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Indicates the
section title.
Denotes tightening torque.
If there is no indication of
tightening torque, refer to
tightening torque. Indicates the Indicates the
group title. group number.

Indicates the page number.

Indicates procedures to be performed be-


fore the work in that section is started, and
procedures to be performed after the work
in that section is finished.

Mark N denotes non-reusable part.

Component diagram
A diagram of the component parts is pro-
vided near the front of each section in order
to give the reader a better understanding of
the installed condition of component parts.

Repair kit or parts sets are shown.


(Only very frequently used parts are shown.)

Maintenance and servicing procedures


The numbers provided within the diagram indicate the Installation steps :
sequence for maintenance and servicing procedures. Specified in case installation is impossible in
Removal steps : reverse order of removal steps. Omitted if
The part designation number corresponds to installation is possible in reverse order of
the number in the illustration to indicate removal removal steps.
steps. Assembly steps :
Disassembly steps : Specified in case installation is impossible in
The part designation number corresponds to reverse order of removal steps. Omitted if
the number in the illustration to indicate dis- assembly is possible in reverse order of
assembly steps. disassembly steps.

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Classifications of major maintenance / service points


When there are major points relative to maintenance and servicing procedures (such as essential maintenance
and service points, maintenance and service standard values, information regarding the use of special tools, etc.).
These are arranged together as major maintenance and service points and explained in detail.
<<A>> : Indicates that there are essential points for removal or disassembly.
>>A<< : Indicates that there are essential points for installation or assembly.

Operating procedures,
cautions, etc. on removal,
installation, disassembly and
assembly are described

The title of the page


(following the page on which
the diagram of component
parts is presented) indicating
the locations of lubrication and
sealing procedures.

Indicates (by symbols) where


lubrication is necessary.

Symbols for lubrication, sealants and adhesives


Grease
Symbols are used to show the locations for lubrication
(Multi-purpose grease unless there is a
and for application of sealants and adhesives.
brand or type specified)
These symbols are included in the diagram of
component parts or on the page following the Sealant or adhesive
component parts page. The symbols do not always Brake fluid or automatic transmission fluid
have accompanying text to support that symbol. Engine oil, gear oil or air conditioning
compressor oil
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(2) For connector color, refer to GROUP 80A,


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(3) Shows the location of the connector(s) from


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(7) Describes possible


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(8) Start of the diagnosis procedure


for that DTC.

(M.U.T.-III Sub Assembly)

(9) Identifies the special tool(s)


necessary for diagnosing that DTC.

(10) Provides the inspection procedure


for that DTC step by step.

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9.0 ± 2.0 N·m 44 ± 9 in-lb
80 ± 17 in-lb
3

1
7
3.5 ± 0.5 N·m
31 ± 4 in-lb

2 11 ± 1 N·m
10 ± 2 N·m 98 ± 8 in-lb
6 89 ± 17 in-lb
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8N

4
5 N (ENGINE OIL)

44 ± 5 N·m
33 ± 3 ft-lb
10

AC500443AB

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31 ± 3 N·m
APPLY ENGINE OIL 11 ± 1 N·m
23 ± 2 ft-lb
TO ALL MOVING 13 ± 1 N·m 98 ± 8 in-lb
PARTS BEFORE 115 ± 9 in-lb
11
INSTALLATION.
18

19 12
47 ± 7 N·m
35 ± 5 ft-lb 21
22
16
14 ± 1 N·m
25 ± 4 N·m 120 ± 13 in-lb
18 ± 3 ft-lb
22 ± 4 N·m
23 16 ± 3 ft-lb
13
24* 17
25* 20
26*
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29* 24*
14 25*
89 ± 9 N·m 27*
65 ± 7 ft-lb 28* N
29*

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AC306536AB

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AC308654AC

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22 ± 4 N·m
16 ± 3 ft-lb

9.0 ± 2.0 N·m


80 ± 17 in-lb
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39 ± 5 N·m 2
29 ± 3 ft-lb 9.0 ± 3.0 N·m 1
80 ± 26 in-lb 26 ± 5 N·m
4 19 ± 4 ft-lb

9.0 ± 1.0 N·m


80 ± 9 in-lb

9.0 ± 3.0 N·m


80 ± 26 in-lb AC306537AB

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102 ± 22 in-lb
5
4 11 ± 1 N·m
6 98 ± 8 in-lb 11 ± 1 N·m
98 ± 8 in-lb
2
3
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7 9.0 ± 2.0 N·m 44 ± 9 in-lb
80 ± 17 in-lb

13 ± 1 N·m
115 ± 9 in-lb

1
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12 ± 2 N·m
102 ± 22 in-lb

AC306539 AB

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16
12

(ENGINE OIL)

13
9
17
11 ± 1 N·m
98 ± 8 in-lb 11 18 N

31 ± 3 N·m 10
23 ± 2 ft-lb

31 ± 3 N·m
23 ± 2 ft-lb
89 ± 9 N·m
65 ± 7 ft-lb
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1 7 9 6 4

AC301454AB

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FUEL $IWHUFRQQHFWLQJWKHIXHOKLJKSUHVVXUHKRVHVOLJKWO\SXOO
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WATER OUTLET MATING


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AC305104 AB

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102 ± 22 in-lb
14 ± 1 N·m
120 ± 13 in-lb 11
10
48 ± 5 N·m
36 ± 3 ft-lb
14 ± 1 N·m
120 ± 13 in-lb
5
8.8 ± 1.0 N·m 8
78 ± 9 in-lb 11 ± 1 N·m
21 ± 4 N·m
98 ± 8 in-lb
16 ± 2 ft-lb
7
44 ± 10 N·m 12
33 ± 7 ft-lb
23 ± 3 N·m
17 ± 2 ft-lb

22 ± 4 N·m
9
16 ± 3 ft-lb

6
79 ± 5 N·m
11 ± 1 N·m 59 ± 3 ft-lb
98 ± 8 in-lb 9.0 ± 1.0 N·m
80 ± 9 in-lb
AC306541AB

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20
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14 ± 2 ft-lb

17
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15
19
18 14
167 N·m 16 8.5 ± 0.5 N·m
123 ft-lb
76 ± 4 in-lb AC306542 AB

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MB991367

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76%5HYLVLRQ
& (1*,1(0(&+$1,&$//(1*,1(!
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12 ± 2 N·m 12 ± 2 N·m
102 ± 22 in-lb 102 ± 22 in-lb

16 19
13

12
11
42 ± 7 N·m
31 ± 5 ft-lb

46 ± 8 N·m 8
34 ± 6 ft-lb

41 ± 6 N·m
58 ± 7 N·m* 83 ± 12 N·m* 31 ± 4 ft-lb
43 ± 5 ft-lb* 61 ± 9 ft-lb*

N 17

9
14

83 ± 12 N·m*
61 ± 9 ft-lb*
7
9.0 ± 2.0 N·m
80 ± 17 in-lb
18
15 10

AC306783AE

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AC304581AB

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RETAINER
AC304582AB

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MB992012

MB991454

MB992013
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MB991928
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MB992012 5HPRYHVSHFLDOWRRO0%

MB991454

MB992013
AC405612AB

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MB991454 7KHQKROHWKHHQJLQHDVVHPEO\ZLWKWKHFKDLQEORFNHWF
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,167$//$7,21
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(STANDARD) • )227 67$1'$5'  0%
(MB991932) • -2,17   0%
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(MB991929)
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(MB991931) (MB991932)
AC306216AB

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FUEL $IWHUFRQQHFWLQJWKHIXHOKLJKSUHVVXUHKRVHVOLJKWO\SXOO
HIGH-PRESSURE 3 mm LWWRHQVXUHWKDWLWLVLQVWDOOHGVHFXUHO\$OVRFRQILUPWKDW
HOSE (0.12 in) WKHUHLVDSOD\DSSUR[LPDWHO\PP LQFK 7KHQLQVWDOO
WKHVWRSSHUVHFXUHO\
$SSO\DVPDOODPRXQWRIHQJLQHRLOWRWKHIXHOOLQHSLSHDQGWKHQ
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FUEL LINE PIPE


(ENGINE OIL APPLIED)
AC301864AB

STOPPER
AC304583AB

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3

88 ± 10 N·m
65 ± 7 ft-lb

1 2N
AC205540AB

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MD998715
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CAUTION
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MD998713 MB991559
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MD998713
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0
CAUTION
5HPRYHDQGDVVHPEOHWKHPDUNHGSDUWVLQHDFKF\OLQGHUXQLW
/()7%$1.!
3 10 ± 2 N·m
89 ± 17 in-lb

16 3.5 ± 0.5 N·m


6 31 ± 4 in-lb
CAM SECTION AND 4 11 ± 1 N·m
JOURNAL SECTION 98 ± 8 in-lb
5
ENGINE OIL
11
1 12
2 31 ± 3 N·m 14 ± 1 N·m
23 ± 2 ft-lb 120 ± 13 in-lb
10 ± 2 N·m
89 ± 17 in-lb N 7
18*
19* 9 10
20* 13
N 21*
22* 22 ± 4 N·m
N8
14 16 ± 3 ft-lb

16
18*
N 17 19*
15 20*
88 ± 10 N·m
65 ± 7 ft-lb 21* N
22*

AC307922AB

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10 ± 2 N·m
11
89 ± 17 in-lb
2
13 12
CAM SECTION AND
1 3 JOURNAL SECTION CYLINDER HEAD

3.5 ± 0.5 N·m ENGINE OIL


31 ± 4 in-lb

5 31 ± 3 N·m
23 ± 2 ft-lb
19 ± 3 N·m
15* 14 ± 2 ft-lb
N 6 16*
17*
9 18* N
15* 19* 11
16* 12 N
17*
N 18* 8
19* 13
N7

N 14
10

88 ± 10 N·m
65 ± 7 ft-lb

AC307923AB

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CAUTION
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KHDG
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SECTION

FLAT-TIPPED
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CAUTION
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MD998772

AC205277AB

<RIGHT BANK>

MD998772

AC205278AB

INSTALLATION POSITION
EXHAUST SIDE
RIGHTBANK

FRONT INTAKE SIDE

LEFTBANK EXHAUST SIDE AC204067AC

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CAUTION
• 9DOYHVWHPVHDOVFDQQRWEHUHXVHG
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VALVE
VALVE
STEM
SEAL
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IDENTIFICATION
COLOR

AC107415AB

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16 ± 3 ft-lb

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120 ± 13 in-lb

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18 ± 2 ft-lb
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24 ± 3 N·m
18 ± 2 ft-lb
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24 ± 3 N·m 10 × 38
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8 × 25 8 × 20
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42 ± 8 N·m THREAD DIAMETER × LENGTH mm (in)


31 ± 6 ft-lb 2
24 ± 3 N·m
18 ± 2 ft-lb
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18 ± 2 N·m 23
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14 ± 2 ft-lb 49 ± 6 N·m
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64 65 66 67 68 69 70
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77 78 79 80 81 82 83

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Input Shaft Speed Sensor System Circuit

IGNITION
SWITCH (IG1)

JUNCTION
BLOCK

JOINT
CONNECTOR (1)

INPUT SHAFT
SPEED SENSOR

POWERTRAIN
CONTROL MODULE

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12 13 14 15 16 17
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START
NE : Engine speed
NOPG-B : Output speed
(output shaft speed sensor)
Transmission fluid No
temperature sensor
voltage < 4.5 V

Yes

Shift stage is 1st or 2nd No


and NE < 2,600 r/min

Yes

Transmission range No
switch position is in
D, 3, 2 or L range
Yes
No
NOPG-B > 1,000 r/min

Yes

Pulses of input shaft speed No


sensor are not inputted

Yes
No
Continuous failure for 4 secs.

Yes

Malfunction Good

END
AC205224

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NE : Engine speed
NOPG-B : Output speed Transmission fluid
No
(output shaft speed sensor) temperature sensor
voltage < 4.5 V
NOPG-B : Output speed change
NIPG-A : Input speed Yes
(input shaft speed sensor)
I : Gear ratio Transmission range
No
switch position is in
D range

Yes
No
NOPG-B < -31.9
-18.5 r/min / 16 msec.

No Yes
NIPG-A > 1,000 r/min

Yes
No
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No
NE > 1,000 r/min
Yes
Yes
No
NE > NIPG-A + 100 r/min
No
Yes NOPG-B < (NIPG-A - 200 r/min) / I

Yes
Pulses of output shaft No
speed sensor are not
inputted

No
Yes Continuous failure for 4 secs.

Continuous failure No
Yes
for 4 secs.
Yes

Malfunction Good Malfunction Good

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CONNECTOR: B-110 CONNECTOR: C-01

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Yes Yes

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END
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END AC501721

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Yes
Malfunction Good

END AC205244 AB

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Yes
Malfunction Good

END AC205245AB

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NE : Engine speed No
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END AC205246AB

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NE : Engine speed No
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Yes
Malfunction Good

END AC500647AB

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NE : Engine speed No
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Yes
Malfunction Good

END AC205248 AD

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Yes

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Yes
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Yes
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Yes

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Yes
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MB991618

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305 ± 25 N·m
225 ± 18 ft-lb
65 ± 6 N·m
29 ± 4 N·m
48 ± 4ft-lb
21 ± 3 ft-lb
4
11 N
13
14
12 N
9.0 ± 2.0 N·m
5 80 ± 17 in-lb

100 ± 10 N·m
74 ± 7 ft-lb 9 8

90 ± 10 N·m
67 ± 7 ft-lb 3
N1
6
10
7
226 ± 29 N·m 2
167 ± 21 ft-lb
AC305336 AC

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CAUTION
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MB990767
AC102462 AC

%!!&$/,3(5$66(0%/<5(029$/
6HFXUHWKHUHPRYHGFDOLSHUDVVHPEO\ZLWKZLUHHWF


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CAUTION
• 'RQRWUHPRYHWKHQXWIURPEDOOMRLQW/RRVHQLWDQGXVH
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VKRZQLQWKHILJXUH

NUT MB991897

BOLT
BALL JOINT AC208247AC

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WRONG AC106821AC

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MB990244

MB990211

MB991354
AC210309AD

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CAUTION
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WKHUHLVQRORDGRQWKHZKHHOEHDULQJV2WKHUZLVHWKH
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MB990767
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9
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21 ± 3 ft-lb
N 11
6 4
<2.4L-RH>
9
N 7 5
41 ± 4 N·m
30 ± 3 ft-lb 3 2 1N
<3.8L-RH> 65 ± 6 N·m
48 ± 4 ft-lb

10
226 ± 29 N·m
167 ± 21 ft-lb

AC401226 AB

5(029$/67(36 5(029$/67(36 &RQWLQXHG


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CAUTION
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MB990767
AC102462 AC

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52'(1'&211(&7,21 5(029$/
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• 'RQRWUHPRYHWKHQXWIURPEDOOMRLQW/RRVHQLWDQGXVH
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CORD
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NUT MB991897

BOLT
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WRONG AC106821AC

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MB990767

MB990244
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MB990242 MB991354
AC102550 AC

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DRIVESHAFT

AC102551AD

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• 'RQRWSXOORQWKHGULYHVKDIWGRLQJVRZLOOGDPDJHWKH
7-RU37-EHVXUHWRXVHWKHSU\EDU
• :KHQSXOOLQJWKHGULYHVKDIWRXWIURPWKHWUDQVD[OHEH
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AC102553 AC
CAUTION
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WASHER
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CAUTION
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MB990767 7LJKWHQLQJWRUTXH±1⋅P ±IWOE
AC210244AB

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• 1HYHUGLVDVVHPEOHWKH%-DVVHPEO\H[FHSWZKHQUHSODFLQJWKH%-ERRW

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13

9
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AC405415 AB

1 5 7 1 4 2
2 5 3 12
7 13
2 1 5 14

6
3 3 9
GREASE GREASE
FOR TJ FOR BJ

TJ BOOT REPAIR KIT TJ REPAIR KIT BJ BOOT REPAIR KIT

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GREASE: REPAIR KIT GREASE

GREASE: REPAIR KIT GREASE


AMOUNT USED: 120 ± 10 g
(4.2 ± 0.3 oz)

CAUTION
THE DRIVESHAFT JOINT USES
SPECIAL GREASE. DO NOT MIX OLD
AND NEW OR DIFFERENT TYPES OF
GREASE.

AC405441AC

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CAUTION
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AC101695 AF

!!%63,'(5$66(0%/<,167$//$7,21
CAUTION
• 7KHGULYHVKDIWMRLQWXVHVSHFLDOJUHDVH'RQRWPL[ROG
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• ,IWKHVSLGHUDVVHPEO\KDVEHHQFOHDQHGWDNHVSHFLDO
FDUHWRDSSO\WKHVSHFLILHGJUHDVH
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CHAMFERED
SIDE

AC102654AC

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$IWHUDSSO\LQJWKHVSHFLILHGJUHDVHWRWKH7-FDVHRU37-FDVH
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ZERO CALIBRATION
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Imbalance = 5 g (0.18 oz) or less Imbalance = more than 5 g (0.18 oz)

Rebalance wheel.
Rotate wheel 1/4 turn.

Imbalance = 5 g (0.18 oz) or less Imbalance = more than 5 g (0.18 oz)

Verify wheel is properly centered.


Verify cones, cup, and wing nut are clean,
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wheel balance.

Attach a 5 g (0.18 oz) weight to the outer rim. STATIC BALANCE


CHECK
Is the imbalance 5 ± 2 g (0.18 ± 0.06 oz) at 170 – 190
degree angle away from the 5 g (0.18 oz) weight?

YES NO

DYNAMIC BALANCE
Attach a 5 g (0.18 oz) weight to the inner rim at 180 CHECK
degree angle opposite the weight on the outer rim.
Is the imbalance 5 ± 2 g (0.18 ± 0.06 oz) at 170 – 190
degree angle away from both 5 g (0.18 oz) weights?

YES NO

Balancer does not require Balancer requires calibration.


calibration. Contact balancer manufacturer.

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15 16
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13 ± 2 ft-lb

BRAKE BOOSTER VACUUM HOSE


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BRAKE FLUID PROPORTIONING VALVES


12 <VEHICLES WITHOUT ABS>
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GREASE: REPAIR KIT GREASE AC308045AB

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3 12 ± 2 N·m
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WINDOW GLASS INSTALLATION


PROCEDURE

BODY SIDE WINDOW GLASS SIDE

REUSING THE GLASS REPLACE THE GLASS

CLEANING OF ADHESION SURFACE CLEANING OF ADHESION SURFACE CLEANING OF ADHESION SURFACE


CUT OFF THE RESIDUAL ADHESIVE COMPLETELY CUT OFF ALL OF THE CLEAN OFF ANY DIRT ADHERING TO
UNTIL THE THICKNESS IS LESS THAN RESIDUAL ADHESIVE. CLEAN THE THE ADHESION SURFACE WITH 3M™
2 mm (0.08 inch). CLEAN THE ADHESION ADHESIVE SURFACE WITH 3M™ AAD AAD PART NO. 8906 OR EQUIVALENT,
SURFACE WITH 3M™ AAD PART PART NO. 8906 OR EQUIVALENT, AND AND LET DRY FOR 3 MINUTES OR
NO. 8906 OR EQUIVALENT, AND LET LET DRY FOR 3 MINUTES OR MORE. MORE.
DRY FOR 3 MINUTES OR MORE.

ATTACHING OF WINDOW SPACER GLUING OF WINDOW DAM AND WINDOW SPACER


ATTACH THE WINDOW SPACER TO SET GLUE THE WINDOW DAM AND WINDOW SPACER TO THE GLASS, FOLLOWING THE
THE POSITIONS FOR THE GLASS TO BE STANDARD POSITION ALL THE WAY AROUND THE INSIDE EDGE OF THE GLASS.
INSTALLED.

APPLICATION OF PRIMER
DO NOT APPLY PRIMER ON RESIDUAL ADHESIVE AS DOING SO MAY AFFECT ADHESION. APPLY ENOUGH PRIMER ON ADHESION
SURFACE EVENLY TAKING CARE NOT TO APPLY IT ON THE RESIDUAL ADHESIVE. AFTER APPLYING PRIMER, LET IT DRY FOR
3 MINUTES OR MORE.

APPLICATION OF ADHESIVE
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ALL THE WAY AROUND THE INSIDE EDGE OF THE GLASS.

INSTALLING THE GLASS


AFTER APPLYING THE ADHESIVE, LIGHTY PRESS THE GLASS
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CLEANING
AFTER REMOVING EXCESS ADHESIVE FROM THE BODY OR
GLASS WITH A SPATULA, ETC. CLEAN OFF WITH 3M™ AAD
PART NO. 8906 OR EQUIVALENT.

CHECKING FOR WATER LEAKS


CARRY OUT A SHOWER TEST TO CHECK THAT NO WATER
LEAKS THROUGH.

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1 1
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B
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16 (0.63) PRIMER
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AC306000
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C AC305998 PRIMER

1 SEAL LINE 16 (0.63)


5
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ADHESIVE: 3M™ AAD PART NO. 8609 SUPER FAST URETHANE AND 3M™ AAD PART NO. 8608 SUPER FAST
URETHANE PRIMER OR EQUIVALENT

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AC002060

GLASS ADHESIVE
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WINDSHIELD SPACER AND GLASS STOPPER INSTALLATION POSITION UNITS: mm (in)
GLASS END LINE

17.5 ± 0.5 (0.689 ± 0.020)

CERAMIC END
LINE ALIGN THE GLASS STOPPER END
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AC107207

GLASS STOPPER WINDSHIELD


SECTION A – A

40.1 ± 1
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WINDSHIELD SPACER
AC306004

WINDSHIELD SPACER

18.2 ± 1
CERAMIC LINE (0.717 ± 0.04)

13 ± 3
GLASS END LINE (5.12 ± 0.12) AC306003
A AC306002
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