1997 Mazda MPV Workshop Manual © 1997 Mazda Motor Corporation (9999-95.0388-87)ts, ee it im the ms ach ted ser not1997 Mazda MPV Workshop Manual FOREWORD This manual contains on vehicle service an diagnosis procedures for the Mazda MP\ A thorough familiarization with this manual i important for proper repair and mainte nance. It should always be kept in a hand place for quick and easy reference. The contents of this manual, including draw ings and specifications, are the latest avai able at the time of printing. As modification affecting repair or maintenance occur, rele Sart eaten supleretr : ume will be made available at Mazd. dealers. This manual should be Kept pte date, Mazda Motor Corporation reserves the tigk—-£@2-2-—@ @—@—@—— toalter the specifications and contents of thi manual without obligation oF advan Mt (= All rights reserved. No part of this book ma be reproduced or used in any form or by an means, electronic or mechanical— incl photocopying and recording and the us@, <= any kind of information storage and ete v= system—without permission in writing. WARRANTY The manufacturer's warranty on Mazd vehicles and engines can be voided improper service or repairs are performed b persons other than those @t 2 ALA 2 ————————————————— Mazda Dealer. M208 MO HR0SHMA, 7 APPLICATION: This manual is applicable to vehicles 6 gir ning with the Vehicle Identification Number (VIN), and related materials shown on th. following page.VEHICLE IDENTIFICATION NUM JM3 LV522%VO 800001— JM3 LV523%VO 800001— RELATED MATERIALS 1989 MPV Service Highlights ... 1989 B-series, RX-7, MPV 4 Wheel Drive Service Highlights 1990 626/MX-6, MPV, 929/928: Service Highlights paren 1996 Protege, MX-3, MX-5, 626/MX-6, 929, MPV, Mille Service Highlights .. 1997 Protegé, MX-5, 626/MX-6, MPV, Millenia Service Highlights .... 1997 MPV Wiring DiagramGENERAL INFORMATION GENERAL INFORMATION .... 00-00 SECTION 00-00 HOWT GENERAL INFORMATION mbal ‘Advisory Messages “Troubleshooting Pr. Pr EC Text ‘Conversion to $I Units SAE STANDARDS ns tc Wiring Harness. ical Tr VEHICLE LIFT (2 SUPPORTS) AND SAFETY ‘STAND (RIGID PACK) POSITION... . 00-00-17 Vehicle Lif and Safety LOCATIONS ..... jemoval-of Paris, Tsassom “Vehicle Identification Number (VIN) Inspection During Removal, Disassembi ijustments (Except Canada) .... A [Rubber Parts and bina ‘Scheduled Maintenance Table Hose Clamps . (Canada)... 00-00- 4HOW TO USE THIS Mj Range of Topics © This manual contair all of the required dures are divided in tions. | (1) Removal / instal (2) Disassembly (3) Replacement (4) Inspection (5) Adjustment Simple operations justby looking at th lation of parts, jacki and visual inspecti¢ Service Procedure Inspection, adjust mer © The procedures for divided into steps. location and cont plained in detail anGENER Repair procedure 1. Most repair operations begin with an overvie, together, and describes visual part inspection. be performed methodically have written instru: 2. Expendable parts, tightening torques, and sym_ tion. In addition, symbols indicating parts whic are also shown, 8. The procedures are numbered and the part tha the corresponding number. Occasionally, there’ to this information when servicing the related ‘SHOWS SERVICE ‘SHOWS PROCEDURE ORDER — FOR SERVICE SHOWS TIGHTENING ree TORQUE SPECIFICATIONS. SHOWS THERE ARE REFERRAL NOTES FOR SERVICE owe Tatlng nk Bal doin, Upper Te omove aoa toy using the SST SHOWS REFERRAL NOTES FOR SERVICE‘Symbols © There are eight syr ant, and the use o points of applying| service. Ap jel Advisory Messages You'l find several War fications and Upper: Warning © AWarning inc ‘ous injury or ing is ignore Caution © A Caution ir ‘damage to thy tion is ignore Note © ANote provid you to comple.Diag eT ft Quic .T k Proc UsinUsing he alk gnosis char Fa Reena en 2 rere oer and spoutientno opch ott con 0 eee scer ect eee ae Soa eer Tree ome © CHOOSE THE ACTUAL ‘SYMPTOM DETERMINE THE (CAUSE OF THE TROUBLE DETER- MINED AT PROCEDURE 2, BASED ON THE RESULT OF THE ) 5 MECHANICAL SYSTEM Test‘STEP sho! of troubles, INsPECTI an inspec to quia the falled] Reteroncs the deta to perto Tons s Text Seg| © Thet|UNITS Eroctical curent [Electric potential Electric power Length Negative pressure Positive pressure | Resistance Torque Volume Weight ‘SAE STANDARDS ON are now used in th manuals up to ny = [Air Condit CC __ = __|Airlow Ser = [Aternator — | ATF Thee — | Atmaspher Vp Battery VolPrevious ¢ ‘Abbr. Catalytic C Circuit Ope ‘Clutch Pos (Crank Angi ‘Crank Angl Diagnosis ( Diagnosis Direct ignit EC-AT Cor Elecironig! System Electronic! Engine Cor Engine Mo Engine RP Evaporativ Exhaust G [Fan Contre Feedback: Flexible Fu Fuel Pump Fully Close Fully Open GroundiEa IC Regulat Idle Speed Ta Igniter Inhibitor Pe Intake Ai Intake Air Intercooler Maltunctior Muliport F (Open Loor Overdrive,Oxygen Sensor Parkour Range. Power Steering Pree so Gonerator J — [Reed Valve — | Secondary Air Inject Sequential Fuel el I = Ser grit [Stoplight Swich — | Test Mode | ee | —__|Wehicle Speed Sens, — [Water Therma j 1-2 Shift Solenoid Shift + A Solenoid Vi FUNDAMENTAL PROCEDUR| Protection of the Vehicle © Always be sure to cover § areas before starting work.Special Tools Use special tools when they are « Disconnection of the Negative Bat Before beginning any work under rect the negative (~) battery cat Removal of Parts While correcting a problem, try al cause, Begin work only after fi parts and subassemblies must be assembled for replacement or rep the part, plug all holes and ports ‘material rom entering. Disassembly ithe disassembly procedure is ¢ many parts to be disassembled, disassembled in a way that will no mance or external appearance ar reassembly can be performed ea Qe ‘@GENERAL INFORN Reassembly Rub! Standard values, such as torques and certain ad- e F justments, must be stricly observed in the reas~ ° sembly of all parts. I removed, these parts should be replaced with new ones: 1 [Ot seals 2 [Gaskets 3 [O-ings | 4 [hockwashers 5 [Cotter pins 6 [Nylon nuts Host oy c Hi Depending on location: 1. Sealant, gasket, or both should be applied to the 4 specified locations. When sealant is applied, parts should be installed before sealant hardens. ‘Hard- ened sealant causes leaks. 2. Oil should be applied to the moving components of arts - 2, Bpocitid oi or grease shouldbe applied atthe pro scribed locations (such as oil seals) before reas- sembly Torg ra 1 4 Adjustments Use suitable gauges and testers when making ad- justments. II—_—_—_—_—_—_:Vise ow of INsTe Htarac eredty fected obser 1. Inv ELEC Electr Batte © Be tri Conn Data ein in,GENERAL INFORI © Connectors can be disconnected by pressing or pulling the lock lever as shown, Re dn AE Locking connector * When locking connectors, listen for a click that will indicate they are securely locked. of ew Ss Ze Inspeotion 1. When a tester is used to check for continuity or to measure voltage, insert the tester probe from the ring harness side. 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 insertin, into the terminal. 00-00-14Sensors, Switct ‘* Handle sens: ‘not drop * Wiring Harness Wiring color co © Two-color wi symbol The frst et andthe sod CODE [ot 8 & BR 6 an C i ie | ua we [tg an Fuse Replacement ‘When rela of the spect has been re land tho wi 2.Be sure th nected beforGENERAL INFORMATION Caution * Donotconnectajumperwire fromthe power Ohmmeter sourcelinetoabody ground; thismaycause The ohmmeter is used to measure the resistance burning or other damage to wiring har- between two points in a circuit, and to check forcon- nesses or electronic components. tinuity and short circuits. Caution '* Do not connect the ohmmeter to any circuit to which voltage is applied. This will damage the ohmmeter. POWER SOURCE LINE ‘GROUND UNE. Voltmeter © The DC voltmeteris usedto measure circuit voltage. A voltmeter with a range of 15 V or more is used by Grameen ue Gonnectng the postive (e) probe (ed lea ire) 0 the point where vallage so be measured and the negative (—) probe (black lead wire) to a body ground VOUMETER POWER Source UNE [ LACK Le weoLeaD oreo su JACKING POSITIONS Warning Front ‘¢ Improperly jacking a vehicle is dangerous. _A the center of the cross member The vehicle can slip off the jack and cause serious injury. Use only the correct front and rear jacking positions and block the wheels. Use safety stands to support the vehicle afterithas been ited, 00-00-16Rear Atthe center of t iS a VEHICLE LIFT ( Vehicle Lift and Front Both sides of the TOWING * Proper towin damage to tr + Laws and re must always # Asa general wth the devi damage of 0 Ce whee! dole + For vehicles hooks, do n cemergencie oh ——=<$<<$<<——=£. £—@$£ = —=@@—< the vehiceTo) To teIDENTIFI Vehicle | Engine |ABBREVIATIONS ‘After Antilo, | Acces Auton TOC ATF ANS BAC BAROTEM [Baron BARO V [aro fee0c [Beto _[Bitevt Brake : ORL EcTV [Engin el Elects ELR__| Emer Far — FHO2S | He HA HU TACV [iaToc v_ ATV rina IGN. lanitPRE-DELIVERY INSPECTION Pre-Delivery Inspection Table Exterior INSPECT and ADJUST, if ne items to specification: Glass, exterior bright metal anc 1 Whee lug nuts and locks (i eq] All weatherstrips for damage 0. Operation of hood release and! Operation of fuel lid Door operation and alignment 5) Headlight aiming INSTALL the following parts: ( Wheel caps or riugs (if equippe| Mast antenna Under hood—engine off | INSPECT and ADJUST, if nec items to specification: 1 Fuel, coolant, and hydraulic ines} ‘and components for leaks Engine oil level Power steering fluid level Brake master cylinder fluid lev C] Windshield washer reservoir te Radiator coolant level J] Tightness of battery terminals Interior \ CHECK the operation of the follow ‘Seat controls (sliding and reci Air bag system using warning f Cruise set using indicator light Ignition switch and steering lo Power window (if equipped) Power door lock (if equipped) Door locks including child procf Transaxle range switch (AT on| All lights including warning an« ignition key reminder buzzer ( Hom, wipers, and washers equipped) Wiper blades performan Clean the wiper blades and wit Antenna 5 Cigarette lighter and clockSCHEDULED MAINTENANCE ‘Scheduled Maintenance Table (Excel Schedule 1 (Normal driving conditio| © The vehicle is mainly operated whe Maintenance item Oilfiter Tension ofall di Engine timing bel Engine timing belt POV valve [Hose and tube for emission Air cleaner, Air cleaner element Ignition system Spark plugs Initial ignition timing Fuel system ‘Automatic transmission fluid Front axle oll (@WD) sar axle ol Transfer case oil (4WD) Steering operation and linkages Front suspension bal ons Driveshaft dust boots (8D) Bolts and nuts on chassis and b Exhaust system heat shields Alooks and ringes Air conditioner system (W equipped) [Refigerantamount ‘Compressor operationMaintene| [Disc brakes ‘Automatic ram Front axe ol Rear axle oil Transfer Drive shaft dy Bolts and nut Exhaust syste All locks and [Refrigerant a ‘Compressor Chart symb 1s Ingpect ar R | Replace L$ Lubricate Remarks After 48.0 intervals. ‘Scheduled Maintens Engine Engine Ol fiter Tension ofall Engine timing Air cleanerod LM Maintenance item — | — Fuel system Idle speed Fuel in andhoses Ful filter POV valve? Emission hoses and tubes (Chassis and body ‘Automatic transmission fui lev st ‘Automatic transmission ol il level in differential and transf| (in models so equipped) [Front torent oi aWO) Rear diferent oi fer case oil (AWD) _ [Driveshan dust bots (WO) | Brake ines and hose Brak id level Brake fuid Disc brak Tire inflation pressure and tre we Tires Power steering fluid level ‘Steering operation and linkages wheel alignment) ‘Suspension components (Font a ‘All chassis and body Nuts rd 6 ——————_________ | Exhaust system heat shields Alllocks and hinges ‘Washer fluid level Function of all lights Air conditioner system (i equ Fofrigerant amount Compressor operation Chart symbols. 1 Inspect and repaie clean, or R : Repiace Lubricate Rt: Rotate (tires) Remarks ‘© After 60 months or 60,000 intervals Refer below for a descript Replacement ofthe timing b to the engine. Tris maintenance is recommy| recall abilTROUBLESHOOTING 8. Start the engine. After repair procedure 4, Select "DIAGNOSTIC TROUBLE CODES" function _1. After repairs, connect the NGS to the data link con- and press TRIGGER, nector 2 2. Select “CLEAR DIAGNOSTIC CODES" function and erase diagnostic trouble codes from the NGS memory. .When "NO CODES RECEIVED/SYSTEM PASS- ED" is displayed, all systems monitored are judged anion 0k. 6. When any of the diagnostic trouble codes is dis- 3. Carry out OBDI drive cycle procedure twice. played, carry out troubleshooting according to the 4. Start the engine. code. 5. Perform diagnostic trouble code inspection again, 7.When “LINK MONITOR ERROR’ is displayed, and verity that no diagnostic trouble codes are dis- check connection of the NGS, played. 8. After all problems have been repaired, carry out “After repair procedure” OBDII Drive Cycle Procedure Note Disconnecting the battery will reset the memory. Do not disconnect the battery during and after this procedure. * Vehicle speed and engine speed detected by the PCM may differ from that indicated by the speedometer and the tachometer. Check the vehicle speed and engine speed during driving mode by using the SST (NGS). ‘Ifthe OBDII system check is not completed while the drive cycle procedure is carriad out, te following cause is guessed, 1. The OBDII system detects the malfunction. 2. The drive cycle procedure is not completed correctly 01-01A-2Comp * eri MODE 1. Ste 2.Ve tor 3.Ve sp 4. ifr, spTROUBLESHOOTING 1 (pm) N2 (rpm) 2000-3000 4000~5000 7. Idle the engine for more than 20 seconds with the electric cooling fan stopped. MORE THAN 1 see. FOR EACH — ENGINE SPEED MORE THAN VEHICLE STOPPED 20 sec. (Prange) ioue. * With electric coating fan stopped, MODE 3 1. Verity that all following conditions are satisfied. MODE 2 1. Start the engine and warm it up 2. Verify that all electrical loads (he tor and rear window defroster) a 3. Drive the vehicle at the constant km/h { 40 mph } for 60 seconds : ‘seconds from engine start. (D re 4, Drive the vehicle at the constant { 42.5—52.5 mph } for 180 sect Note ‘© Driving mode before the cor is not specified. ‘Above 65 kh {a0mph} VEHICLE {oranoe) SPEED |_ Above 300 sec sosec. | | START ENGINE ‘Engine coolant temperature is O—35°C { 32—95°F }, Intake air temperature is 10—60°C { 50—140°F } Barometric pressure is 72.0 kPa { 540 mmHg , 21.3 inHg } or higher. ® Fuel gauge needle points within 15—85 %, 2. Start the engine and race it at 3,500 rpm for 200 seconds to warm it up completely. 3. Within 240 seconds after engine star, start the vehicle and accelerate to 65—95 kmh (40 mately 20 seconds. 4, Drive the vehicle at the constant speed of 65—96 km/h { 40—60 mph } tll 360 seconds afte 01-01A-4TF = ENGINE SPEED 3,500 rs ENGINE SPEED COLD START Diagnostic Trouble Code Table Display on the N| | ECT—CIRCUIT MALFUNCTION TPGIRCUIT MALFUNCTION EXCESSIVE TIME TO ENTER Cl "028 11—CIRCUIT MALFUNCTIO (28 11—CIRCUTT No ACTIVIY| [02s 11—HEATER CIRCUIT MAU P0140 | 02S 12—CIRGUTT NO ACTIVITY| [porai 02s 0170 “0300 | RANDOM MISFIRE DETECTED P0301 CYLINDER 1 MISFIRE DETECTE | Pose OvINDER? MISFIRE DETECTE| P0909 | CYLINDER 8 MISFIRE DETECT 0304 | CYLINDER 4 MISFIRE DETECT Posos — | cvLNDER s MiSFIRE DETECTE P0806 | CYLINDER 6 MISFIRE DETECT | posss [CRANKSHAFT POS SENSOR —< P0420 | BANKC1 CAT EFFICIENCY BELO| Po42_ | EVAP SYSTEM—MALFUNCTIOI Poas3_| EVAP SYSTEM—PURGE CTRL P0446 | EVAP SYSTEM—INCORRECT Pl Jimbo i EVAR SYSTEM INCORRECTIRY P0450 | EVAP SYSTEM—PRESSURE SE Poas5 | EVAP SYSTEM—GROSS LEAKore t os00 | VEHICLE SPEEC | Pos0s IDLE conTROL CLOSED THROT BRAKE SW—MA \ATS (010) OPER HO2S17—INVEF EGRVS—OPEN ‘SGC SIGNAL [eocv—oPeNn c [EVA SYSTEM. ‘ACCELERATE Vj ‘COMM LINE (AT POME (CPU—ly BAT—BAT ORC 1797 _ | PNS—OPEN OF ‘CALIFORNIA 2WD ONLY Diagnostic Trouble Code ' DTC Po100 Al ‘© Input vol DETECTION |« Mass ing CONDITION |” mand |= Mass in voltage "= Mass ai = Open of POSSIBLE Causes |¢ Pero ISTEP] | 2. [1s ECM terminal 38 vot Turn ignition switch to 0 voltage at connector ter Is there continuity betw ‘and ECM terminal 48? 5 | Is there continuity betw and ECM terminal 38 6 | ls mass air flow sensor7 [Is voltage incre valve opening & | Erase diagnost Issame code N pair procedure! DTC Por0 DETECTION |~ _ CONDITION | possiate |! CAUSE. | ISTEP 1 [Does massa nectorhave po Is ECM t Disconnect Turn ignition terminal C? 4 [Is there contin and ECM term Is mass air flo [Dre Pons DETECTION CONDITION POSSIBLE CAUSE STEP OU —————— connector hav2. [Is ECM terminal 3E voltage OK? 3 [Disconnect engine coolant temperatu connector Turn ignition switch ON. Is there 5 V at terminal A? 4 Is there continuity between connector | and ECM terminal 307 '5 [Is engine coolant temperature sensor O| 6 | Erase diagnostic trouble code from mer| Is same code No. present ater performi pair procedure? wev| DTC P0120 TP—CIRCUIT MAL Input voltage trom thot ‘© Throttle opening angle i ‘and mass intake aitlow += Throttle opening angie | airflow is below 10.6 gi ‘Throttle position sensor ‘© Open or short circuit in (Open or short circuit in | (Open or short circuit in Mass airflow sensor ma ISTEP | INSPECTION 1 [Does throttle position sensor connect connector have poor connection? DETECTION CONDITION POSSIBLE CAUSE 2 | Is ECM terminal 3L voltage OK? 3 | Isvoltage increase linear according to th | opening angle? 4 | Disconnect throttle position sensor cont ‘Turn ignition switch to ON. Is there 5 Vat terminal A? \ Is there continuity between connector ‘and ECM terminal 3F? a @ [Is there continuity between connector ‘and ECM terminal SI? 7 [1s mass air low sensor OK?en | =—er a 1 | oe “A se fe AT[STEP 1 | Doas heated om ECM connector Is ECM terminal 3_| Disconnect heal tor. Is there continu and ECM termir Cet _—_—<£<£<£$§$—$——<$<$<————<—————————————————— ‘and ECM termi | Are following un. ‘© Fuol injector ‘© Pressure reg CE ____ Engine coola) 8 | Era i | Issame code No [DTo Porss DETECTION |? CONDITION | POSSIBLE ECM connector 1s EGM termina 3_| Disconnect hea brand ln << positive voltage TEE 4 Is there contin land ECM termir 5 | Is there continu | ana cr 1[ster] INSPECTI 6 | Erase diagnostic trouble code Is same code No. present after pair procedure? DTC _Pot40 028 12. When heated o DETECTION | below 0.55 V for CONDITION | position switch i heater (Rear) Low fuel ‘© Heated oxygen : POSSIBLE ‘© Open or short CAUSE |S Open circuit in 4 Intake-air syste [stEP INSPECT! 1 [Does heated oxygen sensor (F ECM connector have poor conn 2 | ls ECM terminal 2K voltage OK} 3 | Disconnect heated oxygen sene tor. Is there continuity between cor and ECM terminal 30? 4 Is there continuity between cot, and ECM terminal 2K? © | Are following units OK? ‘© Fuel injoctor Pressure regulator Mass air flow sensor Engine coolant temperature Spark plug © Ar suction (Ain/Fuel ratio rich, 6 | Erase diagnostic trouble code # Is same.code No. present after ¢ pair procedure? DS POIaa OH gener | Ean © ECM voltage is CONDITION | "heated oxygen!a fs POSSIBLE CAUSE ISTEP, c POSSIBLE Does heat ECM conn: 7 is ECM termi Di nnect side connectd | tre battery ¢ Is there contin] terminal D an [Is there contin terminal D ang iseamocsce] |patrproceaurg CAUSE [ster here a i 5 2 [ls heated oxy 3. [lstuelline al a a[STEP] 6 | Is fuel injector OK? 7 [Is engine coolant temp: 8 [ase a Fou soword ‘9 | Is throttle position senso 10 | Is closed throttle positior 11 [Is intake air temperature 12. | Is purge solenoid valve 13. [Is PGV valve OK? 14 | Erase diagnostic trouble: Is same code No. presen pair procedure? [STEP conpiTion _|* ECMinp] = larition © Low uel POSSIBLE | Lowbatt CAUSE |* Fust sys Insutfic Cranks NS 1 | is ignition system OK? 2 | Isigniton ting within 3 3 Is orankshall position sa 4 [Is fuel system OK? 5 [Is compression at alloy 6 | Erase diagnostic troubio| Is same code No. preser| pair procedure? DTS Pood ow GoNDmION | * FOM ney > anon reer possieue /> Low ba CAUSE. > Fost Inti Cranish1 [Is ignition sys 2 [is gntion ami, 3 | is crankshat 4 [Is fuel injecto | Is fuel syste 150 dagnoa| issamecode pair procedur| DTC P0302 DETECTION | CONDITION POSSIBLE CAUSE [STEP | wa Ts ignition tim | Is crankshaft Ts fuel injecto| Is fuel syster is compressi DTe P0303 DETECTION _ CONDITION POSSIBLE CAUSE[STEP | + [Isignition syste 2 | Is ignition timin 3 [lecrantshalip 4 [Is fuel injector 5 [is tuel system, [Is compressior 7 | Erase diagnos Is same code air procedure DTC _Pos0s DETECTION “CONDITION POSSIBLE CAUSE [step | 1 [Isignition syst 2 | isianition a 3 [Is crankshaft c 4 Ie fuel injector fuel system 6 | Is compressiol 7 | Erase diagnos Issamecodet i 9. DTC P0305 DETECTION CONDITION POSSIBLE CAUSE4 [lst 5 |istud [6 [ise “7 | Erast Issar aire DTC Po20 DETECTI |_conpiri PossiBl ‘CAUSE[STEP 7 | Does ral connect 2 | Disconnd Is there and ECK is there and ECM 3 | Is cranke| Erase di Issame gy, pale pr DTC _Pos20 DETECTION CONDITION POSSIBLE DTC Pose DETECTION |_CONDITION POSSIBLE CAUSE ee 7 [isEGM 2 [Are eva hose ey [is charee a] — bre Is thare contd DTC _P0s00 DETECTION ‘CONDITION PossisLe |* cause |t [sTeP|_ : 1 [Does vehicle sr, rector have po} 2 | IS ECM termind 3 | Is there contind terminal and EC and speedome Ts vehicle speer Erase diagnost IssamecodeN Pair procedure’ PO5OS DETECTION CONDITION POSSIBLE CAUSE Does ide air o¢ rector have po 2 |isinako-ar ed | Disconnectiai: | continuity betw relay terminal &ster Ng 7 | Erase dagnoste rouble ~ Issame code No. presen pat procedures \ DTC _POBtO cL, DETECTION |» Closed i CONDITION |” too—20 * Ciosed t) Possise | Throtiod! CAUSE |S Open ors 2 Open ord STEP INE 1 | Doas throttle positon = connector have poor co Is ECM terminal SL volt there continuity betwe, | ang ECM terminal 3.7 4 | Is there continuity betwe and ECM terminal 307 & | Isclosed throttle position have poor connection? “6 | Erase diagnostic trouble DTG Pore) [BRA DETECTION | Brake su rogeite 1 | Does brake switch cone. 2 [Is ECM terminal 1@ volSTEP INSPECTION 3 | Is there continuity between brake sw and ECM terminal 107 a | Erase diagnostic trouble code from m Is same code No. present ater perforr pair procedure? DTC Pii0 TATS (01G}—OPE DETECTION |~ Input voltage from int | CONDITION | + Intake air temperature Intake air temperature posse |* Onmorenatcceay OSSBLE [na Sk [sTEP| INSPECTION 1 [Does intake air temperature sen Disconnect intake alr temperature ser ic chamber) connector. Turn ignition — ‘ie 4 [shee contaalty bet068n oN and ECM torminal 307 5 |/s intake air temperature sensor (Dy ber) OK? 8 ea os |[ssomecouo We. prosontatorpr [pair procedure? Dre Pri70 18 DION |. Wii CONDITION | _ reached nocmal oper * Low fuel POSSIBLE | Heated oxygen sense CAUSE |» Open or short circuit «© Intake-air system, fu [STEP PEC ON. s—a—omooaow= 1 | Does heated oxygen sensor (Front) ECM connector have poor connectio 1s ECM terminal 30 voltage OK?Disconnect heated tor. Is there continu ‘A.and ECM termine ‘Are following units Fuel injector *# Prossure regulal © Mass airflow se # Engine coolant t * Spark plug # Aiesuction (Aid diagnostic tr Is sameccode No. p | pair procedure? pre Pies DETECTION |. a, conoition |* &* POSSIBLE |, 5, Cause | | Erase diagnostic |issomecsze te 8 par pocore? DTC P1196 DETECTION |~ Inp CONDITION | _2.0 POSSIBLE | Si CAUSE | Op, ISTEP | 1 | Does starter & aor connection? 2 [Is ECM terminal 1¢ Disconnect starter | Is there continuity ‘and ECM terminal Frese Jaros s same cade No. p pair procedure’ ors Fi TeTeETON |= op Conornon |" Ok possiste |¢ PF cause [2 OPDoes PRC scien __ rector have poor conn Disconnect PRC salen Tun ignition switch O voltage at connector te ts bee oti) 6——$<—<—<—$——— and ECM terminal 42 5 Tis there continuity bet | 6 | Erase diagnostic troub Is same code No. prest pair procedure? a 3 DTG Piass Fi DETECTION |» pon Gonpmon |" Sk ossipue |) FR} cause |¢ Per ste, 1 1+ [Does PRG solenoid noctor have poor conn Vin as 9 | Disconnect PRC 51 EEE voltage at connector 4 |bhee cin _—_—— ‘and ECM terminal 4? 4° m 5 | sher< nin rminals A and 8? Ca. 1888 00 0. O_O pair procedure?POSSIBLE ‘CAUSE ISTEP: Turn ignition switch to | voltage at connector te | and ECM terminal 4G? [Is ECM terminal 4G vos 5 | ls camshatt postion sc Erase diagnostic rouby Is same code No. presi pal procedure? bre _piasa Tey DETECTION |. Onon J CONDITION pen Gf Possiste | 2 Caste CAUSE Open f 1 [Does 6 or ECM connector hi Is ECM terminal 26 vo}, | iarition switch to ON. I | age at hamess side col 4 [Is there continuity betw. nage nsecomenoy[STEP 6 | Erase diagnostic t Is same code No. pair procedure? BTS Pree verecrion |* £ Cuson | & ~ POSSIBLE °c | Pentre [36 sree 1 | Check ifhose ane | coal canister, and ‘Are hose and piph 2 | Check if canister | Is canister drain 3 | Erase diagnostic Is same code N pair procedure? DTC P1455 DETECTION CONDITION POSSIBLE CAUSE STEP 1 | Doas fuel pump have poor connex 2 |Is ECM terminal thes gauge OK" 6 | ster cont y—$<$<——— connector termin7 Erase diagnostic troub Is same code No. prese pair procedure? DTC Ptsat VE DETECTION CONDITION 3/2 POSSIBLE CAUSE 9 ‘Does VAIS solenoid va ior have poor connect 2 [Is ECM terminal 4k vo 3 | Disconnect purge sole ignition swt la | terminal B and ECM te | 5 ||sthere continuity bet ‘minals? 6 | Erase diagnostic rout Is same code No. press pair procedure? Dre Pisa? [AC Ew oetecrion | ECM Gonortion /* He ________________ Bypas possiste 2 ithe CAUSE | Open | 2 Ober sre I 7 | Doss bypass soon connector have poor[STEP I 2 |[Isintake-air system OF 3 | Disconnect bypass ais there continuity betweer main relay terminal D? 4 [is there continuity betw ‘and ECM terminal 1V2 |S there continully bet | valve connector termine 6 | Is Bypass air solenoid w 7 | Erase diagnostic trouble Is same code No. preset pair procedure? el TO P1601 [co DETECTION CONDITION _|* Sana! POSSIBLE [+ Opon CAUSE [+ Openar [STEP Te 1 | Does TGM connector or 2 || there continuity bah TCM terminal 2N? 3 | there continuity betw TOM terminal 2K? Erase diagnostic troubl Is same code No. pres pair procedure? OO DETECTION conoirion_|* ECM POSSIBLE sAUSE | DTC Pi79s BA DETECTION CONDITION © ECMTROUBLES! * Battery malfunction Cee (Open or short circuit in wiring from ECM CAUSE |e Burnt MAIN fuse [stEP| INSPECTION 1 [Is battery fully charged? Yes __ No. 2 [Is MAIN fuse OK? Yes | No. 3 | Doesbattery positive voltage presentat EGM termi- | Yes alr? S 4 | Erase diagnostic trouble code from memory Yes Is same.code No. present after periorming After re- | pair procedure? DTC P1797 PNS—OPEN OR SHORT DETECTION | ECM detected that transaxle range switch CONDITION | _ engine speed is above 1,810 rpm and ver Transaxle range switch malfunction POSSIBLE Neuiral/clutch switch malfunction CAUSE ECM malfunction (pen oF short circuit in witing from ISTEP | INSPECTION | 1 | Does ECM connactor have poor connection? 2 [Is ECM terminal 1L voltage OK? 3 [Is there continuity between transaxle range ewitch | Yes terminal B? 4 | Is transaxle range switch OK? 1 | Erase diagnostie trouble code from memory. Yes Is same code No. present alter performing Alter re- | pair procedure? ENGINE SYMPTOM TROUBLESHOOTING Diagnostic Index Confirm trouble symptom by using the following diagnostic index, then go to appropriate trouble- shooting chart No. TROUBLESHOOTING ITEM Discharged battery o 2 | Willnot crank or cranks slowly 3__ | No combustion 4 | Combustion observed but engine wil no 8 | Cranks normally but hard to start 6 | Low idle speediEngine stalls or vibratesTROUBLESHOOTING ‘TROUBLESHOOTING ITEM DES Tile peed excessively Righ & Idle speed excessively high ‘normal speed after warm-up| Engine runs normally at idle | excessively when load (EL, | 10 _| Engine stalls when vehicl 11__[ Engine stalls on acceleration and while cruising 1 Poor acceleration/Insufficient poweriSurges while cruisingHestates 13 | Runs rough during deceleration/Backtre [ioe ccoursin oust eon Fuel consumplion increased 16 | Poor fuel economy J fe So starting, acceleration, or braly 17 [Fuel odor Fuel odor in passenger or ent Quick Diagnosis Chart 01-01A-30TROUBLESHOOTING 1] Batarped baton 2 | witear aaa canta domly 3 | Neconburton OLoyf- 1 | Segiason obs aoa itt Gen © | Low tt speodnge stats ovvates 7 | Hah speed 3 [ ie apeed hardener Peagh fieteine als when EX, PISor een 1 | Eine date when vohziaboutio ong Te | Pegacsebestoreaticen ponerSaroee sn ula ostioe 7S | ins ough ring decalortonactire 7 | Reecsna 15 | Ovenesing 16 | Poors eco eo melo mm /| imme Fuelaystem 7 | Foster symptom a ae ‘Sane pel ou ~ Tot by “Cranks pion anaoh Inspection aE To acaertor eb FREY Tega Walestbon son | recto segue Syne | o 6 erin | Epa spo ‘Dapiosiewoute | Diagnose woubie cade) poston | Sut Trapecton ving | Inuaon votage nt ger Secisarope”? | ies . 01-01A-31TROUBLESHOOTING TEE EEE 7 ‘ : : : tt : ‘ 1! [Willnot crank or ranks slowy 2 Cont bored od ge rata [4 TH6 Cie mae at 5 aie ‘nat pecieeeweo [ © We Tehanapd 7 ; Tae pond nti 7 : snore : mee : Ene sa wren abate ; Engels onan otio i | [ee Tp " [pameasnotecane meron | we Te: Tare eup daha doronbaave | : cain Seat 7 TE CCE ee are a SEE TET tte 7 "Control deve system - 7 a alils lela lé Trout Plalele| a : Son PLETE tay d Hl, alqia : TlFk ElEla| El & e/a ik alalilal| Elalt came fli Elil: ma Plilelil i 3/2 [8 : 7 < : lds Ble method é £ : nile S)Ele Sa elaslegae Siessla hacia BES a|RSlES/E ELE ee AH = - PUREED EE EE|E TERE BIERERSIERIE Cae ea : aay crag fool: eee 1 | wearion stuck ona pig | PVN : : ‘ol t ‘ : ‘ yt | Gravis white with all plugs aeRERn aiaale Tapers | Sera or ; 1} reper oseat tas a jo r] opr de ‘ uur code inser a tt } Seerenaererency | emee eel ; Q a Sane 01-01A-32= Wo comball co Tae al v [ee Sates dy wat ormTROUBLESHOOTING Dee| va Toe a xe te = co | y p a 01-01A-34 ° Oo o|o o|o ‘Pewous eu NER NAL nero rea 3 SS Jo|_|- - of fT ot] . tobe eer : _ ° - fe}. le a 3 i S i o|o - “ETE. . a fone a od ne ee fe ene df. }O |O ~ olo]o|o ong j EE] nmr son ween : : a ‘Symptom Troubleshooting[+ [Discharge {TROUBLES O Chargingidischar} @Battery (insutt ® Generator (Ing nf [1 [Cary outr Is battery Carry out 2 [Will not f [TROUBLESHOd Starting device Starter (Oama| Te battery ry out Is starter 3_[No comb TTROUBLESHO: Spare roti Siantion coi a tordsconnect Fuel not distrib Fuel pum ro 2) Fuel pump (Pe Low compressio ster 1 | Gany out }ismain co Are conne ‘control me normally € Are inteke nection ar 4 [Carry ou Is fuel pur SS —_—_—_—_—<$—$—————————————— Isstrong e “e | Gary out fewalpur 7 [earn out torso 8 [Cary out IS uel ine oylingersy | Cary out | is ue! preTROUBLESHOOTING (STEP) INSPECTION T “ACTION 10 | Cary out compression inspection Yes | Replace ful Istcompression correc? al [a [Combustion observed but engine wil not start _ [TROUBLESHOOTING HINTS} Spark weak at al oyinders/not sible at specific cinder @ Fuel pump (Insulicient cscharge pxessuravolume—in- IG Spark weak at al cyinders—ignton co (deterioration, teal damage) damage), Distributor cap (damage) Ar sucked in rom intake system J@ Spare na visible at specie cyinder—High-tenion lead Pressure regulator deteroratedidamaged claphyagmn) (damage, excessive internal resistance). spar pug Inauficet intake air amount {Samage, deterioration, contamination) @BAG valve (stuck, clogged internal passage) Anu! mixture too lean iste INSPECTION ACTION [Star engine while depressing accelerator] Ves | Gotonext sap podal sight ——— = Boos enging stat? No | Goto step 4 2 | Carryout IAC valve inspection Yes _| Gotonen step _ fete waive Ok ‘No Replace BAC valve __ 3 | Cary ou air valve operation inspection Yes | Check ECM terminal vallage Is irvalve operation normal? |v | SMIAG valve contol signal No [Replace BAG valve ‘re intake air system hoses rea ofiscon- | Yes [Go to net step | necton an damager Ne Ropar 3 | Carry aut fuel injector operation ispeciion | Yes | Go tonext step Is el injctor operation sound hears? No [Rapa or ralace [Carryout ignition timing contol inspection | Yes | Go to net step Ieignition ming at cranking correct? No | Repair or rapecs 7 | Carry out uel pressure inspection Yes | Goto next step Is tue pressure corect? isi apairorrepo @| Remove al spark plugs and check thr cond | Yes | Replace fl tons Are they OK? No _| Repair or replace | Granks normally buthard to start [TROUBLESHOOTING HINTS) Inaulelent residual uel pressure Percolation JG) Fuel pump (Residual pressure not heid—intemal dam- Pressure regulator control does not operate age) ister INSPECTION ACTION + [Does starter rotate normaly? Yes_[Gotoned slop No | Goto symptom roubieshootng No? “il nok rank or rank slowly = 2 [Does symptom occur ony al staring while | Yes | Carty ut pressure regulator control inspection engine's hot? cum Go resin 3 | Check the ECM terminal voltage Yes | Goto next step Starter signal — Isvotage corect? No _| Repair or replace 7 | Carryout uel prossure hold napeaton Yes | Replace fut Is el presoure hold corect? Ne [Repair or repians ; 01-01A-36TROUBLESHOOTIN 6 | Low idle speed/Engine stalls or vibrutes [TROUBLESHOOTING HINTS] For quick troubleshooting, fist determine when (engine spar coldihoValways) problem occurs, and then where (at all * Inco eylindersispeciic cylinder) it occurs. clogs = Low Problem oocurs only when engine is cold Probier! I air valve (malfunction) © Airk Engine coolant temperature sensor (characteristic © Spar deviated-detects engine hat condition) Problem occurs only when engine is hot I Pressure regulator control inoperative @improper fuel used (percolation) Problem occurs at any engine temperature © Problem occurs at specific oyinder Spark weakinot visible (high—tension lead-damaged, INSPECTION Does Symplom occur only at staring while engine is cold? No Yes Carry oul BAG valve operation nspecon | oa vave operation normal Jo} dh 3 | Garry out ar valve operation inspection 1 Yes | 8 air valve operation normal? No__[Replace Does sympiom occur only at starting while | Gotone| engine is hot? Ino Twihen vol When en] 5 | Cary out pressure regulator convolinspec- | Ves | Replace tion |_ Is PRC operation noemal? No 6 | Carry out intake manifold vacuum inspection | Yes Is there no air suction trom intake-air rc Repair oy Gotore] “No [Remove Carry out eylinder bala Does engine speed dr cylinder inoperative? Test Yes p equally with each eee [eres @ | Carry cut spark test Gotone Isa strong blue spark visible at high-tension toad of suspected faulty cylinder? No 9 | Disconnect IAC valve connector | Yes [Goto sie Does engine speeddrop? | No Cary ou 10 | Remove air cleaner and block airintake port | Yes | Goto nay to check air leakage in intake-ar system. 1 Is there no air leakage when cranking engine? Repair of 41 | Carry out spark test Isa strong blue spark visible at high-tension dof ted faulty cylinder? Carry out IAC vaive inspection ISIAC valve OK? 13 | Carry out fuel pressure inspection | io Are voltages correct? No [Repair o 01-01A-377_ [Hic [TROUBI Intake air I Accetel @airvais TTROUBL BAC valve DBA [step] 20 [Re 30 [Re (RO No AG of ESTEP) Check! = Ac Is voltar ‘8 | Rough [TROUBLESH TAC valve (stut IsteP T | Disco Does & 10 [Engine [TROUBLESF Insufficient fue ID Pressure re Fuel pump ISTEP) Does e Carry Is uel © Thre 2 Gos Are vol 1 [Engin a Broom ose, o D Fuss Tare eC aS Iy cone Ace ints Me tet SS 6 |Ganye Isa Ol 7 [Cary ¢ Is uel72 [Poor acceleration/ins [TROUBLESHOOTING HINT For quick troubleshooting, firs [coldihot, AIC operating/nat op (at specific areaall areas), an itoceurs. Problem occurs only when en, J@ Engine coolant temperatur, (characterisiies deviation Problem occurs enly in speci [STEP D 1 _| Are rough idle, overhey ered? 2 [Does symptom occur ¢ engine is cold? 3 | Does problem occur o1 4 | Does symptom oct ing? 5 [mre ‘AIG cut OFF | 6 | Isairctoaner element 7 | Check following ECM © Throttle position set © Mass ait flow sense Are voltages correct? | Carry out fuel pressure Is fuel pressure corres 9 [Remove all spark plug ‘re they OK? 79-_| Runs rough during d [TROUBLESHOOTING 11'S Fuskout not cared out Gut J@ Thre positon sensor (C (rvsadjsted) |}@ Neutral and clutch switche- Low fue recovery rpm curing © Throttie position sensor (C (misadjusted) Neural and clutch sw 1 _| Does problem occur s shit? Does symptom oecur | engine is cola? 3 [Does engine idle nor 4 | Carry out fuel cut cont |= Is fuet-cut carrie o Is fuel recovery «pre74 [Knoe [TROUBLES Airfuel mixta Pressure Incorrect ignl ignition tir ISTEP) 1 [Wasé Does! 3 |ishe Is spe mulat 4 [Cary Is fue Repla Issyn 15 [Overt [TROUBLES Ineufficiont 2 Cooling fa belt) Engine cools © insutficien ISTEP’ Does D2 isa 3 |isenc 4 [Warn a touct Cove uD Warn Isenc 8 [Carry Is the 6 | Carry Israd Carry Is wal @ |isradTROUBLESHOOTING 76 | Poor fuel economy [TROUBLESHOOTING HINTS} Fuel economy varies with conditions of vehicle and how they are used. Before undertaking actual checks, take a fw minutes to tak with customer to determine wat is ao- tual problem. Vehicle condition out of specification IG Tres (oversize, tow te pressure) }@ intakefexhaust system components changed Operation condition out of ordinary 1 Frequent acceleration deceleration Freguont climbing hill Insufficient maintenance JD Engine of (Contamination) @Air cleaner, cil element (contamination, ciogs) Alrfuel mixture too rich ‘© Mass airflow sensor, engine coolant temperature sensor {characteristics deviation) @ Fuel pressure too high LLockup mechanism inoperative Over cool @ Thermostat (Not completely closed when engine is. ‘cold internal damage) @ Cooling fan (High-speed operation when engine is ‘cold-—intemmal damage) ISTEP INSPECTION ] ACTION | Chock fotowing Yes | Gotonen sep "Air cleaner element (logs) Engine of (contamination, Tid eve) Engine alo » wo | Repairarroplace Bre they OK? 2 | Check engine coolant temperature rise by us- | Yes | Remove all spark pugs and check condone ing water temperature gauge _ Does engine coolant temperature rise nomal- | No | Goo next Sep ly (not slow)? - 3 [Does cooing fan operation speed increase as | Ves | Chock thermostat engine warms up? No ___| Check cooling fan 17_| Fuel odor [TROUBLESHOOTING HINTS} Fuel evaporative gas (fue!) leakage Leakage fram fuel system piping \Chareoal canister (damage, overtlow) 3) Vacuum hoses connecting charcoal canister, purge sole noid valve, and intake manifold (disconnection, damage) Purge contral maltunction (@ Purge solenoid valve (stuck) iste INSPECTION ACTION TT Gheck vacuum hoses between charcoal can’ ] Ves | Goonext sep purge song valve end ina manind — puro soln No | Repair orrepiace 2 | Check charcoal canister Yes | Gotonext sep Isitres rom overiowing? Na [Repel repens + 3 | Check fel system pipina (include Yoel fites) | Yes | Check purge contr inspection Are they free of leakage? No _| Repair or replace ENGINE DIAGNOSTIC INSPECTION Cylinder Balance Test Purpose ‘The purpose of the cylinder balance testis to find weak ‘or non-contributing cylinders. In this test, the high-ten- sion leads are disconnected one by one to shut off the ignition in each cylinder while the engine is running. By carring out the cylinder balance test, a total judgement of the compression pressure, air/luel mixture, and igni- tion is possible. Warning © High voltage in ignition system can cause strong electrical shock. Avoid direct contact to the vehicle body during the cylinder bal- ance test. ‘* High-voltage spark will negatively effect the engine control. To prevent this, ground the high-tension leads and keep away from sen- sors and harnesses. Caution ©. Cylinder balance test can overheat anddam- age the three way catalytic converter. 01-01A-42On | Alp AlpTROUBLESHOOTING [STEP INSPECTION 3 | Chock fuel injector resistance at suspected | Yes faulty oyinder Is resistance cor Gotonentst can be started) Are terminals OK? feuty eyinder Istormnalvttage coroct? | no Repar one T[Wavearbon sak on al plage [TROUBLESHOOTING HINTS] |G) Spark—Spark weak Others ®)Aifluel mixture~Too rich Clogs in int |S Compression-Low compression step INSPECTION 7 le arcloaner coment eo of clogs? Soret — Replace aird 2 | ary out spark est Goto nents iba stony bu spark visible teach cylinder? Bopanna 3 | any oat uel pressure repecon Yes |Gotonexst Ia tue pressure cowaut? No [Repaertr 7 | Gheck folowing ECM erinalwakages | Yes | Got next 5) acs a flow sensor Sigal Engine cosant omporature signal 5 Reted oxygen sencor gal (When engine | No] Rapa air system for air leakage ‘When engine can be started, carry out intake Carry out purge control inepection (When en. | Yoo | Goto noxt of gine ean be started) Is purge control correct? No | Repair or re & | Carry out compression inspection Yes | Check clogs] Is compression correct? hom Reserorrey @_ Grayish white with all plags ROUBLESHOOTING HINTS] | Airfuel mixture-too lean [STEP INSPECTION 1 |When engine cannot be started, check intake- | Yes [Repair orray Is fuel pressure correct? manifold vacuum inspection No | Go to next Is air sucked in from intake-air system? 2. | Cary out fuel pressure inspection Yes: Check — Wass ar cs + Hoate started) + Ground | Ri Inspection Using an Oscilloscope (Reference) Purpose By using an oscilloscope, inspection such as a stuck so- lenoid valve is made possible without actually removing parts, 01-01A-44(1) When normal Counter elecirc the three-way turned off from cause induced by the plunger 20 | | | “| — ENGINE SYSTEM Intake Maniold vt erty 2 Stattho orgie &: Measure tre uum gauge Specification ‘More than 6° 4. It not as specif © Airsuction Throttle bo Intake mai PCV valve © Fuel inject © Accelerato6. Verify that the engine speed dt gine warms up. 6. Ifthe engine speed does not det slowly, check the water hose cc valve for leakage and clogs. 7. If the water hase is okay, Inspe © Airvalve © Idle air contro! valve Idle Air Control inspection 1. Start the engine and run it at i 2. Disconnect the IAC valve conn the engine rotation changes. 8. If the engine condition does n lows. Using the SSTs (NGS) 1. Connect the IAC valve connec] 2. Connect the SSTs (NGS) to thd and battery. Verify that diagnostic troubl displayed. If code No. 0505 is bleshooting of the code No. 0 Warm up the engine to normal ture and run it at idle. Select the “SIMULATION TE! NGS display. Change the duty v to 100% by using the ACV" at speed increases: (1) Ifthe idle spéed increases, (2) the idle speed does not BAC valve (Caritornia 20D) Select the “SIMULATION TE NGS aisplay. Change the duty air solenoid valve ftom OFF “AWS” and verify that the idle ¢ (1) Ifthe idle speed increases,2. Conn tery. 3. Verify displé blest 4. It diay follow ws QT (3) It (a) if <= Fuel Lin Warr oF \ _—2. Connect a fuel pre ter (high pressure Dy Al 3. Connect the nega{ 4. Connect the data GND by using a ju 5. Turn the ignition s: operate the tue! pu 6. Turn off the ignitior sure the fuel press Specification More than 150 7. Disconnect the jur @ Ifthe pressure is fuel line pressure © Ifthe fuel tine sure regulator FUEL INJEC TIONT1. Connect and batte Turn the i Select “SI Select “IG Select “Fi Press ST} Turn the f operat 8. If the ope} pump rele] 9. Ifthe fuel . Wiring] (Mai Pressure Re- Warning © Fuel can deatt and the" (hes 1. Disconne 2. Connect (high-pree@ Turn the PRC sole ON and check if th valve is heard. @ If the operation sc pressure regulator © Ifthe operation so the PRC solenoid Inspection 2 1. Connectthe SSTsto the dé tery, 2 TTum the igasion switch Me 8. Select “SIMULATION TE: display. 4, Turn the PRC solenoid valy ing the “PRCV" and check heard. (1) Ifthe operation sound or damaged vacuum F — PRC solenoid valve (2) If the operation sound PRC solenoid valve. Purge Control Inspection 1. Start and warm up the en temperature. 2. Stop the engine. 3. Connectthe SSTs tothe de tery 4. Turn the ignition switch to 5. Select "PIDIDATA MONIT, press TRIGGER 6. Select SECT aN eS the engine coolant temp 140°F }. 7. Press START. 6 the SSF Ic D1 gg the engine coolant temper 9. Select “SIMULATION TES 10. Select ‘PRGV" and press 11. Press START. 12. Increase the duty value of 10.50% and checkif the op is heard, (1) Ifthe operation sound or damaged vacuum purge solenoid valve (2) Ifthe operation soun purge solenoid valve. Main Relay Operation Ins}Eo 8 Turn the A/C swite Spark Test 1. Disconnect the ne 2. Turn over the front 3: Remove the prote 4, Disconnect the fu 5. Verity that each hil 6: Inspect the ignitor Warning © High voltage: ry. Avoid dire: [STEP | 1 | Remove high-ter high-tension leac {020—0.39 in} Tum ignition ew there isa strong der) 2 | Is high-tension kc Speciticatic 46 kum | Does ECM or di ‘connection? 4 | Are distributor c damage? | Isignition col wi | 6 | Is ignition contro 7 | Arefollowing pa ‘© Crankshait pc ECM termina ToT contol sign: connectors | Ate wiring hares oK? (Open or short) Fue! |njector (per[STEP rele Fuel Cut| 4. Warn 2. Tun 3. Ifthe to th 4. Hf thel data Selec press Selec Press Using, eraticTROUBLESHOOTING [CRUISE CONTI 01-01C TROUBLESHOOTING [CRUISE CC CRUISE CONTROL SYSTEM Tnspedtion ¢ 01-016. for Operat, Trees for Condit 8. Turn and © There are two on-board diagnostic functions: press the: Operation Mode, which checks for and indicates teminspec Correct operation of the input signals to the control inate.) ‘module; and Condition Detection Mode, which indi- cates troubles in the system. ‘* The two functions can be done by using either of the following methods: (1), Checking the flashing patter ofthe cruise setin: dicator light in the instrument cluster. (2) Checking the outputof the data link connector by using the SST (NGS set) Inspection Order START ‘Step 1: Operation Mode No ‘Are input signals to cruise control |~°— module correct? Tre ‘Step 2: Condition Detection Mode | No ‘Are no trouble codes indicated? Yes ‘Step : Parts inspection sspected parts as diag- | in step 1 and 2 END. Inspection of Diagnostic Trouble Codes for Opera- tion Mode Using the cruise set indicator light, Note ‘© Ifan Operation Mode is not indicated, the follow- ing may be the cause of the malfunction, 1. RESUME / ACCEL switch 2. Cruise control main switch 3. Cruise control module 4. Open or short circuit in wiring harness 1. Tum the ignition switch to ON. 2. Verify that the cruise control main switch is of 2. Turnthei 01-01C-1TROUBLESHOOTING [CRUISE CONTROL SYSTEM] 3. Turn and hold the RESUME / ACCEL switch, then _6. Selecet_ “DIAGNOSTIC DATA LINK” and press press the cruise control main switch to activate sys- TRIGGER, teminspection. (The cruise setindicatorlightwililu- 7, Select "CCM ~ CRUISE CONTROL MODULE” and rminate,) press TRIGGER. = 8. Select “DIAGNOSTIC TEST MODE” and press TRIGGER, 9. Select “CRUISE CONTROL INPUT SW SELF TEST” and press TRIGGER. 4, Set the SST (NGS set) to AUX 2. 5, Select "VEHICLE & ENGINE SELECTION" and press TRIGGER. (Select the model and specifica- tions ofthe vehicle you're testing.) 10. Press START. ‘1. Operate each switch as described and note the op- a ae eration code list pattern. Ifa diagnostic trouble code is not indicated, inspect the corresponding system = area 12, Iformal “NO CODES RECEIVED" will then be indi- cated. 1. Remove the SST (NGS set), ea 14. The Operation Mode is canceled by turning theigni- ee tion switch to LOCK or pressing off he cruise ccntrol _ main switch, Operation code list Procedure DIC Output pattern Display ontheNGS | Diagnosed circuit tumsenconsr ewten | at | MIL {fl SETICOAST SW—PRESS | Crise contol ewitsh Turn RESUME/ACCEL, RESUME/ACCEL SW - switch eo | DRESS. Cruise control switch eae Peon owrestatsones | 3+ | FITLIMTL ease re pane 01-01C-2Drive veh {25 mph} Inspectio D Possl cau!TROUBLESHOOTING [CRUISE CONTROL SYSTEM] [step | INSPECTION ACTION 3 _| Remove the passenger's side ont scuff plate. | Yes | Go to slop 6. Remove the passenger's side front side trim. “Tum ignition switch to ON. Press cruise control main éwitch on. No. | Go to next step, Is voltage at terminal A of cruise control switch connector approximately 5 V ? 4 | Is voltage at terminal N of cruise control medule | Yes_| Repair wiring harness. Connector approximately 5 V 7 (Cruise control module—Cruise control swi | No | Replace cruise control module [Rafer ta 0 [CONTROL MODULE REMOVAL / INSTALL J 5 | Tum RESUME/ACCEL switch on. | Yes [Replace cruise contro! module {s voltage at terminal A of cruise control switch EES ee — ‘connector approximately 1.5 V ? | No | Replace cruise control switch [(Refer to 08: 1 | TilOn SWITCH DISASSEMBLY /ASSEMBI (CRUISE CONTROL MODULE CONNECTOR ‘CRUISE CONTROL SWITCH CONNECTOF 7 i «lelTolu] «|i [eteToTa aA tl«lpin]x[stuls {ole D prost BRAKE SWITCH fl ‘Burnt STOP 20 A fuse Damaged cruise cpntrol module POSSIBLE % ental Damaged brake switch (Open or short circuit in wiring hares Poor connection of connector [step | INSPECTION ACTION 1 | Does brake light Numinate when brake pedal de | Yaa [Gata stan 6 Pressed? ___ [No [Goto next step. i 2 [ls STOP 20 fuse normal? Yes [Goto next step. 'No_| Replace fuse after checking and repairing v 3 _| Depress brake pedal Yes | Replace brake pedal, then go to step 5. Is voltage at terminal 18 of brake switch connec || = tor approximately 12 V7 No_ | Release brake pedal, then go to next step. 4 [is voltage at terminal 1A of brake switch connec- | Yes. | Replace brake switch{ (Refer to 04=11 BR: tor approximately 12 V7 REMOVAL / INSTALLATION] No | Repair wiring harness. (STOP 20 A tuso—Brake switch) '5 | Remove the passenger's side front scuff plate. | Yes, Remove the passenger's side front side tim, Depress brake pedal. Is voltage at terminal M of cruise control module | No | Repair wiring hamess. connector approximately 12.V 7 (Cruise control module—Brake switch) | Remove the passenger's side front sculfpiate. | Yes | Goto next step. Remove the passenger's side front side tim. | Depress brake pedal No | Repair wiring hamess. Is voltage at terminal M of cruise control module (Cruise control module—Brake switch) | connector approximately 12 V 7 7 | Disconnect brake switch connector, Turn ignition switch to ON, Press cruise control main switch on. fs voltage at terminal 2B of brake switch connec- | No | Connect brake switch connector, then go te ‘Connect brake switch connector, then go t tor approximately 12 V ? @ [Is voltage at terminal H of cruise control module | Yes | Repair wiring harness. ‘connector approximately 12 V7 (Cruise control module—Brake switch) No | Replace cruise control module[ (Heer 1 OT 01-0104TROUBL [STEP INSPE 9 [Is voltage at terminal 2A oft tor approximately 12 V 7, Depress brake pedal |s voltage at terminal 24 of tor approximately 0 V ? 10 [Is voltage at terminal O of er ‘connector approximately 1: Depress brake pedal Is voltage at terminal O of + connector approximately 0 CRUISE CONTROL MOL DTC a5 TRANS Damaged or POSSIBLE | * Damaged t CAUSE © Open circuit © Poor connec STEP) INSPE 1 [is transmission range switct ou | fj} __ Disconenet transmission rar (Refer io 05-13 TRANSMIS SWITCH REMOVAL/ INST? Ts there continuly between jon range switch conne. ignition switch to ON. Co Press crise control main — ree coer ay Bescomeen ae ce cnan \fonne tosanerserest |Femore we seen = 3 Heme he peso 2 comet approxi — GAUISE CONTE frolic Gtetete Ts Drea7 VEHICL * Damaged or POSSIBLE | + Damaged v CAUSE | + Openc pen [STEP | INSP T [Is vehicle speed sensor OK [INSTRUMENT CLUSTERIE- Speed sensory] EOTROUBLESHOOTING [CRUISE CONTROL SYSTEM] [STEP INSPECTION ‘ACTION 2 _| Remove the front scuff pate right side and front side trim right side ‘Tun over the front floor mat Remove the engine control module protector cov- Disconnect engine control madule connector. Disconnect transmission control module connes- tor. Flemove the mat end plate. Yes “Tum ignition switch to LOGK, then go to step 4 Flomove the rear side trim. Disconnect ALL control module connector. Disconnect instrument cluster connector (ASIEr| {io 09-22 INSTRUMENT. No “Turn ignition ewitch to ON. Press cruise control main switch on. {voltage at terminal 1G of instrument cluster connector approximately 5 V ? Goto next step, 3. | Remove the passengers side front scuff plate. | Yes, Remove the passenger's side front side trim. Repair wiring hamess, (Cruise control module—Instrument cluster) Is voltage at terminal P of cruise control module connector approximately 5 V ? eG) Replace cruise contorl modula (Refer to O12 4 | Disconnect cruise control madule connector. Is there continuity between terminal P of cruise Yes Fiaplace oruise cor trol modulel (Rar ia 01-20 CRUISE] Control module connector and terminal 1G of instrument cluster connector? Ne Repair wiring hamess. (Cruise control modulo—Instrument cluster) INSTRUMENT CLUSTER CONNECTOR 1. ‘CRUISE CONTROL MODULE CONNECTOR efute Papoll= feos Inspection of Diagnostic Trouble Codes for Condi- tion Detection Mode Using the cruise set indicator light Note © Ifthe RESUME / ACCEL switch on the cruise control switch is malfunctioning, the cruise set indicator light will not give a correct indication when you inspect the system. Use the SST (NGS set) to determine the cause of the mal- function. 1. Press on the cruise control main switch. 2 Drive the vehicle. 3. Operate the cruise control system and verify that the deceleration, acceleration, and coast controls func- tion by operating each of the cruise contol switches. 4. Stop the vehicle and let it idle. 8. Turn and hold the RESUME / ACCEL switch for at least 3 seconds. The cruise set indicator light will i- luminate for 3 seconds, and then go out for atleast, 2 seconds. 6. Ifa diagnostic trouble cade is indicated, inspect the corresponding system area. 7. The Condition Detection Mode is canceled by press- ing off the cruise control main switch or driving the vehicle at over 16 km/h { 10 mile/h }. Using the SST (NGS set) 1. Press on the cruise control main switch, 2. Drive the vehicle. 3. Operate the cruise control system and verify that the deceleration, acceleration, and coast controls func- tion by operating each of the cruise control switches. 4, Stop the vehicle and let it idle 01-01C-6TROUBLESHOOTING [CRUISE CONTROL SYSTEM] 5. Connect the SST (NGS set) to the data link connec- tor and battery. 49 T0388 OAO 7. Select “VEHICLE & ENGINE SELECTION" and press TRIGGER. (Select the model and specifica- tions of the vehicle you're testing.) Condition code list 8. Select "DIAGNOSTIC DATA LINK” and press TRIG- GER, 9, Select "CCM— CRUISE CONTORL MODULE” and press TRIGGER 10. Select “DIAGNOSTIC TEST MODE” and press TRIGGER 11. Select “CRUISE CONTROL SELF TEST’ and press TRIGGER, 12, Press START. 18, Ifnormal NO CODES RECEIVED" will ten be indi cated. 14, Ifa diagnostic trouble code(s) is indicated, inspect the corresponding system area 15, Remove the SST (NGS sel). 16. The Condition Detection Mode is canceled by turn- ing the ignition switch to LOCK or pressing Off the cruise control main switch. 01-01C-7TROUBLESH' DIO Output pattern o a 05 o7 " = 2 JUL DULL. » | | Note ‘* When two or more service code Inspection of diagnostic trouble cod: CRUISE A DETECTION CEN GTION | No voltage detected at ~ Damaged eruise cor POSSIBLE | Damaged cruise act CAUSE — [+ Open or short circu '* Poor connection of ¢ ISTEP | INSPECTION 1 | Is wiring hamess between cruise co and cruise actuator OK? 2 | Disconnect cruise actuator connedt Turn ignition switch to ON, ross cruise control main switch on Is voltage a terminal C of cruise ac tor approximately 12 V ? [Is voltage at terminal 28 of 22 ——— tor approximately 12 V ? 4 | Is voltage at terminal 2B of brake sl tor approximately 12V ? ttm __ Cconnecior approximately 12 V7[STEP © | Disconnech Remove t Remove t ‘control ‘actuator ¢] 7 [is there e| control mc| actuator | |e there ce control mel actuator o| Perform oparatil | ec) DETECTION CONDITION POSSIBLE CAUSE Disconnect braki Is there continu switch? bron Perform operat Drei, Perform operatio Dro 15) Replace ruise ¢MECHANICAL 01-10 MECHANICAL [DRIVE BELT INSPECTION — 0 Procedure — =F, Drive Belt Tension Check ‘0110-2 ‘Generator... ‘0110-2 “Timing Belt Removal Note 01=10-5 “Timing Belt Auto Tensioner Installation Note... Timing Crankshaft Pulley Installation Note LINDER HEAD GASKET 01=10-6 | Ql ‘Cylinder Heag Removal Nole. 0110-8 Cylinder Heag Installation Note 01=10-8 PIS OP = Td 01-10-2 | Py OTF ump Installation Note ....... 01-10-11 COMPRESSION INSPEGTION 01=10-3. ENGINE STN at is TIMING BELT REM = Crankshall Pulley Removal N TEI [DiSMOUNING sesettseereeeeeees O07] ENGINE DISASSEMBLY [ASSEMBLY . 01-10-17 BLA REMOVAL INSTALLAHION ott Rocker Arm and Rocker Arr A 4 eer AmandfackerAm Sha | Pie een HLA Removal Note ............. 01-10-11 (Piston, Piston Ring, and Piston Pin 07-10-44 | HLA Installation Note O1=t0-1 O1=10=4 Rocker Arm and Rocker Arm Shaft rankshé a 07-1 iisalaton Nota sess otetocts| —_[ iam Ba ge tae Orin 7 TROUBLESHOOT oat z S ieee 0110-1 Preparation ‘01-10-47 FRONT OIL SEAL REPLACEMENT... 01-10-12] Tanttion Timing 0110-47] REAR OIL SEAL REPLACEMENT ..... 01-10-13] Tale Speed ‘Ora iL INSTALLATION... 01-10-13] Idle Up Spsed (0110-48 DRIVE BELT INSPECTION 1. Check the drive belt deflection when the engine is pys ADJUSTING BOLT Cold, or at least 30 minutes after the engine has stopped. Apply moderate pressure 98 N{ 10 kgf , 22, MEASURING (CRANKSHAFT Ibf} midway between the specified pulleys. GENERATOR —yeasurING POINT, Lock BOLT SK ( (CRANKSHAFT PULLEY PULLEY 01-10-14MECHANICAL anc ADJUSTING BOLT yeAsuAING cold, « Stonoe ween see ‘ue SGuesson Dotto € tin} Dre ba _[ Wow] Use [tit co Tension onertor | (0853201 43°.) 18 28 oas—oary) omy | eae 1-75 pm ies2 | es PS ollpume | (020-029 6/5 S0)) (088) Generator 456.0 al | Nc so-so | as Compressor | (095299) 629-34)) (aie) | [PSotew "Tai thas ber onan ogo ews Tan re minutes. see AIC Seco 2. Wiha detection snot within the speciication.adiust apart GfemoOIODANesTAnusieNnD “Fp 1. Balt tension can be checked in place of belt deflec- tion. Check the drive belt tension when the engine is, DRIVE BELT ADJUSTMENT Generator 1. Loosen generator bolts A and B. Tights 2. Lever the generator outward and apply tension to 38— the belt . PIs Tightening torque z A: 19-25 Nm { 1.92.6 kgfm, 14—18 ft bf} 2 B: 3851 Nm { 385.3 kgfm , 28-38 ft bf} GENERATOR . AIC Comy © Loose ows turning Tighte PIS Oil Pump 2388—$ ‘* Loosen the locknut and adjust the belt deflection by turning the adjusting bolt 01-10-2ADJUSTING BOLT wae COMPRESSION INSPECTION Warning © When the engine and the oil are badly burn. Turn off the engine a they are cool. 1. Verity that the battery is fully charged. necessary. CTIoN 2. Warm up the engine to the normal oper ature. 8. Stop the engine and allow it to coo! off minutes. 4, Remove all spark plugs. 5. Disconnect the distributor connector. 6. Install a compression gauge to the No. hole. TIMING BELT REMOVAL / INSTALLATIG 1. Disconnect the negative battery cable, 2. Drain the engine coolant, 3. Remove in the order indicated in the i 4. Install in the reverse order or removal 5.Fillthe radiator and coolant 6, Garnoct he negate baton cab 7. Start the engine and (1) check the engine oil and engine ce. (Refer to 01 (2) check the ignition timing and idle st} | [0rar 1 2. 19-25 (19-26 (aso ‘Tension lead and spark p, Fresh-air duct Drive belt ‘AIC compressor idler pulley — 6 (Coolant bypat inkshaft Pulley Removal Not ‘Mount the SST on the crankst crankshatt. Remove the crankshaft pulleyCaution © The crankshaft positi the rear of the cranks damaged easily. 8, Remove the crankshaft pul Timing Belt Removal Note 1. Install the crankshaft pulley enit 2. Turn the crankshaft to align pulleys. 3. Mark the timing belt rotatior 4. Remove the timing belt Caution © The following will da en its life; Forcefully side out, bending onit 5. Remove the crankshaft pul ROTATION ees lbt ainow LESS THAN 25 mm (0.98 in , Timing Belt Auto Tensioner 1. Set a plain washer at the| body to prevent damage t3, Position the timing belt in the of hang it on each pulley in the ord pulley. Tightening torque 38-51 Nm (3.85.3 kgtm, 5. Turn Ue crankshaft clockwise tv timing marks. 6. Check that the timing marks are ¢ not, repeat steps 2—5, 7. Remove the pin from the auto te 8. Turn the crankshaft clockwise tr timing marks,4. Install the crankshaft pulley and hand tig pulley lock bolt. 2, Mount the SST on the crankshaft pulley to crankshatt. 3. Tighten the crankshatt pulley lock bolt Tightening torque 157—166 Nem { 16.0—17.0 kgf-m , 1 ftibf} CYLINDER HEAD GASKET REPLACEMEN1 Warning © Fuel vapor is hazardous. It can very sparks and flames away from fuel. ‘© Fuel line spills and leaks are danger age. Fuel can also irritate skin and e, dures” or 1. Disconnect the negative battery cable. 2. Drain the engine coolant {{Refer to 0112 8. Remove the timing belt [eter io 01-10 | —_______________] 4, Remove the intake manifold. (Baler ig Q———d 5, Remove in the order indicated in the table 6: Inotll inthe rovoroe order of removal ind 7. Install the intake manifold [[R@T@r (0 01 TS 8. Install the timing bet. 9. Fllthe radiator and coolant reservar with Tre ERG COGLANT REP 10, Connect the negative battery cable. 41 Starttne engine and (j) check the engine oil and engine coola (2) check the ignition timing and cle spec 12. Check the compression [[Befer 10 O11 0MECHANICAL 35-44Nm( 35—a5ugtem 31-39 not) 19-25( 19-26, 14-10) wi 22-28(22-29,16-20) $8538 )(65—85) 79-407"m (010 gem, 7295s} 19—107m (oO ugrem 70-95 tat) remai2229, 16-20) | {80110 kgtom , 70-95 mnt) aan 4 {35s gt em, Seino) (5225, 127162) “s--96) Tes—38) 20-51 36-53, 20-28) 1925/1026, 14-18) ergs) 7] Ovinger head cover Centar exhaust pipe insuator | Genter exhaust pe Exhaust manifold inslaor Exhaust manifold Cylinder Head Removal Note 1. Loosen the cylinder head bolts in two or three steps in the order shown. 2. Remove the cylinder head. INTAKE EXHAUST SIDE Cylinder Head Installation Note {. Measure the amount of ail control plug projection from the deck of the cylinder block. Projection 5.35.7 mm { 0.209—0.226 in} © | Seal plate 8 _| Cylinder head gasket 2. Apply clean engine oil to new O-rings and install them to the oil contro! plugs. 3. Thoroughly remove all dir, oil, and other material from the top of the cylinder block. 4. Turn the crankshaft clockwise and apply engine oil to the cylinder walls. 5. Place a new cylinder head gasket on the left bank: with the L mark facing upward. 6, Place a new cylinder head gasket on the right bank with the R mark facing upward. 01-10-87. Install the cylinder F 8. Tighten the cylinder (1) Before installat Replace if nece Length IN: 107.7—108.3 EX: 137.7138.5 Maximum, IN: 109 mm { 4.2 EX: 139 mm { 5. (2) Tighten the bott Tightening torque 17.2—22.0 Nm { ftlbf} HLA REMOVAL / INS’ Caution © Removal andi the HLA troub| 1. Disconnect the net2, Remove the [MOVAL 7 INS] 3. Remove the tt 4. Remove in the 65. Install in the re 6. Install the dyn 7- Install the timi 8. Fill the engi 9. Fill the radiat 10. Connect the 11. Start the engi (1) check the! (2) check the 12, Perform a roa 13, Recheck the «| 7 | Distibutor fort LAT yin PLA tion Rocker Arm and 1. Loosen the be shown,© Rem it wit HLA inst 1. Pour arm. 2. Apply 3. Caref HLA TREValve | 1. Re 2 Va,MECHANICAL 9. Tap the oil seal in evenly by using apipe andaham- 10. Install the timing belt pulley, 4 mer. 11. Insert the key with the tapere pump body. Note 12 rata t tming bot Ter] ‘* Oilseal outer diameter: 55.0 mm {2.17 in} ‘© Oil seal inner diameter: 43.0 mm { 1.69 in} 18. Connect the negative batter 14, Start the engine and check Ces ] ovseat +_* 7 g Booy rane REAR OIL SEAL REPLACEMENT 7. Push the oll seal slightly in & 8. Tap the oil seal in evenly hammer. 1. Disconnect the negative battery cable. 2, Remove the transmission. MISSION REMOVAL / INSTALLATION.) Refer to 05-13 DRIVE 4, Cut the oil seal lip by using a razor knife. 5. Remove the oil seal by using a screwdriver pro- i tected with a rag, Hawhter | 9. Installthe drive plate. [eter 10. Instail the transmission. [Ref muse TINSTACL 11, Connect the negative batter 6. Apply clean engine oil to the new oil seal ENGINE REMOVAL / INSTALLATION Procedure Warning © Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injur age. Fuel can also irritate skin and eyes. To prevent this, always complete the “F dures” or U ‘© Fuel vapor is hazardous. It can very easily ign sparks and flames away from fuel. Caution ‘* Cover the fuel hoses with a rag because fuel will spray out when disconnectes, Note ‘© Plug the disconnacted fuel hoses to prevent fuel leakage, 01-10-13MECHANICAL 1. Disconnect the negative battery cable. 2. Drain the engine coolant [{Refer to 01-12 ENGINE COOLANT R 3, Remove the hood. 4, Drain the automatic transmission fluid[ (Refer to 05-13 AUTOMATIC TRANSMISSION FLUID (ATE) REPLACE: | 5, Remove in the order indicated in the table. 6. Install in the reverse order of removal indicated in the table. 7. Fill he transmission with the specified amount and type of automatic transmission fluid [{Refer to 05—13 AUTO- 8. Fill the radiator an« 1d coolant (Rete 9 Install the hood. 10. Connect the negative battery cable. 11. Start the engine and (1) check the engine oil, transmission oil, and engine coolant leakage. (2) check the ignition timing and idle speed (Rete fl 12. Tum off the engine and check the drive belt deflection. 18. Perform a road test. 14, Recheck the engine oil, transmission oil, and engine coolant levels. 7910.7 {80110 Kgtem 7095 not) 78107 Nm (80-10 kgtem, 70-95 nb) NGINE TUN (Refer to 01-10 DRIVE BELT INSPECTION, 19-25(19-26, 14-18) 91 eh 3-81 38-53,28-28) Nm (kgm fb) 1 _| Freshrair duct 3_ | Splash shield 2 [Drive belt 4 [Upper and lower radiator hose 01-10-14Radiator Ar cleaner and a | @ |PiSollpump | -{[Bemoval instalation 10 ‘AIG compressor eePIS Oil Pump Removal Note 1, Remove the P/S oil pump p 2, Remove the PIS cil pump \ nected to them; secure the {as shown in the figure. AIC COMPIOSS0r RV ORM connected to them; secure sor as shown in the figure, Engine Removal Note FstENGINE STAND M Procedure Mounting 4. Remove the engi 2, Remove the gens 8. Install the SST ( the SST foots). | ETO | 4, Assemble the SS the specified po: 6. Install the SST tq EOE 6. Adjustthe SST (b in} of thread ise 7. Make the SST (o the SST (bolts ar, 8. Tighten the SST firmly. 9. Install the engin Warning © Selflocking) stand may isheldinan lead to sudc gine and mc serious inju Never keep position, an dle firmly we ENGINE ISAS SE Auxiliary Parts Warning * Continuous ‘skin by was,mcinnecd 1. Remove the oil drain plug and drain the engine oil. After drai Tightening torque 30—41 Nm { 3.0—4.2 kgfm , 22—30 ftibf} ve snin-tiny oY Bite! 306113853, 22-38) (se-n0,00-435 Engine mount (LH) 7 PIS idler pulley ‘AIG idler pulley and compressor bracket _ Engine hanger Water inet pipe Water bypass hose Distributor assembly note 20 1. Apply clean engine oil to the new O-ring, and posi- t tion it on the distributor. at 01-10-184, Hand tighte Timing Belt 1. Disassemb 2. Assemble j 79-107%m (eo ongrel Crankshaft pi 1. Hold the diMECHANICAL The crankshaft position sensor rotor is on the rear of the pulley, and can be damaged easily. Remove the crankshatt pulley lock bolt. Remove the crankshaft pulley. jing belt disassembly note 1. Mark the timing belt rotation for proper reinstallation it tis reused. 2. Remove the timing belt Caution ‘© The following will damage the belt and short- en its life; Forcefully twisting it, turning it side out, bending it, or allowing oil or grease onit. ARROW Timing belt auto tensioner assembly note 1. Set a plain washer at the bottom of the tensioner body to prevent damage to the body plug. Caution © Pressing the tensioner rod with more than 9,807 N { 1,000 kgf , 2,200 Ibf} can damage the tensioner spring. 2. Press in the tensioner rod slowly by using a press. 01-10-20 Booy 6 PLAIN WASHER, 3. Insert a pin to hold the tensioner rod in the shown, 4. Install the timing belt auto tensioner to the! block: Tightening torque 19—25 Nm{ 1.92.6 kgf.m , 1418 f ToP Timing belt assembly note 1. Install the crankshaft pulley loc enit 2. Verify that the timing marks on the pul aligned. Caution i © The following will damage the belt a en its life; Forcefully twisting it, turr} side out, bending it, or allowing oil ¢ onit 8. Position the timing belt in the original diree hang it on each pulley in the order shown.4. Install the upper idler pull Tightening torque 38-51 Nm {3.85.3 5. Tum the crankshaft clock timing marks. 6. Check that the timing mar not, repeat steps 3—6. 7. Remove the pin from the 8. Turn the crankshaft clock timing marks, 9. Reconfirm that the tim aligned, 410. Check the timing belt defl ate pressure 98N{ 10kgf the timing belt pulley. a — CS ————_— above. Timing belt deflection 5—7 mm { 0.20—0.27157—166 Nm { 16. ftlbt} Cylinder Head 1. Disassemble in the orc 2. Assemble in the reverg 244 Nen( 35 | ww a LZ re02Nm /O" forasina 71-00( 72-82, 59-89) 1 | Ovlinder Read cover — Distributor spacer 2 _3_| Blind cover e— 4 PCV valve 5 | Camshaft pull oc “passer ] aby Asser Note CT 3 _[Seaipiate — 7 | Rocker arm and rocke >(Asseribi Noe] — _[ Disassembly Ne] ssembly Note] @ | Gamshatt ol seal _ |e | 10 _| Thrust plate 11 | Cam:a Install the v Install the § 18 4, Tapthe va der head, > Outer and inn 1. Install the | 2. Install the v 3. Install the ¢ ward the c* 4, Install the i 5. Install the ¢ NARRO pice2. Tighten the cylinder head bolts. (1) Before installation, measure ea Replace if necessary, Length IN: 107.7—108.3 mm { 4.25—4.4 EX: 137.7—136.3 mm{ 543-5. Maximum IN : 109 mm { 4.29 in} EX : 139 mm { 5.47 in} ‘ga (2) Tighten the bolts in the arder sh Tightening torque 17.2—22.0 Nam { 1.75—2.25 kgf ftlbf) INTAKE SIDE (4) Using the mark as a reference, by turning each 85°95" in shown, (6) Further tighten each bolt by Distributor drive gear assembly not —————<—<<—<————<—<—<$<—MECHANICAL 3. Carefully install the HLA into the rocker arm = genus ® ©OO OIL RESERVOIR INTAKE SID Camshaft pulley assembly nc Rocker arm and rocker arm shaft assembly note 1. Verify hatthe anst2t ey —$—$— The intake side shat has twice as many oll holes as the exhaust side shatt. 1. Apply clean engine oil to the rocker arm shafts and rocker arm bearing surface. 2. Assemble the rocker arm and rocker arm shaft as shown in the figure. Qt “Bad 2. Install the camshaft pulley bank) or the R-mark (right shown, EXHAUST SIDE mura 3. Install the rocker arm and rocker arm shaft 4. Verify that the rocker arm shaft spring is not caught between the rocker arm shaft and the mounting boss. 3, Tighten the camshatt pull Tightening torque 71—80 Nm { 7.28.2 kg 5. Tighten the bolts in two or three steps in the order shown, Tightening torque 18—26 Nm { 1.82.7 kgf.m , 144—19 ft bt} Cylinder head cover assemb1 01-10-261. Remove all old silico} head and cover. 2. Coat a new gasket wi it onto the cylinder hed 3. Install the cylinder hee ors. Tightening torque 3.5—4.4 Nim { 35. Cylinder Block (Externa 1. Disassemble in the or 2. Assemble in the rever {30—110 kgm 1) Sacking plate, dive ‘of Disassembly 6 {Assembly Not [End plateMEC © | Rear cover [Assembty Not] © | Rear oil seal {Disassembly Note] {Assembly Note] 7_| Thermostat 8 [Water pump Backing plate, drive plate, adapter disassembI note 1. Hold the drive plate by using the SST. 2; Remove the drive plate bolts. 3, Remove the backing plate, drive plate, and adapte 4, Remove the SST. — 49E011 . io Oil pan disassembly note Caution ©. Pry tools can easily scratch the oll ar a ee cylinder block contact surfaces. Pring the oil pan can also easily bend {he 0! flange. 1. Remove the oil pan mounting bolts. 2. Insert a screwdriver between the oll pan and the cy inder block to separate them. Rear oil seal disassembly note Remove the oil seal using a screwdriver protecte with a rag, 01MECHANICAL Tightening torque 19—25 Nm { 1.92.6 kgfm , 14—18 ftibf} from 2. Cutaway the portion of the gasket that pro the body toward the oil pan side. Rear oll seal assembly note ‘Apply clean engine oil to the lip of new oil seal, Push the oil seal into the rear cover by hand. Press the oil seal into the rear cover by using the SST. ores yA [7 ).g | peancoven Lo] A onsen i Rear cover assembly note 1. Install the rear cover and a new gasket q— Tightening torque 7,910.7 Nim { 80—110 kgf-om , 70—95 insbt} 2. Cutaway the port the body toward th Ol pan assembly no 1. Remove the old sf be alt holes in the cy| Caution 2A Ay If the bolts ar ant from the that has old damage. ply silicon ‘pply silicone seal] of the bolt holes, o pan within five min 4, Tighten the oil par Tightening torqué 01-10-29 6.9-9.8Nm{ 71 ]Gonnea 2 [Lower cf Upper c| Piston o7{id @ | Piston p ADI Connecting rc © Before rem| the connes Piston and ¢ 1. Before rei measure t using Plast 2. Remove th] Piston ring dij ‘© Remove th pander.4, Mount t shown, 6. Verify th fore pres 6. Prass 0 pin, che 500 kgf necting Cee 1. Beforer coranksh 1 2. After rer(7) Install the main bearing caps alo er main bearings according to tl and mark. (8) Tighten the bolts in two or three der shown. Tightening torque 17.2220 Nam { 1.75—2.25 kgm It} (9) Puta paint mark on each bolt h (10) Using this mark as a reference, by turning each 85°—95" in the (11) Further tighten each bolt by t 40°50" oe eZ (175-2128 ghm, 127102 (12) Do not rotate the crankshatt the oll clearances. (18) Remove the main bearing cap ie Hiasligege at corti pural SSS forthe smallest clearance, and ( Boint forthe largest clearance. (14) Ifthe ol clearance exceeds the << <<< RO ings.(3) Puta paint mark on eac (4) Using this mark as a rete by turning each 85°—9t (5) Further tighten each b 40"—50". (6) Verity that the crankshs hand, Hg AO (175-2126, Inspect the crankshaft end ; End play 0.080—0.282 mm { 0.00¢ Maximum (0.30 mm { 0.0118 in} If the end play exceeds th crankshaft and install an ov replace the crankshaft and Thrust bearing width Standard: 2.000—2.050 mm { 0.0MECHANICAL | HEE Insert the SST No.2 into the piston pin as shown and fully screw in the SST No.1 Apply clean engine oil to the piston pin. Set the piston on the SST with the R mark or L mark. facing upward, Verify that the SST fits squarely into the piston be- fore pressing. ero Eon a Ee mungo 9. Press the piston pin into the piston and connecting rod until the SST contacts the stopper bolt 10. While inserting the piston pin, check the pressure force. If itis less than the specification, replace the piston pin or the connecting rod. Pressure force 4,904—14,709 N { 500—1,500 kgf , 1,100—3,300 ot} She en 11. Check the connecting rad oscillation torque. Piston ring assembly note 1. Install the three-piece ol rings on the pistons. (1) Apply clean engine oil to the oil ring spacer and rails. 01-10-35 (2) Insta the ol ving spacer so that the faces upward, (3) Install the upper rail and lower ral Caution © Hfreusing an oil ring, it must be rein: the same place and face the same. as when removed. If this is not dor cause premature and uneven wear. Note © The upper and lower rails are the sa can be installed with either face upwe Verify that the spacer tang separates the) that the rails turn smoothly in both direct Using a piston ring expander, install these with the scraper face downward. Using a piston ring expander, instal the te Apply clean engine oil to the second ard: rings. SPAQER TANG UPPER OILRING SPACER ENDS LOWERRE PISTON ec a = 6. Position the opening of each ring as shoMECHANICAL oi RING UPPER Rall on, Pisto RING NPN SPACER, OL ANS LOWER RAIL assoes Piston and connecting rod assembly note 1. There are three standard cylinder bores and match- ing piston sizes. The pistons and bores must agree if installing new pistons in a standard size bore. (Cylinder block Piston A A No mark No mar c c 2. The pistons and cylinder block are markedas shown in the figures. Refer to the charts for piston and bore sizes. Piston (Measured at 90" {0.866 in } below oil rin Mark [__A 3 No mark Ea c eos 3. Apply clean engine o| and piston rings. 4, Check the piston ring 65. Insert each piston int (left bank) or R mark the engine. Use a pis ing the same procedi clearance. Cylinder block (Bore size) mm{in} — Connecting rod cap as Wark] Size 1. Check the connecting A | s0.015—20022 (35433-35441) No mark {90.007--00.015 ( .5436-—3.5438 ) c {90.000—90.007 (3.543—3.5435 ) lo-== 01-10-362. Align the marks or when installing the (1) Tighten the nut Tightening torqu: 27.0—31.8 Nm ftlbf} (2) Puta paint ma (3) Using the paini nuts 82.5°—9 3. Ifthe oil clearance: crankshaft and ust Oil clearance 0.023—0.064 m Maximum 0.10 mm { 0.00¢ 4, Check each conn Side clearance 0.178—0.330 m Maximum 0.40 mm { 0.01 Inthe clearance e» conneeting rod an’MECHANICAL ENGINE INSPECTION / REPAIR Cylinder Head 1. Inspect the cylinder head for damage, cracks, and leakage of water or oil. Replace if necessary. 2. Using straightedge, measure the cylinder head for distortion in the six directions as shown, Distortion 0.10 mm { 0.004 in } max. 3. Inspect for the following and repair or replace. (1) Sunken vaive seats (2) Damaged intake and exhaust manifold contact surfaces (3) Excessive camshaft ol clearances and end play 4. Ifthe cylinder head distortion exceeds the specifica tion, grind the cylinder head surface. Grinding 0.15 mm { 0.006 in} max. 5. Ifthe cylinder head heights not within the specifica tion, replace it Height 125.25—125.35 6. Using a straighte surface distortion i istortion 0.10 mm { 0.004] 7. Ifdistortion exceeds face or replace the Grinding 0.15 mm { 0.006: Valve Mechanism Valve and valve guide 1. Inspect each valve surface if necessar (1) Damaged or be 2) Sarre] (3) Damage or uné 2. Check the valve hj the valve if neces: Margin thickness THICK: NESS 3, Measure the valve| essary, Marcin | ce Standard IN: 121.31 mm ( EX: 122.63 mm q Minimum IN: 120.91 mm { EX: 122.23 mm 4, Measure the valve tions at three Diameter IN: 6.970—6.98! EX: 8.025—8.04 01-10-38r 5, Measur ditectio: lace tr Inner d IN: 7. EX: 6. Measur: (1) Met Sut) inn (2) Me Me the the Clearar vaInstallation 1. Assemb| Depth L IN: 13. EX 1 2. Tighten f 3. Tap the combus inder he 4. Vefity tha the spec 6. not, rop, 5 Valve seat 1. Inspect valve fa (1) Rout (2) Dam 2. lf neces: valve seDimension L IN: 50.5—51.0 mm { 1.989—2.007 it 19.5—50.0 mm { 1.949—1.968 ii 5 head. (2) If Lis more than below, replace Dimension L IN: 51.1 mm { 2.012 in} EX: 50.1 mm { 4.972 in} Valve spring 1. Inspect each valve spring for cracks art 2. Check the free length and out-of-squara| necessary. Free length and out-of-square ‘Outer | 509 (2.004) [46 A 44,0 { 1.732 } with a set load of 198—147 { 14.0—15.05 , 31—33 ) B 39.5 { 1.555 } with a set load of 9399 (9.4—10.11 , 21-22} © 45.0 (1.772 } with a set load of 232261 { 23.56—26.66 , 52—58 } W Standard Free ex |58.33 (2.206 j |. tena | nts Minimum PN} —_&__] x c Maximum n_| 478(0070) outotsquare [ex | aoa{o.080) [1 mm in}5. Meast ance. (1) Be ce QM Diam: 49.6 (3) Si ar Olt ch No.. No. Maxir ot (4 it th(8) Subtract the rocker arm shatt diam« inner diameter. Oil clearance 0.020—0.074 mm { 0.0008—0.0029 Maximum: 0.10 mm { 0.004 in} HLA Check the HLA face for wear and damay if necessary Remove the HLA only for inspection, hand or use plies protected with a rag Cylinder Block +. Check the cylinder block. Repair orrepla sary. (1) Leakage damage (2) Cracks (3) Scoring of wall 2, Measure the distortion of the top surfac der block in the seven directions as shi Distortion 0.15 mm { 0.006 in} max.(1) Ifthe cylinder bore € bore the cylinder to c (2) Ifthe difference bet and C exceeds the n cylinder to oversize. Taper 0.019 mm { 0.0007 in ice betw and Y exceeds the n bore the cylinder to ¢ Out-of-round 0.019 mm { 0.0007 in ~tl eS 5. If the upper part of the c wear, remove the ridge Piston, Piston Ring, and Pt Piston 1. Inspect the outer circur| seizure or scoring. ReplMECHANICAL 2. Ifthe clearance exceeds the maximum, replace the piston. 3. Inspect the piston rings for damage, abnormal wear, or breakage. Replace if necessary. 4. Insert the piston ring into the cylinder by hand and Use the piston to push itto the bottom of the ring trav- él. 5. Measure each piston ring end gap with a feeler gauge. Replace if necessary. 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 1.0 mm { 0.039 in } Piston and piston pin 1. Measure the piston pin hole diameter in X and Y directions at four points (A, B, C and 0). Diameter 22.988—23.000 mm { 0.9051—0.9055 in} 2. Measure the piston pin diameter in X and Y direc tions at four points (A, B, C and D). Diameter 22.974 22.980 mm { 0.9045—0.9047 in} 3. Calculate the related piston pin-to-piston clearance. Clearance 0.008—0.026 mm { 0.0004—0.0019 in } 4. If the clearance exceeds the specification, replace the piston and/or piston pin, Connecting Rod 1. Measure the connecting rod small end bore. Diameter 22.943-22.961 mm { 0.9033—-0.9039 in } 2. Calculate the interference between the small end bore and piston pin. Interference 0.013-0.037 mm { 0.0005—0.0014 in} 01-10-45Measure @ connecting Bend 0.08 mr Distortion 0.18 mm Length (C 146.25— 4. Ifthe conn, cap, bolts, they are a Crankshaft 1. Check the oil hole cl i, 3. Measure t Replace i 4, Measure at two poi Main jour Diamet .3———— Out-ot Crankpin Diamet 52.94C Out-of-MECHANICAL Projection (free tength) 43-14 mm { 0.52—0.55 in} @ © ENGINE TUNE-UP Preparation 41. Warm up the engine to normal operating tempera- ture. 2. Shift the transmission into P position. 8. Turn of all loads. (1) Headlight (2) Blower motor (3) Rear window detroster (4) Power steering 4, Connect the SSTs (NGS) to the data link connector 2iocated under the driver side dashboard and select the"PID/DATA MONITOR AND RECORD" function DATA LINK, Co CONNECTOR 2 no 5, Select “RPM on the NGS display. Ignition Timing 1. Perform “Preparation”. 2. Connecta timing ight to the high-tension lead No.1 3. Connect the SST (System Selector) to the data link connector. 4, Set switch A to position 1. 5. Set the test switch to SELF TEST. 6. Verify that the idle speed is within the specification; if not, adjust it. Specification '500—800 rpm. 7. Verify that the timing mark (yellow) is within the spec- ification Specification BTDC 10—12" (11 + 1°) A'GNITION TIMING MAPK xg ins 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 01-10-47MECHANICAL f 19-25 Nm { 1.92.6 kgf-m , 14—18 ftlbf} 10. Disconnect the SST (System Selector) 11, Verity that the timing mark (yellow) iswithin the spec- ification. Specification ‘ATDC 2—BTDC 34° Idle Speed 1. Perform “Preparation” 2. Connect the SST (System Selector) to the data link connect 3. Set switch A to position 1 4. Set the test switch to SELF TEST. Test sw 5. Verify that the idle speed is within the specification, Specification 760—800 (780 = 20) rpm Caution © The throttle adjusting screw is set at the fac- tory and must not be adjusted. Any adjust- ment wj forman; 6. If not within] by turning aa GL oy [ 7. Disconnect Idle Up Speed 1. Perform “Pr 2. Verify that tl Specificati Headlil Fear window ¢ a . Excludes te electrical lo: related inpuf 01-10-48LUBRICATION SYSTEM 01-11 LUBRICATION SYSTEM OIL PRESSURE INSPECTION ........ 01-111, ‘OilPan Bam Ott il Pan Instz ENGINE OIL REPLACEMENT. O11 ‘OiL PUMP IL FILTER RE! i=11=5 DISASSEMBI OIL PAN, [Oi Seat Diss EMOVAL | INSTALLATION 01-11-21 [Oi SearAss————______———— Engine Mount (4 x4) Removal Noie 0111-3. Transmission Lower Mount (4 x 4) Removal Note. 01-11-41 OIL PRESSURE INSPECTION 1. Remove the oil pressure switch. 2. Screw the SST into the oil pressure switch installa- tion hole, 3. Warm up the engine to normal operating tempera- ture. 4, Run the engine at the specified speed, and note the gauge readings. Oil pressure 41,000 rpm: 89—245 kPa { 0.92.5 kgficm?, 13-35 psi} 3,000 rpm: 363-519 kPa ( 3.75.3 kaflem? , 53-75 psi} ENGINE OIL INSPECTION 1. Position the vehicle on level ground. 2. Warm up the engine to normal operating tempera- ture and stop it 8. Wait for five minutes. 6.If the pres: ‘cause and 6. Stop the er 8. Apply silic threads as 9. Install the hardens Tightening _ 40. Stat the @£$@—@—§———— 4. Remove th condition. \ Limarks on 8. Add or repl ENGINE OIL REPLACEMENT Warning ‘* When the engine and the engine oll are hot, they can badly burn, Don'tburn yourself with either. © Avehicle that is lifted but not securely sup- Ported on safety stands is dangerous. Itcan slip or fall, causing death or serious injury. Never work around or under a lifted vehicle if itis not securely supported on safety stands. water 1. Position thy 2! Remove th 8. Drain the 0 twit 01-11-41LUBRICATION SY: Tightening torque 30—41 Nem { 3.0—4.2 kgf'm , 22—30 fbf} Oil cay 5, Refillthe engine with the specitied type andamount — [Tatalg of engine oil 6. Refit the ol filer cap. Ore 7. Run the engine and check for oil leaks. ila 8. Check the ol lavel and add oil f necessary. OIL FILTER REPLACEMENT 1. Remove the oil fter by using a SST. SL N EO OIL PAN REMOVAL / INSTALLATION 1. Disconnect the negative battery cable. 2 Drain the engine ol (Refor io 01-11 ENGINE OIL REBLAGEM| 8, Remove in the order indicated in the tabl 4- Install in the reverse order of removal indicated in the table. 4x2Engine 1. Ins Ti 2.8uLUBRICATION SYSTEM 3. Remove the engine mount nuts and lift the engine to gain removal clearance. ‘Transmission Lower Mount (4x4) Removal Note ‘© Support the transmission with a transmission jack before removing the transmission lower mount. ll Pan Removal Note 1. Remove the oil pan mounting bolts. Caution ‘*) Pry tools can easily scratch the oll pan con- tact surfaces. Prying off the oil pan can also easily bend the oil pan flange. 2. Insert a screwdriver between the oll pan and the cyl- inder block to separate them. 3. Remove the oil pan. il Pan Installation Note Caution If the bolts are reused, remove the old seal- ant from the bolt threads. Tightening a bolt that has old sealant on it can cause thread damage. 1. Apply silicone sealant to the ail pan along the inside of the bolt holes, overlap the ends, and install the oil pan within five minutes. 2. Tighten the oil pan bolts. Tightening torque 6.99.8 Nm { 70—100 kgf-om , 61—86 in bt} OIL PUMP DISASSEMBLY / ASSEMBLY 1, Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly indi- cated in the table. 01-11-488 (7800, 674 } ® OIL PUMP IN 1. Cheek th (1) Disto (2) Worn (@) Weak 2, MeasureLUBRICATION SYSTEM Maximum: 0.23 mm { 0.0091 Outer rotor-to-pump body clearance ‘Standard: 0.010—0.196 mm { 0.0004—0.0077 in} 01-11-6| COOLING SY: — a ENGINE COO 1. Remove ti UINGSYST 2. Verify that neck. ENGINE COO Draining 1. Drain the ¢ 2. Remove th drain plug, 3. Drain the of Fiush the 4 of color are Left the sy Tighten thENGINE ¢ 1. Check 2, Remo. 3. Conne diator Cautic . A 1 ot 4. Apply Press 103 RADIAT 3. Verity specit Press 74). ————— 4. ifthe cap is2. Check for damage on the ¢ cracked or deformed seal f 3, Replace the radiator cap if ao — RADIATOR REMOVAL / INST; 1, Disconnect the negative IR SYSTEM COMPONED TION. 4, Remove in the order indica 5. Install in the reverse order the table. 6. Fill he radiator and coolant fied amount and type of en, (Refer to 01-12 ENGINE MENT, Refilling 7. Check the ATF level and ad fer To 05-13 G r 8. Check the ATF and coolant!THERMOS? 4. Discons 2. 3. Remove 4 Install i> 5. Fill her fied am (Reier | NT. 6. Start th an C] ray FACE THIS TO THE FR THE ENGIN 3. Place tr Heat the Initial-openit Ful-open te Fullopen if WATER PU 4. Disconr 2. Turn the TOC of | 8, Drain th] TA 4, Remove (pect at 5, RemoveCOOLING FAN INSPECTION 1. Inspect the following items. RI (1) Fluid leakage from the far (2) Deformation of the bimeta: (3) Excessive play of the cooll01- INTA REN | ‘AIRY TDLE INS, VN INS. WACK INTA SS Le c NNE=SNESSSSSSFSFSFSSSSsePxJ_[_Sjj79-107 Nm Bo HOkgtem, 69.4 (19-26, 14-48] (senas, 14 (e010 kg hii \ Ee 7 [Fesrar| “2 Air intake @_[Airleane a [Mass air — 3 Acoeeray 8 Trot 7 [BAC vad 8 [Bypass al —Dynamic Chamber © Face the bead chamber as sho] ber. oy ifold as shown, ™ AIR VALVE INSPE! 1. Remove the BAC 2. Circulate water it ‘cool the air valve 3. Circulate hot we sage and verily & 3, Measure the res by using an ohmvRIS ¢ 1.0 act 2.Ap the 3.Ap the in) vacu 1 Re 2. Vis 3. Bh vRIs 1. 2. Cr vaACCELEF 1. Remo 2. Install the tat ACCELE!01-14 FUEL SYS] STEM INSPECTION, Fuel System Pressure Drop. ine Pressure FUEL TANK EMOVAL | INSTALLATION Fuel Hoses, Evaporative Hose, Breather Hose Installation Note Nonretum Valve instalation Note [Joint Hose Installation Note... | FUEL FILTER (HIGH PRESSURI REMOVAL | INSTALLATION. FUEL PUMP FUEL PUMP FUEL SYSTEM PRECAUTION Fuel Pressure Release and Servit Warning © Fuel vapor is hazardous. ignite, causing serious in Always keep sparks and fuel. © Fuel in the fuel system is sure when the engine is n Warning © Fuelline spills and leaksai can ignite and cause st death and damage. Fuel skin and eyes. To prevent plete the following “Fuel dures Fuel Line Safety Procedures 1. Release the fuel pressure bef fuel ine. (1) Disconnect the fuel puro r (2) Start the engine. (3) After the engine stalls, turn 1 OFF. (4) Connect the fuel pump rela la3. Turn the ignition sw ff aXo| SYSTEM INSPECTION Fuel System Pressure Warning © Fuelline spills an ignite anc death and dame and eyes. To pr the “Fuel Line ——— 4 FUELS ine Safety Pr 1. Disconnect the neg: 2. Install a fuel pressur 1d the fue sri 3. Connect the negatiy 4. Connect the data li GND with a jumperGn 5, Turn the ignition sw FUEL TANK REMOVA Warning © Fuel vapor is ignite, causine Always keep € fuel. © Fueiline spills can ignite an death and dane skin and eyes. \lete the “Fuel ecto dt=see to Of=14 F. © Repairing a fue erly steam clez sion or fire injury. Alway tank before re 1. Disconnect the neg 2. Remove in the orde 3, Install in the revers. the table,FUEL SYSTEM 77 [Fuel flerppe 12. | Nonretum va ‘pf Installation Net] 15 | Evapprative bose ‘llastallation Nat Fuel Hoses, Evaporative Hose, Breather Hose Inst- allation Note 1. Push the ends of the fuel hoses, evaporative hose, and breather hose onto the respective fitings, Specification 25—30 mm { 0.99—1.18 in} 2. Install the clip on the fuel hoses with its tongues fac Nonreturn Valve Installation Note ‘© Insertthe noreetum valve into the fue! filler pipe until its stopper completely fits the fuel filler pipe, STOPPER e[_ eso sien 8. Install the clip on the evaporative hose and breather hose as shown, 4, Be sure the hoses are not bent or twisted, FUEL HOSES SEEB SEEC umes NONRETURN VALVE INSPECTION 1. Tiltthe nonreturn valve and verify that the ball inside, moves smoothly under its own weight. 2. If not as specified, replace the nonretum valve. Joint Hose Installation Note 1. Push the ends of the joint hose onto the fitting Specification 33-38 mm { 1.31.4 in} 2. Be sure the hose is not bent or twisted. 01-14-4FUEL INST; | FUELFUEL SYSTEM 7. Use a new rubber seal, and install in the reverse order of removal. FUEL PUMP DISASSEMBLY / ASSEMBLY 1, Disassemble in the order indicated in the table. = [Seal nbber 2. Assemble in the reverse order of removal indicated in ihe tole. 7 [Fuel tank gauge sender unit Fuel Hose Assembly Note 1. Donat apply excessive side force when pushing the fuel hose onto the fuel pump nipple. 2, Install the clamps as shown. BRACKET SIDE 4 24mm NG {0,080.15 in He Tp’ ] Samm Fuel Pump Assembly Note ‘© After installing the fuel pump to the bracket, pull the pump down so that itis tight against the bracket. ox. Rubber mount Fue! fit (ow pressure side) Fuel pump connector Fuel pum © [ASSenBIP NOT) Fuel hose, . Ae FUEL PUMP INSPECTION Fuel Pump Continuity 4, Disconnect the fuel pump connector, and check for 1. Remove the No.2 rear seat. Continuity between fuel pump connector ipump 2. Lift up the rear fioormat.. side) terminals C and D. 3, Remove the service hole cover. 01-14-65. theres Fuel Pump Warning © Fuel! 1. Disconne| 2. Connect 4 fuel filter gauge as 8. Connect t 4. Connect # GND with 5. Turn the, pump ma’FUEL SYSTEM FUEL PUMP RELAY REMOVAL / INSTALLATION 1. Lift up the floormat in front of the passenger's seat 2. Remove the protector cover. 3. Remove the fuel pump relay. 4. Install in the reverse order of removal. FUEL PUMP RELAY INSPECTION 1. Remove the fuel pump relay located next to ECM. 2. Check for continuity between the fuel pump relay terminals by using an ohmmeter. 0-0 : Continuity on Terminal iw A B c D == 2 Bs | Grows | Ot 0. PRESSURE REGULATOR REMOVAL / INSTALLATION 8. If not as specified, replace the fuel pump relay. © [Refer to 01-14 FUEL INJECTOR REMOVAL 7 : INSTALLATION, PRESSURE REGULATOR INSPECTION Fuel line pressure Warning © Fuelline spills and leaks are dangerous. Fuel an ignite and cause serious injuries or death and damage. Fuel can also irritate the skin and eyes. To prevent this, always com- 1. Disconnect the negative battery cable. 2. Install a fuel pressure gauge between the fuel fier and the fuel distributor. (Install clamps as shown.) 3. Connect the negative battery cable. 4, Start the engine and run it at idle, 5. Measure the fuel line pressure. Fuel line pressure 206-254 kPa { 2.1—2.6 kgflom? , 30—36 psi } 01-14-8Fuel Pressure Drop Warning © Fuellinespills can ignite ar death and dar skin and eyes lete the “Fue. 4. Disconnect the ner 2. Install a fuel press: and the fuel distrib 3. Connect the negat PRC SOLENOID VAI INSTALLATION © [RelertoOr=13 INT NT REMOVAL / IN. PRC SOLENOID VAL’ 4. Remove the PRC 2: Check for air flow valve. Step a 2 <FUEL INJECTOR RESISTAN| 1, Remove the fuel injector} FUEL INJECTOR REMOVAL| Warning © Fueiline spills andle can ignite and caul death and damage. skin and eyes. To pr plete the “Fuel Line: fer to 01-14 FUEL g| Fuel Line Safety Pro 1. Remove in the order indici 2. Install in the reverse orde} the table, (00 Kgrem FUEL INJECTOR INSPECTIC Fuel Leakage Test Warning © Fuelline spills and ley can ignite and caut death and damage. F|FUEL SYSTEM 1. Remove the fuel injactors together with the fuel dis ‘ribitor. [Refer to 01-14 FUEL INJECTOR Ri MOVAL | INSTALLATION, 2. Aix the fue! injectors firmly to the fuel distributor with wire. 3. Connect the data link connector terminals FIP and GND with ajumper wire. Keep the fuel distributorlev- al. ono WY rip 4, Turn the ignition switch to ON. 65. Til the fuel injectors approximately 60 degrees and verify that no fuel leaks from the fuel injector nozzles. Leakage Specification Less than 1 drop / 1 minutes 6. Turn the ignition switch to OFF and remove the jumper wire. 01-14-11 7. If not as specified, replace the fuel injector. Volume Test Warning © Fuelline spills and leaks are dangerous. Fuel ite and cause serious injuries or death and damage. Fuel can also irritate the skin and eyes. To prevent this, always com- ON 2. Disconnect the fuel injectors. 3. Connect the SST as shown in the figure. 4, Measure the injection volume of each fuel injector by using a graduated container. Injection volume 44—65 ml { 44—G5cc , 1.52.1 floz} / 15 sec.01-15 EXt EXHAUST SYSTEM EXHAUST SYSTEM REMOVAL / INSTAL EXHAUST SYSTEM 1. Start the engine ¢ ‘component for ext EXHAUST SYSTEM I 1. Disconnect the ne 2. Remove in the orc 3, Install in the rever ren 18-23, 12 ‘\ an / \ @7 2 ‘Aftor-ilencer 3 | Heated oxygen sensor (ear) 4 | Three way catalytic converter 5 [Heated oxyger or (frontEMISSION SYSTEM 01-16 EMISSION SYSTEM [EMISSION SYSTEM COMPONENT CHECK VALVE (TWO-\ WAY) aaa aoy Pe ne REMOVAL / INSTALLATION. 0116-1 CANISTER DRAI ee er eciet — [Guecenen Pes EuROe pase eR SSE a wate cr cponeMraee) 7 SVC REITER clic] [reat eemnmesc matte [EMISSION SYSTEM COMPONENT {TPGV) INSPECTION pees 01-164 (IN RIGHT REAR SIDE TRIM) CUT VALVE INSPECTION 0116-5. IR TERRES THM) un. c1te-g| PRAYVALYE NSPE SHON sess ISIE [SEPARATOR INSPECTION . 01-16-3] EMISSION SYSTEM COMPONENT (FUEL TANK SIDE) REMOVAL / INSTALLATION = Fuel vapor is hazardous. It can very easily ig- 1_| Pipe protector Ft par tcheeargous tonnvegesig, (1 [Pesprteger ways keep sparks and flames away from = jarcoal canister bracket my + lowest nate 1 Remove nthe order ndestedin ne abl Soa Re ccs ok oe iced ra Sean ae ayy senzne = is — = aCONT Ter, wrer.,| signal | Connection to Heated ox Ignition sw rr |ensensor | Hoated oxygen front hoster | sensor tron” ge | [Heated on | Ignition sw su | gensensor | Heated ongen kd Crean eater sensor ean ge Bypass ar 1v_ | AWS contri | Bypassiairsote- | BYPASS St noid valve Other aR = 28 = = cvaporaive |TaNK BS | aion ew ‘vaporatve | control valvelcan- 20 | check ister drain cut vave Diagnosis a }_2E = — oF = = | Tom oiag- 26 |nosietest | Tom | ignition sw mode | ‘On-board diagnostic Ignition sw 2H |systom sig. [TOM (Fermin? nal input ground) {From ToM) FT = = 2s = I — Ignlion sw Heated oxy- " ox tested on | Heated oxygen | en sensor (ear) |_—__ Accseraic Decelerat 2L |Fuollevel | Fuel gauge Ignition sw Fuel tank | Fuel tank pre Ignition si SA pressure ‘sure sensor | idle ap MESS IFW | as rw son | HON |wary Et idle ao foaled ox | Heated oxygen gen sensor | sensor (rant) 668 30,CONTROL SYSTEM signal | Connection fest condition Voliege | Possible malfut rror.|] signat | Connection to Test condi 8° | possible mat > ECM ternal Backup 4 2 onstan atery hare "power suppy | Battery Constant 8 eadomene Pressure [AG solenoid | Iale Hot condition) Below 1.0 |* PRC solenoic 45 |requator | PRC soon Nos cont Other B+ |e Related nary © VAIS colenci ak | vais conv | VAIS solenoit vave | valve si 0] ® Related harne | Pressure Idle (Hot condition) Below 1.0 | PRC solenoic at |regulator | PRC solenoic y Noo conta Other [B+ |e Related hamy a = CL Ignition control Ignition switch ON ‘Approx. | Ignition contre 4N [IGT control | module (Distribu- 2 = module i) ide Approx 05 |» Related harm so | = = = ae rs | = = > Ignlion avtoh ON B+ |» tai aircon? 4q |[Bearcon |isearcont [on nON ‘de "ol valve Idle (After warms up) Approx. 10 |@ Related har Ignition evteh ON Aoprox 10 |* ECM termi an |Eane [Tachometer 6 ECM ering sper Idle Approx. 8 1G hamess Ignition awteh ON 8 ssaeume leu punpreay [Cran eee 48 | control Fuel pump relay | Cranking ——————— Reinw 10 | @ Related harn! ide ge solenoid | lantlon switch ON 7 4T | Purge control | Purge solencia | Griten Swi — Be valve | ° idle Fated har | Foal injector | Fusl injector ot | 4U | control No.1_| cylinder) Fuel injector | Fuel injector Wo | 4V | control No.2 cylinder) qr [Fut njactor”| Fue injector Wd onal No.3 | eyinda «Fel injector se) igniion switch ONIdle Be ‘ax_|Fuelinjector | Fuel injector Noa | # Related harm contol No.t_[eyiinder) Fy [Fusliniector | Fuel injector oS | 4% |contottios |ayinden Fuelinoctor | Fualinjetor (No.6 42 | controt No.6 cylinder) Using SSTs (NGS) 1.In the passenger compartment, connect the SST (NGS) fo the data link connector 2 located under the driver side dashboard ro coo oe 01-40-642. Referring to the NGS operatic “PID/DATA MONITOR AND f 3. Referring to the 1997 Servi each ECM input/output signe Note © The “PIDIDATA MONIT function is to monitor th inpuvioutput signals in the value does not always it the related input/output solenoids). PIDIDATA MONITOR table Display on splay 0 Monitor wo AWD distinction sign, Ac RLY — | AIC relay ACSW | AIC switch BAO | Barometric pressure BAROTCM | Barometric pressure BAROV | Barometric pressure BRK SW | Brake switch “r £7 EI 60 a ECTV voltage | el. | Electric load signal FAT terminal oy (Data link connect | FHOeS ted onygen sens FHO2SH | Heated oxygen songCONTROL SYSTEM Display on splay oF Monitor item UnivCondition| Tgniion ow FRALY [Fuel pump relay ONIOFF | Idle: ON Cranking: Fut 0—0. FTLV | Fuel tank ove signal votage v Empty: 2. Halt FP Fuel tank pressure Pa. | mmig [anion se Ignition sx Frey | Fueltnkpressure signal votage ve |i 25— - Fuoltank le air control ve ms Ignition sx acy ll ai contol vane Ignion sy ar Intake air temperature °C |_| intake air 1 atv Intake air temperature signal voltage v eas H Intake air temperature ; Pall | {A706 | (Dynamic chamber) On| aca Intake air temperature signal vollage ay warocy | inane Share e] yt — Ignilon sr, Iesw | lanon swt onore |gmtens” ia (Term ict Ignition timing : idle ATDC Ignition 98 IN uo! injection duration ms Ignition se MAF V —— |Mass air ow signal votage v Ignition sv a ~ Ignition sv ma Mattunction indicator ight ONoFF | DTGexist _|No DTC:« Ignition sv Prov | PRC solenoid valve ONOFF | Idle: OFF a ‘Mer hot ¢ Ignition sv Prove | PRC solenoid valve No2 OWOFF | idle: OFF [ ‘ter hot = PRGV | Purge solenoid valve duty value % Igntion sr PsPsw | PIS pressure switch onorr — {IS nator iE | Readiness function code learning RFC exist nrc FLAG | Ree oniorr — /RFC.exist Ignition 9 Noes | Heated onygen sensor (Rea) vy | Sei Decelerat ECT RHO2SH | Heated oxygen sensor heater (Rear) | onvorF | ECT aboy RPM | Engine speed _ tem, Idle: 760- rar TAT terminal Datalink connector) | ONOFF | Normal: C TEN TEN terminal (Datalink connector) | ONOFF | QPEn tem Throitle postion sensor signal Closed th way voltage v Wide ope 0140-8Display on ] the NGS Tasw | MASS AIRF! Using SSTs | 1. Check th cracks. 2. Remove | 3. Connect Adapter F 4. Measure inthe tab Speciticatior Terminal se, 4A, 5. Ifnot ass (1) Harn cSpecifi Volt 9. Hf n « @ 10. Ifth nuit SS _————— Engin: Taleat 2,500" TNOCONTROL SYSTEM (CAMSHAFT POSITION SENSOR INSPECTION 41. Remove the distributor. 2. Remove the ECM. 3. Connect the SSTs (Monitor, Engine signal and Adapter Harness) to the ECM Eo EE BEET oxi: ‘4. Turn the ignition switch to ON. 5. Rotate the distributor drive by hand and check the output signal Specification Signal Terminal Voltage, ‘SoC 4G___ [Approx 5V (1 pulsarrev) 6.f not as specific (1) Hamess cor, @ Betweer (6-pin) @® Betweer| (G-pin) te @ Betweer tor (6-pir (2) Distributor (: positive vol 7. ifthereis incorre cuit, replace th! CRANKSHAFT POSITION SENSOR INSPECTION Resistance 1. Disconnect the crankshaft position sensor connec tor. 2. Measure the resistance between terminals A and 8 by using an ohmmeter. Specification '950—1250 © [20 °C ( 68 “F }] iN @ ao 3. If not as specified, replace the crankshaft position sensor. CRANKSHAFT POSITION SENSOR REPLACEMENT 1. Disconnect the negative battery cable. 2. Disconnect the crankshaft position sensor connec tor. Air Gap 1. Measure the air crankshaft posi Specification 0.5—1.5 mm (CRANKSHAFT PULLEY SENSOR 2. If not as specif the crankshaft 8. Remove the ord 4. Install in the rev 01-40-11(CRANKSHAFT POSITION ‘SENSOR, = ‘THROTTLE POSITION SENSOR INSPEC Closed Throttle Position Switch 1. Verity that the throttle valve is at the cl Biscom ee 2. Disconnect the throttle position sensor| 3. Check for continuity CWC Sl T_T sor connector terminals G and D by ue meter. 4. if no continuity, adjust the throttle posi 5. Insert a 0.50 mm {0.020 in} feeler gai the throttle adjusting screw (TAS) and ver. Verify that there is no continuity. ERGAUGE 6. If there is continuity, adjust the throttle sor. Teter To ADJUSTMENT, Throttle Position Sensor Using SSTs (Engine signal monitor) 1, Remove the ECM, 2. Connect the SSTs (Monitor, Engine $$$_$_$_$_$_$___ Adapter Hamess) to the ECM.CONTROL SYSTEM 4. Select the “PID/DATA MONITOR AND RECORD” function on the NGS display. 5, Select “TP V" or and shows the v Specification ‘Closed thrott Wide open th (Verify that th portioned to 1 6, Itnotas specifier ‘THROTTLE POSITION SENSOR ADJUSTMENT Caution © The throttle position sensor is adjusted at the factory before shipment. Unnecessary adjustment will negatively effect the engine performance. ‘* Adjusting the throttle position sensor by using the throttle adjusting screw (TAS) will negatively effect the engine performance. 1. Verify that the throttle valve is at the closed throttle position, 2. Disconnect the throttle position sensor connector. 8, Loosen the attaching screws, 4. Insert a feoler gauge between the throttle adjusting sorew (TAS) and the throttle lever. Adjust the cont ‘uty between the closed throttle position switch ter- minals C and D by using an ohmmeter. (Refer to 01-40, ADJUSTMENT, é 5. Tighten the attar Tightening tore 1.6—-2.3N-m Using SSTs (Engir! 1, Remove the EC 2. Connect the S Adapter Hares. 4 | Te 8. Verify that the tt} $$ position 4, Turn the ignitier—£__———_—__—— 5. Rotate the th, ECM terminal 3 Eom Clearance Continuity L (0.15 mm { 0.006 in} __ves (0.50 mm {0.020 in} No. 01-40-13co Specification Closed throttle position: 0.11.1 V Wide open throttle: 2.8—4.5 V (Verity that the voltage increaseis dire. portioned to the throttle valve opening 6. Itnot as specified, replace the throttle posi sor. Using SSTs (NGS) 1. Connect the SSTs (NGS) to the data link 2 located under the driver side dashboard, oo ‘\ DATA LINK eee CONNECTOR e V\ oo THROTTLE POSITION SENSOR REPLACED 1. Disconnect the throttle position sensor cor 2! Remove the attaching screws. 3. Remove the throttle position sensor. 4. Verify that the throttle valve is at the close position. 5. Open the throttle valve slightly and catch t the throttle body on the thrattle position ser tic tabs. Align tang A on throttle body with throttle position sensor. Note tangs on thy body mate with the tab on the throttle posit on the side of the tab without a slot TANGA \ \ TANG 8 oe THROTTLE THROTTLE SODY SIDE POSITION SENSORCONTROL SYSTEM ENGINE COOLANT TEMPERATURE SENSOR INSPECTION 1. Remove the engine coolant temperature sensor. 2. Place the sensor in water with a thermometer, and heat the water gradually. 3. Measure the resistance of the sensor by using an ohmmeter. Specification Temperature ("C {°F }) Resistance (kQ) 20,68) 80{176} 4. If not as specilied, replace th perature sensor. Tightening torque 16—23 Nem { 1.6—2.4 kat HEATED OXYGEN SENSOR INSPECTION Sensor Using SSTs (Engine signal monitor) 1, Remove the ECM. 2. Connect the SSTs (Monitor, Engine Signal and Adapter Harness) to the ECM. 3. Warm up the engine to normal operating tempera- ture, 4, Measure the voltage at ECM terminals 2K and 3C. Specification ECM terminal voltage (¥) a Heated oxygen | Heated oxygen ‘sensor (front) | sensor (rear) Engine condition (2) Fuel system (3) On-board agnosie sys 6. Ifthese systems are OK. rep sensor. Using SSTs (NGS) 1, Connect the SSTs (NGS) to th 2 located under the driver sid 2. Select the "PID/DATA MONI function on the NGS display. ISON 10 ie | 01.0 Deceleration | 0-05 0-05 ‘Acceleration | _05—1.0 051.0 5. If not as specified, inspect the following. (1) Intake-air system 01-40-15CONTROL SYSTEM 3, Select *FHO2S” and *RHO2S" on the NGS display. NGS measures and shows the voltage. Specification i I Voltage (V) Engine condition \— Fao RHOES IG-ON tale. ‘Deceleration | 0-05 0-05 ‘Acceleration 05-10 05-10 Heater 1. Disconnect the heated oxygen sensor connector. 2. Measure the resistance between heated oxygen sensor terminals C and D by using an ohmmeter. Specification Approx. 13 © [20 “C{ 68 °F }] 4. If not as specified, inspect the following. (1) Intake-air system (2) Fuel system (8) On-board diagnostic system 5. Ifthese systems are OK, replace the heated oxygen sensor. aC] A e1b. B FUEL TANK PRESSURE SENSOR INSPECTION Using SSTs (Engine Signal Monitor) 1. Connect the SSTs (Monitor, Engine Signal and Adapter Harness) to the ECM. CoE 2. Apply vacuum to the fuel tank pressure sensor by using a vacuum pump. Measure the pressure at ECM terminal 3A. c 2 FRONT FeAA 3. Itnot as specified, replace the heated oxygen sen- sor. oo R barauiic me CONNECTOR 2 297088 008 2, Select the “PID/DATA MONITOR AND RECORD" function on the NGS display. Specification ame ECM terminal SA Noe Tec oa voltage (V) SES OkPa{Ommrg, OinHgy 25 1 kPa {7.5 mmbig 0.29 intig 28 3. If not as specified, replace the fuel tank pressure sensor. Using SSTs (NGS) 1. Connect the SSTs (NGS) to the data link connector 2 located under the driver side dashboard. 3. Apply vacuum to the fuel tank pressure sersor by using a vacuum pump. 4, Select “FTP V" on the NGS display. The NGS mea- sures and shows the voltage. 01-40-16Specification Vacuum OkPa(O mmHg, One 1 kPa{7.5 mmHg 0.28 POWER STEERING P| 1. Disconnect the pow nector. 2. Start the engine. 3. Check continuity of ter. Specification Steering wheel condi Turned ~ Straight ahead MAIN RELAY INSPEQ 4. Remove the main a 2. Apply baitery posit between terminals, ter. SpecificationTEC 01 ENGINE MECHANICAL Type Cynder arangarent ion chamber ratio n pre Type Oil pump oil fiter [Total (dy Otcapacty [iret Oiland Water pump [Type Typ OpeningTECHNICAL DATA om — Engine NE nada | __ nn Cap valve opening pressure (kPa (kalor® ,pi)) 74702 (075—1.05, 107% 7 Te — Thero-modulated Cooira‘an jesse |e Gem inj [01899 ___[Swiching temperature OFF30N COC FY | ____ &2-88(160—190)... CHARGING SYSTEM - - | ([Votage - st : 2 4 Battery | Pe and eapacty (hour rate) __ 880231 (48), 760261 (62)* Main [Regulated votage : |Seltciagnosistuncion - Eavipped Generator |RotCresistance (Between springs) ——«(@)|_—=SCSCSC«C BBO BOT Brush ‘Standard (mm {in }) 21.6 {0.846} [length Pinimur (mm{in)| 800.315} | Bush [Standard j bry) | 82-43 {092-044 071 Minimum 1.8(0.18 04) tgnttonson- | yp9 Integrated in cstv a [Type Integrated in distribute loiter col | aasance 049-074 [20°C (66° | || 26-81 [20°C (68°F Distrbutor | HP ee Ie Fring oder 456 Hightension | Resistance (kam) 16{20°C (68°F) Spark advance — Eleoronie [NGK BKRSE-11°3 , BKR6E-. Type oo ———_}——— sparkplug NIPPONDENSO | 179, K2OPR] Puggap SS (mim{in)) 1.0—1.1 {0.040—0.04 Tahtening one Tran igim tet | eSBs STARTING SYSTEM _ _ _ Type SSS Reduction Output ei) 121.0, 72 starter [Brush [Standard “ominyy | 123 (048), 165 (08 [length | Minimum cmm{iny[ 7.00.28) Pinion 990 (om (in) With System Selector (49 BOT GAO) fest switch at SELF TEST. Dark current isthe constant flow of current present (for the audio unit, clock, with the ignition key removed. ‘Standard plug. Cold area, ECM ete.) when the ignition 01-50-2SERVICE TOOLS 01-60 SERVICE TOOLS Adjust wrench ya Engine stand Ha, 49. L010 101 ~ fast SOS*~S~S~S~«~S Plate Ams: |e (Part of (Partof ane (Ps 49 L010 111. ~~ [49011 OAR Tad, ; (Part of SS |e suport sew : 49 LOT 006. 49 L011 009° yas 01-60-1a9 Lot oT 78 Holder Ris (Parot br 49 Lott OAOB) cE 49 E011 103 9 Shaft (Part ot 49 E011 1A0) | 49 Lov oot [aq (Part of Installer le 29 L012 0A0A) 49 L012 004 Nu (Part of 49 LOT2 OAOA) 49 BOI OAZ Pivot [29 6012 014 Look nut (Part ot 49 8012 002) set rubber bush 49.0249 010A Remover & installer, valve guide“49.9200 146 ‘Adapter A (Partof 49 9200 145) 49 0269 749 Plate (Part of 49 0259 745) 49 Lov 002 Support (Part of 49 LO19 00) 49 088 0AO NGS set NGS 08D II ‘Adapter (Partot / 49T0880A0) ef (Par @ ‘49 7088 008A Instruction Manual 49 F018 903 SheetSUSPEN TROUBLESHOOTING .. . 02-01 LGENERAL PROCEDURES ..... 02-10] WHEELS AND TIRES ... 02-12 [FRONT SUSPENSION ........ 02-13] 02-01 TROUBLESHOOTING ‘AUTOMATIC LOAD LEVELING (ALL) a iat —— Becmaste eee te ———————— ‘Troubleshooting 02-01-2 AUTOMATIC LOAD LEVELING (ALL) ON-BOARD DI On-board Diagnostic System Outline © Alter the check terminal is grounded and the ignition switch is tumed to ON, the ALL control module changes to the on-board diagnostic mode described below, which checks the operation of the air-intake system, the exhaust system, and the vehicle-height sensor. Ifthe results indicate a problem, the ALL in- dicator light begins flashing, and the system with the problem is indicated by the pattem of the flashing. Vehicle-height adjustment function inspection 1. The work should be done ona surface thatis smooth and flat. Note ©The vehicle height function can be checked au- tomatically by grounding the check connector and performing the following operations 1. Airintake system check ‘A check is made to determine if vehict height increases to NGH (abnormally high) within 150 seconds. Exhaust system che A check is made to determine it vehick height decreases from NGH (abnormal high) to L (low) within 110 seconds. Vehicle-height sensor check er than that sepcified from start af check to finish of check. 02 (1997 MPV) ; Acheck is made to determine if outputs othTROUBLESHOOTING MEASURING POINT A A FENDER, azo ALLINDICATORUIGHT ——uameoios 5. Verify the flashing pattern of the ALL indicator light, then repair the malfunctioning area indicated in the di Dre Flashing patter Diagnosis system component A oss 1 Tes Aiintake system ‘ a aio8 2) ANT Exhaust system 3 125] Vehicle-height sensor | H 4 Urs ‘System is normal anor Diagnostic Trouble Code Troubleshooting bre 1 Airintake system DETECTION | Vehicle height does not increase to NGH (abnormally high) within 160 sec. when checking ai-iniake CONDITION _| system Malfunction of compressor or compressor relay Air pipe clogged or ar leakage '* Damaged shock absorber roling diaphragm '* Malfunction of height sensor ‘© Malfunction of ALL control module ster INSPECTION ACTION | re wring hamess of compressor and compres; | Yes [Goto new sep sorely OK? “No__| Conect as necessary. 2 [Ie compressor relay OK? Yes | Go to next step. e015 IRE RELAY INSPEC a TION teplace compressor relay. [Is output pressure of compressor OK? Yes | Go to next step. {02=15 COMPRESSORE INSPECTION] § yo ; POSSIBLE CAUSE Replace compressor. 4+ [pipe dogged ols area eiaoe? Yes | Replace air pipe No_| Go to next step, (1997 MPV) 02-01-2 Revised 10/98TROUBLESHOOTING STEP INSPECTION AeTION 5 [To lhe shook absorbor ong daphvagm dart] Yes | Raplaze var shook absorbor. coo 2 O=ISREAF SHOOK ABSORBER] | No [Gotwnant ap SECTION, Dishaun ingestion 3 thers a leakage of shock apgober? Yes | elas ear shook absorb TPB ReR SooeeSoeeemT) = : = sPECTION, Air Leakage Ir tion No | Go to next step. 7 | rspec height sensor | Yes [Go to nox sie. [GOS HEIGHT SENSORINSPECTION] | ~ |~°<" — No | Replace hight conser 3 Yes |Gotonew sep — No | Adust hight sensor 3 | Tur niin awich to OFF. then recheak for dag | Yes [Replace ALL contol modula nostic trouble codes. lee ecae ae ee eee No_| There was temporary poor contact in wing hamess or | connector pre 2 Exhaust system DETECTION ici eight dos not dere om NGH (anomaly hight (ow when checking exhaust tem ‘+ Exhaust valve passage clogged or damagedidisconnected harness POssIBLE |» Airpipe ciogaes CAUSE | «Malfunction of height sensor Malfunction of ALL control madule [STEP | INSPECTION ACTION 1 [Is wiring hamess of compressor OK? Goto next step, _ - Correct as necessary. 2) cmp rene o copreser OR {Go tonext step, Replace compressor 1s. spe ogges joris there airleakage? Replace air pipe. | Go tonext step. 4 | Inspect height sensor Yes | Go tonext step. ls tOK? 'No_ | Replace height sensor. | Is height sensor adjusted to specification? Yes | Goto next step. |__PIQETSHEIGHT SENSOR ADJUSTMENT] [no | Adjust height sensor. | Turm ignition atch to OFF, then recheck or dag- | Yes_| Replace ALL control module poe uous codes! No | There was temporarily poor contact in wiring herness or | connector. Is diagnostic trouble cade 2 obtained? pre 3 Vehicle-height sensor DETECTION DETECTION | Output is other than specified when checking vehicle height sensor POSSIBLE — | Height sensor internal crcultry malfunction or damagedidisconnected harness CAUSE | Malfunction of height sensor ISTEP | INSPECTION ACTION 1 |S wing hamess of height sensor OK? Yes | Ga to next step, No [Correct as necessary. 2 | pect nag snes Yes [Go to next step. - ls ROK? No_ | Replace height sensor. 3 | Isheight sensor adjusted to specification? Yes [Go tonext step. so{U2=15 HEIGHT SENSOM ADJUSTMENT] — | No [Adjust height sensor 02-01-3[STEP nostic AUTOMATIC LOAD LEVE! Precaution © Perform the “Basic Ins according to the “Diagr Basic Inspection © Perform | Turn ignition switch to Is diagnostic trouble o trouble codes. the following i [STEP] T_| Perform ALL onvboare| 2-01 AUTOM (ALL) ON-BOAFY FUNCTION Are any DTCs indicate @Vver | Does ‘Door Does © Speed soar Sonomncenss Sep oie, bt Bim erew ee olor | area iy that ALL indi rminate within 10 itilluminate? ‘switch inspectioy |QOpen driver's door Deri that ALL inal within 10 see. itiluminate? i ‘Symptom | © ALL contr [STEP © Airpipe clogged Height sensor electrical 7_ [WHEN ENGINE RUN / EEEIDESCRIENION ES [TROUBLESHOOTING HIN? Height sensor malfunction * Improperly adjusted heigh,, © Exhaust valve stuck or dat Exhaust valve passage ck rol module malt 1 _| Inspect height sensor, POIs HEIGHT |} sit OK7 2 | Isheight sensor adjua ‘02-15 HEIGHT MENT3 [Inspect exhaust valve ‘p[02=15 COMPA Is tOK? 4 [nape Is it OK? Inspect ALL control BALL GOR m sit OK? 2_ [WHEN ENGINE RUN} ‘© Height sensor malfunction Improperly adjusted heigl Poor contact of compress Insufficient output pressu Compressor motor malfun| ALL control module malfu Air pipe clogged or leaking Air leakage from shock a Damaged shock absorber| Height sensor electrical i [ster 1 [ls height sensor adjueh [02-15 HEIGHT MENT rt height eanaorl (2-18 HEIGHT | T Ist OK? > Inepest ai pe. I IsitOK7 Ingpect height sensor IsitOK? [Inspect ALL control 02-15 A SPECTION Is it OKT3_ [WHEN ENGI DESCRIPTION [TROUBLESHOOTIN ‘© Improperiy adjust ALL control modul [STEP ee 1 [isheight sense | pfo-15H MENT Inspect ALL of {02-15 A SPECIE Is itOK? DESCRIPTION [TROUBLESHOOTH # Exhaust valve past * Aicpipe clogged # Height sensor mal) # Improperly adjuste Inspect air pip oT Isit OK? Inspect ai pip 2-15 A Isit OK?TROUBLESHOOT! (6 [WHEN ENGINE RUNNING, ALL INDICATOR LIGHT REMAINS IL DESCRIPTION [TROUBLESHOOTING HINTS] Height sensor malfunction or damagediaisconnected wiring Improperiy adjusted height sensor rod Generator hamess damaged or disconnected Generator maifunction Exhaust valve stuck or damaged!disconnected wiring Exhaust valve leakage Insufficient compressor output pressure or compressor motor malfunctic ‘ALL control module malfunction Ar leakage at air pipes or shock absorber connection ‘¢_ Damaged shock absorber roling diaphragm step INSPECTION 1 [ls hegh sensor adusted to spoottaion? | ves [Govom Wy So-to HEIGHT SENSGH AGIUST- MeN No | Aduatt Teepe hit seneor — Yes [Goton 1 SPE BELG SENSOR NSPESTION) 3 [Inspect generator hamess, Yes |Goton IsitoK? No __| Repairs + [rican Yes |Gotont Is OK? No [Replace 3 | repost exhaust valve ol eompresea: Yes |Gotorl 1 eH SRIPRESSERE A SPecTIN | ct © | nspect apps, Yes |Goton twit No 7 [repectrearareck abeost Yes PP OeSTS HERR SHOU ABSORBER] |__| SpECTION Not Rapiaat teit x? 3 | inspect ALL conra noaue Yes [Sytem pf 02-15 ALL CONTROL MODULE IN- ] SPECTION | | No | Replace tein Ox? [Racing 7__ [WHEN ENGINE RUNNING, ALL INDICATOR LIGHT DOES NOT] DESCRIPTION | [TROUBLESHOOTING HINTS} '* Exhaust valve leakage '¢ Insufficient compressor output pressure © ALL contro! module malfunction ‘Air pipe clogged or air leakage from valve or shock absorber Damaged shock absorber roling diaphragm [step | INSPECTION 1 | est au ae ol emt Yes [Goon sit OK? No | Replac’ 2 |inspectairpipe. SS S*«wSCiéM es [Gotoed 1 RHPPENBEECTIEN “No Repo: 3 | inspect rear shock absorber. | Yes [eq seit SoRECTION No | Replac 02-01-7(STEP) + [ine Isit DE! TTROUBL! © Exhaus Exnaus, Ar leak 2 [Wr DE: (Roust, © Exhaus © Compr $A A Ariel Damag| [STEPTROUBLE 'p{02-15 ALL CONTROL MODULE IN- [specrion [isitox? [STEP INSPECTION 3 [Inspect air pipe, Ye ‘(02-15 AIA PIPE INSPECTION al IsitOKr Nl 4 | Inspect rear shock absorber. Ye K ABSORBER IN N DESCRIPTION 10_ | WHEN ENGINE RUNNING, COMPRESSOR DOES | [TROUBLESHOOTING HINTS] ‘Generator malfunction Compressor malfunction ‘ALL control module malfunction ‘Compressor relay malfunction ‘Compressor motor internal wiring damagedidisconnected Door switch andior cargo compartment light switch malfur [STEP INSPECTION T ¥e N 1 [inspect ganerator ‘p[0i=17 GENERATOR INSPECTION Is tOK? 2 Inspect door switch and cargo compartment light switch BP CARCO CO TENT LIGHT SWITCH INSPECTION sit OK? SS 3 Inspect door switch harness and cargo compartment ight switch IsitOK? Ye Ni 4 Inspect compressor. 5 (i: R-COMPRESSOR INSPECTION] 5 | Inspect compressor harness. IstOK? ‘5 02-15 COMPRESSOR REALY IN- |“ [spection sit OK? 7 inspect ALL control module. | of SPECTION Is it OK? — I ——$ | [TROUBLESHOOTING HINTS} ‘© Compressor relay malfunction {© Compressor motor malfunction 11_ | WHEN ENGINE RUNNING, COMPRESSOR $PEE———<—<—<—<$—_—_—_—___—___———_—_—— DESCRIPTION [STEP | INSPECTION 1 [Inspect comoressor rela 02-15 COMPRESSOR RELAY IV] SPECTION. IsitOK?TROUBLESHOOTING INSPECTION ‘ACTION Yes _| System is normal No __ | Replace compressor. 02-01-10GENERAL PROCEDURES 02-10 GENERAL PROCEDURES CAUTION (SUSPENSION) PRECAUTION (SUSPENSION) Wheels and tires removal/installation * The removal and installation procedures for the wheels and ties are not mentioned inthis section Ifyou must remove a wheel, retighten it to 89—117 Nem { 9.0—12.0 kg-m , 6686 ftlbt}. ‘Suspension links removailinstallation Tighten any part ofthe suspension that uses rubber bushings only after the vehicle has been lowered and unloaded. 02-10-14 Note © Unloaded... Fuel tank full; engine coolant and engine oll at specified levels; spare tire, Jack, and tools in designated position.02-11 WHEEL AL PREINSP, FRONT WE WHEEL AL 1. Check mendet 2. Inspect necess 3. Inspect 4. Inspect excess FRONT Wi Speci [Front whe: Total toein Maximum ¢ | Fuel gauge Camber an Caster ang “Ty Engine Adjust 2: Ditleren Adjustmer 1. Adjust 2. Remov 3. Looser tie rods turning and the Note Tu ee 4, Tighter Tighte 6o— Camber ATightening torque 47—62 Nim { 4.7—6.4 kgf-m , 3446 fbf} Mark. Note ‘* Changing the position of the mounting block changes the camber and caster about 26° WHEEL ALIGNMENT Difference from standard p= Right side re Difference from standard position ‘Camber angle Caster angle A o 28 8 26 c 128 o Left side ‘Camber angle cane] ~_ 28 - $28 | 3 J RIGHTSIDE MARK eer gioh FRONT 02-11-2WHEELS AND TIRES 02-12 WHEELS AND TIRES WHEELS AND TIRES SPECIFICATIONS 2 02-12-4 WHEELS AND TIRES SPECIFICATIONS Standard tire tem Specification [eT Tex6 12 15x6H) a Offset (rom {in} 40157) - Pitch circle diameter (mm4in}) 7143 (4.50) _ | Material Steel Steel or Aluminum aloy Pa Size PLOSI75R15 P2iS/65R15 P2i5/70R16 Air pressure (kPa (kal/om?, psi) 240 (2.4, 35 200 (2.2.32 ‘Temporary spare tire Tem Specification Size 15xaT a Offset tmmin) e077) Pitch Grcle diameter __(mm{in))|__———S—S—S—=«A (4.50) _ [Material Stee! a Sze TiS570D15 Air pressure (Pa (hal 15 (42.60) 02-12-4102-13 FRONT SHO! J URemovan) 0 Pan noa | FRONT LOW INSPECTIO. FRONT LOW EMOVAL |. Lower Arm. H Bushing (fr 1. Jack up t 2. Remove e100; 65-24) Hose | 2 | Boltart Fubbe |FRONT SUSPENSION 6) Piston rod nut ‘Removal Not] 7_|Mounting block 8 _| Spring upper seat 9 [Spring seat 10 | Coll spin finslaaion NTS) 11_| Bump stopper 12_| Shock absorber Piston Rod Nut Removal Note Warning © Removing the piston-rod nut is dangerous. ‘The shock absorber and spring could fly off under tremendous pressure and cause seri ‘ous injury or death. Secure the shock ab- sorber in the SST before removing the pis- ton-rod nut. ‘When using 49 0223 640B and 49 G030 641 1. Loosen the piston rod nut several turns, but do not remove it 2. Compress the coil spring by using the $STs, then re- move the piston rod nut. 3. Remove the coil spring When using 49 T034 140 - Secure the mounting block in a vise. Loosen the piston rod nut several turns, but do not remove it. Assemble the SSTs. ‘Secure the shock absorber in the SSTs. Compress the coil spring by using the SSTs and re- move the piston rod nut. WHEN Coll Spring When using 1. Secure th 2. Apply rubl onto the b 3. Install the shown int FING AU \ 4. Install the the SSTs) 6. Install the x= 02-13-26. Instal shoot 7. Insta 8 Loos 9. Rem: 10. Secu 11. Tight Tigi 64 NN 12. Verity When us 1. Temp seat, thefl perStabiizerbokand nak P81 FRONT STABILIZER REM INSTALLATION. Scbis6ot lil insalalon Nata 3_| Retainer Rubber bushing FRONT LOWER ARM (2WD) REMOVAL /| 1. Jack up the front of the vehicle and sup] 2. Remove in the order indicated in the tal 3. Install in the reverse order of removal iFRONT SUSPENSION 94—116( 9511.9, 69-6) x 118156 12-416, g7 195) e9—107( 90-110, 66-79) jalosd Oo 7 [eater consanert 3 | onerarn ba Conpressonted — 3 | Tie-rod end ball jc ole Eat ond nu) Sec cean ano open Toner arn (2WD) REMOVAL / INSTALLATION, Tieod = —_—— Er Bal oh Rees Note a 7 [Batandnut Seen Lower Arm Ball Joint Removal Note 1. Remove the cotter pin and nut. 2. Separate the ball joint from the knuckle by using the Sst. Dust Boot Removal Note Remove the dust boot by using a chisel. Dust Boot Installation Note 1. Liberally coat the inside of the new dust boot with grease (lthium-based, NLGI No.2). 2. Press the dust boot onto the bail joint by using the SST. CoE 02-13-6FRONT LO 1. Remove 2. Inspect’ Replace 3. Inspect’ it neces 4, Shake t) 5. Connec a Rotatio 2.0% Pull-ses 20-3 FRONT Lo’ 1. Jack up 2. Remov 3. Install a (oatA Oe 11 [Botan 0 [13 [Dust Lower Arm 1. Remove 2. Separate] SSTs. Dust Boot 1, Secure tH] pads. 2, Place a angle shd! 3. RemoveBush 1.8. FROM cleltobe «aoFRON™ . / 5160( 5162, 37-46) 18-25, 19-26, 16-18), 1) Stablizer bolt and nut Tastallaion Note: 2 | Retainer Cc 3_| Rubber bushing Stabilizer Bushing And Bracket Installation Not 1. Align the bushing with the installation mark on stabilizer 2. Insalthe bracket so thatthe F mark aces the fj ofthe venice INSTALLATION FE | ane i ° | CROSSMEMBER (2WD) REMOVAL / INSTALLAT 1, Remove the steering gear and linkage. MOVAL INSTALLATION.) 2, Remove in the order indicated in the table. 2. Install in the reverse order of removal indicat 4. Check the front wheel alignment and adjust it if eeFRONT SUSPENSIC 9417 (10-42, 724-867) (5-08 ease \ 1091281 1¢ 1_[ Brake caliper + [Cy 2 [Lower arm bal joint [ 1 10] 02=13 FRONT LOWER ARNT 2WDY RE] 8 [Fy MOVAL INSTALLATION, Lower Arm Ball amicd Joint Removal Note f-8_{o 3 | Stabilizer bolt and Nut 7_|er >| 8 or INSTALLATION, Stabilizer Bolt And Nut | linstatation Note. Crossmember Nut Removal Note 1. Support the engine by using the SST. 2. Support the crossmember By using a jack, then re move the crossmember nuts. —— —__ ee 02-13-11FRONT Crossmember Bushing Removal Note * Remove the crossmember bushing by using t SSTs. COE EOE CROSSMEMBER (4WD) REMOVAL / INSTALLATIC 1, Remove the undercover. 2, Remove the front differential and AFW componen [ (LaTiON.)} 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal indicated 5. Check the front wheel alignment and adjust i ifr 997505, 65-68) 2 98171 (140-175, 102-128) i L 8 Ss j CFFRONT SUSPENSION Front stabiizer [STALLATION_ | Steering gear and linkage _ ‘06-12 STEERING GEAR AND LINKAGE (4WWD) REMOVAL / INSTALLATION. Grossmember bolt and nut {02=13 CROSSMEMBER (2WD) REMOVALT INSTALLATION , Crossmember Nut Removal Not [Lower arm Crossmember 02-13-13fee REAR STA 1. Jack uy ty stan 2, Remo 3. Install the tab]REAR SUSPENSION 4. Install in the reverse order of removal indicated in the table. 40-50{ 40-52,25-37) @) RIGHT SIDE C300 em 115-156 not) re oT (DLEFT SIDE ALL MODEL. ; (771085675) 2 : 79102 77-105, 56-75) 1s-ngun Ole kgf-cm , 70—106 in tht) um kghm Bt) 1 _[ Splash shield © | Shook absorber 2 | Stabilizer ‘ef Removal NOT] ‘0 02=14 REAR STABILIZER RE 7 MOVAL INSTALLATION, 3 | Nat (ALL model 8 - ‘insta NOS) [Bump stopper 4 [Bot Bolt, nut, and washer ‘Shock Absorber Removal Note 1. Support the lower part of the shock absorber on a. jack, and then raise the jack as necessary to lighten the load on the shock absorber. 02-14-22, Remove the shock absorber: Coil Spring Installation Note © Besure that the larger diamot faces the axle case. UPPER LINK, LOWER LINK Al} 1. Jack up the rear of the vehi 2. Remove in the order indicate all in the reverse order o 120171130175, 95-128) 138171 180-475, 102126)REAR SUSPENSION Lateral Rod installation Note ‘© Install the lateral rod with the mark toward the body. 02-144[AIR PIPE REPLACE [HEIGHT SENSOR If [HEIGHT SENSOR Fil [HEIGHT SENSOR Al AIR PIPE INSPECTI Air Leakage Inspec}AUTOMATIC LOAD LEVELING > a ~ a 4 = x 4 x 4 Air Flow Inspection 2. Blow air through the pipe to verily clear passage. 1. Disconnect both ends of the air pipe to be checked, AIR PIPE REPLACEMENT Atype ‘* Press at the base of the plug, and then pull the air pipe to disconneet it ‘© _ Push in until the air pipe’s ridge catches on the tab on the plug to connect it B type # Remove the boot from the joint, then firmly grasp the air pipe joint tabs and pull out to disconnect i ‘Push in until a click is heard, pul slightly to be sure the connection is secure, then cover the joint with the boot to connect i C ype * Disconnect the pipe by removing the nut # Connect the pipe by tightening the nut 02-15-2(19AUTOMATIC LOAD LEVELING INTERIOR CPU LIGHT (REAR GATE) DOOR SWITCH { { IGNITION SWITCH REAR ALL CONTROL MODULE TERMINAL a ST TOMI TTSTETCTA) : eircetst ht Tote ReaR FRONT ricer FiceT) NG FRONT HEU tee CHECK Conrad Tes Sonus Sone oy VALVE INDICATOR LIGHT} na SOLENOD REVELL) + camer eBsoe! veweve MOTOR ‘SENsOn GENERATOR (CTERMINAL) HEIGHT SENSOR Be: Battery positive voltage Terminal Connected to Condition Voltage Pe ‘aries according to vehicle height ‘(02-15 HEIGHT SENSOR INSPECTION. Vohicle running (10 kmh (6.2 mph H Vehicle speed sensor ene eee SENSE | Vehicle stopped 8 | Door switch Door open ~ > Door closed Vave ON shaust val pee Tae OFF T | compressor relay ‘Compressor ON Compressor OFF 0 Jidteup [Compressor ON Compressor OFF (1997 MPV) 02-154 Revised 10/98v ALL indica Battery po Tanition pe eight ec Height ser Ground _ Check ter, HEIGHT SENSOR INSPE* 1, Usea screwdriver or sit from the height sensor VAIL == =a 2. Check for § V at termi 8. Disconnect the rod. 4, Check that the voltaged ent at terminals (c), ( moved. ‘Sensor ink Vehicle | Seertion height NG H (high) HEIGHT SENSOR REPL. 1. Jack up the rear of the ty stands. 2. Tum the Sar ti C2 ——— let the spare tire carrie in}. 8. Disconnect the hares 4, Remove the bolts, nut 5, Install in the reverse or specified torque. (1997 MPV)AUTOMATIC LOAD LEVELING © Ifthe location of an air leat sLbe founds asoap and-water solution|(Refer to 02—15 AIR PIPE INSPECTION, Air Leakage Inspection), check as deseribed below. 1. Remove the shack absorber. 2. Visually check the diaphragm for damage. 8. Using the SST, make connections as shown in the figure. oo Note o The shock abson outer surface. Do| 6. the above check she i” absorber, replace th 7. After the check i fi 4. Apply approx. 490 kPa { 5 kgflom?, 71 psi} air blowing with compres pressure. 5. Pace the shock absorber in a tank of water and check for air leakage, COMPRESSOR REMOVAL / INSTALLATION 41, Remove in the order indicated in the table. 2. Install in the reverse order of removal indicated in the table. Note ‘¢ An internal circuit breaker is incorporated within the compressor. ltopens to stop the motor ifthe motor temperature exceeds approx. 150 °C{ itself and restarts the motor when the temperature drops below approx. 100 * 02-15-7| Battery [2 [Battery bracke 3 [Headignt bul ‘COMPRESSOR IN} 1. Jack up the reary ty stands. 2. Disconnect the | Connect the SS- 3. Apply battery p 2n¢ (0) 1 re compressor.AUTOMATIC LOAD LEVELING 6. While maintaining the compressor pressure, apply 20—78 kPa 0.2- battery positive voltage between terminals (C) and {) of the compressor connector. 8. Lower the jack slow! 9. Connect the air pip q Tightening torque a 12.8—17.6 Nem {| intbt} 7. Verity that the exhaust valve operation sound is Gm heard and that the pressure gradually decreases. y Check that the following pressure is finally reached and held, Standard COMPRESSOR RELAY INSPECTION 1. Remove the compressor relay. 2, Connect battery positive voltage to terminal (B) and ‘ground terminal (A) 3. Verify continuity between terminals (C) and (0). 4, Ifnot as specified, replace the compressor relay. 02-15-9TEC 02-50 TECHNICAL DATA (OZ SUSPENSION ors OO] 02 SUSPENSION Tem WHEEL ALIGNMENT Toateen | Maximum steering angle Front whee ‘gana alignment (Unladeny"? Caster angle’? fing axis inclination —— [Pitch circle diameter Standard tre wheel [Material Standard tire a Airprossure Pa (aly ‘Sze Temporary spare tre [Ofiset — Ee wheel Pitch circle diameter Material —— |size Ae presse Temporary spare tre Type ‘Stablizer Shock absorbers | REAR SUSPENSION [hp Stabilizer ‘Standard suspension ‘Automatic oad leveling equipped Fue! tank full engine coolant and engine oi 6 —_—_—_—_—_—_—_———————————————— ‘Adjust fo the median when carrying out whee! alg nen ener tone ~_ Shock absorbersat Pr 8 Ay)SERVICE TOOLS oO TOT TOUR OH ao oe one Gauge body Adapter Adater (Partot ator Patel 491028 oA0) 910028 oA0) £91028 ono) 49 U0342A0 - 49 U034 202 7 49 D033 140 Lower arm Support bios Pl, whee! bashing puller Pater i an oe eg wousie ~S*~*~*~*~*~«~RRTOAT 49 FORT 008 Handle Insta st ‘tachment 68 Panot bearing ay arr 910038 140) SS (Partot GEN | sFeron) 9.6026 108 Support block & 02-60-2DRIVELINE TROUBLESHOOTING ....... FRONT AXLE 03-11, REAR AXLE DRIVE SHAFT 03-01 =TROUBLESHOOT IN Ch TROUBLESHOOTING AUTOMATIC FREEWHEEL 1 03-01-4 Diagnostic Index 03-01-14 ‘Symptom Troubleshooting 03-01 a NERAL NOTES | TRANSFER (03-01-3 STEP 1: ‘ON-BOARD DIAGNOSTIC SYSTEM INSPECTION [TRANSFER] ......... 03 01.9. PSTEB RO TRANSEER Losses: 09-01-91 INSPECTION [ TRANSFER 03-01-3 & ‘SYSTEM OPERATION INSPECTION [ TRANSFER 03-01-3 a _ ‘SYMPTOM TROUBLESHOOTING. TRANSFER]. 13-01-4 ‘CHART [ TRANSFER ] -03-01-4 TROUBLESHOOTING [ AUTOMATIC FREEWHEE| Diagnostic Index No. TROUBLESHOOTING ITEM 1__ [No AFW operation (ree to lock) 2 [No AFW operation (ook fee) f‘Symptom Trouble 1_[NOAFWOP DESCRIPTIC [TROUBLESHOOT © Malfunction of loc Maifunction of ac Air leak at vacuut = Mallunction 0 [steP 1 | spect ock ~oa—14 UNIT I i Inspec UNIT Is itOK? 3 | Inspect vacu unr i in Is tOK? & [inspect one asia | “Junin va | Ist OK? [2 [NO AFW OF ~__DESCRIPTIC [TROUBLESHOOT ‘* Malfunction of AF Malfunction of lot Malfunction of ac Air leak at vacuy Malfunction of or [STEP] 1 Inspect AFV | os-14 | Inspect actu ‘Tun IstoK? 4 | Inspect vac 08-14 UNIT a OK? Valve OK?GENERAL NOTES [ TRANSFER ] A problen engine, the dri ‘STEP 2: ELECTRICAL SIGNAL INSP!TROUBLESHOOTING sYMPTOM TROUBLESHOOTING [ TRANSFER ] © Check the Mull:Mode 4WD system for malfune- tions. [[Refer to 03-018 SYMPTOM TROUBLE [SHOOTING [TRANSFERT] STEP 4: ‘QUICK DIAGNOSIS CHART [ TRANSFER ] ‘The quick diagnosis chart shows problems and the components that may be the cause, 1. Problems indicated by " x” in the Exclusion column may be normal operation. 2. The numbers in the chart indicate the order of inspection for easy detection of malfunctions. 03-01-4Nosh TROUBLESHOO’ lj H L E L ; i ie H Sp : Excessive ime fag ‘Abnormal noise 3] BY Bane cag Slo] aw ry (Change metoraRY RT taf alerana mer ‘No ifumination of WD indicator light AWD (Looked) 2WO— AWD (Free) No shift Excessive tne lag Excassive shift shook ‘Abnormal noise wD Free) => [wo tea] aw > 40 (Locked) |+H0 Fee No shift Exeassive ime lag ‘Abnormal nose No cancelation of AWD ingicator ight 4W0 (Free) — 20D No shift Excessive imme lag Excessive shift shock ‘Abnormal noise 1 z WD (Locked) [iro eae No shit Excessive tre fag ‘Abnormal nose ‘No ilumination of CENTER DIFF, LOOK Indicator light No shift Excessive tine lag Excessive shift shock 2wo-- WD (Locked) 1 z 38 [Nocancelation of 35 _ |CENTEADIEF Lock 8 | inadeatr hight briormal nose Roshi Excessive mie ag ‘Renormal nose No ilumnination of WD ‘and CENTER DIFF LOCK inicator lightTROUBLESHOOTING ON-BOARD DIAGNOSTIC SYSTEM INSPECTION [ TRANSFER ] Fail Mode Function * The warning alarm will sound if a maitunction is foundin the change motor or electrical circuit. While in the fail mode, the warning alarm will sound when- ever the 4WD/2WD shift switch or differential lock ‘witch is activated. The fall mode function is can- ‘celed when the ignition switch is turned to OFF. Ita ‘malfunction occurs in ether of the position switches while the change motor is running, the 4WD control module sets the mode to 2WD. If a matfunction oc- curs in either of the limit switches while shifting, the WD control module sets the motor step position. oN or WARNING ALARM © °°: OF MORE 400/20 SHIFT SWITCH ON ALIGN CENTER OFFERENTAL Cece suite INDICATOR LIGHTS. Caution Mode Function ‘The caution alarm will sound as shown if the AWDI2WD switch is activated while driving in 2WD (Locked) mode. ‘The proper sequence isto first turn off the center dif- ferential lock switch to set 4WD (Free) mode; then. activate the 4WD/2WD shift switch to set 2WD mode, oN orr— caurionataam 3 TINES ELECTRICAL SIGNAL INSPECTION [ TRANSFER ] ‘© Check the electrical signals to/from the 4WD control NTHOLM 03-01-6TROUBLESHOOTING ‘SYSTEM OPERATION INSPECTION [ TRANSFER ] 1. On level ground, jack up the vehicle and support it evenly on safety stands. 2. Shit the transmission to N postion 3, Start the engine and let it idle 2WD To 4WD (Free) Mode Shift 11. Turn the center differential lock switch to the OFF position. 2. Verify hat the CENTER DIFF.LOCK indicator lightis OFF, and that the 4WD indicator ight is OFF. INDICATOR LIGHTS. 8. Activate 4WD/2WD shift switch, 4. Verify that the shift alarm sounds as shown, on sHieT ALARM 5, Ifnot correct, check the 4WD/2WD shift switch! fer to 03-16 4WDI21 mT iri 6. Verify that the 4WD indicator light flashes as shown, on ord 7, IHnot correct, check the 4WD ingicator light TESTGr] TOO: REPLACEMENT. 8. Veriy that the 4WD indicator light illuminates. 9. If not correct, go to next step. 10. Tum engine OFF. 11. Turn the front tires clockwise. 12, Verity that the re 13. If the rear tires rc ‘AFW switch. 14, Ifthe rear tires rc lenoid, actuator, ‘motor relay No.1 AWD (Free) To 2WC 1. Turn the center position. 2. Neri that thee @ = OFF, and that th 8. Activate the 4 4, Verity that the s! on fo g 5, i not correct, a Ter to 03-16-41 TION. 6. Verify thatthe 4v 8, Turn the engine| 9. Jack up the front tre Lock ise, —$_— rotates. 03-01-710. Ifthepa free sol (change ule! 4WD (Free! 4, Turn thi position 2. Verify OFF, ar 3. Turn th 4. Verity t comes | 5.If not ¢ AWD re control OO 4. Tum th positior 2. Verity tr ON, anOFF 5. If not correct, che switch and indicato 6. Verify that the 4Wt ctor lights come 7. Hot correct, go to 8. Turn the engine OF, 9. Turn the front tires tires rotate clockwis SYMPTOM 2 1_ [NO SHIFT FRON Does shit alarm WOW shit 2 | Does waming ala 4WDI2WD shifts[STEP — ii alas aSTEP) 2 [Does awedTROUBLESHOOT [STEP | INSPECTION 9 [Is vollage at terminal A of AWD controlmod-_] Yes [© Che ule ov? cont © Che [2 Che No_|Replac '3_[NO SHIFT FROM 4WD (FREE) TO 4WD (LOCKED) MODE [STEP INSPECTION 1 [Does wiring alarm sound when activating cen- ter differential lock switch? 2 | Does CENTER DIFFLOGK indicator ight ‘come ON? 3 [Turn engine OFF Jack up vehicle and turn front tres clockwise. Do rear tires rotate clockwise? Yes [e Ghe char © Che othe No | Check trol mo HOK.¢ Yes_|Gotor No | heck Yes | Vehicle Inspec No |[Gotor 4 | Drive vehicle approx. 0.5 km {1/4 miles } and recheck step 3. Yes [vehi inspec Wo] Check oe oat oF ont + Fro It OK, ‘ i ov? Ts vollage at teminal P of 4WD control module Yes |» Che No. 6 | ls there battery voltage at terminal C of 4WD ‘control module? Yes No__[Repia ————— 03-01-12———_—— [STEP] INSPECTIC 7 [Is voltage at terminals R and P o} ‘tol module OV? [NO SHIFT FROM 4WD (LOCKE” [STEP INSPECTI ‘Does warning alarm sound when] Center differential lock switeh? 2 | Does CENTER DIFFLOGK indie ‘when center diferential lack swt OFF? [Tum engine OF. Jack up vehicle and turn front tr Do rear tires rotate counterclock 7 [Brive wehicie approx 05 ken (1 recneck sop 2 ] 5 | Is voltage at terminals FR and P o- trol module OV? © | ether baton volage a termind control module?[NO SHIFT FROM 2WD TO 4\ ——— 1 [Does warning alarm sound wi ter differential lock shifts Do 4WD and CENTER DIFF.L ights flash? 3 | Do 4W0 end CNTR lights come ON atter diving v 05 km { 1/4 miles }? | 4 | Is voltage at terminal P of 4W ule ov? 5 _| Is there battory vollage at ter | contol moaue? on Ts voltage at terminal N of 4 ule ov? —_ — 7 [fe woltage at terminal © of 4S ule ov?GENERAL PROCEDURES 03-10 GENERAL PROCEDURES PRECAUTION (DRIVELINE / AXLE)... 03-10-1 PRECAUTION (DRIVELINE / AXLE) Wheel and tire removallinstallation * The removal and installation procedure for the wheels and tires are not mentioned in this section Ifyou must remove a wheel, retighten ito 89—117 Nim { 8.012. 0 kgf-m , 66-86 ftibf). ‘Suspension link removal/installation ‘* Tighten any part of the suspension that uses rubber bushings only after the vehicle has been lowered and unloaded. Note * Unloaded....Fuel tank full; engine coolant and engine oil at specified level; spare tie, jack, and tools in designated position. 03-10-1FRONT AXLE 03-11 FRONT AXLE WHEEL HUB, STEERING KNUCKLE WHEEL HUB, STEERING KNUCKLE (4WD) PREINSPECTION. 0311-4 . [Wheel Bearing Pla 03-11-41 WHEEL HUB, STEERING KNUCKLE (4WD} WHEEL HUB, STEERING KNUGKLE (2WD) Locknut installation Note 0311-2. WHEEL HUB, STEERING KNUCKLE (2WD) ISASSEMBLY | ASSEMBLY 03-11-3. ‘ABS Sensor Rotor Disassembly Note | Hub Bolt Disassembly Note... 0311-3] D. +r Disassembly Ni Outer ol mbly Note Wheel hub Component Assembly Note. sasar Rotor Assembly Note. 03—11=4 Tnner il seal Assemiy Note. )ISASSEMBLY / ASSEMBLY 2 03-11-5 ‘Wheel Hub Component Disassembly Note 03-11-6. al As WHEEL HUB, STEERING KNUCKLE PREINSPECTION Wheel Bearing Play 1. Position a dial indicator against the disc plate. Push and pull he disc plate by hand in the axial direction and measure the wheel bearing play. 2. Ifthe bearing play exceeds the specification, check and adjust the hub nut torque or replace the wheel bearing and hub component if necessary. Maximum wheel bearing play 0.05 mm { 0.002 in } WHEEL HUB, STEERING KNUCKLE (2WD) REMOVAL / INSTALLATION 41. Remove in the order indicated in the table, 2. Install in the reverse order of removal indicated in the table. 03-11-14FRONT AXLE WHEEL HUB, STEERING KNUCKLE (2WD) DISASSEMBLY / ASSEMBLY 1. Disassemble in the order indicated in the table. Note 2. Assemble in the reverse order of disassembly indi- * The hub bolts do not needto be removed unless. cated in the table. you are replacing them. ‘* Remove the hub bolts by using a press if necessary. Dust Cover Disassembly Note Note * Thedust cover does not need to be removed un- less you are replacing it 1. Mark the dust cover and knuckle spindle for proper sro reassembly. 2 | ABS sensor rotor [Disassembly Note] eo[sSemoy NOT] 3 | Hub bott >| Disassembly Note] 4 [Dust cover (Disssenr Nae] pov issembly Note wae 5 [Knuckle spindle 2, Remove the dust cover by using a chisel. ABS Sensor Rotor Disassembly Note Note ‘* The sensor rotor does not need to be removed unless you are replacing it, ‘* Remove the sensor rotor by using a chisel. Hub Bolt Disassembly Note 03-11-3Dust Cover Assembly Note 1. Mark the new dust cover as the remoy| 2. Align the marks of the new dust cd knuckle spindle. 8. Install the new dust cover by using the ‘SOCKET WRE! Hub Bolt Assembly Note © Install the new hub bolts by using a pr WHEEL HUB, STEERING KNUCKLE (44 1. Remove in the order indicated in the 2. Install in the reverse order of removalFRONT AXLE 02137( 104-140, 76-101) fae) a4 ee ) 19-25 19-25, 14-18) 130161185165, 98-199) 1 [book nut © 03-17 WHEEL HUB, STEERING KNUCKLE (2WD) REMOVAL / INSTALLATION, Locknut| Installation Note REMOVAL / INSTALLATION, Tie-od End Ball Joint Removal Note 03-11-5Tinnerollseal |r 2 | Wheel hub cor Outer ol seal 4_| Retaing ra 5 | Wheel bearing >{Disasser 3 [obo of 03-11 (ew) D Bot ise foe | aw) D Bolt Asse Wheel Hub Compo © Remove the wh SSTs,Dust cover Disass less you are rq 1. Mark the dust cove reassembly. Dust cover Assembl 1. Mark the new dust 2. Align the marks ¢ knuckle 3. Install the new dus OSE '49 L033 101FRONT AXLE 03-11-803-12 REAR AXLE St PREINSPECTL Wheel Bearin REAR AXLE Sr REMOVAL /IN eat Axle Sh. ‘Oil Seal insta Rear Axle Sh. REAR AXLE SF DISASSEMBL REAR AXLE St Wheel Bearing © Inspect ther same way a: REAR AXLE St 1. Remove in 2. Install in th \ 6088, 50-70, 5REAR AXLE SHAF 1. Disassemble int 2. Assemble in the 0, k/ BBa 7 [Retaning tng 2 | Bearing colar -— [Assert ——] 4 | Bearin | Bearing Collar Dis: 1. Grind a section + mm{ 0.0197 in} backing plate ar 2. Being careful nc shaft, hitthe grov achiselBearing Disass 1. Set the SST 2. Verity that tr and that the the SST. Ad Spray a rus faces indica 4. Tighten the PENETRATI Hub Bolt Disad a Be oe you are © Remov sary. REAR AXLE S| 1. Measure thDRIVE SHAFT 03-13 DRIVE SHAFT DRIVE SHAFT PREINSPECTION ‘* Check the boots on the drive shatt for cracks, dam age, grease leakage, or loose boot bands. Replace it necessary. DRIVE SHAFT REMOVAL / INSTALLATION 1. Drain the differential gear oil 2. Remove in the order indicated in the table. 3, Install in the reverse order of removal. 03-13-1DRIVE SHAFT onm 6-219 (232) 7-291) wom | Bi (eons, 95-28) ‘ “© cs Nemcxgtm, nn 7] ueckat 3 [Lower arm ball font bot and nut 1 O31 WHEEL HUB, STEERING RNUCKIE]| |; -Tugecuer REMOVAL / INSTALLATION, Locknt insta — lation Note Lett drive shalt ‘o[ Removal NO] 2 | Tie-rod eng bal joint _ of O62 STEERING GEAR AND LINKAGE 6 | Right drive shat (2WD) REMOVAL | INSTALLATION, Tie-od ‘= emoval NO] End Ball Joint Removal Note Left Drive Shaft, Right Drive Shaft Removal Note © Separate the drive shatt from the differential by pry- ing with abar inserted between the outer ring and the differential Note © Ifthe drive shaft will not come out of the wheel hub easily, install a discarded nut onto the drive shaft so that the nut is flush with the end of the drive shaft, and tap the nut by using a copper hammer. DRIVE SHAFT DISASSEMBLY / ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 03-13-2DRIVE SHAFT RIGHT DRIVE SHAFT 1 [Bootband 7] inner ring ‘OL ASsemby NOT] of DiSSSSSR IEE] 2 |Cip efRSsembyY NS. ‘o[Disassembly Note] @ | Boot __|_erassembiy Note [DESSERT NOE] 3 | Outer ri efssemby Nore] CASSORBW NET] @ | ABS sensor rotor = [eat | ofDisassembqy Woe TOSS) | SPRsemer nosy 5 | Snap rin Shalt and bal joint component 2 Besseney Na) Note Dust cover 6 [Cage ‘Disassembly Noe pt Rssembly Note Clip Disassembly Note Snap Ring Disassembly Note 4. Mark the outer ring and the cage for proper reas- 1. Mark the shaft, cage, and inner ring for proper reas- sembly. sembl 2, Remove the clip by using a screwdriver. 2, Remove the snap ring by using snap-ring pliers. 03-13-3Cage Disassembly Nc © Turn the cage abot the inner ring Inner Ring Disassemt Remove the inner f Boot Disassembly N © Wrap the splines damaging the boot. band ABS Sensor Rotor Dj Note The sensor rot unless you are| © Tapthe ABS senso] ing a chiselDRIVE SHAF| Boot FP ¢ 2.1 aC a comarars 4 3. Align the marks and install the balls to the inner ring, ¢ 4. Install the cage, inner ring, and ball assembly to the drive shatt in the direction shown in the figure. 65. Fita new snap ring into the ring groove in the shaft, CAGE MARK 3 / SNAP RING GROOVE 6. Install the cage on the innerrring, andturnthe cage ga about 30 degrees with respect to the inner ring, aI 7. Fitthe balls through the cage into the ball grooves of q the inner ring, 8. Apply the specified grease to the cage, inner ring, and balls, Outer Ring Assembly Note 1. Align the marks, and install the outer ring on the shaft 2. Install a new clip onto the outer ring. 03-13-503-14 DIFFE FRONT DIFFERENTIAL | INSPECTION 2.1... FRONT DIFFERENTIAL © REPLACEMENT . FRONT DIFFERENTIAL REPLACEMENT ‘Companion Flange Or Replacement . Differential Oi! Seal (ng Replacement... RONT DIFFERENTIAL FREEWHEEL UNIT REMOVAL / INSTALLA Left and Right Drive Sh Removal Note Front Differential and A Removal Note ONT DIFFERENTIAL ISASSEMBLY_ ‘Output Shaft Disassem Front Differential Come Disassembly Not Tocknut Disassembly § ‘Companion Flange | Disassembly Note Drive Pinion Componer Dis Front and Rear Bearinc IM Rear Bearing Disassen fearin [Rear Bearing Race As: acer Assembly Note) [oheprerane+ ‘Assembly Note. Side Bearing Assomb! Rdusting Screw Assert UTO ‘ASSEMBLY [Oil Seal Assembly Note —— nw FRONT DIFFERENTIAL 1, Remove the filer plug 2. Verify that the oil is u" hole, as shown, — eeDIFFERENTIAL 4, Install the filer plug and a new washer. Tightening torque 4053 N-m { 4.05.5 kgf-m , 2639 ftbt} FILLER PLUG. washer L FRONT DIFFERENTIAL OIL REPLACEMENT 1. Remove the drain plug, filler plug, and washers. 2. Drain the oil into a container. 3. Wipe the plugs clean, 4. Install the drain plug and a new washer. Tightening torque 40—53 N.m { 4.05.5 kgf.m , 28-99 fbf} 5. Add the specified oil through the filler plug hole until the level reaches the brim of the hole. Specified oi pe ‘Above -18 °C { 0°F}: API GL-5, SAE 90 Below -18 °C { 0°F }: API GL-5, SAE 80W Capacity 1.7 L{ 1.8 US at, 1.5 Imp qt} 6. Install the filer plug and a new Tightening torque 4053 Nem { 4.05.5 kgt-m| FILLER PLUG E | WASHER, 1 FRONT DIFFERENTIAL OIL SEAL REPLACEMENT Companion Flange Oil Seal Replacement 1. Jack up the vehicle and support it on safety stands. 2! Drain the differential oil 3. Remove the propeller shaft. 4, Before loosening the locknut, measure the rotation starting torque of the drive pinion (within the range ‘of the drive pinion and ring gear backlash). 5. Hold the companion flange by using the SST, andre- move the locknut. 03-14-267-87 58-98, 50-21) 16-221 15-29, 12-16) $899,501) . ot Ngo] a DIFFERENTIAL 102-137( 194-140, 70-109) Non kgtn 0) Tie-od end ball joint End Ball Joint Removal Note ‘p]U5=12 STEERING GERR AND LINKAGE |2WD) REMOVAL / INSTALLATION, Tie rod Front popeler shalt ;-15 PROPELLER SHAFT FEW INSTALLATION C 6 | Connector and vacuum hose 2 _[ Lower arm ball joint bolt and nut 771 Front diferental and AFW anit 3 [Under cover {Removal Note] 4 @ [Automatic freewheel unit Left and right drive shaft, axle [Removal Nota] 9 [Front diferential 03-14-4Left and Right Drive Shaft, Axle | '* Separate the drive shafts fromth ing with abarinserted between tt differential. Suspendthe dives after removal | Front Differential and AFW Unit F 1. Support the differential on a trar 2. Remove the bolt and nut 3. Remove the front differential an rnonr orenenmat osaseel FRONT DIFFERENTIAL DISASSE ‘© Disassemble in the order indica . x a—S eo \ | | \q wou 1 | Output shat o{Disassombi NOTS) — 2 [Front axle casing 3_|Oitseat __ 4 | Front clferential component “c(Disassemb'y Note} 5_[Bot eed [Lock plate | 7 [Bearingcap 8 _| Adjusting sorew — 9 | Side bearing race — 10 [Look nut ee [DsassoRBY NO) LL 1_| WasherFront Different, 41. Mount the di 2 Mark one b 3, Mark the beg mang Locknut Disast © Holdthe con move the loc weDIFFERENTIAL Side Bearing Disass: © Mark the bearings move them by usit FRONT DIFFERENTIAL ASSEMBLY '* Assemble in the order indicated in the table, y® 2 ase a; 1_| Differential carrier 9 | Spacer 2 | Front bearing race 10 |Oit seal Di Resenbiy NO] Sassen —] Fea teng | Companion fan ofassembly Nore] — 12_| Washer 7 [Dive inion ee * ner seer Nae] _ — © piesa) 14 {Gear case 6 | Rear bearinc 18_| Side gear (Asser RSE] 16 [Pinion gear 7_[Colasibe spacer ——] it Pinion sna [Front bearing 18 | Washer SL ASERBY 03-14-7‘Side bearing Side bearing race “23 | Adjusting screw (Resa NS] 24 [Bearing cap [Air breeder _ Front Bearing Race Ass ‘© Install the front bearing Cora Rear Bearing Race Asse) ‘© Install the rear bearing \ Cor Spacer Assembly Note (Adjustment of drive pin 1. Install the spacer andDIFFERENTIAL 6. Place the SST atop the drive pinion model, then set the gauge body atop the gauge block. 7. Place the feeler of the dial indicator so that it con- tacts where the side bearing is installed in the carri- er. Measure the lowest position on both the left and right sides, 8, Add the two (left and right) values obtained in step 7 and divide the total by 2 oro+e EEE 1 f Il ee ¥ 9. Ifnotwithin the specification, adjust the pinionheight by using a spacer chosen from the table shown, Mark [Thickness | Mark [| Thiekness oe | atte | | ian) [1 | gaizermy | | cossoriny | | corey | | ois oiemy | % | orssrny _| (oiesomy | 1 | arden) 2 | ian | | lst a | caren) | 4 | satan) Note ‘©The identification number is indicated on the outer side of the washer. Drive Pinion and Rear Bearing Assembly Note (Adjustment of drive pinion preload) 1. Install the spacer selected in the procecure above, with the beveled side facing the drive pition. 2. Press the spacer onto the drive pinion urtil the force required starts to increase sharply. 8. Press on the spacer and rear bearing by using the SSTs. SPAGER PEE '49 F401 SOTA Note © Perform the following procedure without the companion flange oil seal installed © The front bearing is pressed and installed by tightening the locknut 4, Apply a light coat of grease to the end face of the companion flange. 5. Install the drive pinion component in the differential carter, 6. Install a new collapsible spacer, the front bearing, new front spacer, companion flange, and washer. 7. Temporarily tighten the new companion flange nut. 8. Hold the companion flange by using the SST, then tighten the nut, Tightening torque 127 Nem { 13.0 kgf-m , 94.0 ftlbt} 9. Turn the companion flange several turns by hand to seat the bearings. 10. Measure the drive pinion preload. 03-14-9DIFFERENTIAL Washer Assembly Note (Adjustment of side gea ‘Adjust the backlash of the follows. 1. Set a dial gauge agai 2. Secure one of the sic 3, Move the pinion gear the end of i. asters ‘Standard backlash 00.1 mm{ 0—0.' 11, Adjust the preload by tightening the nut, then record the required tightening torque. Drive pinion preload 0.91.3 Nem { 9—14 kgt-cm , 7.9—12.1 intbt} Tightening torque 428284 N-m{ 13.0-29.0 kgf-m ,95—209 ft Ibt } 12. Ifthe specified preload is not obtained after tighten: ing the nut to the maximum torque, replace the col lapsible spacer with a new one. 18. Remove the nut, washer, and companion flange. Oil Seal Assembly Note 1. Apply differential ol to the lip of the new oil seal. 2. Install the oil seal by using the SST. Knock Pin Assembly N' © Install a new knock Locknut Assembly Note Stake the knock-pin 1. Using the SST, hold the companion flange and tight- to prevent it from cor ‘on the nut to the tightening torque recorded in “ad- justment of drive pinion preload’. - Ring Gear Assembly N 2. Verify thatthe drive pinion preloadiswithinthe spec- "1. Assemble the ring g ification. 2. Tighten the bolts in t Drive pinion preload 0.91.3 Nem { 914 kgf-om , 7.9—12.1 in-lbf} 03-14-10Tightening torque 6983 Nm { 7.08, ‘Side Bearing Assembly * Pressonthe correct sid ing side by using the ‘Adjusting Screw Assemt (Adjustment of drive pini 4. Install the differential 9g 2. Note the identification m, and install the adjustin. sides. 8. Instali the differential bea the identification marks. the one on the carrier. , Ad 4, Mark the ring gear at fo tervals. Mount a dial in- the feeler comes into ¢ Cone of the ring gear teDIFFERENTIAL (4) Ifitis not good, adjust the pinion height, and then (6) Heel and face contact agjust the backlash. Replace the spacer with a thicker one to bring the drive pinion inward. Go00 contact HEEL CONTACT FACE CONTACT (6) Toe and flank contact : Replace the spacer with a thinner one to move the drive pinion outward TOE CONTACT FLANK CONTACT é € AUTOMATIC FREEWHEEL UNIT DISASSEMBLY © Disassemble in the order indicated in the table, 03-14-12DIFFERENTIAL 7 [onvet box component 2 [wanna 2 [Hub soove 13” [Need bearing 3 [ip ia [oie i 15 | Ouput shat and gear sloove | |} Fe Treuater eI 17_| Automatic freewheel (AFW) switch races 18 | Sona coe | 42 |Sping and bal [-&-[Aajusimentshin C2 Rin 3 [Dust oa! 21 [ohangeres —————E 2 |Shition = LOSSSSERBNNG] 23 [Boot TT [Ot seal 2a [Oi seaDIFFERENTIAL Hub Disassembly Note Bearing Disassembly Note ‘¢ Remove the hub by using the SST. 1, Remove the dust seal and bearing by using the SST. erm 2, Remove the bearing by using a press. Ball Bearing Disassembly Note 1. Remove the ball bearing and the joint shaft by using J apress. uses Oil Seal Disassembly Note ‘* Remove the oil seal by using the SST. 2, Remove the ball bearing by using a press. 49 U027 004 \ wwe AUTOMATIC FREEWHEEL UNIT ASSEMBLY ‘* Assembly in the order indicated in the table. 03-14-14DIFFERENTIAL oo 23-26(23-27,17-18) | SELECTIVE Nm(igten mr) 1 | Ouipat shaft and gear sleeve 7 Bust sea 2 | Oilseal | of Assembly Note] [ASSSEBYNOS: 72_[Needie bearing 3 | Adusiment shim 15. [Gin | olassembynoe) | 5a | Contrbox + [aatbeaing 15 [Of sat |__| _v{Assembiy Nore] __ — - o[Assembly Nore] 3 [Retaining ring wt : _—- 6 [Bese 2 ASSSRBY NS +f Assembly Note 17_| Shit fork __ 7 |Join shat 5 [ohargo od ea me a 2 ASSSRBYNSD] ee aS 20_| Spring and ball | ssemby Net] 21_| Spring cap 10. [ip 22 [Automatic freewheel (AFW) Sutch23__[Actual 24 [Cont ll Seal Ass 1. Apply fro 2. Install the Adjustment i the ball & 2. Install the 3, Measure and the r Maximut 0.15 m 4.1 not as shims. U Availabl 015m mm oe4. If not as specified, adjust spacers. Use no more tha side. ‘valle shin theknoaa 0.1mm { 0.0059in}, ‘mm { 0.0 138 in}, 0. mm { 0.0197 in} Dust Seal Assembly Note ‘© Install a new dust seal by u| Oil Seal Assembly Note Install a new oil seal by us JOINT SHAFT INSPECTION 1, Measure the joint shaft run} Maximum runout 0.03 mm { 0.0012 in}DIFFERENTIAL SHIFT FORK INSPECTION 1. Measure the clearance between the gear sleeve _—_2. I not as specified , replace the gear sleeve or shift and shift fork. fork. Standard clearance |—0.4 mm { 0.0040—0.0157 in} Maximum clearance 0.5 mm { 0.0197 in} AUTOMATIC FREEWHEEL UNIT INSPECTION AFW Switch Inspection ‘One-way Check Valve Inspection 1, Disconnect the AFW switch connector and remove 1. Remove the one-way check valve. the switch. 2. Blow through A and verify that air flows from E. 3. Blow through B and verify that air does not flaw from A ONE-WAY CHECK VALVE ey 2. Check for continuity at the switch by using an ohm- anna meter 4. Ifnotas specified, replace the one-way check valve. ‘Switch Continuity eee = a ‘olenoid Valve Inspection Derreeet a 1. Disconnect the vacuum hoses and the connector Released No from each soleniod valve. FREE SOLENOID LOCK SOLENOID ore on! tenm{oare sea BmmtOS26} ey vino 2. Biow through each valve from port B. 3. Ifnot as specified , replace the AFW switch, 3. Ven that ar lows from the air fier. 03-14-184. Connect 1 valve 5. Blow thro 6. Verity that 7. lnotass Actuator Insy 1. Disconnet and varif Ki REAR DIFFE 1, Remove t 2. Verity tha hole, as s 3. Its low; Specifies ‘Type ‘Abov BLREAR ING REAR DIFFERE 1. Remove the 2. Drain the oll 3. Wipe the pi. 4. Install the dr Tightening 40—53 N- 5. Add the spe reaches the Specitied o' ‘Type ‘Above ~ Below- Capacity SLE 1 REAR DIFFERE 4. Jack up the 2. Drain the cif Rg 4. Before loost record the rc (within range lash), a! _ 5. Hold the cor VTDIFFERENTIAL 7. Remove the oil seal. 8. Apply lthium-based grease to a new oil seal ip and installit by using the SST. EEE Whe ms 10. tnstal ne propel sh Co 11. Add the specified oi! ——$—$— 9. Tighten a new locknut by using the SST to get the starting torque as stated in step 4. REAR DIFFERENTIAL REMOVAL / INSTALLATION Note ‘* When installing the differential, install it within 10 minutes after applying the S—=—_—=—_—_—_— at least 30 minutes after installation before filing the differential with the spe 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal indicated in the table. {Bs0-1.7 (4-120 4G, 25—10¢n wT) 2322 (23331729) 50-58 (50-60 Sra) 23-25(23-27,17-19) 50-55 50-05, 37—«3) 03-14-21UtRear Bearing Disass« © While supporting tl bearing by using th Knock Pin Disassem © Securethegearca x ¢ REAR DIFFERENTIA © Assemble in the oDIFFERENTIAL 5, Place the SST on the surface plate and set the dial indicator to "Zero”. oa 6. Place the SST atop the drive pinion model, then set the gauge body atop the gauge block 7. Place the feeler of the dial indicator so that it con- tacts where the side bearing is installed in the carti- ce. Measure the lowest position on both the left and, right sides, 8. Add the two (left and right) values obtained in step 7 and divide the total by 2. Spectication Bam On) a mE = H : CoE 9. Ifnotwithin the specification, adjust the pinion height, by using a spacer chosen from the table shown. Mark, Thickness ‘Mark | Thickness m | tea | | ates | teat | 9 | oitoriny P| arse) | | (ots oT | @iehy | 8 | corset 2 | aresom | | corsa | | caierty | | attctny | geen, | | oeen, Note ‘© The identification number is indicated on the outer side of the washer. Drive Pinion and Rear Bearing Assembly Note (Adjustment of drive pinion preload) 1. Install the spacer selected in the procedure above, with the beveled side facing the drive pinion. 2. Press the spacer onto the drive pinion until the ‘orce. required stars to increase sharply. 3. Press on the spacer and rear bearing by using the SSTs, SPACER \ 49 F401 331 EE Note '* Perform the following procedure without the companion flange cil seal installed. © The front bearing is pressed and installed by tightening the locknut. 4, Apply a light coat of grease to the end face of the companion flange. 5. Install the drive pinion component in the differential cartier. 6. Install a new collapsible spacer, the front bearing, new front spacer, companion flange, and wasrer. 7. Temporarily tighten the new companion flange nut. 03-14-268. Hold the od tighten the Tightening 27Nm 9. Turn the co: seat the be 10. Measure th 11, Adjust the the requir Drive pini 1347 Tightenin 12828 ftlbf) 12. ifthe speci ing the nut lapsible spy 13, Remove th] Oil Seal Asser 1. Apply differ 2. Install the ¢Knock Pin Assembly Note © Install a new knock-pin to secure the pin! Stake the knock-pin into position by usind to prevent it from coming out. Ring Gear Assembly Note 1. Apply approximately 0.04 em? { 0.04 ce (| } of thread-locking compound to each « threads A and points B. Apply thread-locking compound to bolt | and points B of the gear back face, 2. Install the ring gear onto the gear case. Tightening torque 6983 Nm { 7.08.0 kgf:m , 51—61 Side Bearing Assembly Note * Press onthe correct side bearing on the c ing side by using the SSTs. EEE Adjusting Screw Assembly Note (Adjustment of drive pinion and ring gear 1. Install the differential gear component inDIFFERENTIAL 8. Check the drive pinion and ring gear tooth contact. (1) Coat both surfaces of 6—8 teeth of the ring gear with a uniformly thin coat of red lead. (2) While moving the ring gear back and forth by hand, rotate the drive pinion several times and check the tooth contact, (3) Ifthe tooth contact is good, wipe off the red lead. (4) Ifitis not good, adjust the pinion height, andthen, adjust the backlash, 000 CONTACT (8) Toe and flank contact Replace the spacer with a thinner one to move the drive pinion outward. TOE CONTACT FLANK CONTACT (6) Heel and face contact Replace the spacer with a thicker one to bring the drive pinion inward. HEELCONTACT FACE CONTACT 03-14-2903-15 F REMOVAL | Ri Propeller $ ropeller PROPELLE! DISASSEMI Rear Prope Disasserr Flan Center Cor Dis Center Bee Disasser| Bearin Ri Front Dust Center Bee Flanc Rear Prope Assembh Front and" In FRONT PRO Nut Remov PROPELLEF| 1. Remove i 2. Install inPROPELLER SH/ Xv Z 6 Sevectve © 7 37 52( 3.754, 27-99 1 [Nut — 2 [Lock washer 7 [3 [Bot ff 4 [Bot ral 5 [Waste SC™~SCSY “6 Bushing 7 [Spacer Nut Removal Note 1. Mark the flanges for correct reassembly. 03-15-22. Remove t Propeller Sh 1. Pushara, peller she boot. a 2. When the sion hous extensior Propeller Sh 1, Push a damage Note © New ee 2. Align the1, Remove all mud, 2. Disassemble in th 8. Verity that all part 4, Assemble in the rl PROPELLER, or A = \1_ [Nat 2 [Lock washer Rear Propeller Shaft Disassembly Note 1. Push a rag into the double-offset joint damage to the boot. 2. Mark the center companion flange and proper reassembly, 8. Place the front propeller shaft in a vise a the front and rear shafts, 4. Alter removing the rear propeller shat yoke surface, then seal the vent hole wPROPELLER SHAFT CoE Center Bearing Support Component Disassembly Note ‘¢ Remove the center bearing support component by using the SSTs. - CoE ET Bearing Disassembly Note ‘* Press the bearing from the support component to- ward the rear side by using the SSTs. CoE '49 8025 001 Bearing Assembly Note ‘¢ Install the bearing into the bearing support compo- nent from the rear side by using the SSTs. 49 H025 001 Eo Rear Dust Seal Assembly Note ' 1. Before installing a new rear dust seal into the bear, ing support component, apply lithium-based greas: to the shaded area, (UTHIUM-BASED) 2. Install he rear dust seal into the support componen from the rear side by using the SSTs as shownin th: figure. GROOVE 8 Front Dust Seal Assembly Note 1. Before installing a new front dust seal into the bear- ing support component, apply lithium-based greasy tothe shaded area. —(UTHIUMBASED) 2. Install the front dust seal into the support componer fromthe front side by using the SSTs as shownin th, figure. 03-15-6PROPELLER SHAFT Center Bearing Support Component Assembly Note _Rear Propeller S "instal the Stee Coarng Soppetcomponentonto. tush’ rag tho tom popeler shat) us the 8ST Gamage oth : Coney 2. Apply lithium, Flange Nut Assembly Note install the O-¥ 1, Align the marks on the flange and shatt. 4 y mens 3, Place the fror 2. Install the lock washer and temporarily tighten the 4. Align the mart flange nut the yoke, and 3. Place the center companion flange in a vise. 4, Tighten the flange nut to the specified torque. Tightening t ‘50—58 N-n} Tightening torque 157—176 N-m { 16—18 kgf-m , 116—130 ftbf } PROPELLER SHAFT INSPECTION Front And Rear Propeller Shaft Inspection Replace the 1. Measure the front and rear propeller shaft runout by nent if runoul using a dial indicator. 03-15-7Maximum runout 0.4 mm{ 0.016 in} 2, Move the universal joint cheek for universal join It there is play, replace shaft component, FRONT PROPELLER SH: 1. Remove in the order ing] 2. Install in the reverse ore \~ —m N-®7 [Nat {Rema NE] 2 [Lock washer Nut Removal Note 1. Mark the flanges for correc 2. Remove the nuts. Front Propeller Shaft installs Align the marks and i shaft REAR PROPELLER SHAFT 1. Remove in the order indic 2. Install in the reverse order\L 4 \ Nat oF Look w Bolt Nut Lock ¥ Bolt Bolt Washe 1 Nut Removs 1. Mark the:2. Remove the nuts. Propeller Shaft Removal Note 1 Push araginto the double-ofise! peller shaft straight and to pre boot 2. Remove the rear propeller shi Propeller Shaft Installation Note| 1. Push a rag into the double-o! damage to the boot. Note o New propeller shafts a ee lator to prevent damage to] 2. Align the marks and install the Tightening torque ‘5058 N-m {5.06.0 kat.PROPELLER} Propeller Sha 1, Measure t (0 Replace tH 2. Disassem| 3. Verify that 4, Assemble3 [Flange 7 [rol 3 | Gena No.2 PropelFlan, 1hRear Dust Seal Assembly Note 1. Before installing a new rear dust seal into the bear- ing support component, apply lithium-based grease to the shaded area, (uriu-easen) 2. Install the rear dust seal into the support component from the rear side by using the SSTS as shown in the figure. Groove. 48° Front Dust Seal Assembly Note 1. Before installing a new front dust seal into the bear- ing support component, apply lthium-based grease to the shaded area, (UTHIUW-8Ase0) 2. Install the front dust seal into the support component from the front side by using the SSTS as shown in the figure. PROPELLER SHAFT Center Bearing Supp © Install the center | the front propeller Flange Nut Assemb| 4. Align the marks of 2. Install the lock wai nut. OTA 3, Place the center ¢ 4, Tighten the flange Tightening (1 160—170 N.m{ 03-15-15PROPEL 5. Apply lithium-based grease to a new O-ring. Instal the O-ring into the center companion flange. No.2 Propeller Shaft Component Assembly Note 1, Push a rag into the double-offset joint to preven damage to the boot. PROPELLER SHAFT INSPECTION No.1 Propeller Shaft, No.2 Propeller Shaft Comp¢ nent Inspection 1. Measure the propeller shaft runout by using a dial in dicator. Replace the propeller shaft component if runout i excessive. Maximum runout 0.4mm {0.016 n} 03PROPELLER SHAFT Puut Gauae 3. Measure the starting torque of the spider. wasn 4. Install different snap rings to adjust the starting Starting torque torque if necessary. 0.30.7 Nem{ 3-8 kgf-om , 3-6 in-bf} 03-15-1703-16 CHANGE MO- MOTOR INSI LIMIT SWIT a HAN “4WD RELAY (CHANGE M INSPECTION ferminal Va Continuit ‘4WD/2WD SF INSPECTION | “Terminal V Continuity CENTER DIF] INSPECTIOI seca WD CONTR] INSPECT Transfer C. [Transfer Ca ransmissi Installatio| [OIL SEAL (Fl ‘ON-VEHICL| REPLACEM| ER ¢ CTRANSFt /[eompanioy—— SY Disassem CHANGE MC. 4. Turn the ig 2. Using a w Ch eee mode shi I not as | sp [nat VoltaadLimit SS tor7.Turn nuity| show 3. Verify once CHANG! 4. Align 2H8. fnot aligned, tive voltage a: 4. Apply oil to th motor. q Tightening tc 1925 N-m| 4WD RELAY (CH Terminal Voltage 1. Turn the ignit 2. Using a voltm¢: atthe indicates the 4WD syste Itnot as speci speetion. ~Y SyTRANSFER 4WD Relay No.2 ‘Terminal voltage Mode shit elelalFls aw IGN Sawo Ree | By | OY | OV WD FREE TGN. | MOM. | MOM. “awn Be | Be | Be ‘aWD FREE Ten. [WOM [MOM oy | oy =awb Looked | Br | B+ | Br | 4WD LOCKED | IGN Mapeace ‘se’ | ov | ev | ov | ov | 2WD IGN. =awoocken | pe | °Y | 2V | ov | Ov Continuity 11. Remove the 4WD relay (change motor relay No.1, No.2). 4WD/2WD SHIFT SWITCH INSPECTION Terminal Voltage 1, Remove the column covers. 2. Turn the ignition switch to ON. 3. Measure the voltage between terminal C and a ground. “Terminal voltage ‘Switch Be Released ov | Aativated (Held to let) 4, If not correct, go to the next step. 2. Verify that there is continuity between terminals A and B, and C and F. 3. Connect battery voltage to terminals A and B as shown and verify that there is continuity between ter- rminals C and ECA 4. I not as specified, replace the 4WD reay (change motor relay No.1, No.2). Continuity ‘1. Disconnect the connector. 2, Check for continuity between terminals A and C Ey pa Continuity ‘Switch C yes |_Aatvated (Held toe) No. L Released 3. Ifnot as specified, replace the change knob compo- nent. 03-16-5CENTER DIFFERE Terminal Voltage 1. Disconnect the 2. Turn the ignition 3. Measure the v ground. Be ov 4. not correct, g 4WD CONTROL 1. Tum the ignit control modul Terminal voltag, 2. Ifnotas specif ponent(s), wirirTRANSFER Terminal —[Connectedto | Vote [Condition Sano OFF | ow ‘ticle in 4WD (Fee) mode Free sotnold Venn WD (Locke) med Salenoid: ON Beew SV |" Veritein2wOmode | Body ov = “AD relay (Chango moter vlay Noa): ON we Dung SD Fre) modo 02D mas Drsiny(Cranaemo-| © | _ baring WD Fe) ose SD (ache) mote st 7 WD relay (Change matory No): OFF _ Below 15V |" other than above conditions S| Sdenoid OFF ia Vahietn 2WwO mode - Lock slenid Baenoe on Below 15. | Nenicten aD (Free) mode | Vehicle in aWD (Locked) mode catey Tin seh ON OV [lgiionswich OFF WD relay (Change motor relay No ON |» During WO b AD free) mode eit Ore During 2W0 fo AWD (Locked) mode shit tor relay No.1) During 4WD (Locked) mode to 4WD (Free) mode shift a “AWD relay (Change motor relay No.1): OFF Ey (Other than above conditions Buzzer OFF Be L | Normal onstion | — Buzzer ON | sclow sy |, SWOWD shit svtc activated auton mode function { 7 Fail mode furcton (System fare) be [AWD nscator ont OFF * Vehicle in 2WD mode A a yey [AWD incor ight: ON Le Neti nether AWD mode a | CENTER DIFF. LOCK indicator light: OFF CENTER DIFF. LOOK Venice 24D or 41D (Poe) mode indator int indicator a goow rey | GENTER DIFF. LOCK inceator ight ON Vehicle in 4WD (Locked) mode 03-16-7TRANSFER ‘Terminal Connected to Voltage Postion s Bs Vehic Vehio Position switch A Position s (Inchange motor) Vehio ov Vehic Vehic mode | RFW wit, AW (Remote free- Vehic wheel) switch FEwewl Vehic Position s Vehic Be Vehia Position switch B Vehic (in change motor) |__ mode Postion s ov Vebic Venic Limit swt Norm Limit swt High mode ov High mode High WD Position « Vehic mode Position switch © eee (in change motor) Position « Vehic ou Vehic Vehic Limit switoh + (in change motor Be Limit swit Br Nore | it sit High Limit switch 2 (In change motor) nee ov High mode High wo | _4wo I AWORWO shit ewicn |——_©* | 072 VV Cf Conte iterential lock | Bot set) Center a ov TY) 03-16-8TRANSFER TRANSFER CASE OIL INSPECTION 1. Remove the level plug. 3. Install the plugs and new washers, 2. Verity that the oil is up to the brim of the level plug hole as shown. Tightening torque Ifitis low, adc the specified oil through the filler plug Filler plug: port 40—58 N-m { 4.0—6.0 kgfm , 2943 ft bf} fever ria! Level plug: 19-25 N-m{ 1.9-2.6 kgf-m, 14—18 fbf} FILLER, TRANSFER CASE OIL REPLACEMENT 1. Remove the filler and level plugs. . 2, Remove the drain plug, and drain the oil into a con- tainer. 8, Wipe all plugs clean. 4. Install the drain plug and a new washer. Tightening torque 40—58 N-m {4.06.0 kgf-m , 2243 ft1bf} 6. Install the filler and level plugs and new washers. Tightening torque Na ler plug: y 40—58 N-m { 4.0—6.0 kgf-m , 20—43 fbf} g Level plug: S, 9-25 Nim ( 1.92.6 kgtm , 1418 tibt) DRAIN snes 5. Add the specified oil through the filler plug port until the oil rises to the brim edge of the level plug hole. Specified oil Grade: API service GL-4 or GL-5 i ll-season SAE 75W-80 bove 10 °G { 50 °F} SAE 80W-90 1.5L (1.6 US qt, 1.3 Imp qt} ‘TRANSFER CASE REMOVAL / INSTALLATION INSTALLATION)Warning © Improperly jack that the jack is i 4, Remove in the order 5. Install in the reverse 6. Install the propeller ¢ 7- Install the exhaust sy 8. Fillthe transfer witht 9. Check for leakage of Transmission lowe jemoval Not Tstallation Transmission upp:TRANSFER n Lower Mount Removal Note 2. Suppor the transfer case on a transmission jack. 1. Support the transmission on a transmission jack. 3. Install the transfer case. 2, Remove the transmission lower mount. Tightening torque 387-82 Nim { 3.7—8.5 kgm , 2729 ftlbf} Transfer Case Removal Note 1. Support the transfer case on a transmission jack. Transmission Lower Mount Installation Note 1. Temporarily install washers and nuts A. 2. Tighten bolts B. Tightening torque 44-60 Nom { 4.46.2 kgfm , 32—44 fbf} 8. Tighten nuts A. Tightening torque oy 32-46 Nim { 32—4.7 kgfm,, 24-33 ftlbf} 2. Remove the transfer case by using a plastic ham- mer, Transfer Case Installation Note 1. Apply silicone sealant to the transfer case as shown, S 03-16-11OIL SEAL (1 1. Clean th steam cl 2, Drain th a [CASE 0} J 3, Removel [ fo 4, Remove] awe OIL SEAL ( steam cl a 3 4, Pusha propeller boot. 1. Clean | 5. Remove| 6. Hold the| move th9. Apply using1_[ Protector pate 2 | Change motor 3 [Oring 4 6 ‘Control cover Rear cover ‘ ir 8 | Adjustment shims) 9 | Speedometer drive 96 10 [Key 11 _| Rear chain cover | [Disassembly Ni justment shim(s) 18 [Qushoar 7 Ta [Necdlebearna 15 [Mamet : 16 |Rearcilpipe a7 [Oring 18_| Thrust washer 19_| Change drum 20_| Thrust washer 21 [24 shift rod 22 [2-4 shift fork 23. | Drive gear and chain 24_| Thrust washer ‘Companion Flange Disa 1. Hold the companion flan move the companion fa3. Clean the splines of th put shat Rear Cover Disassembli 1. Remove the rear cove plastic hammer. 2. Remove the sealant ir case surfaces. Rear Chain Cover Disas 1. Separate the chain Co, a plastic hammer.TRANSFER Drive Gear And Chain Component Disassembly Note ‘* Remove the drive gear and chain component by lightly tapping the front drive sprocket. Outer Pump Rotor And Inner Pump Rotor Disassem- bly Note 1. Mark the inner and outer rotor positions without soratching or denting the rotors. 2, Remove the rotors from the housing. Pump Housing Disassembly Note 4. Pry off he pump housing while the ol pipes are con- nected 2, Separate the oil pipes from the pump housing, Input Gear Disassembly Note Press out the input gear. Bearing (input shaft) Disassembly Note Note ‘¢ The bearing does not need to be removed un- less itis being replaced, © Press out the bearing by using the SST. Bearing (output shaft) Disassembly Note Note © The bearing does not need to be removed un- less its being replaced. ‘* Press out the bearing by using the SST Assembly Procedure 1. Measure the thickness of the thrust washer all around its edge. 03-16-17Thickness Standard: 1.950—2. Minimum: N= 2.1 not within | washer. 3. Assemble the measure the| ‘clearance thr] (4) Tooth cle Clearance (2) If not wit pump. (3) Side cle Clearance ‘Standard: Maximum; (4) If not wi pump. (8) Body cleJ 7. If the bearing was removed, install a new bee into the transfer case housing by using the SS} ‘aS - eo see ives teevec Serif i re new oil seal and install itinto the transfer case h ing by using the SST. '49:U027 003 9. Apply oil to a new O-ring and install it onto the ail pipe 10. Install the rear oil pipe component to the tray ‘case housing. 41, Install the baffle plate. Tightening torque 7910.7 Nim { 80-110 kgf-cm , 70-95Adjustment shin 05 {0.020} 0.8 (0.031) 15. Apply oil to ne and rear oil pi 16. Installthe fron & 17. Install the adj Align the oil pi and install the Tightening tc 19-25 Nar 18. Fit the key to ORO 19. Installthe inne inner and out marks facing 1 20. Install the pun82. Align the change drum groove any 2-4 shift fork, then install the cha 34. Adjust the front drive sprocket enc suring A and B, measure 6 times | term and average the results. (1) Measure depth A of the bearit chain cover. (2) Install the front sprocket into tt lightiy tapping on itwith a plaaa | 87. Set the m: 38. Apply seal shown. AX 99, Set the agju the rear cha] 40. Install the re. Tightening 32—46 N. av 41. Verity that t reinstall the46, Install the rear cover. Tightening torque 37-83 Nim ( 3.75.5 kgm , 2739 47. Install the speedometer driven gear. Tightening torque 7.9—10.7 Nim { 80—110 kgf-cm , 70—€ 48. Apply sealant to the output shaft splines a 49. Install the companion flange by using the Tightening torque 428176 Nam { 13-18 kgm , 9413,TRANSFER 54. If not aligned, tur the shaft by applying 12 V as shown, 66. Install the protector plate. Tightening torque 44-54 Nim ( 4.45.6 kgf , 32—4 ey, 55. Apply oll fo a new O-ring and install the change mo- tor. Tightening torque 1925 Nim (1.92.6 kgtim, 1418 ftlbf} ‘SPEEDOMETER DRIVEN GEAR DISASSEMBLY / ASSEMBLY 1. Disassemble in the order indicated in the table, [one 2. Assemble in the reverse order of disassembly ind |} =Pd__ cated in the table. | Rot pin {RSSEREY NOT] 3_| Speedometer driven gaar 4_[ Speedometer gear se “Firrey sPecirie0 1 To mDMDUAL = loi seal ae TeaSSOMbY NOTE Oil Seal Disassembly Note © Remove the oil seal. 03-16-25SS a ;Locknut Disassembl] © Remove the lock} Planetary Carrier Co ‘© Measure the clear and the planetary 1 Clearance Ring Gear Assembly © Measure the inner three times and a Inner diameter Standard: 54.021—54.0TP aL DRIVE GEAR AND CHAIN COMPONENT DISASSI 1. Disassemble in the order indicated in the table. OS Ose 7] Cam roller {| 2 [24 shift fork Assembly Nate] — a 3__|Ghain |-4 |2-4 hub sleeve - cI “S_| Synchronizer _ _ —— 6_| Retaining ring 7 |2-4 clutch hubTRANSFER Drive sprocket of Asser NOTE] 7B Bearing ror Bierman SLE RE] 79 [Bearing ear Beery 20 [Font dive sprocket Bearing (front) Disassembly Note Note The bearing does not need to be removed un- less its being replaced. ‘* Remove the bearing by using the SST. 2. Meas| three Inner] 3. If not Bearing (rear) Disassembly Note fork, Note 2-4 Shit! ‘© The bearing does not need to be removed un- Meas! less itis being replaced. and h and e| ‘¢ Remove the bearing by using the SST. 7 Cleat si Mal 2-4 Shift Fork Assembly Note 1. Assemble the 2-4 shift fork and rod. Verify that the shift fork moves smoothly on the rod. Outer ci bly Note} 1. Set squah 03-16-29Clearance ‘Standard: 0.72—1.59 mm { 0.02 Minimum: 0.70 mm { 0.028 2, Measure the clearance between the the drive sprocket. Measure the ‘around the edge. Clearance Standard: 0.72—1.39 mm { 0.02 Minimum: 0.70 mm { 0.028 in } Spacer Assembly Note ‘Measure the outer diameter of the 5 three times and average the results Outer diameter ‘Standard: 69.971—69.990 mm { 2.7548 Minimum:TRANSFER 2. Align the outer cone grooves with the key grooves of 2. Tighten the locknut. the 2-4 clutch hub before assembly Tightening torque 79—M1.7 Nam { 80—120 kgfom , 70—104 intbt} Cam Roller Assembly Note ae 1. Mount the cam roller onto the 2-4 shift fork. PUMP HOUSING DISASSEMBLY / ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly indicated in the table. 03-16-311 [Spring cap 2 | Gasket 3_| Pressure spring Pressure Spring Assembly Note 1. Measure the spring dimensions. Specifications Outer dia._| Free ength mm {in} mm in} | NO: of colts 6.1 {0.240} [zo0{ore7y| Wv.0 Lo. Choe enced |.TECHNICAL DATA 03-50 TECHNICAL DATA (OS DRIVELINE AXLE nn 03-50-1] (03 DRIVELINE / AXLE Type CJ ao | aw FRONT AXLE [Tipe Strut mounting [Bearing - 7 ‘Rngular ball bering Maximum wheel bearing play (om in) 0:08 (0.002) REAR AXLE _ _ Type _ _ Suink mounting | Supper pe Semiffoating ate shatt [Boating I Ball bearing | Casing Banjo ype housing | Maximum wheel bearing play (amin (057 {00224} FRONT DIFFERENTIAL ~ Type - [Standard | Reduction gear Hypod gear [iterenta gear — _ _ [Sais bevel gear ing gearsizo Temtinyi| 181.6(7.15} | Reduction ratio : | $100 Number of [Ring gear _ a a teeth [Drvepiniongear oo | [eae SSS ~ ~ API Serice GL. Gh Viscosty [ABE=18'C(OFY ‘SAE 90 Below -18°C {0°F } SAE 80W ____ [Capacity CUSahimaty| 18 18 REAR DIFFERENTIAL Type Standard Reavation gear Hypo gear Ditlerenial oar Straight-bevel gear Fing gear size _— (omtiny "208.2 {8.00} edvtion ratio [808 4300 Number of [Ring gear _ - 3 a teeth Drive pinion gear "1 10 [Grade APL sonics GLE ot —____| ___ Sie [sa cow ~ (C{US at imp at) 15{1.6.13) 03-50-1