

R.H.D. L.H.D.

F2 CISF2 CARB

WLWL TURBO

WLWL TURBO

G6 G6

F2 CISF2 CARB


CONTINUED


POWER STEERING

N–11

Fluid Pressure Inspection1. Assemble the SSTs as shown in the figure.

49 1232 670A

49 H002 671

2. Mark both hose connections to ensure that thehose is reinstalled in its original position.

3. Disconnect the pressure hose from the oil pump.Attach the SST (49 G032 304).

Tightening torqueG6:

32—47 N·m 3.2—4.8 kgf·m, 24—34 ft·lbfF2 CIS, F2 CARB, WL, WL Turbo:

30—44 N·m 3.0—4.5 kgf·m, 22—32 ft·lbf

4. Connect the SSTs (49 1232 670A and 49 H002 671)to the SST (49 G032 304).

G6

49 B032 304

49 G032 3A4

49 H002 671

F2 CIS, F2 CARB, WL, WL TURBO

5. Bleed the air from the system.6. Open the gauge valve fully. Start the engine and

turn the steering wheel fully left and right to raisethe fluid temperature to 50—60 °C 122—140 °F.

Caution If the valve is left closed for more than 5

seconds, the fluid temperature will increaseexcessively and adversely affect the oilpump.

7. Close the gauge valve completely. Increase theengine speed to 1,000—1,500 rpm and measurethe fluid pressure generated by the oil pump. If thepressure is not within the specification, replace theoil pump component.

Oil pump fluid pressure8.9—9.3 MPa

90—95 kgf/cm 2, 1280—1350 psiTHERMOMETER50—60 °C 122—140 °F

GAUGE

CLOSE VALVECOMPLETELY

Caution If the steering wheel is kept in the fully

turned position for more than 5 seconds,the fluid temperature will rise excessivelyand adversely affect the oil pump.

8. Open the gauge valve fully and increase theengine speed to 1,000—1,500 rpm .

9. Turn the steering wheel fully to left and right andmeasure the fluid pressure generated at the gearhousing. If the pressure is not within thespecification, repair or replace the steering gearcomponent.

Gear housing fluid pressure8.9—9.3 MPa

90—95 kgf/cm 2, 1280—1350 psiTHERMOMETER50—60 °C 122—140 °F

GAUGEOPEN VALVECOMPLETELY

10. Remove the SSTs. Install and tighten the pressurepipe to the specified torque.


11. Bleed the air from the system.


CONTINUED


POWER STEERING

N–12

Note To determine whether the steering effort is

satisfactory or not, perform the inspection onanother vehicle of the same model and underthe same conditions, and compare the results.

The steering wheel effort varies with conditionsas shown below.1. Road conditions, such as dry or wet, and

asphalt or concrete.2. Tire conditions, such as brand, wear, and

tire pressure.

12. If not as specified, inspect the following points: Air in system Fluid leakage at hose or connectors Function of oil pump and steering gear

STEERING WHEEL AND COLUMNREMOVAL/INSTALLATION(Refer to MANUAL STEERING, STEERING WHEELAND COLUMN REMOVAL/INSTALLATION.)

STEERING SHAFT INSPECTION(Refer to MANUAL STEERING, STEERING SHAFTINSPECTION.)

STEERING WHEEL AND COLUMN INSPECTIONSteering Wheel Play Inspection(Refer to MANUAL STEERING, STEERING WHEELAND COLUMN INSPECTION, Steering Wheel PlayInspection.)

Steering Wheel Looseness Inspection(Refer to MANUAL STEERING, STEERING WHEELAND COLUMN INSPECTION, Steering WheelLooseness Inspection.)

Steering Wheel Effort Inspection1. Inspect the following points:

Tire size and tire pressure Fluid level

2. With the vehicle on a hard, level surface, put thewheels in the straight-ahead position.

3. Start the engine and warm the power steering fluidto 50—60 °C 122—140 °F.

4. Remove the air bag module, if equipped. (Refer to section T, AIR BAG SYSTEM, DRIVER-SIDEAIR BAG MODULE REMOVAL/INSTALLATION.)

5. Measure the steering wheel effort using a torquewrench.

Steering wheel effort7.8 N·m 80 kgf·cm, 69 in·lbf max.


CONTINUED


POWER STEERING

N–13

STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.


R

SST

SST

R

R

SST

79—1577.0—16.0, 58—115

37—543.7—5.5, 27—39

45—584.5—6.0, 33—43

69—787.0—8.0, 51—57

45—584.5—6.0, 33—43

20—262.0—2.7, 15—19

37—543.7—5.5, 27—39

32—473.2—4.8, 24—34

24—352.4—3.6, 18—26

R

SST

SST

1 Cotter pin

2 Locknut

3 Ball joint+ MANUAL STEERING, STEERING GEAR AND

LINKAGE REMOVAL/INSTALLATION, BallJoint Removal Note

4 Locknut

5 Tie rod

6 Center link

7 Idler arm+ MANUAL STEERING, STEERING GEAR AND

LINKAGE REMOVAL/INSTALLATION, IdlerArm Removal Note

8 Bushing

9 Washer


11 Idler arm bracket

12 Pressure pipe

13 Return pipe

14 Bolt


16 Steering gear and pitman arm+ MANUAL STEERING, STEERING GEAR AND

LINKAGE REMOVAL/INSTALLATION, SteeringGear and Pitman Arm Removal Note

17 Dust boot+ MANUAL STEERING, STEERING GEAR AND

LINKAGE REMOVAL/INSTALLATION, DustBoot Disassembly Note

+ MANUAL STEERING, STEERING GEAR ANDLINKAGE REMOVAL/INSTALLATION, DustBoot Assembly Note


CONTINUED


POWER STEERING

N–14

STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.


R

SST

R

R R

R

R

SSTR

R

R

R

R

R

57—645.7—6.5, 42—47

30—443.0—4.5, 22—32

56—635.7—6.5, 42—47

197—23520.0—24.0,145—173

R

1 Nut

2 Pitman arm+ MANUAL STEERING, STEERING GEAR AND

LINKAGE DISASSEMBLY/ASSEMBLY, PitmanArm Disassembly Note

3 Clip

4 Dust boot+ MANUAL STEERING, STEERING GEAR AND

LINKAGE DISASSEMBLY/ASSEMBLY, DustBoot Assembly Note

5 Locknut+ MANUAL STEERING, STEERING GEAR AND

LINKAGE DISASSEMBLY/ASSEMBLY, Locknut(Side Cover), Sector Shaft Disassembly Note

6 Sector shaft+ MANUAL STEERING, STEERING GEAR AND

LINKAGE DISASSEMBLY/ASSEMBLY, Locknut(Side Cover) Sector Shaft Disassembly Note

7 Side cover

8 O-ring

9 Y packing

10 Back up ring

11 Oil seal

12 Back up ring

13 Y packing

14 Dust cover

15 Snap ring

16 Washer

17 Oil seal

18 Valve and piston component+ Assembly Note

19 O-ring

20 Seal ring

21 Gear housing


CONTINUED


POWER STEERING

N–15

Valve and Piston Component Assembly Note

Caution Do not scratch the seal ring and O-ring on

the piston against the entrance to thehousing.

Insert the piston by slightly turning to theleft and right so as not to create flection atthe O-ring and seal ring.

Insert the valve and piston component to the gearhousing.

STEERING GEAR AND LINKAGE INSPECTION(Refer to MANUAL STEERING, STEERING GEARAND LINKAGE INSPECTION, Steering Gear BacklashAdjustment.)


CONTINUED


POWER STEERING

N–16

POWER STEERING OIL PUMP REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.3. For F2 CIS, F2 Carb and G6 engine model, adjust the drive belt.

(Refer to Section B2, DRIVE BELT,DRIVE BELT ADJUSTMENT.)

30—443.0—4.5, 22—32

R

SST

30—393.0—4.0, 22—28


50—595.0—6.0, 37—43

F2 CIS, F2 CARB


CONTINUED


POWER STEERING

N–17


19—251.9—2.6, 14—18

32—473.2—4.8, 24—34

32—463.2—4.7, 24—33

50—595.0—6.0, 37—43

SST

CLAMPPOSITION

30 mm1.2 in

G6

1 Drive belt

2 Locknut+ Removal Note

3 Oil pump pulley

4 Pressure pipe (F2 CIS, F2 Carb), pressure hose(G6)

5 Return hose

6 Power steering fluid pressure switch connector(except F2 Carb)

7 Power steering oil pump component

Locknut Removal Note Secure the pulley using the SST and remove the

locknut.

49 G032 354


CONTINUED


POWER STEERING

N–18


R

R

19—251.9—2.6, 14—18

19—251.9—2.6,14—18

30—443.0—4.5, 22—32

WL, WL TURBO

1 Pressure pipe

2 Return hose

3 Bolt and nut

4 Power steering oil pump

5 O-ring


CONTINUED


POWER STEERING

N–19

POWER STEERING OIL PUMP (F2 CIS, F2 CARB, G6) DISASSEMBLY/ASSEMBLY1. The following procedure is for replacement of the O-rings only. Replace the pump component if other repairs

are necessary.2. Disassemble in the order indicated in the table.3. Assemble in the reverse order of disassembly.


15—19 1.5—2.0,11—14

22—25 2.2—2.6, 16—18

50—68 5.0—7.0,37—50

9.9—13.7 N·m 100—140 kgf·cm,87—121 in·lbf

R

R

R

R

R

R

R

18—21 1.8—2.2, 14—16

22—25 2.2—2.6, 16—18

7.9—11.7 N·m 80—120 kgf·cm,70—104 in·lbf

F2 CIS

G6

SST

À

F2 CARB

16—23 1.6—2.4, 12—17

1 Power steering oil pump component+ Disassembly Note

2 Pressure switch component

3 O-ring

4 Nut (G6)

5 Connector (G6)

6 Connector bolt

7 O-ring

8 Control valve component

9 Spring

10 Suction pipe

11 O-ring

12 Shaft component

13 Rear body+ Assembly Note

14 O-ring

15 Cam ring+ Assembly Note

16 Rotor

17 Vane+ Assembly Note

18 Pin

19 Side plate+ Assembly Note

20 O-ring

21 Oil seal

22 Front body


CONTINUED


POWER STEERING

N–20

Power Steering Oil Pump Disassembly Note

Caution To secure the oil pump in a vise, use the SST

as shown to prevent damage to the pump.

49 F032 301

Side Plate Assembly Note1. Install a new O-ring and the side plate to the front

body.2. Position the side plate using the rear body.

Vane, Cam Ring Assembly Note1. Install the cam ring with the marks facing the front

body.

2. Install the rotor with the mark facing the rear body.

MARK

3. Install the vanes in the rotor with the rounded edgesoutward.

ROUND EDGE

Rear Body Assembly Note After installing the rear body, manually turn the shaft

to verify that it rotates smoothly.


CONTINUED


POWER STEERING

N–21

POWER STEERING OIL PUMP (WL, WL TURBO) DISASSEMBLY/ASSEMBLY1. The following procedure is for replacement of the O-rings only. Replace the pump component if other repairs

are necessary.2. Disassemble in the order indicated in the table.3. Assemble in the reverse order of disassembly.

R

SST

R

R

R

22—252.2—2.6, 16—18

50—685.0—7.0, 37—50

7.9—11.7 N·m80—120 kgf·cm,69.5—104.1 in·lbf


1 Power steering oil pump component+ POWER STEERING, POWER STEERING

OIL PUMP (G6) REMOVAL/INSTALLATION, Power SteeringOil Pump Component Disassembly Note

2 Suction pipe

3 O-ring

4 Connector

5 O-ring

6 Control valve

7 Spring

8 Rear body+ POWER STEERING, POWER STEERING

OIL PUMP (G6) REMOVAL/INSTALLATION, Rear BodyAssembly Note

9 O-ring

10 Cam ring+ POWER STEERING POWER STEERING

OIL PUMP (G6) REMOVAL/INSTALLATION, Cam RingAssembly Note

11 Rotor

12 Vane+ POWERSTEERING, POWER STEERING

OIL PUMP (G6) REMOVAL/INSTALLATION, Vane Assembly Note

13 Side plate+ POWER STEERING, POWER STEERING

OIL PUMP (G6) REMOVAL/INSTALLATION, Side PlateAssembly Note

14 O-ring

15 Front body


CONTINUED


POWER STEERING

P–1

BRAKING SYSTEMGENERAL PROCEDURES P– 1. . . . . . . . . . . . . . . . . . . CONVENTIONAL BRAKE SYSTEM P– 2. . . . . . . . . . .

AIR BLEEDING P– 2. . . . . . . . . . . . . . . . . . . . . . . . . . . VACUUM LINE INSPECTION P– 2. . . . . . . . . . . . . . BRAKE PEDAL INSPECTION P– 2. . . . . . . . . . . . . . BRAKE PEDAL REMOVAL/INSTALLATION P– 3. . BRAKE SWITCH INSPECTION P– 4. . . . . . . . . . . . . MASTER CYLINDER REMOVAL/

INSTALLATION P– 4/6. . . . . . . . . . . . . . . . . . . . . . . . . . FLUID LEVEL SENSOR INSPECTION P– 6. . . . . . MASTER CYLINDER DISASSEMBLY/

ASSEMBLY P– 7/8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER BRAKE UNIT INSPECTION P– 8. . . . . . . . POWER BRAKE UNIT REMOVAL/

INSTALLATION P– 9. . . . . . . . . . . . . . . . . . . . . . . . . . VACUUM SWITCH INSPECTION P– 9. . . . . . . . . . . VACUUM SWITCH

REMOVAL/INSTALLATION P–10. . . . . . . . . . . . . . . VACUUM PUMP INSPECTION P–10. . . . . . . . . . . . . VACUUM PUMP REMOVAL/INSTALLATION P–10. LOAD SENSING PROPORTIONING

VALVE INSPECTION P–11. . . . . . . . . . . . . . . . . . . . . LOAD SENSING PROPORTIONING

VALVE ADJUSTMENT P–11. . . . . . . . . . . . . . . . . . .

LOAD SENSING PROPORTIONINGVALVE REMOVAL/INSTALLATION P–11. . . . . . . . .

FRONT BRAKE (DISC) INSPECTION P–12. . . . . . . FRONT BRAKE (DISC) REMOVAL/

INSTALLATION P–13/14. . . . . . . . . . . . . . . . . . . . . . . . . . DISC PAD (FRONT) REPLACEMENT P–14. . . . . . . CALIPER (FRONT) DISASSEMBLY/

ASSEMBLY P–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE (DRUM) INSPECTION P–15. . . . . . . REAR BRAKE (DRUM) REMOVAL/

INSTALLATION P–15. . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE DRUM INSPECTION P–16. . . . . . . . . . . . . . . WHEEL CYLINDER DISASSEMBLY/

ASSEMBLY P–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE SYSTEM P–16. . . . . . . . . . . . . . . . .

PARKING BRAKE (STICK TYPE)INSPECTION P–16. . . . . . . . . . . . . . . . . . . . . . . . . . .

PARKING BRAKE (STICK TYPE)ADJUSTMENT P–16. . . . . . . . . . . . . . . . . . . . . . . . . .

PARKING BRAKE LEVER (STICK TYPE)REMOVAL/INSTALLATION P–17. . . . . . . . . . . . . . .

PARKING BRAKE CABLE (STICK TYPE)REMOVAL/INSTALLATION P–18/19. . . . . . . . . . . . . . .

GENERAL PROCEDURESWheel and tires removal/installation The removal and installation procedures for the

wheels and tires are not mentioned in this section.When a wheel is removed, retighten it to thespecified tightening torque, referring to section TD.

Brake lines disconnection/connection

Caution Brake fluid will damage painted surfaces. If

brake fluid get on a painted surface, wipe itoff immediately.

If any brake line has been disconnected anytimeduring the procedure, add brake fluid, bleed thebrakes, and inspect leakage after the procedurehas been completed.

Fluid specificationSAE J1703 or FMVSS116 DOT–3 or DOT–4

Brake pipe flare nut tightening Tighten the brake pipe flare nut by using the

SST (49 0259 770B). Be sure to modify the brake pipeflare nut tightening torque to allow for use of atorque wrench-SST combination. (Refer to section GI, FUNDAMENTAL PROCEDURES, TORQUE FORMULAS.)

Connectors disconnection Disconnect the negative battery cable before doing

any work that requires handling of connectors.Reconnect the negative battery cable only after thework is completed.

BACK.TO.MAIN.INDEX

CONTINUED


CONVENTIONAL BRAKE SYSTEM

P–2

CONVENTIONAL BRAKE SYSTEMAIR BLEEDING

Note The reservoir should be kept 3/4 full during

bleeding. The brakes should be bled whenever a brake

line is disconnected. If a hydraulic line isdisconnected at the master cylinder, start at theslave cylinder farthest from the brake mastercylinder, and move to the next farthest slavecylinder until all four cylinders have been bled.If the disconnection point is anywhere exceptthe master cylinder, start at the point closest tothe disconnection, and move to the nextclosest slave cylinder until all four cylindershave been bled.

1. Remove the bleeder cap and attach a vinyl tube tothe bleeder screw.

2. Place the other end of the vinyl tube in a clearfluid-filled container.

3. One person should depress the brake pedal a fewtimes, and then hold it in the depressed position.

4. A second person should loosen the bleeder screw,drain out the fluid and retighten the screw using theSST.

Tightening torqueFront:

9—14 N·m 92—142 kgf·cm, 80—123 in·lbfRear:

5.9—8.8 N·m 60—90 kgf·cm, 53—78 in·lbf

49 0259 770B

5. Repeat steps 3 and 4 until no air bubbles are seen.6. After air bleeding, inspect the following:

(1) brake operation(2) fluid leakage(3) fluid level

VACUUM LINE INSPECTION1. Remove the clamps and the vacuum hose.2. Apply both suction and pressure to the engine-side

hose (Gasoline) or vacuum pump side of the hose(Diesel), and verify that air blows only toward thatside. If air flows in both directions or not at all,replace the vacuum hose.

ENG

CHECK VALVE

BRAKE PEDAL INSPECTIONBrake Pedal Height Inspection Verify that the distance from the center of the

upper surface of the pedal pad to the floor pannelis as specified.

Pedal heightL.H.D.: 214—219 mm 8.43—8.81 inR.H.D.:219—224 mm 8.63—8.81 in

PEDAL HEIGHT


CONTINUED



P–3

Brake Pedal Height Adjustment1. Disconnect the brake switch connector.2. Loosen locknut B and turn switch A until it does not

contact the pedal.3. Loosen locknut D and turn rod C to adjust the height.4. Tighten the bolt with locknut B so that clearance

between the bolt for brake light switch A and pedalstopper is within the specification.

Specification0.1—1.0 mm 0.004—0.039 in

Tightening torque14—17 N·m 140—180 kgf·cm, 122—156 in·lbf

5. Connect the brake switch connector.6. After adjustment, inspect the pedal play and the

brake light operation.

B

DA

C

Brake Pedal Play Inspection1. Depress the pedal a few times to eliminate the

vacuum in the system.2. Remove the snap pin, verify that the holes in the

fork and in the pedal are aligned, and reinstall thepin.

3. Gently depress the pedal by hand until resistanceis felt (approx. 20N 2 kgf, 4.4 lbf ) and inspectthe free play.

Pedal play3—8 mm 0.12—0.31 in

Brake Pedal Play Adjustment1. Remove the snap pin and clevis pin.2. Loosen locknut D and turn rod C to align the holes

in the fork and in the pedal.3. Install the clevis pin and the snap pin.4. Tighten locknut D.


C

D

5. After adjustment, inspect the pedal height and thebrake light operation.

Pedal-to-floor Clearance Inspection1. Start the engine and verify that the distance from

the floor panel to the pedal pad center is asspecified when the pedal is depressed with a forceof 589 N 60 kgf, 132 lbf .

Clearance105 mm 4.2 in min.

PEDAL-TO-FLOORCLEARANCE

2. If the distance is less than specified, inspect thefollowing:(1) Air in brake system(2) Malfunction of the automatic adjuster(3) Excessive shoe clearance

BRAKE PEDAL REMOVAL/INSTALLATIONR.H.D.

The brake pedal is mounted on the bracketintegrated with the clutch pedal and acceleratorpedal. Refer to section F2, INTAKE AIRSYSTEM, ACCELERATOR PEDALREMOVAL/INSTALLATION for the brake pedal removal/installation.

L.H.D.The brake pedal is mounted on the bracketintegrated with the clutch Pedal. Refer to section H, CLUTCH PEDAL REMOVAL/INSTALLATION for the brake pedal removal/installation.


CONTINUED



P–4

BRAKE SWITCH INSPECTION1. Disconnect the brake switch connector.2. Inspect for continuity between the terminals of the

brake switch connector using the circuit tester.: Continuity

ConditionTerminal

ConditionA B

When the brake pedal isdepressed.

When the brake pedal isnot depressed.

A

B

3. If not as specified, replace the brake switch.

MASTER CYLINDER REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.L.H.D.

SST

R

9.81—15.6 100—160, 87—138

*

12.9—21.5130—220, 113—190

SST

* 49 0259 770B N·m kgf·cm, in·lbf


*

9.81—15.6 100—160, 87—138

12.9—21.5130—220, 113—190

* 49 0259 770B

SST

SST

R

R.H.D.

1 Brake fluid level sensor connector

2 Brake pipe

3 Bracket (R.H.D.)

4 Master cylinder+ Installation Note

5 O-ring

Master Cylinder Installation Note1. Loosen the adjusting nut of the SST.2. Place the SST on the power brake unit and tighten

the nut and washer.


100—160 kgf·cm, 87—138 in·lbf

3. Apply 66.7 kPa 500 mmHg, 19.7 inHg vacuum tothe power brake unit using a vacuum pump.

49 B043 001


CONTINUED



P–5

4. Turn the adjusting nut of the SST counterclockwiseuntil the gauge rod just contacts the push rod endof the power brake unit. Push lightly on the end ofthe gauge rod to be sure it is seated. Verify thatthere is no gap between the adjusting nut and SSTbody.

5. Remove the SST from the power brake unit.

TOUCHING

TOUCHING

ADJUSTING NUT

49 B043 001

6. Remove the SST from the power brake unit withoutdisturbing the adjusting nut. Set the SST onto themaster cylinder as shown in the figure.

7. Push lightly on the end of the SST gauge rod to besure that it is contacting the bottom of the mastercylinder piston, but do not push so hard that thepiston moves. Note any clearance between theSST body and the adjusting nut: clearance B, orbetween the body and the master cylinder:clearance C. Adjust the push rod as necessary asoutlined in “Adjustment” below.

AdjustmentMeasurement Push rod

Clearance at B Too long

Clearance at C Too short

No clearance at B or C Okay

CLEARANCE (B)

CLEARANCE (C)

49 B043 001

Clearance at B1. Measure and record the height D1 of the gauge

rod.

(D1)

49 B043 001

2. Turn the adjusting nut until the SST body setsclosely on the master cylinder. Turn only enoughfor the body to touch.

3. Measure and record height D2 of the gauge rod.ADJUSTING NUT

(D2)

CLEARANCE (B)

49 B043 001

4. Subtract D1 from D2. Using the SST, turn the nutto shorten the power brake unit push rod anamount equal to the difference.

49 B043 004

49 E043 003A


CONTINUED



P–6

Clearance at C1. Push lightly on the end of the SST gauge rod, and

measure the clearance between the adjusting nutand the SST body.

CLEARANCE (C)

49 B043 001

2. Using the SSTs, turn the nut to lengthen the powerbrake unit push rod an amount equal to theclearance measured at B.

49 B043 004

49 E043 003A

FLUID LEVEL SENSOR INSPECTION1. Disconnect the sensor connector.2. Connect an ohmmeter to the connector.3. Starting with the fluid level above MIN, verify that

there is no continuity.4. Remove the brake fluid and verify that there is

continuity when the level is below MIN.: Continuity

Fl id levelTerminal

Fluid levelA B

Below MIN.

Above MIN.

5. If not as specified, replace the sensor.

B

A


CONTINUED



P–7

MASTER CYLINDER DISASSEMBLY/ASSEMBLY

Caution If the master cylinder body is damaged, replace the unit as a component. When securing the master

cylinder in a vise, tighten only the flange of the master cylinder.


N·m kgf·cm , in·lbf

2.0—2.4 20—25, 18—21

1.0—1.510—15, 8.7—13

À

R

R

R

R

R

R

1 Cap set

2 Screw

3 Reservoir

4 Joint bushing

5 Fluid level sensor

6 Snap ring

7 Spacer

8 Piston guide

9 O-ring

10 Cup

11 Primary piston stopper

12 Primary piston

13 Stop screw+ Assembly Note

14 O-ring

15 Secondary piston

16 Master cylinder body


CONTINUED



P–8

Stop Screw and O-ring Assembly Note1. Install a new O-ring onto the stop screw.2. Push the primary piston component in full.3. Install and tighten the stop screw.


POWER BRAKE UNIT INSPECTIONPower Brake Unit Function Inspection(Simple method)

Note Replace power brake unit component as

necessary.

Step 11. With the engine stopped, depress the pedal a few

times.2. With the pedal depressed, start the engine.3. If the pedal moves down slightly, immediately after

the engine starts, the unit is operating.

Step 21. Start the engine.2. Stop the engine after it has run for 1 or 2 minutes .3. Depress the pedal with the usual force.4. If the first pedal stroke is long and becomes shorter

with subsequent strokes, the unit is operating.

Note If a problem is found, inspect for damage on

the check valve or vacuum hose, and examinethe installation. Repair as necessary, andinspect it again.

Step 31. Start the engine.2. Depress the pedal with the usual force.3. Stop the engine with the pedal held depressed.4. Hold the pedal down for about 30 seconds .5. If the pedal height does not change, the unit is

operating.

(Inspection using the testers)1. Connect the SSTs, vacuum gauge, and pedal

depression force gauge as shown in the figure.

Note Use commercially available gauges and pedal

depression force gauge. Bleed the air from the SST at gauge A.

VACUUM GAUGE

PEDAL DE-PRESSIONFORCEGAUGE

49 U043 004 49 U043 005

49 U043 006

AA

2. After bleeding the air from the SST, conduct thetest as described in the following steps.

a) Inspection for vacuum lossUnloaded condition

1. Start the engine.2. Stop the engine when the vacuum gauge reading

reaches 66.7 kPa 500 mmHg, 19.7 inHg .3. Observe the vacuum gauge for 15 seconds . If the

gauge shows 63.3—66.7 kPa 475—500 mmHg,18.7—19.7 inHg , the unit is operating.

Loaded condition1. Start the engine.2. Depress the brake pedal with a force of 196 N 20

kgf, 44 lbf .3. With the brake pedal depressed, stop the engine

when the vacuum gauge reading reaches 66.7 kPa500 mmHg, 19.7 inHg .

4. Observe the vacuum gauge for 15 seconds . If thegauge shows 63.3—66.7 kPa 475—500 mmHg,18.7—19.7 inHg , the unit is operating.

b) Inspection for hydraulic pressure1. When the engine is stopped (vacuum 0 kPa 0

mmHg, 0 inHg ) and the fluid pressure is withinthe specification, the unit is operating.

Pedal force Fluid pressure

196 N20 kgf, 44 lbf

790 kPa 8 kgf/cm2, 114 psi min

2. Start the engine. Depress the brake pedal whenthe vacuum reaches 66.7 kPa 500 mmHg, 19.7inHg . If the fluid pressure is within thespecification, the unit is operating.

Pedal force Fluid pressure

196 N20 kgf, 44 lbf

8,240 kPa84 kgf/cm2, 1,200 psi min


CONTINUED



P–9

POWER BRAKE UNIT REMOVAL/INSTALLATION1. Remove the master cylinder. (Refer to

CONVENTIONAL BRAKE SYSTEM, MASTERCYLINDER REMOVAL/INSTALLATION.)

2. Remove in the order indicated in the table.3. Install in the reverse order of removal.L.H.D.


19—251.9—2.6, 14—18

24—342.4—3.5, 18—25

R

19—251.9—2.6, 14—18


24—342.4—3.5, 18—25

R

R.H.D.

1 Vacuum switch connector (Diesel)

2 Vacuum hose

3 Snap pin

4 Clevis pin

5 Nut

6 Power brake unit

7 Gasket

8 Fork

9 Nut

VACUUM SWITCH INSPECTION (DIESEL)1. Remove the vacuum hose from the power brake unit.2. Set the vacuum pump hose (commercially

available on the market) onto the power brake unitas shown.

3. Turn the engine switch on.4. Release the parking brake.5. Apply vacuum to the power brake unit using the

vacuum pump (commercially available on themarket) and verify the operating condition of thebrake light warning light.

Vacuum kPa mmHg, inHg Brake warninglight

Below 10.71.3 8010, 3.20.4 ON

Above 10.71.3 8010, 3.20.4 OFF

6. The vacuum switch is functioning normally if itcorresponds to the above specifications. Replacethe vacuum switch as necessary.


CONTINUED



P–10

VACUUM SWITCH REMOVAL/INSTALLATION(DIESEL)


L.H.D.

N·m kgf·m, ft·lbf20—24 2.0—2.5, 15—18

R.H.D.

N·m kgf·m, ft·lbf20—24 2.0—2.5, 15—18

1 Vacuum switch connector

2 Vacuum switch+ Installation Note

Vacuum Switch Installation Note1. Remove the old sealant.

Caution Do not apply sealant to the tip of the

vacuum switch as a malfunction may occur.2. Apply sealant to the area shown before installation

of the vacuum switch onto the power brake unit,and then tighten it to the specified torque.


DO NOT APPLYSEALANT ONTHIS AREA

VACUUM PUMP INSPECTION (DIESEL)1. Warm up the engine.2. Disconnect the vacuum hose from the vacuum

pump and connect a vacuum gauge as shown inthe figure, then inspect the vacuum.

Vacuum specification (In 20 seconds)Engine speed 1,500 rpm73.3 kPa 550 mmHg, 21.7 inHg

Maximum vacuumEngine speed 3,000 rpm93.3 kPa 700 mmHg, 27.6 inHg

3. If the pressure is less than the specification,inspect for the following.(1) Malfunction of the vacuum pump(2) Shortage of the lubrication oil pressure

VACUUM PUMP REMOVAL/INSTALLATION(DIESEL)


R


19—25 1.9—2.6, 14—18

1 Vacuum hose

2 Bolt

3 Vacuum pump

4 O-ring


CONTINUED



P–11

LOAD SENSING PROPORTIONING VALVEINSPECTION

1. Place the vehicle on level ground.2. Inspect the tire inflations and set them to the

recommended pressure as necessary.3. Prepare the vehicle with a person in the driver’s

seat; include the standard vehicle tools, the sparewheel and tire, and a full tank of fuel.

4. Connect pressure gauges (commercially available)to the front and rear calipers.

Note When applying the specified pressure, the brake

pedal must not be “double pumped” or released. Approximately two seconds after setting the front

wheel cylinder fluid pressure, read the rear pres-sure.

5. Bleed the air from the brake system.6. Slowly depress the brake pedal until the front

pressure gauge indicates the specified pressureshown in the table, then note the reading on therear pressure gauge.

kPa kgf/cm2, psiFront pressure Rear pressure

4,900 50, 711 2,550 26, 370

9,810 100, 1,422 3,530 36, 512

REAR PRESSURE FRONT PRESSURE4,900 50, 711 9,810 100, 1,422

kPa kgf/cm 2, psi

LOADED

A PERSON INDRIVER’S SEAT

7. If not as specified, replace and adjust the LSPV.

LOAD SENSING PROPORTIONING VALVEADJUSTMENT

1. Place the unloaded vehicle on level ground.Unloaded condition: Fuel tank is full. Engine

coolant and engine oil are atspecified levels. Spare tire,jack, and tools are indesignated position.

Note A change of 5 mm 0.197 in dimension L

results in a change of 853 kPa 8.7 kgf/cm 2,124 psi for 42 and 1020 kPa 10.4 kgf/cm 2,148 psi for 44.

2. Adjust main spring dimension L between the LSPVand the adjustment link by loosening andrepositioning the LSPV.(1) Decrease dimension L if the fluid pressure is

low.(2) Increase dimension L if the fluid pressure is

high.

Reference valueDimension L

42: 147.5—154.5 mm 5.808—6.082 in44: 175.5—182.5 mm 6.910—7.185 in

ADJUSTMENT LINK

MAIN SPRING

AXLE CASING

BOLT

3. After adjustment, recheck the fluid pressure. If notas specified, replace the LSPV as a component.

LOAD SENSING PROPORTIONING VALVEREMOVAL/INSTALLATION

Caution Do not disassemble the LSPV. Do not move the nut A.



CONTINUED



P–12

3. After installation, adjust the main spring dimension.(Refer to CONVENTIONAL BRAKE SYSTEM,LOAD SENSING PROPORTIONING VALVEADJUSTMENT.)

SST * SST *

A

12.8—21.5 N·m 130—220 kgf·cm, 113—190 in·lbf

19—25 1.9—2.6, 14—18

* 49 0259 770B

12.8—21.5 N·m 130—220 kgf·cm,113—190 in·lbf

19—25 1.9—2.6, 14—18


1 Brake pipe

2 Nut

3 Bolt

4 Load sensing proportioning valve

FRONT BRAKE (DISC) INSPECTIONDisc Pad Thickness Inspection

1. Jack up the front of the vehicle and support it on safe-ty stands.

2. Remove the wheel and tires.3. Look through the caliper inspection hole and

inspect the remaining thickness of the pads.


4. Replace the pads as a set (right and left wheels) ifeither is at or less than the minimum thickness.

Disc Plate Thickness Inspection1. Measure the thickness of the disc plate.

Caution When it is necessary to machine the disc

plate, if the disc plate is removed from thevehicle then machined, excessive runoutmay result. Machine the disc plate with itinstalled on the vehicle.

Standard24 mm 0.94 in

Minimum22 mm 0.87 in

Minimum thickness after machining by using abrake lathe on-vehicle22.8 mm 0.90 in

2. If the thickness is not within the specification,replace the disc plate.

Disc Plate Runout Inspection1. Verify that there is no wheel bearing looseness.2. Measure the runout at the outer edge of the

contact surface of the disc pad.


3. If the runout is not within the specification, repair orreplace the disc plate.


CONTINUED



P–13

FRONT BRAKE (DISC) REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not drag.

SST


22—29 2.2—3.0, 16—29

108—127 10.4—14.0, 80—94

R

R29—34 2.9—3.5, 21—25

1 Brake hose

2 Bolt

3 Guide pin

4 Dust boot

5 Caliper

6 Disc pad+ Installation Note

7 Plate

8 Guide plate

9 Mounting support


CONTINUED



P–14

Disc Pad Installation Note1. Push the piston fully inward using the SST.2. Install the disc pad.

49 0221 600C

DISC PAD (FRONT) REPLACEMENT1. Remove in the order indicated in the table.2. Install in the reverse order of removal.

SST


29—342.9—3.5, 21—25

R

1 Bolt

2 Caliper

3 Disc pad+ CONVENTIONAL BRAKE SYSTEM, FRONT

BRAKE (DISC) REMOVAL/INSTALLATION,Disc Pad Installation Note

4 Plate

5 Guide plate

CALIPER (FRONT) DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.

R

*SST

SST

9—14 92—143, 80–123

*49 0259 770B N·m kgf·cm, in·lbf

1 Piston+ Disassembly Note

2 Dust seal

3 Piston seal+ Disassembly Note

4 Bleeder cap, screw

5 Caliper body

Piston Disassembly Note

Caution Blow the compressed air slowly to prevent

the piston from suddenly popping out.

Place a piece of wood in the caliper, then blowcompressed air through the hole to force the pistonout of the caliper.

WOOD

Piston Seal Disassembly Note Remove the piston seal from the brake caliper

using the SST.


CONTINUED



P–15

REAR BRAKE (DRUM) INSPECTIONBrake Lining Thickness Inspection

1. Remove the brake drum.2. Inspect the remaining thickness of the lining.


3. Replace both left and right brake shoes if either isat or less than the minimum thickness.

REAR BRAKE (DRUM) REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.3. After installation.

(1) Depress the brake pedal a few times, then verify that the brakes do not drag.(2) Inspect the parking brake lever stroke.

APPLY


12.8—21.5 130—220, 113—190

9.8—12.7 100—130, 87—112

TO SHADED EREA

SST*

*49 0259 770B

1 Brake drum

2 Hold spring, washer

3 Hold pin

4 Lower return spring

5 Upper return spring

6 Pawl lever spring

7 Pawl lever

8 Adjust strut

9 Brake shoe

10 Parking brake cable

11 Operating lever

12 Brake pipe

13 Wheel cylinder

14 Gasket


CONTINUED


(Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION, Parking Brake Lever Stroke Inspection.)

PAGES. FROM. MANUAL

CONVENTIONAL BRAKE SYSTEM, PARKING BRAKE SYSTEM

P–16

BRAKE DRUM INSPECTION1. Measure the inner diameter of the drum.

Maximum diameter42: 271.5 mm 10.68 in44: 296.5 mm 11.67 in

2. Apply chalk to the inside of the brake drum.3. Inspect for scratches and uneven or abnormal

wear inside the drum as shown in the figure.

4. Repair or replace the drum as necessary. Repair ifthe problem is minor.

5. When repairing or replacing the drum, check thecontact with the shoes.

6. Wipe the chalk off after inspection.

WHEEL CYLINDER DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.

N·m kgf·cm , in·lbf * 49 0259 770B

R

R

5.9—8.8 60—90 , 53—78

SST * R

R

1 Dust boot

2 Piston

3 Piston cap

4 Spring

5 Bleeder cap, screw

6 Cylinder body

PARKING BRAKE SYSTEMPARKING BRAKE (STICK TYPE) INSPECTIONParking Brake Lever Stroke Inspection

1. Pull the parking brake lever a few times.2. Verify that the stroke is within the specification

when the parking brake lever is pulled with a forceof 98 N 10 kgf, 22 ibf .

Stroke1—7 notches

3. If not as specified, adjust the parking brake leverstroke.

PARKING BRAKE (STICK TYPE) ADJUSTMENTParking Brake Lever Stroke Adjustment

1. Before adjustment, depress the brake pedalseveral times while the vehicle is moving inreverse.

2. Loosen the locknut A and turn the adjustment nutB so that the stroke is within the above range.

3. After adjustment, tighten the locknut A.


A

B

4. After adjustment, inspect the following points.(1) Turn the ignition (engine) switch on, pull the

parking brake lever one notch, and verify thatthe brake warning light illuminates.

(2) Verify that the rear brakes do not drag whenthe wheels are turned by hand.


CONTINUED


PARKING BRAKE SYSTEM

P–17

PARKING BRAKE LEVER (STICK TYPE) REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.3. After installation, inspect the parking brake lever stroke.

(Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION.)


6.9—9.870—100, 43—86

12.8—18.6 130—190, 113—164

1 Clip

2 Joint pin

3 Cable connector

4 Parking brake switch

5 Clip

6 Pin

7 Clip and joint pin

8 Lever

9 Pin and clip

10 Spring

11 Rachet pawl

12 Stopper

13 Fork joint

14 Spring

15 Guide

16 Rod


CONTINUED


PARKING BRAKE SYSTEM

P–18

PARKING BRAKE CABLE (STICK TYPE) REMOVAL/INSTALLATION1. Remove the under guard. (Refer to section F1–F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)2. Remove in the order indicated in the table.3. Install in the reverse order of removal.4. After installation, inspect the parking brake lever stroke.

(Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION.)

4x2

16—22 1.6—2.3, 12—16

16—22 1.6—2.3, 12—16

4x4


6.9—9.8 N·m 70—100 kgf·cm,43—86 in·lbf

6.9—9.8 N·m 70—100 kgf·cm,43—86 in·lbf

16—22 1.6—2.3,12—16

16—22 1.6—2.3, 12—16

16—22 1.6—2.3, 12—16

16—22 1.6—2.3, 12—16

16—22 1.6—2.3, 12—16


CONTINUED


PARKING BRAKE SYSTEM LHD model with F2 and G6 engine


CONTINUED

1 Nut

2 Bolt

3 Spring

4 Front brake cable

5 Bolt (44)

6 Bracket (44)

7 Grommet

8 Bolt

9 Spring (44)

10 Clip

11 Rear cable (left)

12 Rear cable (right)

P-19

R–1

SUSPENSIONGENERAL PROCEDURES R–1. . . . . . . . . . . . . . . . . . . WHEEL ALIGNMENT R–1. . . . . . . . . . . . . . . . . . . . . . .

WHEEL ALIGNMENT PREINSPECTION R–1. . . . . FRONT WHEEL ALIGNMENT R– 2/3. . . . . . . . . . . . . .

FRONT SUSPENSION R–3. . . . . . . . . . . . . . . . . . . . . . VEHICLE HEIGHT ADJUSTMENT R–3. . . . . . . . . . FRONT SHOCK ABSORBER REMOVAL/

INSTALLATION R–5. . . . . . . . . . . . . . . . . . . . . . . . . . FRONT SHOCK ABSORBER INSPECTION R–5. . TORSION BAR SPRING AND LOWER ARM

REMOVAL/INSTALLATION (42) R– 6/8. . . . . . . . .

TORSION BAR SPRING AND LOWER ARMREMOVAL/INSTALLATION (44) R– 9/11. . . . . . . . .

LOWER ARM INSPECTION R–11. . . . . . . . . . . . . . . . UPPER ARM REMOVAL/INSTALLATION R–12. . . . UPPER ARM INSPECTION R–13. . . . . . . . . . . . . . . . STABILIZER AND TENSION ROD

REMOVAL/INSTALLATION (42) R–13/14. . . . . . . . . STABILIZER REMOVAL/INSTALLATION (44) R–14.

REAR SUSPENSION R–15. . . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER AND LEAF

SPRING REMOVAL/INSTALLATION R–15. . . . . . .

GENERAL PROCEDURESWheels and tires removal/installation The removal and installation procedures for the

wheels and tires are not mentioned in this section.If a wheel is removed, retighten it to the specifiedtightening torque, referring to section TD.

Suspension arms removal/installation Tighten any part of the suspension that uses

rubber bushings only after the vehicle has beenlowered and unloaded*.* Unloaded condition: Fuel tank is full. Engine

coolant and engine oil are at specified levels.Spare tire, jack, and tools are in designatedposition.

WHEEL ALIGNMENTWHEEL ALIGNMENT PREINSPECTION

1. Inspect the inflation of each tire, and set to therecommended pressure, as necessary.

2. Inspect the front wheel bearing play. Adjust thebearing preload or replace bearing(s) asnecessary. (Refer to section M, FRONT AXLE (42), WHEELHUB, STEERING KNUCKLE INSPECTION orFRONT AXLE (44), WHEEL HUB, STEERINGKNUCKLE INSPECTION.)

3. Inspect the wheel and tire runout at all wheels. (Refer to section TD, SUSPENSION, Wheels and Tires.)

4. Inspect the ball joints and steering linkage forexcessive looseness.

5. Place the vehicle on level ground with no luggageand passenger load.

6. The difference in height between the left and rightsides from the center of the wheel to the fenderbrim must not exceed 10 mm 0.39 in. If notwithin the specification, adjust the vehicle height.(Refer to FRONT SUSPENSION, VEHICLEHEIGHT ADJUSTMENT.)

7. Shake the vehicle to settle the suspension.

BACK.TO.MAIN.INDEX

CONTINUED


WHEEL ALIGNMENT

R–2

FRONT WHEEL ALIGNMENTSpecifications

ItemSpecification

Item42 44

Total toe in(mm in) 33 0.120.12

Total toe-in(degree) 0° 16’ 16’ 0° 14’ 14’

Front heel alignmentMaximum steering Inner 35° 00’ +2°

–3° 33° 30’ +2°–3°

Front wheel alignment(*1Unloaded

gangle Outer 33° 00’ +2°

–3° 30° 00’ +2°–3°( Unloaded

condition) Camber angle*2 0° 56’ 30’ 1° 06’ 30’

Caster angle*3 1° 37’ 45’ 2° 02’ 45’

Steering axis inclination(reference value)

8° 04’ 10° 15’

*1 Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designatedposition.

*2 Difference between left and right must not exceed 30’.*3 Difference between left and right must not exceed 45’.

Maximum Steering Angle Adjustment1. Loosen the adjusting bolt locknut.2. Turn the adjusting bolt to provide the correct

turning angle.3. After adjustment, tighten the locknut to the

specified torque.

Tightening torque40—58 N·m 4.0—6.0 kgf·m, 29—43 ft·lbf42

ADJUSTING BOLT44

ADJUSTING BOLT

Total Toe-in Adjustment1. Loosen the tie-rod end locknuts.2. Turn the tie rods by the same amount in the

opposite direction.

Note One turn of the tie rod (both sides) changes the

toe-in by about 30 mm 1.18 in. The left and right tie rods are both right

threaded. To increase the toe-in, turn the righttie rod toward the front of the vehicle and theleft tie rod equally toward the rear.

3. Tighten the tie-rod end locknuts.


TIE ROD


CONTINUED


WHEEL ALIGNMENT, FRONT SUSPENSION

R–3

Caster and Camber Adjustment1. Loosen the upper arm shaft bolt and insert or

remove adjustment shims to provide the correctangle.

No.1—5

FRONT

No.6—11

Adjustment shimNo. Thickness (mm in) No. Thickness (mm in)

1 1.0 0.039 7 1.0 0.039

2 1.6 0.063 8 1.6 0.063

3 2.0 0.079 9 2.0 0.079

4 3.2 0.126 10 3.2 0.126

5 4.0 0.157 11 4.0 0.157

6 0.6 0.024

Note Shims No.1—5 are used on either side. Do not

use more than two. Shims No.6—11 are used at the front and rear

of either sides. Do not use more than one. Camber: A change of shim thickness (at front

and rear) of 1 mm 0.039 in results in achange of about 15’.

Caster: A change of shim thickness (at front orrear only) of 1 mm 0.039 in results in achange of about 30’.

2. After adjustment, tighten the upper arm shaft boltto the specified torque.


FRONT SUSPENSIONVEHICLE HEIGHT ADJUSTMENT

1. Place the vehicle on level ground.2. Inspect the front and rear tire pressure and adjust it

as necessary.3. Measure the distance from the center of each front

wheel to the fender brim.

Left/right difference10 mm 0.39 in max.

Standard vehicle height (reference value) mm in42

Cab type Vehicle height

Regular Cab, Stretch Cab 427 16.8

Double Cab 422 16.6

44Cab type Tire size Vehicle height

Regular Cab, 205R16 519 20.4g ,Stretch Cab 235/75R15 515 20.3

Double Cab205R16 510 20.1

Double Cab235/75R15 506 19.9


CONTINUED


FRONT SUSPENSION

R–4

1. If the difference between left and right is not withinthe specification, adjust the vehicle height byturning the torsion bar spring anchor bolt.42

ANCHOR BOLT44

ANCHOR BOLT


CONTINUED


FRONT SUSPENSION

R–5

FRONT SHOCK ABSORBER REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.


6—8 mm0.24—0.31 in

55—80 5.6—8.2, 41—59

1 Nut+ Installation Note

2 Retainer, bushing

3 Bolt

4 Washer and nut

5 Shock absorber

Nut Installation Note Tighten the nut so that the exposed thread of the

shock absorber piston is 6—8 mm 0.24—0.31 in .

FRONT SHOCK ABSORBER INSPECTION1. Remove the front shock absorber from the vehicle.2. Inspect for damage and oil leakage.3. Inspect the rubber bushing for deterioration and

wear.4. Compress and extend the shock absorber piston at

least three (3) times. Verify that the operationalforce does not change and that there is no unusualnoise.

5. Compress the shock absorber piston and releaseit. Verify that the piston extends fully at a normalspeed.


CONTINUED


FRONT SUSPENSION

R–6

TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2)1. Remove in the order indicated in the table.2. Install in the reverse order of removal.3. Inspect the vehicle height and adjust it as necessary.


SST

R

APPLY THREADLOCKING COMPOUND


118—156 12.0—16.0, 87—115

118—156 12.0—16.0, 87—115

1 Cotter pin

2 Nut

3 Lower arm ball joint/Knuckle arm+ Removal Note

4 Bolt, washer, and nut (shock absorber)

5 Anchor bolt+ Removal Note+ Installation Note

6 Anchor swivel

7 Bolt and washer

8 Torsion bar component

9 Anchor arm

10 Torsion bar spring+ Removal Note+ Installation Note

11 Torque plate

12 Lower arm spindle, washer, and nut

13 Rubber bushing+ Removal Note+ Installation Note

14 Tension rod bolt

15 Stabilizer bolt, bushing, retainer, spacer, and nut+ Installation Note

16 Lower arm

17 Bound bumper, washer, and nut

18 Bolts and washer (ball joint)



21 Lower arm ball joint boot


CONTINUED


FRONT SUSPENSION

R–7

Lower Arm Ball Joint/Knuckle Arm Removal Note Separate the ball joint from the knuckle arm using

the SST.

49 T028 3A0

KNUCKLE

Anchor Bolt Removal Note Mark the anchor bolt and swivel for reference

during installation.

MATCHING MARK

Torsion Bar Spring Removal Note Mark the torsion bar spring and anchor arm and

the torsion bar spring and torque plate forreference during installation.

MATCHING MARK MATCHING MARK

Rubber Bushing Removal Note Remove the rubber bushing from the body using

the SST.

49 UB39 615

Clip Installation Note1. Install the SST to the ball joint stud with the stud

stands straight up.2. Install the clip in the dust boot groove.

49 U034 208

Stabilizer Bolt, Bushing, Retainer, Spacer And NutInstallation Note Tighten the nuts so that 18—21 mm 0.71—0.82 in

of thread is exposed at the end of the bolt.

18—21 mm0.71—0.82 in

Rubber Bushing Installation Note Install a new bushing using the SST.

49 UB39 615


CONTINUED


FRONT SUSPENSION

R–8

Torsion Bar Spring Installation Note1. Before installation, check the identification mark on

the end of the torsion bar spring.

L: Left bar, R: Right bar

2. Align the marks made during removal, and connectthe torsion bar spring to the torque plate.

MATCHING MARK MATCHING MARK

Anchor Bolt Installation Note Install the anchor bolt, and tighten it until the marks

made during removal are aligned.

MATCHING MARK

Note If the anchor bolt was not marked during

removal, install it as follows:(1) Lower the front suspension until the upper

arm contacts the rebound stopper.(2) Install the anchor arm so that the angle A is

34° 4.5°.(3) Install the anchor bolt and tighten it 27.3

turns.

A


CONTINUED


FRONT SUSPENSION

R–9

TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 4)1. Remove the driveshaft snap ring.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.4. Inspect the vehicle height and adjust it as necessary.

SST

R


R

118—156 12.0—16.0, 87—115 118—156 12.0—16.0, 87—115

1 Cotter pin

2 Nut

3 Lower arm ball joint/Knuckle arm+ FRONT SUSPENSION, TORSION BAR

SPRING AND LOWER ARMREMOVAL/INSTALLATION (42), Lower ArmBall Joint/Knuckle Arm Removal Note

4 Bolt, washer and nut (shock absorber)

5 Anchor bolt and washer+ Installation Note

6 Anchor swivel

7 Bolt and washer

8 Torsion bar spring component

9 Anchor arm+ Removal Note+ Installation Note

10 Torsion bar spring+ Removal Note+ Installation Note

11 Torque plate

12 Lower arm spindle (rear), washer and nut

13 Lower arm spindle (front), washer and nut

14 Stabilizer bolt, bushing, retainer, spacer and nut+ FRONT SUSPENSION, TORSION BAR

SPRING AND LOWER ARMREMOVAL/INSTALLATION (42), StabilizerBolt, Bushing, Retainer, Spacer, And NutInstallation Note

15 Lower arm

16 Bound bumper, washer, and nut

17 Bolt, washer and nut


19 Clip+ FRONT SUSPENSION, TORSION BAR

SPRING AND LOWER ARMREMOVAL/INSTALLATION (42), ClipInstallation Note

20 Lower arm ball joint boot

21 Lower arm bushing+ Removal Note+ Installation Note


CONTINUED


FRONT SUSPENSION

R–10

Anchor Arm Removal Note Mark the anchor arm and body for reference during

installation.

Torsion Bar Spring Removal Note Mark the torsion bar spring and anchor arm and

the torsion bar spring and torque plate forreference during installation.

Lower Arm Bushing Removal Note Remove the lower arm bushing using the SST.

49 U034 2A0

Lower Arm Bushing Installation Note1. Apply soapy water to the new bushing.2. Install the bushing using the SST.

49 U034 2A0

Torsion Bar Spring Installation Note1. Before installation, inspect the identification mark

on the end of the torsion bar spring.

L: Left bar, R: Right bar

2. Align the marks made during removal, and connectthe torsion bar spring to the torque plate.

Anchor Arm Installation Note Align the marks made during removal, and install

the anchor arm onto the torsion bar spring.


CONTINUED


FRONT SUSPENSION

R–11

Anchor Bolt Installation Note Install the anchor bolt, and tighten it until the marks

made during removal are aligned.

Note If the anchor bolt was not marked during

removal, install it at follows:(1) Lower the front suspension until the upper

arm contacts the rebound stopper.(2) Install the anchor arm so that the angle A is

60°4.5°.(3) Install the anchor bolt and tighten it 26.9

turns.

A

LOWER ARM INSPECTION1. Remove the lower arm from the vehicle.2. Inspect for damage, cracks, and bending.3. Check the ball joint rotation torque.

(1) Rotate the ball joint five times.(2) Connect the SST to the ball stud, and measure

the rotation torque using a pull scale.(3) Replace it if not within the specification.

Pull scale reading20—34 N 2.0—3.5 kgf, 4.4—7.7 lbf

49 0180 510B


CONTINUED


FRONT SUSPENSION

R–12

UPPER ARM REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.3. Inspect the wheel alignment and adjust it as necessary.

R

SST

1 Clip

2 Cotter pin and nut

3 Upper arm ball joint/Knuckle arm+ Removal Note

4 Bolt and washer

5 Adjustment shim+ Removal Note

6 Upper arm component

7 Bolt and washer

8 Upper arm ball joint


10 Upper arm ball joint boot

Upper Arm Ball Joint/Knuckle Arm Removal Note Separate the upper arm ball joint from the knuckle

arm using the SST.

49 T028 3A0

KNUCKLE

Adjustment Shim Removal Note Note the number, amount and position of the shims

so that they are reinstalled in the correct positions.

Clip Installation Note1. Install the SST to the ball joint stud with the stud

stands straight up.2. Install the clip in the dust boot groove.

49 U034 209


CONTINUED


FRONT SUSPENSION

R–13

UPPER ARM INSPECTION1. Remove the upper arm from the vehicle.2. Inspect for damage, cracks, and bending.3. Check the ball joint rotation torque.

(1) Rotate the ball joint five times.(2) Connect the SST to the ball stud, and measure

the rotation torque using a pull scale.(3) Replace it if not within the specification.

Pull scale reading5.0—24 N 0.5—2.5 kgf, 1.2—5.5 lbf

49 0180 510B

STABILIZER AND TENSION ROD REMOVAL/INSTALLATION (4 2)1. Remove in the order indicated in the table.2. Install in the reverse order of removal.


22—26 2.2—2.7, 16—19

94—127 9.5—13.0, 69—94

94—116 9.5—11.9, 69—86


1 Nut+ FRONT SUSPENSION, TORSION BAR

SPRING AND LOWER ARMREMOVAL/INSTALLATION (42), StabilizerBolt, Bushing, Retainer, Spacer, And NutInstallation Note

2 Retainer

3 Bolt

4 Bushing, retainer and spacer

5 Bolt

6 Stabilizer bracket

7 Bushing

8 Stabilizer bar

9 Tension rod nut+ Installation Note

10 Bushing and retainer

11 Bolt

12 Tension rod


CONTINUED


FRONT SUSPENSION

R–14

Tension Rod Nut Installation Note Tighten the tension rod nuts so that length L is 98.5

mm 3.88 in .

L

STABILIZER REMOVAL/INSTALLATION (4 4)1. Remove in the order indicated in the table.2. Install in the reverse order of removal.


22—26 2.2—2.7, 16—19

1 Nut+ FRONT SUSPENSION, STABILIZER AND

TENSION ROD REMOVAL/INSTALLATION(42), Nut Installation Note

2 Retainer and bushing

3 Bolt

4 Retainer and bushing

5 Retainer, bushing, and spacer

6 Bolt

7 Stabilizer bracket

8 Bushing

9 Stabilizer bar


CONTINUED


REAR SUSPENSION

R–15

REAR SUSPENSIONREAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION

1. Support the frame with safety stands and place a jack under the differential casing. Remove in the orderindicated in the table. While supporting the differential casing with a jack, raise or lower the jack as necessary.

2. Install in the reverse order of removal.

R


59—78 6.0—8.0, 44—57

64—78 6.5—8.0, 48—57

78—98 8.0—10.0, 58—72

R

R

20—26 2.0—2.7, 15—19.5 54—73 5.5—7.5, 40—54

APPLY THREAD LOCKINGCOMPOUND

42

1 Nut, washer, retainer, and bushing


3 Shock absorber

4 Nut and washer

5 Nut and washer

6 U-bolt

7 Spring clamp

8 Stopper rubber

9 Bolt and washer

10 Spring pin

11 Nut and washer

12 Shackle pin

13 Shackle plate

14 Leaf spring component

15 Leaf spring bushing+ Removal Note+ Installation Note


CONTINUED


REAR SUSPENSION

R–16


44

99.1—112 10.1—11.5, 73.1—83.1


64—78 6.5—8.0, 48—57

78—98 8.0—10.0, 58—72

R

R

20—26 2.0—2.7, 15—19.5

59—78 6.0—8.0, 44—57

1 Bolt and nut

2 Washer, retainer, and bushing


4 Shock absorber

5 Nut and washer

6 Nut and washer

7 U-bolt

8 Set plate

9 Spring clamp

10 Stopper rubber

11 Bolt and washer

12 Spring pin

13 Nut and washer

14 Shackle pin

15 Shackle plate

16 Leaf spring component

17 Leaf spring bushing+ Removal Note+ Installation Note


CONTINUED


REAR SUSPENSION

R–17

Leaf Spring Bushing Removal Note Secure the leaf spring in a vise and remove the

bushing using a chisel.

Leaf Spring Bushing Installation Note Press in the bushing using a suitable pipe.


CONTINUED


S–1

BODYBONNET S– 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BONNET REMOVAL/INSTALLATION S– 2/3. . . . . . . . BONNET ADJUSTMENT S– 3. . . . . . . . . . . . . . . . . .

FRONT FENDER PANEL S– 4. . . . . . . . . . . . . . . . . . . . FRONT FENDER PANEL

REMOVAL/INSTALLATION S– 4. . . . . . . . . . . . . . . DOOR S– 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT DOOR REMOVAL/INSTALLATION S– 5. . . FRONT DOOR DISASSEMBLY/ASSEMBLY S– 6. . FRONT DOOR ADJUSTMENT S– 7. . . . . . . . . . . . . REAR DOOR REMOVAL/INSTALLATION S– 7. . . . REAR DOOR DISASSEMBLY/ASSEMBLY S– 8/9. . . REAR DOOR ADJUSTMENT S– 9. . . . . . . . . . . . . . . DOOR LOCK STRIKER

REMOVAL/INSTALLATION S– 9. . . . . . . . . . . . . . . REGULATOR HANDLE REMOVAL S– 9. . . . . . . . . . REGULATOR HANDLE INSTALLATION S– 9. . . . .

POWER WINDOW SYSTEM S–10. . . . . . . . . . . . . . . . . POWER WINDOW MAIN SWITCH

REMOVAL/INSTALLATION S–10. . . . . . . . . . . . . . . POWER WINDOW MAIN SWITCH

INSPECTION S–10/12. . . . . . . . . . . . . . . . . . . . . . . . . . . POWER WINDOW SUBSWITCH

REMOVAL/INSTALLATION S–12. . . . . . . . . . . . . . . POWER WINDOW SUBSWITCH

INSPECTION S–12/13. . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT POWER WINDOW REGULATOR

REMOVAL/INSTALLATION S–13. . . . . . . . . . . . . . . FRONT POWER WINDOW REGULATOR

DISASSEMBLY/ASSEMBLY S–13. . . . . . . . . . . . . . REAR POWER WINDOW REGULATOR

REMOVAL/INSTALLATION S–13/14. . . . . . . . . . . . . . . REAR POWER WINDOW REGULATOR

DISASSEMBLY/ASSEMBLY S–14. . . . . . . . . . . . . . POWER WINDOW MOTOR INSPECTION S–14. . .

POWER DOOR LOCK SYSTEM S–15. . . . . . . . . . . . . . DOOR KEY CYLINDER SWITCH

REMOVAL/INSTALLATION S–15. . . . . . . . . . . . . . . DOOR KEY CYLINDER SWITCH

INSPECTION S–15. . . . . . . . . . . . . . . . . . . . . . . . . . . DOOR LOCK-LINK SWITCH

REMOVAL/INSTALLATION S–15. . . . . . . . . . . . . . . . DOOR LOCK-LINK SWITCH INSPECTION S–15. . . DOOR LOCK ACTUATOR

REMOVAL/INSTALLATION S–15. . . . . . . . . . . . . . . . DOOR LOCK ACTUATOR INSPECTION S–16. . . . . DOOR LOCK TIMER UNIT

REMOVAL/INSTALLATION S–16. . . . . . . . . . . . . . . . DOOR LOCK TIMER UNIT INSPECTION S–17. . . .

FUEL-FILLER LID AND OPENER S–19. . . . . . . . . . . . FUEL-FILLER LID

REMOVAL/INSTALLATION S–19. . . . . . . . . . . . . . . FUEL-FILLER LID ADJUSTMENT S–19. . . . . . . . . .

BUMPER S–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BUMPER

REMOVAL/INSTALLATION S–19. . . . . . . . . . . . . . . FRONT BUMPER

DISASSEMBLY/ASSEMBLY S–19. . . . . . . . . . . . . . . REAR BUMPER

REMOVAL/INSTALLATION S–20. . . . . . . . . . . . . . . REAR BUMPER DISASSEMBLY/ASSEMBLY S–20/21. .

EXTERIOR ATTACHMENT S–21. . . . . . . . . . . . . . . . . . . RADIATOR GRILLE

REMOVAL/INSTALLATION S–21. . . . . . . . . . . . . . . COWL GRILLE

REMOVAL/INSTALLATION S–21. . . . . . . . . . . . . . . WINDSHIELD GARNISH

REMOVAL/INSTALLATION S–21/22. . . . . . . . . . . . . . . SIDE PROTECTOR REMOVAL S–22. . . . . . . . . . . . . SIDE PROTECTOR INSTALLATION S–22/23. . . . . . . . OVER FENDER

REMOVAL/INSTALLATION S–23. . . . . . . . . . . . . . . TAILGATE

DISASSEMBLY/ASSEMBLY S–23. . . . . . . . . . . . . . TAILGATE ADJUSTMENT S–23. . . . . . . . . . . . . . . . . ROPE HOOK REMOVAL/INSTALLATION S–24. . . .

MOLDING S–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD UPPER MOLDING

REMOVAL S–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD UPPER MOLDING

INSTALLATION S–24. . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD SIDE MOLDING REMOVAL S–24. . . WINDSHIELD SIDE MOLDING

INSTALLATION S–24. . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BELTLINE MOLDING

REMOVAL/INSTALLATION S–24. . . . . . . . . . . . . . . REAR BELTLINE MOLDING

REMOVAL/INSTALLATION S–25. . . . . . . . . . . . . . . ROOF MOLDING

REMOVAL/INSTALLATION S–25. . . . . . . . . . . . . . . . OUTSIDE MIRROR S–25. . . . . . . . . . . . . . . . . . . . . . . . .

MANUAL OUTSIDE MIRRORREMOVAL/INSTALLATION S–25. . . . . . . . . . . . . . .

POWER OUTSIDE MIRRORREMOVAL/INSTALLATION S–25. . . . . . . . . . . . . . .

POWER OUTSIDE MIRROR INSPECTION S–25/26. . POWER OUTSIDE MIRROR SWITCH

REMOVAL/INSTALLATION S–26. . . . . . . . . . . . . . . POWER OUTSIDE MIRROR SWITCH

INSPECTION S–26. . . . . . . . . . . . . . . . . . . . . . . . . . . REARVIEW MIRROR S–27. . . . . . . . . . . . . . . . . . . . . . . .

REARVIEW MIRRORREMOVAL/INSTALLATION S–27. . . . . . . . . . . . . . .

REAR WINDOW DEFROSTER S–27. . . . . . . . . . . . . . . REAR WINDOW DEFROSTER SWITCH

REMOVAL/INSTALLATION S–27. . . . . . . . . . . . . . . REAR WINDOW DEFROSTER SWITCH

INSPECTION S–27. . . . . . . . . . . . . . . . . . . . . . . . . . . FILAMENT INSPECTION S–27/28. . . . . . . . . . . . . . . . . . FILAMENT REPAIR S–28. . . . . . . . . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER RELAY

REMOVAL/INSTALLATION S–28. . . . . . . . . . . . . . . REAR WINDOW DEFROSTER RELAY

INSPECTION S–28. . . . . . . . . . . . . . . . . . . . . . . . . . . WINDOW GLASS S–29. . . . . . . . . . . . . . . . . . . . . . . . . . .

WINDSHIELD REMOVAL S–29/30. . . . . . . . . . . . . . . . . . WINDSHIELD INSTALLATION S–30/31. . . . . . . . . . . . . . QUARTER WINDOW GLASS

REMOVAL/INSTALLATION S–32. . . . . . . . . . . . . . . REAR WINDOW GLASS REMOVAL S–33. . . . . . . . REAR WINDOW GLASS INSTALLATION S–33. . . .

DASHBOARD AND CONSOLE S–34. . . . . . . . . . . . . . .

BACK.TO.MAIN.INDEX

CONTINUED

PAGE 1 OF 2


BONNET

S–2

DASHBOARD REMOVAL/INSTALLATION S–34. . . DASHBOARD DISASSEMBLY/ASSEMBLY S–35. . DASHBOARD MEMBER

REMOVAL/INSTALLATION S–36. . . . . . . . . . . . . . . COLUMN COVER

REMOVAL/INSTALLATION S–36. . . . . . . . . . . . . . . FRONT CONSOLE

REMOVAL/INSTALLATION S–36. . . . . . . . . . . . . . . FRONT CONSOLE

DISASSEMBLY/ASSEMBLY S–36. . . . . . . . . . . . . . REAR CONSOLE

REMOVAL/INSTALLATION S–36. . . . . . . . . . . . . . . REAR CONSOLE

DISASSEMBLY/ASSEMBLY S–37. . . . . . . . . . . . . . GLOVE COMPARTMENT

REMOVAL/INSTALLATION S–37. . . . . . . . . . . . . . . METER HOOD

REMOVAL/INSTALLATION S–37. . . . . . . . . . . . . . . TRIM S–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-PILLAR TRIMREMOVAL/INSTALLATION S–38. . . . . . . . . . . . . . .

B-PILLAR TRIMREMOVAL/INSTALLATION S–38. . . . . . . . . . . . . . .

B-PILLAR LOWER TRIMREMOVAL/INSTALLATION S–38. . . . . . . . . . . . . . .

FRONT SIDE TRIMREMOVAL/INSTALLATION S–39. . . . . . . . . . . . . . .

FRONT SCUFF PLATEREMOVAL/INSTALLATION S–39. . . . . . . . . . . . . . .

REAR SCUFF PLATE REMOVAL/INSTALLATION S–39. . . . . . . . . . . . . . .

C-PILLAR TRIM REMOVAL/INSTALLATION S–39. . QUARTER UPPER TRIM

REMOVAL/INSTALLATION S–39/40. . . . . . . . . . . . . . . QUARTER LOWER TRIM

REMOVAL/INSTALLATION S–40. . . . . . . . . . . . . . . BACK UPPER TRIM

REMOVAL/INSTALLATION S–40. . . . . . . . . . . . . . . BACK LOWER TRIM

REMOVAL/INSTALLATION S–40. . . . . . . . . . . . . . . FRONT DOOR TRIM

REMOVAL/INSTALLATION S–41. . . . . . . . . . . . . . . REAR DOOR TRIM

REMOVAL/INSTALLATION S–41. . . . . . . . . . . . . . . HEADLINER S–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEADLINER REMOVAL/INSTALLATION S–42. . . . . FLOOR COVERING S–42. . . . . . . . . . . . . . . . . . . . . . . . .

FLOOR COVERINGREMOVAL/INSTALLATION S–42/43. . . . . . . . . . . . . . .

SEAT BELT S–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAT BELT REMOVAL/INSTALLATION S–44/45. . . . . . SEAT BELT INSPECTION S–45/46. . . . . . . . . . . . . . . . .

SEAT S–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT SEAT REMOVAL/INSTALLATION S–48. . . . FRONT SEAT DISASSEMBLY/ASSEMBLY S–49/50. . . CABLE ADJUSTMENT S–51. . . . . . . . . . . . . . . . . . . . REAR SEAT REMOVAL/INSTALLATION S–51/52. . . . . REAR SEAT DISASSEMBLY/ASSEMBLY S–52/53. . . . SEAT WARMER SWITCH REMOVAL S–54. . . . . . . SEAT WARMER SWITCH INSTALLATION S–54. . . SEAT WARMER SWITCH INSPECTION S–54. . . . . SEAT WARMER UNIT INSPECTION S–54. . . . . . . .

BONNET

Warning Removing the bonnet without supporting it

can be dangerous. The bonnet may fall andinjure you. Always perform theseprocedures together with at least anotherperson.

BONNET REMOVAL/INSTALLATION1. Pull out the windshield washer pipe.2. To remove the bonnet hinge, remove the front

fender panel. (Refer to FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.)

3. To remove the bonnet lock, remove the radiatorgrille.

4. Remove in the order indicated in the table.5. Install in the reverse order of removal.6. Adjust the bonnet.

(Refer to BONNET ADJUSTMENT.)

3.0—3.9 30—40,27—34

7.9—10.780—110,69.5—95.4


AA

Â

ÄÅ

Æ

À

Ã

Á

1 Shroud seal weatherstrip

2 Bonnet

3 Bonnet hinge

4 Bonnet stay


CONTINUED


PAGE 2 OF 2


TO. MODEL .INDEXPAGES. FROM. MANUALRANG.DRFT.REPAIR MANUAL

PAGES. FROM. MANUAL

B-PILLAR UPPER TRIM REMOVAL/INSTALLATION S–38. . . . . . . . . . . . . . .

BODY

BUCKLE REMOVAL/INSTALLATION . . . . . . . . . S–46BUCKLE SWITCH INSPECTION . . . . . . . . . . . . S–47

BONNET

S–3

5 Bonnet lock

6 Bonnet release lever

7 Bonnet release cable

BONNET ADJUSTMENT1. Measure the gap and height between the bonnet

and the body.

Clearancea: 2.7—5.3 mm 0.11—0.20 inb: –1.8—0.8 mm –0.07—0.03 in (sec. A—A)c: –2.3—0.8 mm –0.09—0.03 in (sec. B—B)d: –2.3—0.3 mm –0.09—0.01 in (sec. C—C)e: 6.0—10.0 mm 0.24—0.39 inf: 7.0—13.0 mm 0.28—0.51 in

50 2.0

30 1.2

DD

E

E

C C

B B

A A

a

b , c, de

f

SEC. A—ASEC. B—BSEC. C—C

SEC. D—D SEC. E—E

mm in

2. If not as specified, adjust the gap and height.(Refer to Gap Adjustment.) (Refer to Height Adjustment.)

Gap Adjustment1. Loosen the bonnet installation bolts and reposition

the bonnet.

BOLT

2. Tighten the bonnet installation bolts.

Height Adjustment1. Loosen the bonnet lock installation bolts and move

the bonnet lock to reposition the bonnet.

BOLT

2. Tighten the bonnet lock installation bolts.


CONTINUED


FRONT FENDER PANEL

S–4

FRONT FENDER PANELFRONT FENDER PANEL REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove the front side turn light.3. Remove the front bumper.4. Remove the front turn light.5. Remove the front flap.6. Remove in the order indicated in the table.7. Install in the reverse order of removal.

B

A

B

A

6.87—9.80 N·m70—100 kgf·cm,60.8—86.7 in·lbf

1 Mud guard

2 Front fender panel


CONTINUED


DOOR Front Door Harness Removal Note 1. Disconnect the connectors indicated in the table,

if equipped. Connector name Symbol

Driver's side Passenger's side A Door lock-link switch Door lock actuator

B Power window main switch

Power window subswitch

C Power outside mirror ←

D Front power window regulator ←

E Speaker ←

DOOR FRONT DOOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the door screen.

(Refer to FRONT DOOR DISASSEMBLY/ASSEMBLY.)

3. To remove the front door hinge, remove the front fender panel. (Refer to FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.)

4. To remove the checker, remove the speaker. (Refer to section T, AUDIO, SPEAKER REMOVAL/INSTALLATION.)

5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Adjust the front door.

(Refer to FRONT DOOR ADJUSTMENT.)

1

Front door harness Removal Note

2 Checker pin 3 Front door hinge 4 Front door 5 Checker

2. Disengage the clips.

3. Remove the rubber boot and pull out the door

harness.

S-5


CONTINUED


DOOR

S–6

FRONT DOOR DISASSEMBLY/ASSEMBLY1. Raise the rear edge of the front door glass 80 mm 3.1 in from the fully lowered position.2. Disconnect the negative battery cable.3. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.)4. To remove the inner handle, peel off the door screen partially.5. Disassemble in the order indicated in the table.6. Assemble in the reverse order of disassembly.


WITHOUT POWER WINDOW SYSTEM AND POWER DOOR LOCK SYSTEM

6.87–9.80 70–100, 60.8–86.7

6.87–9.80 70–100, 60.8–86.7

2.0–2.9 20–30, 18–26

4.3–6.143–63,38–54

WITH POWER WINDOW SYSTEM ANDPOWER DOOR LOCK SYSTEM

8.9–12.790–130, 79–112

6.87–9.8070–100, 60.8–86.7

4.3–6.143–63,38–54

AB

B

DE

H

C

C

D

HE

AJ

IG

F

F

G

J

I

1 Inner handle

2 Door screen

3 Front door glass

4 Glass run channel

5 Front glass guide

6 Rear glass guide

7 Front manual window regulator

8 Front power window regulator

9 Outer handle

10 Retainer

11 Door key cylinder

12 Front door lock (manual)

13 Front door lock (power)

14 Door lock knob


CONTINUED


DOOR

S–7

FRONT DOOR ADJUSTMENT1. Measure the clearance between the door and the

body.

Clearancea: 4.0—6.0 mm 0.16—0.23 inb: –1.5—1.0 mm –0.059—0.039 inc: –2.0—0.5 mm –0.078—0.019 ind: 4.5—8.5 mm 0.18—0.33 ine: 1.2 mm 0.047 inf: 3.5—6.5 mm 0.14—0.25 ing: 2.7 mm 0.11 inh: 5.5 mm 0.22 in

DD

EC

C

AA

BB

F

d

e

b

a

c

(+) (+)

(–)SEC. A—A SEC. B—B SEC. C—C

b

(+) f

g(–) h

SEC. D—D SEC. E—E SEC. F—F

f

a

(–)

E

F

2. If not as specified, loosen the door hingeinstallation bolts or the door lock striker installationscrews, and move them to reposition the door.(Refer to FRONT DOOR REMOVAL/INSTALLATION.)

(Refer to DOOR LOCK STRIKER REMOVAL/INSTALLATION.)

3. Tighten the bolts or the screws.

REAR DOOR REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the door screen.

(Refer to REAR DOOR DISASSEMBLY/ASSEMBLY.)3. To remove the checker, remove the ashtray

bracket. (Refer to REAR DOOR DISASSEMBY/ASSEMBLY.)

4. Remove in the order indicated in the table.5. Install in the reverse order of removal.6. Adjust the rear door.

(Refer to REAR DOOR ADJUSTMENT.)


22—302.2—3.1, 16—22

8.9—12.7 N·m 90—130 kgf·cm,79—112 in·lbf

1 Connector

2 Checker pin

3 Rear door hinge

4 Rear door

5 Checker

BACK.TO.CHAPTER.INDEX TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL

CONTINUED

PAGES. FROM. MANUAL

DOOR

S–8

REAR DOOR DISASSEMBLY/ASSEMBLY1. Close the rear door glass completely.2. Disconnect the negative battery cable.3. Remove the rear door trim. (Refer to TRIM, REAR DOOR TRIM REMOVAL/INSTALLATION.)4. Disassemble in the order indicated in the table.5. Assemble in the reverse order of disassembly.

WITH POWER WINDOW SYSTEM

6.87—9.80 70—100, 60.8—86.7

E

E

WITHOUT POWER WINDOW SYSTEM

B

D

D

B

C

A

A

C

4.3—6.1 43—63, 38—54

6.87—9.8070—100,60.8—86.7

6.87—9.8070—100, 60.8—86.7


2.5—3.525—36, 22—31

1 Inner handle

2 Door screen

3 Ashtray bracket

4 Glass hole lid

5 Rear manual window regulator

6 Rear power window regulator

7 Rear door glass+ Removal Note

8 Glass run channel

9 Glass guide

10 Door lock knob

11 Rear door lock

12 Outer handle


CONTINUED


DOOR

S–9

Rear Door Glass Removal Note Draw out the rear door glass through the glass

hole.

REAR DOOR GLASS

REAR DOOR

REAR DOOR ADJUSTMENT1. Measure the clearance between the door and the

body.

Clearancea: 3.5—6.5 mm 0.14—0.25 inb: –1.5—1.0 mm –0.059—0.039 inc: 5.5 mm 0.22 in

D D

A A

E E

B B

a(+)

(–)

(+)

(–)

b b

a

c

a a

b b

(+)

(–)

(+)

(–)

SEC. A–A SEC. B–B SEC. C–C

SEC. D–D SEC. E–E

C

C

2. If not as specified, loosen the door hingeinstallation bolts or the door lock striker installationscrews, and move them to reposition the door.(Refer to REAR DOOR

LOCK STRIKER REMOVAL/INSTALLATION.)

3. Tighten the bolts or screws.

DOOR LOCK STRIKER REMOVAL/INSTALLATION1. Remove the screws.2. Remove the door lock striker.

DOOR LOCKSTRIKER

SCREW 18–261.8–2.7,14–19



REGULATOR HANDLE REMOVAL1. Remove the regulator handle clip using a rag as

shown.

RAG CLIP

2. Remove the regulator handle.

REGULATOR HANDLE INSTALLATION1. Install the clip in the regulator handle.2. Set the door glass at the fully raised position and

push the regulator handle on as shown.

CLIP FRONT


CONTINUED

REMOVAL/INSTALLATION.) (Refer to DOOR


POWER WINDOW SYSTEM

S–10

POWER WINDOW SYSTEMPOWER WINDOW MAIN SWITCHREMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Disengage the clip using a tape-wrapped flathead

screwdriver.3. Pull the switch panel forward, and disengage the

hook.

BODY

CLIP

SWITCH PANEL

BODY

HOOK

4. Disconnect the power window main switchconnector.

5. Remove the screws to remove the power windowmain switch from the switch panel.

POWERWINDOWMAIN SWITCH

SWITCH PANEL

SCREW


POWER WINDOW MAIN SWITCH INSPECTIONRegular Cab, Stretch Cab

1. Remove the switch panel. (Refer to POWERWINDOW MAIN SWITCHREMOVAL/INSTALLATION.)

2. Inspect for continuity between the power windowmain switch terminals using an ohmmeter.

3. When inspecting the driver’s side, connect thebattery positive voltage to terminal F and connectthe ground to terminal D.

4. When inspecting the passenger’s side, turn thepower-cut switch to ON.

Power window switchDriver’s side

: Continuity

Switch Terminalposition F D A (H) B (I)

Manual closeManual close

Off

Auto openManual open

( ): R.H.D.

Passenger’s side: Continuity

Switch Terminalposition F D H (A) I (B)

CloseClose

Off

OpenOpen

( ): R.H.D.

Power-cut switch: Continuity

Switch Terminalposition D A (H) B (I) H (A) I (B)

ON

OFF

( ): R.H.D.


CONTINUED


POWER WINDOW SYSTEM

S–11

5. If not as specified, replace the power window mainswitch.

Double Cab1. Remove the switch panel.

(Refer to POWER WINDOW MAIN SWITCHREMOVAL/INSTALLATION.)

2. Inspect for continuity between the power windowmain switch terminals using an ohmmeter.

3. When inspecting the driver’s side, connect thebattery positive voltage to terminal A (L.H.D.) or F(R.H.D.) and connect the ground to terminal H.

4. When inspecting the passenger’s side and rear,turn the power-cut switch to ON.

Power window switchDriver’s side

: Continuity

Switch Terminalposition A (F) H L (D) J (B)

Manual closeManual close

Off

Auto openManual open

( ): R.H.D.


Switch Terminalposition A (F) H D (L) B (J)

CloseClose

Off

OpenO en

( ): R.H.D.

Rear left: Continuity

Switch Terminalposition A H K I

CloseClose

Off

OpenO en

( ): R.H.D.

Rear right: Continuity

Switch Terminalposition A H E C

CloseClose

Off

OpenO en

( ): R.H.D.

Power-cut switch: Continuity

TerminalSwitch

position HL(D)

J(B)

D(L)

B(J)

E C K I

ON

OFF( ): R.H.D.

L.H.D.


CONTINUED

MANUALOPEN

AUTOCIRCUIT

PASSENGER’S SIDE

DRIVER’S SIDE

CLOSE

POWER-CUT SWITCH

AUTOOPEN

A (H) B (I)

H (A) I (B)

F

D

MANUALCLOSE

CLOSE OPEN

H

I

A

BF D

∗ ∗

OPEN

( ) : R.H.D.

RIGHT

E CK ID B

J

H

A

PAS-SENGER’S


POWER WINDOW SYSTEM

S–12

R.H.D.

5. If not as specified, replace the power window mainswitch.

POWER WINDOW SUBSWITCHREMOVAL/INSTALLATIONPassenger’s side

1. Disconnect the negative battery cable.2. Disengage the clip using a tape-wrapped flathead

screwdriver.3. Pull the power window subswitch forward, and

disengage the hook.

BODY

CLIP

POWERWINDOWSUBSWITCH

HOOK

BODY

4. Disconnect the power window subswitchconnector.


Rear1. Disconnect the negative battery cable.2. Remove the hook by inserting a tape-wrapped,

flathead screwdriver between the switch and therear door trim.

HOOK

POWER WINDOWSUBSWITCH

3. Disconnect the connector, and remove the powerwindow subswitch.


POWER WINDOW SUBSWITCH INSPECTION1. Remove the power window subswitch. (Refer to

POWER WINDOW SUBSWITCHREMOVAL/INSTALLATION.)

2. Inspect for continuity between the power windowsubswitch terminals using an ohmmeter.


Switch positionTerminal

Switch positionA B D E F

OffOff

CloseClose

OpenO en

A

BF D

E

CLOSEOPEN

Rear: Continuity


Switch positionA B D E F

Close

Off

Open


CONTINUED

A

E C K I

K

L

I

J H F D B

E C AD B

J

H

F

PAS-SENGER’S


POWER WINDOW SYSTEM

S–13

ABDF E

OPENCLOSE

A

B

D

F

E

3. If not as specified, replace the power windowsubswitch.

FRONT POWER WINDOW REGULATORREMOVAL/INSTALLATION

1. Raise the rear edge of the front door glass 80 mm3.1 in from the fully lowered position.

2. Disconnect the negative battery cable.3. Remove the front glass guide and the rear glass

guide. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.)


A

8.9—12.790—130, 79—112

D

B

C

CD

B

A

6.87—9.8070—100, 60.8—86.7


1 Front power window regulator connector

2 Bolt

3 Nut

4 Front power window regulator

FRONT POWER WINDOW REGULATORDISASSEMBLY/ASSEMBLY


3.0—4.9 N·m30—50 kgf·cm, 27—43 in·lbf

1 Bolt

2 Power window motor+ Disassembly Note+ Assembly Note

3 Frame

Power Window Motor Disassembly Note Make marks on the gear and base of the frame

before disassembling the power window motor.

BASE

MARK

GEAR

Power Window Motor Assembly Note Align the marks of the gear and the frame to install

the power window motor.

REAR POWER WINDOW REGULATORREMOVAL/INSTALLATION

1. Raise the rear door glass completely.2. Disconnect the negative battery cable.3. Remove the door screen.(Refer to DOOR, REAR DOOR DISASSEMBLY/ASSEMBLY.)4. Remove in the order indicated in the table.5. Install in the reverse order of removal.


CONTINUED


POWER WINDOW SYSTEM

S–14

A

D

C

A

6.87—9.80 N·m70—100 kgf·cm,60.8—86.7 in·lbf

1 Rear power window regulator connector

2 Bolt

3 Rear power window regulator

REAR POWER WINDOW REGULATORDISASSEMBLY/ASSEMBLY


3.1—4.8 N·m31—49 kgf·cm, 27—42 in·lbf

1 Bolt

2 Power window motor+ Disassembly Note+ Assembly Note

3 Frame

Power Window Motor Disassembly Note Make marks on the gear and base of the frame

before disassembling the power window motor.

MARK

BASE GEAR

Power Window Motor Assembly Note Align the marks of the gear and base of the frame

to install the power window motor.

POWER WINDOW MOTOR INSPECTION1. Remove the power window motor.

(Refer to FRONT POWER WINDOW

POWER WINDOW REGULATORDISASSEMBLY/ASSEMBLY.)

2. Apply battery positive voltage to the power windowmotor terminals and inspect the operation of thepower window motor.

B+: Battery positive voltageConnection

Motor operationB+ GND

Motor operation

A B Up

B A Down

UP DOWN

A

B

A B

3. If not as specified, replace the power windowmotor.


CONTINUED

REGULATOR DISASSEMBLY/ASSEMBLY.) (Refer to REAR


POWER DOOR LOCK SYSTEM POWER DOOR LOCK SYSTEM DOOR LOCK-LINK SWITCH REMOVAL/INSTALLATION

Note • The door lock-link switch is mounted to the

driver-side door lock.

1. Disconnect the negative battery cable. 2. Remove the driver-side door lock.

(Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.)

3. Remove the screws. 4. Remove the door lock-link switch from the front

door lock.

5. Install in the reverse order of removal. DOOR LOCK-LINK SWITCH INSPECTION 1. Disconnect the negative battery cable. 2. Remove the driver-side door screen.


3. Disconnect the door lock-link switch connector. 4. Inspect for continuity between the door lock-link

switch terminals using an ohmmeter.

5. If not as specified, replace the door lock-link

switch. DOOR LOCK ACTUATOR REMOVAL/INSTALLATION Front

Note • The front door lock actuator is mounted to

the passenger-side door lock. 1. Disconnect the negative battery cable. 2. Remove the passenger-side door lock.


3. Remove the screws. 4. Remove the front door lock actuator from the

front door lock.


S-15


TO. MODEL .INDEX

CONTINUED

POWER DOOR LOCK SYSTEM

5. If not as specified, replace the door lock actuator. DOOR LOCK TIMER UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the flasher unit.

(Refer to section T, EXTERIOR LIGHTING SYSTEM, FLASHER UNIT REMOVAL/INSTALLATION.)


1 Door lock timer unit connector 2 Nut

Rear Note

• The rear door lock actuator is mounted to the rear door lock.

1. Disconnect the negative battery cable. 2. Remove the rear door lock.

(Refer to DOOR, REAR DOOR DISASSEMBLY/ASSEMBLY.)

3. Remove the screws. 4. Disconnect the rod. 5. Remove the rear door lock actuator from the rear

door lock.

6. Install in the reverse order of removal. DOOR LOCK ACTUATOR INSPECTION 1. Disconnect the negative battery cable. 2. Remove the door screen.

(Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) (Refer to DOOR, REAR DOOR DISASSEMBLY/ASSEMBLY.)

3. Disconnect the door lock actuator connector. 4. Apply battery positive voltage to the door lock

actuator terminals and inspect the operation of the door lock actuator.

3 Bracket

B+: Battery positive voltage

4 Door lock timer unit

Terminal A B Actuator operation

GND B+ Lock B+ GND Unlock

S-16


TO. MODEL .INDEX

CONTINUED

POWER DOOR LOCK SYSTEM

DOOR LOCK TIMER UNIT INSPECTION 1. Remove the flasher unit.

(Refer to section T, EXTERIOR LIGHTING SYSTEM, FLASHER UNIT REMOVAL/INSTALLATION.) 2. Measure the voltage at the door lock timer unit terminals as indicated below. 3. Disconnect the door lock timer unit connector before inspecting for continuity at terminals A, C, D, and H. 4. If not as specified, inspect the parts listed under "Inspection area" and the related wiring harnesses. 5. If the parts and wiring harnesses are okay but the system still does not work properly, replace the door lock

timer unit.

Terminal Voltage List (Reference) B+: Battery positive voltage

Terminal Signal Connection Test condition Voltage (V) /Continuity Inspection area

A GND Body ground Constant: inspect for continuity to ground Yes -

B Power supply D/L 30 A fuse Constant B+ D/L 30 A fuse Door lock-link switch is at lock: inspect for continuity to terminal H No

C Unlock input Door lock-link switch Door lock-link switch is at unlock: inspect

for continuity to terminal H Yes

Door lock-link switch

Door lock-link switch is at lock: inspect for continuity to terminal H Yes

D Lock input Door lock-link switch Door lock-link switch is at unlock: inspect

for continuity to terminal H No

Door lock-link switch

Door lock actuators are locked 0 → B+ → 0 E Lock output Door lock

actuator Other 0 Door lock actuator

Door lock actuators are unlocked 0 → B+ → 0 F Unlock output Door lock

actuator Other 0 Door lock actuator

G - Not used - - -

H GND Terminal A of door lock timer unit

Constant: inspect for continuity to terminal A Yes -

S-17


TO. MODEL .INDEX

CONTINUED

FUEL-FILLER LID AND OPENER, BUMPER

S–19

FUEL-FILLER LID AND OPENERFUEL-FILLER LID REMOVAL/INSTALLATION

1. Remove as indicated in the table.2. Install in the reverse order of removal.

1 Fuel-filler lid

FUEL-FILLER LID ADJUSTMENT1. Measure the gap and height between the fuel-filler

lid and the body.

Clearancea: 3.5—5.5 mm 0.14—0.21 inb: –0.5—2.0 mm –0.01—0.07 in

12345678

SEC.A–A

A

A

a

b

2. If not as specified, loosen the fuel-filler lidinstallation bolts and reposition the fuel-filler lid.

3. Tighten the fuel-filler lid installation bolts.

BUMPERFRONT BUMPER REMOVAL/INSTALLATION


63—93 6.4—9.5, 47—68


63—93 6.4—9.5, 47—68

6.87—9.80 N·m70—100 kgf·cm,60.8—86.7 in·lbf

6.87—9.80 N·m70—100 kgf·cm,60.8—86.7 in·lbf

1 Front bumper

2 Front bumper stay

FRONT BUMPER DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.


6.87—9.80 70—100, 60.8—86.7

0.2—0.8 2—9, 2—7

0.2—0.3 2—4, 2—3

1 Front bumper side fascia

2 Front bumper upper fascia

3 Front bumper lower fascia


CONTINUED


BUMPER

S–20

REAR BUMPER REMOVAL/INSTALLATIONWith Step

1. Remove the bolts, then remove the rear bumper.

REAR BUMPERBOLT


79—1168.0—11.9,58.0—86.0


Without Step1. Disconnect the negative battery cable.2. Disconnect the rear fog light connector.3. Remove in the order indicated in the table.4. Install in the reverse order of removal.

12345678

79—1168.0—11.9,58.0—86.0 16—22

1.6—2.3,12—16


1 Rear bumper stay

3 Rear bumper fascia

REAR BUMPER DISASSEMBLY/ASSEMBLYWith Step


A

A

A

B

B

B

B

A


32—463.2—4.7,24—33

6.87—9.80 N·m70—100 kgf·cm,60.8—86.7 in·lbf

6.87—9.80 N·m70—100 kgf·cm,60.8—86.7 in·lbf

0.30—0.78 N·m3.0—8.0 kgf·cm,2.7—6.9 in·lbf

1 Side bumper step+ Removal Note

2 Center bumper step+ Removal Note

3 Rear bumper fascia

4 Rear bumper stay

5 Rear bracket

6 Set plate

Side Bumper Step Removal Note1. Disengage clips A using pliers.2. Pull the side bumper step upward, then remove it.

A A A A

AA

SIDE BUMPER STEP

CLIP A

Center Bumper Step Removal Note1. Remove the screws.2. Disengage clips A using pliers.3. Disengage clips B, then remove the center bumper

step.


CONTINUED


BUMPER, EXTERIOR ATTACHMENT

S–21

A

A A A A

AA

B B B BSCREW SCREW

SCREWSCREW CENTER BUMPER STEP

CLIP B CLIP A

EXTERIOR ATTACHMENTRADIATOR GRILLE REMOVAL/INSTALLATION

1. Pull the radiator grille toward you, then disengageclips A to remove the radiator grille.

A

RADIATOR GRILLE

CLIP

A A A A

AA

A


COWL GRILLE REMOVAL/INSTALLATION1. Remove the windshield wiper arm and blade.

(Refer to section T, WIPER AND WASHER,WIPER ARM AND BLADEREMOVAL/INSTALLATION.)

2. Remove the weatherstrip.3. Remove the screws, then remove the cowl grille.

SCREW

WEATHERSTRIP

COWL GRILLE


WINDSHIELD GARNISH REMOVAL/INSTALLATION1. Remove the screws.2. Pull the windshield garnish upward, then

disengage hook A from the cowl grille.


CONTINUED


EXTERIOR ATTACHMENT

S–22

A

WINDSHIELDGARNISH

HOOK

SCREW

A

COWL GRILLE


SIDE PROTECTOR REMOVAL

Warning Using a razor knife with bare hands can

cause injury. Always wear gloves whenusing a razor knife.

1. Pry the side protector end 20—30 mm 0.8—1.1in using a flathead screwdriver or a razor knife.

2. Pull the side protector, then remove it.

Note The side protector is installed with

double-sided adhesive tape. If the sideprotector is difficult to remove, soften thedouble-sided adhesive tape using a hot airblower.

SIDE PROTECTOR INSTALLATION1. Remove the adhesive remaining on the side

protector (if it will be reused) and the body using arazor knife.

2. Remove any grease or dirt from the adhesionsurface of the side protector (if it will be reused)and the body.

3. Attach double-sided adhesive tape to the sideprotector as shown (if it will be reused).

Clearancea : 0—3.0 mm 0—0.11 inb : 37.5 mm 1.48 inc : 10.0 mm 0.39 ind : 2.0—5.0 mm 0.08—0.19 ine : 25.0 mm 0.98 in

b

a a cc

c a

d d d

c

c

a

a

d d bc a

aa cc c

c ac

e

d

a c

e e

FRONT SIDE PROTECTOR

REAR SIDE PROTECTOR

DOUBLE-SIDED ADHESIVE TAPE

CENTER SIDEPROTECTOR(REGULAR CAB)

CENTER SIDEPROTECTOR(STRETCH CAB)

e

4. Peel off the backing paper from the double-sidedadhesive tape and attach the side protector ontothe body as shown.

Clearancea : 4.8—5.8 mm 0.19—0.22 inb : 5.0—6.0 mm 0.20—0.23 inc : 13.0—14.0 mm 0.51—0.55 ind : 16.5—17.0 mm 0.65—0.66 ine : 12.3—13.3 mm 0.49—0.52 inf : 6.0—8.0 mm 0.24—0.31 in

Regular Cab

b c

a

FRONT SIDE PROTECTOR REAR SIDEPROTECTOR

CENTER SIDE PROTECTOR

SEC. A—A

A

A

f

Stretch Cab

SEC. A—A

b

a

d

FRONT SIDE PROTECTOR REAR SIDEPROTECTOR

CENTER SIDE PROTECTOR

f

A

A


CONTINUED


EXTERIOR ATTACHMENT

S–23

Double Cab

SEC. A—A

b

e

FRONT SIDE PROTECTOR

REAR SIDE PROTECTORf

A

A

5. After installing the side protector to the body, applypressure of 50 N·m 5.0 kgf·m, 37 ft·lbf or morewith a roller, etc.

OVER FENDER REMOVAL/INSTALLATION1. Remove the screws.2. Remove the fasteners.3. Disengage clips A of the over fender using a

fastener remover, then remove the over fender.FRONT

REAR

OVER FENDERFASTENER

SCREW

CLIP

SCREW

FASTENER

OVER FENDER

A

CLIP

A A A

A

A

A

AA

A

A

AA


TAILGATE DISASSEMBLY/ASSEMBLY1. Remove the cover.2. Remove the nuts attaching the tailgate lock.3. Disconnect the rods from the tailgate lock.4. Remove the tailgate lock.

TAILGATE LOCK

NUT

ROD

5. Remove the bolts, then remove the latch guide,latch and rod.

LATCH

BOLT

LATCH GUIDE

ROD

6. Remove the handle.7. Assemble in the reverse order of disassembly.

TAILGATE ADJUSTMENT1. Loosen the bolts.2. Move the striker forward and rearward until the

tailgate will lock properly.3. After the correct adjustment is made, tighten the

bolts securely.

STRIKER

BOLT


CONTINUED


EXTERIOR ATTACHMENT, MOLDING

S–24

ROPE HOOK REMOVAL/INSTALLATION1. Remove the screws and bolts, then remove the

rope hook.

ROPE HOOK

SCREW

BOLT

ROPE HOOK


MOLDINGWINDSHIELD UPPER MOLDING REMOVAL Remove the windshield upper molding from the

windshield. (Refer to WINDOW GLASS,WINDSHIELD REMOVAL.)

WINDSHIELD UPPER MOLDING INSTALLATION Install the windshield upper molding to the

windshield. (Refer to WINDOW GLASS,WINDSHIELD INSTALLATION.)

WINDSHIELD SIDE MOLDING REMOVAL Remove the windshield side molding from the

windshield. (Refer to WINDOW GLASS,WINDSHIELD REMOVAL.)

WINDSHIELD SIDE MOLDING INSTALLATION Install the windshield side molding to the

windshield. (Refer to WINDOW GLASS,WINDSHIELD INSTALLATION.)

FRONT BELTLINE MOLDINGREMOVAL/INSTALLATION

1. Lower the front door glass fully.2. Remove the manual outside mirror or the power

outside mirror.(Refer to OUTSIDE MIRROR, MANUAL

MIRROR, POWER OUTSIDE MIRRORREMOVAL/INSTALLATION.)

3. Pull the rear end of the front beltline molding todisengage the hook.

FRONT BELTLINE MOLDING

HOOK

4. Pull the front beltline molding upward, then removeclips A.

CLIP

A

BELTLINEMOLDING

A A A



CONTINUED

OUTSIDE MIRROR REMOVAL/INSTALLATION.) (Refer to OUTSIDE


MOLDING, OUTSIDE MIRROR

S–25

REAR BELTLINE MOLDINGREMOVAL/INSTALLATION

1. Lower the rear door glass fully.2. Pull the rear end of the rear beltline molding to

disengage the hook.

REAR BELTLINE MOLDING

HOOK

3. Pull the rear beltline molding upward, then removeclips A.

CLIP

A

BELTLINEMOLDING

A A A


ROOF MOLDING REMOVAL/INSTALLATION1. Pull the rear edge of roof molding upward, then

disengage clips A.

A

CLIP

ROOF MOLDINGROOF MOLDING

BODY

AA

A


OUTSIDE MIRRORMANUAL OUTSIDE MIRRORREMOVAL/INSTALLATION

1. Remove the inner garnish.2. Remove the front door trim. (Refer to TRIM,

FRONT DOOR TRIM REMOVAL/INSTALLATION.)3. Remove the screws.4. Remove the manual outside mirror.

MANUAL OUTSIDE MIRROR

SCREW


POWER OUTSIDE MIRRORREMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove the inner garnish.3. Remove the front door trim. (Refer to TRIM,

FRONT DOOR TRIM REMOVAL/INSTALLATION.)4. Partially peel off the door screen.5. Disconnect the power outside mirror connector.6. Remove the screws.7. Remove the power outside mirror.

POWER OUTSIDE MIRROR

SCREW

POWER OUTSIDE MIRRORCONNECTOR


POWER OUTSIDE MIRROR INSPECTION1. Disconnect the negative battery cable.2. Remove the inner garnish.3. Remove the front door trim. (Refer to TRIM,

FRONT DOOR TRIM REMOVAL/INSTALLATION.)4. Partially peel off the door screen.5. Disconnect the power outside mirror connector.6. Apply battery positive voltage to the power outside

mirror and inspect the operation of the poweroutside mirror.


CONTINUED


123456567

OUTSIDE MIRROR

S–26

B+: Battery positive voltageConnection Mirror

B+ GND operation

A C Up

C A Down

C D Left

D C Right

*

UP

M

M

A DC

DOWN

RIGHTLEFT

1. If not as specified, replace the power outsidemirror.

POWER OUTSIDE MIRROR SWITCHREMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove the fuse block cover.3. Remove the fuse block installation screws, and

push the fuse block into the dashboard.4. Insert your hand into the hole for the fuse block,

and press the hooks of the power outside mirrorswitch.

5. Push the power outside mirror switch out, thenremove it.

6. Disconnect the power outside mirror switchconnector.

POWER OUTSIDEMIRROR SWITCH

POWEROUTSIDEMIRRORSWITCHCONNECTOR


POWER OUTSIDE MIRROR SWITCH INSPECTION1. Remove the power outside mirror switch.

(Refer to POWER OUTSIDE MIRROR SWITCHREMOVAL/INSTALLATION.)

2. Inspect for continuity between the power outsidemirror switch terminals using an ohmmeter.

: Continuity

Switch Terminalposition I L A D C B K

Up

LHDown

LHLeft

Right

Up

RHDown

RHLeft

Right

3. If not as specified, replace the power outside mirrorswitch.


CONTINUED


REARVIEW MIRROR, REAR WINDOW DEFROSTER

S–27

REARVIEW MIRRORREARVIEW MIRROR REMOVAL/INSTALLATIONRegular Cab

Note The rearview mirror is attached to the interior

light. (Refer to section T, INTERIOR LIGHTING SYSTEM, INTERIOR LIGHT REMOVAL/INSTALLATION, Regular Cab.)

Stretch Cab, Double Cab1. Remove in the order indicated in the table.2. Install in the reverse order of removal.

2.0—3.9 20—40, 18—34


1 Cover

2 Screw

3 Rearview mirror

REAR WINDOW DEFROSTERREAR WINDOW DEFROSTER SWITCHREMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove the meter hood.3. Press the hooks of the rear window defroster

switch and push the switch out.

METER HOOD

REAR WINDOWDEFROSTERSWITCH

HOOK


REAR WINDOW DEFROSTER SWITCHINSPECTION

1. Remove the rear window defroster switch.2. Inspect for continuity between the rear window

defroster switch terminals using an ohmmeter.: Continuity : Bulb

Switch Terminal

position A B C D

ON

OFF

D A

C B

C

D B

A

3. If not as specified, replace the rear windowdefroster switch.

FILAMENT INSPECTION1. Turn the ignition switch to ON position.2. Turn the rear window defroster switch on.

Caution Directly touching the rear window defroster

filament with the lead of the circuit testerwill damage it. Wrap aluminum foil aroundthe end of the lead and test the filament bytouching it with the foil.


CONTINUED


REAR WINDOW DEFROSTER

S–28

LEAD OF THE CIRCUIT TESTER

FILAMENT

ALUMINUM FOIL

PUSH

1. Connect the positive () lead of the voltmeter tothe positive side of each filament and the negative() lead to ground.

2. Gradually, slide the positive () lead from thepositive side to the negative side and measure thevoltage. Verify that the voltage decreasesaccordingly.

Measurement place Voltage (Reference value)

(1) (2) Approx. 12 V Approx. 0 V

NEGATIVE SIDE

POSITIVESIDE

(1)(2)

3. If the voltage is not as specified or it changesrapidly, the filament is faulty. Repair the filament.

FILAMENT REPAIR1. Use white gasoline to clean around the damaged

section of the filament.2. Attach tape above and below the damaged section

of the filament.

BROKEN FILAMENT TAPE

SECTION TO BE REPAIRED

3. Using a small brush or marking pen, repair thefilament with silver paint or equivalent.

4. After approximately 2—3 minutes, carefullyremove the tape without disturbing the repairedarea.

Caution Do not use the rear window defroster until

the paint is completely dry. It may causeother malfunctions if it is used before thepaint is dry.

5. Use a hot air blower heated to 150C 302F for30 minutes or let the paint set for 24 hours at25C 77F to allow it to dry completely.

REAR WINDOW DEFROSTER RELAYREMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Disconnect the rear window defroster relay

connector.3. Slide the rear window defroster relay upward, then

remove it.

REARWINDOWDEFROSTERRELAY

REAR WINDOW DEFROSTER RELAY CONNECTOR


REAR WINDOW DEFROSTER RELAY INSPECTION1. Remove the rear window defroster relay.

(Refer to REAR WINDOW DEFROSTER RELAY REMOVAL/INSTALLATION.)

2. Inspect for continuity between the rear windowdefroster relay terminals using an ohmmeter.

: Continuity B+: Battery positive voltage

StepTerminal

StepA B C D

1

2 B GND

A

BD

C

A

B

D

C

3. If not as specified, replace the rear windowdefroster relay.


CONTINUED


WINDOW GLASS

S–29

WINDOW GLASSWINDSHIELD REMOVAL

1. Remove the cowl grille.(Refer to EXTERIOR ATTACHMENT, COWL GRILLE REMOVAL/INSTALLATION.)

2. Apply protective tape to the headliner, the bodyand the dashboard.



Note The windshield upper molding and windshield

side molding are replacement parts.

3. Cut the lip of the windshield upper molding using arazor knife.

WINDSHIELD UPPER MOLDINGPROTECTIVE

TAPE

LIP

R

Not Reusing Windshield

Warning Using a piano wire with bare hands can

cause injury. Always wear gloves whenusing a piano wire.

Note For the areas of the sealant that are difficult to

cut, use a piano wire and follow the proceduresunder “Reusing Windshield”.

1. Use a tool like that shown in the figure, and insertthe blade into the sealant.

2. Pull through the sealant around the edge of theglass.

3. Remove the windshield.4. Remove the spacers from the body.

Reusing Windshield1. Make a hole through the sealant from the inside of

the vehicle using an awl.2. Pass the SST (piano wire) through the hole.

PROTECTIVE TAPE

WINDSHIELD UPPERMOLDING

WINDSHIELDSEALANT

HEADLINERPROTECTIVE TAPE

DAM

R

49 0305 870A

3. Wind each end of the wire around a bar.

Note Use the entire length of piano wire to prevent it

from breaking when cutting through thesealant.

4. Working with another person, saw through thesealant around the edge of the glass, being carefulnot to damage the body.

49 0305 870A

5. Remove the windshield.6. Remove the spacers from the body.7. Remove the spacer and the dam from the glass.

CENTER

DAM

SPACER R

R

8. Remove the windshield upper molding and thewindshield side molding from the windshield.


CONTINUED


WINDOW GLASS

S–30

WINDSHIELD

WINDSHIELD UPPER MOLDING

WINDSHIELD SIDE MOLDING R

R

WINDSHIELD INSTALLATION



Caution To prevent the sealant from cracking or the

glass from being pushed out by airpressure if a door is closed, open all of thewindows and leave them open until thesealant has hardened.

1. Cut away the old sealant using a razor knife so that1—2 mm 0.04—0.07 in thickness of sealantremains around the circumference of the frame. Ifall the sealant has come off in any one place, applysome primer after degreasing, and allow it 30minutes to dry. Then put on new sealant to createa 2 mm 0.08 in layer.

2. Clean and degrease an approximately 50 mm1.97 in wide strip around the circumference ofthe glass and the bonding area on the body.

3. Align the center mark on the windshield uppermolding with the glass mark.

4. Install the windshield upper molding from thecenter toward both sides.

WINDSHIELD UPPER MOLDING

MARK

GLASS MARK

WINDSHIELD

5. Align the upper edge of the windshield sidemolding with the glass mark.

6. Install the windshield side molding from the upperpart towards the lower part.

GLASS MARK

WINDSHIELDSIDE MOLDINGWINDSHIELD

7. Securely bond a dam along the circumference ofthe glass 8.5 mm 0.33 in from the upper edgeand 14.5 mm 0.57 in from the lower and sideedge.

8. Install the spacer to the glass.

CENTER8.5 0.33

14.5 0.57

DAM

SPACER14.5 0.57

6.0 0.24

14.5 0.57

CERAMICPARTINGLINE

mm in

9. Install spacers into the hole of the body.10. Temporarily install the glass onto the body and

adjust the glass to body clearance.11. Make a mark on the glass directly above the

V-notch of spacers.12. Verify that the gap along the upper edge is

7.5 mm 0.30 in .

SPACER

7.5 0.30

mm in

CENTER MARKINGBODY

13. Remove the windshield.

Caution Keep the area free of dirt and grease, and

do not touch the surface or the primer maynot properly bond to the surface of theglass and body, which may cause leaks tooccur.

14. Use a brush to apply primer to the bonding area ofthe glass and body within the region shown. Useonly glass primer on the glass and body primer onthe body and molding. Allow it to dry forapproximately 30 minutes .


CONTINUED


WINDOW GLASS

S–31

8.5 0.3314.5 0.57

GLASSPRIMER

BODYPRIMER

13.0 0.51

GLASSPRIMER

SIDE

19.00.75

GLASSPRIMER

LOWER

19.0 0.75

16.0 0.63

BODYPRIMER

BODYPRIMER

WINDSHIELDSIDE MOLDING

WINDSHIELDUPPER MOLDING BODY PRIMER mm in

BODYPRIMER

14.5 0.57

UPPER

15. Once the primer is dry, apply a 11.0 mm 0.43 inhigh, 5.0 mm 0.20 in wide bead of sealant alongthe dam around the entire circumference to fill thegap between the dam and the edge of thewindshield.

11.00.43

DAM

5.00.20

mm in

16. Align the glass marks with the V-notches inspacers and install the glass onto the body.

17. Press firmly inward on the glass to compress thesealant.

18. Verify that the gap along the upper and side edgeis 7.5 mm 0.30 in .

19. Adjust the sealant as indicated in the figure.

UPPER

WINDSHIELDBODY

DAM

SEALANT ADJUST SEALANTIN THIS AREA

SIDE

WINDSHIELD

DAM

ADJUST SEALANTIN THIS AREA

BODY

Hardening time of sealant

Temperature Surface hardening time

Time requireduntil car can beput into service

5 °C 41 °F Approx. 1.5 h Approx. 12 h

20 °C 68 °F Approx. 1 h Approx. 4 h

35 °C 95 °F Approx. 10 min Approx. 2 h

20. Use white gasoline to remove any sealant thatoozes out.

21. Install the cowl grille. (Refer to EXTERIOR ATTACHMENT, COWL GRILLE REMOVAL/INSTALLATION.)


CONTINUED


WINDOW GLASS

S–32

QUARTER WINDOW GLASS REMOVAL/INSTALLATIONStretch Cab

1. To remove the quarter window hinge, remove the quarter upper trim. (Refer to TRIM, QUARTER UPPER TRIM REMOVAL/INSTALLATION.)


1 Hinge cover

2 Quarter window hinge

3 Quarter window lock

4 Quarter window glass

5 Quarter window glass weatherstrip


CONTINUED


WINDOW GLASS

S–33

REAR WINDOW GLASS REMOVAL1. Remove the headliner. (Refer to HEADLINER,

HEADLINER REMOVAL/INSTALLATION.)2. Remove the rear window defroster connector if

equipped.3. While another person presses the rear window

glass, use the SST to push the lip of the rearwindow weatherstrip from the inside.

REAR WINDOW WEATHERSTRIP

LIP49 0259 866A

4. After the top of the rear window weatherstrip isremoved, push the rear window glass outside andremove it with the rear window weatherstripattached.

5. Remove the rear window weatherstrip from therear window glass.

REAR WINDOW GLASS INSTALLATION1. Clean and degrease the body and the rear window

glass.2. Install the rear window weatherstrip to the rear

window glass.REAR WINDOW WEATHERSTRIP

3. Fit the SST into the rear window weatherstrip andcross the ends as shown, leave 200 mm 7.87 in .

49 0259 866A


200 7.87mm in

4. Apply soapy water as shown.

BODY


SOAPY WATER

5. Align the rear window glass with the rear windowweatherstrip and body.

6. While another person lightly taps the outside of therear window glass near the rear windowweatherstrip all around its circumference, pull oneend of the SST and install the rear window glass.

49 0259 866A

7. Install the rear window defroster connector ifequipped.

8. Install the headliner. (Refer to HEADLINER, HEADLINER REMOVAL/INSTALLATION.)


CONTINUED


DASHBOARD AND CONSOLE

S–34

DASHBOARD AND CONSOLEDASHBOARD REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove the driver-side air bag module.

(Refer to section T, AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)3. Remove the passenger-side air bag module.

(Refer to section T, AIR BAG SYSTEM, PASSENGER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)4. Remove the steering wheel.

(Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)5. Remove the installation bolts then lower the assembled steering shaft from the dashboard.

(Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)6. Remove the meter hood.7. Remove the instrument cluster.8. Remove the front console. (Refer to FRONT CONSOLE REMOVAL/INSTALLATION.)9. Remove the glove compartment.

10. Remove the bonnet release cable installation nut.11. Remove the A-pillar trims. (Refer to TRIM, A-PILLAR TRIM REMOVAL/INSTALLATION.)12. Disconnect the wires for both the blower unit and the heater unit.

INSTALLATION.)

14. Remove in the order indicated in the table.15. Install in the reverse order of removal.16. Adjust the wires for both the blower unit and the heater unit.

(Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT ADJUSTMENT.)

7.9—11.7 80—120, 70—104

7.9—11.7 80—120, 70—104

7.9—11.7 80—120, 70—104


1 Bolt 2 Dashboard


CONTINUED

(Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT REMOVAL.) (Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT

13. Remove the fuse block.



S–35

DASHBOARD DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.

1 Defroster nozzle

2 Side demister nozzle

3 Center duct

4 Duct

5 Dashboard crash pad


CONTINUED



S–36

DASHBOARD MEMBER REMOVAL/INSTALLATION1. Remove the dashboard.

(Refer to DASHBOARD REMOVAL/INSTALLATION.)2. Remove the bolts, then remove the dashboard

member.

16—22 1.6—2.3,12—16

BOLT

DASHBOARD MEMBER


16—22 1.6—2.3,12—16

16—22 1.6—2.3, 12—16

16—22 1.6—2.3, 12—16


COLUMN COVER REMOVAL/INSTALLATION1. Remove the screws, then remove the column

cover.

COLUMNCOVER

SCREW


FRONT CONSOLE REMOVAL/INSTALLATION1. Remove the rear console.2. For manual transaxle vehicle, remove the shift

lever knob.3. Remove the screws, then remove the front

console.

Caution In order to prevent noise caused by

interference with the dashboard, install thescrews to the rear of the front consolebefore installing the front of the frontconsole.

SCREW

FRONT CONSOLE


FRONT CONSOLE DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.

1 Screw

2 Front console

3 Boot

4 Set plate

REAR CONSOLE REMOVAL/INSTALLATION1. Remove the screws.2. Pull the rear console upward, then remove it.

SCREW

REAR CONSOLE



CONTINUED



S–37

REAR CONSOLE DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.

1 Screw

2 Console lid outer

3 Console lid inner

4 Rear console

5 Console lid lock

6 Console lid hinge

7 Console lid bracket

GLOVE COMPARTMENT REMOVAL/INSTALLATION1. Open the glove compartment and bend the sides

inward to disengage the pins.2. Pull the glove compartment downward, then

disengage clips A.

PIN

PIN

CLIP

GLOVE COMPARTMENT

A

A

A


METER HOOD REMOVAL/INSTALLATION1. Remove the screws.2. Pull the meter hood toward you, then disengage

clips A and pins B.

PIN

A

CLIP

SCREW

AA

A A

A

A

B

B

B

B

A

3. Disconnect the connectors, then remove the meterhood.



CONTINUED


TRIM

S–38

TRIMA-PILLAR TRIM REMOVAL/INSTALLATION

1. Remove the quarter upper trim. (Regular cab,stretch cab) (Refer to QUARTER UPPER TRIMREMOVAL/INSTALLATION.)

2. Remove the B-pillar upper trim. (Double cab)(Refer to B-PILLAR UPPER TRIMREMOVAL/INSTALLATION.)

3. Pull the A-pillar trim toward you, then disengageclips A and pin B.

4. Pull the A-pillar trim upward, then disengage thehook.

A A

A

A

A

B

A B

CLIP PIN

A-PILLAR TRIM

HOOK


B-PILLAR TRIM REMOVAL/INSTALLATIONRegular Cab

1. Turn over the seaming welt.2. Remove the seat belt upper anchor installation

bolt.3. Remove the back upper trim.4. Pull the B-pillar trim toward you, then disengage

clips A and pins B.5. Remove clip C.6. Remove the seat belt from the B-pillar trim.

A

B

CLIP

PIN

B-PILLAR TRIM

A

A

A

A

B

CLIP C

A

AB


B-PILLAR LOWER TRIM REMOVAL/INSTALLATIONDouble Cab

1. Remove the front scuff plate.2. Remove the rear scuff plate.3. Turn over the seaming welt.4. Pull the B-pillar lower trim indicated by the arrow,

then disengage clips A and pin B.5. Remove the seat belt from B-pillar trim.6. Pull the B-pillar lower trim upward, then disengage

hooks C from the body.

A

B

CLIP

PIN

B-PILLARLOWER TRIM

HOOK

A

A

A

CC

A

B

C


B-PILLAR UPPER TRIM REMOVAL/INSTALLATIONDouble Cab

1. Remove the B-pillar lower trim.(Refer to B-PILLAR LOWER TRIM REMOVAL/INSTALLATION.)

2. Remove the front seat belt upper anchorinstallation bolt.

3. Remove the C-pillar trim. (Refer to C-PILLAR TRIM REMOVAL/INSTALLATION.)

4. Remove the fastener.5. Pull the B-pillar upper trim toward you, then

disengage clips A and pins B from the body.

CLIP

HOOK

B-PILLAR UPPER TRIM

FASTENER

A

B

A A A

A

A

A

B

A

B



CONTINUED


TRIM

S–39

FRONT SIDE TRIM REMOVAL/INSTALLATION1. Remove the scuff plate.2. Loosen the nut.3. Pull the front side trim in the direction indicated by

the arrow, then remove it.

NUT

FRONT SIDE TRIM


FRONT SCUFF PLATE REMOVAL/INSTALLATION1. Remove the screws.2. Pull the front scuff plate upward, then disengage

pin A.

SCREW

FRONT SCUFF PLATE

A

PIN

A


REAR SCUFF PLATE REMOVAL/INSTALLATIONDouble Cab

1. Remove the screw.2. Pull the rear scuff plate upward, then disengage

clips A and pin B.

SCREW

REAR SCUFF PLATE

CLIP PIN

A B

A

AB


C-PILLAR TRIM REMOVAL/INSTALLATIONDouble Cab

1. Turn over the seaming welt.2. Remove the rear seat. (Refer to SEAT, SEAT

REMOVAL/INSTALLATION, Double Cab, Rear.)3. Remove the rear seat belt upper anchor installation

bolt.4. Remove the fasteners.5. Pull the C-pillar trim toward you, then disengage

clips A and pin B.6. Remove the seat belt from C-pillar trim.

CLIP

PIN

C-PILLAR TRIM

FASTENER

A

BA A

A

A

A

B

7. Pull the C-pillar trim upward, then remove it fromthe body.


QUARTER UPPER TRIM REMOVAL/INSTALLATIONStretch Cab

1. Remove the back upper trim.2. Remove the upper anchor of the seat belt.3. Remove the quarter window lock.

(Refer to WINDOW GLASS, QUARTER WINDOW GLASS REMOVAL/INSTALLATION.)

4. Remove the hook.5. Remove the fasteners.6. Pull the quarter upper trim toward you, then

disengage clips A and pins B.


CONTINUED


TRIM

S–40

A

B

AA A

A

A

AA

AA

A

B

B

QUARTER UPPER TRIM

FASTENER

CLIP

PIN

HOOK


QUARTER LOWER TRIM REMOVAL/INSTALLATIONStretch Cab

1. Remove the quarter upper trim. (Refer to QUARTER UPPER TRIMREMOVAL/INSTALLATION.)

2. Remove the back lower trim.3. Remove the fasteners.4. Pull the quarter lower trim toward you, then


FASTENERQUARTER LOWER TRIM

A B

CLIPPIN

A

A

A

A

A

B

B


BACK UPPER TRIM REMOVAL/INSTALLATION1. Pull the back upper trim toward you, then


BACK UPPER TRIM

A

B

CLIPPIN

A

A

A

A

A

A

A

AA

AA

A

B

B

B

A


BACK LOWER TRIM REMOVAL/INSTALLATION1. Remove the fasteners, then remove the back lower

trim.

FASTENER

BACK LOWER TRIM



CONTINUED


TRIM

S–41

FRONT DOOR TRIM REMOVAL/INSTALLATION1. Disconnect the negative battery cable if equipped

with a power window system.2. Remove the regulator handle if equipped.3. Remove the inner garnish.4. Remove the power window switch if equipped.5. Remove the screws and the fastener.6. Pull the front door trim toward you, then disengage

clips A.7. Pull the front door trim upward, then disengage

hook B.

FASTENER FRONT DOOR TRIM

SCREW HOOK

CLIP

A

B

A

A

A AA

A

A

A

A

B

FASTENER FRONT DOOR TRIM

SCREW

HOOK

CLIP

A

B

A

A

A AA

A

A

A

A

B


REAR DOOR TRIM REMOVAL/INSTALLATIONDouble cab

1. Disconnect the negative battery cable if equippedwith power window.

2. Remove the regulator handle if equipped.3. Remove the power window switch if equipped.4. Remove the screws.5. Remove the ashtray.6. Pull the door trim toward you, then disengage clips

A.

ASHTRAY

REAR DOOR TRIM

SCREW

HOOK

CLIP

A

B

INNER HANDLE

A

A

AA

AA

A

A

A

A

B

7. Extract the inner handle from the rear door trim.8. Pull the rear door trim upward, then disengage

hooks B.9. Install in the reverse order of removal.


CONTINUED


HEADLINER, FLOOR COVERING

S–42

HEADLINERHEADLINER REMOVAL/INSTALLATION

1. Remove the A-pillar trims.2. Remove the B-pillar upper trims.

(Refer to TRIM, B-PILLAR UPPER TRIMREMOVAL/INSTALLATION, Double Cab.)

3. Remove the quarter upper trims. (Refer to TRIM, QUARTER UPPER TRIMREMOVAL/INSTALLATION, Stretch Cab.)

4. Remove the C-pillar trims. (Refer to TRIM, C-PILLAR TRIM REMOVAL/INSTALLATION, Double Cab.)

5. Remove the assist handle.6. Remove the rearview mirror.7. Remove the sunvisors and adapters.8. Remove the interior light.

(Refer to section T, INTERIOR LIGHTING SYSTEM, INTERIOR LIGHT REMOVAL/INSTALLATION.)

9. Remove the fasteners, then remove the headliner.

HEADLINER

ASSIST HANDLEFASTENER

SUNVISOR

ADAPTER

10. Remove the headliner from the vehicle through thepassenger-side door.

HEADLINER


FLOOR COVERINGFLOOR COVERING REMOVAL/INSTALLATIONRegular Cab, Stretch Cab

1. Remove the dashboard member. (Refer to DASHBOARD AND CONSOLE, DASHBOARD MEMBER REMOVAL/INSTALLATION.)

2. Remove the quarter lower trims. (Refer to TRIM, QUARTER LOWER TRIMREMOVAL/INSTALLATION, Stretch Cab.)

3. Remove the back lower trim.4. Remove the front seats. (Refer to SEAT, SEAT

REMOVAL/INSTALLATION, Regular Cab.) (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Stretch Cab, Double cab, Front.)

5. Remove the rear seat. (Refer to SEAT, SEAT

cab, Rear.)6. Remove the rear console bracket.7. Remove the lower anchor installation bolts of front

seat belts.8. Remove the front side trims.9. Remove the air outlet ducts.

(Refer to section U, BASIC SYSTEM, AIR OUTLET DUCT REMOVAL/INSTALLATION.)

10. Remove the footrest.11. Remove the fasteners, then remove the floor

covering.

FASTENER

FLOOR COVERING


Double cab1. Remove the dashboard member.

(Refer to DASHBOARD AND CONSOLE, DASHBOARD MEMBER REMOVAL/INSTALLATION.)

2. Remove the B-pillar lower trims. (Refer to TRIM, B-PILLAR LOWER TRIMREMOVAL/INSTALLATION.)

3. Remove the C-pillar trims. (Refer to TRIM,C-PILLAR TRIM REMOVAL/INSTALLATION)


CONTINUED

REMOVAL/INSTALLATION, Stretch Cab, Double


FLOOR COVERING

S–43

4. Remove the front seats and rear seat. (Refer to SEAT, SEAT REMOVAL/INSTALLATION,

REMOVAL/INSTALLATION, Stretch Cab, Double cab, Rear.)5. Remove the rear console bracket.6. Remove the lower anchor installation bolts of front

seat belts and rear seat belts.7. Remove the front side trim.8. Remove the air outlet duct.

(Refer to section U, BASIC SYSTEM, AIR OUTLET DUCT REMOVAL/INSTALLATION.)

9. Remove the footrest.10. Remove the fasteners, then remove the floor

covering.FASTENER

FLOOR COVERING

Type 1

Type 2

FASTENER

FLOOR COVERING



CONTINUED

Stretch Cab, Double cab, Front.) (Refer to SEAT, SEAT


SEAT BELT

S–44

SEAT BELTSEAT BELT REMOVAL/INSTALLATION

Caution The ELR has a spring that will unwind if the

retractor’s cover is removed. The springcannot be rewound by hand. If this occurs,the ELR will not work properly. Therefore,do not disassemble the retractor.

Regular CabDriver’s side and passenger’s side

1. Remove the B-pillar trim if equipped with a B-pillartrim. (Refer to TRIM, B-PILLAR TRIMREMOVAL/INSTALLATION, Regular Cab.)



39—78 3.9—8.0, 29—57

39—78 3.9—8.0, 29—57

1 Anchor cover

2 Retractor cover (if equipped)

3 Seat belt

Except driver’s side and passenger’s sideExcept Europe and UK


39—78 3.9—8.0, 29—57


1 Seat belt

Stretch CabFront

1. Remove the quarter lower trim. (Refer to TRIM, QUARTER LOWER TRIMREMOVAL/INSTALLATION.)


39—78 3.9—8.0, 29—57

39—78 3.9—8.0, 29—57 N·m kgf·m, ft·lbf

1 Anchor cover

2 Seat belt

Rear1. Remove the quarter lower trim.

(Refer to TRIM, QUARTER LOWER TRIMREMOVAL/INSTALLATION.)



CONTINUED


SEAT BELT

S–45

39—78 3.9—8.0, 29—57


39—78 3.9—8.0, 29—57

1 Anchor cover

2 Seat belt

Double CabFront

1. Remove the B-pillar lower trim. (Refer to TRIM, B-PILLAR LOWER TRIMREMOVAL/INSTALLATION, Double Cab.)


39—78 3.9—8.0, 29—57

39—78 3.9—8.0, 29—57


1 Anchor cover

2 Seat belt

Rear1. Remove the C-pillar trim. (Refer to TRIM,

C-PILLAR TRIM REMOVAL/INSTALLATION.)2. Remove in the order indicated in the table.3. Install in the reverse order of removal.

39—78 3.9—8.0, 29—57


39—78 3.9—8.0, 29—57

1 Anchor cover

2 Seat belt

SEAT BELT INSPECTIONBelt

1. Inspect the webbing for scars, tears, and wear.2. Inspect the fitting for deformation or damage.3. If a problem is found, replace the seat belt.

ELR1. Verify that the belt can be pulled out smoothly, and

that it moves smoothly when worn.2. Verify that the retractor locks when the belt is

quickly pulled.

3. Remove the retractor.4. Make sure that the seat belt does not lock when

the retractor is tilted slowly up to 15° from themounted position. Make sure that the seat beltlocks when the retractor is tilted 40° or more .


CONTINUED


SEAT BELT

S–46

RETRACTOR

5. If any of the above-mentioned steps are not asspecified, replace the seat belt.

BUCKLE REMOVAL/INSTALLATIONBench SeatDriver’s side and passenger’s side

1. Disconnect the negative battery cable.2. Remove as indicated in the table.3. Install in the reverse order of removal.


39—78 3.9—8.0, 29—57

1 Buckle

Except driver’s side and passenger’s sideExcept Europe and UK



39—78 3.9—8.0, 29—57

1 Buckle

Bucket SeatFront

1. Disconnect the negative battery cable.2. Remove the side cover. (Refer to SEAT, FRONT

SEAT DISASSEMBLY/ASSEMBLY, Bucket Seat.)3. Remove as indicated in the table.4. Install in the reverse order of removal.


39—78 3.9—8.0, 29—57

1 Front buckle

Stretch CabRear



39—78 3.9—8.0, 29—57

1 Rear buckle

Double CabRear

1. Remove the seat cushion. (Refer to SEAT, REARSEAT REMOVAL/INSTALLATION, Double Cab.)



39—78 3.9—8.0, 29—57

1 Rear buckle


CONTINUED


SEAT BELT

BUCKLE SWITCH INSPECTION 1. Disconnect the negative battery cable. 2. Disconnect the buckle switch connector. 3. Inspect for continuity between the buckle switch


4. If not as specified, replace the buckle.

S-47


CONTINUED


SEAT

S–48

SEATFRONT SEAT REMOVAL/INSTALLATIONBench Seat



35—63 3.5—6.5, 26—47

35—63 3.5—6.5, 26—47

1 Front seat+ Installation note

Front seat installation note1. To install the seat, tighten the bolts in the order


LEFTSIDE

RIGHTSIDE

FRONT

2. Verify that the seat slider is securely locked inposition before fully tightening the bolts.

3. After installing the seat, slide it forward andbackward and verify that the seat slider securelylocks in position.

Bucket Seat1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.


35—63 3.5—6.5, 26—47

35—63 3.5—6.5, 26—47

1 Connector

2 Cover

3 Front seat+ Installation note

Front seat installation note1. To install the seat, tighten the bolts in the order


TUNNELSIDE

DOORSIDE

FRONT

2. Verify that the seat slider is securely locked inposition before fully tightening the bolts.

3. After installing the seat, slide it forward andbackward and verify that the seat slider securelylocks in position.


CONTINUED


SEAT

S–49

FRONT SEAT DISASSEMBLY/ASSEMBLYBench Seat



32—463.2—4.7, 24—33

A

A

1 Headrest

2 Pole guide

3 Recliner lever

4 Side cover

5 Lower cover

6 Seat back trim

7 Seat back pad

8 Seat back frame

9 Seat cushion trim

10 Seat cushion pad

11 Seat cushion frame

12 Cable

13 Slide adjuster

14 Connecting rod


CONTINUED


SEAT

S–50

Bucket Seat1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.3. When removing the cable (passenger’s seat), adjust the cable. (Refer to CABLE ADJUSTMENT.)


37—533.7—5.5, 27—39

A

B

39—783.9—8.0, 29—57

C

B

A

C

PASSENGER’S SEAT

39—78 3.9—8.0, 29—57

1 Headrest

2 Recliner lever

3 Side cover

4 Front buckle

5 Spring (stretch cab)

6 Cable (stretch cab)

7 Wire

8 Connecting rod

9 Slide adjuster No.1



12 Pole guide

13 Seat back trim

14 Seat back warmer unit (Europe only)

15 Seat back pad

16 Seat cushion trim

17 Seat cushion warmer unit (Europe only)

18 Seat cushion pad

19 Seat cushion frame


CONTINUED


SEAT

S–51

CABLE ADJUSTMENT Verify the slide adjuster slides and locks smoothly

when the slide adjuster lever is operated.

LEVER

LEVER

LOCKSLIDE

REAR SEAT REMOVAL/INSTALLATIONStretch CabSeat back

1. Remove the back upper trim.2. Remove the bolts.3. Lift the seat back up in the direction of the arrow,

then unhook it from the body.

SEAT BACK

BOLT6.87—9.8070—100, 60.8—86.7


HOOK

HOOK

HOOK

Seat cushion1. Lift up the rear seat cushion.2. Remove the screws.3. Remove the bolts, and then remove the seat

cushion.

SEAT BACK

BOLT16—221.6—2.3, 12—16


SCREW2.0—2.9 N·m20—30 kgf·cm,18—26 in·lbf

Hinge1. Remove the back lower trim. (Refer to TRIM,

BACK LOWER TRIM REMOVAL/INSTALLATION.)2. Remove the fasteners, and then turn over the floor

covering.3. Remove the bolts, and then remove the hinge.

HINGE

BOLT16—221.6—2.3, 12—16



CONTINUED


SEAT

S–52

Double Cab1. Remove in the order indicated in the table.2. Install in the reverse order of removal.


16—221.6—2.3,12—16

35—633.5—6.5,26—47

16—221.6—2.3,12—16

16—221.6—2.3, 12—16

35—633.5—6.5,26—47

PULL

1 Seat cushion

2 Seat back+ Installation note

3 Hinge

4 Striker

Seat back installation note After installing the seat back, verify that it securely

locks to the striker.

REAR SEAT DISASSEMBLY/ASSEMBLYStretch Cab


1 Seat cushion trim

2 Seat cushion pad


CONTINUED


SEAT

S–53

Double Cab1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.

1 Headrest

2 Pole guide

3 Seat back trim

4 Seat back pad

5 Rear back catch

6 Side cover

7 Stopper

8 Seat back frame

9 Seat cushion trim

10 Seat cushion pad


CONTINUED


SEAT

S–54

SEAT WARMER SWITCH REMOVAL1. Disconnect the negative battery cable.2. Insert your hand under the dashboard near the

fuse block, grasp the hooks of the seat warmerswitch and pull it forward to remove it.

3. Disconnect the seat warmer switch connector, andthen remove the seat warmer switch.

HOOK

SEAT WARMERSWITCHCONNECTOR

SEAT WARMER SWITCH INSTALLATION1. Connect the seat warmer switch connector.2. Insert the seat warmer switch in the hole to install

it.3. Connect the negative battery cable.

SEAT WARMER SWITCH INSPECTION1. Remove the seat warmer switch.

(Refer to SEAT WARMER SWITCH REMOVAL.)2. Inspect for continuity between the seat warmer

switch terminals using an ohmmeter.

: Continuity : Bulb


Switch positionD C F

On

Off

FC

D

F

3. If not as specified, replace the seat warmer switch.

SEAT WARMER UNIT INSPECTION1. Remove the front seat. (Refer to FRONT SEAT

REMOVAL/INSTALLATION, Bucket Seat.)2. Inspect seat warmer unit at roor temperature of 20

°C 68 °F.3. Apply battery positive voltage to the seat warmer

unit terminal A, connect the ground to terminal B,and measure the temperature of the thermometalswitch with a thermometer.

A

B

A

B

THERMOMETER

THERMOMETALSWITCH

4. When the temperature of the thermometal switch isapproximately 40 °C 104 °F, inspect theresistance between the seat warmer unit terminalsusing an ohmmeter. Verify that the resistancechanges from approximately 4.8 Ω toapproximately 13.0 Ω.

5. Remove battery positive voltage from seat warmerunit terminals.

6. When the temperature of the thermometal switch isapproximately 30 °C 86 °F, inspect theresistance between the seat warmer unit terminalsusing an ohmmeter. Verify that the resistancechanges from approximately 13.0 Ω toapproximately 4.8 Ω.

7. If any of the above-mentioned steps are not asspecified, replace the seat back pad (with seatwarmer unit) and seat cushion pad (with seatwarmer unit).


CONTINUED


T–1

BODY ELECTRICAL SYSTEM

POWER SYSTEM T– 3. . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE SERVICE CAUTION T– 3. . . . . . . . . . . . . . . . . MAIN FUSE REMOVAL/INSTALLATION T– 3. . . . . IGNITION SWITCH

REMOVAL/INSTALLATION T– 3. . . . . . . . . . . . . . . IGNITION SWITCH INSPECTION T– 3. . . . . . . . . . . KEY REMINDER SWITCH

REMOVAL/INSTALLATION T– 3. . . . . . . . . . . . . . . KEY REMINDER SWITCH INSPECTION T– 4. . . . CIGARETTE LIGHTER

REMOVAL/INSTALLATION T– 4. . . . . . . . . . . . . . . CIGARETTE LIGHTER INSPECTION T– 4. . . . . . .

EXTERIOR LIGHTING SYSTEM T– 5. . . . . . . . . . . . . . FRONT COMBINATION LIGHT

REMOVAL/INSTALLATION T– 5. . . . . . . . . . . . . . . HEADLIGHT AIMING T– 5. . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BULB

REMOVAL/INSTALLATION T– 5/6. . . . . . . . . . . . . . . PARKING LIGHT BULB

REMOVAL/INSTALLATION T– 6. . . . . . . . . . . . . . . FRONT TURN LIGHT

REMOVAL/INSTALLATION T– 6. . . . . . . . . . . . . . . FRONT TURN LIGHT BULB

REMOVAL/INSTALLATION T– 6. . . . . . . . . . . . . . . FRONT SIDE TURN LIGHT

REMOVAL/INSTALLATION T– 6. . . . . . . . . . . . . . . REAR COMBINATION LIGHT

REMOVAL/INSTALLATION T– 7. . . . . . . . . . . . . . . REAR COMBINATION LIGHT BULB

REMOVAL/INSTALLATION T– 7. . . . . . . . . . . . . . . REAR FOG LIGHT

REMOVAL/INSTALLATION T– 7. . . . . . . . . . . . . . . REAR FOG LIGHT BULB

REMOVAL/INSTALLATION T– 7. . . . . . . . . . . . . . . LICENSE PLATE LIGHT

REMOVAL/INSTALLATION T– 8. . . . . . . . . . . . . . . COMBINATION SWITCH

REMOVAL/INSTALLATION T– 8. . . . . . . . . . . . . . . COMBINATION SWITCH

DISASSEMBLY/ASSEMBLY T– 8. . . . . . . . . . . . . . LIGHT SWITCH

REMOVAL/INSTALLATION T– 8. . . . . . . . . . . . . . . LIGHT SWITCH INSPECTION T– 8/9. . . . . . . . . . . . . . HAZARD WARNING SWITCH

REMOVAL/INSTALLATION T– 9. . . . . . . . . . . . . . . HAZARD WARNING

SWITCH INSPECTION T– 9. . . . . . . . . . . . . . . . . . . REAR FOG LIGHT SWITCH REMOVAL T–10. . . . . REAR FOG LIGHT SWITCH

INSTALLATION T–10. . . . . . . . . . . . . . . . . . . . . . . . . . REAR FOG LIGHT SWITCH

INSPECTION T–10. . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT LEVELING SWITCH

REMOVAL T–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT LEVELING SWITCH

INSTALLATION T–10. . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT LEVELING SWITCH

INSPECTION T–10. . . . . . . . . . . . . . . . . . . . . . . . . . . BACK-UP LIGHT SWITCH

REMOVAL/INSTALLATION T–11. . . . . . . . . . . . . . . BACK-UP LIGHT SWITCH INSPECTION T–11. . . .

FLASHER UNIT REMOVAL/INSTALLATION T–11. . . . . . . . . . . . . . .

FLASHER UNIT INSPECTION T–12. . . . . . . . . . . . . . HEADLIGHT LEVELING ACTUATOR

REMOVAL/INSTALLATION T–12. . . . . . . . . . . . . . . HEADLIGHT LEVELING ACTUATOR

INSPECTION T–13. . . . . . . . . . . . . . . . . . . . . . . . . . . REAR FOG LIGHT RELAY

REMOVAL/INSTALLATION T–14. . . . . . . . . . . . . . . REAR FOG LIGHT RELAY INSPECTION T–14. . . . RUNNING LIGHT RELAY

REMOVAL/INSTALLATION T–14. . . . . . . . . . . . . . . RUNNING LIGHT RELAY INSPECTION T–14/15. . . . .

INTERIOR LIGHTING SYSTEM T–16. . . . . . . . . . . . . . . INTERIOR LIGHT

REMOVAL/INSTALLATION T–16. . . . . . . . . . . . . . . INTERIOR LIGHT INSPECTION T–16. . . . . . . . . . . . DOOR SWITCH

REMOVAL/INSTALLATION T–17. . . . . . . . . . . . . . . DOOR SWITCH INSPECTION T–17. . . . . . . . . . . . . . PANEL LIGHT CONTROL SWITCH

REMOVAL/INSTALLATION T–17. . . . . . . . . . . . . . . PANEL LIGHT CONTROL SWITCH

INSPECTION T–18. . . . . . . . . . . . . . . . . . . . . . . . . . . WIPER AND WASHER T–19. . . . . . . . . . . . . . . . . . . . . .

WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION T–19. . . . . . . . . . . . . . .

WINDSHIELD WIPER MOTOR INSPECTION T–19. . . . . . . . . . . . . . . . . . . . . . . . . . .

WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION T–19. . . . . . . . . . . . . . .

WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT T–19. . . . . . . . . . . . . . . . . . . . . . . . . .

WINDSHIELD WIPER LINKREMOVAL/INSTALLATION T–20. . . . . . . . . . . . . . .

WINDSHIELD WASHER TANK REMOVAL/INSTALLATION T–20. . . . . . . . . . . . . . .

WINDSHIELD WASHER MOTOR REMOVAL/INSTALLATION T–20. . . . . . . . . . . . . . .

WINDSHIELD WASHER MOTOR INSPECTION T–20. . . . . . . . . . . . . . . . . . . . . . . . . . .

WINDSHIELD WASHER NOZZLE REMOVAL T–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WINDSHIELD WASHER NOZZLE INSTALLATION T–20. . . . . . . . . . . . . . . . . . . . . . . . . .

WINDSHIELD WASHER NOZZLE ADJUSTMENT T–21. . . . . . . . . . . . . . . . . . . . . . . . . .

WINDSHIELD WASHER PIPE REMOVAL/INSTALLATION T–21. . . . . . . . . . . . . . .

WINDSHIELD WIPER AND WASHER SWITCH REMOVAL/INSTALLATION T–21. . . . . . .

WINDSHIELD WIPER AND WASHER SWITCH INSPECTION T–21. . . . . . . . . . . . . . . . . . .

WARNING AND INDICATOR SYSTEM T–22. . . . . . . . INSTRUMENT CLUSTER

REMOVAL/INSTALLATION T–22. . . . . . . . . . . . . . . INSTRUMENT CLUSTER

DISASSEMBLY/ASSEMBLY T–22. . . . . . . . . . . . . . INSTRUMENT CLUSTER INSPECTION T–22/24. . . . . INSTRUMENT CLUSTER REPAIR T–24. . . . . . . . . .

BACK.TO.MAIN.INDEX

CONTINUED

PAGE 1 OF 2


POWER SYSTEM

T–2

WARNING AND INDICATOR LIGHT BULB REMOVAL/INSTALLATION T–24. . . . . . . . . .

FUEL GAUGE SENDER UNIT INSPECTION T–24/25. . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER TEMPERATURE SENDER UNIT REMOVAL T–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER TEMPERATURE SENDER UNIT INSTALLATION T–25. . . . . . . . . . . . . . . . . . . . . . . . . .

WATER TEMPERATURE SENDER UNIT INSPECTION T–25. . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PRESSURE SWITCH INSPECTION T–25. . . . . HORN REMOVAL/INSTALLATION T–25. . . . . . . . . . HORN RELAY REMOVAL/INSTALLATION T–25/26. . . HORN RELAY INSPECTION T–26. . . . . . . . . . . . . . . CLOCK REMOVAL/INSTALLATION T–26. . . . . . . . .

AUDIO T–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUDIO UNIT REMOVAL T–26. . . . . . . . . . . . . . . . . . . AUDIO UNIT INSTALLATION T–26. . . . . . . . . . . . . . . SPEAKER REMOVAL/INSTALLATION T–26/27. . . . . . . SPEAKER INSPECTION T–27. . . . . . . . . . . . . . . . . . . ROOF ANTENNA REMOVAL T–27. . . . . . . . . . . . . . . ROOF ANTENNA INSTALLATION T–27. . . . . . . . . . ROOF ANTENNA INSPECTION T–27/28. . . . . . . . . . . . ANTENNA FEEDER

REMOVAL/INSTALLATION T–28. . . . . . . . . . . . . . . ANTENNA FEEDER INSPECTION T–28. . . . . . . . . .


CONTINUED

PAGE 2 OF 2


BODY ELECTRICAL SYSTEM

CONDENSER REMOVAL/INSTALLATION T–28. . .

123456567

POWER SYSTEM

T–3

POWER SYSTEMFUSE SERVICE CAUTION

Caution Determine and correct the cause of the

burnt fuse before replacing it with thespecified type. If the fuse is replaced beforedoing this, it may burn again.

MAIN FUSE REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.

G6, WL, WL TURBO, F2 CIS

F2 CARB

1 Nut

2 Bolt

3 Main fuse

IGNITION SWITCH REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the column cover.3. Disconnect the ignition switch connectors.4. Remove the screw to remove the ignition switch.

IGNITIONSWITCH

SCREWIGNITIONSWITCHCONNECTOR


IGNITION SWITCH INSPECTION1. Remove the column cover.2. Disconnect the ignition switch connectors.3. Inspect for continuity between the ignition switch

terminals using an ohmmeter.: Continuity

Ignition key Terminalg yposition 2A 2B 1D 1C 1B 1A

LOCK

ACC

ON

START

2A 2B

1B1C 1D 1A

2B 2A

1C 1A

1D 1B

START

ON ACCLOCK

START

ON ACCLOCK

4. If not as specified, replace the ignition switch.

KEY REMINDER SWITCH REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the column cover.3. Disconnect the key reminder switch connector.4. Remove the key reminder switch.

STEERINGLOCK

KEY REMINDERSWITCH



CONTINUED


POWER SYSTEM

T–4

KEY REMINDER SWITCH INSPECTION1. Remove the column cover.2. Disconnect the key reminder switch connector.3. Inspect for continuity between the key reminder

switch terminals using an ohmmeter.: Continuity

Key positionTerminal

Key positionA B

Inserted

Removed

B A

B

A

4. If not as specified, replace the key reminder switch.

CIGARETTE LIGHTER REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the center panel.3. Remove in the order indicated in the table.4. Install in the reverse order of removal.

1 Cigarette lighter plug

2 Connector

3 Socket+ Removal Note

4 Ring

Socket Removal Note1. Pry up the stopper with a tape-wrapped

screwdriver.2. Pull the socket by prying up the stopper.

CIGARETTE LIGHTER INSPECTION Verify that the cigarette lighter plug will move

normally within 10—20 seconds , after pressingthe plug into the socket. If the plug does not move,replace the cigarette lighter.


CONTINUED


EXTERIOR LIGHTING SYSTEM

T–5

EXTERIOR LIGHTING SYSTEMFRONT COMBINATION LIGHTREMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove the radiator grille.

(Refer to section S, EXTERIOR ATTACHMENT, RADIATOR GRILLE REMOVAL/INSTALLATION.)

3. Remove the front turn light. (Refer to FRONTTURN LIGHT REMOVAL/INSTALLATION.)

4. Remove in the order indicated in the table.5. Install in the reverse order of removal.6. Adjust the headlight aiming.

(Refer to HEADLIGHT AIMING.)

1 Front combination light connector

2 Front combination light+ Removal Note

3 Spring

Front Combination Light Removal NoteRemoval with pliers

Caution When pressing the hook of the adjusting

screws and the screw with the pliers, do notdamage the front combination lightmounting.

1. Press the hook of the adjusting screws and thescrew with the pliers.

2. Pull the front combination light out of the adjustingscrews and the screw.

HOOK

SCREW

ADJUSTING SCREW

FRONT COMBINATION LIGHT MOUNTING

If it is difficult to remove front combination lightwith pliers Remove the adjusting screws and the screw by

loosening them.

SCREW

ADJUSTINGSCREW

ADJUSTINGSCREW

HEADLIGHT AIMING1. Adjust the tire air pressure to the specification.2. Position the unloaded vehicle on a level surface.3. Seat one person in the driver’s seat.4. Start the engine and charge the battery fully.5. Position the vehicle straight ahead and

perpendicularly to a wall.6. Set the headlights 7.6 m 25 ft from the wall.7. While adjusting one headlight, disconnect the

connector of the other.

Caution Always tighten the adjusting screws last.

When loosening the adjusting screws, loosenthe screws first and then tighten them.If the adjusting screws are tightened first,then loosened, they will continue to loosenwhen the vehicle is in motion and maycause the headlights to become misaligned.

8. Adjust the headlights by turning the adjustingscrews as shown in the figure. Loosen the screwsfirst, then tighten them.

UP

DOWN

OUT-WARD

IN-WARD

HEADLIGHT BULB REMOVAL/INSTALLATION

Caution A halogen bulb generates extremely high

heat when it is used. If the surface of thebulb is soiled, excessive heat will build upand the light’s life will be shortened. Whenreplacing the bulb, hold the metal flange,not the glass.


CONTINUED



T–6


1 Headlight bulb connector

2 Cover+ Installation Note

3 Headlight bulb

Cover Installation Note Align the TOP mark with top side.

TOP MARK

PARKING LIGHT BULB REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.

1 Socket

2 Parking light bulb

FRONT TURN LIGHT REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.

1 Screw

2 Front turn light

3 Front turn light connector

FRONT TURN LIGHT BULBREMOVAL/INSTALLATION


1 Socket

2 Front turn light bulb

FRONT SIDE TURN LIGHTREMOVAL/INSTALLATION


FRONT

REAR

1 Front side turn light

2 Front side turn light connector

3 Socket

4 Front side turn light bulb


CONTINUED



T–7

REAR COMBINATION LIGHTREMOVAL/INSTALLATION


1 Screw

2 Rear combination light

3 Rear combination light connector

REAR COMBINATION LIGHT BULBREMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove the rear combination light.3. Remove in the order indicated in the table.4. Install in the reverse order of removal.

1 Screw

2 Lens+ Removal Note

3 Rear turn light bulb

4 Back-up light bulb

5 Brake light/taillight bulb

Lens Removal Note Push the hook upward with your finger.

HOOK

REAR FOG LIGHT REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.

WITHOUT REAR BUMPER

1 Rear fog light connector

2 Nut

3 Spring washer

4 Rear fog light

WITH REAR BUMPER

1 Rear fog light connector

2 Screw

3 Rear fog light

REAR FOG LIGHT BULBREMOVAL/INSTALLATION


1 Screw

2 Lens

3 Rear fog light bulb


CONTINUED



T–8

LICENSE PLATE LIGHT REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.

1 Screw

2 License plate light

3 License plate light bulb

4 Socket

5 License plate light connector

COMBINATION SWITCH REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. For vehicles without air bag system, remove the

horn cap. For vehicles with air bag system, removethe driver-side air bag module. (Refer to AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)

3. Remove the steering wheel. (Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

4. For vehicles with air bag system, remove the clockspring. (Refer to AIR BAG SYSTEM, CLOCKSPRING REMOVAL/INSTALLATION.)

5. Remove the column cover.6. Remove in the order indicated in the table.7. Install in the reverse order of removal.

1 Screw

2 Combination switch

3 Combination switch connector

COMBINATION SWITCHDISASSEMBLY/ASSEMBLY


1 Screw

2 Windshield wiper and washer switch

3 Light switch

4 Body

LIGHT SWITCH REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the column cover.3. Remove in the order indicated in the table.4. Install in the reverse order of removal.

1 Light switch connector

2 Screw

3 Light switch

LIGHT SWITCH INSPECTIONHeadlight Switch

1. Remove the light switch. (Refer to LIGHT SWITCH REMOVAL/INSTALLATION.)

Note When the flash-to-pass switch is on, the

contact of the low-high switch is at neutral.

2. Inspect for continuity between the light switchterminals using an ohmmeter.


CONTINUED



T–9

: ContinuitySwitch position Terminal

Light Dimmer Flash-to-pass

P(B)

D(N)

L(H)

F(J)

H(L)

OFF –Off

OFF –On

TNS –Off

TNS –On

Head LowOff

Head-light

LowOn

lightHigh –

( ): Light switch right side lever

N L H

OFFTNS

LOWHIGHFLASH-TO-PASS

HEAD-LIGHT

(O) (*)

D

H L P

F D

HEAD-LIGHT

OFF

TNS

(J) (N)

(L) (H) (B)

*(M)*

(K)* E

(*) C

(*) A

(*) P

(J)*

(B)*

(*) F

( ): LIGHT SWITCH RIGHT SIDE LEVER

3. If not as specified, replace the light switch.

Turn Switch1. Remove the light switch.

(Refer to LIGHT SWITCH REMOVAL/INSTALLATION.)2. Inspect for continuity between the light switch



Switch positionC (M) A (K) E (O)

Right

Off

Left( ): Light switch right side lever

N L H

(O) (*)

D

* (M)*(K)* E

(*) C

(*) A

(*) P (J)*

(B)*

(*) F

( ): LIGHT SWITCH RIGHT SIDE LEVER

C

(M)

A E

(O)(K)

3. If not as specified, replace the light switch.

HAZARD WARNING SWITCHREMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove the meter hood.

(Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.)


HOOK

1 Hazard warning switch

HAZARD WARNING SWITCH INSPECTION1. Remove the meter hood.


2. Inspect for continuity between the hazard warningswitch terminals using an ohmmeter.

: Continuity : Bulb

Switch Terminalposition F D B A C I K H J

Off

On

H

K I C A

* J D BFH

K F D

BAJ I

C

C

3. If not as specified, replace the hazard warningswitch.


CONTINUED



T–10

REAR FOG LIGHT SWITCH REMOVAL1. Disconnect the negative battery cable.2. Insert your hand under the dashboard near the

fuse block, grasp the hooks of the rear fog lightswitch and pull it forward to remove it.

3. Disconnect the connector to remove the rear foglight switch.

CONNECTOR

REAR FOGLIGHT SWITCH

HOOK

REAR FOG LIGHT SWITCH INSTALLATION1. Connect the rear fog light switch connector.2. Insert the rear fog light switch in the hole to install

it.3. Connect the negative battery cable.

REAR FOG LIGHT SWITCH INSPECTION1. Remove the rear fog light switch. (Refer to REAR

FOG LIGHT SWITCH REMOVAL/INSTALLATION.)2. Inspect for continuity between the rear fog light



Switch positionA D F

Off

Neutral

On

F

A D

F D

A

3. If not as specified, replace the rear fog light switch.

HEADLIGHT LEVELING SWITCH REMOVAL1. Disconnect the negative battery cable.2. Insert your hand under the dashboard near the

fuse block, grasp the hooks of the headlightleveling switch and pull it forward to remove it.

3. Disconnect the connector to remove the headlightleveling switch.

HOOK

CONNECTOR

HEADLIGHT LEVELING SWITCH

HEADLIGHT LEVELING SWITCH INSTALLATION1. Connect the headlight leveling switch connector.2. Insert the headlight leveling switch in the hole to

install it.3. Connect the negative battery cable.

HEADLIGHT LEVELING SWITCH INSPECTION1. Remove the headlight leveling switch.

(Refer to HEADLIGHT LEVELING SWITCHREMOVAL/INSTALLATION.)

2. Inspect for continuity between the headlightleveling switch terminals using an ohmmeter.

: Continuity : Resistance : Bulb


Switch positionC D A B

00

11

22

33

R1:1600 Ω 2: 560 Ω 3:300 Ω

* * * D

* C A

B

C

B

A

D

0 1 2 3

R1 R2 R3

3. If not as specified, replace the headlight levelingswitch.

R3

R2+R3

R2+ R3R1+


CONTINUED



T–11

BACK-UP LIGHT SWITCHREMOVAL/INSTALLATION


R


25—34 2.5—3.4, 19—24

1 Back-up light switch connector

2 Back-up light switch

3 Gasket

BACK-UP LIGHT SWITCH INSPECTION1. Disconnect the back-up light switch connector.2. Inspect for continuity between the back-up light


Shift lever Terminalposition A B

Reverse

Other

A

B

BA

3. If not as specified, replace the back-up light switch.

FLASHER UNIT REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.

DRIVER-SIDEFRONT SIDE TRIM

1 Nut

2 Flasher unit

3 Flasher unit connector


CONTINUED



T–12

FLASHER UNIT INSPECTION1. Measure the voltage at the flasher unit terminals as indicated below.2. Disconnect the flasher unit connector before inspecting for continuity at terminal C.3. If not as specified, inspect the parts listed under “Inspection area” and the related wiring harnesses.4. If the parts and wiring harnesses are okay but the system still does not work properly, replace the flasher unit.

Terminal Voltage List (Reference)B+: Battery positive voltage

C

A

B

Terminal Signal Connection Test condition Voltage (V)/Continuity

Inspection area

Hazard warning switch onAlternatesB+ and 0

Hazard

A Flasher unit output

Hazard warningswitch Hazard warning

Ignition switch atON position

B+ Hazard warning switch Turn signalout ut switch Hazard warning

switch off Ignition switch atLOCK or ACCposition

0

Turn signallight

Hazard warning switch on B+ HAZARD 10 A

B Power supplyHazard warning

Hazard warning

Ignition switch atON position

B+

HAZARD 10 Afuse

METER 15 AB Power su ly

switch Hazard warningswitch off Ignition switch at

LOCK or ACCposition

0

fuse Hazard warning switch

CFlasher unitground

GNDConstant: inspect for continuity toground

Yes GND

HEADLIGHT LEVELING ACTUATORREMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove the radiator grille.

(Refer to section S, EXTERIOR ATTACHMENT, RADIATOR GRILLE REMOVAL/INSTALLATION.)

3. Remove the front turn light. (Refer to FRONT TURN LIGHT REMOVAL/INSTALLATION.)

4. Remove the front combination light. (Refer to FRONT COMBINATION LIGHTREMOVAL/INSTALLATION.)

5. Remove the headlight leveling actuator connectorfrom the bracket.

6. Disconnect the headlight leveling actuatorconnector.

7. Remove the nuts.8. Remove the headlight leveling actuator.

HEADLIGHTLEVELINGACTUATOR

HEADLIGHT LEVELING ACTUATOR CONNECTOR



CONTINUED



T–13

HEADLIGHT LEVELING ACTUATOR INSPECTION1. Measure the voltage at the headlight leveling actuator terminals as indicated below.

Note Because the headlight leveling actuator connector is waterproof, it is impossible to measure the voltage at

the headlight leveling actuator terminals. When inspecting, measure the voltage at the terminal of the partwhich is connected to the headlight leveling actuator.

(1) To measure the voltage at the terminal A of the headlight leveling actuator, remove the column cover andmeasure the voltage at the terminal N of the light switch connector.(Refer to LIGHT SWITCH INSPECTION.)

(2) To measure the voltage at the terminal B of the headlight leveling actuator, remove the headlight levelingswitch with the connector connected and measure the voltage at the terminal C of the headlight levelingswitch connector. (Refer to HEADLIGHT LEVELING SWITCH INSPECTION.)

(3) Disconnect the headlight leveling actuator connector before inspecting for continuity at terminal C.2. If not as specified, inspect the parts listed under “Inspection area” and the related wiring harnesses.3. If the parts and wiring harnesses are okay but the system still does not work properly, replace the headlight

leveling actuator.


A B C

Terminal Signal Connection Test condition Voltage ( V )/Continuity

Inspection area

A

Headlight leveling Combination

Headlight illuminated B+Combination switchA

gactuator power supply

switchHeadlight unilluminated 0

Combination switch

Headlight levelingswitch at 0

6.2

BHeadlight leveling switch

Headlight HeadlightHeadlight levelingswitch at 1

4.2Headlight leveling switchB leveling switch

position

gleveling switch

gswitch on Headlight leveling

switch at 22.1

Headlight leveling switch

Headlight levelingswitch at 3

0

C

Headlightleveling actuatorground

GNDConstant : inspect for continuityto ground

Yes GND


CONTINUED



T–14

REAR FOG LIGHT RELAYREMOVAL/INSTALLATION

Note Because the lock section of the relay is

damaged easily, do not remove the relay fromthe bracket unless replacement is necessary.Always perform an inspection of the rear foglight relay before removal.

1. Disconnect the negative battery cable.2. Disconnect the rear fog light relay connector.3. Remove the rear fog light relay by prying the lock

section of the upper part with a flatheadscrewdriver.

BRACKET

REAR FOGLIGHT RELAY

REAR FOG LIGHTRELAY CONNECTOR


REAR FOG LIGHT RELAY INSPECTION1. Remove the bracket and pull it toward you.2. Inspect for continuity between the rear fog light

relay terminals using an ohmmeter.: Continuity B+: Battery positive voltage

StepTerminal

StepA B C D

1

2 B+ GND

C A

D B

C A

D B

3. If not as specified, replace the rear fog light relay.

RUNNING LIGHT RELAY REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the washer tank from the bracket.3. Remove the running light relay with the cover

attached.

RUNNING LIGHTRELAY WITH COVER

NUT

4. Remove the cover.5. Disconnect the running light relay connector.

COVER

RUNNING LIGHTRELAY

RUNNING LIGHTRELAY CONNECTOR


RUNNING LIGHT RELAY INSPECTION1. Remove the running light relay.

(Refer to RUNNING LIGHT RELAYREMOVAL/INSTALLATION.)

2. Inspect for continuity between the running lightrelay terminals using an ohmmeter.

: Continuity : DiodeTest

condiTerminal

cond -tion A B C D E F

Constant

B C A

F E D

AC

BD

E

F


CONTINUED



T–15

3. Connect the terminal A to the positive batteryterminal and the terminal D to the negative batteryterminal.

4. Verify that there is continuity between terminals Aand E, and that there is no continuity betweenterminals B and F.

AC

BD

E

F

B C A

F E D

5. Connect the terminal C to the positive batteryterminal and the terminal D to the negative batteryterminal.

6. Verify that there is no continuity between terminalsB and F, and between terminals A and E.

AC

BD

E

F

B C A

F E D

7. If not as specified, replace the running light relay.


CONTINUED


INTERIOR LIGHTING SYSTEM

T–16

INTERIOR LIGHTING SYSTEMINTERIOR LIGHT REMOVAL/INSTALLATION


ALL VEHICLES EXCEPTREGULAR CAB

REGULAR CAB

1 Lens+ Removal Note

2 Interior light bulb

3 Screw

4 Spacer

5 Interior light+ Installation Note

6 Interior light connector

Lens Removal NoteAll vehicles except regular cab

1. Insert a tape-wrapped flathead screwdriver into thelens.

2. Twist the screwdriver to remove the lens.

Regular cab Push the areas indicated by the arrows to pull out

the lens.

Interior Light Installation NoteRegular cab

Note The spacer acts as a ground. If the spacer is

not installed in the position shown in the figure,the interior light may not illuminate.

1. Tighten the screw fully. (More than 4 mm 0.2 inof thread should be exposed.)

2. Install the interior light.

SCREW

SPACERINTERIOR LIGHT

4.0 mm0.2 in

INTERIOR LIGHT INSPECTION1. Remove the interior light.

(Refer to INTERIOR LIGHT REMOVAL/INSTALLATION.)2. Inspect for continuity between the interior light

terminals using an ohmmeter. : Bulb

StepTerminal

StepA B Body GND

ON

DOOR

OFF

ONOFF

DOOR

A

B

A B

3. If not as specified, replace the interior light.


CONTINUED



T–17

DOOR SWITCH REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.

1 Screw

2 Door switch

3 Door switch connector

DOOR SWITCH INSPECTION1. Remove the door switch.2. Inspect for continuity between the door switch


Switch conditionTerminal

Switch conditionA Body GND

Pressed

Released

A A

BODY GND

3. If not as specified, replace the door switch.

PANEL LIGHT CONTROL SWITCHREMOVAL/INSTALLATION




HOOK

1 Panel light control switch


CONTINUED



T–18

PANEL LIGHT CONTROL SWITCH INSPECTION1. Remove the meter hood without disconnecting the panel light control switch connector.

(Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.)2. Measure the voltage at the panel light control switch as indicated below.3. Disconnect the panel light control switch connector before inspecting for continuity at terminal G.4. If not as specified, inspect the parts listed under “Inspection area” and the related wiring harnesses.5. If the parts and wiring harnesses are okay but the system still does not work properly, replace the panel light

control switch.


G

H F D B

A

Terminal Signal Connection Test condition Voltage (V)/Continuity

Inspection area

APanel light control output

Each illumination

Inspect using an oscilloscope+ A terminal inspection

— Each illumination

B — Not used — — —

DPower supply

Light switchHeadlight switch at TNS or headlight position

B+ Light switch TAIL 10 A fusesupply

gHeadlight switch at OFF position 0

TAIL 10 A fuse

F — Not used — — —

G

Panel light controlswitchground

GNDConstant: Inspect for continuity toground

Yes GND

H — Not used — — —

A Terminal Inspection1. Measure the wave pattern of the A terminal on the

panel light control switch using an oscilloscope.

PANEL LIGHTCONTROL SWITCH OSCILLOSCOPE

2. Set the headlight switch to either the TNS orheadlight position.

3. Set the panel light control switch to the brightestposition.

4. Verify that the pattern of the screen is as shown inthe figure.

V

0

5. Verify that the pattern on the screen matches thepattern shown in the figure as the panel lightcontrol switch is gradually turned to the darkestposition.

B+

01—3.2 ms

5—15.4 ms

V


CONTINUED


WIPER AND WASHER

T–19

WIPER AND WASHERWINDSHIELD WIPER MOTORREMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Disconnect the connector.3. Loosen the bolts.4. Pull the windshield wiper motor forward until the

connection between the windshield wiper motorand windshield wiper link is in the engine room.

5. Pry off the connection between the windshieldwiper motor and windshield wiper link.

6. Remove the windshield wiper motor.

4.0—6.8 40—70, 35—60

WINDSHIELD WIPER MOTOR

CONNECTOR

WINDSHIELDWIPER LINK BOLT



WINDSHIELD WIPER MOTOR INSPECTION1. Disconnect the windshield wiper motor connector.2. Connect battery positive voltage and inspect the

operation of the windshield wiper motor asindicated below.

Terminal Operation

A High

C Low

A

B

C

D

3. Connect battery positive voltage to terminal C ofthe windshield wiper motor to operate thewindshield wipers at low speed.

4. Disconnect battery positive voltage from terminal Cof the motor while the wipers are operating.

5. Verify that the wipers do not stop in the parkposition.

6. Short between terminal C and B of the motor, andconnect battery positive voltage to terminal D ofthe motor.

7. Verify that the wipers operate at low speed again,then stop in the park position.

8. If not as specified, replace the windshield wipermotor.

WINDSHIELD WIPER ARM AND BLADEREMOVAL/INSTALLATION

1. Remove in the order indicated in the table.2. Install in the reverse order of removal.3. Adjust the windshield wiper arm and blade.

(Refer to WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT.)

16—191.6—2.0,12—14


1 Cap

2 Nut

3 Windshield wiper arm+ Installation Note

4 Windshield wiper blade

5 Rubber brush

Windshield Wiper Arm Installation Note Clean the windshield wiper arm connector shafts

with a wire brush before installing the windshieldwiper arms.

WINDSHIELD WIPER ARM CONNECTOR SHAFT

WINDSHIELD WIPER ARM AND BLADEADJUSTMENT

1. Operate the windshield wiper motor to set thewindshield wipers in the park position.

2. Align both ends of the wiper blades to the markson the ceramic section.

CERAMIC SECTION

MARK


CONTINUED


WIPER AND WASHER

T–20

WINDSHIELD WIPER LINKREMOVAL/INSTALLATION

1. Remove the windshield wiper arm and blade.(Refer to WINDSHIELD WIPER ARM AND BLADEREMOVAL/INSTALLATION.)

2. Remove the cowl grille.3. Remove the windshield wiper motor.

(Refer to WINDSHIELD WIPER MOTORREMOVAL/INSTALLATION.)

4. Remove in the order indicated in the table.5. Install in the reverse order of removal.6. Adjust the windshield wiper arm and blade.

(Refer to WINDSHIELD WIPER ARM AND BLADEADJUSTMENT.)


6.87—9.80 70—100, 60.8—86.7

1 Bolt

2 Windshield wiper link

WINDSHIELD WASHER TANKREMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Disconnect the connector.3. Disconnect the windshield washer pipe from the

windshield washer motor.4. Pull the windshield washer tank up and slide it off

the bracket.

WINDSHIELDWASHER TANK

BRACKET

WINDSHIELDWASHER PIPE

CONNECTOR


WINDSHIELD WASHER MOTORREMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove the windshield washer tank.3. Remove in the order indicated in the table.4. Install in the reverse order of removal.

1 Windshield washer motor

2 Grommet

WINDSHIELD WASHER MOTOR INSPECTION1. Disconnect the windshield washer motor

connector.2. Connect battery positive voltage to terminal B and

ground to terminal A of the motor.3. Verify that the windshield washer motor operates.

B

M

A

A

B

4. If the motor does not operate, replace thewindshield washer motor.

WINDSHIELD WASHER NOZZLE REMOVAL1. Disconnect the windshield washer pipe from the

windshield washer nozzle.2. Remove the windshield washer nozzle using a 10

mm 0.4 in deep socket wrench from underneaththe bonnet.

DEEP SOCKET WRENCH WINDSHIELD WASHER NOZZLE

WINDSHIELD WASHER NOZZLE INSTALLATION1. Connect the windshield washer pipe to the

windshield washer nozzle.2. Push the windshield washer nozzle into the

installation hole.3. Adjust the windshield washer nozzle. (Refer to

WINDSHIELD WASHER NOZZLE ADJUSTMENT.)


CONTINUED


123

WIPER AND WASHER

T–21

WINDSHIELD WASHER NOZZLE ADJUSTMENT Insert a needle or equivalent tool into the spray

holes of the windshield washer nozzle and adjustthe nozzle direction as shown.

mm in

MOLDINGEND LINE

WINDSHIELDGLASS END LINE

CENTER

390 15.4320 12.6

1003.9

1003.9

1807.1

27010.6

29011.4

29011.4

WINDSHIELD WASHER PIPEREMOVAL/INSTALLATION

1. Disconnect the windshield washer pipe from thewindshield washer nozzle and the windshieldwasher motor.

2. Remove the clips.3. Remove the windshield washer pipe.

CLIP WINDSHIELDWASHER PIPE


WINDSHIELD WIPER AND WASHER SWITCHREMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove the column cover.3. Disconnect the connector.4. Remove the screws.5. Remove the windshield wiper and washer switch.

SCREW

WINDSHIELDWIPER ANDWASHERSWITCH

CONNECTOR


WINDSHIELD WIPER AND WASHER SWITCHINSPECTION

1. Remove the column cover.2. Remove the windshield wiper and washer switch.3. Inspect for continuity between the windshield wiper

and washer switch terminals using an ohmmeter.: Continuity

One-Terminal

Switch positionOne-touch L(F)

G(E)

M(C)

N(D)

C(M)

OFFOff

Wiper

OFFOn

Wiperswitch

INTswitch

LO

HI

Washerswitch

On

( ): Wiper and washer switch left side lever

HI HILO

LO

OFFOFF

INTINT

INTRELAY

WIPERSWITCH

ONE-TOUCH

WASHERSWITCH

(D)

N

L

(F)

M

(C)

G

(E)

C

(M)

0 (*)

* N (*)

L (*)

H (*)

G (*)

*

M * (E) C

* (A)

* (F)

* (J)

H

(J)

* (D)

( ): WIPER AND WASHER SWITCH LEFT SIDE LEVER

4. If not as specified, replace the windshield wiperand washer switch.


CONTINUED


WARNING AND INDICATOR SYSTEM

T–22

WARNING AND INDICATOR SYSTEMINSTRUMENT CLUSTER REMOVAL/INSTALLATION


(Refer to section S, DASHBOARD AND CONSOLE,METER HOOD REMOVAL/INSTALLATION.)


1 Screw

2 Instrument cluster connector

3 Instrument cluster

INSTRUMENT CLUSTERDISASSEMBLY/ASSEMBLY

Caution If the print plate on the back of the

instrument cluster is damaged, the systemwill not operate properly and it may becomethe cause of trouble or malfunction.


1 Screw

2 Bulb

3 Alarm

4 Front lens

5 Instrument cluster

INSTRUMENT CLUSTER INSPECTIONSpeedometer

1. Adjust the tire air pressure to the specification.2. Using a speedometer tester, verify that the

speedometer indication is within the allowablerange indicated in the table.

Speedometer tester Allowable range (km/h)pindication (km/h)

Allowable range (km/h)

20 18—22

40 36—44

60 54—66

80 72—88

100 90—110

120 108—132

140 126—154

160 144—176

180 162—198

3. Verify that fluctuation of the speedometer needle iswithin the allowable range.

Needle fluctuation allowable rangeWithin 0.5 km/h

4. If the speedometer needle does not move or if theindication is outside of the allowable range, inspectthe vehicle speedometer sensor and related wiringharness.

5. If the vehicle speedometer sensor and relatedwiring harness are normal, replace the instrumentcluster.

TachometerUsing the SSTs (NGS kit) or a dwell tacho tester

Caution If the engine speed exceeds the allowable

range, the engine could be damaged.Therefore, when inspecting the tachometer,do not allow the engine speed to exceed theallowable range indication on thetachometer.

1. Follow the appropriate procedure for using theSSTs (NGS kit) or dwell tacho tester.

Using the SSTs (NGS kit)(1) Connect the SSTs (NGS kit) to the data link

connector and battery.

DIAGNOSTIC PROGRAM CARD

NGS KIT


CONTINUED


R1

R2

R1

R2


T–23

(2) Select “VEHICLE & ENGINE SELECTION” andpress TRIGGER. (Select the model andspecifications of the vehicle you are testing.)

(3) Select “PCM-POWERTRAIN CTRL MODULE”and press TRIGGER.

(4) Select “PID/DATA MONITOR AND RECORD”and press TRIGGER.

(5) Select “RPM” and press TRIGGER.(6) Press START.

Using a dwell tacho tester Connect a dwell tacho tester to the terminals K and

B of the PCM connector.

2. Verify that the tachometer indication is within theallowable range indicated in the table.

Dwell tacho tester Allowable range (rpm)indication (rpm)

Allowable range (rpm)

650 583—705

1000 926—1060

2000 1954—2120

3000 2980—3180

4000 4008—4240

3. If the tachometer needle does not move or if theindication is outside of the allowable range, inspectthe PCM and related wiring harness.

4. If the PCM and related wiring harness are normal,replace the instrument cluster.

Fuel Gauge1. Disconnect the fuel gauge sender unit connector.2. Connect the red lead of SST (Fuel And

Thermometer checker) to terminal B of the fuelgauge sender unit connector and black lead toground.

3. Set the resistance of SST (Fuel And Thermometerchecker) to 180 Ω.

*

C B

49 N088 0A0

49 0839 285

4. Turn the ignition switch to ON position.5. Verify that the needle is below E.6. Turn the ignition switch to LOCK position.7. Set the resistance of SST (Fuel And Thermometer

checker) to 10 Ω.8. Turn the ignition switch to ON position.9. Verify that the needle is above F.

10. If the needle does not move or moves irregularly,remove the instrument cluster. (Refer to INSTRUMENT CLUSTERREMOVAL/INSTALLATION.)

11. Measure the resistance between the fuel gaugeterminals using an ohmmeter.

: Resistance

StepTerminal

StepFUEL + FUEL – GND COM

1

2R1, R2: 140—200 Ω

FUEL+

FUEL–

GND

COM

12. Verify that the difference in resistance between R1and R2 is less than 6 Ω.

13. If not as specified, replace the instrument cluster.

Water Temperature Gauge1. Disconnect the water temperature sender unit

connector.2. Turn the ignition switch to ON position.3. Verify that the needle is below C.4. Ground terminal A of the water temperature sender

unit’s vehicle side connector.

A

5. Verify that the needle is above H.6. If the needle does not move or moves irregularly,

remove the instrument cluster.(Refer to INSTRUMENT CLUSTERREMOVAL/INSTALLATION.)

7. Measure the resistance between the watertemperature gauge terminals using an ohmmeter.

: Resistance

StepTerminal

StepTEMP + TEMP – V+ COM

1

2R1, R2: 140—200 Ω


CONTINUED



T–24

TEMP+

COM

TEMP–V+

8. Verify that the difference in resistance between R1and R2 is less than 6 Ω.

9. If not as specified, replace the instrument cluster.

INSTRUMENT CLUSTER REPAIR

Note The needle of speedometer or tachometer may

continue to rotate clockwise until it rests on themask plate. If a customer complains of thisconcern, repair the needle position accordingto the following steps.

1. Verify the concern.

TACHOMETER SPEEDOMETER

2. Turn the ignition switch to LOCK position.3. Remove the ROOM fuse, then wait for 10 minutes

or more until the power supply in the instrumentcluster is spent.

4. Turn the ignition switch to ON position.5. Verify that the needle returns to zero.

TACHOMETER SPEEDOMETER

6. After the needle returns to zero, install the ROOMfuse with the ignition switch at ON position. If theneedle does not return to zero, remove the frontlens and carefully move the needle to zero byhand. (Refer to INSTRUMENT CLUSTERDISASSEMBLY/ASSEMBLY.)

WARNING AND INDICATOR LIGHT BULBREMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove the instrument cluster.

(Refer to INSTRUMENT CLUSTERREMOVAL/INSTALLATION.)

3. Turn the socket counterclockwise to remove thebulb as shown in the figure.

BULB


FUEL GAUGE SENDER UNIT INSPECTION1. For G6, F2 CIS, or F2 Carb engine vehicles, remove

the fuel pump unit. (Refer to section F2, FUELSYSTEM, FUEL TANK REMOVAL/INSTALLATION.) For WL or WL Turboengine vehicles, remove the fuel gauge sender unit.(Refer to section F2, FUEL SYSTEM, FUEL TANKREMOVAL/INSTALLATION.)

2. Using an ohmmeter, measure and verify that theresistance between terminals B and C (WL, WLTurbo) or A and B (G6, F2 CIS, F2 Carb) of the fuelgauge sender unit is as shown in the followingchart while slowly moving the unit arm from emptyto full.

Measuring point Resistance ( Ω)

Full 18.4—26.4

1/2 81.5—93.5

Empty 136—154

253.7 9.988

EMPTY

FULL

1/2

169.7 6.681 *

87.0 3.43 *

B

mm in

C*

* DOUBLE CAB2WD, STRETCHCAB 2WD65.5 2.58

158.1 6.224

WL, WL TURBO


CONTINUED



T–25

255.7 10.067

EMPTY

FULL

1/2

B

mm in

A

67.5 2.66

160.1 6.303

G6, F2 CIS, F2 CARB

3. If not as specified, replace the fuel gauge senderunit. (Refer to section F2, FUEL SYSTEM, FUEL TANK

FUEL SYSTEM, FUEL PUMP UNIT

FUEL SYSTEM, FUEL PUMP UNITREMOVAL/INSTALLATION.)

WATER TEMPERATURE SENDER UNIT REMOVAL1. Disconnect the negative battery cable.2. Disconnect the connector.3. Remove the water temperature sender unit.

CONNECTOR

WATER TEMPERATURESENDER UNIT

WATER TEMPERATURE SENDER UNITINSTALLATION

1. Apply sealant from the third thread to the topthread.

6—80.24—0.31

THIRD THREAD

mm in

2. Install the water temperature sender unit.


120—180 kgf·cm, 105—156 in·lbf

3. Connect the water temperature sender unitconnector.


WATER TEMPERATURE SENDER UNITINSPECTION

1. Remove the water temperature sender unit.2. Place the sender unit in a container of water.3. Heat the water gradually.4. Using an ohmmeter, measure and verify that the

resistance between terminal of the sender unit andthe sender unit body is as shown below.

Water temperature ( °C °F ) Resistance ( Ω)

49.8—50.2 121.7—122.3 189.4—259.6

5. If not as specified, replace the water temperaturesender unit.

OIL PRESSURE SWITCH INSPECTION1. Verify that the oil pressure warning light illuminates

when the ignition switch is turned to ON position.2. Verify that the oil pressure warning light goes off

when the engine is started.3. If the oil pressure warning light does not illuminate

or remains illuminated, inspect the oil pressurewarning light bulb and related wiring harness.

4. If the oil pressure warning light bulb and relatedwiring harness are normal, inspect the oil pressure.(Refer to section D, LUBRICATION SYSTEM, OILPRESSURE INSPECTION.)

5. If the oil pressure is normal, replace the oilpressure switch.

HORN REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Disconnect the horn connector.3. Remove the bolt.4. Remove the horn.

HORN

BOLT

HORN CONNECTOR


HORN RELAY REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the driver-side front side trim.



CONTINUED

REMOVAL/INSTALLATION.) (Refer to section F2,DISASSEMBLY/ASSEMBLY.) (Refer to section F2,


WARNING AND INDICATOR SYSTEM, AUDIO

T–26


1 Nut

2 Horn relay connector

3 Horn relay

HORN RELAY INSPECTION1. Remove the horn relay.

(Refer to HORN RELAY REMOVAL/INSTALLATION.)2. Inspect for continuity between the horn relay

terminals using an ohmmeter.: Continuity B+: Battery positive voltage

StepTerminal

StepA B C D

1

2 B+ GND

AD

C B

A

BD

C

3. If not as specified, replace the horn relay.

CLOCK REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the meter hood.


3. Remove the screws and remove the clock.

CLOCK SCREWSCREW


AUDIOAUDIO UNIT REMOVAL

1. Disconnect the negative battery cable.2. With the beveled parts of the SST (Removing tool)

facing inward, insert them into the unit.3. Pull the SST (Removing tool) outward and

rearward to slide out the unit.

49 D066 801A

4. Disconnect the connectors and antenna jack.

AUDIO UNIT INSTALLATION

Caution If the harness or the antenna feeder is

caught between the unit and dashboard, itmay become the cause of trouble ormalfunctions. Make certain that the wiringharness and antenna feeder are not caughtbetween the unit and dashboard.

1. Connect the connectors and antenna jack.2. Insert the unit until each clip clicks.3. Connect the negative battery cable.

SPEAKER REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the front door trim.

(Refer to section S, TRIM, FRONT DOOR TRIMREMOVAL/INSTALLATION.)

Caution When removing or installing a speaker,

touching the radio cone paper could causepoor sound quality. When removing orinstalling a speaker, hold the speaker’sbracket and handle with care.



CONTINUED


123456567

R

123456567

AUDIO

T–27

1 Screw

2 Speaker+ Installation Note

3 Connector

Speaker Installation Note When installing the speakers, position the

speakers so that the terminals face downward.

SPEAKER INSPECTION1. Remove the speaker.

(Refer to SPEAKER REMOVAL/INSTALLATION.)2. Inspect for resistance between the speaker


: Resistance

Test conditionTerminal

Test conditionA B

ConstantR: 4 Ω

3. Touch the leads of an ohmmeter to the speakerterminals and verify that the speaker clicks.

Range1 Ω

4. If not as specified, replace the speaker.

ROOF ANTENNA REMOVAL1. Disconnect the negative battery cable.2. Remove the driver-side front side trim.

(Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.)

3. Disconnect the connection between the roofantenna and the antenna feeder.

ROOF ANTENNA

ANTENNAFEEDER

4. Remove the screws and pull out the roof antenna.

ROOF ANTENNA

SCREW

ROOF ANTENNA INSTALLATION1. Tape the antenna jack to the antenna drain hose.

2. Pass the roof antenna and antenna drain hosethrough the A-pillar from the hole in the roof.

3. Connect the antenna feeder.4. Install the screws.5. Install the driver-side front side trim.



ROOF ANTENNA INSPECTION1. Disconnect the negative battery cable.2. Remove the driver-side front side trim.


3. Disconnect the connection between the roofantenna and the antenna feeeder.

4. Verify that there is no continuity between roofantenna terminals A and B using an ohmmeter.

5. Inspect for continuity between the roof antennaterminals using an ohmmeter.

: Continuity

StepTerminal

StepA B C D

1

2

B

A

C

D


CONTINUED


123456567

AUDIO

T–28

6. If not as specified, replace the roof antenna.

ANTENNA FEEDER REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the driver-side front side trim.

(Refer to section S, TRIM, FRONTSIDE TRIM REMOVAL/INSTALLATION.)

3. Disconnect the connection between the antennafeeder and the roof antenna.


1 Clip

2 Antenna feeder

ANTENNA FEEDER INSPECTION1. Disconnect the negative battery cable.2. Remove the driver-side front side trim.


3. Disconnect the connection between the antennafeeder and the roof antenna.

4. Verify that there is no continuity between theantenna feeder terminals A and B using anohmmeter.

5. Inspect for continuity between the antenna feederterminals using an ohmmeter.

: Continuity

StepTerminal

StepA B C D

1

2

CDB

A

6. If not as specified, replace the antenna feeder.

CONDENSER REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.

IGNITIONCOIL

1 Screw

2 Clip

3 Nut

4 Condenser


CONTINUED


U–1

HEATER AND AIRCONDITIONER SYSTEMS

SERVICE WARNINGS U–2. . . . . . . . . . . . . . . . . . . . . . . HANDLING REFRIGERANT U–2. . . . . . . . . . . . . . . . STORING REFRIGERANT U–2. . . . . . . . . . . . . . . . .

SERVICE CAUTIONS U–2. . . . . . . . . . . . . . . . . . . . . . . HANDLING COMPRESSOR OIL U–2. . . . . . . . . . . .

REFRIGERANT SYSTEM SERVICE PROCEDURES U–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANIFOLD GAUGE SET INSTALLATION U–3. . . . RECOVERY U–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING U–3/5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REFILLING U–5/6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REFRIGERANT CHARGE CHECK U–6/7. . . . . . . . . . REFRIGERANT PRESSURE CHECK U–7. . . . . . . PERFORMANCE TEST U–7. . . . . . . . . . . . . . . . . . . .

BASIC SYSTEM U–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . STRUCTURAL VIEW U–8/9. . . . . . . . . . . . . . . . . . . . . . BLOWER UNIT REMOVAL/INSTALLATION U–10. . BLOWER UNIT DISASSEMBLY/ASSEMBLY U–10. COOLING UNIT REMOVAL/INSTALLATION U–10/11. . COOLING UNIT DISASSEMBLY/ASSEMBLY U–12. EVAPORATOR INSPECTION U–13. . . . . . . . . . . . . . HEATER UNIT REMOVAL/INSTALLATION U–13. . . HEATER UNIT DISASSEMBLY/ASSEMBLY U–14. . HEATER CORE INSPECTION U–15. . . . . . . . . . . . . . A/C COMPRESSOR

REMOVAL/INSTALLATION U–15. . . . . . . . . . . . . . . CONDENSER REMOVAL/INSTALLATION U–16. . . CONDENSER INSPECTION U–16. . . . . . . . . . . . . . . RECEIVER/DRIER

REMOVAL/INSTALLATION U–16/17. . . . . . . . . . . . . . . REFRIGERANT LINES

REMOVAL/INSTALLATION U–17/18. . . . . . . . . . . . . . . CONTROL SYSTEM U–19. . . . . . . . . . . . . . . . . . . . . . . .

STRUCTURAL VIEW U–19. . . . . . . . . . . . . . . . . . . . . . MAGNETIC CLUTCH

DISASSEMBLY/ASSEMBLY U–20. . . . . . . . . . . . . . MAGNETIC CLUTCH CLEARANCE

ADJUSTMENT U–20/21. . . . . . . . . . . . . . . . . . . . . . . . . . MAGNETIC CLUTCH INSPECTION U–21. . . . . . . . . A/C RELAY No.1

REMOVAL/INSTALLATION U–21. . . . . . . . . . . . . . . A/C RELAY No.1 INSPECTION U–22. . . . . . . . . . . . . A/C RELAY No.2

REMOVAL/INSTALLATION U–22. . . . . . . . . . . . . . . A/C RELAY No.2 INSPECTION U–22. . . . . . . . . . . . . REFRIGERANT PRESSURE SWITCH

REMOVAL/INSTALLATION U–22. . . . . . . . . . . . . . . REFRIGERANT PRESSURE SWITCH

INSPECTION U–23. . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSWITCH INSPECTION U–23/24. . . . . . . . . . . BLOWER MOTOR

REMOVAL/INSTALLATION U–24. . . . . . . . . . . . . . . BLOWER MOTOR INSPECTION U–24. . . . . . . . . . . RESISTOR REMOVAL/INSTALLATION U–24. . . . . . RESISTOR INSPECTION U–25. . . . . . . . . . . . . . . . . . CLIMATE CONTROL UNIT REMOVAL U–25. . . . . . CLIMATE CONTROL UNIT INSTALLATION U–25. . CLIMATE CONTROL UNIT

DISASSEMBLY/ASSEMBLY U–25/26. . . . . . . . . . . . . . CLIMATE CONTROL UNIT WIRE

ADJUSTMENT U–26/27. . . . . . . . . . . . . . . . . . . . . . . . . . CLIMATE CONTROL UNIT INSPECTION U–27. . . .

TROUBLESHOOTING U–28. . . . . . . . . . . . . . . . . . . . . . . FOREWORD U–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING INDEX U–28. . . . . . . . . . . . . . SYMPTOM TROUBLESHOOTING U–28/39. . . . . . . . . .

BACK.TO.MAIN.INDEX

CONTINUED


SERVICE WARNINGS, SERVICE CAUTIONS

U–2

SERVICE WARNINGSHANDLING REFRIGERANT Avoid breathing air conditioning refrigerant or

lubricant vapor. Exposure may irritate eyes,nose and throat. If accidental system dischargeoccurs, ventilate work area before resumingservice.

Do not pressure test or leak test R-134a serviceequipment and/or vehicle air conditioningsystem with compressed air. Some mixtures ofair and R-134a have been shown to becombustible at elevated pressures. Thesemixtures, if ignited, may cause injury orproperty damage. Additional health and safetyinformation may be obtained from refrigerantmanufacturers.

Do not allow the refrigerant to leak near fire orany kind of heat. A poisonous gas may begenerated if the refrigerant gas contacts fire orheat such as from cigarettes and heaters.When carrying out any operation that cancause refrigerant leakage, extinguish orremove the above-mentioned heat sources andmaintain adequate ventilation.

Handling liquid refrigerant is dangerous. Adrop of it on the skin can result in localizedfrostbite. When handling the refrigerant, weargloves and safety goggles. If refrigerantsplashes into the eyes, immediately wash themwith clean water and consult a doctor.

STORING REFRIGERANT The refrigerant container is highly pressurized.

If it is subjected to high heat, it could explode,scattering metal fragments and liquidrefrigerant that can seriously injure you. Storethe refrigerant at temperatures below 40 °C104 °F.

SERVICE CAUTIONSHANDLING COMPRESSOR OIL Use FD46XG (G6, WL, WL turbo) or ZXL 100PG

(F2, F2 Cab) compressor oil for this vehicle.Using a PAG oil other than FD46XG (G6, WL,WL turbo) or ZXL 100PG compressor oil candamage the A/C compressor.

Do not spill compressor oil on the vehicle. Adrop of compressor oil on the vehicle surfacecan eat away at the paint. If oil gets on thevehicle, wipe it off immediately.

FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2,F2 Cab) compressor oil (PAG oil) has a highermoisture absorption efficiency than thepreviously used mineral oil. If moisture mixeswith the compressor oil, the refrigerant systemcould be damaged. Therefore, install capsimmediately after using the compressor oil orremoving refrigerant system parts to preventmoisture absorption.

MOISTURE ABSORPTION

FD46XG (G6, WL, WL turbo) or ZXL100PG (F2, F2 Cab) COMPRESSOROIL

MINERAL OIL

TIME


CONTINUED


REFRIGERANT SYSTEM SERVICE PROCEDURES

U–3

REFRIGERANT SYSTEM SERVICEPROCEDURESMANIFOLD GAUGE SET INSTALLATION

1. Fully close the valves of the SST (49 C061 001).2. Connect the SSTs (49 C061 002, 49 C061 003) to

the high- and low-pressure side joints of the SST (49 C061 001).

3. Connect the SSTs (49 C061 006A, 49 C061 007)to the ends of the SSTs (49 C061 002, 49 C061 003).

4. Connect the SSTs (49 C061 006A, 49 C061 007)to the charging valves.

49 C061 001

49 C061 006A

49 C061 002

49 C061 003

49 C061 007CAP

CHARGINGVALVE OFHIGH-PRESSURESIDECHARGING VALVE OF

LOW-PRESSURE SIDE

CAP

RECOVERYConnect an R-134a recovery/recycling/rechargingdevice to the vehicle and follow the devicemanufacturer’s instructions.

CHARGINGCharging Recycled R-134a RefrigerantConnect an R-134a recovery/recycling/rechargingdevice to the vehicle and follow the devicemanufacturer’s instructions.

Charging New R-134a Refrigerant

Caution Do not exceed the specification when

charging the system with refrigerant. Doingso will decrease the efficiency of the airconditioner or damage the refrigerationcycle parts.

1. Install the SSTs (Manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.)

2. Connect the tap pin side of the SST (49 C061 004)to the air purge valve of the SST (49 C061 001).

3. Connect the SST (49 C061 005) to the center jointof the SST (49 C061 001).

4. Connect the SST (49 C061 005) to the vacuumpump.

5. Connect the SST (49 C061 004) to the refrigeranttank.

6. Place the refrigerant tank on the scale.

Regular amount of refrigerant550 g 19.4 oz

49 C061 004

49 C061 001

49 C061 005

TAP PIN SIDE AIR PURGE VALVE

REFRIGERANTTANK

SCALE

VACUUM PUMP

7. Open all the valves of the SST (49 C061 001).

Caution Close the SST (49 C061 001) valve

immediately after stopping the vacuumpump. If the valve is left open, the vacuumpump oil will flow back into the refrigerationcycle and cause a decrease in the efficiencyof the air conditioner.

8. Start the vacuum pump and let it operate for 15 minutes .

49 C061 001

CLOSE

9. Verify that high- and low-pressure side readings ofthe SST (49 C061 001) are at –101 kPa –760 mmHg, –29.9 inHg . Close each valve ofthe SST (49 C061 001).

49 C061 001

10. Stop the vacuum pump and wait for 5 minutes .11. Check the high- and low-pressure side readings of

the SST (49 C061 001). If the reading haschanged, inspect for leakage and then repeat fromstep 7. If the reading has not changed, go to step12.

12. Open the valve of the refrigerant tank.13. Weigh the refrigerant tank.


CONTINUED



U–4

Warning If the refrigerant system is charged with a

large amount of refrigerant when checkingfor gas leakage, and if any leakage shouldoccur, the refrigerant will be released intothe atmosphere. In order to prevent theaccidental release of refrigerant which candestroy the ozone layer in the stratosphere,follow the proper procedures and chargewith only a small amount of refrigerantwhen checking for gas leakage.

If charging the system with refrigerantusing service cans, running the engine withthe high-pressure side valve open isdangerous. Pressure within the servicecans will increase and the cans couldexplode, scattering metal fragments andliquid refrigerant that can seriously injureyou. Therefore, do not open thehigh-pressure side valve while the engine isrunning.

14. Open the high-pressure side valve of the SST (49 C061 001).

49 C061 001

OPEN

15. When the low-pressure side reading increases to0.098 MPa 1.0 kgf/cm 2, 14 psi , close thehigh-pressure side valve of the SST (49 C061 001).

49 C061 001

16. Inspect for leakage from the cooler pipe/hoseconnections using the SST (Gas leak tester). Ifthere is no leakage, go to step 17. If a leakage isfound at a loose joint, tighten the joint and inspectfor leakage again. If there is still leakage at thesame joint, discharge the refrigerant and thenrepair the joint. Repeat the charging procedurefrom step 7. If there is no leakage after tighteningthe joint, go to step 17.

Warning If charging the system with refrigerant

using service cans, running the engine withthe high-pressure side valve open isdangerous. Pressure within the servicecans will increase and the cans couldexplode, scattering metal fragments andliquid refrigerant that can seriously injureyou. Therefore, do not open thehigh-pressure side valve while the engine isrunning.

17. Open the high-pressure side valve of the SST (49 C061 001) and charge with refrigerant until theweight of refrigerant tank has decreased 300 g10.6 oz from the amount in step 13.

49 C061 001

OPEN

18. Close the high-pressure side valve of the SST (49 C061 001).

49 C061 001



19. Start the engine and actuate the A/C compressor.20. Open the low-pressure side valve of the

SST (49 C061 001) and charge with refrigerant until therefrigerant tank is empty.


CONTINUED



U–5

49 C061 001

OPEN

21. Close the low-pressure side valve of the SST (49 C061 001) and the valve of the refrigerant tank.

22. Stop the engine and A/C compressor.23. Inspect for leakage using the SST (Gas leak

tester). If there is no leakage, go to step 24. Ifleakage is found at a loose joint, tighten the jointand inspect for leakage again. If there is still a leakat the same joint, discharge the refrigerant andthen repair the joint. Repeat the chargingprocedure from step 7. If there is no leakage aftertightening the joint, go to step 24.

24. Disconnect the SSTs (49 C061 006A, 49 C061 007) from the charging valves.

25. Install the caps to the charging valves.

49 0061 00749 C061 006A

CAP

CAP

REFILLING

Caution Do not exceed the specification when

charging the system with refrigerant. Doingso will decrease the efficiency of the airconditioner or damage the refrigerationcycle parts.

1. Install the SSTs (Manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.)

2. Connect the tap pin side of the SST (49 C061 004)to the air purge valve of the SST (49 C061 001).

3. Connect the SST (49 C061 005) to the center jointof the SST (49 C061 001).

4. Connect the SST (49 C061 005) to the vacuumpump.

5. Connect the SST (49 C061 004) to the refrigeranttank.

49 C061 004

49 C061 001

49 C061 005

TAP PIN SIDE AIR PURGE VALVE

REFRIGERANTTANK

VACUUM PUMP

6. Open only the center valve of the SST (49 C061(49 C061 001).

Caution Close the SST (49 C061 001) valve

immediately after stopping the vacuumpump. If the valve is left open, the vacuumpump oil will flow back into the refrigerationcycle and cause a decrease in the efficiencyof the air conditioner.

7. Start the vacuum pump and let it run for 1 minute .

49 C061 001

CLOSE

8. Close the center valve of the SST (49 C061 001).

49 C061 001

9. Stop the vacuum pump.10. Open the valve of the refrigerant tank.




CONTINUED



U–6

11. Start the engine and actuate the A/C compressor.12. Open the low-pressure side valve of the

SST (49 C061 001).

49 C061 001

OPEN

13. Refer to refrigerant charge check and refill with refrigerant.

SIGHT GLASS

L.H.D.

SIGHT GLASS

R.H.D. (WL, G6, F2 Cab)

SIGHT GLASS

R.H.D. (WL turbo)

14. Close the low-pressure side valve of the SST (49 C061 001) and the valve of the refrigerant tank.

15. Stop the engine and the A/C compressor.16. Disconnect the SSTs (49 C061 006A,

49 C061 007) from the charging valves.17. Install the caps to the charging valves.

CAP

CAP

49 C061 007 49 C061 006A

REFRIGERANT CHARGE CHECK

Caution The FD46XG (G6, WL, WL turbo) or ZXL

100PG (F2, F2 Cab) compressor oil willseparate from refrigerant at hightemperatures of 50 °C 122 °F or more. Ifthis happens, the sight glass will change toa milky-white color, and there is apossibility that you might mistakenlybelieve the refrigerant amount to beinsufficient and recharge with additionalrefrigerant.If the system is overcharged withrefrigerant, the sight glass will becomeclear and give a false indication. You willmistakenly believe that the refrigerantamount is correct. Therefore, when checking the refrigerantamount, verify the refrigerant pressure andcooler pipe temperature in addition to thesight glass condition.

1. Warm up the engine and run it at a constant 1,500 rpm .

2. Set the fan switch at 4th.3. Set the temperature control dial to MAX COLD.4. Close all the doors and windows.5. Check the refrigerant amount condition according

to the following table.


CONTINUED



U–7

Amount Condition ofsight glass

Other conditions

Insufficient

Bubbles

High-pressure side coolerpipe is warm;low-pressure side coolerpipe is cool.

High- and low-pressureside readings are lowerthan normal.

Air cooling ability is low.

CorrectClear

Milky white

High-pressure side coolerpipe is hot; low-pressureside cooler pipe is cold.

High- and low-pressureside readings are normal.

* If sight glass ismilky-white, pour waterinto condenser forapproximately 20seconds to cool it off,then the sight glass willclear.

Over

Clear

High-pressure side coolerpipe is hot; low-pressureside cooler pipe is cold.

High- and low-pressureside reading are higherthan normal.

Air cooling ability is low.

6. If not as specified, troubleshoot the refrigerantsystem. (Refer to TROUBLESHOOTING.)

REFRIGERANT PRESSURE CHECK1. Install the SSTs (Manifold gauge set).

(Refer to MANIFOLD GAUGE SET INSTALLATION.)2. Open the bonnet.3. Close all the doors and windows.4. Warm up the engine and run it at a constant

1,500 rpm .5. Set the fan switch at 4th.6. Set the temperature control dial to MAX COLD.7. Measure the ambient temperature and the high-

and low-pressure side reading of the SST (49 C061 001).

8. Verify that the intersection of the pressure readingof the SST (49 C061 001) and ambienttemperature is in the shaded zone.

PRESSURE READING OF MANIFOLD GAUGE

HIGH-PRESSURE SIDE

LOW-PRESSURE SIDE

AMBIENT TEMPERATURE

2.021, 299

Mpakgf/cm 2, psi

2068

0.22.0, 28

1.515, 213

0.11.0, 14

40104

2577

3086

3595

°C°F

1.010, 142

9. If not as specified, troubleshoot the refrigerantsystem. (Refer to TROUBLESHOOTING.)

PERFORMANCE TEST

Note After servicing the refrigerant system, the test

is performed.

1. Install the SSTs (manifold gauge set).(Refer to MANIFOLD GAUGE SET INSTALLATION.)

2. Open the bonnet.3. Close all the doors and windows.4. Warm up the engine and run it at a constant

1,500 rpm .5. Set the fan switch at 4th.6. Set the temperature control dial to MAX COLD.7. Record center ventilator right side temperature.8. Determine and record ambient temperature.9. Verify that the temperature reading is in the shaded

zone.

AMBIENT TEMPERATURE

2068

40104

2577

3086

3595

°C°F

CENTER VENTILATORTEMPERATURE

°C °F

0 321 342 363 374 395 416 43

10. If the performance is not within the shaded zone,troubleshoot the refrigerant system. (Refer to TROUBLESHOOTING.)


CONTINUED


BASIC SYSTEM

U–8

BASIC SYSTEMSTRUCTURAL VIEW

L.H.D. (G6)

L.H.D. (WL, WL turbo)

RECEIVER/DRIER

CONDENSER

COOLERHOSE(HIGH)

COOLERPIPE(HIGH)

A/CCOMPRESSOR

HEATERHOSE

COOLERPIPE(LOW)

HEATER UNIT

COOLING UNIT

BLOWER UNIT

BLOWER UNIT

COOLING UNIT

HEATER UNIT

HEATERHOSE

COOLERPIPE(LOW)

COOLERPIPE(HIGH)

CONDENSER

RECEIVER/DRIER

A/CCOMPRESSOR

COOLERHOSE(LOW)

L.H.D. (F2, F2 Cab)

BLOWER UNIT

COOLING UNIT

HEATER UNIT

COOLERPIPE(LOW)

COOLERPIPE(HIGH)

HEATERHOSE

A/CCOMPRESSOR

COOLERHOSE(HIGH)

CONDENSER

RECEIVER/DRIER


CONTINUED


BASIC SYSTEM

U–9

COOLING UNIT

SIGHT GLASSCOOLERPIPE(HIGH)

HEATER UNIT

COOLERHOSE (LOW)

CONDENSER

RECEIVER/DRIER

A/CCOMPRESSOR

COOLERHOSE (HIGH)

HEATERHOSE

R.H.D. (WL, WL turbo)

WL turbo

BLOWER UNIT

R.H.D. (G6)

HEATER UNIT

COOLING UNITHEATERHOSE

BLOWER UNIT

COOLERPIPE(HIGH)

COOLERHOSE(LOW)

A/CCOMPRESSOR

CONDENSER

COOLERHOSE (HIGH)

RECEIVER/DRIER

R.H.D. (F2 Cab)

HEATER UNIT

COOLING UNIT

BLOWER UNIT

COOLERPIPE(HIGH)

COOLERHOSE (LOW)

A/CCOMPRESSOR

CONDENSER

RECEIVER/DRIER

HEATERHOSE


CONTINUED


BASIC SYSTEM

U–10

BLOWER UNIT REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the glove compartment.3. Remove the cooling unit.

(Refer to COOLING UNIT REMOVAL/INSTALLATION.)4. Remove the passenger’s side front side trim

(L.H.D. only.)5. Remove as indicated in the table.6. Install in the reverse order of removal.

1 Connector

2 Blower unit

BLOWER UNIT DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.

AA

B

B

C

C

L.H.D.

AA

B

B

C

C

R.H.D.

1 Blower motor

2 Resistor

3 Blower harness

4 Polyurethane protector

5 Inlet duct case (front)

6 Inlet duct case (rear)

7 Blower case (upper)

8 Blower case (lower)

9 Air intake door

10 Air intake link

11 Air intake crank

COOLING UNIT REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Discharge the refrigerant from the system.

(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, RECOVERY.)

(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, CHARGING.)

3. Remove the glove compartment.4. Disconnect the air intake wire from the cooling unit.

(Refer to CONTROL SYSTEM, CLIMATECONTROL UNIT WIRE ADJUSTMENT.)

Caution If moisture or foreign material enters the

refrigeration cycle, cooling ability will belowered and abnormal noise will occur.Always immediately plug all open fittingsafter removing any refrigeration cycle partsto keep moisture or foreign material out ofthe cycle.


CONTINUED


BASIC SYSTEM

U–11

5. Remove in the order indicated in the table. Do notallow compressor oil to spill.

6. Install in the reverse order of removal.7. Carry out the refrigerant system performance test.

(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, PERFORMANCE TEST.)

L.H.D.

R

15—21 N·m1.5—2.2 kgf·m,130.2—190.9 in·lbf R 6.9—9.8 N·m

0.7—1.0 kgf·m,60.8—86.7 in·lbf

9.81—19.61 N·m100—200 kgf·cm,86.8—173.5 in·lbf

20—29 N·m2.0—3.0 kgf·m,15—21 ft·lbf

R

R

R.H.D.

1 Cooler hose (low)+ REFRIGERANT LINES

REMOVAL/INSTALLATION, Refrigerant LinesRemoval Note

+ REFRIGERANT LINESREMOVAL/INSTALLATION, Refrigerant LinesInstallation Note

2 Cooler pipe (high)+ REFRIGERANT LINES

REMOVAL/INSTALLATION, Refrigerant LinesRemoval Note

+ REFRIGERANT LINESREMOVAL/INSTALLATION, Refrigerant LinesInstallation Note

3 Connector

4 Cooling unit+ Removal Note+ Installation Note

Cooling Unit Removal Note (R.H.D. only) Turn the cooling unit 90 degrees to the right, and

remove the cooling unit.

Cooling Unit Installation Note When installing a new cooling unit (evaporator),

add FD46XG (G6, WL, WL turbo) or ZXL 100PG(F2, F2 Cab) compressor oil into the refrigerationcycle.

Supplement amount40 ml 40 cc, 1.4 fl oz


CONTINUED


BASIC SYSTEM

U–12

COOLING UNIT DISASSEMBLY/ASSEMBLY



1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.L.H.D.

R.H.D.

1 Cooler case (upper)

2 Cooler case (lower)

3 Thermoswitch clip

4 Thermoswitch+ Assembly Note

5 Evaporator

6 Expansion valve+ Assembly Note

7 High pressure pipe

Expansion Valve Assembly Note Replace the O-rings at the expansion valve joints

and apply compressor oil to the O-rings andconnect the joints.

Tighten the joint to the specified torque using twoopen-end wrenches.

Assemble the heat-sensing tube as shown in thefigure.

20—24 N·m2.0—2.5 kgf·m,15—18 ft·lbf

11.8—14.7 N·m120—150 kgf·cm,105—130 in·lbf

HEAT-SENSING TUBE

Thermoswitch Assembly Note1. Insert the thermoswitch probe in location as shown

in the figure.

40 mm1.6 in

EVAPORATOR


CONTINUED


BASIC SYSTEM

U–13

EVAPORATOR INSPECTION1. Remove the cooling unit.

(Refer to COOLING UNIT REMOVAL/INSTALLATION.)2. Remove the evaporator from the cooling unit.3. Inspect for cracks, damage, and oil leakage. If any

problems are found, replace the evaporator.4. Inspect for bent fins. If they are bent, use a

flat-head screwdriver to straighten them.

HEATER UNIT REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Drain the engine coolant.

(Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) (With heater core only)

3. Remove the dashboard. (Refer to section S, DASHBOARD AND CONSOLE, DASH BOARD REMOVAL/INSTALLATION.)


*

* WITH HEATER CORE ONLY

1 Heater hose

2 Heater unit


CONTINUED


BASIC SYSTEM

U–14

HEATER UNIT DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.

*

**

* *

*

* WITH HEATER CORE ONLY

1 Heater core

2 Air mix rod

3 Air mix link

4 Air mix crank (1)

5 Air mix crank (2)

6 Air mix shaft

7 Airflow mode main link

8 Airflow mode crank (1)




12 Airflow mode sub link (1)

13 Airflow mode sub link (2)

14 Heater case (1)

15 Heater case (2)

16 Heater case (3)


CONTINUED


BASIC SYSTEM

U–15

HEATER CORE INSPECTION1. Remove the heater unit.

(Refer to HEATER UNIT REMOVAL/INSTALLATION.)2. Remove the heater core from the heater unit.3. Inspect for cracks, damage, and coolant leakage. If

any are found, replace the heater core.4. Inspect for bent fins. If any are bent, use a flathead

screwdriver to straighten them.5. Verify that the heater core inlet and outlet are not

distorted or damaged. Repair with pliers if necessary.

A/C COMPRESSOR REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Discharge the refrigerant from the system.

(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.)

3. Remove the drive belt (P/S + A/C).4. Remove the air cleaner and air hose. (WL turbo

only) (Refer to section F2, INTAKE-AIR SYSTEM,INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)

5. Loosen the A/C compressor bolts, then slide theA/C compressor. (WL turbo only)


refrigeration cycle, cooling ability will belowered and abnormal noise will occur.Always immediately plug all open fittings afterremoving any refrigeration cycle parts to keepmoisture or foreign material out of the cycle.


7. Install in the reverse order of removal.8. Adjust the drive belt (P/S + A/C). (Refer to section

B2, DRIVE BELT, DRIVE BELT ADJUSTMENT.)9. Carry out the refrigerant system performance test.


R

R

15—211.5—2.2,11—15


24—352.4—3.6,18—26

G6, WL, WL turbo

F2, F2 Cab


30—393.0—4.0,22—28

R

1 Connector

2 Cooler hose (high)+ REFRIGERANT LINES

REMOVAL/INSTALLATION, Refrigerant LinesInstallation Note

3 Cooler hose (low)+ REFRIGERANT LINES


4 A/C compressor+ Installation Note

A/C Compressor Installation Note Remove the following amount of compressor oil

from the new A/C compressor when replacing theA/C compressor.

Compressor oil to be removed = 180 ml 180 cc, 6.08 fl oz – [compressor oil from oldA/C compressor + 15 ml 15 cc, 0.5 fl oz ]


CONTINUED


BASIC SYSTEM

U–16

CONDENSER REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Discharge the refrigerant from the system.

(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, RECOVERY.) (Refer toREFRIGERANT SYSTEM SERVICEPROCEDURES, CHARGING.)

3. Remove the radiator grille.4. Remove the charge air cooler and air hose. (WL

turbo only)(Refer to section F2, INTAKE-AIR SYSTEM,INTAKE-AIR SYSTEMREMOVAL/INSTALLATION.)

5. Remove the receiver/drier. (Refer to RECEIVER/DRIER REMOVAL/INSTALLATION.)






D

B

C

B

A

D

A

15—21 N·m1.5—2.2 kgf·m,11—15 ft·lbf

C

R

1 Cooler pipe+ REFRIGERANT LINES


2 Bonnet lock stay

3 Condenser+ Installation Note

Condenser Installation Note When installing a new condenser, add FD46XG

(G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab)compressor oil into the refrigeration cycle.

Supplemental amount30 ml 30 cc, 1.0 fl oz

CONDENSER INSPECTION1. Inspect for cracks, damage, and oil leakage. If any

problems are found, replace the condenser.2. Inspect for fins clogged by dust. If any are clogged,

remove the dust from the fins.3. Inspect for bent fins. If any are bent, use a flathead

screwdriver to straighten them.

RECEIVER/DRIER REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Discharge the refrigerant from the system. (Refer to

REFRIGERANT SYSTEM SERVICE PROCEDURES,RECOVERY.) (Refer to REFRIGERANT SYSTEMSERVICE PROCEDURES, CHARGING.)

3. Remove the radiator grille.






R

R

6.85—9.80 N·m70—100 kgf·cm, 60.8—86.7 in·lbf


CONTINUED


BASIC SYSTEM

U–17

1 Connector

2 Cooler pipe+ REFRIGERANT LINES


3 Condenser+ CONDENSER REMOVAL/INSTALLATION,

Condenser Installation Note

4 Receiver/drier+ Installation Note

Receiver/drier Installation Note When installing a new receiver/drier, add FD46XG

(G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab)compressor oil into the refrigeration cycle.

Supplemental amount35 ml 35 cc, 1.2 fl oz

REFRIGERANT LINES REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Discharge the refrigerant from the system.




3. Remove the radiator grille.4. Remove the front bumper.

(Refer to section S, BUMPER, FRONT BUMPERREMOVAL/INSTALLATION.)

5. Remove the radiator. (WL turbo only)6. Remove in the order indicated in the table. Do not

allow compressor oil to spill.7. Install in the reverse order of removal.8. Carry out the refrigerant system performance test.


B

A

C E

E

A

B

C

D

DF

F

RR

R

R

B

E

R

A

C

R

B

R

RA

C

D

R

R

AB

L.H.D.


CONTINUED


BASIC SYSTEM

U–18

A: 6.85—9.80 N·m 70—100 kgf·cm, 60.8—86.7 in·lbfB: 15—21 N·m 1.5—2.2 kgf·m, 11—15 ft·lbfC: 20—29 N·m 2.0—3.0 kgf·m, 15—21 ft·lbfD: 9.81—19.61 N·m 100—200 kgf·cm, 86.8—173.5 in·lbfE: 24—35 N·m 2.4—3.6 kgf·m, 18—26 ft·lbf

B

CA

D

B

A

DC

R

R

B

B

E

R RD

C

A

R

R

R.H.D.

1 Cooler hose (low)+ Removal Note+ Refrigerant Lines Removal Note+ Refrigerant Lines Installation Note

2 Cooler hose (high)+ Removal Note+ Refrigerant Lines Installation Note

3 Cooler pipe (high)+ Refrigerant Lines Removal Note+ Refrigerant Lines Installation Note

Cooler Hose Removal NoteWL turbo only Loosen the A/C compressor bolts, then slide the

A/C compressor, and remove the cooler hose boltfrom the A/C compressor.

Refrigerant Lines Removal Note Loosen the nut using two spanners, then remove

the cooler pipe or hose.

Refrigerant Lines Installation Note1. When installing a new cooler pipe or hose, add

FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2Cab) compressor oil into the refrigeration cycle.

Supplemental amountCooler hose (low): 8 ml 8 cc, 0.3 fl ozCooler hose (high): 5 ml 5 cc, 0.2 fl ozCooler pipe: 3 ml 3 cc, 0.1 fl oz

2. Apply compressor oil to the O-rings and connectthe joints.

3. Tighten the joints.(1) Tighten the nut or bolt of the joint by hand.(2) Tighten the joint to the specified torque. If it is a

nut joint, tighten the nut using a spanner andtorque wrench.


CONTINUED


CONTROL SYSTEM

U–19

CONTROL SYSTEMSTRUCTURAL VIEW

L.H.D.

REFRIGERANT PRESSURE SWITCHA/C RELAY No.2*

A/C RELAY No.1 MAGNETIC CLUTCH

CLIMATECONTROL UNIT

RESISTOR

BLOWER MOTOR

THERMOSWITCH

R.H.D.

MAGNETIC CLUTCH

A/C RELAY No.2*

REFRIGERANT PRESSURE SWITCH

A/C RELAY No.1 CLIMATECONTROL UNIT

THERMOSWITCH

RESISTOR

BLOWER MOTOR

* F2 Cab only


CONTINUED


CONTROL SYSTEM

U–20

MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.3. Adjust the magnetic clutch clearance.

(Refer to MAGNETIC CLUTCH CLEARANCE ADJUSTMENT.)

10.1—15.0 N102—153kgf 89—132in·lbf

1 Bolt+ Removal/Installation Note

2 Pressure plate+ Installation Note

3 Shim

4 Snap ring

5 A/C compressor pulley

6 Stator+ Removal Note+ Installation Note

Bolt Removal/Installation Note When removing or installing the bolt, hold the

pressure plate in place as shown in the table.

A/C COMPRESSORBOLT

Stator Removal Note Set a straight-socket (17 mm 0.67 in) on the shaft

of the A/C compressor to protect it. Remove the stator using a pulley puller as shown

in the table.STRAIGHT-SOCKET(17 mm 0.67 in)

Stator Installation Note Install the stator perpendicularly using the SST and

a pulley puller as shown in the table.

49 H061 005

Pressure Plate Installation Note When installing the pressure plate, carry out

magnetic clutch clearance adjustment.

MAGNETIC CLUTCH CLEARANCE ADJUSTMENTG6, WL, WL turbo Only

1. Set the A/C compressor on a level block.2. Turn on the magnetic clutch by connecting the

battery positive voltage to the magnetic clutchconnector terminal and the ground to the A/Ccompressor body.

3. Fix a dial gauge on a magnetic base and set themeasuring probe onto point A on the pressureplate surface.


CONTINUED


CONTROL SYSTEM

U–21

4. Turn off the magnetic clutch by disconnecting theground from the A/C compressor body, thenmeasure the dial gauge readings.

5. Measure the clearance for point B and C on thepressure plate surface by repeating the abovesteps 2 through 4.

Clearance0.35—0.75 mm 0.014—0.029 in

MEASURING POINT

BA

C

6. If the clearance is not as specified, adjust it bychanging the shim.

Note The seven shim sizes from 0.7 mm 0.028 in

to 1.3 mm 0.051 in differ in 0.1 mm 0.004 inincrements.

F2, F2 Cab Only1. Measure the clearance around the entire

circumference between the pressure plate and A/Ccompressor pulley using a thickness gauge.

2. Verify that the clearance is within the specification.

Clearance0.3—0.6 mm 0.01—0.02 in

3. If not within the specification, remove the pressureplate and adjust the clearance by changing theshim (0.1 mm 0.004 in, 0.3 mm 0.012 in, 0.5mm 0.020 in) or the number of shims.

MAGNETIC CLUTCH INSPECTION1. Disconnect the magnetic clutch connector.2. Connect battery positive voltage to terminal A of

magnetic clutch and ground to the A/C compressorbody.

A

A

3. Verify that the magnetic clutch operates.4. If not as specified, replace the stator.

A/C RELAY No.1 REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.

1 Connector

2 A/C relay No.1


CONTINUED


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CONTROL SYSTEM

U–22

A/C RELAY No.1 INSPECTION1. Remove the A/C relay No.1.2. Inspect for continuity between the A/C relay No.1


StepTerminal

StepA B C D

1

2 B+ GND

D

A

B

C

A

B

C

D

3. If not as specified, replace the A/C relay No.1.

A/C RELAY NO.2 REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.

1 Connector

2 A/C relay No.2

A/C RELAY NO.2 INSPECTION1. Remove the A/C relay No.2.2. Inspect for continuity between the A/C relay No.2


StepTerminal

StepB D A C

1

2 B+ GND

A B

C D

BD

AC

3. If not as specified, replace the A/C relay No.2.

REFRIGERANT PRESSURE SWITCH REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Discharge the refrigerant from the system.


3. Remove the radiator grille.



4. Remove as indicated in the table.5. Install in the reverse order of removal.6. Carry out the refrigerant system performance test.


5.9—7.8 N·m 60—80 kgf·cm,53—69 in·lbf

R

À

1 Connector

2 Refrigerant pressure switch+ Installation Note

Refrigerant Pressure Switch Installation Note Apply compressor oil to the O-ring and connect the

joint.


CONTINUED


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CONTROL SYSTEM

U–23

REFRIGERANT PRESSURE SWITCH INSPECTION1. Install the SSTs (manifold gauge set).

(Refer to MANIFOLD GAUGE SET INSTALLATION.)2. Disconnect the refrigerant pressure switch

connector.3. Verify the high-pressure side reading of the SST

(Manifold gauge).4. Inspect for continuity between the terminals of the

refrigerant pressure switch using an ohmmeter.

0.18—0.21 1.8—2.2, 26—31

CONTINUITY

NO CONTINUITY

0.4—0.7 4.0—8.0, 57—113

3.0—3.330—34, 427—483

0.02 0.25, 3.56OR LESS

MPa kgf/cm 2 , psi

ABAB

5. If not as specified, replace the refrigerant pressureswitch.

THERMOSWITCH INSPECTIONTo Determine if the Switch is Functioning

1. Remove the glove compartment.2. Start the engine.3. Turn the fan switch on.4. Turn the A/C switch on.5. Connect the positive (+) and negative (–) probes of

the voltmeter to terminal A and terminal B of thethermoswitch respectively. (The wiring harnessconnector must be connected to the thermoswitchconnector.)

6. Inspect the voltage as shown below.

WITH HEATER CORE: Continuity

Magnetic cl tchTerminal

Magnetic clutchA C

On

Off

WITHOUT HEATER CORE: Continuity

Magnetic cl tchTerminal

Magnetic clutchA B

On

Off

A B

WITHOUTHEATER CORE

WITH HEATERCORE

A B C

7. If not as specified, inspect on/off points of thethermoswitch.

To Inspect On/Off Points of the Thermoswitch1. Disconnect the negative battery cable.2. Remove the cooling unit

(Refer to BASIC SYSTEM, COOLING UNITREMOVAL/INSTALLATION.)

3. Remove the thermoswitch. (Refer to BASIC SYSTEM, COOLING UNITDISASSEMBLY/ASSEMBLY.)

4. Connect the negative battery cable.5. Connect the thermoswitch connector to the wiring

harness connector.6. Turn the ignition switch to ON position.7. Turn the A/C switch on.8. Turn the fan switch on.9. Immerse the sensor part of thermoswitch in a

container of ice water.10. Connect the positive (+) and negative (–) probes of

the voltmeter to terminal A and terminal B of thethermoswitch respectively.

11. Inspect the voltage as shown below.

WITH HEATER CORE: Continuity

Water temperat reTerminal

Water temperat ureA C

3°C 37°F or more

1°C 34°F or less

WITHOUT HEATER CORE: Continuity

Temperaturecontrol dial Water temperat re

Terminalcontrol dial

positionWater temperat ure

A B

MAX COLD0—3°C 32—37°F

MAX COLD3°C 37°F or more

1/27—11°C 45—52°F

1/211°C 52°F or more

MAX WARM14—18°C 57—64°F

MAX WARM18°C 64°F or more


CONTINUED


CONTROL SYSTEM

U–24

A B

WITHOUTHEATER CORE

WITH HEATERCORE

A B C

12. If not as specified, replace the thermoswitch.(Refer to BASIC SYSTEM, COOLING UNITDISASSEMBLY/ASSEMBLY.)

BLOWER MOTOR REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the glove compartment.3. Remove as indicated in the table.4. Install in the reverse order of removal.

1 Connector

2 Blower motor

BLOWER MOTOR INSPECTION1. Remove the glove compartment.2. Disconnect the blower motor connector.3. Connect battery positive voltage to terminal B and

ground to terminal A of the blower motor, and verifyits operation.

4. If not as specified, replace the blower motor.

RESISTOR REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the glove compartment.3. Remove as indicated in the table.4. Install in the reverse order of removal.

1 Connector

2 Resistor


CONTINUED


CONTROL SYSTEM

U–25

RESISTOR INSPECTION1. Remove the glove compartment.2. Disconnect the resistor connector.3. Verify that the resistance between the terminals of

the resistor is as shown in the table.

Terminal Resistance ( Ω)

1A–1B (2A) R1: 0.43—0.47

1A–1C R2: 1.04—1.16

1C–1D R3: 1.47—1.63

1D 1C 1A 1B 2A

1C 1A

1D 1B

2A

R3 R2 R1

4. If not as specified, replace the resistor.

CLIMATE CONTROL UNIT REMOVAL1. Disconnect the negative battery cable.2. Remove the glove compartment.3. Disconnect the air intake wire from the blower unit.4. Disconnect the air mix wire and airflow mode wire

from the heater unit.5. With the beveled parts of the SST facing inward,

insert them into the climate control unit.6. Pull the SST outward and rearward to slide out the

climate control unit.

49 D066 801A

7. Disconnect the climate control unit connectors.

CLIMATE CONTROL UNIT INSTALLATION1. Connect the climate control unit connectors.2. Insert the climate control unit until each clip clicks.

3. Adjust the wire of the climate control unit. (Refer to CLIMATE CONTROL UNIT WIRE ADJUSTMENT.)

4. Install the glove compartment.5. Connect the negative battery cable.

Climate Control Unit Removal/Installation NoteWith heater core Set the temperature control dial at MAX COLD, the

airflow mode control dial at DEF.

CLIMATE CONTROL UNITDISASSEMBLY/ASSEMBLY


WITH HEATER CORE


CONTINUED


CONTROL SYSTEM

U–26

WITHOUT HEATER CORE

1 Dial

2 Knob+ Removal Note

3 A/C switch

4 Panel

5 Fan switch

6 Climate control unit harness

7 Illumination bulb

8 A/C amplifer

9 Air mix wire

10 Airflow mode wire

11 Air intake wire

11 Cap

13 Body

Knob Removal Note Use a wire to push the knob from the reverse side

and remove it as shown in the figure.

KNOB

WIRE

CLIMATE CONTROL UNIT WIRE ADJUSTMENTAir Intake Wire

1. Set the air intake lever at FRESH.2. Set the air intake link to FRESH in the direction of

the arrow and insert a screwdriver into the set hole.L.H.D.

AIR INTAKE WIRE

SET HOLE

AIR INTAKE WIRE

SET HOLE

R.H.D.

3. Connect the air intake wire to the air intake link.4. Clamp the air intake wire to wire clamp.5. Verify that the air intake lever moves its full stroke.

Air Mix Wire (With heater core only)1. Set the temperature control dial at MAX COLD.2. Set the air mix link to MAX COLD in the direction of

the arrow and insert a screwdriver into the set hole.

SET HOLE

AIR MIX WIRE

3. Connect the air mix wire to the air mix link.4. Clamp the air mix wire to wire clamp.5. Verify that the temperature control dial moves its

full stroke.


CONTINUED


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CONTROL SYSTEM

U–27

Airflow Mode Wire1. Set the airflow mode control dial at DEF.2. Set the airflow mode link to DEF in the direction of

the arrow and insert a screwdriver into the set hole.SET HOLE

AIRFLOW MODE WIRE

3. Connect the airflow mode wire to the airflow modelink.

4. Clamp the airflow mode wire to wire clamp.5. Verify that the airflow mode control dial moves its

full stroke.

CLIMATE CONTROL UNIT INSPECTIONA/C Switch

1. Remove the climate control unit. (Refer to CLIMATE CONTROL UNIT REMOVAL.)

2. Inspect for continuity between the A/C switchterminals using an ohmmeter.

: Continuity

Switch Terminalposition A B

OFF

ON

A C B

B AC

3. Connect battery positive voltage to terminal C andground to the terminal A.

4. Turn the A/C switch on.5. Verify that the LED illuminaltes.6. If not as specified, replace the A/C switch.

Fan Switch1. Remove the climate control unit.

(Refer to CLIMATE CONTROL UNIT REMOVAL.)2. Inspect for continuity between the fan switch


Switch Terminalposition A B C D E F

0

1

2

3

4

0

4 3 2 1

F E B C D A

A

D B

CE

F

3. If not as specified, replace the fan switch.


CONTINUED


TROUBLESHOOTING

U–28

TROUBLESHOOTINGFOREWORD Refer to section GI. Thoroughly read and understand the basic flow of troubleshooting in order to properly

perform the procedures. When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while

doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. Ifthere is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly andundamaged.

The areas for inspection (steps) are given according to various circuit malfunctions. Use the chart below toverify the symptoms of the trouble in order to diagnose the appropriate area.

TROUBLESHOOTING INDEXNo. Malfunction symptom

1 Insufficient blown air volume and/or no blown air depending on airflow mode.

2 No blown air in any airflow mode.Blown air volume does not change at any fan speed.

3 Airflow mode does not change.

4 Improper air circulation and/or no air circulation.

5 No temperature control.(For climate control unit without variable thermistor only)

6 Air from vent not cold enough.

7 No cool air.

8 Noise while operating A/C system.

SYMPTOM TROUBLESHOOTING1 Insufficient blown air volume and/or no blown air depending on airflow mode.

TROUBLESHOOTING HINTS1 Malfunction in VENT mode system

Steps 1—42 Malfunction in HEAT mode system

Step 53 Malfunction in DEFROSTER mode system

Steps 6—8


1 When airflow mode control dial is operated, isappropriate resistance felt and can it be moved

Yes Go to next step.appropriate resistance felt and can it be movedthroughout its full range? No Go to Step 1 of troubleshooting index No. 3.

2 Does air blow out when in VENT mode? Yes Go to Step 5.

No Go to next step.

3 Is vent clogged? Yes Remove obstruction, then go to Step 9.

No Go to next step.

4 Is duct in dashboard properly installed? Yes Inspect duct for clogging, deformity and airleakage, then go to Step 9.

No Install duct securely in the proper position, thengo to Step 9.

5 Does air blow out when in HEAT mode? Yes Go to next step.

No Inspect vent for clogging, then go to Step 9.

6 Does air blow out when in DEFROSTER mode? Yes Operation is okay. Recheck malfunctionsymptoms.

No Go to next step.

7 Is vent clogged? Yes Remove obstruction, then go to Step 9.

No Go to next step.

8 Is defroster duct properly installed? Yes Inspect duct for clogging, deformity, and airleakage, then go to next step.

No Install duct securely in the proper position, thengo to next step.


CONTINUED


CONTROL SYSTEM

U–29


9 Does air blow out? Yes Troubleshooting completed. Explain repairs tocustomer.

No Recheck malfunction symptoms, then repeat fromStep 1 if malfunction recurs.

2 No blown air in any airflow mode.Blown air volume does not change at any fan speed.

TROUBLESHOOTING HINTS1 Blower motor, resistor, fan switch malfunction

Step 12 Blower unit malfunction

Steps 2—4


1 Inspect the following systems and electrical parts: Yes Go to next step. Blower motor, resistor, fan switch.

Are they okay?No Repair or replace malfunctioning part, then go to

Step 5.

2 Turn ignition switch to ON position.Turn fan switch on

Yes Go to next step.Turn fan switch on.Is noise coming from blower unit? No Go to Step 4.

3 Inspect fan in blower unit. Is fan free of interference from blower unit

case?


case? Is fan free of foreign material and

obstructions?Is fan okay?

No Remove obstruction, repair or replace fan andblower unit case, then go to Step 5.

4 Is blower unit intake vent clogged? Yes Remove obstruction, then go to next step.

No Inspect if there are any obstructions in passagebetween blower unit and heater unit, then go tonext step.

5 Does air blow out? Yes Troubleshooting completed. Explain repairs tocustomer.


3 Airflow mode does not change.

TROUBLESHOOTING HINTS1 Malfunction in heater unit’s airflow mode main link, airflow mode rod, airflow mode cranks, airflow mode sub link, airflow

mode wire or wire clampSteps 1, 2

2 Bevel gear set (2) in climate control unit, airflow mode wire or wire clamp malfunctionStep 3

3 Malfunction in one or more heater unit doorsSteps 4, 5


1 Inspect heater unit’s airflow mode main link,airflow mode rod, airflow mode cranks, airflowmode sub links, airflow mode wire and wireclamp. Is there grease on airflow mode main link,


g ,airflow mode cranks and airflow mode sublinks?

Are airflow mode main link, airflow mode rod,airflow mode cranks, and airflow mode sublinks installed securely and in the properposition?

Is wire clamp free of deformation?Are above items all okay?

No Apply grease or install airflow mode main link,airflow mode rod, airflow mode cranks and airflowmode sub links securely in their proper positions,repair wire clamp, then go to Step 6.


CONTINUED


TROUBLESHOOTING

U–30


2 Is airflow mode wire positioned securely and Yes Go to next step.correctly in relation to the heater unit’s airflowmode main link?

No Adjust airflow mode wire or install it correctly, thengo to Step 6.

3 Inspect climate control unit. Is bevel gear set properly engaged?

Yes Go to next step.g y g g

Is airflow mode wire properly installed incorrect direction on bevel gear?

Is wire clamp free of deformation?Are above items okay?

No Properly engage bevel gear set or install airflowmode wire in correct direction, repair or replacewire clamp, then go to Step 6.

4 Is there any foreign material or obstruction in any Yes Remove obstruction, then go to Step 6.of heater unit’s doors? No Go to next step.

5 Are all doors within heater unit securely andproperly positioned?

Yes Inspect each door for cracks or damage, then goto next step.

No Install malfunction doors securely in properposition, then go to next step.

6 Does airflow mode change? Yes Troubleshooting completed. Explain repairs tocustomer.


4 Improper air circulation and/or no air circulation.

TROUBLESHOOTING HINTS1 Malfunction in blower unit’s air intake crank, air intake link, air intake wire or wire clamp

Steps 1, 22 Climate control unit air intake wire or wire clamp malfunction

Step 33 Blower unit air intake door malfunction

Steps 4, 5


1 Inspect blower unit’s air intake crank, air intakelink and wire clamp. Is there grease on air intake crank and air


gintake link?

Are air intake crank and air intake link securelyand properly positioned?


No Apply grease or install air intake crank and airintake link properly and securely, repair wireclamp, then go to Step 6.

2 Is air intake wire positioned securely and correctly Yes Go to next step.in relation to the blower unit’s air intake link? No Adjust air intake wire or install securely in correct

position, then go to Step 6.

3 Inspect climate control unit. Is air intake wire properly installed in correct

direction in relation to the air intake lever of


direction in relation to the air intake lever ofclimate control unit?


No Install air intake wire securely in correct position,repair or replace wire clamp, then go to Step 6.

4 Is there any foreign material or obstruction in Yes Remove obstruction, then go to Step 6.blower unit’s air intake door? No Go to next step.

5 Is blower unit’s air intake door securely andproperly positioned?

Yes Inspect air intake door for cracks or damage, thengo to next step.

No Install air intake door securely in proper position,then go to next step.

6 Does air circulate? Yes Troubleshooting completed. Explain repairs tocustomer.



CONTINUED


CONTROL SYSTEM

U–31

5 No temperature control.(Without variable thermistor in climate control unit only)

TROUBLESHOOTING HINTS1 Malfunction in heater unit’s air mix rod, air mix link, air mix cranks, air mix shaft, air mix wire or wire clamp

Steps 2, 32 Bevel gear set (2) in climate control unit, air mix wire or wire clamp malfunction

Step 43 Heater unit air mix door malfunction

Steps 5, 6


1 Is coolant sufficiently warmed up? Yes Go to next step.

No Warm engine up, then go to Step 7.

2 Inspect heater unit’s air mix rod, air mix link, airmix cranks, air mix shaft and wire clamp. Is there grease on air mix rod, air mix link and


g ,air mix cranks?

Are air mix rod, air mix link, air mix cranks, andair mix shaft securely installed in their properpositions?


No Apply grease or install air mix rod, air mix link, airmix cranks, and air mix shaft securely in theirproper positions, repair wire clamp, thengo to Step 7.

3 Is air mix wire securely installed in the correct Yes Go to next step.position in relation to heater unit’s air mix link? No Adjust air mix wire or install securely in correct

position, then go to Step 7.

4 Inspect climate control unit. Is bevel gear set properly engaged?

Yes Go to next step.g y g g

Is air mix wire properly installed in correctposition in relation to bevel gear?


No Properly engage bevel gear set or install air mixwire in correct position, repair or replace wireclamp, then go to Step 7.

5 Is there any foreign material or obstruction in Yes Remove obstruction, then go to Step 7.heater unit’s air mix door? No Go to next step.

6 Is heater unit’s air mix door securely and properlyinstalled?

Yes Inspect door for cracks or damage, then go tonext step.

No Install door securely in proper position, then go tonext step.

7 Does unit operate in every temperature setting? Yes Troubleshooting completed. Explain repairs tocustomer.


6 Air from vent not cold enough.

TROUBLESHOOTING HINTS1 Drive belt malfunction

Step 12 Malfunction in blower unit or condenser

Steps 4, 53 Malfunction in receiver/drier or expansion valve (valve closes too much)

Steps 8, 94 Malfunction in refrigerant lines

Steps 10, 115 Malfunction in piping connections

Steps 1, 2, 136 A/C compressor system malfunction, insufficient compressor oil

Steps 15, 167 Compressor oil over-full, malfunction in expansion valve or heater unit air mix link system

Steps 17—20


CONTINUED


TROUBLESHOOTING

U–32


1 Inspect drive belt. Yes Go to next step.

+ Section B2, DRIVE BELT, DRIVE BELTINSPECTION

Is it okay?

No Adjust or replace drive belt, then go to Step 21.+ Section B2, DRIVE BELT, DRIVE BELT

ADJUSTMENT

2 Carry out refrigerant system performance test.+ REFRIGERANT SYSTEM SERVICE

PROCEDURES PERFORMANCE TEST

Yes Operation is normal. (Recheck malfunctionsymptoms.)

PROCEDURES, PERFORMANCE TESTIs operation normal? No Go to next step.

3 Are refrigerant’s high-pressure and low-pressure Yes Go to next step.values both high? No Go to Step 6.

4 Is blower unit intake clogged? Yes Remove obstruction, then go to Step 21. (If airdoes not reach evaporator within cooling unit,heat exchange does not occur and refrigerantpressure rises. Therefore, removal of obstructionis necessary.)

No Go to next step.

5 Inspect condenser.+ BASIC SYSTEM, CONDENSER INSPECTIONIs it okay?

Yes Add or subtract refrigerant to make specifiedamount, then go to Step 21. (Excessive amountof refrigerant.)

No Replace condenser, or repair and cleancondenser fins, then go to Step 21.

6 Are refrigerant’s high-pressure and low-pressure Yes Go to next step.values both low? No Go to Step 14.

7 Immediately after A/C compressor operates, doesrefrigerant’s high-pressure value momentarily rise

Yes Go to next step.g g y

to correct value, then fall and stay below it? (Isthere negative pressure on low-pressure side?)

No Go to Step 10.

8 Turn A/C switch off and let air conditioner stop for10 min tes

Yes Go to next step.10 min utes .Start engine.Turn both A/C switch and fan switch on.Does malfunction occur after A/C compressorturns on?

No Start vacuum pump for 30 minutes and replacereceiver/drier, then go to Step 21. (Sincereceiver/drier has become saturated with water,replacement is necessary.)

9 Is expansion valve heat-sensing tube withincooling unit securely installed in proper position?

Yes Replace expansion valve, then go to Step 21.(Since valve closes too much, replacement isnecessary.)

No Install heat-sensing tube securely in properposition, then go to Step 21.

10 Inspect refrigerant lines. Is piping free of damage and cracks? Are piping connections free of oil grime?

(Visual inspection) Are piping connections free of gas leakage? Are piping installation points on condenser free

of gas leakage?


g g Are piping installation points on receiver/drier

free of gas leakage? Are piping installation points on A/C

compressor free of gas leakage? Are piping installation points on cooling unit

free of gas leakage?*Perform gas leak inspection using gas leaktester.Are above items okay?

No If piping or an A/C component is damaged orcracked, replace it. Then go to Step 21. If there isno damage, go to Step 13.


CONTINUED


CONTROL SYSTEM

U–33


11 Are piping connections for evaporator in coolingunit free of gas leakage?

Yes If the A/C compressor is making noise, add 10 ml 10 cc, 0.34 fl oz of compressor oil andverify that malfunction does not occur.Add or subtract refrigerant to make specifiedamount, then go to Step 21.

No If piping is damaged or cracked, replace it. Thengo to Step 21. If there is no damage, go to nextstep.

12 Are piping connections for evaporator in coolingunit loose?

Yes Tighten connections to specified torque. If the A/Ccompressor is making noise, add 10 ml 10 cc,0.34 fl oz of compressor oil and verify thatmalfunction does not occur.Tighten connections to specified torque, add orsubtract refrigerant to make specified amount,then go to Step 21.

No If the A/C compressor is making noise, add 10 ml 10 cc, 0.34 fl oz of compressor oil andverify that malfunction does not occur.Replace O-ring on piping, add or subtractrefrigerant to make specified amount, then go to Step 21.

13 Are piping connections loose? Yes Tighten connections to specified torque. If the A/Ccompressor is making noise, add 10 ml 10 cc,0.34 fl oz of compressor oil and verify thatmalfunction does not occur.Tighten connections to specified torque, add orsubtract refrigerant to make specified amount,then go to Step 21.

No If the A/C compressor is making noise, add 10 ml10 cc, 0.34 fl oz of compressor oil and verifythat malfunction does not occur.Replace O-ring on piping, add or subtractrefrigerant to make specified amount, then go to Step 21.

14 Does refrigerant’s high-pressure value hardly Yes Go to next step. (Pressure hardly increases.)increase? No Go to Step 17.

15 When engine is racing, does high-pressure value Yes Return to Step 3.increase? No Go to next step.

16 After compressor oil is replenished each 10 ml10 cc, 0.34 fl oz , does high-pressure value

Yes Troubleshooting completed. (Explain to customerthat cause was insufficient compressor oil.)

increase? No Replace A/C compressor, then go to Step 21.(Cause is defective A/C compressor.)

17 Is only refrigerant low-pressure value high? Yes Go to Step 20.

No Go to next step.

18 Are heater unit’s air mix rod, air mix link, air mix Yes Go to next step.cranks and air mix shaft securely and properlyinstalled?

No Repair or install air mix rod, air mix link, air mixcranks and air mix shaft securely in properposition, then go to Step 21.


CONTINUED


TROUBLESHOOTING

U–34


19 1. Set the fan switch at 4th position.2. Turn the A/C switch on.3. Set to FRESH mode.4. Set the temperature control to MAX COLD.5. Set to VENT mode.6. Run engine at a constant 1,500 rpm for

10 minutes .7. Run engine at idle speed for 1 minute.8. 1 engine speed cycle is defined as going from

idle speed to 4,000 rpm and back to idle speedover a period of 12 seconds . Perform 5 cycles

Yes Go to Step 21.

Perform 5 cycles .9. Run engine at idle speed for 30 seconds .

10. Remove all compressor oil from A/Ccompressor and verify that it is 105 ml 105 cc,3.55 fl oz .

11. If it is more than 105 ml 105 cc, 3.55 fl oz ,put only 105 ml 105 cc, 3.55 fl oz back into A/C compressor.

12. Carry out above steps 1 to 10 again and verifythat compressor oil is 105 ml 105cc, 3.55 floz .

Is there 105 ml 105 cc, 3.55 fl oz ofcompressor oil in A/C compressor?

No Carry out 1 to 10 of step 19 again untilcompressor oil is 105 ml 105 cc, 3.55 fl oz .

20 Is expansion valve heat-sensing tube withincooling unit securely installed in proper position?

Yes Replace expansion valve, then go to next step.(Since valve opens too much, replacement isnecessary.)

No Install heat-sensing tube securely in properposition, then go to next step.

21 Does cool air blow out? (Are results of refrigerantsystem performance test okay?)

Yes Troubleshooting completed. Explain repairs tocustomer.


7 No cool air.

TROUBLESHOOTING HINTS1 A/C compressor system malfunction

Step 22 Incorrect amount of refrigerant

Step 33 A/C switch indicator light malfunction

Steps 4—64 A/C relay system malfunction

(WL, WL turbo, F2 Cab) Steps 7, 11—13(G6, F2) Steps 7, 11, 12

5 Refrigerant pressure switch malfunctionStep 8

6 PCM A/C cut-off control system(WL, WL turbo) Steps 9, 26(G6, F2) Step 9

7 PCM (IG1 signal) system malfunctionSteps 10, 25

8 Magnetic clutch system malfunctionStep 14

9 PCM (A/C signal) system malfunction(WL, WL turbo) Steps 15, 20(G6, F2) Steps 15, 19, 20(F2 Cab) Step 15

10 Thermoswitch, A/C switch malfunction(WL, WL turbo, G6, F2) Steps 21—24(F2 Cab) Steps 16—18


CONTINUED


CONTROL SYSTEM

U–35


1 Does air blow out? Yes Go to next step.

No Go to Step 1 of troubleshooting indexes 1, 2.

2 Start engine.Turn both A/C switch and fan switch on

Yes Go to Step 1 of troubleshooting index 6.Turn both A/C switch and fan switch on.Does A/C compressor operate? No Go to next step.

3 Inspect refrigerant amount.+ REFRIGERANT SYSTEM SERVICE

Yes Go to next step.+ REFRIGERANT SYSTEM SERVICE

PROCEDURES, PERFORMANCE TESTIs it okay?

No Add or subtract refrigerant to specified level, thengo to Step 27.

4 Does A/C switch indicator light illuminate? Yes Go to Step 7.

No Go to next step*5 Turn ignition switch to ON position.

(With air mix wire) Remove airflow mode wire, airintake wire and air mix wire. Remove climatecontrol unit.(Without air mix wire) Remove airflow mode wire


(Without air mix wire) Remove airflow mode wireand air intake wire. Remove climate control unit.Remove A/C switch from climate control unit andconnect A/C switch connector.Test voltage at A/C switch terminal C (IG2 signal).Is voltage approximately 12 V ?

No Repair wiring harness between fuse block andA/C switch, then go to Step 27.

*6 Inspect A/C switch.+ CONTROL SYSTEM, CLIMATE CONTROL

UNIT INSPECTION

Yes Inspect wiring harness between A/C switch andresistor, then go to Step 27.

UNIT INSPECTIONIs it okay? No Replace A/C switch, then go to Step 27.

7 Are A/C relay power supply fuses okay? Yes Go to next step.

No Check for a short to ground on blown fuse’scircuit.Repair or replace as necessary.Install appropriate amperage fuse.

*8 Remove radiator grille. Disconnect refrigerantpressure switch connector. When refrigerant

Yes Inspect refrigerant pressure switch, then go to Step 27.

pressure switch connector terminals A and B (onwiring harness side) are shorted, does cool airblow out?

No WL for ISRAEL: Undo short, reconnectrefrigerant pressure switch connector, then go toStep 10.Other models: Undo short, reconnect refrigerantpressure switch connector, then go to next step.

*9 Check the DTC for the PCM ON-BOARDDIAGNOSTIC SYSTEM.Are the following DTCs displayed? DTC 09 (WL or WL turbo) DTC 0120 (F2 or G6)

+ Section F2, ON-BOARD DIAGNOSTICSYSTEM, DIAGNOSTIC TROUBLE CODEINSPECTION

Yes Go to appropriate inspection procedure. (Theengine coolant temperature sensor (DTC 09) orthrottle position sensor (DTC 0120), which sendsthe PCM’s A/C cut off control input signal, may bethe cause of the trouble.)

No Go to next step.

*10 Turn ignition switch to ON position.Does magnetic clutch operate when A/C relay

Yes Go to Step 15.Does magnetic clutch operate when A/C relayconnector terminal B (IG2 signal) is grounded? No Go to next step.


CONTINUED


TROUBLESHOOTING

U–36

STEP INSPECTION ACTION*11 Turn ignition switch to ON position.

Test voltage at the following A/C relay connectorterminals:


terminals: Terminal A (IG2 signal) Terminal C (A/C control signal)

Is voltage approximately 12 V ?

No Repair wiring harness between fuse block andA/C relay, then go to Step 27.

*12 Test voltage at A/C relay terminal D (A/C controlsignal).

Yes G6 or F2: Go to Step 14.Other models: Go to next step.

Is voltage approximately 12 V ? No Inspect A/C relay, then go to Step 27.*13 Disconnect refrigerant pressure switch connector.

Test voltage at refrigerant pressure switchconnector (on wiring harness side) terminal A

Yes Reconnect refrigerant pressure switch connector,then go to next step.

connector (on wiring harness side) terminal A(A/C control signal).Is voltage approximately 12 V ?

No Repair wiring harness between A/C relay andrefrigerant pressure switch, then go to Step 27.

*14 Test voltage at magnetic clutch connector Yes Inspect magnetic clutch, then go to Step 27.terminal A (A/C control signal).Is voltage approximately 12 V ?

No G6 or F2: Repair wiring harness between A/Crelay and magnetic clutch, then go to Step 27.Other models: Repair wiring harness betweenrefrigerant pressure switch and magnetic clutch,then go to Step 27.

*15 Turn A/C switch off. Remove glove compartment.Turn ignition switch to ON position. Test voltageat the following thermoswitch connector terminal(A/C signal):

Yes F2 Cab: Go to next step.Other models: Go to Step 21.

(A/C signal): Terminal B (with variable thermistor in climate

control unit) Terminal A (without variable thermistor in

climate control unit)Is voltage approximately 12 V ?

No F2 Cab: Repair wiring harness between A/C relayand thermoswitch, then go to Step 27.G6 or F2: Go to Step 19.Other models: Go to Step 20.

*16 Turn ignition switch to LOCK position.Disconnect thermoswitch connector.Start engine.Turn both A/C switch and fan switch on.When following thermoswitch connector terminals(on wiring harness side) are shorted does cool

Yes Undo short, then go to next step.

(on wiring harness side) are shorted, does coolair blow out? Terminal A—C (with variable thermistor in

climate control unit) Terminal B—C (without variable thermistor in

climate control unit)

No Undo short, then go to Step 18.

*17 Turn ignition switch to ON position.Test voltage at the following thermoswitchconnector terminals (IG2 signal): Terminal B (with variable thermistor in climate

Yes Inspect thermoswitch, then go to Step 27.

Terminal B (with variable thermistor in climatecontrol unit)

Terminal A (without variable thermistor inclimate control unit)


No Repair wiring harness between fuse block andthermoswitch, then go to Step 27.

*18 Turn ignition switch to ON position.Turn A/C switch on.Turn fan switch off.Test voltage at A/C switch connector terminal A

Yes Inspect wiring harness between thermoswitchand A/C switch, then go to Step 27.

Test voltage at A/C switch connector terminal A(A/C signal).Is voltage approximately 12 V ?

No Inspect A/C switch, then go to Step 27.

*19 Disconnect refrigerant pressure switch connector.Test voltage at refrigerant pressure switchconnector (on wiring harness side) terminal A

Yes Repair wiring harness between thermoswitch andrefrigerant pressure switch, then go to Step 27.

( g )(A/C control signal). Is voltage approximately 12 V ?

No Go to next step.


CONTINUED


CONTROL SYSTEM

U–37

STEP INSPECTION ACTION*20 Turn ignition switch to ON position.

Test voltage at the following PCM connectorterminals (A/C signal): Terminal G (WL or WL turbo) Terminal Q (G6 or F2)

Yes G6 or F2: Repair wiring harness between PCM andrefrigerant pressure switch, then go to Step 27.Other models: Repair wiring harness betweenPCM and thermoswitch, then go to Step 27.

Terminal Q (G6 or F2)Is voltage approximately 12 V ? No Inspect PCM, then go to Step 27.

*21 Turn ignition switch to LOCK position.Disconnect thermoswitch connector.Start engine.Turn both A/C switch and fan switch on.When following thermoswitch connector terminals(on wiring harness side) are shorted does cool

Yes Undo short, then go to next step.

(on wiring harness side) are shorted, does coolair blow out? Terminal B—C (without variable thermistor in

climate control unit) Terminal A—C (with variable thermistor in

climate control unit)

No Go to Step 23.

22 Turn ignition switch to ON position.Test voltage at the following thermoswitchconnector terminals (IG2 signal):

Yes Inspect thermoswitch, then go to Step 27.

( g ) Terminal A (without variable thermistor in

climate control unit) Terminal B (with variable thermistor in climate

control unit)Is voltage approximately 12 V ?

No Repair wiring harness between fuse block andthermoswitch, then go to Step 27.

*23 Turn ignition switch to ON position.Turn A/C switch on.Turn fan switch off.


Test voltage at A/C switch connector terminal A(A/C signal).Is voltage approximately 12 V ?

No Inspect A/C switch, then go to Step 27.

*24 Test voltage at thermoswitch connector terminal Yes Go to next step.C (A/C signal).Is voltage approximately 12 V ?

No Repair wiring harness between thermoswitch andA/C switch, go to Step 27.

*25 Test voltage at the following PCM connectorterminals (A/C signal): Terminal L (WL or WL turbo)

Yes WL or WL turbo: Go to next step.Other models: Recheck malfunction symptoms.

Terminal L (WL or WL turbo) Terminal J (G6 or F2)


No Repair wiring harness between A/C relay andPCM, then go to Step 27.

*26 Inspect the following input signal components: Engine coolant temperature sensor and PCM

Yes Recheck malfunction symptoms. Engine coolant temperature sensor and PCM

wiring harness (A/C cut-off control).Are they okay?

No Replace input signal components, then go to nextstep.

27 Does cool air blow out? (Is refrigerant systemperformance test result correct?)

Yes Troubleshooting completed. Explain repairs tocustomer.



CONTINUED


TROUBLESHOOTING

U–38

8 Noise while operating A/C system.

TROUBLESHOOTING HINTS1 Magnetic clutch operation noise

Step 32 A/C compressor operation noise

Steps 4—83 A/C compressor slippage noise

Steps 9—114 Hose or refrigerant line interference noise

Step 12


1 Is there a squeaking or whirling sound (A/C Yes Go to Step 9.compressor slippage noise)? No Go to next step.

2 Is there a rattling or vibrating sound (interference Yes Go to Step 12.noise)? No Go to next step.

3 Is there a clicking sound (magnetic clutchoperation noise)?

Yes Adjust clearance between magnetic clutchpressure plate and A/C compressor pulley, thengo to Step 13.+ CONTROL SYSTEM, MAGNETIC CLUTCH

CLEARANCE ADJUSTMENT

No Go to next step.

4 Is noise heard continuously for more than 3 Yes Go to next step.seconds after A/C compressor comes on? No Condition is normal. (Noise normally occurs for

2—3 seconds immediately after A/C compressorturns on.)

5 Inspect idle speed.+ Section F2, ENGINE TUNE-UP, IDLE SPEED

ADJUSTMENT


Is it okay?

No Adjust idle speed, then go to Step 13.

6 Drain compressor oil. Yes Go to next step.Is it contaminated with metal particles? No Replace A/C compressor, then go to Step 13.

7 Is compressor oil whitish and mixed with water? Yes Replace entire A/C system (excluding heater),then go to Step 13.

No Go to next step.

8 Is compressor oil darker than normal andcontaminated with aluminum chips?

Yes Replace A/C compressor and receiver/drier, thengo to Step 13. (Since A/C compressor may beworn and receiver/drier may be clogged,replacement of receiver/drier is necessary.)

No Condition is normal. Recheck malfunctionsymptoms.

9 Inspect drive belt.+ Section B2, DRIVE BELT, DRIVE BELT

INSPECTION


Is it okay?

No Adjust or replace drive belt, then go to Step 13.

10 Is drive belt worn? Does it have foreign materialimbedded in it, or have oil on it?

Yes Remove obstruction, remove oil, or replace drivebelt, then go to Step 13.

No Go to next step.


CONTINUED


CONTROL SYSTEM

U–39


11 Inspect magnetic clutch.+ CONTROL SYSTEM, MAGNETIC CLUTCH

INSPECTION

Yes Replace A/C compressor (excluding pressureplate, A/C compressor pulley, and stator), then goto Step 13.

Is it okay? No Replace magnetic clutch, then go to Step 13.

12 Is noise coming from A/C compressor? Yes Visually inspect A/C compressor, replaceappropriate parts if necessary, then go to nextstep.

No If noise is coming from refrigerant lines, repairany detached or missing clips, tighten loose bolts,then go to next step.

13 Has A/C compressor noise stopped? Yes Troubleshooting completed. Explain repairs tocustomer.



CONTINUED


TD–1

TECHNICAL DATATECHNICAL DATA TD– 1. . . . . . . . . . . . . . . . . . . . . . . .

ENGINE TD– 1/3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION SYSTEM TD– 4. . . . . . . . . . . . . . . . . COOLING SYSTEM TD– 4. . . . . . . . . . . . . . . . . . . . . FUEL AND EMISSION CONTROL

SYSTEMS TD– 5/6. . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE ELECTRICAL SYSTEM TD– 6/10. . . . . . . . . CLUTCH TD–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MANUAL TRANSMISSION TD–10/11. . . . . . . . . . . . . . .

PROPELLER SHAFT TD–11. . . . . . . . . . . . . . . . . . . . FRONT AND REAR AXLES TD–11. . . . . . . . . . . . . . STEERING SYSTEM TD–12. . . . . . . . . . . . . . . . . . . . BRAKING SYSTEM TD–12. . . . . . . . . . . . . . . . . . . . . SUSPENSION TD–13/14. . . . . . . . . . . . . . . . . . . . . . . . . . BODY ELECTRICAL SYSTEM TD–14/15. . . . . . . . . . . HEATER AND AIR

CONDITIONER SYSTEMS TD–15. . . . . . . . . . . . .

TECHNICAL DATAENGINE

ItemEngine

ItemG6

GeneratorNew 10.0—12.0 0.40—0.47

Drive belt deflectionGenerator

Used 12.0—14.0 0.48—0.55Drive belt deflection[Applied pressure

P/SNew 6.6—7.2 0.26—0.28[

98 N 10 kgf, 22 lbf]( i )

P/SUsed 7.2—8.0 0.29—0.31

(mm in)A/C

New 8.5—10.0 0.34—0.39A/C

Used 10.0—11.5 0.40—0.45

GeneratorNew 491—588 50—60, 110—132

GeneratorUsed 393—490 40—50, 88—110

Drive belt tension P/SNew 412—470 42—48, 93—105

(N kgf, lbf)P/S

Used 354—402 36—41, 80—90

A/CNew 557—641 56.7—65.4, 125—143

A/CUsed 471—556 48.0—56.7, 106—124

Compression (kPa kgf/cm2 psi [rpm])Standard 1255 12.8, 182 [270]

Compression (kPa kgf/cm2, psi [rpm])Minimum 882.6 9.0, 128 [270]

Pushing distance of the front oil seal (from the edge of the chain cover) (mm in)

0—0.7 0—0.027

Pushing distance of the rear oil seal (from the edge of the rear cover) (mm in)

0—0.5 0—0.019

BACK.TO.MAIN.INDEX

CONTINUED


TECHNICAL DATA

TD–2

ItemEngine

ItemWL, WL Turbo

New 7.0—9.0 0.28—0.35

Generator Used 8.0—10.0 0.32—0.39

Limit 16.0 0.63Drive belt deflection [A li d 98 A/C (meas ring

New 5.0—6.2 0.20—0.24[Applied pressure 98N 10 kgf 22 lbf]

A/C (measuringpoint a)

Used 6.0—6.5 0.24—0.25N 10 kgf, 22 lbf]

(mm in)oint a)

Limit 11.3 0.44( )

A/C (meas ringNew 9.5—11.8 0.38—0.46

A/C (measuringpoint b)

Used 11.0—12.5 0.44—0.49oint b)

Limit 18.0 0.71

New 442—637 45—65, 99—143

Generator Used 383—539 39—55, 86—121

Drive belt tension Limit 177 18, 40

(N kgf, lbf) New 403—519 41—53, 91—116

A/C Used 354—431 36—44, 80—96

Limit 181 18.5, 41

Valve clearance [Engine cold] (mm in)IN 0.05—0.15 0.0020—0.0059 (0.100.05 0.00390.0020)

0.15 0.0059 [Engine hot (Reference)]Valve clearance [Engine cold] (mm in)

EX 0.15—0.25 0.0060—0.0098 (0.200.05 0.00790.0020)0.25 0.0098 [Engine hot (Reference)]

Compression (kPa kgf/cm2 psi [rpm])Standard 2,942 30, 427 [200]

Compression (kPa kgf/cm2, psi [rpm])Minimum 2,648 27, 384 [200]

Timing belt deflection [Applied pressure 98 N 10 kgf, 22 lbf]

(mm in)Standard 9.0—10.0 0.36—0.39

Bolt head mark WStandard 101.2—101.8 3.985—4.007

Cylinder head boltBolt head mark W

Minimum 102.5 4.035ylength (mm in)

Bolt head mark NStandard 113.2—113.8 4.457—4.480

Bolt head mark NMinimum 114.5 4.508

Camshaft oil seal tapping amount (mm in) 0.5—1.0 0.02—0.03

Front oil seal tapping amount (mm in) 0—0.4 0—0.01

Rear oil seal tapping amount (mm in) 0—0.5 0—0.01


CONTINUED


TECHNICAL DATA

TD–3

ItemEngine

ItemF2 CARB F2 CIS

GeneratorNew 7.0—8.0 0.28—0.31

Drive belt deflectionGenerator

Used 8.0—9.0 0.32—0.35Drive belt deflection[Applied pressure

P/SNew 5.0—6.0 0.20—0.23[

98 N 10 kgf, 22 lbf]( i )

P/SUsed 5.5—6.5 0.22—0.25

(mm in)A/C

New 10.0—12.0 0.40—0.47A/C

Used 12.0—14.0 0.48—0.55

GeneratorNew 510—588 52—60, 115—132

GeneratorUsed 432—509 44—52, 97—114

Drive belt tension P/SNew 393—490 40—50, 88—110

(N kgf, lbf)P/S

Used 344—441 35—45, 77—99

A/CNew 373—490 38—50, 84—110

A/CUsed 275—372 28—38, 62—83

Compression (kPa kgf/cm2 psi [rpm])Standard 1196 12.2, 173 [300] 1226 12.5, 178 [300]

Compression (kPa kgf/cm2, psi [rpm])Minimum 837 8.54, 121 [300] 858 8.75, 124 [300]

Timing belt deflection New 8.0—9.0 0.32—0.35g[Applied pressure 98 N 10 kgf, 22 lbf] (mm in) Used 9.0—10.0 0.36—0.39

Pushing distance of the front oil seal (from the edge of the chain cover) (mm in)

0 0

Pushing distance of the rear oil seal (from the edge of the rear cover) (mm in)

0—0.5 0—0.019


CONTINUED


TECHNICAL DATA

TD–4

LUBRICATION SYSTEM

ItemEngine

ItemF2 G6 WL WL Turbo

Oil pressure (kPa kgf/cm2, psi [rpm])

295—3923.0—4.0,43—56[3000]

305—4023.1—4.1,45—58[3000]

452—5294.6—5.4,66—76[3000]

402—4804.1—4.9,59—69[3000]

Oil capacitOil replacement 3.9 4.1, 3.4 4.5 4.8, 4.0 5.6 5.9, 4.9

Oil capacity(L US qt lmp qt)

Oil and oil filter replacement 4.2 4.4, 3.7 4.7 5.0, 4.4 6.3 6.7, 5.5(L US qt, lm qt)

Total (dry engine) 4.6 4.9, 4.0 5.5 5.8, 4.8 6.7 7.1, 5.9

Engine oil API service SG API service CD

Above 30C 86F SAE 40 —

0°C—40C 32F—104°F SAE 30 —

–10°C—20C 14F—68°F SAE 20W-20 —

Above –25C –13F SAE 10W-30*, 10W-40, 10W-50 —

Viscosity Above –10C 14F SAE 20W-40, 20W-50 —

Below –20C –4F SAE 5W-20 —

Below 0C 32F SAE 5W-30* —

–15°C—40C 5F—104°F — — SAE 10W-30

Below 10C 50F — — SAE 5W-30 European specification vehicles use only those oils marked with an asterisk

COOLING SYSTEM

ItemEngine

ItemF2 G6 WL WL Turbo

Coolant capacity (L US qt lmp qt)With heater 7.5 7.9, 6.6 9.4 9.9, 8.3

Coolant ca acity (L US qt, lm qt)Without heater 6.9 7.3, 6.1 8.8 9.3, 7.7

Thermostat

Opening temperature (C F)83.5—89.5183—193

Sub:83.5—86.5183—187

Main:86.5—89.5188—193

80—84 176—183

ThermostatFull-open temperature (C F) 100 212 95 203

Full-open lift (mm in)8.5 0.33

min.

Sub: 1.50.06 min. Main: 8.0

0.31 min.

8.5 0.33 min.

Radiator capCap valve opening pressure

(kPa kgf/cm2, psi)

74—1020.75—1.05,10.7—14.9

94—122 0.95—1.25, 13.5—17.7


CONTINUED


TECHNICAL DATA

TD–5

FUEL AND EMISSION CONTROL SYSTEMSCIS vehicles

ItemEngine

ItemG6 F2

Idle speed (rpm) 730—770 (75020) 730—770 (75020)

Injection timing (BTDC °/rpm) 4—6/750 5—7/750

Idle speed*1 (rpm)A/C ON*2 700—800 (75050) 780—880 (83050)

Idle speed 1 (rpm)P/S ON*3 700—800 (75050)

CO concentration Within the regulation

HC concentration Within the regulation

Fuel pressure Hold pressure More than 340 3.5, 50(kPa kgf/cm2, psi) Fuel pump maximum pressure 500—630 5.0—6.5, 72—92

Fuel leakage(drop/2 minutes)

Less than 1

Fuel injector Injection volume(ml cc, fl oz/15 sec.)

55—71 55—71, 1.9—2.3 46—60 46—60, 1.6—2.0

Resistance(Ω) [20°C 68°F]

12—16

Pressure regulator

Fuel pressure (at vacuum ON)(kPa kgf/cm2, psi)

210—250 2.1—2.6, 30—36Pressure regulator

Fuel pressure (at vacuum OFF*4)(kPa kgf/cm2, psi)

270—310 2.7—3.2, 39—45

*1: Excludes temporary idle speed drop just after the loads (A/C, P/S) are turned on.*2: A/C switch and fan switch are turned on.*3: Steering wheel is fully turned.*4: Hot condition at start.

DIESEL vehicles

ItemEngine

ItemWL Turbo WL

Idle speed (rpm)760—800 (78020)*1

700—740 (72020)*2 700—740 (72020)

Injection timing ATDC 10°

Boost relief pressure (kPa kgf/cm2, psi)107—115 1.09—1.18,

15.5—16.8—

Idle-up speedWhen A/C is operated 825—875 (85025)

805—855 (83025)825—875 (85025)*3

Idle u s eed(rpm) When P/S is operated — —

When engine is cold 1200—1500 (1350150)

Injection pump Cam lift (mm in) 2.48 0.098

Injection nozzle

Injection starting pressure(MPa kgf/cm2, psi)

New: 11.4—12.2 116—124, 1650—1760Inspection: More than 10.0 102, 1450

Injection nozzleNozzle leakage

No leakage when pressure of 8.8 MPa 90 kgf/cm2, 1280 psi)is applied.

Diesel smoke (%) Within the regulation*1: General (L.H.D.)*2: Europe and UK*3: Europe


CONTINUED


TECHNICAL DATA

TD–6

CARB vehicles

ItemEngine

ItemF2 CARB

Idle speed (rpm) 800—850 (800 )+50–0

Injection timing (BTDC°) 5—7 (61)

A/C Operated 1400—1600 (1500100)

Idle up speed (rpm)P/S Operated —

Idle-up speed (rpm)D/P Operated 1900—2100 (2000100)

T/P Operated 1050—1250 (1150100)

CO concentration (%) 2.0—2.5 (2.0 )*1, 2.0—3.0 (2.50.5)*2+0.5–0

HC concentration (ppm) —

Fuel pumpDischarge pressure (kPa kgf/cm2, psi) 20—25 0.2—0.25, 2.8—3.6

Fuel umDischarge amount cc cu in min. 1150 70.2

Float level (mm in)H 8—9 0.315—0.354

CarburetorFloat level (mm in)

L 44—45 1.732—1.772

Primary throttle opening angle (°) 48—52 502*1: GULF*2: General

ENGINE ELECTRICAL SYSTEM

ItemEngine

ItemG6

Electrolyte gravity 1.27—1.29

Back-up current *1 (mA) Max. 20

Battery

Test load chart(A)

Battery type 80D26R 195Battery

Slow charge (A)

Battery type (5-hour rate)

80D26R (55) 5.5—6.5

Quick charge(A/30 min.)


80D26R (55) 35

Rotor resistance (Between slip rings) (Ω) 3.7—4.4

Brush lengthStandard (mm in) 18.5 0.73

Brush lengthMinimum (mm in) 5.0 0.20

Brush spring forceStandard (N kgf, lbf) 4.8—6.0 0.48—0.62, 1.06—1.36

Brush s ring forceMinimum (N kgf, lbf) 2.2 0.22, 0.48

Ignition switchB B+

GeneratorIgnition switchON

Terminal L Approx. 1GeneratorStandard voltage

ONS B+g

(V)Idle

B 14.1—14.7Idle [20C 68F]

Terminal L 13.0—14.0[20 C 68 F]

S 14.1—14.7

Generated current*2 Engine speed (rpm)1000 Approx. 0—43

(Reference) (A)Engine s eed (r m)

2000 Approx. 0—62*1: Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition

switch is at OFF position and the ignition key is removed.*2: Must not be 0 A.


CONTINUED


TECHNICAL DATA

TD–7

ItemEngine

ItemG6

Ignition Resistance Primary coil (Ω) 0.81—0.99gcoil [20C 68F] Secondary coil (kΩ) 10—16

TypeNGK

ZFR5F–11*3, *5, ZFR6F–11*4, *5,BKR5E*3, BKR6E*4

S

Ty eDENSO

KJ16CR11*3, *5, KJ20CR11*4, *5

K16PR–U*3, K20PR–U*4

Sparkplug Plug gap (mm in)

1.0—1.1 0.040—0.043*5, 0.7—0.8 0.028—0.031

Resistance (kΩ)NGK

3 0—7 5Resistance (kΩ)DENSO

3.0—7.5

Tightening torque (N·m kgf·m, ft·lbf) 15—22 1.5—2.3, 11—16

No.1 lead 2.9—7.7

High-Resistance

No.2 lead 4.3—10.8Hightensionl d

Resistance(kΩ ) [20 C 68 F]

No.3 lead 5.4—13.5lead (kΩ ) [20 C 68 F]

No.4 lead 6.6—16.2

Center lead 4.5—11.2

Commutator Standard (mm in) 29.4 1.16diameter Minimum (mm in) 28.8 1.14



StarterBrush spring force

Standard (N kgf, lbf) 180—243 18.3—24.8, 40.3—54.5Brush s ring force

Minimum (N kgf, lbf) 57.7 5.88, 12.9

Pinion gap (mm in) 3.0 1.118

No load testVoltage (V) 11.5

No load testCurrent (A) Below 100

*3: Standard plug*4: Cold type plug*5: Europe


CONTINUED


TECHNICAL DATA

TD–8

ItemEngine

ItemF2 CARB F2 CIS


Back-up current *1 (mA) Max. 20

Test load chart Battery type34B19R 110 —

Battery(A)

Battery ty e55D23R 180

BatterySlow charge Battery type 34B19R (27) 3.0—4.0 —g

(A)y y

(5-hour rate) 55D23R (48) 4.5—5.5

Quick charge Battery type 34B19R (27) 20 —g(A/30 min.)

y y(5-hour rate) 55D23R (48) 30

Rotor resistance (Between slip rings) (Ω) 3.7—4.4



Brush spring forceStandard (N kgf, lbf) 4.8—6.0 0.48—0.62, 1.06—1.36


Ignition switchB B+

GeneratorIgnition switchON

Terminal L Approx. 1GeneratorStandard voltage

ONS B+g

(V)Idle

B 14.1—14.7Idle [20C 68F]

Terminal L 13.0—14.0[20 C 68 F]

S 14.1—14.7

Generated current*2 Engine speed (rpm)1000 Approx. 0—43

(Reference) (A)Engine s eed (r m)

2000 Approx. 0—62

Ignition Resistance Primary coil (Ω) 1.035—1.265 0.81—0.99gcoil [20C 68F] Secondary coil (kΩ) 10—16

DistributorCentrifugal spark advance °/rpm

0—2/1200, 9—13/2200,19—23/6000

—Distributor

Vacuum spark advance °/kPa mmHg, inHg0—2/20 150, 5.9,

11—15/53.3 400, 15.7—

Type

NGKBKR5E*5

BKR6E*3

BKR7E*4

BPR5ES–11*3

BPR6ES–11*4

Sparkplug

Ty e

DENSOK16PR–U*5

K20PR–U*3

K22PR–U*4

W16EXR–U11*3

W20EXR–U11*4

lugPlug gap (mm in) 0.7—0.8 0.028—0.031 1.0—1.1 0.040—0.043

Resistance (kΩ)NGK

3 0 7 5Resistance (kΩ)DENSO

3.0—7.5

Tightening torque (N·m kgf·m, ft·lbf) 15—22 1.5—2.3, 11—16

No.1 lead 2.75—7.07

High-Resistance

No.2 lead 4.19—10.43Hightensionl d

Resistance(kΩ ) [20 C 68 F]

No.3 lead 4.38—10.88lead (kΩ ) [20 C 68 F]

No.4 lead 5.73—14.08

Center lead 2.00—5.33 3.9—9.9*1: Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition

switch is at OFF position and the ignition key is removed.*2: Must not be 0 A.*3: Standard plug*4: Cold type plug*5: Hot type plug


CONTINUED


TECHNICAL DATA

TD–9

ItemEngine

ItemF2 CARB F2 CIS





Standard (N kgf, lbf) 19.2 1.95, 4.25Brush s ring force

Minimum (N kgf, lbf) 8.83 0.90, 1.98

Pinion gap (mm in) 0.5—2.0 0.020—0.078

No load testVoltage (V) 11.5


ItemEngine

ItemWL, WL Turbo


Back-up current *1 (mA) 20 max.

Test load chart75D26L 195

Test load chart(A)

Battery type 75D26R 195(A)

95D31R 250

BatterySlow charge Battery type

75D26L (52) 5.5—6.5Slow charge

(A)Battery type (5-hour rate)

75D26R (52) 5.5—6.5(A) (5-hour rate)

95D31R (64) 6.5—8.0

Quick charge Battery type75D26L (52) 35

Quick charge(A/30 min )


75D26R (52) 35(A/30 min.) (5-hour rate)

95D31R (64) 40

Rotor resistance (Between slip rings) (Ω) 2.50



Brush spring forceStandard (N kgf, lbf) 2.65 0.27, 0.59


B B+

Engine switch TerminalA B+

G

gON

TerminalS 0

GeneratorStandard voltage I 2.0—4.0g

(V) B 14.05—14.85

Idle TerminalA 14.05—14.85

[20C 68F]Terminal

S 7.025—7.425

I 13.00—14.85

Generated current*2 Engine speed 1000

Terminal Bcurrent

Approx. 0—58

(Reference) (A)g

(rpm)2000

Terminal Bcurrent

Approx. 0—74

*1:Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the engineswitch is at OFF position and the engine key is removed.

*2:Must not be 0 A.


CONTINUED


TECHNICAL DATA

TD–10

ItemEngine

ItemWL, WL Turbo





Standard (N kgf, lbf) 27.0—33.0 2.75—3.37, 6.05—7.41Brush s ring force

Minimum (N kgf, lbf) —

Pinion gap (mm in) 3.0 0.12

No load testVoltage (V) 11


CLUTCHItem Specification

Clutch pedal

Height (mm in) 241.6—246.6 9.52—9.70

Pedal free play (mm in) 3.0—8.0 0.12—0.31

Clutch disc

Runout limit (mm in) 0.7 0.027 max.

Clutch fluid

Type SAE J1703 or FMVSS116 DOT-3 or DOT-4

MANUAL TRANSMISSIONM15M-D

Item Specification

Type API service GL-4 or GL-5

All-season SAE 75W-90Transmission oil Viscosity Above

10 C 50 FSAE 80W-90

Capacity (L US qt, lmp qt) 2.0 2.1, 1.8

M15MX-DItem Specification



10 C 50 FSAE 80W-90



All-season SAE 75W-90Transfer oil Viscosity Above

10 C 50 FSAE 80W-90


R15M-DItem Specification



10 C 50 FSAE 80W-90



CONTINUED


TECHNICAL DATA

TD–11

R15MX-DItem Specification



10 C 50 FSAE 80W-90



All-season SAE 75W-90Transfer oil Viscosity Above

10 C 50 FSAE 80W-90


PROPELLER SHAFT

Item Propeller shaft (4 2) Front propeller shaft(44)

Rear propeller shaft(44)

Runout limit (mm in) 0.4 0.016 0.4 0.016 0.4 0.016

Starting torque of universal(N·m kgf·cm, in·lbf)

0.3—1.13.0—12.0, 2.7—10.4

0.3—0.7 3.0—8.0, 2.7—6.9

0.3—1.1 3.0—12.0, 2.7—10.4

FRONT AND REAR AXLESItem 42 44

Play (mm in) 0 0

Front axle Wheel bearingPreload

(N·m kgf·cm, in·lbf)0.4—0.7 4.0—8.0, 3.5—6.9

Pull scale reading (N kgf, lbf)

5.9—10.7 0.6—1.1, 1.4—2.4

Rear axle Wheel bearing play (mm in) 0.05—0.25 0.002—0.010

Drive shaft Shaft length Left side 551.0—561.0 21.7—22.0Drive shaft g

(mm in) Right side 619.0—629.0 24.4—24.7

Pinion height (mm in)Front –0.032—0.032 –0.001—0.001

Pinion height (mm in)Rear –0.254—0.254 –0.010—0.010

Backlash of side gear and differential Front 0—0.1 0—0.003gpinion (mm in) Rear —

Drive pinion preload (N·m kgf·cm in·lbf)Front 0.9—1.3 9.0—14.0, 7.9—12.1

Drive inion reload (N·m kgf·cm, in·lbf)Rear 1.8—2.6 18.0—27.0, 15.7—23.4

Backlash of drivepinion and ring

Standard0.09—0.11 0.0036—0.0043 [Front]

0.12—0.20 0.005—0.008 [Rear]inion and ringgear Minimum 0.05 0.002 [Front], 0.12 0.008 [Rear]

Differential(mm in) Allowance variation 0.07 0.003 [Front], 0.08 0.005 [Rear]

DifferentialGrade API service GL-5

ViscosityFront —

Above-18C 0F: SAE 90Below-18C 0F: SAE 80

Standardy

Rear SAE 90

Oil Capacity (L US qt lmp qt)

Front —1.20 1.27, 1.06 [MFW]1.50 1.59, 1.32 [RFW]

(L US qt, lmp qt)Rear 1.40 1.48, 1.23 1.85 1.96, 1.63

Grade API service GL-6

LSD Viscosity SAE 90

Capacity (L US qt, lmp qt) 1.40 1.48, 1.23 1.85 1.96, 1.63


CONTINUED


TECHNICAL DATA

TD–12

STEERING SYSTEM

Item Manual steering Engine speed sensingpower steering

Steering wheelPlay (mm in) 0—30 0—1.18

Steering wheelEffort (N·m kgf·cm, in·lbf) 45 460, 399 max. 7.8 80, 69 max.

Backlash (mm in) 0 0

Steering gearWorm shaft preload (N·m kgf·cm, in·lbf)

1.0—1.3 10—14, 8.7—12.1

0.7—1.2 6.5—12.5, 5.7—10.8

Gear housing pressure(MPa kgf/cm2, psi)

—8.9—9.3

90—95, 1280—1350

OilGrade API service GL-4, SAE 90

ATF M-III or equivalent(e.g. DexronII )

Capacity (L US qt, lmp qt) 0.34 0.36, 0.30 1.1 1.2, 1.0

Power steeringoil pump

Oil pump fluid pressure(MPa kgf/cm2, psi)

—8.9—9.3

90—95, 1280—1350

BRAKING SYSTEM

Item42

44ItemF2, G6 WL, WL Turbo

44

Brake pedal

Brake pedal height (mm in) L.H.D.: 214—219 8.43—8.81R.H.D.: 219—224 8.63—8.81

Brake pedal play (mm in) 3—8 0.12—0.31

Brake pedal-to-floor clearance (mm in) 105 4.2 min.

Power brake unit

Fluid pressure whenpedal depressed at

Power brake unitat 0 kPa 0 mmHg,0 in Hg

790 8, 114 min.

196 N 20 kgf ,44 lbf)(kPa kgf/cm2, psi)

Power brake unit at66.7 kPa 500mmHg, 19.7 in Hg

8,240 84, 1,200 min.

Vacuum pump

Vacuum specification [In 20 seconds] [When engine speed 1,500 rpm]

(kPa mmHg, in Hg)73.3 550, 21.7

Maximum vacuum[When engine speed 3,000 rpm]

(kPa mmHg, in Hg)93.3 700, 27.6

Braking force control device

Type LSPV

Rear fluid pressure when front pressure is4,900 kPa 50 kgf/cm2, 711 psi

(kPa kgf/cm2, psi)2,550 26, 370

Front disc brake

Disc pad thickness limit (mm in) 2.0 0.08

Disc plateThickness limit (mm in) 22 0.87

Disc lateRunout limit (mm in) 0.05 0.002

Rear drum brake

Brake lining thickness limit (mm in) 1.0 0.04

Drum maximum diameter (mm in) 271.5 10.68 296.5 11.67

Parking brake

Parking brake lever stroke[When pulled at 98 N 10 kgf, 22 lbf]

(notches)1—7

Brake fluid

Type SAE J1703 or FMVSS116 DOT-3 or DOT-4


CONTINUED


TECHNICAL DATA

TD–13

SUSPENSIONSuspension

Item 42 44

Total toe-in(mm in) 33 0.120.12

Total toe-in(Degree) 016’ 16’ 014’ 14’

Front wheelli

MaximumInner 3500’ +2

–3 3330’ +2–3

alignment[unloaded*1]

Maximumsteering angle

Outer 3300’ +2–3 3000’ +2

–3Camber angle 056’30’ 1 06’30’

Caster angle*2 137’45’ 202’45’

Exposed thread of shock absorber piston (mm in) 6—8 0.24—0.31

Lower arm ball joint rotation torque(Pull scale reading) (N kgf, lbf) 14—44 0.7—4.5, 1.6—9.9

Upper arm ball joint rotation torque(Pull scale reading) (N kgf, lbf) 3.4—32.5 0.4—3.2, 0.9—7.0

Exposed thread of stabilizer control link bolt (mm in) 18—21 0.71—0.82*1: Fuel tank is full. Engine coolant and engine oil are at specified levels. Spare tire, jack, and tools are in

designated positions.Adjust to the median when carrying out wheel alignment.

*2: Difference between left and right must not exceed 45’.

Wheels and TiresEurope

Item 42 44

SizeFront

195R14C-8PR 205/75R14C 235/75R15 105S 205R16C-8PRSizeRear

195R14C-8PR 205/75R14C 235/75R15 105S 205R16C-8PR

Front

Up to fullpassenger

180 1 8 26200 2.0, 28

180 1 8 26180 1.8, 26

Tire Air pressure

FrontFullloaded

180 1.8, 26220 2.2, 31

180 1.8, 26200 2.0, 28

Air ressure(kPa kgf/cm2, psi)

Rear

Up to fullpassenger 180 1.8, 26 200 2.0, 28 180 1.8, 26 180 1.8, 26

RearFullloaded 450 4.5, 63 250 2.5, 35 450 4.5, 63

Wear limit (mm in) 1.6 0.06

Wh l

Size 145J 145 1/2J 145 1/2J 156 1/2JJ 166JJ

Wheel Offset (mm in) 40 1.57 25 0.98 35 1.38

Pitch circle diameter (mm in) 139.7 5.45

Tightening torque (N·m kgf·cm, in·lbf)

Standard wheel: 89—117 9—12, 65—86Styled wheel (166JJ): 118—147 12—15, 87—108

Wheeland tire Runout limit (mm in)

Horizontal 2.0 0.078and tire Runout limit (mm in)

Vertical 1.5 0.059

Imbalance limit (g oz) 10 0.35 One balance weight: max. 60 g 2.1 oz. If the total weight exceeds 100 g 3.5 oz on one side, rebalance after moving the tire around on the rim. Do not use more than two balance weights on either side of the wheel.


CONTINUED


TECHNICAL DATA

TD–14

GeneralItem 42 44

SizeFront 185R14C- 195R14C- 205R16C- 235/75R15 P235/75R1 P235/75R1SizeRear

185R14C8PR

195R14C8PR

205R16C8PR

235/75R15105S

P235/75R15 105S

P235/75R15 106S

Front

Unloaded(Up tofullpassenger)

180 1.8, 26

180 1.8, 26

180 1.8, 26

Tire Air pressure

Loaded(Fullloaded)

200 2.0, 28

200 2.0, 28

Air ressure(kPa kgf/cm2, psi)

Rear

Unloaded(Up tofullpassenger)

180 1.8, 26

Loaded(Fullloaded)

450 4.5, 63 250 2.5, 35

240 2.4, 34

2602.6, 36

Wear limit (mm in) 1.6 0.06

Wheel

Size 145J145J 1451/2J

166JJ 156 1/2JJ

WheelOffset (mm in) 40 1.57 35 1.38 25 0.98

Pitch circle diameter (mm in) 139.7 5.45

Tightening torque (N·m kgf·cm, in·lbf)

Standard wheel: 89—117 9—12, 65—86Styled wheel (166JJ): 118—147 12—15, 87—108

Wheeland tire Runout limit (mm in)

Horizontal 2.0 0.078and tire Runout limit (mm in)

Vertical 1.5 0.059

Imbalance limit (g oz) 10 0.35 One balance weight: max. 60 g 2.1 oz. If the total weight exceeds 100 g 3.5 oz on one side, rebalance after moving the tire around on the rim. Do not use more than two balance weights on the inner or outer side of the wheel.

BODY ELECTRICAL SYSTEMItem Specification

Headlight High beam/Low beam* 60/552

Parking light 52

Front turn light 212

Exterior light bulb capacity (W)Brake light/taillight 21/52

Exterior light bulb ca acity (W)Rear turn light 212

Back-up light 212

Rear fog light 211

License plate light 52

Interior lightStretch cab, Double cab 101

Interior light bulb capacity (W)Interior light

Regular cab 81

Instrument cluster illumination 3.44


CONTINUED


TECHNICAL DATA

TD–15

Oil pressure warning light 1.41

Generator warning light 1.41

Sedimentor warning light 1.41

Brake system warning light 1.41

Warning and indicator light Rear window defroster indicator light 1.41Warning and indicator light bulb capacity (W) Glow indicator light 1.41

High beam indicator light 1.41

Turn indicator light 1.42

Air bag system warning light 1.41

44 indicator light 1.41

LOCK indicator light 1.41*: Also remains illuminated when high beam turned on.

HEATER AND AIR CONDITIONER SYSTEMS

ItemSpecification

ItemG6, WL F2

Refrigerant Regular amount (g oz) 550 19.4

A/C compressorLubricating oil

Sealed volume (ml cc, fl oz)

180 180, 6.08A/C com ressor

Magnetic clutch clearance(mm in)

0.35—0.75 0.014—0.029 0.3—0.6 0.012—0.023


CONTINUED


SPECIAL TOOLS SPECIAL TOOLS.............................................. ST-1 FRONT AND REAR AXLES ......................... ST-3/5

ENGINE ........................................................ ST-1 STEERING SYSTEM ...................................ST-6 LUBRICATION SYSTEM ............................... ST-1 BRAKING SYSTEM ......................................ST-7 COOLING SYSTEM ...................................... ST-2 SUSPENSION ..............................................ST-7 FUELAND EMISSION BODY ...........................................................ST-7 CONTROL SYSTEMS................................. ST-2 BODY ELECTRICAL SYSTEM .....................ST-8

CLUTCH ....................................................... ST-2 HEATER AND AIR PROPELLER SHAFT .................................... ST-3 CONDITIONER SYSTEMS ......................ST-8

SPECIAL TOOLS ENGINE 49 S013 1A1 Compression gauge set

49 9200 020A Belt tension gauge


49 8010301 Oil seal installer


49 S011 102A Crankshaft lock tool

49 B025 001 Body

49 G033 107A Dust cover installer

49 S120 710 Coupling flange holder

49 P005 204 Oil seal installer

49 H011 101A Crankshaft lock tool

—

LUBRICATION SYSTEM

490187280 Oil pressure gauge

49 G014 001 Oil filter wrench

—

ST-1

BACK TO MAIN INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

TO. MODEL .INDEX

CONTINUED

CONTINUED

SPECIAL TOOLS

COOLING SYSTEM

49 9200 145 Radiator cap tester adapter set

— —

FUEL AND EMISSION CONTROL SYSTEMS

49 8120 215B Pulley puller

49L018901 Injector checker

49H01S9A1A Self-diagnosis checker

49 B019 9A0 System selector

499140074 Cam lift measuring device

49 T088 0A3*1

49 T088 0A5*2 NGS set

Program card

SST No. for Program card varies with language • 49 T088 030E (English & French) • 49 T088 031 E (English & German) • 49 T088 032E (English & Dutch) • 49 T088 033E (English & Swedish) • 49 T088 034C (English & Spanish) • 49 T088 035C (English & Portuguese) • 49 T088 036C (English & Italian)

• 49 T088 037B (English & Danish) • 49 T088 038B (English & Norwegian) • 49 T088 039B (English & Czech) • 49 T088 041 B (English & Greek) • 49 T088 042B (English & Hungarian)

49 T088 043B (English & Polish) • 49 T088 044B (English & Spanish) • 49 T088 045B (English & Portuguese)

*1: Except Europe *2: Europe only

CLUTCH

49 0259 770B Flare nut wrench

49 E011 1A0 Ring gear brake set

49 SE01 310A Clutch disc centering tool

49 1285 071 Needle bearing puller

— —

ST-2


TO. MODEL .INDEX

CONTINUED

SPECIAL TOOLS

PROPELLER SHAFT

49 0259 440 Mainshaft holder

49 S 120 440 Mainshaft holder

—

FRONT AND REAR AXLES

49 T028 3A0 Ball joint puller set

49 T028 303 Body (Part of 49 T028 3A0)

49 T028 304 Attachment (Part of 49 T028 3A0)

49 H033 101 Bearing remover

49 B025 001 Body

49 F019 001 Oil seal installer

49 S231 635 Front hub locknut wrench

49 S231 660 Needle bearing puller

49 S033 108 Bearing installer



49 F027 007 Attachment ∅72


49 S120 645A Rear shaft holder

49 0603 635A Rear shaft nut wrench

49 S 120 748 Attachment


49 U027 003 Oil seal installer

ST-3


TO. MODEL .INDEX

CONTINUED

SPECIAL TOOLS 49 H025 001 Bearing installer

49 M005 561 Differential hanger carrier

49 0727 570 Pinion height gauge body

49 8531 565 Drive model pinion

49 0305 555 Gauge block

49 0259 720 Differential side bearing adjust nut wrench

49 0839 425C Bearing puller set

49 F027 005 Attachment ∅62 (Part of 49 F027 0A1)

49 S120 710 Coupling flange holder

49 H027 002 Bearing remover

49 G030 795 Oil seal installer

49 G030 338 Attachment E

49 F401 331 Body (Part of 49 F401 330B)

49 S026 2A1 Rear shaft bearing puller

49 S026 204 Plate (Part of 49 S026 2A1)

49 S026 205 Rod (Part of 49 S026 2A1)

49 S026 208 Attachment (Part of 49 S026 2A1)

49 0710 520 Bearing puller

49 W027 0A0 Oil seal installer set

49 W027 001 Body (Part of 49 W027 0A0)

49 U027 004 Oil seal remover

49 M005 795 Oil seal installer

49 U027 005 Bearing installer


ST-4


TO. MODEL .INDEX

CONTINUED

SPECIAL TOOLS 49 U027 007 Oil seal installer

49 0813 215A Tubular dowel puller

49 F028 204 Bushing installer

49 M005 796 Body (Part of 49 M005 795)

49 U027 0A0 L.S.D. replacer set

49 UN27 003 Collar A

49 UN27 004 Collar B

49 U027 008 Gauge block

49 F027 009 Attachment ∅68 & ∅77

49 U027 009 Oil seal installer

49 UB71525 Bearing installer


49 0107 680A Engine stand

49 U027 011 Shaft (Part of 49 U027 0A0)

49 U027 012 Attachment A (Part of 49 U027 0A0)

49 U027 013 Attachment B (Part of 49 U027 0A0)

49 U027 014 Bolt (Part of 49 U027 0A0)

—

ST-5


TO. MODEL .INDEX

CONTINUED

SPECIAL TOOLS STEERING SYSTEM


49 T028 303 Body (Part of 49 T028 3A0)

49 T028 304 Attachment (Part of 49 T028 3A0)

491232670A Power steering gauge set

49 1232 672 Gauge (Part of 49 1232 670A)

49 1232 673 Valve body (Part of 49 1232 670A)

49 H002 671 Adapter

49 0180 510B Preload measuring attachment

49 U032 3A0 Pitman arm puller

49 B032 304 Adapter

491243785A Dust boot installer

49 U034 209 Clip guide

49 U032 201 Locknut wrench

49 G032 354 Adjust wrench

49 G032 3A4 Power steering gauge adapter set

ST-6


TO. MODEL .INDEX

CONTINUED

SPECIAL TOOLS

BRAKING SYSTEM

49 U043 0A0 Oil pressure gauge set

49 U043 004 Oil pressure gauge (Part of 49 U043 0A0)

49 U043 005 Joint (Part of 49 U043 0A0)

49 U043 006 Hose (Part of 49 U043 0A0)

49 0259 770B Flare nut wrench

49 B043 001 Adjust gauge

49 0221 600C Disc brake expand tool

49 E043 003A Turning lock tool

49 0208 701 A Boot air out tool

49 B043 004 Socket wrench

— —

SUSPENSION


49 0180 510B Preload measuring attachment


49 UB39 615 Bushing puller & installer set

49 U034 2A0 Lower arm bushing puller & installer set


BODY

49 0305 870A Window tool set

49 0259 866A Window inserting tool

—

ST-7

CONTINUED


TO. MODEL .INDEX

SPECIAL TOOLS BODY ELECTRICAL SYSTEM

49 H066 002 Deployment tool

49 D066 002 Adapter harness

49 0839 285 Fuel And Thermometer checker (OLD)

49 N088 0A0 Fuel And Thermometer checker (NEW)

49 D066 801 A Removing tool

49 T088 0A3*1

49 T088 0A5*2 NGS set

Program card

SST No. for Program card varies with language • 49 T088 030E (English & French) • 49 T088 031E (English & German) • 49 T088 032E (English & Dutch) • 49 T088 033E (English & Swedish) • 49 T088 034C (English & Spanish) • 49 T088 035C (English & Portuguese) • 49 T088 036C (English & Italian)

• 49 T088 037B (English & Danish) • 49 T088 038B (English & Norwegian) • 49 T088 039B (English & Czech) • 49 T088 041 B (English & Greek) • 49 T088 042B (English & Hungarian) • 49 T088 043B (English & Polish) • 49 T088 044B (English & Spanish) • 49 T088 045B (English & Portuguese)

*1: Except Europe *2: Europe only

HEATER AND AIR CONDITIONER SYSTEMS

49 C061 0A0A Manifold gauge set (R-134a)

49 C061 012 Anti-back flow valve (R-134a)

49 C061 013 Gas leak tester (R-134a)

49 D066 801A Removing tool

49 H061 005 Attachment

—

ST-8


TO. MODEL .INDEX

ranger drifter repair manual f161!10!99a

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