2000-2005 Toyota Celica Repair Manual Volume2

once wonad =>) ee MANUAL »® ENGINE »= CHASSIS = BODY » ELECTRICAL a er VOLUME 2FOREWORD This manual (Volume 2) contains repair procedures for the engine, chassis and body, and electrical service procedures for the 2000 CELICA, Applicable models: 2ZT230, 231 series For maintenance, preparation, specifications and diagnostics service procedures, refer to VOLUME 1 (Pub. No. RM744U1). The manual is divided into 21 sections with a thumb index for each section at the edge of the pages. Please note that the publications below have also been prepared as relevant service manuals for the components and systems in this vehicles Hanzal Name Tene = URHOE Automate Transaxle Repair Manual Avg. 1958) frau = UR40E, Set Automate Tarsanle Repair Monin! (Aug 1969) Ga + 2000 CELIGA Eisenia! Wring Diagram Saas = 2000 GELIGA New Gar Fealvos ReET Al information in this manual is based on the latest product information at the time of publication. However, specitications and procedures are subject to change without notice. TOYOTA MOTOR CORPORATION ©2000 TOYOTA MOTOR CORPORATION Al rights reserved. This book may not be repio- duced or copied, in whole or in pad, without the nitten permission of Toyota Motor Corporation First Printing: Jul. 14, 1999 01-980714-00 Fourth Printing: Mar, 14, 2000 04-000014-01CAUTION This manual does not include all the necessary items about repair and service. This manual is made for the purpose of the use for the persons who have spacial techniques and certifications. In the cases that non~specialized or uncertified technicians perform repair or service only using this manual or without proper equipment or tool, that may cause severe injury to you or ether people around and also cause damage to your customer's vehicle. In order to prevent dangerous operation and damages to your customer's vehicle, be sure to follow the instruction shown below. Must read this manual thoroughly. Itis especially important to have good understanding all the contents written in the PRECAUTION of "IN" section. The service method written in this manual is very affective to perform repair and service. When performing the operations following the procedures using this manual, be sure touse tools spesified and recommended. If using non-spesified or recommended tools and service method, be sure to confirm safety of the technicians and any possibility of causing personal injury or damage to the customer's vehicle before starting the operation. ifpartreplacementis necessary, must replace the part with the same part number or equivalent part. Do not replace if with inferior quality. Itis important to note that this manual contains various "Cautions" and "Notices" that must be carefully observed in order to reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the vehicle or render it unsafe. Itis aiso important to understand that these “Cautions” and "Notices" are not exhaustive, because it is important to wam of all the possible hazardous consequences that might result from failure to follow these instructions.NOTE: The screen toned sections below are in VOLUME 1 (Pub. No, RM744U1), ENGINE MECHANICAL EMISSION CONTROL SFI COOLING LUBRICATION IGNITION STARTING CHARGING CLUTCH C56 MANUAL TRANSAXLE C60 MANUAL TRANSAXLE U240E AUTOMATIC TRANSAXLE U341E AUTOMATIC TRANSAXLE SUSPENSION AND AXLE BRAKE STEERING SUPPLEMENTAL RESTRAINT SYSTEM BODY ELECTRICAL BODY AIR CONDITIONING ALPHABETICAL INDEX Al ea GERBEEEESEERRSEERESEREENGINE MECHANICAL come EMA COMPRESSION ...... setters EMS VALVE CLEARANCE : eM IGNITION TIMING cectiteteseree EMS IDLE SPEED... . EMS TIMING CHAIN cee EM-15 CYUNDER HEAD . EM-36 ENGINE UNIT coe EM-70 CYLINDER BLOCK : M85 EXHAUST SYSTEM 20.0.0 0.60ccceceee EMENSeM ENGINE MECHANICAL CONC CO/HC INSPECTION HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 7. INSTALL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) Air pipes and hoses of air induction system connected (d) All accessories switched OFF (e) Ail vacuum tines properly connected (SFI system wiring connectors fully plugged {@)__ Ignition timing check correotly ‘Transmission in neutral position fem} ‘Tachometer and CO/HC meter calibrated by hand START ENGINE RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SE- coNDS 4, INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM Complete the measuring with 3 minutes. HINT: When doing the 2 mode (idle and 2,500 rpm) test, these measurement order prescribed by the applicable local regulations. 2220]ENGINE MECHANICAL —__COHC If the CO/HC concentration does not comply with regulations, troublesheot in the order given below. Check heated oxygen sensor operation (See page 0-49), See the table below for possible causes, and then Inspect and correct the applicable causes if neces: sary. 60 He Problems Causes Nowa Hig Rough ite 1. Fait gations: stncosret tng + Fouled, shorted or improperly gapped ye Oper crossud high-tension enxe's 2. Inconect valve clearance 3. Loakyinlake and-exhaust valves 4 teaty ovincers Tae Roxane (Fuctunting HC toactng) 5 vaca ake *PCV nase trae anit Tesoro boxy IAC vats Brake boot tne 2 Loan mixture causing ise igh Hg Roogh ilo (Blk smaka from exhaust) 3. Rested after 2. Piugaed PCY vaive 3, Fauty SF systems: -Fauty pressure regulator Detective ECT sensor + Oetectve sensor Fatty EOM Faulty yectors Faulty tote postion sensorENGINE MECHANICAL — —¥ Compression Gauge ae y SES COMPRESSION COMPRESSION INSPECTION HINT: EMS If there is lack of power, excessive oil consumplion or poor fuel economy, measure the compression pressure 1. WARM UP AND STOP ENGINE Allow the engine fo warm up to normal operating temperature, 2, REMOVE IGNITION COIL (See page IG-8) 3. REMOVE SPARK PLUGS 4, _ INSPECT CYLINDER COMPRESSION PRESSURE (a) Insest a compression gauge into the spark plug hole. (b) Fully open the throttle. (c) While cranking the engine, measure the compression. pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. ()__ Repeat steps (a) through (c) for each cytindex. NOTICE: ‘This measurement must be done in as short a time as possible. (e) ‘Compression pressure: 12Z-FE 1,500 kPa (15,3 kgficm®, 218 psi) 2ZZ~GE 1,400 kPa (14.3 kgtiem?, 203 psi) or more, Minimum pressure: 1ZZ-FE 1,000 kPa (10.2 kaficm2, 145 psi 222-GE 1,000 kPa (10.2 kgt/em?, 145 psi) Difference between each cylinder: 12Z-FE 100 kPa (1.0 kgficm?, 15 psi) or less. 22Z~GE 110 kPa (1.1 kgticm?, 16 psi) or less If the cyfinder compression in one more cylinders is (ow. pour a small amount of engine oil into the cylinder trough the spark plug hole and repeat steps (a) through (c} for cylinders with tow compression. + If adding oil helps the compression, itis likely that the piston tings andor cylinder bore are worn or damaged. + i pressure slays low, a valve may be sticking or seating is improper, or there may be teakage past the gasket REINSTALL SPARK PLUGS INSTALL IGNITION COIL (See page IG-7)EM ENGINE MECHANICAL — VALVE CLEARANCE VALVE CLEARANCE ADJUSTMENT HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE CYLINDER HEAD COVER (See page EM-18) 2, SET NO. 1 CYLINDER TO TOC/COMPRESSION (a) Tum the crankshaft pulley, and atign its groove with the timing mark "0" of the timing chain cover. (b) Cheok that the point marks of the camishail timing sprock- 8 Pain Wane 2 ets are in straight line on the timing chain cover surtace Or NY as shown in the illustration. Hf not, turn the crankshaft 1 revolution (360°) and align the marks as above. 3. INSPECT VALVE CLEARANCE (@) Check only the valves indicated. + Using a feeler gauge, measure the clearance between the valve lifter and camshaft + Record the out-of-specification valve clearance measuremants. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): 122-FE: Intake 0.15 - 0.25 mm (0,006 — 0.010 in.) Exhaust 0.25 ~ 0.35 mm (0.010 - 0.014 in.) 2Z2-GE. Intake 0.15 ~ 0.25 mm (0.006 - 6.010 in.) Exhaust 0.35 ~ 0.45 mm (0.014 ~ 0.EMS ENGINE MECHANICAL VALVE CLEARANCE (b) @ (@ ) (e) (a) “Turn the crankshaft 1 revolution (360°) and atign the mark as above (See procedure in step 2). ‘Check only the valves indicated as shown, Measure the vaive clearance (See procedure in step (a)). 1ZZ-FE: ADJUST VALVE CLEARANCE Set the No. 1 cylinder to the TDC/compression (See procedure in step 2) Place matchmarks on the timing chain and camshatt timing sprockets. Remove the 2 bolts and chain tensioner. Remove the camshaft and timing sprocket assemblies (See page EM-42). (1) 19 camshaft bearing cap bolts (2) 9 camshatt bearing caps (No. 1 & No. 3) (3) Exhaust camshaft and timing sprocket assembly (4) Intake camshatt and timing sprocket assembly HINT: ‘When disconnect the timing chain from the camshatt timing sprocket, holding the timing chain. fe) Tie the timing chain with a string as shown in the illustration, NOTICE: 0 Be careful not to drop anything inside the timing chain cover. Do not allow the chain to come into contact with water or dust. Remove the valve litters.ENGINE MECHANICAL -_VALVE CLEARANCE (g) Determine the replacement valve lifter size according to these Formula or Charts: + Using a micrometer, measure the thickness of the removed lifter. + Calculate the thickness of a new fitter so the vaive clearance comes within the specified value. Thickness of used lifter ..- Measured valve clearance Nevo Thickness of new lifter Intake: N= T + (A — 0.20 mm (0.008 in.)) Exhaust: N= T + (A~0.30 mm (0.012 in)) + Select a new iter with a thickness as close as possible to the calculated values. HINT: Litter are available in 35 sizes in increments of 0.020 mm (0.0008 in.}, from 5.060 mm (0.1992 in.) 10 5.740 mm (0.2260 in). 5. 22Z-GE: ADJUST VALVE CLEARANCE (a) Remove the adjusting shim {i) Tum the crankshaft so that the cam lobe of camshatt on the adjusting valve points upward. (2) Using SST, press down the valve. (3) Using SST, remove the adjusting shim. (4) Determine the replacement shim size according to these Formuia or Charts: + Using dial indicator, measure the thickness of the removed shim. + Calculate the thickness of a new shim so the valve clearance comes within the specified value.EM-7 LENGINE MECHANICAL _—-_ VALVE CLEARANCE, Te-weeu Thickness of used shim Avnunee Measured valve clearance Thickness of new shim Intake: N= T+ (A 0.20 mm (0.008 in.)) Exhaust: N = T+ (A — 0.40 mm (0.016 in.)) + Select anew shim with a thickness as close as possible to the calculated values. HINT: ‘Shim are available in 41 size in increments of 0.020 mm (0.0008 in), from 2.000 mm (0.0787 in.) to 2.800 mm (0.1102 in.)EMS ENGINE MECHANICAL VALVE GLEARANGE (eciz al oees 2 lesezoares| » liseizo)soe9| @ leseedous| 2: [usiedoers % frrezaicars| ox oncom! oy [issoechoaes| ce | (sezz-orcnas| es [larwectores| ry |irorcdooes| te [ecezorooes | 29 liveveooers| ev |ceoneaonrs| cae ave ov _|Csne08" 9 iei2e 002s 8 [beacon scare oss 3 [teioewaar | ieee 0) 0085| ¥ [(eooe aoa) eas choos § ( x6 |‘eeorctoors| oe [izssr loss) + OH) sau oN LA aan] PR | au l Tub it Sou eR MON ssonou | ui 2902°0) wis oges eur eoeicay oor'0 st 29020} wus oSe'S 84, “Idx = 900'0) wu €2°9. XpIog) soueseajo angen oxeIUt (eeu eK uonsstas sour] eNeA 34-ZzbeM VALE OL EARANGE ENGINE MECHANICAL vere ievizolors| oe lerecoloses | oa beeweaicers| oe or 4 20.8.9) uw OES aun aneIeay ‘ (U12210-0) Ww Opy 081 20verEAD Banoo Gut z ue (payeisuy si 9yn Cu ZOLZ-0) Ww OFE'S ByL ITdINYXa 100 040°0) ww $e"0~ g2'0 (109) eousseays anien ysneyea (were chores] va ‘cizeoioess| 23 (soze'a) 0085] 09 lueicooass) nena cicees| ze jouge 0908" 20 gene) oes ‘@sevooss 90 seouvanys Taos Sora i wan {asneuxa) Weud uonostes 20417 OER:EM-10 VALVE CLEATANOE SNGINE MECHANICAL — SUIUS Op “ON mou B UBM GAYS ('U: S>6O'D} Wa! doy z @uI soe\CoN, 8 £§40°9) Uw OCY'D S! SURES DeINsBAW aul ue ‘paypisut si uutus (ui sze0'O) wus Oge'Z 34x “STeWWXE Tearareaee [Reso (Cut 840° - 990°0) wut sz'0- SLO (280 (piog) souRseajs aAjen exe ‘urge LY Choreleere yer ipo oere re pia Seer ooo 2 res sor olgaae | [Lee OEE erate 35 | Tatao OSES" ee ee Liiseoatoee Bee eiepraera 2 ps. 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S| WINS (u! 29R0'0) WL OOg'2 BAL SFTEAYXS (lesot Wome + waco atone a OF torso or care fez> a mObs toe wuee ee [leenratee ee a a {(plog) souereayo aaren ishelica po re a at 3500" isreocboed sO} TD OTSTE | BE eases oro e | FO, COTTE ESOMeTE eatin ey ear TONE LIS re a Heoneacas| = anf ae Tasees ease Esso (ag seme GIB) omen Uo a tau seu UNIE MEN, Bilsestelastetel-lereel inelatalsla Ie [ees sineretsteys a | PPL ile il SSH HE Epson ar os 2 : eS SEER ESE SEEEE E oaHee) ‘ aEMA12 ENGINE MECHANICAL VALVE CLEARANCE 6 fa) (b) (c) @ te) 5 wo POO (ens iON A | 222-GE: (hy 6 o 7 122-FE: REINSTALL CAMSHAFT Reinstall the valve lifters (See page EM-61). Align the crankshaft pulley groove with the timing mark "0" of the timing chain cover. Hold the timing chaia, and place the intake camshaft and timing sprocket assembly. Align the matchmarks on the timing chain and camshatt timing sprocket. Reinstall the camshaft and timing sprocket assemblies (See page EN-65}, Check that the point marks of the camshaft timing sprockets are in straight line on the timing chain cover surtace as shown in the illustration, Check that the matchmarks on the timing chain and camshalt timing sprockets. Install the chain tensioner (See page EM-25). Recheck the valve clearance (See procedure in step 3). ‘Check the valve timing (See page EM-25). REINSTALL CYLINDER HEAD COVER (See page EM-25)EM13 ENGINE MECHANICAL IGNITION THANG IGNITION TIMING INSPECTION 1, WARM UP ENGINE ‘Allow the engine to watm up to normal operating temperature. 2. CONNECT TOYOTA HAND-HELD TESTER OR OBDit SCAN TOOL (a) Connect the TOYOTA hand-held tester or OBDI! scan tool to the DLCS. (b)} Please refer (0 the TOYOTA hand-held tester or OBDI scan tool operator's for further details. 3. CONNECT TIMING LIGHT TO ENGINE 4. INSPECT IGNITION TIMING Using a timing light, check the ignition timing. Ignition timing: 1Z2-FE: 10-18" BTDC @ idle 222-GE: 8-12" BTDC @idle (Transmission in neutral position) HINT: After engine rpm is kept at 1,000 ~- 1,200 rpm for § seconds, check that it returns to idle spead. 5, DISCONNECT TIMING LIGHT FROM ENGINE 6 DISCONNECT TOYOTA HAND-HELD TESTER OR OBDI SCAN TOOL,eMa4 ENGINE MECHANICAL. OLE SPEED IDLE SPEED INS! 1 (a) 0) ©) @) ) h @ (hy i) the PECTION INSTALL CONDITIONS Engine at normal operating temperature Air cleaner installed All pipes and hoses of air induction system connacted All vacuum lines properly connected SF? system wiring connectors fully plugged All operating accessories switched OFF Ignition timing check correctly ‘Transmission in neutral position Ait conditioning switched OFF CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL Connect the TOYOTA hand-held tester or OBDI scan tool to the DLCS. Please refer to the TOYOTA hand-held tester or OBDEI scan tool operator's manual for further details. INSPECT IDLE SPEED Race the engine at 2,500 1pm for approx. 90 seconds. Check the idle speed Idle speed (w/ Cooling fan OFF): 122-FE ‘WIT 700 50 rpm WT 750 + 50 rpm 22Z-GE MIT 600 + 50 rpm AT 750 + 50 rpm idle speed is not as specitied, check the IAC valve and air intake system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOLEM-15 ENGINE MECHAMIGAL — THANG CHAIN TIMING CHAIN COMPONENTS Upper Front Fender Apron Seal £S Oil Pressure Drive Belt Switch Connector wi 37} { i PS Pump “Ge oe. ~ Sp Upper Radiator Support Me Tp Seal Be, Generator Wie — soneraton Generator gg : Connector 122-F€- 350,35) Wire Clamp FH Engine Mounting insulator coon PR 222-GE, Piven Moving lf Ingulator (26H)EM16 ENGINE MECHANICAL. THANG CHAN, 12Z-FE: RH Engine Mounting Bracket No. 2 Cylinder Head Cover Wire Harness Protector {geition Coit (ignitor) Front Crankshaft Oil Seat ES Crankshatt go 9 ; Pulley 6 @ Gasket Camshatt Timing Sprocket Water Pump Valve Timing Contialier ‘ety of {AS ‘Crankshatt Timing Sprocket Chain Vibration Dumper ns Crank Angle Sepsor Plate: Bl | : Speciied torque sable patENGINE MECHANICAL TIMING CHINN EM-17 222-GE: (990,36) | e Driver Belt Tensioner Timing Ghain Tensionor Front Grankshall g, OWSeat | (ane Cranksbatt Pulley. Cain Tensioner ‘Slipper Jp [Mim (KaFem, iby]: Specit “pRan reusable pat BH Engine Mounting Bracket ose Owens “ees tater Pap Puloy Thang Chain Wter Pump," 8 Wire Harness Protector no Crankshalt Position Sensor Gamshatt Timing Sprocket Crankstialt Timing Sprocket Chain Vibration Oumper Grank Angie Sensor Plate fied torque 8 Dipstick Guide O-RingEM-18 ENGINE MECHANIGAL > TUNG CHAN REMOVAL 6. fa) (b) HINT: REMOVE UPPER FRONT FENDER APRON SEAL AND UPPER RADIATOR SUPPORT SEAL DRAIN ENGINE COOLANT REMOVE RH FRONT WHEEL REMOVE RH ENGINE UNDER COVER REMOVE DRIVE BELT AND GENERATOR (See page CH-7) DISCONNECT PS PUMP FROM ENGINE Disconnect the PS oil pressure switch connector. Remove the 2 nuts and through bolts, and disconnect the PS pump from the engine (See page SR~24). Put aside the pump and suspend it to the cowl with a string, 7 fa) (b) HINT: Place a wooden biock between the jack and engine. REMOVE RH ENGINE MOUNTING INSULATOR Set the jack to the engine. 1ZZ-FE. Remove the 4 bolts, 2 nuts and RH engine mounting insu- fator. 222-GE: Remove the 5 bolts, 2 nuts and RH engine mounting insulator. 122-FE: REMOVE CYLINDER HEAD COVER Remove the 4 bolts and No. 2 eylinder head cover. Remove the 4 ignition coils (See page 1G~6) Disconnect the 2 PCV hoses trom the cylinder head,@ 9. fa) io} {c) td) (e) cv] (g) 10. fa) (o EM-19 ENGINE MECHANICAL —_ TIMING GHAI Remove the 9 bolts, 2 seal washers, 2 nuts, cylinder head cover and gasket. 2ZZ-GE: REMOVE CYLINDER HEAD COVER Remove the 4 boits and No. 2 cylinder head cover, Remove the ignition coils (See page iG~6) connect the 2 PCV hoses from the oylinder head cov- or. Remove the 2 nuts, bolt and disconneet the No. 3 ventilation hose from the No. 4 ventilation pipe. Remove the No, 1 ventilation pipe and gasket Remove the 9 bolts, wire harness protector, cylinder head cover and gasket Remove the O-zing from the cylinder head cover. SET NO. 1 CYLINDER TO TDC/COMPRESSION ‘Tum the crankshaft pulley, and align its groove with timing mark "0° of the timing chain cover Check that the point marks of the camshaft timing sprockets are in straight line on the timing chain cover surlace as shown in the illustration. IF not, turn the crankshaft 1 revolution (60°) and align the marks as above,EM-20 ENGINE MECHANICAL —_TaMING CHAIN 11. REMOVE CRANKSHAFT PULLEY (a) Using SST and 2 nuts (width: 10 mm (0.25 in), remove the pulley bolt SST 08213-70010, 09330-00021 (6) Remove the crankshaft pulley. HINT: I necessary, remove the pulley with SST, SST 08950-60012 (09951-05010, 09952-05010, (09953-05020, 09954-05020) 12, DISCONNECT CRANKSHAFT POSITION SENSOR FROM TIMING CHAIN COVER Remove the 2 bolts and crankshaft position sensor. 13, REMOVE DRIVE BELT TENSIONER Remove the bolt, nut and drive belt tensioner. 14. REMOVE RH ENGINE MOUNTING BRACKET (a) 1ZZ-FE Flemove the 8 bolts and mounting bracket. (o) 222-GE: Remove the 4 bolts and mounting bracket, 18. REMOVE CHAIN TENSIONER Remove the 2 nuts and chain tensioner. 16, REMOVE WATER PUMP (See page CO-5) 47. 122-FE: REMOVE TIMING CHAIN COVER (a) Remove the 11 bolts and aut. {b) Using atorx wrench socket (E8), remove the stud bolt (c) Remove the timing chain cover by prying the portions be tween the oylinder head and cylinder block with a serew- driver. NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.EM-21 ENGIWE MECHANICAL —_Ti4iNG CHAIN 18. 22Z-GE: REMOVE TIMING CHAIN COVER (a) Remove the 12 bolts. (0) Using a torx wrench socket (E8), remove the stud bolt. (c) Remove the timing chain cover and 2 gaskets. 19. REMOVE GRANK ANGLE SENSOR PLATE 20. REMOVE CHAIN TENSIONER SLIPPER Remove the bolt and siipper, 21. REMOVE TIMING CHAIN AND CRANKSHAFT TIMING SPROCKET It the crankshaft timing sprocket cannot be removed by hand, use 2 screwdrivers. NOTICE: Position shop rags as shown to prevent damage. 22, REMOVE CHAIN VIBRATION DAMPER: Remove the 2 bolts and damper. 23. REMOVE VALVE TIMING CONTROL ASSEMBLY AND CAMSHAFT TIMING SPROCKET Hold the hexagonal head wrench portion of the camshaft with wrench, and remove the bol, valve timing controller assembly and timing sprocket. NOTICE: + Be carefut not to damage the cylinder head and valve lifter with the wrench. + De not disassembie the vaive timing controller assembly.EMA22 ENGINE MECHANICAL _- TIMING CHAIN 122-FE: INSPECTION 1, INSPECT TIMING CHAIN AND TIMING SPROCKETS, (@) Using a vernier calipers, measure the length of 16 links with the chain dully stretched. Maximum chain elongation: 122.6 mm (4.827 in.) Ii the elongation is greater than maximum, replace the chain. HINT: Make the same measurements pulling at 3 or more places selected at random, (} Wrap the chain around the timing sprocket, (©) Using a vernier calipers, measure the timing sprocket diameter with the chain, NOTICE: Vernier calipers must contact the chain rollers for measuring. Minimum sprocket diameter (w/ Chain): Camshaft 97.3 mm (3.831 in.) Crankshaft 51.6 mm (2.031 in.} It the diameter is less than minimum, replace the chain and sprockets. 2. INSPECT CHAIN TENSIONER SLIPPER AND VIBRA- TION DAMPER Measure the chain tensioner stipper and vibration damper woars. Maximum wear: 1.0 mm (0.039 in.) IW the wear is greater than maximum, replace the slipper and/or damper.EM-23 ENGINE MECHANICAL TIMING CHAIN ¥ 3. (@) ) INSPECT CHAIN TENSIONER: Check that the plunger moves smoathly when the ratchet paw is raised with your finger. Release the ratchet pawl and check that the plunger is locked in piace by the ratchet pawl and does not move: when pushed with your finger. INSPECT Olt JET (See page LU-11)ENGINE MECHANICAL -_TIMING CHAIN REPLACEMENT HINT: ‘There are 2 methods (A and B) to replace the oil seal which are as follows: REPLACE CRANKSHAFT FRONT OIL SEAL (a) timing chain cover is removad from cylinder block (1) Using a screwdriver and a hammer, tap out the oil seal (2) Using SST and a hammer, tap in a new cil seal untit its surface is flush with the timing chain cover edge. SST 09309-37010 (3) Apply MP grease to the oll seal lip. TTT Fy (b) _Iftiming chain cover is instalted to the cylinder block, a J " ehy A. Cut Position (1) Using a knife, cut off the oil seal tip, e i a (2) Using a screwdriver, pry out the olf seal. & yak NOTICE: AS Be careful not to damage the crankshaft. Tape the screw- Ce ee | driver tip. (3) Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge. SST 09303-37010M25 ENGINE MECHANICAL — TRAINS CHAN INSTALLATION 1 (a) (b) INSTALL VALVE TIMING CONTROLLER ASSEMBLY AND CAMSHAFT TIMING SPROCKET Apply engine oil in the range from the tip of the intake ‘samshaft 10 16 mm from that tip. Align the timing mark on the value timing controtier assembly witl the kaock pin, and install the value timing controller assembly to the cam shaft NOTICE: Do not push valve timing controller assembly to the camshatt forcibly when Instalting it. fe) (2) e) ib) Align the knock pin hole in the cam shaft timing sprocket with the knock pin of the cam shaft, and exhaust the sprocket to the cam shaft ‘Temporarily install the timing sprocket bot, Hold the hexagon wrench head portion of the camshatt witt a wench, and tighten the timing sprocket bolt. Torque: 12Z-FE 45 N-m (460 kgt-om, 33 ft-lbt) 22Z-GE 54 N.m (551 kgt-cm, 40 ttlbf) SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the hexagonal wrench head portion of the camshafts, and align the point marks of the camshaft timing sprockets. Using a crankshaft pulley bolt, Turn the crankshaft and set the set key on the crankshaft upward.ENGINE MECHANICAL —_SIMING CHAIN 3, INSTALL CHAIN VIBRATION DAMPER. Install he damper with the 2 bolts Torque: 12Z-FE 11 N-m (113 kgfom, 8 fib!) 222-GE 20,5 N-m (209 kgf-cm, 15 ft.lbf) 4, INSTALL TIMING CHAIN AND CRANKSHAFT TIMING SPROCKET (a) _ Install the timing chain on the crankshatt timing sprocket with the yellow color link aligned with the timing mark an the crankshaft timing sprocket. HINT: li necessary, install the sprocket with SST. SST 09223-22010 (bo) 122-FE Install the timing chain on the camshatl timing sprockets with the yeow color links aligned with the timing marks on the camshaft timing sprockets. (0) 222-GE: Install the timing chain on the camshaft timing sprockets with the orange color links aligned with the timing marks on the camshatt timing sprockets,EM.27 ENGINE MECHANICAL —_TIMING CHAIN, (d) Check that the tension between the intake camshalt timing sprocket and crankshatt timing sprocket. 5. INSTALL CHAIN TENSIONER SLIPPER, (a) _ Install the slipper with the bolt, ‘Torque: 12Z-FE 18.5 N.m (189 kgf-cm, 14 ft-lb) 2ZZ-GE 20.5 Nom (209 kgf-cm, 15 ft-lbf) (b) Check that the slipper moves is caught on the oylinder head stopper. NOTICE: DO not turn the crankshatt. Stopper y us| 6. _ INSTALL CRANK ANGLE SENSOR PLATE Install the pate with the "F” mark facing forward.M28 ENGING MECHANICAL — TANG CHAIN, Seal Width 1.5mm iN y Seal Width am SS} 2 | | Seal foe FH en ies 7. 1ZZ-FE: INSTALL TIMING CHAIN COVER AND WATER PUMP (2) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. + Using a razor blade and a gasket scraper, remove. all the old packing (FIPG) material from the gasket surfaces and sealing grooves. + Thoroughly ciean ali components to remove all the loose materi + Using a non-residue solvent, clean both sealing surfaces. (©) Apply seal packing to the timing chain cover as shown i the illustration. Seal packing: Part No. 08826 ~ 00100 or equivalent + Install a nozzle that has been cut to a 1.6 mm (0.16 ~ 0.20 in.) opening, HINT: Avoid applying an excessive amount to the surface. + Parts must be assembled within 3 minutes of application. Otherwise the materiat must be removed and reapplied. + Immediately remove nozzle from the tube and rein- slall cap. (6) Apply seal packing to 2 locations as shown in the illustration, Seal packing: Part No, 08826 - 00080 or equivalent + Install a nozzle that has been cut toa 1.5 mmm (0.16 = 0.20 in.) opening. HINT: Avoid applying an excessive amount to the surlace. + Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied + Immediately remove nozzle from the tube and reinstall cap.EM-29 ENGINE MECHANICAL — TIMING CHAN (2) Install the timing chain cover, O-zing and water pump with the 17 bolts and nut. Uniformiy tighten the bolts and, nut in several passes. Torque: 10 mm head: 9 N.m (82 kgf-cm, 80 in-Ibf) for C 18 N-m (133 kgf-cm, 10 ft.lbt) for A 11 Nem (113 kgt-em, 8 ftlbf) for others 12 mm head: 18.5 N-m (189 kgt-cm, 14 fbf) NOTICE: + Pay attention not to wrap the chain and slipper over the chain cover seal line. + After installing the chain cover, must install the ‘mounting bracket and water pump within 15 minutes. HINT: Each bolt fength in indicated in the illustration. A 45 mm (4.77 In) B 35 mm (1.38in) © 30 mm (1.18 in.) D 25 mm (0.98 in.) {e} Using a torx wench socket (E8), install the stud bolt. Torque: 9.3 N-m (95 kgF-cm, 82 in-Ibf)EM-30 ENGINE MECHANICAL —_ TIMING GHAIN 8 2ZZ-GE: Seal Width INSTALL TIMING CHAIN COVER AND WATER PUMP 18mm | (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, eylinder head and eylinder block, + Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surlages and seating grooves. ry + Thoroughly clean all components to remove all the loose material + Using a non-residue solvent, clean both sealing surfaces. (©) Apply seal packing lo the timing chain cover as shown in the illustration, Seal packing: Part No. 08826-00100 or equivalent + Instat a nozzle that has been cut toa 1.5 mm opening. HINT: Avoid applying an excessive amount to the surface. () Parts must be assembled within 3 minutes of application, Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. Install the 2 gasket to the timing chain cover as shown in the illustration. (a) HINT: Seal Width 4~ 5 mm - Apply seal packing lo 4 locations as shown in the illustra tion. Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that has been cuttoa4=5 mm (0.16 ~ 0.20 in.) opening. Avoid applying an excessive amount to the surface. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap.EMI ENGINE MECHANICAL —_TMUNNG CHAIN (e) Install the timing chain cover, O-ring and water pump wih the 19 bolts. Uniformly tighten the bolts in several passes Torque: A: 21 Nem (214 kgt-cm, 15 ftlbf) B: 11 Nim (113 kgtom, 8 ftlbf) ©: 9.0 Nem (92 kgf.om, 80 in.tbf) D: 9.0 N.m (92 katom, 80 in.ibf) NoTici + Pay attention not to wrap the chain and slipper over the chain cover seal line. + After install the chain cover, must install the mounting bracket and water pump within 15 minutes. (f) Using a torx wrench socket (E8), install the stud bol. Torque: 9.3 N-m (95 kgt-cm, 82 in-Ibf) 9, 1ZZ-FE: INSTALL RH ENGINE MOUNTING BRACKET (a) Apply seal packing to threads of the mounting bolt Seal packin Part No, 08826 ~ 00080 or equivalent HINT. Do not apply seal packing to 2 oF 3 threads of the bolt end. {b) Install the mounting bracket with the 3 bolts Torque: 47 Nm (479 kgt-cm, 35 ft-bt) 10. 222-GE: INSTALL RH ENGINE MOUNTING BRACKET Install the mounting bracket with the 4 bolts Torque: 49 N.m (500 kgt-om, 36 ft-lbf) 11. INSTALL DRIVE BELT TENSIONER (a) Check the appegrance before installing the drive belt ten sioner. lin case of having the oll leakage, crack, and ete., replace the drive belt tensioner. {b) Install the drive bolt tensioner. Torque: Bolt 122-FE 69 Nem (704 kgf-om, 51 ft.ibf) 22Z-GE 100 N-m (1,020 kgt-cm, 74 ftibs) Nut 29 Nom (296 kgf-cm, 21 ftibf) (©) Hook the toc! on the hexagonal portion of the drive beit tensioner brackel and operate drive belt tensianer 3 times, with full stioke HINT: Tako 8 seconds oF more for 1 full stroke.EM-32 ENGINE MECHANICAL TIMING CHAIN y ssn 12. 13, fa} tb) (c) 14, fa) (b) «) INSTALL CRANKSHAFT POSITION SENSOR Torque: 9.0 N.m (92 kgf-cm, 80 In-lIbf) INSTALL GRANKSHAFT PULLEY Clears the crankshaft pullay inside. Align the pulley set key with the Key groove of the pulley, and slide on the pulley. Using SST and 2 nuts (width: 10 mm (0.25 in}, install the pulloy bolt, SST 09213-70010, 09330-00021 Torque: 12Z-FE 138 N-m (1,409 kgt-cm, 102 fbf) 222-GE 120 N-m (1,200 kgf-cm, 87 ftlbt) INSTALL CHAIN TENSIONER ‘Check the chain tensioner, (See page EM~16) Release the ratchet pawl, fully push in the plunger and apply the hook to the pin 0 that the plunger cannet spring out Insert the O-ring with your hand until it reaches to the chamfering position and install nut temporally. Then, by tightening the nut, insert the chain tensioner to the installation position. HINT: In the case that the hook is released while pushing in, apply the hook again and push the tensioner in, Pay attention not to catch the O-ring as itis built in the chain tenisioner previously. Tighten tho 2 nuts. Torque: 9.0 N.m (92 kgf.cm, 80 in.bt)Emad ENGINE MECHANICAL —_ TIMING GHAI 15, SET CHAIN TENSION (a) Turn the crankshatt counterclockwise, and disconnect the plunger knock pin from the hook. ¢ Negecctl {) Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger. HINT: If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver or your finger so that the hookis released from the knock pin and the plunger springs out. 16. CHECK VALVE TIMING (a) Turn the crankshaft pulley, and align its groove with ieing mark “0’ of the timing chain cover. NOTICE: Always turn the crankshaft clockwise. {b) Check that the poirtt marks of the camshaft timing sprockets are in straight line on the timing chain cover surface. as shown ia the illustration. ff not, turn the crankshaft 1 revolution (860°) and align the marks as above. 17. ZZ-FE: INSTALL CYLINDER HEAD COVER (a) Remove any old packing (FIPG) material (b} Apply seal packing to 2 locations as shown in the ilkist’a~ tion. Seal packing: Part No. 08826 — 00080 or equivalentEM-34 ENGINE MECHANICAL _THWHNG CHAIN (©) _Insiall the gasket to the cylinder head cover. HINT: Part must be assembled within 3 minutes of application Otherwise the material must be remove and reapplied (d} Install the cylinder head cover with the 9 bolts, 2 seal ‘washers and 2 nuts. Uniformly tighten the bolts and outs, in the several passes, in the sequence shown Torque: wo washer 11. Nem (113 kgt-em, 8 ft-bf) wi washer 9.0 Nem (92 kaf-cm, 80 in-Ibf) (e) Connest the 2 PCV hoses to the cylinder head cover. (1) Install the ignition coil (See page IG~7). 18, 222-GE: INSTALL CYLINDER HEAD COVER {a} Remove any oid packing (FIPG) material. HINT: When FIPG on the head cover gasket side cannot be elimi nated completely, replace the gasket, (b) Apply seal packing to 2 locations as shown in the ilustration Seal packing: Part No. 08826-00080 or equivaient (c} _ install the gasket to the cylinder head cover. HINT: Part must bo assembled within 3 minutes of application. Other- wise the material must be remove and reapplied. (2) Install a new O-ring 10 the oyiinder head cover.EM-25 ENGINE MECHAWICAL —_ TRUNG CHAN fe) i (@) (b) @) at, 22, 23. 24. 25. 26. Install the cylinder head caver and wire hamess protector with thea bolts. Uniformly tighten the bolts, in the several passes, in the sequence shown, Torque: 10 Nem (100 kgf.om, 7 fbf) Connect the 2 PCV hoses to the cylinder head cover. Install a new gasket and No. 4 ventitation pipe with 2 nuts and bolt. Torque: Nut 10 N.m (100 kgt-cm, 7 ftlbf) Bolt 25 Nem (255 kgt-om, 18 ftlbt) Connect the No. 3 vantiation hose to the No. 1 ventilation pipe. install the ignition coil (See page IG-7). INSTALL RH ENGINE MOUNTING INSULATOR: AZZ-FE: install the RH engine mounting insulator with the 4 bolts and 2 nuts, Torque: 52 N-m (530 kgf-cm, 36 ftlbf) 222-GE Install the RH engine mounting insulator with the § bolts and 2 nuts. Torque: 52 N-m (530 kgf-cm, 38 ft-bf) INSTALL PS PUMP Install the PS pump with the 2 through bolts and nuts Torque: 36 N-m (370 kgf-cm, 27 ft-lbt) Install the PS pump pulley with the pulley nut Connect the PS oil pressure switch connector. INSTALL GENERATOR AND DRIVE BELT (Soo page CH-17) INSTALL RH ENGINE UNDER COVER INSTALL RH FRONT WHEEL FILL WITH ENGINE COOLANT (See page CO-2) INSTALL FRONT FENDER APRON SEAL AND UPPER RADIATOR SUPPORT SEAL START ENGINE AND CHECK FOR COOLANT LEAKSEM-36 ENGINE MECHANICAL ~._ CYLINDER HEAD CYLINDER HEAD COMPONENTS Upper Front Fender Apron Seal ive PS 0 Pressure Drive Bet Switch Connector Generator yg wre o Generator Fe Connector Wire Ciamp Seay . AZZ~FE: BH Engine Mounting Insulator (area * 272-GE: BH Engine Mounting Insulator ' waaay | be BH Engine Under Cover ‘ee (asta, 3 oe Front Exhaust Pipe O-Ring!EM-37 ENGIVE MECHANICAL CYLINDER HEAD 122-FE: No. 2 Cylinder Head Cover Upper Heated Insulator Wire Harness Exhaust Manitoid Protector Lower Heated Insulator Exhaust Maniloid Gasket S Ignition Coit goo wien y ¢ YY PCV Valve: | ch of Grommet . Slay Soe f 4 4 PV Hose Daivery Pipe and Fuel ~ Tube Assembly, Injector Crank Angle Sensor Plate “Chair Vibration Damper = Crankshaft Postion SensorEM40 ENGINE MECHANICAL CYLINDER HEAD 222-GE: ? oe # Gasket Cylinder Head Cover No.1 Veatiation Pipe Bearing Cap Intake Carmshale No. 1Camshat Bearing Caps TP pont ef f Exhaust Camshalt—_ a No. 3 Camshaft RH Engine Bee coat 1 ve asta : S86 page ENCE! ist (Bee 26) 2nd Turn i Drive Belt Tensioner (RIE. }-o~ : a WoO foe _- # Cylinder i Chain Head t Tensioner Gasket Slipper Chain Tensioner La be Bee ng Pat ation ay} | EEE, OC ms ah - ‘Chain Vibration Damper ore ~ rr 7 Pulley oe ~~ Grankshatt Position Sensor TEibA_] : Specitiod torque abo pat soe Crankshatt Pulley [Nim fot ao Nen-reENGINE MECHANICAL _-_GYLINDEF HEAD. EM4t 222-GE Valve Rocker Arai Ks ws ee LZ er Oil Pressure Saitoh Rocker No. 4 Shaft for WT e— Shim ® — Keeper @— spring Retainer Valve Spring @-—— Spring Seat . il Control Vaive for VT 7 ene. oneir Valve Gasket jae, WBA] Species torque p-réusable pait asker Ol Control ValveEM-a2 ENGINE MECHANICAL GyL/NDERLUEAD REMOVAL 1 Noo SoD % fa) (b) © () REMOVE BATTERY REMOVE ECU BOX (See page EM-74) DRAIN ENGINE COOLANT DISCONNECT ENGINE COOLANT RESERVOIR REMOVE AIR CLEANER ASSEMBLY DISCONNECT ACCELERATOR CABLE REMOVE DRIVE BELT AND ALTERNATOR {See page CH-7) REMOVE EXHAUST PIPE (See page EM~74) 1ZZ-FE: REMOVE EXHAUST MANIFOLD Remove the 3 balts and exhaust manifold stay. Remove the 6 boits and upper heat insulator. Remove the 5 nuts, exhaust manifold and gasket. Remove the 3 bolts and lower heat insulator.EMAg ENGINE MECHANICAL CYLINDER HEAD. 10. fa) ) ©) (a) it 12. 13. 14, 18. 16. f) ) () i) fe) 22Z-GE: REMOVE EXHAUST MANIFOLD Remove the 4 bolts and exhaust manifold stay. Remove the 5 bolts and upper heat insulator. Remove the 3 bolts, 2 nuts, exhaust manifold and gasket. Remove the 4 bolts and lower heat insulator. REMOVE IGNITION COIL (See page IG-6) REMOVE SPARK PLUG (See page iG-1) REMOVE PCV HOSES REMOVE THROTTLE BODY (See page SF-36) REMOVE INJECTOR (See page SF-21) 1Z2-FE: DISCONNECT ENGINE WIRE FROM CYLINDER HEAD Disconnect the ECT sensor connector. Disconnect the camshaft position sensor connector. Disconnect the oil contro! valve for VVT connector Disconnect the 2 ground wires Disconnect the 2 clamps and engine wire protector from the intake manifold. 22Z2-GE: DISCONNECT ENGINE WIRE FROM CYLINDER HEAD Disconnect the ECT sensor connector. Disconnect the camshatt position sensor connector. Disconnect the oil control valve for VWT connectors. Disconnect the oil control valve for VVTL connectors. Disconnect the oil pressure switch connector. Disconneot the 2 ground wires. Remove the 2 bolts, and disconnect the engine wire. Remove the intake manifold No. 2 insulator. 422-FE: REMOVE INTAKE MANIFOLD Disconnect the EVAP hose for ORVR, Disconnect the brake booster vacuum hose. Remove the 4 bolts, 2 nuts, intake manifold, 2 wire harness slays and gasketEMaa ENGINE MECHANICAL CYLINDER HEAD 19, 222-GE: REMOVE INTAKE MANIFOLD (a) Disconnect the EVAP hose for ORVR. {b) Disconnect the brake booster vacuum hose. (©) Remove the boltand disconnect the No. 1 ventilation pipe and cit dipstick and guide. (@) Remove the 2 bolts, nut and stay. fe) Remove the 4 bolts, 2 nuts, intake manifold and gasket. {Remove the intake manifotd insulator. 20. REMOVE CAMSHAFT POSITION SENSOR 21. REMOVE ECT SENSOR 22, REMOVE PCV VALVE AND GROMMET 23, REMOVE OIL FILLER CAP 24, REMOVE CAMSHAFT TIMING SPROCKETS (See page IG-9) 25. 1ZZ-FE: REMOVE CAMSHAFT Uniformly loosen and remove the 19 bearing cap bolts, in several passes, in the sequence shown, and remove the 9 bearing caps, intake and exhaust camshatts. 26. 2Z2-GE: REMOVE CAMSHAFT Uniformly loosen and remove the 20 bearing cap bolts, in severai passes, in the sequence shown, and remove the 9 bearing caps intake and exhaust camshaft.EM-45 ENGINE MECHANICAL — CYLINDER HEAD 27. REMOVE CYLINDER HEAD {a) Disconnect the upper radiator hoses from the water hose union {) Disconnect the heater water hose trom the water hose union (c)_ Using a 10 mm bi-hexagon wrench, uniformly loasen and rémove the 10 cylinder head bolts, in several passes, in the sequence shown. Remove the 10 cylinder head bolts and plate washers. NOTICE Head warpage or cracking could result from removing bolts in an incorrect order. ()_ Remove the bolt holding the water bypass pipe to the cyl indor head. (@) _Liftthe cylinder from the dowels on the cylinder block and replace the cylinder head on woaden blocks on a bench, HINT: Ifthe cylinder head is dificult to lit off, pry between the oylinder head and cylinder btock with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and oylinder block.EM-46 ENGINE MECHANICAL CYLINDER HEAD. 8 scone DISASSEMBLY 4. REMOVE OIL CONTROL VALVE for VWT Remove the bolt and cam timing oil control valve. 2. REMOVE OIL CONTROL VALVE FILTER Remove the bolt, gasket and oil contro! valve filter. 3. 22Z-GE: REMOVE OIL CONTROL VALVE HOUSING {a) Remove the bolt and oil control valve for VWTL. (©) Using SST, remove the oil pressure switch. SST 09816-30010 (©) Remove the 3 bos, 2 nuts, oil conteal valve housing and gasket. ()_ Remove the oil control valve filter. 4 222-GE: REMOVE VALVE ROCKER ARM {a) Remove the 2 bolts, rocker No. 1 and No. 2 shatis. (©) _ Remove the 8 valve rocker arm. HINT: ‘Arrange the rocker arms in the correct order. 5. REMOVE VALVE LIFTERS HINT: Arrange the valve fitters in the correct order. 6. REMOVE VALVES {a) Using SST, compress the valve spring and remove the 2 keepers. SST 09202-70020 (09202-00020) {b) Remove the spring retainer. (c} Remove the vaive spring. () Remove the valve. (e) Using needle-nose pliers, remove the oll seal.EMa7 ENGINE MECHANICAL ~_CYLNDEANEAD. (Using compressed air and magnetic finger, remove the spring seat by blowing air. HINT: Arrange the valves, vaive springs, spring seats, and spring re- {ainers in the correct order.EM-48 ENGINE MECHANICAL CVLINDEA HEAD INSPECTION 4. CLEAN TOP SURFACES OF PISTONS AND CYL- INDER BLOCK (a) Turn the crankshait, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all he carbon from the piston surface. {b) Using @ gasket scraper, remove all the gasket material trom the cylinder block surtace. (©) _ Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high pressure compressed alr. 2. REMOVE GASKET MATERIAL Using a gasket scraper. remove all the gasket material from the cylinder block contaet surface (NOTICE: Be careful nat to scratch the cylinder block contact surface. 3, CLEAN COMBUSTION CHAMBERS Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder block contact surface. 4. CLEAN CYLINDER HEAD Using a soft brush and solvent, thoroughly clean the cylinder head.EM-49 ENGINE MECHANICAL —_OYLINOERHEAD, Intake Manifold Side_ (casreeen | Exhaust Manifold Side ~~ 5. CLEAN VALVE GUIDE BUSHINGS Using a valve guide bushing brush and soivent, clean all the quide bushings: & INSPECT FOR FLATNESS Using a precision straight edge and feeter gauge, measure the surface contacting the cylinder block and the manifolds for warpage. Maximum warpage: 0.05 mm (0.0020 in.) It warpage is greater than maximum, replace the oylinder head. 7. INSPECT FOR CRACKS Using a dye penetrate, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, repiace the cylinder head. 8 CLEAN VALVES fa) _ Using a gasket scraper, chip off any carbon from the valve head. {b) Using a wire brush, thoroughly clean the valve.ENGINE MECHANICAL GvunDeR HEAD i 9. (a) (b) fe) INSPECT VALVE STEMS AND GUIDE BUSHINGS Using a caliper gauge. measure the inside diameter of the quide bushing, Bushing inside diameter: 12Z-FE 8.510 ~ 5.530 mm (0.2169 ~ 0.2177 in.) 2ZZ-GE 5.500 ~ 5.518 mm (0.2165 ~ 0.2172 in.) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 122-FE Intake 5.470 ~ 5.485 mm (0.2154 ~ 0.2159 in.) Exhaust 5.465 ~ 5.480 mm (0.2152 ~ 0.2157 In.) 227-GE Intake 5.460 ~ 5.475 mm (0.21496 ~ 0.21855 in.) Exhaust 5.445 ~ 5.470 mm (0.21437 ~ 0.21535 in.) Subiract the valve stem diameter measurement from the guide bushing inside diameter measurement Standard oil clearance: 122-FE Intake 0.025 ~ 0.060 mm (0.0010 — 0.0024 fn.) Exhaust 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in.) 222-GE intake 0.025 ~ 0.058 mm (0.00098 — 0.00228 in.) Exhaust 0.030 - 0.063 mm (0.00118 — 0.00248 In.) Maximum oil clearance: 122-FE Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 In.) 22Z-GE 0.10 mm (0.0039 in.) Ithe clearance is greater than maximum, seplace the valve and guide bushing 10. (a) (0) INSPECT VALVES Check the valve is ground to the correct valve face angle. Valve face angle: 44.5° Check that the surface of the valve for wear. I the valve face is worn, replace the valve.EM-s1 ENGINE MECHANICAL — CYLINDER WEAD Margin Thickness Overall Length rie Ine, (©) Check the valve head margin thickness. ‘Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.7 mm (0.02! ) lf the margin thickness is less than minimum, replace the valve {d) Check the vaive overall length. ‘Standard overall fength: 122-FE Intake 88.65 mm (3.4902 in.) Exhaust 68.69 mm (3.4917 In.) 22Z-GE Intake 114.3 mm (4.382 In.) Exhaust 111.7 mm (4.398 in.) imum overall length: 122-FE Intake 88.35 mm (3.4783 in.) Exhaust 68.39 mm (3.4799 in.) 22Z-GE Intake 110.9 mm (4.366 in.) Exhaust 111.3 mm (4.982 in.) Is the overall length is less than minimum, replace the valve, {e) Check the surface of the valve stem tip for wear. ifthe valve stem tip is worn, replace the valve, 11. INSPECT AND CLEAN VALVE SEATS {a) Using a 45° carbide cutter, resurtace the vaive seats. Remove only enough metal to clean the seats. {b) After resurfacing the valve seat 45°, measure the residuary width of the valve seat 45°, Minimum residuary length: Intake 3.3 mm (0.130 in.) Exhaust 3.2 mm (0.126 in.) lithe valve seat 45° residuary wiath less than minimum, replace the cylinder head. (c)_ Check the valve seating position. Apply a light coat of prussian blue (or white lead) 10 the valve face. Lightly press tho valve against the seat. Do no! rotate valve: (@ Check the vaive face and seat for the following + If blue appears 960° around the face, the valve is concentric. not, replace the valve.EM-52 ENGINE MECHANICAL, CYLINDER HEAD + If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat. + Check thal the seat contact is in the middle of the vaive face with tha following wiath: 1.0 ~ 1.4 mm (0.039 - 0.055 In.) It not, correct the valve seats as follows (1) _ Ifthe seating is too high on the vatve face, use 30" and 45° cutters to correct the seal. (2) _ If the seating is too iow on the valve face, use 75° and 45° cutters to correct the seat. 1s 9~ 1.4m (e) Hand~lap the valve and valve seat with an abrasive compound. () After hand-lapping, clean the valve and valve seat. QOS vaso 12. INSPECT VALVE SPRINGS (a) Using a steel square, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 In.) Maximum angie (reference): 2° It the deviation is greater than maximum, replace the valve springEM-63 ENGINE MECHANICAL —_ CYLINDER HEAD, {b) Using vernier calipers, measure the free length of the valve spring, Free iength: 4ZZ-FE 45.90 mm (1.8070 in.) 22Z-GE Intake 46.4 mm (1.830 in.) Exhaust 46.5 mm (1.831 in.) (6) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 122-FE 199.6 ~ 154.4 N (14.2 - 15.8 kgf, 31.3 ~ 34.8 Ibf) at 33.6 mm (1.323 in.) 222-GE intake 220.2 ~ 243.8 N (22.5 ~ 24.7 kgf, 49.6 - 55.5 Ibf) at 38.5 mm (1.516 in.) Exhaust 208.2 ~ 229.8 N (21.2 — 23.4 kgf, 47.6 - 62.6 Ibf) at 38.5 mm (1.516 in.) Maximum working tension: 1ZZ-FE 244.9 ~ 276.1 N (25.5 ~ 28.1 kgf, 56.2 ~ 61.9 Ibf) at 24,6 mm (0.969 in.) 222-GE Intake 533 — 589 N (54.4 — 60.1 kgf, 119.9 - 132.5 Ibf) at 27.3 mm (1,075 in.) Exhaust 495.5 — 548.5 N (50.5 — 56.9 kgl, 111.3 — 123.2 Ibf) at 28.5 mm (1.122 in.) if the instalied tension is not as specified, repiace the vaive spring 13, INSPECT CAMSHAFT FOR RUNOUT (a) Place the camshaft on V-btocks. (©) Using @ dial indicator, measure the circle runout at the center journal Maximum circle runout: 0.03 mm (0.0012 in.) 'the circle runout is greater than maximum, replace the cam- shaltEM 5S ENGINE MECHANICAL CYLINDER HEAD INSPECT CAM LOBES Using a micrometer, measure the cam lobe height. ‘Standard cam lobe height: 1ZZ-FE: Intake 44.333 ~ 44.433 mm (1.7454 ~ 1.7493 in.) Exhaust 43.761 ~ 43.861 mm (1.7229 ~ 1.7268 in.) 222-GE: INTAKE No. 1 40.607 ~ 40.707 mm (1.59586 - 1.59979 In.) No. 2 38.769 ~ 38.869 mm (1.52362 ~ 1.52755 in.) 222-GE: EXHAUST No. 1 40.019 ~ 40.119 mm (1.57275 ~ 1.57668 in.) No, 2 38.863 ~ 38.963 mm (1.52732 ~ 1.53125 in.) Minimum cam lobe height: 12Z-FE: Intake 44.18 mm (1.7394 in.) Exhaust 43,61 mm (1.7169 in.) 222-GE: Intake No.1 40.45 mm (1.5925 in.) ‘No.2 38.61 mm (1.5201 in.) Exhaust No.1 39.86 mm (1.5693) No.2 38.71 mm (1.5240) ithe cam lobe height is less than minimum, replace the cam- INSPECT CAMSHAFT JOURNALS Using a micrometer, measure the journal diameter. 1ZZ-FE: No.1 Journal diameter: 34.489 ~ 34.465 mm (1.3863 ~ 1.3569 In.) Others journal diameter: 22.949 - 22.965 mm (0.9035 - 0.9041 in.) 27Z-GE: No.1 Journal diameter: 34.449 ~ 34.465 mm (1.35626 ~ 1.95669 in.) Other journal diameter: 27.949 ~ 27.965 mm (1.10035 ~ 1.10098 in.) If the journal diameter is not as specified, check the oll ciear- anco.EM-55 ENGINE MECHANICAL —_ CYLINDER HEAD. 16. INSPECT CAMSHAFT JOURNAL CLEARANCE (a) Clean the bearing caps and camshaft journals. (0) Place the camshafts on the cylinder head. {c) Lay astrip of Piastigage across each of the camshaitjour- ral. (0) _ Install the bearing caps (See page EM-65). Torque: 42Z-FE: No.1 23 Nem (235 kgf-cm, 17 ftlbf) No.3 13 N.m (133 kgf-cm, 10 fbf) 222~GE: 18.5 N-m (189 kgf.cm, 14 ft.lbt) NOTICE: Do not turn the camshaft. (e) Remove the bearing caps. (8. Measure the plastigage at its widest point. 122-FE: ‘Standard oil clearance: 0.035 — 0.072 mm (0.0014 ~ 0.0028 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) 222-GE: Standard oil clearanc No. 1 journal 0.035 - 0.076 mmm (0.00138 — 0.00299 in.) Other journal 0.035 - 0.072 mm (0.00138 ~ 0.00283 in.) Maximum olf clearance: 0.10 mm (0.039 in.) Ifthe oi clearance is greater than maximum, replace the camshaft, necessary, replace the beating caps and oylinder head as a set (@) Completely remove the Piastigage. (h) Remove the camshafts.EM-56 ENGINE MECHANICAL -_ CYLINDER HEAD 17. INSPECT CAMSHAFT THRUST CLEARANCE (a) _ Install the camshatts. (See page EN-G5) (©) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. 1ZZ-FE: Standard thrust clearance: 0.040 - 0.095 mm (0.0016 - 0.0037 in.) Maximum thrust clearanc 0,11 mm (0.0043 in.) 222-GE: Standard thrust clearance: 0,04 ~ 0.14 mm (0.0016 ~ 0.0085 in.) Maximum thrust clearance: 0.15 mm (0.0059 In.) If the thrust clearance is greater than maximum, replace the ‘camshaft. f necessary, replace the bearing caps and cylinder head as a set, (©) Remove the camshafts. 48, INSPECT VALVE TIMING CONTROLLER ASSEMBLY (@) Apply vinyl tape to all the ports except the one indicated by the arrow in the illustration. NOTICE: 18mm Do not appiy tape In the range from the tip of the camshaft to 18 mm from that tip. (b) install the valve timing controtler assembly. ‘Torque: 47 N-m (480 kaf-cm, 35 fbf) n asus} NOTICE: Do not push valve timing controller assembly to the camshaft forcibly when installing i. {c) Check that the valve timing controller assembly will not turn, {d) Wind tape around the tip of the air gun and apply air of approx. 100 kPa (1 kgtcm®, 14 psi to the port of the camshaft, NOTICE: ‘When the oll splashes, wipe it off with a shop rag and the tikes. HINT: Pertorm this in order to release the lock pin for the maximum delay angle focking,EM67 ENGINE MECHANICAL CYLINDER HEAD. {e) Under the condition of (2), turn the valve timing controller assembly to the advance angei side (the arrow marked direction in the illustration) with your hang. Standard: Must turn HINT: Depending on the alr pressure, the valve timing controller assembly will turn to the advance angle side without applying force by hand. Aiso, under the condition that the pressure can be hacdly applied because of the ait leakage from the port, there may be the case that the lack pin could be hardly released. () Except the position where the lock pin meets at the maximum delay angle, let the valve timing controller assembly turn back and forth and cheek the movable range and that there is no disturbance. Standard: Movable smoothly in the range about 30° (9) Turn the valve timing controller assembly with your hand and lock it at the maximum delay angef position, 12Z-FE: INSPECT VALVE LIFTERS AND LIFTER BORES Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31,000 ~ 31.025 mm (1.2205 ~ 1.2215 in.) Using a micromoter, measure the liter diameter. Lifter diameter: 30.966 — 30.976 mm (1.2191 — 1.2195 in.) ‘Subtract the iifter diameter measurement from the titer bore diameter measurement. Standard oll clearanca: 0.024 - 0.059 mm (0.0009 ~ 0.0023 in.) Maximum oil clearance: 0.079 mm (0.0031 in.) IF the oil clearanes is greater than maximum, replace the lifter it necessary, replace the cylinder headEM58 ENGINE MECHANICAL. CYLINOER HEAD 20. INSPECT INTAKE MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.10 mm (0.0039 in.) it warpage is greater than maximum, replace the manifold. 23. INSPECT EXHAUST MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.70 mm (0.0276 in.) If warpage is greater than maximum, repiace the manifold. 22, INSPECT CYLINDER HEAD BOLTS Standard outside diamete 9.0 - 9.2 mm (0.354 ~ 0.362 In.) Minimum outside diameter: 98.0 mm (0.354 In.) Ifthe outer diameter is less than minimum, replace the bolt.EN-59 ENGINE MECHANICAL — CYLINDER HEAD Both intake and exhaust Bushinadorw diameter | Busting sien | 10.285 - 10.306 (0.4049 ~ 0.4057) Use STO 10.835 ~ 10.356 (64068-04077) | Use OS0.05 | REPLACEMENT REPLACE VALVE GUIDE BUSHINGS (a) Gradually heat the cylinder head to 140 ~ 130 °C (230 — 286 °F}, () Using SST and a hammer, tap out the guide bushing, SST 09201-01085, 09950-70010 (09951-07100) (6) Using a caliper gauge, measure the bushing bore diameter of the cylinder head. (@) 122-FE: Select the new guide bushing (STD or O/S 0.05) Itthe busting bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bushing bore to the fol- fowing dimension: 40.335 ~ 10.356 mm (0.4068 ~ 0.4077 in.) It the bushing bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in,), replace the cylinder head. (e) 1ZZ-FE: Gradually heat the cylinder head to 80 — 100 °C (176 — 212 °F)EM-60 ENGINE MECHANICAL = CYLINDER HEAD. ) 222-GE: Both intake and exhaust Select the new guide bushing (STD or O/S 0.06). Bushingborediameter | ‘mm (in) 10.488 ~ 10.566 (0.4129 - 0.4136) 10.598 — 10.856 IF the bushing bore diameter of the cylinder headis greater than 10.506 mm (0.4136 in.}, machine the bushing bore to the following dimension: Bushing size Use STO 10.538 — 10.556 mm (0.4149 ~ 0.4156 in.) Ifthe bushing bore diameter of the cylinder heads greater than Use 0/S 0.05 | 19.556 mm (0.4186 In.], replace the cylinder head. {g) 222~GE: Gradually heat the cylinder head to 110 ~ 180 *C (230 ~ 266 “F). th) Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. SST 09201-01055, 09950-70010 (09951-07100) Protrusion height: 122-FE 8.7 - 9.1 mm (0.342 - 0.358 in.) 222-GE 15.3 ~ 15.7 mm (0.602 - 0.618 in.) a sharp 5.5 mm reamer, reain the guide bushing to obtain the standard specified clearance (See page EM-~48) between the guide bushing and valve stom, wiM61 ENGINE MECHANICAL CYLINDER HEAD. REASSEMBLY HINT: + Thoroughly clean all parts to be assembled. + Beforeinstalling the parts, apply fresh engine oilto all sliding and rotating surfaces. + Repiace oil seals with new ones. 1. _ INSTALL WATER HOSE UNIONS HINT: For Heater Hose (6) | When using a new cylinder head, water hose unions must be 20mm installed. {a} Matk the standard position away from the edge, onto the water hose union, mmm FOF Radiator Hose (A) (b) Apply adhesive to the water hose union hole af the eylinder head Adhesive: Part No.08833-00070, THREE BOND 1324 or equiva- tentENGINE MECHANICAL Exhaust Light Brown Gray 222-GE: 222-GE: Black Green CYUINDES HEAD. {c) Using a press, press in a new water bose union until here is protruding from the oylinder head. Standard protrusion: A29mm (1.14 in) B 66.5 mm (2.618 in.) © 24 mm (0.95 in.) ‘D 69.8 mm (2.630 In.) NOTICE: Avold pressing a new water hose union in too far by measuring the amount of protrusion while pressing. 2 INSTALL VALVES (2) Using SST, push in a new oil seal, SST 0920-41020 HINT: + 1Zz-FE: The intake valve il seal Is light brown and the exhaust valve oil seal is gray. + 2Z2-GE: The intake valve oil seal is black and the exhaust vaive oi! seat is green. NOTICE: Pay much attention assembling the oil seal for intake and exhaust, Assembling the wrong one may cause a fallure.M63 ENGINE MECHANICAL CYLINDER HEAD > Exhaust Side AO AWC eos a va oe y ge y (b) install tho vaive (1), spring (2), vaive spring (3), and spring retainer (4) (©) Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202-70020 (09202-00020) (@ Using a plastio-faced hammer and the valve stem (not in use) tip wound with vinyl tape, lightly tap the vaive stem tip to ensure a proper fit. NOTICE: Be careful not to damage the valve stem tip, 3. INSTALL VALVE LIFTERS {a) Install the valve litter. {b) Chock that the valve lifter rotates smoothly by hand. 4, 22Z-GE: INSTALL VALVE ROCKER ARM (a) Set the 8 valve rocker arms, (6) install the rocker No, 1 and No. 2 shaft with the 2 bolts Torque: 7.5 N-m (76 kgf-cm, 66 in-Ibf) HINT: + Position the slit of the locker shaft ins the direction shown In the iflustration, + Align the locker shaft end with the cylinder head end. 5. 222-GE: INSTALL OIL CONTROL VALVE HOUSING (a) Install the oil control valve filter (©) _ Install the gasket and oil control valve housing with the 3 bolts and 2 nuts. Torque: 9.0 Nem (92 kgt-cm, 80 in.tbf}em-64 ENGINE MECHANICAL CYLINDER HEAD. (0) Apply adhesive to 2 or 3 threads of the oll pressure switch. Adhesive: Part No, 08832-00080, THREE BOND 1344, LOCTITE 242 of equivalent (d) Using SST. install the oil pressure switch, SST 09816-30010 Torque: 13 N-m (130 kgf-cm, 9 1hlbt) (e) Install the oil control valve for VTL. with the bolt 6, INSTALL CONTROL VALVE for VVT Install the oil control valve for VVT with the bolt. 7. INSTALL OIL CONTROL VALVE FILTER Install the oil control vaive filter and new gasket with the bolt Torque: 29 Nim (300 kgt-em, 22 ft-Ibf)EM-65 ENGINE MECHANICAL. CYLINDER MEAD INSTALLATION HINT: + Thoroughty clean all parts to be assembled. + Before installing he paris, apply fresh engine oifto ail sliding and rotating surfaces. + Replace ail gaskets and oil seats with new ones. 1. PLACE CYLINDER HEAD ON CYLINDER BLOCK (a) Place a new oylinder head gasket on the cylinder block surface with the Lod No. stamp upward. NOTICE: Be careful of the installation direction. (b) Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head. 2, INSTALL CYLINDER HEAD BOLTS HINT: + The cylinder head bolts are tightened in 2 progressive steps (steps (b} and {d)). + any cylinder head bolt is broken or deformed, replace it (a) Apply a light coat if engine oil on the Uwreads and under the heads of the oylinder head bolts, (0) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 oylinder head bolts and plate washers, in several passes, in the sequence shown Torque: 122-FE; 49 N-m (500 kgf-cm, 36 ft-lb) 22Z-GE: 35 N-m (375 kgt-cm, 26 ttIbf) IF any one of the cylinder head bolts does not maet the torque specification, replace the eylinder head bott (©) Mark tha front of the cylinder head bolt with paint, (@) 122-Fe: Retighlen the cylinder head bolts 90° in the numericat order shown, (e) 222-GE: Retighten the cylinder head bolls 180° in the numerical order shown, W) 12Z-FE: ‘Check that the paint mark is notat a 90° angle to the front.EM-66 ENGINE MECHANICAL GYtINDGA HEAD (9) th) wo YD (b) HINT: e) (a 272-GE: Cheek that the paint mark is nol at a 180° angle to the front. {install the boit holding the water bypass pine to the oylinder head. Torque: 9.0 Nm (92 kgf-cm, 80 in.-Ibf) Connect the upper radiator hose to the water hose unions, Connect the heater hose to the water hase unions. INSTALL CAMSHAFTS Place the 2 camshalts on the cylinder head with the No 1 cam lobes facing as shown the illustration. Install the bearing caps in their proper locations. 122-FE: No. 3 camshaft bearing cap has a number and front mark. 222-GE No. 2, No.3 camshaft bearing cap fas a number and front mark. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts 1ZZ-FE: Install and unitormiy tighten the 19 bearing cap bolts. After tightening the No. 1 camshaft bearing cap, tighten thon in several passes, in the sequence shown. Torque: No. 1 23 Nem (235 kgf-om, 17 ftbf) No. 3.13 N-m (133 kgf-cm, 10 ft-lbf)eM-67 ENGINE MECHANICAL CYLINDER HEAD, fe) 10. fa) ib} (c) ce fa) (b) ) @ {e) o 222-GE: Jnstail and unitormly tighten the 20 bearing cap bolts. After tightening the No. 1 camshaft bearing cap, lighten then in several passes, in the sequence shown, Torque: 18.5 N-m (189 kgf.cm, 14 ftlbf) CHECK AND ADJUST VALVE CLEARANCE (See page EM-4) INSTALL CAMSHAFT TIMING SPROCKETS AND VALVE TIMING CONTROLLER ASSEMBLY (See page EM-25) INSTALL OIL FILTER CAP INSTALL GROMMET AND PCV VALVE INSTALL ECT SENSOR (See page SF-63) INSTALL CAMSHAFT POSITION SENSOR (See page 1G-10) 122-FE: INSTALL INTAKE MANIFOLD Install a new gaskel, the intake manifold with the 4 bolts and 2 nuts, Torque: 18.5 Nem (189 kgt-em, 14 fhlbt) Connect the brake booster vacuum hose. Connect the EVAP hose for ORV. 222-GE: INSTALL INTAKE MANIFOLD install the intake manifold insulator to the cylinder block Install a new gasket, the intake manifold with the 4 bolts and 2 nuts. Torque: ‘Ai 27 Nem (275 kat-om, 20 ftibf) 16 Nem (489 kgf-cm, 34 ttf) Install the stay with the 2 bolts and nut. Torque: 24 N.m (245 kgf-cm, 18 ftbt) Install the oil dipstick and guide with the bolt Torque: 25 N.m (255 kgf-cm, 18 fbf) Connect tha brake booster vacuum hose. Connect the EVAP hose for ORV.M68 ENGINE MECHANICAL —_GYLINDER HEAD 12. fa) (b) o) (@) fe) 13. fa) (b) CF (a) (e) 0 (9) (hy 14. 15, 16, 17, 18. 19. fa) tb) © (a) 12Z-FE: CONNECT ENGINE WIRE TO CYLINDER HEAD Connect the 2 clamps of engine wire to the intake man- old. Gonnect the 2 ground cables. Connect the oif control vaive for VVT connector, Connect the camshaft position sensor connector. Sonnect the ECT sensor connector 222-GE: CONNECT ENGINE WIRE TO CYLINDER HEAD install the intake manifold insulator No. 2. ‘Connect the 2 ground cables. ‘Connect the oil pressure switch connector. Connect the oit control vaive for VVT connectar. Connect the oil control valve for VVTL connector. Connect the camshait position sensor connector. Connect the ECT sensor connector. Instal the accelerator cable bracket with the 2 bolts. INSTALL INJECTORS (See page SF-24) INSTALL THROTTLE BODY (See page SF-39) INSTAL PCV HOSES INSTALL SPARK PLUGS (See page IG-1) INSTALL IGNITION COIL (See page 1G-7) 122-FE: INSTALL EXHAUST MANIFOLD Install the lower heat insulator with the 3 bolts. Torque: 12 Nem (123 kgtom, 9 ft-lbf) Install a new gasket, and the exhaust manifold with the 5 ‘uts. Uniformly tighten the nuts in severai passes. Torque: 37 N-m (377 kgf-cm, 27 ttbf) Install the upper heat insulator with the 6 bolts, Torque: 12 N.m (123 kgf.cm, 9 ttlbf) Install the exhaust manifold stay with the 3 bolts. ‘Torque: 49 N.m (500 kgf-cm, 37 ft-lb)EM-69 ENGINE MECHANICAL, OVLINDER HEAD 20. (a) tb} © (a) 21. 22, 24. 25. 27. 28. 29, 222-GE: INSTALL EXHAUST MANIFOLD Install the lower heat insulator with the 4 bolts. Torque: 20 Nm (204 kgf-cm, 15 ftlbf) Install the exhaust manifold with the 3 bolts and 2 nuts. Torque: 50 N-m (510 kgf-cm, 37 ttIbf Install the upper heat insulator with the 5 bolts. Torque: 20 N.m (204 kgf-cm, 15 ftlbf) Install the exhaust manifold stay withe 4 bolts. ‘Torque: 50 N-m (510 kgf-cm, 37 ftlbf) INSTALL EXHAUST PIPE (See page EM-80) INSTALL GENERATOR AND DRIVE BELT (See page CH-17) CONNECT ACCELERATOR CABLE INSTALL AIR CLEANER ASSEMBLY INSTALL ECM BOX (See page EM-80) INSTALL BATTERY FILL WITH ENGINE COOLANT (See page CO-2) START ENGINE AND CHECK FOR LEAKS RECHECK ENGINE COOLANT LEVEL AND OIL LEV- ELEM-70 ENGINE UNIT COMPONENTS ENGINE MECHANICAL = ENGINE UNKT Upper Front Fender Apron Seal Upper Radiator ‘Support Seat Battery Clamp > } stony - Battery Tray [68.70.61 in. Toh Ny g ECM Box Cover ECM Box a te a om E ae VSV for EVAP, Cruise Control Accumulator RH Engine Under SSS Air Cleaner Cap ver LH Engine Under Cover Air Cleaner Case NESTE ABT : Specie torouw coalENGINE MECHANICAL ENGINE UNt EM71 Drive Belt been AIG Compressor Engine Coolant Heservoir Condensar ‘ Upper Support Radiator Upper Support Radiator — AssemblyEM-72 ENGINE MECHANICAL enuGuNte wrt Stabilizer Bar Bracket Stabilizer Bar geacan 7) Rear Engine Mounting a Insulator Rear Engine Mounting ’ Bracket Ve . RH Drive Shatt o seafren f ‘52 (630, 36) . LH Drive Shaft Gasket @ Gasket Front Exhaust Pipe \ oe ET chy a (ate { Ni Tigfem, bi) ] = Spoctied torque ny @Nor-reusabile partEM-73 ENGINE MECHANICAL ENGINE Unur Upper Front Fender Apron Seat AZZ-FE: No. 2 Cylinder Head Cover 222-GE: No, 2 Cylinder Head 1ZZ-FE: Exhaust Manltold 122-FE: Lower Heated Insulator io _ 22z-Fe: seer Lower Heated 7 Gasket Incutaor > Exhaust Maritold 222-GE: Exhaust Manifold 122-FED i22-Fe: ~ Sey RH Engine Mounting ‘Exhaust Manifold oR Insulator Stay 200, ’ Q, ’ ~ - ~LBe 2 . e we AT 22E-GE! = Transmission Contra! Cable RH Engine Mounting Insulator ' Transmission Control Cable ‘Nin than, TBH] Specitied torque es anEM-T4 ENGINE MECHANICAL ENGINE UNIT REMOVAL 1, REMOVE BATTERY AND TRAY 2. REMOVE HOOD 3. REMOVE ENGINE UNDER COVERS. 4, DRAIN ENGINE COOLANT 5. DRAIN ENGINE OIL, 6. DRAIN TRANSAXLE OIL 7, REMOVE BUMPER COVER AND HEAD LIGHT 8 REMOVE AIR CLEANER CAP (a) Disconnect the MAF meter connector. (b) Disconnect the VSV for EVAP. (c) Disconnect the 2 hoses. {d) Disconnect the 3 clamps, and disconnect the air cleaner ‘cap from the air cleaner case. (0) Loosen the hose clamp, and discennect the air cleaner hose from the throttle body. 9, REMOVE AIR CLEANER CASE (a) Remove the air filter () Disconnect the hose from the VSV for Canister Closed VALVE (CVC). {c) Disconnect the hose from the intake air controt valve. (d) Remove the 2 bolts, and disconnect the air cleaner case, (e) Disconnect the 2 hoses from the air cleaner case. 10. REMOVE ECM BOX (a) Remove the 2 bolts and ECM cover. (b) Disconnect the 4 connectors from the ECM. (c) Disconnect the 2 connectors from the ECM box. (a) Remove the ECM from the ECM box. {e) Disconnect the ctamp from the ECM box. () Disconnect the 2 engine wires from the ECM box. (g) Remove the 3 bolts and ECM box (n) Remove the 2 nuts, bolt and ECM box stayEM-75 ENGINE MECHANICAL ENGINE UNIT 11. DISCONNECT ENGINE WIRE FROM ENGINE COMPARTMENT RELAY BOX (@) Remove the relay box upper cover, ib) Disconnect the 3 connectors. (c} Disconnect the 7 claws and JB from the relay box. (@) Disconnect the 3 connectors, (6) Disconnect the engine wire from the relay box. 12. w/ Cruise Control System: DISCONNECT CRUISE CONTROL ACTUATOR (a) Disconnect the actuator connector. (db) Remove the 3 bolts and disconnect the actuator from the body. 13. REMOVE RADIATOR ASSEMBLY (See page CO-17) 14. REMOVE DRIVE BELT AND GENERATOR (See page CH-7) 15, wi A/C: DISCONNECT A/C COMPRESSOR (a) Disconnect the A/G compressor connector. (©) Remove the 3 bolts, and disconnect the A/C compressor from the engine. HINT: Suspend the A/C compressor securely. 16. DISCONNECT TUBE AND HOSE (a) Disconnect the fuel tube from the fuel pipe on vehicle side. {B) Disconnect the 2 heater hases from the engine side. o Disconnect the brake booster vacuum hose.EM-76 ENGINE MECHANICAL —_ ENGINE UNIT akon \ 17. (a) (b) 18, 19, 20, a. fa) (b) ) 22. (a) (b) ) 23. (a) () (c) Mm DISCONNECT CLUTCH RELEASE CYLINDER Remove the 3 bolts, and disconnect the brackets from the transaxle. Remove the 2 bolts, and disconnect the release cylinder from the transaxle, DISCONNECT TRANSAXLE CONTROL CABLE (S) DISCONNECT 2 GROUND CABLES REMOVE DRIVE SHAFT (See page SA-20) REMOVE EXHAUST PIPE Disconnect the 2 heated oxygen sensor. Remove the 4 bolts and springs. Disconnect the 2 O-rings, and remove the exhaust pipe and 2 gaskets. 122-FE: REMOVE EXHAUST MANIFOLD Remove the 6 bolts and upper heat insulator. Remove the 3 bolts and exhaust manifold stay. Remove the 5 nuts, exhaust manifold and gasket. 2Z2-GE: REMOVE EXHAUST MANIFOLD Remove the 5 bolts and upper heat insulator. Remove the 4 bolts and exhaust manifold stay. Remove the 2 nuts, 3 bolts, exhaust manifold and gasket.EMIT ENGINE MECHANICAL ENGINE Wie N rons 24, DISCONNECT PS PUMP (a) Disconnect the PS cil pressure switch connector. (0) Remove the 2 nuts and through bolts, and disconnect the PS pump from the engine (See page SA-24) HINT: Put aside the pump and suspend it to the cow! with a siring 25. REMOVE STABILIZER BAR BRACKET (See page SA-51) 26. DISCONNECT PS GEAR Remove the 4 bolts, and disconnect the PS gear from the sus. pension member. HINT: Suspend the PS gear securely. 27. REMOVE SUSPENSION MEMBER Remove the 9 bolts, 3 nuts and suspension member. 28. ATTACH ENGINE SLIDING DEVICE TO ENGINE HANGER (2) Remove the 4 bolts and No, 2 cylinder head cover. (b) Disconnect the PCV hoses from the cylinder head cover,ENL78 ENGIVE MECHANICAL ENGINE UIT n ise (©) @) Instali the 2 engine hangers in the correct direction, Engine hanger part No. 1ZZ-FE Front: 12261-22021 Rear: 12281-15040 or 12281-15050 Bolt: 91512-B1016 222-GE Front: 12281-88600 Rear: 12282-88600 Bolt: 91512-61020 Torque: 38 Nem (388 kgt-cm, 28 ftlbt) Altach the engine sling device to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. @ © (b) fe) REMOVE REAR ENGINE MOUNTING Remove the through bolt and rear engine mounting insulator. Remove the 3 bolts and rear engine mounting bracket. REMOVE ENGINE AND TRANSAXLE ASSEMBLY Remove the LH engine mounting through bolt and nut 12Z-FE: Remove the 4 bolts, 2 nuts and RH engine mounting insulator. 222-GE: Remove the Sbolts, 2 nuts and RH engine mounting insulator.EM-79 ENGINE MECHANICAL —_ ENGINE UNI. (@) Lower the engine out of vehicle slowly and caretully, and raise the vehicle HINT: Make sure the engine is clear of all wiring, hoses and cables. {e) Place the engine and transaxle assembly onto the stand. 91. SEPARATE ENGINE AND TRANSAXLE (C56 MIT: See page MX-4) (C60 MIT: See page MX-4) (U240E AZ: See page AX-31) (U341E A/T: See page AX-31)M80 ENGINE MECHANICAL ENGINE WIT INSTALLATION 1 (a) (b) © a te) tH ) {b) ASSEMBLY ENGINE AND TRANSAXLE (C56 M/F: See page MX-8) (C60 MIT: See page MX-8) (U240E A/T: See page AX-35) (U341E AMT: See page AX-35) INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE Attach the engine sling device to the engine hangers. Slowly lower the vehicle, and raise the engine into the engine compartment Keep the engine lovel, and align RH and LH mountings with the body bracket. 12Z-FE: install the RH engine mounting insulator with the 4 bolts and 2 nuis. Torque: 52 N-m (530 kgf-cm, 36 ft-bf) 22Z-GE: Install the RH engine mounting insulator with the 5 bolts and 2 nuts, Torque: 52 Nm (530 kgf-cm, 38 tttbf) Install the LH engine mounting through bolt and nut. Torque: 80 N-m (816 kgt-cm, 59 fbf) REMOVE ENGINE SLING DEVICE INSTALL REAR ENGINE MOUNTING install the rear engine mounting bracket with the 3 bolts. ‘Torque: 64 N.m (653 kgf.om, 47 ftlbf) ‘Temporarily install the rear engine mounting insulator with the through bolt.mat ENGINE MECHANICAL ENGINE unit 5. fa) (b) 6. INSTALL SUSPENSION MEMBER instal the suspension member with the Sbolts and 3 nuts. Torque: A52 Nam (530 kgt-om, 32 ftubt) B 52 Nem (530 katem, 32 fof) © 157 Nem (1,600 kgf-cm, 116 ft-ibt) D157 Nem (1,600 kgt-om, 116 ft.ibf) £ 39 Nem (400 kgf-cm, 29 ftbf) Nut 52 N:m (530 kgf-cm, 32 ttbf) Tighten the rear engine mounting through bolt. Torque: 87 N-m (687 kgf-cm, 64 ftlbf) CONNECT PS GEAR Instail the PS gear with the 4 bolts (a) tb) fe) 10, (a) Torque: 45 Nim (460 kgf-cm, 33 fbf) INSTALL STABILIZER BAR BRACKET {See page SA-53) CONNECT PS PUMP Install the PS pump with the 2 through bolts and! nuts (See page SR-32). Torque: 36 N-m (370 kaf-cm, 27 ftibt) Connect the PS oil pressure ewiteh connector 1ZZ-FE: INSTALL EXHAUST MANIFOLD Install the gasket and exhaust manifoid with the 5 nuts. Torque: 37 N.m (377 kghem, 27 ftbf) Insiall the exhaust manifold stay with the 3 boits, Torque: 49 N-m (500 kgt-cm, 37ftb1) Install the upper heat insulator with the 6 bolts. Torque: 12 Nm (123 kgf-cm, 9 ftlbf) 222-GE: INSTALL EXHAUST MANIFOLD Install the gasket and exhaust manifold with the 2 nuts and 3 bolts Torque: 50 N-m (510 kgf-cm, 37 ftibt) Install the exhaust manifold stay with the 4 bolts. Torque: 50 N-m (510 kaf-cm, 37 ft-lbf) Instalt the upper heat insulator with the 5 bolts. Torque: 20 N-m (204 kgt-cm, 15 ft-lbf)ENGINE MECHANICAL = _EhGUVE UNIT nN (a) (b) ) (a) 12. 13. 14, 15. fa) (b) now wees] 16. @ (bo) © INSTALL EXHAUST PIPE Install the 2 gaskets and exhaust pipe. Connect the 2 O-rings. Install the 4 springs and bolts. Torque: 43 N-m (440 kgf.om, 32 ttbf) Connect the 2 heated oxygen sensor. INSTALL DRIVE SHAFT (See page SA~32) CONNECT 2 GROUND CABLES CONNECT TRANSAXLE CONTROL CABLE (S) wt CONNECT CLUTCH RELEASE CYLINDER Instal the release oylinder with the 2 bolts, Torque: 12 N-m (120 kgf-cm, 9 ftIbf) Install the brackets with the 3 bolts Torque: Boll A 12 Nm (120 kgt-cm, 9 ftbf) Boit B 4.9 N.m (50 kgf-om, 43 in..Ibf) CONNECT TUBE AND HOSE Conneet the brake booster vacuum hose. Conneat the 2 heater hoses to the engine side. Connect the fuel tube to the fue! pipe on vehiicle side. wr AC: INSTALL A/C COMPRESSOR Install the A/C compressor with the 3 bolts. Torque: 25 Nem (255 kgf-cm, 18 fbf) Connect the A/C compressor connector. INSTALL GENERATOR AND DRIVE BELT (See page CH-17) INSTALL RADIATOR ASSEMBLY (See page CO-23)Ewes ENGINE MECHANICAL — ENGINE UNIT 20. (a) (b) 24. fab {b) © @) (e) (a) w! Cruise Control System: INSTALL CRUISE CONTROL ACTUATOR Install the actuator with the 3 bolts Connect the actuator connector. CONNECT ENGINE WIRE TO ENGINE COMPART- MENT RELAY BOX install the engine wire to the relay box. Conneet the 3 connectors. Connect the J/B to the relay box. Connect the 3 connectors, Install the relay box upper cover. INSTALL ECM BOX Install the ECM box stay with the 2 nuts and bolt Torque: Nut 12 Nem (120 kgf-cm, 9 ftlbt) Bolt 18 N-m (185 kgf-cm, 13 ft-ibf) instal the ECM box with the 3 bolts, Torque: 6.9 N-m (70 kgf-cm, 61 in-Ibf) Connect the 2 engine wire to the ECM box. Connect the clamp to the ECM box. install the ECM to the ECM box. Connect the 2 connectors to the ECM box. Connect the 4 connectors to the ECM Install the ECM cover with the 2 bolts, Torque: 6.9 N-m (70 kgf-cm, 61 in.bt)EM84 ENGINE MECHANICAL = _ ENGINE UNIT 23. fa) i) {o (a (2) 24, (a) (b) (ey (3) (e) u oe aoc] 25. 26. 27. 28. 29, 30. 31. 32. 33. 34. 35. INSTALL AIR CLEANER CASE Connect the 2 hases to the air cleaner case. Instalt the air cleaner case with the 2 bolts Torque: 5.0 N.m (51 kgf-cm, 44 instbf) Connect the hose to the intake air control valve. Connect the hose to the VSV for canister closed valve {evC). tnstall the ai filter. INSTALL AIR CLEANER CAP Install the air cleaner hose to the throttle body with the hose clamp. Connect the air cleaner cap to the air cleaner case with the 3 clamps. Connect the 2 hoses. Connect the VSV for EVAP. ‘Connect the MAF meter connecior. INSTALL HEADLIGHT AND BUMPER COVER. INSTALL BATTERY AND TRAY FILL WITH TRANSAXLE OIL FILL WITH ENGINE OIL FILL WITH ENGINE COOLANT (See page CO-2) ‘START ENGINE AND CHECK FOR LEADS PERFORM ENGINE ADJUSTMENT CHECK FRONT WHEEL ALIGNMENT INSTALL ENGINE UNDER COVERS INSTALL ENGINE HOOD ROAD TEST VEHICLE Check for abnormal noises, shock slippage, correct shift points and smooth operation, 36. RECHECK ENGINE COOLANT AND OIL LEVELS:ENGINE MECHANICAL CYLINDEA BLOCK CYLINDER BLOCK COMPONENTS EM-95 122-FE: Water Bypass Pipe (202; 90mOT] Gasket -— COUTTS Engine Coolant Brain Uoion | Oil Dipstck (200200. 387 sorting Knosk Sensor a e 2) Thermostat #Gasket Water Iniet Spocitfiod torque Er |... Oil Guide andEM-86 ENGINE MECHANICAL -__CVLINDER BLOCK. 222-GE: Water Bypass Pipe Engine Coolant Drain Union | + Specified torque Lao (REE Knock Sensor To cgi No. 3 Ventilation Hose Ventilation Case. 3.2 va os @ Gasket ~@ Water inlet + Non--reusablo partEM87 ENGINE MECHANICAL CYLINDER BLOGK. ZF E, No.1 Compression fine sy 7 Sh @ Connecting Red Bushing No.2 Compression Rng SS citring it Bing (Expander) —— (Sica Fai, - Seu Piston ———— fe Ley ~~ Connecting Rod Bearing 4 Snap Fing———9y” —— Connecting Rad Upper Main Bearing. Grankshatt Thryst Washer——-—Y Crankshatt — Bearing Cap Sub Assombiy- lL Fiter Union # Gasket [0806.2] ‘at22 (23816) 2nd 44(488,02) Sra Tue as aeTun gs Forte: i) |} —@ q _ # Gasket | :Specitiod torque ‘@Noo-reusable part anorEM-g8 ENGINE MECHANIGAL CYLINDER BLOCK, 222-GE: No. 1 Compression wo EB 4 Connesting Red Bushing No. 2 Compression Fin On Ring CT Sie Hai |-—~—~ Connecting Rod Oi Ring (Expanden = eT Connecting Rod Bearing Connecting Rod Cap Se oF Nozze —— Crankshaft Thrust Washer [See page EM. 106 | “22 (28,16) 2nd 44(849,32) ard Turn" Ea bo t of-cm, fribf} | =Specifiediorque Gasket n_$Non-teusabie part ;EM-a9 ENGINEMEGHAWICAL — CYLINDER BLOCK 5 DISASSEMBLY ; MT: REMOVE FLYWHEEL 2 aM REMOVE DRIVE PLATE 3. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY 4. REMOVE TIMING CHAIN AND SPROCKETS (See page EM-18) 5. REMOVE ENGINE WIRE 6. REMOVE CYLINDER HEAD (See page EM~42) 13, fa) to} 122-FE: REMOVE OIL DIPSTICK AND GUIDE Remove the bolt and oil dipstick and guide. Remove the O-ring from the dipstick. REMOVE WATER BYPASS PIPE move the 2 nuts, bolts and water bypass pipe. REMOVE THERMOSTAT (See page CO-9) REMOVE KNOCK SENSOR REMOVE ENGINE COOLANT DRAIN UNION REMOVE OiL PUMP (See page LU-9) 222-GE: REMOVE VENTILATION CASE Remove the 3 nuts, ventilation case and gaskel. Remove the clip and No. 3 ventilation hose.EM-90 ENGINE MECHANICAL CYLINDER BLOOK. PX oe AO ye ‘Oil Filter ou 14, REMOVE OIL FILTER (See page LU-3) 15, REMOVE OIL FILTER UNION Using a 12 mm hexagon wrench, remove the oil filter union. 16. REMOVE OIL PAN (a) 1Z2-FE: Remove the 14 bolts and 2 nuts. (b) 222-GE: Remove the 12 bolts and 4 nuts, (c)__ Insen the blade of SST between the bearing cap sub-assembly and oii pan, and cut off applied sealer and remove the oil pan, SST 08032-00700 NOTICE: + Be careful not to the damage the oil pan contact surface of the bearing cap sub~assembly. + Be careful not to damage the oll pan flange. 17. 12Z-FE: REMOVE OIL STRAINER Remove the 2 nuts, bolt, oil strainer and gasket 48, 22Z-GE: REMOVE OIL STRAINER AND OIL PAN BAFFLE fa) Remove the 2 nuts, bolt, oii strainer and gasket. (b) Remove the 4 bolts, 2 nuts and oil pan battle.M91 ENGINE MECHANICAL CYLINDER BLOCK 19. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the conneeting tod back and forth Standard thrust clearance: 0,160 ~ 0.342 mm (0.0063 ~ 0.0135 In.) Maxirnum thrust clearance: 0.342 mm (0.0135 in.) Hf the thrust clearance is greater than maximum, replace the connecting tod assembly(s}. It necessary, replace the orank- shaft Connecting rod thickness: 19.788 ~ 19.840 mm (0.7791 — 0.7811 in.) 20. REMOVE CONNECTING ROD GAPS AND CHECK OIL. CLEARANCE (a) Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. {b) Remove the 2 connecting red cap bolts. (©) Using the 2 removed connecting rad cap bolts, remove the connecting rod cap and lower bearing by wiggling the ‘connecting rod cap right and left. HINT: Keep the lower bearing inserted with the connecting rod cap. {@) Clean the crank pin and bearing (e) Check the orank pin and bearing for pitting and scratches. Ifthe crank pin or bearing is damaged, replace the bearings, If necessary, raplaca the crankshatEM-92 ENGINE MECHANICAL CYLINDER BLocK Plastigage “oe © @ NoTICI Lay a stip of Plastigage the crank pin. Install the connecting rod cap with the 2 bolts (See page EM-106). Torque: Ist: 122-FE: 20 Nem (204 kgt-cm, 15 feibf) 22Z-GE: 30 N-m (306 kgf.cm, 22 ft-lb) 2nd: Turn extra 90° Do not tum the crankshatt. () o Remove the 2 bolts, connecting rod cap and lower bearing. (See procedure (b) and (c) above) Measure the Plastigage at its widest point. Standard oll clearance: 1ZZ-FE: 0.028 -- 0.060 mm {0.0011 ~ 0.0024 in.) 222-GE: 0.028 ~ 0.052 mm (0.0011 ~ 0.0020 in.) Maximum oil clearance; 0.08 mm (0.0031 In.) IF the ol clearance is greater than maximum, replace the bear ings. 1 necessary, grind or replace the crankshaft.EM-93 ENGINE MECHANICAL CYLINDER BLOCK. od Maris: 42003 Mark 1,203 HINT: If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", “2” and "3" accordingly. Reference Standard bearing center wall thickness 1ZZ-FE: Ne ran in) 1 1.486 ~ 1490 (0.0565 0.0587) = 1490-1494 (0.0587 ~ 0.9508) 1.4941 498 (0.0588 0.0590) min 1482 — 1486 (0.0885~0.0585), 1385 1490 (00585 0.0887) ABO” 4494 (00887 — 0 0580) 24. fa) to) Completely remove the Plastigage REMOVE PISTON AND CONNECTING ROD ASSEMBLIES Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder biock. HINT: (a) (o) fo) Kop the bearings, connecting rod and cap tagethor. Arrange ihe piston and connecting rod assembligs in the correct order. REMOVE BEARING CAP SUB-ASSEMBLY AND CRANKSHAFT REAR OIL SEAL, AND CHECK OiL. CLEARANCE 222-GE: Remove the 4 screw plugs from the bearing cap sub-assembly. Remove the 10 hexagon head bearing cap sub-assembiy bolts. Uniformly loosen and remove the 10 bearing cap sub-assembly bolts, in several passes, in the sequence shown.EM.98 ENGINE MECHANICAL —_ CYLINDER BLOCK (@) _ Using a screwdriver, remove the bearing cap sub~assembly by prying the portions between the cylinder black and bearing cap sub-assembly. Remove the 5 lower main bearings. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and bearing cap sub-assembly. HINT: Keep the tower bearing and bearing cap sub-assembly together. (e) Remove the crankshatt rear oil seal (i) Lift out the crankshaft. HINT. Keep the upper bearings together with the cylinder block, = (g) Clean each main journal anet bearing. oS (h) Check each main journal and bearing for pitting and scratches. Hf the journal or bearing is damaged, replace the bearings. if necessary, replace the crankshatt {)) Place the crankshatt on the cylinder block, {)) Lay astrip of Plastigage across each journat. (x) _ Install the bearing cap sub-assembly (See page EM--108). NOTICE: Do not turn the crankshaft. () Remove the bearing cap sub-assembly (See procedures {a) to (2) above). (m) Measure the Plastigage at ils widest point ‘Standard oll clearance: ZZ-FE: 0.015 ~ 0.032 mm (0.0006 ~ 0.0013 In.) 22z-Gi 0.016 — 0.032 mm {0.0006 ~ 0.0043 in.) Maximum ol clearance: 6.050 mm (0.0020 in.) Hf the oil clearance is greater than maximum, replace the bear ings. Il necessary, replace the crankshattEM95 ENGINE MECHANICAL CYLINDER BLOCK }Mark 0, 1,2 aN : eh Nes 2 Mark 0, 1, 2. Now. Saors “Nos G® WZ (nh) 122-FE: {fusing a standard bearing, replace il with one having the ‘same number. If the number of the bearing cannot be de. termined, select the corract bearing by adding together the numbers imprinted on the cylinder block and crankshaft, hea selecting the bearing with the same number as the total. There are 4 sizes of standard bearings, masked "1 °2",°3" and "4" accordingly — Tolalmumber Number mark | Cylinder block (A) + o-2 | a-5 | 6-3 | 9-1 Crankshatt (8) i Usebeaing | "|e * EXAMPLE: Cylindor block "4" (A) + Crankshaft "3" (6) = Total number 7 (Use bearing “3°) (0) 222-GE: fusing standard bearing, replace it with one having the ‘same number. If the number of the bearing cannot be de- termined, refer to the following table to select bearing Number mark n Not Nod ~ No.8 sar Standard bearings selection chart ‘Oykinder block Crank shalt cunibor mark oO EXAMPLE: Gyiindar block vank shait"3", Use bearing “SEM-96 ENGINE MECHANICAL —_GYLINDER BLOCK. Reference ten ark monn) ‘Gyinder lock main jouat bro dameter (A) 7 52 008-52 00 (2.0472 — 2.0473) 1. 52.002 - $2,005 (2.0879 ~ 2.0874) e 152.005 ~ 52.007 (2.0474 ~2.0475) 52.007 ~52010 (2.0476 - 20876) e 2010-82012 2.0976~ 2.0877} : 52012 ~ 52014 2.047? - 2.0870) “ 52,014 82016 (20878-20879) [Crankahat in urea diameter) “47098 46.000 (1 897 ~ 1 8995} 447.998 47.096 (1.5896 1.8887) 447 994 ~47 996 (1.8898 ~ 1.8896) e 47992 ~ 47-994 (1.9894 1.8895) “ 47.990 -47 992 (1.8898 ~ 1.8884) 8 47.988 47 990 (1.8892 — 1.8893) 172 FE a {595 ~ 1-496 (00788-00706) Standard bering center wallthickross 2 #986 ~ 1.999 (90786-00787) s.9 2.002 ja.07e7 ~0.0705) « 2.002~ 2.005 20788-00789) Danse 19691 692 (9.97e3-~007e4) ‘Standard besring centr walltekness 2 yee 1.895 120784 0.0785), o 1905 ~ 1.886 (0.0788 -00787) “« $.988-2 001 (09787-00786) s 2.00% ~ 2.004 (0.0788 - 6.0788) {e) Completely remove the Piastigage. 23, CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04. 0.24 mm (0.0016 - 0.0094 In.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the thrust washers asa set Thrust washer thickness: 2.430 — 2.480 mm (0.0987 — 0.0976 in.) 24, REMOVE CRANKSHAFT (a) Lift aut the crankshaft (o) Remove the 5 upper main bearings and 2 thrust washers from the oylinder block. HINT: ‘Arrange the main bearings and thrust washers in the correct order.M97 ENGINE MECHANICAL ~_ CYLINDER BLOCK. 25. CHECK FIT BETWEEN PISTON AND PISTON PIN, Try to mova the piston back and forth on the piston pin. Ifany movement is felt, replace the piston and pin as a sot 26. REMOVE PISTON RINGS {a) Using a piston ring expander, remove the 2 compression rings. (b) Remove the 2 side rails and oil ting by hand, HINT: Arrange the piston rings in the correct order only. 27. DISCONNECT CONNECTING ROD FROM PISTON (a) Using a small screwdriver, pry out the 2 snap rings. () 122-FE: Gradually heat the piston to 80 ~ 90°C (176 ~ 194"F} () 1Z2-FE: Using a plastic~taced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. HINT: + The piston and pin are a matched set + Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. (@) 222-GE: Remove the pin and connecting rod from the piston.4 EF INSPECTION 1. REMOVE GASKET MATERIAL Using a gasket seraper, remove all the gasket material fromthe top surface of the oylinder block. 2 CLEAN CYLINDER BLOCK Using a soft brush and solvent, thoroughly clean the cylinder block. NOTICE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash the cylinder block at a temperature of 45°C (133°F) or less. 3. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS, Using a pracision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) ltwarpage is greater than maximum, replace the cytindor block, 4, _ INSPECT CYLINDER BORE DIAMETER Visually check the cylinder for vertical scratches, I deep scratches are present, repiace the cylinder block.EN-99 ENGINE MECHANICAL, —_ CYLINDER BLOCK. y ye Thnst OTe Front a Taipee i 1D 7 osm f ¢ > ‘ bate, ® re ‘? | o-ing (WE) rom Egnaust Pipe Hess Onsen Ser seasor wire ecnterlockise 9 ant 1/2 wns = Alter instating oxygen sensor, check al Sengor wir sot ised. His ised. nota Teibh) | Specified torque é | | i | @ Non-reusable part | amove oxom gong_MEMO-EMISSION CONTROL EMISSION CONTROL SYSTEM Ee PARTS LAYOUT AND SCHEMATIC DRAWING «6.0... bit EGO POSITIVE CRANKCASE VENTILATION (PCY) SYSTEM oo. cscsscecseseeeeeterneee E04 EVAPORATIVE EMISSION (EVAP) CONTROL, SYSTEM : 0-5 THREE-WAY CATALYTIC CONVERTER (TWO) SYSTEM cette BQHe041 EMISSION CONTROL, EMISSION CONTROL SvSTEM EMISSION CONTROL SYSTEM PURPOSE The emission contro} systems are installed to reduce the amount of GO, HG and NOx exhausted from the engine ((3) and (4)), to prevent the atmospheric release of blow-by gas—containing HC (1) and evaporated fuel containing HC being released from the fuel tank (2), The function of each system is shown in these table System ‘ABavaon Fonction {i Posiive Grankcase Vantiaten ov Reduces HO (2) Bvaporativa Emission Control EvaP | Reduces evaporated MC (G) Trvee-way Catatyte Converter ywe | Reduces HO, CO and NOx 4) Sequential Malport Fuel ijactian™ SFI Injocs a precisoly trad, optimum amount of lua tor reduces exhaust antasions Remark: “For inspection and repair of ihe SFI sysiam, refer to the SF section of this manual.EC eC-2 EMISSION CONTROL PARTS LAYOUT AND SCHEMATIC DRAWING PARTS LAYOUT AND SCHEMATIC DRAWING LOCATION EVAP Service Part VSV for EVAP. SV for Canister Closed Valve (COV) VSV for Prossure Switching Valve | 7 Line Air inlet Line Purge LineFCs EMISSION CONTHOL, ~_ PARTS LAYOUT AND SCHEMATIC DRAWING DRAWING \VSV for EVAP Purge Lina =L Vapor Pressure Sensor Vert tine i EVAP Line EVAP Sevise Pont VSV for Pressure Switching Valve Fuel Tank Cap Charcoal Canister iz Fuel Tank BS Air Drain Hose | Ait Inlet Line Ea VSY for Canister - Filor Pipe Closed Valve (CCV) Heated Oxygen Sensor (Bank 1 Sensor 1) Heated Oxygen Sensor (Bank t Sensor 2) Two u aeEC-4 EMISSION CONTROL - _BOStII¥ECRANKCASE VENTILATION Ov} i22-FE: Cylinder Head Side. Clean Hose wis Intake Manifold Side 4 4 ‘Clean Hose POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM INSPECTION 1. REMOVE PCV VALVE {a} Disconnect the PCV hose from the PCV valve (b) Remove the PCV valve. 2, INSTALL CLEAN HOSE TO PCV VALVE 3. INSPECT PCV VALVE OPERATION (a) Blow air into the cylinder nead sida, and check that air passes through easily CAUTION: Do not suck air through the valve. Petroleum substances inside the vaive are harmful. (b) Blow air into the intake manifold side, and check that air passes through with difficuity, I operation is not as specified, replace the PCV valve, 4, REMOVE CLEAN HOSE FROM PCV VALVE 5. REINSTALL PCV VALVE 6. VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS: Check for cracks, leaks or damage.EMISSION CONTROL —_ EVAPORATIVE EMISSION (EvAP) CONTROL SYSTEM EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM COMPONENTS ECs Heated Insulator ~ Charcoal Canister pn Tal Pipe 0) me ~ _-— Air Drain Hose f Arbirvose Purge Lino Hose SP Vent ine Hi ~ neniose | EVAP Une Hose | [iim fkghom, eH) VSV Connector for jy # Non-reusable part Pressure Switching Valvefee EMISSION CONTROL —_ EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM INSPECTION 1, REMOVE EXHAUST TAIL PIPE AND HEATED INSULA- TOR (See page EM-115) 2, INSPECT LINES AND CONNECTORS Visually check for toose connections, sharp bends or damage. 3. INSPECT FUEL TANK FILLER PIPE Visually check for detormation, cracks or fuel leakage. 4, INSPECT FUEL TANK CAP Visually check if the cap and/or gasket are deformed or damaged. I necessary, repair or replace the cap. 5. INSPECT EVAP SYSTEM LINE (a) Warm up the engine and stop the engine. Allow the engine to warm up tonormat operating temperature. (b) Install a vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge ine. e set {c) TOYOTA hand-held tester: Forced driving of the VSV for the EVAP, (1) Connect a TOYOTA hand-held tester to the DLC3. (2) Stat the engine. (3) Push the TOYOTA hand-held tester main switch ON. (4) Use the ACTIVE TEST mode on the TOYOTA hand-held tester to operate the VSV for the EVAP. (d} Ifyou have no TOYOTA hand-held tester: Forced driving of the VSV for the EVAP. (1) Disconnect the VSV connector for the EVAP. (2) Connect the positive (+) and negative (-) leads from the battery to the VSV terminals for the EVAP. (3) Start the engine.Er EMISSION CONTROL - EVAPORATIVE EMISSION (EVAP) CONTROL SVSTER Air Drain Hose { Hose Clipper Pressure (e) Check the vacuum at idle, Vacuum: Maintain at 0.368 - 19,713 in.Hg (5-268 in.Aq) for over 5 seconds HINT: the vacuum does nol change, you can conclude that the hose connecting the VSV to the service port has come toose ot is blocked, or the VSV is malfunctioning, @ (@) (b @ a) Ifyou have TOYOTA hand-held tester: Conclude forced driving of the VSV for the EVAP. (1) Stop the engine. (2) Disconnect the TOYOTA hand-held tester from the DLs, Ifyou have no TOYOTA hand-held tester: Conclude forced driving of the VSV for the EVAP. (1) Stop the engine. (2) Disconnect the positive (+) and negative (-) leads from the battery, and from the VSV erminais for the EVAR. (3) Connect the VSV connector for the EVAP. Disconnect the vacuum gauge from the EVAP service port on the purge line. Connect a pressure gauge to the EVAP service port on the purge line. Check the pressure. (1) Close off the air drain hose al the marked position of the canister with a hose clipper or similar instrument. (2) Add the pressure (13.5 ~ 15.6 in.Ag) from the EVAP sorvice port Pressure: 2 minutes alter the pressure Is added, the gauge should be over 7.7 ~ 8.8 in.Aq. HINT: H you can't add pressure, you can conclude that the hose con necting the VSV-canister-fuel tank has slipped off or the VSV is open.EMISSION CONTROL CY Fuel Tank Cap PurgeLine Hose EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM: (2) Check it the pressure decreases when the fuel tank cap is removed while adding pressure. HINT: it the pressure does not decrease when the filler cap is re moved, then you can conclide that the hose connecting the service port to the fuel tank is blocked, etc. {&) Disconnect the pressure gauge from the EVAP service port on the purge line. 6. CHECK AIRTIGHTNESS IN FUEL TANK AND FILLER PIPE fa) Disconnect the EVAP line hose from the charcoal canis ter. (1) Pinch portion A. (2) Pull out the connector. {b) Pressurize and make the internal pressure in the fuel tank 4 kPa (41 glicm?, 0.58 psi}, {) Check that the internat pressure of the fuel tank can be held for # minute. (a) Check the connected portions of each hose and pipe. (e) Check the installed parts on the fuel tank, It there is no abnormality, replace the fuel tank and filler pipe. () Reconnect the EVAP ling hose to the charcoai canister 7. INSPECT FUEL CUTOFF VALVE AND FILL CHECK VALVE (a) Disconnect the purge line hose and EVAP line hose from the charcoal canister. (b) Plug the cap to the air drain hose. (©) Pressurize 4 kPa (41 gl/cm®, 0.58 psi) to the purge port and check thal there is ventilation through the EVAP line hose. HINT: In the condition that the fuel is full, as the floal value of the fit check valve is closed and has no ventilation, itis necessary to check the fuel amount (volume). (a) Check if there is anything stuck in the vent line hose and EVAP line hose. If there is nothing stuck in them, replace the fuel cut aff valve and fil check valve. (e) Reconnect the purge line hose and EVAP line hose to the: charcoal canister.EC-9 EMISSION CONTROL, --_CVAPORATIVE EIMSSION EVAR) CONTHOL SYOTENE 8, CHECK AIR INLET LINE fa) Disconnect the air inlet ine hose from the charcoal canister. (b) Check that there is ventilation in the air inlet tine. (6) Reconnect the air inlet line hose to the charcoal canister. "Air Inlet Line Hose iS ear 9. REMOVE CHARCOAL CANISTER ASSEMBLY (a) Disconnect the VSV connector. {b) Disconnect the purge line hose, EVAP line hose and air inlet ling hose trom tha charcoal canister. {c}_ Disconnect the vent line hoge from charcoal canister. (1) Push the connector deep inside. (2) Pinch portion A (3) Pull out the connector. fd) Remove the 8 nuts and charcoal canister assembly. 10. INSPECT CHARCOAL CANISTER fa) Visually check the charcoal canister for cracks or damage. 6 ems - (0} Inspect the charcoal canister operation. 2 Purge Post (1) Plug the vent port with a cap. ‘Vent Pon (2) While holding the purge port closed, blow air (1.76 oe kPa, 18 oficm?, 0.26 psi} into the EVAP port and check that air flows from the air drain port. Neal Cap Sf f EVAP Pon Ai ‘oatEC-10 EMISSION CONTROL @) EVAP Port N Port som 4) (8) 13. EEVARORATIVE EMISSION (EAP) CONTROL SYSTEM While holding the purge port and the air drain port closed, blow air (1.76 kPa, 18 gl/cm?, 0.26 psi the EVAP port and check that air does not flow from. the air intet port Apply vacuum (3.43 kPa, 25.7 mmHg, 1.01 inHg) to the purge port, check that the vacuum does not decrease when the air inlet port is closed, and check that the vacuum decreases when the air inlet port is released, ‘While holding the air iniet port closed, apply vacuum (3.43 kPa, 25.7 mmHg, 1.01 in.Hg) to the EVAP port and check that air flows into the purge pont 11a problem is found, replace the charcoal canister. (6) Remove the cap from the vent port. 11. INSPECT VSV FOR EVAP- {See page SF-57) 12. INSPECT VSV FOR CANISTER CLOSED VALVE (CCV) N {See page SF-59) INSPECT VAPOR PRESSURE SENSOR (See page SF-65) 14, REINSTALL CHARCOAL CANISTER ASSEMBLYTHREE-WAY CATALYTIC CONVERTER (TWC) SYSTEM EMISSION CONTROL ~ THREE WAY CATALYTIC CONVERTER (TWG} Ec-t Systew INSPECTION 1. CHECK TWC FOR DENTS OR DAMAGE If any port of the heat insulator is damaged or dented to the extent that it contacts the three-way catalytic converter, sepair oF repiace it 2 3. 4a 5. CHECK EXHAUST PIPE CONNECTIONS FOR LOOSENESS OR DAMAGE CHECK EXHAUST PIPE CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE CHECK HEAT INSULATOR FOR DAMAGE CHECK FOR ADEQUATE CLEARANCE BETWEEN EXHAUST SYSTEM AND HEAT INSULATOR ON THE BODYMEMO ~SFI SFISYSTEM FUEL PUMP oe FUEL PRESSURE REGULATOR INJECTOR FUEL TANK AND LINE MASS AIR FLOW (MAF) METER THROTTLE BODY . IDLE AIR CONTROL (1AC) VALVE CAMSHAFT TIMING Olt. CONTROL VALVE EFIMAIN RELAY oo... CIRCUIT OPENING RELAY VSV FOR INTAKE AIR CONTROL VALVE .. ‘VSV FOR EVAPORATIVE EMISSION (EVA?) VSV FOR CANISTER CLOSED VALVE (CCV) cesses SV FOR PRESSURE SWITCHING VALVE. ENGINE COOLANT TEMPERATURE (ECT) SENSOR VAPOR PRESSURE SENSOR, KNOCK SENSOR HEATED OXYGEN SENSOR ENGINE CONTROL MODULE (ECM) FUEL CUT APM SF SFG SFIS SF-18 SF-26 SF-23 SF-33 SF-40 SF-46 SF-52 SF-53 SF-54 SF-56 SF-68 SF-80 SF62 SF-64 SF-86 SF-69 Srv SF-7a EGSh se srisystem SFISYSTEM PRECAUTION 1, BEFORE WORKING ON THE FUEL SYSTEM , DIS- CONNECT THE NEGATIVE (-) TERMINAL CABLE FROM THE BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negalive (~) terminal cable is removed trom the battery. Therofore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery, 2, DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4, MAINTENANCE PRECAUTIONS (a) In event of engine misfire, these precautions should be taken. (1) Check proper connection to battery terminals, ete, (2) _ After repair work, check that the ignition cait termi- als and all other ignition system lines are recon: nected securely. (3) When cleaning the engine compartment, be especially careful to protect the electrical system from water. (b} Precautions when handling oxygen sensor. (1) Danotallow oxygen sensor to drop or hit against an object. (2) De not allow the sensor to come into contact with water. If vehicle is Equipped with Mobile Radio System (HAM, CB, etc.) Mthe vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. 5. AIR INDUCTION SYSTEM {a) Separation of the engine oil dipstick, oit filer cap, PCV hose, etc, may cause the engine to run out of turn. {b) Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run out of turn. 6 ELECTRONIC CONTROL SYSTEM {a) Before removing SFI wiring connectors, terminals, ete., first disconnect the power by either turning the ignition ‘switch to LOCK or disconnecting the negative (-~) terminal cable from the battery. HINT: ‘Always check the diagnostic rouble cade botare disconnecting the negative (-) terminal cable from the batterySF-2 Fuel Pump __ Connector Vinyl Bag ~~ (b) to (e) fe) © (@) (hy 0 ra @) SA_-_Srisystest When installing the battery, be especially careful not to in- correctly connect the positive (+) and negative (-) cables. Do not permit parts to receive a severe impact during re~ moval or installation, Handle all SFI parts carefully, especially the ECM. Be careful during troubleshooting as there are numerous: transistor circuit, and even slight terminal contact can cause further troubles, Do not open the ECM cover. When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment, prevent water from getting on the SF? parts and wiring connectors. Parts should be replaced as an assembly ‘Care should be taken when pulling out and inserting wiring connectors. (1) Release the lock and pull out the connector, pulling on the connectors. (2) Fully insert the connector and check that itis locked, Use SST for inspection or test of the injector or its wiring connector. SST 09842-30060 FUEL SYSTEM When disconnecting the high uel pressure fine, a large amount of gasoline will spill out, so observe these procedures. (1) Disconnect the fuel pump connector. (2) Start the engine. After the engine has stopped on its own, turn the ignition switch to LOCK. (3) Disconnect the fuel tube (See page SF-11). (4) Drain the fuel remained inside the fue! tube. (6) Prevent the disconnected uel tube from damaging and mixing foreign objects by covering them with a vinyl bag.b wore Rieiy O-ting ‘CORRECT 2] Debary Pipe Injector ay = = ™» WRONG ~ Delivery Pipe — Spacer O-ting Pipe ib) fe) @ Sra SF_—_seisysten. (6) Puta container under the connection. Observe these precautions when removing and installing the injector. (1) Never reuse the O-ring. (2) When placing a new O-ting on the injector, lake care not to damage it in any way. (3) Coat a new O-ring with spindle oil or gasoline before installing never use engine, gear or brake oil " Install the injector to the delivery pipe and cylinder head, as shown in the illustration. Before in installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe ora cylinder head touches on O-ring of the injector. Observe these precautions when disconnecting the fuel delivery pipe. The structure of the metallic connector is. shown as left (1) Remove the fuel pipe clamp. (2) Get the metallic connector of the fuel tube assem: bly, pull out towards the rear and hold it as its. (3) Assemble SST to the connection as shown. SST 09268-21030SF4 __SFi_—_SFISYSIEM (oe) (4) Turn SST, align the retainers inside the connector with SST chamfered parts and incert SST into the connector. (8) Hold SST as it at step 4, push the connector towards SST to pul the retainers on SST champfered parts. (© Slide SST and the connector together towards the fuel lube assembly. ‘Observe these precautions when disconnecting the fuel tubs connector (quick type). (1) Remove the fuel pipe clamp. (2) Check if there is any dirt like mud on the pipe and around the connector before disconnecting them: ‘and clean the dirt away. (8) Be sure to disconnect with hands. (4) When the connector and the pipe are stuck, pinch tho retainer between the hands, push and pull the connector to free to disconnect and pull it out. Do ‘nol use any tool al this time. (5) _ Inspect if theres any dit or the likes on the seal surface of the disconnected pipe and clean it away. (6) Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag.SF-S Reyainor ns DLCS = pore a (a) (hy SEL SeiSYSIEM Observe these precautions when connecting the fuel tube connector {quick type} (2) Do not reuse the retainer removed trom the pipe, (2) Must use hands without using tools when to remove the retainer from the pipe. (3) Check if there is any damage or foreign objects on the connected part of the pipe. (4) Match the axis of the connector with axis of the pipe, and push in the connector until selainer makes & “click” sound. In case that the connections is tight, apply little amount of new engine oilon the tip of the pipe. (5) After having finished the connection, check if the pipe and the connector are securely connected by pulling them. (8) Install the fuet pipe clamp. (7) Check if there is any fuel leakage. ‘Observer these precautions when handling nylon tube. a) (2) 3) (4) Pay attention not to turn the connected part of the nylon tube and the quick connector with force when ‘connecting them. Pay attention not to kink the nylon tube. Do not remove the nylon tube. Must not close the piping with the nylon tube by bending it Check that there are no tue! leaks after doing maintenance anywhere on the fuel system. a (2) (3) a (5) 6) cc) @) Connect the TOYOTA hand-held tester to the pica. Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. Select the active test mode on the TOYOTA hand— hold tester. Please relerto the TOYOTA hand-held tester operator's manual for further details, you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the bat tery to the fuel pump connector. (Seo page SF-6) Check that there are no leaks from any part of the ‘tual system. ‘Turn the ignition switch to LOOK, Disconnect the TOYOTA hand-held tester from the pica.Fuel Tubs Connector SF FUEL PUMP FUEL PUMP ON-VEHICLE iNSPECTION 1. CHECK FUEL PUMP OPERATION (a) Connect the TOYOTA hand-hold tester to the DLG3. (©) Turn the ignition switch ON and TOYOTA hand-held tester main switch ON NOTICE: Do not start the engine. (c}_ Select the active test mode on the TOYOTA hand-held tester. (d) Please refer to tho TOYOTA hand-held tester operator's, manual for further details. (e) Ifyou have no TOYOTA hand-held tester, connect the positive (+) load from the battery to terminal 4 of the con- neoter, and the negative (~) tead to terminat 5. () Check that there is pressure in the fuel infet pipe from the fel tine. HINT, there is fuel pressure, you will hear ihe sound if fuel following. I there is no pressure, cheok these parts, Fusible link, Fuses, EFI Main relay, Fuel pump, ECM, and Witting connector. (9) Turn the ignition switch to LOCK. {h) Disconnect the TOYOTA hand-held tester from the Dic. 2. CHECK FUEL PRESSURE (a) Check the battery positive voltage is above 12 V. (b) Disconnect the negative (~) terminal cable from the battery. {) Purchase the new fuel tube and take out the fuel tube connector from its pipe. Part No.: 122-FE: 23901-22100 27Z-GE: 23271-88600(@) fe) SF-7 Se _ FUEL PUMP. Remove the fuel pipe clamp. Disconnect tho fuel tube (fuel tube connector) trom the fuel pipe. CAUTION: (h) Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions. As there is retained press! vent If from splashing in ment. in the fuel pipe line, pre- the engine comport Insta SST (pressure gauge) as shown in the illustration by using SST and fuel tube connector. SST 09268-41047 (95336-08070), 09268-45014 (09268-41200, 09268-41220, 09268-41250) Wipe off any splattered gasoline. Reconnect the negative {-) terminal cable to the battery.SF1_= FUEL PUNE. (Connect the TOYOTA hand-held tester to the DLC3. you have no TOYOTA hand-held tester, connect the positive (+) lead from the battery to terminal 4 of the connecter, and the negative (~) load to terminal 6. Measure the fuet pressure. Fuet pressure: 301 ~ 347 kPa (3.1 - 3.5 kgt/om?, 44 — 50 psi} pressure is high, ceplace the fuel pressure regulator. It pressure is low, check the Fuel hoses and connections, Fuel pump, Fuel filer, and Fuel pressure regulator. (Disconnect the TOYOTA hand-held tester from the DLCs. () Start the engine. (m) Measure the fuel pressure at idle. Fuel pressure: 301 — 347 kPa (3.1 — 3.5 kgt/om?, 44 — 50 psi) (n) Stop the engine. (0) Check that the fuel pressure remains as specified for 5 sninutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgt/em?, 21 psi) or more {f pressure is not as specified, check the fuet pump, pressure regulator and/or injectors. (p) After checking [uel pressure, disconnect the negative (-} terminal cable from the battery and carefully, remove the SST and fuel tube connector to prevent gasoline from splashing, SST 09268-41047 (96336-08070), 09268-45014 (09268-41200, 09268-41220, 09268-41250) (a) Reconnect the fue! tube {tuel tube connector). CAUTION: Perform connecting operations of the fuel tube connector (quick type) ater observing the precautions. (1) Install the fue! pipe clamp. (s} Reconnect the negative (-) terminal cable to the battery. (Check for fuel leakage. 3. REMOVE REAR SEAT CUSHION 4. REMOVE FLOOR SERVICE HOLE COVER 5. DISCONNECT FUEL PUMP & SENDER GAUGE CON- NECTORsrg SL FUEL PUMP 6. _ INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 — 3,0 2 at 20°C (68 “F) lthe resistance is not as specified, replace the {uel pump. 7. INSPECT FUEL PUMP OPERATION Connect the positive (+) lead from the battery to terminal 4 of the connector and the negative (-) terminal 5. Check that the pump operates, NOTICE: + These tests must be done quickly {within 10 seconds) to prevent the coll burning out. + Keep fuel pump as far away from the battery as pos: sible. + Always do the switching at the battery side. it operation is not as specified, repiace the fuel pump or iead wire. 8, RECONNECT FUEL PUMP & SENDER GAUGE CON- NECTOR 9. REINSTALL FLOOR SERVICE HOLE COVER 10. REINSTALL REAR SEAT CUSHION“ a SF-10 COMPONENTS: Fuel Pump & Sender ‘Gauge Connector Vapor Pressure Sensor Connector: Fuel Tube Outlet (asm 381855} —F Gasket — a fim figrer, y_@Non-reusable pat Floor Service Hole Cover DB ~ Eton Tube cic S~ s0-Fing )____ Fue Tank Vent Tube: Cap 7 Set Plate 2 Qo Fos Pressure Regulator {HED |: Specitied torque SFL_=_ FUEL pune Rear Seat Cushion a2 Yoo Peso g Tovevoit ip no Fue Suction Suzan gta w= —~ O-Ring ~ Fuel Pump Assembly Fuet Pump Filler Fuel Pump Harness. '@— Fuel Filter Seal B——— Fuel Pump Spacer i fp Fuel Pump & Rubber Cushion 7 4 Gy No.2 Fuel Suction SupportSF-11 ‘SFI. FUEL PUMP REMOVAL CAUTION: Do not smoke or work near an open flame when working on the fuel pump. 1 (2) A) 5. fa) {b) REMOVE REAR SEAT CUSHION REMOVE FLOOR SERVICE HOLE COVER DISCONNECT FUEL PUMP & SENDER GAUGE CON- NECTOR AND VAPOR PRESSURE SENSOR CON- NECTOR DISCONNECT FUEL TUBE AND EMISSION TUBE ‘Wash away the mud, dust and the likes on the fuel suction plate with water. Pull off the tube joint clip from the No. 1 fuet suction plate. Disconnect the fuet tube from the fuel pump assembly. Disconnect the emission tube from the fuel pump assembly. Attach the tape in order to protect the port portion from the dust, Protect the disconnected fuel tube from damage and for eign material by covering it with a plastic bag. REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK, Remove the 8 bolts and fuel tank vent tube set plate. Pull out the fuet pump assembly NOTICE: fe) Do not damage the fuel pump filter. Be careful that the arm of the sender gauge should not bent. Remove the gasket from the pump assembly.Sra PSUR PUM DISASSEMBLY 1. REMOVE NO. 2 FUEL SUCTION SUPPORT (@)_ Using a small screwdriver, remove the No. 2 {uel suction support (0) Remove the rubber custion. 2, REMOVE NO. 1 FUEL SUCTION SUPPORT {a) Disconnect the fuel sender gauge connector and earth piate. (b) Using a small screwdriver, remove the No. 1 {uel suction suppor NOTICE: Do not damage the fuel suction support and fuel suction plate. (©) Disconnect the fuel pump harness trom the No. 1 fuel suction support and {uel pump, 3, REMOVE VAPOR PRESSURE SENSOR Pulloff the joint clip and remave the vapor pressure sensor from No. 1 fuel suction support 4, REMOVE FUEL PRESSURE REGULATOR Pull out the fuel pressure regulator and O-ring from the fuel fil ter 6, REMOVE FUEL PUMP Remove the pump from the fuel fitter.Se SF-13 SF FyeL PUMP REASSEMBLY 1 INSTALL FUEL PUMP Connecl the fuel pump to the fuel filter. 2, INSTALL FUEL PRESSURE REGULATOR {a) Install the O-ting to the pressure regulator. HINT: Apply a light coat of gasoline to a new O-ring, and install it 10 the pressure regulator. (b) Connect the pressure regulator to the ful filter. 3. INSTALLNO. 1 FUEL SUCTION SUPPORT (@) Connect the fue! pump hamess to the No. 1 fuel suction support and fuel pump. (b) Install the No. 1 fuel suction support to the fvel filter. (©) Connect the fuel sender gauge connector and earth plate. 4, INSTALL NO. 2 FUEL SUCTION SUPPORT (@) _ Install the rubber cushion. (©) _ Install the No. 2 fuel suction support to the No, 1 fuel suc tion support. 5, _ INSTALL VAPOR PRESSURE SENSOR: Install the vapor pressure sensor and connect the joint clip to the No. 1 fuel suction support.SF14 SFI_=_ FLUE. PUM, INSTALLATION 1. INSTALL FUEL PUMP ASSEMBLY (a) _ Install the new gasket to the fuel pump assembly. {b) _ Install the fuel pump assembly to the fuel tank. NOTICE: + Do not damage the fuel pump filter. + Be careful that the arm of the sender gauge should not bent. (0) _Installthe 8 bolts and fuel tank vent tube set plate from the fuel tank. Torque: 4.0 N-m (40 kgtiem, 35 invibf) 2. CONNECT FUEL TUBE {a) Clean up around the fuel tube. {b) Connect the fuel tube and emission tube to the fuel pump assembly, {€) Connect the tube joint clip to the fuel suction plate. 3, CONNECT FUEL PUMP AND SENDER GAUGE CON- NECTOR AND VAPOR PRESSURE SENSOR CON- NECTOR rar] HINT: Starl the engine, cheok for fuel leakage. 4, INSTALL FLOOR SERVICE HOLE COVER (a) Install the service holo cover, (6) Install the floor carpet. 5. INSTALL REAR SEAT CUSHIONSFA15 SFI_—_ FUEL PRESSURE REGULATOR FUEL PRESSURE REGULATOR COMPONENTS Rear Seal Cushion Floor Service Hole Cover Fuel Pump & Sender Gauge Connector No. + Fue! Suction Suppor Tube Joint Clip Fuel Tank Vent Tube [AoiG6. 26 into Set Plate ge — Fual Pressure Regulator eo © O-Ring Ful Filer with Fuel PumpSF-16 SFI. FUEL PRESSURE REGULATOR REMOVAL a 1 2 REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK (See page SF~11) REMOVE NO. 1 FUEL SUCTION SUPPORT (See page SF-12) REMOVE FUEL PRESSURE REGULATOR Pull out the pressure regulator. Remove the O-ring from the pressure regulator.SFT SFI_—_ FUEL PRESSURE REGULATOR INSTALLATION 1. INSTALL FUEL PRESSURE REGULATOR (a) _ Install the O-ting to the pressure regulator. HINT: Apply a light coat of gasoline to a new O-ring, and install it to the pressure regulator. (b) Connect the pressure regulator from the fuel filter. 2 INSTALL NO. 1 FUEL SUCTION SUPPORT (See page SF—13) 3. INSTALL FUEL PUMP ASSEMBLY TO FUEL TANK (See page SF-14)SF18 f= _aueTOn. INJECTOR ON-VEHICLE INSPECTION 4. REMOVE NO. 2 CYLINDER HEAD COVER 2. CHECK OPERATION SOUND FROM EACH INJECTOR (a) Connect the PCV hose to oylinder head cover. {b) With the engine running or cranking, use @ sound scope to check that there is normal operating noise in proportion to engine speed. {c) Ifyou have no sound scope, you ean check the injector transmission operation with your finger. Ino sound or unusual soundis heard, check the wiring conneo- tor, injector signal from the ECM. {d) Disconnect the PCV hose from cylinder head cover. 3, INSPECT INJECTOR RESISTANCE (a) _ Disconnect the injector connector. (b) Using an ohmmneter, measure the resistance between the terminals. Resistance: 13.4 ~ 14.2 0 at 20°C (68°F) Ifthe resistance is not as specified, replace the injector (©) Reconnect the injector connector. 4, INSTALL WIRE HARNESS PROTECTOR COVER (a) Install the wire harness protector cover with bolt and 2 nuts. (b) Connect the PCV hose to cylinder head cover.) COMPONENTS SFL —_wwegton SF-19 172-FE: © O-Ring [Rm (katem, 0) ] : Spectied toave Non-rousabie part No. 2 Cylinder Head Cover ——— Fuel Datvery Pipe and Fue LO Tube Assembly }— Pov HosesF20 __ SFL wyecton 222-GE: Ta) | No. 2 Gylinder Head Cover Fuel Dolivery Pipa and Fuel Tube Assembly Injector + Grommet ~~ [RR kor, HEAT]: Spectied esque «_# Non-revsable pit =SF-21 SH_—_ywectos REMOVAL 1. REMOVE NO. 2 CYLINDER HEAD COVER, 2. 1ZZ-FE: @EMOVE PCV HOSE 3, DISCONNECT FUEL TUBE {a) Remove the fue! pipe clamp. tb) Disconnect the fuel tube (fuel tube connector} from the fuel pipe. CAUTION: + Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions. + As theres retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment. 4, REMOVE DELIVERY PIPE AND INJECTORS NOTICE: Be careful not to drop the Injectors when removing the delivery pipe. {a) Disconnect the 4 injector connectors from injector. (0) Remove the 3 bolts and delivery pipe together with the 4 injectors and fuel pipe. (c)_ Remove the 2 spacers from the oylinder head. (a) Pull out the 4 injectors from the delivery pipe {e) Remove the O-ring and grommet from each injector.SF-22 be _% = vee CHa Sea sar Sinan) st ‘Gimp Fuste Greil Fuel Tube Connector SST. (ose ~Fuel Tube Connector Fuel Pipe Ea 1 S81 tHose) ‘SST (Union}-— o-Fing—' | > TOYOTA Hand-Hald Te: ster ad SEL___INJECTOR INSPECTION 1. INSPECT INJECTOR INSPECTION CAUTION: Keep Injector clear of sparks during the test. (a) Purchase the new fuel tube and take out the fusl tube connector from its pipe. Pret No. 23901-22010 {) Connect SST {hose} and fuel tube connector to the fuel pipe. SST 09268-41047 CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions. {c) Install the grommet and O-ring to the injector. {a} Connect SST (union and hose) to the injector, and hold the injector to prevent gasoline from splashing out SST 09268-41047 {e) Put the injector into a graduated cylinder. HINT: Install a suitable vinyl tube onto the injector to prevent gasoline from splashing out. (Connect the TOYOTA hanc--held tester to the DLC3. (g) Turn the ignition switch ON and TOYOTA hand-held tes ter main switch ON, NOTICE: Do not start the engine. th) Select the active test mode on the TOYOTA hand-held tester. (i) Please refer to the TOYOTA hand-held tester operator's ‘manual for further details.SF-23 Sr nurcton @) Ityou have no TOYOTA hand-held tester, connect the positive (+) and negative (~) leads trom the battery to the uel pump connector (See page SF-18) (k) Connect SST (wire) to the injector and battery for 15 seconds, and measute the injection volume with a graduated cyiinder. Test each injector 2 or 3 times. SST 09842-30080 Volume: 47 ~ 58 cm? (2.7 ~ 3.3 cu in.) per 15 sec. Difference between each injector: 10 cm? (0.6 cu in.) or less Ifthe injection volume is not as specified, replace the injector. 2, INSPECT LEAKAGE (a) _ Inthe condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. SST 09842-30080 Fuel drop: 4 drop of less per 12 minutes () Turn the ignition switch to LOCK. (c) Disconnect the negative (-) terminat cable from the battery. (a) Remove the SST and fuel tube connector. SST 09268-41047 CAUTION: + Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions, + As there is retained pressure in the fuel pipe fine, prevent it from splashing inside the engine compartment. {@) Disconnect the TOYOTA hand-held tester from the pics.SF-24 SF) INJEDTOR, INSTALLATION 1. INSTALL INJECTORS AND DELIVERY PIPES. (@) install the grommet to each injector. (b) Apply a light coat of spindle oil or gasoline to new O-ring ‘and install them to each injector. (©) Apply a light coat of spindle oil or gasoline on the place where a delivery pipe touches on O-ring. (d) While 1uming the injector clockwise and counterclock- ‘wise, push it to the delivery pipes. Install the 4 injectors. (e) Position the injector connector outward ()) Place the 2 spacers in position on the cylinder head. {g) Apply a light coat of spindle oi! or gasoline on the place where a cylinder head touches an O-ring of the injector. (h) Place the delivery pipe and fuel pipe together with the 4 injectors in position an the cylinder head. () Temporarily install the 2 bolts holding the delivery pipe to the cylinder head. (Temporarily install the boll holding the fuel pipe to the cyl: Inder head. {k) _ Cheok that the injectors rotate smoothly. HINT. It injectors do not rotate smoothly, the probable cause is incor tect installation of O-ring. Replace the O-ring, ()) Position the injector connector connector outward,SF-28 SFL_— INJECTOR {m) Tighten the 2 bolts holding the delivery pipe to the oylinder head. Torque: 1ZZ-FE: 19 N-m (190 kgf-em, 14 ftlbf) 2ZZ~GE: 29 Nem (290 kgt-cm, 21 fbf) {a} Tighten the boltholding the fuel pipe to the cylinder head. Torque: 9 N-m (92 kgt-om, 7 ft-lbf) . CONNECT FUEL TUBE (a) Connect the fuel tube {fuel tube connector) to the {uel pipe. CAUTION: Perform connecting operations of the connector (quick type) after observing the precautions. (b) Install the fuel pipe clamp. 3. INSTALL NO. 2 CYLINDER HEAD COVER,SF-26 SEL_—_ EVEL TANK AND Lie FUEL TANK AND LINE PRECAUTION + Always use new gaskets when replacing the fuel tank or component parts. Apply the proper torque to all parts tightened.‘SF-27 SEL _FUFL YANK AND UNE: COMPONENTS —_ uot Tank Vont Tube Set Plata SP ac Fuel Infat Pipe hy Rear Floor Heat Fuel Inlet Hose Ingulalor L @ but Tank No. 2 Fuel Tak fut ot Protein T bane J No. 4 Front Floor Heat Insulator oe No. 2 Front Floor Heal Insulator Tail PipeS28 Gratk Leakage Deformation Pipe BF mm (0.08-0.28in) Hose O~3mm(O-0.42iN) spon SEI PUIEL TAN AND LINE INSPECTION INSPECT FUEL TANK AND LINE fa) (b} (o) (a) Check the fuel fines for cracks or leakage, and all connec: tions for deformation Check the tual tank for deformation, cracks fuel leakage oF tank band looseness. Check the filter neck for damage or fuel leakage. Hose and tube connections are as shown in the illustea- tion. It a problem is found, repair or replace the part as necessary.MASS AIR FLOW (MAF) METER COMPONENTS y # Non-reusable part S29 j= _ MASS AiR FLOW QMAE METER, Mass Air Flow Meter Mass Air Flow Meter ConnectorSF-30 SFI_=_MASS AN PLOW (MAF METER REMOVAL _ REMOVE AIR FLOW METER Remove the 2 screws, air flow meter and O-ring,& THA Obmmeter SF-31 SF _WASS AIM FLOW (uae) METER INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance betwoen terminals THA and E2, 26 Resistance: Sonate Resistance Temperaiu THAW Tae 4K 2CCrr AES 2a 260K 206 58°F} THA e2 040-057 Bore 40°F) IFthe resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION {a) Connect the MAF meter connecter. (0) Turn the ignition switch to ON. (6) Using a voltmeter, connect the positive (#) tester probe to torminal VG, and negative (-) tester probe to terminal E2G (2) Blow air inio the MAF moter, and check that the voltage fluctuates. operation is not as specified, replace the MAF meter. (e) Tum the ignition switch LOCK. (Disconnect the MAF meter connector.SF-32 SFI_-_ MASS Alf FLOW (MAE) METER, INSTALLATION INSTALL AIR FLOW METER Install the air flow meter and a new O-ting with 2 screws,SF-33 SF _TOTLE so0r THROTTLE BODY ON-VEHICLE INSPECTION 1, INSPECT THROTTLE BODY Check that the throttle iinkage moves smoothly. 2. INSPECT THROTTLE POSITION SENSOR (a) Remove the air cleaner assembly with atr flow meter. {) Disconnect the throttle position sensor cormnector. (©) Using an ohmmeter, measure the resistance between OY each terminal ‘ XS | [ereerance poten ver iy) ae a Betecontonninats Fasianea A Om (ing Via ee freeerny Lf Sener) [Trot va tly epan VIA 2 20102 KA = ar 25-5940, {d) Reconnect the throttle position sensor connector. {e) Reinstall the air cleaner assembly with air flow moter.SF-34 _Sf_=_THnoTTEnopy. COMPONENTS 172-FE: Air Cleaner Gap with Air Flow — Meter and Air Cleaner Hose ~ Air Flow Meter Connector — POO folk ren Cable af) oa PCV Hose 7h a No. 2 Water By-pass Pipe: ‘ - $ Gasket [Ream (gh, Tip ] Speci cuss a {kgtem b peciied torque Water By-pass Hose — [ 24(210, 75) y.@ Non-rousable partSF-35 sf. tnnome gopy 222-GE: 707i, 8210.1 No. 2 Cylinder Head Cover ic Cleaner Gap with Air Flow. Mater and Air Cleaner Hose Ai Flew Mater Connector Accelerator Gable — IAG Valve Connector —~ § Z ‘Throttle Body Feb] : Species torque bn 4 & Non-rousable partSF-36 SFl_—_THROTILE BODY. REMOVAL 1. DRAIN ENGINE COOLANT 2. DISCONNECT ACCELERATOR CABLE 3. REMOVE NO. 2 CYLINDER HEAD COVER 4. REMOVE AIR CLEANER HOSE AND CAP WITH MAF METER (a) _ Disconnect the VSV for EVAP. (b) Disconnect the 2 air hoses trom air cleaner cap. {) Loosen the air cleaner hose clamp bolt {¢) Disconnect the mass air flow meter connecter. (e) Disconnect the 3 air cleaner cap clips. (Disconnect the air cleaner hose from the throttle body, and remove the air cleaner cap together with the air cleaner hose. REMOVE THROTTLE BODY Disconnect the throtle position sensor connector. Disconnect the 1AG valve connector. Disconnect the PCV hose from throttle body. 122-FE: Remove the 2 bolts and disconnect the No. 2 water by— pass pipe. Disconnect the 2 water bypass hoses.SF-37 SFL 2HRONILE BoD¥ (f) Remove the 2 bolts, 2 nuts and throttle body from the in take manifold, (g} Remove the throttle body gasket.SF-38 SFI _TNROTTLE spy 222-GE: Lever 122-FE: Throttle Stop Screw INSPECTION minal, 1. INSPECT THROTTLE VALVE Check that there is no clearance between the throttle stop sorew and throttle lever when the closed throttle position. 2. INSPECT THROTTLE POSITION SENSOR Using an ohmmeter, measure he resistance between each ter- Clearance botwesn lever acc tee ermoes teminals Resistance Grmioiny | vate ben Tivo vave tay pen VIA Fe 20- 10240 - Von? 25- 88HSF-39 SFI_-_ THROTTLE BODY. INSTALLATION 1, _ INSTALL THROTTLE BODY (a) 1ZZ-FE: Install a new gasket on the intake manifold, as shown in the illustration. (b} 222-GE: Install a new gasket on the intake manifold, as shown in the illustration (¢) Install the throttle body with the 2 bolts and 2 nuts. Torque: 1Z2-FE: 21 Nem (210 kgt-cm, 15 ftibf) 222-GE: 22 Nem (220 kgf.cm, 16 ttibf) > = [2ST LE | TY, 1 ‘Sy Y A) in 5 LAS Connect the 2 water bypass hoses to the throttle bady. 4ZZ-FE: Install the No. 2 water by-pass pipe with the 2 bolts. Connect the IAC valve connector. Connect the throttle position sensor connector, Connect ne PCV hose to throtile body. INSTALL AIR CLEANER HOSE AND CAP WITH MAF METER INSTALL NO. 2 CYLINDER HEAD COVER FILL RADIATOR WITH ENGINE COOLANTSF-40 8 7/6|s]4/312| Sf1_=_IDLEAIR CONTROL (AC) VALVE IDLE AIR CONTROL (IAC) VALVE ON-VEHICLE INSPECTION INSPECT IAC VALVE OPERATION (@) Initial conditions: Engine at normal operating temperature + Idle speed set correctly Transmission in neutral NG switch OFF (b) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18020 (c) After engine speed are kept at 900 — 1,200 rpm for 5 seconds, check iat they return to idle speed. #f the rpm operation is not as specified, check the IAC valve, wiring and ECM. {d) Remove the SST from the DLC. SST 09843-180203 ska SFL AIL CONTROL HAC) VARVE, COMPONENTS 1ZZ-FE: 7.8(71, 62 in. el) | ——S e eo eek aa /— VSV for EVAP Se Ait Cleaner Cap with Air Flow Matar and Aie Cleaner Hose Accelerator” Gable * 4 Gaskol —- HAC Valve f° ‘Thattle Position Sensor Connector @ @ Connector gO Awa Waler By-pass Hose | :Spected torque 4. Non-reusabie pant oraFIDL AI CONTROL WAC) VALVE No. 2 Cylinder Haad Cover Air Cleaner Cap with Air Flow Meter and Ais Cleaner Hose: & ee c Air Flow Meter Connector ~ @ Gasket Pov Hose7 / Water By-pass Hose A Cab se | Throttle Position IAG Valve | _- Conner | S880" Connecter IAC Valve (216) Y [Nii fegrem, WBF] : Specified torque “@ Non-rousable partSF-43 SFL_=_IDUE AIR CONTROL AG) VALVE REMOVAL 1. REMOVE THROTTLE BODY (See page SF-36) 2. REMOVE IAC VALVE Romove the 4 screws, IAC valve and gasketS44 SF1_=_JDLE AIF GONTHOI, AG) VALVE INSPECTION INSPECT IAC VALVE OPERATION {a) Check that the IAC valve is half opened. {b) Connect the IAC valve connector to the IAC valve. (@} Disconnect the ECT sensor connector from the ECT sen- Sor, (@) Turn the ignition switeh ON. (@) _ Check that the IAC valve moves. HINT: Repeat connecting and disconnecting of IAC valve connector several times and check the operation of the valve. H operation is not as specified, replace the IAC valve. (Turn the ignition switch OFF, {@) Connect the ECT sensor connector to the ECT sensor. {h) Disconnect the IAC valve connector from the IAC vaive.BFL_= OLE AIR CONTROL AC) VALVE INSTALLATION Installation Is in reverse order of removal (See page SF-43). HINT: Install the IAC valve with a new gasket. SFa5SEI_._ CAMSHAFT TIMING OIL CONTAGE VALVE CAMSHAFT TIMING OIL CONTROL VALVE ON-VEHICLE INSPECTION INSPECT Oi. CONTROL VALVE RESISTANCE (a) Remove the No. 2 cylinder head cover. (bo) 222-GE: Disconnect the 2 PCV hoses. (@} Disconnect the oil control valve connector. (d) _ Using an ohmmeter, measure the resistance between the terminals. Resistance: 6.9 ~ 7.9 Q at 20°C (68°F) tthe resistance is nol as specified, replace the valve. (e) Reconnect the oi control vaive connector. () Reinstall the V-bank cover.SF-a7 cel = onset mungon conn ye COMPONENTS = wat: irancienm—e g— % 8 Oil Control Valve No.2 Cylinder Head CoverSEL_<_CAMSHATY TIMING O# CONTROL VALVE (ama UPPe" Front Fender Apron Seat No. 2 Cylinder Head Cover Uppor Radiator Support Seal ee Sot e Pov Hote Generator Bracket sic Generator O-Ring Y Sev tor ws A ooh aN »); Generator Wire Generator i Connector 0-ting $ Gasket 85 (7, 75 in-tbty YE Dy Ws fl - a OCV for VTL O ~ 85 (67, 78 insti) No.t Ventilation Pipe y [Rea (gin, Wb) |; Specitied torque @ Non-rellsable partSF~a9 F1_= CAMSHAFT TMG OL CONTROL WAVE REMOVAL ° 1. REMOVE NO. 2 CYLINDER HEAD COVER 2. 22Z-GE: DISCONNECT 2 PCV HOSES, UPPER FRONT FEND- ER APRONSEAL AND UPPER RAKIATOR SUPPORT SEAL 3. 222-GE: REMOVE GENERATOR (See page CH-7) 4. 222-GE: REMOVE NO. 1 VENTILATION PIPE (@) Remove the 2 nuts, bolt and gasket. HINT: At the time of installation, please refer to the fallowing items, Use anew gasket (b) _reomve the hose clamp and disconnect No.1 ventilation pipe. 5. 12Z-FE: REMOVE CAMSHAFT TIMING OIL CONTROL VALVE (a) Disconnect the oll control valve connector. {0} Remove the bolt and oil contro! valve. Torque: 7.5 Nem (80 kgt-cm, 66 in-Ibt) ()_ Remove the O-ring trom the oil contrat valve. HINT: Al the lime of installation, please refer to the following items, Use a new O-Fing. 6 222-GE: KO ~ A REMOVE 2 CAMSHAFT TIMING OIL CONTROL ( Ces VALVES bo G Res {a) Disconnect the oil control valve connecter. SQ. CAYCAPLA~~ | 0) Remove the 2 bolts and oil contral valves. 7 SY SMP fo Torque: 8.5 N-m (87 kgf-cm, 75 in.-Ibf) Se w/} S| (©) _ Remove the O-ring from the each ofl control vaive. we TALE HINT: EAA 8 {At the time of installation, please rater to the following items. Use a new O-ring.SF50 F1_=_ CAMSHAFT TAMING OM CONT AOL VALVE INSPECTION INSPECT CAMSHAFT Olt. CONTROL VALVE OPERATION Connect the positive (+) lead from the battery to terminal 1 and negative (-} lead to terminal 2, and check the movement of the valve. Battery positive volingeis appied | Vawemoves in fam tection Battery posiive votage's cutott | Valve movesia *1 A diecton It operation is not as specified, replace the valve.S51 SEL_—_ CAMSHAFT TIMING OH CONTROL VALVE INSTALLATION Installation Is in the reverse order of removal. (See page SF-49)SF52 SFL_—_FEIMAIN RELAY EFI MAIN RELAY INSPECTION 1. REMOVE EFt MAIN RELAY (Marking: EFI) 2. INSPECT EFI MAIN RELAY CONTINUITY (a) Using an chmmeter, check that there is continuity between torminals 1 and 2. I there is no continuity, replace the relay. (b) Cheok that there is no continuity between terminals 3 and 5. If thore is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION (a) Apply battery voltage across terminals 1 and 2. (©) Using an ohmmeter, check that there is continuity between terminals 3 and 5. I there is no continuity, replace the retay. 4, REINSTALL EFI MAIN RELAYSontinuity. S53 SPI_-_ CIRCUIT OPENING RELAY. CIRCUIT OPENING RELAY INSPECTION 1. REMOVE CIRCUIT OPENING RELAY 2, INSPECT CIRCUIT OPENING RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 1 and 2. le there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 3 and 5. {f there is continuity, replace the relay. 3. INSPECT CIRCUIT OPENING RELAY OPERATION (2) Apply battery voltage across terminals 1 and 2. {b) Using an chmmeter, check that there is continuity between terminals 3 and 8. If there is no continuity, replace the relay. 4, REINSTALL CIRCUIT OPENING RELAYSF-54 SEL_—_VSV FOR INTAKE AA CONTHOL VALVE, VSV FOR INTAKE AIR CONTROL VALVE COMPONENTS SV for EVAP Air Flow Meter Connector Upper Radiator ‘Support Seal‘Obnumoter Continuity SF-55 SF_=_VSY FOR INTAKE AIR. CONTROL VALVE INSPECTION INSPECT VSV (@) Inspect the VSV for open circuit. Using an ohmmeter, check that there is no continuity between the terminals. Resistance: 37 ~ 44 @ at 20°C (68°F) there is no continuity, replace the VSV. {b) Inspect the VSV for ground. Using an ohmmeter, check that there is no continuity between each terminal and the body. there is continuity, replace the VSV. () Inspect the VSV operation. {1} Check that air flows from ports E 10 G. (2) Apply battery positive vottage across the terminals. (3) Check that air flows from ports E to F if operation is not as specified, replace the VSV.SF-56 FI_=_YSV FOR EVAPORATIVE EMigs:On (EVAP) VSV FOR EVAPORATIVE EMISSION (EVAP) COMPONENTS Se VSV for EVAPOhmmeter (a oo inuity ‘Ohmmeter SEL_—_VSv FOR EVAPORATIVE e11SSION EVAP) INSPECTION 1. REMOVE VSV {a) Disconnect the 2 EVAP hoses from the VSV, (b) Disconnect the VSV connector. (©) Remove the bolt and VSV. 2, INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check thal there is continuity between the terminals. Resistance: 27 ~ 33 0 at 20°C (68°F) It there is no continuity, replace the VSV. 3. INSPECT VSV FOR GROUND Using an chmmeter, check that there is no continuity between each terminal and the body. I there is continuity, replace the VSV. 4. _ INSPECT VSV OPERATION (@) Check that air flows with difficulty from port E to port F. (&) Apply battery voltage across the terminats {c}_ Check that air flows from port E to port F. If operation is not as specified, replace the VSV. 5. REINSTALL VSV (a) install the VSV with the bolt (0) Connect the VSV with the bolt (c]_ Connect the 2 EVAP hoses to the VSV.SF-58 F1__VSV FOR CANISTER CLOSED VALVE iow) VSV FOR CANISTER CLOSED VALVE (CCV) COMPONENTS Air Cleaner Hose yer Closed Valve‘Okmmeter ia) 30] Continuity No Continuity ‘SF-59 SF1_—_vSy FOM GaNisTER CLOSED VALVE COVE INSPECTION 1. REMOVE VSV 2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, cheok that there is continuity between the terminals Resistance: ese reer if there is no continuity, replace the VSV. 3. INSPECT VSV FOR GROUND Using an ohmmeter, chack that there is no continuity between each terminal and the body. H there is no continuity, replace the VSV. 4, INSPECT VSV OPERATION fa) Check that air tlows from ports A to B. (b) Apply battery positive voltage across the terminals. (©) Check that air does not flow from ports A to B. operation is not as spocitied, replace the VSV. 5. REINSTALL VSV‘SF-60 F|_—_VSY FOR PRESSURE SWITCHING VALVE VSV FOR PRESSURE SWITCHING VALVE COMPONENTS Charcoal Canister Assembly ——--———~ oon ‘le VSV for Pressure Switching Valve Rear Floor Heat Insulator——--~ [82 (630, 48) y_@ Non-reusable part axr|SF-61 ‘SP1_=_YSV FOR PRESSURE SWITCHING VALVE INSPECTION 1. REMOVE VSV 2, INSPECT VSV FOR OPEN CIRCUIT No Continuity sore Onmmeter | 2 _ ral Using an ohmmeter, check that there is continuity between the Last terminals. OC) | Resistance: A120 6 (88 "F) wan Continuity At 120°C 248 F) ee a Continuity I there is no continuity, replace the VSV. 3. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. HW there is no continuity, replace the VSV. 4. INSPECT VSV OPERATION (a) Check that air does not flow from ports E to F. (b) Apply battery positive voltage across the terminals {e} Check that air ows trom ports E to F It operation is not as specified, replace the VSV. 5. REINSTALL VSVSF-62 |< _ ENGINE COOL ANT TEMPERATURE (EOL) SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR COMPONENTS (790762 ino} No.2 Cylinder Head Cover No. 2 Cylinder Head Caver Engine Coolant Temperature Sensor @ Non-reusable patRESISTANCE Ka ‘Ohmmeter [a] (00) “-pptpavaapengt, ‘TEMPERATURE "C (“F) SF-63 SF)_>_ ENGINE COOLANT JEMPERATURE (EC) SENSOR INSPECTION 1. DRAIN ENGINE COOLANT 2, REMOVE NO.2 CYLINDER HEAD COVER: 3. REMOVE ECT SENSOR 4. _ INSPECT ECT SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals 1 (E2) and 2 (THW). Resistance: Refer to the graph I the resistance is not as specified, replace the ECT sensor. 5. REINSTALL ECT SENSOR Install a new gasket to the ECT sensor. 6. REINSTALL NO.2 CYLINDER HEAD COVER 7. FILL RADIATOR WITH ENGINE COOLANTSF-64 Sf|_— VAPOR PRESSURE SENSOR VAPOR PRESSURE SENSOR COMPONENTS Rear Seat Cushion vooenew Floor Service Hole Cover [7 Vapor Pressure Sensor Joint Clip“a? Voltmater SF-65 S£l_-_ VAPOR PRESSURE SENSOR INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR {a) _ Disconnect the vapor pressure sensor connector. HINT: Near the fuel tank. (b) Turn the ignition switch ON. (c) Using a voltmeter, measure the voltage between connector terminals 1 and 3 of the wiring hamess side, Voltage: 4.5 ~ 5.5 V (a) Turn the ignition switch to LOCK. (e) Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR {a) Turn the ignition switch ON. (0) Remove the fuel tank cap. {) Connect @ voltmeter to terminals 2 and 3, and measure the output voltage. Voltage: 3.0- 3.6 V (4) Reinstal the fuel tank cap.SF-66 KNOCK SENSOR COMPONENTS ‘SE1_=_KNOGK SENSOR AZZ-GE: eo ¢ (ReMET}-» ; Log : © No, 2 Cylinder < | Head Cover Upper Front Fendor Apron Seal Upper Radiator ‘Support Seat © &e Sir Flow Meter Connector Radiator Reservoir Intake Manifold No. 2 Water By-pass Pipe‘SF-67 F_=_ KNOCK SENSOR 222-GE: Foi, ] No. 2 Cylinder Head Cover Upper Front Fender Apron Seal : Upper Radiator , pT ‘Support Seal ia ee fe A Radiator sh © Reservow Air Cleaner v Cap Air Cleanor ‘Air Cleaner Case Center Bracket (eames eH, Water By-pass Hose Thoottle Body (2680.35 ‘Accelerator Cable r Ll Bracket Cushion Gasket “ Harness Clamp ~ a \ Bot [AER RGF SAID: Spectes voraue vy #Non-rausable part vaneSF-68 S#1_-_KNOGK SENSOR INSPECTION 1, REMOVE THROTTLE BODY (See page SF-36) 2. REMOVE RADIATOR RESERVOIR (See page CO-17} 3. REMOVE INTAKE MANIFOLD (See page EM-42) 4, REMOVE KNOCK SENSOR (a) Disconnect the knock sensor connector. (b} Using SST, remove the knock sensor. SST 09816-30010 5, INSPECT KNOCK SENSOR Using an ohmmeter, check that there Is continuity between the terminal and body. Hf there is continuity, replace the sensor. 6, REINSTALL KNOCK SENSOR (a) _ Using SST, install the knock sensor. SST 09816-30010 (b) Connect the knock sensor connector. rows] 7. REINSTALL INTAKE MANIFOLD (See page EM-65) 8, REINSTALL RADIATOR RESERVOIR (See page CO-23) 9, REINSTALL THROTTLE BODY {See page SF-39)SF-69 SFi_~_ HEATED OXYGEN SENSOR HEATED OXYGEN SENSOR COMPONENTS “ (Gant Sogn Head Qxygensanser (Bank! Sensor2}sF70 SFI_—_MEATED OXYGEN SENSOR INSPECTION 1. INSPECT HEATER RESISTANCE OF HEATED OXY- GEN SENSOR (Bankt Sensor1) (a) Disconnect the oxygen sensor connector. (b) Using an ohmmeter, measure the resistance between the terminals +B and HT. Resistance: 11 ~ 16 ©2 at 20°C (68°F) a 7 If the resistance is not as specified, replace the sensor. ¥ tose Torque: 44 N-m (450 kgf-cm, 31 ftibf) (©) Reconnect the oxygen sensor connector. ORAASET] 2. INSPECT HEATER RESISTANCE OF HEATED OXY- Z de GEN SENSOR (Bank1, Sensor2) {a) Remove the passenger's seat. (b) Take out the floor carpet. (c) Disconnect the oxygen sensor connector. {d) Using an ohmmeter, measure the resistance between the terminats +B and HT. < Resistance: 11 ~ 16 <2 at 20°C (68°F) ow 7 teane]_ l the resistance is not as specifi, replace the sensor. Torque: 44 Nem (450 kgf-cm, 31 fbf) (e) Reconnect the oxygen sensor connector. {) Resistance the floor carpet. ig) Reinstall the passenger's seatSF7I SFi_: ENGINE CONTROL MODULE (ECM) ENGINE CONTROL MODULE (ECM) COMPONENTSSF-72 SFI ENGINE CONTROL MODULE ECM) INSPECTION 4. REMOVE ECM 2. INSPECT ECM (See page DI-20) 3, REINSTALL ECMSF-73 SFL. FUELoUTAPM, FUEL CUT RPM INSPECTION 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. CONNECT TOYOTA HAND-HELD TESTER OR OBD It SCAN TOOL {a) Connect the TOYOTA hand-held tester or OBD if scan tool to the DLC (b) Please refer to the TOYOTA hand-held tester or OBO It ‘scan tool operator’s manual for further details. 3, INSPECT FUEL CUT OFF RPM (a) _ Increase the engine speed to at least 3,500 rpm. (b) Use a sound scope to check for injector operating noise. () Check that when the thrattle lever is released injector, operation noise stops momentary and then resumes. HINT: Measure with the A/C OFF. Fuel return rpm: 1,400 rpm 4, DISCONNECT TOYOTA HAND-HELD TESTER OR OBD I SCAN TOOL= MENO ~ seCOOLING COOLANT WATER PUMP ‘THERMOSTAT RADIATOR ELECTRIC COOLING FAN .... COOLING FAN RELAY cot CO-a co-8 cone cO-24 costcont COOUING — COOLANT COOLANT INSPECTION HINT: Check the coolant fevel when the engine is cold. 4. CHECK ENGINE COOLANT LEVEL AT RESERVOIR ‘The engine coolant level should be between the "LOW" and "FULL" line. I low, check for leaks and add “Toyota Long Life Coolant” or equivalent up to the *FULL" line, 2, CHECK ENGINE COOLANT QUALITY (a) Remove the reservoir cap. CAUTION: ‘To avoid the danger of being burned, do not remove the reservolr the cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (®) There should not be any excessive deposits of rust or scale around the reservoir cap or reservoir filer hole, and the coolant should be free from oil It excessively dirty, replace the coolant. (c) Reinstall the reservoir cap.co-2 N Engine Drain Plug OOLING = _CODLANT REPLACEMENT HINT: For replacing the heater parts such a heater core or heater hase, refer to AC~29. 4, DRAIN ENGINE COOLANT (a) Remove the reservoir cap. CAUTION: ‘To avold the danger of being burned, donot remove the res ervoir cap while the engine and radiator are still hot, as. fluid and steam can be biown out under pressure. (b) Loosen the radiator drain plug (on the left under side of the radiator tank) and engine drain plug on the engine cootant drain union (on the left reat of the cylinder block}, and drain the coolant. (0) Close the drain plugs. Torque: 12.7 N-m (130 kgf-cm, 9 flbf) for engine 2. FILL ENGINE COOLANT {a) Remove the upper front fender apron seal and upper radiator support seal {) Remove the 2 bolts. {c)_ Disconnect the 3 clamps and 2 hoses, then place hoses on air cleaner case. (a) Lift the engine coolant reservoir and hook it on a hood tate to fix, {e) Remove the bieeder plug (Supply coolant of approx. 2.7 liters into the reserve tank until the fevel reaches FULL tine, + Use of improper coolants may damage engine coo! ing system. + Use "Toyota Long Life Coolant” or equivalent and mix it with plain water according to the manufac: lures directions. + Use of the coolant which includes more than 50% {freezing protection down to~35°C (-~31"F}] or 60% {freezing protection down to ~60°C (~58°F}] of eth- ylene-alycol is recommended, but not more than 70%,co-3 200LNG_-_ COOLANT NOTICE: + Do not use an alcoho! type coolant or plain water alone. + The coolant should be mixed with plain water (profer- ably demineralized waler or distilled water). Capacity: 1ZZFE: Mer 57 iners (60 US qs, 5.0Imp. a's) a SBmors (5.8 US as, 48m. ath 22Z-GE: Ma 5.9 ers (62 US qe 52mm. as) ME 5.8 mor (6.1 US ge, 6.1 imp. g's HINT: When the level can not be lowered before the supply of the 3.7 liters coolant, squeeze the radiator lower hose several times while blocking the hole in the bleeder plug with a finger, and surely supply the coolant. {g) Start the engine with the reservoir cap and the bleeder plug removed and warm it up until the cooling fan blows first and then stops. HINT: At this time, the A/C switch should be OFF. (h) Additionally supply 500 ce coolant with the engine idling. ()__Install the bleeder plug and reservoir cap. HINT: Close the reservoir cap by marking approx. 2.5 rotations until licks is heard. (Repeat 5 sec. engine operation at 3,000 rpm and 5 see. idling alternately for 15 min. or more. (k) Alter complete cooling of the engine, the level shall be between Low and FULL. HINT: After warming-up of engina, the level shall be over the FULL. (9) Connect the 2 hoses and clamps. {m} install the 2 botts. (n) _ Instali the cover. 3. CHECK FOR COOLANT LEAKS 4, CHECK ENGINE COOLANT SPECIFIC GRAVITY COR. RECTLYco COOLING. WATER PUMP WATER PUMP COMPONENTS ~ Upper Front Fende Drive Bet 222-GE: ‘Water Pump Puiloy cE 3 SEE (uae ‘ei 7 227-GE: Water Pump. Water Pum ‘ PIs ong = = ow Beit By 073.8) | ee A AH Engine Under Cover (i ia ATH) |: Speciied torque yo Non-6usabFe 5 ee sareCOOLING WATER PUMP. REMOVAL 1. REMOVE RH ENGINE UNDER COVER 2 DRAINENGINE COOLANT 3. REMOVE DRIVE BELT (See page CH-7) ; 4 EZ-FE: REMOVE WATER PUMP {a) Remove the 6 bolts, water pump and O-ring. {b) Clean up the engine coolant from the water chamber room. 5. 22Z-GE: REMOVE WATER PUMP {a) Using SST, remove the 4 water pump pulley set bolts. SST 09960-10010 (08962-01000, 08983-00600) (b) Remove the water pump pulley {c) Remove the 6 bolts, water pump and O-ring. (@) Clean up the engine coolant from the water chamber room, NOTICE: Do not remove the RH engine mounting bracket and generator when the water pump alone is replaced.co-6 COOLING WATER PUMP. INSPECTION INSPECT WATER PUMP (a) Visually check the drain hote for cootant leakage. It leakage is found, replace the water pump. (b) Turn the pulley, and check that the water pump bearing moves smoothly and quietly It necessary, replace the water pump.co-7 COOLING WATER PUMP INSTALLATION 1. 1ZZ-FE: INSTALL WATER PUMP (2) Place anew O-ring on the timing chain cover. {b) Install the water pump with the 6 bolts. Torque: Bolt A 9.0 Nem (92 kgt-cm, 80 in.bf) Bolt B 11 N.m (113 kgt.cm, 8 ttibf) HINT: Each bolt length is indicated in the itustration. A: 30 mm (1,18 in.) 1B: 35 mm (1.38 In.) 22Z-GE: INSTALL WATER PUMP (a) Place a new O-ring on the timing chain cover. (b) _ Install the water pump with the 6 bolts. Torque: 9.0 N.m (92 kgt-cm, 80 in.Ibt) HINT: Each bolt length is indicated in the ifustration, A: 30 mm (1.18 In.) 1B: 35 mm (1.38 in.) (©) Install he water pump pulley. {d) Using SST, tighten the 4 water pump pulley set bolts. SST 09960-10010 (09962-01000, 09963-00600) Torque: 15 Nem (153 kgf-om, 11 ftbf) 3. INSTALL AH ENGINE UNDER COVER 4. INSTALL DRIVE BELT (See page CH-17) 5. FILL WITH ENGINE COOLANT 6, START ENGINE AND CHECK FOR LEAKS 7, RECHECK ENGINE COOLANT LEVELco-8 COOLING. THERMOSTAT THERMOSTAT COMPONENTS = Upper Front Fender Apron Seal 122-FE: No, 2 Gylinder Head Cover Upper Radiator ‘Sypport Seal Generator Gonnecior Wire Clamp. © Gasket Water Inigt ff) |: Specified torqueSOQUING = _THEAWOS EAT REMOVAL HINT: Removal of the thermastat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if he engine tends to overheat. 1. DRAIN ENGINE COOLANT 2. REMOVE DRIVE BELT AND GENERATOR (See page CH~7) 3. REMOVE WATER INLET AND THERMOSTAT (a) Remove the 2 nuts, and disconnect the water inlet from the cylinder block. (b) Remove the thermostat {oc} Remove the gasket from the thermostat.co-10 G00LING —_ THERMOSTAT INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening tempera- ure. (a) immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Valve opening temperature: 80.0 ~ 84,0°C (176 - 183°F) lithe vaive opening temperature is not as specified, replace the thermostat. (©) Check the vaive lift, Valve lift: 10 mm (0.39 In.) or more at 80°C (194°F) If the valve lit is not as specitied, replace the thermostat. (d) Check that the valve is futly closed when the thermostat is at low temperatures (below 40°C (104°F}). not closed, replace the thermostat.con coouNG ._pirnwosrar INSTALLATION 1. PLACE THERMOSTAT IN CYLINDER BLOCK {a) _ Install a new gasket fo the thermostat. {b) Install the thermostat with the jiggle valve upward, HINT: ‘The jiggle valve may be set within 10” of either side of the prescribed position. 2. INSTALL WATER INLET Install the water inlet with the 2 nuts. ‘Torque: 10 Nem (100 kgf-om, 7 ftlbt) 3. INSTALL GENERATOR AND DRIVE BELT (See page CH-17) 4. FILL WITH ENGINE COOLANT 5. START ENGINE, AND CHECK FOR COOLANT LEAKSco-12 COOLING - RADIATOR, RADIATOR ON-VEHICLE CLEANING Using water or a steam cleaner, remove any mud or ditt from the radiator core. NOTICE: ifusing a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Main- tain a distance between the cleaner nozzle and radiator core.)ae! Reeervair Cap Radiator Cap Tester co-13 COOLING RADIATOR. ON-VEHICLE INSPECTION 1, REMOVE RESERVOIR CAP CAUTION: ‘Toavoid the danger of being burned, do not remove the reservoir cap while the engine and radiator are stil hot, as. fluid and steam can be blown out under pressure. 2. INSPECT RESERVOIR CAP NOTICE: + Ifthe reservoir cap has contaminations, always rinse it with water. + Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water. + When performing steps (a) and (b} below, keep the radiator cap tester at an angle of over 30° above the hor- izontai. (a) _ Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum valve. Pump speed: 1 pushi(3 seconds or more) NOTICE: Push the pump at a constant speed. Hairis not coming from the vacuum valve, replace the reservoir cap. (©) Pump the tester and measure the relief valve opening pressure. Pump speed: 1 push within 1 seconds NOTICE: ‘This pump speedis for the first pump only (In orderto close the vacuum valve). After this, the pump speed can be re- duced. ‘Standard opening pressure: 93 ~ 123 kPa (0.95 ~ 1.25 kgt/cm?, 13.5~ 17.8 psi) Minimum opening pressure: 79 kPa (0.8 kgficm?, 11.5 psi) HINT: Use the tester’s maximum reading as the opening pressure. Ifthe opening pressure is less than minimum, replace the reservoir ea.COOLING = RADIATOR 3, INSPECT COOLING SYSTEM FOR LEAKS (a) Fillthe radiator with coolant and attach a radiator cap tester. {b) Warm up the engine. (6) Pumpitto 118 kPa (1.2 kgticm?, 17.1 psi, and check that the pressure daes not drop. Ifthe pressure drops, check the hoses, radiator or water pump Radiator Cap Tester | for leaks. if no external teaks are found, check the heater core, ‘eewo| cylinder block and head. 4, REINSTALL RESERVOIR CAPco-15 COOLING —_naDiAtOR COMPONENTS Upper Front Fender Apron Seat Engine Coolant “ ¥ Gauise Control i, Actuator Hood Lock eE ° Upper Radiator Support Seal Upper Radiator VSV for EVAP Stppot SY for B MAE Sensor Cant race CH / Comecior } \ fated 222-GE: RH Engine Mounting Bracket oY Drive Bell Tensioner ; tentioncos —f o é i fo Igniten ~? a“ ey | Timing Chain?! Toner Ting Grab Cover S49 ‘*Crenkshalt 2 ‘i Front Git et i Crankshaft Pulley Crankshatt Position Sensor A oe a Pump me tr Pur Putey a eye \ J con Vibration \ JY. Damper \ cy ath Grankshalt Timing Sprocket Crank Angie Sensor Plate [Rim Gea NIT] : Speciten torque “@Non-reusablé pari Wite Harness Protector re eee yp Bxé Ho. 2ylinder ‘ Head Covet yo. Ventilation, Pipe Guide oP Oi Dipstick f O-RingLu-e LUBRICATION -__OlL PUMP. ge" SZ sine it Pump Body TS AZZ-FE 2 222-GE S Drive Rotor | riven Rotor Oil Pump Body Covertus LUBRICATION OWL PUMP ye REMOVAL IVEY af Sp ONY, © | 4.” DRAIN ENGINE ONL ON) 2. REMOVE TIMING CHAIN AND CRANKSHAFT TIMING y i SPROCKET (See pages EM-18) 3. REMOVE OL PUMP Remove the § boits, oil pump and gasket.L109 LUBRICATION. —__ Ok. PUNE DISASSEMBLY 1. REMOVE RELIEF VALVE Remove the plug, spring and relief valve. 2, REMOVE DRIVE AND DRIVEN ROTORS (a) 3Z2-FE: Remove the 3 screws, pump body cover, drive and driven rotors. (b) 222-GE Remove the 5 screws, pump body cover, drive and driven rotors,Luts LUBRICATION — oH PUNE, INSPECTION 1, INSPECT OIL JET Check the oil jet for damage or clogging. W necessary, replace the oil pump assembly. 2. INSPECT RELIEF VALVE ‘Coat the vaive with engine oi! and check that it falls smoothly into the vaive hole by its own weight Hit does not, replace the relief vaive. If necessary, replace the oll pump assembiy. 3. INSPECT ROTOR SIDE CLEARANCE Using a teeter gauge and precision straight edge, measure the clearance between the rotors and precision straight edge. Standard side clearance: 0.030 ~ 0.080 mm (0.0042 — 0.0031 in.) Maximum side clearance: 0.16 mm (0.0062 in.) Hf the side clearance is greater than maximum, replace the rotors as a sel. If necessary, replace the oil pump assembly. 4. INSPECT ROTOR TIP CLEARANCE Using a feefer gauge, measure the clearance between the drive and driven rotor tips. Standard tip clearance: 0.060 ~ 0.180 mm (0.0024 — 0.0071 in.) Maximum tip clearan 0.35 mm (0.0138 in.) ifthe tip clearance is greater than maximum, replace the rotors asa set. 5. INSPECT ROTOR BODY CLEARANCE, Using a feeler gauge, measure the clearance between the driven rotor and body. Standard body clearance: 0.125 - 0.180 mm (0.00492 - 0.00709 in.) Maximum body clearance: 0.326 mm (0.01280 in.) | the body clearance is greater than maximum, replace the rc sone) (018 aS a Set. If necessary, replace the ail pump assembly.Lute LUBRICATION, —__ OIL PUMP REASSEMBLY INSTALL DRIVE AND DRIVEN ROTORS a Place the drive and driven rotors into pump body with the ‘marks facing the pump body cover side. (b) 122-FE: Install the pump body cover with the 3 screws, Torque: 10.5 N-m (107 kgt-cm, 8 ft-lb) (c) 222-GE: install the pump body cover with the § screws, Torque: 10.5 N-m (107 kgf-cm, 8 ft-lb) 2, INSTALL RELIEF VALVE Insert the relief valve and spring into the pump body hole, and install the plug. Torque: 1ZZ-FE: 37 N-m (375 kaf-cm, 27 ft-lb) 2Z2-GE: 49 N-m (500 kgf-cm, 36 ft-lbt)Luts LUBRICATION on PUMP. @ (bo) () INSTALLATION INSTALL OI. PUMP Place a new gasket on the cylinder block. Engage the spline teeth of the oi! pump drive rotor with the large teeth of the crankshatt, and slide the oil pump. install the oif pump with the 5 boils. Torque: 9.0 N-m (92 kgf-em, 80 in-Ibf) INSTALL CRANKSHAFT TIMING SPROCKET AND TIMING CHAIN (See pages EM~25) FILL ENGINE WITH OIL START ENGINE AND CHECK FOR LEAKS RECHECK ENGINE OIL LEVELtua LUBRICATION = _ Qu. NOZZLE @77-CE) OIL NOZZLE (2ZZ-GE) COMPONENTS No.1 Compression Fis 2 | = # Connecting Rod Busting No. 2 Compression Rin “Of Ring ¢ ° 7 ide Bail) Connecting Rod Oi Ring (Expander) a> ! — Connecting Rod Bearing Piston. ———--| 4 Snap Ring —_—~< (Cylinder Block —— 00 nib] Upper Main Bearing Trust Washer Grankshatt Thrust Washer il Pan Battie Crankshatt-—&- sp fate ‘ [Soe page Eu-105, 15123 (228,16) 30 ate Jot Sah times a @—— 04 Fier Union “Sa + Gasket—___ seta “I A Bours + i sranar——-24 vA [08] I OP Le = @ GasketLuts LUBRICATION — Ol NOZZLE 222-085 REMOVAL 1. REMOVE CRANKSHAFT (See page EM-29) 2, REMOVE OIL NOZZLE (WITH RELIEF VALVE) Using a § mm hexagon wrench, remove the bolt and ail nozzle.L416 LUBRICATION. — OU NOZZLE 227-66 INSPECTION INSPECT RELIEF VALVE (OIL NOZZLE) Push the valve with a wooden stick to check if itis stuck. If stuck, replace the relief vaive,Luni7 LUBRICATION —_ OL NOZZLE ez7-aEy INSTALLATION 1. INSTALL OIL NOZZLE (WITH RELIEF VALVE) Using a 5 mm hexagon wrench, install the oil nozzle with the bolt, Torque: 9.0 Nm (92 kgt-cm, 80 in.-tbf) 2, INSTALL CRANKSHAFT (See page EM-106)— MEMO ~IGNITION IGNITION SYSTEM 02.2... - 1-41 IANITION COIL bese es CAMSHAFT POSITION SENSOR, ioe CRANKSHAFT POSITION SENSOR ....... 0 IG-11IGuiTiON —_IGNUTION SYSTEN, IGNITION SYSTEM ON-VEHICLE INSPECTION NOTICE: “Cold” and "Hot" in these sentences express the temperature of the coils themselves. "Cold" is from—10°C (14°F) to 50°C (122°F) and "Hot" is from 50°C (122°F) to 100°C (212°), 4, INSPECT IGNITION COIL (WITH IGNITER) AND. SPARK TEST Check that the spark occurs. (1) Remova the ignition coils (with igniter). (See page 1G-6} (2) Using a 16 mm (0.63 in.} plug wrench, remove the spark plugs. (3) _ Install the spark plugs to each ignition coils (with ig- nites), and connect the ignition coit connectors. (4) Disconnect the 4 injactor connectors. (5) Ground the spark plugs. (6) Check if spark occurs while engine is being cranked. NOTICE: cE To prevent gasoline from being injected trom injectors during this test, crank the engine for no more than 5 ~ 10 seconds at time.i IGNITION _—_sGuiTion svSTEM, Ifthe spark does not occur, do the test as follows: [SPARK TEST TNO. [CHECK CONNECTION OF IGNITION COIL CONNECTOR |——~| Connect securely. BAD {oK EHANGE I TO NORMAL IGNITION COIL (WITH IGNITER) AND PERFORM SPARK TEST AGAIN ‘Ropiaes the ignition con (with ignitor) NO. GHECK POWER SUPPLY TO IGNITION COIL (WITH “Ghack wing betwoon ignition switch IGNITER) ‘oignition coll with ignite). {Turn ignon switch to ON. exo 2, Check that hore s batery voltage atignticn oot positive (4) termina TOK GHECK RESISTANCE OF CAMSHAFT POSITION Haplacs the camshati postion sensor SENSOR (See step 3) Cold Hot BAD Resistance: 835~1,4000 1,060 ~ 1,645 0 OK CHECK RESISTANCE OF CRANKSHAFT POSITION Fopiace the erankshalt position sensor. SENSOR (See stop 4) Cold Hot BAD Resistance: 1,630-2,74042 2,085 ~ 3,225.0 OK (SHECK IGT SIGNAL FROM ECU Check wing beween ECU and (See page DI-114) SAG “| Go with gtr) an thon ty another BCU. Tox (a) (b) V6 (0.63 in.) -j Plug Wench [FRY ANOTHER IGNITION COIL (WITH IGNITER) (7) Using a 16 mm (0.63 in.) plug wrench, instal! the spark plugs, Torque: 18 N-m (184 kgf-om, 13 ftbf) (8) _ Instali the ignition coils (with igniter). (See page IG-7) INSPECT SPARK PLUGS Remove the ignition coils (with igniter). (See page IG-6} Using @ 16 mm (0.63 in.) plug wrench, remove the spark plugs.Ie-3 IGNITION —_iGwrion svsrext (0) Clean the spark plugs. Inthe electrode has traces of wet carbon, allowit to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgficm?, 85 psi) Duration: 20 seconds or less HINT: lethere are traces of cil, remove it with gasoline before using the spark plug cleaner (d) Check the spark piug for thread damage and insulator damage Jf abnormal, replace the spark plug. Recommended spark plug: 122-FE: BERSO mas seioni NG mao {FaSANL 222~GE: see TENSO mace! Seana BGK made {FAGAN Lag v (©) Adjust electrode gap. AA Ly Carefully bend the outer electrode to obtain the correct, l electrode gap. Electrode gap: 1.1 mm (0.043 in.) Ll (Using a 16 mm (0.63 in.) plug wrench, install the spark te plugs. L t Torque: 18 N-m (184 kgf-cm, 13 ftibf) ¢ j (@) Install the ignition coils (with igniter) ON ene (See page IG-7)IGNITION IGNITION gysTExt 3. INSPECT CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (©) Using an chmmeter, measure the resistance between ter- mminals. Resistance: oid a58— 14008 Het 1.080 —1.545.0 ithe resistance is not as specified, replace the camshaft position sensor. () Connect the camshaft position sensor connector,GON —_sNITON SOM, IGNITION COIL COMPONENTS ies 222-GE: No. 2 Cylinder Head Cover 122-FE: No. 2 Cylinder Head Cover ® wire Hamess Protector (SOUR Few} —y x4 sa ~ lion Coit wit ignitor)JoNMON IGNITION COR, REMOVAL 2 (a) (b) (©) REMOVE NO. 2 CYLINDER HEAD COVER REMOVE IGNITION COILS (WITH IGNITER) FROM SPARK PLUGS. Remove the 2 bolts and disconnect the wire hamess protector. Disconnect the 4 ignition coil connectors. Remove the 4 bolts and pull out the 4 ignition coils (with igniter) Torque: 9.0 N-m (92 kgf-om, 79 in.-lbf)SGNMION ._IGWTIONCOK, INSTALLATION installation is in the reverse order of removal (See page IG-6).o8 IGNITION —_GAMSHAFT POSITION SENEON. CAMSHAFT POSITION SENSOR COMPONENTS AZZFE: No.2 Cylinder Head Cover GE: No. 2 Cylinder Head Cover (ai60.78m-159 | |e ———— 222-GE: Camshatt Position Sensor 7” 12Z-FE: . ‘Camshaft Position Sensor ib S807 “ii : Speciied torqueIGNITION. GAMSHAE; POSITION SENSOR, REMOVAL 1, REMOVE NO. 2 CYLINDER HEAD COVER 2 122-FE: REMOVE CAMSHAFT POSITION SENSOR fa) Disconnect the connector. {b) Remove the bolt and camshaft pasition sensor. Torque: 8.8 N.m (90 kgf-cm, 78 in-tbf} 3. 222-GE: REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the connector. (6) Remove the 2 bolts and camshatt position sensor. ‘Torque: 8.8 N-m (90 kgf-cm, 78 in..Ibf)16-10 IGNITION = _ CAMSHAFT POSITION SENSOR. INSTALLATION Installation Is in the reverse order of removal (See page IG-9).Io-t IGNMION CRANKSHAFT POsTION SENSOR CRANKSHAFT POSITION SENSOR COMPONENTS 122-FE} No. 2 Cylinder Head Cover yg for EVAP. Upper Front Fender Apron Seat Connector ad. LS Air Cleanes ' # Gasket Intake Manitord eh Wire Harness Brackel x Tete Position Sensor ? ‘onnector 4 Air Cleaner Case Throttle Body JAC Valve Connector Crankshaft Position Sensor [Win Tan, bi - spoctios torque py @Non-réusable partIa-12 IGNITION -_CRANKSHAET POSTION SENSOR 222-GE: Upper Front Fender Apron Seal No. 2 Cylinder Head Cover yg for EVAP & MAF Sensor Connector bn) Air Cleanar Cap. Air Filter Oil Dipstick and Oil Guide| Intake Manifold Generator Frrottle Pasition Sensor Bracket pret 8 Engine Wire . 2 Sa Thiottle Body JAC Z Connector [Ba%66, 70m.) }—e Crankshaft Position Sensor "] : Speeiied torque16-13 IGNITION. -_CRANSHAKE POSTION SENSOR REMOVAL 1. REMOVE INTAKE MANIFOLD (See page EM-42) 2, REMOVE ENGINE UNDER COVER RH 3, REMOVE CRANKSHAFT POSITION SENSOR (@) Disconnect the crarkshafi position sensor connector. (b) Remove the 2 bolt and crankshaft position sensor. Torque: 8.8 N-m (90 kgf-cm, 78 In.-tbf)Iota Ohmmeter IGNITION = CRANKSHAFT POSITION SENSOR. INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensor itself, "Cold" is trom—10°C (14°F) to.50°C (12°F) and "Hot" is from 50°C (122"F) to 100°C (212°F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold: 1,630 ~ 2,740 2 Hot: 2,065 3,225 0 ifthe resistance is not as specitied, replace the crankshaft posi: tion sensor.Ia15 IGNMON CRANKSHAFT POSITION SENSOR, INSTALLATION = Installation is in the reverse order of removal (See page !G-13).MEMO —STARTING STARTING SYSTEM see STH STARTER ooo. ecesereeeoe She STARTER RELAY sieeeeeeee starSTARING —_ STARTING sysrEM STARTING SYSTEM ON-VEHICLE INSPECTION NOTICE: Before changing the starter, check these items again: + Connector connection Accessory installation, e.g.:theft deterrent system stST-2 STARTER COMPONENTS STARTING —_SIARIER VSV for EVAP— Air Cleaner Cap-— 35} wk SSH UE Starter “Sy — Starter Wire ‘ir Flow Meter Connector —— LH Engine Under Coverst-3 STARTING — STARTER 222-GE: ¢ Front Bearing End Cover | Oe Brush Holder itd Frame . | & Armature 6 Front Boaring # Rear Bearing . ‘Through Bolt —T sieet Ban Idier Gear Steet Bal Bearing (070, 1) ¥ Terminal Nut . ~ Wave Washer &, RNa Ferminat pee & Terminal Boir ay 1 Terminal G it Part ‘Terminal insulator—-—<> Terminal nsulotor— a) | Wave Washer | O-Ring Tosminl Nui paging | —~# tamil 0 Kt Pon [Nm ikorom, felt} |; Specified torquesT-4 mi J i i= Ts LAL 7 E B Se My vy STARTING — STARTER REMOVAL 2 3. (a) (b) cc REMOVE UPPER RADIATOR SUPPORT SEAL REMOVE AIR CLEANER ASSEMBLY (See page EM~74) REMOVE RH AND iH ENGINE UNDER COVER: REMOVE STARTER Disconnect the starter connector. Remove the nut, and disconnect the starter wire, Remove the 2 bolts and starter.ST-5 SqanVING —_ StanTeH DISASSEMBLY REMOVE FIELD FRAME WITH ARMATURE FROM MAGNETIC SWITCH ASSEMBLY (a) Remove the nut, and disconnect the lead wire from the magnetic switch terminal. (b) Remove the 2 through bolts. (©) Remove the 2 screws and end cover from the fied frame, {9} Remove the O-ring from the field frame, (e) Using a screwdriver, hold the spring tank back and disconnect the brush from the brush holder. Disconnect the 4 brushes and remove the brush holder. (f) Pullout the fieié frame from the magnetic switch assembly. (@) Remove the O-ring,ST 7 STARTING ._StARTED. 2 fa) tb) 3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEARS Remove the 2 bolts. Torque: 5.9 Nm (60 kgt-cm, 82 InIbf) Remove these parts from the magnetic switch assembly: (1) Starter housing (2) Wier gear (3) Bearing (4) Clutch assembly (8) Return spring REMOVE STEEL BALL Using a magnetic finger, remove the steel ball from the clutch shaft hole, 4, REMOVE ARMATURE FROM MAGNETIC SWITCH AS- SEMBLY (a) 122-FE Remove the armature from the magnetic switch assem- by. (be) 222-GE: Using @ press, remove the armature from the magnetic switch assembly.Continuity No Continuity st-7 STARING —_ srantEs INSPECTION 1, INSPECT ARMATURE COIL COMMUTATOR FOR OPEN CIRCUIT Using an chmmeter, check that there is continuity between the segments of he commutator. W there is no continuity between any segment, replace the armature. 2, INSPECT ARMATURE COIL COMMUTATOR FOR GROUND Using an ohmmeter, chack that there is no continuity between the commutator and armature cal core. It there is continuity. replace the armature. 3. INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACES {T the surface is dirty or burnt, correct with sandpaper (No.400) oralaihe. 4, INSPECT COMMUTATOR CIRCLE RUNOUT (@) Place tho commutator on V-blacks, (b) Using a dial gauge, measure the cicie uncut Maximum circle runout: & 0.05 mm (0.0020 in.) tthe cicle runout is geeater than maximum, correct ton a lathe, 5. INSPECT COMMUTATOR DIAMETER Using vernier calipers,measure the commutator diameter. Standard diameter: 30 mm (1,18 in.) Minimum diameter: 29 mm (1.14 in.) It the diameter is tess than minimum, raplace the armature, 6. INSPECT COMMUTATOR UNDERCUT DEPTH Check that the undercut depth is clean and free of foreign mate- rials. Smooth out the edge ‘Standard undercut depth: 0.6 mm (0.024 in.) Minimum undercut depth: 0.2 mm (0.008 in.) le the undercut depth 's fess than minimum, correct it with a hacksaw blade,sts Ohmmneter if Continuity STARTING ~_ STABTES 7. INSPECT FIELD FRAME (FIELD COIL) FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the lead ware and fold coit brush lead. there is no continuity, replace the field frame. 8. INSPECT FIELD FRAME (FIELD COIL) GROUND Using an ohmmeter, check that there is: no continuity between the field coil end and field frame. If the is continuity, repair or replace the field frame, 9. INSPECT BRUSH LENGTH Using vernier calipers, measure the brush length. Standard length: 45,5 mm (0.610 in.) Minimum length: 10.0 mm (0.394 in.) Ifthe length is less than minimum, replace the brush holder ané fied frame. 10. INSPECT BRUSH SPRING LOAD ‘Take tho pull scale reading the instant the brush spring sepa- rates from the brush. 14 KW type Standard spring Installed toad: 17.6 23.5 N (1.80 ~ 2.40 kgf, 4.0 ~ 5.3 Ibf) Minimum spring installed load: 11.8 N (1.20 kgf, 2.6 Ibf) 1.2 kW type ‘Standard spring installed load: 13.7 ~ 19.6 N (1.40 ~ 2.0 kgf, 3.1 — 4.6 Ibf) Minimum spring installed load: 8.8 N (0.9 kgf, 2.0 Ibt) {1 the installed load is not within specification, replace the brush springs.No Continuity mes ‘Ohmameter ‘Ohmmator ‘Switch Body xa sT-9 STARTING ~ STARTER 11. INSPECT BRUSH HOLDER INSULATION Using an chmmeter, check that there is no continuity between {he positive (+) and negative (-) drush holders. If there is continuity, repair or replace the brush holder, 12, INSPECT GEAR TEETH Check the gear teeth on the pinion gear, idler gear and clutch assembly for wear or damage. if damaged, replace the gear or clutch assembly. Ht damaged, also check the drive plate ring gear for wear oF damage. 13. INSPECT CLUTCH Rotate the clutch pinion gear clockwise, and check that it turns freely. Try to rotate the clutch pinion gear counterclockwise and check that t locks. itnecessary, replace the clutch assembly 14, DO MAGNETIC SWITCH PULL-IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminals 50 and C. there is no continuity, check and replace the magnetic switch. 18, DO MAGNETIC SWITCH HOLD-IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminal 60 and the switch body. Ht there is no continuity, replace the magnetic switch.sT-10 STARTING. STARTER REPLACEMENT 1, INSPECT BEARING Turn the bearing by hand while applying inward force. It resistance is felt or if the sticks, replace the bearing, 2. REPLACE BEARINGS {a} _ Using SST, remove the bearing SST 09286-46017 {b) Using SST and a press, press in a now front bearing SST 09820-00030 (e) Using a press, press in a new rear bearing 3. REMOVE MAGNETIC SWITCH END COVER (@) Remove the 3 bolts, end cover, gasket and plunger. (b) Inspect the contact plate for wear. Using vernier calipers, measure the contact piate tor depth of wear. Maximum wear: 0.9 mm (0.035 In.) tthe depth of wear is greater then the maximum, replace the contact plate. (6) Remove the terminal kit parts ()_ Using SST, loosen the terminal nuts. SST 09810-38140 2) Terminal c: Remove the terminal nul,wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate and terminat insulator (jasi¢e).st STARTING ._ STARTER, {3} Terminal 30: Remove the terminal nut, wave washer, terminal in sulator (outside), packing, O-ring, terminal bolt, contact plate, and terminal insulator (inside). (3) Temporarily install a new terminal 30 Kil parts. (1) Install a terminal insulator (inside) NOTICE: Be careful to install the terminal insulator in the correct, direction. 42) Insiall a contact plate. {8) Install a terminal bott. (4) Install a O-ring. (©) Install a packing and terminal insulator (outside). Insiall the packing to the terminal insulator, and install them. HINT: Match the prottusion of the insulator wilh the indentation of the housing. (6) install a wave washer. (2) install a terminal nut. {e) Temporatily install new terminal C kit parts. (1) Instalt a terminal insuiator (inside). (2) Install a contact plate. (3) Instalt a terminal bolt, (4) Install a O-ring, (5) _ Install a terminal insulator (outside). (6) install a wave washer. 47) install a terminal nut. NOTICE: Be careful to install the terminal insulator (inside) in the correct direction. (Temporarily tighten the terminal nuts.sT-12 , Wocden Block STARTING — STARTER (g) Tighten terminal nut. (1) Put a wooden block on the contact plate and pross it down with a hand press, Dimensions of wooden block: 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.) Press force: 981 N (100 kgf, 221 Ibf) NOTICE: Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 Ibf) of force Is applied. Gauge pressur 100 kgt (kgticm?) = ¢ Ram diameter (6m)\’ 9.4/2) 2 224 it tos) = (am alameter im) 9.14 (n) tka) = (kgtiom?) x 98.1 tkpa) = (psi) x6.9 If the contact plate is not pressed down with the specified pressure, the contact plate may ti due to coll deformation or the tightening of the nut (2) Using SST, tighten the nuts to the specified torque. SST 09810-38140 Torque: 17 Nem (173 kgf.cm, 12 fbf) NOTICE: It the nut Is over tightened, it may cause cracks on the inside of the insulator. (®) Clean contact surfaces of contact plate and plunger Clean the contact surtaces of the remaining contact plate and plunger with a dry shop rag (Reinstall magnetic switch end cover. Install he plunger, new gasket, end cover with the 3 bolts. Torque: 2.5 N-m (26 kgt-cm, 23 in.bf)sT-13 STARTING —_ STARTER REASSEMBLY HINT: Use high-temperature grease to lubricate the bearings and gears when assembling the starter, 1. fa) (by (e) (a (a) (b) fa) @) INSTALL ARMATURE TO MAGNETIC SWITCH AS- SEMBLY 222-GE: Rotating the ring of the front bearing, set it properly so that the projection of the ring is positioned in the narrowest part. Apply grease to the armature bearings. 12Z-FE: Install tho armature to the magnetic switch assembly. 222-GE Using a press, install the armature to the magnetic switch assembly. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE Apply grease to the steel ball. Insert the steel ball into the clutch shaft hole. INSTALL STARTER HOUSING, CLUTCH ASSEMBLY AND GEARS Apply grease to the return spring Insert the retum spring into the magnetic switch hole,sT-14 STARTING STARTER {) Place these parts on the starter housing: (1) New O-ring (2) Starter cluten assembly (3) Idler gear (@) Bearing Install the starter housing to the magnetic switch with the 2 screws. Torque: 9.3 N.-m (95 kgf-cm, 82 in.-tbf) 4, INSTALL FIELD FRAME (a) _ Install a new O-ring to the groove of the filed frame. (b) Align the protrusion of the field frame with the groove ot the magnetic switch, and install the field frame. 5. INSTALL BRUSH HOLDER (a) Place the brush holder on the fieid frame. (b) Using a screwdriver, hold the brush spring back, and connect the brush into the brush holder. Connect the 4 brushes. NOTICE: ‘Check that the positive (+) lead wires are not grounded. 6. INSTALL END COVER (@) Install a new O-ring to the groove of the field frame. (b) Install the end cover to the field frame with the 2 screws. Torque: 3.8 Nem (39 kgf-cm, 34 in-Ibf) (c) Install te field frame and armature assembly with the 2 through bolts, Torque: 9.3 Nem (95 kgf-om, 82 in-Ibf) (d) Connect the lead wire to terminal C with the nut Torque: 5.9 N-m (60 kgf-cm, 52 in-Ibf) 7. INSTALL NEW DUST PROTECTORTerminal © Disconnect Terminat 3 sT15 STARTING STARTER, TEST NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coll. 1. DO PULL-IN TEST {a) Disconnect the field coil lead wire trom termina C. (b) Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward, Ifthe clutch pinion gear does not move. 2, DOHOLD-IN TEST With battery connected as above with the clutch pinion gear ut, disconnect the negative (-) lead from terminal C. Ifthe clutch pinion gear returns inward. 3. INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative (-) iead from the switch body. Check that the cfutch pinion gear returns inward, IW the clutch pinion gear does nat return. 4, DO NO-LOAD PERFORMANCE TEST (a) Connect the battery and ammeter to the starter as shown. (©) Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the ammeter shows the specified current Specified current: 90 A or less at 11.5 VST-16 STARTING STARTER INSTALLATION 1. INSTALL STARTER {a) _ Install the 2 bolts and starter. HINT: Each bolt length is indicated in the illustration, Boll length A64 mm (2.72 in.) B54 mm (2.12 in) () Connect the starter wire, and install the nut. (©) Connect the siarter connector. 2, INSTALL RH AND LH ENGINE UNDER COVER 3. _ INSTALL AIR CLEANER ASSEMBLY 4. INSTALL UPPER RADIATOR SUPPORT SEALOhmmoter ram star STARTING — STARTER RELAY STARTER RELAY INSPECTION 1. REMOVE STARTER RELAY 2. INSPECT STARTER RELAY CONTINUITY (@) Using an ohmmeter, check thal there is continuity between terminals 1 and 2, there is no continuity, replace the relay. {b) Chock that there is ao continuily between termina's 3 and 5 I there is continuity, replace the relay. 3. INSPECT STARTER RELAY OPERATION (a) Apply battery positive voltage across terminals 1 and 2. (b) Using an ohmmeter, check tiat there is continuity between terminals 3 and 5 Ii there is continuity, ceplace the relay. 4, REINSTALL STARTER RELAY~ MEMO ~CHARGING CHARGING SYSTEM GENERATOR oH CHSCHARGING CHARGING SYSTEM cs CHARGING SYSTEM PRECAUTION ‘Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running.CHARGING GHARGHES SYSTEM ON-VEHICLE INSPECTION 1. CHECK BATTERY ELECTROLYTE LEVEL Check the efectroiyte quantity of each cell Maintenance-Free Battery: under the lower level, replace the battery (or add distiled wae ter if possible} and check the charging system. Except Maintenance-Free Battery: funder the lower level, add distiied water. 2. Except Maintenance-Free Battery: CHECK BATTERY SPECIFIC GRAVITY Check the specific gravity of each cot, ‘Standard specific gravity: 4.25 - 4.29 at 20°C (68 “F) Ir the specific gravity is tess than specification, charge the battery. CHECK BATTERY VOLTAGE After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and tum on the electrical system (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. Turn the ignition switch OFF and tum off the electrical systems. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery. Standard voltage: 12.5 - 12.9 V at 20°C (68°F) II the voltage is less than specification, charge the battery. HINT: Check the indicator as shown in illustration, 4, CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES Blue white Red (a) Check that the baitery terminals are not loose er cor PROD FX roves ww LO Oy (b} Check the fusible link, H-fuses and fuses for continuity. OK Charging insutficient Necessary Waterchs CHARGING — cuangnis sysrew 5. INSPECT DRIVE BELT (2) Visually check the boll for excessive wear, frayed cords N atc. ae — it any detect has been found, replace the drive belt HINT: ~ + Cracks on the rib side of a belt are considered acceptable. 4 the bett as chunks missing from the ribs, it should be replaced + The drive belt tension can be released by turning the belt tensioner ciockwise. (©) Check the belt tensioner operation + Check that belt tensioner moves downward when the drive belt is pressed down at the points indicated in the illustration with approx. 98 N (10 kgt, 22.0 If) of force + Check the atighment of the belt tensioner pulley to make sure the drive belt will not slip off the pulley. Itnecessary, replace the belt tensioner. HINT: + After installing @ bell, check that it fits properly in the ribbed grooves. + Check with your hand to confirm that the belt has not dasaaan! Lannaals slipped out of the groove on the bottom of the pulley. + Afierinstatling a new bells, run the engine for about § min- GORREGY WRONG WRONG utes and check the bott tension existing 6. VISUALLY CHECK GENERATOR WIRING AND LIS- oon TEN FOR ABNORMAL NOISES (2) Check that the wiring Is in good condition. (©) Check that there is no abnormal naise from the generator while the engine is running, INSPECT DISCHARGE WARNING LIGHT CIRCUIT (@) Turn the ignition switch "ON". Check that the discharge warning fight comes on. (o) Start the engine. Check that the light goes olf. Ifthe light does not operate as specified, troubleshoot the dis- ‘charge warning light circuit,CHARGING Disconnect Wiro from Terminal & Generator [vat CuAnons sys ret 8 _ INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: {1 a balteryigenerator tester is available, connect the tester to the charging circuit as permanufacturer’s instructions. fa) If a tester is not available, connect a voltmeter to the charging citeuit as follows: + Disconnect to the wire from terminal B of the generator and connect it to the negative (-) lead of the ammeter. + Connect the positive (+) fead of the ammeter to ter- minai B of the generator. + Connect the positive (+) lead of the voltmeter to terminal B of the generator. + Ground the negative (-) lead of the voltmeter, (©) Check the charging circuit as follows: With the engine running fram idle to 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: 10A or less Standard voltage: 13.2 ~ 14.8 V the voltmeter reading is more than standard voltage, replace the votage regulator. {tthe voltmeter reading is less than the standard voltage, check the voltage regulator and generater as follows: + With terminal F grounded, start the engine and ‘check the voltmeter reading of terminal B. + Ifthe voltmeter reading is more than standard volt ‘age, replace the voltage regulator. + Ifthe voltmeter reading is less than standard voltage, check the generator. 9. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater biower switch at oH (b) Check the reading on the ammeter. Standard amperage: 30 A or more the ammeter reading is less than standard amperage, repair the generator. HINT: If the battery is fully charged, the indication will sometimes be less than standard amperage.CHARGING GENERATOR COMPONENTS 2_ GENERATOR Ces Upper Front Fender Apron Seal > TZE-FE 5a (540, ay (eae wil Be L LE + (Nn fhatem, fbi): Species torque 222-GE: Generator Bracket Genorater 80: 2 Cylinder Head CoverCHARGING GENERATOR Generator Washer @ Rear Bearing | Bearing Cover Bearing Cover Brush Hoider Cover ~~~. Plate Terminal End Frame oT Insulator “So “e Rectier Bush Holder axe of Wire Clip Voltage Reguiator i “Torminal Insulator Reat End Gaver [Nm (hatin, fH |: Specitied torque T# Noi reusable pan sunscH? CHARGING GENEAKION REMOVAL 1, REMOVE DRIVE BELT Turn the drive belt tensioner slowly clockwise and loosen tt Then, remove the drive belt and replace the drive belt tensioner file by litle and fix it quietly REMOVE GENERATOR Disconnect the wire clamp trom the wire clip on the cect: ‘or and irame. Romove the rubber cap and nut, and disconnect ihe gon erator vire. Disconnect the generator connector. 227-GE Femove the 2 bolts and generator bracket Remove the 2 bolts and generator.cH8 waRGING — GENERATOR DISASSEMBLY 1 fa) (b) @) tb) fe) fa) ©) @ (o) (co) (a) REMOVE REAR END COVER Remove the nut and terminal insulator. Remove the bolt, 3 nuts, plate terminal and end cover. REMOVE BRUSH HOLDER AND VOLTAGE REGULA- TOR Remove the brush holder cover from the brush holder. Remove the 5 scrows, brush hoider and voltage regulator. Remove the seal plate from the rectifier end frame. REMOVE RECTIFIER HOLDER Remove the 4 screws and rectifier holder. Remove the 4 rubber insulators. REMOVE PULLEY Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820-63010 Torque: 39 N-m (400 kgf-cm, 29 ftlbf) ‘Check that SST (A) is secured to the rotor shaft. Mount SST {C) in a vise, Insert SST (B} into SST (C), and attach the pulley nut to SST (6).CH-9 CHARGING —_ GENERATOR (e) To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the: pulley nut more than one-half of a turn. (Remove the generator from SST (C) (9) Turn SST (B), and remove SST (A and B). {h) Remove the pulley nut and pulley. 5. REMOVE RECTIFIER END FRAME (a) Remove the 4 nuts and wire clip. {b) Using SST, remove the ‘eciifies end frame. SST 09286-46011 {c) Remove the generator washer from the rotor 6. REMOVE ROTOR FROM DRIVE END FRAMEcH-10 CHARGING SENERATOR INSPECTION 1. _ INSPECT ROTOR FOR OPEN GIRCUIT Using an ochmmeter, check that there is continuity between the slip rings Standard resistance: MT 2.7 ~ 3.1 & at 20°C (68°F) AT 2.1 ~2.5 at 20°C (68°F) there is no continuity, replace the rotor. 2. INSPECT ROTOR FOR GROUND Using an ohmmeter, check that there is no continuity between the slip ring and rotor, It there is continuity, repiace the rotor. 3. INSPECT SLIP RINGS (@) Check that the slip rings are not rough or scored. {rough or scored, replace the rotor. (©) Using a vernier caliper, measure the slip ring diameter. Standard diameter: 14.2 — 14.4 mm (0.559 — 0.567 in.) Minimum diameter: 12.8 mm {0.504 In.) euen] it the dlameter is less than minimum, replace the rotor. 4, INSPECT STATOR (DRIVE END FRAME) FOR OPEN cIRCUIT Using an ohmmoter, check that there is continuity between the coil leads. H there is no continuity, replace the drive enc frame assembly Ohnmeiar | 5. INSPECT STATOR (DRIVE END FRAME) FOR GROUND No Continuity {A} Using an ohmmeter, check that there is no continuity between IDO) the coil load and drive end frame, It there is continuity, replace the drive end trame assemblycH CHARGING GENERATOR 6, _ INSPECT EXPOSED BRUSH LENGTH Using vernier calipers, measure the exposed brush length, ‘Standard exposed length: 9.5 ~ 11.5 mm (0.374 ~ 0.453 in.) Minimum exposed length: 4.5 mm (0.059 in.) {the exposed length is less than minimum, replace the brush owas} holder assembly. 7, INSPECT POSITIVE RECTIFIER HOLDER (a) _ Using an chmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. (©) Reverse the polarity of the tester probes and repeat step (a). (¢} Check that one shows continuity and the other shows no continuity, Is continuity is not as specified, replace the rectifier holder. Positive (6) Terminal Rectifier Terminal 8. INSPECT NEGATIVE RECTIFIER HOLDER Negative () | {@) Using an ohmmeter, connect one tester probe to each negative (-) terminal and the otter to each rectifier terminal. (b) Reverse the polarity of the tester probes and repeat step (a) {c) Check that one shows continuity and the other shows no. continuity It continuity is not as specified, replace the rectifier holder. ‘Chmmeter 9. INSPECT FRONT BEARING Check that the bearing is not rough or worn, 40, IF NECESSARY, REPLACE FRONT BEARING {@) Remove the 4 screws, beating retainer and bearingCH-2 CHARGING GENERATOR [Socket Wrench (b) (e) @ nn 12, fa) Using SST and a press, press out the bearing. SST 09950-60010 (09951-00350) 09950-70010 (09851-07100) Using SST and a press, press in a new bearing. SST 09950-60010 (09951-00530) 09950-70010 (09951-07100) Install the bearing retainer with the 4 screws. Terque: 3.0 N-m (31 kgf-cm, 27 In-Ibf) INSPECT REAR BEARING Check that the bearing is not rough or worn, IF NECESSARY, REPLACE REAR BEARING Using SST, remove the bearing caver (outside) and bearing. SST 09820-00021 NOTICE: Be careful not to damage the fan. (b) (e) Remove the bearing cover (inside) Place the bearing cover (inside) on the rotor.cH13 CHARGING — GENERATOR sst (d) Using SST and a press, press in a new bearing. SST 09820-00030 (e) Using SST, push in the bearing cover {outside}. SST 09285-76010Chota CHARGING Pulley 1 fa) (b) fa) {b) /¥GO nlow/ fake Cpe g Hea © ©) |ENERATOR, REASSEMBLY INSTALL ROTOR TO DRIVE END FRAME Place the drive end frame on the pulley. Install the rotor to the drive end frame. INSTALL RECTIFIER END FRAME Place the generator washer on the rotor, Using a 29 mm socket wrench and press, slowly press in the rectifier end frame. Install the wire clip and 4 nuts. Torque: Nut A 4.5 Nem (46 kgf-cm, 40 In.tbf) Nut B 5.4 Nem (55 kgf-cm, 48 intbf) INSTALL PULLEY install the pulley to the rotor shaft by tightening the pulley nut by hand. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820-63010 Torque: 39 N.m (400 kgf-om, 29 ft1bA) Check that SST (A) is secured to the pulley shaftchs CHARGING — GENERATOR (4) Mount SST (C) in a vise. 1 vw (e) Insert SST (B) into SST (C), and attach the pulley nut to K ea) “f SST (C). SST ICL () To torque the pulley nut, tun SST (A) in the direction shown in the illustration. Torque: 111 Nem (1,125 kgf-cm, 81 ft-Ibf) {g) Remove the generator from SST (C). (h) Turn SST (B), and remove SST (A and B) 4. INSTALL RECTIFIER HOLOER (a) _Instati the 4 rubber insulators on the lead wires. NOTICE: Be careful of the rubber insulators Installation direction. (©) Instail the rectitier holder while pushing it with the 4 screws Torque: 2.9 N-m (30 kef-om, 26 In.)CHARGING . GENERATOR, 5. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER (a) Place the seal plato on the rectifier end frame. (0) Place the voltage regulator and brush holder on the rectifier end frame. NOTICE: Be careful of the holder Installation direction. (©) Install the 5 screws. Torque: 2.0 Nem (20 kgf-cm, 18 in-Ibf) (d) Place the brush holder cover on the brush holder. 6. INSTALL REAR END COVER (a) Install the end cover and plate terminal with the bolt and 3 nuts. Torque: Nut 4.4 Nem (45 kgt-om, 39 in-Ibf) Bolt 3.9 N.m (39 kgt-cm, 35 Invibf) {b) _ Install the terminal insulator with the nut. Torque: 4.1 Nem (42 kgf-cm, 36 In-tbf) 7. CHECK THAT ROTOR ROTATES SMOOTHLYcH? CHARGING. GhueATON (by () (a) (e) 2. INSTALLATION INSTALL GENERATOR Install the 2 bolts anid generator. Torque: 14. mm head 25 Nem (250 kgf.cm, 18 ft.lbt) 17 mm head 1ZZ-FE: 54 Nem (550 kgt-cm, 40 ftibf) 22Z-GE: 58 N-m (S90 kgt-cm, 43 fi-tbt) 222-GE Install the generator bracket with the 2 bos. Torque: 29 Nim (295 kaf-cm, 21ftIbf) Connect the generator connector, Connect the generator wire, and install the nut and rubber cap. Connect the generator wire, and install the rubber cap and nut INSTALL DRIVE BELTMEMO ~CLUTCH TROUBLESHOOTING ..... cee Ch CLUTCH PEDAL 2... - OLe CLUTCH MASTER CYLINDER... cL CLUTCH RELEASE CYLINDER ous CLUTCH UNIT seve outaSLUTOH — TROYBLESHOOTING. TROUBLESHOOTING PROBLEM SYMPTOMS TABLE ct Use the table below to help you find the cause of the problem. The numbers indicate the priarity of the likely cause of the problem. Check each part in order. necessary, repiace these parts. ‘Simp ‘Suspect Aes See pago ‘Clutch graschatiers Engine mounting (Looser) ‘Chit ase (Runes wxcessiva) {Chien se (O15) Ste ese (een out) (Cite ci torsion rubber (Damaged Clute cise (laze Diaphagen sping (Out of ip agony 1 Chueh toe (rine) - ‘Cate peda spongy 2, Mactor nda cup ‘Damaged on 3. Rolanse eytrdr op (Oamagecs) ena 1. Foleasa bearing (Wor, dry, or damaged) cos Ckach eis 2. Clutch esc torsion ber (Camaged ue 7 Chtch pedal Freeplay out of ahustinen oe 2 Clutch ese (Oy) cus 3. Chath dss (Wom on cits Cluten sips 4 Disparagm sprea (Oamaged) cota ‘9. Pressure plate (Datorlon) cu 5, Flynhcel Distoon), - 1 Gluch posal (Fee play out et aausimend abe 2, Chute ine (8 ina) 3. Master cyinder cup (Damaged) 4. Rolsase cyindereup (Oamaged) 5. Clues ase feu! af we) 6, Clutch disc (Rusontis wxcassiva} ‘Gaon dons nor asengage 7 Gish die (ing Beker) 8, Ciulen ae (Diey or burg) 19, teh aise (Oy) 10.Giaton ie Lack feo groase) Biaptragm spring Damaged) 2.0iaphragm sping (Out ofp agent) 18.Pressurn plate (OBIOMONcL Push Rad Play and Free Play Adjust Point fog 6) } / ibn if © Play \ Pedal Height Adjust Point Push Rod Full Stroke: End Position \ CLUTCH —_GLUTCH PEDAL CLUTCH PEDAL INSPECTION 1. (a) (b) 3. (a) (b) f@ tb} fc) 5. @ (o) @ @ CHECK PEDAL HEIGHT Pedai height from asphalt sheet: Standard pedal: 135.6 ~ 145.6 mm (5.339 ~ §.732 in.) ‘Sport pedal: 136.9 ~ 146.9 mim (5.390 ~ 5.783 in.) iF NECESSARY, ADJUST PEDAL HEIGHT Leosen the lock aut and turn the stopper bolt until the height is correct. Tighten the lock nut CHECK PEDAL FREE PLAY AND PUSH ROD PLAY Depress the pedal until clutch resistance begins to be felt. Pedal free play: 1.0 — 5.0 mm (0.039 ~ 0.197 in.) Genily push on the pedal until the resistance begins to in crease a litte. Push rod play at pedal top: 5.0 ~ 15.0 mm (0.197 — 0.591 in.) If NECESSARY, ADJUST PEDAL FREE PLAY AND PUSH ROD PLAY Loosen the lock nut and turn the push rod until the tree play and push rod play are correct. Tighten the lock nut. iter adjusting the pedall free play, check the pedal height CHECK CLUTCH RELEASE POINT Pull the parking brake laver and install wheel stopper. Start and idle the engine. Without depressing the clutch pedal, slowly shift the shift lever into reverse position until the gears contact Gradually depress the clutch pedal and measure the stroke distance from the point the gear noise stops (re ease point) to the fuil stroke end position. Standard distance: 25 mm (0.98 in.) or more (From pedal stroke end position to release point) I the distance is not as specified, perform the following operations. + Inspect pedal height + Inspect push rod play and pedal free play. Bleed the clutch fine, + Inspect the cluteh cover and disc.cls cLuTCH CLUTCH PEDAL 6. CHECK CLUTCH START SYSTEM (2) Check that the engine does not start when the clutch ped. alis released, (®) Check that the engine starts when the clutch pedal is fully depressed WWnecessary, replace the clutch start switch 7. INSPECT CLUTCH START SWITCH CONTINUITY ‘Check the continuity between terminals when the switch is ON and OFF, ‘Sitch posiven Sonation ON (pushed Comimaty OFF tree} ‘No contoutycL CLUTCH CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER COMPONENTS lip fntet Union| Reservoir Hose t # Grommet Clutch Line (asa 1] ~ Slot Spring Pin “ele Serra. git Push Rod ° 3. Piston a0} Master Cylinder ly [Nem fkoP era, RBA) ] : Specified torque @ Non-reusable part “Lithium soap base glycol grease Boot Washer Snap Ring Clevis lip q 1”) Pincis SLUTCH CLUTCH MASTER crLDER REMOVAL 1. REMOVE BRAKE BOOSTER (See page BR-15) 2, DISCONNECT RESERVOIR HOSE (@} Using pliers, disconnect the clip. (b) Disconnect the reservoir hose from the inlet union. (6) Use a container to catch the fluid, 3. DISCONNECT CLUTCH LINE (a) Using SST, disconnect the clutch fine. SST 09023-00100 (b) Use a container to catch the fluid. 4. REMOVE CLIP AND PIN Using needie--nose pliers, remove the clip and pin. 5. REMOVE 2 MOUNTING NUTS AND PULL QUT MAS- TER CYLINDERcL CLUTCH. CLUICH MASTER CYLINDER DISASSEMBLY 1, REMOVE INLET UNION (@) Using a pin punch (3 mm) and hammer, drive oul the slotted spring pin. () Remove the inlet union, (©) Remove the grommet. 2, REMOVE CLEVIS Loosen the lock nut to remove the clevis and remove the lock nit 3, REMOVE BOOT FROM CYLINDER 4, REMOVE PUSH ROD (2) While pushing the push rod, using snap sing pliers, remove the snap ring. (©) Pullout the push rod and washer. 5. REMOVE PISTON WITH SPRING FROM CYLINDERcL-7 CLUTCH ~ CLUToHMAS EER cvLNDEN REASSEMBLY 1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN IN ILLUSTRATION 2. INSERT PISTON WITH SPRING INTO CYLINDER 3. INSTALL PUSH ROD {a) Install the washer to the push rod, (©) Push the push rod into the piston, using snap ring pliers, instal the snap ting. 4, INSTALL BOOT TO CYLINDER 5. TEMPORARILY INSTALL LOCK NUT AND CLEVIS Protusion 7 6 INSTALL INLET UNION 1.5=2.5mm owe ‘\ (a) _Instali a new grommet. (0.059 —0.098.in.) aC >) (b} Install the inlet union. - (6) Using pin punch (3mm) and hammer. drive in the slotted spring pin x MS sncle. CLUTCH — CLUTCH MASTER CYLINDER, INSTALLATION 4, INSTALL MASTER CYLINDER WITH 2 MOUNTING NUTS ‘Torque: 12 N-m (120 kgf-cm, 9 ft-Ibf) 2. INSTALL PIN AND CLIP 3. CONNECT CLUTCH LINE Using SST, connect the clutch line, SST 09023-00100 ‘Torque: 15 Nim (155 kgf-em, 11 fhibf) 4. CONNECT RESERVOIR HOSE (@) Connect the reservoir hose to the iniet union. NOTICE: Facing the yellow mark upwards. {b) Using pliers, connect the clip. 5. INSTALL BRAKE BOOSTER (See page BR-16) 6. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEM (See page BR-4) 7. ADJUST CLUTCH PEDAL (See page CL-2) 8. CHECK FOR LEAKSCLUTCH — CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER COMPONENTS cL-9 Bleeder Plug 65 TEES, 9} ‘Clutch Line [isass.) } Specitied torque we glyool grease: Clutch Line Bracket Release Cylinder SpringcL-40 CLUTCH CLUTCH RELEASE CYLINDER, REMOVAL 4. DISCONNECT CLUTCH LINE fa) _ Raise the vehicle. CAUTION: Make sure that the vehicle is securely supported. (b) Remove the LH and RH engine under covers. (c) Using SST, disconnect the olutch line. SST 08023-00100 (d) Use a container to catch the fluid. (e) Lower the vehicle. 2. REMOVE RELEASE CYLINDER (a) Remove the air cleaner case assembly with the air hose. (0) Remove the clutch tine clamp set bolt. (c) Remove the 2 bolts, ciutch line bracket and release cykn- der.cut CWTCH —_ CLUTCH RELEASE CYLINDER DISASSEMBLY 1. REMOVE BOOT AND PUSH ROD {a) Pull out the boot with the push rod. {b) Remove the boot from the push rod 2, REMOVE PISTON AND SPRING Using compressed air, remove the piston with the spring from NOTICE: + Blowing off the alr may cause the piston’s jump—out. ‘When removing the piston, hold it with your hand using a waste cloth. Take care notto splash brake fluid when air-blowing. REMOVE BLEEDER PLUGcL? cwUTCH = GiVicH nELeASE cvLNOER REASSEMBLY 1. INSTALL BLEEDER PLUG Torque: 8.4 N.m (85 kgf-om, 74 in.-lbf) 2, COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN 3, INSTALL PISTON AND SPRING INTO CYLINDER 4, INSTALL BOOT AND PUSH ROD (@) install the push rod to the boot. (©) install the boot with the push rod to the cylinder. coer zw)cL-13 CLUTCH —_ GLUTOH RELEASE CYUNDER INSTALLATION 1. INSTALL RELEASE CYLINDER (a) _ Install the release cylinder and clutch line bracket with the 2 bolts, Torque: 12 N.m (120 kgf-cm, 9 ttibt) (©) _ Install the clutch line clamp fo the elatch line bracket with the bott Torque: 4.9 N.m (50 kgf-cm, 43 in-Ibt) (c) Install the air cleaner case assembly with the air hose. 2. CONNECT CLUTCH LINE AND BLEED CLUTCH SYS- TEM (a) Raise the vehicle. CAUTION: Make sure that the vehicle is securely supported. {b) Using SST, connect the clutch line. SST 09023-00100 Torque: 15 Nem (155 kgf-cm, 11 ftibf) (6) Fill the brake reservoir tank with brake fluid and bleed clutch system, {¢) Check for the leaks. {e) Install the LH and RH engine under covers. (Lower the vehicle,cits CLUTCH UNIT CLUTCH CLUTCH UT COMPONENTS ey Folease ~“ x6 cip. b—— \ “ ReleasoFork Clutch Disc Chute Cover sal Release Fork Suppo = (Bra 7 ~ _ an {Rim akom, ib |: Species torque : # Non-reusable part > Civich spline groase > Roloase hub grease BootCLs ciuren cure ur REMOVAL 1. REMOVE TRANSAXLE FROM ENGINE (C56: See page MX-4) (C60: See page MX-4) 2, REMOVE CLUTCH COVER AND DISC (a) _ Align the matchmark on the clutch cover with the one on the flywheel. (b) Loosen each set bolt ane turn ata time until spring tension is released. {) Remove the set bolts, and pull off the clutch cover with the clutch disc. NOTICE: Do not drop the clutch disc. 3. REMOVE RELEASE BEARING AND FORK FROM TRANSAXLE Remove the release bearing with the fork together and then separate them. 4, REMOVE RELEASE FORK SUPPORT AND BOOTcle LUTCH —cuyToH Una INSPECTION 1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE Using vernior calipers, measure the rivet head depth. Minimum rivet depth: 0.3 mm (0,012 In.) It necessary, repiace the clutch disc. 2, INSPECT CLUTCH DISC RUNOUT Using a dial indicator, check the dise runout, Maximum runout: 0.8 mm (0.031 in.) Itnecessary, replace the clutch disc runout. 3. INSPECT FLYWHEEL RUNOUT Using a dial indicator, check the flywheel runout. ‘Maximum runout: 0.1 mm (0.004 in.) Wnecessary, replace the flywheel. ‘Torque: 49 N-m (500 kgt-cm, 36 fbf) 4. _ INSPECT DIAPHRAGM SPRING FOR WEAR Using vernier calipers, measure the diaphragm spring for depth and width of wear Maximum: A (Depth): 0.5 mm (0.020 in.) B (Width): 6.0 mm (0.236 in.) Ht necessary, replace the clutch cover, 5. INSPECT RELEASE BEARING ‘Turn the bearing by hand while applying force in the axial direction HINT, “The bearing is permanently lubricated and requires no cleaning ‘or lubrication. M necessary, replace the release bearing.cl oLUTGH —_ Lures nur INSTALLATION 1, INSTALL CLUTCH DISC AND CLUTCH COVER ON FLYWHEEL (@} Insert SST in the clutch diso, then insert them in the fy- wheel SST 09301-00210 HINT: ‘Take care not to insert clutch disc in the wiong direction. (b) Align the matchmarks on the clutch cover and flywheel (©) Following the procedures shown in the illustration, tighten the 6 bolts in the order starting the bolt locating near the knock pin on the top. Torque: 19 N.m (195 kgf-cm, 14 ftibf) HINT: + Following the order in the illustration, tighten the bolts at atime evenly. + Move SST up and down, right and left lightly, after check ing that the disc is in the center, tighten the bolts. 2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT Using a dial indicator with roller instrument, check the dia: phragm spring tip alignment. ‘Maximum non-alignment: 0.5 mm (0.020 in.) f alignment is not as specified, using SST. adjust the diaphragm spring tip alignment. SST 09333-00013, 3. INSTALL BOOT AND RELEASE FORK SUPPORT TO TRANSAXLE Torque: 37 N.m (375 kgf-cm, 27 ftibf) 4, APPLY RELEASE HUB GREASE Apply release hub grease to the release fork and hub contact, release fork and push rod contact and release fork pivot points. Sealant: Part No, 08687-01806, RELEASE HUB GREASE or equivalent 5. APPLY CLUTCH SPRING GREASE Apply clutch spline grease to the input shatt spline, Seatant: Part No, 08887-01706, CLUTCH SPLINE GREASE or equivalent 6, _ INSTALL RELEASE BEARING AND FORK TO TRANS- AXLE Install the bearing to the reiease fork, and then install them to ‘the transaxle. 7. INSTALL TRANSAXLE TO ENGINE (C56: See page MX-8) (C60: Sea page MX-8)MEMO ~MANUAL TRANSAXLE (C56) TROUBLESHOOTING MANUAL TRANSAXLE UNIT 2.0.0.0. MANUAL TRANSAXLE ASSEMBLY INPUT SHAFT coe ‘OUTPUT SHAFT ‘SHIFT AND SELECT LEVER SHAFT DIFFERENTIAL CASE SHIFT LEVER AND CONTROL C. MX Mix-2 Mx-g MX-26 MX-34 MX-a4 Mx-45 Mx-52MANUAL TRANSAXLE (G56) —THOUBLESHOOIING. TROUBLESHOOTING PROBLEM SYMPTOMS TABLE MX Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. i necessary, replace parts. Sympiom ‘Suspact Area Soe pa {Oi Leveson) Mea Noi 2 On @ong} Me wone 43. Goar (Worn or camsced} Mee 4 Bearing (Worn or damaged rg 1 Oi (Laverton nigh) aKa 2 Gasket (Damaged) Meo oitteakaoe 23,0) seal (Worn cr damages} ba 4. 0-fing Hox ox damage WK Cont cable (Fauiy) x52 2. Synehvenizer ring (Worn or damaged) M4 K-29 Had 0 shit or wi not shit Max 38 8. Shifting key spring (Damaged) ca 9x20 x6 1 Locking ball spring Darnaged) no .Jomps out of goar 2, Gear shit fuk Worn, cel lumps out of gear 8.Gear fHorn or damaged, x4 4.Beanng (Wom ordsmaged) MxK-2 MANUAL TRANSAXLE (C56) MANUAL TRANSAXLE UNIT. MANUAL TRANSAXLE UNIT COMPONENTS Air Cleaner Case Assembly with Air Hose Hi (91, dite bs ECM Cover Holé—Down Clamp (70, Gti. i) No. 2Gylinder Head Cover a. Battory Carrior | aeeeean uv EOM Outlet Ouct radiator Wite Harness ————— [6 65,33) soe, caacanagae Wire Harness, Back-Up Light Switeh Connector —_, [1680.8 a Washer ‘Speed Sensor Gonnector — ze tp oi Starter Connector iy Lx} ‘ Starter 4 Wire f ‘ena > eB ei6 a] a ran tg The Control Cabie Engine Left Mounting Bracket TransaxleMANUAL TRANSAXLE (C56). MANUAL TRANSAXLE UNIT BH Front Drive Shatt Oxygon Sensor [#.050,395) ai resis | {TSHy rrontematrpe Fg | Sanpresin rasan a ¢ 1 (GATE 15} roe Engine Rear | i Hat alter | Engine Roar Ye a Mourn ackat lew Front Sub-Fame and Lower ~ ‘Suspension Arm 7 A cacory ti | 3 2eaw)| — UH Engine Under Cover a ABA] : Speciiod torque Non-reusable pan @ ConerPin Lit Front Dove Shaft 49 (500, 36) |) ? i Lock Mut [216 @.200, 158) ]uxX-4 MANUAL TRANSAXLE (C50)_~_ MANUAL TRANSAXLE UNIT REMOVAL 4. REMOVE HOOD HINT: At the time of installation, please refer to the following item Adjust the hood. (See pags BO-9) 2, REMOVE NO. 2 CYLINDER HEAD COVER Remove the 2 nut caps, clips and No. 2 oylinder head cover. Torque: 7.0 Nem (71 kgf-om, 62 in-tbf) 3. DISCONNECT RADIATOR RESERVOIR ‘Remove the bolt and disconnect the radiator reservoir. Torque: 4.9 N-m (50 kgf-cm, 43 in.-Ibf) 4. REMOVE BATTERY 5. REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR HOSE AND ECM BOX (a) Remove the 2 bolts and ECM cover. Torque: 6.9 N-m (70 kgt-cm, 61 In. Ibf) (b) Disconnect the ECM connectors trom the ECM (©) Remave the ECM outlet duct (d) Remove the air cloaner case assembly with the air hose, {e) Remove the 3 bolts and ECM box. Torque: 6.9 N-m (70 kgf-cm, 61 in-lbf) (Disconnect the wire hamess, and remove the 2 nuts, bolt and battery cartier. Torque: Bolt: 18 Nem (185 kgf-cm, 13 ftlbf) Nut: 12 Nem (120 kgt-cm, 9 ftibf) 6 DISCONNECT CONTROL CABLE (a) Remove the 2 clips and washers. (o) Remove the 2 clips and disconnect the control cables from the transaxle. 7. DISCONNECT GROUND CABLE Remove the 2 set bolts of the 2 ground cables from the transaxle. 8. DISCONNECT SPEED SENSOR AND BACK-UP LIGHT SWITCH CONNECTORS.X65 MANUAL TRANSAXLE (C56) — MANUAL TRANSAXLE UNIT 9 fa) } 10, fa) (o) co] n @ (b) 42, 13, (a) tb) DISCONNECT CLUTCH RELEASE CYLINDER Romove the 4 set bolts of the olutch line. Torque: Bott A: 12 Nem (120 kgf-cm, 9 ftbf) Bolt B: 4.9 N-m (50 kgf-cm, 43 in.-bf) Remove the 2 set bolts of the clutch release cylinder and hutch line bracket. Torque: 12 Nem (120 kgf-cm, 9 ft-Ibt) REMOVE STARTER Disconnect the starter connector. Remove the nut and disconnect the starter wire. Remove the 2 bolts and starter. ‘Torque: 37 N-m (378 kgt-cm, 28 ft-lbs) REMOVE CONTROL CABLE BRACKET Disconnect the wire hamess from the clamp. Remove the 2 bolts, clamp and control cable bracket from the transaxle. Torque: 25 N.m (250 kgt-cm, 18 ftibf) REMOVE 2 TRANSAXLE UPPER SIDE MOUNTING BOLTS ‘Torque: 64 Nem (650 kgt-om, 47 ftibf) ATTACH ENGINE SLING DEVICE TO ENGINE HANG- ER Disconnect the 2 PCV hoses. Install the No. 1 and No. 2 engine hangers in the correct direction Parts No.: No. 4 engine hanger: 12281-22024 No. 2 engine hanger: 12281~15040 or 12281-15050 Bolt: 91512-B1016 Torque: 38 Nm (387 kgf-cm, 26 ft-lbf)MX-6 MANUAL TRANSAXLE (C56) —_ MANUAL TRANSAXLE UNIT = Oil Level neg (0-0.02 ee C4 0- Sam in) {c) Attach the engine chain hoist fo the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. 44, REMOVE ENGINE LEFT MOUNTING BRACKET 3 SET BOLTS AND NUT Torque: Bolt A: 60 N-m (610 kgt-om, 44 ft-lb) Nut B: 80 N-m (820 kgf-cm, 59 ft.lbf) 15. REMOVE ENGINE LEFT MOUNTING BRACKET Lower the transaxle side, and remove the bolt and engine left mounting bracket. Torque: 60 Nem (610 kgf-cm, 44 ftbf) 16. RAISE VEHICLE CAUTION: Make sure that the vehicle is securely supported. 17. REMOVE CENTER, LH AND RH ENGINE UNDER COV- ERS 18. DRAIN TRANSAXLE OIL Oil grade: API GL-4 or GL-5 Viscosity: SAE 75W-90 Capacity: 1.9 liters (2.0 US qts, 1.7 imp. gts} Torque: 39 N-m (400 kgt-om, 29 ftlbf) 19, REMOVE LH AND RH FRONT DRIVE SHAFTS (See page SA~18) 20, REMOVE FRONT EXHAUST PIPE {a) Disconnect the 2 heated oxygen sensors. Torque: 44 N-m (450 kgt-cm, 33 ftlbt) BINT: At the time of installation, please refer to the following items. + Before installing the heated oxygen sensor, twist the sen: sor wire counterclockwise 3 and 1/2 turns. + After installing the heated oxygen sensor, check that the sensor wire is not twisted, If it is twisted, remove the heated oxygen sensor and reinstall i, (b) Remove the 4 bolts, compression springs and 2 gaskets, Torque: 43 N-m (440 kgf.cm, 32 ftIbf)MX-7 MANUAL TRANSAXLE (C56)_—_WANUJAL TRANSAXLE UNIT {c) Disconnect the front exhaust pipe trom the pipe supports and remove it 21. REMOVE FRONT SUB-FRAME AND LOWER SUS- PENSION ARM (@) Tie the PS gear assembly to the proper position with a ‘code or an equivatent to suspend the assembly securely {b) Remove the 4 set bolts of the PS gear assembly, Torque: 45 N.m (459 kaf-cm, 33 fbf) (©) Disconnect the LH and RH stabilizer bar links from the shock absorber. (See page SA-51) (6) Remove the front subframe and lower suspension arm, (See page SA-42} 22. REMOVE ENGINE REAR MOUNTING INSULATOR AND BRACKET (a) Remove the bolt and engine rear mounting insulator. ‘Torque: 87 Nm (890 kgf-cm, 64 fbf) () Remove the 3 bolts and engine rear mounting bracket. ‘Torque: 64 N-m (650 kgf-cm, 47 fbf) 23, JACK UP TRANSAXLE SLIGHTLY Using a transmission jack, support the transaxle. Cc 24. REMOVE 4 TRANSAXLE LOWER SIDE MOUNTING BOLTS Torque Bolt A: 47 N-m (480 kgf-cm, 35 tt-lbf) Bolt B: 23 N-m (230 kgf-cm, 17 ftibt) 25. REMOVE TRANSAXLE Lower the engine left side and remove the transaxle from the engine HINT: At the time of installation, please refer to the following items. + Align the input shaft with the clutch disc and install the twansaxle to the engine + Temporarily tighten the transaxle mounting bolts.Mx-8 MANUAL TRANSAXLE (C56) _—_ MANUAL TRANSAXLE UNIT INSTALLATION installation is in the reverse order of removal. (See page MX~4) HINT: ‘Alter installation, check and inspect items as follows. + Front wheel alignment. (See page SA~4) + Do the road testMANUAL TRANSAXLE (C56) MANUAL TRANSAXLE ASSEMBLY. MANUAL TRANSAXLE ASSEMBLY ux-3 COMPONENTS - ge] i ~-— Vehicle Speed Sensor ip —— @ O-Ring ———«<> Control Cable Bracket \ehicte Speed Sensor Oren Gest Se (2508.27) —@ Transaxle Case -— # 04 Seat ¢ toptshatfrort Bening QD Output Shatt Cover ——— @ Output Shatt Front Bearing Boating Lock Plate {J Differential Case Assembly Cig }———D Specified torqueMX—10 MANUAL TRANSAXLE (C56) MANUAL TRANSAXLE ASSEMBLY. > Straight S Ph No.1 GaarShitFoke gpa ren Pg overs Shit rm Bracet Roe rovssesuitFox |G Sey ~ [18,160 1) par XSI No. t Gear Shitt Fork, Shatt —--- No. 3 Gear Shift Fork Shaft ~ Tray “ys — Battery Carrier 1 ECM Oialet Duct _ y Carr Radiator B Wire Harness ———— Ss) Reservoir Controt Cable Bracket Wire Harness Back-Up Light Switch Connector ~~ Cem agnor ‘Speed Sensor Connector Be oii ae” C0) 5 Gap Starter Connector X Starter, ” Wire ~— Sy a (B7 67.297} . “Starter i Be ALL a, 0, 83 in tbA) cushion Le cM ab Transaxle 25 (0,18) Ground Cable a ee Engine Left Mounting BracketMANUAL TRANSAXLE (C60) —_VANUAL THANSANLE UNIT MxX-3 RH Front Drive Shaft _ ' LH Front Drive Shaft a0.) | a oo Oxygen Sonccr — ESAS#-ADLT I (ee =) Gey, | ee. 9 — © Gasket ane A 2 Comprossion j- Searmorson! + Snap Ring [aataio, oa) 7 62 pipe Suppor Compression Spring Mounting Bracket he it Bi fon pan aA, Engino Rear Mounting insulator Front Sub-Frame and Lowor Suspension Arca (ae) tf | ert ss, (2150, 1055] @ Lock Nut ——— Center Engine Under Cover (70 2200, 1555] ~~ LH Engine Under Cover ‘ei, Wb) | : Specified torque ® Non-fousable partMx-4 MANUAL TRANSAXLE (G00) _- MANUAL TRANSAXLE RT REMOVAL 1, REMOVE HOOD HINT. At tho time of installation, please refer to the following item. Adjust the hood. (See page BO-9) 2. REMOVE NO. 2 CYLINDER HEAD COVER Remove the 4 bolts and No. 2 cylinder head cover. ‘Torque: 7.0 N-m (71 kgf-cm, 62 in.-tbf) 3. DISCONNECT RADIATOR RESERVOIR Remove the bolt and disconnect the radiator reservolr. Torque: 4.9 N-m (50 kgtom, 43 inclbt) 4. REMOVE BATTERY 5. REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR HOSE AND ECM BOX (@) Remove the 2 botts and ECM cover. Torque: 6.9 N-m (70 kgf-cm, 61 in. Ibf) {®) Disconnect the ECM connectors from the ECM. {c)_ Remove the ECM outlet duct. {d)_ Remove the air cleaner case assembly with the air hose. (e) Remove the 3 bolts and ECM box Torque: 6.9 N-m (70 kgf-om, 61 in.-tbf) () Disconnect the wire harness, and remove the 2 nuts, bolt and battery carrier. Torque: Bolt: 18 Nm (185 kgt-cm, 13 ft:lbf) Nut: 12 N.m (120 kgf-cm, 9 ttf) 6 DISCONNECT CONTROL CABLE (a) Remove the 2 clips and washers. (©) Remove the 2 clips and disconnect the control cables fom ne ance 7. DISCONNECT GROUND CABLE Remove the 2 set bolts of the 2 ground cables trom the transaxle, 8. DISCONNECT SPEED SENSOR AND BACK-UP LIGHT SWITCH CONNECTORSMX-5 MANUAL TRANSAXLE (C50) — MANUAL TRANSAXLE UNIT aod est 8. {a} (b) 10. fa) (e) (o} nt (a) (e) 12. 13. fa) ib) DISCONNECT CLUTCH RELEASE CYLINDER Remove the 4 set bolls of the clutch line, Torque: Bolt A: 12 N-m (120 kgf-cm, 9 ftibf) Bolt B: 4.9 N-m (50 kgf-cm, 43 in-Ibf) Remove tha 2 set bolts of the clutch release cylinder and clutch line bracket Torque: 12 Nem (120 kgf-cm, 9 ftibf) REMOVE STARTER Disconnect the starter connector. Remove the nut and disconnect the starter wire. Remove the 2 bolts and starter. Torque: 37 N.m (378 kgf.cm, 28 ftibf) REMOVE CONTROL CABLE BRACKET Disconnect the wire harness from the clamp. Remove the 2 bolts, clamp and control cable bracket from the transaxie, Torque: 25 N-m (250 kgf-cm, 18 fbf) REMOVE 2 TRANSAXLE UPPER SIDE MOUNTING a BOLTS Torque: 64 N.m (650 kgf-cm, 47 fbf) ATTACH ENGINE SLING DEVICE TO ENGINE HANG- ER Disconnect the 2 PCV hoses. Instaif the No. $ and No. 2 engine hangers in the correct direction. Parts Ne No. ¢ engine hanger: 12281-88600 No. 2 engine hanger: 12282-88600 Bolt; 91512-61020 Torque: 38 N-m (387 kgf-.cm, 28 ftlbt)MX-6 MANUAL TRANSAXLE (C90) = MANUAL TRANSANL UNIT (6) Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. 14, REMOVE ENGINE LEFT MOUNTING BRACKET 3 SET BOLTS AND NUT Torque: Bolt A: 60 N-m (610 kgt-cm, 44 ft-lb!) Nut B: 80 N.m (820 kgf-cm, 59 ft.Ibf) 15, REMOVE ENGINE LEFT MOUNTING BRACKET Lower the transaxle side, and remove the bolt and engine left mounting bracket. Torque: 60 Nem (640 kgf-om, 44 ft Ib) 16. RAISE VEHICLE CAUTION: Make sure that the vehicle is securely supported. 17, REMOVE CENTER, LH AND RH ENGINE UNDER COV- ERS 18. DRAIN TRANSAXLE OIL Ol grade: API GL-4 or GL-5 Viscosity: SAE 75W-90 Capacity: 2.3 liters (2.4 US qts, 2.0 Imp. gts) Torque: 39 N-m (400 kgf-cm, 29 ftlb!) 19. REMOVE LH AND RH FRONT DRIVE SHAFTS (See page SA~18) 20. REMOVE FRONT EXHAUST PIPE (a) Disconnect the 2 heated oxygen sensors. Torque: 44 N-m (450 kgf-cm, 33 ft-lb!) HINT: {At the time of installation, please refer to the foltowing items. + Before installing the heated oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 tums. + Alter installing the heated oxygen sensor, check that the sensor wire is not twisted. If itis twisted, remove the heated oxygen Sensor and reinstall it, (0) Romove the 4 bolts, compression springs and 2 gaskets. Torque: 43 N.m (440 kat-cm, 32 ftlbf)MX-7 MANUAL TRANSAXLE (060) MANLIAL TRANSANLE UNIT C (a) tb) (c} @ 22. fa) () 23. 24. 25. Disconnect the front exhaust pipe from the pipe supports and remove it REMOVE FRONT SUB-FRAME AND LOWER SUS- PENSION ARM Tie the PS gear assembly to the proper position with a ‘code or an equivalent to suspend the assembly securely. Remove the 4 set bolts af the PS gear assembly. Torque: 45 N.m (459 kgf-cm, 33 ftlbf) Disconnect the LH and FH stabilizer bar links from the. shock absorber. (See page SA~51) Romove the front sub-trame and lower suspension arm, (See page SA-~42) REMOVE ENGINE REAR MOUNTING INSULATOR AND BRACKET Remove the bolt and engine rear mounting insulator, Torque: 87 N-m (890 kgf-cm, 64 f.ibt) Remove the 3 bolts and engine rear mounting bracket, Torque: 64 N-m (650 kgf-cm, 47 ft.tbt) JACK UP TRANSAXLE SLIGHTLY Using a transmission jack, suppod the transaxle REMOVE 4 TRANSAXLE LOWER SIDE MOUNTING & BOLTS Torque: Bolt A: 47 N-m (480 kgf-cm, 35 ft.lbf) Bolt 8: 23 N.m (230 kgt-cm, 17 ft-lb!) REMOVE TRANSAXLE Lower the engine left side anc remove the transaxle from the engine. HINT: At the time of installation, please refer 10 the following items. Align the input shaft with the clutch disc and install the transaxle to the engine. ‘Temporatily tighten tho transaxle mounting bolts.MKB MANUAL TRANSAXLE (C60)_— MANUAL YTANGANLE Ut INSTALLATION =“ Installation is in the reverse order of removal. (See page MX-) HINT: After installation, check and inspect items as follows. + Front wheel alignment, (See page SA~4) + Do the road test.MK-9 MANUAL TRANSAXLE (C60)_-_ MANUAL TRANS/X,& ASSEMBLY. MANUAL TRANSAXLE ASSEMBLY COMPONENTS ge vom== Vehicle Speed Sensor Clip ~~" O-Ring ——— Control Cable Bracke! Vehicle Speed Sensor — Driven Gear Transaxle Case InputShattFrom Beating ~ (Output Shaft Gover—-— + Ourput Shatt Front Bearing Bearing Lock Plate. Diffoentiai Case Assembly (Hs. }—-— arch, F165] - Species torque »_# Nonreusable pant oteMx-10 MANUAL. TRANSAXLE (059)_—_ MANUAL TRANSANLE ASSEMBLY Reverse Idler Gear Reverse Shitt rem Straight Screw Plug 4 (Be Ta x [186025] 9 er wl cworns No. 3 Gear Shit Froverse ShitArm Bracket 0.8 G2e! Rovarse Idler Gear No. 8 Gear Shitt Fark Shaft 8 Snap Ring eon} % | : No.2 Gese Shit Fork Shatt No.1 Gear _Shift Fork "No, 1 Gear Shift Fork Shalt - Lpcc 0 on samp Ping] up sat (FAB No.2 Gear Shit Fork yy eT] -5tn Driven Goar ‘tn Ovven Gear Output Shatt Rear Radial Input Shatt A S ~~ Ball Bearing Assembly ‘ a Can Needle Roller Bearing y No. 3 Synchronizer Ring (For 6th Gear) No. 8 Synchronizer Ring (For Sih Gear) No.3 Hub Sleeve boy 6th Gear — Input Shaft Rear Radial Ball Searing Stiting Key Spring — No.3 Clutch Hub No.3Shiting Key =~—S& ‘Snap Ring sting Key Spring i): Spected toraue @ Non-reusablo part > Precoated pantwt MAWUAL TRANSAXLE (C80) —_MANAL TRANGAXLE ASSEMBLY + [ae Contol Shatt Cover Gasket a (709,19 }-——~¢q Oil Receiver Pipe ———~- _ LoskBal Straight Serow Plug Oil Receiver Pipe OS, 00.2} — ©" Bushing G's ow Seat oft) Dust Boot. - Lever Lock Pin” Control Shaft 28 60.18) | Assembly —— Selecting Botcrank GO, & . Assembly po AEE Fo Wave Washer ——@ mo De J [Nim (kakom, if | = Specitied torque y ® Non-reusabie pant > Precosted pan # Apply MP grease Back-Up Light Switch 0 (41030) No.3 Straight Screw Plug Seat + (38008,20)} Snap Ring Gasket & AY) cdmnprssion | £ &. suasnn a ole Compression Spring Spring i Assembly ® GY oe Spring Seat or Shitt and Select Lever Shatt Assembly Transmission Caco Cover Ge ea Bares 7 - Wave Washor 6 met @—__ roma] Control Beticrank Dust CoverX12 MANUAL TRANSAXLE (C89) ManlUAL TRANSAXLE ASSEMBLY ant DISASSEMBLY REMOVE FILLER PLUG AND DRAIN PLUG WITH 2 GASKETS Torque: 39 N-m (400 kgf-om, 29 ftibf) 2, REMOVE VEHICLE SPEED SENSOR {a} Remove the bolt and vehicle speed sensor, Torque: 11 N.m (115 kgt-om, 8 ftibf) (b) Using a small screwdriver, remove the clip trom the vehiole speed sensor. (Remove the vehicle speed sensor driven gear trom the speed sensor, (d) Using a small screwdriver, remove the O-ring from the vehiole speed sensor. 3, REMOVE BACK-UP LIGHT SWITCH WITH GASKET Torque: 40 N-m (410 kgf-cm, 30 ft-bf) 4, REMOVE CONTROL CABLE BRACKET lemove the 2 bolts and control cable bracket. Torque: 25 N-m (250 kgt-cm, 18 tt-bf) 5, REMOVE CONTROL SHAFT ASSEMBLY Remove the 2 nuts, wave washer and control shaft assembly. ‘Torque: 12 Nm (120 kgf-cm, 9 fbf) 6, REMOVE SELECTING BELLCRANK ASSEMBLY (a) Remove the 2 bolts and selecting beticrank assembly. Torque: 25 N-m (250 kgf-cm, 18 ft-lbf) NOTICE: At the time of reassembly, please refer to the foltowing iter. Fit the selecting bellcrank assembly pin part with the dust ‘cover Into a groove In the control shift lever. (b} Remove the contro! belterank dust cover from the selecting bellerank assembly. NOTICE: At the time of reassembly, please refer to the following tem. Apply MP grease to the inside circumferential surtace of the control belicrank dust cover.MX-13 MANUAL TRANSAXLE (C50) MANUAL TRANSAXLE ASSEMBLY 7, REMOVE CONTROL SHIFT LEVER AND DUST BOOT (a) Remove the nut and wave washer. Torque: 12 Nem (120 kgf-cm, 9 ft.lbt) (b) Using a pin punch and hammer, drive out the lever lock pin, NOTICE; At the time of reassembly, please refer to the following item, When fixing the lever lock pin, properly position the shaft groove. (©) Remove the control shift lever and dust doo. NOTICE: At the time of reassembly, please reter to the following items. * Install the dust boot into a groove in the control shitt lever. + Be sure to install the dust boot in the correct dirot tion, as shown in the illustration. 8 REMOVE PLUG, LOCK BALL ASSEMBLY AND CON- ‘TROL SHAFT COVER ASSEMBLY {a) Using a hexagon wrench, remove the plug and gasket. ‘Torque: 39 N-m (400 kgt-cm, 29 ft-ibt) (0) Remove the tock ball assembly. Sealant Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivatent Torque: 29 N.in (300 kgf-cm, 22 ft.tbf) (©) Remove the 4 bolts and control shaft cover assembly with the gasket Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 20 N.m (260 kgf.cm, 14 ftlbf)MX-14 MANUAL TRANSAXLE (C80)_. MANUAL TRANSAXLG ASSEMBLY 9. DISASSEMBLE CONTROL SHAFT COVER AS- SEMBLY {a) Using snap ring pliers, remove the snap ring. {b) Remove the No. 3 select spring seat and compression spring 10, REMOVE SHIFT AND SELECT LEVER SHAFT AS- SEMBLY {a) Remove the shift and select lever shaft assembly. NOTICE: At the time of reassembly, please refer to the following item. Set tho claws of the shift interlock plate into the shitt head part of the gear shift fork shaft securely. (6) Remove the select spring seat and compression spring from the shift and select lever shaft assembly. 11. REMOVE TRANSMISSION CASE COVER (a) Remove the 9 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft1bf) (©) Carefully tap the projection of the transmission case cover with a brass bar and hammer and remove it HINT: At the time of reassembly, please refer to the following item. Apply FIPG to the transmission case side, as shown in the illustration. FIPG: Part No, 08826-00090, THREE BOND 1281 or equiva- Tent 42, INSPECT 6TH GEAR THRUST CLEARANCE Using a dial indicator, measure the thrust clearance. Standard clearance: 0,10 — 0.60 mm (0.0039 ~ 0.0236 in.) ‘Maximum clearance: 0.60 mm (0.0236 in.)Mx15 MANUAL TRANSAXLE (CED) HJANUAL TRANSAXLE ASSEMBLY. 13. INSPECT 6TH GEAR RADIAL CLEARANCE Using a dial indicator, measure the radial clearance. Standard clearance: 0.009 ~ 0.050 mm (0.0003 ~ 0.0020 in.) Maximum clearance: 0.050 mm (0.0020 in.) if the clearance exceeds the maximum, replace the gear, needle rallar beating or shaft. 14. REMOVE OUTPUT SHAFT REAR RADIAL BALL BEARING, 6TH DRIVEN GEAR AND SPACER (@) Using 2 screwdrivers and a hammer, tap out the snap fing, HINT: At the time of reassembly, please refer to the following item. Select a snap ring from the table below that will make the thrust Clearance of the output shaft rear radial bali bearing less than 0.1: mm (0.0039 in.) wom [ tenes on | ak] na map Fe ST TT eer tse 2790198 2 [sso | ae] te €_[Fewosin PT Sone ET aes ng Ta (eT storey = i (b) Using SST, remove the rear radial ball bearing and 6th driven gear. SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04021, 09957-04010, 09958-04011) HINT: A‘ the lime of reassembly, please reter to the following items. + Using SST and a hammer, drive in the 6th driven gear. SST 09325-12010 NOTICE: Be sure to install the 6th driven gear in the correct direc tion, as shown in the illustration.Mx-16 MANUAL TRANSANLE (960)_— MANUAL TRANSAXLE ASSEMBLY + Set SST to the rear radial ball bearing inner race securely, drive in the bearing with a hammer. SST 09517-12010 {c} Remove the spacer. 18. REMOVE INPUT SHAFT REAR RADIAL BALL BEAR- ING AND 6TH GEAR (a) Using 2 screwarivers and a hammer, tap out the snap ring, HINT: [At the time of reassembly, please refer to the following item. Select a snap ring from the table below that will make the thrust clearance of the No. 3 clutch hub less than 0.1 mm (0.0039 in.).. Mane | Tsknese mmgny | Muk | Tidaoes nv tin) x 1.70 0.0669) 6 2.00 0.0787), e 1.76 (0.0689) # 205 0.0807), © 1.80 (0.0709) ! "270 16.0827) 2 1,99 (0.0720), K 2.15 (0.0848) E 7.90 0.0748) L 220 0.0868), £ 1.95 (0.076) M 2.25 (0.0886) (b) Using SST, remove the rear radial ball bearing and 6th gear. SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04021, 09957-04010, 09958-04011) HINT: At the time of reassembly, please refer to the following item. Set SST to the rear radial ball bearing inner race securely, drive in the bearing with a hammer. SST 09517-12010 (©) Remove the needle roller bearing and spacer.MX-17 MANUAL TRANSAXLE (660) _—_ MANUAL THANSANLE ASSEMBLY 16. REMOVE NO. 3 SYNCHRONIZER RING (FOR 6TH GEAR) NOTICE: At the time of reassembly, please refer to the following items. + Align the No. 3 synchronizer ring slots with the No. 3 shifting keys. + Distinguish the No. 3 synchronizer ring (for the 6th gear) by the teeth on the synchronizer ring, 17. REMOVE NO. 3 GEAR SHIFT FORK AND NO. 3 HUB SLEEVE Remove the bolt, No. 3 gear shift fork and No. 3 hub sleeve. Sealant; Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 16 Nem (160 kgf-cm, 12 ft-lb!) 18. INSPECT STH GEAR THRUST CLEARANCE Using @ dial indicator, measure the thrust clearance. ‘Standard clearance: 0.10 - 0,62 mm (0.0039 ~ 0.0244 In.) Maximum clearance: 0.62 mm (0.0244 in.) 19. INSPECT 5TH GEAR RADIAL CLEARANCE Using a dial indicator, measure the radial clearance. Standard clearance: 0,015 -- 0.056 mm (0.0006 — 0.0022 in.) Maximum clearance: 0.056 mm (0.0022 in.) It the clearance exceeds the maximum, replace the gear, needle roller bearing or shatt.x18 MANUAL TRANSAXLE (090)_—__ MANUAL TRANSAXLE ASSEMBLY 20. REMOVE 5TH GEAR, NO. 3 SYNCHRONIZER RING (FOR STH GEAR) AND NO. 3 CLUTCH HUB AS- SEMBLY (a) Using 2 screwdrivers and a hammer, tap out the snap fing. HINT: At the time of reassembly, please refer to the following item. Selecta snap ring from tho table below that will make the thrust clearance of the No, 3 clutch hub less thaa 0.4 mm (0.0039 in.). Wooden Block Marc | _Thicknass cm ny [Mork [__Tcknoss eam (in) A 1.750.088), E 2.00 (0.0787) 8 180 (00708) © 2205 (0.0807) © 25 (0.0728) # 219 (0.0827) a 180 (0.0748 4 2.15 0.086) E 135 0.0768) = (b) Using SST, remove the No. 3 clutch hub assembly. SST 09950-3001 (09951-03010, 69953-03010), 99950-50012 (09954-05030) HINT: At the time of reassembly, please refer to the following items. Before driving in the No. 3 clutch hub assembly and input shaft rear radial ball bearing, place the suitable sized wooden block on the rear side of the input shaft, as shown inthe dlustration. When driving them in, fix the input shatt firmly so thatitis not pushed downward. Otherwise the input shaft center bearing is overloaded, it might be damages. Using SST and a hammer, drive in the No. 3 clutch hub assembly. SST 03612-22011 NOTICE: Align the No. 3 synchronizer ring slots with the No. 3 shifting keys. Be sure to install the No. 3 clutch hub assembly in the correct direction, as shown in the illustration.MX-19 MANUAL TRANSAXLE (C60) _-_ MANUAL TRANSAXLE ASSEMBLY. For ih Gear (©) Remove the No. 3 synchronizer ring (for the 5th gear) and Sth gear from the input shat. NOTICE: At the time of reassembly, please refer to the following item Distinguish the No.3 synchronizer ring (for the 5th gear) by the teeth on the synchronizer ring. (@) Using 2 screwdrivers and a hammer, tap out the snap fing. {e) Remove the needte roller bearing and 2 spacers. 21, REMOVE STH DRIVEN GEAR Using SST, remove the 5th driven gear. SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03021) HINT: At the time of reassembly, please refer to the following item. Using SST and a hammer, drive in the Sth driven gear. SST 09612-22011 22, REMOVE REAR BEARING RETAINER Remove the 5 bolts and rear bearing retainer. Seatant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent ‘Torque: 27 N-m (280 kgf-cm, 20 ft-lbf) 23, REMOVE BEARING SNAP RING Using a snap ring expander, remove the 2 snap rings. HINT: {fits dificult to remove and install the snap rings, pull up the shattsMx-20 MANUAL, TRANSAXLE (G80) — MANUAL TRANSAXLE ASSEMBLY 24, REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND GASKET Sealant: Part No, 08833-00080, THREE BOND 1344, LOCTITE 242 of equivaient ‘Torque: 29 N-m (300 kgt-cm, 22 ftlbf) 26. REMOVE SNAP RING FROM NO. 2 SHIFT FORK ‘SHAFT Using 2 screwdrivers and a harnmer, tap out the snap ring, 26. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING AND BALL {a} Using a hexagon wrench, remove the 3 straight screw plugs Sealant: Part No, 08833-00080, THREE BOND 1344, LOCTITE 242 of equivatent Torque: 25 Nim (250 kgf-cm, 18 f-lbt) {o) Using a magnetic finger. remove the 3 seats, springs and balls 27, REMOVE STRAIGHT SCREW PLUG Using a hexagon wrench, remove the 2 straight screw plugs. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivaient Torque: Plug A: 13 Nem (130 kgf-cm, 9 ft-lb) Plug B: 39 N.m (400 kgf-om, 29 ftibf) 28. REMOVE TRANSMISSION CASE (2) Remove the 16 boits. Torque: 29 N-m (300 kgt-cm, 22 ttlbf) (©) Carefully tap the transmission case with a plastic hammer and remove it HINT: Ai the time of reassembly, please refer to the following item Apply FIPG to the transaxie case side, as shown in the illustration FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent N tO orsMx-21 MANUAL TRANSAXLE (060) — MANUAL TRANSAXLE ASSEMBLY Nw 29, REMOVE OIL RECEIVER PIPE Remove the 2 bolts and oil receiver pipes from the transmission case, ‘Torque: 17 Nm (175 kgt-om, 13 ftlbf) NOTICE: At the time of reassembly, please refer to the following items, + Prevent the oil receiver pipes from being deformed. + Install the oil receiver pipes while placing it against the transmission case, as shown in the Illustration. 30, REMOVE REVERSE SHIFT ARM BRACKET Remove the 2 bolts and reverse shift aim bracket. Torque: 17 N-m (175 kgf.cm, 13 fbf) At the time of reassembly, please refer to the following items, + Set the pin on the top of the reverse shitt arm into a groove on the reverse idler gear. + Fit the claw of the reverse shift arm bracket with the notch of the input shaft front bearing. 31. REMOVE REVERSE IDLER GEAR, THRUST WASHER AND SHAFT NOTICE: At the time of reassembly, please refer to the following item. Install the reverse idler gear, thrust washer and shaft, as shown in the illustration, 32. REMOVE GEAR SHIFT FORK SHAFT SNAP RING Using 2 screwativers and a harmimer, tap out the 2 snap rings from the No. 1 and No. 3 gear shift fork shafts.Mx-22 MANUAL TRANSAXLE (C60) _—_ MANUAL TRANSAXLE ASSEMBLY ey : a 33. REMOVE NO. | GEAR SHIFT HEAD, NO. 1 AND NO. 2 GEAR SHIFT FORKS 3 SET BOLTS Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 16 N-m (160 kgf-om, 12 ft-lbf) NOTICE: At the time of reassembly, please refer to the following item. Make sure that the 3 gear shift heads are positioned, as ‘shown in the illustration. 34, REMOVE NO. 2 GEAR SHIFT FORK SHAFT Remove the No. 2 gear shift fork shatt from the No. 2 gear shift fork, No. 1 gear shift head, No. 1 gear shift fork, reverse shift tork and transaxle case. 35. REMOVE NO. 1 GEAR SHIFT FORK SHAFT Remove the No. 1 gear shift fork shat from the No. 1 gear shift fork and transaxle case. 36. REMOVE NO, 1 GEAR SHIFT HEADMx-23 MANUAL TRANSAXLE (G60) — MANUAL TRANSAXLE ASSEMBLY y sori 97, REMOVE NO. 1 GEAR SHIFT FORK FROM REVERSE GEAR GROOVE 38. REMOVE NO. 3 GEAR SHIFT FORK SHAFT AND RE- VERSE SHIFT FORK (a) Remove the No. 3 goar shift fork shaft from the reverse shift fork and transaxle case. () Remove the reverse shift fork: 99. REMOVE NO. 2 GEAR SHIFT FORK FROM NO. 2 HUB SLEEVE GROOVE 40. REMOVE INPUT AND OUTPUT SHAFTS TOGETHER FROM TRANSAXLE CASE 41, REMOVE DIFFERENTIAL CASE ASSEMBLY NOTICE: At the time of reassembly, please refer to the following item, Before reassembly, inspect the differential tapered roller bearing preload, (See page MX~52) 42, REMOVE MAGNET FROM TRANSAXLE CASE 43. DISASSEMBLE NO. 3 CLUTCH HUB ASSEMBLY {a) _ Using @ screwdriver, remove the 2 shifting key springs. NOTICE: At the time of reassembly, please refer to the following item, Position the shitting key springs so that their end gaps are not aligned. (b) Remove the 3 No. 3 shifting keys from the No. 3 clutch hub,Mx-24 MANUAL TRANSAXLE (C50) _—_ MANUAL TRANSAXLE ASSEMOLY. INSPECTION 1, INSPECT 5TH AND 6TH GEARS SYNCHRONIZER RING (a) Gheck for wear or damage, (b) Check the braking effect of the synchronizer ring, Turn the synchronizer fing in one direction while pushing it to the ‘gear cone. Check that the ring locks. if tha braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together. NoTICI Ensure the fine lapping compound is completely washed off after rubbing. (c) Check again the braking effect of the synchronizer ting. (a) Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.75 mm (0.0295 in.) If the clearance is less than the minimum, replace the synchronizer ring, and apply a smalt amount of the fine lapping compound on gear cone. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. 2. INSPECT GEAR SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and gear shift fork. ‘Maximum clearance: 0.89 mm (0.035 in.) If the clearance exceeds the maximum, replace the gear shill fork or hub sleeve. 3. REMOVE TRANSAXLE CASE RECEIVER Remove the bolt and transaxle case receiver from the transaxle IF NECESSARY, REPLACE INPUT SHAFT FRONT BEARING AND OIL SEAL Using SST, remove the input shaft front bearing. SST 09612-65044MX-25 MANUAL TRANSAXLE (080)_—_ MANUAL TRANSAXLE ASSEMBLY. (b) Using a screwdriver, remove the oil seal (c) Using SST and a hammer, drive in a new oil seal, SST 09950-60010 (09951-00360), 69950-70010 (09951-07150) Drive in depth: 15.8 + 0.2 mm (0.622 + 0.008 in.} (@) Coat the tp of the oil seal with MP grease. (2) Using SST and a press, install a new input shatt front bearing, SST 09950-60010 (09951-00400), 09960-70010 (99951-07150) Drive in depth: 0 — 0.3 mm (0 ~ 0.012 In.) NOTICE: ‘Be sure to install a new bearing in the correct direction, as. shown in the illustration, 5. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING AND OUTPUT SHAFT COVER (a) Remove the bolt and bearing tock plato. (©) _ Using SST, pull out the output shaft front bearing SST 09308-00010 {e) Remove the output shaft cover. (¢) _ Install the output shat cover, NOTICE: Install the output shaft cover projection into the case side holiow.MX-26 MANUAL TRANSAXLE (C60) ___ MANUAL TRANSAXLE ASSENDEY (e) Using SST and a press, install a new output shaft front bearing. SST 09950-60010 (09951-00560), 08950-70010 (99951-07150) NOTICE: Be sure to install a new bearing in the correct direction, as shown in the illustration. () Install the bearing lock plate with the boll Torque: 11 N-m (115 kgf-cm, 8 tt-lbt) 6. INSTALL TRANSAXLE CASE RECEIVER install the transaxle case receiver to the transaxle case with the bolt. Torque: 11 N.m (115 kaf-cm, 8 ft-bt) 7, IF NECESSARY, REPLACE TRANSMISSION CASE BUSHING (a) _ Using a socket wrench (12 mm), extension bar and plastic hammer, drive out the bushing. NOTICE: ‘When driving out the bushing, be careful not to damage the transmission case by the socket wrench. (®) Using SST and a hammer, drive in a new bushing. SST 09950-60010 (09951-00180), 09950-70010 (09951-07100) Drive in depth: 0.80 — 1.30 mm (0.0315 ~ 0.0512 In.) 8. IF NECESSARY, REPLACE TRANSMISSION CASE OIL SEAL (@) Using a screwdriver and hammer, drive out the oll seal.Mx-27 MANUAL TRANSAXLE (C60)_— MANUAL TRANSAXLE ASSEMBLY. Plastic Hammer Socket Wrench | 10.0 * 0.9 mn tb) oF Using a socket wrench (17 mm) and plastic hammer, drive in a new oi seal. Drive in depth: 10.0 + 0.3 mm (0.394 + 0.012 in.) Coat the lip of the oit seal with MP grease.MX-28 MANUAL TRANSAXLE (C50) _—__ MANUAL TRANSAXLE ASSEMBLY REASSEMBLY Reassembly is in the reverse order of disassembly. (See page MX~12) NOTICE: When working with FIPG material, you must observe the followings. Using a razor blade and gasket scraper, remove all old FIPG material from the gasket surfaces. Thoroughly clean all components to remove ali loose material. + Clean both seating surfaces with a non-residue solvent. Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface. Parts must be assembled within 10 minutes of application, Otherwise, the FIPG materiat must be removed and reapplied. HINT: Goat all of the sliding and rotating surfaces with gear oil before reassembly.Mx-29 MANUAL TRANSAXLE (050)__—_ INPUT SHAFT INPUT SHAFT COMPONENTS Needle Rotfer Bearing No. 2 Synchronizer Ping (For 3rd Gear) No. 2Hub Sleeve No. 2 Syachronizer LP Ring (For 4th Gear) ‘Snap Ring 3rd Gear } [Spacer vs 2 85 CD coer sae oe * q tr ‘> No.2 Shiting Key Spring | 6 No. 2 Cute Hub S Needie Roller Bearing} an Gea Cee Sc RingMX-30 MANUAL TRANSAXLE (060) _—_INPLU-SHAPT DISASSEMBLY 4, INSPECT 3RD AND 4TH GEARS THRUST CLEAR- ANCE Using a feeter gauge, measure the thrust clearance. Standard clearance: 3rd gear: 0.10 — 0.35 mm (0.0039 - 0.0138 in.) 4th gear: 0.10 ~ 0.55 mm (0.0039 ~ 0.0217 in.) Maximum clearance: Std gear: 0.35 mm (0.0138 in.) 4th gear: 0.55 mm (0.0217 in.) 2. INSPECT 3RD AND 4TH GEARS RADIAL CLEAR- ANCE Using 2 dial indicator, measure the radiat clearance between the gear and shaft. Standard clearance: KOYO made: 0.015 - Maximum clearance: KOYO made: 0.058 mm (0.0023 in.) NSK made: 0.056 mm (0.0022 in.) It the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft. 3. REMOVE SNAP RING Using 2 screwdrivers and a hammer, tap out the snap ring. HINT: “Take care not to damage the journal surtace of the input shaft REMOVE CENTER RADIAL BALL BEARING, 4TH GEAR, NEEDLE ROLLER BEARING, SPACER AND NO. 2 SYNCHRONIZER RING (FOR 4TH GEAR) FROM INPUT SHAFT (a) Using SST and a press, remove the center radiat ball bearing and 4th gear. SST 09950-00020 HINT: ‘Support the input shaft assembly by hand so that it wif not be dropped offMX-31 MANUAL TRANSAXLE (C60)_~_ INPUT SHAFT (o) 5. Remove the needie roller bearings, spacer and No. 2 syn- ‘hronizer ring (for the 4th gear), REMOVE SNAP RING Using 2 screwdrivers and a hammer, tap out the snap ring, HINT: ‘Take care not to damage the journal surtace of the input shaft. 6 (a) REMOVE NO. 2 HUB SLEEVE ASSEMBLY, 3RD GEAR, NO. 2 SYNCHRONIZER RING (FOR 3RD GEAR) AND NEEDLE ROLLER BEARING Using SST and a press, remove the No. 2 hub sieeve assembly, 3rd gear and No. 2 synchronizer ring (for the 3d geen) SST 09950-00020 HINT: ‘Support the input shaft by hand so that itwill nol be dropped oft {b) % (a) (b) Remove the needle ralter bearings, DISASSEMBLE NO. 2 HUB SLEEVE ASSEMBLY Remove the No. 2 bub sleeve from the No. 2 clutch hub. Remove the 3 No. 2 shifting keys and No. 2 shifting key springs trom the No, 2 clutch hub.MX-32 MANUAL TRANSAXLE (C60)_—_INPUT SHAFT INSPECTION 1, INSPECT SYNCHRONIZER RING {@) Check for wear or damage. {b) Check the braking effect of the synchronizer ring, Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ting locks Ii the braking effect is insufficient, apply a small amount of the {ine lapping compound between the synchronizer ting and gear cone. Lightly fub the synchronizer ring and gear cone together. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing, (©) Check again the braking effect of the synchronizer ring, (a) Using a fester gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 3rd gear: 0.65 mm (0.0256 in.) 4th gear: 0.75 mm (0.0295 in.) lithe clearance is less than the minimum, replace the synchro: sizer ring, and apply a small amount of the fine lapping compound on gear cone. NOTICE: Ensure the tine lapping compound is comptetely washed off after rubbing. 2, INSPECT GEAR SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and gear shift fork, Maximum clearance: 0.35 mm (0.014 In.) Iv the clearance exceeds the maximum, replace the gear shift fork or hub sleeve,X33 MANUAL TRANSAXLE (C60) —_ INPUT SHAFT 3, INSPECT INPUT SHAFT {a) Check the input shaft for wear or damage. (©) Using a micrometer, measure the outer diameter of the input shaft journal surface Minimum outer diameter: Part A: 21,991 mm (0.8658 In.) Part B: 24.885 mm (0.8797 in.) Part C: 28.985 mm (1.1411 in.) Part D: 30.985 mm (1.2199 in.) Part E: 24.985 mm (0.9837 in.) the cuter diameter is less than the minimurn, reptace the input shaft for, check the shaft runout. 0.03 mm (0.0012 in.) the runout exceeds the maximum, replace the input shaft.MX-34 MANUAL TRANSAXLE (C80) WwHUT SHAFT REASSEMBLY HINT: cui) | Coat al ofthe sliding and rotating surtaces with gear oil before coassombly. 5 1. ASSEMBLE NO. 2 HUB SLEEVE ASSEMBLY & nd (a) Instalt the 3 No. 2 shifting key springs and No. 2 shifting o keys to the No. 2 clutch hub, (0) _ Install the No. 2 hub sleeve to the No. 2 clutch hub. one] NOTICE: N bozse Assemble the No. 2 hub sleeve and No. 2 clutch hub in the direction shown In the illustration. 2, INSTALL NEEDLE ROLLER SEARING, 3RD GEAR, NO. 2 SYNCHRONIZER RING (FOR 3RD GEAR) AND NO, 2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT. {a} Apply gear oil to the needle roller bearings and install it. (b} install the 3rd gear and No. 2 synchronizer ring (for the 3rd gear) NOTICE: Distinguish the No.2 synchronizer ring (for the 3rd gear) by the teeth on the synchronizer ring. (c) install the No. 2 hub sleeve assembly so that the No. 2 synchronizer ring slots and No, 2 shifting keys are aligned. NOTICE: Be sure to install the No. 2 hub sleeve assembly In the correct direction, as shown in the illustration. (@)__Using a press, install the No. 2 hub sleeve assembly.MX-35 MANUAL TRANSAXLE (C60) — INPUT SHAFT 3. INSTALL SNAP RING (a) Select a snap ring from the table below that will make the thrust clearance of the No. 2 clutch hub less than 0.1 mm (0.0089 in.) Mark] Tckwess mm gn} [tam | thicknase romten) o 2.30 (0 0906) a 2.48 0.0976), 2.36 (0.0909) 4 234 (0.1000) 2 292 (00953) 2 2.69 (0.1029) (©) _ Using a screwdriver and hammer, tap in the snap ring HINT: ‘Take cate not to damage the journal surface of the input shaft. 4, INSPECT SRD GEAR THRUST CLEARANCE (See page MX-30) 5. INSTALL SPACER, NEEDLE ROLLER BEARING, NO. 2 SYNCHRONIZER RING (FOR 4TH GEAR), 4TH GEAR AND CENTER RADIAL BALL BEARING fa) Instail the spacer. (b) Apply gear oif to the needle roller bearings and install it. (©) Place the No. 2 synchronizer ring (for the 4th gear) on the No. 2 hub sleeve assembly and align the No, 2 synichro- nizer ring slots with the No. 2 shifting keys. (a) _ Install the 4th gear. NOTICE: Distinguish the No. 2 synchronizer ring (for the 4th gear) by the teeth on the synchronizer ring. (e) Using SST and a press, install the center radial ball bearing. sST 09608-00071 NOTICE: Be sure to install the center radiai ball bearing in the correct direction, as shown in the illustration. HINT: Sel SST to the bearing inner race securely.MX~36 MANUAL TRANSAXLE (C60)_—_INPUT SHAFT 6. INSTALL SNAP RING {a} Select a snap sing from the table below that will make the thrust clearance of the center radial ball bearing less than 0.4. mm (0.0039 in.) Wark | _Theknoss_mem in) [Mame [Thickness mm fin) 2.29 0.0909) ° 247 (0972) 2.95 (0928), E 2.69 (.0096) a 2.47 10.0049) E 259,0.1920)| (©) Using a screwdriver and hammer, tap in the snap ring. HINT: ‘Take care not to damage the journal surface of the input shat. 7. INSPECT 4TH GEAR THRUST CLEARANCE (See page MX-30)MANUAL TRANSAXLE (069) —_ OUTPUT SHAFT OUTPUT SHAFT COMPONENTS Mx-37 Front Bearing Inner Race | ns sea ote Beg ® 1st Gear Snap Ring No. 1 Synchronizer Ring ? i Q Reverse Gear Ourput Shaft 1stGear Thrust Washer Needle Rolier Boating No. 1 Shiting Key Spxing No. 1 Shitting Key oe to. can Dbo ad Oven mi ‘Snap Ring Output Gear Spacer Spacer No. 2 Synchronizer Ring 4th Driven Gear Center Radial Ball BearingMx-38 MANUAL TRANSAXLE (CHO)_-_QUTPUT SHAFE DISASSEMBLY 1, INSPECT 1ST AND 2ND GEARS THRUST CLEAR- ANCE Using a feeler gauge, measure the thrust clearance. Standard clearance: 1st gear: 0.10 — 0.40 mm (0.0039 — 0.0187 in.) 2nd gear: 0.10 — 0.55 mm (0.0039 - 0.0217 in.) Maximum clearance: ‘4st gear: 0.40 mm (0.0157 in.) and gear: 0.55 mm (0.0217 in.) 2, INSPECT 1ST AND 2ND GEARS RADIAL CLEAR- ANCE Using a dial indicator, measure the radial clearance between the gear and shaft Standard clearance: KOYO made: 0.015 — 0.058 mm (0.0006 ~ 0.0023 in.) NSK made: 0.015 - 0.056 mm (0.0006 - 0.0022 in.) Maximum clearance: KOYO made: 0.058 mm (0.0023 In.) NSK made: 0.056 mm (0.0022 in.) If the clearance exceeds the maximum, replace the gear, needle roller beating or shaft 3, REMOVE CENTER RADIAL BALL BEARING, 4TH DRIVEN GEAR AND OUTPUT GEAR SPACER FROM OUTPUT SHAFT {a} Using SST and a press, remove the center radial ball bearing and 4th driven goar SST 09950-00020 HINT: ‘Suppor the output shaft assembly by hand so that it will not be dropped off. (b) Remove the output gear spacer.x39 MANUAL TRANSAXLE (C60) —_ QUTPUTSHAEE 4. REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE ROLLER BEARING, SPACER AND NO. 2 SYNCHRO- NIZER RING (a) _ Shifl the reverse gear into the 1st gear. (0) Using SST and a press, remove the 3rd driven gear and 2nd gear. SST 09950-00020 HIN” Support the output shatl assembly by hand so that it will not bo dropped of (6) Remove the needle roller bearing, spacer and No. 2 synchronizer rings. 5, REMOVE SNAP RING Using 2 screwdrivers and a hammer, tap out the snap ting, HINT. Take care not to damage the journal surface of the output shatt. 6. REMOVE REVERSE GEAR ASSEMBLY, 1ST GEAR, NO. 1 SYNCHRONIZER RING, NEEDLE ROLLER BEARING, 1ST GEAR THRUST WASHER AND BALL (a) Using a press, remove the reverse gear assembly, 1st gear and No. 1 synchronizer ring. HINT: ‘Support the oviput shaft assembly by hand so that it will not be dropped off. (b) Remove the needle roller bearing and ‘st gear thrust washer. (c) Using a magnetic finger, remove the ball. 7. REMOVE SNAP RING Using 2 screwdrivers and a hammer, tap out the snap ring. HINT: Take care not lo damage the journal surface of the output shaftMx~40 MANUAL TRANSAXLE (C60) = OUTPUT SHAFT 8. REMOVE FRONT BEARING INNER RACE Using SST and a press, remove the front bearing inner race. SST 09980-00020 NOTICE: ‘When replacing the front bearing inner race, replace the output shaft front bearing along with it. HINT: ‘Support the output shaft by hand so that i will not be dropped off. 9, DISASSEMBLE REVERSE GEAR ASSEMBLY (a) Remove the reverse gear from the No. 1 clutch hub. {o) Remove the 3 No. 1 shifting keys and No. 1 shitting key springs from the No. 1 clutch hub.Mx-41 MANUAL TRANSAXLE (G50) —_ OUTPUT SHAFT INSPECTION 4. INSPECT 1ST GEAR SYNCHRONIZER RING (a) Check for wear or damage. (©) Cheok the braking effect of the synchronizer ring, Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. {tthe braking effect is insufticient, apply a small amount of the line tapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer cing and gear cone together. NOTICE: Ensure the fine lapping compound Is completely washed off after rubbing. (6) Check again the braking effect of the synchronizer ring (d) Using a teeter gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.75 mm (0.0295 in.) the clearance is tess than the minimum, replace the synchronizer ring, and apply a small amount of the fine tapping compound on gear cone NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. 2. INSPECT 2ND GEAR SYNCHRONIZER RING (@) Check for wear or damage. () Check the braking effect of the synchronizer ring, ‘Turn the synchronizer ring in one direction white pushing ito the gear cone. Check that the ring locks. tthe braking effect is insufficient, replace the synchronizer ring, (c) Using a fecler gauge, measure the clearance between the synchronizer ring back and gear spline end, Minimum clearance: 0.70 mm (0.0276 in.) 4 the clearance is less than the minimum, replace the synchro: rizer ring,x42 MANUAL TRANSAXLE (060) OUIPUT SHAFT a @) ® INSPECT GEAR SHIFT FORK AND REVERSE GEAR CLEARANCE Using a feeler gauge, measure the clearance between the reverse gear and gear shift fork Maximum clearance: 0.35 mm (0.014 in.) It the clearance exceeds the maximum, replace the gear shift {otk or hub sleeve. INSPECT OUTPUT SHAFT Check the output shatt for wear or damage. Using a micrometer, measure the cuter diameter of the output shaft journal surface. Minimum outer diameter: Part A: 32.985 mm (1.2986 In.) Part B: 37.985 mm (1.4955 in.) Part C: 31.985 mm (1.2592 In.) oweu} tthe outer diameter is less than the minimum, replace the out- ©) put shait. Using a dial indicator, check the shaft runout Maximum runout: 0.03 mm (0.0012 in.) if the runout exceeds the maximum, replace the output shaft.Mx-43 MANUAL TRANSAXLE (060) OUTPUT SHAFT REASSEMBLY HINT: Coat ail ofthe sliding and rotating surfaces with gear oli betore reassembly. 1. _ INSTALL FRONT BEARING INNER RACE Using SST and a press, install the front bearing inner race, SST 09223-50010 NOTICE: Be sure to Install the front bearing inner race in the correct direction, as shown in the illustration, 2. INSTALL SNAP RING (a) Select a snap ring trom the table below that will make the thrust clearance of the front bearing Inner race fess than 0.1 mm (0.0039 in). Mark ["Ticknoce wating [Mare [thickness mim tal 7 1.85 (0728) 3 2.05 00807) ® 1900-9748) 4 2 10,0087) n #.9840.0768) 5 2 15 (0. 0eaa 2 20000787), 6 220 10.0966) (0) _ Using a sereweriver and hammer, tap in the snap ring. HINT: Take care not to damage the journal surface of the oulput shaft. 3. ASSEMBLE REVERSE GEAR ASSEMBLY {a) Install the 8 No. 1 shifting key springs and No. 1 shitting keys to the No. 1 clutch hub. (b) _ Install the No. 1 clutch hub to the reverse gear. NOTICE: Assemble the No. 1 clutch hub and reverse gear in the direction shown in the illustration.MANUAL TRANSAXLE (C60) —_QUTPUT SHAET 4, INSTALL BALL, 1ST GEAR THRUST WASHER, NEEDLE ROLLER BEARING, 1ST GEAR, NO. 1 SYN- CHRONIZER RING AND REVERSE GEAR ASSEMBLY TO OUTPUT SHAFT {a) Using a magnetic finger, install he bal to the output shatt. (b) Fit the ist gear thrust washer groove securely over the locking ball when installing the thrust on the output shaft. {c) Apply gear oil to the needle roller bearing and install i {¢) _ Install the 1st gear and No. 1 synchronizer ring NOTICE: Distinguish the No. 1 synchronizer ring by the teoth on the synchronizer ring, (e) Place the reverse gear assembly and align the No. 1 synchronizer ring slats with the No. 1 shifting keys. () Using a press, install thie reverse gear assembly. NOTICE: + Be sure to install the reverse gear assembly in the correct direction, as shown in the illustration. + When installing, make sure that the ball Is placed in a groove of the 1st gear thrust washer. 5. INSTALL SNAP RING (a) Select a snap ring from the table below that will make the thrust clearance of the No. 1 clutch hub less than 0.1 mm (@.0059 in). Bank Townes mine] Maw [Tones amin A 250048) ° 250193085) 3 25661008) € 274108079) 3 220.1095) 5 2.9 0.708 tb) Using a screwdriver and hammer, tap in the snap ring,MX45 MANUAL TRANSAXLE (¢60)_—_ OUTPUT SHAFT For 2nd Gear Middle Ring ‘Syncheonizer HINT: ‘ake care nol to damage the journal surface of the output shaft. 6. _ INSPECT 1ST GEAR THRUST CLEARANCE (See page MX-38) 7. INSTALL SPACER, NEEDLE ROLLER BEARING, NO.2 SYNCHRONIZER RING, 2ND GEAR AND 3RD DRIVEN GEAR {a) Install the spacer. (©) Apply gear oil to the needle roller bearing and insiall (@)_ Place the No. 2 synchronizer rings on the 2nd gear. NOTICE: + Properly fit the synchronizer middle ring claws into the holes in the 2nd gear, + Distinguish the No, 2 synchronizer ring by the teeth on the synchronizer ring. (8) Place the 2nd gear with the No. 2 synchronizer rings and align the No. 2 synchronizer ring slots with the No. 1 shifting keys. NOTICE: Fit the synchronizer inner ring claws into the slots in the No. 1 clutch hub. (©) _ Using a press, install the 3rd driven gear NOTICE: Be sure to install the 3rd driven gear in the correct direction, as shown in the illustration. 8 INSPECT 2ND GEAR THRUST CLEARANCE (See page MX-38)MANUAL TRANSAXLE (060) QUTPUT SHAFT 9. INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN GEAR AND CENTER RADIAL BALL BEARING (a) _ Install the output gear spacer. (b) Using SST and a press, install the 4th driven gear and center radial balt beating. SST 09608-00071 NOTICE: Be sure to install the 4th driven gear and center radial ball bearing in the correct direction, as shown in the illustration. HINT: Set SST to the bearing inner race securely.Mx-47 MANUAL TRANSAXLE (G60) — SHIFT AND SELECT LEVER SHAFT SHIFT AND SELECT LEVER SHAFT COMPONENTS = Shift and Select Lever Shaft Shit 7 No. 2Snittinner Lever No.4 Shift InnerLever pt APD MP orease cessMX88 MANUAL TRANSAXLE (C60) — DIFFERENTIAL CASE DIFFERENTIAL CASE . COMPONENTS # Oil Seal Transavte Case —~ Spacer [FT WOLET M x8 er Boaing anduterR i2@ ¢ Tapered Rotor Beating and Outer Race sai Pn Vehicle Speed Sensor Drive Gear ~ Pinion Shatt mee PO. > Pinion Thrust Washer ‘Thrust Washer a ‘Transmission Case —- #0 Seat [Nm Ibi) |: Specified torque # Non-reusable part je Appiy MP grease _ “alX49 MANUAL TRANSAXLE (C50) DIFFERENTIAL CASE: _-Matchmacks DISASSEMBLY 1. REMOVE RING GEAR (a) Place maichmarks on the ring gear and differential case. (b) Remove the 8 boits. {c) Using a copper hammer, tap on the ring gear to remove il from the differentiai case. Vehicle speed sensor drive gear side: REMOVE TAPERED ROLLER BEARING FROM DiF- FERENTIAL CASE (a) Using SST, remove the tapered rolter bearing SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00350) HINT: Set the claw of SST to the bearing inner race securely. (b) Remove the vehicle speed sensor drive gear. 3. Ring gear side: REMOVE TAPERED ROLLER BEARING FROM DIF- FERENTIAL CASE Using SST, remove the tapered roller bearing, SST 09950-40011 (09951--040%0, 09952-04010, 09953-04020, 09954-04610, 09965-04061, 03957-04010, 09958-04011), 09950-60010 (09951-00350) HINT, Set the claw of SST to the bearing inner race at the position where the differential case is indented, 4, INSPECT SIDE GEAR BACKLASH Using a dial indicator, measure the backlash of one side gear while holding one pinion toward the differential case. Standard backlash: 0.05 — 0.20 mm (0.0020 - 0.0079 in.) It the backlash is not within the specification, install the correct thrust washer to the side gears,MANUAL TRANSAXLE (060) .._ DIFFERENTIAL GAGE 5, DISASSEMBLE DIFFERENTIAL CASE fa) Using a pin punch and hammer, drive out the straight pin {b) Remove the pinion shaft from the differential case. (6) Remove the 2 pinions and side gears with the 4 thrust washers from each gear. 6. Transmission case side: IF NECESSARY, REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE (a) Using SST, pull out the tapered roller bearing outer race and shim. SST 09612-65014 (0) Using SST and a hammer, drive out the oil seal \ | SST 09226-10010 (@} Using SST and a hammer, drive in a new cil seal. SST 09226-10010 Drive in depth: 9.9 & 0.3 mm (0.390 + 0.012 in.) {@) Coat the lip of the oil seal with MP grease. {e) Place the shim into the differential case. 2 Best () Using SST and a press, install the tapered roller bearing outer race. SST 09950-80020 (09951-00710), 09950-70010 (09951-07150) NOTICE: When replacing the tapered roller bearing outer race, replace the tapered roller bearing along with it.MX-51 MANUAL. TRANSAXLE (060) —_ DIEFERENTIAL CASE 1 fa) (b) © id) ‘Transaxle case side: IF NECESSARY, REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE Using a screwdriver and hammer, drive aut the oll seal, Using SST. pull out the tapered roller bearing outer race and spacer. SST 09612-65014 Place the spacer into the differential case. Using SST and a press, install the tapered roller bearing outer race. SST 09950-60020 (09951-00680), 63950-70010 (09951-07150) NOTICE: When replacing the tapered roller bearing outer race, replace the tapered roller bearing along with It. e) (th Using SST and a hammer, drive in a new olf seal. SST 09710-28021 (09710-08041) Drive in depth: 1.9 + 0.3 mm (0.075 + 0.012 in.) Coal the lip of the cit seat with MP grease.MX-52 MANUAL TRANSAXLE (CE0) — DIFFERENTIAL CASE. REASSEMBLY 1. ASSEMBLE DIFFERENTIAL CASE (a) Install the correct thrust washers and side geers. Roter to the table below, select thrust washers which will ‘ensure that the backlash is within the specification. Tr, “9 select washers of the same size for both sides. Standard backlash: 0.05 - 0.20 mm (0.0020 ~ 0.0079 in.) veanaes mith) “Thickness own fa) 0.85 (0.0878) 10,004) 1.99 0.0388) 1.15 (0.5659) 1.05,0.043) zo wore (6) _ Install the thrust washers and side gears in the differential case. (6) tnstall the pinion shaft, {d) Using a dial indicator, check the side gear backlash. ‘Measure the side gear backlash while holding ene pinion toward the differential case. Standard backlash: 0.05 — 0,20 mm (0.0920 0.0079 in.) I the backlash is not within the specification, install a thrust washer of different thickness. {e} Using a pin punch and hammer, drive in the straight pin through the differential case and hoie in the pinion shaft. (f) Using a chisel and hammer, caulk the pin Roles around the circumference of the ditferential case. 2. Ring gear side: INSTALL TAPERED ROLLER BEARING Using SST and a pross, install the tapered roller bearing SST 09350-32014 (09351-32120, 09351-32140) NOTICE: ‘When replacing the tapered roller bearing outer race, replace the tapered roller bearing along with it. HINT: Set SST to the bearing inner race securelyMx-53 MANUAL TRANSAXLE (COD) — DIFFERENTIAL CASE al me 2, Vehicle speed sensor drive gear side: INSTALL TAPERED ROLLER BEARING (a) Place the vehicle speed sensor drive gear in position to stop it turning, and install the vehicle speed sensor drive gear. NOTICE: Be sure to install the vehicle speed sensor drive gear in the correct direction, a shown In the illustration. (0) Using SST and a press, install a new side bearing, SST 09346-60011 (09316-00011), 09350-32014 (09951-32120) NOTICE: When replacing the tapered roller bearing outer race, replace the tapered roller bearing along with it. HINT: Set SST to the bearing inner race securely, 4, INSTALL RING GEAR ON DIFFERENTIAL CASE fa) Clean the contact surtace of the differential case. (2) Heat the ring gear in boiling water. {c} Carefully take the ring gear out of the water. (3) After the moisture on the ring gear has compietely evaporated, quickly install the ring gear to the differential case. HINT: Align the matchmarks on the differential case and contact the ting gear. (e) Temporarily install the 6 set boits. CAUTION: ‘The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently. (After the ring gear has cooted suificiontly, torque the ring gear set bolts uniformly at a time, Torque: 77 Nem (790 kgf-cm, 57 ftlbf) 5. INSPECT DIFFERENTIAL TAPERED ROLLER BEAR- ING PRELOAD NOTICE: Perform this only when reptacing the tapered rolier bearing and outer race of the differential case. (a) Install the differential case assembly to the transaxle case. (©) _ Instat the transmission case to the transaxle case with the 16 bolts. Torque: 29 N-n (300 kgt-om, 22 ft.ibf)MX-54 MANUAL TRANGAXLE (C69). DIVERENTIAL CASE. (c)__ Using SST and a torque wrench, turn the differential case assembly right and lefl 2 or 3 fimes lo allow the bearings to settle SST 09564-92011 (a) Using SST and a torque wrench, measure the proload. SST 09564-32011 Pretoad (at starting): New bearing 0.8 ~1.6Nim (8 — 16 kgf-cm, 6.9~ 13.9 in-tbt) Reused bearing 0.5 ~ 1.0 Nm (5 - 10 kgf.om, 4.3 -8.7 in-Ibf) I the preload is not within the specilication, remove the transmission case side outer race of the tapered roller bearing with SST (See page MX~49}. Select an appropriate shim HINT: ‘The preload will change by about 0.3 ~ 0.4 N-m (3-4 kghom, 2.6 ~ 3.5 in.bf) corresponding to a change of 0.05 mm (0.0020 in.) in shim thickness. Mark Taioerese mm (9) wan | Tripnese em gn) a 2.10 (0.0827) a 2.50 0 1028) ee, 2.15 0.0846) ai 265 (05088), ES 22910-0888) na 2.70 (0.1063), BD 2.25 10.0006) PP. 2.75,0-1089), ee 2.90 (0.0006) 2.80,(0.1102), Fe 2.35 00925), AR. 28510-1122) 68 2.40 (0.0945), 8, 290 (0.1042), 1 2.45 (5.0965) Tt 2.95 0.1969) 2» 2.50 0.0964), uw 300 (0.1184) Ke 2.69 :0.1004) = = (ec) Remove the 16 boils and transmission case. () Remove the differential case assembly.MANUAL TRANSAXLE (060) —__ REVERSE Sir WARNING oUZzER SYSTEM REVERSE SHIFT WARNING BUZZER SYSTEM LOCATION MK-55 Combination Meter (Reverse Shitt Warning Buzzer) Back-Up Light SwitehMaX-56 MANUAL TRANSAXLE (C60)__—_ AEVERSE SHIFT WARMING BUZZER SYSTEK INSPECTION cs 2 INSPECT REVERSE SHIFT WARNING BUZZER SYSTEM (See page BE-46) INSPECT BACK-UP LIGHT SWITCH CONTINUITY (See page BE-30)Mx-57 MANUAL TRANSAXLE (060)_— SHIFTLEVER AND CONTROL CABLE SHIFT LEVER AND CONTROL CABLE COMPONENTS Passenger Aibag Assembiy Front Pilar Garnish Me LE Instrument Panel » te Cowl Side Tim ; 8 —(aeieoa 6 —- Front Door Opening Trim = Finish Pane! = <~ Door Scuff Plate “es Clock — Center Guster ‘Combination Motor Finish Panel Lower No. 1 “@ ._ Panel] E. Heater cont SE, Name Platio~ © Lower Finish “eq. Wiper and Washer a HeaterControlKnob Pane! eae SQN custer Finish Q™ Shit Lover Kaod Vopr caenncr TS oem Upper Console somes @ 5 Panel ring Wt af ; seat Oona Ee ©. 0 Stes 1 Mi Pomer window: ad ~~ Bec ~ Radio fora Camh - @& ‘oom | Junction Block ” Front Door Opening Trim RH End Finish Panel 9 F Heater Control and ws | Accessory Assembly Door Scutf Plate Cow! Side Trim Nein (kgt-om, fibi) |: Specified torque PeMx-58 MANUAL TRANSAXLE (C60) ___ SHIFT LEVER AND CONTRO, CABLE Instrument Panel Heater Hose 4 O.Ring Clamp Pa . Suction Tube! en Clamp No.1 Brace © «4 Blower Unit ‘© Non-sousabie part ooMX-59 MANUAL TRANSAXLE (C60) _—_SHIFF LEVEN AND CONTEOL CABLE Air Cloaner Case Assembly with Air Hose Specified torque iby) ECM Cover Holé-Down 1 Clamp tay ECM Connector ECM Outlet Duct Select Control Cable Washer shit Lover AssombiyMEMO ~AUTOMATIC TRANSAXLE (U240E) AUTOMATIC TRANSAXLE SYSTEM .... VEHICLE SPEED SENSOR SPEED SENSOR - ATF TEMPERATURE SENSOR PARK/NEUTRAL POSITION (PNP) SWITCH . : VALVE BODY ASSEMBLY DIFFERENTIALOIL SEAL... SHIFT LOCK SYSTEM FLOOR SHIFT ASSEMBLY AUTOMATIC TRANSAXLE UMIT . TORQUE CONVERTER CLUTCH AND DRIVE PLATE, Ax aXe AX AX-6. AX8, A190 Ax AX AX? AX-30 AX-36AX AUTOMATIC TRANSAXLE(UZ408)_-._AUTONATIC TRANSAXLE SYSTEM, AUTOMATIC TRANSAXLE SYSTEM PRECAUTION If the vehicie is equipped with a mobile communication system, refer to the precautions in the IN section.AX2 AUTOMATIC TRANSAXLE {U2A0F)_._ AUTOMATIC TRANSAYLE SYSTEN OPERATION Chute (Fa) ist & Reverse Brake (Bz) Forward Clutch (C,) C.. Operating Fawet AX-3. AUTOMATIC TRANSAXLE (U240E) _._VEvEC! E Speen sewSOR VEHICLE SPEED SENSOR ON-VEHICLE REPAIR 1. REMOVE BATTERY 2. REMOVE ECM AND ECM CASE 3. REMOVE ECM BRACKET 4. DISCONNECT VEHICLE SPEED SENSOR CONNEC- TOR 5, REMOVE VEHICLE SPEED SENSOR ASSEMBLY (a) Remove the bot and vehicle speed sensor assembly, (b) Remove the elip and speedometer driven gear trom the vehicle speed sensor. (6) Remove the O-ring from the vehicle speed sensor. 6 INSTALL VEHICLE SPEED SENSOR ASSEMBLY Vehicle Speed Sensor (@) Coat a new O-ring with ATE and install it to the vehicle DrivenGear speed sensor. \ - (0) Install the speedometer driven gear to the vehicle speed ea sensor with clip. Ce ov {c)_ Install the vehicle speed sensor assembiy with the boll. "2 Chip Torque: 5.5 N-m (56 kgf-em, 49 in-Ibf) 7. CONNEGT VEHICLE SPEED SENSOR CONNECTOR: cua] 8 INSTALL ECM BRACKET Torque: Bolt; 18 N-m (185 kgf-cm, 13 ft-Ibf) Nut: 12 N-m (120 kat-om, 9 ft:lbs) 9. INSTALL ECM AND ECM CASE Torque: 6.9 N-m (70 kgf-cm, 6t in-Ibf) 10. INSTALL BATTERYAxa AUTOMATIC TRANSAXLE (U230E) a SQUS =_Serep SENSOR SPEED SENSOR ON-VEHICLE REPAIR 1 2. 3. (o) 6. (a) ib) REMOVE BATTERY REMOVE ECM AND ECM CASE REMOVE ECM BRACKET DISCONNECT INPUT TURBINE SPEED SENSOR CONNECTOR REMOVE INPUT TURBINE SPEED SENSOR Femove the bolt and input turbine speed sensor. Remove the O-ring from the input turbine speed sensor. INSTALL INPUT TURBINE SPEED SENSOR Coat a new O-ring with ATF and install it to the input turbine speed sensor, Instail tke input turbine speed sensor with the bolt Torque: 11 Nim (115 kgt-cm, 8 ft-lbt) CONNECT INPUT TURBINE SPEED SENSOR CON- NECTOR DISCONNECT COUNTER GEAR SPEED SENSOR CONNECTOR REMOVE COUNTER GEAR SPEED SENSOR Remove the bolt and counter gear speed sensor. Remove the O-ring rom the counter gear speed sensor. INSTALL COUNTER GEAR SPEED SENSOR Coal a new O-ring with ATF and instaltit to the counter gear speed sensor. Install the counter gear speed sensor with the bolt Torque: 11 Nem (115 kgt-cm, 8 ftlbf) CONNECT COUNTER GEAR SPEED SENSOR CON- NECTORLE 12, 13. 14. AX-S INSTALL ECM BRACKET Torque: Bolt: 18 N.m (185 kgf-cm, 13 ftlbf) Nut: 12 N-m (120 kgf-em, 9 ft-lb) INSTALL ECM AND ECM CASE ‘Torque: 6.9 N-m (70 kgf-cm, 61 in.) INSTALL BATTERYAUTOMATIC TRANSAXLE (U2H0E) —_AIF [6MPERAIUKE SENSCH ATF TEMPERATURE SENSOR ON-VEHICLE REPAIR 1. DISCONNECT SOLENOID CONNECTOR 2, REMOVE LH ENGINE UNDER COVER 3. REMOVE DRAIN PLUG AND DRAIN ATF 4, REMOVE OIL PAN AND GASKET NOTICE: ‘Some fluid wilt remain in the oil pan. Remove the 18 bolts, and carefully remove the ail pan assembly. Discard the gasket. 5. REMOVE OIL STRAINER fa) Remove the 3 bolts and oi! strainer. (b) Remove the O-ring. 6. DISCONNECT 5 SHIFT SOLENOID VALVE CONNEC- TORS 7, REMOVE ATF TEMPERATURE SENSOR: Remove the bolt and lack plate, and remove the ATF fempara- ture sensor. 8. SEPARATE WIRE HARNESS FROM 2 CLAMPS: 9. CLAMP WIRE HARNESS TO 2 CLAMPS. 10, INSTALL ATF TEMPERATURE SENSOR Install the ATF temperature sensor with the lock plate and bolt. Torque: 6.6 Nem (67 kgt.cm, 88 in.-tb) 41. CONNECT 5 SHIFT SOLENOID VALVE CONNECTORSAUTOMATIC TRANSAXLE (UQ40E) ATE TEMPERATURE SENSOR 12, INSTALL OIL STRAINER (@) Coat a new O-ring with ATE. (b) Insta the O-ring to the ail strainer. (6) Install the aif strainer with the 3 bolts Torque: 11 Nem (110 kgf-cm, 8 ft-bf) 43. INSTALL OIL PAN Instal the oil pan and a new gasket with the 18 bolts. ‘Torque: 7.8 N-m (80 kgf-cm, 69 in.-Ibf) 14. INSTALL DRAIN PLUG Install a new gasket and drain plug. ‘Torque: 49 Nam (500 kgf.cm, 36 ftlbf) 18, CONNECT SOLENOID CONNECTOR 16. FILL ATF AND CHECK ATF LEVEL (See page DI-157) 47. INSTALL LH ENGINE UNDER COVER, Ao v ~ Ae yo FY . oomAK-8 AUTOMATIC TRANSAXLE (U2H06) —_ PAEICNEUTRAL POSITION {PNP) SWITCH PARK/NEUTRAL POSITION (PNP) SWITCH ON-VEHICLE REPAIR 1, REMOVE AIR CLEANER ASSEMBLY 2, DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3, REMOVE PARK/NEUTRAL POSITION SWITCH (a) Remove the nut. tb} Remove the nut, washer and control shill fever. (0) Using a screwdriver, pry off the tock plate. {d)_ Remove the nut and lock plate. {e) Remove the 2 bolts and pull out the parkinautral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH {a} _ Install the park/neutral position switch with the 2 bolts, Torque: 5.4 Nom (55 kgf-cm, 48 in. tf) {b) Install a new fock plate and nut Torque: 6.9 Nm (70 kgt-cm, 61 In.tbf) ‘Bend the claws on the lock pate to fix the aut P ~ wens} (0)Axo AUTOMATIC TRANSAXLE (U240E) ~ _PARIUNEUITRAL POSITION (PNP) SWITCH. Se \e Fhe «fh aN f (d) _ Install the control shift lever with the nut, Torque: 13 N-m (130 kgt-cm, 9 fbf) (€} Connect the contro! cable to the control shaft Torque: 12 N-m (120 kgf-cm, 9 ftibt) 5, CONNECT PARK/NEUTRAL POSITION SWITCH CON- NECTOR 6. CHECK PARK/NEUTRAL POSITION OPERATION Check that the engine can be started with the shift lever only in the Nor P position, but notin other position ifthe engine can not be stated not as started above, carry out the adjustment procedure (See page D!-157) 7. INSTALL AIR CLEANER ASSEMBLY 8 TEST DRIVE VEHICLEA410 AUTOMATIC TRANSAXLE (U249E)_._VALVE BODY ASSEMBLY: VALVE BODY ASSEMBLY ON-VEHICLE REPAIR 1, REMOVE LH ENGINE UNDER COVER 2, REMOVE DRAIN PLUG AND DRAIN ATF 3. REMOVE OIL PAN AND GASKET NOTICE: Some fluid will remain in the oit pan. Remove the 18 bolts, and carefully remove the olf pan assembly. Discard the gasket. 4, EXAMINE PARTICLES IN OIL PAN Remove the magnets and use them te collect any steel chips, Look carefully al the chips and pariicles in the pan and on the ‘magnet fo anticipate what type of wear you wil find in the transaxle. Stee! (magnetic)..bearing, gear and plate wear Brass (non~magnetic)... bushing wear 5. REMOVE OIL STRAINER (a) Remove the 3 bolts and oil strainer. {b) Romove the O-ring. 6 DISCONNECT 5 SHIFT SOLENOID VALVE CONNEC- TORS 7. REMOVE ATF TEMPERATURE SENSOR Remove the bolt and lock plate, and remove the ATF ternpera- ure sensor, 8. SEPARATE WIRE HARNESS FROM 2 CLAMPSAX AUTOMATIC TRANSAXLE (U240E) _—_VAIVE BODY ASSEMBLY 9. REMOVE VALVE BODY Remove the 17 bolts and valve body, NOTICE: Be careful not to drop the check valve body, spring and accumulator piston. 10. REMOVE CHECK BALL BODY AND SPRING 41, REMOVE 3 APPLY GASKETS. 12, REMOVE SHIFT SOLENOID VALVE Remove the § bolts and 5 shit solenoid valves. 13, INSTALL SHIFT SOLENOID VALVE Install the 5 shift sclenoid valves with the 5 bolts, Torque: Bolt A: 6.6 Nem (67 kgf-cm, 58 inIbf) Bolt B: 14 Nem (110 kgf-em, 8 ftbf} Bolt length: Bolt A: 12 mm (0.47 in.) Bolt B: 45 mm (1.77 in.) 14. INSTALL APPLY GASKET (@) Coat 3 new apply gaskets with ATF. {b) Install the gaskets to the transaxte caso.AX-12 AUTOMATIC TRANSAXLE (U240E)_—_VALVE BODY ASSEMBLY 15. INSTALL CHECK VALVE AND SPRING 16. INSTALL VALVE BODY (a) Align the groove of the manual vaive with the pin of the manual vaive lever. (b) Temporarily install the valve body with the 17 bolts. Bolt length: Bolt A: 25 mm (0.98 in.) Bolt B: 44 mm (1.61 in.) Bolt C: 45 mm (1.77 in.) (©) Check that the manual valve lever contacts the center of the roller at the tip of the detent spring. (@ Tighten the 17 bolts. Torque: 11 N.m (110 kgf-om, 8 ft-Ib1) 17. CLAMP WIRE HARNESS TO 2 CLAMPS 18. INSTALL ATF TEMPERATURE SENSOR Install the ATF temperature sensor with the lock plate and bolt. Torque: 6.6 N-m (67 kgf-cm, 58 in..Ibf) 19. CONNECT 5 SHIFT SOLENOID VALVE CONNECTORS: 20. INSTALL OIL STRAINER {a) Coat a new O-ring with ATF. {b) Install the O-ring to the oil strainer.AXA AUTOMATIC TRANSAXLE (U240E)_—_VALVE BODY ASSEMBLY (©) Instali the oll strainer with the 3 bolts. Torque: 11 Nm (140 kgf-cm, 8 fbf) 21. INSTALL MAGNET IN OIL PAN Install the 3 magnets in the oil pan, as shown in the illustration, 22. INSTALL OIL PAN install the oif pan and a new gasket with the 18 bolts. ‘Torque: 7.8 N-m (80 kaf-em, 69 in.-bf) 23. INSTALL DRAIN PLUG Install a new gasket and drain plug, ‘Torque: 49 N-m (500 kagf-cm, 36 ft-lbf) 24, FILL ATF AND CHECK ATF LEVEL (See page DI-157) 25. INSTALL LH ENGINE UNDER COVERAxa AUTOMATIC TRANSAXLE (U2AQE) =. DIEEESENTIAL OIL SEAL DIFFERENTIAL OIL SEAL ON-VEHICLE REPAIR 1. DRAIN ATF FROM FRONT DIFFERENTIAL CASE 2, REMOVE LH AND RH DRIVE SHAFTS: (See page SA-20) 3, REMOVE LH AND RH SIDE OI. SEAL Using SST, drive out both the side oil seals. SST 09308-10010 4. INSTALL LH SIDE OIL SEAL (@) Using SST and a hammer, drive in a new oil seal. SST 03350-32074 (09351-32150), 09950-70010 (09951-07150) Ol seal drive in depth: 2.7 0.5mm (0.108 + 0.0201n.) () Coat the oil seal lip with MP grease. 6. INSTALL RH SIDE OIL SEAL (a) Using SST and a hammer, drive in a new oil seal. SST 09223-00010 Oil seal drive in depth: 0 + 0.5 mm (0 * 0.020 in.) (b) Coat the oil seal tip with MP grease. 6, INSTALL LH AND RH DRIVE SHAFTS (See page SA-32) 7. FILL ATF AND CHECK ATF LEVEL (See page 01-157}AX15 AUTOMATIC TRANSAXLE (U240F) SHIFT LOcK SySTEM SHIFT LOCK SYSTEM COMPONENTS Stop Light Switch 8 Shit Lack Control Unit Assembly wesAX16 AUTOMATIC TRANSAXLE (U240E)_-_SHIFE LOOK SYSTEM INSPECTION INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY Using a voltmeter, measure the voltage at each torminal. HINT: Do not disconnect the shift lock control unit assembly con “ec- to “eeminat ensuring Corson Yoraie W) S16) ion seach ON wo-14 BoAISTP_£) | Qepressing brave peda gaAXAT AUTOMATIC TRANSAXLE (U240E)__—_ FLOOR SHIET ASSEMBLY. FLOOR SHIFT ASSEMBLY COMPONENTS ~~ Roinforcoment Front Pilar Garnigh _ post Ai hey ee ~~ Front Door Cow Side Trim Opening Tern No. 1 Brace Door Seutt SS Dod rl Bord or) Bort) Lower Finish Panel Instrument ae s Combination Moter Finish Panel Heater Contsal Name Plate Sciusier Finish Panel Lower No. 1 C¥*r sieotg Wet Fr Paoe! A ar Spiral Cable, Headigh Dimmer Switch ~~ Upper Console Panel Lower Gotan ~ Go® Cover 3 re Ponas ndo Y Power inion th Front PilarGamish Radi ; lato FrontDoor Opening Trim Heater Console ana Accessory Assembly LH End Finish Panel Door Sef Pale mW bl: Species torque Console Box CowiSide ad [> [iAX418 AUTOMATIC TRANSAXLE (U2406) FLOOR SHIFT ASSEMBLY Heater Hoses Clamp # Non-reusable part 0m Key Interlock Cable _ Flocr Shit Assemb [im Rotem, Bh ] : Specitiod torque ¥ rnsax AUIOMANC TRANSAXLE (U240E) FLOOR SHIFT ASSEMBLY HINT: Screw shapes and sizes are indicated in the table below. The codes ("A’~"N") correspond to those indicated on the previous page. eau Shape Size Size ize o| (fem | 2 fo) Cite | 2 Jo) (itm | bs (0.63) (0.59) (0.87) FI o-8 o-e | | 9-520 eee fe 02 (0) (fem (0.63) |, or | I | T ~ | e-8 | | a= 2 |o| Crane 2%, 02 fo) (hm | he (0.55) | (@.83) |Ax20 AUTOMANIC TRANSAXLE (U2t0E) FLOOR SHIFT ASSEMBLY Slide Cover Shift Lock Release Button Lower Position n_*_Precoated past Indicator housing ‘Shaft Control Upper Position Indicator Housing Sleeve Control Position Indicator Plate Shift Levee Kaob Shift Lever Knob Button Guide Psi Loo mat lar be. ae—9, ui ‘ Indicator Lamp Wire Sub-assembly Shift Lever Knob Button ‘Shift Lever Knob g— Gompression ng Shit Lover Stop Pin 0/0 Main Switeh Manual Detent Spring : Grooyed Pin| Shift Lever Sub-assembiyAX-21 AUTOMATIC TRANSAXLE (W240E} — FLOOR SHIFT ASSEMBLY REMOVAL 1 2 3. fa) (b} fo @ 4. fa) (b) © REMOVE INSTRUMENT PANEL (See page BO-79) REMOVE AIR CONDITIONING UNIT (See page AC-26) REMOVE KEY INTERLOCK CABLE Remove the cable end from the rod of the floor shift assembly, Pull out the cable while pressing the olip of the key interlock cable. With the key in ACC, remove the cable cap claw from the key interlock and pull it. Disconnect the 2 key interlock cable clamps. REMOVE FLOOR SHIFT ASSEMBLY Disconnect the 2 connectors, Disconnect the 2 wire harness clamps from the floor shift ‘assembly. Remove the 4 bots from the floor shift assembly,AK-22 AUTOMATIC TRANSAXLE (U2008)_—__ FLOOR SHIET ASSEMBLY (d) Remove the cable end from the rod of the floor shift assembly. (@) Pull out the cable while pressing the clip of the transaxle contro} cable. (f) Remove the tloor shift assembly.Ax 23 AUTOMATIC TRANSAXLE (U2W0E) -_fLOOR SHIFT ASSENBLY DISASSEMBLY 1, REMOVE O/D MAIN SWITCH TERMINAL (@)_ Remove the O/D main switch connector from the shift le ver plate. (b) Disengage the secondary locking device. {o) Release the locking log of the terminals 5 and 6, and pull the terminals out from the rearward 2, REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY fa} Remove the 2 screws and shift ever knob sub-assembly, NOTICE: Pay attention not to apply unnaturai load to O/D main switch wire harness. (b) Remove the O/D main switch. (©) Remove the No. 2 slide cover. (6) Remove the shift lever stop pin, shifl tever knob button, shift lever knob button guide and compression spring, . REMOVE UPPER POSITION INDICATOR HOUSING (a) Remove the upper position indicator housing. (0) Remove the control position indicator piate (c) Remove the 4 slide covers from the lower positian indica- {or housing 4, REMOVE LOWER POSITION INDICATOR HOUSING (a) Remove the indicator lamp wire sub-assembly. (0) Remove the 4 screws and iowet position indicator housing, (©) Remove the bulb cap and bulb from the indicator tamp wire sub-assembly, (@) Remove the screw and indicator lamp wire sub-assem- by. (2) Remove the shift lock release button and spring,AX-24 AUTOMATIC TRANSAXLE (U2t0r) — LOOM SHHFT ASSEMBLY 6. REMOVE SHIFT LOCK UNIT Remove the 2 screws and shift lock unit. 6. REMOVE SCREW AND MANUAL DETENT SPRING 7. REMOVE SHIFT LEVER SUB-ASSEMBLY Using a screwdriver and hammer, drive off the shaft control while disongaging the claw of the shall control and remove the shift ever sub-assembly. 8 REMOVE DETENT ROD (a) Seta 14 mm doep socket wrench, ib) Using a punch and hammer, remove the grooved pin, (@)_ Remove the detent rod and spring, {d) Remove the shift lever knob sleeve from the detent rod, 9. REMOVE COLLARS Using a screwdriver and hammer, remove the 4 collars.AK-25, AUTOMATIC TRANSAXLE {U2406) FLOOR SitFT ASSEMILY Shift Lever Sub-assembly = Detent Rod — — —- Grooved Pin REASSEMBLY 1, INSTALL COLLARS 2. INSTALL DETENT ROD {a) Install the shift lever knob sleeve to the detent rod. tb) Apply MP grease on the detent rod and spring. (©) install the spring and detent rod. (d) Using 2 punch and hammer, install the grooved pin to the detent rod pin hole. A: 8.0 + 0.2 mrn (0.315 + 0.008 in.) le) Check the detent rod operation. 3. INSTALL SHIFT LEVER SUB-ASSEMBLY (a) Apply MP grease on the spring {b) install the shift lever sub-assembly and shaft control to shift lever plate HINT: ‘Check that the claw of the shaft control is fit onto the shifl lever plate 4, INSTALL MANUAL DETENT SPRING AND SCREW (a) Apply MP grease to the parts indicated by the arrows manual detent spring and shift lever plate in the fllustra- tion, {b) Install the manual detent spring with the sorew. 5, INSTALL SHIFT LOCK UNIT Install the shift lock unit with the 2 screws.AX-26 AUTOMATIC TRANSAXLE (2406). F.COR SHIFT ASSEMBLY 6 INSTALL LOWER POSITION INDICATOR HOUSING (@) Apply MP grease on the spring. {b) Install the spring and shift lock release button. {c) Install the indicator lamp wire sub-assembly with the screw. (2) Install the bulb and bulb cap to the indicator lamp wire sub-assembly. {e) Install the lower position indicator housing with the 4 screws. {) Install the indicator tamp wire sub-assembly. 7. INSTALL UPPER POSITION INDICATOR HOUSING (a) Instali the 4 slide covers to the lower position indicator housing, as shown in the illustration (©) Install the control position indicator plate, (©) Install the upper position indicator housing. 8 INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (a) Apply MP grease on the compression spring, (b) Install the compression spring, shift lever knob button guide, shift lever knob button and shift fever stop pin, {c) Install the No. 2 slide cover. (d)__ Install the O/D main switch. (@} Install the shift lever knob sub-assembly with the 2 screws. HINT: Coat the threads of screws with sealant. Sealant: oS Part No. 08833-00080, THREE BOND 1344, LOCTITE nfs aN pases 242 or equivalent NOTICE: Make sure not to catch 0/D main switch wire harness. 9. INSTALL O/D MAIN SWITCH TERMINAL {a) Connect the 2 O/D main switch terminals to the connector. {®) Connect the connector to the shift lever plate.AX27 AUTOMATIC TRANSAXLE (U2405) — FLOOR SHIFT ASSEMBLY INSTALLATION 1. INSTALL FLOOR SHIFT ASSEMBLY (@) Pull in the cable while pressing the clip of the transaxle control cable to the floor shift assembly. (©) _ Install the cable end from the rod of the floor shift assem- by. {e) Install the floor shitt assembly with the 4 bolts. Torque: 12 N.m (120 kgt-cm, 9 tIbt) (d) Connect the 2 wire harness clamps from the floor shift assembly. {e) Connect the 2 connector. 2. INSTALL KEY INTERLOCK CABLE (a) Pass the key interlock cable end through the hole in the floor shift assembly. ‘HINT: Make sure that the claws shown by the arrow in the illustration are locked. (b) With the shitt iever in N position, set the hole of the cable end to the floor shift assembly to assembie them. (c)_Atthe time of reassembiy: With the key in ACC, push a claw into lock key. At this time, be careful not to apply undue force on bending to the cable (Cable length adjustment is completed). HINT, Check that the key lock cam is contact with the cam stopper. (4) With the key in ACC, install the cable cap claw to the key interlock.AX-28 AUTOMATIC TRANSAXLE (2306) — FLOOR SHIFT ASSEMBLY With the brake pedal depressed, shift while holding the lock re= tease bution in. (The ignition switels must be in ON position) Shift while holding the tock release button in, Shift normally e) ) 4 (ay {b). (c} © fe) 6 fa Connect the 2 Key interlock cable clamps. Pullin the cable while pressing tho clip of the key interlock cable. INSTALL AIR CONDITIONING UNIT (See page AC-29) INSTALL INSTRUMENT PANEL (See page BO-85) INSPECT KEY INTERLOCK AND SHIFT LOCK OP- ERATION Check that a key can be turn trom ACG to LOCK enly when the shift lever is in P position. Check that the key cannot be tured to LOCK when the shift lavar is position in other than P position. When the ignition key is in LOCK, check that pressing the shifl release buiton enables the shift lever to shift from P position to other positions. When shifting it to each position, make sure that the shitting lever moves smoothly, can be moderately operated and the position indicator displays correctly. Positions which can be operated without pressing the shift lever knob button RoN>DoM5D,L>2505N Positions which can be operated only while pressing the shift lever knob button D+ 2oLNoROP Positions which can be operated only while pressing the shift lever knob button, ignition switch ON and brake pedal depressed Pon When starting the engine make sure that the vehicle moves forward when shifting form N to D position, and moves rearward when shitting to R position. ADJUSTMENT IN CASE OF MALFUNCTION ‘When the key can not be turned from ACC to LOCK even though the shitt lever is in P position: This is the condition where the cable end on the ignition key side is not retumed to the position where it can be locked. The condition is caused by undue bending of the cable, rotative resistance of the pin on the shift lever side, 7 increased resistance due to any reason such as twist- ing of the cable. Reinstall and readjust the key interlock cableow AUTOMATIC TRANSAXLE (U2406)__—_ FLOOR SHIFT ASSEMBLY ace (©) When the key is tumad from ACG to LOCK even though the shift lever is in other than P Position: Since the cable is too long due to improper adjustment at the automatic adjustment part of the key can nol be locked. Readjust the key interlock cable. 7. _READJUSTMENT OF KEY INTERLOCK CABLE HINT: Assembly shall be undertaker in the same way as step 2 (a) Using a screwdriver, unlock the claw at the lock Key of the automatic adjustment part. (b) Remove the key interlock cable end from the rod of the floor shift assembly. (6) Pull out the cable while pressing the clip of the key inter lock cable. ()_ Remove the cable clamp from the other, fe) With the key in AGC, install the cable cap claw to the key interlock.AX-30 AUTOMATIC TRANSAXLE (2408) _— AUTOMATIC TRANSAXLE UNIT COMPONENTS \IOMATIG TRANSAXLE UNIT No. 2 Gylinder Head Cover ae ECM Bracket 650,47) 38,165.79) ] tl ari oy ‘Torque Converter Clutch (Bee) Seg se ot Cooler, (3776.20) Je, Hose NSD ioe ‘Control Cable- RH Engine Under Cover Pressure Plug Suspension Member ee | Center Engine UniderCover LH Engine Under Gover [Nem tkat'em, AAbH |: Species torque nv_# Not--reusable part Sa. Vee > “Test For Line - ° Insulator sce # Snap ons ~—(7 ew] Sh LH Drive Shaft >>. Gear Assombly {~ fo EES) ‘e879 ] [R6i66.58))] <._..Engine Left Mounting J Ae pyacket Engine Rear MountingAX AUTOMATIC TRANSAXLE {U240F) AUTOMATIC TRANSAXLE UN REMOVAL 1. REMOVE HOOD Torque: 13 N-m (130 kgf-cm, 9 ft-tbf) 2. REMOVE BATTERY 3, REMOVE ECM AND ECM CASE Torque: 6.9 N-m (70 kgf-cm, 61 in.-tbf} 4. REMOVE ECM BRACKET Torque: Bolt: 18 Nem (185 kaf-cm, 13 fl.tbf) Nut: 12 Nam (120 kgfem, 9 ftibt) REMOVE AIR CLEANER ASSEMBLY REMOVE NO. 2 CYLINDER HEAD COVER Torque: 7.0 Nim {71 kgt-cm, 62 in.ibf) pe 7. REMOVE 2 GROUND CABLES Torque: 18 Nim (185 kgf.cm, 13 ftbf) 8, DISCONNECT CONTROL CABLE FROM CLAMP 9. DISCONNECT INPUT TURBINE SPEED SENSOR CONNECTOR 10. DISCONNECT COUNTER GEAR SPEED SENSOR CONNECTOR 11. REMOVE VEHICLE SPEED SENSOR CONNECTOR awa! We 12, REMOVE 2 UPPER SIDE TRANSAXLE MOUNTING BOLTS FROM TRANSAXLE ‘Torque: 64 N-m (650 kgf-cm, 47 ftlbf) 13. DISCONNECT SOLENOID CONNECTOR AND PARK! NEUTRAL POSITION SWITCH CONNECTOR Disconnect the solenoid connector and paridneutrat position switch connector. 14, DISCONNECT CONTROL CABLE (a) Remove the nut from the control shift lever. Torque: 12 N.m (120 kgf-om, 9 ftlbf) (b) Remove the clip and disconnect the control cable.AUTOMRNC TRANSAXLE (U2H0E) — AUTOMATIC TRANSA UNIT 15. REMOVE BOLT AND DISCONNECT RADIATOR RES- ERVOIR: Torque: .9 Nam (50 kgf.om, 43 in.-bf) 16. REMOVE STARTER (a) Romave the nut and wire, and disconnect the connector. (b) Remove the 2 bolts and starter. ‘Torque: 37 N-m (378 kgt-cm, 28 ft-Ibf) 17. REMOVE LH, RH, CENTER ENGINE UNDER COVERS: 18. DRAIN ATF FROM FRONT DIFFERENTIAL CASE Torque: 54 N-m (550 kof-cm, 40 ftlbf) 19. REMOVE LH AND RH DRIVE SHAFTS. (See page SA-20) 20. DISCONNECT LH AND RH STABILIZER BAR LINKS FROM SHOCK ABSORBER Torque: 44 Nem (450 kgf-cm, 32 ft-Ibf) 21, REMOVE 4 BOLTS AND DISCONNECT PS GEAR AS- SEMBLY HINT: ‘Support the PS gear assembly securely. Torque: 45 Nem (459 kgf-cm, 33 fbf)AX-33 AUTOMATIC TRANSAXLE (U2806)_~ _ALIOMATIC TRANSAXLE UNIT 22, REMOVE SUSPENSION MEMBER (2) Remove the 9 bolts and 3 nuts. Torque: Bolt A: 157 Nem (7,601 kgt-cm, 116 tt1bf) Bolt B: 52 N-m (530 kgf-cm, 38 ftlbf) Bolt C: 39 N.m (398 kgt-cm, 29 fbf) Nut: 2 Nem (530 kgf-cm, 38 tllbf) (b) Remove the suspension membar. 23. REMOVE ENGINE REAR MOUNTING INSULATOR Remove the bolt and engine rear mounting insulator. Torque: 87 N.m (890 kgf-cm, 64 ft-bf) 24, ATTACH ENGINE SLING DEVICE TO ENGINE HANG- ERS (@) Disconnect the 2 PCV hoses. (©) _ Install the No. 1 and No. 2 engine hangers in the correct, direction. Parts No. = No. 1 engine hanger: 12281-88600 No. 2 engine hanger: 12282-88600 Bolt: 91512-61020 Torque: 38 N-m (387 kgf-cm, 28 fbf) (c} Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.AX-34 AUTOMATIC TRANSAXLE (U2408) AUTOMATIC TRANSAXLE UNIT 25, REMOVE UPPER SIDE ENGINE LEFT MOUNTING, NUT AND BOLT Torque: 80 N.m (816 kgf-cm, 59 ft.1bf) 26, REMOVE OIL COOLER HOSE Loosen the 2 clips and disconnect the 2 oil cooler hoses. 27. SUPPORT TRANSAXLE WITH A JACK 28, REMOVE TORGUE CONVERTER CLUTCH MOUNT- ING BOLT ‘Turn the crankshaft to gain access and remove the 6 bolts hold ing the crankshaft pulley set bolt with a wrench, Torque: 41 N-m (418 kgt-cm, 30 fttbf) HINT: At the time of instaltation, please refer to the following item. First instalt black colored bolt and then 5 othor bolts. 29, REMOVE TRANSAXLE ASSEMBLY (a) Remove the 4 bolts. Torque A bolt: 46 Nim (470 kgf-cm, 34 ft.lbf) B bolt: 23 N-m (230 kgf-cm, 17 fbf) (b) Separate the transaxle from engine, and lower the transaxle.AX-35 AUTOMATIC TRANSAXLE (U240E)_— AUTOMATIC TRANSAXLE UNIT INSTALLATION 1. CHECK TORQUE CONVERTER CLUTCH INSTALLA- TION Using calipers and a staight edge, measure the distance between the installed surface and the front surface of the transaxle housing Correct distance: More than 13.3 mm (0.524 in.) 2 TRANSAXLE INSTALLATION Installation is In the reverse order of removal (See page AX-31). HINT: + After instalation, adjust the shit contol cable and park! neutral position switch (See page Dl-157). + Fil ATF and check the fluid level (See page Di~157) + Perform the test drive of the vehicie. + Adjust the hood (See page BO-8),AX-36 AvTOMAtIG-TRANSAMLE W240) = TORQUE CONVERTER GLUTEN Ak DAVE FATE gsr TORQUE CONVERTER CLUTCH AND DRIVE PLATE INSPECTION = 1, INSPECT ONE-WAY CLUTCH (a) _ Install SST into the inner race of the one-way clutch SST 09350-32014 (09951-92010) {b) Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch. SST 09350-32014 (09351-32020) {c} With the torque converter clutch setting up on its side, check that the clutch locks when turned counterciock- wise, and sotates smoothly clockwise. if necessary, clean the converter and retest the clutch. Replace the converter il the clutch stil fails the test. 2, MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR (a) Set up a dial indicator and measure the drive plate runout (2) Check the damage of the ring gear. Maximum runout: 0.20 mm (0.0079 in.) If the runout is not withia the specification or ring gear is damaged, replace the drive plate, ‘Torque: 88 N-m (897 kgf-cm 65 ftlbt) 3, MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT Temporarily mount the torque converter clutch on the drive plate. Set a dial indicator and measure the torque converter ‘clutch sleeve runout. Maximum runout: 0.30 mm (0.0118 In.) {the runout is net within the specification, try to correct by rear enling the installation of the converter.ed AXa7 AUTOMATIC TRANSAXLE (U2\0E}_—_ TORQUE CONVERTER CLUTCH AND DRIVE PLATE HINT: Mark the position of the converter clutch to ensure the installa: tion is correctly performed.MEMO ~AUTOMATIC TRANSAXLE (U341E) AUTOMATIC TRANSAXLE SYSTEM VEHICLE SPEED SENSOR INPUT TURBIN SPEED SENSOR ATE TEMPERATURE SENSOR PARK/NEUTAAL POSITION (PNP} SWITCH we VALVE BODY ASSEMBLY DIFFERENTIAL OIL SEAL SHIFT LOCK SYSTEM... FLOOR SHIFT ASSEMBLY AUTOMATIC TRANSAXLE UNIT TORQUE CONVERTER CLUTCH AND DRIVE PLATE AXA AK AX AXS, AGT AX axa AXA4 AXH6: AX-30. AK-26Akt AUTOMATIC TRANSAXLE (U341E) AUTOMATIC THANSAXLE SYSTEM AUTOMATIC TRANSAXLE SYSTEM PRECAUTION ™ I the vehicle is equipped with a mobile communication system, refer to the precautions in the iN section.AL AUTOMATIC TRANSAXLE (U2 16) OPERATION = AUTOMATIC TRANGANLE SYSTEM. Roverse Brake (Ca) Direct Gluten (Cah— ~- Op & 2nd Brake (By} No. 2 One-way Clutch (Fat 191 Reverse Brake (Bg) Forward uch Ci) [sos pon akg Operating Reverse “Neutral st 2nd 8rd OD tf ” tat 2 | i aad 1stAX3 AUTOMATIC TRANSAXLE (U341E)____VEHIOLE SPEED SENSO VEHICLE SPEED SENSOR ON-VEHICLE REPAIR 1. REMOVE BATTERY 2 REMOVE ECM AND ECM CASE 3, REMOVE ECM BRACKET 4, DISCONNECT VEHICLE SPEED SENSOR CONNEC- TOR 5, REMOVE VEHICLE SPEED SENSOR ASSEMBLY (a) Remove the bolt and vehicie speed sensor assembly. (©) Remove the clip and speedometer driven gear from the vehicle speed sensor. (6) Remove the O-ring from the vehicle speed sensor. 6. INSTALL VEHICLE SPEED SENSOR ASSEMBLY Vehicle Speed Sensor (a) Coat a new O-ring with ATF and install it to the vehicle Driven Gear speed sensor. as (} Install the speedometer driven gear to the vehicle speed eyo Rents ‘sensor with clip. oy of {c) Install the vehicie speed sensor assembly with the bolt. 9 Clip, Torque: 5.5 N-m (56 kgf.cm, 49 in-Ibf) 7. CONNECT VEHICLE SPEED SENSOR CONNECTOR coun] 8. INSTALL ECM BRACKET Torque: Bolt: 18 N-m (185 kgf-cm, 13 ftibt) Nut: 12 Nem (120 kgf-om, 9 ft.lbt) 9, INSTALL ECM AND ECM CASE Torque: 6.9 Nem (70 kgf.cm, 61 in.tbt) 10, INSTALL BATTERYAXA AUTOMATIC TRANSAXLE (u3S1E) INPUT TURBIN SPEED SENSOR, INPUT TURBIN SPEED SENSOR ON-VEHICLE REPAIR 1. REMOVE BATTERY 2, REMOVE ECM AND ECM CASE 3, REMOVE ECM BRACKET REMOVE INPUT TURBIN SPEED SENSOR Disconnect the connector. Remove the bolt and input turbin speed sensor. Remove the O-ring from the input turbin speed sensor. INSTALL INPUT TURBIN SPEED SENSOR Coata new O-ring with ATF and installitto the input turbia speed sensor. install the input turbin speed sensor with the bolt Torque: 5.4 N-m (55 kgf-cm, 48 in.Ibf) Connect the connestor INSTALL ECM BRACKET Torque: Bolt: 18 Nem (185 kgt-cm, 13 ftbf) Nut: 12 N-m (120 kgf-cm, 9 ft-lb!) 7. INSTALL ECM AND ECM CASE Torque: 6.9 Nem (70 kgt-em, 61 in-Ibf) 8. INSTALL BATTERYAXS: AUTOMATIC TRANSAXLE (US41E)_—_AFETEMPERATURE: senso ATF TEMPERATURE SENSOR ON-VEHICLE REPAIR 1. DISCONNECT SOLENOID CONNECTOR 2, REMOVE LH ENGINE UNDER COVER 3. REMOVE DRAIN PLUG AND DRAIN ATF 4, _ REMOVE OIL PAN AND GASKET NOTICE: Some fiuid will remain in the oll pan. Remove the 19 bolts, and carefully remove the oil pan assem. bly. Discard the gasket. 5. REMOVE OIL STRAINER (a) Remove the 3 boits and oil strainer (0) Remove the O-ring. 6 DISCONNECT 5 SHIFT SOLENOID VALVE CONNEC- TORS 7. REMOVE ATF TEMPERATURE SENSOR o {a} Remove the bolt and lock plate, and remove the ATF tem> porature sonsor. (0) Remove the O-ring from the ATF temperature sensor. 8 INSTALL ATF TEMPERATURE SENSOR (a) Goat a new O-ring with ATE and it to the direct clutch speed sensor. (©) tnstall the ATF temperature sensor with the Jock plate and boit Torque: 10 Nm (110 kgf-cm, 8 ttf) 9. CONNECT 5 SHIFT SOLENOID VALVE CONNECTORSAX AUTOMATIC TRANSAXLE (US#1E)_—_AIF TEMPERATURE S2NSOR ote 10. INSTALL OIL STRAINER (a) Coat a new O-ring with ATF. (b) Install tne O-ring to the oil strainer. (©) _ Install the oil strainer with the 3 bolts. Torque: 11 N-m (110 kgf-om, 8 ft-lbf) 11, INSTALL OIL PAN Install the oil pan and a new gasket with the 19 bolts. Torque: 7.8 Nem (80 kgl-cm, 69 in.-Ibf) 12, INSTALL DRAIN PLUG install a new gasket and drain plug Torque: 49 Nem (500 kgf-cm, 36 ftlbf) 13, CONNECT SOLENOID CONNECTOR 14, FILL ATF AND CHECK ATF LEVEL (See page Di-220) 16, INSTALL LH ENGINE UNDER COVERAX-7 AUTOMATIC TRANSAXLE (US4IE)_~_PARKAEUTRAL POSITION (ONE) SWITCH 1 (b) ) (a) a vam fe) fa) (b) fe) PARK/NEUTRAL POSITION (PNP) SWITCH ON-VEHICLE REPAIR REMOVE AIR CLEANER ASSEMBLY DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR REMOVE PARK/NEUTRAL POSITION SWITCH Remove the nut, Remove the nut, washer and control shift lever. Using a screwdriver, pry off the lock plate. Remove the nut and lock plate, Remove the 2 bolts and pull out the park/noutral position ‘switch, INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Install the park/neutral position switch with the 2 bolts. Torque: 5.4 Nm (55 kgf-cm, 48 in-Ibf) Install a new lock plate and nut. Torque: 6.9 Nem (70 kgf-cm, 61 in.-lbf) Bend the claws on the iack plate to fix the nut.AX-8 AUTOMATIC TRANSAXLE (U94))_~_ PARKINEUTRAL POSITION (PN) SWITOH {d) Instat the control shift lever with the nut Torque: 13 N-m (130 kgf-om, 9 ft-lbf) {e) Connect the shift control cable to the control shaft. Torque: 12 Nem (120 kgf-cm, 9 ft-tbf) §. CONNECT PARK/NEUTRAL POSITION SWITCH CON- NECTOR 6. CHECK PARK/NEUTRAL POSITION OPERATION ‘Check that the engine can be started with the shift lever oniy in the N or P position, but not in other position. Ifthe engine can not be stated not as started above, carry out the adjusiment procedure (See page DI-220). 7. INSTALL AIR CLEANER ASSEMBLY 8. TEST DRIVE VEHICLEAxo AUTOMATIC TRANSAXLE (U361E)_-._ VALVE BODY ASSEWERY VALVE BODY ASSEMBLY ON-VEHICLE REPAIR: 1. REMOVE LH ENGINE UNDER COVER 2, REMOVE DRAIN PLUG AND DRAIN ATF 3. __ REMOVE OIL PAN AND GASKET NOTICE: ‘Some fluid will remain in the oll pan. Remove the 19 bolts, and carefully remove the oll pan assembly, Discard the gasket. 4. EXAMINE PARTICLES IN OIL. PAN Remove the magnets and use them to collect any steel chips, Look carefully at the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the transaxle. Stoel {magnetic)...bearing, gear and plate wear Brass (non-magnetic)... bushing wear 5. REMOVE OIL STRAINER {a} Remove the 3 bolts and oil strainer, (>) Remove the O-ring. 6, DISCONNECT 5 SHIFT SOLENOID VALVE CONNEC- TORS 7. REMOVE ATF TEMPERATURE SENSOR Remove the bolt and lock plate, and remove the ATF temperature sensor.AX-10 AUTOMATIC TRANSAXLE (U341E)_~ VALVE BODY ASSEMBLY. 1b Oelent A oe 2 8 REMOVE VALVE BODY (a) Remove the 3 bolts, cover and detent spring. (0) Remove the 12 bolts and valve body. NOTICE: Be careful not to drop the check valve body, spring and e ~- cumulator piston. 9. REMOVE CHECK BALL BODY AND SPRING 40. REMOVE 2 APPLY GASKETS: 11. REMOVE SHIFT SOLENOID VALVE, Remove the 5 bolts and 5 shift solenoid valves. 12, INSTALL SHIFT SOLENOID VALVE Install the 5 shift solenoid valves with the 5 bolts. Torque: Bolt A: 6.6 Nom (67 kgf-cm, 58 in.-lbf) Bolt B: 11 Nm (110 kgt-cm, 8 ftlbf) Bolt length: Bolt A: 14 mm (0.55 in.) Bolt B: 55 mm (2.17 in.) 43. INSTALL APPLY GASKET {a) Coat 2 new epply gaskets with ATF. {b) Install the gaskets to the transaxie caso.Akt AUTOMATIC TRANSAXLE (US1JE)_—. VALVE BODY aSSEMELY 14. INSTALL CHECK VALVE AND SPRING 15. INSTALL VALVE BODY (a) Align the groove of the manual valve with the pin of the manual vaive lever. {b) Temporarily install the vaive body with the 12 bois. Bolt length: Bolt A: 55 mm (2.17 in.) Bolt B: 45 mm (1.77 in.) Bolt C: 32 mm (1.26 in.) Boit D: 22 mm (0.87 in.) (6) Temporarily instail the detent spring and cover with the 3 bolts. Bolt length: Bolt B: 45 mm (1.77 In.) Bolt C: 32 mm (1.26 in.) Bolt E: 14 mm (0.55 in.) (@) Check that the manual valve lever contacts the center of tive roller at the tip of the detent spring. (e) Tighten the 15 bots. Torque: 11 N-m (110 kgt-cm, 8 f.tbf) 16. INSTALL ATF TEMPERATURE SENSOR install the ATF temperature sensor with the lock plate and bolt. Torque: 10 N-m (100 kgt-cm, 8 fbf) 17. CONNECTS SHIFT SOLENOID VALVE CONNECTORS: 18, INSTALL OIL STRAINER (a) Coat a now O-ring with ATE. (b) Install the O-ring to the oil sirainer.AX2 AUTOMATIC TRANSAXLE (US41E)_= VALVE BOOY ASSEMBLY (©) _ Instat! the oil steiner with the 3 bolts, Torque: 11 N-m (110 kgf-cm, 8 ft-Ibf) 19. INSTALL MAGNET IN OIL PAN Install the 2 magnets in the oi! pan, as shown in the illustration. 20. INSTALL OIL PAN install the oil pan and a new gasket with the 19 bolts, Torque: 7.8 N-m (80 kgf-cm, 69 in.-lbf) 21. INSTALL DRAIN PLUG Install a new gasket and drain plug Torque: 49 Nem (500 kgf-om, 36 ftlbf) 22, FILL ATF AND CHECK ATF LEVEL {See page DI-220) 23. INSTALL LH ENGINE UNDER COVERAXA3. AUTOMATG TRANSAXLE (US1E)_—_ DIFFERENTIAL OWL SEAL DIFFERENTIAL OIL SEAL. ON-VEHICLE REPAIR 1, DRAIN ATF FROM FRONT DIFFERENTIAL CASE 2, REMOVE LH AND RH DRIVE SHAFTS (See page SA-20) 3, REMOVE LH AND RH SIDE OIL SEAL Using SST, drive out both the side oll seals SST 09308-10010 4, INSTALL LH AND RH SIDE OIL SEAL (a) Using SST and a hammer, drive in a new oil seal. SST 09223-90010 Oil seal drive in depth: LH side: 2.7 + 0.5 mm {0.106 + 0.020 in.) RH side: 0 + 0.5 mm (0 + 0.020 in.) (b) Goat the oil seal lip with MP grease. 5. INSTALL LH AND RH DRIVE SHAFTS (See page SA-32) 6. FILL ATF AND CHECK ATF LEVEL (See page DI-220)= SWETLOCK SYSTEM, AUTOMATIC TRANSAXLE (U341E) SHIFT LOCK SYSTEM COMPONENTSAX-15 AUTOMATIC TRANSAXLE (U9H1E) —_SWIETLOCK svSTEN INSPECTION INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY Using a voltmeter, measure the voltage at each terminal. HINT: Do nol disconnect the shift tock control unit assembly connec: tor K ate “orinal ensuring Gonaion esioge (0) 6106-8) Igeon etch ON, 10-14 B= ISTP=E) [Depressing brake pedal 11AXE AUTOMATIC TRANSAXLE (U341E)__._ FLOOR SHIFT ASSEMBLY. FLOOR SHIFT ASSEMBLY COMPONENTS Front Pilar Garnish & bee 2Brace ‘2. —~-~ Front Door fe SAS owt side tim || penta in No.4 an yu Door Set Plate Insiument Panel >: Bor) Bor a ive 4, a Lower Finish Panel Conter Cluster h amor Combination Meter Fiisit Panel loator Control Name Plata Say im © ye bor °8 CE» [pe too 2 Was an yea Convot pe st 2 Konb ‘Upper Column Sitch S Cluster Finish Panel Lower No. 1 O°" ee Stearing Wheel * Fins Panel cane ve Powe inane Headlight Dinner Sich recover ton > Upper Console Panel Lower Column > ‘Go, Oo® Cover ‘wi Power window Front Pilar Garnish S Power Window Switch Radio Healer Console anc Foon Door Opening Trim pening Aocessory Assay LH End Finish Panel ~ _v Door Scuff Piate Specified torque Console Box _ (Nim fear ci RiD}AX AUTOMATIC YAANSAXLE (U381E) — FLOOR SHIFT ASSEMOLY Instrument Pane-—— Heater Hoses clamp Liquid Tube + O-Rings AG Unit Suction Tube a” g - Clamp ower Unit a No.2Brace—_ff © Reintorcement § © —- No.1 Brace: Ip @ Non-reusable part Key interlock Cable Trangaxle Control Gable [aes Floor Shitt Assembly ln [Wim fkghem, fbi) | : Speciied torqueAX-18 AUTOMATIC TRANSAXLE (UQ4TE)_-_FLOON SMIFT ASSEMBLY. HINT: Screw shapes and sizes are indicated in the table below. ‘The codes ("A" ~"N") correspond to those indicated nthe previous page. fn in) "Shape Size | Shape | Sze | | Shape _ Size a=8 a= 3) o=6 (0.82) r (0.32 (o24) (oa to) tan ons o~8 o=s20 (0.24) (0.24) (0.2055) ° ©) lo} Gltmmm | 2 fo) (Fama | 22 (0.63) (071) (0.63) —} | rr pe 0-522 os | | 0-8 } (0.2055) (0.20) i (0.20) @| 22 jo] (fname (C8 jo! Cm | 2% | {0.63} (ori) | | (0.63) {| 0-5 ons | ons a) 25 | an ° 2 lel dean | PA Lo (=> ee (0.63) (0.55) (0.63) 8 a6 | 8 wah fel EE ees ® - scaAX-19 AUTOMATIC TRANSAXLE (USA1E)_._ FLOOR SHIFT ASSEMBLY Upper Position Indicator Housing siti Lever Knob Button— @ Shift Lever Knob . Button Guide Compression Shit Lever Stop Pin Control Position Indicator Plate Shift Lever Knob ~~ Sleave a ‘Shift Lever Knot (JD Main Swit Dotont Roo—~ | No. 2 Slide Slide Cover” Sever Spring Grooved Pin Lower Position Indicator housing Shift Lever Sub-assembly ‘Shait Conteol Indicator Lamp Wire ‘Sub-assemibly — Shift Leek Unit Ye le _* _Precoated part connAX-20 AUIQMATIC TRANSAXLE (U341E}_— FLOOR SHIFT ASSEMRL REMOVAL i 2 fa) ®) © (e) REMOVE INSTRUMENT PANEL (See page BO-79) REMOVE AIR CONDITIONING UNIT (See page AC-26) REMOVE KEY INTERLOCK CABLE Remove the cable end from the rad of the floor shift as~ sembly. Pull out the cable while pressing the clip of the key interlock cable. With the key in AGG, remove the cable cap claw from the key interlock and pul it Disconnect the 2 key interlock cable clamps. REMOVE FLOOR SHIFT ASSEMBLY Disconnect the 2 connectors. Disconnect the 2 wire harness clamps from the fleor shift assembly, Remove the 4 bolts from the floor shift assembly.et AK-21 AUTOMATIC TRANSAXLE (U341E)_-_FLOOH SHIFT ASSEMALY @ (e} o Remove the cable end from the rod of the floor shift assembly. Pull out the cable whife pressing the clip of the transaxle control cable. Remove the floor shift assembly.AX-22 AUIOMATIC TRANSAXLE (U3418) FLOOR SHIFT ASSEMBLY ee i oO ‘Secondary Locking Devico DISASSEMBLY 1 fa) (0) © 2 a) REMOVE O/D MAIN SWITCH TERMINAL Remove the O/D main switch connector from the shift iever plate. Disengage the secondary locking device. Release the locking log of the terminals § and 6, and pull the terminals out from the rearward, REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY Remove the 2 screws and shift lever knob sub-assembly. NOTICE: Pay attention not to apply unnatural load to O/D main awitch wire harness. to) fc) (a) fa) (b) fo) @ ®) (c) (d) Remove the O/D main switch. Remove the No. 2 slide cover. Remove the shift lever stop pin, shift lever knob button, shift lever knob button guide and compression spring REMOVE UPPER POSITION INDICATOR HOUSING Remove the uppor position indicator housing. Remove the control position indicator plate. Remove the 3 stide covers from the lower position indica~ tor housing, REMOVE LOWER POSITION INDICATOR HOUSING Remove the indicator lamp wire sub-assembly. Remove the 4 screws and lower position indicator housing. Remove the bulb cap and bulb trom the indicator lamp wire sub-assembly. Remove the shift lock release button and spring.AX-23, AUTOMATIC TRANSAXLE (US416),_-_ FLOOR SHIFT ASSEMBLY z oz 5. REMOVE SHIFT LOCK UNIT Remove the 2 screws and shift lock unit 6. REMOVE SCREW AND MANUAL DETENT SPRING 7. REMOVE SHIFT LEVER SUB-ASSEMBLY Using @ screwdriver and hammer, drive off the shaft control while disengaging the claw of the shaft control and remove the shift lever sub-assembly. 8 REMOVE DETENT ROD (2) Seta 14 mm deep socket wrench. (b) Using a punch and hammer, romove the grooved pin. (c) Remove the detent rod and spring (@) Remove the shift ever knob sleeve from the detent rod, 9. REMOVE COLLARS Using a screwdriver and hammer, remove the 4 collars.AX-24 AUTOMATIC TRANSAXLE (U341E)_— FLOOR SHIFT ASSEMSLY REASSEMBLY 4. INSTALL 4 COLLARS 2, INSTALL DETENT ROD {a) install the shift lever knob sleeve to the detent rod. {b) Apply MP grease on the detent rod and spring. {c) _ Install the spring and detent rod. (6) Using a punch and hammer, install the grooved pin to the detent rod pin hole. A: 8.0 + 0.2 mm (0.318 0.008 in.) (0) Check the detent rod operation Shift Lever Sub-assemnbly Grooves Pin 3, INSTALL SHIFT LEVER SUB-ASSEMBLY (@) Apply MP grease on the spring. (b) _ Install the shift lever sub-assembly and shaft contro! to shift lever plate, 7 HINT: Chock that the claw of the shaft contral is fit onto the shift lever plate 7 4, INSTALL MANUAL DETENT SPRING AND SCREW I (a) Apply MP grease to the parts indicated by the arrows manual detent spring and shitt lever plate in the iliustra- tion. (b) _ tnstall the manual detent spring with Ihe screw.AX-25 AUTOMATIC TRANSAXLE (USS1E) —_ FLOOR SHIFT ASSEMBLY 5. INSTALL SHIFT LOCK UNIT install the shift lock unit with the 2 screws. fa) ) © ‘) io) 2 fa) (b} «) © td) {e} INSTALL LOWER POSITION INDICATOR HOUSING Apply MP grease on the spring. Install the spring and shift lock release button. Instalt the bulb and bulb cap to the indicator lamp wire sub-assembly Install the lower position indicator housing with the 4 screws. Install the indicator lamp wire sub-assembly. INSTALL UPPER POSITION INDICATOR HOUSING. Install the 3 slide covers to the lower position indicator housing, as shown in the illustration. Instalt the contro! position indicator piate. Install the upper position indicator housing. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY Apply MP grease on the compression spring. Install the compression spring, shift lever knob button guide, shift lever knob button and shift tever stop pin. Install the No. 2 slide cover, install the O/D main switch install the shift lever knob sub-assembly with the 2 screws, HINT: Coat the threads of screws with sealant, Sealant: Part No. 08633-00080, THREE BOND 1344, LOCTITE 242 or equivaientX26 AUTOMATIC TRANSAXLE (US41E)_-_ FLOOR SHIETASSEMALY NOTICE: Make sure not to catch O/D main switch wire harness. 9. INSTALL O/D MAIN SWITCH TERMINAL (a) Connect the 2 O/D main switch terminais to the connector. {b) Connect the connector to the shift lever plate.Ax-27 AUTOMATIC TRANSAXLE (U341E) FLOOR SHIFT ASSENNBLY INSTALLATION 1. INSTALL FLOOR SHIFT ASSEMBLY (a) Pull in the cable while pressing the clip of the transaxle contro! cable to the floor shitt assembly. {b) install the cable end from the rod of the floor shift assem bly. {c) _Instali the floor shift assembly with the 4 bos. Torque: 12 Nm (120 kgt-cm, 9 fbf) (qd) Conneet the 2 wire harness clamps from the floor shift assembly. fe) Connect the 2 connector. 2. INSTALL KEY INTERLOCK CABLE (@) Pass the key interlock cable end through the hole in the floor shift assembly. HINT: ‘Make sure that the claws shown by the arrow in the illustration are locked. (©) With the shift lever in N position, set the hole of thie cable end to the tloor shift assembly to assembie them. (0) At the time of reassembly: With the key in ACC, push a claw into lock key. At this time, be carelul not to apply undue force on bending to the cable (Cable length adjustment is completed), HINT: Check that the key iock cam is contact with the cam stopper. (d) With the key in ACC, install the cable cap claw to the key interlock,AX-28 AUTOMATIC TRANSAXLE (U3I1E)_— FLOOR SHFTASSEMALY fe) Connect the 2 key interlock cable clamps. {f) Pullin the cable while pressing the clip of the key interlock cable. 3. INSTALL AIR CONDITIONING UNIT (See page AC-29) 4, _ INSTALL INSTRUMENT PANEL (See page AC-29) 5. INSPECT KEY INTERLOGK AND SHIFT LOCK OP- ERATION (a) Check that a key can be turn from ACG to LOCK only when the shift lever is in P position (b) Check thal the key cannot be turned fo LOCK when the shift lever is position in other than P position. (c)_ When the ignition key is in LOCK, check that pressing the shift release bution enables the shift levor to shift from P position to otter positions (d) When shifting it fo each position, make sure that the shifting lever moves smoothly, can be maderately operated and the position indicator displays correctly. Positions which can be operated without pressing the shit lever knob button RON +D2D,.L+2>D-9N Positions which can be operated only while pressing the shift lever knob button D+2-L.NoR OP With the brake pedal depressed, Positions which can be operated only while pressing Sri vite navsing the Tock re- the shift lever knob bution, ignition switch ON and (The ignition switch must be in brake pedal depressed ON position) PoR Shift white holeing the lock (e) When starting the engine make sure that the vehicle FF cease button in moves forward when shifting form N to D position, and moves rearward when shifting to F. position BD shit normaly 6. ADJUSTMENT IN CASE OF MALFUNCTION (a) When the key can not be turned from ACC to LOCK even soa though the shitt lever js in P position This Is the condition where the cable end on the ignition key side is not returned to the position where it can be locked. The conaition is caused by undue bending of the cable, rotative resistance of the pin on the shift lever side, or Increased resistance due to any reason such as twisl- ing of the cable. Reinstall and readjust the key interlock cableAK-29 AUTOMATIC TRANSAXLE (U341E)_-_ FLOOR SHIFTASSEMBLY () When the key is turned from ACC to LOCK even though the shift lever is in other than P Position: ‘Since the cable is too long due to improper adjustment at tne automatic adjustment part of the key can not be focked. Readjust the key interlock cable. 7, _READJUSTMENT OF KEY INTERLOCK CABLE HINT: ‘Assembly shall be undertaker in the same way as step 2. {a) Using a screwdriver, unlock the claw of the lock key of the automatic adjustment part. {b) Remove the key interlock cable end trom the rod of the floor shift assembly. (©) Pull out the cable while pressing the clip of the kay interlock cable. {6) Remove the cabie clamp from the other. (©) With the key in ACC, instail the cabie cap claw to the key interlock.AX-30 AUTOMATIC TRANSAXLE (USATE) —_AUTOMAIIC TRANSAXLE UNIT AUTOMATIC TRANSAXLE UNIT COMPONENTS ” No. 2 Cylinder Head Cover in| ‘Sy © e& (a aia TEM case ed | co i Battory (isan Kibtwr Remon ne 47) 16 (470. 3 ; SAIN) a AH Drive —— oon Plug — [6a a0, a7 | [801 a soa wan EY THER) enna Lt Mona SB Bracket Torque Converter. B coma” Engine Rear Mounting ae ¥ S00 Ann Starter . } LH Drive Shaft {TE OY] S. Le Tost For Line Pressure Plug Hole ug suspension Member 336 (2,200, 7)AUTOMATIC TRANSAXLE (U3416) MOVAL RE! 7 % 9%. 10. ". 12. 43. fa) 4b) AX-31 AULOWATIC TRANSAXLE UNIT REMOVE HOOD Torque: 13 Nim (130 kgf-cm, 9 ftbt) REMOVE BATTERY REMOVE ECM AND ECM CASE Torque: 6.9 N-m (70 kgf-cm, 6 REMOVE ECM BRACKET Torque: Bolt: 18 Nm (185 kgf-om, 13 ft-lbf) Nut: 12 Nem (120 kat-cm, 9 ftlbt) REMOVE AIR CLEANER ASSEMBLY REMOVE NO. 2 CYLINDER HEAD COVER, Torque: 7.0 Nm (71 kgf-cm, 62 In.-tbf) bf) REMOVE 2 GROUND CABLES Torque: 18 N-m (185 kgf.cm, 13 ft-lbt) DISCONNECT CONTROL CABLE FROM CLAMP DISCONNECT INPUT TURBINE SPEED SENSOR CONNECTOR REMOVE VEHICLE SPEED SENSOR CONNECTOR REMOVE 2 UPPER SIDE TRANSAXLE MOUNTING BOLTS FROM TRANSAXLE Torque: 64 N-m (650 kgf-cm, 47 ft-lbf) DISCONNECT SOLENOID CONNECTOR AND PARK/ NEUTRAL POSITION SWITCH CONNECTOR Disconnect the solenoid connector and park/neutral position switch connector. DISCONNECT CONTROL CABLE Remove the nut from the conteal shitt lever. Torque: 12 N-m (120 kgt-cm, 9 ttbf) Remove the clip and disconnect the control cable.AX-32 AUTOMATIC TRANSAXLE (U341E)_—_AUTOMATIOTRANSAXLE UNIT 14, 15. fa) (b) 16. 17. 18. 19. 20. REMOVE BOLT AND DISCONNECT RADIATOR RES- ERVOIR Torque: 4.9 N-m (50 kgt-om, 43 inl) REMOVE STARTER Remove the nut and wire, and disconnect the connector. Remove the 2 bolts and starter. Torque: 37 N-m (878 kgf-cm, 28 ftlbf) REMOVE LH, RH, CENTER ENGINE UNDER COVERS DRAIN ATF FROM FRONT DIFFERENTIAL CASE Torque: 54 Nem (550 kgt.cm, 40 ftlbf) REMOVE LH AND RH DRIVE SHAFTS (See page SA-20) DISCONNECT LH AND RH STABILIZER BAR LINKS FROM SHOCK ABSORBER Torque: 44 N-m (450 kgf.cm, $2 ftlbf} REMOVE 4 BOLTS AND DISCONNECT PS GEAR AS- ‘SEMBLY HINT: ‘Support the PS gear assembly securely. Torque: 45 N.m (459 kgf.cm, 33 tlbt)AUTOMATIC TRANSAXLE, AX-33 (USM1E) = _AUIOMATIG TRANSAXLE UN 21, REMOVE SUSPENSION MEMBER (a) Remove the 9 bolts and 3 nuts. Torque: Bolt A: 157 N.m (1,601 kgtom, 116 ftibf) Bolt B: 52 N-m (530 kgf.cm, 38 ftlof) Bolt C: 39 N-m (398 kgf.cm, 29 ft.lbf) Nat: 52 N-m (830 kgt-cm, 38 ft-Ibf) (b) Remove the suspension member. 22, REMOVE ENGINE REAR MOUNTING INSULATOR Remove the bolt and engine rear mounting insulator. ‘Torque: 87 N-m (890 kgf-cm, 64 ft-lbf) 23. ATTACH ENGINE SLING DEVICE TO ENGINE HANG- ERS (a) Disconnect the 2 PCV hoses. (b) Install the No. 1 and No. 2 engine hangers in the correct direction, Parts No. : No. 1 engine hanger: 12261-22021 No. 2 engine hanger: 12281-15040 or 12281-15050 Bolt: 91512-B1016 Torque: 36 N-m (387 kgf-cm, 28 fbf) {o) Attach the engine chain hoist io the engine hangers. CAUTION: Po not attempt to hang the engine by ooking the ehain to. any other part.AUTOMATIC TRANSAXLE (UD41E) —_AUTOMATIO TRANSAXLE UNIT 24, REMOVE UPPER SIDE ENGINE LEFT MOUNTING, NUT AND BOLT Torque: 80 N-m (816 kgf.cm, 59 ft-lbf) 25, REMOVE Oll COOLER HOSE Loosen the 2 clips and disconnect the 2 oli cooler hoses. 26. SUPPORT TRANSAXLE WITH A JACK 27, REMOVE TORQUE CONVERTER CLUTCH MOUNT- ING BOLT (a) Remove the hole plug. (0) Turn the crankshatt te gain access and remove the 6 bolts holding the crankshaft pullay set balt with a wrench. Torque: 41 Nem (420 kgf-cm, 25 fbf) HINT: Al the time of installation, please refer to the following iter First install black colored bolt and then 5 other bolts. 28, REMOVE TRANSAXLE ASSEMBLY fa) Remove the 4 bolts. Torque: A bolt: 46 N-m (470 kgt-om, 34 ftibt) B bolt: 23 Nem (230 kgt-cm, 17 ftibf) (©) Separate the transaxle from engine, and lower the trans- axleAX35 AUTOMATIC TRANSANLE (US41E)_—_ AUTOMATIC TRANSAXLE UNIT INSTALLATION “ 1. CHECK TORQUE CONVERTER CLUTCH INSTALLA- TION Using calipers and a straight edge, measure the distance between the installed surface and the front surface of the transaxle housing, Correct distance: More than 13.3 mm (0.524 in.) 2, TRANSAXLE INSTALLATION Installation is in the reverse order of removal (See page AX~31). HINT: + Alter installation, adjust the shift control cable and parks neutral position switch (See page Dl-220). + Fill ATF and check the fluid level (See page DI-220). + Perform the test drive of the vehicle. + Adjust the hood (See page BO-9)AX-36 TRANSAXLE (U341E) 5ST UE COs 1 oFVE PLA TORQUE CONVERTER CLUTCH AND DRIVE PLATE INSPECTION 1. INSPECT ONE-WAY CLUTCH (a) _ Install SST into the Inner race of the one-way cluich. SST 99350-32014 (09951-32010) (©) Insiall SST so that i fits in the notch of the converter huts and outer race of the one-way clutch, SST 09350-32014 (09351-32020) {) With the torque converter clutch setting up on its side, check that the clutch locks when turned counterclockwise, and rotates smoothly clockwise. H necessary, clean the converter and retest the clutch, Replace the converter ciutch if the clutch stil fails the test. 2. MBASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR (a) Setup adial indicator and measure the drive plate runout. (b) Check the damage of the ring gear. Maximum runout: 0.20 mm (0.0079 In.) If the runout is not within the specification or fing gear is damaged, replace the drive plate. Torque: 78 N-m (800 kgf-cm, 58 ftibt) 3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT Temporarily mount the torque converter olutch on the drive plate. Set a dial indicator and measure the torque converter clutch sleeve eunoua, Maximum runout: 0.30 mm (0.0116 in.) Ifthe runout is not within the specification, try to correct by ceort centing the installation of the converter.axa7 AUTOMATIC TRANSAXLE (USI1E)_- TORQUE CONVERICR CLUCHANN OnIVE PLATE HINT: Mark the position of the converter clutch to ensure the installa tion is correctly performed.MEMO ~SUSPENSION AND AXLE TROUBLESHOOTING se SAE TIRE AND WHEEL eee ccc SA2 FRONT WHEEL ALIGNMENT ... SAA REAR WHEEL ALIGNMENT... SAB FRONT AXLE HUG: beet SAM FRONT WHEEL HUB BOLT . SAT FRONT DRIVE SHAFT... so SAB FRONT SHOCK ABSORBER ce SABE FRONT LOWER SUSPENSION ARM... SA~a1 FRONT LOWER BALLJOINT oo. .cce., SAAB. FRONT STABILIZER BAR SA-50 REAR AXLE CARRIER 6... SA-S4 REAR WHEEL HUB BOLT SA-60 REAR SHOCK ABSORBER ..... SA-61 REAR UPPER SUSPENSION ARM ........ SA~6B. REAR LOWER SUSPENSION ARM SAT! REAR STABILIZER BAR... Sher5SUSPENSION AND AXLE TROUaLESHOOTING TROUBLESHOOTING PROBLEM SYMPTOMS TABLE Use the tabie below to help you find the cause of the problem. The numbers indicate the priority of the ikely cause of the problem, Check each part in order. I necessary, replace these parts, Syontom Suspes Area Soe p30 1 Tie (Wor oe propery naga ‘SA? 12. Weee!afgarnont sere SA Ske 3. Steering fnkage Loose or wou) - ‘Wane 4 Hub bearing om sate 5A-§5 2, Steering 9oar (Out of adustment or broken parry 5. Suspension pats Worn . 1 Vehicle (Overoaded) - 2 Spring oak BA Bostoming SA-61 8. Shock abaoAse Wor) 8A-$5 sae 1. Tire (Worn er improper wed) ‘sae 2, Staicor bar (Bento Broken aso ‘Sways'ptches 8A75 8. Shock abmorber (eben) SAS SAGE 5. Two (Wor ar npn nated SRP 2 Whee! Cute bance a2 3. Shock absorber (Worn) SA 4 Woe algreant inca Sh Frost weet shinny 4, Banjo (Worm) Sara 5. Hob bearing (Worn) BAe 7. Steering tneage eLoose or wom - 8. Stwotang gear (Out of arian or bron, Sh.98 1 Tie (Pen orp ate BAP 2, Weel algnnent incon Shed Abnormal te wear 8. Shock absorber Porm) SAG Shas 4 Suspansign pts (Moen) =SA-2 USPENSION AND AXLE —_ TIRE AND WHEEL Boer TIRE AND WHEEL INSPECTION 4. INSPECT TIRE (a) Check the tires for wear and proper Cold tire inflation pressure 122-FE engine models: lation pressure, y Front Rear ore Pa tater? os) Pa em? pit TeStGOR IB igsia0h5 871 B10 (2 28) 210 81.20) 222-GE engine models: Tose Fron ear si Pa gto, pei ea tha? omesni6 er Po0sssRIS 8” 220 (22.32) 220 22,32) 20816 7 (b) Using a dial indicator, check the tire runout. Tire runout: 1.0 mm (0.039 in.) or less. 2, ROTATING TIRES. HINT: See the illustration for where to rotate each tire when you include the spare tire in the rotation and when you do not. It the rotating direction is specified, do not exchange the tires between the right and teftSUSPENSION AND AXLE —_TWRE AND WHEEL 3 INSPECT WHEEL BALANCE (@) Chock and adjust the Otf-the-car balance. (0) necessary, check and adjust the On-the-car balance. Imbalance after adjustment: 8.0 g (0.018 Ib) or loss 4, CHECK WHEEL BEARING LOOSENESS (a) Using a diat indicator, check the backlash near the center of the axle hub. Maximum: 0.05 mm {0.0020 in.) I the backlash exceeds the maximum, replace the bearing. (0) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub boll Maximum: 0.07 mm (0.0028 in.) It the deviation exceeds the maximum, roplace the axle hub. 5. CHECK FRONT SUSPENSION FOR LOOSENESS 6 CHECK STEERING LINKAGE FOR LOOSENESS 7. CHECK BALL JOINT FOR LOOSENESS 8 CHECK SHOCK ABSORBER WORKS PROPERLY Check that oll leaks Check mounting bushings for wear Bounce front and rear of the vehicleSUSPENSION AND AXLE ~_ FRONT WHEEL ALIGNMENT ‘Alignment “ester FRONT WHEEL ALIGNMENT INSPECTION 4, MEASURE VEHICLE HEIGHT Vehicle height: ie size Front? mm fin) Roar? main) | 1 SorGU 1S, FOSEORIE 190 (48) Pea 88) 2OSSERIS, P2OSBERTS Tan 7 a8) 225 190) 20580RI6 53.50), 205 (8.86) Front measuring point Measure the distance from the ground to the center of the front side lower suspension arm mounting bolt. “2; Rear measuring point Measure the distance ftom the ground to the center of the rear side lower suspension arm suspension member side sel bolt NoTict Before inspecting the wheel alignment, adjust the vehicle height to the specified value. I the vehicle height is not the specified value, try to adjust it by pushing down on oF iting the body. 2, INSTALL CAMBER-CASTER-KINGPIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TES- TER Follow the specilic instructions of the equigment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS. INCLINATION Camber, caster and steering axis Inclination: 195/60R15, P195/60R15 tire: Camber “ores 2 45 047" = 078) Fightelt ore 45: (075"}0" ess Caster BOP 4b iz 18 2075) Figh-ioh ewer 4510.75" Jor lees Seenng ax nemation 19°09 = AB S.I5" = O75") Fighi-iet wror 5 (0.75" Jor ntsSUSPENSION AND AXLE — _:fONT WHEEL ALIGNMENT SAS 205/55R15, P205/SSR15 tire: (Cambor “ores 2 a5 (OAR 2 076) gyrate $540.76") orless Caster or 249 BON 207) Aightiet enor 28 (0.78")r oss ‘Sleorng ax einatan Wor a5 (307 20785 Figh-tel ror 45,9125" p0r ss 205/50R16 tire: Garber “oe 3 as OAH O78) Fight-tot ono 4510.75") oF ess Caster B02 245 Bas" =0.787) Fight-let oor 45 O75" jor ess Steering ans neination 11 = 4eGaF SOT) ight tot ena 450.79") oss It the caster and steering axis inci: cified values, after the camber has ation are not within the spe- been correctly adjusted, te- check the suspension parts for damaged and/or worn out parts. 4, ADJUST CAMBER NOTICE: After the camber has been adjusted, inspect the toe-in. {a) Remove the front wheel {b) Remove the 2 nuts on the lower side of the shack absorber. () Coat the threads of the nuts with engine oil (d) Temporarily install the 2 nuts.SA6 SUSPENSION AND AXLE —_ FRONT WHEEL ALIGHMENT {e) Adjust the camber by pushing o puiting the lower side of the shock absorber in the direction in which the camber adjustment is required. () Tighten the nuts. Torque: 153 N-m (1,560 kgf-om, 113 fttbt) {g) _ Instalt the front wheel. Torque: 103 N-m (1,050 kgf-cm, 76 ft-Ibf) (h) Check the camber. HINT. + Try1oadjust the camber to the center of the specified valve. + Adjusting value for the set bolts is 6 ~ 30'(0.1° - 0.5") It the camber is not within the specified value, using the foliowing table, estimate how much additional camber adjustment will be required, and select the camber adjusting boll Set Bolt ‘Adjusting Bolt ‘90105-15001 | go105-s5008 1 Dot Bolt Adjusting Vaiue 18 ° 90° oo e 451 e v0" e “15 e 1°30 ° Ta () Do the steps mentioned above again. Between step (b) and (c), replace 1 or 2 selected bolts. HINT: When replacing the 2 bolts, replace 1 bolt for each time. 5, INSPECT TOE-IN 3 Toe-in; if the toe—in is not within the specified value, adjust it al the rack VY nes, 6, ADJUST TOE-iN (a) Remove the rack boot set clipsSAT SUSPENSION AND AXLE — FRONT WMEEL ALIGNMENT (0) Loosen the tie rod end lock nuts. (©) Tum the right and felt rack ends by an equal amount to adjust the ten, HINT: Try to adjust the toe~in to the center of the specified value. (d)_ Make sure thal the lengths of the right and feft rack ends are the same. Rack end length difference: 1.5 mm (0.058 in.) or less {e) Torque the tie rod end lock nuts. Torque: 74 Nem (750 kgf.cm, 54 ttlbf) (1) Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. a6 ByA 7. INSPECT WHEEL ANGLE - ‘Tur the steering wheel fully, ani measure the turning angie. Wheel turning angle: Front 195/60R15, P195/60R15 tire: tM ile ee Eee Weer) Guisite wreck Retwrence 5 2988.35) | Asloside 205/56R 15, P205/55R15 tire: B: Outside 7 Insse wheel aera 8 GT aD) sel Duis whoo! Noteronce Sap 2 205/50R 16 tire: Ifthe right and left inside wheal angles differ trom the specified value, check the right and left rack end lengths. gESAB SUSPENSION AND AXLE REA WHEEL ALIGNMENT REAR WHEEL ALIGNMENT INSPECTION 1. MEASURE VEHICLE HEIGHT (See page SA~4) 2, INSTALL CAMBER-CASTER-KINGPIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TES- TER Follow the specific instructions of the equipment manufacturer. 3, INSPECT CAMBER Camber: canber Fives ete 0757) Fight eror 45075} octess {the éamber is not within the specified vatue, after the tov-in is inspected, see stap 5. to adjust. 4. INSPECT TOE-IN Toe-in: Toon Rewoiws Os =027 ora G-D-9 + 29m (N42 = 0080) IFthe toe-in is not within the specified value, see step 6. to adjust 5. ADJUST CAMBER AND TOE-IN fa) Measure the distance fram the LH lower suspension arm bracket set bolt to the RH axle carrier rear side set bolt as shown in the illustration, (b) Employ the same manner to the RH-LH. Length difference: 6 mm or less. Itit exceeds the specified value, adjust it by turning the adjusting cams. {c) Loosen the upper and lower arm adjusting cam set nuts. (@) Adjust the camber and toe~in by turning the adjusting cams, HINT: ‘Try to adjust the camber and toe-in to the center of the specitied values. (e) Torque the upper and lower arm adjusting cam set nuts. Torque: 74 N-m (755 kgf-cm, 55 ft-Ibf}SA9 SUSPENSIONAND AXLE —_ REAR WHiCEL AUGNMENE 6. HOW TO READ ADJUSTMENT CHART (EXAMPLE) (a) Measure the present alignment, Example: Camber (RH): -0°26" (-0.43°) Camber (LH): ~1°56" (-1.93") Toe-in (total): IN 7 mm (0.28 in.) (b) Mark the difference between the standard value (A) and the measured valuo (B) on the adjustment char. ‘Standard value: Cambor: 1°11" 1.18") Toe-in (total): IN 3mm (0.12 in.) Formula: A- B =C Camber (RH): -1°11" ~ (-0°26") = 0°45" Camber (LH): ~1°11" ~ (-1°56") = 0°45" Toe-In (total): IN3—IN7 = OUT 4 Toe-in (each side): OUT 2 (c)__ As shownin the example chan, read the distance from the oe marked point to the origin of the chart, and adjust the up- er and/or lower arm adjusting cams accordingly Amount to turn adjusting cams (by graduation): Upper arm cam (AH): + (Inward) 3.2 Lower arm cam (RH): + (Inward) 0.8 Upper arm cam (LH): - (Outward) 2.3 Lower arm cam (LH): + (Inward) 1.0 cy &)SA-10 OAR WHEEL ALIGNMENT SUSPENSION AND AXLE _— Upper armcam graduation (+) inward de ga oe ioe (4) Inward | Lowerarm eam graduation ) Outward ¢ (Outward Steoring Knuckle with Axle Hub Bise # Lock Nut [6.200.159] + Snap Ring # Cotter Pin Prose Bm - Axle Hub Lower Balt Joist TIDE |: Speed torque a, # Noreteusabi partSA12 SUSPENSION AND AXLE — FRONT AXLE HUB REMOVAL 4. REMOVE FRONT WHEEL ‘Torque: 103 N-m (1,050 kgf-cm, 76 ftlbf) 2, CHECK BEARING BACKLASH AND AXLE HUB DEVI- ATION fa) Remove the 2 bolts, brake caliper and disc. (b) Support the brake caliper securely. (©) _ Using a dial indicator, check the backlash near the center of the axle hub. ‘Maximum: 0.05 mm (0.0020 in.) Ifthe backlash exceeds the maximum, replace the bearing. (a) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt, ‘Maximum: 0.07 mm (0.0028 in.) Ifthe deviation exceeds the maximum, replace the axle hub. (e) _ Install the disc, 2 bolts and brake caliper. Torque: 107 N.m (1,090 kgf-cm, 79 ft.tbf) 3, REMOVE DRIVE SHAFT LOCK NUT (a) Using SST and a hammer, unstake the staked part of the lock nut SST 09930-00010 (©) White appiying the brakes, remove the nut Torque: 216 Nem (2,200 kgf-cm, 159 ftbf) {c) Remove the brake caliper and disc. (d) Support the brake caliper securely. 4, wi ABS: REMOVE ABS SPEED SENSOR Torque: 8.0 Nom (82 kgf.cm, 71 in.-lbf)SA-13 SUSPENSIONAND AXLE FAONT AXLE HUB 5, LOOSEN 2 NUTS ON LOWER SIDE OF SHOCK AB- SORBER ‘Torque: 183 N-m (1,560 kgf-cm, 113 ftbf) HINT: Do not remove the 2 bolts and nuts. 6. DISCONNECT TIE ROD END FROM STEERING KNUCKLE (a) Remove the cotter pin and nut Torque: 49 N-m (500 kgf-cm, 36 ftibt) HINT. Atthe time of installation, ifthe holes for a ew cotter pin are not aligned, tighten the nut further up to 60°. (b) Using SST, disconnect the tie rod end from the steering knuckle. SST 09610-20012 7, DISCONNECT LOWER SUSPENSION ARM FROM LOWER BALL JOINT Remove the 2 nuts and bolt Torque: 142 N-m (1,450 kgf-cm, 105 ftlbf) 8, REMOVE STEERING KNUCKLE WITH AXLE HUB (@) Remove the 2 bolts and nuts on the lower side of the shock absorber. HINT: At the time of installation, coat the nut’s thread with engine oil (b)_ Remove the steering knuckle with the axle hub, NoTIct Be careful not to damage the boot and ABS speed sensor rotor.2 DISASSEMBLY 1. fa) to) @) (b) 3, 4 (a) ) oy REMOVE LOWER BALL JOINT Remove the cotter pin and nut. Using SST, remove the lower ball joint SST 09628-62011 REMOVE AXLE HUB Using SST, remove the axle hub. SST 09520-00031 (09520-00040, 09521-00010, 09521-00020) Using SST and a press, remove the inner race (outside) from the axle hub. SST 09555-55010, 09950-60010 (09951-00380), 09950-70010 (09951-07150) REMOVE DUST COVER Using a tor« socket (T30), remove the 3 bolts and dust cover. REMOVE BEARING FROM STEERING KNUCKLE Using snap ting pliers, remove the snap ring, Place the inner race on the outside of the bearing. Using SST and a press, remove the bearing. SST 09527-17011, 09950-60010 (09951-00650), 09850-70010 (08951~07150}SA45 SUSPENSION AND AXLE — FRONTAXLE HUF. 1 fa) REASSEMBLY INSTALL, BEARING Using SST and a press, install a now bearing to the steering knuckte SST 09950-60020 (09951-00730), 09950-70010 (08951~07150) Using snap ting pliers, install a new snap ring, INSTALL DUST COVER 9} Place the dust cover and using a torx socket (T30), install the $ bolts. 3. 4. fa) (b) Torque: 8.3 N-m (85 kgf-cm, 74 in-Ibf) INSTALL FRONT AXLE HUB. Using SST and a press, install the axle hub. SST 09608-32010, 09950-60010 (09951-00550) 09950-70010 (09951-07150) INSTALL LOWER BALL JOINT Install the lower bat joint and tighten the nut. Torque: 103 N-m (1,050 kaf.cm, 76 ftlbf) Install a new cotter pin, Ifthe hotes for the cotter pin are not aligned, tighten the nut fur. ther up to GO".SA-16 SUSPENSION AND AXLE — FRONT AXLE HUB, INSTALLATION Installation is in the reverse order of removal (See page SA~12}. HINT: Alter installation, check the ABS speed sensor signal (See page DI~276) and front wheel alignment (See page SA~4),SAAT SUSPENSIONAND AXLE —_ FRONT WHEEL Hut GOUT FRONT WHEEL HUB BOLT REPLACEMENT 1. REMOVE FRONT WHEEL 2. REMOVE BRAKE CALIPER AND DISC {a} Remove the 2 bolts, brake caliper and disc. (©) Support the brake caliper securely. 3, REMOVE HUB BOLT Using SST, 2 nuts and a screwdriver or an eguivalenl, remove the hub bolt SST 09628-10011 4, INSTALL HUB BOLT (@) Install a washer ancinut to a new hub boll as shown in the itustration. (b) Using a screwdriver or an equivalent to hold, install the hub boil by torquing the nut. {c) Remove the 3 nuts and washer. 5. _ INSTALL DISC AND BRAKE CALIPER Install the disc, brake caliper and 2 bolts. Torque: 107 N-m (1,090 kgf-cm, 79 ft-bt) 6. INSTALL FRONT WHEEL. Torque: 103 N-m (1,050 kgfem, 76 ft-bt)SA-18 SUSPENSION AND AXLE —_ FRONT ORIVE SHAFT FRONT DRIVE SHAFT COMPONENTS "ZZ-FE engine (M/F) and 222-GE engine: Center Bearing Bracket (aor) + Cottar Pin Tie Rod End oe (Saaw Dive Shak (LH) @ Clamp ~ mf sam Gage Lower Suspension Arm _ Pear i # Boat S Y Stering Krcklo TT wih ane Hab —-{ 142 (ASG, 105) J Center Bearing fe Straight Pin # Snap Ring s Bat | # Sap Ring “) Genter Bearing os i el Cave @ Dust Cover L # Dust Cover i b Inboard Joint Shaft l 4 Ouier Snap Ring Dyparnis Damper Karam, ftibi) | : Specified toque x Nor-rousable part _sA-19 SUSPENSION AND AXLE —_ PHONY OHIVE SHAFT 122-FE engine (AT): Drive Shaft (RH) Center Bearing Bracket © Cotter Pin A ne We Rod En ! + Snap Ring # Clamp # Boot oe # Conter Bearing + i Outboard Joint Shaft Od {Inboard Joint Shate 6 Pe Straight Pin be ? Hi Inboard Joint Shatt Center Bearing Case | | # Dust Cover t @ Dust Cover : " Nin (kotcm, HbA] : Specified torque # Non-reusable partSA-20 SUSPENSION AND AXLE. —_ FRONT OF IVE SHAFT REMOVAL NOTICE: (0) 5. fa) ‘The hub bearing could be damaged if it is subjected to the vehicle weight, such as when moving the vehicle with the drive shaft removed, Therefore, if itis absolutely necessary to place the vehicle weight on the hub bearing, first support It with the SST. SST 09608-16042 (09608-02021, 09608-02041) wi ABS: After disconnecting the drive shaft from the axle hub, work carefully so as not to damage the ABS speed sensor rotor Serrations on the drive shat. REMOVE FRONT WHEEL Torque: 103 N-m (7,050 kgt-em, 76 ft-lbf) REMOVE ENGINE UNDER COVER DRAIN GEAR OIL (M/T) OR ATF (A/7) REMOVE DRIVE SHAFT LOCK NUT Using SST and a hammer, unsiake the staked part of the Jock nut, SST 09930-00010 ‘White applying the brakes, remove the nut. Torque: 216 Nem (2,200 kgf.cm, 159 ft-lbt) DISCONNECT TIE ROD END FROM STEERING KNUCKLE Remove the cotter pin and nut. Torque: 48 N-m (500 kgt-om, 36 ftibf) HINT: ‘At the time of instaitation, if the holes for a new cotter pin are not aligned, tighten the nut further up to 60° ib) Using SST, disconnect the tie rod end from the steering, knuckle. SST 09610-20012SA-21 SUSPENSION AND AXLE —_EROWT DRIVE SHAFT 6. DISCONNECT LOWER BALL JOINT FROM LOWER SUSPENSION ARM Remove the 2 nuts and bolt. Torque: 142 Nm (1,450 kgt-cm, 105 ftibt) 7. DISCONNECT DRIVE SHAFT FROM AXLE HUB Using a plastic hammer, disconnect the rive shaft from the axle hub. NOTICE: Be careful not to damage the boot and ABS speed sensor rotor. RH drive shatt: REMOVE DRIVE SHAFT Remove the 2 bolts on the center bearing bracket and pull out the drive shalt togettier with the center bearing case. Torque: 64 Nom (650 kgf-cm, 47 ttf) NOTICE: Be careful not to damage the oil seai and dust cover. 9, LH drive shaft: REMOVE DRIVE SHAFT {a) Using SST, remove the drive shaft SST 09520-01010. 09520-24010 (09520-32040) NOTICE: Be careful not to damage the oil seal and dust cover. HINT: ‘At the time of installation, please refer to the foliowing items. + Apply gear oit to the inboard joint shatt and differential case sliding surfaces. + Before installing the drive shaft, set the snap ring with its ‘opening side facing downward. + Whether inboard joint shaft is in contact wilh pinion shaft ‘or not can be known from the sound or feeling. + Alor installation, check that thore is 2-8 man (0.08 ~ 0.12 in.) of play in the axial direction, + Affer installation, check thal the drive shaft cannot be removed by hand. ib) Using a screwdriver, remove the snap ring fom the inboard joint shattSA-22 SUSPENSION AND AXLE. FRONT ORIVE SHAET DISASSEMBLY 1. 12Z-FE engine (M/T) and 2Z2-GE engine: DISASSEMBLE DRIVE SHAFT (a) Check the drive shaft. (1) Check to see thal there is no remarkable play in the outboard joint (2) Check to see that the inboard joint slides smoothly ia the thrust direction (3) Check to see that there is no remarkable play in the radial direction of the inboard joint. (4) Check the boots for damage. (b) Remove the inboard and outboard joint boot clamps. (1) Using a screwdriver, disclamp the 2 inboard joint boot clamps. (2) Using a side cutter, cut the 2 outboard joint boot clamps and remove them. () MA Remove the dynamic damper clamp. Using a screwdriver, disclamp the dynamic damper clamp. {d) Remove the inboard joint shat. (1) Slide the inboard jeint boot toward the outboard joint, (2) Place matchmarks on the outboard joint shaft and inboard joint shaft NOTICE: Do not punch the marks. (3) Using a screwdriver, remove the snap ring. (4) Remove the inboard joint shaft from the outboard joint shaftSA-23 SUSPENSION AND AXLE —_ FRONT ofive SHAFT Matchmarks {e) Disassemble the outboard joint shaft, (1) Place matchmarks on the outboard joint shalt, inner face and cage. NOTICE: Do not punch the marks. (2) Remove the 6 balls. (8) Slide the cage toward outboard joint. (4) Using a snap ring expander, zemove the snap ring, (5) Using a brass bar and hammer, remove the inner race. NOTICE: Be careful not to damage the inner race. (6) Remove the cage. () Remove the dynamic damper (MrT), damper clamp (M/T), inboard and outboard joint baots and inboard joint ciamps. NOTICE: Do not disassemble the outboard joint. 2 12Z-FE engine (AT): DISASSEMBLE DRIVE SHAFT (a) Check the drive shaft. (1) Check to see that there is no remarkable play in the outboard joint. 2} Check to see that the inboard joint sides smoothly in the thrust direction (8) Chock to see that there is no remarkable play in the radial direction of the inboard joint (4) Check the boots for damage. (®) Remove the inboard and outboard joint boot clamps. (1) Using @ screwdtiver, disclamp the 2 inboard joint boot ctainps. (2) Using a side cutter, cut the 2 outboard joint boat lamps and remove them, (6) Remove the inboard joint shaft (1) Slide the inboard joint boot toward the outboard joint.SA-24 SUSPENSION AND AXLE FRONT DRIVE SHAFE Matchmarks 5 A wanes (2) Place ratchmarks on the inboard joint shat, tripod and outboard joint shatt NOTICE: Do not punch the marks. (3) Remove the inboard joint shaft from the outboard joint shat. {d) Remove the tripod. (1) Using a snap ring expander, remove the snap ring. 12) Piace matchmarks on the outboard joint shaft and tripod. NOTICE: Do not punch the marks. (8) Using a brass bar and hammer, remove the tripod from the outboard joint shaft, NOTICE: Do not tap the roller. fe) Remove the inboard and outboard joint boots and inboard joint clamps. NOTICE: Do not disassemble the out board joint. 3, DISASSEMBLE INBOARD JOINT SHAFT (a) UH: Remove the dust cover. Using SST and a press, remove the dust caver. SST 09950-00020 {b) LH shalt of 122-FE engine (M/T) and 222-GE engine: Using a snap ring expander, remove the outer snap sing. i) RH Remove the transaxte side dust cover. Using a press, remove the transaxle side dust cover.SA-25 SUSPENSION AND AXLE ~ FRONT DRIVE SHAFT gst @ RH: Remove the center bearing. (1) Using a screwdriver, remove the outside snap ring. (2) Using a press, remove the center bearing case. (@) Using apin punch and hammer, remove the straight pin from the center bearing case. (4)_ Using SST and a press, remove the dust cover, SST 09950-00020 (5) _ Using @ snap ring expander, remove the inside snap ting. (6) Using a press, remove the center bearing,SA-26 SUSPENSION AND AXLE. ERONT DRIVE SHAFT REASSEMBLY REASSEMBLE INBOARD JOINT SHAFT ® LH: Install dust cover. Using a press, install a new dust cover. {b) LH shatt of 122-FE engine (W/T) and 2Z2~GE engine: Using a snap ring expander, instalt a new outer snap ting, (RH Instalt center b (1) Using a pin punch and hammer, install the straight pin into the center bearing case, (2) Using SST and a press, install a new center bearing into the bearing case. SST 09950-60010 (09951-00650), 69950-70010 (09951-07150) (3) Using a screwdriver, install a new outside snap ring (4) Using SST and a press, install the center bearing with the bearing case assembly to the inboard joint shall SST 09710-30021 (09710-03141) (6) Using a snap ring expander, install a new inside snap ring (6) Using SST, an extension bar and press, install a new dust cover. SST 09508-35050 HINT: ‘The clearance between the dust cover and bearing should be Kept in the ranges as shown in the istration.SA-27 SUSPENSION AND AXLE —_ ERUWT Dive SHAFT /86~87 own (8.39-3.43 in} Vin Tape. ‘Matchmatks QS (ay 2 (a) RH: Install tho transaxle side dust cover. Using a steei plate and press, install a new transaxle sido dust cover until the distance from the tip of the inboaret joint shaft to the dust cover reaches the specified value, ‘as shown in the illustration. 12Z-FE engine (AT): REASSEMBLE DRIVE SHAFT ‘Temporary install new outboard and inboard joint boots and new clamps. HINT: Before installing the boots, wrap the spline of the outboard joint shalt with vinyl tape to prevent them from being damaged, (©) (1) Place 2 new clamps on a new outboard joint boot and install them to the outboard joint shaft (2) Place 2 new clamps on anew inboard joint boot and install them to the outboard joint shaft. Install the tripod. (1) Place the beveled side of the tripod axial spline {o- watd the outboard joint. (2) Align the matchmarks placed before removal. (8) Using a brass bar and hammer, tap in the tripod to the outboard joint shatt NOTICE: Do not tap the roller, © (dy (4) Using a snap ring expander, instal a new snap ring, Install the boot to outboard joint. Before assembling the boot, pack the outboard joint and boot with grease in the boot kit. Grease capacity: (Color = Yellow ocher) 110-120 g (3.9 -4.2 07.) Install the inboard joint shaft to outboard joint shatt (1) Pack the Inboard joint and boot with grease in the boot kit, Grease capacity: (Color = Yellow ocher) 180 - 190 g (6.3-6.7 02.) (2) Align the matchmarks placed before removal, ard instal! the inboard joint shaft to the outboard joint shaft (3) Temporarily install the boot to the inboard jointSUSPENSIONAND AXLE —_ FRONT DRIVE SHAFT. Vinyl Tape eee {e) Assemble the boot clamps to both boots, (1) Make sure that the boots are on the shaft grooves. (2) Make sure that the boots are not stretched or con- tracted when the drive shaft is at standard length Drive shaft standard length: me 854.0 = 50 mimi93G08 2 D487 np m7 5659 = $0 0m 122.270 30.107 (3) Bend the band and lock the inboard joint boot clamps with a screwdriver. (4) Secure the 2 outboard joint boot clamps onto the boot (5) _ Place SST onto the outboard joint large boot clamp. SST _ 09521-24010 (6) Tighten the SST so that the large clamp is pinched. NOTICE: Do not overtighten the SST. (7)_ Using SST, adjust the clearance of the large clamp, SST 09240-00020 Clearance: 0.8 mm (0.031 in.) ot less (8) Employ the same manner to the outboard joint ‘small boot clamp, 3. 1ZZ-FE engine (M/T) and 27Z-GE engine: REASSEMBLE DRIVE SHAFT (@) Temporarily install dynamic damper (M/T), new outboard and inboard joint boots and new clamps, HINT: Before installing the boots, wrap the spline of the outboard joint shaft with vinyl tape to prevent them from being damaged. (1) Place 2 new clamps on a new outboard joint boot and instail them to the outboard joint shaft MIT: Place naw clamp on the dynamic damper and install them to the outboard joint shaft. (3) Place 2 new clamps on a now inboard joint boot and install them to the outbeard joint shaftSA-29 SUSPENSION AND AXLE FRONT OAIVE SHAET Matchmarks (©) Assemble the outboard joint shaft. (1) _ Iastail the cage to the outboard joint shaft NOTICE: The side with smailer diameter must face outboard joint, (2) Align the maichmarks on the inner tace and out board joint shatt (3) Using abrass barand hammer, tapin the inner race to the oulboard joint shaft NOTICE: Be careful not to damage the inner race. (4) _ Using a snap ring expander, install a new snap ring, (8) Align the matchmarks on the cage and inner race. {6) _ Install the cage to the inner race. (7) install the 6 balls. HINT: Apply grease onto the balls to keep them from falling. (2) Install the boot to outboard joint Before assembling the boot, pack the eulboard joint and boot with grease in the boot kit. Grease capacity: (Color = Black) 115 - 15 g (2.1 — 4.8 oz.) (2) _ Install the inboard joint shatt to outboard joint shat. (1) Before assembling the boot, pack the inboard joint and boot with grease in the boot kit Grease capacity: (Color = Gray) 100 ~ 120 g (3.5~ 4.207)SA-30 [SUSPENSION AND AXLE — 2) 3) (ay 6) le) a) @) FRONT Dfuve SHAFT ‘Align the matchmarks on the inboatd joint shaft and ‘outboard joint shaft. Install the inboard joint shaft to the outboard joint shatt Instali a new snap sing. Temporarily install the boot to the inboard joint shaft Assemble the boot clamps to both baots. Make sure that the boots are on the shatt grooves Make sure that the boots are not stretched or con- tracted when the drive shaft is at standard length. Drive shaft standard length: Be 045.5 = Som (80.207 + 0.197 1m) te S627 2 80 nr (22.198 = 0.197 0) @) 4) {5) ssT 6) NOTICE: (7) ssT @) Bend the band and lock the inboard joint boot clamps with a screwdriver. Secure the 2 outboard joint boot clamps onto the: boot Place SST onto the outboard joint large boot clamp. 09621-24010 Tighten the SST so that the large clamp is pinched. Do not overtighten the SST. Using SST, adjust the clearance of the large clamp. 09240-00020 Clearance: 1.2 ~ 4.0 mm (0.047 - 0.157 in.) Employ the same manner to the outboard joint small boot clamp.SA-31 SUSPENSION AND AXLE FONT DAVE SHACT Mr: Assemble the dynamic damper clamp. (1) Set the dynamic damper distance, as described be- tow. Distance: 155.0 + 2.0 mm (6.102 x 0.079 in.) (2) Bend the band and lock the dynamic damper clamp with a screwdriver, CHECK DRIVE SHAFT (See page SA-22)SA-32 SUSPENSION AND AXLE —_ FRONT DRIVE SHAET INSTALLATION installation is in the reverse order removal (See page SA~20). HINT: ‘Attor inslallation, check the ABS speed sensor signal (See page D!-276) and front wheel alignment (See page SA-4).SA-39 [SUSPENSION AND AXLE, - FRONT SHOOx ABSORBER, FRONT SHOCK ABSORBER COMPONENTS ™ Qo — of 7536) KD — suspension Suppon @-——-— Dust Seat ED s0r050 “ Upper Insulator Stabilizer Bar Link . (eae, Ti soscyessoner oo} Gail Spring ‘Shock Absorber with Coil Spring Gs bones <> Lower Insulator (ana T} coe Flexible Hose—-——~ [Rin fkgfom, ftlbij |< Specified torque 1. Non-reusable panSA34 SUSPENSION AND AXLE FRONT SHOCK AUSOROER, REMOVAL 4. REMOVE FRONT WHEEL Torque: 103 Nem (1,050 kgf.cm, 76 tt-bt) 2. DISCONNECT ABS SPEED SENSOR WIRE HARNESS: CLAMPS FROM SHOCK ABSORBER Remove the bolt and disconnect the ABS speed sensor wie harness clamp. Torque: 8.0 N.m (82 kgf-om, 71 in-Ibf) 3. DISCONNECT FLEXIBLE HOSE Remove the bolt and disconnect the flexible hose from the shock absorber bracket Torque: 19 Nem (192 kgf-cm, 14 ftbf) 4, DISCONNECT STABILIZER BAR LINK Remove the nut and disconnect the stabilizer bar link from the shock absorber. Torque: 44 N.m (449 kgt-om, 32 ftlbf) HINT: {1 the bail joint urns tagather with the nut, use ahexagan (5 mm) wrench to hold the stud. 8. REMOVE SHOCK ABSORBER WITH COIL SPRING {a) Loosen the 2 nuts on the lower side of shock absorber. Torque: 153 Nim (1,560 kgf.cm, 113 fulbf) HINT: Do not remove the 2 bolts. {b) Remove the 3 nuts on the upper side of the shock absorb- 9. Nem (400 kgf-om, 29 flbf) {) Remove the 2 nuts and bolts on the lower sidle of shook absorber. HINT: At the time of installation, coat the nut's thread with engine oil (@) Remove the shock absorber with coll spring.SA-35 SUSPENSION AND AXLE — FRONT SHOCK ABSORBEN DISASSEMBLY REMOVE COIL SPRING (a) _ Install 2 nuts and a bolt to the bracket at the lower side of the shock absorber and secure it ina vise. (©) Using SST, comprass the coil spring. SST 09727-30021 (09727-00010, 09727-00021. 09727-00031) NOTICE: Do not use an impact wrench. It will damage the SST. (C}_ Remove the cap from the suspension support. Using SST to hold the spring seat, remove the nut SST 09729-22031 Remove the suspension support, dust seal, spring seat, upper insulator, coi! spring. spring bumpar and lower insulator.SUSPENSION AND AXLE PONT SHOCK ABSORBER INSPECTION INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual sound during operation, W there is any abnormality, replace the shock absorber with a now one, NOTICE: When disposing of the shock absorber, see DISPOSAL on page SA-37,SA-37 SUSPENSION AND AXLE —_ FRONT SHOCK ansonRER DISPOSAL 4, FULLY EXTEND SHOCK ABSORBER ROD 2, DRILL HOLE TO DISCHARGE GAS FROM CYLINDER Using a drill, make a hole in the oylinder as shown in the illustration to discharge the gas inside. CAUTION: + When drilling, chips may fly out, work carefully. + The gas is colorless, odorless and non-polsonous.JUSPENSION AND AXLE —_FHONT SHOCK ANSOrIBER Tab > REASSEMBLY 4. INSTALL LOWER INSULATOR ONTO SHOCK AB- SORBER 2, INSTALL SPRING BUMPER TO PISTON ROD 3. INSTALL COI SPRING {a} Using SST, compress the coll spring. SST 09727-30021 (09727-00010, 09727-00021, 09727-00031) NOTICE: Do not use an impact wrench. It will damage the SST. (b) _ Install the coil spring to the shock absorber, HINT: Fit the lower end of the coil spring into the gap of the spring iow- or seat. {e) install the upper insulator as shown in the ilustration, {d) _ Install the spring seat to the shock absorber with the “A” mark facing to the outside of the vehicle. {e) Install the dust seal and suspension suppor. (f) Using SST to hold the suspension support, install a new ut. SST 09729-22031 Torque: 47 N.m (475 kgt-em, 34 ftlbf) (a) Remove the SST. SST 09727-30021 (09727-00010, 09727-00021, 09727-00031)SUSPENSION AND AXLE — FRONT SHOCK ASSORBER (h) Apply MP grease into the suspension support, (i) jnstall the cap. SA-39SA-40 SUSPENSION AND AXLE —__ FRONT SHOCK ABSORBER INSTALLATION instatlation is in the reverse order of removal (See page SA-34), HINT: Atter installation, check the front wheel alignment (See page SA~4)Saat SUSPENSION AND AXLE FRONT LOWER SUSPENSION ARM FRONT LOWER SUSPENSION ARM COMPONENTS “— LY vat S i RH] # Cotter Pin (8 00,39} Engine Rear “Bs, (a3) De [Rare HH] Speci torque a Non-reusable partSAnAZ SUSPENSION AND AXLE FRONT OWER SUSPENSION ARM REMOVAL 4. REMOVE FRONT WHEEL Torque: 103 N-m (1,050 kgt-cm, 76 ttibf) 2 MfTor AT RH side: REMOVE LOWER SUSPENSION ARM (a) Remove the engine under cover {b) Remove the bolt and 2 nuts, and disconnect the lower suspension arm from the lower ball joint Torque: 142 Nm (1,450 kgf-cm, 105 ftIbf) {e) Remove the 2 bolts, nut and tower suspension arm Torque: 137 Nem (1,397 kgf-em, 101 ftlbf) HINT: At the time of installation, atter stabilizing the suspension, torque the bolts, 3. ATLH side: REMOVE LOWER SUSPENSION ARM (a) Remove the engine under covers. (b) Disconnect the AH and LH tie red ends. (1) Remove the cotter pin and nut Torque: 49 Nem (500 kgf-cm, 36 ftibt) HINT: At the time of installation, if the holes tor a new cotter pin are not aligned, tighten the nut further up to 60° (2) Using SST, disconnect the tie rod end from the steering knuckle. SST 09610-20012 (3) Employ the same manner described above to the other side.SA-a3 SUSPENSION ANDAXLE — _FFIONT LOWER SUSPENSION Aft (©) Disconnect the RH and LH stabilizer bar links, (1) Remove the nut and disconnect the stabilizer bar link trom the shock absorber. Torque: 44 N.m (449 kgf-cm, 32 ftibh) HINT: I the ball jointturns together with the nut, use a hexagon {5 mm) wrench fo hold the stud. (2) Employ the same manner described above to the other side. (9) Disconnect the RH and LH lower suspension arms from the lower ball joints, (1) Remove the bolt and 2 nuts, and disconnect the fower suspension arm from the lower ball joint Torque: 142 N-m (1,450 kgf-cm, 105 ftlbt) (2) Employ the same manner described above to the other side (©) Loosen the lower suspension arm set bolts ‘Torque: 137 N-m (1,397 kgt-cm, 101 fbf) HINT: Al the time of installation, after stabitizing the suspension, torque the bolts, (Remove the engine hood (See page BO-9). {g) _Aitach the engine siing device to the engine hangers. (1) Disconnect the 2 PCV hoses. {2) Install the No. + and No. 2 engine hangers in the correct direction. Parts No. : (12Z-FE engine) No. 1 engine hanger: 12281-22021 No. 2 engine hanger: 12281~15040 or 12281-15050 Bolt: 91512-81016 N aad Parts No. : (22Z-GE engine) No. 1 engine hanger: 12281-88600 No. 2 engine hanger: 12282-88600 Bolt: 91512-61020 Torque: 38 N.m (387 kgf-cm, 28 ftibf) {3) Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.SUSPENSION AND AXLE — _ERONT LOWER SUSPENSION ARH (h) Disconnect the PS gear assembly from the suspension member. (1) Remove the 4 set bolts. Torque: 58 Nm (591 kgf-om, 43 ftlbf) (2) Tie the PS gear assembly to suspend it securely (1) Remove the bolt A and 3 nuts, and disconnect the engine rear mount. Torque: 52 Nem (530 kaf-cm, 38 ftibf) () Remove the 2 bolts (B) and disconnect the engine front mount. Torqure: 52 N.m (530 kgt-cm, 38 ftlbf) (k) Using a transmission jack, support the suspension mem: ber. () Remove the 6 bolts (C and D) and lower the suspension member. Torque: Bolt C: 157 N-m (1,600 kgf-em, 116 ft-lbf) Bolt D: 39 N.m (400 kgf-cm, 29 ft-lbf) (m) Remove the 2 bolts, nut and lower suspension arm. 8 so]SUSPENSION AND AXLE —_ FRONT LOWER SUSPENSION Arts INSTALLATION Installation is in the reverse order of removal (See page SA~42). HINT. After installation, check the front wheel alignment (See page SA~). SA-45SAG SUSPENSION AND AXLE FRONT LOWER BALL JOINT. FRONT LOWER BALL JOINT COMPONENTS oP CRI) ABS Spaed Sensor (war © Cotier Pin arn —— Steering Knuckle with Axle Hub me r Lower Suspension Ann, Ep serves [EIA TE: Spectator a er] gNon-reusablepartSA-a7 SUSPENSION AND AXLE —_ FRONT LOWER BALL Jou REMOVAL 1 2 @) (b) REMOVE STEERING KNUCKLE WITH AXLE HUB (See page SA-12) REMOVE LOWER BALL JOINT Romove the cotter pin and nut Using SST, remove the lower ball joint SST 09628-62011SUSPENSION AND AXLE FRONT LOWER BALL JOINT INSPECTION INSPECT LOWER BALL JOINT FOR ROTATION CONDI- TION (a) As shown in the illustration, lip the ball joint stud back and forth § times, before installing the nut. (b) Using a torque wrench, turn the nut continuously at a rate of 24 seconds per 1 turn and take the torque reading fon the 5th tum, Turning torque: 1.0 - 4.9 Nm (10 ~ 50 kgt-cm, 8.7 - 43 in-Ibf)SA-49 ITLOWER BAL JOINT INSTALLATION 1. INSTALL LOWER BALL JOINT {2} _ Install the lower ball joint and tighten the nut Torque: 103 N-m (1,050 kgf-cm, 76 ftlbf} (b) Install a new cotter pin. ifthe holes for the cotter pin are not aligned, tighten the aut further up to 60 * 2. INSTALL STEERING KNUCKLE WITH AXLE HUB (See page SA-16) 3. CHECK ABS SPEED SENSOR SIGNAL (See page DI-276) 4. CHECK FRONT WHEEL ALIGNMENT (See page SA-4)SA-50 SUSPENSION AND AXLE. FRONT STABILIZER BAB FRONT STABILIZER BAR COMPONENTS Stabilizer Bar Link ee Eg Ross Mout @ | . a es / i} Bushing 52 (536, 38) |: Spected torqueNe! SABA QUSPENSIONANDAXLE -_ FRONT STAGILIZER BAR PaintLine \, aa’ Ko REMOVAL 1. REMOVE STABILIZER BAR LINKS fa) Remove the 2 nuts and stabilizer bar link. Torque: 44 Nom (449 kgf-cm, 32 ftbt) HINT: Ifthe ball joint turns together with the nut, use ahexagon (5 mm) wrench to hold the stud. (b) Employ the same manner described above to the other side. 2. REMOVE FRONT SUSPENSION MEMBER WITH LOW- ER SUSPENSION ARM (See page SA-42) 3. REMOVE STABILIZER BAR fa) Remove the 2 bolls, bracket and bushing ‘Torque: 19 N-m (194 kgf-cm, 14 fbf) HINT: At the time of installation, please refer to the following items. + Install the bushing so that the cutout will face to the rear. + Install the bushing to the outside of the paint line on the stabilizer bar. (b) Empioy the same manner described above to the other sido. (¢) Remove the stabilizer bar.SA-62 SUSPENSION AND AXLE _._PRONT STABILIZER BAR, = INSPECTION ws oe? INSPECT STABILIZER BAR LINK BALL JOINT FOR ROTA- A _ TION CONDITION Mt LA (a) As shown in the illustration, fp the ball joint stud back and torth 5 times, before installing the nut, (©) Using a torque wrench, turn the nut continuously at a rate of 24 seconds per f tusn and take the torque reading on the 8th turn. Turning torque: 0.05 ~ 1.0 N-m (0.5 — 19 kgf-cm, 0.4 ~ 8.7 In.bf)SA-53 SUSPENSION AND AXLE FRONT STABILIZER BAR INSTALLATION Installation is in the reverse order of removal (See page SA-51). HINT: After installation, check the front wheel alignment (See page SA-4).SA-54 SUSPENSION AND AXLE REAR AXLE CARRIER, REAR AXLE CARRIER COMPONENTS wi ABS: ABS Speed Sensor Connector y SS oS, ay. ADO —— cam Plate wi ABS: @_ ~ @ ABS Speed Sensor eG On CRE meat ‘Aun [Nom (kgfom, ttibij_]: Specified torque 1@ Non-réusabie part veseo SA-85 SUSPENSION AND AXLE — REAR AXLE CARIEH, REMOVAL Tm 1. REMOVE REAR WHEEL Torque: 103 N-m (1,050 kgf-om, 76 ftibt) 2 wi Disc brake: REMOVE BRAKE CALIPER AND DISC (a) Remove the 2 bolts, brake caliper and disc. Torque: 47 Nm (475 kgf-cm, 34 ft-lbf) (b) Support the brake caliper securely. 3. w! Drum brake: REMOVE BRAKE DRUM 4, CHECK BEARING BACKLASH AND AXLE HUB DEVI- ATION (a) _ Using a dial indicator, check the backlash near the center of the axle hub, Maximum: 0.05 mm (0.0020 in.) Ifthe backlash exceeds the maximum, replace the axle hub. (©) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bol Maximum: 0.07 mm (0.0028 in.) {the deviation exceeds the maximum, replace the axle hub. 5. w/ ABS: DISCONNECT ABS SPEED SENSOR CONNECTOR, 6. REMOVE REAR AXLE HUB (a) Remove the 4 bolts and axle hub assembly. Torque: 56 N-m (571 kgf-om, 44 ft-ibf) (b) Support the backing plate securely. 7. DISCONNECT STABILIZER BAR LINK Remove the nut and disconnect stabilizer bar link: Torque: 44 N.m (449 kghem, 32 f-lbf) HINT: ! the ball joint ius together with the nut, use a hexagon (5 mm) wrench to hold the stud,SA-56 SUSPENSION AND AXLE = REAS AXLE CARRIER, 8, DISCONNECT UPPER SUPPORT SUSPENSION ARM Remove the bolt and nut, and disconnect the upper suspension asm, Torque: 74 N-m (755 kgt-cm, 55 fbf) NOTICE: Do not turn the nut. HINT: At the time of installation, after stabitizing the suspension, torque the bolt 9. REMOVE REAR AXLE CARRIER (a) Remove the front side bolt and nut of the lower suspen sion asm. Torque: 74 Nem (755 kat-om, 85 ft-lb!) HINT: At the time of installation, after stabifizing the suspension, torque the aut. () Place matchmarks on both the carn plate and lower suspension arm. (©) Remove the nut, cam plate and cam bolt. Torque: 74 N.m (755 kgt-om, 55 ft-ibf) HINT: At the time of instalation, after stabilizing the suspension, torque the nut {@) Remove the tear axle carrier.SA-S7 SUSPENSION AND AXLE —_ REARANLE CAREER DISASSEMBLY wi ABS: REMOVE ABS SPEED SENSOR (a) Using a pin punch and hammer, drive out the 2 pins and remove the 2 attachments trom SST. SST 09520-0908" (09520-00040, 09521-00020) (b)_ Mount the axle hub assembly in a soft jaw viso. NOTICE: Replace the axle hub assembly if it is dropped or a strong shock is given to it. (c}_ Using SST and 2 bolts (Diameter: 12 mm, Pitch: 1.5 mm), remove the ABS speed sensor. SST 99520-00031 (09520-00040, 09521-00020}, 99950-00020 NOTICE: + Donotallow any foreign matter sticking to the sensor rotor. + Pull out the ABS speed sensor straightly not to damage the sensor rotor. + Ifdamage has occurred to the sensor rotor, replace the axle hub assembly. + Donot scratch the contacting surface of the axle hub and speed sensor.SA-58 SUSPENSION AND AXLE REAR AXLE CARRIER REASSEMBLY wi ABS: INSTALL NEW ABS SPEED SENSOR (a) Clean the contacting surface of the axle hub and @ new ABS speed sensor. NOTICE: Do notaliow any foreign matter sticking to the sensor rotor. (b) Place the ABS speed sensor on the axle hub so that the ‘connector is set al the bottom under the on-vehicle condition (©) Using SST and a press, install a now ABS speed sensor to the axie hub. SST 09214-76011 NOTICE + Do not tap the speed sensor with a hammer directly. + Check that there should be no foreign matter on the speed sensor detection portion. + Press in the ABS speed sensor straightly and slowly.SA-89 [SUSPENSION AND AXLE. __REAH AXLE CARRIER INSTALLATION = Installation is in the reverse order of removal (See page SA-55). HINT: After installation, check the ABS speed sensor signal (Seo page DI-276) and rear wheel alignment (See page SA-8).SA-60 SUSPENSION AND AXLE — REAR WHEEL HUB BOLT REAR WHEEL HUB BOLT REPLACEMENT “ ane se N fos roms] 4 2 fa) (b) 3. 4 REMOVE REAR WHEEL wi Disc brake: REMOVE BRAKE CALIPER AND DISC Remove the 2 boits, brake caliper and disc. Support the brake caliper securely. wi Drum brake: REMOVE BRAKE DRUM REMOVE HUB BOLT Using SST and a brass bat, remove the hub bolt. SST 09628-10011 INSTALL HUB BOLT Install a washer and nut to a new hub boll as shown in the illustration, Using a brass bar to hold, install the hub bolt by torquing the nut w! Drum brake: INSTALL BRAKE DRUM w/ Disc brake: INSTALL DISC AND BRAKE CALIPER Install the disc and brake caliper and 2 bolts. 8. Torque: 47 N.m (875 kgf-cm, 34 thbf) INSTALL REAR WHEEL Torque: 103 N-m (1,050 kgf-cm, 76 ftlbf)SA-61 SUSPENSION AND AXLE — REAR SHOCK ABSORBEN REAR SHOCK ABSORBER COMPONENTS Package Tray Trim Rear Deck Trim Cover Spring ~{ 63 (a0, 32) ‘Suspension SS Sopot ~ Spring Bumper e QA cou sping Lowa Suspension Aen 0 -{ 06.8) | ABS Speed 79 (194, 14) Sensor ———~aaf” J Wire Hanoes nee eI] 3 Gan Pats how 8 35.) Use 4 Cam BoltSA-62 SUSPENSION AND AXLE —_REAA SHOOK ABSOROER, REMOVAL 1, REMOVE REAR WHEEL Torque: 103 N-m (1,050 kgf-cm, 76 ft-lbf) REMOVE PACKAGE TRAY TRIM REMOVE LUGGAGE COMPARTMENT MAT REMOVE REAR DECK TRIM COVER REMOVE DECK TRIM SIDE PANEL REMOVE REAR LOWER SUSPENSION ARM {See page SA-72) eesen 7. REMOVE REAR SHOCK ABSORBER Remove the 3 nuts and rear shock absorber. Torque: 80 N-m (816 kgf-cm, 59 ft-lbf)SA-63 SUSPENSION AND AXLE — REAR SHOOK ABSOREE DISASSEMBLY REMOVE COIL SPRING fa) Using SST, compress the coil spring SST 09727-30021 (09727-00010, 09727-00021, 09727-00031) NOTICE: Do not use an impact wrench. It will damage the SST. {b) Using a 6 mm hexagon wrench to hold the piston rod, remove the nut. {c) Remove the washer, cushion, spring bracket, upper insulator, suspension suppor, spring bumper and coll spring,SAGA SUSPENSION AND AKLE REAR SHOCK ABsOnonA, INSPECTION INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual sound during opera- Hon, IT there is any abnormality, replace the shock absorber with a new one. NOTICE: When disposing of the shock absorber, see DISPOSAL on page SA-65.SA-65 SUSPENSION AND AXLE = ican SHOOK ARgORIER DISPOSAL = 1. FULLY EXTEND SHOCK ABSORBER ROD 2, DRILL HOLE TO DISCHARGE GAS FROM CYLINDER Using a drill, make a hole in the cylinder as shawn in the ilustration to discharge the gas inside. CAUTION: + When drilling, chips may fly out, work carefully. + The gas is colorless, odorless and non-poisonous.SA-66 SUSPENSIONAND AXLE REAR SHOCK ANSOABER, REASSEMBLY 1. INSTALL COIL SPRING fa) Using SST, compress the coil spring SST 09727-30021 (09727-00010, 09727-00021, 09727-00031) NOTICE: Do not uso an Impact wrench. it will damage the SST. {b) insert the coil spring to the shock absorber. HINT: Fit the lower end of the coil spring into the gap of the spring low er seat. 2. INSTALL SPRING BUMPER AND SUSPENSION SUP- PORT 3. INSTALL SPRING BRACKET {a} Set the upper insulator to the spring bracket. {b) Position the spring bracket with upper insulator as shown in tho illustration. (c) Install the cushion and washer. (@) Temporarily tighten the center nut. {e) Remove the SST. SST 09727-30021 (09727-00010, 09727-00021, 09727-00031} {f) Recheck the direction of the spring bracket. {g)__Using a 6 mm hexagon wrench to hold the piston rod, tighten the nut, Torque: 56 N.m (571 kgt-cm, 41 ftlbf)SUSPENSION AND AXLE ~_ REAR SHOCK ABSORBER, INSTALLATION Installation is in the reverse order of removal (See page SA-62). HINT: After installation, check the rear wheel alignment (See pago SA-8). SA-67SA-68 SUSPENSIONAND AXLE —_REAR UPPER SUSPENSION Ant REAR UPPER SUSPENSION ARM COMPONENTS Heat insulator | o toner ts or? K ae) bee | ee cam Bor | (a | seas) | Tape : Spiing ‘BH_| Species torque oat sanSA-69 SUSPENSION AND AXLE —_FIEAN UPPER SUSPENSION ARM. REMOVAL 1. REMOVE REAR WHEEL Torque: 103 N-m (1,050 kgf-cm, 76 ftlbf) 2, REMOVE TAILPIPE AND HEAT INSULATOR (a) Remove the 2 boits, springs, gasket, 3 O-rings and tail pipe. Torque: 43 N-m (440 kgf-cm, 32 [tibf) (b) Remove the 4 boits and heat insulator. 3, REMOVE UPPER SUSPENSION ARM fa) Place matchmarks on both the cam plate and suspension rember. (b) Remove the nut, cam plate and cam bolt Torque: 74 N.m (755 kaf.cm, 85 fl.lbt) i: At the time of installation, after stabilizing the suspension, torque the nul. (@) Remove the bolt, nut and upper suspension arm. Torque: 74 N-m (755 kgf-cm, 55 ft-lbs) NOTICE: Do not turn the nut. RINT: At the time of installation, after stabilizing the suspension, torque the bolt,SA-70 SUSPENSION ANO AXLE REAR UPPER. SUSPENSION ARW, INSTALLATION installation is in the reverse order of removal (See page SA-69). HINT: After installation, check the rear wheel alignment (See page SA-).SUSPENSION AND AXLE — REAR LOWER SUSPENSION ARM sat . REAR LOWER SUSPENSION ARM ; COMPONENTS N /r Bh VER a (sagsaemen) SSSA) os RS S ~ SY e Phrking Brake cable ‘Lower Suspension Arm F675. 5H | ees) \ og REST Stopper \ Suspension Arm Bracket a Fe Soon Piao e . 7 ri ¢ p 74 (755,55), Cam Bolt [Rat tafa HT] sSpeciiedinaue I n @ Non-reusable part weaSA-72 [SUSPENSION AND AXLE —_NIEAHL LOWER SUSPENSION ARIA REMOVAL 1, REMOVE REAR WHEEL Torque: 103 N-m (1,050 kgt-om, 76 ft.lbf) 2. REMOVE ABS SPEED SENSOR WIRE HARNESS CLAMP Remove the bolt and disconnect the ABS speed sensor wire harness clamp. Torque: 19 N:m (194 kgf-cm, 14 ttibf) 3, REMOVE TAILPIPE Remove the 2 botts, springs, gasket, 3 O-rings and tailpipe, Torque: 43 N.m (440 kgt-om, 32 ftlbf) 4. DISCONNECT PARKING BRAKE CABLE CLAMP Remove the 2 bolts and disconnect the parking brake cable clamps, Torque: 5.4 N:m (55 kgt-cm, 48 in-Ibt) 5, LOOSEN 3 BOLTS ON FRONT SIDE OF LOWER SUS- PENSION ARM Torque: 65 N-m (663 kgf-cm, 48 ft-Ibf) HINT: + Do not remove the bolis. + Aithe time of installation, after stabilizing the suspension, torque the bolts. 6 DISCONNECT REAR AXLE CARRIER FROM LOWER ‘SUSPENSION ARM (a) Remove the front side bolt and nut. Torque: 74 N.m (755 kgt-om, 55 ftlbt) HINT: At the time of installation, after stabilizing the suspension. torque the nut (b) Place matchmarks on both the cam plate and lower suspension arm,SA-73 SUSPENSION AND AXLE NEAR LOWER SUSPENSION Ant (c} Remove the nat, cam plate and cam bolt Torque: 74 N.m (755 kgt-om, 85 ft-lb) HINT: At the time of installation, after stabilizing the suspension, torque the nut. {d} Disconnect the rear axte cartier from the iower suspension arm. 7, DISCONNECT REAR SHOCK ABSORBER Remove the bolt and nut and disconnect the reat shock absorb: or, Torque: 140 N-m (1,428 kgf.cm, 103 ftbf) NOTICE: Do not turn the nut. HINT: AL the time of installation, after stabilizing the suspension, torque the bolt. 8, REMOVE LOWER SUSPENSION ARM {a) Remove the bolt and nut on the rear side of lower suspension arm. Torque: 74 N.m (755 kgf-cm, 55 ftibf) HINT At the time of installation, after stabilizing the suspension, torque the nut (b) Remove the front side 3 bolts and lower suspension arm, 9. REMOVE SUSPENSION ARM BRACKET Remove the nut, suspension arm bracket and stopper. Torque: 110 N.m (1,122 kgf-cm, 81 tb) HINT: At the time of installation, after stabilizing the suspension, torque the nut,SA-T4 SUSPENSION AND AXLE — REAR LOWER SUSPENSION ARM. INSTALLATION wes Installation {s in the reverse order of removal (See page SA-72). HINT: ‘After instaliation, check the rear wheel alignment (See page SA-8).SA-75 SUSPENSIONAND AXLE REAR SIASILZER AAR, REAR STABILIZER BAR COMPONENTS Stabiizer Bar gna} —e. Stabilizer Bar Link 63 Bushing t be Heat Insulator 7 O-Fing —— Tailpipe 2 Spring eo cert, feibA)_| : Specified torque nv Non-rousabta partSA-76 SUSPENSION AND AXLE ~_AEAR STABILZER BAR REMOVAL 1, REMOVE REAR WHEEL Torque: 103 Nem (1,050 kgt.cm, 76 ftlbf) 2. REMOVE TAILPIPE AND HEAT INSULATOR {a) Remove the 2 bolts, springs, gasket, 3 O-rings and tail pipe. Torque: 43 Nem (440 kgf-cm, 32 ftlbf) {b) Remove the 4 bolts and heat insutator. 3. REMOVE STABILIZER BAR LINKS {a) Remove the 2 nuts and stabilizer bar link. Torque: 44 N.m (449 kgf.cm, 32 ftibf) HINT: {the ball joint turns together with the nut, use a hexagon (5 mm} wrench to hold the stud. {b) Employ the same manner described above to the other side. 4, REMOVE STABILIZER BAR BRACKETS AND BUSH- INGs (a) Remove the 2 bolts, bracket and bushing. Torque: 18 Num (184 kgf-cm, 13 ftbt) HINT: At the time of installation, install the bushing to the outside of the stopper on the stabilizer bar. (b) Employ the same manner described above to the other side, 5. REMOVE STABILIZER BARsae! SA-77 SUSPENSION AND AXLE REAR STAGILIZER BAR. INSPECTION INSPECT STABILIZER BAR LINK BALL JOINT FOR ROTA- TION CONDITION fa) As shown in the iltustration, flip the ball joint stud back and forth 5 times, before instailing the nut (6) Using a torque wrench, turn the nut continuously at a rate of 2~ 4 seconds per 1 tum and take the torque reading on the 5th turn, Turning torque: 0.05 — 1.0 N.m (0.5 10 kgf-cm, 0.4 ~ 8.7 inwIbf)SA-78 SUSPENSION AND AXLE REAR STABLZERBAR INSTALLATION Installation is in the reverse order of removal (See page SA-76).BRAKE BRAKE SYSTEM en TROUBLESHOOTING BRAKE FLUID 2.2. BRAKE PEDAL ..... PARKING BRAKE LEVER: BRAKE MASTER CYLINDER... 20.0.0 BRAKE BOOSTER ASSEMBLY FRONT BRAKE PAD FRONT BRAKE CALIPER, REAR DRUM BRAKE . REAR BRAKE PAD CAR GRAKE CALIPER PARKING BRAKE PROPORTIONING VALVE (P VALVE} ABS ACTUATOR oes ec ccseees FRONT SPEED SENSOR, REAR SPEED SENSOR . BR BR-2 BR BRS ere BR-9 BR-413 eR47 BR-20 BRB BR-33 BR-36 BRAD BRA? BRHg BR 8R-58BRA BRAKE -_BhAKE gy5TEM BRAKE SYSTEM PRECAUTION = Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts of the same part number or equivalent. + itis very important to keep parts and the area clean when repairing the brake system. + If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section.BR-2 TROUBLESHOOTING PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem, The numbers indicate the priarty of the likely cause of the problem. Check each part in ofder. If necessary, replace these parts. BRAKE = TROUBLESHOOTING — Sopa es T Faioastepaesyaen rs 2 Arbtmesyaon ee 5 paca omg oe cong coy we |4. Rear brake shoe clearance (Out of adjustment}, BRS? & Monroe oe SB ph en one + Botany Ubi) ake 2 Pannge ora vr ago oe 5 banngbeto we Sty : 2 faursoc sc cramen Ondlageanon | Ona ons +: Paton ace tr nr ons ows one muta «en Sc me ors oe ove ta nt a ones ts «rote pd tt eds cee itso asa io 1 Pn oe oes oe mo ot sep 9. Pou az me ons 4. bets on or + Padres oer ons ora oeBRAKE. TROUBLESHOUTIN ars pada but brake inoticlent Fludleaks for bake syst 2, Airin brake syst 3. Pad orfining (Worn) 4 Pad or ning (Crackes wr stoned) 5, Roar brako shoo dleaarce (Out of adstnea, 6. Pag or ining (Ci) 7 Pad or ieing (Cazes) 8, Dise (Seared) 9. Booster push rod (Out ofasjustnara s0.Vacuum leaks for boostcsystew Noise fom beakes 1 ad orig (Cracked or astertod) ‘nctataon bot jLeos0) Biss Sere Pad suppon plate (0056) ‘ing in (Worn) Pad or tiving (Diy) 7, Pad ertring (Oiaxed 8. Anchor. tension or return spring ¢Fauly) 9, Ant-squect shim Damages) 10 Shea rols-down epring (Damages)BR N xs BRAKE. GRAKE FLU BRAKE FLUID BLEEDING HINT: ifany workis done on the brake system or itairin the brake fines is suspected, bleed the air from the brake system. NOTICE: ‘Do not let brake fluid remain on a painted surface. Wash it off immediately. 4, FILL BRAKE RESERVOIR WITH BRAKE FLUID Fluid: SAE J1703 or FMVSS No. 116 DOT3 2, REMOVE BATTERY 3. BLEED MASTER CYLINDER HINT Iv the master oylinder has been disassembled oF if the reservoir becomes emply, bleed the air from the master oylinder, (a) Disconnect the brake Hines from the master cylinder. SST 09023-00100 {0} Slowly depross the brake pedal and hold it. (c) Block off the outlet piug with your finger and release the brake pedal. {@) Repeat (b) and (c) 3 oF 4 times. 4, BLEED BRAKE LINE {a} Conneet the vinyl tube to the caliper. {b) Depress the brake pedal several times, then Isosen the bleeder plug with the pedal held down {c) Al the point when fluid stops coming out, tighten the bloeder plug, then release the brake pedal. {d) Repeat (b) and (6) until ail the air in the fluid has been blod out. {e) Repeat the above procedure to bieed the air aut of the brake line for each wheelaR-s BRAKE —_UfAKE FLUID 5. CHECK FLUID LEVEL IN RESERVOIR: Check the fluid level and add fluid if necessary Fluid: SAE J1703 or FMVSS No. 116 DOT3BR-6 Switch Podat Height Stop Light Pedal Freeplay Pedal Reserve Distance BRAKE —_ SHAKE PEDAL BRAKE PEDAL ON-VEHICLE INSPECTION on CHECK PEDAL HEIGHT Pedal height from asphalt sheet: 139.8 ~ 149.8 mm (5.504 ~ 5.698 in.) Ifthe pedal height is incorrect, agjust it 2 fa) to) (ec) a (e) 0 ig) thy w o ih) IF NECESSARY, ADJUST PEDAL HEIGHT Remove the lower No. + panel and finish panel, Disconnect the connector from the stop light switch. ‘Loosen the stop light switch lock nut and remove the stop light switch Loosen the clevis tock nut. Adjust the pedal height by turning the pedal push rod Tighten the clevis lock not Torque: 25 N-m (260 kgf-cm, 19 ttIbf) Install the stop fight switch. Connect the connector to the stop light switch. Push the brake pedal in 5 ~ 15 mm (0.20 ~0.59 in}, tun the stop light switeh 10 lock the nut in the position where the stop light goes otf. Push the brake pedal in § ~ 15 mm (0.20 - 0.591n.), check that stop fight lights up. Alter adjusting the pedal height. check the pedal treeplay. CHECK PEDAL FREEPLAY Stop the engine and depress the brake pedal several times until there is no more vacuum toft in the booster. Push in the pedal until the beginning of the resistance is felt, Measure the distance, as shown Pedal freeplay: 1 - 6 mrn (0.04 ~ 0.24 in.) I incorrect, check the stop light switch clearance. Ifthe clearance is OK, then troubieshool the brake system. 4, Stop light switch clearance: 0.5 ~ 2.4 mm (0.020 ~ 0.094 in.) CHECK PEDAL RESERVE DISTANCE Release the parking brake lever. Wit engine running, depress the pedai and measure the pedal reserve distance, as shown. Pedal reserve distance from asphalt sheot at 490 N (80 kgf, 110.2 Ibf): More than 65 mm (3.35 In.) if ncortect, troubleshoot the brake system.BRAKE BRAKE PEDAL COMPONENTS AT: Cushion Plata [3767827 --D Clovis Pin Wave Washor Pedat Pad |: Specified torque par fy Lithium soap base glycol greasea Lock Nut BRAKE —_ PARKING QHAKE LEVER PARKING BRAKE LEVER ON-VEHICLE INSPECTION 1. CHECK PARKING BRAKE LEVER TRAVEL Pull the parking brake lever all the way up, and count the num ber of clicks. Parking brake lever travel at 496 N (20 kgt, 44.1 Ibf): 7-6 clicks sf incorrect, adjust the parking brake. 2. IF NECESSARY, ADJUST PARKING BRAKE HINT: Bofore adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted. For shoe clearance adjusimenl, see step 4 on page BR-45 or see step 2 on page BR-32, (a) _ Remove the console box {b) Loosen the lock nut and turn the adjusting nut until the Te- ver travel is correct {) Tighter the lock nut. Torque: 5.4 Nem (55 kgt-cm, 48 i {d) Install the console box bf)ORAKE — BRAKE WASTER CYLINDER, BRAKE MASTER CYLINDER COMPONENTS Hoid-down Clamp Bracken Oo” Staines Resesoir NZ On 4 — se ont a Sos [Rin aon. THEA |: Specied torque ‘@ Non-reusable part sc Lithiam soap base glycol qoaso Grommet « Tas Brake Booster Level Warning Switch Connector Reservoir po Reservoir Stopper BR-9BR-10 BRAKE BRAKE MASTER GvEINDEN, REMOVAL 1, REMOVE BATTERY 2. DISCONNECT LEVEL WARNING SWITCH CONNEC- TOR 3. DRAW QUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 4 MMT DISCONNECT RESERVOIR HOSE & DISCONNECT BRAKE LINE (a) wo ABS: Using SST. disconnect the 5 brake lines from the master eylinder and 3-way union. SST 09023-00100 Torque: 15 Nem (155 kgt-om, 11 ftlbf) (b) wi ABS: Using SST, disconnect the 2 brake lines {rom the master oylinder. SST 09023-00100 Torque: 15 N-m (155 kgt-om, 11 ftibf) 6. REMOVE MASTER CYLINDER (a) Remove the 2 mounding nuts. Torque: 13 Nem (130 kgf.cm, 9 fbf) (b) wio ABS: Pull out the check valve bracket, 3-way and master cylin: der. (co) wf ABS: Pull out the chack valve bracket and master cylinder. {d)_ Mlemove the gasket from the master cylinder.BR BRAKE —_BAAKE MASTER CYLINDER 7. REMOVE RESERVOIR (a) Pull out the reservoir stopper. HINT: At the time of installation, make sure to insert the reservoir stop- por through holes of the reservoir and the master cylinder groove. () Remove the reservoir and 2 grommets. (c)_ Remove the cap and strainer from the reservoirBRAZ BRAKE. _DAAKE MASTER CYLINDER, INSTALLATION Installation is in the reverse order of removal (See page BR-10). HINT: + Bolore instattation, adjust length of brake booster push rod (See page BR-16). + Afferinstailation, fil the brake reservoir with brake fluid, bleed the brake system (See page BR-4), and ‘check for leaks. + Check and adjust brake pedal (See page BR-6).GooD We VAS se tt 2nd NO Goo ha BRA3 BRAKE gnAKE BOOSTEN ASSEMBLY BRAKE BOOSTER ASSEMBLY ON-VEHICLE INSPECTION 1. OPERATING CHECK (a) Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance, (b) Depress the brake pedal and start the engine. If the pedal goes down slightly. operation is narmat. 2, AIR TIGHTNESS CHECK (a) Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. If the pedal goes down farthest the tst time, but gradually rises after the 2nd or 3rd time, the booster is airtight. (b) Depress the brake pedal wile the engine is running, and stop the engine with the pedal depressed. If there is no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is airtight.BR44 BARKE — BRAKE pOOSTERASSAMALY COMPONENTS Return Spring L825] HHold-down Clamp # Gasket Vacuum Hose Waster Gyindor (saa TN. Chock Valve fj Bracket > x a Batey Front LH Brake Line ABS Actuator ‘Assombiy Lower No. 1 Panel ECM Bracket Finish Panel [Nm fkgtem, 1H J : Speciios torque + Hion-reusabie part x savBRS BRAKE BRAKE BOOSTER ASSEMPLY REMOVAL 1, REMOVE FRONT LH WHEEL Torque: 103 N-m (1,050 kgfcm, 76 ft-lbt) 2, REMOVE MASTER CYLINDER (See page BR-10) 3. DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER 4. WIABS: REMOVE ABS ACTUATOR ASSEMBLY (See page BR-53) 5. REMOVE FRONT LH BRAKE LINE (a) Using SST and spanner, disconnect the brake kine from the flexible hose of front LH brake. SST 09751-36011 (b) Pull out the brake iine with the grommet trom the body, 6 REMOVE BRAKE BOOSTER (a) Remove the lower No. t panel and finish panel. {b) Remove the return spring, clip and clavis pin (©) Remove the clevis and 4 nuts, (¢) Pull out the brake booster and gasketBR6 BRAKE BRAKE BOOSTER ASHEN INSTALLATION INSTALL BRAKE BOOSTER io Install a new gasket and brake booster with 4 nuts. Torque: 13 Nem (130 kaf-cm, 9 ftlb) {b) Install the clevis, and torque the lock nut. Yorque: 25 Nem (260 kgt-cm, 19 ft.lbt) (c) _Insiall the clevis pin into the clevis and brake pedal, and install the clip to the cfevis pin. (d) Install the pedal return spring . INSTALL FRONT LH BRAKE LINE (a) _ Insert the brake line with the grommet into the body, and install the grommet to the body. (b) Using SST and spanner, connect the brake fine to the llexible hose of front LH brake. SST 09751-36011 Torque: 15 N-m (155 kgtom, 11 flibf) 3. wi ABS: INSTALL ABS ACTUATOR ASSEMBLY (See page BR-54) 4. When replacing the brake master cylinder only: ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD (a) Apply chalk to the tip of an accessory 1001 {b) Place the accessory too! to the brake booster. () Measure the clearance between the brake booster push rod and acvessory tool Clearance: 0 mm (0 in.) HINT: Adjust the clearance in following cases: + ifthere is a clearance between the accessory too! and the shell of the booster (fioating accessory tool), the clear ance is small, + I the chalk does not stick on the tip of the pus rod, the cleatance is large. (d) Ifthe clearance is outside of the specified range, depress the brake pedat and adjust the length of the protruding push rod of the brake booster NOTICE: Make an adjustment with the booster having no vacuum, (Depress the brake pedal several times with the engine stopped.) 5. CONNECT VACUUM HOSE TO BRAKE BOOSTER 6 _ INSTALL MASTER CYLINDER (See page BR-12) 7. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR~4) 8 CHECK FOR FLUID LEAKAGE 9. CHECK AND ADJUST BRAKE PEDAL fa) Cheek and adjust the brake pedal (See page BR-6) {b) Install the finish panel and lower No. + panel 40. DO OPERATIONAL CHECK (See page BR-13) Accessory TootBRAKE — FRONT ARAKE PAD FRONT BRAKE PAD COMPONENTS BRAT 22Z-GE engine: Pad Support Plato Anti~squeal Shien & Pad Wear J Plate (0.85) 7 vf — i — ets anc Ant-qveat Shen nner Antt-squeal Shi rn Spore 12Z-FE engine: Anti-squeal Shim — Pad Suppor Plate te Inner Aati-squeat Shim ——— Outer Pad tenee Pad — Inner Anti-squeal Shim <=> Antiesqueal Shim Peds re bf} 1: Specified torque.N sxe BRAKE _STONTARAKE PAD REPLACEMENT 4. REMOVE FRONT WHEEL 2, INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspection hole and replace the pads if they are not within the specilication. Minimum thickness: 1.0 mm (0.039 in.) 3. LIFTUP CALIPER {a) Hold the sliding pin and remove the bottom side installation bott. HINT: Do not disconnect the flexible hose from the brake caliper. (b) _Liftup the caliper and suspend it securely. 4. REMOVE 2 PADS WITH 4 ANTI-SQUEAL SHIMS AND PAD WEAR INDICATOR PLATES 5. REMOVE 2 PAD SUPPORT PLATE NOTICE: The support plates can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particies cleaned off. 6. CHECK DISC THICKNESS AND RUNOUT (See page BR-24) 7, _ INSTALL PAD SUPPORT PLATES install the 2 pad support plates. NOTICI Do not assemble the upper and lower pad support plates in reverse. 8, INSTALL NEW PADS NOTICE: When replacing worn pads, the anti-squeal shims and ‘wear Indicator plates must be replaced together with the pads. (a) 2Z2-GE engine: Install a pad wear indicator plate on the each pad. (b) | 222-GE engine: Apply disc brake grease to both sides of each inner anti~ squeal shim (See page BR~17). (0) 1ZZ-FE engine: Apply disc brake grease to both sides of the inner anti~ squeal shim position outside (See page BR-17). (@) _ Install the 2 anti-squeal shims on each pad.BR-19 BRAKE FRONT BRAKE PAD (e} install the pads with the pad wear indicator plate facing upward, NOTICE: There should be no oll or grease adhering to the friction surfaces of the pads or the disc. 9, INSTALL CALIPER (a) Draw out a smait amount of brake fluid from the reservoir. (b) Press in the piston with a hammer handle or similar imple- ment. HINT: IW the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. {(¢) Install the caliper. (@) Hold the sliding pin and torque the installation bolts. ‘Torque: 34 N-m (350 kgf-cm, 25 ft-lbf) 10. INSTALL FRONT WHEEL Torque: 103 N-m (1,050 kgf-cm, 76 Itibt) 11. DEPRESS BRAKE PEDAL SEVERAL TIMES 42. CHECK THAT FLUID LEVEL IS AT MAX LINEBR-20 BRAKE ._FRON! BRAKE CALIPER FRONT BRAKE CALIPER COMPONENTS 1ZZ-FE ongine: © Gasket Sting Pin- —— aS @ Dust Boot ee Siding ia — Ba Anli-squeat Shim alt Inner Ped Innge Anti-squeat 2G mee nesses Toca Prato @, = Inner Anti-squea! Shin ED 8. '¢) -— Anti-squeal Shim Pad Support Plate Brake Caliper - > Roh-reusable pat 2% Lihium soap base glycol grease Anti-squeal Shim a,°2 Disc brake aroaseBR-22 BRAKE FRONT BRAKE CaLIpER, REMOVAL 1. REMOVE FRONT WHEEL Remove the wheel and temporatily fasten the diss with hub nuts, ‘Torque: 103 N-m (1,050 kgf-om, 76 feibt) 2, DISCONNECT FLEXIBLE HOSE {a) Remove the union bait and gasket from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 N-m (310 kgt-cm, 22 ftibf) HINT: ‘At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. (b) Use a container to catch the brake fluid as it drains aut. 3, REMOVE CALIPER (a) Hold the sliding pin and remove the 2 instaliation bolts. Torque: 34 N.m (350 kaf-cm, 25 ft-bf) () Remove the caliper from the torque plate. 4, REMOVE 2 PADS WITH ANTI-SQUEAL SHIMS, 5. REMOVE 2 PAD SUPPORT PLATESBA-23 BRAKE FRONT OAAKE CALIPER, DISASSEMBLY 1. REMOVE SET RING AND CYLINDER BOOT Using a screwdriver, remove the set ring and eylinder boot from the cafiper, 2. REMOVE PISTON {a) Place a piece of oloth or similar, between the piston and the caliper. {b) Use compressed air to remove the piston from the cytin. der CAUTION: Do not place your fingers in front of the piston when using compressed air. 3. REMOVE PISTON SEAL Using a screwdriver, remove the piston seal from the cylinder. 4. REMOVE SLIDING PINS AND DUST BOOTS. (a) Remove the 2 siiding pins from the torque plate. (bd) 1Z2-FE engine: Remove the 2 dust boots, (©) 222-GE engine: Using a screwdriver and hammer, tap out the 2 dust boots. HINT: ‘Av the time of reassembly, use a 19 tm socket wranch and tap in 2 new dust boots into the torque plate. Notice: At the time of reassembly, check that the metal plate portion of the dust boot fits snugly in the torque plate.BR24 BRAKE FRONT BRAKE GAUIPER INSPECTION 1, MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. ‘Standard thickness: 12Z-FE engine: 11.0 mm (0.433 in.) 22Z-GE engine: 11.5 mm (0.483 in.) Minimum thickness: 4.0 mm (0.039 in.} Replace the pad if the pads thickness is at the minimurm thickness or less, or if the pad has severe, uneven wear. 2, MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. ‘Standard thickness: 25.0 mm (0.984 In.) Minimum thickness: 23.0 mm (0.906 in.) Replace the disc if the disc's thickness is at the minimum thickness or fess. Replace the disc or grind it on a lathe if it is badly scored or worn unevenly. 3. MEASURE DISC RUNOUT Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the disc. Maximum disc runout: 0.05 mm (0.0020 in.) {the disc's runout is maximum value or greater, check the bearing play in the axial direction and check the axle hub runout (See page SA~12). IF the bearing play and axle hub runout are not abnormal, adjust the dise runout of grind it on a "On-car* brake lathe. 4, IF NECESSARY, ADJUST DISC RUNOUT (a) Remove the 2 bolts and torque plate from the knuckle. (6) Remove the hub nuts and the disc. Reinstall the disc in the position turned 1/5 from ils criginal position on the hub. Install and torque the hub nuts. ‘Torque: 103 N-m (1,050 kgf-cm, 76 ft-lbs) Remeasure the disc runout, Make @ note of the runout and the disc’s position on the hub.se BR-25 BRAKE FRONT ARAKE CALIPER «) @ fe) w Repeat (b) until the disc has been installed on the $ re ‘maining hub positions. lF-the minimum runout recorded In (b) and (c} is fess than 0.05 mm (0.00290 in.}, install the disc in that position. | the minimum runout recorded in (b) and (c) is greater than 0.08 mm (0.0020 in.), replace the disc and repeat step 3 Install the torque plate and torque the mounting bolts. Torque: 107 N-m (1,090 kgf-cm, 79 ft.ibt)BR-26 DRAKE FRONT BAKE CALPER. REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR-23). NOTICE: ‘Apply lithium soap base glycol grease to the parts Indicated by arrows (See page BR-20).BR-27 BRAKE — FRONT URE CALIPER INSTALLATION Installation is in the reverse order of removal (See page BR-22). HINT: + After installation, fill the brake reservoir with brake fluid and bleed brake system (See page BR~). + Check for leaks.BR-28 REAR DRUM BRAKE COMPONENTS BRAKE — BEAL ORUN BRAKE Inspection Hole Plug es dd, Parking Brake Lever Automatic ‘ating Brake Lever Adjusting Lever Rear Shoe Shoe Hald-Oown Spring @— cap A a hor Spring Shoe Hoid-Dowin Spring f Adjusting Lever Spring [Ran | : Spected torque $ Won toussblo pant high temperature groase ty 4 Lithum soap base lyon grease ems Brake DrumBR-29 BRAKE REAR ORUM BAAR REMOVAL 1, INSPECT SHOE LINING THICKNESS Remove the inspection hole plug, and check the shoe lining thickness through the hole. If ess than minimum, replace the shoes. Minimum thickness: 1.0 mm (0.039 in.) 2. REMOVE REAR WHEEL. 3, REMOVE BRAKE DRUM (3) Rolease the parking brake lever, and remove the brake drum, HINT: IW the brake drum cannot be removed easily, do the following steps, (©) Remove the plug and insert a screwdriver through the hole in the backing plate. (©) Using another screwdriver, reduce the brake shoe adjust er by turning the adjusting wheel. 4, REMOVE FRONT SHOE (a) _ Using SST, disconnect the adjuster spring from the rear shoe. SST 09703-30010 {b) Using needle-nose pliers, remove the anchor spring (c)_ Using SST, remove the cap, shoe hold-down spring and pita rom the front shoe. SST 09718-00010 {d) Remove the adjuster and adjuster spring together with the front shoe. {e) Remove the adjuster together with the adjuster spring trom the front shoe. (Using needie-nose pliers, remove the adjusting lever spring (@) Remove the automatic adjusting lever trom the front shoe. 5, REMOVE REAR SHOE fa) Using SST, remove the cap, she hole-down spring and pin. SST 09718-00010BRAKE EAR OSUM orAKE tb) @) ) (b) 8. (a) tb) (©) @ Using needle-nose pliers, disconnect the parking brake cable from the parking brake lever, and remove the rear shoe, REMOVE PARKING BRAKE LEVER, Remove the C-washer. Remove the parking lever from the rear shoo, REMOVE WHEEL CYLINDER Using SST, disconnect the brake line. Use container to catch the brake fluid. SST 09751-36011 Torque:15 N-m (155 kgf.cm, 11 fbf) Remove the 2 bolts and the whee! cylinder Torque:¥0 N-m (100 kaf-cm, 7 tt-lbf) DISASSEMBLE WHEEL CYLINDER Remove the 2 boots from the wheel eylinder. Remove the 2 pistons from the wheel cylinder. Remove the spring from the wheel cylinder. Remove the 2 piston cups from each piston.BR-31 BRAKE -_AEAH UAUM AKE INSPECTION 1. INSPECT DISASSEMBLED PARTS inspect the disassembled parts for wear, rust or damage 2. MEASURE BRAKE SHOE LINING THICKNESS, Using a ruler, measure the shoe lining thickness, ‘Standard thickness: 4.0 mm (0.157 in.) Minimum thickness: 1.0 mm (0.039 in.) Ie the thickness is less than the ininimum or shoe lining shows signs of uneven wear, replace the brake choos. HINT. Wa brake shoes needs replacing, the brake shoes must be replaced as a set 3, MEASURE BRAKE DRUM INSIDE DIAMETER Using a brake drum gauge or equivalent, measure the inside diameter of the drum, Standard inside diameter: 200.0 mm (7.874 in.) Maximum inside diameter: 201.0 mm (7.913 in.) ithe drum is scored or worn, the brake drum may be lathed to tho maximum inside diameter. 4, INSPECT REAR BRAKE LINING AND DRUM FOR PROPER CONTACT Iv the contact between the brake lining and drumis improper, repair the fining with a brake shoe grinder, or replace the brake shoe assemblyBraz BRAKE REAR ORUM BALAKE INSTALLATION Installation is in the reverse order of removal (See page BR-29). NOTICE: Apply lithium soap base glyco! grease and high temperature grease to the parts indicated by the arrows (See page BR-28). 1. CHECK OPERATION OF AUTOMATIC ADJUSTING MECHANISM () Move the parking brake lever of the rear shoe back and forth. Chock that the adjuster turns. lf the adjuster does net turn, check for incorvect installation of the roar brake. (b) Adjust the adjuster length to the as short as possible. {) Install the brake drum. {d) Pull the parking brake lover all the way up until a clicking sound can no longer be heard 2. CHECK CLEARANCE BETWEEN BRAKE SHOES AND DRUM (a) Hemove the brake drum (b) Measure the brake drum inside diameter and diameter of the brake shoes. Check that the difference between the diameters is the correct shoe clearance. ‘Shoe clearance: 0.6 mm (0.024 in.) IFincortect, check the parking brake system, (e) Install tha brake drum. 3. FILL BRAKE RESERVOIR WITH BRAKE FLUID 4. BLEED BRAKE SYSTEM (See page BR—4) 5. CHECK FOR LEAKS 6. INSTALL REAR WHEEL Torque: 103 N.m (1,050 kgf-cm, 76 ft.1bf)REAR BRAKE PAD COMPONENTS BRAKE, AGAR BRAKE PAD BR-33 Anti-squeal Shim P Inner Pad Anti-rautle Spring y
. ‘Shoe Hold-down Spring Brake Caliper Assembly [Nim Wofcm, #ibi | : Specitied torque ED High temperature greaseBRas BRAKE — PARKING DRAKE DISASSEMBLY 1. REMOVE REAR WHEEL Torque: 103 N-m (1,050 kgt-em, 76 ftlbt) 2. REMOVE REAR DISC BRAKE ASSEMBLY (@) Remove the 2 installation bolts and rear brake caliper Torque: 47 N-m (475 kgt-cm, 34 ft-lbf) HINT: Do not disconnect the flexible hose from the brake caliper. (©) Suspend he disc brake securely. Ensure that the hose is not stretched, 3. REMOVE DISC Release the parking brake lever, and remove the disc. HINT: Ifthe disc cannot be removed easily, turn the shoe adjuster until the wheel tums freely. REMOVE SHOE RETURN SPRINGS AND TENSION SPRING Using nesdle-nose pliers, remove the 2 shoe return springs and tension spring 5. REMOVE SHOE STRUT |. REMOVE FRONT SHOE AND ADJUSTER {a) Using SST, remove the shoe hold-down spring and pin thorn the front shee. SST 09718-00010 (b) Remove the front shoe and adjuster.BRae BRAKE PARKING BRAKE, 7. REMOVE REAR SHOE (a) Using SST, remove the shoe hold-down spring and pin from the rear shoe. SST 09718-00010 (b) Bisconnect the tear shoe from the parking brake shoe lever, and remove reat shoe, 8. REMOVE PARKING BRAKE SHOE LEVER Using needle-nose pliers, disconnect the parking brake cable from the parking brake shoe lever.BR-a5 BRAKE —_ PARKING BRAKE INSPECTION 4. INSPECT DISASSEMBLED PARTS inspect the disassembled parts for wear, rust or damage. 2, MEASURE BRAKE SHOE LINING THICKNESS. Using a ruler, measure the thickness of the shoe fining, ‘Standard thickness: 2.0 mm (0.079 in.) Minimum thickness: 1.0 mm (0,039 in.) If the fining thickness is at the minimum thickness or less, ar if there is severe, uneven wear, replace the brake shoe 3. MEASURE DISC INSIDE DIAMETER Using a brake drum gauge or equivalent, measure the inside diameter of the disc. Standard inside diameter: 173.0 mm (6.811 in.) Maximum inside diameter: 174.0 mm (6.850 in.) Replace the discif the inside diameter is at the maximum value or more. Replace the disc or grind it with @ ‘athe i the disc is scored or is worn unevenly. 4. INSPECT PARKING BRAKE LINING AND DISC FOR PROPER CONTACT Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fil. If the contact between the disc and the brake stioe lining is improper, repair it using a brake shoe grinder oF replace the brake shoe assembiy.BRAG BRAKE = PARKING BRAKE REASSEMBLY Reassembly is In the reverse order of disassembly (See page BR~43). NOTICE: Apply high temperature grease to the parts indicated by the arrows (See page BR-42). 1 (a) (b) () @) ©) 2 (@ &) cc ) 3. ADJUST PARKING BRAKE SHOE CLEARANCE ‘Temporarily install the hub nuts. Remove the hole plug, Turn the adjuster and expand the shoes until the disc looks. Return the adjuster 8 noiches. install the hole plug, SETTLING PARKING BRAKE SHOES AND DISC Drive the vehicle al about 80 krivh (31 mph) ona safe, level and dry road. With the parking brake release button pushed in, pull on the lever with 98 N (10 kgf, 19.8 Ibf) of force. Drive the vehicle for about 400 meters (0.26 mile) in this condition Repeat this procedure 2 or 3 times. CHECK AND ADJUST PARKING BRAKE LEVER TRAVEL (See page BR-8)BR-a7 BRAKE -_PROPORTIONING VALVE (H VALVE, PROPORTIONING VALVE (P VALVE) ON-VEHICLE INSPECTION 1. _ INSTALL LSPV GAUGE (SST) AND BLEED AIR SST 09709-29018 2, BLEED AIR FROM FLUID PRESSURE GAUGE 3. RAISE MASTER CYLINDER PRESSURE AND CHECK REAR WHEEL CYLINDER OR REAR BRAKE CALIPER PRESSURE 12Z-FE engine: ‘aster evade fuidpresaure| Flea whe! evince Nau pressino BOE KPa (SO Aglins a2? pal) 2a Wea 20 Kyle 427 2.5 KPa (BO nglcw?_ «$38 pa 475 KPa H8-S2QVEM?, 689 pe) 222-GE engine: ‘Mastorcyieder td pressure ‘ir baka calor td prone 1B KPa (20 tor? 208 psp T85APa 20 kgem?, 284 pep 7.5 KPa 0 kgton®, . 198 psp '5.g1 MPa (522 age? 819 poh When inspecting the fluid pressure, inspect the left font and right rear together, and the right tront ane felt rear together. It the rear fluid pressure is incorrect, replace the P valve assembly, 4. BLEED BRAKE SYSTEM (See page BR-4) 5. CHECK FOR LEAKSyTA Hand-held Festcr Pa aee— BRAKE —_ARSACIUSTOR ABS ACTUATOR ON-VEHICLE INSPECTION 1. _ INCASE OF USING TOYOTA HAND-HELD TESTER: (@) Connect the TOYOTA hand-held tester to the DLCA (b) Start the engine and run it al idl. {c) Select the ACTIVE TEST mode on the TOYOTA hand- hold tester. HINT: Please refer to the TOYOTA hand-held tester operator's manu al for further details. 2, INSPECT ACTUATOR MOTOR OPERATION (@) With the moter relay ON, check the actuator motor operation noise. {b) Turn the motor relay OFF. {c) Depress ihe brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be depressed. (d)_ With the motor relay ON, check that the pedal does not pulsate. NOTICE: ‘Do not keep motor relay ON for more than § seconds continuously. When operating it continuously, set the interval ‘ot more than 20 seconds. {e) Tum the motor relay OFF and release the brake pedal 3. INSPECT RIGHT FRONT WHEEL OPERATION NOTICE: Never turn ON the solenoid which is not described below. (a) With the biake peda! depressed, perform the following operations (b) Turn the SFRH and SPAR solenoid ON simuitaneously, and check that the pedal cannot be depressed. NOTICE: Do not keep solenoid ON for more than 10 seconds continuously. When operating it continuously, set the interval of more than 20 seconds. (c) Turn the SFRH and SFAR solenoid OFF simultaneously, and check that the pedal can be depressed (d) Tum the motor relay ON, and check that the pedal re turns, NOTICE: Do not keop motor relay ON for more than § seconds continuously. When operating it continuously, set the interval of more than 20 seconds. (e} Tum the motor relay OFF and retease the brake pedal. 4. INSPECT OTHER WHEEL OPERATION ‘Asin the same procedure, check the solenoids of other wheels. HINT: Loft front wheel: SFLH, SFLA Right rear wheel: SRAH, SRRA Left rear wheel: SRLH, SRLRBR49 SRaKe —_aasactuaron 5. CLEAR DTC (See page DI-276) 6. IN CASE OF NOT USING TOYOTA HAND-HELD TES- TER: HINT: Using the ABS actuator checker (SST), check the operation of the actuator. If the actuator does not operate, check the operation of sub-wire hamess G according to the instructions on pages DI-300 and DI-295. if the solenoid and/or pump motor relay are abnormal, replace the relay and inspect the actuator operation again. 7. INSPECT BATTERY POSITIVE VOLTAGE. Battery positive voltage: 10 - 14 V 8 DISCONNECT CONNECTORS Disconnect the 2 connectors from the actuator. 9. CONNECT ACTUATOR CHECKER (SST) (a) Connect the actuator checker (SST) to the actuator side wire harness via the sub-wire harness (SST), as shown, SST 09990-00150, 09990-00250, 09990-00300, 09990-00360 (©) Connect the red cable of the checker to the battery posi tive (+) terminal and black cable to the negative (-) terminal. Connect the black cable of the sub-wire harness to the battery negative (-) termina! or body ground. ‘Sub-Wite Harness | (SST)BR-50 BRAKE... Ags ACTUATOR 10. INSPECT ABS ACTUATOR OPERATION OF REAR LH at WHEEL ‘esc aovunrON EMECAER HINT: os se The functions of the ABS actuator checker switches are shown in the table below. Mui! ONOFF a Front Li soienaid OWOFF © ~ e Fear Ri solanod E Froot i slenold e Roar LH soto S ‘Solonaid ONOEF (a) Start the engine and run it at idle. (b) Turn select switch of the actuator checker to the “F” post tion. (c) Push and hold in the "A" switch for a few seconds. Make sure thal you can hear the motor running (d) Depress the brake pedal and hold it unti step (g) is completed. (ec) Push and hold ia the “G” switch for a few seconds, and ‘check that the brake pedal does not go down. NOTICE: Do not keep the "G” switch pushed down for more than 10 seconds. (Release the f soa down. switch and check that the pedal goes (g)_ Push the "A" switch and check that the pedal returns. th) Release the brake pedal e set 4) Push and hold in the "A’ switch for a few seconds, 4) Depress the brake padal and hold it for about 15 seconds. ‘As you hold the pedal down, push the "A switch for a few seconds and check that the brake pedal dees not pulsate, {K) Release the brake pedal. 11. INSPECT FOR OTHER WHEELS (a) Turn the selector switch to "E” position (for front RH wheel) e routs] (b) Repeating (c) to () to the step 4, check the actuator operation similarly.“aioe sc ACTURTOR CHECKER BR-51 BRAKE —_ABSACTUATON (©) _ Similarly, inspect “front LH” and “rear RH" wheel. HINT: When inspecting the “tront LH” wheel, push the "8" switch instead of the POWER SWITCH. This makes it possible to inspect wherever the selector switch position indicates. 12. PUSH MOTOR SWITCH (a) Push and hold in the “A” switch for a few seconds. (b) Stop the engine. 13, DISCONNECT ACTUATOR CHECKER (SST) FROM ACTUATOR (@) Disconnect the actuator checker (SST) and 3 sub-wire harness (SST) from the actuator. SST 09990-00150, 09990-00250, 09990-00300, 09990-00360 () Connect the actuator connectors. (c} Clear the DTC (See page D276).BR-52 BRAKE. AUS ACTUATOR COMPONENTS gf seem Battory~-f¥ i i a Check Valve Bracket hl a # Gasket . \ ‘ < evel Waning — stan og (iaiso-9} Master Cylinder 3 Se [ists ] &, 2 GEE Front LH Brake Line ECM Bracket (aE a 32. (198,14) ABS tT ° Holder Lee A nosed, A on slualor 1 » e Holder Assembly WE — Glamp 4 o— Cushion ‘Actuator Bracket [Nim ner, tbl] Spection torque ‘# Non-ieusable pari 8BR-53 BRAKE Ang acTuAron, REMOVAL 1, REMOVE BATTERY Remove the hold-down clamp, battery and battery tray. 2. REMOVE MASTER CYLINDER (See page BR-10) 3, REMOVE ECM AND ECM BRACKET fa) Remove the 3 bolts, and move the ECM aside, (©) Disconnect the harness clamp, and remove the boil, 2 nuts and ECM brackot Torque: 19 Nem (195 kgf-cm, 14 fbf) 4, DISCONNECT 2 CONNECTORS 5. DISCONNECT BRAKE LINES Using SST, disconnect the 6 brake lines. SST 09022-00100 Torque: 15 N.m (155 kgt-cm, 11 fb) 6. REMOVE ABS ACTUATOR (a) Disconnect the hose clamp from the actuator bracket un: der side. {b) Remove the bolt, nut and ABS actuator assembly. Torque: 19 Nem (195 kgfem, 14 fh:lbt) (c) Remove the 2 nuts and ABS actuator from the actuator bracket Torque: 5.4 N-m (55 kgf.cm, 48 in-tbf) (@) Remove the 2 holders and 3 cushions from the ABS actuator,BR 54 BRAKE —_ABS ACTUATOR, INSTALLATION Installation is in the reverse order of removal (See page BR-53). HINT: + Affer installation, fil the brake reservoir with brake fluid and blead brake system (See page BR-4) + Check for teaks.BRAKE -_ FRONT SHEED StNGOR FRONT SPEED SENSOR COMPONENTS BR-55BR-5G BRAKE -_FHONT 5060 stnson ma REMOVAL 1. DISCONNECT SPEED SENSOR CONNECTOR, fa) Remove the front wheel ‘Torque: 103 N-m (1,050 kgf-cm, 76 ftbt) (©) Remove the fender finer, (6) Disconnect the speed sensor connector and resin clip. 2. REMOVE SPEED SENSOR (2) Remove the 2 ctamp bolts holding the sensor harness from the bedy and shock absorber. Torque: 8.0 Nem (82 kgf-cm, 71 int-tbf) (6) Remove ihe speed sensor installation bolt from the steoring knuckle Torque: 8.0 Nm (82 kgf-cm, 71 in-tbt) NOTICE: At the time of installation, please refer to the following item. + There are no foreign objects on the sensor or the part of the knuckle to which the sensor is to be installed. + The sensor is installed flat against the knuckle when you tighten the bolt.BR-S7 BRAKE -_FROWT SPcCD SENSOR INSTALLATION Installation is in the reverse order of removal (See page BR-56). AFTER INSTALLATION, CHECK SPEED SENSOR SIGNAL (See page DI-276)BR-5B if REAR SPEED SENS! BRAKE REAR SPEED SENSOR COMPONENTS "| Specitied torque em, FBR)Reh RAY BR-59 BRAKE — REAR SEEED SeNSOH, REMOVAL 1, REMOVE REAR WHEEL 2. DISCONNECT SPEED SENSOR CONNECTOR Disconnect the connector from the speed sensor. 3. REMOVE SPEED SENSOR WITH REAR AXLE HUB (See Page SA~55) 4, REMOVE SPEED SENSOR (a) Using a pin punch and hammer, drive out the 2 pins and remove the 2 attachments from SST. SST 09620-00031 (b)_ Mount the rear axto hub in a soft jaw vise. NOTICE: Replace the axle hub assembly if it is dropped or a strong shock is given to it. (©) Using SST and 2 bolts (Diameter: 12 mm, Pitch: 1.5 mm), remove the speed sensor, SST 09520-00051 (09520-00040, 09521~00020}, 09950-00020 NOTICE: + Ifadamage is inflicted to the sensor rotor, replace the axle hub assembly. + Donotscratch the contacting surtace of axle hub and speed sensor. 5. IF NECESSARY, REPLACE SPEED SENSOR WIRE HARNESS (a) Remove the seat cushion, seatback and quarter trim {Seo page BO-88). (b) Disconnect the speed sensor wire hamess connectorBR-6O BRAKE =_REARSPEFO SENSOR fc) Remove the 2 clamp bolts holding the sensor harness from the lower arm and body. 219 Nem (195 kgtom, 14 ftelbt) Body side: 8.0 Nem (82 kgf-em, 71 in-tbt) (d) Replace the sensor wire harness with the grommet.BR-61 BAAKE — nan sPecD SENSOR INSTALLATION 1. INSTALL NEW SPEED SENSOR (a) Clean the contacting surface of the axle hub and a new speed sensor NOTICE: Do not stick any foreign objects to the sensor rotor. (b) Place the spead sensor on the axle hub so that the connecior makes the most downward position under the on~ vehicle condition. (c) Using SST and a press, install a new speed sensor to the axle bub, SST 0924-76011 NOTICE: + Do not tap the speed sensor with a hammer directly. + Check that there should be no foreign objects on the speed sensor detection portion. + Press in the speed sensor straight and slowiy. 2. INSTALL SPEED SENSOR WITH REAR AXLE (See page SA-59) 3. CONNECT SPEED SENSOR CONNECTOR 4. INSTALL REAR WHEEL Torque: 103 N-m (1,050 kgf-cm, 76 fttbf) ‘CHECK SPEED SENSOR SIGNAL (See page DI-276)STEERING STEERING SYSTEM TROUBLESHOOTING DRIVE BELT POWER STEERING FLUID .. STEERING WHEEL ‘TILT STEERING COLUMN: POWER STEERING VANE PUMP POWER STEERING GEAR SR sR-2 Shs SA SRS srg SR-22 SR-33SRA STEERING —_ STEERING SySTEM STEERING SYSTEM PRECAUTION Care must be taken to replace parts properly because they could affect the performance of the steering system and resuit in a driving hazard. + The CELICA is equipped with an SRS (Supplemental Restraint System) such as the driver airbag and front passenger alrbag. Failure to carry aut service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly feading to a serious aceident. Before servicing (including removal or installation ot parts, inspection or reptace- ment), be sure to read the precautionary notices in the RS section.SR-2 TROUBLESHOOTING PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem, Check each part in the order shown. If necessary, repair or replace these parts. STEERING _THOUBLESHOOTIN ‘Symptom ‘Suepoet Awa Seo page 1 Ties improper nlatod) Be 2, Power soering had love (Lo) SRS, 8. Dio bo (Loose) saa 4, Front whee! algamant ncorect) Sat Hard stmoiog 5. Steering aytem jainte Wort) _ 6. Swspansion arm bal jones (orm) ease 7. Steering cokumn Birding) ~ 8. Power sleoing vane pump sA-2e 8. Power seeing gest S53 1 hes (urprepesiy tated) SA2 2. Front wheal alipument fncorect) SA4 Por rtwn 4. Steering coum (Binding) ~ 4 Power seeing goat sR8 1. Stowning system jms (Wore - 2. Suspension arc ta jos (en Saas Exeassiva pay 4. ntronctate shat, Shing yoke (Hora) - 4 Fon whee! bearing orm saz 5. Power steoing goat sh-29 1. Power stoering Pui evel Lam) Shes sonormal ise 2. Storing system acts (Wom) - 3. Poworetoenng vane pump sre 4, Power stoosing gaat SRCORRECT = WRONG WRONG Sha STEERING. vAIVE BELL DRIVE BELT INSPECTION = INSPECT DRIVE BELT Visually check the drive bell tor excessive wear, frayed cords, etc. If any defect has been found, replace the drive belt. HINT: + Cracks on the rib side ol a belt are considered acceptable. {the missing chunks from the ribs are found on the drive belt, it should be replaced. Alter installing a drive belt, check that it is properly in the ribbed grooves. Check with your hand to contirm that the drive belt has not slipped out of the groove on the bottom of the pulley.SRo STEERING -_ POWER stEEANG ELUIO POWER STEERING FLUID BLEEDING 1. CHECK FLUID LEVEL (See page SR-5) 2, JACK UP FRONT OF VEHICLE AND SUPPORT iT WITH STANDS 3. TURN STEERING WHEEL With the engine stopped, turn the steenng wheel slowly from lock to lock several times, 4, LOWER VEHICLE 5. START ENGINE Run the engine at ide tor a few minutes 6. TURN STEERING WHEEL (a) With the engine idling, turn the steering wheel to left or right full lock position and keep it there for 2-3 seconds, then tuzn the steering wheel to the opposite full lock position and keep it there for 2-3 seconds (b) Repeat (a) several times. 7 STOP ENGINE 8. CHECK FOR FOAMING OR EMULSIFICATION if the system has to be bled twice specifically because of foaming of emulsitication, check for fluid leaks in the system. 8. CHECK FLUID LEVEL (See page SR-5)Abnormal Simm (0.20 in) or less, Engine lating ie Al 3 rr S Engine Stopped | SRS STERRING __ POWER STEEAING FLUID INSPECTION 1, CHECK FLUID LEVEL (a) Keep the vehicle level. (o} With the engine stepped, chock the fluid level in the oil reservoir Hnecessary, add fluid, Fluld: ATF DEXRON® II or til HINT: ‘Check that the fluid level is within the HOT LEVEL range on the reservoir, I the fluid is cok, check that it is within the COLD LEVEL range. (0) Start the engine and run it at idle. (d) Turn the steering wheel from lack to lock severat times to boos! fluid temperature. Fluid temperature: 80°C (176"F) (©) Check for foaming or emulsification. there is foaming or emulsification, bleed power steering system (See page SR-4) () With the engine idling, measure the fluid levet in the oil reservoir. (9) Stop the engine, (h) Wait a few minutes and remeasure the fluid level in the oil reservoir. Maximum fluld level rise: 5 mm (0.20 in.) fa problem is found, bleed power steering system (See page SR-4). 4) Check the fluid lever.SR-6 STEERING _._ POWER STEERING FLUID 2. CHECK STEERING FLUID PRESSURE (a) Disconnect the pressure feed tube from the PS vene pump (See page SR-24). (b) Connect SST, as shown in the illustration below. SST 09640-10010 (09641-01010, 09641-01030, 09641-01060) NOTICE: Check that the valve of the SST is In the open position. Attachment Pressure Feed Tube “7 Attachment PS Vane Pump N sens (©) Bleed the power steering system (See page SRA) (9) Start the engine and run it at idle. {e) Tum the steering wheel from lack to lock several times to boost fluid temperature. Fluid temperature: 80 °C (476 “F) () With the engine fating, close the valve of the SST and ob- (oa serve the reading on the SST. “reservoir Minimum fluid pressure: 7,355 kPa (75 kgticm?, 1,087 psi) cegaf) —[¥_| nonce: — + Bo not keep the valve closed for more than 10 se- So PSvane conds. a Pome + Do not let the fluid temperature become too high.> Cc resenvir SST oil sR? STEERING — PoWERSTEERMG FLUID (9) ) With the engine idling, open the valve fully. Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Ditference fluid pressure: 490 kPa (5 kat/om?, 71 psi) or less NOTICE: Do nat tum the steering wheel, a With the engine idling and vaive fully opened, turn the steering wheel to full lock, Minimum fluid pressure: 7,355 kPa (75 kgticm?, 1,067 psi) NOTICE: @ a) 0 Do not maintain lock position for more than 10 seconds. ‘Do not let the fluid temperature become too high. Disconnect the SST. SST 09640-10010 (09641-01010, 09641-01030, 09641-01060) Connect the prossure feed tube to the PS vane pump (See page SR-32). Bleed the power steering system (See page SR-4).She STEERING STEERING WHEEL, STEERING WHEEL INSPECTION 4. CHECK STEERING WHEEL FREEPLAY (a) Stop the vehiole and face the tites straight ahead. (b) Rock the steering wheel gently up and down with a finger lightly, check the steering wheel freeplay. Maximum freeplay: 30 mm (1.18 In.) 2, CHECK STEERING EFFORT (a) Center the steering wheel. (b) Remove the steering whee! pad (See page SR-11). {c) Start the engine and run itat idle. (d) Measure the steering effort in both directions, Steering effort (Reference): 6.5 Nem (65 kgf-cm, 58 in.Ibt) HINT: Take the tire type, pressure and contact surface into consider- ation before making your diagnosis. (e) install the steering wheel set nut. Torque: 34 N.m (350 kgf.cm, 25 ftibf) Install the steoring wheel pad (See page SR-19)srg STEERING TWF SIEEHING coL\jMN TILT STEERING COLUMN COMPONENTS = 6 w! Speed control main switch: ‘Speed Control Main: pete Assembly Steering Wheel Pad 625) | Wi Transmission _—_ shift switch: instrument Cluster aa Transmission Shitt reser ea? hares: ~ or Sere Wiper and Washer Switch Steering Wheel $ are BH| Light Control Switch and Headlight Dimmer Switch \ \ A -- Steering Column Assombly Column Lower Cover (Sez) No. 2 Intermediate Shaft Assembly LowerNo. 1 Instrument Finish Panel Instument Finish Panel iim {kotem, tb} |- Specified torqueSR-10 STEERING 1th STEERING COLUMN Key Oylinder Column Upper Bracket Key Uniock Warning Switch — “itt Spring, S No. 2 Support Collar Tilt Lever Lock Bolt Bracket “ ‘910.1 Support Collar Stopper # No. 1 Support Tit Steering Support i588.) ® Main Shaf! Bushing \p Nim fkatom, ttibt | : Specified torque Non-reusable part 4 Hoiytcenum disutio ttbium base grease bk ‘Main Shatt Assembly 4 Tapored-head Bott GS coun Un Clap ~ Ignition Switet D— ¢ snap Ring Colima Tube Adjusting Nut (fee SFT) No. 1 Support Reinforce, ~ @Snap RingAirbag Contoctor Correct Oo SRa11 STEERING —_ Twi STEERING COL nN REMOVAL 1. REMOVE STEERING WHEEL PAD NOTICE: If the alrbag connector is disconnected with the ignition switch at ON, DTCs will be recorded. (a) Place the front wheels facing straight ahead (©) Using a tore socket wrench, loosen the 2 torx screws until the groove along the screw circumference caiches on the screw case. (©) Pull out the whee! pad from the steering wheel and disconnect the airbag connector. CAUTION: + When storing the wheel pad, keep the upper surface of the pad facing upward. + _ Never disassemble the wheel pad, NOTICE: When removing the wheel pad, take care not to pull the airbag wire harness. 2, REMOVE STEERING WHEEL {a) Disconnect the connector. (b) Remove the steering wheel set nut. (©) Place matchmarks on the steering wheel and main shalt assembly. (@) Using SST, remove the steering wheel, SST 09950-50012 (09951-05070, 09952-05010, 09953-05020, 09954-05020) 3. REMOVE LOWER NO. 1 INSTRUMENT FINISH PANEL {a) Remove the 2 screws and disconnect the hood lock release lever. {b) Remove the 2 bolts and iower No. 1 instrument finish pan- al (c}_ Disconnect the connector. 4. REMOVE INSTRUMENT FINISH PANEL Remove the 2 bolts and instrument finish panel 5. REMOVE INSTRUMENT CLUSTER FINISH PANEL Fiemove the 2 screws and instrument cluster finish panel,S12 EU arcbnas Bon a OS é SS Atcha N 6 STEERING —_TLISTEESING COLUMN, REMOVE COLUMN UPPER AND LOWER COVERS Remove the 3 screws, column upper and lower covers. 7 fa) (b) {c) (a) (e) REMOVE SPIRAL CABLE, LIGHT CONTROL SWITCH AND HEADLIGHT DIMMER SWITCH AND WIPER AND WASHER SWITCH Discomnect the 3 connectors from the spiral cable, light control switeh and headlight dimmer switch and wiper and washor switch Disconnect the airbag connector from the spital cable. Push the claw and pull out the light control switeh and headlight dimmer switch, Employ the same manner described above to the wiper and washer switch Remove the spiral cable. NOTICE: Do not disassemble the spiral cable or apply ol to It. 8. ArT: REMOVE KEY INTERLOCK CABLE With the key in ACG, push the claw and pull out the kay interlock cable. 9 10. (a) (b) nn fa) ) 12. @ &) REMOVE COLUMN HOLE COVER SILENCER SHEET DISCONNECT NO. 2 INTERMEDIATE SHAFT AS- SEMBLY Place matchmarks on the No. 2 intermediate shaft assembly and intermediate extension, Loosen the bolt A and remove the bolt B, then disconnect the No. 2 intermediate shaft assembly. REMOVE STEERING COLUMN ASSEMBLY Disconnect the connectors. Remove the 2 bolts, auts and steering column assembly. REMOVE NO. 2 INTERMEDIATE SHAFT ASSEMBLY Place matchmarks on the No. 2 intermediate shaft assembly and main shaft assembly. Remove the bolt and Na. 2 intermediate shaft assembly,8 Horn Switeh Terminal Secondary Locking Device SR-1g STEERING TILT STEERING COLUMN 13, @ to} ©) () 14, (a) ©) () (a) 15. (a {b) © fd) fe) wi Transmission shift switch: REMOVE TRANSMISSION SHIFT SWITCH AS- SEMBLY FROM STEERING WHEEL Remove the 2.screws, Disengage the secondary looking device of the connector. Release the locking lug of the terminal 1 (horn switch terminal), and pult the terminal out of the rear. Remove the transmission shift switch assembly, ‘w/ Speed control main switch: REMOVE SPEED CONTROL MAIN SWITCH AS- SEMBLY FROM STEERING WHEEL Remove the 2 screws. Disengage the secondary focking device ot the connector. Release the locking lug of the terminal 1 (hom switeh terminal), and puil the terminal out of the rear Remove the speed contra! main switch assembly. w/ Transmission shift switch and speed control main switch: REMOVE TRANSMISSION SHIFT SWITCH AS- ‘SEMBLY AND SPEED CONTROL MAIN SWITCH AS- ‘SEMBLY FROM STEERING WHEEL Remove the 2 scrows from the transmnission shift switch assomby. Remove the 2 screws from the speed control main switch assembly. Disengage the secondary locking device of the connestor. Release the locking tug of the terminal 1 (horn switch terminal), and pull the terminal out of the rear. Remove the transmission shift switch assombly and speed control main switch assembiy.Sha STEERING Screw Extractor Mikes Extension Bar n 500] n som XUTSTEERING COLUMN DISASSEMBLY 1 (a) } to) 2 REMOVE COLUMN UPPER BRACKET AND COLUMN UPPER CLAMP Using a centering punch, mark the center of the 2 tapered-head bolts. Using a3 -4 mim (0.12 0.16 in.) drill, drill into the 2 bolts. Using a screw extractor, remove the 2 bolts, column upper bracket and column upper clamp. REMOVE TILT STEERING SUPPORT Remove the bolt and tit steering support. 3. fa) (b) HINT. REMOVE SRACKET SPACER AND 2 NO. 1 SUPPORT COLLARS Using an extension bar and.a hammer, tap out the bracket spacer Using a screwdriver, remove the 2 No. + support collars, REMOVE TILT LEVER AND BREAK AWAY BRACKET Remove the tit spring Remove the No. 2 tit lever lock bolt and No. 1 support reinforce, This bolt is left-handed one.

2000-2005 Toyota Celica Repair Manual Volume2

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2000-2005 Toyota Celica Repair Manual Volume2

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