Kiapregio

- Pregto . Workshop Manual | FOREWORD Seneaioee i_General information This Workshop Manual provides information — Favgiing normal service, repairs, and maintenance, Engivie(d2 Engine) for all systems of the Pregio, " Engine(ata En This manual is organised into Groups covering = —— —— “Proeral systems. . Within each=Group, the |: Lubrication System(i2 Engine) : information is further divided into Sections. There is | Lubrication System(JTA Engine) i> ghe Section for each component or sub-system ee ine) Some Groups contain. a Service Section to cover “| Cooling System(s2 Engine) ’ Subgystome gainer o.several components or n s¥StemU2 Engine) > subsystems within the Group. In general, sacy |_ Cooling Systemeita Engine) Section contains an Outline Description, ine § [foubleshooting, Adjustments, - Remcval ;_dnleke and Exhaust Sy ; Installation, Disassembly, Assembly and Inspection procedures for the component covered in tne Section. “Diagnosis and. Testing is inclucted in ine first section of some Groups to help you. systematically locate and correct probiecs encountered. -In.most cases, Specifications are included al the end of each Settion 7o.810 in locating specitic subjects'in this manual, use the Table of Contents cn the following pages, 8 a lirther ai, tere is inden onthe feet page ot each Group which lists the Section tila lar sage Component covered within the group. this Group Section. breakdown is also indicated in the page number iocated at the top of each page, Example: 424-35 = (Group) 424, (Page) 36, gine} stom{sTA En lem{JTA Enging} ihe, Ce8erptions and specications containein this manual Kae vceatat a the tin this man was approved fr pining Ue Motors Corouration raserves the right to iscontinus ove, Kia Motors Corporation SEOUL, KOREA Alr Conditioner GS Ay Copyright © 2001, kia Motors Ccrporation ‘ Bi. rntezia Korea Fasano: WARNING oy Appropriate service methods and proper repair procedures are essential forthe safe, reliable operation of all motor vehicles as well as the personal safely of:the individual doing the repair. There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well aS in the skill Of the-individual doing the work. This manual cannot possibly anticipate all such variations and provide’ advice or caution to each. ‘Accordingly, anyone who departs from the instruction provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools, or parts. The following list contains. general warnings that should always be followed while working on a vehicle. + Always wear safety glasses for eye protection. + Use Safely stands whenever a procedure requires underbody work. Be sure ignition switch is always off unless otherwise specified by a procedure. Set the parking brake when working on the vehicle. Operate the engine only in a well ventilated area. Keep clear of moving parts when engine is running + To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. + Do not smoke while working on a vehicle. CAUTION oo Severe engine and transaxle damage may resift from the use of poor quality fuels and lubricants that do not meet Kia speciticalions. You must always use high quality fuels and lubricants that meet the specifications described on the specification section in the relevant group of the Workshop Manual.bei | i sd GENERAL INFORMATION ot | ABBREVIATIONS enesanon 0 8 i FUNDAMENTAL PROCEDURE 0-8 i IDENTIFICATION NUMBER LO: 0-9 ’ YAGK AND SAFETY STAND POSITIONS |. 00- 7 fl. i” TOWING . 0o- 8 | SITS ~00- § \ i 00-7 | | i iFUNDAMENTAL PROCEDURES GENERAL. INFORMATION 00-3 fi * FUNDAMENTAL PROCEDURES - SYMBOLS ‘There are six symbols indicating ol, grease, and seatinl, These symbols show ‘materials during service. the points of aopiying such _ Symbol Meaning i Apply oll ‘New engine oll or gear oil as appropriate i Apply brake Muid Only brake tuid ! | 5 - | | | ‘Apply automatic transaxie tid Oniy ATE : i Apply grease Appropriate grease |x! | en | ea | oat Apply sealant Appropriate sealant Sa @ ‘Apply petroleum jely | ‘Appropriste Note . +, When speciall oll or grease is needed, this is shown in the illustration, NOTES, CAUTIONS; AND WARNINGS ‘eeu, ead through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS, Each one is there for a speciic purpose. NOTES give you added information that wis help you to complete a particular Pagedure, CAUTIONS are given to prevent you from making an error thar eoces damage the vehicle. WARNINGS remind you to be especially careful in those areas, where carelessness can cause personal in- Jury. The following ist contains some general WARNINGS you should icin ates you work on a vehicle, PROTECTION OF THE VEHICLE Always be sure to cover fenders, seals, ard ‘loor areas belore- | starting work,00-4 GENERAL INFORMATION FUNDAMENTAL PROCEDURES: ‘AWORD ABOUT SAFETY e The following precautions must be followed when jacking up the vehicle, 1. Block the wheels. 2. Use only the specified jacking positions. 3. Support the vehicle with safely stands. Start the engine only after making certain the engine compari- ‘ments clear of tools and people. ( PREPARATION OF TOOLS AND MEASURING EQUIPMENT Be’ sure that all necessary tools’and measuring equipment ara f avallable before starting any work. | q SPECIAL TOOLS Use special tools when they. are required. REMOVAL OF PARTS While correcting a problem, try also to determine its cause. Begin work only alter first learning which parts and subassem- 4 biies must be removed and disassembled for replacement of repair. DISASSEMBLY If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that wil not affect their performance or external appearance and ‘identified so that reassembly can be performed easily and eff- ciently.FUNDAMENTAL PROCEDURES GENERAL INFORMATION 00-5 INSPECTION OF PARTS: When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems. | ARRANGEMENT OF PARTS ‘All disassembled parts should be carclully arranged for re~ assembly. Be sure to separate or otherwise identify the parts to be re- | placed from those that will be reused. J CLEANING PARTS FOR REUSE All parts to be reused should be carefully and thoroughly ‘ cleaned in the appropriate method. ‘ REASSEMBLY: Standard values, such as torques and cerlain adjustments, vow must be strictly observed in the reassembly of all parts. If removed, these parts should be replaced with new ones \ 4. Oil seals 2. Gaskets 3. O-rings (4. Lock washers . 5. Cotter pins 6. Nylon nuts Depending on location : c 4. Sealant should be spplied or new gaskets used. 2. Oil should be applied to the moving components cf par’. 8. Specified oll or grease should be applied al the prescribed locations (such as oil seals) before reassemblyADJUSTMENTS. Use sultable gauges and/or testers when making adjustments. RUBBER PARTS AND TUBING . Prevent gasoline or oil from getting on rubber parts ar tubingJACK AND SAFETY STAND POSITIONS, VEHICLE LIFT POSITIONS GENERAL INFORMATION 00-7 Us JACK AND SAFETY STAND POSITION FRONT END . Jack position : Safety stand positions : At the front crossmember On both sides of the body trae —] ole | NT e/ C | | | Be == | ee i - mai) — “ANS000007 REAR END Jack position : Safety stand position : ‘At the center of the axle housing On both sides of the axle housing | Vey U vu "eS r : : uy VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS . + FRONT END REAR END | + Side sills Side sils ~~ | Ton) ~ i I i ° J aTOWING Proper towing’ equipment is necessary to provent damage ‘c the vehicle during any towing operation. Laws and regulations applicable to vehicles in tov srs: ni be observed. As a tule, towed vehicles should be px! wheels off the ground. he With elther actomatic or manual transaxle 41. Set the ignition switch in the ACC positice 2. Place the selector lever or shill lever in (veutral) 3. Release the parking brake. Caution +” The power assist for the brakes and steering are in- operable while the erigine is off. +: Do not use the hook loops under the front or rear of the vehicle for towing, ‘These hook loops are de- signed ONLY for transport tiedown. If tiedown hook loops are used for towing the front or rear skirt and bumper will be damaged. RE# IDENTIFICATION NUMBER LOCATIONS GENERAL INFORMATION 00-9 9M. IDENTIFICATION NUMBER LOCATIONS ry ENGINE MODEL NUMBER VEHICLE IDENTIFICATION NUMBER(VIN) i i oye | oy ata: UNITS Nem kaon, oc kg-om, Powervainconrot | Ip-ft or Ib-in) v Torque \ module. i ble ann Revoir perms | Mutiport fel injection Elecical pad ~ | Exhaust | \ ~ i Grune | . {aunty negative) | Hpac asus | -mmtig (neg) on ! (usually negative) Intake | W coco » Watt Intermittent 1 ters (U8 eh imp ei. Volume ide arcontot | mm (in)... Length 1 Lett hand i I Motor i ‘ : oo Matunetion aceator | = lamp i ABBREVIATIONS ws Manual stecting | — MT Manual transaxle 1 Asoc ‘Alter bottom dead | op " ~~ Overdtive I ter ore seh off i lac conditioner oN ‘Switch on | Ace! Accessories Pov Postve crankease at. tomati transaxle vention | roe ‘Mor op dead con Doce seting | AF. “automa wansaste Prossun open | fig seme rel 9 BAC... w-« Bypass air contro! controt ‘8800 --» Before bottom dead Powar window Belore * “Right hand Toc. Bolore top dead center | 5 Special service tool | cru. Cental processing unt, i Stat | DRL “Daytime running ight | ; Surteh eet Electroncaly-contoted Top dead cet an automatic ansaxle “Tal number eat mp. |ae Se. J2 ENGINE COMPRESSION PRESSURE DISASSEMBLY / ASSEMBLY .. ENGINE TUNE-UP PROCEDURE. IDLE SPEED ... IOLE.JP SPEE INJECTION TIMING . INSPECTION AND REPAIR. REMOVAL / INSTALLATION SPECIAL TOOLS. SPECIFICATION .. se TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE ENGINE 10A-3 ° TROUBLESHOOTING GUIDE Problem Possible Cause ‘Action Ingutfletent power | Improper valve clearance ‘Adjustment : . Valve seat compression leakage Repair i Valve stam slezed Roplace : Valve spring weak or broken Replace or: Cylinder head gasket damaged i Cylinder nead cracked of distorted Replace \ Piston ring sticking worn, damaged Replace i Piston cracked or worn Replace Fuel system mallunctioning Refer to Section 228 Intake and exhaust system matfunctioning Reler to Section 20A, ya Excessive engine | Piston ring or piston ring groove wo1n Replace alleoneumption | oraiekng Piston or eynder worn popiace or eps ate seat worn | opiace Valve stem and guide worn | Replace ' Ot tcakage fer o Secon 11 Diieutte stan _| Wor piston, piston ng and ender Replace ea. Cylinder heed damaged or datos pepe Fool atom manuncving [TV reeyeseaonzea | Elect system maltunctoning Retetto Section 208 ‘Abnormal combustion | Wrong adlustment of vale clearance | Aust i Valve damaged or seking | ‘replace | Valve spring weak or broken 1 Repiave 1 ‘Carbon deposit in combustion chamber | Removal v . Injection nozzle maltunetioning | Replace | i“ Reler to Section 22h, Fuel system malfunctioning L Poor Iaiing * Impropér valve clearance Improper valve to valve seat contact Cylinder head gasket damaged Agjustznent RRepait or Replace Replace Fuel system mattunctioning Fefer to Section 2A Repiace or Repair Replace Replace or Repair Replace or Repair Replace Replace Engine noise Exeessive oil clearance of main bearing e o8 Main bearing seized or heat damage Excessive end play of crankshalt Excessive cl clearance of connecting od bearing Connecting rod bearing seized or neat damage . Connecting rod bush worn or seized410A-4 ENGINE TROUBLESHOOTING GUIDE € eo * Problem Aetion Engine nolse Worn evinder Replace l . ‘Worn piston or piston pin Replace Piston sticking Repiace Piston rng sticking or damaged Replace Bent of connecting rod Replace e Excessive valve clearance ‘Adjustment : Vatve spring cracked . Replace ! Excessive valve guid clearance Replace Water pump bearing mnatunaion Replace Improper fan belt tension cine ‘Alternator bearing malfunction Repldce 4 ¢ Cooling fa bearing mallunction Replace 7 Exhaust gas leakage . | Repair Gas leakage ai nczzle holder Assembly Repairoo « ENGINE TUNE-UP PROCEDURE ENGINE. 10A-5 ENGINE TUNE-UP PROCEDURE ENGINE OIL Inspection. 1. Be sure that vehicle is on level ground. 2. Werm up the engine to normal operating temperature and stop It : 8. Wait for § minutes, and then check oil level and its condition by using the oil level gauge. 4, Fil or replace oil if necessary, Caution a a er) > . Excessive filling oll over F level can cause engine * j failure, Note | + Oil quantity Is about 1.8 1 (1.9US gt, 1.61mp qt) between Fend L level of oll level gauge. ENGINE COOLANT Warning + Do not open the radiator cap when engine is hot. + When-opening the radiator cap, wrap it with t cloth and open it with caution, . Inspection 4. Verily if the coolant level is near the radiator filing cap. 2. Check if the level of reservoir tank is between F and L marked level, and fil coolant if necessary. inspection of contamination Check i any foreign material is in engine coolant and engine oil, replace Itt necessary. DRIVE BELT Inspection 1. Verify that the belt is correctly mounted on the pulleys es shown in the figure. 2. Check if the belt is worn, cracked or damaged, replace it if necessary. 3. Check the drive belt deflection by applying moderate pres- Sure 10kg(S8N, 22 Ib) midway between the pulleys. Caution + Measure the belt deflection between the specified pulleys. Taro + Consider the belt as a new one if it has been used on a running engine for less than five minutes, + Check the belt deflection when the engine is cold or at least 30 minutes after the engine is stopped.i Aiemaior | S-11035-0.8) Pic |__9-11(0.95-0.43)_— | [iG |__r-ajo.27-0.38) + Ifthe’detlection is not cor $10095-043) rect, adjust the belt. Note + For inspecting the tension by the tension gauge tka, 0) — Bett New Used ‘Atternatoy | 41-S80(45~65, 99-121) | 952-441 09-45, 9E-O9) B6I=441(G7-45, 81-09) _| 328-962I9-07, 79-81) 7 (rae 18 421-027(49-04, 05-141) | 3 3) Alternator drive belt 1. Loosen the mounting bolt ® ior alternator and the adjusting bolt ®. 2, Adjust the belt deflection. Deflection (When applying 98 N(10 kg, 22 Ib)) New one : 9~11 mm(0.35~0.43 in) Used one : 1112 mm(0.43~0.47 in) 8, After making the adjustment, tighten the mounting bolt @ and adjusting bolt @. ‘Tightening torque @ 37~52 N-m(3.8~5.3 kg-m, 28~38 Ib) @ 19-25 N-m(1.9~2.6 kg-m, 14-19 tb) Power steering drive belt 1. Loosen the idler pulley mounting bolt ®. 2. Adjust the belt deflection by turning the adjusting bolt @ Deflection (When applying 98 N(10kg, 22 Ib)) New one : $~11 mm(0.35~0.43 In) Used.one : 11-12 min(0.43-0.47 in) 8. Aer making the austment, tighten the ier pulley moun ing bolt. Tightening torque 37~62 N-m(3.8~5.3 kg-m, 28~38 Ib) Air conditioner drive belt . Do twit he same way a8 measured for PIS belt tension reer ._ ting figure. ‘Adjust the belt, deflection with the same way as described for “Power steering drive belt” Deflection’ New one : 7~9 mm(0.27~0.35 In) Used one : 9-41 mm(0.35~0.43 in) AREDTOOTS EOIi ENGINE TUNE-UP PROCEOURE ENGINE 10A-7 _* VALVE CLEARANCE Inspection / Adjustment ms 1, Remove the cylinder head cover. 2. Set the No. 1 piston to TOC by rotating the crankshatt ., L * 8, Check and adjust the valve clearance. Valve clearance (at cold): ; ” 4: Loosen the tightening nut, rotate the adjusting serew and adjust the valve clearance. \9 ‘Tightening torque : 12-18 Nem(1.2~1.8 kg-m, 8.7=13 Ib) ‘Turn the crankshaft 1 revolution and check another vaive, a Intake : No. 3; No. 4 Exhaust : No. 2, No. 4> “ON-VEHICLE MAINTENANCE 40A-8. ENGINE IDLE SPEED, IDLE UP SPEED, INJECTION TIMING. (DLE SPEED INJECTION TIMING, CAM LIFT Preparation +1. Warm up the engine upto the norme! operating temperature, 2, Operate the engine at idle. Put the change lever in neutral! position. Put the steering in neutral, Turn the ignition switch OFF. ‘ 8. Check if the deflection of accelerator cable is within the Specification (refer to Section 20). ‘Speciticatio 13 mm(0.04~0.12 in) Inspectlor / Adjustment 4, measure the engine idle speed by using a tachometer. Specification ; 700-750 rpm(AIT) 750~790 rpm(MiT) 2, I it exceeds the specification, loosen the lightening nut and adjust it by rotating the idle adjust screw. Tightening torque : 5.0~8.8 N-m(0.5~0.9 kg-m, 3.7-6.5 Ib-f) Caution + The idle speed adjustment should be done by the idle adjusting screw. IDLE UP SPEED(A/T ONLY) +. Check and adjust the idle speed. 2. Start the engine and turn the air conditioner switch ON. 3. Check that the idle speed is within the specitied range. Specification : 850~800 rpm 4, It It exceeds the specification, Ioesen the No. 1 idle di- aphragm tightening nut and adjust it by rotating the idle ad- |usting sorew. Tightefting torque : 4.48~1.47 Nem(0.12~0.15 kg-m, 0.87~1.09 Ib-ft) 5. If adjustment can not be done, loosen the holt and reacjust ity using the actuator body. ‘Tighténing torque : 811 Nem(0.~1.1 kg-m, 6~8 Ib- 6. Connect the vacuum hose and operate AVC, then turn the blower switch on and verify the engine speed. Specification ; 850-800 rpm INJECTION TIMING INSPECTION / ADJUSTMENT 1. Rotate the crankshatt slowly and align to ATOC 7°,INJECTION TIMING ENGINE 19K} 2. Remove the injection pipe between the injection pump and Ta the nozzle, ~*~ - ’ ws 8. Atter removing the cover of hydraulic pait of injection pump, Cd install SST. Caution | + Be careful for fuel leak during removing th 4 pump. | | .¢ ~ + Install itso that SST indicates about 2 mm(0.079 in}. 4. Rotate the crankshalt pulley in roverse to align it to 8TOC 0°, then install the dial gauge so that ils indicator can nol be moved. §. Align the indicator of dial gauge to 0, rotate the crankshalt pulley in left and right, and then verily the position of indica tor. 8. Rotate the crankshalt pulley again to align it to ATOC 7°, and then check the die! gauge reading Specification : 10.02 mm (Litt) O-u.-@ 7. If the dial gauge reading exceeds the specification, loosen the stay bolt of injection pump. &, Loosen the tightening nut © tor the injection pump by using a socket wrench. s 6 8. Rotate the injection pump body so that the dial gauge indi Gates 0.98~1.02 mm (0.039~0.040 inJat ATOC 7° “ 70. Tighten the stay bolt of injection pump and the tightening bolt. Tightening torque : 19-25 Nim(1.9~2.6 kg-m, 14~19 lett) 11. Remove SST. 12. Insert a cap alter inserting a new gasket Tightening torque : 14~20 N.m(1.4~2.0 kg-m, 10~16 Ib-ft) 16, Tighten the injection pipe temporarily and tighten nuts(4 EA) on pump side, TightBning torque : 25~29 N-m(2.5~3.0 ka-m, 18-22 Ibett) 14. After starting engine, check if there is any fuel leakage. - INSPECTION OF CAM LIFT 1. Check the maximum dial gauge reading during inspecting © and adjusting injection timing, ™ 2. Rotate the pulley so that it passes TOC, then check the maximum dial gauge reading. Cami Lift : 2.6 mm(0.1 in)J0A-10 ENGINE compression PRESSURE: COMPRESSION PRESSURE INSPECTION 1+ Warm up engine upto the normal operating temperature, Stop engine and disconnect the connector of fuel cui solenoid. 2. Remove all injection pipes, nozzles and washers. 8. Attach SST to the nozzle hole, 4. Measure the compression pressure during cranking, nn [Specification Nera | 20.0;200, rey Umi 810200 : (Cyinderie-oyinder pressure direrce Below 3.0 8. Do ebove step 3 ~ step 4 again for each cylinder, 6. It the measure value is below the limit, consider it as abra- sion of damage of piston and piston ring, misaligament of .f valve, damage of gasket etc.,* | | ei ee eae ey 9 REMOVAL / INS) luarony ENGINE 10A-11 REMOVAL / INSTALLATION 1. Remove the negative cable of battery. 2, Drain the engine coolant and transmission oll, 8, Remove in steps as shown in figure, and install in reverse order of removal. 4, After installing, fl the engine coolant, engine oil and transmission oil as specified, &. Aiter driving tests, check for water or oil leakage, and inspect the coolant level and engine oil level again. ‘STEP 1. (SEAT AND PARKING BRAKE FRAME) 1. Passenger seat 2. Driver seat 3. Service cover 4, Console box 5, Parking brake frame 6. Fuel tank opener cable 7. Parking brake cable40A-12 ENGINE REMOVAL / INSTALLATION STEP 2. (HOSES AND ACCELERATOR CABLE) a i ERE 1. Reserve tank hose 6. Heater hose 2. Radiator upper hose 7. Solenoid hose 8. Radiator lower hose 8. Accelerator cable 4, Fuel hose 9. Throttle cable (ATX only) 5. Air hose. ’ | REMOVAL / INSTALLATION ENGINE 10A-13 STEP 3. (WIRING HARNESS) y aT 41. Oil pressure switch 9.¥Fuel cut Solenoid connector 2. Water thermo switch (ATX only) 10, Pickup connector 3. Alternator connector 11. FICD solenoid connector 4, Starter 12. Speedsensor connector 8. Thermo switch 18. TPS connector (ATX only) 6. Heat gage unit 14, Speed sensor connector (ATX only) + _7.Glow plug connector 15. Solenoid sensor connector (ATX only) 8. Air con compressor connector 16. “i ‘switch conneator (ATX only)40A-14 ENGINE REMOVAL / INSTALLATION STEP 3. 31-48 7, 34), ‘AH SIDE« ae « a ey J. Engine under cover 2. Transmission under cover 3. Cross pipe 4, Cross member 5. Thermo modulator fan cover 8. Thermo modulator fan ?, Radiator ~ 8. Alternator REMOVAL NOTE Power steering off pump 1. Remove the power steering oil pump with bracket gine body. 2, Remove the power steering al pump with oi hose attached, and fk It by wire somewhere the engine remover ac not be interfered, Caution + Be careful not to damage the hose, Alr con compressor *- Remove the alr con compressor with bracket from engine Caution REMOVAL /INSTALLATION ENGINE 1OA-15 9. Air con,compressor 10, Power ‘Steering oil pump. 11, Glutch release cylinder (MTX only) 12. Selector lever cable (ATX only) 13. Exlaust pips 14. ATF pipe (ATX only) 15, Prebelier shaft 16. Engine mount asym from en-40A-16. ENGINE REMOVAL / INSTALLATION STEP 4. (ENGINE AND TRANSMISSION) e 16-29(1.0-23, 7 97-52(9.8-53, 27-98) | | { 1. Starter motor 2, Gusset plate(LH) 3. Gusset piate(RH) 4. Under cover 5, Transmission mounting &. Auto transmissionDISASSEMBLY / ASSEMBLY ENGINE 10A-17 DISASSEMBLY / ASSEMBLY 4. Drain the engine oil, | 2. Remove in the sequence shown in the figure below, and isan the revers2 order of removal. 3, Refer to each notes for disassembly and assembly. Caution + Mark all parts removed from cylinder so that those can be properly intatled late. \ (Piston, piston ring, connecting rod, vaive spring etc.) + Wash parts thoroughly with steam cleaner, blow out any water left with compressed air. « Kéep the assembly order in mind during disassembly of any part or system. Careful also for any deformation, wear or damage. OTHERS 8-12{60-120 kg-em, 5.8-8.7) 8-12(80-120 ko-om, 6.8-8.7) i ® & , | X 97-52(0.8-8:3, 27-28) @ oN EZ o-AING., REPLACEJ0A-18_ ENGINE DISASSEMBLY / ASSEMBLY 1. Qi level gauge 8. Injection pipe 2. Ojl level gauge Pipe 7. Intake manifold and gasket > 3. Alternator strap 8, Exhaust manifold insulator 4. Nozzle cover 9. Exhaust manifold and gasket 5. PCV hose Disassembly note t . 1. Install SST to engine alter removing the exhaust manifold and alternator. Assembly note 1. Install the oll hose after installing alternator. Tightening torque : 588~B52 N-m(60~90 kg-m, 435-689 lb-ft) RRO e eDISASSEMBLY / ASSEMBLY ENGINE {0A-19 2 CYLINDER HEAD GasKer. @ Rerlice 1. Engine hanger oo 41. Rocker arm shatt 2. Cylinder head cover 12. Valve cap 8. Thermo case and gasket 13. Valve cotter 4. Cylinder head bolt 14. Upper valve spring seat 5, Rocker arm and rocker arm shaft assembly 18. Valve spring 6. Push rod 16. Valve seal 7. Cylinder head 17: Intake valve 8. Cylinder head gasket 18. Exhaust valve 9. Rocker arm 19. Lower valve spring seat 40. Rocker arm spring10A;20_ ENGINE DISASSEMBLY / ASSEMBLY ———— DISASSEMBLY NOTE Cylinder Head Bolt Loosen the cylinder head bolts in two or three steps in the num- bered order as shown in the figure, Valve Cotter . Remove the valve cotter by using SST as shovin in the figure Valve Seal Pull the valve seal out by using. SST. HTDISASSEMBLY / ASSEMBLY ENGINE 10A-21 ENGINE 104-21 » ASSEMBLY NOTE Valve Seai os Push the valve seal by using SST as shown in the figure, Cylinder Head Bolt : Note + © mark inthe figure means short bolt, 0 mark means long bolt. * Caution + Measure the length of eYlinder head bolt, replace if necessary. Long bolt : 158 mm(6.22 mm) : Short bolt : 123 mm(4.84 mm) 1. Apply engine oil onto the surlace and thread of cylinder head bolt, and install to oylinder head. ° 2, Tighten cylinder head bolts with 44-74 N-m(4.5~7.5 kg-m, 33-54 Ib-t) of tightening torque, in the order shown in figure (1st temporary tightening). 8,, Tighten it with rotating 90° (2nd tightening), 4, Tighten it with rotating 90° (3rd tightening). Valve Cotter 1. Compress the spririg by using SST to install the valve cotter, 2, Check if tre cotter is completely positioned, by tapping the end of valve stem slightly with a plastic hammer. Water Outlet Housing 1. After tightening the thermo case to cylinder head temporarily by using “D" bolt and “S” nut, tighten “R" and “W" complete. 'y, then *D" and “S" completely, Tightening torque D, R, S, Wi 19~25N-m(1.9~2.6 kg-m, 14~19 Ibett) AN9o 60810A-22 ENGINE DISASSEMBLY / ASSEMBLY FLYWHEEL AND OIL PAN 343-902 | GASKET, eM i NY N, 1 (35.0-40.0), fea . | Bes hownen ome e, |) HOS > Gornoioem en AEAASE ase o SH"? oning, ~ o-niNa, i Repiace © : ANS | Ct, ~° Js ‘ Se 19:25 . i (et, | ; 5) a . : ATX VEHICLE, i | ®. = ay “ (eats, 19-25(1.9-26, 14-19) weciag| ® pA : Nmtiom, bt | _ "ANDOTOOO? 4, Crankshatt pulley 7. Oil strainer and pipe 2. Clutch cover (MTX only), backing plate (ATX only) 8. Oil Pump . .. Clutch disc. (MTX only), drive plate (ATX only) 9. Water pump and gasket 4. Flywheel (MTX only), adapter (ATX only) 10. Oil fiter body and gasket ™, 5, End plate 11. Oll cooler 3 +8, Ollpan : 12. Engine mountingace 7 wel : . DISASSEMBLY / ASSEMBLY ENGINE 10A-23 ISAS DISASSEMBLY NOTE —— Crankshaft Pulley, Clutch Cover 1. Hold the flywheel with the SST, 2. Remove the crankshaft Pulley. 8. Remove the clutch covar by loosening the bolts in two or three steps. Flywhee! Te-lpstall SST to the flywheel link gear so thal st can not'bo ro- tated. Hold the flywheel with the SST. 2, Loosen the tightening bolt for tlywheel in two or three steps | ASSEMBLY NOTE Clutch Disc, Clutch Cover ~ 1, Align the center of clutch disc by using SST.40A:24 ENGINE DISASSEMBLY / ASSEMBLY ‘TIMING GEAR CASE » on Se, Sve 6 Rerace@e \ 19-25 19°26, 14-10) eansxer, 1 SSEPLACE 19-25;1.5-26, 8-11(80-110 kg-em, 6-8) 7-2(08-5., 27-08) lg © 14-19) a ‘~ e * DISASSEMBLY / ASSEMBLY ENGINE 108-25 1. Front oll seal 2, Injection pump gear cover 3. Seal plate 4. Timing gear cover 5.. Friction gear 6 7. 8. 8 Injection pump gear . Friction gear . Camshatt gear . Thrust plate DISASSEMBLY NOTE Camshaft Gear 1. Hold the camshaft gear with the SST. 2. Remove the lock nut ot injection pump gear. 3, Remove the Injection pump gear by using SST as shown in the figure. 4, Remove the camshatt gear and idling gear. ASSEMBLY NOTE Timing Gear Note - + Install the timing gear so that Its mark can be aligned to BTDC 30° 1. Install all gears with aligning all matching marks of gear together as shown in the figure. 10. Idle gear 11. Spindle 12. Fuel injection pump 13. Oil deflector 14. Friction gear spring 15. Friction gear 16. Timing gear case 17. Rear oil seal10A-26 ENGINE biSASSEMBLY / ASSEMBLY CYLINDER BLOCK - JOURNAL PART ;— HOWTO TIGHTEN + connEtTING ROD CAP LOOSEN IT AFTER TIGHTENING WITH 7.0 gem, AND RE-TIGHTEN WITH 3.0 ko-m, ‘THEN TIGHTEN 90° AGAIN. + CRANKSHAFT MAIN BEARING CAP LOOSEN IT AFTER TIGHTENING WITH 8.0 gem, AND NE-TIGHTEN WITH 4.5 kj-7, ‘THEN TIGHTEN 90° AGAIN, 4. Woodruff key 2. Camshaft thrust plate 3. Camshaft 4. Tappet &. Connecting rod cap 8. Connecting rod and piston assembly 7. Conniegting rod bearing 8. Connebting rod 8. Piston ring 10, Snap ring and piston pin 14, Connecting rod bush . INSERT SLOWLY WITH ROTATING LINER Heme om 12, Piston 18, Main bearing cap 14. Lower main bearing + 15. Crankshaft 16. Upper main bearing 17. Piston cooling jet 18. Cylinder liner 49. Cylinder block 20. Upper thrust metal 21. Lower thrust metal| DISASSEMBLY / ASSEMBLY ENGINE 10A-27 ‘4 DISASSEMBLY NOTE . Connecting Red and Cap . Before removing the connecting rod, clean the bearing, con- [ necting rod and crankpin, and check the following, , + Connecting rod side clearance. (refer to page 10A-28) \ « Crank pin oil cleararice. (refer to page 10A-28) i : Main Bearing Cap aefore removing the maln bearing cap, clean the bosring and main journal cap, and check the following. « Crankshaft end play. (refer to page 104-27) ‘+ Main journal oil clearance. (refer to page 104-27) | OP RING seg0%0 a wae OIL RING ASSEMBLY NOTE : ! Piston Ring i |” 4 Assemble in the order of the oil ring expander, oil ring, sec nd ring and top ring. | Crankshaft Main Journal Bea Play 4, Remove any foreign material or oll from the journal and bearing. 2, Install the upper main bearing to cylinder block. ‘ ~ 8 Align the crankshaft to the cylinder block. * 4, Install the plastic gauge onto the upper side of journal in axial direction. 1g Oil Clearance and End ‘ 5. Loosen after tightening with 78 N-m(8.0 kg-m,58 Ib-it) and retighten with 44 N-m(4.5 kg-m, 33 Ib-t) then tighten: 90° again. Caution : + Do not rotate the crankshaft when measuring the oil clearance. 6. 'Remove the main bearing cap and measure the plasti ’ gauge at each journal. If the oll clearance exceeds the maxi- Tum value, grind the crankshaft and use the undersized main bearing. Oll clearance No.1, 2,4, 5 : 0.038~0.071 mm(0.0015~0.0028 ir) ~ + uk Bee :0.060~0.093 mm(0.0024~0,0037 in) imit : i No.4, 2, 4, § : 0.41 mm(0.0043 in) > No.3 : 0.15 mm(0.0059 in) ATONE10A-28. ENGINE DISASSEMBLY / ASSEMBLY 7. Apply a liberal amount of oil to the main bearing, thrust bearing and main journal. +. 8. Loosen after tightening with 78 N-m(@.0 kg-m, $8 Ib-ft) and retighten with 44 N-m(4.5 kg-m, 33 Ib-ft) then tighten 90° again. 9, Check the crankshatt end play. : End play : 0.14~0.90 mm(0,0055~0.0118 in) Maxirriuim : 0.32 mim(0.0125 in) 10. It the end play exceeds the maximum value, grind the crankshaft arid use the. oversized thrust bearing, or replace the orankshatt and thrust bearing, Ta & Thrust bearing width mmiin) Oversize ‘Specification — ara Crank pin oll clearance / connecting rod side ciearance PLASTI GAUGE 1. Place a piece of plasti gauge on the crankshaft at connect- Ing rod journal. Caution * Do not rotate the crankshaft when measuring the oit Clearance. ~ 2% Remove any ditt or other material trom the contact surface ‘of the connecting rod bearing and connecting rod bearing cap. " 8. ‘Install the. connecting rod beating and the connecting rod Cap, aligning the matching markes on the connacting rod and connecting rod cap. ‘4. Tighten the connecting rod cap nut as follows. (1) Apply engine oil to the thread of connecting rod and the surface of tightening nut, and tighlen to 69 Nem(7.0 kg- m, 51 lb-ft) then loosen it ‘ (2) Retighten with 44 Nem(4.5 kg-m, 33 Ib-tt) then tighten 90° again, oryDISASSEMBLY / ASSEMBLY ENGINE 10/ —— ee 5. Measure the oll clearance with the plasti gauge after assembling the connecting rod cap. Standard : 0.036~0.067 mm(0.0014~0.0026 in) Limit : 0.10 mm(0.0039 In) It it-exceeds the limit value, replace the bearing o: use the undersized bearing after grinding the crank pin. ramiin) Bearing sao Crank pin grinding tnt] Standard 57-106-57.124(2.2489-2.2490) Ti 705 Under sie 38.856-66.874(2.2086-2.2591) 750 Under size 58.606-66.624(0.2206-2.2293) O78 Under 38,350-80.074(2.2187-22108) 6. Tighten the connecting rod cap as follows. (1) Apply engine oil to the lubricating surface of crank pin and connecting rod bearing. @) Install the connecting rod cap, aligning the matching marks on the cap and on the connecting rod. (8) Tightening order of the connecting rod cap nut ‘After applying engine oil to the thread of connecting rod tightening bolt and nut, tighten it to 69 Nem(7.0 kg-m, 51 tb-f). and loosen it. Retighten with 29 N-m(3.0 kg-m, 22 Ib-f) then tighter 80° again. 7. Install a dial gauge. 8. Measure the side clearance while moving the connecting rod back and forth, Standard : 0.239~0.390 mm(0,0084~0.0159 in) Limit : 0.85 mm(0.0138 in) {tit exceeds the limit value, replace the connecting rod and cap. Tomm 10A-30_ENGINE INSPECTION AND REPAIR | . INSPECTION AND REPAIR 1. Clean all parts thoroughly and remove gasket fragments, dir, oil or grease, carbon, moisture and other foreign material completely. Caution . . . + Do not give damage to the Joints or sliding surface of aluminum alloy parts (cylinder head , piston). 2. Check if all parts are suitable with following standard value, replace or repair if necessary. i Tem Speaiioaton Remarks Cylinder Head ~~ | Distorion of ey [ Conan CaSO, head surface Lateral 0.10(0.004) | __ [ Bistorton of ide soace ae) 0:15(0.08) ! [Lengeot eyinder heed —"] Shotbot[Siandara Terie 078-48) i meg Ti 725 0689 | Tang bal [Standard T57=167310.17-8) ; tii 15801622) | Valve L { ‘Valve thickness (margin) Intake 1,35(0.05) { rome) | Exhaust 75(0.06) | Wake danaor | hana Sandal ——aaeoraani-a 3] | ~ mrntin) Limit 8.395(0.3305) \ Exhaust ‘Standard 18.440-8.463(0.3923-0.3332)| ¥ ra 6908105296) i ‘Valve guide inner diameter ____mrn(n} [8518-8 540(0.9054~0.9960) : Oil’ clearance Intake ~~ 10.027~0.074(0.0011~0.0029)| - Clearance between valve. | rn [Eshaus .085-0.100(0.0922-0.099}] guide imerclameter and . ini 0.116(0.0046 valve stom dlameter Valve seat angle © [intake 45 : enaut 5 Beatwieth nny [Intake = aaro085) Facing wih betwoon valve « Exhaust 4.98(0.078) face and valve seat : Valve seat aking Standard [ake T55=.250.041-0.048) j emir) eonevat 80-1. 10(0.035-0.059) | Tim [take 25010087 ' Exhaust 2.500 087) ! ‘Valve epring length ‘Standard T 49.5(1.95) i =f} — 28 | ‘Valve spring squarenessmmin)| Umit [ .63(0.064), | Rookor Arm and Rocker Arm Shaft ~ ~~ Rocker arm ier daeler ‘Boeo-ieariig7as-o70a] ' [Rocker em sat over daiay———— a.s80-16 se0(0.746-0747 { Gilcesrance min) | Standard ~~ ]o.086-0.0620.0006-<.0024) ' iit 1.07(0,008), Push Red [oetecien rai ayINSPECTION AND REPAIR NGINE 40A:31 a Tarn ‘Specification Remarks: Cylinder Block Distortion ‘wmGny | _Longiivainal PEE) Laterar 0.10(0.008) © [Oninder bore Taner —tamtay |e oe — [2700-97 sr906.8088-S8a8%) lameter YY axis 97.515-97.526(5.6091-0.6906) Gyiindertner cuter mmtay| “Vv ae 37 480-87 495(9.8976-0.8085) . ameter VV ans 57 489-97 S06(6 8683-5 6009) Platon,Platon Pin Piston outer diameter tay BaaToBaabe Measured al apaiod From . - (8.7194-8.7208) 1 lower end of piston Piston clearance img) 0.089-0.085 | Ditference between axial (0.0015-0.0026) Inner dameter of eytiner Ring groove ‘men(in) |__Top fing £.96-0.10{0,0024-0.0088)" |" Clearance barrece piston + | elearance ‘Secona ing $EE2 B80.9016-6.0082) rig groove and piston og oO Olli ring 0.03~0.0740.007 Measured on all around. : : Limit I 0.90(0.012) » Rrdtgap etpision ana Top rng 0:35-0:35(0.010-0 01a) 7 mm(in) | Second ring 0.30-0.45(0.012~1 018) “ i Oi ring '0.20-0.40(0.008-0.016) | List 1.50(0.06) | [stor pin outer aiamater tnenin) [28'994-80.000(5.1800-1-18T) ) i Connecting Rod ’ Bush Inner clametar ‘omtn) [s0.012-30 0000 eELIaaH os, Olclearance mmiah | Sianaara 2.072°0.089(0.0008-0.0015) | ‘Diterence bemoan boay i Umit _ 0.05(0,002) inner diameter end piston ‘Alowablo wit Pete) | 0:05(0002) per oom aay Camshart ~ Ruriout ema) [00.0085 ‘Cam height ‘wmtin)] Standard [Intake #2.389(1.6607) Exhaust 42,333(1.6667) : Umit intake 41.833( 1.6470) Exnausi $1.889(1.6470) | _ [Seumaleiameter —rimtay | hoy |51.810-51 940@.0487-20848)| Mer messumng ne journal 1 «|e tip No-2 -—[f2sesrsinznne-zosso} weenie ! No. {Sitios este c240-2.0350)| “eecton, @ i . No.4 s1.160=51.190(0.0149-F 0160] exceeds, YY. { Limi 0.08(0.003) | Camshaft bearing imer | "Not 52.000-82,090(2.0479-2.0¢88) diameter smmin) |“ No. 2 $1.750-61.760(2.0374-2.0386) | ~~ _] No.8 Si.500-51.690(20276-2 0287) | | No.4 51.250-1,28012.0177-2.0190) 181 TOiesance > matey ‘Standard 908-0.12(0.0024-0.0047) | Dlerence bewween Gemstar} Bearing inner diameter nay —| —canshalt four outer simeter | i [Enapiae ‘wmiin) | Carghan 0.02-06(0.0008-0.0570) 1 (axial play) Idle gear ‘| e.05=0. 18(0.0020-0.0070) | ~——"~ a PoE Umit 6.30(0.0118) i »i c 10A-32 ENGINE INSPECTION AND REPAIR, SPECIFICATION em q Specification I Remarks Tappet ‘Outer diameter mina) | TERE PESTO ESVE-O.SBDH Bore in cylinder biock ‘Glearance between cyindsr” Bieck bore and tappe raze mmiin} £ 319(0:5625~0.5637) | “/0.055-0.101(0.0022-0.0040) SPECIFICATION . tans - —_ To Cae Ferrand ager al [Combustion chamber ype _ ~ Swit Total displacement 2665 Symon ae Tae x ORE TET [Compression ratio as ‘Compress pressure (kglem?-rpm) ~ "30-200 Valve timing intake [Opening ‘BTOC 12° 5 __ia - ‘NADC 40> chaust [Opening BOC 60° ‘ [Closing — ATDC 17° tae soar fae ———] cnmay FE saateigcane sous Idle speed 700~750(A/T), 750-790(MIT) Injection timing(static) Hi ~ ATDG 7°) Firing order 7 2SPECIAL TOOLS SPECIAL TOOLS ENGINE 10A-33 a = << 9k670 130 010 Measuring cam lit oK71€ 191 001 Measuring Qe eS i | 1 Engine hanger Valve spring arm Replacing valves oka93 120 004 Pivot Assembling vale 0k999 120 006 Valve seal romover, Removing valve seal 9K710 120004 seal Instaier tnsiating vo } ks90 111 091 Ring gear brake set Protecting engine ‘tom rotating 0K130 160 010 Clutch diso centering too! Assembiing clutch dise 0k190 111 004 Holder coupling flange Removing camshaft | gear 0K670 131 005 Injection pump ‘gear remover Removing injection pump goaroy oe LUBRICATION SYSTEM } (J2 ENGINE) SPECIFICATION .. ENGINE OIL ‘OIL COOLER OIL FILTER... OWL vET OlL PAN... OIL PRESsU OIL PUMP... SPECIAL TOOLS RE SWITCH TROUBLESHOOTISe TROUBLESHOOTING GUIDE ' TROUBLESHOOTING GulDE LUBRICATION SYSTEM 114-3 Possibie causes Problem |. Engine hard starting Improper engine oi! Insufficient cit Excessive oil Oil working up ‘consumption Ollleakage Low oll pressure Insufficient oi Ollleaksge Worn or damaged o¥ pump gear or rotor Wein plunger (i side 6it pump), oF weak spring Clogged ol strainer Excessive main bearing or connecting rod clearance Low oil pressure Malfunction of oil pressure switch Maifunetion of electri system ‘Warning tight on during engine ‘operation Reterto Section 10a | Repair ‘Add oil Feepair Replace Replace Clean Flor to Section 108 aad Same as above Replace | Repair#) © 6. Tighten the oil filer cap, 114-4 LUBRICATION SYSTEM ENaINE oI ENGINE OIL INSPECTION 1. Be sure that the vehicle is on level ground 2. ‘Start the engine and let it warm up to normal operating temperature. 8. Turn the engine off and wait for § minutos. 4 Check the engine oil fevel and its condition by using iho cil level gauge. Fill or replace oil if necessary. Note + Check If off quantity is between "L" and mark of ollilevel gauge, Oll Pressure 1. Remove the oil pressure switch. 2 Connect SST to the attaching hole of ol pressure switch on Ton cylinder block, = ox S. Slart the engine and tet i warm up to rormal operating toi perature. 4. Read the. gauge indicating during keeping engine at ‘3000rpm, ‘Standard oll pressure: 952.0-431.2 kpa(3.6~4.4 kglom, 51.15~62.52 psi} SS 5 {oll pressure is not as speciied stancrd, inspect sach par and repair if necessary, RE 1. 2. 2. Remove the oi filer cap and oil pan drain 3. Drain the oil inte a suitable container, Warning * Since oil is hot whén engine is hot, wait a minute ‘and drain oil carefully. 4. Installa new gasket and en the drain plug, Tightening torque : 32~41 N-m(3.2~4.2 kg-m, 23-30 to-tty 8 Add the specitiog ot into the engine up to "F* level, Oil pan capacity : 6.7 1 (6.0 US at, 6.0 imp qt) 7. Check the oil level atter running engine, e « PRESSURE, Swirce e ‘ ° AeeTOTO am fame] Ol. PUMP LUBRICATION SYSTEM 114-5 OIL PUMP REMOVAL / INSTALLATION 1, Remove the battery negative cable, then remove the under cover. 2. Drain the oil into a suitable container. 3. Remove each part in steps as shown inthe igure. 4, Indtall in the reverse order of removal. | 08(60- 10 kere See 14, 18.7-22.5(1.6~2,3, 11:6~16.7) 37,2~82(3, 27,5~38,.3) em—- Nentkg-m, Ib-t0) ~ — “ANG 1005, 4.0ilpan 3. Oil strainer 2. Oil pipe 4, Oil pump= 114-6. LUBRICATION SYSTEM oll puMP DISASSEMBLY / ASSEMBLY 1 el _» 1. Disassemble in the sequence shown in the figure. {od 92 Assemble ine reverse order of isassemoly i f os a 7 | | } 4 ; | | e | i 9 i ¢ | | ‘ j i | | . i | . e Ls. pump cover © 2. Outer rotor 8. Inner rotor, 4, Drive gear (using press) 5, Pump body QC a4 IM < INSPECTION Oil PUMP LUBRICATION SYSTEM 114-7 Ingpect the followings, and repair if a problem is found. 4. Distortion or damage of the pump body or cover. 2. Wear or damage of the valve. 3. Weak or crack of the valve spring. 4, ‘The clearance between the inner and outer rotor. Standard : 0.04~0.08 mm(0.0016~0.0031 inj Limit : 0.10 mm(0.0040 in) 5.: The clearance between the outer rotor and the pump body. Standard : 0.10~0.21 mm(0.0040~0.0089 in) Limit : 0.25 mm(0.0098 in) 6. The clearance between the rotor and the pump cover. Standard : 0.03~0.10 mm(0.0012~0.0040 in) Limit : 0.15 mm(0.0089 in) “ANGOTIO1O41A-8_ LUBRICATION SYSTEM CiL PAN OIL PAN 7 Oneovar | ~"{.- Remove the battery negative cable. 2. Drain the engine ol 3. Remove the under cover. 4. Remove the hose attached to the vacuum pump ard the side of oll pan. 6. Remove the oil level gauge pipe trom this rubber hose. ©. Remove the oi pan. Lo INSPECTION 1. Remove any dir or chips in the oil pan, * 2. Check the ‘oil pan tor crack, the thread of drain plug for damage and inspect the bolt holes for damage. at Repair or replace if necessary. INSTALLATION 1, Remove the old sealant thoroughly or the cylinder biock and oll pan, 2. Apply a continuous bead of sealant to the oil pan along the inside of the bolt holes, and ovgriap the ends. 3. Tighten the oil pan installation bolts with epecitied torque. Tightening torque : 18.7+22.5 N-m(1.6~2.3 kg-m, 11.6~16.7 Ib-tt)OIL COOLER. LUBRICATION SYSTEM 114-9 OIL COOLER DISASSEMBLY / ASSEMBLY 1. Drain the engine coolant and oil. 2. Remove the fuel pipe, : 3, Disassemole in steps as shown in the figure, assemble in the reverse order of cis: assembly. 4, Check tor any oll leakage after assembling, ® wepurce 2 ee REPLACE ooking. i ae in 6~29.4(200~: ern, | sag Reespooe om. HSER IY toe | Hemtkgem. ets | 1. Oil cooler cover 2, Gasket 5.Contra! spring». 3, Oilcopler 6 Ph 7. Plug 8. Relief valve spring ger 9. Stee! ball114-10, LUBRICATION SYSTEM oit cooLeR INSPECTION 4, Oil Cooler 1. Inspect visually the core for clogging or damage place it if a problem is found. Plunger Controt 1. Check the plunger control for conneciicn or wear 2. Check the plunger contre! spring for weak. Olt Rellet Vaive 1. Check the stee! ball for wear or damage. 2. Check the relief valve spring for weak. pngor eraona ms aT om] | ~ < « OIL FILTER, OIL PRESSURE SWITCH, OIL JET_LUBRICATION SYSTEM 11A-11 OIL FILTER ~ REMOVAL / INSTALLATION 1. Remove the oil fiter by using wrench | 2. Apply a small amount of engine oil fo the "O" ring ol the new oll filter | Caution + Do not use any tool for tightening. i 3, Tighten the oil filter by hand. bo rrr * Tightening torque : . © 21,6-24.5 Nim(2.2~2.5 kg-m, 15.9~18.1 theft) 4, Add a specified amount of the engine oil 5. Start the engine and check for leakage at the filter. . OIL PRESSURE SWITCH INSPECTION. Ma 1. Turn'the ignition switch on (no start), then check if the warning light ist. 2. Start the engine and check if the warning lighi is turned off. + The oll pressure switch is normal it itis lit in step 1 and turned off in step No. 2. + Inspect the electric circuit if it is not lt in step 1, replace ‘the oll pressure switch if no problem is found (reler to the electric wiring diagram}. . + Measure the oll pressure if itis lit in step 1 and not tuned off in step No. 2, replace the oll pressure switch if the oil pressure is normal. OIL JET INSPECTION . 1. Check the oil passage for clogging. 2. Check the oil jet valve spring for damage. Valve opening pressure : 198 kpa(2.0 kgicm*, 28.4 psi) | Doe41A-12 LUBRICATION SYSTEM spec ICATION, SERVICE SPECIAL TOOL, : | SPECIFICATION Tabrication system [Toa et avery ——~ = ‘Ol quanity in of pan OF pO Foree-fed prossuro ‘Gitpump —— Ol ter body” Raping vale ato ‘On _ ‘ll cooler —_ ulin waior cooled [Warring tt operas pressure 2503.43) | [Engine oti = — ' Four seasons : SAE. SW-90 (25-30) API Sersice GF-4 or C4 | i Four winter : SAE, 10W-30 (20°C~300) | SERVICE SPECIAL TOOL (SST) a [ee van 018 Facswemen | . Oil pressure7. ew ressing and réleasing repeatedly the head of fuel fier, 2 Alter draining the water, do air bleeding for the fuel lie; the detector from the sedimentor. Keeps the heating temperature of glow plug through the preheat timer by turing the glow relay on and of. Y te + Operating condition ; ignition switch ON —+ STA . 7 - Keeps the heating temperature of glow plug through the preheat timer while ignition switch is in | ‘STA position. ~ i 3. After glow timer . ~ Operating condition ; ignition switch ON ~~ STA — ON {when water temperature is below 30°C(56°F). ~ Tums the glow rélay on and off for about 1 seconds in order to improve idle stability alter starting and | reduce white smoke when engine is cold. { i Note ° ‘+ Turning the glow relay on and off can be verified by operation noise. [. 4, Lamp timer | \ +_Turns the glow indicator lamp on for about 5 seconds when ignition switch is in ON position, / ‘WATER TEMPEANTURE ELON s0rcGe"A) WATER TEMPERATURE :ABOVE 301G6HR) 1 WATER TwerwO-SwTer ony (WATER Teno SuNTONOFF) H IGNITION SwitGH ON ‘etution switen On isumion (i ‘ow Oh fa ‘SwmTcH OFF Sure OFF e i. cow ili ciow Ot we oO, LAN OFF — SLOW Puue: stow Pius eat ¥° Ot may ee Ot OFF OFF | Max, 190% [= =e ae, (1982°F) TEMPERATURE =| (1982¢F owes aiowews | | : Ley , IGNITION SWITCH : ON—STA—ON . ‘oun i . icumon STA] « . vewmon STA IcurTion : | Sn . Of OF . iow stow en uae , Fl: Gow OFT : Stow Plus oy, i guoW PLUG Gy aw OF OF e noe) TewpenaTure wruRe Glow ewe gions ae » Ee —_ ANDOGTONOC QUICK START systeM (ass) ‘STARTING SYSTEM 314-0 —— @ CONTROL UNtT — [ irepection . Cte rs ‘1. Connect a voltmeter to the control unit as shown in the fig- a lel fate 2. Ure. : = | 2 Referring tothe following specication, inspect each termi- | | @ | : Hl nal voltage, and replace the control unit if necessary oO { “Note . i + If each terminal voltage Is beyond specitication, in- i e ‘spect the control unit after checking the connection |. 4 } . condition at all wiring. : TTT | . |. Terminal voltages : f i eal [creas DpeaiG OEE ee | Pa © | Glow pug amp Tgnllonswich ON | ForB see ty og ameter set) : ‘iter see_| About 12V _ . 4 z S| Glow pug relay Tailor swigh ON |For? see About iev| ~~ i (winout staring) [Aer 7 866" About o-t2v - | i | Seon [ (oa : | | apton sich OR —"] - [ioifon swien (STAR [ About 13 7 IL Weems aici] perso Fae | Ta BETS : (oathout starting) ‘Aboul OV —|"‘Waler erp. above 37°C 7“ wp} Glow pig ig bout 12V {i | or 1 eer sata Aeau.O27| Waser :beow are } | aa een ater 1600 Rect] Cor: ie ee mminspection S1A-10_ STARTING SYSTEM QUICK START SYSTEM (QSS), SPECIFICATION ae GLOW PLUG RELAY. . Measure the coil resistance (@~@ terminal) of the glow plug relay by ohmmeter. Resistance : About 130 2. Check if D~@ terminal is opened. 1. Apply the battery voltage to @)~@ terminal, Check if O~@ tetminal is closed. If not; replace it. GLOW PLUG Inspection . 1, Do the continuity test with ohmmeter between thé (+) termi nal of glow plug and the cylinder head. 2. Ititis opened, replace the glow plug. REMOVAL / INSTALLATION Remove in the following steps. 1.” Glow plug connector tightening nut 2. Glow plug connector 3. Glow plug {Install is in the reverse order of removal. Tightening torque : 15~20 N-m(1.5~2.0 kg-m, 11~15 Ib-(1) Note + Be sure to use the same type of glow plug. The as- ‘sembling mark of glow plug Is red. WATER THERMO SWITCH Inspection 1, Check if the water thermo switch is closed at specilied tern. erature, and réplace if necessary. Specified temperature : below 30°C (36°F) SPECIFICATIONCe ; i} I [. ° CHARGING SYSTEM | (J2 ENGINE) cumaaves “4 ‘ - SESE STALLATION Bet TROUBLESHOOTING « Gui 5 2 ne c bosrr 77 28 = —— « OUTLINE STRUCTURAL VIEW 1. Alternator 2. Vacuum pump OUTLINE CHARGING SYSTEM 32A-3 RRR 3. Battery324-4 CHARGING SYSTEM ALTERNATOR | ALTERNATOR +. This is battery voltage sensing type to directly sense the charging voltage fram battery, and keaps the best charging condition by controlling the alternator output voltage. Clreult Diagram f oO ~ | stator : . I co. so wannie Ue oh . © A rarer tH ‘ Jeon. ) | RESTA sanmon seatcx Sona” artery TPE : t — ANDOSOR ON-VEHICLE MAINTENANCE - ' Drive Belt 1. Check visually the bell for wear, crack or loose, and replace I itnecessary. 2. Apply moderate pressure (10 kg, 98 N) to the center portion obelt and check the tension, and adjust if necessary. : Doflection (Alternator drive bett) mm(in) ' Bante To Teed t Atemater | S100.31-030) | voreO8a-oa7 | | Note +, New one means a belt driven for below § minutes. © 5 inspection for detiection shout Se tee ates en- -§ine Is cold or at 30 minutes after engine is stopped. ALTERNATOR PULLEYane a ros on, amie TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE CHARGING SYSTEM 32A-5- ALTERNATOR Sep TnapeatToR TT Belions J T | Measure inp battery vatage Goto next sep \ 3 | Alter staring engin, cheskit the warning lamp. | Yas wapectstes a] y turns of [NO | Geto ned sien 3 | Ohecki he aerator teminal 1 "Yes! Tepecl the bub of warming lamp. — Check he wing between L terial and (Crema “ipawien oN Trae | the warning tap. 3 about av | 14.t=147 | | , | L ‘about 1V_ 141-147 | : . Ss bout 12V" sania7] | «No | Replace the alternator if 1 Wiring, | j -AN9032002- + ‘4 |. T.Connect a ammeter (min.100A) belween 8 | Ves — terminal and wiring | i 2. Tum off all electc load ater stating engine, j 3. Koop the engine speed to 2500-2000rnm, | 4 Check if the output current increases when | {urning elect load on. = [Nees tonextatep —— Caution i Do not connect 8 terminal o ground. | | | | e i 4 | . | 3 Gheekitthe defection of erve balls nomad” Yes "Replace the alemaisr “—— i 132A-6 CHARGING SYSTEM TROUBLESHOOTING GUIDE Vacuum Pump: ++ onnect a tachometer to the alternator pultcy. 4. Connect a vacuum gauge to the vacuum hose which is con- ected to.the vacuum pump and the power brake unit, and then inspect the specification. Alternator : 1600:pm (engine 750rpm) ‘after 20 seconds : above 58 kpa(440mmHg, 17.3 ing) Alternator : 3000rpm (engine 1500rpm) after 20 seconds : above 77 kpa(S80mmHg, 22.8 inHg} BATTERY .., . Connection 1. Check all terminals for looseness. 2. Check if the battery cable Is.corroded or damaged. 3. Inspect-the rubber protector for proper coverage. 4, Clean terminals and coat them with grease afler tightening Electrolyte Level 1. Check if the electrolyte level is between the upper and lower level. 2. Add distilled water upto the upper level i itis insulliciont Caution + Do not overilli distilled water. Specific Gravity . Ay Measure the specific gravity of electrolyte by using a hy- \ drometer. Standard: 1.280 (at 25°C, 77°F) 2. “Il the specilic gravity is below standard, charge the battery. CHARGING . Charge the battery, referring to a table of emperature vs. specific gravity. Quick charging Remove the battery {fom vehicle and do quick charging after removing the vent plugs. Caution +” Before inspecting or charging battery, turn all elec- trie loads off and stop engine. + Flmove the negative terminal at first when removing, but connect the positive terminal at first, then tho negative terminal later when installing. + During quick charging, put the battery in a container filed with water to protect the battery {rom overheating. Normal charging 4, Stop engine. -2.. Turn all electric loads off 7. After removing the negative terminal, do normal charging (7~BA). Note + Add distilled water if charging is necessary. «If the specific gravity is below standard, do normal charging. ‘aN6052008REMOVAL/ INSTALLATION CHARGING SYSTEM $2A- = ——————_—_ C e "REMOVAL / INSTALLATION @Double synchronizer ting : 1.3 mm(0.051 in) “Single synchronizer ring : 1.5 mm(0.059 in) Linait : 0.8 mm(0.0348 in) “Clutch Hub Sleeve 1. Mesure the clearance of the clutch hub and shift fork. Standard clearance 10.2~0.8 ‘mm(0.0078~0.0118 in) Limit: 0:8 mm(0.0315 in AAI "ANBOAI024CHANGE CONTROL_ MANUAL TRANSMISSION ata e = Sibapeclis.yinsscuauy 10Ve in.the steps shown in the figure. 2" Ingpect all parts, and repair or replace if necessary. ulreferring the notes for installation. 19+2611.9-2.6; 14~19) | Nemtkg-m, tb-11] 5 “ANBOAT0RS . 4, Nut 7. Select cable 5. Spring washer 8, Change lever assembly 6. Shift cable 9. Knob : iagtlietion note Hold the ae ene @ and install it during paying attention To . “citnot to be ber 1 pepe elo ot select cable is red.ANUAL. TRANSMISSION sPeciFicATIONS (CTION/ADJUSTMENT ‘Wien the change lever Is trembled inlet and right loosen ut @ and lighten alter adjusting, ntening torque? 10~15.N. Hmi(4.0-% 1.8 kg-m, 711 Ib) penthe changé lever is trembled in back and forth, loosen tH hut ‘®@and Uahten attr adjusting. ghtening: torque : 10-15 Niam(1.0—1.6 kg-m, 7-11 lb} ations sa SITET [3 seats Stanarad "~“Fonvard S-speed, Reveree speed _ Synchro mesh (ist and Bnd ; Double synchro) ] nea oar “07 aa19 2nd aaa me 30 1.425 ‘ath 1.000 sth “oan ~ Reverse 3.956 i Capaciy CT 220032) Grade ‘API Service Class GLé am oe“roots MANUAL TRANSMISSION 41-15 oe Fixing drive shaft (0K580 170 004 Main ave ‘Assembling bearing - Flomoving bearing ‘0K590 171"009 shit \ geese Assombling interlock in (0K580 171 005, ‘Assembling! Disassembling | look mut of hub Interlock pin guide Removing gear and | 0K599 170 007/003 bearing - Yransmission beeing nsister” esul a el i : | PROPELLER SHAFT ae INSPECTION .... DISASSEMBLY/ASSi ‘SPECIFICATIONS .. noeayOUTLINE_PROPELLER SHAFT 43- OUTLINE STRUCTURAL VIEW 12 seats AT 12 seats WT 18 seats MT SL43-4 PROPCLLER OO TROUBLESHOOTING GUIDE . Problem Possible cause Vibration ‘Bont propel shalt ~ linbalanced propeller sheft (Cracked sleove yoke spline Loose yoke joints Noise. ‘Cracked sieeve yoke spline \Womn or cracked spider bearing Loose yoie joints INSPECTION Spline backlash 1. Check for loose yoke joints and tighten if necessary. 2. Check for spline and universal joints backlash. Bend, 1, Ralse thé vehicle and support it with Safety stand. 2.. Measure how sharply propeller shaft is bent by turning wheels by hand and replace if necessary. Limit : 0.4 mm(0.016 in)DISASSEMBLY/ASSEMBLY . 12 seats at : . set eed “4d i 7 Mr bol | i r | - ee i \ 1 e 49-8§15.0-6.0. 36-43) | at . ° \ temtkg-m, thet) . — ~ y ~ —_ ANGOAIOTO | | _ ‘ vay ‘ ; 1. Sliding yoke(A/T) 6. Universal joint xe i 2. Propellar shaft(A/T) 7. Snap rin 2 1S 4 | 8:Stiding jointawn 8, Universal joint “el 4. Dust seal ! 9] S:rmerationtyoke iccnaeeraes neeneeamnaresmarnt 15 seats 89-58(6.0-60, 95-49), 1. Center bearing bracket 6. Rea universal joint yoke ==. Companion lange |_| 2: Universal joint yoxe 7. Front oll seal 12: Plain washer & 3.-Universal joint 8, Center beating 13, Washer spring Fx | 4: Snap ring 9. Rear ll sea 14, Conter bearing support >. | 5: Front universal joint yoke 10. Center bearing rubber 15. Rubber holderi DISASSEMBLY NOTE 1. Mark spider, yoke and propeller shaft for reassembling. Caution + Incomplete joint between propeller shaft spider and yoke at the time of assembly may cause vibration. ASSEMBLY NOTE 1. Apply grease to spider and bearing. 2, Assemble yoke and spider to propelier shall, and bearing to yoke by tapping with a plastic hammer. Caution + Be sure to have assembly marks of spider and yoke go exactly right. 3. Assemble with a new snap 'ring. Caution + - Do not reuse'snap rings. + Use four(4) snap rings with same thickness. + Ensure snap rings be completely seated and firm. INSPECTION 1, Check for bend of propeller shat Note + Measure from the center of propeller shaft, it: 0.4 mm(0.016 in) 2. Check moving torques of universal joints. Torque: AIT : 0.3-0.8 N-m(3~8 kg-cm; 2.6~7 Ib-in) MIT : 0.5~1.4 Nem(S~14 kg-om, 4.9~12 It-In) Caution + Replace and adjust snap rings if the torques are not within specification. (Refer to Page 43-8)Le awd PROPELLER SHAFT SPECIFICATIONS SPECIFICATIONS 1. Length(between joints) and diagram [Proper shan STE BGS | ae ¥-28(0 0504) ~~ __1:80(0.0511) rr Ta Haass OITe7 25 76. -32(0,0519) ir 1 SA00827 1,36(0.0535) 1.38(0.0549) ur os \ _frenny Paar Trekness Pad namber i Thikaass OwooT 35 177K TaB.087) OWOOT 25 SR ——} 1s50.08a7) “Dwo0T 25 1734 1.48(0.0883) “~~ 0K41025 O71 i ~7.60(670829) W001 25 1758 54(0.0606) | ok35 25 071 I 1.50(0.590) (O01 25 17aa ~~ ~ ~ 3. Tightening torque ‘Transmission x propeller shalt Ti 49-69(5-6, 96.5-43, | Propeter shall x dilerontal 48-89(6.06.0, 96.3-23, 8) L t . _ “48-58(5~6, 365-43 { iFRONT AND REAR AXLE SPECIFICATIONS ‘TROUBLESHOOT!TROUBLESHOOTING GUIDE FRONT AND. REAR’AXLE 50.3 . TROUBLESHOOTING GUIDE - FRONT AXLE - [ Problem I Possible cause . | ‘Action ” * | Steering whee! vibration Improper adjustment of wheel Bearing - 1 Aajst Wot or damaged whee! beating Adjust oe Dragging or puls to one side Worn or damaged wheel beaing Replace Improper adjustment of wheel bearing Adjust ‘| Excessive clearance of | Poor adjustments of wheel bearing ‘Adjust “] | stering whos! REAR AXLE . Problem t Possible cause ‘Action ‘Abnormal noise ~~ Bearing housing bent - Floplace ~ | Drive shaft bent Replace Wort or damaged whee! bearing Replace i__Worn drive shalt spline . Replace, Oil leaks 1 Worn or broken oi seat Replace DIFFERENTIAL GEAR j ee i Problem Possible causo ‘Action a ‘Abnormal noise 1 "Shortage of eifeental of ‘Ade ol ~ yy Improper adjustment of rng gear backlash Replace {Improper adjustment of ring gear backlash Adjust . | Poor engagement of ring gear surtaces Adjust . | Worn or damaged side bearing Replace | | Wor or broken ring gear |: Replace ae | | Wom or damaged ave pinion bearing oploce ve | Worn or damaged pinion and side gear | Replace Side gears contact with its case Replace . ‘Worn gear spline Roplace | { Worn pinion shaft Replace | Loose companion flange nuts Tighten Worn thrust washer Replace Improper adjustment of side bearing preload Adjust |L__Worn output shatt spi Replace Z | Overheat Shortage o etrentiat ot ‘Ade oi ' | Gearbacklash shortage \ ‘Adjust Excessive beavng preload Adjust | Oieare | Too much afereniat on > Remove ot | |. Airhole logged \ Repair i [Loose citterential carior Tighten and repair Wor or damaged oil seal - L Replace | erentel gear mation Improper assembly ~ 4 Repair ~] y t~ 80-4 PRON Ne ae ee FRONT AXLE REMOVALIINSTALLATION 1. Remove as shown in the figure. 2: Check parts if necessary. Repair or replace as required. 3. Install in the reverse order of removal. 4. After installation, check wheel alignment. REPLACE - 88~127(10~19, 12~94) 29~39(3~4, 22~28) is7~seetis~18, reign REPLACE | | LL _ __. Nemnikg-m, tb-t1) 7050001 1. Hub cap 7. Disc plate 2. Dividing pin and cover set 8. Dust cover 3. Lock nut 9, Tie-rod end 4, Washer 10. Lower arm 8, Brake caliper assembly 6. Front whee! hub assembly 11. Knuckle spindlef ee ND REAR AXLE 50-5- ———— INSPECTION Wheel bearing play 1. Remove wheels aid tires. 2. Remove brake caliper assembly. 3. Install dial gauge to wheel hub and measure’ wheel beatin play by pushing and pulling it to the shaft direction. Replace wheel bearing if necessary. Bearing play : 0.025~0.152 mm(0.001~0.006 in} REMOVAL NOTE Tie-rod end Caution + Be sure not to damage dust boot. 1. Loosen nut and remove tie-rod ond using SST. CSET Lower arm 1. Loosen nut and remove lower arm using SST. "ANGOSO00450-6 FRONT AND REAR AXLE REAR AXLE REAR AXLE REMOVAU/INSPECTION/INSTALLATION 1, Remove es shown in the figure. 2. Check ali parts, and repair or repi 2. Install in the reverse —_——_—— as required, | | | | <> 1 | | | \ 4 | 1 | Eo _ seg aot 4. Brake drum 8. Brake pipe 2, Hold pin 6. Backing plate and rear axle shaft assembly 9, Brake shoe assembly 7. Oil seal 4, Parking brexe cableREAR AXLE_ FRONT AND REAR AXLE 50-7 = | DISASSEMBLY/ASSEMBLY | 1. Disassemble as shown in the figure. Caution + Pay an extra atterition to bearing lock nut of left wheel as it is left-handed nut. * 2. Assemble in the reverse order of disassembly. ‘ 274~314(28~92. . 202~231) ® Nemikger, Ib-f1) "ANDDSO008 1, Lock nut 5. Oil seal 2. Lock washer 6. Oil seal retainer 3. Bearing outer lace 7. Backing plate 4. Wheel bearing: 8. “T axle shait DISASSEMBLY NOTE Bearing Caution + Put the protecting pad to the vise. 1, Remove bearing using SST. + Specification of grease : SHELL RETINAX LX2 or equivalent INSPECTION . Rear axle shaft 1. Measure shaft runout with the dial gauge. 2. Adjust axle shaft if runout is not within specification, Runout : 0.5 mm(0.2 in)50-8 FRONT AND REAR AXLE DIFFERENTIAL DIFFERENTIAL DIFFERENTIAL OIL CHECK Inspection 1. Remove tiler plug 2, Checkif ois enough to'be seen trorn the filing hole. Supply more regular oil if oil is not enough: 3. Assemble filler plug, Tightening torque : $9~54 N:m(4.0~5.5 kg-m, 29~40 lb-ft) Replacement Remove drain and filer piug and drain oil Clean plug. Put sealant on the thread of drain plug, Put new washer and tighten drain plug. Bens Tightening torque : 39~54 N.m(4.0~5.5 kgm, 29~40 lb-ft) 5. Add oil until the level reaches filing hole. Regular oil Spec. : Higher than -18°C(-0.4°F) : API GL-5, SAE 90 Lower than -18°C(-0.4°F) : API GL-5, SAE 80 Qty: 1.3L(1.37 qt)-12 seats, 1.6L(1.69 qt)-15 seats 6. Tighten filer plug, Tightening torque : 39-54 N-m(4,0~5.5 kgem, 29~40 lb-ft) ANDOL DEFERGNTAY FRONT AND REAR'AXLE 50.9 REMOVALJINSTALLATION Remove as shown in the figure, + Install differential within 10 min. after applying sealant, 2. Install in the reverse order of removal, Of fate: asec see seas) | ! 98~118¢10~12, 72~87) 23~26(2.3~2.7, 16.6~19.5) ee _ Nemtkg-m, tb-f1) ‘ansosoo72 1. Brake drum 4. Backing plate & rear exle assembly 2. Parking brake cable 5. Propeller shatt 3. Brake pipe 6. Differential assembly60-10 FRONT AND REAR AXLE DIFFERENTIAL = 2 Cneer pig inthe reverse order of disassembly, refering lo he notes for assembiy. ul DISASSEMBLY/ASSEMBLY . Lf. DISPeassembie as shown in the figure, referring to the notes for disassembly. if > 2, Check every part ‘and repair or replace, as required. ‘ i 12 seats) 49~59(6~6, 36-43) yee j f A | Pe ‘ t is : k - | FOR COACH { { i Oy? | 2tmzeaci9~28 oo | |e Bea \ | 62%) | boy : emthgem, to-t0 oo ~ a TO "ANBO50013 1. Bolt 10. Bearing inner lace 19. Ring gear 2. Lock plate 11, Collapsible spacer 20. Gear case cover 3. Bearing cap 12. Bearing outer lace +. 21. Gear case i; 4, Adjusting screw 13. Differential carrier 22. Thrust washer - 5, Bearing outer lace 44. Bearing outer lace 23, Side gear 6. Lock nut 45. Bearing inner lace 24; Pinion gear 4 7. Washer 16. Spacer 25. Spider q 8. Companion flange 17. Drive pinion * 26.LSD is 9. Oil seal 18, Bearing inner !ace. 27. Thrust blockDIFFERENTIAL FRONT AND REAR AXLE 60-11 (18 seats) 49~69(6~6, 36~43) > 196~343(20~35, 144~259) 1 fynagen, tet ‘ "ANSOSOU1SB 1. Bolt _ 10. Bearing inner lace ‘19. Bearing inner lace 2. Lock plate 11. Shim, 20. Ring gear 3. Bearing cap pacer 21. Gear case cover 4. Adjusting screw searing outer lace 22. Gear case ‘S. Bearing outer lace . 14. Differential carrier 23. Thrust washer 6. Lock nut 15, Shim 7. Washer 48. Bearing outer lace 8. Compainion flange 17. Bearing inner lace 9.Oilseal * 18. Drive pinion‘50-12 FRONT AND REAR. AXLE: DIFFERENTIAL DISASSEMBLY NOTE Differential carrier {Install differential gear assembly to SST. 2. Mari bearing cap and carrier for jointing. Companion flange 4. Remove lock nut, after holding companion jlange with SST. 2, Remove companion flange using SST. Rear bearing Remove bearing using SST. Note + Use your hand for drive pinion not to drop. Side bearing Remove side bearing from gear case using SST. Note \ «Make an alignment mark on bearing for reassembly. CeINSPECTION Collapsible spacer : 12 seats At the time of differential assembly, replace collapsible spacer with new one. Standard length : 54.8~56.09 mm(2.16~2.21 in) Assembly note Adjustment of pinion height 1. Assemble front bearing outer lace using SST. 2. Assemble rear bearing outer lace using SST. (12 seats) Assemble rear bearing outer lace using SST. After adjusting to the differential carrier. (15 seats) 3. For assembly of pinion, use drive pinion model(0K993 270 A01), pinion height atjustment gauge body(0K993 270 A0S) and gauge block(ht. 28 mm(1.102 in)). 4. Assemble spacer and rear bearing inner lace to pinion model and fix it with O-ring, (12 seats) Assemble rear bearing inner lace to pinion miodel and fix it with O-ring, (15 seats) ~ Note + Use spacer disassembled.(12 seats) ANBOSOOTR CETTE CEEEa_| “anie050022 19080023OU-14 FAUNAS 5, Install pinion model assembly to carrier. & ‘Assemble front bearing, collar, companion flange washer, ‘and lock nut. Note = Use washer and lock nut disassembled. 7. Tighter lotk nut. Note + Tighten to the extent the companion flange can be screwed by hand. 8. Put pinion height adjusting gauge body al right angle and adjust it to 0. ‘ 9. Put pinion’ height adjusting gauge body and gauge block to the upper side of pinion model. 40, Dial gauge needle should be placed al the lowest part of side bearing 11, Measure minimum positions of both sides (LH, RH). 42. Add both values and divide it by 2. 13. the value of the above step 12 is not within specification, use new spacer adding the values to current spacer.(12 seats) Standard clearance : -0.025~0.025 mm(-0.001~0.001 in) Ta | TRESS te fase} ee hh} sanereen se | 332001907 af 3.14(0.1236) i 3 3.95(0.1318) 17 i 8.170.1248) i 8 3.38(0.1330) me | 32001780) a | Senora @ | aoam | a | Senso 26 |__ 3200.28 ot aaie3se) If the value of the above step 12 is not within speciticatidh, use new shim adding the values to current shim.(15 seats) ox as REAR BEARING ‘O-RING -AONT BEARING. TRESS “ ras ear (0.0680) aDGed = e812 —arast0. 0007 e986 6918, 3:15(0,0059) — _ ‘anooso027Adjustment of drive pinton Preload(12 seats) 2 2. Push rear bearing in using SST, Note * feep pressuring until the sudden increase of neces. ‘sary power. * Place the’ spacer tor adjusting pinlon height, ensur- {ng exact direction of Installatie 3.{nstall collapsible spacer. &: Push front bearing in using SST, & Install rive pinion assembly. 6. Install companion flange anvi tighten lock nut. Tightening torque : 127~284.N.m(13~29 kg-m, 94~210 Ib-ft) Note + Donot install olf seal, 7" Tum companion flange by hand so that bearing be put at the right place, . Measure preload of drive Pinion. if the Fesult is not within ‘Specification, use now Collapsible spacer and measure again, Preload : 127~176 Nim(i3—18 kg-om, 94~130 Ib-fty Adjustment of drive pinion preload(15 seats) ': Push rear bearing in using SST toaes drive pinion. Note ‘ + Keep pressuring until the ‘Sudden increase of neces. : sary power, * Pace the shim for adjusting pinion height, ensur- we 'ng exact direction of installation” 2. Install spacer, + 8. Push the front bearing in using SST atter installing the shim, § iMstall crive pinion assemby. 5. Install companion flange angi tighten lock nut, Tightening torque : 196-348 N-m(20~35 kgem, 144~253 Ib-ty e: Note * Do not install oll seat, 8. Turn companion tlange by hang $0 that bearing be put at the right place. 7. Measure preload of drive pinion. If the result is not within Specification, adjust i withthe shim ans ‘measure again, Preload : 147~196 Num(15~20 kg-em, 108-144 tb-ttO0-16 FRONT AND REAR AAG bt cic e Cee || Backlash adjustment 1. Insert bearing inner lace using SST. ANBOEOOSO 2. Install differential gear assembly to carrier 3. Pay attention to the marks of the adjuster for its right posi- tioning 4. Make sure that the mark of the cap identifes with one of the cartier atthe time of installation of differential bearing cap. Tightening torque : 72-108 N-mn(7.4~10.9 kg-m, 53~78 Ib-ft) 8. Mark ring gear every 90 degree and install dial indicator to carrier in the position that the indicator needle makes a right angle with side surfaces of ring gear. 6. Turn both bearing adjusters together using SST until the backlash reaches 0.09~0.11 mm(0.0035~0.0043 in). 7. Check backlash {rom three different marks. Be sure thal the minimum backlash is not less than 0.05 mm and the differ- ence between the minimum and maximum values does not exceed 0.07 mm(0.13 in) . ANSOSOOSS 8.. Tighten adjuster until the distance between the pilots on (> > bearing cap reaches following values, Limit : 204.428~204.5 mm(8.048~8.051 in)(12 seats), 219.428~219.5 mm{6.638~8.641 in)(15 seats) Note + Be careful adjustment of differential bearing preload not to effect the backlash of drive pinion and ringl } ' DIFFERENTIAL FRONT AND REAR AXLE 60-17 = Ring gear-to-pinion gear contact adjustment 6 1. Coat both surfaces of 6-8 ring gear teeth with prussian blue CC - or white grease. MS 2. Rotate the marked ring gear teeth back and forth past the pinion 3. If the ring gear pinion marks are not Near the center of the 7 ring gear teeth, disassemble, and adjust pinion in or out. } r & iow | | (1) Toe and flank contact marks “Use thinner pinion spacer to move pinion out, oi (2) Heel and face contact marks Use thicker pinion spacer to move pinion in. 7 or aoOoOOn oO50-18 FRONT REAR SHAFT SPECIFICATIONS, SPECIAL TOOLS SPECIFICATIONS ——— ome MTX ‘2 [eronitana Bearing preloeaiwihaut a sea Tenia SCE : oc [Rearaxe ~ ~ co Fiype _ i: ‘Semi oat 1 ST earig apy —— age Gastec02) “+ [bifferentiat ~ __ i Rleduetion gear ~ _ “Hypoia ge : Siaigh bevel gear Final geal aa 4.2 2 ea), ATIC val on [Grade AALGLS [Viscosity SAE SAE eo = [Ri aa ‘Seals),1.6(7,69)16 seats) SPECIAL TOOLS -Y { FRONT AXLE : [ok 130 263 Gat For disassembly of T oK670 321 019 For disassembly of balljoint bal oi Baljit pute (a Bal join puler Er io Ag Y ‘ . XK : DIFFERENTIAL, 0K670 $90 AAD For disassembly of |" 9K130 175008 } For disassembly of side bearing front, Bearing instar g Pan pul bos beating eat puller 0K 190 175 A13 Foressembiy 0x03 270 801 For assombly of ol ede Dearing ‘outer lace Body U2 Handle — _—— —— OKS93 270 ADS For(Front bearing) 0K993 289 AOS: ‘| For(Rear bearing) | outer lace assembly ‘outer lacer ‘tachment (072) Atachmeat (082) assembly oeSPECIAL TOOLS FRONT REAR SHAFT 50-19 I. Geran BOA Fasting | oao ia TV reraacaa r assembly \ " Attachment | Counting flange holder 0 a — C oKs89 270 A08 For eusng noah | OX eB ztp avo For adusing ee of drive pinion, height of 4 | Orive pinion : | sve pn model Cp —ae fi | : poly \ 0K983 270 A08 height | 0K993 270 014 : For adjusting i ctéivepinion | screw dassembly | Gauge block Adjusting nut waerch PP | | | | ° 1 L L L. _ REAR AXLE : [exten 22001 ee : esr xt Se cy [Petr RN For rear axle shalt Dearing disassembly aro rm re ame Ve °oi) STEERING 1 i { MANUAL STEERING 1-3 ! POWER STEERING .... 1 8 i POWER STEERING Oil PUMP 1213 ei SPECIAL TOOLS 1-14 j SPECIFICATIONS 1-14 STEERING GEAR AND LINKAGE 112 boy MmMonmm a a e C CMANUAL STEERING STEERING 61-3 3 t MANUAL STEERING : STRUCTURAL VIEW ' - a e @ oO | 1 j | iy i ’ : | \ @ ne ; { . OO Tet | g i a } Ss | | 1 i - | Poo 1. Steering wheel 3. Bevel gear 2. Steering shaft 4. Steering gear51-4 STEERING MANUAL STEERING { ‘TROUBLESHOOTING GUIDE Problema Possibie causa | Action | Sioorng heavy Improper tie air prossure 1 aejust Incorret adjustment of preload of bevel gear | Adjust Incoweet adjustment of oraload ol pinion | Adjust Incorret adjsiment of wheol alignment Adjust Unsmeeth operation of nage bal joints Replace Unnecessary contact cuing steering shat unin. Ropairreplace Steering whens Ties not property infateg Adjust dentreturn = | improper wheel aignonect Adjust propery Unsmeoth poration of tiikege Ball joints Replace Unnecessary contact during sleerng shat tcring Repalereplace 'neosrect edlustment of preload of bevel gear ane pinion Adjust Evrae Unnecessary contact during steering shat uring and pone Bon Repairetighten steering Unsmocth operation of steering nage Repatereplace Improper acjusiment of preload of bevel gear Adjust Steering whee! Improper ie ar pressure Replace pulls to Malpas terran thee! beating prcload and worn wheel bearing | Rake epace one side Misagnment of wheat ‘Aciust Poor steering gear Replace ‘Abnormal noise ‘Steering linkage loose or woon Replace, Tighten Worn steering joints Replace tncorec agjustment of backiash of gear box Adjust Leaks of bevel Damaged gasket Replace ‘ear grease Damaged dust booth | Replace Samaged ip seal Replace . boaMr NG STS INSPECTION AND ADJUSTMENTS. Steering wheel play 1. Place the front wheels in the straight ahead position and check if the play meets the standard by tuming the steering wheel from side to side. . Play : 0~40 mm(0~1.57 in) } Note : + When the standard is not met, check if each steering Joint is worn or too much backlash of steering gear . Steering wheel force 1. With-the vehicle on the: ground level, place the front wheels in the straight ahead position. 2. Attach a pull scale t9 the outer end of the steering wheel spoke and pull he spring scale to rotate the wheel Required force : 225 N(23 kg, 51 Ib) Note + When checking, turn wheel more than 5 times to have correct measurement. 5 : 3. Check the followings if the results of the checking do not Aaa meet the standard. Pinion torques, ball joints torques, improper joints a : Steering wheel looseness, rattte rs : <1, Attempt to move wheel axially in and out @, left & right side —~ i @, @ and check for worn column bearings, clunking of ted steering shatt joints, loose steering and column couplers.ca Y BOOT : Replacement 1. Remove tire and wheel. 2. “Remove in the riumerical order as shown in the figure. 3. Install in'the reverse order of removal. : : 4, Check wheel alignment after installation. | RRO 1. Coiter pin : 5. Boot band: 2.Nut 6. Boot wire 3. Tie-rod end 7. Boot 4. Lock nut Removal 1. Remove cotter pin from tie-rod end stud ard loosen until the ut reaches very end of stud, Caution . + Tighten screw temporarily ensuring its thread not to be damaged. CSET 2.. Separate tie-rod end from steering knuckle using SST.MANUAL STEERING STEERING 51-7 T STEERING SHAFT ASSEMBLY t Removal and Installation Remove the negative terminal of the battery. . Position vehicle straight ahead. . Remove in the numerical order as shown in the figure, Install in the reverse order of removal. eo 4 7 ‘ @ 2rs9te~s, ° a: 4 n2~2000.2~27 ra SQ u 4 Q GES « er) \ Nmtkgem. toe) ~ a 7 “ARISOS 10080 1. Horn cap 7 6. Bevel gear 2. Lock nut 7. Steering shaft 3. Steering wheel 8. Universal joint 4. Column cover 9. Intermediate shaft 5. Combination switeti 10. Universal jointPOWER STEERING STRUCTURAL VIEW 51-8 STEERING POWER STEERING _ 1. Steering whee! 2. Steering shaft 3. Bevel gear 4. Steering gear 5, Oil pump 6. Oil pipe & hose 7. Reservoir ARDDSTOOTAFOWERSTEEHING DI EEK ory TROUBLESHOOTING GUIDE Problem ~] Possible cause Action Sloering heavy don't retuen properly Erratic steering Steering wheels Power steering belt loose or damaged Lack of power steering fluid or ai in system Hose kinked or twisted Pipe kinkod Low pressure of tuig Tres not properly inflated leproper adjustment of wheel alignment Poor operation of steering gear linkage Stooting column touehing othor parts Ties not properly inlated Improper agjustment of whee! alignment Poor operation of steoring gear linkage Steering gear out of oder Loose power steering belt Steering column out of order or loose bolts Unsmooth operation of steering linkage Defective steering gear ‘Adjust or reriace ‘Add tld oF bleed air Roplace Replace | Repair or replace Repair or replace Adjust Adjust Feopair or replace Ropair or roplace Adjust 1 “Adjust | Repair or replace | | Alopiace [—————_. Adjust Repair or tighten Repair or replace Replace Steering wheel Ties not properly inated Adjust pulls to one Incorrect adjustment of preload or win wheel beerngs ‘Adjus or replace fide Improper adlusiment of wheel alignment Adjust Steering gear out of order Replace Power steering Trouble at hose couplings Repair or replace fig oaks Hose damaged or clogged || Reace Power steering ud servo damaged 1 Feplacel | | Overtow | Alrbleed, Adjust uid ameunt Power steering pump oui of ordar | Replace 1 Steering gear mallunction | Poplace | Noise “Power steering pump out of order Tighien } Loose steering gear Tighten Loose power stexing pump bracket Tighten Loose power stering pump pulley nuts “Tighten Belt lose or excessive largues Adjust Air in system Alr bleed | ‘Steering gear out of order Replace. t Power steering pump out of order Replace Stosring columo: pressure hose touching other parts Repal or replace Sleetng inkage loa | Adjust or replaceeth baile il el POWER STEERING PRESSURE TEST Caution + Verity. that power steering system gauge valve is ‘opened for the system to operate. + Do not leave steering wheel turned longer than 15 seconds. CECT) | ReseAvoR | |. Remove high pressure pipe and install power slaering system gauge using adapter. 2. Insert a thermometer into power steering fluid tank, 8. Perform air bleeding as following procedures, 1) Check fluid level in the reservoir, and add fluid es necessary..- 2) Raise and support the front of the vehicle. 3) Turn steering wheel to the extreme left and right 10 times. : 4) Check fluid level again, and add fluid if reduced, 5) Until fluid reaches and remains at the proper level, re- eat steps 3) and 4). 6) Start engine and let idle. 1) Turn steering wheel to the exireme left and right positions 10 times. 8) Verify that any bubble is created. As bubbles indicate air In system, repeat steps 2)~7), Caution 5 + Check air leaks in system it bubbling keep taking place. <=} 4. Check temperature of Power steering fluid. If the temperature is not in the range of 50°C~60°C(92~110°F), tum steering wheel to the left and fight positions until the Specilication is obtained. Caution + Close valve for a second to read the pressure. + Do.not leave it closed for longer than 15 seconds. 5. Close power steering system gauge valve, and measure Power steering pump relief pressure increasing engine rpm to 1000-1500. 8. Increase engine rpm to 1000-1800 with power steering system gauge valve opened, 7 Read pressure with steering wheel in the extreme right or lett. . 8. Seperate adapter from power steering system gauge. Reconnect high pressure line and lighten*io 16-24 Nem(1.6-2.4 kg-m, 12-17 Ibeft) 9. Remove thermometer and olved air as described in the step 3. POWER sTEER- Power ING PUMP BSKOSIONE? aege POWER STEERING SIEGHING OI11 Steering wheel force 1. Put thermometer into power steering fluid tank, Caution ‘ + Do not leave steering wheel turned for more than 16 seconds ata time, Start engine and turn steering wheel in the right and left positions several times until fluid temperature reaches. ei 50°C-60°C(92~110°F). * & Place vehicle on ground level with steering wheel in the straight ahead direction, «+ 4 Attach @ pull scale to the outer end of the steering wheel - spoke and measure necessary force to rotate the wheel. ‘The operational force should be less than 29.4 N(3.0 kg, 6.6 I). Caution : + For accurate measure, pull the pull scale in a direc- : tion perpendicular to the radius of the steering e wheel. 5: Ifthe force exceeds Specification, inspect for lack or leakage of steering fluid, air in system, power steering pump pressure, steering gear pressure and tire inflation, 6. Remove thermometer. Power steering fluid check 1. Check the fluid level of the power steering at the reserve e tank. Add fluid so that indiestor comes between Max and 5 jin, — —— a 2. Let the engine run and make steering wheel 10 tums in the extreme right and left positions until normai opetational temperature. e 3. Stop engine with steering wheel in the straight head posi- Me tion. 4. Check steering fluid and add fluid so that indicator comes between Max and Min. Air bleeding 1. Check the fluid level of the power steering 2. Raise and support the front of the vehioie. 3. Turn steering whee! in the extreme left and right positions several times with engine off 4. Check the fluid level again and add fluid as required. 1 e 5. Repeat the slep 2 ard 3 until fluid reaches and remains at the proper level. " 6. Start the engine and let run at idle spees. 7. Turn steering wheel in the extreme right and let positions several times. rs 8. Check the power steering fluid at the reserve tank. There Oo should be no foam in the fluid. 9. Add fluid it necessary, and repeat the step 7 and 8.7 51-12 STEERING STEERING GEAR AND LINKAGE, STEERING GEAR AND LINKAGE “ e |) REMOVAL AND INSTALLATION . 1 =" 4. Loosen wheel nug nul. . 2. Raise and support the front part of vehicle with jack stands. | 3. Remove tires. ‘ 4. Remove in the numerical order as shown in the figure for next procedure. 1 5, Install in the reverse of order removal. | 6. Alter installation, bleed air from steering system and adjust toe-in as required. I “ i | 1 | : . i¢ ‘ 5 10~26(1,8~2.7, 13-201 i ‘o | : 14~93(7.6~9.5. 55~69) | . i; ee : _ | \ miko oto_| ie “ ANSOBIOTO $ a 1. Bevel gear and intermediate shaft 6. Returi'pipe and pressure}pipe 2. Bolt 7. Steering gear and linkage 4. 3. Bracket 4. Nut t 5. BoltPOWER STEERING OIL PUMP STEERING 51-13 POWER STEERING OIL PUMP REMOVAL AND INSTALLATION 1. Remove in the numerical order as shown inthe figure. Cauticn + When disconnecting pressure Pipe and return hose, prepare a sultable container to catch power steering fluid as it drains, 2. Install in the reverse order of removal, 3. After installation, following should be done. 1) Adjust bet, 2) Add power steering fluid and bleed air, ) Inspeet for fuid leak at connecting point of cil pump and hose pipe. 23.6~35.9(2.4~9.6, 17.3~26.0) o—rePLice 37~48(3,8°4.7, 27~34) - Q—ren | 37~48(3,0~4-7 ePuAce 27~34) = 1. Pressure hose 2. Oil pump assembly 4. Tensioner and bracket 5. Oil pump bracket 3, BracketC » SPECIFICATIONS x C c L 51-14 STEERING SPECIFICATIONS, SPECIAL TOOLS yy teeth ime Power steering Treeing wel sOiEA Toes) Sioetng sha = Calais joints Joins pe F ‘aiveral ins Frtstoke — a7 Sierng gear = ak 8 pon & linkage ~ = _ TS [Legis speed serang ype 164 “input 16 Ouipul 8 i135 38.12" 7 Ou 380 out ene < co Canes : STAD _ Cpe =I = PSF SPECIAL TOOLS. ‘Tok1s0 283 021 ~ ~~] Fortie rod end '0K201 323 AAD For measuring: , Gsessonthy | sea Pte, bal int and assenbly Gauges! OnE B= —— | | eos | aeBRAKE SYSTEM BRAKE PEDAL .. FRONT DISC BRAKE LOAD SENSING PROPORTIONING VALVES(LSPV) .. MASTER CYLINDER .. OUTLINE, REAR DRUM BRAKE SPECIAL TOOLS SPECIFICATIONS .. TROUBLESHOOTING GUIDEOUTLINE BRAKE SYSTEM 52-3 OUTLINE STRUCTURAL VIEW TRUCE 1. Brake pedal 6. Load sensing proportioning valve(LSPV) 2. Brake master cylinder 7, Parking brake lever 8. Power brake unit 8, Parking brake cable({ront) 4. Front disc plate 8. Parking brake cable(rear) 5. Rear drum brakeu Ree DRAKE STOLEM TROUBLESHOOTING GUIDE . f = fos TROUBLESHOOTING GUIDE ‘ ec Problem ‘etion 4 _| "Poor braking Brake tid teak Repair ¢ ; Ain pipe Bees air m C Mom fe trig renace Pad oF lining stained with orake fluid, grease or water Clean or replace: } Harden surface of pad fling, por contact, Grind or replace [ Mallunction a dise brake piston, Peplace “ Mallunction of master eyrcer or whee oyinger Repalror replace Mallunetion of power braxe wit Replace r ‘Maltunction of check valve(vacuum hose) Replace 2 1 “| Camaged vacuum hose Replace Aged flexible hose Replace P Malfunction of LSPV ‘Adjust or replace “8 l Pull to right Worn pad or lining Replace 2. * ortatt adorning stained wir bake Tid, grease or water + | Clean o rebiace e Hardon surlace of pad o ining, poor contact, Grind or replace Abnormaly worn disc of lng or ised Repair or replace Backing plate bots ose or deformed Tighten or replace A ‘Malfunction of wheel cylinder Repair or replace 1 Incorrect adjustment of wheel alignment Reter to Section 54 Inconsistent te ar pressure \ Fler to Section 53, 2 Brakes do No clearance of brake podal | “aust notrolease Incorret adjustment of push rod cvarance ‘aust Clogged master oylnder return port Clean Poor returning of shoe Clearyor replace . Poo return wa eyndar Gealorepace | “ “Malfunction of disc brake piston seal Replace Excessively wor dae plato Replace H Incorrect ajustment of wheel bearing preloas Rater to Section 50 : [os [excessive Ingorrect adjustment of pedal play ‘dust © | pedal stroke Worn ning Replace z. Damaged master cylinder Replace 1 ? Air in pipe Bleed air } Nise or Worn pad orig Replace { vibration Damaged surface of pad o* lining Gitind oF replace } P| curing braking Brakes do not release, Repair L S Foreign matter on o seratched cso plate Clean ‘ Loose bolts of backing plate or caliper Tighten Damaged surtace of dsc or drum Repair : Poor peds o ining contects Repalror replace ee Lack of grease in each moving part Apply grease > Malianeion Excessive lever aroke Aust L | ofparing Stuck or damaged brake cable Repaior replace brakes ning stained wth bake Fuld or ct Clean or replace ~ | arden lining sutace or poor contact Grind or replace \ON-VEHICLE INSPECTION HEIGHT OF BRAKE PEDAL Inspection Check if the distance between center of pedal face.and floor mat meets the specication. Height of pedal : 244 mm(a.6 in) Adjustment : 1. Loosen Idck nut ®, and adjust height by rotating push rod ® - 2. After adjusting, tighten lock nut ®. PEDAL PLAY Inspection 1. Depress the pedal several times to get alr out of system 2, Lightly depress the pedal by hand and check the pedal play. Pedal play : 7~9 mm(0.28~0.35 in) Adjustment 1, Loosen lock nut @, and adjust height by rotating push rod 2. Aller adjusting the play, tighten lock nut @. Note + After adjusting pedal height and play, check if stop lamps work properly and adjust as required. PEDAL-TO-FLOOR CLEARANCE Inspection 1. Apply pedal with S88N (60kg, 132 Ib) force alter starting en- Ging, and inspect it the Clearance Retween Magy End cantar Of peal face is as species. Pédal-to-floor clearance : 74 mm(2.9 in) 2. If the distance is less than the specification, check for the followings. (1) Air in brake system (2) Worn pads (3) Excessive clearance of shoe (4) Automatic adjuster malfunction Disassembly part bieeding location ON-VEHICLE INSPECTION BRAKE SYSTEM 52. FLOOR MAT “#N9052002 Right tet tsev Waster eylinder TSPv Wheel oyinder | Front. | Right Let [Rear= [Right tet |t 92-6 BRAKE SYSTEM BRAKE PEDAL BRAKE PEDAL . se (\ REMOVAL/INSTALLATION ‘1. Remove in the order as shown in the figure. 2. Inspect all parts and repair or replace as required, [ 3. Install in the reverse order of removal. 4, After instaliation, inspect and adjust pedal height and play. ‘ ® + Neentkgem, tof) ARGOER0 6. Return spring of 7. Brake pedal Pedal pad. 5. Bushing(2EA) . INSPECTION Brake pedal 8 4. “Inspect for worn bushing, pedal bounce, damaged return ‘ ‘spring, and bent bolts, and replace if necessary. k zy Stop lamp switch 41, Disconnect stop lamp switch connector. 2. Connect an ohmmeter and check for continuity when applying pedal. e qmaw a [ MASTER CYLINDER BRAKE SYSTEM 52-7 MASTER CYLINDER REMOVALJINSTALLATION 1. Remove inthe order as shown in the figure. 2. Install in the reverse order of removal 3. After installation, fill reservoir tank, check for flu = , | leakage and bleed brake system. o- - o. S@ seniors | & eo ae 8¢ rein ! °@ 9 ops611.o~1.6, 712 ~2201.3~2.2, 9~ 19-2201.3~2.2, 9-18) ssrzzn sea ey f Neentkg-mn"Ib-fs) ARBDEOONS 1. Rubber packing 5, Master cylinder 2. Brake pipe 8. Power brake unit 3.Nut 7. Brake fiuid level sensor connector 4, Spring washer 8. Reservoir tank INSPECTION Master cylinder 1. Measure clearance between power brake unit push rod and master cylinder piston using SST. aaa 2. It the clearance is not within specification, adjust it once | . i again by rotating push rod. rT SOG) SSC mTOR UTES Brake fluid level sensor 1. Check for continuity with brake fluid level in the range of MIN+3mm(0.118 in) using an ohmmeter.AD SENSING PROPORTIONING VALVES(LSPYV).. LOAD SENSING PROPORTIONING VALVES(LSPV) e REMOVALIINSTALLATION 1. Remove in the order as shown in the figure. 2. Install in the reverse order of removal. 3._ Alter installation, fill reservoir tank, check for fluid leakage and bleed brake system. f | ; —— ® ‘ i 1“ | 22~9002.2~3 1, 16-22) © Se" | aaa ° \ ! . Phas } 4 | . { | a ° 1. Adjusting nut 8. Brake pipe | 2. Spring 4. Bolt INSPECTION Spring 1. Inspect length of spring after placing vehicle on the ground level with no occupants. Specification : 89.5~90.5 mm(3.52~3.56 in) 2. Ifthe length is not within the specification, adjust by rotating adjusting nut and apply lock tite. (#271) Lspv 3. Install pressure gauge in front and tear brake wheel, 2. Bleed air in brake line. 3. Apply brake pedal until fluid pressure cf front wheel reaches A. 8 andsinspect if the fluid pressure A, B of rear wheel is: within specication kgrer'(os [Writ no sectpants —[—Newnal sonaitan | : Tato T j Wee ee tetas as tae tice) 1227) | an | | ty | Gs) | oy Lay 1313 fe, Go| er ge ae | ao 18) #8 | | GB | tor : 7 50 2 | care Tid i tt | eet eB | 108015895, ————_____}' } 50] 607 60 | 78 F110 “Angnse008 0) 28 ee glem(psi) . ; icle [Natal cenaiion p@ Vehicle 7 efalelb ls 35 [ 15?) 28 | 26-36 60) we -Ge-| Tio, as seals £088) | (36 | 5129 | 60) | 385) 365] fos) | 205] SVANT $4, T dy | by | Ge | 108), 108] 120 18S $89) | oy | 687 |r| tsar 205 | 82] AB 4 .. [SVAN] '30-T 307 40 | 63-1 ti] 110] 125 | i60 : : abe |e | oy | Ral a] | aS) | iti Caution t oatectinsony kg/em* + Incase of defective LSPV, replace asan assembly. | fusca gaeene OFF e WHEEL BRAKETENE MSY BRAKE BRARE STOLEN 92-9 FRONT DISC BRAKE j REMOVALIINSTALLATION | Be~127610~13, 7238) - - - a Ld tes SI pxwosas 0 . 1, Flexible hose . 6. Hub cap 2. Bolt 7. Pin washer nut i 8.Caliper . 8. Front hub 4. Supporting plate 9. Disc plate 5. Brake pads 10. Dust cover Inspection . 4 1. Thickness of disc pad Standard : 11.0~11.5 mm(0.433~0.452 in) Minimum: 1.5 mm(0.059 in) e 2. Disc plate Standard 26 mm(1.023 in) ” - Minimum: 24 mm(0.944 in) » 3, Runout (mm) (at 8~12.mm(0.315~0.472 in) from.the outside edge of disc) { Maximum: 0.1 mm(0.004 in) ‘Caution . + Do not allow grease and oil on the brake pad surfaces. a7 8 : boy ( hi52:10 BRAKE SYSTEM REAR DRUM BRAKE |. REAR DRUM BRAKE is, REMOVAL/INSTALLATION Bee 13h a A. . Nem(kgem, Ib-ft) aNaS20TT 1. Brake drum 7. Pull off spring 18. Operating lever, anti-rattle 2. Shoe hold spring sleeve 8. Shoe spring spring o 8. Back spring 9. Retum spring 14. Wheel cylinder 4. Shoe hold pin 10. Adjuster 8. Adjusting lever 11, Secondary shoe 6. Link 12. Primary shoe INSPECTION : 4 1. Thickness of lining pads Specification : 5.0 mm(0.2 in) Minimum: 1.0 mm(0.04 in) Inner diameter of drum , . . « ‘Specification : 260.0 mm(10.2 in) * Limit + 261.5 mm(10.3 In) ‘Caution | + Alte time of assembly of shoes, do not contuse primary shoe with secondary one. + Apply rubber grease lightly at the contact surface of shoe and back plate. + Grease, oll or any foreign material + After installation, adjust brakes. must be kept off lining surfaces.PARKING BRAKE_BRAKE SYSTEM. 52-11 PARKING BRAKE REMOVAL/INSTALLATION Remtkg-m, tb-f) ‘aNas2072 4, Parking brake lever cover 5, Return spring 2. Parking brake lever 6.Pin 3. Front parking cable 7. Bolt 4, Rear parking cable . VW INSPECTION i 1. Check parking brake lever sirokes when pulled with 294N “a ( (30kg, 66 Ib) of force. j oe 7 i ‘Specification : 4~14 notches | 4 t 2 2. Turn the ignition switch on and pull the parking brake one ; i notch, and check that the parking brake warning lamp ilumi- 3 nates. v4 4 Ee) | B Parking brake one notch! Warning lamp (Dy {®) Light stay on, @ =) ADJUSTMENT * 4. Start engine before adjusting and apply brake pedal several i times while moving vehicle backward. - <2. Check that the rear brakes do not drag.§2-12 BRAKE SYSTEM SPECIFICATIONS, SPECIAL TOOLS SPECIFICATIONS andem(Levl sensor installed)-pararral type ‘Specitieations J] "Suspension pe 4070.18) 145157), | [Cylinder inner diametor ‘tunfini!_©23.81(For ABS 9 25.4) (0.94, 1) Front aise Tipe’ _ Venilated ise [cake [ovina bare Tt Baba BXe] Tizolarea x INcknose) ma? xml Camber: +0.2+0.5 (No Passenger Load) 0.25: 0.5 (6 Passenger Load) Caster: 2.80.5 (No Passenger Load) 3.4£0.5 (6 Passenger Load) CAMBER ADJUSTMENT(RIGH ONE) 1. Turn the front spindle clockwise until the number "2" mark is aligned with the vertical line on the spindle bracket. 2. Turn the rear spindle counterclockwise until the number "2* mark is aligned with the vertical line on the spindle bracket. Note + Each numerical point indicated on the spindle increases the camber by 0.4 degrees when tured to the vertical line. . ROOST CASTER ADJUSTMENT(RIGHT ONE) ‘ : 1, Tum the front spindle clockwise until the number "2* mark is aligned with the vertical line on the spindle bracket. - , 2. Tum the rear spindle clockwise until the number "2" mark is aligned with the vertica! line on the spindle bracket Note + Each numerical point indicated on the spindle increases the caster by 0.55 degrees,when turned lo the vertical line,| FRONT SUSPENSION SUSPENSION 549 te @ FRONT SUSPENSION Note r C s + Be sure to ground vehicle when forquing nuts of arms and links to ‘specifications, s 43~8s A i \ 187~1e5(16~18, 116~137) Nemtkgrm, tb-tt) | 49 Wam5.5, 22~26(2.2~2.7, 16~20) 3240) “aNosa02 4. Stabilizer bar 4. Front shock absorber assembly | * 2. Knuckle steering 5. Lower arm assembly 3. Upper arm assembly 8. Cross member assemblySTABILIZER REMOVALINSPECTION/INSTALLATION 1. Raise the trot part of the vehicle on jack stands. 2. Remove in the order as shown in the figure. 3. inspect all parts and repair or replace if necessary. 4. Install n the reverse order or removal. Reler to the notes for installation when installing. [ | | i 22--26(2.2~2.7, 16~20) Nemikg-mn, lb-ft) - _— ANOECDT 1-Pivot link 3. Stabilizer : 2. Drop link Installation note : 1. Apply rubber grease to inside of stabilizer bushings. 2. Align bush to the marks on the stabilizer. “piwnne ner | (WHITE UNE) Caution + Be sure not to change assembly direction of pivot fink’ + Tighten bolts and nuts to specifications.FRONT SHOCK ABSORBER AND SPRING REMOVALJINSTALLATION 1. Raise the front part of the vehicle on jack stands, 2. Remove wheels. 8. Remove'in the order as shown in the figure. 4. Inspect all parts and repair or replace if necessary. 5. Install in the reverse order of installation, FRONT SHOCK ASSORBER ANO SPRING SUSPENSION 54-11 Lee t * | { EXPLODED wiew 2746t8.0~4,7, 27-30) | | ORR «, j 9 OES : | : —@ o—-O so | e—@ | be) S32 | : @—-o | eo | : -® ans | Es oNirsitgrn eto Toa AOE Nut 1. Upper retainer 6. Lower isulaor 2. Drop link . 2. Upper insulator 7. Lower retainer 3. Shock absorber and spring 3. Centering washer 8. Coil spring _ 4. Mountain block ‘9. Dust boot and jounce siop 5. Upper spring seat 1, Attach shock absorber to vise. Caution + Install protecting panel to vise. 2. Press coil spring using SST. 3. Set the end of the coil spring to the lower spring seat and install coil spring. 4. Tighten the piston rod nuts to specitications. Tightening torque : 37~46 N-m(9.8~4,7 ig-m, 28~34 Ibtt) 5. Measure the projected thread of piston rad endl. (12 seats) Specification ; 8.8 #0.5 mm(0.35 + 0.02 in) * 10. Lower spring seat54-12 SUSPENSION UPPER ARM UPPER ARM . | 4 REMOVALJINSPECTION/INSTALLATION i 1. Raise the front part of the vehicle on jack stands. EN 2. Remove wheels. _ 8. Remove in the order as shown in the figure. 4. Inspect all parts and repair or replace if necessary. j 5. install in the reverse order of removal. Nemtkg-m. Hb tt) ‘ANG0S@017 “ANGOEAOTS 4. Nut 1. Upper arm 2. Frontirear spindle 2. Bushing Removal note 1. Before loosening upper spindle nuts, mark bracket and spindle for installation, 2. Replace upper arm bushing using SST. Caution + Use soapy water when replacing with new bushing. + Replace dust boot only when failure is detected. + When reinstalling upper arm, adjust camber and caster.. LOWER ARM SUSPENSION 54-13 ‘ *| 7 LOWER ARM a REMOVAL/INSPECTION/INSTALLATION Ri. °! 1, Raise the front part of the vehicle on jack stands. tt “a 2. Remove wheels. : s 8. Remove in the order as shown in the figure. 2 4. Inspect all parts and repair or replace if necessary. fe 5. Install in the reverse order of removal. ne ~ 7 Pf]. | 1 | wean i | | ez || i Bi > No OL Beese.s ae : eeea2) *, \ . o— 187-186 (1819, 116-137) - TANBOEAEZO ARDOEAOT 4. Nut(knuckle) 4. Bushing . . 2. Drop link 2. Bushing 3, Nut(lower arm) 8. Snap ring we 4. Lower arm 4. Ball joint b Removal note 1. Replace lower arm bushing after installing SST to lower co am, a) 0° 0 ood o : . 1d SATE 2. Flemove knuckle after installing SST. ae Caution i + Apply soapy water when replacing with new bushing. . + When reinstalling lower arm, adjust whee! alignment if necessary. BOEING54-14 SUSPENSION REAR SUSPENSION(S LINK TYPE) REAR SUSPENSION(5 LINK TYPE) : 12 seats coach lon a REMOVAL/INSPECTION/INSTALLATION 1. Remove in the order as shown if the figure and install in the reverse order of renioval. : 2. Inspect all parts and replace if necessary. . ta Bien eae mem * roe 2 f ® a i LS ye we | 7e > ti « aseaena.shss~ ' sqssta asd Lg ee Nester ovost sam sects / ; & i 5 vase, UG ; a ee = a : en A 8907.660.6, 5580) i Uma Wig, et) TREO 1. Stabilizer bar 4, Upper arm assembly Se 2. Shock absorber 5. Lower arm assembly fl 3. Panhard rod 6. Spring i Inspection i 1. Tighten the stabilizer nuts so that the specified lengih of the thread is exposed. ! /@ Specification : 21~25 mm(0.83~0.96 in) 2, Tighten the shock absorber nuts until the specified length of the thread is exposed. Specification : 10.5~11.5 mm(0.41~0.45 in) Caution + Tighten bolts and nuts lightly, and after lowering the vehicle(no passenger load condition) tighten it to the specified torque. ~ + Do not remove rear jounce stop unless damage is detected.REAR SUSPENSION(LEAF SPRING TYPE) SUSPENSION 54-15 == ——— REAR SUSPENSION(LEAF SPRING TYPE) : Van, 15 seats REMOVAL/INSPECTION/INSTALLATION J. Raise the rear part of the vehicle and support it with safety stands, . ia 2. Remove in the order as shown in the figure and install in the reverse order of removal, 3. Inspect all parts and replace if necessary. Nemikg-m, tb-ft) i "ANDOSHO28 ~ % 1. Wheel and tire 7. Spring pin neo’ 2. Nut, washer, retainer and bushing 8 Shackle pin : 3. Shook absorber 9, Shacite plate 4. Nut and washer. 5. U bolt and set plate 6. Stopper rubber and spring clamp 10. Leat spring assembly | Caution { + Tighten bolts and nuts lightly, and afier lowering the e vehicle(no passenger load condition) tighten it to specified torque. ” + Fit leaf spring dowel into axle casing hole. + Tighten the shock absorber nuts until the specitied | ~y length of the thread Is exposed. Specifi ation : 10.5~14.5 mm(0.41~0.045 in}54-16 SUSPENSION SPECIFICATIONS, SPECIAL TOOLS SPECIFICATIONS items T ‘Specifications Suspension se TT BRUBIE Wishbone ype eat spring — 7 } r [ea sOSa25 | !€ passengertoad——f— Fa5z05 Front Wheat aignment | Camber | No passenge’ load | Fo2e05 G passengerload | =025=05 . Caster [No passenger oad 28205 _ ‘Spassengerload | _ 34205 Shock sbsorber ype [I Double acing pe Siabitze ype "Torion bar ype Fear Suspension type Sink rigid exe, ~. Leal spring” Shock absorber pe Double acing WBS * Speciication for van/1 seats ° SPECIAL TOOLS OR BARD [ Foremost 3 ako Forrenorno, instling ca springs instling oil spring Bye | user ousni Seg rubber bushing once | else Se ‘ f SS . ia I K710 342 017 | 0K670 321 019 For removing . tie rod boot |, Ballon attjoint . installer. i | ‘ __! : | 9x130 283 021 “Tie tod and 0k710 83: 008 For gauge adapter bal ois Ball joint puller \ | caster, camber { gauge edepter ‘0Ke88 263 025 Fer staling dust boot . : Dust i i boot installer t \ ' | I - | 1 Le — Lg ° i oeBODY | BACK DOOR... BONNET . DOOR MIRROR FRONT BUMPE! FRONT DOOR: . INSTRUMENT PANEL. ... POWER DOOR Lock SYSTEM POWER WINDOW SYSTEM .. REAR BUMPER .. SEAT SLIDE DOOR ..i ’ BONNET : a ww REMOVALIINSTALLATION . . 1. Remove in the order es shown in the figure, & 2. Install in the reverse order of removal. j ‘ C ‘ Caution + Remove the’bonnet with ariother person for secure safety. 0" REET 4. Bolt 5. Bonnet stay 2. Bonnet hinge 6. Release wire 3. Bonnet 7. Bonnet lock 4,,Bonnet stay holder60-4 BODY FRONT BUMPER FRONT BUMPER REMOVALIINSTALLATION 1. Remove the combination lamp and the head lamp. 2. Remove in the order as shown in the figure. 8. Install in the reverse order of removal. Note + When installing, use new fasteners. REPLACEMENT 1, Dummy grill amp 2. Fog lamp 3. Bumper face 4, Reinforcement 5, Bumper stay ARO3 REAR BUMPER .BODY 60-5 Wa ’ REAR BUMPER ee REMOVAL/INSTALLATION ‘ 1. Disassemble in the order as shown in the figure. oe . 2. Install in the reverse order of removal. “e 1. Back door striker 2. Bumper face 8.. Reinforcement 4. Bumper stay60-0 BODY FRONT DOOR — FRONT DOOR C * REMOVALJINSTALLATION }. Remove in the order as shown in the figure. 0 ag oe Install in the reverse order of removal, “Caution © ‘ + Remove the screen carefully to use again, : + Apply grease to the checker slide part before installing, 1. Inner handle 8, Weatherstrip 2. Door pull handle 8. Glass - Door trim 1G. Glass guide Pull handle bracket 11. Outer handle ‘Speaker 12, Door lock assembly ‘Screen 13. Checker Door lock knob; | C SUDE DOOR BODY 60-7 SLIDE DOOR. REMOVAL/INSTALLATION J. Install a jack under the slide door panel with a wooden block wrapped by cloth, 2. Remove in the order as shown in the figure. 8..Install in the reverse order of removal: Caution + Remove the soreen carefully to use again, c od 1. Inner handle 7. Striker 14, Shimming welt 2. Pull open stopper 8, Wedge and striker 18. Chassis 3: Door trim 8. Upper roller 16. Glass run channel 4: Screen 10. Center roller 17. Sliding glass 5. Outer handle 11. Lower roller 18. Center seal 8. Door lock and remote con- 12. Center guide rail 19. Lock troller 18. Weatherstrip INSTALLATION NOTE 1. Apply grease to the frictional part. 2. Check the roller bearing for damage and operation. «. 3. Check and adjust the operating force of the door. 4, Check the standard clearance of door each part.60-8 BODY sack DooR a BACK. DOOR ‘ « " REMOVAL/NSTALLATION 1. Remove in the order as shown in the figure. 4 2, Install in the reverse order of removal “ ‘Caution + Remove the screen Carefuliy to use again, + Work with another person for secure safely, ° oe - a ° Ta 3. 1Hinge 8. Outer handle 2. Stay damper ‘9. Door lock anli remote controller 3. Back door assembly > 10. Striker 4. Dovetall and wedge 11. Back door garnish \ ; 5. Door trim 12. Weatherstrip 4 8. Screen : 118. Back door wiper afm and blade “ 7. Key cylinder 14, Back door wiper motor+ TO MINDSHIELD WIPER AND WASHER -BODY 60-9 WINDSHIELD WIPER AND WASHER REMOVALIINSTALLATION 1. Remove in the order as shown in the tigure. 2. Install in the reverse order of removal. 3. Check the wiper motor switch. a ———> Y lee . boy G&G ® ae . roy “1. Wiper blade 2. Wiper arm and washer nozzle 8. Washer tank 4. Washer tank and bracket 5. Washer motor > TT 6. Wiper motor , 7. Wiper motor bracket { 8. Wiper link gy 8. Washer hose ‘Co eR eee WINDSHIELD WIPER AND WASHER (Only for RHD) REMOVALJINSTALLATION 1. Flemove in the order as shown in the figure. 2: Install in thésreverse order al removal. 8. Check the wiper motor switch, | ~ 4 ° ° i at : ——— S : . -e i ® i ‘ ot c tL _ —_— THT 1. Wiper blade 6. Wiper motor 2. Wiper arm and washer nozzle 7. Wiper motor bracket 8, Washer tan 8. Wiper link ) Washer tank and bracket 5. Washer motor 9 Washer hose ~?WINDSHJELD WIPER AND WASHER BODY 60-11 INSPECTION Wiper motor 1. Disconnect the wiper motor connector. 2. Check if current passes between terminals by an ohmmeter. 3. Cheok if the motor is operated when 12V is connected to the motor connector. . z z & 7 OFF Tow HIGH “Link assembly 1. Check if each part of the link is moved smoothly by hand. if ‘not, disconnect the connecting part and apply grease to it. RADDA ADJUSTMENT Washer fluld spray points 11. Adjust the spraying points of the washer fluid by inserting a ‘needle or similar material into the nozzle holes. AROS i 5 Only for RHO RRBOGOOTEN60-12 BODY INSTRUMENT PANEL INSTRUMENT PANEL e REMOVAL/INSTALLATION 1. Remove in the order as shown in the figure. pe 2. Install it in the reverse order of removal. faa | 1 3 i @ e —————~ won| ‘Hom cap 9. Glove box . 2. Steering wheel 10. Lower cover(RH) 3.Column cover 11. Center lower cover 4. Meter hood 12. Cup holder 8. Meter set 13. Switch cover 6. Side cover 14. Center panel 7. Fuse box cover 16. Instrument panel 2 B.Lowercover(LH)INSTRUMENT PANEL BODY 60-13 —_—S= = INSTRUMENT PANEL (Only for RHD) REMOVAL/INSTALLATION 1. Remove in the order as shown in the figure. \ . 2. Install itin the reverse order of removal. } + = . Horn cap 9. Glove:box 2, Steering wheel 10. Lower cover(RH) 3. Column cover 11. Center lower cover 4. Meter hood 12. Cup holder 5. Meter set 18. Switch cover 8. Side cover 14, Center panel 7. Fuse Box cover 16. Instrument panel 8. Lower cover(LH) AROOEDTET60-14 BODY sear SEAT FRONT SEAT Removal/installation . e 1..Remove in the order as shown in the figure. 2. Install it in the reverse order of removal. | e ° \ | | e ‘ { | 1., Knob. 6. Seat back 2. Cover. 7. Seat cushion 8. Reclining nuckie 8. Seat under cover, 4, Seat adjust 9. Seal 5. -Head rest 2:SEAT_BODY, 60-15 REAR SEAT = 1. wy l ~ | | & ~~ ~ ~ ~ “ANBOGOO18 4. Knob 6. Cushion 2. Tur tever 7. Seat adjust .3, Side cover 8. Tum base 4, Reclining nuckle 9. Head rest 5. Seat back :FRONT SEAT Removal/installation : ‘1. Remove in the order as shown in the figure. w 2. Install tin the reverse order of remioval. OTA 1. Knob 2, Cover 3, Reclining nuckle 5. Seat back 6. Seat cushion 7. Seat under cover 4. Head rest 8. SealDOOR MIRROR: BODY 60-17 o REAR SEAT a , = ce 1 0 Ae & | - ia 4. Knob 6. Cushion 2, Turn lever 7. Seat adjust 3,, Side cover 8. Turn base +4. Reclining nuckle 9. Head rest 5. Seat backSos BODY 000R miRROR DOOR MIRROR REMOVALIINSTALLATION 1. Remove in the order as shown in the figure. | . 2. Install it in the reverse order of removal. 1. Inner garnish 3. Door mirror 2. Seal 4. Remote controller switchDOOR MIRROR BODY. 60-19 , INSPECTION Remote control mirror 1. Check if current passes between the baltery terminals by an ‘ohmmeter. C Terminal oO 8 Items Flomoie ‘motor cq . ABO Heat 0-0 : continuity Remote control mirror switch 1. Disconnect the remote control mirror switch. 2. Check if current passes between the battery terminals by an ohmmeter. “Terminal [tems Passenger | up 0~0 : continuity60-20 BODY POWER.DOOR LOCK SYSTEM OWER DOOR LOCK SYSTEM ‘STRUCTURAL VIEW o 1, Front door lock 3. Back door lock controller 2, “Slide door lock controllerPOWER DOOR LOCK SYSTEM ‘BODY 60-21 a POWER DOOR Lock SYSTEM (Only for RHD) STRUCTURAL VIEW m 774 —~ | 1. Front door i ea 3. Back door lock controller + 2. Slide doot lock controller hoywee cee ere el tree POWER WINDOW SYSTEM 3 STRUCTURAL VIEW PASSENGER SIDE © 1. Power window switch fI SUNROOF BODY 60-23 SUNROOF i Ec REMOVAL/INSTALLATION i 1. Remove each pillar trim, 3 - Remove itn the order as shown in the figure, i 8. Install itin the reverse order of removal, . An o co al [ \ . | - | C i, (ee i * 7 a 1. Rear switch bezel 4. Drain hose 2. Aircon system cover 5. Rear switch and bracket 3. Top sealing 6. SI ing sunroof assembly60-24 BODY SUNROOF “ L INSPECTION 1. Inspection for the friction resisting force of the roof lid glass « Alter removing the sunrool motor, check the Iriction resisting foree of the roo! lid glass as follows. (1) Remove the top ceiling. ron (2) Remove the decoration cover. (3) Tie a wire at the front of the roof lid glass installation nuts. {4) Remove the motor with the roof lid giass open. (©) Measure the friction resisting force of the roof lid glass by a spring balancer. ‘Standard : 216 N (22 kg, 48 Ib) (6) If the friction resisting force of the roo! lid glass is above the standard, check the followings. + assembled status of the sunroo! assembly, deformation and inclusion of foreign material + sluck drive cable clined soo! lid glass 2: inspection for the sliding force of the sunroof motor clutch. (1) After inserting the emergency handle into the hexagonal hole of the motor drive shatt, install a gauge as shown in the figure. (2) After connecting battery power source between the connector terminals 1 and 3 of the sunroof motor, rotate the motor. (3) Measure the toad of the pull scale when the rotating force of the sunroot motor and the tensile force are bal- anced. Standard : 29~59,N (3~6 kg, 22~44 Ib) Caution + Maintain the pull scale in a direction Perpendicular to the emergency handle. +, Ifthe emergency handle other than the one provided in the vehicle Is used, the sliding force of the clutch may change that be sure to use the one Provided In the vehicle. + If the sliding force of the clutch is out of the standard, replace the sunroof motor, 8. Inspection for the sunroof motor. DRIVE GEA Check the rotating direction of the drive gear when the bat- " tery is connected to the connector terminals, Ree | .CLoRK. a3] — Fotaing dros line deve gear Cloak [inntectoane—i SREEICATIONS AIR CONDITIONER 62-25 components} i i | | | | | | Le. Heater | ‘component Pressure of | rerigerant Type. ‘Outlet flow Coalng | asiman” | Font eraporior eam capacity [cooing ___[ Reer evaporator ~~ ‘irtlow ~~ lSrnt evaporate” any } | | _[ Rear evapora:or inh o Power | Front motor cw o. consumption Rear motor (WeV) 2 Heating | Maximum | Front heater (Kea o capacity ~ | heating Rear heater ‘(Kau ° _| Blower capacliy | Front heater wa ° Rear evaporaior —(rahy ° Power Front heater ° 1 consumption | Rear heater © 0, Compressor ° ‘Magnelié clutch ingin condenser| ‘Sub condenser | | L Blower capacity j Front [ype | evaporator | Expansion valve Thermostat [For detrosten) Rear | evaporator Receiver diier Type Fin and tube type im nemal pressure Ope ZEOLITE (9) | Dual pressure switchkgtm’.S) | pr Low pressure sige Used religerant(charged amount)

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