Professional Documents
Culture Documents
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, "NI5SAN
240SX
-
,'.
1989
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SERVICE<
MANUAL
"
"
\,
NISSAN
j
24DSX
MODEL
S13
SERIES
GENERALINFORMATION
GI
MAINTENANCE
MA
ENGINEMECHANICAL
EM
ENGINELUBRICATION
& COOLING
SYSTEMS-
LC
ENGINEFUEL& EMISSIONCONTROL
SYSTEM-
EF
ENGINECONTROL,
FUEL& EXHAUST
SYSTEM-
FE
CLUTCH
CL
MANUALTRANSMISSION
MT
AUTOMATIC
TRANSMISSION
AT
PROPELLER
SHAFT& DIFFERENTIAL
CARRIER-
PD
FRONTAXLE& FRONTSUSPENSION
FA
REARAXLE& REARSUSPENSION
RA
BRAKESYSTEM
SR
STEERING
SYSTEM
ST
BODY
SF
HEATER
& AIRCONDITIONER
HA
ELECTRICAL
SYSTEM
EL
,
cg 1988 NISSAN MOTOR CO., LTD.
Printed in U.S.A.
Not to be reproduced in who~e or in part without the prior written permission of Ni~n
..
<""
&EC
FOREWORD
This manual contains maintenance and repair procedures for the 1989
Nissan 240SX.
In order to assure your safety and the efficient functioning of the
vehicle, this manusl should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.
All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in
specifications and methods at a~y time without notice.
IMPORTANT
SAFETYNOTICE
The proper performance of service is essential for both the safety of the
technician and the efficient functioning of the vehicle.
The service methods in this Service Manual are described in such a
manner that the service may be performed safely and accurately.
Service varies with the procedures used, the skills of the technician and
the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by
NISSAN must first completely satisfy himself that neither his safety
nor the vehicle's safety will be jeopardiz~d by the service method
selected.
NISSAN MOTORCo.,LTD.
Overseas Service Department
Tokyo, Japan
GENERAL
INFORMATION
I
GI
SECTION
CONTENTS
PRECAUTIONS
GI- 2
GI- 5
GI- 7
GI-10
IDENTIFICATION INFORMATION
GI-13
"""''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''
GI-17
GI-20
PRECAUTIONS
Observe the following precautions ~o ensure safe and proper
servicing. These precautions are not described in each individual section.
SGI232
SGI233
GI-2
PRECAUTIONS
6. Before servicing the vehicle, protect fenders, upholstery and
carpeting with appropriate covers.
Take caution that keys, buckles or buttons on your person
do not scratch the paint.
SGI234
SGI291
1. Before connecting or disconnecting E.F.I. or E.C.C.S. harness connector to or from any E.F.I. or E.C.C.S. control unit,
be sure to turn the ignition switch to the "OFF" position and
disconnect the negative battery terminal.
Otherwise, there may be damage to control unit.
2. Before disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure to eliminate
danger.
3. Be careful not to jar components such as control unit and
air flow meter.
GI-3
PRECAUTIONS
Precautions for Catalyst
Clean floor
SG 1290
GI-4
Pad retainer
r;~'~
Torque
member
,/I
J~
5~ 641556.5.40
~.
::;:;:::
Pin boot
r-
471
Main pin
IE!
to sliding portion
Outer shim
SBR364A
6. THE SMAll IllUSTRATIONS show the important steps such as inspection, use of special tools,
knacks of work and hidden or tricky steps which are not shown in the previous large illustrations.
Assembly, inspection and adjustment procedures for the complicated units such as the automatic
transaxle or transmission, etc. are presented in a step-by-step format where necessary.
7. The followings SYMBOLS AND ABBREVIATIONS are used:
~
E1I
~
rJ
~
~
EaI~
@>
"f:l
S.O.S.
L.H., R.H. .
Tightening torque
Should be lubricated with grease.
Unless otherwise indicated, use
recommended multi-purpose grease.
Should be lubricated with oil.
Sealing point
Checking point
Always replace after every disassembly.
Apply petroleum jelly.
Apply A.T.F.
Select with proper thickness.
Adjustment is required.
Service Data and Specifications
Left-Hand, Right-Hand
GI-5
M/T
A/T
Tool
L.H.D.
R.H.D.
A.T.F.
0,
02
03
D.
0.0.
22
2,
12
1,
Manual Transaxle/Transmission
Automatic Transaxle/Transmission
Special Service Tools
Left-Hand Drive
Right-Hand Drive
Automatic Transmission Fluid
Drive range 1st gear
Drive range 2nd gear
Drive range 3rd gear
Drive range 4th gear
Overdrive
2nd range 2nd gear
2nd range 1st gear
1st range 2nd gear
1st range 1st gear
",.
.
.
.
GI-6
WIRING DIAGRAM
Symbols used in WIRING DIAGRAM are shown below:
Example
CONNECTOR
Th is shows that these con nectors
white 6 terminal connectors.
POWER SUPPLY
-This shows the ignition switch position
in which the system
can be ope rated.
- See POWER SUPPLY
ROUTING in EL
section for the detai led
wiring diagram.
are
BRANCH
M/T model
n
~
'-LAMP-!
1m
lG~
~B~
A/T model
~ 2
~~
~~B-SCLG~
~
: MfT model
: AfT model
>
lyw IiliJ
~Whi"~
LOCATION NUMBER
This number shows where the
connector is located. See
HARNESS LAYOUT in EL
section. The number is
identical with the one in
HARNESS LAYOUT.
I
ABBREVIATIONS
~@!
I:
l-l
SWITCH
.rn '""".~
'""
~
---
SWITCH
This shows that continuity exists between
terminals CD and CID,
when the switch is
turned to ON position.
Instrument
harness
'WIRE
-b
BODY D
GROUN
COLOR CODING
BR
B -BI,,'
OR
W
R
G
Y
L
P
PU
GY
SB
LG
~
~
~
~~
White
Red
Green
Blue
Yellow
.
Brown
Orange
Pink
Purple
Gray
Sky Blue
ht Green
~ Llg
.
d the base
is stripe,
.
When. the iven
wire first,
co orfollowe d by the stripe
color as
IS gshown below:
Example:
L/W
M:
Main harness
S G 1543
SWITCH POSITIONS
Normally open
~~
Normally closed
........
0---
..
.
~
SEL764E
GI-7
Example
..4:
Connector
SG 1362
Example
EE
M.~ te,m;nal
G";d'-[~
Connector
Connector symbol
Female terminal
Efj
Guide
Connector
Connector symbol
SG 1363
MULTIPLESWITCH
The continuity of the multiple switch is identified in the switch
chart in wiring diagrams.
Example
WIPER SWITCH
-R.
-W/B
-L/Y
CONTINUITY CIRCUIT
OFF
B E
C (f)
1 5
@ 2
-B.
3-4
INT
3 - 4,5 - 6
LO
3-6
HI
2.6
WASH
1 -6
-yo
Continuity circuit:
CID terminal
- Wiperswitch (@ - @:
SG 1365
GI-8
Example
STARTING
STARTING SYSTEM
Wiring Diagram
rnIJ ~
SYSTEM
FF
Dm3
A"angament
Check
0
0
[ ,=fd:0CI~ crhKk
0
'"
],
,~
r-
liJ
.-::
:=
y--R
.S.M.J.
L--S
't
( (Foldout
page).
r-R~
~B
(Main harness)
DO
L---1
+-+
BR~
(Instrument
harness)
r-B
(Main harness)
(Instrument
harness)
BR---l.
SEL653F
GI-9
m"
INSPECTION START)
~m
-=-
SG I561
iii
~
lu
iii
_MECT
[ill
rill
~~
00
on
SG 1562
O.K.
NOTICE
The flow chart indicates work procedures required to diagnose
problems effectively. Observe the following instructions before
diagnosing.
1) Use the flow chart after locating probable causes of a
problem following the "Preliminary Check" or the "Symptom Chart".
2) After repairs, re-check that the problem has been completely eliminated.
3) Refer to Component Parts Location and Harness Layout
for the Systems
described
in each section
for
identification/location
of components and harness connectors.
4) Refer to the Circuit Diagram for Quick Pin Point Check.
If you must perform circuit continuity between harness
connectors more detail, such as in case of sub harness is
used, refer to Wiring Diagram and Harness Layout in EL
section for identification of harness connectors.
5) When checking circuit continuity, ignition switch should be
"OFF" .
6) Before checking voltage at connectors, check battery
voltage.
7) After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness
connectors are reconnected as it was.
GI-10
HOW TO FOllOW
.--
Check
voltage between
Procedure,
measurement
steps or
results
O.K.
I2J Measurement
results
Required results are indicated in bold type in the corresponding block, as shown below.
These have the following meanings:
Battery voltage ~ 11 14V or approximately
12V
Voltage:
Approximately OV ~ Less than 1V
Example
View from terminal side
Connector symbol
Direction
mark
~
View from harness side
Connector
Connector
symbol
~
[it
Direction
Direction mark
A direction mark is shown to clarify the side of connector (terminal side or harness side).
Direction marks are mainly used in the illustrations indicating
terminal inspection.
.
.
~:
~:
Viewf,omhernessside .n
H.S.
mark
SGI364
GI-11
side are
Symbol explanation
..-cT
IV
CONNECT
)
@-
00
00
OOACC
Symbol
Symbol explanation
AIC switch
Fan switch is "ON". (At any position except for "OFF" position)
"cfi1234.
OOF
0
trJ
Drive vehicle.
or check
is "OFF".
with engine
Depress
running.
brake
pedal.
CffH
l!V
La)
II CIUIIT
foi--
II
Le1J
Currentshould be measuredwith
an ammeter.
GI-12
'
IDENTIFICATION INFORMATION
Model Variation
Destination
Model
Body
Transmission
Engine
Coupe
HLS13FU
Fastback
RHLS13FU
Coupe
HLS13AU
Fastback
RHLS13AU
Coupe
HLS13FV
Fastback
RHLS13FV
Coupe
HLS13AV
Fastback
RHLS13AV
Coupe
HLS13FN
Fastback
RHLS13FN
Coupe
HLS13AN
Fastback
RHLS13AN
Differential
carrier
FS5W71C
Non-California
RE4R01A
FS5W71C
California
KA24E
R200
RE4R01A
FS5W71 C
Canada
RE4R01A
0:
R :
Coope
Fastba~
H:
KA24E engine
L:
L.H. drive
L S13
N (R)
Non-California
A : Automatic transmission
F :
0 : means no indication.
GI-13
IDENTIFICATION
INFORMATION
Identification Number
Vehicle identification
plate
Vehicle identification
label
number plate
SGI547
VEHICLE IDENTIFICATION
NUMBER ARRANGEMENT
IN 1 H S 3 6 P X K W 000051
Manufacturer
IT
Manufacture plant
W: Kyushu
Model year
K: 1989 year model
. Vehicle line
S: NISSAN 240SX
Check digit (0 to 9 or XI
The code for the check digit is
determined by mathematical
computation.
Model change (0 to 91
Body type
4: Coupe
6: Fastback
Restraint system
S: Standard
P: Automatic
GI-14
IDENTIFICATION
INFORMATION
PLATE
~:it
~i:J
ill
1
2
3
4
5
6
7
8
9
CHASSIS NO
NO DE CHASIS
MODEL
.&
MOOElO
0
I
&"
",-COlOR
TRiM
f 'Jk COlOR GUMNICION
;,.0
'/;,.0
ENGIN[
MOTOR
ffi&
&&
CC
& &
I tf;
::::A
MADEINJAPAN
Type
Vehicle identification number (Chassis numbed
Model
Body color code
Trim color code
Engine model
Engine displacement
Transmission model
Axle model
SGI315
TL 1006M
MANUAL TRANSMISSION
NUMBER
AUTOMATIC
SGI274
TRANSMISSION
NUMBER
SGI513
GI-15
IDENTIFICATION INFORMATION
Dimensions
Unit: mm (in)
Coupe
Fastback
Overall length
4,520 (178.0)
4,520 (178.0)
Overall width
1,690 (66.5)
1,690 (66.5)
Overall height
1,290 (50.8)
1,290 (50.8)
Front tread
1,465 (57.7)
1,465 (57.7)
Rear tread
1,460 (57.5)
1,460 (57.5)
Wheelbase
2,475 (97.4)
2,475 (97.4)
Steel
6-JJx 15
Aluminum
6-JJx 15
Offset
Tire size
mm (in)
40 (1.57)
Conventional
195/60R 15 86H
205/60R 15 89H *
Spare
T125/70D 15
*: Option
GI-16
.
.
SGI552
GI-17
Sill
//
a suitable
attachment
with slit.
Note:
Lift-up points
are the same as
pantograph jack
points.
SGI553
~
~
'i::ij,iiii.2ii;~1',,,';1tiii:.;
-.
SG 1383
GI-18
LIFTING
POINTS
TOWING
Front
Rear
CE1 DD9M
GI-19
Grade
Bolt size
Bolt
dia-
meter* mm
Pitch mm
4T
M6
6.0
M8
8.0
M10
M12
12.0
M14
14.0
M6
6.0
M8
7T
M10
M12
9T
10.0
8.0
10.0
12.0
6.1
0.62
4.5
5.1
1.25
13
1.3
15
1.5
11
1.0
13
1.3
16
1.6
12
1.5
25
2.5
18
29
3.0
22
1.25
25
2.6
19
30
3.1
22
1.75
42
4.3
31
51
5.2
38
1.25
46
4.7
34
56
5.7
41
1.5
74
7.5
54
88
9.0
65
1.0
8.4
0.86
6.2
10
1.0
1.25
21
2.1
15
25
2.5
18
1.0
22
2.2
16
26
2.7
20
1.5
41
4.2
30
48
4.9
35
1.25
43
4.4
32
51
5.2
38
1.75
71
7.2
52
84
8.6
62
1.25
77
7.9
57
92
9.4
68
14.0
1.5
127
13.0
94
147
15.0
108
M6
6.0
1.0
12
1.2
15
1.5
11
M8
8.0
1.25
29
3.0
22
35
3.6
1.0
31
3.2
23
37
3.8
26
27
1.5
59
6.0
43
70
7.1
51
1.25
62
46
74
7.5
54
1.75
98
6.3
10.0
72
118
12.0
87
1.25
108
11.0
80
137
14.0
101
1.5
177
18.0
130
206
21.0
152
M12
M14
10.0
12.0
14.0
4T
7T
9T
3.8
1.0
kg-m
0.52
M14
M10
Grade
ft-Ib
*: Nominal diameter
Mark
4
7
9
GI-20
6
""""L-
'..~
MAINTENANCE
MA
.J
SECTION
CONTENTS
PERIODIC MAINTENANCE ...
MA- 2
GENERAL MAINTENANCE.
MA- 4
MA- 6
ENGINE MAINTENANCE
MA- 8
"'"''''''''''''
MA-14
:"
MA-20",
l1li
PERIODIC MAINTENANCE
The following charts show the normal maintenance schedule. Under severe driving conditions, additional or
more frequent maintenance will be required. Refer to "Maintenance under severe driving conditions".
The periodic maintenance schedule is repeated beyond the last mileage and period shown by returning to the
first 15,000 miles (24,000 km) or 12 months.
EMISSION CONTROL SYSTEM MAINTENANCE
MAINTENANCE. OPERATION
Perform at number of miles,
kilometers or months, whichever
comes first.
Drive belts
MAINTENANCE
15
30
INTERVAL
45
60
Miles x 1,000
7.5
(km x 1,000)
(12)
(24)
(48)
(72)
(96)
12
24
36
48
1*
Months
Vapor lines
Fuel lines
Fuel filter
Engine coolant
Egnine oil
type or equivalent.)
Ignition wires
MA-8
MA-10
MA-13
MA-9
MA-10
MA-8
MA-11
MA-11
Spark plugs
Reference page
MA-12
MA-12
Miles x 1,000
15
(km x 1,000)
(24)
12
Months
I
I
I
MAINTENANCE
INTERVAL
30
45
(48)
24
I
I
I
I
I
(72)
36
I
I
I
60
Reference page
(96)
48
I
I
I
I
I
MA-16
MA-17
MA-14,15,16
MA-18, FA-4,RA-4
MA-14
NOTE:
(1) After 60,000 miles (96,000 km) or 48 months, inspect every 15,000 miles (24,000 km).
(2) If vehicle is operated under extremely adverse weather conditions or in arees where ambient temperatures are either
extremely low or extremely high, the filters might become clogged. In such an event, replace them immediately.
(3) Maintenance items and intervals with "." are recommended by NISSANfor reliable vehicle operation. The owner need
not perform such maintenance in order to ~aintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required.
Abbreviations:
MA-2
PERIODIC MAINTENANCE
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle
is mainly operated under severe driving conditions as shown below, more frequent maintenance is required to.
be performed on the following items as shown in the table.
Severe driving conditions
A - Repeated short trips less than 5 miles (8 km) and outside temperatures remain below freezing
B - Extensive idling and/or low speed driving for a long distance such as police, taxi or door-to-door delivery use
C - Driving in dusty conditions
D - Driving on rough, muddy, or salt spread roads
E - Towinga trailer, usinga camper or a car-top carrier
Driving condition
C
ABC
A.
.
A.
DE
C D E
item
Maintenance
interval
Reference
More frequently'
MA-10
MA-11
MA-17
MA-14, 15, 16
D .
Maintenance operations:
operation
D E
Maintenance
D E
CD.
.
Maintenance
page
MA-18,FA-4
MA-14
= Replace.
MA-3
GENERAL MAINTENANCE
General maintenance includes those items which should be checked during the normal day-to-day operation
of the vehicle. They are essential if the vehicl~isto continue operating properly. The owners can perform the
checks and inspectionsthemselvesor they can have their NISSANdealers do them for a nominal charge.
Item
Reference page
MA-18
Wheel alignment and balance If the vehicle should pull to either side while driving on a
straight and level road, or if you detect uneven or abnormal tire wear, there may be a need
for wheel alignment. If the steering wheel or seat vibrates at normal highway speeds, wheel
balancing may be needed.
MA.17
FA-6
RA-6
Windshieldwiper blades Check for cracks or wear if they do not wipe properly.
Doors and engine hood Check that all doors and the engine hood operate smoothly as well as
the trunk lid and back hatch. Also ensure, that all latches lock securely. Lubricate if necessary. Make sure that the secondary latch keeps the hood from opening when the primary
latch is released.
When driving in areas using road salt or other corrosive materials, check lubrication frequently.
INSIDE THE VEHICLE
The maintenance items listed here should be checked on a regular basis, such as when
performing periodic maintenance, cleaning the vehicle, etc.
Lights Make sure that the headlights, stop lights, taillights, tUrn signal lights, and other lights
are all operating properly and installed securely. Also check headlight aim.
MA-19
Warning lights and buzzers/chimes Make sure that all warning lights and buzzers/chimes are
operating properly.
Windshield wiper and washer Check that the wipers and washer operate properly and that
the wipers do not streak.
Windshield defroster Check that the air comes out of the defroster outlets properly and in
sufficient quantity when operating the heater or air conditioner.
Steering wheel Check that it has the specified free play. Be sure to check for changes in the
steering condition, such as excessivefree play, hard steering or strange noises.
Free play: Lessthan 35 mm (1.38 in)
Seats Check seat position controls such as seat adjusters, seatback recliner, etc. to ensure
they operate smoothly and that all latches lock securely in every position. Check that the
head restrains move up and down smoothly and that the locks (if so equipped) hold securely
in all latched positions. Check that the latches lock securely for folding-down rear seatbacks.
.
Seat belts Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and
retractors) operate properly and smoothly, and are installed securely. Check the belt
webbing for cuts, fraying, wear or damage.
MA-4
MA-19
GENERAL MAINTENANCE
Item
Reference page
Clutch pedal Make sure the pedal operates smoothly and check that it has the proper free
travel.
CL-5
Brakes Check that the brake does not pull the vehicle to one side when applied.
Brake pedal Check the pedal for smooth operation and make sure it has the proper distance
under it when depressed fully. Check the brake booster function.
BR-7
Parking brake Check that the lever has the proper travel and confirm that your vehicle is
held securely on a fairly steep hill with only the parking brake applied.
BR-23
Automatic transmission "Park" mechanism Check that the lock release button on the
selector lever operates properly and smoothly. On a fairly steep hill check that your vehicle
is held securely with the selector lever in the "P" position without applying any brakes.
MA-9
Radiator and hoses Check the front of the radiator and clean off any dirt, insects, leaves,
etc., that may have accumulated. Make sure the hoses have no cracks, deformation, rot or
loose connections.
Brake and clutch fluid levels Makesure that the brake and clutch fluid levelsare between the
"MAX" and "MIN" lines on the reservoir.
MA-14,16
Engine drive belts Makesure that no belt is frayed, worn, cracked or oily.
MA-8
Engine oil level Check the level on the dipstick after parking the vehicle on a level spot and
turning off the engine.
MA-11
Power steering fluid level and lines Check the level when the fluid is cold and the engine is
turned off. Check the lines for proper attachment, leaks, cracks, etc.
MA-18
Automatic transmission fluid level Check the level on the dipstick after putting the selector
lever in "P" with the engine idling.
MA-15
Exhaust system Make sure there are no loose supports, cracks or holes. If the sound of the
exhaust seems unusual or there is a smell of exhaust fumes, immediately locate the trouble
and correct it.
MA-14
Underbody The underbody is frequently exposed to corrosive substances such as those used
on icy roads or to control dust. It is very important to remove these substances, otherwise
rust will form on the floor pan, frame, fuel lines and around the exhaust system. At the end
of winter, the underbody should be thoroughly flushed with plain water, being careful to
clean those areas where mud and dirt can easily accumulate.
Fluid leaks Check under the vehicle for fuel, oil, water or other fluid leaks after the vehicle
has been parked for a while. Water dripping from the air conditioner after use is normal. If
you should notice any leaks or gasoline fumes are evident, check for the cause and correct it
immediately.
MA-5
oil filter
oil
gear oil
US
measure
Imp
measure
Liter
3-3/4 qt
3-1/8 qt
3.5
3-3/8 qt
2-7/8 qt
3.2
7-1/8 qt
5-7/8 qt
6.7
3/4 qt
5/8 qt
0.7
5-1/8 pt
4-1/4 pt
2.4
API GL-4*2
2-3/4 pt
2-1/4 pt
1.3
API GL-5*2
8-3/4 qt
7-1/4 qt
8.3
1 qt
0.9
3/4 qt
TM
Type DEXRON
TM
Brake fluid
Multi-purpose grease
MA-6
Range
OIL
140 .
C",OF
-----
+4011+104"'--+30111+86
+16111+60--+10111
0111+32
+50
-181110
-29111-20- -5W-30
T10002
T10003
MA-7
ENGINE MAINTENANCE
Water pump
lAJQ'
l:~:o,
Crank pulley
T : Tension checking points
IAJ: Adjusting bolts
lAJA;,,ood;,;oo",
compressor
Unit:
mm (in)
8MAOO2C
Set deflection of
new belt
Limit
Adjusted
deflection.
Alternator
11 (0.43)
7-8
(0.28 - 0.31)
6-7
(0.24 - 0.28)
Air conditioner
compressor
12 (0.47)
7-8
(0.28 - 0.31)
(0.24
Power steering
oil pump
13 (0.51)
8-9
(0.31 - 0.35)
7-8
(0.28 - 0.31)
Applied pushing
force
6.7
- 0.28)
~~~
[~O1234
~
~
.-
WARNING:
To avoid being scalded, never change the coolant when the
engine is hot.
1. Move heater "TEMP" control lever all the way to "HOT"
position.
8M AOO3C
MA-8
"'.
ENGINE MAINTENANCE
Changing Engine Coolant (Cont'd)
3. Remove cylinder block drain plug.
4. Close drain cock and tighten drain plug securely.
Apply sealant to the thread of drain plug.
to;J:34 44 N.m
(3.5 - 4.5 kg-m, 25 - 33 ft-Ib)
6. Fill radiator with water and close air relief plug and radiator
cap.
7. Run engine and warm it up sufficiently.
8. Race engine 2 or 3 times under no-load.
9. Stop engine and wait until it cools down.
10. Repeat step 2 through step 9 until clear water begins to
drain from radiator.
11. Drain water.
MAX.
MIN.
SMA412B
MA-9
ENGINE MAINTENANCE
Checking Fuel Lines
CAUTION:
3 mm 10.12 in)
~--,'-'
(Cont'd)
--T-+-+--J__J.-_J
SMA804A
.
.
Changing
Air Cleaner
Filter
The viscous paper type filter does not need cleaning between
renewals.
MA-10
ENGINE MAINTENANCE
Front
SMAOO9C
3.5 (3.3/4,3-1/8)
3.2 (3-3/8,2-7/8)
CAUTION:
tOJ:29 - 39 N.m
SMA042C
Changing
Oil Filter
2. Before installing new oil filter, clean the oil filter mounting
surface on cylinder block, and coat the rubber seal of oil
filter with a little engine oil.
SMA010
MA-11
---
ENGINE MAINTENANCE
Changing Oil Filter (Cont'd)
3. Screw in the oil filter until a slight resistance is felt, then
tighten additionally more than 2/3 turn.
4. Add engine oil.
Refer to Changing Engine Oil.
2/3 of a turn
SMA229B
Changing
N.G.
O.K.
Spark Plugs
SMA017
R
16mmV1
'o.um~
SEM294A
Side electrode
iii
- 29
N.m
SMA476
SMA015A
MA-12
ENGINE MAINTENANCE
"
MA-13
SMA211A
Max.
Min.
SMA941B
Checking
M/T Oil
,
SMA429A
SMA103
Changing
~~~
.,.
M/T Oil
~.;. ~"~
SMA255A
MA-14
Checking
AIT Fluid
.
SMA430A
Front side
Hot: 50 - aooc
(122 - 176F)
Add"
O.K.
Changing
AIT Fluid
SMA921B
MA-15
SMA012C
SMA257 A
Changing
~~
0,,;" PI~
~
SMA363A
MAX
MIN
Check brake fluid lines and parking brake cables for improper attachment and for leaks, chafing, abrasions, deterioration, etc.
SMA732A
MA-16
Rear
CL22VB
CL9H
Standard thickness
20.0 (0.787)
9.0 (0.354)
Minimum thickness
18.0 (0.709)
8.0 (0.315)
CALIPER
SMA922A
PAD
Check for wear or damage.
Unit: mm (in)
Minimum thickness
Front
Rear
CL22VB
CL9H
10.0 (0.394)
9.5 (0.374)
2.0 (0.079)
SMA847B
Balancing
Wheels
MA-17
FRONT
Do not include the T-type spare tire when rotating the tires.
Wheel nuts:
~: 98 - 118 N.m
(10.0 - 12.0 kg-m, 72 - 87 ft-Ib)
A!
SMA650B
.
.
.
.
Q
torque
SMA851 B
SMA940B
SST107B
MA-18
lEI
=~~
m.
SMA999B
CAUTION:
1. AUseat bait a..mblies, including retractors and
attaching hardwares such as guida rail set, etc"
should ba inspacted after any collision. Ni...n
recommends that aUseet bait ...amblies in use
during a collision ba replaced unless the collision was minor and the baits show no damage
and continue to operete properly. Seat bait
assemblies not in use during a collision should
allO ba inspacted and replaced if eithar damage
or improper operation is noted.
2. If tha condition of any component of a seat
bait is questionable, do not have seat bait
repaired, but raplaced as a bait 8118mbly.
3. If wabbing is cut, frayed, or damaged, replace
bait assembly.
4. Do not spill drinks, oil, etc. on inner lap bait
buckle. Never oil tongue and buckle.
5. Use a NISSAN genuine ..at bait assembly.
~ Anchor
bolt
24-31 N.m
(2.4 - 3.2 kg-m, 17 - 23 ft-Ib)
For automatic seat bait, refer to BF section.
MA-19
SMAOO1C
Limit
Alternator
Set deflection of
new belt
11 (0.43)
7-8
6-7
(0.28 - 0.311 I (0.24 - 0.28)
6-7
7-8
(0.28 - 0.311 I (0.24 - 0.28)
Air conditioner
compressor
12 (0.47)
Power steering
oil pump
8-9
ZFR5D-11
Hot type
ZFR4D-11
Cold type
ZFR6D.11
Plug gap
Ignition wire
Resistance kS1
TIGHTENING
7-8
I
Standard type
N'm
kg-m
ft-Ib
Spark plug
20- 29
2.0 - 3.0
14- 22
25 - 33
22.29
3.5 (3-3/4,3-1/8)
Without
3.2 (3-3/8,2-7/8)
oil filter
Coolant capacity
Unit: 2 (US qt, Imp qt)
With reservoir
tank
TORQUE
Unit
Drain plug
Less than 30
6.7 (7-118,5-7/8)
MA-20
Engine block
34 44
3.5-4.5
Oil pan
29-39
3.0-4.0
Unit: mm (in)
Unit: mm (in)
- 196 (7.32.7.72)
186
Disc brake
Pad
Standard thickness
CL22VB
10.0 (0.394)
CL9H
9.5 (0.374)
Minimum thickness
CL22VB
Camber
degree
Caster
degree
Toe-in
mm (in)
to 0
2.0 (0.079)
CL9H
600' . ~30'
Rotor
Standard th ickness
CL22VB
0 - 2 (0 - 0.08)
(Total toe-in)
degree
0' - 12'
Kingpin inclination
degree
1230'- 1400'
2.0 (0.079)
20.0 (0.787)
CL9H
Minimum thickness
CL22VB
9.0 (0.354)
39
egree
-43 /33
18.0 (0.709)
CL9H
*: Tankful of fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools, mats in designated position.
8.0 (0.315)
Pedal
Free height
M/T
177
A/T
degree
Toe-out
mm (in)
(Total toe.out)
degree
-136'
Free play
1 - 3 (0.04 - 0.12)
to -036'
Depressed hElight
[under force of 490 N
(50 kg, 110 Ib) with
engine running]
0 - 5 (0 . 0.20)
0' - 28'
*: Tankful of fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools, mats in designated position.
Parking brake
Number of notches
[at pulling force 196 N
(20 kg, 44 Ib)]
6-8
Wheel bearing
Front
Rear
0.03 (0.0012)
or less
0.05 (0.0020)
or less
147 216
(15 22,
235 314
(24-32,
108- 159)
174- 231)
Wheel balance
Wheel balance
(Maximum allowable unbalance
at rim flange)
g (OZ)
Tire balance weight
MA-21
g (OZ)
10 (0.35)
TORQUE
Unit
N'm
Clutch
Pedal stopper lock nut
Clutch switch lock nut
16 22
- 15
1.6 - 2.2
12 - 16
12
1.2 - 1.5
9 - 11
25
- 34
2.5 - 3.5
18 - 25
59 -98
6 - 10
43-72
Filler plug
Front axle and front
59 -98
6 - 10
43-72
37 - 46
3.8 - 4.7
27 - 34
12.6 - 14.6
91 - 106
Manual transmission
suspension
Tie-rod lock nut
kg-m
124
- 143
ft-Ib
69 -88
7.0-9.0
51 - 65
69 -88
7.0-9.0
51 -65
7-9
Brake system
Air bleed valve
0.7 - 0.9
5.1 -6.5
12
- 15
1.2 - 1.5
9 - 11
16
-22
1.6 - 2.2
12 - 16
10.0 - 12.0
72 -87
98 - 118
MA-22
ENGINEMECHANICAL
EM
SECTION
EM
CONTENTS
PRECAUTION
EM- 2
PREPARATION
EM- 3
EM- 6
COMPRESSION PRESSURE
EM- 7
OIL PAN
EM- 8
TIMING CHAIN
EM-10
EM-16
CYLINDER HEAD
EM-18
ENGINE REMOVAL
EM-32
CYLINDER BLOCK
EM-34
SERVICE
DATA
AND
SPECIFICATIONS
(S.D.S.)
"""''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''
EM-46
PRECAUTION
LIQUID GASKET APPLICATION
~~
Groove
'
I~r
Side
Bolt hole
SEM371C
PROCEDURE
EM-2
PREPARATION
SPECIAL SERVICE TOOLS
Tool number
(Kent.Moore No.)
Tool name
Description
ST0501S000
(
Engine stand
assembly
CD ST05011 000
(
)
Engine stand
@ ST05012000
(
Base
KV10105001
)
(
Engine attachment
KV101092SO
)
(
Valve spring
compressor
CD
CI<
KV10109210
(
)
Compressor
@KV10109220
)
(
Adapter
KV109B0010
(
)
Valve oil seal drift
~
Installing valve oil seal
KV10110300
(
~
?~~
EM-3
PREPARATION
Tool number
(Kent-Moore No.)
Tool name
Description
EM03470000
(J8037 )
Piston ring compressor
(J36467)
Valveoil
seal remover
KV10111100
(
Seal cutter
WS39930000
(
)
Tube presser
ST1661 0001
(J23907)
Pilot bushing puller
~
T
EM-4
PREPARATION
COMMERCIAL SERVICE TOOLS
Tool name
Spark plug wrench
Description
c:Y
Q
16mm
(0.63 in)
Pulley holder
--
~
\
~~.-
installing
Removingand
spark plug
A:~
mm (in)
----
Intake
Exhaust
10.5 (0.413)
11.5 (0.453)
6.6 (0.260)
7.6 (0.299)
Diameter:
~-
D.
EM;.5
mm (in)
Intake
Exhaust
01
7 (0.28)
8 (0.31)
Os
11.2 (0.441)
12.2'(0.480)
OUTER COMPONENT
PARTS
KA24E ENGINE
16 21 (1.6.2.1_,12
-15)
16
-21
(1.6
-21.
, 12-15)
B.P.T. valve
.
I A A umt
LI-I~~
I.-L
~
rA'..
(0.5-0.6,
3.6-4.3)
,r"
Adjusting bar
~~
142
10-12 (1.0-1.2,7 - 9)
EM-6
COMPRESSION
PRESSURE
Measurement of Compression
1.
2.
3.
4.
5.
Pressure
Warm up engine.
Turn ignition switch off.
Disconnect fusible link for injectors.
Remove all spark plugs.
Disconnect distributor center cable.
Q)
6. Attach a compression tester to NO.1 cylinder.
7. Depress accelerator pedal fully to keep throttle valve wide
open.
8. Crank engine and record highest gauge indication.
9. Repeat the measurement on each cylinder as shown above.
Always use a fully-charged battery to obtain specified
engine revolution.
Compression pressure:
kPa (kg/cm2,. psi)/rpm
Standard
1,324 (13.5, 192)/300
Minimum
981 (10, 142)/300
Difference limit between cylinders
98 (1.0, 14)/300
10. If cylinder compression in one or more cylinders is loyi. pour
a small amount of engine oil into cylinders through spark
plug holes and retest compression.
.
If. adding oil helps compression, piston rings may be worn
or damaged. If' so, replace piston rings after checking
piston.
If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valve and valve seat. (Refer
to S.D.S.) If valve or valve seat Is damaged excessively,
replace them.
If compression in any two adjacent cylinders is low and if
adding oil does not help compression, there is I,akage
past the gasket surface. If so, replace cylinder head
gasket.
SEM 113B
.
.
EM-7
OIL PAN
Removal
1. Raise vehicle and support it with safety stands.
2. Drain engine oil.
3. Remove front stabilizer bar securing bolts and nuts from
side member.
4. Lift engine.
(jJ)
0
...Q...
2-
Front
@
@
Loosen bolts in reverse order.
@
SEM337C
.
.
(2) Slide Tool by tapping its side with a hammer, and remove oil
pan.
SEM884A
EM-8
OIL PAN
Installation
Scraper
SEM338C
SEM339C
Cut here.
~
Liquid gasket
:J
SLC906
7 mm 10.28
in)
--Lt-.
.
.
Inner
side
Groove
Bolt hole
SEM909B
EM-9
TIMING CHAIN
r
~
~
118.
Camshaft sprocket
'
,65787 - 1161
(1:~ain'tenSioner
7-8
08 5.'-5.81
(0.7.
. ,
rJ
L--.
Qj
Front cover
.~
.,
.
Crankshaft
sprocket
13-1.
(1.3 -1.9,
9 -141 .
L.
SEM578C
CAUTION:
EM-10
TIMING CHAIN
Removal
1.
2.
3.
4.
..
.
Q
Front
SEM199C
.
..
..
Rocker
SEM200C
SEM201C
EM-"
cover
TIMING CHAIN
Removal (Cont'd)
8. Remove oil pan. (Refer to OIL PAN.)
9. Remove front cover.
SEM202C
Crank~h3ft
sprocket
SEM203C
Inspection
Check for cracks and excessivewear at roller links. Replace
if necessary.
Jf)
~
,~
'
SEM204C
EM-12
TIMING CHAIN
crankShaft
Crankshaft
~prOCket
~
~
Installation
1. Install crankshaft sprocket, oil pump drive gear and oil
thrower.
. Make sure that mating marks of crankshaft sprocket face
engine front.
.
"4~
.
O;I:;:~~~'\
n
~ 0
Front.
SEM205C
~~~
'/0
(O@
\000
~.
'~ "
\\
II ~ Can ,",ocke<
))
"
ii
~r C"ok
.p-"
"
e: Punchmark
SEM206C
EM-13
TIMING CHAIN
Installation (Cont'd)
7. Apply liquid'gasket to front cover.
2.0
-3.0 mm
..
SEM453C
of CYLINDER
12. Install oil pump and distributor driving spindle with new
gasket in front cover.
(1) Assemble oil pump and driving spindle, aligning punchmark
on driving spindle with oil hole.
Punchmark
SEM212C
EM-14
TIMING CHAIN
Installation (Cont'd)
(2) Make sure that driving spindle is set as shown in figure.
Front
SEM136C
Q
Front
SEM199C
EM-15
(J36467)
KV10980010
(
4. Apply engine oil to new valve oil seal and install it with Tool.
Before installing valve oil seal, install valve spring seat.
15.6. 16.2
(0.614.0.638)
Valve
spring seat
Unit: mm (in)
SEM246C
Engine
inside
Engine
outside
Dust seal lip
SEM715A
EM-16
9i-
SEAL REPLACEMENT
3. Apply engine oil to new oil seal and install it using suitable
tool.
SEM115B
.J'I;
it
5. Apply engine oil to new oil seal and install it using suitable
tool.
Diameter of
Iiqu id gasket:
2.0 - 3.0 mm
~ (0.079
0.118 in)
EM-17
CYLINDER HEAD
~~-8
.,'0..
37 - 41
(3.8 - 4.2, 27 - 30)
Intake
Spring
retainer
Valve
'~w,
,\;~
~
,\
~J
@
~~
E'M":~
Oilseal
springseatA
\\
V"Wg";..~~
Valve seat
Cylinder head
\J @<~
'b@cg
Head bolt
~:
EM-18
CYLINDER HEAD
CAUTION:
When installing sliding parts such as rocker arms, camshaft and oil seal, be sure to apply new engine oil on their
sliding surfaces.
. When tightening cylinder head bolts and rocker shaft bolts,
apply new engine oil to thread portions and seat surfaces
of bolts.
O.K.
Ii
SEM878B
N.G.
.
.
SEM868B
Removal
1. Drain coolant from radiator and drain plug of block.
2. Remove the following parts.
Power steering drive belt
Power steering pump, idler pulley and power steering
brackets
Vacuum hoses of S.C.v. and pressure control solenoid valve
Accelerator wire bracket
3. Disconnect E.G.R. tube from exhaust manifold.
4. Remove bolts which hold intake manifold collector to intake
manifold.
5. Remove bolts which hold intake manifold to cylinder head
while raising collector upwards.
6. Remove rocker cover.
When removing rocker cover, do not hit rocker cover against
rocker arm.
.
.
..
EM-19
CYLINDER HEAD
Removal (Cont'd)
7. Set NO.1 piston at T.D.C. on its compression stroke.
-5/0
5 10 15 20
Red painted
~
Front
SEM199C
SEM218C
EM-20
CYLINDER HEAD
Removal (Cont'd)
10. Remove front cover tightening bolts to cylinder head.
SEM2106
<ID
CID
.
.
-- SEM220C
Disassembly'
10
01
(Q
~
(])
~
@
~
@
Q)
CD
SEM445C
KV10109210
(
)
EM-21
CYLINDER HEAD
Inspection
~
~~~
CAMSHAFT RUNOUT
1. Measure camshaft runout at the center journal.
Runout (Total indicator reading):
0 - 0.02 mm (0 - 0.0008 in)
2. If it exceeds the limit, replace camshaft.
in)
SEM549A
CAMSHAFT
JOURNAL
CLEARANCE
"
EM-22
- 1.3002
in)
CYLINDER HEAD
Inspection (Cont'd)
3. Measure outer diameter of camshaft journal.
Standard outer diameter:
32.935 - 32.955 mm (1.2967 - , .2978 in)
4. If clearance exceeds the limit, replace camshaft and/or
cylinder
head.
END PLAY
SEM228C
CAMSHAFT
SPROCKET
RUNOUT
SEM232C
SEM449C
EM-23
\
\
CYLINDER HEAD
Inspection (Cont'd)
VALVE GUIDE REPLACEMENT
1. To remove valve guide, heat cylinder head to 150 to 160C
(302 to 320F).
SEM223C
SEM225C
"
EM-24
CYLINDER HEAD
Inspection (Cont'd)
VALVESEATS
Check valve seats for any evidence of pitting at valve contact
surface, and reseat or replace if it has worn out excessively.
Before repairing valve seats, check valve and valve guide.
for wear. If they have worn, replace them. Then correct
valve seat.
Cut with both hands to uniform the cutting surface.
REPLACING
I
Recess diameter
I
SEM795A
1. Bore out old seat until it collapses. The machine depth stop
should be set so that boring cannot continue beyond the
bottom face of the seat recess in cylinder head.
2. Ream cylinder head recess.
Reaming bore for service valve seat
Oversize [0.5 mm (0.020 in)):
Intake
36.500 - 36.516 mm (1.4370 - 1.4376 in)
Exhaust
42.500 - 42.516 mm (1.6732 - 1.6739 in)
Reaming should be done to the concentric circles to valve
guide center so that valve seat will have the correct fit.
SEMOO8A
"::I
SEM892B
EM-25
CYLINDER HEAD
Inspection (Cont'd)
VALVE DIMENSIONS
Check dimensions in each valve. For dimensions, refer to S.O.S.
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace\lalve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less.
T (Margin thickness)
cr
d
L
SEM188A
Jdi-----SEM288A
EM113
VALVE SPRING
Squareness
1. Measure "s" dimension.
Out-of-square:
Outer
Intake
Less than 2.5 mm (0.098 in)
Exhaust
Less than 2.3 mm (0.091 in)
Inner
Intake
Less than 2.3 mm (0.091 in)
Exhaust
Less than 2.1 mm (0.083 in)
2. If it exceeds the limit, replace spring.
Pressure
Check valve spring pressure.
Pressure: N (kg, Ib) at height mm (in)
Standard
Outer
Intake
604.1 (61.6, 135.8) at 37.6 (1.480)
Exhaust
640.4 (65.3, 144.0) at 34.1 (1.343)
Inner
Intake
284.4 (29.0, 63.9) at 32.6 (1.283)
Exhaust
328.5 (33.5, 73.9) at 29.1 (1.146)
Limit
Outer
Intake
567.8 (57.9, 127.7) at 37.6 (1.480)
Exhaust
620.8 (63.3, 139.6) at 34.1 (1.343)
Inner.
Intake
266.8 (27.2, 60.0) at 32.6 (1.283)
Exhaust
318.7 (32.5, 71.7) at 29.1 (1.146)
If it exceeds the limit, replace spring.
EM-26
CYLINDER
HEAD
Inspection (Cont'd)
ROCKER SHAFT AND ROCKER ARM
1. Check rocker shafts for scratches, seizure and wear.
2. Check outer diameter of rocker shaft.
Diameter mm (in):
21.979 - 22.000 mm (0.8653 - 0.8661 in)
SEM234C
Assembly
1. Install valve component parts.
Always use new valve oil seal. Refer to OIL SEAL REWide pitch
Narrow
pitch
.
.
.
.
PLACEMENT.
SEM6388
Place
upside.
SE M236C
SEM273C
EM-27
CYLINDER HEAD
'"
Assembly (Cont'd)
4. Install rocker shaft with rocker arms.
Front
Intake
Exhaust
Exhaust
SEM579C
Cutout
SEM274C
Front
(j)
CD
0
@
0
@
Q)
[Q:
@
.Q.
.Q.
.Q.
QJ
@)
SEM445C
EM-28
CYLINDER HEAD
Installation
1. Set No.1 piston at T.D.C. on its compression stroke as
follows:
(1) Align mark on crankshaft pulley with "0" position and
confirm that distributor rotor head is set as shown in figure.
-5~ 0:5 10 15 20
Red painted
Q
Front
SEM199C
SEM442C
.
2. Install cylinder head with new gasket and tighten cylinder
CD @
I
order.
or
CID
clockwise
with an angle
EM-29
CYLINDER HEAD
Installation (Cont'd)
3. Set chain on camshaft sprocket by aligning each mating
mark. Then install camshaft sprocket to camshaft.
Silver
Rubberplugsshouldbe replacedwithnewones.
Rubber plugs should be installed within 5 minutes of
applying liquid gasket.
..
.
(2) Install rubber plugs. then move them with your fingers to
uniformly spread the gasket on cylinder head surface.
Rubber plugs should be installed flush with the surface.
Do not start the engine for 30 minutes after installing
rocker cover.
Wipe clean excessive liquid gasket from cylinder head top
surface.
o/!I!IIJl
--N.G.
Good
SEM933B
EM-30
CYLINDER HEAD
Installation
(Cont'd)
(2) If valve lifter moves more than 1 mm (0.04 in), air may be
inside of it.
(3) Bleed air off by running engine at 1,000 rpm under no-load
for about 20 minutes.
(4) If hydraulic valve lifters are still noisy, replace them and
bleed air off again in the same manner as in step (3).
between
rocker
cover
and
~:J
@
SEM546C
@
@\
.g,
-""6'-
(2) Then tighten bolts to 7 to 10 N.m (0.7 to 1.0 kg-m, 5.1 to 7.2
ft-Ib) in order shown in figure.
9. Install any parts removed.
@
@
,0,
.-JJ@
CD
@
SEM547C
EM-31
ENGINE REMOVAL
M/T model
tC!]13 -16
(1.3- 1.6.9.12)
M43.~
.
(4.4 - 5.6. 32 - 41)
tC!]43-55
~
j
0
(4.4.5.6.32
~
~
//'
tC!]43-55
(4A-5.6.32-41)
- 41)
tC!]22 -28
r
~
'-,
(2.2 2.9.
16.21)
L~
LtC!] 22
-28
43-55
(4.4
-5.6.32-41)
.I?:
~
'''"'
~/
EM-32
..
ENGINE REMOVAL
WARNING:
a. Situate vehicle on a flat and solid surface.
b. Place chocks at front and back of rear wheels.
c. Do not remove engine until exhaust system has completely cooled off.
Otherwise, you may burn yourself and/or fire may break
out in fuel line.
d. For safety during subsequent steps, the tension of wires
should be slackened against the engine.
e. Before disconnecting fuel hose, release fuel pressure from
fuel line.
Refer to "Releasing Fuel Pressure" in section EF & EC.
f. Be sure to hoist engine and transmission in a safe manner.
g. For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:
When lifting engine, be careful not to strike adjacent parts,
especially accelerator wire casing, brake lines, and brake
master cylinder.
In hoisting the engine, always use engine slingers in a
safe manner.
.
.
"5
:1,;
",.
.,"'"
EM-33
CYLINDER BLOCK
Main bearing
cg
Drain plug
29-39
(3.0-4.0,
22- 291~
.
rJ
EM-34
CYLINDER BLOCK
Disassembly
PISTON AND CRANKSHAFT
/;~y
1.
2.
3.
4.
5.
6.
,
I
I.~'
~~\ I~(
~105~O1
ST0501 5000
II
-)
SEM744
7. Remove pistons.
When disassembling piston and connecting. rod, remove
snap rings, then heat piston to 60 to 70C (140 to 158F) or
use piston pin press stand at room temperature.
SEM877B
KV10110300
EM156
.
.
Inspection
PISTON AND PISTON PIN CLEARANCE
1. Measure inner diameter of piston pin hole "dp".
Standard diameter "dp":
20.987 - 20.999 mm (0.8263 - 0.8267 in)
;
..
SEM149B
EM-35
CYLINDER BLOCK
Inspection
(Cont'd)
dp - Dp = 0 - 0.004mm (0 - 0.0002In)
If it exceeds the above value, replace pi!3ton assembly with pin.
SEM821 B
SEM249C
2nd ring
0.03 - 0.07 mm (0.0012 - 0.0028 In)
011 ring
0.065 - 0.135 mm (0.0026 - 0.0053 in)
Max. limit of side clearance:
0.1 mm (0.004 in)
If out of specification, replace piston and/or piston ring assembly.
SEM250C
End gap:
Top ring
0.28 - 0.43 mm (0.0110 - 0.0169 in)
2nd ring
0.45 - 0.60 mm (0.0177 - 0.0236 in)
(R or T is punched on- the ring.)
0.55 - 0.70 mm (0.0217 - 0.0276 in)
(N is punched on the ring.)
Oil ring
0.20 - 0.60 mm (0.0079 - 0.0236 in)
Max. limit of ring gap:
0.5 mm (0.020 In)
If out of specification, replace piston ring. If gap still exceeds the
limit even with a new ring, rebore cylinder and use oversized piston
Refer to S.D.S.
EM-36
CYLINDER BLOCK
Inspection
(Cont'd)
Measuring points
Distortion:
Less than 0.10 mm (0.0039
in)
SEM255C
-_N
O!CD""
. . ~.
MM
ON--0
'00
I
I
I
I
I
ffi
,
I
N
... CD ...
,,
Unit: mm (in)
PISTON-TO-BORE CLEARANCE
1. Using a bore gauge, measure cylinder bore for wear,
out-of-round and taper.
Standard inner diameter:
89.000 - 89.030 mm (3.5039 - 3.5051 in)
Wear limit:
0.2 mm (0.008 in)
Out-of-round (X-V) limit:
0.015 mm (0.0006 in)
Taper (A-B) limit:
0.015 mm (0.0006 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder
block if necessary.
2. Check for scratches and seizure. If seizure is found, hone it.
EM-37
CYLINDER BLOCK
Inspection
(Cont'd)
Q
Front
SEM257C
SEM258C
CRANKSHAFT
A B
x
y
Taper:
Out-of-round:
A- B
X- Y
SEM316A
cracks.
2. With a micrometer, measure journals for taper and out-ofround.
Out-of-round (X-Y):
Main journal Less than 0.01 mm (0.0004 in)
Crank pin Less than 0.005 mm (0.0002 in)
Taper (A-B):
Main journal Less than 0.01 mm (0.0004 in)
Crank pin Less than 0.005 mm (0.0002 in)
EM-38
CYLINDER BLOCK
Inspection (Cont'd)
3. Measure crankshaft runout.
Runout (Total indicator reading):
Less than 0.10 mm (0.0039 in)
BEARING
CLEARANCE
SEM448C
SEM964
EM-39
CYLINDER BLOCK
Inspection (Cont'd)
,Q
rg
Front
SEM266C
bl
roJ
[5j
rd
SEM272C
Crankshaft
journal grade number
0
For example:
Main journal grade number: 1
Crankshaft journal grade number: 2
Main bearing grade number = 1 + 2
=3
EM-40
CYLINDER BLOCK
Inspection (Cont'd)
4. Measure outer diameter "Dp" of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C Dp
Standard:
'
0.010 - 0.035 mm (0.0004 - 0.0014 in)
Limit: 0.09 mm (0.0035 in)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bearing.
Refer to step 7 of "BEARING CLEARANCE - Main bearing".
8.
rod
grade number
SEM567B
.
.
EM142
SEM151B
EM-41
CYLINDER BLOCK
Inspection (Cont'd)
2. Measure outer diameter "Dp" of piston pin.
3. Calculate connecting rod bearing clearance.
C - Dp =
0.005 - 0.017 mm (0.0002 - 0.0007 in) (Standard)
0.023 mm (0.0009 in) (Limit)
If it exceeds the limit, replace connecting
and/or piston set with pin.
rod assembly
Micrometer
SEM903A
REPLACEMENT
OF CONNECTING
ROD
BUSHING
(Small end)
1. Drive in small end bushing until it is flush with end surface
of rod.
Be sure to align the oil holes.
2. After driving in small end bushing, ream the bushing so that
clearance between small end bushing and piston pin is
specified valve.
Clearance between small end bushing and piston pin:
0.005 - 0.017 mm (0.0002 - 0.0007 in)
SEM062A
FLYWHEEL/DRIVE
PLATE RUNOUT
SEM261 C
Dial gauge
Assembly
PISTON
1. Install new snap ring on one side of piston pin hole.
SEM166B
Cylinder number
SEM262C
EM-42
CYLINDER BLOCK
Assembly (Cont'd)
KV10110300
EM156
,'..."
g;r
'
rn::::
SEM264C
Oil ring
expander
..
Front
V-
i?
8 Top ring
.8
~
-""'-.) K'
/"')
-:::
!/
"~
Ojl ring
upper rail
Oil ring
lower rail
SEM 1606
CRANKSHAFT
~~
~ ~~:O.5
50 ~
~
No.3
t2
Front
No.1
No.2
SEM44BC
.
.
.
EM-43
CYLINDER BLOCK
Assembly (Cont'd)
3. Measure crankshaft end play.
Crankshaft end play:
Standard
0.05 - 0.18 mm (0.0020 - 0.0071 in)
Limit
0.3 mm (0.012 in)
If beyond the limit, replace bearing with a new one.
rod caps.
.Referconnecting
Confirm that correct bearings are used.
to "Inspection".
. Install
bearings so that oil hole in connecting
oil hole of bearing.
SEM159B
..
- 0.016
in)
Limit
0.6 mm (0.024 in)
If beyond the limit, replace connecting rod and/or crankshaft.
EM-44
CYLINDER
BLOCK
Assembly (Cont'd)
REPLACING PILOT BUSHING
1. Remove pilot bushing (M/T) or pilot convertor (A/T).
ST16610001
(J23907)
or su itable tool
..
Crankshaft side
M/T
A/T
SEM163.B
EM-45
General Specifications
KA24E
Engine model
4, in-line
Cylinder arrangement
Displacement
Bore x stroke
mm (in)
2,389 (145.78)
89 x 96 (3.50 x 3.78)
Valve arrangement
O.H.C.
Firing order
1-3-4-2
2
1
Oil
Number of main bearings
Compression ratio
9.1
1,324
(13.5,
192) /300
981 (10,142)/300
98 (1.0, 14)/300
EM-46
(S.D.S.)
BLOCK
10
(0.39)
60 (2.36)
120 (4.72)
H
SEM447C
Unit:
Distortion
Inner diameter
Cylinder bore
0.1 (0.004)
Grade 2
Grade 3
0.2 (0.008)*
Out-of-round (X-V)
Taper (A-B)
0.2 (0.008)
0.2 (0.008)**
Piston-to-cylinder clearance
Cylinder block height
(From crankshaft cented
* Wear limit
** Total amount
of cylinder
CYLINDER
HEAD
head resurfacing
and cylinder
Unit:
block
Limit
Height (H)
98.8 - 99.0
(3.890 - 3.898)
0.2 10.008)*
Surface distortion
0.03 (0.0012)
0.1 (0.004)
of cylinder
head resurfacing
and cylinder
resurfacing
mm (in)
Standard
Total amount
resurfacing
Limit
Grade 1
Standard
block
EM-47
mm (in)
VALVE GUIDE
t-
SEM571 B
SEM225C
Unit:
Standard
Service
Limit
Intake
Exhaust
Intake
Exhaust
(L)
52.6 (2.071)
56.0 (2.205)
52.6 (2.071)
56.0 (2.205)
11.023 - 11.034
(0.4340 - 0.4344)
12.023 - 12.034
(0.4733 - 0.4738)
11.223 - 11.234
(0.4418 - 0.4423)
12.223 - 12.234
(0.4812 - 0.4817)
7.000 - 7.018
(0.2756 - 0.2763)
8.000 - 8.Q18
(0.3150 - 0.3157)
7.000 - 7.018
(0.2756 - 0.2763)
8.000 - 8.Q18
(0.3150 - 0.3157)
10.975 - 10.996
(0.4321 - 0.4329)
11.975 - 11.996
(0.4715 - 0.4723)
11.175-11.196
(0.4400 - 0.4408)
12.175 - 12.196
(0.4793 - 0.4802)
Length
Interference fit
Stem to guide clearance
Tapping length (Q)
0.040 - 0.070
(0.0016 - 0.0028)
14.9
0.020 - 0.053
(0.0008 - 0.0209)
EM-48
mm (in)
0.040 - 0.070
(0.0016 - 0.0028)
0.1 (0.004)
Standard
Service
D1
D1
SEM178
SEM177
Unit:
mm (in)
Service
Standard
Intake
Exhaust
Intake
Exhaust
36.000 - 36.016
(1.4173 - 1.4179)
42.000 - 42.016
(1.65:35 - 1.6542)
36.500 - 36.516
(1.4370 - 1.4376)
42.500 - 42.516
(1.6732 - 1.6739)
36.080 - 36.096
(1 .4205 - 1.4211)
42.080 - 42.096
(1.6567 -1.6573)
36.580 - 36.596
(1.4402 - 1.4408)
42.580 - 42.596
(1.6764 - 1.6770)
45
45
45
45
1.7- 2.1
(0.067 - 0.083)
1.6 - 1.7
1.7 - 2.1
1.6 - 1.7
(0.063 - 0.067)
(0.067 - 0.083)
(0.063 - 0.067)
EM-49
VALVE
T (Margin thickness)
----
SEM188A
Standard
Limit
Unit:
mm (in)
In.
34.0-34.2
(1.339- 1.346)
Ex.
40.0 - 40.2
(1.575 - 1.583)
In.
119.9- 120.2
(4.720-4.732)
Ex.
120.67 - 120.97
(4.7508 - 4.7626)
In.
6.965 - 6.980
(0.2742 - 0.2748)
7.948 - 7.960
Valvelength (LI
(0.3129 - 0.3134)
In.
4530'
Ex.
45 30'
In.
1.15 - 1.45
(0.0453 - 0.0571)
Ex.
1.35 - 1.65
(0.0531 - 0.0650)
0.5 (0.020)
VALVE SPRING
Unit:
Standard
Limit
Intake
Exhaust
Intake
Exhaust
Outer
57.44 (2.2614)
53.21 (2.0949)
Inner
53.34 (2.1000)
47.95 (1.8878)
Outer
567.8 (57.9,127.7)
at 37.6 (1.480)
Inner
284.4 (29.0,63.9)
at 32.6 (1.283)
266.8 (27.2,60.0)
at 32.6 (1.283)
Outer
2.5 (0.098)
2.3 (0.091)
Inner
2.3 (0.091)
2.1 (0.083)
Pressu re
N (kg,lb)
at height
Out-of-square
mm (in)
EM-50
..
;#
. DC
EM120
SEM568A
Unit:
Standard
limit
10.4 (0.409)
0.2 (0.008)
0.12 (0.0047)
0 -0.02 (0 -0.0008)
Camshaft f1Inout
0.2 (0.008)
248
240
57
12
56
0.012 - 0.050
(0.0005 - 0.0020)
21.979 - 22.000
(0.8653 - 0.8661)
22.012 - 22.029
(0.8666 - 0.8673)
EM-51
mm (in)
Pistonring
Unit: mm (in)
=::::::::::::=
Standard
limit
Top
0.040 - 0.080
(0.0016 - 0.0031)
0.1 (0.004)
2nd
0.030
(0.0012
Oil
0.065 - 0.135
(0.0026
0.0053)
d
Side
clearance
0.28 - 0.43
Unit:
Standard
Piston skirt
diameter (A)
Service
(Oversize)
Dimension (a)
Piston pin hole diameter
(d)
Piston-to-c:ylinderbore
clearance/'
0.45 - 0.60
10.0177 - 0.0236)*1
0.55 -0.70
10.0217 0.0276)*2
88.970 - 88.980
(3.5027 - 3.5031)
Grade
No.2
88.980 - 88.990
(3.5031 - 3.5035)
Grade
No.3
88.990 89.000
(3.5035 - 3.5039)
0.5
(0.020)
89.470 - 89.500
(3.5224 - 3.5236)
1.0
(0.039)
89.970 - 90.000
(3.5421 - 3.5433)
0.1 (0.004)
0.1 (0.004)
0.5 (0.020)
0.5 10.020)
mm (in)
Grade
No.1
- 0.0169)
(0.0110
2nd
Ring gap
-0.0028)
-
Top
SEM444C
- 0.070
0.20 - 0.60
Oil
Irail ring)
- 0.0236)
(0.0079
0.5 (0.020)
CONNECTING
ROD
Approximately 52 (2.05)
20.987 - 20.999(0.8263- 0.8267)
Piston pin
Unit: mm (in)
Standard
limit
20.989- 21.001
(0.8263.0.8268)
0 - 0.004
(0 - 0.0002)
0.005 0.017
(0.0002 0.0007)
=::::::::::::=
Standard
limit
164.95 - 165.05
16.4941 - 6.4980)
Bend
[per 100 mm (3.94 in)]
0.1510.0059)
Torsion
0.3 (0.012)
21.000 - 21.012
mm (in)
10.8268
- 0.8272)
53.000
12.0866
- 53.013
- 2.0871)
Side clearance
* Without
EM-52
bearing
0.2 -0.4
10.008 - 0.016)
0.6 10.024)
(S.D.S.)
CRANKSHAFT
@- Ci)
Out-of-round
Taper@ .@
~.
\J57
Om
EM715
Op
SEM394
Unit: mm (in)
Grade
Grade
No.O
No.1
No.2
No.O
No.1
No.2
Standard
Limit
Journal
0.01 (0.0004)
Pin
0.005 (0.0002)
Journal
0.01 (0.0004)
Pin
0.005 (0.0002)
0.10 (0.0039)
0.3 (0.012)
Total
reading
mm (in)
Standard
limit
0.020 - 0.047
(0.0008 - 0.0019)
0.1 (0.004)
0.010 - 0.035
(0.0004 - 0.0014)
0.09 (0.0035)
EM-53
Standard
Standard
Grade
number
Thickness
mm (in)
Identification
color
Grade
number
Thickness
mm (in)
1.821 - 1.825
10.0717 - 0.0719)
Black
1 .505 - 1.508
(0.0593 - 0.0594)
1.825 - 1 .829
10.0719 - 0.0720)
Brown
1.829 - 1 .833
10.0720 - 0.0722)
Green
1.833 - 1.837
10.0722 - 0.0723)
Yellow
1.837 - 1.841
10.0723 - 0.0725)
Blue
1.508 - 1.511
(0.0594 - 0.0595)
Brown
1.511 - 1.514
10.0595 - 0.0596)
Green
Undersize (service)
Unit: mm (in)
Thickness
Undersize
(service)
Unit: mm (in)
Thickness
0.25
10.0098)
1.952 - 1.960
10.0769- 0.0772)
Identification
color
Mein journal
diameter "Dm"
0.08
10.0031 )
1.540 - 1.548
(0.0606 - 0.0609)
0.12
(0.0047)
1.560 - 1 .568
10.0614 - 0.0617)
0.25
10.0098)
1.625 - 1.633
10.0640 - 0.0643)
MISCELLANEOUS
COMPONENTS
Unit: mm (in)
Flywheel runout
[T.I.R.]
[T.I.R.]
* Total indicator
EM-54
reading
ENGINELUBRICATION
&
COOLING
SYSTEMS
I
LC
SECTION
CONTENTS
...
PREPARATION
;.....
ENGINElUBRICATIONSYSTEM "
ENGINE COOLING SYSTEM
."..
""''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''"""''''''''''''''''''''''''''''''''
''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''
""
lC- 2
,.. lC- 3
lC-
lC-12
lC-16
PREPARATION
SPECIAL SERVICE TOOLS
Tool number
(Kent-Moore No.)
Tool name
ST25051 001
(J25695-1 )
Oil pressure gauge
ST25052000
(J25695-2)
Hose
EG17650301
(
Description
U!!
[j
LC-2
+-
Oil gallery in
cylinder block
-..-
By-passpassage
----
Intermittently
oiling portion
<i=
0 iI passage
-- ---
--
----------
r0-
OI
W
Hydraulic
valve lifter
I
'"
r
(')
co
I\)
:r>
Cam ;Urlace
I
.
.
Engine rpm
Idle speed
3,000
SLC926
LC-4
~tOJ
6. 10 (0.6 - 1.0,4.3.7.2)
--.::>/pump
body
Gasket
tOJ:
iT.
~~1~
Punch-
~AU)
mark
Oil
hole
Front
~~"4A
REGULATOR
VALVE INSPECTION
EL076
LC-5
CD
Unit: mm (in)
Rotor
tip clearance CD
SLC732
LC-6
Thermostat:
Open
Thermostat:
Closed
Radiator
Thermostat
SLC186A
System Check
WARNING:
Never remove the radiator cap when the engine is hot;
serious burns could be caused by high pressure fluid escaping from the radiator.
Wrap a thick cloth around cap and carefully remove the cap
by turning it a quarter turn to allow built-up pressure to
escape and then turn the cap all the way off.
CHECKING
COOLING
SYSTEM HOSES
LC-7
CHECKING RADIATORCAP
To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
78
SLC613
Water Pump
~
::~~~.~.~.m~
12'~'
\
~',P/
)!!7
.
SLC187A
INSPECTION
Check for excessive end play and rough operation.
(f
SLC738
INSTAllATION
Remove liquid gasket from mating surface of pump housing
using a scraper.
.
..
SLC188A
LC-8
.
.
Cut here.
KP510-00150
SLC822
in)
SLC189A
Thermostat
INSPECTION
1. Check for valve seating condition at ordinary temperatures.
It should sea.ttightly.
Water inlet
SLC192A
Upward
Jiggle valve
~~
A~
--~
76.5 (170)
8/90 (0.31/194)
.
SLC097
temperature.
SLC343
LC-9
(Cont'd)
INSTAllATION
.
.
.
.
SLC790
Cut here.
KP510.()0150
]
SLC822
SLC824
'(
.~
LC -1 0
Radiator
A/T model only
~3 2 -4.2
10.33-0.43,
2.4-3.1)
7~
Automatic
transmission
@I
'~
~~3.2
-4.2
. ,""lIlY
10.33-0.43,2.4 -3.1)
LJ
~:
Radiator shroud
N-mIkg-m,ft-lb)
SLC190A
CAUTION:
When filling radiator with coolant, refer to MA section.
Cooling Fan
DISASSEMBLY AND ASSEMBLY
-~
'\"
<1( L-.J
~:
Fan
N'm (lrg-m;ft-Ibl
\~ ~o.~~1.0,4.3-7.2)
SLC558
INSPECTION
Check fan coupling for rough operation, oil leakage or bent
bimetal.
SLC072
LC-11
BATTERY
fus Ib I e
I GNI TI ON SWITCH
ACC or- ON
I GNITI ON SWITCH
ON or- START
FUSE
AIR
@D~
CONDI TI ON
RELAY
36
r(")
t'1
P
P
11
!fI
41
n
a
z
-I
::0
a
r
c
z
....
-I
I
~
THERMOSWITCH
To ther-mo
contro
I amp.
M
41
-=
36
0
!II
r
0
I\,)
w
m
@4Ib
CONDENSER
FAN MOTOR
=
(Sub-h arness)
~
-
CONNECTOR-ll
CONDENSER
F AN
MOTOR
@)
~ mIi]
Ie
lR;l ~
't1H
Ilnk-
Ii [!t
L/OR
~::;CD
~13Id
~
[!t
S.
M.
[Refer to
(Fo Idout
y..>r;;;,
<ff~
~ "
Ii]
CONNECTOR-I
Green)
(Eng i ne
harness)
L/OR
room
~CD
'"
J.
L/OR
@)
FUSE BLOCK
(Refer
to pPOWER
SUPPL Y ROUTINGp
In EL section.)
last
page
page). J
UP
(Main
harness)
>-
CD
lBIB@
[EttBr;;--,
~
(E. F. I.
harness)
@l@)
1i
r--
>-
'" '"
,
'"
,
IGNITION
ON or
,,
CD...)
, ,
...
To thermo
SWITCH
START
contro
I amp.
'"...
BODY GROUND
E. ~ ~ S
(Refer to
CONTROL UNIT
EF&EC sect Ion. )
SLC238A
LC-13
SLC191A
@i5
00
'+
L:::
000
-=
SLC239A
_MEeT
Iu
@i5
[]I]
SLC241A
N.G.
lu
SLC242A
i5
O.K.
@is
N.G.
L--to
@is
CHECK RELAY.
Refer to HA section.
O.K.
E
N.G.
r Replace relay.
LC-14
-=
SLC243A
EB
terminal.
8 "G" fusible link
If N.G. replace them.
O.K.
00
00
O.K.
CHECK THERMOSWITCH.
Check continuity between
thermoswitch terminals @ and
CD.
Condition
ContinuitY
Above
Yes
92 -98C (198 -2OSF)
Below
No
92 -98C (198 -2OSF)
iii
DISCONNECT
Ii]
lo.K.
'
Ii
[!]
Ii
SLC240A
N.G.
iJ
Ii]
O.K.
[ill
[!]
terminal
8 Fuse
8 Ignition switch
EB
iii
34
i5l
0
-=
SLC244A
[it
lOK
CHECK HARNESS
CONTINUITY,
1) Turn ignition switch "OFF",
2) Check continuity between
relay harness connector
terminal @ and fan motor
harness connector-I terminal
@.
Continuity should exist.
N.G.
[R]
~i5@
SLC245A
"-
LC-15
Unit:
Engine rpm
Idle speed
412.481 (4.2.4.9,60
3.000
- 70)
mm (in)
Radiator
mmfc
c (OF)
76.5 (170)
(infF)
8/90 (0.31/194)
lC-16
78
.psi)
/"
ENGINEFUEL&
EMISSION
-CONTROL
SYSTEM
SECTIONEF
&
EC
CONTENTS
PREPARATION
PRECAUTIONS """""""""""""""'"''''''''''''''''''''''''''''''''''''
EF & EC-
EF & EC-
EF & EC-
EF & EC- 16
EF & EC- 26
TROUBLE DIAGNOSES
EF & EC- 31
EF & EC-153
EF & EC-155
EF & EC-157
EF & EC-158
PREPARATION
SPECIAL SERVICE TOOL
Tool number
(Kent-Moore No.)
Tool name
EG11160000
(
Description
EF & EC-2
Measuring
engine speed
PRECAUTIONS
E.C.U.
Do not disassemble E.C.C.S.
control unit. (E.C.U.)
Do not turn diagnosis mode
selector forcibly.
.
.
.
.
BATTERY
. Always use a 12 volt battery as
a power source.
WIRELESS EQUIPMENT
When installing a C.B. ham
radio or a mobile phone, be
sure to observe the following,
as installation location may affect the electronic control systems.
1) Keep antenna as far as possible away from electronic control units.
2) Keep antenna feeder line more
than 20 cm (7.9 in) away from
harness of electronic controls.
Do not let them run parallel for
a long distance.
3) Adjust antenna and feeder line
so that standing-wave ratio can
be kept smaller.
4) Be sure to ground radio to vehicle body.
INJECTOR
Do not disconnect injector har~
ness connectors with engine
running.
Do not apply battery power directly to injectors; otherwise
injectors will be damaged.
Do not disconnectbattery
FUEL PUMP
Do not operate fuel pump
when there is no fuel in lines.
Do not reuse fuel hose clamps.
Tighten fuel hose clamps to
the specified torque.
.
..
.
.
.
~~
WHEN STARTING
Do not depress accelerator
pedal when starting.
Immediately after starting, do
not rev up engine unnecessarily.
.
Do not rev up engine just prior
to shutdown.
.
.
SEF121H
EF & EC-3
.
.
.
E.C.C.S.relay
. Fuelpumprelay
Fuel pump
Pressure regulator
~~b
Pressure
regu lator control
solenoid valve
LA.A. unit
S.C.V.control
~'iWIW
~.~,
Fuel filter
e
A'I'V'
~
~
"
control
solenoid
valve
0
a
~~
G
E. .R . control
solenoid valve
Distributor
-.w~
..f ~~;:~~
sensor
~.,~.
~"
A;,flowm.'"
Exhaust gas
sensor
SEF122H
EF & EC-4
E.G.R. control
Exhaust gas temperature sensor I.
(For California model)
\
solenoid valve7
"\
Ignition
switch
Throttle
valve
.sensol
7
: -'r---~-L-
"TI
J20
m
(")
I
C1I
lFuel pressure
regulator
I'.
!..
Engine
temperatu re
sensor
Transmission
lSJ
\'1'
\.Spark
C.
Vehicle
speed sensor
plug
\1
'11
Carbon
canister
Exhaust
gas sensor
A.I.V. control
solenoid valve
A.I.V.
Q:
en
m
-'"
"TI
w
:I
...:
Exhaustgasflow
Air flow me
Crankanglesensor
.1
I
Ignition switch
Starter switch
Idle switch
Throttle sensor
Power transistor
A.I.V. control
.
.
.
"
Injectors
E.C.C.S.
control
unit
,"
Fuel pump
.~
Air regulator control
Air regulator
Acceleration cut
control
S.C.V. control
solenoid valve
Inspection lamps
(On the control unit)
Battery
Fail-safe function
. Air flowmeter
. Throttle sensor
. Enginetemperaturesensor
EF & EC-6
@
-@-a
@-b
E.G.R. control
valve
~TWI~
@
Air regurator
tJi)
@ ./"'1
Canister
@/
1
Vacuum tubes-1
Air duct
SEF355H
EF 8r. EC- 7
I GNITION SWITCH
OFFACCON ST
FUSIBLE
LINK
-c8J-
CK
Ij/]
(
(
'-:::./
CHECK
FUSE
J-----rs}
r<:::"7I
46
NJ. NlOR
E. C. C. S.
RELAY
<t
No.2
No.3
BA TTERY
34 382336
10 I
=
=
103
AI R FLOW
r --------1
-------T
I
I
>--
gAUST
To tachometer
SENSOR
::-
."
mm-
I "-------1
f20
RESISTOR
TRANSISTOR
{O
(")
PDWER
DISTRIBUTOR
rm
J>r
-<
"U
:[
c :]
L.:::T
AIR
108--<
>J
>J
116 --<
en
45
("")
0
43
Z
-i
;0
0
r
c
Z
....
-i
CONDENSER
co- co-
co- co-
ANGLE
SENSOR
SPARK PLUG
For
tt
11
Cal ifornla
REGULATOR
PUMP
::-
--
A/T
model
For
@:
M/T model
@:
For
5TH POSITION
SWITCH
(/)
m
"
w
0.....
:x:
With
Without
heaa-up
display
SWITCH
-v<::,...FULL
'Q
NEUTR
' SWITC
35
41
II
ENGINE
TEMPERATURE
3D
31
18
22
4D
SENSOR
EXHAUS T GAS
37
Canada
32
lIS
SENSOR
C
TEMPERA@URE
-n ------__n_--_n_n--_--_--_----
.HEAD-U
DISPLA
UNIT
THROTTLE
SENSOR
CONT
(
MJ
1 I I
r---
28
A/T
UNIT
CONTR&L
display
head-up
VALVE
IDLE
THROTTLE
POWER
STEERING
OIL PRESSURE
33
U. S. A.
A.S. C.D.
-=
44
I NHIB
RELA
2D
:
I NHI B
RELAY
r-=
VALVE
FUELL..:....J
[Tl
CRANK
!:
...----J
SWITCH
I NHI BIT
29
co-
lIB;
L..::..:J
21--
::I
"U
L..::J
107
13
L::...J
A. A. C.
113
104
I GNITI ON COIL
co
VALVE
S. C. V. CONTROL
SOLENOID VALVE
12
16
17
39
48
19
SOLENOID
A. 1. V. CONTROL
SOLENOID VALVE
109
METER
REGULATOR
E. G. R. CONTROL
SOLENOID VALVE
102
4
47
PRESSURE
CONTROL
IDS
112
::-
LI
GHT C
ENGINE@
5
24
25
106
110
No. 4r:::=
L....:-
CONNECTOR
'--
SENSOR
Photo
diode
Wave
forming
SEF613B
circuit
Rotor
plate
SEF853B
Rotor plate
A
Air flow
meter
B
c
Battery
sou rce
Output voltage
Ground
16
E.C.C.S.
17 control
unit
109
SEF285H
Temperature
compensation
resistor
.. r-f
The air flow meter measures the mass flow rate of intake air.
Measurements are made so that the control circuit will emit an
electrical output signal corresponding to the amount of heat
dissipated from a hot wire placed in the stream of intake air.
The airflow past the hot wire removes the heat from the hot
wire. The temperature of the hot wire is very sensitive to the
mass flow rate. The higher the temperature of the hot wire, the
greater its resistance value. This temperature change (resistance) is determined by the mass air flow rate. The control
circuit accurately regulates current (I) in relation to the varying
resistance value (RH) so that VA always equals VB. The air flow
meter transmits a voltage value VA to the control unit where the
output is converted into an intake air signal.
RH;:~-Hotwire
RH
RK
RA. RB
EF & EC-9
SEF903D
>
Not used
.,---0'---
~
~
(Full throttle
~:50
Idle
switch
Throttle
sensor
. 4.0
switch)
2
3 )
Supply voltage:
5V (Applied between
terminal
NO.4 and 6)
6.0
Output voltage between
terminal NO.4 and 5
~
~
'"
!'"
-0
6}
f2.0
~
5
g
...
"
9"
0
45
90
Throttle valve opening angle (deg)
135
SEF287D
Fuel Injector
The fuel injector is a small, elaborate solenoid valve. As the
E.C.U. sends injection signals to the injector, the coil in the
injector pulls the needle valve back and fuel is released ,into the
intake manifold through the nozzle. The injected fuel is controlled by the E.C.U. in terms of injection pulse duration.
Brass wire is used in the injector coil and thus the resistance is
higher than a conventional injector.
SEF359H
EF &. EC-10
Pressure Regulator
0 vacuum
Intake manifold
Air chamber
Fuel chamber
Fuel return
from injector
To
fuel tank Q
SEF6058
Connector
Holder
Isolation bushing
Contact plate
SEC336A
?:
;;
'"
0>
~0
>
...
:J
C.
8 0I
Rich
---
~
I
Ideal ratio
--Lean
Mixture ratio
SEF288D
Fuel Pump
Outlet
0
Fuel damper
Motor
1)
Inlet
SEF043C
Power Transistor
The ignition signal from the E.C.U. is amplified by the power
transistor, which turns the ignition coil primary circuit on and off,
inducing the proper high voltage in the secondary circuit. The
ignition coil is a small, molded type.
SEF125H
EF & EC-11
Idle
adjusting
screw
SEF126H
Air
SEF040E
SEF286H
Magnetic
\ /'
line
Reed
Reed
~SWitch
N S
(sS
I
G:0
Fieldplate
M;;Qnetic
I.me I\
//
"{
N) switch
t;\
y-/
Fieldplate
SEF624B
EF & EC-12
SEF632B
B.P.T. Valve
To E.G.A.
control valve
Air
filter
".'.1'
~~~'ff'
t
Exhaust pressure
EC344A
EF & EC-13
\.
The E.G.R. system is controlled only by the E.C.U. At both lowand high-speed engine revolutions, the solenoid valve turns on
and accordingly the E.G.R. valve cuts the exhaust gas leading
to the intake manifold.
vacuum signal.
Fuel Filter
The specially designed fuel filter has a metal case in order to
withstand high fuel pressure.
SEF256A
Carbon Canister
The carbon canister is filled with active charcoal to absorb
evaporative gases produc~d in Jhe fuel tank. These absorbed
gases are then delivered to the intake manifold by ,manifold
vacuum for combustion purposes.
The vacuum in the intake passage upstream of the throttle valve
increases in response to the amount of the intake air.
When the vacuum of the intake passage is higher than a preset
value, the 2nd purge control valve opens and the absorbed
gases are sucked into the intake passage for combustion
purposes.
EF & EC-14
box.
SEF296H
SEF072G
\.
EF &. EC-15
Engine temperature
Engine temperature
sensor
Density of oxygen in exhaust gas
Throttle
sensor
Idle switch
E.C.C.S.
control
unit
Injector
Gear position
Vehicle speed
Vehicle speed sensor
Ignition switch
Start signal
Battery voltage
Battery
CONTROL
The amount of fuel injected from the fuel injector, or the length
of time the valve remains open, is determined by the E.C.U. The
basic amount of fuel injected is a programmable value mapped
in the E.C.U. ROM memory. In other words, the programmable
value is preset by engine operating conditions determined by
input signals (for engine rpm and air intake) from both the crank
angle sensor and the air flow meter.
~i
Low
Water temperature
High
SEF923C
EF & EC-16
FeedAgnal
Exhaust
~
E.C:C.S.'
control
~nit
/ .
ection pulse
InJ
(gas
sensor) t\
combusti~
Injector
injection
SEF639B
CONTROL
fL
Injection pulse
rL
No.2 cylinder
No.3 cylinder
No.4 cylinder
1---1
SEF976E
enginecycle--j
No.1 cylinderJl
No.2 cylinder.Jl
No.3 cylinder.Jl
1L1LfL-
.
No. 4 cyIInd er J1
f"L-
Fuel is injected once a cycle for each cylinder in the firing order.
1 engine cycle
SEF841D
EF & EC-17
Enginetemperature sensor
Idle switch
Throttle sensor
E.C.C.S.
control
unit
Neutral position
Start signal
Ignition switch
,
E.
EF & EC-18
Power transistor
In addition to this,
1 At starting
2 During warm-up
3 At idle
4 At low battery voltage
5 During swirl control valve operates
6 Hot engine operation
7 At acceleration
the ignition timing is revised by the E.C.U. according to the other data stored in the ROM.
Tp
(msec)
I
1.75I
1.50I
Injection
pulse
width
1.25 I
1.00 I
0.75 I
---
600
- ---
1,000
-1,400
---
1,800
N
2,200
EF & EC-19
Enginetemperature sensor
1
I
Ignition switch
Engine temperature
Start signal
Idle switch
I
.1
Inhibitorswitch
switch(M/T)
(A/T)
Neutral
1 Neutral
I
A.A.C. valve
Powersteeringoil pressureswitchI
.
Battery voltage
Battery
E.C.C.S.
control
unit
position
1I
Vehicle speed
SYSTEM DESCRIPTION
This system automatically controls engine idle
speed to a specified level. Idle speed is controlled
through fine adjustment of the amount of air
which by-passes the throttle valve via AAC. valve.
The A.AC. valve repeats ON/OFF operation at a
rate of 100 to 200 Hz according to the signal sent
from the E.C.U. The crank angle sensor detects
the actual engine speed and sends a signal to the
EF & EC-20
Engine speed
E.C.C.S.
control
unit
Start signal
SYSTEM DESCRIPTION
Condition
Stops in 1 second
Stops
E.C.C.S.
control
unit
SYSTEM DESCRIPTION
Condition
EF
Air regulator
Air regulator
operation
Operates for
5 seconds
Operates
OFF in 1 second
OFF
8r. EC-21
E.C.C.S.
control
unit
Engine speed
Crank angle sensor
A.LV. control
solenoid valve
Vehicle speed
SYSTEM DESCRIPTION
The air induction system is designed to send
secondary air to the exhaust manifold, utilizing the
vacuum caused by exhaust pulsation in the exhaust manifold.
The exhaust pressure in the exhaust manifold
usually pulsates in response to the opening and
closing of the exhaust valve and decreases below
atmospheric pressure periodically.
If a secondary air intake pipe is opened to the
atmosphere under vacuum conditions, secondary
Enginecondition
Water temperature
c (oF)
Idle or deceleration
ON
Operates
EF
8r.
EC-22
-.
1
I
Enginetemperature sensor
Engine temperature
..,..
Start signal
Ignition switch
I
DESCRIPTION
In addition, a system is provided which precisely
cuts and controls port vacuum applied to the
E.G.R. valve to suit engine operating conditions.
This cut-and-control operation is accomplished
through the E.C.U. When the E.C.U. detects any of
the following conditions, current flows through the
solenoid valve in the E.G.R. control vacuum line.
E.C.C.S.
E.G.R. control
solenoid valve
control
unit
SYSTEM
Condition
When starting
Below 60 (140)
Water temperature
ON
c (oF)
Above 105 (221)
Other conditions
Above 60 (140)
Below 105 (221)
Exhaust gas
pressure
Operation
High
Closed
Throttle position
E.G.R. control
solenoid valve
E.G.R. system
Partially open
OFF
Operates
EF & EC-23
SIGNAL LINE
Engine temperature
E.C.C.S.
Start signal
Ignition switch
P.R. control
solenoid valve
control
unit
Engine speed
Crank angle sensor
SYSTEM DESCRIPTION
The fuel "pressure-up" control system briefly increases fuel pressure for improved starting performance of a hot engine. Under normal operating
conditions, manifold vacuum is applied to the fuel
pressure regulator. When starting the engine,
however, the E.C.U. allows current to flow through
the ON/OFF solenoid valve in the control vacuum
line, opening this line to the atmosphere. As a
result, atmospheric pressure is applied, throttling
the fuel passage to increase fuel pressure.
START
Ignition
switch
OFF
P.R.control
OFF
ON
solenoid
valve
ON
.. Approx. 3 min
SEF741B
0<'
-r,
Idle signal
Start signal
Ignition switch
Engine speed
Enginetemperature sensor
E.C.C.S.
control
unit
S.C.V. control
solenoid valve
Engine temperature
SYSTEM DESCRIPTION
This system has a swirl control valve (S.C.V.) in
the intake passage of each cylinder.
While idling the S.C.V. closes. Thus the velocity of
the air in the intake passage increases, promoting
the vaporization of the fuel and producing a swirl
in the combustion chamber.
Because of this operation, this system tends to
increase the burning speed of the gas mixture,
Idle switch
Water temperature
Engine rpm
Solenoid valve
S.C.V.
ON
Below 1,400
ON
Close
OFF
Open
Except above
EF & EC-24
Cut Control
E.C.C.S.
control
unit
Air conditioner
relay
SYSTEM DESCRIPTION
When accelerator pedal is fully depressed, air
conditioner is turned off for a few seconds.
This system improves acceleration when air conditioner is used.
Fail-safe System
AIR FLOW METER MALFUNCTION
If the air flow meter output voltage is above or
below the specified value, the E.C.U. senses an air
flow meter malfunction. In case of a malfunction,
the throttle sensor substitutes for the air flow
meter.
Though air flow meter is malfunctioning, it is
possible to drive the vehicle and start the engine.
But engine speed will not rise more than 2,400
rpm in order to inform the driver of fail-safe
system operation while driving.
Operation
System
E.G.R. control system
Fixed condition
ENGINE TEMPERATURE
MALFUNCTION
20C (68F)
80C (176F)
OFF
A duty ratio is fixed at
the preprogrammed value.
Fuel is shut off above
THROTTLE
2,400 rpm.
(Engine speed does not
exceed 2,400 rpm.)
Engine
temperature decided
SENSOR
SENSOR
MALFUNCTION
EF & EC-25
.
.
..
parts are in
Battery
Ignition system
.
Engine oil and coolant levels
Fuses
. E.C.U.harnessconnector
. Vacuumhoses
. Air intakesystem
(Oil filler cap, oil level gauge, etc.)
Fuel pressure
..
A.I.V. hose
.
.
Engine compression
E.G.R. control valve operation
Overall inspection
sequence
INSPECTION START
N.G.
Perform self-diagnosis.
Repair or replace.
/
O.K.
N.G.
N.G.
O.K.
O.K.
N.G.
I Repair or replace harness.
O.K.
Check base idle CO.
N.G.
O.K.
Replace exhaust gas sensor.
INSPECTION END
EF & EC-26
INSPECTION START
. Gaskets
SEF457C
2 ,~,,\""\""L"""):
"'~
1{
0;
.1OOO,/m,"
...'.6
"!:-\
~1
f
-8
I
O.K.
SEF477B
I
Check and clean injectors, and replace injectors if
necessary.
N.G.
N.G.
O.K.
EF & EC-27
IDLE SPEED/IGNITION
TIMING/IDLE
N.G.
Adjust ignition timing by turning distributor
after loosening bolt which secures distributor.
1S:t2 B.T.D.C.
3
4
2 '*"""~"""'" 5
'~"-.(6
~
1'1'
0=
,'000""';"
~7
1.8I
SEF477B
~r\
~V~~J
~/~
SEF450H
~r\
~V ~~/-i~/
'--'~Jf))
,
@
r,'
iDIY
'
"-'"
No
INSPECTION END
J~
SEF292H
D'
EF &. EC-28
C'
~~'!
E.C.C.S. harness
19
nl'-'~'
SEF353H
~i
Continuity exists.
Continuity does not exist """"""'''''''''
N.G.
O.K.
O.K.
N.G.
Start engine and warm it up until water temperature indicator points to the middle of gauge.
(Wait more than 5 minutes after starting.)
Race engine two or three times under no-load then
run engine at idle speed.
O.K.
EF & EC-29
G'
N.G. Run engine at 2,000 rpm and make sure that green
inspection lamp on E.C.U.goes ON and OFF more
than 5 times during 10 seconds.
. O.K.
Check injector.
(See page EF & EC-126.)
Clean or replace if necessary.
EF & EC-30
TROUBLE DIAGNOSES
Contents
How to PerformTrouble Diagnosesfor Quick and Accurate Repair
EF & EC- 33
"
Diagnostic Table
EF & EC- 37
1. Impossible to start
no combustion
EF & EC- 38
2. Impossible to start
3. Impossible to start
4. Impossible to start
EF & EC- 39
EF & EC- 40
5. Hard to start
6. Hard to start
7. Hard to start
8. Hard to start
9. Abnormal idling
10. Abnormal idling
11. Abnormal idling
12. Unstable idling
13. Unstable idling
14. Poor driveability
15. Poor driveability
16. Poor driveability
17. Poor driveability
18. Engine stall
19. Engine stall
20. Engine stall
21. Engine stall
22. Engine" stall
23. Engine stall
24. Backfire
25. Backfire
partial combustion
partial combustion (not affected by throttle position)
partial combustion (throttle position changes
combustion quality)
before warm-up
after warm-up
every time
morning after a rainy day
no fast idle
low idle (after warm-up)
high idle (after warm-up)
before warm-up
after warm-up
stumble (while accelerating)
surge (while cruising)
lack of power
detonation
during start-up
while idling
while accelerating
while cruising
while decelerating/just after stopping
"
while loading (power steering, air conditioner,
headlamps, etc.)
through the intake
through the exhaust
Self-diagnosis-
Description
EF & EC- 60
EF & EC- 61
EF & EC- 62
.."..
EF & EC- 63
EF
EF
EF
EF
EF
EF
"
"
"
&
&
&
&
&
&
ECECECECECEC-
67
67
68
74
76
82
EF & EC- 84
EF & EC- 86
~
~
EF & EC- 88
EF & EC- 90
~
~ E.G.R. FUNCTION
Diagnostic Procedure 9
~ EXHAUST GAS SENSOR
Diagnostic Procedure 10
~ EXHAUST GAS TEMPERATURE
EF & EC- 41
EF & EC- 42
EF & EC- 43
EF & EC- 44
EF & EC- 45
EF & EC- 46
EF & EC- 47
EF & EC- 48
EF & EC- 49
EF & EC- 50
EF & EC- 51
EF & EC- 52
EF & EC- 53
EF & EC- 54
EF & EC- 55
EF & EC- 56
EF & EC- 57
EF & EC- 58
EF & EC- 59
EF & EC- 92
EF & EC- 94
EF & EC~ 98
"
EF & EC-100
EF & EC-104
SENSOR
EF & EC-31
EF & EC-106
TROUBLE DIAGNOSES
Contents (Cont'd)
Diagnostic Procedure 11
THROTTLE SENSOR
~
~
EF & EC-110
DiagnosticProcedure12
INJECTOR LEAK
Switch ON/OFF diagnostic item
Diagnostic Procedure 13
IDLE SWITCH
Diagnostic Procedure 14
START SWITCH
Not self-diagnostic item
Diagnostic Procedure 15
FUEL PUMP
Diagnostic Procedure 16
PRESSURE REGULATOR (P.R.) CONTROL SOLENOID VALVE
Diagnostic Procedure 17
INJECTORS
Diagnostic Procedure 18
SWIRL CONTROL VALVE (S.C.v.) CONTROL SOLENOID VALVE
Diagnostic Procedure 19
AIR REGULATOR
Diagnostic Procedure 20
AUXILIARY AIR CONTROL (A.A.C.) VALVE
"
Diagnostic Procedure 21
LA.A. CONTROL (F.LC.D. CONTROL)
Diagnostic Procedure 22
AIR INDUCTION VALVE (A.LV.) CONTROL SOLENOID VALVE
DiagnosticProcedure23
.
NEUTRALSWITCH,INHIBITORSWITCHAND INHIBITORRELAY
Electrical Components Inspection
EF & EC-114
EF & EC-116
EF & EC-118
EF & EC-120
EF & EC-124
EF & EC-126
EF & EC-128
EF & EC-130
EF & EC-134
EF & EC-136
EF & EC-138
;
EF & EC-140
EF & EC-142
EF 8r. 'EC-32
TROUBLE DIAGNOSES
~ .~.~
:A
~wol """
~~
SEF232G
INTRODUCTION
The engine has an electronic control unit to control major systems such as fuel control, ignition control, idle speed control,
etc. The control unit accepts input signals from sensors and
instantly drives actuators. It is essential that both kinds of signals
are proper and stable. At the same time, it is important that
there are no conventional problems such as vacuum leaks, fouled
spark plugs, or other problems with the engine.
It is much more difficult to diagnose a problem that occurs
intermittently
rather than continuously. Most intermittent
problems are caused by poor electric connections or faulty
wiring. In this case, careful checking of suspicious circuits may
help prevent the replacement of good parts.
A visual check only may not find the cause of the problems.
A road test with a circuit tester connected to a suspected circuit
shou Id be performed.
Before undertaking actual checks, take just a few minutes to
talk with a customer who approaches with a driveability complaint. The customer is a very good supplier of information on
such problems, especially intermittent ones. Through the talks
with the customer, find out what sy.mptoms are present and
under what conditions they occur.
Start your diagnosis by looking for "conventional" problems
first. This is one of the best ways to troubleshoot driveability
problems on an electronically controlled engine vehicle.
SE F234G
EF & EC-33
TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)
WORK FLOW
CHECK
STEP 1
SERVICE MANUAL
REFERENCE ITEMS& PAGES
IN
------
LISTEN TO CUSTOMERCOMPLAINTS
DIAGNOSTIC WORKSHEET
EF & EC-35
------
STEP 2
Can be
performed
<'
<
---
Self-diagnosis
EF & EC-63
Diagnostic Procedure
EF & EC-84
No
DUPLICATIONOF
OPERATING CONDITIONS
THAT LEAD TO MALFUNCTION
STEP 3
STEP 4
STEP 5
STEP 6
STEP 7
INTERMITTENT
SIMULATION
EF & EC-36
<
r.
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
J
I
REPAIR/REPLACE
:N.G.
I
L
FINAL CHECK
O.K.
CHECK OUT
EF & EC-34
-------
PROBLEM
~~~~~~;able
Diagnostic Procedure
EF & EC-86
TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)
KEY POINTS
WHAT
WHEN
WHERE
HOW
Operating conditions,
Weather conditions,
Symptoms
DIAGNOSTIC WORKSHEET
There are many kinds of operating conditions that lead to malfunctions on engine components.
A good grasp of such conditions can make trouble-shooting faster
and more accurate.
In general, feelings for a problem depend on each customer. It is
important to fully understand the symptoms or under what conditions a customer complains..
Make good use of a diagnostic worksheet such as the one shown
below in order to utilize all the complaints for trouble-shooting.
Worksheet sample
Customer name
MR/MS
VIN
Engine #
Trans.
Mileage
Incident Date
Manuf. Date
In Service Date
0 Startability
0 No combustion
0 Partial combustion
0 Impossible to start
0 Partial combustion affected by throttle position
0 Partial combustion NOT affected by throttle position
0 Possible but hard to start
0 Othl!rs [
0 Idling
0 No fast id Ie
0 Others [
0 Driveability
0 Stumble
0
0 Intake backfire
0 Others [
0 Detonation
Surge
0 Exhaust backfire
Symptoms
0 Engine stall
Frequency
Weather conditions
0 Not effected
Weather
0 Fine
Temperature
0 Hot
0 Cold
0 In town
Driving conditions
0
0
0
0
Lack of power
While idling
While decelerating
0
0
0
0
2,000
Others [
Cold
Highway
20
Not turned on
EF & EC-35
Humid
30
40
of
I
J
8,000 rpm
While idling
0 At racing
0 While cruising
0 While turning (RH/LH)
10
Sometimes
After warm-up
I
I
I
4,000
6,000
In suburbs
Snowing
Cool
'
In the daytime
During warm-up
Not affected
At starting
0
While accelerating
While decelerating
0 Turned on
Low idle
0 - While loading
Raining
Vehicle speed
High idle
]
0 Recently
0
0 At night
Warm
E.
d I
ngme spee
0
Road conditions
0
0
Incident occurrence
Engine conditions
Unstable
50
I
60 MPH
TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)
INTERMITTENT PROBLEM SIMULATION
In order to duplicate an intermittent problem, it is effective to
create similar conditions for component parts, under which the
problem might occur.
Perform the activity listed under Service procedure and note the
resu It.
'
Variable factor
1
Mixture ratio
Ignition timing
Influential part
Target condition
Service procedure
Made lean
Made rich
Advanced
Retarded
Pressure regulator
Distributor
Mixture ratio
feedback control
Suspended
Control unit
Operation check
Raised
Idle speed
I.A.A. unit
Lowered
Poor electric
connection or
faulty wiring
Tap or wiggle.
Electric
connection
(Electric
continuity)
Temperature
Harness connectors
and wires
Cooled
Warmed
Control unit
Wet.
[WARNING:
Moisture
Electric parts
Damp
Electric loads
Load switches
Loaded
Idle switch
condition
Control unit
ON-OFF switching
Ignition spark
Timing light
10
EF &. EC-36
TROUBLE DIAGNOSES
Diagnostic Table
To assist with your trouble diagnoses,some typical diagnostic procedures for the following symptoms are.
described.
REMARKS
In the following pages, the numbers such as 0, . in the above chart correspond to those in the
serviceprocedure described below.
Possiblecauses can be checked through the serviceprocedure shown by the mark "0".
EF 8r. EC-37
TROUBLE DIAGNOSES
SPECIFICATIONS
1 II mpossible
to start
no combustion
POSSIBLECAUSES
.. 8 8 0
"
0 8
0
0
Ignition timing
FUEL SYSTEM
0
0
IGNITION
SYSTEM
Ignition switch
Main relay
Ignition coil
Power transistor
0
0
Spark plugs
CONTROL SYSTEM
SERVICE PROCEDURE
LISTEN
LISTEN
N.G.
---+
~~
../
f)
Fuel pump
,
SEF279G
Listen for fuel pump
operating sound.
'-
N.G
-.:
START
2l'
,,\
o-~
' 5
\.
[0 .! Timinglight
. CHECK
I.*
@
~
-6 /.
Tachometer
Ignition
switch
SEF283G
SEF281G)
.~
~
//11
. II
.,
--+ ,.
N.G.
ignition
SE
Injector
F280G
MEASURE
~
\UyJ
N.G.
--+
O.K.
,0
---+
CHECK
SEF315G
Measure resistance of
suspect wires.
N.G. AdJust
'
..
Ignition timing.
--+
((@S""~G
Check
injector circuit.
CHECK
N.G.
--+Check
timing.
EF &. EC-38
TROUBLE DIAGNOSES
Diagnostic
SYMPTOM & CONDITION
Table (Cont'd)
POSSIBLE CAUSES
0 f)
"
Mixture ratio
0
0
Ignition timing
FUEL SYSTEM
"
Fuel pump
Injectors (clogged)
SERVICE PROCEDURE
LISTEN
N.G.
-.~
.1
~
.
Fuel pump
sou,
L
~K
.1
~
\.
:J
APPL Y
,.
Improved
Checkinjectorcircuit.
Injector
SEF280G
operating
r.
D
PRESSURE
,
SEF291G..I
MEASURE
Fuel pressure gauge
'SE".6G
1
Check mixture ratio
feedback system.
[See page EF & EC-26.J
CHECK
~
~~~:ng
..
N.G.
~.VACUUM
//11II
SEF279G
LISTEN
f)
sm~G
"<
EF & EC-39
TROUBLE DIAGNOSES
Diagnostic
SYMPTOM& CONDITION 31 Impossible to start
- partial combustion
. . .. . . . . . 0 .
POSSIBLE CAUSES
SPECIFICATIONS
Mixture ratio
0
0
Injectors (clogged)
Pressure regulator
0
0
0
Ignition switch
INTAKE SYSTEM
CONTROL SYSTEM
Engine temperature
SERVICE PROCEDURE
LISTEN
N.G.
//11
InJ'ector
, "
. ,
SEF280G
Listen for injector operating
sound.
sensor
Ignition timing
FUEL SYSTEM
Table (Cont'd)
CHECK
N.G.
--+
Throttle chamber
throttle
valve.
s~
. lo.K.
CHECK
O.K.
1---+
'A
MEASURE
REMOVE
Pressureregulator
Improved
,.
2.
Fuel pressure
Connect vacuum hose to
pressure regulator and
measure fuel pressure.
SEF291G
Remove vacuum hose from
pressure regulator, and try
to start.
SEF287G
Check vacuum hose of pressure regulator for clogging.
1 N.G.
Repair or replace the hose.
CHECK
CHECK
MEASURE
, , Timing light
N.G.
~.
- (r@.<..~
""'~G
Ignition
1 N.G.
Adjust ignition timing.
[See page EF & EC-26.J
resistance
of
'","oct;'"}~~'
Replace
N.G.
Self-diagnosis
Mode IV
CHECK
wire
-~
PERFORM
G>
O.K.
if?rn
SEF315G
Measure
SEF283G
Check flashes of timing
light for weakness.
(!)
Perform self-diagnosis
Mode IV (for start signal).
EF &.EC-40
the wires.
Spark plug
SEF282G
Remove spark plugs and
check their ignition sparks
by cranking.
TROUBLE DIAGNOSES
Diagnostic
SYMPTOM & CONDITION
41 Impossibleto start
POSSIBLE CAUSES
INTAKE SYSTEM
Table (Cont'd)
partial combustion (throttle position changes
combustion qu~lity)
10
Neutral switch
SERVICE PROCEDURE
r.
CHECK
N.G.
Throttle chamber
Cleantheports.
~.
..~
SEF290G
Check throttle valvefor
clogging.
..
CHECK
.
N.G.
jj
CHECK
Throttle chamber
SEF293G
CHECK
N.G.
.,~"
START
,
@*
SEFOO6H
Check terminal voltage of
A.A.C. valve while cranking.
EF & EC-41
N.G.
Cleanthe valve.
---+
TROUBLE DIAGNOSES
Diagnostic
SYMPTOM & CONDITION
51 Hard to start
Table (Cont'd)
before warm-up
POSSIBLE CAUSES
Mixture ratio
0 f) 8 0 0
IGNITION SYSTEM
INTAKE SYSTEM
Air regulator
Engine temperature sensor
Idle switch
SPECIFICATIONS
CONTROL SYSTEM
OTHERS
0
0
0
0
0
Neutral switch
SERVICE PROCEDURE
CHECK
N.G.
START 1
+
"i,. ;5
o-~ -6
"
Tachometer
MEASURE
N.G. (less than 12V)
--+Charge
the battery.
I.*
@
~
Ignition
switch
SEF281G
SEF296G
Measure battery voltage.
'0
f)
CHECK
N.G.
+ Check air regulator and/or
its circuit.
[See page EF & EC-130.J
if
"
CRANK
g
i)~
Self-diagnosis
Mode IV
Perform self-diagnosis
Mode IV (for start signal
and idle switch!.
stays
N.G.
START ~Check
PERFORM
SEF285G
SEF293G
sensor circuit.
[See page EF & EC-90.J
~ @
~
Ignition
EF & .EC-42
N.G.
--+
TROUBLE DIAGNOSES
Diagnostic
SYMPTOM & CONDITION
61 Hard to start
Table (Cont'd)
after warm-up
POSSIBLE CAUSES
SPECIFICATIONS
FUEL SYSTEM
00
Mixture ratio
Fuel pressure
..
0
OTHERS
SERVICE PROCEDURE
CHECK
MEASURE
'0
N.G.
f)
STARTI~
,*
2~'
~
@
,,'
o-~
SEF281G
SEF296G
Measure battery voltage.
'
S eIf-diagnosIs
Mode IV
SEF374G
Cool fuel lines with wet
rags, etc. and try to start.
PERFORM
LINES
Ignition
switch
No
change
~
Proceed to other steps.
CRANK
FUEL
I ",5
-6 /.
Tachometer
N.G.
171~
SEF285G
Perform self-diagnosis
Mode IV (for start signal),
CHECK
O.K.
--+
SEF287G
Check vacuum hose of
pressure regulator for
clogging.
CHECK
1 N.G.
(pressure
regulator
control solenoid
0\
N.G.
--+
LISTEN
Pressure regulator
control solenoid
0'
START
i;.~
Ignition
'-SEF294G
switch
Check terminal voltage of
pressure regulator control
solenoid while cranking.
EF & EC-43
Improved
+ Proceed to other steps.
If everything is O.K.,
check fuel vapor pressure.
TROUBLE DIAGNOSES
Diagnostic
SYMPTOM & CONDITION
71 Hard to start
every time
. . . o . (I). G . . . .
POSSIBLE CAUSES
SPECIFICATIONS
Table (Cont'd)
Mixture ratio
Fuel pressure
0
0
IGNITION SYSTEM
0
0
Ignition timing
0
0
Idle switch
OTHERS
Neutral switch
SERVICE PROCEDURE
LISTEN
N.G.
---+Check
fuel pump and/or
related circuits.
[See page EF &I;C-120.]
START --+
It ,,\2i' CHECK
',5
0-~~
..
N.G.
~*
switch
Check mixture
REMOVE
N.G.
ratiO
;]
SEF297G
feedback system.
Advance/retard ignition
[See page EF & EC-26.]
timing and try to start.
Improved
Measurebattery voltage.
SEF281G
Make sure tachometer
indicates about 300 rpm
while cranking.
CHECK
No change
Distributor
-+
Proceed to other steps.
Advance ST ART
~
Retard ~
Ignition
Battery
rMEASUREl
switch
CRANK
.--
@
~
-"
N.G.
Tachometer Ignition
,
SEF279G
Listen for f.uel pump
operating sound.
/.*
ro---MEASURE,
+\
Fuel pressure
..
PERFORM
N.G.
Self-diagnosis
Mode IV
N.G.
--+
tN,G.
MEASURE
I>
MEASURE
O.K.
--+
Ignition wire
if?rn
SEF283G
Check flashes of timing
light for weakness.
Perform self-diagnosis
Mode IV (for idle switch).
SEF291 G
~";~
,
SEF298G
Check vacuum hose of
-~
SEF315G
Measure resistance of
suspect ignition wires.
O.K.
--+
I.
CHECK
S~'k'~G~
Spark plug
SEF299G
EF &. EC-44
SEF282G
Check ignition sparks.
TROUBLE DIAGNOSES
Diagnostic Table (Cont'd)
SYMPTOM & CONDITION
SPECIFICATIONS
IGNITIONSYSTEM
POSSIBLECAUSES
8 f) 8 0
Ignition coil
"
0
0
0
0
0
0
0
0
0
SERVICE PROCEDURE
MEASURE
CHECK
N.G.r.
8"
---+,
Ignition
N.G.
--+
wire
~rn
.~
SEF315G
Measure resistance
suspect wires.
jO.K.
DRY
8
Distributor
'-
Can start
---+
Replace the parts.
~0
~~,
of
No
change
---+
(0
MEASURE
O.K.
---+
Ie
CHECK
1 Gap
~~pa'k P'"'
SEF299G
Remove spark plugs and
measu re thei r gaps.
SEF282G
Check ignition sparks.
EF & EC-45
TROUBLE DIAGNOSES
Diagnostic Table (Cont'd)
SYMPTOM & CONDITION
SPECIFICATIONS
POSSIBLECAUSES
0 f)
Mixture ratio
0
0
0 0
Ignition timing
INTAKE SYSTeM
SERVICE PROCEDURE
CHECK
N.G.
~~~
I
Improved
Adjust ignition timing.
[See page EF & EC-26.J
~
~~~:ng
""9~G
"
CHECK
VACUUM
PRESSURE
Pressu re
regu lator
CRANK
N.G.
g
is; 9 ~.
1)
hose for
'- SEF284G
START
...
SEF300G
Check blow-by
clogging.
APPLY
BIOW-bY'
SEF293G
, N.G.
CHECK
Ignition
EF & EC-46
N.G.
Check mixture ratio
feedback system.
[See page EF & EC-26.J
TROUBLE DIAGNOSES
SYMPTOM & CONDITION
Diagnostic
Table (Cont' d)
10 Abnormal idling - low idle (after warm-up)
0 f) 8 0 0 0
POSSIBLE CAUSES
Mixture ratio
SPECIFICATIONS
0
0
0
0
0
0
Loadswitches(remainingOFF)
SERVICE PROCEDURE
CHECK
~
~~~;ng
rm
~
,SEF300G
m~~G
Check ignition timing.
~
-
IN.G.
Adjust ignition timing.
[See page EF & EC-26.1
APPLY
.. ThrottleCHECK
chamber
.. ThrottleCHECK
chamber
.,~
BIOW-bY
"
CHECK
f)
IN.G.
PERFORM
Improved
+ Check mixture ratio
VACUUM
feedback
PRESSURE 1
Pressure
regulator
SEF291G
No change
+ Check load signal circuit.
Self-diagnosis
Mode V
system.
SEF285G
[SeeELsection.]
lNG
'A
~
~'
RUN
g
IT
II
::
,~
START
\ t"
N.G.
@1
~page
EF & EC-90
Ignition
EF & EC-47
Check throt
clOgging.,,;
.J{fAr
Clean the valve:-
~.
SEF290G
TROUBLE DIAGNOSES
Diagnostic
Table (Cont'd)
...
POSSIBLE CAUSES
SPECIFICATIONS
Mixture ratio
CONTROL SYSTEM
.-CHECK
leak
~
~
SE F301 G
Check intake system for
Check ignitiontiming.
~ O.K.
N.G'air leaks.
Check throttle wire for
rough sliding.
Repair/replace the part.
1 N.G.
MEASURE
REMOVE
Fuel pressure
Pressu re
regulator
. SEF291G
1
idling.
Check the part and/or
[See HA section.]
CHECK
Throttle chamber
s~
~N.G.
Check air regulator and/or
its circuit.
[See page EF & EC-130.J
CHECK
~ N.G.
Clean the ports and/or
throttle valve.
N.G.
--+
SEFOO7H
~.
Perform self-diagnosis
Mode IV (for idle switch).
PERFORM
CHECK
SEF293G
Make sure air regulator
stays closed after warm-up.
I)
Self-diagnosis
Mode IV
SEF981
()III~
En gine
~sm~
CHECK
f)
~~~tg
C)
SERVICE PROCEDURE
OTHERS
G>
8e
N.G.
N.G.
CRANK
((
i5 ;U~
~
START
(l]
Ignition
circuit.
EF & EC-48
TROUBLE DIAGNOSES
Diagnostic Table (Cont'd)
SYMPTOM & CONDITION
POSSIBLE CAUSES
SYSTEM
SYSTEM
0 0
Ignition timing
INTAKE
f) 8
Mixture ratio
SPECIFICATIONS
E.G.R. SYSTEM
~...
SERVICE PROCEDURE
.-CHECK
~~~:ng
~
~ ""':G
Check ignition
--
CHECK
Checkmixtureratio
feedback system.
[See page EF & EC-26.J
Pressu re
regu lator
SEF291G
CHECK
~~
a
~
(j"E.G.R.
I!
control
valve
,
SEF547A...J
Check E.G.R. control valve
for operation.
SEFOO7H
SEF293G
PRESSURE
iit
Improved
VACUUM
N.G.
~Check
timing.
APPLY
CHECK
f)
N.G.
--+Adjust
ignition timing.
[See page EF & EC-26.J
Stays
~rw
/A
CHECK
'0
RUN
E.G.R. solenoid
"
~Ui6~
,l:c;\ :::
S'J
N.G
ST ART
~*
:.Ji!J
"
~"~
SEF303G
1
Check the solenoid circuit.
[See page EF & EC-100.J
EF & EC-49
r
Check senso
[S
$
p'"
'
"
CircUit
EF & EC-90.]
TROUBLE DIAGNOSES
Diagnostic Table (Cont'd)
SYMPTOM & CONDITION
SPECIFICAnONS
POSSIBLE CAUSES
Mixture ratio
Ignition sparks
G) 4D f)
Ignition timing
Compression pressure
FUEL SYSTEM
IGNITION SYSTEM
INTAKE SYSTEM
Ignition coil
Ignition wires
0
0
Idle switch
Load switches
E.G.R. SYSTEM
E.G.R. solenoid
SERVICE PROCEDURE
CHECK
~~
BIOW_bY
hose
1 N.G.
leaks.
Repair/replace the hose.
~";f:t
SEF298G
1 N.G.
1 N.G.
CHECK
Timing light
CHECK
N.G.
--+
CHECK
MEASURE
'.
IgOitlon wIre
O.K.
.0
~~
SEF315G
MEASURE
CHECK
~~
COMPRESSION
PRESSURE
SEF309G
Measure compression
pressu reo
N.G.
6~
~
E.G.R'
control
valve
,
SEF547A/
Check E.G.R. control valve
for operation.
Stays
I~'"
(~
CHECK
E.G.R. solenoid
~fii6~
u ~.~
SEF303G
Check terminal voltage of
E.G.R. solenoid while idling.
1
Check cylinder head and
gasket.
[See EM section.]
~
-
~.=.
SEF303G
+ N.G.
Check the solenoid circuit.
[See page EF & EC-124.J
CHECK
SEF282G
Measure resistance of
suspect wires.
~ N.G.
Replace the wire.
CHECK
Pressure regulator
control solenoid
o~
~ru
SEF283G
r~
11/"-'
SEF301G
Check intake system for
air leaks.
SEF300G
Check blow-by hose for
0.,
Leak
Engine
CHECK
~ N.G.
Check the solenoid circu it.
[See page EF & EC-100.J
EF & EC-50
~"""~G
Check ignition timing.
~ N.G.
Adjust ignition timing.
[See page EF & EC-26.J
PERFORM
f)
Self-diagnosis
Mode IV
SEF285G
Perform self-diagnosis
Mode IV (for idle switch).
1 N.G.
Check the idle switch circuit.
[See page EF & EC-116.J
TROUBLE DIAGNOSES
Diagnostic Table (Cont'd)
14 Poor driveability - stumble (while accelerating)
. f) 8 0
POSSIBLECAUSES
SPECIFICATIONS
Mixture ratio
(;)
Fuel pressure
FUEL SYSTEM
Injectors (clogged)
IGNITION
SYSTEM
Ignition coil
CONTROL
SYSTEM
0
0
0
0
0
0
0
Engine temperature
sensor
Power transistor
INTAKE SYSTEM
SERVICE PROCEDURE
"
0,
CHECK
MEASURE
--
N.G.Replacethe wires.
--
N.G.
Timing light
Ignition wire
\{I
i
CHECK
O.K.
GJ
-'}
SEF315G
SEF283G
Measure resistance
suspect wires.
Leak
N.G.
--
Repair/replacethe part.
N.G.
Self-diagnosis
ModeIV
SEF301G
PERFORM
()III~
Eng ine
.--
SEF282G
of
for
"
Improved
. I0
MEASURE
SEF285G
Perform self-diagnosis
Mode IV (for idle switch).
. feedback
Check mixture ratio
system.
~.
SEF291G
Remove vacuum hose from
pressure regulator, and try to drive.
PERFORM
!)
Self-diagnosis
~V
U%'~
SEF285G
Perform self-diagnosis Mode
V (for air flow meter).
N.G.
DISCONNECT
-.."
1:8
Improved
II!
No change
sensor
('.,~
~;
E'h,"~";~'/'>=
~~.
SEF307G
EF & EC-51
TROUBLE DIAGNOSES
Diagnostic Table (Cont'd)
SYMPTOM & CONDITION
15 Poor driveability
0 f)
POSSIBLE CAUSES
. e
SYSTEM
(missing)
INTAKE SYSTEM
CONTROL
Ignition timing
IGNITION
0 0 8 fi) "
0
SYSTEM
0
0
SERVICE PROCEDURE
.~ ~p!
~CHECK
CHECK
leak
()11/
Engine
(t@s"'~a
CHEC~
for
Check
ignition
timing.
II
. e
:::"./:
control
valve
SEF547 A./
REMOVE
Improved
Pressure regulator
~.
. 0
~N.G.
Check the solenoid circuit.
[See page EF & EC-100.J
MEASURE
Fuel pressure gauge
feedback system.
[See page EF & EC-26.1
'",,,.,a
PERFORM
DISCONNEC!.-"
Self-diagnosis
N.G.
PERFORM
Self<liagnosis
Mode IV
SEF285G
Perform self<liagnosis
Mode IV (for idle switch).
'0
0'
SEF285G
Perform self-diagnosis Mode
V (for crank angle sensor,
air flow meter, ignition
signal.!
fj
SEF291G
Remove vacuum hose
from pressure regulator,
and try to drive.
~-~SEF303G
valve
E.G.R. solenoid
iki
E.G.R.
CHECK
Stays lifted (
1 N.G.
N.G.
'
"\
SEF301 G
,"10
Exhaust ga
sensor
C1O'.:
,
Disconnect
connector,
EF & EC-52
/'~
~N.G.
Check the idle switch
circuit.
[See page EF & EC-116.J
Improved
. Replace the sensor.
No change
. Check mixture ratio
feedback system.
[See page EF & EC-26.J
SEF307G
exhaust gas sensor
and try to drive.
TROUBLE DIAGNOSES
Diagnostic
SYMPTOM & CONDITION
. . . 0 . .. . .. 0 . .
POSSIBLECAUSES
SPECIFICATIONS
Table (Cont'd)
I
Fuel pressure
0
Ignition timing
0
0
Injectors (clogged)
IGNITION
SYSTEM
0
0
CONTROL
SYSTEM
0
0
SERVICE PROCEDURE
CHECK
SEF320G
element
~ ."':0-
~ N.G.
Adjust ignition timing.
(See page EF & EC-26.J
MEASURE
--+
COMPRESSION
PRESSUR-E
IN.G.
Replace the part.
~
~~~tg
~
AIR CLEANER
ELEMENT
CHECK
CHECK
Throttle
chamber
~~
~SEF290G
Check throttle valve for
rough movement.
SEF283G
Check flashes of timing
light for weakness.
N.G.
CHECK
O.K.
Measure compression
pressure.
G PressuREMOVE
re regu lator
~.
SEF291G
PERFORM
G:I
SEF315G
SEF282G
lgnitionWire
.--
SEF309G
~N.G.
MEASURE
Measure resistance of
suspect.wires.
+ N.G.
Replace the wires.
.-- DISCONNECT
-.
~
Self-diagnosis
SEF286G
Connect vacuum hose to
pressure regulator and
measure fuel pressure while
driving.
1
Check mixture ratio
feedback system.
[See page EF & EC-26.]
c5:
Exhaustges
sensor
71~
~4"l
SEF285G
Perform self-diagnosis
Mode
V (for air flow meter).
~ N.G.
Check the malfunctioning
parts and/or circuit.
[See page EF & EC-88.J
EF & EC-53
lv.iU
IIP=
.,
) '.'
SEF307G
Nochange
l'
mproved
TROUBLE DIAGNOSES
Diagnostic Table (Cont'd)
SYMPTOM & CONDITION
POSSIBLECAUSES
SPECIFICATIONS
detonation
CONTROL SYSTEM
OTHERS
6) e
Injectors (clogged)
0
0
SERVICE PROCEDURE
CHECK
Too high
~
Check cooling system.
[See LC section.]
Water temperature
,
~r;~~
SEF312G
Check water temperature.
CHECK
N.G.
~
8~
~"'.~~
Check ignition
REMOVE
Improved
~.
.I 0
MEASURE
Fuel pressure gauge
SEF291G
PERFORM
N.G.
Self-diagnosis
_SEF285G
Perform self-diagnosis
Mode V (for crank angle
sensor and air flow meter).
EF &. EC-54
timing.
TROUBLE DIAGNOSES
Diagnostic Table (Cant' d)
SYMPTOM & CONDITION
during
start-up
0 f) 8 e 41) 0
POSSIBLECAUSES
SPECIFICATIONS
(i) 0
Ignition timing
IGNITION SYSTEM
0
0
0
0
SERVICE PROCEDURE
CHECK
CHECK
Timing
i9ht
~
,
N.G.
--+
Adjust
ignition
timing.
~ sm.:G
~ttl:
SEF290G
CHECK
N.G.
--+
'
SEF283G
-TRY
valve
MEASURE
SEF315G
N.G.
Ignition wire
~rn
-~
--+Replace
CHECK
COMPRESSION
. PRESSURE
SEF309G
Measure compression
Improved
--+
Replace the canister and/or
the hoses.
Spark plug
SEF282G
Remove spark plugs and
check their ignition sparks.
pressu reo 1
Check cylinder head and
gasket.
[See EM section.]
No
L1X
MEASURE
the wires.
O.K.,.
--+
Measure resistance of
ignition wires.
the part.
C) ,, Timinglight
N.G.
--+Repair/replace
change
Canister purge
'SEF314G
Shut evaporated fuel to
intake valve and try to drive.
APPLY
Improved
~
-
VACUUM
PRESSURE
Pressu re
regulator
No change f
. Check mixture ratio .feedback system.
[See page EF & EC-26.]
Replace the sensor..
SEF291G
Apply vacuum pressure to
pressure regulator after
disconnecting vacuum
hose, and try to drive.
EF & EC-55
.,
DISCONNECT
ij
\11
sensor
Improved
CJQu
E'h,""'i~'f"=
~
SEF307G
TROUBLE DIAGNOSES
Diagnostic
SYMPTOM & CONDITION
while idling
. f). e 8 . . .. .
POSSIBLECAUSES
SPECIFICATIONS
Table (Cont'd)
I
0
0
FUEL SYSTEM
IGNITION SYSTEM
INTAKE SYSTEM
CONTROL SYSTEM
0
0
0
0
Loadswitches(remainingOFF)
SERVICE PROCEDURE
'.
REMOVE
Improved
Pressure regulator
~.
SEF291G
1'" \
o-~
I I
.
,
CHECK
,, Timinglight
N.G.
.1
-6
SEF283G
Check flashes of timing
light for weakness.
C)
CHECK.
Spark plug
and/or
ark plug
!.EF8G
SEF299G
PERFORM
CHECK
4;)
SEF981 F
Check terminal voltage of
F.I.C.D. solenoid.
~ N.G.
Check the part and/or circuit.
[See page EF & EC-134.J
~ N.G.
Check the part and/or circuit.
[See HA section.]
SEFOO7H
CHECK
SEF316G
'."286G
Connect vacuum hose to
pressure regulator and
measure fuel pressure.
MEASURE
Tachometer
MEASURE
Fuel pressure gauge
'f)
Self-diagnosis
Mode IV
SEF285G
Perform self-diagnosis
Mode IV (for idle switch).
EF & EC-56
N.G.
Checkthe idleswitchcircuit.
[See page EF & EC-116.J
TROUBLE DIAGNOSES
Diagnostic
SYMPTOM & CONDITION
20 Engine stall
I
Table (Cont'd)
while accelerating
POSSIBLE CAUSES
SPECIFICATIONS
0 f} 8 0
Mixture ratio
0
0
SYSTEM
0
0
0 0
0
0
SERVICE PROCEDURE
CHECK
0 , Timing
MEASURE
f)
N.G.
light
N.G.
Ignition wire
'.
~Hjl
O.K.
. Replacethe wires.
CHECK
SEF31~
SEF283G
Measure resistance of
suspect wires.
SEF282G
MEASURE
N.G.
COMPRESSION
PRESSURE
SEF309G
Measure
'0
compression
pressure.
.CHECK
Self-diagnosis Mode II
N.G.
DISCONNECT
'"IV
sensor
5 times or
'
C10u
Exhoon
~r,fF
Disconnect exhaust gas
sensor connector, and try
to drive.
Self-diagnosis
7I~
SEF307G
No change
PERFORM
Cf
SEF285G
Perform self-diagnosis
Mode
V (for cra n k ang Ie senso r
and air flow meter!.
.lmprOVed
Replace the sensor.
EF & EC-57
N.G.
TROUBLE DIAGNOSES
Diagnostic Table (Cont'd)
SYMPTOM & CONDITION
SPECIFICATIONS
Mixture ratio
0
..
0
0
SERVICE PROCEDURE
'0
.!
CHECK.
Timing light
N.G.
..
CHECK
MEASURE
N.G.
Ignitio n wire
~rn
-~
SEF283G
SEF315G
Measure resistance
suspect wires.
.-CHECK
,
Self-diagnosisMode II
N.G.
"
.
DISCONNECT
{'')~
l-.,~-
ED
"~
11\
Exhaust gas
sensor
SEF282G
Remove spark plugs and
check their ignition sparks.
of
,:
Improved
. Replace
No change
. Check mixture ratio
feedback system.
[See page EF & EC-26.]
SEF307G
Self-diagnosis
Move V
N.G.
the sensor.
SEF285G
Perform self-diagnosis
Mode V (for air flow meter
and crank angle sensor).
EF 8r. EC-58
TROUBLE DIAGNOSES
Diagnostic
SYMPTOM & CONDITION 22
Table (Cont'd)
0 f)
POSSIBLE CAUSES
Mixture ratio
SPECIFICATIONS
IGNITION SYSTEM
(m issing)
INTAKE SYSTEM
CONTROL
SYSTEM
0 0
0
0
feedback control)
0
SERVICE PROCEDURE
."
CHECK
PERFORM
'Q
N.G.
SEF283G
N.G.
~
Self-diagnosis
Mode V
SEF285G
Perform self-diagnosis
Mode V (for ignition signal
and crank angle sensor).
MEASURE
N.G.
~
CHECK
Tachometer
SEFOO7H
SE F316G
Measure
Check terminal
A.A.C. valve.
idle speed.
CHECK
Self-diagnosisMode
I~
N.G.
Exhaust
sensor
5 times or
(~)
more/10 sec.'-.J
,-SEF373G
Check mixture ratio by
flashes of inspection
lamps.
voltage of
DISCONNECT
C~,.:
""""''' Improved
18
gas
\I~
11\
Left OFF
--+
Check the circuit.
No change
--+
Checkmixtureratio
feedback system.
[See page EF & EC-26.J
SEF307G
,
Disconnect exhaust gas
sensor connector, and try
to drive.
EF & EC-59
TROUBLE DIAGNOSES
Diagnostic Table (Cont'd)
SYMPTOM & CONDITION 231 Engine stall - while loading
.. f) 8 o
POSSIBLECAUSES
SPECIFICATIONS
CONTROL SYSTEM
Ignition timing
INTAKE SYSTEM
0
0
0
0
SERVICE PROCEDURE
MEASURE
N.G.
---+Adjust
idle speed.
[See page EF & EC-26.]
Tachometer
2
I ...
0-&..~
idle speed.
N.G.
~
SEF981F
Check terminal voltage of
F.I.C.D. solenoid.
PERFORM
~)
CHECK
voltage of
Mode IV
ignition timing.
CHECK
Self-diagnosis
---+Adjust
~ ""~G
SEFOO7H
,,'
-6
Check terminal
A.A.C. valve.
N.G.
~~~tg
~
SEF316G
Measure
CHECK
N.G.
SEF285G
Perform self-diagnosis
Mode IV (for idle switch).
EF &. EC-60
TROUBLE DIAGNOSES
Diagnostic
SYMPTOM& CONDITION 24
SPECIFICATIONS
Backfire
Table (Cont'd)
POSSIBLE CAUSES
0 f) 8 8
CONTROL
Injectors (clogged)
INTAKE SYSTEM
0
0
SYSTEM
SERVICE PROCEDURE
CHECK
CHECK
Leak
Engine
N.G.
---+
f)
~.
CLEAN
'0
Improved
+ Check mixture ratio
feedback system.
[See page EF & EC-26.]
or
SEF317G
SEF291G
1
.--
PERFORM-------N.G.
Self<liagnosis Mode II
sm~G
REMOVE
Pressu re regu lato r
N.G.
---+
Adjust ignition timing.
[See page EF & EC-26.]
r&~
s:1i~ duct~
~
light
(')
T iming
DISCONNECT
"
IV
CHECK
Improved
. Replace the sensor.
\II
No change
. Check mixture ratio
feedback system.
[See page EF & EC-26.]
sensor
5 times or
.["ore/10 sec. SEF373G
Check mixture ratio by
flashes of inspection
lamps.
C~,.;
E'h'".";~'~
SEF307G
Self<liagnosis
:w~
SEF285G
Perform self-d iagnos is
'Mode V (for air flow meter).
1 N.G.
Check the circuits.
[See page EF & EC-88
(air flow meted.]
EF &. EC-61
TROUBLE DIAGNOSES
Diagnostic
SYMPTOM& CONDITION 25
Backfire
Table (Cont'd)
POSSIBLE CAUSES
SPECIFICATIONS
FUEL SYSTEM
IGNITION
(missing)
SYSTEM
INTAKE SYSTEM
CONTROL
SYSTEM
. 8 .. 0 0 ..
0
0
0
0
SERVICE PROCEDURE
CHECK
N.G.
---+
APPLY
AIR CLEANER
ELEMENT
SEF291G
Apply pressure to pressure
regulator after disconnecting
vacuum hose, and try to
drive.
N.G.
Mode IV
Self-diagnosis
Mode V
N.G.
-+
SEF285G
Perform self-diagnosis
Mode IV (for idle switch).
PERFORM
SEF285G
CHECK
SEF375G
Check secondary air to
exhaust system.
regulator
PERFORM
Self-diagnosis
-+
~.P'~M'
SEF320G
Check air cleaner element
for clogging.
Improved
PRESSURE
0
.'(0:
"
CHECK
Left ON
A.I.V. solenoid
~
u
t~
"~mG
EF
&
EC-62
TROUBLE DIAGNOSES
Self-diagnosis
Description
SEF297H
.
.
.
Idle switch
Starter switch
Vehicle speed sensor
..
EF &. EC-63
TROUBLE DIAGNOSES
Self-diagnosis
Description
Q .~
Gr'
r:~i
(Cont'd)
MODES
'--~Cij'\
~/~)jFlashin
gNt
Mode N
'
Imes
SE F288H
SEF989D
EF & EC-64
TROUBLE DIAGNOSES
Self-diagnosis
~~E~
Description (Cont'd)
.
.
Code No.
Malfunction
12
13
14
31
32
E.G.R. function
33
35
43
45
Injector leak
sensor circuit
DIAGNOSIS START
r
Turn ignition switch "ON" and make sure
that check engine light comes "ON".
O.K.
Perform self-diagnosis and check which code
is displayed in Mode III.
EF & EC-65
)
N.G.
Replace bulb.
TROUBLE DIAGNOSES
Self-diagnosis
Description (Cont'd)
@
1
Erase the self-diagnosis memory.
DIAGNOSIS
END
EF & EC-66
TROUBLE DIAGNOSES
Self-diagnosis
monitor)
This mode checks the exhaust gas sensor for proper functioning. The operation of the E.C.U. L.E.D. in this mode differs with
mixture ratio control conditions as follows:
Mode
L.E.D.
Green
Mode I
(Monitor A)
Red
Engine
stopped
(Ignition
switch
"ON")
Engine running
ON
ON
*Remains ON or OFF
Blinks
OFF
CHECK
Mode
L.E.D.
Green
Engine
stopped
(Ignition
switch
"ON")
ON
Engine running
Open loop condition
*Remains ON or OFF
Blinks
Compensating mixture ratio
Mode II
(Monitor B)
*Remains ON or OFF
Red
OFF
More than
5% rich
Between 5%
lean and 5% rich
More
OFF
Synchronized
with green L.E.D.
Remains ON
EF & EC-67
TROUBLE DIAGNOSES
Self-diagnosis
system)
.
.
NonCalifornia
12
13
Code No.
11
Detected items
14
21
31
32
33
35
43
45
Injector leak
55
X: Available -:
Not available
EF 8r. EC-68
TROUBLE DIAGNOSES
Self-diagnosis
system) (Cont'd)
The
diagnostic results
RETENTION
TERM
CHART
(Example)
I
Code
No.
I'
CRANK ANGLE
SENSOR
100
50
I
200
50 times
11
-------------------------
-------------ENGINE
TEMPERATURE
SENSOR
150
13
t?//////// J'd
If the same diagnostic item is
judged to be malfunctioning before
the starter is operated fifty times,
it will be stored in E.C.U. memory
until the starter is operated fifty
times from this point in time.
: Retention term
SEF793D
EF &. EC-69
TROUBLE DIAGNOSES
Self-diagnosis
system) (Cont'd)
SELF-DIAGNOSTIC PROCEDURE
DIAGNOSIS START
.~
Flashing 3 times
~ ..~
SEF288H
.
Write down the malfunctioning Code No.
Make sure that inspection lamps are displaying Code No. 55.
O.K.
- - -- - -- - -- ~- - _Memory
erasingprocedure--
~r\
-- -- -- -- ----
,
After the inspection lamps have flashed 4 times, turn diagnostic mode selector
on E.C.U. fully countercl.ockwise.
.
Flashin g 4 t Imes
Mode IV
---------
- -- ---
DIAGNOSIS
END
CAUTION:
During display of a code number In self-diagnosis mode (Mode m), If another diagnostic mode is to be performed, be sure to note the malfunction code number before turning diagnostic mode selector on E.C.U.
fully clockwise. When selecting an alternative, select the diagnosis mode after turning switch "OFF". Other. wise, self-diagnosis
Information in the E.C.U. memory will be lost.
Return the DIAGNOSTICMODE selector to the previous position.
EF & EC-70
I
I
I
I
SEF288H
I
I
I
I
&i~~)
\~t ~~
Mode III
TROUBLE DIAGNOSES
Self-diagnosis - Mode III (Self-diagnostic
system) (Cont'd)
DECODING
DISPLAY CODE
CHART
MALFUNCTIONING CIRCUIT OR
PARTS
.
Code No. 11
.Q
(0.
Red
(I
Green
Either
-\
-V
SYSTEM INSPECTION
See page EF & EC.g6.
SEF042F
.
Code No. 12
.Q
. """.
--..
Red
(I
..
'",,,'
Air flow meter circuit
Green
-\
-V
SYSTEM INSPECTION
See page EF & EC.g8.
SEF043F
ENGINE TEMPERATURE
Code No. 13
-D
{iQ)
,m"
--..
Red
(I
"!!'"
,Green
...
)V
SYSTEM INSPECTION
See page EF & EC-90.
SEF044F
. Signalcircuit is open.
CodeNo. 14
0,,,,,,,
''''''D ---.. (Qit
,
{fQ)
,"",
. ....
Red
Green
-'\
vi
SYSTEM INSPECTION
See page EF & EC-92.
SEF074G
EF & EC-71
TROUBLE DIAGNOSES
Self-diagnosis - Mode III (Self-diagnostic
system) (Cont'd)
CONTROL UNIT SHOWS A
MALFUNCTION SIGNAL WHEN
THE FOLLOWING CONDITIONS
ARE DETECTED.
MALFUNCTIONING CIRCUIT OR
PARTS
DISPLAY CODE
Code No. 21
mm
.".
CO$
,iiim
,.....
.. .
Green
Red
-\
.-VI
SYSTEM INSPECTION
See page EF & EC-94.
SEF045F
CodeNo.31
.;,.
, .,.".
CQ'j)
.,=,
{tQ)
... .
Red
".,.
'.
E.C.U.calculation function
Green
..
)
SYSTEM
INSPECTION
E.G.R. function
.
... ..
Code No. 32
{f0
'iiii"
Red
0-
, 'mii'
E.G.R. function
Green
~
-I
SYSTEM
INSPECTION
CodeNo.33
''''O
{iQ)
'ii'"
, "",.
... ...
Red
Green
)
SYSTEM INSPECTION
See page EF & EC-104.
SEF078G
EF &. EC-72
TROUBLE DIAGNOSES
Self-diagnosis
system) (Cont'd)
MALFUNCTIONING
PARTS
DISPLAY CODE
CIRCUIT OR
Signalcircuit is open.
CodeNo.35
.0
CQ:t
O:H:,
Green
"H'"
Red
... .....
...
SYSTEM INSPECTION
See page EF & EC-106.
SEF393G
b
.0
.... ...
short.
Code No. 43
Red
Green
11
SYSTEM INSPECTION
See page EF & EC-110.
SEF079G
INJECTOR LEAK
~
.
.... .....
Code No. 45
"''''.
[)-
Red
""'"
,..,..
Injector
leak
Green
SYSTEM INSPECTION
See page EF & EC-114.
SEFOSOG
Code No. 55
~
{fQ
Red
'$
,..
Green
...9.
SEF984F
EF &. EC-73
TROUBLE DIAGNOSES
Self-diagnosis
diagnostic system)
In switches ON/OFF diagnosis system, ON/OFF operation of
the following switches can be detected continuously.
..
. Vehicle speed sensor
(1) Idle switch & Starter switch
Idle switch
Starter switch
"
EF & EC-74
TROUBLE DIAGNOSES
Self-diagnosis - Mode IV (Switches ON/OFF
diagnostic system) (Cont'd)
SELF-DIAGNOSTIC
DIAGNOSIS
PROCEDURE
START
~
Pull out E.C.U. from under the assist
kick panel.
~
~C"
~
~0'-~)
<q
~S""'H
r:~
~'I
.-r~ \~---~~0~'-~
. >~
O.K.
i~
("'I
riJf!jt
~--;'t\0)
~
~'-~
SE F299H
N.G.
DIAGNOSIS
END
CAUTION:
SE F288H
N.G.
~SE'29.H
Mode IV
-.----O.K.
Accelerator pedal
S;~~T
Flashing 4 times
For safety, do not drive rear wheels at higher speed than required.
EF & EC-75
TROUBLE DIAGNOSES
Self-diagnosis
Mode V
(Real-time diagnostic
system)
In real-time diagnosis, if the following items are judged
to be
Ignition signal
Air flow
meter
Consequently,
the
above
output
signal
this diagnosis
systems
cause
Compared
with
self-diagnosis,
sitive and
can
detect
regarded
as
malfunction,
real-time
malfunctions
malfunctions
during
diagnosis
instantly.
in this diagnosis
whether
driving
However,
are
test.
is very
not
senitems
stored
in
E.C.U. memory.
SELF-DIAGNOSTIC PROCEDURE
DIAGNOSIS START
I
Pull out E.C.U. from under
the
assist
seat.
Start engine.
Turn
diagnostic
mode
selector
on
E.C.U.
fullyclockwise.
selectorfully
counterclockwise.
~r\
~V
~(~~
'-~C0
(
Make
lamps
N.G.
are not
Mode V
SEF288H
Ifflashing,count no. of
flashes.
idling or racing.
O.K.
SE F292 H
Turn
ignition switch
Turn
"OFF".
See
ignition switch
decoding
"OFF".
chart.
Perform
DIAGNOSIS END
system
real-time diagnosis
inspection.
If malfunction
part is found,
CAUTION:
In real-time
diagnosis,
pay
attention
to
inspectio.n
lamp
flashing.
E.C.U.
the inspection.
EF &. EC-76
displays
the
malfunction
code
only
once
TROUBLE DIAGNOSES
Self-diagnosis - Mode V (Real-time diagnostic
system) (Cont'd)
DECODING CHART
DISPLAY CODE
MALFUNCTIONING
OR PARTS
CIRCUIT
- ModeIII.)
RED L.E.D.
3.2
3.2
3.2
'9' ON-[
0 OFF
REAL-TIME DIAGNOSTIC
INSPECTION
See page EF & EC-86.
SEF047F
.
GREEN
LED
..
:0:
','
3.2
Unit: sec
3.2
3.2
ON
0 OFF
LI1.6lnl1.61
0.4
0.60.4 V
--0.6
-V
1.6
0.4
0.6
REAL-TIME DIAGNOSTIC
INSPECTION
See page EF & EC-88.
SEF048F
IGNITION SIGNAL
.
Unit: sec
GREEN
3.2
3.2
"L.E.D. rT
'9,: ON --
~~
r
Malfunction of ignition signal
0 OFF
1.8
0.2
REAL-TIME DIAGNOSTIC
INSPECTION
See page EF & EC-94.
SEF049F
EF & EC-77
TROUBLE DIAGNOSES
Self-diagnosis-
Mode V (Real:-timediagnostic
system) (Cont'd)
I
REAL-TIME DIAGNOSTIC
X : Avallab Ie
-: Not available
INSPECTION
Check parts
Check
sequence
Check items
Check
conditions
E.C.U.
harness
connector
If malfunction, perform
the following items.
Middle
connectors
Sensor &
actuator
During
real-time
diagnosis
Go to check item 2.
Go to check item 3.
Engine
at connector.
stopped
Engine
stopped
Engine
stopped
Engine
stopped
Replace terminal.
During
real-time
diagnosis
CJ
L J
-E.C.U.
harness connector
SEF130H
EF & EC-78
TROUBLE DIAGNOSES
Self-diagnosis-
system) (Cont'd)
I
x: Available
-: Not available
I
Check parts
Check
sequence
Check items
Check
conditions
Middle
connectors
Sensor &
actuator
E.C.U.
harness
connector
During
real-time
diagnosis
Go to check item 2.
Engine
stopped
Go to check item 3.
Engine
stopped
Engine
stopped
Engi ne
stopped
Replace terminal.
During
real-time
diagnosis
If malfunction, perform
the following items.
=-l
E.C.U. harness connector
.. I"~
,<1/A
SEF131H
EF & EC-79
TROUBLE DIAGNOSES
Self-diagnosis-
system) (Cont'd)
I
Ignition Signal
X:
-:
Available
Not available
Check parts
Check
sequence
Check items
Check
conditions
If malfunction, perform
the following items.
Middle
connectors
Sensor &
actuator
E.C.U.
harness
connector
During
real-time
diagnosis
Go to check item 2.
Engine
stopped
Go to check item 3.
Engine
stopped
Engine
stopped
Engine
stopped
Replace terminal.
During
real-time
diagnosis
EF & EC-80
TROUBLE DIAGNOSES
NOTE
EF &. EC-81
TROUBLE DIAGNOSES
Diagnostic Procedure
CAUTION:
SEF290H
SEF291H
SEF330D
SEF292H
EF & EC-82
perform
TROUBLE
DIAGNOSES
Diagnostic
Procedure
(Cont'd)
7. When measuring E.C.U. controlled components supply
voltage with a circuit tester, separate one tester probe
from the other.
If the two tester probes accidentally make contact with
each other during measurement,
Solenoid valve
SEF599D
EF 8r. EC-83
'
TROUBLE DIAGNOSES
Diagnostic Procedure 1
MAIN POWERSUPPLYAND GROUND CIRCUIT
COMBINATION METER
@ ,
With
~,
head-up display
CHECK
ENGINE
LIGHT
CHECK
ENGINE
LIGHT
I GNI T! ON SWITCH
ON or START
17o--@--<>I 6,
FUSE BLOCK
(Refer to "POWER
SUPPL Y ROUT! NG"
r-t
1:1 r.iiI
~
E. C. C S
CONTR'OL'
UNIT
Iii
~
~ottt-O
tWh I te)
1""'00arness)
107-B.'---
jI
108-B
'Fi'r;;n'\
(E. F.
-~
~
CID
..
12
I (~~strument
@)eo@
116-B
4-R/B
05
[rmef-H-iJ[gOO:!]
In EL section.)
@ ;;
2' 0---@
~~
rness)
J.
harness)
6-B
13-B
"II"
EE
~I"I~
@@
24-R
UTI
harness)
B/W~
~~~~ine
room
36-B/R
48-B
'1!
1391481
@)
~~ @)
E.
~
C.
~@)
OFFACCON ST
J J
1
J J
2
J
3
4
11m
5
\
link
~.
EF
&
EC-84
ITiJ~
FUSIBLE
LINK
FUSE AND
FUSI BLE LI NK
S.
I GNI
T! ON
SWITCH
~
BATTERY
Component location
I
C.
RELAY
ENGINE
GROUND
/"BR;'
fusible
~"G" fusible link
~~
..
@)lMJ
47-B/W
'1:
~:~
....
39-B
"481391
Iffl
:~:--,,:~:~
@@)
1111
~.. ~
"
SEF261H
TROUBLE DIAGNOSES
"-
INSPECTION START
='
<tITD
SEF153D
Ii)
-
O.K.
CHECKPOWER SOURCE
Cl'UNIT
II
Ef CONNECTOR
is
II
00
@N.G.
CONNECTOR
3948
~
~
@N.G.
SEF259H
[i
c..'UN1T
116107108136
O.K.
iZJ
II
FOR E.C.U.
1) Turn ignition switch "ON".
2) Verify that red and green
inspection lamps on the
E.C.U. illuminate.
3647
00
Ii)
e\
srt.J
Check following items.
1) "s R" fusible link
2) Harnessor connectors
between terminal @ and
battery
[R]
00
3) Harness or connectors
SEF260H
[i
CHECK GROUND CIRCUIT.
1) Turn ignition switch "OFF".
2) Disconnect E.C.U. harness
connector.
3) Check continuity between
terminals @, @, ~, @,
@,
@,
@ and ground.
Continuity should exist.
O.K.
Reinstall any part removed.
INSPECTION END
EF &. EC-85
N.G.
TROUBLE DIAGNOSES
Diagnostic Procedure 2
CRANK ANGLE SENSOR (Code No. 11)
E. C. C. S.
CONTROL
fF2\
UNIT
I...:::..)
4-R/B
~'
(E. F. 1harness)
(Eng Ine
B/W~
room
harness)
~B/W
@@)
22-G/B
30-
,- "" \
G/B
31-G/Y
40-G/Y
147
:47
,,
,,
R/B~
I: ,
,,
,
~R/B
W
@@)
ij
, , ,
d... j ,..
"'..'" ..
47-B/W
@)~
~..
"
..0: 0:0:
~m
i@)
161~
m IiIln1
CRANK
ANGLE
SENSOR
Component location
-Crank
~harness
SEF147H
angle sensor
connector
C.
C.
RELAY
~-'~
EF & EC-86
~:~
FUSIBLE
LINK
FUSE AND
FUS IBLE LI NK
(ln RELA Y BOX)
E.
@ ~~
@)~
@lMJ
ENGINE
GROUND
:G~
S.
~BATTERY
SEF221H
TROUBLE DIAGNOSES
fa
INSPECTION START
fa
COIIIET
)
@J
(lli)
~0
~~
SEF142H
Ii]
ClUNIT
II
8'
~ i5
Ii]
O.K.
CONNECTOR II
N.G.
22303140
[ill
N.G.
[!J
00
i5~
SEF143H
[!J
CYJ
_T
IV
00
N.G.
O.K.
(!1
f~
SEF144H
(!1
[:tI~
O.K.
N.G.
DlSCGIINt:CT
lu
[ill
+:
CHECK COMPONENTS.
Check crank angle sensor.
(See page EF & EC-147.)
O.K.
INSPECTION END
EF & EC-87
N.G.
TROUBLE DIAGNOSES
Diagnostic Procedure 3
AIR
FLOW
METER
CONTROL
UNIT
Ii)
E. c. c. s.
@2
f1
,.?7I!i1Ii1IUJ
~@)
~"'.
'"
III'
CE.F. 1-
fff1I
hsrness)
1D9-8/W
"
,
,
I
I
,
4-R/8
I
,
,
I
I
I
I
I
I
I
,
,
,
I
I
,
'
,
,
,
,
,
,
,
,
,
,
16-W
17-8
uJ
,
,
,
,
,
,
I
I
I
I
~ ~
(Engine
'1:IL B/W
8/W$
room hsrnes~
FUSE
@@
Wd
R/8--;
~R/8
@@
WJ
w
-J:
~~
"'''' "''''
.
@)~
;1
~@)
E. C.C.S.
RELAY
Component location
EF &. EC-88
~~
FUSIBLE
LINK
FUSE AND
FUSI BLE LI NK
<I n RELA Y BOX)
@)lMJ
ENGINE
GROUND
@)
~
BATTERY
SEF222H
TROUBLE DIAGNOSES
~-
INSPECTION START
E)
[Y]
@)
:E
~r,
,IV~
SEF136H
I;]
~u
I;]
CONNECT
16
IU
N.G.
N.G.
[ill
[!J
00
i5~~
SEF137H
[!J~~
CONNECT
E)
@)
[Y]
:E
SEF138H
Ii]
00
SEF141
O.K.
_IECT
lu
N.G.
O.K.
Ii]
I
{D
connector.
4) Check continuity between
terminals @ and @.
Continuity should exist.
_IECT
O.K.
[ill
N.G.
CHECK COMPONENTS.
Check air flow meter.
(See page EF & EC-147.)
,
O.K.
O.K.
INSPECTIONEND
EF & EC-89
N.G.
TROUBLE DIAGNOSES
Diagnostic Procedure 4
ENGJNE TEMPERATURE SENSOR (CodeNo. 13)
E. c. c. S.
CONTROL
UNIT
18-
L/OR
(E. F. I.
harness)
21-8
29-8
m[;]
jf!
.rb@)
\mm
ENGINE
TEMPERATURE
SENSOR
SEF223H
Component location
SEF150H
EF & EC-90
TROUBLE DIAGNOSES
Fa
INSPECTION START
r1I
eJ
CHECK COMPONENTS.
Check engine temperature sensor.
(See page EF & EC-147.)
[ill
i5[II
Ii]
Fa
21 29
r1I
C;'UNIT
CONNECTOR
II
SEF148H
i5
~i5u
sensor.
O.K.
Ii]
r-ClUNIT
N.G.
[ill
00
18
CONNECTOR II
SEF149H
O.K.
O.K.
Reinstall any part removed.
EF & EC-91
N.G.
TROUBLE DIAGNOSES
Diagnostic Procedure 5
VEHICLE SPEED SENSOR (SwitchON/OFF diagno~tic item) (Code No. 14)
HEAD-UP DISPLAY
CONTROL UNIT
IGNITION
SWITCH
ON or START
~Ii
I@
I!]
U
I'
28
~~~
~@ "
"
"
iiD
'">-
COMBINATION METER
~ GD~~
.....
>->.
>-
>- >-
@"..QD
~ (Refer
FUSE BLOCK
to "POWER
SUPPL
E. C. C. S.
8S7iROL
ROUT
I NG"
@@
In EL sect Ion.)
r-=-.
@@
11
@~<)
.~o
BODY
GROUND
G
Y/8
Y/l
".II,~.
y/G
(E.
F.
(Main)
I.
harness)
, ,
... ..
>- >-
harness
@D
Y/8
Y/G (jnstru nt
harnes~f
~ ~
age
Y/l
Y/8~
>-
(Eng
I Ine room
harness)
I
3'-
Y/l
ffi..ffi
".
\;t!::
Y/l
' ,
>-
<Foldou
ReferiOpa~e).
::
"
~
0
tI
S. M. Y' st
[t!J
@@])
(Eng
I ne
harness
room
no. 2)
.....
Y/G
"
>->-
@:D~
@
~,
EF
head-up
&
display
EC-92
SPEED
SENSOR
SE F224H
TROUBLE DIAGNOSES
INSPECTION START
PI
Is speedometer
working
No
properly?
Yes
PI
SEF804F
Ii]
II
ClUNIT
~i5
&a
SEF151H
]CONNECTORII
32
[ill
O.K.
INSPECTION END
Ii]
CHECK CONTINUITY
BETWEEN E.C.U. AND
VEHICLE SPEED SENSOR.
1) Turn ignition switch "OFF".
2) Disconnect E.C.U. harness
connector.
3) Check continuity between
E.C.U. terminal @ and
ground by rotating rear wheel
by hand.
Continuity should come and
go.
N.G.
O.K.
Reinstall any part removed.
O.K.
INSPECTION END
EF & EC-93
N.G.
TROUBLE DIAGNOSES
Diagnostic Procedure 6
IGNITION
SIGNAL
E. C.C.S.
CONTROL
UNIT
r.11;:t
p:leJ
FUSE AND
FUSI BlE LI NK
<I n RELAY BOX)
FUSE
@)!
1-W
36-B
Y/R
bill
(E. F. 1harness)
- -- - - - - - - - - -- -- - ---,
I'I' ,
I'"
@@
bID
", '
"I I
13-B
harnesS>
B/R~
I I
I I
-w
~B/R
," ,
I I
I I
I I
""
""
""
"
,,
:I
':
I"
III
@)L8
@)i - i@)
.
ENGINE
GROUND
1111
~'"
"''\
FUSIBLE
LINK
f1
IGNITION
"
III
~~
@I~
ii ~ ~@
III
~~
cn
@)g
," I
," ,
"
i:I I I
'"
fJ
@)
LQ
'"
'\
~111~
~mm[i] 1Ir!1
III
([@~
DISTRIBUTOR
~ ij
POWER
TRANSISTOR
CONDENSER RESISTOR
BATTERY
~
- - - SPARK PLUG
111]
1
2
3
4
5
OFFACe ON ST
c
0
C
:J
0
I GNI TI ON SWITCH
SEF225H
Componentlocation
l
SE F34 7H
EF & EC-94
TROUBLE DIAGNOSES
"..
mLit~
CGIIBT
00
Battery
---.
<f>
ID
SEF370H
~ ~i5
O.K.
CCNECTOR
II SEF444H
[!]
Ii]
[!]
~i5
~Jur
[ill
./
IE)
....,
INSPECTION START
CGIIBT
N.G.
nectorterminal CD andground
with logic probe.
Pulse signal should exist.
If N.G., check the E.C.U. pin
terminals for damage or the
E.C.U. harness connection.
O.K.
lo.K.
00
1$ 81
ID
I'
e
SEF152H
Ii]
~[
~
00.
ClUNIT
1
'8
CONNECTOR
II
CONIIECT
tID
Battery
<f>
e
Logic probe
II
CHECK POWER SUPPLY.
1) Stop engine.
2) Disconnect harness connector
from ignition coil.
3) Turn ignition switch "ON".
4) Check voltage between ignition coil harness connector
terminal @ and ground.
Battery voltage should exist.
O.K.
SEF153H
00
Ii!lCoili~i5
::E
SEF154H
EF & EC-95
N.G.
TROUBLE DIAGNOSES
Ii
ffi
cilltv~i5
Ii
[ill
~i5~
SEF366H
[!1
cillE>~i5~
[!1
[ill
SEF156.H
-=-
N.G.
O.K.
2) Check continuity.
3) Check engine ground.
O.K.
CHECK COMPONENTS.
Check ignition coil and power
transistor.
(See page EF & EC-148.)
N.G.
O.K.
Reinstall any part removed.
EF & EC-96
N.G.
TROUBLE DIAGNOSES
NOTE
EF & EC-97
TROUBLE DIAGNOSES
Diagnostic Procedure 7
ENGINE CONTROL UNIT (Code No. 31)Q
INSPECTIONSTART
Yes
Replace E.C.U.
No
INSPECTION END
EF & EC-98
TROUBLE DIAGNOSES
NOTE
EF & EC-99
TROUBLE DIAGNOSES
Diagnostic Procedure 8
81
E. C. C. s.
CONTROL
UNIT
~
@)W -<> Ii]
"'II::
...I"
105-
LG
FUSE
till
@@)
B/R
(E. F. I.
harness)
(Eng I ne room
harness)
8R-'
'-B
BR
B~
~
..
(ill) [IJI
1
2
3
4
5
:J
(
c
I GNITI ON
SWITCH
FUS Bt~D LI NK
F~SI
RELA Y BOJO
Un
=~~
BATTERY
EF & EC-100
FUSIBLE
LINK
@)Q
OFFACC ON ST
~:~ ~
~
~
SE F269H
TROUBLE DIAGNOSES
INSPECTION START
Responds
SEF445H
Ii]
INSPECTION END
Ii]
SEF157H
[i
~-
~~
Clagg'og
=='--
.:C\
N.G.
Replace E.G.R. control valve.
N.G.
O.K.
Ii]
Ii]
CONNECT
001
trJ C.f'H
100
SEF158H
Engine
condition
Idle
(I
II
CONNECT
C;'UNI T
105
CONNECTOR
II
tD
Racing
Voltage
Battery
voltage
Temporarily
drops to 0 - 1 V
O.K.
)
00
(I
. Improperconnection
~ ""
CHECK COMPONENT.
Check E.G.R. control valve.
(See page EF & EC-148J
N.G.
[i
O.K.
N.G.
Voltage
Battery
voltage
Temporarily
dropstoO-1V
O.K.
UW
C.f'H
SEF159H
EF &. EC-101
TROUBLE DIAGNOSES
Ii
Test condition
Drive vehicle under the following conditions
with a suitable shift position.
. Engine speed:
3,100:1:300
3,000:1:400
rpm (AfT)
rpm (MfT)
mmHg, -12.60:1:2.36
CHECK COMPONENT.
1) Stop engine.
2) Check E.G.R. control solenoid valve. (See page EF &
EC-149J
inHg)
Driving mode
Test condition
16 seconds or more
@
N.G.
O.K.
CHECK COMPONENT.
Check E.G.R. control valveand
B.P.T. valve.
(See page EF & EC-148J
Vehicle
driving
N.G.
O.K.
For non-California
O.K.
For California
INSPECTION END
Idling ----.
Ignition'JLj
Time
switch: I IC))
0 F F -+-t----Until green and red inspection lamps go off.
CD Start engine and warm it up sufficiently.
@ Turn off ignition switch and keep it off
until green and red inspection lamps go off.
CID Start
engine and make sure that air conditioner switch and rear defogger are turned
"OFF" during driving test.
@ Shift to suitable gear position and drive
in "Test condition" for at least 16 seconds.
CID Decrease
engine revolution to less than
2,000 rpm.
@ Repeat steps @ through CID at least 1
time.
SEF037H
[!1
Ii
Perform driving test under the
following conditions.
1) Warm up engine sufficiently.
2) Use test driving modes
indicated in figure Ii.
~~E~
[!1
Comes
EF & EC-102
TROUBLE DIAGNOSES
NOTE
EF &. EC-103
TROUBLE DIAGNOSES
Diagnostic Procedure 9
(E. F. 1harness)
19-W
:~:
nnn
,m
ii
nnnnnnnnn_nn
I
I
I
I
I
I
I
mmmm
m__m
I
I
I
I
I
I
I
1:_'
m_:::::::::~I
(ill)
@-=<>
Ii]
i@
"::"
EXHAUST
GAS
SENSOR
ENGINE
GROUND
SEF226H
Component
location
EF & EC-104
TROUBLE DIAGNOSES
INSPECTION START
':)
([IT))
SEF153D
I;]
I;]
.-cT
eJ
II
~IT
~
=
[ill
connector
'8 CONNECTOR
II
19
Exheust
ges sensor
O.K.
INSPECTION END
~
.-cT
eJ
SEF446H
N.G.
N.G.
O.K.
Replace exhaust gas sensor.
EF & EC-105
N.G. .
TROUBLE DIAGNOSES
Diagnostic Procedure 10
EXHAUST GAS TEMPERATURE SENSOR (CodeNo. 35)
E. C. c. S.
CONTROL
f'"F2I
UNI T
~
(E. F. 1harness)
8-R/L
@
(Eng I ne room
R/~j t:/L
21-8
harness)
(Eng I ne
harness
room
no. 2)
R/L]tiJ ~R/LI<
<1881mB
I:IR/~::ft) ~~/LII:
@@
..J
"aiD<
F7
Ii1[!]
@E)Q?~
~
1i1[!]
:A/T
mode I
:M/T
model
~
EXHAUST
GAS
TEMPERATURE
SENSOR
SEF204H
Component
location
A/T mOde;
(/- /rv
SEF~73H
EF & EC-106
TROUBLE DIAGNOSES
INSPECTION START
m~~
CONNECT
)
[Y]
:+:
~0
I~~
H
SEF201
Ii)
~~i5
[ill
Condition
'+:. ,-
00
~i{)u
[i
Voltage
CIUN!:!:8COtNECTOR
When vacuum
II
applied
control
SEF202H
~i5
1.0- 2.0V
is
0 - 1.0V
to E.G.R.
valve
[ill
N.G.
Ii)
'+
00
~i5u
O.K. EBEB
21
3) Disconnect
N.G.
exhaust gas
'terminals @ and @.
Continuity should exist.
[i
O.K.
CHECK GROUND CIRCUIT.
Check continuity between
terminals @ and @.
Continuity should exist.
O.K.
EB
EF & EC..'07
N.G.
TROUBLE DIAGNOSES
CHECK COMPONENTS.
Check exhaust gas temperature
sensor. (See page EF & EC-149.)
N.G.
O.K.
.....-O.K.
INSPECTION END
EF & EC-108
N.G.
TROUBLE DIAGNOSES
NOTE
EF & EC-109
TROUBLE DIAGNOSES
Diagnostic Procedure 11
E. C.c. S.
CONTROL f<O'\
UNIT
I:t.., nil
~~eu~es
(E. F. 1harness)
--n-_n--nn
-- un
---u"
------- U___n-n------_n-----_n--n- n_n-nn-_nn
--U_-,, ,,
,, ,,
,, ,,
,,
",, ,,
,,
,,, ,,,
," ,
~_nnnn__u-
20-W
21-8
29-8
33-Y/
44
1371
37-
LG
/R
H-Y
,,
,, ,,
I'
i
I' ,
B--.
0:
"
@~
@i
ENGINE
GROUND
THROTTLE
VALVE
SWITCH
@ CfPfl
~
...J
EF &. EC-110
W
...J
~
~
PI Ii][!]Ii
THROTTLE
SENSOR
SEF211H
TROUBLE DIAGNOSES
,-
db ~
i)
:f
i3~
~
START
[2]
r;) cllitD
......
INSPECTION
SEF207H
./
N.G.
O.K.
IIISCOIIIlECT
18
[ill
r---o
~i5[[
[i1
ClUNIT
~
~
~.)
37
CONNECTOR II
SEF208H
CONNECT
[Y]
HARNESS CONTINUITY
BETWEEN THROTTLE
SENSOR HARNESS CONNECTOR AND E.C.U.
1) Turn ignition switch "OF F".
2) Disconnect throttle sensor
harness connector.
3) Disconnect E.C.U. harness
connector.
4) Check continuity between
terminals @ and @.
Continuity should exist.
If N.G., repair or replace
harness or connector.
Ii]
[i1
O.K.
CHECK INPUT SIGNAL
CHECK INPUT SIGNAL
r----+
(Throttle sensor side).
(E.C.U. side).
Makesure that voltage between
Makesure that voltage between
terminal @ and ground changes
terminal @ and ground changes
when accelerator pedal is dewhen accelerator pedal is depressed.
pressed.
Voltage:
Voltage:
Approximately 0.5 -4.0V
Approximately 0.5 - 4.0V
N.G.
lo.K.
Repair or replace harness or
connectors between terminals @
and @.
i3~
SEF209H
81
Ii]
II
c.;uNIT
CONNECTOR ~
riI i)
20
[Y]
00.
+, ,-
i3
81 clliID
SEF367H
~ i5
[ill
00
i5~[[
r---o
ClUNIT
21 29
CONNECTOR II
SEF210H
Ej
EF & EC-111
N.G.
TROUBLE DIAGNOSeS
CHECK COMPONENT.
Check throttle sensor.
N.G.
Replace throttle sensor.
iii
SE F346H
O.K.
N.G.
O.K.
Reinstall any part removed.
EF & EC-112
N.G.
TROUBLE DIAGNOSES
NOTE
EF & EC-113
TROUBLE DIAGNOSES
INJECTOR LEAK (Code No. 45)
Diagnostic Procedure 12
INSPECTION START
SEF832F
Ii)
Engine racing mode
@ : 10 seconds or more
Runs smoothly
2,000 rpm
Idling
Stays off
Ignition
switch: .
OFF
Time
SEF392G
[+J
Does not
stay
off
"
Do not blink
m
1) Stop engine.
2) Remove all spark plugs from
intake manifold. Are plugs
wet with fuel?
Yes
INSPECTION END)
No
~~E~
CHECK ENGINE LIGHT
SEF924F
EF & EC-114
TROUBLE DIAGNOSES
r
Erasethe self-diagnosismemory
by following the procedure.
1) Start engine and warm it up
sufficiently.
2) First disconnect air flow
meter connector, and start
and run engine for at least
30 secondsat 2,000 rpm.
3) Stop engine and reconnect air
flow meter connector.
4) Make sure Code No. 12 is
displayed in Mode III.
5) Erasethe self-diagnosis
memory. Make sure Code
No. 55 is displayed in Mode
III.
Ii]
Perform engine racing by the use
of indicated in figure
Ii].
Comes
[i
Make sure check engine light does I "ON" 1) Perform self-diagnosis and
find malfunction code.
not come "ON" during engine
racing.
2) According to displayed Code
Does not
come "ON"
INSPECTION END
EF & EC-115
TROUBLE DIAGNOSES
Diagnostic Procedure 13
IDLE SWITCH (Switch ON/OFF diagnostic item)
E.
C.
C.
S.
CONTROL
f"F2\
UNIT
~
33- Y/W
44
TI'
(E.F. 1harness)
H-Y
J nmm
@)r@~
THROTTLE
VALVE
m
j
SWI TCH::J LL
..J
0
SEF212H
EF & EC-116
SEF369H
m[lt
CONNECT
TROUBLE DIAGNOSES
INSPECTION START
[Y]
~
I!J~
.--r
IV
00
SEF375H
@ID
[Y]
SEF449H
O.K.
Repair or replace harness or
connector between throttle valve
switch harness connector terminal @ and E.C.U. harness
connector terminal @.
Voltage
Approximately
Fully closed
8- 10V
OV
Open
-=
INSPECTION END
N.G.
@J
O.K.
N.G.
I!J
O.K.
N.G.
CHECK COMPONENT.
Check idle switch.
O.K.
O.K.
INSPECTION END
EF 8r.EC-117
Replace E.C.U.
TROUBLE DIAGNOSES
Diagnostic Procedure 14
START SIGNAL (Switch ON/OFF diagnostic item)
E.C.C.S.
CONTROL
UNIT
UP
FUSE
BLOCK
(Refer
to
npOWER
SUPPLY
ROUTINGn
In El sect Ion. )
tf2'I
~
@@
..
I
,
>-
FUSE
m
(E.
F.
1.
harness)
JI
OR
(Ma In h arness )
rnJ
OR
~
,
m
>-
S. M. J.
~efer to last age
(FoIdout page). f
@])
~nglne
room harnes~
w
w
BR~
...
cD
>-
,
m
~:~
~~
@)
I
,
m
>-
34-0R
~~
@)g
FUSIBLE
LINK
FUSE
AND
FUS I BlE LI NK
(In RElA Y BOX)
1m
OFFACC ON ST
c
0
I
c
0
2
0
3
4
5
I GNITI
ON
SWITCH
~
-
BATTERY
SEF214H
EF & EC-118
TROUBLE DIAGNOSES
m
II
CAJNIT
lit is
INSPECTION START
8 CONNECTORII
34
00
SEF213H
INSPECTION END
N.G.
O.K.
INSPECTION END
EF & EC-119
N.G.
TROUBLE DIAGNOSES
Diagnostic Procedure 15
FUEL PUMP (Not self-diagnosticitem)
FUEL
PUMP
E. C.C.S.
CONTROL~
UNIT @~....
r=I r=I
G;J
..?7 iii Inl
@J){i@5)
IU-8/P
rffi3l~
>-
BODY
GROUND
107-8
..
--1
..
>-
,..
@
(E. F. 1.
harness)
@@
--
(Ma I n
harness)
FUSE
S.M.J.
m,
>..
8/R
(Eng I ne room
harness)
8/W
~8/Y
,.. ~
>-
,
....
@)
@Y~
,~ ....
~~
@lMJ
IIlnii if Ifm
FUEL
PUMP
RELAY
AIR
REGULATOR
III
~:~
~
\!!!I
1
2
3
4
5
SEF268H
EF & EC-120
FUSI
LI NKBlE
FUSE AND
FUSI BlE LI NK
(I n RElA Y BOX)
BATTERY
Component location
[DJ~
@)Q
OFFACC N ST
I GNI TI ON
SWITCH
8~
I'
0:
page
[Refer
to
'ast
(Fa I dout
page).)
SEF236H
TROUBLE DIAGNOSES
INSPECTION START
m~~
~tttill1
i5
[Y]
~
(2J
SEF264H
I!J
~~_r
IImtalV
00
O.K.
[!J
SEF266H
[:iI
.--r
CHECK COMPON~NTS.
1) Turn ignition "OFF".
2) Check fuel pump.
(See page EF & EC-149,)
If N.G., replace fuel pump.
I!J
N.G.
[ill
[!J
O.K.
:filiL
@"l)]
10
[Y]
. "BR" fusiblelink
O.K.
lZJOO
Ii]
~
_r
IV
00
=
SE F377H
illTI:0"'lII
rnJ
CHECK COMPONENTS.
1) Turn ignition "OFF".
2) Check fuel pump relay.
(See page EF & EC-150,)
Ii]
i5[:i1~
SEF379H
N.G.
O.K.
harnessconnectorterminal CD
and fuel pump harness connector terminal @.
O.K.
EF & EC-121
N.G.
TROUBLE DIAGNOSES
Ii
CONNECT 104
If)
00
IT B" CONNECTOR
II
0
SEF266H
Ii
_r ~
ClUNrT J CONNECTOR
III/!.r:!:\
II
'liiV ~
104
Ii
[ill
00
1211
4R3
SEF267H
Ii
INSPECTION END
~
_r
N.G.
@.
@.
O.K.
Recheck the E.C.U. pin terminals
for damage or the connection of
E.C.U. harness connector.
IV
EF & EC-122
TROUBLE DIAGNOSES
NOTE
EF & EC-123
TROUBLE DIAGNOSES
Diagnostic Procedure 16
,
PRESSURE REGULATOR (P.R.) CONTROL SOLENOID VALVE (Not self-diagnostic
item)
PRESSURE
REGULATOR
CONTROL
SOLENOID
VALVE
go~'T~;l
UNIT
@~
/7
[;]
~
@W~ml!J[;]
LID
I06-PU
FUSE
8/R
@@)
(E. F. 1.
harness)
8RJ
8R
t8R
(=m::~
I@l~~~~
~
ID
I'\. OFFACC ON ST
r
1
c
::>
2
::>
3
4
5
I GNITI ON
SWIT CH
FUSIBLE
, LINK
@)~
FUSE AND
FUSI BLE LI NK
<In RELA Y BOX)
=~~
BATTERY
Component location
EF &. EC-124
SEF267H
TROUBLE DIAGNOSES
m
INSPECTION START
.q:ffip
m
IllsalllllECT
18
@) LjCYJ
SEF253H
TINUITY BETWEENP.R.
CONTROL SOLENOID VALVE
AND BATTERY.
Check following.
. Fuse
. Ignitionswitch
. Harnessor connectors
O.K.
Ii] [11
CONNECT
00
U
ID
UCYJ
CfH
SEF255H
[f]
IllsalllllECT
ffiiJ)
18
cc
Ii]
[ill
SEF256H
106
[I
CoIUNIT
CHECKCOMPONENTS.
1) Turn ignition switch "OFF".
2) Check P.R. control solenoid
valve. (See page EF & EC-149J
O.K.
[1I_T
18
~
CONNECTOR
II
O.K.
INSPECTION END
EF & EC-125
[f]
N.G. ~HECK HARNESS CONTINUITY BETWEEN P.R.
CONTROL SOLENOID VALVE
AND E.C.U.
1) Stop engine.
2) Disconnect P.R. control
solenoid valveharness connector.
3) Disconnect E.C.U. harness
connector.
4) Check continuity between
terminals @ and @.
Continuity should exist.
If N.G.. repair harness or
connector.
O.K.
1) Perform E.C.U. input/output
signal inspection test.
2) If N.G., recheck the E.C.U.
pin terminal @ for damage
or the connection of E.C.U.
harness connector.
TROUBLE DIAGNOSES
Diagnostic Procedure
17
NO.1
CONTROL
UNI
T
f'""F2I
~
!!L
1
jJ
@)W @W
::;t m -;! m
L..i "'~
101-W/B
103-
G/B
110-
Y/B
NO.4
~ ~ ~ ~
(iJIJ
E. C. C. S.
NO.2
mIJ
"'~
W@
W@
"'ci
"'~ ~
IImIJ IIm[ill
m~
II mIJ
FUSE
rnJ
112-L/B
UTI
(E.F. I.
(Eng I ne room
harness)
harness)
RiiR
@
@)
[TI]~
~
@)~
i46
(61
@)
FUSIBLE
LINK
FUSE AND
FUSI BLE LI NK
(1 n RELA Y BOX)
H-R
BAHERY
SEF251H
Component
location
Harness connector
------
EF & EC-126
TROUBLE DIAGNOSES
INSPECTION
eJ
-CSZJ
'+
SE F247 H
I;)
~
~
ClUNIT
19111,0193112
eJ
N.G.
OO
. "G"fusiblelink
. Harness
O.K.
CONNECTOR ~
[Y]
00
:+:..-
I~~
~~
II
START
SEF249H
No.1
No.2
No.3
~-.r
~
No.4~
[ill
-.r
eo ~
101110
'03112~ fol CClNNECTCIR II
II
c.1INJT
SEF250H
CHECK COMPONENTS.
1) Turn ignition "OFF".
2) Check injectors.
(See page EF & EC-150.)
Ii)
O.K.
INSPECTION END
N.G.J
1 Replace injectors.
II
N.G.
lO.K.
Recheck the E.C.U. pin terminals for damage or the
connection of E.C.U. harness
connector.
EF &. EC-127
TROUBLE DIAGNOSES
Diagnostic Procedure 18
SWIRL CONTROL VALVE (S.C.V.) CONTROL SOLENOID VALVE (Not self-diagnostic item)
ECC.S.
C'ONTROL
UNI
T
[iJ
S. C. V.
CONTROL
SOLENOID
VALVE
f"'F2'\
~
~Weill)
f!ruuI
>-'"
"CD
FUSE
@)
~nglne
rnJ
room harnes~
8/R
8RJP '-BR
12-GY
8R
~. F. 1.
harness)
w
w
8q] ~
~:~
@)
'"
,
~
CD
(illY~
1m
1
2
3
4
5
OFFACC ON ST
c
c
J
J
1 GN1TI ON
SWI TCH
@)~
[ll)
FUSIBLE
LINK
FUSE AND
FUSI BLE LI NK
(1 n RELA Y BOX)
~BATTERY
SEF231H
Component location
EF & EC-128
TROUBLE DIAGNOSES
INSPECTION START
m
eJ.
CH ECK
[Y]
L.:::
SEF227H
1!1
N.G.
. "G" fusiblelink
. Ignitionswitch
. Harness
O.K.
CIIIIET
)
00
ID
IJ
YJ
CH
SEF229H
O.K.
Ii)
~~i5
12
CAJN~
CONtECTaR II
SEF230H
Lass than
"approx. 1,400 rpm
0.5 - 1.0V
More than
approx. 1,400 ';Pm
Battery
voltage
engine.
Voltage
between
terminal @
and grou nd
Engine speed
[!J
N.G.
[ID
00'
~i511
N.G.
CHECKCOMPONENTS.
1) Turn ignition switch "OFF".
21 Check S.C.V. control solenoid
valve. (See page EF & EC-149.)
terminals @ and @
O.K.
1) Perform E.C.U. input/output
signal inspection test.
(Terminal @)
2) If N.G., recheck the E.C.U.
pin terminals for damage or
the connection of E.C.U.
harness connector.
O.K.
CHECK COMPONENT.
Check swirl control valve
actuator.
(See
and
EF & EC-150.)
page
I
O.K.
INSPECTION
END
EF & EC-129
TROUBLE DIAGNOSES
Diagnostic Procedure 19
AIR REGULATOR
(Not self-diagnosticitem)
FUEL
PUMP
E. C. C. S.
CONTROL fM\
UNIT
~~~U8
nil nil
@D~@])
10'-B/P
~~
107-B
BODY
GROUND
rffBl@)
...
,
.0
I (Ma I n harness)
...
,
.0
@
(E. F. r.
harness)
@iD
--
GJ
...
FUSE
page
,.0
@@
B/P-ffi
B/Y~
S. M. J.
last
(Fo I dout page).]
ffiefer to
B/R
(Eng I ne
harness)
room
ffi-B/P
~B/Y
B/W
W
BR~
I"
0:
,.. ;t
[!]1]1i
...
,
.0.0
"
S\ ".0.0 .0.0
@lMJ
...Q.
@)
d;fh
m(;]1]
WJ
.
;1
@i
ENGINE
FUEL
PUMP
RELAY
~~
;t;t
1m
OFF ACC ON ST
:) :)
1
:J
2
3
4
5
I GNITI ON
SWITCH
'I
EF & EC-130
cn~
@)~
rru\
~
FUSI
LI NKBlE
FUSE AND
FUSI BlE LI NK
<In RELAY BOX)
~BATTERY
Component location
~:;
;t
SEF240H
TROUBLE DIAGNOSES
11
[:it~
eJ
C
11
_CT
[Y]
@a
SEF236H
[;]
[:it
..-cT
10
00
[ill
.'2J1l
m=ru
eJ
00
~oo
-=
SEF377H
I]
CHECK COMPONENTS.
1) Turn ignition "OF F"
2) Check fuel pump relay.
(See page EF & EC-150.)
I]
~IV
[:it
00
[;]
Checkfollowing.
. Harnessor connectors
. "BR" fusiblelink
. Fuse
O.K.
:+'
-IV~~
CHECK COMPONENTS.
1) Turn ignition "OFF".
2) Check fuel pump relay.
(See page EF & EC-150.)
If N.G. replace air regulator.
O.K.
[!J
-=
[:it
_T
N.G.
SEF237H
[!J
INSPECTION START
SE F380H
N.G.J
O.K.
harnessconnectorterminal CD
-and fuel pump harness connector terminal @.
O.K.
EB
EF &. EC-131
N.G.
TROUBLE DIAGNOSES
ffi
[1t
iii
COllECT
[[
ClUNIT
104
U
00
f CONNECTOR
[SLJ
+,
~
Ii
II
CIWIIT"8
104
II
SEF238H
CONNECTORII
~
rw
St:J I..dI
[ill
00
iii
Ii
O.K.
INSPECTION END
SEF267H
@.
O.K.
Recheck the E.C.U.pin terminals
for damage or the connection of
E.C.U. harness connector.
IIISaIIIIECT
1211
4R3
N.G.
I()
EF & EC-132
TROUBLE DIAGNOSES
NOTE
EF &. EC-133
TROUBLE DIAGNOSES
Diagnostic Procedure 20
AUXILIARY AIR CONTROL (A.A.C.) VALVE
(Not self-diagnosticitem)
A.A.C.
SOLENOID
VALVE
Wd
E C c. S.
CON'TROl
FUSE
<i:DJ
B/R
(ill)
BR
n~-:-
UNIT
113-SB~
~
mliJ[!J
w
w
B~
~B:~
@@)
BR~
BR~
~
BR
~BR
(Eng Ine 'oom
harness
harness)
BR
@tI)
~~
'3-BR
1m
() :A/T
@ :M/T
model
model
@)
d
c
BR'-
IJJ
IJJ
4)
C
''"
.c
E
0
0
@1)
'-
lB
OFF ACC ON ST
J
1
")
2
~[!J
@)
g@)
[DJ~
FUSIBLE
, LINK
FUSE AND
FUSI BlE LI NK
(1n RELAY BOX)
BR'
;1
(E. F. I.
!i@)
3
4
5
.",
GROUND
IGNITION
SWITCH
BATTERY
Component location
EF & EC-134
""'lOR
STEERI NG
OIL PRESSURE
SWITCH
-SEF218H
TROUBLE DIAGNOSES
INSPECTION START
~~i5
CHECK COMPONENTS.
Check A.A.C. valve.
(See page EF & EC-150J
[Y]
N.G.
. Replace A.A.C. valve.
[
o~
-=
SEF215H
Ii]
O.K.
CONNECT
~[11)
~
N.G.
CHECK CONTINUITY
BETWEENA.A.C. VALVE
AND BATTERY.
Check following.
.
.
.
.
Fuse
"G" fusiblelink
Ignitionswitch
Harnessorconnectors
O.K.
t\\-Y1
~~ ~
[I
';
Cf'~H
SEF217H
~i5
Ii]
CHECK INPUT SIGNAL.
ill]
I
IW
~c;\
_CT
L.dII WiiV
II
c.-uNIT
113
[I
~
8
E
CONNECTOR
I
SEF452H
O.K.
INSPECTION END
N.G.
O.K.
1) Perform E.C.U. input/output
signal inspection test.
(Terminal @.)
2) If N.G. recheck the E.C.U.
pin terminals for damage or
the connection of E.C.U.
harness connector.
EF & EC-135
TROUBLE DIAGNOSES
Diagnostic Procedure 21
I.A.A. CONTROL
(F.I.C.D.
CONTROL)
(Not self-diagnosticitem)
I GNI TI ON SWITCH
ACC or ON
F. 1. C. D.
SOLENOID
VALVE
IiJ
E.C.C.S.
CONTROL
UNI T
@)
~ -<>
.J
.
1!1[!J
BATTERY
'"a
,.J
(Ma In
harness)
UP
II:
I
FUSE BLOCK
!Refer
to 'POWER
SUPPLY ROUTI NG'
In EL section.)
'"
a
I
,.J
(ill)
(E. F. 1.
harness)
G/Y~
~G/Y
L/G e:r
L/G
[Refer
(Fo I dout
cD
'"
a
,.J
ffi
@@
ll-G/Y
S. M.J.
::
to
last
page).
age
!Eng I ne room
harness)
'"
"",
a >-"'0
,.J '"
"'.J.J
@~
I.
i@)
AIR
CONDI TI ONER
RELAY
ENGINE
GROUND
SEF270H
Component location
EF 8r. EC-136
TROUBLE DIAGNOSES
INSPECTION START
\.
m
A/C
..
PU
Yes
up
sufficiently.
2) Does engine revolution rise
when air conditioner switch is
turned "ON"?
SEF129GI
No
r;]
!f
eJ
SEF447H
-eJ ,
nal @ andground.
00
ClUNIT
11
N.G.
'
I I CHECK
COMPONENTS.
1) Turn ignition switc'.h .OFF"
SEF448H
HECKGROUNDCIRCUIT.
rEIDl
II
CONNECTOR II
lEL
JJ
N.G.
Voltage
0.5 - 1.0V
OFF
Battery voltage
INSPECTIONEND
TINUITY BETWEEN
BATTERYAND E.C.U.
Check following.
8 Fuse
8 Ignition switch
8 Harness or connectors.
I O.K.
Recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness
connector.
O.K.
EF & EC-137
connectors.
relay.
terminal @ andground.
Continuityshouldexist.
If N.G.,repairharnessor
O.K.
I;]
2) Check
(See HA
air section.)
conditioner
IO.K.
[i
00
filii
INSPECTIONEND
CHECK COMPONENTS.
Check F.I.C.D. solenoid valve.
(See page EF & EC-151J
If N.G., repair or replace F.I.C.D.
solenoid valve.
1) Stop engine.
[:it
CONNECT
O.K.
CHECK POWERSOURCE.
ilJ
I;]
r;]
oo
[i
I O.K.
TROUBLE DIAGNOSES
Diagnostic Procedure 22
AIR INDUCTION VALVE (A.I.V.) CONTROL SOLENOID VALVE (Notself-diagnosticitem)
E. C.c. s.
CONTROLtf2)
UNIT
/'
FUSE
[i
room harnes~
~nglne
P
102-P
(E. F. 1.
harness)
ii
B/R
BR
:req]
@)
G=I]
G=I]
[ll]
(ill)
FUSIBLE
LINK
FUSE AND
FUSI BLE LI NK
(1 n RELAY BOX)
'"
,ID ~
'"
lDo.
(@)~
@)&
1m
rims?
A. 1. V.
CONTROL
SOLENOID
VALVE
OFFACCON ST
1
0
C
2
c
3
4
5
IGNITION
SWITCH
BATTERY
SEF234H
Component location
EF & EC-138
TROUBLE DIAGNOSES
II
INSPECTION START
18
II
[Y]
&
m
I;]
SEF227H
N.G.
O.K.
COllECT
if)
ool
tID
,
[!] @}
CHECK COMPONENTS.
' N.G.
1) Turn ignition switch "OFF".
2) Check A.I.V. control solenoid
valve. (See page EF & EC-149.)
CYH
l1t
SEF229H
i5
~
~
DlSCGltIlt:CT 102
1811
ClUNIT
[!]
N.G.
[ill
~
O.K.
I;]
Ef C~CTOR
II
Accelerator
pedal position
Released
SEF233H
Depressed
Voltage
0.5 - 1.0V
Battery
voltage
O.K.
CHECK COMPONENT.
Check air induction valve.
(See page EF & EC-151.)
,
O.K.
INSPECTION END
N.G.
EF & EC-139
TROUBLE DIAGNOSES
Diagnostic Procedure 23
NEUTRAL
SWITCH, INHIBITOR
E. C. c. S.
CONTROL
UNIT
RELAY
(Not self-diagnosticitem)
I GNI T! ON SWITCH
ON or START
@
@
@
:A/T
model
:M/T
mode I
:A/T
model
:A/T
mode I without
UP
with
..
A. S. C. D.
FUSE BLOCK
(Refer
to "POWER
SUPPL Y ROUT! NG"
1n EL sect Ion. )
A. S. C. D.
...J
,"
(MaIn harness)
[Refer
@)@)
S. M.J.
to Iast
(Fa I dout
W-G/OR
(~a~;"' I:Ss)
35- G/OR
G/OR-Im
j[[
::r-
0:
"ID
ID
m[l<==-~@)
SWITCH
i5 [:it
-ffi. .ffi.@83"~@3)
r:=I
ell
~~~~
IJ
M
IDID
J;!;II ~
81
,'"
...J
room
no. 2)
~~
~dP
@)
QJ 0
=arness
G/
@)
QD
II
0:
0
,"'ID
lMJ@)
L,WJ
=
I~I
I NHI BI TOR
I NHI BI TOR
RELAY
RELAY
CSZJ
OO(D
"
<>
harnes~
G/OR
@@)
INHIBITOR
page).
,"
(Eng i ne
'0:
1;]81
room
--"
35
~ngine
age
...J
-=
SEF350H
EF & EC-140
ft i@
-=-=-=
@!@)
BODY
GROUND
m~~
NEUTRAL
SWITCH
SEF246H
TROUBLE DIAGNOSES
INSPECTION START
I;]
~[@b)
IIISCOIIIlECT
N.G.
EO
CHECK COMPONENTS.
Check neutral switch (M/T) or
inhibitor switch and inhibitor
relay (A/T).
(Seepage EF & EC-152.)
[ill
taEO~
[ill
N.G.
CHECK CONTINUITY
BETWEEN SWITCH AND
GROUND.
I;]
SEF243H
M/T
. Fuse
. S.M.J.
model
Check continuity
between
terminal @ and ground.
[!J A/T model
1) Turn ignition switch "OFF".
2) Check continuity betWeen
terminals @, CD and ground.
Continuity should exist.
(;]
~C@Th)
IIISCOIIIlECT
[ill
EO
~
35
r="'
Cf'UNI T
CONNECTOR II
SEF244H
CHECK CONTINUITY
BETWEEN SWITCH (M/T),
RELAY (A/T) AND E.C.U.
(;] M/T
131~
i5
00
131
" ~i5
NI
T
T CONNECTOR
model
SEF245H
II
INSPECTION END
~; i5 ~
-~
[ill
liI
35
SEF349H
O.K.
i5~[[
I1Cf'U
[!J
~~_IIECT~
O.K. (A/T)
O.K. (M/T)
SEF242H
ClUNJ
CONNECTOR II
IIISCOIIIlECT
E0
EF
&.
EC-141
N.G.
TROUBLE DIAGNOSES
ITEM
*Dataare referencevalues.
CONDITION
*DATA
0.3 - 0.6V
Ignition signal
1.2 - 1.5V
Engine speed is 2,000 rpm
Ignition check
- 12V
0 -1V
4
E.C.C.S.relay
(Mainrelay)
BATTERY VOLTAGE
(11.14V)
Exhaustgastemperature I
I sensor(Onlyfor California
model)
,.
1.0 - 2.0V
L Idle speed
- ,
0 -1.0V
0 -1.0V
BATTERY VOLTAGE
(11.14V)
0 - 1.0V
12
EF & EC-142
BATTERY VOLTAGE
(11 . 14V)
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
*Data are reference values.
EF & EC-143
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
*Data are reference values.
TERMINAL
NO.
*DATA
CONDITION
ITEM
OV
Ignition switch
BATTERY VOLTAGE
(11
- 14V)
37
Approximately
38
47
BATTERY VOLTAGE
(11-14V)
II
.~~o~ers~~~chlare "ON".
5V
OV
BATTERY VOLTAGE
Air conditioner switch is "OFF".
(11 - 14V)
ne is running.1
S
43
0.1 - 0.3V
I 11::11\:1"'1::
I~IUII'"II\:I.I
.
8-9V
.
Approximately
I
44
I I Ignnlon SWIl:cnVI'II I
Throttle valve:
Except idle position
..
45
G
I
ear ISIn 5th position.
I I Ignl1lon SWltcn VI'll I
- 10V
BATTERY VOLTAGE
(11
- 14V)
rOV
I
6-8V
46
I I Ignition
switch "OFF"I
EF & EC-144
BATTERY
(11
- 14V)
VOLTAGE
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont' d)
*Data are reference values.
TERMI.
NAL
CONDITION
ITEM
*DATA
NO.
Injector No.1
103
Injector No.3
BATTERY VOLTAGE
(11.14V)
Engine is running.
110
112
Injector No.2
I
Injector No.4
0.1.0V
102
104
Engine is running.
0.7.0.9V
"
Engine is cold.
Water temperature
0.7.0.9V
is below
60C (140F).
105
E.G. R. control
valve
solenoid
After warming up
Water temperature
BATTERY VOLTAGE
(11.14V)
BATTERY VOLTAGE
(11.14V)
is between
[ (221F).
EF & EC-145
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
*Data are reference values.
TERMINAL
NO.
*DATA
CONDITION
ITEM
0 - 1.0V
(for 3 minutes after ignition switch
is turned off.)
106
Water temperature
90C (194F)
is above
BATTERY VOLTAGE
(After 3 minutes)
BATTERY VOLTAGE
(11 - 14V)
is below
7 -10V
113
A.A.C. valve
4-7V
TERMINAL LAYOUT
~i)
SEF419H
EF & EC-146
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
E.C.C.S. RELAY
Check continuity between terminals
CID
and
CID.
Condition
Continuity
Yes
No supply
No
SEF054F
SEF364H
(I
SEF176E
for dust.
SEF365H
ENGINE TEMPERATURE
SENSOR
sensor
resistance.
Temperature c (F)
Resistance kQ
20 (68)
2.1 - 2.9
80 (176)
0.30 - 0.33
[ill
SE F536H
EF & EC-147
TROUBLE
[ill
DIAGNOSES
Electrical Components
Inspection
IGNITION COIL
Check ignition coil resistance.
(Cont'd)
Terminal
Resistance
@-@
Approximately O.7il
SEF332H
POWER TRANSISTOR
[ill
SEF333H
Tester polarity
EB
EB
EB
EB
Continuity
No
Yes
No
Yes
SEF820F
B.P.T. VALVE
Plug one of two ports of B.P.T. valve.
Apply a pressure above 0.490 kPa (50 mmH20, 1.97 inH2O) to
check for leakage. If a leak is noted, replace valve.
13
t
EC381A
EF & EC~148
TROUBLE
DIAGNOSES
Electrical Components
Inspection (Cont'd)
E.G.R. CONTROL SOLENOID VALVE, A.I.V. CONTROL
SOLENOID VALVE, P.R. CONTROL SOLENOID- VALVE
AND S.C.V. CONTROL SOLENOID VALVE
Check air passages continuity.
Condition
@
SEF335H
terminals
CD
Air passage
continuity
between @ and @
Air passage
continuity
between @ and @
Yes
No
No
Yes
and @
No supply
SENSOR
THROTTLE SENSOR
Make sure that resistance between terminals
changes when opening throttle valve manually.
Resistance should change.
FUEL PUMP
Check continuity between terminals @ and @.
Continuity should exist.
EF & EC-149
and CD
TROUBLE DIAGNOSES
Electrical Components, Inspection (Cont'd)
FUEL PUMP RELAY
Check continuity between terminals
and @.
Continuity
Condition
12V direct current supply
Yes
betweenterminalsCID and @
No
No supply
CD
SEF537H
INJECTORS
Close
No supply
Open
-------
SEF371H
AIR REGULATOR
[ill
SEF339H
A.A.C. VALVE
Check A.A.C. valve resistance.
Resistance:
Approximately 10 n
SEF538H
A~ve'--GV
EF & EC-150
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
Check plunger for seizure or sticking.
..
SEF381H
F.I.C.D. SOLENOID
VALVE
SEF341H
L l:I"(~
Plunger
SEF342H
IDLE SWITCH
terminals
@ and
Continuity
Fully closed
Yes
Open
No
EF & EC-151
@ while
TROUBLE DIAGNOSES
Electrical Components Inspection (Co nt' d)
NEUTRAL SWITCH
[:it
[ill
c;JJ
~~
Continuity
Shift to Neutral
Yes
No
INHIBITOR
SWITCH
Continuity between
terminals @ and CD
Yes
No
No
Yes
Shift to positions
other than "P" and "N"
No
No
Conditions
SEF344H
INHIBITOR
RELAY
Condition
Battery
CD and
W (WithoutA.S.C.D.),
Yes
[ill
No supply
Battery
SEF348H
EF & EC-152
No
Fuel Pressure
Pressure regulator
SEF135H
Check
EF & EC-153
Vacuum
Fuel pressu re
vacuum changes.
to
pressure regulator
SEF718B
.
.
B.P.T. valve
EF & EC-154
Fuel tank
()
0~
Carbon canister
: Air
..
: Fuelvapor
SEC544A
Q@
@c)
Inspection
CARBON CANISTER
Check carbon canister as follows:
@:
Blow air and ensure that there is no leakage.
@:
Blow air and ensure that there is leakage.
EF &. EC-155
EVAPORATIVE
EMISSION
Inspection
CONTROL
SYSTEM
(Cont'd)
~
SEC308A
..
~
..
Air
Fuel vapor
SEC309A
\
l'
EF & EC-156
Steel net
Baffle plate
-
{t9t=R:/lL '--Seal
lBJ
..
SEF156E
C:?
..
type oil
lever gauge
: Fresh air
: Blow-by gas
Inspection
P.C.V. (Positive Crankcase Ventilation)
With engine running at idle, remove ventilation hose from P.C.V.
valve; if valve is working properly, a hissing noise will be heard
as air passes through it and a strong vacuum should be felt
immediately when a finger is placed over valve inlet.
SEC137A
VENTILATION HOSE
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air. If any
hose cannot be freed of obstructions, replace.
ET277
EF &.
EC-157
, '1
General Specifications
IGNITION
TIMING
IDLE SPEED
S.T.D.C.
15%2
M/T 750%50
rpm
Inspection
and Adjustment
20C (68F)
80C (176F)
2.1 -2.9
0.30 - 0.33
k11
IDLE SWITCH
Engine speed when idle switch
is changed from "OFF" to
"ON"
rpm
FUEL PRESSURE at idling
(Measuring point: between fuel
filter and fuel pipe)
Vacuum hose is connected
kPa (kg/em' ,psi)
Vacuum hose is disconnected
kPa (kg/em' , psi)
FUEL INJECTOR
Coil resistance
11
AIR REGULATOR
Resistance
11
M/T
A/T
1,000% 150
1 ,000% 150
Approximately
226 (2.3,33)
Approx imately
294 (3.0,43)
Approximately
10 15
Approximately 75
k11
85.3:t8.53
EF & EC-158
(S.D.S.)
ENGINECONTROL,
FUEL"
EXHAUST
SYSTEMS
I
FE
SECTION
~~I~~~~!~
SYSTEM
FE-2
FE-3
,
FE-4
.
.
.
..
Lock nut
tOJ 8
- 11 (0.8 -1.1,5.8
- 8.01
Adjusting nut
tOJ8 -11 (0.8 -1.1,5.8
-8.01
A.S.C.D. actuator
wire
Adjusting nut
tOJ3 -4
~-.
o:~
Locknut
tOJ 8 12
(0.8 -1.2,
5.8 -8.7)
Adjusting nut
Accelerator
pedal
Throttle drum
SFE012A
FE-2
FUEL SYSTEM
WARNING:
When replacing fuel line parts, be sure to observe the following:
:"-
~~~
I
L!
~26-36
12.7 - 3 7
20 - 27j ,
"-tDJ
!
26 -36 12.7 -3.7,20
-27)
SFE013A
FE-3
EXHAUST SYSTEM
CAUTION:
.
.
.
Catalytic
conve'rter
13-16(1.3-1.6,9-121
SFE014A
FE-4
CLUTCH
I
CL
SECTION
CONTENTS
PRECAUTIONSAND PREPARATION
CL- 2
CLUTCH SYSTEM
CL- 4
CL- 5
HYDRAULICCLUTCH CONTROL
,. CL- 7
CL-10
CL-12
CL-14
III
..
.
.
.
~
GG9431 0000
(
)
SBR500
WARNING:
Preparation
SPECIAL SERVICE TOOLS
Tool number
(Kent-Moore No.)
Tool name
Description
,
ST20050010
(
)
Base plate
. - ~"., . ,
., :',
~'::..
. -,:,
"
,.- :
ST20050100
(
)
Distance piece
GG9431 0000
)
(
Flare nut torque
wrench
ST20600000
(J26366)
Clutch aligning bar
ST20050240
- )
(
Diaphragm spring
adjusting wrench
-@:j
@~
.
\!II
~m
-~
t"'
==-p
~
~ ~
CL-2
SERVICE TOOLS
Description
Bearing puller
Bearing drift
a~
CL-3
a: 50 mm (1.97
In".mn, "I
in) dia.
be,,;n,
r~
~
~f
c
1/
,~
h
~
~~8-11
(0.8- 1.1,5.8-8.01
~~
~
~
~--
16- 22
Return spring
----",.
Lock nut
12-15 (1.2-1.5,9-111
. Pedal stopper
-~
'~
16-22(1_6-2.2,1
Clutch switch
Pedalstopper
rI
Release
bearing
~
c'"";, p;" m~-//
Clutch pedal
EI(b)
III
(')
r
to)
en
I\)
.A:
~ . Clutch
switch
Lock nut
- 11
1/
.-
~ . Clutch
switch
22 11.6.2.2,12 - 16)
).<" A
\ ~
Pad
16
\
~,"-'
..
Dash lower
panel
Melt sheet
N.m Ikg-m.ft-Ib)
SCL323
- U.S.A. model only 3. Adjust clearance "C" between pedal stopper rubber and
threaded end of clutch interlock switch while depressing
clutch pedal fully.
Clearance C:
1.0 - 2.0 mm (0.039 - 0.079 in)
SCL274
CL-5
SCL288
SCL203
CL-6
Return spring
Reservoir
Piston assembly
cap
Reservoir
Reservoir band
Cylinder body
EI @
Rubbing
surface
to piston
assembly
Dust cover
lEI @
Stopper ring
Packing
. Apply brake fluid when assembling.
Valvestopper
Rubbing surface to
push rod
Push rod
lEI @ Contact surface to piston assembly
EI
.
.
IJJJ.JJJJJJJJJj
em
--
--
~11J)
Groove
n
SCL214
CL-7
.
.
.
.
.
Operating Cylinder
~
l
Piston assembly
~I Operating
lEI @
cylinder
Rubbing surface to piston assembly
Piston spring
Piston cup
IEI@
lEI @ :
INSPECTION
.
.
.
.
CL-8
~~I[';:':
\\ \ \
~
L Bleeder screw
~ ..,.,
lEI @
Spring
Piston cup EI
,.o.U-721
Rubbing surface to
piston assembly
Piston assembly
Contact surface to piston assembly
Damper rubber
Damper
EI @
cover
EI
INSPECTION
Check cylinder and piston rubbing surface for uneven wear,
rust or damage. Replace if necessary.
Check damper rubber and piston cup for cracks, deformation or damage. Replace if necessary.
.
.
CL-9
c;7
;6e:z
.
~
:;:d'~"7 r~~~:~?~
m(Q
m(Q
---
~
~
~
~
'
Release sleeve
Release bearing
m (b):
~-.
-~
~~!)
U)o///~..
-~-
-.
10
(')
.J
SCL217
CL145
Drift
SC L222
CL-10
with suitable
drift.
.
.
LUBRICATION
IEEI(!): Apply
mOlybdenum
disulphide.
SCL223
CL-11
jJ
.
Clutch Disc
INSPECTION
Check clutch disc for wear of facing.
Wear limit of facing surface to rivet head:
0.3 mm (0.012 in)
sa
I E
C')
ci
SCL229
SCL221
INSTAllATION
portion.
Too much lubricant
CL-12
might damage
.
.
.
.
AND ADJUSTMENT
SCL219
ST20050240
FLYWHEEL INSPECTION
Flywheel
.
.
burns
or
SCL349
INSTAllATION
/(c)
~
Insert Tool into clutch disc hub when installing clutch cover
and disc.
Q)J
CL-13
CLUTCH CONTROL
SYSTEM
CLUTCH DISC
Hydraulic
Model
mm (In)
CLUTCH OPERATING
. Inner diameter
mm (In)
15.87 (5/8)
225 LTD
Facing size
(Outer dia. x inner dia.
x thickness)
mm (in)
CYLINDER
17.46
CLUTCH COVER
(11/16)
C225S
Model
CLUTCH DAMPER
Inner diameter
mm (in)
Fuilioed
N (kg,lb)
4.413 (450,992)
19.05 (3/4)
CLUTCH PEDAL
Unit: mm (in)
Unit: mm (in)
Pedal height "H*"
186.196
Model
(7.32.7.72)
Diaphragm
1.0-2.0 (0.039.0.079)
CLUTCH DISC
Unit: mm (In)
225L TD
0.3 (0.012)
1.0 (0.039)
spring height
Model
C225S
107.5 (4.23)
0.9 (0.035)
CL-14
33.0.36.0
(1299 - 1.378)
0.7 (0.028)
MANUALTRANSMISSION
.
MT
SECTION
CONTENTS
PREPARATION
ON-VEHICLE SERVICE
MT- 2
""'"''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''
MT- 4
MT- 5
MAJOR OVERHAUL
MT- 6
DISASSEMBLY
MT- 9
INSPECTION
MT-14
ASSEMBLY
MT-16
MT-26
PREPARATION
SPECIAL SERVICE TOOLS
Tool number
(Kent-Moore No.)
Tool name
Description
9
~
ST2381 0001
(
..
VW
. ..
KV31100401
(
Transmission press
stand
ST23540000
(J25689-A)
Pin punch
ST22350000
(J25678-01 )
Drift
ST23800000
(J25691-01)
Drift
ST30031 000
(J22912-01 )
Puller
ST22360002
(J25679-01 )
Drift
w
~
ST22520000
(J26348)
Wrench
ST23860000
(
)
Drift
'Or;",~
mm11.50I.' do.
::: :mm
(1.30 in)dia.
MT-2
PREPARATION
Tool number
(Kent-Moore No.)
Tool name
ST33400001
(J26082)
Drift
ST33290001
(J25810-A)
Puller
Description
ST30720000
(
)
Drift
LS
r~7mmC3'.3;")d'"
~
ST30613000
(J25742-3)
Drift
iJ
ST33200000
(J26082)
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm 11.752 in) die.
Description
Puller
;!V/
MT-3
ON-VEHICLE SERVICE
INSTAllATION
~ST33400001
,(J26082)
SMT477A
~
----
Gear position
Continuity
Reverse
Yes
Except reverse
No
NEUTRAL SWITCH
Check continuity.
Gear position
Continuity
Neutral
Yes
Except neutral
No
SMT384B
O.D. SWITCH
Check continuity.
Gear position
Continuity
5th
Yes
Except 5th
No
MT-4
Removal
~
~
.
..
.
.
.
.
Installation
~
@
SMT381 B
Gusset to
engine
MT-5
Qmm(in)
70
60
30
25
(2.76)
(2.36)
(1.18)
(0.98)
-
Neutral switch
(OJ 20 29 (2.0 . 3.0, 14 22)
r4 Thread
of bolts
3:
-I
I
Drain plug
(OJ 25. 34 (2.5 . 3.5, 18 . 25)
C/)
s:
-i
w
to
(II
to
r4:
",.
Apply reco
genuine par
equivalent.
MAJOR OVERHAUL
Gear Components
Needle
bearing
---------------------
sh''''n''n~7i~-J
.j
"
~
\~~3ro&4Oh
<oooUn, hub
.I,~-(:r
synchronizer
3rd & 4th
Spread sprin g
'ftJ}~J
'.
Steel roller
,/
~' ballr/~
/
M,'",h."
~'l
lu -,
j"'
gear
~
~'
/ (~
main
mOUWMh"
,- M,,",hof.b,II bw'...
~1
'0
"n,
2n'm.'n...' '\
r.:>.
hub-(:r
- ~ :\
//
"'"'
r'/
~
~
~
'
"
" "
"
R)
~Q
;?j~)
1 '
~~
~
~~
0.0
~~'
Snap ring
Snapring*
~ "
~~MainShaftIOC~
Thrust
l\\f'\'\J
synchronizer
N d
~
~
~
'
,"~
b"dn.
Sh,"on9i-" *"---4?
,
Ins~rt
""on.
IU & 2n'
S peedometer driveg ge
N"dI,""''''
~
=
~~~'
"'.JY
jI
ring (~)~J
washe
(W
""
n." 137.'.7
r
IthoutT
Countershaft
I
I
R~I""',i...
. (5th ge~r
bushing WMh" * ~
Ow""w
tOJ 98 . 127 0'
(
~
main gear
aulk
ever.ring
counter gear
'
;J
~\1
10.0. 13.0,
72.941
/"<
In~
ffi1a'n"
'oJ'
'
.-; I~
ffinn'
r
W
oo'ru" k"
"",,",'iw <oon
R'..~ <oon"
"'....
-'
~',"", I
'-
..\.~1:AV'(
>/
~~\ )j \
Coon'" .h,,, J
front bearing
Snap r',n,
* ~""
\\;
\(
.Y L
:"-- drive
Counte
gear'"
t..
'- R
'-
in.
~,~
idl"oil .h."
P y geer
to
geers
synchronizers,
.end be ,~heft.,
Ap
* I: S e Iect with
washer
_mbllng.
", : Payatt
,proper thickness.
WhM
I'n'I : N'm (k g-m,
entlonft-Ib)
to"'''''
its d' Irectlon.
.
SMT037B
MT-7
Return
Return
spring
RM"';~~??\
If)
spring plug
f.4
Thread
of bolts
Bushing
m
Mating surfece to control
lever
Returnspring
'i
Select check plunger
Striking arm J
Lockpin -
/'
<::A
I ~-
Striking lever
-I
tDJ 9.12',9.'..,
~ ~
., ( "V"@@
-25 . -101
tDJ MO"'.i 11,'
" -~~.O, 1O. 131
1.
i1I
~; "2.0
~,
R...,";~ pl.
@
/ .
2 ...8.7
D TII,.., ofbo",
CII",' boil
M12 bolt:
~~;"';..
O SocketIE!
@{
~/
CII"" "",..
00
rr@
\~
s:
r ~/
;:
~
\
Mating surface,
to housing and
control
lever
Spring
C.."o' 110..'..--\ \
Interlock plunger
Retainingpin ~/
"";
~ ~
3rd & 4th fork rod ~
""C'
'6."",,d,..-
a.D.
~\Y/~~
II)
s:
-I
w
C
'-I
C
a.D.
~
~T~
49 59 (5 - 6, 36 - 431
~/
~:
f.4
: Ap
ge
eq
DISASSEMBLY
Case Components
1. Remove rear extension.
a. Remove control housing, check ball, return spring plug,
select check plunger and return springs.
SMT982
Soft hammer
:r
SMT320B
')
//
0~
SMT011
TM753
,.
~.
SMT035
MT-9
DISASSEMBLY
Shift Control Components
1. Set up Tool on adapter plate.
2. Remove check ball plugs, check springs, and check balls.
ST2381 0001
(
)
TM754
rods and
ST23540000
(J25689-A)
""
SMT984
MT -1 0
DISASSEMBLY
Shift Control Components (Cont'd)
7. Draw out 0.0. and reverse fork shaft by rotating 0.0. and
reverse bracket counterclockwise. .
.
.~
SMT792A
~
Gear
Mainshaft
bushing
or
_1
Gear Components
EndPlaY
~,~
SMT025
2. Mesh 2nd and reverse gear, then draw out counter front
bearing with suitable puller.
3. Remove snap ring and then remove sub-gear bracket,
sub-gear spring and sub-gear.
Suitable
puller
SMT174A
4. Draw out counter drive gear with main drive gear assembly
with suitable puller.
When drawing out main drive gear assembly, be careful
not to drop pilot bearing and baulk ring.
MT -11
DISASSEMBLY
Gear Components
(Cont'd)
b. Pull out 0.0. counter gear with bearing with suitable puller.
c. Draw out reverse counter gear and spacer.
d. Remove snap rings from reverse idler shaft and draw out
reverse idler gear, thrust washers and reverse idler gear
bearing.
e. Remove speedometer drive gear and steel ball.
Suitable puller
f.
g.
h.
i.
j.
k.
SMT040B
SMT751A
c. Press out 2nd main gear together with 1st gear bushing and
1st & 2nd synchronizer assembly.
d. Remove mainshaft front snap ring.
ST30031000
(J22912-01
SMT384A
MT-12
DISASSEMBLY
Gear Components (Cont'd)
e. Press out 3rd main gear together with 3rd & 4th synchronizer assembly and 3rd gear needle bearing.
SMT385A
SMT420A
MT -13
INSPECTION
Shift Control Components
Check contact surface and sliding surface for wear,
scratches, projections or other damage.
SMT137
Gear Components
GEAR AND SHAFT
..
SMT386A
Counter
gear
SMT550A
Shifting
insert
SYNCHRONIZERS
..
SMT387A
MT -14
INSPECTION
Gear Components
(Cont'd)
Standard
1st
1.2 - 1.6
(0.047 - 0.063)
1.2 - 1.6
(0.047 - 0.063)
a.D.
1.2 - 1.4
(0.047 - 0.055)
Unit: mm
(in)
Wear limit
0.8 (0.031)
SMT140
If the clearance is smaller than the wear limit, replace baulk ring.
bulk ring
Inner\ 2nd
a. Inner baulk ring.
. hr onizer cone
~~r
ST30031000
(J22912-01)
SMT041 B
Unit: mm (in)
~Dial
indicator
ST30031OO0
(J22912-01 )
Dimension
Standard
0.6 - 1.1
(0.024 - 0.043)
0.7 - 0.9
(0.028 - 0.035)
Wear limit
0.2 (0.008)
Feeler gauge
!5"
""
Synchronizer cone
SMT042B
BEARINGS
Make sure bearings roll freely and are free from noise, crack,
pitting or wear.
SMT418A
MT -1 5
ASSEMBL Y
Gear Components
lJ')
~"-
Upper
'*
Front
SMT028
MT-16
ASSEMBL Y
Gear Components (Cont'd)
3. Install main drive gear bearing.
a. Press main drive gear bearing.
b. Install main drive gear spacer.
c. Select proper main drive gear snap ring to minimize clearance of groove and install it.
.
Allowable clearance of groove:
0 - 0.13mm (0 - 0.0051 In)
Main drive gear snap ring:
Refer to S.D.S.
SM T 426A
4. Assemble synchronizers.
1st & 2nd synchronizer
1 ~Insert
spring
CoupJ.ing sleeve
Front.id.
SMT045B
MT -1 7
ASSEMBL Y
Gear Components (Cont'd)
SMT046B
SMT047B
Coupling
Synchronizer
/
(
0.0. synchronizer
sleeve
hub
- -, ,
Shi~t~g}l!sert
SMT095A
1st gear
thrust washer
SMT752A
MT -1 8
ASSEMBL Y
Gear Components (Cont'd)
c. Install steel ball and 1st gear washer.
Apply multi-purpose grease to steel ball and 1st gear
washer before installing.
SMT403A
KV31100401
(
)
TM439
ST33200000
(J26082)
I
KV31100401
(
)
\\
.
Coupling
Synchronizer
/
r
hub
- --,
sleeve
,
I
Shi!ti~9_il}sert
MT -1 9
ASSEMBLY
Gear Components (Cont'd)
f.
Press counter drive gear with main drive gear with Tool.
KV311OO401
(
),
TM442
Front.
SMT620A
TM366
i.
ST22360002
(J25679-01 )
KV311OO401
(
)
TM443
MT-20
ASSEMBL Y
Gear Components
(Cont'd)
Front
L-~
TM451
SMT095A
Gear bushing
.
.
SMT531
SMT043
ST22520000
IJ263481
SMTOO3A
MT - 21
ASSEMBLY
Gear Components (Cont'd)
Tool
Torque wrench
L m (ft)
0.10 m'
(0.33 ft) N.m
(ft-lbI
157(kg-m)
(16)
(110)
147
(15)
'"
::J
c-
'"
'"
a:
137
(100)
(14)
0.6
.
SMTOO4A
Mainshaft
(1.5)
L: Length
(2.0)
of torque
0.7
I
0.8
m
(2.5) (h)
wrench
Countershaft
refer to DIS-
Interlock
ball
SMT992
SMT989
MT-22
ASSEMBL V
Shift Control Components (Cont'd)
b. 3rd-4th shift fork
SMT990
c. a.D.-reverse
SMT991
SMT791 A
MT-23
ASSEMBLY
Case Components
1. Install front cover oil seal.
Apply multi-purpose grease to seal lip of 011seal before
installing.
SMT036
SMT013
MT-24
ASSEMBL Y
Case Components (Cont'd)
A: Distance from bearing
surface to transmission
@
case
1 Transmission case
2 Counter gear front bearing
3 Counter gear
TM371
SMT982
MT-25
(S.D.S)
General Specifications
Transmission model
FS5W71C
5
Number of speeds
Shift patern
Gear ratio
Number of teeth
Mainshaft
Countershaft
I.
I
4
1st
2nd
3rd
4th
O.D.
Reverse
3.321
1.902
1.308
1.000
0.759
3.382
Drive
1st
2nd
3rd
O.D.
Reverse
22
33
27
26
21
36
Drive
1st
2nd
3rd
O.D.
Reverse
31
14
20
28
39
15
Remarks
Warner
Synchromesh type
Oil capacity
21
2.4 (5-1/8, 4-1/4)
Sub-gear
Mainshaft braking
mechanism
2nd synchronizer
MT-26
Mainshaft front
Gear
End play
Allowable clearance
mm (in)
1st gear
0.31 -0.41
(0.0122
-0.0161)
2nd gear
0.11 -0.21
(0.0043
-0.0083)
3rd gear
0.11 -0.21
(0.0043
-0.0083)
O.D. gear
CLEARANCE
AND GEAR
Thickness mm (in)
Part number
2.4 (0.094)
2.5 (0.098)
2.6 (0.102)
- 0_01611
32263-V5200
32263-V5201
32263-V5202
0 - 0.14 mm (0 - 0.0055
in)
Part number
Unit: mm (in)
Standard
1st
1.2-1.6
(0.047 - 0_063)
1.2 - 1.6
(0.047 - 0.0631
O.D.
1.2- 1.4
(0.047- 0.055)
1.1
1.2
1.3
1.4
Wear limit
(0.043)
(0.047)
(0.0511
(0.055)
32228-20100
32228-20101
32228-20102
32228-20103
0.8 (0.031)
Thickness mm (in)
Unit: mm (in)
Part number
1.4 (0.055)
1.5 (0.059)
1.6 (0.063)
32215-E9000
32215-E9001
32215-E9002
AVAILABLE SHIMS
Counter front bearing
Standard
0.6 - 1.1
(0.024 - 0.043)
SMT0448
mm (in)
CD
@
Wear limit
0.2 (0.008)
1 Transmission case
2 Counter gear front bearing
3 Counter gear
0.7 - 0.9
Unit:
(0.028 - 0.035)
TM371
clearance
Thickness mm (in)
1.73
1.80
1.87
1.94
2.01
2.08
(0.0681)
(0.0709)
(0.0736)
(0.0764)
(0.0791)
(0.0819)
Thickness
of shim
"A"
Part number
32204-78005
32204-78000
32204-78001
32204-78002
32204-78003
32204-78004
4.42
4.32
4.22
4.12
4.02
3.92
MT-27
(0.1780
-4.51 (0.1740
-4.41 (0.1701
-4.3110.1661
-4.21 (0.1622
-4.11 (0.1583
-4.01 (0.1543
-0.1854)
-0.1776)
-0.1736)
-0.1697)
-0.1657)
-0.1618)
- 0.1579)
Part number
Not necessary
0.1
0.2
0.3
0.4
0.5
0.6
(0.004)
(0.008)
(0.012)
(0.016)
(0.020)
(0.024)
32218-V5000
32218-V5001
32218-V5002
32218-V5003
32218-V5004
32218-V5005
AUTOMATIC
TRANSMISSION
AT
SECTION
/
CONTENTS
PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-. . . . . . . . . . . . . . . . . . . .. ATPRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. AT-
AT-
"
AT- 11
AT- 85
AT- 86
DISASSEMBLY. . . ., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIR FOR COMPONENTPARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMB LY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AT-
AT-165
AT-101
AT -146
.
.
90
PREPARATION
SPECIALSERVIC~ TOOLS
Tool number
(Kent-Moore No.)
Tool name
/f
Description
ST2505S001
(J25695-A)
Oil pressure gauge set
CD
/CD
CID
~ ~ ----@
ST25051001
(
)
Oil pressure gauge
@ ST25052000
(
'
Hose
CID
ST25053000
(
)
Joint pipe
@ ST25054000
(
~.:.
U!!
"
o/~~
Adapter
CID
ST25055000
(
Adapter
ST07870000
(J37068)
Transmission case
stand
KV31102100
(J37065)
Torque converter oneway clutch check tool
ST25850000
(J25721-A)
Sliding hammer
KV31102400
(J34285 and
J34285-87)
Clutch spring
compressor
~,
0
ST33200000
(J37067)
Drift
(J34291 )
Shim setting gauge
set
Ir;==:J
~T~t~~
1?1/li
~~
AT-2
PRECAUTIONS
.
.
.
.
.
Service Notice
Before proceeding with disassembly, thoroughIy clean the outside of the transmission. It is
important to prevent the internal parts from
becoming contaminated by dirt or other
foreign matter.
Disassembly should be done in a clean work
area.
.
.
AT-3
I
Lock-up
solenoid
/'011
[cooler
~~~,~
L'
relielvalve
lubrlcalion
Modifier
accunlulator
L~r
I~'ve
lubrication
II"Lr-
Pressure
modifier
valve
m,
Ii
,'
Servo
changer
valve
converter
/;;;'t
~~
Ii
'-
--
II=::II"
I/)
~
Co)
1
1
1
I
I
I
I
I
I
I
I
I
I
,
JlIT:Jill:JUL
I=;
Feedback
accumulator
piston
~~~~
~:~
I
J[
Pilot valve
Line pressure
solenolo
r
II
--'~
-J~
USh~
1m;~~oiO A
solenOIOB
Z Overrun
-- -
x
n --
I
I
PRND21
I
I
"~"
solenoid
w
r~
'Manual
~~-
valve
Vehicle signal
Speed sensor
. Electrical singnal
: Hydraulic pressure
Vehicle signal
Engine
Overdrive
switch
Kickdown switch
AfT
Overdrive off
indicator lamp
Power supply
Control signal'
---------r----I
I Inhibitor switch
I
temperature
I Fluid
.
sensor
I
I
Revolution
I
sensor
I
Idle switch
Full-throttle
switch
Throttle sensor
Engine rpm
signal
Shift solenoid A
Shift solenoid B
Overrun clutch
solenoid
lock-up solenoid
- - - - _.~
---------
L__--
AfT control
unit
SAT8178
Mechnical Operation
Band servo
Shift
position
Reverse
clutch
High
clutch
Forward
clutch
Overrun
clutch
2nd
apply
3rd
re lease
4th
apply
Forward
one-way
clutch
Low
one-way
clutch
Low &
reverse
brake
Lock-up
PARK
*4
1st
2nd
.,
*20
4th
*30
1st
2nd
1st
0
0
2nd
0
0
0
NEUTRAL
.. .
3rd
1
*
REVERSE
Remarks
Automatic shift
1-2-3-4
..
.
0
0
Automaticshift
1-2
in 1st
speed 1 ..... 2
*2. Oil pressure is applied to both 2nd "apply" side and 3rd "release" side of band servo piston. However, because oil pressure area on the
"release" side is greater than that on the "apply" side, brake band does not contract.
*3. Oil pressure is applied to 4th "apply" side in condition *2 above, and brake band contracts.
*4. A/T will not shift to 4th when overdriveswitch isset to "OFF" position.
. Operates.
. Operates
when throttle
opening
is less than
1/16.
AT-5
/~
Lock-up
piston
Torque
converter
Converter
housing
Transmission case
Rear planetary
Forward
gear
clutch
Brake band
Forward one-way clutch
Reverse clutch
Overrun clutch
High clutch
~
I
0)
\00 \0
010
0
en
:I>
j
I\J
C1
III
Input shaft
Oil pumlJ
Control
valve
Outpu
ON-VEHICLE SERVICE
Length mm (in)
37 (1.46)
50 (1.97)
.
.
AT-7
""
ON-VEHICLE SERVICE
'\
AT-8
ON-VEHICLE SERVICE
Parking Components Inspection (Cont'd)
3. Remove rear extension from transmission case.
4. Replace parking components if necessary.
5. Reinstall any part removed.
Always use new sealing parts.
SAT133B
,\
--1\
SAT081B
AT-9
ON-VEHICLE SERVICE
NOTE
AT-'O
TROUBLE DIAGNOSES
Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair
AT-13
Preliminary Check
:
AT-14
AfT Electrical Parts Location
AT-25
Circuit Diagram for Quick Pin Point Check
AT-27
Wiring Diagram
AT-28
Self-diagnosis
''''''''''''''
AT-30
SELF-DIAGNOSTIC PROCEDURE
AT-30
JUDGEMENT OF SELF-DIAGNOSIS CODE
:
AT-32
REVOLUTION SENSOR CIRCUIT CHECK """'"''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''
AT-36
SPEED SENSOR CIRCUIT CHECK
; AT-36
THROTTLE SENSOR CIRCUIT CHECK
AT-37
SHIFT SOLENOID A CIRCUIT CHECK
(
AT-38
SHIFT SOLENOID B CIRCUIT CHECK
j
AT-39
OVERRUN CLUTCH CIRCUIT CHECK
AT-40
LOCK-UP SOLENOID CIRCUIT CHECK
AT-41
FLUID TEMPERATURE SENSOR CIRCUIT AND A/T CONTROL UNIT
POWER'SOURCE CIRCUIT CHECKS
AT-42
ENGINE REVOLUTION SIGNAL CIRCUIT CHECK
AT-43
LINE PRESSURE SOLENOID CIRCUIT CHECK
;
AT-44
INHIBITOR, OVERDRIVE, KICKDOWN AND IDLE SWITCH CIRCUIT CHECKS
AT-45
Diagnostic Procedure 1
(SYMPTOM: 0.0. OFF indicator lamp does not come on for about 2 seconds
when turning ignition switch to "ON".)
AT-47
Diagnostic Procedure 2
(SYMPTOM: Engine cannot be 'Started with selector lever in "P" or "N" range or
engine .can be started with selector lever in "0", "2", "1" or "R" range.)
AT-48
Diagnostic Procedure 3
(SYMPTOM: Vehicle moves when it is pushed forward or backward
with selector lever in "P" range.)
""""""""""'"
AT-48
Diagnostic Procedure 4
(SYMPTOM: Vehicle moves forward when setting "N" range.)
AT-49
Diagnostic Procedure 5
(SYMPTOM: There is large shock when changing from "N" to "R" range.)
AT-50
Diagnostic Procedure 6
(SYMPTOM: vehicle does not creep backward when selecting "R" range.)
AT-51
Diagnostic Procedure 7
(SYMPTOM: Vehicle does not creep forward when selecting "0" , "2" and "1" range.)
AT-52
Diagnostic Procedure 8
(SYMPTOM: Vehicle cannot be started from 01 on Cruise test-Part
1.) """''''''''''''''''''''''''''''''''''
AT-53
Diagnostic Procedure 9
(SYMPTOM: A/T does not shift from 01 to 02 at specified speed.
A/T does not shift from 04 to O2when depressing accelerator pedal fully at
the specified speed.)
. AT-54
Diagnostic Procedure 10
(SYMPTOM: A/T does not shift from 02 to 03 at the specified speed.)
AT-55
Diagnostic Procedure 11
(SYMPTOM: A/T does not shift from 03 to 04 at the specified speed.) ""'"''''''''''''''''''''''''''''''''''''
AT-56
Diagnostic Procedure 12
(SYMPTOM: A/T does not perform lock-up at the specified speed.)
AT-57
Diagnostic Procedure 13
(SYMPTOM: A/T does not hold lock-up condition for more than 30 seconds.)
AT-58
Diagnostic Procedure 14
(SYMPTOM: Lock-up is not released when accelerator pedal is released.) ""'"''''''''''''''''''''''''''''''
AT-58
AT-11
TROUBLE DIAGNOSES
Contents
(Cont'd)
Diagnostic Procedure 15
(SYMPTOM: Engine speed does not return to idle smoothly when AfT is shifted
from D4 to D3 with accelerator pedal released.
Vehicle does not decelerate by engine brake when changing overdrive switch
to "OFF" position with accelerator pedal released.
Vehicle does not decelerate by engine brake when changing selector lever
from "D" to "2" range with accelerator pedal released.)
AT-59
Diagnostic Procedure 16
(SYMPTOM:
Vehicle
AT-60
Diagnostic Procedure 17
(SYMPTOM:
to
"OFF"
Vehicle
position.)
"""""""""""
overdrive
switch
"'"''''''''''''''''''''''''''''
"""'"''''''''''''
AT-'60
""""'"
Diagnostic Procedure 18
(SYMPTOM:AfT does not shift from D3on D2when changing selector lever
from"
D"
to "2"
range.)
""""""""""
"""''''''''
""''''''''''''''''''''''
AT-61
""""""""""
Diagnostic Procedure 19
(SYMPTOM: Vehicle does not shift from 22 on 11when changing selector lever
from "2" to ",1" range.)
""""
Diagnostic Procedure 20
(SYMPTOM: Vehicle does not decelerate by enigne brake when shifting from 22 (12) to 1,.)
Electrical Components
Final Check
Symptom
Chart
...
AT-61
AT-61
AT-62
. AT-68
Inspection
"""""""""""""""
""""""'"
""""""""'"
""
AT-72
AT-75
""""""""""""""
,.
AT-75
AT-76
AT-77
(SYMPTOM: Selector lever cannot be moved from "P" range when applying
brake pedal or can be moved when releasing brake pedal.)
DIAGNOSTIC PROCEDURE 2
AT-78
(SYMPTOM: Ignition key cannot be removed when selector lever is set to "P" position
or can
be CONTROL
removed when
lever is set to any position except "P".)
SHIFT
LOCK
UNIT selector
INSPECTION
SHIFT LOCK CONTROL UNIT INSPECTION TABLE
COMPONENT CHECK
'"''''''''''''''''''''''''''''''''
AT-12
\
'"''''''''
AT-80
AT-82
AT-83
AT-84
TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accura,e Repair
WORK FLOW
CHECK IN
<
Reference item
LISTEN TO CUSTOMER
COMPLAINTS.
LEVEL
r-----I
I
I
I
I
I
I
I
I
--
I
I
I
I
I
I
I
I
I
I
I
I
I
I
--~I
.
.
Self-diagnosis
(See page AT-30.)
Self-diagnosis
(See page AT -30.)
INSPECT MALFUNCTION ON
THE BASIS OF EACH COMPONENTS CONDITION.
Diagnostic Procedure
(See page AT -47.)
Symptom Chart
(SeepageAT -72.)
REPAI R/REPLACE.
L- ---------N.G.
ROAD TESTING
(SeepageA T-15.)
FINAL CHECK
AT-13
Final Check
(See page AT -68.)
TROUBLE DIAGNOSES
Preliminary
~
~Q
81
~~
Check
SAT767B
,
SAT801A
Suspected problem
Milky pink
Water contamination
SA T638A
AT-14
Oxidation
-
TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
ROAD TESTING
0
I
3. Cruise test.
2. Check at idle.
0
I
Description
The purpose of this road test is to determine overall
performance of automatic transmission and analyze causes
of problems.
The road test consists of the following three parts:
1. Check before engine is started
2. Check at idle
3. Cruise test
SAT786A
.
.
SA T639A
AT-15
TROUBLE DIAGNOSES
--
0
Park vehicle on flat surface.
SAT787A
fA
Move selector lever to "P"
range.
fA
fir:)
~
.IJ
SA T768B
No
a:J\
~
SAT836B
Perform self-diagnosis.
- Refer to SELF-DIAGNOSIS
PROCEDURE and note N.G.
items.
Go to "ROAD TESTING
- 2. Check at idle".
AT-16
Perform self-diagnosis. .
- Refer to SELF-DIAGNOSIS
PROCEDURE.
TROUBLE DIAGNOSES,
Preliminary Check (Cont'd)
2. Check at idle
0
Park vehicle on flat surface.
6
SA T787 A
Is engine started?
Yes
NI
SAT7698
BJ
BJ
Yes
Go to Diagnostic Procedure 2.
SAT7708
II
II
Move selector lever to "P" range.
SA T7688
Yes
Does vehicle move when it is
pushed forward or backward?
I
No
SAT796A
AT-17
Go to DiagnosticProcedure 3.
TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
:A)
SAT771B
."';"";"
fJ
~t,ST
Brake peda I
~
I
SA T797 A
fJ
[NO
Appl'Y'foot brake.
m
Move selector lever to "R" range.
Yes
Is there large shock when
changing from "N" to "R"
range?
No
SAT772B
Brake pedal
Yes
iii]
iii]
I
Go to Diagnostic.Procedure 7.
SAT773B
AT-18
Go to Diagnostic Procedure 6.
TROUBLE DIAGNOSES
t half throttle open
~
~
AfT control~it
terminal
\Atfull
..
\throttleopen
~~I.J~
SAT802A
Cruisetest - Part 1
0
SAT779A
II
i]
II
Set overdrive switch to "ON"
position.
-.
ID
Move selector lever to "P" range.
SAT7748
II
II
Move selector lever to "D" range.
SAT7758
SA T803A
AT-19
Go to Diagnostic Procedure 8.
TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
~
II
'll N
8/8
m ,...-
6
0/8
.. , ..
8/811
II
IU
?l
~~
0/8
~l
SAT805A
IEm
81)
0T-------------
0/8
If
SA T806A
IE II]
8/8
,..
.,..,..
...-,..
...("
I
I
I
0/8
("--
Nb
No
Go to Diagnostic Procedure 11.
No
Go to Diagnostic Procedure 12.
Go to Diagnostic Procedure 9.
Yes
No
Yes
m
.
~I
l~
SA T804A
IE
I Yes
8,
" ,..'"
I
,..,.."
,..-----
--- --
O~O
'I
m
Is lock-up released when
accelerator pedal is released?
No
Go to Diagnostic Procedure 14.
_..?l
'I)
~)
SA T807 A
IE
.I Yes
II]
Does engine speed return to idle
smoothly when AfT is shifted
from D4 to D3 ?
Yes
Stop vehicle.
I Go to "Cruise test
AT-20
Part 2".
No
Go to DiagnosticProcedure 15.
TROUBLE DIAGNOSES
Check (Cont'd)
Preliminary
Cruise test
Part 2
SA T803A
Hlilf-way
.0
/
Accelerate vehicle by half
throttle again.
8/8
Yes
0/8
Accelerato~ pedal
II
8/8
II
O ta
O-.!.:T 21W
/
Depress
fully
Release
/.
.!}
Release
Go to Diagnostic Procedure 9.
No
No
Yes
8/81,
Yes
Release accelerator pedal after
shifting from D2 to D3.
------
6
Does AfT shift from D3 to D4
and does vehicle decelerate by
engine brake?
SAT810A
Yes
[;)6
II
Accelerator
pedal
SAT808A
II
No
-- -- n 1W
8/8 SrI~~j_._m__C
03
Stop vehicle.
~
04
I
0/8 S~
Go to "Cruise test
~s
SATB11A
AT-21
Part 3".
No
,+j Go to Diagnostic Procedure 11.
TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
Cruisetest - Part3
.0
SAT812A
fA
.'-
fA
Release accelerator pedal.
I]
Set overdrive switch to "OFF"
position while driving in D4
range.
II
I
( D3 (O.D. OFF))
Engine brake
"ED
6(;]
IIDII
Stop vehicle.
~
I
...
SAT777B
~19
No
Yes
Engine brake
~ Yes
,~
Yes
CD3 (0.D.OFF0
SAT776B
G)
Yes
I]
+-
No
....
SAT778B
AT-22
TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
Vehicle speed when shifting gears
Vehicle speed km/h (MPH)
Throttle position
D,
D, --> D,
D, -+ D.
D.
Full throttle
52 - 56
(32 - 35)
95 - 101
(59 - 63)
146 - 156
(91 - 97)
140 - 150
(87 - 93)
89 - 95
(55 - 59)
40- 44
(25- 27)
53 - 57
(33 - 35)
Half throttle
38 - 42
(24 - 26)
72 -78
(45-48)
111-121
(69 -75)
55 - 65
(34-40)
33 - 39
(21 - 24)
10 - 14
(6-9)
53 - 57
(33 - 35)
D,
-+
-+
D,
D, -+
D.
D,
-+
D,
1,
-+
1,
Full throttle
Half throttle
Lock-up
"ON"
Lock-up
"OFF"
ON
[D.]
146 - 156
(91 - 97)
140 - 150
(87 - 93)
OFF
[D,]
95 - 101
(59 - 63)
89 -95
(55 - 59)
ON
[D.]
112 - 120
(70 -75)
102-110
(63 - 68)
OFF
[D.]
76 - 84
(47 - 52)
71 - 79
(44-49)
AT-23
TROUBLE DIAGNOSES
Check (Cont'd)
Preliminary
Shift schedule (Overdrive ON)
Upshift
-- - - 8/8
Downshift
, Kickdown range
7/8
I
I
I-
6/8
1--r-2
I
I
/,
I
/
/
I
I
/
I
I
I
I
I
L-.I
2/8 II
I
1/81I
I
g> 5/8
'cCD
84/8
CD
t:
e 3/8
.c
I-
0/8
0
10
20
30
(10)
(0)
40
I
L,
(20)
50
70
60
80
(40)
(30)
(50)
90
100
I'
(60)
110
"
120
'
(70)
130
.'
(80)
140
"
150
'
(90)
160
170
180
','
(100)
190
,,
(110)
200
'
(120)
SAT804B
- - - -8/8
Downshift
.
I
7/8 ,
Kickdown range
I
I
I
6/81--
I
c: 6/8
'cCD
1-;-2
""
I
I
8- 4/8
I
I
CD
..
.c 3/8
I-
L_I
2/8
/,
/
Lock~p "ON"
I
I
I
I
1/8I0/8
0
I
(0)
10
'
20
, '
(10)
30
"
(20)
40
I
60
'
(30)
60
'
(40)
70
'
80
I
(60)
90
"
100
I
(60)
110
'r
(70)
AT-24
120
I
130
I
(80)
140
160
160
170
"
'
(90)
(100)
180
I'
(110)
190
200
"
'
(120)
SA T805B
TROUBLE DIAGNOSES.
Control
valve
upper body
)
SAT806B
AT-25
TROUBLE DIAGNOSES
AfT Electrical Parts Location (Cont'd)
1;Inhibitor
switch
~
harness connectorrf'
:. AfT solenoid
,:;?harness connector
~
~~
SAT8258
AT -26
0 [SIEE]
@!j ~
lGNI TI ON SWITCH
ON or START
IGNITION
COIL
To distributor
0 ffiHBJ
a@0~
35213
db
'2112
15
."
r
INHIBITOR
SWITCH
@I
-i
"lJ
-0
m
::I
(fI
m
@T 2:u
I
I
I
(fI
m
Z
(fI
;U
26 19 20 I 2
~(t)
A/T
6
8
......
23
12
29 30 28
24
@~
.:;;
r.-:1t;0
-=
r
c
-i
m
:u
@crb
:u
m
<
0
we
POWER
TRANSISTOR
crb
THROTTLE
SENSOR
<-i
;:; :I
0. r;u
~c
1;U
I
I
-. m-i
<0
..0
-i
.~ (fir
:Em
:r..
-or
,Q
..0 -i-
..
-..
16
15
:r
17
10
CONTROL UNIT
35
36
22
21
34
33
s~
r-
0
;U
0
-Z
-=
Cl(t)
;U
m
@~
01
~v.XcgONTROL
E!!3
ION
@;
IOFF
-I
00
-=
(fI
:I
(")
."
-i
m~
@)
I/)
- 6 @
A
-=
~
-i
<
m
-."
(fI
:I
-i
-=
(fI
0
r
m
Z
0
(fI
0
r
m
Z
0
Z
0
tD
-=
;U
;U
C
Z
"lJ
;U
r
C
-i
(")
:I
-=
-i
0
;U
(")
(fI
0
r
m
(")
:I
r
0
(")
A
I
C
"lJ
-rZ
(fI
(fI
C
;U
m
(fI
0
(fI
0
Z
0
Z
0
0
r
m
-=
w
00
,/
r
m
-=
:I
II
27
25
31
32
"lJ
"lJ
O. D. OFF
INDICATOR
(")
@)
-=
TROUBLE DIAGNOSES
Wiring Diagram
COMBINATION
METER
IGNITION
ON or
[Jffi@II]
CONTROL
SWITCH
n ~t;J
12
HEAD-UP
CONTROL
28
~~ll~o~~
co
@
f)3\
\.!::.J
co
-'III
III'
>- co ">->-
ID
Vi
GD
II
Y/G
Y/8
Y/L
G
(J nstrument
DI SPLA
UNIT
[J-t-W.H-t-j]
">->- >-,
KICKO. D. OFF
DOWN
I NDI CATOR SWITCH
O. D.
24
ELECTRIC
SPEEDOMETER
SWITCH
START
harness)
o.
I
co
FUSE BLOCK
(Refer
toP POWER ;;:~
SUPPLY ROUTINGp co",
in EL section.)
Effi
0EW'" @~'"
@)~
..
.. ..
co,co
ID'co
@
Y/G.
Y/8.
Y/L.
G
MIh i te)
J I~
C?
IGNITION
ON or
co
(Black)
SWITCH
START
@IIIII~I~
IDIII
iii
@fi~
- -
@jj)fi@}}
BODY
GROUND
BODY
GROUND
@ 11111~11IIl
co
(E. F. 1. harness)
L
11S-L
:::::::::::::
1-W
3-
LG/R
Y/W
Y/G
W/L
8
LG/8
L
Y/R
Y/R
-{]II
I
@
:, :,
18-L/OR
21-8
28-W/L
29-8
,"
--_n
2D-W
nn
_n
n_n_' '
""
",
nn__nn_n
32-Y/G
33-Y/W
37-LG/R
44-Y
n_nn-
-,
"" ,
,,
""
,, ,,
,, ,,
,, ,
nn-
'' ,
,,
,'"
co
,111
~1
co ,
1
~
I~~:
co
..JID~
E. C. C. S.
CONTROL UNIT
(Refer
to "E. C. C. S.
SYSTEM" In
EF&EC sect Ion. )
~@)
@)ii
ENGINE
GROUND
00
RESISTOR
~@)
III
bJ~@)
..J>->-
$.~
~
"::>
...
POWER
TRANSISTOR
~c
THROTTLE
To
AT-28
@)
distributor
VALVE
SWITCH
~
I
..J~ID
THROTTLE
SENSOR
III..J
ENGI NE
TEMPERA TURE
SENSOR
TROUBLE DIAGNOSES
Wiring Diagram (Cont'd)
DROPPING
RESISTOR
- -
REVOLUTI ON
SENSOR
@m :Wlth
in!
@)~@I~II~I
.E~~E ~
"''''
I
~
~~'~E'" ~
B9
B7
CB
AB
ClD
Hll
111
@
S.
E.
L'~""
.
a..
M.
...
To back-up
L'E
0
braking
lamp
EE~
'"
""""~L"'''''''~''
..a E"''''o
~~L~~"
INHIBITOR
SWITCH
=...
=N
5B
G/R
G/R
R/B
G/L
Y/B
Y/L
=0
=Z
BRG/W
BR
G/W
BR
G/L
G/B
J.
last
anti-lock
<;J;>@)
(@)
!Refer
to
(Fo Idout
:Wlthout
system
L___n_--5B
-G/R
-G/R
-R/B
-G/L
-Y/B
-Y/L
head-up display
:Wlthout head-up display
:Wlth anti-lock braking
system
~
~
page
page). )
'---
(ill)
=0..
@)
G~W
a:::J-
I
.
1'i"W
P/L
harness)
OR/L
B
PU
GY/R
L/Y
L/W
L
LG/R
Y/W
Y/B
W/L
B
LB/B
L
ii
GY
R
rJil ~~!~Dr
lJU
(Subharness)
B
W
L
Y
G
Y/R
()
"
l6!B@)
:;a
"E
~ ~
..
~
......
.....
@)!i@)
BODY
GROUND
~(@)
"
......
-=
.....
(EngI ne
ess room
no.
harn
2)
Y/L-Lh
Y/B-G"
==O
SPEED
SENSOR
0
n....
::10
IZ
)lUl
u..J
'")0
'JI
-=
1:
U
I::I
..J
<
U
0
0
...
z...
0
::10
It:Z I-Z
It:W U.UI
UI..J .....J
>0
1:0
OU)
U)U)
m
0
...
0
I-Z
u.w
.....J
1:0
U)U)
-=
UI
It:
::I
U)
U)
UlO
It:...
0..0
Z
UIUI
Z..J
...0
It:
0
U)
Z
UI
U)
W
It:
0::1
...1::1<
..J1t:
U.UI
a..
1-:1:
..JU)
(@)
SAT101C
AT-29
TROUBLE DIAGNOSES
Self-diagnosis
SELF-DIAGNOSTIC
PROCEDURE
DIAGNOSIS START
Start engine and warm it up to normal engine operating temperature.
~-
fa
SAT774B
II
(g
position.
PJ
fifif:j
SAT779B
Yes
~i
.'
'
~
.
fNo
'
I Go to
I]
Move selector lever to "0"
range.
II
-CD
SA T780B
fifif:j
position.
~~
..&\ OVER
. \
'ON DRIVE,
OOFF
m
~ve
fit
I."
6
Move selector lever to "1"
SAT781 B
range.
Accelerator pedal
;;;:
Depress
Release
SAT754A
AT-30
TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
A
II!]
II!]
~-
DIAGNOSIS END
SAT782B
'---
AT-31
TROUBLE DIAGNOSES
Self-diagnosis
JUDGEMENT
OF SELF-DIAGNOSIS
(Cont'd)
CODE.
Damaged circuit
,&
//1\'
OlD
OFF
Self-diagnosis
start
Start
flickers-- signal 1Q-judgement
- Light
f--
- -
Shade
t, t,t, t, t, t, t, t, t, t, t,
tl
SAT723B
OlD
//1\
Revolution sensor
OFF
--,..---
--
Lig ht
16
r--
--
15
.. Go to REVOLUTION
SAT140B
SAT724B
~()~ OlD
//1\' OFF
Speed sensor
- - .....--.-
- - Light
24
Arr
1---1-
,-'
control
unit
Shade
SAT726B
SAT760A
sensor
~).l(~ OlD
/)r\' OFF
---
R-M-.- - - Light
.",.
15
- Shade
..
SA T726B
tl
= 2.5 seconds
t2
= 2.0
seconds
t3
=1.0 second
AT-32
11
AfT
control
10
unit
TROUBLE DIAGNOSES
Self-diagnosis
(Cont'd)
Damaged circuit
~()~ OlD
/11\' OFF
Terminal
cord
assembly
Self-diagnosis
start
-=
- -- Light
35
- Shade
SA T727 B
':()/
:;/1\'
A/T
control
unit
OlD
OFF
--
--
Terminal
cord assembly
Light
36
'
--
- Shade
SAT728B
SAT767A
OlD
OFF
---
-----
Terminal
assembly
Light
cord
21
- Shade
SA T729B
~~
//1\'
Go to OVERRUN CLUTCHSOLENOID
CIRCUIT CHECK.
SAT768A
OlD
OFF
Terminal
cord assembly
--
-=
-- Light
22
---
- Shade
SAT730B
AT-33
-----
TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
0.0. OFF indicator lamp:
Damaged circuit
OlD
/11\
OFF
Terminal cord
assembly
Self-diagnosis
start
--
- Light
..
Shade
SAT731 B
CHECK.
SAT143B
OlD
OFF
-0-
Resistor
- -....--.-
- - Light
25
+-
~-
AfT control
Shade
SAT733B
10th judgement
others.
flicker
is longer than
to ENGINE REVOLUTION
.. Go
CHECK.
solenoid
Dropping
resistor
- Light
34
'
4-- Shade
AfT
SAT732B
33
control
unit
CHECK.
~O/D
~'
OFF
- Light
- - Shade
t.
SAT734B
= 1.0
SAT624B
Terminal
cord
assembly
- - ...--.-
t4
SIGNAL CIRCUIT
..:::()~ OlD
/11\' OFF
unit
second
AT-34
SAT776A
This
TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
O.D. OFF indicator lamp:
Dama~ed circuit
010
OFF
Self-cliagnosls
start
- - - - - - - - - - -.- - -
Light
---
Shade
Throttle
valve
switch
.<:
~
.~
..
'"
-=-
SAT157C
Overdrive
switch
ION
Kickdown
switch.
..
-=
/
\
.....
'\
AT-35
TROUBLE DIAGNOSES
Self-diagnosis
(Cont'd)
REVOLUTIONSENSORCIRCUIT CHECK
Revolution sensor
CHECK REVOLUTION
SENSOR. Refer to "Electrical
.Components
O.K.
N.G.
15
~
f"
t:;!
SAT140B
.'' '.-'
I~
trJ
ST
",:"",.,.
,
I!
>}
. Harnesscontinuitybetween
revolution sensor andE.C.U.
(Mainharness)
. Ground circuit for E.C.U.
- Refer to section EF & EC.
-~,
.-~
. Harnesscontinuitybetween
Inspection".
PI
16
N.G.
'/
O.K.
Perform self-diagnosis again after
driving for a while.
N.G.
. O;K.
00
INSPECTION END
"
-=-
SAT737B
PI
PI
Speed
sensor
-=
CHECK
N.G.
'(,~I
24
A/T contrOl unit
~I
t05V
---.-O.K.
Perform self-diagnosis again after
driving for a while.
O.K.
INSPECTION END
SA T738B
AT-36
N.G.
TROUBLE DIAGNOSES
Self-.diagnosis .(Cont'd)
-THROTTLESENSOR CIRCUIT CHECK
Throttle sensor
Perform self-diagnosis(Mode
III) for engine control.
O.K.
N.G.
N.G.
N.G.
II
";"
15
11
10
AfT control
unit
SAT761A
II
13
1.1
2. Check voltage between AlT
controlunit terminals @ and
@ while accelerator pedal is
depressed slowly.
Voltage:
Fully-closed throttle:
0.2- 0.6V
Fully-open throttle:
2.9- 3.9V
(Voltage rises gradually in
response to throttle valve
opening.)
[iI
O.K.
COllET
SA T739B
AT-37
TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
SHIFTSOLENblDA CIRCUITCHECK
Shift solenoid A
m
N.G.
unit
SAT766A
m
Sub-harness
connector
(@)~
is
1.1
I
2. Disconnect terminal cord
assembly connector in engine
compartment.
3. Check resistance between
terminal @ and ground.
Resistance: 20. 30il
SA T740B
I!)
DISCONNECT
[:it
18
1 O.K.
CHECK POWERSOURCE
CIRCUIT.
13
lo.K.
INSPECTION
[ill
I!)
1.1
-=-
CLE SERVICE".
2. Check the following items.
8 Shift solenoid A Referto
"Electrical Components
Inspection".
8 Harnesscontinuity of terminal
cord assembly
13
35
AfT control
Terminal
cord
assembly
SAT741B
AT-38
END
."
N.G.
TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
SHIFT SOLENOID B CIRCUIT CI:IECK
Shift solenoid B
m
N.G.
unit
SAT767A
~
lu
[;]
IIIKOIIIIECT
O.K.
N.G.
CHECK POWERSOURCE
CIRCUIT.
"1
-;:-
1.1
I
2. Disconnect terminal cord
assembly connector in engine
compartment.
3. Check resistance between
terminal @ and ground.
Resistance: 20 - 30n
36
SAT742B
16-pin connector.
[;]
_IIECT
~ IV
O.K.
N.G.
END
I
for damage
SAT743B
AT-39
TROUBLE DIAGNOSES
Self-diagnosis
- (Cont'd)
Overrun clutch
solenoid
m
N.G. 1. Removecontrolvalveassembly.- Referto "ON-VEHI.
CHECKGROUNDCIRCUIT.
Terminal cord
assembly
1.1
21
~
IV
1 O.K.
N.G.
SA T744B
Subharness
connector
betweenAlTcontrolunit and
CIRCUIT.
-eJ
I CHECK POWERSOURCE
1.1
I!]
CLE SERVICE".
2. Check the following items.
8 Overrun clutch solenoid.
Refer to liElectrical Components Inspection".
8 Harnesscontinuity of terminal
cord assembly
I!]
-=
18
18
lo.K.
INSPECTION END
P/L
[ill
SAT745B
AT-40
N.G.
TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
LOCK-UP SOLENOID CIRCUIT CHECK
Look-up
solenoid
m
CHECK GROUND CIRCUIT.
1.
N.G.
"ON-VEHICLE SERVICE".
2. Check the following items.
. Lock-up solenoid - Refer to
Ia
22
AfT control
unit
SA T769A
liElectrical Components
Inspection"
. Harnesscontinuityof terminal
cord assembly
m
IIISQIIIIECT
EO
O.K.
Ii)
~
~
-=-
SA T746B
Ii]
IIISCONIIECT
[:iI
fm'I
IV
Sub-
E1tE1harness
GY/R
22
J connector
O.K.
Perform self-diagnosis after
driving for a while.
. O.K.
[:ill{)
INSPECTION END
EEfHm
[ill
SAT747B
AT-41
N.G.
TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
Fluid temperature
sensor
Terminal cord
assembly
SAT143B
~
CIINNECT
)
AfT control unit
terminal
SAT748B
I!]
Subharness
connector
EW3 @
yo12 15~
~
IIISCOIINECT
18
[ill
m
CHECK AfT CONTROL
UNIT POWER SOURCE.
1. I
N.G.
Harnesscontinuity between
ignition switch and AfT con.
trol unit (Mainharness)
. Ignition switch and fuse
- Refer to section EL.
O.K.
I!]
N.G.
CHECK FLUID TEMPERA.
TURE SENSOR WITH
TERMINAL CORD ASSEMBLY
1.
SAT749B
AT-42
TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
@
[i
CHECK INPUT SIGNAL OF
FLUID TEMPERATURE
SENSOR.
'"
1.1
"'i"
'
!
13
G ' ON
'}
~
CONNECT
lD2;
:," ~.'
,)I;,
, ,",
N.G.
II
O.K.
Perform self-diagnosis after
driving for a while.
"::"
N.G.
O.K.
SAT750B
INSPECTION END
N'~I
N.G.
O.K.
control
unit
SA T624B
m~
0HHm:B l1t
CONNECT
"13
2. Check voltage between A/T
control unit terminal @ and
ground.
Voltage: 9.5 - 12V
-=-
SAT751B
. Ignitioncoil-
Refer to
sectionEF&EC.
O.K.
. Resistor
O.K.
INSPECTION END
AT-43
TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
LINE PRESSURE SOLENOID CIRCUIT CHECK
Li ne pressu re
solenoid
Terminal
cord assembly
Dropping
resistor
34
1.1
33
AfT control
unit
SA T776A
m Sub-
harness
connector
34\
@ID)
IV
SAT762B
-.. 1.
2. DisconnectAfTcontrolunit
16-pinconnector.
8 Harnesscontinuity between
AfTcontrolunit @ and
terminalcordassembly
(Mainharness)
~i5
[!]
1O.K.
CHECK POWERSOURCE
CIRCUIT
1.1
em
3. Checkresistance between
1!1[!]
!O.K.
CHECK POWERSOURCE
CIRCUIT.
1.1
=-
N.G.
A/T control
unit terminal
SA T763B
O.K.
INSPECTION END
AT-44
I
N.G.
TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
INHIBITOR, OVERDRIVE, KICKDOWN AND IDLE SWITCH
CIRCUIT CHECKS
m
CHECK INHIBITOR SWITCH
CIRCUIT.
A/T control
unit terminal
@ @
@ CD CV
P,N
O.K.
1!1
BR/W
BR
CHECK OVER~RIVE
CIRCUIT.
1.
-=SAT7838
1!1
_caD
t!(g
Switch position
Voltage
ON
Battery voltage
OFF
1V or less
O.K.
lit
CIIIIIECT
~10~
IV n
(t'l
SWITCH
~-
~G/R
-=SA T7848
Refer to
"Electrical Components
Inspection".
. Harnesscontinuity between
ignition switch and inhibitor
switch (Mainharness)
. Harnesscontinuity between
inhibitor switch and AfT
control unit (Mainharness)
fi/f:J..
Lever
position
. Inhibitorswitch-
1. I
SAT7368
N.G.
AT-45
IN.G.
to
Harnesscontinuity of ground
circuit for overdrive switch
(Main harness)
TROUBLE DIAGNOSES
Self-diagnosis (Cont'd)
@
[!II!]
[!1
1.1
CONNECT
t)
N.G.
.
.
Kickdown switch
Harnesscontinuity between
AfT control unit and kick.
down switch (Mainharness)
. Harnesscontinuity of ground
circuit for kickdown switch
I!]
IN.G.
CHECK IDLE SWITCH
CI RCUIT.
SAT754S1 I. Check voltage between AfT
control unit terminal @ and
ground in the same way as
kickdown switch circuit.
Voltage:
When releasing accelerator
pedal: 8 15V
When depressing accelerator
pedal fully: 1V or less
,
O.K.
Perform
self-diagnosis
again after
drivingfor a while.
.
O.k.
I N.G.
AT-46
Check id Ie
switch circuit
for engine
INSPECTION END
N.G.
TROUBLE DIAGNOSES
Diagnostic Procedure 1
SYMPTOM: 0.0. OFF indicator lamp does not come on
for about 2 seconds when turning ignition
switch to "ON".
0,
CHECK AfT CONTROL
UNIT POWER SOURCE.
1.
-=-
t8
SAT755B
11
6
I
Fuse
0.0. OFF
indicator
lamp
O.K.
I]
[:tI
([ill)
[ill
Ignition
switch
CONNECT
N.G.
SAT756B
I]
N.G.
N.G.
Check again.
O.K.
INSPECTION END
AT-47
TROUBLE DIAGNOSES
Diagnostic Procedure 2
OlD
OFF
Self-diagnosis
start
- - - - - - - - - - - - - - Light
--- Shade
SAT157C
D
Does self-diagnosis show damage
to inhibitor switch circuit?
Yes
No
fA
N.G.
Repair or replace inhibitor switch.
O.K.
Check starting system. - Refer
to sectionEL.
O.K.
SA T838B
INSPECTIONEND
Diagnostic Procedure 3
D
Check parking components. Refer to "ON-VEHICLE
SERVICE".
SAT133B
O.K.
INSPECTIONEND
AT-48
N.G'I
TROUBLE DIAGNOSES
Diagnostic Procedure 4
010
OFF
Self -diagnosis
start
- - - - - - - - - - - - - - Light
- - Shade
No
SAT157C
"P" range
Yes
f)
N.G.
O.K.
Refill A.T.F.
O.K.
II
Lock nut
00
LCiCk nut @
SA T788B
O.K.
11
Check again.
O.K.
INSPECTIONEND
SA T638A
II
SAT171 B
AT-49
N.G.
1.
2.
.
.
.
.
DisassembleAfT.
Check the following items.
Forward clutch assembly
Overrun clutch assembly
Reverseclutch assembly
Accumulator piston D
TROUBLE DIAGNOSES
Diagnostic Procedure 5
~O
/1 \ '
\1//
OFF
Self-diegnosis
start
._-----
SAT7588,
fJ
Fluid
'temperature
sensor
0
Does self-diagnosis show damage
to throttle sensor, line pressure
solenoid or fluid temperature
sensor circuit?
Yes
to "Self-diagnosis".
No
.I)
E.C.U.
O.K.
N.G.
Dropping
resistor
O.K.
SA T0888
. Linepressuresolenoid
0
N.G.
Check again.
O.K.
INSPECTIONEND
SA T643A
AT-50
TROUBLE DIAGNOSES
Diagnostic Procedure 6
SYMPTOM:"Vehicledoes not creep backwardwhen
.~~~
"R" range.
0
0
SA T638A
N.G'.f RefillA.T.F.
O.K.
N.G. in both "1"
and" R" range
r
fA
Check stall revolution with
selector lever in" 1" and" R"
range.
O.K.
O.K. in "1" range
N.G. in "R" range.
II
N.G.
N.G.
r Check again.
O.K.
r
8 Reverseclutch assembly
8 High clutch assembly
8 Low & reverse brake assembly
8 Low one-way clutch
O.K.
SA T643A
O.K.
II
INSPECTION END
SAT171B
AT-51
TROUBLE DIAGNOSES
Diagnostic Procedure 7
SYMPTOM:Vehicle does not creep forward when
0
I
N.G.
.1
Refill A.T.F.
O.K.
B1
N.G.
Check stall revolution with
selector lever in "0" range.
- Refer to "STALL TESTING".
.
O.K.
SA T638A
B1
N.G.
IA
SA T642A
. Linepressuresolenoid
3. DisassembleA/T
O.K.
II
. Forwardclutchassembly
. Forwardone-wayclutch
. , Lowone-wayclutch
. Torqueconverter
O.K.
B1
N.G.
Check again.
O.K.
INSPECTION
II
SAT171B
AT-52
END
TROUBLE DIAGNOSES
~~
/11\'
OlD
OFF
Self-diagnosis
start
Light
--- --~Shade
SA T760B
Diagnostic Procedure 8
Revolution sensor
Speed sensor
Shift solenoid A
Shift solenoid B
Cruise test -
Part 1.
Go to Diagnostic Procedure 7.
Yes
No
7""
Refer to I N.G.
N.G.
1. Remove control valveassembly. - Refer to "ON-VEHICLE SERVICE".
2. Check the following items.
O.K.
II
I]
O.K.
O.K.
O.K.
SA T643A
II
N.G.
Check again.
O.K.
INSPECTIONEND
SAT171B
AT-53
.
.
.
.
.
.
Shift valveA
Shift valveB
Shift solenoidA
ShiftsolenoidB
Pilotvalve
Pilotfilter
3.
4.
.
.
.
.
.
.
DisassembleA/T.
Check the following items.
Forward clutch assembly
Forward one-way clutch
Low one-way clutch
High clutch assembly
Torque converter
Oil pump assembly
TROUBLE DIAGNOSES
D 0
Diagnostic Procedure 9
OlD
OFF
Self-diagnosis
start
- - - - - - - - - - - - - - Light
- - Shade
SA T157C
m
Revolution sensor
Procedures 7 and
Yes
m
Speed
sensor
Speedometer
Yes
N.G.
No
Check revolution
sensor and
"Self-diagnosis"
SA T629B
Go to Diagnostic Procedure 7 or :
8.
Refer to
O.K.
iJ
O.K.
N.G.
O.K.
O.K.
O.K.
N.G.
Check again.
O.K.
INSPECTION END
8/8
8/8
+".
Dl.:TD2"
/
Depress
fully
6)
0/8
SAT118B
SAT171B
D27D3
(
0/8
~/(
Release
0
AT-54
sensor.
DisassembleA/T.
Check the following items.
Servo piston 'assembly
Brake band
Oil pump assembly
TROUBLE DIAGNOSES
Diagnostic Procedure 10
DID
OFF
5elf-diagnosis
start
- - - - - - - - - - - - - - Light
Yes
D
- - Shade
SAT157C
Go to Diagnostic Procedure 7 or
B.
Yes
O.K.
1. Remove oil pan.
2. Check A/T fluid condition.
N.G.
.O.K.
O.K.
BJ
O.K.
.
.
3.
4.
.
.
.
SAT1718
II
8/8
II
II
N.G.
Check again.
Jl
O.K.
INSPECTION
0
0/8 l
'1
SAT1198
AT-55
END
Pilot valve
. Pilotfilter
DisassembleAlT.
Check the following items.
Servo piston assembly
High clutch assembly
Oil pump assembly
TROUBLE DIAGNOSES
\1/
/~
.
Diagnostic Procedure 11
Revolution sensor
OlD
r:I
OFF
Self-diagnosis
start
spee~sensor.
Shift solenoid
A
Shift s?lerioid B
Fluid
specified speed.
/ / r .-
::;;~ature
Light
Are
Di~gnostic Procedures 7 and
8 O.K..
- ---_M_M_-M-M---M--uShadel
.
SAT761B
light
10
" - mUH H
~.
I No
II
-' Go
8. to Diagnostic Procedure 7 or
Yes
Yes
to Self-diagnosIs.
. O.K.
1:01
I!I
./
/'
N.G.
11
O.K.
. 2.
.
O.K. ~ .
.
O.K. II.
.
Checkthe followingitems.
Shift valveB
Overrunclutchcontrolvalve
Shift solenoidB
Pilotvalve
Pilotfilter
3. DisassembleA/T.
SAT171BI
II.
8/8 U
II
I.
II
Check again.
I0 .K .
0/8
II
SAT120B
INSPECTIONEND
I
I
AT -56
4. Checkthe followingitems.
. Servopistonassembly
. Brakeband
Torqueconverter
. Oil pumpassembly
signal inspection.
TROUBLE DIAGNOSES
,\1//
Diagnostic Procedure 12
OlD
:;8,'" OFF
Self.<Jjagnosis
start
0
- -- Light
- Shade
Yes
No
PJ
N.G.
. ShuttleshiftvalveD
.
II
8/8
l~
. Lock-upsolenoid
. Pilotvalve
. Pilotfilter
~l
O.K.
IJ
N.G.
Check again.
O.K.
INSPECTION END
0/8 II
~l
SAT121B
AT-57
TROUBLE DIAGNOSES
Diagnostic Procedure 13
~C5~ 010
/11\'
OFF
Self-diagnosis
start
0
--
Light
- Shade
.fA
,No
fA
Yes
N.G.
. O.K.
O.K.
O.K.
Pilot valve
. Pilotfilter
3. Disassemble A/T.
4. Check torque converter and
oil pump assembly.
SAT171B
N.G.
Check again.
O.K.
INSPECTION END
Diagnostic Procedure 14
010
OFF
Self-diagnosis
start
---- --- - - - - - - -
Light
--
Shade
SAT157C
fA
N.G.
O.K.
INSPECTION END
'1'-
j~
0/8
-------------
Yes
- Refer
No
fA
Check again.
ff
SA T806A
AT-58
TROUBLE DIAGNOSES
~\ l/-::: 010
/11'-- OFF
Self-diagnosis
stert
no
Light
--Shade
SA T7648
Diagnostic Procedure 15
SYMPTOM: Engine speed does not return to idle
smoothly when AfT is shifted from D4to D3
with accelerator pedal released.
Vehicle does not decelerate by engine
brake when changing overdrive switch to
"OFF" position with accelerator pedal
released.
Vehicle does not decelerate by engine
brake when changing selector lever from
"D" to "2" range with accelerator pedal
released.
0
Does self-diagnosis show damage
to overrun clutch solenoid circuit
after cru ise test?
Yes
No
Check throttle sensor. - Refer
to section EF & EC.
.
O.K.
II
N.G.
O.K.
O.K.
SAT1718
O.K.
3.
4.
.
.
II
8/8
I
/'"
//
(
I
I
I
0/8
...'"
.../
...//
//
"'" ....
""
""
-,..."'"
--. 1"""'"
8~O
--~(
1. Removecontrol valveassem.
bly. - Refer to "ON-VEHI.
CLE SERVICE".
2. Check the following items.
. Overrun clutch control valve
. Overrun clutch reducing valve
. Overrun clutch solenoid
II
N.G.
Check again.
O.K.
~
INSPECTION END
( D3 (O.D. OFF))
+
C0
Engine brake
SAT7658
AT -59
DisassembleAlT.
Check the following items.
Overrun clutch assembly
Oil pump assembly
TROUBLE DIAGNOSES
D '\Ol/~
/II\~
OlD
OFF
Diagnostic Procedure 16
Revolution sensor
Speed sensor
Shift solenoid A
Shift solenoid B
D
- - light
Yes
-- Shade
SAT7668
1 No
1 N.G.
Check again.
I
lo.K.
Go to Diagnostic Procedure 8.
Diagnostic Procedure 17
010
OFF
Self-diagnosis
start
- - - - - - - - - - - - - - light
---
Shade
SAT157C
D
Does self-diagnosis show damage
to overdrive switch circuit after
cruise test?
No
Go to Diagnostic Procedure 10.
AT-GO
TROUBLE DIAGNOSES
Diagnostic Procedure 18
OlD
OFF
Self-diagnosis
start
- - - - - - - - - - - - - - Light
Does
self-diagnosis show
to inhibitor switch
- - Shade
damage
Yes
circuit after
Refer
to
"Self-diagnosis".
cruise test?
SAT157C
No
.
Go
to Diagnostic
Procedure
Diagnostic
OlD
OFF
9.
Procedure
19
Self-diagnosis
start
- - - - - - - - - - - - - - Light
D
Yes
Does
self-diagnosis show
to inhibitor switch
- - Shade
damage
after cruise
Refer
to
"Self-diagnosis".
test?
SAT157C
No
11
11
,~
Check again.
f
I
fT
1. Per orm A
contro Unit
input/outputsignalinspection.
2.
rO.K.
~~
~.
If N.G..
recheck
AfT
INSPECTION END
control
for damage
or connection
of AfT
unit harness
connector.
control
@
Engine brake
SAT778B
Diagnostic Procedure 20
SYMPTOM: Vehicle does not decelerate by engine
procedure
0. K.?
Yes
Go
to Diagnostic
AT-61
Procedure
15.
Go
to
Diagnostic
11.
Procedure
6.
TROUBLE DIAGNOSES
Electrical Components Inspection
INSPECTIONOF AfT CONTROLUNIT
Measure voltage between each terminal and terminal @ or
CONNECT
.u
SA T842 B
16-pin connector
20-pin connector
SAT818A
T"
Item
No.
Judgement
standard
Condition
Battery voltage
1V or less
Battery voltage
)
1V or less
8 -15V
1Vorless
5-8V
1V or less
--1
4
Idle switch
I {inthrottle valve
switch}
-+5
A.S.C.O. D.O.
cut signal
AT-62
TROUBLE DIAGNOSES
Electrical Components
No.
Terminal
Item
I Kickdown switch
Judgement
standard
Condition
Inspection (Cont'd)
A.S.C.D. cruise
signal
I
1
I
When performing
("CRUISE"
light comes
A.S.C.D.on.)cruise.
'\
10
Overdrive switch
(Power source)
Battery voltage
When
not performing
("CRUISE"
light does A.S.C.D.
not comecruise.
on.) I 1V or Iess
When setting overdrive switch in
"ON" position.
I Battery
I 1V or less
I Throttle sensor
I 1V or less
0
I
3-SV
voltage
I 4.5 - 5.5V
I
When depressing accelerator pedal
slowly after warming up engine.
11
I Throttle sensor
Fully-closed
throttle:
0.2 - 0.6V
12
-13
I
I Fluid temperature
sensor
is 20C
WhenA.T.F.temperatureisSOC
(176F).
Fully-open
throttle:
2.9 - 3.9V
1.56V
0.45V
I-
14
15
16
Throttle sensor
(Ground)
I Revolution sensor
(Measure in AC range)
I
AT-63
OV
TROUBLE DIAGNOSES
Electrical Components
Terminal
No.
17
Item
Inspection (Cont'd)
Judgement
standard
Condition
1Vorless
Battery voltage
1Vorless
Battery voltage
1Vorless
Battery voltage
1V or less
8- 15V
1V or less
Battery voltage
1V or less
Vary from 0 to
5V
9.5 - 12V
Approximately
10V
Battery voltage
1V or less
- 15V
18
19
20
21
22
23
24
25
26
Overrun clutch
solenoid
Lock-up solenoid
Speed sensor
Engine revolution
signal
~
~
27
AT-64
TROUBLE DIAGNOSES
Electrical Components
Terminal
No.
28
Item
3f
32
33
34
35
Judgement
standard
Condition
~o,
29
30
Inspection (Cont'd)
Battery voltage
Battery voltage
Battery voltage
1V or less
O.5V or less
1.5 - 2.5V
O.5V or less
Battery voltage
Ground
Linepressuresolenoid
(with dropping resistor)
Shift solenoid A
operate.
(When driving in "02" or "03",)
36
- 14V
Shift solenoid B
Battery voltage
lV or less
OVERDRIVE SWITCH
Continuity
ON
No
OFF
Yes
SA T785 8
AT-6S
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
INHIBITOR
.~-
SWITCH
~{I
CD CV @
~~~~~~tr
~{~c@
'uP~,..~o,.}!//
~,~
SAT067
(j)
Lever position
0- -0
-0
N
-0
-0
SAT843B
2. If N.G., check again with manual control linkage disconnected from manual shaft of AIT assembly. - Refer to step
1.
3. If O.K. on step 2, adjust manual control linkage. - Refer to
"ON-VEHICLE SERVICE".
SAT851
p::-~
e~
~\
SA T844B
~[ill
OJ:
~ GPt)
REVOLUTION SENSOR
For removal and installation, refer to "ON-VEHICLE SERVICE".
Check resistance between terminals CD, @ and @.
.
.
Terminal No.
Resistance
CD
500 - 650n
CV
No continuity
CD
No continuity
AT-66
TROUBLE DIAGNOSES
Electrical
Components
Inspection
(Cont'd)
.
.
c tF)
Resistance
20 (68)
Approximately 2.5 kn
80 (176)
Approximately 0.3 kn
.
.
Resistance:
Lock-up solenoid 10 - 16n
Line pressure solenoid 2.5 - Sfl
SAT846B
Ground
.
.
_T~
IV~
/
/'
"
,','
/
/,//
,,I
I (
,
"'-'
Terminal No.
Shift solenoid A
Shift solenoid B
Ground
terminal
mJ
"'--SAT847B
DROPPING RESISTOR
Check resistance between two terminals.
l:tI
_tT
18
~
'
SAT848B
AT-67
Resistance
20 - 30n
TROUBLE DIAGNOSES
Final Check
STALL TESTING
Stall test procedure
1. Check AIT and engine fluid levels. If necessary, add.
2. Warm up engine until engine oil and A.T.F. reach operating
temperature after vehicle has been driven approx. 10 minutes.
A.T.F. operating temperature:
50 - 80C (122 - 176F)
SA T779A
SA T597
~
~Q
5. Start engine, apply foot brake, and place selector lever in "0"
range.
.- ': I
~~)
~~-
SAT767B
SA T598
SAT771B
AT-68
TROUBLE DIAGNOSES
Final Check (Cont'd)
Judgement of stall test
Judgement
L
Damaged
---1
components
----=>
..
,--
UW
fJ
p
b
;=
L- -
j::
II
D.
==J
,J
II"
--
to;
I!.
=::J
l
oMwdtth
II
r"'\'
'"
-\
clutch
..t1-
.I
Overrun
//
--:511
'>i<I1.-iF=5Jr'lr'dl- .'In
t-
Forward clutch
1UJ
linepressurecontrol
.\
.
D
Judgement
SAT107B
AT-69
TROUBLE DIAGNOSES
Final Check (Cont'd)
PRESSURE TESTING
.
..
Front
SAT782A
~~'I
~~-=~
SAT779A
ST2505S001
(J25695-AI
SAT180B
R range -
SA T597
AT-70
TROUBLE DIAGNOSES
Final Check (Cont'd)
5. Start engine and measure line pressure at idle and stall
speed.
When measuring line pressure at stall speed, follow the
stall test procedure.
Line pressure:
Engine speed
rpm
SA T643A
JUDGEMENT
Stall
1,020 - 1,098
(10.4 - 11.2, 148 - 159)
1.422 - 1,500
(14.5 - 15.3,206 - 218)
8
8
8
8
8
....
....
657 696
(6.7 -7.1, 95 -101)
t:
471 510
(4.8 - 5.2, 68 - 74)
Suspected parts
.!!:!
IV
R range
32
CI>
D, 2 and 1 ranges
Idle
Judgement
a.
<II
circuit
AT-71
TROUBLE DIAGNOSES
Symptom Chart
OFFvehicle
ON vehicle
~
~
..
W
..
:I
c
9,
14
66
67,
106
70
67
67
E1-
,!
~ ~
'tI .. '..
-c
~ 6
s.~!5c';;~
..= ';;!
I.=~!
.1
:!1
.D
cs? .-::1
:!1
g..
ic(
ID~
::!1
z g
~.!!
:!1!
g::l
U
.!! i! .. c
11 2
48
49
61
214
137
126" 130
134
144
.c"
u'"
~
I!
'=.D
f..
c
0
..
31 6
4, .
61 1 31 7
6, .
62
1 21.
8.. u~
.. E I.i!
&~ i~
!5::
1-0
i:.!!'
et:J:
~ , '5~ :
~ g 2,
"E"E~!
2
i~
~.!
ce..
~~~~~~
0...1 .;.lID
ILl'-
1..
~
u
~
i..
IS.
.
.1.
31.
@ . lev . I<ID
<ID@I<v . I@ . I@
@I@.!@
214
. 3,.
4 6
.
.
2 3
21 1 .16
211
.16
211
.I 4 .
64,
66,
66
112
3 4
.1.
@ <v1@@1 . @
.14
31.
@@@.
@.I.
ev
6,.
.
.
2
214
214
AT-72
.1. .1.
6
.I(j])
.,. .
.
@<IDI. .I
.1. .1. .1. .1. .1. .1. .1. . . . . -@
.1. .1. .1. . I. .1. . I. @.
<V
6
.
.@
<V
@.
4 8
~ ~~ ~,g
.c
5.c
. .<V@
to "0.".
.c
~
.=
U
>
..
:g)
1 2
creep.
::1::1 ::I C
48
314
E..::I ]1!!]11
II II H 'c
g ~ ] H c(c(
c(!!!
~:J ...IOILc(
213
cI
~~
...
M 't.. i
':'NM.ct:
~ ~ 1!!5 !5!5!5,~~
'.= &~
No creep at all,
124
it, 1;:
S ~z~ iii
O.c
48
61,62
120' 126'
..
:!1
Excellive
101
:?
~c ~e ~'6> '6>!
8~
u::8.E~et:.:i.jj:J
90,
- I
.c
!5
!
!
~
66
7,
67
@
3
.<ID
TROUBLE DIAGNOSES
Symptom Chart (Cont'd)
9,
14
Reference pege (A T-
ifI
.
66
66
~ 8.1;; .:!
.:!. "2 '"
'Q ..;;
~
to
to
"D,".
31 5
31 5
31 5
to
II
z 1;;
IIIO:!!.
;9
:;;z
<:'
~E
EE
~1
M.c
II~
Eo
.EII.ai!i!
.c
U
~
~
c:
II
.><
I!!
II
c:
0
.:! .0
20
0.
~
u
. ..
0
~
~
4111 II
~it:;;i.EE
~888jn
0=
~.~ ~~
...!!!
~ 0 II:: J: ...... ~-' -'III
ij:;;
00
@I
4
.<;
01
.<;
$
1
..
..
5 3 4
6 4
@ICID
@ .10
@I
@@
3 4
15
..
CIDI@
Qj)'@1@0
5
5 3 4
01
@I. @I
.(j;
112
31 4
211
31 4
pedal in "D."
to "D,"
@. . . .0
c:
to "D."
144
.@
from "D."
g.!!
.c
~
:J
U
>
1::
Kickdown
126. 1130
134
to "D,"
-~ ..
@@I
Kickdown
:!!
:!! i
g S
to "D,"
126,
137
120'
124
~
.. .c
-N
:;;5505.~ ;~ -fi5.c.2!-fi' ~ ~ !
~!~:2:!!!!S
=!1~~!au
~~~~~I
80.u~
uO .:! i ."2
:2
0.c:
.:J
:J:J :J c:
~!~.!
to "D,".
i.
0.
214
"D,"to"D.".
c:
90,
101
to "D, ".
>
:0
!~eaa~:;02
's.!
t::!::!:!
,jj::;8~~::;3o
~g~=~.~
':;C::E1~~
ii:8.E~lI::w
7,
67
67
-~~lIg~
I-o.';:;~
67
t: i
67,
106
70
c:
c:
!
of
II::
OFF vehicle
ON vehicle
@0. . . . @
@0.@
@"l ,. .1.
@
AT-73
I OJ
TROUBLE DIAGNOSES
Symptom Chart (Cont'd)
ON vehicle
~
..:.
~
..
i'
a.
8
c:
!
of
..
tr
Reference
9,
14
pege (A T-
66
66
i01
?:
.Q
E
61
-
"1,"
when
.;!
21 1
120'
124
126'
137,
126'1130
134
144
.c:
~
.:
u
.c:"
u '"
015 01
M
E
01
c:
0
a.
E
0
u
'"
c:
0
c:
01
'tI '0
M
.-
..
-I:
a: ~
~
c:
01
M
e
:J
a)~
f! ~
~c:a e '0~"5
~ ~2
.. u
>01
OIM
a. E.!!!
~ e~ ~ ~ ~ ~ ; ~
c:
~~ ~~
(I)..J
(I)
OI:J
g~ .ag
..JOIL
N M
.:. N
0 0
1;j 1;j
'5 '5
E E
:J:J
~~
... ..
M.c:
o.~
1;j ~
'5 c:
E 0
:J';
8 8 g'c
.!!!
.c:
8a.~~
~
~~
a. 0I.c:
> '"
~ 0 I~ i
~
0'
~
"5 ~ .c: u 01
~..
~ > t:
~g~~i"2
'E'E c:!
~.!
~~
ILIL
~~ ~e
O..J ..Ja)
514
@.
@.I@.
314
range.
.'
..
Transmission overheats.
416
@cvl@@I@.I@ .I@@
@<IDICID
.I@ .Icv@
1
3 1 2 4
1
57
@ .Icv
i..
IL
21 1
range.
90,
101
renge.
in "I"
:2
=a"iic:
:gM
71 1 2
in "2" renge.
'tI
.g
c:
i
8, "5-= ~.g ~
.. ." ~ ~.: ~ e ~ ~
001
to "2,"
~"ii
S"2a.
'0 ...;;;
-~~&gg
~=
7,
67
67
~
E
..
67
~
c:
.!
-g~E~.~
~g:c~
~~ .~.~
U:u -=1- trw W..J
61
67,
106
70
OFF vehicle
1 2
2
7
5
4
8
@<IDI@CIDICV
'I@ 'I@@
@
CV
3
4
543
AT-74
"
TROUBLE DIAGNOSES
/---------
",
cOnnector
\,
SAT8358
AT-75
TROUBLE DIAGNOSES
AIT Shift Lock System (Cont'd)
CIRCUIT DIAGRAM FOR QUICK PIN POINT CHECK
"
11
@!!I
tillKEY SWITCH
5
DETENTI ON
SWITCH
FUSE
~~
~~
2
3
To stop lamp
I GN IT ION
SWITCH
ON or START
I...,
Z
::J
...J
0
0::
IZ
0
U
:.::
u
0
...J
lLL
...,
:I:
II)
...
KEY LOCK
SOLENOID
10
SHI
FT
LOCK
@
m"
5 19
SOLENOID,
~
~
"::"
SAT815B
AT-76
I GNI TI ON
SWI TCH
ON or START
BA TTERY
UP
*
@
I
GI:U
FUSE BLOCK
(Refer to "POWER
~~
@D@
(Eng ine
KEY LOCK
!i
I
SOLENOID
room
.~
R/W
KEY
SWITCH
G
~
He"
L/R
Y/R
ill
Y/R
H9
ffieferto
~~~:
G9
S.
@J)
(Fo Idout
M.
harness)
R/W
L/R
.....
.....
r::o- L
~L/R
(Ma In
harness)
J.
last page
page).]
To time control
BA TTERY
unit
:u
,
~
L
L
@)
[C]]
[
FUSE
L
Y
[C]]
~~~~~
~ ~
~ II II III
GI
FUSI BLE
GI
GI
p
~
LI NK
ID
@fi@J)
!II
J>
-I
Q)
..
01
Q)
BODY GROUND
TROUBLE
DIAGNOSES
R/W
N.G.
CHECK POWER SOURCE.
1.1
-=-
SAT818B
Control unit
terminal
. Fuse
. Ignitionswitch
@i)[9
~EIDJ
[Y]
. Harnesscontinuitybetween
battery and control unit
LIB
N.G.
SAT819B
1.1
I]
RIG'
OJ
Control unit
terminal
Selector lever
release butto n
Voltage
Not pressed
-=-
Battery
voltage
SA T820B
I]
CHECK INPUT SIGNAL
(STOP LAMP SWITCH).
1. I
fI!if::j
O.K.
AT-78
N.G.
. Stop lampswitch
. Harnesscontinuitybetween
stop lampswitchand control
unit
TROUBLE DIAGNOSES
AfT Shift Lock System (Cont'd)
II
i5~ ~
Shift lock
harness I2<r::ITJ
connector
!YJ
LIT1D
1
A:
@TIY
II
L/G
CHECK
'"
1. I
SAT821B
OUTPUTSIGNAL
N.G.
fiIiif:j
terminal
CD
Voltaga
Release
Battery voltage
Depress
OV
O.K.
Check shift lock solenoid.
(Refer to "COMPONENT
CHECK".)
N.G.
O.K.
N.G.
Recheck shift lock operation.
O.K.
INSPECTION END
AT-79
TR~OUBLE DIAGNOSES
, 'AIT
R/W
D
-=-
SAT818B
(g
. Fuse
. Ignitionswitch
mm~
[Y)
.1
1.
@i)~
Control unit
terminal
N.G..
VIR
:+'
O.K.
6
-=I]
@i)[iI
rtiBL~
[Y)'
Control unit
terminal
N.G.
CHECK INPUT SIGNAL
(Key switch).
1. Insert ignition key into
ign ition .switch.
2. Check voltage between
control unit terminal (j]) and
ground.
Battery voltage should exist.
SAT822B
LIB
:+:
. HarnesscontinuitybetWeen
key switchandcontrolunit.
O.K.
I]
-::-
SAT819B
N.G.
"I
(g.
Voltage
Release
Battery
voltage
A
AT-SO
TROUBLE DIAGNOSES.
AfT Shift Lock System (Cont'd)
II
iVr:it
II
N.G.
Check harness.continuity
between control unit and key
lock solenoid.
Ia
[Y]
SA T823B
O.K.
N.G'
Check key lock solenoid.
(Refer to "COMPONENT
CHECK".)
O.K.
N.G.
Recheck key lock operation.
O.K.
INSPECTION END
AT-81
TROUBLE DIAGNOSES
AfT Shift Lock System (Cont'd)
SHIFT LOCK CONTROL
12-pin connector
ITIiliI::QJ:ill
UNIT INSPECTION
SA T824B
AT-82
TROUBLE DIAGNOSES
A/TShift
<t)
Condition
Judgement standard
Battery voltage
ov
Except above
Power source
Battery voltage
Battery voltage
ov
Power source
Battery voltage
Detention switch
Battery voltage
ov
Ignition signal
Battery voltage
Battery voltage
I 10
91
10
11
I Ground
I Key switch
(Approximately0.1
seconds)
Exceptabove
OV
Battery voltage
(Approximately 0.1
seconds)
Except above
OV
Battery voltage
OV
AT-83
TROUBLE DIAGNOSES
AIT Shift Lock System (Cont'd)
i5~
Shift lock
harness connector
COMPONENT CHECK
Shift lock solenoid
Check operation by applying battery voltage to shift lock
harness connector.
Detentionswitch
Check continuity between terminals @ and @ of shift lock
harness connector.
Condition
[ill
Continuity
Yes
No
SAT832B
Key lock
solenoid
harness
connector
SAT833B
Key switch
Check continuity between terminals @ and CDof key switch
harness connector.
i5~
~
~ Key switch
Condition
[ill
G~~--
Continuity
Yes
No
SAT834B
AT-84
Removal
~~~
J~Q~
..
.
.
Installation
SA T718
.
..
. Tighten
bolts
CD
CD ~:
AfT -+ Engine
@'\ ~ : Engine
to AfT (gusset)
Bolt No.
.
.
.
.
transmission.
39
40 (1.57)
50 (1.97)
25 (0.98)
20 (0.79)
1
2
3
SAT111C
securing
Gusset to
engine
SA T638A
AT-85
MAJOR OVERHAUL
~:
~:
KP610.(0250) or equivalent.
Apply A.T.F.
: Select with proper thickness.
: Adjustment is req~ired.
~:
S 'lde seal
x~
~~
,V:.::-J~
i'>
~~~ \~
~.~,'
~~
.tJPJ
I
.
I
..
.\
,.
.'
~' ~~ ~JJ~.)
.~1~
IJ
'
,~
~
~.
~/
1-
r.t\
~. ~
:\~
'
. .
\.
Needle bearing
m q.
m q/
,./..
EI ~
Beari~grace'
~1
/
Fmm
"'"...' J
Needle bearing
Needle"
f'\~f::\
~W~
bilseal~~./
011pump cover
R.,,;";",
~...*
'''ko~y
Gasket
~
~,~
Overrunclutch hUb
Thrust washer mq
Retaining
plate*/
//
,
./
Ealq
BearingraceElq
~~S""';"'
~ (i
B'l~\
-
~~~\
~
~
(with
Front rear
internal
planetary
gear carrier)
~~
-
.
I
~
7
. .X~)~
L
:e
~ ~Needlebearingmq
Front planetary carrier
AT-86
E.nd bearing
\ Snap ring
Thrust washer
D-ring~~.
/
'
Y\S";';"'~EI~
r'\1
~~OiIPumpcoverbearingrace*EI
q
/
'
Needle bearing
/
""
'
B
q
.
eanng race Eli>
'D
12 - 151 :
\
~~
~~
~o~~
,~
"~16-21
(1'6_2'1'
,,/
~
~~
o.,;",~/
~J'
./
(4.0-5.0,2~361
/
O-ring~EI
coo,.";;::':,~ -
Friction ring/
~VaneElq./
/'
1\
..~
Vanering.,/
Oil pump
./ housing
~ ~TOrqUeConverter
39 -49
<:\
,J,
..,(
'-. Cam ring i
'\.. O-ring
EI
Input shaft
./5 ,~
~/./
"":<:'i~ ,
/
'.
~ \\})
iP':>..~
:i~~
/'
61 64
~~.~,;~~
l~.
~~ ~~
'-
Pivot Pin--v>~
Control pistonR
o-ring~~
Side seal
OiIPumPhOUSingOilseal~~
S pnng seat
m q
MAJOR OVERHAUL
D-ring
~~
'1
Oilseal ~~
_~~I
~~}"
(~~'J
I
~"}
I
),
//
./"
'(
Fo~.", oI.'''..~mblv
R...,o'
N"""b..,In.EI<B ''''-~
0-"",
So",,;o.
S~. pi...
J~'<Y
\/,-'f ~
1.4-
5 pacer
C';~
.-.
poo,oo.""bl
0-,;",
Pm"", """
oom~@)"10~1
Loc' pi...
So","'"
poooou
.,:,::"'O"'b'<OO
all seal~h,,"
M
N...,.b.."",
.26,
~ ~'.9)
,.
""
22-29)
,~b
.
rf"
'"
.I
O"'~'~@>~
'//
.~mblv
V'
l
t:!@>~
9 Am.m.'"''
mblv
So","
9.
~~
;::--
~
/'.
'
/l
~ 7. 9 '.7-0.9,6., .
/"
.'L
Parking
i
~
Revolutio~
"".m" flow,
."
,-.
.6 -0.7,
3~0-7
6
. , 14 - 18)
. .6".
20 - 2S '2.0 -2 6
..,
1"1
..
'
D
Il-A""m.,"@>
.':
...
I."-
~1I
0.",."",,, '''10""''''
o-,~ogt:!@>
~ .nog..,EI<B~)..-'
.
\,..~<tl..~ all
strainer
GaSket~
O.n",
t:!r.w=8~~A-~~
7 -9'.7
D-rlng
Gasket ~~
N"
~ ' ~/.1OJ ~
,~ I-'
co"ro,.,,1O
~
O'
-1 >
g ge
Parkin
0
'
.'-tf~:
..1;1
,,,",," %
..CoT
/
Ano"".oo
00"
/'. R~
-./'
0-';",
,. ,', l:;;'
EI<B' \ \
~/
~
I~
\
~
$
~
a-ring
Gu'" t:! .,
~o~.,
~
0.,;", t:!@)
. - .,7-22),--
. -4.0,
T..mlo.oo",
assembly
.
(2430
(30
-~
'6-20'
Low
. ~".
~~
~,~ "1'
T"nom'
~f;'/~7'/)
~ 4-6'4
...A'
,
, - '''o~:,;,4.3I,
spring Manual plate
n
~~
'
(..~
f\.~
~J
y
~ ~)'J)~-
t:! @)
-~
~1
"
So","0'
Oil seal
"'=
LnwO",~"".":::~::'"
~;.,. ~
r~~~
/',/
OilN" t:!"'Ti"
O-no't:!@)
Overrun clutch
(~~~y
LowO~
~f/1
...,ffi\)
- --
'\
n Oil pan
AT-87
SA T1848
MAJOR OVERHAUL
Oil Channel
1 -+ 2 accumulator drain
3 -+ 4 & N -+ R accumulator
shoulder pressure
--3 -+ 4 & N -+ R accumulator back pressure
High-clutch pressure
Front lubricating hole
Oil pump discharge hole
-~r/
-==
-.S/
AT-SS
Oute
CD
<ID
(j)
Ite
num
@
@
@
@
(j)
It,
num
CD
<I
~
I
co
CD
Out
en
-i
0'1
.....
Item
number
Bearingrace
(black) location
@
@
@
Rear side
Front
Rear side
In
DISASSEMBLY!
Disassembly
1. Remove torque converter by holding it firmly and turning
while pulling straight out.
SAT0198
_._~
._~-
._-~--
SAT1868
5. Place transmission into Tool with the control valve facing up.
II-:cr.IWl-.
SAT1878
AT-90
DISASSEMBLY
Disassembly (Cont'd)
6. Check oil pan and oil stra,inerfor accumulation of foreign
particles.
. If materials of clutch facing are found, clutch plates may be
worn.
. If metal filings are found, clutch plates, brake bands, etc.
may be worn.
If aluminum filings are found, bushings or aluminum cast
parts may be worn.
In above cases, replace torque converter and check unit for
cause of particle accumulation.
.
/
SAT171B
sensor
SATOO8B
Screen
V(g)
~---~
'-.
SAT025B
~~~I
SATOO9B
AT-91
DISASSEMBLY
Disassembly (Cont'd)
b. Remove bolts @ and @, and remove control valve assembly from transmission.
Bolt
Length
37 mm (1.46 in)
50 mm (1.97 in)
AT-92
DISASSEMBLY
Disassembly (Cont'd)
11. Remove converter housing.
a. Remove converter housing from transmission case.
SAT999A
SAT995A
SA T027 B
AT-93
DISASSEMBLY
Disassembly
(Cont' d)
d. Removeneedle bearing and thrust washer from oil pump
assembly.
SAT108B
SAT029B
SA T655
AT-94
DISASSEMBLY
Disassembly
16. Remove
a.
clutch
Remove
sun
gear)
b. Remove
c. Remove
Ir~
')"
'"
...
Oil groove
SAT974A
/:
~~
and
front
g.
Remove
'
clutch
0/
high
case.
Remove
Remove
,',,;:;:.
:::.. ll--=:.I
components.
clutch,
e.
f.
l~/
<'~ ~:JP~
transmission
gear
~'
and
(reverse
d. Remove
lf}
-,,,.:(ll
~c o~S
..
pack
~c:::-'::'
.~~~
~
~"~\~)
1
\~ r
from
~--(-~
(Cont'd)
AT-95
case. '
DISASSEMBLY
~
Disassembly (Cont'd)
17. Remove rear extension.
a. Remove rear extension from transmission case.
b. Remove rear extension gasket from transmission case.
SA T190B
AT-96
DISASSEMBLY
Disassembly (Cont'd)
d. Remove output shaft and parking gear as a unit from
----
transmission case.
e. Remove parking gear from output shaft.
f.
AT-97
DISASSEMBLY
Disassembly (Cont'd)
d. Remove rear internal gear, forward clutch hub and overrun
clutch hub as a set from transmission case.
SAT951A
SA T034B
f.
SAT035B
SAT037B
AT-98
DISASSEMBLY
Disassembly
(Cont'd)
SAT038B
Accumulator
piston
~fi
SAT040B
f.
(2~3)
Accumulator
Front.
(3--+4,N--->R)
t? ~~b'
(1~2)
Accumulator
piston C
SA T937 A
AT.. 99
DISASSEMBLY
Disassembly (Cont'd)
b. Remove retaining pin from transmission case.
Oil seal
\:
Transmission
case
SA T042 B
\
e. Remove spacer and detent spring from transmission case.
f.
-In~
~~.~
'0_L
-/
~-~j-/c
@~~\I
I
\
r
,)
yj-
~
SAT044B
AT -1 00
Oil Pump
EI. ~
Friction ring
O-ring
~ <@
@:
Pivot pin
Side seal
EI ~
Control
Oil seal
O-ring
~<@
piston
Side seal
,~~
lEal~
Vane ring
Cam ring
Sp ring seat
Cam ring spring
.M-~EI~
SA T648A
DISASSEMBLY
1. Loosen bolts in numerical order and remove oil pump cover.
SAT649A
Inscribe
identification
mark
AT-101
..
oil pump
SAT655A
INSPECTION
Oil pump cover, rotor, vanes, control piston, side seals, cam
ring and friction ring
Check for wear or damage.
SA T656A
AT -1 02
Side clearances
Measure side clearances between end of oil pump housing
and cam ring, rotor, vanes and control piston in at least four
places along their circumferences. Maximum measured values should be within specified ranges.
Before measuring side clearance, check that friction rins~,
O-ring, control piston side seals and cam ring sprinb are
removed.
Standard clearance:
Cam ring
0.01 - 0.024 mm (0.0004 - 0.0009 in)
Rotor, vanes, control piston
0.03 - 0.044 mm (0.0012 - 0.0017 in)
If not within standard clearance, replace oil pump assembly
except oil pump cover assembly.
.
.
Vane
SAT657A
Clearance
lr
Seal ring
.
.
SA T658A
ASSEMBLY
1. Drive oil seal into oil pump housing.
Apply A.T.F. to outer periphery and lip surface.
.
.
AT-1 03
d. Assemble cam ring, cam ring spring and spring seat. Install
spring by pushing it against pump housing.
SAT662A
AT -104
E!!I@
Large dia.
seal rings
j~~~
--::::~>
~~
YL~
~==,/- ~--:-,
SA T663A
AT -1 05
Harness clips
Harness clips
Lower body
~.-
~. -'
Separator plate
Side plate
Upper body
\
'~
~~-~.
\-
O-"og~
wOO'CO""" ,o'oooid
-~
-;~
\
O-'og~
~\
AT-106
SAT194B
SA T667 A
SAT668A
SA T670A
AT-107
SAT671A
INSPECTION
Lower and upper bodies
Check to see that there are pins and retainer plates in lower
body.
SAT672A
.
.
Check to see that there are pins and retainer plates in upper
body.
Be careful not to lose these parts.
Check to make sure that oil circuits are clean and free from
damage.
Check tube brackets and tube connectors for damage.
SAT673A
Tube
connector
O'o'--.r
00
0000
) ~ 00
o~
o~-
g,oooo
0 6' 00' 0
'0
0
0 C ' 00
0
'0
0 Do
0
00
OC 0
0 '"
0
0 0",", o~ 0
00
0 0
I
00
0'
0 0
'0
~ ,00
"0
Co 0
"",,,00
D "5
g
0 "c0
0
oo ~
" 00 C '0 0
'b 0 015 00
= 0,
0 c"g
0
g c? 0 00 OC "go
=
,[l
=
cc"
0'
0 00
DOO
Separator plates
. Check to make sure that separator plate is free of damage
and not deformed and oil holes are clean.
g
0
0
0
.0.
SAT675A
AT - t08
SA T676A
Lock-up solenoid
Check that filter is not clogged or damaged.
Measure resistance. - Refer to "Electrical
Inspection".
.
.
SAT091
Components
.
.
Components
SAT092B
SAT095B
SAT196B
AT -1 09
Refer to "Electrical
Components
c. Place oil circuit of lower body face up. Install orifice check
spring, orifice check valve and pilot filter.
SAT682A
Unit: mm (in)
SAT197B
AT-110
SAT198B
g.
Install
and
@--
mm (in)
70
(2.76)
50
(1.97)
33
(1.30)
27
(1.06)
2. Install solenoids.
a. Attach a-ring and install lock-up solenoid and side plates
onto lower body.
Side plate
SA T200B
b. Attach a-rings
upper body.
SAT668A
SAT667A
AT-111
CD R
/
Lock-up control valve
1
1;
Upper body
'
0
1~
13 Return spring
Pin
\
!i
@ Return spring
II
PI'ot"'"
II
\ \
~
crm1rn
i\
Retainer Plate/
\
'
-r
~/
.
~fjYP
~~/ ~
.
. ~
.r-..,~
;; 77
//
~~~GG/~/
\
/
,
\U
mPlug~
0Cf
'\
j@R"''''':",
P'"
~
mkco
I~
crnQ
Shift valve B
amL
~
~
=yd]
Overrun clutch
reducing valve
eturn spnng
4-2 relay valve
~Pi
Plug
Return
Sho
'
Retainer pl
Pin
/1'1"1;(<0
R
(7)
eeve
@R"'"
CID
spnng
SI
;t fl~12L!: ~o
Ar I , ~
. .
'(Cf)
--.I
G1
CL.'
C-L-.
-'iO
@ Return spring
I
'"
/0~
CV Return s
P",~""",~" "',,
,r-'-~
'
cV /
- cJI-/
//
Pin-~\
!II
~
~
CD
W
....
CD
"W~#'
\
@"'7/
((((O
#.
Plug
'\)
spring
~/~?7
' ~9--'
(j])Return
.~
!~ct
Sleeve
Plug
C
,
Shift
[((0
@ Return spring
'
({{((((CQ".
valve
<tV
'B" R t
Retainer plate
'
'''
~e~~
~~n
P'"'
~~Pin
Plug
Numbers preceding valve springs correspond
shown in Spring Chart on page AT-115,
SAT834A
-42/b4Q)2)0;,)y ~
~---~~0
/e~~~I\\~,-,
~
,u--"u!(-'l--.l~~
~ r
~'~)(S:f/
v~-:::::y~
") ) ,L"/~
~~"~---"-S
-":;)'--~' 7'(\ "~
~u-~d':.7"-'
'
'-J'
(J
'~
\
~<:::;;~~J~-'-'CJ~-'0r
~~
('\\\ -~
/
u -7~:::
i::::/-S-,Y
.,<:2?C::::::'0~1:,:::;-<:::7"
"\
I ' v( /-C:::;'
~~~
~~
-@/~j,~'it
'
.
.
Soft hammer
SA T824A
Retainer plate
SAT825A
AT-113
SA T826A
.
.
soft hammer.
Be careful not to drop or damage valves, sleeves, etc.
Soft hammer
SAT827A
.
I~
Parallel
:r--~//( .~
(~
.--::.-~ /~..-
i~
'~~
~l
/.//.::~~;-~
:",-.J~~6/.-S
~(~\\IJ~IJ\\
Shiftw~
( '(0:;'
u~-:S?u;JI/-S/~
)?'
v,:::--::::::./.<:,~~
J.:s:0~
)~rv/:-~u
~,>~~~~\
~~~ ~;p~-;.':S5(~
~,,~
pin
4-2 sequence valve and relay valve are located far back in
upper body. If they are hard to remove, carefully push them
out using stiff wire.
Be careful not to scratch sliding surface of valve with wire.
(S;
~~
SAT828A
AT-114
'"
i5
~
:;
0
0
Valve springs
Measure free length and outer diameter of each valve spring.
Also check for damage or deformation.
Numbers of each valve spring listed in table below are the
same as those in the figure on AT-112.
.
.
--r\
\\\ \
Q . Free length
SAT829A
Inspection standard
Unit: mm (in)
Item
Part No.
Parts
CD
31742-41X18
32.3 (1.272)
9.0 (0.354)
CV
31742-41X16
61.5 (2.421)
8.9 (0.350)
CID
31742-41 X19
31.95 (1.2579)
6.8 (0.268)
31762-41XOO
26.5 (1.043)
6.0 (0.236)
CID
31756-41 XOO
29.1 (1.146)
6.95 (0.2736)
<@
31762-41 X01
25.0 (0.984)
7.0 (0.276)
31756-41XOO
29.1 (1.146)
6.95 (0.2736)
31762-41 X01
25.0 (0.984)
7.0 (0.276)
31762-41X03
23.6 (0.929)
7.0 (0.276)
31742-41 X20
32.5 (1.280)
7.0 (0.276)
([j)
31762-41X04
51.0 (2.008)
5.65 (0.2224)
31742-41X13
25.7 (1.012)
9.1 (0.358)
31742-41X22
18.5 (0.728)
13.0 (0.512)
Control valves
Check sliding surfaces of valves, sleeves and plugs.
AT -11
~
'
':;'" -
~I I
~~
r
II
~.
--.J::::
~ij
C)J~"
I~
'\'\';!
II u71)) 7~
p.,'h',"~
Ughtly
in while turning It.
) If
!
'r'
If pressure
regulator
h
Vin ylI ~
tape
)'::---
-I
\~/"
I SAT832A
Accumulator control plug
. Align protrusion of accumulator control sleeve with notch in
plug.
Align parallel pin groove in plug with parallel pin, and install
accumulator control valve.
Notch
/"
1(0:;
~JJ
~~f~,
,
-----------
to
Center plug
n C-:J~/.~
~I
sleeve
in spool
bore
;..{
=--=--=--'--::
properly,
I ""'l7<\
"-
r--:-~'CZ~
II!
~_I"~)
~~
,=
""
~II
P - ~,-,='7S"S
':::-i)
-:.() l
'- ::,I'
.J--":-'Y' -x:...
~
c \ /' '"
~ r
Sleeve
Y-'--"';
+---rr~)~l~.
SA T833A
SA T834A
AT-116
~.,
:::2...y-/---uO-..:::::J
u~...:::;::-u;J~~:>'''>
v, ~r.:::--';:::::::::;;
~,.~~~~k/$~'
':J
~
rE
v/:-
,~}p!n~
~-'--&
Parallel
I,
':>
I.//. '--
,:J,,&~
':::::::::::
~-:
~(j~~~~;:;fS
Cj\\C) ~
Wire
if1-J-:G
.
II
GG
SAT835A
Retainer plate
00
SAT836A
AT-117
Lower body
Pin
!i
I
...
...
co
Retainer plate
@ Return spring
--,
CD
~--
f!!!j-- Plug
RetainerPlate---\cl
~Pin
Manual valve
en
~
-i
(I)
to>
"
~
SA T838A
INSPECTION
:;;
Qj
E
as
'6
:;;
'5
0
0
Valve springs
Check each valve spring for damage or deformation. Also
measure free length and outer diameter.
Numbers of each valve spring listed in table below are the
same as those in the figure on AT-118.
.
.
.~
.-
\\\ \
Q : Free length
SAT829A
Inspection standard:
Unit: mm (in)
Item
Part No.
Parts
31742-41X15
30.5 (1.201)
9.8 (0.386)
31756-41X05
25.4 (1.000)
6.75 (0.2657)
CID
31742-41 X08
20.55 (0.8091)
6.75 (0.2657)
31742-41X06
23.0 (0.906)
6.7 (0.264)
CD
'@
Control valves
Check sliding surfaces of control valves, sleeves and plugs
for damage.
ASSEMBLY
Install control valves.
For installation procedures, refer to "ASSEMBLY" of Control
Valve Upper Body.
SA T838A
AT -11 9
Reverse Clutch
For the number of clutch sheets (drive plate and
driven platel. refer to the below cross-58ction.
~:
Apply A.T.F.
: Select with proper thickness.
R.~~. d"Iohd,"m~
Dish plate
Retaining plate
Snap ring
SAT839A
DISASSEMBLY
1. Remove reverse clutch assembly from clutch pack.
SA T840A
SAT841A
AT -1 20
SAT842A
SAT843A
6. Install seal ring onto oil pump cover and install reverse
clutch drum. While holding piston, gradually apply compressed air to. oil hole until piston is removed.
Do not apply compressed
air abruptly.
7. Remove D-ring and oil seal from piston.
INSPECTION
Reverse clutch snap ring and spring retainer
Check for deformation, fatigue or damage.
SAT844A
...
Q)
Q;
E
<II
'6
...
Q)
'5
0
c
.-
\\;
Inspection standard:
Unit: mm (in)
Parts
Part No.
fl
Spring
30505-41 X02
19.69 (0.7752)
11.6 (0.457)
fl . Free length
SAT829A
.
.
Thickness
Facing
Core plate
SA T845A
AT-121
..
.
SA T846A
Oil seal
C@
ASSEMBLY
1. Install O-ring and oil seal on piston.
Apply A.T.F. to both parts.
SAT847A
@)
SA T848A
SAT849A
SAT843A
AT-122
SA T850A
Snap ring
[;';':;[
Retaining plate
Drive plate
Di,h
PI'''/\:~~J!
Driven plate
SAT851A
SAT841A
AT-123
I" D-ring(Large)
I
I
~ @
~~
D-ring (Small)
Clutch piston
~
Driven plate
,.
'"
Snap ring
R"um",,;,,)
Spring retainer
Drive plate
~
*
: ApplyA.T.F.
AT -1 24
I.
KV31102400
(J34285 and
J34285-87)
SA T855A
....
CI)
Q;
E
01
'i'i
....
CI)
'5
0
c
-~
.-
Inspection standard:
. .
\\,
\
\
Part No.
31505-21 X03
Unit: mm (in)
Q
22.06 (0.8685)
D
11.6 (0.457)
Q : Free length
SAT829A
Thickness
Facing
Core plate
SA T845A
SA T858A
AT -1 25
Snap ring
Retaining plate *
Snap ring
Drive plate
Retaining plate *
Drive plate
- Driven plate
@t>
---IJ
Dish plate
'
Forwad
~lutchPlate
O"'o,~@P
If
,~
So.."0'
O"_I~""""-
'
.-,it"
JI-'C
r <m,~@P
"=-'
~
I~~-311
#lib..
,,~Ii(1
""\\
JV
O~)J
'H"
..N
"'"
, ,"'"
retainer
0
~
I seal ~~ ~
II
""
II
...
..
"-/
.J
' "~"hdrum~
'='
'
IRII 11
"'"
II \
~~'-- Fm
"
Return
spring
,.':'~
'
Driven plate
@
*
: Apply A.T.F.
: Selectwithproperthickness.
SAT810B
AT-126
case by
SAT862A
SA T863A
AT -127
KV31102400
(J34285 and
J34285-87 )
SAT864A
...
Q)
Q;
E
<II
'5
...
Q)
:;
~.
~
.-
Inspection
springs
of forward
clutch
and overrun
Part
return
Unit: mm (in)
Inspection standard:
\\.,,
clutch
35.77 (1.4083)
9.7 (0.382)
No.
31505.41 X01
Q : Free length
SAT829A
Thickness
Facing
Core plate
SAT845A
Thickness
Facing
Core plate
SAT845A
AT-1 28
SA T867 A
/'
SA T868A
AT -1 29
Snap ring
Retaining plate *
Driven plate
Direction
m~:
*
of oil seal
: Apply A.T.F.
Driveplate
Apply petroleum jelly.
: Select with proper thickness.
SAT811B
DISASSEMBLY
1. Check operation
brake.
a. Install seal ring onto oil pump cover and install reverse
clutch. Apply compressed air to oil hole.
b. Check to see that retaining plate moves to snap ring.
c. If retaining plate does not move to snap ring, D-ring or oil
seal may be damaged or fluid may be leaking at piston
check ball.
SAT873A
AT-130
SAT875A
t
OJ
E
'"
'5
t
:;
0
0
. .
\\
\
Inspection standard:
Q : Free length
Unit: mm (in)
Part No.
31521-21XOO
23.7 (0.933)
11.6 (0.457)
SAT829A
Thickness
.
.
Facing
Core plate
Measure
thickness
of facing.
SAT845A
AT-131
SAT877A
r Clearance
..
.
~ng
Install a new seal rings onto low one-way clutch inner race.
Be careful not to expand seal ring gap excessively.
Measure seal ring-to-groove clearance.
Inspection standard:
Standard value: 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Allowable limit: 0.25 mm (0.0098 in)
If not within allowable limit, replace low one-way clutch inner
race.
SAT878A
C)-m
(!>J
ASSEMBLY
1. Install bearing onto one-way clutch inner race.
Pay attention to its direction - Black surface goes to rear
side.
Apply petroleum jelly to needle bearing.
...
SAT112B
Oil seal
D-ring<:@
SAT879A
t
3. Install piston by rotating it slowly and evenly.
Apply A.T.F. to inner surface of transmission
case.
AT -1 32
5. Install dish plate, low and reverse brake drive plates, driven
plates and retaining plate.
6. Install snap ring on transmission case.
Driven plate
Drive plate
SAT812B
SAT872A
~J
I
'
/\
",]
~ I\
'
"
'\
[\ \
/"
~'-
~r
=~
~~
"
~- U
".
\ r.
;;'.
\
I,
"
~
I
-(
~=
t/.
,,*'/,~.
/1
f
,
(;-~
..
"
..
~,
17
'\:IC
~\
II.
"
I~N
I~
..
( \0
SAT884A
AT -1 33
Needle bearing
Snap ring
Low one-way clutch
Side plate
Snap ring
~
~
~"
~
-''''''''
0.., -.
J;J-. -. '>
-. -.
-!.
.., I
(
SAT886A
DISASSEMBLY
1. Remove snap ring from forward clutch drum.
0.
SA T888A
\/
SA T889A
AT -1 34
SAT891A
INSPECTION
Forward clutch drum
Check spline portion for wear or damage.
Check frictional surfaces of low one-way clutch and needle
bearing for wear or damage.
.
.
~~
...~
SAT892A
SAT893A
ASSEMBLY
1. Install needle bearing in forward clutch drum.
SAT113B
AT-135
clutch drum by
SAT894A
SAT895A
)
4. Install side plate onto forward clutch drum.
5. Install snap ring onto forward clutch drum.
AT -1 36
Thrust washer
lEI @
Forward clutch hub (with forward one-way clutch outer race)
Snap ring
Forward one-way clutch
6ri~
End bearing
lEI
DISASSEMBLY
1. Remove rear internal gear by pushing forward clutch hub
forward.
SA T897 A
f)
SAT898A
SAT899A
AT-137
~...~
~
B/
IIT'n,,,
-~0'GIi)~
SAT900A
...
"-
:::=-~!)
Illh
I-~~,f),
SAT955A
SAT901A
INSPECTION
Rear internal gear and forward clutch hub
Check gear for excessive wear, chips or cracks.
Check frictional surfaces of forward one-way clutch and
thrust washer for wear or damage.
Check spline for wear or damage.
..
..
.
..
..
SAT902A
oc)
00
SAT903A
AT -1 38
SAT901A
.
.
SAT905A
AT-1 39
~~
Piston stem
O-ring
O-ring
~ <&V
O-ring
~ @V
~ <&V
O-ring
~ <&V
Gasket
~
0.0. servo
piston retainer
SAT908A
DISASSEMBLY
1. Block one oil hole in 0.0. servo piston retainer and the
center hole in 0.0. band servo piston.
2. Apply compressed air to the other oil hole in piston retainer
to remove 0.0. band servo piston from retainer.
3. Remove O-ring from 0.0. band servo piston.
SAT909A
SAT910A
E-ring
SAT911A
AT-140
"e
n_@
SAT912A
SAT913A
SAT914A
INSPECTION
..
....
..
Spring B
Return springs
. Check for deformation or damage. Measure free length and
outer diameter.
Inspectionstandard:
Spring A
SAT916A
Unit: mm (in)
Parts
Free length
Outer diameter
Spring A
45.6 (1.795)
3.3 (1.350)
Spring B
53.8 (2.118)
40.3 (1.587)
Spring C
29.0 (1.142)
27.6 (1.087)
AT-141
PARTS
.
.
SAT919A
'@&
~@
SAT912A
AT-142
SAT921 A
7. Install band servo piston assembly onto servo piston retainer by pushing it inward.
SAT922A
SAT923A
SAT924A
AT-143
24
- 29 N.m
17
- 22 ft-Ib)
Rear extension
Output shaft
SA T205B
DISASSEMBLY
1. Slide return spring to the front of rear extension flange.
SAT927A
AT-144
'"
SAT929A
ASSEMBLY
1. Install rod guide and parking actuator support
extension.
2. Insert parking pawl shaft into rear extension.
onto rear
SAT927A
AT-145
ASSEMBL Y
Assembly
1.
a.
.
.
b.
\
e. Align groove in shaft with drive pin hole, then drive pin into
position as shown in figure at left.
SA T933A
f.
AT -146
ASSEMBL Y
Assembly (Cont'd)
h. Install lock nuts onto manual shaft.
SAT936A
Front..
Accumulator
piston B
Accumulator
tJ tr{'Ob
AE..o,
piston A
Accumulator
Accumulator
29 (1.14)
32 (1.26)
45 (1.77)
29 (1.14)
Largediameter end
45 (1.77)
50 (1.97)
50 (1.97)
45 (1.77)
piston C
SA T937 A
A onto transmission
Unit: mm (in)
Free length
43 (1.69)
c.
Install accumulator
pistons
A, S, C and D.
SAT941 A
AT -14 7
ASSEMBLY
Assembly (Cont'd)
b. Install band servo piston onto transmission case.
Apply A.i.F. to O-ring of band servo piston and transmission case.
ST07870000
(J37068)
SAT943A
.;:I
SAT944A
-----------------
SAT945A
AT ~ 148
ASSEMBL Y
Assembly (Cont'd)
d. Install thrust washer onto front of overrun clutch hub.
. Apply petroleum jelly to the thrust washer.
Insert pawls of thrust washer securely into holes in
overrun clutch hub.
Hole for
pawl
SAT946A
SAT947A
f.
SAT948A
hub rotates
as shown while
SAT949A
SAT950A
AT-149
ASSEMBLY
Assembly (Cont'd)
i.
j.
I.
AT -1 50
ASSEMBL Y
Adjustment
When any parts listed in the following table are replaced, total
end play or reverse clutch end play must be adjusted.
Total end play
Part name
Reverse clutch
end play
Transmission
case
Low one-way
clutch
Overrun
clutch
Rear internal
inner race
hub
gear
Rear planetary
carrier
planetary
Front
sun gear
High clutch
carrier
hub
Reverse clutch
drum
.
.
.
SAT967A
AT -151
ASSEMBL Y
Adjustment (Cont'd)
d. While rotating forward clutch drum clockwise,
planetary carrier on forward clutch drum.
..,
SAT969A
.
F rant planetary
carrier
'.-=
Portion
install front
...:::.'.
Portion B
SAT970A
O---El~
~~
~f}Jj
~
r~:
""--~-L
'
//
.
.
/
SA T204B
f.
SAT973A
AT -1 52
ASSEMBLY
Adjustment
(Cont' d)
d. Remeve To.el and use feeler gauge to. measure gap between
gauging cylinder and gauging plunger. This measurement
sheuld give exact tetal end play.
Total end play "T,":
0.25 - 0.55 mm (0.0098 - 0.0217 in)
If end play is eut ef specificatien, decrease er increase
thickness ef eil pump cever bearing race as necessary.
Available oil pump cover bearing race:
Refer to S.D.S.
SAT979A
AT -1 53
ASSEMBL Y
Adjustment (Cont'd)
3. Adjust reverse clutch drum end play.
Reverse clutch drum end play "12":
0.55 - 0.90 mm (0.0217 - 0.0354 in)
SAT981A
Feeler gauge
SAT984A
AT-154
ASSEMBL Y
Assembly
1. Install output shaft and parking gear.
a. Insert output shaft from rear of transmission case while
slightly lifting front internal gear.
Do not force output shaft against front of transmission
case.
;~T216B
b. Carefully push output shaft against front of transmission
case. Install snap ring on front of output shaft.
Check to be sure output shaft cannot be removed in rear
direction.
SA T960A
AT -1 55
ASSEMBL Y
Assembly (Cont'd)
2. Install rear extension.
a. Install oil seal on rear extension.
Apply A.T.F. to oil seal.
SAT219B
SAT191B
SA T963A
f.
SAT189B
AT-156
ASSEMBL Y
Assembly (Cont' d)
3. Install front side clutch and gear components.
a. Install rear sun gear on transmission case.
Pay attention to its direction.
.
.
.
SAT967A
SAT969A
Front planetary
carrier
Portion A
Portion B
SAT970A
.
.
Front
Rear
SAT971A
AT-157
ASSEMBLY
Assembly (Cont'd)
f.
SAT220B
SAT985A
AT-158
ASSEMBLY
Assembly (Cont'd)
7. Install oil pump assembly.
a. Install needle bearing on oil pump assembly.
Apply petroleum jelly to the needle bearing.
b. Install selected thrust washer on oil pump assembly.
Apply petroleum jelly to thrust washer.
.
.
SA T989A
c. Carefully install seal rings into grooves and press them into
the petroleum jelly so that they are a tight fit.
Seal ring
m~
a-ring
lEI ~
SAT991A
SAT992A
f.
SAT993A
AT-159
ASSEMBL Y
Assembly (Cont'd)
Transmission
case
SAT114B
b. Apply
recommended
sealant
(Nissan genuine
part:
KP610-00250 or equivale.nt) to outer periphery of bolt holes
in converter housing.
Do not apply too much sealant.
SAT997A
c. Apply
recommended
sealant
(Nissan genuine part:
KP610-00250 or equivalent) to seating surfaces of bolts that
secure front of converter housing.
SA T998A
AT -1 60
ASSEMBL Y
Assembly (Cont'd)
d. Install converter housing on transmission case.
- 6 N.m
AT-161
66 (2.60)
45 (1.77)
58.4 (2.299)
ASSEMBL Y
Assembly (Cont'd)
b. Install manual valve on control valve.
Apply A.T.F. to manual valve.
SATOO58
Bolt
Length
37 mm (1.46 in)
50 mm (1.97 in)
SAT2218
AT -1 62
ASSEMBLY
Assembly (Cont'd)
tI::~~1
i.
j.
SATOO98
Connector
SAT0118
SAT0128
II
SAT0138
AT -163
ASSEMBL Y
Assembly (Cont'd)
d. Tighten bolts while inserting 4.0 mm (0.157 in) dia. pin
\\
--\\
SAT014B
.
.
SAT015B
SAT016B
AT-164
General Specifications
KA24E
Engine
Autorriatic transmission model
RE4R01A
45X06
2.0: 1
2.785
1.545
1.000
0.694
2.272
Automatic transmission
fluid Type DEXRONTM
Recommended oil
Oil capacity
8.3 (8-3/4,7-1/4)
GEARS
Vehiclespeed km/h (MPH)
Throttle position
DI -> D,
D, -> D.
D. -> D.
D. ->D.
D. -> D,
D, ->DI
1,->11
Full throttle
52 -56
(32 - 35)
95 - 101
(59 - 63)
146 - 156
(91 -97)
140 - 150
(87 - 93)
89-95
(55- 59)
40-44
(25 -27)
53 - 57
(33 - 35)
Half throttle
38-42
(24 - 26)
72 -78
(45-48)
111-121
(69 -75)
55-65
(34 - 40)
33 - 39
(21 - 24)
10 - 14
(6-9)
53 - 57
(33 - 35)
AND
STALL
REVOLUTION
Stall revolution
O.D. switch
[Shift range]
Lock-up
"ON"
Lock-up
"OFF"
ON
[D.]
146 - 156
(91 -97)
140 - 150
(87 -93)
OFF
[D.]
95
Full throttle
-101
2,050
(59-63)
Engine speed
rpm
ON
[D.]
112-120
(70 -75)
102-110
(63 -68)
OFF
[D.]
(47 - 52)
71 -79
(44 -49)
76
-84
-2,250
LINE PRESSURf;
89-95
(55-59)
Half throttle
rpm
AT-165
R range
Idle
657 . 696
(6.7 -7.1,95 -101)
Stall
1,020 . 1,098
(10.4 -11.2,148 -159)
1.422 - 1,500
(14.5 - 15.3,206 - 218)
SPRINGS
Unit: mm (in)
Item
Part No.
Free length
Outer diameter
31742-41X18
32.3 (1272)
9.0 (0.354)
31742-41X16
61.5 (2.4211
8.9 (0.350)
31742-41 X19
31.95 (12579)
6.8 (0268)
31762-41XOO
26.5 (1.043)
6.0 (0.236)
31756-41XOO
29.1 (1.146)
6.95 (02736)
31762-41 X01
25.0 (0.984)
7.0 (0.276)
31756 -41XOO
29.1 (1.146)
6.95 (0.2736)
31762-41X01
25.0 (0.984)
7.0 (0276)
31762-41X03
23.6 (0.929)
7.0 (0276)
31742-41X20
32.5 (1280)
7.0 (0.276)
31762-41 X04
51.0 (2.008)
5.65 (0.2224)
31742-41 X13
25.7 (1.012)
9.1 (0.358)
31742-41X22
18.5 (0.728)
13.0 (0.512)
31742-41X15
30.5 (1201)
9.8 (0.386)
31756-41X05
25.4 (1.000)
6.75 (02657)
31742-41 X08
20.55 (0.8091)
6.75 (02657)
31742-41X06
23.0 (0.906)
6.7 (0264)
Parts
Upper
body
Control
valve
Lower
body
Reverse clutch
16 pcs
30505-41 X02
19.69 (0.7752)
11.6 (0.457)
High clutch
16 pes
31505-21X03
22.06 (0.8685)
11.6 (0.457)
Forward clutch
(Oiierrun clutch)
Low & reverse
brake
20 pes
31505-41X01
35.77 (1.4083)
9.7 (0.382)
18 pcs
31521-21XOO
23.7 (0.933)
11.6 (0.457)
Spring A
31605-41X05
45.6 (1.795)
34.3 (1.350)
Spring B
31605-41XOO
53.8 (2.118)
40.3 11.587)
Spring C
31605-41X01
29.0 (1.142)
27.6 (1.087)
Accumulator A
31605-41X02
43.0 (1.6931
Accumulator B
31605-41X10
66.0 (2.598)
Accumulator C
31605-41X09
45.0 (1.772)
Accumulator D
31605-41X06
58.0 (2283)
Band servo
Accumulator
AT-166
-------------------
O-RING
Diameter mm (in)
Accumulator
IForward
29 (1.14)
32 (1.26)
45 (1.77)
29 (1.14)
45(1.77)
50 (1.97)
50 (1.97)
45 (1.77)
IReverse clutch/
Number of drive plates
2.0 (0.079)
1.8 (0.071)
Clearance
mm (in)
Standard
Allowable limit
2.0 (0.079)
1.8 (0.0711
Clearance
mm (in)
Standard
Allowable limit
Thickness
mm (in)
4.6
4.8
5.0
5.2
5.4
5.6
5.8
31537-21XOO
31537-21 X01
31537-21X02
31537 -21 X03
31537-21X04
31567-41X13
31567-41 X14
1.6 (0.063)
1.4 (0.055)
Clearance
mm(in)
Standard
Allowable limit
(0.142)
(0.150)
(0.157)
(0.165)
(0.173)
(0.181)
(0.189)
(0.197)
IOverrun
Part number
(0.181)
(0.189)
(0.197)
(0.205)
(0.213)
(0.220)
(0.228)
IHigh clutch I
Thickness
mm (in)
clutch
Number of drive plates
31537.41X61
31537-41X62
31537-41X63
31537-41X64
31537-41 X65
31537-41X66
31537-41 X67
31537-41X68
AT-167
(0.315)
(0.323)
(0.331)
(0.339)
(0.346)
(0.354)
(0.362)
31537-41
XOO
31537-41X01
31537-41 X02
31537-41X03
31537-41 X04
31537-41X05
31537-41X06
clutch
Number of drive plates
2.0 (0.079)
1.8 (0.071)
Clearance
mm(in)
Standard
Allowable limit
Part number
8.0
8.2
8.4
8.6
8.8
9.0
9.2
Part number
Thickness
mm (in)
Part number
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6(0.181)
4.8 (0.189)
5.0 (0.197)
5.2 (0.205)
31537-41X79
31537-41 X80
31537-41X81
31537-41 X82
31537-41X83
31537-41 X84
31537-41 X20
8.6
8.8
9.0
9.2
9.4
9.6
(0.339)
(0.346)
(0.354)
(0.362)
(0.370)
(0.378)
31667-41X03
31667-41X04
31667-41X05
31667-41X06
31667-41X09
31667-41 X10
4.6
(0.4 - 0.6, 2.9 - 4.3)
Number of returning
revolutions for anchor
end bolt
TOTAL
END PLAY
0.25 - 0.55 mm
(0.0098 0.0217 in)
Thickness
mm (in)
0.8
1.0
1.2
1.4
1.6
1.8
2.0
(0.031)
(0.039)
(0.047)
(0.0551
(0.063)
(0.071)
(0.079)
1 ..1 (0.043)
(0.051)
(0.059)
(0.067)
(0.075)
2.5
0.03
31528-21 XOO'
31528-21 X01
31528-21X02
31528-21 X03
31528-21 X04
31528-21 X05
31528-21 X06
Part number
Part number
Brake band
Anchor end bolt tightening
torque
N.m (kg-m, ft-Ib)
- 0.90 mm
0.7 (0.028)
0.9 (0.035)
1.3
1.5
1.7
1 .9
0.55
2.0 (0.079)
1.8 (0.071)
Clearance
mm lin)
Standard
Allowable limit
Part number
31429-21 XOO
31429-21 X01
31429-21 X02
31429-21 X03
31429-21X04
31429-21 X05
31429-21 X06
AT-168
(1.1-1.5
11 15 N.m
kg-m, 8 -11 ft-Ib)
in)
PROPELLER
SHAFT&
DIFFERENTIAL
CARRIER
I
PD
SECTION
CONTENTS
PREPARATION...
."
"""""""""""
PROPELLER
SHAFT
ON-VEHICLE
SERVICE
"'..0
""'''''''''''''''''''0''''''''''''''''''''
(Final drive)
FINAL
DRIVE
DISASSEMBLY
INSPECTION
ASSEMBLY
"""'"''''''''''''''''''''
0..
0
0"'"
0'''''
0...0"""0"
"'"''''''''''''''''''''''''''''''''''''''
"""''''''0'''''''''''''0''''''''
o.0
0 PD-
PD-
PD- 9
''''''''''''''''''''''''''''''''''''''''''''''''''''''
0
0
0"
..
""""''''''''''''''''''''''''''''
ADJUSTMENT
0'"''''
PD-11
0
"""""'''''''''''''...0
""""""'"''''''''''
'"''''''''''''
0'"''''''''''''0'''
...".
"''''''''''''''''''''''
0'"''''
0..""'''''''...0.0
PD-12
PD-13
0. PD-17
0'0'"''''''''''''''
0
PD-18
PD-25
PD-30
PREPARATION
SPECIAL SERVICE TOOLS
Tool number
(Kent-Moore No.)
Tool name
ST38060002
(J34311)
Drive pinion flange
wrench
KV38100800
Equivalent tool
(J25604-D 1)
Differential
attachment
Description
ST309OS000
ST30031000
(J22912-D1)
Puller
@ ST30901000
Equivalent tool
(J26010-D1)
Base
~
~
ST3306S001
Differential side
bearing puller set
CD ST33051001
(
Equivalent tool
(J22888)
Body
@ ST33061 000
(J8107-2)
Equivalent tool
(J26010-D1)
Adapter
ST30611000
(J25742-1)
Drift
Q}fi
~~
~~ ~~\~.;II';~J..i'Hi1tlI'itr;;;'WJJ
PD-2
PREPARATION
Tool number
(Kent-Moore No.)
Tool name
Description
ST30613000
(J25742-3)
Drift
~.
ST30701000
(J25742-2)
Drift
KV381 00200
(J26233)
Gear carrier
side oil seal
drift
KV38100500
KV381 00300
(J25523)
Differential side
bearing inner cone
KV38100600
(J25267)
Side bearing spacer
drift
ST3127S000
(See J25765-A)
Preload gauge CD GG91030000
(J25765)
Torque wrench
@ HT62940000
~
roo
~
~
CD
r;==~
~-~
Socket adapter
@ HT62900000
(
)
Socket adapter
HT72400000
(
)
Slide hammer
PD-3
PREPARATION
Tool number
(Kent-Moore No.)
Tool name
Description
(J34309)
Differential shim
selector
Adjusting bearing
preload and gear height
(J25269-4)
Side bearing discs
(2 Req'd)
(J8129)
Spring gauge
PD-4
PROPELLER SHAFT
.~
3S63A-T
Washer
Apply a coat of multi-purpose lithium grease
containing molybdenum disulfide to the end
face of the center bearing and both sides of
the washer.
Lock nut
~245 -294
125- 30, 181 - 217)
25-39
'fh<i'-"\\l-/
~QjoJ~
~~
~~
r
-
lJi~
34 -4413.5 -4.5,25-33)
Companion flange
Center
bearing
lower
mounting
bracket
: N.m Ikg-m.ft-Ib)
SPD899
3S63A-R
Washer
Apply a coat of multi-purpose lithium grease
containing molybdenum disulfide to the end
face of the center bearing and both sides of
the washer.
25
-Lock nut
245 294
125
- 30,
181
-217)
39
Companion flange
25
19 - 29)
PD-5,
PROPELLER SHAFT
On-vehicle
,~
Service
Unit: mm (in)
Center
Model
~i"'
ABC
3S63A-R
Coupling.
Center
3S63A-T
3S63A-R
175 (6.89)
155 (6.10)
165 (6.50)
'165 (6.50)
185 (7.28)
185 (7.28)
Distance
~~"m"
Journal
ABC
SPD872
.
.
/
Removal
Transmission
SPD359
PD-6
PROPELb.ER SHAFT
.Installation.
~nted
~rk-j~
Painted mark;;::
Inspection
Inspect propeller shaft run'out. If runout exceeds specifications, replace propeller shaft assembly.
Runout limit: 0.6 mm (0.024 in)
~
SPD106
.
//
/~~
SPD874
Disassembly
CENTER BEARING
1. Put matchmarks on flanges, and separate 2nd tube from 1st
tube.
/\
SPD109
SPD110
PD-7
PROPELLER SHAFT
Disassembly
(Cont'd)
SPD 111
SPD112
Assembly
CENTER BEARING
.
.
.
.
SPD117
~'\
pl1:8
P.D-9
-)
3. Apply multi-purpose
PD-'O
.
.
.
.
.
Installation
:C!;' :
Filler opening
SPD882
PD-11
Side
,"'"
er
~
bearing
spacer
Sidel?e
""
\:
'''~
"'0
./
CI
w"",,,,"
P'Inion
, height adjustin g ,,,.
P'"'O"
N
P''00"'"
'
"',,'"'
'00'"
0..",
~
~2)~
P',moo
, "',,'"
'''''
'
spacer*
g adJusting
.
P,,'oo b""O"
washer*
g adJusting
,
""
/'I
~" Q
I,
"-.! /
.
'"
r0
/"
/~
'
\..J
"
"
,:.
/'
/'
;PIQtn
0
' '
'
,IJI
Differential
.et
~."
Ie
case
"'''
Fioo",'w'
Co... '.,',
~\ ~,-. 88.,.
./ /
B.",",~P
0
,l~ ~
"'/'
'
(]
.. -721
//J"WL/'
'
((JJ
/::---
,,,,'
~./,/
'" II
>
"1)
0
IX)
IX)
w
L'-. ?
/"
'
Y'0
'00
rn':'
Companion
en
R", ,.,,,
~
In'
~ )Y'
/~, //
~r
Rn,-,
'
'
LockP'" t:9
~\
~\J
~~
'
P~
e,,,"'"
'"'OO-,""''"ru
CI
p",O""". ,."
,h,f<-
LA
I
Inner
"i"'~
Breath
' ,
mate
nO r, J
~'''''
l~O
Pinion
", "
Spe
""",,
bea
flange
* : Adjustment is re
* : Using locking ag
: N.m (kg-m, ft-Ib
DISASSEMBLY
Pre-inspection
Before disassembling final drive, perform the following inspection.
Total preload
1) Turn drive pinion in both directions several times to set
bearing rollers.
2) Check total preload with Tool.
Tool number: ST3127S000 (See J25765-A.)
Total preload:
1.4 - 1.7 N.m
(14 - 17 kg-em, 12 - 15 in-Ib)
SPD884
SPD513
.
.
0-
../"/11
SPD887
Differential Carrier
1. Using two 45 mm (1.77 in) spacers, mount carrier on Tool.
Tool number:
PD-13
KV38100800
DISASSEMBLY
Differential Carrier (Cont'd)
2.
SP D889
HT72400000
out with
Tool.
)
PD344
6
?
Keep the side bearing outer races together with inner cone
do not mix them up.
~.
SPD527
SPD890
PD-14
flange.
DISASSEMBLY
Differential Carrier (Cont'd)
SPD891
6. Take out drive pinion (together with rear bearing inner race,
bearing spacer and adjusting washer).
7. Remove oil seal.
8. Remove front bearing inner race.
9. Remove side oil seal.
PD349
\ ""'-7
<.~.
_H..
.--.
.
/.'-
-~
./
11. Remove pinion rear bearing inner race and drive pinion
height adjusting
.Tool
----- -
-- -PD179
PD-15
washer
DISASSEMBLY
Differential Case
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in groove.
Tool number:
@ ST33051001( )
Equivalent tool (J22888)
@ ST33061000 (J8107-2)
SPD529
SPD022
4. Drive out pinion mate shaft lock pin, with punch from ring
gear side.
Lock pin is calked at pin hole mouth on differential case.
SPD025
PD-16
INSPECTION
Ring Gear and Drive Pinion
Check gear teeth for scoring, cracking or chipping. If any part is
damaged, replace ring gear and drive pinion as a set (hypoid
gear set).
SPD909
Bearing
1. Thoroughly clean bearing.
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged, replace outer race and inner cone as a set.
SPD715
PD-17
ADJUSTMENT
For quiet and reliable final drive operation, the following five
adjustments must be made correctly.
1. Side bearing preload
2. Pinion gear height
3. Pinion bearing preload
4. Ring gear-to-pinion backlash (Refer to ASSEMBLY.)
5. Ring and pinion gear tooth contact pattern
6
011
~
~
1. Make sure all parts are clean and that the bearings are well
lubricated with light oil or DexronTMtype automatic transmission fluid.
2. Place the differential carrier, with side bearings and bearing
races installed, into the final drive housing.
SPD527
3. Put the side bearing spacer in place on the ring gear end of
the carrier.
PD-18
ADJUSTMENT
Side Bearing Preload (Cont'd)
5. Install the side bearing caps in their correct locations and
torque the bearing cap retaining bolts.
Specification:
88 - 98 N.m
(9 - 10 kg-m, 65 - .72 ft-Ib)
6. Turn the carrier several times to seat the bearings.
L--I
I
I
.---i., ,
'-, ,
10. Remove the carrier from the final drive housing, saving the
selected preload washers for later use during the assembly
of the final drive unit.
PD344
- iPt= I
1. Make sure all parts are clean and that the bearings are well
lubricated.
I- ~
I!DIiIIIIIIIIII
18
!:J
SPD769
PD-19
ADJUSTMENT
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
~!
C'/'
1\1 SPD893
SPD770
PD-20
ADJUSTMENT
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
7. Place the J-34309-11 "R200A" pinion height adapter onto
the gauge plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.
8. Place the solid pinion bearing spacer, small end first, over
the J-34309-2 gauge anvil and seat the small end squarely
against the tip of the J-34309-1 gauge screw in the tool
recessed portion.
you get with your gauges is the thickness of the adjusting washer required. Select the correct washer from the
following chart.
Drive pinion bearing preload adjusting washer:
Refer to S.D:S.
SPD774
PD-21
ADJUSTMENT
Pinion Gear Height and Pinion Bearing Preload
(Cont'd)
-
11. Now, position the side bearing discs, J-25269-4, and arbor
firmly into the side bearing bores.
Install the side bearing caps and tighten the cap bolts to
proper torque.
SPD775
PD-22
ADJUSTMENT
15. Select the correct pinion height washer from the following
chart.
Drive pinion height adjusting washer (R200):
Thickness mm (in)
3.09
3.12
3.15
3.18
3.21
3.24
3.27
3.30
(0.1217)
(0.1228)
(0.1240)
(0.1252)
(0.1264)
(0.1276)
(0.1287)
(0.1299)
3.33
3.36
3.39
3.42
3.45
3.48
3.51
(0.1311)
(0.1323)
(0.1335)
(0.1346)
(0.1358)
(0.1370)
(0.1382)
3.54.(0.1394)
3.57 (0.1406)
3.60 (0.1417)
3.63 (0.1429)
3.66 (0.1441)
Part No.
38164-P60 17
38154-P6Q 18
38154-P60 19
38154-P6020
381 54-P6021
38154-P6022
38154-P6023
38164-P6024
38154-P6025
38154-P6026
38154-P6027
38154-P6028
38154-P6029
38154-P6030
38154-P6031
38154-P6032
38154-P6033
38154-P6034
38154-P6035
38164-P6036
16. Remove the J-34309 pinion preload shim selector Tool from
the final drive housing and disassemble to retrieve the
pinion bearings.
PD-23
ADJUSTMENT
Tooth Contact
Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion.
Hypoid gear sets which are not positioned properly may be
noisy, or have short life, or both. Low noise and a long life can
be assured with a pattern check.
SPD357
3. Hold companion flange steady and turn the ring gear in both
directions.
Usually the pattern will be correct if you have calculated the shims correctly and the backlash is correct.
However, in rare cases you may have to use trial-and-errorprocessas until you get a good tooth contact pattern.
The tooth pattern is the best indication of how well a differential has been set up.
Heel contact
Face contact
Toe contact
~~
~~
.
CM""-..
Flank contact
~
PD-24
v-t~
SPDOO7
ASSEMBLY
Differential Case
1. Install side gears, pinion mate gears, thrust washers and
thrust block into differential case.
SPD552
SPD553
SPD828
SPD030
SPD322
PD-25
ASSEMBLY
Differential Case (Cont'd)
6. Apply locking sealant to ring gear bolts, and install them.
Tighten bolts in a criss-cross fashion, lightly tapping bolt
head with a hammer.
Tool@
Tool @
PD353
Differential Carrier
~/~
if
Pinion front
bearing
outer race
w~
@
SPD679
Press
Adjusting
washer
SPD377
PD-26
ASSEMBL Y
Differential Carrier (Cont'd)
4. Place pinion front bearing inner cone in final drive housing.
r-"
~
)~
E!!I
SPD581
J' ~
be'
ad'
arlng
JuH;"~~'~~
@
. .
Pinion fron t b earln g Inner race
E:
lIE!
SPD897
SPD896
SPD557
PD416
PD-27
ASSEMBLY
Differential Carrier (Cont'd)
8. Turn drive pinion in both directions several times, and
measure pinion bearing preload.
Pinion bearing preload:
1.1 - 1.4 N.m
(11 - 14 kg-em, 9.5 - 12.2 In-Ib)
When pinion bearing preload is outside the specifications,
replace pinion bearing adjusting washer and spacer with a
different thickness.
SP D884
5'
SPD527
11. Insert left and right side bearing adjusting washers in place
between side bearings and carrier.
~~~
,
~( ::;..;;-..f\:i{;!
Tool
~~'
SPD559
13. Align mark on bearing cap with that on gear carrier and
install bearing cap on gear carrier.
PD-28
ASSEMBL Y
SP0560
gear-to-drive
pinion
backlash with
a dial
.
.
SP 0884
SP0524
PD-29
SPECIFICATIONS
SPECIFICATIONS
AND ADJUSTMENT
Unit: mm (in)
Applied model
Transmission
type
Propeller shaft
model
Propeller
M/T
A/T
3S63A-R
3S63A-T
Number of joints
Coupling method
with transmission
Sleeve type
Type of journal
bearings
Distance between
yokes
Shaft length
(Spider to spider)
1st
2nd
Shaft outer
diameter
1st
2nd
Unit: mm (in)
395.0 (15.55)
432.0 (17.011
605.0 (23.82)
605.0 (23.82)
75.0 (2.953)
75.0 (2.953)
shaft model
75.0 (2.953)
... Large side
63.5 (2.500)
... Small side
/~
PD-30
3S63A-R
3S63A- T
0.6 (0.024)
0 (0)
SPECIFICATIONS
R200
4.083
Number of teeth
(Ring gear/Drive pinion)
49/12
Available
1.8 (3-7/8,3-1/8)
3.80 - 3.82
3.82 - 3.84
3.84-3.86
3.86 - 3.88
3.88 - 3.90
3.90 - 3.92
3.92 - 3.94
3.94-3.96
3.96 - 3.98
3.98 - 4.00
4.00-4.02
4.02 - 4.04
4.04 - 4.06
4.06 - 4.08
4.08 - 4.10
(R200)
drive pinion
bearing preload
Thickness mm (in)
preload
N.m (kg-em, in-Ib)
With front oil seal
205 (8.07)
Gear ratio
Drive pinion
(0.1496 - 0.1504)
(0.1504 - 0.1512)
(0.1512 -0.1520)
(0.1520 - 0.1528)
(0.1528 - 0.1535)
(0.1535 - 0.1543)
(0.1543 - 0.1551)
(0.1551-0.1559)
(0.1559 - 0.1567)
(0.1567 - 0.1575)
(0.1575-0.1583)
(0.1583 - 0.1591)
(0.1591 - 0.1598)
(0.1598 - 0.1606)
(0.1606 - 0.1614)
adjusting
washer
Part number
38125-61001
38126-61001
38127-61001
38128-61001
38129-61001
38130-61001
38131-61001
38132-61001
38133-61001
38134-61001
38135-61001
38136-61001
38137-61001
38138-61001
38139-61001
mm (in)
3.09 (0.1217)
3.12
3.15
3.18
3.21
(0.1228)
(0.1240)
(0.1252)
(0.1264)
3.24 (0.1276)
3.27 (0.1287)
3.30
3.33
3.36
3.39
3.42
3.45
3.48
3.51
3.54
3.57
3.60
3.63
3.66
(0.1299)
(0.1311)
(0.1323)
(0.1335)
(0.1346)
(0.1358)
(0.1370)
(0.1382)
(0.1394)
(0.1406)
(0.1417)
(0.1429)
(0.1441)
Part number
Length mm (in)
38154-P6017
38154-P60 18
38154-P6019
38154-P6020
38154-P6021
38154-P6022
38154-P6023
38154-P6024
55.10
55.40
55.70
56.00
56.25
38154-P6025
38154-P6026
38154-P6027
38154-P6028
38154-P6029
38154-P6030
38154-P6031
38154-P6032
38154-P6033
38154-P6034
38154-P6035
38154-P6036
PD-31
(2.1693)
(2.1811)
(2.1929)
(2.2047)
(2.2146)
Part number
38165-B4002
38165-B4003
38165-B4004
38165-61001
38166-61001
Total preload
Adjusting shim
0.03
-0.0910.0012
- 0.00351
Part number
38453-N3100
38453-N3101
38453-N3102
38453-N31 03
38453-N3104
38453-N3105
38453-N3106
38453-N3107
38453-N3108
38453-N3109
38453-N3110
38453-N3111
38453-N3112
38453-N3113
Thickness mm Iinl
Part number
0.80 10.03151
0.85 10.03351
0.90 10.03541
0.95 10.03741
1.00 10.03941
1.0510.04131
1.1010.0433)
1.1510.04531
1.2010.04721
1.25 10.04921
1.3010.05121
1.3510.05311
1.4010.05511
1.4510.05711
1.5010.05911
38424-40FOO
38424-40F08
38424-40F01
38424-40F09
38424-40F02
38424-40F10
38424-40F03
38424-40F 11
38424-40F04
38424-40F12
38424-40F05
38424-40F13
38424-40F06
38424-40F 14
38424-40F07
---------
PD-32
mm Iinl
0.05 10.00201
FRONTAXLE&
FRONT
~USPENSION
,
~
FA
SECTION
CONTENTS
PRECAUTIONS AND PREPARATION
...
"""""'"''
FA- 2
"'"''
"
FA-
On-vehicle
FA- 5
FRONT AXLE
FA- 9
FRONT AXLE -
FRONT AXLE -
Baffle Plate
FA-10
"
FA-13
FRONT SUSPENSION
FRONT SUSPENSION -
FA-14
Coil Spring and Strut Assembly
FA-15
;
,'
FA-17
FA-18
FA-19
.
.
SBR500
Preparation
SPECIALSERVICETOOLS
Tool number
(Kent-Moore No.)
Tool name
HT72520000
(J25730-A)
Balljoint remover
HT71780000
(
Spring compressor
ST35652000
(
Strut attachment
GG94310000
(
Description
~
e5E
~~
~
~
FA-2
Description
OO)!
Wheel bearing drift
2J
FA-3
in) dia.
Coil spring
Strut assembly
46 52
(4.7- 5.3,
34- 38)
"'.$. ~
I,
~39-49
(4.0-5.0,
29 -36)
c:::?
Front
Transverse
link assembly
~
Brake disc roter
Tension rod
FA~4
On-vehicle
SMA525A
(4) Check front axle and front suspension parts for wear, cracks
or other damage.
SFA541A
Check strut
damage.
(shock
absorber)
Check suspension ball joint for grease leakage and ball joint
dust cover for cracks or other damage.
FA'" 5
On-vehicle
.
..
.
"
\
SFA543A
Inside
~.
SFA575S
.
..
to S.D.S.
Check front suspension for looseness.
Refer
..
..
SFA894
Kingpin inclination:
1230' 1400'
90
SFA573B
FA-6
On-vehicle
(Cont'd)
SFA103A
Camber:
-130' to 0
Camber
90
SFA574A
SFA105A
(2) Next replace adjusting pin with flat portion facing upward.
(3) Turn adjusting pin to adjust.
Camber changes
about 5' with each graduation
of adjusting pin.
(4) Tighten adjusting pin to specified torque.
~: 124
Adjusting
pin
SFA106A
TOE-IN
1. Draw a base line on tread surface of tires.
After lowering front of vehicle, move it up and down to
eliminate friction, and set steering wheel in straight-ahead
position.
SMA123
FA-7
On-vehicle
(Cont'd)
2. Measure toe-in.
Measure distance "A" and "B" at same height as hub center.
Toe-in:
8M~
Front
t#
Toe-in =A
Total toe-in
SFA234A
-B
= 29
3. Adjust toe-in by varying length of steering tie-rods.
(1) Loosen lock nuts.
(2) Adjust toe-in by turning forward and reverse tie-rod.
~,
-,
-~
~: 37 - 46 N.m
(3.8- 4.7 kg-m,27 - 34 ft-Ib)
SFA545A
SMA 127
't
Front
Inside wheel: A
39 - 43
Outside wheel: B
33
Full turns
A: Inside
B: Outside
SFA898
FA-8
FRONT AXLE
Knuckle spindle
Suttle plate
Snap ring
Wheel hub
FA-'9
FRONT AXLE
Removal
SFA090A
SFA547A
SF,o,571 B
Adjusting'pin
FA-10
FRONT AXLE -
Installation
..
SFA114A
SFA543A
Disassembly
CAUTION:
When removing wheel bearing from wheel hub, replace wheel
bearing assembly (outer race, inner races and grease seal)
with a new one.
. Remove circular clip with suitable tool.
SFA215A
.press.
Inspection
WHEEL HUB
. Check
wheel hub for any cracks by
exploration or dyeing test.
CIRCULAR CLIP
. Check
circular clip for wear or cracks.
Replace if necessary.
FA-11
using a magnetic
FRONT AXLE
Assembly
1. Press new wheel bearing assembly into wheel hub from
inside of rotor disc (with wheel hub).
Maximum load P:
29 kN (3 t, 3.3 US ton, 3.0 Imp ton)
CAUTION:
..
Grease seal
Circular clip
SFA218A
FA-12
FRONT AXLE
Baffle Plate
Removal
..
SFA548A
Installation
SFA549A
FA-13
FRONT SUSPENSION
cap
~~
59 78 (6.0
- 8.0,~"(
43 - 58)
~~
39 54 (4.0
-5.5,29- 40)
GaSket~
Strut
mounting
insulator
~~
Lock washer~
Bound bumper
u""''''''~
Coil spring
Strut assembly
PI..,;, d;P\
Front
fi
suspension
member
I
V
~~88-108
~ ~-J(9.0- 11.0,
65- SO)
f)~
}~"""J
"
J)
link
L~~46-52
(4.7-5.3,
39 - 49 (4.0 -5.0,~
29 - 36)
'
34-38)
~ ~88 - 108
(9.0.11.0,65- 80)
If ~
Tension rod
bracket
4-/r/~>\
~\
"~:J
a~~\
'
/
~:
Transverse
"-Tension
rod
",
l'\1~
FA-14
FRONT SUSPENSION
Strut upper portion
I~
Removal
.
..
Adjusting pin
Disassembly
1. Set strut assembly on vise with Tool, then loosen piston rod
lock nut.
Do not remove piston rod lock nut.
Suitable
bar
SFA134A
2. Compress spring with a Tool so that strut mounting insulator can be turned by hand.
HT71780000
(
)
SFA135A
ST35652000
(
)
SFA136A
Inspection
STRUT ASSEMBLY
.
.
.
portion.
FA-15
Inspection (Cont'd)
STRUT MOUNTING INSULATOR
Check cemented rubber-to-metal portion for separation or
cracks. Check rubber parts for deterioration.
Assembly
Top
Bottom
SFA760
r=sA"
\,
Fl.. .."
~"'"d
SFA'"
.
{}
Left
Front
Cutout
Install upper spring seat with its cutout facing the inner side
of vehicle.
Right
"
SFA576A
FA-16
FRONT SUSPENSION
SFA552A
Press.
,
SF A553A
~D"ft
Front
.
.
SFA554A
SFA555A
View from B
mA~
~~
O.K.
~~
N.G.
SFAOO2A
FA-17
FRONT SUSPENSION
.
.
.
SFA552A
Inspection
TRANSVERSE
.
.
LINK
Measuring
turning
Check ball joint for play. If ball stud is worn, play in axial
direction is excessive or joint is hard to swing, replace
transverse link assembly if necessary.
torque
SFA757
~\(
~ lower
Pry bar /
Dial
indicator
//:%
SFA556A
FA-18
...
General Specifications
COIL SPRING
Model
Item
Except Sports
package
Sports
package
Item
Wire diameter
mm (in)
13.3 (0.524)
13.5 (0.531)
Coil diameter
mm (in)
170 (6.69)
170 (6.69)
Free length
mm (in)
326 (12.83)
311 (12.24)
Orange x 1,
Purple x 1
Pink x 1,
Purple x 1
Stabilizer diameter
mm (in)
Identification color
Spring constant
N/mm (kg/mm, Ib/in)
Identification color
STRUT
Model
Item
Piston rod diameter
mm (in)
Stroke
Sports
package
Except Sports
package
20.0 (0.787)
mm (in)
160 (6.30)
Damping force
[at 0.1 m (0.3 ft)/sec.]
N (kg,lb)
Expansion
Compression
Damping force
[at 0.3 m (1.0 h)/sec.]
N (kg,lb)
Expansion
Compression
412-608
(42 - 62,93
471-706
- 137)
206 - 304
(21 - 31, 46 - 68)
(48 -72,106
- 159)
235 - 353
(24 - 36, 53 - 79)
FA-19
Except Sports
package
Sports
package
24 (0.94)
25 10.98)
White
Orange
degree
-130'
to 0
Caster
degree
6 00'
- 7 30'
Swing force
(Measuring point: cotter pin
hole of ball stud)
Toe-in (Total)
N (kg, Ib)
mm (in)
Kingpin inclination
- 0.091)
degree
l' - 6.5'
degree
1230' - 1400'
Turning torque
N'm (kg-cm, in-Ib)
0.49 - 3.43
(5.0 - 35, 4.3 - 30.4)
7.8 - 55.9
(0.8 - 5.7,1.8 - 12.6)
egree
39
mm (in)
-43 /33
*1: Tankful of fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools, mats in designated position.
*2: On power steering models, wheel turning force (at circumference of steering wheel) .of 98 to 147 N (10 to 15 kg,
22 to 33'lb) with engine idle.
0 (0)
Radial runout
Aluminum wheel
mm (in)
WHEEL BEARING
lateral runout
Steel wheel
mm (in)
FA-20
(0.031) or less
REARAXLE &
REARSUSPENSION
,
RA
SECTION
CONTENTS
PRECAUTIONS AND PREPARATION
"'"''.'''''''''''''''''''''''''''''''
RA-
RA- 4
On-vehicle
" RA- 5
RA- 8
REAR AXLE -
RA- 9
REAR AXLE -
Drive Shaft
RA-13
REAR SUSPENSION
RA-19
REAR SUSPENSION -
""'"''''''''''''''''''''''''''''''''''''''''''''''
RA-20
RA-22
RA-23
RA-24
III
~,
GG9431 0000
(
.
.
.
SBR500
Preparation
SPECIALSERVICETOOLS
Tool number
(Kent-Moore No.)
Tool name
HT71780000
(
Spring compressor
ST35652000
(
-.
)
Strut attachment
GG94310000
(
ST38280000
(
Description
~
~----.
~
~
~
~
~
RA-2
Precautions (Cont'd)
COMMERCIAL SERVICE TOOLS
Tool name
Attachment
Wheelalignment
Description
}aJJ}
lIID)
1:EID J
Rear drive shaft plug
seal drift
rED
RA-3
mm (in)
It
Dust cover
Coil spring
~-1S.'2-14)
~
Shock absorber
;:.E- 19
69 -88
Lower link
69 -88
I~
77 -98
(7.9 -10.0,
57 -721
Upper link
rear
L~43 -55
.
(4.4 - 5.6,32 -41)
~98-118
I
110.0
- 12.0,72
- 871
77 98
(7.9 - 10.0,57 -721
9-12
(0.9 -12,6.5
-8.71.
~:
N.m (kg-m,ft-Ib)
SRA093A
RA-4
CHECK ANDADJtlSTMENT -
On-vehicle
wear or
SMA525A
SMA113
Check suspension ball joint for grease leakage and ball joint
dust cover for cracks or other damage.
RA-5
On-vehicle
.
..
SRA107A
Inside
~.
SFA575S
be sure to make
..
.
.
.
.
CAMBER
SRA096A
Camber:
-136'
'/
SRA097A
RA-6
to -036'
On-vehicle
(Cont'd)
~:69 - 88 N.m
(7.0 - 9.0 kg-m,51 - 65 ft-Ib)
SRA098A
TOE-IN
1. Draw a base line across the tread.
After lowering rear of vehicle, move it up and down to
eliminate friction.
SMA123
2. Measure toe-in.
Measure distance "A"
center.
Toe-in:
A-B
Lines parallel to
center line of body
and "B"
1.5' - 12.5'
Front
~
SFA234A
Toe-in = A
6
-B
Total toe-in = 26
with each
- 88 N.m
Drive Shaft
Check boot and drive shaft for cracks, wear, damage or grease
leakage.
SRA796
RA-7
SRA 100A
.
.
SFA110A
.
.
SRA101A
RA-8
REAR AXLE
Adjusting cap
L.~
Wheel bearing
withflange~
~
: N'm(kg-m,ft-Ib)
SRA102A
Removal
SFA110A
RA-9
REAR AXLE
Removal (Cont'd)
SFA181A
SRA104A
Remove wheel bearing with flange, and wheel hub from axle
housing.
SRA105A
Installation
..
- 314N.m
SRA106A
SRA107A
RA-10
REAR AXLE
SRA108A
CAUTION:
Wheel bearing with flange usually does not require maintenance. If any of the following symptoms are noted, replace
wheel bearing assembly (including flange, and inner and outer
seals).
Growling noise is emitted from wheel bearing during
operation.
Wheel bearing drags or turns roughly when hub is turned
with your hand after bearing lock nut is tightened to
specified torque.
After wheel bearing is removed from hub.
.
.
.
WHEEL HUB
. Remove
wheel bearing (with flange) and wheel hub as one
unit from axle housing before disassembling.
WHEEL BEARING
Using a press and drift as shown in figure at left, press
wheel bearing out.
Discard old wheel bearing assembly. Replace with a new
wheel assembly.
Press.
.
.
SRA109A
CAUTION:
ST30031 000
(J22912-01 )
SRA110A
RA-11
REAR AXLE
Disassembly (Cont'd)
AXLE HOUSING
SRA111A
.
.
Ensure axle housing bore is free from scratches or deformities before pressing bushing into it.
Attach bushing to chamfered bore end of axle housing and
press it until it is flush with end face of axle housing.
SRA112A
Inspection
WHEEL HUB AND AXLE HOUSING
.
.
Assembly
. Place hub on a block. Attach a drift to inner race of wheel
bearing and press it into hub as shown in figure at left.
Be careful not to damage grease seal.
Drift
Block
SRA113A
RA-12
REAR AXLE
Drive Shaft
Drive shaft
~I
(24.32,
~~"'''~-~
235.314174 - 231)
Insulator
@)~
Adjusting cap
SRA114A
Removal
When removing drive shaft, cover boots with waste cloth to
prevent damage to them.
WHEEL SIDE
Installation
.
.
.
RA-13
REAR AXLE
Drive Shaft
Spider assembly
IE!
Housing
inner
side
m
Wheel hub side
;>
Boot band
SRA117A
Disassembly
Slide joint
housing
SRA118A
RA-14
Shaft
Disassembly (Cont'd)
5. Pry off snap ring, then remove spider assembly.
CAUTION:
Do not disassemble spider assembly.
6. Draw out slide joint housing.
7. Draw out boot.
Cover drive shaft serration with tape to prevent damage to
the boot.
SRA119A
WHEEL SIDE
SFA963
4. Pry off snap ring "A" with a screwdriver, and pull out slide
joint housing.
SRA120A
SFA964
Inspection
Thoroughly clean all parts in cleaning solvent, and dry with
compressed air. Check parts for deformation or other damage.
DRIVE SHAFT
Replace drive shaft if it is twisted or cracked.
BOOT
Check boot for fatigue, cracks, or wear. Replace boot with new
boot bands.
RA-15
REAR AXLE
Drive Shaft
Inspection
(Cont'd)
JOINT ASSEMBLY
.
.
Check
spider
assembly
for
bearing,
Slide joint
Stamped number
Part No.
00
3972010V10
01
39720 10V11
02
3972010V12
SRA121A
Assembly
.
.
1. Install new small boot band, boot and slide joint housing to
drive shaft.
Cover drive shaft serration with tape to prevent damage to
boot during installation.
Tape
SFA800
RA-16
REAR AXLE -
Drive Shaft
Assembly (Cont'd)
2. Install spider assembly securely, making sure marks are
properly aligned.
Press-fit with spider assembly serration chamfer facing shaft.
3. Install new snap ring.
*"{E;=
{r
~
<
Su itable tool
Chamfer
SFA397
4. Install coil spring, spring cap and new plug seal to slide joint
housing. Press plug seal.
Apply sealant to mating surface of plug seal.
CAUTION:
.
SRA123A
LI
SRA124A
SFA395
RA-17
REAR AXLE
Assembly
Drive Shaft
(Cont'd)
SFA472
WHEEL SIDE
1. Install new small boot band and boot on drive shaft.
Cover drive shaft serration with tape to prevent damage to
boot during installation.
Tape
SFA800
~"
{I
05=
~
Suitable tool
Chamfer
SFA397
SRA125A
SFA395
RA-18
REAR SUSPENSION
~~A16-19
Upper link rear
~~
69.88
C;~ 17,.,"..".061-
Suspension m
ember
43.55
fi/
~
Ao'I'
32 - 41)
\ ~'
Ii ~
..@I
~
~
11. 98
(1.9.10,51.12)
C;~
~ 11. 77.9817.9".,'7.721
98
(4.4 . 5,6,
'"
'"
.. -'
(1.9. 10,51.
11.6.1.9,12.14)
Gasket
~~18.24
(1.8.2.4,13.11)
Upper plate
Bushing
Upper spring seat
Upper rubber
12)
Mem';',
~ ~'~~i
1'
~21
(2.;.2.1,16.20)
I"
'
:j);
'
c;
~
'
21.26(2.1.2.1,16.20)
Differential
/~
Yf0/!
'\~ )
,
.@
@@.l
34. ~
(3.5.4.5,
Stabilizer
26. 33)
BUShingA
43.55
(4.4.5.6,32.41)
~ 71...
(1.2 . 8.8,
52.64)
~~88.108
:"
,
- '-"""Mm
(et,I
~(~
~. 98.118110.12,12.81)
'",
69-88 (1.0.9.0,61.66)
~A49'69
(1;9-10,51-12)
"."2.72.871
~ ...~-~"'.11 -98~
~98.118
'
~Dustcover
-~~
Plate
c;~I:~"~,2.6," 8.7~
<:I'
vr
26
seat
Bushing
N--><
'
(9.0.11,86.80)
Drive shaft
-'---t :
~~
Shock absorber
'
Axle assembly
-
q"
Connecting
'.
rod
>B~
e
@
~~
A
~
9.12
(0.9.1.2,6.5.8.1)
CAUTION:
Do not jack up at lower arm.
When installing each rubber part, final tightening must
be carried out under unladen condition* with tires on
ground.
* Fuel, radiator coolant and engine oil full. Spare
tire, jack, hand tools and mats in designated
positions.
J7! I~
235 314
(24.32,114.231)
Insulator
Adjusting
cap
SAA 132A
RA-19
REAR SUSPENSION
Removal
..
Disassembly
1. Set shock absorber on vise with attachment, then loosen
piston rod lock nut.
. Do not remove piston rod lock nut.
SRA782
SRA783
SRA784
Inspection
SHOCK ABSORBER
.
.
.
ASSEMBLY
RA-20
RI;ARSUSPENSION -Coil
Inspection (Cont'd)
COIL SPRING
Assembly
Top
Bottom
SFA760
r==A,.FI"""
\
\,
~"~d
Bigger inner diameter
side of lower
bushing
,,,.,,
Vehicle front
Outside of
vehicle
Smaller inner
diameter side
of lower
bushing
SRA126A
RA-21
REAR SUSPENSION
Stabilizer Bar
Removal
Inspection
.
.
Installation
Connecting rod
Stabil izer
SRA128A
RA-22
REAR SUSPENSION
.
.
SRA129A
J;
Inspection
REAR SUSPENSION
MEMBER
Replace suspension member assembly if cracked or deformed or if any part (insulator, for example) is damaged.
UPPER AND LOWER LINKS
SUSPENSION
Swing force
Vertical end play
SRA131A
.
.
if cracked
or
Ball joint
specifications
RA-23
General Specifications
SHOCKABSORBER
COIL SPRING
Model
Except Sports
package
Item
Wire diameter
mm (in)
Coil diameter
mm (in)
Free length
mm (in)
Spring constant
N/mm (kg/mm, Ib/in)
11.0 (0.433)
Sports
package
11.3 (0.445)
I 367.5
(14.47)
355 (13.98)
Model
Pink x 2
mm (in)
12.5 (0.492)
Stroke
'mm (in)
155 (6.10)
Damping force
[at 0.1 m (0.3 ftl/sec.]
N (kg, Ib)
Expansion
314 - 471
(32 -48,
71 - 106)
392 . 588
(40 -60,
88 - 132).
Compression
157 - 235
(16 -24,
35 -53)
196 - 294
(20 -30,
44 -66)
Ught green x 2
Damping force
[at 0.3 m (1.0 ftl/sec.]
Expansion
Compression
DRIVE
Sports
package
Identification color
Except Sports
package
Item
N (kg,lb)
647 - 902 (66 .92, 146 - 203)
363 - 539 (37 - 55, 82 -1211
SHAFT
Final drive side
Joint type
Final drive side
TS82F
TS82C
Wheel side
Diameter
Wheel side D I
mm (in)
30 (1.18)
Grease name
Final drive side
Wheel side
SRA133A
Wheel side
Wheel side
Boot length
mm (in)
Final drive side (LI)
Wheelside (L2 )
REAR STABILIZER
Item
Identification color
BAR
Model
Stabilizer diameter
L2
SRA134A
mm (in)
. Except Sports
package
Sports
package
15 (0.59)
17 (0.67)
Ught green
Light blue
RA-24
(Unladen*)
degree
-136'
to -036'
Toe-out
mm (in)
(Total) degree
and Adjustment
WHEEL RUNOUT
Wheel type
Radial runout
Aluminum wheel
.mm (in)
Steel wheel
mm (in)
Lateral runout
0.3 (0.012)
0.5 (0.020)
or less
or less
0.8 (0.0311
or less
WHEEL BEARING
Wheel bearing axial end play
mm(in)
12.7 -90.2
(1.3 - 9.2,2.9 - 20.3)
I 235 -314
(24
-32, 174.231)
RA-25
mm (in)
BRAKESYSTEM
I
BR
SECTION
CONTENTS
PRECAUTIONS
AND
PREPARATION
CHECK
AND ADJUSTMENT
BRAKE
HYDRAULIC
LINE
BRAKE
PEDAL
BRACKET
BRAKE
BOOSTER
VACUUM
AND
BR- 2
BR- 3
""""""".'.""'.'"''''''''''''.'''''''''''''''''''
BR- 4
BR- 6
''''''''''''''''''
PIPING
BR- 8
"'"''''
""""""""""""",.",.,.,.,.",,,,,,,,,,,,,...,
MASTER CYLINDER
BR-10
BR-12
Caliper
BR-13
Rotor
BR-17
Caliper
BR-18
Rotor
BR-22
BR-23
BR-25
TROUBLE DIAGNOSES
BR-29
BR-54
all
.
.
.
.
.
WARNING:
. Clean brake pads and shoes with a waste cloth, then
collect dust with a dust collector.
SBR500
Preparation
SPECIAL SERVICE TOOL
Tool number
(Kent-Moore No.)
Tool name
GG94310000
(
)
Flare nut torque
wrench
Description
~
~
KV991V0010
(
)
Brake fluid
pressure gauge
KV999P1000
(
- )
A.B.S. checker
0
@
o.
0
KV999P1010
- )
(
A.B.S. checker adapter
harness
BR-2
.
.
MAX
MIN
6/@
*"
Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts.
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
Check for oil leakage by fully depressing brake pedal.
SMA 732A
valve.
SBR992
..
.
BR-3
Proportioning
valve
(Do not disassemble.)
: Primary line
: Secondary
line
Bleeding
SBR471A
Procedure
CAUTION:
.
.
t
Left front caliper
,j,
Right front caliper
SBR992
BR-4
SBR500
Inspection
Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
BR-5
~16
S;
!@j"
-22
(1.6-2.2 12
,-161
/,/<
[.q]12-15
(1.2 -1.5,
9 -111
A.S.C.D. cancet
switch
A (1.2-1.5,9-111
12-15
Brake pedal
Inspection
Check brake pedal for following items.
Brake pedal bend
..
.
BR-6
Floor carpet
Dash insulator
Melt sheet
~:
1. Adjust pedal free height with brake booster input rod. Then
tighten lock nut.
Make sure that tip of input rod stays inside.
SBR930
2. Adjust clearance "C1" and "C2" with stop lamp switch and
A.S.C.D. switch respectively. Then tighten lock nuts.
3. Check pedal free play.
Make sure that stop lamp is off when pedal is released.
4. Check brake pedal's depressed height while engine is
running.
If depressed height is below specified value, check brake
system for leaks, accumulation of air or any damage to
components (master cylinder, wheel cylinder, etc.); then
make necessary repairs.
BR-7
BRAKE BOOSTER
Removal and Installation
(
'"
"
I
,)
//
,"""
/ ,\
\.~
~---\
...// /
v..~,'"..-,
(~'>r---
,:..~
/
......-
\...,).-'~,\"......\' \ .
,...~:>\,
./
~;,~"
, "'"
~'\.
f,'~\
,~
-...--
/-<:~, \;.,.........-
''!
~:
Inspection
OPERATING
.
.
CHECK
SBROO2A
AIRTIGHT
O.K.
N.G.
CHECK
Start engine,
Depress
SBR365A
SBR281A
BR-8
BRAKE BOOSTER
Inspection (Cont'd)
BR-9
VACUlfM PIPING
Chod<
..w
~~~{a
~
DJ
Brake
booster
IJ.
Intake manifold
CAUTION:
Do not apply any oil or lubricants
to vacuum hose end check valve.
SBR474A
'''_J)-=I
E=;=-;=:3
.. side
Brake
booster or
Intake
manifold ..
vacuum pump side
SBR202A
Inspection
HOSES AND CONNECTORS
BR-'O
V~CUUM PIPING
Inspection (Cont'd)
CHECK VALVE
..
Manifold
side
SBR475A
BR-11
MASTER CYLINDER
cap
0;' fil'''~
Float~
Reservoir
tank
Primary
Seal
Dual proportioning
valve
(Do not disassemble.)
Secondary
piston
.";
~. I
'
f!. 1
..
.. .
Primary
.
':
SBR476A
..
..
!;
':
piston
,.
;
,.
...
..,.
'"
'Ii
11II=II
.
Piston cup.
);.
SBR011A
piston assembly
SBR012A
BR-12
Caliper
CL22VB
IEI@
Pin bolt
22
Outer
shim
Torque member
fixting bolt
72 97
(7.3
-9.9,
53
(2.2 3.2,
16 23)
Dust seal~lEI@
lEI @
-31
- 72)
A:
N.m (kg-m, ft-Ib)
lEI @ : P.B.C. (Poly Butyl Cuprysil)grease or
silicone-based \lrease point
IE! @ : Rubber grease points
SBR477A
@ : Brake fluid point
.~
CL25V A
Torque member
fixing bolt
22
-31
(2.2
- 3.2,
16
- 23)
A 72 -97
(7.3
- 9.9, 53 - 721
Air
bleeder
A7-9
(0.7.0.9,
5.1 -6.5)
lEI
lEI
:
:
A:
BR-13
Connecting bolt
A17-20
(1.7 - 2.0,12 - 14)
Brake
hose
Caliper
Pad Replacement
1. Remove pin bolt.
SBR453A
SBR220A
Disassembly
Push out piston with dust seal using compressed air.
SBR772
BR-14
Caliper
Inspection
CYLINDER
BODY
Check piston for scoring, rust, wear, damage or foreign materials. Replace if any condition exists.
CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign materials are stuck to sliding
surface.
or other
Assembly
.
.
Place piston boot over rear of piston. Fit piston boot's lip
properly in corresponding groove on cylinder body.
Insert piston into cylinder body and fit boot's lip properly in
corresponding groove on piston.
SBR480A
Inspection (On-vehicle)
INSPECTION OF BRAKE DRAG FORCE
1. Swing cylinder body upward.
2. Make sure that wheel bearing is adjusted properly. Refer to
section FA.
3. Measure rotating force (F1).
SBR456A
4.
5.
6.
7.
8.
SBR457A
BR-15
- Caliper
DISC PAD
Check disc pad for wear or damage.
Pad standard thickness (A):
10.0 mm (0.394 in)
Pad wear limit (A):
2.0 mm (0.079 in)
SMA364A
BR-16
Rotor
Inspection
RUBBING
SURFACE
RUNOUT
Adjust wheel bearing preload. Check runout using a dial
indicator.
Rotor repair limit:
Maximum runout
(Total indicator reading at center of rotor pad
contact surface)
0.07 mm (0.0028 in)
SBR826
THICKNESS
Standard thickness:
20.0 mm (0.787 in)
Minimum thickness:
18.0 mm (0.709 in)
SBR827
BR-11
7 .9 (0.7 .0.9,5.1
~
-3.2,
Pin bolt
22 31 (2.2
- 6.5)
16-23)
~ j--~
~
}
e
Cylinder body
tC:J : N.m (kg-m, ft-Ib)
.'
B~:
P.B.C.(PolyButYICuprysil)
1
b
d
grease or Sl Icon- ase
grease point
Cam
grease
point
point
~~
'~
~\
/'
I.
- ,S2)'"
/'
,~
~.:
O-ring
Spring
m@
(!,
IE!I@
/
- '-..J'
~
'"
/'---
,/
Piston seal
fixingbolt
38 -52 (3.9 -5.3,28-38)
~ m@
Inner shim
0
~
Adjusting nut
Cup~m@
~..oo boo'
E!@
Pin
~
)) ~ ~~~
R
padr;.tainerm
In
~
~
Inner'
pad
uter pa
' ,:.;a@,
.
.
Pad
"";OM EII@~
EII@
~
'-.,
~"N'4)
I'J@OO'OCOh'mj!?,-
rr-,,25.29(2.5-3.0'
~-"
18 -22)
Torquemember
>
&~"OO
i~~RingA
>-.J)
A~wavewasher
'~D_:-spacer
Ball bearing
/~
Spring washer
.(/
,~Spacer
,/~'
Return spring
~~Spring
<..:: -~. RlngB
Lever
dI
Cable stay
!--tC:J26 -36
m@
1.
'
Rod
Push rod
Key plate
RlngC
m@
Cam bolt
tC:J22-31
16-23) (2.2-3.2,
~,
J..~ .
Seat
Gl..//
"I
/'.
~.
(v
-14)
Brake hose
":>, ,/
/'
r-
\)'
BU
@ : Rubber
"'@:Brakefluid
17 20 (1.7.2.0,12
Caliper
~/'
"
'~~
/'
'
W,
~/
Torque member
saR48' A
Pad Replacement
CAUTION:
When cylinder body is swung up, do not depress brake pedal
because piston will pop out.
Remove parking cable stay fixing bolt, pin bolts and lock
spring. Then remove pad retainers, pads and shims.
.
.
SBR641
BR-18
Caliper
SBR482A
Disassembly
1. Remove piston by turning it counterclockwise
longnose pliers.
with suitable
SBR646
2. Pry off ring A from piston with suitable pliers and remove
adjusting nut.
SBR648
SBR891
SBR485A
BR-19
Caliper
Disassembly (Cont'd)
4. Remove return spring and lever.
..
SBR877
Inspection
CYLINDER
.
.
BODY
MEMBER
::::::::::::::
~f\t1t
1
I::::::::::::::
SBR849
.
Convex
Fit push rod into square hole in key plate. Also match
convex portion of key plate with concave portion of cylinder.
portion
@
SBR893
BR-20
c~
Keyplate
~.h
Caliper
(Cont'd)
"1B'>
,oo-j
Rod
fi)
SB R878
Tool
SBR492A
Inspection
.
FI
(On-vehicle)
SBR227A
4.
5.
6.
7.
8.
DISC PAD
Check disc pad for wear or damage.
Standard thickness (A):
9.5 mm (0.374 in)
Pad wear limit (A):
2.0 mm (0.079 in)
SMA364A
BR-21
Rotor
Inspection
RUBBING
SURFACE
..
RUNOUT
.
.
SBR845
THICKNESS
Rotor repair limit:
Minimum thickness
8.0 mm (0.315 In)
SBR847
BR-22
m
.
~
~
l. H. rear
cable
Ell
SBR487A
REMOVAL
Before removing parking brake control, remove console box.
Loosen cable using control lever adjuster, and separate
front and rear cables.
Break clinched portion of control lever using a hammer and
chisel as shown in figure at left, and replace cables with new
parts.
Apply multi-purpose grease to areas between control lever
drum and cables.
.
.
.
SBR488A
INSTALLATION
Cable guide
Matchmark
SBR489A
Inspection
1. Check control lever for wear or other damage. Replace if
necessary.
2. Check parking brake cables, lamp and switch. Replace if
necessary .
3. Check parts at each connecting portion for deformation or
damage. If found, replace.
BR-23
Box wrench
Adjustment
1. Ensure that parking brake releases when control lever is
pulled down completely. If control lever does not release
parking brake, proceed as follows:
Pull control lever up by 4 or 5 notches.
Insert a box wrench into opening in control lever and loosen.
self-lock adjusting nut to slacken cables. Completely push
control lever down.
2. Forcefully depress brake pedal about five times (so that
caliper is automatically set in position.).
3. Pull lever up by 4 or 5 notches.
4. Turn adjusting nut as shown in figure at left and adjust lever
stroke to specified value.
5. Completely push control lever down and ensure that:
Parking brake is released completely.
Rear brakes are free from dragging.
..
SBR490A
.
.
SBR491 A
SBR493A
Parking brake
warning lamp switch
plate
BR-24
lamp
: Harness
: Piping
Front wheel sensor
SBR516A
Hydraulic Circuit
Proportioning
valve
(Do not disassemble.)
Master cylinder
,'
--Check valve
(Front L.H.)
Feeling
valve
(Front)
-~
Feeling
valve
Check valve
(Read
(Read
SBR517 A
BR-25
ACTUATOR
]0
FRONT
WHEEL
SENSOR
0
I: : :
;0
;01/1
m
-<Z
0
6 6 6
]1
017>
n
"0
"
~P
@~
BODY
GROUND
II
..~
I
I I
I ,
I ,
Et
"'..,.....
..."',
",..
r:-
....
"..
~r
lmum-
,
...
--:
S. M. J.
[Refer to
en
~ngine
room
8R/Y
R/Y
L/Y
-Y
G/Y
L/R
LG/R
GY/R
L
-W/L
OR/L
rnnn~
@
@
[j
:IE:IE
"'..
FUSE
FUSIBLE
RELAY BOX)
.."''''
BODY
GROUND
LINK
rnI
I
I
I
I
I
I
I
I
I
I
I
I
I
I
8R/Y
R/Y
L/Y
YG/Y
L/R
LG/R
GY/R
LW/LOR/L
(B I ack)
(Ma in
R/GG/L-
harness)
I
n_nnn_~
~mmn__nmnm
8R/Y
R/YL/Y-
~- u- - - - n - - - -_h- ---n-
_n_-
- - - _n_-
- - - -. -- - - _u- - ---
iW/R
:IE
,..
Y/L
Y/G
I
I
I
~@)
II
,
,
..
rEtffi@Y
:IE
@)
..
(Engine
harness
room
no. 2)
::BODY
GROUND
FRONT
VJ
CD
:0
0>
II)
U1
:I>
..
BATTERY
:IE
- Y
G/Y
L/R
LG/R
GY/R
L
W/L
OR/L
W/R
W/R
.~
~~
,...,...
c;;p
8
W
8
8
8
,"-un_un_nnn-
EI
E2
DI
DII
FI
83
U
G2
85
G6
H5
16
18
"1
' I
I
I
I
I
I
Iast page:
(FaIdout page).]
<@)
harnes~
I
I
I
I
I
I
I
I
I
I
I
I
~".)
o.
OJ
3
"C
R/Y~
FUSE BLOCK
(Refer
to
"POWER
SUPPLY
ROUTING"
in EL sect ion. )
harness)
III
c+
0
"C
...'"
G/L
(E. F. 1-
-i
9t@
....
"
9@
Ii
l_mn
"',...,...
<
r
<
m
UP
21 9 7
..
OJ
:IJ
I
N
::-
m::o;o<
00
;0 Z Zr
-i
-i<
;0 rm
;r ;r
mo
rr
;o",,
3
-<
R. H.
STOP
LAMP
SWITCH
WHEEL
SENSOR
L. H.
W/R
i3J~
ALTERNATOR
I
I
I
I
I
I
~u_-~
"_n-n_-
@
-
Y/L
Y/G-f
-_or -r-'-"
I~:-- -L_,,-_!J
"
~
~
: N.m(kg-m,ft-Ib)
SBR519A
REAR SENSOR
Rear speed
seflsor
-294
-30,137.217)
Sensor rotor
.-///
Companion flange
SBR520A
BR-27
flange after
..
.
BR~28
to
TROUBLE DIAGNOSES
Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair
Symptom Chart
Preliminary Check 1
BR-30
BR-33
BR-34
BR-35
...
PreliminaryCheck2
Preliminary Check 3, 4 ...
Self-diagnosis
Component Parts Location
...
Harness Connector Location
Ground Circuit Check
Circuit Diagram for Quick Pinpoint Check
Diagnostic Procedure 1 ..
Diagnostic Procedure 2 .
DiagnosticProcedure3
......
BR-36
BR-37
...: BR-38
BR-39
...
""'''.'
BR-40
BR-41
BR-42
BR-43
."."."""""""""'.""""".'."""""""'.'...'..'."...'
'..'...".."""""""""'.""'."".""
BR-44
...
... BR-44
...
...
...
...
...
BR-45
...
...
...
...
BR-45
...... BR-46
BR-47
BR-48
BR-49
...
BR-50
BR-51
... BR-52
BR-29
TROUBLE DIAGNOSES
SEF234G
BR..30
"
TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair (Cont'd)
WORK FLOW
CHECK IN
r--------------------
I
I
I
I
I
I
I
I
item
LISTEN TO CUSTOMER
COMPLAINTS
DIAGNOSTIC WORKSHEET
(See page BR-32.)
Symptom Chart
(See page BR-33.)
Preliminary Check
(See pages BR-34 - 36.)
Self-diagnostic item
I
I
I
I
,I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
<Reference
Self-diagnosis
(See page BR-37.)
Self-diagnosis
.
DIAGNOSTIC
WORKSHEET
ELIMINATE GOOD PART(S),
HARNESS(ES) OR CONNECTOR(S) THROUGH ELECTRICALL Y TESTING
(Seepage BR-32.)
Diagnostic Procedure(s)
(See pages BR-42 - 45.)
. Circuit Diagramfor Quick
'Pinpoint Check
(See page BR-41.)
Malfunctioning
harness(es) and
connector(s)
. HarnessConnectorLocation
Malfunctioning parts
INSPECTION
ON THE BASE
OF EACH COMPONENT
REPAIR OR REPLACE
-- -- -- -----N.G.
FINAL CHECK
BR-31
Diagnostic
Procedure(s)
(See pages BR-46 - 51.)
TROUBLE DIAGNOSES
Vehicle model
Date, Frequencies
Road conditions
Operating conditions,
Weather conditions,
Symptoms
Worksheet sample
Model & Year
VIN
Engine #
Trans.
Mileage
Incident Date
Manuf. Date
In Service Date
MRIMS
Customer name
Symptoms
0
Warning
activates
0
Long
stopping
distance
0
Abnormal
pedal
action
Engine conditions
0 When starting
0 Engine speed: 5,000 rpm or more
Road conditions
Drivingconditions
0
0
0
0
0 Suddenly
0 Gradually
Other conditions
0
A.B.S.
doesn't
work
0 After starting
0 Gravel 0 Other)
BR-32
0
0
A.B.S.
A.B.S.
works
works
but warning frequently
activates
-HS
tJ:J
~
~
...
7':'
'"
0
I
n
~. OJ
<
.
I en
.. .
m0~
...
'"7':'
.CD
..
.c
c::
CT
c::
..
..
...
::I
5
ce
CD
::I
<:
~
I
"!>
OJ
a.
0
'"
::I
..'
CD
~
0
...
7':'
CT
::I
0
3
~
"
CD
a.
~
I
n
..
<5"
::I
b
::I
ce
'"
..
""0
5'
ce
a.
~.
...
::I
5'
ce
I
n..
<'
I
..
CD
'"
I
::I
fa
"'tI
CD
a.
~
<
CT
...
I
~,
0
::I
g;o
::I
0
iii'
CD
-<
s:
"'tI
-I
0
s:
G')
BR-34
"'tI
Preliminary Check 2
BR-35
~
3
Preliminary Check 3
BR-36
Preliminary Check 4
BR-36
Diagnostic Procedure 1
BR-42
Diagnostic Procedure 2
BR-43
Diagnostic Procedure 3
BR-44
Diagnostic Procedure 4
BR-44
Diagnostic Procedure 5
BR"-45
Diagnostic Procedure 6
BR-45
LE.D. flashing1 - 4
BR-46
0
0
0
0
"'tI
:IJ
0
(')
m
0
C
:IJ
m
:IJ
m
-n
m
:IJ
m
Z
(')
m
"'tI
en
Preliminary Check 1
0
:E
I
::I
I
...
-<
(')
::I"
CD
n
7':'
0
iii'
ce
::I
0
'"
..
c)"
"'tI
...
0
nCD
a.
c::
...
CD
--.(I)
LE.D. flashing5 - 8
BR-47
L.E.D. flashing9
BR-48
LE.D. flashing 10
BR-49
LE.D. flashing 16
BR-50
BR-51
----
Sensor shield
BR-40
(')(')G')
::I"-, ...
CD n 0
Motor ground
BR-40
CD
CD
~9.
-. I
::Ice
-"'::I
iiii
!!;-~;.
5' -. n
ce 0 "'tI
::I ...
Z~o
? ;:+. 2
::I" a.
r~
j"CD
0
0
n c:: c::
7':' ..
-, a.
::I
-"
Actuator inspection
BR-52
.::.~
1-18'1:>WOldw'<S
S3S0NDVIO 3'SnOH~
..::IO(')CD
o'-e i 0 ~
::I !!: ::I 3 ::!.
TROUBLE DIAGNOSES
Preliminary
Check
CHECK
N.G.
--+
Fill up brake fluid.
MAX
MIN
CHECK
O.K.
&@
."
.
N.G.
Repair b rake system. +--
SMA732A
10K
CHECK
N.G.
.
Repalr or rep Iace b ooster system. +--
CHECK
O.K.
..
SBROO2A
N.G.
. .
+ Replace malfunctioning parts.
SMA364A
BR-34
TROUBLE DIAGNOSES
Preliminary Check 2
SBR522A
CHECK.
B = Clearance
SBR523A
Clearance mm (in)
Front wheel sensor
0.275 - 0.75
(0.010B - 0.0295)
Rear sensor
0.35 - 0.625
(0.0138 - 0.0246)
N.G.
. Breakage
O.K.
N.G.
N.G.
---+
Replace sensor rotor with wheel hub or
companion flange as a set.
SBR525A
/
BR-35
TROUBLE DIAGNOSES
Preliminary Check 3, 4 Preliminary Check 4
CHECK
N.G.
c=
Rep Iace.
O.K.
SBR528A
Measureeachsensor resistance.
0.8 -1.2 kQ
CHECK
O.K.
1 N.G.
Check fuse.
Check bulb condition and remedy.
CHECK
N.G.
.
L.E.D.
SBR529A
Controller
~O.K.
DRIVE
SBR681A
~
__FF
SBR530A
L
HECK
N.G.
SBR529A
O.K.
---+
If Preliminary Check 2 is not performed
and there is abnormal A.8.S. operation,
perform Preliminary Check 2.
BR-36
TROUBLE DIAGNOSES
Self-diagnosis
CHECKING THE NUMBER OF L.E.D. FLASHES
When a problem occurs in the A.B.S., the warning light on the instrument panel comes on. As shown in
the Table, the control unit performs self-diagnosis.
To obtain satisfactory self-diagnosing results, the vehicle must be driven above 30 km/h (19 MPH) for at
least one minute before the self-diagnosis is performed. After the vehicle is stopped, the number of L.E.D.
flashes is counted while the engine is running.
The L.E.D. is located on the control unit, identifying a malfunctioning part or unit by the number of flashes.
Both the warning light and the L.E.D. persistently activate, even after a malfunctioning part or unit has
been repaired, unless the ignition switch is turned "OFF". After repairs, turn the ignition switch "OFF".
Then start the engine and drive the vehicle over 30 km/h (19 MPH) for at least one minute to ensure that
the malfunctioning part or unit has been repaired properly.
If more than two circuits malfunction at the same time, the L.E.D. will flash to indicate one of the
malfunctioning circuits. After the circuit has been repaired, the L.E.D. will then flash to indicate that the
other circuit is malfunctioning.
No. of l.E.D.
flashes
30r4
7 or 8
9
10
16
Control unit
Example
Improper operation of left front rotor sensor circuit
1 cycle
L.E.D. "ON"
L.E.D. "OFF"
n-
1 - 2 sec.
Repeat
5 - 10 sec.
SBR631A
TROUBLE DIAGNOSES
Component Parts Location
//
SBR532A
BR-38
TROUBLE DIAGNOSES
SBR533A
BR-39
TROUBLE DIAGNOSES
Check
resistance
between
both terminals.
Resistance: on
Resistance: on
Resistance: on
BR-40
TROUBLE DIAGNOSES
~ ~
To stop
I GNI TJ ON
SWI TCH
ON or START
lamp
t'fD ~
FRONT
L H.
SA TTERY
FRONT
R.H.
-=
REAR
FRONT
L H.
~
FRONT
R. H.
REAR
SOLENOID
~.~
-=
-=
-=
ALTERNATOR
BR-41
TROUBLE DIAGNOSES
Diagnostic Procedure 1
SYMPTOM: Pedal vibration and noise
Refer to worksheet results.
Brake pedal
Yes
No
Yes
SA T797 A
00
00
~~
No
Yes
Check whether the symptom
appeared when the vehicle speed
is within 10 km/h (6 MPH) after
starting engine.
Speedometer
,.
Yes
SBR539A
No
--=-
No
1 Yes
I No
SBR530A
I
gradually.
Check whether b'rake is applied
Yes
. Shifting
Brake pedal
. Operating clutch
. Passingprotrusion
NO
Yes
@
For such condition, if there is
considerable wheel speed
variation and, A.B.S.will work
normally.
SA T797 A
BR-42
Yes
~
TROUBLE DIAGNOSES
Diagnostic
Procedure
1 (Cont'd)
T
Check whether engine speed is
over 5,000 rpm with vehicle
stopped.
Yes
No
Check whether electrical equip-
Yes
No
N.G.
--===-
Remedy.
O.K.
Replace
control
unit.
Diagnostic Procedure 2
SYMPTOM: Long stopping distance
Refer to worksheet results.
SBR530A
Yes
Yes
1 No
'--
BR-43
TROUBLE DIAGNOSES
Diagnostic Procedure 3
SYMPTOM: Abnormal pedal action
Refer to worksheet results.
Check whether brake pedal
stroke is abnormally large.
Yes
No
SBR540A
Checkthat brakepedalforceis .
firm but brakeiseffective.
Yes
Normalcondition.
I
No
Yes
No
Procedure 4
SYMPTOM: A.B.S. doesn't work.
Diagnostic
IEJ
C:I
Yes
No
SBR52BA
(I
Solenoid valve
indicator
.........
'~
(5) Checker:[.KV999P1000
l
(
Harness: KV999P1010
Motor switch
3.4 select switch
)
SBR660A
Ma in switch
" ,\L.."
ALL
.'L
KIf'
O.K. but
A.B.S. still doesn't work.
(I
BR-44
TROUBLE DIAGNOSES
Diagnostic Procedure 5
SYMPTOM: A.B.S. works but warning activates.
Check whether alternator
produces proper output.
Refer to EL section.
No
Remedy.
Yes
Check whether
battery has
No
Remedy.
enough voltage.
Refer to E L section.
.Yes
Diagnostic Procedure 6
SYMPTOM: A.B.S. works frequently.
B
CHECK BRAKE FLUID
~
\
Q Front
B
..
..~)
PI =P,
\""
, ,,'
D,
SBR642A
I!J
,,'
.5::0 .>l
.. "
a:~
Check 1.
77
5
-~l
Perform Preliminary
PR ESSU R E.
--d--.
:;
'"
.."'.. .-'"
Q,Q,
'tJ ,,"
N.G.
L~_--_---
O.K.
Yes
Remedy.
No
nn~
I
I
I
I
~
PI kPa (kg/em'. psi)
Front brake fluid pressure
SBR643A
I!J
(\
SMA626A
BR-45
TROUBLE DIAGNOSES
Diagnostic Procedure 7
-)J_T
[ill
eJ
~
INSPECTIONSTART
Remove battery negative
terminal connector.
m
I
SBR544A
iii
O.K.
Replace control unit.
Actuator connector
~
\:ill!
SBR545A
iii
N.G.
Replace actuator.
BR-46
O.K.
tROUBLE
DIAGNOSES
Diagnostic Procedure 8
WHE~LSPEED SENSOR (L.E.D. flashing number 5 - 8)
)J
INSPECTION START
Remove battery negative
terminal connector.
[:iIi5
m
SBR546A
O.K.
0.8
- 1.2
kil
N.G.
Refer to Preliminary Check 3
result.
Check whether sensor has 0.8 1.2 kQ resistance.
N.G.
Re~air harness between sensor
connector and control unit connector.
BR-47
N.G.
Replace sensor.
TROUBLE DIAGNOSES
Diagnostic Procedure 9
INSPECTION START
Remove battery negative
terminal connector.
~i5
[i]
Fa
SBR547 A
Ii)
Actuator connector
Effij
i5 ~
.Ii)CHECK MOTOR
[ill
SBR548A
~~
\:mEY
[ill
SBR550A
~0
O.K.
Repair harness
between
actuator and
control unit.
RELAY
. Yes
[i]
DEACTIVATION.
Disconnect actuator connector.
Check continuity between
actuator connector (actuator
side) terminals @ and @.
No
0
~
-,
eJ
Motor rela;
SBR688A
BR-48
No
II
N.G.
Replace
motor
relay.
TROUBLE DIAGNOSES
Diagnostic Procedure 10
ACTUATOR SOLENOID
number 10)
~~
_CT
INSPECTION START
Remove battery negative
terminal connector.
18
rnJ
Actuator connector
@)
~)
Ii
SBR552A
Ii)
IVr:II~
[ill I
Ii)
SBR553A
[i
N.G.
Replacesolenoid valve
relay.
[i
Yes
r~
L~eplace solenoid valverelay.
No
Check if solenoid valve relay
fuse is blown.
Yes
Ii
Replacefuse.
Actuator connector
-,
@~eo~
[ill
SBR556A
BR-49
No
N.G.
O.K.
Replace
controlunit.
TROUBLE DIAGNOSES
Diagnostic Procedure 11
CONTROL UNIT (L.E.D. flashing number 16)
INSPECTION START
BR-50
TROUBLE DIAGNOSES
()
)J
Diagnostic Procedure 12
CONTROLUNITOR POWERSUPPLYANDGROUND
CIRCUIT(Warning activates but L.E.D.comes off.)
ij~
INSPECTION START
PI
-=SBR557A
Ii)
()
I~
[Y]
[:iI ij
Ii)
SBR55BA
()
SBR559A
O.K.
CHECK ALTERNATOR L
TER~INAL VOLTAGE.
Disconnect control unit connector.
Check voltage between control
unit connector (vehicleside)
terminal @ and body ground
after engine starting.
Voltage: 6V or more
O.K.
(!J
Check continuity between
control unit connector (vehicle
side) terminal @ and body
ground with ignition switch
"OFF" .
O.K.
Replace control unit.
BR-51
N.G.
Repair harness
between alternator and
control unit.
N.G.
Repair ground harness.
Malfunctioning
alternator.
',.,
TROUBLE DIAGNOSES
Motor relay indicator
Power supply
indicator
'"'$SUR'
DEC
....
~/
in switch
item)
INSPECTION START
,
mt5)." Checker~"W KV999P1000
(
Harness: KV999P1010
(
Motor switch
3,4 select switch
SBR560A
No
Yes
Check checker valve relay
indicator for coming on.
Yes
Select one valve.
Select pressure decreasing
position by switch then turn
motor switch on.
Turn motor switch off.
Select pressure increasing
position.
CAUTION:
Do not hold switch at the
pressure decreasing position
for more than 5 seconds.
Otherwise, solenoid valve
may be overheated and
damaged.
No
Yes
Check motor for operational
sound beside the actuator in a
quiet place.
Yes
~.~
~~R691A
BR-52
No
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
Ii:
N.G.: No vibration
Check brake pedal for vibration
while motor switch is turned on,
O.K.: Vibration
N ..:
G
I'
.
N 0 VIb ration
O.K.: Vibration
Replace actuator as assembly.
O.K.
Actuator works normally.
BR-53
CL22VB
CL25VA
mm (in)
54.0 (2.126)
57.2 (2.252)
mm lin)
CL9H
mm lin)
33.96 (1.3370)
mm lin)
mm (in)
Master cylinder
Cylinder bore diameter
mm lin)
Control valve
Valve model
22.22 (7/8)
23.81 (15/16)
M23
mm lin)
M195T
Primary
Secondary
230 (9.06)
Brake fluid
Recommended brake fluid
DOT3
Parking brake
Control type
Center lever
BR-54
205 (8.07)
180 (7.09)
CL22VB
Free height
MfT
mm (in)
177.0
- 187.0
(6.97.7.36)
Item
AfT
Pad wear limit
Minimum thickness
mm(in)
Rotor repair limit
Minimum thickness
mm (in)
Maximum runout
mm (in)
2.0 (0.079)
18.0 (0.709)
20.0 (0.787)
0.07 (0.0028)
Depressed height
[under force of 490 N
(50 kg, 110 Ib) with
engine running)
mm (in)
CL9H
Pedal free plav at clevis
mm (in)
Item
Pad wear limit
Minimum thickness
mm(in)
Rotor repair limit
Minimum thickness
mm (in)
Maximum runout
mm (in)
1.3
(0.04.0.12)
2.0 (0.079)
PARKING BRAKE
8.0 (0.315)
Center
lever
Item
0.07 (0.0028)
Number of notches
[under force of 196 N
(20 kg, 44 Ib))
Number of notches
(when warning switch
comes on)
BR-55
6-8
STEERING
SYSTEM
ST
SECTION
CONTENTS
PRECAUTIONS
PREPARATION
"
ON-VEHICLE
INSPECTION
ON-VEHICLE
INSPECTION
STEERING
WHEEL
ST - 3
ST- 5
(Power
steering)
AND STEERING
POWER
STEERING
GEAR
POWER
STEERING
OIL PUMP
SERVICE
ST- 2
""""""'"''
AND
ST- 7
COLUMN
LINKAGE
(Model
ST-10
PR24SC)
ST-14
ST-27
(S.O.S.)
ST-31
IDI
PRECAUTIONS
..
.
.
.
.
ST-2
PREPARATION
SPECIAL SERVICE TOOLS
Tool number
(Kent-Moore No.)
Tool name
KV48100700
(J26364)
Torque adapter
ST27180001
(J25726-A)
Steering wheel puller
HT72520000
(J25730-A)
Ball joint remover
ST27091 000
(J26357)
Pressure gauge
KV48102500
ST3127S000
(See J25765-A)
ill GG91030000
(J25765-A)
Torque wrench
@ HT62940000
Socket adapter
@ HT62900000
Description
~n
~
~@
~@
CJI@
Measuring turning
torque
CD-fJ
@~
@-o
Socket adapter
Reforming teflon ring
KV481 04400
(
ST-3
PREPARATION
COMMERCIAL SERVICE TOOLS
Tool name
Description
~"'di'
Pinion oil seal drift
v:2.,.,dg
Oil pump attachment
Welding ,\1-\O.a.1\
40
11.57)
12
.;.~fb~10.47)
"".
,,\~ ~o.\
,~.
qp
Unit: mm lin)
ST-4
SST481 A
Disassembling and
assembling oil pump
ON-VEHICLE INSPECTION
Checking
Steering
Wheel
Play
If it is
35 mm (1.38
not
in) or less
within
specification,
check
rack' and
pinion
assembly.
N.G.
Pre-checking
.
gear
is centered
before
removing
the
wheel.
Checking
.
Check
wheel
when
.
SST104B
position, remove
the
steering
wheel
reinstall it correctly.
If the
tie-rod
neutral
lock
position
nut
by the same
compensate
and
is between
move
amount
two
tie-rod
on
serrated
in the
teeth, loosen
opposite
direction
right sides to
position.
. Rotatesteeringwheel
turning
right
and
left;measure
angle.
SMA 127
.
If it is not
within
specification,
SST086B
ST-5
check
rack
stroke.
ON-VEHICLE INSPECTION
Checking Gear Housing Movement
If movement
exceeds
mount
insulator
after
ST~6
Checking
Fluid Level
..
Do not overfill.
Recommended
fluid is Automatic
"DEXRONTM
Type".
Checking
Transmission
Fluid
Fluid Leakage
Check the lines for improper attachment and for leaks, cracks,
damage, loose connections, chafing or deterioration.
1. Run engine at idle speed or 1,000 rpm.
Make sure temperature of fluid in oil tank rises to 60 to
80C (140 to 176F).
2. Turn steering wheel right-to-Ieft several times.
3. Hold steering wheel at each "lock" position for five seconds
and carefully check for fluid leakage.
CAUTION:
SST107B
ST-8
ST27091000(J26357)
...
Low-pressure
hose
CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds.
Oil pump maximum standard pressure:
6,865 kPa (70 kg/cm2, 995 psi)
at idling
4. If oil pressure is below the standard pressure, slowly close
shut-oft valve and check pressure.
When pressure reaches standard pressure, gear is damaged.
When pressure remains below standard pressure, pump is
damaged.
CAUTION:
Do not close shut-off valve for more than 15 seconds.
5. If oil pressure is higher than standard pressure, pump is
damaged.
6. After checking hydraulic system, remove Tool and add fluid
as necessary, then completely bleed air out of system.
..
SST834
ST-9
~~~
~
~L"!]~:'o ~.o.
22 - 291
~N~
\L"!]
13'
- 19
(1~
- >,9 - 13]
to.) 13.1811.3.1.8,9.13)
Removal
STEERING
WHEEL
SST110B
SST275B
ST -1 0
STEERING
WHEEL
SST112B
STEERING
'
COLUMN
CAUTION:
After installing steering column, turn steering wheel to make
sure it moves smoothly and that the number of turns from the
straight forward position to left and right locks are equal.
Be sure that the steering wheel is in a neutral position when
driving straight ahead.
Lower joint
SST800A
ST -11
Hole cover
Steering column
upper shaft
.
.
.
SST428A
---n
Upper shaft
SST770A
ST -1 2
and Assembly
(Cont'd)
Tilt mechanism
SST114B
Steering
lock
~~
i
Self-shear screw
SST742A
Inspection
L,
F~-
:1
SST098B
L2
SST115B
L.
SST116B
ST -1 3
G." hoo.'ooonO.M'OO
b~,k..
~I\
17.22)
V,",". "00'
~o
~
'
[qJ 29 . 39 (3 -4,
22 .29)
..,.I>
18
SST783A
CD
Low-pressure side
tOJ: 27
39 N.m (2.8 - 4.0 kg-m, 20 - 29 ft-Ib)
@ High-pressure side
.
tOJ:15 - 25 N.m (1.5 - 2.5 kg-m, 11 - 18 ft-Ib)
SST080B
ST -14
.
.
Observe specified tightening torque when tightening highpressure and low-pressure pipe connectors. Excessive
tightening can damage threads or damaged connector
O-ring.
The O-ring in low-pressure pipe connector is larger than that
in high-pressure connector. Take care to install the proper
O-ring.
.
arm
SST824A
.
.
ST -1 5
..
.
.
@ Boot
@ Boot
..
..
.
..
@ Cylinder tube
..
Replacement
. Replacement
. Replacement
. Replacement
Cylinder tube
Copperwasher
Boot clamp
I I Replacecylinder
tube.
I
I
Service parts
to be prepared
kit
..
SST117B
ST -1 6
~r~
l ~ 0r
O'@J
~@
~16-21
~.
(1.6-2. 1 , 12-15)
R~
Adjusting screw
----~:9n_U~9
(40-6.0,
SP~;r~ng disc
29-43)
1J
be
rWasher
Pinion assembly
%@@
evli.",,,"
40"""\
So"og
~
-.!
Retainer
CenterbUShing\
Rack oil seal~
Pinion
seal
ring
<::::::>--O-ring
~Shirr:~
~ >< Pinion oil seal ~ m
"'"
jt;;g
\\\)~
R~kO'I_'~
rn:
43 -54'
E.
Tie-rod
~
\
:~O,~
Bro,"'d~ ~
~~
~JL. Bo",",m,
Rack spacer
'\-.LOCkPlate
rJ
~
socket
Inner.
~Tie-rod
78 -98
(8.0 - 10"0 58 - 72)
Tie-rod outer
Do not disassemble.
~:
N.m (kg-rn,ft-Ib)
ssn1SB
ST -1 7
.
.
.
SST1198
SST881
SST450A
SST0818
10. Remove
Using a
(104F).
Remove
Replace
.
.
.
Rack seal
ring
SST0828
ST -18
+1:''''0
"" 29mm..ok"
SST472A
Assembly
1. Using a heat gun, heat rack seal ring (made of Teflon) to
approximately 40C (104F) and install it onto rack with your
hand.
~R"'k
",' cO",
SST083B
KV481 04400
(
)
Rack teeth
~lIJIfi11lJJJ11II11IIiIJ!I.
Position and
secu re seal.
SST084B
.~
.
.
.~--
Film~~
Rack oil seal j
SST201A
3. Install center bushing and rack oil seal with rack assembly.
SST830A
ST -1 9
SST081B
2-3mm
CO.08- 0.12 in)
End cover
assembly
SST073B
SST086B
7. Coat seal lip of oil seal with multi-purpose grease and install
new pinion oil seal to pinion housing with suitable tool.
Make sure lip of oil seal faces up when installed.
...
Suitable tool
Oil seal
SST381
SST074B
ST -20
.
.
SST085B
SST075B
SST552
Gear housing
SST121B
- Protrusion
ST -21
(Cont'd)
.
.
SST087B
~(
r{ ~
@
<1;",h.
CD.
specified
'-CD
<ID
SST123B
SST 435
~'L~"~
SST093B
L'
SST086B
ST -22
SST967A
- 15 mm
- 0.59
(0.20
.~
SST097B
in)
y
Vehicle
front
SST125B
\.~
SST440A
0
CI
M
SST126B
ST-23
Adjustment
Lock nut
Adjusting screw
SSTOB9B
ST3127S000
-(See J25765.A)
SST072B
10. Prevent adjusting screw from turning, and tighten lock nut
to specified torque.
SST557A
ST3127SQOO
- (See J25765.A)
SST072B
Inspection
Thoroughly clean all parts in cleaning solvent or automatic
transmission fluid "DEXRONTMType", and blow dry with
compressed air, if available.
BOOT
Check condition of boot. If cracked excessively, replace it.
RACK
Thoroughly examine rack gear. If damaged, cracked or worn,
replace it.
PINION ASSEMBLY
.
.
Ci
CO)
~!
ri
0
CD
Unit:
*: Measuring
points
mm (in)
SST750A
SST751A
ST -25
Axial end
plav
If cracked
excessively,
SST435A
CYLINDER
TUBES
ST -26
Oil seal
~ lEI
(qJ 27 . 35
(2.8
-3.6,
20 . 261
transmission
fluid "Type
DEXRON
TM" 1
SST127B
Pre-disassembly Inspection
Disassemble the power steering oil pump only if the following
items are found.
Oil leak from any point shown in the figure.
Deformed or damaged pulley.
.
.
SST12BB
ST-27
.
.
.
.
Extension bar
SST010B
SST034A
Remove connector.
Be careful not to drop spool.
Front housing
of
SST036A
Inspection
PULLEY AND PULLEY SHAFT
..
.
ST-28
Assembly
Assemble oil pump in the reverse order of disassembly, noting
the following instructions.
Before installation, coat the a-rings and oil seal with A.T.F.*
Make sure a-rings and oil seal are properly installed.
When assembling vanes to rotor, rounded surfaces of vanes
.
.
.
.
SST289A
Faces inside
Flat portion
SST843A
CAUTION:
Do not remove spool valve from connector.
SST499A
Spring
ApplyA.T.F.*to a-ring.
*:
SST536A
ST-29
D,
SST497A
ST -30
CID
as shown at left.
Steering model
PR24SC
16.8
3.1
Collapsible, tilt
GENERAL
Steering wheel axial play
0 (0)
mm (in)
Steering wheel play
mm (in)
- 35
(0
PR24SC
Item
- 1.38)
9.12- 91.30
(0.93-9.31;2.05- 20.53)
N (kg,lb)
STEERING
COLUMN
Steering
column
0.29-2.94
(3.0-30.0,2.6-26.0)
Rotating torque
N'm (kg-em, in-Ib)
mm(in)
0.5 (0.020)
N (kg, Ib)
8.14 - 122.6
(0.83 - 12.5, 1.83 - 27.6)
force*
Rotating torque
mm (in)
)1~J
0 (0)
L,
176.8 (6.96)
*: Measuring point
SST098B
~'L~"J
SST093B
0.78
L2
- 1.27
mm (in)
SST115B
~~
,'\
".'
--,
ST-31
',,',',
d:P
~:-
",
'p'
SST086B
N (kg, Ib)
of power steeringfluid
C (0 F)
166.7 - 255.6
(17.0 - 23..0, 37.5 - 50.7)
39 (4,9) or less
0.9 (1,3/4)
6,865
(70, 995)
ST -32
..
CONTENTS
GENERAL
SERVICING
BF- 2
BF- 6
BODY END
DOOR
(Including
"Power
INSTRUMENT
INTERIOR
Window"
PANEL.
AND
& "Power
Door
.............................
EXTERIOR
...................................
BF-20
BODY
ALIGNMENT
BF-30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B F-32
TROUBLE DIAGNOSES...................................................
SUN ROOF..............................................................
WINDSHIELD AND WINDOWS.............................................
MIRROR - Door Mirror...................................................
REAR COMBINATION LAMP...............................................
FRONT AND
B F-12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BF-18
Lock")
BF-39
BF-66
BF-70
BF-77
BF-78
.........................................
BF-79
................................................
B F-80
DIAGRAMS".
for power distribution
circuit.
--
GENERAL SERVICING
.
.
.
.
.
.
Precautions
When removing or installing various parts, place a cloth or padding onto the vehicle body to prevent
scratches.
Handle trim, molding, instruments, grille, etc. carefully during removing or .installation. Be careful not
to soil or damage them.
Apply sealing compound where necessary when installing parts.
When applying sealing compound, be careful that the sealing compound does not protrude from parts.
When replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust
prevention measures.
Symbol
Shape
Removal:
Remove by bending up with
a flat.bladed scr_driv8l'.
CD
SBF092B
CD
SBF109B
1f
SBF094B
::
SBF114B
SBF113B
='0=
Removal:
Pull up by rotating.
5."3'.
SBF115B
Removal:
SBF141B
SBF142B
BF-2
SBF143B
GENERAL SERVICING
Clip and Fastener
No.
Symbol
Removal:
Removewith a flat-bladed
screwdriversor plier.
W
SBFOS9B
Shape
(VI
(Cont'd)
"t
CS@
=1
SBF091B
SBF090B
I
2j)DI
cO])
...
Pi
"
Installation:
SBF319C
SBF31SC
SBF147B
SBF104B
SBF103B
SBF320C
R__".
-!-
Removal:
/\)
Clip
Then bend up
CD..E([
Push
SBF654B
SBF653B
I
<f01
\ )
SBF 1730
\U U)
SBF1740
BF-3
Removal:
Removewith a flat-bladed
screwdriveror pliers.
'T'
SBF1750
GENERAL SERVICING
Clip and Fastener (Cont'd)
No.
Symbol
Shape
Clip-A
Removal:
Flat-bladed screwdriver
_fFiniSher
<f~1})
SBF035C
SBF036C
Body
panel
SBF652B
Clip-B (Grommet)
Removal:
Flat-bladed screwdriver
~CUP~
<fF21])
.
Sealing
washer
SBF150D
...
Clip-B
(Grommet)
-<f
Body
panel
SBF652B
SBF151D
Removal:
Holder portion of clip must be
spread out to remove rod.
c~~
~)Q~
SBF768B
SBF770B
i
(~op
~
SBF138B
(~ 0])
Removal:
Screw out with a Phillips
screwdriver.
SBF139B
SBF363B
SBF364B
BF-4
l4
SBF140B
GENERAL SERVICING
Clip and Fastener (Cont' d)
No.
Symbol
Removal& Installation
Shape
Removal:
Screw out with a Phillips
screwdriver.
i
CfO:V
T
SBF361B
SBF362B
BF-5
SBF140B
BODY END
Body Front End
.
.
Hood
Hood
hood
Hood
Bumper reinforcement
Energy absorber form
@@@
.~<~
./" /."
~'
Bumber height
At vehicle center
Condition:
Curb weight & normal
tire pressure on level
grou nd
512 . 562 mm
(20.16 .22.13 in)
~
Ground
BF-6
@@
BODY END
Body Front End (Cont' d)
5 mm
(0.20 inl
Hood
C1G:
~
Secondary latch
BF-7
B,ODY END
.
..
/
Back door adjustment: Adjust at hinge-body portion for proper back door fit.
Back door lock system adjustment: Adjust lock & striker so that they are in the center. After
adjustment, check back door lock operation.
Trunk lid adjustment:Adjust at hinge-trunk lid portion for proper trunk lid fit.
Trunk lid lock system adjustment: Adjust striker so that it is in the center of the lock. After adjustment,
check trunk lid lock operation.
WARNING:
a. Be careful not to scratch back door stay when installing back door. A scratched stay may cause
gas leakage.
b. The contents of the back door stay are under pressure. Do not take apart, puncture, apply heat or
allow fire near it.
. Opener cable: do not attempt to bend cable using excessive force.
After installation, make sure that trunk lid/back door and fuel filler lid open smoothly.
FASTBACK
Before removing rear bumper, remove right drafter which is secured with two upper nuts and butyl seal.
Bumper height
k door]
Ii1 [Hinge-bac
rn'I 21 - 26
~-.. 12.1-2.7,
"'-----
15-20)
572.1 - 622.1 mm
122.52 - 24.49 in)
""\".
\
[Hinge-body (Behind rear roof
rail garnish)]
c,.~
~
21
-26
~12.1-2.7,15-20)
BF-8
BODY END
Body Rear End and Opener (Cont' d)
\
*
tOJ:
BF-9
BODY END
Body Rear End and Opener (Cont'd)
COUPE
\""
~ iii
//
/
~~'
I
//
iii
BF-10
1!1
II
BODY END
Body Rear End and Opener (Cont'd)
Ii)
[!J
~d
.
\OCk
~~:::~~
t;r~
".
.l~
\/ 7I
~/~
nu~
Ii]
Ii
,--
Striker
adjustment
Bumper height
TI
-606.7
mm
(21.92.23.89
in)
556.7
SBF~
SF-11
DOOR
Bencrank
adjustment
Regulator assembly
adjustment
5.1 -6.5
(0.52-0.66,3.8 -4.8)
Ii]
handla
Ii)
~5.1-6.5
(0.52-0.66,
3.8 -4.8)
BF-12
DOOR
Ii)
Outside
handle
Holder
escutcheo~)//
1/
'
U--
0.5 - 1.5 mm
(0.020 - 0.059 in)
Outside
handle adjustment
-"
Striker adjustment
[+J
tOj13-16
(1.3_1.6'
9 -12)
..
...
t~
~~
.
@
'{~d~";~"~:'m
(0.039
Ii]
Glass portion
in)]
Outside
Weatherstrip
retainer
c=>
Glass portion
fA
SBF177
BF-13
IGNITION SWITCH
ON or START
POWER WINDOW REGULATOR
(Driver side)
BA HERY
fusible
(V ia
I Ink-Gree~
Downward
Upward
@
W/R"""4..l.I
L/R-;::n,
~@
r-",
BREAKER
. I CIRCUI
T
I
@
(Door harness
L.H.)
W/B
R~B~
R/W~
~
.
(Main
harness)
W/B
R~B
:;!~I~:U~I
R/W
g,
."
R/W
I
~
R/B
W/B
.@
r-
r-~~
,,,,r-"'OI'
POWER
WINDOW
AMPLI
F I ER
~~
.
(Door harness
R. H. )
R/W
R/W
R/B
W~B
R/B
L
W/B
~:a~:ar-r:a0l0l~0I~
~@
DRIVER SIDE
LOCK
ONESWITCH
TOUCH MANUAL
U N 0 U N D ON OFF
a
1
a
a
2
:3
0
0
a
4
POWER W
(Passen
PASSENGER
SIDE
U N 0
a
<>
0 0
a
MOTOR
CIRCUIT
BREAKER
@ii()
- BODY GROUND
CJI
w
W
I'J
m
@ 8
01"""
5
6
7
m
"11
I GN I TI ON
RELAY
Wi
ope
di
DOOR
Power Window (Cont'd)
POWER WINDOW AMP. INSPECTION
FRONT DRIVER SIDE POWEfI
WINDOW SWITCH
Connections
AMP
AMP
~~
9
From
AMP
power
window
Ground
-=-
IGNITION SWITCH ON or ST
(Via power window relay)
VOLTMETER
FRONT DRIVER
SIDE POWER WINDOW
REGULATOR
Window
operating
direction
Upward
f I Current
flow
Downward
I\.1
direction
AMP.
\
51
52
-53
54
55
56
57
58
OPERATION
Connections
Operations
Manual operation
One-touch (Autol Operation
Power source OGNI
12V
12V
12V
12V
12V
12V
Ground
Gmund Ground Gmund Gmund Gmund
Ground
ON
or
ST
ON
or
ST
From ignition SW(ON or STI
ON or ST ON or ST ON or ST
ON or ST
To FR driver side power
OFF
OFF
OFF
OFF
OFF
ON
window SW (AUTO) Q)
'0;
To
FR
driver
side
power
OFF
ON
OFF
OFF
,
OFF
OFF
window SW (UP) @
To FR driver side power
OFF
ON
OFF
OFF
OFF
ON
window SW(DOWN) CV
.
I
Regulator
Approx,
OV
Approx.
over 9V
Approx.
OV
Approx.
OV
Approx.
OV
Approx.
OV
Approx.
OV
Approx.
OV
Appmx.
over 9V
Approx.
OV
Aprrox.
over 9V
Approx.
over 9V
Stop
Upward
operation
Down.
ward
opera.
tion
Starting
Keeping opera.
tion until fully
open, then
"ops
automatically.
Operating
Condition
Stop
Downward
operation
CIRCUIT
Time (sec.)
BREAKER
100
'
50
20
10
8
5
1
0
SBF284E
INSPECTION
10 20 30 40 50 60 70
Current (A)
BF-15
SID~ D
PASSENGER
BATTERY (V I a
fus I b I e I Ink-Green)
ORB'L
~t
([ill)
@
CIRCUIT~
BREAKER~
rn::;-L/R
@@D
~W/R
DOOR LOCK CO
Lock
Between
lock"
un lock
n
a
Fom
I
lock to
un lock
Fom
I
un lock
to lock
PASSENGER SIDE
POSISTOR
c I rcu I t
<Therm
breaker
",{eli",{e
(Sub
harness)
W(GR
ORs"B
gJ
."
(Main
harness)
LG
L G/B
LG
~~
. C
W(GR
ORs"B
LG/B
L G/B
(Door
@)
harness
L G/B
:::rTLn
LG I8:I8l.I
R.H.)
Cu~~ent
ActuBto~
ope~Btlng
dl ~ect Ion
OR/L
Lockwa~d
I
~
0')
1~~~1
~~~
~"''''''
.,.,....
<Door harness
L. H. )
OR/L
[:J
(FrontR. H. dash
~~
OR/B=EI3
~@)
OR/L
~ ~
ORB'B
OR/L =tf
EE}:OR/B
LG ::::co... .J:D=
LG;S -H::J!I W-
(ill)
LG
LG;S
BODY GROUND
om
lock to
unlock
I
Fom
unlock,
to lock,
POSISTOR(Therma
c I rcu i t breaker
s I de)
@fi@Y
"IJ
@)
.,
(II
m
."
w
W
w
m
DOOR LOCK CO
Between
Lock lock ..
un lock
DOOR
Power Door Lock (Cont'd)
DOOR LOCK TIMER
TESTING
INSPECTION
OPERATION
Ii SW-A
c:
0> operation
.;;;
... SW-B
0.
.= operation
OFF
Turns
ON
ON
Turns
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
Turns
ON
ON
After SW-A
Turns operation, Turns
OFF immediately OFF
turns ON
ON
(Approx. OFF
1.0 sec.)
... OFF
OFF
ON
(Approx. OFF
1.0 sec.}
-+ OFF
OFF
Turns ON
Turns
OFF
---
TESTLAMP
BATTERY
SW-B
=
=
-=-
SW-A
DOOR
-::-
LOCK TIMER
CIRCUIT CONNECTIONS
- +
+ -
31
32
33
34
35
39
SBF377E
BF-17
INSTRUMENT PANEL
f
When removing instrument panel assembly, remove defroster grille, combination meter, A/C or heater
control, cluster lid C and S.M.J. first.
Super Mutiple
Junction
CS-M.J.) Fa
~
-~
Pewl
Ii)
;;;.
/~
-~*
.'
rPawl (I
~
.
~~
Combination meter
~~
Cluster lid C
~.Metal
cliPIJ
'1'"
BF-18
~/
~P8WI
Ii]
INSTRUIYIENT PANEL
(j]
'
@J
--
Super Multiple
Junction (S.M.J.I
-:- Instrument
harness
Fuse block
Ii]
II
Ii
[!1
1:1
IJ
Ia
II
Tape H.U.D.'s
reflective surface
rWindshield
Metalclip
Cloth
or vinyl sheet
SBF178E
BF-19
~
0
-;?o,;',
Speaker
--~:.
~
."."- fT
Door corner
finisher [i]
Metal clip
panel
Ii]
iii
~
U-:!
Assist grip
removal
\I
BF-20
[!I
Ii]
[!]
(I
Ii
;t=.~~~
Garnish
Ii]
Pawl
Pawl
Pawl
[!I
SBF179E
BF-21
Coupe
~=,1J~\
Garnish
SBF180E
LUGGAGE
ROOM TRIM
Coupe
Clip removal
Ii)
Ii)
J-~
Removal
SBF181E
Bf=-22
Back door
weatherstrip
Coupe
.~~
~R~f
"'m ~,.". m
r-
/)
Ii)
1ass
HoodnO;"'
M""<"p
~l
panel
\ r)}. 0-
~ ~
r-.~
~~tXL\
BF-23
INTERIORAND EXTERIOR
Exterior
@>
(j)
SBF192E
BF-24
Method 1
Exterior (Cont'd)
CID,@ Cowl top grilleand hood rear sealingrubber
~.q~
~"~,
<@J;
Apply sealant
molding.
to top portion
of
~()
~9
~.,.,.,.,.,.,..:
~~;~
':1:--4
SBF211E
...
CID
'r"~
SEV
.',','.'.','. ."
':i/":::: 'J
Method 2
1. Cut off sealant at glass end.
2. Clean the side on which panel was mounted.
3. Set molding fastener and apply sealant &
primer to body panel, and apply primer to
molding.
Apply primer."\
Glass~
Dam rubber
~
(
-,
Apply sealant.
SBF519B
s"u"'~"h7
~.
Grommet
'
Sealing washl
Grommet?'
SBF213E
BF-25
~
II
: Butyl tape
[!) Coupe
Removal
ButYl tape
.--;
Double-faced
adhesive tape
Ii]
Windshield
pi liar garn ish
Body side welt
II
Weatherstrip
retainer
Ii
Body side
weatherstrip
Body side
weatherstrip
Seal
SBF214E
BF-26
@ Door weatherstrip
Apply butyl sealant where necessary
while installing the weatherstrip.
t""h"
W,""
\
SBF215E
SBF217E
~
"
(9 places)
Trunk lid
' weatherst .
.;..
np
There is a marking
at vehicle center.
SBF401B
SBF216E
BF-27
adhesive tape
(When install ing fastener. heat
body panel
and fastener
to approx.
30 to 40C
(86 to
104 F)).
(Cont' d)
Butyl seal
Sealant
Body
panel
SBF757Q
SBF873C
SBF218E
.///j
Roof panel
./ Sun roof lid
'
weatherstrip
Sun roof rd
I
I
SBF824D
BF-28
BF-29
SEAT
Front Seat
IRJ 43 -55
(4.4.5.6,32.41)
IRJ
SBF183E
BF-30
SEAT
Rear Seat
Striker
installation
Seat back
I!J
adjustment
I!J
~
Bushing
~Grommet
~ '3.,.~1-::lli
(1.3-1.6j
9-12)'
I
SBF184E
BF-31
(10
..
)
[!J
Pawl
Drive motor
Lap belt
Ii) )
(Installation
~43
-55
14.4- 5.6,32 - 411
Shoulder belt assembly
(Installation m)
~~43-55
~.
oD
i~.
Lap belt buckle
(L.H. only)
switch
~43-55
14.4 - 5.6, 32 - 411
Control unit
BF-32
I~
rA
43-55
(4.4-5.6,32 -41)
Ii]
Lapbelt
retractor
~I
~~t~
A43 - 55
(4.4 - 5.6, 32 - 41)
[!J
Guide rail assembly
Rear limit switch
(Bottom color: Green)
Guide cable
~~
J>ff
Shoulder belt
buckle assembly
.~.~
A
SBF185E
BF-33
BATTERY (V I a
fus i b I e I Ink-Green)
(Eng i ne room
harness)
S. M.J.
[Refer to
(Fo Idout
I ast
I GNI TI ON
SWITCH
ON or SART
page)
page
.J
'"
~@})
m,
u:
'"
@D
WARNING
CHIME
E1
@r7
@~~'"
'" ..J
, ,
"
"''''
..J ~
..J
I
~.
R/B
(Mai n harness)
@
G
FUSE BLOCK
(Refer to npOWER SUPPLY
ROUTINGnln EL section.)
..J
'III
>-
~@
~@
(Ma I n harness)
..J
'III
>-
'"
,
'"
>-
'iii
U)
Q)
EEIBHEE @
CWhi te)
'-
III
.c
(B lack)
Q.
E
III
tHHHffil@
'"
,>-
'"
(J nstrument
harness)
WI)
,>-
~@
'"
'"
""
>-
[Sffi:B]@
~QD
I
~
@--<>
SEAT BELT
WARNING
LAMP
'III
>-
EW
'"
91 o
..J
E
0
0
0:
92
:
I
~
91 o @
o 92
SEAT BELT
WARNING
LAMP
[g
R. H. SIDE
COMBINATION
FRONT LIMIT
METER
BF-34
SWITCH
SEAT
BELT
CONTROL
UNIT
~:With
head-up
~:Without
~
~
display
head-up
display
~~@V
m~~~~~~
""",m
~~~~~~~
,~~
~m
~~~~
~~
~~
~~~~
~~
',m"~~m"
R. H. SIDE
CD
~
~~~
G;R
G/B
j1
D
~L/W~~
~Lr~
w
~
Shoulder
REAR
LIMIT
SWITCH
belt
buckIe condItlon
'53
rst
Shoulder
buck Ie
SHOULDER \
BELT
Fastened
BUCKLE 55
:J
SWITCH 54
:J
belt
condl t Ion
IUnfastened
I
I
Belt
ope rat In9
dl rect Ion
rlFrontward
Raarward
L. H. SIDE
@E)
~~~
LG;R
LG/B
jl
CD~
~ti~R~
~L/W J
L~
i-.I
"'~Rl
~
REAR
LIMIT
SWITCH
SHOULDER
BELT
BUCKLE
SWI TCH
55
54
II J ~
II 1: ~
W
~
. 0
i=9
Door condition
ODen Close
m'
@~
@Y~
~ ~
171
1121
BUCKLE
H.
s I de
dIdI
(R.H.side
door harness)
Door condition
ODen Close
@D
@})
BODY
GROUND
~M18 fn.)
DI
~
~
R:~
-0..
(L.H.sIde
door harness)
11
12
L. H. SIDE
DOOR LATCH SWITCH
@ ii
@D(@@~
LAP BELT
(L.
~ FID
~
,m
11
~
R. H. SIDE
DOOR LATCH SWITCH
BODY GROUND
SWITCH
on
I y)
L. H. SI DE
FRONT
LI MIT
SWITCH
SBF784E
BF-35
1';;;
:;
0.
OFF
ON
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
OFF
OFF
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
ON
OFF
Front
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
ON
ON
ON
ON
ON
OFF
OFF
ON
ON
ON
ON
OFF
OFF
ON
ON
ON
ON
OFF
OFF
OFF
ON
ON
ON
OV
OV
OV
OV
OV
12V
12V
OV
OV
OV
OV
OV
12V
12V
OV
OV
OV
OV
12V
12V
OV
OV
OV
OV
12V
12V
OV
OV
OV
OV
OV
OV
Stop
Stop
Start to
move
Moving
Stop
Start to
move
Mov ing
Stop
Start to
move
Moving
Stop
Stop
Start to
move
Moving
Stop
Stop
Front
Between
Front&
Rear
Between
Front &
Front
Between
Front &
Rear
Rear
Between
Front &
Front
Front
switch
limit switch
o!:
1
';;;
OFF
Ignition
operation
:;0.
:;
0
Drivemotor power
source
for rearward
operation
Function
Shoulder
buckle
belt
Position
Front
Front
Rear
Rear
TIMER
Rear
Front
Rear
Rear
Rear
If limit switch does not operate (when accomplishing frontward operation, front limit switch can not be
turned "OFF" or when accomplishing rearward operation, rear limit switch can not be turned "OFF"),
control unit will continue to supply power to drive motor for 15 secondsand control unit will stop supplying power.
QUICK WARNING
If front limit switch is not turned "OFF" after accomplishingfrontward operation, control unit will stop
supplying power 15 seconds later and warning lamp will flash and chime will operate rapidly for approximately
seconds.
REAR LOCK
If quick warning functions twice successivelywhile ignition switch is "ON", shoulder belt buckle will move
to rear position when the door is closed as normal but will remain in rear position even if door is opened.
This function is canceledwhen ignition switch is "OFF".
BF-36
(Cont'd)
WARNING
Priority
Warning item
Ignition switch
Shoulder anchors
ON
Lamp
lock position.
Chime
I
OFF -* ON
I
Lamp
Chime
.
And,",
Lamp
n..
R'~I - _h"
Chime
t::
Within 6 sec.
ON
I Shoulder belts
are not fastened.
Ancho,
Lamp
R'~
ON
OFF
Chime
ON
OFF
Belts
Unfastened
Fastened
Lamp
Ch
'
100 sec.
ON
OFF
ON
.me
Belts
OFF
Unfastened
Fastened
Lamp
O~~
Chime
Belts
ON
OFF
Unfastened
Fin
3
OFF -* ON
belt is not
fastened.
6 sec.
Fasten~~.I~ec.
Lamp
Chime
Belts
Within 6 sec.
r-aSIenea
OFF -* ON
Lamp
Chime
ON
OFF
O~~
BF-37
6 sec.
BF-38
TROUBLE DIAGNOSES
Contents
Symptom Chart
Preliminary Check
BF-40
BF-41
Harness Layout
Circuit Diagram for Quick Pin Point Check
Diagnostic Procedure 1
(Check motor circuit and stop signals.)
Diagnostic Procedure 2
(Check door switch circuit)
Diagnostic Procedure 3
(Check front limit switch circuit)
Diagnostic Procedure 4
(Check rear limit switch circuit)
Diagnostic Procedure 5
(Check shoulder belt switch circuit)
Diagnostic Procedure 6
(Check lap belt switch circuit)
Diagnostic Procedure 7
(Check warning chime circuit)
Diagnostic Procedure 8
(Check warning lamp circuit.)
Electrical Components Inspection
BF-45
BF-46
BF-48
BF-49
BF-52
BF-54
BF-56
.."..
BF-58
BF-60
BF-62
BF-63
BF-64
Since left and right component parts are basically the same, harness layout and methods for electronic
components inspection are shown for one side only.
Although methods for checking component parts on both sides are described in the flow chart, making it
easier to trouble-shoot, apply checking procedures to either side that have problems during trouble diagnoses. For those methods enclosed by double rectangulars,however,component parts on both sides must be
checked as problems occurring on either side cannot be easily determined by a symptom.
BF-39
TROUBLE DIAGNOSES
Symptom Chart
0
Motor
BF-64
0
0
BF-64
co
Shoulder
BF-64
:i
Ii
BF-64
BF.64
..
...
c:
..
c:
BF-65
BF-64
Motor
BF-64
BF-64
BF-65
Warning chime
Warning lamp
c:
0
of;
co
0
0
8
BF-64
t..
iii
BF-64
"
-0
0;;;
:i
....i
0
0
0
0
BF-63
Procedure 8
BF-62
Procedure 7
BF-60
Procedure 6
BF-58
Procedure 5
BF-56
Procedure 4
BF.54
Procedure
BF-52
Procedure
BF-49
Procedure
BF-45
Procedure
BF-45
Procedure 1
BF-43
Procedure 2
BF-41
Procedure 1
'
f
;,
iu
e
a.
u
ji;
0c:
i
i5
:D"E
.. "E o.><
a.;'G
c: 0.
-0.00
e o!::6
.><
.E
'f
a.
e;,
iu
0
Q:
co
i
0.
..u
"c:
j!
..
a:
0
0
0
0
0
0
0
-8i
i
..E 1ii
u
E
.. 0co-0
0
o:;;;
c: "':>< 0.
02 c: u ...
Ia.
>CI)
1iiC
;, c:
....
.0..
co co E
g-
0-00
c:
zE
BF-40
..
..c>-
.!!
'><-o
u co
;'-0
.0.... ..
a;:i
.c.
a: ai
..
"..
:J:. ...
0
CI)..Jc:
-.. c:
:>< 0
u..
.&11_
""
!11
.. c: ..
...:..
:2.. f
;,
000
...
EE
ij;'''- 0
.011"
... .. 11
-!..
.a..!
:De g
-0.."
3::
000
EE
...
....
!..
.. .
00.
'"
c:
of
co
.. u ;,
;:...
.2..
-0
>
'" c:
.: 02
E0
...
u
05
'fROUBLE DIAGNOSES
Preliminary Check
PROCEDURE
Open door.
Close door.
r
Connect battery cable.
STEP 1
Does shoulder belt buckle move frontwards?
Yes
No
Open door.
STEP 2
Go to Diagnostic Procedure 2.
(See page SF.52.)
No
Yes
Close door, and turn ignition switch "ON".
STEP 3
No
Does shoulder belt buckle move rearwards?
Yes
END
BF-41
Go to Diagnostic Procedure 4.
(See page SF-56.)
TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
STEP 4
Does shoulder belt buckle move rearwards?
Yes
No
Go to Diagnostic Procedure 2.
(See page BF-52.)
Close door.
...
STEP 5
Does shoulder belt buckle move rearwards?
No
Go to PROCEDURE 2 of Main
Power Supply and Ground
Circuit Check.
Yes
Go to Diagnostic Procedure 3.
(See page BF-54.)
BF-42
TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
PROCEDURE
No
Go to Diagnostic Procedure 7.
(See page BF-62.)
Yes
STEP 2
No
Go to Diagnostic Procedure 8.
(See page BF-63.)
Yes
Go to Diagnostic Procedure 4.
(See page BF-56.)
No
Go to Diagnostic Procedure 5.
(See page BF-58.)
Yes
No
Bf-43
Go to Diagnostic Procedure 5.
(See page BF-58.)
TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
No
Yes
END
BF-44
Go to Diagnostic Procedure 6.
(See page SF-60.)
TROUBLE DIAGNOSES
W/L
SBF336E
Terminals
Ignition switch "ON"
@ - Ground
Yes
No
- Ground
Yes
Yes
Yes
Yes
Yes
Yes
<@)- Ground
- Ground
Ground circuit
i5~
I~I
~
Terminals
l~
~
B
C.U.
connectors
Continuity
- Ground
Yes
@ - Ground
Yes
@ - Ground
Yes
-=SBF337E
_T
IV [it
Terminal
L.H. side: ~ and @
R.H. side: @ and @
PROCEDURE
Battery voltage
existence
L.H. side
<@)
- Ground
Yes
R.H. side
- Ground
Yes
Terminals
Continuity
L.H. side
@ - Ground
Yes
R.H. side
@ - Ground
Yes
SBF33BE
-=-
BF-45
TROUBLE DIAGNOSES
Harness Layout
m Room
lamp
harness
m
--------------------@
R.H. front
limit switch
@
Body
ground
I;]
@
r.
.
18 Warning
(without
lamp
Warning
chime
head-up
display)
Warning lamp
(with head-up display)
[!1
@Dl.H. door latch switch
J@])R.H.
/~
i' \
@!I
B F -46
TROUBLE DIAGNOSES
Harness Layout (Cont'd)
Ii
SBF368E
BF-47
TROUBLE DIAGNOSES
Circuit Diagram for Quick Pin Point Check
I GNI TI ON SWITCH
ON or START
(WIth
head-up
d I sp lay)
@!
0~
SEAT
BELT
WARNING
(WI thout
head-up
LAMP
d I sp lay)
BREAKER
2]
[IJ
M
9 0
BELT
33
30
26
SEAT
CONTROL UNIT
'36
29
39
@
nlO1
44
4]
45
'0 HH
40
3 9 H3'
38
37
46
25
26
43
42
3]
36
32
35
I
11::0
-I
I ,1/);2
I/)
O:J
-m
I...J
.W
...Jm
0@
-:EI--
I/).II::
IO
.0
-10
1/)1--
@i)
OC
@)
:JO
:...J-
@I
Will
m.I
Q...
5d
@!D-::!:~
I/)
I0
WI-0
-...J
I/)
.11::
IO
.0
11::0
@-::!:@Y
.11::
I
.w
...JII::
I
11::0
WI-...J
:JI/)
0
IW
0@
WO
O:J
Ei
I/)...J
-m
I/)
.1-I...J
.W
!r:m
.>
.11::
...JO
I/)
I
0
I--
I--
W:E
0-...J
I/)
.11::
I
.W
!r:1I::
I
0
I--
.Z
IO
.11::
-ILL
11lIM
0-
wO...J
@
I/)W
0-...J
W:E
I/).1--
(0
I--
Ei
IW
WO
I
0
I--
I
0
0
I--
CD @
51/)
@@
5...J :
G)
@
@Y @})
I
0
I-
I-.>
.11::
I/)W
11::0
w6
en:
WARNING
34
\5
52
CHIME
--
S@
51
AUTOMATIC
22
CIRCUIT
'
@!
0~
G)@
1/1 FUSE
FUSE
0
I--
(0
I--
:E
WO...J
1/)1-.Z
IO
.11::
II::LL
@!D-::!:~
SBF7B5E
BF-48
TROUBLE DIAGNOSES
_T
Fa
@p
LHo"iwl
~40
IU
tt4~
aHHo"d'
START
Fa
CHECK MOTOR CIRCUIT.
1) Disconnect 10-pin connector
from control unit.
2) Check continuity.
~'Gm
SBF339E
m
C.U. 10-pin connector
IU
R.H. side:
LG/S
@-@
@-@
R.H. side
Terminal
L.H. side: @
N.G.
Terminals
L.H. side
~
~
@p
Diagnostic Procedure 1
Yes
Terminals
SBF340E
[!]I~
C.U.10-pin
connector
"IJ
i5~
Frontward
operation
L.H.side
@ - Ground
R.H. side
- Ground
No
[!]I
I
O.K.
N.G.
Go to DRIVE MOTOR ASSEMSLY of Electrical Components
Inspection. (See page SF-64.)
Rearward
operation
LG/R
O.K.
Rearward
GIS operation
G/R
SBF341E
BF-49
N.G.
Replace drive motor assembly.
TROUBLE DIAGNOSES
Diagnostic Procedure 1 (Cont'd)
1i]@P
~motor connector
Drive
C.U.
10-pin connector
L.H. side
Ii]
1) Disconnect connector from
drive motor assembly.
2) Check continuity.
N.G.
Repair harness.
Terminals
LG/R
LG/B
@-<@
@-@
@-@
@-<@
L.H. side
R.H. side
~
Drive
motorconnector
~c.u.
10-pin connector
R.H. side
~i5
O.K.
Check drive motor harness for
open circuit.
O.K.
G/R
r.I_CT
ellU
~
~
-.Eer
~Drivemotor
fill
D
52
LG/B4~'
L.H.
side IV ~R.H. sidelll
52
tEJ
connector G/Bhi'
Drivemotor
connector
Yes
Repair harness.
There will be incorrect grounding.
Terminals
@ - Ground
L.H. side
SBF343E
":"
<@ - Ground
-=-
@ - Ground
R.H. side
<@ - Ground
No
Check drive motor harness for
incorrect grounding.
O.K.
BF-50
N.G.
Repair drive motor harness.
TROUBLE DIAGNOSES
Ii <p
_NEeT
C.U. 10-pin
connector
Eu
Terminal
l.H. side: @
RH. side: @
VIR
N.G.
Go to Diagnostic Procedure 3
(See page BF-54.) and return to
next step.
Terminals
-=-
SBF344E
l.H. side
@ - Ground
@ - Ground
R.H. side
III
N.G.
Go to Diagnostic Procedure 4
(See page BF-56.) and return to
next step.
Rearward
operation
LG/R
Terminals
RH. side
l.H. side
RH. side
- Ground
- Ground
Rearward
operation
O.K.
Yes
No
SBF341 E
III
~
IJISCOIINEeT
C.U. 16-pin
connector
18
Go to PROCEDURE 1 (START)
of Preliminary Check.
(See page BF-41.)
Terminal
l. H. side: @
RH. side: @
-=
SBF345E
BF-51
TROUBLE DIAGNOSES
lu
_IECT
Diagnostic Procedure 2
C.U. 16-pin
connector
Terminal
L.H. side: @
RH. side: @
-=
SBF346E
START
Ter-
Ii)~
C.U. 16-pin
connector
switch connector
lu ~
_T~
_IEtT~
IU ~
L.H. side
~1a1
+
C.U. 16-pin
connector
_IEtT~
lu
LEvB
c.@9>
IIISCIIIIIECT
Door latch
switch connectorlU
I~R.H.side
L
rmJ
Door
condition
&
@Ground
Open
Yes
Close
No
RH.
side
@Ground
Open
Yes
Close
No
N.G.
N.G.
~
L.H.
side
R.H.
side
Continuity
L.H.
side
Ii)
nfFOil~
minals
O.K.
Repair harness.
Terminals
@-@
@ - Ground (eM!>,~J
@-@
@ - Ground (~,
J]:
1
[;]
_IECT
12J
~
~
Ug~IJ~[;]
CQD)or <9>
Doorlatchswitch
connectorConnector
L.H. side:<@)
R.H. side:@9:>
Harness color
L.H. side: R
R.H. side: L
SBF348E
O.K.
SBF347E
-::-
Yes
Terminals
L.H. side
C!ill>
@ - Ground
RH. side
<t511Q>
@ - Ground
Go to DOOR LATCHSWITCH
of Electrical Components
Inspection. (See page BF-64.)
.
N.G.
O.K.
Repair harness.
There will be incorrect grounding
between terminals @ and (j]) or
@ and (j]).
Go to PROCEDURE 1 (START)
of Preliminary Check.
(See page BF-41.)
BF-52
TROUBLE DIAGNOSES
Diagnostic Procedure 2 (Cont'd)
@
1
-
Go to PROCEDURE 1 (START)
of Preliminary Check.
(See page BF-41.)
SF-53
Yes
Replace control unit.
TROUBLE DIAGNOSES
_CT
Diagnostic Procedure 3
[it
,8:~
~C.U.10-pin
connector
WiV
Terminal
L.H. side: @
R.H. side: @
START
-=
SBF344E
Frontward
operation
Terminals
L.H.
side
LG/R
Shoulder
belt
.buckle
position
Continuity
At front
No
Not
at front
Yes
At front
No
Not
at front
Yes
@Ground
R.H.
side
Rearward
operation
@Grou nd
R.H. side
N.G.
[!]
~
-~~NB
Rearward
operation
G/R
UW/L \:.J
<&1~vC.U. 10-pin
IE)
SBF341E
<@)Front
limit
switch
connector'
connector
<&1~1).
C.U. 10-pln
~m
Terminals
L.H.
side
R.H.
side
@-G)
<V-Ground(<@P.~)
@.G)
<V- Ground(~.~)
O.K.
IlELJ
,Q
-=
eJ
- fit
H' side
rtffiB
EEE
D'
Y/L
SBF349E
IE)~
m
[ill
connector
i5~
[!]
O.K.
Y/R
R8
Front
-[II
~
limit
~
0
CID~;,'" 00""':,',.',
II,Q II
SF-54
N.G.
Repair harness.
TROUBLE DIAGNOSES
Diagnostic Procedure 3 (Cont'd)
Ii]
A)
_MECT
':c;\
~V
~
~
Ii]
Does continuity
Yes
exist?
Connector
Repair harness.
Terminals
- Ground
L.H. side
@g)
CD
R.H. side
@)
CD - Ground
No
-::"
C@Front
O.K.
Replace guide rail assembly.
N.G.
Check front limit switch harness
N.G.
Repair front limit switch harness.
O.K.
SBF350E
-=-
Go to PROCEDURE
of Preliminary Check.
(See page BF-41.)
BF-55
1 (START)
Yes
Replace control
unit.
TROUBLE DIAGNOSES
[it
C~V
Diagnostic Procedure 4
Terminal
L.H. side: @
R.H. side: @
C.U. 16-pin
connector
START
-=-
SBF345E
O.K.
(Go to @
B on next page.)
Shoulder
Terminals
L.H.
side
LG/R
@
GrOud
buckle
belt
position
@Ground
at rear
Not
at rear
tinuity
Con-
o
Yes
At rear
R.H.
side
Rearward
operation
No
I
Yes
iii Refer
R.H. side
Frontward
GtB operation
N.G.
[!J
N.G.
SBF341E
[!J
IIISC8IIIECT
EO
assembly
[it
connector
I~
_CT
,0;\
~
IIISC8IIIECT
12J
~rn
o
[it
()
Rear
~~j)CU.I.~;"
oonMctor
L.H.
side
R.H.
side
@-(@
@-Ground
(~.
@-(@
@ Ground
(~.
~)
<ill>)
O.K.
switch
IIISQIIIIIECT
assembly,o;\
connector Wis.J
I~J
SBF352E
[it
Terminals
[it
0
LlLillJ
~
=
[ill
fJ
~
LM
tfj
L
BF-56
Repair harness.
TROUBLE DIAGNOSES
DiagnosticProcedure4 (Cont'd)
Ii]
o
i5~
CIDor()
~3 Rear switch
assembly
connector
Connector
L.H. side: CID
R.H. side: ()
Harness color
L.H. side: L/W
R.H. side: L/W
Ii]
Does continuity
----- Connector
LID
Yes
exist?
Terminals
L.H. side
CID
- Ground
R.H. side
CID
- Ground
Repair harness.
There will be incorrect grounding
between terminals @ and ~ or
@ and ~.
No
SBF353E
-=-
~
Check rear limit switch harness
for open or short circuit.
O.K.
1
Is this the second time?
No
Reinstall any part removed.
Go to PROCEDURE 1 (STEP 3)
(See page BF-41.) or PROCEDURE 2 (STEP 3) (See page
BF-43.) of Preliminary Check.
BF-57
TROUBLE DIAGNOSES
-,
IV
~
C.U. 16-pin
connector
rw
~
Diagnostic Procedure 5
Terminal
@
l.H. si.de:
R.H.
side:
START
Y/B
SBF354E
i5~
l.H. side
RH. side
Ter-Shoulder
minals
beit
Continuity
l.H.
side
@Ground
Fasten
Yes
Unfasten
No
R.H.
side
@-
Fasten
Yes
Ground
Unfasten
No
belt buckle is
SBF355E
N.G.
[i
Repair harness.
@-~
@- Ground (~,
~)
@-~
@ - Ground ~,
RH.
side
N.G.
Terminals
l.H.
side
C.U. 16-pin
connector
[;) If shoulder
O.K.
~)
Continuityshouldexist.
O.K.
Ii]
Yes
---
ConnectorTerminals
l.H. side
<ID
- Ground
RH. side
CID
- Ground
Repair harness.
There will be incorrect grounding
between terminals @ and ~ or
@ and ~.
No
Ii]
(IDor CID
Rear switch
assembly
connector
[JlJ
SBF357E
Connector
l.H. side: CID
R.H. side: CID
Harness color
l.H. side: B
R.H. side: B
-=
Go to SHOULDER BELT
BUCKLE SWITCH of Electrical
Components Inspection.
(See page BF-64.)
N.G.
BF-58
O.K.
(Go to @ on next page.)
TROUBLE DIAGNOSES
DiagnosticProcedure5 (Cont'd)
T
Check shoulder belt buckle
switch harness for open or short
circuit.
O.K.
Replace rear switch assembly.
No
Go to PROCEDURE 2 (STEP4)
of Preliminary Check.
(See page BF-43.)
BF-59
TROUBLE DIAGNOSES
_T
,c:;>,
1I8v ~
Diagnostic Procedure 6
~C.U.16-pin
connector
START
-=
SBF358E
CHECK
SWITCH
CIRCUIT
Lap
~
cV
C.U. 16-pin
S8"S9'
[!]
~
1180
DISCONNECT
@ - Ground
~
18
connector
belt
on next
page.)
Continuity
Lap belt
Fasten
No
Unfasten
Yes
~~~
N.G.
Ii]
[]l]
N.G.
L/R
~
l..m
connector
~ l.oIIIIB
~;..h
boo".
E"V ~1J'
fQ;,j
L/R
(Go to
(L.H.only).
~E)
O.K.
[;)i5
Repair harness.
2) Check continuity.
Terminals
@-@
@-Ground~.~)
connector
[ill
O.K.
[!]
Yes
Terminals
Repair harness.
There will be incorrect grounding.
@ - Ground
SBF360E
-=-
No
Go to LAP
SWITCH of
BELT
BUCKLE
Electrical
O.K.
(Go to @ on next page.)
Com-
ponents Inspection.
BF-60
N.G.
TROUBLE DIAGNOSES
Diagnostic Procedure 6 (Cont'd)
T
Is this the second time?
No
Reinstall any part removed.
Go to PROCEDURE 2 (STEP 6)
of Preliminary Check.
(See page BF-44.)
../
BF-61
TROUBLE DIAGNOSES
Diagnostic Procedure 7
m <&IT9P
C.U. 16-pin connector
iS~
START
m
I
~GM
N~"
Ground
intermittently.
-=-
SBF361E
Terminals
@)Warnlng
chime
connector
I!J <&;li)pC.U.16.pin
connector
ijril
ij[il
m
GM
GM
(Go to @ below.)
Result
Ground
interI Sound
mittently.
N.G.
I!J
N.G.
Repair harness.
Terminals
SBF362E
[!]
-Ground
Method
O.K.
@-@
is [iI
O.K.
[!]
[Q]
Ves
Repair harness.
There will be incorrect grounding.
Terminals
@ -Ground
SBF363E
Ii]
-=
No
Ii]
is~
N.G.I Repairharness.
For details, refer to POWER
SUPPLV ROUTING in EL
section.
Terminals
@ Ground
Battery voltage should exist.
O.K.
Go to WARNINGCHIMEof
Electrical Components Inspection. (See page BF-65.)
SBF364E
-=
O.K. r.
Is this the second time?
No
Reinstall any part removed.
Go to PROCEDURE2 (START)
of Preliminary Check.
(See page BF-43.)
BF-62
N.G.
Replace warning chime.
r-@
Replace control unit.
TROUBLE DIAGNOSES
Diagnostic Procedure 8
DISCOIINECT
~
~
E~,
I~
Ii)
Combination
meter connector
ffiJl f
T'G
SBF365E
START
C
m
Terminals
Resu It
@ - Ground
Glow
O.K.
(Go to @ below.)
N.G.
Ii)
N.G.
i5
Repair harness.
[
2) Check continuity.,
Y/G
Terminals
<ID
6
@-@
Y/G
fO'WID7
O.K.
Ii)
Yes
Repair harness.
There will be incorrect grounding.
Y/G
Terminals
@ - Ground
[ill
No
[i
-=-
@) - Ground
~
[tmOO
0
Repair harness.
For details, refer to POWER
SUPPLY ROUTING in EL
section.
Terminals
[ii5~
91
N.G.
Battery
Combination meter
connector
voltage
should exist.
O.K.
Replace bulb.
~VJ
No
rR=fcHEl
~forE/D
SBF367E
-=
Yes
No
Reinstall any part removed.
Go to PROCEDURE 2 (START)
of Preliminary Check.
(See page BF-43.)
BF-63
TROUBLE DIAGNOSES
i5l11
Condition
L.H.side
Continuity
Push
~/.
Pushed
No
Released
Yes
SBF369E
REAR LIMIT
i5l11
SWITCH
Condition
Bottom
color:
Black
Continuity
Pushed
Released
SHOULDER
IU~
No
Yes
_IIECT~
Bottom
color:
Black
Condition
Continuity
Pushed
Yes
Released
No
SBF371E
i5r:i1
Continuity
Open
Closed
Yes
No
[ill
SBF290E
i5~
~
Terminals
-52~--1511!~
"\
1I
I
I
I
I
I
I
I
I
I
EB
(@
Lengthen
(@
Shorten
-~
SBF373E
BF-64
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
WARNING CHIME
i5~
184is6!.
Condition
Operation
Sounds
SBF373E
i5~
Condition
Continuity
Fastened
No
Unfastened
Yes
[ill
SBF374E
SF-6S
SUN ROOF
~GUide
rail
(Attached with
screws and sealant)
Link guide bracket
Urethane
1:~
m:
Grease-uppoints
BF-66
forming
SUN ROOF
Electrical Sun Roof (Cont'd)
Finisher plate removal & installation
I!J
l
"
Pulling up pawl
.c-
Draw out
finisher
plate.
Finisher plate
Retainer bracket
Removal:
Raise pawl of retainer bracket,
shift finisher plate and remove
locating pins from retainer
bracket.
Then remove finisher plate.
[;)
rLink
bJ.i
guide
bracket
Front stoppe~
..
SBF187E
BF-67
SUN ROOF
Wiring Diagram
@@
(Ma i n harness)
J:EI]W/B
W:BD~~
I~u:~1/i::~!
@
IGNITION
RELAY
M9
fi156\
~
r.;;)
-CI
II:]-
~:'i~
W/B
(Raom I amp
harness)
R/L
@
BODY
B-[Jp}-,
(Sun
roo f
harness)
-~
-:!:- GROUND
I GNITI ON SWITCH
ON or START
@~@})
!t!t
- -
BATTERY (Via
fusible I ink-Gree~
'\ rI RCUIT
I
2
3
\REAKER
@)
R~L::!;DJ
BODY GROUND
SLI DE
N C ose
0 en
0
0
0
SLI DE
RELAY-Close
Lid
operBt in9
direct Ion
~:
~
@
e-B
W/B
C
P/B
I2f3::
SB
:~:
P
@)
~y::ent
I
'i~~
direction
Openward
CIoseward
SLI DE
RELAY-Open
LIMIT
SAFETY
RELAY
!:l@
~~'~1
@
PU8'W~
SWITCHCSafety)
OUTER LID POSITION
Fully
opened
i
II
12
Between
approx.
IODmm
(3.94InJ
opened
and
fully
opened
Approx.
IOOmm
(3.94InJ
opened
0
6
Between
fully
closed
and
approx.
IOOmm
(3. 941nJ
opened
0
<5-
Fully
closed
0
0
SBF334E
BF-68
SUN ROOF
Manual
Sun Roof
Handle adjustment
Female hinge
Hinge bracket
SBF186E
BF-69
INSTALLATION
. Use genuine Nissan Sealant kit or equivalent. Follow instructions furnished with
it.
. After installation, the vehicle should remain stationary for about 24 hours.
. Do not use sealant which is more than 12 months past its production date.
. Do not leavecartridge unattended with its cap open.
. Keep primers and sealant in a cool, dry place. Nissan recommends that they are
stored in a refrigerator.
. Be lure to install moldings.
WARNING:
Keep heat or open flames away as
primers are flammable.
.I
Body side
CAUTION:
Be careful not to scratch glass when
removing.
SBF413B
Body side
Install spacers to panel with
double-feced tape.
Glass side
spacer
Body
panel
(19.09)
.I.~ Vehicle
<>:
center
SBF1 96E
Spacer mounting
portion
(Spacer should be installed
at slit portion of dam rubber.)
SBF198E
Fastener
,/1
(
~
"-
Panel
Double-faced
adhesive tape
SBF197E
~~~
Apply primer A.
~m
rubber
joint portion
Unit: mm (in)
i~OO
vehicle
center
'
of glass
SBF719C
CAUTION:
Allow primers to dry for 10 to 15
minutes before proceeding to the next
step.
BF- 70
1
Apply sealant evenly.
Apply primer E.
Morethan
12 (0.471
Glass
Unit: mm (in)
SBF038B
SBF199E
CAUTION:
Windshield glass should be installed
within 15 minu18sof applying 88alant
88alant starts to harden 15 minu18l
at18r it is applied.
CAUTION:
Allow primers to dry for 10 to 15
minute, before proceeding to the next
step.
Apply sealant additionally to Io_r portion of gland make it uniform as shown below:
Glass
SBF720C
CAUTION:
For sealant drying time, refer to
"Drying Time for Sealant".
Install moldings.
(For details, refer to "Exterior".)
BF-71
CAUTION:
Molding must be installed securely 10
that it is in position and I88V8Ino gap.
Back Window-Coupe
.
.
.
Construction and removal/reinstallation methods of back window are basically the same as those of
windshield.
For details of service procedures, refer to "Windshield".
The difference between windshield and back window is as follows:
For sealant drying period, refer to "Drying Time for Sealant",
For details of moldings, refer to "Exterior",
Sealant quantity
",(/
~-
--
"
'I
:
II
1I
II
II
I I
II
II
1I
I I
III ,
Ii)
~N_'
More
than
Vehicle
More than
12 (0,471
Ii]
Double-faced
adhesive tape
I
Spacer
fastener,
When installing it, heat body panel and
fastener to approx. 30 to 40C (86 to
104 F).
420i
(16,54)
7 (0281
Unit: mm (in)
Unit: mm (in)
Ii] double-faced
Install dam rubber and spacers with
adhesive tape. (Body side)
Lower portion
Vehicle
center
Lbem rubber
joint portion
SBF200E
BF- 72
.
.
.
.
Construction and removal/reinstallation method of back door window are basically the same as those of
windshield.
Major differences are that sealant & dam rubber are instailed to back door panel instead of glass surface.
Spacer position is also changed. Moreover, there are locating pins in lower portion of glass. For details,
refer to following figure.
For sealant drying period, refer to "Drying Time for Sealant".
For details of moldings, refer to "Exterior",
Locating
pin
(Left and right) 1m
xx:
Spacer
.:
Locatingpin
0:
Molding clip
Lower molding
(;J
1m
Ii]
Molding
When
panel
30 to
fastener
installing it, heat body
& fastener to approx.
40C (86 to 104FI.
[!)
Spacer
Unit: mm (in)
Backdoor side
~mOlding//
~u_~
Morethan
12 (0.47) ~n
=
Backdoor glass
7 (0,28)
Welt
Unit: mm (in)
BF- 73
SBF201E
Wire
Side
window
Body
panel
Wire
SBF376E
FASTBACK
Sealant
portion
I)
Double-faced
adhesive tape
More than
7 (0.28)
I)
(;]
Morethan
'12 (0.47)
Body panel
Body panel
More than
7 (0.28)
Unit: mm (in)
Unit: mm (in)
BF- 74
Unit: mm (in)
J
SBF203E
"
Seelent portion
Clip
E1
I]
Ii]
[I
Ii]
Dam rubber
30
(1.181
Clip
(Bonded to glassl
Unit: mm (in)
Sealant quantity
I]
Morethen
710.281
Unit: mm (in)
SBF202E
BF- 75
WINDSHIELD
AND WINDOWS
50
25
40 (104)
1.5
2.5
5.0
25 (77)
2.5
4.0
7.5
5 (41)
5.0
13.0
20.5
'c (oF)
CAUTION:
Advise the user of the fact that vehicle should not be driven on
rough roads or surfaces until sealant has properly vulcanized.
.~
.-Flat stick
Apply sealant.
..,.
T,;m~
,V,,:
""
POlysulphide
or polyurethane
..
4'
1!f!/
4~60
/~
Work into joints.
sealant
SBF543B
BF-76
MIRROR
Door Mirror
~
('
Fa
Mirror removal Fa
Mirror
SBF188E
WIRING DIAGRAM
I GNI TI ON SWITCH
ACC or ON
FUSE BLOCK
ITIIJI]]]
~..
(Refer
to "POWER
SUPPLY ROUTING"
In EL sect
ion. )
Y/B
PU/W
L/B
R. H. SIDE
DOOR MIRROR
II
@
Y/B
,-PyU::
Pu/w====-.rL/B
L/B
(Door
harness
Mirror
operat Ing
dl rectlon
~ Leftward
Rightward
R. H. )
L/W
(Main
harness)
III'
...J
~'"
~, J
_JlI>O:
'" J
>->
~~
Y/L
PU/W
L/R
~~15~~1
MIRROR
L. H. SIDE
DOOR MIRROR
II
~ Leftward
i Rightward
Mirror
operat Ing
dl rect Ion
~ Downward
i Upward
SW. CHANGE
OVER SW.
(1)A~
~~
6
7
DOOR MIRROR
,-
Y/L
PyU:;::
PU/W===-.sL/R
L/R
(Ooor
harness
L. H. )
Mirror
ope rat Ing
direct Ion
SWITCH
BODY GROUND
SBF335E
BF-77
Rear combination lamps are installed with nuts and butyl sealant.
Installation
Removal
Butyl seal
.
.
BF-78
.
.
When installing, make sure that there are not gaps or waves at ends of air spoiler.
Before installing spoiler, clean and remove oil from surface where spoiler will be mounted.
/
r;7~~~
'----.
~
Double-faced
adhesive tape
'-~
r;1;:;;J/
~~~_/-o
~/~
I~J
,
~"'" ""'
I
r;-r r-.~
W~-
Double-faced
adhesive tape
SBF190E
SBF191E
BF- 79
BODY ALIGNMENT
.
.
.
.
.
.
"X"
@)
(:J
=JQ
"Z"
"X"
"Z"
I-)
... I ...
1+1
''V''
@:
L.H.side
@:
R.H. side
Engine Compartment
MEASUREMENT
Unit: mm
SBF193E
BF-80
BODY ALIGNMENT
POINTS
Unit: mm
I'
SBF223E
"
'
'CID1
()
<::)
CJ
SBF220E
SBF221E
SBF222E
SF-81
()
<)
6dia.~
<')
()
()
SBF224E
SBF225E
BODY ALIGNMENT
Underbody
MEASUREMENT
~1J
E
E
...
'c
:J
~
...
cq.~
1
... 'It.
..., *
i
* *
coM
... GI
'It M
1
:2
<II
.
J:
.J
..
q~
...
an
GI
*
~
'It
~,t
a:
0
@
0
*
'It
* 1m
10
...
C!.
...
*
,..
0
C't
...
]~
SBF194E
BF-82
BODY ALIGNMENT
Underbody
MEASUREMENT
(Cont'd)
POINTS
/
~u
CD
"0
~y
.J
~~.
J::
CD
~;
a::
J~
..@
~0
u.
SBF196E
BF-83
BODY ALIGNMENT
Underbody
(Cont'd)
Unit: mm
Coordinates:
@,@
X: 542.2
Y: 63.5
z: 725.7
CD ,CD
X: 474.5
Y: 2,500
z: 658.9
Coordinates:
@,@
X: 132.9
Y: -582
z: 189
F~n1::!/
Rear:CD.
CD
48
@,@
X: 370
Y: -304
z: 255
die.
@,@
X: 384.2
Y: 32
z: 255
@.@
X: 375
Y: 700
z: 106.2
~,@
X: 420
Y: 1,150
z: 1'06.2
]D
SBF271E
SBF226E
Center side member.
Rear suspension
end
Coordinates:
Q),CD
X: 303
Y: 2,635
z: 65.8
member
rear mounting
Coordinates:
bolt threaded
@,CD
X: 422.5
Y: 1,650
Z:
104
@'@
X:
380
Y: 2 ,030
z:
195.8
@,@
x: 520
Y: 3,050
z: 398.8
SBF227E
:nO ~
~ U /~ r'
ChJ, CD
12 die.
r.1', I I
L ),~) I
1/ I \
r.1',~_1
rK'
\!y.'JY
16 die.
~\
L , \" \
'"
\
~
.;;; /-1
~ '-y--J
...J
ChJ
X: 528
Y: 3,221
z: 386
(1)
X: 528
Y: 3,200
z: 400
0
0
BF-84
HEATER&
AIR CONDITIONER
I
HA
SECTION
CONTENTS
AIR FLOW AND COMPONENT LAYOUT
DOOR CONTROL
DESCRIPTION - PushControl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUSH CONTROL UNIT
HEATER
ELECTRICAL
PRECAUTIONS.
CIRCUIT
. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . .
. .. .. . . .. . .. .. . .. . .. . .. .. . .. .. . .. . .. . .. .. . .. . .. .. .. . .. . .. .
HAHAHAHA-
2
5
7
9
HA-12
HA-13
HA-14
HA-15
HA-17
HA-24
HA-25
HA-28
HA-33
HA-35
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HA-40
HA-42
HA-44
HA-73
mil
if
~~~
0123~1
if
10
.'"";'
To floor
CD To ventilator
if
Bi-Ievel
'O~~~
~..~
if
To defroster
CD To ventilator
.Ie
...
To floor
:>
: Airpassedthroughheatercore
+~
HA-2
..
.." "..
VENT
B/L
FOOT
F/D
'4;1
I
I
I
I
I
I
I
I
I
I
I VENT
I
DEF
(%)
100
I
I DEF
I
I
I
I
I
I
I
I
I
I
- I
I
I
I
I
I
I
I
I
I
I
I
80
I
I
I
I
I
I
I
I
I
50
40
0
RHA372A
HA-3
.'
~--~..
J:
Jl
:II
:r
~
w
....
w
~
':
H."""""
Cooling unit
(Air conditioner)
DOOR CONTROL
Control
Cable
Adjustment
MODE DOOR
1. Move side link with hand and hold mode door in VENT mode.
2. Install mode door motor on heater unit and connect it to
body harness.
3. Turn ignition switch to ACC.
4. Turn VENT switch ON.
5. Attach mode door motor rod to side link rod holder.
6. Turn DEF switch ON. Check that side link operates at the
fully-open position. Also turn VENT switch ON to check that
side link operates at the fully-open position.
~
Mode door motor
CONNECT
(2J
RHA894A
'"
Air mix
door lever
Link lever
r----
(
w---
/PuSh.
/\\U\\<
/ RHA375A
Clamp cable while pushing cable outer and air mix door lever in
direction of arrow.
After
"
\ \
'-.
"
RHA376A
HA-5
DOOR CONTROL
Control Cable Adjustment (Cont'd)
INTAKE DOOR
1. Connect intake door motor harness connector before installing
on intake door motor.
2. Turn ignition switch to ACC.
3. Turn REC switch ON.
4. Install intake door lever.
5. Set intake door rod in REC and secure door rod to holder. .
6. Check that intake door operates properly when REC switch is
turned ON and OFF.
RHA895A
HA-6
DESCRIPTION
Push Control
swl tches
are bu i I t
I inked to
and mechanically
FUSE
THERMO
m
~
CONTROL
AMP.
DUALPRESSURE~
SW! TCH @W
:2'8
=
I[j
@
@
RES! S TOR
122161514~
11><17181
MODE
DOOR
MOTOR
f@;1
From
.
I I I umInat Ion
system
.
-~
RHA378A
This push control system operates the intake and mode door motors to activate their corresponding doors.
FUNCTIONS
Indicator illuminates
AIC I
I 0
- ..
I 0
......
-fJ
AIC
-
...
...
..;
... J
......
.
...-..
Air outlet
Intake air
I 0
B/L
I 0
FOOT
F/D
FRE
DEF
FRE
Compressor
ON*1
0
I
HA-7
b:2: --------I.
.REC
ON*1
DESCRIPTION
Push Control
~I
MP---1
-
~
To push
control.
door
llntake
motor
{
RHA379A
*: Current flows as
VENT indicated by the
arrow, motor
actuates as indicated by the words.
1
To
push
control
Terminal No.
Direction
of linkage
rotation
(j)
Stop
Stop
EB
VENT--DEF
Clockwise
EB
DEF --VENT
Counterclockwise
RHA380A
HA-8
~gj" fR92~1
BB8
0,
Cluster lid C
\/
RHA384A
2.
Push
If control
asse'mbly
)U[f
Remove
audio
(radio).
===1,
Overhaul
Co""o'
"..~
Control knob
1- -
',-
"-
1/'1
v'
~
~~
~
Control
box
'",,-- Finisher
plate
'/L
Coa,ro' ,,,...
A
,~84
'\
L E-ring
Temperaturecontrollever
RHA386A
HA-9
Overhaul -
Small flat-bladed
,
screwdriver
:J~
Illumination
harness
"-
AHA390A
HA-10
Overhaul -
..
-.
"
\
'"
HA-11
,.,..
Wiring Diagram
I GNIT ION SWITCH
ACC or ON
BLOWER
MOTOR
~
@)~
L/R
L/R
L/OR
Iii
, 0::,
..J ..J
1J
FUSE BLOCK
(Refer to "POWER
SUPPLY ROUTING"
in EL section.)
MODE
DOOR
MOTOR
G/Y
L/~
L/W
L/R
L/Y
L/OR
B
li)
V
B/L
FOOT
F/D
DEF
UI
Q)
cc
.- L
alai
5.:
INTAKE
DOOR MOTOR
G/Y
G/B
L/OR
j
0
@)
To A/C system
G/Y
R/Y
-LG
LG/B
L/OR
G/Y
G/B
R/L
- B
- G
L/Y
L/W
- L
L/B
L/R
L/OR
~1J0::>-II>
~~~~~II>
1J
0::
>-11>
""
..J..J..J..J
@lffiJ
[]
RESISTOR
o~J
(Subharness)
@)~~~
~~~
'" OFF
4
25
26
27
23
28
21
20
1
If
I LLUMI
1314
1211
169
815
.17
7
65
43
2 I
8
19
20
21
PUSH
CONTROL
UNIT
4
From
illumination
} system
FAN
SWITCH
)l
NA TI ON
II>
@)~(@)
BODY GROUND
RHA392A
HA-12
PRECAUTIONS
WARNING:
.
.
. Keep refrigerantaway from open flames because poisonous gas will be produced if it burns.
.
.
.
CAUTION:
N.G. \3
SHA919A
.
.
HA-13
cycle components,
Plug
SHA058
o,rin~
not apply
oom".~,oil.w.,nw,
011.
N.G.
.
.
N.G.
Inflated
portion
O.K.
SHA897A
unlo@
.
No'
~~~
~
D
&
I~
~4)
SHA898A
HA-14
PREPARATION
SPECIAL SERVICE TOOLS
Tool number
(Kent-Moore No.)
Tool name
KV998VROO1
(
KV99231010
(
KV99235160
(J29751 )
Nut wrench
Description
\\Y
HA-15
PREPARATION
SERVICE TOOLS
Tool name
.0
Description
Manifold gauge
Charging hose
Charge valve
Thermometer
"
Dischargingand charging refrigerant
.;
Checking temperature
C'-
-3
Vacuum pump
Evacuating refrigerant
Nomineillftlitivity:
1..25. '0.53.""
UII
..
HA-16
*1
When it is necessary to replace
pa rts
Point-'
Repair.
Discharging
I
i.
Replace
t
Add refrigerant
parts.
I
New AIC system
Point-2
Evacuating
Run pump for over 5 minutes.
Point-g
!
Checking airtightness
O.K.
*2
Once evacuating
N.G.
Point-4
Repair.
Twice evacuating
Point-6
Charging
Evacuating
Point-3
N.G.
Checking airtightness
Point-5
1 O.K.
Evacuating
In
Point-7
Charging
Checkingrefrigerantleaks
l O.K.
Checkoperationof AICsystem.
HA-17
N.G.
To low-pressure
service valve
Point-1
Discharging
.
SHA240B
To high-pressure
service valve
To low-pressure
service valve
Low
~I
.
-
Vacuum
-,
Elevation
m (ft)
pump
SHA241 B
Vacuum of system*
kPa (mmHg, inHg)
0 (0)
101.3 (760,29.92)
300 (1,000)
98.0 (735,28.94)
600 (2,000)
94.61710,27.95)
900 (3,000)
91.3 (685,26.97)
Point-21
Point-3
Checking Airtightness
I
Point-4
Repair
If a problem is noticed under IPoint-31 above, locate and repair
the leaking point using the following table as a guide.
Leak at/around pipe connection
HA-18
.
.
.
.
To low-pressure
service valve
To high-pressure
service valve
~I:
10
='
pOint-51
Vacuum pump
SHA241B
I Point-61
fU
Charging
Close
Close
SHA242B
To low-pressure
service valve
To high-pressure
service valve
LR~
RHA278
CAUTION:
To low-pressure
service valve
To high-pressure
service valve
SHA244B
HA-19
Turn
In or out
SHA245B
IL~ n ~
#>~fr
-..
Point-71
Charging
To high-pressure
service valve
Ii:) Close
H.h
II
1. Open manifold gauge low-pressure valve and charge refrigerant into system.
WARNING:
Ensure that engine is off.
2. When refrigerant charging speed slows down, start engine air conditioning system ON, maximum cold temperature set,
maximum blower speed set, can in upright position.
Monitor sight glass. Charge is complete when sight glass is
clear.
Cycling clutch systems will produce bubbles in sight glass
when clutch engages. Therefore, allow 5 seconds after clutch
engages to determine if bubbles continue, and, if so, add
refrigerant to clear sight glass.
WARNING:
Never charge refrigerant through high-pressure side (discharge
side) of system since this will force refrigerant back into
refrigerant can and it may explode.
3. Charge refrigerant while controlling low-pressure gauge
reading at 275 kPa (2.8 kg/cm2,40 psi) or less by turning in
or out low-pressure valve of manifold gauge.
Be sure to purge air from charging hose when replacing
can with a new one.
RHA504
HA-20
IPoint-71
Charging (Cont' d)
The state of the bubbles in the sight glass can only be used for
checking whether the amount of charged refrigerant is small or
not. The amount of charged refrigerant should be correctly
judged by means of the discharge pressure.
5. After charging, be sure to install valve cap on service valve.
6. Confirm that there are no leaks in system by checking with a
leak detector.
HA-21
DISCHARGING,
.
.
.
.
.
Almost
no refrigerant
Insufficient
Open
ON
Max. COLD
4
lapse of about
Suitable
five
Check item
Temperature
of highpressure and lowpressure lines.
AImost transparent.
Bubbles may appear when
engine speed is raised and
lowered.
AC256
Pressure
Repair.
a.
of system.
AC257
AC258
HA-22
high.
cold. '~
SHA733A
UNION TYPE
RHA279
PLATE TYPE
~~L
RHA280
MEASUREMENT
STAN.DARD
HA-23
DESCRIPTION
OF AIR CONDITIONER
Acceleration
Cut System
switch
ENGINE
TEMPERATURE
SENSOR
COMPRESSOR
HA-24
SERVICE PROCEDURES
Refrigeration Cycle
REFRIGERANT
FLOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser, the receiver
drier, through the evaporator, and back to the compressor.
"The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion
valve, located inside the evaporator case.
FREEZE PROTECTION
The compressor cycles on and off to maintain the evaporator temperature within a specified range. When
the evaporator coil temperature falls below a specified point, the thermo control amplifier interrupts the
compressor operation. When the evaporator coil temperature rises above the specification, the thermo
control amplifier allows compressor operation.
REFRIGERANT SYSTEM PROTECTION
Dual-pressure switch
The refrigerant system is protected against excessively high or low pressures by the dual-pressure switch,
located on the receiver drier. If the system pressure rises above, or falls below the specifications, the
dual-pressure switch opens to interrupt the compressor operation.
Fusible plug
Open at temperature above 105C (221F), thereby discharging refrigerant to the atmosphere. If this plug
is melted and opened, check the refrigerant line and replace receiver drier.
Pressure relief valve
The refrigerant system is also protected by a pressure relief valve, located on the end of high flexible hose
near compressor. When the pressure of refrigerant in the system increases to an abnormal level [more
than 3,727 kPa (38 kg/cm2, 540 psi)], the release port on the pressure relief valve automatically opens and
releases refrigerant into the atmosphere.
Pressu re
relief valve
~
t '
High-pressure .
gas
'j High-pressu re
liquid
~
I,':':':':':':':d
Low-pressure
liquid
Low-pressu re
gas
lill
Outside air
Compressor
Condenser
0
Blower motor
.
Expansion valve
Receiver drier
Fusible plug
Dual-pressure switch
RHA393A
HA-25
SERVICE PROCEDURES
Refrigerant Lines
~
~
10.20
7.14)
(1.0.2.0,
15.25 (1.5.2.5,
11 -18)
rg
[]]J[1J
Expansion
valve
Condenser fan
motor* (U.S.A. only)
Low-pressure
(Suction)
service valve
Ie]
~~
-12.3)
D (Tightening torque)
0 0 (Wrench size)
!AJ
Ie]
[g
20
-29
10
(2.0
-3.0,
14
-22)
~:
N.m (kg-m,ft-Ib)
RHA394A
HA-26
SERVICE PROCEDURES
Compressor Mounting
60
(4.6.6.1,33.44)
co;J 45
.
~.
~-
"
~~
co;J 45 - 60
(4.6-6.1,33-44)
RHA395A
RHA396A
Belt Tension
Refer to MA section.
HA-27
-;
MODE switch:
(Ventilation) set
REC switch: ~(Recirculation) set
FAN lever position: Max. position
Engine speed: 1,500 rpm
Time required before starting testing after air conditioner starts operating: More than 10 minutes
For U.S.A. model, make sure that condenser fan motor does not operate during the following tests.
TEST READING
Recirculating-to-discharge
Air temperature
c (oF)
50 - 60
60 -70
20 (68)
25 (77)
30 (86)
35 (95)
40 (104)
20 (68)
25 (77)
30 (86)
35 (95)
40 (104)
pressure table
Ambient air
Relative humidity
%
50 -70
20 (68)
25 (77)
30 (86)
1,402
- 247)
35 (95)
40 (104)
Air temperature
c tF)
HA-28
Condition
INSUFFICIENT 'REFRIGERANT
Probable cause
CHARGE
Corrective action
I.
Refrigerant is low, or
leaking slightly.
1. Leak test.
2. Repair leak.
3. Charge system.
Evacuate, as necessary, and
recharge system.
AC352A
ALMOST NO REFRIGERANT
No cooling action.
A lot of bubbles or
something like mist
appears in sight glass.
AC353A
Slight cooling.
Sweat or frosting on
expansion valve inlet.
AC354A
HA-29
No cooling.
Sweat or frosting on
suction line.
(Cont'd)
Probable cause
Corrective action
Malfunctioning expansion
valve.
1. Dischargesystem.
2. Replacevalve.
3. Evacuate and charge
system.
1. Dischargesystem.
2. Replacereceiver drier.
3. Evacuat~and charge
system.
1. Discharge system.
2. Replace receiver drier
(twice if necessary).
3. Evacuate system completely. (Repeat 30minutes evacuating
three times.)
4. Recharge system.
AC356A
IAIR
IN SYSTEM
AC359A
MOISTURE IN SYSTEM
AC360A
HA-30
MALFUNCTIONING CONDENSER
Corrective action
Usually a malfunctioning
condenser.
"
(Cont'd)
Probable cause
Condition
Test Diagnoses
@
AC361A
HIGH PRESSURE
LINE BLOCKED
Insufficient cooling.
Frosted high-pressure
liquid line.
1. Dischargesystem.
2. Removereceiver drier
or strainer and replace
it.
3. Evacuate and charge
system.
1. Discharge system.
2. Remove and check compressor.
3. Repair or replace compressor.
4. Check oil level.
5. Replace receiver drier.
6. Evacuate and charge
system.
AC362A
MALFUNCTIONING
COMPRESSOR
Insufficient cooling.
AC363A
HA-31
Probable cause
Condition
TOO MUCH 01 L IN
SYSTEM (Excessive)
Test Diagnoses
Insufficient cooling.
AC364A
HA-32
(Cont'd,)
Corrective action
Refer to COMPRESSOR01L
for correcting oilleve!.
COMPRESSOR OIL -
Checking
'I
is
and Adjusting
4. Check the purity of the oil and then adjust oil
level following the procedure below.
(a) When oil is clean;
Unit: mQ (US fl OZ, Imp fl oz)
Amount of oil drained
OIL CAPACITY
Unit: mQ (US fl OZ, Imp fl oz)
Applied model
Capacity
Total in system
Amount of oil which can
be drained
Compressor (Service
parts) charging amount
All models
Adjusting procedure
*:
HA-33
COMPRESSOR OIL
Example:
Unit: mi! (US fl OZ,Imp fl oz)
Amount of oil drained
from used compressor
"
70 (2.4,2.5)
70 (2.4, 2.5)
90 (3.0, 3.2)
HA-34
.
.
.
.
.
.
Whel\ s~ring a compressor, be sure to fill it with refrigerant \to prevent rust formation. Add refrigerant at the
low-pressure side and purge air at the high-pressure side,
while rotating shaft by hand.
COMPRESSOR
HA-35
COMPRESSOR
Key
Adjusting shim
tOJ 29
-39
Center bolt
tOJ 9.1 . 11.8 (0.93 - 1.2,6.7 - 8.71
tOJ:
HA-36
COMPRESSOR
Compressor Clutch
REPLACEMENT
.
.
When removing center bolt, hold clutch disc with clutch disc
wrench.
Using clutch disc puller, clutch disc can be removed.
SHA052B
.
.
~ c::t
After flattening lock washer tab,
loosen lock nut.
SHA053B
INSPECTION
Clutch disc
If the contact surface shows signs of damage due to excessive
heat, the drive plate and pulley should be replaced.
Pulley
Clutch disc
Coil
~
SHA703B
Pulley
Check the appearance of the pulley assembly. If the contact
surface of the pulley shows signs of excessive grooving due to
slippage, both the pulley and drive plate should be replaced.
The contact surfaces of the pulley assembly should be cleaned
with a suitable solvent before reinstallation.
Coil
Check coil for loose connection or cracked insulation.
0.3 -0.6
Adjusting shim
(0.012 -0.024) [Thickness - 0.1, 0.3, 0.5, 0.8
(0.004,0.012,0.020,0.031)]
ADJUSTMENT
BREAK-IN
OPERATION
~ ~
Unit: mm (in)
RHA843
HA-37
COMPRESSOR
Thermal Protector
.
.
Thermal protector
SHA055B
HA-38
COMPRESSOR -
NOTE
HA-39
THERMAL
I GNI TI ON SWITCH
ON or START
PROTEC1OR
nU
(V I a
IInk-Gree~
"
THERMO-
SWITCH
"
~i
h.cn.s~
~(SUb
AIR
@)
0
(J
~],I
~
~@)
~~ ci~ ~~, ~~~
CAN]""
CONDENSER
FAN
MOTOR
@)~ to
~~
"
to ,,,,III
111
u.s.A.
....
<ff@)
,'"
III
~III
@)A@)
DUALPRESSURE
SWITCH
~~
BODY
GROUND
~nglne
room
harnes~
i)-LG ~LG/R
>- to
'"
to
III
"
@~
@~
>- to
"
@)
to
""
,'"
III
~~~/G
F. I. C. D.
SOLENOID
VALVE
III
~
- @
ENGINE
GROUND
(E. F. I.
li
:~~~~~~~~~~~~---------------f~
~
'"
,
@@
~o:
1-0
OVJ
O:Z
ILU
I-VJ
~:
to
""~III
harness)
~
I~
::J
,
IIII....
ffi@)
0
Z
::J
0
0:
(!Jill
~o:
zo
wO@
z~
(!J7
~VJ
(!JZ
ZLU
WVJ
@~I~~IIIFNlbb1Ii
Z
W
III ~ I~ II~
~ ~ ~ &
(Refer to
HA-40
I!!,.I'llII6MII'F!Ii
CONTROLUNIT
EF&EC sect Ion. )
BLOWER
L/R
L/R
L/OR
31' I>:
'\ '\
..J ..J
Iii
@~
FUSE BLOCK
(Refer
to "POWER
SUPPLY ROUTING"
in EL sect
ion. )
MODE DOOR MOTOR
G/Y
G
V
B/L
FOOT
F/D
DfF
@
INTAKE
DOOR MOTOR
G/Y
G/B
L/OR
S. M. J.
ffiefer
to
age
last
(@)
@)
@
THERMO
CONTROL AMP.
(Main
harness)
-L/OR
112
L/OR
-LG
HI2
LG -
-LG/R
HID
LG/R
L/G
LG/B
L/OR
:W
~RM'STOR
()
G/YR/Y-
- LG
1314
1211
LG/B
L/OR
G/Y
G/B
R/L
- B
I'"
@)
169
815
17
87
65
43
2 1
L/Y
L/W
L/B
L/R
L/OR
31'1>:>-'"
'\'\'\'\
..J..J..J..J
@~
RESISTOR
@)
(Subharness)
~~~
~~~
'\. OFF 1
24
2
26
27
2
8
21
20
1
1
19
0
21
~3:I>:>-'"
PUSH
CONTROL
UNIT
4
From
illumination
} system
FAN
SWITCH
(tJ(tl-\....,
I LLUMI NATI ON
'"
~:
@@~
(CAN):
For
For
U. S. A.
Canada
BODY GROUND
RHA398A
HA-41
Resistor
Inteke door motor
Engine compartment
\ Ther';'oswitch\
(U:S.A.
onl\)
\\
-'.~:
::
...1.--\'~
HA-42
~/
RHA403A
HA-43
TROUBLE DIAGNOSES
Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair
Symptom Chart
Preliminary Check
PRELIMINARY CHECK 1
(Intake door is not set at "FRESH" in DEF or FOOT mode.)
PRELIMINARY CHECK 2
(A/C does not blow cold air.) '"''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''
PRELIMINARY CHECK 3
in DEF
mode.)
PRELIMINARY CHECK 4
(Air outlet does not change.)
PRELIMINARY CHECK 5
(Noise)
Main Power Supply and Ground Circuit Check
Harness Layout for AIC System
Circuit Diagram for Quick Pin Point Check
Diagnostic Procedure 1
(SYMPTOM: Blower motor does not rotate.)
Diagnostic Procedure 2
(SYMPTOM: Air outlet does not change.)
Diagnostic Pfocedure 3
(SYMPTOM: Intake door does not change in VENT, B/L or FOOT mode.)
HA-45
HA-46
HA-48
HA-48
HA-49
"
HA-50
HA-51
HA-52
HA-53
HA-55
HA-56
HA-57
HA-59
HA-61
Diagnostic Procedure 4
(SYMPTOM: Magnet clutch does not engage with A/C switch and fan switch are ON.)
HA-62
Diagnostic Procedure 5
(SYMPTOM: Illumination or indicators of push control unit do not come on.)
Electrical Components
Inspection
HA-66
HA-70
HA-44
TROUBLE DIAGNOSES
<
Reference item
LISTEN TO CUSTOMER
COMPLAINTS AND CONFIRM.
----------------I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Symptom Chart
(See page HA-46 - 47.)
Preliminary Check
(See page HA-48 - 52.)
Main Powerf.;upplY
and Ground Circuit
Check
(See page HA-53 - 54.)
. Harness Layout
for A/C System
(See page HA-55.)
Malfunctioning
harness(es)/
connector(s)
Malfunctioning
part(s)
REPAIR/
REPLACE.
/1
I
I
L
-- -- - -
----
N.G.
O.K.
CHECK OUT
HA-45
TROUBLE DIAGNOSES
Symptom Chart
DIAGNOSTIC
TABLE
Preliminary
Check
PROCEDURE
a)
It)
REFERENCE
It)
.It)
It)
.J:;
CJ
CJ
II)
.J:;
CJ
a)
PAGE
:I: :I:
It)
SYMPTOM
CJ
II)
.J:;
CJ
>
IV
c:
N
.J:;
CJ
>
IV
c:
>
IV
c:
>
IV
c:
CJ
II)
.J:;
CJ
>
IV
c:
'E
'E
'ii
'ii
'ii
'ii
Q.
'ii
Q.
Q.
Q.
Q.
.- N
:I: :I: :I:
M
II)
::::s
::::s
::::s
Q,
Q,
'i
CJ
0
Q,
CJ
.+:;
...
0
c:
C)
IV
i5
..
M
It)
It)
II)
..
::::s
::::s
Q,
"II)
.+:;
...
0
c:
C)
IV
.+:;
...
0
Q,
CJ
.+:;
...
0
C)
C)
i5 i5
i5
CJ
.+:;
...
0
c:
C)
IV
CJ
CJ
c:
IV
M
It)
,<
:I:
It)
c:
IV
i5
...
'c
:I
'0
...
II)
...
::::s
51
::::s
u.
It) .0
.-
u.
ci
E
IV
'0
...
c:
0
CJ
0
...
c:
0
CJ
E
.J:;
II)
...
::::s .J:;
Q.
I-
..
<0
II)
It)
II)
0
<0
I"'It)
..-
Main Power
Supply and
Ground Circuit
Check
Diagnostic
Procedure
..
0 ..
HA-46
\\
0
Blowermotor
Resistor
A/C switch
REC switch
VENTswitch
BILswitch
FOOT switch
FID switch
DEF switch
::I:
I
~
"'-01
Fanswitch
Modedoor motor
Intakedoor motor
A/C relay
Dual-pressur, switch
Compressor (Magnetclutch)
Thermal protector
E.C.C.S.control unit
Illumination system
Knob illumination
Push
control
unit
Harness
Compressor
&
R
E
TROUBLE DIAGNOSES
Preliminary Check
PRELIMINARY CHECK 1
Intake door is set at "FRESH" in DEF or F/D mode.
No
Is intake door in "Fresh" position
when REC switch is turned from
ON to OFF at VENT, B/L or
FOOT mode with ignition switch
at. ACe and fan speed at 4?
(Can you hear air moving from
the intake unit?)
Go to DiagnosticProcedure 3.
Yes
No
Go to Diagnostic Procedure 3.
Yes
Is intake door in "Fresh" positionl
when F/D switch or DEF switch
is pushed?
(Can you hear air moving from
the intake unit?)
Yes
INSPECTION END
HA-48
No
TROUBLE DIAGNOSES
Preliminary
"
PRELIMINARY CHECK 2
A/C does not blow cold air.
Check (Cont'd)
N.G.
CHECK BLOWER
MOTOR
OPERATION.
Go to Diagnostic
Procedure 1.
O.K.
CHECK COMPRESSOR BELT
TENSION.
Refer to MA section.
N.G.
CHECK COMPRESSOR
OPERATION.
CHECK REFRIGERATION
CYCLE PRESSURE WITH
MANIFOLD GAUGE
CONNECTED.
Refer to Performance Chart.
TN.G.
Adjust or replace
compressor belt
CHECK REFRIGERANT.
Go to Performance
Test
O.K.
(Does not
freeze up)
CHECK VENTILA.
TOR DUCT FOR
AIR LEAKS.
Go to Diagnostic Procedure 4
N.G.
(F reeze up)
Diagnoses.
N.G.
CHECK FOR
REFRIGERANT
LEAKS
evaporator freezes.
O.K.
N.G.
O.K.
O.K.
O.K.
No
Yes
I. O.K.
I CHECK EVAPORATOR
/
CHECK THERMO
CONTROL
AMP. OPERATION.
Refer to Electrical
Components
Inspection.
HA-49
,.
TROUBLE DIAGNOSES
Preliminary
PRELIMINARY CHECK 3
Magnet clu,ch does not engage In DEF mode.
Perform PRELIMINARYCHECK 2 before referring to the following flow chart.
No
Go to Diagnostic Procedure 4.
Yes
Push A/C switch and turn A/C
system OFF. Make sure that
magnet clutch is disengaged.
No
Yes
INSPECTION END
HA-50
TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
PRELIMINARY CHECK 4
Air outlet does not change.
No
DOES AIR COME OUT FROM EACH DUCT NORMALLY WHEN
EACH MODE SWITCH IS PUSHED WITH IGNITION SWITCH AT
ACC?
Go to Diagnostic
Indicator illuminates
...,1 ,..
...
...
,1
...
"Q)
0
.
........
....1
Air outlet
VENT
0
,..
.
....I
........
Air distributionratios
FOOT
VENT S/L
F/D
... ; s....
... .,...
'
DEF
DEF
...
I
I
I
I
I
I
I
I
I
I
I VENT
I
I
I
I
I
I
I
I
I
I
I
f
'''
(%)
100
80
50
40
I
I
Yes
INSPECTION END
HA-
51
Procedure
2.
TROUBLE DIAGNOSES
,
------
Belt
Replace
expansion valve.
Replace
compressor.
(
Readjust belt tension.
Refer to ENGINE
MAINTENANCE
in MAsection.
HA-52
TROUBLE DIAGNOSES
Main Power Supply and Ground Circuit Check
POWER SUPPLY CIRCUIT CHECK FOR AIC SYSTEM
Check power supply circuit for air conditioning system.
Refer to "POWER SUPPLY ROUTING" in EL section and AIC
ELECTRICAL CIRCUIT.
Thermo control
connector
@
THERMO
amp.
AMP. CHECK
Check power supply circuit for thermo control amp. with ignition
switch ON.
1. Disconnect thermo control amp. harness connector.
2. Connect voltmeter from harness side.
3. Measure voltage across terminal No. @ and body ground.
~~
L/OR
i5
Voltmeter terminal
Voltage
00
':"
CONTROL
RHA406A
EB
Body ground
Approx. 12V
(
.,
Thermo con trol amp.
ne ctor @
'O"~
[ill
-=
LG/B
~
i5
.~
00
RHA509A
Check body ground circuit for thermo control amp. with ignition
switch OFF, AIC switch ON and fan switch ON.
1. Disconnect thermo control amp. harness connector.
2. Connect ohmmeter from harness side.
3. Check for continuity between terminal No. @ and body
ground.
Ohmmeter terminal
EB
Body ground
HA-53
Continuity
Yes
TROUBLE DIAGNOSES
Main Power Supply and Ground Circuit Check
(Cont'd)
..-cT
lit IV 00
PUSH CONTROL
~n
~!
RHA431A
Ei1
Body ground
Voltage
Approx.12V
Check body ground circuit for push control unit with ignition
switch OFF.
1. Disconnect push control unit harness connector.
2. Connect ohmmeter from harness side.
3. Check for continuity between terminal No. @ and body
ground.
[ID
IBffiEHEI
Voltmeter terminal
litij~
UNIT CHECK
::
RHAB96A
HA-54
TROUBLE DIAGNOSES
@
@
Engine compartment
'.
:;r.
~/
Main harness
Dual-pressure switch
Condenser fan motor
AIC relay
Compressor (Magnet clutch)
Compressor (Thermal protector)
HA-55
RHA404A
BATTERY
(Via
fusible IInk-Green)
FUSE
'N
INTAKE
DOOR
MOTOR
@3
<8
@ 10
m
m
DUALPRESSURE~
SWITCH @W
O~@@
1][1 6~~~~gL
~
AMP,
811213
I 3 5 7 1 159
1114 ~
246
PUSH
CONTROL _UNI T
THERMISTOR
r--
::E:
0)'
~rcr
BLOWER
MOTOR
ED
RESI STOR
DEF.
~
~
F/O.
U1
en
VENT
,;:~
2
2
'---1'1
~
21
OEF;o
'
(1
F/0
B/L
6~~
~
\1-1
~ffi
-1;0
m::I
~~u
ILLUMINATION
~~
or.
U. S. A.
For Canada
l ~
11>1
.
.
All
connectors
shown
in this illustration
"-
zz
::I
zo
0'
Ci\ am
6 ;0
g~
~
~
-::!..
:1
<
~
m'
-I
O::Y;:
'
'
~
~
en."."
, ~
~
~
~
;0
From
~
I@
m
;0
:D
:I
~
~
0
(,II
~
en
en
FOOT 0
(J: ) ---1(2
(~):
~
EF
'~\1
E.
CO
UN
MODE
DOOR
MOTOR
<8
~:
~ FUSE
30
I'm
~
I
~~
The unit 'side connectors with a double circle" 0 " are connected to the harness side connectors
shown in the "Harness Layout for A/C System", (See page HA-55,1
. The terminal numbers in the connector coincide with the circuit numbers surrounded by a single circle"
.: These switches are built in push control unit and mechanically linked to corresponding switches.
TROUBLE DIAGNOSES
Diagnostic Procedure 1
Flow chart
No.
INCIDENT
rn
L1J
Fa
\&",l1tis
~
"cfi'
[;J
;l1tiJ
Blower4m~
1
II
L1J
B)
(Q)
(g
O.K.
[;J
2 3 4,
RHA407A
rn
Fa
Blower motor
connector @
to the
N.G.
O.K.
Q
00
connector @
(Refer to Electrical
Components
N.G.
"~~
RHA510A
Inspection.)
[i]
Resistor@
~m l1t i)
[i]
00
(
"0'
-=
23 4
RHA408A
Ii]
l1tu
Blower motor
connector @
O.K.
[ill
Ii]
Note
No.
harness terminal
and resistor
No. @.
Resistor
connector @
Y~~lfOO
L/W
N.G.
L/W
A
(Go to next page.)
Note:
If the result is N.G. after checking circuit continuity, repair harness or
connector.
RHA518A
HA-57
TROUBLE DIAGNOSES
Diagnostic
Procedure
1 (Cont'd)
c
B'
~
RHA409A
00
O.K.
II
AHA897 A
':"
[]J
Fan switch
@
L/R
connector
L/Y
LIB
Flow chart
No.
Terminal No.
[itij
@
@
~
Body Approx.
ground 12V
O.K.
--,
Lffl
27---,
L/Y
Resistor connector @
-'
Voltage
@
@
.-. L/R
~~i5
II
-eft' 2 3 .
':"
Fan switch
connector @
iii
D'
II
~
~
~
00
N.G.
[2]
RHA519A
O.K.
iii
N.G.
Replace fan switch.
Note
ground.
O.K.
Replace blower motor.
Note:
If the result is N.G. after checking circuit continuity, repair harnessor
connector.
HA~58
Note
TROUBLE DIAGNOSES
Diagnostic Procedure 2
_lET
eJ
00
t
-=
(;)
SYMPTOM:
RHA410A
connector@
.-r
Eu
00
RHA411 A
II
m
CHECK MODE DOOR MOTOR POSITION SWITCH.
1. Turn VENT switch ON with
ignition switch at ACC
position.
2. Turn ignition switch OFF.
Disconnect push control unit
connector.
3. Check if continuity exists
00
,-,.-r-r
, ,
,(..,
---
,~\('
'O\(..,'-,~
,---,
,.
,
Q>'
>,
~~~:,
654
321
Conti-
nuity
CD or @
B/L
@ or CID
FOOT
CIDor @
F/D
@ or <ID
DEF
<IDor @
Body
ground
Yes
O.K.
II
Note
(f)
ContJ-fltlity-..
CD
CD
@'
CID
CID
<ID
<ID
(j)
(j)
Yes
O.K.
SHA297C
VENT
7 8
Note
(;)
Terminal No.
Terminal No.
(f)
@
(Go to next page.)
Note:
If the result is N.G. after checking circuit continuity, repair harness or
connector.
HA-59
TROUBLE DIAGNOSES
Diagnostic Procedure 2 (Cont'd)
@
IJ]
lit
COI8ECT
(
\
00
Reconnect
push control unit and
mode door motor harness connectors.
IJ]
I~
[2J
Terminal
No.
CSZJ
RHA412A
(])
ffi
Stop
VENT
-- DEF
DEF
--VENT
Clockwise
Counterclockwise
O.K.
J
ffi 8
N.G.
HA-60
----------
TROUBLE DIAGNOSES
Diagnostic Procedure 3
SYMPTOM:
_r
IV
00
1
I;]
RHA414A
.eJ
dih
G/B
~
-=
~
Continuity should exist when
test leads are connected as
":"
[!]
RHA415A
m
CHECK POWER SUPPLY
FOR INTAKE DOOR
MOTOR.
Disconnect intake door motor
harness connector.
Do approx. 12 volts exist betWeen intake door motor harness
terminal No. @and body
ground?
I;]
O.K.
O.K.
N.G.
Note
[!]
O.K.
Replace control amp. built-in
push control unit.
'
[8E5J;i8]~ ij
00
~kill
Intake door
GI
motorconnector@Bf
r
,G/YIIQ
II
G~~~
,.
RHA898A
Note:
If the result is N.G. after checking circuit continuity, repair harness or
connector.
HA-61
TROUBLE DIAGNOSES
Diagnostic Procedure 4
Compressor
connector @-1
~ lit is
L/G
00
m
I
CHECK POWERSUPPLY
~
1!1
RHA416A
Thermal protector
connector @-2
1~i5~
B
FOR COMPRESSOR.
Disconnect compressor harness
connector.
Do approx. 12 volts exist betWeencompressor harness terminal No. @ and body ground?
1!1
[ill
"
RHA899A
N.G.
5
(Goto !)extpage.)
O.K.
CHECK THERMAL
PROTECTOR.
Disconnect thermal protector
harness connector.
Does continuity exist betWeen
thermal protector harness
terminal No. @ and body
ground?
O.K.
Check magnet clutch coil.
O.K.
Replace magnet clutch.
Refer to COMPRESSOR -
Model
HA~62
N.G.
Replace thermal protector.
TROUBLE DIAGNOSES
Diagnostic Procedure 4 (Cont'd)
m1
~ ~[
COIIIfCT
E)
For U.S.A.
A/C relay
L/G
Ii]
[Y]
LIG
181
II
rl;]or
L/G
Canada
~
_T
eJ
Ii]
LIG
Note
Check circuit continuity between AIC relay harness terminal No. @ and compressor
harness terminal No. @.
00
Compressor
connector
O.K.
A/C relay
connector @)
For U.S.A.
II
connector
42@)
For Canada
~LIG
RHA418A
m1
CIRCUIT AND10A
FUSE"
AT FUSE BLOCK.
Refer to "Power Supply
ROUNTING" in EL section
and AIC ELECTRICAL
CIRCUIT.)
RHA523A
IIISCIIIIIIECT
~eJ
00
A/C relay @)
conm.-
L/OR
~~~.A.
~
L/OR
N.G.
Replace AIC relay.
O.K.
Reconnect AIC relay.
RHA522A
iii
iii
~i)
II
((g~
unit
N.G.
O.K.
RHA419A
(C
(Go to next page.)
Note:
If the result is N.G. after checking circuit continuity, repair harness or
connector.
HA-63
TROUBLE DIAGNOSES
Diagnostic Procedure 4 (Cont'd)
B
[!1
[!1
E.C.C.S.controlunit
connector @
,
II
CIIJIIIT
tft\I
I
G/Y
Check circuit continuity between AIC relay harness terminal No.@ and E.C.C.S. control
unit harness terminal No. @.
43
III
fo1 CONNECTOR
II
RHA524A
~~i)
L/G
IJ
N.G.r::
Note
..
..
Check circuit continuity b etween E.C.C.S. control unit
harnessterminal No.@ and
thermo control amp. harnessterminal No. @.
O.K.
O.K.
00
D
&] [It
LGtB
i5 ~
"o,,~~
~
RHA900A
=u
'
IJ
II
ClUNIT
LtG
N.G.
IV
00
unit
II
Note
O.K.
~,
E C.C.E. control
unit connector
RHA420A
O.K.
44
101 COIMCTOR
II
RHA525A
II
Thermo control
6o~amp.
1,3
lit,
lu
00
connector
LGtB
Q,
(Go to next page.)
113
Push control
connector
unit
RHA901
Note:
If the result is N.G. after checking circuit continuity, repair harness or
connector.
HA-64
TROUBLE DIAGNOSES
DiagnosticProcedure4 (Cont'd)
D
II
[ill
~i5(
II
CHECK PUSH CONTROL
UNIT.
Does continuity exist between
push control unit terminals
No. @ and @?
Dual-pressure
switch connector
@)
[1t
~ij
~oo
lEEHEHB
III
lO.K.
RHA422A
III
N.G.
~i5
III
Note
/
I
O.K.
III
N.G.
CHECK DUAL-PRESSURE
SWITCH
O.K.
Continuity
exists: O.K.
RHA423A
U~
Dual-pressure
switch connector
LG/R @)
[it
-,
eJ
Note
O.K.
Ii
Note
O.K.I
N.G.
Replace fan switch.
RHA903A
Ii
'\
[ill
::-
RHA904A
Note:
If the result is N.G. after 'checkingcircuit continuity, repair harness or
connector.
HA-65
..
TROUBLE DIAGNOSES
Diagnostic Procedure 5
SYMPTOM: Illumination or indicators of push control unit do
not come on.
. Perform Main Power Supply and Ground Circuit Check
KNOB ILL.
)
/
ILL. VENT
RHA427A
'\
AIC
to repair"
/
Go to DIAGNOSTIC
PROCEDURE
5-1.
Go toDIAGNOSTIC
PROCEDURE
5-2. ...
Go to DIAGNOSTIC
PROCEDURE
5-3.
'\
0
Go toDIAGNOSTIC
PROCEDURE
5-4.
DIAGNOSTIC
PROCEDURE
5-1
N.G.
MINATION SYSTEMS
EXCEPT FOR A/C SYSTEM.
Do the other illumination come
on with ignition switch and
lighting switch ON?
CHECK IllUMINATION
SYSTEM.
Refer to illumination/Wiring
Diagram in E l section.
.O.K.
m
I
CHECK IllUMINATION
BULB.
Remove push control unit and
disconnect,harness connectors-.
Remove illumination bulb(s) and
check them.
N.G.
Replace illumination bulb(s).
O.K.
A
(Go to next page.)
HA-66
TROUBLE DIAGNOSES
Diagnostic Procedure 5 (Cont'd)
[E)
IV 00
[E)
~
"
A H A428A
O.K.
[I
[I
Note
N.G.
[ill
[It 15
I'R/Y
IEEEEmm00
::-
RHA429A
:/
'-
[ill
~i5
Push control unit
connector
~
~
Go to Diagnostic Procedure 4.
O.K.
of
N.G.
Replace control amp. built-in
push control unit.
Note:
If the result is N.G. after checking circuit continuity, repair harness or.
connector.
HA-67
TROUBLE DIAGNOSES
Diagnostic Procedure 5 (Cont'd)
DIAGNOSTICPROCEDURE5-3
_IIECT
~ eJ 00
~n
~!
RHA431A
I!)
~i5~
[JlJ
I!)
IEHBHEBI
::
RHAB96A
O.K.
N G r-
..\
. . Check
10t fuse at fuse block.
(Referto 'POWERSUPPLY
ROUTING" in EL section and
AIC ELECTRICALCIRCUIT.)
Note
----
Note:
If the result is N.G. after checking circuit continuity,
connector.
HA-68
repair harness or
TROUBLE DIAGNOSES
Diagnostic Procedure 5 (Cont'd)
DIAGNOSTIC PROCEDURE 5-4
~ij~
[ill
IEHffiHEI
RHA896A
Note
Note:
If the result is N.G. after checking circuit continuity,
connector.
HA-69
repair harness or
TROUBLE DIAGNOSES
Electrical Components Inspection
FAN SWITCH
Check continuity between terminals at each switch position.
2 I 3 I 4
RHA399A
BLOWER MOTOR
Confirm smooth rotation of the blower motor.
Ensure that there are no foreign particles inside the intake
unit.
BLOWER RESISTOR
Check continuity between
Coh"h";"
oh~k
HA- 70
terminals.
TROUBLE DIAGNOSES
..
'-In
Push control unit I: ~~
'rY
.,
connector
~~
LElJ
~
Switch condition
AIC
DEF
ON
ON
ON
OFF
OFF
ON
Terminal No.
Continuity
Yes
RHA469A
DUAL-PRESSURE SWITCH
High-pressure side line pressure
kPa (kg/cm2, psi)
Operation
Continuity
Turn OFF
Turn ON
Exists
Decreasing to
177 - 216 (1.8 - 2.2, 26 - 31)
Increasing to
2,452 . 2,844 (25 . 29, 356 . 412)
Increasing to
177 - 235 (1.8 - 2.4, 26 - 34)
Decreasingto
1,863 . 2,256 (19 . 23, 270 - 327)
1i
i
THERMAL PROTECTOR
Temperature of compressor
c (oF)
Operation
Turn OFF
Turn ON
HA-71
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
I
Thermo
II I
Voltmeter
II I
control
THERMO
~I~/G
AMP.
amp. connector
~)
)
~1
CONTROL
1111
II
II
1---------
Thermo amp.
operation
Tester
Turn OFF
Approx.12V
Turn ON
Approx.OV
A/C RELAY
~
For U.S.A.
SHA128C
THERMOSWITCH
[ill
Water temperature
c tF)
Operation
Continuity
Decreasingto
CD
85 - 91 (185 - 196)
Turn OFF
Thermoswitch
Increasing to
92 - 98 (198 -208)
Turn ON
Exists
~connector
~_"CT
~eJ
SHA129C
HA- 72
(S.D.S.)
General Specifications
LUBRICATION
~MPRESSOR
ATSUGI meke
Model
Displacement
Direction
cm'
(cu inllRev.
of rotation
ATSUGI make
Model
NVR 140S
Type
OIL
Vane rotary
Type
140 (8.54)
Capacity
NVR 140S
SUNlsa 5GS
Clockwise
200 (6.8,7.0)
Drive belt
Poly V
Approx.
100 (3.4,3.5)
200 (6.8,7.0)
REFRIGERANT
R-12
Type
Capacity
Inspection
and Adjustment
Model
NVR 140S
BELT TENSION
..
COMPRESSOR
kg (lb)
mm lin)
0.3 -0.6
(0.012.0.0241
'--...
HA-
73
~~
ELECTRICAL
SYSTEM
EL
SECTION
CONTENTS
HARNESS CONNECTOR...
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .'. . . . . . . . . . . . . . . . . . EL- 2
STANDARDIZEDRELAY.................................................
POWERSUPPLYROUTING...............................................
BATTERY.. .,. . .. . ., . . . . .. ... .. . ..
. .. . .. . . .. .. . . .. . . . . . .'. . . . .. . . . ..
STARTINGSYSTEM.....................................................
STARTINGSYSTEM-Starter '...
CHARGINGSYSTEM
.....................
CHARGING SYSTEM -Alternator -........................................
COMBINATIONSWITCH..................................................
HEADLAMP
EXTERlOR LAMP
';"""""""""""""""""
~..................................
;"
~.
. .. .. . . .. . . . . .. . . . . .. . . .
INTERIORLAMP
METERAND GAUGES...................................................
WARNING LAMPS AND CHIME
...................................
SUPER MULTIPLEJUNCTION(S.M.J.)
..~ ..
.,/t.;. . .\ . . .
"
EL- 3
EL- 5
EL- 7
EL- 15
EL- 17
EL-.23
EL- 25
EL- 33
EL- 35
EL- 46
EL- 52
EL- 54
EL- 61
EL- 65
EL- 75
EL- 81
EL- 82
EL- 85
EL- 88
EL- 97
EL- 99
EL-117
LOCK-UP
CONTROL. . . . . . . . . . . . . . . . . . . . . .
Q.D.CONTROL.
........................
AT SECTION
AT SECTION
ELECTRIC DOOR MIRROR,SUN ROOF, DOOR LOCK,
POWER WINDOW AND AUTOMATIC SEAT BELT. . . . BF SECTION
HEATER AND AIR CONDITIONER.
. . . . . . . . . . . . HASECTION
I!II
~ARNESS
CONNECTOR
'----
Description
HARNESS CONNECTOR
All harness connectors have been modified to prevent accidental looseness or disconnection.
The connector can be disconnected by pushing or lifting the locking section.
.
.
CAUTION:
the connector.
[Example]
LIFT
PUSH
~
PUSH
PUSH
$J
PUSH
/'
PUSH
(For combinetion met...)
(For r.l.y)
SEL769D
EL-2
STANDARDIZED RELAY
Description
NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS
Relays can mainly be divided into three types: normal open, normal closed and mixed type relays..
Flows
u.
u.
9
Does not
flow Q I
Flows
=
Does not c:>
flow
I =
::>
IL'
BATTERY
SW 1
BATTERY
BATTERY
Does not
flow
-1'""1
sw 1
0
SW 1
BATTERY
Does not
flow
I.-J
SW 1
BATTERY
Flows
0
SW 1
II
s
SW 1
I'
BATTERY
SEL881H
1 Make
1 Transfer
2M
1M.l B
2 Make
1 Make 1 Break
2M
1M
1M
2M
,--- r',
,.
," (
'.
...
...
~~),
----
"
lM.1B
1T
1T
I
I
\
'I'
'
?---
...
'-r,
'
t 0','-
\
I
,'
'
:
\
I
I
1'
1B
\
~
1\
\
"
,\
"
1M
SE L882H
EL-3
STANDARDIZED RELAY
Circuit
Outer view
Type
Connector symbol
and connection
Casecolor
"<V
BLACK
1T
t:==I
1M
BLUE
@
<ZL
<D@@
=
BROWN
2M
@
CD
GRAY
1M.1B
SEL883H
EL-4
/--~
I
2
3
4
5
Bulb
""H
I-I
...
.-
Sh I ft
..,c
...
l'fl'l
JON
@,
lac k
~::II
~
'" '"
I
~'"
.,~ ~
~ ci'
~
@~
"'
~!
~~
,
'"
@
IQ:W~L
(Blue)
W~B~
IQ:W~B
AII' conditioneI'
@(B s. Iac
M.J.k)@)
[Refer to I ast page
(Fa Idout page).]
Head Iamp R. H.
fog
Horn.
A. S. C. D.
L/W-
Rea
was
lamp
L
Bn
B/R
L/R
U1
Ciga
l/OR-
Heat
.~
FUSE
BLOCK
E1'
Ell
FII
Fl'
-R/B
-
@)
(@)
.l
U.f
r=r
"~...
'"
'"
~."
-c
:J(I)
"
rn
m
ren
....
Q)
s:
. ~o
~
~
~@~@
FUSE
0(1)
"~~
Rn
G/l
m
;>J
m
r-z
0
-<."
tDC
x~tD
:;;@)
r-
...",
~@ ~@
"''''
'"
~
--
BATTERY
Win
OR/B-
t~~ ~ IBlo
Head Iamp L H.
Front
Tur
Hea
Tim
Rea
Met
crys
",
(@)
W~L~
GROUND
Me
disp
Aut
con
L -
'" ~
@
~.
I11R?1I @fIR:iJ
...
33
~ ~1 '" '""''''
~~~
1>\
\SJ (!---,;w
A. S
G/W-
lG
BODY
m
r-
"''''1''
RELAY- \,-
relay
--
G/Y
~~
@)~@)
swl tCh/
Retract
LAY
contra I u~ if"
RE
I GNITI ON
IIIIIIi r,."
''''
T
!\W1@i)1WJ
~ '" r.;;;;-,
Fue I pump.
All' regulator
Key
CheCk
relay
ACCESSORY
OFFACC ON ST
0 0
0 0
0
~~
CJ RCUJ T BREAKER
..
n
U3
~;
@@j)~
BODY
GROUND
34
SB
G/R
--
OR G/l -
IRe
Jnte
~~~
chim
cont
cont
belt
Stop
unit.
Haza
Head
Not
Exter
Lice
Illum
Head
unit
E. C
Bac
A/T
cont
A. B
O.K.
Fuse
a. If fuse
Blown
SEL954J
Fusible Link
SEL387L
15
20
30
35
40
Brown
Green
Red
Black
Gray
*Temperature condition:
El-6
BATTERY
CAUTION:
a. If it becomes necessary to start the engine with a booster
battery and jumper cables, use a 12-volt booster battery.
b. After connecting battery cables, ensure that they are tightly
clamped to battery terminals for good contact.
c. Never add distilled water through the hole used to check
specific gravity.
SEL711E
/
SEL712E
Hydrometer
SEL442D
EL-7
BATTERY
How to Handle
Battery
CHECKING ELECTROLYTE
WARNING:
'\
(Cont'd)
LEVEL
.
.
SELOO1K
Charging
voltage
1
Charging current
~
"-'
Normal battery
Sulphated
battery
Charging
voltage
SEL709E
SPECIFIC GRAVITY
SULPHATION
When a battery has been left unattended for a long period of
time and has a specific gravity of less than 1.100, it will be completely discharged, resulting in sulphation on the cell plates.
Compared with a battery discharged under normal c.onditions,
the current flow in a "sulphated" battery is not as smooth
although its voltage is high during the initial stage of charging,
as shown in the f~gureat the left.
CHECK
SE L442D
EL-8
BATTERY
How to Handle Battery (Cont'd)
Hydrometer ~I~
/'
TI"~o-'
SEL710E
Converted
specific gravity
(5201
1.30
en
1.28
II
1.26
II
Q
1.2"
I!
E
>
1.22
eti
1.20
..-
1.18
II
..
?;
'>
..
;;.
.!:!
'u
II
Q
I/)
1.16
1.1"
1.12
1.10
-30
1-221
-20
1-"1
-10
11..1
0
1321
Electrolyte
10
1501
20
1681
temperature
c (0 F)
SE L042D
_/
EL-9
BATTERY
~
Chart I
VISUAL INSPECTION
. Check battery case for cracks or bends.
. Check battery terminals for damage.
. If the difference between the max. and min. electrolyte level in cells is within 10 mm (0.39 in),
it is O.K.
N.G.
O.K.
Replace
SLOW CHARGE
Refer to "A: Slow
Charge" .
STANDARD CHARGE
Refer to "B: Standard
Charge" .
CAPACITY TEST
Refer to "Chart II".
O.K.
Reacty
for use
battery .
Charge" .
CAPACITY TEST
Refer to "Chart II".
N.G.
Replace
battery.
CAPACITY TEST
Refer to "Chart II".
Ready
for use
. "STANDARDCHARGE" is recommended in -
N.G.
Ready for use
. Mount battery again
and check loose ter.
minals. Also, check
other related circuits.
RECHARGE
Refer to "C: Quick Charge".
.If battery temperatUre rises above 60C
C14O"F), stop charging. Always charge
battery when its temperatUre is below
60C (140FI.
O.K.
CAPACITY TEST
Refer to "Chart II".
QUICK CHARGE
Refer to "C: Quick
N.G.
Replace
battery.
EL-10
QUICK CHARGE
Refer to "C: Quick
Charge" .
. Time required: 45 min.
CAPACITY TEST
Refer to "Chart II".
O.K.
Ready
for use
N.G.
Replace
battery.
BATTERY
Battery Test and Charging Chart (Cont'd)
Chart II
1//
Check battery
type and
Fig. 1 DISCHARGING
(load tester)
Test using battery
checker.
Follow manufacturer's
instructions
when specified
to check and
determine if battery
serviceable.
O.K.
Ready for use
discharging
is
N.G.
Go to next step.
CURRENT
Type
Current (A)
28B19R(l)
34B19R(l)
46B24R(l)
55B24R(l)
50D23R(L)
55D23R(l)
65D26R(l)
80D26R(l)
90
99
135
135
150
180
195
195
75031 R(L)
95031 R(L)
95E41 R (l)
130E41R(L)
210
240
300
330
Go to next step.
~~
..
0
6010
SE L697 B
/"
EL-11
BATTERY
.~
Battery
Chart (Cont'd)
A: SLOW CHARGE
Fig. 2 INITIAL
CHARGING
TYPE ==
==
BATTERYT
a:a:
0101
- IDID
4.0
(A)
Below 1.100
. Charge battery.
. Check charging voltage 30 minutes after
starting the battery charge.
.
.
CURRENT
SETTING
(Slow charge)
:i
:i:i
:i:i
:i:i
:i
a:a:
:i:i
a:a:
a:a:
a:
a: a:
NN
00
1n0
<OlD
M
0
In
M..,.
Ow
In In
.....
0101
8.0
(A)
9.0
(A)
..,...,.
NN
IDID
<01n
..,.In
MM
NN
00
Oln
Inln
5.0
7.0
(A)
(A)
<0<0
a:
- -
10.0
(A)
..,.
W
14.0
(A)
N.G.
Below 1.150
Above 1 .240
1 .1 50 - 1 .200
Replace battery.
Continue to charge for
12 hours.
Charge for 5 hours.
at initial charging
current setting.
TEST".
CAUTION:
Conduct additional charge as per
Fig 3. if necessary.
Go to "CAPACITY
TEST".
a.
d.
EL-12
BATTERY
Battery
B: STANDARD
~
Fig.4
CHARGE
TYPE ::;::;
a:a:
mm
CDNVERTED
Determine
specific
initial charging
gravity. referring
current
Conduct
additional
alai
::;::;
a:a:
::;::;
::;::;
NN
alai
COLtl
VLtl
NN
00
OLtl
vv
a:a:
MM
LtILtI
a:a:
coco
NN
00
LtlO
COal
::;
::;::;
M
0
"''''
a:
LtI
,..
a:a:
Mv
Ow
mm
LtILtI
GRAVITY
to Fig. 4.
......
SPECIFIC
from
Chart (Cont'd)
::!
a:
1.100 -1.130
4.0 (A) 5.0 (A) 6.0 (A) 7.0 (A) 8.0 (A) 9.0 (A) 13.0 (A)
1.130 -1.160
3.0 (A) 4.0 (A) 5.0 (A) 6.0 (A) 7.0 (A) 8.0 (A) 11.0 (AI
1.160-1.190
2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A) 6.0 (A) 7.0 (A) 9.0 (A)
1.190 - 1.220
2.0 (A) 2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A) 5.0 (A) 7.0 (A)
charge as per
Fig. 5. if necessary.
TEST"
Above 1 .240
Go to "CAPACITY
TEST".
CAUTION:
a. Do not use standard charge method on a battery whose specific gravity is less than 1.100.
b. Set charging current to value specified in Fig. .4. If charger is not capable of producing specified current
value, set its charging current as close to that value as possible.
c. Keep battery away from open flame while it is being charged.
d. When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this
may cause a spark.
e. If battery temperature rises above 60C (140 F), stop charging. Always charge battery when its temperature is below 60 C (140 F).
EL-13
BATTERY
Battery
C: OOICK CHARGE
Fig.6
Chart (Cont'd)
:J:J
a: a:
mm
--
:J:J:J
Iilili
VvM
:J:J:J
:J:J:J
a: a: a: a: a: a:
MCOCO
NNN
IDIDO
coono
vonon
onono
onCOID
on on on
r-mm
10 (A)
15 (A)
20 (A)
30 (A)
IDv
NM
NNN
000
---
IDID
MMv
Oow
1.100-1.130
2.5 hours
1 . 130 - 1.160
2.0 hours
1.160 - 1.190
1.5 hours
1.190-1.220
1.0 hours
Above 1.220
:J
a:
;W
!i!
-
40 (A)
Charge battery
Go to "CAPACITY TEST".
.
.
Check battery type and determine the specifiedcurrent using the table
shown above.
After starting charging.adjustment of chargingcurrent is not necessary.
CAUTION:
a. Do not use quick charge method on a battery whose specific gravity is less than 1.100.
b. Set initial charging current to value specified in Fig. 6. If charger is not capable of producing specified
current value, set its charging current as close to that value as possible.
c. Keep battery away from open flame while it is being charged.
d. When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this
may cause a spark.
e. Be careful of a rise in battery temperature because a large current flow is required during quick-charge
operation.
If battery temperature rises above 60C (140 F), stop charging. Always charge battery when its temperatu re is below 60 C (140 F).
f. . Do not exceed the charging time specified in Fig. 6, because charging battery over the charging time can
cause deterioration of the battery.
Service
Applied area
Type
CapaciW
V-AH
(S. D. S.)
U,S.A.
Canada
55D23R
65D26R
12-60
12-65
EL-14
STARTING SYSTEM
MfT MODEL
Wiring Diagram
INTERLOCK
IGNITI
ON
CLUTCH
SWITCH
1
2
3
4
5
OFFACC ON ST
:J
0
:J
WI
~@Y
~~
'"
Q<f? ~"
~>-
"
"''''
W@
~(@)
~
~~
"
",0:
'"
'"
~'"
'"
@)ft@)
BODY
(Eng i ne
harness)
room
GROUND
@)@)
~8/Y...o,.0
"O-8/Y
~8/W-'Q'
@,
For
@),
For Canada
U. S. A.
(Eng i ne
harness
room
no. 2)
>-
,'"
@)g
@.?)O
FUSI BlE
LINK
888 88J
cr:=::o cr:=::o
~M
FUSE
BATTERY
(ill)
STARTER MOTOR
SEl466L
AfT MODEL
INHIBITOR
IGNITION
SWITCH
1
2
3
4
5
SWITCH
N IP
OFFACC ON ST
:J C
()
WI
~@Y
~~
~@
'"
~@)
~~
....
(Eng Ine
harness)
@)1f2W
~
room
en ~
8/Y-o' "O-8/Y
(Eng I ne
harness
room
no. 2)
]
~
FUSI BlE
LINK
>-
,
'"
@)Q
@.?)O
888 88J
cr:=::o cr:=::o
lINK
8/R
FUSE
(ill)
SA HERY
STARTER
MOTOR
SE L67BM
EL-15
N.G.
Check Fuse and Fusible link
I
Does starter
motor
No
turn?
O.K.
.1
VIS
Replace
.
.
N.G.
Ch
Re
batt
O.K.
Check pinion rollar clutch for damage.
Replace if necessery.
N.G.
Check wir ing of starting
Repair
. Ign
. Clut
swit
. Star
. Con
system.
O.K.
Check reduction geer. armature and gear
shaft for damage.
Replace if necessary.
Rep
Ves
m
r-
Is meshing condition
gear O.K.7
....
0')
N.G.
Adju
Che
retu
for
Cor
and
O.K.
Ves
N.G.
.,
Ch
and
Re
Ch
Re
O.K.
Does engine turn by replacing
motor with a new one7
starter
Ves
Repair or replace starter motor.
No
i
<Che
If an
~:on
Adjusting plate
Plate thickness:
0.5 (0.020)
0.8 (0.031)
Dust cover
6.4-8.3
~.~
'
IEI@
@
Spring
~m
L J~
r-
I
~
'"
Pinion assembly
Brush holder
Washer
\\ ~
~~"
ro~
/
Lrmature
c<.w bn."k..(A)
en
I!J
Unit:
:
;:
lEI
Yoke assembly
mm Iinl
: N'm
: High-temperature
(kg-m.
ft-Ib)
grease points
Throug h-bolt
4.9-6.4
Adjusting plate
Plate thickness:
0.25 (0.00981
0.50 (0.01971
Magnetic
switch assembly
Packing
Sleeve bearing
mCBJ
m
~I
-'
CO
mCBJ
Gear case
Pinion assembly
Brush
Pinion stopper
Stopper
Brush (+)
clip
Armature
mCBJ
~
[;;
~m
Unit: mm (inl
co:J : N'm (kg-m. ft-Ibl
CBJ: High-temperature grease point
STARTING SYSTEM
Starter
/
Magnetic Switch Check
..
1.
.
Ohmmeter
QJ
SEL036H
SEL038H
Pinion/Clutch Check
1. Inspect pinion teeth.
Brush Check
BRUSH
~-
Vernier
caliper
SEL626B
EL-19
STAFtTING SYSTEM
;
Starter
M1T72781
BRUSH HOLDER\
-.
.
.
SEL568B
S114-519A
\
.SEL558E
Armature Check
1. Continuity test (between two segments side by side).
No continuity... Replace.
Ohmmeter
SE L625B
SEL 104E
EL-20
STARTING SYSTEM
- Starter -
'.
Commutator
SEL418A
u""'"'",..OC"'"'..~
0.5 . 0.8 mm
Round
10.020.0.031
inl
Correct
-e=\.
Commutator
~~Old
Incorrect
EE021
Assembly
Apply high-temperature
grease to lubricate the bearing,
and frictional surface when assembling the starter.
Carefully observe the following instructions.
8 Gear case metal
8 Moving portion of shift lever
8 Plunger of magnetic switch
8 Internal gear
8 Planetary gear
8 Shaft
EL-21
gears
STARTING SYSTEM
Starter
Assembly (Cont'd)
PINION PROTRUSION
Switch
I Battery
-'-
SE L299E
Adjusting
LENGTH ADJUSTMENT
Clearance
plate
"Q"
SEL633B
Type
(S.D.S.)
S114-519A
M1T72781
HITACHI make
MITSUBISHI make
Applied model
System voltage
12
No-load
Terminal voltage
11.0
Current
Revolution
A
rpm
Less than 85
More than 2,750
50 -75
-4,000
3,000
32.0 (1.260)
28.8 (1.134)
11.0 (0.433)
12.0 (0.472)
17.7-21.6
(1.8 - 2.2,4.0 - 4.9)
13.7 -25.5
(1.4 -2.6,3.1 -5.7)
0.2 10.008)
0.3 -1.5
(0.012 - 0.059)
0.5-2.0
(0.020 - 0.079)
EL-22
N (kg, Ib)
RELA Y BOX)
G1 G1"
LINK
FUSE
G1
a::::::IJ
..'"
:(:(
BULB CHECK
RELAY
IGNITION SWITCH
ON or START
1rinrrnr
FUSIBLE
(ill)
@J
@)~..:(
WI
[D-w
::-
;j
""
'"
@])@
BATTERY
(Eng ine room
harness)
(Ma in
harness)
BR~BR
W/R~W/R
S. M. J.
ffiefer to last page
(Fo Idout page). J
rI
N
W
~
'"
I
@~II~P4111
IIII
(Black)
QD~llfbdlllI
IlIl
,'"
:(
,'"
:(
J:1~
i@
BODY GROUND
:(
@c;9
@9~
(@)~
..:(
:(
~@)
we
~@])
:(
,'"
:(
QDG1
[!::I:Em
@V
ij
B
rJJ
m
r
(IT
CD
~
~
<eo- B
<eo- w
rB=W~R
ALTERNATOR
~:
~:
With
head-up
Without
display
head-up
display
O::HHH:
I 7 o----@---ol
CHARGE
COMBINATIO
.~
CHARGING SYSTEM
Trouble-shooting
Bef~re conducting an alternator test, make sure that the battery is fully charged. A 3D-volt voltmeter and
suitcible test probes are necessary for the test. The alternator can be checked easily by referring to the
Inspection Table.
Before starting trouble-shooting, inspect the fusibl~ link.
WITH IC REGULATOR
@
Ignition
switch "ON"
With alternator
side L terminal
grounded,
internal short occurs
when + diode is short-circuited.
Burned-out
bulb. Replace
and Proceed
to "A".
Disconnect
connector
(5.
U and ground
L lead wire.
I
I
I
I
Dim light
Light fl ickers
Bright light
IorDamaged
IC-RG
A.C.G.
I (MITSUBISHI
:~a~e~
Check or replace
drive belt.
Engine
- ~Damaged IC-RG.
Replace.
idling
Engine speed:
1 ,500 rpm
Lighting
switch "ON"
Engine speed:
1 ,500 rpm
(Measure B
terminal voltage.)
1)
2)
SEL766D
5)
EL-24
-- --E.
CHARGING SYSTEM -
Alternator
Construction
Front
cover
Rotor
*Rear bearing
~,:;~(
Front bearing
"
Condensor~
~K~.
~--
A 3.1-3.9
10.32- 0 40
-," -'->-
.'-./,
hrOU9h-bOlt
..,-.
'
i--
. .2.3. 2,91
Rear cover
8,",h
"_bS-
A2T14094
Rotor
I~~
IC voltage
assembly
regulator
A:
Stator
t:>
N'm Ikg-m.ft-Ib)
SEL695L
*Rear bearing
CAUTION:
Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. Be careful not to
'
EL-25
CHARGING SYSTEM -
Alternator
Disassembly
REAR COVER REMOVAL
CAUTION:
Rear cover may be hard to remove because a ring is used to
lock outer race of rear bearing. To facilitate removal of rear
cover, heat just bearing box section with a 200W soldering
iron.
Do not use a heat gun, as it can damage diode assembly.
SEL628D
Ohmmeter
Ohmmeter
Replace rotor.
2. Insulator test
SE L630D
Brush Check
1. Check smooth movement of brush.
Not smooth ... Check brush holder and clean.
SE L631 D
2 mm 10.08 inl
Spring pressure:
Refer to S.D.S.
Not within the specified values ... Replace.
E E049
EL-26
ap-
CHARGING,SYSTEM
Stator
AI.ternator
Check
SE L587
[MITSUBISHI make]
Long nose pliers
used as a heat sink
[HITACHI
make]
1. Continuity test
. No continuity... Replace stator.
[MITSUBISHI make]
EL-27
CHARGING SYSTEM
Alternator
Continuity
SE L384L
EL-28
exists.
'" Replace
stator.
-~
CHARGING SYSTEM -
Alternator -
Diode Check
/
MAIN DIODES
Continuity
Negativee
Diode terminals
Yes
Diode terminals
No
Diode terminals
No
Diode terminals
Yes
[HITACHI make]
[MITSUBISHI
make]
Sub-diodes
Negative diode
plate
SE L768D
EL-29
Positive
diode plate
Diode terminals
SEL385L
CHARGING SYSTEM
--~
Diode
Check
Alternator
(Cont'd)
SUB-DIODES
[MITSUBISHI make]
.
.
SE L494H
[HITACHI make]
(~:1
\ !I
{(
,J
~
.~
(- J
1/)
;'//.'
/.-
.
.
- (]Do
~
.4..L c--
Assembly
Carefully observe the following instructions.
When soldering
each stator
WHEN SOLDERING
[MITSUBISHI make]
Position brush so that its wear limit line protrudes 2 mm
(0.08 in) beyond end face of brush holder.
Wear
limit line-,
SEL386L
[HITACHI make]
(1) Position brush so that it extends 10.5 to 11.5 mm (0.413 to
0.453 in) from brush holder.
SEL595A
EL-30
CHARGING SYSTEM
Alternator
Assembly (Cont'd)
(2) Coil lead wire 1.5 times around terminal groove. Solder
outside of terminal.
When soldering, be careful not to let solder adhere to
insulating tube as it will weaken the tube and cause it to
break.
Soldering points
/
After soldering.
place insulating tube
on terminal.
1 mm 10.04 inl
SE L596A
EL-31
CHARGING SYSTEM
-"-
Alternator -
Type
LR180-715
A2T14094
All
Applied model
Nominal rating
V-A
12-80
Groung polaritY
Negative
Alrpm
mm (in)
6.0 (0236)
8.0 (0.315)
N (g, oz)
1.471 - 3.334
(150 -340,
5.29 - 11.99)
3.040 -4217
(310-430,
10.93 -15.17)
26.8 (1.055)
22.1 (0.870)
EL-32
14.1 -14.7
COMBINATION SWITCH
Check
Variable
intermittent
wiper switch
----
TURN SIGNAL
R
{[
LIGHT
WASH
n:,(j
"
2nd
OFF
HI
<}
L
For wiper
switch
LIGHTING
QFF
A B CA
5
0
0
6
7
8
0
0
9
10
11
12
25
26
27
For A.S.C.D.
and Horn
For lighting
switch
INTERMITTENT
WIPER VOLUME
SWITCH
1
2
B C A B C
100
22
4
rq II
RNL
OO
HORN SWITCH
.Q.
2
3
TURN
SIGNAL
SWITCH
28
SEL388L
EL-33
,~
COMBINATION SWITCH
Replacement
Wiper and
washer
switch
.~
,
Lighting switch
SEL389L
Attaching screw
SE L390L
EL-34
FUSE
~
I~A
TTERY
-0
RETRACTOR
SWITCH
OFFI
RETRACT
RELAY-4
ON
6
I~
<;>
...
I--
@5
RETRACT
RELAY-l
f--
,---
inat
RETRACT
RELAY-3
.--vm=;:
[of
~OJ
..L-
i I Ium
system
r1S
-=-
.-
To
I r+- }
RE TRAC
T
-=-
RELAY-2
m
rI
W
(J'I
-l--
cnc
::Err
~~
~rr,
nn
:r~
, ~
Z
G1
~ ~~--
l
-~,
1I
~D~W~ ~P~
4'~
3
G1
5'
..L
-=-
HEADLA~P
m
r
MOTOR L.H.
-~~
HEADLAMP
MOTOR
~!
~
R. H.
t1!
:~f*
@t,
>
1-
-~O~N
~ ~ ~~
[L1J
IS
~- --d,~~~
~U~
4
3
--4--
---
<
<
I
I
L--
HEAD LAMP
TIMER
-~
HEADLAMP MOTOR R. H.
RETRACT
RELAY-]
(D
RETRACT
RELAY-2
RETRACT
RELAY-3
RETRACT
RELAY-4
iii[l@~
~@)
..
..~
~
~@)
..
~@)
c..
rftl@
~~
..:~ ~~
~~~
".
.. .....
HEADLAMP TJ MER
RETRACTOR
SWI TCH
~> ~~~:"
..:~
OFF ON
1 a
2 a
3
4
5
6
B
1.1
@ -~@)
~,,~~~..~~~~ ~~
".
~.. ..
jj
To
Illumination
system
O~
m
r-
HEADLAMP
R. H.
en
rE~?LAMP
~
~
HEADLAMP MOTOR L. H.
BR/W
PU/W
OR
B
BR
EA
PU
'iff!:2
BR
-mBR/WOR
@)
P/B
~G/l
't}: R/G
@
~G/Y
@])@)
OR
P/B
P/B
R/G
BR/Y
R/l
G/R
R/B
OR/B
58
BR
PU
BR/W
BR/Y
....
(Eng I ne
harness)
~R/B
room
BR/Y
E2
FI
"'
01
A2
AS
C3
Cl
El
02
F2
..
B2
Bl
A'
C'
C'
C2
BR
PU
EA
ORBR/W m
OR
P/B
P/B
R/G
BR/ Y .ffi
R/l
G/R
R/B
OR/B
'B
SR
PU
BR/W""
8R/Y
(Ma i n harness)
S. M. J.
ffiefer to last page
(FoIdout page). ]
(D1.~P:f
cc
..,,"''''
..,".
......
~@!)
Ii
LIGHTING
SWITCH
FUSE AND
FUSI BLE LI NK
(J n RELA Y BOX)
[3[
s:
'" "''''
~~@)
FUSE
@
en
m
r
UI
CIO
UI
'"
~~
BATTERY
Ii
@)@)
BODY
GROUND
HEADLAMP
Description
BASIC OPERATION
Operation
Cond ition
Lighting switch
Retractor switch
OFF
1ST
OFF
1ST
2ND
OFF
2ND
1ST
OFF
1ST
OFF
OFF
Momentarily turned
to PASSING
OFF
*: Referto
C/O*
Headlamp motor
No operation
[A)
Open
Headlamps
OFF
ON after headlamp motor reaches
fully open position.
OFF
[B)
Closed
OFF
OFF
[C)
ON
[D)
Open
CIRCUIT OPERATION.
EL-37
HEADLAMP
Description (Cont'd)
CIRCUIT OPERATION
[A]
When lightingswitch is switched from "1ST"
A-1:
"2ND"
To Illumination
system
RETRACT
RELAY-4
RETRACT
RELA Y-3
RETRACT
RELAY-!
RETRACT
RELA Y-2
""
..."
0"
c-"
.m
I
--.J
~~
MEADLAMP
MOTOR L. H.
A-2:
7!J
'
,,>
.~"
"
"'"
~~
':">
~~
ij"
""
---~
HEADLAMP
Tl MER
HEADLAMP
MOTOR R. H.
SEL657L
To
Illumination
J system
RETRACT
RELA Y- 4
RETRACT
RELAY-3
RETRACT
RELAY-!
RETRACT
RELAY-2
""
..."
0"
~
'"
...m
""
"
I
~~
HEADLAMP
MOTOR
L. H.
~!J
HEADLAMP
TIMER
HEADLAMP
MOTOR R. H.
SEL658L
EL-38
HEADLAMP
Description
[B]
(Cont'd)
"OFF"
To
Illumination
} system
RETRAC
RELAY-4
T
LI GHT! NG
SWI T CH
0
RETRACT
RELAY-3
RETRACT
RELAY-I
RETRACT
RELAY-2
..~
I
r~
.m
~
.~
.
I
HEADLAHP
HEADLAHP
MDTDR
L. H.
[C]
C-1:
TIHER
_.~
+oJ
"..
"'~
;,~
.0
r
""
r~
~~
..
;:~
""
..
HEADLAMP
MOTOR
R. H.
SEL659L
To Illumination
} system
RETRACT
RElAY-4
RETRACT
RELAY-3
RETRACT
RELA Y-I
RETRACT
RELAY-2
.
I
--.J
.:J
HEADLAMP
MDTDR
L. H.
HEADLAMP
MOTOR
R. H.
r~
.m
~
.~
"'~
;,~
.~
"
..~
r~
~~
..
;:~
..""
..
SEL660L
EL-39
HEADLAMP
Description (Cont'd)
C-2:
To Illuolna<lon
system
RETRACT
RELAY-'
RETRACT
RElAY-3
RETRACT
RELAY-I
RETRACT
RElAY-2
r",
O~
~
r:::
..""
..
HEADlAHP
HDTDR
l.
[D]
~!J
H.
L-_~HEADlAHP TI
HER
HEADlAHP
HDTDR R. H.
SEL661L
To Illumlna<lon
systam
RETRACT
RELAY-'
LIGHTING
SWI TCH
Oi
IIi
RETRACT
RElAY-'
RETRACT
RElA Y-I
~~
r",
O~
r~
I
I
--.J
HEADlAMP
HDTDR
l.
~!J
H.
HEADLAHP
T)MER
HEADlAMP
HDTDR R. H.
'
~~
':e
~
~
'm
".
.:e
"~
'"
rm
..
~"
--_=:J
SEL662L
EL-40
HEADLAMP
\
-" ...~tin"e.
Lid
Lid can be removed
Headlamp motor
. Headlamp motor should
be removed together with
the headlamp bracket as
an assembly.
\-~:w,
1---
Link B
-~
~-~-
c::=
~
Headlamp bracket
~
~
Finisher
SEL391 L
!I
EL-41
HEADLAMP
Assembly
1. Install headlamp motor, ball joint and link A (as one unit) on
headlamp bracket.
2. While turning link S, install link A's ball joint on headlamp
housing's ball joint.
3. Set distance between centers of upper and lower ball joints
as shown in figure at left, and tighten lock nuts.
4. Assemble head lamp, finisher and lid.
SEL392L
Lock nut
Motor side
SEL393L
Approx.
6.8 (0.2681
Approx.6.0
(0.236)
I,
Approx.6.0
(0.236)
~~I
Unit: mm (inl
SEL394L
lllllllllllli I
---------
-----------
LLLlLlllll[
lllll.
Ill llllll
\.\.\.\\\\\\\,,~
Adjust lid, hood and fender for alignment while opening and
closing headlamp with motor manual knob.
Use motor manual knob to open and close headlamp, and
adjust alignment while checking that lid is not interfering
with hood.
lLLllLlllllllllllllllll
SEL395L
~-
~~_isflush.
Ad;""ro,,4
S~L396L
EL-42
HEADLAMP
Installation and Adjustment (Cont'd)
3. Adjust stopper.
1) Loosen lock nut on stopper.
2) Turn motor manual knob to open headlamp assembly completely.
3) Adjust stopper screw.
LSE L399 L
Up
SEL495G
Press the rubber cap firmly so that the lip makes contact with
the head lamp body.
Press
Bulb
SEL841 H
EL-43
HEADLAMP
Aiming Adjustment
When performing headlamp aiming adjustment, use an aiming
machine, aiming wall screen or headlamp tester. For operating
instructions of any aimer, it should be in good repair, calibrated
and used according to respective operation manuals supplied
with the unit.
If any aimer is not available, aiming adjustment can be done as
follows:
For details, refer to the regulations in your own country.
-----CAUTION:
WL = 1.067
.
.
(42.01)
lamp centers I
I"':
7lZ.
~pper
~igh
'" ""
edge of
intensitY zone
1100
(4)
100 (4)
100
(4)
100 (4)
f.iOOfWo
(4) (4)
Left edge of high
intensitY zone
~ = ACCEPTABLE
RANGE
Unit: mm lin)
SEL914D
ADJUSTING SCREWS
lU
lU
=--=l\~\\\\\\~~\~
lllnUl
1~IWl~~~ll
7.)
\\1illtlllllllllllllllll
i
SEL400L
EL-44
HEADLAMP
Aiming Adjustment (Cont'd)
AlMER ADJUSTMENT MARK
1LHorizontal
side: 4
\
SE L401 L
LVertlcal
EL-45
side: 2
---------
FRONT SIDE
MARKER
STOP
LAMP
SWITCH
BATTERYI
LAMPR. H.
@D
UP
<t;>@)
'"
'III
,..
L..J
to
HPOWER
SUPPLY ROUTINGH.)
@Y
JII
""''''
FUSE BLOCK
(Refer
"'-<
II
FRONT
COMBI NATI ON
LAMP R. H.
<Eng Ine
harness)
I"..can,.~~,
room
--
0
G/R
R/L
B
D2
S. M.J.
[Refer to last
(Fo I dout
R/L~
""''''
R:G~
-<'"
R/Lj:b
R~G=1:P 18
@V
@)
F2
R~L=Q]]
(Ma i n harness)
G/R
R/L
page).
B [},~
R/L-D'
@9
page
(Bac k
harne
r-
R~G=83ffi:R~G
en
LI GHTI NG SWITCH
FRONT
COMBI NATI ON
LAMP L. H.
I "..c.n,.
~,
;~m
'"
III'
,..
~@)
B --0,
R/L-D'
@!O)
R/Lj:b
R~G=1:P
R/L~
R:G~
@IV
R/L
I
'"
@)~@)
(fj
m
r
:.
-.j
...
r
BODY
GROUND
FRONT SIDE
MARKER
LAMP L. H.
'"
@jJ
B:
~
@@
BODY
~ROUND
'R
FRONT SIDE
MARKER
LAMP
STOP
R. H.
LAMP
SWITCH
<f?@)
'"
'III
r-
UP
@
L-....fT5A
~'"
FUSE BLOCK
(Referto "POWER
@D
~~
@)~ "''''
"
-<~
SUPPL
Y ROUTI
NG".)
FRONT
COMBI
LAMP
NA TI ON
R. H.
room
harness) -
Clearance
~R:L
~@
G/R
R/L
F2
D2
@9
(Ma in harness)
G/R
R/L
B -Q,
R/L-Q'
S. M. J.
[Re fer
to
Iast
@D@
(Eng i ne
~
Il
R~L::ern
page
r-I
R/G=EB
B
"
()
LI GHTI NG SWI TCH
FRONT
Clearance
B --0,
R/L-Q'
COMBINATI
ON
LAMP
L. H.
~@
:~m
R:L
'"
5
6
7
8
9
10
11
12
25
26
27
28
@
B
III'
r-
en
m
r
"...
I\)
r
BODY
GROUND
R/L
B ::ern
@),,@
~
FRONT SIDE
MARKER
LAMP
@ill)
~@
@)~@)
L. H.
~~
BODY GROUND
EXTERIOR LAMP
Back-up Lamp/Wiring Diagram
INHIBITOR SWITCH
I GNI TI ON
SWI TCH
ON or START
il
@I l
@!)
_G/w-Q ~
BACK-UP
'z:1
B --E:J~
LAMP
--------
FUSE BLOCK
@)~
(Eng Ine
(Refer to "POWER
SUPPL Y ROUTING".)
room
harness)
G/L
G/L
G/W
@)
10
HI
H2
=[9
0:
A/T model
@:
M/T model
@:
Fastback
@:
Coupe
()
..J
~
'" ~
'"
<illY
!1
R. H.
G/L
G/L
G/W-
~IG;I~-UP
REAR
COMB
LAMP
(Main
harnesS>
I NA TI ON
R. H.
@D
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S. M. J.
ffiefer to last page
(Fo Idout page). J
BACK-UP
B --E:J
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LAMP L K
~~
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II
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(Eng Ine
harness
room
no. 2)
G/L-{},
G/W--QJ
REAR
COMB
El-48
BACK-UP
LAMP
SWITCH
LAMP
I NA TI ON
L H.
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GROUND
SEL679M
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25
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27
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OR/L
G/L
OR
R/G
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(MaIn
harness)
S. M. J.
ffiefer to
(Fo I dout
last
page
page).]
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FRONT FOG ~
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page
page). J
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head-up
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.
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display
head-up
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HAZARD
SWITCH
to-.
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display
braking
anti-lock
system
braking
system
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- BODY
GROUND
UI
(X)
01
~
EXTERIOR LAMP
Combination Flasher Unit Check
.
.
---
Battery
SEL122E
Bulb Specifications
Item
Headlamp (Sealed)
Wattage (W)
65/35
27
3.8
3.8
27
Stop/Tail lamp
27/8
Back-up lamp
27
7.5
Interior lamp
10
Spot lamp
3.4
Luggagecompartment lamp
18
EL-51
BATTERY
TIME
(Refer
to
I1TIME
CONTROL SYSTEMI1.)
UP
*
@
r FUSE
III~@
@
BLOCK
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r,c:",
(Refer
to "POWER'"
SUPPLY
ROUTI NG", )
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2
3
4
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displ
CASSETTE
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rt
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SWITCH
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FRONT FOG
LAMP SWI TCH
PER
REAR
AND W SHER
SWITCH
REAR WI NDOW
DEFOGGER
SWITCH
SPO
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INTERIOR
LAMP
INTERIOR
LAMP
UP,
FUSE
(Refer
BLOCK
to "POWER
:G
SUPPL Y ROUT I NG". ) ~
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harness)
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harness)
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LAMP
L.
H. LAMP
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R.H.
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R/W
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20
11
17
14
16
30
12
24
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18
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7
6
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25
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21
22
23
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9
27
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I
....
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6
2
SEL577M
EL-54
CJ
[
10 0 0 03
21
10
0101
8) (FUel~
(j;)
(j;)
(j;)
~
Head-up
10
display
1, 14
unit
23
21
18
17
d-up display
con
*1:To
@:
I unit
For
Ca I Iforn
Ia
Z
0
@)
if if
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u....,
W(!J
*1
0
20
0
8
6
9
6
15
6
19
13
IZ
uw
gj
11
...:
a::
Ij
16
12
24
CD
5
SEL403L
EL-55
DISPLAY
r---,
Inn
I,u,-,
~--j
HEAD-UP
DISPLAY
UNIT
DIGITAL
COMBINATION
HEAD-UP
ON-OFF
METER
Dl SPLA Y
SWITCH
FUSE
II
MPH
HEAD-UP
CONTROL
DISPLAY
UNIT
1 7
6 2 3
II
km/h
5
8 9
To
}
Illumination
control system
To ~ ~ ~ &
-=
control unit
SPEED
SENSOR
SEL480L
EL-56
G
L
I GNITI ON SWITCH
ON or
START
...
.~
@~~
-
BODY GROUND
DIGITAL
COMBINATION METER
R/B
(Re~~~E BLOCK
SUPPLyt~O~POWER
TING"
(@Y @)
FB
~ng
a
Ine
rness)
r--
III
Y/B
HII
"
@@~-<-<
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.....
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. .
Y/L
harness)
km/h
Y/B
S.
M
[Refer
t
r'"
m
r-
.
(Main
room
Y/L
HEAD-UP DISPLAY
ON-OFF SWITCH
"
r",
(FaIdout
page). J
Iast page
'H-<
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",...r
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a:amm
(81 ack)
WVh
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(
ToE.
C. C. S.
control
III
m
r
OJ
OJ
IX)
SPEED
SENSOR
To
unit
I I lumlnatlon
control
system
[
COMBINATION
I GNI TI ON SWITCH
ON or START
*
UP
FUEL TANK
GAUGE UNIT
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-u
HEAD-UP
DISPLAY
I/DDI
~
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,...
HEAD-UP
DISPLAY
UNIT
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BODY
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HEAD-UP
DISPLAY
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UNIT
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m'
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cm
r
m
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m
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m
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19
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12
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m
m
0
0
:J:
m
-i
m
::u
FUSE BLOCK
to "POWER
SUPPLY ROUTING".)
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ME
17
we
\'"
::0
~~~
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,...@
~
,... @
m
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en
@@
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harness)
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Y/G
I I
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3-Y/R
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--nnn,
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@tb
E. C. C. S
ENGI NE
CONTROL' UNIT
GROUND
00 ffiefer to ~ C C S
m SYSTEMin'
Y/L
L/B
Y/R
Y/G
Y/R
Y/G
G/L
L/B
sect
. .
ion,
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,...
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0
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1J ;I
1;;
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::::::
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(B lack)
~:
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,...'"
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@:
!9!!9!
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RESISTOR
POWER
TRANSISTOR
@I
::-::-@
BODY
IGNITION
GROUND
Y/B
COIL
::SPARK
PLUG
::-
Y/L
(Eng
<
""
<+0'
(Q en'
'"
0?
"-<-<
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t..
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ENGINE
GD (ID::
@'"
Q~@
i
te)
. 0
Y/B
[Q]
32-Y/G
harness)
~;u
'"
b; EF&EC
II
~
1
<Wh l
(Ma i n
Ine
room
THERMAL
TRANSMITTER harness)
J~
\
'\
INSPECTION START
O.K.
SEL404L
Needle type
~~
@ (Temp.)
@ and@:
~~
2) Ignition relay
----------
O.K.
oo
o.
. @ and @:
E!) (Fuel)
@ (Temp.)~
[Y] \tt:m:IU
~C)(..."
- Fuel gauge
Water temperature gauge SEL405L
~
N.G.
O.K.
N.G.
~
and @:
@ (Temp.)
Repair or replace.
Fuel gauge
O.K.
CHECK COMPONENT.
Check gauge units and harness.
Refer to "Fuel Tank Gauge Unit
Check" or "Th~rmal
Transmitter Check".
O.K.
Reinstall any part removed.
I
.Y.
INSPECTION
EL-59
END
N.G.
Repair or replace.
Refer to FE section. (Fuel gauge)
~
*3
SEL407L
Float position
mm (in)
(-)
Resistance
Q
57.6
(15-1/4,12.5/8)
*1
Full
Approx.
64 (2.52)
4.3 - 6.3
*2
1/2
Approx.
137 (5.39)
27.7 - 34.3
Empty
Approx.
210 (8.27)
73.3 - 84.8
*3
Fuel value
Q (US gal, Imp gal)
32.9
(8.3/4,7-1JM
7."2(1-7/8,1-5/8)
Resistance
60C (140F)
Approx. 70 - 90Q
100C (212F)
Approx. 21 - 24Q
EF329A
Ohmmeter
Continuity
Engine start
NO
Engine stop
Less than 10 . 20
(0.1 - 0.2, 1.4 . 2.8)
YES
SEL748K
':'
of oil pressure
Voltmeter
+ -
11 rId M
Speed
sensor
pinion
[Alternating
current (A.C.)]
App<ox.05V
SEL408L
EL-60
Warning Lamps/Schematic
TIME CONTROL
UNIT
I'
SEAT BELT
SWITCH
E
41
+'
In
>In
C!
C
z
"
SEAT BELT
is
I'
AUTOMATIC
SEAT
CONTROL
UNIT
.JI::
III
t.
.c
-III
<.
uj
.JI::
C
t.
0
-0
III -C
III III
+'
III
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0
....
:j
t.
0
u.
tJ
tJ
t.
0
u.
t.
0
u.
-.
..
-.
BELT
ANTI-LOCK
I'
-I
~ a ~
III
.c.
+'
CONTROL UNIT
CHECK ENGINE
CL
I'
..
@@@@
~ ~ ~ ~
CONTROL UNIT
OIL
I'
OIL PRESSURE
SWITCH
FUEL
II
FUEL TANK GAUGE UNIT
WASHER
I'
WASHER
DOOR
1
I
II
DOOR
SWI TCH
COr iver
s Ide)
I'
UI
'"
:J
U.
DOOR
SWITCH
<Passenger
side)
BRAKE
I'
BRAKE
J:
tJ
1-1...It:
~<
"'IZ
(!J
...
LEVEL
SWITCH
.
.1
II
'"
at.
...0
I...z
ZO
FLUID
PARKING
UI
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:J
U.
BRAKE SWITCH
I.
BULB CHECK
RELAY
ALTERNATOR
CHARGE
I'
SE L578M
EL-61
BULB
CHECK
RELAY
B
~~=
TIME CONTROLUNIT
I~I
AUTOMATICSEAT BELT
CONTROLSYSTEM'.)SWITCH
i
@)IWI
..,.,'".n"
o:n:B:r:m
":::~III:.
~I
,III
~I
(Refer
@ ~~
ICI:I?PI
en.."
to BF sect Ion.)
.@IIII\II~~~II
CO""" ""n
"" ,m
I GNI TI ON
SWITCH
ON
or
START
11,119~ ~ I
",
~~ ~
en
FUSE
BLOCK
(Refer
to
'POWER
SUPPLY
ROUTI NG'. )
UP
W/R
Y/W
t
0
~@
R/W
Y/pu
~I
@@
G
R
l
0
Y/G
PARKI
IT:rY/pu
~~
WASHE~G
WARNI
LAMP
r.Cr-R/L
ON or
<+0;I
"0 -L'
B/R
FUSE
~~
~
enen::-en
amt ;;;;;0111..
[b :R~
(6)
l=.J
:::~,~S
r..~~
:J
J
. "0
-..
c:
~~~~
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3~.
I>:J
OIl>
OI
~.,
0
i~~!
"
I>
~/
m@
ILIJ
AND
FUSIBLE
RELAY
BOX)
~..
@)
LINK
(Refer to -POWER
SUPPLY ROUTING',)
@ ~6
Y/W
R/L
L/R
f
0
~/~
R
Y/pu
A @.
La @) ~~ @): For
@@~:
For
With
;u
~:
()..
f]
~
fi-
@~
.
d Isp Iay
head-up
anti-lock
BODY
GROUND
~
I"
Q~
~
Canada
Call fornla
head-up
To
d Isp Iay
@!V;u
(E F
h;'rn
g~~~ector
f?ri1
;I)
~ ?i
r@J
l9
".@n"
W/R
~28~ND@ , WIthout
@'
-=-
I
III
Y/W
For U.S.A.
WIth
GROUND
FUEL TANK
GAUGE UNI T
(Eng Ine room harness
no.2)
~~
W/R
BODY
CONTROL UNIT
to BR sect Ion. )
c:..
~ ~
LEVEL SWITCH
(III~I~II~~I~~IPI
I"
'III
~ & &
(Refer
..
FUSE
(J n
;U
FUSIBLE
LINK
\ KJ
DOOR SWITCH
..
f.ill\
rrn1
..r
53
..
n
,..
[( 11'1~1~"J~II9~I~~1
~ :R; ~
r,
.
R/B
I>
BR
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g."
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@
Y/wY/GR/WL/R CM.:
R/BW/R-
@)~@
"
..,..
~rc:~~ ~
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0 ...
TART
Wj
Y/pu
-.. I~,~
~~
S SWITCH
(!!,
"0- G \0
IGNITION
en
Y/w
Y/G
R/W
illl/R
R/B
W/R
~~
-=-
GROUND
roI
(Me In harness)
frili6I BRAKE
~
SWITCH
BO~Y-=-
NG
R/B
'1 ~ f'
..
~jJ8
-mr
en
~ ~~
;I)-=-
;I)
en
m
r
U1
....
ID
s:
~
\
\
LI GHTI NG SWITCH
5
6
7
B
9
10
11
12
2S
26
27
28
UP
I lie
Inl
t-
I I(
'"
FUSE BLOCK
"'~
(Refer
to pPOWER \.\.
SUPPL Y ROUTI NGp. ) ~'"
(Eng i ne
harness)
room
S. M. J.
ffiefer
to last
page
(Fa I dout
page).]
G/R
~@V
r~
'"
@f
$E$E ~
~I
G/R
KEY SWITCH
tl
~@
IDA
~R/L
r-
I~I
~~0
m'
I GNI TI ON SWITCH
ON or START
R/L
Y/R
~~~~
0
2
D2
H9
(Ma i n
harness)
G/R
R/L
Y/R
@D@
0)
W
$E
I I
\.
$E$E
II
$E
a::::IJ
CB[EE
o::::::IJ
Hr
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FUSE
f/)
m
,en
.....
0
s:
.L1
g@
I!I
FUSIBLE
OJ
-<
$E
LINK
LINK
BATTERY
0ii
=
DOOR SWITCH
(Dr iver
side)
BODY
GROUND
..
SEL901F
~JJl
Diode
SEL409L
EL-64
Schematic
(0
u
(0
C
(0
U
lJJ
V)
::J
LL
L
0
LL
=
To rear
window
defogger
:::(OQ)
I')~ CE
C\I~ 'e+:;
---
L
Q)'t-
1-0
REAR WINDOW
I
U
1-1~o::
=:~
DEFOGGER
R~LAY
--t
V) IV)
Z
OL
~o
I~Z
ZO
t!I
REAR WINDOW
DEFOGGER
SWITCH
If'I
I')
I'
>D
0
If'I
I'
SEAT BELT
SWITCH
DOOR SWITCH
(Driver
side)
WARNING
CHIME
0'
<0
I.
.
I'
I>0::
W
lI~
::J
...J
aJ
KEY
SWITCH
>D
0
0::
Iz
0
ILLUMINATION
CONTROL SWITCH
lJJ
I:
<0
I-
I'-HTEN
DARKEN
I'
LI GHTI NG
(J LL.
SWI TCH
I LLUMI
NA TI
ON
I NTERMI
C\J
TTENT
WIPER VOLUME
I
U
I~Z
--t
I'
=:0
V)
L
Zo
0
~U
I-U
~~
Z
t!I
C\J
I')
FRONT
WASHER
SWITCH
lJJ
V)
::J
LL
I'
FRONT
WASHER
MOTOR.
INTERMITTENT
SWITCH
~IO:
~
FRONT
WIPER
AMP.
I'
}TO
front
wiper
motor
I'
SEL486L
EL-65
DIODE
imWmI
~
@J)~....
~ ,
'"
~
GH
"'~
~@~
@~ ~I
~ rri
z
I
g:~
3'"R/l
G/R
BODY GROUND
-.
C
3
I~I
OJ
"
...
a
OJ
S. M.J.
ffieferto last page
ine room
(Fa Idout
harness)
~Y/R
R/l
G/R
Y/R
PU
P
l/Y
lG/8
8
lG
R/W
LINK
en
@)
en
c~~
page). J
r---l
(Main harness)
R/l
G/R
Y/R
PU
P
l/Y
l G/8
8
lG
02
F2
H9
812
Al1
811
AIO
810
012
Ii
@
W
en
m
l p--.riTl
G-'::j"JJ
R/W
lE~8
~ ~8GRdJ
8R
WASHER
FRONT
MOTOR
BODY
AMP.
EE WIPER
IIBJ
"'"
"'""
~ ~:R~
::j
lG/R
~
8
FUSIBLE
LINK
BATTERY
To front
@ID-w
wiper motor
\G:'
PU
([ill)
@)Ii@)
It
FRONT
WASHERW1:fR
1111~II1JJ~~D
(BIackJ
1"'~"9@
~
(jnstrument
harness)
~,
19
.@
""-<
AND
OFFINT La HI WASH
13
TCH
14
15
..n
16
t
r
17
t
18
120
BODY GROUND
,'"
~
eft
@'@
8R
(Main
harness)
@()
@'@
s:
ilia
3
@j)~
~~
III
m
r
C11
OJ
-.J
--i
TI
(Eng
-=-
CONTROL UNIT
I~I
AzI
Ii
KEY SWITCH
TIME
~
~
;0
OJ
SWI TCH
~@
""
'"
"''''
c
@})
'-!.
cEtE
m
r-
WARNI NG
CHI ME
T.
27
28
SEA T
BEL T
SWI TCH
"YJ
'"
'"
~@
~
24 0---@---02
SEAT BELT
3 ' 17 o---@---o
WARNING LAMP
13
SEA T BEL T
WARNING LAMP
METER
" ~,
[liHE3ifI]
COMBINATION
_L
~,
@'
@'
Time control
functions.
Details of control
Item
1
Intermittent
Illumination control
When driver's door is opened with ti9ht switch ON and ignition switch
OFF, warning chime sounds.
OPERATING
control
CONDITIONS
,'
Item
wiper control
OOt/) tertrJifli31
t ter.
trJ/fli31
Intermittent wiper
Power
source from
battery
Ignition
switch
@or@
CD
ON
ACC or ON
combination control
ON
ACC or ON
Illumination control
(fJ)
ON
ON
OFF or ACC
ON
OFACC
ON
ON
OFF or ACC
ON
control
Washerand wiper
timer
chime
Driver's side
door switch
switch -----*1
Light
switch
Wiper switch
"INT"
Washer
\@
ON
Seat belt
switch
*2
Illumination
control
switch
(j) or @
/
ON
ON
ON
ON
ON
ON
EL-67
Symptom
Illumination
Intermittent
Intermittent
Seat belt warning lamp does not go off nor come on.
Warning
Rear defogger
[it
9
terminals
Continuity
SEL689L
(+)
(-)
Body ground
@'@~
SEL690L
Yes
terminals
Ignition
switch position
(+)
(-)
OFF
ACC
ON
Approx. 12V
Approx. 12V
Approx. 12V
OV
OV
Approx. 12V
OV
Approx. 12V
Approx. 12V
EL-68
DIAGNOSTIC PROCEDURE-1
Intermittent wiper does not operate.
~
~
8191101
1
1181i915<1
~
-
O.K.
[Y]
SEL652L
WIPER SWITCH
Check continuity
CIRCUIT
between
TifT
I w;p" ~;",h
"ONT"
N.G.
Replace
wiper
relay.
O.K.
N.G.
SEL653L
~@?]
taJ
[Q]
Check harness
between T.C.U.
and wiper relay.
Check harness
between T.C.U.
and wiper switch
#1kn
O.K.
N.G.
Ii)
CHECK
@ and @.
~oo
@
Ii)
~
~
(Cont'd)
~~
DIAGNOSTIC PROCEDURE-2
Intermittent time of wiper cannot be adjusted.
O.K.
Check intermittent
volume circuit.
Intermittent
wiper
knob
on at "S"
position
Approx
1kna;"L"
..
position
SEL654L
Replace
wiper
switch.
wiper
Replace T.C.U.
N.G.
Check intermittent
volume.
wiper
O.K.
Check harness between T.C.U.
and intermittent wiper volume.
EL-69
Trouble-shooting
(Cont'd)
DIAGNOSTIC PROCEDURE-3
Wiper and washer activate individually but not in combination.
N.G.
O.K.
N.G.
Check T.C.U. output for wiper
motor.
Replace T.C.U.
[
O.K.
DIAGNOSTIC PROCEDURE-4
Illuminationcontrol system does not actuate.
~oo
~
Light switch
m
Check T.C.U. output for light
switch circuit.
... ON
O.K.
Approx.12V
O.K.
[1100
[!]
kJ
IllUMINATION
CHECK
O.K.
Replace T.C.U.
SEL649L
CONTROL CIRCUIT
1E5L---,
III 00
@@
[aJ
[ill
+
Ohmmeter
(+1 (-I
@
!J)
@
@
lIIum;nat;oncontrol .wltch
OARK
BRIGHT
on
Excep. on
Except on
on
ISEL650L
EL- 70
(Co nt' d)
DIAGNOSTIC PROCEDURE-5
Light warningchime does not activate.
Do other warning chimes
activate?
O.K.
N.G.
Go to "PowerSupply
Check".
Circuit
O.K.
O.K.
~oo
@
f\Tl
LY'.J
+ -
Replace T.C.U.
DIAGNOSTIC
@ .Light
switch ... 1ST
Approx.12Vwhen
driver's side door is closed.
.
PROCEDURE-6
O.K.
Check T.C.U. output for chime
circuit.
N.G.
. ~oo
W
[ill
+ -
O.K.
Replace T.C.U.
SEL643L
EL-71
LAMP
switch
PROCEDURE-7
Seat belt warning lamp does not go off nor comes on.
DIAGNOSTIC
is "ON".
~oo
N.G.
~ooJ il~
1 O.K.
SEL651L
EL-72
N.G.
Replace T.C.U.
~oo
w
.
DIAGNOSTIC
PROCEDURE-8
I Checkkey
switch or harness.
O.K.
Approx. 12Vwhen
SEL639L
DOOR SWITCH CI RCUIT CHECK
Check continuity
N.G.I
O.K.
DRIVER'S
(Cont'd)
between @ and @.
.
O.K.,
N.G.
N.G '
.~
O.K.
~oo
LaJ
Driver's side door
Replace T.C.U.
... Open
SEL640L
CHECK
@ and@.
[it
@
laJ
@-~
'A
SEL641L
EL-73
1 2 3 4 5 6 7 8 9 10
1819
111213141516
lNJ
[Y]
+ -
DIAGNOSTIC PROCEQURE-9
Rear defogger does not activate, or does not go off.
00
Rear defogger
(Co nt' d)
Rear defoggerswitch
"N": Approx. 12V
ON
N.G.
O.K.
. "TIMER":
Reardefogger
switch
Approx.OV
SEL644L
O.K.
defpgger relay.
N.G.
N.G.
Check defogger switch circuit.
[ilOO
0
@.
~d- j
O.K.
"f'
I
Replace T.C.U.
SEL645L
-,
EL-74
WIPER
~:
~:
anti-lockbraking
system
With
Cill:@
UP
LG
@:@I~I
r
o",rlll
111"'"'''
111
(MaIn
harness)
S. M.J.
WIPER
(Eng I ne
.r
-=
m
r-
room
harness)
LG/B
LG
PU
PAIl
B
L/Y
LG
OR
LG~B
LG/R
.....
UI
AI0
012
BI2
BIO
BII
i i
LG/B
LG
PU
P
B
L/Y
,L
@])@
WIPER
([@)
MOTOR
WASHER
~M
BR
LG/B
L/Y
@
~LG
~
LGfR
PU
[]
SWITCH
OFFINT LO HI WASH
13 0
14 0
IS
16
17
18
19
20
111
en
m
r
U1
OJ
OJ
s:
@)@@)
BODY GROUND
AND
WASHER
c
c
0
,....
i'
1
0
REAR WIPER
I GNI T1 ON SWITCH
ACC or ON
AMP.
[;]
UP
IDA
,~
r-
~~
r-r-r-r... "',,'"
::a~u~
FUSE BLOCK
(Refer to "POWER
SUPPLY ROUTING".)
(Main
harness)
@ill)
L/W
(Back
L/W
harness)
:[
Lg~R . l?:
0 Lg~R
(@})@)
m
r-
L/W
(Eng I ne
harness)
.....
en
rr-",
"~...
room
I::"l
L/W
(Main
harness)
LG/B~LG/B
S. M. J.
ffiefer
to last
page
(Fo I dout page). J
B -B.3 ffi~@
L/R
R/Y
'
To I I I um I nat Ion
contro
I system,
[
@])A~@A(@)
~~
~~
- -
(/)
m
r
a>
"
~
BODY
REAR WASHER
MOTOR
LGB"B
R/LI
~@
GROUND
door
le.~
~
2
~3
4
@
L~W
Lg~R
@@
';
Before removing front wiper motor link, turn wiper switch OFF
and disconnect motor leads at connectors.
1. Remove wiper ,arm.
2. Remove cowl cover.
3. Remove bolts which secure wiper motor.
,
4. Extract wiper motor so that wiper motor link comes out of
hole in front cowl top panel. Then, pull motor straight;out to
disconnect ball joint which connects motor link and wiper
link. Wiper motor can then be removed.
SEL411L 5. Remove wiper link pivot blocks on driver and passenger
sides.
6. Extract wiper link and pivot blocks (as one unit) from oblong
hole on left side of cowl top.
Pull
straight
ahead.
..
r
FRONT WIPER INSTAllATION
,\
""
~
.:.
Wiper
motor
link
Cowltop
front panel
Insert securely.
1. Position wiper link and pivot blocks (as one unit) in cowl top
through oblong hole.
2. Before installing pivot blocks on cowl top, hold end (motor
link side) of wiper link at hole in front cowl top panel and
insert motor link's ball pin into hole in wiper link.
3. Install front wiper in reverse order of above removal procedures.
Apply a small amount of grease to ball joints before
installation.
/'
SEL412L
EL- 77
-"-"~
Rear wiper
motor
SEL413L
INSTAllATION
1. Prior to wiper arm installation, turn on wiper switch to operate wiper motor and then turn it "OFF"
(Auto Stop).
2. Lift the blade up and then set it down onto glass surface to set the blade center to clearance "L1" &
"L2" immediately before tightening nut.
3. Eject washer fluid. Turn on wiper switch to operate wiper motor and then turn it "OFF".
4. Ensure that wiper blades stop within clearance "L1" & "L2".
Clearance "L/': 17.5 - 32.5 mm (0.689 - 1.280 in)
Clearance "L2": 25 35 mm (0.98 - 1.38 in)
Tighten wiper arm nuts to specified torque.
Front wiper: 17 - 23 N.m (1.7 - 2.3 kg-m, 12 - 17 ft-Ib)
Rear wiper: 13 - 18 N.m (1.3 - 1.8 kg-m, 9 - 13 ft-Ib)
*1:
*2:
*3:
*4:
*5:
*6:
*7:
*8:
50 (1.971
28 (1.101
43 (1.691
21 (0.831
144 (5.671
155 (6.101
273 (10.751
385 (15.161
0
Clearance
Unit: mm (in)
* All the diameters of these circles are
less than 80 (3.151.
*7
"L,"
Clearance"
rt
rr~~.
Glass
end
'8
L1"
~
~
SEL425L
Glass end
*1:
*2:
*3:
*4:
93
85
38
25
(3.661
(3.351
(1.501
(0.981
Nozz~e1~b
Unit: mm {inl
SEL414L
EL- 78
SEL415L
.
SEL024J
SEL117K
Check Valve
reservoir
':;0
F'om
To
~ D";'e
c~ ".I~
..
SEL411H
EL- 79
Wiper relay
~~
:4;
Test
lamp
SEL6S1 I
EL-80
CIGARETTE
LlGHTER
~
HORN
RELAY
~
~
~
@~
SLl
RI NG
- --
~~~~~~~
'
+t=
:,
:
.
.
SET/COAST
SWI TCH
HORN
~=SWITCH-
- n .~
fl
. (3
= 0 SWITCH
::
~
RES~ME/ACCEL
I GNI TI
AC
,
(
@~
III 0
:oJ
III
P0
,
:E
'"
,,
:E'III
"'''''''
,.
en
(Ma In
harness)
@:
:oJ
III
@:
III
HORN- HIGH
rr\--.@)
m
r-I
00
rJoIhite)
ii
rr\--.
~@)
HORN-
ii
@J) @~
[D- G
BODY
~:
~:
@~I
III
~[D-G
-=
EEHHE:EJ EHffiIrn@)
III
~QD:oJ
(Black)
@)
GROUND
::r;:::
ID:J
,m
:Jc+
CD,
me
m3
CD
:J
c+
LOW
.~
'
'"
:E
,
III
'"
,
:E
Q0
:E
o=:::IJo::::IJ
FUSE
II
'"
III
:oJ
'" '"
HORN
FUSIBLE
SWITCH
en
m
r
0>
....
"-I
s=
g@)
LlNK
FUSE AND FUSIBLE LINK
<In
RELAY
BOX)
BATTERY
REAR WINDOW
DEFOGGER RELAY
I GNITI ON SWITCH
ON or START
UP
FUSE BLOCK
(Refer
to "POWER
SUPPLY ROUTING".)
~@
r
rr
Ii1
Ii1 r
'rli1
;0
,r'
-<;0
(Back door
harness)
HBJL/R-c:J
m
rco
I
()
G
G/Y
L/G
[[J-L/R
L/R-cD
@ill)
CO
-=
CP)L/R-cD
(Ma in
harness)
CONDENSER
J~~n~~~ym~~~i~~n -=
\
(1-
@~(
!II
m
r
'"-.I
W
~
BODY GROUND
;o;or
'IDID'"
1
2
3
OFFON
0
0
X (P
4
5
X (
6
REAR WINDOW
DEFOGGER SWITCH
BODY
Filament Check
I-]
SE L263
[+]
[V]
SEL264
12 volts
H
[+]
r/
r'n
Burned-out point
0 volts
SE L265
[+]
~
(VI
S E L266
EL-83
Heat wire
Drawing
Unit:
pen
mm (in)
BE540
Repaired
REPAIRING PROCEDURE
1. Wiper broken heat wire and its surrounding area clean with
.
a cloth dampened in alcohol.
2. Apply a small amount of conductive silver composition to tip
of drawing pen.
Shake silver composition container before use.
3. Place ruler on glass along broken line. Deposit conductive
silver composition on break with drawing pen. Slightly
overlap existing heat wire on both sides [preferably 5 mm
(0.20 in)] of the break.
4. After repair has been completed, check repaired wire for
continuity. This check should be conducted 10 minutes after
silver composition is deposited.
Do not touch repaired area while test is bei",gconducted.
point
~
[0
@
SEL012D
Repaired
point
SE L013D
EL-84
I GNITI ON SWITCH
ACC or ON
0-1
00
:J
c+-.
3
1/)'<:J
1/)1
c+c+
FUSE BLOCK
(Refer
to "POWER
SUPPLY ROUTING".)
(1)30
:J
@1Mll~@
@~
"-<
:0
:0..
.. ~"""""
~>,... ~ ~~~:o""""'"
RD
DECK
DIN
0-c
UP
CASSETTE
RAOI 0
,-
CODE
I~
~@ @1Mll~@
....
"",...
III""
.. ~""""III
,..
~>,... ~ ~~~
,...~g g
co
:0
"..
,...
(Main
harness)
m
rI
co
c.n
@:
Radio
@):
@:
Cassette
Active
@:
Except
only
type
deck
type
speaker
type
MJII
@)ii@JJ
BODY
GROUND
@
@D
@)
@
III""":;;
-<:IE
rnl
@
DOOR
DOOR
SPEAKER
en
m
r
01
....
~
~
[D=ru
~I
AMP..
UNIT
11>'1
III
III"":;;
:IE
(Ai
tl.j~L/Y1
@
0
@ill)
'
L/W m'
L.
H.
SPEAKER
L. H.
eM:
..
..,...:;;
:IE
..,...,,:;;
-<:IE
mBR/W~
U BR ~
DOOR
SPEAKER
R ~
@ill)
L/W
L/Y
LG
l';'
.:1
BR/W
LG
(Door harness
L. H.)
(Door harness
R. H. )
BR
I~
o.
AMP.
UNI T
L
~~
Loosen~~
~2N~
--
~
~,-(
\\
~1
\ \
\ \
\ \
\
\ \
\ \
\ \
)f/~.
r[~
Radio
(For AM/FM electronic tuning)
SEL416L
\
~
EL-86
Ohmmeter
[TI
@
SEL2501
Ohmmeter
[TI
@.
---'
No continuity
Continuity
exist
SEL251\
SEL2521
Ohmmeter
[TI
@
SEL2531
ELEMENT REPAIR
Refer to REAR WINDOW DEFOGGER "Filament Repair".
EL-87
I GNITI
ON
SWITCH
ACC
or
ON
I GNI TI ON
SWITCH
ON
or
START
-@
FUSE
FUSE
A. s. C. D.
OFFI
A. S. C. D. STEERING
SWI
TCH
N ON
I
SWITCH
RESUME/ACCEL
SWITCH
A. S.
C. D.
HOLD
RELAY
-=-=-
To horn
A. S. C. D.
rI
~ ~ ~ ~
co
co
13
::I0
mo
--i::I
mro
;oz
12
0
;0
c
Ct1
m
--i
~
a
z
CONTROL
UNIT
10
CANCEL
SWITCH
11
A.
S.
C.
5
9
8
-r-'
To
D.
CLUTCH
SWITCH
A. S. C. D.
ACTUATOR
i I Iu
control
A/T
CONTROL
UNIT
-=-
~
-=-
SPEED
SENSOR
To
i IlumlnatiOn
control
rJ)
m
r
<.n
CX)
'"
-=-
system
-=[
0, A/T
@' M/T
@), With
@), Witho
@' With
syst
@' Witho
syst
C C1
+' C1
'v
.-p
P",
c >-
"'"'
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COMBINATIONMETER
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I
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ZO
0
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0 V
OP
1_~~
@@
HEAD-UP
10
ILL
01SPLA Y
CONTROL UNI
'
ILL
II
.1
(LIQUID CRYSTAL>
20
ILL.
ILL.
(LIQUID
CRYSTAL>
I~I
~~~--~
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.",
~
CRUISE
CRUISE
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m"
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:J
I V
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bIIII
~~~~
U 111'4 b II E:j
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.
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z
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ti
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@)
II
~G/OR
'~I'
'-~I'
A,
Y/G
R/G
G/R
S, C, 0,
CLUTCH
SWI
T CH
A,
u;
"'
v
C
L
'"
r
S, C. 0,
U SWITCH
CANCEL
~ffim~
u:
.,
G/W
'---
O/B--o..
-NO<>
"
Ai:
!!!
@ @
G/Y
G/W
SLI
P
RING
O..J
~~~
O:::J
~
~
@
O/B---o'"
@~ffi
Ln.'
o~
LL
LL
<>
'
'
"
,:
@
,G/L--{'k
11
~.
"'~O~V)r~
L .~
..
I<
I'
>--
V)
0
0
U;
I,
.,
@@@@
~111,d~IIE:j
I
is
>-- >-- P P
(Black)
V +-'
~ ~ rrr
harness)
(White)
@~I,~II,II~
nstrument
(j
I
UB-
('<i) a
@ \:::)
. G/OR
G/Y-
~~~:
G/R-
Y/'
L/WG/LY -
Y/L
G/W-
='
50
'= Y/'
Y/L
(.;) ~
~C
"'
v"'
-~~
C1L
~~
B~
L-
\;,;;!
@ ~@)~
@
Y
1<
G/W
.~::~
@
~
0
OJ
A
U
...J '"
000
~UJv)
IUJZ
UJQ.UJ
> V) V)
u;
<
SE L590M
EL-89
f".-
.~r
--
SEL419L
CAUTION:
.
.
EL-90
Trouble Diagnoses
DIAGNOSTIC
PROCEDURE
Symptom
A.S.C.D. control unit cannot be set properly.
Engine hunts.
A/T model
only
A.S.C.D. control
unit
Q)I
R.H. dash
side
~
SEL418L
CID
EL-91
~oo
O.K.
Approx. (4) @
12V
[Y]
O.K.
Voltmeter
O.K.
N.G.
[ilOO
:11
Approx.
12V
Brake pedal
Step on.
O.K.
SEL629L
Approx.
O.K.
[iI@a
l5J
O.K.
Voltmeter
~@a
J~\
Lfi-J
Approx.O.5V
Voltmeter
SEL630L
EL-92
Replace actuator.
PROCEDURE-2
N.G.
Check resume switch circuit.
rilOO
Q)
1
O.K.
Replace A.S.C.D. control unit.
::~rox. @
lilJ
[YJ
Resume-switch
- ON
+ Voltmeter
SEL636L
/
DIAGNOSTIC
PROCEDURE-3
riI~
Q)or@ Approx.
~~~
Voltmeter
Cancel switch
- ON
O.K.
Replace A.S.C.D. control unit.
j
SEL637L
EL-93
PROCEDURE-4
Engine hunts.
Check vacuum hose for
O.K.
Does A.S.C.D.wire move
smoothly?
O.K.
Go to "Actuator Check".
N.G. [
Replace actuator.
O.K.
Replace A.S.C.D. control unit.
DIAGNOSTIC
PROCEDURE-5
N.G.
Replace wire or actuator.
O.K.
Check vacuum hose for
O.K.
Go to "Actuator Check".
O.K.
Replace A.S.C.D. control unit.
EL-94
I~
I~
Replace actuator.
CID
DIAGNOSTIC
PROCEDURE-6
O.K.
OV
[JZJ
+ -
~oo
3 Brake pedal-> Step on.
Clutch pedal
(M/T)-> Step on.
AfT control-> "N" range
lever (A/T)
CHECK
Replace actuator.
O.K.
CID
~
@
O.K.
Check actuator. Refer to
"Actuator Check".
Voltmeter
N.G.
Check stop lamp circuit.
Approx.
12V
[JZJ
Voltmeter
SEL631L
2. MeasurevOltageacross @ and
CID
DIAGNOSTIC PROCEDURE-7
AfT model only:
.
.
.
0.0. control
switch -> ON
O.K.
Voltmeter
SEL640M
EL-95
N.G.
Actuator Check
18
'~~
[ill
-
DISCONNECT
Check actuator.
-1'0
234
'\
O.K.
/ \ /J
Release valve
Air valve
Vacuum valve
SEL423L
N.G.
Replace actuator.
and @.
O.K.
Ii)
Check to see if A.S.C.D. wire is
pulled when 12V D.C. is applied
across CD. CV.:IDand @ .
I;)
Replace actuator.
[!)
SE L691 L
N.G.
N.G.
~
I
(;]
N.G.
Replace actuator.
!
Actuator is O.K.
[!)
~
SEL693L
(;]
~
SE L694L
EL-96
Replace actuator.
[
1/
~
[AJ
FRONT
[eJ
BrOwn
(Canada: Blue )
(
'~
~ ~";'
f?'
,/
Fuse block
/~
'
I ~
Headlamp
(Black)
Headlamp retract
(Black)
retract relay-3
relay-1
SEL420L
EL-97
Passenger Compartment
Accessory
relay-1
(Blue)
Circuit breaker
Ignition relay
With power window: Brown
Without power window: Blue)
Bulb check relay (Blue)
Rear window defogger
relay (Black)
S.M.J.
\I
--
Headlamp timer
SEL421L
EL-98
HARNESS LAYOUT
Outline
Back door harness
Fastback
R.H. .
Instrument harness
\
Engine room harness no. 2
E.F.I. harness.
SEL496L
Coupe
Engine room
harness
.D
EL-99
HARNESS LAYOUT
Main Harness
EL-100
@
@
@
@
@)
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@)
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@)
@
@
@
@
@
@
@
@
@
m
rI
~
0
~
en
m
r
UI
CD
~
s:
@
@
@)
@
@
@
@
@
@
@
@
@
@
@)
@
@
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Diode
@
Lighting switch
r
~
Retractor re
Headlamp ti
Lighting swi
L-
Headlamp R
Bulb check
Time control
L-
Seat belt sw
Bodygro""~
m
rI
...a
0
N
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
(Y :
(j) :
(3) :
@@) :
(9 :
~
:
e
:
(V :
~
:
(V :
~ :
(D :
:
@9 :
~
:
~
:
@ill) :
~
:
(!) :
~
:
@) :
:
Body ground
Lap belt buckle switch (For U.S.A.)
Seat belt switch (For Canada)
Ash tray illumination
Cigarette lighter
Door mirror control switch
Automatic seat belt control unit (For U.S.A.)
Parking brake switch
AfT device (AfT illumination and O.D. control switch) (AfT model)
Shift lock solenoid (AfT model)
Door switch L.H.
Automatic seat belt motor assembly L.H. (For U.S.A.)
Body ground (For U.s.A.)
Body ground
Rear speaker L.H.
Rear side marker lamp L.H.
Rear combination lamp L.H.
m
rI
...a
0
Co\)
~
C/J
m
r-
U1
II)
0
s:
r-I
...\
0
~
--
@:
~
~
@B) :
~ :
@9 :
@lJ :
~ :
@V :
~ :
@i) :
@3) :
@ill) :
() :
@l7) :
~
~
:
:
~ :
:
@ill) :
(3) :
@ill) :
~
:
@B) :
@@) :
:
:
@ :
~
:
@ :
:
Body ground
Lap belt buckle switch (For U.S.A.)
Seat belt switch (For Canada)
Ash tray illumination
Cigarette lighter
Door mirror control switch
Automatic seat belt control unit (For U.S.A.)
Parking brake switch
AfT device (AfT illumination and a.D. control switch) (AfT model)
Shift lock solenoid (AfT model)
Door switch L.H.
Automatic seat belt motor assembly L.H. (For U.S.A)
Body ground (For U.S.A.)
Body ground
Rear speaker L.H.
,...
I
~
0
U'I
en
m
r
(II
00
s:
--------
HARNESS LAYOUT
Instrument Harness
CID : To main harness @ (Black)
@ : To main harness @ (White)
@ : Head-updisplaycontrol unit
@:
@:
@:
Combination meter
(Model with head-up display)
Combination meter
(Model without head-up display)
Combi nation meter
(Model with head-up display)
QD :
@
Combination meter
(Model without head-up display)
: Combination meter
(Model without head-up display)
EL-106
SE L501 L
HARNESS LAYOUT
NOTE
EL-107
HARNESS LAYOUT
'U
C
::I
0
..01
>
'U
0
ID
EL-108
@
@
@
@
@
@
.
:
:
:
:
:
:
m
r-I
@
@
@)
@
@
@
@
@':
@
@
@
@
@
@
@
@
@
@
@
@
@
0
@
: To engine room harness no. 2 ~
: Body ground
@D
@)
@
@
@
@
:
:
:
:
:
:
Low.pressureswitch
Battery
.Battery
Bodyground
Clutch interlock relay (MfTmodel for U.S.A.)
Front side marker lamp R.H.
@
@
@
@
@)
@
@
0
CD
en
m
r
UI
(XI
I\)
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
m
rI
..a
..a
0
@)
"'P
~~
~
(@j)
1t.7ii'\
0
0
E112 El11
@j) :
@3) :
0
0
B
(fJ
m
:
:
:
To main harness @
To main harness @ (Blue)
To main harness @ (Black)
Clutch switch (M/T model for U.S.AJ
Key lock solenoid
(AfT model)
Key switch
r-
@!) :
(@Y : gnition switch
0:
@
UI
CD
N
ombination switch
: C mbination switch
([8)
0
~
0
@Y
@
@
@
: To main
: E.C.C.S
: To engi
(AfT mo
: To engin
Body ground
(MfT mo
: To engine
: To engin
: To engin
: F.I.C.D.
m
r-
-'
-'-'
I
en
m
r
UI
co
W
;:
@) :
@
:
@
:
@
:
@) :
@
:
@
:
@
:
@
:
@
:
@
:
@) :
@) :
@
:
@
:
@
:
@) :
@
:
@
:
@
:
@
:
@
:
@
@
A.A.C.va
Injector n
Air regula
Injector n
Pressurere
S.C.V. con
Exhaust g
Injector n
Injector no
Enginegro
Crank ang
Enginetem
Thermal tr
Throttle v
Throttle se
E.G.R. con
Air flow m
Resistor
Condenser
Ignition co
Power tran
Front whe
(For Anti-l
: Body groun
: Air tempera
m
rI
...a
...a
~
~
~
en
m
r
01
0
....
: Neutral switch
(M/T model!
HARNESS LAYOUT
@D
(Qlli)
@ill)
~
:
:
:
:
:
:
@
:
@D :
~
:
@ill) :
~
~
SEL505L
EL-113
Body ground
m
r-
-'-'
~
I
In
m
r
U1
0
~
r
Room
@
:
@)
:
@
:
@
:
(~
:
@
:
@
:
lamp harness
To main harness @
To sun roof harness @
Spot lamp (Model with sun roof)
Interior lamp (Model without sun roof)
Interior lamp (Fastback with sun rootl
Interior lamp (Coupe with sun roof)
Automatic seat belt front limit switch (For U.S.A.)
Sun ro
:
@ :
@ :
@ :
@ :
@ :
@ :
@
:
HARNESS LAYOUT
Door Harness
L.H.
@
@
@
@
@
@
:
:
:
:
:
:
To main harness @
To main harness @
Door speaker (Active speaker type)
Door speaker (Standard speaker type)
Door mirror motor
Power window regulator
@)
@
@
@
@
@D
:
:
;
:
:
R.H.
~8
.@ill)~
@B
@)
@)
8
~
: To main harness @
: To main harness @
: Door speaker
(Active speaker type)
: Door speaker
(Standard speaker type)
: Door mirror motor
:
:
.~
:
@:IV :
@IV :
EL-115
SEL504L
HARNESS LAYOUT
NOTE
j
l,
~
r
l,
,
I
~
r
I
I
EL-116
.
.
S.M.J.
SEL422L
EL-117
HARNESS
\
AlA2A3A4ASA6 A7A8A9AliA11A12
BIB2B3B4BsB6
CIC2C3C4CsC6
01 02
El E2
Fl F2
Gl G2G3G4GsG6
HIH21H3
H4HsH6
11121314IS16
B7B8B9BID
B11B12
C7C8C9CID
C11C12
LJ
011 012
Ell E12
F11 F12
G7G8G9GlDG
11612
H7H8H9HID
H11H12
171819IIDI11112
~
~
/
ENGINE ROOM HARNESS
[11
View from harness side
EL-118
INCHTO METRICCONVERSION
TABLE
METRICTO INCHCONVERSION
TABLE
<Rounded.off
for automotiveuse)
<Rounded.off
for automotiveuse)
inches
.100
.110
.120
.130
.140
.150
.160
.170
.180
.190
.200
.210
.220
.230
.240
.250
.260
.270
.280
.290
.300
.310
.320
.330
.340
.350
.360
.370
.380
.390
.400
.410
.420
.430
.440
.450
.460
.470
.480
.490
.500
.510
.520
.530
.540
.550
.560
.570
.580
.590
.600
mm
2.54
2.79
3.05
3.30
3.56
3.81
4.06
4.32
4.57
4.83
5.08
5.33
5.59
5.84
6.10
6.35
6.60
6.86
7.11
7.37
7.62
7.87
8.13
8.38
8.64
8.89
9.14
9.40
9.65
9.91
10.16
10.1
10.lp7
10.92
11.18
11.43
11.68
11.94
12.19
12.45
12.70
12.95
13.21
13.46
13.72
13.97
14.22
14.48
14.73
14.99
15.24
inches
.61,0
.6;20
.630
.640
.650
.660
.670
.680
.690
.700
.710
.720
.730
.740
.750
.760
.770
.780
.790
.800
.810
.820
.830
.840
.850
.860
.870
.880
.890
.900
.910
.920
.930
.940
.950
.960
.970
.980
.990
1.000
2.000
3.000
4.000
5.000
6.000
7.000
8.000
9.000
10.000
20.000
mm
15.49
15.75
16.00
16.26
16.51
16.76
17.02
17.27
17.53
17.78
18.03
18.29
18.54
18.80
19.05
19.30
19.56
19.81
20.07
20.32
20.57
20.83
21.08
21.34
21.59
21.84
22.10
22.35
22.61
22.86
23.11
23.37
23.62
23.88
24.11
24.38
24.64
24.89
25.15
25.40
50.80
76.20
101.60
127.00
152.40
177.80
203.20
228.60
254.00
508.00
mm
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
inches
.0394
.079
.118
.157
.197
.236
.276
.315
.354
.394
.433
.472
.512
.551
.591
.630
.669
.709
.748
.787
.827
.866
.906
.945
.984
1.024
1.063
1.102
1.142
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.535
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
1.969
mm
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
inches
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.031 .
3.071
3.110
3.1 50
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
3.937
;&
OUiCKREFERENCE
CHART:24081
/
I 1989
'
I,'FRONTWH-EELBEARING----
Engine model
KA24E
Firing order
1.3-4-2
Idle speed
MfT
Tightening
,.
mmtinl
750tSO
750tSO
Valve clearance
IREARWHEELALIGNMENT (Unladen.)
I
15'2
. .
Camber
(Hod
mmtinl
.",
kn
c,able resistance
Non-adjustable
.'ii".
Standard
Type
ZFR4D-11
Cold
ZFR6D-11
Gap
Drive belt deflection (Cold)
..
.,
if
.'
Adjusted
Limit
dellection
11 (0.43)
6.7
(0.24 . 0.28)
)'
12 (0.47)
7,,8
(0.28 - 0.311
6.7
(0.24.0.281
I,
13 (0.511
8.9
(0.31 . 0.35)
7.8
(0.28 . 0.311
'
Power It;'ering
pump
Applied pressed force
N.m
{ Tightening torque
<
29-39
1.5'.12.5'
3.0.4.0
mmtinl
BRAKE"
Rotor thickness
Front side
18.0 (0.709)
Rear side
8.0 (0.315)
,j
AIT model
,,'.,( I'CLUTCHPE"AL ~
Unit:
186
Ped~!."e~
.I' Pedal free play
- 196
Camber
degree
-130' to 0
Caster
degree
600' -730'
Toe-in
"
,'/
mmtin}
degree
Innerwheel
.:
Unit
KA24E
Fuel tank
Coolant
Engine
Transmission
Differential
60
15-7/8 gal
6.7
7-1/8 qt
3.&'3.2
3-3/4 qt
3.3/8 t
33
.~'
carrier
MIT
2.4
5-1/8 P.
AIT
8.3
8-3/4 qt
R200
1.3
2-3/4pt
0.9
6-8
Engine model
38 .43
system
Refrigerant
0.9 - 1.0 kg
,I
--~.
~!
"';"1\
REFILL CAPACIT'ES,.'
Full turns
Outer wheel
'1: Under foree of 490 N (50 kg, 110 Ib) with engine running
'2: At pulling force: 196 N (20 kg, 44lb)
0.12)
Parking brake
Number of notches'2
mm (in I
(7.32 - 7.721
1- 3 (0.04-
. 1''-
Unit: mm tinl
"i
.
2.0 (0.019!
..I!'pairlimit
22.29
Disc brake
Pad repair limit
14,.22
ft.lb
kg.m
2.0.3.0
20-29
Spark plug
mmtinl
98 (10, 22)
N (kg,lb,!'
I
Set dellection
of new belt
7.8
(0.28 . 0.31)
Alternator
':
I,
I
.,
Air conditioner
compressor
cl
::..m tin)
mmtinl
-136' to -036'
degree
ZFR5D-11
Hot
degree
Toe-in
Less than 30
h"
,; Spark plug
torque
rpm
Ignition timing
(degree B. T.D.C. at idle speed)
; High tension
1 qt
2.0 - 2.21b
.,
....
IN U:S.A. "~
Post Office
Gardena,
California
Telephone:
Box 191
90247-7638
(213) 532-3111
'
'
J'SERVICE BULLETIN
Classification:
EF&EC89-004
Reference:
Models:
1989 240SX
Date:
number KA24-012039*
SERVICE INFORMATION
To improve driveability
as follows:
The following
Compression
.
.
.
Idle speed.
Self-diagnosis
.
~
--
~--
~.
mmm!I
,..
pages reflect
Pressure
~or E.G.R.
these changes.
CONTENTS
- Measurement
-
General
Specifications
System
':>
~,
"
Circui t Diagram
Engine and Emission Control Parts
Air Temperature
Diagram"
................................... 65
7
Description
.........................\............
Sensor
Procedure
~lectrical
Components Inspection
9
.11
.12
13
15
16
24
.,.19
21
;... .23
pages
of
the
,t
EM and EF&EC
f'
*Vehicles
.modified
Sensor
1/23
on the
air
cleaner
I
~
COMPRESSION
-It'
PRESSURE
Measurement
1.
2.
'3.
4.
5.
of Compression
Pressure
Warm up engine.
Turn igr;1ition switch off.
Disconnect fusible link for injectors.
Remove all spark plugs.
Disconnect distributor center cable.
g
6. Attach a compression tester to NO.1 cylinder.
7. Depress accelerator pedal fully to keep throttle valve wide
open.
8. Crank engine and record highest gauge indication.
9. Repeat the measurement on each cylinder as shown above.
Always use a fully-charged battery to obtain specified
engine revolution.
Compression pressure:
kPa (kg/cm2, psi)/rpm
Standard
1,206 (12.3, 175)/250
Minimum
1,010 (10.3, 146)/250
Difference limit between cylinders
98 (1.0, 14)/250
SEM113B
.
.
'
",.
. 2/23
oil'
Specifications
"
KA24E
Engine model
4, in-line
Cylinder arrangement
Displacement
Bore x stroke
mm lin)
2,3891145.78)
89 x 9613.50 x 3.78)
Valve arrangement
O.H.C.
Firing order
1-3-4.2
Compression ratio
2
1
5
8.6
3/23
v.:
0\;,
;j
E.C.C.S.control unit
E.C.C.S.relay,
Fuelpump
E.G.R. control
Exhaust gas
temperature sensor
(For California model)
valve
t~
Pressure regulator
Pressure solenol
regUla.~Or
control
valve'
~ ~
s.c.v.contrOI
fijif~ ~
I.A.A. un"it
~"o,
Fuel filter
t9
Throttle sensorl
Throttle valve switch
Throttle chamber
Air temperature
~
)
E.G.R. control
solenoid valve
iT
Engine
temperatu re
sensor
ankangle
cr
~"'o,
'"~
Jec or
o;?J ~
Exhaust gas
sensor
4/23
sensor
SEF4601
--
E.G.R. control
solenoid valve
Ignition switch
r Air regulator
, , ,
Throttle
valve
8a
sensoi
:-)" r--L
-,
Ignition
coil
01
--N
W
,
Fuel pressure
regulator
/
valve
Engine
Transmission
g
=
'\
Swirl control""'"
{}
temperature
sensor
Carbon
canister
':;. speed
Vehiclesensor
Exhaust
gas sensor
"
A.I. V. control
solenoid valve
A.I.V.
en
m
"~
C>
..
: Exhaustgasflow
- Air flow me
E.C.C.S.
CONTROLSYSTEM
Crank angle sensor
Engine temperature
.1
sensor
'System Chart
.I
Exhaust gassensor
.1
~.
Ignition switch
Idle switch
I Throttle sensor
Canister
control&
E.G.R. control
control
E.C.C.S.
unit
switch
)1
Auxiliary
air control
(A.A.CJ valve
)I
valve
E.G.R.control
solenoid
AJ.V. control
~I
Air conditioner
Injectors
)f Power transistor
~
~
~I
--1
[ Starter switch
Fuel injection&
,/1
Fuel pump
I
I
Air regulator
Neutral
Inhibitor switch
switch (M/T)
(A/T)
Vehicle speedsensor
, switch
Battery
~I
I Acceleration cut
control
I
S.C.V.(Swirl control
I valve) control
~I
I monitor
Exhaust &
gasself-diagnosis
sensor
~I
I Pressu
reregu
Iator
S.C.V.control
solenoid valve
(On
the control
Inspection
lampsunit)
model)
sensor
Pressure regulator control
solenoid valve
control
Fail-safe function
8
8
8
8
6/23
~
IGNITION
FUSIBLE
LINK
SWITCH
CHECK CONNECTOR
r-
OFFIACCION I ST
{8J-
-@
CHECK
ENGINE
LI GHT@
FUSE
f--1S}
>34 382336
-0
E. C. C. s.
...:-.
iii
RELAY
SATTERY
46
5
24
10 I
25
INJECTOR
~
~
~
~
U
ffi3
PRESSURE REGULATOR
CONTROL
106
SOLENOID
110
105
103
112
SOLENOID VALVE
A. 1. V. CONTROL
102
SOLENOID VALVE
S. C. V. CONTROL
-=-
VALVE
E. G. R. CONTROL
12
47
SOLENOID
VALVE
109
16
17
I ~--_m-7
I A~~E~LOW
113
To tachometer
-=-
n---__n_-1...
'-.I
-....
I\.)
W
m48
1] 6
"'p
Y'
RESISTORm
_n--nn
$
-= -=
-= -=
For
(0
A/T model
en
m
"T1
~
C'I
'"
13
n
0
Z
--i
;u
0
r
@:
A/T model
@:
~:
A/T mode
With
~:
Without
head-up
THROTTLE
VALVE
SWITCH
SWITCH
~LL IDLE
--i
4]
11
<n__n
i-+-I
3D
31
18
..:::::::.J
22
40
I
32
For Canada
01SPLAY
eo
HEAO-IE
UNIT
I] I
~
~~~~6~LE
28
II
A. S. C. D.
L->
.,!,.
S ENS 0 R
EXHAUST GAS
TEMPERAl.URE
SENSOR (g
I'.tI
AIR
TEMPERATURE
SENSOR
26
115
H
--~:::::::::::::::~
37
A. S. C. D.
ENGINE
TEMPERATURE
21LL
29
For U.S.A.
display
POWER STEERING
OIL PRESSURE
35
display
head-up
5TH POSITION
-=-
20
wi thout
'R
44
33
@:
with
~=~
~SWITCH
43
CONDENSER
ANGLE
SENSOR
@:
INHIBIr
-=-
Ca I Iforn Ia
M/T modeI
PUMP
45
c
z
cn__m_-T
CRANK
SPARK PLUG
n_-
RELAY
AIR REGULAT~
FUEL
!'1
INHIBITOR
SWI TCH @
A.A.C. VALVE -a
107
19
~:~
~~ [ff:i!I:i:
104
39
EXHAUST
GAS
SENSOR
a
a
a
a
A/T
CONTRQL
UNIT ~
SPEED
SENSOR
Sensor
+~I
SEF1651
~.
8/23
DESCRIPTION
INPUT/OUTPUT
SIGNAL LINE
d
E .
Crank angle sensor
Amount
'ti on
d Dist
of intake air
I
Engine temperature
Engine temperature
Air temperature
sensor
Intake air temperature
sensor
Throttle
Idle switch
I
E.C.C.S.
control
unit
Power transistor
Throttle sensor
Neutral position
Start signal
Ignition switch
9/23
'--
SYSTEM DESCRIPTION
The ignition timing is controlled by the E.C.U. in
order to maintain the best air-fuel ratio in response to every running condition of the engine.
The ignition timing data is stored in the ROM
located in the E.C.U., in the form of the map
shown below.
The E.C.U. detects information such as the injection pulse width and crank angle sensor signal
which varies every moment. Then responding to
this information, ignition signals are transmitted to
the power transistor.
e.g.
N: 1,800 rpm, Tp: 1.50 msec
A S.T.D.C.
Tp
(msec)
1.75i
1.50I
Injection
pulse
width
1.25i
1.00I
0.75
600
- ---
1,400
1,000
1,800
2,200
10/23
Idle switch
I
Idle signal
Start signal
Ignition
switch
Engine speed
SYSTEM DESCRIPTION
This system has a swirl control valve (S.C.V.) in
the intake passage of each cylinder.
While idling the S.C.V. closes. Thus the velocity of
the air in the intake passage increases, promoting
the vaporization of the fuel and producing a swirl
in the combustion chamber.
Because of this operation, this system tends to
increase the burning speed of the gas mixture,
Idle switch
Water temperature
Engine rpm
Solenoid valve
S.C.V.
ON
Below 1,800
ON
Close
OFF
Open
Except above
S.C.V. control
solenoid valve
Enginetemperature
E.C.C.S.
control
unit
This table shows the control when starting enginetemperatureis above 10C (50F).
~
11/23
Operation
Condition
Fixed condition
20C (68F)
80C (176F)
OFF
A duty ratio is fixed at
the preprogrammed value.
Fuel is shut off above
THROTTLE
2,400 rpm.
(Engine speed does not
exceed 2,400 rpm.)
Engine
temperature decided
Operation
System
SENSOR
SENSOR
MALFUNCTION
SENSOR
12/23
..
..
--
--~
-~~
INSPECTION START
. Gaskets
. Throttle valveand throttle valveswitch operation
I~~I
SEF457C
""
)!'
1..!
0::
3
4
~,."..~",L../" 5
'~<I,6
+(
fI
-8
~1
."""',,"',"
SEF477B
O.K.
O.K.
Check ignition timing with
a timing light.
1S:t2 B.T.D.C.
~~
N.G.
O.K.
~~~--,-'-~fj
50 A.T.D.C.
20 B.~
1// /'
-100 B.T.D.C~ '"'
~~~.,
@
13/23
1
~
Check ignition timing with
a timing light.
15:t2 B.T.D.C.
N.G.
O.K.
3
2
>,.",,,,,,~,,,,,,. 5
1~
=
0:
.""""Im;n
'v"-(6
~~
~1
~
~8
SEF477B
~~\
~V
j\.(r)J
~/~
SEF450H
~r\
~~
No
INSPECTION END
'--~(r)
d~,/i~~
SEF292H
j
D
14/23
TROUBLE DIAGNOSES
Self-diagnosis
system)
Code No.
California
NonCalifornia
11
12
13
14
21
31
32
E.G.R. function
33
35
41
X
X
43
45
Injector leak
55
15/23
TROUBLE DIAGNOSES
Diagnostic Procedure 8
[Not self-diagnostic
item (For non-Californiamodels)]
E. G.R.
CONTROL
SOLENOID
VALVE
E. C. C. S.
CONTROL
UNI T
@)
Iij
@)W
"'''' -=<> Ii]
_"XI
IDS-LG
FUSE
WJ
B/R
@)@)
(E. F. I.
harness)
(Eng I ne
harness)
BR-' tBR
room
BR
w
BR~
I~ ~:~
"1
2
3
4
5
~
<II
n
0
-('r --0
:J
I GNITI ON
SWITCH
FUSIBLE
LINK
FUSE AND
FUSIBLE
LINK
(] n RELAY BOX)
~8~
1m
~
BATTERY
Component
location
16/23
CDJ~
@g
OFF ACC ON ST
SEF4631
--'-
'1
TROUBLE DIAGNOSES
Diagnostic
Procedure 8 (Cont'd)
INSPECTION START
Responds
SEF445H
~-
~$\
aoggi.,
=='---
. -::C'\
"-
"
Improper connection
SEF816F
oo
tD
CfH
":"
SEF158H
Engine
condition
Idle
~~u
CONNECT
ClUNIT
105
00
?~
~L:t-r-J Cf~H
'8
CONNECTOR II
CHECK COMPONENT.
Check E.G.R. control valve.
(See page EF & EC-148.)
I
N.G.
Replace E.G.R. control valve.
N.G.
Racing
Voltage
Battery
N.G.
voltage
Voltage
Idle
Racing
Temporarily
drops to 0 1V
O.K.
.
E.C.U. OUTPUT
CHECK
SIGNAL (Solenoid side).
1) Start engine and warm it up
sufficiently.
2) Check voltage betwen E.G.R.
control solenoid valve harness
CONNECT
O.K.
O.K.
Ii]
I
Ii]
N.G.
[!)
INSPECTION END
(;]
[!)
Battery
voltage
Temporarily
drops to 0 -1V
[Y]
+'
SEF159H
17/23
TROUBLE DIAGNOSES
Diagnostic Procedure 8 (Cont'd)
(j
Test condition
CHECK COMPONENT.
1) Stop engine.
.
.
kPa
mmHg, -12.60:1;2.36
O.K.
N.G.
CHECK COMPONENT.
Check E.G.R. control valve and
B.P.T. valve.
(SeepageEF & EC-148.)
Driving mode
Test condition
16 seconds or more
@
Vehicle
driving
valve.
Replace E.G.R. control solenoid
2) CheckE.G.R.control sole-
13,200:1;400 rpm I
Intake manifold vacuum:
-42.7:1;8.0
(-320:1;60
N.G.
O.K.
For non-California
O.K.
For California
Idling ---u
Ignition l.ILJ
switch: I I,'f
Time
OF F +---+-Until green and red inspection lamps go off.
INSPECTION END
(j
~~E~
/'
'-
"ON"
18/23
END
./
TROUBLE DIAGNOSES
Diagnostic Procedure 24
AIR TEMPERATURESENSOR(Code No. 41)
E. C.C.S.
CONTROL
UNIT
(E. F. I.
harness)
26-L
21-B
2'-B
at;]
~mf
~@)
~ ala]
AIR
TEMPERATURE
SENSOR
SEF4641
Component
location
19/23
""'"
TROUBLE DIAGNOSES
Diagnostic Procedure 24 (Cont'd)
""
~,
INSPECTION START
(bla
lu
CHECK COMPONENTS.
Check air temperature sensor.
(See page 20.)
~
i5~u
<='
2"' 29
I;]
bla
~i5
N.G.
1)
minals @. @.
Continuity should exist.
I;]
r=Cl'UNIT
O.K.
[ill
~
~i5n
N.G.
_6
CONNECTORII
SEF3131
O.K.
N.G.
O.K.
Reinstall any part removed.
O.K.
INSPECTION END
20/23
N.G.
TROUBLE DIAGNOSES
Electrical Components Inspection
E.C.U. INPUT/OUTPUT
E.C.U. inspection table
TERMINAL
NO.
SIGNAL INSPECTION
*Data are reference values.
ITEM
*DATA
CONDITION
1.0- 3.0V
16
Engine is running.
1.0- 5.0V
18
19
Engine is running.
0 - Approximately 1.0V
0.4 - Approximately 4V
20
Throttle sensor
22
30
Engineis running.I
Do not run engine at high speed
under no-load.
0.2 - 0.5V
1.0 - 1.5V
Air temperature is 20C (68F).
26
28
31
40
Engine is running.
0.3 - Approximately3V
2.0 - 3.0V
Approximately9 - 10V
33
Idle switch (
Throttle
valve:
Throttle
valve:
e side)
Any position
34
idle position
Start signal
OV
8 - 12V
Cranking
OV
35
21/23
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
AIR TEMPERATURE
SENSOR
Temperature c (oF)
Resistance kn
20 (68)
2.1 -2.9
80 (176)
0.27 - 0.38
SEF2651
22/23
(S.D.S.)
General Specifications
~
IGNITION
TIMING
15:t2
B.T.D.C.
M/T 700:t50
A/T 750:t50
rpm
IDLE SPEED
Inspection
and Adjustment
20C (68F)
80C (176F)
2.1 -2.9
0.30 -0.33
20C (68F)
80C (176F)
2.1.2.9
0.27 - 0.38
kn
Resistance
IDLE SWITCH
Engine speed when idle switch
is changed from "OFF" to
"ON"
rpm
FUEL PRESSURE at idling
(Measuring point: between fuel
filter and fuel pipe)
Vacuum hose is connected
kPa (kg/cm' ,psi!
Vacuum hose is disconnected
kPa (kg/cm' , psi)
FUEL INJECTOR
Coil resistance
AIR REGULATOR
Resistance
M/T
A/T
1,OOO:t150
1 ,OOO:t 150
Approx imately
226 (2.3,33)
Approximately
294 (3.0,43)
Approximately
10 15
Approximately 75
kn
85.3:1:8.53
NISSAN
MOTOR
CORPORATION
IN U.S.A.
Technical
Publications
Department
23/23