34263197-Mazda-121-2-2

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Mazda
121

CONTENTS Tifle General lnlomatlon

Workshop Manual
Volume2 of 2
FOREWORD for manuaiis intended use Thisworkshop Mazda ot technicians Authorized bv service Mazda vehicles to D'ealers helpthemservice to and operators It canatsobe useful owners vehicles in diagnosing some of Mazda limitedrepairand problems and performing on maintenance Mazdavehicles. a For proper repair and maintenance, is with familiarization thismanual am' thorouqh portant: it should be always keptin a hanand dv placefor quickand easyreference. 'All ol the contents this manual,including avail' are and drawings specifications, the latest As the timeof printing. modifications ableat occur,relevant repairor maintenance affecting will to supplementary thisvolume information be made availableat AuthorizedMazda This manual should be kept uP Dealers. to-date. the reserves right l\razdaMotorCorporation and contentsof this to alterthe specifications notice or obligation advance without manual No All rightsreserved. partof this bookmay or be reproduced usedin anyformor by any or means,electronic mechanical-including photocopying recording and the use of and any kind of inlormationstorageand retrieval permission writing. in sysiem-without Mazda Motor Corporatlon HIROSHI A. JAPAN
APPLICATIONi

Inspecilon and Pre-Dellvery scrvice llalnlenance Scheduled
LubrlcationSystem Coollng System ContolSystrem FuelandEnission EnglneEleclrlcal System

itanual T(ansaxle Automatlc Tranaaxle

Frontand RearAxles
Steedng Syatem Braking System Wheelsand Tires

Suspension
Body Body ElectrlcalSystem Healerand Air ConditionerSystems TechnicalData SpecialTools

"Diasram 3$i:5;X3 "'*'' wirins
The s€cilon 2 is publkhed sePaEte lrom thi3 menual.

o l99O MazdaMotor Corporation '90

ocT.

1249 r0.90J

@

to manual apdicable vehicles is This @inning (VlN) Numbers ldentification withthe Vehicle page. shownon the following

(VlN) NUMBERS vEHtcLE IDENTIFICATION
Jttl0DBlosl 00 100001-

FRONT AND REARAXLES
I N D E X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . .M.- . 2. . . . . . , . . . . O U T L I N.E. . . . . . . . . . . . . . . . . . . . , , . . . . . . . . . . . . . .M.- .3. . . . . . . . . . SPECIF|CAT|ONS.................................... M_ 3 TROUBLESHOOTTNG GUtDE...................... 3 MFRONT AX1E............................,............ M_ 3 REAR AX1E..............................,............ M- 3 FRONT AXLE........................................... M_ 4 PREPAFATION....................................... M_ 4 H U B8 O 1 T . . . . . , . . . . . . . . . . . . , . . . . . . . . . . . . . .M.-. .5. . . . . . . . WHEEL HUB,STEERING KNUCKLE.......... 6 MREAR AXLE...............................,............. M_l3 PREPARAT|ON..................................,.... M_i3 DRUMBRAKE TypE.............................., M-l3 DRTVE SHAFT.....,............................,....,.. M-l7 PREPARAI|oN.........-............................. M-i7 DRTVE SHAFT JOTNT)................. M-l7 ORtpOD

INDEX

INDEX

J, SEFIVICE, SECTION, K

1- Frontaxle pageM- 5 Replacement.............................. pageM- 6 Preinspection............................. page ................. M- 6 Installation Removal/ page / Inspection........... M- 8 Disassembly pageM-10 Assemb1y...................................

2. Rearaxle ... page Preinspection.......................M-13 / Inspection Removal/ . ................. .... page[r-l4 Instal|ation page / Assembly............ M-16 Disassembly 3. Driveshaft pageM-17 Preinspection............................. pageM-l Installation................. 7 Removal / pagelvl-20 ... .. .... . " " overhaul

M-2

OUTLINE. TROUBLESHOOTING GUIDE

OUTLINE
SPECIFICATIONS
llem Faontaxle
Beaangplay. ax,aldtreclol Bearingplay, axlaldireclion Drlve 3hatt Lengthof jolnl (between cenle's of joinis) Shatldiameter

TEnsaxle
mm (r) mm (in)

lilTX

ATX 0 (0) o.o5(0.002)

Rightsde
mm (n) L€tt side mm (in)

659.7(25.97) 3857 05.1s) 20.0(0.79)

6580 (259r) (1s 386.0 20) 21.0(0.83)

TROUBLESHOOTING GUIDE
FBONTAXLE
Problem Steerlng wheel vlblallon Sleerlngwhe€l pulla or on6€lded braklng Exc$slvo steedng whe€l play Posslble Caus€ Worn damaged or wheel bearng Excessive wheelbeaing play wheel Wornor damaged bearlng Excessive whe€lbearingplay Excessiv€ wh€€lb€arng play Bentor worn drive shalt Worn damaged or wheel bearing grcasen joinlor on spllnes driveshalt Insutficient ot Worn driveshafi lripodjoint Greas€ leakage trom boot Damaged brokenboot or Page t\,{- 6 l\4- 6
l\,1- 6 M-6

M-6 M17 M-6 M20 M-22 M-20 M-20 M-20

REARAXLE
Problem St6€rlng whe€l vlbration Sl€erlng urheel pulls or one.sided braking Excesslvesleering wheel play Abnomal noi3e Po3albleCau3e
Wom or damagedwheel bearing Excessive wheel bearins play Worn or damagedwheel beaing Excessive wheel trearlng play

action

Pag6 I\,{-14 l\,1 14

Tighten €place or

[4 14

Ercessive sheel bearingplay
Wom of damagedwheel bearng M-14

M-3

AXLE FRONT FRONTAXLE
PREPARATION

49 0727 575

850C 49 0118

49 FO26 143 Putier,wheelhub F --_{ l]l

49 8026140

49 G030727

49 G033102

49 8026 1A0)

49 8026 rAO)

2AO 49 DO17
bearng

49 F40t 3664
bearlng

beanng

49 D0172A0)

372 49 BA92 F Attachmenr (Parr of 49 Dor 2AO) 7 ,6 \V
beaang

49 F 01 361

Remove, bea,ins

#
lll]l

49 0t 80 321A

49 G025001

49 G030 797

;:::::j::" \@
49 FO27041

Handle {Pari or 49 G030 795)

49 F027005

49 F027 0A1)

M-4

5) er as shown in the fioure. and 3. Pullin the newhub boltwitha nut(L4 2x1. to hub 4. Cutaway hole thedust the of cover removethe bolt. Usethe SST to remove hub bolt. M-5 . Bemove brakecaliper the assembly discplate. .FRONTAXLE 49 BOO1727 49 0180 5108 49 8001 795 49 8001796 inslallation oil ot Body iParl ol 49 8001795) @ HUBBOLT Replacement '1 Remove wheeland tire. the 1 anda flatwash5. the 2.

.. . . -.. . .. ./ it and 1-Jackup the frontof the vehicle support withsaletystandsRemove wheelandtire. . to in 3.. .3.. . . g. .... . . .Remove wheeland tire.. 4. . .. . M. . . Lowerarm 3...Pushand a 3.. ... .. Remove brakecaliper the against wheelhub. 116-1?3) 4. Discplate knucle 7. Locknut pageMnote. the 2.. ..i. c.... ... . STEERING Pr€inspection Wheel bearlngplay '1.. . . .. . . Wheelhub. . Installalion Removal... . 31--{2) REPLACE 157-235 (1C-2/r. . .reterring RemovalNote referring InstallationNole to orderol removal. ltthe bearing exceeds the wheel bealing if the locknuttoroue. .. ..5. ..n S e r v i c e ...e . . . ... Brakecaliperassembly Se . .... Installation pageMnote... .. . check adjusi and play specification.0 . . Remove the ordershownin thetigure. . .... 7 Installation 2.. . Position dialindicator and pullthewheel byhandintheaxialditection meashub ure the wheelbearing Play... . lnstall the reverse .. . .oP.. Nut. ..2-57 (4... 1. .. . . ..FRONTAXLE KNUCKLE WHEELHUB. 7 page Removal -.. ..steering S e r v i c e . the 2....8 / lnspection Disassembly A s s e m b 1 y ..... .... . 6. . the and assembly disc plate. . ..Section page . or replace necessary. . a . . .. . ..t. Tle rod end 1.. .-. . .. . bolt .e-5..p .. . M-6 . . .M . l\r.. .. Wheel bearingPlaY:omm (0 in) max.. . ..... . .. . in 4.7 note. .... . .

as shown. Measure wheelbearing the axialplay. Install nutand secure withthe newcotterpin. Do not damageihe dust boot. it the Tighleningiorque: 42-57 N. Tightenlngtorque: ls7-235 N|n (16-24 m-kg.8 m-kg.FRONTAXLE Removalnote Tie rod end Caution . oll''--'--'- // lnstallatlonnote Tie rod end Caution .Install newlocknut a and stakeit.3-5.) to lr" - I M-7 . Do not damagethe dust boot. /' . the Loosen nutandusethe the SSTtodisconnect tierodend. 116-173 ft-lb) 2.m(4. (Refer pageM-5. 3l-42 ft-lb) Locknut 1.

Bearing note Disassembly PageL4.. .. .Steering (inner) (outeo 6. .9 .a .e . Spacer knuckle 10.p . 4.. .. Wheelbearing for Inspect wearand note Disassembly note Disass€mbly operation M PageM. g.v l .9 .. . . .I Disassembly note Wheel hub assembly the tjse the SST to remove wheelhub assembly M-8 . . .9 .I a. .. . Page H (inne0 1 1 .. .FRONTAXLE / olaagsemblv Inspection Note to t. .. ... . Wheel for Inspect wearand note Disassembly for Inspect wearand operation M. . Disa""".6t" in the ordershownin the figure relerring Disassembly as all 2.. .el. Wheelbearing for Inspect wearand note Disassembly note Disassembly damage M. Dustcover race(outer) 5. . .I M. . Bearing hub assembly 1... . . Disassembly page lvl. . . ..g. . u bb o l t 7.I p .. Inspect partsand repairor replace necessary 9. . Wheel note Disassembly note Disassembly below note.. Oil seal(oute4 hub 12. .. . .P a g e 2.. .. Oil seal 3..I Page damage (inne0 race 8. . .

oll seal (outer) Caulion . Remove oil sealfinner) the witha screwdriver.Remove wheelbearing (outer) theSlsTanda press. bearing raco (inner) 1. the wih 2. the Hub bolt Cautlon . Hold ihe wheel hub to prevent lt lrom lalling. for 2. Duat @ve. Remove the bearingrace (inner) with the SST and a hammer. . 2. Remove hub boltswith a oress.FBONTAXLE Wheel bearlng (outer). Caution . (nner). 1. '1. the with Caution . Remove wheelbearing the 3. Do not reuae lhe hub bolts It removed. Tap on the bea ng race 0nner) only. the M-9 . Do not damagethe wheel hub when removingthe oil seal. Remove dustcoverwitha chisel. Marklhe dustcoverand knuckle properreassembly. Do not reuae the duat covel lf removsd. Do not remove the duat cover it not ngceasary. Remove oil seal(outer) a screwdriver. Beadng race (outer) Remove bearing with the race(outer) the SSTand a press. Do not remove the hub bolts if not necessary. wheel bearing (lnner). Oil seal (inner). Cautlon . .

Wheelbearing 6..... .......... . | \ @ E o/\ \Y'6"'l \YIY6 | (b *REPLAoE 6)E l@E (innet (oute4 9.... .... .. Duatcover as 1. ...... M . race(inner) 5...........pageM ...... pageM-12 '''''''''''''''''''''' 4.1 2 2. ............... ...... .1 2 M ..... M-11 Assembly note Hub bolt in Press the newhubbolts........ .. ....... Wheel bearing 1.. Oil seal (outer) note.. Dustcover hub 10.. .. .pageM p a..t .. the M-l0 ... a . Spacer note Assembly Assemblynote Assembly note . . Steering pageM-13 .g. Hubbott note Assembly note below Assembly note. REPIACE E ...... Bearingrace (outer) 11.... . .Oilseal0nneq 8............ Assembly note Assembly Assemblynote knuckle 3.... .. .FRONTAXLE Assembly to referring AssemblyNoie in Assemble the ordershownin the figure... . ....e ..Wheel below 7...p . g...eM . ... Bearing Assemblynote page .......l 1 . ....Mark newdustcover theonersmoved.. Assembly page .....

Securethe bottomol the SST. M-l I . withtheSST anda hammer. and the 2. Taoon the newdustcover Bearlngrace(outer) lnstallthe with bearing (outer) theSSTanda hammer race until contacts steerina it the knuckle. Note .torque in sleps ot 49 Nm (5 mk9. 3. adiust the wheel bearlngpreload. Bearing race (inner) Pressin the bearing with race(inner) the SST.FRONTAXLE 2. After replacing a beadng racs. Urhentlghtening. torque. Insert two wheel the bearings removed and spacerintothe steering knuckle attach SST. 36 ft-lb) to preve applylng excessive preload. 3. Alignthe marks the newdustcoverand the steering of knuckle. Tighten nutof the SSTto the specified the Tlghtening torquer ls7-23s Nm (16-24 m-kg. olEo|MX{122 Adluatment of whsel beadng preload 1. l 16-174 ftlb) Caulion .

965 (0.2585) 6. 1.25-1.2711) 6-885 6-925(0.64 lb) (pull scale re€ding) the select proper specilication' is 6.25-1.U5 \O.725lO.765(0. wheel bearlngpreload: 0.€05(0.5 inlb) .845 (O2695) (0.2474) 6. The ranli marklng is stamPedon the ouisr periphery ol the apacer. lt the preload notwithin to adjus{it. 2.2538) 6. lhe preload changesir.2n4l 7.2490) 6.405 (02522) 6 445 (0.m(2.6e5 12 14 15 17 l8 19 21 6. lncrsaselhe spac€rthicknessto reducethe plsload and dscGase it to increase the prgload.2 to 0. 7.325(0.64s(0. Measure wheel sca|e.2570) 6-s65 (0.27ep) m Note . Remove SST.1? N. 0.2742) 7 oo5 (0.2506) 6. spacerlrom the table 1 2 3 5 6 7 I 9 10 6.245Q.Install wheelbearing the to 2.2663) 6.2616) (0. completelytlll the ahaded areashovtnin the llgure with llthium glease.0 to 4.lnstallthe newoil seal(ouler) a hammer a plale knuckle it is flushwiththe steering so that at that 4. 1.272q 6.4A) 6. Whena spacerla changedby I rank. .2679) 6.2754) 7. lnstall spacer wasselected the preload". the 5. Install wheelbearing ''Adjuslment wheel of M-12 .55-2. Nv 01E0MX{23 (oute4.5-1 r.2554) 6.41 ln'lb) 2. oll s€al (outer) and spacer Note .OA5 @.17-10.2600) 6.5-12 cm-kg.605 (0.2 kg. Rotatethe steeringknuckleto seatthe whoel bearings.FRONTAXLE 4.0 cm-kg.525 (0.7 to 3.4 lsm (2. Applygfease the hpof the newoil seal(outer) and with 3.7 N (0.445 (0.2631) 6. the Wh€cl beadng(outer & inn€r). bearing (inner). preload theSSTanda pull with bearing the 5.365 (0.

to 2.05mm(0. 5. REARAXLE oIEOMX-O3I ssT PREPARATION 49 0259 77OB Wench. Installthe oilseal(inner) the SSTanda hammer new with so thaiit is flushwiththe steering knuckle. Whe€lbearingplay: 0.FBONTAXLE.500kg. hubintothesteering with Plessure:24. and measure wheelbearing the 3.Push and pulltherearbrake assembly handin theaxialdirection by play. or replacethe wh€el bearingif necessary. llare nLl 9r-€--€ I For oj I insiailalion I oraxeprpe 01E0MX-O53 DRUMBRAKETYPE Prslmpscilon Whod beadngplay 1. 2. Remove wheel the and iire.002in) mar.500 lb) max. Applygrease the lip of the new oil seal(inner). Oll seal (inner) 1. Position dialindicator a againstthe brake drum. M-l3 . REARAXLE Wheelhub Press wheel the knuckle theSST. checkand adjust the locknuttorque.500N (2. lf the bearingplayexceeds specification.

.-.... tck uo theiear of the vehicle the 2.. Locknut Installation note pipe 7. Afterinstalling.Backing service.... ... ro-iq Elfl e.. 13-22f3-2..5*"[g FEPLACE hub assembly 5.. to in 3. Parking 4. Note.. P Seclion u-14 ..Hubcap 2...... ..... I ... P 1. ... Nut L Spindle lor lnspect wearand damage plate 10.t!...:move wheeland tire..a-1al Nf 000-150 d... pagel\r-15 8.2.. Brake drum Section SeMce..REARAXLE Removal/ Inspection / lnatallation stands..pageM-15 Removal note lnstallation ... 5. Wheel Disassembly / page Assembly.. ...... Screw brakecable 6. P Section Servic€..reterring Removal partsand repairor replace necessary as all 4. 8t-r30 |Flb) . it and support withsafety 1....... Remove the ordershownin the figure. Brake note.. ... M-16 page M-l5 Inspect wearand tor operation 3... Insiall the reverse P to fromthe brakesystem(Refer Section ) bleedair 6..... Insoect reterring InstallationNote to in orderof removal.

) M-l5 .2 m-kg. Measure wheelbearingaxialplay. as snown. the lnstallation note Brake plpe Tighten brakepipewiththe SST. the (Referto page l\. a and Tightenlng torque: 167-215 N{n (17-22 m-kg. 123-159 ft-lb) 2.REARAXLE Femoval note Brake plpe Cautlon . 10-16 ftlb) Locknul 1. lnstall newlocknut stakeit. plug lt to avoid lluid leakage..|-13.3-2. the Tigl enlng torque: 13-22 N{n 11. Atter dlsconnecthg the b6ke plp€. Disconnect brakeDipewith the SST.

Do not r€use the hub bolts lf removsd' Remove hub boltwitha Press the 0lEoMx4a2 Assemblynote Hubbolt Press thenewhubbolt........ in 063 01EoMX M-l6 ....... ..... Assembly hub 2 Wheel as replace assembly) (Notrepairable' Dlsassembly nole Hub bolt Caulion ... z.. . Disassembly . b-e-"........REARAXLE Dlsassembly/ Ass€mbly Note' to i. rn the ord.. be|ow note. Do nol remove the hub bolG ll not n€cessary..q$"rOfl in ttt" reverse REPLACE 'L Hub bolt .referring Dlsassembly to reterring A$embly Note' orderof disassehbly....r shownin the figure............. ...-. ...... below note.""rrjt...

M lnstaliation note page 2.. Checkthedriveshaft bending. .pageM-18 note. Drive shaft Installation note Removal Removal note.) 5..a g e .. to R. to (Refe. grease leakage.Jackup the rearol the vehicle it and support withsafety stands. 116-tta) FEPLACE 1. Repair replace driveshaftif necessary....3. lV-18 page Overhaul.... balliont DRTVE SHAFTORTPOD JOTNT) Prelnapectlon Drive shaft 1.. Checkthe trontwheel alignment.....pageM-18 . ... . Tie rod end 5..referring RemovalNote.damage. l/'l-20 tt-17 . . .) /B-t2 (a.. 2. the oil to J. in 3.pageM-18 . or the Removal/ lnstallalion 1. Locknut 3. a loosebootband. reterring InstallatlonNote. (Refer Section 6. and 2.. Checklhe dustbooton thedriveshaftfor cracks.. for cracks..Instiall the reverse in ord€rol removal. Lowerarm ... 3... Sections K. l2l4 1t-2?5 (13-24. Remove the ordershownin the figure. Nut Removal note..p. Remove wheel the and tire...1 9 4.a-5. to 4... wearol joints and or spltnes. Check transaxle amount.DRIVESHAFT DRIVESHAFT ssT PREPARATION 49 0118 850C Puller... .. .

Note .DRIVESHAFT Removal note Tie rod end Cautlon . Pushthe driveshattintothetransaxle Caution . the 2. lhe with Prylhe driveshaftkom thetransaxle a screwdriver.pull the tront hub outwardto verily that the drive shaft ls held. Prydownon the lowerarmto disconnect ballioint. Do not damagethe oll seal. 2.Inslallthe driveshaftwiththe gapof clip facingupward. '1. Drlve shaft Cautlon . Be caretul not to damagelhe ball ioint dust boot. Aftel instaltalion. Cauilon . Do nol damage the dust covet or oll seal. lnstallationnote Drlve shatt Caution . Remove clinchboltand nut. Do not damaqEthe dust boot. the Loosen nutandusetheSSTto disconnect tie rodend the Lower arm the 1. Do not damage dustcoveror oil seal. M-l8 .

Tlghi€nlng torque: 157-235 N. as shown.m(16-24 m.DRIVE SHAFT Locknut lnslalla new locknutand slakeit. l16-173 tt-lb) lt-l9 .kg.

.... .... Retaining 5...... ........ to orderot disassembiy... Outerring note Disassembly .corroslon.. Snapring 'l1.... .........eM ..g. Secure tlre iolnt in a vise wlth plotectivs material (such as copper plales) on the vise Jaws' . ..... . Do not dlaassemble wheel slde ball iolnt......Clip 2. ...eM ..eign malerlaldoes not enler lhe ioint whlle lhe work is b€lng p€rlormed... 'dtrl 1. M-22 M-20 .... PlaY rotataon damper 10. 12. Tripodjoint Assemblynote note Disassembly page .."*".P a g e ... ... M-22 ring 4.... . Disassemble the ordershown the figure.. ... ........... . ..........2 3 3.... ..2 1 . page ... in 3. M-23 .2 2 13. .Shatt tor Inspect wearancl for Inspect splines damage damage and wear 9... ...... ..... Boot(transaxle and balljointassembly 14. Bootband damage Assembly note note page Assembly .DRIVESHAFT Overhaul Caution ...Dynamic Assemblynote page ... . the . . . Bootband note Assembly M .". .... .. Bootband wheel sidejointfor lnspect note Assembly and rough pageM-23 excessive ....g. for Inspect wearand 7... lnsoect referring AssemblyNote.. Nole........ Be carefultfi6t dust or other fo.... ..p a.. Do not wash the ioint unless it is being disaaaembled..... to in in 1... . . .Bootband for Inspect wearand Assemblynote damage .... . scoring note Assembly page ........ M-21 Page lnspect insideborefor and wear. ... .relerring Disassembly as all oansand repairor replace necessary' 2... ....Boot(wheel .Bootband 6. Nr-23 Assemblynote side) p a... . . Asaemble the reverse DO NOT DISASSEMBLE (ONLYRIGHTDRIVESHAFD FEPIACE FEPTACE FEPLACE BEPLACE frl'.... ... M-23 pageM-21 side) 8. .

Fillthe boot(wheel side) withthe speaified Greaae amount MTX:60 + l0g (2. 1. Remove uipodjointtromthe shafl.3(3.DRIVESHAFT Dlaasaemblynote Outer rlng 1. 2.82 + 0.23) 85. Markthe outerringandthe shaftfor properreassembly. the Trlpod lolnt 1. the Caution .35 oz) ATx: 80 + l0g (2. 2.2(3. Markthe shaft andtripodlointfor properreassembly. ATX 82. 3. M-21 .0(3.12 + 0.35 oz) and the side 2. Uselhe specifiedgreasethat lt is suppliedin the boot klt and ioit kit. Flemove oulerrino. The whegl side and transaxle side boots are dlllerent. the Asaemblynole Boot (wheel slde) Caution . Wraothesplines thetransaxle shaft. install ol wheelsideboot.36) 80.16) MTX ]BAN$O(E SIDE WHEELSIOE @ caution 0rEoMx{45 . Do nol damage lhe bearing. grease. Remove snapringwithsnatrringpliers.

lde + 5 (35.-lnslall dvhamic the damper. length.20) 63r.DRIVE SHAFT Dynamlcdamper as damper shownin the figure. 2. M-22 . Setthe driveshaftto the standard Standard length Tr.06 + 0. covered a screwdriver the 5. Do nol damagethe bearlng.20) 906. Fillthe outerringandboot(transaxle withthe specifiedgrease. side) 1. Release with a rag. 1.20) 908. Verily driveshaftlength.Alignthe marks a hammer. Uae the specified grsase that it ls supplled ln the boot kit and lolnt klt.98 + 0. Install newsnapringwithsnaPringpliers.4 * 5 (24. Greaseamount:115 + 109 (4.4 634. 3. the and install tripodjointwitha bar and 1. Install newouterring.13 0.96+ 0.nsaxle M]'X AfX Lelt 3lde mm(n) Rlgm .12In) Tdpod iolnt Cautlon . lnstall nirwbootbandontothe dynamic NEW BOOTBANO 4 {19.0+ s (35.67+ 0.35 oz) the 2.0+ 5 (24. the 2.76+ 0.20) using boot air traoped frominsidethe (wheelside) 4. a Ouler ring Cauilon .

M-23 . .DRIVESHAFT Boot band Caulion . Foldthe band backby pulling end of jt withpliers. Lockthe end of the bandby bending locking lhe clips. '|. the 2. Always use ngn. band€. The bandaahouldbe mountedIn the direclionoF posite lhe forward aevolvingdireclion of thg drive shatt.

............ STEERING GEAR ANDLINKAGE N-38 POWER STEERTNG PUMP........-............... OtL tNDEX.8 STEERING N-r ........................................................................................................... N WHEEL ANDCO1UMN....... NTROUBLESHOOTTNG GUtDE. N-26 WHEEL ANDCOIUMN..... N-4 MANUALSTEERING N-4 PREPARATION ... ouTLlNE.......................................... 3 STEERING GEAR ANDLINKAGE E}IGINE SPEEDSENSING powER STEER|NG....... 5 N-6 BOOT ............................. N-22 TROUBLESHOOTING GUtDE.............. ................ N-20 pREPARAT|ON N-20 ...... powERSTEERtNG N-23 F1UtD.............SYSTEM STEERING N-2 N-4 N-4 sPECtFtCAT|ONS.................. STEERING N-27 ...... N-23 AtRBLEED|NG....

. 9 / / Disassembly Inspection pageN-11 Assemb|y....... I on-v.....Boot pageN........... pageN-13 pageN-15 pageN-17 N-2 . Steeiing pageNinspection.....18 in)l '1.... whoeland column 2.....6 Rep1acement..... Assembly.......... gear and linkage 3 Steering Installation Removal/ / Inspection Disass€mbly " .....INDEX INDEX IIANUALSTEEHING WHEELPLAY ISTEEFING o_sl)mm(0-1............hicle pageN/ BemovalInstal|ation...........................................

......................... Disassembly / Inspection / pageN-39 Assemb|y.......................... pageN-41 Adjustment.........6 2............31--o................22lb) ) (PFESSED I | in) I NEw:8-9mm (0. Drivebelt pageN-41 Inspection.. pageN-23 RemovalInsta||ation......... Powersteering fluid Insp€ction......... Power steering pump oil pageN-23 Air b1eedin9............... pageN-38 Removal / Ins{a||ation.... Boot Rep|acement............ 3............................. Steering wheeland column pageN-26 On-vehicle inspection.............. 9 pageN/ Disassembly / Inspection / pageN-11 Assemb|y.. 6................c'o" f o"........* "........................................................................................... pageN-27 / Disassembly page / Inspection... pageN-32 5.......1L9 ( USED: J 1....... N-28 Assemb1y..rtAr 9eN (101€.35--0....INDEX pOWERSTEERTNG (ESPS) E]{G|i{E SPEEDSENST]{G STEEFING W1IEEL 0-30mm (0-i.................................. N-3 ..............3r5 I in) 9-10mm (0..................... pageN-23 gear and linkage 4... Steering Air bleedin9.....18 in) FLUIO SPECIBCANON: ATXOoxronotr M-Itr or orr...... pageN--41 Rep1acement...... pageN...... Removallnsta||ation.............

N OUTLINE SPECIFICATIONS litn wh€el Sleering Steeing shaft and ioinl gear St€edng MANUALSTEEAING OUTLINE. Outerdaameler Lockl+lock Shaft Msnual 3t€cdng 370 (14. Typ.53) 0.boot 49 01805108 Pr€load N-4 . toint ball 49 803a 785 Insiall€r. lmpqt) nack-and-pinion co (intinite) 136 13(5. 0.6) Power steerlng 3.III (0-63.8 Joint Type G6arra o Rackslroke mm (in) Powerst€eringsystem liter FlLrid cap€city (USql.6 MANUALSTEERING ssT PREPARATION 49 0118850C Puller.3 Collapsible mm [n) iums 3.35:i@) Enginesp€€dsensing or ATF Dexronotr M.

dng wheel vlbrti€3 clrcunfercnti!lly) N-13 N_13 N-6 Seclron M Section Q SeclionR N-13 N-'t3.ralfunction sl€eringgear of Crackedor worn stee ng gearmounling rubber MalfuncUon suspension oi Damagedsleeringlinkage Damagedwheelor fte Malfunction baking system of Malf unctionof slspension Wornor damagedsleeringjoints lmproperst€eing gear preload Damagedsleeringlin!€ge Damagedwheelor tire Malf unctionof suspension Maruncliono.lubricalion.Sc N_ Repairor replace N-19 N-13 N-9 N-13.nei6l ln3tablltty whllc drlvlng N-6 N-19 N-13 S€ction O SeclionR N-13.eringuheel pulls Replace G.15 N-13 N-6 Abnolmrl no|3e t om 3t8adng 3y3tem Tighten Tiqhlen N-5 .15 N-6 N-13 N-13 N-6 N-6 St€erlng t6€16 un3table Exccaslv! slecdng wtr. or sluck damaged sleering joint ball Impropersteeing gear preload Damagedsteeing gsar Maltunction ge€ring $afl joinl of l.MANUALSTEERING TROUBLESHOOTING GUIDE Probl6n St€crlng l6ob heavy (v€hicle Fck6d up) Pos€ible cau3e Poo. ioreign mateialin mechanism. 15 N-13 Seclion R N-13 S€ction Q S€clion P Seclion R S_t.cl pby Poor aleedng whecl N-r3 Adjusl S€clion Q S€c'tionR Tighlen Replace Shlnrry (alo. steeringgear Malluncliono{ steeringjoints Maltunclion steeing linkage ol Wornor damagadsteeringloi s Loo€esteeringgear mounlingbolts Stuckor damagedsteedngjoints lmpropersteeing gear prcload Damagedwh€€lor lire Mallunction suspen{ion ol Damagedsteeing linkaqe Loosesteeing gear mountingbolts Stuckor damagedst6e nq joints Damagedor wornJrontwheelbearing Damaged wheelor tir€ Mallunclion €uspension of Loosesteeing gear mountng bolls Mallunction steeringgoat ol Obslructron nearst€eringcolumn Loosesteeing linkage Actlon P.

pageN-7 lnsta 5.MANUALSTEERING BOOT Rgplacament the 1.............. Loosen lie rod nut. iiiJ i""t"1i1on......... Tierod end/Steering bebw note.. Remove wheel..separate with knuckle the SST. S'teering 4..... REPIACE @ t 6. .. the lhe 2... "n""t<1fie iteering angteand-toe-inand adjustit n€cessary.. Loosen wheellug nuts...... . Locknut pageN-7 note.. Withthe n'rtprotecting tie rod endstud... aiion note .. Tie rod end boot pin 1.... tie rod endliom the sleering N-6 .. Removal/ 2...L Bootwire Removal gear boot 9. 2... Bootciamp knuckle 3.. Tierod end ...... Removal Removal nole Tle rod end/Steedng knuckle the 1...... lnstall the reverce (Referto SectionR.referring Romoval to orderot removalreferring InstsllationNote in 5....... Nut 7... Jack uD the lront of ihe vehicleand supportit with safetystands' the 3. Note to in 4........ Cotter page N-7 note Installation ... Remove the ordershownin the figure.........) 6.....

when Tle rod end bool Cautlon . the Steering gear boot Verifythat the boot is not twisted.iIANUAL STEERING Locknut Before loosening locknut theiierodend. Put a smallamountof grease(littriumbase)into the new boot and set it onto the tie rod end. he frorn make mark a lor reference tighlening. N-7 . lnsiallation note Tie rcd snd bool 1. Secure tie rod end in a vise. 2. Press bootontotltetierod endwiththeSSTanda Dress.Remove boot by taFF the ping it witha hammer. Do not scar lhe parl where lhe boot ls attached to the tie rod end.Place chisel the a against the bootand holdit attheangleshown.

26. It the play excesdsspecllicatlon. Atlach a pull scaleto the outermost wheelsDoke. Movethe O.steering shaft wear. joint play. lf not withinspecification. position. the in Witn wheets thestraighrahead the steeringwheelto the leftand rightand verilythat the play is withinsoecification. and@ tocheck steerin. Steering whgel etlolt: 118 N (12 k9. Mov€1he steering poslton. either lhe ateer' wom or the backlash ot lhe sleering ing ioints ale geat l3 excessive. ahead point ot the steering 2. N-8 .steering for columnbearing looseness. Loogenesaor play ol steeting wheel _ wheelin directi=ons@. ing torqueof pinion(referto page N-19) and steering ioints. meae in with 3. S'tarting fle wheels thestraight-ahead to ure th6 efiortrequired turnthe steeringwheelto the left and to the right. and wheellooseness. Play: 0-30mm (0-1.18 In) Note .4 lb) or le$s lduring one tum of steerlng vrheeu startroiation checkthe following: 4. column Steerlng wheel ellorl in wheeltoputthe wheels the straight1.MANUALSTEERING WHEEL AND COLUiIN STEERING On-vehlcle Inspectlon Steerlng wheel play gentlyturn position.

..... Steering shaft DisassemblyInspection / / pageN-11 Assemb|y.9 Xrn (44--{O d-Lq..... 2..... 35--62 In...... 11....MANUALSTEERING Removal lnstallailon / 1...... Disconnect negative the battery cable...... pageN-10 .......... Remove the ordershownin the figure.0-5... u_ 6and 9........ 52-7a ! t) 1............Plate Removal note....tb) @o- 16-26 (r... 3.. Section T 6..... Steering wheel Removai note.referringto Installation Note.............. Column cover 5. Hornpad 2.... Keyinterlock cable(Al-4 7........... Locknut 3.7.... 10 pageN4. in to 3......Dust cover N-9 ... Intermediate shaft 10.....10 pageNInstallation note....referring RemovalNote... Installin the reverseorder of removal..... r3-2o) xn (60-90 fr*g... Combination switch Removal / lnstallation.....3-2....

Do not try to remove the steedng wheel by hitling The columnwill collapse. N-10 . puller' wheel witha suitable the Remove steering Plate the and Reachunderthe insulator remove nuts lnstallationnote Steerlngwheel position.MANUALSTEERING Removd noie Steerlngwheel Cautlon . sieerinstallthe in With wheels thestraight-ahead the ing wheelas shown. the shaft wlth a hammer.

Steering below shatt note..........referring Disassembly in to Note.........._ Assembiy 2. to b_ 's_26(r...... below Disassembly note Sleerlnglock mountingbolt and bracket 1... Usea chiselto make groove theheads thesteering a in of lockmounting bolts..... referring AssemblyNole........... 4.. 2.. Steering lockassembly Inspeqton. thatit moves inthe LOCK and freely thekeyin with otherpositions.......... 3...... Remove steering assembly. Assemble the reverse in orderof disassemblv..... N-l1 .....?... Disassemble the ordershownin thefigure...... 2.............. Remove bohswitha screwdriver... .... the lock Inspectlon Sleerlng lock assembly (ATX) Verify thecableconnector that cannot move when keyis the position.....5_r.... pageN-12 pageN_12 1nspection.... the 3......................... 13_ror 1.. Steering lockmounting and bracket joant bolt 3..MANUALSTEERING Disassembly Inapection Assembly / / 1....__.... Universal Disassembly note.. Inspectall partsand replaceas necessary.

the tollowing replace column necessary.04 In) Assemblvnole Stesringlock mounting bolt and bracket on lock 1. Column damage bushing 2. N-l2 . Inslall steering assembly the jacket.1 + lmm (23. damage bearing 1. Instail new steering mourtingbolts. Lenght: 603. the correctly key operates 2. Column shaftlength Steering 3.74 + 0. 4.MANUALSTEERING Steerlng shaft if assenbly the and Check1. Veritythat the lock the 3. Tightenthe bolts untilthe headsbreak ofi.

.......... the 2.. relerringto Removd Note.. in 5.. checkthe maximum steering................ Mounting bracket bolt Installation pageN-14 note. Steering pageN-1 Removal note..........lCEa--=1 pin 1.......... 3....P ....... 4 pageN-14 Installation note.....MANUALSTEERING STEERING GEARAND LINKAGE Removal/ lnaiallallon 1. Tie rod end/steering knuckle Removal note....... Afterinstallation.... to 6. Loosen wheellug nuts....... N-l3 ....... Cotter 2..............ngle and thetoe in andadjustil necessary.......... Nut 3... gearand linkage 6.... Remove the order shownin the figure...... 4.... Remove wheels the and tires.......) a... page Disassembly / Inspection. 6 pageN4.N-l 5 pageN-17 Assemb|y..... (Refer Section to R....... Intermediate bolt shaft 5.... Instiall the reverse in orderof removal... referrino lnstallatlonNote.. Jack up the frontof the vehicle and support withsalety it stands...............

MANUALSTEERING Removal nole Steeringgear and llnkage Cautlon . gearand linkage fromthedrivels side. the Tlghienlngtorque: gz-sz t'lm (3.8-5. Install steering the lrounting bracket bolt in Tiohten boltsin the ordershown the figure. Do not damagethe booia when removlngthe aleer' ing gear and linkage. gear from Removethe steering andlinkage thedriver's lnstallatlon note Steeringgear and linkage Caulion .3 m-kg. Do not damagethe boots when Installlng the steering gear and llnkage. side. 27-38 ft'lb) N-l4 .

...Oil seal pageN-16 Disassembly no1e.....Gearhousing Inspect cracks for and damage Inspect bushing wearand damage for N-15 ..... 16 Inspect cracks... Washer 8..Pinion shaftassembly for Inspect pooroperation Inspect teethlor wearand damage 18.Tie rod end pageN-16 Disassembly note......Yokespring Inspect wearand damage for 12... Bootwire gearboot 5. Steering Inspect cracksand damage for 6.. 2... pageN 17 Inspec1ion........Back pageN-16 Disassembly note...Snapring 17....... Inspect bending for Inspect jointfor damage ball and poor operation 7. 15.......Stopring 16. pageN Disassembly note...... lnspectballjointfor damage and poor operation 2......Mounting bracket rubber 20.Support Inspect wearanddamage lor 14... for wear... Adjusting bolt 10.....MANUALSTEERING Disassembly / Inspectlon 1. frrr-^ -66Ws '/\ - L\ -...referring Dlaassembly in to Note.-......and damage 22.... 4@\ ) -%o^ \--'-'' B 1.....-...........g$fr\ R . gS B@\ "q b @ %-/ " .... Inspectall partsand replac€as necessary....... Disassemble the ordershownin the figure..............Adjustang cover 11...... Bootclamp 4.. Locknut 9.. Locknut 3..... Tie rod pageN-16 Disassembly note.Spacer yoke 13..... @ \ @ trH l \ r*fqou........... 19.Mounting Rackbushing 2'1... @ \q \.......

the Rackbushing Cautlon . Do not damage rack bushlng wilh the rack teeth.MANUALSTEERING Dlsaslembly note Tle rod end and Markthe tie rod. locknut. the the tab Depress locking to remove rackbushing. Do not damagethe tie rod or the rack. Uncrimp washer. . Tle rcd Cauilon . Use protective plates in the laws ot the vise. Donot removethe rack bushing lf not necessary. the 2. Cautlon . Oll s€al Remove oil sealwith the a screwdriver.. the 1. tie rod end for properreas' semoty. the Rack sidethe Remove racklromthe housing Caullon . Remove tie rod. Do not damage columnwhen removlng. the 01E0NX{45 N-l6 .

ol Runout 0. the N-l7 . (2) Install stop ring. 3. Caution . toothwear. the (3) Applygrease the lip of a newoil seal. lf not within specification.O25 Asssmbly 1. Oil seal (1) lnstall new snap ringwiththe tapered a side facing upward. 2. lhe 01E0NX. Do not damagethe rack bushlng. Rackbushing (1) Align taboftherack the with in bushing hole thecdumn. 3. Measure runout the the rack.MANUALSTEEBING Inspectlon Rack 1. for damage. (2) inslallthe pinion shafiwithlhe nobhpositioned shown as position. Mounting bracket. mounting rubber (1) lnstall mounting the bracket mounting and rubber. (2) Carefully slidethe rackin fromthe housing side.016in) max.replace and if necessary_ 2. 4. Rack (1) Secure mounting the in bracket a vise. (2) Pushthe rackbushing unlilit is locked placeby in in the tab.4mm(0. to (4) Install oil seal. in the iigurewhenthe rackis at the center o- g- OIL SEAL STOPRING SNAPRING 5. Inspect cracking. Pinion shaftassembly ('l) Applygrease theupperbearing theteethofthe to and oinionshaft. replace rack.

Use protectlve plal€a in lhe iaws of lhe vlse' (1) Secure rackteethin a vise. Sleerino oear boot withtheadjuslin bracket thevise (1) Secure mounting f|e ing coverholelacingupward in (2) Applygrease the bootas shown the figure. the Cautlon . Do not damage the rack and tie rod.wrapa newbootwirearound two (2) the ' twislit four (4)or five(5)times. Verity lhat the boot is not twletod or dented. (5) Applygrease the balljointof thetrerod to 7. times. to it (3) Install bool. (5) Install bootclamp.then (4) Foldrhe twistedpart to the bracketside. Tie rod Caution . Suooort voke yoke ot (1) Appli grease thecontact surlace thesupport to (2) Installthe supportYoke . Tighteninglorquer ss-ze Nm (6-8 m-kg. (4) Align the washerwith the rack grooveand stakethe washer. (3) Install spacer and yokespnng the olE0NX{64 N-18 . lhe (2) Install newwasher. a (3) lnstallthe tie rod.MANUALSTEEBING 6. 43-58 ft-lb) Caution . 8.

5 N.lb). 9. Do nol allow the adiusiing boh io lurn.1 oz) Any other posltion: 1. (2) Insiall adjusting $e cover.lANUAL STEERING L Adjustingcover (1) Applysealant thethreads the adjusting lo ol cover.100 t 200 g (38. (4 Tighten locknut the whileholding adjusting the bolt.8-14. Tlghteningtorque: 39-s9 N.8 In-lb) Pull scalereadlng:1.7 N.Tierod end Installthe rodendsand tie align themwiththemarks made belore disassembly. readjust byturningthe adjust bolt10o-40o. N-l9 . and loosen 10"-40" fromthat position.0 oz) or less (6) lf notwithin specitication. Tightenlngtorque: 9. 13 ln-lb) or less Pull scale readingi1.8 + 7.7 bolt in.m(il-6 m-kg. 8.1 + 0.m(15 cm-kg. 29-43 ttlb) (3) Iighten the adjusting to I Nfl (10 cm-kg. it (4) Slide rackto the leftand rightslowly (5)times the five yoke. to seatthe support (5) Measirethepinion torque theSSTanda pullscale. with Plnlontorque Neutralpoaltlon + 90": 1.2 iln (11 + 2 cm-kg.m(10(F150 cm-kg. 01EONX{3S 10.87-130 in-lb) Caution .5 r 1.500g (53.ll.

oil seal & bea ng (Partot 49 D0323A0) 49 D032308 up nngandoil ing & oil seal (Partof 3AO) 49 OO32 49 D032307 & beaing (Partot 49 D0g2340) 49 D032303 (Panof 49 D032340) Deanng 49 FO32 303 bearinoand irF siallation oil oi Handle 340) 49 DO32 up rlngand oil 49 0032 3t)t oil sesl& bea ng (Parlof 49 D0323AO) 49 D032302 of installation oil bea ng installatonol oil 49 D0323A0) 49 D082312 ol installairon Guide."' @ N-20 .N ssT PREPANAT|oN STEERING POWER SPEEDSENSING ENGINE STEERING POWER SPEEDSENSING ENGINE 49 D0323A0 Repairset. seeling (Part 3A0i 49 DO32 sea nng installation ol upp€r beanng #. afld installation 304 4S DO32 Ingallor.oil seal (Partof 49 D0323oA) ot installation 311 49 D032 rack (Pat of 3A0) 49 DO32 49 D032314 Fomer& guide. st€eringgetr 49 D032 306 (Pad ol 49 D032 3A0) upp€rbeanng. sealmg (Panol 49 D032340) 305 49 DO32 and beaing (Panot 49 D0323AO) 49 D0g23@ inslallalonol cil seal (Panof 49 I)032 340) installation ol 49 D032315 installation ol st€€ringmck Forner & guide.

Tension N-21 . powsr steering 49 1232673 (Pand 49 1232670A) 49 1232 672 anspeclon oJ Gauge (Parlol 49 1232 670A) 49 H002671 $eennggauge 49 BG32 304 fluid pfessure 49 G0323A1 inspelion ol $eenng gsar 49 G032 317 (Partoi 43 G032 3At) inspeclion ol ste€ringgear 49 G032319 (Padot 49 G032341) e 49 8032 305 steeing gear Holder er sle€ringoil p!mp 49 01805108 pinion pfeoad beainq preload moasunng 49 9200020 gaugo. joint ball 49 12326704 Gauges€t.POWER STEERING ENGINESPEEDSENSING N 49 DO32316 49 D032310 installtion of adjus|ing cover (Part of 49 D032 340) shatl (Part oi 49 DO32340) lnstallation of plug assembly 49 0118 850C Puller.

STEERING POWER ENG]NESPEEDSENSING GUIDE TROUBLESHOOTING Problem stccdng fecb htavy Po€alblecaule sluckor material mechanism in Joreign Poor lubiication. 28 N-36 S€ction O S€ction R N-27. 2A N-27.usr Tighlen Abrcrmd nol66 lrcm lLcrlrg ryden Iighten Rapajl Tighten Replace Tighten -fighten Ble€darr N-22 . 2A N-24 N-23 N-38 N-41 Seclion O B Seclion N-27. 2a N-27. 28 N-9 N-27 N-27. 28 Seclion O SeclionB N-41 N-27. 2A O Section SeclionP SectionR N-6 N-36 N-27. 2A N-41 N-38 Nl8 N-23 N-38 SLadng whe€l pulls to o||o slde Gencrel lmteblllly Adjust Slcorlng teals undrble Ercaa3lvo 3lccrlng Yrhrcl pley SLcrlng whc6l doesn't retum ProP€1ly Shlmnry (3lt ilng wh€cl vlbraie6 clrcunfa16ntlally) Replace Tioht€n Ad. 2A N-27. lke ol Malrunclion susp€nson Loosest€€ringgear mountingbolts ot MalJoncion steeing gear nearsteeringcofumn Obstruction Loos€st€eringllnkage Worn or damag€dsteeringball jcinl Looseor damagedP/Soil pump drivebeft LooseP/S ctl pump bracket bolls LooseP/Sojl pump mountjng Maltunctonol P/Soil pump Actlon Page N-27 Adjust Add lluid or bl€ed a( N-36 N-27. 2A hion M SeclionR N-27 N-27. 2a N-27 N-27. 2A N-9 N-27. abnormalwearol sleeing ballioinl lmpropef steetingpinionPrcload Damagedsteeing gear of Malfunction steeringshanjoinl Malfunction stee ng gear oi L€akageof tlujd Low fluid levelor air ansystem l/alfunctionol PE oil pump Damagedor looseP/Soil pump driveb€[ P/S Clogged lines Damagedwheelor tire MalJurrton ot susp€nsion Damagedde€dng linkage Damagedwhe€lor tire Maltunction brakingsyslem ot Malfunction suspenston ol steeringballjoir'l Wom or damaged sle€nngpinionpreload tmprcper Damagedste€ ng linkage Damagedwheelor l(e Mallunclion suspengon ol Loos€P/S cil pump dive belt ol Maliunctjon steennggear ol Malfunction st€eringballioinl ol Maltunction steeringlinkage Worn steeing g€ar Worn or damag€dsteeringballjolnl Loos€stse ng gear mouning bolts Sluck or damagedst€€ringballjoant lmpropersleeing prnlonpreLoad Damagedwheelor iite of Maiiunction srsoension Damagedsteeing linlage Loo6esteeringgoar mountngbolls Stuckor damagedsteednqballioint Damagedor worn front whe€lb€aring Damagedwheelo. 28 N-27 N-27.2a N-27.

(Refer below. not 4.Check fluidlevel. Recheck fluidlevel. Start engine the and let it idle.ENGINESPEEDSENSING POWER STEERING AIR BLEEDING '1. 8. the add fluid.) the to 2. and POWER STEERING FLUID Inapgctlon Fluid level Check powersteering level. Jack up the frontof the vehicle. 3. Fluld spsclticallon: ATF Dexrpn@tr lrl-Itr or N-23 . the fluid Add fluidto the specified level. Verify the fluidis notfoamyand thatthe fluid levelhas that not drooDed. Tllrn the steeringwheellully to the lett and right several ltmes. Tumhe $€€ring wheel to the leftandrightseveral tully times withthe engine running. 5. Cautlon . L Add fluid if necessary repeatStepsO and @. Repeat Steps@ and @ untilthe fluid levelstabilizes. 7. Useonly the sp€cltledpower steerlngfluid.if necessary.lf it hasdropped. 6.

m ti. Fluld pr€sure 't. Ass€mble SST as shownin the figure.o m-t<s. to wheeltullyto leftand the Turn steering the and the start engine letit idle. check lluid right apply pressure. Nole .STEERING ENGINESPEEDSEIISINGPOWER Fluld leakage cautlon -ro . forlluldleakage.29-36 fl-lb) N-24 . the Tlqhlsnlnqtoroue: ie-ag l.o-s. The polnts where fluld leakage may occur are Indicated ln the tlgure. preventaamase the stesflng system.do nol ksepthe steerlngwheelln ihe tully turned to posilion tor more it|an 15 saconds.

Increase engine the the speed 1. pressure notwithin replace gearhousthe is specifjcation.848 kPa (75-80 kg/cm'.omthe system.500 rpm andmeasure fluidpresto is suregenerated lhe oilpump.848 kPa (75-80 kg/cm'. the Oll pump tluid pFssure: 7. the (Befer pageN-23. Gearhousinglluld presaure: 7.067-1. the to the 4.138 psi) gauge the 6. the fluid temperature will Increaseexcessivelyand adverselyatfecl the oil pump. Openthe gaugevalve fully. replace oil pumpassembly.000-1.358-7. 1. Remove gauge Instailand the set. Bleed air f. Bleed air fromthe system. ing assembly.) 3.ENGINE POWEFSTEEBING SPEEDSENSING Note . hoseto the sDecified toraue. 5.lfthepre9sure notwithby in specification. Stia( engine turnthe and steering wheeliully leftand rightto raisethefluidtemperatureto 50-60"C (122-140on. tluid temperathe ture will riae excqgsively and adversely aftect the oil pump.500 rpm. lf the valve ls left cloaedtor morethan 15 seconda. 1. Openthe valvefullyand increase engine speed to 1.4 m-kg. Disconnect high-pressure fromtheoil pumpand the hose attach SST to the pump. the THENMOMETEF sO-@"C (e-14"F N-25 . Closelhe gaugevalvecompletely. Cautlon .067-1. 7. Caution . 2. ll the steering wheel is kept In th€ fully turned poalllonlor mgrethan 15seconds. Turn steering the and the wheelfullyto leftandrioht measgenerated lfthe urethefluidpressure bythegearhousing. 12-17 tt-lb) (Refer pageN-23.138psl) tigfnen high-pressure the 8. Belorc dlsconnecting the hose.6-2. Tightenlngtorque: l6-24 Nn (1.) to 9. make marks at lhs connections tor proper reinstallation.000-1.358-7.

POWERSTEERING SPEEDSENSING ENGINE WHEELAND COLUI/|N STEEFING On-vehlcle lnsp€ction Sieering$rheelelfod put on 1 Withi-he vehicle a hard. 6.6 lb) or less ldurihg one turn ot lhe steeringwheell lluid checkthe following: level' 4. funcat hoseor conn@tions tluidleakage arrin system.levelsurtace. Withthe enginerunning idle'attach pull scale the pointol the steering wheelspoke outermost posiin withthe wheels the slraight-ahead Then. tt notwithinspecification.measura etlort to the leftand to the right. pump and gearbox' and tlle pressure' t|onot oil N-26 . to a at 3.starting wheel to required turnthesteering the tion. thewheels in the straiaht-ahead Position fluld to 2. Startthe eigine and warm the powersteering s0-6ooc (122-140oD. Steering wheel etfort: 29 N (3 kg.

.t-2....................... Use a container or rags to collect the power stee ng fluid when disconnecting the preasure pipe and retum hose...(Referto page N-23. Loosen wheellug nuts... bly pageN-32 Assembly. Tighten necessary all boltsand nutsto the specified torques...) a9-{a (4.. 2!t-:l}) 1O-26 (1.0-6.6-53.... 3.. 27-€a) EI pin 1. Afterinstallation: (1) Checkfor fluidleakage..... lntermediate bolt shaft page N-6 7......) to (2) Bleedair trom the system.... in 5.....referring Removal in to Note...7.. N-27 ......... 4 pageN-14 Installation note....... 6.. Jack up the front of the vehicleand supportit with satetystands. Note .......... Install the reverse orderof removal.. 7....... pageN-28 Disassem / lnspection . Return pipe 5.... Pressure 6..0..ENGINE SPEEDSENSING POWER STEERING STEERING GEARAND LINKAGE Removal Installation / 1.... Remove wheels. Remove the ordershownin the figure... the 2. fi]-20) 37-52 (1..... Mountjng bracket bolt pageN-14 Installation note. pipe 4. Nut 3. (Refer pageN-24........ Tierod end/Steering knuckle Removal note....... relerring Instaltation to Note........ gear L Steering and linkage pageN-1 Removal note... Cotter 2................ the 4....

-i'sasserfile in tlie ordershownin the figure.N STEERING POWER ENGINE SPEEDSENSING Dlsassembly/ Inspection Note to i. Insoect \ fl.referring Disassembly partsand repairoareplace necessary as all 2.w \e'-'\ \"r -%o^ N-28 .

... O-ring Inspect jointfor damage ball and 34. Pinion (tie 3......................Steering Inspect cracks..Sealring pageN-31 8. Inspect weakness damage for lnspect cracks lor and otherdamage and yoke 15......... pageN-30 46.. Inspect wear.... Washer Disassembly note..... N-3'1 7... Boot Disassembly note..Support 39.. Retaining ring 40......... Holder page Disassembly note. Tie rod pageN-30 Disassembly Inspect wearand damage for note. control for oil 42... Spacel passage page . wear and 12..Steering rackassembly page N-30 6.......Upperbearing Disassembly pageN-30 Disassembly Inspect wear............... damage............Control 2.....23..... N-31 damage inspect va........damage.. mallunction for and Inspect teethof pinionshaft wearand lor 4l......Yokespring Disassembly note. Inspect jointfor damage ball and 27..Oil seal Inspect damage for Disassembly note. 21. for and malfunctjon 44...Stopring 5......plugthe pons to prevsnt the entery ot dirt into the steering gear housln9...Oilpipe 22...... pageN-30 note.Oil seal 45.damage.........ENGINE SPEEDSENSING POWER STEERING 1.... maliunction for and note...... (adjusting rack Locknut cover) 37. Backuprjng page N-31 14.. N-31 clogging and sealring and friction Disassembly note... Mounting Disassembly nole.....Sealring pageN-30 26....... 36............ Inspect cracks for and otherdamage 32....... Locknut rod end) 29......Center bearing pageN-31 note..... Bootwire 31.. Mounting bracket 4.. wear and 18... 19........ Tle rod end 25..... Lowerbearing pageN-3'1 17......... Gearhousing ... -..........-. O-ting malfunction shatt 28... oage N-31 and wear '16..... Oilseal page Disassembly note............ surlace wearand damage Inspect cracks... Housing cover O-ring 9.. for damage......... Atter removlnglho oll pipes..........Y-packing malfunction 35.Sealring Disassembly note....Plugassembly 43...... Disassembly -..Adjusting cover for 13............ -....Oring Disassembly note Oil pipe Cauilon ......ve damage......... N-29 ......... Inspect wear.Pinion shaftassembly Disassembly note.......damage... Bootclamp 30.........Locknut Disassembly note. -. Mounting bracket rubber 20........... Inspect bending for 33. -................. shatt) '1'1......Snapring below for valve Inspect clogging and damage 24. pageN-31 (pinion 10...Plate 38. Plug Disassembly note.

Upper bearingand oll seal shatt.Remove stopring wrtha pln punch the the tighen tie rod to thetubesideand pullit 2. Use copperor aluminumplatesIn the laws of the vise. the 3. Cauilon . Do not damagethe lack. Pressoul the upiper fromthe Plug. the 1. Secure mounling ring. Do not tap on the lowel beadng. Remove O-ring Stesring rack assembly '1. Tap the pinionshaftwitha punchto remove Cautlon . Remove pluqassembly the and oil sealwiththe SST bearing 2. the 2. and Markthetierod. Remove tie rod. Remove retaining I 3. N-30 .locknut tie rodendfor proper Tie rod Caution . Temporarjly to removethe rack assembly. Uncrimp washer. Do noi damagethe tie rod or the rack. Cautlon . tromthe pinion t. the 2. Pinlon shatt assembly in bracket a vise the 1.STEERING POWER ENGINE SPEEDSENSING Tie rod snd reassembly.

\m.: Lowel bea ng Taptheendofthegearhousing column remove lower to the beanng. Do not damagelhe groovewhen removing Remove seal ring and O-ringwiht a screwdriver. Oll seal. TaptheSSTfromgear housing sidetoremove backup the ring and the oil seal. Whenremoving holder. Seal ring and O-dng Caution . 2.ENGINE SPEEDSENSING POWER STEERING Holder Cautlon . Cauiion . not damage inlhe do ils side bore by lhe end ot the rack. N-31 . the Backuprlng and oll seal 1. spacer. spacerand center bearing Press theoilseal. thecenter out the and bearing with the SST. Insiall SST (attachment) the onto the end of the SST (handle). Do nol tap at the gear houslngbearingsectlon.

l'Itr)to newOdngandseal ATF rino. Do not damagethe edge ot lhe aeal ng. Orinq and sealring (1) Apply (Dexron@tr a or l\. (2) Press the centerbearing the SST. in (4) Applygrease a newoil sealand set it in lhe gear to houstno. center and (1) Applybrease thecenter bearing setit inthe gear to housano. 4. bearing and 2.6413ff in) (3) Setthe spacer the gearhousing. handuntillheheight (5) Press theoilsealwiththeSST-by in (0. (3) Remove SST (guide).Mounting rubber and bracket mounting (1) Install mounting rubber. Backupringand oil s€al (1) ApDlvqrease a newoil seal. '1.64 I8Uiin) is in shown thetigure 16.spacer.3j8Srnm 3. with in 163 i33mm (0. lo i2t lnstailihe oil s€al to the SST (protector body and ' guide). the N-32 . (3) Fromthe sealring by hand. (2) InJallth O-ringand sealring in the grooveof the rack Cautlon .POWER STEERING ENGINESPEEDSENSING A€s€mbly Note . the (2) Tap the mountingbracketon with a plastichanmer. Oil seal. Use protective plales In the iaws ol the vise duting assehbly to prevent damageio the various part8.

614 0.replace oil seal.ack trom the (5) Installthe backupringwiththesrnall facing gear. 15. Holder (1) Applygrease a newY-packing install intolhe to and it holder. (2) Install newGring ontothe holder.ooin) (2) Verity the dislance that the between end oftherackand the holderis 15. 8.5 t 2mm(0. Caullon . (2) Apply400mmHg(l 5.7InHg)vacuum a vacuum with pumpand verifythatit is heldtor at least30 seconds.79ln). the / (j. a (3) Installthe overthe SST rackendandinstallthe holder. to of (2) Slide rackjntothegearhousing thetubeside th€ from withthe SST. end the rack teeth side to the piston. Do not press over 400 kg (880 lb). seal (1) Press thenewoil seal in fromtubesidewitha suitable DiDe. Dlameter: 20mm (0.08in).Remove SST.ENGINE POWER SPEEDSENSING STEERING (4) Slidethe oil seal and the SST overthe . Hearmetic sealing inspection (1) Connect SSTto thepowercylinder the section the of gearnousng. (4) ApplyATFto the inside boreof the holder. the 5. (3) It vacuum not held.5 + 2mm(0. is the N-33 . 6.61+ 0. (5) Install stopring. Steering rackassembly (1) Applygrease theteeh andfiictionsurface the rack.

the through SSTto formtheG (2) Pass pinion shaft the ringand the sealrings. assembly (5) lnstall newsnapringto the pinionshaft a '10.Plugassembly and (1)lppv ATFto a newupperbearing a newoilseal. Do not damage the sdge ol the a€al ring and the contol valve. as shaflwiththenotchpositioned siown i4i lnslallthe oinion ' rackis at the centerposition in the tiourewhenthe Cauilon . (3) Installnew sealrings ontothe controlvalveand form themwiththe ssT. SEALBINGS (3) Atlachthe SST to the gear housing. Controlvalve ontothepinaon (1) Installa newOring andnewsealrings shatt.4 h) 11. (2) ApplyATFto the newsealringsandthe kictionsurface of the cortrol valve. {a Setthe oil seal into the Plug (3i Press the oil sealwiththe SST in N-34 . Caution . pin shalt alignthe pq and (4) Remove SSTfrompinion the valvewiththe threadof the pinion sitionol the control and shaftassembly installthe controlvalveassemDly.STEERING POWER ENGINE SPEEDSENSING 9. 62mn (2. Usethe loose slde of the SST tirst thsn the tlghter slde. Pinion shaftassembly ol to (1) Applya liberal amount grease theteeth thepanof ion shaft.

N-35 . 14. into (5) Press the upperbearing in withthe SST. Do not damagethe rack or tie rod. (6) Install newOring to the plug assembly. (3) Installthe tie rod to the rack.lie rod (1) Secure rackteethin a vise. the (2) lnstall newwasher a ontothetie rod. (5) Loosely tighten adjusting the cover. 13. (2) Apply grease thelower to bearing insiall onto and it the pinion shaft.Adjusting cover (1) Secure mounting the bracket a vise. a (7) Attach SST to the pinionand install plugasthe the semory.ENGINE POWER STEERING SPEEDSENSING (4) Putthe upperbearing the plug. Lowerbearing (1) Secure mounting the bracket a visewiththe lower in bearing boreof the gearhousing lacingupward. Tighteningtorque: 78-98 Nrn (8-10 m-kg. '12. 58-72 ft-lb) (4) Crimpthe washer. Caution . in (2) Apply greaseto the supportyoke and installit. (3) Install yokespring the (4) lnstallthe plate. (8) Install newretaining a ring.

(6) Measure pinion torquewiththeSSTanda pullscale the Standard: Center of rack + 90" 0.s m-kg.2-45. around (2) Install bootandwrapa newbootwiretwice the larqeend. {7) lf notwithin cover' the (8i Tighten locknut whileholding ad.Boot to (1) Applygrease the bootas shownin the figure.Adiustino (1)'Secu-re mounting bracketin a vise the (2) Set the rack to the center position coverwiththe SST to 4. 33-40 ft'lb) 18.Locknut (1) Secure mounting bracketin a vise the torque.8-1. cover 16. the Tlohteninotoroue: -+l-s+ it.m (l.3o0 kg (28.9-ll'3 in'lb) Scalereading8oo-1. Cautlon .9 oz) (6) (3) Steps through repeat specilication. (3) Bendthe wiredownagainst bracket the N-36 .thentwistit four (4)or live (5)times the side. 22-29lt-lbl (3) Loosenthe adjusting cover.6.POWEFSTEER]NG SENSING SPEED ENGTNE (housing cover) 15. ol (4) Applysealant lhe threads lne locKnul to (5) Loosely the install locknut.s m-rg.9 Nm i3) Tiohten adiustinq the ' (5-ocm-kg.43-54 lt-lb) cover 17.s-s. +i in-lb1tnreetimes then returnit 25 degrees.usting the Tidhienlnqtorouei -sg-z+ -t*m (6-z.Housino (1) Secure mounting bracketin a vise lhe cover' ol (2) Applysealant the threads ihe housing to (3) Install housing cover. Do not break the boot wire. it and a i2i Inslall newlocknut tighten tothespecified Tiohtenlnotorque: -zg-sg -N{n (it-l m-rg.3 Nfn (8-13 cm'kg.

6-2.Tierod end ('1)Installthe rod endsand alignthemwiththe marks tie made befo.4 m-kg. 12-17 ft-lb) N-37 . 19. Oilpipe (1) Secure mounting the bracket a vise. the Tightenlng torque: 15-24 N{|| (1.edisassembly. in (2) Install oil pipes.ENGINESPEED SENSING POWER STEERING (4) Installthe boot clamponto the smallend of the boot. 20.

.......... 2.a-53.... Pressure hose 4...5............ 27-3q REPLACE a6-s1 pJ--.. 2. use a contatner or rags to collect the power sleerlng tluid when disconneciing the pressure plpe and retu. Drivebelt pageN-41 Inspection.(Referto page \4....12-1n 17-52 (l.......O-ring 6......n--4' 1.n hose............... Return 5. Note . to for (2) Bleedair lrom system. pageN-41 Rep|acement.. Afterinstallation: (Reler pageN-24 ) (1) Checkall connections fluidleakage...3... lnstallin the reverseorder of removal 3... Powersteeringpressureswitchconnecior pipe 3................5...52{3....6-2A............. Removs the ordershownin the figure... 7.a-s.. 27--34) ........ Oil pumpbracket N-38 .POWER STEERING ENGINESPEEDSENSING OIL STEERING PUI'P POWER Removal/ lnstallation in 1......... pageN-41 Adjustment.t6-2a 11........ Oil pumpassembly / / Inspection Disassembly pageN-39 Assemb|y......) _ 3?--..

....lront pageN-40 Assembly note. Assemble the reverseorder of dis€ssembly..Replace pump lhe assemblyother if repairs are necessary. and wear 8....Pumpbody........ 6-10 l{i (00-1@ . Pressure switchassembly 4.. Bracket 10.POWER ENGINE SPEEDSENSING STEERING Disassembly/ Inap€ction / Assembly '1...Gring 18... lor Inspect friction surface wear 15............DLq...... Inspect cracks.. Vane pageN-40 Assembly note...O-ring 17....rear pageN-40 Assembly note. for damage.. O-ring 5. for damage.22---25) REPLACE pipe 1....O-1....... lnspect cracks...... Inspectfrictionsurfacelor wear '13. and wear 11..Pin 19....Plate for Inspect iriction surface wear 16.... 2. Rotor pageN-40 Assembly note. O'ring 3.... Inspectfrictionsurfacelor wear '14.. O-ring 7.Pumpbody.Suction 2...O-ring 12...... 2a--35 (S.....referring Dlsassembly in to Note....... in referringto Assembly Note....... Disassemble the ordershownin the figure..... clogging.Spring Inspect damage lor and weakness 9....... 3.... following procedure tor replacement theO-ring The is of only...Camring pageN-40 Assembly note....-...Connector 6.. and wear N-39 ............. for damage. Control valve Inspect cracks..O....

Cam rlng downward.IG note Di3assembly Oll pump Caution . mark the lnstall rotorwiththe identification fackjng Vane edges outward into the lnstall vanes rotorwiththe rounded I --\9J. N-40 . To s€curethe oil pumpIn a vlse. thatthepulley rotatedby hand. lhe secuting PumP Roior upward.lront Caution . use the ssT as to damage the Pump' shownto prevent |DENNflCATION A$ombly note Pumpbody. mark Installcam withtheidentification facing ring Pump body rear when rotates smoothly verify Atterinstallation.POWER STEERING ENGINE SPEEDSENSII. Use protectivePlatesthe laws ot the vlse when body.

and adjusting D. 110-132 tb) Used:422-491 N (43-50 kg. Adiustmenl '1 Loosen P/S pumpboltA and nutsB andC.Checkthedrivebeltfor wear. 27-40 ft-lb) O: 37-52 N.m(3.31-0. Deflection (depressed 98 N [10 kg.3 m-kg. Replace necessarv.39 In) Tension New:491-589 N (50-60 k9.9-2.ENGINESPEEDSENSING POWER STEERING DRIVE BELT lmpection 1. Lossen A. nutsB and C. and the 3. the Adiustif necessarv. 14-19 ftnb) @: @: 36-54 N. Checkthe driveb€ft deflection applying presby moderate sure(98 N. if 2. l0 kg.35 In) Uaed:9-10mm (0. 27-38 fl-lb) Replacement 1.) to CFANKSHAFT PULLEY N-41 . (Refer above.8-5.7-5.22 lb) midway between pulleys. bolt bolt 2. by the bolt CR^NKSHAFT PUTTEY Tightenlng torque 19-25 Nm (1.cracks. Adjust deflection the (tension). Belt tension can be measutedbetweenany two pulleys.|n(3.5 m-kg.6 m-kg.35-0. and fraying. Remove replace drivebelt. 95-tt0 lb) Note . 22 tbl) at New : 8-9mm (0. Adjust oil the beltdeflection turning adjusting D.

P BRAKING SYSTEM P-2 P-3 P-3 P-4 P-4 P-5 P-6 P-6 P-8 P-8 P-t0 P-i6 P-i9 P-20 P-23 P-25 P-27 P-2a P-2a P-2a P-24 P-29 P-30 .

Removai 1 n s p e c t i o n . / / RemovalInspection 6. .. ....-...... Brakepedal ..1 ...... .. .... ... .... . .................... . .. ..... .... ...... 9.... g. ............ page Adjustment... lever brake pageP-1I Parking Rep|acement.. . 9 ........... ...... .. ........ Assemb|y. ... ...... ......... I n s p e c t i o n .... ..... P-2 ......... 0 pageP-27 Assemb1y. . Powerbrakeunit . .. 10.a.... . .... .... ...... Dualproportioning ...... pageP-29 .. ..... ........pageP-21 / 1nstal|ation... .... ... . a .. ..2.e ....1. .......... .. Caliper hydraulic line 1.. ... .....paSei-?9 Inspection 4..4.p ... ..Brake / / lnspection Disassembly / / InspectionRemoval pageP-23 p a... Instal|ation..... eP......... . P........... pagePlnspection (on-vehicle).. ...... Inspection brakecable pageP-1 / 1nsta||ation........ ..SAEJ1703 116 7. .... .... ..'... .7 Inslallat:on. .. . ................. . Insta||ation.....Parking g . ....... . ...... .. ... ...... .........P INDEX INOEX OF (WHEN wlTH FORCE 9sN I10 kg.....22lbl) PULLEo LEVER STFIoKE 6_S NOTCHES FMVSS DOTs......... . 8 11..... ...... 8.e...... ........ . ...... (on-vehicle)....... . 8 lnspection / Removal/ lnspeation / Inspection Removal/ pageP-25 pageP-10 Insta|1ation.g.. Inspection pageP-20 Rep1acement... ..... Wheelcylinder cylinder 3....g e... (on-vehicle)..... .....P .P-28 pageP-16 (on-vehicle).. Frontbrake(disc) pageP-30 pageP-20 Insta|lation... p.. .... . Master / / Inspection pageP-1 Disassembly Removal / 1nsta|lation. .. .. ......Parking Flemoval / / RemovalInspection valve 5................ .... / / Inspection Disassembly tYPe) p...2.. pageP-25 (on-vehicle).a ..... ........... ....... Rearbrake(drum) 2.......P . ...'12.. .. brake(lever Assemb1y.......

64(0.39) 10 ATX:235x 18 (9. DOT3.63) x 30x 157 4 0 (1.800(5.71) MTX 235x 12 (9.ng €lve FMVSS116.8(2.2sx0. O.47) x Leadingrrailing Pad dimensions {areax thickness) mm. Dualproport'on.26 137.81) Ml'* Soliddisc Type Cylinderbore mm (rn) 50.(in')xmrn (in) Discplatedimensions mm (n) x {ouier dlarneler thickn€ss) Tvpe Wheelcylinder daneter mm inner (in) Lining dimensions mm (in) (width lenslh x xthickness) Druminner di€m€ler (in) mn1 15.44) 189 ATX 214 {8_43).18 x 0.16) i80 o.25 0.18x6.OUTLINE P Sp6cltication Suspsnded OUTLINE SPEC1FICATIONS llem Blako pedal lvlaxLmum stroke mm (in) 4. SAE:J17q3 Mechanical hro rear \&heel control Tvpe Brake lluid Operation sygem P-3 .6 15.42) (wih levelsenso4 Tandem rype Cyljndefinnerdlameter mm (if) 20.00) 3.89)x (0.87 {0.09) Shoe clearance adluslment Tvpe Diameter Bearwheelhydraulic controlsyslem r\4TX.

P PREPANATlo'{ BBAKESYSTEM CONVENTIONAL BRAKESYSTEM CONVENTIONAL ssT 49 0259 7708 brak€pipe 49 F043001 Gaugo. installation ot front disc brake) P-4 .adjust 49 8043001 Ga'rge.adiust 49 804U003 Turninqlock tool ol adjuslment 49 8043004 49 0208701A 49 0221600c Expantontool.

Hardenrng pad or liningsudace poorconlacl ot of Maltunclion disc brak€ piston ol Mallunction masler oi cylinder wh€€l or cylinder N4alunction powerbrake unit of Malluncnon checkvalve(vacuum ot hose) Damaged vacuumhose Deterioralion llexiblehose ot Malfunction dualproportioning ot valve Brakes pull lo one alde Reparr Bleed an Grindor replace Psge P-6 P-20.oil. or linins of Malfuncrion ol aulomatic adjuster Loosene-qs backing plate / dust cover mounting bolts of Tighten Malfunclion lrted cylinder ol Adjust hproperly adi'rsted wh€ei alignment Unequallire ar pressures P-20. pLat€of drum conLoos€ness of backing plate / dusl cover or caliper mounlingbolls Damaged disc or drum coniact sudace Poor contacl of pad or lining Insuflicienl grease on slid ng parts P 20. or wateron pad or lining Hardeninsol pad or linins sudaceor poor contact G nd or redace Abnomal weaf or distoriion disc.ote) vlbrrtion du.BRAKESYSTEII' CONVENTIONAL TROUBLESHOOTING GUIDE Problom Poor braklng Poe9lblecaus€ Leakagoof brakelluid Brake lluid.25 P-20.grease. P-21 P-20..25 Clean Tighten SeclionM.25 s*.23.25 P.ing bralh9 Bleedair Deteriorated pad or llning Brakes do not release Foreign material or scGtcher on dis.25 Grease Sl€erlng wheelpullg Dragging brake lvlalfunclion ste€rlngsyslem of Damaged unbalanced \ihee{(s) or Incorrect air pressure lire Malf unction suspension ol SeclionN Seclion O Section Q SeclionR P-5 .27 P-18 P. grease. pad.on nl P 23.25 P-6 Brakesdo nol No brakepedalplay lmprop€nyadjusledpush rcd cloarance Cloggedmastercylinderreturnport Weakbrake pad or shoe retlrn spring propedy Wheel not cylinder caliper returning or Malfunction pislonseal ol disc brake ol Exc€ssive runoulof disc plate lmproperly adjusled pedal play Clean Padal go6s too tar (too much pedal st.25 P-20.27 SeclionR Section Q P-9 P25 P-21 P-22 P 9 P-20. or waleron pad or lining ol.drum.1a P-18 P-19 P-2j.21 P-10.25 P-m.25 8€ke fluid.

Remove bleeder bleeder oluq.C' Hmiso-go cm-kg... Check Clean awayanyspilled L Veritythatthereis no fluid leakage.... Flexible 1. Caulion .... OneDersonshoulddepressthe brakepedala few times. it and support withsafety 1. flud withrags.. Be su]e the pedal l€mains depresseduiliilthe bleed screw i3 tlghtened. Brakepipe / InspectionRemoval/ / InspectionRemoval / .P BRAKESYSTEM CONVENTIONAL AIR BLEEDING stands. s2-78 In'lb) Note ... th.. pageP-7 Insta||ation...Jackup the vehicle Cautlon .. up ffuidto the reservolr the 9.... are 4 SteDs and 5 untilno air bubbles seen 6. Reoeat for correct brake operation 7.. LINE BRAKEHYDRAULIC hose 2. The brake fluld reservolr must be kept 3/4 tull durIng alr bleedlng. 4... 3.. Place dtherendol thevinyllube in a clearcontiainer. andihen hold it in the depressed drain screw..... Afterbleeding air.. pageP-7 Installation .. .. Air bleedlng mual be done lrom the bleeder sc.gw ladhest trom the dlsassembledpartsto the neal€at...add brake level. the person loosen bleeder should 5.. to the sDecified Tiohteninqtorcue: E.. and retighten screwwith the SST.... position..-. P-6 ..s-g.... A second the out the fluid. Ths two p€rsons should stay in volce contact with each othef.. ... .. st a cap and attach vinylhoseto the the 2..

Remove brakeoiDewiththe SST.damage.BRAKESYSTEi' CONVENTIONAL Inspection (On-vehlcls) Brske plpe Checkfor cracks. Removal 1. 9-16 ftlb) P-7 .t +t/ /Y Flexible hose hose. #t I . the hose fromthe 2. 1. Checklor scars. Cautlon . Fixthe flexible hosein the bracket and installthe pipeandtighten hose thebrake to the 2. of Replacethe pipe or llare nut if necessary. Verlly thal the hose is not twisted. Connect flexible the flare nut with the SST. lnstallation clip. Tightenlngtorque: 13-22 N{n (1. Disconnect cllpand remove flexible the the bracket. swelling and oftheflexible Rs placethe hosejf necessary. . cracks.3-2.2 m-kg. and corrosion the brakepipe. Verlly that lhe hose does not contact other parts when the vehlcle bouncesor when the steering wheel is turned lully dght or lett.

Disconnect stoplight 2.) to fluiduntilonly the and bteeding replacing brake 2. age of the brake Brake Fluid Level Leakaqe check the is Veritu thetluidlevelinthe reservorr beween MAX that res€rvoir. Loosen brakepedal. inspect leakthe DepreJs 6rakepedalseveral linesand system.Tighten tuin it an addiiional switchconn€ctor. 1o'.23 In) Speclflcation: Adiustment conneclor' switch the 1.80-8. LoosenlocknutB and turn switchA until it does not contactthe pedal.* \ BRAKEFLUID Inapgctlon Leakag€inspectlon for and times. and hllN lineson the Add fluidii it is belowMAX. Replacament in outlined "Air Bleeding".. Verifyoperation the stoplights. r l P-8 .BRAKESYSTEM CONVENTIONAL \\'W t. to 3. bontinue cleanfluidis expelled. i 1 BBAKE PEDAL Inspectlon(On-vehicle) Brake pedal helght Inspectlon Verifythat the distancefromthe centeron the pedal pad to the floor mat is as specified. Connectthe stoplight of 6. the switch it contacts peda|then until the 4. the 1. Tiohten stoolioht locknuts and D B 1/2turn. height ofthe D lbcknut andturnrodC 10adjustthe 3. Follow procedure (Reter 9aqeP-6. Fillthe reservoir the MAX level. 198-209mm (7. 5.

l\ralfunction automatic of adjuster(reardrum brakes) 3. '. is check thefollowing for proo|ems: 1.. Loosen locknut andturnrodC to adjust freeplay. 2. D the 2... i i I i I Pedal-To-Floor Clearance lnapecllon Verify the distance that fromthe floorpanel thecenter to of the pedal pad is as specifiedwhenthe pedal is depressed witha forceof 589 N (50 kg.28 in) r'a.BRAKESYSTEM CONVENTIONAL P PedalPlay Inspection 1.Air in brakesystem 2.i "->i( tr .'r Adiustment '1. Gently depress pedal handandcheckthe play the free by (until resistance fell). is Frea play: 4-7mm (0. Pedal-te.37 In) mln. Wornshoes pads or P-9 ..Verify pedal the height thestoplight and operation.floor clearanc€: 60mm (2. Depress pedal lewtimes eliminate vacuum the a to the in the system.{.16-0. PEDAL-TOFLOOR CLEAFANCE lf the distance lessthanspecified. 132 lb).

..P.... Washer 6. lnstallation 3. Afterinstallation.. .P-1.r}|q.. Inspect partsand repairor replace necessary. Return for Inspect wearand damage 4. lnstall the and hee playif necessary' the checkand adiust pedalheight 4. .. . Brakepipe n . . 1a-17 t|ln {r/o-lao.bleedair.. . . . 37-r$ hrb) @R^--q*(3) ro-te 000-160 cd*t. Brakepedal and lnspect bending lor damage 10. 14.P a d Inspecttor wear switch 12. Clevis spring 3. . . .ASTER CYLINDEF Removal / |nstallation to in 1.'"-'o f / nm-160 cGr9.. ..ffi.. Remove the ordershownin the figure...Remove the ordershownin the figure in as all 2. .Stoprubber for Inspect wear 1 1 . . . in 3.. Afterinstallation.BRAKESYSTEM CONVENTIONAL Removal / Inspection / Installatlon '1. Bolt 7. ..Spring pin 2. R e m o v a lo t e .. P-l0 . reverse orderof removal. ..g . . . .. .. to referring InstallatlonNote orderof removal. and checkfor fluidleakage i':... r?2-156 lDls) @J FEPLACE pin 1. in 2. Oring cylinder 5. .. Install the reverse add 3. . . .. Conneclor 2.... A s s e m b | y ... . . .. . ... ...... . Spacer 8.-.. brakefiuid..Stoplight T.... Master pageP-1 note...page..... . . . Bushing tor Inspect wear 9.. .. Nut and washer 4. 37-136 hnb) 1.1 page P-13 note. .referring RemovalNote... .. Nut 5. ... . 1 lnstallation / / Inspection Disassembly p ...a.... .. e . . ..

87-138 In'lb) usinga vacuum mmHg(19. gaugeusedin Step1 and placeit on 3.1--0. to 2. mmHg(19. ll it is not omm (0 the and the In).ium applied1ounit CLEARANCE Pushrodlcpiston cle€ranc€ in) 0.4mm 5OO Approx. Apply500 mmHg(l 9.6mm(0. lnstallationnole ]{aster cylinder Plston to push rod clearance Siandard type Turnthe adjusting cylinder. Turnthe oftheSSTclockwise fullyretracl gauge nut rod. By maklng the above adiusimsnt.BRAKESYSTEII' CONVENTIONAL Removal note Brake plpe Disconnect brakepipefromthe mastercylinderwiththe the ssT.7 inHg) vacuum the powerbrake unitwitha vacuum oump. and the the between endotthegauge 4.016 in) inHg) 0. Cautlon . Vao.4-o.7 Recessedtype lhe to 1. Note . Place SST on the master the boft until it bottomsin the push rod hole in the piston. Measure clearance push rod of the power brakeunit. Do not allow the brake nu|d to get on palnted surfaces.m(100-160 cm-kg.lhe clearancebe' twson the push rod and pFton (atter installation ol the brake master cyllnder to ihe power brake unll) wlll be as shown in the iable below.P P-'r 1 .004-0. Attachthe SST to the power brakeunit. Cautlon .024 (0 0 mmHg inHg) (0. Invertthe adjustment the powerbrakeunit.7InHg)vacuum 2. Install wlih ihe gauge rod tully retracted.016-0. Apply5OO PU. loosen pushrod locknut turnthe pushrodto makethe adjuslment. Tighteningtorque: l0-16 N. 1. It it doea. wtpe lt off lmm€diately.

Pushlightly the endof the SSTgaugerod to be sure in it is bottomed the mastercylinderpiston.P BRAKESYSTEM CONVENTIONAL tl qil ti untilthe nut 3. Turnthe adiustino ottheSSTcounterclockwise brake gaugerodlld co.ushrodan amount equaltotheclearance at B. Pushlightyonthe endof thegaugerodto be sureit is seat' nut the that ed. Verify thereis no gap between adjusting and SST body. ingtheadjusting SettheSSTontothemasler as shownin the figure. below.tacts pushrodendol lhe po\.and note any nut the between SST bodyand the adjusting clearance (clearance or between body and the mastercyljnlhe B) as the der (clearance Adiust pushrod asnecessary outC).and meason nut the between adjusting andthe SST urethellearance body.ver the unit. Pushliohtlv theendot theSSTgaugerod. The thrsads of ths push rod ale specially deslgned so that the bolt becomeshardet lo turn paal a car' tain polnt to preventloosenlng ot the bolt' Tum the boltbnly wlthin this range whsn adlusting' Clearance at B 1.turnthe nutto lengthen powerbrake measured unit. Caullon . the 2. 'fuf'f"J "u' o-'!srwe 4.dadlng wlll occur. on 5. when pushing useonly enough prsssure to bottom the rod in the pi8ton' lf too much presaurs is aF plied a talso . linedin "Adiustment" CIEAFANCE(C) clearanceat (B) at Clearanc€ (C) at No clearance (B) or (C) Too long OK Adlusiment Note . Bemove SSTfromthe powerbrakeunitwithoutdisiurbthe cylinder nut. P-12 . usinothe SST.

lhe clearancebe' tween the push rod and piaton (afler Installation of the brake maater cyllnder to the power brake unli) wlll be aa shown In the iabl€ beloyr.turnthe nutto D1 shorten powor the brakeunitpushrod an amounl equal to the difference.BRAKESYSTEM CONVENTIONAL Clsarance at C 1. -t\ ---- \q AqJUSTING NUT 2.7 inHs) 500 Pushrod-tcpistonclearance 0. (Reter to page P-6. Measure recordheightD2 of the gaugerod.) (2) Check for lluid leakage. the Tlghtenlngtorque: 13-22 Nrn (1. (Reter to page P-6. Turntheadjusting until SSTbodysets nut the squarely on (Iurn only enoughlor the bodyto the master cylinder. Measure record and heightD1 of the gaugerod. Vacuumappliedto unil 0 mmHg(0 inHg) Approx. and 4. mmHg(19. 10-16 finb) Note .) P-l3 .6mm(0.3-2.4mm(0-004-0. By making the alrove adiustment.016 Br. CLEAAANCE Note . Subtract fromD2ithenusingthe SST. touch.ke pips Tjghten brakepipeflarenut withthe SST.016-0.kg.4-0.2 m.) 3. Atter lnatallatlon: (l) Add brakelluld and bleed air.1-0.024 in) in) 0.

BRAKESYSTEM CONVENTIONAL
DEassembly / InsPectlon, As8€mbly Cautlon . S€cure ihs ma3tet cyllnd€r flange In a vla€ when ngc€ggary. . Replace the plEton assembly, it neca€s8ry. 1. Drainthe brakelluid Note' to referring Disassembly in z. oisassemote the ordershownin the figure, and repair or replaceas necessary 3. lnsoecl all Darls to referring A$€mbly Note 4. As;mbb i; the revers;orderot disassembly'

TYPE RECESSED

I
FEPLACE

FEPLACE

5.9--!J (60-100, 52_a7)

\a----^
5.9-e.a 0o-1@. 52J7)

STANDARDTYPE

1. Cap set 2. Float 3. Fluidlevelsensor 4. Screw 5. Reservoir Inspectfor damage 6. Jointbushing 7. Snapring page note.......................P-15 Disassembly 8. Spac€r 9. O-ring 10.Pigonguide page note.......................P-15 Disaasembly

1'1. Cup 12.Slopper '13. piston assembly Primary page note.......................P-15 Disassembly '14. screwand O-ring Stopper ........ note................... pageP-15 Adsembly piston assembly 15.Secondary .... note Disassembly .,........... ....pageP-15 '16. O-ring body cylinder 17.Master for lnspect damageand craclG of lnspect inside body for corrosaon

P-14

CONVENTIONAL BRAKESYSTEM
Dlsassemblynoie Snap dng Pushthe pistonwith a screwdriver remove installthe and or pliers. snapringwithsnaFring

Plstonguldeand prlmaryplatonassembly guide piston Remove piston the assembly primary and assemblyby gradually blowing compressed into cylinder. air the

piston assembly Secondary pistonassembly graduallyblowRemove secondary the by ing compressed intothe cylinder. air Cautlon . Uae a rag lo stop the secondary piston assembly.

Aaaembly nole Stopper screw and O{ing 1. lnstall newO-ring the ontothe stopper screwpiston 2. Pushthe primary assembly fully. in 3. Install tighten stopper and the screw. Tighteninglorqu€: 5.9-9.8 m (60-100 cm-kg,52-87 InJb) 4. Pushand release piston verjty thestopperscrew the to that is installed correctly.

P-l5

BRAKESYSTEM CONVENTIONAL

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POWENBRAKE UNIT Qulck Inspection (On.vehlcle) Power brake unit functioncheck (Shple method) Siep 1 the depress brakepedala few slopped, 1.Withthe engine nmes. start 2. Withthe oedaldepressed, the engine. down starts pedalmoves the afier 3. lf immediately theengine unitis operating. the slightly, Step 2 1.Stanthe enoine. 'l atterit hasrun tor or 2 minutes 2. Stopthe engine withtheusualtorce the 3. Deoress pedal wth shorter 4. lt the firstpedalsroke is longand becomes the strokes, unitis operatng. subseouent valve of for inspect damage thecheck is 5. lf a oroblem found, Repairif the installation or vacuumhoseand ev€mine and inspectlt once agatn necessary,

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/A\FtFsTSECONO

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\ ^W,r:gs"?^1"" natureol theproblemisstillnotclearalterthethree(3) ll the
in checkdescribed folloi the moredetailed stepsabove, "Methodusingtesters," below

Step 3 1. Startthe engine. the 2. Deoress pedalwiththe usualforce. wilhthe pedalhelddepressed the 3. StoD enoine c. Holbthe pedaldownfor about 30 seconds. the doesnotchange, unitis operating. 5. lt the pedalheight valve to lor check damage thecheck 6 lf ther; is a oro6lem. if lheconnectonRepair neceshose,andcheck or vacuum saryand checkonceagain.

(Method uslng tesiers) gauge, pedaldepresand gzuge, vacuum donnecta presstrre the Afterbleeding in sionforcegaugeadshown the figure. gauge, the conduct testas described ak tromthe pressure in the stepsbelow. Note . Use commerciallyavailable gauges and pedal depressionlorce gauge. a) Checklng lor vacuum loss Unloadedcondltion 1.Startthe engine. gauge reacnes readlng the when vacuum engine 2. Stopthe 500 mmHg(19.7inHg). gauge 15 seconds ll thegauge ior the 3. Observe vacuum shows475-500 mmHg(18.7-19.7 inHg),the unit is operaiing.

P-l6

CONVENTIONAL BRAKESYSTEM

P

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R @ II \k9
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A

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F ,4"
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196 N (A) kg, 44 rb)

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Loadedcondliion 'l. Start engine. the pedal 2. Depress brake the witha lorceof 196N (20 kg, 44 tbt. pedaldepressed, 3. With brake the stopthe enginewhen the gauge vacuum reading reaches mmHg(19.7inHg). 500 gauge 15 seconds.lf thegauge 4. Observe vacuum the for shows475-500 mmHg(18.7-19.7 InHg),the unit is operating.

Fr
a
E

6\

@ \\v 16r
TI
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tlt \u 1 | \ &

b)Checkingtor hydraulicpreaaurc '1 lf,withtheengine (vacuum mmHg), iluidpresthe . stopped 0 sureis within specification, unit is operating. the

,

ps) Flurdpressure kPa (kq/cm?, 196 N (20 kg, 44 lb)

1,275 185) min. {13,

whenthevacu2. Stalr engine. the Depress brakepedal the umreaches mmHg(19.7inHg).lf thefluidpressure 500 is withinspecification, unitis operating. the

u.'"""\r$

,
196 N (2O kg, 44 lb)

ATX

[4ry

ps) FluidpressurekPa(kg/cm', 7,26004, 1,053) min. 5,690(58, 825)min.

P-17

P

BRAKESYSTEM CONVENTIONAL
Check valvg Inso€ction irom checkvalve) hos€(withintenal the 1. Disconnect vacuum side. the engine

side fromtheengine to and 2. Applysuction pressure the hose the Verifu air flowsonlvtoward englne that Cautlon . ll the check valve is bad, replace the hose containing the valve.

/ Removal Inatallation '1.Remove the ordershownin the figure. in orderof removal in 2. lnstall the reverse
REPLACE FEPLACE

r'-25 (1.9-2.6, ra-rg)

e? \ l
\
l{n (100-l@ dr-lq, a7-l$ lFlb)

6. Nut cylinder assembly 3. Master 1. Conneclor brakeunn T Power Nole lnslallation 2. Brakepipe pageP-11 8. Gasket ....................... Removal Note..pageP-11 hose 4. Vacuum pin pin pageP-13 5. Spring and clevis

'*'l*:1..):::

Caution Take the tollowing steps after Installation: . Add fluld and bleed the alr. (Referto page P-6.) . Checkall pais for lluid leakage.(Referto pageP-6.) . Adlud ana check the brake pedal operation.(Reterlo page P-{.) . Makean on-vehiclecheck ot the unit. (Reterlo page P-16.)

P-18

CONVENTIONAL BRAKESYSTEM
OUALPROPORTIONING VALVE lnspeclion gauges (9,810kPa [100kg/cm2, 1.Connect two pressure 1,422psil)to the brakepipeswithadapters shownin as the figure. Adapterand llare nut tlghiening torque: 13-22 Nm (1,3-2.2 n-kg, 10-16 ftlb) Note . Disconnect and connect the brake plpes wlth the

ssr,

f
B'

2. Bleedthe air fromthe brake system. (Reter pageP-6.) to pedal themastercylinder pressure 3. Depressthe brake until equals thenrecord A; rearbrakepressure A'. pedal pressure 4. Depress brake the again, applyadditional untilthe pressure equals thenrecordpressure B; B'.

Fluid pressure
B l',lTX ATX

kPa (kg/cmz, psi) B'

2,943 2,943 (3O, 42n l3o,427) + 196 (2, 28)

5,886 (60, 8s3)

(39, 3,826 555) + 294(3,€) (36,512) 3,532 * 294(3,43)

Cautlon . Do not attemptto adiust the dual proportionlng valve. . After the inspection,bleedthe air from the bmke system and checkfor tluld leakage. . It the measurements not within specitlcatlon, are replace the valve assembly.

neplacement 1.Remove the order in shown thefigure. in 2.Install thereverse in order removal. ol

1.Brakepipe RemovalInstallation page p-20 / Note.........

2. Boft 3. Dualproportioning valve

P-l9

BRAKESYSTEM CONVENTIONAL
Removal / Inatallation note Brakepip€ lhe Loosen ahd tiqhten brakepipeswiththeSST.

FRONTBRAKE(DISC) Ouick Inspection(On-vehicle) Dlsc Dad it and 1. Jaik up thefrontof thevehicle support withsarely stands. the 2. Remove wheels. of thickness the pads the 3. Verify remaining 2.0mm(0,08in) min. Thickneaa:

Reolacement Disc pad in 1. Remove the ordershownin the figure. orderof removar. in the reverse 2. lnstall

1.M-spring 2.W-pin 3. Padpin

shim 5.Antisqueak 4. Discpad 6. Outershim Note lnstallation p. .e . . . . . . . . . . . . . . . . .a.g . P. - 2 1 7. lnnershim . above 1nspoction.................

P-20

.a .......Flexible hose 2. Discpad assembly 1nspectjon.. Inslall the reverse In orderof removal 6) se-ae 1.. Discplate lnspection... ........ Removal Installation / Callper 1............ the the fully with the SST and an old pad.. ... in 2. P-21 ..CONVENTIONAL BRAKE.. e .2 3 p .... ... .-.. P-22 page ... ...... .. Remove ihe order in shown theliaure...... Bolt 5... pageP-22 4... Padpin 3... .....g P 6.. ...... Caliper Disassembly / Inspection / A s s e m b l y ...........SYSTEM Inaiallationnote Dlsc pad push piston inward When installing discpads..... ...

ck br oil or grease thefacing. ry\. lvleasure thickness the lining.) . ot the Standard ATX: lSmm (0. Check for fluid le8kige. in) Runoutr 0.39 In) suredgeof thecontact at the 2. Theremust be no whselbeating looaoness. (Reterto pege P-6.P BBAKESYSTEM CONVENTIONAL Cautlon Take the following stops aftel Installstion: .1mm Cautlon .ih€n vertfythai the rcar brakesdo not drag rvhlle rolatlng the whe€|. CheckMsually damage wearof the guideplate Dlsc plate '1-Measure thickness the discplate.71 In) MT* l2mm (0. and deterioration of the 2.09 in) lrlnimum or for 3.004 max.) . Ch. Measure runout theouter faceof the disc Dad.47In) llinimum ATX: 16mm(0.63 In) MTx: lomm (0. cracks. \ - Inspectlon DIsc oad wearor on 1. Depressthe brakepadala iew time3. (Refer io Prge P-8. (0. Add lluid and bleedthe ah.0mm(0. P-22 . Speciliedthlckness:10mm(0.abnormal or damagelrom heat.39 in) : 2.

.. 2..CONVENTIONAL BBAKESYSTEIII CALIPER Dlsassembly/ Inspection / Assembly 1.. 8.... Disassemble the ordershownin the figure. Caliper body Inspect damage.... a\ P-23 .. for wear... tor wea... 52-73 & !) pin 1.. Rubber and bleeder cap screw.Sleeve 2.relerdng Dlsassembly in to Note... Piston seal pageP-24 Disassembly Note.......?t' Dlsa&semblynote Rubber cap and bleeder screw Remove rubbercap and remove bleeder ihe the screwlrom the brakecaliper withthe SST................ Dustseal 6. Below 4.. !€lgeP-24 Inspect damage.....and rust tL'-:'<32 ... uoot 3... Assemble the reverse in orderof disassemblv.. ?3 w^ (60-90 frr9.. Retaining ring 5.. Piston Disassembly Note....and rust 7....

the P-24 . Blowthe compressed slowlyto prevent pis. blow a piston of thecaliper' out the air through holeto forcethe Caution . ton trom suddenly Platon seal Remove pistonsealfromthe brakecaljperwiththe SST. the air popplng out.BRAKESYSTEM CONVENTIONAL Plston compressed then in ol Place oiece wood thecaliper.

Holdpin 1..... . 4. . as all 2... Lowerreturnsprang '16.... (1... P-26 6. Trailing note P lnstallation ....Wheelhub and bearing pin Inslallation note 5.. . ....BBAKESYSTEi' CONVENTIONAL REANBRAKE(DRU ) Ouick lGpectlon (On-vehlcle) 'L Jack up the rearof the vehicleand supportit with safety SI€LNOS.2...... Brake page above Inspection....-. Holdspring plate note 25.. Screw page Assembly.. .Upperreturnspring 'I1. Clevis page assembly ... Hubcap / / Disassembly lnspection 13.... .. 10-16) 13---22 ro-ra -{rm-160 cn*e... 20...... .Leading shoe drum 3.. Bemove liningin the ordershownin the figure.. assembly Wheelcylinder 12. pipe Brake 24..Holdspring 2...Nut Ouadrant spring 7.. ...) of thickness the lining. ' . Holdpin '17..0mm(0. referring Removal to the 1. Spring 22.Operating lever 4.Anti-rattle spring P-25 .P a g e . P-26 18. the the 3.......(Seebelow.. P-27 14.Hub spindle 8... Gasket Inspection. . 2.. Remove wheels....Locknut pin 15.. .. referring InstallatlonNote..04in) min.... tlemove brakedrum.......Backing Removallnstallation / shoe 9... . Removal Inspection/ Inatallation / Note..Bolt 10.. .. Verity remaining the Thlcknessr1. above page . 67-130 @ f '19.. to 3. P-26 21. Install the reverse in orderof removal.... Inspect partsand repairor replace necessary.. 23.3-2....2 6 Inspection. ..

DeDress brake the $d rcat brakesdo not dragwhile rota ng the wheel.) pedala tew times.smm (7. ch€ck for lluld teakage. Check the parking brake lever atroke.z m-tg. the uniilit touches backing Inspection Brakedrum ol 1.) ( \ . Measure innerdiameter the drum. (Retef io page P-28.15 in) Cautlon . \ - Removal/ Inatallallon noie Blake pipe pipetrom^othewheel cyf the Disconnit or connect brake inderwiththe SST.BRAKESYSTEM CONVENTIONAL Caution Take lhs followlng sieps atler inatallation: . . then verify thai .0mm Maxlmumdiamster:18l. Tlohteninqtorque: is-zz-N. (Relerto page P-8. Whenrepairingor replacingthe drum' chsck lhe contact wlth ihe sho$. Add lluid and bleed the alr' (Rster to page P-6.g-z. P-26 . the (7.) . 10-16 ft-lb) note lnstallatlon Baqklngplate in by gieisetotneareaindicated thearrows thellgure Appty BACKING PIATE Operating lever the in Aaiust thtouadrantas shown the figureby moving it plate.09 in) Slandalddiameter: 180.m (i.

CONVENTIONAL BRAKESYSTEM 2. Nots . Replacethe wheel cyllnder assemblylf a problem is found. / .\ \ olE0Px460 WHEELCYLINDER Disa$smbly / Inspectlon/ Assembly Caution . 1. Check scralches. Wheelcylinder body Insp€ct corrosion damage lor and P-27 . Piston cup 4. tor uneven. abnormal or wearinside the orum. Steel ball 7. Disassemble the ordershown the figure. Piston Inspect corrosion damage tor and 3. hspect all parts and repair or replaceas necessary. Assemble the reverse in orderol disassemblv. Spring and cup 5. Repair the problemis minor. 3. Rubbercap and bleeder screw 6. Dustboot 2. in in 2. '6P 6 0lE0Px{33 1.

Afteradiustment. ino lamD (2) Ve-rify the rear brakesdo not drag ttiat P-28 . Stopthe engine. Tiohten loosen adiusting points: checkthe following 5. le' brake ON.pullthe parkrng (1) Turnthe ignilion swhch ' ' parking warnbrake that and ver onenotch. brakelever Stroke: 5-8 notches Adlustmenl the and start 1. Before adiustment.ck thatthestroke withln is pulledwitha lorce of 98 N (10 kg' 22 lb). verifv the illuminates.P GUIDE TROUBLESHOOTING Problam Bleke3 do not PARKINGBBAKESYSTEM PARKINGBRAKESYSTEM Possible cau6e lmprcperreturnof parking brakecableor imprcperadleverstroke Excessive Brakecable sluckor damagsd B€kefluidor oilon linrng or sudace poorconlacl Hadening lining of Repair adjusl or P. screwas necessary' the or 4. Remove holecover.g€ P. theengine depress brake in is pedalseveraltimes thevehicle moving reverse. to TYPE) BRAKE(LEVER PARKING lnagection when specification the parking ts Ch.29 Parldng brsko does nol hold well P-24 P-29 G nd or rcplace BRAKESHOE PARKING Removal/ Inspection/ Installatlon Refer pageP-25. the 3. while 2.

. .PARKING BBAKESYSTEM PARKING BFAKE CABLE Removal Inapectign/ Installation / Caution . . . . . Power windowswitch connector 2.r-2.c .q 1a-. Atter Inslalling. n . Install the reverse in orderof removal 19-25 (r. . Cablecover 6. S e.i . Inspect partsand repairor replace necessary. . ln 2.te) 1.t . . . Clevis 8. Adjusting screw 5. Depre€sthe b€ke pedal a tew times and verlty that the rear brakeado not drag whlle rotaiing the wheels. . Rearconsole Removal/ Installation . 1. Springpin pin 7. . . . adiust the parking brakelever stroko. Parking cable Inspectfor damageand P-29 . Clip 4. . . . Clip L Cablebracket '10. . . . all as 3. oS 3. . Remove the ordershownin the figure.

. iriiir irrJignition svyttchON.Power windowswitch connector 2. Parking Inspectfor damageand wear P-30 . in 2....Remove the ordershownin the figure. and verlfy that the parklng brake wamlng lamp lllumlnatos with the lever pulled one (l) notch... . Install lhe reverse (Refet pageP-28.... Rearconsole Section Installation. in 3. ttre pa*lnS brake swltch ao that h contacts lhe parking btaks lever when th€ lever ia ft..rlly released... '1....) to adjustthe parkingleverstroke. (1.4-2. ra-19) '1. 4... Inspectall parts and repair or replaceas necessary.. Parklngbrake switch 4.. Adjustingscrew brakelever 6. Clip 5. Afterinstallation. orderot rcmoval.BRAKESYSTEM PARKING PARKINGBnAKE LEVER Romoval / In€psction / Inslallailon Caulion -tnitait . S Removal/ 3.4..

........................... o-6 ouTLtNE......................... o-2 ....... GU1DE.....AND TIRES WHEELS o-2 SPECIFICATIONS... o-6 WHEEL BALANCE ADJUSTMENT...4 o-4 TNSPECTTON / A0JUSTMENT.....-............... o-3 TROUBLESHOOTING o-4 WHEELS AND TIRES ABOUT WHEELS NOTES SPECIAL Q-4 ANDTrBES.......---. TIRE Q NOIESREGARDING REPLACEMENT....... o-6 REMOVAL / tNSTA11AT|ON.....

psD 180(r 8. 26) SpareTire Temporary Item Size otlset Pitchcircle diameter lVaterlal Size Sp!clflcallons mm (n) mm (in) 14^47 .94) Sieel T105/70D14 41214.94) 78H I75/60R14 Size kPa(kg/cm'.77) 100(3.2.psD o-2 .6Oj Tire A|l pressure hPa(ksicm'.OUTLINE OUTLINE SPECIFICATIONS StandatdTlre llcm Speclflcsllons 14x51l2JJ Size Olisel Pitch circle diame!ff mm (in) mm (n) 4511.77) 45 11 1oo(3.

lalfunclion st€€ringsystem of Maltunction suspension of lrcorr€ct ti.laltunclion suspen€ion of Unequal air prcssures tire Msltunction taking sysrem oJ lnsuJf icient air'pressure tire lvlallunclion st€€ringsyst€m of l\.btttty Uneven(one€lded) bf3king H.16|rli.lalf unclionof suspension Insuflioern air pressure tre Maliunctjon stee ng syslem ol Majlunctjon suspensjon ol Adjust o-2 S€clion P Q-2 S€ction N Seclion R Stcldng whc€l doean't retuan prop€fly o-2 kion N S€cton F Q-3 .avy handling Malfuncljon sloeringsystem oi l\.ing whe6l vibr.l Incorr€ct air pressure lire lncorrecttire air pressure Insufficient air pre€sure lire Detormed wheelor tire E)(cessive and $heel runoui tire Tlghten Cracked wom engine or mount rubber Crackedor wom lransaxlemountrubber Adjust o-2 (>2 o-2 o-5 Road nolse or body vibretion (Sto6.s ajf pressure Excessive irfegulartire wear or Malluncfion sieeringsystom of Malfunclion brakng systsm of Malfunclion suspension of Unequaj air prcssur€s tire Deformed wheelor tire Section M S€ctlonN SeclionR Stalrlng whe€l pulla lo one sldo o-2 Seclion N S€ction P Seclion B Q-2 Tighten Section N SeclionR Ceneral drlvlng Inat.lly) Excessive and wheelrunout tire Loo€e nuts lug lnsutticiont air pressure tir€ pr Damaged worn fronl wheelbeadng l\.tes up/down) Q-5 SectionB Seclions J.TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Probl€m iltegulfi tirc wear Posaible Cau3e R€lerto page O-5 lor delals Actlon Pag6 Premalure tlre Tiae !qu6.K Tighten o-6 "Shlmmy" occurs (Stc€rlng wheel t.

Be surethe air valve to 6. a softcloth. not allowboiling do vehicle steam is washtnemas soonas wheels' (suchas saftwater roadsalt9geton aluminum or compounds 3. Tire Wear tread.never wirebrushor sandpaper' use aluminum 3. Uie i wirebrustr. clothto cleanand remove rustand dirttromthe 1m edgeand the Z. A tireshould replaced thewearindicators expos€d. TIREREPLACET'ENT REGARDING NOTES ontothe wheels fromor mounted pointswhentiresare to be removed Notethe following the 1. . Aluminum the waterto contact wheels. cleaned.nails. Whencleaning in items embedded the tiretread' glass. the inflate tireto 250-300 kPa(255-3. 5. otherforeign and any +. a wheels. Aitlrhountind the Thenreduce pressure are ontothe rimandthatthere noair leaks. correctly thatthe beadlsseated level. Checkthe remaining tread Remalning tires: 1. sureto usea pieceof rubberbetween be a L tt a tire ironis usedto change tireon an aluminum Workshould doneon a rubbermat. rim bead. Standard 50ortot tread Snow tiles: are it be 2. z. or rougnsunace. is and deformation otherproblem found. Be carelulnotlo damage tire bead the rim boad'or the edgeof the rim all or sand-paper.6mm(0.06 kg/cm''3tj-42 psr)venry a tneontoa wheel.not on a hard be it and the wheelto avoiddtmagelo the wheel. Remove iebbles. Do not usewheels tiresotherthanthe specified them'usea softcloth'nevera wirebrush'lf the Whdnwasning scratched. Applya soapysolution the tire beadand the edgeof the rimbefore-molnllng . is installed correctly.WHEELSAND TIRES AND TIRES WHEELS AND TIRES NOTES ABOUTWHEELS SPECIAL types or 1. wheels easily are 2. to the specified wheel. ffiffi Q-4 / INSPECTIONAINUSTMENT Visual Inspeciion lnspectlon(flre and wheel) damage if be A theel or rireshould replaced any cracks. 1.063in) min. ll alkatine detergent possible prevent Useonly a neutral to damage.

Tighteningtorque: 88-118 N. oll-ol. includjng sparetire. Measufe adjusta[ press!€ and . Repailor repace aie and SHOULDEB WEAF CENTEBWEAFI 1b) . rncorrcct cambs (onesde worn) .Indrecl lmber or cssl€r .WHEELS AND TIRES Abnormaltlrs wear patterns Abnormal wear ti.r@nd brakedrumor die . the Air pressure:Reterto pageO-2 E Air Leakage Veriiythatthereis no air leakage fromthe air valve. Repai. and . Othermehanicalproblem . 65-87 ft-lb) Q-5 .or repla€ dle and TOE-INOR 'OEOUT WEAF Alr Pregsure Checkthe pressure alltires. Mafunclion suspenslon nS .Flefer thechart thepossjble to for causes actions.e shown theillustration ocin can cur. necessary. Measurg adjustair pregre and (c) FEATHEBED EDGE .m(9-12 m-kg. Loose Lug Nut Verify thelug nuts tightened thespecified that are to torque. air of the with gauge. Undeinlalon (bolhsdes worn) . an air pressure lf adjust air pressure.

1 oz)' It the total weight exceeds I 009 (3. One balanceweight. wheel (at Maximumunbalance rim edge) whesl: 1Og(0.06) 2. welghb for steel or alumiSelectsultablebalance num alloy wheela. After. Do nol Include"TEi'PORARYUSEONLY" spar€li. lebalance rlm.5 ou) on lhe one atter movlngthe lire aroundon the slde. Jack uo the vehicle support on safety probeof a dialindicator theMeel.65-87 ttlb) Cauilon . Caution .rotiate tires tire To prolong lifeandassure every7500km (4650miles).it may cauaetranaaxledamag€. Setthe one through lull revolution ure ths runout Runoutlimit Radialdireclion Lateraldirecnon 1. surfaces contact 1. Do noi uae more than lwo balance welghts on the lnner or outsr gide ot the wheel.olatlng the tlres.) fted air pressur€.ANDTIBES WHEELS Wheel and Tlre Ruaout stands it and 1.5(0. max. BALANCE WEIGHT + g o-6 . The wheel-to-hub torque specitied the 2. Ugeihe best tlres on the front axle' .ansaxle models.0 (0. Retighten ihe lug nuts to the specilled torque alter aboui 1000km (620 miles)ol drlvlng.5(0. Tighten lug nutsto the Tlqhteninqtorque: -gS-lt8 Hm (g-rz m-kg.35oz) l4-inch Caulion . adiust sach tlr6 to lhe specl(Reterto page O-2. Do not use an on-car balanceron automatlc t.e in rotailon.08) mm(n) Sleel Almimum if the 3. andmeas' againsl 2. 609 (2. TIRE ROTATION the tire uniform wear. ADJUSTMENT WHEELBALANCE or or unbalanced if a tire is repiaced ll a wheelbecomes to withinspecification mustbe rebalanced the reoaired. Attach the balancsweightstightly to ihe wheel. Replace wheel necessary. REIIIOVAL/ INSTALLATION lnstallation mustbe clean. .10) 2.

........ AND R-20 REAR SHOCK R-23 TRAILING ARMBUSHING......EARSUSPENSTON BEAM AXLE) R-19 PREPARAT1ON...... RTROUBLESHOOTTNG GUtDE.........6 PREPARATTON ................................................. R-15 FRONT LOWER ARM...................................................... R.............. FRONT R-l0 SUSPENSTON R-r0 PREPARAT|ON ....................................6 PREINSPECTTON .................-......... AND R-II FRONT SHOCK ABSORBEF SPRING.... ............ R-l9 ABSORBER SPRING.. R........................................6 WHEEL R.............................. FRONT STABTLTZER .. WHEEL ALTGNMENT .......... (STRUT)....4 SPECtFtCAT|ONS..........6 RR................ B-26 TORSTON BEAM AX1E.....8 REAR A1IGNIVENT............ R...... FRONT WHEEL ALtGNT\...................1ENT..............................................SUSPENSION rNDEX. R..........................................................-.........................2 R.....................4 ouTLtNE..... B-17 (TORS|ON f..

... .. ....... 1 n s t a l | a t i o n .. . e ..... ... .12+ 0... ... . 2.. Front ...0012' + 10') ANGLE: O. ..... Frontlowerarm / / Removal Inspection .-.. R-2 .. ...7. B .. .... ... / RemovalInstallation..12in. .5O' 4 45' CAMBEFI ANGIE: 16l|0 + 45 CASTER 14625' ANGLE: KINGPIN and shockabsorber spring 1..INDEX FBONTSUSPENSION FRONI WHEELALIGNMENT ANGLE:41' + 2" (INNER).. Front / / Removal Inspection p .. ..1.a.34" + 2d (OUTEF) STEEFING MA)(IMUM TOT L rOE-N 3 a 3hm (0..... pageR-11 / / Inspection Disassembly pageR-12 Assemb|y.. .... . .. .... ...g .. . . pageR-15 stabilizer 3. .... . . Installation... ...

.... Trailing arm bushing pageR-23 Removal / Insta|jation....121 o............. Torsion beamaxle Removallnspection / / pageF-26 1nsta|Iation................. REAR WHEEL ALIGNMENT * TOTALTOE-IN:3 3mm(0............... 3. R-3 .oclo' + iO) -Oor5' + 45' CAMBEF ANGLE: 01Eotx{o3 1......12in...... 2... Rearshockabsorber spring and Removal/ Inspection / pageR-20 Insta|1ation...................INDEX REARSUSPEI{SION 6f^...

36) 90.r {0.0 03.5(14.74) 373.0(3.59) Tvpe D|arneler mm (in) degree angle Camber 3+3(0.70) 7.39) 1O.49 Shockabsorber Stabrlizer gas (!ow i:Fo' ca oouuteaa'ng pressrre cnargeo) mm (n) 15 (0.6 {15.!F.t .jack.R OUTLINE SPECIFICATIONS Front Suspension OUTLINE fu* Tvp€ ldentiiication MTX Slltrl ATX Lightgreen Orange 10.24 385.ik tu[: radiator loolsin designated tevelst sparctirc.O 95.15) 6.40) 95.ancl and oit and cootant engrne at specified R-4 .12+0.12) -0015 + 45 (Unladed.0 (3.74) Coilspring Wlrediameler Coil centerdiameter Freel€ngth Coilnumber mm (in) mm (in) mm (n) tums (0.94) Outer mm (in) 3*3(012r0.3) 'lMain ident'tication markcolor:On s€condco Jrombottom 'lAuxrl'ary maa dentrlication color Onth:rdcol lrombotom posrtions .2(0.54) 334.0(3.12) oo50' + 45' 14"25 RearSuspension llem Spcdflcatlon Tvpe ldenlilication Orange Coilspring Wirediameler Ccil centerdiameter Freelength Co number Type mm (in) mm (in) mm fin) 9.18) Tvpe Stabilizer Diameter sr€€nng angre Wheelalignmenl (Unladed-) Totaltoein Cambs angle Caderangle Kingprn angle mm (n) 7_89 double_acting(OiHilled) Cylind cal 24 (0.

bility Replace Adjust tle.20 B-12.20 R-15 R-17 F-6 B-15 SectionN SectionQ B-6 SeciionN Section O R-12.20 R-17 Replace a-17 R-12.TROUBLESHOOTING GUIDE R Action Page TROUBLESHOOTING GUIDE PGsible Caus€ Aody"rolle' Woln or deteioratedslabilizerbushing Wornor deteriorated lowerarm bushing Malfunction shockabsorb€r of lvlallrnclionoi shockabsorber Eody leana Wornor deleriorated lower arm bushing Abnormal nol36 trcm suapenaionsystem Poorlubricalion wearol lower or am balljoinl Looseness perph€ral of connectons Maltunclion shock ot absorber Wornor deteriorated slabilizerbushng Wornor deterioraled lowerarm bushing Wornor dslerioraled lfailing armbushing Malfunciion shockabsorb€r of Wornor dstedoEled lower am bushing Wofn or deterioraled stabilizer bushinq lmprope y adjustedwh€€lalgnmert Damaged low€rarm balljo'nt lvaliunclionoi sleeringsyslem Damaged unbalanced or wlreei(s) Poorlubricanon wealot lower or arm bal joint lmpropeny adjustedwheelaljgnmeni Mallunclion steedngsystem of Damaged unbalanced or wheel(s) Damaged slrutbearing worn or deteriorated stabilizer bushing Wornor deleriorated lowerarm bushing Oamaged lowerarm ballioint lmpropery adjusled wheel alignment Maliunclion steeringsyslem of lvalfunction brakingsystem of Damaged unbalanced or wheel(s) Damaged lowerarm ballloint Malfundionot shockabsorber Looseshockabsorbermounting Wornor deleriorated lowerarm bushing Wornor dereriorated siabilizerbushing lmprcp€nyadjustedwheelalignment Damaged wom whe€lbearing or .lalunclionol sleerinqsyslem Damag€d unbalanced or Mreel(s) Sluckor damaged lower am balljoinl Damaged sirutbeaing lmproperly adjustedwheelalignment Mallunclion sleeing syst€m oi Damaged unbalanc€d or wheel(s) Tiqhten F-l2.20 R-12 R-l7 a-15 ff-6 SectionN Seclion Q R-15 Tighien R-11.20 R.15 B-15 Poor rldlng contort n-23 R-12.20 R-15 R-17 Seclion M S€ciion N Section Q Genereldriving irct.20 R 12.vy sle€ring Adjusl Sl66ring wheelpulb to ono side Beplace (Eta€ringwheel vlbrat€s circuht€rentially) Sl6€.20 R 12.20 R-11.lng wheel do6n't lelurh pmperly R-l5 R-12 R-6 SeciionN SectionO R-5 .

linkage anyexcesfor and steering the 4. FRONT WHEELALIGNMENT MaxlmumSteerlngAngle Inspecllon the angleby placing fiont steering Melsurethe maximum gauge.12 In) R-6 . play.) sure if necessary. ground havenoluggage and muslbeon level 5. llaxlmum leruright difference:3mm (0.39In). Insbect ballioints slve loosen€ss.replace bearing the bearing 2. or passenger from the in between leftandrightsides 6.replacethe shockab(Refer pagesR-11. lf the vehicleis slow stop shaking. Thevehicle |oao. Thedifierence height to thefenderbrimmustnotexceed the centerof the wheel l0mm (0. on wheels a turning-radius lnward :4loOO' + 2" Outuvard: 34o00' + 2c B: OUTWABD Adluslmenl and tie Lo6sen lettandright rodlocknuts turnthetierods the equaly. lnsDect wireelrunout.) to sorbers. of 7 shaketfb vehic6to checkogeration theshockabsorbers. Gefer to SectionM.) (Reler Section ) to Q the 3.20.WHEELALIGNUENT WHEELALIGNMENT PREPARATION ssT 49 8001605 Jauge PREINSPECTION presand inflations settotherecommended 1. Checkthetire (Referto SectionO. lnsoect frontwheel the if necessary.

Tighten mounting the blocknutsto the specified torque. 4. Adjust toe-in the afteradjusting steering the angle. Camber and Caster Inapeciion gauge.m(3. Note . the 3. 1. Caster : /|(. ll6-174 ftJb) Adiustment Not€ . I/easure caster the and camber. Caster is not adlustable. Tightenlngtorque: (3.WHEELALIGNMENT 2. 2. Attach caster/camber the 5.m(16-24 n-kg. 25-37 ttlb) 3. Place frontwheels a turning-radius the on 2.5-s. turnit 180 degrees and so that the directionindicatorlaces the outboardof the vehicle.1 m-kg. Whenfacingthe indicaloroutboard. Tighten tie rod locknuts.7 m-kg. Push mounting he blockdownward. Remove mounting the blocknuts.' max. Install newlocknut crimpit. 3. the gaugeto the SST. Remove locknut. 1.0-3. Jack up the front of the vehicleand supportit withsafety stands. the Tighteningtorque: 34-50 N. Attach SST to the wheelas shownin the fioure.nrn R-7 .cambcris adlusted by +28'. 6. a and Tightenlngtorque: ls7-235 N. 22-27 lt-lb) 29-36 N. Camberangle: 6c5g' + 45' Caaterangle ' 1c40' + 45' Lefuright diflerence Cambgr: 30' max. 4.

Lower vehicle. at the the between markedlines thefront 4. Fiaise rearol the vehicleuntilthe wheels the oround. Tiohlenlnotorque: -Hm Zz-sz (l. The lell and rlqht tle rods are both rlght threaded' the to lncrease toe. 3t-42 tt-lb) FRONT 4 ALIGNi'ENT REARWHEEL Tolal Toe. the R-8 .a-s. turnthetie rodsequally.g m-ts. iurn thewheels hand. Tighten tie rod locknuis.12+ 0. Measure distance A and rearB of the wheels. Note . One iurn ot the tle rod (bolh sldgs) changF the toein by about 6mm (0.in Inspection clearthe t.24 in)' the 2. Place frontwheels the straight-ahead lowerthevehicle. of by 2.and marka linein thocenter block treadusinga scribing eachtire 3. tiaisethe front of the vehicleuntilthe wheels oround.and marka linein thecenter block.in (dlstance greater al rear than front): 3 + 3mm(0. Csutlon .iurn thewheels hand. ot by 2. Both measuremsnts must be taken at equgl distances trom ihe ground. ioosentheleftand righttie rod locknuts. .12in) Adiustment and 1. tum lhe rlghl tie rod toward the lrcnt ol the vehicle and lhe left tle rod equally toward the lear. Toe.in.WHEELALIGNMENT Tolal Toeln Insgection clearthe 1. usinga scribing eachtiretread position and in the 3.

12+ 0. Install newlocknut a and crimpit. 123-159 ttlb) R-9 . Toe-in is not adiustable. 5. Attach caster/camber the to 4. the Camberangl€: -. Measure camber. 3.ltols' + 45' Nole . Remove wheelhub cao andlocknut.12in) Note . a Camber lnspectlon 1. Attach SST to the wheelhubas shown thefioure. the 2.WHEELALIGNI'ENT FBONT 4. Tighlenlngtorque: 167-216 N|n (17-22 m-kg. Measure distance the the b€tween marked linesat thefront A and rearB of the wheels. Camberi6 not adiustable. the in gauge the SST. Toe-in:3 + 3mm (0.

e_l \. sprrng compressor d-:-:€I-i@ 4s0223 6408 ffi ingallation ot coil spring @ sping 11fr""^i*ii'"" .eq s-. \.e-l 49 Dm4 202 49 DO34240 Puller installer & bushing ot installation Supportblock (Padoi 49 D034 2A0) inslallatronof bushmg 203 49 DO34 Puller& ir'staller (Partot 49 DO3l 2A0) ot installalon b|$hing 49 D034201 inslallstion of 49 01805108 joinl R-l0 .R PREPARATION (sTRUr) SUSPENSIoN FRONT (STRUT) FRONTSUSPENSION ssr 49 0370641 corr screw.4.

. the and Note ..... Cautlon .-. Lower the vehlcle and tlghten them the ap€clfiedtorque wiih the vehicleunladed.d. Frontshockabsorber spring and Installation note. Shockabsorber clinchbolt 3... in 4......(STRUT) FRONT SUSPENSTON FRONT SHOCKABSORBER AND SPRING Removal/ lnstallatlon 1....a.. and install shockabsorber spring........... LoGely tlghten the shock abso..bsrbolls and nuts. Remove the ordershownin the figure.... lusied by +28'.. Install the reverse orderof removal.. the in 3.5-'l2.. 2.. When taclng the indicator outboa...... 5.. pageR-12 Inslallatlonnote Frontahock absorbeland spring Facethe directionindicatorof the mountingblock inboard..... below Disa$sembly / Inspection / Assemb1y.... Nd 4.. adjustit if necessary the and r@-127 O0.... Afierinstallation... Remove wheels. referring Installatlon to Note.. R-l1 .......... Jackup the frontof the vehicle support withsafety and ii stands...Clip 2. t!-tg omax{20 1. camber ls ad. measure trontwheelalignment.

referring AssemblyNote to orderof disassembly' in 3. ( u-' ! L Springseat(upper) ..... Bump and damage for Inspect cracks 12..........C a p rod 2...-...F5. Mounting 5....... Seatrubber 10. Inspect partsand replace necessary.. Assembly stopper 1'1... Adjusting rubber 4.. Dustseal 7...... 3 Disassembly plate 3.. as all 2.....9......(STRUT) FRONTSUSPENSION / Disassemblv lnspeciion / Assembly Note to referring Disass€mbly in 1....Disassem6le the ordershown. aO-54) @-' g- @---@ @-@ @--@ (A)-ro #-.......... Bearing Inspect wear and damage for R-l2 .......... Assemble the reverse 11-6) I a 55-63 (5.............. B-14 Assembly 9............ ffi iq 1 .Coilspring pageR-13 note.Washer 6. Piston nut pageR-1 note.........Frontshockabsorber pageR-13 Inspection.... page note.........

FRONTSUSPENSTON (STRUT) Dlsasagmblynote Plslon rod nut 1. Caulion . Compress coilspringwiththe SST. noi . Loosen piston nuta fewturns. 1. 1. Verily the operational doesnotchange that that lorce and thereis no unusual noise. rod the Do Caulion . Install coilspring thatthelower ofthecoilspring the so end is s€ated the stepol the lowerseat.Secure mounting the block. the rod 5. the 4.Compress coilspringwithlhe SST.n a vise. Remove coilspring. the 2. Use protective plates in the iaws ot the vlse. 2. Remove piston nut. Use proleclive plates in lhe iauvsol the vlse. Inspect damage for and oil leakage. Compress expand shockpistonat least and the threetmes. Do not rcmove lhe nut. on R-l3 . 2. the Inapection Front shock absotbel Checkfor the following replace shockabsorber and the if necessary.emoveit. 3. Asaembly note Coll spring Caullon .

(UPPEF) SPBING SEAT R-14 . the and shown.R (STRUT) FRONTSUSPENSION Spring eeat (uppel) as to niignthe holeol the springseat(upper) the bracket install springseat(uppeD.

....... to Caution .. all as 5... Front lowerarm Inspection. pageR-16 Installation -......... lnspect frontwheelalignment adjust il necessary..a-5.. in reterring RemovalNote.... Loosely tlghten the lower arm bolts...R-l 8 note page 3. to 4...... stabilizer bushing Installation . the 3.............5-6. Rubber bushing assembly 2.9..5i 32--ao) nepuceEEE . note pageR-'17 5...... Inspecl padsand repairor replace necessary... Bemove wheeland tire.... Lower arm bushing Removal pageR-16 note... R-l5 ........ Balljointdustboot Removal note... the and it f....... 5il-Jl (s..... 6.. pageB-'16 4........4-53................. Stabilizer washer.....-.Jackup the frort ol the vehicle and support withsafety it stands....=_ \t a3-62 (4. Remove the ordershownin the flgure............... Install the reverse in orderof removal............. !12-3a) t" n{b} 1............. ao-so) /a-t{ {a..... 2.. relerring Installa on Note.. Installation pageR-16 note......... stabitizer plate nuts and stabllizer nut 0ower aim slde)....FRONTSUSPENSTON (STBUT) FRONT LOWERARM Removal Inapectlon/ Installatlon / '1.. Low6 the vehicle and tlghten a[ nuts and bols td the specifiedtorqueswirh rhd vehlcle unladei....@.

joinlroiation torque for 2.(STRUT) FRONTSUSPENSION Removal note Ball lolnt dust boot Bemove dust bootwitha chisel. the R-l6 .m(18-31 cm-kg' 15. Rotationtorque: 1. Inspect damage. the Cautlon . cracks for 1.0 N.100 g (63.9 in-lb) Pull scalereading: I.8-3. in Press newbushing withthe SST. Inspect ball (1) Rotate ballpint two (2)or three(3)times the (2i Connecl SSTto theballstud'andmeasure ro the the iationtorquewitha Pullscale. Installthe bushtngso that the F matk faces lorwald. and bending.4 oz) lnsiallation note Lower arm bushing MAAK INSTAILATION Cautlon .800-3. Lower arm bushlng out the Press lowerarm bushing withthe SST Inspectlon Front lower arm Checkfor the followingand replaceif necessary. oo not damagethe btll loint stud.5-109.6-26.

. Liberally the inside thenewdustbootwithgrease.. Inspect partsand replace necassary....R-i 8 note page 3... all as 4. Looselytightenthe stabillzerplate nuts and stabitizer (loweram side).... Stabilizer mounting bracket 6..9. Inspect deterioration wear for and (rear) 2. #----o e---_----4sr2 (... pageR-18 note ... FRONT STABILIZEF Removal/ Inspection / lnstallation 1.... /rO-50) \*i** corrEn pN.0.....Lowerthe vehicle nut and tighlen all nuts to the specifiedtorques with the veliiqteunladed.... Frontstabilizer Inspect bending. 32-30) 1. coat of 2....FFONTSUSPENSTON (STRUT) Ball ioint dust boot 1.. Rubber bushing assembly Installation . referring InstallationNote... a7-54 \ -qK{ \e) o 5!F3a F....Jackup the frontol the vehicle and support withsalety it stands.... for damage and cracks B-17 . Stabilizer (rearand front) bushing Inspect deterioration wear lor and (front) 4.... 2....3.. Stabilizer washer Installation ... Pressthe dust boot ontothe balljoint with the SST...... Remove the ordershownin the fioure.....5-3.. I note 5... Install the reverse in orderof removal...a-5.... c6-r (5... Stabilizer washer pageR-1 Installation .. in 3.... to Caution ......5-7.

Be caretul to Install the stabllizer waahera In the directlona shown.\. Rubberbushing asssmbly it mark with Alignthe bushing theinstallation andattach with the seamfacing forward.s0tt z:ss\g FFoNT GI Cautlon .(STRUT) FRONTSUSPENSION lnstallatlon note Stablllzer washel . R-18 .

Deanng insiallation o. trailing arm trushing 49 02597708 installalion of brake pipe R-l9 .(TORSIONBEAMAXLE) REAR SUSPENSION R (TORSTON REARSUSPENSTON BEAMAXLE) ssT PREPAFATION 49 0839 425C Puller s€t.

. R-20 .... Bumpstopper lnspectlor damageand cracks (loweo 12...............Cap 2....(TORSION BEAiI AXLE) REARSUSPENSION AND SPRING REARSHOCKABSORBER / Inetallatlon Removal/ lnsleclion 'rear ot the vehicleand supportit at the body withsatetystands f ....... note............ 12-171 l-- 1. Lower the vehicle and tighten them to ihe specffi6diorques wlth lhe vehlcle unladed... page note.......... Spring 7. the to in 3. R-22 lnstallatjon 3. (Refer pageR-B) to the 6....... Damper 9...Rearshockabsorber pageR-21 Inspection....R-22 Installation and wear Inspectfor deterioration bolt 5.. Stopper casing 10.. Remove the ordershownin the tigure...... Inspect rearwheelalignment. Coilspring (lower) bushing 8.Dustcover Inspectfor damageand cracks '11....... 5 lnsiall the reverse in Caution l-ioJs... Damper page note. (upper) bushing 4........ Remove wheels tires........pageR-21 Removal page note.....Spring seatrubber 13..... ....6---2............... Retainer pageR-22 Ins{allation note......... Shock absorber .. lnsoect pansand replace necessary' all Note' lo referring Installation orderof removal.......v rbhten rhe shock absorber bolt and nut. Nut ...relerring RemovalNote' as 4..........laii up tne and 2..... *===w \ @ \ I r---------€ o-=___={? lt.......... R-21 Removal (upper) seatrubber 6..

Insp€ct rubberbushing delerioration wear. Discard shockabsorber.Verify the operational that and thatthereis no unusual noise. the R-21 . 2. Allowlhe gas to escape 4. and nontoxic. 1. the Inspeclion Rear shock absorber Checkthe followingand replaceif necessary. of 2. wsar safsty glassss as drllling chlps may be expelled by the pre8aurlzedgas. Inspect damageand oil leakage. 1.Jack up the torsion beamaxleat thecenter the axle. the 3. Remove bolt. 4. 2.08-0. Layihe shockabsorber flat.Drilla holein the shockabsorber Ddll slze: 2-3mm (0. piston and release it.oderleag. Remove nuts. 3. bodv. The gas In lhe ahock absorbells colorless. Dlapo8al ol ahock absolbel Cautlon .Lower torsion the beamaxle.12 in) fromlhe shockabsorber.(TORSION BEAMAXLE) REARSUSPENSION Removd notg Nut 1. . Compress and extendthe shock pjslonat leastthree (E forcedoesnotchange times. (1) Compress shockabsorber the (2) Verify the piston that extends at a normal lully speed. the Shock absorber bolt '1. for for and 2.

7 + 1mm(0. the rhe lowernut. 4.o-z. Tlohlenlnqtoroue: -ttm (i. 6. to 1. and 3. Ja.Retainer.66+ 0 04 the at is iniof threads exDosed the end of thestud.k up thetorsion the through hole to passthe piston and (upper) the retainer.t is-zl l2-17 lt'lb) m-t<g.Nll body. Lowerthe torsion beamaxle. R-22 .tighten uppernutto thespeci5. Install damperbushing the looselytightenthe nuts.BEAU AXLE) REARSUSPENSION CTORSION lnstallatlon note Damperbushing (uPper). Tiohten lowernutso that 16. Aliirnthe shockprston the hoiein thevehicle beamaxlebelowlhe shockabsorber 2. H'olding fiedtorque.

Remove the ordershownin the figure....... Jack up the rear of the vehicleand supportit with safetystands... 2.referring Rgmovd Noie.Washer 3... referring Installation to Notg..... Trailing bushing arm pageR-24 Removai . Rubberstoooea 4.............5-ri.......... Installation R-23 .... lnspectall pads and replaceas necessary........... 5.... 01EOBX{46 1.. Caullon ....--a! {s. 3... pageR-25 Installation note..... Install the reverse in orderof removal........ 2...... Loosely tighten the toBlon beam axle bracket lastenera. nreucE EEII B-irro. note pageR-24 no1e.-6..a. Remove wheels the and tires............... Lower the vehlcle and tlghten them to lhe apecifiediorquea wlth the vehicle unladed.......(TORS|ON REARSUSPENSTON BEAit AXLE) ARI' BUSHING TRAILING Removal/ lnatallatlon 1.Torsionbeam axle bracket pageR-24 Removal note.... in to 4...s--a..) \ ao-ao) a. a...l.....

AoolvsoaDv whh in Z. FUBBERSTOPPER Cautlon . Applyrubber and bushing. Usin!tneSSt press thebushing theF markfacing lorwarq.ubber grease into the bushlnE plpe. Caullon . arm the Remove trailing bushing lnstallatlon note Trailing a]m buahing arm bushing.ana between washer 01E0e({51 R-24 . Do not sirstch the brake hoae when lowerlng. 4. and rubber the grease between bracket to 3. Remove torsionbeamaxle bracket.(TORSION BEAMAXLE) REARSUSPENSION Removal note Torsion bsam axle brsckel 'l. Do not atlow ths. Remove bolts. Loosenthe torsion beamaxle bracketboltsand nuts. waterto the newtrailing 1. the stbbier. Trallinq a]m bushlng withthe SST. the beamaxleslowly. Jack up thelorsionbeamaxleslowly. Lower torsion the 5. 2. the 3.

to R-25 .) tiedtorques. Loosely tightenthe to6ion beamaxle bracketbolts. Set the torsionbeamaxle bracketas shownand looselv tighten bushing the boit. Jackup the torsion beamaxle. 5. 3. 4.FEARSUSPENSION OORSIONBEAMAXLE) Toralon beam axls bracket 1. 2. Lowerthe torsionbeamaxle. Lowerthe vehicleand tightenthe fusteners the sp€cito (Refer page R-23.

......... .... arm 7...(Reler Section (Reler S€ction P) to (2i Adiust parking brakeleverstrokethe (!e"t i9!399 X:9:) alignment..... .lnsiallin the reverse Caulion l-tf........... Insoectall Dartsand replaceas necessary..(TORSION BEAMAXLE) REARSUSPENSION TORSIONBEATI AXLE Removal / InsD€ctlon / Installatlon 1... ..... ..a-131 a4--Lat(5. Trailing bushing bracket 3.. ac-40) 5.s-rr..iaety ttshten the shock absorber bolts and the torslon beam axle bracksi bolts. ...... o b . 5... i ... 4. to referring Inslallatlon ole orderol removal...a. Alter installation: to (1) Checklor the brakefluidleakage and bleedthe air. . ... ..... ..i... Removein the order shownin the figure.... . Torsion 2............ .... Torsionbeam axle R-24 . the a3i Ch-eck rearwheel @. .. . SDindle c e drumassembly.. Lower the ritrt"t"'ani llgLten all bolts to the apecifled torques wlth the vehicle unleded' 6. ... ./ s-117 (t. .... beamaxle 6. ........ Shockabsorber R-26 ........ ... .. Jack up the rear of the vehicleand supportit with safetystands.. . ..... Brakepipe ' S e r vand . 1.... lnstallation note.. Removal page R-24 . the 2......... ... . pageR-25 note.....page note. at--lt) I2e 1t-2... ..... ..... referringto Removal Note..... . .. pageR-24 Removal note. Parkingbrake cable Inspectlor damageand cracks P Section S€rvice..5-c................S e c t i o n M P Section Service. (1a--'t 2...... a....... Remove wheelsand tires 3....... Installation bolt 4. ......

.......................... S-22 3-67 cor\rPoNENTS............. S-5I CANVAS coMPoNENTS....... .. REPLACEI\... ...........................-.............. S-23 coMPoNENTS...-........ S-4s coMPoNENTS.............. S-31 cotvlPoNENTS.... COI\. ..................................... . coMPoNENTS.................. CANVAS MAIN S-50 coMPoNENTS.. .............-.. S-32 ........................................ S-74 S-24 coMPoNENTS......... ...... .................................. ................................. S-24 ....................... S-2r 5-64 cot\4PoNENTS...............4.... .......9 SPREPARATION ................................................... .......... S-4r coMpoNENTS...... ......................-....... ...... s-31 REMOTE CONTROL t\.. S-20 5-64 TRtM..... S-38 FRONT WINDOW REGULATOR.............. ................... S-22 SEAT BELT . S-41 AND GU|DE.-.. ................ 7 SANDWASHER SWITCH .... .....................--....7 WASHER MOTOR.. S-45 REAR DOOR.. S-r3 TOP SWITCH....................... ..... S-24 coMPoNENTS.............................. S.-..... ..... S-72 ROOF DEFLECTOR .. GUIDE S-29 01A06X................. .............. .................... ................-............ S-22 S-68 .........9 coMPoNENTS....-....-..............................-................... 5-36 DOOR............. S-II GLASS . FRONT S. ......... S-sl CANVAS REARDOORLOCKAND OPENER. ... coMPoNENTS....................... PREPARATTON S-rr .......S5 wtPER MOrOR.......... S-37 WIPER coMPoNENTS. S-72 coMPoNENTS.... .. OLD|NG............. S-29 coMPoNENTS............................ s-49 caNvAs REGULATOR...-......... ................. ................. S-77 DOOR M|RROR.......... LID S-I9 INSTRUMENT PANELAND coMpoNENTS.................7...................................-........... .................................................... S-53 coMPoNENTS.................................... S..................t6 coMPoNENTS.. . S-12 coMPoNENTS.....................1ENT 5-60 FUEL-FILLEN AND OPENER................ PREPARATION ...-..................... S-20 S-5r coMPoNENTS........... S-41 FRONTDOORLOCKAND OPENER........ 5-67 RADTATOR GRTLLE ................................ S-16 TOP REPAIR CANVAS ........ S-52 TRUNK LtD..... S-I5 TOPMOTOR ASSEMBLY..........................8 coMPoNENTS..................-..... GUIDE S-34 cot PoNENTS.................... REARBUi|PER........ ........................... ........IPONENTS........... ...................................-...... .........-.................................................... 5-36 PREPARATTON ....... .... GLASS................... OF S-59 TRUNKLID LOCKAND OPENER... ...... REARWINDOW GUIDE S-49 TROUBLESHOOTING ............ S...................... S-I8 FORREPAIR AND TOOLS S-r8 coMpoNENTS......-................ AND GU|DE. ....m1 REMOTE CONTROL MIRROR swtTcH .......... .... wtNDsHtELD............................ S-12 ToP...... S................................. S................................................. S-r9 coNsoLE............ S E A T ................BODY WIPERAND WASHER S-34 .............................. S-77 TROUBLESHOOTING ..... CANVAS TOP..................... FRONT FL4P.......... GLASS... HEADL|NER....-........................5 TROUBLESHOOTING ............ s-61 FRONT BUi|PER.-... S-23 S-73 sEAr8E1T.......2 WINDSHIELD BONNET.......... S-15 CoNTROL UNrT. .... S......S-22 EXTRACTOR CHAMBER S-68 coMPoNENIS.......... tNDEX....................... . .. coMPoNENTS.........flRROR........... S-45 REAFWTNDOW coMPoNENTS.. ... S-2r FLOOR MAT............. S-r3 TOPSUBSWrTCH................. .........................

................ ................ ... top 13........... S-11 / Installation Removal lid 5. ............. Removal 8...... pageS-34 ............. Troubleshooting pase9-qg Inspection... door 2................................. Bonnet pageS/ Instal|ation............... I Removal 4............................ Troubleshooting page3-36 Inspection....... 8 Removal page ............. ...... Radiator pageS-22 / Installation.... .......... page top. Roofdeflector pageS-23 / lnsta||ation.............................. S-53 / RemovalInstallation page S-58 Adjusiment. Frontdoor lockand opener page ...... S......... page .. ..............pageS-49 ......... Removal pageSAdjustment.... S-24 / Installation Removal 10............ lvolding page ..............Canvas guide. pageS-29 Troubleshooting paseq-q1 lnspection..Windshield guide.....pageSJ2 Installation Removal/ of Replacement mirrorglass..8 glass........................ Removal 9.. S-59 Repak canvas of s-2 .... pageS/ Insta|Iation............ pageS-33 and washer wiPer 11........ ....... Fuel-filler and opener pageS-1 / Instaj|ation.. Frontbumper pageS-20 / Insta||ation................ .................. and gulde 3.... Frontwindowregulator. I Removal 6...-............. Adjustment.....pageS-38 / RemovalInstallation pageS-39 Adiustment............... Removal grille 7.pageS-........... / Assembly ...INDEX INDEX 1..Windshield pageS-41 Removal / Insta||ation..............................................40 Disassembly 12...............Doormirror guide. ................ Front pageS/ Insta||ation.

........ Rear window pageS-45 Removal / Insta|Iation.......... SF18 / Installation 6..... Rear windowregulator............. Molding page ..................... S-24 RemovalInstallation / glass 9............ Reardoor page Removal / Installation .. 2.... and guide Removal / Installation page ...................... S-22 / 8... s-3 ...................... Reardoor lockand opener RemovalInstallaiton / page ..... 5... E)dractor chamber page RemovalInstallation .. Bearbumper pageS-2 Removal / Insta|lation.......... S-13 3............ S-'15 4......... 1 7... S-12 glass.......... SFI6 pageS-17 Adiustrnent......Trunkljd lockand opener page Removal ................. Trunklid Bemoval1nsta||ation page / ........INDEX 1.

.......... Seatbelt .. paqe5-69 7.. .......................pageS-72 Removal/ pageS-73 Inspection........................ Floormat page5-67 / Installation.....INDEX 1... 5-76 Disassembly s-4 ... 9 Removal and console 3. Trim page5-64 / Insta||ation..... Installation........ Removal 6........ . ....... Fuefliller and opener pageS-1 / Installation.......... ... ...... 8......... Instrument Panel page5-61 / lnstallation............. (canvas top).. lid 2............. ....Trunklid lock and opener pageS-18 Flemoval / Insta||ation..... Removal 4........ (normal roo0.... pageS 68 / RemovalInstallation ........ Seat ...........--.... Headliner / RemovalInstallation .. Removal 5......pageSF74 Installation Removal/ page / Assembly.......

. 6 pageS. 2............ Bonnet deflector 4.. L Bonnet stay L Release cable s-5 . (Referto page S-22.. Remove lhe radlator grille for removal ol the bonnel lock.............) r...q 14-19) 0raosx{os pipe 1..... pageS... Noie . Bonnet hinge 7.BONNET BONNET COMPONENTS Removal/ Installatlon 1........6 Adjus1ment.. 69_9s tD|b) re-2s fl..... Surround weatherstrip seal 3..................... Bonnet Adjustment................. Bonnet hingebracket 6.Washer 2...6 5.........o-r I xfl lao-r to ant('. Bonnet lock pageSRemoval Note..referring Removal in to Note..e-2. Install the reverse in orderof removal. Remove the ordershownin the figure.

6 m-kg.andalignth€lock on withthe striker the bonnet. orEosx!06 Adlustment Bonnet the by laterally vertically loosening and the Adiust bonnet lhe bolts mounting andrepositioningbonnet bohnet-tohinge Tiohienlnqloroue: -N{n is-zs {i.9-2.l4-19 ft-lb) (0. Tlohteninqtorcue -Bolt: 7.A-a Bonnet lock has lock tho Adiust bonnet alterthe bonnet beenalignedLoog bolts lock enihebonnet mounting andnut.s m-tg.s-z.04) ffi F_:.6-1f N{I| (80-ll0 Gm-kg.16 + 0. 14-19 ft'lb) s-6 . \!'=:_: sEc.BONNET Removal Note Bonnel lock boltsandnutwithpaint lock the Markaround bonnet mounting for properreassembly.m(1.69-95 In'lb) Nut: 19-25 N.

"u". LOCATIONTORXTOOL MUSTBE USED TOFXSCBEW DOORLOCKSTFIKER TOFXTOO! (r4{') s-7 .FRONTDOOR S FRONTDOOR PREPARATION (r4o) ro'x rcor | l"o"in"-"."|:--fi : ) ) o. *rn*t " o"- TORXTOOL (T40) 1."'. 2.+ .. ILLUSTNAT|oN .

tl-113 lD5) ri l 01Eosx 010 connector 1. Veritu rearotfsetol the door to the body lf there is a ilie horizontally the probiem.. in 3.s-2..) h. Frontdoor 5..FRONTDOOR COiIPONENTS Removal / lnsiallation cable. Checker 3. Harness (if equipped) pin 2.. T s-8 Adlustment Door lock sidker and easily thatthereis 1..7 m-kg.n (i. 2. lnstall the reverse Note . Verifv thedoorcanbe closed that mount' loosen striker the lf thereis a problem. Disconnect negative shownin the ligure in 2. himove ttre trlm and door scrsen for removal ot lhe door ch€cker.Doorlockstriker below Adjustment.a-1t rh (...Remove the order orderot removal.o-r!o cnt... Doorhinge 4. adjustby moving doorlockstriker Tiqhtenlnqtolque: -N. 13-20 ft-lb) ig-zs . battery the 1. and the andadjustby moving slrikerhorizontaily ingscrews venicallv.. (Seebelow... no bbseness.. Checker 6. Adlusl the door lock stllker.. Remov€the door screencaretully 8o that it may be rcused.. (Reler to page S-9') . ..t@ 3.

... 3. 5-64 6. in to 4..... Remove the ordershownin the figure. S-24 10.. Installin the reverseorder of removal. Innerhandle 5. Disconnect negative the battery cable. ar-JT lFlb) r?-26 ! 5) 01A6X.$6 l....Frontdoor glass 11.. GLASS.. S*32 Doormirror 2.. 6..Manual windowregulator 12.lnner garnish Removal/ page Installaiton. 61-47 4tr.0-2.. Frontbeltline Removal/ page Installation. Regulator Removal Note. GLASS. Caution . Removethe door screen carefully so that il may be reuaed.9 In) lromthe tully]owered the 2.. glassaboutloomm (3...e-03 r+n FO-100 6-lle.referring RemovalNote..AND GUIDE FRONTWINDOWREGULATOR..H..16) 11-\N'/\v i---' I 2. Frontdoortrim Removal/ page Installation.FRONTWINDOWREGULATOR..Glassrun channel s_9 ....reterringto Inglallation Note..pageS*10 lnstallation page Note. handle 3. Raise frontdoo.. Bracket pad 7.AND GUIDE COMPONENTS nemoval/ Inatallatlon position.. S-10 4..a l+r tro-roo drFlq. Sealing 8. Doorscreen molding 9.a llfl (20-!O cr*g' 6. 1.

136 lnstallation Note Regulator handle handle on and cliD lnstallthe in thehandle pushtheregulator as shown. Not€ . Removal llote Rogulator handle Reirove the regulatorhandleclip with a rag as shown. 01E06X. Sei door glass at fully-raised posltlon' <F FFONT s-l0 .AND GUIDE FRONTWINDOWREGULATOR.GLASS.

. 6. t 6 t . Inn€rgarnish Removal / Installatjon pageS-32 . Innerhandle 8.. Frontdoorlockassembly 4. Front doortrim L Outerhandle Bemoval / '10. Remove the ordershownin the tigure. Caution .Raise frontdoor glassfully.FRONTDOORLOCKAND OPENER FRONTDOORLOCK AND OPENER COI'PONENTS Removal/ Inatallatlon '1.. nemove the door acreen cargtully ao that lt may be reused. Disconnect negativebatterycable the 3.. 1. Fegulator Removal Nole. Lockcylinder 5.i I'h rr[-r00 st($ 6t-!7 kl-|b) ) )tl fl-1-.. in 4.. Bracket pad 6.... Sealing s-l1 . lnslallin the reverseorder of removal. handle 2.a-r. Lockcylinder retainer . Installation page5-64 '11... Doorscreen 3. pageS-10 Instiallation pageS-10 Note 7.. the 2.

Remove the door screen ca]€ ully so thal it m8y be rsused.. s-l2 01E06N r33 Adlu8tmsnt Door lock st ker easily thatthereis and 1.. Remove the ordershownin the figure. Verifu the doorcan be closed that the loosen stiker mountlf no loosene$s...) .. lf there is a problem. Checker 6. t.. Disconnect negative in 2.thereis a problem..REARDOOR REAR DOOR COIIPONENTS Removal / Installailon cable. Doorlockstriker below Adjustment.a-13 l{. Checker 3..7 m-ks. Reardoor 5. 3.....8-2. 13-20) !.00-rao qn{t ?!-llt lflb) 01E0sx413 connector 1. Remove the trim and door scleen for removal of the door checkel.. Harness (if equipped) pin 2.7. (Refer to page S-13. 2. lnstallin the reverse Note . battery the 1. Tlghtenlngtorque: i8-26 I'tm (1. ordr ot removal. Doorhinge 4. 13-20 ft-lb) . Verifvtlie rear ofisetof the door to the body.. the adjuslby moving doorlockslrikerhorizontally. and fle horizontially and by ing screws adiusl moving striker verticallv.. +lffilo A w1F2a 0r--2.

about160nm (6.. Removelhe door screen carefully so that lt may b€ reused. Doofscreen 7.referring Remova! in to Note.q / ' 6jr1 Gi {r ar .oos 1.. 4. Reardoortrim Removal/ Installation page5-64 .Sealing 6.. Disconnect negativebatterycable the 3.AND GUIDE REARWINDOWREGULATOR.3 in) fromfullylowered 2.0--4r lrr oo-10o ir'rc. Remove the ordershownin the figure. 3r--... Innerhandle 3.. Rearbeltline molding Removal/ Installation pageS-24 . 8. to Caullon .'P 6...REARWINDOWREGULATOR. Regulator handle Removal Note. GLASS.Rear door glass 11. 4..referring Installaiion Note.pageS-14 Insiallation pageS-14 Note 2.lanual window regulator 12. Holecover guide L Glass 10. \\ \ \.. Installin the reverseorder of removal.AND GUIDE COI'PONENTS Removal/ lnstallatlon 'L Raise reardoorglass the position..l\. GLASS.Glass channel run s-l3 . Bracket pad 5.7Ino) 01aosx.

raised positlon. clip Remove regulator the lnstallallon Nole Regulatorhandle push regulator handle on the Installthe in thehandleand cliD as snown.GLASS. Sel door glass at tully.AND GUIDE WNDOW REGULATOR. \ FRONT 01E!SX-r9() t s-l4 . Note . Removal Note Regulator handle handle witha rag as shown.

REAEDOORLOCKAND OPENEB REARDOORLOCKAND OPENER OOII|PONENTS Removal / lnstallation fully. Raise reardoorglass the 2. Sealinq 6.tb) o handle 1. in 3. Holecover 9. 6l--Jr trb) &D'/ a2--a? N{ l*t--ait 4. Remove the door screen carelully so that it may be reused. S-64 4. Bracket 2.... l. Install the reverse in orderof removal Caution . i$6 o0-l0o. Doorscreen 7. Regulator 3. Remove the ordershownin the figure. Outerhandle s-15 ...Ftg. 4. Disconnect negative the battery cable. 1.H..pageS-14 Removal / page Inslallation pageS-14 Note lnstallation. Reardoorlockassembly 8..lnnerhandle pad 5.t9. 37-55 td. Reardoortrim Removal Note.

2. S-17 3. irFl9 1... TRUNKLID @IIIPONENTS Removal/ Installatlon in 1. Trunklid hinge s-l6 ..a-2.. Remov€ the ordershownin the figure in orderof removal... Trunklid page Adjustment..4. Install the reverse LID TRUNK rt-25 o. Staydamper 2.

the after the Loosen thetrunk striker lid mounting bolts align strikand er withthe lockassembly. 14-19 finb) #-F nn (n) Trunk lld strlker Adjust trunklidstriker thetrunklidhasbeenaligned.kg.TRUNKLID Adluslmelil Trunk lld nuts as Loosen trunklid hingemounting andadjust shown.8-ll Nn (80-110 cm-kg.9-2. Tlght€nlngtorque: 7.6 m.69-95 in-lb) s-17 . the Tlghtenlngtorque: l9-25 Nm (1.

Installation Page connector L Floormat 6. Frontscuff plate 4.. Remove the ordershown the figure in the reverse orderof removal 2.Trunklid lock 2.3-rr Nfr O0-rro *19.. lnstall 7.. lever Opener Adjustment.. 6Hl rn-rb) Trunk lld lock 1.. Trunklid striker '10.'|. Opener s-l8 .. Retainer 3. Lockcylinder Openerlever Trunk lld strlker 8...Frr l|n (@-ll0 cm. Lock protector / Bemoval lamp 5. Trunkcompartment 3-64 .TRUNKLID LOCKAND OPENER TRUNKLID LOCKAND OPENER COT{PONENTS Removal / Installation in in 1.. S-'17 Page cable 7...!. lg5 lFlb) @ 6 ) l @ R 7.

. Opener lever s-l9 . Opener cable Op€nerlever 5..... 5-64 6... Filler opener lid 4..... Filler lid Flller lld opener 2.FUEL..FILLER AND OPENER LID FUEL....FILLER AND OPENER LID COIIPONENTS Removal Installation / 1. Remove the ordershownin the figure.. in in 2.. Inslali the reverse orderof removal. Frontscuff plate page Bemovallnstallation / . Liftspring 3. Filler lld 1. Floor mat 7.

.. Remove the ordershownin the figure orderof removal in 2.. T Removal/ grille 2. Removal/ 5 Frontbumper cover 6 Bumper pageS-38 s-20 ...... 3t-55 h-lb) rr--6.m*9.. Radiator page .. Install the reverse *k /n r (r. S-22 Removallnstallation / guard 3........S BUMPER FRONT FRONTBUMPER @MPONENTS Removal / Inslallatlon in 1...-............. Frontcombination Section Installatlon....2 ih tight 1.6-23...12-r' ({3-as . Mud tank 4 Washer lnstallation.

License lightconnector 3.Splash shield 2.l 4. 37-55 In.6-2.REARBUMPER S REARBUMPER @I'PONEIITS Removal Inatallation / 1. 12-19) .2-4.2 X{ {43-63 cn-tt. i6-25 (1. Flear bumper s*21 .tb) 1.6. Remove lhe ordershownin the fioure. in 2. Install the reverse in orderof remova].

.. Install the reverse grille 1... Install the reverse 2.:. Rearbumper ...CHAMAER GRILLE. 1. 2. R€move the ordershownin the ligure..... S-21 / Installation Removal Page chamber 2. Radiator CHAMBER EXTRACTOR COMPONENTS Removal/ Installation in 1.EXTAACTOR RADIATOR GRILLE RADIATOR COIIPONENTS nemoval / Installatlon in 1. Extractor s-22 ... in orderol removal.. Flemove the ordershownin the figure.. in orderol removal..

lnstall the reverse in orderof remova]. Remove the ordershownin the fioure. Roofdeflector s-23 . in 2. REPIACE '1.ROOFDEFLECTOR ROOFDEFLECTOR COMPOI'IENTS Removal/ Insiallation 1.

. page Note. / RemovalInstallation.... pageS-41 Removal/ molding lower 2... Note...................... Removal molding 5. Install the rev€rse Note -iimove ......... Bearwindow ..pageS-26 Removal s-24 .. ........ .. ...................... .... .........-. Note. Noie.... Rear .. Removal ... Remove the ordershownin the tigure relening Removal-Note' Nole' to referring Installatlon orderol removal' in 2..... pageS-41 molding 3...... Note.......... the windshleld for rcmoval / insiallatlon ot the windshlsld upper and lower molding' (Refer to Page S-41 ..... . . ........... Windshield ....page5-26 lnstallation molding lower 7....) :z uppermolding 1....... Removal uppermoldang window 6...... s-26 lnstallation molding 4. Rearbeltline pageS-25 .. Frontbeltline pageS-25 Note. page9-25 Note...... Windshield ... . installation.............. Rool .MOLDING MOLDING PNEPANATION ssT 49 0305870A 49 G0501A0 installatonot rc3r molding COIIPONENTS Removal/ lnstallatlon to in 1........ page5-26 Removal .........

the 2. s-25 .r E-J 0146X415 Rool moldlng 1. Bemove bel ine molding the mounling fasleners. Remove door minor.lIIOLDING Removal l{otg Front and rsar beltllne moldlng 1. Pushthe hook with a protecledscrewdriver and removethe belflinemolding.(Refer pageS-32.. Remove roof moldinglrom the body witha protectedmoldingremover. FRONT s o @ @ z @ . Remove roofmolding the lrom thejointmolding.@ c-_/o 6 ) @ o o @ . 3.) the to 2..

A-A Rearwindow upper molding (seebelow) lowermolding. the 1. Do not reuse lhe rear wlndow uPper molding. the jointmolding 2. the s-26 .--. near bodyas shown the barto cut the sealant Caution . Push roolportion themolding ningfromthe front(2). ninglrom the top Rear wlndow upper moldlng the tape along upperedge of the body 1. to with 2. pullonthe the (A). sEc.MOLDING {T n*F f f - W SEAI. Twist molding Caullon . Do not damage the glass or body' and of 3. screws mounting the fromthe roofmolding. Remove roolmolding the Gpillars to 3. Rear window lower molding '1. Do not demage body. Applyprotectii. Remov€ @ t/ . prolectit from damage.-------> + + + lnstallatlonNote Rool molding '1.h rearDortion themolding the nino from the top (O. ontothe body'begin' of 4. Pus:h frontportidn themolding the (4). ontothebody begin' of 3. Cuithe uppersealant a razorknifeas shown.Remove molding and fasteners.Insen rool molding the iointmolding (1) into the ontothe body'beginof the 2. at beginning the end to separate the 4. Remove r6ir window at the 2.ANT . it.. Pus. Theuppermoldingis adhered the rearwindowby sealantas shown. Caution . lnseri blade theSSTintothesealant.

near Cautlon . Useonly theglassprimeral the glassandihe body primer al lhe body and moldlng.30 minutes. the and sionsurlace the body. Remove muchsealant possible as from between as the bodyand glass.MOLDING 4. the 6. Cutthe sealant neartheglass(C). With the repair ssal cartrldge prepared as shown. Keepthe areafree ot dlrt and grease. the 01E06X 192 5. 7.Reshape reDair as shown. of thebodyandthenewrear window uppermolding. the seal -' F Aq. Caution . Do not damage glass. 01E0sx{52 10. Do not touch the surface. removelt immediately. CABTFIDOE 9. .UST SEAIANT s-27 . use a pleceof vrlreto breakthrough the seal film. It prlmergels on the akln. Ins€rtthe blade theSSTintothesealant. Caulion . Applyprimerwith brush a tothebonding area theglass. aland low it to dry for approx. Carefully clean around edgeoftheglass theadhe.12in) of s€al between glass the and the body. Applya beadof repair to a height 3mm (0. Note . at 0rEosx050 EODY 8. Note . and lhen applythe seal. Do not damage glaaaor body. Dullon ol and the barto cut the sealant the glassas shown (B).

Aliqnthe end ot the uppermolding the glass(1). is a scraperas shown. 3.C {41oD Time requir€dunt car can be P'it into service 12 hl 2hl zooc(68"R 35. atop is that 4. Check water the welland repeat installation. outside time ot rePairseal Hardening time Surface hardening 5.InJalltheuppermolding theglass beginning (2). a leakisfound. Verity Iheuppermolding overlapped theouler (if equipped).D OUIEB WEATHENSIRIP otf wipethewater lf for leaks. top weatherstrio the canvas of with the reposition uppermolding Ittheoverlap opposite. s-28 .IIOLDING lo 1 1.C (95. fromthe to 12.

DOORMIRBOR s NUMBER SHOWSIEP NUMBER DOOR MIRROR TROUBLESHOOTING GUIDE ChcultDiagram (E) ]GNITION SIlITCH (F) CIGAB 15A t/f L-01 o co SIiITCH LEFT 3o I o HIGHI 3 -01 LG LG LO "l Bp./f BF BF LG (B) LGIB DF1) (r) r ret (F) ql ro'tn D B 1 ) - L-0 LEFT+ F I G H T+ + DOy1N Bh BB oF?) oF1) L-02 F .!oToF I -01 FEMOTECONTBOLMIFBOF SIiITCH (]] FEMOTECONTFOL M]BBOF MOTOFFH L L 0 2 F E M O T E O N ] F O L I q H O FM O T O B H ( C M FEI{OTE CONTFOL (DB2) coFo BB L-03 FEMOTECONTBOLI{IFBOF I.. -03 -LEFT +FIIGHT F DOI'{N BEMOTEC O N T B O L'iIBBOF 1..1O BH (DF1) TOF FEIVIOTE CONTBOL oBll COFD s-29 .

. Delecllve and ground wiring harne$s INSPECIION SIE9 15Afus€OK? ls CIGAB DOORMIRROR DoEsNor oPERATE svuprorl aenore coNTRoL tRRoR nEsuLl ACTION and wiing harness rephcetuse Reparr 2 swilch ON. Delective remotecontrolmi(or switch .Remole next step Go to FeDai wrinq hatness (B. CIGAF oul 15Aluse is burned .s POSSIBLE CAUSE .Bemotecon o mirfoo s-30 . ls lhere12Val teminal_ Turnignition wife Gm of remoteconlrol mirrorswitchcon_ NO 3 Disconnect remotecontlol mirrorswitchcon_ the nectorits there continuilybetweenleminal_wire (B)to grcund? ls thereremotecontrolmirtor swilch OK? !7 Pogo S-31 winngharness Feparr mirror switch) control (Frs€box . I wi€ up:{BR) (LG) wife Down: ILG/BI wire Risht(LG)ILG/BI (BRIO wi€ Len: ILG/BI side l: Righl No wirinqharnass ReDair (Rdmote coitrol miro' s*tcl" . Delective remotecontrolmirror . .mob cdirol millor swnchGround) NO Go to next step NO Replace r€motecontrolmirrorswitch the mfior Checklhe remotecornrol e p!96 Hl 5 lhe Reconn€ct remolecontrolmiror swtch con_ ot nector:ls there 12v at terminal-wires remote \r.trileoperatingswilch conlrolmirror conn€ctor . .

DOORMIRROB MIRROR SWITCH REMOTE CONTFOL Inspoctlon 'L Remove remotecontrolmirror switch.-=g a G o I c UP DOWN LEFI RIGHT UP DOWN Righl o- -o -o oG -o -o -o oooG -o -o o- -. Check operation remote control mirror motor lvhen12V of is aDDlied the terminals shown. lf not as specified. lf not as specified.o --o ooo- -o -o ooo- -o -o -o LEFT RIGHT (:)*--o: Indicates continuity -o -o o- replace switch. Checkcontinuity Tcamlnal swltch condlilbtt-=. RE]IIOTE CONTROL ii|IRROR Inapectlon 1. replace mirror. of 2. the between terminals switch. Disconnect remote mirror connector. the control 2. the 3. the s-31 . to as Operallon DOWN LEFT RIGHT Conncct to t2v Ground a d 3.

.... Remove the ordershownin the figure..........TFOL iIANUAL @I{TROL Rearylew mll'or 1.... Knobcover 2. Remote page SJ1 Inspection... Door mirror pageS-31 (Remote controD... Disconnect negative in 2..... Installin the reverseorder of removal............ Knob 3. Innergarnish 4...DOORTIIRROR COIIPONENTS Removal/ Inalallatlon mirror') femotecontrol cabie..(With battery the 1. Replace Remotoconitot mlror awitch swnch mirror control 5.. Inspection pageS-33 glass) (Mirror . 3......... s-32 .. REIOTE @I.....

DOORMIRROR Replacementol lirror Glasg glass witha hotairblower. press into secure it it.Warm frame the mirror the and glassandtheframe. Insert scraper a between mirror and prythe glassloose. in Gently 5. 1. lnstall glass theframe. 3. Remove remaining and lhe surlace theframe themirrorwith of 4. the 2. the s-33 . the adhesive. Warm adhesive a hot air blower.

'.ryw.e' I wwrrr IGNITION ITCH i./oI T .lrPEB liAsHEF D-01 WINDSH]ELD WIPET D .9]NDSHlELO IdIPEF MOTOB D-02 WINDSHIELD MOTOF WASHER D-03 L/O I swrrcH a iliDsHrELo v.s WIPERAND WASHER WINDSHIELD AND WASHER WIPER WINDSHIELD GUIDE TROUBLESHOOTING Clrcuil Dlagram NUMAERSHOWSTEPNUMSEA ffB-..0 2 l / I I N D S H I E L D _ W I P E F A WASHEBSWITCH(F) INOSHTELO I{ASHEF MOTOR I L.. T L--:J s-34 .

WINDSHIELD WIPERAND WASHER WIPEFS NOTOPEMTE IN ANY POSITION DO 3YIIPTOMI POSSIBLE CAUSE . Hlr(Lr$ 12V ls lhere 12V at lerminal-wires wiperswrtch oi connectorwilh switchas shown? .Wiper (M|ST) o E TOUCH CTTON FU DOESNOr OPERATE POSSIBLE CAUSE .r wrring harness Wpef motor Grouno Reparr winng harness motor) Wp€. Defectiv€ wip€r switch . Defeclive windshiddwipermotor . INTand LO:(UR)12V . Defoclive winns harness .is there12Val terminalwi€ (L) of wipermotorconneclon NO Ropairwiringhaness (Fusebox. swtch.^JY) 12v Go to nextstep NO c:. DeJeclive widngharnessor ground rNspEcfloN SIEP tEstLl ls WIPER tuseOK? 20A Go to nextsl€p No s ACNON fuse Repairwiringharness and repl€ce 2 Tumignilion swilch ON. Deleclive wiperswitch 3IEP u{sPEcTtoN R:SUTI 8 ls wiper swilchOK? Replacewip€rswilch r? p€g€ Sl7 ACTION cr Secuon T s-35 . wife (Lm of wiperswitchconn€cto? No t7 page S-37 ACTION 7 ls lhere 12V at leminal'wire(L/0 ot wjper No Repa. Delective windshield Wper swilch . WIPER 2OAluse is burnedout . INTand LO:(UB) 12V .Wips motor) 3 ls lhere12Val lerminal-wres wipormotor of witlrswiichas shown? connector .wiper switch) F page S-37 5 Disconn€ci wiper switchconnector. Hl: (L.peg€ 5-36 Reparrwiringhan€ss Wpef molor. therc lhe is (B) contlnuitybelween terminal-wne to ground? No (Wiperswich R€panwil]ng harness Grouno TYXPTO ] wlPER PARK FUNCTIOI{DOESTOT WORK POSSIBLE CAUSE . D€lectiv€ groundot wiper motor STEF |l'tsPEcTtol{ NEs|'LT 6 Turnignition s1/vitch is lher€12Val teminaON.

WIPERAND WASHER WINDSHIELD ryxpro l wAsBER DoEs Nor oPERATE(wlPEFs oPERATEoK) CAUSE POSSIBLE . lf not as specified. tor with the wiper in Tefminal Continuity Conlinuity totheter12V by operation applying anda ground 3. Check minals the motorconnector.) 1. MOTOR WASHER lnsDection to tank.replacethe washermotor- s-36 .Washer$itch) Fepairwiringhaness (Washer WIPERiIOTOR Inapgction the 1. lf not as sDecified. Connect to verifvthat the motor operates 3.pagp S-37 motor. Defective washermotor . to a 2.(Feter pageS-38. Disconnect wipermotorconnedor of terminals themotorconnecbetween continuity 2.is therc12Val t€rminalTurniqnition 9 wire d) of washermotorconnecloa (Fuse molo4 box Washet Feparr winngnamess 10 (UO)of washer ls ihere 12Val terminal-wire NO t l Go to next step Checkwashermotor(Seeb€low) Checkwasherswttch NO (UO)of washer ls th€rc 12Vat teminat_wire !:. Def€clive washerswtch . iemove the washer '12V terminal anda ground terminal and b. Defeclivswiing harness ACTION GSULI NSPECTION swilch ON. Check parkedposition. of 12V b Teminal Grounct speed Op€ralion High the replace wipermotor' 4.

WINDSHIELD WIPERAND WASHER WIPER AND WASHER SWITCH Inspoctlon (Refer Section 1. . Remove combination the switch. to T.) 2. replace the combination switch. Check continuity between terminals thewiperandwasher of switch connector.o-i------=Term'nal d OnetouchOFF oOnetouchON b I -o F -o -o G. lf nol as specified. s-37 . INT ll rHiohl H: Indicates continu ly oG -o -o G -o 3.

................. pageS-40 Disaesembly 6.. at-122 In-lb) 6.. orderof removal.......WIPERAND WASHER WINDSHIELD OOiIPONENTS Removal/ Inatallation cable baftery the 1........0-1a ||n {rd-lrlo d{g.. Bushing 5... 6r-a7 bD}------€ 6....9-......-.... .... Disconnect negative in 2..Washer '12..... / Assembly.Cup tank 11........ ....Washer ... .......... Panelcover 7.3 tld aro-r@ d-tg.. washermotor .......... Wiperarm and blade pageS-39 Adjustnent. 51-47 lDlb) Wip€r 1... .. page$-36 Inspection '13....9-!. Adjustment. cap 3....Wiperarmcover 2... Removo the ordershownin the ligure..1 N{ fto-roo mlq.... . in 3. l\rudguard(if necessary) 10.. Seal 4... Sealcover L Wiperlink Washer g.. Wipermotor page5-36 inspection.. pipe Washer nozzie 14.. pageS-39 s-38 .. lnstall the reverse 9..........

as MOLIXNG 3t)*2 (r. 87-122 lnlb) Washer nozzle lnsert needle similar a or obiect thenozleholeandmove into to the nozzle adjustthe spiaydirection. Turn ignitionswitchON and turn the wiperswilchON to ooerate wipers. Setthe arm height shown.18 + O. 3.04) (1.18+ 0. Turnthewiperswitch OFFto setthewipers theparkposition.08)l 30+2 Tlghtenlnglorque: 9. the in 2. MOIDING s-39 .8-14 N{r (100-140 cm-kg.WINDSHIELD WIPERAND WASHER Adlustment Arm height 1.

Motorgearshaft s-40 .AND WASHER WIPER WINDSHIELD DlsasEembly/ Assembly in 1. CIRCU|TANF4XEA motor 1. Assemblein the reverseorder of disassembly. Disassem5b the ordershownin thefigure 2. Brush 3.Wiper plate holder 2.

.. Headliner 7...... Roofmolding page ... Removein the ord........... '10..... 1.. to 3... pageS-43 Installation Note. - '1.......... Windshield page S-42 Removal Note.... 8...WINDSHIELD WINDSHIELD ssT PREPARATION 49 0305 a70A ffi --('\ l l insiallalion ol COTIPONENTS Removal/ Inatallallon the cable.Wiperarm and blade pageS-39 Adjustment............... and Sunvisor adaptor mirror 2............ Rearview (canvastop) (canvas top) 4... Overhead console 5.......referring Inatallatlon l. Rearview mirrorand interior lamp 3.... referring Removal Note... Installin the reverseorder of removal..Spacer s-41 .r shown in-thefig. A-pillar trim page RemovalInstal|ation / ...Windshield lowermolding 12.. Disconnect negative battery to 2... 5-64 6.......re.Darn 13........ Windshield uppermolding 11..... S-24 RemovalInstallation / 9...........lote..........

Note . 9. sideof the wirethrough hole. 5. . but tnekdot ttrewindshield a razorknife as shown.a tool like lhai shown In the ligure may be us€d. fre around edgeof the glass. (Reter DaoeS-23. Insert bladein the sealant. Windeachend of the wirearound bar. lt the glass b not to be r€used. person. Apply protective tect it from damage.make holethrough sealant an the vehicle. Using awl. . s-42 and 8. Do not damagethe glaaa.WINDSHIELD RemovalNole Wlndshield (if the 1. Caution . Use a long sawlng action lo spread the work ovet the whole length of wlre io preventlt lram breqking. Working the Thenremove glass. fromtheinthe a 4. Be careful thal the wlre do€a not rub on the body or irstrumsnt Panel. Remove roofdeflector equipped).) to with upper lowermolding and 2. Do not reusa the windshleld upper and lower moldlng. v. . the 01E0sx{€3 awayfromthe windshield. pullon the bars. Cauilon . Do not damagethe glassor body. saw throughthe sealant with anoth€r 7. Passpiano a 6. Pulltheupperandlowermolding Cautlon . tape alongthe edge of the body to pro3.

applysomeprimerafterdegreasing.30 minutes. Carclully cleanan arca5 cm (1. 14 (0. Press lightly ontothe glass compress sealant *_5J LowEi Mot-DrNG tothebonding areaofthe glass 7. apply repair can to sealarou the entire nd circumference filltttegap between witha ridgeof sealant the damandtheedgeof theglass llmm (0. reshapingit wherenecessarv a soatula. Prepare nozle of the sealant the thatcanrunalongfie edgeotthe glassanda V fromwhich the sealant flow.elyand allow lt to dry. Keepthe bead ol sealantsmoothand even. Keepthe area tree ot dirt and grease.43in) high. Bond the dam secu. to allow 30 mlnuteg dry. Use new windshleldupper and lovrermoldlnga.04lo 0.97 in) wldearoundthecirof cumference theglassandthe bondingareaon the body. to the 6.WINDSHIELD lnstallatlon Note Windshleld 1. with s-43 .rcumference the glassas shown. Cuta\4Ey oldsealar witha razorknifesothatI to2mm the (0. Press leftendofthe molding the ontothecornerof the glass (1). Do not touch the surface. (3). Caution . lf prlmergets on the skin.Thenputon newsealant cre it to ate a 2mm (0. 4. Applyprimerwith brush a andthebody.08 in) thickness sealanl remains around the of circumference the frame. removelt lmmediately.55) of 3. Caution .08 In) layer. Note . ontothe cornerof the 5. Useonlythe glassp merat lhe glassand ihe body primerat the body. SEALANT CENTER tub€sothatit hasa flange 8. .andallowitto dryfor approx. Press rightendof the molding the glass(2). 4'__:I)):z=a Caution .lf all the sealanthascomeofi of and in anyoneplace. 2. Bondnewdam alongthe c.Oncethe primeris dry.

Insiall spacers caution .5 5oc (41'D Approx. 12. min Time required unlil car can be put inloseruce 12 nl 2ll leaks. the to firmlyin on the glass compress sealant. 13. Damagedspacers musl be rcPlacea' \ ontothe body.35in) on clearance both sides.Putthe lowe. hr 20"c (68oF) 10 3s. 10.WINDSHIELD ontothe body. H4 . a leakis found where olf wellandaddsealant wipe of at the top or bottom thewindshield. wipelhe water lf lf needed.Checkfor water '14.Press mm (in) Caution . Open the windows to prevent the glass from belng pushed oul by 8ir pressure ll a door is closed. a leakis toundat thesideol the glass. the welland ginning.molding it into 11. Hardonlng tlme ol repalr aeal tme Sudac€harclening 1. thewaterotl glass Reinstallthe tromtheberemove glass.c (95oD Approx. the 9. Settheglass the bodyandadjust to gmm(0.

2...GLASS REAR WINDOW REARWNDOW GLASS ssr PREPARATION 49 0305870A tfu"4 l l installalion rear of COIIPONENTS Removal Installation / the battery cable 1.r shownin'thefigure..... Roofmolding page RemovalInstallation / .referringto Inatallatlon Note..... Spacer s-45 ........... Rear windowlowermolding pageS-24 Removd Instaj|ation....... L DaIn 9.... Remove the ord...... / 5. Rearpackage trim page$-& Removal / Instai|ation. 2...................................... 3.... 1...referring R€moval 3.. page5-46 Instiallation Note............ Headliner 4.. Rear window uppermolding page . S-24 Removallnstailation / glass 7........... Disconnect negative in to Note.. Rear window page5-46 Removal Note..... Installin the reverseorder of removal.......... $-24 6.......C-pillar trim page5-64 Removal / Instiallation....................

Then atea 2mm (0. the an 5 clean area cm (1.08In) thickness sealant oi has ll oi circumferencetheframe. saw throughthe sealant with another 5. Caretullv area thebody. a tool llks that shown in ths tigure may be used. on and of cumferencetheglass thebonding for withpaintas shown 3. Be caretul thtl ihe wire does not rub on ihe body. allthe sealant comeotf primer and after degreasing. applysome inanyoneplace.make holethrough sealant theinside of the vehicle. person. and the 6. Us€ a long aawlng action to sPread the work over the whole length ot wlre to prEventit lrom bteaking. tect it from the a an 2.97In)widearound cir2. puton newsealant cre' to it allow 30 mlnut€ to dry.04to 0. Using awl. edgeof the around-the cautlon . Workinq glass. the remains around (0. lf the glassis not to be tcused. lnsert bladein the sealant. lnstallatlon Note Rear wlndow glasa '1 Cutawavtheold sealant a razorknifesothatI to 2mm with .GLASS REARWINDOW Removal Nole Real wlndow glass lhe tape L Applyprotective along edge of the bodyto prc from damage. pullon the bars. Note . Windeachend of thewirearounda bar. Markthe outeredgeof the glass reinstallation. the 3. oroDer s-46 .08 In) layer. the Thenremove glass. . Passpianowirethrough hole 4. v.

Setthe glassintothe bodyand adjust clearance the be tween lhetop of theglass thebodyto 8mm (0. Keepthe area free ot did and grease. Open lhe wlndows lo prevenl the 9la8strom b€ing pushedout by all pressureIt a door ls closed. Useonly the glass pdmer at the glassand ihe body primeral the body and molding. withthe V notches spacers in and install glassintothe body.30 mlnutes. the body. Bond the dams securelyand allow them io dry. the 10.Press fimly in on the glass compress sealant. the up L Remove glassfromthe body.a3) 0n) mm SPACER ff. Keepthe bead of sealant smoothand even.2) Alignthe glassmarks 1'1.31In) and by moving spacers or down. 6. removeit immedlately. Applyprimer a brush thebonding oftheglass.and and allowit to dry for approx. lf pimer gets on the skln.28 in) fromthe edge.REARWINDOW GLASS 4. Bondnew damsontothe bodyas shown. . Install spacers the ontolhe bodyas shown. s-47 . 11(0. Damagodapacers must be aeplaced. the 12. Preparc nozzle thesealant the of tubesothatit hasa flange thatcanrunalongtheedgeof the glassanda V fromwhich the sealant flow.reshapingit wherenecessarv with a soatula. Cautlon . .Do not touch thg audace.applyrepair can the is sealaroundthe entire circumference fillthegap between to the damand the edgeof the glasswitha ridgeof s€alant llnm (0. 5. Cautlon . 8. Cautlon . Note . Vedfy thal the clearance|3 betweenthe top ol the gtassand the body 8mm (0.43 ln) high.o@li1 ^tr-t lilEJrl 5 (0. 7.Once primer dry.31 in). with to area the newrearwindow uppermolding. Bondnewdamalong circumferencetheglass the of 7mm (0. to the V NOTCH I t I il @o lil l]Eil Cautlon .

o#.lt a leakis foundat the sideor bottom the glass.Checkfor waterleaks. outside I 16. f IN THIS Timerequired car until time can b€ pli intoservEe Sudace hardening 1. hr 12 hl 2hl 20oc (68.D ".C (95.C (41oF) W )'.Installthe (2). Usea scraperto smoothawayany sealant oozesout ot Add more sealantto any poants poor contact Caution . 15.5 Approx. a leak the wateroff welland add sealant trom uppermolding the be' atthetop. Adiust the upper sealantas shown.GLASS BEARwlNDOW Hardening tlme of repair seal GLASS AODY 5.R 35. wipe of 17. and 14.Alignthe end of uppermolding the glass from beginning the to uppermolding the glass. ll whereneeded. (1).r^. I 6 -WM that 13.1-g5.reinstallthe isfound ginning or Eosxro4 s-48 .

CANVASTOP CANVASTOP TROUBLESHOOTING GUIDE CircuitDiagram 01E06Xl05 S-49 .

below and a body gloundas shown console. Teminal voltage lerminal Connected to -rOP 20A fus€ CANVAS Insp!4!9!tt999g!9_ Con$arn Frontooen swikh ON Excepl lronl open swilchON Vollag€ 12Y 12V OV Powercut switchOFF pow€r cut sw ch OFF E4cep1 't2v Fronl autoopen switch I h Fronl auto open switchON ToiaoDrot I sec.CANVASTOP TOP MAINSWITCH CANVAS lnsoeclion '1 iemove the overhead kom the body console switch of terminals ihemain between the Measure voltage 2.*tch oN and m-aln opensw ch oN a"o man tearopen'wilcnoN rxcepr.rtoopen swilchOFFor excepttront aulo ooen swnchoN ON clos€switch Front ON frontcloseswitch Excepr rear Sat€lv. aiterfiont a.aiTrvswtcnol Iatdv swncnOt.l anOma'n rear closeswitchON Constant 't2v 't2v OV 12V Ground s-50 . the replace overhead 3 lt not as soecffied.

Termlnalvoltage Termlntl Connected to Sub rearopenswilch Inspecllon Drocedure lvain rear open swilchON Exceot main r6ar oDen swltch ON Vohage 12V Powercut switchOFF Exceot Dower cut switch OFF d 't2v 't2v OV 12V '12V OV Sub rearclose switch Sub rearcloseswilch Sub rearclcse switchON Exceolsub rearcloseswitchON lvlainrear closeswilchON man rearclo6e Exceol switch ON Sub rear ooen switchON s Sub rcar open swilch Exceotsub rearooen switchON FRONT CANVAS TOP IIIOTOR ASSEMBLY Inspection Motor 1. Remove motorfromthe frame. Desconnect motorconnector. the Limit switch 1. the 3. replace sub switch. Check continuity between terminals themotor of tor as shown. Check operation applying anda ground theterby minals the motorconnector. ol ----\-------qq91 REAA volage Ooeralion_^-\ 12V b b Gfound 't2v d Ground d "f dt-:.-b '-Fa Open C ose 3.CANVASTOP s CANVAS TOP SUBSWITCH Inspection 1. replace motor. 2. Measure voltage the between terminals thesubswitch of and a bodygroundas shownbelow. Remove sub switch the fromthe motorcover. the 12V to 2. lf notas specified. c-ljli_-b =_--____!e!l Lrm[ sw ch ON OFF -{emind G b b d '-+ -+-' rr swrlcH o G c (Hi Indicales continuily the 3. s-51 . the connec2. lf not as specified. replace motor. ll notas specified.

Measure voltage and a bodygroundas shown. the replace control 3. afteriront autoopen switchOFFor exceptlror auto op€n swtch ON FrontcloseswitchON Exceot lroni close swtch ON 12V 12V Subswitch Powercut switchoFF Erc€pt powercut swdchoFF s-s2 . lf notas soecified.39in) e"cepr'earot rop ooen.rorerhanlomm (039 in) Frontoi top tully open Except Jronl of top lully open 12V OV 12V (within irontmoiod CANVAS TOP 2OA iUSE Constanl Powercu1swilchOFF cut Erceot Dower swtch oFF Fronl aulo open swtch ON 12V 12V Fronlauto open switch For aDooii sec.CANVASTOP UNIT CONTROL Inspectlon unit I Remove control lrom lhe rame the unit of terminals thecontrol the between 2. Termlnalvoltage T€rmlnal connectedlo Frontopen switchON Ercepi lrod op€n swLtchON b Inspoctlon procedure Volt gs 12V ov 12V Ground d swrtch Ott rrom openor autooPen fxceot trontopen or autoopen switcnOttl FTarof too ooen morethan 10mm(0. unlt.

relerring InstallationNoie.rb) '1. 57-79 ir.. pageS-54 Installation page5-56 Note rail 4..... Inspection.9 ns Ga-$ cD*g. S-52 13... 1.Guide rail Installation pageS-57 Note 11.. to 3... Front cover < linar rc..Drainhose 15. S-58 2.. pageS-55 Removal Installation page5-56 Note 6......Install the reverse in orderof removal... Canvas top Removal Note...referring RemovalNote. E-ring 8..amhh/ 9. Rearguideassembly Note. Motorcover 10.Driveunitassembly 14.CANVASTOP COMPONENTS Femoval/ Inslallation the battery cable.... S-51 page Adjustment.Disconnect negative to in 2.. MOTOF) IFEAR OPEN/CLOSE t 3. Remove the ordershownin the figure. pageS-55 Removd Note...Control unit page Inspection..Innerweatherstrip 17.Frame Installation Notepage 5-56 16..s--{. Canvas motorassembly top Note Removal / Installation pageS-58 page Installation page5-69 .Rear cover rail 12.. pageS-55 Removal Note. Frontguideassembly 3.Outer weatherstrip Notepage 3-56 Installation s-53 .Headliner 7.

Remove frontand rearof thelinerassembly the canvaslop.113 the top nuts the 5.CANVASTOP Bemoval Note Canvas top FAONT Note . s-54 . Remove mounting and remove canvas from the frontouide. ner wealherslripedgewlth the emergency from the 1. Openthe ftont of lhe canvastoP about290mm(1I . i-he 3. top the nuts the 2. Remove mounting and remove canvas from the rearouide. oIEOSX'117 from assembly the the and the 4.7in)from lhe in' ofthe canvastop about170mm handle. Remove bandtromthe fronlguideandroll backthe canvastop. the androlllorward ihe 6. Remove bandlromtherearguide canvastop. -:: --==--==-=-:=:01E0sx. Remove E-ring remove liner frontguade.4 Ini ftom the inner weEthe6tripedgeand lhe rear (6.

4.CANVASTOP 7. 2. Cautlon . Front and . the 5. Remove guiderailmounting the screws. Do nol damagethe guide rail or frame. Do not disassemblethe |rom or rear gulde assembly. Pullthe canvas off the linerassembly top ribs. Remove frontrajlcoverirom the guiderail. Slidethe rearguidefromthe guiderail. Remove guidesof the linerassembly the guide the from rail. Caulion . Theguiderallsare adheredlo the trameby sealant as shown. 3. the Caulion . s-55 . Slidethe frontguidelrom the guiderail.ear guide assembly 1. pushit downto separate guiderailfrom and the the trame. Insert protective a screwdriver between guiderailand the thelrame. 2. Do not damagelhe rear rall cover. Remove motors the fromthe frame.moving guiderailinward. Liner assembly '1. 3. GUIOEMIL Note .Remove front the and rearrailcovermountina screws.

the Nole . Apply a llberal coat of greaseio lhe drlve cable and ldction surfce of the front gulde assembly. lnsert drve cableintothe guiderail. Remove oiginal double sideadhesive fromthe lrame.insert drivecableintothe guiderail. Front gulde assembly 1. Deorease framewithethylalcohol. 01Eosx. Install rearguideto the guiderail. of the outerweatherstrip the lf the overlapis opposite.repairit with a scraperasshown Rear gulde assembly '1.so thatthe rearof the pushshaftis linedup on the guiderail. the Note . s-56 . the Note . Apply a liberal coal ol greaseto the drive cabl€ and fliction eurtaceof ihe rear guide asa€mbly.127 the 2. srdeadhesive to 4. 3 lnsLllnewdouble. tapeontothetrame. the 2. OUTERWEATHERSTBIP Frame atop Verify the rearwindowuppermoldingis overlapped that canvastop. lnstall weatherstrip the frame. Take care that there are no lolds or wrlnkles In the top or the wealherstrlP.CANVASTOP lnstallation ote outer weatherstdp tape the 1.

the 2.sothatthetrontend 2. Insert guides theliner assembly thegrooves the to of the of guiderail. 4. Install canvas to the frontand rearguades. Gulde rall 1. Install linerassembly the canvas the to top. Alignthe rightand leftsides the frontand rearguides. the 01E06X-133 ol 6. Insertthe drive cable of the front and rearguide intothe tubeof driveunit. FAILMOUNTING GUIOE Not€ . 3.2mm (0. Apply alsothe outer guide rail adhealve mounllng hole of ihe frame. the top s-57 . 5. Note .CANVASTOP guiderail.08 in) bead of adhesive fte lrame. Degrease trame and guide rail wjth ethylalcohol. Apply 0. to 3. Insallthe frontguidetothe of the pushshaftis linedup on the guiderail. Install guiderailsontothe frame. 7. Pull torward and llne up.

39-48 In'lb) withthe palvlwasher.openthe rearof the canvas tully 2. 1-lJncrhothe oawl @ @ 01E06X. Us€the emslgency handleto positlon the mark correctly It necessary. 3. Install lhe l.lote .CANVASTOP the between guiderailand the 8. Applya beadof silicone rrame.l-s. . l. Use the emergency handle to positlon the toe correctly It nec€sary. lnsert emeroencv the to caivaslop fully. l\4ovino-motor openthefrontol the canvas fully' to ttieframewif| limitswitchONas shown 2. Use a torque wrenchto tighten the locknut (set toroue). Vertly that the llmtt switch ls louching ihe toe ot the oear.134 2. g.(Refer pages-54 ) . to closethe top lrovlngby hand. Canvastop motor assembly Fronl motor top bv hand. Rear motor to handle the trontmotorand useit 1. Lockthe locknut s-58 . tnsatinehotor to theframe markol the withthe aligning hole' of gearaligned withthecenter the motormounting Nolg . -l. Tiohtgnlnoioroue. Adiu3tment top Carwaa motor assembly the and washer loosen locknut.i ttmils-ss cm-kg.

Theninstallthe back repairsheel fromthe underside thetop. R€ter to page SJo tor tear repah. Ins€rt repairsheetsquarelyintothe sectionof the canthe vastop beingrepaired. Apply adhe€ive W0 agent(K180 313)or equivalent the to section beingrepaired. Letthecanvas slanduntiltheadhesive top agentistullydry. . a sectionout of both the canvastop and the Cut repair sheet whha razorknifeand a straightedge. Trimthe canvastop and the reDairsheetswith scissors. Place repalrsheet(82Y5R1 211) overthedamaged the section. the backreand oair sheet. ot 7. Repalr ol Hole In CanvasTop 1. Degrease repairsheets the withethylalcohol. Press repair the sheets irmly together. 3. Repai.CANVASTOP REPAIR CANVAS OF TOP FEPAIFSHEET Note . 8. @ffip EIHYL ALCOI{OL 5.CCK BEPAIR SHEET W SECNON AENG BEPAIRED 4.ing a hole in the canvas iop dlfters lrom ropairlng a tear in the canvas top. ADHESIVE AGENT BEPAIB SHEET 6. Let stand tor a tew mlnutes. pieceof repairsheetlargerthanthefirstfor use 2. repair the sheet. B. Note . s-59 . Cutanother as a back repairsheet. Apply a substartial amount ol the adheslve agent to the cloth.

TOP CANVAS Repair ol Tear in Canvas ToP thanthe 1. Apply a substanttal amountot the adheslveagent to the cloth.Ialcohol For clesningrepafed parts s-60 . lnstall backrepair togelher. Apply adhesive and section beinqrepaired the backrepairsheet. of lromtheunderside thetop. agentisfully adhesive untilthe stand 6. Letthetoofabric AIF SHEET TOP CANVAS AND REPLACEMENT TOOLSFORREPAIR K180W0 313 B2Y5R1211 For repaiing canvss top Fof repairingcanvastop Eth!. Press reDair dry. DegrAsethe repair SHEFI REPTF @ F x r* ETHYLAICOHOL SECTPN AENG FEPAIRED to W0 agent(K180 313)or equivalent the 3. Note . firmly the sections 5. . Lst stand tor a tew minutes. sheet the 4. eut a piece lepalrsheet(82Y5R1211) larger ol damaqedsectionfor use as a back repair sheet withethylalcohol sheet 2.

page5-62 14..0--{...Instiall the reverse in referring Inatallation orderof removal.Center holecover Removai Note. Section N 3. Centerpanel assembly 15.. Section T 5. Meterhood ass€mbly 01A0sx-o33 6.INSTRUMENT PANELAND CONSOLE PANELAND CONSOLE INSTRUMENT OOI'FONENTS Removal/ Installation Note .2t-ta) '1. in 2... Remove the order shown in the figure. referringto Femovd Note.0.Horncap 2.. i..Sidepanel assembly 7. to Note....7 rr-b) 7.page5-62 L Rearconsde ass€mbly 13. Disconnect negative the battery cable..Fusebox Removal Note.. 5l--a.!-r2 rn (ao-120 d ('. Glovebox assembly lnstallation Notepage 5-62 18. lhe '|. Remove col|lrol wires ol the heaterunit and blower unll tor removalol thg inslaumentpanel.a-12 |{n (40-120 cF*g. lnstrument cluster 12.Frontconsole assembly 17..Bonnet release knob 9. 7. Ste€ring wheel Removal / Installation..page3-62 '16. Cdumncover 4.. Sidedemister duct panel 10. Ashtray Bemoval Note. 3..controlunit assembly s-61 .Heate.7 he) dd' 0--6...Instrument 11. Combination switch Removai / lnstallation .

lhet ll movits the tull stroke s-62 . lnstallatlon Note lnstrument panel lnstallthe controlwlresto the heaterunit and blowerunit as panel the belowafterinstalling instrument described 01EOSX. Insert lever the and holeandconnect clamo wirewiththeshutler on the heaterunit at its closestpoint. Remove the upwatdto rs 3. mounling the 1.and verto verlly thatthe wlre ls securely from Detrost lo Vent. Cautlon . Remove rearconsole cover.1{A Alrflow mode whe position. Atler tnstallation. Pullthe centerpanelassembly harness connector' the 3.6mm 2.24 In) diameter screwddver the set 0.PANELAND CONSOLE INSTRUMENT @ @ @ @ @ Removal Note Conter Panel ass€mbly screws. to lever VENT modecontrol 1. Setthe airflow into (0. Pullthe tront of the rearconsoleassembly move it. Disconnect cigerlighter Side panel aaaembly forwardto removeit Pullthe side Danelass€mblv Rear conaole assembly mounling screw assembly the 1. 2. Remove centerpanelass€mbly it torward remove to 2. move the airflow modecor rclle' altachsd.

Aftel lnatallation.movelhe ReeFr€sh levsr to veity lhat lhe wit€ is securely attach€d. Temperature blendwlre '1.-e-. i"-"iii-0. Caurlon .INSTRUMENT PANELAND CONSOLE i.5mm(0. and lhal lt moves the tull siroke trom Hot to Cold.Set the selectorleverto Fresh oosition SEI HOLE s-63 .iini ii"-i"tJiJ". unit Cautlon .and that lt movea lhe lull stroke from Reclrculation to Fresh. REGFRESH wlrc '1.24in) diameter screwdriver the set into holeand connect clampthe withtheshutter wire and lever on the heater lullyto the right.i. Atlsl installallon."ilo. Ins€rt 0.Setth€temperature position. blendleverto Max-Hot 2. move the temperaiure bl€nd lever to verlly thd the wlre la aecurely altrched.!'o'iu"rinto set the holeand connect clampthe withtheshuterlever and wire on the blowerunitat its clqseslpoint.

... B-piller page5-65 ... A-pillar page5-65 ......... Femoval 10... Rearpackage ................ ...Rear doortrim ............. pageS-66 Removal end trim 11. Removal 3. Removal door trim 9...................Trunk s4 ..Trunk sidetrim 12.......-Cernove trimOipaandfo€teners................. C-piller page5-66 Note..TRIM TRIM @IIPONENTS Removal/ lmtallatlon to in in and ttre t . lnstallin the reverseorder of removal T 1.... Removal trim 7.. ........ Front sidetrim trim 2... Note............. Front page5-66 Note. Removal uppertrim 6.... Rearscuff plale lowertrim 5..... Note.......... Frontscutf Plate 4..... remove theordershown thefigure'referring Removd NoG 2...... B-piller page5-65 Note.. ................ Note. pageS5 Removal trim 8... Note................

piller upper trim 1. 2. Pullthe A-pilbrtrimto remove clipsfromthe body. the 3.(See above. Rear package trlm '1. Remove seaming the welt.) the 3. @ @ B-plllarlower trlm 1. the 7. Pullthe A-oiller uoward remove hookfromthe trim to ooqy.Remove rearseatcushion. Pullthe &pillerlowertrimto remove B.) 4. Remove frontseatbeltuoDer the the the 3. (Refer pageS-75. 2. 3. Pull B-piller the upper upward remove hook trim the body. s-65 . the package mounting fasteners. Remove B"piller lower trim. Remove frontoflhe rearpackage fromthe body. trim to the lrom 4. kim 5. Remove rear the trim 6.) the anchor. Remove rear seatside back. Pull B-piller the upper to remove clipfrom body. (Refer Section to T. Remove seaming the it. the 2.) to the 2. the welt. (Referto page S-75.TRIM *+?' HOOK Removal Noie A-plller lrlm 1. Pullthe to clipsfrom rearpackage forward removethe trim the body. Lowerthe rear seat back. Remove highmount stoplight. Remove frontand rearscutfplate.

Remove seaming clipsfromthe body trim 4. it. Remove reardoortrimmountlng the the 2.TRIM Golller tlim to trim (Refer pageS-65. Remove capandfront 159 01EOSX the the 3. 3. hemove rearpaakage the 2. Pull frontdoortrimto remove clipsfromthe body. the 3. Liftup the frontdoortrimto remove Reat door trim screw 1. Pullthe reardoortrimto remove clipsiromthe body. Remove rears€atbeltupperanchor' welt. I 4. Liftup the reardoortrimto remove o1EA5X. the 1. Pullthe C-piller to remove Fror doortrim handle.) the 1.Remove inner screws doortrimmounting the 2.]61 s-66 .

Frontseat belt loweranchor. lowertrim.) c.(Reter page5-64. (Refef pagesS-74. Frontseatsand rear seat cushion. Footrest equipped) Bracket 2.) a. Floormat s-67 . To remove lloormat. to b. Remove remaining the 4. the (Refer page 5-61. Frontsidetrim. 75.scufiplates.(Referto page S-72.) to paneland frontconsole. the 2. lnstallin the reverseorder of removal (if 1.) partsin the ordershownIn the figure. 3. 3.lirst remove. Disconnect negativebatterycable.) to e. Center to and B-pillar d.FLOORMAT FLOORMAT OOl||PONENTS Removal/ Installaiion 1. (Refer page5-61. Rearconsole.

... Headlaner ..Sunvisor adapter mirror 2. Interior handle 4.-.......... s-70 lnstallation s-68 ...... B-pillar page . Remove the ordershownin the figure.. A-pillar page5-64 / Installation.......S HEADLINER HEADLINER COIIIPONENTS Removal Installation / battery cable the 1.. lnstall the reverse I{ORIIAL ROOF and 1... Assist welt 5.......... Removal uppertrim 7... page Note.. Seaming trim 6.. referring InstallationNote to orderof removal..... 5-64 / RemovalInsta||ation 9.. 5-64 Removal / Installation tim C-pillar L page .. .. Rearview lamp 3................ Disconnect negative in 2..... in 3...

.....Seaming (canvas welt top) 11.... A-pillar trim page5-64 Removal / Installation..... c-pillartrim page Removal / Installation. 5-64 8.......--. 7............. Canvastop sub switch 10.. Note S-71 s-69 ....... Seaming (dooO welt 5... Sunvisor adapter and 4.....lnterior lampand rearview mirror 2....... 6.. Overhead console 3. Lrolorcover 9... B-pillar uppertrim page5-64 Removal / Installation..Headliner page Installation ................HEADLINER CAI{VASTOP Po l......

lnsta . I FIGUFE 3 FIGURE 2 FIGURE s-70 . degrease withethylalcohol tape adhesive i. and C-pillars doubleside to 9. tne originddouble'side reused). lnslall sideot the headliner the body (Figure tape' adhesrve with to the 8. Insert wires rear panel.ew double-side the panel'and install lront (B) (A)ot theheadli#r withthe pointer df thefrontheader i. and installthe (D) V not"ntC) ol the heaain.HEADLINER Removal l{ote Headliner(Normalroof) tape was installed ildJi'iii"d-. lion tne V notct' l) to ol [he headliner the body. tapeontothe headliner adhesive 3.(Figure (Figure 2) intothe holder.rwit6the pointer of the rearheader tn" 6. Install headliner the A-.av wiit' "thyt at"hol where the double'sideadhesive (when it and fromthe headliner. (whenreused).ih" o. n"iiou. S.qiion 3) to ot the headliner the bodv (Figure 4) to the 7.. Instalithe fasteners the body. the 5.

with and install rear the of the headliner the body. B-.andinstall headliner the body. Remove original the doublesideadhesive tapefromthe headliner. degrease withethylalcohol and it reus€d).(Figure to (D) 5. and C-pillars doubleside the to with tape. Degrease bodywithethylalcholwherethe double-side the adhesive tape was installed. (whenreused). lnstall sideof the headliner the body. Alignthe V notch(A)of the headliner the pointer of thefrontheaderpanel. Install new doubleside adhesive tapeontothe headliner (B) 4. adhesive 9. (when 2.(Figure the on 4) 8. with the to (Figure 2) (R 6. Alignthe mark(C)of theheadliner the V notch of the body. 3. Install headliner the A-.(Figure to 3) 7.HEADLINER s Headllner(Canvas iop) 1. Install fasteners the body. the with and install front '1) of the headliner the body. the to FIGUFE 2 FIGUBE 3 POINTEB(R FIGUFE 4 E AOHESIVE TAPE FIGUEE 2 s-71 . Alignthe V notch(C)of the headliner the pointer of the rearheaderpanel.

..... &pillarlowertrim page .... 5-64 / Removal lnstallation 2..... 5-64 RemovalInstallation 3... Do not dlsassembl€ the buclde or rettac-torassembly.....................0........ Front seat bell 1................. S-75 RemovalInstallation / packagetrim 8............ Frontseat belt pageS-73 Inspection.......... 5-64 Removallnstallation I L Rearseatbelt page$73 Inspection.....SEATBELT SEAT BELT @iIPONENTS Removal / Inslallatlon '1.. Rearconsole 5......... Frontscull plate page . page ...... 3!-7a €....... 5-64 RemovalInsta||ation / 4................... Buckle Rear aeat bell 7.............. ffi1 RemovalInstallation / 6........e-+... Rear page ..... Rearseatcushion page ..... Rearscutf plate page / .... in Installin the reverseorder ol removal.. Cautlon .. 2..Remove the ordershownin theligure............. s-72 ....

FFONT 3. wearandfor delorf|e for mationof the fittings. 2. Remove retractor. 3(l degreesincli6. Verilythatthe retractor nation. 01E0sx-164 Emergsncy locklng retrac-tor and 1. Slo\.replacethe seatbelt assembly.vly inclineihe retractorwtile pullingout the belt. 7. locksat apptox. s-73 .tears. thatit movessmoothly whenworn. Inspeci webbing scafs. lf not as specified. the 4. Holdlhe retractor it wouldbe installed. ll any problemis found.SEATBELT SEAT BELT Inapecllon Webblng and 1. replacethe seatbelt assembly. as 5. Verifythat the beltcan be pulledout smoothly. 2. Verify the retractor that lockswhenthe beltis quicklypulled.

. orderof removal. Install the reverse FNONTSEAT 3F5r 3!-51 (3. Frontseat ..SEAT SEAT COIIPONENTS Rsmovd / Inatallatlon in 1..9-52.. Remove the ordershownin the tigure. 5-61 / Removal Installation 2.. Rearconsole page . page5-76 Disassembly s-74 . .......9_5.. 2t-34) €.. in 2... / Assembly ......... 2l-31) & Y '! I 'i.2.

.r1 1.1..a-11. Bearseal side back 5..1.. 16-2' t.1rrt- o \ It\J.. Rear seatcushion 2. 15-Zr) ..(2..SEAT REAFSEAT z2---3. S-64 6.....6f z2--0. Hinge 4.. (22--3.t Xn {90-rm m*$ 73-l0a !rl!) 01..A06X4..-o z--tD (22--4.2--3.. Rear seatback 3. Rearpackage trim page Removal/ Installation . Striker s-75 ...

Side 3. in 2. Assemble the reverseof U I \tl 1 L _ knob 1.SEAT Dlsassembly/ A8a€mbly Note' to shownin the ligure. Headrest 7. Seatback s-76 . Headrest guide 6. oisassemSte te ord-er disassembly.referring Dlsassembly in t. R€clining cover 2. Seatslide 4. Seatcushion 5.

Remove the ordershownin the figure.r!rl {H> lh L- 0tE06x-193 flap 1.FRONTFLAP FRONTFLAP COITIPONENTS / Removal Installation in 1.a'. lnstall the reverse tl' \i r/ . in orderof removal 2. Front s-77 .

..................... T-A5 FLASHER UNtT............................................. PROCEDURE.......... T-10 HEAD1tGHT...... VtEW T-{S TROUBLESHOOT|NGS............................ T-14 BACK-Up 1|GHT...2 FUSE.......................................................................................... T-23 HORN SW|TCH..........................3 I ............................................ VtEW T-81 FUSE BOX...................... T-85 swtTcH ...................!01 WATER THERMOSENSOR.............................. T-12 POSITION LIGHT.................. T-39 FUSE GAUGE SENDER UNIT..............T-10 STRUCTURAL ........................................................... VtEW T-85 TURNAND HAZARD WARNING HORN .................................... T-95 STRUCTURAL ............ AUDtO................ T-28 T-89 TNSTRUMENT CLUSTER ....... T..............T-72 FtNDtNG SHORT C|RCUtT... T-21 lRouBLESHOOT|NG.. T-.................. T...... T-28 CONNECTOR TERT/INAL REAR WINDOW DEFROSTER sPECtFtCATjONS............................. EXTER|On T........................... T-70 RESISTANCE .................... VtEW T-29 DOOR SPEAKER.. T-95 PREPARATTON .................................................. T-2s STRUCTURAL .. T-46 INTERIOR LIGHTING SYSTEM................ T-{2 BELAY.................... 6 TENGINE PRESSURE OIL SWITCH............................... T-85 HORN RE1AY............. T-47 DEFROSTER. I T-t TURN STGNAL 11cHT...................................... T-22 HORN......................................................................................... T-24 T-€5 STRUCTURAL .................. T-19 ILLUt\4tNAT|ON 1Atip..............48 TFOUBLESHOOTTNG GUTDE .................................. T-30 REAR SPEAKER............................. T-40 swrTcH............................... T-46 EXTERIOR LIGH1NG SYSTEM.... VtEW T-72 sYM8O1S...........I WARNING ANDINDICATOR LAI'PS T-47 AUDtO...... T-73 FUSE .......... VrEW r-19 REARWINDOW DEFROSTER... T-{6 rGNrTtoN swtTcH.................. T-22 DEFROSTER FI1AMENT........... USING ELECTRICAL TEST L|CENSE T-60 EQUrPMENT............................ T-4t FUNCTrON. T-81 MArN FUSE 81OCK............................ T__96 TNSTRUMENT CIUSTER........................................................ T_79 STRUCTURAL .. 7 TBRAKE FLUID LEVEL SENSOR............................................................. T-84 STRUCTURAL V|EW......................... VIEW T-86 coMBtNAT|ON SW|TCH... T-............................... VrEW T-24 PREPARATTON .. T-96 TBOUBLESHOOTtNG.............................. T-13 sTop1tcHT....... T-23 STRUCTURAL .......................................................... CABLE T-39 tNDEX..... T-54 HANDLTNG CONNECTORS.....5 TWARNtNG 8U22ER................................... T-17 tNTER|OR LAMP ........ T-29 ANTENNA ANDFEEDER CABLE...............................................I L|GHT|NG SySTEir. TROUBLESHOOTtNG....................... T-46 HORNAND REAR WINDOW PARKTNG BRAKE SW|TCH.... T-29 AUDTO UNtT.......... T-87 HMARDWARNING SWITCH .......................... T_67 MEASURING CONTINUITY/ FEARCOMBINATION LIGHT ............... T.... T-88 swtTcH ...................... T-{9 PRECAUTTONS .......t5 |NTER|OR LAitp SYSTE ................. T-20 STRUCTURAL .................................... T............................... T-63 MEASURTNG VO1TAGE............................... TAILLIGHT AND pLAtELtcHT..2 RE1AY.............................................. T-25 FUNCTION ANDOPERATING PANEL LAMPCONTROL SWITCH T-27 ..... rRouBLESHOOT|NG.......... T.............. T-16 STRUCTURAL .................................................................... T-3s 01A0tx.....4 T-4r TNSTRUMENT C1USTER..........BODYELECTRICAL SYSTEM WARNING AND INDICATOR SYSTEII|S...... T-39 SpEEDOMETER ....

..... Fus€ pase Specifications...... I-?1 page .............INDEX '1............... I-?9 pageT-20 ...........Mainluse block paSe Specilications.................................. Inslallation Removal / box 2.... T-21 Removal / Installation T-2 .........

........ Hornrelay pageT-23 Inspection ............ 2................INDEX NELAY 1.......to Section Refer F T-3 ..... Cooling relay fan lnspection... Circuit opening relay Inspection ............. 3...............Turnand hazard warning flasher unit pageT-23 Inspection ...to Section Refer 5.............Section Refer to E 4............................................... Mainrelay F Inspection ......

8.. S to Refer Section top 9..p... .... .. . ..-.. .. ... .T-28 / Installation Removal pageT-28 ..... .. I n s p e c i t o n . Hazard pageT-28 Removal / Insta||ation.. .. lnstallatlon. . . . RemovalInstallation . ........ ..... . ... pageT-27 U to ..8 ....a.. . .....T . pageT 26 1nspection. .....-.. . .a. .. lgnition .g e.....g e.2. ... .. 7.. . . pageT 27 Removil/ page . .. ... .... Combination S to .. ..... Refer Section -.... . .5 . T-4 . ... .... . ... . .. Disassembly / Assembly .... Panel switch 1.......pageT-25 / U to Section Reler switch............... ... switch mirror 6........ Rearwindowdefroster page .. ..T . switch 3. . . .... T-25 Installation Removal/ ...... .. Inspection warning swltch 4.. A/Cswitch.-....-. ..... .... .. .... . . . .... . Reter Section .....Remote control swtch 2.... ........ .. .. Blower ..-...... .. .2. .. .. p..a g e f 2 7 p.... ....INDEX swlTcH switch lampcontrol 5.... ....... . Canvas switch.... . 1 n s p e c t i o n . .. ... .. I n s p e c t i o n . .. .... .. ...

Tachometer pageT-37 Inspection .... Odometer 1.F ............ T-5 . 2...../\ ^....1 ...... Fuelgauge page T-37 Inspection .. Speedometer pageT-37 Inspection .............. I2 4......Z ...........-...... gauge 3..........INDEX NSTRU ENT CLUSTER T ....\v r l ' r 7 2 T............. lamps 5.. Watertemperature pageT-38 Inspection .... Tripmeter 7............................................ 6........ Warning indicator and page T-47 Rep|acement.................-............

............. Position pageT-65 page Insaection......................... ...... Back-up light turn signal 3..... pageT-59 Inspection / Insta||ation....... pageT-59 Removal / Installation.......... Front pageT-69 ............ T-52 RemovalInstallation / lightswitch 9.............. Liconse 1.............pageT-62 pageT-53 RemovalInstallation / Aiming.INDEX SYSTEM LIGHTING EXTERIOR platelight 6.-......... light 5............... / Assembly Disassembly T-6 ......... / RemovalInstaliation............................ Stoplight light 2............... Headlight ..... .-.............. switch 8....... High-mount / 1nsta]lation.. pageT-52 stoplight 7.Inhibitor light 4........... Removal .............pageT-66 ............ . pageT-53 Rep1acement............... Removal switch 10........................... Removal pageT-70 Replacement.......................... Rearcombination (1)Taillight (2) Rear light turnsignal (3) Stoplight (4)Back-up light pageT-70 / Instal|ation.. pageI-71 ............ Sideturn signal T-69 ....... page Inspection........

T-78 pageT*78 Inspection ............ lnterior lamp(without canvas top) page"l-77 Removallnstallation / .-...................-.. Interior lamp(with canvas top) page Removal/ Installation ..- T-7 . 2...... Trunkcompartment switch page Removal/ Installation .................. lamp 5.. T-77 3..... Doorswitch page RemovalInstallation / .........................--............ T-77 4............. Trunkcompartmeni lamp page Removal/ Installation ...INDEX INTERIOR LIGHTING SYSTEI' 01aorx{o7 1...................... T-78 pageT-78 Inspection ...-..............

.......................INDEX DEFROSTER HORNAND REARWINDOW '1.............. Repairing swttch defroster 3....... .... Inspection ........ .................. Rearwindow page ........... Inspection pageT-€4 ........... .. Bemoval/ 2........ Bear windowdelroster pageT-84 .....Horn pageT-85 Installation........ T-28 T-8 .

.. pageT-96 3................................................ Antenna feeder and cable page Removal / lnsta1|ation............... Door speaker Removal pageT-96 / Insta||ation.INDEX AUDIO o N 1................. T-95 2.................... T-96 / page Inspection ................ T-95 T-9 ... Rearspeaker page Removallnstallation .....Audiounit Removallnslallation page / . Inspection .......... T-96 4.........

T TBOUBLESHOOTINGS System GUIDE TROUBLESHOOTING GUIDE TROUBLESHOOTING Sy|r|ptom is does not operaleor indicatjon not corr€cl Speedometer does not operaG Tachomeler gauge does not operale water temp€ralure Fuelgauge doss not operale alam cloesnol opefate remainder Light-off illuminated lampremains Engine warning orl Engineoil warningtamp does not come on when€nginestoppeo (lgnnion ON) swilch Irak" "ystet *.to? ry3reln r-44 T-45 T-45 T-46 T-50 T-55 T-57 T-58 Edcrior llghling system T-61 T-64 T-65 T-64 r-74 T-€O T-43 T-89 T-92 T-94 Inteilor lamp systGm Rear wlndow deftooter 3vslc|n Audio aystem T-10 ."||ng la-p remalns lumnat€d Brakesystemwafning lamp does not comeon when parkng brakels on (lsnfion swibn ON) Brakssystemwaminglamp does nol como on $hen b€ke fluid in aeserwirlank .l3 T-€ W. No lightsilluminale not operaE (all) do Sloplights stoplightdoes nol operate(oneonly) Back-upligh(s) does not operal€ InGior lamp do€€ not illuminale with doorsclo€€d Interiorlamp remainsilluminated lampcontroldoes not op€rate llluminatron Raerwindowdefrosterdoes nol op€rate Speake(s)do not sound Poorsound qualityor noiss(Raclio) tape playei Poorsound quality(Cass€tle Ralerancepaga r-32 T-34 la€trunant clustcr r42 T .rning and lndlc.s b€low MIN Roarwindowdetroslerindic€lorlamp does not comoon whenrsar swrtchON windowde{roster do€s not operate Headlight(s) Turnand hazardwarninglighlsdo not opefate Turnsigml(s)flash€srapidly Hazardwanrng functon does not operale parkinglightsand licensedate lights) (tajllighls.

.TROUBLESHOOTING GUIDE PRECAUTIONS Nolelhe following itemswhenservicing electrical the system. 6nglne)to r€moveslackand to th6 prcventcontactresultnglrom vlbration. awh€n mounting comPonenb. Do notalter wiring electrical the or equipment anyway. T-11 . sua€ lhe De hamessls not caughtor oarnag€o.e ol a larg6rcapacity a than d6signated may damagecomponents caus6a ire. Replac6 blowntus€swith on€s havingthe safnedesignat€d WXW r0A t5a caution a Be surc lhat the ignltionand otherswitches ott arc betoredlsconnecting connacting batt6ry or the Fajlureto do so may damagethe semiconductor Caulion . o Disconnect heat-sensitive parls (for exarnple. the .thjsmaydamage vehicle cause firefrom in the or a short-circuiting a circuitor overloading it. hamessthat may rub or bump agalnst shan €dg€slo prolectlt ftom damage.Always djsconnect negative(-) battorycabtefrst and the r€€onnecl lastwhendisconnectng ba(ery. Makesurelhat lh6 conn€ctors securely ar€ instail6d. or a Secure harnesssswith providedclampsto take up slack. Donot handle €ledricat components roughly drop or them. B€placing tuse witho. . r€laysand ECUS) wh€n pertorming malntenance whers {suchas w€lding) lemp€ratur€s may €xc6€d 80t076'R. Cauton aclamp all hamess€snear vibratingcomponents (tor example. .

Make t€rminalis securely mountedIn th€ reinstalling. 2. when dlsconnecting them' Conn€ctot rcnloval Checklng conn€ctor contacts Ch€cklngfor loose termlnals t€rminals Repalrlng 1. Lilt the tab wilh a and smallscr€wdriv€r f€mov€ l€rmrnar. in connector when6ngag€d. Lightlypullsach wirelo makesllr€ tl|e teminal does not pullout of the T-12 . ground conneclors> <Common 3.Openthe rear cov€r.1y' {t/. Caulion r4 conn€ctor> <General -. z.tit the lab wilh a terminal. lhere is no loo€€ness surethe 3.GUIDE TROUBLESHOOTING @NNECTORS HANDLING Cautlon liilure to srasp the connectoe.Uft the lerminalto a Wh€nusing matchlng Makesurelhe terminals mak€sur€ are not pushedoul of the malelefminal. not the wiles.Ufr lh6 tab w ir a caullon engaged lmproperty wlll connectors causs poorterminalcontact.Openlhe cover. th€ b <Boundconnedors> 1.

diodes Using largsa oThelampwlllllghlll thecifcuit capacltybulbmaydamagethe is energized th6 point lo CPU. conn€cted parallel. the oTouch leads lhecheck the to ljs6d to ch€ckalt€matorouFut. in T-13 . th€ circuit. to and da* cun€ntwilhin a circuil. posilive(+) leadto the a Conn€ct ammelerin series lhe power-side temlnal 6ndlh€ with lhe circuit.Zefo the ohmmeler. Darkcunentis the current fowingthrough circuat the the ignitionswitchis OFF. Connect positiv€(+) lead the th€ o. a Do not connect powersld€ lha clirectly a ground. a circuit fnd possible to opens to wherevoftag€ls to bo measured lhe nsgative 6nd (-) leadto a ground. a Connect ammeter series a Set the rangeto the desired the in withthe carcuil touching by tho arnperage. a Us€lhe s€ryic€holewhen measuring voltageat the the dlagnosisconn6clor.4W use belweenlh€ chcuitb€lng or 3. aconn€ct the voltrneter in parallelwilh th€ circuit. to ch€aksensor and 6-azero th€ msteralt6rswilching to tll6 rn€asufing range.4Wbulbsor light-omhing m6asured a grcund. m€asurjng voltag€ . currentsupplled lh€ starter. a B€foreusingthe ohmmel6r.to confrm conlinulty L__jil ol switches. Usedlo createa temporary a Connect jumperwire lhe b€twe€n t€rminalsot a th€ ctcuit lo bypassa switch. may to lhis bum lhe hamess damage or el€ctrical compon6nts.lreto lhe posirive (+) l6adlo accessnanow Ohmmet€r Usedtoind opens andshorts in .TROUBLESHOOTING GUIDE USINGELECTFICAL TESTEOUIPMENT Equipmont Test lamp Usa Testto fnd opan or shoned Opsratlon precautlons Handllng aconnectlh6lsstlamp a Testlamps 12V|. . makesurelhe ignitionswitch (-) is ofi or the negalive batery cabl€is disconnected to preventbuming the averit thatcurenlisnot towing lhrough carcuil.& )t. a Tie a lhln s.sbrdh . Theammetor n€gallve(. Us€dfo.r$. a S€t th6 rangeto th€ desked voltag€. and (1E05).) i6adto th6 may b€ bumedit il js ground-sid5 temlnal.

T-14 .or loose VoltrnEt6r l€ad voltageol groundunlt Measudng lead io the groundwire whenchecking Touchthe voltrneter $e qroundcircuit. measudag @ 12v d r2v 'd r2v d r2v r2v 'd o @ r2v b rzv u o o Ground2 1 Ground ct: TestlampON x : T6st lampOFF voltageot connectors Poorconlacl Msasuring connecta terminalwhen A vollm€td l€ad may momentarily rsadlng and giv€ an srroneous intolh€ connoctor lns€rted poor for whenchecking lmpropo y engag€dconnectors' termlnals.T VOLTAGE i.EASURING GUIDE TROUBLESHOOTING Ba$€ry (posltive teminal) 1. use a voltneter or tesl lampto ascenainvoltagsat lhe points. t€rmlnalcontacls.

is according lhe dhecdonof the posltive to Conlinuity check€d (+)andn€gativs leads lh6 ohmm€tor lhe cifd. the posltive {+) lead to the negatlve termlnal of the battery. NO Connect ohmmeter the leadslo the sensoror solenoldvalve leminals to checkresistance.TROUBLESHOOTING GUIDE CONTINUITY/RESISTANCE iIEASURING T Touchlhe ohmmeter leadsto lhe switchterminalsto check Caution Verirylhe operating stateot lhe swltchbelorech€cklng conlinuilybecause r€adings vary accordingly. lhe Connecuon Conlinualy Th€ negative (. The capacitor good ll lhe needl€ol lhe ohmmeterswings onceand retumsto lts odginalposition. Shortbelween terminals the rangelo x1ok 0 and connectil to the 2. Caution V€ily lhe op6rallng stale ot the sensorbetorechecklng resistance b€cause readings vary accordingly.iit (-) of in containing dlode. wilh a iumperwir€ to dlscharg€ 1.) lead ol lhe ohmm€t€r is connecled lo lhe poslliv€terminaloflhe inlernalohhmeter banery. Sel the ohmm€ter capacitor teminals. is 3. T-15 .

I beginning connectol. aThe tuse is not m€lted. t + condltions exisl as whenthe valueis 0 Q.'6.The CPUthinks switch lh€ ON bocause samg lhe exlst conditions as when is switch ON. Checkthe vottrneier s€e I or il the t€st lampllghtsas the conn€dorsare connecl€o bumsout aThe CPUt ansistor is whenth€ilnitionswitch A short hasoccurr€dwher€ths turned ON. 3. Disconneci connectors ln el€clricalcomponents lhe circuat. Circults connectedto control unlt Examples Short location Shon (A) lndlcatlon Findlng thott clrcuit Snod(4 Sol€nold shod (B) (B) (c) Shorr sho't (c) 1. ' zufi|lll|| | Short(C) the near€st power M shon(D) | /. l" 3.. Dlsconnect connectors components of €lecmcal ln lhe circult.The CPUequlpp€d lhe r€adsoV or &e test larlP voltmeter sell{jagnosl$ lunctionoulputs code. has A short occuredwherclhe readlngchang€sor the lest voltmet6r lamplights. conn€ctrolhe switcrv conn€dor. sowce. whenths lgnitton reconnect r.I connestor./4.l (D) Shod (D) is the . Atrachthe test tampor 1 votmeler to lhe cPu ^l cPU. Examples BailsrY l€ dnar) - Short locatlon lndication Flnding short citcult the 1. R€movethe fus€ and main luse ol lhe circuit ol all 2."* ts howthe circurt roueo determining finding shortcircuitrequires a Therelore. besinnins H rFn fl fl | pow€rsourc€. resastance A short hasoccured whelelhe with . q---A 2.l I Tssl lamp Short(B) O--1. Ch€cklhevonmeter se€ I lhe tobeoQ because same if lhe tesl lamplights. Attacha voltmeteror test a Solenoida operaiesnomally Testlamp lamPto the fuse box and switch is €achconneclol. ihe maltuncton T-16 . vollm€t$ rcadingchangesor the test lampilghts. op€ral€s aThe motor the ot reqardlsss whelh€r thdmoswirchis ON or OFF wh€nthe ignltionswilchis oN. all 2. the a1he mainfusemsltswhen ignition switch themoand swiich are ON andthe f6layis operamg. Check voheter ot the see lf lhe test lamPlights as lhg connedorsare connected. Remove tuseand mainfuseol the circult. . 0 sho.oacn a voltmeteror lest lamPnto fus€ box and the ". " 4._) to nearest th€ oN. Shon(E) Sensodswitch . ['Ji5 l( i !-5i ft | shon(A) l. sensol LV l\l me aThe CPUsenses sensor -f or 3. l.GUIDE TROUBLESHOOTING SHORTCIRCUITS FINDING sidesol a ckcuit' and gro'rnd (negative) betweenttre power (positive) 3i.

wire pointwhere . Electrical switching component. <Box typ$ <cartridg€ typ6> (Cartrldge) lan( Fi's lR€. polntlo .conv€rts €lect ical €nergyhto mechanical energy.Connecling to or body wire wherec!ffentllows olherground from positve to negativelemlnal of battery. a Tums on wh6nvollage is appllsdto the base(B).r. Fleading t9 gases liqulds.lowthrough circull a ll ground faulty.ound point vehicle .6€ hru6 (1 Transisior ) . Mells when currenttlow exceeds thal speciied for circuit.Ground (r) indlcales ground a bodythrough harness. stoppingcurfent (box) Fus€(2) .6r lry Transistor(2) a "o" Eq9 .Go'hd (2)indicales component grounded is dir€cdy to . ls Fuse{1) . Gen€rates oleclricity through . (1) Ground (2) G. . coil @ T-17 . a A rcs|siorwl$ a COnStan! a Mainlyusedto protectelectrjcal in componenls carcuils maintaining by ratedvollage. Supplies direcl curentto circults. a Reading resistanc€ values. Curontwillnot. a Pullsin andexpels and I I o Emitslaghl generates and healwhen cufient iows throughflament cigarettelighter a El€ctrical that generaleshea!.TROUBLESHOOTING GUIDE SYITIBOLS T Meaning Symbol Battery Meaning . code. ctccr.Do not r€placewith lus€s exceeding specified capaclty. Symbol vaue.

--Kplungers. diode does not gonerateheatwhonlit. T-18 .T Symbol GUIDE TROUBLESHOOTING Moanln9 a Generatessoundwhencurent iows Symbol (1) Swltch Meaning cun€nt iow bY or aAllows breaks circults. a Knownas a s€miconductor lh€ dlodoallowscurent llow In one dir€ctiononly. a Connected aTuming ignillonkeyoperatesswitch vadouscircuits. c. contactsto complete (Connected) lgnllionswitch R6lay (1 ebcromagnefc forc€ causingcontactlo open or close acun€nt llowinglhroughcoil produces ri t: q 4 (NC) open r€lay(NO) Normally Normally clossd t€laY (NC) f ""** l*Diode -----*{- "'*' | changes S€nsor(variaDl€) aBeslstorwhossresistance of wilh oDerafion othercomponeats.Unlikeordlnary bulbs. and opening closing SPeaker Switch (2) m rr-] Heater hsatwhencunentnows.allowscurrent up to a (Zen6rdiod€) oncemat electomagnelictorc€to op6rat6 ro llow in the otherdir€c0on '. calhod6(K)-3{anods(A) capacitor acompon6ntlhalt6anporafllyslofes el€ctrlcalcharge. a ljnconnectedint€rsscting Sp€edsensor t_fl ol a Movement magnet in spoedomeler (Not connected) tums contactwllhin s€nsoron and olt intersec0ng harness.(|9-L.rrd. Carhode(K) Anodo(A) Flowot €leclriccuff6nt Sol€noid cur€ntto iow Inonedir6ction acurem iowing lhroughcoil g6n€rates F€terence daode aAllowscertainvoltage. --txn- r€cllier.. voltageis exc€€dsd.^mdq4 changes Sensor(lhermistor) a Bosistorwhos€rcsistahce Ugh!€dning diod6 a A dlod€that lightswh€n cun€dtiows (LED) light the . a Generates harness.

...FUSE FUSE VIEW STRUCTURAL 1................... Removal/Installation........... page ...... Fuse box pageI-?1 Sp€cifications..... Mainfuseblock pageT-20 Specifications........ T-20 Removal/ Installation FuseColor Code Fu3e amFcraqe 10A 15A 2.....pageT Colorcode R€d Blue Llght gr6€n Locdlon 20A 30A 30A 80A Pink Black T-19 .....................................

lnstall the reverse Plate fuse in supplied fuse..".-tt-. T-20 .r^M "ffi. .usethe fusepuller a Whenreplacing plate the fusebox cover.t ULJU T.FUSE MAINRJSEBLOCK Soecltlcations LOCATIOt'l FUSE C-FAN ATIPERES 204 PLATE 104 80A TYPE L-:r t-Jt-.I 2 3 ST MAIN INJ 304 304 CAFTEIDGE 5 HEAD / Removal Installallon Cartridge tuse (80A) bolts 1. Remove mainfuseblockmounting the the luseblocklid and remove bolt 2. 3. Remove in orderof removal 4. Openthe main MAIN80Afuse.

LOCK) STOP HAZABO 204 20A 15A 154 FUSE AIIPERES 204 r-14-l l-is--l ENBHBNN rid-"I ri--l EEtsHBNfl 4 5 6 7 ROOr\. ol T-21 . Pushbuttonto resetclrcult breaker atteroperating dlagnosls maltunctlon.FAN 2 3 TAiL (D.WNDO\9 MEIEB WIPER ENGINE 304 20A 30A 154 I 9 10 11 204 15A 15 cfioP 17 CIGAR 204 15A Removal Installation / Plate lqse When replacingfuse. ClrcuitIreaker Note .FUSE FUSEBOX Specltlcatlona LOCATION ADD.4 (CIBCUIT BLOWER BREAKER) DEFOG (P. pullersuppliedthetuse a usethefuse in box cover.

.............. Refer Section Inspection relav 5... Hornrelay pageT-23 Inspection. 4............ ...... Coolinq relav E Ref to Section er InspEction. 2...RELAY RELAY VIEW STRUCTUBAL )1 llasherunit warning 1.. .. pageT-23 Inspection...:............. lan 3... Crrcuit oDenino F Refer to Inspeition........-................................................. Mainrelav F to ......... Section T-22 ....Turnand hazard .

Apply12Vto terminal and ground h terminal a.reDlace unit. Check thetestlamp that whichis connected termjnal g to flashes whenappling to terminal 12V e. the TURNAND HAZARD WARNING FLASHER UNIT lnaoectlon 1. lf not as specified.Check continuity between terminalsand3.replace unit. Apply12Vto terminal andground 2 terminal Check 4. replace relay. to Siep4. the to d 2. lf the testlampsdo notflash. both whengrounding terminalc. replace relay. Il correct. Connect testlamps (23VV) terminal and g. the go 3. 4. the 4. lf the testlamodoesnotflash. the T-23 . Check thetestlampwhichis connected terminal that to d flashes whenappling to terminal 12V f. for continuity between teminals and3. Checkthat testlarnps flashes. 1 Terminal Conlinuity 2.RELAY HORN RELAY Inspection 1. lf not as specilied. lf the testlampdoesnotflash.reolace unit. 3. 1 Terminal Continuily 5. the 5.

.... ..p a.. / Installation Removal ............ to Section switch defroster 3...................... T-25 / Insta||ation Removal to U Reter Section 7.... . Hazard page . lgnition page ....... ........................... T-25 / Installation Removal page -27 f ............ . ......-.swtTcH swtTcH VIEW STBUCTURAL switch 5............ ...... Rearwindow page T-28 .. . T-28 Inspection switch warning 4.. . ..............2..... 1-27 / lnstallation Removal page ...... Combination to S Refer Section page .. .-....5... ........... . . swltch control mirror 6...Section I-26 Inspecti0n.......... ...........-........ ... .-.............. ..... ......... .... .. ...- T-24 ... ..g. .... T-28 / Installation Removal pageT-28 Inspection. pageT-27 / Assembly Disassembly U Refer to page 8.. .... ...e .. Remote switch 2....... Panellampcontrol switch 1............. S Refer top 9.... lnspection I n s p e c t i o n .. ...-............ .... AJC switch.. page .. T ...... Blower switch..... Canvas switch............

...... replace ignition the switch. lnslall the reverse !n orderof removal.o ---o Indcaiescont nuily SWITCH COMBINATION Romoval/ lnstallation 1.Check lor continuitybetweenthe terminals wlth an ohmmeter..... 4.4 4........ lf notas specilied.......... Remove the ordershownin the figure.. f.-' 0140rx.. Steering 3.... Remove steering the columncover. Steering column cover 4. 3... Horncap wheel 2........Disconnect negative the battery cable. 2.. Switch LOCK G_ B] 82 Tslminsis ACC tG2 ST ---o (l ON START H. lnstall the reverse in orderof removal. T-26 T-25 .017 1.. ACC I G2 Inspectlon l.. ffi A9 L. in 2. Disassembly / Assembly page Inspection.-.Remove screwand ignition the switch... c+ o-- oo- --. 2.SWTCH IGNITION SWTCH Removal lnstallation / '1...... Combination switch page1-27 .

lf not as specified.--o Turnsignalswltch Terminal Lelt Aighl (H: Indlcates continu'ly TL G TR o o -o wiper and washerswltch Wlndshield -_'\Terminat OFF INT Posiro.--o o.--o -o o.Check for continuitybetweenthe terminals onmmeler. dlmmer.and Passlngswitch Terminal HB OGHigh beam --o fiL HU BA BTN TNS Headlighl oo- --o --o o. indicatss continuily O-Oi --o o.\-'.-o Pa3sing parkng Tail.--o | (Low) ll (Hiqh) O---{: indicalesconlinuity T-26 .m OFF ON AS WIG swL SWH E ooo- --o --o o.replacethe defectiveswitch Llght.swtTcH lnsoection with an 1. 2..--o o.

Remove panellampcontrol the switch. replacethe panellampcontrolswitch. Checkthatthe voltage terminal changes al a lineady when turning the controlswitch. Apply 12Vto terminal and ground c terminal b. Spring 3. / as 1. T-27 . 3. Cover 4. lf not as specified. Printed circuit PANEL LAflP CONTROL SWITCH 1. Switch Min.position Vdiaq€ 10v 4.Cancel cam 2.swtTcH Dlsassembly/ As€embly DisassembleAssemble shown in the figure. 2.

Checkfor continuity the switch. Remove hazard of the between terminals the switch 2. Checkfor continuitybetween replacethe switch. delroster 1. Apply thop towl to avoid any damage. warning movethe hazard Nots . the and remove fuse box the 2. lnspection swtch warning the 1. ll not as specified. ll not as sp€cified. 3. Remove screws switchas shownin the defroster the 3.replace Swilch b d oll o-- On (:rc Indicates conlinuity o.swtTcH HAZARDWARNINGSWITCH Removal/ Installation locksand re release (flat Usinga standard tip)screwdriver. Remove rearwindow the of the terminals the switch 2. Swtch a b otf On CF---O| Indicates conlinuity o .---o s --o h SWITCH DEFROSTER REARWINDOW Removal/ Installation the 1. Remove rearwindow fioure. the 4. switch. Remove fusebox cover. Inistall switchin the reverseorderof removal- :EH T-28 Inspectlon switch. 3.

. Water page TJ8 Inspection ....... Iz 4.......................... lamps and 5. 2......... Fuelgauge pageT-37 Inspection.................... Warning indicator pageT-47 Rep|acement... Inspection gauge temperature 3........-..................................... Odometer .rZ 'rc Tffi 'S \+ 1................ Tripmeter 7......CLUSTER INSTRUTIENT CLUSTER INSTRUMENT ssT PREPARATION 49 0&39285 fuel Checkef..................... Speedometer pageT-37 Inspection ... 6.... VIEW STRUCTURAL q? "-..... Tachometer page T-37 ............

t l e9'e)@ 2 'fi : r IUJ f€l rrn E! E E a' 5 . t .T TROUBLESHOOTING Clrcull Diagram CLUSTER INSTRUItIENT r q t .? 0 @He T-30 .

replace speeoomerer. Veritythat the speedometer go to Step2. ter andtransaxle whenturnedby 2. the 4. or gear. replace speedometer the cable 3. lf the connections OK.Checkspeedometer cabletromtheinstrument clus the 1. are cable Step 2 . lf the speedometer cableand gearare OK. Verify the cableandgearspineasily that nano. Step I .Check speedometer cable connection cable is connectedproperly. Disconnecl speedometer case. ltthe cableor gearis stiff.INSTRUMENT CLUSTER Symptom: Speedometer does not operate or indicatlon is not corlgct. T-31 .

speed.movethe instrument 1H terminals and2L between a 2.nl) Step 2 1.t. Stanthe enoine. indicates engine 2.lgniteo T-32 .sr-r^c"ou.CLUSTER INSTBUMENT Symptom: Tachomster does not operate. Step I (Refer pageT-35 ) to cluster' 1.ff t. R. Connect testtachometer sideconnector. Ch€ckthatihe testtachometer Repairwking hamess (lnstrum€nt clusler. ol the harness -7 .

Verituthat the needleindicates correctvalues. the wllH TACHOMETER WITHOUT TACHOMETER *) -/t- t l . Setthe SST to the resistance valuesshownin the figure. 2. Symplom:Watertemperature Step I '1.Waterlhermosensor) gaug€ Redac€wEtertemperature . Contlnuethe abovech€cks for at leasl two mlnutes each to conectly ludge ihe condltlon. 4. Connect red leadof the SSTto the connector the the and blackleadto a bodyground. Slep 2 1.) 2.uster. Gaugedisdays corect NO WITHTACHOMETEFWITIIOUTTACHOMET€R Replace water$ermo€ensor Go to Step2 i". Remove instrument the c.andcheck the needle that indicates correct the values. Setthe SST to the resistance 5. 3. The allowable Indlcatlon error la lwlce the wldth ot ihe needle. T-33 . " la l l a R€p8ir wiringhames8 (lnsuument clustef.terminal 2d th. ''J *[] * VV \\P '*\io Caulion . The allowable Indlcatlon error ls twlc€ths wldth ot the needle. Turntheignition switch ON. 4. .SJO. Connect red leadol f|e SSTto terminaiI f andthe Hack fie lead to a negativebatteryterminal.INSTRUMENT CLUSTEB gaugedoeanot operaie. . Condnue above the checkslor at leasltwo mlnutes each io conectly ludge tft€ condltlon. valuesshownin the figure. fromthe water Disconnect connector the thermos€nsor.:!T Caution . Apply12Vto terminal and ground.(Referto page T-35. 3.

Z \ gso I T-34 ^/. Cbhriect redteaool f|e SsT lo teminal1g andtheblack tne terminal. SteD 2 't." "* Cautlon . leadto a negativebattery . .sff o" 3i valuesshownin the figure. Disconnect connector thefuelgaugesender "Y" the 2. Verily WfTHTACHOMETER WTHOUITACHOMEIEF ""*\n-. ignition 4. 4. Contlnuethe above checksfor at least lwo minuiea each to correctly iudge the condltlon' . 3. The allowable lndlcation €ror ia twlce the wldth ot the needle. . WTrll TACHOMEIER WITHOUTTACHOMETEFI """\n:--Z N ". Continuethe above checkefol at leasi two mlnules each to cofl€ctly tudgs the condltion.. lu€l Replace gauges€nderunit 0n tueltank) Go to Step2 NO Cautlon .-- n--1 NO wldnghamsss Reparr (lnslrum€nt unil) clusler luel gauges€nder gauge tuel Replac€ \'=1 _/".un 's'eu/ eso valuesshownin the figure. Setthe SST to the resistance the that the needleindicates correct values 5. the th. The allowable inabatlbn etrol is twlca the wldth ol the needle.move inslrumed (Refer pageT-35 ) to cluster. 2d 2.0 ! mr - o."1 . x\.]. Setthe SST to the resistanc€ indithat switch andverity the needle ON. Apply12Vto lerminal and groundterminal g.*'r Nrl Step I unit from the 1.CLUSTER INSTRUMENT Symptom:Fuel gaugsdoeanot oPerate. R. Turnthe cat€sthe correctvalues. Connect redleadof theSSTto the terminal wire andthe blackleadto a bodyground.

.INSTRUMENT CLUSTER INSTRUTIIENT CLUSTER Removal lnstallaiion / 1............. lnstall the reverse in orderof removal.. o \ 01A0TX{26 5. ireterhood 4...... 4 //t / a i 1....... Speedometer cable pageT-39 1nspection.... Disassembly / Assembly pageT-37 Inspection ..... in 2... Remove the orderas shownin the fiqure...... Steering 3. Instrument cluster pageT-36 .................. Horncap wheel 2...... T-35 ....................

orderof disassembly in 2. Water 7. Speedometer 3. Socket 8.Windplate 2. Fuel gauge temperature 6.CLUSTER INSTRUMENT Disa$eembly/ Assembly in 1-Disassem6b the orderas shownin the figure.Tachometer gauge 4. WITIIOUTTAC}IOUETER 1.Case T-36 . Combination gaugesj (Fueland watertemperature gauge 5. Bulb I 6UZZet '10. Assemble the reverse TACHOrrEIER WITH ? ? ^ \r >( ^<'6 \ "(q&. Printed circuit 11.

Whsn removing01installlng lhe tachometer. Check tachometer allowable the for indication error.540 Fuel gauge 1. Connect redlead lheSSTio teminalIgandtheblack he of leadto a negative battery terminal. Fleolace necessarv.940-2. and checkthe operation the of odometer. Cautlon . the \ m r "". emt '-' ll / \ - 1r - .84 120-126 Inspectlon Speedometer 1.43 80. . Bemove jnstrument lhe (Refer pageT-35. . 30 60 90 (mph) 30-32 60-63 Standard Indication (lpm) 1.090 1.) clusterto 2.000 2.000 5.u0 /-.do not drop it or subiect it to aharp shocks. in 5.lf lt is normal. Tachometer 1..480-4. Caulion . Connect testtachometer the engane. Setthe SSTto the resistance values shown thefioure.450 5. Checkthe speedometer fluctuation for and/orabnormal nose.820-6.000 (rpmJ 450-1. WITH TACHOMEIER WITHOUT T 4. remove the speedometer cable.850-5. Using speedometer check speedometer ala tester.000 6. T-37 . Theallowable indication error ls twlce the width of ths needle. lt slgnlllcant tlucluatlon oqcurs or ihe speedomoter doea not move at all. stadthe a to and engrne.180 2.360 4. Verity the needle that indicates correqvalues.ReDlace il necessary.000 4. Tlre wear and lmproper inf. if 2. Apply12Vto terminal and oroundterminal h.rcplacethe speedomeler assembly.INSTRUMENT CLUSTER Standard indicaUon (km/tt) 40 80 120 Slandardindicalion (mph) (kInft') T 40.1 950 ' l Cauilon . 2. Conlinuethe abovechecks lor at least lwo minutes each to col|ectly ludge the condlilon. 2d t 3.910-3.000 3. the for lowable indication error.270 3.atlon wlll Increase apee{tometerefioa.

Turntheignition values. Contlnueihe abovechecks for al lgasl iwo minules each to coneclly iudge the condltlon. *:e#r. *'l\ o t shownin theligure values 4. Check cableshaft ino the soeedometer per replace the 3. ll ihereaie nollourouleses shaftrotation (Refer pageT-36.) to speedometer. ihe th. t*t ?V \\2 '*\€ SDeedsensor (Reter pageT-35. . lead to a negative TACHOMETEB WITH WITHOW TACHOMETEF 'nl*. Remove instrument 2n terminals and 1dwhilerotatbetween continuity 2. ADolvl2V to lerminai 1t ot s. 2d and groundterminal 2. 5. Setlhe SSTto theresistance needle indithatthe andverity switch ON. Cbhriect reatead theSSTto terminal andfre black the batteryterminal.Remove instrumenl (Reler pageT-35 ) to cluster.CLUSTER INSTRUMENT water temperature gauge '1. catesthe correct Caution . The allowable error is twlce the widlh ot Indication the needle.3 T-38 .) to cluster' the 1.

SPEEDOi'ETER CABLE Inspection 1. the 3. the 2. the in 3.(Refer Sectjon the to F. replace fuelgaugesender the unit. Checkresistance slowly while moving unitarmfrompoint the F to Doint E. ll notcorrect. the 3. Verify the cableandgearspineasily that whenturnedby nano. lf the resistance notas specified.INSTRUMENT CLUSTER WATERTHERIIIOSENSOR Femoval/ lnstallalion 1. is replace sensor. Remove thermosensor. checktheresistance the and of sensor withan ohmmeter. Disconnect speedometer the cableiromtheinstrument cluster and transaxle case. Remove sensor. 2. Inspection 1. 4. the 2. replace speedometer the cable. Place sensor water. Remove fueltankgaugeunit. Install the reverse in orderof removal. Heatthewatergradually. Disconnect fuelgaugesenderunitconnector. lf thecableor gearis stiff.D FUELGAUGE SENDER UNIT Removal Installatlon / Relerto SectionF. Disconnect connector. lhe Resistance:t92-2600 at 50oc (122. T-39 . 3.) 2. Inspection 1. 4.

5 kPa (0.25ks/cm'.3.T FUNCTION llem SYSTEMS AND INDICATOR WARNING SYSTEMS AND INDICATOR WARNING opcraffYe condltlon lgnitionswitchOFF Heacllighl switchON (Fnstor secondposfion) switchON lonalion V. Parkingbrakeswtch oN . lgnitionswitchON BrakelevelsersorON lonitionswrtchoN is L V. lsnilion switchON .fiage at alternator termina] lowel ll|an ba$eryvoltage lamp Bearwindowdeiroster indicstor Hold indicator (ATX) ON lonilion switch switchON Cdr windowdefroster lgnition sivqtchON Hold swllch ON T-40 .56Psi) .taqe at alernator L teminal is lowerthan batt€ryvoltage Engineoil wamlng R6ma cluger Buzer is in instrum€nt ReJer S€ctonG to romainder Ught-oti larnp warning Brake system lonitionswitchON is Engineoil pressure lowerthan24.

WARNING AND INDICATOR SYSTEMS TROUBLESHOOTING Clrcult Dlagram T T-41 .

1. Step 2 (Refer pageT-35 ) to cluster. lf the buzzer the between instruwire repair (B/Y) 5. Light-otfRemlndsrAlarm Symptom:Lightgon r€minderala. R-emove instrument the clustheinstrument by the 2. Geterto oaoe and verity in as voltage shown the figure' 3. ll normal. switch.mdo€s not operale tde"s'. mentcluster and ignition T-42 .SYSTEMS AND INDICATOR WARNING Note . lf the lampscomeon. switch and cluster the headlight instrument 2. reler to the lollowlng troubleahooting. 4. dheck the meter 15A luse In the fuse box belore troubleshooting. ltihe lamps notcomeon. The powsr supptyllne lot llluminationlamps and ligm-ofi remlndsl buzzerale connec'ledIn common. Tiirnthe ionition clusler thal ON 2.\iitch andverity theinstrument comeonillumination lam9s (Fl/B)wire the between check do 3. lf the buzer sounds. switch 1. Remove buzzer disassembling T-36.) ter. Appiya batteiy sounds. doesnot sound.'. 4.> \t:24fl4 /<-J"\e SteD I OFF. Tumthelights. thatthe buzer redacethe buzer. go to SteP Note .

Checkenglneoll level Checkengine level. Connect ohmmeter an ground.repairwire(Y/R) switchand the instrumenl cluster. whentheengine slopped. wire(Y/R) between engine pressure the oil 4.repair cluster.WARNING AND INDICATOF SYSTEMS EnglneOll WarnlngLamp Symplom: Engineoil warning lamp rmains llluminated Step I . lf notas specified. 2. oil Engine level oil Bdow L Pourengineoilandadjustoil level Go to Sl€p2 Slep 2 .Check englne oll pressule awltch bstween engine pressure the oil 1. 2. switchand instrument T-43 . lf correct. 3. Symptom: Engine oil waming lamp does not come olt when engins stopped (lgnition switch ON) Remedy b€tween engine pressure the oil 1. Checklor continuity theswitch of Condilion contnuny Engine stopped replace engine pressure the oil switch. lf thecordinuity notasspecified. D. Connect ohmmeter an switch and a bodyground. Check continuity theswitch the of Condilion Enginestopp€d Engine run Conlinuty No is checkthelubrication sys 3. switch and a body underbelow condition. lf correct.Gelerto Section between engine pressure the oil 4.) tem.

go to SteP Slep 3 . lf the sensor OK.to Section 3.) Gefe. Disconnect parkingbrakeswitchconnector. and ol the between terminal theswitch a continuity 2. is 3. P.Check parklng brake swltch the 1. Check ground. is 4. repairthe wiringharness T-44 . Step I .SYSTEi'S AND INDICATOR WABNING Brake System Warning LamP Symptom:Brakesyslemwarninglamp remalnsilluminated. lf notasspecfied. Check Brakefluid level Below MIN Conlnufy NO the replace levelsensor' ll notas specified. B€ke fluid level Below MIN (Reterto Section P) Go to Step2 Step 2 . 1.Check brake fluld level sensor of continuity the sensor. body Conlinuiiy s\titch brake the or adjust replace parking 3.Check brake tluld levsl Checkbrakefluidlevel. ll the switch OK.

Contrn!ity brake switch. Remedy fluidlevelsensor connector. lf notas specified. Checkcontinuity the braketluidlev€lsensor. lf the switchis OK. Symptom: Brakesystemwarninglampdoesnot comeon whenbraketluid in reservoir tank ls belowMlN. of Brakeiuid level Below MIN Conlinuily NO the sensor. the the ol and 2. Disconnect brake the 2.ingharness. Disconnect parking brakeswitch connector. lf notasspecified. (lgnltlon switch ON. adjust redacetheparking or 3. repair wi. Check continuity between terminal theswjtch a bodyground. lf the sensor OK. the 4.) nemedy 1. 1. 3.repair wiringharnees. is T-45 . replace level the 4.SYSTEMS WABNINGAND INDICATOR Symptomr Brake system wamlng lamp does noi come on when paddng brake ls on.

the is 2. T-46 .) to clusler.replacethe buzer. ll the buzzerdoes not sound. underthebelow 3. switchand a body condition. lI the bulb harness widng 4. BRAKEFLUIDLEVELSENSOR Inspectlon 'L Checkcontinuity the sensor' of Cohtinuity MIN Below No replace levelsensor. Checkcontinuitv theswitch of Condilion Engineslopp€d run Engine continuity No +T Y ) . AppV a battery and verity in as v6ttage shown thefigure. Checkthe bulbof the lt. repair cluster) swilch Inslrument (Rear windowdelroster BUZZER WARNING lnsoection (Refer pageT-35 ) to cluster' the 1. Delroster Indicator Lamp R Symptom: earwlndow defroster indlcator lamp does not comeon when rear wlndow detrGler swltch ON. \ \ l[:<r 4. Disconnect engine pressure oil the between engine pressure an 2. (Rearwlndowdelrosler systemopelatesnomally) Remsdv (Reter pageT-35. ll not as specified. Rem6ve instrument the lamp. no. SWITCH ENGINE OIL PRESSURE lnspectlon connector' swilch oil the 1. that the buzzersounds 4.) lo cluster. indicator detroster rearwindow 2. Connect ohmmeter ground. out. 1.SYSTE]IIS AND INDICATOR WARNING Rear luindoy. lt the bulb is OK. Remove waming (Refer pageT_36. lf continuity not as specified. g. replace is burned 3. Fiemove instrument the buzer bydiassembling indrumert the 2.replac€the switch.

(Reter to Sectton TD. or the rngDraKe swllcn. Conlinuity Cr. Replace faultybulbsas shownin thefigure. Remove instrument the (Refer pageT-35. WARNING AND INDICATOR LAMPS Replacement 1. lf continuity notas specified. Disconnect parking the brakeswitch connector. Use the ap€citisd bulb only. rs adjust replace park. Check continuity for between switch the conn@tor a and bodyground.) N \3 J T47 .*d 3. 2.WARNING AND INDICATOR SYSTEMS PARKINGBRAKESWITCH Inapectlon 1. to 2. the Cautlon .) cluster.

.. pageT-59 platelight 6.. lnspection '10............ ...... ..ICTURAL light 5.. ........P a g e . ........ Sideturn signallight / Bemoval Installation .................. Stoplight Inspection........T-71 / Removal Installation PageT-59 4... . ..... ..... Headlight (1)Iaillight pageT-53 Aiming.. (2) Rear light turn signal / Removal Installation (3) Stoplight T-52 Page (4) Back-uplight Replacement.5 2 Page / Assembly Disassembly 3... T-70 T . Ucense Flemoval Installation / page .... .. ... T-65 Page 9..... ........ Position lnstallalion PageT-70 Removal/ Replacement...... Frontturn signallight page ...T-62 stoplight 7......SYSTEi' LIGHTING EXTERIOR SYSTEM EYIERIORLIGHTING VIEW ST| .. Back-uplighl switch pageT-69 .. .... Inspection PageT-69 T-48 . T-66 switch 8. T-53 Page RemovalInstallation / light 2. switch lnhibitor . ....... ....... Rearcombination 1............. High-mount / RemovalInstallation page ..

EXTERIOR LIGHTING SYSTEIII HEADLIG}IT Troubleshooting Wirlngdlagram T 5 F'1* B -l s Ifl t- *l fuJ_* .

1. lf a bulb 3.Turnhe headlight of the 2. chek (R/W) High boam Otherc BAttery Right (R/L) Olhers wke B) Go to step 4 Chek for poor headlight (B) Ohers co lo s'teD4 T-50 . replace is burned. necessary. 2. d)ek wire GUL) Go ro s'lep 4 Go to step 4 nqht sido Batt€ry Next. 2. if ino harness. go to SteP Step 2 bulbs. ll the bulbsare OK. 3.Checkthe headlight rt. Measure voitageat the followingterminal'wires the as shown. the it. lf thetuseis burned.SYSTEM LIGHTING EXTERIOR Symptom: Headllght(s)does not operate. replace Checkand repair war2. ost 0Tx-2s7 Step 3 ON. !T Slep I 1. lf the luseis OK. ciheckHEAD3oAtusein the mainfuseblock. check voltage wire (B) Repajrground wir6 (B) wir6 6UL) Go to Slep 4 Balt€ry Noit. headlightconnector H€edligll H€sdlight Vollage Battery (R/v4 Leit (R/L) High b€am Oth€rs Olhsrs (B) Olhers Nen. go to SleP3. switch 1.

Check continuity for between terminals shown as ohmmeter.--o o./W) 3oA Repairwlre (R)(HEAD luse-Headlighl slrtch) Baneryvoltaq€ Ne'1.--o o.Headlight switch iGpec. 4. HB Headlight High b6am c|. check wile (8.EXTERIOR LIGHTING SYSTEM Slep 4 1. withan 2. l/easure voltage the following the at (jn headlight switch connectors thecombination switch)as shown. checkfor a poorconnection the system. Remove column the cover. in T-51 . lf correct. Disconnect headlight the switch connectors.Parkng Indic€tes cofiinuity O-O: --o o.--o replace headlight the switch.tion 1. terminal-wiresthe of 2. Headlighl Voltage Balt€ry voltaq€ Ne'd.--o o.chechwire (a/L) ON (RI/9 (High be-am) Others Go !o Steo5 Ch€ckfor poorconnectjon of vollage headlight Banery ON switchconn€ctor (R/L) (Low beam) Olhers Go io Step 5 Others (R) Step 5 .--o o-- HL Terminal HU BA BIN -TNS -o --o oo- Parkjng Tail. 3. lf not as specified.

Headlight 3. the the 2.SYSTEi' LIGHTING EXTERIOR Rsmoval / Inatallation 't.101 grille 1. Remove headlight shownin the figure as the orderol removal. Radiator unit 2. Headlightbulb light bulb 5.lnstatl headliqhain reverse 'll1tt'"" 01EoTX. Cover 4. Position t-52 .

Remove coverandthe headlight a bulb. Position unloaded the vehicle a flat leveisurface. T-53 . Inapectlon Headlightswitch(Combination switch) Referto page T-26. Alming 1. 2.EXTERIOR LIGHTING SYSTEM Bqlb Replacement '1.Disconnect headlight the connector. 3. the to 2. Cautlon . Adjust tireair pressore specification. Do noi touch the glass portlon ol ihe bulb. Install headlight in the reverse the bulb orderof removal. Adjust headlights meetlocalregulations turning the to by the adjustingscrews. on 3. Always hold the base.

SYSTEM LIGHTING EXTERIOR TURNSIGNALLIGHT TroubleshoolinE circuit dlagram fEE d" c :9 AP. :E E = I G 5i 4 : i z.t s --r{ ax( ZE .a T-54 .

ch€ck wire (B) Repair wire(8n) (Fus€-Turn and ha2ard Nen. Step 2 Measurethe voltage theterminal-wires at oftheturnandhaz" ard warning llasher connector.go lo Step2. ON Turnsgnal Turnsignal switch B ghl Tumsignal c/) (G) Batlery Olhers Next. replace Check it. HMARD15A 2. Check following the fuse.checkwire(O) Bepairwre (B) warning Oumand hazard ilasher unil-Bodv Oround) Go to Step 6 Constanl Olhers Olhers (o) ing s. necessary. I-I I I I l n Effil W U u i l [I I E L I I-------E:= [ [ [ [ Step 1 1. if 3. checkwire(G) Go ro Slep 5 (Gl. lf theluseis burned.EXTERIOR LIGHTING SYSTEM Symptom:Turn and hazardwarninglights do not operate.witch. unit Condilion Battery {BR) Constanl Olhers OV (B) Nsn.li) Nexl d'eck wirer(G/B)and Go lo Step 5 Go lo Step 3 Baitery vonage Others (G/B) Others Turnsignal (G/vv)swilch: ghl 0V muluallv R Others Replace iurn and hazard vollage and Go to Step 3 R€place lurn and hazard T-55 . . lf thefuseis OK. and repair wire lhe harness.

lf the bulbsare OK.go to SteP SteD 4 ON.4) Ourn and hazard nashor unil-Bulb) warnins Step 5 cover' the 1. check wlre (O) hazardwamingswilch Replace Olhers (o) waming wire 0urn nazara nopair 1O1 anO warning swlich) llasher unit-Hazard T-56 .Tirrnthehazard ol at the 2.SYSTEM LIGHTING EXTERIOR Step 3 the 1. switch warning 1. Condition Baltery Nen. checkwkes(O and {G) (Bfo Constant Others swnch) iar! switdF Batery Repaiwlr€0') (tum signal Turn signal vo[aq€ Turnand hazadllasher unit) switch combinalion Ohers Reolace Repakwire (G) Oum signalswitchggnal Batlery Tlrm and hazsrdllasherunit) (G) Tum Bighl switch: ssrtch combination Others Reolace wire nepair (ruse-rurn signat m Step 6 ol the attheterminal-wires turnandhazvoltage Measurelhe unit ard flasher connector. it. Condition (B) Hazatd switchON waning Baltery Repairwire (B) (Hazard swlch-Body grcund) Olhers Ne)d.Check bulbs. 4. f/easure voltage theterminalwjres theturnsagnal switchconnector. lf a bulbis burned. Remove column of at the 2. replace 2. unit haza warning rd Lighl Frcnt LH LH Side (G/B) LH ReaT SideRH Olhers Bepajrwro €) Oum and hazard fla$er unit-Bodyground) waroino wire (G/B)Ourn and hazard Frepair warninollasherunit-Bulb) wire FEFi-ir (a) fiurn anahazatd flasher lni-Body ground) wamino Others Repanwire (G. Measure voltage ihe terminal-wiresthe turn and tlasher connector. 3.

Remedy Check bulbsandthewiring the harness between eachbulb flashing and the bodyground(rapidly side). T-57 . Note ' . Rapld tla8hing ls a llaaher unlt lunclion lo warn of a bad bulb or an open circuit.EXTERIOB LIGHTING SYSTEi' Symptom: Turn signal(s) tlashes rspldly.

check wjrc (B) Olhers Olhers OV Go to Step3 Hazard warninos{tch .qo to Slep2. (Iurn slgnalsfuncilon normally. Remove hazard of terminals the switch between 2. (o) Battery voltage Gl6her unit . warning swtch. lf the cluster step 2 of re Measu the voltageat theterminal-wires the hazardwarnconnectoras shown. tf not as specified.Check hazardwarningswitch. switch 4.SYSTE]II LIGHTING EXTEBIOR SymptomrHazardwarningfunction doea not operate.) Slep 1 .Bodvground) iasher unn turn BeDlace anclhazard Stsp 3 (O) the al Check voltage terminalwire of theturnandhazard unit flasher connector. Checkcontinuity Swilch Terminal b d ON OFF (Hj lndicat€scontnuity warning switch. the 1. the replace hazard 3.Hazsrdwaminqswitch) ReDlace turn and ha?ardflasherunit Others T-58 . ing switch (o) (B) Battery Next. is OK.

Install turnsignallightin the reverse the orderof removal. the 3.EXTERIOR LIGHTING SYSTEM Removal/ Inatallation Rearlurn algnal light (Rear comblnatlon llght) Reterto page T-70. Apply shop towl to avold any body damage. the 2. to Turnand hazard warnlng tlasherunit Refer pageT-23. Remove sideturn signallight bulb. remove sideturn signal the lighthousing. Turnsignal lightbulb Sldetum slgnal llght (flat 1. Cautlon . Housing 2. to T-59 .Remove turn sjgnallightas shownin the figure. 01aoTx{sa 1. Usinga standard tip) screwdriver. Installthe side turn signallight in the reverseorder ol removal. Fronl turn signal llght 1. 2. 01A0TXO50 lmpectlon Tum slgnal swltch (Comblnation swilch) Refer pageT-26.

I . E T-60 .T SYSTEII LIGHTING EXTERIOR PLATELIGI{T AND LICENSE LIGHT.TAILLIGHT POSITION Troubleahooting Clrcult diagram g @ @ 39t G el @ 2t t E 3 2 3A .

the 3. replace Check it. 2. 2. lf the fusesare OK. Measure voltageat the followingterminal-wires the the of combinatlon switchconnector. T-61 .EXTERIOR LIGHTING SYSTEII SymptomrNo llghts llluminate(tai ights pafitng fights 8nd tic€me ptate ttghts). go to Step2.body groundot each lighl) Olhers Redace headlight savitch [[[Ei[[ Step I 1. lf thefuseis burned. Turnthe headlight switch ON. CheckTAIL10Afuse.if necessary. repair wiringharness. and. (wiB) (F/B) Eatl€ryvoliage CheckrExt wire Othe|s Reoairwire harness M/B) Repair wiing hamess the Batteryvoltags (Combinalion switch. [![H[[ffi St€p 2 1.

Llcense plate llgltt platelightas shownin the figure the 1. 4. Install license platelightbracket 1. Lens 5. Remove license platelightin the reverse orderof removal the 2. Talllight (Reercombinatlonlighl) Relerto page T-70. Cover Insp€ctlon Headllghi swltch Referto page T-26. Bulb T-62 . License 2. Bulbassembly 3.SYSTEM LIGHTING EXTERIOR / Removal Installation Posltlonlight Relerto page T-52.

1 ) ENGINE CONTBOL UNTT (SECTION -1b) B 6r) T G (B) r- I I I G (R) STOPLIGHT STOPLIGHT F_OB STOPLIGHT SWI GHMOUNT IEHT (FJ E-07 STOPLIGHT LH E OB STOPLIGHTBH r:--.119 T-63 .EXTERIOR LIGHTING SYSTEiI STOPLIGHT Troubleahooting Clrcull diagram NUIT (SECT ION H-?) SHlFT-LOCK EC-AT CONTFOLUNIT ( S E C T l O NH .l t " l Lan 01E0TX.

\./itch) Battery Go to Step3 Others Checkstoplishtswilctr (G) Step 3 bulbs. CheckSTOP ll thefuseis burned. ll a bulbis burnedreplace 4. go to SteP ofthe terminal-wires right i. uo*n" ".SYSTEM EXTERIOR LIGHTING Symptom: Stopllghts do not operate (all)' mIF[[[ [[ilHIgl sToP 20 Step 1 20Aluse.t#". conditon Battsry Nextcheckwire (G) Conslant Brak p€dal (G/\'V) Fepairwire (G/w) Olh€rs {STOP 20A tuse-Stoplights.if necessary.X" . Checkthe stoplight it.Checkand repairthewirehar' ness.n.replaceit. 2. lf the bulbsare OK. thefollowing connectors. and leltstoplight Voltag€ Batt€ry Nen check wire (8) (G) Brakepedal (B) Repairwne (G) Ohers Glodiom switch-Sloplioht) of Checkfor poor connection conOthers Fepair oroundwire(8) T-64 . go to SteP Step 2 of terminal-wires thestoP the at Measure voltage thelollowing light switchconnector. lf the fuseis OK.

lf a bulbis burned replace it. Check continuity between theterminals ofthestoplight the switch. T-65 . the switch 2. Step 2 Measure voltage the following terminal-wiresfie tautty ol the at stoplight connector. Step I Check stoplight the bulb ol the faultyside.LIGHTING EXTERIOR SYSTEM SymplomrStoplightdoes not operate(one only). Voltage Aarcry Next checkwire (B) (G) Elake pedal R€pairwire (G) Othars lstooliohtswilch-Stoolioht) Checkfor poor conoectron coft oi Others Re@iroroundwire (B) (B) lnspection Slopllghtswltch '1. lf the bulbis OK. lf notspecified. Condibon Coriinuity 0tEoTXj24 3. replace stoplight the switch.go to Step2.Disconnect stoplight connector.

Socket 4. Lens 3. in stoplight the reverse the Install high-mount '1. Cover 2.SYSTE LIGHTING EXTERIOR Removd / Installatlon Stopllght (Rear comblnation light) Referto page T-70. Hlgh-mountsloPlight Removal/ In3tallatlon as stoplight shownin the figure. Lightbody T-66 . the Remove high-mount orderol removal. Bulb 5.

1 ) V@ | "rBAcK-uPL I G H T ldlstiJrcH B/C (E) B/C {F) A.EXTERIOR LIGHTING SYSTEM BACK-UP LIGHT Tloubleshootlng Clrcuh dlag..am IGNII]ON SI9ITCH B/Y tF) I B/Y I (E) INHIBITOB SWITCH (SEcTION H .U PL I G H T SXITCH ) € E 02 HOFN SITITCH tu/ F tq___J E. @ *@ R/G tR) -o7 ILH' E-O7 P/G gACK_UPr r e r r ( F ) E-Oa (RHJ E-OA ) F-10 HOFN BELAY{f ( F-11 HOFN F) F _ 1 2 B A C K .O7 BACK'UP LIGHT LH (F) E-08 EACK-UPLIGHT FH (B) T-67 . tt Y-.

SYSTEM LIGHTING EXTERIOR

Symptom:Back-uplight(s)does nol operate'

InlF[[!
[[ilHlIl

Step t 15A CheckMETER fuse. the repair wireharit replace Checkand lltheiuseisburned, ness,atnecessary. 2. lf the fuseis OK,go to SteP

Step 2 Checkthe back{P lightbulbs it replace lf a bulbis burned, go to SteP 3. ll the bulbsare OK,

St€p 3 lo switchON, and shiftthe transaxle 1. Turn the ignihon reverse, ol at the 2. Measure voltage theterminal-wiresthe back'up lightconnectors.
liqht Back-up
(FiG) Lefl Othels

Voltage
Batt€fy

Next,ch€ckwire (8)
Go to Step 4 Ch€ck fol poor conn€ction ol back-uplight conneclor

{B)
(F/G) Right

Olhe|s Others

qround wne (B) Feoarr
Go to Slep 4

Batt€ry Next, ch€ck wire (B)
ot Checkfor poor conn€ction back-uplight connecior Others Fepair sroundwrc (B)

(B)

T-68

EXTERIOR LIGHTING SYSTEM
Step 4 (MTD 1. Disconnect back-up the lightswitch connector. 2. Checkcontinuity between terminals the switch the of with transaxlein reverse.
Continuity (METER 5A tuse Reoairwire haaness 1 Back{p light swllch- Back-uplisht)
No

(Arx)
1. Disconnect inhibitor the switch connector2. Checkcontinuity between terminals theswitch the of wjth the transaxle reverse. in
Continuity Beoair wireharness ftETER 15AluseInhibitof swilch Back-up lighl
NO

FeplaceInhrbilor ch sw

lnspectlon Back-upllght swlich (irTX) 1.Disconnect back"up the lightswitch connector. 2. Checkcontinuity between terminals theback-up the of light switch connector.
Continurty Others

3. lf not as specitied, replace back-up the lightswitch. Inhlbitorswitch (ATX) '1. Disconnect inhibitor the switch connectors. 2. Check continuity the between terminals the olthe inhibitor switch connectors.
Contnuily Others
NO

3. lf not as specified, replace inhibitor the switch. Removal/ Installation Back-uplight (Rearcomblnatlonlight) Relerto page T-70. Back-upllghl swltch Befer Section to J. Inhlbltorswitch Relerto SectionK.

T-69

SYSTEM LIGHTING EXTEFIOR
LIGHT REARCOMBINATION Removal/ Installation light the 1. Remove rearcombination as shownin thefigure orderof removal' light the 2. Install rearcombination in the reverse

'r@ffi
T-70

Replac€ment in the 1. boenthetrunklid,and remove bulbsas shown the lioure. orderof removal. the 2. ln;stall bulbsin the reverse

EXTERIOR LIGHTING SYSTEiI
Dlsass€mbly '1 Usea hot . air blower soften "hot melt"(bonding to the agent) around lens. the

2. Removethe lensfrom light the housing pushing rear by the of the lenswitha hammer handleor roundbar.

Note . Remove "hot melt" in the light housingwhen lhe the new hot melt is used.

Assembly 1. lf the newhotmeft used, Uni-sealer put (8531 739) is 77 groove. adhesive the lighthousing in 2. Fitthenewlensontothe lighthousing. Press lensfirmthe ly so thatit willadhere.

3. lmmerse combinatjon in water checkfor leaks the light to afteraboutonehour.

T-71

LAMP SYSTEII INTERIOR

LAMP SYSTEM INTERIOR
VIEW STRUCTURAL

top) canvas lamp(without 1. Interior .. pageT-77 ...... / Removallhstallatjon . top) 2. Interiorlamp (withcanvas page ..............,... T-77 / Removall;stallation lamp 3. Trunkcompartment .. Installation . . ... .. pageT-77 Removai/

4. Door switch . ...... / Removallnstallation ........ pageT-78 . pageT-78 Inspection............................ lampswtch 5. Trunkcompartment pageT-78 Removai/lnstallation........ .... Inspection..................... pageT-78

f-72

INTERIOR LAMP SYSTEM
INTERIOR LAMP Troubleshooting Circull diagram
BOOM 15A

T

ttt/B \F)

INTEFIOF

r- 10
COMPEBTMENT

r-10

DOORSI{IICHES

btt
TBANK COMPERTMENT LAMP SI{ITCH

I 05 INTEFIOF LAMP (IN)

I 06 DOOFSWITCHFL {B)

1_07 DOOF S'{ITCH FB (F) lF /r ld--l

I-OA OOOASWITCH BL (F) lalulrf__--l

lB/r,{lqJ
I09 O O O B I , i I T C HF B S (B) I_ 1O TBANK COMPERTMENT

I- 11 TBANK COMPEBTMENT LAMf ( S W I T C HR ) lE ld--l

lB,/w lL__l

T-73

LAMPSYSTEM INTERIOR

lr Symptom: eriorlampdoesnot illumlnate.

and slvitch the i5R lr" t *or" *.pto. bvop€rating control
Step the opening doors.Go lo the specified

symptom
-erior lsmp do€s not luminatewhencontrd switchis In anv posnron ii-"."lr-" ittu.inaes *hen controlsw\tchis in oN poston but doesnot with doot open wh€n switch€ in DOORpcition illuminate

Go to Step 2 S'tep5

[ [

t::-

I [il N U tI Il
lUl fI ] I
l t 1 1
TJ

St€p 2 1.Checkthe RooM 15Atuse. 2. ll the fuseis burned,replaceit. Checkand repairth€ wire harnessil necessary. 3. lf the fuse is OK, go to SteP3.

r-------t t

ROOM154

T-74

lftheswitches OK. the 2.1a3 T-75 . the connector. lf the bulb is OK. 1. ll notas specified. lf a bulb is burned. Check bulbof the interior lamp. replace doorswitch. the (lnterior wire lampDoor 3.INTERIOR LAMP SYSTEM c Step 3 1. Step 4 1. replace it.r/itch DOOR to (R/W) 2. Measure voltage terminal-wire of the interior the at lampconnector. 3. Switch Rdeas€d Contnuily NO 2. Measure voltage the attheterminal-wire of theinterior |ampconnector. Voltege Banery voltaq€ Go ro S:iep 6 (F/r ) Reolace int€ftor lamo bodv Others Step 6 '1 Disconnec{ doorswitch . go to step 4. to (UR) 2. Op€nall doors. Setthe control switch ON position. are switch) 05uoTx. checkcontinuity and of each switch.repair (R/vV). vdtaq€ B€Dlace inle or lamo bodv Baltery th€ Repair wne {UR) Others (ROOM tuse-lnlerior lamp) (UB) Slep 5 po€ition.andsetthecontrol s\.

(Cont. 3. Closeall doors. 2. ll the switihesare OK go to Step2 Step 2 1. Disconnecl ir$eriorlampconnectors. tinuitybetween Continuity (R/\tBody ground NO wire Repan (FUw) (lnt€riof lamp-Doorswtch) lamp assembly intedor Reolace fiEOrX. and checkconthe 2. ty Swilch Corninuity NO R€leasecl the replace door switch. Disconnect doorswitch ihe of each switchas shown. (RAV) terminal-wire anda body ground.olswitch: DOORPosition) Slep 1 and connectors. checkcontinui 1.169 T-76 . lf not as soecified.INTEFIORLAMP SYSTEM Symptom:It erior lamP remalnsilluminatedwlth doorsclosed.

1. Install trunkcompartment the lamoin the reverse orderol removal.Lens 2. 2.INTERIOB LAMP SYSTEII Interlor Lamp Fsmoval / lnatallatlon 'L Remove interior the lampas shownin the flgure.ta WITHOUT CANVAS TOP olatllx-115 1.unk Compariment Lamp Removal Installatlon / 1. €> Ad k--t. 2. Lamobodv 4. Installthe interiorlamp in the reverseorder of r€moval. Bulb(5 W) f-77 . Bulb(10W) 3. Remove trunkcompartment the lampas shownin the tigure. Lens 2. Over-head'console T.

Condiron Releas€d ContLnulty NO .Remove protector. Remove screw thetrunkcompartment switch orin lamp trunk compartment switch thereverse 3. Remove screwand oullout the doorswitch a the and 2.Check Condition Pushed Releesed Conirnuity NO lamp the replace trunkcompartment 3.eplace doorswitch. LamPSwitch Trunk Compartment / Removal Installation 1.Remove trunkcomDartment switch lamp compartment switch. switch. the 3.LAMP SYSTEM INTEBIOR . Checkcontinuity the doorswtch.d /2*: t €.lf not as specilied. derof lmpcctlon lamp the 1. Disconnect connectdr remove doorswitch. lnstallthe removal. Remove door switch. ol continuity thetrunk 2. Inapection 1. Iloor Swltch Removal/ Installation 1. lf not as specified. T-78 . a orderol removal Installlhe doorswitchin the reverse 3. a lamp and a 2. the of 2.

ffi 2 T-79 .INTERIOR LAMP SYSTEM ILLUIIINATION LAIIIP Troubl€ahooilng Clrcult dlagram z a c $ ec X .

Eachl€mp) Olhets Reolace oanel lamp conlrol swtch T-80 . Measure vohage the lollowing connector' switch lampcontrol Danel (B) OV Others Nex| check wtrs (R/B) wire (B) Reparr (Panellarnocontrolswtch .Bodygtouno (R/B) 8at€ryvo age Nextchec&wire (R) Repanwire (R/B) Others larnp contol switch) ftAlL 10Alus€ . Turnthe headlight 2.position wires the of terminal at the 3. Remedy ON. switch 1.LAMPSYSTEM INTERIOR Symptom: lllumlnation lamp control doea not operate. Set the Danellamp controlswitchto Max.Panel wiing harness (R) Reparr (Paneltampcontrolswtch .

... ......... T-28 2................REARWINDOW DEFROSTER REARWINDOWDEFROSTER STRUCTURAL VIEW 01AO-rX{84 1....................... Rear windowdefrosterfilament pageT-84 ............................................ Inspection pageT-84 Repair....... Rearwindowdelrosterswitch page Inspection ............

am DEFROSTER REAFWINDOW lir(E) B(E w/B {F) BOOM 15A TGNIT]ON ITCH L (F) DEFOG 204 r-01 FEAF I{INDOIi DEFFOSTEF SI{ITCH ILLUMINATION (SECTION 1_3) r-01 TNSTFUMENT CLUSTEB (SECIION C) ENGlNE CONIFOL UN]T (SECTION -1bJ B r-03 1-02 BEAF WINBOW DEFHOSTEFI CIGAFETTE LIGHTEB DIGITAL CLOCK T-03 r-02 F61 BEAFwrNool SVIITCH(I) DEFBOSTEB I-O2 FIEAF V{INDOVI (B] DEFFOSTEB I 03 CIGAHbI IE L]6HTEF (IJ @E EE 01E0TX-1zl T-82 .T TROUBLESHOOTIl{G Orcult Dlag.

Batteryvoltage (B/BR) Olher Bafleryvoltaq€ (B/L) Olher Next. CheckDEFOG I::- i l !w f i l i l t lI H i i l [ --- Condilion OK DEFOG 2OA Burnedo|rt Go lo Stsp 2 lhen Chsckwidngharn€ss A "@" Step 2 '1. Measure voltage theterminal-wire ofthe defroster the at filamentconnector(leftside). (B/L) Aatbry voltag€ Olhers Go to St€D3 Go lo Step 4 Step 3 1.measure lerminal-wire €/L) R€pai wiringharness (DEFOG tuse.Turnthe rearwindow defroster switch ON.Bear 20A windowdelrcelerswtch) Repatr wiringharness (Bearwindowdefrcster fibmenl) switch* Delro€ter Check rea \iiindow defrcsler switch {Refef lo page T-28) T-83 . ON Turnthe rearwindow defroster switch (ryL)ofthe defroster 2.REARwlNDOW DEFROSTER Symptom: Rgar wlndow defroater does nol operate Step 1 20Afusein the fusebox. Measure voltage thetermin+wire fle at filamentconnector(rightside). filament Ch€ckdslroster lReferto oaoeT-84) Repairwjringharness (Delroster filam€nt Body oround) (8) Olhels Stop 4 '1.Turnlhe rearwindow switch ON. (B) 2. Measure voltage the terminal-wire the at of the rear windowdefrosterswitchconnector. delroster (B/80and(B/L) 2.

it can be driedIn aboul30 minutes Note . Repair laultyportion described below. filament.. Letlhe paihisetior 24 hoursat 25oC(77'D to let ^dry (lt completely. Attach part brushor markingpen'coatthedamaged 3.t usegasoline similarsolventsto cleanthe ot damagedPart. T-84 . Do not use the tear wlndow defroster untll the paint ls drv. 283577 600)or equivalent' 4. is voltage higherthanspecified 1)lf the measurement portion in the rightsideasfar as measur+ is Thefaulty mentPoint. is voltage lowerthanspecilied 2) li the measurement is Thefauftv Dortlon in the lefl sideas far as measurementpoiirt. Ljsino amall a wilhiilver oaint(partno. iurn the rearwindow switchON de{roster points thedelroster on at the Measure voltage thefollowing 2. @-@' @-@' o-o' 10-12 V Balteryvoltage decidethe laultypodionas follows: 3. in as the 4.ise oai'nt of thefllament. part of tapeto bothsides the damaged oftheflament 2. thinner ahvl alcohol cleanthe damaged t . a blowdryer is used lo neatll lo rou"u r3o2on. . BFOKEN WIRE CORRECTIONPOFIIION Repalring part to o. Do n. lf notas specified.DEFROSTER REARWINDOW FILAMENT DEFROSTER lnsDeclion 'f.

T-85 . Install hornin the reverse the orderof removal.HORN HORN SThUCTURAL VIEW 01EoTX. Confimthatthehorn(s) sound thehornswitch pressed il is withsterring wheelanypositjon. do checkthe horn(s). 2. Remove horn(s) shownin the figure. HORN SWITCH On-vehlcle Inspsclion 1. combination switch and wirinoharness. lf horn(s) not sound.r35 1 . Hornswitch HORN Removal/ lnstallation 1. the as 2.Horn 2.

.... ..... Installation Removal/ p"S"I99 pageT-96 pageT-95 T-86 ..........-........ / Rembvd lnstallation .....' T-95 Removal/ 2.... InsDection 3 Rearspeaker Installation Removal/ Inspection cable and 4 Antenna feeder ...... Audiounit page lnstallation........T AUDIO AUDIO ssT PREPARATION 49 D066801 VIEW STRUCTURAL '1..............pageT-96 paie T-96 .. Doorspeaker .

5 . To sdect band. . To setstatron.and hold it tor morethan 1.lurn BASMBEBLE clockwise For lesslows. . .pressa or V for morethan 0. (Prcssing AM/FMaltemales AM.or FM2andfrequencywill be displayecl Balance convol AM.pess n ior higheriiequency and pressV for lowerliequency . .turn BASS/TREBLE counlerclockwise To shilt soundto left. @@@@@@o@ Noie .tlm BASS/TREBLE counterclockwise PressBASS/TREBLE Formorelows. To seeklune siation. . .the indlcaiorreturns io clock mode.AUDIO AND OPERATING PROCEDURE FUI'ICTION T "i!#ilrfti{ VV . To manually lune station. FMl or FM2andfre quency be disdayed will hrning Seek presel Channel tuning T-87 . . F[. . Press desircdchannelpres€tbutlon Displ3y AM. . pressAM/F[. .11 and FlV2) . . Radlo Functlon To turnladioON or OFF To Op€lalion €nd proceduie Press VOLUME turn ON to Press VOLIJME againto turn OFF TumVOLUME adjust to PullBASS/TREBLE For morehighs. Ten secondsafter completing operation an lhal is shownon the display.5 s€conds To tunepreselchannel .tum BASS/TREBLE clockwis€ For lesshighs.llm BALANCE counterclockwse pressAM/FM To choos€eilherAM or Fl\r. . FM1. pfessone channeinumber. . lurn BALANCE clockwise lo To shiltsound iight.

push or dependon APC(AulomaLc Program .rsht.prcss of or APCthen FF(for next program) REW(tor presenl) Clock Note . .otrequencv T'. The clock can be set whlle ladio or tape/CD player is ON' Functlon Tlmedisplay gtjng clock Opedlion and Prccrdur€ CLOCK"dil ttomatcallv displavcurrenlrad. open_edge ight tape lhroughcasselte Ins€ncassetla (Svstern sMches to tape opefation) automatically reversetape play At end of tape.. Nc lfont dghl @ lamps) m: Speaker . eCC j : Nc b: Nc ttorn b[ O k i Soeake. or mode 'or appror. hoirs. pressSToP/EJECT . To resume @IINECTONTERI'INALSPECIFICATION Componcnl Audlo unll j Connector X h X j I Telmlnal I : Spsakerrear ighl O t"'dl tetl O I .no*"iltd6pby*J. nvesecondsbelorerevering to lim€ mode' currentlime wll flash 6 aai. pressH. to advanceminutes pressM To ad'vance pressCLOCK again notm€l dlsplay.-+- b l b l " l T-88 .et rear righl O h Sp€aker b : S.AUDIO cassotte Tape Player to slot.. pr""s ct-OCKtor approx.two s€conds. To last loMard or rewindtape. To ejecttap€.sttime. To s€archior b€ginning pres€ntor nexl program.eake' rear lelt O NC i c:Nc d:NC J :NC h:NC u. Spear. : TNS iluminalion {lor Jrontight o n : Speaker | : Nc O a : Inpd signal b : hpul €ignalO @ Input signal O Inpulsignal Door 6laakcl ngll 3Deakcr . sysl€rnwill automallcally . | : Sb€ake'iront lefte .

A\ A sp€eker Table speaker Fador Balanco Lett Rightdoor Righl Left NO Judgemenr Leitdoor spoak€r OK Lefldoor speaker cncuii taulty Bighldoor speaker OK Bighl laulty doorspeaker circuit Left lear speakff OK Right rear Righl No Letl rearspeaker circuil iaulty Fighlrearspeaker OK nightrearspeaker circuit laulty T-89 . Before troubleahooting.(Refer pageT-95. Batlery voltage Ne't. 1.AUDIO TROUBLESHOOTING Symptom: Speake(s) not sound do Note . to position. 2. E-E Step 2 1. ol go 4. . tone. It not.uct in the proper operating procedures.refer1 of ringto Table 2. as Checkoperation eachsoeaker. 3. tor of 3. Check illumination the clockdisplay. go to Step3.) 01AOTX 095 Step I 1. checkwne(uR) Check CIGAB 15Aluse (UB) OV ll CIGAFl5A fuseOK.Turnthe ignition switch ON. to the nextstep. Step 3 Locate farfty the speakerG) using by thefader. Remove audiounit. advise or inst.volo BAL BAss FAo aF CLOCK^ TRE ^ / /4A. Check voltage thelollowing at terminal-wiresthe audio of unitconnector.repair wireharness 15A {ROOM fus€-Audiounit) sw.) the to 2. Play prerecorded andsetthevolume thecenter a tape.go to Step2. Fromresults Table testing. I'TL A. (Refer to page T-A7.andbaf ancecontrols.repair wiroharness (CIGAF 15Atuse-Audiounil) 12V CheckROOM 15Atuse (UR) ll ROOM 15AfuseOK. lf the clockdisplay doesnotcomeON. Setthe laderand balance controls shownin Table1. to 3. Turnthe ignition switch ACC. ll the clockdisplay comesON. Turnthe ignition switch ACC. verily that the cuslomeris usingthe audlo system cotrec y. 4. to 2.

lf theconnection OK. lf necessary. go to Step8 Siep 6 Left rearsDeaker S to trim.(Refer Section connecled. is 2. lf necessary.(Refer Section ) the 1. Checkif the speaker properly the repairor reconnect connector' 3. lf necessary. 3.AUDIO Table2 l{en slsP Rightdoorspeaker Rightrcarsp€aker Step4 Step5 Step 6 Step 7 "€)Cz Slep 4 Left door sDeaker ihe 1. Remove leftfront door trim.) to the 1. is 2. is 4. is 4.-Remove rightlrontdoortrim. Checkif the speaker properly the repairor reconnect connector. (Relerto SectionS. is if 2. go to StepI sJ (z Step 5 Riohtdoorsoeaker S. lf the connection OK.) connected. Remove package connected. Check the speaker properly the repairor reconnect connector 3. go to Step8. is 4. T-90 . lf the connection OK.

repairthe wire harness. lf lhe speakeris OK. repairor reconnect connector. Measure resistance between terminalsof the speaker. (Referto SectionS. is Step 8 '1. the 4. Checkil the speakeris properlysonn€cted. (Speakers-Audio unit) T-91 . go to Step 8.St€p 7 Rightrearsp€eker 1. lf necessary. lf the conneclion OK. 2. Resbtance: 40 3.Disconnectthe connector lrom the suspected faulty speakers. R€move package the trim. 4. 3.) 2. replacethe speaker. lf not as specilied.

ll thesound Go circuit. tionmav be in the soeaker quality same astheotherunit'the malfuncis 3. lf thesound buality inferior theotherunit. Reslstance: 40 redace or has 4. connectors ot conn@tion speaker 2. qualityis the sameas the otherunit. the are 5. Disconnect thesoeaker of each sp€aker. Checktor Drooer resi$ance and connectoas.AUDIO Radlo Symptom:Poor soundqualityor noise Step 1 'L Tuneto the strongest station (Reterto pageT-87 ) AM that vehicle has with soundquality thatof another 2. to Stsp2. Piay known a typeauo|o that vehicle hasthe same wilhanother oualitv ' dnit. lf there is continuity. ii the speakers OK. go to is 3.lhe sys4. to Step4. Checkfor damage the spealGrs. tionmay be in the antenna Step 3 to 1. measJre 3. Checkthatthereis nocontinuity {ntiniteohms) and a bodyground. ffi% V Step 2 sound goodcassette andcomparethe tape.replace audiounit Step 4 the between 1. antenna replacethe anienna. 2. t. go 3. quality interior theotherunit'themalfuncto is 2. lf thereis no continuity. lf thesound Go circuit. to Step5 ANTENNA T-92 . to Step3. lf a speaker incorectresistance is damaged. Compare the sametvoe audiounit. lf the sound tem is OK.

lf the installation OK. Checkfor properinstallation the antennamast. lf the no continuity OK. is audiounit. Checkfor no continuity the feedercableas shown. is lightenit. 3. 2. is 3. Remove audiounit. lf the installation loos€.) the to ol 2.replace T-93 .AUDIO Step 5 of 1.(Reler pageT-95. Slep 6 1.go to Step6.

ll thereis no oxideor dirt.reter to "speake(s) doesnot operat€". lf oxideor dirt is found.go to Step3.conlirm that the cuatomeruaesaudiosystemby proper operatlng to ploc€durg. lf the speakersare OK. Disconnect speaker of €ach speaker. ffi\E V Step 2 't. 2.replace or has 4.) . tapeis defective.lf not. Check for damageto the speakers. and checkthe sound qualfiy. advlceor leach the Plopel operatlngProcadule cudomel' (Reterio pageT-47. 3. and pinch aoller. troubleshootlng.capstan. T-94 . of 2. Check for properconnection the speakerconnectors resis{ance and all connec'iors. 5.cleanthe partswitha headcleaner.reter to pageT-€9 Stsp I '1.go to Step2. lf the souna audiounit. iompare soundquality hat of anohervehicle has the sametype of audio system. Reslstance: 40 resistance |sdatraged.AUDIO Cassette TaPe Playet Symptom:Poor sound quajity Nots -aetore . It a speaker incorrect n. The is the 2. the quality inferior the other unit'replace to is 2. f s6undquality normal. go to Step4 steo 4 '| that with . lf sound qualityis still poor. 3. measJre 3. Checkfor oxideor dirton the head. li " spe"lfirtil ao".Piay a knowngood tape. Stsp 3 1. not opelate. system is OK.

Bemove antenna teeder and cableas shown the lioure. thenoushthe audiounitintothe slot. Install antenna order6f removal.AUDIO AUDIOUNIT Removal/ lnstallailon 1. 3. Remove frontsidetrim.) the 4. the and 4. 01aoTX-111 ANTENNA AND FEEDER CABLE Removal/ Inatallatlon 1. To install audiounitconnect connectors feeder the cable. to the 3. in the and teeder cablein the reverse 5.thenremove the and the audiounit. lnsert SST intothe holesol the audiounit. the 2.(Refer Section to S. T-95 . Pullthe SSTapart@ and slideout theaudiounit@ as shownin the figure. Bemove inslrument cluster. the and (Refer pageT-35.) the 2. Disconnect connectors feedercable. Remove audiounit(if equipped) the audiopanel.

01EoTXj9t REANSPEAKER Removd / Inaiallatlon to S. of the 2. T-96 . Remove screwsand the rearspeaker. 2. ll not as specified. 3. Installthe door speakerin the reverseorder ot removal n*€)(-z )\ <3" r Inapection the 1.(Refer Section 1.) the trim. Measure resistance the rear speaker' Standard reslstanc€: 40 3. Removethe 3.AUDIO DOORSPEAKER nemoval / Installation S. of the 2.replacethe rear speaker. In$all the rear speakerin the reverse Inapsction 1. Remove doorspeaker.) to the 1. Remove door trim. Remove package the 2.(Refer Section screwsand the door speaker. Measure resistance the door speaker' Standad resistance: 40 replacethe door speaker. Removethe rear speaker. ordsr ol removal 3. lf not as sDecified.

................................................................................................. U-27 AIR COND|T|ONER.......................... u............................................................... U-22 BLOWER UNtT.................5 SYSTEM DTAGRAM .........HEATERAND AIR CONDITIONER SYSTEMS 1NDEX................................................ U-39 AJC SUBRE1AY..................... U-30 STRUCTURAL V1EW.............................................. 7 UFUNDAMENTAL PROCEDURES OF TROUB1ESHOOT|NG............................................ U........................ U-40 ............................... U............................. U-21 HEATER UNtT........................8 cHECKL|ST.. . U-€6 CoNDENSER..2 HE4TER....... U-41 RECETVER/DRtER........................................2 AtRCOND|T|ONER ........ U-............. u............................. U-31 A/CRE1AY.... U-30 REFRTGERANT SYSTEt\r.... U-l0 HEATER................... U-42 REFRIGERANT PRESSURE SWITCH .............4 UcoNNECTOR 1OCATION..........................................6 UTROUBLESHOOTTNG GUtDE..3 UTROUBLESHOOTTNG GUtDE......................................9 FLOWCHART..................................................................................................................t6 tucswtTcH ..........U.. 7 UELECTRICAL TROUBLESHOOTING TOOLS....... FAN U-{3 REFRTGERANT 1tNES.. U-45 coMPBESSOR....... U-44 MAGNETTC C1UTCH..................43 coNDENSER ........ U-21 STRUCTURAL V|EW... U-24 HEATER CONTROL UNtT.............................................. 4 UclRcutTDIAGRAM ............................................................. U-39 ! coolrNG uNtT............. U.

Mix wire pageU-29 Adjustment........ ....................................... U-25 Disass€mbly unit) motor(in blower Blower pageU-26 1nspection........... U-22 / pag€ / Assemb|y.................... / Assembly.. pageU-28 Disassembly Blowerswitch pageU-29 Inspection................................ Heater page RemovalInslaj|ation..... (ln blowerunit) assembly Resistor pageU-26 Inspection...-......................................................... U-23 Disassembly unit 2...................................U-24 page / Assembly............ Heatercontrolunrt ...... Blower page / RemovalInsla1|ation.................... U-27 ..INDEX INDEX HEATEN unn 1.. wire Rec-Fresh pageU-29 Adjusiment. u-2 ....... Modewite pageU-29 Adjustrnent............. page nemoJaI tnstattation.................... 3..

.......................... Condenser Removal Instal|ation............ pageU-46 2................. U-37 pageU-37 Rep|acement...... pageU-41 5...... Condenser lan RemovalInsta1|ation........U-38 page ..... pageU-46 Adjustment...........................................INDEX AIR @NDITIONER 1..........-.......... U-42 / 4............... 9... / ........... pressureswitch 6..................................... U-46 page Inspection.............A.... Magnetic clutch Disassembly /Assemb|y.......... 10.. 7......... U-49 page Adjustment........./Cswitch pageU--40 Inspection............ U-47 page / Disassembly / Assemb|y............................. U-4'1 / page 1nspection... Cooling unit RemovalInslallation.................................................U-43 page / Inspection...Compressor Removal Insta||ation..... Refrigerant pageU-43 hspection................. u-3 .......... pageU-43 8....................... Receiver/Drier page Bemoval Insta|Ialion..................................................................... ...... lnsp€ct4on..........pageU-36 page Disassembly /Assembly.... AJCrelay pageU-39 hspection...... pageU-46 3..... L/C sub relay pageU-39 Inspection......

U DIAGBAM CIFCUIT GUIDE TROUBLESHOOTING GUIDE TROUBLESHOOTING : ^ +. n t i T_l tcl fl-n q a{ 0 EIIIHIF 2 \gr' u-4 .. e Y e 4in l : ! : n ! tit E r c d I _l HI .

/Crelayconnector 7. A. Blower motorconnector 5. Pressure switch connector 2. Condenser connector tan 3. A/C sub relay connector L Blowerswitchconnector L A.TROUBLESHOOTING GUIDE CONNECTOB LOCATION 1. Thermoswitch connector u-5 . Resistor assembly conn€ctor 6./Cswitchconnector 10. Magnetic clutch connector 4.

j .U DIAGRAM SYSTEM A/c swlTcH GUIDE TROUBLESHOOTING BLOIIVER SWIICH REC FRESH DOOF i' .4 -fr1 . / PFESSUFE swtTcH CLU MAGNETIC u-6 . .

. Cautlon .Doingso may burnor otherwise damagethe ohmmEler. Do noi connectthe iumper wire betweena power aourceand a bgdy ground. u-7 . Never@nnect the ohmmeierto any drcull io which voltageis applied. to Ohmmeler Theohmmeter usedto measure resistance is the between two pojntsina circuit. it is firstneccessary separate to thesetwo systems proce whentollowing checking inspection the and dures. This may cauaeburnlng or olher damage to harneaaeaand electronlc components. checkfor continuity. Voltmeter TheDCvoltmeter used measurementcircuit is for of voltaoe. A voltmeter a range 15Vor moremustbe used.it is in generalpreferable checkthe refrigerant evacuation the refrigerant of to system afterchecking the electrjcal system. 93G0UX 004 ELECTRICAL TROUBLESHOOTING TOOLS Jumper lvlre Thejumper wireis usedfor testing short-circujting by switch terminals to verify condition ground and the ol connections. for thatreason is important checkandconfirm operation the system. to diagnose to and short carcuits. cause a problem theheater the of of or air conditioner. to theambient to due temperature.TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Troubleshoollng Poinls . lt is sometimes diflicuft discover. Because air conditioner coniposedof two systems: refrigerant an is the system and the electrical system. Because replacement components therefrigerant the of of system donein conjunction the is with gas.li rs with ol (+) usedby connecting positive probe(redlead) the the to pointwhere voltage to be measured connecting is and the (-) negative probe(blacklead) a body ground. and it to the of It is thereforesuggestedthat a sequencebe established checkthe operataon thatthe symptoms to so of the Droblemcan be accuratelvdetermined. Caution .

Delermine ol svmptoms problembased ol upon r€6ull.useflowchatsaccording to symdofis of prollem .. lo .GUIDE TROUBLESHOOTING OF PROCEDURES TROUBLESHOOTING 'piJ6J'illir'' FUNDAiIENTAL the of the heaterand air conditionerbv following s'tepsbelow' i6"06'"fi.When checking.s checkingbv check llst .Repair or redacecomponenqs) as u-8 .ls syslemoperalion normap . check ol syslern oporalonaccording chsck list procsdule .

of u-9 .love BEC-FRESH in se lever quencefrorn MAX-BEC posilion posilion 1oMAX-FBESH Movemix lev€r MAXCOOL io Checkfor changes air outets at whenmodelever moved. at 7 Checkfor changes temperature Temperature air lrom air outleis of oJ of airtlowfiom alr outlels. each awitch or lever actlvatedshould remainas is lor th9 nert step. tan Magnetic clutch does not opefate 10 1l 12 t3 15 10 Check tor outllow of cool aif. Foreachstepol the checking operation eachcomponent of otthesystem should jnspected be visually and. Note .Checkoperaton condens€r of fan Condensef and magnetic ian clutchdo nol operate. procedure. Condemer and magnetic fan Condenser do€s not op€rate. No outllow coolair. Check changes RECJor at FRESH whenFECFRESH lever No changed AEC-FRESH air 8 9 a Switch air conditioner ON switch. Itom Symplom norcll3d Checkoperation blowermolor of at each swjichposllion. l\. Unlessolherwise specified.Go to that llow chartto checkthe systemfurther. an abnormal lf condition discovered. in addition. volume. operation the sound. Nochange air oullets. anyhowerswitch Blowermolor does not operate wtrenblowerswitchat lst Blowermolordoes not operare whenblowefswtch al 2nd Blowefmotordoes nol oprate whenblower swilch 3rd at Blower motof does not operate when blower switch at 4th 1 2 3 5 6 Set blowerswnchto 4th posdion 4 5 6 Movemode lever in sequence trom VENTpositionto DEF Movemodeloverto VENT lllove mix levor n sequence lrom MAX HOT posillonto [4AXCOOL Positjon. Blowermotordoes not operateat position. 93G0UX006 Heater Air conditioner / Step Check proc*dure Stadengine and lel it wam up. Blowermotorconlinuesto operate when blowerswitchOFF.TROUBLESHOOTING GUIDE CHECK LIST How lo U€e Check Llst. to the flowchart is reter number for the symptomat the rjght side of the page. (Enginecoolantremperalure: 4OoC higher) or Move blower switch from OFF position to 4lh posilion in sleps. temperature the air beingemitted and of fromthe air outlets shouldalsobe checked.

..... Mallunclonol blowermotor Ch€ckdower motor(Relerto page U-26) Ertlery voltag€ (L/\iV) t€sistorassemof vollag€at tefminal-wire Measur€ .. €ach awltch or leverac vatedshould rsmaln as B lor the naxt alep... swiich oFF ignilionswitch connector r€sjslorassembly 2. Mallunction blowerswilch ol check blowerswitch(Retsrto pag€ u-29) u-10 . ottrenntsespeclfled.. Short{ircuitof wire hame€s salch wir€s(L) (L/O ot (Res|sto' assernbly-blower (UF) Repa{ wirchamess .. Malfunction wire harness of (Circuitbreaker blowermotot:wire (UB)) Repairw€ harness .. Malfunclion wire harness ol wire (Blowermotor-r€sistorassernblyr (L/W)) wireharn€€s Reparr B.. M€asure Betlery vollaga (L voltageat terminal_wire V) ol blowermotor Meas.......Blowermotor' Rosrstor Checkcircuitbr€aker 30A (ln tuso box) BLOWER ..and verifythat blower . Disconn€ct 2. motor Rahied compor€nts..Fuse.....ire . Shoft{ircuit of wirs hamess wire (L/W)) (Blowermotor-resistor assembly: RePa[wire hamess swtchposlton doesnotoperabat anyblower Blowef Svmotorn..U FLOWCHART GUIDE TBOUBLESHOOTING Noto -t]:nuss .. swilchoN ignton swilch (UB) ol nower voltaqeal t€rminal_wre 2... SwitchON ignition$/itch... Matlunclon Uowsrswl'tch ol Ch€ck dower swilch(Relefto page U-29) 1.ttery volttg€ (B) voltageat terminal'wire of blowerswitch Measure ... Disconnect 3... lvalfunclion wire hatness of ground:wite (B)) (Blowerswitch-body Repairwireharness .... Short-circuit wire hamess ot wite harness.r€€elcircuitbfeal€r After checking 1.. swilch OFF when blow€r to cordnues operate Blow€r Svmotom.. and verifvthat blower mG tor op€lates .--.... SwitchON ignitionswitch..alower switch wire hameEs - blowerswilchconnsctor 1. motor Blow€rswnch wrre narn€ss aEs€mblv Fabied componeds.

Resistor assembly. Mal.. SwitchON ignitionswilch (UR) of rcsistor 2. Malluhction blowerswitch o....... SwilchON ignitionswitch 2....minal-wire assemoly connedor i Malluncton resistor of assemdy (Relerto pags U-26) Checkredstorassembly (UR) ol blowerswitch Mea€urs voliageol lorminal'wire .. motor Btower do€6notop€rate when uowsr switch ist positon at I components.. molordo€snotoperat€ Btower wh€nbtower switch 2nd po€iton at I componen!s.. Switch ignition ON swich 2.W(e harness 4 | Relalisd 1.... MalfuncUon resistor oJ ass€mbly (Refeflo page U-26) Ch€ckrcsistor assembly (L) Measure voltagsot terminal-wire of Howorswitch . Resistor ass€mbly.wne ot resislo. Measurcvoltageof ie... Blower switch..... (Resistor assembly-blower svvitch: (L)) wire Repairwireharness . Resstorassembtv..Wre harn€ss 3 | Belated U 1.. Mallunclion wire harness of (Besistor ass€mbly-blower swilchrwt. Measurevolag€ al terminal-wn€ (1..Wre harness 1...unction wir€ harness of (Resistor as€embly-blower swilch:wife Gm)) Bepairwireharne€s ..e (UY)) Ropairwirehamess ... Maltunclion resigoras€embly of (Relerto page U-26) Check€sjslor ass€mbly Measure voltageat lerminal'wie (L ) of blowerswtch ............. M€lfunction blowerswilch oi Check blowerswitch(Retsrto page U-29) Symptom............ Etower switch.......TROUBLESHOOTING GUIDE Flo*chlrt No.. (L) al assembly connector . Btower switch.. Measure voltage teminal. Mallunction blowerswitch ol Check blowerswitch(Relerto page U-29) .. Ch€ck blowerswitch(Relerto page lJ-29) Flowch!?r i{o.. Malfunclion wire haness o.......ry) resislor oi assembly conn€clor .. molordo€snotoperate Blower whenblower wvitch 3d po€irion at Related componenls... Symp1om. Synplom.

lmorooeradiustrnent Mix wite of CdrecnyadiuslMir ffrc (Relerto page U-29) lrom MAXCooL Veify that Mix levet movessmoothly to MAXHOT posiron ....lixwire to lvix leveror insufliof of cie.rnotom....t lubricalion Mix levef 8f*lffH:....... Mrx wire Mix door' Mir levet ot and Checkinstallation connecUon Mixwre ... lncorrectconneciion Modewire to Mode leveror ol of lubrication lvlodelever insuificient ..Ternperat'ite alr ftom alt oulletsdoes not change niaiea comoonents. .Modewre..pon. s\4notom. poslton Blower sw{chwire harness A'aaiio*r.... change air outels svmotom.. S!.... ...TIfffi orduct .. Malfunclion wire harness of switch:wire (L/W) (Resstor assembly-blower ol Maliunction blow€rswncn Checkblowe! switch(Reterto page U_29) €l No ........... SwihhON iqnion swilch voliageol terminalwre (L V)of blower 2.. nesstorassembry 1.....amased crossed u-12 ..... Measure ...nrs.. Mallunction Mode dclor ol Ch€ckwhethetMode door damagedor ducl c|oggeo ot .. nbaieocomoonens.. lncorect connection l\.. Modedoor..re (Felerlo p€ge U 29) irom VENTto Verig that Mode levermovessmoothly DEFposition . lever ..GUIDE TROUBLESHOOTING al Blow€rmotor do€s not operalswhen blowersiwdch 4lh ......lvlode of and Checkinstallation conn€ction Modewire . . lmDroDer ot adiuslrnenl Mode$4re Cdnecrlv adiuslMode w.

.FRESH movessmoothly lever from MAX position RECto MAXFRESH .. tever U and Checkinstallation conneclion FEC'FRESH ol wre .... lvalluncUon wire harness (th€mos$tch . Measure voltageat le|minal-wire oi. Maliinclion ot wir6 hamess (Fuse. SwilchOFFignitionswitch 2.TROUALESHOOTING GUIDE No change recirclauon (FEC) at air andtresh (FRESH) air lymptom... reley...wne connector Battory voltage 1. hproper adjuslment REC-FRESH of wre CorecUy adjusl REC-FBESH wire (R€lerto page U-29) Veit i\at REC. REGFRESH REC-FRESH REC-FRESH wire. door..and verifythat A../C relayconn€dorand (G/W) thermosMchcon..tl6ry voltlge .. ol 3.ON switch.FRESH to HECoJ wirc FRESH leveror insufficient lubrication REC-FRESH ol . condenser andmagnenc ral ctutch notoperate cto I componenis........... Measure voltagest terminal.. Maltunclioo REC-FRESH ol door Check wheth€r REC-FRESH damaged doo. SwitchON blowerswitch 5.... lvlalunctionof ECUor wire harness€s (A/C rclay-Ecu: wife (UO).. swtch... Belaled components. Symp1on.l-use.AJCrelay:wne (L)) Repairwire harnsss (UO) ol IUC rela.]AJC ol swilch:wrre(G)) Repairwire harness u-l3 ..... Incorrectconneclion REC./C condenser and magnelicclLJich Jan operate do not opoaata Measurs voltageal lerminal-wire (G/B)of thermoswitch &ttery voltagF \. Connecliumperwre between temina wir€ (UO) ot A. Short-circuit wire harness ol Aftercheckingwire harness rcplacefuses 1.and EclJ-Themoswitch: Ch€ckECU or rcpairwjre harness (ReJer S€ctions and F2) to F1 ..ECU A/C tO I Relaled Check luses AD FAN 20A. Swilch ignilion ON switch 2..6JCrclay (L) B. Malfunction thermoswilch of (Feferto page U-38) Ch€ckthermoswitch . lr'C ftem oswircn. WPER 20A (in tuse box) .. SwitchON lgnitionswitch 4....Swiich. Flowchart No..........!ltage al termjnalwn€ of l/C swnchconMeasure (c) Batery voltege Italiunctionoi AJCr€lay CheckA/C relay(Refer pageU-39) to .

/C$'vilch Check l'lc switch (Feler to page U {0) 'L SwilchOFFignilionswiich 2.irevoltageat term.. ConnectlJC switchconnector conn€ctor 3. SwitchON ignitionswitch.vvitch.and veify that condenser clulch oP€rate tan and magnetic .. Malfunction ..blowetsw{cn: wrres{UB) and (L/n) Repar wire hames€ .......blowerswitch:wire (UB)) wire harness Reparr . Maifundionof wi.nal_wr€ Belt ry voltage cround terminalwirc(UB) of A.om ]A/Crelay connector t'sconn€ci termi...a./C swilch ot to CheckdJCswilch(Refer pag€ U-40) ./Crclay connectot and fan veritythat condens€r and magnelicclulch operate do not opgrflc (R) vollageat terminal-wire ol A.e hatness wire (G/w) or fiC r€lav (ECU. Maltunction of A.. Disconnect switchconnector AJC 2.rnotom..NC telay wrs { Bepanwrreharn€ss . Shon{ircuit in wirc harness (Ihermo€witch A.Thermoswitch./Cswiich Msae..wilch and 4.. Mallunclion wire harness of (Fuse.Themoswitch: ECU:wir€(UO) Fep€lrwile harness ot Matfunction .that .Dsconn*l lhernos.../Crelaycor! Moasure Battery vollage (UB) ot IJC relaycon_ voltageat terminal'wne Measure BalLry voltag6 .U GUIDE TROUBLESHOOTING (UB) ol A....Wireharness cornpoflents. Maltunction wite harness ol (L/C ssltcn ..A/Crelay Ch€ckA/C rclay(Referto PageU-39) u-l4 . SwilchON ignilions. switch. vedlythal condenser clutchoperale lan and magnetic . R'6laied '1..al_wire fan condenser and magnelc clutch and verify.. AJC ECU./Cswhch:wircs{G/B)and (B) Repairwire harn€ss (UO)i. Malfunction AJCrelay ol to Check..^'/Crday (Refer page U-39) remain on clutch fan Condens€r andmagnetic S!. MalJunction wire harness ol (A/Crelay.

. | Relatedc. Magnetc clutch doesnot operate Relaled components.. Ma./Csub relay Measure voltageat terminal-wkes Batery Yoltage jumper wie bslweenteminal-wire(B) of 1.aJC relay 2./Csub relay. Mafunctonof wre harness (!JC r€lay. Wircharness 1. Magnetic A/C ctutch..body gound: terminal-wire fan (B)) Repair wire harn€ss Symptom. Malfunclion \rire hamess of (4./Csub relay(Referto page U-39) .. Mallunclion condens€r ol lan Checkcondenser (Referto page U 43) fan . Switch igntionswilch ON 2... ran I symptom ... Measure voltageat terminal-wire sub Betr.. Pressure switch.magnetic clutch:wil€ (UB)) Reparwirehamess u-l5 . Mallunction pressure oJ switch Checkpressure switch(Reterto page U-€) ..Connect A...../C sub relay connectorand body ground (B/L)of ....leasure voltageal rerminal-wi'e c Brtlery vohage Malluncl of magneticclulch on Checkmagnelicclutch(Raferto page U-46) . Mallunclion l.Condenserlan. Swnc. cond€nser oo€€noroperar6.tunction wirc harness ol (1.. Wr6 $rness 1......TROUBLESHOOTING GUIDE Flowch8n o' t2 U ... sub relay..... SwilchON blowerswitch 3..body ground:wire (B)) Repair wire harness (B/L) ol magnet I\...preserreswitch:wire (UB)) .. .. SwilchON blowerswitch 3..Swilch ignition ON switch 2.I/C sub relay:wke (UG)) Repair wire harness .mponenls. Mallunction wire hamess ol (Condenser ../Csub felay . Swirch A/C swrch and Measure ON voltageat termnal-wire(UB) of condenser connector fan . Malfunclion wirc harness: of (Arc rehy ./C sub relay ol CheckA..condercerfan: wre {UBD (B) [4easure voltageat t€rminai-wire of condenser ran ..ON A"/Cswitchand maasure vohagear teminal-wire switchconnector {UB) oJ pressure Batlery voltag€ M€asure voliage at teminal-wirc(UG) ol pressure Battery vohagc (UG) of A.... MaliuMion ol wireharness (Ple€sure swilch.ry voltage (B) Checklor contjnuityb€tw€enterminal-wife l/C sub relayconnector and ground .

s6r Mix leverto MAX COOLpoGition 5. Appror. of 6.atl-r. engine 1. (2. manifold 1.5 kg/cm'..0-'15.8 kg...nd circJbton ol religerant are bofi normsl checl as No. 245 l(P.15 in described Flowchart Cleaa (No v|3lble bub6l€../c|n'... Switch air conditioner ON 5. 327 P.5 kPt (0.. 2. 245 kPe (2. ESPGI) 687-1. Set blowerswitchto 4th posilion 3.Make check In d-€scribedFlowchad 13 8u!!k5 (odr) rLbL Correctamounlol retrigeranl (through glass)cond ion oi rehgerani at srghl Check eveninough amounlol relt'geranl fll coolinqinsuflicient OFF morn€nt whonAJCswitchswitchecl .5 kgL/cnu.5 kgy'cnr.. 't5-3 15-! 78H&l l(Pa (8-9 kgy'cm" lla-128 F.. (?3 rg/cid... 7...l) Apprcx.472 l(Pa fr-15 l(g. 3s'6 pC) Flowchan o..l) t5-c 15-d l5-o r.......256 l(P. 4._ijtorc llotc chacklng or sawlclng tha t€ftlgerant ryrtem.. SetMix leverto l\raxCoolposition. Readindication manilold Normal preasure HlqhDreaaurg slde: t?zs-t.000rpm 3..gez toa (rs-zo kg/Gof. '1.... flontt) vlCbh lnsutfic|orn retKFrart No ..... 245 kP..0kg/cm'.. Startthe engine..tzzwa (t9.-.0 InHg) ol vacuuh 50 cnHg (2.21. Connect and 2..OInHg) ot vlcuum147kP.185-213 psi) Lorv-Dressureslde: 196-294 kPe (2-3 kg/cltf' 28-43 p3l) relerring iable below.a pd) Approx.. swtch. to p. PeD 392-ss9 |es (a-6 rg/d ". (1. run it at 2. syslem Reftig€rant Reletedcomponent. slstem Rslrigerant Relatedcomponent. 580 kP! (6 kg/cnf... Start 2. '..']llaure 3lde gaugeset.) ffi @ Hlgh... bubblea or foam) ot Ch€ck pressure system Air oltflownotcoolonougn Sympiorn.. Ct-10 rcr'cr#. gauge. ba 3u1glo r€ad thc 3ection conccmlng !..... 57-€5 PsD 15-l 15{ u-l6 .5 l(g'/crf. 270-284 p3D '100-142 ss?-gsi l@. SwilchON IJC swnch 4./cmu. 76 cmHg (3.Ch€ck(throughsight glass)conditionof r€figerant Clc!i a$b|... Lou+reaaule alde ll... (2.lt/|clng note3' (ndo.ge U-31.3P6l) Appror. 85'6iol) 35..962kPa (m kg/cm'. lf not as specilied.. 78.Maie check desc bed In FlowchartNo 15 (l{o vlaibl.D Appror.. SwitchON blowerswitch.GUIDE TROUBLESHOOTING circulaton and reltjgerant Ch€ck (thrcughsigh qlass)amountof r€ftigerant No oufflow coolalr of Svmolom. to checksystem. 100-213 p.5DC) Applox. or loam) Relflq€ranl ov€rcharged . 284 p|D Apprcr.

. 11. Exc!€slw r€frlg€l.. (0. (2.Ch€ck O-nngat connectron...962 |ea (20 *g/crd.venlyno leakageat piping and components rci geranlq.l Hlgh-prF3urEslde: 785--A83kP.yno dolormation ancyor contamination ol Clean./drt'.... 114-128 psl) ___-l LovJfr€33uru 3ld€: I Approx.. replaceil necessary (R€for pase U-44) to Usingga+leaktester.. 284 psD Low. side: ApprDx.pr. (&-9 kg.repairor replacecondenser (Relerto page U-41) u-17 .|rt or poor coollng ol condens€r Veri. Veily no oil slaim or contamination piping al Gas le€lage ifom piping conneclion .. 2{5 lf.6ur..€tsm ol Gas leakage lrcm piping of system component . 35.8 kgL/cm'..Replace O'rinS pipinS al conneclion rsplace or System normal{Gaslea}€gedue to age) ..6 p8l) I Cause.4 F ) I Inautllcbnt ietiigarant I Caus€.5 kg/cm'..78..5lrP.Charge with refrigeranl Ftowchrd No..l j 15-b High.Feaaurc aHe: Approx..TROUBLESHOOTING GUIDE U No.. 1..

Lesveas is lor approx.ll lhc alma problam b apparcnt aner a vlc||um |! created. SwitchON A/C sfrtch and measure l{oimal prela|||E lllglFpr..85 PGD slde: Low-pre33uaa 75 cnHg (3.. 327 p6l) Low-prcaaurecda: Approl.0 InHg) ot Vacuutr Cru3e.Replacs expanston vaNe u-l8 .rirl. 1.. md then lollow lhc !F progdate prgcedua4lo cl6ar away lhe obstrudbn. Alr In rattlgcaant systen Pioa!ufa Hlolr-or€s|||l !lda: &plox.F ol ant Daaasqo ihc arpatEion valve 15obstruclad by watar (fto' zani or foir€lon mtlcrisl' Fl'3t. Slsrt onqine 3. rcplac! the a€calve/dtler (Melfuncdon ot t€celve/driei) FoGignmaterialmix€din swtem ..... 35. lt cen be p€rumcd thst problbly thc rulrlg..GUIDE TBOUALESHOOTING Hlgh-9rua3urcdde: Apprcx. 245 |fe (2.lnce note: . the]cto|r' ch!'d( whelhcr lhe obiructlon dwater or lorclgn n..e$urr rlde: 2-3 kgLldn- . Conn€ctmanifdd gaug€ 2...tefl minutes causels valvewill meli) water.lr: l3'0-15.. ln th|! in3tance. (23 ldc|rt'...EvacuaterdhiserantIn sysl€m(Rel€rto pageu-33) l'lota: .0-kg/c# Low-p.. S:wlchON dow€r switch(Arc s{iich OFF) (ll 4.33u]G C.256 kP.5 kgy'dn'.ice insideexpansion pr€ssure 5.. 5ss kPr (6 kgr'cmr.6 psl) Caule. 2...t.RaLlg€lant not clrql|'led Rafc.

5 kgr'cmr.eceive/dier Pr€aurc !^ I --'l Hlghpre$ur€ alde: I.. 270-284 pBD I Low-or*3ure aide: Aflirox.-.. Betalgerant clrculatad not Evacuale relrigerantsyslem(Referto page U-33) (Belerlo page lJ-33) Charge with rofrigeranl Checkpressufes lf samepfoblemoccurs..TROUBLESHOOTING GUIDE Ptos3ura High-preaaure 3lde: 687-1. (t9-20 tg/ctl.E64-1.. llXF213 psD Low-Drts6urerlde: 50 cmHg(2..0 inHgt_ot Vacuum147tPa (1.. 245 |fr (2.. (r-15 kgfctr|.3p8i) Cause.ttatton ot i caplll..5 kgldtl'.42 fP...6 p3t) ' C4u3e.35..ry tubo 15-l Vedlyinstallation capillarytub€ (Referto page U-38) ol Reinstall capillary iube (Retefto page U-38) Replac€ €xpansion valve(Referto page U-37) u-19 .. ilaltuncdonot the arpanslon vslve or lmpropor In3t...... 21.rcplace.962rO..

..13 In of Majlunction compr€ssor (Ref€rlo page U-47) . (4-6 lg/om" 57-05 P3D Cause.. SwilchON A/C swnch 4 Verilythat magn€ticclutch actjvaled clutch Malfunclion magnelic of . Start 2....u GUIDE TROUBLESHOOTING Pieaaute !lda: Hldh-or€63urc 6-8?-4a1 lde Cf-10 kg/cm'. Incortecl compressor oPtrttlon engne 1....Replac€compressor u-20 .Checka€descnbed Flowchart No. SwilchON blowerswitch 3. 100-142 pal) Low-Drelsra rid€: 392-589 l(P.

..... u-21 ............ pageU-29 Adjustment .................. Heater controlunit page Removal/ lnstallation.. Blower unit Removal page / lnstallation.............................. U-27 page Disassembly / Assembly.............HEATEB HEATER STRUCTURAL VIEW 01c0ux{31 1........... ................................. U-24 Disassembly page / Assemb|y.................. pageU-22 Disassembly/Assembly.................. U-25 1nspection..... pageU-23 2.......... U-28 pageU-29 1nspection. Heater unit Removal/ 1nstal|ation..... pageU-26 3.............. .....

Adjust d '. Remove orderof removalin 4. Remove dashboard. Heater 1.) lo the 2. shownin the flgure as 3.'-iilease Note the clamp. (Reler Section S. Install the reverse to the Mix and Modewires (Refer pageU-29) 5.HEATER UNIT HEATER Removal/ Inslallatlon 1. and remove the seal plale together with the heater unlt' unit 2.Sealplate u-22 . Drainthe enqinecoolant.

Heater case unit u-23 . Checktor the lollowing and repairor replace heater the coreas necessary. Disassemble the ordershownin the figure. @Dislorted 3. Assemble the reverse in orderof disassemblv. Mix door assembly 4. oamage. (3)6enllrns. Modedoor assembly 3.HEATER Dlsassembly / Assembly in 1. Heater core 2. (ruracKs. 1. and bentinlet. ano waler|eaKage. 2.

(Reter pageU-29. and remove the s€al plate together with the blow€r unll' unit 2.) the 4.(Refer Section shownin the figure. lnstallin the reverseorder of removal to wire. Seal Plafe the screw. Blower case v-24 . Remove 3. iimove '1.) to the 1. as 2. Remove glovebox.HEATER UNIT BLOWER Removal/ Installation S. Adiust Rec-Fresh Note .

Blower Inspection . Resistor assembly 3... Rec-Fresh assembly door page U-26 4.HEATEB Diaa$embly / Assembly Disassemble assemble blowerunitas shown the floure. morcr 2. U-26 u-25 ......... Blower fan 5. Blower case unit page Inspection.... and the in 01G0ux{34 1..

(Refer Section connectors assembly the 2.) to the 1. Remove glovebox. Disconnect resistor terminals. Resiator assembly S.(Refer Section ) the 2. Disconnect blowermotorconn@tors. ll not as specified. between 3. ll not as specified. Veritvthatthe blowermotorrunswhenconnectingbattery b.replacethe resistorassembly. replace 4. Remove glovebox. u-26 . 3. terminal to a volta'ge terminat and grounding the blowermotor.HEATER lnspecilon Blower molor I S to the 1. Checkcontinuity T€rminals b d o o o(H: o o lndicales continuity 4.

Mixwke 8. Glove box 6. Mode. Remove tle ordli sho. (Reterto page U-29. Atter Instrlling lhe lrlix. Disconnect negative the battery cable z. and ReeF|ceh wlres.) 1.HEATER HEATER CONTROL UNIT Removal/ lnstallatlon 1. Heatercontrolassembly v-27 . adlusi each wh€s. Center 4. in 3.ih.tg. Installin the reverseorder of removal.re.e 9. Rear consol 2. Rec-Fresh wi. Modewire 7. Frontconsol 5. Asytray panel 3.. Note .'.

HEATEB
Dlsassembly/ Assembly unitas shownin the figure control the assemble heater Oisa""etnOfe-.na

'n@

@

'@

5. Modewire 1. Knob panel Adiustment pageU-29 2. Switch 6 Mix wire booy i. switctr Adjustment . pageU-29 wire 4. Rec-Fresh ' ';diuament....... lever page U-29 7. Rec'Fresh

lever 8 l\4ode 9 Mrxlever switch l0 Blower ..lnspection 11 lJC switch

pageU-29

u-24

HEATER
Inapection Blowe. swltch 1.Checkcontinuity between terminals the blower ol switch.
Swi!ch OFF 1

Termnal
d

oG-

--a

--o ---o --o

2 3

o- ---o oG --o Ooo- ---o

---o

O-O:

Indlcates conlinuity

2. lf not as specified, replace blowerswitch. the

AdiBtment Rec-lresh wire 1.Setthe Rec-Fresh to FRESH lever oosition. 2. Connect Rec-Fresh to the Rec-Fresh the wire door. (0.24 diameter 3. Insert 0.6mm a in) screw driver sethole into and clamp wireintoolace. the 4. Verity the Rec-Fresh movesits full stroke. that lever

ltlode wlre 1.Setthe Modeleverto VENTposition. 2. Connect Modewireto the Modedoor. the (0.24 diameter 3. Insert 0.6mm a in) screw driver s€thole into andclamD wireintoplace. the 4. Verity the Modelevermoves full stroke. that its

Mix wire 1.Setthe Mixleverto HOTposition. 2. Connect Mix wireto the Mix door. the (0.24 diameter 3. Insert 0.6mm a in) screw driver sethole into andclamothe wireintoDlace. 4. Verify the Mix levermoves full stroke. that its

u-29

AIR CONOITIONER

AIR CONDITIONER
VIEW STRUCTURAL

1. Compressor pageU-47 / Instajlation.................. Removal page / Assemb|y............. U-49 Disassembly pageU-46 Adjustment................................clutch 2. Maqnetic pageU-46 / Assembly........... D-isassembly pageU-49 Inspection................................-.. pageU-46 AdjusFnent...................-............. 3. Receivet/Drier .. / RemovalInstallaiion............pageU-42 4. Condenser page / RemovalInstal|ation.................. U-4'1 pageU-4'l Inspection...................................

unit 5. Cooling ... / Removallnstallation.... .... . pageU-36 .... / Assembly .. .. pageU-37 Disassembly paSe Rep|acement.............................. !.1-92 U-38 Inspection..................-..;............. PaQe swficn 6. Relrigerant Pressure . .... page Ingection.-......................... U-43 lan 7. Condenser page / RemovalInsta||ation.................. U-43 .. ...page Inspection......................... U-4i, 8. A,/Crelay pageU-39 ......... Inspection....................... 9. AJCsub relay pageU-39 Insp€ction................................. 10.AJCswitch pageU-40 ........ Inspection.......................

u-30

AIR CONDITIONEB
REFRIGERANT SYSTE1II Safety Precautlon 1. R-12liquidrefrigerant highly is volatile. dropof it on the A skincouldresult localized in frostbite. Whenhandling the refrigerant,be sureto weargloveg. 2. lf the refrigerant splashes theeyes, into washfiem withdean waterimmediately. Always weargoggles glasses prc or as tectaon.

pressurized 3. The R-12contajner a highly is vessel. Neversubject to highheat, besurethatthetemper it and alurewhereit is stored below52cCO25.6"D. is 4. A halideleak detectoris oftenusedto checkthe system for refrigerant leakage. Remember R-12, that uponcoming intocontact the{lame. produces phosgene, toxwilh a provide ic gas.Always adequate ventilation.

Refrlgersnl System Servlce Baalcs Retrlgeranl container s€wice valve '1.Turn the handle counterclockwise connectjng fully before the valveto the refrjgerant container, 2. Turn the outletvalvecounterclockwise it reachesits until position. highest

3. Turntheoutlet valve clockwise hand.Connect lully by the centerhoseto the valvefitting. 4. Turnthe handle clockwise puncture sealed to the can. 5. Turnthehandle counterclockwisefillthecenterhose. fullv to Do not openthe high-or low-pressure manual valves.

6. Loosen hosenutconnected thecenter the to fitting the ol gauge. manifold Allow airtoescape retighten nut. then the

u-31

AIR CONDITIONER
Installatlon ot manilold gauge set Not€ . Fitllngs lor altachlng the manilold gaugosel are on the hlgh- and low-Pressure Pipes' gaugeset. of 1. Closebothhandvalves the manifold fitting hose the 2. Connect low-pressure to the low-pressure titting. hose and high-pressure to the high-pressure the 3. Tighten hosenutsby handonly. Leak test (refer pageU-33),checkfor to the Afterevacuating system teaKs. valve to container the service a 1. Connect lull refrigerant valveto charge systhe manual 2. Openthe high-pressure gas. tem with refrigerant

gaugereads kPa (1 kg/cm2, 98 3. Whenthe low-pressure manual valve psi). close high'pressure the 14 for gas leakdetector checkthe system leaks lf to 4. Usea or componenl connedpn; repair faulty the leakisfound, a the then evacuate systemagain.

Discharging system. gaugesetto the refrigeration 1. Connect manifold the hoseon a shoptowelor ol thecenter the 2. Place freeend the connect hose (preferably where regulations specify) or to a freon qas receptacle. manual valve allowthe to openthe high.pressure 3. Slowly to refrigerant escape.
TO LOW.PRESSUFE FITTING GAUGE TO HIGH-PRESSU'IE FITTINO GAUGE

Cautlon . Open the vatueqnly slightly. ll lgtrigerant is gllowedto e€capetoo fast, the com' pressoroil wlll be drawn oui ot the system. 4. Checkthe shoptowelto makesureno oil is beingdis' valve. partially close manual the lf charced. oil is present, 34:l kPa(3.5 gaugereading dropsbelow manilold 5. Atlerthg manual open the low-pressure kg/cm', 50 psl), slowly gradually openboththehigh' drops, 6. Astheswem pressure read0 until manualvaives bothgauges and low-presstlre kPa (0 kg/cm', 0 psi).

e)
\_-/

6 -{,qN
144 F1

\LrY

u-32

AIB CONDITIONER
Evacuatlon Whenever refrigeration the systemhas beenexposedto the atmosphere, mustbe purgedof moistureand air. it 1. Connect manifold gaugeset.(Refer pageU-32.) the to 2. Connect centerhose ol the gaugeset to the vacuum the pumpinlet. pumpand openbothmanual 3. Start vacuum the valves.

6ryd

a{d

gaugeindicates 4. Whenthelow-pressure approximately 760 mmHg(29.9 InHg),closebotr|manual valves stopthe and vacuum oumo. 5. Verifythatthe pressure remains samelor 5 mlnules the or more.lfthe pressure changes, check syslern leaks, the for ano reparr necessary. as 6. lf no leaks found, are closebothmanual valves stop and pumo. the vacuum gumo. 7. Disconnect hosefromthe vacuum the Charglng 1. Discharge refrigeration the system. 2. Connectthe relrlgerant container thecenter to hose the of manifoldgauge set. 3. Openlhe high-pressure manual side valveto charge the gas. systemwith the specifiedamountof refrigerant First charge Rstrlgerant amounti 500 g (17.65oz)

HIOH-PRESSURE OPEN SIOE: -PFESSUAE SIDE:CIOSED

4. Close high-pressure manual the side valve themanifold ol gaugeset. 5. Start engine the and operate compressor. ihe Caution . Be sure io keep lhe codainer In the uprlght positlon to prcvent llquid .efrlgerant from belng charged Inlo the aystemthrough the suctlon slde, possibly damaglng lhe compressor, . Never open the hlgh-pressure alde manual valve whlle charglng the system with the A,fCON. Doing ao may cauao the Btrigsrant can to explode. . Whllecharglng,h b not abnormalthata chattedng sound wlll be heard. 6. Openthelow-pressure manual side valveof the manffold gauge. 7. Charge system the specified the with amount refrigerant. of Second charge Ret igerani amount : 200 g Ct.06 oz) Total relrigerantamount 700 g (24.71oz) 8. Close low-pressure manual the side valve the service and valveof the refrigerant container. L Stoptheengine. gaugeset. 10.Remove manilold the

€,,a

UU

u-33

AIR OONDITIONER
Perfolmance test test Afterlinishingrepairs,conducta perlormance of the air lollows. as system conditioning gauges€t.(Reler pageU-32 ) to manifold 1.Connectlhd speed 2'000 rpm at and engine runthe engine the 2. Start coollng at the airconditioner maximum 3. Operate and 4. Ooenall windows doors. outlet. in thermorneter the centervontilator a 5. Place drv-bulb inlet' blower closetothe thermometer a 6. Place dry-and-wet

e)@
\--l

stabilizes. temperature outlet 7. Waituntiltheaircondfioner Slablllzed condltlon Blower inl€t temperature:25-35oC (z-95cD Hloh-oressure slde: i,1i's-i,tzz*pa(ts.0-15.0 kg/cm',185-214 psi) Note . lt lhe hioh-Drsssur€slde becomes too high' Poul cool waier 6n the condena€r. ll lt is too low, cover ihe troni ol the condensef. read stabilizes, the dry andwetther 8. Aftertheairconditioner at mometer theair inlet. lromf|e chartbelowby com$e 9. Calculate rdativehumidity paringthe wet-and dry-bulbreadings

{c') (F1

z\

24

75

a)
t6

€a
61

at 10. Readthe dry thermorneter the air outl€t,and calculate dry-bulb and f|e between inletdry-bulb oudet thedifferenci! temoeratures. '1 . Veriivthatlhe inters€ction the relative and humidity temof 1 is in the shadedzone. peraiuredifierence

qt

t2
I

31
116

gE
PS

60 50 RELATIVE

u-34

and lhen sighl glassbecomes clear Amountol rel oerant lnsullicienlrslriosrant Too muchor properamounlol relrigeranl Too mlch relrigerant Proporamountol retrigeranl check remoetant oressure Tumair condilioner OFF.000 the at er to maximum cooling. Determine amount relrigeranl shownbelowby obhe of as serving sightglass. Measure low-and high-pressure the sides. 185-214 psl) u-35 .AIR CONDITIONER Checklng relrlgerani charge 1.0-15. 3.275-1.(Refer pageU-32. Checking retrigerant pressure gaugeset. Operate air conditioner maximum the at cooling a few for mtnutes.refigerant toams. Connect manifold to the rpmandsettheaircondition2. Runthe engine a fastidle.-prgssur€ gid€: 147-294 kPa (1.rctrigerant sighlglass slaysclear in Wh€nair condilioner tumed OFF.0 kg/cm'. Nomal pressure Los. the Iten 2 3 SymPtom BubblesDresent siqhialass in No bubblespresentin sight glass lmmedialoly airconditioner aner tufned OFF.472 kPa (13.5-3. Operate engine 2.) 1.and walchbubbles(Belerto lt€ms3 and 4) Checkref igeranl pressure R€lrig€Ent amount nolmal @N ZffiN w al. 3.0 kg/cm'. 2l-43 psi) Hfgh-prcsaure sidei 1. at 2.

.AIR CONDITIONER UNIT COOLING Removal/ lnstallation (Reter pageU--32 ^ .oolingunitas shownin the figure.8 ft-lb) \ \ €) unit 1. U-37 Disassembly 2. oil . olt: Compressor 50 cc (3.Cooling page / Assemb|y. .7 Nm (1:3-1'5 m-kg' 9.. ) the 1.t1-lb) In|et pi'pri:12..1-3. Remove the to the.4-10. lmmediatelyplug all open ftttings to keep moistureout ol aystem' lnstgllalionNote i'i'iilLriifte iofinS unit so that tts connections match lhose of the heater unlt and blower unil. Remove to referring InstgllallonNole order removal' in uinit the reverse the 4. add impressor ott rhroughrhe high-pre$ure pipe port ot the compresaor.. to qlovebox and instrument 2.. to syslem. Discharge relrigeration panelstay (Heter .a-gn. Db'not apply compres€or to the litting nuts.05cu in) Tighteningtorque -ou$er ilpe: ilo..7-14.. wrriii i"&iiii^g " Irew cooling unir..@Ilon n . 22.3-25'2. Sealplate u-36 ...g um (3.^..roferring Removal ote -of 3.5 n-kg. lppiv "i""n *tpi"ssor oil to the new o-rings b€lore connectlng the tittings' .. Install cooling RemovalNote .

AIR CONDITIONEB
Dbassembly / Asaembly Disassemble assemble shownin the fioure. and as

H
'l. Evaporator 2. Cooling case unit 3. Thermoswitch Replacement Expanslon valve Note . Belore replacement ot lhe expansion valve, caretully check the retrlgeralion system, referdngto ihe troubleshooting inlormatlonon pageU-16. '1.Remove cooling the unit.(Refer pageU-36.) to 2. Disassemblethe cooling unit.Remove evaporator the and exoansion valveas an assemblv. 3. Disconnect inletand ouflet;ioes. the 4. Remove capillary the tubefromthe outletpipeand remove. the expansion valve. 5. Installin reverse the orderof removal, noting thefollowing. Note . Apply clean comprcssoroil to the Grlngs betore connectinglhe tittings. Tighteninglorque Inlot plpe : 12-15 N{n (1.2-1.5 m-kg,9.-11 tt-lb) Outlelplpe:22-25 N.m(2.2-2.6 m.kg,15-19 tilb) 4. Expansion valve

u-37

AIR CONDITIONER
lnspectlon Evaporalor the or and lor Check thelollowing repair replace evaporalor as necessary. leakage. Ocracks, darnage,and refrigerant lins. @Bent and @Distorted bentinlet.

valve ExDanaion bulb sensing by refer' of installationtheheat Ch;klor proper rinoto the fioure. bulb. the reinstall heatsensing lf tie installation incorrect, is

ThermoBwltch by of 1. Checkfor properinsiallation the thermoswitch referrinoto the fiqure. bulb. heat reinslallthe sensing is lf tlie installationincorrect,

ol the between terminals the switch 2. Checklor continuity the replace thermoswich ll thereis no continuitv,

0 r 1 o c( 3 2+ t . o o D

Note is . Theoperationol the ihermos{vitch shownln thb llgure.

u-38

AIB CONDITIONER

u

A/C RELAY Removal/ lnstallation 1. Remove glovebox (Refer Section the to S.) 2. Disconnect AJCrelay the connector remove A,/C and the relay fromcooling unit. 3. Install AJCrelayin the reverse the orderof removal.

Insp€cilon '1.Disconnect theA,/C relay connector, check and continuity between terminalsof the relay.
Batlery
d b
I

H{.-d(--o
d

H€(:)_.€

---o

(H: d{o:

hdicatesconlinuitv lndicates dio.ie

2. lf notas specified, replace A,/C the relay.
B RELAY

A/C SUB RELAY Removal Installation / 1. Disconnect A,/C the sub relayconnector remove and the AJCsub relay. 2. Installthe relayin the reverse A,/C orderof the removal.

lnsoection 1. Disconnect AJCsub relayconnector, checkconthe and tinuity between terminals the relay. of
Batlery
b

Terminal

ob

-----o o-

d

----o

(H:

Indicates continuity

2.ll notas specified, replace A,/C the relaysub relay.

u-39

AIR CONDITIONER
A/C SWITCH Removal / Inatallallon FeJerto page U-28 lnsp€ction '1.Remove NC switchand checkcontinuity terbetween the of minals the switch.
Switch
OFF

Terminal
b

(H: 6f.o:

ON Indicates cortinuily Indicat€s diode

G--

--o-].€

H

----o

replacethe A,/Cswitch 2. tf not as specffied,

u-40

AIF CONDITIONER
CONDENSER Removal lnstallalion / 1. Discharge refrigeration (Refer pageU-32.) the system. to 2. Remove radiator grille. (Refer Section the to S.) 3. Remove recejver/drier. the (Reter pageU-42.) to 4. Mark position thehood the of lockstay proper tor reassembly,thenremove hoodlock stay. the 5. Remove condenser shown thetigure, the as in referring to Removal Note. 6. Installlhe condenser thereverse in order removal. of referrjngto Inslallation Note. Removd Note . Inaed a proteclor such ae cardboardbetws€nlhe condenaet and the.adlator. . lmm€dlatelyplug the open tiflings to keep moistqreout of ihe system. InstallationNote . Apply clean compressor otl to the new O,rlngs before connecting the fltiings. . Do not apply compressoroll to the titting nuts, . Remove the protector before installlng the radlator brackets. . W-h€n inslalllng a new condenser,add compressor pipe port oilthrough the high-presaure ot the compressor. Compressor 30 cc (1.83 cu in) oll: Tlghlenlnglorque Condenaer inlelr 20.6-24.5 N.m(2.1-2,5 m-kg, r5-tO ft-tb) Condenser outlet: 7.8-11.8 N.m(0.9-i.2 m-ka,5.3-9.6 fr-ib)

1.Condenser

2.Condenser bracket Inspection lor Check thefollowing repair replace condenser and or the as necessary. 1. CracK,damage, refrigerant or leakage. 2. Bentfins. 3. Distorted damaged or condenser or outlet. inlet

u-41

AIR CONDITIONER
Recelvet/Drler Removal/ Installation sysiem the 1. Discharge refrigeration (Refer pageU-32.) to tank 2. hemovetire enginecoolantreservoir

connector' switch the 3. Disconnect pressure

il-l) -v>
{,,$
.W
F

Note . lmmediateryplug the open finlngs to ke€pmol8turc out ot the 6ystem. and the 4. Remove receiver/drier bracketas an assembly

tr1

from bracket. the 5. Remove receiver/drier referorderof rcmoval, in receiver/dderthe reverse 6. Installthe rino to lGtallation Note. system. 7. Evicuate charge,and test the refrigeration lnatallation Note . Apply clsan compressor oil to new the G ngs be lore connectlng the tiltlngs. . Do not apply compre$or oil to the fltting nuts. . when inilillng a new rcceiver/drier, add compres' sor oll thlough the htgbPressure piPe port of lh€ compressor. oil: Com'Pressor l0 cc (0.61 cu in) Tlghtenlngiorque Recelver/drler Inlet: 7.8-11.8 N.m(0.8-1.2 m'kg, 5.8-8.6 ftJb) Receiver/drier ouilel: 7.8-11.8 tl{n {0.8-1.2 m-kg' 5.8-8.6 ttlb)

HJ us|

u-42

AIR CONDITIONER
REFRIGERANT PRESSURE SWITCH Ingpgctlon 1. Connect manilold the gaugeset.(Reter pageU-32.) to 2. Verity the high-pressure pressure 206-2,060 that side is kPa(2.1-21 kg/cmr, 30-299 psi). 3. After disconnecting pressure the swilchconneclor,verifv that there is continuitybetweenthe pressureswitchteimrnals. 4. Replace pressure the switchwith receiver/drier an asas sembly, not as specjfied. if Note . lf csnaln trouble3occur ln lhe reftigeratlon system, eleclrlcal power to the magnetic clutch ls Intenupted to prolecn fte comptesaot, . The operation ot the retrigerant preasureswltch is shown in the tigure.

REFFIGEFANT PFESSUAE 2.0 + 0.2 kg/cm: 27 + 2 kgtcfil

+ 0.5 kg/cn,

2t a 1*gtcm1

CONDENSER FAN Inspeclion 1. Disconnect condenser connector. the fan 2. Apply12Vto terminala ground and terminalb. Verify that the condens€r ooerates. lan 3. lf not as specified, replace condenser the lan.

Removal Inslallatlon / 1. Bemove radiator grille.(Refer Section the to S.) 2. Disconnect condenser connector. the fan 3. Remove boltsand remove condenser the the fan. 4. Installanthe reverseorder to removal.

u-4it

e-r.1 2.) to system.# &m-presso'r ott to ttie new o:rlngs betore connecting the fittings' .and testthe retrigeration 3. Reglacem€nt (Reter pageU-32. hoseH 1.9 4-10 8 mti) 29-5-2a5 l'i.0 m-kg. charge. Tightenlng torqu. Flexible pipe No. Replace faultyPiPeor hose. Ob'n-ot apply corirplessoroll to the fitting nuts.s.4-29. ihe 1.g-t. Note .1-3.5 m_kg23-25ltlb) 19.t--. .4N{n (2.0-3. Cooler hoseL Flexible 5. system.8-8. bischarge refrigeration the 2. lmmediaielv oluq the open finings to keep moiatule out ol the system' .16.(O.Z.3 Nm (3..1-18 fttb) 304-34.3 4.t. kg.AIR CONOITIONER LII{ES REFRIGERANT On-vehlcle Inapectlon if by Chif for rcaU'geat connections usinga gas leak tester'(Referto page U-32 ) Repairor replace necessary. Evacuate.i"-. @ @ @ iZ. 5.s m-kg.t112. kg. Cooler Tlghtening torque (flttings): Locrlion pipe No.z-r+Z r. Cooler pipe No.6Jt lb) zsJl3 u-44 .rtn tr.2 3.i.15-21 tHb) N.

Set the ohmmeterto x1. (0. Assemble magneticclutch in the revers€order of removal. between stalor Note . 2. It there is no continuity.008) 0.5mm ln) Ttickness mm (n) 0. Stalor 4.7 N. Tlghtenlngto. Pressure pulley 2. lO. Inslall the pressure plate according to tighienlng torque.020 Clearance: 0. Rotor 3.AIR CONDITIONER MAGNETIC CLUTCH Dlsassembty/ Assembly 1.2 {0.que: 14.016---{t.4---lt. replacethe stator. Adiustmenl llagnetlc clutch clearanc€ Adjustthe clearance plateand the rc the between pressure tor pulley selecling installing prop€r by and the shim(s). 2.000 6nge.Disassemble magnetic the clutchas shownin the figure.Verify continuity the terminals.5 (0020) 845561 115 8456 6t 1 1 5 u-45 .m(1.8 ftnb) @b ??o @ I oDo@ @ plate 1.5 m-kg. Shim Inspection Stator 1. the Aasembling note .

bolt-@and nut O. Magnetic 3.Flexible hose clutchconnector 2. Remove compressor shownin the figure referorderol removal' in 4. '1. Cover lhe iniectlon body vrlth shop lov. Vehlcle with Doweral€erhg '1)Loosen bolt'@. the 3) Remove drive belt.Compressor u-46 . the 3) Remove drivebelt.) to the 2. 2) Loosenadjustbolt (9. as the 3. Evdcuate. Vehtcle 'l) Loosen A. Discharge refrigeration (Refer pageU-32. nut bolt 2) Loo€en B. Inslall compressor the reverse the rino to Installallon Nole. the 1. the 4i Remove air cleaner(Referto SectionF. system chargeand test the r€frjgerant 5. without Power steerlng.l to prevent any damage. Remove drive beltas follows.AIR CONDITIONER coltPREssoR RemovalInstallation / system.) movethe P/Spump the SiRemove bolt@ andcarefully head cylinder on the engine Note .

39in) 3) Tightennd A.31-0.m(3.m(3.3 m-kg. Vehlcle wlthout power sleering 1) Loosen A.m(1. 27-39 tiJb) Bolt @: 37-53 N.22 lb) 8-gmm (0.2-5.35in) 9-r0mm {0.s m-kg. Tlghteningtorque Nut @: 32-51 tlm (3.3t-{. bolt Tightening torque Bolt @: 37-53 N. .9-2. 27-39 ft-tb) Nut @: 19-25 N. bolt@ and nut @. 22 lb) 8-smm (0. bolt@ and nut O. . Apply clean compt€esor oll to lhe new Orlngs betor€ connectlng the tlttings. 14-18 tub) u-47 . 2) Tun the adjusting bolt O and adjustthe deflection lhe of drive belt to withinsoecification.5 m-kg. Adlust the dollsctlon of the drlve belt as lollows.35in) Flomm (0. Replace lhe O-rlngs.AIR CONDITIONER Installatlon llote .7-5.7-5.6 m-kg. 22 tb) Vehicle wlth power steering 'l) Loosen bolt@.35-0. 24-38 ft-lb) 98 N (10 kg. nut 2) Turnadjusting B and adjustthe detlection the drive bolt of beftto withinspecificaiton.39 in) 3) Tighten @.31-0. Bdt Used D€fleclion: Whenapplyingmoderatoprss$fe 98 N (10kq. Belt Deflection: Whenapplyingmoderatepr€ssure 98 N {10 ko.

ComDressor 2. Shaftseal valvebody 4. Discharge 5. Shattseal Dlate 3. Thermalprotector valveplale 6 Discharge / uEcnarge vaNe u-48 .u Dlsa$embly / Asssmbly Preparation AIR CONDITIONER ssT 49 8061 005 49 8061 006 Structutalview body 1.

u) 2.AIR CONDITIONER l. Removal themal protoctor ot 1)Bemove bolts remove discharge body. Removal of shaft seal Remove shaftsealusingthe SST. the u-49 . the 2) Remove shaft the seatptate usingthe SST. lhe @* 3. the and the valve 2) Rernove snap ring and the thermalprotector. R€movalof shalt seat plate 1)Remove snapring.

Rsplacethe o-dng. Installatlon ot lh€mal prolec'lor Caution . PBOTECTOF THERMAL 1) lnstallthe thermalProtector.94Nm (30 cm-kg. lnstalldion ol dlscharge valve valvepiate valveanddischarge the Install discharge Tlghtenlngtorque: 2. 2) Installthe snap ring. the u-50 . discharge DISCHARGE OISCHABGE 5. 26 inJb) 6. 7. lnstrllatlon ol shaft seal Install shaftsealusingthe SST. To]que bons A and then bolts B in an X-Patern. Replace the gaaket.s Nm (100cm-kg' 87 In-lb) Cautlon .AIR CONDITIONEB VALVE DISCIIARGE VALVE DISCHAFGE 4. the 3) lnstall discharge Tlgt enlng torque:9. valvebody. Cautlon . Snuglytgmen bo|t A andB. Removal ol dlacharge valve valveplateand the Rdmove boltsthen remove discharge the valve.

nut Tighteningtorque: 32-51 N.5 m-kg.2-5.m(3.39in) 3. Beh Used MAGNETIC Defl€ctjon: Whenapplyingmoderatepross.ire 98 N 00 kg.35-0.6 m-kg.m(3.35-0.7-5. 2) Install snapring. Loosen A.m(3.3 m-kg. 27-39 ft-lb) Nut B : 37-53 N. 27-39 ftJb) Nut C: 19-25 N.Tighten A.lurn adjusting B andadjust deflection bolt the otthedrive beltto withinsDecification.ire 98 N (10kg. Turnadjusting D andadjust deflection the bolt ofthedrive beltto withinspecification. B€lt Deflection:Wh€n applying modefate press. boit 2.35 in) F1omm (0.39 in) 3. Inalallailon ot shaft seal plate 'l) Install shafisealplate the usingthe SST.5 m-lg. nut 2.AIR CONDITIONER 8.m(1. Tighten A boltB andnutC. 14-18 ftJb) Vehlcle wlihout power sleerlng 1.35in) 9-l0mm (0.31-0. boltB andnut C. bolt Tighteninglorque: Bolt A: 37-53 N.9-2. 22 lb) 8-gmm (0. 24-38 ftlb) DEFLECTION u-51 . the Adjustment Orivs belt Vehlcle wlih power steerlng '1.Loosen A.7-5. 22 lb) 8-9mm {0-31-0.

....TD TECHNICAL DATA cooLtNG sYsTE............6 ENG1NE................. TD-l3 STEER|NG SYSTEMS.....................................l7 ............ 5 TD- FUELAND EMISSION CONTROL SYSTEMS (EGt-s)................................................................. TD..............................? ENGINE ELECTRICAL SYSTEM ...... TD-i4 WHEELS ANDT|RES................ TD......+.............. TD-i7 HEATER AND AIR coNDtTtoNER SYSTEMS................. TtLls susPENStoN ... TD-...8 CLUTCH..................... TD................................ TD-i3 BRAKTNG SYSTEMS.....I MANUAL TRANSAXLE..........9 auToMATtc TRANSAXLE .. I TDFRONT AND REAR AXLES.............. TD............................................................ TIL16 BODYELECTRTCAL SYSTEMS....................TO. TD......................................................2 LUBRTCATTON SYSTEM................................ TD-l7 STANDARD BOLTAND NUT TIGHTENTNG TORQUE..............

69:]) TD_2 .6 015 (0006)max 0.985 (0.030-0.4'io33i:6.uo5) 16.3 (0.r e . beltiriven16 valves .4.Pm M€ximum Inline4{yinder OHc.m (0.0O10-O.2941ffi 952 (9.304) 109.693).U:Jr .34 5..0 (1.012) 0.2366-0.m11-0.80x 3.i6 U.4 1412114.970-5. p€i)-.20 (0.ti* Ginding valva rnd wlvc gulde Valvehead diameter (malgin) Valvehead thickness mm {n) mm (in) IN E X -lN.U14.74 14.2348-0.7) 9.060 (0.urr-u. .oO24) 0.linl mm (n) @ ffi -d-- IN Valvel€ngfi mm (in) EX IN IN EX Slandard Standarcl Stancla. S€etsinking mm (in) EX Standard aiTs:a:05nttG:l@ 43.wo.S8O (0.2€) 1323(80.d 10a.4 lO. mm (in) IN EX 0F1.x 83.vo lr.012) 1074-107.0026) 0.138)-300 196(2.008) I 1Oa.20 (o ooa) max oisr. ENGINE |lon DATA TECHNICAL Englne Btl a! lumber Cylind$ afiangement chamber Combuslion Bore -Totd x Stoke oisloi displacement ralio Compression Standard Minim!m prqssure Comprassion betw€€n ditferenoe kPa(ks/c#.r . u J .2374) oo25-0.0.285) mm {in) EX Guideinner d'amel6r Valveslemlogurd€ clearance Guideprojection valvc alat s€at angle s€at contactwidlh IN S'tandard mm !!l IN mm (in) EX mm (n) l+__ IN EX r@ -u.3 (0.2356) 596F5.28) 40" 5o rI!!! !!L cc (cu DL IN Valvetiming EX (Warmenqin€) mm(in) Valveclearance Open BTDC ABDC Closa OoenBBDC CloseATDC IN EX 0.u*4r.241) (4.4-1/.- m.o --a-07.2350-0.065 (0.2354) 6.TD B.261) 107.05s) 4r.0r-6.7.6(2.2414.d*l.4 (U.

006) 19.10(0.O1 Q. 5 No2.327 .010) oversr2e Cylinderbore diameler 0.7(1 3.065-0. 0.513 52-2-8155) 71.lindarclearance mm{in) TD-3 .8056\ (2.15(0.15(0.0007) 9 7O.4380) 36.lbymmfin) Standard mm (n) l.709-1 .413 7 t .25(0.1s (0.75 (o.7 29. 4 No.88-33.1.133 43 440-43 465 11 lO-1 .4134-2.0o16-0.006) max.4235\ 71.1.2-150.7955-2.711 .0m)oversiz€ mm [n) 0.2.0025-O.0 0.425-43.4233-2.039-0.81)/36.37.263 e.0 .527 36.1 I 5 (0. 0.967(2.410-'Kt.008) mar.41 1.29.711.rze E 0.linimum N (l(g lb)imm (in) mr (n) IN EX out.0029) 0.01 (0.961-71. (0.006) 0.7493) 18.4349-2.006-72.3 No.0033) 0.3 mm lin) Standard 0.4225\ 36.959-1 8.5 EX Joumaldiamsl€r mm (n) Camshaft bearing oilclearance mm fn) Camsialt runout Camshalt end play mm (in) No.020)oversize (0. 133.lng IN Free length TD Bi' 4O.*1-7 0.OO45) 0.8333) 0.967 2.763 Q.030)oveFize groove mm (in) 1.5O(0.7(1.450 (1.980(0.01 {2.88-33.004) .709-1.756*71.417) 4O.81 71.21 Q.7 -2.055) (1.13(0.aO2A\ 71.085 0.006-71.074 (0.006) Fockeaaammd rocker |lm rhdl Rocksram inner diameter Rockerarm shafrdiameter Rockeram to shaft clearance Cyllnd.mo ovetsiza 1.lve sp.467 e.650in) belowoil ng 0.0031 00 ) 0.37.720) ma:.4352\ 3 0.7l|a0-0.5813.7 43.7472) 0. 4 No.04-0.0051) 0.05 (O.50(0.4304) (t.010)oversize Mea$red at 9Ooto pin boreaxisand 16. 0 m (0.7 939) 937 7 7 t.25 (0.040-0. 71.710\ 43.461-71 .75 (0.00(0 04) oversze Cylinde.7 17Q.04)oversize Slandard Pislon-to€!.8036-2.000.7958) 3 71.333 0.19_033(0.0O2O) max.0020-0.0012) max.A25O-2.8331-2.2-150.602) Englne S'tandard mm iin) Minimum N {ko.050-0.1 (0.4253) 72.602) (1 7) 133.ol-square Ct|nahatt Lobeheight mm (in) (13.81y36.7 r-71 .20(0.0s2 10.15(0.506-71.AO53-2.0016-0.0O (0.020-0.2| -7 1.5 221 (4.58-13.256-7 t .0008-0.bore iaper and out ol-round mm (in) P|3ton Standard !.7464-0.710) Standard Standard No.435 (1.5mm 0.001s-0-0020) o.43o1l 11 36.42(0.r block He'qht mm lin) mm (in) mm lin) Stanclard mm (in) Distonion Gnndrns mm fin] mm (inl Standardsize 0.TECHNICAL DATA Itcm V.

o5 our-ot-rounO CEfu'n taperanO lldn bea.706 o.5!ll) 3e..50(0.9470-1.e5o (r.TD Thokn€s mm (in) DATA TECHNICAL Englnc 83 1 1 7 .8618) q1 r0-0.L5791) 39. 1 9( 0 .5528-1.030) Slandard (1.5534) 39.dtlnd rod b€lrlnc (0. 0 4 6 9 ) in Endgap (Measured cylinder) mm (n) Second Too S€cond Oil (rail) 147-1.nS .8598-0.75 (0./50 94 0075 (0.9474 43.5515) (r.35?!rq!!) 13s3s-136.940-s9.006) o.. (o.152 max 0.004) -o.q4?9!!4!) 3ers0-3s206 (1.25(0.o4 {0.70(0.956 0.208 0.006-0. beaingoilcleafance mm {in) Crankpin oearins FEEEi6 r.:.0s991q9999) Pistondngloting grooveclearance _.9450) a9.070 1s20-1540(0.0 Bing groovewidlh in Pislon Top mm (in) Second oil 1220-1 240 (0.25(0.030) Standard Mii-iourna raperanooutot.0030) mm(in) Standard 0.004) 0.158 (o.78s?qiqlg) 19.890(0.oo1 1-o. 0 4 6 1 .0043-0.Y@ | .070(0.068 0.9570) 49.hg mm(in)Standard mm('n) Standard oil bearing clearance Mainjoumal oeanng eva-illue undersrzed mmun) 0.018-o036(o.30(0.zs o.0 .zs (-oro).rnaeaizeo mm(n) (o. .908 0..20-0.262 (0.0.iouna Slandard mm(n) Standard 49.oo24 -o2s-o.9373) (1. (oogo) o.658 391440194s6 (1.012) ol5--0. Main mm (rn) 0.05 (0.001 2-0 0!28) (0.1 .0103) 0.30 (0.7866) 0013-0 03/ (u.008-0.o2o) max o.0118) max.10(0..708 (1.956q-1.936-49.020) Standard 0. Second mm trn.uuus-o w rol mm(in) 'nm (in) N (kq' lb) a71 aeo5-1 5 (sco-Lqq!!9-9!99(s.hd dnn.00'16) 49.000-43.0s87) 2) 0r 5-0.m6-0.5712) 0.30 0.6929-1.50(0.. 0.10(0.980(0.9372-1.5724.01 (0.I woo' Gdt' tc."t to *n60 mm(in) mm(rn) mm (rn) mrn(n) mm(rn) Standard Bendinq smal end bore Bio end bor€ wion Bio-end rod Connecting side clearance mm (n) Ornt st att rrnout Standard (1 max.q991 1.uou/-u (rur4.030) 025 (03r0).010) Slandard diametermm (an) Crankpin (1..49 (0.05t0.010) Standard joumal diameter .4020 .75(0.408 0.1s i-s974-r9.693t a 338-21.ozo).01{1.s6m-l 5q9a 395e0-49.75{0.020).001 o33O-0.204--49.e61 6 43.9548) 49.943-19. o. Diamelef -tnter{erence rn conn€clrngrod pre""rd hst"ll.904 0-9644 (1.so(0.0579-0.704-49.020) 39.028) (0.7864-0.0028) 0 030-0.so TD-4 .020) Siandad 0.6s2 43354-49 4s8 (1.^d .=.11seq l !92) 3320-3'040 2-0.93s1) 49.5613) 39.0199iq!1!q (0.

lmpqt) Oil lilter Grade APIService Above 30oC {86oF) 06c-40oc (32oF 104oF) _10oc_20oc (14oF 68oD A b o v €.5.2.25 (0..SEor SF SAE4O SAE30 Tvpe Bele1pressure dlterental kPa (ko/cr' . LUBRICATION SYSTEM ----------.43-0.. paper element 78-118(0..0012-000€) 0.625-2.0.02 0.50-64) 294-392 {3..--_----.43-5r.0 (3.2..005s) Fllfl ow.1 0 6 C ( 1 4 o D _25oc_3ooc(13oF_86oD Above -25oC (-13oD sAE20W.16(00008-0. 0..0) 3.0.09.---"tt Lubricating melhod tnn'n" B3 Oll pump Tvpe kPa(ks/cm'.03 0..1 053) (0.TECHNICAL DATA ftem Thrust bearing Crankshalt play end mm(in) Slandardsize Bearins widlh Tlmlng b€lt Be\ de4ecron mm (in) 0.030) oversize mm{rn)/98 {10 kq 22 tb) N D..18.000 0.6) (0.8-1.18(0.3. 11-14 3.0-4.4 (3.47 5-2..20 SAE20W-40 20W.152\ 1 (0..0-r3.282 0.5-4.50 or sAE10W-30 SAE10W40 10W-50 or aebw 0'C (32oR -2ooc (-4'R B€low sAE5W-30 sAE5W-20 TD-5 .3...0063) 0.1 2.080-0...0071) 0-22(0.0 Englne Standard 0....30(0 012) (0.50 (0-020)oversize o-75(0.0078) 0.20(0.2.r 2.0035-0..010)oveGze TD B3 (0_0031 0.750-2.0087) 0.675 033-0..800 2.1083-0I 102) 2.17 015) SD..6. 1 1 32 O. ps) Englneoll Total(dryensine) Capacrty Oil Dan (US llters ql.925 @.11{0..500-2.51) 11.0984-0.0111 0.-.14{0.550 004) (0.psi) pressure Regulated kPa Standard Innerrotortooih tip lo ouler rotor cl€arance mm(in) Standard Outerrotorto body ctea€nce mm (in) Sideclearance Oil llltol mm(in) Standard gear Trcchoid 343-441 (3.

a) 6"X q/o Volum€percentage Coolart 65 4{.TD E. l1-15) Tvpe 6iEGi6 ooenino oressute d-tino-i'rcuit chect<ino oressure kPa(lg/cm' psi) kPa (kg/cm' psi) 19) 103 0.5fl87-193) (?14 1OO 8.7F1.05. 1.066 55 1. Electic Numberof blades outeraiatneter Capacity Cunent mm(in) soo(11. COOLINGSYSTEIII Coolinsmethod DATA TECHNICAL B3 mi- forcedcirculation Water.031 1.9) 80-12 6. 10 12. V'beltdriven Cenlrilugal.76) 6 1 .5-89.ro doachv (US Iners ql lmPqt) Coolanlproteclion -16'C (3oD Above -26oC (-1soD Above -4ooc {-4ooR Above 5.05 seal Unifed mechanical | AlI i oeler ciameter mm (in) uaoes Nifroer ot irnpette' Soeedratio Thaamo6tel t€mperaturc ooenino tempetalure Full-opeD Ful-op€nlift 'C fD 'C fD 86.coobd.335)or !9!9 fn Corrugated 74-103 (0.6r1 *.078 TD-6 .0 a. 45 | s3) Iq (63' Specficgravityat 2ooc(68"D 1.5 (0.05.

o'€ss.rre srde Pr€aaurc regulator pressure Begulaung In. @ B€€islancs Air tryp$a aolenold velye @ Resistance Solenoid valve (Purge conlroD Besi$ance Waler thermo3€naor Resistanc€ 22-28 29-35 29-35 29-41 '14.nol. FUELAND E |SS|ONCONTROL SYSTEI'(EG|-S) -------______ Irom ldle speed lqniliontminq' TD I | 16 frarca{e BTDC lPs (kq/cnP p6i) TX 75O11(N€utral) ATX 1.6.92) (buin fuelpump) Nylon €lernenl in side I Low-pr€ssu€ THGh.21-2.ctor Iype of drjve pst lPa (kg/cmz.TECHNICAL DATA F.35 Bypass type oi hol-wire 3-5 40 (10. 34-40) Cuflent Resisisnce Alr bypass sol. 0 D 0 o O -200c (-400 2OoC(68oD kO 40oc 004oF) 235-27 s 12. tmpqt) 'TEN teminal oi diagnosisconn€ctor grounded TD-7 . 8.29-0.69 0.nk qapacrty Ah cl€aner Element type Fuel Sp€ciicatjon liiers(USqt.D kO Tvpe B€sista&e(HWN-HWP) Fuel l.6-17.4.4-2.8 2.8) Oil p€rmoated (RON90 or hqher) Unleaded 80.5.c (176.100lX (P ranse) Fuelpump Maxmtim oqpd pressure Fu€l ltel Eelow ffa (6.l valv6 O B€sislance Aii bypass solenold valv.

.45) ESA 16 connectorgrouno€o) fiEN t€minal ol diagnosis lgnilion ccil coil windino (2ooc168"R) Secondary Unleaded lu6l Pluooao NGK NIPPONDENSO mm (in) 0.24) s.043) 1-3-4-2 sparkpl'rg Fidnoordel H. 17 (0.039-0. Hn" Bauery Dalk current' m Max.5-7.0 (0. ENGINE DATA TECHNICAL Brt Typ€ and cspaciry t2Ghour€!9) 50D201(5OAtl) a6B2aL(a5AH).15) 18o C4 rhcknass Tvpe Clutchpedal fFiv"GGde mm(ill.6-14.21-0-28) 6...ush lenglh mm (n) Sparkadvancetype Sisndafd v kW 25 (0.5 (0.72--4.30) Drrect l2{.5(0. A.1 (0.23-O. 3aB19LS(33A$.0-7.95.(MTX).65) 11.C.94:](300.11 K16PR-U11 K2OPF. mm(in) - M Heighl(Wifncarpet) TD-8 . CLUTCH Pte Clulch conttol Clutchcover Ctulchdisc B:I A5M"R M€c*|anical s€tload Outer diameter lnner diameter N Eg.12E 3. 12-55 -Transi$otizod(buin-inlcreoulator) Tvpe Output Feguletortyp€ Reoulat€d voliage Standafd Brushlenglh mm (in) Di!€ belt dell€clion L's6d V Stader Distrihlot 6utout B.2 (0.118) Susp€nded 5.11 BKR6E.TD SYSTEU ELECTRICAL G.(ATX) t2435.92) 3.840 9.98) 6 (0.4 kO BKRsE.68-0.660) 125(4.U11 io-i.llL rnllllll mD !!l I Pre€$ire olate mm {ln) 2.0 (0.433) -m7 Q.83 138 (5.

125-140 1.8 2.392 1.8 (0.12s{o.46 1. 2.2 2.G30 0.055) 1.45.6 {0.003tt-0.64.6 1. S.600 0.05 0.071).63-80 716-a63 0. (0.632114.2 2.00591) 5 15 0.1.039-0. M2C3SF sAET5W€O 2. 104-125) 863-1.oss). ho ol) Enoineslall soeed rDm D.00453} Oil p0mp mm(n) Standsrd diameter mm (n) plates Numberof diveJdriven plals thickness Standard Ddve mm(in) 3-4 clulch clearance mm1in) Snap ring slze Number of ddvdddven plates 0.087).3 (6.7.0.21 Gearralio 5rh Final ged ratio Grade oil Capacrty liters(US qt.6(0.001(8.7.07s).0S4). pd) Throde pr€qsurs kPa ftg/crn'. (0.3-8.071). lmp ql) K.1 (0_00157--{).4-5.6 0.0019n 0.SsndLranges B ranqe D ranoe D rsnoe Oute.35.5 (2.102.5) 2. (0. L and R ranoes N-D ranoe Time lag s€cN-R ranoe D.2.0 2.06i}) 1.r10) 3.454 1.4 duEh mm(in) Ddvedale thickness Standard mm (in) Forwardclutchclearance mm fin) Snapringsize mm(in) TD-9 .8-10.4O9-t .5-0./3 1.0669) 0.08n.and inner rotor clearance mmtn) Standad Standard 0.2.o(x92) 1.058 D€xronotr.2.75-1.583 4.063) 1. (0.7 4:]2-559 (4.U.4(0. (0.09-0.050 1.4(0.4(o. 1 2. 11-1S) 4 t7-535 /L4. 1.TECHNICAL DATA (BsM-R) J.3-1.04(0.170 rc.079).944 '1. AUTOi'ATICTRANSAXLE Englne/Tlansaxb Item To6ue convederstallloroue ratio Gear ralio 2^d 3rd OD 83 EO|-S F4A-EL 2. psD D. 2.736 Dexronollof M-III 6.051-0.0m79-0.300-2.6 r0.04---0.8't0 3.36-16.1 {0.063) 1.4 rO.6-0.6(0.Mn 1.5. @-7n Finalgear ratio Autornalic vansaxlefdd (ATD Capacily liters(US ql.333 3.02-0.0 (o.||3axle It6m Synchrom€sh system tst 2nd 3rd 4th TD B3 85l|-R Floorshift FoMard:Synchromesh Reverser S€leclive sliding 3. MANUALTRANSAXLE Englne/fr. 204-234 74-132 (0.2{0.76 2.2.800.8(0.25-5.094) 3.SandLranges kPa(kg/cm'.540 1_0m o.0015n (0.063).4 (0.8.

2.075(2.0-1.425(1.039-0.039-0!!l) 22 .26-7.7s 4.1 (0. 2.aza) O-0.030 53.8) 0.40 (00s5) 145(0054 1.063) 1.171) 4.0.164.021p.35i0.oo(0 039) 1 05 (0041) 0. (0.2 io.1sa).055).4(0.70 4.055) Drive platethickness Standard mm (in) blal€clearancemm (n) andrev€r€€ Low mm (in) Snap ring size Cader hub Sungeardrum Smallslrn goar fotatenOptay Enclplay adiust €ce tdEa' b""'l"s F'd*d mnier mm (in) olanet inner Bushing diameter mm (in) inner Bushing diamet€r mm {n) mm (in) mm (n) rrllb) Nm {cm-kg.0 o.165).6 12 {o3aa.so(0.o63I L75 {0n69).173).1O2).028) 30.110).0?0) o25-0.40(0. (0.5 (0. 1.9o (0.0s1).ffin.15O).4 (o083-0. mm (in) Nm (cm-kgint) mm (n) .4(0.6(0.o71).157). 0 0.075) 05 (0081) 2 2.2-0.17s)' a.181).65 4.10 4. mm (in) Sandard -0.o3si.TD DATA TECHNICAL Endlne/Tran€exle Numb€r ol dnve/ddv€n Plates 83 EGI-S F4A-EL coaslng clutch D ve dat€ lhickness Standard mm (in) clutch clearance mm (in) Coastno mm (in) Snap ring gze Numberol drive/drjven Plales Drive platethicKness Siandard mm (in) mm (in) Feve6e clulch clearance mm (in) Snap ng size Nrjmbs ot drive/dr ven Plales 2t2 1. (0.50(0.45 4.25 r.0(0.3-9.4\o. 3.05ti.0.25 4.i70. lO 1 2. (0. 1. (0. (0 187) d. (0.o2o).35 4. 4.o7s).95 o 90 io.6(0.m (0. {0.rn inlb) kg.001 0. 0 50 (o. 0..091) 2. (0.80 4.0 2-8 2. (0. 33s-drsa.6iO.163) (0.o$). io.35io.0.@4t.0!4) 0 025-0.1.ozz). (0.9-3.3(0.118) 1.bu (u uz4l u o.8o(0.7oio.169).088) 53.079).u.159). tv.7s(0o30).81) 3. i0.50 (0. 3. (o.15(0.55 (0.044 2 i6T.r-2.o43j.26-7. 85 (0033) o. (0.r.8 10).198) 21.090) Standard TD-l0 .90(o.185).7 (0.60(0.3O 4. 2.6(0.047).vzo.087) 2.160.o3-o9 (0.6 o.05 4.4{0.063).063) 1.2 2. {0.183). (0049)' '.s5 (0.18) 0.2.2.20(0.0.1 3.15 4. (0.053). (0.6io. 4.2 {0. 1.8io.156).0c?) 1. (0.20 | 10 io.2.2lO.4(0. 1.63-09 (0.055) 1O-r.171. (0. 3.55 4. 26-J5) Preloadadiustshims preload dutlnt sear uearing Pretoadaciiustshims geann-g preloao Preloadadjug shims ol Bacldash side gear and pinion mm (jn) Bushinginner diameter mm {in) N{r (c.30i0.008-0.9 (30-40.o8n.4 -0'ga\' zc(ao7 9't.098) 65 (0 1041 2t2 1.3-9.01 1.020) (2.045).050 1.037).OAn. 'r.o2gi.1o2).

311 TD No.0 20.075) 5.039) 0.3) 7. 9 8 1 .197) 30.2 11.4/{0.6(0.1(0.291J 7.7 fi.031) 23.611.2 15.3 minosorino 3 2 timinqspirno 3-4shinspino Bypasssprrng 2-3shiilsping Converterreliefsprng Lockup control spnng Spring 1-2accumulator small sorino 1-2accumulator largesprinq 2 3 accumulator small sprino larqesonnq 2.315) 2 9 . 4 4 1 ) 4.4(2.197) 1.4(2.8 (0.4 {0.2lO.339) 68.031) 0.8 Q.551) 88.805i 5.2(0.0 12_O mm alnl 0.219) 27.394) 71.5(1.0 (0.610) r6.591) 94.7(3.2(3.0 12.6 i0 024) 1.5 21.0t0.5{1.3(0.45.0(0.4 0.819) 26.441\ 9r.O4n 0.88 lt.287) z)45 {0.0s5) 2.3(O563) 10.U7) 1.319) 5.9 (0.441) 34.0 24. 3{ O .594) 7.512) 53.2(3.087) 11.5 12.6 0.630) 91.1(0.O 4.9{0.3 '1.929) 40.610) (3.0€7) 7.075) 1 4 (0.2 12.2 16.75(0.5 1.213) 5.8 24.55 (0.03r) 1.0{0_315} 27 U 11.203) 1r 5 (0.210.185) 5.5 21.55(0.0(0. ol coil 10.6{0.425) r01. 0 5 1 l 24.441) 8.693i (1.1510.0(0.4 11.047) 1 .O 27.3r9) 88.3581 Oil pump 3 4 clurch Coastinq c urch 8.0 u2 11 346J 36.310.9(0.465) 14.063) 1.3 accumu/alor N-DAccumulator smallspring N-DAccumulator largespnnq N-BAccumulalor spnng tro N-BAccumulatorrear sorinq Outer dlameter mn fin) 8.291) 3 6 .051) 1.022) 0.022) 1.r93) 27.291) 36.611.0(0.824 15. 6( 1 .1 13.0(0.031) 0 8 (0031) 0.0(0.0 10.0 12.0 (0.8 t2.096\ 8.0 10.2lO.8(0.030) Return spring Return spring 43.031) 0.Azn 10.0 i0. 6{ 1 .5 Free lenglh rnm {ln) 4 1 .O o.0(0039) 0.TECHNICAL DATA Spring Specificalion Sp ng name Throtlle modulator sorino Thronle sorino Throltleassisl so no Pressure reoulalor no sor 1.0(2.8(0.709) 8.703) 3.213.058) 29.0 '16.472) 74.031) 0.9 t0.8 (0.8(0.0i0.4(0.4 (0.s5(0.984) 15.591) 71. 1 8 0 ) { 7.88(0035) 0.2 (0.5 31.0(3.2shillsorino Low reducino sDrino 2.091) 14.079) 1.25(1.7 10.8(0.r26) TD-l1 . 6 3 8 1 46.

5V) s OD-Ds D3-Dl (81-87) 131-141 80-88 (50-55) 4349l.650-3.150-5.350-3.750 2.2VJ Fullyclo6ed(0.500 2.z)0 2.550 2.9m-3.550 2.600 3.650 3.4@-2.600 5.500 s.750-3.150*5.750 80-88 (50-55) *-45124-2Aj fu y open(4.350 2.6-2.750 2.150-2.750-3.<7 117-231 49-65 (30-40) 143-149(89-92) 8-14 (5-9) th * t)2 2.7s0 2.400 2.850-3.5V) D2 .150-2.0V) shfft D2-D3 DruIn 3p€cd aDrn 5.850-3.2V) Fullycloced(0.150-5.750 3.100-5.D 2 D Haf hrctue (1.€d lan/h (mph) 51-57 (32--35) 9?-too (5/-oz) 1€-1 53 (89-95) D3-OD D 1.850--3.750 2.Cr3 D3-OD Lockuo ON (OD) OD-D3 D3-Dr OD-D3 D3-0e D2-D1 D 1.750-3. DATA TECHNICAL Thrcttl€ cohdnbn Bange (Thronb 3tmo.300-2.D 2 D2*D3 D 1.27-3o' 51-57 (32-35) 92-1oO(57-64 2A.0V) Hall thro0e 11.800-3.400 Vchlcle !p.150-5.150-2.900-3.750 300-500 31-37 (19-23) 8-14 (F9) ORlilAL Fullyopen (4.600-3.200 2.6-2.D 2 D 1+ D 2 D2-D1 51-57 (32-35) 28-37 (17-23\ 3H5124-2e) 27-g 117-20') 4O-5O (25-31) 143-149 (89-92) 92-98 (57-60 43-49 (27-30) o HOLD Dr-D2 D2-D3 s OD-D3 D3-D2 D2-D1 TD-l2 .750 5.2Vi D2-D1 D 1.550 2.0v) L H€lf lhrotle (1-6-2.750 5.200-3. Yollasa) Fully op€n (4.600-3.550 5.100-5.D 2 D2-D3 2A-37 117-23) 49-65 (30-40) 77-103 (48-64) 104-135 (64-E4) 8m-950 300-500 3.600 2.750 2.TD Veh'rle Spesd at ShlftPolnt Table llod.

300(31. N. FRONT AND REARAXLES TD ATX |to|nrul6 Froot atla B€a ng play a\ial dir€clion B€aflnoDreload" MTX mm (n) Nm (cm.79) 115 + r0 (4.83) + 115+ 10 (4.7-45.4+ s P4.63.9-1.oo2) 908. lmDot) Measuredby torquewreflch Nm rcm-ko.20) 631 i 5 (2496 + 020) 21 (0.20) 20 {0. STEEHING SYSTEM lia||r Stccdng whael oljl€r diam€ler Typc mm fin) llrnud aleering 370 (14. m lt|e boot lo equalize lhe pr€€€llre wilhin it. 7.4)or less 29 (3.18) 118(12.3(9-13.35 r3s) TD-13 .12+ 0.9) 1.5(0.9) 800-1. lb) 0-30 {0-1.0. 2.57) Powar alrerlng Fr€6play Op€ralion lorco nm fin) N (kq. 6.35) 80 + 10 {2.30o(28.6) or lass 3.TECHNICAL DATA M.14Q.82 + 0.5-12.inlbl Moasu€d by F'jll scale with atiachmenl o lozl Limitol rack housingmovement Dislsnce betweenlelt ancl ioht brackets Racksroke mm (in) mm lin) mm (in) 136:! {s.35) 906 * 5 (35.8 3.inlb) Raarlxls play axiaidirection Beanng Orlvc rheft Shalt lengfi" mm (in) Hiohtside 0 (0) 0.8-1.35) 60 + 10 (2.5:} 0.35) Shalldiameter Grc3se amounl S (oz) " B€to€ measl.06 0.iring the drive shalt lenglh.76 + 0.9-11.25-1.3(8-13.06) 330_0 2.4 * 5 €5.ko.3 Rackand pinion Inftnite {6) 0 (0) EnoirEsDeed sensino ATF Dexronollor M-m 0.2-45.06+ 0.6 {0.99) Sr.€rlng g!!1 Tvpe Sle€rinq oear ratio Backlash betweenrack and oinion FluidcaDacilv Pinion preload mm /in) liters{USot.05(o.7-11.20) 634.3) 900-1.98 + 0.17-1O!2J mm lin) Lsft side mm (in) 0.6.67 + 0.3) 0.26.

(60 ksicml.63) MTX:10 (039) 0.39) 2 (0.23) 4-7 (0.04) 181..71) MTX:12 (044 ATx: 16(0. 60 (2.7inHg) MTX a. 427 psD i td outpd pressur€ (kg/cm'.004) & Ttarling 4 (0. Psi) WheninDutoressureat kPa sgs6 kP. onlrol .80-8.37) Bore Fluidtype mm(rn) 20.1q ol Thickne€s lining diameter Druminside mm (in) mm (n) Standard Slandard r (0. BRAKING DATA TECHNICAL rtem E u*e_999l----mm (in) H. min.I P.1(0. 726004.427 + 2Al AIX: 3532 + 294(36 + 3. 44 lb) _ at Vacuum 50OmmHg ATX kPa(ks/cr#.64(0. 1053) (58.5 O.rht (witl carp€t) mm (rnl Freeplay mm (in) travet Rsserve at when pedal depress€d 589 N (60 kg' 132 lb) c. (30 l(g/cm'.earance I Spaclllcatlon3 r98-209 (7. 555 + 43) Wheninout oressureal 2943 kP.81) DOTS 0r sAEJ1703 FMVSSIi6 Solid ol Thickness pad ol Thicknoss disc plate -Runou ol disc plate mm (n) mm (in) Standard S'tandard Minimum qllin) 1o (0.TD SYSTEI.16-0?9 mn. pei) (19. 5690 valve DualoroDortionang 2943+ 196(30 + 2.15) l$crearwhe€l control Mechanic€i 180 0.22 lb) 6-8 Vacuum o mmHg(o inHg) d p€dalforc€at 196 N (20kg. 512 + 43) tvrx: 3826 + 294(39 + 3.185)min.vstam 1275 {13.18 (0.q9) Parkinobral€ levet noEhes Whe.825) min.08) ATX.r whol hv.lrrrll. 853 psi) TD-14 .bver |s oulledat 98 N (10 hg.

psi) S!aclfi6tlona ' 1 4x 51l2JJ TD mm linl mm lin) 45 lt.059) 14 inch: 10 (0.94) 17560R1478H 180(1.94) Sleel T10580D14 412 14.079) 2.60) kPa (kgfcm'.2.8.77) 100(3. psi) Wheeland tire Item Hunout limit Unbslance lmit (at rim edge) mm (n) Horizonrsl g (o4 Spcclffc. WHEELS AND TIRES Standard tlre Item Size Offset Pitchcirclediameter Material Size Iirc kPa (kgflcm'.Uons Aluminum whe€l: (0.5(0.35) TD-l5 .26) Temporary spare tirc Itom Size Oftset Pitchcircl€ diameter Matsrial Sze Spoclllcetion3 14x47 mm fin) mm (in) 45 (1.0 1.TECHNICAL DATA O.74 100(3.

doubleadlna (low ptessure qas charg€d) rc lu.18) 385.s4) 334. * 45 Camb€rangle " u-Fioet tiRcation matt color on s€condcoil lrom boltom " Auxiliary mark cdor: On lhird coilJrorn-bo-nofn' iclertifrcanon :. positrons toors rire anc spare jact'and indesisnated TD-l6 ..24 7.74) 373.2(0. 1 0.l'S:H#J.74) ShockabGoruel Srabilizel Oiarnets sieedngangle (Unlad€d'r) Outer 24 tO.rmtar Typ€ mm(n) lurns 90.t(u.70) (15.iJieves.couoteaaing(oillilleo Lightgrcen Orange 10. r'.i"E.5(14.0(3.6 7.12) 0010'+ 10 0050 * 45' Cambd angle Casterangle Kinooin anole Tvpe ldenlrlication Cdl sping M' orange wrreoiamaer flrnerdrameter mm{i!L 9 .94) mm(an) t+ 3 (o12 + 0.0 (3.TD R.0(0..40) alx wire oiameter Coil centerdiametet free tengM coil number mm!!L mm !!L mm (in) turq mm (in) s5. SUSPENSION lLm tdentificalron Coil spnng TECHNICALDATA Type TX SVul 10.i#"li.39) 95.49 ar/indncal. Tvpe Oarneter Total toein mm{in) cregree mm (in) 0olo' * t0 _0015.89 cvt'-vt'nonca..oy.0 (3.36) mm (in) Fr€elil Shockabsorber S'tablizer Whs6ldiqme {Unladed') coit ru.15) 6.0(13.11iffi. i]:i"A?iffi.reEUr.

ssr) .43 -O. BODYELECTRICAL SYSTEM llem Headlighl Position light TD SpeclticatioE (W) 60/55 Erterorlamps Frodsidelurntighl Stodraillight Bear tum signal light Back-up light 5 21t5 21 7.7 10 (0.4 3.039) 4.4 3.2-6.4 U.25 (0. 18€F213 psD .6a 1..059) 34-50 1.6 Fsj) STANDARD BOLTAND NUTTIGHTENING TOROUE Olamctar Pltch mm llnl mm (lnl NM 6 (0.tb o.O 5.O-7.2 7 .'np Hrgh beam Tuh light 10 5 Brake Hold hdicaior and warning llerce Oil pressure Rearwindowdefroster Rearlog lllumioation Pading brak€ 3.46 116-157 6T 8T m-|(q ft-tb N{n m-kg ft.0-15.5(0.2 1.7 23-34 36-54 2740 41-59 6.1 1 .4 3.059) 18 (0.8-14.059) 20IO.4-2.059) 22rc.0-1.O-2-9 14-21 3.5_42.4 3.4' 43-54 307-416 41-56 298-403 536-726 55-74 396-536 TD-l7 .4 3.1 25--37 tr-tb 6.71 ol s Highpfessure: 1276-1471kPa (13.4 3.8 16-23 31-46 55-80 75-103 -t67-225 231-314 314-423 475-f.0 kg/cm.059) 24 (0.5(0.4 1.866) 1.A 2.7-to.7-1.t37 1 0 .7 13-m 3.5-5.28. HEATER AIID AIR CONDITIONER SYSTEMS Ite|n Hslflgeranl amount Sp€dficetlon 7OO (24.5 14 rc.0kgr'crn'.4 3.70S) 1.5 (0.s {0.7a7\1. Low pressure 197-294 kPa : (2.s 56-76 102.TECHNICAL DATA T.945) 1.2-10.1 4 75-101 12-16 85-116 156-211 't6-22 1 1 5 .5 46-69 7.5 (0.0-3.315) 1. 8 .3 18-26 1.3s4) 'l .8-1.1 5 6 123-166 221-299 23-31 163-221 24-32 171*231 3(E-417 31-43 32-43 231-312 417-56.236) 1 {0.25(0.5 (0.5 7.5 piale tight License lnredor lamp Trunkcompadinenita.059) 4f nHq ).630) 1. A o.059J 1 16 (0.24 12IO_472\ (0.2-4.0491 20.6-2.049 9.2 8 {0.4-9.9-9.

..3 CLUTCH AND MANUALTRANSAXLE.. ST.......... ST.....................-...... ST....7 STEER|NG AND SUSPENS|ON... 8 STCHECKER AND OTHEBEOUIPI'ENT......... ST........................ 5 STBRAKE ANDAXj-E.----............. 2 STE GtNE.......................................ST SPECIAL TOOLS GENERAL TNFORMATTON .............4 AUTOttATtC TRANSAXLE........... sT-r0 .........................9 atRcoNDtTtoNER.............

to perform Nole -W.Indispensable and easily' safely' satisfactorily' operations for rire ioott'ianrcae in thislistareindisp€nsable performing lt efficiently..Seleclive as The toolsin this list are not as neces€ary tools rankedA' but all serviceshopsshouldhavethesetools repairs moreeasilyand moreefficiently..002 sT-2 ..'iristeaa ot oraedng the a€t.. thereloreadvisablethat all serviceshopshave thesetools B. order only those new tools thEl are needed' 9MUSD(.. is.nen .. lf they ire. orOeringtool sels that conslst ot several tools.ST SPECIALTOOLS INFORUAIION GENERAL of of the columnindicate degree importance eachtool' A the letters and B in the priority A.e iftaf ""me lools are not dupllctted In other Bels you may already have... check the Lisi In the Parts Catalogue to-.."f! iu..

SPECIAL TOOLS ENGINE T(X)L NU AER PN|oRITY & DESCRTPT|OIi 49 0107680A Enginestand Ncw SST 49 DO15 001 ST ILLUSTRATIO'. engine stand Go r#rk #.ring gear 49 9200 O20 gauge. valve gu|de ? 49 L012 040 .I 49 0636 1008 Valvespring li{t€r 49 AO12 005 installer.e 49 D011 001 Supportblock body 49 H011 0018 Supporiblock head 43 BOt20M 49 8134045 Pistonpin guide sT-3 . pin 49 D011 i02 Ncw SST 49 E301060 Brake.e "* o2lt' 49 0147280 Oilpr€ssure gauge gu|de *W 49 D011003 piston Installer. Tansjon V-ribb€dbelt 43 DO15 0A0 Radialortesler I6u SST 49 L0101A0 Hangerset.

ST (CONT'D) ENGTNE TOOL UIIBER & oEscRlPTlol{ 49 Al3/ 044 pin Piston guid€ SPECIALTOOLS TOOLNUi'BEF PRIORITY & DESCRIPTIOII PE|oR|TY ILLUSTRATIOT ILLUSTRATIOI{ AND IIANUAL TRANSAXLE CLUTCH TOOL ]{UMBEF & oEscRlPTlol{ 49 G0175AO Enginesupport PRIORITY ILLUSTBATION TOOL NU AEB PRIORITY & DESCRIPTIOII 49 0839 425C b€a ng ILLUSTRATION 310A 49 SE01 Ce eino tool. dllf. side gear I 49 FT01 361 49 D0172MA Rfu t2 49 07105m Puller. t{ew SST 337A 49 F401 49 D027 001 Holdet. bearing 49 00i7 101 49 F401 366.q 040 43 GO19 49 8092371 At6chmentE sT-4 .

oil seal 49 0147 520 shaft bearing 49 1245 071 Puller. trubin€shaft sT-5 .beaing 49 0636145 49 DO27 N2 AUTOMATIC TFANSAXLE T(X)L NUi'AER & DESCRIPTION PRIOFITY 49 8019007 ILLUSTRATIO]'I TOOLNUMBEB & DESCEIPTION PR|oN|tY 49 G019 013 ILLUSTRATION 49 DO19 001 Bdr 49 FT01384 Collar 49 FT01 439 Hddsr.SPECIALTOOLS (CONT'D) CLUTCH AND I'ANUAL TRANSAXLE TOOL I{UI'BEF PRIORITY & DESCA|PTTOI{ 49 F401331 Body ILLUSTBATION TOOLI{UIIBEF & DESCRIPnON PRtORlfv 49 0017 201 ST ItrusTBATtot{ 49 G030 795 Installer. idle gear shafi 49 G0t9 0A2 Holder.

ILLUSTRATIOI{ PR|oNTlTY ILLUSTRATIOlI 49 0378400A Gauges€t.9S1m 785 Inslaller. s€al oil 43 BOig9A2 Gaugesel. 49 FT01515A 49 H019002 Adapl€r 49 8019 002 Body 008 49 BO19 49 GO19 025 BodyB 4SG019026 43 G019027 49 G019029 NUt 49 G019 021 Bolt sel $N 49 G019017 Installer.ST TRANSAXLE(@NT'D) AUTOIIIATIC TOOL ]{UXBER & oEscRlPTloll 49 8019 006 PBIORITY SPECIALTOOLS TOOL I{UIBEN & DESCAIPT|O 4. sT-6 .

joint ball sT-7 . 49 F026103 49 G025001 49 G033102 Handle m5 49 FO27 Attachment C62 49 G030727 49 BOg2 372 49 0727 s75 Puller.TOOLS SPECIAL BRAKEAND AXLE TOOL NUIIBER PRIORITY & DESCRIPTIOT 49 0259 7708 ILLUSTRATION TOOL T{UIIBER PRIORITY & DESCRIPTION 49 0221 60U) Expandlool. oil seal 6rx) 727 49 BOO1 Spacerselec'tor 49 F043001 Adjustgauge (Mrx) 49 80. disc brake B ST tLtusrRAltoll 49 B04i)003 Tuninglock tool 49 8001 795 Installer.13004 49 804:] 001 Adjustgauge (ATX) (Arx) 49 01803214 b€aing lrEtaller.

a H/ . . gaugeset 304 49 BO32 49 B0B2305 $eering pump sT-8 .r' \€_/ A_ol 49 8038785 Insiall€r.N 49 D(R4 2AO Puller& install6r 49 D034ml 43 G032319 6 6 317 49 GO32 49 1232670^./ la6.A 49 8001 605 gaugeadapier \9.ST AND SUSPENSION STEERING TOOL iIUIIBEF PRIORITY & DESCAIPTIOI{ 5108 49 0180 Pr6load B TOOLS SPECIAL TOOL }IUMSER & oEscRlPTlol{ 49 0370 641 Compr€ssor ILLUSTRA'ION PRIORITY ILLUSTRATIOII 49 0223 6408 coilspnng th. 49 0208701A B 49 0118850C Puller.balllornt 49 H002671 49 DG92 3AO .

49 G019 9014 EC-AT tesier 49 F019 901 49 D066801 Femoving lool New SST 49 9200 162 Engine signal 49 GO50 1AO 49 G018903 49BOr9 9Ar EC-AT selector 49 G018904 Sheet 49 DO19 901 l{ew SST sT-9 .SPECIAL TOOLS CHECKER AND OTHEREOUIPMENT IOOL NUTIBER & DESCB|PT|O]{ PAloN|TY 49 8019 9AO slstem selector ST ILLUSTRATION ILLUSTRATION TOOL UMEEA PBION|TY & DESCA|pTION 49 0305870A 49 E301 144 Removing plate 49 H018 9A1 Selldiagnosis 49 0839 285 Ch€cker.

TOOL '{UXBER PRIORITY sPEclALTOOITS TOOL}IUI'BER PBIORITY ILLIJSTR TION ILLUSTRATIOI & oEscRrmo 49 8061 006 irdaller. se€l sT-l0 .ST AIR OONDITIONEB & oEscRlPrroN 49 8061005 Redacer.

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