Nissan Almera n15 Series Service Manual

<COMBINED EDITION>
QUICK REFERENCE INDEX
GENERAL INFORMATION GI
MAINTENANCE MA
ALMERA ENGINE MECHANICAL EM

MODEL N15 SERIES ENGINE LUBRICATION & LC
COOLING SYSTEMS
ENGINE CONTROL SYSTEM EC
ACCELERATOR CONTROL, FE
FUEL & EXHAUST SYSTEMS
CLUTCH CL
MANUAL TRANSAXLE MT
AUTOMATIC TRANSAXLE AT
FRONT AXLE & FRONT SUSPENSION FA
REAR AXLE & REAR SUSPENSION RA
BRAKE SYSTEM BR
STEERING SYSTEM ST
RESTRAINT SYSTEM RS
BODY & TRIM BT
HEATER & AIR CONDITIONER HA
ELECTRICAL SYSTEM EL
ALPHABETICAL INDEX IDX

Edition: July 1995
Printing: July 1995 (01)
Publication No. SM5E-0N15E0
NISSAN EUROPE N.V.

© 1995 NISSAN EUROPE N.V. Printed in THE NETHERLANDS
Not to be reproduced in whole or in part without the prior written permission of Nissan Europe N.V., Amsterdam, The
Netherlands.
FOREWORD
This manual contains maintenance and repair procedures for
NISSAN model N15 series.
In order to assure your safety and the efficient functioning of the

vehicle, this manual should be read thoroughly. It is especially impor-
tant that the PRECAUTIONSin the GI section be completely under-
stood before starting any repair task.
All information in this manual is based on the latest product informa-

tion at the time of publication. The right is reserved to make changes
in specifications and methods at any time without notice.
IMPORTANT SAFETY NOTICE

The proper performance of service is essential for both the safety of
the technician and the efficient functioning of the vehicle.
The service methods in this Service Manual are described in such a
manner that the service may be performed safely and accurately.
Service varies with the procedures used, the skills of the technician
and the tools and parts available. Accordingly, anyone using service
procedures, tools or parts which are not specifically recommended by
NISSAN must first be completely satisfied that neither personal safety
nor the vehicle's safety will be jeopardized by the service method
selected.
pe"fl NISSAN MOTOR CO., LTD.

Overseas Service Department
Tokyo, Japan
GENERAL INFORMATION •
SECTION GI
CONTENTS
PRECAUTIONS 2 HOW TO FOLLOW FLOW CHART IN TROUBLE
Supplemental Restraint System (SRS) "AIR DIAGNOSES 29
BAG" (Dual Air Bag System) 2 CONSULT CHECKING SYSTEM 32
Supplemental Restraint System (SRS) "AIR Function and System Application 32
BAG" (Single Air Bag System) 2 Lithium Battery Replacement.. 32
Precautions for NATS V2.0 (For Gasoline Checking Equipment 32
Engine Model) 3 IDENTIFICATION INFORMATION 33
General Precautions 3 Model Variation 33
Precautions for Multiport Fuel Injection Identification Number 36
System or ECCS Engine 5 Dimensions 39
Precautions for Three Way Catalyst 5 Wheels and Tires 39
Engine Oils 5 LIFTING POINTS AND TOW TRUCK TOWING ..40
Precautions for Fuel 6 Preparation 40
HOW TO USE THIS MANUAL 7 Board-on Lift 40
HOW TO READ WIRING DIAGRAMS 9 Garage Jack and Safety Stand 41
Sample/Wiring Diagram - EXAMPL - 9 2-pole Lift 42
Description 11 Tow Truck Towing 43
Wiring Diagram Codes (Cell Codes) 17 TIGHTENING TORQUE OF STANDARD BOLTS 44
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR SAE J1930 TERMINOLOGY LIST 45
AN ELECTRICAL INCIDENT 18 SAE J1930 Terminology List.. 45
Work Flow 18
Incident Simulation Tests 19
Circuit Inspection 23
PRECAUTIONS
Observe the following precautions to ensure safe and proper

servicing.
Supplemental Restraint System (SRS) "AIR

BAG" (Dual Air Bag System)
The Supplemental Restraint System" Air Bag" used along with
a seat belt, helps to reduce the risk or severity of injury to the
driver and front passenger in a frontal collision. The Supple-
mental Restraint System consists of air bag modules (located
in the center of the steering wheel and on the instrument panel
on the passenger side), a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable. Information necessary to ser-
vice the system safely is included in the RS section of this Ser-
vice Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could
increase the risk of personal injury or death in the event of
a collision which would result in air bag inflation, all main-
tenance must be performed by an authorized NISSAN
dealer.
• Improper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system.
• Do not use electrical test equipment on any circuit related
to the SRS unless instructed to in this Service Manual. SRS
wiring harnesses are covered with yellow insulation either
just before the harness connectors or for the complete
harness, for easy identification.

BAG" (Single Air Bag System)
The Supplemental Restraint System "Air Bag" and used along
with a seat belt, helps to reduce the risk or severity of injury to
the driver in a frontal collision. The Supplemental Restraint
System consists of an air bag module (located in the center of
the steering wheel), a diagnosis sensor unit, warning lamp,
vice Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could
increase the risk of personal injury or death in the event of
a collision which would result in air bag inflation, all main-
tenance must be performed by an authorized NISSAN
dealer.
• Improper maintenance, including incorrect removal and
installation of the SRS, can lead to personal injury caused
by unintentional activation of the system.
GI-2
PRECAUTIONS
• Do not use electrical test equipment on any circuit related •

to the SRS unless instructed to in this Service Manual.
Precautions for NATS V2.0 (For Gasoline Engine

Model)
NATS (Nissan Anti-Theft System)
NATS V2.0 will immobilize the engine if someone tries to start
it without the registered key of NATS V2.0.
Both of the originally supplied ignition key IDs have been NATS
registered.
The NATS security indicator is located on the instrument panel.
The indicator blinks when the ignition switch is in "OFF" or
"ACC" position. Therefore, NATS warns outsiders that the vehi-
cle is equipped with the anti-theft system.
• When NATS detects trouble, the malfunction indicator lamp
(MIL) blinks.
This blinking indicates that the anti-theft is not functioning,
so prompt service is required.
• When servicing NATS (trouble diagnoses, system initialisa-
tion and additional registration of other NATS ignition key
IDs), CONSULT hardware and CONSULT NATS software is
necessary.
SGI916 Regarding the procedures of NATS initialisation and NATS
ignition key 10 registration, refer to CONSULT operation
manual, NATS V2.0.
Therefore, CONSULT NATS software (program card and oper-
ation manual) must be kept strictly confidential to maintain the
integrity of the anti-theft function.
• When servicing NATS V2.0 (trouble diagnoses, system ini-
tial isation and additional registration of other NATS ignition
key IDs), it may be necessary to re-register original key
identification. Therefore, be sure to receive all keys from
vehicle owner.
A maximum of four key IDs can be registered into NATS.
• When failing to start the engine first-time using the key of
NATS V2.0, start as follows.
(1) Turn ignition key to "OFF".
(2) Wait approx. 5 seconds.
(3) Turn ignition key to "START" again while keeping the
key apart from any others on key-chain.
General Precautions
• Do not operate the engine for an extended period of time
without proper exhaust ventilation.
Keep the work area well ventilated and free of any flamma-
ble materials. Special care should be taken when handling
any flammable or poisonous materials, such as gasoline,
refrigerant gas, etc. When working in a pit or other enclosed
area, be sure to properly ventilate the area before working
with hazardous materials.
Do not smoke while working on the vehicle.
SGI285
GI-3
PRECAUTIONS
General Precautions (Cont'd)
• Before jacking up the vehicle, apply wheel chocks or other
tire blocks to the wheels to prevent the vehicle from mov-
ing. After jacking up the vehicle, support the vehicle weight
with safety stands at the points designated for proper lifting
before working on the vehicle.
These operations should be done on a level surface.
• When removing a heavy component such as the engine or
transaxle/transmission, be careful not to lose your balance
and drop them. Also, do not allow them to strike adjacent
parts, especially the brake tubes and master cylinder.
• Before starting repairs which do not require battery power:

Turn off ignition switch.
Disconnect the negative battery terminal.
SEF289H
• To prevent serious burns:

Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.
SGI233
• Before servicing the vehicle:

Protect fenders, upholstery and carpeting with appropriate
covers.
Take caution that keys, buckles or buttons do not scratch
paint.
SGI234
• Clean all disassembled parts in the designated liquid or

solvent prior to inspection or assembly.
• Replace oil seals, gaskets, packings, O-rings, locking
washers, cotter pins, self-locking nuts, etc. with new ones.
• Replace inner and outer races of tapered roller bearings
and needle bearings as a set.
• Arrange the disassembled parts in accordance with their
assembled locations and sequence.
• Do not touch the terminals of electrical components which
use microcomputers (such as ECMs).
Static electricity may damage internal electronic compo-
nents.
GI-4
PRECAUTIONS
General Precautions (Cont'd)
•
• After disconnecting vacuum or air hoses, attach a tag to
indicate the proper connection.
• Use only the fluids and lubricants specified in this manual.
• Use approved bonding agent, sealants or their equivalents
when required.
• Use tools and recommended special tools where specified
for safe and efficient service repairs.
• When repairing the fuel, oil, water, vacuum or exhaust
systems, check all affected lines for leaks.
• Dispose of drained oil or the solvent used for cleaning parts
in an appropriate manner.
Precautions for Multiport Fuel Injection System

or ECCS Engine
• Before connecting or disconnecting any harness connector
for the multiport fuel injection system or EGM (EGGS control
module):
Turn ignition switch to "OFF" position.
Disconnect negative battery terminal.
Otherwise, there may be damage to EGM.
• Before disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure.
• Be careful not to jar components such as EGM and mass air
flow sensor.
Precautions for Three Way Catalyst

If a large amount of unburned fuel flows into the catalyst, the
catalyst temperature will be excessively high. To prevent this,
follow the instructions below:
• Use unleaded gasoline only. Leaded gasoline will seriously
damage the three way catalyst.
• When checking for ignition spark or measuring engine
compression, make tests quickly and only when necessary.
• Do not run engine when the fuel tank level is low, otherwise
the engine may misfire causing damage to the catalyst.
Do not place the vehicle on flammable material. Keep flamma-

ble material off the exhaust pipe and the three way catalyst.
Engine Oils
Prolonged and repeated contact with used engine oil may
cause skin cancer. Try to avoid direct skin contact with used oil.
If skin contact is .made, wash thoroughly with soap or hand
cleaner as soon as possible.
HEALTH PROTECTION PRECAUTIONS

• Avoid prolonged and repeated contact with oils, particularly
used engine oils.
• Wear protective clothing, including impervious gloves
where practicable.
• Do not put oily rags in pockets.
• Avoid contaminating clothes, particularly underpants, with
oil.
• Heavily soiled clothing and oil-impregnated footwear should
not be worn. Overalls must be cleaned regularly.
• First Aid treatment should be obtained immediately for open
cuts and wounds.
• Use barrier creams, applying them before each work
period, to help the removal of oil from the skin.
GI-5
PRECAUTIONS
Engine Oils (ConI' d)
• Wash with soap and water to ensure all oil is removed (skin
cleansers and nail brushes will help). Preparations contain-
ing lanolin replace the natural skin oils which have been
removed.
• Do not use gasoline, kerosine, diesel fuel, gas oil, thinners
or solvents for cleaning skin.
• If skin disorders develop, obtain medical advice without
delay.
• Where practicable, degrease components prior to handling.
• Where there is a risk of eye contact, eye protection should
be worn, for example, chemical goggles or face shields; in
addition an eye wash facility should be provided.
ENVIRONMENTAL PROTECTION PRECAUTIONS

Burning used engine oil in small space heaters or boilers can
be recommended only for units of approved design. The heat-
ing system must meet the requirements of HM Inspectorate of
Pollution for small burners of less than 0.4 MW. If in doubt check
with the appropriate local authority and/or manufacturer of the
approved appliance.
Dispose of used oil and used oil filters through authorized
waste disposal contractors to licensed waste disposal sites, or
to the waste oil reclamation trade. If in doubt, contact the local
authority for advice on disposal facilities.
It is illegal to pour used oil on to the ground, down sewers or
drains, or into water courses.
The regulations concerning the pollution of the environment
will vary between regions.
Precautions for Fuel

GASOLINE ENGINE:
For Europe
Unleaded gasoline of at least 95 octane (RON)
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage
the catalytic converter.
Except Europe
Unleaded gasoline of at least 91 octane (RON)
DIESEL ENGINE*:
Diesel fuel of at least 50 cetane
If two types of diesel fuel are available, use summer or
winter fuel properly according to the following temperature
conditions.
• Above -rc (20°F) Summer type diesel fuel.
• Below -rc (20°F) Winter type diesel fuel.
CAUTION:
• Do not use home heating oil, gasoline, or other alternate
fuels in your diesel engine. The use of those can cause
engine damage.
• Do not use summer fuel at temperature below _7°C (20°F).
The cold temperatures will cause wax to form in the fuel. As
a result, it may prevent the engine from running smoothly.
• Do not add gasoline or other alternate fuels to diesel fuel.
GI-6
HOW TO USE THIS MANUAL
• ALPHABETICAL INDEX is provided at the end of this manual so that you can rapidly find the item
and page you are searching for.
•
• A QUICK REFERENCE INDEX, a black tab (e.g. I=J;J ) is provided on the first page. You can quickly
find the first page of each section by mating it to the section's black tab.
• THE CONTENTS are listed on the first page of each section .
• THE TITLE is indicated on the upper portion of each page and shows the part or system .
• THE PAGE NUMBER of each section consists of two letters which designate the particular section
and a number (e.g. "BR-5").
• THE LARGE ILLUSTRATIONS are exploded views (See below) and contain tightening torques, lubri-
cation points, section number of the PARTS CATALOG (e.g. SEC.440) and other information neces-
sary to perform repairs.
The illustrations should be used in reference to service matters only. When ordering parts, refer to
the appropriate PARTS CATALOG.
"Example"
SEC. 440
Pad retainer
(Upper side) 1]\
~ jL"J 54 ... 1'5 • '.5, 40 • '71
/~ ~ D Main pin
Torque
/ m to sliding portion
member
~ Copper washer
,~
o ~ D ~ /~ 17 - 20
~ ~ ---------- <~ ~ ~ ~ (1.7 - 2.0, 12 • 14)
Pad retainer ~
(Lower Side)m~
'(~
i":: I cftJ ~ ~Air
,
~
bleeder
Brake hose
V 1111 7
• 9 (0.7 - 0.9, 61 - 78)
Outer shim Pin bolt
~ 22 - 31 (2.2 - 3.2, 16 • 23)
-Cylinder body ~-~
Piston seal m~
Piston I] ~: N.m (kg-m, ft-Ib)
It]. N'm (kg-m, in-Ib)

SBR364AC
• THE SMALL ILLUSTRATIONS show the important steps- such as inspection, use of special tools,
knacks of work and hidden or tricky steps which are not shown in the previous large illustrations.
Assembly, inspection and adjustment procedures for the complicated units such as the automatic
transaxle or transmission, etc. are presented in a step-by-step format where necessary.
GI-7
HOW TO USE THIS MANUAL
• The following SYMBOLS AND ABBREVIATIONS are used:

to;J, l\tI Tightening torque M/T Manual Transaxle/Transmission
IE! Should be lubricated with grease. A/T Automatic Transaxle/
Unless otherwise indicated, use Transmission
recommended multi-purpose A/C Air Conditioner
grease. PIS Power Steering
Should be lubricated with oil. Tool Special Service Tools
Sealing point SAE Society of Automotive Engineers,
Checking point Inc.
Always replace after every disas- ATF Automatic Transmission Fluid
sembly. 01 Drive range 1st gear
IE! ~ Apply petroleum jelly. O2 Drive range 2nd gear
@ Apply ATF. 03 Drive range 3rd gear
Select with proper thickness. 04 Drive range 4th gear
*
1I Adjustment is required. 00 Overdrive
SDS Service Data and Specifications 22 2nd range 2nd gear
LH, RH Left-Hand, Right-Hand 21 2nd range 1st gear
FR, RR Front, Rear 12 1st range 2nd gear
11 1st range 1st gear
• The UNITS given in this manual are primarily expressed as the Sl UNIT (International System of Unit),
and alternatively expressed in the metric system and in the yard/pound system.
"Example"
Tightening torque:
59 - 78 N'm (6.0 - 8.0 kg-m, 43 - 58 ft-Ib)
• TROUBLE DIAGNOSES are included in sections dealing with complicated components.
• SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference
of data.
• The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal
injury and/or damage to some part of the vehicle.
WARNING indicates the possibility of personal injury if instructions are not followed.
CAUTION indicates the possibility of component damage if instructions are not followed.
BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information.
GI-8
HOW TO READ WIRING DIAGRAMS
•
Sample/Wiring Diagram - EXAMPL -
• For Description, refer to GI-11.
G/-EXAMPL-02
!-_ ••
~Refer
4
to optional splice
~ fjJ
_____ -_G/R ~o EL.EXAMPL
~"G~'P.g.
I
UG
r~ ....
I
BA ~TO GI.EXAMPL.04
1 t
I 21
':@
I
I
I
••
I
RELAY
QID
•
e-:._.~~_.
G/R BA
l!4Jl ffi rn
POWER POSITION POSITION SIGNAL
A B
III M @])
"OWP ~~,
MODULE @D
• •
UNIT~
~@
!.M~--------------.L..! .i~.-26------.'T
@ :MfT models
!-~--~-~-~
I B B :
r-------------------
i~ rnrcrni@)
@
Aefer to last page (Foldout page).
@.@)
@D
,------------------ I I ----~¥----
:.a-o~: @
ctrn @ B
~ @
W
lffu @) '--------~ ---- ---_.
W
<ffu@])
GY
ffiS:8 cmW5~
SGI904
GI-9
Sample/Wiring Diagram - EXAMPL - (Cont'd)
OPTIONAL SPLICE
Optional splice
MfT models AfT models
10A lOA
(ffi (ffi
<& L_.I
L
I
L CID
G/R
I
._G/R~
I
G/R
~
~L_. I
L
~CID
L
I
IrfJ~.~~.m
......@) '-II-' I~I@)
L G/R L
l
o
RELAY
~
!l
n RELAY
U @ U @
~ l!:j:JJ ~ l!:j:JJ
SGI858
GI-10
•
Description
Number Item Description
• This shows the condition when the system receives battery positive voltage
CD Power condition
(can be operated) .
• The double line shows that this is a fusible link.

@ Fusible link • The open circle shows current flow in, and the shaded circle shows current
flow out.
• This shows the location of the fusible link or fuse in the fusible link or fuse
<ID Fusible link/fuse location
box. For arrangement, refer to EL section ("POWER SUPPLY ROUTING").
• The single line shows that this is a fuse.

@ Fuse • The open circle shows current flow in, and the shaded circle shows current
flow out.
CID Current rating • This shows the current rating of the fusible link or fuse .
• This shows that connector @) is female and connector @ is male .

• The G/R wire is located in the A1 terminal of both connectors.
@ Connectors
• Terminal number with an alphabet (A1, B5, etc.) indicates that the connector
is SMJ connector. Refer to GI-16.
• The open circle shows that the splice is optional depending on vehicle appli-
rJ) Optional splice
cation.
@ Splice • The shaded circle shows that the splice is always on the vehicle.
• This arrow shows that the circuit continues to an adjacent page.

@ Page crossing
• The A will match with the A on the preceding or next page .
• The dotted lines between terminals show that these terminals are part of the
@) Common connector
same connector.
@ Option abbreviation • This shows that the circuit is optional depending on vehicle application.
• This shows an internal representation of the relay. For details, refer to EL

@ Relay
section ("STANDARDIZED RELAY") .
• This shows that the connector is connected to the body or a terminal with
@ Connectors
bolt or nut.
• This shows a code for the color of the wire.
B = Black BR = Brown
W = White OR = Orange
R = Red P = Pink
G = Green PU = Purple
L = Blue GY = Gray
@ Wire color
Y = Yellow SB =: Sky Blue
LG = Light Green CH = Dark Brown
DG = Dark Green
When the wire color is striped, the base color is given first, followed by the
stripe color as shown below:
Example: LlW = Blue with White Stripe
@ Option description • This shows a description of the option abbreviation used on the page.
• This shows that continuity exists between terminals 1 and 2 when the switch
@) Switch is in the A position. Continuity exists between terminals 1 and 3 when the
switch is in the B position .
• Connector terminal in component shows that it is a harness incorporated
@ Assembly parts
assembly .
• This identifies each page of the wiring diagram by section, system and wiring
@ Cell code
diagram page number.
GI-11
Description (Cont'd)
Number Item Description
• Arrow indicates electric current flow, especially where the direction of stan-
dard flow (vertically downward or horizontally from left to right) is difficult to
@) Current flow arrow follow.
• A double arrow" .... " shows that current can flow in either direction
depending on circuit operation .
• This shows that the system branches to another system identified by cell
@) System branch
code (section and system) .
• This arrow shows that the circuit continues to another page identified by cell
code.
@ Page crossing
• The C will match with the C on another page within the system other than the
next or preceding pages.
@ Shielded line • The line enclosed by broken line circle shows shield wire.
Component box in wave • This shows that another part of the component is also shown on another
@)
line page (indicated by wave line) within the system.
@ Component name • This shows the name of a component.
• This shows the connector number .

• The letter shows which harness the connector is located in.
@) Connector number Example: M: main harness. For detail and to locate the connector, refer to EL
section ("Main Harness", "HARNESS LAYOUT"). A coordinate grid is
included for complex harnesses to aid in locating connectors .
• The line spliced and grounded under wire color shows that ground line is
@ Ground (GND)
spliced at the grounded connector.
@ Ground (GND) • This shows the ground connection.
• This area shows the connector faces of the components in the wiring dia-
@) Connector views
gram on the page.
• Connectors enclosed in broken line show that these connectors belong to the
@) Common component
same component.
• This shows a code for the color of the connector. For code meaning, refer to
@l Connector color
wire color codes, Number @ of this chart.
• This shows the arrangement of fusible link(s) and fuse(s), used for connector
views of "POWER SUPPLY ROUTING" in EL section.
@ Fusible link and fuse box
The open square shows current flow in, and the shaded square shows cur-
rent flow out.
• This shows that more information on the Super Multiple Junction (SMJ) and
@ Reference area
Joint Connectors (J/C) exists on the foldout page. Refer to GI-16 for details.
GI-12
•
Example CONNECTOR SYMBOLS
View from terminal side Most of connector symbols in wiring diagrams are shown from
Connector symbol
the terminal side.
• Connector symbols shown from the terminal side are
enclosed by a single line.
~ • Connector symbols shown from the harness side are
Direction mark
enclosed by a double line and followed by the direction
View from harness side

[:it mark~
Connector symbol
~I
Direction mark
Connector
lit 8GI364
Example • Male and female terminals

Connector guides for male terminals are shown in black and
Male termlnar ~ female terminals in white in wiring diagrams.
G'id'V
Connector symbol
Connector
Female terminal
Guide
Connector
Connector symbol
8GI363
GI-13
SWITCH POSITIONS
Normally open Switches are shown in wiring diagrams as if the vehicle is in
the "normal" condition.
A vehicle is in the "normal" condition when:
• ignition switch is "OFF",
• doors, hood and trunk lid/back door are closed,
• pedals are not depressed, and
• parking brake is released.
Normally closed
5GI860
DETECTABLE LINES AND NON-DETECTABLE LINES

In some wiring diagrams, two kinds of lines, representing
wires, with different weight are used.
• A line with regular weight (wider line) represents a "detect-
able line for DTC (Diagnostic Trouble Code)". A "detectable
line for DTC" is a circuit in which ECM (ECCS control mod-
VEHICLE
ule) can detect its malfunctions with the on-board diagnos-
Y
SPEED tic system.
SENSOR
@ • A line with less weight (thinner line) represents a "non-de-
~
tectable line for DTC", A "non-detectable line for DTC" is a
lill-G_G~ circuit in which ECM cannot detect its malfunctions with the
on-board diagnostic system.
llli-G-R~
I~I SPEED
.,= OMETER
Y/G @Z) _ : Detectable line
I
for DTC
- : Non-detectable
Y/G
line for DTC
26
VSP
ECM
(ECCS CONTROL MODULE)
[] @)
SGI862
GI-14
•
MULTIPLE SWITCH
The continuity of multiple switch is described in two ways as
shown below.
• The switch chart is used in schematic diagrams.
• The switch diagram is used in wiring diagrams.
Example
(SWITCH CHART)
WIPER SWITCH
WIPER
SWITCH
f' 80th switches are turned in

combination.
f
Continuity circuit of wiper switch
SWITCH POSITION CONTINUITY CIRCUIT
OFF 3-4
INT 3-4,5-6
LO 3-6
HI 2-6
WASH 1-6
SGI875
GI-15
FOLDOUT PAGE
The foldout page should be opened when reading wiring diagram.
Super multiple junction (SMJ)
In wiring diagram, connectors consisting of terminals having terminal numbers with an alphabet (81,
DO, etc.) are SMJ connectors.
If connector numbers are shown in Reference Area, these connector symbols are not shown in Connec-
tor Area. For terminal arrangement of these connectors, refer to the foldout page at the end of this
manual.
Joint connector
Joint connector symbols are shown in Connector Area in the wiring diagram concerned. Foldout page
also carries inside wiring layout together with such joint connector symbols.
Example
Super Multiple Junction
(SMJ)
L----S
AlB1Cl 01 El FIGl Gl Fl El 01 Cl Bl Al
I (Main
R harness)
@
1~~_~_5 __1~1
I
BR
....... @ID .......

L (Engine
Iroom I
BR
A2B2
A3B3C3
A4B4
5 B5
A6B6
@]
C2 02 E2 F2 G2
0
E3F3G3
F4G4
F5 5
F6G6
G3 F3 E3
G4F4
G5 F5
G6 F6
C
2F2E2 C2B2A2
02
C3 B3 A3
B4A4
B5 A5
86 A6
harness) A7B7 F7 7 G7F7 B7A7
A8B8C8 E8F8G8 G8F8 E8 C8 88 A8
09 09
A989C9 E9F9G9 G9 F9 E 9 C9 89 A9
AO BO CO DO EO FO GO GO FO EO 0 CO BO AO
r-BR (Main harness)

(Engine room harness)
BR----{
STARTI G SYSTEM STARTING SYSTEM

Wirin Diagram ~r- SUPER MULTIPLE UNCTION (SMJ)
Terminal Ar angement
JOINT CONNECTOR
Terminal Arrangement
[Jcheck
* * r::t::rrm::m:J 'M'i'
CJ
[ill]II!J ~
OCh~'
o
rDI.TI:IImP
*~=fH+H=1 [II @)
[ill]![ill] @g)
'tffB' @) Qfu@
@(3)
@)
@
[J rll"
~
! ! ! I ! I II !I I
~lllll!I!!lIllbV 'J ~
~
"-)-~ y
Connector Area
Reference Area:
Refer to the foldout page for the terminal arrangement
of the connectors shown here in the "Reference Area".
SG1859-A
GI-16
Wiring Diagram Codes (Cell Codes)

Use the chart below to 'find out what each wiring diagram code •
stands for,
Code Section Wiring Diagram Name Code Section Wiring Diagram Name
AACIV EC IACV-AAC Valve KS EC Knock Sensor
ABS BR Anti-lock Brake System Torque Converter Clutch Solenoid
LKUP EC
A/C HA Manual Air Conditioner Valve
Air Conditioner Cut Control LOAD EC Load Signal

A/CCUT EC
MAFS EC Mass Air Flow Sensor
A/T AT Automatic Transmission
Main Power Supply and Ground
AIM EL Headlamp System MAIN EC
Circuit
AIRREG EC IACV-Air Regulator
Speedometer, Tachometer, Temp.
AT/C EC A/T Control METER EL
and Fuel Gauges
AUDIO EL Audio MIL, Data Link Connector For
MIL EC
BACK/L EL Back-up Lamp CONSULT
CHARGE EL Charging System MIRROR EL DOOR MIRROR
CHIME EL Warning Chime NATS EL NISSAN ANTI-THEFT SYSTEM
CMPS EC Camshaft Position Sensor 02S EC OXYGEN SENSOR
COOllF EC Cooling Fan Control EVAP CANISTER PURGE CON-

PGCIV EC
TROL SOLENOID VALVE
DEF EL Rear Window Defogger
PARTIAL LOAD ADVANCE CON-
D/LOCK EL Power Door Lock PLA EC
TROL
Headlamp - With Daytime Light
DTRL EL PARK/NEUTRAL POSITION
System PNP/SW EC
SWITCH
Engine Coolant Temperature
ECTS EC POWER EL POWER SUPPLY ROUTING
Sensor
POWER STEERING OIL PRESSURE
EGR and canister Control Solenoid PST/SW EC
EGRCIV EC SWITCH
Valve
R/FOG EL REAR FOG LAMP
FCUT EC Fuel Cut Solenoid Valve
SROOF EL SUN ROOF
F/FOG EL Front Fog Lamp
SUPPLEMENTAL RESTRAINT SYS-
FICO EC IACV-FICD Solenoid Valve SRS RS
TEM
F/PUMP EC Fuel Pump
S/SIG EC START SIGNAL
GLOW EC Quick-glow system
START EL STARTING SYSTEM
Headlamp - Without Daytime
H/LAMP EL STOP/L EL STOP LAMP
Light System
CLEARANCE, LICENSE, AND TAIL
H/SEAT EL Heated Seat TAllIL EL
LAMPS
HEAT HA Heater
TPS EC THROTTLE POSITION SENSOR
HLC EL Headlamp Washer
TURN SIGNAL AND HAZARD
H02S EC Heated Oxygen Sensor TURN EL
WARNING LAMPS
HORN EL Horn, Cigarette Lighter, Clock VSS EC VEHICLE SPEED SENSOR
IATS EC Intake Air Temperature Sensor VTC EC VTC SOLENOID VALVE
IGN/SG EC Ignition Signal WARN EL WARNING LAMPS
ILL EL Illumination WINDOW EL POWER WINDOW
INJECT EC Injector WIPER EL FRONT WIPER AND WASHER
Interior, Spot and Trunk Room WIP/R EL REAR WIPER AND WASHER
INT/L EL
Lamps
GI-17
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT
Work Flow
- - - - - - - - - - - - - - - - - - - STEP 1
--------------------- STEP 2
----------------------- STEP 3
- - - - - - - - - - - - - - - - - - - - - - - - - - - - STEP 4
--------- -------------------- STEP 5
- - - - - - - - - - - - - - - - - - - - - - - - STEP 6
SGI838
STEP DESCRIPTION
STEP 1 Get detailed information about the conditions and the environment when the incident occurred.
The following are key pieces of information required to make a good analysis:
WHAT Vehicle Model, Engine, Transmission and the System (i.e. Radio).
WHEN Date, Time of Day, Weather Conditions, Frequency.
WHERE Road Conditions, Altitude and Traffic Situation.
HOW System Symptoms, Operating Conditions (Other Components Interaction).

Service History and if any After Market Accessories have been installed.
STEP 2 Operate the system, road test if necessary.

Verify the parameter of the incident.
If the problem can not be duplicated, refer to "Incident Simulation Tests" next page.
STEP 3 Get the proper diagnosis materials together including:
POWER SUPPLY ROUTING

System Operation Descriptions
Applicable Service Manual Sections
Identify where to begin diagnosis based upon your knowledge of the system operation and the customer com-
ments.
STEP 4 Inspect the system for mechanical binding, loose connectors or wiring damage.
Determine which circuits and components are involved and diagnose using the Power Supply Routing and Har-
ness Layouts.
STEP 5 Repair or replace the incident circuit or component.
STEP 6 Operate the system in all modes. Verify the system works properly under all conditions. Make sure you have
not inadvertently created a new incident during your diagnosis or repair steps.
GI-18
•
Incident Simulation Tests
INTRODUCTION
Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create
the conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diag-
nosis. The following section illustrates ways to simulate the conditionslenvironment under which the
owner experiences an electrical incident.
The section is broken into the six following topics:

• Vehicle vibration
• Heat sensitive
• Freezing
• Water intrusion
• Electrical load
• Cold or hot start up
Get a thorough description of the incident from the customer. It is important for simulating the condi-
tions of the problem.
VEHICLE VIBRATION
The problem may occur or become worse while driving on a rough road or when engine is vibrating
(idle with AIC on). In such a case, you will want to check for a vibration related condition. Refer to the
illustration below.
Connectors & harness

Determine which connectors and wiring harness would affect the electrical system you are inspecting.
Gently shake each connector and harness while monitoring the system for the incident you are trying
to duplicate. This test may indicate a loose or poor electrical connection.
Hint
Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector
terminals. A visual inspection may not reveal this without disconnecting the connector. If the problem
occurs intermittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect
and clean the terminals on related connectors in the system.
Sensors & relays

Gently apply a slight vibration to sensors and relays in the system you are inspecting.
This test may indicate a loose or poorly mounted sensor or relay.
Vibration test Tap gently.
Bend gently.
8GI839
GI-19
Incident Simulation Tests (Cont'd)
Possible cause
Any probe entering the
terminal may enlarge
I, II the contact spring
::0 Po
1/
opening creating an
intermittent signal.
II
\':!J I~
Intermittent
signals
through
pierced
insulation
Enlarged Normal Proper crimp Insulation not Wire strands

removed missing
DEFORMED (ENLARGED) FEMALE TERMINALS
DEFECTIVE INSULATION STRIPPING
Female half
Seal
Intermittent
Check for unlocked terminals by
pulling each wire at the end of
[1/ /
the connector.
contact
TERMINAL NOT PROPERLY SEATED

SGI840
Tester probe
When probing a connector it is possible to enlarge the contact
spring opening. If this occurs it may create an intermittent sig-
nal in the circuit. When probing a connector, use care not to
enlarge the opening. The probe of the Digital Multimeter (DMM)
may not fit into the connector cavity. In such cases make an
extension of a "T" pin and probe it from the harness side of the
connector. Most DMMs have accessory alligator clips. Slide
these over the probe to allow clipping the "T" pin for a better
contact. If you have any difficulty probing a terminal, inspect the
SGI841 terminal. Ensure you have not accidentally opened the contact
spring or pulled a wire loose.
GI-20
Engine compartment
There are several reasons a vehicle or engine vibration could •
cause an electrical complaint. Some of the things to check for
are:
• Connectors not fully seated.

• Wiring harness not long enough and is being stressed due
to engine vibrations or rocking.
• Wires laying across brackets or moving components.
• Loose, dirty or corroded ground wires.
• Wires routed too close to hot components.
To inspect components under the hood, start by verifying the

integrity of ground connections. (Refer to GROUND INSPEC-
TION described later.) First check that the system is properly
grounded. Then check for loose connection by gently shaking
the wiring or components as previously explained. Using the
wiring diagrams inspect the wiring for continuity.
Behind the instrument panel

An improperly routed or improperly clamped harness can
become pinched during accessory installation. Vehicle vibra-
tion can aggravate a harness which is routed along a bracket
or near a screw.
Under seating areas

An unclamped or loose harness can cause wiring to be pinched
by seat components (such as slide guides) during vehicle vibra-
tion. If the wiring runs under seating areas, inspect wire rout-
ing for possible damage or pinching.
HEAT SENSITIVE
Heating test
The owner's problem may occur during hot weather or after car
has sat for a short time. In such cases you will want to check
for a heat sensitive condition.
To determine if an electrical component is heat sensitive, heat
the component with a heat gun or equivalent.
Do not heat components above 60°C (140°F). If incident occurs
while heating the unit, either replace or properly insulate the
component.
Do not heat above 60°C (140°F).
8GI842
GI-21
FREEZING
Freezing test
The customer may indicate the incident goes away after the car
Water in warms up (winter time). The cause could be related to water
connector freezing somewhere in the wiring/electrical system.
There are two methods to check for this. The first is to arrange
for the owner to leave his car overnight. Make sure it will get
cold enough to demonstrate his complaint. Leave the car
parked outside overnight. In the morning, do a quick and thor-
ough diagnosis of those electrical components which could be
Solenoid affected.
SGI843 The second method is to put the suspect component into a
freezer long enough for any water to freeze. Reinstall the part
into the car and check for the reoccurrence of the incident. If it
occurs, repair or replace the component.
WATER INTRUSION
Water Intrusion test
The incident may occur only during high humidity or in rainy/
snowy weather. In such cases the incident could be caused by
water intrusion on an electrical part. This can be simulated by
soaking the car or running it through a car wash.
Do not spray water directly on any electrical components.
SGI844
Electrical load test

ELECTRICAL LOAD
The incident may be electrical load sensitive. Perform diagno-
sis with all accessories (including A/C, rear window defogger,
radio, fog lamps) turned on.
COLD OR HOT START UP

AIC
On some occasions an electrical incident may occur only when
the car is started cold. Or it may occur when the car is restarted
hot shortly after being turned off. In these cases you may have
to keep the car overnight to make a proper diagnosis.
SGI845
GI-22
•
Circuit Inspection
INTRODUCTION
In general, testing electrical circuits is an easy task if it is approached in a logical and organized method.
Before beginning it is important to have all available information on the system to be tested. Also, get
a thorough understanding of system operation. Then you will be able to use the appropriate equipment
and follow the correct test procedure.
You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wir-
ing harness or electrical component to do this.
OPEN A circuit is open when there is no continuity through a section of the circuit.
SHORT There are two types of shorts.
When a circuit contacts another circuit and causes the
• SHORT CIRCUIT
normal resistance to change.
When a circuit contacts a ground source and grounds the
• SHORT TO GROUND
circuit.
TESTING FOR "OPENS" IN THE CIRCUIT

Before you begin to diagnose and test the system, you should rough sketch a schematic of the system.
This will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce
your working knowledge of the system.
Inspection for opens
[YJ (Voltage check)
- +
DMM
Ll
~SE.
~L9~K
I I
I __-,----
B + SIDE I OPEN
I
L
I
-.J
A
[ill DMM
SGI846
Continuity check method

The continuity check is used to find an open in the circuit. The Digital Multimeter (DMM) set on the
resistance function will indicate an open circuit as over limit (OL, no beep tone or no ohms symbol). Make
sure to always start with the DMM at the highest resistance level.
To help in understanding the diagnosis of open circuits please refer to the schematic above.
1. Disconnect the battery negative cable.

2. Start at one end of the circuit and work your way to the.other end. (At the fuse block in this exam-
ple)
3. Connect one probe of the DMM to the fuse block terminal on the load side.
4. Connect the other probe to the fuse block (power) side of SW1. Little or no resistance will indicate
that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would
indicate an over limit or infinite resistance condition. (point A)
5. Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of
the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over
limit or infinite resistance condition. (point B)
6. Connect the probes between the relay and the solenoid. Little or no resistance will indicate that por-
tion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate
an over limit or infinite resistance condition. (point C)
Any circuit can be diagnosed using the approach in the above example.
GI-23
Circuit Inspection (Cont'd)
Voltage check method
To help in understanding the diagnosis of open circuits please refer to the previous schematic.
In any powered circuit, an open can be found by methodically checking the system for the presence of
voltage. This is done by switching the DMM to the voltage function.
1. Connect one probe of the DMM to a known good ground.
2. Begin probing at one end of the circuit and work your way to the other end.
3. With SW1 open, probe at SW1 to check for voltage.
voltage; open is further down the circuit than SW1.
no voltage; open is between fuse block and SW1 (point A).
4. Close SW1 and probe at relay.
voltage; open is further down the circuit than the relay.
no voltage; open is between SW1 and relay (point B).
5. Close the relay and probe at the solenoid.
voltage; open is further down the circuit than the solenoid.
no voltage; open is between relay and solenoid (point C).
Any powered circuit can be diagnosed using the approach in the above example.
TESTING FOR "SHORTS" IN THE CIRCUIT

To simplify the discussion of shorts in the system please refer to the schematic below.
Inspection for shorts
(Resistance check)
IGN "ON"
t OR "S~:R.T~ '::~SE BLOCK RELAY
I I
-=
'- SWl
I
B+SIOEl~~-:-~
I
~r-o ~
[YJ DMM
SHORT
A
SHORT
B
~I SW2
SH~
c
+ - (Voltage check)
1 SGI847
Resistance check method

1. Disconnect the battery negative cable and remove the blown fuse.
2. Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the
fuse.
3. Connect one probe of the ohmmeter to the load side of the fuse terminal. Connect the other probe
to a known good ground.
4. With SW1 open, check for continuity.
continuity; short is between fuse terminal and SW1 (point A).
no continuity; short is further down the circuit than SW1.
5. Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good
ground. Then, check for continuity.
continuity; short is between SW1 and the relay (point B),
no continuity; short is further down the circuit than the relay.
6. Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse termi-
nal and a known good ground. Then, check for continuity.
continuity; short is between relay and solenoid (point C).
no continuity; check solenoid, retrace steps.
GI-24
Voltage check method
1. Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid •
disconnected) powered through the fuse.
2. Turn the ignition key to the ON or START position. Verify battery voltage at the B + side of the fuse
terminal (one lead on the B + terminal side of the fuse block and one lead on a known good ground).
3. With SW1 open and the DMM leads across both fuse terminals, check for voltage.
voltage; short is between fuse block and SW1 (point A).
no voltage; short is further down the circuit than SW1.
4. With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals,
check for voltage.
voltage; short is between SW1 and the relay (point B).
no voltage; short is further down the circuit than the relay.
5. With SW1 closed, relay contacts jumped with fused jumper wire check for voltage.
voltage; short is down the circuit of the relay or between the relay and the disconnected sole-
noid (point C).
no voltage; retrace steps and check power to fuse block.
GROUND INSPECTION
Ground connections are very important to the proper operation of electrical and electronic circuits.
Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion
(rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit
works.
Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can
drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the cir-
cuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface.
When inspecting a ground connection follow these rules:
1. Remove the ground bolt screw or clip.
2. Inspect all mating surfaces for tarnish, dirt, rust, etc.
3. Clean as required to assure good contact.
4. Reinstall bolt or screw securely.
5. Inspect for "add-on" accessories which may be interfering with the ground circuit.
6. If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure
all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are
cased in one eyelet make sure no ground wires have excess wire insulation.
Ground Inspection
• • •
Remove boll (screw). Inspect mating surfaces Reinstall bolt (screw)
for tarnish. dirt. rust. etc. securely.
Clean as required to
assure good contact.
SGI853
GI-25
VOLTAGE DROP TESTS
Voltage drop tests are often used to find components or circuits which have excessive resistance. A
voltage drop in a circuit is caused by a resistance when the circuit is in operation.
Check the wire in the illustration. When measuring resistance with ohmmeter, contact by a single strand
of wire will give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this
single strand of wire is not able to carry the current. The single strand will have a high resistance to the
current. This will be picked up as a slight voltage drop.
Unwanted resistance can be caused by many situations as follows:
Undersized wiring (single strand example)
Corrosion on switch contacts
Loose wire connections or splices.
If repairs are needed always use wire that is of the same or larger gauge.
Measuring voltage drop - Accumulated method

1. Connect the voltmeter across the connector or part of the circuit you want to check. The positive lead
of the voltmeter should be closer to power and the negative lead closer to ground.
2. Operate the circuit.
3. The voltmeter will indicate how many volts are being used to "push" current through that part of the
circuit.
Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb.
Symptom: Dim bulb or no operation
o (zero) ohm
resistance
between switch
and bulb
DMM --
------------------~
~~~~
-,
\
I
OV I
12V
11.9V: 'I
I
Switch
--
Load)
Connection with
-- high resistance
l ;
Ground Battery
t • __ Ground
SGI848
Measuring voltage drop - Step by step

The step by step method is most useful for isolating excessive drops in low voltage systems (such as
those in "Computer Controlled Systems").
Circuits in the "Computer Controlled System" operate on very low amperage.
The (Computer Controlled) system operations can be adversely affected by any variation in resistance
in the system. Such resistance variation may be caused by poor connection, improper installation,
improper wire gauge or corrosion.
The step by step voltage drop test can identify a component or wire with too much resistance.
GI-26
1. Connect the voltmeter as shown, starting at the battery and •

working your way around the circuit.
2. An unusually large voltage drop will indicate a component or
wire that needs to be repaired. As you can see the illustration
above, the poor connection causes a 4 volt drop.
The chart that follows illustrates some maximum allowable voltage drops. These values are given as a guideline, the exact value for each
component may vary.
COMPONENT VOLTAGE DROP

Wire negligible <.001 volts
Ground Connections Approx. 0,1 volts
Switch Contacts Approx. 0.3 volts
SGI854
GI-27
Relationship between open/short (high resistance) circuit and the ECM pin control
System Description: When the switch is ON, the ECM lights up the lamp.
Case 1 TERMINAL: 1 TERMINAL: 2
Monitoring Power supply Lamo
of the switch to light up
operation (ON/OFF) the lamp
Battery 2
'-----v--J \~--~y j
'"-----v~----) ~
ECM
Short: FUSE blows. Short: FUSE blows Short & Open: Short: No problem
Open: Inoperative lamp when switch is ON. Inoperative lamp Open: Inoperative lamp
Open: Inoperative lamp
High resistance:
(Single strand) See below.'
Input-output voltage chart

Pin Item Condition Voltage In 1:aseof high resistance
No. value [V] such as single strand [V] *
1 Switch Switch Battery Lower than battery voltage

ON voltage Approx.8 (Example)
OFF Approx.O Approx.O
2 Lamp Switch Battery Approx.O

ON voltage (Inoperative lamp)
OFF Approx.O Approx.O
The voltage value is based on the body ground.
: If high resistance exists in the switch side circuit (caused by a single strand), terminal 1 does not detect battery voltage. ECM
does not detect the switch is ON even if the switch does turn ON. Therefore. the ECM does not supply power to light up the lamp.
Case 2
TERMINAL: 2
TERMINAL: 1 Monitoring
Lamp
Ground control of the switch Switch
to light up the lamp operation (ON/OFF)
Battery 2
o
'---v---J \.----v )
ECM \~--~v~--_.J "---y-----.J
Short: FUSE blows. Short: Lamp stays ON. Short: Lamp stays ON. Short: No problem
Open: Inoperative lamp Open: Inoperative lamp (Same as the switch ON) Open: Inoperative lamp
Open: Inoperative lamp
High resistance: See below.

(Single strand)'
Input-output voltage chart
Pin Item Condition Voltage In case of high resistance
No. value [V] such as single strand [V] *
1 Lamp Switch Approx.O Battery voltage

ON (I noperat ive lamp)
OFF Battery Battery voltage

voltage
2 Switch Switch Approx.O Higher than 0

ON Approx. 4 (Example)
OFF Approx.5 Approx.5
The voltage value is based on the body ground.
• : If high resis1ance exists in the switch side circuit (caused by a single strand), terminal 2 does not detect approx. OV. ECM does
not detect the switch is ON even if the switch does turn ON. Therefore, the ECM does not control ground to light up the lamp.
SG1849-A
GI-28
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES
•
NOTICE
The flow chart indicates work procedures required to diagnose
problems effectively. Observe the following instructions before
diagnosing.
1) Use the flow chart after locating probable causes of a prob-
lem following the "Preliminary Check", the "Symptom
Chart" or the "Work Flow".
2) After repairs, re-check that the problem has been com-
pletely eliminated.
3) Refer to Component Parts and Harness Connector Location
for the Systems described in each section for identificationl
location of components and harness connectors.
4) Refer to the Circuit Diagram for Quick Pinpoint Check.
If you must check circuit continuity between harness con-
nectors in more detail, such as when a sub-harness is used,
refer to Wiring Diagram in each individual section and Har-
ness Layout in EL section for identification of harness con-
nectors.
5) When checking circuit continuity, ignition switch should be
"OFF" .
6) Before checking voltage at connectors, check battery volt-
age.
7) After accomplishing the Diagnostic Procedures and Electri-
cal Components Inspection, make sure that all harness con-
nectors are reconnected as they were.
Example
-=-=~-----------~
m.. INSPECTION START
~i5 CHECK POWER SUPPLY. Check the following

[YJ 1) Turn ignition switch "ON". items.
2) Check voltage between terminal @ 1) Harness continuity
and ground. between camshaft
~Ba"ery voltage should exist. position sensor and
battery
SGI561 OK
2) ECCS relay-1
3) "SR" fusible link
2 4) Power source for
~ ECM
OISCONNECT
5) Ignition switch
18
Ii)
CHECK GROUND CIRCUIT. NG Check the following
1) Turn ignition switch "OFF" items.
2) Disconnect camshaft position sensor 1) Harness continuity
SGI562
harness connector. between camshaft
3) Check resistance between terminal position sensor and
@ and ground. ground
Resistance: 2) Ground circuit for
Approximately on ECM
OK
SG1800-C
GI-29
HOW TO FOllOW THIS FLOW CHART

OJ Work and diagnostic procedure
Start to diagnose a problem using procedures indicated in
enclosed blocks, as shown in the following example.
-+- Check item being per-

CHECK POWER SUPPLY.
formed.
1) Turn ignition switch "ON".
2) Check voltage between terminal @ Procedure, steps or mea-
and ground. } surement results
Battery voltage should exist.
[2] Measurement results

Required results are indicated in bold type in the corre-
. sponding block, as shown below:
These have the following meanings:
Battery voltage - 11 . 14V or approximately 12V
Voltage: Approximately OV - Less than 1V
~ Cross reference of work symbols in the text and
illustrations
Illustrations are provided as visual aids for work proce-
dures. For example, symbol m indicated in the left upper
portion of each illustration corresponds with the symbol in
the flow chart for easy identification. More precisely, the
procedure under the "CHECK POWER SUPPLY" outlined
previously is indicated by an illustration m.
[4J Symbols used in illustrations
Symbols included in illustrations refer to measurements or
procedures. Before diagnosing a problem, familiarize your-
self with each symbol.
Direction mark
Refer to "CONNECTOR SYMBOLS" on GI-13.
GI-30
•
Key to symbols signifying measurements or procedures
Symbol Symbol explanation Symbol Symbol explanation
DISCONNECT
Check after disconnecting the connec- Current should be measured with an
~8 tor to be measured. ~ ammeter.
CONNECT
Check after connecting the connector
E) to be measured. 00 Procedure with CONSULT
(lr~~ Insert key into ignition switCh. @ Procedure without CONSULT
(lr..~ Remove key from ignition switch.

~
AIC switch is "OFF".
Turn ignition switch to "OFF" position. AIC switch is "ON".

~ ~
"
~
Turn ignition switch to "ON" position. @:; Fan switch is "ON". (At any position
except for "OFF" position)
Turn ignition switch to "START" posi- "

~ tion. @'~ Fan switch is "OFF".
Turn ignition switch from "OFF" to Apply positive voltage from battery
~~ "ACC" position. BA; with fuse directly to components.
~
~~r
Turn ignition switch from "ACC" to
"OFF" position.
m-
~'~:
,
@J~ ~(e.-
..
.-=. L
Drive vehicle.
Turn ignition switch from "OFF" to

OON "ON" position. ~~
BAi
Disconnect battery negative cable.
Turn ignition switch from "ON" to

Depress brake pedal.
~F "OFF" position. ~
Do not start engine, or check with
Release brake pedal.
~ engine stopped. ~
ID Start engine, or check with engine run-

ning. .
~ . Depress accelerator pedal.
~
Apply parking brake.
i!J ..
Release accelerator pedal.
Release parking brake. Pin terminal check for SMJ type ECM
~ ~ and AIT control unit connectors
or
Check after engine is warmed up suffi- For details regarding the terminal
Cff~H ~
ciently. B arrangement, refer to the foldout page.
Voltage should be measured with a ~io lltlllliR ~

~
lJ9j
voltmeter.
Circuit resistance should be measured

.
[YJ
-
~
t~~~18
lfJJ
with an ohmmeter.
GI-31
CONSULT CHECKING SYSTEM
Function and System Application
Diagnostic
Function ECCS Air bag ASS NATS*1
test mode
This mode enables a technician to adjust some devices

Work support faster and more accurately by following the indications on x - - -
CONSULT.
Self-diagnostic
Self-diagnostic results can be read and erased quickly. x x x x
results
ECU discriminated Classification number of a replacement ECU can be read to

No. prevent an incorrect ECU from being installed.
- x - -
Data monitor Input/Output data in the ECM can be read. x - x -

Diagnostic Test Mode in wh.ich CONSULT drives some actua-
Active test tors apart from the ECMs and also shifts some parameters x - x -
in a specified range.
ECM part number ECM part number can be read. x - x -
Conducted by CONSULT instead of a technician to determine
Function test
whether each system is "OK" or "NG".
x - - -
Control unit initiali- All registered ignition key IDs in NATS components can be
sation initialised and new IDs can be registered.
- - - x
Self-function check ECM checks its own NATS communication interface. - - - x
x : Applicable
*1: NATS: Nissan Anti-Theft System
Lithium Battery Replacement

CONSULT contains a lithium battery. When replacing the battery obey the following:
WARNING:
Replace the lithium battery with SANYO Electric Co., ltd., CR2032 only. Use of another battery may
present a risk of fire or explosion. The battery may present a fire or chemical burn hazard if mistreated.
Do not recharge, disassemble or dispose of in fire.
Keep the baitery out of reach of children and discard used battery conforming to the local regulations.
Checking Equipment
When ordering the below equipment, contact your NISSAN distributor.
Tool name Description
NISSAN CONSULT
CD CONSULT unit
and accessories
@ Program card (EE 940)
(AE930)*1, (AE950)*2,
(NATS-E940)*3
NT004
*1: For Australia

*2: Regarding ASS for Australia, a revised program card (AE950) will be applicable to this system in 1995.
*3: An order for NATS program card must be placed only with NISSAN EUROPE N.V.
GI-32
IDENTIFICATION INFORMATION
•
Model Variation
For Europe LHO
Europe LHD
Engine GA14DE GA16DE CD20
5F 5F AT 5F
Transaxle
RS5F30A RSSF31A RL4F03A RS5F31A
L BAVALBF-EGA
LX BAVALDF-EGA BA YALDF-EGA BAYALDA-EGA BVCALDF-NGA

4-door Sedan
SLX BAVALFF-EGA BA YALFF-EGA BAYALFA-EGA BVCALFF-NGA
SR BA YALQF-EGA
L EAVALBF-EGA
LX EAVALDF-EGA EA YALDF-EGA EAYALDA-EGA EVCALDF-NGA
3-door Hatchback SLX EAVALFF-EGA EA YALFF-EGA EA YALFA-EGA EVCALFF-NGA
SR EAVALQF-EGA EAY ALQF-EGA
GTI
L FAVALBF-EGA
LX FAVALDF-EGA FAYALDF-EGA FAYALDA-EGA FVCALDF-NGA

5-door Hatchback
SLX FAVALFF-EGA FAYALFF-EGA FAYALFA-EGA FVCALFF-NGA
SR FAVALQF-EGA FAYALQF-EGA
For Europe RHO

Europe RHD
Engine GA14DE GA16DE CD20
SF 5F AT SF
Transaxle
RS5F30A RS5F31A RL4F03A RS5F31A
L BAVARBF-EEA
LX BAVARDF-EEA BA YARDF-EEA BA YARDA-EEA BVCARDF-NEA

4-door Sedan
SLX BAVARFF-EEA BA YARFF-EEA BAYARFA-EEA BVCARFF-NEA
SR BAYARQF-EEA
L EAVARBF-EEA
LX EAVARDF-EEA
3-door Hatchback SLX EAVARFF-EEA EAYARFF-EEA EAYARFA-EEA
SR EAVARQF-EEA EA YARQF-EEA
.
GTI
L FAVARBF-EEA
LX FAVARDF-EEA FAYARDF-EEA FAYARDA-EEA FVCARDF-NEA

5-door Hatchback
SLX FAVARFF-EEA FAYARFF-EEA FAYARFA-EEA FVCARFF-NEA
SR FAVARQF-EEA FAYARQF-EEA
GI-33
Model Variation (Cont'd)
For Australia
Australia
Engine GA16DE SR20DE
5F 4AT 5F 4AT
Transaxle
RS5F31A RL4F03A RS5F32A RL4F03A
LX BAYARDF-EMA BA YARDA-EMA
4-door Sedan
SLX BA YARFF-EMA BAYARFA-EMA
LX FAYARDF-EMA FAYARDA-EMA
Q FAYARDF-EMA FAYARDA-EMA
5-door Hatchback
SLX FAYARFF-EMA FA YARFA-EMA
SSS FBYARUF-EMA FBYARUA-EMA
Except Europe and Australia

RHD Except Europe and Australia
Engine GA15DE GA16DE
5F 4AT 5F 4AT
Transaxle
RS5F30A RL4F03A RS5F31A RL4F03A
LX BAWARCF-EWA BAWARCA-EWA
4-door Sedan
SLX BAYARGF-EWA BAYARGA-EWA
XI FAWARCF-EWA FAWARCA-EWA
5-door Hatchback
XIR FAYARGF-EWA FAYARGA-EWA
GI-34
Model Variation (Cont'd)
•
Prefix and suffix designations:
B AV A L B F N15 E G A
T
T A: Standard
E: RHO models for Europe

G: LHD models for Europe
W: RHO models except Europe and Australia
M: Australia
E: Multiport fuel injection system engine
N: Diesel engine
Model
A: 4-speed automatic transaxle

F: 5-speed manual transaxle
B: L C: LX or XI
0: LX or Q G: SLX or XIR
F: SLX
Q:SR
U: GTI or SSS
L: Left-hand drive
R: Right-hand drive
A: 2-wheel drive models
AV: GA14DE engine

AW: GA15DE engine
AY: GA16DE engine
BY: SR20DE engine
VC: CD20 engine
B: 4-door Sedan
F: 5-door Hatchback
E: 3-door Hatchback
GI-35
Identification Number
Vehicle identification number Vehicle identification plate
Emission control information label
SGI908
VEHICLE IDENTIFICATION NUMBER ARRANGEMENT

For Europe
: JN1 B A A N15 U 0 xxxxxx ..
T T
T
~ehicle serial number
o : Stopgap (no meaning)
Destination
U : Europe
Model
A : 2-wheel drive
Engine type
A: GA14DE engine
C : GA16DE engine
E : SR20DE engine
F : CD20 engine
Body type
B : 4-door Sedan
F : 5-door Hatchback
E : 3-door Hatchback
Manufacturer
JN1 : Nissan, Passenger vehicle
GI-36
Identification Number (Cont'd)
•
For Australia and New Zealand
JN1 B c A N15 A 0 xxxxxx
T T
T
Destination
A : Australia and New Zealand
Model
A : 2-wheel drive
Engine type
B : GA15DE engine
C: GA16DE engine
E : SR20DE engine
Body type
B : 4-door Sedan
Manufacturer
Except for Europe, Australia, New Zealand

JN1 B C A N15 Z 0 xxxxxx
T T
T
Destination
Z . Except Europe, Australia, New Zealand
Model
A : 2-wheel drive
Engine type
B : GA15DE engine
C : GA16DE engine
Body type
B : 4-door Sedan
Manufacturer
GI.37
Identification Number (Cont'd)
IDENTIFICATION PLATE
Europe Except Europe

1 Type approval number
2 Vehicle identification
NISSAN MOTOR CO.,L TD.JAPAN NISSAN MOTOR CO., LTD. JAPAN number (Chassis number)
I It I ~ it ii:J b 3 Gross vehicle weight
4 Gross combination weight
&, CHASS~ NO
NO DE CHASIS Gross vehicle weight
it MODEL
MDDELO
+ Gross trailing capacity
(Weight)
0 ill iliO o ~;::~:~~NlctDN o 5 Gross axle weight (Front)
1- ill kg .:t;..-
~:,...
ENGINE
MOTOR
CC
6 Gross axle weight (Rear)
7 Type
2- &, kg ~ ';; Y 3 ;..- TRANS~ AXl.£ 8 Body color code
7P;;<'. ll!AIIS.EJt:
Tri'[ COlOR.iRIM 9 Trim color code
TYP 11 fARBE,POLSl & &, 10 Model
i Lilli M4DE IN JAPAN
11 Engine model
12 Engine displacement
13 Transaxle model
14 Axle model
SGI704
ENGINE SERIAL NUMBER

GA 14DE, GA 15DE and SR20DE engine CD20 engine
GA16DE engine
£~b-=~~rrf~)
Front
(J~~~6
c:::?
SGI912
MANUAL TRANSAXLE NUMBER AUTOMATIC TRANSAXLE NUMBER
RS5F30A, RS5F31A and RS5F32A
SGI913 SGI656
GI-38
Dimensions
Unit: mm (in) •
Sedan Hatchback
Overall length 4,320 (170.1) 4,120 (162.2)
Overall width 1,690 (66.5)
Overall height 1,395 (54.9)
1,480 (58.3)* 1
Front tread
1,470 (57.9)*2
1,445 (56.9) *1
Rear tread
1,435 (56.5)*2
Wheelbase 2,535 (99.8)
*1: For models with 13-inch road wheels

*2: For models with 14-inch or 15-inch road wheels
Wheels and Tires

Steel 13 x 5J 14 x 5-1/2JJ -
Road Offset mm (in) 35 (1.38) 40(1.57)

wheel Aluminum 13 x 5J 14 x 5-1/2JJ 15 x 6J
Offset mm (in) 35 (1.38) 40 (1.57) 40 (1.57)
175170R1382S 175/65R1482H
Conventional 195/55R1584V
Tire size 165SR13 185/65R 14 86H
Spare Conventional Conventional Conventional
GI-39
LIFTING POINTS AND TOW TRUCK TOWING
Preparation
SPECIAL SERVICE TOOLS
Tool number
Description
Tool name
LM4086-0200
Board on attachment
NT001
LM4519-0000
Safety stand attachment
NT002
\
Board-on Lift
\\
'\
F
\1_ L. --
Front CAUTION:
Make sure vehicle is empty when lifting.
• The board-on lift attachment (LM4086-0200) set at front end
\ 'f- --
<
of vehicle should be set on the front of the sill under the
front door opening.
r\-=- Attachment
• Position attachments at front and rear ends of board-on lift.
Attachment
Side sill ISST. No. LM40B6.0200)
AGI016
GI-40
•
Garage Jack and Safety Stand
WARNING:
• Never get under the vehicle while it is supported only by the jack. Always use safety stands when
you have to get under the vehicle.
• Place wheel chocks at both front and back of the wheels on the ground.
Garage jack points
Note:
Safety stand
points are the
same as
pantograph
jack points.
Use safety stand

adapter as shown
for stable support.
Attachment
SST No. LM4519.0000
Safety stand
8GI909
GI-41
2-pole Lift
WARNING:
When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the
vehicle are well balanced.
When setting the lift arm, do not allow the arm to contact the brake tubes and fuel lines.
Note:
Lift-up points are the same
as pantograph jack points.
Put the sill in the groove of the 11ftpad to prevent the

sill from deforming. If the pad does not have a groove,
~LiftPad
Sill ~ ~__~ ~ .. prepare a suitable attachment with one.
~--- 8GI910
GI-42
Tow Truck Towing •

CAUTION:
• All applicable local laws regarding the towing operation
must be obeyed.
• It is necessary to use proper towing equipment to avoid
possible damage to the vehicle during towing operation.
Towing is in accordance with Towing Procedure Manual at
dealer.
• When towing with the rear wheels on the ground, release
the parking brake and move the gearshift lever to neutral
position.
NISSAN recommends that vehicle be towed with the driving
(front) wheels off the ground as illustrated.
TOWING AN AUTOMATIC TRANSAXLE MODEL WITH

FOUR WHEELS ON GROUND
Observe the following restricted towing speeds and distances.
Speed:
Below 50 km/h (30 MPH)
Distance:
~ Less than 65 km (40 miles)
SGI80S
CAUTION:
Never tow an automatic transaxle model from the rear (i.e.,
Automatic transaxle model
backward) with four wheels on the ground as this may cause
serious and expensive damage to the transaxle.
TOWING AN AUTOMATIC TRANSAXLE MODEL WITH

REAR WHEELS RAISED (With front wheels on ground)
Never tow an automatic transaxle model with rear wheels
raised (with front wheels on ground) as this may cause serious
and expensive damage to the transaxle. If it is necessary to tow
it with rear wheels raised, always use a towing dolly under the
front wheels.
SG1806-A
TOWING POINT
Always pull the cable straight out from the vehicle. Never pull
on the hook at a sideways angle.
CAUTION:
Remove the front spoiler when towing the vehicle forward.
Otherwise, the towing device may damage the front spoiler.
Front Rear
Sedan models Hatchback
models
Towing hook
SGI911
GI-43
TIGHTENING TORQUE OF STANDARD BOLTS
Tightening torque (Without lubricant)

Bolt
Pitch
Grade Bolt size diameter' Hexagon head bolt Hexagon flange bolt
mm
mm
N'm kg-m ft-Ib in-Ib N'm kg-m ft-Ib in-Ib
M6 6.0 1.0 5.1 0.52 3.8 45.1 6.1 0.62 4.5 53.8
1.25 13 1.3 9 - 15 1.5 11 -

M8 8.0
1.0 13 1.3 9 - 16 1.6 12 -
1.5 25 2.5 18 - 29 3.0 22 -

4T M10 10.0
1.25 25 2.6 19 - 30 3.1 22 -
1.75 42 4.3 31 - 51 5.2 38 -
M12 12.0
1.25 46 4.7 34 - 56 57 41 -
M14 14.0 1.5 74 7.5 54 - 88 9.0 65 -
M6 6.0 1.0 8.4 . 0.86 6.2 74.6 10 1.0 7 87
1.25 21 2.1 15 - 25 2.5 18 -

M8 80
1.0 22 2.2 16 - 26 2.7 20 . -
1.5 41 4.2 30 - 48 4.9 35 -

7T M10 10.0
1.25 43 4.4 32 - 51 5.2 38 -
1.75 71 7.2 52 - 84 8.6 62 -
M12 12.0
1.25 77 7.9 57 - 92 9.4 68 -
M14 14.0 1.5 127 13.0 94 - 147 15.0 108 -
M6 6.0 1.0 12 1.2 9 - 15 1.5 11 -
1.25 29 3.0 22 - 35 3.6 26 -
M8 8.0
1.0 31 3.2 23 - 37 3.8 27 --
1.5 59 6.0 43 - 70 7.1 51 -
9T M10 10.0
1.25 62 6.3 46 - 74 7.5 54 -
1.75 98 10.0 72 - 118 12.0 87 -
M12 12.0
1.25 108 11.0 80 - 137 14.0 101 -
M14 14.0 1.5 177 18.0 130 - 206 21.0 152 -
1. Special paris are excluded.

2. This slandard is applicable 10 bolls having the following
marks embossed on the boll head. *: Nominal diameter
Grade Mark
M 6
4T 4
T
7T
9T
7
9
T Nominal diameter of bolt threads (Unit: mm)
Metric screw threads
GI-44
SAE J1930 TERMINOLOGY LIST
•
SAE J1930 Terminology List
All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly,
new terms, new acronyms/abbreviations and old terms are listed in the following chart.
"': Not applicable
NEW ACRONYM /
NEW TERM OLD TERM
ABBREVIATION
Absolute pressure sensor '" '"
Air cleaner ACL Air cleaner
Barometric pressure BARO ."
Barometric pressure sensor-BCDD BAROS-BCDD BCDD
Camshaft position CMP '"
Camshaft position sensor CMPS Crank angle sensor
Carburetor CARB Carburetor
Charge air cooler CAC Intercooler
Closed loop CL Closed loop
Closed throttle position switch CTP switch Idle switch
Clutch pedal position switch CPP switch Clutch switch
Continuous fuel injection system CFI system '"
Continuous trap oxidizer system CTOX system ...
Crankshaft position CKP '"
~.**
Crankshaft position sensor CKPS
Data link connector DLC
,..
Data link connector for CONSULT DLC for CONSULT Diagnostic connector for CONSULT
Diagnostic test mode DTM Diagnostic mode
Diagnostic test mode selector DTM selector Diagnostic mode selector
Diagnostic test mode I DTM I Mode I
Diagnostic test mode II DTM II Mode II
Diagnostic trouble code DTC Malfunction code
Direct fuel injection system DFI system
..
,
Distributor ignition system DI system Ignition timing control

Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater
Early fuel evaporation system EFE system . Mixture heater control
Electrically erasable programmable read only
EEPROM '"
memory
Electronic ignition system EI system Ignition timing control
Engine control module ECM ECCS control unit
Engine coolant temperature ECT Engine temperature
Engine coolant temperature sensor ECTS Engine temperature sensor
Engine modification EM '"
Engine speed RPM Engine speed
Erasable programmable read only memory EPROM '"

Evaporative emission canister or Canister EVAP canister or Canister Canister
Evaporative emission canister purge control EVAP canister purge con-

Canister control solenoid valve
solenoid valve trol solenoid valve
GI-45
SAE J1930 Terminology List (Cont'd)
***: Not applicable
NEW ACRONYM /
NEW TERM OLD TERM
ABBREVIATION
Evaporative emission canister purge control EVAP canister purge con-

Canister purge cut valve
valve trol valve
Evaporative emission canister vent control EVAP canister vent control

***
valve valve
Evaporative emission canister purge volume EVAP canister purge vol-
Canister purge control valve
control valve ume control valve
Evaporative emission control system pressure EVAP control system pres-

***
sensor sure sensor
Evaporative emission shut valve EVAP shut valve Shutoff valve
Evaporative emission system EVAP system Evaporative emission control system
Exhaust gas recirculation valve EGR valve EGR valve
Exhaust gas recirculation control-BPT valve EGRC-BPT valve BPT valve

Exhaust gas recirculation control-solenoid
EGRC-solenoid valve EGR control solenoid valve
valve
Exhaust gas recirculation temperature sensor EGR temperature sensor Exhaust gas temperature sensor
Flash electrically erasable programmable

FEEPROM ***
read only memory
Flash erasable programmable read only

FEPROM **.
memory
Flexible fuel sensor FFS ***
Flexible fuel system FF system ***
Heated Oxygen sensor H02S Exhaust gas sensor
Idle air control system lAC system Idle speed control
Idle air control valve-air regulator IACV-air regulator Air regulator

Idle air control valve-auxiliary air control
IACV-AAC valve Auxiliary air control (AAC) valve
valve
Idle air control valve-FICO solenoid valve IACV-FICD solenoid valve FICO solenoid valve
Idle air control valve-idle up control solenoid IACV-idle up control sole-
Idle up control solenoid valve
valve noid valve
Idle speed control-FI pot ISC-FI pot FI pot

Idle speed control system ISC system ***
Ignition control module ICM ***
Indirect fuel injection system IFI system ***
Intake air temperature sensor IATS Air temperature sensor
Knock *** Detonation
Knock sensor KS Detonation sensor
Malfunction indicator lamp MIL Check engine light
Manifold absolute pressure MAP ***
Manifold absolute pressure/Barometric pres- MAP/BARO switch solenoid

***
sure switch solenoid valve valve
Manifold absolute pressure sensor MAPS **.
Manifold differential pressure MOP ***
Manifold differential pressure sensor MOPS ***
GI-46
NEW ACRONYM /
NEW TERM OLD TERM
ABBREVIATION
Manifold surface temperature MST
...
Manifold surface temperature sensor MSTS ...
Manifold vacuum zone MVZ ...
Manifold vacuum zone sensor MVZS ...
Mass air flow sensor MAFS Air flow meter
Mixture control solenoid valve MC solenoid valve Air-fuel ratio control solenoid valve
Multipart fuel injection System MFI system Fuel injection control

Neutral position switch ... Neutral switch
Non-volatile random access memory NVRAM
...
On-board diagnostic system OBO system Self-diagnosis
Open loop OL Open loop
Oxidation catalyst OC Catalyst
Oxidation catalytic converter system OC system ...
Oxygen sensor 02S Exhaust gas sensor
Park position switch ... Park switch
Park/neutral position switch PNP switch Park/neutral switch
Periodic trap oxidizer system PTOX system
...
Powertrain control module PCM ...
Programmable read only memory PROM ...
Pulsed secondary air injection control sole-
PAIRC solenoid valve AIV control solenoid valve
noid valve
Pulsed secondary air injection system PAIR system Air induction valve (AIV) control
Pulsed secondary air injection valve PAIR valve Air induction valve
Random access memory RAM ...

Read only memory ROM
...
Scan tool ST ...
Secondary air injection pump AIR pump ...
Secondary air injection system AIR system ...
Sequential multiport fuel injection system SFI system Sequential fuel injection
Service reminder indicator SRI

. ...
Simultaneous multipart fuel injection system
... Simultaneous fuel injection
Smoke puff limiter system SPL system ...

Supercharger SC
...
Supercharger bypass 5CB
...
System readiness test 5RT
...
Tank fuel temperature sensor
... ...
Thermal vacuum valve TVV Thermal vacuum valve
Three way catalyst TWC Catalyst
Three way catalytic converter system TWC system

...
Three way + oxidation catalyst TWC+OC Catalyst
GI-47
"': Not applicable
NEW ACRONYM I
NEW TERM OLD TERM
ABBREVIATION
Three way + oxidation catalytic converter sys-

TWC + OC system
..,
tem
Throttle body TB Throttle chamber
SPI body
Throttle body fuel injection system TBI system Fuel injection control
Throttle position TP Throttle position
Throttle position sensor TPS Throttle sensor
Throttle position switch TP switch Throttle switch
Torque converter clutch solenoid valve TCC solenoid valve Lock-up cancel solenoid
.
Lock-up solenoid
Turbocharger TC Turbocharger
Vacuum cut valve
..
,
Vacuum control valve
Vacuum cut valve bypass valve

..
, ...
Vehicle speed sensor VSS Vehicle speed sensor
Volume air flow sensor VAFS Air flow meter
Warm up oxidation catalyst WU-OC Catalyst
Warm up oxidation catalytic converter system WU-OC system

..
,
Warm up three way catalyst WU-TWC Catalyst
Warm up three way catalytic converter system WU-TWC system

..
,
Wide open throttle position switch WOTP switch Full switch
GI-48
MAINTENANCE
SECTION MA •
CONTENTS
PRECAUTIONS AND PREPARATION 3 Changing Positive Crankcase Ventilation
Supplemental Restraint System (SRS) "AIR (PCV) Filter 26
BAG" (Dual Air Bag System) 3 Checking EVAP Vapor Lines 26
Supplemental Restraint System (SRS) "AIR Checking Oxygen Sensor (02S) or Heated
BAG" (Single Air Bag System) 3 Oxygen Sensor (H02S) 27
Special Service Tools 4
Commercial Service Tool 4 ~ --ll SR I I
PRE-DELIVERY INSPECTION ITEMS 5
ENGINE MAINTENANCE 28
GENERAL MAINTENANCE 6
Checking Drive Belts 28
PERIODIC MAINTENANCE (Except for Europe) 7
Changing Engine Coolant... 29
Engine and Emission Control Service 7
Checking Cooling System 31
Chassis and Body Service 8
Checking Fuel Lines 32
Maintenance Under Severe Driving Conditions 9
Changing Fuel Filter 32
PERIODIC MAINTENANCE (For Europe) 10
Changing Air Cleaner Filter 33
Engine Oil & Minor Service 10
Changing Engine Oil 33
Engine and Emission Control Service 11
Changing Oil Filter 34
Chassis and Body Services 12
Changing Spark Plugs (Platinum-tipped type) 34
Maintenance Under Severe Driving Conditions 13
Checking Ignition Wires 35
RECOMMENDED LUBRICANTS AND FLUIDS 14
Checking EVAP Vapor & Purge Lines 36
Lubricants and Fluids 14
Checking Heated Oxygen Sensor (H02S) 37
SAE Viscosity Number 15
Anti-freeze Coolant Mixture Ratio 16
~_~ ..-JI CD I I
~ --ll GA I I ENGINE MAINTENANCE 38
Manifold Nut Check 38
ENGINE MAINTENANCE 17
Checking Drive Belt 38
Checking Drive Belts 17
Changing Engine Coolant. 38
Changing Engine Coolant... 19
Checking Cooling System .40
Checking Cooling System 21
Checking Fuel Line .40
Checking Fuel Lines 22
Changing Air Cleaner Filter 41
Changing Fuel Filter 22
Water Draining, Fuel Filter Check and
Cleaning and Changing Air Cleaner Filter 23
Replacement 41
Changing Engine Oil 24
Changing Engine Oil .41
Changing Oil Filter 24
Changing Engine Oil Filter 42
Checking and Changing Spark Plugs 25
Checking Injection Nozzle 43
Checking Ignition Wires 26
Checking Idle Speed .44
Replacing Timing Belt 44
CONTENTS (Cont'd.)
CHASSIS AND BODY MAINTENANCE 45 GA

Checking Exhaust System .45
SERVICE DATA AND SPECIFICATIONS (505) 53
Checking Clutch Fluid Level and Leaks .45
Engine Maintenance 53
Checking Clutch System .45
Checking MfT Oil .45
SR
Changing MfT Oil 46
Checking AfT Fluid Level .46 SERVICE DATA AND SPECIFICATIONS (505) 54
Changing AfT Fluid .47 Engine Maintenance 54
Checking Brake Fluid Level and Leaks 47
Checking Brake System .47 CD
Changing Brake Fluid .47
Checking Brake Booster, Vacuum Hoses,
Engine Maintenance 55
Connections and Check Valve ~ 48
Checking Disc Brake .48
Checking Drum Brake .49
Chassis and Body Maintenance 56
Balancing Wheels 49
Tire Rotation 50
Checking Steering Gear and Linkage 50
Checking Power Steering Fluid and Lines 50
Lubricating Locks, Hinges and Hood Latches 51
Checking Seat Belts, Buckles, Retractors,
Anchors and Adjusters 51
Checking Body Corrosion 52
PRECAUTIONS AND PREPARATION

The Supplemental Restraint System "Air Bag", used along with a seat belt, helps to reduce the risk or •
severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint i
System consists of air bag modules (located in the center of the steering wheel and on the instrument
panel on the passenger side). a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses are covered with yellow insulation either just before the
harness connectors or for the complete harness, for easy identification.

The Supplemental Restraint System "Air Bag", used along with a seat belt, helps to reduce the risk or
severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an
air bag module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp,
wiring harness and spiral cable. Information necessary to service the system safely is included in the
RS section of this Service Manual.
WARNING:
• Do not use electrical test equipment on any circuit related to the SRS.
MA-3
Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Engine application

Description
Tool name GA SR CD
KV10115801 Removing oil
filter
KV10115800
(Kent-Moore Europe
make)
- X -
Oil filter wrench ~14"'" Inner span: 64.3 mm (2.531 in)
(Faceto oppositeface)
NT362
KV10105900
Oil filter cap wrench
X - X
15 faces,
Inner span: 80 mm (3.15 in)
~ (Faceto oppositecorner)
NT555
KV11102600
Lifter plate replacer
EG17650301
Radiator cap tester
NT556
1 - - X
adapter
~ ct~4b a: 28 (1.10) dia. X X X
b: 31.4 (1.236) dia.
"
~ a+ciP q]J+a c: 41.3 (1.626) dia.
I NT564 Unit: mm (in)
Commercial Service Tool
Engine application
GA SR CD
Spark plug wrench

. Wrench with a
0
magnet to hold
Q
16 mm
spark plug
X X -
(0.63 In)
NT047
MA.4
PRE-DELIVERY INSPECTION ITEMS
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
•
Perform applicable items on each model. Consult text of this section for specifications .
UNDER HOOD - engine off UNDER BODY

o Radiator coolant level and coolant hose con- o Manual transmission/transaxle, transfer and
nections for leaks differential gear oil level
o Battery fluid level, specific gravity and condi- D Brake and fuel lines and oil/fluid reservoirs
tions of battery terminals for leaks
o Drive belts tension D Tighten bolts and nuts of steering linkage and
D Fuel filter for water or dusts, and fuel lines gear box, suspension, propeller shafts and
and connections for leaks drive shafts
[] Engine oil level and oil leaks ~ Tighten rear body bolts and nuts (Models with
D Clutch and brake reservoir fluid level and wooden bed only)
fluid lines for leaks
o Windshield and rear window washer and ROAD TEST
headlamp cleaner reservoir fluid level D Clutch operation
D Power steering reservoir fluid level and hose D Parking brake operation
connections for leaks [J Service brake operation
D Automatic transmission/transaxle shift timing
ON INSIDE AND OUTSIDE and kickdown
D Remove front spring/strut spacer (If applica- [] Steering control and returnability
ble) o Engine performance
D Operation of all instruments, gauges, lights D Squeaks and rattles
and accessories
o Operation of horn(s), wiper and washer ENGINE OPERATING AND HOT
[] Steering lock for operation D Adjust idle mixture and speed (and ignition
[] Check air conditioner for gas leaks timing*1)
o Front and rear seats, and seat belts for oper- n Automatic transmission/transaxle fluid level
ation ~ Engine idling and stop knob operation (Diesel
n All moldings, trims and fittings for fit and only)
alignment
[J All windows for operation and alignment
n Hood, trunk lid, door panels for fit and align-
FINAL INSPECTION
ment n Install necessary parts (outside mirror, wheel
[1 Latches, keys and locks for operation covers, seat belts, mat, carpet or mud flaps)
rl Weatherstrips for adhesion and fit [1 Inspect for interior and exterior metal and
[l Headlamp aiming paint damage
I~ Tighten wheel nuts (Inc. inner nuts if applica- [] Check for spare tire, jack, tools (wheel
ble) chock), and literature
IJ Tire pressure (Inc. spare tire) n Wash, clean interior and exterior
Il Check front wheels for toe-in
IJ Install clock/voltmeter/room lamp fuse (If "1: Not required on models with a direct ignition system
applicable) ~ : Not appiicable to this model.
~ Install deodorizing filter to air purifier (If
applicable)
~ Remove wiper blade protectors (If applicable)
MA-5
GENERAL MAINTENANCE
General maintenance includes those items which should be checked during the normal day-to-day
operation of the vehicle. They are essential if the vehicle is to continue operating properly. The owners
can perform the checks and inspections themselves or they can have their NISSAN dealers do them.
Item Reference pages
OUTSIDE THE VEHICLE

The maintenance items listed here should be performed from time to time, unless oth-
erwise specified.
Tires Check the pressure with a gauge periodically when at a service station, including
the spare, and adjust to the specified pressure if necessary. Check carefully for damage,
cuts or excessive wear.
Windshield wiper blades Check for cracks or wear if they do not wipe properly.
Doors and engine hood Check that all doors, the engine hood, the trunk lid and back
door operate properly. Also ensure that all latches lock securely. Lubricate hinges,
latches, rollers and links if necessary. Make sure that the secondary latch keeps the hood
MA-51
from opening when the primary latch is released.
When driving in areas using road salt or other corrosive materials, check for lubrication
frequently.
Tire rotation Tires should be rotated every 10,000 km (6,000 miles). MA-50
INSIDE THE VEHICLE

The maintenance items listed here should be checked on a regular basis, such as when
performing periodic maintenance, cleaning the vehicle, etc.
Lights Make sure that the headlights, stop lights, tail lights, turn signal lights, and other
lights are all operating properly and installed securely. Also check headlight aim.
Warning lights and buzzers/chimes Make sure that all warning lights and buzzers/chimes
are operating properly.
Steering wheel Check for change in the steering conditions, such as excessive free play,
hard steering or strange noises.
Free play: Less than 35 mm (1.38 in)
Seat belts Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters
and retractors) operate properly and smoothly, and are installed securely. Check the belt
webbing for cuts, fraying, wear or damage.
UNDER THE HOOD AND VEHICLE

The maintenance items listed here should be checked periodically e.g. each time you
check the engine oil or refuel.
Windshield washer fluid Check that there is adequate fluid in the tank.
Engine coolant level Check the coolant level when the engine is cold. MA-19,38
Engine oil level Check the level after parking the vehicle on a level spot and turning off
MA-24, 33, 41
the engine.
Brake and clutch fluid levels Make sure that the brake and clutch fluid levels are between
MA-45,47
the "MAX" and "MIN" lines on the reservoir.
Battery Check the fluid level in each cell. It should be between the "MAX" and "MIN"
lines.
MA-6
PERIODIC MAINTENANCE (Except for Europe)
The following tables show the normal maintenance schedule. Depending upon weather and atmospheric
conditions, varying road surfaces, individual driving habits and vehicle usage, additional or more fre-
quent maintenance may be required.
•
Periodic maintenance beyond the last period shown on the tables requires similar maintenance .
Engine and Emission Control Service

Abbreviations: I = Inspect and correct or replace as necessary. R Replace. A = Adjust, C = Clean.
MAINTENANCE OPERATION MAINTENANCE INTERVAL
Perform either at number of kilometers (miles) km x 1,000 10 20 30 40 50 60 70 80 Reference page

or months, whichever comes tirst. (Miles x 1,000) (6) (12) (18) (24) (30) (36) (42) (48)
Months 6 12 18 24 30 36 42 48
Underhood and under vehicle GA SR
Intake & exhaust valve clearance (GA15DE & GA16DE engines) See NOTE (1) EM 41 -
Drive belts I I MA 17 24
Engine anti-Ireeze coolant (Ethylene glycol base) (LLC) R R MA 19 29
Engine coolant (Soft water) R R R R R R R R MA 19 29
Cooling system I I I I MA 21 31
Fuel lines I I MA 22 32
Air cleaner filter (Dry paper type)* C C C R C C C R MA 23 -

Air cleaner filter (Viscous paper type)* R R MA 23 33
Engine oil (Use API SE, SF. SG or SH oil)* R R R R R R R R MA 24 33
Engine oil filter* R R R R R R R R MA 24 33
Fuel filter* R R MA 22 32
Spark plugs (except Platinum-tipped type) R R MA 25 -

Spark plugs (platinum-tipped type) Replace every 100,000 km (60.000 miles). MA - 34
Ignition wires I I MA 26 35
PCV filter* R R MA 26 -
Vapor lines I I MA 26 36
(Heated) Oxygen Sensor I I MA 27 37
NOTE: (1) If valve noise increases, check valve clearance.

* Maintenance items with "*"
should be performed more frequently according to "Maintenance under severe driv-
ing conditions".
MA-7
Chassis and Body Service

Abbreviations: I = Inspect and correct or replace as necessary, R Replace, L = Lubricate.
km x 1,000 10 20 30 40 50 60 70 80 Refer-
Perform either at number of kilometers (miles) or ence
(Miles x 1,000) (0.6) (6) (12) (18) (24) (30) (36) (42) (48) page
months, whichever comes first.
Months 6 12 18 24 30 36 42 48
Underhood and under vehicle
MA-47,
Brake, clutch & automatic transaxle fluid or oil (For level & leaks)*
45, 46
Brake fluid* R R MA-47
Brake booster vacuum hoses, connections & check valve MA-48
Power steering fluid & lines (For level & leaks) I' MA-50
" " "
MA-47,
Brake, clutch & exhaust systems
45
Manual transaxle oil (For level & leaks)* I' I' I' MA-45
"
MA-50
Steering gear & linkage, axle & suspension parts & drive shafts* I' FA-5
RA-4
Outside and Inside
MA-49
Wheel alignment, If necessary, rotate & balance wheels
FA-6
Brake pads, disc & other brake components* MA-48
Brake linings, drums & other brake components MA-49
Locks, hinges & hood latch* L' L L' L L' L L' L MA-51
Seat belts, buckles, retractors, anchors & adjuster MA-51
BR-11,
Foot brake, parking brake & clutch (For free play, stroke & operation) I' I' I' I' 37
CL-5
Air bag system See NOTE (1) RS-11
NOTE: (1) Inspect at the first 10 years, and then every 2 years.
* Maintenance items with "*"
should be performed more frequently according to "Maintenance Under Severe Driv-
ing Conditions".
*: Except for Australia models
MA-8
Maintenance Under Severe Driving Conditions

The maintenance intervals shown on the preceding pages are for normal operating conditions. If the
vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance •
must be performed on the following items as shown in the table. •
SEVERE DRIVING CONDITIONS

A - Driving under dusty conditions F - Driving in high humidity areas or in moun-
B - Driving repeatedly short distances tainous areas
C - Towing a trailer or caravan G - Driving in areas using salt or other corro-
D - Extensive idling sive materials
E - Driving in extremely adverse weather con- H - Driving on rough and/or muddy roads or in
ditions or in areas where ambient temper- the desert
atures are either extremely low or - Driving with frequent use of braking or in
extremely high mountainous areas
Driving Maintenance Maintenance Maintenance Reference

condition item operation interval page
GA SR
A Air cleaner filter
Dry paper type Clean MA 23 -

All types Replace More frequently MA 23 33
PCV filter Replace MA 26 -
A B C D Engine oil & oil filter Replace Every 5,000 km

MA 24 24
(3,000 miles) or 3 months
A E Fuel filter Replace Every 20,000 km MA 22 32
F Brake fluid Replace (12,000 miles) or 12 months MA-47
C H Automatic & manual transaxle Replace Every 40,000 km

MA-46,45
oil (24,000 miles) or 24 months
G H Steering gear & linkage, axle & Check MA-50

Every 10,000 km
suspension parts & drive shafts FA-5, 7
RA-4
A C G H I Brake pads, discs & other brake Check Every 5,000 km

MA-48
components (3,000 miles) or 3 months
A C G H 1 Brake linings, drums & other Check Every 10,000 km

MA-49
brake components (6,000 miles) or 6 months
G Lock, hinges & hood latch Lubricate Every 5,000 km

MA-51
Maintenance operation: Check = Check. Correct or replace if necessary.
MA-9
PERIODIC MAINTENANCE (For Europe)
The following tables show the normal maintenance schedule. Depending upon weather and atmospheric
conditions, varying road surfaces, individual driving habits and vehicle usage, additional or more fre-
quent maintenance may be required.
Periodic maintenance beyond the last period shown on the tables requires similar maintenance.
Engine Oil & Minor Service

GASOLINE ENGINE
Abbreviation: R = Replace.
Perform either at number of kilometers (miles) or km x 1,000 15 30 45 60 75 90 105 120 Reference

months, whichever comes first. page
(Miles x 1,000) (9) (18) (27) (36) (45) (54) (63) (72)
Months 12 24 36 48 60 72 84 96

Engine 011 (API SG or SH 011)* R R R R R R R R MA-24
Engine oil filler* R R R R R R R R MA-24
DIESEL ENGINE
Abbreviations: R = Replace, I Inspect and correct or replace as necessary
MAINTENANCE OPERATION
Perform either at number of kilometers (miles) or km x 1,000 10 20 30 40 50 60 70 80 Reference

months, whichever comes first. page
(Miles x 1,000) (6) (12) (18) (24) (30) (36) (42) (48)
Months 6 12 18 24 30 36 42 48

Engine oil (Use APi CD oil)* R R R R R R R R MA-41
Engine oil filter* R R R R R R R R MA-41
Drive belts MA-38
Idle speed MA-44
NOTE: * Maintenance items with "*" should be performed more frequently according to "Maintenance Under Severe Driv-
ing Conditions".
MA-10
Engine and Emission Control Service

Abbreviations: I = Inspect and correct or replace as necessary, R Replace,
•
Perform either at number of kilometers (miles) km x 1,000 30 60 90 120

or months, whichever comes first. Reference page
(Miles x 1,000) (18) (36) (54) (72)
Months 12 24 36 48
Underhood and under vehicle GA CD
Engine anti-freeze coot ant (Ethylene glycol base) (LLC) See NOTE (1) R MA-19 MA-38
Cooling system I I I I MA-21 MA-40
Fuel lines I I MA-22 MA-40
Air cleaner filter (Viscous paper type)* R R MA-23 MA-41
Intake & exhaust valve clearance See NOTE (2) EM-41 -

Drive belts See NOTE (3) I I I MA-17,18 -
w
z
Ci Fuel filter* R MA-22 -
z
w
w
Spark plugs See NOTE (4) R R R R MA-25 -
z
:::; Ignition wires' I MA-26 -
0
(fJ
<{
PCV filter* R R MA-26 -
Cl
Vapor lines (Hoses, connections, etc.) See NOTE (5) I I MA-26 -
(Heated) oxygen sensor' I I MA-27 -
Fuel filter R R - MA-41
--,w
wz
(fJ- Nozzles See NOTE (6) - MA-43
w Cl
-z
Ow EM-120,
Timing belts for camshalt and injection pump Replace every 90,000 km (54,000 miles) -
124
'. Except for Swedish models
NOTE: (1) Replace at the first 90,000 km (54,000 miles) or 60 months, then every 60,000 km (36,000 miles) or 24 months, which-
ever comes first.
(2) If valve noise Increases, check valve clearance.
(3) After 60,000 km (36,000 miles) or 24 months, inspect every 30,000 km (18,000 miles) or 12 months, whichever comes
first.
(4) For Swedish models, perform al mileage interval only.
(5) For Swedish models, inspect al the first 90,000 km (54,000 miles), and then every 60,000 km (36,000 miles) or 24
months, whichever comes first.
(6) If engine power decreases, black smoke is emitted or engine noise increases, check and, if necessary, adjust the
fuel injection nozzle's starting pressure and the fuel spray pattern.
*
Maintenance items with "*"
should be performed more frequently according to "Maintenance Under Severe Driv-
ing Conditions".
MA-11
Chassis and Body Services

Abbreviations: R = Replace. Inspect, and correct or replace as necessary.
Perform either at number of kilometers (miles) or months, km x 1,000 30 60 90 120

whichever comes first. Reference page
(Miles x 1,000) (18) (36) (54) (72)
Months 12 24 36 48
CHASSIS AND BODY Underhood and under vehicle
Brake & clutch oil (For level & leaks)* MA-47,45
Automatic transaxle fluid (For level & leaks)* MA-46
Brake f1uid* R R MA-47
Brake booster vacuum hoses, connections & check valve MA-48
Power steering fluid & lines (For level & leaks) MA-50
Brake & clutch systems MA-47,45
Manual transaxle oil (For leaks)* MA-45
MA-50, 45, FA-5,

Steering gear & linkage, axle & suspension parts & exhaust system*
RA-4
Drive shafts* FA-7
Outside and Inside
Wheel alignment (If necessary, rotate & balance wheels) MA-49, FA-6
Brake pads, disc & other brake components* MA-48
Brake linings, drums & other components* MA-49
Headlamp aiming EL-75
Foot brake, parking brake & clutch (For free play, stroke & operation) BR-11, 37, CL-5
Body corrosion Annually MA-52
Air bag system See NOTE (1) RS-11
NOTE: * Maintenance items with "*"

should be performed more frequently according to "Maintenance under severe driving
conditions" .
(1) Inspect at the first 10 years and then every 2 years.
MA-12
Maintenance Under Severe Driving Conditions

The maintenance intervals shown on the preceding pages are for normal operating conditions. If the
vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance •
must be performed on the following items as shown in the table. •
SEVERE DRIVING CONDITIONS

A - Driving under dusty conditions F - Driving in high humidity areas or in moun-
B - Driving repeatedly short distances tainous areas
C - Towing a trailer G - Driving in areas using salt or other corro-
D - Extensive idling sive materials
E - Driving in extremely adverse weather con- H - Driving on rough and/or muddy roads or in
ditions or in areas where ambient temper- the desert
atures are either extremely low or - Driving with frequent use of braking or in
extremely high mountainous areas
Driving Maintenance Maintenance Maintenance Reference

condition item operation interval page
A B C D Engine oil & oil filter
Gasoline engine Replace Every 7.500 km (4,500 miles) MA-24

or 6 months
Diesel engine Replace Every 5.000 km (3,000 miles) or MA-41

3 months
A Air cleaner Ii Iter & PCV filter Replace MA-23, 41
A E Fuel filter Replace MA-22,41

Every 30,000 km (18,000 miles)
F Brake fluid Replace or 12 months MA-47
G H Steering gear & linkage, axle & suspension parts & exhaust Check MA-50,45
system FA-5
RA-4
C H Automatic & manual transaxle oil Replace Every 60,000 km (36,000 miles) MA-46,45
or 24 months
A C G H I Brake pads, discs & other brake components Check MA-48

Every 15,000 km (9,000 miles)
A C G H I Brake lining, drums & other brake components Check or 6 months MA-49
C H Drive shaft Check FA-7
Maintenance operation: Check = Check. Correct or replace if necessary.
MA-13
RECOMMENDED LUBRICANTS AND FLUIDS
Lubricants and Fluids
Capacity (Approximate) Recommended lubricants

Liter Imp measure and fluids
Engine oil (Refill)
Gasoline
For Europe:
With oil filter GA 3.2 2-7/8 qt
API SG or SH*1
SR20DE 3.4 3 qt
Except for Europe:
Without oil filter GA 2.8 2-1/2 qt
API SE, SF, SG or SH*1
SR20DE 3.2 2-718 qt
Diesel
With oil filter CD20 5.1 4-1/2 qt API CD*1
Without oil filter CD20 4.6 4 qt
Cooling system
(With reservoir tank)
Gasoline
With heater GA series (M/T) 5.9 5-1/4 qt
GA series (A/T) 6.4 5-5/8 qt
SR series (M/T) 6.1 5-3/8 qt
SR series (A/T) 6.6 5-7/8 qt

Anti-freeze coolant
Without heater GA series (M/T) 5.6 4-7/8 qt
(Ethylene glycol base)
GA series (A/T) 6.1 5-3/8 qt
or soft water
SR series (M/T) 5.8 5-1/8 qt
SR series (AfT) 6.3 5-1/2 qt
Diesel
With heater CD20 5.2 4-5/8 qt
Without heater CD20 4.9 4-3/8 qt
Manual transaxle gear oil

RS5F30A 2.8 - 3.0 4-7/8 - 5-1/4 pt
RS5F31A 2.9 - 3.2 5-1/8 - 5-5/8 pt API GL-4*1

RS5F32A 3,7 - 3.9 6-1/2 - 6-7/8 pt
Automatic transaxle fluid Genuine NISSAN ATF or equiv-

RL4F03A 7.0 6-1/8 qt alent*2
Power steering fluid Type DEXRON™
Brake & clutch fluid For Europe:

0013 or DOT4 (US FMVSS
NO. 116)*3
Except for Europe:
DOT3 (US FMVSS NO. 116)
Multi-purpose grease NLGI NO.2 (Lithium soap base)
*1: For further details, see "SAE Viscosity Number". _

*2: For morainformation regarding suitable fluids, contact a NISSAN dealership for correct brand of DEXRON 'P: liE or
DEXRON:A III.
*3: Never mix different types of fluids (DOT3 and 0014).
MA-14
SAE Viscosity Number
Outside Temperature Range Outside Temperature Range
•
Anticipated Before Next Oil Change Anticipated Before Next Oil Chahge
GASOLINE ENGINE OIL DIESEL ENGINE OIL
°C of
lI)
~ +40 +10 -- -------

~
0 0
------~
0
0 '"~ '<t +30 +86 -------
o
----- -0
...
'i ~ ~ 0
+15 +59 -----

~ 0
(\J +20 +68 0
'"~ ~ --- - -
'"
0 0
+15 +59 '" '!2 '"0

0
~ ~ 'i?: 't
0 0
'i'
;: '"
+32 0
~ 0
0
'7
~ -
'"
'"
N
-t
+32
-10 +14 0
~ ~
-10 +14 ;:
-20 ~
-20 -4 - 'i'
-30 ~
* Not recommended -30 -22
for sustained high
speed driving • Not recommended
for sustained high
speed driving
TI0005 TIOOG6
• For cold and warm areas: • For cold and warm areas:
10W-30 is preferable for ambient tempera- 10W-30 is preferable for ambient te~pera-
tures above -20°C (-4°F). tures above -20°C (-4°F).
• For hot areas: • For hot areas:
20W-40 and 20W-50 are suitable. 20W.40 and 20W-50 are suitable.
Outside Temperature Range

Anticipated Before Next 011Change
GEAR OIL
140
°C of
90
+40 +104 -------
+30 +86
+10 +50 -
0
%
-10
-29 -20
75W BOW 75W-90

BOW-90
TI0003
• SOW-90 is preferable for ambient tempera-

tures below 40°C (104°F).
MA-15
Anti-freeze Coolant Mixture Ratio

The engine cooling system is filled at the factory with a high-
quality, year-round, anti-freeze coolant solution. The anti-freeze
solution contains rust and corrosion inhibitors. Therefore, addi-
tional cooling system additives are not necessary.
CAUTION:
When adding or replacing coolant, be sure to use only an eth-
ylene glycol anti-freeze with the proper mixture ratio. See the
following examples:
Outside temperature
Anti- Soft
down to
freeze water
'C 'F
-15 5 30% 70%
-35 -30 50% 50%
The use of other types of coolant solutions may damage your

cooling system.
MA-16
ENGINE MAINTENANCE
Checking Drive Belts

EXCEPT FOR GA14DE ENGINE
Power steering pump

(or Idler pulley)
Idler pulley
~ 25.5 - 32.4 (2.60 - 3.30, 18.8 - 23.9)

•
Compressor ~ 16 - 21
(1.6 • 2.1, 12 • 15)
Crankshaft
With air conditioner
pulley
Power steering
~.
pump
(or Idler pulley)
Alternator
~6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)

Crankshaft pUlley
~ : Checking point
A : N.m (kg-m, ft-lb) Without air conditioner
III : N.m (kg-m, in-Ib) SMA786CA
1. Inspect for cracks, fraying, wear or oil adhesion. If

necessary, replace with a new one.
2. Inspect drive belt deflections by pushing on the belt midway
between pulleys.
Adjust if belt deflections exceed the limit.
Belt deflection:
Unit: mm (in)
Used belt deflection

Deflection of new
Deflection after belt
Limit
. adjustment
Alternator
With air condi- 5.5 - 6.5

10 (0.39) 6 - 7 (0.24 - 0.28)
lioner compressor (0.217 - 0.256)
Without air condi-

11 (0.43) 7 - 9 (0.28 - 0.35) 6 - 8 (0.24 - 0.31)
lioner compressor
Power steering oil

7.5 (0.295) 4 - 6 (0.16 - 0.24) 3 - 5 (0.12 - 0.20)
pump
Applied pushing force 98 N (10 kg, 22 Ib)
Inspect drive belt deflections when engine is cold.
MA-17
ENGINE MAINTENANCE
Checking Drive Belts (Cont'd)
FOR GA14DE ENGINE
Idler pulley lock nut __

~ 25 • 32 (2.6 • 3.3, 19 - 24)
)~'\c, ~ Crankshaft
'~~UlleY
~\ Idler pulley
Loosen
~~-
~ / ~
- With power steering
.
Crankshaft pulley
L Idler pulley
Without power steering
SMA357CB

between pulleys.
Adjust if belt deflections exceed the limit.
Belt deflection:
Unit: mm (in)

Deflection of new
Deflection alter belt
Limit
adjustment
Alternator
With power steer-

11 (0.43)
ing 7- 9 6- 8
Without power (0.28 - 0.35) (0.24 - 0.31)
10 (0.39)
steering
Air conditioner com- 6- 8 5- 7

9.5 (0.374)
pressor (0.24 - 0.31) (0.20 - 0.28)
Power steering oil 4-6 3- 5

7.5 (0.295)
pump (0.16 - 0.24) (0.12 - 0.20)
Applied pushing force 98 N (10 kg, 22 Ib)
MA-18
ENGINE MAINTENANCE
Changing Engine Coolant

WARNING:
To avoid being scalded, never change the coolant when the
•
engine is hot.
-DRAINING ENGINE COOlANT-

1. Move heater "TEMP" control lever all the way to "HOT".
• Make sure that blower switch is "OFF".
AMA054
2. Open radiator drain plug at the bottom of radiator, and

Front
'*' LOOSEN
'--
3.
remove radiator cap.
Remove reservoir tank, drain coolant, then clean reservoir
tank.
Radialor Install it temporarily.
• Be careful not to allow coolant to contact drive belts.
Fronl
DI1211M
4. Remove cylinder block drain plug and air relief plug.
-FLUSHING COOLING SYSTEM-

S. Install radiator drain plug, cylinder block drain plug and air
relief plug CID securely.
6. Fill radiator with water until water spills from the air relief
plug @ hole, then install air relief plug @.
Fill radiator and reservoir tank with water and install radi-
ator cap.
Air relief plug:
~ : 7 - 8 N'm (0.7 - 0.8 kg-m, 61 - 69 in-Ib)
MA-19
ENGINE MAINTENANCE [QK]
Changing Engine Coolant (Cont'd)
7. Warm up engine until cooling fan operates, then race
engine 2 or 3 times under no-load.
8. Stop engine and wait until it cools down.
9. Drain water.
10. Repeat steps 2 through 9 until clear water begins to drain
from radiator.
-REFILLING ENGINECOOLANT-
11. Install reservoir tank, radiator drain plug, cylinder block
drain plug and air relief plug @.
• Apply sealant to the thread of cylinder block drain plug.
toJ:34 - 44 N.m (3.5 - 4.5 kg-m, 25 - 33 ft-Ib)
12. Fill radiator with coolant until coolant spills from the air
relief plug @ hole, then install air relief plug @.
13. Fill radiator and reservoir tank with coolant up to specified
level and install radiator cap.
Air relief plug:
~: 7 - 8 N.m (0.7 - 0.8 kg-m, 61 - 69 in-Ib)
For coolant mixture ratio, refer to MA-16.
Coolant capacity (With reservoir tank):
Unit: f (Imp qt)
With heater Without heater

M/T 5.9 (5-1/4) 5.6 (4-7/8)
AIT 6.4 (5-5/8) 6.1 (5-3/8)
Reservoir tank capacity (for MAX level):

o.n
(5/8 Imp qt)
Pour coolant through coolant filler neck slowly to allow air in
system to escape.
14. Warm up engine to normal operating temperature.
MAX,
15. Run engine at 2,500 rpm for 10 seconds and return to idle
speed.
MIN. • Repeat 2 or 3 times.
Watch coolant temperature gauge so as not to overheat the
engine.
SMA4128
MA-20
ENGINE MAINTENANCE @KJ
Changing Engine Coolant (Co nt' d)
16. Stop engine and cool it down.
• Cool down using a fan to reduce the time.
17. Remove the radiator filler cap and check coolant level.
• If necessary, refill radiator up to filler neck with coolant. •
18. Refill reservoir tank to Max line with coolant. •
19. Repeat step 14 through step 18 two or more times.
20. Warm up engine, and check for sound of coolant flow while
running engine from idle up to 4,000 rpm with heater tem-
perature control set at several positions between COOL and
HOT.
• Sound may be noticeable at heater water cock.
21. If sound is heard, bleed air from cooling system by repeat-
ing steps 14 through 18 until coolant level no longer drops.
• Clean excess coolant from engine.
CAUTION:
When heater unit is removed or replaced, refill engine coolant
Water as shown, removing heater hose at feeding connector on
inlet engine.
Water
outlet
SLC053B
Checking Cooling System

CHECKING HOSES
Check hoses for improper attachment and for leaks, cracks,
damage, loose connections, chafing and deterioration.
CHECKING RADIATOR CAP

Apply pressure to radiator cap with cap tester to see if it is sat-
isfactory.
Radiator cap relief pressure:
Standard
78 - 98 kPa
(0.78 • 0.98 bar, 0.8 - 1.0 kg/cm2, 11 . 14 psi)
Limit
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi)
SLC613-A
MA-21
ENGINE MAINTENANCE ~
Checking Cooling System (Cont'd)
Pull the negative-pressure valve to open it. Check that it closes
completely when released.
SMA871B
CHECKING COOLING SYSTEM FOR LEAKS

Apply pressure to the cooling system with cap tester to check
for. leakage.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
Higher pressure than the specified value may cause damage to
radiator.
Checking Fuel lines

Inspect fuel lines and tank for improper attachment and for
leaks, cracks, damage, loose connections, chafing and deteri-
oration.
If necessary, repair or replace faulty parts.
SMA803A
CAUTION:
3 (0.12) Unit: mm (in)
Tighten high-pressure rubber hose clamp so that clamp end is
-- --- ----,;~-r--1
-,-,-, , ~-
"
3 mm (0.12 in) from hose end.
_______ .J",_~ __
Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that screw does not contact adjacent parts.
28 (1.10)
~ Fuel hose clamps

1.0 - 1.5 N.m
(0.10 - 0.15 kg-m,
8.7 - 13.0 in-Ib)
MMA104A
Changing Fuel Filter

WARNING:
Before removing fuel filter, release fuel pressure from fuel line
to eliminate danger.
MA-22
ENGINE MAINTENANCE @KJ
Changing Fuel Filter (Cont'd)
1. Remove fuse for fuel pump.
2. Start engine.
3. After engine stalls, crank engine two or three times to make
sure that fuel pressure is released. •
4. Turn ignition switch off and install fuse for fuel pump. i
AECBBO
5. Loosen fuel hose clamps.

6. Replace fuel filter.
• Be careful not to spill fuel over engine compartment. Place
a shop towel to absorb fuel.
• Use a high-pressure type fuel filter. Do not use a synthetic
resinous fuel filter.
• When tightening fuel hose clamps, refer to Checking Fuel
Lines.
Cleaning and Changing Air Cleaner Filter

VISCOUS PAPER TYPE
The viscous paper type filter does not need cleaning between
renewals.
DRY PAPER TYPE

Clean or replace element more often under dusty driving con-
ditions.
SMA384C
MA-23
ENGINE MAINTENANCE
Changing Engine Oil

WARNING:
• Be careful not to burn yourself, as the engine oil is hot.
• Prolonged and repeated contact with used engine oil may
cause skin cancer; try to avoid direct skin contact with used
oil. If skin contact is made, wash thoroughly with soap or
hand cleaner as soon as possible.
1. Warm up engine, and check for oil leakage from engine
components.
2. Remove drain plug and oil filler cap.
3. Drain oil and refill with new engine oil.
Refill oil capacity (Approximate):
Unit: f (Imp qt)
.With oil filter change 3.2 (2-7/8)

Without oil filter change 2.8 (2-1/2)
Regarding the Anti-freeze Coolant Mixture Ratio, refer to "REC-

OMMENDED FLUIDS AND LUBRICANTS".
CAUTION:
• Be sure to clean drain plug and install with new washer.
Drain plug:
~: 29 - 39 N'm (3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
• Use recommended engine oil "API SE, SF, SG or SH" with
suitable viscosity.
• Refill oil capacity changes depending on the oil temperature
and drain time. Use these values as a reference and be
certain to check with the dipstick when changing the oil.
4. Check oil level.

5. Start engine and check area around drain plug and oil filter
for oil leakage.
6. Run engine for a few minutes, then turn it off. After several
minutes, check oil level.
Refill oil to this

"H" level.
Do not overfill.
SMA822C
Changing Oil Filter

1. Remove oil filter with Tool.
WARNING:
Be careful not to burn yourself, as the engine and the engine
oil are hot.
MA-24
Changing Oil Filter (Cont'd)
2. Before installing new oil filter, clean the oil filter mounting
surface on cylinder block, and coat the rubber seal of oil fil-
ter with a little engine oil.
•
SMA010
3. Screw in the oil filter until a slight resistance is felt, then

tighten an additional 2/3 turn.
4. Add engine oil.
Refer to Changing Engine Oil.
2/3 of a turn • Clean excess oil from engine.
Checking and Changing Spark Plugs

1. Disconnect ignition wires from spark plugs at boot. Do not
pull on the wire.
SMA302CA
g
2. Remove spark plugs with spark plug wrench.
3. Clean plugs in sand blast cleaner.
Wrench with a magnet
to hold spark plug
4. Check insulator for cracks or chips, gasket for damage or
deterioration and electrode for wear and burning. If they are
excessively worn away, replace with new spark plugs.
16 mm
5. Check spark plug gap.
(0.63 In)
Spark plug:
GA16DE & GA15DE engine

GA16DE & GA14DE engine
except for Europe and
for Europe and Israel
Israel
SMA294A
Type
Standard BKR5E BKR5E-11
Cold BKR6E, BKR7E BKR6E-11, BKR7E-11
0.8 - 0.9 1.0 - 1.1

Plug gap mm (in)
(0.031 - 0.035) (0.039 - 0.043)
MA-25
Checking and Changing Spark Plugs (Cont'd)
Side electrode
6. Install spark plugs. Reconnect ignition wires according to
It,
nos. indicated on them.
Spark plug:
~: 20 - 29 N'm (2.0 - 3.0 kg-m, 14 - 22 ft-Ib)
SMA476
Checking Ignition Wires

1. Inspect wires for cracks, damage, burned terminals and for
improper fit.
2. Measure the resistance of wires and check for intermittent
breaks.
Cylinder No. Resistance kQ [at 25'C (77'F)]
Approximately 11
2 Approximately 10
SMA813C 3 Approximately 8
4 Approximately 6.5
If it exceeds the limit, replace the ignition wire with a new one.
Changing Positive Crankcase Ventilation (PCV)

Filter
Remove air cleaner cover and replace pev filter.
Checking EVAP Vapor Lines

1. Visually inspect EVAP vapor lines for improper attachment
and for cracks, damage, loose connections, chafing and
deterioration.
2. Inspect vacuum relief valve of fuel tank filler cap for
clogging, sticking, etc.
Refer 10 EVAPORATIVE EMISSION SYSTEM INSPECTION in EC
section.
MA-26
ENGINE MAINTENANCE
Checking Oxygen Sensor (02S) or Heated

* MONITOR * NO FAIL 0 Oxygen Sensor (H02S)
CMPS'RPM(REF) 2000rpm
•
MIR FIC MNT RICH
Checking procedure
INSPECTION START
~
Start engine and warm it up until water
RECORD I
MEC711B
temperature indicator points to the mid-
dle of gauge.
mm@] 1
~y~r
GrJ-~
00 1. See "MIA FIC MNT" in "Data
monitor" mode.
2. Run engine at about 2,000 rpm
for about 2 minutes under
no-load.
Data link connector for CONSULT 3. Maintaining engine at 2,000
(Connect CHK and IGN terminals rpm under no-load (engine is
with a suitable harness.) warmed up sufficiently.),
check that the monitor fluctu-
SEF909P ates between "LEAN" and
"RICH" more than 5 times
during 10 seconds.
1 lime RICH -> LEAN ->
'e/'\ I / RICH ->

2 limes RICH -> LEAN ->
RICH -> LEAN ->
RICH ......
- CHECK- OR
/
/ I \
" 00 1. Set' 'Oxygen sensor
monitor"*1 or "Heated oxygen
sensor monitor"*2 in the Diag-
nostic test mode II.
Malfunction indicator
(Refer to EC section.)
lamp
SEF051PA 2. Run engine at about 2,000 rpm
no-load.
3. Maintaining engine at 2,000
rpm under no-load, check to
make sure that malfunction
indicator lamp on the instru-
ment panel goes ON and OFF
more than 5 times during 10
seconds.
OK NG
Check and adjustment

should be made by refer-
ring to IDLE SPEEDI
IGNITION TIMINGIIDLE
I INSPECTION END MIXTURE RATIO INSPEC-

TION (BASIC SERVICE
PROCEDURE) in EC sec-
tion.
*1: Except for Australia

(A/T), Israel and Europe
*2: For Australia (A/T),
Israel and Europe
MA-27
ENGINE MAINTENANCE
Checking Drive Belts
Crankshaft
pulley
Crankshaft
Without air conditioner
pulley Compressor
A : N.m (kg-m, ft-Ib)
With air conditioner " : Check point
SMA808C

between pulleys.
Altemetor drive belt fitting piece Adjust if belt deflections exceed the limit.
(Modell without elr conditioner) Belt deflection:
Alternator drive belt
Unit: mm (in)
r Crankshaft
/ pulley Used belt deflection
Deflection Deflection of
Drive belts
o Limit after adjust- new belt
Engine
ment
front
Alternator
Alternator 11.5 - 12.5 6.5 - 7.5

With air conditioner com- 7 -8
drive belt (0.453 - (0.256 -
pressor (0.28 - 0.31)
0.492) 0.295)
Without air conditioner 12 - 13 8-9 7- 8
compressor (0.47 - 0.51) (0.31 - 0.35) (0.28 - 0.31)
<;:J
Engine 3.5 - 4.5
6-7 4-5
front Power steering oil pump (0.138 -
(0.24 - 0.28) (0.16 - 0.20)
0.177)
Alternator Applied pushing force 98 N (10 kg, 22 Ib)

pulley
Set a belt in both crankshaft
and alternator pulleys shown Inspect drive belt deflections when engine is cold.
in the figure. SMA328C
MA-28
ENGINE MAINTENANCE

WARNING:
To avoid being scalded, never change the coolant when the
engine is hot.
-DRAINING ENGINECOOLANT-
1. Turn ignition switch "ON". Move heater "TEMP" control
knob all the way to "HOT".
•
2. Open radiator drain plug at the bottom of radiator, and
remove radiator cap.
Front
CiIt LOOSEN 3. Remove reservoir tank, drain coolant, then clean reservoir
tank.
'--
Radiator Install it temporarily.
• Be careful not to allow coolant to contact drive belts.
Front
DI1211M
MA-29
4. Remove cylinder block drain plug and air relief plug.
-FLUSHING COOLINGSYSTEM-
5. Install radiator drain plug and cylinder block drain plug
securely.
6. Fill radiator with water until water spills from the air relief
hole, then install air relief plug.
Fill radiator and reservoir tank with water and install radi-
ator cap.
Air relief plug:
!II: 10 N.m (1.0 kg-m, 87 in-lb)
7. Warm up engine until cooling fan operates, then race
engine 2 or 3 times under no-load.
8. Stop engine and wait until it cools down.
9. Drain water.
10. Repeat steps 2 through 9 until clear water begins to drain
from radiator.
-REFILLING ENGINECOOLANT-
11. Install reservoir tank, radiator drain plug and cylinder block
drain plug.
• Apply sealant to the thread of cylinder block drain plug.
SMA380C
!II:
8 - 12 N.m (0.8 - 1.2 kg-m, 69 - 104 in-lb)
12. Fill radiator with coolant until coolant spills from the air
relief hole, then install air relief plug.
13. Fill radiator and reservoir tank with coolant up to specified
level and install radiator cap.
Air relief plug:
~ : 10 N'm (1.0 kg-m, 87 in-lb)
For coolant mixture ratio, refer to MA-16.
Coolant capacity (With reservoir tank):
Unit: r (Imp qt)
M/T 6.1 (5-3/8) 5.8 (5-1/8)
AfT 6.6 (5-7/8) 6.3 (5-1/2)
Reservoir tank capacity (for MAX level):

o.n(5/8 Imp qt)
Pour coolant through coolant filler neck slowly to allow air in
system to escape.
MAX.
MIN.
SMA4128
MA-30
ENGINE MAINTENANCE [][]
15. Run engine at 2,500 rpm for 10 seconds and return to idle
speed .
• Repeat 2 or 3 times. •
Wat~h coolant temperature gauge so as not to overheat the i
engme.
16. Stop engine and cool it down.
• Cool down using a fan to reduce the time.
17. Refill reservoir tank to Max line with coolant.
18. Repeat step 15 through step 17 two or more times.
19. Warm up engine, and check for sound of coolant flow while
running engine from idle up to 4,000 rpm with heater tem-
perature control set at several positions between COOL and
HOT.
• Sound may be noticeable at heater water cock.
20. If sound is heard, bleed air from cooling system by repeat-
ing steps 14 through 17 until coolant level no longer drops.
CAUTION:
Water
as shown, removing heater hose at feeding connector on
inlet engine.
Water
outlet
SLC0538

CHECKING HOSES
Check hoses for improper attachment and for leaks, cracks,

Apply pressure to radiator cap with cap tester to see if it is sat-
isfactory.
Standard
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
limit
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi)
MA-31
ENGINE MAINTENANCE [][]
Checking Cooling System (Cont'd)
Pull the negative-pressure valve to open it. Check that it closes

Apply pressure to the cooling system with cap tester to check
f~r leakage.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
Higher pressure than the specified value may cause damage to
radiator.
SMA811C
Checking Fuel Lines

Inspect fuel lines and tank for improper attachment, leaks,
cracks, damage, loose connections, chafing or deterioration.
If necessary, repair or replace faulty parts.
SMA803A
CAUTION:
3 (0.12) Unit: mm (in)
Tighten high-pressure rubber hose clamp so that clamp end is
_._-- --,"'~'r---1
- "
- ---;--, ,
-,--- 3 mm (0.12 in) from hose end.
•• J .. _J- __
Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that screw does not contact adjacent parts.
28 (1.10)
~ Fuel hose clamps

1.0 - 1.5 N.m
(0.10 - 0.15 kg-m,
8.7 - 13.0 in-Ib)
MMA104A
Changing Fuel Filter

• FUEL PRES RELEASE. 0
WARNING:
FUEL PUMP WILL STOP BY Before removing fuel filter, release fuel pressure from fuel line
TOUCHING START DURING to eliminate danger.
IDLE_
CRANK A FEW TIMES AFTER
rF.i\ 1. Start engine.
ENGINE STALL. ~ 2. Perform "FUEL PRESSURE RELEASE" in "WORK
SUPPORT" mode with CONSULT.
3. After engine stalls, crank engine two or three times
to make sure that fuel pressure is released.
---S-T~-RT-- 4. Turn ignition switch off.
SEF823K
MA-32
Changing Fuel Filter (Cont'd)
~ 1. Remove fuse for fuel pump.
~ 2. Start engine.
3. After engine stalls, crank engine two or three times
to make sure that fuel pressure is released. •
4. Turn ignition switch off and install fuse for fuel pump. i
SMA790C
5. Loosen fuel hose clamps.

6. Replace fuel filter.
• Be careful not to spill fuel over engine compartment. Place
a shop towel to absorb fuel.
• Use a high-pressure type fuel filter. Do not use a synthetic
resinous fuel filter.
• When tightening fuel hose clamps, refer to "Checking Fuel
Lines" .
Changing Air Cleaner Filter

Viscous paper type
The viscous paper type filter does not need cleaning between
renewals.
Changing Engine Oil

WARNING:
• Be careful not to burn yourself, as the engine oil is hot.
hand cleaner as $oon as possible.
components.
2. Remove drain plug and oil filler cap.
3. Drain oil and refill with new engine oil.
Refill oil capacity (Approximate):
Unit: C (Imp qt)
With oil filter change 3.4 (3)

CAUTION:
• Be sure to clean drain plug and instCliliwith new washer.
Drain plug:
~: 29 - 39 N'm (3.0 4.0 kg-m, 22 - 29 ftolb)
0
• Use recommended engine oil (API SE, SF, SG or SH grade).

The refill capacity changes depending on the oil temperature
and drain time, use these values as a reference and be certain
to check with the dipstick when changing the oil.
MA-33
ENGINE MAINTENANCE [}[]
Changing Engine Oil (Cont'd)
4. Check oil level.
5. Start engine and check area around drain plug and oil filter
for oil leakage.
6. Run engine for a few minutes, then turn it off. After several
minutes, check oil level.
Refill oil 10 this

"H" level.
Do not overfill.
SMA390C
Changing Oil Filter

WARNING:
Be careful not to burn yourself, as the engine and the engine
oil are hot.
2. Clean oil filter mounting surface on cylinder block. Coat

rubber seal of new oil filter with engine oil.
SMA010
3. Screw in the oil filter until a slight resistance is felt, then

tighten an additional 2/3 turn.
4. Add engine oil.
Refer to Changing Engine Oil.
2/3 of a turn • Clean excess oil from engine.
OK
Changing Spark Plugs (Platinum-tipped type)
------- 1. Disconnect ignition wires from spark plugs at boot. Do not
pull on the wire.
MA-34
ENGINE MAINTENANCE lliJ
Changing Spark Plugs (Platinum-tipped type)
g
(Cont'd)
Wrench with a magnet 2. Remove spark plugs with suitable spark plug wrench.
to hold spark plug Spark plug:
16 mm
(0.63 In)
Make
Standard type
Alternative
NGK
PFR5B-11
PFR6B-11
PFR7B-11
•
SMA294A
• Do not use a wire brush for cleaning.

• If plug tip is covered with carbon, spark plug cleaner may
be used.
Cleaner air pressure:
Less than 588 kPa (5.9 bar, 6 kg/cm2, 85 psi)
Cleaning time:
Less than 20 seconds
• Checking and adjusting plug gap are not required between

Do not gap
change intervals.
3. Install spark plugs Reconnect ignition wires according to
numbers. indicated on them.
Spark plug:
~: 20 - 29 N'm (2.0 - 3.0 kg-m, 14 - 22 ft-Ib)
SMA806C
Checking Ignition Wires

1. Inspect wires for cracks, damage, burned terminals and for
improper fit.
2. Measure the resistance of wires and check for intermittent
breaks.
Resistance:
Cylinder No. Resistance kQ [at 25°C (77°F)]

Approximately 11
2 Approximately 9.5
SMA813C
3 Approximately 8
4 Approximately 7
If it exceeds the limit, replace the ignition wire with a new one.
MA-35
ENGINE MAINTENANCE
Checking EVAP Vapor & Purge Lines

1. Visually inspect EVAP vapor and purge lines for improper
attachment and for cracks, damage, loose connections,
chafing and deterioration.
2. Inspect vacuum relief valve of fuel tank filler cap for
clogging, sticking, etc.
Refer to EVAPORATIVE EMISSION SYSTEM in EC section.
MA-36
ENGINE MAINTENANCE
Checking Heated Oxygen Sensor (H02S)

* MONITOR * NO FAIL D
Checking procedure
CMPS.RPM(REF) 2000rpm
•
M/RFICMNT RICH INSPECTION START
1
Start engine and warm it up until water
temperature indicator points to the mid-
__ R_E_C_O_R_D __ I dle of gauge.

MEC711B
m(;]ri 1
~~:?~;~ ~~r 00 1. See "M/R F/C MNT" in "Data
monitor" mode.
l~~~~V
~~ -~~
Data link connector for CONSULT
no-load.
(Connect CHK and IGN terminals rpm under no-load (engine is
with a suitable harness.) warmed up sufficiently.),
check that the monitor fluctu-
SEF909P ates between "LEAN" and
"RICH" more than 5 times
........
e./
during 10 seconds.
\ I / 1 time RICH
RICH
-4
-4
LEAN -4
2 times RICH -4 LEAN -4
- CHECK- RICH -4 LEAN -4
./ ........ RICH ......

OR
/ I \
@ 1. Set "Heated oxygen sensor
monitor" in the Diagnostic test
lamp mode II.
SEF051PA
(Refer to EC section)
no-load.
rpm under no-load, check to
make sure that malfunction
indicator lamp ~n the instru-
ment panel goes ON and OFF
more than 5 times during 10
seconds.
OK NG
. Check and adjustment

should be made by refer-
ring to IDLE SPEEDI
INSPECTION END IGNITION TIMING/IDLE
MIXTURE RATIO INSPEC-
TION in EC section
MA-37
ENGINE MAINTENANCE
Manifold Nut Check

1. Remove exhaust manifold cover.
2. Tighten manifold bolts and nuts to the specified torque.
Refer to "SERVICE DATA AND SPECIFICATIONS (SOS)".
3. Install exhaust manifold cover.
Checking Drive Belt

WARNING:
Inspect drive belt deflections when engine is cold. When engine
is hot, check deflections at least 30 minutes after engine has
been switched off.
1. Inspect belts for cracks, fraying, wear or oil adhesion. If
necessary, replace with new ones.
Air conditioner between pulleys.
compressor 3. Adjust belt deflection if it exceeds the limit.
SMA442C
Belt deflection:
Unit: mm (in)

Deflection of new
Deflection after belt
Limit
adjustment
11 - 13 9 - 11
Alternator 14 (0.55)
(0.43 - 051) (0.35 - 0.43)
Air conditioner 11 - 13 9 - 11
14 (0.55)
compressor (0.43 - 051) (0.35 - 0.43)
Power steering oil

8 (0.31) 5 - 7 (0.20 - 0.28) 4 - 6 (0.16 - 0.24)
pump
Water pump
without power - 8 (0.31) 6 (0.24)
steering
Applied pushing
98 N (10 kg, 22 Ib)
force

WARNING:
To avoid the danger of being scalded, never attempt to change
the coolant when the engine is hot.
1. Set heater "TEMP" control dial to the max. "HOT" position.
• Make sure that air conditioner switch is "OFF".
AMA054
MA-38
ENGINE MAINTENANCE @[]
2. Open drain plugs on the bottom right of radiator and on the
left side of cylinder block.
3. Remove radiator cap and drain coolant.
4. Close drain plugs and fill radiator with water up to filler •
neck. •
5. Warm up engine and repeat steps 2, 3 and 4 one or two
times to drain old coolant.
Drain plug (Radiator)
6. Open air bleeder on intake manifold.

7. Fill radiator with coolant up to filler neck.
Follow instructions attached to anti-freeze container for anti-
freeze to water mixing ratio.
Pour coolant slowly to allow air in system to escape.
Coolant capacity:
Unit: C (Imp qt)
With heater 5.2 (4-5/8)

Without heater 4.9 (4-3/8)
Regarding the Anti-freeze Coolant Mixture Ratio, refer to "REC-

OMMENDED FLUIDS AND LUBRICANTS".
8. Securely close air bleeder.
9. Fill reservoir tank with coolant up to "MAX" level.
10. Warm up engine at about 2,000 rpm to normal operating
MAX.
temperature.
11. Stop engine and allow it to cool.
12. Check coolant level and refill reservoir tank if necessary.
MIN.
SMA412B
CAUTION:
as shown, removing heater hose at feeding connector on
engine.
Water
outlet
SLC053B
MA-39
ENGINE MAINTENANCE

HOSE AND CLAMP CHECK
Check hoses for improper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.

1. Check relief pressure with cap tester.
Standard
78.98 kPa
(0.78.0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
Limit
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi)
Replace radiator cap if pressure is not within the specified
SLC613-A values.
2. Pull the negative-pressure valve to open it, and check that
it closes completely when released.

Hose adapter Apply pressure to the cooling system with cap tester to check
for leakage.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
Use of higher pressure than that specified value may cause
damage to radiator.
SMA990A
Checking Fuel Line

Inspect fuel lines and tank for improper attachment, leaks,
cracks, damage, loose connections, chafing and deterioration.
If necessary, repair or replace malfunctioning parts.
SMA803A
MA-40
ENGINE MAINTENANCE
Changing Air Cleaner Filter

The viscous paper type air cleaner filter does not require any
cleaning operation between renewals.
•
Water Draining, Fuel Filter Check and
Replacement
DRAINING WATER
Open drain valve at the bottom of fuel filter.
FUEL FILTER CHECK

Check fuel filter for fuel leakage, damage and other abnormal
signs.
SMA794C
REPLACING FUEL FILTER

1. Disconnect water sensor connector and replace fuel filter
with a new one.
Hand-tighten fuel filter by about 2/3 turn after O-ring touches
mounting surface. Follow the instructions on fuel filter.
2. Connect water sensor connector and bleed fuel system.
FUEL SYSTEM AIR BLEEDING

1. Move priming pump up and down until there is suddenly
more resistance in the movement. Then stop this action and
start the engine.
2. If engine does not operate smoothly after being started,
race it two or three times.
When refilling empty- fuel tank, bleed air out of fuel system.
Changing Engine Oil

WARNING:
• Be careful not to burn yourself, as engine oil is hot.
hand cleaner as soon as possible.
components.
2. Remove oil drain plug and drain oil.
MA-41
ENGINE MAINTENANCE
Changing Engine Oil (Cont'd)
3. Tighten oil drain plug.
4. Fill with engine oil.
Oil refill capacity:
Without oil filter
4.6 C (4 Imp qt)
With oil filter
5.1 C (4-1/2 Imp qt)
• Use recommended engine oil "API CD" with suitable vis-

cosity.
5. Confirm oil level and warm up engine.
6. Recheck oil level and adjust it to "H" level if necessary.
Refill oil to this

"H" level.
Do not overfill.
SMA822C
Changing Engine Oil Filter

WARNING:
Be careful not to burn yourself, as engine and engine oil are
hot.
SMA412C
SMA167B
2. Before installing new oil filter, wipe clean oil filter mounting
surface on cylinder block, and apply a little engine oil to
rubber seal of oil filter.
SMA010
MA-42
ENGINE MAINTENANCE @Q]
Changing Engine Oil Filter (Cont'd)
3.
Screw oil filter on until a slight resistance is felt, then tighten
an additional 2/3 turn.
4. Warm up engine and check oil level.
5. Adjust oil level if necessary. •
2/3 of a turn Refer to Step 4 in "Changing Engine Oil", MA-42. i
• Clean excess oil from engine.
SMA229B
Checking Injection Nozzle

1. Remove injection delivery tubes and fuel spill tube.
2. Remove nozzle with a suitable tool [span 27 mm (1.06 in)].
WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to come into contact with your hand or
body, and make sure that your eyes are properly protected.
3. Clean and check nozzles.
4. Install nozzle to injection nozzle tester and bleed air from
flare nut.
5. Check initial injection pressure by pumping tester handle
one time per second.
EF791A
6. Install injector to pressure tester.

7. Check initial injection pressure by pumping tester handle
slowly (one time per second).
Injection pressure:
12,749 kPa (127.5 bar, 130 kg/cm2, 1,849 psi)
• Always check initial injection pressure before installing new
nozzle.
SEF672A
8. Check fuel spray pattern by pumping tester handle quickly

(4 or 6 times per second).
9. If initial injection pressure or injection nozzle is not normal,
adjust or clean injection nozzle or replace it.
Refer to EC section for injection pressure adjustment.
10. Install all injection nozzles and securely connect fuel spill
tube and delivery tubes.
, ,
\
I
11. Bleed air from fuel system and check for fuel leakage with
I engine running.
Good Wrong
EF794A
MA.43
ENGINE MAINTENANCE
Checking Injection Nozzle (Cont'd)
Nozzle side
Combustion
chamber side
SEF668A
Checking Idle Speed

PREPARATION
1: Make sure that injection timing is correct.
2. Make sure that injection nozzles are in good condition.
3. Make sure that the following parts are in good condition.
• Air cleaner clogging
• Glow system
• Engine oil and coolant levels
• Air intake system (Oil filler cap, oil level gauge, etc.)
4. Set shift lever in "Neutral" position. Engage parking brake
and lock both front and rear wheels with wheel chocks.
5. Turn off air conditioner, lights and accessories.
7. Attach a diesel tacho tester.
8. Race engine two or three times and check idle speed.
Idle speed (M/T):
700~go rprn
9. If it is out of specification, adjust idle speed with idle speed

adjusting screw.
Securely lock the adjusting screw with lock nut.
Idle speed
adjusting screw
Fuel injection pump

SMA420C
Replacing Timing Belt

Refer to "TIMING BELT" in EM section.
MA-44
CHASSIS AND BODY MAINTENANCE
Checking Exhaust System

Check exhaust pipes, muffler and mounting for improper attach-
ment and for leaks, cracks, damage, loose connections, chafing
and deterioration. •
SMA211A
Checking Clutch Fluid Level and Leaks

If fluid level is extremely low, check clutch system for leaks.
SMA449C
Checking Clutch System

HYDRAULIC TYPE
Check fluid lines and operating cylinder for improper
attachment, cracks, damage, loose connections, chafing and
deterioration.
jJ I SMA"",
MECHANICAL TYPE
Check cable and links for improper attachment, chafing, wear
and deterioration.
SMA141A
Checking MIT Oil

• Check that oil is not leaking from transaxle or around it.
• Remove speedometer pinion and check that the oil level L
at vehicle rear side is within specification.
Specified Specified oil level (Dimension L):
oil level RS5F30A 58 - 66 mm (2.28 - 2.60 in)
RS5F31A
GA engine 57 - 66 mm (2.24 - 2.60 in)
CD engine 54 - 61 mm (2.13 - 2.40 in)
RS5F32A 39 - 44 mm (1.54 - 1.73 in)
SMT512C
MA-45
Changing MIT Oil

1. Drain oil from drain plug and refill with new gear oil.
2. Check oil level. (Refer to "Checking M/T Oil".)
Oil grade:
API GL-4
Viscosity:
See "RECOMMENDED FLUIDS AND LUBRICANTS",
MA-14.
Capacity:
RS5F30A 2.8 - 3.0f (4-7/8 - 5-114 Imp pi)
RS5F31A 2.9 - 3.2£ (5-1/8 - 5-518 Imp pt)
RS5F32A 3.7 - 3.9£ (6-112 - 6-7/8 Imp pt)
Drain plug:
(OJ: 15 - 20 N'm (1.5 - 2.0 kg-m, 11 - 14 ft-Ib)
GA engine models Checking AIT Fluid Level

• Front side 1. Warm up engine .
HOT [50 • 80°C (122 • 176°F))
2. Check for fluid leakage.
OK
3. Before driving, fluid level can be checked at fluid tempera-
tures of 30 to 50°C (86 to 122°F) using "COLD" range on
dipstick.
a. Park vehicle on level surface and set parking brake.
b. Start engine and move selector lever through each gear
position. Leave selector lever in "P" position.
c. Check fluid level with engine idling.
SMA579CB
d. Remove dipstick and note reading. If level is at low side of
either range, add fluid to the charging pipe.
SR engine models
e. Re-insert dipstick into charging pipe as far as it will go .
• Front side
HOT [50 • 80"C (122 - 176"F)] f. Remove dipstick and note reading. If reading is at low side
o'f.. of range, add fluid to the charging pipe. Do not overfill.
4. Drive vehicle for approximately 5 minutes in urban areas.
5. Re-check fluid level at fluid temperatures of 50 to 80°C (122
to 177°F) using "HOT" range on dipstick.
SMA827C
6. Check fluid condition. If fluid is very dark or smells burned,

or contains friction material (clutches, band, etc.), check
operation of AlT. Refer to AT section for checking operation
of AlT.
Check fluid for contamination.

SMA853B
MA-46
Changing AIT Fluid

1. Warm up AIT fluid.
2. Stop engine.
3. Drain AIT fluid from drain plug and refill with new AIT fluid .•
Always refill with same volume as drained fluid. i
Fluid grade:
Genuine Nissan ATF or equivalent
See "RECOMMENDED FLUIDS AND lUBRICANTS",
MA-14.
Fluid capacity (With torque converter):
7.0£ (6-1/8 Imp qt)
Drain plug:
toJ: 29. 39 N'm (3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
4. Run engine at idle speed for five minutes.
5. Check fluid level and condition. Refer to "Checking AIT
Fluid". If fluid is still dirty, repeat steps 2 through 5.
Checking Brake Fluid Level and Leaks

Max, line
If fluid level is extremely low, check brake system for leaks.
Min, line
OK
MIN
SBR418C
Checking Brake System

Check brake fluid lines and parking brake cables for improper
attachment and for leaks, chafing, abrasions, deterioration, etc.
Changing Brake Fluid

1. Drain brake fluid from each air bleeder valve.
2. Refill until new brake fluid comes out from each air bleeder
valve.
Use same procedure as in bleeding hydraulic system to
refill brake fluid.
Refer to "CHECK AND ADJUSTMENT" in BR section.
• Refill with recommended brake fluid.
See "RECOMMENDED FLUIDS AND lUBRICANTS".
• Never reuse drained brake fluid.
SBR404C
• Be careful not to splash brake fluid on painted areas.
MA-47
Checking Brake Booster, Vacuum Hoses,

Connections and Check Valve
Check vacuum lines, connections and check valve for improper
attachment, air tightness, chafing and deterioration.
Checking Disc Brake

Check condition of disc brake components .
.
ROTOR
Check condition and thickness.
Standard thickness:
CL22VD and CL22VE 18.0 mm (0.709 in)
AD22VF 26.0 mm (1.024 in)
CL7HB 7.0 mm (0.276 in)
CL9HC 9.0 mm (0.354 in)
SBR944A Minimum thickness:
AD22VF 24 mm (0.945 in)
CL7HB 6.0 mm (0.236 in)
CL9HC 8.0 mm (0.315 in)
CALIPER
Check for leakage.
SMA922A
PAD
Check for wear or damage.
Standard thickness:
AD22VF 10.0 mm (0.394 in)
CL7HB and CL9HC 10.0 mm (0.394 in)
Minimum thickness:
CL22VD, CL22VE and AD22VF 2.0 mm (0.079 in)
CL7HB and CL9HC 1.5 mm (0.059 in)
SMA847B
MA-48
Checking Drum Brake

Check condition of drum brake components.
WHEEL CYLINDER
Check for leakage.
•
SBR205A
DRUM
Check condition of inner surface.
Standard diameter:
180.0 mm (7.09 in)
Drum repair limit (Inner diameter):
181.0 mm (7.13 in)
SMA848B
LINING
Check for wear or damage.
Standard thickness:
4.0 mm (0.157 in)
Lining wear limit (Minimum thickness):
1.5 mm (0.059 in)
SMA849B
TEMPORARY METHOD FOR CHECKING LINING WEAR

Remove inspection hole plug and check for lining wear.
Balancing Wheels
• Adjust wheel balance using road wheel center.
Wheel balance (Maximum allowable unbalance):
Refer to SDS (MA-56).
MA-49
Radial tires Tire Rotation
0 0 0 0 • Do not include the T-type spare tire when rotating the tires .
Wheel nuts:
~: 98 - 118 N'm (10.0 - 12.0 kg-m, 72 - 87 ft-Ib)
H H
~ /0 0 0
(2)
5 wheels
4 wheels
SMA785C
Checking Steering Gear and Linkage

STEERING GEAR
• Check gear housing and boots for looseness, damage or
grease leakage.
• Check connection with steering column for looseness.
STEERING LINKAGE
Q : Check grease leakage • Check ball joint, dust cover and other component parts for
• : Check tightening torque looseness, wear, damage or grease leakage.
SMA851B
Checking Power Steering Fluid and Lines

• Check fluid level with engine off.
• Check fluid level using dipstick on reservoir cap, or refer-
ring to the scale on reservoir tank. Use "HOT" range at fluid
temperatures of 50 to 80°C (122 to 176°F). Use "COLD"
range at fluid temperatures of a to 30°C (32 to 86°F).
CAUTION:
• Do not overfill.
• Recommended fluid is Automatic Transmission Fluid
''DEXRON™,, type or equivalent.
SST280B
SST476C
• Check lines for improper attachment, leaks, cracks,

• Check rack boots for accumulation of power steering fluid.
MA-50
lubricating locks, Hinges and Hood latches
/ Hatchback
•
"
S.d"
m
~
__ m__
MMA106A
Checking Seat Belts, Buckles, Retractors,

Anchors and Adjusters
CAUTION:
• After any collision, inspect all seat
belt assemblies, including retractors
and other attached hardwares (i.e.
guide rail set). Nissan recommends
to replace all seat belt assemblies Check anchors for
in use during a collision, unless not loose mounting.
damaged and properly operating after
minor collision.
Also inspect seat belt assemblies not
in use during a collision, and replace
if damaged or improperly operating.
• If any component of seat belt
assembly is questionable,
do not repair.
Replace as seat belt assembly.
• If webbing is cut, frayed, or damaged,
replace belt assembly.
• Never oil tongue and buckle.
• Use a genuine seat belt assembly.
For seat belt pre.tensioner,

refer to section RS.
Check function of
Anchor bolt buckles and tongues
tcJ 43 • 55 N.m when buckled
(4.4 • 5.6 kg-m, and released.
32 • 41 ft.lb)
MMA107A
MA-51
Checking Body Corrosion

Visually check the body sheet metal panel for corrosion, paint damage (scratches, chipping, rubbing,
etc.) or damage to the anti-corrosion materials. In particular, check the following locations.
Hemmed portion
Hood front end, door lower end, trunk lid rear end, etc.
Panel joint
Side sill of rear fender and center pillar, rear wheel housing of rear fender, around strut tower in engine
compartment, etc.
Panel edge
Trunk lid opening, sunroof opening, fender wheelarch flange, fuel filler lid flange, around holes in panel,
etc.
Parts contact
Waist molding, windshield molding, bump.er, etc.
Protectors
Damage or condition of mudguard, fender protector, chipping protector, etc.
Anti-corrosion materials
Damage or separation of anti-corrosion materials under the body.
Drain holes
Condition of drain holes at door and side sill.
When repairing corroded areas, refer to the Corrosion Repair Manual.
MA-52
SERVICE DATA AND SPECIFICATIONS (SOS)
Engine Maintenance
INSPECTION AND ADJUSTMENT Engine oil capacity (Refill capacity)
•
Unit: r (Imp qt)
Drive belt deflection
GA14DE engine except for Europe With oil filter change 3.2 (2-7/8)
Unit: mm (in) Without oil filter change 2.8 (2-1/2)

Deflection of
Deflection Coolant capacity (Refill capacity)
Limit after adjust- new belt
ment With reservoir tank
Unit: ( (Imp qt)
Alternator
With air
6- 7 55 - 6.5
conditioner 10 (0.39) M/T 5.9 (5-1/4) 5.6 (4-7/8)
(0.24 - 0.28) (0.217 - 0.256)
compressor
A/T 6.4 (5-5/8) 6.1 (5-3/8)
Without air
7- 9 6- 8
conditioner 11 (0.43)
(0.28 - 0.35) (0.24 - 0.31)
compressor Spark plug
Power steering 4- 6 3- 5
7.5 (0.295)
oil pump (0.16 - 0.24) (0.12 - 0.20) GA16DE & GA14DE GA16DE & GA15DE
engine for Europe engine except for
Applied pushing
98 N (10 kg, 22 Ib) and Israel Europe and Israel
force
Type
Standard BKR5E BKR5E-11

GA14DE engine for Europe
BKR6E-11,
Unit: mm (in) Cold BKR6E, BKR7E
BKR7E-11
0.8 - 0.9 1.0 - 1.1
Deflection of Plug gap mm (in)
Deflection (0.031 - 0.035) (0.039 - 0.043)
ment
Alternator
With power
11 (0.43)
steering
7- 9 6- 8
Without (0.28 - 0.35) (0.24 - 0.31)
power steer- 10 (0.39)
ing
Air conditioner 6- 8 5- 7
9.5 (0.374)
compressor (0.24 - 0.31) (0.20 - 0.28)
Power steering 4- 6 3- 5
75 (0.295)
oil pump (0.16 - 0.24) (0.12 - 0.20)
Applied pushing
98 N (10 kg, 22 Ib)
force
MA-53
Engine Maintenance
Unit: f (Imp qt)
Unit: mm (in) With oil filter change 3.4 (3)
ment
Coolant capacity (Refill capacity)
Alternator
With reservoir tank
With air con-
11.5-12.5 7- 8 6.5 - 7.5 Unit: f (Imp qt)
ditioner com-
(0.453 - 0.492) (0.28 - 0.31) (0.256 - 0.295)
pressor With heater Without heater
Without air MIT 6.1 (5-3/8) 5.8 (5-1/8)
12 - 13 8-9 7- 8
conditioner
(0.47 - 0.51) (0.31 - 0.35) (0.28 - 0.31) AIT 6.6 (5-718) 6.3 (5-1/2)
compressor
Reservoir tank 07 (5/8)
Power steering 6 - 7 4-5 3.5 - 4.5
oil pump (0.24 - 0.28) (0.16 - 0.20) (0.138 - 0.177)
Applied pushing
98 N (10 kg, 22 Ib) Spark plug (Platinum-tipped type)
force
Make NGK
Type
Standard PFR58-11
PFR68-11
Alternative
PFR78-11
MA-54
SERVICE DATA AND SPECIFICATIONS (50S)
Engine Maintenance
Unit: [ (Imp qt) •
Unit: mm (in) Without oil filter 46 (4)
With oil filter 51 (4--1/2)

Injection nozzle
ment
Unit: kPa (bar, kg/cm', psi)
11 - 13 9 - 11
Alternator 14 (055) Injection pressure 12,749 (127.5, 130, 1,849)
(0.43 - 0.51) (0.35 - 0.43)
Air conditioner 11 - 13 9 - 11
14 (0.55)
compressor (0.43 - 0.51) (0.35 - 0.43)
Idle speed
Power steer- 5- 7 4- 6 Unit: rpm
8 (0.31)
ing oil pump (0.20 - 0.28) (0.16 - 0.24)
Standard
Water pump
without power - 8 (0.31) 6 (0.24) M/T 700 'go 800'
steering ': Air conditioner "ON"
Applied push-
98 N (10 kg, 22 Ib)
ing force
TIGHTENING TORQUE
Unit N'm kg-m ft-Ib in-Ib
Coolant capacity (Refill capacity)
Manifold nuts &
Unit: f (Imp qt) 18 - 22 1.8 - 2.2 13 - 16
bolts
With heater 5.2 (4-5/8) Rocker cover
2- 4 0.2 - 0.4 1.4 - 2.9 17 - 35
Without heater 49 (4-3/8) screw
Reservoir tank 0.7 (5/8) Alternator, power

steering mounting 62 - 75 6.3 - 76 46 - 55
bolt
Cooling system check Alternator, power

Unit: kPa (bar, kg/cm', psi) steering adjuster 16 - 21 1.6 - 2.1 12 - 15
lock bolt
Radiator cap relief pressure
Cylinder block
78 - 98 54 - 74 5.5 - 7.5 40 - 54
Standard drain plug
(0.78 - 0.98, 08 - 1.0, 11 - 14)
Engine oil pan
59 - 98 29 - 39 3.0 - 4.0 22 - 29
Limit drain plug
(0.59 - 0.98, 06 - 10, 9 - 14)
Injector (To head) 59 - 69 6.0 - 7.0 43 - 51
Radiator testing pressure 157 (1.57, 1.6,23)
Spill tube 39 - 49 4.0 - 5.0 29 - 36
Delivery tube 22 - 25 2.2 - 2.5 16 -18
MA-55
Chassis and Body Maintenance

INSPECTION AND ADJUSTMENT
Wheel balance
Dynamic
Maximum (At rim flange) 10 (0.35) (one side)
allowable g (oz)
unbalance
Static g (oz) 20 (0.71)
MA-56
ENGINE MECHANICAL
SECTION EM •
CONTENTS
PRECAUTIONS 3 SR
Parts Requiring Angular Tightening 3
OUTER COMPONENT PARTS 59
Liquid Gasket Application Procedure 3
COMPRESSION PRESSURE 62
PREPARATION 4
Measurement of Compression Pressure 62
Special Service Tools 4
OIL PAN 63
Commercial Service Tools 8
Removal 63
Installation , 66
GA TIMING CHAIN 68
OUTER COMPONENT PARTS 9 Removal 69
COMPRESSION PRESSURE 15 Inspection 73
Measurement of Compression Pressure 15 Installation , 73
OIL PAN 16 OIL SEAL REPLACEMENT 82
Removal 16 ACCEL-DRUM UNIT 84
installation 17 CYLINDER HEAD 85
TIMING CHAIN 18 Removal 86
Removal. 20 Disassembly 86
Inspection 23 Inspection 88
Installation 23 Assembly 93
OIL SEAL REPLACEMENT 30 Installation , 97
CYLINDER HEAD 32 ENGINE REMOVAL 98
Removal 34 RemGval 99
Disassembly 34 Installation " 100
Inspection 34 CYLINDER BLOCK 101
Assembly 40 Disassembly 102
Installation 40 Inspection , 102
VALVE CLEARANCE 41 Assembly 109
Checking 41
Adjusti ng 41 CD
ENGINE REMOVAL .44
OUTER COMPONENT PARTS 113
Removal 45
COMPRESSION PRESSURE 115
Ins ta IIat ion " 46
OIL PAN 118
CYLINDER BLOCK 47
Removal 118
Disassembly 48
Installation 118
Inspection 48
Assembly 55
CONTENTS (Conl'd.)
TIMING BELT 120 GA

Camshaft Timing Belt 120
Injection Pump Timing Belt 124
General Specifications , 155
OIL SEAL REPLACEMENT 126
Inspection and Adjustment. 156
CYLINDER HEAD 128
Removal 129
SR
Disassembly 129
Inspection 130 SERVICE DATA AND SPECIFICATIONS (505) 163
Assembly 136 General Specifications 163
Installation 137 Inspection and Adjustment. 163
ENGINE REMOVAL 140
CYLINDER BLOCK 143 CD
Preparation 144
SERVICE DATA AND SPECIFICATIONS (50S) 171
Disassembly 144
Inspection and Adjustment.. 171
Inspection 145
Assembly 152
PRECAUTIONS
Parts Requiring Angular Tightening

• Use an angle wrench for the final tightening of the follow-
ing engine parts:
(1) Cylinder head bolts
(2) Main bearing cap bolts (SR engine only)
(3) Connecting rod cap nuts (SR and CD engine)
• Do not use a torque value for final tightening. •
• The torque values for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with
engine oil.
Liquid Gasket Application Procedure

a. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
Inner
side b. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket or equivalent.)
• For oil pan, be sure liquid gasket diameter is 4.0 to 5.0
mm (0.157 to 0.197 in) for SR engine. Be sure liquid
gasket diameter is 3.5 to 4.5 mm (0.138 to 0.177 in) for
GA and CD engine.
SEM164F
• For areas except oil pan, be sure liquid gasket diame-
ter is 2.0 to 3.0 mm (0.079 to 0.118 in).
c. Apply liquid gasket to inner surface around hole perimeter
area.
d. Assembly should be done within 5 minutes after coating.
e. Wait at least 30 minutes before refilling engine oil and
engine coolant.
EM.3
PREPARATION
Engine
Tool number application
Description
Tool name
GA SR CD
ST0501S000 When overhauling engine

Engine stand assem-
bly
G) ST05011000
Engine stand X X X
@ ST05012000
Base
NT042
KV10106500 When overhauling engine

Engine stand shaft
X
NT028
~
KV10115300 When overhauling engine
Engine sub-attach-
ment X
~
NTOO8
Engine attachment When overhauling engine

assembly
G) KV10106500
Engine attach-
ment
X
@ KV10113300
Sub-attachment
NT029
G) KV10108101 When overhauling engine

Engine attach-
ment
KV10106500
1
Engine stand
X
shaft
or
@ KV10102500 ~
Engine stand
shaft NT366
ST10120000 Loosening and tightening

Cylinder head bolt
wrench
b cylinder head bolt
a; 13 (0.51) dia.
X X
b: 12 (0.47)
c: 10 (0.39)
~~
NT583 C Unit: mm (in)
EM.4
PREPARATION
Special Service Tools (Cont'd)
Engine
Description
Tool name
GA SR CD
KV10116200 Disassembling and
Valve spring assembling valve
•
compressor mechanism
CD KV10115900 X X
Attachment
NT022
KV101092S0 Disassembling and

Valve spring assembling valve
compressor mechanism
0
CD KV10109210 0
Compressor X
@ KV10109220
Adapter
NT021
KV10115600 Installing valve oil seal

Valve oil seal drift
-HaP
c d
Side A Side B
a: 20 (0.79) 20 (0.79)
X X
Side A b: 13 (0.51) 14.2 (0.559)
(Side (Side
a c: 10.3 (0.406)
d: 8 (0.31)
11 (0.43)
8 (0.31)
A) A)
e f e: 10.7 (0.421) 10.7 (0.421)

f: 5 (0.20) 5 (0.20)
NT603 Unit: mm (in)
KV10107902 Removing valve oil seal
Valve oil seal puller
CD KV10116100
Valve oil seal X X X
puller adapter
I ~
\
~
'...:_.~---/
./
NT605
KV10115700 Adjusting shims

Dial gauge stand
NT012
0 X
KV101151SO Changing shims

Lifter stopper set
CDKV10115110
Camshaft pliers
@ KV10115120
@t as l J
:~
X
Lifter stopper
F &)
NT041
EM-5
PREPARATION
Engine
Description
Tool name
GA SR CD
EM03470000 Installing piston assembly

Piston ring compres- into cylinder bore
sor X X X
~
NT044
KV10107400 Disassembling and

Piston pin press assembling piston pin
stand
G) KV10107310
Center shaft
@ ST13040020
Stand X X
@ ST13040030
Spring
@ KV10107320
Cap
@ ST13040050
Drift NT013
KV10109300* Removing and installing

Pulley holder 0 camshaft sprocket
X
a
a: 68 mm (2.68 in)
b b: 8 mm (0.31 in) dia.
NT628
ED19600000* Measuring compression

Compression gauge pressure
set
X
p'
NT626
KV11100300* Loosening and tightening
(J
Nozzle holder socket injector nozzle
NT563
KV10111100 Removing oil pan

Seal cutter
X X X
NT046
~
WS39930000 Pressing the tube of liquid
Tube presser gasket
X X X
NT052
*: Special tool or commercial equivalent
EM-6
PREPARATION
Engine
Tool number
Description application
Tool name
GA SR CD
KV10112100 Tightening bolts for bear-

Angle wrench ing cap, cylinder head,
etc.
x x
NT014
ST16610001* Removing pilot bushing

Pilot bushing puller
x X
NT045
KV11102900* Removing injection pump

Pulley puller pulley
NT647
KV101056S0* Preventing crankshaft

Ring gear stopper from rotating
G) KV10105630
a: 3 (0.12)
Adapter
b: 6.4 (0.252)
@ KV10105610
c: 2.8 (0.110)
Plate assembly
d: 6.6 (0.260)
x
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
NT617 Unit: mm (in)
*: Special tool or commercial equivalent
EM-7
PREPARATION
Commercial Service Tools
Engine
Tool name Description application
GA SR CD
Spark plug wrench Removing and installing
NT047
Q
16 mm
(0.63 In)
0 spark plug
X X
Valve seat cutter set Finishing valve seat

dimensions
X X X
~
NT048
Piston ring expander Removing and installing

piston ring
X X X
~
NT030
Valve guide drift Removing and installing

valve guide
'~ SR
a =
Intake
9.5 mm
& Exhaust
(0.374 in) dia.
X X
b = 5.0 mm (0.197 in) dia.
GA Inlake & Exhaust
a = 9.5 mm (0.374 In) dla.
NT015 b = 5.5 mm (0.217 in) dla.
Valve guide reamer Reaming valve guide G)

or hole for oversize valve
guide @
d, \J SR Intake & Exhausl

d, = 6.0 mm (0.236 in) dia. X X
d, = 10.175 mm (0.4006 in)
~ @ dia.
GA Intake & Exhausl
d, = 5.5 mm (0.217 in) dia.
d, = 9.685 mm (0.3813 in)
NT016 dia.
Front oil seal drift Installing front oil seal
X X
a = 75 mm (2.95 In) dla.
NT049 b = 45 mm (1.77 in) dia.
Rear oil seal drift Installing rear oil seal
X X
a = 110 mm (4.33 In) dla.

NT049 b = 80 mm (3.15 in) dia.
EM-8
OUTER COMPONENT PARTS
GA16DE WITHOUT VTC, 14DE AND 15DE
SEC. 140.150.210.211.220.221.253
•
CIDco:J 19.6 • 29.4 (2.00 .3.00, 14.46 • 21.69)~
-Q;Jj
Si ""~ /4J 0/)'
l
~ 15.7 • 20.6 (1.60 • 2.10,11.58 - 15.19) ~ff?~~
1ii]•. 28 • '.34 '0.'" • 0.851, 55.' • 73.9)/ ijJ'.28 - '.34 (0.'" • 0.851, 55.' • 73.9)
[jJ : N.m (kg-m, in-Ib)
~ : N.m (kg-m, fHb)
~ : Apply liquid gasket.
SEM060FA
G) Oil pressure switch @ Thermal transmitter (J) Oi I filter

@ Distributor @ Intake manifold @ Thermostat
@ Spark plug @ Intake manifold supports @ Water pump
EM-9
GA16DE WITHOUT VTe, 14DE AND 15DE

SEC. 140-147-163-164
GA15DE
tOJ : N.m (kg-m, ft-Ib)
iii : N'm (kg-m, in-Ib)
* Throttle body bolts tightening procedure

1) Tighten all bolts to 9 to 11 N. m (0.9 to 1.1 kg-m, 6.5 to 8.0 fl-Ib)
2) Tighten all bolts to 18 to 22 N'm (1.8 to 2.2 kg-m, 13 to 16 ft-Ib)
Engine A
Iront y
Tighten in numerical order. Tighten in numerical order.
SEM220F
CD Throttle position sensor @ Engine coolant temperature @l Pressure regulator

@ Mass air flow sensor sensor @ EGR valve (GA15DE
IJ) Air relief plug M/T model only)
@ IACV-AAC valve
@ Injector @ Intake manifold
@ IACV-FICD solenoid valve
@ Injector tube @ IACV-AAC valve (GA15DE
@ Throttle body
engine models only)
EM-10
GA16DE WITH VTC

SEC. 130.140.150.210.211.221.226.253 ~
~ ,... -26.5 {2.1' - '.70, :5.19_19.5Sl-\,,4

r
COJ 15.7 - 20.6
~ 9 -
COJ 15.7 - 20.6 (1.60 - 2.10, 11.58 - 15.19)

~~~/~ ->
* : Refer to "Tightening Order".
~: N.m (kg-m. ft-Ib) .f' !il6.28 _ 8.34 (0.641 - 0.851, 55.6 - 73.9)
~: N.m (kg-m. in-Ib) ~ 6.28.8.34 (0.641 - 0.851, 55.6 - 73.9)-.1
SEM223F
G) Oil pressure switch @ VTC solenoid valve (J) Water pump

@ Knock sensor @ Intake manifold gasket @ Thermostat housing
@ Distributor @ Intake manifold assembly @ Thermostat
EM-11
GA16DE WITH VTC
SEC. 140.163.164
~ 1st. 7.85 • 10.8

(0.8. 1.1, 5.8.8.0)
SEM064FB
G) Intake manifold collector @ Collector gasket (J) Pressure regulator

@ Gasket @ Fuel gallery assembly @ Intake manifold gasket
@ Throttle body @ Insulator @ Intake manifold
EM-12
Tightening order
* Intake manifold collector bolts tightening order *Intake manifold bolts and nuts tightening order
•
Tighten in numerical order. Tighten in numerical order.
*Throttle body bolts tightening procedure

1) Tighten all bolts to 8.8 to 10.8 N.m (0.90 to 1.10 kg-m, 6.5 to 8.0 ft-Ib)
2) Tighten all bolts to 17.7 to 21.6 N.m (1.81 to 2.20 kg-m, 13.06to 15.93 ft-Ib)
• Make sure the direction of the gasket is as shown in figure.
o o
,,-0
Gasket
Tighten in numerical order
SEM066FB
EM-13
SEC. 120-140-147-210
Front
4
For Australia
Except for Australia

SEC. 140-208-226 P::~ 40 • 50 (4.1 • 5.1, 30 • 37)
~29-34
'r • , t::~ (3.0 - 3.5, 22 - 25)
L Ji
f'~~~
~37'~
I'!
(0.38 - 0.51,
330 - 443)
~
c
-
~
r
-____
~
r
J
~
~Q;f;~
O'-rlng~L"'}. J)
~l
r
~ r.e.t
tf -------
~ 3.7 - 5.0
(0.38 • 0.51,
330-4431
[O;J 16 - 21 _ y-' "
(1.6 - 2.1, ~
12 • 15) '\
---
,-"
~~~I
!il',0 _
(0.92 -1.2,
,,+ · <1J1'>:t;)
-- -
79.9 _ 104.2).../
. •
~1iI3.7
to.] 16 - 21
(1.• - 2.1, 12 - 15)
- 5.0
Tighten in
numerical order.
~ : N.m (kg-m, ft-Ib)

rrTl (0.38 • 0.51,
1iI : N'm (kg-m, in-Ib)
~-~ 29 - 34 (3.0 • 3.5, 22 • 25) 33.0 • 44.3)
a: Apply liquid gasket.
SEM242F
G) Crankshaft pulley @ Water outlet • Oxygen sensor

@ Gusset IJ) Water drain plug (Except Australia AIT models
@ • Heated oxygen sensor and Europe models)
@ Gasket
(Australia AIT models and @ Three-way catalyst
@ Exhaust manifold
Europe models)
@ EGR tube
EM-14
COMPRESSION PRESSURE
Measurement of Compression Pressure

1. Warm up engine.
2. Turn ignition switch off.
3. Cut fuel line.
Release fuel pressure.
Refer to "Releasing Fuel Pressure" in EC section. •
4. Remove all spark plugs.
5. Disconnect distributor center cable.
6. Attach a compression tester to NO.1 cylinder.
7. Depress accelerator pedal fully to keep throttle valve wide
open.
8. Crank engine and record highest gauge indication.
9. Repeat the measurement on each cylinder as shown above.
• Always use a fully-charged battery to obtain specified
engine revolution.
20 mm (O.79 In) dls.
Compression pressure:
Unit: kPa (bar, kg/cm2, psi)/rpm
Use compressor tester whose end (rubber Compression

portion) is less than 20 mm (0.79 in) dia. Difference limit
ratio
Otherwise, it may be caught by cylinder Standard Minimum between cylin-
head during removal. Refer to SOS
ders
(EM-155).
SEM387C
1,324 (13.24, 1,128 (11.28,
9.5
13.5, 192)/350 11.5, 164)/350
1,353 (1353, 1,157 (11.57, 98 (0.98, 1.0, 14)/
9.8
13.8, 196)/350 11.8, 168)/350 350
1,373 (13.7, 14, 1,177 (11.8,12,
9.9
199)/350 171)/350
10. If compression in one or more cylinders is low:

a. Pour a small amount of engine oil into cylinders through
spark plug holes.
b. Re-test compression,
• If adding oil helps compression, piston rings may be worn
or damaged. If so, replace piston rings after checking pis-
ton.
• If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valve and valve seat. Refer
to SOS (EM-156, 159). If valve or valve seat is damaged
excessively, replace them.
• If compression stays low in two cylinder that are next to
each other:
The cylinder head gasket may be leaking, or
both cylinders may have valve component damage.
Inspect and repair as necessary.
EM-15
OIL PAN
SEC. 110
SEM070FA
Removal
1. Remove undercovers.
2. Drain engine oil.
3. Remove front exhaust tube. Refer to "Exhaust system" in FE
section.
4. Remove center member.
5. Remove engine front and rear gussets.

6. Remove engine lower rear plate (AfT models).
7. Remove oil pan.

(1) Insert Tool between cylinder block and oil pan.
• Be careful not to damage aluminum mating face.
• Do not insert screwdriver, or oil pan flange will be
deformed.
(2) Slide Tool by tapping its side with a hammer, and remove
oil pan.
EM-16
Oil PAN
Installation
1. Before installing oil pan, remove all traces of liquid gasket
from mating surface using a scraper.
• Also remove traces of liquid gasket from mating surface of
cylinder block.
SEM295C
2. Apply a continuous bead of liquid gasket to mating surface

•
of oil pan.
• Use Genuine Liquid Gasket or equivalent.
Cut here.
• Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide.
7 mm (0.28 in) • Apply liquid gasket to inner sealing surface as shown in
figure.
-1 ~ • Attaching should be done within 5 minutes after coating.
•
liquid gasket
Inner
side
3. Install oil pan.

Q Engine front
• Tighten oil pan bolts in the numerical order.
@ @ CV @ @ • Wait at least 30 minutes before refilling engine oil.
~ ==O=O=O~o
4. Install other removed parts in the reverse order of removal.
@o~L-J~\
~~C:;;;}Oc=J/
~ =:J Of
I
I
i
_/o@ %
~
([Do :=JODI I o@
~\I JL.-=o=o 0
~ = 0 ~--- <:::::==
(j) CID CD W @
SEM072F
EM-17
TIMING CHAIN
WITH VTC
SEC. 111.120.130.135
~~
\£It''J 132.' .152 .• (13.... 15.... 97.&6.112.12)
SEM069FB
CD Upper timing chain (J) Idler sprocket @ Crankshaft sprocket

@ Upper timing chain tensioner @ Lower timing chain tensioner @ Oil pump drive spacer
@ VTC camshaft sprocket (Intake) @ Gasket @ Front cover
@ Camshaft sprocket (Exhaust) @) Slack side timing chain guide @ Oil seal
@ O-ring @ Timing chain tension guide @ Crankshaft pulley
@ Idler shaft @ Lower timing chain @ Cylinder head front cover
EM-18
TIMING CHAIN
WITHOUT VTC
SEC. 111.120.130.135
~: N.m (kg-m, in-lb)

~ : N'm (kg-m, ft-Ib)
fJ : Lubricatewith new
engineoil.
SEM068FA
G) Upper timing chain (j) Idler sprocket @ Crankshaft sprocket

@ Upper chain tensioner @ Lower chain tensioner @ Oil pump drive spacer
@ Camshaft sprocket (Intake) @ Gasket @) Front cover
@ Camshaft sprocket (Exhaust) @ Slack side timing chain gUide @ Oil seal
@) a-ring @ Timing chain guide @ Crankshaft pulley
@ Idler shaft @ Lower timing chain @ Cylinder head front cover
EM-19
TIMING CHAIN
CAUTION:
• After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.
• When installing camshafts, chain tensioner, oil seals, or
other sliding parts, lubricate contacting surfaces with new
engine oil.
• Apply new engine oil to bolt threads and seat surfaces when
installing cylinder head, camshaft sprocket, crankshaft
pulley, and camshaft brackets.
Removal
1. Drain engine coolant from radiator and cylinder block.
Be careful not to spill coolant on drive belts.
2. Release fuel pressure. '
Refer to "Releasing Fuel Pressure" in EG section.
3.. Remove the following belts.
• Power steering pump drive belt
• Alternator drive belt
4. Remove power steering pulley and pump with bracket.
5. Remove air duct to intake manifold collector.
6. Remove front right-side wheel.
7. Remove front right-side splash cover.
8. Remove front undercovers.
9. Remove front exhaust tube.
10. Remove cylinder head front mounting bracket.
11. Remove rocker cover.

Without
12. Remove distributor cap.
VTC
14. Remove intake manifold support.
15. Set NO.1 piston at TOG on its compression stroke.
EM-20
TIMING CHAIN @KJ
Removal (Cont'd)
• Make sure No.1 cylinder is at TDC by looking at distributor
rotor position.
16. Remove distributor.
17. Remove cylinder head front cover.
18. Remove water pump pulley.
19. Remove thermostat housing.

•
20. Remove lower chain tensioner.
21. Remove upper chain tensioner.

22. Loosen idler sprocket bolt.
23. Remove camshaft sprocket bolts.
24. Remove camshaft sprockets.
25. Remove camshaft brackets and camshafts.
• These parts should be reassembled in their original posi-
tions.
• Bolts should be loosened in two or three steps.
26. Remove idler sprocket bolt.
27. Remove cylinder head with manifolds.

• Head warpage or cracking could result from removing in
incorrect order.
• Cylinder head bolts should be loosened in two or three
steps.
28. Remove idler sprocket shaft from rear side.
29. Remove upper timing chain.
31. Remove oil pan. Refer to "Removal" in "OIL PAN" (EM-16).
Loosen in numerical order. 32. Remove oil strainer.
SEM546D 33. Remove crankshaft pulley.
34. Support engine with a suitable hoist or jack.
EM-21
TIMING CHAIN
Removal (Coni' d)
35. Remove engine front mounting.
36. Remove engine front mounting bracket.
37. Remove front cover bolts and front cover as shown.

*1: Located on engine front mounting bracket
*2: Located on water pump
*3: Located on power steering pump adjusting bar
SEM081F
38. Remove idler sprocket.

39. Remove lower timing chain.
40. Remove oil pump drive spacer.
41. Remove chain guides.
Slack side 42. Remove crankshaft sprocket.
chain gUide
EM-22
TIMING CHAIN
Inspection
Check for cracks and excessive wear at roller links. Replace if
necessary.
SEM1190
No. 1 cylinder at TDC Installation

1. Position crankshaft so that No. 1 piston is at TOC and key
way is at 12 o'clock.
a. Install crankshaft sprocket.
• Make sure mating marks on crankshaft sprocket face front
of engine.
b. Install oil pump drive spacer.
SEM377CC
2. Install chain guide.

3. Install crankshaft sprocket and lower timing chain.
• Set timing chain by aligning its mating mark with the one on
/ Same number link crankshaft sprocket.
/// • Make sure sprocket's mating mark faces engine front.
• The number of links between alignment marksare the same
40 rollers- --40 rollers for the left and ri.Qht sides. Either side can be used during
alignment with the sprocket.
• : Mating mark (different color)

SEM127F
EM-23
TIMING CHAIN ~
Installation (Cont'd)
4. Before installing front cover, remove all traces of liquid
gasket from mating surface using a scraper.
cylinder block.
SEM083F
5. Apply liquid gasket to front cover.

6. Install front cover.
• Check alignment of mating marks on chain and crankshaft
sprocket.
• Align oil drive spacer with oil pump.
• Place timing chain to the side of chain guide. This prevents
the chain from making contact with water seal area of front
cover.
• Make sure two O-rings are present.
Front cover • Be careful not to damage oil seal when installing front
SEM110F cover.
7. Install engine front mounting bracket and mounting.

8. Install oil strainer.
9. Install oil pan. Refer to "Installation" in "OIL PAN" (EM-16).
10. Install crankshaft pulley.
Position 11. Install center member.
for
O-ring
SEM122D
12. Set idler sprocket by aligning the mating mark on the larger
sprocket with mating mark on the lower timing chain.
13. Install upper timing chain and set it by aligning mating
marks on the smaller sprocket with mating mark on upper
timing chain.
• Make sure sprocket's mating mark faces engine front.
14. Install idler sprocket shaft from the rear side.
Idler
sprocket
Lower
timing chain
Upper
timing chain
•. Mating mark (different color)

SEM126F
EM-24
TIMING CHAIN []K]
15. Install cylinder head with new gasket.
• Be sure to install washers between bolts and cylinder head.
• Do not rotate crankshaft and camshaft separately, or valves
Cylinder head bolt washer
will strike piston heads.
0__0 • Apply new engine oil to cylinder head bolt threads and seat
surfaces.
•
Cylinder head side
•
SEM877A
• Tightening procedure
@ Tighten bolts to 29.4 N'm (3 kg-m, 22 ft-Ib).
@ Loosen bolts completely.
@ Turn bolts 50 to 55 degrees clockwise or if angle wrench is
not available, tighten bolts to 58.8:1:4.9 N'm (6:1:0.5 kg-m,
43.4:1:3.6 ft-Ib).
CD Tighten bolts (@ - @) to 6.3 to 8.3 N'm (0.64 to 0.85 kg-m,
Tighten in numerical order.
55.6 to 73.8 in-Ib).
SEM124D
Tightening torque N'm (kg-m, ft-Ib)
@ @ @ @ @,CD
50 - 55
~ 58.8 (6, 43) degrees or
Ol
"" Bolts 58.8:1:4.9

E 29.4 (3, 22) 58.8 (6, 43) 0(0,0) 29.4 (3, 22)
z ((1) - @») (6:1:0.5,
~ 29.4 (3, 22) 43.4:1: 3.6
E!" ft-Ib)
2
Ol
c 6.3 - 8.3
'c
QJ
Bolts (0.64 -
.E
Cl
o - - - -
i= (@ - @) 0.85,55.6 -
SEM614EA
73.8 in-Ib)
16. Install idler sprocket bolt.
17. Install camshaft.

Intake Exhaust
• Make sure camshafts are aligned as shown in figure.
SEM547D
EM-25
TIMING CHAIN
• Identification marks are present on camshafts.
18. Install camshaft brackets and distributor bracket.

Intake side
• Make sure camshaft brackets are aligned as shown in fig-
ure.
o~ ~ ~NO.5~
L
~ ~No. 4 ~
~
"\J;;\
"'DNo. 3" ~
No. 2 ~V~NO'
~~FronOt mark ~
Front .......,
Exhaust side
SEM549D
• Apply liquid gasket to distributor bracket as shown in the

figure.
Distributor bracket • Apply new engine oil to bolt threads and seat surface.
I~
Apply liquid gasket.
• Tighten camshaft bracket bolts in the following steps.
(Bolt @> is applied only for GA16DE)
rl~FL~~I~~~~
@ Tighten bolts @ - @>, then CD - @).
~: 2.0 N'm (0.204 kg-m, 17.7 in-Ib)
@ Tighten bolts CD - @>.
@ @@
),i
~ .@ /~0l1..0) (
o)(oo~-.'.- o'(!l@ 0
~: 5.9 N'm (0.60 kg-m, 52.1 in-Ib)
@ Tighten bolts CD - @.
@ cID CD~cID oc1) 10 @ ~: 9.8 - 11.8 N'm (1.00 - 1.20 kg-m, 86.8 - 104.2 in-Ib)
Tighten bolt @>.
SEM550D ~: 6.3 - 8.3 N'm (0.64 - 0.85 kg-m, 55.6 - 73.8 in-Ib)
• If any part of valve assembly or camshaft is replaced, check
valve clearance according to reference data.
After completing assembly check valve clearance. Refer to
"Checking" and" Adjusting" in "VALVE CLEARANCE" (EM-
41).
Reference data valve clearance (Cold):
Intake
0.25 - 0.33 mm (0.010 - 0.013 in)
Exhaust
0.32 -0.40 mm (0.013 - 0.016 in)
EM-26
TIMING CHAIN @K]
19. Assemble camshaft sprocket with chain.
• Set timing chain by aligning mating marks with those of
camshaft sprockets.
• Make sure sprocket's mating marks face engine front.
20. Install camshaft sprocket bolts.
• Apply new engine oil to bolt threads and seat surface .
•
16 rollers
• : Mating mark (different color)

SEM129F
21. Install upper chain tensioner.

• Before installing chain tensioner, insert a suitable pin into
pin hole of chain tensioner.
• After installing chain tensioner, remove the pin.
22. Install lower chain tensioner.

CAUTION:
• Check no problems occur when engine is rotated.
• Make sure that No. 1 piston is set at TOC on its compres-
sion stroke.
SEM657D
• Make sure of the direction of the gasket before installing

lower chain tensioner.
2.0.3.0 mm 23. Apply liquid gasket to thermostat housing.

(0.079 - 0.118 In) • Use Genuine Liquid Gasket or equivalent.
24. Install thermostat housing.
25. Install water pump pulley.
EM-27
TIMING CHAIN ~
~Groove rru 26. Install distributor.
• Make sure that position of camshaft is as shown in figure.
rI~~~-"
~~r
J;;! ~
of ~ams~~
-il{~
o' j ~1~1M ~~~

=,-fDistributor - I SEM087F
27. Install cylinder head front cover.

Without VTC
• Apply liquid gasket to cylinder head front cover.
SEM597EA
With VTC
SEM088F
• Tighten bolts and nuts in numerical order as shown in the

Without
VTC
figure.
@o
cID @ @
o o o
SEM089F
Without VTC
Without VTC 2.0 _ 3.0 mm (0.079.0.118 In)
28. Apply liquid gasket to cylinder head.
Cylinderhea~
I $ HI
Rocker cover gasket
Ci ======;;::::::/::J
o gi
SEM090F
EM-28
TIMING CHAIN
Without VTC
29. Apply liquid gasket to rocker cover gasket.
~(0.39)
Engine front
Unit: mm (in)
With VTC
* -\
~1-J--10
3 (0.12)
(0.39)
Z~ Liquid
gasket
SEM59BEA
With VTC
•
Cylinder head 'l:tJ 28. Apply liquid gasket to mating surfaces of the cylinder
and cylinder head front covers shown in the figure.
head
~ / 2.0-3.0mm
Cylinder head front cover (0.079 - 0.118 In)
SEM091F
With VTC 29. Apply liquid gasket to rocker cover gasket.
7~'\
\.....
-4'
~-'?
~'0391
Engine front
*
~10
3 (0.12)
(0.39)
Zr.a--1
liquid
gasket
Unit: mm (in) SEM111F
30. Install rocker cover and tighten in numerical order as shown

Without
in the figure.
VTC
31. Install all spark plugs and leads.
32. Install engine front mounting bracket and mounting.
33. Install front exhaust tube.
With VTC
34. Install front undercover.
35. Install front right.splash cover.
36. Install front right wheel.
37. Install air cleaner.
38. Install power steering pulley and pump with bracket.
To check power steering fluid, refer to MA section ("Check-
ing Power Steering Fluid and Lines", "CHASSIS AND BODY
MAINTENANCE").
39. Drive belts.
For adjusting drive belt deflection, refer to MA section
("Checking Drive Belts", "ENGINE MAINTENANCE").
EM-29
OIL SEAL REPLACEMENT
VALVE Oil SEAL

2. Remove camshaft.
3. Remove valve spring. Refer to "CYLINDER HEAD".
4. Remove valve oil seal with a suitable tool.
KV10l07902
Piston concerned should be set at TOC to prevent valve from
falling.
5. Apply engine oil to new valve oil seal and install it with Tool.
SEM136D
10.5 mm
(0.413 In)
SEM137D
FRONT Oil SEAL

1. Remove the following parts:
• Engine undercover
• Right-side splash cover
• Alternator and power steering drive belts
• Crankshaft pulley
2. Remove front oil seal from front cover.
Be careful not to damage oil seal portion.
• Install new oil seal in the direction shown.
Engine /', ~ Engine

inside Y Youtside
Oil seal lip Dust seal lip
SEM715A
EM-30
3. Apply engine oil to new oil seal and install it using a suit-
able tool.
REAR OIL SEAL

•
1. Remove flywheel or drive plate.
2. Remove rear oil seal retainer.
3. Remove traces of liquid gasket using scraper.
4. Remove seal from rear oil seal retainer.
Be careful not to scratch rear oil seal retainer.
/' SEM096F
Engine /'-l_ _ ~ Engine

inside Y LV outside
SEM715A
able tool.
SEM097F
EM-31
CYLINDER HEAD
WITH VTC
SEC. 111.130
~ : N.m (kg-m, in-Ib)

f] :Lubricate with new
engine oil.
SEM099FB
G) Oil filler cap @ Cylinder head bolt @ Valve oil seal

@ Rocker cover @ Shim @ Valve guide
@ Rocker cover gasket @ Valve lifter @ Cylinder head
@ Oil seal @ Valve cotter @) Cylinder head gasket
@ Camshaft bracket @ Valve spring retainer @) Valve seat
@ Intake camshaft @ Valve spring @ Valve
(J) Exhaust camshaft @ Valve spring seat @ Cylinder head front cover
@ Distributor bracket
EM-32
CYLINDER HEAD
WITHOUT VTC
SEC. 111-130
Ij] . N.m (kg-m, in-Ib)
f) : Lubricate with new engine oil.
SEM244F
G) Oil filler cap @ Cylinder head bolt @ Valve oil seal

@ Rocker cover @) Shim @ Valve guide
@ Rocker cover gasket @ Valve lifter @ Cylinder head
@ Oil seal @ Valve cotter @ Cylinder head gasket
@ Camshaft bracket @ Valve spring retainer @ Valve seat
@ Intake camshaft @ Valve spring @ Valve
(J) Exhaust camshaft @ Valve spring seat @ Cylinder head front cover
@ Distributor bracket
EM-33
CYLINDER HEAD
CAUTION:
• When installing camshaft, oil seals or other sliding parts,
lubricate contacting surfaces with new engine oil.
• When tightening cylinder head bolts, camshaft sprocket
bolts and camshaft bracket bolts, lubricate thread portions
and seat surfaces of bolts with new engine oil.
• Attach tags to valve lifters so as not to mix them up.
Removal
• This removal is the same procedure as those for timing
chain. Refer to "Removal" in "TIMING CHAIN" (EM-20).
Disassembly
1. Remove valve components with Tool.
2.. Remove valve oil seal with a suitable tool.
Inspection
CYLINDER HEAD DISTORTION
Clean surface of cylinder head.
Use a reliable straightedge and a feeler gauge to check the
flatness of cylinder head surface.
Check along six positions shown in figure.
Head surface flatness:
Standard:
Less than 0.03 mm (0.0012 in)
Limit:
0.1 mm (0.004 in)
If beyond the specified limit, replace it or resurface it.
Resurfacing limit:
The resurfacing limit of cylinder head is determined by the cyl-
inder block resurfacing in an engine.
Amount of cylinder head resurfacing is "A".
Amount of cylinder block resurfacing is "8".
The maximum limit is as follows:
A + 8 = 0.2 mm (0.008 in)
After resurfacing cylinder head, check that camshaft rotates
freely by hand. If resistance is felt, cylinder head must be
replaced.
Nominal cylinder head height:
117.8 - 118.0 mm (4.638 .4.646 in)
CAMSHAFT VISUAL CHECK

Check camshaft for scratches, seizure and wear.
EM-34
CYLINDER HEAD
Inspection (Cont'd)
CAMSHAFT RUNOUT
1. Measure camshaft runout at the center journal.
Runout (Total indicator reading):
Standard:
Limit:
SEM154D
2.
CAMSHAFT
0.1 mm (0.004 in)
If it exceeds the limit, replace camshaft.
CAM HEIGHT
•
1. Measure camshaft cam height.
Unit: mm (in)
GA16DE GA16DE
GA16DE
with VTC with VTC
Engine model GA14DE GA15DE without
for Aus- except for
VTC
tralia Australia
39.880 - 39.380 -
40.070 39570 40.610 - 40.800
Intake
39.380 - (1.5701 - (1.5504 - (1.5988 - 1.6063)
SEM549A Standard 39.570 1.5776) 1.5579)
cam height (1.5504 - 40.056 - 39.880 - 39.910 - 40.056 -
1.5579) 40.246 40.070 40.010 40.246
Exhaust
(1.5770 - (1.5701 - (1.5713 - (1.5770 -
1.5845) 1.5776} 1.5752) 1.5845}
Cam wear limit 0.20 (O.0079)
2. If wear is beyond the limit, replace camshaft.
CAMSHAFT JOURNAL CLEARANCE

1. Install camshaft bracket and tighten bolts to the specified
torque.
2. Measure inner diameter of camshaft bearing.
Standard inner diameter:
No. 1 bearing
28.000.28.021 mm (1.1024.1.1032 in)
No. 2 to No. 5 bearings
24.000 • 24.021 mm (0.9449 . 0.9457 in)
3. Measure outer diameter of camshaft journal.

Standard outer diameter:
No.1 journal
27.935.27.955 mm (1.0998 .1.1006 in)
No.2 to No.5 journals
23.935 - 23.955 mm (0.9423 • 0.9431 in)
4. If clearance exceeds the limit, replace camshaft and/or cyl-
inder head.
Camshaft journal clearance:
Standard
0.045 • 0.086 mm (0.0018 • 0.0034 in)
Limit
0.15 mm (0.0059 in)
EM-3S
CYLINDER HEAD rnJ
Inspection (Conf'd)
CAMSHAFT END PLAY
1. Install camshaft in cylinder head.
2. Measure camshaft end play.
Camshaft end play:
Standard
For Europe 0.070 - 0.143 mm (0.0028 - 0.0056 in)
Except for Europe 0.115 • 0.188 mm (0.0045 - 0.0074
in)
Limit
0.20 mm (0.0079 in)
SEM157D
CAMSHAFT SPROCKET RUNOUT

1. Install sprocket on camshaft.
2. Measure camshaft sprocket runout.
Limit 0.1 mm (0.004 in)
3. If it exceeds the limit, replace camshaft sprocket.
SEM158D
VALVE GUIDE CLEARANCE

1. Measure valve deflection in a parallel direction with rocker
arm. (Valve and valve guide mostly wear in this direction.)
Valve deflection limit (Dial gauge reading):
Intake & Exhaust
0.2 mm (0.008 in)
2. If it exceeds the limit, check valve to valve guide clearance.

a. Measure valve stem diameter and valve guide inner diam-
eter.
b. Check that clearance is within specification.
Valve to valve guide clearance:
Unit: mm (in)
Standard Limit
0.020 - 0.050
Intake 0.1 (0.004)
(0.0008 - 0.0020)
SEM938C 0.040 - 0.070

Exhaust 0.1 (0.004)
(0.0016 - 0.0028)
c. If it exceeds the limit, replace valve or valve guide.
EM-36
CYLINDER HEAD []KJ
Inspection (Cont'd)
VALVE GUIDE REPLACEMENT
1. To remove valve guide, heat cylinder head to 110 to 120°C
(230 to 248°F).
SEM008A
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2

•
US ton, 2.0 Imp ton) pressure] or hammer and suitable tool.
3. Ream cylinder head valve guide hole.

Valve guide hole diameter
(for service parts):
Intake & Exhaust
9.685 . 9.696 mm (0.3813 - 0.3817 in)
4. Heat cylinder head to 110 to 120°C (230 to 248°F) and press

service valve guide into cylinder head.
Projection "l":
11.5 - 11.7 mm (0.453 - 0.461 in)
MEM09SA
5. Ream valve guide.

Finished size:
Intake & Exhaust
5.500 - 5.515 mm (0.2165 - 0.2171 in)
EM-37
CYLINDER HEAD
Inspection (Cont'd)
VALVE SEATS
Check valve seats for pitting at contact surface. Resurface or
replace if excessively worn.
• Before repairing valve seats, check valve and valve guide
for wear. If they have worn, replace them. Then correct
valve seat.
• Cut with both hands to uniform the cutting surface.
REPLACING VALVE SEAT FOR SERVICE PARTS

I 1. Bore out old seat until it collapses. Set machine depth stop
I
Recess 1 diameter
so that boring cannot contact bottom face of seat recess in
cylinder head.
2. Ream cylinder head recess.
Reaming bore for service valve seat
Oversize [0.5 mm (0.020 in)]:
Unit: mm (in)
GA16DE without VTC,

Engine model GA 16DE with VTC
SEM795A
14DE and 15DE
30.500 - 30.516
(1.2008 - 1.2014) 31.500 - 31.516
Intake
31.500 - 31.516 (1.2402 - 1.2408)
(1.2402 - 1.2408).
25.500 - 25.516 26.500 - 26.516

Exhaust
(1.0039 - 1.0046) (1.0433 - 1.0439)
.: GA 16DE without VTC
Use the valve guide center for reaming to ensure valve seat will
have the correct fit.
EM-38
CYLINDER HEAD
Inspection (Conl'd)
3. Heat cylinder head to 110 to 120°C (230 to 248°F).
4. Press fit valve seat until it seats on the bottom .
5. Cut or grind valve seat using suitable tool at the specified

•
dimensions as shown in SOS (EM-159).
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition.
Seat face angle "a":
45°15' - 45°45' deg.
Contacting width "W":
Intake
1.06 - 1.34 mm (0.0417 - 0.0528 in)
Exhaust
SEM8928 1.20 - 1.68 mm (0.0472 - 0.0661 in)
T (Margin thickness) VALVE DIMENSIONS

--1,- Check dimensions in each valve. For dimensions, refer to SOS
(EM-156).
ml a When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace valve.
III' ~ o d
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less.
~-
I
-L .\
SEM188A
VALVE SPRING
Squareness
1. Measure "S" dimension.
Out-of-square:
2. If it exceeds the limit, replace spring.
SEM288A
Pressure
Check valve spring pressure.
Pressure: N (kg, Ib) at height mm (in)
Standard
344.42 (35.12, 77.44) at 25.26 (0.9945)
Limit
More than 323.73 (33.01, 72.79) at 25.26 (0.9945)
If it exceeds the limit, replace spring.
EM113
EM-39
CYLINDER HEAD
Inspection (Cont'd)
VALVE LIFTER AND VALVE SHIM
1. Check contact and sliding surfaces for wear or scratches.
SEM160D
2. Check diameter of valve lifter and valve lifter guide bore.

Valve lifter diameter:
29.960 • 29.975 mm (1.1795 • 1.1801 in)
SEM161D
Lifter guide bore diameter:

30.000 - 30.021 mm (1.1811 .1.1819 in)
Clearance between valve lifter and valve lifter guide
0.025 - 0.061 mm (0.0010 - 0.0024 in)
If it exceeds the limit, replace valve lifter or cylinder head
which exceeds the standard diameter tolerance.
SEM162D
Assembly
1. Install valve component parts.
• Always use new valve oil seal. Refer to OIL SEAL
Wide pitch
REPLACEMENT (EM-30).
• Before installing valve oil seal, install valve spring seat.
• After installing valve components, tap valve stem tip with a
Narrow pitch plastic hammer to assure a proper fit.
• Install uneven pitch type spring with its narrow pitch end
o
Cylinder head side
toward cylinder head. (Identification
present.)
color side down, if
SEM638B
Installation
• This installation is the same procedure as those for timing
chain. Refer to "Installation" in "TIMING CHAIN" (EM-23).
EM-40
VALVE CLEARANCE
Checking
Check valve clearance while engine is warm and not running.
3. Set NO.1 cylinder at TOC on its compression stroke.
•
• Align pointer with TOC mark on crankshaft pulley .
• Check that valve lifters on NO.1 cylinder are loose and valve
lifters on NO.4 are tight.
If not, turn crankshaft one revolution (360°) and align as

above.
4. Check only those valves shown in the figure.
1 1 2 2
• Using a feeler gauge, measure clearance between valve

lifter and camshaft.
• Record any valve clearance measurements which are out of
specification. They will be used later to determine the
required replacement adjusting shim.
Valve clearance for checking (Hot):
Intake
0.21 - 0.49 mm (0.008 . 0.019 in)
Exhaust
0.30. 0.58 mm (0.012 - 0.023 in)
5. Turn crankshaft one revolution (360°) and align mark on

crankshaft pulley with pointer.
6. Check those valves shown in the figure.
• Use the same procedure as mentioned in step 4.
7. If all valve clearances are within specification, install the
following parts.
• Rocker cover
• All spark plugs
2 2 4 4
SEM140D
"-
Tool (A} KV10115110
Adjusting
,
Adjust valve clearance while engine is cold.
1. Turn crankshaft, to position cam lobe on camshaft of valve
that must be adjusted upward.
2. Place Tool (A) around camshaft as shown in figure.
Before placing Tool (A), rotate notch toward center of cylinder
head (See figure.), to simplify shim removal later.
CAUTION:
Be careful not to damage cam surface with Tool (A).
SEM141D
EM-41
VALVE CLEARANCE [QKJ
Adjusting (Cont'd)
3. Rotate Tool (A) (See figure.) so that valve lifter is pushed
down.
4. Place Tool (8) between camshaft and valve lifter to retain

valve lifter.
CAUTION:
• 'Tool (B) must be placed as close to camshaft bracket as
possible.
• Be careful not to damage cam surface with'Tool (B).
5. Remove Tool (A).
6. Remove adjusting shim using a small screwdriver and a

magnetic finger.
7. Determine replacement adjusting shim size following for-
mula.
• Using a micrometer determine thickness of removed shim.
• Calculate thickness of new adjusting shim so valve clear-
ance comes within specified values.
R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance
Intake:
N = R + [M - 0.37 mm (0.0146 in)]
Exhaust:
N = R + [M - 0.40 mm (0.0157 in)]
Shims are available in 50 sizes from 2.00 mm (0.0787 in) to 2.98
mm (0.1173 in), in steps of 0.02 mm (0.0008 in).
• Select new shim with thickness as close as possible to cal-
culated value.
SEM145D
Shim
Type A
Indicate
T = 2.68 mm (0.1055 In)
Type B
SEM104F
EM-42
VALVE CLEARANCE []K]
Adjusting (Cont'd)
8. Install new shim using a suitable tool.
• Install with the surface on which the thickness is stamped
facing down.
9. Place Tool (A) as mentioned in steps 2 and 3.

•
10. Remove Tool (B).
11. Remove Tool (A).
12. Recheck valve clearance.
Valve clearance:
Unit: mm (in)
For adjusting For checking
Cold'
Hot Hot
(reference data)
0.32 - 0.40 0.25 - 0.33 0.21 - 0.49

Intake
(0.013 - 0.016) (0.010 - 0.013) (0.008 - 0.019)
0.37 - 0.45 0.32 - 0.40 0.30 - 0.58
Exhaust
(0.015 - 0.018) (0.013 - 0.016) (0.012 - 0.023)
': At a temperature of approximately 20"C (68"F)

Whenever valve clearance are adjusted to cold specifications, check that the
clearances satisfy hot specifications and adjust again if necessary.
EM-43
ENGINE REMOVAL
SEC. 112 ffit"J 44 - 54 (4.5 - 5.5. 33 - 40)
d
GA 15DE and GA 16DE with VTe
except for Australia
u~
to.J 44 • 54 (4.5 • 5.5, 33 • 40)
MIT models ~44. 54

(4.5 . 5.5, 33 . 40)
~
I )-<~ to.J 44 - 54
9
10 ~;:J o (4.5 - 5.5,
33 • 40)
('.~
V~)
'v1( ./'"/$1L[OJ 44 • 54
" / (4.5 • 5.5,
33 - 40)
@(For Europe)
to.J : N'm (kg-m, ft-Ib)

* : Located at front cover. SEM237F
(1) Engine front mounting @ Transaxle mounting @ Center member

@ Cylinder head front mounting @ Transaxle mounting bracket @J Buffer rod bracket
bracket (f) Engine rear mounting @ Buffer rod
@ Engine front mounting bracket @ Dynamic damper (AfT models)
@ Engine rear mounting bracket
EM-44
ENGINE REMOVAL
WARNING:
a. Situate vehicle on a flat and solid surface.
b. Place chocks at front and back of rear wheels.
c. Do not remove engine until exhaust system has completely
cooled off.
Otherwise, you may burn yourself and/or fire may break out
•
in fuel line.
d. For safety during subsequent steps, the tension of wires
should be slackened against the engine.
e. Before disconnecting fuel hose, release fuel pressure from
fuel line.
Refer to "Releasing Fuel Pressure" in EC section.
f. Be sure to hoist engine and transaxle in a safe manner.
g. For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:
• When lifting engine, be sure to clear surrounding parts.
Take special care for accelerator wire casing, brake lines
and brake master cylinder.
• In hoisting the engine, always use engine slingers in a safe
manner.
• In removing drive shaft, be careful not to damage grease
seal of transaxle.
Engine cannot be removed separately from transaxle. Remove
engine with transaxle.
Removal
1. Drain water.
2. Remove hood.
3. Remove battery.
4. Remove reservoir tank and bracket.
5. Remove drive belts.
6. Remove alternator, compressor and power steering oil
pump from engine.
Power steering pump does not need to be disconnected from
power steering tubes.
• Right and left front tires
• Under covers
• Splash covers
• Brake caliper assembly
~: 72 - 97 N'm (7.3 • 9.9 kg-m, 53 • 72 ft-Ib)
Brake hose does not need to be disconnected from brake cali-
per assembly.
Never depress brake pedal.
• Disconnect tie-rod ball joint (RH & LH).
~: 29 - 39 N'm (3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
• RH & LH drive shaft
When removing drive shaft, be careful not to damage transaxle
side grease seal.
EM-45
ENGINE REMOVAL mJ
Removal (Cont'd)
• Disconnect control rod and support rod from transaxle. (M/T
models)
Control rod:
to:J:14 - 18 N.m (1.4 - 1.8 kg-m, 10 - 13 ft-Ib)
Support rod:
to:J:35 - 47 N.m (3.6 - 4.8 kg-m, 26 - 35 ft-Ib)
• Disconnect control cable from transaxle. (A/T models)
• Center member
• Front exhaust tube
• Stabilizer
• Cooling fan
• Radiator
• Cylinder head front mounting bracket
• Remove air duct and disconnect wires, harness, pipes,

hoses and so on.
8. Lift up engine slightly and disconnect or remove all engine
mountings.
When lifting engine, be careful not to hit it against adjacent
parts, especially against brake tubes and brake master cylin-
der.
9. Remove engine with transaxle as shown.
Installation
When installing the engine, adjust the height of buffer rod as
shown. (For M/T)
• Installation is the reverse order of removal.
EM-46
CYLINDER BLOCK
SEC. 110.120
ij] 6.3 • 8.3

(0.641 • 0.851, 55.6 - 73.9)
I] to;J 83.5 • 93.3

(8.51 - 9.51,
61.6 • 68.8)
•
f] to.J 93.3 • 103.1 (9.51 - 10.51, 68.8 - 76.0)
to;J : N. m (kg-m, ft-Ib)

f] :Lubricate with new engine oil.
SEM238F
CD Oil level gauge guide @ Drain plug @ Connecting rod

@ Cylinder block @) Buffer plate @ Connecting rod bearing
@ Rear oil seal retainer @ Top ring @) Connecting rod cap
@ Rear oil seal @ 2nd ring (Only Europe models*) @l Key
@ Rear plate @ Oil ring @ Main bearing
@ Flywheel @ Piston @ Thrust bearing
(J) Rear lower plate @ Snap ring @ Crankshaft
@ Drive plate @ Piston pin @ Main bearing cap
*: Applies to GA 16DE without VTC, 14DE.
EM-47
CYLINDER BLOCK
CAUTION:
• When installing sliding parts (bearings, pistons, etc.), lubri-
cate contacting surfaces with new engine oil.
• Place removed parts such as bearings and bearing caps in
their proper order and direction.
• When installing connecting rod nuts, and main bearing cap
bolts, apply new engine oil to threads and seating surfaces.
Disassembly
PISTON AND CRANKSHAFT
1. Place engine on a work stand.
2. Drain coolant and oil.
3. Remove timing chain.
Refer to "Removal" in "TIMING CHAIN" (EM-20).
4 Remove pistons with connecting rods.

• When disassembling piston and connecting rod, remove
snap ring first, then heat piston to 60 to 70°C (140 to 158°F)
or use piston pin press stand at room temperature.
5. Loosen main bearing cap in numerical order as shown in

the figure.
6. Remove bearing caps, main bearings and crankshaft.
• Before removing bearing caps, measure crankshaft end
play.
Inspection
PISTON AND PISTON PIN CLEARANCE
1. Measure inner diameter of piston pin hole "dp".
Standard diameter "dp":
18.987 - 18.999 mm (0.7475 - 0.7480 in)
AEM023
EM-48
CYLINDER BLOCK ~
Inspection (Conl'd)
2. Measure outer diameter of piston pin "Op".
Standard diameter "Op":
18.989 - 19.001 mm (0.7476 - 0.7481 in)
3. Calculate piston pin clearance.
dp - Op = -0.004 to 0 mm (-0.0002 to 0 in)
If it exceeds the above value, replace piston assembly with
•
pin.
I
Micrometer
AEM024
PISTON RING SIDE CLEARANCE

NG Side clearance:
Top ring
0.040 - 0.080 mm (0.0016 - 0.0031 in)
2nd ring (Only Europe models)
0.030 - 0.070 mm (0.0012 - 0.0028 in)
Max. limit of side clearance:
0.2 mm (0.008 in)
If out of specification, replace piston and/or piston ring assem-
bly.
PISTON RING END GAP

End gap:
Feeler
gauge Top ring
0.20 - 0.35 mm (0.0079 - 0.0138 in)
2nd ring (Only Europe models)
0.37 - 0.52 mm (0.0146 - 0.0205 in)
Ring
Oil ring
0.20 - 0.60 mm (0.0079 - 0.0236 in)
Max. limit of ring gap:
Measuring point
1.0 mm (0.039 in)
SEM8228 If out of specification, replace piston ring. If gap exceeds max-
imum limit with new ring, rebore cylinder and use oversize
piston and piston rings.
Refer to SOS (EM-161).
• When replacing the piston, check the cylinder block surface
for scratches or seizure. If scratches or seizure is found,
hone or replace the cylinder block.
CONNECTING ROD BEND AND TORSION

Bend:
Limit 0.15 mm (0.0059 in)
per 100 mm (3.94 in) length
Torsion:
Limit 0.3 mm (0.012 in)
If it exceeds the limit, replace connecting rod assembly.
EM-49
CYLINDER BLOCK
Inspection (Co nt' d)
SEM003F
CYLINDER BLOCK DISTORTION AND WEAR

Straightedge
Feeler gauge 1. Clean upper face of cylinder block and measure the distor-
tion.
Limit:
0.10 mm (0.0039 in)
2. If out of specification, resurface it.
The resurfacing limit is determined by cylinder head resur-
facing in engine.

Amount of cylinder block resurfacing is "B".
A + B = 0.2 mm (0.008 in)
Nominal cylinder block height
from crankshaft center:
213.95 - 214.05 mm (8.4232 . 8.4271 in)
3. If necessary, replace cylinder block.
SEM102F
PISTON- TO-BORE CLEARANCE

1. Using a bore gauge, measure cylinder bore for wear, out-
of-round and taper.
,,
I
I
GA16DE 76.000 - 76.030 mm (2.9921 - 2.9933 in)
, !
GA14, 15DE 73.600 - 73.630 mm (2.8976 - 2.8988 in)
A Wear limit:
X-V 0.2 mm (0.008 in)
B If it exceeds the limit, rebore all cylinders. Replace cylinder
Unit: mm (In) block if necessary.
SEM166DA Out-of-round (X - Y) standard:
0.015 mm (0.0006 in)
Taper (A - B) standard:
0.01 mm (0.0004 in)
EM-50
CYLINDER BLOCK []K]
Inspection (Cont'd)
2. Check for scratches and seizure. If seizure is found, hone
it.
Cylinder bore • If cylinder block or piston is replaced, match piston grade
grade number with grade number on cylinder block lower surface.
No. 4
Cylinder block
SEM426C
3. Measure piston skirt diameter.

•
Piston diameter "A":
Refer to SDS (EM-161).
Measuring point "a" (Distance from the bottom):
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance "B":
0.015 - 0.035 mm (0.0006 - 0.0014 in)
5. Determine piston oversize according to amount of cylinder
wear.
Oversize pistons are available for service. Refer to SDS (EM-
161).
6. Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter "A".
Rebored size calculation:
D=A+B-C
where,
0: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps and tighten bolts to the specified
torque. This will prevent distortion of cylinder bores.
8. Cut cylinder bores.
• When any cylinder needs boring, all other cylinders must
also be bored.
• Do not cut too much out of cylinder bore at a time. Cut only
0.05 mm (0.0020 in) or so in diameter at a time.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper.
• Measurement should be done after cylinder bore cools
down.
EM-51
CYLINDER BLOCK ~
Inspection (Cont'd)
A B CRANKSHAFT
1. Check crankshaft main and pin journals for score, wear or
cracks.
2. With a micrometer, measure journals for taper and out-of-
round.
Out-of-round (X - V):
y
Less than 0.005 mm (O.0002 in)
Taper (A - B):
Taper: A - B Less than 0.002 mm (O.0001 in)
Out-at-round: X - y
SEM316A
3. Measure crankshaft runout.

BEARING CLEARANCE
• Use Method A or Method B. Method A is preferred because
it is more accurate.
Method A (Using bore gauge & micrometer)
Main bearing
1. Set main bearings in their proper positions on cylinder
block and main bearing cap.
Oil groove
SEM366E
2. Install main bearing cap to cylinder block.

Tighten all bolts in correct order in two or three stages.
3. Measure inner diameter "A" of each main bearing.
4. Measure outer diameter "Om" of each main journal in

crankshaft.
5. Calculate main bearing clearance.
Main bearing clearance = A - Om
Standard:
0.018 . 0.042 mm (O.0007 . 0.0017 in)
Limit: 0.1 mm (O.004 in)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bear-
ing.
EM-52
CYLINDER BLOCK [ill
Inspection (Conl'd)
When grinding crank pin and crank journal:
Main journal and pin journal
a. Grind until clearance is within specified standard bearing
clearance.
b. Fillets should be finished as shown in the figure.
R: 2.3 - 2.5 mm (0.091 - 0.098 in)
R
SEM588A
8. If crankshaft, cylinder block or main bearing is reused

•
~ Front
again, measure main bearing clearance. If the above parts
are all replaced, select thickness of main bearings as fol-
lows:
a. Grade number of each cylinder block main journal is
No. 5 punched on the respective cylinder block. These numbers
Main journal are punched in either Arabic or Roman numerals.
grade number
Cylinder
block
SEM427C
b. Grade number of each crankshaft main journal is punched

on the respective crankshaft. These numbers are punched
in either Arabic or Roman numerals.
Crank journal c. Select main bearing with suitable thickness according to the
grade number following table.
Main bearing grade color:
Main journal
grade number
0 1 2
Crankshaft
journal grade number
SEM436C
0 Black Brown Green
\i1hOle 1 Brown Green Yellow
2 Green Yellow Blue
Front
o,.",,!f0 ~ ~
For example:
Main journal grade number: 1
Crankshaft journal grade number: 2
Q I\}:J Main bearing grade number = 1 + 2 Yellow
Identification color ~
SEM194C
Connecting rod bearing (Big end)

1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque.
3. Measure inner diameter "C" of each bearing.
)=====
.-:::::::======_ ..
;::..----
AEM027
EM-53
CYLINDER BLOCK . @K]
Inspection (Cont'd)
4. Measure outer diameter "Op" of each crankshaft pin jour-
nal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C - Dp
Standard:
0.014 - 0.039 mm (0.0006 • 0.0015 in)
Limit: 0.1 mm (0.004 in)
ing. Refer to step 7 of "BEARING CLEARANCE - Main
bearing" (EM-52).
8. If bearing, crankshaft or connecting rod is replaced with a

new one, select connecting rod bearing according to the
following table.
Connecting rod bearing grade number:
Grade numbers are punched in either Arabic or Roman numer-
als.
Connecting rod bearing

Crank pin grade color
grade color
a
1 Brown
SEM437C
2 Green
Method B (Using plastigage)

CAUTION:
• Do not turn crankshaft or connecting rod while plastigage is
being inserted.
• When bearing clearance exceeds the specified limit, ensure
that the proper bearing has been installed. Then if exces-
sive bearing clearance exists, use a thicker main bearing or
undersized bearing so that the specified bearing clearance
is obtained.
CONNECTING ROD BUSHING CLEARANCE (Small end)

1. Measure inner diameter "C" of bushing.
EM-54
CYLINDER BLOCK ~
Inspection (ConI' d)
2. Measure outer diameter lOOp" of piston pin.
3. Calculate connecting rod bushing clearance.
Connecting rod bushing clearance = C - Dp
Standard:
0.005 • 0.017 mm (0.0002 • 0.0007 in)
Limit:
0.023 mm (0.0009 in) •
If it exceeds the limit, replace connecting rod assembly or con-
necting rod bushing andlor piston pin.
AEM030
REPLACEMENT OF CONNECTING ROD BUSHING (Small

end)
1. Drive in small end bushing until it is flush with end surface
of rod.
Be sure to align the oil holes.
2. Ream the bushing so that clearance with piston pin is within
specification.
Clearance between connecting rod bushing and piston
pin:
0.005 - 0.017 mm (0.0002 - 0.0007 in)
SEM062A
FLYWHEEL RUNOUT
Flywheel (MIT model)
Drive plate (AIT model)*
*: Measuring points
Approximately 115 mm (4.53 in) from crankshaft
center
SEM291C
Assembly
PISTON
1. Install new snap ring on one side of piston pin hole.
2. Heat piston to 60 to 70°C (140 to 158°F) and assemble piston,

piston pin, connecting rod and new snap ring.
• Align the direction of piston and connecting rod.
• Numbers stamped on connecting rod and cap correspond to
each cylinder.
• After assembly, make sure connecting rod swings
smoothly.
SEM367E
EM-55
CYLINDER BLOCK @KJ
Assembly (Coni' d)
Punch mark side up
3. Set piston rings as shown.
(if mark is present.) CAUTION:
• When piston rings are not replaced, make sure that piston
rings are mounted in their original position.
• When piston rings are being replaced and no punch mark
is present, piston rings can be mounted with either side up.
For Europe and Israel models
SEM965E
Oil ring
• Top ring
expander tf V • Oil ring
~ upper rail
Engine
;l
front
Q
/')
IJ Oil ring
~ ~ lower rail
SEM160B
Top and second ring Except for Europe and Israel models
Punch mark side up
(if mark is presen!.)
.::::::::J c::
SEM208F
Oil ring
expander *c: ~ It upper
Top ring
Oil ring
rail
Engine
front
il
~
!J
~.Oil ring
lower rail
SEM200F
#5 CRANKSHAFT
#4 ~
Oil hole #3 ~- 'U 1. Set main bearings in their proper positions on cylinder
~"\)~ ~ • Confirm that correct main bearings are used. Refer to
"Inspection" (EM-52).
~~ • Apply engine oil to bearing surfaces.
Oil groove
SEM366E
EM-56
CYLINDER BLOCK
Assembly (Cont'd)
Identification No.
\ca p
NO.1
t.:? Engine front
SEM420C
2. Install crankshaft and main bearing caps and tighten bolts

•
to the specified torque.
• Apply new engine oil to bolt threads and seat surface.
• Prior to tightening bearing cap bolts, place bearing cap in
Front its proper position by shifting crankshaft in the axial direc-
tion.
• Tighten bearing cap bolts gradually in two or three stages.
Start with center bearing and move outward sequentially.
• After securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.
3. Measure crankshaft end play.

Crankshaft end play:
Standard:
0.060 - 0.180 mm (0.0024 - 0.0071 in)
Limit:
0.3 mm (0.012 in)
If beyond the limit, replace thrust bearing with a
new one.
4. Install connecting rod bearings in connecting rods and con-

necting rod caps.
• Confirm that correct bearings are used. Refer to
"Inspection" (EM-52).
• Install bearings so that oil hole in connecting rod aligns with
oil hole of bearing.
• Apply engine oil to bolt threads and bearing surfaces.
5. Install pistons with connecting rods.

Piston ring compressor
a. Install them into corresponding cylinders with Tool.
• Be careful not to scratch cylinder wall by connecting rod.
• Arrange so that front mark on piston head faces toward
front of engine.
• Apply engine oil to piston rings and sliding surface of pis-
ton.
SEM293C
EM-57
CYLINDER BLOCK [ill
Assembly (Cont'd)
b. Install connecting rod caps.
Tighten connecting rod cap nuts to the specified torque.
tD.J: Connecting rod cap nuts
(1) Tighten to 13.72 to 15.68 N'm (1.399 to 1.599
kg-m, 10.120 to 11.566 ft-Ib).
(2) Turn nuts to 35° to 40° degrees clockwise with an
angle wrench. If an angle wrench is not avail-
able tighten nuts to 23 to 28 N'm (2.3 to 2.9 kg-m,
17 to 21 ft-Ib).
6. Measure connecting rod side clearance.

Connecting rod side clearance:
Standard:
0.200 - 0.470 mm (0.0079 - 0.0185 in)
limit:
0.52 mm (0.0205 in)
If beyond the limit, replace connecting rod
and/or crankshaft.
7. Install rear oil seal retainer.

a. Before installing rear oil seal retainer, remove all traces of
liquid gasket from cylinder block and retainer with a
scraper.
b. Apply a continuous bead of liquid gasket to rear oil seal
retainer.
• Apply around inner side of bolt holes.
Rear oil seal retainer

SEM736D
EM-58
SEC. 130-140-150-210-211-221
~ __to:J 13 • 16 (1.3 - 1.6, 9. 12)
to:J 16 • 21 (1.6. 2.1, 12. 15)

to:J 20 • 29
(2.0 • 3.0,
14 . 22)
•
to:J 41 - 52 (4.2 - 5.3, 30 - 38)
~----
D_?
~~~
. 'J ~0 -t::;-.....~ / , 0
to:J 21 - 26 ./"
(2.1. 2.7, ,./"~ /'
to:J 16 • 19
(1.6 - 1.9,
12 - 14)
to:J 18. 21
(1.8 • 2.1,
13 - 15)
12 - 1~)
,
fs\
~
to:J 16 • 21
(1.6 - 2.1,
to:J
to:J
19
45 _ 60
(4.6 • 6.1,
33 • 44)
16 • 21
to:J -~~7
16 • 21
(1.6 - 2.1,
12 • 15)
Q
1
0 Ii] 6.3 _ 8.3
(0.64 • 0.85,
12 • 15)
t"J f" -~ t"J 15 • 21 r::! * H ...----4lJ

16 • ,.
~~'. '1~ Jr \~ ~~'..,:; 1, ~Q. /¥i-;: --'Il
1il3.7 - 5.0
(0.38 _ 0.51, A~
J~ --A)
-
to:J 16 - 21
(1.6.2.1, 12 • 15)\...,//
~1 1V>/
~to:J 20.29 (2.0 - 3.0, 14 - 22)
33.0 • 44.3) Y &' /-:f~l to:J 20 • 26 (2.0 • 2.7, 14 - 20)
to:J : N'm (kg-m, fl-Ib) to:J 16 - 21 (1.6 - 2.1, 12 - 15)~/
Ii] : N'm (kg-m, in-Ib) •
~ : Apply liquid gasket. *: Refer to LC section

("Thermostat", "ENGINE COOLING SYSTEM"). SEM231F
G) Oil filler cap @ Oil catcher @ Thermostat

@ Rocker cover @ Oil filter @ Water inlet
@ PCV valve @ Water pipe assembly @ Starter motor
@ Camshaft position sensor, igni- @ Thermal transmitter @ Power steering oil pump
tion coil and power transistor @ Engine coolant temperature adjusting bar
built into distributor sensor @ Power steering oil pump
@ Intake manifold supports @ Thermostat housing bracket
@ Knock sensor @ Air relief plug
rJ) Oil filter bracket
EM-59
SEC.
~ 2.9.3.8
(0.30 - 0.39,
26.0 - 33.9.)
1
I {O.,'OgO
J{"ogO
?
to 18 to 22 N'm
(1.8 to 2.2 kg-m,
Tighten in numerical order. 13 to 16 ft-Ib).
~ ; N'm (kg-m, ft-Ib)

SEM232F
G) Injector @ EGRC-BPT valve @ Throttle body

@ Pressure regulator (J) Intake manifold collector @ IACV-air regulator
@ Intake manifold @ Rod @ IACV-AAC valve
@ EGR tube @ Accel-drum unit @ IACV-FICD solenoid valve
@ EGR valve @) Throttle position sensor
EM-60
SEC. 118-140-230-275
•
tc.J 37 • 48
(3.8 • 4.9, 27 . 35)
tc.J 40.50 (4.1 - 5.1, 30 - 37)
tc.J : N'm (kg-m, ft-Ib)
D : Apply liquid gasket.

SEM233F
(}) Oil level gauge @ Water outlet @ Exhaust manifold

@ Alternator adjusting bar @ Drain plug @ Heated oxygen sensor
@ Compressor bracket (J) Crankcase ventilation oil sepa- @ Exhaust manifold cover
@ Alternator bracket rator
EM-61
Measurement of Compression Pressure

1. Warm up engine.
2. Turn ignition switch off.
3. Release fuel pressure.
5. Disconnect distributor coil connector.
6. Attach a compression tester to NO.1 cylinder.

7. Depress accelerator pedal fully to keep throttle valve wide
open.
8.' Crank engine and record highest gauge indication.
9. Repeat the measurement on each cylinder as shown above.
• Always use a fully-charged battery to obtain specified
engine speed.
Compression pressure: kPa (bar, kg/cm2, psi)/300 rpm
Standard
1,226 (12.26, 12.5, 178)
Minimum
1,030 (10.30, 10.5, 149)
Difference limit between cylinders
98 (0.98, 1.0, 14)
10. If compression in one or more cylinders is low:

20 mm (0.79 In) dls. a. Pour a small amount of engine oil into cylinders through
spark plug holes.
Use compressor tester whose end (rubber b. Retest compression.
portion) is less than 20 mm (0.79 in) dia. • If adding oil helps compression, piston rings may be worn
Otherwise. it may be caught by cylinder
head during removal.
or damaged. If so, replace piston rings after checking pis-
ton.
SEM387C • If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valve and valve seat. Refer
to 50S. If valve or valve seat is damaged excessively,
replace them.
• There is leakage past the gasket surface if the following is
observed. Compression in two adjacent cylinders is low and
adding oil does not improve compression. If so, replace
cylinder head gasket.
EM-62
OIL PAN
SEC. 110
~I ~ 1.9 - 2.5
~ ReIer to "Installation".
(0.19 - 0.25,
16.5 - 21.7)
•
CD Side gallery baffle plate
W Aluminum 011 pan
6 @ Rear cover plate
@l DraIn plug
@ Steel 011 pan
SEM142FA
Removal
1. Remove engine under cover.
2. Drain engine oil.
@ @ 3. Remove steel oil pan bolts.
@ojooEE~CD
~o o~
~]DOCn[l[ ~ CID
~ @o JCJC)Ol~CI / i
~:~~ne ~ ~ l[lCJLL ~
@ ~ ~'llrrlriQ)
@ =0
Q]J 5
Loosen in numerical order. SEM040D
4. Remove steel oil pan.

a. Insert Tool between aluminum oil pan and steel oil pan.
• Be careful not to damage aluminum mating surface.
deformed.
SEM602E
EM-53
OIL PAN [][]
Removal (Coni' d)
b. Slide Tool by tapping on the side of the Tool with a hammer.
c. Remove steel oil pan.
SEM603E
d. Remove baffle plate.
SEM717E
5. Remove front tube.

6. Set a suitable transmission jack under transaxle and hoist
engine with engine slinger.
8. Remove AIT shift control cable. (A/T only)
9. Remove compressor gussets.
EM-64
OIL PAN
Removal (Cont'd)
11. Remove aluminum oil pan bolts.
Loosen in numerical order.

SEM044D
12. Remove the two engine-to-transaxle bolts and install them

•
into open bolt holes shown. Tighten the bolts to release
aluminum oil pan from cylinder block.
13. Remove aluminum oil pan.

a. Insert Tool between cylinder block and aluminum oil pan.
• Be careful not to damage aluminum mating surface.
• Do not insert screwdriver, or oil pan flange will be dam-
aged.
b. Slide Tool by tapping on the side of the Tool with a hammer.
KV10111100
r SEM047D
14. Remove the two engine-to-transaxle

installed in aluminum oil pan.
bolts previously
EM-65
OIL PAN
Installation
1. Install aluminum oil pan.
a. Use a scraper to remove all traces of liquid gasket from
mating surfaces.
cylinder block and front cover.
SEM050D
b. Apply a continuous bead of liquid gasket to mating surface

Cut here.
of aluminum oil pan.
~ 7 mm (0.28 In) • Use Genuine Liquid Gasket or equivalent.
liquid gasket ---j.~ • Be sure liquid gasket diameter is 4.0 to 5.0 mm (0.157 to
0.197 in).
oruu
• Attaching should be done within 5 minutes after coating.
Groove Bolt hole

SEM357E
• For areas marked with "*", apply liquid gasket to the outer
side of the bolt hole.
SEM065D
c. Install aluminum oil pan.

• Install bolts in the reverse order of removal.
CD • @) bolts:
~: 16 - 19 N'm (1.6 - 1.9 kg-m, 12 - 14 ft-Ib)
@, @ bolts:
~: 6.4 - 7.5 N'm (0.65 • 0.76 kg-m, 56.4 - 66.0 in-Ib)
2. Install the two engine to transaxle bolts.

For tightening torque, refer to MT or AT section ("REMOVAL
AND INSTALLATION").
3. Install rear cover plate.
EM-66
OIL PAN
4. Install compressor gussets.
5. Install AfT shift control cable. (AfT only)
6. Install center member.
7. Install front tube.
8. Install baffle plate.
1I I \
_ 4)
<?pmpressorbr~ket
~
,_
'
gusset
Rear compressor
~ ~
SEM363D
9. Install steel oil pan.

•
a. Use a scraper to remove all traces of liquid gasket from
mating surfaces.
aluminum oil pan.
SEM051D
Cut here. b. Apply a continuous bead of liquid gasket to mating surface

of steel oil pan.
7 mm (0.28 in) • Use Genuine Liquid Gasket or equivalent.
~
Liquid gasket
~. ~ f-
- j'u ~::'
•
•
Be sure liquid gasket diameter is 4.0 to 5.0 mm (0.157 to
0.197 in).
Attaching should be done within 5 minutes after coating.
Groove Bolt hole

SEM015E
~f
~ JUUL
00 1'
o
JO~~
JO (QJ 0
o
;)JL- 4.0.5.0 mm
(0.157 - 0.197 In)
c. Install steel oil pan.

@ CD • Install bolts in the reverse order of removal together with
@~IUUUl~~@ heated oxygen sensor harness bracket.
iJOOOOLL ~, • Wait at least 30 minutes before refilling engine oil.
~lOOGnO[ \~
~
Engine
@o
~
]C)e]OLoL/"'
~O(l(I~ \ o~@
front ~ (--.. I L.,
@ ~ '1'lrlnr j QD
@ ~o
@ 7
Tighten in numerical order. SEM053D
EM-67
TIMING CHAIN
SEC. 120.130.135
~ 16 • 19 (1.6 • 1.9, 12 - 14)
(14.0 • 16.0, 101 - 116)
~ 13. 19 (1.3 • 1.9, 9 - 14) ~~
rJ : Lubricate with new engine oil.

~; N.m (kg-m, ft-rb)
~: N.m (kg-m. in-Ib)
SEM718EC
CD Cylinder block @ Chain guide @ Crankshaft sprocket

@ Chain guide @ Front cover @l Chain guide
@ RH camshaft sprocket (J) Crank pulley @ Timing chain
@ Chain tensioner @ Oil pump spacer @ LH camshaft sprocket
EM-68
TIMING CHAIN
CAUTION:
• After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.
• When installing rocker arms, camshafts, chain tensioner, oil
seals, or other sliding parts, lubricate contacting surfaces
with new engine oil.
• Apply new engine oil to bolt threads and seat surfaces when •
installing cylinder head, camshaft sprockets, crankshaft
pulley, and camshaft brackets.
Removal
1. Release fuel pressure.
2. Remove engine under covers.
3. Remove front RH wheel and engine side cover.
4. Drain coolant by removing cylinder block drain plug and
radiator drain cock.
5. Remove radiator.
6. Remove air duct to intake manifold.
7. Remove drive belts and water pump pulley.
8. Remove alternator and power steering oil pump.
9. Remove vacuum hoses, fuel hoses, wires, harness, connec-
tors and so on.
11. Remove rocker cover and oil separator.
12. Remove intake manifold supports.
EM-69
TIMING CHAIN [][]
Removal (Conl'd)
13. Remove oil filter bracket and power steering oil pump
bracket.
14. Set NO.1 piston at TOG on the compression stroke by rotat-

ing crankshaft.
• Rotate crankshaft until mating mark on camshaft sprocket is

set at position indicated in figure at left.
15. Remove chain tensioner.
16. Remove distributor.

Do not turn rotor with distributor removed.
EM-70
TIMING CHAIN
Removal (ConI' d)
17. Remove timing chain guide.
18. Remove camshaft sprockets.

•
19. Remove camshafts, camshaft brackets, oil tubes and baffle

plate.
Loosen in numerical order. SEM7870A
20. Remove starter motor.
21. Remove the following water hoses.

• Water hose for cylinder block.
• Water hoses from heater.
22. Remove knock sensor harness connector.
EM-71
TIMING CHAIN
Removal (Cont'd)
23. Remove cylinder head outside bolts.
24. Remove cylinder head bolts.

~5. Remove cylinder head completely with intake and exhaust
manifolds.
26. Remove oil pans.
Refer to "Removal" in "OIL PAN" (EM-63).
SEM978C
27. Remove oil strainer.
28. Remove crankshaft pulley.
SEM980C
29. Set a suitable transmission jack under main bearing.
SEM213F
EM-72
TIMING CHAIN
Removal (Cont'd)
30. Remove front engine mounting.
31. Remove front cover and oil pump drive spacer.

•
• Inspect for oil leakage at front oil seal. Replace seal if oil
leak is present.
SEM721E
32. Remove timing chain guides and timing chain.
Inspection
Check for cracks and excessive wear at roller links. Replace
chain if necessary.
SEM984C
Installation
1. Install crankshaft sprocket on crankshaft.
• Make sure that mating marks on crankshaft sprocket face
front of engine.
Engine ~ ~ Crankshaft
front Y--J !..--..V side
Crankshaft sprocket
SEM470E
EM-73
TIMING CHAIN []K]
2. Position crankshaft so that No.1 piston is set at TOG and key
way is at 12 o'clock. Fit timing chain on crankshaft sprocket,
aligning the mating marks.
~c
MatingmarkC
CO',
t ':'
@
~!
M''''', mwk
• Mating mark color on timing chain.
eD
@,
Gold
CID: Silver
56 coli'" ~ t .. coli."
CD
Matingmark SEM500E
3. Install timing chain and timing chain guides.
4. Before installing front cover, remove all traces of liquid

cylinder block.

of front cover.
• Be sure to install new front oil seal in the right direction.
Refer to EM-82.
EM-74
TIMING CHAIN ~
6. Install oil pump drive spacer and front cover .
• Wipe off excessive liquid gasket.

•
Wipe off
liquid gasket
SEM214F
7. Install front engine mounting.
8. Install crankshaft pulley.

9. Set NO.1 piston at TDG on its compression stroke.
EM.75
TIMING CHAIN
10. Install oil strainer.
11. Install oil pan.
Refer to "Installation" in "Oil PAN" (EM-66).
12. Before installing cylinder head gasket, apply a continuous

bead of liquid gasket to mating surface of cylinder block.
Cylinder head bolt 13. Install cylinder head completely with intake and exhaust
manifolds.
• Apply engine oil to threads and seating surfaces of cylinder
head bolts before installing them.
OJ 1I111111111111111111111111111111D • Be sure to install washers between bolts and cylinder head.
CAUTION:
L'A,,=J The cylinder head bolts can be reused providing dimension "A"
is not exceeded.
Dimension "A":
158.2 mm (6.228 in)
SEM020D
Cylinder head bolt washer
0__0
•
Cylinder head side
SEM877A
• Tightening procedure:
@ Tighten all bolts to 39 N'm (4.0 kg-m, 29 ft-Ib).
@ Tighten all bolts to 78 N'm (8.0 kg-m, 58 ft-Ib).
@ Loosen all bolts completely.
@ Tighten all bolts to 34 to 44 N'm (3.5 to 4.5 kg-m, 25 to 33
ft-Ib).

SEM986C
EM-76
TIMING CHAIN []B]
@ Method A: Turn all bolts 90 to 95 degrees clockwise with
Method A
Tool or suitable angle wrench.
Method B: If angle wrench is not available, do the follow-
ing. Mark the side of all bolts with paint marks
facing the front of the engine. Then turn them 90
to 95 degrees clockwise.
CD Turn all bolts 90 to 95 degrees clockwise. •
@ Ensure that paint mark on each bolt faces the rear of the
engine. (Method B only)
Do not turn any bolt 180 to 190 degrees clockwise all at once.
Method B 90 + 5 degrees
-0
Engine Paint mark

front
Tightening torque N'm (kg-m, ft-Ib)

@ 39 (4.0, 29)
:0 118
~ (12,87) Plastic zone @ 78 (8.0, 58)
EO
78
0, @ 0(0,0)
~ (8, 58)
E 39 @ 34 - 44 (3.5 - 4.5, 25 - 33)
z (4,29)
@ 90 - 95 degrees (90 degree preferred)
CD 90 - 95 degrees (90 degree preferred)
SEM074DA
14. Install cylinder head outside bolts.

15. Install the following water hoses.
• Water hose for cylinder block.
• Water hoses for heater.
16. Install knock sensor harness connector.
EM-77
TIMING CHAIN
17. Install starter motor.
SEM354D
18. Remove all traces of liquid gasket from mating surface of LH

f'J liquid gasket camshaft end bracket.
Apply liquid gasket •. Also remove traces of liquid gasket from mating surface of
to the hatched area.
cylinder head.
19. Apply liquid gasket to mating surface of LH camshaft end
bracket as shown in illustration.
o~ LH camshaft end bracket
SEM075DA
20. Install camshafts, camshaft brackets, oil tubes and baffle

plate.
• Position camshaft.
• LH camshaft key at about 12 o'clock
• RH camshaft key at about 10 o'clock
Apply engine oil to bearings and cam surfaces of camshafts
before installing them.
• Position camshaft brackets as shown in illustration.

RH camShaft./'::~nd bracket Apply engine oil to threads and seating surfaces of camshaft
brackey
~
0
"
E d b
n
k t
rac e (1)
bracket bolts before installing them.
~~~;~ ~.o o. 00 '{'
NO.1 to 4 0
brackets LH camshaft
NO.1 to 4 brackets bracket
SEM098DA
EM-78
TIMING CHAIN
STEP 1:
RH camshaft
Tighten bolts @ - @l in that order then
tighten bolts CD - @ in that order.
~: 2 N'm (0.2 kg-m, 1.4 ft-Ib)
•
LH camshaft
Tighten bolts @ - @ in that order then
tighten bolts CD - @l in that order.
LH ~: 2 N'm (0.2 kg-m, 1.4 ft-Ib)
camshaft
Tighten in numerical order. SEM987CA STEP 2:
Tighten bolts in the specified order.
~ Engine front ~: 6 N'm (0.6 kg-m, 4.3 ft-Ib)
STEP 3:
Tighten bolts in the specified order.
Bolt type @ CID CID ~ (f)
~: 9.8 - 11.8 N'm
(1.0 - 1.2 kg-m, 7.2 - 8.7 ft-Ib)
Bolt type @
~: 18 - 25 N'm
(1.8 - 2.6 kg-m, 13 - 19 ft-Ib)
21. Install camshaft sprockets.

Line up mating marks on timing chain with mating marks on
camshaft sprockets.
, "--_ . ./ / I
SEM696DA
• Lock camshafts as shown in figure and tighten to specified

torque.
~: 137 - 157 N'm
(14.0 - 16.0 kg-m, 101 - 116 ft-Ib)
Apply engine oil to threads and seating surfaces of camshaft
sprocket bolts before installing them.
SEM584D
22. Install timing chain guide.
EM-79
TIMING CHAIN []K]
23. Install distributor.
• Make sure that position of camshaft is as shown in figure.
• Make sure that No.1 piston is set at TOe and that distribu-
tor is set at No.1 cylinder spark position.
24. Install chain tensioner.

Make sure the camshaft sprockets are tightened completely.
Press cam stopper down and "press-in" sleeve until hook can
be engaged on pin. When tensioner is bolted in position the
hook will release automatically. Make sure arrow "A" points
toward engine front.
SEM990C
SEM991C
25. Install oil filter bracket and power steering oil pump bracket.
EM-80
TIMING CHAIN
26. Install intake manifold supports.
27. Remove all old liquid gasket from mating surfaces of rocker
•
cover gasket and cylinder head.
28. Apply a continuous bead of liquid gasket to mating surfaces
of rocker cover gasket and cylinder head.
10 (0.39) • Use Genuine Liquid Gasket or equivalent.
Unit: mm (in)
Engine front n' 1+
3 (0.12)
.,.. I
~LiqUid
gasket
SEM366D
1
3 mm (0.12 In)r~ liquid gasket
tJ$j
SEM367D
29. Install rocker cover and oil separator.

@ (1) Tighten nuts C!J - @l - @ - @ - cID in that order to 4 N'm
(0.4 kg-m, 35 in-Ib).
8l"-L~~[c,.l~ Q (2) Tighten nuts d) through @ in numerical order to 8 to 10
N'm (0.8 to 1.0 kg-m, 69 to 87 in-Ib).
[0 O@O 0 30. Refit spark plugs and leads.
CD 31. Install vacuum hoses, fuel hoses, wires, harness, connec-
tors and so on.
32. Install power steering oil pump and alternator.
Oil separator 33. Install water pump pulley and drive belts.
Tighten in numerical order. SEM585D 34. Refit air duct to intake manifold.
35. Install radiator.
36. Refit hoses and refill with coolant. (Refer to MA section.)
37. Install engine side cover and front RH wheel.
38. Install engine under covers.
EM-81
VALVE OIL SEAL

1. Remove accelerator cable.
2. Remove rocker cover and oil separator.
3. Remove camshafts and sprockets.
4. Remove spark plugs.
5. Install air hose adapter into spark plug hole and apply air
pressure to hold valves in place. Apply a pressure of 490
kPa (4.9 bar, 5 kg/cm2, 71 psi).
6. Remove rocker arm, rocker arm guide and shim.
Air SEM077D
7. Remove valve spring with Tool.

Piston concerned should be set at TOe to prevent valve from
falling.
8. Remove valve oil seal.
9. Apply engine oil to new valve oil seal and install it with Tool.
FRONT OIL SEAL

• Engine under cover
• Front RH wheel and engine side cover
• Drive belts
• Crankshaft pulley
2. Remove front oil seal.
Be careful not to scratch front cover.
SEM997C
EM-82
Engine /'i ~ Engine
•
inside Y Youtside
Oil seal lip
SEM715A
able tool.
REAR OIL SEAL

1. Remove transaxle. (Refer to MT or AT section.)
2. Remove flywheel or drive plate.
3. Remove rear oil seal.
Be careful not to scratch rear oil seal retainer.
SEM999C
Engine /'i ~ Engine

inside Y Youtside
able tool.
SEM001D
EM-S3
ACCEL-DRUM UNIT
Adjust accel-drum unit whenever any of the following parts

(new or old) are installed:
• Accel-drum unit
• Throttle chamber
• Rod (Always replace with a new one after removal.)
1. Install accel-drum unit and throttle chamber.
..:;:r-- Coupling 2. Apply grease all over the inside of the rod couplings .
Use genuine Nissan grease or equivalent.
Ii!Grease
3. Insert each one coupling to ball links of throttle chamber
Rod
and accel-drum unit.
Throttle body 4. Loosen lock nut.
5. Loosen adjusting screw enough.
Coupling
LCOUPJing
~ 9
Ii!Grease ~
When closed 4a'" link
SEM205D
Tr;rn ~Adjusting serew

6. Manually turn accel-drum until throttle valve is fully open.
_ /- Aeeel-drum • Check that stopper lever is not touching adjusting screw.
"""7'i'i\. If it is, loosen adjusting screw to maintain clearance
Stopper lever between the two.
7. Turn adjusting screw until it touches stopper lever.

8. Back off accel-drum.
SEM208D
9. Turn adjusting screw 3 rotations clockwise.

Lock nut 10. Tighten lock nut.
Turn adjusting screw 3
rotations clockwise.
~ 4.0 - 5.4 N.m

(0.41 - 0.55 kg-m, 35.6 - 47.7 In-rb)
SEM209DA
EM-84
CYLINDER HEAD
SEC. 111.130
~ Refer to "Installation" In "riMING CHAIN".
Rocker cover gasket ~

20 f) ~ Refer to "Installation" in
"rIMING CHAIN" .
Ii ~
~stside
~ \9 "'I •
~f::l
If;
!~ l~~ \alve oil seal ~
04 ~ ~
rn, : Refer to "Installation" in "TIMING CHAIN".

~-J: N.m (kg-m, ft-Ib)
fJ : Lubricate with new engine oil.
SEM722ED
G) Oil filler cap @ Camshaft sprocket @ Valve spring seat

@ Rocker cover @ Camshaft @ Valve spring
@ Rocker arm guide @) Camshaft bracket @ Valve spring retainer
@ Rocker arm @ Oil tube @ Valve collet
@) Shim @ Water outlet @ Spark plug
@ Hydraulic lash adjuster @ Cylinder head @> Cylinder head bolt
(J) Chain. tensioner @ Valve
EM-8S
CYLINDER HEAD
CAUTION:
• Apply new engine oil to the sliding surfaces when installing
sliding parts. Sliding parts include rocker arms, camshafts,
oil seal, etc.
• Apply new engine oil to bolt thread and seat surfaces when
tightening the following: Cylinder head bolts, camshaft
sprocket bolts and camshaft bracket bolts.
• If a hydraulic lash adjuster is kept on its side, there is a risk

of air entering it. After removal, always set hydraulic lash
adjuster straight up, or keep it soaked in new engine oil.
OK ~
• . Do not disassemble hydraulic lash adjusters.
• Attach tags to lash adjusters so as not to mix them up.
@ Removal
• This removal procedure is the same as for timing chain.
Refer to EM-69.
SEM878CA
Disassembly
Rocker~arm guide-
Rocker arm 1. Remove rocker arms, shims, rocker arm guides and hydrau-
i
Shim lic lash adjusters from cylinder head.
Hydraulic I
CAUTION:
o,h .dJ""~ !\ '! Keep parts in order so that they can be installed in their origi-
nal positions during assembly.
SEM202D
2. Remove crankcase ventilation oil separator.

3. Remove exhaust manifold cover.
4. Remove exhaust manifold.
5. Remove water outlet.
EM-86
CYLINDER HEAD
Disassembly (Cont'd)
6. Remove intake manifold supports.
7. Remove fuel tube assembly.

•
Refer to "Injector Removal and Installation" in EC section.
8. Remove intake manifold.
Intake manifold
collector Loosen in numerical order.
SEM607E
9. Remove intake manifold collector from intake manifold.
10. Remove thermostat housing with water pipe.

- Thermostat housing
SEM785E
11. Remove valve components with Tool.
EM-87
CYLINDER HEAD
12. Remove valve oil seal with a suitable tool.
Inspection
. Head surface flatness:
Standard
Limit
0.1 mm (0.004 in)
If beyond the specified limit, replace or resurface.
Resurfacing limit:
The resurfacing limit of cylinder head is determined by the cyl-
SEM925C
inder block resurfacing in an engine.
A + B = 0.2 mm (0.008 in)
freely by hand. If resistance is felt, cylinder head must be
replaced.
Nominal cylinder head height:
136.9 - 137.1 mm (5.390 - 5.398 in)

CAMSHAFT RUNOUT
Standard
Limit
0.1 mm (0.004 in)
2. If it exceeds the limit, replace camshaft.
EM-88
CYLINDER HEAD ~
Inspection (Cont'd)
CAMSHAFT CAM HEIGHT
Standard cam height:
Intake
38.408 - 38.598 mm (1.5121 . 1.5196 in)
Exhaust
2.
37.920 • 38.110 mm (1.4929. 1.5004 in)
Cam wear limit:
Intake & Exhaust
0.2 mm (0.008 in)
If wear is beyond the limit, replace camshaft.
•
1. Install camshaft bracket and tighten bolts to the specified
torque.
2. Measure inner diameter of camshaft bearing.
28.000 - 28.021 mm (1.1024 - 1.1032 in)
Measure outer diameter of camshaft journal.

27.935 . 27.955 mm (1.0998 - 1.1006 in)
If clearance exceeds the limit, replace camshaft and/or cyl-
inder head.
Camshaft journal clearance:
Standard
0.045 - 0.086 mm (0.0018 . 0.0034 in)
Limit
0.15 mm (0.0059 in)
CAMSHAFT END PLAY

Camshaft end play:
Standard
0.055. 0.139 mm (0.0022 - 0.0055 in)
Limit
0.20 mm (0.0079 in)
CAMSHAFT SPROCKET RUNOUT

1. Install sprocket on camshaft.
2. Measure camshaft sprocket runout.
Limit 0.25 mm (0.0098 in)
3. If it exceeds the limit, replace camshaft sprocket.
SEM929C
EM-89
CYLINDER HEAD [][]
Inspection (Cont'd)
1. Measure valve deflection in a parallel direction with rocker
arm. (Valve and valve guide mostly wear in this direction.)
Valve deflection limit (Dial gauge reading):
Intake & Exhaust
0.2 mm (0.008 in)
2. If it exceeds the limit, check valve to valve guide clearance.

a. Measure valve stem diameter and valve guide inner diam-
eter.
b. Check that clearance is within specification.
Valve to valve guide clearance:
Standard
Intake 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust 0.040 - 0.073 mm (0.0016 - 0.0029 in)
Limit
Intake 0.08 mm (0.0031 in)
SEM938C Exhaust 0.1 mm (0.004 in)
c. If it exceeds the limit, replace valve or valve guide.

1. To remove valve guide, heat cylinder head to 110 to 130°C
(230 to 266°F).
2. Press out valve guide or use a hammer and suitable tool.
EM-gO
CYLINDER HEAD
Inspection (Cont'd)
3. Ream cylinder head valve guide hole.
Valve guide hole diameter
(for service parts):
Intake & Exhaust
10.175 - 10.196 mm (0.4006 - 0.4014 in)

•
service valve guide onto cylinder head.
Projection "L":
14.0 - 14.2 mm (0.551 - 0.559 in)
SEM083D

Valve guide inner diameter:
Intake & Exhaust
6.000 - 6.018 mm (0.2362 - 0.2369 in)
VALVE SEATS
Check valve seats for any evidence of pitting at valve contact
surface. Reset or replace if it has worn out excessively.
• Before repairing valve seats, check valve and valve guide
for wear. If they have worn, replace them. Then correct
valve seat.
• Cut with both hands to uniform the cutting surface.
REPLACING VALVE SEAT FOR SERVICE PARTS
r
I 1. Bore out old seat until it collapses. Boring should not con-
I
I
Recess diameter
tinue beyond the bottom face of the seat recess in cylinder
head. Set the machine depth stop to ensure this.
2. Ream cylinder head recess.
Oversize [0.5 mm (0.020 in)]:
Intake 35.500 - 35.516 mm (1.3976 - 1.3983 in)
Exhaust 31.500.31.516 mm (1.2402 - 1.2408 in)
Be sure to ream in circles concentric to the valve guide center.
SEM795A This will enable valve seat to fit correctly.
EM-91
CYLINDER HEAD
Inspection (Cont'd)
3. Heat cylinder head to 110 to 130°C (230 to 266°F).
4. Press fit valve seat until it seats on the bottom.
5. Cut or grind valve seat using a suitable tool at the specified

dimensions as shown in SDS (EM-165).
6. After cutting, lap valve seat with abrasive compound.
Seat face angle "u":
44°53' - 45°07'
Contacting width "W":
Intake
1.05 - 1.35 mm (0.0413 - 0.0531 in)
Exhaust
SEM892B 1.25 - 1.55 mm (0.0492 - 0.0610 in)
T (Margin thickness) VALVE DIMENSIONS

~Ir Check dimensions in each valve. For dimensions, refer to SDS
nw a
(EM-164).
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace valve.
III' ~ D d
Grinding
less.
allowance for valve stem tip is 0.2 mm (0.008 in) or
L
-l
SEM188A
VALVE SPRING
Squareness
1. Measure "S" dimension.
Out-of-square:
2. If it exceeds the limit, replace spring.
SEM288A
Pressure
Check valve spring pressure.
Pressure: N (kg, Ib) at height mm (in)
Standard
578.02 - 641.57 (58.94 - 65.42,
129.96 - 144.25) at 30.0 (1.181)
Limit
More than 549.2 (56.0, 123.5) at 30.0 (1.181)
If it exceeds the limit, replace spring.
EM113
EM-92
CYLINDER HEAD
Inspection (Cont'd)
• HYDRAULIC
1.
LASH ADJUSTER
Check contact and sliding surfaces for wear or scratches .
SEM935C
2. Check diameter of lash adjuster.

•
Outer diameter:
16.980 - 16.993 mm (0.6685 - 0.6690 in)
3. Check lash adjuster guide inner diameter.

Inner diameter:
17.000 - 17.020 mm (0.6693 - 0.6701 in)
Standard clearance between lash adjuster and
adjuster guide:
0.007 - 0.040 mm (0.0003 - 0.0016 in)
Rocker arm ROCKER ARM, SHIM AND ROCKER ARM GUIDE

Check contact and sliding surfaces of rocker arms, shims and
rocker arm guides for wear or scratches.
SEM694D
Assembly
1. Install intake manifold collector to intake manifold.
Intake manifold
collector Tighten in numerical order. SEM609E
EM-93
CYLINDER HEAD [][]
Assembly (Cont'd)
2. Install intake manifold.
3. Install fuel tube assembly.
Refer to "Injector Removal and Installation" in EC section.
Intake manifold
collector Tighten in numerical order.
SEM610E
4. Install thermostat housing with water pipe.

• Tightening procedure:
Thermostat housing 1) Tighten bolt @ to 2 - 5 N'm (0.2 - 0.5 kg-m, 1.4 - 3.6 ft-Ib).
2) .Tighten bolt @ to 16 - 21 N'm (1.6 - 2.1 kg-m, 12 - 15 ft-Ib).
3) Tighten bolt @ to 16 - 21 N'm (1.6 - 2.1 kg-m, 12 - 15 ft-Ib).
4) Tighten bolt CID to 16 - 21 N'm (1.6 - 2.1 kg-m, 12 - 15 ft-Ib).
SEM786E
5. Install exhaust manifold.

6. Install exhaust manifold cover.
SEM594D
7. Install water outlet.

a. Before installing water outlet, remove all traces of liquid
cylinder head.
of water outlet.
~ Liquid gasket
SEM086D
8. Install intake manifold supports.

9. Install crankcase ventilation oil separator.
EM-94
CYLINDER HEAD ill]
Assembly (Cont'd)
• Install valves with larger diameter head on the intake side .
• Always use new valve oil seal.

•
Refer to OIL SEAL REPLACEMENT.
• Before installing valve oil seal, install valve spring seat.
Wide pitch .' Install valve spring (uneven pitch type) with its narrow
pitched side toward cylinder head side (paint mark).
• After installing valve component parts, tap valve stem tip
Narrow pitch
with plastic hammer to assure a proper fit.
Paint mark
Cylinder head side SEM085D
11. Check hydraulic lash adjusters.

a. Push rocker arm at hydraulic lash adjuster location, and see
if rocker arm moves. If it moves at least 1 mm (0.04 in), it
indicates that there is air in the high pressure chamber.
Noise will be emitted from hydraulic lash adjuster if engine
is started without bleeding air.
SEM093D
b. Remove hydraulic lash adjuster and dip in a container filled

Proper rod with engine oil. While pushing plunger as shown in figure,
• rEngine oil
lightly push check ball using a thin rod. Air is completely
- - , t-=1=i bled when plunger no longer moves.
Air cannot be bled from this type of lash adjuster by running the
engine.
SEM772C
12. Install rocker arms, shims, rocker arm guides and hydrau-
Rocker arm 9UVide lic lash adjusters.
Rock~rarm
CAUTION:
i\\
Shim
Hydraulic I Install all parts in their original positions.
.,h .dj"'" j
SEM202D
EM-95
CYLINDER HEAD ~
Assembly (Cont'd)
13. Select a suitable shim when replacing any of the following
parts with a new one: Cylinder head, shim, rocker arm guide
1!!i1*Shim
and valve seat. Proceed as follows to select the shim of
~ I::: / ~ Rocker arm guide

Ij9 ~ ~ Valve collet correct thickness.
Valve spring a. Install valve component parts to cylinder head (Except
l!I retainer
shim).
I!1!i! ~ 'Valve spring
• Always replace rocker arm guide with a new one.
~ ~~ ~Valve spring seat
j Valve
Valve
oil seal ~
SEM364D
b. Remove hydraulic lash adjuster.

Dial gauge c. Install Tool* into hydraulic lash adjuster fixing hole.
* Tool (KV10115700) is screwed into magnetic stand rod
used with dial gauge.
Rod
KV10115700
SEM365DA
SEM899D
d. Make sure that the following parts are installed to the cyl-
inder head: Valve, valve spring, collet, retainer and rocker
arm guide (except shim). Measure difference (T1) between
sliding surface of rocker arm gUide and valve stem end on
shim side.
When measuring, lightly pull dial indicator rod toward you to
eliminate play in Tool (KV10115700).
e. Select proper shim.

Shim thickness (T):
T1 :l: 0.025 mm (0.0010 in)
• Shims are available in different thicknesses from 2.800 mm
(0.1102 in) to 3.200 mm (0.1260 in) in increments of 0.025 mm
(0.0010 in).
\.
/~-
/
Indicate
L shim
T = 2.800 mm
(0.1102 In)
SEM096D
EM-96
CYLINDER HEAD
Installation
• This installation is the same procedure as those for timing
chain. Refer to "Installation" in "TIMING CHAIN" (EM-73) .
EM-97
ENGINE REMOVAL
~, r1jl~
~ 44 - 54 ~V/~
~~.'/, / \ ~"-
)
~v)~.
~",
~~~
~l"J 22.29
(4.5 • 5.")
33.40)
-
/'
Y ) .,
(2.2 • 3.0, 16 • 22)
<RJB),»/'
~
Z:::.~ ~
\l"J 44."
(4.5 • 5,5, 33 • 40)
Front
I~
~ l"J 44."
22 • 29 (2.2 • 3.0, 16.22)
(4.5. 5.5,33' 40) .~.
>
MIT models [OJ 44 • 54
[OJ 64. 74
! ,~
rf:{l"A,
t
(6.5 - 7.5,
(4.5 - 5.5, 47 • 54) .../
33 - 40)
~ /1.;'0 -
1~ /~ /[(1\ ~ ~:5- _5~.5, 33 - 40) \

ol~ [OJ
~A1k
74 - 91 "'~' .• ~~ ~ \
Ill.~, (8.0 - 9.~~,,, 0 I I '. ,
;~ 58 - 67) /' \ [OJ 44 _ 54 ~
;&6 ~Ol
[OJ 44 - 54
(4.5 - 5.5,
~--W
I
[OJ '64 - 74
(6.5 - 7.5, 47. 54) ~~ r~ (4.5 - 5.5, 33 • 40)
33 - 40) 0
c~ ___ [OJ 44 - 54
(4.5 - 5.5, 33 - 40) t?
~I~,
I ~
!
~
~,"7 ~~
"
o
"SR" marked direction 44 • 54 (4.5 • 5.5,33.40)
[OJ 44 - 54 I 0
(4.5 • 5.5, ~
33 • 40)
@> ~ 44 • 54 (4.5 • 5.5, 33 • 40) [OJ : N'm (kg-m, ft-Ib)
V SEM234F
G) Rear engine slinger @ Rear insulator (J) Front engine slinger

@ Front engine mounting @ Center member @ Rear engine mounting
@ Mounting bracket @ Buffer @ Dynamic damper
EM-98
ENGINE REMOVAL
WARNING:
• Situate vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• Do not remove engine until exhaust system has completely
cooled off.
•
Otherwise, you may burn yourself and/or fire may break out
in fuel line.
• For safety during subsequent steps, the tension of wires
• Before disconnecting fuel hose, release fuel pressure from
fuel line.
• Be sure to hoist engine and transaxle in a safe manner.
• For engines not equipped with engine slingers, attach
CAUTION:
• When lifting engine, be careful not to strike adjacent parts,
especially the following: Accelerator wire casing, brake
lines, and brake master cylinder.
manner.
Removal
1. Remove engine under cover and hood.
2. Drain coolant from both cylinder block, and radiator.
3. Drain engine oil from drain plug of oil pan.
4. Remove vacuum hoses, fuel hoses, wires, harness and con-
nectors and so on.
5. Remove exhaust tubes, ball joints and drive shafts.
6. Remove radiator and fans.
8. Remove alternator, compressor and power steering oil
pump from engine.
9. Set a suitable transmission jack under transaxle. Hoist
engine with engine slinger.
SEM092D
11. Remove engine mounting bolts from both sides and then
slowly lower transmission jack.
EM-99
ENGINE REMOVAL
Removal (Co nt' d)
Installation
1. Install engine mounting bracket and fixing bolts.
Be sure that insulators are correctly positioned on the brack-
ets.
2. Carefully lower the engine onto engine mounting insulators.
SEM312D
When installing the engine, adjust the height of the engine

mounting as shown. (For M/T)
3. Installation is in the reverse order of removal.
EM-100
CYLINDER BLOCK
SEC.
Snap ring ~
f) to:J Refer to "ASSembIY"'-~
: Apply liquid gasket.

Lubricate with new engine 011
CD Rear oil seal retainer @ Piston @ Side gallery baffle plate

@ Cylinder block @ Piston pin @ Main bearing beam
@ Water pump @ Connecting rod @ Main bearing cap
@ Power steering oil pump @ Connecting rod bearing @ Pilot converter
adjusting bar @ Baffle plate @ Drive plate
@ Front cover with oil pump @ Aluminum oil pan @ Reinforcement plate
@ Oil strainer @ Rear cover plate @ Flywheel
(J) Thrust bearing @ Drain plug @ Pilot bushing
@ Crankshaft @J Steel oil pan @ Rear plate
@ Connecting rod bushing @ Baffle plate @ Main bearing
@J Piston rings
EM-101
CYLINDER BLOCK
CAUTION:
• When installing sliding parts (bearings, pistons, etc.), apply
new engine oil to the sliding surfaces.
• Place removed parts such as bearings and bearing caps in
their proper order and direction.
• Apply new engine oil to bolt thread and seat surfaces when
tightening the following: Connecting rod bolts and main
bearing cap bolts.
• Do not allow any magnetic materials to contact the ring gear
teeth of flywheel/drive plate.
Disassembly
2. Remove cylinder head.
3. Remove oil pan.
Refer to "Removal" in "OIL PAN" (EM-63).
4. Remove timing chain.
SEM141FA
5. Remove pistons with connecting rods.

jPiSIOn healer • When disassembling piston and connecting rod, remove
snap ring first. Then heat piston to 60 to 70°C (140 to 158°F),
or use piston pin press stand at room temperature.
6. Remove rear oil seal retainer.
SEM877S
7. Remove bearing beam, bearing cap and crankshaft.

• Before removing bearing cap, measure crankshaft end play.
Loosen in numerical order.

SEM007D
Inspection
1. Measure inner diameter of piston pin hole "dp".
Standard diameter "dp":
21.987 - 21.999 mm (0.8656 - 0.8661 in)
AEM023
EM-102
CYLINDER BLOCK [][]
Inspection (Cont'd)
2. Measure outer diameter of piston pin "Dp".
Standard diameter "Op":
21.989 - 22.001 mm (0.8657 - 0.8662 in)
3. Calculate piston pin clearance.
dp - Op = -0.004 to 0 mm (-0.0002 to 0 in)
If it exceeds the above value, replace piston assembly with
•
pin.
Micrometer
AEM024

NG Side clearance:
Top ring 0.045 - 0.080 mm (0.0018 - 0.0031 in)
2nd ring 0.030 - 0.065 (0.0012 - 0.0026 in)
Max. limit of side clearance:
gauge
F•• ~K
0.2 mm (0.008 in)
OK If out of specification, replace piston and/or piston ring assem-
~- Feeler gauge
bly.
SEM024AA
PISTON RING END GAP

P;""A
pre.it
Feeler
End gap:
gauge Top ring 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd ring 0.35 - 0.50 mm (0.0138 - 0.0197 in)
Oil ring 0.20 - 0.60 mm (0.0079 - 0.0236 in)
~
Max. limit of ring gap:
Ring
1.0 mm (0.039 in)
If out of specification, replace piston ring. If gap still exceeds
Measuring point
the limit even with a new ring, do the following. Rebore cylin-
der and use over-sized piston and piston rings.
SEM822B Refer to 50S (EM-168).
• When replacing the piston, inspect cylinder block surface
Bend for scratches or seizure. If scratches or seizure are found,
hone or replace the cylinder block.

Bend:
Limit 0.15 mm (0.0059 in)
Torsion:
Limit 0.30 mm (0.0118 in)
If it exceeds the limit, replace connecting rod assembly.
SEM003F
EM-103
CYLINDER BLOCK ~
Inspection (Cont'd)
CYLINDER BLOCK DISTORTION AND WEAR
1. Clean upper face of cylinder block and measure the distor-
tion.
Standard:
Limit:
0.10 mm (0.0039 in)
2. If out of specification, resurface it.
The resurfacing limit is determined by cylinder head resur-
facing in engine.
SEM123C

Amount of cylinder block resurfacing is "8".
A + 8 = 0.2 mm (0.008 in)
Nominal cylinder block height
from crankshaft center:
211.25 - 211.35 mm (8.3169 - 8.3208 in)
3. If necessary, replace cylinder block.
SEM008D
y PISTON- TO-BORE CLEARANCE
ii-El)'
--
N 0+
00
-X
of-round and taper.
<D ...
86.000 - 86.030 mm (3.3858 - 3.3870 in)
Wear limit: 0.20 mm (0.0079 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder
block if necessary.
Out-of-round (X - Y) standard:
Unit: mm (in)
SEM363E Taper (A - 8 and A - C) standard:
2. Check for scratches and seizure. If seizure is found. hone
it.
• When replacing both cylinder block and piston with new
ones, select piston making sure of grade numbers. Piston
grade number should be the same as the grade number
punched on cylinper block upper surface.
3. Measure piston skirt diameter.

Piston diameter "A": Refer to SDS (EM-168).
14.0 mm (0.551 in)
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance "B":
0.010 - 0.030 mm (0.0004 - 0.0012 in)
5. Determine piston oversize according to amount of cylinder
wear.
Oversize pistons are available for service. Refer to SDS (EM-
168).
EM-104
CYLINDER BLOCK ~
Inspection (Cont'd)
6. Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter "A".
Rebored size calculation:
D=A+B-C
where,
D: Bored diameter
A: Piston diameter as measured •
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps, and tighten to the specified
torque.
• Otherwise, cylinder bores may be distorted in final assem-
bly.
8. Cut cylinder bores.
• When any cylinder needs boring, all other cylinders must
also be bored.
• Do not cut too much out of cylinder bore at a time. Cut only
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper.
• Measurement should be done after cylinder bore cools
down.
A B CRANKSHAFT
1. Check crankshaft main and pin journals for score, wear or
cracks.
2. With a micrometer, measure journals for taper and out-
of-round.
Out-of-round (X - Y) standard:
y
Main journal:
Taper: A - B Pin journal:
Out-at-round: X - y Less than 0.005 mm (0.0001 in)
SEM316A Taper (A - B) standard:
Main journal:
Pin journal:
Less than 0.0025 mm (0.0001 in)
3. Measure crankshaft runout.

Runout (Total indicator reading) limit:
EM-105
CYLINDER BLOCK
#5 BEARING CLEARANCE
#4 ~ • Use either of the following two methods, however, method
i1 hole #3 ~~ \) "A" gives more reliable results and is preferred.
Method A (Using bore gauge & micrometer)
#2 ~~,
Main bearing
~#1~~~ ~~
1. Set main bearings in their proper positions on cylinder
12 ~~
Engine front~
SEM685D
2. Install main bearing cap and main bearing beam to cylinder

block.
Tighten all bolts in correct order in two or three stages.
3. Measure inner diameter "A" of each main bearing.
4. Measure outer diameter "Om" of each crankshaft main

journal.
Standard: 0.004 • 0.022 mm (0.0002 • 0.0009 in)
Limit: 0.050 mm (0.0020 in)
ing.
a. When grinding crankshaft journal, confirm that "L" dimen-

sion in fillet roll is more than the specified limit.
"L": 0.1 mm (0.004 in)
b. Refer to SOS for grinding crankshaft and available service
parts.
SEM964
8. If crankshaft is reused, measure main bearing clearances

and select thickness of main bearings.
If crankshaft is replaced with a new one, select thickness of
main bearings as follows:
a. Grade number of each cylinder block main journal is
punched on the respective cylinder block. These numbers
are punched in either Arabic or Roman numerals.
SEM313D
EM-106
CYLINDER BLOCK ~
Inspection (Conl'd)
Type I b. Grade number of each crankshaft main journal is punched
Main journal grade number
on the respective crankshaft. These numbers are punched
No. 5
in either Arabic or Roman numerals.
c. Select main bearing with suitable thickness according to the
following table.
How to select main bearings
•
No.1 No. 4
(Identification mark and color)
Crankshaft
Cylinder block main journal grade number
Crankshaft main journal
front view SEM013D grade num-
0 1 2 3
ber
Type II
Main journal grade number 0 1 2 3
0
NO.1 (A, Black) (B, Brown) (C, Green) (0, Yellow)
.
1 2 3 4
1
(B, Brown) (C, Green) (0, Yellow) (E, Blue)
2 3 4 5
2
(C, Green) (0, Yellow) (E, Blue) (F, Pink)
3 4 5 6
3
Crankshaft (0, Yellow) (E, Blue) (F, Pink) (G, No color)
front view
SEM203D
For example:
Main bearing grade number = 1 + 2
= 3 (D, Yellow)
Connecting rod bearing (Big end)

2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque.
3. Measure inner diameter "C" of each bearing.
4. Measure outer diameter "Dp" of each crankshaft pin jour-

nal.
Connecting rod bearing clearance = C - Dp
Standard: 0.020. 0.045 mm (0.0008 . 0.0018 in)
Limit: 0.065 mm (0.0026 in)
ing. Refer to step 7 of "BEARING CLEARANCE - Main
bearing" (EM-106).
EM-107
CYLINDER BLOCK ~
Type I Main journal grade number
8. If crankshaft is replaced with a new one, select connecting
rod bearing according to the following table.
Connecting rod bearing grade number:
These numbers are punched in either Arabic or Roman numer-
als.
No.1 No. 4 Connecting rod bearing grade

Crank pin grade number
number
o o
1 1
Crankshaft 2 2
front view SEM013D
Type II
No. 3 Identification color:
No. 4 cylinder
Grade 0; No color
Grade 0
Grade 1 Grade 1; Black
Grade 2 Grade 2; Brown
Crankshaft
rear view SEM204D
Method B (Using plastigage)

CAUTION:
• Do not turn crankshaft or connecting rod while plastigage is
being inserted.
• When bearing clearance exceeds the specified limit, ensure
that the proper bearing has been installed. If incorrect bear-
ing clearance exists, use a thicker or undersized main bear-
ing to ensure specified clearance.
CONNECTING ROD BUSHING CLEARANCE (Small end)

1. Measure inner diameter "C" of bushing.
AEM029
2. Measure outer diameter "Dp" of piston pin.

3. Calculate connecting rod bushing clearance.
Connecting rod bushing clearance = C - Dp
Standard:
0.005 - 0.017 mm (0.0002 - 0.0007 in)
Limit:
0.023 mm (0.0009 in)
If it exceeds the limit, replace connecting rod assembly or
connecting rod bushing and/or piston set with pin.
AEM030
EM-108
CYLINDER BLOCK [][]
Inspection (Conl'd)
REPLACEMENT OF CONNECTING ROD BUSHING (Small
end)
1. Drive in small end bushing until it is flush with end surface
of rod.
Be sure to align the oil holes.
•
2. After driving in small end bushing, ream the bushing. This
is to ensure the clearance between connecting rod bushing
and piston pin is the specified value.
Clearance between connecting rod bushing and piston
pin:
SEM062A 0.005 - 0.017 mm (0.0002 - 0.0007 in)
REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT
CONVERTER (A/T)
1. Remove pilot bushing or pilot converter using Tool or suit-
. able tool.
2. Install pilot bushing or pilot converter as shown.
Crankshaft side
M/T AIT
SEM163B
FLYWHEEL/DRIVE PLATE RUNOUT

Flywheel (MfT model)
Drive plate (AfT model)
CAUTION:
Do not allow any magnetic materials to contact the ring gear
teeth.
Assembly
PISTON
1. Install new snap ring on one side of piston pin hole.
EM-109
CYLINDER BLOCK []:[J
Assembly (Conl'd)
2. Heat piston to 60 to 70°C (140 to 158°F) and assemble piston,
Front mark Piston grade piston pin, connecting rod and new snap ring.
number
• Align the direction of piston and connecting rod.
each cylinder.
Oil hole
• After assembly, make sure connecting rod swings
Engine smoothly.
front
Cylinder
number
SEM946C
3. Set piston rings as shown.

CAUTION:
• When piston rings are not replaced, make sure that piston
Top rings are mounted in their original positions.
• When replacing piston rings, those without punchmarks can
be mounted with either side up.
Oil
SEM199F
Oil ring
expander *v
Engine!/
front
(:J
#5 CRANKSHAFT
#4 ~ 1. Set main bearings in their proper positions on cylinder
il hole #3 ~~ \) block and main bearing cap.
• Confirm that correct main bearings are used. Refer to
#2 ~~ ,
"Inspection" of this section.
~#1~~~ ~~ • Apply new engine oil to bearing surfaces.
12 ~~
Engine front~
SEM685D
EM-110
CYLINDER BLOCK [][]
Assembly (Co nt' d)
2. Install crankshaft and main bearing caps and tighten bolts
to the specified torque.
• Apply new engine oil to thread of bearing cap bolts.
• Prior to tightening bearing cap bolts, shift crankshaft back
and forth to properly seat the bearing cap.
a. Tighten all bolts to 26 to 32 N'm (2.7 to 3.3 kg-m, 20 to 24 •
in-Ib).
b. Turn all bolts 75 to 80 degrees clockwise with Tool or suit-
able angle wrench.
Tighten in numerical order. c. Loosen all bolts completely.
SEM015D
d. Tighten all bolts to 32 to 38 N'm (3.3 to 3.9 kg-m, 24 to 28
ft-Ib).
e. Turn all bolts 45 to 50 degrees clockwise with Tool or suit-
able angle wrench.
• If an angle wrench is not available, mark all bearing cap
bolts on the side facing engine rear. Then, turn each bolt
specified degrees clockwise. Confirm angle of degrees with
a graduator, not by eye-measurement.
• After securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.
3. Measure crankshaft end play.

Crankshaft end play:
Standard
0.10 - 0.26 mm (0.0039 - 0.0102 in)
Limit
0.30 mm (0.0118 in)
If beyond the limit, replace thrust bearings with new ones.
'::::::-.... Align oil hole. 4. Install connecting rod bearings in connecting rods and con-
necting rod caps.
• Confirm that correct bearings are used. Refer to
~~
'~~- •
"I nspection" .
Install bearings so that oil hole in connecting rod aligns with
oil hole of bearing.
• Apply new engine oil to bolt threads and bearing surfaces.
SEM159B

a. Install them into corresponding cylinders with Tool.
• Be careful not to scratch cylinder wall by connecting rod.
• Arrange so that front mark on piston head faces toward
front of engine.
• Apply new engine oil to piston rings and sliding surface of
piston.
EM-111
CYLINDER BLOCK ~
Assembly (Cont'd)
b. Install connecting rod caps.
Tighten connecting rod cap nuts to the specified torque.
Tightening procedure:
1) Tighten nuts to 14 to 16 N'm (1.4 to 1.6 kg-m, 10 to
12 ft-Ib).
2) Turn nuts 60 to 65 degrees clockwise with
angle wrench. If angle wrench is not available,
tighten nuts to 38 to 44 N'm (3.9 to 4.5 kg-m, 28
to 33 ft-Ib).
Connecting rod cap nut
SEM017D

Connecting rod side clearance:
Standard
0.20 - 0.35 mm (0.0079 - 0.0138 in)
Limit
0.50 mm (0.0197 in)
If beyond the limit, replace connecting rod and/or crank-
shaft.
7. Install rear oil seal retainer.

a. Before installing rear oil seal retainer, remove all traces of
liquid gasket from mating surface using a scraper.
cylinder block.
SEM218D

of rear oil seal retainer.
SEM219D
EM-112
Right side
SEC. 130.135.185.186.210.213.233
I~ 16 - 21 (1.6 - 2.1, 12 - 15)7
I
~: N.m (kg-m. in-Ib)
.~
[ClJ : N.m (kg-m. ft-Ib)
SEM044FA
G) Starter motor @ Injection nozzle @ Timing belt
@ Injection pump @ Spill tube @ Injection pump sprocket
@ Injection tube !J) Water outlet @ Rear camshaft sprocket
@ Thermostat housing @ Belt cover @ Rear back cover
@ Oil cooler
@ Gasket
EM-113
Left side
SEC. 120.135.140.210.230
L ~-@@~
-@
~ 18 • 22 (1.8 - 2.2, 13 . 16)
l"J 16 • 21 (1.6 .2.1. 12 • 7

<, ~
/
7~ /
~ 16 - 21 (1.6 • 2.1, 12 • 15)~~""
~
~~ ~2. 75 (6.3.7.6,46 - 55)
Ii] : N.m (kg-m, in-Ib)
~ : N.m (kg-m, fl-Ib)
SEM045FA
CD Belt cover upper @ Crankshaft pulley (J) Exhaust manifold
@ Water pump pulley @ Alternator @ Gasket
@ Belt cover lower @ Alternator bracket @ Intake manifold
EM-114
1. Warm up engine sufficiently.

2. Disconnect injection tubes on nozzle side and loosen injec-
tion tubes on pump side. Release clamps on injection tubes.
• Use two wrenches to prevent delivery holder on pump side
from loosening.
3. Remove spill-tube assembly.

• To prevent spill tube from breaking, remove it by gripping
nozzle holder.
4. Remove all injection nozzles using a suitable tool.
5. Disconnect fuel-cut solenoid valve connector.
EM-115
6. Fit compression gauge to cylinder head.
SEM505D
7. Crank engine and read compression gauge indication.

Cranking speed: 200 rpm
Compression pressure: kPa (bar, kg/cm2, psi)
Standard
3,138 (31.4, 32, 455)
Limit
2,452 (24.5, 25, 356)
Limit of difference between cylinders
490 (4.9, 5, 71)
8. If the pressure appears low, pour about 3 me (0.11 Imp fl oz)
of engine oil through nozzle holes and repeat test.
For indications of test, refer to the following table.
Gauge indication during tests Trouble diagnosis
Second
First reading
reading
• Piston rings are worn or damaged.
Increased
reading
• If two adjacent cylinders are low, gasket is damaged .

• Valve is sticking .
• Valve seat or valve contact surface is incorrect.
Same
reading
maintained
EM-116
@
..
Nozzle side
9. Replace
New nozzle
Nozzle
~: 59
nozzle gaskets and re-install injection nozzles.
gaskets must be installed in the direction shown.
to cylinder head:
- 69 N'm (6 - 7 kg-m, 43 - 51 ft-Ib)
Combustion
chamber side
SEM511D
10. Install spill tube by holding nozzle holder.

•
Spill tube nut:
~: 39 - 49 N'm (4 - 5 kg-m, 29 - 36 ft-Ib)
11. Install injection tubes using two wrenches as shown.

Injection tubes:
~: 22 - 25 N'm (2.2 - 2.5 kg-m, 16 - 18 ft-Ib)
EM-117
OIL PAN
Removal
1. Drain oil.
2. Remove oil pan using tool as illustrated.
1) Insert Tool between oil pan and cylinder block.
• Do not drive seal cutter into oil pump or rear oil seal
retainer portion, or aluminum mating surfaces will be dam-
aged.
deformed.
2) Slide Tool by tapping it with a hammer, and remove oil pan.
Installation
1. Before installing oil pan, remove all traces of liquid gasket
Scraper '""'\
from mating surface using a scraper.
cylinder block.
SEM3508
• Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)

wide.
Use Genuine Liquid Gasket or equivalent.
Cut here.
~--=J Liquid gasket
SLC906
2. Apply liquid gasket to inner sealing surface as shown at left.

7 mm (0.28 In)
-1 Inner
side
Groove Bolt hole

SEM9098
EM-118
OIL PAN [][]
3. Apply liquid gasket to oil pan front oil seal and rear oil seal.
~ : Sealing point
SEM894BA

•
of oil pan.
• Attaching should be done within 5 minutes after coating.
5. Install oil pan and tighten bolts in the order shown in the
figure.
Wait at least 30 minutes before refilling engine oil.
Oil pan bolts:
~: 7 - 8 N"m (0.7 - 0.8 kg-m, 61 - 69 in-Ib)
SEM369D
EM-119
TIMING BELT
Camshaft Timing Belt

CAUTION:
a. Do not bend or twist timing belt.
b. After removing timing belt, do not turn crankshaft and camshaft separately because valves will strike
piston heads.
c. Ensure that timing belt, camshaft sprocket, crankshaft sprocket and belt tensioner are clean and free
from oil and water.
@)
~5 {O.' - 0.5, " - 43'
~: N.m (kg-m, in-Ib)

A: N.m (kg-m, ft-Ib)
L : Locking sealant SEM046FA
C"O Front camshaft sprocket @ Belt cover lower @ Belt cover upper
@ Idler @ Belt cover center (Engine @ Gasket
@ Belt tensioner mounting bracket) @) Front camshaft sprocket plate
@ Crankshaft sprocket (1) Timing belt
REMOVAL
1. Drain engine coolant from radiator.
2. Remove upper radiator hose and upper belt cover.
EM-120
TIMING BELT em
Camshaft Timing Belt (Cont'd)
4. Set NO.1 cylinder at TDC on its compression stroke. (TDC
is indicated by crankshaft pulley notch without painted
mark.)
5. Remove starter motor, and install ring gear stopper using

•
mounting bolt holes.
6. Remove crank pulley bolt.
7 .. Remove crank pulley using puller.
Be sure to securely attach puller jaws. Attach jaws only to
the rear side of pulley.
8. Remove lower belt cover.
9. Remove timing belt.

(1) Loosen tensioner pulley bolt, turn tensioner pulley counter-
clockwise then tighten bolt.
(2) Remove camshaft sprocket plate.
SEM520D
(3) Remove idler pulley.
SEM515D
(4) Remove timing belt with crankshaft sprocket.

(5) Remove tensioner pulley and return spring.
EM-121
TIMING BELT
Camshaft Timing Belt (Co nt' d)
INSPECTION
Timing belt
Visually check the condition of timing belt.
Replace if any abnormality is found.
Item to check Problem Cause

Tooth is broken/tooth • Camshaft jamming
root is cracked. • Distributor jamming
• Damaged camshaft/crankshaft oil seal
SEM394A
Back surface is • Tensioner jamming

cracked/worn. • Overheated engine
• Interference with belt cover
SEM395A
Side surface is worn. • Improper installation of belt

• Malfunctioning crankshaft pulley plate/timing
belt plate
• Belt corners are worn and round.

• Wicks are frayed and coming out. SEM396A
Teeth are worn. • Poor belt cover sealing

• Coolant leakage at water pump
• Camshaft not functioning properly
- Rotating direction
- • Distributor not functioning properly
• Excessive belt tension
• Canvas on tooth face is worn down .

• Canvas on tooth is fluffy, rubber layer is
worn down and faded white, or weft is worn
down and invisible. SEM397A
Oil, coolant or water is • Poor oil sealing of each oil seal

stuck to belt. • Coolant leakage at water pump
• Poor belt cover sealing
EM-122
TIMING BELT [f[]
Belt tensioner, tensioner spring and idler
1. Check belt tensioner and idler for smooth turning.
2. Check condition of tensioner spring.
SEM558
Crankshaft sprocket and front camshaft sprocket

•
Check teeth for abnormal signs.
INSTALLATION
1. Install crankshaft sprocket plate in correct direction.
2. Confirm that NO.1 piston is set at TDC on its compression

stroke. (TDC is indicated by crankshaft pulley notch without
painted mark.)
SEM517D
3. Install tensioner and return spring.

Temporarily tighten bolts so that tensioner is set at the fully
outside position.
4. Install idler and tighten bolt to the specified torque.
SEM518D
EM-123
TIMING BELT @[]
5. Install timing belt with crankshaft sprocket.
a. Align white lines on timing belt with punchmarks on cam-
shaft sprocket and crankshaft sprocket.
b. Point arrow on timing belt toward belt cover.
6. Install camshaft sprocket plate and secure screws with lock-
tite.
7. Adjust timing belt tension.

1) Loosen tensioner lock bolt to apply tension to timing belt.
2) Rotate crankshaft clockwise two turns to apply the specified
tension to timing belt.
3) Tighten tensioner lock bolt while holding tensioner pUlley
with hexagon wrench. .
Belt tension:
147.1 :1:24.5 N (15:1:2.5 kg, 33.1 :1:5.5 Ib)
SEM520D
Injection Pump Timing Belt
SEC. 130-135 ~
.~\(~[-~~'
?\~-d(~K.
c
-"~
~1 Timing
t£
belt
r
Tensioner spring
J J N 0~lJ'00
c '0
~ / Tensioner
l\J~.~l:~
J 'Gl ~')U r~ /~
t0JD/~h~J/
It
'SP/
I L~0--~
_-z,}) ~ A
' ~htiJ
"
16 - 21 (1.6 - 2.1,12 - 15)
[/ .......
, ....... InJeclion ~
....~.
• '~~
-;;, pump@J_
sprocket ~ "fc;,~~-
@ ~ 59 - 69-.1
Rear camshaft sprocket .~ (6.0 • 7.0,
1m[O;l 43 - 51)
87 • 107
(8.9 - 10.9, 64 • 79)
~ . N'm (kg-m, in-Ib)
~ : N.m (kg-m, ft-Ib) SEM225F
REMOVAL
1. Set NO.1 cylinder at TDC on its compression stroke. (TDC
is indicated by crankshaft pulley notch without painted
mark.)
2. Remove air duct with resonator and timing belt cover.
EM-124
TIMING BELT [fQ]
Injection Pump Timing Belt (Cont'd)
1) Loosen tensioner lock nut and turn tensioner clockwise to
free belt from tension. Then temporarily tighten tensioner
nut.
2) Remove timing belt.
Injection pump pUlley

INSTAllATION
•
1. Confirm that NO.1 piston is set at TDC on its compression
stroke. (TDC is indicated by crankshaft pulley notch without
painted mark.)
• If injection pump pulley was removed, confirm that it is
re-installed as illustrated.
Identification of alignment:
Use mark "A"
2. Set timing belt.

a. Align white lines on timing belt with punchmarks on cam-
shaft sprocket and injection pump sprocket.
b. Point arrow on timing belt toward belt cover.
3. Adjust belt tension.

1) Loosen tensioner lock nut to apply tension to timing belt.
2) Rotate crankshaft clockwise two turns.
Do not turn crankshaft by camshaft sprockets.
3) Tighten tensioner lock nut while holding tensioner with a
screwdriver.
Belt tension:
147:l:49 N (15:l:5 kg, 33:l:11 Ib)
INSPECTION
Refer to INSPECTION in "Camshaft Timing Belt" (EM-122).
INJECTION TIMING ADJUSTMENT

Refer to EC section.
EM-125
VALVE Oil SEAL

1. Remove both timing belts.
2. Remove camshaft sprockets and back covers.
3. Remove camshaft brackets by loosening bracket nuts from
center to outside in two or three stages.
4. Remove camshaft oil seals and camshaft.
5. Remove valve lifters and mark order No. on each lifter.

6. Replace valve oil seal according to the following procedure.
When replacing valve all seal, set the corresponding piston at
TOe. Failure to do so causes the valve to drop into the cylin-
der.
1) Set NO.1 cylinder at TOG.
2) Remove valve springs and valve oil seals for NO.1 and No.
4 cylinders. Valve spring seats should not be removed.
3) Install new valve oil seals for No.1 and NO.4 cylinders as
+0.3
15.2 -0.3 mm
illustrated. Reinstall valve springs. (narrow pitch side
toward cylinder head)
(0598 +0.012 In) 4) Install valve spring retainers on intake valves and valve
. -0.012
rotators on exhaust valves, and remount valve assembly.
5) Set NO.2 cylinder at TOG.
6) Replace valve oil seals for No.2 and No.3 cylinders accord-
ing to steps 2) and 3).
7) Install valve lifters in original positions.
~
SEM512D
CAMSHAFT AND CRANKSHAFT Oil SEAL INSTALLING

DIRECTION AND MANNER
• When installing camshaft and crankshaft oil seals, be care-
ful to install them correctly, as shown in the figure.
• Apply engine oil to oil seal lip, outer face, camshaft and
Engine /'t r-l'\. Engine
inside Y LV outside
bracket. .
• Wipe off excess all after installing oil seal.
SEM715A
CAMSHAFT Oil SEALS

1. Remove timing belts, sprockets and back covers.
2. Pull out oil seal with a suitable tool.
EM-126
3. Install new oil seals with a suitable tool.

Confirm turning direction of both oil seals and camshaft .
Rear Front
SEM240D
CRANKSHAFT FRONT OIL SEAL

•
1. Remove valve timing belt and crankshaft sprocket.
2. Remove oil seal with a suitable tool.
3. Apply engine oil to new oil seal and install oil seal using a
suitable tool.
CRANKSHAFT REAR OIL SEAL

1. Remove transaxle assembly. (Refer to "REMOVAL AND
INSTALLATION" in MT section.)
2. Remove flywheel.
3. Remove rear oil seal with a suitable tool.
4. Apply engine oil to new oil seal and install oil seal using a
suitable tool.
EM-127
CYLINDER HEAD
SEC. 111-130-135
[O.J 87 - 107 (8.9 - 10.9, 64 - 79)
/ Swirl chamber
(Combustion chamber)
Valve seat
[O.J 87 • 107 (8.9 - 10.9, 64 - 79)
[O.J : N. m (kg-m, ft-Ib)
f] : Lubricate with new engine oil.

SEM226F
G) Camshaft @ Selective cylinder head gasket @ Hydraulic valve lifter

@ Front oil seal @) Valve @ Rear back cover
@ Collar @ Spring seat @ Rear camshaft sprocket
@ Grommet @ Valve spring @ Grommet
@ Front back cover @ Valve oil seal @) Collar
@ Front camshaft sprocket plate @ Spring retainer (INT)/Valve @ Rocker cover gasket
(J) Front camshaft sprocket rotator (EXH) @ Cam bracket
@ Spring @ Valve cotter @ Rear oil seal
For hydraulic valve lifter

• Before starting engine, make sure that valve does not hit piston when rotating crankshaft by hand.
• When bleeding air out from hydraulic valve lifter, run engine at more than 2,400 rpm for 20 minutes
or more.
EM-128
CYLINDER HEAD
Removal
1.
Drain coolant and disconnect front exhaust pipe from man-
ifold.
2. Remove water hoses, air duct and intake manifold.
3. Remove heat shield and exhaust manifold.
•
4. Remove rocker cover and injection tubes .
5. Remove both timing belts.
Set NO.1 cylinder at TDC on its compression stroke. Refer
to "TIMING BELT" (EM-120).
After timing belts have been removed, do not rotate crankshaft
SEM373D
and/or camshaft separately as valves will hit piston heads.
6. Remove cylinder head in numerical order as shown in the
figure.
SEM682D
Disassembly
1. Remove front camshaft sprocket plate, front and rear
sprockets using special service tool or a suitable tool, and
front back cover.
2. Remove camshaft brackets in order from outside to inside.
• Loosen camshaft bracket nuts in two or three stages.
3. Remove camshaft and oil seals.
SEM864
4. Remove valve lifters.

For hydraulic valve lifter
• Do not set hydraulic valve lifters as illustrated as air will
enter valve lifter causing malfunction.
• Do not disassemble hydraulic valve lifters.
• Attach tags to valve lifters to prevent mixing them up.
• Valve lifters must be put in engine oil after removal.
SEM715B
5. Remove valve component parts using special service tool

or a suitable tool.
• Keep each valve and its components together and mark
them so they can be reassembled in their original positions.
EM-129
CYLINDER HEAD
6. Remove valve oil seals using special tool.
Inspection
1. Visually check for cracks and deformation.
2. Check cylinder head for distortion.
Head surface flatness:
If beyond the specified limit, replace or resurface cylinder
head.
Resurfacing limit:
Warpage of surface: The resurfacing limit of the cylinder head is related to the
Less than 0.1 mm (0.004 in) amount of resurfacing of the cylinder block.
When:
"A" is the amount of resurfacing needed for the cylinder head
and "8" is the amount of resurfacing needed for the cylinder
block, the maximum limit is determined by
A + 8 = 0.1 mm (O.004 in)
freely by hand. If resistance is felt, the cylinder head must be
replaced.
Nominal height of cylinder head:
137.9. 138.1 mm (5.429 . 5.437 in)
SEM595A

1. Measure deflection across the cylinder head as illustrated.
Valve deflection limit (dial gauge reading):
0.1 mm (0.004 in)
2. If exceeding the limit, check valve-to-guide clearance.

_ Mic~rmeter a) Measure valve stem diameter and valve guide inner diam-
eter as illustrated.
l
..;-
~
@f b) Check that clearance is within the specification .
Valve stem to valve guide clearance limit:
--I\" Y 0.1 mm (O.004 in)
'~~':-- +x c) If exceeding the limit, replace valve or valve guide.
'~o rA1 - Center
[gJ Bottom
Valve guide Valve

SEM244D
EM-130
CYLINDER HEAD []Q]
Inspection (Cont'd)
1. Heat cylinder head in oil to 150 to 160°C (302 to 320°F).
2. Drive out valve guide using a press or hammer and a suit-
able tool.
3. Ream cylinder head valve guide bore.

•
Reaming bore (service part):
11.185.11.196 mm (0.4404 . 0.4408 in)

service valve guide onto cylinder head.
Final size:
7.000 . 7.015 mm (0.2756 . 0.2762 in)
VALVE SEATS
1. Check valve and valve seat for contact.
Coat the valve face with prussian red lead. If contact is
wrong, correct valve seat. If the valve red lead appears 360°
around face, the valve stem and face are concentric. If not,
repair or replace valve.
NG NG
SEM722BA
2. Check valve seats for pitting at contact surface. Resurface

or replace if excessively worn.
Correct valve seat surface.
When repairing valve seat, check valve and valve guide for
wear beforehand. If worn, replace them. Then correct valve
seat.
EM-131
CYLINDER HEAD [£Q]
Inspection (Cont'd)
VALVE SEAT REPLACEMENT
I 1. Bore out old seat until it collapses.
I
I
Recess diameter
Set machine depth stop so that boring cannot contact bot-
tom face of seat recess in cylinder head.
2. Ream the cylinder head recess.
[Oversize 0.5 mm (0.020 in)]:
Intake 41.432 - 41.454 mm (1.6312 - 1.6320 in)
Exhaust 35.432 - 35.454 mm (1.3950 - 1.3958 in)
Use the valve gUide center for reaming to ensure valve seat will
SEM795A have the correct fit.
3. Heat cylinder head to a temperature of 150 to 160°C (302 to
320°F) and press fit seat until it seats on the bottom.
4. Install valve seats.
When replacing valve seat, valve should be replaced as well.
5. Cut or grind valve seat using a suitable tool at the specified

dimensions as shown in SOS (EM-172).
The cutting should be done with both hands to obtain a uniform
and concentric finish.
SEMB76
6. Apply a small amount of fine grinding compound to the

valve's contacting face and put the valve into its guide.
Lap valve against its seat until proper valve seating is
obtained.
SEM877
W: Refer to SOS.
SEM635AA
EM-132
CYLINDER HEAD @Q]
Inspection (Cont'd)
T (Margin thickness)
VALVE DIMENSIONS
II
,
1. Check dimensions of each valve. For dimensions, refer to
SDS (EM-171).
a 2. Correct or replace any valve that is faulty .
.
~I T(Th)
D
d •
L
L-~
SEM188A
3. Valve face or valve stem end surface should be refaced by

using a valve grinder.
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace the valve.
Grinding allowance tor valve stem tip is 0.5 mm (0.020 in) or
less.
VALVE SPRING SQUARENESS

Check valve spring for squareness using a steel square and flat
surface plate.
If spring is out of square "S" more than specified limit, replace
with new one.
Out-at-square:
Outer
Inner
less than 1.9 mm (0.075 in)
SEM333
VALVE SPRING PRESSURE LOAD

Measure the free length and the tension of each spring. If the
measured value exceeds the specified limit, replace spring.
EM113
HYDRAULIC VALVE LIFTER
• 1. Check contact and sliding surfaces for wear or scratches .
SEM7238
EM-133
CYLINDER HEAD
Inspection (Cont'd)
2. Check diameter of valve lifters.
Outer diameter:
34.959 - 34.975 mm (1.3763 - 1.3770 in)
SEM724B
3. Check valve lifter guide bore.

Bore diameter
34.998 - 35.018 mm (1.3779 - 1.3787 in)
Standard clearance
0.023 - 0.059 mm (O.0009 - 0.0023 in)
COMBUSTION CHAMBER REPLACEMENT

Usually combustion chambers should not be removed.
However, if they show cracks or extensive damage, they should
be replaced.
1. Remove glow plug connecting plate, glow plugs and injec-
tion nozzle.
2. Heat cylinder head in oil to between 150 and 160°C (302 and
320°F).
3. Remove combustion chamber so that cylinder head will not
be damaged.
SEM720B Be careful not to scratch inside of nozzle hole.
4. Install combustion chamber.
WKOO"'P;O a.
b.
Heat cylinder head 150 to 160°C (302 to 320°F) in oil.
Align combustion chamber knock pin with cylinder head
notch, and install it into cylinder head using a plastic-tip
Notch
hammer.
~~~
SEM721B

CAMSHAFT END PLAY

2. Tighten bracket bolts to the specified torque.
Camshaft end play: Standard
0.115 - 0.188 mm (O.0045 - 0.0074 in)
EM-134
CYLINDER HEAD
Inspection (Cont'd)
CAMSHAFT RUNOUT
Limit 0.05 mm (0.0020 in)
2. If it exceeds the limit, replace camshaft.
CAMSHAFT CAM HEIGHT

•
Cam height: Standard
Unit: mm (in)
Intake 49.20 - 4925 (1.9370 - 1.9390)
Exhaust 49.15 - 49.20 (1.9350 - 1.9370)
2. If wear is beyond the limit, replace camshaft.

Using micrometer
1. Measure the inner diameter of camshaft bearings.
30.000 - 30.021 mm (1.1811 - 1.1819 in)
Tighten bracket bolts to the specified torque.
2. Measure the outer diameter of camshaft journals.

29.935 - 29.955 mm (1.1785 - 1.1793 in)
If clearance exceeds the limit, replace camshaft and/or cylinder
head.
Standard clearance:
0.045 - 0.086 mm (0.0018 - 0.0034 in)
Limit: 0.1 mm (0.004 in)
Using plastigage
1. Wipe off oil from camshaft journal bracket caps and brack-
ets.
2. Install camshaft in journal bracket caps and put plastigage
on each camshaft journal.
3. Install cam bracket caps and tighten cam bracket cap nuts
in the correct order to the specified torque.
~: 18 - 22 N'm (1.8 - 2.2 kg-m, 13 - 16 ft-Ib)
EM-135
CYLINDER HEAD [£Q]
Inspection {Co nt' d)
4. Remove cam bracket caps and measure maximum width of
plastigage.
Camshaft bearing clearance:
Limit
0.1 mm (0.004 in)
5. If clearance appears to exceed the limit, replace camshaft
or cylinder head.
• Which parts to be replaced should be decided upon after
measuring the diameters of the parts concerned.
Assembly
Install valve spring with its narrow pitch side toward cylinder
head side.
• Always install new valve oil seals.
Refer to oil seal replacement.
• Before installing oil seal, install valve-spring seat.
• When installing valve, apply engine oil on the valve stem
and lip of valve oil seal.
• Check whether the valve face is free from foreign matter.
SEM202
• Install valve spring retainers on the intake side and valve

rotators on the exhaust side.
• Valve rotators cannot be disassembled.
SEM731BA
Grade number 2. Install camshaft and brackets and tighten bracket nuts to the
Tightening sequence specified torque in two or three stages.
Camshaft-bracket nuts:
r
1@@
~: 18 - 22 N'm (1.8 - 2.2 kg-m, 13 - 16 ft-Ib)
~.~.~
o W ,..0
•
•
•
Tighten bracket from center to outside.
Apply sealant to brackets No. 1 and No.5.
When installing "brackets, set camshaft so that the pin of
@ @ @ camshaft front head is uppermost.
Facing front of engine • Install new camshaft oil seals.
(position 2) Refer to oil seal replacement.
SEM528D
17.5 (0.689) 13.0 (0.512)
o
NO.1 journal bracket No.5 journal bracket
Unit: mm (in) SEM676D
EM-136
CYLINDER HEAD
Cylinder head bolt Installation

1. Install cylinder head gasket.
• When replacing only cylinder head gasket, install same
grade gasket as the one formerly used.
• When replacing or repairing cylinder block, piston, connect-
ing rod and crankshaft, select gasket referring to "Selecting •
cylinder head gasket".
• Pay attention to the direction of the cylinder head bolt
washer as shown in the figure.
2. Install cylinder head and tighten cylinder head bolts accord-
ing to the following sequence.
Tightening procedure
• Apply engine oil to threads and underhead seating face of
each bolt.
1.- Tighten bolts in numerical order shown in the figure follow-
ing steps below.
@ 39 N'm (4.0 kg-m, 29 ft-Ib)
@ 83 - 93 N'm (8.5 - 9.5 kg-m, 61.2 - 68.6 ft-Ib)
@ Return to 0 N'm (0 kg-m, 0 ft-Ib)
@ 39 N'm (4.0 kg-m, 29 ft-Ib)
@ Tighten to 75 - 80°
If it is difficult to check tightening angle of bolt, tighten to 83
to 93 N'm (8.5 to 9.5 kg-m, 61 to 69 ft-Ib).
N.m (kg-m, ft-Ib)

83 - 93
(8.5 - 9.5, (Iii (~)
61.2 - 68.6)
39 (4.0, 29)
o N.m (0 kg-m, 0 ft-Ib)
SEM673DA
2. Install rocker cover.

• Install rocker cover in the sequence shown at left.
SEM678D
EM-137
CYLINDER HEAD @[]
• Apply sealing compound (THREE-BOND No. 10 or equiva-
lent) to both ends of brackets No.1 and No.5.
Selecting cylinder head gasket

When replacing only cylinder head gasket, install the same
grade (Number of notches) gasket as the one formerly used.
Step 1
Measure projection of piston to cylinder head surface.
a) Set dial gauge and needle on cylinder block and adjust dial
gauge to zero.
b) Set dial gauge needle at measuring point on piston, taking
care not to disturb its zero setting.
c) Rotate crankshaft around the top dead center position.
d) Read and write down the maximum value.

e) Reset dial gauge on cylinder block and confirm that zero
setting has not been disturbed during measurement.
f) Repeat steps b through d for all measuring points as illus-
trated and for each cylinder.
• Be sure that piston whose projection is being measured is
at its TDC.
Step 2
Calculate the average value of measurements taken for each
piston.
Unit: mm (in)
SEM529D Step 3
Calculate the average value of measurements for all pistons
from the values obtained from step 2.
Step 4
Round off the value obtained.
Step 5
Determine required thickness of gasket, referring to chart A.
EM-138
CYLINDER HEAD [£[]
Relation between piston average projection and cylinder head
gasket (Chart A)
Average value of Grade

Gasket thickness
piston projec- (Number of
mm (in)
tions notches)
•
mm (in) New parts In assembly
1.1~gg~
1.25 (0.0492) 0
Less than 0.505 (0.0433 ~ ggg;~)
(0.0199) 1.15 _+gg~
SEM530D
1.30 (0.0512) 1
(0.0453 ~ggg~g )
0.505 - 0.555 1.20_+gg~
1.35 (0.0931) 2
(0.0199 - 0.0219) (0.0472 ~ ggg~g)
. Over 0.555 1.25_+gg~
1.40 (0.0551) 3
(0.0219) (0.0492 ~ ggg~g)
Step 6
Check if the average value of each projection obtained from
step 2 is larger than the max. value of the standard projection
(of selected gasket) incremented by 0.05 mm (0.0020 in).
If so, use gasket that is 1 grade thicker. If not so, use gasket as
selected in step 4.
Example
Unit: mm (in)
Cylinder No.
Step 1 2 3 4
Item
M1 M2 M3 M4 M1 M2 M3 M4 M1 M2 M3 . M4 M1 M2 M3 M4
Measured
1. 0.53 0.56 0.53 0.56 0.59 0.55 0.59 055 0.53 0.58 0.57 0.54 0.58 0.51 052 0.57
value
(0.0209) (0.0220) (0.0209) (0.0220) (0.0232) (0.0217) (0.0232) (0.0217) (0.0209) (0.0228) (0.0224) (0.0213) (0.0228) (0.0201) (0.0205) (0.0224)
Average
0.545 0.57 0.555 0.545
2 value of each
(0.0215) (0.0224) -(0.0219) (0.0215)
piston
Average
3 value of all 055375 (0.02180)
pistons
Round off
4. 0.554 (0.0218)'1
value
Determined
gasket thick-
5. 120 (0.0472) (Grade 8)
ness (Tempo-
rarily)
X: Maximum value of standard projection of selected gasket ... 0.555 (0.0219) (in chart A) + 0.05 (0.0020) = 0.605 (0.0238)
6. Y: Maximum value in step 2 = 0.57 (0.0224)
The relationship between X and Y is "X > Y.... 2
Determined
7. gasket th ick- 1.20 (0.0472) (Grade 8)'2
ness (Finally)
*1: II the average value 01 projections lor all pistons is, lor example, 0.553 (7) 5, as shown in the table above, it should be rounded oil as fol-
lows:
II the digit in the forth decimal place (which is enclosed by a circle in this case) is smaller than 5, the average value should be regarded
as 0.553 mm (0.0218 in); il it is larger than 5, the average value should be regarded as 0.554 mm (0.0218 in).
*2: II X < Y, then the thicker grade C gasket must be used.
EM-139
ENGINE REMOVAL
SEC. 112
~ 44.54 (4.5.5.5,33 - 40)
~44 . 54 (4.5 . 5.5, 33 . 40) ~~
~ 44 • 54 (4.5 . 5.5, 33 • 40)"\

~~'
~ -~1J. ~1
~
~64.74 ,
_' 2 (6.5 . 7.5, / \
~ 47.54),/'
rJ44. 54 (4.5.5.5,33 - 40) ~ \
'" ~~~44.54 \....
.- ,9 (4.5 . 5.5,
ttJJ 44 - 54 (4.5 • 5.5, 33 - 40) 7 ttJJ 64 . 75 ------ ~

@--." ('.5 • 7.5, 4~' \ y~
~~.~~ /'Oolk..,
k(j'
ttJJ 64.75 (6.5 • 7.5, 47 • 54)
~ ~f;fi\~~~'~i':-l~"
~
--. II!~o'
~'o @ \ ~
8 ,.'~
~- I 2 rJ64. 75 (6.5 .7.5,47.54)..1"""-../ ~2 ft -."~ ° >
j~~~1 ~-/A.~/
.Vi
~44. 54 ~@ ttJJ44. 54 (4.5 - 5.5, 33. 40)
(4.5 - 5.5, 33 • 40) ti ~ ~ 44 • 54 ~'@
5~' ! -'~ ~35'-4~.)5'~ ~ / ,0 7
~ I~. ' rJ44. 54 (4.5.5.5,33.40)
~ ~l
~l
~
I...",;S'" 1. 'l o.o~
..J'-;:7o 6
\
'LrJ
ttJJ 44 • 54 (4.5 • 5.5, 33 • 40)
ttJJ 44 . 54 (4.5 • 5.5, 33 • 40)
44 • 54 (4.5 - 5.5, 33 • 40)

ttJJ 44 . 54 (4.5 . 5_5, 33 . 40)
rJ N.m (kg-m. ft-Ibl
SEM050F
G) Engine front mounting @ Buffer rod @ Roll damper

@ Engine mounting bracket @ Center member @) Engine rear mounting
@ Gusset (J) Transaxle mounting @ Engine rear mounting bracket
@ Buffer rod bracket @ Transaxle mounting bracket @ Dynamic damper
WARNING:
• Situate vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• Do not remove engine until exhaust system has completely
cooled off. Otherwise, you may burn yourself and/or fire
may break out in .the fuel line.
• For safety during subsequent steps, the tension of wires
• Before removing front axle from transaxle, place safety
stands under designated front supporting points. Refer to GI
section for lifting points and towing.
• Be sure to hoist engine and transaxle in a safe manner.
• For engines not equipped with engine slingers, attach
CAUTION:
• When lifting engine, be sure to clear surrounding parts.
Take special care for accelerator wire casing, brake lines
and brake master cylinder.
manner.
• In removing drive shaft, be careful not to damage transaxle
oil seal.
EM-140
ENGINE REMOVAL
1. Remove engine undercovers and splash covers.

2. Remove front exhaust tube.
3. Drain coolant and disconnect lower water hose from radia-
tor.
4. Drain transaxle oil.
5. Disconnect electrical wiring from cooling fan.
6. Remove power steering mounting bolt. •
7. Drain coolant from cylinder block.
8. Disconnect water hoses and remove radiator.
9. Disconnect fuel tubes and vacuum tubes.
10. Release power steering belt adjusting nut and remove
power steering pump from engine.
Bind pump properly to the vehicle.
11. Disconnect or remove electrical wiring where necessary.
12. Release clutch lever cable and accelerator cable.
13. Remove speedometer pinion connector from transaxle.
14. Remove front wheels.
15. Remove brake caliper mounting bolts and bind caliper prop-
erly to vehicle (coil spring) LH & RH.
SFA110A
16. Remove lower ball joint nuts and release the upper hub
mounting bolts.
17. Release steering arm ball joint using a suitable tool.
Remove drive shafts from transaxle.
1) RH: Split drive shaft center thrust bearing.
2) RH & LH: Remove hub mounting bolts and remove drive
shaft carefully from transaxle.
SFA 1538
18. Mount suitable slingers to cylinder head. Fit hoist with

studge and hoist engine to release force on engine mount-
ings.
SEM534D
EM-141
ENGINE REMOVAL
19. Remove engine mounting bracket.
SEM535D
20. Release transaxle shift linkages.
SEM536D
21. Release transaxle mounting.
22. Remove center member from chassis.
EM-142
CYLINDER BLOCK
SEC. 110-120
(]~ • 83 - 93
l
(8.5 - 9.5
61 - 69)
o
o @f]-
@~~
(] ~ 76 - 78 (7.8 - 8.0, 56 - 58)
~
Piston ring
!~ l"J R,t" I. "A,~mbly".
(J) Rear plate

f] : Lubricate
@
with new engine oil.
Main bearing
SEM227F
CD
@ Piston @ Flywheel @ Crankshaft
@ Piston pin @ Rear oil seal @ Main bearing
@ Connecting rod bearing @) Rear oil seal retainer @ Gusset
@ Connecting rod @ Gusset @ Drain plug
@ Main bearing cap @ Cylinder block @ Pilot bushing
EM-143
CYLINDER BLOCK
Preparation
• Drill a hole into the attachment (KV10108101).
Unit: mm (in) 183.0 (7.205) SEM707D
Disassembly
2. Drain coolant and oil.
4. Remove water pump.
5. Remove oil pan and oil pump.
6. Remove cylinder head.
7. Remove pistons with connecting rods.
When disassembling piston and connecting rod, heat piston to

60 to 70°C (140 to 158°F) or use piston pin press stand at room
temperature.
Heater
SEM360D
8. Remove bearing cap and crankshaft.

Place the bearings and caps in their proper order.
Upper bearings (cylinder block side) have oil groove.
Loosen in numerical order. SEM564A
9. Remove piston rings with a tool.
SEM291
EM-144
CYLINDER BLOCK
Inspection
1. Measure outer diameter of piston pin and inner diameter of
piston pin hole.
2. Calculate piston to piston pin clearance.
Pin diameter: •
24.994 • 25.000 mm (0.9840 - 0.9843 in)
Pin hole diameter:
24.991 - 24.999 mm (0.9839 - 0.9842 in)
Clearance:
-0.004 to 0 mm (-0.0002 to 0 in)
(Interference fit)
Service parts are available as a set of piston and piston pin.

Side clearance:
Unit: mm (in)
Standard Limit
0.060 - 0.095
Top ring 0.10 (0.0039)
(0.0024 - 0.0037)
0.040 - 0.075
2nd ring 0.10 (0.0039)
(0.0016 - 0.0030)
0.030 - 0.070
Oil ring 0.10 (0.0039)
(0.0012 - 0.0028)
If out of specification, replace piston and/or piston ring assem-

bly.
EM-145
CYLINDER BLOCK
Inspection (Cont'd)
PISTON RING END GAP
Feeler
End gap:
gauge Unit: mm (in)
Standard Limit
Bore grade 1, 2, 3
0.20 - 0.30 (0.0079 - 0.0118)
Top ring 1.0 (0.039)
Bore grade 4, 5
0.12 - 0.22 (0.0047 - 0.0087)
SEM599A 2nd ring 0.38 - 0.53 (0.0150 - 0.0209) 0.7 (0.028)
Oil ring 0.30 - 0.55 (0.0118 - 0.0217) 0.6 (0.024)
• If out of specification, replace piston ring. If gap exceeds

maximum limit with new ring, rebore cylinder and use over-
size piston and piston rings.
• When replacing the piston, check the cylinder block surface
for scratches or evidence of seizure. If scratches or evi-
dence of seizure is found, hone or replace the cylinder
block.
MAIN BEARING CLEARANCE

1. Install main bearings to cylinder block and main bearing
cap.
2. Install main bearing cap with bearing to cylinder block.
Tighten all bolts in two or three stages.
~: 44 - 54 N'm (4.5 - 5.5 kg-m, 33 - 40 ft-Ib)
3. Measure inside diameter" A" of main journal.
4. Measure outside diameter "Om" of main journal of crank-

shaft.
Journal diameter:
Standard:
0.039 - 0.065 mm (0.0015 - 0.0026 in)
• If it exceeds the limit, replace the bearing.
SEM506A
• If crankshaft main journal is worn or shows any

abnormality, regrind crank journal and use undersized
bearings to maintain the specified oil clearance.
• Refer to SOS for regrinding crankshaft journal diameter and
available service parts (EM-174).
• When regrinding crankshaft journal, do not grind fillet-roll.
Main jOUrnal~
Maintain more than 0.13 mm (0.0051 In)

SEM566B
EM-146
CYLINDER BLOCK @[]
Inspection (Cont'd)
• If either bearing, crankshaft or cylinder block is replaced
with a new one, select main bearing according to the fol-
lowing table. These numbers are punched in either Arabic
or Roman numerals.
Main bearing housing grade number
•
0 1 2
Main bearing grade number
0 0 1 2
Crankshaft main jour-
1 1 2 3
nal grade number
2 2 3 4
NO'1 main journal grade number

Identification color:
NO.2 No.4 Grade 0 Yellow
"" No. 3 / No. 5
~ ~'S"bci~
0000 "') N 1
Grade 1 Green
~ o. Grade 2 Brown
- Counterweight
"\ /i Grade 3 Black
Grade 4 Blue
SEM706DA
No. 1 journal grade number For example:

~No. 5
Main bearing grade number = 1 + 2 3
Main bearing thickness:
Q
Front 0
SEM706A
CONNECTING ROD BEARING CLEARANCE (Big end)

2. Install connecting rod cap with bearing to connecting rod.
Apply oil to the thread portion of bolts and seating surface of
nuts.
toJ:
37 - 45 N'm (3.8 - 4.6 kg-m, 27 - 33 ft-Ib)
3. Measure inside diameter "C" of bearing.
SEM507A
EM-147
CYLINDER BLOCK [][]
Inspection (Cont'd)
4. Measure outside diameter "Dp" of crankshaft pin journal.
Connecting rod bearing clearance = C - Op
Standard:
0.031 - 0.055 mm (0.0012 - 0.0022 in)
• If it exceeds the limit, replace the bearing.
Pin jOUrnal~ • If crankshaft pin journal is worn or shows any abnormality,
regrind crank pin and use undersized bearings to maintain
the specified oil clearance.
• Refer to SOS for regrinding diameter of crankshaft pin and
Maintain more than 0.13 mm (0.0051 in)
SEM361D available service parts (EM-174).
• When regrinding crankshaft pin, do not grind fillet-roll.
Selective connecting rod bearing

NO' 1 pin journal grade number • If either bearings or crankshaft are being replaced with new
NO' 2 No.3 ones, select connecting rod bearings according to the fol-
__ NO.4
,/ lowing table. Grade numbers are punched in either Arabic
o J 0 0 ~ NO.1
~ ~ ~ C,"'''ffl.;ghl or Roman numerals.
Crankshaft pin journal grade number
0 1 2
Connecting rod baring grade num-
0 1 2
ber
SEM705D
Identification color
Grade 0: Black
Grade 1: Yellow
Grade 2: Blue
CONNECTING ROD AND PISTON PIN CLEARANCE

(Small end)
Clearance (0 - d):
0.025 - 0.044 mm (0.0010 - 0.0017 in)
• If clearance exceeds the specifications, replace the bearing.
Clearance =0 - d
SEM575B
EM-148
CYLINDER BLOCK
Inspection (Cont'd)
Bearing replacement
1. Remove bearing with a suitable tool.
Do not scratch inner surface of connecting rod .
2. Install new bearing with oil holes aligned correctly.

•
3. Ream bore using a suitable tool.
Ream bore:
25.025 - 25.038 mm (0.9852 - 0.9857 in)

Bend and torsion [per 100 mm (3.94 in) length]:
Bend Less than 0.025 mm (0.0010 in)
Torsion Less than 0.025 mm (0.0010 in)
A B CRANKSHAFT
1. Check crankshaft journals and pins for score, bias, wear or
cracks. If faults are minor, correct with fine crocus cloth.
2. Check journals and pins with a micrometer for taper and
out-of-round.
Out-of-round (X - V):
y
Taper (A - B):
Taper: A - B Less than 0.005 mm (0.0002 in)
Out-ot-round: X - y
SEM316A
3. Check crankshaft runout.

EM-149
CYLINDER BLOCK
Inspection (Cont'd)
CYLINDER BLOCK DISTORTION
Measuring points
Clean upper face of cylinder block and measure the distortion.
Limit:
0.10 mm (0.0039 in)
If out of specification, resurface it.
The resurfacing limit of cylinder block is determined by cylin-
der head resurfacing in an engine.
Warpage of surface:
SEM655A

A + B = 0.1 mm (0.004 in)
If necessary, replace cylinder block.
SEM008D
CYLINDER BORE
~ Moving the bore gauge
1. Check for scratches or seizure. If seizure is found, hone
as shown, take the
//p' minimum reading. bore.
of-round or taper.
Standard bore diameter:
84.500 - 84.550 mm (3.3268 - 3.3287 in)
Unit: mm (in)
Bore wear limit 0.2 (0.008)
Out-aI-round (X - Y) standard 0.015 (0.0006)
Taper (A - B) standard 0.010 (0.0004)
y If it exceeds the limit, rebore all four cylinders. Replace cylin-

der block if necessary.
If cylinder block or piston is replaced, match piston grade with
grade number on cylinder block upper surface.
Unit mm (in)
SEM704DA
EM-150
CYLINDER BLOCK
Inspection (Cont'd)
Front 0000
SEM1768
Reboring
•
1. The size to which cylinders must be honed, is determined
by adding piston-to-cylinder clearance to the piston skirt
diameter" A".
Dimension "a":
Approximately 62 mm (2.44 in)
Rebored size calculation
o = A + B - C = A + [0.03 to 0.05 mm
62 mm (0.0012 to 0.0020 in)]
(2.44 in)
where,
SEM904-A o Honed diameter
A Skirt diameter as measured
B Piston-to-wall clearance
C Machining allowance
0.02 mm (0.0008 in)
2. Install main bearing caps and tighten bolts to the specified
torque. This will prevent distortion of cylinder bores.
3. Cut cylinder bores in the order of 2-4-1-3.
Do not cut too much out of the cylinder bore at a time. Cut only
4. Hone the cylinders to the required size referring to SOS
(EM-173).
5. Measure the finished cylinder bore for out-of-round and
taper.
Measurement of a just machined cylinder bore requires utmost
care since it is expanded by cutting heat.
PISTON- TO-BORE CLEARANCE

Using micrometer
1. Measure piston and cyl inder bore diameter.
Piston diameter "A":
Bore diameter "0":
Measuring point (Distance from the top):
2. Check that piston clearance is within the specification.
Piston clearance (0 - A):
0.025 - 0.045 mm (0.0010 - 0.0018 in)
EM-151
CYLINDER BLOCK @[]
Inspection (Cont'd)
Using feeler gauge
1. Set piston and feeler gauge with spring scale.
2. Measure extracting force while pulling up scale slowly.
Feeler gauge used:
0.05 - 0.07 mm (0.0020 - 0.0028 in)
Extracting force:
7.8 - 14.7 N (0.8 - 1.5 kg, 1.8 - 3.3 Ib)
SEM550
Assembly
PISTON
each cylinder. Care should be taken to avoid a wrong com-
bination including bearing and connecting rod direction.
SEM703D
• Install new snap ring on one side of piston pin hole.

• When assembling piston and connecting rod with piston pin,
heat piston to between 60 and 80°C (140 and 176°F) and
install piston pin with a suitable tool.
• Install new snap ring.
KV101070S0 • After assembling, ascertain that piston swings smoothly.
EM156
~r~~
• Install piston rings with a suitable tool.
Punch mark side up
Selective top ring; When installing new top ring or replacing
cylinder block, select top ring to adjust ring gap.
~ Tetl~n tube set position Cylinder bore grade
~ ,0 Top ring grade No.

1,2,3
No mark
4, 5
Ql 0 SEM251D
CRANKSHAFT
1. Set main bearings in the proper position on cylinder block
and main bearing caps.
• If either crankshaft, cylinder block or main bearing is reused
again, it is necessary to measure main bearing clearance.
• Upper bearings (cylinder block side) have oil groove.
• Apply new engine oil to bearing surfaces.
SEM617
EM-152
CYLINDER BLOCK [ill
Assembly (Cont'd)
2. Apply engine oil to main bearing surfaces on crankshaft
journal side.
3. Install crankshaft and main bearing caps.
Main bearing cap bolt:
~: 44 - 54 N'm (4.5 - 5.5 kg-m, 33 - 40 ft-Ib)
4. Tighten main bearing cap bolts.
• Arrange the parts so that the indicated numbers on bearing •
caps are in a row from the front of engine.
• Tighten bearing cap bolts gradually in two or three stages
and outwardly from center bearing in sequence.
• After securing bearing cap bolts, ascertain that crankshaft
turns smoothly.
• Apply new engine oil to threads of bearing cap bolts.
Engine front 1
t;J
SEM230F
5. Measure crankshaft free end play at center bearing.

Crankshaft free end play:
Standard
0.05 - 0.18 mm (0.0020 - 0.0071 in)
Limit
0.30 mm (0.0118 in)
PISTON WITH CONNECTING ROD

1. Install connecting rod bearings in the connecting rods and
connecting rod caps.
• Confirm that correct size of bearings is used.
Refer to "Inspection" (EM-147).
• Install the bearings so that the oil hole in the connecting rod
aligns with the oil hole of the bearing.
• Apply engine oil to connecting rod bearing surfaces on the
crankshaft journal side.
• Set piston rings as shown.
~~~:::~"
IJ
~ 2nd ring
SEM909
EM-153
CYLINDER BLOCK lliJ
Assembly (Conl'd)
EM03470000 or suitable tool
• Install them into corresponding cylinder using Tool.
• Be careful not to scratch cylinder wall with connecting rod.
• Apply engine oil to cylinder wall, piston and bearing.
• Arrange so that the front mark on piston head faces to the
front of engine.
3. Install connecting rod bearing caps.

• Apply engine oil to the thread of connecting rod bearing nut.
(1) Tighten connecting rod bearing nut to 15:1:1 N'm (1.5:1:0.1
kg-m, 10.8:1:0.7 ft-Ib).
(2) Then tighten an additional 60 +_~'.turns with an angular tight-
ening wrench.
~: 15:1:1 N'm (1.5:1:0.1 kg-m, 10.8:1:0.7 ft-Ib) plus
60+'::;. or
~: 37 - 45 N'm (3.8 - 4.6 kg-m, 27 - 33 ft-Ib)

Connecting rod side clearance (Big end play):
Limit
0.3 mm (0.012 in)
FLYWHEEL RUNOUT
EM-154
General Specifications
GENERAL SPECIFICATIONS
Engine GA14DE GA15DE GA16DE
Classification Gasoline
Cylinder arrangement
Displacement
Bore x stroke
Valve arrangement
Firing order
cm3 (cu in)
mm (in)
1,392 (84.94)
73.6 x 81.8 (2.898 x 3.220)

4, in-line
1,498 (91.41)
73.6 x 88.0 (2.898 x 3.465)
DOHC
1-3-4-2
1.597 (97.45)
76.0 x 88.0 (2.992 x 3.465)

•
Number of piston rings
Compression 1'2,2
.
Oil 1
Number of main bearings 5
Compression ratio 95 9.9 9.8'1, 9.9'2
Valve timing
~-r-y'
~U&l'
f 0,0
~J}&
BOC
EM120
Unit: degree
a b c d e
GA14DE 214" 214° 0° 34° _4° 38°
GA15DE 222° 222° 0" 42° -40 46°
GA16DE without
222° 214° 0° 34° 0° 42°
VTC
GA16DE with VTC

222" 236° _12° 68° 0° 42"
for Australia
GA16DE with VTC

except for Austra- 222° 248° 2" 66° -4" 46"
lia
'1: For Europe and Israel

'2: Except for Europe and Israel
EM-155
Inspection and Adjustment

ENGINE COMPRESSION PRESSURE CYLINDER HEAD
Unit: kPa (bar, kg/cm2, psi)/rpm Unit: mm (in)
Compression Standard Limit

Difference
ratio
Standard Minimum limit between Head surface Less than
Refer to SDS 0.1 (0.004)
cylinders flatness 0.03 (0.0012)
(EM-155).
117.8 - 118.0
1,324 (13.24, 1,128 (11.28, Height -
9.5 (4.638 - 4.646)
13.5, 192)/350 11.5, 164)/350
1,353 (13.53, 1,157 (11.57, 98 (0.98, 1.0,

9.8
13.8, 196)/350 11.8, 168)/350 14)/350
1,373 (13.7,14, 1,177 (11.8,12,

9.9
199)/350 171)/350
VALVE
Unit: mm (in)
---L
SEM188-b
GA14DE and GA15DE GA16DE
28.9 - 29.2 29.9 - 30.2

Intake
(1.138 - 1.150) (1.177 - 1.189)
Valve head diameter "0" 23.9 - 24.2 (0.941 - 0.949): without VTC
23.9 - 24.2
Exhaust 24.9 - 25.2 (0.980 - 0.992):
(0.941 - 0.953)
with VTC
Intake 92.00 - 92.5 (3.6220 - 3.6417)

Valve length "L"
Exhaust 92.37 - 92.87 (3.6366 - 3.6563)
Intake 5.465 - 5.480 (0.2152 - 0.2157)

Valve stem diameter "d"
Exhaust 5.445 - 5.460 (0.2144 - 0.2150)
Valve face angle "u" 45°15' - 45°45'

.
Valve margin 'T' limit 0.9 - 1.1 (0.035 - 0.043)
Valve stem end surface grinding limit Less than 0.2 (0.008)
Valve clearance
Unit: mm (in)
For adjusting For checking
Hot Cold* Hot
0.32 - 0.40 0.25 - 0.33 0.21 - 0.49

Intake
(0.013 - 0.016) (0.010 - 0.013) (0.008 - 0.019)
0.37 - 0.45 0.32 - 0.40 0.30 - 0.58

Exhaust
(0.015 - 0.018) (0.013 - 0.016) (0.012 - 0.023)
*: At a temperature of approximately 20°C (68°F)

Whenever valve clearances are adjusted to cold specifications,
check that the clearances satisfy hot specifications and adjust again
if necessary.
EM-156
SERVICE OATA AND SPECIFICATIONS (SOS)
Inspection and Adjustment (Cont'd)
Available shims Shim
Type A
Thickness mm (in) Identification mark
2.00 (0.0787) 200
2.02 (0.0795) 202
2.04 (0.0803) 204 Indicate
•
T = 2.68 mm (0.1055 In)
2.06 (0.0811) 206
Type B
2.08 (0.0819) 208
210 (0.0827) 210
2.12 (00835) 212
SEM104F
2.14 (0.0843) 214
216 (0.0850) 216
2.18 (0.0858) 218
2.20 (0.0866) 220
2.22 (00874) 222
224 (00882) 224
2.26 (0.0890) 226
2.28 (0.0898) 228
2.30 (0.0906) 230
2.32 (0.0913) 2.32
2.34 (0.0921) 234
2.36 (0.0929) 236
2.38 (0.0937) 238
240 (0.0945) 240
2.42 (0.0953) 242
2.44 (0.0961) 244
2.46 (0.0969) 246
2.48 (0.0976) 248
2.50 (00984) 250
2.52 (0.0992) 252
2.54 (0.1000) 254
2.56 (01008) 256
2.58 (0.1016) 258
2.60 (0.1024) 260
262 (0.1031) 262

2.64 (0.1039) 264
2.66 (0.1047) 266
2.68 (0.1055) 268
2.70 (0.1063) 270
2.72 (0.1071) 272
2.74 (0.1079) 274
2.76 (0.1087) 276
278 (0.1094) 278
2.80 (0 1102) 280
282 (0 1110) 282
284 (0.1118) 284
286 (0.1126) 286
2.88 (0 1134) 288
290 (0.1142) 290
2.92 (0.1150) 292
294 (0.1157) 294
296 (0.1165) 296
2.98 (0.1173) 298
EM-157
Valve guide
Unit: mm (in)
Intake Exhaust
Standard Service Standard Service
Valve gUide
9.523 - 9.534 9.723 - 9.734 9523 - 9.534 9.723 - 9.734

Outer diameter
(0.3749 - 0.3754) (0.3828 - 03832) (0.3749 - 0.3754) (0.3828 - 0.3832)
Valve guide
Inner diameter
5500 - 5.515 (0.2165 - 0.2171) 5.500 - 5.515 (0.2165 - 0.2171)
[Finished size]
9.475 - 9.496 9.685 - 9.696 9.475 - 9.496 9.685 - 9.696

Cylinder head valve guide hole diameter
(0.3730 - 0.3739) (0.3813 - 0.3817) (0.3730 - 0.3739) (0.3813 - 0.3817)
0.027 - 0.059 0.027 - 0.049 0.027 - 0.059 0.027 - 0.049

Interference fit 01 valve guide
(0.0011 - 0.0023) (0.0011 - 0.0019) (0.0011 - 0.0023) (0.0011 - 0.0019)
Stem to guide clearance 0.020 - 0.050 (0.0008 - 0.0020) 0.040 - 0.070 (0.0016 - 0.0028)
Valve deflection limit

0.2 (0.008) 0.2 (0.008)
(Dial gauge reading)
Projection length 11.5 - 11.7 (0.453 - 0.461)
Valve spring
Free height mm (in) 41.19 (1.6217)
344.42 (35.12, 77.44)

Standard
Pressure N (kg, Ib) at at 25.26 (0.9945)
height mm (in) 32373 (33.01. 72.79)
Limit
at 25.26 (0.9945)
Out-aI-square mm (in) Less than 1.80 (0.0709)
Valve lifter
Unit: mm (in)
Valve lifter outside diameter 29.960 - 29.975 (1.1795 - 1.1801)
Lifter guide inside diameter 30000 - 30.021 (1.1811 - 1.1819)
Clearance between lifter and

0.025 - 0.061 (0.0010 - 0.0024)
lifter guide
EM-158
Valve seat
Unit: mm (in)
INTAKE EXHAUST
Standard Standard
5.65 (0.2224) •
Oversize.
5.65 (0.2224)
@dia.
~dia~.-'--
<V dia.
'Cylinder head machining data
• Cylinder head machining data
SEM239F
SEM573DA
Dia. GA16DE without VTe GA14DE and 15DE GA16DE with VTe
@ 27.8 - 28.0 (1094 - 1 102) 26.4 - 26.6 (1.039 - 1.047) 27.8 - 28.0 (1.094 - 1.102)
@ 29.5 - 29.7 (1.161 - 1.169) 285 - 28.7 (1.122 - 1.130) 29.5 - 29.7 (1.161 - 1.169)
@ 319 - 32.1 (1.256 - 1.264) 302 - 30.4 (1.189 - 1.197) 31.9 - 32.1 (1.256 - 1.264)
@ 31.500 - 31.516 (1.2402 - 1.2408) 30.500 - 30.516 (1.2008 - 1.2014) 31.500 - 31.516 (1.2402 - 1.2408)
(f) 23.5 - 23.7 (0.925 - 0.933) 235 - 23.7 (0.925 - 0.933) 24.5 - 247 (0.965 - 0.972)
CD 25.200 - 25.4 (0.9921 - 1.0000) 25.200 - 25.4 (0.9921 - 1.0000) 26.2 - 26.4 (1.031 - 1.039)
@ 25.500 - 25516 (1.0039 - 1.0046) 25.500 - 25.516 (1.0039 - 1.0046) 26.500 - 26.516 (1.0433 - 1.0439)
EM-159
CAMSHAFT AND CAMSHAFT BEARING CYLINDER BLOCK
Unit: mm (in)
Camshaft
Unit: mm (in)
GA16DE
GA16DE
with
GA16DE with
Engine VTC
GA14DE GA15DE without VTC for
model
VTC
except
for
Europe
Aus-
tralia T
Q)
""
<1l 39,380 -
39,880 -
40070
(1.5701 -
39,380 -
39,570
(1.5504 -
40,610 -
40,800
(1.5988 -
40,610 -
40800
(1.5988 -
1
Cam C 1.5776) 1.5579) 1.6063) 1.6063) Crankshaft center
39.570
height -
(1,5504 - 40.056 - 39.880 - 40.056 - 39.91 -
"A" SEM171D
U; 1.5579)
:::l 40.246 40,070 40.246 40.100
<1l GA14DE
.c (1.5770- (1.5701 - (1.5770 - (1.5713 -
x GA16DE
w 1,5845) 1,5776) 1.5845) 1,5787) GA15DE Limit
Cam wear Standard
0.20 (0.0079)
limit Less than
Surface flatness 0,1 (0,004)
0,03 (0.0012)
213.95 - 214.05
Height "H" (nominal) -
(8.4232 - 8.4271)
Standard
Inner diameter
73.600 - 76.000 -
73,610 76,010
Grade No.1
EM671 (2.8976 - (2,9921 -
2.8980) 2.9925)
73.610 - 76.010 -
73,620 76020
Grade NO.2 0.2 (0,008)
(2.8980 - (2.9925 -
Camshaft bearing 2.8984) 2.9929)
Unit: mm (in)
73,620 - 76.020 -
Standard Limit 73.630 76.030
Grade No.3
(2,8984 - (2.9929 -
Camshaft journal to bear- 0,045 - 0.086
0,15 (0.0059) 2.8988) 2,9933)
ing clearance (00018 - 0.0034)
Out-ot-round Less than
28.000 - 28,021 -
NO.1 (X - Yi 0,015 (0.0006)
Inner diameter (1.1024 - 1 1032)
of camshaft - Less than
Taper (A - B) ._-
bearing No. 2 to 24,000 - 24021
0.01 (0.0004)
No, 5 (0.9449 - 0.9457)
Difference in inner
27.935 - 27.955 0,2 (0.008)
NO.1 diameter between 005 (0,0020)
Outer diameter (1,0998 - 1.1006)
cylinders
of camshaft .-
journal No. 2 to 23935 - 23.955

No, 5 (0,9423 - 0,9431)
Less than
Camshaft runout [TIR'1] 01 (0,004)
0.02 (0.0008)
0070 - 0 143
(0,0028 -
0.0056)'2
Camshaft end play 020 (0,0079)
0,115 - 0,188
(0.0045 -
0.0074)'3
'1: Total indicator reading

'2: GA 16DE without VTC and 14DE
'3: GA16DE with VTC and GA15DE
EM-160
SERVICE OATA AND SPECIFICATIONS (SDS)
PISTON, PISTON RING AND PISTON PIN Piston ring
Unit: mm (in)
Piston
Unit: mm (in) Standard Limit
0.040 - 0.080
Top
Side (0.0016 - 0.0031)
0.2 (0.008)
•
clearance 0.030 - 0.070
2nd'
(0.0012 - 0.0028)
0.20 - 0.35
Top
(0.0079 - 0.0138)
0.37 - 0.52
End gap 2nd' 1.0 (0.039)
(0.0146 - 0.0205)
0.20 - 0.60
Oil
(0.0079 - 0.0236)
': Applies to GA16DE without VTC, and 14DE.

SEM658D
GA16DE GA16DE
GA14DE GA15DE without with Piston pin
VTC VTC
Unit: mm (in)
Piston skirt diame-
ter "A" 18.989 - 19.001
Piston pin outer diameter
(0.7476 - 0.7481)
Standard
-0.004 to 0
Piston pin to piston clearance
Grade 73.575 - 73.585 75.975 - 75.985 (-0.0002 to 0)
NO.1 (2.8966 - 2.8970) (29911 - 2.9915)
Piston pin to connecting rod, 0.005 - 0.017
Grade 73.585 - 73.595 75.985 - 75.995 bushing clearance (0.0002 - 0.0007)
No. 2 (2.8970 - 2.8974) (2.9915 - 2.9919)
Grade 73.595 - 73.605 75.995 - 76.005

No. 3 (2.8974 - 2.8978) (2.9919 - 2.9923)
76.475 -
CONNECTING ROD
05 (0.020)
74.075 - 74105 Unit: mm (in)
oversize (ser- 76.505
(2.9163 - 2.9175)
vice) (3.0108 - 3.0120)
140.45 - 140.55
Center distance
1.0 (0.039) (5.5295 - 5.5335)
74.575 - 74.605 76.975 - 77.005
oversize (ser- Bend limit [per 100 (3.94)]
(2.9360 - 2.9372) (3.0305 - 3.0317) 0.15 (0.0059)
vice)
Torsion limit [per 100 (3.94)] 0.3 (0.012)
7.5 7.9 9.5 9.9
"a" dimension
(0.295) (0.311) (0.374) (0.390) Connecting rod bushing inner 19.000 - 19.012
diameter' (small end) (0.7480 - 0.7485)
Piston pin hole
18.987 - 18.999 (0.7475 - 0.7480)
inner diameter Connecting rod big end inner 43.000 - 43.013
diameter (1.6929 - 1.6934)
Piston pin outer
18.989 - 19.001 (0.7476 - 0.7481)
diameter Side clearance
Piston to bore Standard 0.200 - 0.470 (0.0079 - 0.0185)

0.015 - 0035 (0.0006 - 0.0014)
clearance Limit 0.52 (0.0205)
': After installing in connecting rod
EM-161
CRANKSHAFT MAIN BEARING
Unit: mm (in)
Standard
GA15DE
GA14DE
I GA16DE
Grade No.
Thickness "T"
Identification color
Main journal dia. mm (in)
"Dm"
1.827 - 1.831
Grade No. 0 49.956 - 49.964 (1.9668 - 1.9671) 0 Black
(0.0719 - 0.0721)
Grade NO.1 49.948 - 49.956 (1.9665 - 1.9668)
1.831 - 1.835
1 Brown
Grade NO.2 49.940 - 49.948 (1.9661 - 1.9665) (0.0721 - 0.0722)
Pin journal dia. "Dp" 1.835 - 1.839
2 Green
Grade No. 0 39.968 - 39.974 (1.5735 - 1.5738) (0.0722 - 0.0724)
Grade NO.1 39.962 - 39.968 (1.5733 - 1.5735) 1.839 - 1.843
3 Yellow
Grade No.2 39.956 - 39.962 (1.5731 - 1.5733) (0.0724 - 0.0726)
40.85 - 40.95 43.95 - 44.05

Center distance
Out-ot-round
"r"
(X - Y)
(1.6083 - 1.6122) I (1.7303 - 1.7342)
4
1.843 - 1.847
(0.0726 - 0.0727)
Blue
Standard Less than 0.005 (0.0002)

Taper (A - B)
Undersize
Unit: mm (in)
Runout [TIW]
Thickness "T"
Free end play 0.25 (0.0098) 1.960 - 1.964 (0.0772 - 0.0773)
Standard 0.060 - 0.180 (0.0024 - 0.0071) 0.50 (0.0197) 2.085 - 2.089 (0.0821 - 0.0822)
Limit 0.3 (0.012)
': Total indicator reading
AVAILABLE CONNECTING ROD BEARING

Unit: mm (in)
Grade No. Thickness Identification color or number
0 1.503 - 1.506 (0.0592 - 0.0593) -

Standard 1 1.506 - 1.509 (0.0593 - 0.0594) Brown
2 1.509 - 1.512 (0.0594 - 0.0595) Green
0.08 (0.0031) 1.542 - 1.546 (0.0607 - 0.0609) 8
Undersize 0.12 (0.0047) 1.562 - 1.566 (0.0615 - 0.0617) 12
0.25 (0.0098) 1.627 - 1.931 (0.0641 - 0.0642) 25
Bearing clearance MISCELLANEOUS COMPONENTS

Unit: mm (in) Unit: mm (in)
Main bearing clearance Camshaft sprocket runout limit

0.17 (0.0067)
[TIW]
0.018 - 0.042
Standard
(0.0007 - 0.0017) Flywheel runout [TIW] Less than 0.15 (0.0059)
Limit 0.1 (0.004) Drive plate runout [T1R'] Less than 0.2 (0.008)
Connecting rod bearing ': Total indicator reading

clearance
0.014 - 0.039
Standard
(0.0006 - 0.0015)
Limit All 0.1 (0.004)
EM-162
Cylinder arrangement In-line 4 Valve timing
Displacement cm3 (cu in) 1,998 (121.92)
Bore and stroke mm (in) 86 x 86 (3.39 x 3.39)
•
Valve arrangement DOHC
Firing order 1-3-4-2
Number of piston rings
Compression 2
Oil
Number of main bearings 5
Compression ratio 9.5 BOC

EM120
Unit: degree
a c e

COMPRESSION PRESSURE CYLINDER HEAD
Unit: kPa (kg/cm2, psi)/300 rpm Unit: mm (in)
Compression pressure Standard Limit
Standard 1,226 (12.5, 178) Less than

Head surface distortion 0.1 (0.004)
0.03 (0.0012)
Minimum 1,030 (10.5, 149)
Differential limit between

98 (1.0, 14)
cylinders
SEM043F
136.9 - 137.1
Nominal cylinder head height "H"
(5.390 - 5.398)
Resurfacing limit 0.2 (0.008)"
'Total amount of cylinder head resurfacing plus cylinder block

resurfacing
EM-163
VALVE Hydraulic lash adjuster (HLA)
16.980 - 16.993
T (Margin thickness) HLA outer diameter
(0.6685 - 0.6690)
1r- HLA guide hole diameter
17.000 - 17.020
r1)1a Clearance between HLA and HLA guide

(0.6693 - 0.6701)
0.007 - 0.040
III' ~
hole (0.0003 - 0.0016)
o Valve guide
L Unit: mm (in)
SEM188A
Valve head diameter "0"
Intake 34.0 - 34.3 (1.339 - 1.350)
Exhaust 30.0 - 30.2 (1.181 - 1.189)
Valve length "L"
101.19 - 101.61
Intake
(3.9839 - 4.0004)
102.11 - 102.53
Exhaust
(4.0201 - 4.0366)
SEM083D
Valve stem diameter "d"
Standard Service
Intake 5965 - 5.980 (0.2348 - 0.2354)
Valve gUide
Exhaust 5.945 - 5.960 (0.2341 - 0.2346)
10.023 - 10.034 10.223 - 10.234
Valve seat angle "a" Intake
Outer (0.3946 - 0.3950) (0.4025 - 0.4029)
Intake diameter 10.023 - 10.034 10.223 - 10.234
Exhaust
Exhaust (0.3946 - 0.3950) (0.4025 - 0.4029)
Valve margin "T" Valve gUide
Intake 1.1 (0.043) Inner

Intake 6.000 - 6018 (0.2362 - 0.2369)
diameter
Exhaust 1.3 (0.051) (Finished
Exhaust 6.000 - 6.018 (0.2362 - 0.2369)
Valve margin "T" limit More than 0.5 (0.020) size)
Valve stem end surface 9.975 - 9.996 10.175 - 10.196

Less than 0.2 (0.008) Cylinder head Intake
grinding limit (0.3927 - 0.3935) (0.4006 - 0.4014)
valve guide
hole diameter 9.975 - 9.996 10.175 - 10.196
Exhaust
(0.3927 - 0.3935) (0.4006 - 0.4014)
Valve spring
Interference fit of valve
0.027 - 0.059 (0.0011 - 0.0023)
guide
Free height mm(in) 49.36 (1.9433)
Standard Limit
Pressure
N (kg, Ib) at height mm (in) 0.020 - 0.053
Intake 0.08 (0.0031)
Stem to guide (0.0008 - 0.0021)
578.02 - 641.57
(58.94 - 65.42, clearance 0.040 - 0.073
Standard Exhaust 0.1 (0.004)
129.96 - 144.25) (0.0016 - 0.0029)
at 30.0 (1.181)
Valve deflection limit 0.2 (0.008)
549.2 (56.0, 123.5)
Limit Projection length "L" 14.0 - 14.2 (0.551 - 0.559)
at 30.0 (1.181)
Out-aI-square mm(in) Less than 2.2 (0.087)
EM-164
Valve seat
Unit: mm (in)
Cylinder head
H
4 D
H
D
•
Standard Standard
h
'26°
I
I
'31.9 - 32.1 (1.256 - 1.264)

I '27.4 - 27.6 (1.079 - 1.087)
'44°53' - 45°01'
'33.6 - 338 '29.4 - 29.6 (1.157 - 1.165)
d (1.323 - 1.331) '50° d
Contacting width (W): 1.05 - 1.35 (0.0413 - 0.0531) Contacting width (W): 125 - 1.55 (0.0492 - 0.0610)
Oversize Oversize
'31.9 - 321 (1.256 - 1.264) - '27.4 - 27.6 (1.079 - 1.087)

'44°53' - 45°01', I '44°53' - 45°01'
33.6 - 33.8 I '29.4 - 29.6 (1.157 - 1.165)
d (1.323 - 1.331) I d
Contacting width (W): 1.05 - 1.35 (00413 - 0.0531) Contacting width (W): 1.25 - 1.55 (0.0492 - 0.0610)
': Machining data SEM243F
Standard Service
In. 35000 - 35.016 (1.3780 - 1.3786) 35500 - 35.516 (1.3976 - 1.3983)

Cylinder head seat recess diameter (D)
Ex. 31.000 - 31.016 (1.2205 - 1.2211) 31.500 - 31.516 (1.2402 - 1.2408)
In. 0.064 - 0.096 (0.0025 - 0.0038)

Valve seat interference fit
Ex. 0.064 - 0.096 (0.0025 - 0.0038)
In. 35.080 - 35.096 (1.3811 - 1.3817) 35.580 - 35.596 (1.4008 - 1.4014)

Valve seat outer diameter (d)
Ex. 31.080 - 31.096 (1.2236 - 1.2242) 31.580 - 31.596 (1.2433 - 1.2439)
In. 6.25 (0.2461)

Depth (H)
Ex. 6.25 (0.2461)
In. 62 - 63 (0.244 - 0.248) 5.4 - 5.5 (0.213 - 0.217)

Height (h)
Ex. 6.2 - 6.3 (0.244 - 0.248) 532 - 5.42 (0.2094 - 0.2134)
EM-165
SERVICE DATA AND SPECIFICATIONS (SDS)
Valve shim clearance adjustment
Unit: mm (in)
Rocker arm
Valve shim clearance (cold) guide
Intake & Exhaust Less than 0.025 (0.001)
Shim thickness "T" T, :l: 0.025 (0.001)
Available shim
SEM095D
Thickness mm (in) Identification mark
28
2.800 (0.1102)
00
28
2.825 (0.1112)
25 T
28
2.850 (0.1122)
50
28
2.875 (0.1132)
75
Indicate
2.900 (0.1142)
29 T = 2.800 mm
00 (0.1102 In)
29
2.925 (0.1152) SEM096D
25
29
2.950 (0.1161)
50
29
2.975 (0.1171)
75
30
3.000 (0.1181)
00
30
3.025 (0.1191)
25
30
3.050 (0.1201)
50
30
3.075 (0.1211)
75
31
3.100 (0.1220)
00
31
3.125 (0.1230)
25
31
3.150 (01240)
50
31
3.175 (0.1250)
75
32
3.200 (0.1260)
00
EM-166
CAMSHAFT AND CAMSHAFT BEARING CYLINDER BLOCK
Standard Limit
Camshaft journal to 0.045 - 0.086

0.15 (00059)
bearing clearance (0.0018 - 0.0034)
•
Inner diameter 01 cam- 28000 - 28.021
shaft bearing (1.1024 - 1.1032)
Outer diameter of 27.935 - 27.955

camshaft journal (1.0998 - 1.1006)
Less than
Camshaft runout [TIW] 0.1 (0.004)
002 (0.0008)
Camshaft sprocket Less than

runout [TIW] 0.25 (00098)
SEM964E
0.055 - 0.139 y
Camshaft end play 020 (0.OC79)
(0.0022 - 0.0055)
EM6?1
SEM686D
Cam height "A"
Surface Ilatness
38408 - 38.598
Intake Standard Less than 0.03 (0.0012)
(1.5121 - 1.5196)
Limit 0.1 (0004)
37.920 - 38.110
Exhaust
(14929 - 1.5004) Cylinder bore
Wear limit 01 cam Inner diameter
0.2 (0.008)
height
Standard
Valve lift
Grade No.1 86.000 - 86.010 (3.3858 - 3.3862)
Intake 10.0 (0.394)
Grade NO.2 86.010 - 86020 (3.3862 - 3.3866)
Exhaust 9.2 (0.362)
Grade No.3 86020 - 86.030 (33866 - 3.3870)
"Total indicator reading
Wear limit 020 (0.0079)
Out-aI-round (X - Y)
Taper (A - B and A - C)
Difference in inner
diameter between cylin-
ders
Limit Less than 0.05 (0.0020)
Main journal inner

diameter
Grade No. 0 58944 - 58950 (2.3206 - 2.3209)
Grade NO.1 58.950 - 58.956 (2.3209 - 2.3211)
Grade NO.2 58956 - 58962 (2.3211 - 2.3213)
Grade NO.3 58962 - 58968 (23213 - 2.3216)
EM-167
PISTON, PISTON RING AND PISTON PIN Piston ring
Unit: mm (in)
Piston
Unit: mm (in) Side clearance
Top
0.045 - 0.080
Standard
(0.0018 - 0.0031)
Limit 0.2 (0.008)
2nd
0.030 - 0.065
Standard
(0.0012 - 0.0026)
Limit 0.2 (0.008)
Ring gap
Top
0.20 - 0.30
Standard
(0.0079 - 0.0118)
Limit 1.0 (0.039)
SEM750C 2nd
Piston skirt diameter "A" 0.35 - 0.50

Standard
(0.0138 - 0.0197)
Standard
Limit 1.0 (0.039)
Grade NO.1 85.980 - 85.990 (3.3850 - 3.3854)
Oil
Grade NO.2 85.990 - 86.000 (3.3854 - 3 3858)
020 - 0.60
Grade NO.3 86000 - 86.010 (3.3858. 3.3862) Standard
(0.0079 - 0.0236)
020 (0.0079) over-
86.180 - 86210 (3.3929 - 3.3941) Limit 1.0 (0.039)
size (Service)
"a" dimension 14.0 (0.551)
Piston clearance to cylin-

0.010 - 0.030 (0.0004 - 0.0012)
der block Piston pin
Unit: mm (in)
Piston pin hole diameter 21.987 - 21.999 (0.8656 - 0.8661)
Piston pin outer diameter 21.989 - 22.001 (08657 - 0,8662)
Interference fit of piston pin

o - 0004 (0 - 0,0002)
to piston
Piston pin to connecting

rod bushing clearance
Standard 0005 - 0.017 (0,0002 - 0,0007)
Limit 0,023 (0,0009)
• Values- measured at ambient temperature of 20°C (68°F)
EM-1G8
CONNECTING ROD CRANKSHAFT
Center distance 136,30 (5,3661) Main journal dia, "Om"
Bend [per 100 (3,94)] Grade No, 0 54.974 - 54.980 (2,1643 - 2,1646)
Limit 0,15 (0,0059) Grade No, 1 54.968 - 54.974 (2.1641 - 2,1643)
Torsion [per 100 (3,94)]
Limit
Connecting rod small end

inner diameter
Piston pin bushing inner

diameter'
0,3 (0,012)
24,980 - 25,000 (0,9835 - 0,9843)
22,000 - 22,012 (0,8661 - 0,8666)

Grade No, 2
Grade No, 3
Pin journal dia, "Op"
Grade No, 0
Grade No,
54.962 - 54.968 (2,1639 - 2,1641)
54,956 - 54,962 (2,1636 - 2,1639)
47968 - 47,974 (1,8885 - 1,8887)
47,962 - 47.968 (1,8883 - 1.8885)

•
Grade No, 2 47,956 - 47,962 (1,8880 - 1,8883)
Connecting rod big end
51,000 - 51,013 (2,0079 - 2,0084)
inner diameter Center distance "r" 42,96 - 43,04 (1,6913 - 1,6945)
.
Side clearance Out-ot-round (X - Y)
Standard 0,20 - 0,35 (0,0079 - 0,0138) Main journal Less than 0,005 (0,0002)
Standard
Pin journal Less than 0,0025 (0,0001)
Limit 0,5 (0.020)
Taper (A - B)
•After installing in connecting rod
Main journal Less than 0,005 (0,0002)
Standard
Pin journal Less than 0,0025 (0,0001)
Runout [TIR)
Limit Less than 0.05 (0,0020)
Free end play
Standard 0,10 - 0.26 (0,0039 - 0,0102)
Limit 0.30 (0,0118)
Om
Op
Out-at-round @ - (J)
Taper @-@
@ @
LU
\JY
SEM954C
EM-169
MAIN BEARING CONNECTING ROD BEARING
#5
#4 ~ Standard size
Unit: mm (in)
il hole #3 ~~ \)
Grade Identification
Thickness "T" Width "W"
number color (mark)
#2 ~~'
1.500 - 1.503
~#1~~~ ~~ 0 No color (A)
(0.0591 - 0.0592)
1.503 - 1.506 16.9 - 17.1

L2 ~~ 1
(0.0592 - 0.0593) (0.665 - 0.673)
Black (B)
Engine front~ 1.506 - 1.509

2 Brown (C)
(0.0593 - 0.0594)
SEM685D
Undersize
Unit: mm (in)
Standard
Unit: mm (in) Crank pin journal
Undersize Thickness "T"
diameter "Op"
Grade Identification
Thickness "T" Width "W"
number color (mark) 1.541 - 1.549
0.08 (0.0031)
(0.0607 - 0.0610)
1.977 - 1.980
0 Black (A) Grind so that bear-
(0.0778 - 0.0780) 1.561 - 1.569
0.12 (0.0047) ing clearance is the
(0.0615 - 0.0618)
1.980 - 1.983 specified value.
1 Brown (B)
(0.0780 - 0.0781) 1.626 - 1.634
0.25 (0.0098)
(0.065 - 0.00256)
1.983 - 1.986
2 Green (C)
(0.0781 - 0.0782)
1.986-1.989 18.9 - 19.1

3 Yellow (D)
(0.0782 - 0.0783) (0.744 - 0.752) Bearing clearance
1.989 - 1.992 Unit: mm (in)
4 Blue (E)
(0.0783 - 0.0784)
Main bearing clearance
1.992 - 1.995
5 Pink (F) Standard 0.004 - 0.022 (0.0002 - 0.0009)
(0.0784 - 0.0785)
Limit 0.05 (0.0020)
1.995 - 1.998
6 No color (G)
(0.0785 - 0.Q787) Connecting rod bearing clearance
Standard 0.020 - 0.045 (0.0008 - 0.0018)
Limit 0.065 (0.00256)

Undersize
Unit: mm (in)
Main journal MISCELLANEOUS COMPONENTS

Undersize Thickness "T"
diameter "Om"
Unit: mm (in)
Grind so that bear-
2.109 - 2.117 Camshaft sprocket runout limit
0.25 (0.0098) ing clearance is the 0.25 (0.0098)
(0.0830 - 0.0833) [TIR]
specified value.
Flywheel runout limit [TIR] 0.15 (0.0059)
Drive plate runout limit [TIA] 0.2 (0.008)
EM-170

COMPRESSION PRESSURE VALVE
Unit: kPa (bar, kg/cm2, psi) at 200 rpm Unit: mm (in)
Standard 3,138 (31.4, 32, 455)

T (Margin thickness)
•
Limit 2,452 (24.5, 25, 356)
1t
f"~
Difference limit
490 (4.9, 5, 71)
between cylinders
if
CYLINDER HEAD
Unit: mm (in)
Head surface flatness

SEM188
Limit 0.1 (0,004)
Valve head diameter "D"
Nominal cylinder head 137.9 - 138.1
height (5.429 - 5.437) Intake 39.0 - 39.3 (1.535 - 1.547)
Exhaust 32.0 - 32.2 (1,260 - 1.268)
Valve length "L"
CAMSHAFT AND CAMSHAFT BEARING Intake

100.53 - 100.97
Unit: mm (in) (3.9579 - 3.9752)
100.38 - 100.82
Standard Max. tolerance Exhaust
(3.9520 - 3.9693)
Camshaft journal 0.045 - 0.086
0.1 (0.004) Valve stem diameter "d"
clearance (0.0018 - 0.0034)
6.965 - 6.980
Inner diameter of 30.000 - 30.021 Intake
(0.2742 - 0.2748)
camshaft bearing (1.1811 - 1.1819)
6.945 - 6.960
Outer diameter of 29.935 - 29.955 Exhaust
(0.2734 - 0.2740)
camshaft journal (1.1785 - 11793)
Valve seat angle "u" 45°30'
Less than
Camshaft runout 0.05 (0.0020)
0.02 (0.0008) Valve margin "r limit 0.5 (0.020)
0.115 - 0.188 Valve stem end surface grinding
Camshaft end play 0.5 (0.020)
(0.0045 - 0.0074) limit
EM671
Cam height "A"
Intake 49.20 - 49.25 (1.9370 - 1.9390)
Exhaust 49.15 - 49.20 (1.9350 - 1.9370)
EM-171
Valve spring Valve seat resurfacing
Unit: mm (in)
Free height mm (in)
Outer 43.2 (1.701)

Intake
Inner 38.2 (1.504)
Standard (Original)
Standard
Assembled height
mm/N (mm/kg, in/lb)
Outer 36.1/164.8 (36.1/16.8,1.421/37.0)
Inner 32.6/78.5 (32.6/8.0, 1.283/17.6)
Out-of-square "S"
mm (in)
1.8:t 0.05
Outer 2.1 (0.083) (0.0709:t 0.0020) 38.6 - 38.8 (1.520 - 1.528)
Inner 1.9 (0.075)
0.5 (0.020) Oversize
'\ 'RO.3 - 0.5 (0.012 - 0.020)

. '41.4_~- 4!:.,454 (1.~312 - 16320)
Valve guide
Unit: mm (in)
Standard Service
'9.85
Valve guide - 10.15
(0.3878
11.023 - 11.034 11.223 - 11.234 - 0.3996)
Outer diameter
(0.4340 - 0.4344) (0.4418 - 0.4423)
1.8:t0.05 38.6 - 38.8 (1.520 - 1.528)
Valve guide (0.0709:t 0.0020)
Inner diameter 7.000 - 7.015
(Finished size) (0.2756 - 0.2762) ': Cylinder head machining data
SEM917-B
Cylinder head valve 10.985 - 10.996 11.185 - 11.196
guide hole diameter (0.4325 - 0.4329) (0.4404 - 0.4408)
Interference fit of valve 0.027 - 0.049 Exhaust

guide (0.0011 - 0.0019)
Standard (Original)
Standard Max. tolerance
Stem to guide clear-

ance
0.020 - 0.050
Intake 0.10 (0.0039)
(0.0008 - 0.0020)
2.1 :to.05
0.040 - 0.070
Exhaust 0.10 (0.0039) (0.0827 :t 0.0020)
(0.0016 - 0.0028)
31.6 - 31.8 (1.244 - 1.252)
Valve deflection limit 0.1 (0.004)
0.5 (0.020) Oversize
r
,- 'RO.3 - 0.5 (0.012 - 0.020)
'35.432 - 35.454 (1.3950 - 1.3958)
'10.45
- 10.75
(0.4114 (0.0614)
- 0.4232)
2.1 :t 0.05
31.6 - 31.8 (1.244 - 1.252)
(0.0827 :t 0.0020)
Cylinder head machining data
SEM113FA
EM-172
VALVE LIFTER CYLINDER BLOCK
Valve lifter outer diameter
34.959 - 34.975
Standard
(1.3763 - 1.3770)
•
Cylinder head valve lifter hole 34.998 - 35.018
diameter (1.3779 - 1.3787)
Clearance
0.023 - 0059
Standard
(0.0009 - 0.0023)
Limit 0.1 (0.004)
y
SEM902-A
Standard Limit
Surface flatness Less than 0.05 (0.0020) 0.10 (0.0039)
Grade No.1
84.500 - 84.510
(3.3268 - 3.3272)
Grade NO.2
84.510 - 84.520
(3.3272 - 3.3276)
Grade No.3
Inner 0.2
84.520 - 84.530
diameter (0.008)
(3.3276 - 3.3279)
Cylinder Grade NO.4
bore 84.530 - 84.540
(3.3279 - 3.3283)
Grade NO.5
84.540 - 84.550
(3.3283 - 3.3287)
Out-of-
round Less than 0.015 (O.0006) 004 (0.0016)
(X - Y)
Taper
Less than 0.010 (O.0004) 0.04 (0.0016)
(A - B)
Piston to cylinder 0.025 - 0.045
-
clearance (0.0010 - 0.0018)
Grade No. 0
56.654 - 56.663
(2.2305 - 2.2308)
Grade NO.1
Main journal inner
56.663 - 56.672 -
diameter
(2.2308 - 2.2312)
Grade NO.2
56.672 - 56.680
(2.2312 - 2.2315)
EM-173
PISTON, PISTON RING AND PISTON PIN Piston pin
Unit: mm (in)
Piston
Unit: mm (in) 24.994 - 25.000
Piston pin outer diameter
(0.9840 - 0.9843)
84.465 - 84.475
Grade NO.1 Interference fit of piston pin to
(3.3254 - 3.3258) -0.004 to 0 (-0.0002 to 0)
piston
84.475 - 84.485
Grade NO.2 Piston pin to connecting rod 0.025 - 0.044
(3.3258 - 3.3262)
clearance (0.0010 - 0.0017)
84.485 - 84.495
Standard Grade NO.3
(3.3262 - 3.3266)
Piston
skirt 84.495 - 84.505
Grade NO.4
diam- (3.3266 - 3.3270) CONNECTING ROD
eter Unit: mm (in)
84.505 - 84.515
Grade NO.5
(3.3270 - 3.3274) Bend [per 100 mm (3.94 in)]
84.715 - 84.765
0.25 (0.0098) Standard Less than 0.025 (0.0010)
(3.3352 - 3.3372)
Oversize Torsion
84.965 - 85.015
0.5 (0.020) Standard Less than 0.025 (0.0010)
(3.3451 - 3.3470)
Measure position (From Top) 62 (2.44) 25.025 - 25.038

Piston pin bore dia.
(0.9852 - 0.9857)
24.991 - 24.999
Piston pin hole diameter
(0.9839 - 0.9842) Big end play
Limit 0.3 (0.012)
Piston ring
Unit: mm (in)
Side clearance CRANKSHAFT

Unit: mm (in)
Top
Grade No. 0
. Standard 0.060 - 0.095 (0.0024 - 0.0037)
52.967 - 52.975
Limit 0.10 (0.0039) (2.0853 - 20856)
Grade No.1
2nd
Main journal dia. 52.959 - 52.967
Standard 0.040 - 0.075 (0.0016 - 0.0030) (2.0850 - 2.0853)
Grade NO.2
Limit 0.10 (0.0039)
52.951 - 52.959
Oil (2.0847 - 2.0850)
Standard 0.030 - 0.070 (0.0012 - 0.0028) Grade No. 0
49.968 - 49.974
End gap
(1.9672 - 1.9675)
Top Grade NO.1
Pin journal dia. 49.961 - 49.968
Standard
(1.9670 - 1.9672)
Bore grade 1, 2. 3 0.20 - 0.30 (0.0079 - 0.0118) Grade NO.2
49.954 - 49.961
Bore grade 4, 5 0.12 - 0.22 (0.0047 - 0.0087)
(1.9667 - 1.9670)
Limit 1.0 (0.039)
Out-of-round (X - Y) and
2nd taper (A - B)
Standard 0.38 - 0.53 (0.0150 - 0.0209) Standard Less than 0.005 (0.0002)
Limit 0.7 (0.028) Runout
Oil Standard Less than 0.05 (0.0020)

Standard 0.30 - 0.55 (0.0118 - 0.0217) Free end play
Limit 0.6 (0.024) Standard 0.05 - 0.18 (0.0020 - 0.0071)
Limit 0.3 (0.012)
EM-174
AVAILABLE MAIN BEARINGS
No.1, No.2, No.4 and No. 5 main bearings
Grade number Thickness "T" mm (in) Width "W" mm (in) Identification color
o 1.816 - 1.820 (0.0715 - 0.0717) Yellow
•
1.820 - 1.824 (0.0717 - 0.0718) Green
20.0 (0.787)
2 1.824 - 1.828 (0.0718 - 0.0720) Brown
17.8 (0.7011'
3 1.828 - 1.832 (0.0720 - 0.0721) Black
4 1.832 - 1.836 (0.0721 - 0.0723) Blue
Contacting width
No.3 main bearings
Grade number Thickness "T" mm (in) Width "W" mm (in) Identification color
o 1.816 - 1.820 (0.0715 - 0.0717) Yellow
1.820 - 1.824 (0.0717 - 0.0718) Green
27.95 (1.1004)
2 1.824 - 1.828 (0.0718 - 0.0720) Brown
20.8 (0.819)'
3 1828 - 1.832 (0.0720 - 0.0721) Black
4 1.832 - 1.836 (0.0721 - 0.0723) Blue
Contacting width
Main bearing undersize Bearing clearance

Crank journal diameter Main bearing clearance
52951 - 52.975 0.039 - 0.065

STD Standard
(2.0847 - 2.0856) (0.0015 - 0.0026)
52.701 - 52.725 Connecting rod bearing clearance

0.25 (0.0098) undersize
(2.0748 - 2.0758)
0.031 - 0.055
Standard
(0.0012 - 0.0022)
Connecting rod bearing undersize

Unit: mm (in) MISCELLANEOUS COMPONENTS
Crank pin diameter Unit: mm (in)
49.968 - 49.974 Flywheel

Grade 0 Black
(1.9672 - 1.9675)
Runout [TIR"] Less than 0.15 (0.0059)
49961 - 49.968
STD Grade 1 Yellow Total indicator reading
(1.9670 - 1.9672)
49.954 - 49.961
Grade 2 Blue
(1.9667 - 1.9670)
49.874 - 49.894"
0.08 (0.0031) undersize
(1.9635 - 1.9643)
49.834 - 49.854"
0.12 (0.0047) undersize
(1.9620 - 1.9628)
49.704 - 49.724"
0.25 (0.0098) undersize
(1.9568 - 1.9576)
": Reference value
EM-175
ENGINE LUBRICATION &
COOLING SYSTEMS
SECTION LC
•
CONTENTS
PRECAUTION 2 CO
PREPARATION 3
ENGINE LUBRICATION SYSTEM 26
Lubrication Circuit... 26
GA Oil Pressure Check 27
ENGINE LUBRICATION SYSTEM 5 Oil Pump , 27
Lubrication Circuit.. 5 Oil Cooler 30
Oil Pressure Check 6 ENGINE COOLING SYSTEM 31
Oil Pump 7 Cooling Circuit 31
ENGINE COOLING SySTEM 9 System Check 32
Cooling Circuit 9 Water Pump , 33
Water Hose Drawing 10 Thermostat 34
System Check 12 Radiator 35
Water Pump 13
Thermostat 14 GA,SR,CO
Water Outlet 15
ENGINE COOLING SYSTEM 37
Radiator 16
Radiator (Aluminum type) 37
SR
GA,SR
ENGINE LUBRICATION SYSTEM 17
SERVICE DATA AND SPECIFICATIONS (SOS) 40
Lubrication Circuit. 17
Engine Lubrication System (GA) 40
Oil Pressure Check 17
Engine Cooling System (GA) 40
Oil Pump 18
Engine Lubrication System (SR) 40
Oil Fi Iter 20
Engine Cooling System (SR) 40
ENGINE COOLING SYSTEM 21
Cooling Circuit 21
CO
System Check 21
Cooling System Inspection 21 SERVICE DATA AND SPECIFICATIONS (SOS) 41
Water Pump 22 Engine Lubrication System .41
Thermostat 23 Engine Cooling System 41
Water Outlet 24
Radiator 25
PRECAUTION
LIQUID GASKET APPLICATION PROCEDURE

a. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
Inner
b. Apply a continuous bead of liquid gasket to mating surfaces.
side
(Use Genuine Liquid Gasket or equivalent.)
• For oil pan, be sure liquid gasket diameter is 4.0 to 5.0
mm (0.157 to 0.197 in) for SR engine and 3.5 to 4.5 mm
(0.138 to 0.177 in) except for SR engine.
• For areas except oil pan, be sure liquid gasket diameter
SEM164F is 2.0 to 3.0 mm (0.079 to 0.118 in).
c. Apply liquid gasket to inner sealing surface around hole
perimeter area.
(Assembly should be done within 5 minutes after coating.)
d. Wait at least 30 minutes before refilling engine oil and
engine coolant.
LC-2
PREPARATION

The actual shapes of Kent-Moore tools may diller from those of special service tools illustrated here.
Tool number
Tool name
ST25051001'
Oil pressure gauge
ST25052000'
Hose
NT559
KV10115801 Removing oil filter

KV10115800
(Kent-Moore Europe o 14 faces,
make) Inner span: 64.3 mm (2.531 in) x
(Face to opposite face)
Oil filter wrench
~
NT362
KV10105900 Removing oil filter

Oil filter wrench KV101 05900
15 faces,
Inner span: 80 mm (3.15 in)
~ (Face to opposite corner)
8T1930oo01 x x
a
a: 78 mm (3.07 in)
(Face 10 opposite cor-
NT638 ner)
WS39930000 Pressing the tube of

Tube presser liquid gasket
x x x
NT052
'; Special tool or commercial equivalent
LC-3
PREPARATION
Engine
Description
Tool name
GA SR CD
EG17650301 Adapting radiator

Radiator cap tester
adapter
NT564
~
,
~
atet?
C~~4b
cDJt
a
cap tester to radia-
tor filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
X X X
KV99103510 Installing radiator

Radiator plate upper and lower
pliers A tanks
X X X
~
NT224
KV99103520 Removing radiator

Radiator plate upper and lower
pliers B tanks
X X X
~
NT225
LC-4
ENGINE LUBRICATION SYSTEM
Lubrication Circuit
Oil drop
./~.
•
VTC
Main gallery
Idler sprocket
Chain tenfioner
Oil strainer "~ __.
SLC0048
<:;=::J 011 passage

~ Oil qallely In cylinder block
~ ..- 8y.pass passage
..-- Drain
Only models
with VTC
SLC052B
LC-5
Oil Pressure Check

WARNING:
• Be careful not to burn yourself, as the engine and oil may
be hot.
• Oil pressure check should be done in "Neutral" gear posi-
tion.
1. Check oil level.
2. Remove oil pressure switch.
Engine speed Approximate discharge pressure

rpm kPa (bar, kg/cm2, psi)
Idle speed More than 59 (0.59, 0.6, 9)

ST25051001
2,000 More than 245 (2.45, 2.5, 36)
6,000 More than 422 (4.22, 4.3, 61)
3. Install pressure gauge.

4. Start engine and warm it up to normal operating tempera-
SLC926-A ture.
5. Check oil pressure with engine running under no-load.
If difference is extreme, check oil passage and oil pump for oil
leaks.
6. Install oil pressure switch with sealant.
LC-6
Oil Pump
SEC. 135.150
•
Front cover side
lil
~.
N.m (kg-m, in-Ib)
N.m (kg-m, ft-Ib)
rJ . Liquid gasket
a~:oo"
Oil pump
cover side
SLC985AA
CD Oil pump cover I]) O-ring @ Spring

@ Inner gear @J Oil strainer @ Washer
@ Outer gear (J) Regulator valve @) Plug
@ Front cover
REGULATOR VALVE INSPECTION

Spring] 1. Visually inspect components for wear and damage.
7I I 2. Check oil pressure regulator valve sliding surface and valve

Regulator valve spring.
3. Coat regulator valve with engine oil. Check that it falls freely
into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump assembly.
SLC986A
OIL PRESSURE RELIEF VALVE INSPECTION

Inspect oil pressure relief valve for movement, cracks and
breaks by pushing the ball. If replacement is necessary, remove
valve by prying it out with suitable tool.
•
Front Install a new valve in place by tapping it.
Cylinder
block
SLC418A
LC-7
Oil Pump (ConI' d)
DISASSEMBLY AND ASSEMBLY
• Always replace oil seal with a new one.
• When installing oil pump, apply engine oil to gears.
• Make sure that O-ring is fitted properly.
OIL PUMP INSPECTION
Using a feeler gauge, check the following clearance.
Unit: mm (in)
Body to outer gear clearance CD 0.110 - 0.200 (0.0043 - 0.0079)
Inner gear to crescent clearance @ 0.217 - 0.327 (0.0085 - 0.0129)

SLC420A
Outer gear to crescent clearance @ 0.21 - 0.32 (0.0083 - 0.0126)
Body to inner gear clearance @ 0.05 - 0.09 (0.0020 - 0.0035)
Body to outer gear clearance @ 0.05 - 0.11 (0.0020 - 0.0043)
Inner gear to brazed portion of

0.045 - 0.091 (0.0018 - 0.0036)
housing clearance @
• If the tip clearance (@ ) exceeds the limit, replace gear set.

Feeler gauge • If body to gear clearances ( (1), ~, @, @, @) exceed the
limit, replace front cover assembly.
SLC419A
SLC222A
LC-8
ENGINE COOLING SYSTEM
Cooling Circuit
Reservoir tank
... Thermostat: OPEN
~ Thermostat: CLOSED
Water outlet
Thermostat
housing
•
Throttle
body Heater
Intake manifold
SLC9S7AA
LC-9
Water Hose Drawing
GA14DE and GA16DE without VTC
GA15DE
GA16DE with VTC except for Australia
MLC084A
CD Intake manifold to thermostat @ Radiator lower hose to water @ Throttle body to thermostat
housing-1 inlet housing
@ Intake manifold to thermostat @ Intake manifold to throttle body
housing-2
LC-10
Water Hose Drawing (Cont'd)
GA16DE with VTC for Australia
Intake manifold
•
5
Q) Intake manifold to Thermostat @ Water pipe lower @ Throttle body to Water pipe
housing (upper) CID Water pipe lower to Throttle upper
@ Intake manifold to Thermostat body @ Intake manifold to Water pipe
housing (lower) @ Water pipe lower to Intake upper
@ Water jacket to Water pipe manifold @ Water pipe upper to Thermostat
lower (J) Water pipe upper housing
SLC021BA
LC-11
System Check
WARNING:
Never remove the radiator cap when the engine is hot; serious
burns could be caused by high pressure fluid escaping from the
radiator.
Wrap a thick cloth around cap and carefUlly loosen it a quarter
turn to release built-up pressure. Then remove the cap com-
pletely.
CHECKING COOLING SYSTEM HOSES


To check radiator cap, apply pressure to cap with a tester.
Standard
78 - 98 kPa
2
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm , 11 - 14 psi)
Limit
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi)
SLC613-A
Pull the negative pressure valve to open it. Check that it closes

To check for leakage, apply pressure to the cooling system with
a tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
Higher than the specified pressure may cause radiator damage.
SLC422A
LC-12
Water Pump
SEC. 210
l
~ 6.28 - 8.34 (0.641 - 0.851, 55.6 - 73.8)
~ Liquid gasket
•
IiJ 6.28 - 8.34 (0.641 - 0.851, 55.6 - 73.8)
Water pump pUlley
~ N.m (kg-m, in-Ib)

SLC989AB
CAUTION:
• When removing water pump assembly, be careful not to get
coolant on timing chain.
• Water pump cannot be disassembled and should be
replaced as a unit.
• After installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
REMOVAL
1. Drain coolant from radiator and cyl inder block.
2. Remove drive belts for compressor, power steering pump
and alternator.
INSPECTION
1. Check body assembly for rust or corrosion.
2. Check for rough operation due to excessive end play.
SLC162A
LC-13
Water Pump (Cont'd)
INST ALLATION
Use a scraper to remove liquid gasket from water pump.
Be sure liquid gasket in grooves is also removed.
• Remove liquid gasket from mating surface of front cover.
• Remove all traces of liquid gasket using white gasoline.
SLC425A
• Apply liquid gasket to mating surface of pump housing as

shown.
SLC426A
[J Liquid gasket Thermostat

Thermostat housing 7
INSPECTION
Ther~st~
W"",?~: . 1. Check for valve seating condition

It should seat tightly.
at ordinary temperatures.
~. ~~628-634
P"L' 'd (0.641 - 0.851,
~ IqUI gasket 55.6 _ 73.8)
~ ~6.28 - 8.34 (0.641 - 0.851, 55.6 - 73.8)
~: N.m (kg-m. in-Ib) SLC990AC
Jiggle valve
(top side)
Up
11
SLC499A
2. Check valve opening temperature and maximum valve lift.
Valve opening temperature °C CF) 76.5 (170)

Valve lift mml"C (inI"F) More than 8190 (0.311194)
3. Then check if valve closes at 5°C (9°F) below valve opening

temperature.
• After installation, run engine for a few minutes, and check
for leaks.
SLC343
LC-14
Thermostat (Cont'd)
INSTALLATION
When installing water inlet apply liquid gasket as shown .
SLC428A
Water Outlet
INSPECTION
Visually inspect for water leaks. If there is leakage, apply liq-
•
uid gasket.
SLC429A
INSTALLATION
When installing water outlet, apply liquid gasket as shown.
2.0.3.0 mm
(0.079 • 0.118 In) die.
SLC430A
LC-15
Radiator
SEC. 214 ~ 3.7.5.0 (0.38 - 0.51, 33.0 • 44.3)
. ~I L! ~~ 3.8 .4.5
\[jj
(0.39 • 0.46, 33.9 .39.9)
3.' - 4.5 (0.39- 0.45,3>' - 39.')
~,,~
I
'fl '~~WI-<D
,
--
),
5 '\ 1
"~
10
" It, -~ ~ , .../ "-- -. / "-- ~ ~ n .- /

r~ ~ ~'" . ~
i
i
I
~ ""
Jl~J)
~
",,~~@
@ '0)"
1~ ~
<>!. 0
I
6.86
(0.70, 60.7)
•

SLC991AB
G) Reservoir tank @ Washer @l Radiator

@ Reservoir tank bracket (J) Drain plug @ Lower hose
@ Radiator cap @ Mounting rubber @ Cooling fan
@ Mounting bracket @ Oil cooler hose (AfT models) @ Cooling fan motor
@ Upper hose
Cooling fan control system
• Cooling fans are controlled by the ECM. For details, refer to
EC section ("Cooling Fan Control", "TROUBLE DIAG-
NOSES").
Refilling engine coolant
• For details on refilling engine coolant, refer to MA section
("REFILLING ENGINE COOLANT", "Changing Engine
Coolant").
LC-16
Lubrication Circuit
... Return
~Feed Oil tube

Camshaft
--Hydraulic lash adjuster
•
Oil pan
SLC0248
<i= : Oil passage
.- : Oil gallery
4-. - . By-pass passage

....--. To oil pan
SLC0258
~~ Oil Pressure Check

9
Oil pressure switch WARNING:
be hot.
• Oil pressure check should be done in "Neutral position".
1. Check oil level.
~IfSLC518A
LC-17
ENGINE LUBRICATION SYSTEM ~
Oil Pressure Check (Conl'd)
3. Install pressure gauge.
4. Start engine and warm it up to normal operating tempera-
ture.
5. Check oil pressure with engine running under no-load.

rpm kPa (bar, kg/cm2, psi)
3,200 314 - 392 (3.14 - 3.92, 3.2 - 4.0, 46 - 57)
If difference is extreme, check oil passage and oil pump for oil
leaks.
Oil Pump
REMOVAL
2. Remove cylinder head. (Refer to EM section.)
3. Remove oil pans. (Refer to EM section.)
4. Remove oil strainer and baffle plate.
5. Remove front cover assembly.
r~3.7- 5.0 (0.38 - 0.51, 33.0 - 44.3)
_d!:, r!il6.4 . 7.5

o -----~ (0.65 • 0.76, 56.4 • 66.0)
~ liquid gasket
-----
" ~ •.• - 7.'

(0.65 • 0.76, 56.4 - 66.0)
[OJ : N'm (kg-m, ft-Ib) ~ \ [OJ 16 • 19 (1.6 - 1.9, 12 - 14)

I) :Apply engine oil. ~[OJ39 - 69 (4.0 - 7.0, 29 - 51)

SLC048B
G) Oil pump cover @ Regulator valve @ Plug

@ Front cover @ Spring @ Regulator valve set
@ Inner gear (J) Shims @ Oil strainer
@ Outer gear
• Always replace oil seal, gasket and O-ring with new ones.
• When installing oil pump, apply engine oil to inner and outer
gears.
• Be sure that O-rings are properly fitted.
LC-18
Oil Pump (Conl'd)
INSTALLATION
• Before installing front cover assembly, remove all traces of

liquid gasket from mating surface using a scraper.
cylinder block.
SLC491A
1.
•
Apply a continuous bead of liquid gasket to mating surface
of front cover assembly.
2.' Installation is the reverse order of removal.
•
SLC492A
Feeler gauge
SLC494A
@-@=~ SLC450A
I
SLC860A
LC-19
Oil Pump (Cont'd)
INSPECTION
Using a feeler gauge, check the following clearances:
Unit: mm (in)
Body to outer gear clearance G) 0.114 - 0.200 (0.0045 - 0.0079)
Inner gear to outer gear tip clearance

Below 0.18 (0.0071)
@
Body to inner gear clearance @ 0.05 - 0.09 (0.0020 - 0.0035)
Body to outer gear clearance @ 0.05 - 0.11 (0.0020 - 0.0043)
Inner gear to brazed portion of housing

0.045 - 0.091 (0.0018 - 0.0036)
clearance @
• If the tip clearance ( @) exceeds the limit, replace gear set.

• If body to gear clearances (d), CID, @, CID) exceed the
limit, replace front cover assembly.

1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil.
Check that it falls smoothly into the valve hole by its own
weight.
If damaged, replace regulator valve set or oil pump cover.
SLC049B
4. Check regulator valve to oil pump cover clearance.

Clearance:
<ID : 0.040 • 0.097 mm (0.0016 • 0.0038 in)
If it exceeds the limit, replace oil pump cover.
@-@=@
SLC451A
Oil Filter
The oil filter is a small, full-flow cartridge type and is provided
with a relief valve.
• The new and eXisting oil filter designs differ from each other
and are not interchangeable.
• Use Tool KV10115801 for removing oil filter.
LC-20
Cooling Circuit
• : Thermostat open
o :Thermostat closed
-~.=-~::
--_-_-_-~
~~=1 Reservoir tank I
•
Water outlet
SLC043B
System Check
WARNING:
radiator.
Wrap a thick cloth around the cap and carefUlly remove it by
turning it a quarter turn to allow built-up pressure to escape
and then turn the cap all the way off.
Cooling System Inspection

CHECKING HOSES
Check water hoses for proper attachment, leaks, cracks,

Standard
SLC613-A 78 • 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
Limit
59 - 98 kPa
2
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm , 9 - 14 psi)
LC-21
Cooling System Inspection (Cont'd)
Pull the negative pressure valve to open it.
Check that it closes completely when released.

a tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
Water Pump
REMOVAL
1. Drain coolant from radiator.
2. Remove cylinder block drain plug located at left front of
cylinder block and drain coolant.
3. Remove front RH wheel and engine side cover.
5. Remove front engine mounting.

CAUTION:
• When removing water pump assembly, be careful not to get
coolant on drive belt.
• Water pump cannot be disassembled and should be
replaced as a unit.
• After installing -water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
A16 - 21 N.m ~/
(1.6 • 2.1 kg-m,
12 - 15 ft.lb)
INSPECTION
1. Check body assembly for rust or corrosion.
2. Check for rough operation due to excessive end play.
SLC408C
LC-22
ENGINE COOLING SYSTEM ~
Water Pump (Cont'd)
INSTAllATION
1, Before installing, remove all traces of liquid gasket from
mating surface of water pump using a scraper.
cylinder block.
~
SLC433A
Liquid gasket
2.
•
Apply a continuous bead of liquid gasket to mating surface
of water pump,
•
SLC434A
Thermostat
SEC. 210 ~--
m
!i1I6.3 • 8.3 (0.64 - 0.85, 55.6 - 73.8) -,
I - r;.~''(
/;; oj;\~ to:J
~'i;JJ;' 16 - 21 (1.6 - 2.1, 12 - 15)
~1r
III'63 • 8 .3 A'Ir re I'Ie f pug Thermostat
7
1
, "
(0.64 . 0.• 5, 55.•. 73.6) I (if" ,q";PP'dl'\~."_,, __

h~,O, USIn~,-", 0,:' /
\ Thoem"t".,
J O~
~)~~\-~~~
,
~~~~~t - \ I[~J
~~~~~:t ~'----O~
[OJ 16
[OJ ;:6- _2~.1,
12 - 15)
- 21 (1.6 - 2.1, 12 - 15)
,~,
)!
[OJ . N'm (kg-m, fHb)
2
,~( /-.....
-
a
/0
2.0-3.0mm
(0.079 - 0.118 in)
I~
(2.0
0
- 3.0 mm
(0.079. 0.118 in)
~ : N'm (kg-m, in-Ib)

~1 SLC050B
LC-23
ENGINE COOLING SYSTEM ~
Thermostat (Co nt' d)
Upper REMOVAL AND INSTAllATION
;::g= Jiggle valve 1.

2.
3.
4.
Drain engine coolant.
Remove lower radiator hose.
Remove water inlet, then take out thermostat.
Install thermostat with jiggle valve or air bleeder facing
upward.
for leaks.
• Be careful not to spill coolant over engine compartment.
Use a rag to absorb coolant.
SLC767
INSPECTION
1. Check for valve seating condition at ordinary temperatures.
2. Check valve opening temperature and valve lift.
Valve opening temperature °c (OF) 76.5 (170)

Valve lift mmrC (inrF) More than 8/90 (0.31/194)
3. Then check if valve closes at 5°C (9°F) below valve opening

temperature.
Water Outlet
INSPECTION
Visually inspect for water leaks. If there is leakage, apply liq-
uid gasket.
SLC460A
INSTAllATION
1. Before installing, remove all traces of liquid gasket from
mating surface of water outlet using a scraper.
cylinder head.
of water outlet. .
~ Liquid gasket
SEM086D
LC-24
Radiator
SEC. 214
10
•
SLC039BA
CD Reservoir tank @ Washer @) Radiator

@ Reservoir tank bracket (J) Drain plug @ Lower hose
@ Radiator cap CID Mounting rubber @ Cooling fan
@ Mounting bracket @ Oil cooler hose (AfT models) @ Cooling fan motor
CID Upper hose

EC section ("Cooling Fan Control", "TROUBLE
DIAGNOSES").
Coolant").
LC-25
Lubrication Circuit
Note: .. : Oil gallery in cylinder block
~ : Oil passage
.... - : By-pass passage
I
Oil pump I
Oil filter Oil cooler
Relief valve 0
Hydraulic valve
lifter
SLC609AA
LC-26
Oil Pressure Check

WARNING:
Oil pressure switch
be hot.
• Oil pressure check should be done in "Neutral" gear posi-
tion.
1. Check oil level.
SLC461
3.
4.
Install pressure gauge.
Start engine and warm it up to normal operating tempera-
ture.
5.. Check oil pressure with engine running under no-load.
•
ST25051 001
Approximate discharge pressure
Engine rpm
kPa (bar, kg/cm2, psi)
2,000 294 (2.9, 3, 43)
ST25052000
SLC926.A If difference is extreme, check oil passage and oil pump for oil
leaks.
Oil Pump
REMOVAL AND INSTAllATION
1. Drain engine coolant and engine oil.
2. Remove upper radiator hose, drive belts, crank pulley, tim-
ing belt covers and timing belt.
3. Remove exhaust front tube, timing belt pulley and rear
engine gusset (bar type), then remove oil pan.
SLC462A
~ 12.16 N.m 4. Remove oil pump assembly with oil strainer.

(1.2 . 1.6 kg-m, 9 - 12 ft.lb) 5. Reinstall any part removed. Refill engine oil and engine
coolant.
• Apply liquid gasket to oil pump.
• Apply liquid gasket to oil pan.
• Apply liquid gasket to both ends of oil pan oil seals.
• Install oil pan, fitting oil seals in the correct position.
SLC463A
LC-27
Oil Pump (Conl'd)
When installing oil pump, apply engine oil to inner and outer
gears.
SEC. 150
0'00"""
ct"",,,,
tt'.J : N. m (kg-m, ft-Ib)
SlC0468
• Apply liquid gasket when installing oil pump onto engine.
2.5:t 0.5
(0.098 :t 0.020) dia. BoriYl,t
hole 2.5 :t.O.5
(0.098 :t 0.020)
dis.
Unit:m~
SlC566A
LC-28
Oil Pump (Cont'd)
INSPECTION
Using a feeler gauge, check the following clearances.
Unit: mm (in)
Body to outer gear clearance CD 0.12 - 0.20 (0.0047 - 0.0079)
Outer gear to inner gear clearance

less than 0.18 (0.0071)
@
•
Housing to inner gear clearance @ 0.05 - 0.09 (0.0020 - 0.0035)
Housing to outer gear clearance @ 0.05 - 0.11 (0.0020 - 0.0043)

SLC560A
Inner gear to housing clearance @ 0.05 - 0.09 (0.0020 - 0.0035)
If it exceeds the limit, replace gear set or entire oil pump

assembly.
SLC561C
SLC568A

1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil. Check that it falls freely
into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump assembly.
SLC049B
LC-29
Oil Pump (Cont'd)
OIL PRESSURE RELIEF VALVE INSPECTION
Inspect oil pressure relief valve (indicated by arrow) for
movement, cracks and breaks by pushing the ball. If replace-
ment is necessary, remove valve by prying it out with a suitable
tool. Install a new valve in place by tapping it.
SLC446
Oil Cooler
SEC. 150-213 / tOJ LHO
RHO 11~ 34 - 44
f:1(3.5 - 4.5, 25 - 33)
Front
~ Front
~
tOJ 16 - 21
(1.6. 2.1, 12 • 15)
: N.m (kg-m, ft-Ib)
SLC047B
CD Oil cooler @ a-ring @ Gasket

@ Connector @ Oil filter bracket @ Cover
INSPECTION
1. Check oil cooler element and housing for cracks.
2. Check coolant inlet of oil cooler for clogging by blowing
through it.
Replace it if necessary.
Oil cooler
SLC465A
LC-30
Cooling Circuit
Oil cooler
Cold start device

•
_ == == == =.j Reservoir tank I
Oil cooler
Heater unit
~ : By-pass passage
SLC407
LC-31
System Check
WARNING:
radiator.
Wrap a thick cloth around cap and carefully loosen it a quarter
turn to release built-up pressure. Then remove the cap com-
pletely.
CHECKING COOLING SYSTEM HOSES


Standard
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
Limit
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi)
SLC613-A
Pull the negative pressure valve to open it. Check that it closes

a tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
SLC422A
LC-32
Water Pump
REMOVAL AND INSTALLATION
1. Drain engine coolant from radiator and cylinder block.
2. Remove upper radiator hose, timing belt covers, front
engine mounting bracket and timing belt.
3. Remove timing belt tensioner and idler and timing belt
lower back cover.
•
~
• For installation, apply liquid gasket to water pump as shown

in the figure.
2.5:!:0.5
Bolt hRille (0.098:!:0.020r12.5:!: 0.5
die. (0.098 :!:0.020)
dIe.
Unit: mm (in) SLC565A
*: Apply liquid sealant to the thread.
~/ ~~;>
~/ ~l!.
to.J M7: 16 - 20 N.m (1.6 - 2.0 kg-m, 12 - 14 ft-Ib)
M8: 16 - 21 N.m (1.6 - 2.1 kg-m, 12 - 15 ft-Ib)
SLC563A
LC-33
Water Pump (Cont'd)
INSPECTION
• Check body assembly for rust or corrosion.
• Check for rough operation due to excessive end play.
SLC760
Thermostat
SEC. 210-211
From cold start device

From 01'I cooler .. ..
/
From heater unit ~ ~
Thermostat housing
2.5+'5
:. •• uo.02O)~'28l
0 ¥a o
o 2.5:t 0.5 (0.098:t 0.020) die.

Unit: mm (in)
Bolt hole 2.5 :t 0.5 (0.098:t 0.020) die.
F2.5+0.5
,-a, (0.098:t ~.020) die.
\r
Bolt hole
rTfJ ~
/2.5+0.5
(0.098:t 0.020) die.
toJ : N.m (kg-m, ft-Ib)
SLC564AA
• Apply liquid gasket to water outlet, thermostat housing and

water inlet.
LC-34
Thermostat (Cont'd)
• Install thermostat with jiggle valve uppermost.
Upper
.. Jiggle valve ----¥- for leaks.
A~ ...g
~~-
SLC097
INSPECTION
1. Check for valve seating condition at ordinary temperatures.
•
2." Check valve opening temperature and valve lift.
Valve opening temperature °c (OF) 88 (190)
Valve lift mmrC (inrF) More than 10/100 (0.39/212)
3. Then check if valve closes at SOC(9°F) below valve opening

temperature.
SLC343
Radiator
SEC. 214
1i13.7 - 5.0
\~~8_-4~.~~-_ ~ i 1jJ,.7 - 5.0 (0.38 - 0.51, ".0 - 44.')
~l~@~----
~~9 ._~1
I
~ . -~
~ ._~
~~ J'
.
.~ ~
@ 1t1 '''~.l!jO 14
L
,
~1.5 .82.5
(0.15 • 0.25,
13.0. 21.7)
A;:
iii 3.7 • 5.0 (0.38 . 0.51, 33.0 • 44.3) ~ 6.86 (0.70, 60.7)
SLC054B
CD Reservoir tank @ Washer @ Cooling fan

@ Reservoir tank bracket (J) Radiator drain plug @ Cooling fan motor
@ Radiator cap @ Mounting rubber @ Shield spacer
@ Mounting bracket @ Radiator @ Cooling fan motor shield
@ Upper radiator hose @l Lower radiator hose
LC-35
ENGINE COOLING SYSTEM @J
Radiator (Cont'd)
EC section ("Cooling Fan Control", "TROUBLE
DIAGNOSES").
Coolant").
LC-36
ENGINE COOLING SYSTEM I GA, SR, CD I
Radiator (Aluminum type)
SEC. 214
r Upper tank
r Sealing rubber ~
CJ~~
~
/"""-.
. /
/~ ..........
"-. '-..
-~
....,
@
~ ,>" (
'-""",
0..~ ~>..
1 I
/ ~Oil
6<,~8
Sealing rubber ~
cooler securing nut -

• 12 N.m (0.8 • 1.2 kg-m, 69 - 104 In-Ib)
!--Conical washer ~
•
, ~ I "~"- Washer
/ / ~, ,-O-ring ~
,
Lower tank -.I I /' ,_ Oil cooler
o
AIT model only
SLC882AB
PREPARATION
1.5 (0.059) 1. Attach the spacer to the tip of the radiator plate pliers A.
Spacer specification: 1.5 mm (0.059 in) thick x 18 mm (0.71
H" = 7.6 in) wide x 8.5 mm (0.335 in) long.
(0.299) 2. Make sure that when radiator plate pliers A are closed
dimension H" is approx. 7.6 mm (0.299 in).
3. Adjust dimension H" with the spacer, if necessary.
• If the radiator core rims cannot be crimped as specified,
further modification of the radiator plate pliers A is
Unit: mm (in) required. Refer to the Technical Bulletin LC91-001.
SLC655C
D1SASSEMBL Y
1. Remove tank with Tool.
• Grip the crimped edge and bend it upwards so that Tool

slips off.
Do not bend excessively.
*
LC-37
Radiator (Aluminum type) (Cont'd)
• In areas where Tool cannot be used, use a screwdriver to
bend the edge up.
Be careful not to damage tank.
2. Make sure the edge stands straight up.

3. Remove oil cooler from tank. (AfT models only)
SLC931
ASSEMBLY
1. Install oil cooler. (AfT models only)
Pay attention to direction of conical washer.
~ Conical washer ~
SLCB94
2. Clean contact portion of tank.
SLC932
3. Install sealing rubber.

Push it in with fingers.
Be careful not to twist sealing rubber.
LC-38
Radiator (Aluminum type) (Cont'd)
4. Caulk tank in specified sequence with Tool.
CD @
10~~103~ \ ~' SLC904
•
Keep tool perpendicular to
the radiator.
o X
(Grip is insufficient.)
SLC896
• Use pliers in the locations where Tool cannot be used.
5. Make sure that the rim is completely crimped down.

Standard height "H":
8.0 - 8.4 mm (0.315 - 0.331 in)
6. Confirm that there is no leakage.
Refer to Inspection.
INSPECTION
Apply pressure with Tool.
Specified pressure value:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
WARNING:
To prevent the risk of the hose coming undone while under
pressure, securely fasten it down with a hose clamp.
Attach a hose to the oil cooler as well. (A IT models only)
SLC933
LC-39
SERVICE DATA AND SPECIFICATIONS (50S) I GA, SR I
Engine Lubrication System (GA)

Oil pressure check Oil pump inspection
Unit: mm (in)
rpm kPa (bar, kg/cm?, psi) Body to outer gear
0.110 - 0.200 (0.0043 - 0.0079)
clearance
Inner gear to crescent
2,000 More than 245 (2.45, 2.5, 36) 0.217 - 0.327 (0.0085 - 0.0129)
clearance
6,000 More than 422 (4,22, 4.3, 61)
Outer gear to crescent
0.21 - 0.32 (0.0083 - 0.0126)
clearance
Body to inner gear

0.05 - 0.09 (0.0020 - 0.0035)
clearance
Body to outer gear

0.05 - 0 11 (0.0020 - 0.0043)
clearance
Inner gear to brazed portion of

0.045 - 0.091 (0.0018 - 0.0036)
housing clearance
Engine Cooling System (GA)

Thermostat Radiator
Unit: kPa (bar, kg/cm?, psi)
Standard
78 - 98
Valve opening temperature °C ("F) 76.5 (170) Standard
Cap relief (0.78 - 0.98, 0.8 - 10, 11 - 14)
More than pressure
Valve lift mml'C (inI'F) 59 - 98
8/90 (0.31/194) Limit
(059 - 0.98, 06 - 10, 9 - 14)
Leakage test pressure 157 (1.57, 16,23)
Engine Lubrication System (SR)

Unit: mm (in)
Engine speed Approximate discharge
rpm pressure kPa (bar, kg/cm?, psi) Body to outer gear clearance 0,114 - 0,200 (0.0045 - 0.0079)
Idle speed More than 78 (0.78, 0.8, 11) Inner gear to outer gear tip
Below 0.18 (0.0071)
clearance .
3,200 314 - 392 (3.14 - 3.92, 3.2 - 4.0, 46 - 57)
Body to inner gear clearance 0.05 - 0.09 (0.0020 - 0.0035)
Body to outer gear clearance 0.05 - 0.11 (0.0020 - 0,0043)
Regulator valve inspection Inner g-ear to brazed portion of

0.045 - 0,091 (0,0018 - 0,0036)
housing clearance
Unit: mm (in)
Regulator valve to oil pump

0040 - 0097 (0,0016 - 0.0038)
cover clearance
Engine Cooling System (SR)

Thermostat Radiator
Unit: kPa (bar, kg/em?, psi)
Valve opening temperature °C (OF) 765 (170)
78 - 98
More than 8/90 Standard
Valve lift mml"C (inI"F) (0.78 - 0,98, 0.8 - 1,0, 11 - 14)
(0,31/194) Cap relief
pressure 59 - 98
Limit
(0,59 - 0.98, 0.6 - 1.0, 9 - 14)
Leakage test pressure 157 (1.57, 1.6,23)
LC-40
Engine Lubrication System

Unit: mm (in)
Approximate discharge pressure
Engine rpm Body to outer gear clearance 0.12 - 0.20 (0.0047 - 0.0079)
Outer gear to inner gear clearance Less than 0.18 (0.0071)
Housing to inner gear clearance 0.05 - 0.09 (0.0020 - 0.0035)
2,000 294 (2.9, 3, 43)
•
Housing to outer gear clearance 0.05 - 0.11 (0.0020 - 0.0043)
Inner gear to housing clearance 0.05 - 0.09 (0.0020 - 0.0035)
Engine Cooling System

Thermostat Radiator
Unit: kPa (bar, kg/cm2, psi)
Valve opening temperature
88 (190) Cap relief Standard 78 - 98 (0.78 - 0.98, 0.8 - 1.0,11 - 14)
°c (OF)
pressure Limit 59 - 98 (0.59 - 0.98, 06 - 1.0, 9 - 14)
Valve lift
More than 10/100 (0.39/212)
mmrC (inrF) Leakage test pressure 157 (1.57,1.6,23)
LC-41
ENGINE CONTROL SYSTEM
SECTION EC
CONTENTS
•
PRECAUTIONS AND PREPARATION 4 ENGINE AND EMISSION BASIC CONTROL
Special Service Tools 4 SYSTEM DESCRiPTION 23
Supplemental Restraint System (SRS) "AIR System Chart.. 23
BAG" (Dual Air Bag System) 7 Multiport Fuel Injection (MFI) System 24
Supplemental Restraint System (SRS) "AIR Distributor Ignition (01) System 27
BAG" (Single Air Bag System) 7 Air Conditioning Cut Control 28
Fuel Cut Control (at no load & high engine
GA,SR speed) 28
EVAPORATIVE EMISSION SYSTEM 29
PRECAUTIONS AND PREPARATION 8
Inspection 29
Engine Fuel & Emission Control System 8
POSITIVE CRANKCASE VENTILATION 31
Precautions for ECCS Trouble Diagnosis of
Description 31
Engine 9
Inspection 32
Precautions 9
BASIC SERVICE PROCEDURE 33
Fuel Pressure Release 33
c= ~ GA
Fuel Pressure Check 33
ENGINE AND EMISSION CONTROL OVERALL Fuel Pressure Regulator Check 33
SYSTEM 11 Injector Removal and Installation 34
Circuit Diagram - Except for Australia 11 Idle Speed/lgnition Timing/ldle Mixture Ratio
Circuit Diagram - For Australia 12 Adjustment , 35
System Diagram - GA 14DE, GA 16DE for ON-BOARD DIAGNOSTIC SYSTEM DESCRIPTION .44
Europe and Israel 13 Malfunction Indicator Lamp (MIL) 44
System Diagram - GA15DE 14 CONSULT .48
System Diagram - GA 16DE except for TROUBLE DIAGNOSIS - General Description 58
Europe, Israel and Australia 15 Introduction 58
System Diagram - GA 16DE for Australia 16 Work Flow 59
ECCS Component Parts Location - GA 14DE, Description for Work Flow 60
GA 16DE for Europe and Israel 17 Diagnostic Worksheet 61
ECCS Component Parts Location - GA15DE 18 Diagnostic Trouble Code (DTC) Chart 62
ECCS Component Parts Location - GA 16DE Fail-Safe Chart 64
except for Europe, Israel and Australia 19 Basic Inspection 65
ECCS Component Parts Location - GA 16DE Fast Idle Cam (FIC) Inspection and
for Austral ia 20 Adjustment - For Europe and Israel 68
ECCS Component Parts Location 21 Fast Idle Cam (FIC) Inspection and
Vacuum Hose Drawing 22 Adjustment - Except for Europe and Israel. 68
Symptom Matrix Chart 71
CONTENTS (Cont'd.)
CONSULT Reference Value in Data Monitor ENGINE AND EMISSION BASIC CONTROL
Mode 74 SYSTEM DESCRiPTION 233
Major Sensor Reference Graph in Data Multipart Fuel Injection (MFI) System 233
Monitor Mode 76 Distributor Ignition (01) System 235
ECM Terminals and Reference Value 78 Air Conditioning Cut Control 236
TROUBLE DIAGNOSIS FOR POWER SUPPLY 88 Fuel Cut Control (at no load & high engine
Main Power Supply and Ground Circuit.. 88 speed) 237
TROUBLE DIAGNOSIS FOR DTC 11 94 EVAPORATIVE EMISSION SYSTEM 238
Camshaft Position Sensor (CMPS) 94 Description 238
TROUBLE DIAGNOSIS FOR DTC 12 101 Inspection 238
Mass Air Flow Sensor (MAFS) 101 POSITIVE CRANKCASE VENTILATION 240
TROUBLE DIAGNOSIS FOR DTC 13 108 Description 240
Engine Coolant Temperature Sensor (ECTS) 108 Inspection 240
TROUBLE DIAGNOSIS FOR DTC 21 113 BASIC SERVICE PROCEDURE 241
Ignition Signal 113 Fuel Pressure Release 241
TROUBLE DIAGNOSIS FOR DTC 34 119 Fuel Pressure Check 241
Knock Sensor (KS) 119 Fuel Pressure Regulator Check 242
TROUBLE DIAGNOSIS FOR DTC 41 124 Injector Removal and Installation 242
Intake Air Temperature Sensor (IATS) 124 Idle Speed/Ignition Timing/Idle Mixture Ratio
TROUBLE DIAGNOSIS FOR NON-DETECTABLE Adjustment 243
ITEMS , '" .128 ON-BOARD DIAGNOSTIC SYSTEM DESCRIPTION ..250
Throttle Position Sensor 128 Malfunction Indicator Lamp (MIL) 250
Vehicle Speed Sensor (VSS) 133 CONSULT 254
Start Signal 138 TROUBLE DIAGNOSIS - General Description 264
Injector 141 Introduction 264
Fuel Pump 145 Work Flow 265
Idle Air Control Valve (IACV) - Auxiliary Air Description for Work Flow 266
Control (AAC) Valve 150 Diagnostic Worksheet 267
Cooling Fan Control 156 Diagnostic Trouble Code (DTC) Chart 268
Power Steering Oil Pressure Switch 169 Fail-Safe Chart 270
Park/Neutral Position Switch 173 Basic Inspection 271
EVAP Canister Purge Control Solenoid Valve 179 Symptom Matrix Chart. 274
EGR Valve and EVAP Canister Purge Control CONSULT Reference Value in Data Monitor
Solenoid Valve 183 Mode 277
Heated Oxygen Sensor (H02S) 189 Major Sensor Reference Graph in Data
Oxygen Sensor (02S) 194 Monitor Mode 279
Valve Timing Control (VTC) 198 ECM"Terminals and Reference Value 281
IACV-FICD Solenoid Valve 204 TROUBLE DIAGNOSIS FOR POWER SUPPLY 286
Electrical Load Signal 211 Main Power Supply and Ground Circuit.. 286
Torque Converter Clutch Solenoid Valve 219 TROUBLE DIAGNOSIS FOR DTC 11 289
MIL & Data Link Connectors 223 Camshaft Position Sensor (CMPS) 289
TROUBLE DIAGNOSIS FOR DTC 12 293
SR Mass Air Flow Sensor (MAFS) 293
ENGINE AND EMISSION CONTROL OVERALL
Engine Coolant Temperature Sensor (ECTS) 297
SYSTE M 226
Circuit Diagram 226
Ignition Signal 301
System Diagram 227
ECCS Component Parts Location 228
Knock Sensor (KS) 306
Vacuum Hose Drawing 231
System Chart... 232
CONTENTS (Cont'd.)
TROUBLE DIAGNOSIS FOR DTC 43 309 FUEL SYSTEM CHECK 381

Throttle Position Sensor 309 Priming Pump Check 381
TROUBLE DIAGNOSIS FOR NON-DETECTABLE Fuel Cut Solenoid Valve 381
ITEMS 314 CRANKCASE VENTILATION SYSTEM 382
Vehicle Speed Sensor (VSS) 314 Ventilation Hose 382
Start Signal 317 ENGINE AND EMISSION CONTROL OVERALL
Exhaust Gas Recirculation (EGR) Valve and SYSTEM 383
EVAP Canister Purge Control 319 Component Parts Location 383
Injector 324 System Diagram 384
Fuel Pump
Idle Air Control Valve (IACV)-Air Regulator
Idle Air Control Valve (IACV) - Auxiliary Air
Control (AAC) Valve
Idle Air Control Valve (IACV)-FICD Solenoid
Valve '"
:
327
332
335
339
Circuit Diagram
System Chart.
TROUBLE DIAGNOSES
ECM Terminals and Reference Values
Quick-glow System
Partial Load Advance (PLA) Control
, 385
386
387
387
390
399
•
Cooling Fan Control 343 Cooling Fan Control 404
Power Steering Oil Pressure Switch 354 Air Conditioner Cut Control 413
Park/Neutral Position Switch 357 Fuel Cut Control 416
Heated Oxygen Sensor (H02S) 362
Torque Converter Clutch Solenoid Valve 367 GA
Malfunction Indicator Lamp (MIL) & Data Link
SERVICE DATA AND SPECIFICATIONS (505) .417
Connector (DLC) for CONSULT 370
General Specifications 417
Inspection and Adjustment.. 417
CD
INJECTION SYSTEM 371 SR

VE.TYPE INJECTION PUMP 372
SERVICE DATA AND SPECIFICATIONS (505) .418
Removal 372
Installation 373
Inspection and Adjustment.. .418
Adjustment 374
INJECTION NOZZLE 376
CD
Removal and Installation 376
Disassembly 376 SERVICE DATA AND SPECIFICATIONS (505) .419
Inspection 377 VE-type Injection Pump 419
Cleaning 377 Injection Nozzle 419
Assembly 378
Test and Adjustment 379
When you read wiring diagrams:

• Read GI section, "HOW TO READ WIRING DIAGRAMS" .
• See El section, "POWER SUPPLY ROUTING" for power distribution circuit.
When you perform trouble diagnoses, read GI section, "HOW TO FOllOW FLOW CHART IN TROU-
BLE DIAGNOSES" and "HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT".
Engine
Tool number
Description application
Tool name
SR GA
EG11140000 Measuring engine speed

Ignition coil adapter
harness x x
NT338
KV10117100 Loosening or tightening

Heated oxygen sensor heated oxygen sensor
wrench x
NT630
KV10114400 Loosening or lightening

Oxygen sensor wrench heated oxygen sensor
x
NT636 a: 22 mm (0.87 in)
FOR CD ENGINE VE- TYPE INJECTION PUMP

Adjusting device on vehicle
Tool number
Description
Tool name
KV11229352 Measuring set length of plunger spring

Measuring device
CD KV11229350
Holder
@ KV11229360
Nut
@ KV11229370
Pin
@ KV11254410
Dial gauge NT570
KV11102900 Removing injection pump sprocket

Pulley puller
NT647
EC-4
FOR CD ENGINE INJECTION NOZZLE
Tool number
Description
Tool name
KV11289004
Nozzle cleaning kit
CD KV11290012
Box
@ KV11290110
Brush
@ KV11290122
•
Nozzle oil sump
scraper
@ KV11290140
Nozzle needle tip
cleaner
@ KV11290150
Nozzle seat scraper
@ KV11290210
Nozzle holder
!J) KV11290220
Nozzle hole cleaning
needle
NT296
KV11292010
Nozzle centering device
NT293
KV11100300
Nozzle holder socket
NT563
EC-5
NOTE
EC-6

severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint
panel on the passenger side), a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.
WARNING:
by an authorized NISSAN dealer. •
• Do not use electrical test equipment ~n any circuit related to the SRS unless instructed to in this

WARNING:
Service Manual.
EC-7
PRECAUTIONS AND PREPARATION I GA, SR I
Engine Fuel & Emission Control System
ECM WIRELESS EQUIPMENT

• Do not disassembly EGM (EGGS control • When installing C.B. ham radio or a
module). mobile phone, be sure to observe the
• Do not turn diagnosis mode selector following as it may adversely affect
forcibly. electronic control systems depending
• If a battery terminal is disconnected, on its installation location .
the memory will return to the ECM 1) Keep the antenna as far as possible
value. away from the EGM.
The ECM will now start to self-control 2) Keep the antenna feeder line more than
at its initial value. Engine operation can 20 em (7.9 in) away from the harness
vary slightly when the terminal is of electronic controls.
BATTERY disconnected. However, this is not an Do not let them run parallel for a long
• Always use a 12 volt battery as power indication of a problem. Do not replace distance.
source. parts because of a slight variation. 3) Adjust the antenna and feeder line so
• Do not attempt to disconnect battery that the standing-wave ratio can be
cables while engine is running. kept smaller.
4) Be sure to ground the radio to vehicle
body.
INJECTOR
• Do not disconnect injector harness
connectors with engine running .
• Do not apply battery power directly to
injectors.
ECCS PARTS HANDLING

• Handle mass air flow sensor carefully to
avoid damage.
• Do not disassemble mass air flow
sensor. WHEN STARTING
• Do not clean mass air flow sensor with • Do not depress accelerator pedal when
any type of detergent. starting. FUEL PUMP
• Do not operate fuel pump when there
• Do not disassemble IACV-AAC valve. • Immediately after starting, do not rev up
is no fuel in lines.
• Even a slight leak in the air intake engine unnecessarily .
• Do not rev up engine just prior to • Tighten fuel hose clamps to the
system can cause serious problems.
specified torque.
• Do not shock or jar the camshaft shutdown.
position sensor.
ECCS HARNESS HANDLING
• Securely connect EGGS harness
connectors.
A poor connection can cause an
extremely high (surge) voltage to
develop in coil and condenser, thus
resulting in damage to ICs .
• Keep ECGS harness at least 10 em (3.9
in) away from adjacent harnesses, to
prevent an EGGS system malfunction
due to receiving external noise,
degraded operation of IGs, etc .
• Keep EGCS parts and harnesses dry .
• Before removing parts, turn off ignition
switch and then disconnect battery
ground cable.
SEF320R
EC-8
Precautions for ECCS Trouble Diagnosis of

Engine
CAUTION:
• Be sure to turn the ignition switch "OFF" and disconnect the negative battery terminal before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc.
will cause malfunction.
• Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause malfunction due to the open circuit. (Be sure the connector is free from water, grease, dirt,
bent terminals, etc.)
• Be sure to route and clamp the harnesses properly after work. The interference of the harness with
a bracket, etc. may cause malfunction due to the short circuit.
• Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube •
may cause malfunction.
• Be sure to erase the unnecessary malfunction information (repairs completed) in the ECM before
returning the vehicle to the customer.
Precautions
• Before connecting or disconnecting the ECM harness
connector, turn ignition switch OFF and disconnect negative
battery terminal. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned off.
SEF289H
• When connecting ECM harness connector, tighten securing

bolt until red projection is in line with connector face.
SEF725H
• When connecting or disconnecting pin connectors into or

from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.
Bend Break
SEF291H
EC-9
Precautions (Cont'd)
• Before replacing ECM, perform Terminals and Reference
Value inspection and make sure ECM functions properly.
Refer to EC-281 for SR engine model and EC-78 for GA
engine model.
/ " MEF040D
• After performing each TROUBLE DIAGNOSIS, perform

"OVERALL FUNCTIONCHECK" or "DTC (Diagnostic Trou-
\ I / ble Code) CONFIRMATIONPROCEDURE".
The DTC should not be displayed in the "DTC CONFIRMA-
'~/" TION PROCEDURE"if the repair is completed. The "OVER-
- CHECK- ALL FUNCTION CHECK" should be a good result if the
/
/ , \
.......
repair is completed.
SEF051P
• When measuring ECM signals with a circuit tester, never

allow the two tester probes to contact.
Accidental contact of probes will cause a short circuit and
damage the ECM power transistor.
NG
@~ )
~K
Circuit tester .1
SEF34BN
EC-10
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
Circuit Diagram - Except for Australia

H
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HEC060
EC-11
ENGINE AND EMISSION CONTROL OVERAll SYSTEM
Circuit Diagram - For Australia

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EC-12
System Diagram - GA14DE, GA 16DE for

Europe and Israel
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EC-13
System Diagram - GA 15DE
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EC-14
System Diagram - GA 16DE except for Europe,

Israel and Australia
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SEF450QA
EC-15
System Diagram - GA 16DE for Australia
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SEF121R
EC-16
ECCS Component Parts Location - GA 14DE,

GA 16DE for Europe and Israel
Fast idle cam EGR valve & EVAP canister purge control solenoid valve
Mass air flow sensor
Throttle position sensor
Power steering oil

pressure switch
Engine coolant temperature

sensor
IACV-FICD solenoid valve Distributor with built-in camshaft position
sensor, power transistor and ignition coil
IACV-AAC valve
SEF122R
EC-17
ECCS Component Parts Location - GA 15DE
EGR valve & EVAP canister purge control solenoid valve

Mass air flow sensor (Only M/T models)
EGR valve (Only M/T models)
f
Fuel filter
EVAP canister

Distributor with built-in camshaft position
sensor
IACV-AAC valve sensor, power transistor and ignition coil
Oxygen sensor
(with FICD
solenoid valve)
SEF123R
EC-18
ECCS Component Parts Location - GA 16DE

except for Europe, Israel and Australia
Engine coolant EVAP canister purge

temperature sensor control solenoid valve
Power steering oil (Only M/T models)
,,,,,"to 'WI"h~~>- __ "7-_
VTC solenoid valve

Oxygen sensor
Engine coolant temperature sensor

VTC solenoid valve
SEF451QA
EC-19
ECCS Component Parts Location - GA 16DE for

Australia
EGR valve & EVAP

canister purge Throttle position sensor
Engine coolant temperature control solenoid valve IACV-AAC valve (with FICO solenoid valve)
sensor
VTC solenoid valve
Heated oxygen sensor Distributor with built-in camshaft position

(AfT models) sensor, power transistor and ignition coil
Oxygen sensor
(MfT models)

VTC solenoid valve
SEF124R
EC-20
ENGINE AND EMISSION CONTROL OVERALL SYSTEM []K]
ECCS Component Parts Location
Behind the center console
•
SEF452Q
EC-21
Vacuum Hose Drawing
GA 14DE, GA 16DE for Europe
~. "
Throttle body
10
\1--"~
EGR valve ~L/
I t~:::-
z:
1 ~ EGR valve & EVAP
0 5 L W canister purge
~ 4 control solenoid
8 To EVAP canister ¥ valve
EGR valve & EVAP canister purge BPT valve 3-way connector
control solenoid valve
GA15DE MIT models AIT models
AIT models
Pressure regulator
SEF125R
(1) Pressure regulator to intake (j) EGR valve & EVAP canister @ Throttle body to EVAP canister
manifold purge control solenoid valve to @ EVAP canister purge control
@ EGR valve to 3-way connector air cleaner valve to throttle body
@ 3-way connector to 3-way con- @ EGR valve & EVAP canister @ EVAP canister purge control
nector purge control solenoid valve to valve to EVAP canister
throttle body @ EVAP canister purge control
@ BPT valve to 3-way connector
@ Pressure regulator to throttle valve to resonator
@ 3-way connector to EVAP canis-
body @ Throttle body to EVAP canister
ter
@ EGR valve & EVAP canister
@l EGR valve & EVAP canister
purge control solenoid valve to
air duct
3-way connector
EC-22
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
System Chart
I Camshaft position sensor

Fuel injection & mixture Injectors
'1 ratio control
Knock sensor
Distributor ignition system Power transistor

*4
Idle air control system IACV-AAC valve (With FICD
•
solenoid valve)
sensor
Fuel pump control Fuel pump relay

Ignition switch
2
Oxygen sensor monitor Malfunction indicator lamp
& On-board diagnostic system (On the instrument panel)
Neutral positionllnhibitor
switch 5 '5
ECM
(ECCS Torque converter clutch can- Torque converter clutch sole-
Air conditioner switch control cel solenoid valve control noid valve
module) (A/T models)
Battery voltage
Cooling fan control Cooling fan relay
Power steering oil pressure

switch Air conditioner cut control Air conditioner relays
during acceleration
I Vehicle speed sensor

6 *6
*2 Valve timing control VTC solenoid valve
I Oxygen sensor 7
*3 EVAP canister purge control EVAP canister purge control

solenoid valve
Intake air temperature sensor
8 '8
Electrical load
EGR & EVAP canister purge EGR valve & EVAP canister
• Rear defogger switch
control purge control solenoid valve
• Lighting switch
*1: Except for Europe and Israel

*2: Heated oxygen sensor (For Europe and Israel, and Australia A/T models)
Oxygen sensor (Except for Europe and Israel, and Australia A/T models)
*3: For Australia
*4: IACV-AAC valve and IACV-FICD solenoid valve (For Europe and Israel)
IACV-AAC valve (with FICD solenoid valve) (Except for Europe and Israel)
'5: Except for Europe
*6: GA16DE except for Europe and Israel
*7: GA 16DE MIT models except for Europe, Israel and Australia
*8: For Europe and Israel and Australia, and GA15DE MIT models
EC-23
Multipart Fuel Injection (MFI) System

INPUT/OUTPUT SIGNAL LINE
Camshaft position sensor Engine speed and piston position
Mass air flow sensor Amount of intake air
Engine coolant temperature sensor Engine coolant temperature
*1
Density of oxygen in exhaust gas
Oxygen sensor
Throttle position sensor Throttle position

Throttle valve idle position ECM
(ECCS Injector
Neutral position/Inhibitor switch Gear position
control
module)
Vehicle speed sensor Vehicle speed
Start signal
~gnition switch
Air conditioner switch Air conditioner operation
Power steering oil pressure switch Power steering load signal
Battery Battery voltage
BASIC MUL TIPORT FUEL INJECTION VARIOUS FUEL INJECTION

SYSTEM INCREASE/DECREASE COMPENSATION
The amount of fuel injected from the fuel injector In addition, the amount of fuel injected is com-
is determined by the ECM. The ECM controls the pensated to improve engine performance under
length of time the valve remains open (injection various operating conditions as listed below.
pulse duration). The amount of fuel injected is a < Fuel increase>
program value in the ECM memory. The program • During warm-up
value is preset by engine operating conditions. • When starting the engine
These conditions are determined by input signals • During acceleration
(for engine speed and intake air) from both the • Hot-engine operation
camshaft position sensor and the mass air flow • When selector lever is changed from "N" to
sensor. "D" (AfT models only)
• High-load, high-speed operation
< Fuel decrease>
• During deceleration
EC-24
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION [ill
Multipart Fuel Injection (MFI) System (Cant' d)
CLOSED LOOP MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP
CONTROL CONTROL)
The mixture ratio feedback system provides the best air-fuel
Feedback signal
mixture ratio for driveability and emission control. The three
way catalyst can then better reduce CO, HC and NOx emissions.
This system uses an oxygen sensor*1 in the exhaust manifold
to monitor if the engine operation is rich or lean. The ECM
adjusts the injection pulse width according to the sensor volt-
age signal. This maintains the mixture ratio within the range of
stoichiometric (ideal air-fuel mixture).
MEF025DC This stage is referred to as the closed loop control condition .
OPEN LOOP CONTROL

The open loop system condition refers to when the ECM detects
any of the following conditions. Feedback control stops in order
to maintain stabilized fuel combustion.
• Deceleration and acceleration
•
• Engine idling
• Malfunction of oxygen sensor*1 or its circuit
• Insufficient activation of oxygen sensor*1 at low engine
coolant temperature
• High-engine coolant temperature
• After shifting from "N" to "D"
• During warm-up
• When starting the engine
MIXTURE RATIO SELF-LEARNING CONTROL

The mixture ratio feedback control system monitors the mixture
ratio signal transmitted from the oxygen sensor*1. This feed-
back signal is then sent to the ECM. The ECM controls the basic
mixture ratio as close to the theoretical mixture ratio as possi-
ble. However, the basic mixture ratio is not necessarily con-
trolled as originally designed. Both manufacturing differences
(i.e., mass air flow sensor hot film) and characteristic changes
during operation (i.e., injector clogging) directly affect mixture
ratio.
Accordingly, the difference between the basic and theoretical
mixture ratios is monitored in this system. This is then com-
puted in terms of "injection pulse duration" to automatically
compensate for the difference between the two ratios.
* 1: Heated oxygen sensor (For Europe and Israel, and Austra-
lia AIT models)
Oxygen sensor (Except for Europe and Israel, and Australia
AIT models)
EC-25
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION @K]
Multipart Fuel Injection (MFI) System (Cont'd)
/ Injection pUlse FUEL INJECTION TIMING
No.1 cylinder ---r:T _ Two types of systems are used.
No.2 cylinder rL Sequential multiport fuel injection system

Fuel is injected into each cylinder during each engine cycle
No.3 cylinder n.... _ according to the firing order. This system is used when the
engine is running.
No.4 cylinder n....
__
~ 1 engine cycle ----j
Sequential multiport fuel injection system
MEF522D
Simultaneous multiport fuel injection system

No. 1 cylinder jl n n- Fuel is injected simultaneously into all four cylinders twice each
No.2 cylinder jl n n- engine cycle. In other words, pulse signals of the same width
are simultaneously transmitted from the ECM.
No. 3 cylinder .n n rL- The four injectors will then receive the signals two times for
each engine cycle.
No.4 cylinder j1~ n.... rL-
This system is used when the engine is being started and/or if
f--- 1 engine cycle -l the fail-safe system (CPU) is operating.
Simultaneous multiport fuel injection system
FUEL SHUT-OFF
MEF523D
Fuel to each cylinder is cut off during deceleration or operation
of the engine and the vehicle at excessively high speeds.
EC-26
Distributor Ignition (DI) System

Engine speed and piston position

Camshaft position sensor
Amount of intake air


Vehicle speed sensor

Throttle position
Throttle valve idle position

Vehicle speed
Start signal
ECM
(ECCS
control
module)
Power
transistor
•
Ignition switch
*1
Engine knocking
Knock sensor
Gear position
Neutral position/Inhibitor switch
Battery voltage
Battery
Tp SYSTEM DESCRIPTION
(msec)
1.75 The ignition timing is controlled by the ECM to maintain the best
A air-fuel ratio for every running condition of the engine.
~ 1.50 The ignition timing data is stored in the ECM. This data forms
.~
the map shown.
~ 1.25
"S The ECM receives information such as the injection pulse width
0.
C 1.00 and camshaft position sensor signal. Computing this informa-
o
tion, ignition signals are transmitted to the power transistor .
.~ 0.75
e.g., N: 1,800 rpm, Tp: 1.50 msec
E
AOBTDC
N
600 1,000 1,400 1,800 2,200 During the following conditions, the ignition timing is revised by
Engine speed (rpm) SEF742M
the ECM according to the other data stored in the ECM.
• At starting
• During warm-up
• At idle
• Hot engine operation
• During acceleration
• During high-load operation (VTC on) - GA 16DE except for
Europe and Israel
Except for Europe and Israel
The knock sensor retard system is designed only for emergen-
cies. The basic ignition timing is programmed within the anti-
knocking zone, if recommended fuel is used under dry condi-
tions. The retard system does not operate under normal driv-
ing conditions.
If engine knocking occurs, the knock sensor monitors the con-
dition. The signal is transmitted to the ECM (ECCS control mod-
ule). The ECM retards the ignition timing to eliminate the knock-
ing condition.
EC-27
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION ~
Air Conditioning Cut Control

Air conditioner "ON" signal

Air conditioner switch
Neutral position
Throttle valve opening angle

Engine speed ECM

(ECCS Air conditioner
control relay
Engine coolant temperature module)
Start signal
Ignition switch
Vehicle speed
Power steering load signal

Power steering oil pressure switch
SYSTEM DESCRIPTION
This system improves acceler8.tion when the air conditioner is used.
When the accelerator pedal is fully depressed, the air conditioner is turned off for a few seconds.

speed)
Vehicle speed
Neutral position
ECM
Throttle position (ECCS
Throttle position sensor control Injectors
module)
Engine speed
If the engine speed is above 2,500 rpm with no load (for

example, in neutral and engine speed over 2,500 rpm) fuel will
be cut off after some time. The exact time when the fuel is cut
off varies based on engine speed.
Fuel cut will operate until the engine speed reaches 2,000 rpm,
then fuel cut is cancelled.
NOTE:
This function is different than deceleration control listed under
"Multiport Fuel Injection (MFI) System" on EC-24.
EC-28
EVAPORATIVE EMISSION SYSTEM
r--- -- - ---- -- - ----- ---------,

To EGR I
I
'1 EVAP canister
purge control
solenoid valve
valve
,
I
or 1
Throttle valve ~ 1
I
'2 EGR valve & I
------------, I
EVAP canister I
I
I purge control
I solenoid Vacuum :
Intake manifold I
I valve signal line I
I I
I I
I I
•
I I
Fuel check valve I I
I I
'- -- - - - -- -- ------ __ ....J
'1 : GA 16DE M/T models except for Europe,

Israel and Australia
'2 : For Europe, Israel and Australia,
and GA 15DE M/T models
~ : GA 15, 16DE AlT models except for
Europe, Israel and Australia EVAP canister
.. : Air Fuel filler cap
with vacuum
Q : Fuel vapor
relief valve SEF126R
The evaporative emission system is used to reduce hydrocar-

bons emitted into the atmosphere from the fuel system. This
reduction of hydrocarbons is accomplished by activated char-
coals in the EVAP canister.
The fuel vapor from sealed fuel tank is led into the EVAP can-
ister when the engine is off. The fuel vapor is then stored in the
EVAP canister. The EVAP canister retains the fuel vapor until
the EVAP canister is purged by air.
When the engine is running, the air is drawn through the bot-
tom of the EVAP canister. The fuel vapor will then be led to the
intake manifold.
When the engine runs at idle, the EVAP canister purge control
valve is closed. Only a small amount of vapor flows into the
intake manifold through the constant purge orifice.
As the engine speed increases and the throttle vacuum rises,
the purge control valve opens. The vapor is sucked through
both main purge and constant purge orifices.
Inspection
EVAP CANISTER
Check EVAP canister as follows:
@Q 1. Blow air in port @ and ensure that there is no leakage.
2. Apply vacuum to port @. [Approximately -13.3 to -20.0 kPa
(-133 to -200 mbar, -100 to -150 mmHg, -3.94 to -5.91 inHg)]
3. Cover port CID with hand.
4. Blow air in port @ and ensure free flow out of port CID .
@ AEC664
EC-29
Inspection (Cont'd)
..
"?
Fuel tank side
FUEL CHECK VALVE
Check valve operation
1. Blow air through connector on fuel tank side.
A considerable resistance should be felt and a portion of air
QAir
flow should be directed toward the EVAP canister side.
... Fuel vapor
2. Blow air through connector on EVAP canister side.
..
EVAP canister side
<? 3.
Air flow should be smoothly directed toward fuel tank side.
If fuel check valve is suspected of not properly functioning
in steps 1 and 2 above, replace it.
MEC744B
FUEL TANK VACUUM RELIEF VALVE

1. Wipe clean valve housing.
2. Suck air through the cap. A slight resistance accompanied
by valve clicks indicates that valve A is in good mechanical
condition. Note also that, by further sucking air, the resis-
tance should disappear with valve clicks.
3. Blow air on fuel tank side and ensure that continuity of air
passage exists through valve B.
~V""B 4. If valve is clogged or if no resistance is felt, replace cap as
Valve A an assembly.
Fuel tank side
SEF427N
EC-30
POSITIVE CRANKCASE VENTILATION
Description
This system returns blow-by gas to the intake into the crankcase. In this process the air passes
manifold collector. through the hose connecting air inlet tubes to
The positive crankcase ventilation (peV) valve is rocker cover.
provided to conduct crankcase blow-by gas to the Under full-throttle condition, the manifold vacuum
intake manifold. is insufficient to draw the blow-by flow through
During partial throttle operation of the engine, the the valve. The flow goes through the hose con-
intake manifold sucks the blow-by gas through nection in the reverse direction.
the pev valve. On vehicles with an excessively high blow-by, the
Normally, the capacity of the valve is sufficient to valve does not meet the requirement. This is
handle any blow-by and a small amount of venti- because some of the flow will go through the
lating air. hose connection to the intake manifold collector
•
The ventilating air is then drawn from the air duct under all conditions.
For Europe and Israel, and GA15DE

Cruising Acceleration or high load
pcv valve
Filter
PCV valve operation

Engine not running
.~
Cruising
or backfiring
~~
GA16DE except for Europe and Israel Idling or Acceleration
Cruising Acceleration or high load decelerating or high load
-~ .~
.. Q:
•
Fresh air
: Blow-by gas
SEF127R
EC-31
Inspection
PCV (Positive Crankcase Ventilation) VALVE
With engine running at idle, remove PCV valve from rocker
cover. A properly working valve makes a hissing noise as air
passes through it. A strong vacuum should be felt immediately
when a finger is placed over the valve inlet.
AEC904
PCV HOSE
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air. If any
hose cannot be freed of obstructions, replace.
ET277
EC-32
BASIC SERVICE PROCEDURE
Fuel Pressure Release

• FUEL PRES RELEASE. D
Before disconnecting fuel line, release fuel pressure from fuel
FUEL PUMP WILL STOP BY line to eliminate danger.
TOUCHING START DURING (ij\ 1. Turn ignition switch "ON".
IDLE.
~ 2. Perform "FUEL PRESSURE RELEASE" in "WORK
ENGINE STALL SUPPORT" mode with CONSULT.
3. Start engine.
4. After engine stalls, crank it two or three times to
release all fuel pressure.
---S-T~-RT-- 5. Turn ignition switch "OFF".
SEF823K
00 ~: 3.
Remove fuse for fuel pump.
Start engine.
After engine stalls, crank it two or three times to
•

4. Turn ignition switch off and reconnect fuel pump
fuse.
SEF921P
Fuel Pressure Check

• When reconnecting fuel line, always use new clamps.
• Make sure that clamp screw does not contact adjacent
parts.
• Use a torque driver to tighten clamps.
• Use Pressure Gauge to check fuel pressure.
• Do not perform fuel pressure check with system operating.
Fuel pressure gauge may indicate false readings.
1. Release fuel pressure to zero.
2. Disconnect fuel hose between fuel filter and fuel tube
(engine side).
3. Install pressure gauge between fuel filter and fuel tube.
4. Start engine and check for fuel leakage.
5. Read the indication of fuel pressure gauge.
At idling:
With vacuum hose connected
Approximately 245 kPa (2.45 bar, 2.5 kg/cm2, 36 psi)
With vacuum hose disconnected
If results are unsatisfactory, perform Fuel Pressure Regula-
tor Check.
Fuel Pressure Regulator Check

Vacuum Fuel pressure 1. Stop engine and disconnect fuel pressure regulator vacuum
hose from intake manifold.
2. Plug intake manifold with a rubber cap.
3. Connect variable vacuum source to fuel pressure regulator.
..... 4. Start engine and read indication of fuel pressure gauge as
vacuum is changed.
LTo pressure regulator Fuel pressure should decrease as vacuum increases. If results
are unsatisfactory, replace fuel pressure regulator.
SEF7188
EC-33
BASIC SERVICE PROCEDURE @[]
Injector Removal and Installation

2. Remove injector tube assembly with injectors from intake
manifold.
3. Remove injectors from injector tube assembly.
• Push injector tail piece.
• Do not pull on the connector.
Loosen in numerical order
4. Install injectors.
~~2.27 - 3.04 N.m • Clean exterior of injector tail piece.
"l!.ti!?n (0.231 - 0.310 kg-m,
~ 20.1. 26.9 in-Ib)
• Use new O-rings.
r;m / Injector • Face metal plate of upper insulator to injector.
Upper
insulator
J~tf
/" \
a-ring ~
~ . ......--: ~
.
CAUTION:
After properly connecting injectors to fuel tube assembly, check
~ connections for fuel leakage.
Engine 5. Assemble injectors to injector tube assembly.
o
front
0 -
6. Install injector tube assembly to intake manifold.
Lower ins~~or ~ MEC741B
7. Tighten fuel tube bolts to 7.86 - 10.8 N'm (0.801 - 1.10 kg-m,
5.8 - 8.0 ft-Ib) as shown in the figure. Then tighten the bolts
to 15.7 - 20.6 N'm (1.60 - 2.10 kg-m, 11.6 -15.2 ft-Ib).
EC-34
Idle Speedllgnition Timinglldle Mixture Ratio

Adjustment
PREPARATION (12) Evaporative emission system
• Make sure that the following parts are in • On models equipped with air conditioner,
good order. checks should be carried out while the air
(1) Battery conditioner is "OFF".
(2) Ignition system • On models equipped with automatic
(3) Engine oil and coolant levels transaxle, when checking idle speed, ignition
(4) Fuses timing and mixture ratio, checks should be
(5) ECM harness connector carried out while shift lever is in "N" position.
(6) Vacuum hoses • When measuring "CO" percentage, insert
(7) Air intake system probe more than 40 cm (15.7 in) into tail pipe .•
(Oil filler cap, oil level gauge, etc.) • Turn off headlamps, heater blower, rear
(8) Fuel pressure defogger.
(9)' Engine compression • Keep front wheels pointed straight ahead.
(10) Throttle valve • Make the check after the cooling fan has
(11) EGR valve operation - For Europe and stopped.
Israel and Australia, and GA15DE M/T mod-
els
Overall inspection sequence
INSPECTION
Perform diagnostic test mode 1/ NG Repair or replace.

(Self-diagnostic results).
Check & adjust ignition timing.
Check & adjust idle speed.
Check oxygen sensor*1 function. Check oxygen sensor*1 har- NG Repair or replace harness.
ness.
OK
Check CO%. OK Replace oxygen sensor* 1.
NG
Check emission control parts NG Check oxygen sensor*1 function. OK

and repair or replace if neces-
sary.
INSPECTION END
*1: Heated oxygen sensor (For Europe and Israel, and Australia AfT models)
Oxygen sensor (Except for Europe and Israel, and Australia AfT models)
EC-35
BASIC SERVICE PROCEDURE @K]
Idle Speed/Ignition Timinglldle Mixture Ratio
Adjustment (Cont'd)
ADJUSTING VALUE
GA16DE
Engine GA14DE, GA16DE GA16DE
GA15DE (Except for Europe and
models (For Europe and Israel) (For Australia)
Israel, and Australia)
MfT
(Without AfT AfT AfT AfT

(With day- (in "N"
Transaxle daytime (in "N" MfT (in "N" MfT (in "N" MfT
time light
light sys- position) position) position) position)
system)
tem)
Base idle
speed 625::t50 625::t 50 725::t50 580::t50 700::t 50 625::t50 725::t50 600::1:50 750::t50
(rpm)
Idle speed
800::t50 700::t50 800::t50 630::t 50 750::t 50 675::t50 800::t50 650::1:50 800::t 50
(rpm)
Ignition
timing 10::t2 10::t 2 10::t2 6::t2 6::t2 8::t2 8::t2 10::t2 10::t2
CBTDC)
EC-36
BASIC SERVICE PROCEDURE eM]
Idle Speed/Ignition Timing/Idle Mixture Ratio
Adjustment (Cont'd)
START
Visually check the following:

• Hoses and ducts for leaks
• Electrical connectors
• Gasket
SEF455Q • Throttle valve and throttle position sensor operation
m
Start engine and warm it up until water temperature
indicator points to the middle of gauge.
Ensure engine stays below 1,000 rpm.
•
iii
Open engine hood and run engine at about 2,000 rpm
SEF247F for about 2 minutes under no-load.
[iJ
Perform ECM on-board diagnostic system (Diagnostic
test mode II).
OK lNG
Repair or replace components as neces-

MALFUNCTION INDICATOR LAMP sary.
SEF217M
I!]
Run engine at about 2,000 rpm for about 2 minutes
1
under no-load.
Race engine two or three times under no-load, then run
engine for about 1 minute at idle speed.
SEF248F
EC-37
BASIC SERVICE PROCEDURE @]
Idle Speed/Ignition Timing/ldle Mixture Ratio
Adjustment (Cont'd)
@
l
Ii 1) Turn off engine and disconnect throttle
position sensor harness connector.
2) Start engine.
Race engine (2,000 - 3,000 rpm) 2 or 3 times

under no-load and then run engine at idle
speed.
Ii
Check ignition timing with a timing light.
Ignition timing: Refer to EC-36.
OK
lNG
Adjust ignition timing to the specified value by
turning distributor after loosening bolts which
secure distributor.
Ignition timing: Refer to EC-36.
(])
@
[!1
l
1) Turn off engine and disconnect throttle
SEF695L position sensor harness connector.
2) Start engine.
~
@
EC-38
BASIC SERVICE PROCEDURE @KJ
Adjustment (Cont'd)
1
Check base idle speed. Refer to EC-36.
OK NG
I
Race engine (2,000 - 3,000 rpm) 2 or 3 times under no-
load and run engine at idle speed.
.
III
Adjust idle speed by turning idle speed adjusting screw .
Base idle speed: Refer to EC-36.

•
1) Turn off engine and connect throttle position sensor harness connec-
tor.
2) Start engine.
1
Start engine.
Race engine (2,000 - 3,000 rpm) 2 or 3 times under no-
load and run engine at idle speed.
EC-39
BASIC SERVICE PROCEDURE @KJ
Idle Speedllgnition Timing/Idle Mixture Ratio
o Adjustment (Cont'd)
1:< MONITOR 1< NO FAIL 0 @
MIR F/C MNT RICH
Check idle speed. Refer 10 EC-36.
OK NG
Check IACV-AAC valve and replace if necessary.
__ R_E_C_O_R_D __ I
SEF515Q
Check IACV-AAC valve harness and repair if neces-
sary.
Check ECM function- by substituting another known

good ECM.
- ECM may be the

cause of a problem,
but this is rarely the
case.
SEF987K
o
(ij\E 1. See "MIA F/C MNT" in "Data monitor"
NG
_ ~~::
~~r mJ
~ mode.
2. Run engine at about 2,000 rpm for about 2
(g~
minutes under no-load.
l~~~~V
-~
3. Maintaining engine at 2,000 rpm under
no-load (engine is warmed up sufficiently.),
check that the monitor fluctuates between
"LEAN" and "RICH" more than 5 times dur-
(Connect CHK and IGN terminals ing 10 seconds.
with a suitable harness.) 1 lime: RICH -> LEAN -> RICH
2 limes: RICH -> LEAN -> RICH ->LEAN ->
RICH
SEF909P OR
Set "Oxygen sensor monitor" in diagnostic

test mode II.
(See page EC-47.)
2. Run engine at about 2,000 rpm for about 2
3. Maintaining engine at 2,000 rpm under
no-load, check that the malfunction indicator
lamp on the instrument panel goes ON and
OFF more than 5 times during 10 seconds.
MALFUNCTION INDICATOR LAMP OK
SEF217M
END
EC-40
BASIC SERVICE PROCEDURE ~
II For Australia Adjustment (Cont'd)
CD
II ECM ~ CONNECTORII ~
DISCONNECT
46
18 II
Check oxygen sensor*1 harness: *1: Heated oxygen sen-
1) Turn off engine and disconnect battery sor (For Europe and
~ Israel, a nd Australia
ground cable.
2) Disconnect ECM harness connector from AIT mod els)
ECM. Oxygen sensor

SEF056PA 3) Disconnect oxygen sensor*1 harness connec- (Except for Europe
•
tor. Then connect harness side terminal for and Isra el, and Aus-
II Except for Australia oxygen sensor*1 to ground with a jumper tralia AI T models)
wire.
II ECM 19' CONNECTOR II 4) .Check for continuity between terminal No. 46

or No. 19 of ECM harness connector and
19
body ground.
Continuity exists ................................................ OK

Continuity does not exist .................................. NG
OK lNG
SEF194R
I Repair or replace harness .
• ACTIVE TEST. 0
Connect ECM harness connector to control unit.
COOLANTTEMP 20°C
===MONITOR===
CMPS.RPM (REF) Orpm ~ III
INJ PULSE O.7msec
IGN TIMING 5BTDC
00 1) Connect battery ground cable.
2) Select "ENG COOLANT TEMP" in
"ACTIVE TEST" mode.
3) Set "COOLANT TEMP" to 20°C (68°F)
AEC681
by touching "au" and "ad" and
"UP", "DWN".
OR
!;j:~:~~'~";"'"
Engine coolant
DISCONNECT temperature
@ 1) Disconnect engine coolant tempera-
ture sensor harness connector.
10 2) Connect a resistor (2.5 kQ) between
terminals of engine coolant tempera-
~ ture sensor harness connector.
00 2.5 k n resistor
[+]
SEC242BA Start engine and warm it up until water temper-
ature indicator points to middle of gauge.
~
@
SEF455Q
EC-41
BASIC SERVICE PROCEDURE ~
Idle Speed/Ignition Timinglldle Mixture Ratio
Adjustment (Cont'd)
~\\~\\\\""1"'1///1. @
#'
{2{
~
7 5 ~
6~
~ Ii 1
Race engine two or three times under no-load, then run engine at idle
speed.
?1 7-=1
:;::. .;f
~o 84 1
xl000 rlmin Check "CO"%.
SEF248F
Idle CO: Less than 10%
[!J
After checking COOJo,
00 1) Touch "BACK".
@ 1) Disconnect the resistor from terminals of engine coolant tem-

perature sensor h.arness connector.
2) Connect engine coolant temperature sensor harness connector
to engine coolant temperature sensor.
SEF913J
NG OK
1;:( MONITOR 1;:( NO FAIL 0

Replace oxygen sensor'1.
MIR FIC MNT RICH
m
00 1. See "M/R FIC MNT" in "Data monitor" mode.
2. Maintaining engine at 2,000 rpm under no-load
(engine is warmed up sufficiently.), check that
__ R_E_C_O_R_D __ I the monitor fluctuates between "LEAN" and
"RICH" more than 5 times during 10 seconds.
SEF515Q
1 time : RICH -> LEAN -> RICH
2 times: RICH -> LEAN -+ RICH -> LEAN ->
RICH
OR
Ii)
1. Set "Oxygen sensor monitor" in diagnostic test
@ .mode II.
(See page EC-47.)
2. Maintaining engine at 2,000 rpm under no-load,
check that the malfunction indicator lamp on the
instrument panel goes ON and OFF more than 5
SEF987K times during 10 seconds.
I NG OK
~~~~N
(gJ~
l~~i~V-=~
-~
(Connect CHK and IGN terminals
@
'1: Heated oxygen
and Israel, and
els)
Oxygen sensor
sensor (For Europe
Australia AIT mod-
(Except for Europe

@
with a suitable harness.) and Israel, and Australia AIT mod-

els)
SEF909P
EC-42
BASIC SERVICE PROCEDURE []KJ
Adjustment (Cont'd)
@
Connect oxygen sensor harness connector to oxygen

sensor.
Check fuel pressure regulator.
•
(See page EC-33.)
.
Check mass air flow sensor and its circuit.
(See page EC-107.)
Check injector and its circuit.

(See page EC-141.)
Clean or replace if necessary.
Check engine coolant temperature sensor and its cir-

cuit.
(See page EC-112.)
Check ECM function* by substituting another known

good ECM.
*. ECM may be the caus e of a problem,

but this is rarely the c ase.
EC-43
ON-BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator lamp (Mil)
'e/'
1. The malfunction indicator lamp will light up when the igni-
\ I / tion switch is turned ON without the engine running. This is
a bulb check.
- CHECK- • If the malfunction indicator lamp does not light up, refer to
EL section ("WARNING LAMPS AND CHIME") or see
/ .......
EC-223.
/ I \ 2. When the engine is started, the malfunction indicator lamp
should go off.
lamp
SEF051PA Diagnostic Diagnostic
Condition
Test Mode I Test Mode II
Engine
stopped SELF-DIAGNOSTIC
Ignition BULB CHECK
RESULTS
switch in
~
"ON" posi-
tion Engine
*1
running MALFUNCTION
OXYGEN SENSOR
~
ID WARNING
MONITOR
*1: Heated oxygen sensor (For Europe and Israel, and Australia AIT models)
Oxygen sensor (Except for Europe and Israel, and Australia AIT models)
EC-44
Malfunction Indicator lamp (Mil) (Cont'd)
Turn ignition switch "ON".
(Do not start engine.) HOW TO SWITCH DIAGNOSTIC TEST MODES
Diagnostic Test Mode I - BULB CHECK Diagnostic Test Mode I

- MALFUNCTION WARNING
o,~yr;;~N
(Turn diagnostic test mode
selector on ECM fully clockwise.)
~-~
with a suitable harness.)
•
Wait at least 2 seconds.
O,~/~N
~-~
(Turn diagnostic test mode (Disconnect CHK and IGN terminals
selector fully counterclockwise.) with a suitable harness.)
DIAGNOSTIC TEST MODE II ~ Q~ Diagnostic Test Mode II

- SELF-DIAGNOSTIC RESULTS ON ~
- OXYGEN SENSOR MONITOR*1
S art engine.
0'
[gJ~ ~~~~~
~~r
~!~~:V
• Switching the modes is not possi-
ble when the engine is running.
• When ignition switch is turned off
during diagnosis, power to ECM
will drop after approx. 5 second.
-~ The diagnosis will automatically
(Connect CHK and IGN terminals return to Diagnostic Test Mode I.
with a suitable harness.) • Turn back diagnostic test mode
selector to the fully counterclock-
wise position whenever vehicle is
Wait at least 2 seconds. in use.
1 *1: Heated oxygen sensor (For Europe and Israel,

and Australia AfT models)
Ol
g2g~E;V
W:jr
Oxygen sensor (Except for Europe and tsrael,
and Australia AfT models)
or
~~ ~~~;::
-~
(Disconnect CHK and IGN terminals
EC-45
ON-BOARD DIAGNOSTIC SYSTEM DESCRIPTION @KJ
DIAGNOSTIC TEST MODE I-BULB CHECK
In this mode, the MALFUNCTIONINDICATOR LAMP on the instrument panel should stay ON. If it remains
OFF, check the bulb. Refer to EL section ("WARNING LAMPS AND CHIME") or see EC-223.
DIAGNOSTIC TEST MODE I-MALFUNCTION WARNING
MALFUNCTION INDICATOR LAMP Condition
Engine coolant temperature sensor circuit malfunction or overheating is detected, or
ON
the ECM's CPU is malfunctioning.
OFF No malfunction.
• These Diagnostic Trouble Code Numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOS-
TIC RESULTS).
DIAGNOSTIC TEST MODE II-SELF-DIAGNOSTIC RESULTS
In this mode, a diagnostic trouble code is indicated by the number of blinks of the MALFUNCTION INDI-
CATOR LAMP as shown below.
Example: Diagnostic trouble code No. 12 and No. 43
0.6 03 0.6 0.3
ON
111-'1 II
OFF
j ~
~~
Q9 O~
-I. --.1
21
-4--1--
OB Q9 2.1 Unit: second
'--------v----' '--------v------~
Diagnostic trouble code No. 12 Diagnostic trouble code No. 43
AEC490
Long (0.6 second) blinking indicates the number of ten digits, and short (0.3 second) blinking indicates
the number of single digits. For example, the malfunction indicator lamp blinks 4 times for about 2.5
seconds (0.6 sec x 4 times) and then it blinks three times for about 1 second (0.3 sec x 3 times). This
indicates the DTC "43" and refers to the malfunction of the throttle position sensor.
In this way, all the detected malfunctions are classified by their diagnostic trouble code numbers. The
DTC "55" refers to no malfunction. (See DIAGNOSTIC TROUBLE CODE CHART, refer to EC-62.)
HOW TO ERASE DIAGNOSTIC TEST MODE II (Self-diagnostic results)
The diagnostic trouble code can be erased from the backup memory in the ECM when the diagnostic
test mode is changed from Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer to "HOW TO
SWITCH DIAGNOSTIC TEST MODES" on previous page.)
• If the battery terminal is disconnected, the diagnostic trouble code will be lost from the backup
memory within 24 hours.
• Be careful not to erase the stored memory before startin~ trouble diagnoses.
• If the MIL blinks or "NATS MALFUNCTION" is displayed on
• SELF-DIAG RESULTS. 0 "SELF-OIAG RESULTS" screen, perform self-diagnostic
FAILURE DETECTED TIME results mode with CONSULT using NATS program card
NATS MALFUNCTION 0 (NATS-E940). Refer to EL section.
• Confirm no self-diagnostic results of NATS is displayed
before touching "ERASE" in "SELF-DIAG RESULTS" mode
with CONSULT.
• When replacing ECM, initialisation of NATS V2.0 system and
registration of all NATS V2.0 ignition key 10s must be car-
I ERASE II PRINT I
SEF288Q
ried out with CONSULT using NATS program card (NATS-
E940).
Therefore, be sure to receive all keys from vehicle owner.
Regarding the procedures of NATS initialisation and NATS
manual, NA TS V2.0.
EC-46
ON-BOARD DIAGNOSTIC SYSTEM DESCRIPTION [QKJ
DIAGNOSTIC TEST MODE II-OXYGEN SENSOR*1 MONITOR
In this mode, the MALFUNCTION INDICATOR LAMP displays the condition of the fuel mixture (lean or
rich) which is monitored by the oxygen sensor*1.
MALFUNCTION INDICATOR LAMP Fuel mixture condition in the exhaust gas Air fuel ratio feedback control condition
ON Lean
Closed loop system
OFF Rich
*2 Remains ON or OFF Any condition Open loop system
*2: Maintains conditions just before switching to open loop.
To check the oxygen sensor*1 function, start engine in Diagnostic Test Mode II. Then warm it up until
engine coolant temperature indicator points to middle of gauge. •
Next run engine at about 2,000 rpm for about 2 minutes under no-load conditions. Make sure that the
MALFUNCTION INDICATOR LAMP comes ON more than 5 times within 10 seconds with engine running
at 2,000 rpm under no-load. .
*1: Heated oxygen sensor (For Europe and Israel, and Australia AfT models)
Oxygen sensor (Except for Europe and Israel, and Australia AfT models)
EC-47
CONSULT
CONSULT INSPECTION PROCEDURE
1. Turn off ignition switch.
2. Connect "CONSULT" to data link connector for CONSULT.
(Data link connector for CONSULT is located behind the fuse
box cover.)
for CONSULT
E3==/
3. Turn on ignition switch.
NISSAN 4. Touch "START".
+: Program card
CONSULT AE930: For Australia
EE940 + EE940: Except for Australia
!DiI
II START
I
SUB MODE I
SEF253Q
5. Touch "ENGINE".
~ SELECT~S_Y_S_T_EM I
ENGINE----~
SEFS95K
6. Perform each diagnostic test mode according to each ser-

~ SELECT DIAG MODE lill vice procedure.
WORK SUPPORT I For further information, see the CONSULT Operation Manual.
SELF-DIAG RESULTS I
DATA MONITOR
I ACTIVE TEST
I ECM PART NUMBER
I FUNCTION TEST
SEF136P
EC-48
CONSULT (Cont'd)
ECCS COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
DIAGNOSTIC TEST MODE
SELF-DI- FUNC-
Item WORK DATA ACTIVE
AGNOSTIC TION
SUPPORT MONITOR TEST
RESULTS TEST
Camshaft position sensor X X

Mass air flow sensor X X
Engine coolant temperature sensor X X X
Oxygen sensor'1 X X X
•
Vehicle speed sensor X X
Throttle position sensor X X X X
Intake air temperature sensor.'2 X X
INPUT Knock sensor'3 X
Ignition switch (start signal) X X
Closed throttle position X X

I/)
l-
ll: Air conditioner switch X
<
~
I-
Park/Neutral position switch X X
Z
UJ Power steering oil pressure switch X X
z
0
~ Electrical load signal X
:E
0 Battery voltage X
u
I/)
u Injectors X X X
u
UJ X (Ignition
Power transistor (Ignition timing) X X X X
signal)
IACV-AAC valve X X X X
Valve timing control solenoid valve X X X
Air conditioner relay X

OUTPUT
Fuel pump relay X X X X
Cooling fan X X X
EVAP canister purge control solenoid

X X X
valve'4
EGR valve & EVAP canister purge control
X X X
solenoid valve'5
X: Applicable
'1: Heated oxygen sensor (For Europe and Israel, and Australia AIT models)
Oxygen sensor (Except for Europe and Israel, and Australia AIT models)
'2: For Australia
'3: Except for Australia
'4: GA16DE MIT models except for Europe and Israel, and Australia
'5: For Europe and Israel and Australia, and GA15DE MIT models
EC-49
CONSULT (Cont'd)
FUNCTION
Diagnostic test mode Function
A technician can adjust some devices

Work support faster and more accurately by following
indications on CONSULT.
Self-diagnostic results can be read and

Self-diagnostic results
erased quickly.
Data monitor Input/Output data in the ECM can be read.
CONSUL T drives some actuators apart

Active test from the ECM's and also shifts some
parameters in a specified range.
ECM part numbers ECM part numbers can be read.
Conducted by CONSULT instead of a tech-

Function test nician to determine whether each system
is "OK" or "NG".
WORK SUPPORT MODE

WORK ITEM CONDITION USAGE
THRTL POS SEN ADJ CHECK THE THROTTLE POSITION SENSOR SIGNAL. When adjusting throttle position
ADJUST iT TO THE SPECIFIED VALUE BY ROTATING sensor initial position
THE SENSOR BODY UNDER THE FOLLOWiNG CONDI-
TIONS .
• IGN SW "ON"
• ENG NOT RUNNING
• ACC PEDAL NOT PRESSED
IGNITION TIMING ADJ • IGNITION TIMING FEEDBACK CONTROL WILL BE When adjusting initial ignition
HELD BY TOUCHING "START". AFTER DOING SO, timing
ADJUST IGNITION TIMING WITH A TIMING LIGHT BY
TURNING THE CAMSHAFT POSITION SENSOR.
IACV-AAC VALVE ADJ SET ENGINE SPEED AT THE SPECIFIED VALUE UNDER -
THE FOllOWING CONDITIONS .
• ENGINE WARMED UP
• NO-LOAD
FUEL PRESSURE RELEASE • FUEL PUMP Will STOP BY TOUCHING "START" When releasing fuel pressure
DURING IDLING. from fuel line
CRANK A FEW TIMES AFTER ENGINE STALLS.
EC-50
CONSULT (ConI' d)
SELF-DIAGNOSTIC MODE
Regarding items detected in "SELF-DIAG RESULTS" mode, refer to "Diagnostic Trouble Code (DTC)
Chart" (Refer to EC-62.)
DATA MONITOR MODE

Monitored item ECM
Main
[Unit] input Description Remarks
signals
signals
CMPS.RPM • Indicates the engine speed computed • Accuracy becomes poor if engine
(REF) [rpm] from the REF signal (180' signal) of speed drops below the idle rpm.
0 0 the camshaft position sensor. • If the signal is interrupted while the
engine is running, an abnormal value
•
may be indicated .
MAS AIR/FL SE [V] • The signal voltage of the mass air • When the engine is stopped, a certain
0 0 flow sensor is displayed . value is indicated.
COOLAN TEMP/S • The engine coolant temperature • When the engine coolant temperature
['C] or ['F] (determined by the signal voltage of sensor is open or short-circuited,
0 0 the engine coolant temperature sen-
sor) is displayed.
ECM enters fail-safe mode. The
engine coolant temperature deter-
mined by the ECM is displayed .
02 SENSOR [V] • The signal voltage of the oxygen sen-
0 0 sor*1 is displayed .
M/R F/C MNT • Display of oxygen sensor signal dur- • After turning ON the ignition switch,
[RICH/LEAN] ing air-fuel ratio feedback control: "RICH" is displayed until air-fuel mix-
RICH ... means the mixture became ture ratio feedback control begins.
"rich", and control is being affected • When the air-fuel ratio feedback is
0 0 toward a leaner mixture. clamped, the value just before the
LEAN ... means the mixture became clamping is displayed continuously.
"lean", and control is being affected
toward a rich mixture .
VHCL SPEED SE • The vehicle speed computed from the
[km/h] or [mph] 0 0 vehicle speed sensor signal is dis-
played .
BATTERY VOLT [V] • The power supply voltage of ECM is
0 0 displayed .
THRTL POS SEN [V] • The throttle position sensor signal
0 0 voltage is displayed.
INT/A TEMP SE ['C] • The intake air temperature deter-
or ['F]*2 mined by the signal voltage of the
0 intake air temperature sensor is indi-
cated.
START SIGNAL • Indicates [ON/OFF] condition from the • After starting the engine, [OFF] is dis-
[ON/OFF] 0 0 starter signal. played regardless of the starter sig-
nal.
CLSD THLIPOSI • Indicates the closed throttle position
[ON/OFF] [ON/OFF] determined by the throttle
0 0 position sensor signal.
ON: Closed throttle position
OFF:Other than closed throttle position
AIR COND SIG • Indicates [ON/OFF] condition of the
[ON/OFF] 0 0 air conditioner switch as determined
by the air conditioning signal.
PIN POSI SW • Indicates [ON/OFF] condition from the
[ON/OFF] 0 0 park/neutral position switch signal.
PW/ST SIGNAL • Indicates [ON/OFF] condition of the
[ON/OFF] power steering oil pressure switch
0 0 determined by the power steering oil
pressure signal.
NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display auto-
matically.
*2: For Australia
EC-51
CONSULT (Coni' d)
Monitored item ECM
Main
signals
signals
LOAD SIGNAL • Indicates [ON/OFF] condition from the
[ON/OFF] rear defogger signal and/or lighting
switch.
0 0 ON: Rear defogger is operating

and/or lighting switch is on.
OFF: Rear defogger is not operating
and lighting switch is not on.
INJ PULSE [msec] • Indicates the actual fuel injection • When the engine is stopped, a certain
0 pulse width compensated by ECM
according to the input signals.
computed value is indicated.
IGN TIMING [BTDC] • Indicates the ignition timing computed

0 by ECM according to the input sig-
nals.
IACV-AACIV [%] • Indicates the idle air control valve
(AAC valve) control value computed
nals.
A/F ALPHA [%] • Indicates the mean value of the air- • When the engine is stopped, a certain
fuel ratio feedback correction factor value is indicated.
0 per cycle. • This data also includes the data for
the air-fuel ratio learning control.
AIR COND RLY • Indicates the air conditioner relay
[ON/OFF]
0 control condition (determined by ECM
according to the input signal).
COOLING FAN*2 • Indicates the control condition of the
[ON/OFF] or [LOW/ cooling fans (determined by ECM
HI/OFF] according to the input signal).
0 ON ... Operating
LOW ... Operates at low speed
HI ... Operates at high speed
OFF ... Stopped
FUEL PUMP RLY • Indicates the fuel pump relay control
[ON/OFF]
0 condition determined by ECM accord-
ing to the input signals.
VALVE TIM SOL*1 • The control condition of the valve tim-
[ON/OFF] ing solenoid valve (determined by
ECM according to the input signal) is
indicated.
ON ... VTC operating
OFF ... VTC not operating
EGRC SOLIV (EVAP • Indicates the control condition of the
canister purge con- EVAP canister purge control solenoid
trol solenoid valve valve or EGR valve & EVAP canister
or EGR & EVAP can- purge control solenoid valve (deter-
ister purge control mined by ECM according to the input
solenoid valve) 0 signal).
[ON/OFF] ON '" EVAP canister purge operation
cut-off
OFF ... EVAP canister purge operation
not cut-off
VOLTAGE • Voltage measured by the voltage
[V] probe.
PULSE • Pulse width, frequency or duty cycle • Only "#" is displayed if item is
[msec] or [Hz] or measured by the pulse probe. unable to be measured .
[%] • Figures with "#"s are temporary
ones. They are the same figures as
an actual piece of data which was just
previously measured.

*2: GA16DE engine A/T models for Europe without heavy duty kit have a 2- step control [ON/OFF] system. "LOW" and "HI"
are shown on CONSULT screen to represent "ON" condition.
EC-52
CONSULT (Cont'd)
ACTIVE TEST MODE
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
• Engine: Return to the original

• Harness and connector
trouble condition If trouble symptom disappears,
FUEL INJECTION • Fuel injectors
• Change the amount of fuel see CHECK ITEM.
• Oxygen sensor*1
injection using CONSULT.
• Engine: After warming up, idle
the engine.
IACV-AACIV Engine speed changes according • Harness and connector
• Change the IACV-AAC valve
OPENING to the opening percent. • IACV-AAC valve
opening percent using CON-
SULT.
ENG COOLANT
TEMP
trouble condition
• Change the engine coolant .
temperature indication using
CONSULT.
If trouble symptom disappears,
see CHECK ITEM.
• Engine coolant temperature
sensor
• Fuel injectors
•
trouble condition
IGNITION TIMING • Timing light: Set • Adjust initial ignition timing
see CHECK ITEM.
• Retard the ignition timing using
CONSULT.
• Engine: After warming up, idle • Harness and connector

the engine. • Compression
POWER • A/C switch "OFF" • Injectors
Engine runs rough or dies .
BALANCE • Shift lever "N" • Power transistor
• Cut off each injector signal one • Spark plugs
at a time using CONSULT. • Ignition coils
• Ignition switch: ON
• Turn the cooling fan "ON" and • Harness and connector
COOLING FAN*3 Cooling fan moves and stops.
"OFF", or "LOW" and "HI" • Cooling fan motor
and "OFF" using CONSULT.
• Ignition switch: ON (Engine
stopped)
FUEL PUMP Fuel pump relay makes the oper- • Harness and connector
• Turn the fuel pump relay "ON"
RELAY ating sound. • Fuel pump relay
and "OFF" using CONSULT
and listen to operating sound.
EGRC SOLENOID
VALVE
(EVAP canister
purge control
• Turn solenoid valve "ON" and Solenoid valve makes an operat- • Harness and connector
solenoid valve or
"OFF" with the CONSULT and ing sound. • Solenoid valve
EGR valve &
listen to operating sound.
EVAP canister
purge control
solenoid valve)
VALVE TIMING • Turn solenoid valve "ON" and Solenoid valve makes an operat- • Harness and connector
SOL*2 "OFF" using CONSULT and ing sound. • Solenoid valve
listen to operating sound.
SELF-LEARNING • In this test, the coefficient of self-learning control mixture ratio returns to the original coefficient by
CONT touching "CLEAR" on the screen.
*3: GA16DE engine A/T models for Europe without heavy duty kit have a 2- step control [ON/OFF] system. "LOW" and "HI"
are shown on CONSULT screen to represent "ON" condition.
EC-53
CONSULT (Cont'd)
FUNCTION TEST MODE
FUNCTION TEST
CONDITION JUDGEMENT CHECK ITEM (REMEDY)
ITEM
SELF-DIAG (Engine stopped)
RESULTS • Displays the results of on-
- Objective system
board diagnostic system .
(Engine stopped)
Throttle valve: opened OFF • Throllle position sensor
• Closed throllle position is
• Throllie position sensor
CLOSED THROTTLE tested when throttle is
adjustment
POSI opened and closed fully.
• Throttle linkage
(Closed throllie position is
Throttle valve: closed ON • Verify operation in DATA
selected by throttle posi-
MONITOR mode.
tion sensor.)

• Throttle position sensor
(Engine stopped)
Range (Throllle valve fully • Throllle position sensor
THROTTLE POSI • Throllle position sensor More than
opened - Throllle valve adjustment
SEN CKT circuit is tested when 3.DV
fully closed) • Throllie linkage
throllie is opened and
• Verify operation in DATA
closed fully.
MONITOR mode .
(Engine stopoed) Out of NIP positions OFF
• Neutral position switch or
PARK/NEUT POSI • Inhibitor/NelJlral position
inhibitor switch
SW CKT switch circuit is tested
• Linkage or inhibitor switch
when shift lever is manip- In NIP positions ON
adjustment
ulated .
(Engine stopped)
• Fuel pump
FUEL PUMP • Fuel pump circuit is tested There is pressure pulsation on the fuel
• Fuel pump relay
CIRCUIT by checking the pulsation feed hose.
• Fuel filter clogging
in fuel pressure when fuel
• Fuel level
tube is pinched .
EGRC SOllV (Engine stopped)
CIRCUIT (EVAP can- • EVAP canister purge con-
• EVAP canister purge con-
ister purge control trol solenoid valve or EGR
The solenoid valve makes an operating trol solenoid valve or EGR
solenoid valve or valve & EVAP canister
sound every 3 seconds. valve & EVAP canister
EGR valve & EVAP purge control solenoid
purge control solenoid
canister purge con- valve circuit is tested by
valve
trol solenoid valve) checking solenoid valve
operating noise .
(Engine stopped) • Harness and connector
VALVE TIMING SIV • Valve timing SIV circuit is The solenoid valve makes an operating • Valve timing solenoid
CKT*1 tested by checking sole- sound periodically. valve
noid valve operating
sound
'1: GA16DE except for Europe and Israel
EC-54
CONSULT (Conl'd)
FUNCTION TEST
ITEM
COOLING FAN The cooling fan rotates and stops every
• Cooling fan circuit is • Cooling fan motor
CIRCUIT 3 seconds.
tested when cooling fan is • Cooling fan relay
rotated .
• Ignition switch: ON -.
START
• Start signal circuit is
tested when engine is
•
started by operating the
starter. Before cranking,
START SIGNAL battery voltage and engine • Harness and connector
Start signal: OFF -. ON
CIRCUIT coolant temperature are • Ignition switch
displayed. During
cranking, average battery
voltage, mass air flow
sensor output voltage and
cranking speed are dis-
played .
(Engine running) Locked position ON
• Power steering circuit is
PW/ST SIGNAL • Power steering oil pres-
tested when steering
CIRCUIT sure switch
wheel is rotated fully and
OFF • Power steering pump
then set to a straight line Neutral position
running position .
• Vehicle speed sensor cir-

VEHICLE SPEED cuit is tested when vehicle Vehicle speed sensor input signal is
• Vehicle speed sensor
SEN CKT is running at a speed of 10 greater than 4 km/h (2 MPH)
• Electric speedometer
km/h (6 MPH) or higher .
• After warming up, idle the

engine.
• Adjust ignition timing (by
• Ignition timing adjustment
moving camshaft position
is checked by reading The timing light indicates the same
IGN TIMING ADJ sensor or distributor)
ignition timing with a tim- value on the screen.
• Camshaft position sensor
ing light and checking
drive mechanism
whether it agrees with
specifications.
• INJECTION SYS (Injector,
fuel pressure regulator,
harness or connector)
• Air-fuel ratio feedback cir- • IGNITION SYS (Spark
cuit (injection system, igni- plug, power transistor,
tion system, vacuum ignition coil, harness or
MIXTURE RATIO system, etc.) is tested by Oxygen sensor'1 COUNT: More than 5 connector)
TEST examining the oxygen times during 10 seconds • VACUUM SYS (Intake air
sensor'1 output at 2,000 leaks)
rpm under non-loaded • Oxygen sensor'1 circuit
state. • Oxygen sensor'1 opera-
tion
• Fuel pressure high or low
• Mass air flow sensor
'1: Heated oxygen sensor (For Europe and Israel, and Australia AIT models)
EC-55
CONSULT (Cont'd)
FUNCTION TEST
ITEM

engine .
• Injector operation of each • Injector circuit (Injector,
cylinder is stopped one harness or connector)
after another, and result- • Ignition circuit (Spark
Difference in engine speed is greater
ant change in engine rota- plug, power transistor,
POWER BALANCE than 25 rpm before and after cutting off
lion is examined to evalu- ignition coil, harness or
the injector of each cylinder.
ate combustion of each connector)
cylinder. (This is only dis- • Compression
played for models where a • Valve timing
sequential multi port fuel
injection system is used.)
engine.
• IACV-AAC valve
• IACV-AAC valve system is
Difference in engine speed is greater • Air passage restriction
IACV-AACIV tested by detecting change
than 150 rpm between when valve open- between air inlet and
SYSTEM in engine speed when
ing is at 80% and at 20%. IACV-AAC valve
IACV-AAC valve opening
• IAS (Idle adjusting screw)
is changed to 0%, 20%
adjustment
and 80%.
EC-56
ON-BOARD DIAGNOSTIC SYSTEM DESCRIPTION []K]
CONSULT (Cont'd)
REAL TIME DIAGNOSIS IN DATA MONITOR MODE
CONSULT has two kinds of triggers and they can be selected by touching "SETTING" in "DATA
MONITOR" mode.
1. "AUTO TRIG" (Automatic trigger):
• The malfunction will be identified on the CONSULT screen in real time.
In other words, DTC and malfunction item will be displayed at the moment the malfunction is
detected by ECM.
DATA MONITOR can be performed continuously until a malfunction is detected. However, DATA
MONITOR cannot continue any longer after the malfunction detection.
2. "MANU TRIG" (Manual trigger):
• DTC and malfunction item will not be displayed automatically on CONSULT screen even though
a malfunction is detected by ECM. •
DATA MONITOR can be performed continuously even though a malfunction is detected.
Use these triggers as follows:
1. "AUTO TRIG"
• While trying to detect the DTC by performing the "DTC CONFIRMATION PROCEDURE", be sure
to select to "DATA MONITOR (AUTO TRIG)" mode. You can confirm the malfunction at the
moment it is detected.
• While narrowing down the possible causes, CONSULT should be set in "DATA MONITOR (AUTO
TRIG)" mode, especially in case the incident is intermittent.
Inspect the circuit by gently shaking (or twisting) suspicious connectors, components and harness
in the "DTC CONFIRMATION PROCEDURE". The moment a malfunction is found the DTC will be
displayed. (Refer to GI section, "Incident Simulation Tests" in "HOW TO PERFORM EFFICIENT
DIAGNOSIS FOR AN ELECTRICAL INCIDENT".)
2. "MANU TRIG"
• If the malfunction is displayed as soon as "DATA MONITOR" is selected, reset CONSULT to
"MANU TRIG". By selecting "MANU TRIG" you can monitor and store the data. The data can be
utilized for further diagnosis, such as a comparison with the value for the normal operating con-
dition.
I~ SELECT MONITOR ITEM I~ SET RECORDING COND
ECM INPUT SIGNALS AUTO TRIG I MANU TRIG MANU TRIG
MAIN SIGNALS HI SPEED I LONG TIME HI SPEED
SELECTION FROM MENU
SETTING II START
___
"SETTIN-G"
1__
"AUTO TRIG" "MANU
1 TRIG"
A malfunction can be A malfunction can not be
displayed on "DATA displayed on "DATA
MONITOR" screen MONITOR" screen
automatically if detected. automatically even if
detected.
SEF674Q
EC-57
TROUBLE DIAGNOSIS - General Description
Introduction
Sensors The engine has an ECM to control major systems such as fuel
control, ignition control, idle air control system, etc. The ECM
~ ECM Actuators accepts input signals from sensors and instantly drives actua-
~~.~
tors. It is essential that both input and output signals are proper
and stable. At the same time, it is important that there are no
problems such as vacuum leaks, fouled spark plugs, or other
problems with the engine.
It is much more difficult to diagnose a problem that occurs
intermittently rather than continuously. Most intermittent prob-
MEF036D
lems are caused by poor electric connections or improper wir-
ing. In this case, careful checking of suspected circuits may
help prevent the replacement of good parts.
A visual check only may not find the cause of the problems. A
road test with CONSULTor a circuit tester connected should be
performed. Follow the "Work Flow" on the next page.
Before undertaking actual checks, take just a few minutes to
talk with a customer who approaches with a driveability com-
plaint. The customer can supply good information about such
problems, especially intermittent ones. Find out what symptoms
are present and under what conditions they occur. A "Diagnos-
tic Worksheet" like the example on EC-61 should be used.
Start your diagnosis by looking for "conventional" problems
first. This will help troubleshoot driveability problems on an
electronically controlled engine vehicle.
SEF234G
EC-58
Work Flow
CHECK IN
Listen to customer complaints. (Get symptoms.) ................................................ STEP I
Check, print out or write down, and erase Diagnostic Trouble Code (DTC). .. STEP II
Symptoms No symptoms, but
•
collected. Malfunction Code
exists at STEP II.
Verify the symptom by driving in the conditiOn the

*1
customer described. ......................................................................................... STEP III
Normal Code Malfunction Code

(at STEP II) (at STEP II)
Verify the DTC by performing the "DTC CONFIRMATION PROCEDURE". .. *1 STEP IV
Choose the appropriate action. . STEP V

*2
Malfunction Code (at STEP II or IV) Normal Code (at both STEP II and IV)
BASIC INSPECTION
SYMPTOM BASIS (at STEP I or III)
Perform inspections
according to Symptom
Matrix Chart.
TROUBLE DIAGNOSIS FOR DTC XX. STEP VI
REPAIR/REPLACE
NG FINAL CHECK
Confirm that the incident is completely fixed by performing BASIC INSPECTION
.......................................... STEP VII
and DTC CONFIRMATION PROCEDURE (or OVERALL FUNCTION CHECK).
CHECK OUT
*1: If the incident cannot be duplicated, refer to GI section ("Incident Simulation Tests", "HOW TO PERFORM EFFICIENT DIAG-
NOSIS FOR AN ELECTRICAL INCIDENT").
*2: If the on-board diagnostic system cannot be performed, check main power supply and ground circuit. Refer to "TROUBLE
DIAGNOSIS FOR POWER SUPPLY", EC-88.
EC-59
TROUBLE DIAGNOSIS - General oescrip_ti_on I_G_A_'
Description for Work Flow
STEP DESCRIPTION
Get detailed information about the conditions and the environment when the incident/symptom occurred
STEP I
using the "DIAGNOSTIC WORKSHEET" as shown on the next page.
Before confirming the concern, check and write down (print out using CONSULT) the Diagnostic Trouble
Code (DTC), then erase the code. The DTC can be used when duplicating the incident at STEP III & IV.
STEP II
Study the relationship between the cause, specified by DTC, and the symptom described by the customer.
(The "Symptom Matrix Chart" will be useful. Refer to EC-72.)
Try to confirm the symptom and under what conditions the incident occurs.
The "DIAGNOSTIC WORK SHEET" is useful to verify the incident. Connect CONSULT to the vehicle in DATA
STEP III MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. Refer to GI section.
If the malfunction code is detected, skip STEP IV and perform STEP V.
Try to detect the Diagnostic Trouble Code (DTC) by driving in (or performing) the "DTC CONFIRMATION
PROCEDURE". Check and read the DTC by using CONSULT.
During the DTC verification, be sure to connect CONSULT to the vehicle in DATA MONITOR (AUTO TRIG)
mode and check real time diagnosis results.
STEP IV If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. Refer to GI section.
In case the "DTC CONFIRMATION PROCEDURE" is not available, perform the "OVERALL FUNCTION
CHECK" instead. The DTC cannot be displayed by this check, however, this simplified "check" is an effec-
tive alternative.
The "NG" result of the "OVERALL FUNCTION CHECK" is the same as the DTC detection.
Take the appropriate action based on the results of STEP I through IV.
If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC XX.
STEP V
If the normal code is indicated, proceed to the BASIC INSPECTION. Refer to EC-65. Then perform inspec-
tions according to the Symptom Matrix Chart. Refer to EC-72.
Identify where to begin diagnosis based on the relationship study between symptom and possible causes.
Inspect the system for mechanical binding, loose connectors or wiring damage using (tracing) "Harness
Layouts".
Gently shake the related connectors, components or wiring harness with CONSULT set in "DATA MONITOR
(AUTO TRIG)" mode.
Check the voltage of the related ECM terminals or monitor the output data from the related sensors with
STEP VI
CONSULT. Refer to EC-74.
The "DIAGNOSTIC PROCEDURE" in EC section contains a description based on open circuit inspection. A
short circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE. For details,
refer to GI section ("HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT", "Circuit
Inspection' ').
Repair or replace the malfunction parts.
Once you have repaired the circuit or replaced a component, you need to run the engine in the same condi-
tions and circumstances which resulted in the customer's initial complaint.
Perform the "DTC CONFIRMATION PROCEDURE" and confirm the normal code (Diagnostic trouble code No.
STEP VII 55) is detected. If the incident is still detected in the final check, perform STEP VI by using a different
method from the previous one.
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) DTC in ECM.
Refer to EC-46.
EC-60
Diagnostic Worksheet
KEY POINTS There are many operating conditions that lead to the malfunc-
tion of engine components. A good grasp of such conditions can
WHAT ..... Vehicle & engine model make troubleshooting faster and more accurate.
WHEN Date, Frequencies In general, each customer feels differently about a problem. It
WHERE Road conditions is important to fully understand the symptoms or conditions for
HOW Operating conditions, a customer complaint.
Weather conditions,
Utilize a diagnostic worksheet like the one shown below in
Symptoms
order to organize all the information for troubleshooting.
SEF907L
WORKSHEET
Customer name
Engine #
Incident Date
SAMPLE
MR/MS Model & Year
Trans.
Manu!. Date
. VIN
Mileage
In Service Date
•
o Impossible to start o No combustion o Partial combustion
o Startability
o Partial combustion affected by throttle position
LJ Partial combustion NOT affected by throttle position
o Possible but hard to start o Others [ 1
o No fast idle o Unstable o High idle o Low idle
o Idling
o Others [ 1
Symptoms
o Stumble o Surge o Knock o Lack of power
o Driveability i.J Intake backfire o Exhaust backfire
o Others [ 1
o At the lime of start o While idling
[.J Engine stall o While accelerating o While decelerating
o Just after stopping o While loading
o Just after delivery o Recently
Incident occurrence
o In the morning o At night o In the daytime
Frequency o All the time o Under certain conditions o Sometimes
Weather conditions o Not affected
Weather o Fine DRaining o Snowing o Others [ 1

Temperature o Hot o Warm o Cool o Cold o Humid OF
o Cold o During warm-up o After warm-up

Engine conditions Engine speed I I I I I I I I I
0 2,000 4,000 6,000 8,000 rpm
Road conditions o In town o In suburbs o Highway o Off road (up/down)

o Not affected
o At starting o While idling o At racing
o While accelerating o While cruising
Driving conditions
o While decelerating o While turning (RH/LH)
Vehicle speed I , I I I I I I I I I I I
0 10 20 30 40 50 60 MPH
Malfunction indicator lamp o Turned on o Not turned on
EC-61
Diagnostic Trouble Code (DTC) Chart

ENGINE RELATED ITEMS
Detected items
Diagnostic
trouble code Malfunction is detected when ...
(Screen terms for CONSULT,
No.
"SELF-DIAG RESULTS" mode)
11 Camshaft position sensor circuit • Either l' or 180' signal is not detected by the ECM for the first few
(CAMSHAFT POSI SEN) seconds during engine cranking .
• Either l' or 180' signal is not detected by the ECM often enough
while the engine speed is higher than the specified rpm .
• The relation between l' and 180' signals is not in the normal range
during the specified rpm .
12 Mass air flow sensor circuit • An excessively high or low voltage is entered to ECM.
(MASS AIR FLOW SEN) • Voltage sent to ECM is not practical when compared with the cam-
shaft position sensor signal and throttle position sensor signal.
13 Engine coolant temperature sen- • An excessively high or low voltage from the sensor is detected by
sor circuit the ECM.
(COOLANT TEMP SEN)
21 Ignition signal circuit • The ignition signal in the primary circuit is not detected by the ECM
(IGN SIGNAL-PRIMARY) during engine cranking or running .
28*1 OVER HEAT • The engine coolant temperature sensor output voltage is below
0.35V.
34"2 Knock sensor circuit • An excessively low or high voltage from the sensor is detected by
(KNOCK SENSOR) the ECM.
41*3 Intake air temperature sensor cir- • An excessively high or low voltage from the sensor is detected by
cuit the ECM.
(INT AIR TEMP SEN) • Voltage sent to ECM is not practical when compared with the engine
coolant temperature sensor signal.
55 No failure • No malfunction is detected by the ECM.
(NO SELF DIAGNOSTIC FAILURE
INDICATED...)
"1: Except for Australia

"3: For Australia
*4: This is Quick Reference of "DTC CONFIRMATION PROCEDURE".
Details are described in each TROUBLE DIAGNOSIS FOR DTC XX
Abbreviations are as follows:
IGN: ON : Turning the ignition switch ON is required for the ECM to detect a malfunction (if one exists).
RUNNING: Running engine is required for the ECM to detect a malfunction (if one exists).
*5: • The "OVERALL FUNCTION CHECK" is a simplified and effective way to inspect a component or circuit.
In some cases, the "OVERALL FUNCTION CHECK" is used rather than a "DIAGNOSTIC TROUBLE CODE CONFIRMA-
TION PROCEDURE".
When no DTC CONFIRMATION PROCEDURE is available, the "NG" result of the OVERALL FUNCTION CHECK can be
considered to mean the same as a DTC detection .
• During an "NG" OVERALL FUNCTION CHECK, the DTC might not be confirmed.
EC-62
TROUBLE DIAGNOSIS - General Description mJ
Diagnostic Trouble Code (DTC) Chart (Cont'd)
X: Applicable
-: Not applicable
"DTC *4 *5
Check Items CONFIRMATION "OVERALL FUNC- Fail Reference Page
(Possible Cause) PROCEDURE" TION CHECK" Safe
Quick Ref. Quick Ref. System
• Harness or connectors
(The sensor circuit is open or shorted.)
RUNNING - - EC-94
•
• Starter motor
• Starting system circuit (EL section)
• Dead (Weak) battery
• Harness or connectors .
(The sensor circuit is open or shorted.) RUNNING RUNNING X EC-101
(The sensor circuit is open or shorted.) IGN: ON - X EC-108
• Engine coolant temperature sensor
(The ignition primary circuit is open or shorted.)
• Power transistor unit RUNNING - - EC-113
• Camshaft position sensor circuit
• Harness or connector IGN: ON

- (after warming up)
- EC-108
(The sensor circuit is open or shorted.) RUNNING - - EC-119
• Knock sensor
IGN: ON - - EC-124
• Intake air temperature sensor
• No failure
- - - -
EC-63
Fail-Safe Chart
The ECM enters fail-safe mode, if any of the following DTCs is recorded due to the open or short circuit.
DTC No. Detected items Engine operating condition in fail-safe mode
12 Mass air flow sensor Engine speed will not rise more than 3,000 rpm*1 due to the fuel cut.
circuit
13 Engine coolant tem- Engine coolant temperature will be determined based on the time after turning ignition
perature sensor cir- switch "ON" or "START".
cuit Except for Europe and Israel
Condition Engine coolant temperature decided
Just as ignition switch is turned ON or Start 30'C (B6'F)
More than 5 minutes after ignition ON or Start BO'G (176'F)
30 - BO'C (B6 - 176'F)

Except as shown above
(Depends on the time)
For Europe and Israel
Just as ignition switch is turned ON or Start 35'C (95'F)
More than 4.5 minutes after ignition ON or

BO'G (176'F)
Start
35 - BO'C (95 - 176'F)

When the fail-safe system for engine coolant temperature sensor is activated, the cooling
fan operates while engine is running.
43 Throttle position Throttle position will be determined based on the injected fuel amount and the engine
sensor circuit speed.
Therefore, acceleration will be poor.
Condition Driving condition
When engine is idling Normal
When accelerating Poor acceleration
- ECM Fail-safe system activating condition when ECM is malfunctioning

The computing function of the ECM was judged to be malfunctioning.
When the fail-safe system activates (i.e., if the ECM detects a malfunction condition in
the CPU of ECM), the MALFUNCTION INDICATOR LAMP on the instrument panel lights to
warn the driver.
Engine control, with fail-safe system, operates when ECM is malfunctioning
When the fail-safe system is operating, fuel injection, ignition timing, fuel pump
operation, IACV-AAC valve operation and cooling fan operation are controlled under cer-
tain limitations.
Operation
Engine speed Engine speed will not rise more than 3,000 rpm
Fuel injection Simultaneous multipart fuel injection system
Ignition timing Ignition timing is fixed at the preset valve
Fuel pump' relay is "ON" when engine is running and "OFF" when engine
Fuel pump
stalls
IACV-AAG valve Full open
Cooling fan relay "ON" when engine is running, and "OFF" when engine
Cooling fans
stalls
EC-64
Basic Inspection
Precaution:
Perform Basic Inspection without electrical or mechanical loads
applied;
• Headlamp switch is OFF,
\\ •
•
Air conditioner switch is OFF,
Rear defogger switch is OFF,
• Steering wheel is in the straight-ahead position, etc.
~
m
~
SEF1421 BEFORE STARTING
1. Check service records for any recent
repairs that may indicate a related •
~use box
problem, or the current need for
scheduled maintenance.
2. 9pen engine hood and check the fol.
lowing:
~-~ • Harness connectors for improper con-
nections
vll-JI-
Data link connector~'
• Vacuum hoses for splits, kinks, or
improper connections
• Wiring for improper connections,
pinches, or cuts
CONNECT CONSULT TO THE VEHICLE.

Connect "CONSULT" to the data link
connector for CONSULT and select
"ENGINE" from the menu. Refer to
EC-36
No
DOES ENGINE START? Go to (J.
NG
CHECK IGNITION TIMING. Adjust ignition timing by
1. Warm up engine sufficiently. turning distributor.
2. Stop engine and disconnect throttle
position sensor harness connector.
3. Start engine.
4. Check ignition timing at idle using
timing light.
Ignition liming:
Refer to EC-36.
OK
(Go to @ on next page.)
EC-65
Basic Inspection (Coni' d)
@
(;] 1
CHECK IDLE ADJ. SCREW INITIAL SET
NG
Adjust engine speed by
~
RPM. turning idle adjusting
Base idle speed: Refer to EC-36. screw.
II t K
CHECK THROTTLE POSITION SENSOR

NG
~ Adjust output voltage to
IDLE POSITION. 0.50 :l: 0.1V by rotating
throttle position sensor
00 1. Perform ''THRTl POS SEN
ADJ" in "WORK SUPPORT"
mode.
body.
2. Check that output voltage of

throttle position sensor is
approx. 0.35 to 0.65V (Throttle
valve fully closes.) and "ClSD
THlIP SW" stays "ON".
OR
00 Measure output voltage of throt-

tle position sensor using
voltmeter, and check that it is
approx. 0.35 to 0.65V. (Throttle
valve fully closed.)
OK
RESET IDLE POSITION

MEMORY.
1. Warm up engine suffi-
ciently.
2. Turn ignition switch
"OFF" and wait at
least 5 seconds.
3. Disconnect throttle
position sensor har-
ness connector.
4. Start engine and wait
at least 5 seconds in
"N" position .
• THRTl POSSEN ADJ. 0 5. Reconnect throttle
*** ADJ MONITOR *** ness connector while
running engine.
THRTLPOSSEN 0.52V
==========
MONITOR ========== @
CMPS.RPM (REF) Orpm (Go to next page)
CLSD THLIPOSI ON
SEF516Q
SEF12BR
EC-66
Basic Inspection (Cont'd)
CID
NG
CHECK IDLE SPEED Adjust idle speed. Refer
Check idle speed. Refer to EC-36. EC-35.
OK
After this inspection, unnecessary diag-

nostic trouble code No. might be dis-
played.
Erase the stored memory in ECM.
OK
INSPECTION END
EC-67
Fast Idle Cam (FIC) Inspection and Adjustment

* MONITOR * NO FAIL o - For Europe and Israel
ENG TEMP SEN 80°C 1. Start engine and warm it up.
(ij\ 2. See "ENG TEMP SEN" or "COOLAN TEMP/S" in
~ "DATA MONITOR" mode with CONSULT.
3. When engine coolant temperature is 80:l: 5°C
(176:l:9°F), make sure that mark @ is aligned with
mark ~ as shown in the figure.
RECORD
SEF214N
Cam follower
lever
SEF147N
2. Disconnect engine coolant temperature sensor har-

ness connector and check resistance as shown in
the figure.
3. When the resistance of engine coolant temperature
sensor is 0.26 to 0.39 kQ, make sure that mark @ is
aligned with mark @ as shown in the figure.
• If NG, adjust by turning adjusting screw .
Adjusting serew tightening torque:
0.98 - 1.96 N.m (10 - 20 kg-em, 8.7 - 17.4 in-Ib)
SEF536H
Fast idle earn 4. Stop engine.

rF.i\ 5. Turn ignition switch "ON" and see "ENG TEMP
~ SEN" or "COOLAN TEMP/S" in "DATA MONITOR"
Cam follower mode with CONSULT.
lever Thermo-
6. When engine coolant temperature is 25:l: 5°C
element
(77:l: 9°F), make sure that mark CID is aligned with
mark @ as shown in the figure.
~ 5. When the resistance of engine coolant temperature
~ sensor is 1.65to 2.40 kQ, make sure that mark CID is
aligned with mark @ as shown in the figure.
• If NG, replace thermo-element and perform the above
SEF148N inspection and adjustment again.
- Except for Europe and Israel
1. Remove throttle body from engine.
2. Wait for at least 3 hours.
(This step is necessary to bring the temperature of the
thermo-element to the room temperature
EC-68
TROUBLE DIAGNOSIS - General Description ~
- Except for Europe and Israel (Cont'd)
Thermo-element
3. Measure thermo-element stroke (L) and room temperature.
4. Check thermo-element stroke (L) as shown in the figure.
L: Thermo-element stroke
Go to step 5* 2**
17
(0.669) 1645 *: Thermo-element is normal. Adjust first idle cam only.
16 1(0.6476)
**: Thermo-element is malfunctioning. Replace thermo-element, and perform
C (0630) I
"" 15 15.35 inspection beginning with step 2.
~ (0591) : (06043)
::J 14 '14.24
•
-; (0.551) : (05610)
t5 13 I
fJi (0.512)
: 1290 :
12 11.05 I (0.508) I
(0472) (0435) I I
I I
11
I I
(0433)
: I
10 I r
(0.394) 9.95 I r
(0.392) r I
I I
-20 0 20 25 40
HI (32) (68) (77) (104)
Thermo-element temperature °C (OF)
SEF0810
GA15DE 5. Adjust clearance @ between throttle stopper and throttle

adjusting screw to specification by turning adjusting screw
Adjusting (8).
screw (s)
Lock nut Engine models Clearance @ mm (in)
Fast idle M/T 0.40 - 0.75 (0.0157 - 0.0295)
carn GA15DE
A/T 0.61 - 0.95 (0.0240 - 0.0374)
M/T 0.72 - 1.18 (0.0283 - 0.0465)

GA16DE
A/T 0.95 - 1.43 (0.0374 - 0.0563)
SEF0820
GA16DE
6. Rotate adjusting screw (8) clockwise or counterclockwise
by Z turns according to the following equation, then tighten
the adjusting screw lock nut.
L (mm) - L8* (mm) L (in) - L8* (IN)
Z = -------~ / Z = --------
Y (mm) Y (in)
*. Value of the specified line (Ls) at the temperature of thermo-
element actually measured.
Clearance Y = 0.5 (GA 15DE)
@ 0.8 (GA 16DE)
SEF0830
• Direction of adjusting screw (8) rotation
(1) Positive (+) Z: Counterclockwise
(2) Negative ( - ) Z: Clockwise
EC-69
TROUBLE DIAGNOSIS - General Description []A]
- Except for Europe and Israel (Cont'd)
For example:
Case I Case II
Thermo-element
25 (77) 40 (104)
temperature .C l"F)
Thermo-element
specified stroke (Ls) 14.0 (0.551) 15.35 (0.6043)
mm (in)
Thermo-element
14.5 (0.571) 14.60 (0.5748)
stroke (L) mm (in)
Revolutions of 14.5. 14.0 14.60 - 15.35

Z = =0.63 I Z =
0.80
= -0.94 I
0.80
adjusting screw (Z) 0.571 - 0.551 0.5748.0.6043
mm/in = 0.63 0.0315
= -0.94
0.0315
Direction of revolu-
Counterclockwise Clockwise
tion
EC-70
TROUBLE DIAGNOSES - General Description
Symptom Matrix Chart
SYMPTOM
:c
z (!l
~ 0 I
:c i= w
<{
cL ~ 0::
0::
z W
<.) 0 w =' CJ
x Cl.
en
-I
w ~ 0 Z 0::
~ z <.) 0::
w
i=
Cl.
0 <{
:c
~ ~ 0 <.) w i=
-I Cl. ::? Cl. <.)
0:: -I
u..
i= <{
Q ::? =' ::?
<{ <{
en 0::
SYSTEM ~
en <Ii z 0::
0 CJ 0
W
~ z ='
en w Reterence
w z 0 0 w z ~ 0 0
- Basic engine control system
0:: <3
~
w Cl. -I
i= z z
0::
w <.)
Z
0
Z page
j::: ii Q z ~ <.) 2-
•
0:: 0 0 0:: -I
;;: w :s: =' ='
<{
W 0
0:: -I ='
en :s: :c i= ~ :s: ='
-I
<{
~
en
-I
<{
~ Z
<.)
0 0
0
-I w
-I
<{
0:: w
0:: en~ u..
W
6
W
<{
w
0
en 0 z Cl. W Q
III
> >
0
Z i= ~ LL -I :; 0
z
<{
w U5 U5
>-
0::
W
z
<{
~ ~ 0 Q :c (!l :c en en w
2i 0:: ~ :c CJ z ~ 0:: W W ~
~
0:: <3 U5 <{ <.)
CJ =' :J 0 w <.) <.)
<{ Z W Cl. <{ 0 -I > X X <{
I
:c w :c en -I :c 0:: Q en 0 w W III
AA AB AC AD AE AF AG AH AJ AK AL AM HA
Fuel Fuel pump circuit
• • • 0
• • • • 0 EC-145
Fuel pressure regulator system
• • • 0
• 0
• • 0
• EC-33
Injector circuit
Evaporative emission system
• • •
0 0 [)
0
0
•
• •
0 () 0 0 0
•
0
EC-141
EC-29
Air Positive crankcase ventilation system
Incorrect idle speed adjustment
0
0 0
• 0 0 0
• • 0
() (~) C)
U
0
()
0
EC-31
EC-35
IACV-AAC valve circuit
IACV-FICD solenoid valve circuit
• • •
C) () ()
(,
~)
()
• • • • 0•
0 C) (~, ()
•
0
0 EC-150
EC-204
Ignition Incorrect ignition timing adjustment 0 0
• • • • • • EC-35
EGR
Ignition circuit
(EGR valve &) EVAP canister purge
• • • • • • • • EC-113
control soienoid valve circuit • • • 0

• EC-179,183
EGR system
Main power supply and ground circuit
U
()
• • () ()
•
0
• • 0
r)
0
(,)
() Ci ()
0
0 ( ~
EC-179. 183
EC-88
Cooling I Cooling tan circuit () :.'-1 U () (,) ',) C) t) U n
u (J 0 EC-156
Air conditioner circuit () Co u () CJ U U "
, C: ~, () HA section
• ; High Possibility Item (continued on next page)

(), Low Possibility Item
EC-71
Symptom Matrix Chart (Cont'd)
SYMPTOM
:I:
Z C)
~ 0 I
:I: i= UJ
« a:
c.: I-
0
a: :J Z
[ij'
u UJ I-
0 z C)
X ll.
(f)
--l
UJ « a:
~ I-
z U a: i=
ll.
0 «
0 u UJ i= :I:
I-
a:
« «
UJ
--l ll. :2 ll. U
--l i= :2 :J
« u. « a: 9 :2 a:
SYSTEM I-
(f) az z
0
0
0 w
C)
Z
0
UJ
I-
(f)
Z
0
:J
(f)
z
UJ
Cl
Reference
- ECCS system UJ
a: c; l- --l
i=
I- a:
w u z page
UJ
ll.
9 z z z 0
2-
i==: a: Cl ii: :J 0 a: I-
« --l U
a:: :J l2 UJ ~ i= :J
~
UJ --l Cl
« --l
--l
(f)
U ~ 0
:I:
« I- :J
u. (5 «
I-
(f) « Z 0 0 --l UJ
--l
a:: UJ
a:: en w W
UJ
Cl
l- 0 z ll.
W 9
[]) I-
« > >
0 (f)
i= ::.:: u. --l ;; 0
in in >-
Z UJ « ::.:: 0 9 :I: z UJ
:I:
a::
aa:: z
c;
I-
in
a::
«
::.::
u :I:
C)
:J
C)
z ~
0
a::
UJ
(f)
UJ
U
(f)
UJ
U
UJ
I-
I-
« z C) :J «
:I: w
UJ
:I:
ll.
(f)
«
--l i
0
a:: 9
--l
(f)
>
0
X
UJ
X
UJ [])
AA AS AC AD AE AF AG AH AJ AK AL AM HA
ECCS Camshaft position sensor circuit
• • • 0 0 () 0 0 EC-94
Mass air flow sensor circuit
• • • 0
• • • • EC-101
(Heated) oxygen sensor circuit
• • 0
• • • • EC-189,194
circuit • • • 0
• • • • • • EC-108
Throttle position sensor circuit

Incorrect throttle position sensor
• • • • • • • • EC-128
adjustment • () ()
• 0 0
• () EC-65
Vehicle speed sensor circuit 0 C) () 0 EC-133

Knock sensor circuit 0 0 0 0 EC-119
ECM 0 () 0 0 () 0 () () () 0 0 EC-64
Start signal circuit 0 EC-138
Park/Neutral position switch circuit 0 0 0 0 0 EC-173
Power steering oil pressure switch cir-
0 (J 0 EC-169
cuit

0; Low Possibility Item
EC-72
SYMPTOM
J:
Z CJ
~ 0 I
J: i= LU
« a:
cL I- a: ::J UJ
0 0 LU I-
Z
CJ
>< D..
<JJ
-'
LU « 0 z a:
~ I-
z 0 a: i=
D..
0 «
I- « 0 0 LU LU i= J:
0: i= « -' D.. :2 D.. 0
-' :2 ::J :2
SYSTEM
« LL « 0: 9 LU C/J ::J
a:
I-
0 Z 0 CJ I- Z LU Reference
C/J 0 0 C/J 0
- Engine mechanical & other LU z 0 LU Z I- 0: 0 Z Z page
0: (3 I- D.. -' i= z LU 0 0
;::: a:
LU
0 a: 9 z
::J 0
Z
a: I-
« -' 0 2-
0:
« -'
::J
C/J
~ LU
5:
5: J: i=
«
::J
I- 5:
LU
::J -' 0
«
-' 0 0 W (5
I- « Z 0 0 -' -'
a: LU
a: en LL LU
•
C/J LU LU 0
I- 0 Z D..
W 9
CD I-
« > ~
0
z
C/J
i= ~ LL -' :> 0
Z LU (ij C/J
>-
a:
0
LU
Z
« ~ 0 9 J: CJ J: C/J C/J LU
a: (3
I- 0: ~ J: CJ Z ~ a: LU LU I-
(jj « 0 CJ
::J
:J 0 LU 0 0 I-
« z LU D.. « 0 -' > >< >< «
J: LU J: C/J -' J: a: 9 C/J 0 LU LU CD
AA AS AC AD AE AF AG AH AJ AK AL AM HA
Fuel Fuel tank 0 U
Fuel piping 0 0 0 () 0 0 0 0
Vapor lock U
Valve deposit 0 0 0 0 0 0 0 0
Poor fuel (Heavy weight gasoline, Low
0 C) 0 0 () 0 0 0 -
octane)
Air Air duct 0 0 0 0 0 0
Air cleaner 0 0 0 0 0 0
Air leakage from air duct ("
() (J () () 0 0 0 0 )
C'
(Mass air flow sensor - throttle body)
Throttle body, Throttle wire
Air leakage from intake manifold/
• • • • • • • • • FE section
Collector/Gasket
0
• (~) 0 tJ 0 U C; U -
Cranking Battery 0 U () (J 0 0 0 ':J

Alternator circuit () 0 0 0 (J 0 0 (J EL section
Starter circuit
•
Flywheel
Clutch interlock switch
•
0
-
CL section
Inhibitor switch () AT section
Engine Cylinder head
• • • • • • • ()
Cylinder head gasket

• • 0 • 0 U () 0 () C'
Cylinder block
• 00 0 0 () (J 0 0
Piston
• • • 0 (J () () () 0
Piston ring
Connecting rod
•
('
U
0
0
0
0
0
0
0
U
)
()
U
U
()
()
Bearing (i 0 () 0 () U 0 C
Crankshaft Cl (~) 0 0 () () 0 0
Valve Timing chain
• • • CJ0 0• n () ('
mechanism Camshaft
• • • • ':J• 0
Intake valve
• 0 00 • 0 () 0 l~'
Exhaust valve
HydraUlic lash adjuster
• 0 0 0 0
C) () () U
()
u
()
()
0
0
-
Exhaust Exhaust manifoldlTube/Muffler/Gasket C) c: () () 0 U () U
Lubrication
Three way catalyst
Oil pan/Oil strainer/Oil pump/Oil filter/
• • 0 U 0 0 () 0
Oil gallery • Ci 0 0 0
• • () 0
Oil level (Low)/Filthy oil () 0 () () () (J 0 U ()
Cooling Radiator/Hose/Radiator filler cap () 0 0 () () C) U U ()
Thermostat 0 0 0 0 C) 0 () 0 0 0 Cl
Water pump u 0 U 0 0 () Ci C) U
Water gallery U () 0 () 0 0 U 0 U
Cooling fan 0 () CJ U 0 U I) U () CJ (i
Coolant level (low)/Contaminated cool-

U 0 0 0 0 0 0 () )
ant
• ; High Possibility Item

U; Low Possibility Item
EC-73
CONSULT Reference Value in Data Monitor

Mode
Remarks:
• Specification data are reference values .
• Specification data are output/input values which are detected or supplied by the ECM at the connec-
tor.
* Specification data may not be directly related to their components signals/values/operations.
(Le., Adjust ignition timing with a timing light before monitoring IGN TIMING. Specification data might
be displayed even when ignition timing is not adjusted to specification. This IGN TIMING moni-
tors the data calculated by the ECM according to the input signals from the camshaft position
sensor and other ignition timing related sensors.)
• If the real-time diagnosis results are NG, and the on-board diagnostic system results are OK, when
diagnosing the mass air flow sensor, first check to see if the fuel pump control circuit is normal.
MONITOR ITEM CONDITION SPECIFICATION
• Tachometer: Connect Almost the same speed as the CON-

CMPS.RPM (REF)
• Run engine and compare tachometer indication with the CONSULT value . SULT value .
• Engine: After warming up

Idle 1.0 - 1.7V
• Air conditioner switch: OFF
MAS AIRIFL SE
• Shift lever: "N"
2,000 rpm 1.5 - 2.1V
• No-load
COOLAN TEMPIS • Engine: After warming up More than 70°C (158°F)
02 SEN 0- 0.3V <-+ 0.6 - 1.0V

Maintaining engine speed at 2,000 LEAN <-+ RICH
• Engine: After wflrming up
MIR FIC MNT rpm Changes more than 5 times
during 10 seconds .
• Turn drive wheels and compare speedometer indication with the CONSULT Almost the same speed as
VHCL SPEED SE
value the CONSULT value
SA TTERY VOLT • Ignition switch: ON (Engine stopped) 11 - 14V
• Ignition switch: ON Throttle valve fully closed 0.35 - 0.65V

THRTL POS SEN
(Engine stopped) Throttle valve fully opened Approx. 4.0V
START SIGNAL • Ignition switch: ON --> START --> ON OFF --> ON --> OFF
Throttle valve:
ON
• Ignition switch: ON Idle position
CLSD THLIPOS
(Engine stopped) Throttle valve:
OFF
Slightly open
AIC switch "OFF" OFF

• Engine: After warming up, idle the
AIR COND SIG AIC switch "ON"
engine ON
(Compressor operate&)
Shift lever "P" or "N" ON

PIN POSI SW • Ignition switch: ON
Except above OFF
EC-74
TROUBLE DIAGNOSES - General Description @KJ
Mode (Cont'd)
Steering wheel in neutral position

• Engine: After warming up. idle the OFF
PW/ST SIGNAL (forward direction)
engine
The steering wheel is turned ON
IGNITION SW • Ignition switch: ON --> OFF ON --> OFF
Rear window defogger is operating

ON
and/or lighting switch is on
LOAD SIGNAL • Ignition switch: ON
•
Rear window defogger is not operat-
OFF
ing and lighting switch is not on

Idle 2.4 - 3.2 msec.
INJ PULSE .
2.000 rpm 1.9 - 3.2 msec.
• No-load
Idle 6 _10' BTDC

IGN TIMING ditto
2.000 rpm More than 25' BTDC
Idle 20 - 40%
IACV-AACIV ditto
2.000 rpm -
Maintaining engine speed at 2.000

A/F ALPHA • Engine: After warming up 75 - 125%
rpm
AIR COND RLY • Air conditioner switch: OFF --> ON OFF --> ON
• Ignition switch is turned to ON (Operates for 5 seconds)

• Engine running and cranking ON
FUEL PUMP RLY • When engine is stopped (stops in 1.0 seconds)
• Except as shown above OFF
• When cooling fan is stopped OFF
COOLING FAN • When cooling fan operates at low speed LOW
• When cooling fan o!Jerates at high speed HI
Idle OFF
VALVE TIM SOL'1 • Engine: After warming up Racing engine quickly from idle to
ON
4.000 rpm
EGRC SOLIV
(EVAP canister Idle ON
purge control sole-
noid valve or EGR
• Shift lever: N
valve & EVAP can- Racing engine from idle to
• No-load OFF
ister purge control 3.000 rpm in 1st position
solenoid valve)
EC-75
TROUBLE DIAGNOSES - General Descrip_ti_o_n I_G_A_'
Major Sensor Reference Graph in Data Monitor

Mode
The following are the major sensor reference graphs in "DATA MONITOR" mode.
(Select "HI SPEED" in "DATA MONITOR" with CONSULT.)
THRTL POS SEN, CLSD THLIPOSI
Below is the data for "THRTL pas SEN" and "CLSD THLIPOSI" when depressing the accelerator pedal
with the ignition switch "ON".
The signal of "THRTL pas SEN" should rise gradually without any intermittent drop or rise after "CLSD
THLIPOSI" is changed from "ON" to "OFF".
CLSD THUPOSI -00"09 THRTL POS SEN -00'09
10:22 +02"69 10:22 XO.1V +02'69
OFF ON o 13 26 38 51,
Full { ~ I ~ \
' ..
Release
Full
Depress {
SEF673Q
CMPS,RPM (REF), MAS AIR/FL SE, THRTL POS SEN, 02 SENSOR, INJ PULSE
Below is the data for "CMPS.RPM (REF)", "MAS AIR/FL SE", "THRTL pas SEN", "02 SENSOR" and
"'NJ PULSE" when revving quickly up to 4,800 rpm under no load after warming up engine sufficiently.
Each value is for reference, the exact value may vary.
: ..
E
0-
./ .•.•.....•., o "CMPSoRPM(REF)" should increase gradually
C5 C\J - ........... while depressing the accelerator pedal and
LL~C? .........
wX should decrease gradually after releasing
a:
.................................... _ ....... __ ._....
~ co_ the pedal without any intermittent drop or rise.
a..
a: ...
ci> 1l) .,_,.
a..C\J
;:a"
(.)~o L.-r-
... ------------------
CO" ...
OCOIt)
gg
, + CD-
C')
.../ ....
>
... co
~C\J .': o "MAS AIRIFL SE" should increase when
W
C/)
depressing the accelerator pedal and should
,.. .... - ... _ ••,. •••• \ •••• ,.. _ ...... ~ .. _ ... _- ...... "¥'.,. ... """""'... _ .... _ .. _ ... _ .. - .... _.
-J .... ' decrease at the moment "THRTL POS SENu is
~ ~- closed (accelerator pedal is released).
<It)
C/)C\J
< ..
..,0)0
"",,0 L.r--------------------
...
SEF059P
EC-76
TROUBLE DIAGNOSES - General Description mJ
Mode (Cont'd)
cD
0
0
....
cD
~
-
ll)
0
9 +
co
M
,.
.....
> • "THRTL pas SEN" should increase while

re depressing the accelerator pedel and should
z ~
w decrease while releasing it.
en
•
en M
0
0..
-' -'
b:
:r:
ll)
C\l
a; 0 A
t- o
cD
0
....
cD
cD
ll)
b ~ C\l
9 0+
>
<3
-
C\l
C1l
IX)
ci C\l
><
.~. --._------
• ''02 SEN" may increase immediately after
depressing the accelerator pedel and may
--
v decrease after releasing the pedal.
cD
z
w
en
C\l
ll)
C\l
a; 0
-
A
.......
0 0
cD
0
....
cD 0
b ~ C\l
9 0+
ll)
u
w
en
:!
-
0 :~.
• "INJ PULSE" should increase when depressing
~---
w ll) the accelerator pedal and should decrease
en when the pedal is released.
-' j
::> ."""\
a. '.
.., ll)
C\l
a;
\ I
z 0
0
A
SEF259QA
EC-77
ECM Terminals and Reference Value

PREPARATION
1. ECM is located behind the center console panel. For this
inspection, remove the center console under cover.
2. Remove ECM harness protector.
MEF140D
3. Perform all voltage measurements with the connectors con-

nected. Extend tester probe as shown to perform tests eas-
ily.
~~
Tester probe MEC4868 ECM HARNESS CONNECTOR TERMINAL LAYOUT
For Australia
~9
@]8 .1~~~~.41i i5~
~1
101 102 03 104 105 106
107 lOB 09 110 111 112
113 114 115 116 117 lIB 3 1 4950 70
51
SEF130R
SEF131R
EC-78
TROUBLE DIAGNOSES - General Description @K]
ECM Terminals and Reference Value (Conl'd)
ECM INSPECTION TABLE - GA16DE for Australia
Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TER-
WIRE
MINAL ITEM CONDITION DATA
COLOR
NO.
[Efl9ine is running. I
0.3 - 0.6V
L Idle speed
1 WIB Ignition signal
IEngine is running. I
Approximately 0.9V
L Engine speed is 2,000 rpm.
3
GYIR
LIB
Ignition check
Tachometer
IEngine is running.
L Idle speed
[Engine is running.
L Idle speed
IEngine is running.
I
I
I
Approximately 12V
Approximately 0.9V
•
Ilgnition switch "OFF'.' 0- 1V
ECCS relay (Self-shut- L For a few seconds after turning ignition

4 WIG
off) switch "OFF"
Ilgnition switch "OFF" I
BATTERY VOLTAGE
L A few seconds passed after turning ignition (11 - 14V)
switch "OFF"
Ilgnition switch "ON" I
L For 5 seconds after turning ignition switch
0.07 - 0.20V
"ON"
8 BIP Fuel pump relay IEngine is running. I
BATTERY VOLTAGE
L More than 5 seconds after turning ignition (11-14V)
switch "ON"
10 BIW ECCS ground Engine ground
L Idle speed
IEngine is running. I BATTERY VOLTAGE
Cooling fan relay ~ Cooling fan is not operating. (11-14V) .
13 LG (High speed: For AIT Cooling fan is operating at low speed.
models) I Engine is running. I
Approximately OV
L Cooling fan is operating at high speed.
L Cooling fan is not operating. (11-14V)
Cooling fan relay
14 LGIR
(Low speed) IEngine is running. I
0.07 - 0.30V
L_ Cooling fan is operating.
I Engine is running. I
L Both AIC switch and blower switch are 0.08 - 0.2V
15 Y Air conditioner relay "ON".

LAIC switch is "OFF". (11 - 14V)
EC-79
TROUBLE DIAGNOSES - General Description ~
ECM Terminals and Reference Value (Cont'd)
TER-
WIRE
MINAl ITEM CONDITION DATA
COLOR
NO.
/'gnition switch "ON'" Approximately 50mV
18 OR/l
lamp
L Idle speed (11.14V)
19 BIW ECCS ground Engine ground
L Idle speed
I'gnition switch "ON" I Approximately OV
20 BIY Start signal BATTERY VOLTAGE
I'gnition switch "5T ART" I (11-14V)
L Both air conditioner switch and blower Approximately OV
21 G Air conditioner switch switch are "ON" (Compressor operates)

L Air conditioner switch is "OFF" (11 - 14V)
Neutral position switch

(M/T models)
t
I'gnition switch "ON'"
Ge., po,"'on " "Ne"".1 po,ltlon" (MIT

models)
Gear position is "N" or "P" (A/T models)
Approximately OV
22 G/OR
Inhibitor switch (A/T AIT models:
models) llgnition switch "ON'" BATTERY VOLTAGE
(11 - 14V)
L Except the above gear position M/T models:
Approximately 5V
0.35 - 0.65V
23 Y Throttle position sensor

L Accelerator pedal released
!'gnition switch "ON" I
Approximately 4V
L Accelerator pedal fully depressed
/Engine is running.1
Approximately OV
25 Pu/W
Power steering oil pres- L Steering wheel is being turned
sure switch IEngine is running.1
Approximately 5V
L Steering wheel is not being turned
Approximately
26 PUIR Vehicle speed sensor L Front of vehicle raised and front wheels are 1.8 - 2.4V (AC voltage)
rotating
Approximately OV
Torque converter clutch L Idle speed
30 PIB solenoid valve IEngine is running. I (Warm-up condition)
(A/T models only) BATTERY VOLTAGE
L Vehicle speed is 64 km/h (40 MPH) or more (11-14V)
in "D" position
I,gnition switch "ON" ,
35 lG/B Blower fan switch Approximately OV
L Blower fan switch is "ON"
EC-80
TER-
WIRE
COLOR
NO.
Ilgnition switch "OFF"1 OV
38 BIR Ignition switch BATTERY VOLTAGE
llgnition switch "ON"!
(11 - 14V)
39 B ECCS ground Engine ground
L Idle speed
40 l Camshaft position sen- IEngine is running. I Approximately 2.7V
•
44 l sor (Reference signal) L Idle speed (AC voltage)
i'gnition switch "ON'" Approximately OV
42 PUlW IACV-AAC valve (Close) I

IEngine is running. (Warm-up condition) BATTERY VOLTAGE
L Engine speed is 2,000 rpm. (11 - 14V)
Engine ground
IEngine is running. I (Probe this terminal with
43 B ECCS ground
L Idle speed e tester probe when
measuring.)
41 B/W Camshaft position sen- IEngine is running.1 Approximately 2.7V

45 B/W sor (Position signal) L Idle speed (AC voltage)
o - Approximately 1.0V
46 W Oxygen sensor L After warming up sufficiently and engine (periodically change)
speed is 2,000 rpm.
IEngine is running. I (Warm-up condition)
1.0 - 1.7V
47 OR Mass air flow sensor

L Idle speed
I Engine is running.! (Warm-up condition)
1.5 - 2.1V
Mass air flow sensor I Engine is running. I (Warm-up condition)

48 W 0.005 - 0.02V
ground L Idle speed
49 P/l j!gnition switch "ON"I Approximately 5V
power supply
50 B Sensors' ground 0.001 - 0.02V
L Idle speed
0- 4.84V
Output voltage varies
51 BRIY
Engine coolant tempera-
ture sensor
1Engine is running. I with engine coolant tem-
perature.
I Engine is running.!
54 W Knock sensor 2.0 - 3.0V
L Idle speed
Ilgnition switch "ON'"
Approximately OV
Rear defogger relay

L Rear defogger is "OFF".
55 LlR
Ilgnition switch "ON"I BATTERY VOLTAGE
L Rear defogger is "ON". (11 - 14V)
56 W/R BATTERY VOLTAGE

Power supply for ECM Ilgnition switch "ON"I
61 W/R (11 - 14V)
EC-81
TER-
WIRE
COLOR
NO.
BATTERY VOLTAGE
ILighting switch "ON"I
60 RIG Headlamp switch (11 - 14V)
ILighting switch "OFF"I Approximately OV
0- 5.0V
Intake air temperature Output voltage varies
63 RIY
sensor
IEngine is running. I with intake air tempera-
ture.
64 GIR IEngine is running. I Approximately OV
Data link connector for
65 GY/L
CONSULT L Idle speed (CONSULT is connected and Approximately 4 - 9V
68 GIW turned on) Approximately 3.5V
70 W/L Power supply (Back-up) I,gnition switch "OFF" I BATTERY VOLTAGE

(11 - 14V)
BATTERY VOLTAGE
Ilgnition switch "ON"I
(11 - 14V)
IACV-AAC valve
101 SS
(Open) IEngine is running. I (Warm-up condition)
0- 4V
102 RIB Injector No.1
104 GIS Injector No.3 BATTERY VOLTAGE
Engine is running
107 YIB Injector No.2 (11 - 14V)
109 LIB Injector No.4
BATTERY VOLTAGE
~ MIT models: Jack up front wheels and drive
EGR valve & EVAP can-
103 P .ister purge control sole-
L wheels at 16 kmlh (10 mph)
(11 - 14V)
Engine speed is 2,000 rpm.
noid valve
Approximately OV
L Idle speed
106 BIY ECCS ground Engine ground
L Idle speed
L Idle speed
IEngine is running. I . BATTERY VOLTAGE
114 YIR VTC solenoid valve

L Idle speed (11 - 14V)
Approximately OV
115 OR
Heated oxygen sensor
heater ground
L Engine speed is above 3,200 rpm. (11 - 14V)
(A/T models)
Approximately OV
L Engine speed is below 3,200 rpm.
118 SlY ECCS ground Engine ground
L Idle speed
EC-82
ECM INSPECTION TABLE - Except GA 16DE for Australia
Specification data are reference values and are measured between each terminal and @ (ECCS ground).
TERMINAL WIRE
ITEM CONDITION DATA
NO. COLOR
IEngine is running.1
0.2 - 0.3V
L Idle speed
1 WIB Ignition signal
IEngine is ru~
Approximately 0.7V
•
Tachometer IEngine is running.1
2 LIB (Models with tachome- 0.7 - 0.9V
ter) L Idle speed
jEngine is running.1
3 GYIR Ignition check Approximately 13V
L Idle speed
Engine is running.'
I
Ignition switch "OFF"I 0- 1V

4 WIG switch "OFF"
off)
llgnition switch "OFF"I
BATTERY VOLTAGE
L A few seconds after turning ignition (11-14V)
switch "OFF" and thereafter
IEngine is running.1 BATTERY VOLTAGE
Cooling fan relay (Low L Cooling fan is not operating. (11-14V)

9 LGIR
speed) IEngine is running.1
Approximately OV
L Cooling fan is operating.
10 LG
Cooling fan relay (High
t Cooling fan is not operating.
Cooling fan is operating at low speed.
BATTERY VOLTAGE
(11 - 14V)
speed)
Approximately OV
L Both AIC switch and blower fan switch Approximately OV
11 Yor G Air conditioner relay are "ON".


VTC solenoid valve L Idle speed
(11 - 14V)
(GA16DE engine mod-
12 YIR IEngine is running.1
els except for Europe
and Israel) L Engine is racing quickly from idle to 4,000
Approximately OV
rpm at 1st position.
EC-83
TROUBLE DIAGNOSES - General Description rnJ
TERMINAL WIRE
ITEM CONDITION DATA
NO. COLOR
IEngine is running./ (Warm-up condition)

1.2 - 1.8V
16 OR or G Mass air flow sensor

L Idle speed
IEngine is running.1 (Warm-up condition)

1.7-2.3V
0- 5.0V
BR/Yor Engine coolant temper- Output voltage varies
18 IEngine is running.'
GY ature sensor with engine coolant
temperature.
Oxygen sensor (Except IEngine is running.1

19 W o - Approximately 1.0V
for Europe and Israel) L After warming up sufficiently
Ilgnition switch "ON"I (Warm-up condition)

0.40 - 0.60V
20 Y Throttle position sensor

L Accelerator pedal released
jlgnition switch "ON"I

Approximately 4V
For Israel
Camshaft position sen-
22 1.5 - 3.0V
L sor (Reference signal: IEngine is running.1
30 Except for Israel
Except for Europe)
0.1 - 0.4V
Ilgnition switch "ON'"

Approximately 1.5V
24 ORIL
lamp IEngine is running.1 BATIERY VOLTAGE
(11 - 14V)
Knock sensor (Except IEngine is running.1

27 W Approximately 2.5V
for Europe and Israel) L Idle speed
Camshaft position sen-
L sor (Reference signal: 1.5 - 3.0V
For Europe)
31
Camshaft position sen- IEngine is running.1
40
sor (Position signal:
B/W 2.0 - 3.0V
Except for Europe and
Israel)
32 PUIR Vehicle speed sensor t

Eog'oe stopped aod gea, posit;oo

tral position".
While rotating drive wheel by hand
'S "Neu- Varies from 0 to 5V
t Rear window defogger switch is "ON".

Lighting switch is "ON".
BA TIERY VOLTAGE
(11 - 14V)
33 R Electric load switch

t Rear window defogger switch is "OFF".

OV
EC-84
TERMINAL WIRE
ITEM CONDITION DATA
NO. COLOR
Approximately OV
34 BIY Start signal
pgnition switch "ST ART"I BATTERY VOLTAGE
(11 - 14V)
pgnition switch "ON"I
t "N" or "P" position (A/T)

Neutral position (M/T)
OV
•
Neutral position switchl For Europe and Israel
35 G/OR Approximately 5V
Inhibitor switch
llgnition switch "ON"1
.L Except the above gear position Israel
BATTERY VOLTAGE
(11 - 14V)
Ilgnition switch "OFF"!

OV
Ignition switch (Except
36 B/R
for Europe) !Ignition switch "ON"I BATTERY VOLTAGE
(11 • 14V)
Throttle position sensor Ilgnition switch "ON"I

37 P/L Approximately 5V
power supply
38 BATTERY VOLTAGE
W/R Power supply for ECM Ilgnition switch "ON"I
47 (11 - 14V)
L Both air conditioner switch and blower Approximately OV
41 G or GY Air conditioner switch fan switch are "ON".
!Engine is running.1 BATTERY VOLTAGE

L Air conditioner switch is "OFF". (11 - 14V)
IEngine is running.!
OV
Power steering oil pres- L Steering wheel is being turned.
43 PU/W
sure switch IEngine is running.1
Approximately 5V
L Steering wheel is not being turned.
jlgnition switch "OFF"I OV

Ignition switch
44 B/R BATTERY VOLTAGE
(For Europe) pgnition switch "ON"I
(11-14V)
Thermo control amp. L Both air conditioner switch and blower fan Approximately OV
44 R/L (Except for Europe and switch are "ON".
Israel) IEngine is running.1 BATTERY VOLTAGE
Approximately OV
LG/B or L Blower fan switch is "ON".
45 Blower fan switch
G/Y IEngine is running.!
Approximately 5V
L Blower fan switch is "OFF".
EC-85
TROUBLE DIAGNOSES - General Description mJ
TERMINAL WIRE
ITEM CONDITION DATA
NO. COLOR
BATTERY VOLTAGE
46 WIL Power supply (Back-up) Ilgnition switch "OFF'"
(11 - 14V)
101 RIB Injector No. 1
103 GIB Injector No.3 BATTERY VOLTAGE

IEngine is running./
110 Y/B Injector NO.2 (11-14V)
112 LIB Injector NO.4

102 OR heater ground
(For Europe and Israel) IEngine is running.1
Approximately OV
L Engine speed is below 3,200 rpm.

"ON" Approximately OV
Fuel pump relay /Engine is running.1

104 B/P
(Except for Europe)
BATTERY VOLTAGE
L 5 seconds after turning ignition switch (11 - 14V)
"ON" and thereafter
EVAP canister purge

control solenoid valve IEngine is running.1 (Warm-up condition)
Approximately OV
(GA16DE MIT models
except for Europe &
L Idle speed
Israel)
105 P
EGR valve & EVAP can-
ister purge control sole- BATTERY VOLTAGE
noid valve (For Europe L Engine is racing from idle to 3,000 rpm in (11-14V)
and Israel, and GA15DE 1st position.
MIT models)

"ON" 0.7 - 0.9V
Fuel pump relay IEngine is running.1

106 SIP
(For Europe)
-
BATTERY VOLTAGE
"ON" and thereafter
10 - 13V
L Idle speed
111 5B
IACV-AAC valve (Open-
ing signal: Except for
Europe and Israel) l
51.."" wheel t, be'" I,med

Air conditioner is operating.
Rear window defogger switch is "ON".
Approximately 5.0V
EC-86
TROUBLE DIAGNOSES - General Description [ill
TERMINAL WIRE
ITEM CONDITION DATA
NO. COLOR
7 - 13V
L Idle speed
PU/W
IACV-AAC valve (Clos-
ing signal: Except for
Europe and Israel) t
~gine is running.1
Stee,'", wheel', be'", t,med

11 - 14V

113
•
11 - 14V
L Idle speed
IACV-AAC valve I~ngine is running.1

5B
(For Europe and Israel)
~ Steee'", wheel " be'", t,med 1 - 10V
Approximately OV
Torque converter clutch L Idle speed
solenoid valve
115 P/B
(A/T models except for
IEngine is running I (Warm-up condition)
BATTERY VOLTAGE
Europe and Israel) L Vehicle speed is 60 km/h (37 MPH) or (11-14V)
more in "0" position.
EC-87
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
EC-MAIN-01
W~L
7.5A
[ill
Refer to EL-POWER.
~ <:MID
'iIi' G
m
30A
OJ
Refer to EL-POWER.
0-<0- W!L ~ W/L --- .....
~ ST IGNITION
SWITCH
W!L IE7n7\
OF
d::,~ <S1W
I~I <BID
/ JUNCTION BOX NO.2
~ (JOINT CONNECTORS) 4=Jl
B/R
"T <fill)--, I
0-<0- W/L ~ __ ~~ W!L (1J: LHD models
I
O--<ID- W/L ~
@Jew
W/L ~ ~~1~
~
B/R
laiml ~~1~ 1$1
~
B/R
@: RHO models
@: For Europe and
Israel
@: Except@
~ W/L ~ W/L -<W-O B/R B/R @: For Europe
.....
-_,.-.--=--.1I
~ (F4)
I
• I
<t--.J>
I
@: Except@
~H :
-:
@44
@36
Detectable line
W/L W/L
~$ for DTC
IT ~I
-: Non-detectable
ECCS line for DTC
tU"Affi B/R B/R tcr:n\
~ RELAY
@
~T
@4=U T~
1bi=U@
lbi=Jl1!:idl B/R B/R
WIG W/R
~__ <f
W/L
I
WIG
'-9-<U1
W/R W/R W/R B/R
I
14~1
BATT
m
SSOFF
I;BI
VB
114'71 11~1
VB CRTN
n*ll
IGN ECM
SW (ECCS
CONTROL
MODULE)
em
Refer to last page

~------------------~ (Foldout page) .
fJjlll~@
3456 W ~'I'fIl@
4567B W +@:mm f3T5m
2 1 L :~@~@<S1W: :
5 I
L W W I
~
HEC026
EC-88
TROUBLE DIAGNOSIS FOR POWER SUPPLY []K]
Main Power Supply and Ground Circuit (Cont'd)
Except GA 16DE for Australia
EC-MAIN-02
-: Detectab Ie 1ine
for DTC
-: Non-detectable
line for DTC
ECM
•
(ECCS
CONTROL
GND GND GND GND GND GND GND MODULE)
-C -C -1 -1 -E -E -E em
13•91
B
1~81
B
.~
B/W
~
B/W
1r1
B/Y
l 11~1
B/Y
11~61
B/Y
L. L._._._.
~
B B/Y
L~
-!-
(F14)
<:ED
L
HEC027
EC-89
TROUBLE DIAGNOSIS FOR POWER SUPPLY @KJ
GA16DE for Australia
EC-MAIN-01
7.5A Refer to EL-POWER. 30A
~ IT]
W/L tE77\i\
r=:b~
I~ICMID Refer to EL-POWER.
W/L
IctJl~
=r@
ST IGNITION
SWITCH
W/L ~
e,--,,-,
I
I4J
B/R
W/L W/L
I
IT ~I
lbf=n~
WIG W/R
ECCS
~ RELAY
@
B/R tE77\i\
r=:b~
I~I<BID
B/R
cb~
'4=ll@
tm'i'\\
W/L
I "__~
WIG W/R W/R
B/R
I
B/R
17~1
BATT
m
SSOFF
1I~61
VB
If6TI
VB
~
IGN ECM
SW (ECCS
CONTROL
MODULE)
GND
-C
GND
-C
GND
-I
GND
-I
GND
-E
GND
-E
GND
-E em
13.9I I ~31 ~ ~ n1~61 11~21 111:81
B B B/W B/W B/Y B/Y B/Y
L, I_I ,-e-e-=e---J I
I I I I I
B B B B/Y
-: Detectable line
~..I L~ -:
for DTC
Non-detectable
-!- -! line for DTC
CF13) ffi
Refer to last page

(Foldout page) .
III' I 'liJ
3456 (ffi
W T
~ @
L
~~
t3RIID W
101 102 103 104 105 106

107 108 109 110 111 112
113 114 115 116 117 118
HEC062
EC-90
TROUBLE DIAGNOSIS FOR POWER SUPPLY ~
INSPECTION START
II ECM
36 36
Start engine. CHECK POWER SUP-
Is engine running? PLY-I.
Yes "ON".
@: Except for Australia and Europe -= 2. Check Yoltage between
and Israel ECM terminal @, @
@ : For Australia or @ and ground with
CONSULT or tester.
@ : For Europe and Israel SEF132R Voltage: Battery volt-
•
age
If NG, check the follow-
ing .
~i) • Harness connectors
GD,@orUD,
II ECM P!CONNECTORII @
46 70 • Harness connectors
OO,@))
• Harness for open or
short between ECM
and ignition switch
@: Except for Australia If NG, repair harness or
connectors.
@ : For Australia
SEF133R
-!.OK
Go to III "CHECK
~i) GROUND CIRCUIT" on
next page.
ECM E[coNNECTORII
~;~~
CHECK POWER SUPPLY-II. Check the following.
1. Stop engine. • Harness connectors
2. Check voltage between ECM terminal CID, @O)ui)r UD,
~ or @) and ground with CONSULT @or F4,@
or tester. • Harness connectors
Voltage: Battery voltage 00, @)) or Cill,
~ @ , @: Except for Australia @
~FF @, @: For Australia SEF134R
OK • Harness connectors
@,@))
• Joint connector @
~85 ~r5 • 7.5A fuse

II ECM EJ CONNECTOR II ~53 1

short between ECM
and battery
If NG, repair harness or
~'.S~ ~
connectors.
[!]
CHECK POWER SUPPLY-III. ~ Go to III "CHECK
1. Turn ignition switch "ON" and then GROUND CIRCUIT" on
@ , @: Except for Australia "OFF". next page.
@ ,@: For Australia 2. Check Yoltage between ECM terminals
SEF135R
@, @, or @, i@ and ground with
CONSULT or tester. Case-1: Battery voltage
After turning ignition switch "OFF", does not exist for a
battery voltage will exist for a few few seconds.
seconds, then drop to approximately Case-2: Battery voltage
av. exists for more than
a few seconds.
NG
Case-2
Case-1 Go to [!1 "CHECK ECCS
RELAY" on next page.
EC-91
TROUBLE DIAGNOSIS FOR POWER SUPPLY ffiJ
@
(i] 1 NG
CHECK HARNESS CONTINUITY
BETWEEN ECCS RELAY AND ECM
--.. Repair harness or con-
nectors.
1. Disconnect ECM harness connector.
2. Disconnect ECCS relay.
3. Check harness continuity between
ECM terminals @, @, or @, @
and terminal @.
Continuity should exist.
If OK, check harness for short. Check the following .
SEF129R • Harness connectors
OK
~''fflDr~,
M41 or F4 , M71
• Harness connectors
~,@IDorQD,
Ii M78
NG • Harness connectors
CHECK VOLTAGE BETWEEN ECCS ---+- @,@ID
RELA Y AND GROUND.
• Joint connector
1. Check voltage between terminals G),
@ and ground with CONSULTor @
tester. • Harness for open or
Voltage: Battery voltage short between ECCS
relay and battery
OK If NG, repair harness or
connectors.
AEC6B4
Ii
NG
CHECK OUTPUT SIGNAL CIRCUIT. ~ Repair harness or con-
1. Check harness continuity between nectors.
ECM terminal @ and terminal @.
ContinUity should exist.
If OK, check harness for short.
OK
[I
CHECK ECCS RELAY. Replace ECCS relay.
1. Apply 12V direct current between ~
relay terminals G) and @.
2. Check continuity between relay ter-
minals @ and @.
12V (G) - @) applied:
Continuity exists.
No voltage applied:
No continuity
OK
SEF023M
EC-92
TROUBLE DIAGNOSIS FOR POWER SUPPLY em
~i5~ NG
II ECM B' CONNECTOR II

CHECK GROUND CIRCUIT.
1. Turn ignition switch "OFF".
2. Loosen and retighten engine ground
Repair harness or con-
nectors.
.6-13-39-107-108-116 , screws.
ECM terminals @, @, @, @,
Gill, Gill, Gill, or @), @, @, @,
GID, GID, @ and engine ground.
•
For Australia If OK, check harness for short.
~i5@a OK
Che~k ECM pin terminals for damage

II ECM B' CONNECTOR II or the connection of ECM harness con-
nector.
.10-19-39-43-106-112-118 ,
INSPECTIONEND
SEF136R
EC-93
TROUBLE DIAGNOSIS FOR DTC 11
Camshaft Position Sensor (CMPS)

Light emitting The camshaft position sensor is a basic component of the
diode EGGS. It monitors engine speed and piston position. These
input signals to the EGM are used to control fuel injection, igni-
tion timing and other functions.
The camshaft position sensor has a rotor plate and a wave-
forming circuit. The rotor plate has 360 slits for a 1 (paS) sig-
0
nal (except for Europe and Israel) and 4 slits for a 180 (REF) 0
Wave signal. The wave-forming circuit consists of Light Emitting

formingcircuit Diodes (LED) and photo diodes.
The rotor plate is positioned' between the LED and the photo
diode. The LED transmits light to the photo diode. As the rotor
plate turns, the slits cut the light to generate rough-shaped
pulses. These pulses are converted into on-off signals by the
wave-forming circuit and sent to the EGM.
SEF653B
1800 signal
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible cause)
No.
11 • Either l' or 180' signal is not entered to ECM for • Harness or connectors
the first few seconds during engine cranking. (The camshaft position sensor circuit is open or
shorted.)
• Either l' or 180' signal is not entered to ECM often • Camshaft position sensor
enough while the engine speed is higher than the • Starter motor (Refer to EL section.)
specified engine speed. • Starting system circuit (Refer to EL section.)
• The relation between l' and 180' signal is not in
the normal range during the specified engine
speed.
EC-94
TROUBLE DIAGNOSIS FOR DTC 11 @KJ
Camshaft Position Sensor (CMPS) (Cont'd)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
fiii\ 1) Turn ignition switch "ON" and select "DATA
\JV MONITOR" mode with CONSULT.
2) Crank engine for at least 2 seconds.
---------- OR -----------
~ 1) Crank engine for at least 2 seconds.
~ 2) Turn ignition switch "OFF", wait for at least 5 seconds
and then turn "ON".
3) Perform "Diagnostic Test Mode II" (Self-diagnostic
results) with ECM.
EC-95
TROUBLE DIAGNOSIS FOR DTC 11 []KJ
EC-CMPS-01
(b): LHD models *1 : @ 40
Refer to @: RHO models @30
7.5A EL-POWER. JUNCTION BOX
@: For Europe *2: @31
[11] No.2 (JOINT
CONNECTORS) @: For Israe 1 @22
W!L ~ <:MID <MW
6-<D-- W!L ~ W!L ~-==_-==~~ -----<p W!L
<l- ./L ~
~ <:MID
./L ----------.....:(B)-O
I
W!L@
-:
-:
Detectable
for OTC
Non-detectable
line
4n @
W!L
line for DTC •
W!R I
DISTRIBUTOR
(CAMSHAFT
POSITION
~
W!L
rT W!L
SENSOR)
m
~
B
~
L
t
I[XI
~
lbjJJ~
ECCS
RELAY
@
..._...--.1
(
I
:.I W!R WIG
JOINT
I I I
~=~.
I I
CONNECTOR-6 : :
@ I I
.--rq~==~ J
ri-i
I
B
11
BB
" ~~
REF REF
W!R W!R W!R WIG
~ff17n~m
CRTN VB VB SSOFF ECM
t.J 1
ffi) ffi)
(ECCS
CONTROL
MODULE)
em
Refer to last page
~cw
ITIIJ:IITIIill GY
~'I'I~@
3456 W
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(Foldout page) .
HEC028
EC-96
TROUBLE DIAGNOSIS FOR OTC 11 mJ
EC-CMPS-02
BATTERY ]
7.5A Refer to EL-POWER. -: Detectable line
for DTC
ffi] -: Non-detectable
W!L line for DTC
I
W/L
1FsB1~
~CBID
W!L
I~IQMD
W/L
@)
tE7iIT\
W/R
m
I
DISTRIBUTOR
(CAMSHAFT
POSITION
SENSOR)
•
I <ffi)
Ti
W!L W!L
~~~
L B/W
---
B
t ( ,
IT]I
1bf=!J~(U)
WIG W/R
ECCS
~ RELAY
I'
I
I
I
I
I
I
I
1
...
I
I
I
I
I
I
I
.I--_..
I I
I I JOINT
I I CONNECTOR-6
I I
I ern
l'" --- .... --iCY=_ -=~--
•
I
WIG
T,
W/R W/R
iT T,
L L B/W B/W
mmIT17TI
SSOFF VB VB
12~1';01 If31iI I 4.0 I
REF REF POS POS II
ECM
(ECCS 8 B 8
CONTROL
MODULE)
(ill t.J m1
(l=J3)
Refer to last page

(Foldout page) .
~'4 5 6 I7'~8 @) ~ <ffi)

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W (1121341516) GY [[[[OOJOJOJD GY
HEC029
EC-97
TROUBLE DIAGNOSIS FOR DTC 11 rn:J
EC-CMPS-01
Refer to EL-POWER. -: Detectable line

for DTC
-: Non-detectable
line for DTC
W/L
I
W/L IE7iU\
r=::b'!JQ.!.,
I~I@
w!L
1m, ~
=r ern
DISTRIBUTOR
(CAMSHAFT
W/L POSITION
SENSOR)
I m
T-, 1hp~lbi=!J
L B/W B
W!L W/L
---
ECCS
t (
'" r---
.-1"I
I~~I
U:::i=JIlbiJcrn
~ RELAY I
I
I
I
I
WIG W/R I
.I--_ ..
I
I JOINT
I
~.----.-.~=_~=m--•
CONNECTOR-6
I
l@
fi1=il~~
SSOFF VB
"
WIG W/R W/R
VB
r' "
L
14.0 I
REF REF
L
n14n ~
B/W
POS POS
B/W
114'51
ECM
....,
(ECCS B B B
CONTROL
MODULE)
em t.... 1
(ffi) m
fIJ' I 'fi) ern

3456 W
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Refer to last page
(Foldout page) .
101 102 103 104 105 106

107 lOB 109 110 111 112
113 114 115 116 117 118
HEC063
EC-98
TROUBLE DIAGNOSIS FOR DTC 11 ~
Camshaft Position Sensor (CMPS) (Conl'd)
Camshaft position sensor DIAGNOSTIC PROCEDURE
harness connector
\ INSPECTIONSTART
CHECK POWER SUPPLY.

NG Check the following.
1. Turn ignition switch "OFF". • Harness for open or
2. Disconnect camshaft position sensor short between camshaft
harness connector. position sensor and
3. Turn ignition switch "ON". ECCS relay
AEC815 4. Check voltage between terminal If NG, repair harness or
•
@ and ground with CONSULT or connectors .
tester.
Voltage: Battery voltage
NG Repair harness or con-

1. Turn ignition switch "OFF". nectors.
screws.
terminal @ and engine ground.
SEF524Q
~i5 @a CHECK INPUT SIGNAL CIRCUIT. Repair harness or con-

1. Disconnect ECM harness connector. nectors.
(i1'lmI51~ 2. Check harness continuity between
terminal @ and ECM terminals @.
@), or @, @ or @, @ terminal
@ and ECM terminals @), @ or
@,@.
SEF463Q Continuity should exist.
OK
NG Replace camshaft position

CHECK COMPONENT
(Camshaft position sensor). sensor.
Refer to "COMPONENT INSPECTION"
on next page.
OK
Disconnect and reconnect harness con-

nectors in the circuit. Then retest.
Trouble is not fixed.
Check ECM pin terminals for damage

or the connection of ECM harness con-
nector. Reconnect ECM harness con-
nector and retest.
INSPECTIONEND
EC-99
@]
Il ECM
~io ECONNECroRl1
~IO
~JlI0
~29, ~
@, @: For Israel
@, @: For Europe
~ IDISCO~
l41 V ~io
~~TGo[rnID
1=1 =E=CM=:!iE[il=CO=NN=EC=ro=RII
@, @ , @, @ : Except for Australia @a

@,@,@,@ : For Australia SEF137R
COMPONENT INSPECTION
1. Start engine.
2. Check voltage between camshaft position sensor terminals
CID, @ and ground with AC range.
Terminal Voltage
@ : Except for Europe and Israel

@: For Europe and Israel (180.
Tester's pointer fluctuates between
AEC689 signal)
5V and OV.
@ : Except for Europe and Israel
(1. signal)
3. If NG, replace distributor assembly with camshaft position

sensor.
4. Remove distributor cap. Visually check signal plate for dam-
age or dust.
After this inspection, diagnostic trouble code No. 11 might be
displayed with camshaft position sensor functioning properly.
Erase the stored memory.
SEF887K
EC-100
Mass Air Flow Sensor (MAFS)

The mass air flow sensor measures the intake air flow rate by
taking a part of the entire flow. Measurements are made in such
a manner that the ECM receives electrical output signals var-
ied by the amount of heat emitting from the hot wire placed in
the stream of the intake air.
When intake air flows into the intake manifold through a route
around the hot wire, the heat generated from the hot wire is
taken away by the air. The amount of heat depends on the air
flow. On the other hand, the temperature of the ..hot wire is
SEF154N automatically controlled to a certain number of degrees.
Therefore, it is necessary to supply the hot wire with more •
electric current in order to maintain the temperature of the hot
wire. The ECM knows the air flow by means of the electric
c~ange.
SEF695K
Diagnostic
Check Items
Trouble Malfunction is detected when ...
(Possible Cause)
Code No.
12 • An excessively high or low voltage from the sensor • Harness or connectors
is entered to ECM. (The sensor circuit is open or shorted.)

PROCEDURE
rif\ 1) Turn ignition switch "ON", and wait for at least 6
~ seconds.
2) Select "DATA MONITOR" mode with CONSULT.
3) Start engine and wait for at least 3 seconds.
----------OR ----------
r<ff\ 1) Turn ignition switch "ON", and wait for at least 6
~ seconds.
2) Start engine and wait for at least 3 seconds.
3) Turn ignition switch "OFF", wait for at least 5 seconds
and then turn "ON".
results) with ECM.
EC-101
Mass Air Flow Sensor (MAFS) (Coni' d)
GA14DE, 16DE engine for Europe and Israel, and GA15DE engine
EC-MAFS-01
7.5A Refer to EL-POWER.
[ill : LHD mode1s
W i L <tl@ (][)
@:
@:
RHO models
For Europe and Israe 1
0-<:0- W!L ~ W!L @: Except@
<!>
W!L
_.
-:
Detectable
for DTC
Non-detectable
line
d= (EI0l) line for DTC

I~I CHID
/ JUNCTION BOX NO.2
~RL (JOINT CONNECTORS)
'T'
0-<:0- W/L q---~
~
W!L
I
O-<li>-
@)@
W/L ~ W/L ~
W/R
rrh
4D- MASS AIR
-<W-O
I
W/L ~ W/L FLOW SENSOR
<lli)
~cm .- ~ lbj:n
r-'
W/L W/L
t B
;
G
It ~I
I I
! !t
~~
WIG W/R
ECCS
~ RELAY
@
I
I
~ .
I
I
W
JOINT
CONNECTOR
-6
SSOFF
I i-t-O~
WIG
m~rr17n
W/R
VB
W/R
VB
W/R
riN9n
CRTN
~~
B
~
GND
-A
B
":91~
GND QA+
-A
G
ECM
(ECCS
r~1
•
B
I..J
B B
Sg~GE~f -!- =
(IT) ffi ill)
Refer to last page

~1111~cm ~1111~cm J&Lm -~-@ (Foldout page) .
3456 W 4567B W <IJg]]) GY ITIITITIITIII GY
T.
2
5
1
@
L
HEC030
EC-102
Mass Air Flow Sensor (MAFS) (Cont'd)
GA 16DE engine models except for Europe and Israel
EC-MAFS-02

for DTC
-: Non-detectable
line for DTC
W!L
I
•
W!L
1$1 (~~1; I
W!R
W!L
IEtJI QHD rn
=r CfID MASS AIR
W!L FLOW SENSOR
I rn>
T-,
W!L W!L
t lbiJ~
OR W
( "
ECCS I' ....1
n
IT~I RELAY 1 1
1 1
U (IT) 1 1
1 1
~~
~!
1
WIG W!R 1
1 t
.I--_.
I I
I I JOINT
I 1
I 1 CONNECTOR
I
I
I
I
em
~....
,
1----
.....--u1 ~
I
SSOFF V8
"
WIG W!R W!R
IFh~Wfl
V8
OR
1rf6il~
QA+
W
QA- ECM 8
II
8 8
(ECCS
CONTROL
MODULE)
em t...J 1
ffi ill
Refer to last page

(Foldout page) .
~I
45678
I l!jj CEID
W
+2
5
1
(IT)
L
~rn>
ill]]]D 8R
~em
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HEC031
EC-103
TROUBLE DIAGNOSIS FOR OTC 12
Mass Air Flow Sensor (MAFS) (Conl'd)
EC-MAFS-01

for DTC
-: Non-detectable
line for DTC
W/L
I
W /L tETt'i7\
r=b~
I~I@)
W/R
W/L
11iJ,@
W
3MASS
=r@ AIR
W/L FLOW
SENSOR
I
4=!Ilbj:Jlrn>
T.
W/L W/L
OR W
ECCS
t (
I'
I
,
I.
I~~I
~U:jJJ@
~ RELAY I
I
I
I
I
WIG W/R I
.I--_ ...
I
I
1
I JOINT
I CONNECTOR-6
--.~=-
I
I @
I ...
r,
I -=~I--""
WIG
SSOFF VB
"
W/R
mlf5'sil~
W/R
VB
OR
II}; 1 14-81
QA+ QA-
W
ECM B
11
8B
(ECCS
CONTROL
MODULE)
em t...l 1
~ ~
Refer to last page

(Foldout page) .
~I 11[iJ
3456
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101 102 103 104 105 106

107 108 109 110 111 112
113 114 115 116 117 118
HEC064
EC-104
Mass Air Flow Sensor (MAFS) (Conl'd)
For Europe ~ GA15DE engine DIAGNOSTIC PROCEDURE
and Israel I~ ",,~~)rl INSPECTION START
\~\" /JJ~
' Mass air flow sensor
1 _ harness connector
==---,
I-
1
I I CHECK POWER SUPPLY.
NG
nectors.
d.- I
~ Mass air flow sensor 2. Disconnect mass air flow sensor har-
;~ ness connector.
~(~lr~~ SEF138R
3. Turn ignition switch "ON".
4. Check voltage between terminal @
•
and ground with CONSULT or tester.
Voltage: Battery positive voltage
OK
NG
CHECK GROUND CIRCUIT. Repair harness or con-
screws.
terminal @ and ECM terminal @ or
@ or engine ground.
NG
CHECK INPUT SIGNAL CIRCUIT. Repair harness or con-
Check harness continuity between ter- nectors.
minal CD and ECM terminal @ or @.
*1 For Europe and Israel, and GA15DE engine
*2 : GA16DE engine models except for
Europe and Israel SEF139R
NG
CHECK COMPONENT Replace mass air flow
(Mass air flow sensor). sensor.
on page EC-107.

nectors in the circuits. Then retest.

nector and retest.
,~\ C/ INSPECTION END

Power steering\'
tluic! reservxr ..--\ /, '"
W~ Meo,"""
EC-105
Ii) For Europe and Israel, and
GA15DE engine
~i5
cill1D
GA16DE engine models except for

Europe and Israel
~15
1=' =E=CM==:!iH CONNECTOR II
17 48
@ : Except for Australia

@ : For Australia SEF140R
[!J For Europe and Israel, and

GA15DE engine models
~i5 ~i5
II ECM Ef CONNECTOR II c:illli:>
16
@a
GA16DE engine models except for
Europe and Israel
~io ~i5
II ECM El'CONNECTORII ULffhD
16 47
@: Except for Australia

47 : For Australia SEF141R
EC-106
2. Start engine and warm it up sufficiently.
3. Check voltage between terminal CD and ground.
Conditions Voltage V
* - -
1 : For Europe and Israe( and GA 15DE engine
Ignition switch "ON" (Engine stopped.) Less than 1.0
models Idle (Engine is warmed-up sufficiently.) 1.2 - 1.8
*2 : GA 16DE engine models except for
Euro e and I rael SEF142R 4. If NG, remove mass air flow sensor from air duct. Check hot
•
wire for damage or dust.
SEF154N
EC-107
Engine Coolant Temperature Sensor (ECTS)

The engine coolant temperature sensor is used to detect the
engine coolant temperature. The sensor modifies a voltage sig-
nal from the ECM. The modified signal returns to the ECM as
the engine coolant temperature input. The sensor uses a ther-
mistor which is sensitive to the change in temperature. The
electrical resistance of the thermistor decreases as tempera-
ture increases.
SEF594K
20 < Reference data>

18 Engine coolant temper-
6 Voltage Resistance
ature
9 4
'C ('F)
(V) (kQ)
B 2
Iii 10 -10 (14) 4.4 7.0 - 11.4
1ii 0.8
'0
£ 0.4 20 (68) 3.5 2.1 - 2.9
0.2 50 (122) 2.2 0.6 - 1.0
0.1
-20 0 20 40 60 80 100 90 (194) 0.9 0.23 - 0.26
(-4) (32) (68)(104)(140)(176)(212)
Temperature 'C (OF)
SEF012P
Diagnostic
Check Items
Trouble Code Malfunction is detected when ...
(Possible Cause)
No.
is entered to ECM. (The sensor circuit is open or shorted.)

PROCEDURE
(F.i\ 1) Turn ignition switch "ON".
~ 2) Select "DATA MONITOR" mode with CONSULT.
3) Wait for at least 5 seconds.
------------OR------------
fU\ 1) Turn ignition switch "ON" and wait for at least 5 sec-
~ onds.
and then turn "ON".
reSUlts) with ECM.
EC-108
(Cont'd)
EC-ECTS-01
ENGINE COOLANT
TEMPERATURE
SENSOR
m
@: For Europe and
Israel
@: Except@
*1",@
-:
GY, @BR!Y
Detectable line
for DTC
•
-: Non-detectable
line for DTC
t
B B
~ ~
GND GND ECM
-A -A (ECCS
CONTROL
MODULE)
em
lZlfll)
<I[g) GY
HEC032
EC-109
TROUBLE DIAGNOSIS FOR DTC 13 []K]
(Cont'd)
GA 16DE for Australia
EC-ECTS-01
~ENGINE COOLANT
TEMPERATURE
SENSOR
(ffl)
U:iJ lbi=ll -: Detectable line
BR/Y B for DTC
-: Non-detectable
line for DTC
BR/Y B
IT5TI 115"0 I
TW GND ECM
-A (ECCS
CONTROL
MODULE)
em
~<rrD
@ GY
101 102 103 104 105 106

107 108 109 110 HI H2
113 114 115 116 117 118
HEC065
EC-110
Engine coolant temperature (Cont'd)
sensor harness connector
~/ DIAGNOSTIC PROCEDURE
INSPECTION START
m
CHECK POWER SUPPLY. NG Check the following.
2. Disconnect engine coolant tempera- short between ECM
ture sensor harness connector. and engine coolant
•
3. Turn ignition switch "ON" temperature sensor
4. Check voltage between terminal @ If NG, repair harness or
~Io and ground with CONSULT or tester.

~oltage:
Approximately SV
connectors.
Ii)
CHECK GROUND CIRCUIT. NG Check the following.
~ 1. Turn ignition switch "OFF". • Harness for open or
2. Check harness continuity between short between ECM
SEF518Q terminal G) and engine ground. and engine coolant
Continuity should exist. temperature sensor
If OK, check harness for short. If NG, repair harness or
~Io connectors.
ten
CHECK COMPONENT NG Replace engine coolant
(Engine coolant temperature sensor). temperature sensor.
on next page.
SEF519Q


nector and retest.
INSPECTION END
EC-111
, '(Cont'd)
Check resistance as shown in the figure.
Temperature °C (OF) Resistance kQ
20 (68) 2.1 - 2.9
50 (122) 0.68 - 1.00

SEF152P 90 (194) 0.236 - 0.260
If NG, replace engine coolant temperature sensor.
EC-112
Ignition coil & power Ignition Signal

transistor harness connectors
COMPONENT DESCRIPTION
Ignition coil & power transistor (Built into distributor)
The ignition coil is built into distributor. The ignition signal from
the ECM is sent to the power transistor. The power transistor
switches on and off the ignition coil primary circuit. As the pri-
mary circuit is turned on and off, the proper high voltage is
induced in the coil secondary circuit.
AEC832
Diagnostic
21
Trouble
Code No.
Malfunction is detected when ...
• The ignition signal in the primary circuit is not

entered to ECM during engine cranking or running.
Check Items
(Possible Cause)
•
• Power transistor unit.
• Resistor

PROCEDURE
Note: If both DTC 11 and 21 are displayed, perform TROUBLE
DIAGNOSIS FOR DTC 11 first. Refer to EC-94.
(F.i\ 1) Turn ignition switch "ON".
3) Start engine.
----------OR ----------
2) Start engine.
and then turn "ON".
results) with ECM.
EC-113
Ignition Signal (Cont'd)
EC-IGN/SG-01
<r:> :
LHD models
(8): RHO models
Refer to EL-POWER.
30A @: For Europe and Israel
OJ @: Except @
G -: Detectable line
for DTC
OFF
m -: Non-detectable
line for DTC
ST IGNITION
SWITCH B/R
'e- @
ACC ~
4J
B/R
• t CONDENSER
m~
4>1> B/R B/R
'le'(tiQ])
IGNITION
COIL
POWER
TRANSISTOR
DISTRIBUTOR
~
W
QID~ ~@
B/R B/R
1>J ~
G
~~
W/B B/W
I
II t II To ECM
@
4-' B/R
IctJ,
B/R
IrtJl@
G
RESISTOR
.-
-
B/Y.
(ECCS
control
module)
=r CEID
W
(H) 9F
B/R B/R ~
2
tJ SPARK PLUG GY/R

rn
W/B
m B/Y B
nB
ECM
(ECCS
CONTROL
MODULE)
(IT)
IGN
CK
IGN
f.J
m
1 ffi)
~--------------------~ r---------------------, Refer to last page
:~@R@<flB):
I I I
I (Foldout page) .
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3456 (H)
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EC-114
EC-IGN/SG-01

30A
for DTC
OJ -: Non-detectable
line for DTC
'e-
ACC
~
B/R
r=b(fW
IGNITION
SWITCH
@
t
B/R
7
•
lap'CM[) CONDENSER
DISTRIBUTOR
B/R IGNITION
IUJI@
COIL
POWER m
'9Fem
B/R
TRANSISTOR ~
~ ~lkj:!J
G W/B B/W
II t II To ECM
G
.- B/Y .. (ECCS control
~ module)
RESISTOR
SPARK PLUG
W
GY/R
2
~
W/B
mIGN
m
IGN ECM B/Y
n
B B
(ECCS
1
CK
CONTROL
MODULE)
CED i.J
~ rn
r-------------------,
I I Refer to last page
I I (Foldout page) .
~@W
B:I! em I 1)(1 m 1Zl~'
GImJ W 3456I'~ W : (11213\41516) GY CZIID GY :
I I
~-------------------~
101 102 103 104 105 106
107 108 109 110 111 112
113 114 115 116 117 118
HEC066
EC-115
DIAGNOSTIC PROCEDURE
INSPECTION START
Yes
Turn ignition switch "OFF", and restart
engine.
Is engine running?
No
NG
AEC832 CHECK POWER SUPPL V. Check the following.
1. Turn ignition switch "OFF". • Harness connectors
2. Disconnect ignition coil harness con- QD,@orGD.
nector. @
3. Turn ignition switch "ON". • Harness connectors
4. Check voltage between terminal (J) @.<illD
and ground with CONSULT or tester. • Harness for open or
Voltage: Baltery voltage short between ignition
coil and ignition switch
OK
connectors.
NG
SEF468Q
2. Disconnect power transistor harness
connector.
~15 @3 If OK, check harness for short.
OK
NG
ill~ 1. Disconnect ECM harness connector. nectors.
ECM terminal G) and power transis-
tor terminal G).
SEF469Q
OK
~85 ~85 CHECK COMPONENTS

(Ignition coil, power transistor).
Refer to "COMPONENT INSPECTION",
NG
Replace malfunctioning
component(s).
II ECM ~CONNECTORII (tI2IffllsI6) EC-118.
1
OK •

SEF470Q

nector and retest.
INSPECTION END
EC-116
@
(;J
CHECK INPUT SIGNAL CIRCUIT. NG Repair harness or con-
1. Stop engine. nectors.
2. Disconnect ignition coil harness con-
nector.
3. Strip tape covering resistor and dis-
connect the connector.
•
ignition coil terminal @ and resistor
~io
terminal (!), resistor terminal @
~i8 and ECM terminal @ or @.

dIb cffiJ If OK, check harness for short.
OK
CHECK COMPONENTS NG Replace resistor.

(Resistor).
on next page.
~i5
1=1 =E=CM====!:E' CONNECTOR II
3
@3) Check ECM pin terminals for damage

CD : For Australia or the connection of ECM harness con-
SEF143R
nector and retest.
INSPECTION END
EC-117
Ignition Signal (Co nt' d)
Ignition coil
1. Disconnect ignition coil harness connector.
2. Check resistance as shown in the figure.
Terminal Resistance [at 25°C (7rF))
(j) - CID (Primary coil) Approximately 1Q
(j) - secondary terminal on distrib-

Approximately 10 kQ
utor head (Secondary coil)
If NG, replace ignition coil.

3. For checking secondary coil, remove distributor cap.
4. Check resistance between ignition coil harness connector
terminal q) and the secondary terminal on the distributor
head.
If NG, replace distributor.
Power transistor Power transistor

terminals ~ .B.. 1. Disconnect power transistor harness connector.
(615143121D (~l..?)
2. Check power transistor resistance between terminals @
and @ .
Terminals Resistance Result
NotOQ OK
@ and CID
OQ NG
If NG, replace distributor.

SEF473Q
Resistor
1. Disconnect resistor harness connector.
2. Check resistance between terminals CD and @.
Resistance: Approximately 2.2 kQ [at 25°C (77°F)]
If NG, replace resistor.
AEC841
EC-118
Knock Sensor (KS)

The knock sensor is attached to the cylinder block. It senses
engine knocking using a piezoelectric element. A knocking
vibration from the cylinder block is sensed as vibrational pres-
sure. This pressure is converted into a voltage signal and sent
to the ECM.
PIEZO-ELEMENT
SEF598K
34
Diagnostic
Trouble Code
No.
Malfunction is detected when ....
• An excessively low or high voltage from the knock

sensor is entered to ECM.
Check Items
(Possible Cause)
(The knock sensor circuit is open or shorted.)
•
• Knock sensor

PROCEDURE
rif\ 1) Turn ignition switch "ON" and select "DATA
\J!I) MONITOR" mode with CONSULT.
2) Start engine and run it for at least 5 seconds at idle
speed.
---------- OR ----------
00 1) Start engine and run it for at least 5 seconds at idle
speed.
and then turn "ON".
results) with ECM.
EC-119
Knock Sensor (KS) (Cont'd)
EC-KS-01
ECM
(ECCS
CONTROL
MODULE)
KNK em -: Detectable line
112: I for DTC
w -: Non-detectable
line for OTC
f .--------.
I I
I I
I I
I I
I I
l~ •
w~
wOO
rn
JOINT
CONNECTOR-6
CW
f • 1
I I
I I
I I
I I
I I
I I
I': )
w
m
KNOCK
SENSOR
<F102)
@g)
<Ern> ~oo ~cw
BR LL.@y B I1IIIITITDII GY
HEC034
EC-120
EC-KS-01
-: Detectable line
for DTC
-: Non-detectable
ECM line for DTC
(ECCS
CONTROL
MODULE)
KNK em
I
I
I
I
5 4
1 • 1
w
f .------
I I
I
I
I
I
..... •
I I
1':- •
w
<ffi)
w <EW
rn
JOINT
CONNECTOR-6
(F2)
fI • I 1
I I
I I
I I
I I
!.:- j
w
m
KNOCK
SENSOR
0:102)
fl<ill}
\!.1.SJ
GY
~@
rn:IIIITIIIII GY
101 102 103 104 105 106

107 108 109 110 111 112
113 114 115 116 117 118
HEC067
EC-121
Knock Sensor (KS) (Conl'd)
For Europe and Israel, and GA15DE.L..l DIAGNOSTIC PROCEDURE
- en~ine m\~\.Y
~:e?,
Is Eng~e ground @'~@) 1 _
INSPECTION START
J--
Loosen and retighten engine ground
screws.
Fa
--. nectors.
2. Disconnect ECM harness connector
and knock sensor sub-harness con-
nector.
terminal @ and ECM terminal @ or
,~\ C-/ @.
Power steerin9\'
fluid reservoir /' \ /-:
.~~ :,c"", r
CHECK SUB.HARNESS CIRCUIT.
1. Disconnect knock sensor harness
connector. @,@
2. Check harness continuity between If NG, repair harness or
knock sensor harness connector ter- connectors.
minal @ and knock sensor sub-har-
ness connector terminal @.
OK
Fa ~i5 CHECK COMPONENT

(Knock sensor).
NG Replace knock sensor.
II ECM ]9'CONNECTORII Refer to "COMPONENT INSPECTION"

27 54
on next page.
OK

@: For Australia
@: Except for Australia Trouble is not fixed.
SEF144R
Check ECM pin terminals for damage or

the connection of ECM harness connec-
tor. Reconnect ECM harness connector
and retest.
INSPECTION END
SEF776Q
EC.122
Knock Sensor (KS) (ConI' d)
Knock sensor
• Use an ohmmeter which can measure more than 10 MQ.
1. Disconnect knock sensor harness connector.
2. Check resistance between terminal @ and ground.
Resistance: 500 - 620 kQ [at 25°C (77°F)]
CAUTION:
Discard any knock sensor which has been dropped or under-
gone shocks; use a new one.
AEC719
EC-123
Intake Air Temperature Sensor (IATS)

The intake air temperature sensor mounted to the air cleaner
housing, detects intake air temperature and transmits a signal
to the ECM.
The temperature sensing unit uses a thermistor which is sen-
sitive to the change in temperature. Electrical resistance of the
thermistor decreases in response to the temperature rise.
This sensor is not directly used to control the engine system. It
is used only for the on-board diagnosis.
Diagnostic
Check Items
(Possible Cause)
No.
41 a) An excessively low or high voltage from the sen- • Harness or connectors
sor is entered to ECM. (The sensor circuit is open or shorted.)
• Intake air temperature sensor.
b) Voltage sent to ECM is not practical when com-
pared with the engine coolant temperature sensor
signal.

* MONITOR * NO FAIL PROCEDURE
COOLANTEMP/S 30°C
For the malfunction a) and b)
fF.I\ 1) Wait until engine coolant temperature is less than 90°C
~ (194°F).
(a) Turn ignition switch "ON".
(b) Select "DATA MONITOR" mode with CONSULT.
(c) Check the engine coolant temperature.
RECORD I
SEF002P
(d) If the engine coolant temperature is not less than
90°C (194°F), turn ignition switch "OFF" and cool
down engine.
II ECM a
51
CONNECTOR
CONNECT
II I) ~
~
4) Wait for at least 5 seconds.
---------OR ---------
~ 1) Wait until engine coolant temperature is less than
~ 90°C (194°F.).
(a) Turn ignition switch "ON".
(b) Check voltage between ECM terminal @ and
ground.
Voltage: More than 1.2 (V)
SEF006P (c) If the voltage is not more than 1.2V, turn ignition
switch "OFF" and cool down engine.
2) Turn ignition switch "ON" wait for at least 5 seconds.
and then turn "ON".
results) with ECM.
EC-124
TROUBLE DIAGNOSIS FOR OTC 41 ~
Intake Air Temperature Sensor (IATS) (Cont'd)
EC-IATS-01
INTAKE AIR
TEMPERATURE
SENSOR
~
-:
-:
Detectable line
for DTC
Non-detectable
line for DTC
•
t
R/Y B
~ 15"0 I
TA GND ECM
-A (ECCS
CONTROL
MODULE)
em
~
@ GY
101 102 103 104 105 106

107 108 109 110 111 112
113 114 115 116 117 118
HEC073
EC-125
TROUBLE DIAGNOSIS FOR DTC 41 rnJ
INSPECTION START
~
'" '\ --
Intake air temperature
sensor harness connector
CHECK POWER SUPPLY.
• Harness continuity
2. Disconnect intake air temperature between ECM and
sensor harness connector. intake air temperature
AEC550 3. Turn ignition switch "ON". sensor
4. Check voltage between terminal @ If NG, repair harness or
~ DISCONNECT
and ground. connectors.
Voltage:
ciili 10 Approximately SV

1. Turn ignition switch "OFF". • Harness continuity
2. Check harness continuity between between ECM and
terminal G) and engine ground. intake air temperature
AEC723 Continuity should exist. sensor
OK
~i5 ~ NG
connectors
dID CHECK COMPONENT

(Intake air temperature sensor).
Replace intake air tem-
perature sensor.
on next page.
OK

AEC724 nectors in the circuit. Then retest.

nector.
Reconnect ECM harness connector and
retest.
INSPECTION END
EC-126
TROUBLE DIAGNOSIS FOR DTC 41 @K]
Intake air temperature sensor
9
fl
ffi
20
19
10
iii 0.8
'w
6
4
2
Intake air temperature
'c ('F)
20 (68)
50 (122)
Resistance kQ
2.1 - 2.9
0.68 - 1.0
•
& 04
0.2
0.1 -20 0 20 40 60 80 100

(-4) (32) (68)(104)(140)(176)(212)
Temperature 'c (OF)
SEF012P
EC-127
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS
Throttle Position Sensor

The throttle position sensor responds to the accelerator pedal
movement. This sensor is a kind of potentiometer which trans-
forms the throttle position into output voltage, and emits the
voltage signal to the ECM. In addition, the sensor detects the
opening and closing speed of the throttle valve and feeds the
voltage signal to the ECM.
Idle position of the throttle valve is determined by the ECM
receiving the signal from the throttle position sensor. This one
controls engine operation such as fuel cut.
i
SEF089K
CIl Supply voltage:
-i.~h
__ ~3_ 45 'V ,Appl.' b.... ffi t~miMI, No 1 ,,' 31
I
l ~_
=~r--=-tfr ~N~
r I
1 I
Throttle position sensor g -g
'5 ::: 0.5
0-
'5 0 0 ----- -_.- -- ------_.
OZ 0 90
Throttle valve opening angle (deg_) SEF520Q
EC-128
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS ~
Throttle Position Sensor (Cont'd)
EC-TPS-01
THROTTLE
POSITION @: For Europe and Israe 1
SENSOR _: Detectable line
@ for DTC
-: Non-detectable
line for DTC
t
fI
I
II
I
I
I
I
1
I
J J •
I
I
JOINT
CONNECTOR-6
@
I: .-.----...f~:==:P:JI---..
t
P!L Y B B
~~um
AVCC TVO GND
12"g I
GND ECM
-A -A (ECCS
CONTROL
MODULE)
em
JXL@ _.. ~@
<I@TI) BR IIIillITIIIIl GY
HEC035
EC-129
EC-TPS-01
THROTTLE
POSITION
_. Detectable line
for DTC
SENSOR -: Non-detectable
CEID line for DTC
fI "1
I
I I
t I
I
I
q J
I
I I
I I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I JOINT
I CONNECTOR-6
I
I
J
I~
.- em
rq ~
t J J
P/L
1:91 1:31
AVCC TVO
y B
15.0 I
GND
B
n
B B
-1 -A ECM
(ECCS
CONTROL
MODULE)
!J 1
em (fi3) (Fi4)
~CEID ~cw
~BR EIITIIIIIIIIJ GY
101 102 103 104 105 106

107 lOB 109 110 111 112
113 114 115 116 117 11B
HEC068
EC-130
m GA15DE DIAGNOSTIC PROCEDURE
INSPECTION START
m 1 NG
CHECK POWER SUPPLY.
------. Repair harness or con-
nectors.
2. Disconnect throttle position sensor
harness connector.
4. Check voltage between terminal CD
•
and ground with CONSULTor tester.
Voltage: Approximately SV
m 1 0K
NG
------. Check the following.
2. Loosen and retighten engine ground short between ECM
screw. and throttle position
3. Check harness continuity between sensor
terminal @ and engine ground. If NG, repair harness or
Continuity should exist. connectors.
[!J 1 0K
NG
CHECK INPUT SIGNAL CIRCUIT.
------. Repair harness or con-
nectors.
ECM terminal @) or @ and terminal
@.
~OK
SEF480Q ADJUST THROTTLE POSITION SEN-

SOR.
Perform "Basic Inspection", EC-65.
~
NG
CHECK COMPONENT
(Throttle position sensor).
------. Replace throttle position
sensor. To adjust it, per-
Refer to "COMPONENT INSPECTION" form "Basic Inspection",
on next page. EC-65.
~OK

~Trouble is not fixed.

nector and retest.
,~\ C/
i
Power steering)\ INSPECTION END
EC-131
~io
~
SEF461Q
~i8
II ECM E CONNECTOR II
20 23
@: For Australia
@: Except for Australia SEF229R
1. Disconnect throttle position sensor harness connector.
2. Make sure that resistance between terminals @ and @
changes when opening throttle valve manually.
Throttle valve conditions Resistance (at 25'C (77'F)J
Completely closed Approximately 0.5 kn

Partially open 0.5 - 4.0 kn
SEF146R
Completely open Approximately 4.0 kn
If NG, replace throttle position sensor. To adjust it, perform
"Basic Inspection", EC-65.
EC-132
Vehicle Speed Sensor (VSS)

LHD models
EC-VSS-01
FUSE Refer to EL-POWER.

BLOCK
(JIB)
•
~
COMBINATION
METER ~ R/Y -illfr R/Y
rITO)l~ ~I~
~ ~ R/Y -Ia~ )
VEHICLE
SPEED
(SPEED- 0:@..; I~ ~ I~ (SENSOR
OMETER)
~ ~ R -lliW~ R ~ ~ R ~ @ID
~
1*.51
PU/R
PUIR
I
d:::,~
IG"An\
I~ICEID @: Models with tachometer

PU/R @: Models without tachometer
I
*1... @30 , @40
*2"'@12 @33
*3... @10 '@15
PU/R *4"'@ ,
9 '@31
~ *5... @ 13 , @32
VSP ECM -: Detectable line
(ECCS for DTC
CONTROL -: Non-detectable
MODULE) B/R line for DTC
ill) -!-
~
Refer to last page

(Foldout page) .
L ~
~~ ~@ID
tIDID11ID B tID GY
em
L
HEC036
EC-133
Vehicle Speed Sensor (VSS) (Cont'd)
RHO models
EC-VSS-02
IGNITION SWITCH
ON or START

10A BLOCK
[]] (JIB)
~
COMBINATION
METER ~ R/Y .j~ R/Y .j ~ R/Y~ ..gVEHICLE
(SPEED- rTIO\llE7iIT\ 1E"n\1~ ) SPEED
~ I'l:1Q.y ~ I~ (SENSOR
OMETER)
~ ~ R .j1IDJ- R .j ~ R ~ ~
~
1*151
PUIR
I
PU/RtG7?l\
r=b~ @: Models with tachometer
I~I@ @: Models without tachometer
PU/R *1 @30 @40
I
PU/R
1
*2
*3
*4
@ 12 '@33
@ 10 '@ 15
@ 9 '@31
*5... @13
,
, @32
13 21 -: Detectable line
VSP ECM for DTC
(ECCS -: Non-detectable
CONTROL line for aTC
MODULE) B/R
em -!-
<f@
Refer to last page

(Foldout page) .
L ~
~~ ~WID
tmm:lID B tgj GY
em
L
HEC037
EC-134
Vehicle Speed Sensor (VSS) (Conl'd)
EC-VSS-01
IGNITION SWITCH -: Detectable line
ON or START for DTC
-: Non-detectable
line for DTC
FUSE Refer to EL-PDWER.
10A BLOCK
[]] (JIB)
(M15)
•
COMBINATION
METER ~ R/Y ~~
~I~
R/Y ,
~I~
U- R/Y~{1VEHICLE
) SPEED
(SPEED- ~ I 'l::.!Q!, ~ J ~ C SENSOR
OMETER)
~ ~ R ,~ R 'U- R {] ~
@
~
PU/R
I
PU/RIGM'l\
r=b,~
I~I@
PU/R
PU/R
I
1~61
VSP ECM
(ECCS
CONTROL
MODULE) B/R
(ill -!-
~
~---------------------------------,
Refer to last page
~~ (Foldout page) .
L ~
~ GY
@ Fff2T3T4j (E202)
w IID:illIID B
101 102 103 104 105 106

107 10B 109 110 111 112
113 114 115 116 117 11B
HEC069
EC-135
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS @!J
The vehicle speed sensor is installed in the transaxle. It con-
tains a pulse generator which provides a vehicle speed signal
to the speedometer. The speedometer then sends a signal to
Vehicle speed the ECM.
sensor
AEC110
.V~HICLE SPEED SEN CKT.
INSPECTION START
AFTER TOUCH START.
DRIVE VEHICLE
AT 10km/h (6mph) OR
MORE WITHIN 15 see
OK
CHECK OVERALL FUNCTION. INSPECTION END
1. Jack up drive wheels.
l---- __ ,~--'
(ij\ 2. Perform "CAR SPEED SEN
-N-EX-T -II STA-RT- ~ CIRCUIT" or "VEHICLE
SPEED SEN CKT'" in "FUNC-
MEF559D
TION TEST'" mode with CON-
SULT
-(;( MONITOR -(;( NO FAIL 0 OR
2. Read "CAR SPEED SEN"' or
VHCL SPEED SE 20km/h "VHCL SPEED SE" signal in
PIN POSI SW OFF "DATA MONITOR" mode with
CONSULT.
CONSULT value should be the
same as the speedometer indi-
cation.
OR
3. Rotate drive whe'el by hand.
RECORD
SEF941N
4. Check voltage between ECM
terminal @ or @ and body
ground.
fijf..... CONNECT fIr:J:J:. ~ Voltage should vary between
1A1£) ~~ approx. 0 - 5V.
II ECM 19' CONNECTOR II ~ NG

32 26 ~l NG
CHECK SPEEDOMETER FUNCTION. Check vehicle speed sen-
Make sure that speedometer functions sor and circuil.
properly. (Refer to "Inspectionl
Speedometer and Vehicle
OK Speed Sensor" of
@: For Australia "METER AND GAUGES"
in EL section.)
EC-136
m Models with tachometer @
II ECM CHECK INPUT SIGNAL CIRCUIT.

NG
Check the following.
2. Disconnect ECM harness connector GD,@
and combination meter harness con- • Harness for open or
nector. short between ECM
3. Check harness continuity between and combination meter
ECM terminal @ and terminal @ or If NG, repair harness or
@ : For Australia @, ECM terminal @ and terminal connectors.
•
@.
Models without tachometer If OK, check harness for short.
OK

II ECM

SEF147R
nector and retest.
INSPECTION END
EC-137
Start Signal
EC-S/SIG-01
Refer to EL-POWER.
OF
IGNITION
ST SWITCH
~
_.
@: For Europe and Israle
@: Except for Europe and
Israle
Detectable line
for DTC
-: Non-detectable
line for DTC
FUSE
7.5A BLOCK
1261 (JIB)
~
0:106)
UN•411
B/Y
B/Y
I
r::b@
I[QJI CEID
B/Y
B/Y
I
~
ST ECM
SW (ECCS
CONTROL
MODULE)
(IT)
r--------------------, Refer to last page

I I
(Foldout page) .
IFmfl ~ I
: rmm<ID ~@~:
:
L W W :
~
HEC038
EC-138
Start Signal (Cont'd)
EC-S/SIG-01
30A
Refer to EL-POWER.
OJ
-: Detectable line
•
for DTC
-: Non-detectable
IGNITION line for DTC
ST SWITCH
~
FUSE
7.5A BLOCK
1261 (JIB)
<fill)
IN.41 CE106)
SlY
I
BIY
r.::b@
l/¥ll@)
SlY
I
SlY
~
STSW ECM
(ECCS
CONTROL
MODULE)
ern
Refer to last page

~~ (Foldout paglil).
tmI W
101 102 103 104 105 106

107 108 109 110 111 112
113 114 115 116 117 118
HEC070
EC-139
• STARTSIGNAL CKT.
INSPECTION START
CLOSETHROTTLE.SHIFT
TO P OR N RANGE.
2. TOUCH STARTAND
START ENGINE
IMMEDIATELY.
OK
I NEXT II START
00 1. Turn ignition switch "ON".
2. Perform "START SIGNAL
CKT" in "FUNCTION TEST"
MEF481B
mode with CONSULT.
OR
m * MONITOR * NO FAIL 0 00 2. Check "START SIGNAL" in

"DATA MONITOR" mode with
CONSULT.
START SIGNAL OFF
CLSDTH/PSW ON IGN "ON" OFF
AIR COND SIG OFF IGN "START" ON
PIN POSI SW ON I
OR
1. Turn ignition switch to
"START".
terminal @ or @l and
~ __ RE_C_O_R_D_---,l ground.
SEF111P
Voltage:
Ignition switch "START"
~I)~ID Battery voltage

Except above
Approximately OV
II ECM B34
II
20
CONNECTOR
NG
NG
Check if 7.5A fuse is OK. Replace 7.5A fuse.
OK
@: For Australia
NG
34 : Except for Australia SEF231R CHECK INPUT SIGNAL CIRCUIT. Check the following.
2. Disconnect ECM harness connector (ID,@
~Io and 7.5A fuse.

short between ECM
II ECM ET
34 20
CONNECTOR II ECM terminal @ or @l and fuse
block.
and fuse block
If OK, check harness f<;>rshort.
OK
@: For Australia

nector and retest.
INSPECTION END
EC-140
Injector
EC-INJECT-01
Refer to EL-POWER.
(b): LHO models

G @: RHO models
rh @:
@:
•
OFF ST IGNITION Israle
SWITCH
'e- -: Detectable line
ACC
~ for DTC
-: Non-detectable
4J
SIR
line for DTC
SIR
~$ SIR
m r=b t= (EiOt)
<:BID I~I ~ <:BID
SIR SiR
1;>-1> .-----'.-----.-----
~m
ernl4=Jl
~.
SIR
I
SIR IG7'A\
rn~
l!::i=Jl@
t
SIR
I
rn4=B
I
INJECTOR
NO.1
2(EJ])
I
BIR
INJECTOR
NO.2
~2rn rn
4=B
BIR
INJECTOR
NO.3
fi1=i1 ~
4JJ
rn
BIR
4=B
2
INJECTOR
NO.4
(F21)
SIR SIR RIS Y/B GIB LIB
U RIB
rmru
I I
Y/B
In10iJ
I
G/B
11~31
LIB
I
11~21
INJ INJ INJ INJ ECM
#1 #2 #3 #4 (ECCS
CONTROL
MODULE)
ill)
~------------------~
, , Refer to last page
'FITm ~ I 1&1 (EJ]),rn,@,~ (Foldout page;J .
:rnrnID@~@@: @B B B B
:
L W W :
~
<:BID ~ I
rn'3456I 'fil ernW ~I

87654
,1f.I)@
W
HEC039
EC-141
Injector (Cont'd)
EC-IN0ECT-01
-: Detectable line
for OTC
Refer to EL-POWER. -: Non-detectable
line for DTC
IGNITION
SWITCH
'e- tEi7A\
AGG ON ~
~
BIR
1r$1~
BIR <:BID
4J@
B/R@
I
e----e----e----I
I I I
m m
BIR BIR BIR BIR
( ~ :1 No.1
INJECTOR OCI NO.2
INJECTOR INJECTOR
No.3 INJECTOR
NO.4
~ @ @ m
L4J
RIB
4J
Y/B
I4=!J
GIB
L4J
LIB
RIB
I I
Y/B
I
GIB
I
LIB
~ 11~71 11~41 h1~1
INJ INJ INJ INJ ECM
#1 #2 #3 #4 (EGGS
CONTROL
MODULE)
(ED
~~
rmrn W
(![~lifilCIT>
3456 W ~
~ ~,m,@,m
B B B B
Refer to last page
(Foldout page) .
101 102 103 104 105 106

107 108 109 110 111 112
113 114 115 116 117 118
HEC071
EC-142
Injector (Cont'd)
The fuel injector is a small, precise solenoid valve. When the
ECM supplies a ground to the injector circuit, the coil in the
injector is energized. The energized coil pulls the needle valve
back and allows fuel to flow through the injector into the intake
manifold. The amount of fuel injected depends upon the injec-
tion pulse duration. Pulse duration is the length of time the
injector remains open. The ECM controls the injection pulse
duration based on engine fuel needs.
SEF596K
===
• ACTIVE TEST.
••• POWER BALANCE •••
MONITOR
CMPS.RPM(REF)
MAS AIR/FL SEN
IACV-AAC/V
==
737rpm
098V
41%
D
=
INSPECTION START
CHECK OVERALL FUNCTION. OK

INSPECTION END
•
(F.I\1. Start engine.
~ 2. Perform "POWER BALANCE"
110Q]Q]~ in "ACTIVE TEST" mode with
CONSULT.
DDDDc:J MEF354F
3. Make sure that each circuit
produces a momentary engine
speed drop.
OR
fff\ 1. Start engine.
~7~
~ \)drJ
/~~ ~ 2. Listen to each injector operat-
At idle
Click ing sound.
Ct. Clicking noise should be
'~.+ heard.
--
/I
SEF730L 2. Disconnect injector harness connec- @,@or@,
tor. @
Fuel injector harness
connector 4. Check voltage between terminal @ @,CillD
II and ground with CONSULT or tester. • Harness for open or
Voltage: Battery voltage short between injector
and ignition switch
connectors.
AEC872
AEC755
EC-143
Injector (Cont'd)
r.ii3I For Australia @
~ ~15
1=' =E=CM=Ef CONNECTOR II 1 NG
CHECK OUTPUT SIGNAL CIRCUIT.
.102 • 107. 104. 109,
2. Disconnect ECM harness connector. short between ECM and
3. Check harness continuity between injector
injector harness connector terminal If NG, repair harness or
QLand ECM terminals GID, @, connectors.
(@:No.1 cylinder @:No.3cylinder @, CTID or 00, CIID, Gill, @).
@: No.2cylinder @: No.4cylinder Continuity should exist.
Except for Australia If OK, check harness for short.
II
~io
ECM'g CONNECTOR II CHECK COMPONENT
OK
NG Replace injector.
(Injector).
.101.110. 103.112 ,
below.
OK

@ :NO.1cylinder @: No.3cylinder nectors in the circuit. Then retest.
@:No.2cylinder @:No.4cylinder
SEF148R Trouble is not fixed.

and retest.
INSPECTION END
Injector
1. Disconnect injector harness connector.
2. Check resistance between terminals as shown in the figure.
Resistance: 10 - 140 [at 25°C (77°F)]
If NG, replace injector.
AEC559
EC-144
Fuel Pump
SYSTEM DESCRIPTION
Engine speed
Camshaft position sensor ECM
Fuel
(ECCS
pump
control
Start signal relay
Ignition switch module)
•
The ECM activates the fuel pump for several sec-
Condition Fuel pump operation
onds after the ignition switch is turned on to
improve engine startability. If the ECM receives Operates for
Ignition switch is turned to ON.
0
a 180 signal from the camshaft position sensor, 5 seconds
it knows that the engine is rotating, and causes Engine running and cranking Operates
0
the pump to perform. If the 180 signal is not
When engine is stopped Stops in 1 second
received when the ignition switch is on, the
engine stalls. The ECM stops pump operation Except as shown above Stops
and prevents battery discharging, thereby
improving safety. The ECM does not directly
drive the fuel pump. It controls the ON/OFF fuel
pump relay, which in turn controls the fuel pump.
A turbine type design fuel pump is used in the fuel tank.
AEC801
EC-145
Fuel Pump (Co nt' d)
EC-F/PUMP-01
IGNITION SWITCH
ON or START
FUSE
15A BLOCK Refer to EL-POWER.
ITZJ (JIB)
@: For Europe
<M:W @: Except for Europe
*1 : @ 106 , @ 104
/IN•61 I N.61 -: Detectable line
for DTC
IT
BIL B/W
-: Non-detectable
line for DTC
n PUMP
I~IFUEL
U RELAY
Ibi=JI~CMD
B/P B/Y
aID@)
I
------ B/Y ~ I- B/Y ------1
B/Y
m
lbi=Jl~
B
1
FUEL
FUEL TANK
B/P IG":4rn M PUMP GAUGE
r::b~ ~ UNIT
IIlJI CEID ~ <ell>
B/P lbi=Jl
B
I m~
B/P lbi=Jl
wrn
FPR ECM
(ECCS
CONTROL
MODULE)
,-,
B
I
B B
em -::!:- ~
~~
ACMD
T L
~@
rnrn W
~~
w.g; GY
rQ,~
L!J.gj
Refer to last page
(Foldout page) .
HEC040
EC-146
Fuel Pump (Conl'd)
EC-F/PUMP-01
IGNITION SWITCH
ON or START
-: Detectable line
for oTC
-: Non-detectable
FUSE Refer to EL-POWER. line for oTC
BLOCK
(J/B)
~
UN•51 I ~51
slL B/W
II!'I~In (UEL
~1bi=Jl@)
PUMP
U RELAY
•
s/P s/Y
1 s/Y -if] r s/Y -----1

(@ ([D
s/Y
ITil
~~
S
1
FUEL
FUEL TANK
s/P~ M PUMP GAUGE
r=:b~
~
UNIT
'Ill'
B/P
CEID ~
~
~
s
I
S/P ~
ITil~
m
,.
B
FPR ECM I
(ECCS
CONTROL
MODULE) B S
(ill -:!: ..L..
(J311) @
AQID
T L
~(@
tmJ W @
~
GY
~~
\J.l.SI
rQ,~
W£.J
Refer to last page
(Foldout page) .
101 102 103 104 105 106

107 108 109 110 111 112
113 114 115 116 117 118
HEC072
EC-147
Fuel Pump (Cont'd)
INSPECTION START
m
~
2. Pinch fuel feed hose with fingers.
Fuel pressure pulsation should be felt
on the fuel feed hose for 5 seconds
AEC884
after ignition switch is turned "ON".
Driver's dash lower NG
Ii)
--+ • 15A fuse
2. Disconnect fuel pump relay from relay • Harness for open or
box. short between fuse and
3. Turn ignition switch "ON". fuel pump relay
4. Check voltage between terminals G), If NG, repair harness or
@ and ground with CONSULTor connectors.
MEC266B tester.
~ DISCONNECT
OK
~ E~D [!]
CHECK POWER GROUND CIRCUIT. NG Check the following.
--.. • Harness connectors
2. Disconnect fuel pump harness con- @,CID
nector. • Harness connectors
3. Check harness continuity between @,@)
terminal @ and body ground, termi- • Harness for open or
nal G) and fuel pump relay connector short between fuel
SEF479P
terminal CID. pump and body ground
Continuity should exist. • Harness for open or
If OK, check harness for short. short between fuel
pump and fuel pump
OK
relay
connectors .
.
IE
CHECK OUTPUT SIGNAL CIRCUIT. NG Check the following.
Fuel pump harnessconnector 1. Disconnect ECM harness connector. • Harness connectors
0111 ~ MEC267BA 2. Check harness continuity between CID,@
ECM terminal @, @ or @ and • Harness for open or
fuel pump relay connector terminal short between ECM and
@. fuel pump relay
Continuity should exist. If NG, repair harness or
If OK, check harness for short. connectors.
OK
SEF4B7Q
EC-148
Fuel Pump (Cont'd)
~i5 @
II ECM
8
Ej'coNNECTORII
104 108 CHECK COMPONENT
1 NG Replace fuel pump relay.
(Fuel pump relay).
Refer to "Component Inspection" below.
OK
104 : Except for Europe and Australia CHECK COMPONENT NG Replace fuel pump.
106 : For Europe (Fuel pump).
8 : For Australia SEF149R Refer to "COMPONENT INSPECTION"
•
below.
Ii • ACTIVE TEST. D OK
FUEL PUMP RELAY ON Di!?connect and reconnect harness con-
= = = MONITOR --- nectors in the circuit. Then retest.

CMPS.RPM(REFj Orpm Trouble is not fixed.

I ON I_I OFF I
MEF309F
and retest.
INSPECTION END
= Fuel pump relay
Check continuity between terminals CID and CID.
Conditions Continuity
12V direct current supply
Yes
between terminals CD and @
No current supply No
If NG, replace relay.

SEF511P
-Fuel pump
1. Disconnect fuel pump harness connector.
Resistance: 0.2 - 5.0n [at 25°C (77°F)]
If NG, replace fuel pump.
EC-149

SYSTEM DESCRIPTION
Control (AAC) Valve
Engine speed

I Mass air flow sensor I

Engine coolant temperature sensor ~
I
Start signal
Ignition switch
I

~
I
Inhibitor switch (A/T models)/ Park/Neutral position

Neutral position switch (M/T models) ECM
(ECCS

Air conditioner operation control
module)
! IACV-AAC valve I
~ Battery voltage
I Battery
Vehicle speed
Cooling fan operation

Cooling fan relay
Electrical load
Load switch'
Blower fan operation

Blower fan switch
': Rear window defogger switch and headlamp switch.
This system automatically controls engine idle speed to a specified level. Idle speed is controlled
through fine adjustment of the amount of air which bypasses the throttle valve via IACV-AAC valve. The
IACV-AAC valve opens and closes (except for Europe and Israel), or repeats ON/OFF operation (for
Europe and Israel), according to the signal sent from the ECM. The camshaft position sensor detects
the actual engine speed and sends a signal to the ECM. The ECM then controls the IACV-AAC valve so
that engine speed coincides with the target value memorized in ECM. The target engine speed is the
lowest speed at which the engine can operate steadily. The optimum value stored in the ECM is deter-
mined by taking into consideration various engine conditions, such as during warm up, deceleration, and
engine load (air conditioner, power steering and cooling fan operation).
IACV-AAC valve - Except for Europe and Israel
The IACV-AAC valve is moved by open and close signals from
the ECM. When the open signal is sent to the valve, the amount
of air that will flow through the valve increases. The more air
that flows through the valve, the higher the idle speed. When
the close signal is sent to the valve. the amount of air
decreases.
EC-150
Control (AAC) Valve (Cont'd)
IACV-AAC valve - For Europe and Israel
The IACV-AAC valve is moved by ON/OFF pulses from the ECM.
The longer the ON pulse, the greater the amount of air that will
flow through the valve. The more air that flows through the
valve, the higher the idle speed.
EC-151
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS [EJ
EC-AAC/V-01

10A BLOCK
1251 (JIB)
~
IIN~91 @: For Europe and Israel
@: Except for @
BR
I -: Detectable line
~-------~ -:
for DTC
Non-detectable
line for DTC
BR BR
~T T@
@~ ~@
BR BR
m
~
BR
IACV-
AAC
VALVE
flQ): @
3
BR
IACV-
AAC
VALVE
QID:@
SB ~1!4J
~
PU/W 5B
SB PU/W 5B
Ii1t3n Ii1t3nffiru
I5C ISC ISC ECM
-C -0 (ECCS
CONTROL
MODULE)
(IT)
Refer to last page

(Foldout page) .
rn' 11fi] @
3456 W
(ill II~
4567B
@
W
~rn
@ BR
~@
~BR
HEC043
EC-152
TROUBLE DIAGNOSIS FOR NO~-DETECTABLE ITEMS []K]
EC-AAC/V-01

lOA BLOCK
1251 (JIB)
•
~
IIN;91
BR
.I
BR
_.
-:
Detectable
for DTC
line
Non-detectable
line for DTC
IrfJl@
BR
em
3
BR
I
IACV-
AAC
VALVE
CEID
4=Uli4=ll
~
PU/W 58
PU/W 58
~~
ISC ISC ECM
-c -0 (ECCS
CONTROL
MODULE)
em
Refer to last page

fIjl I I~ (IT)
3456 W
~CEID
~8R
(Foldout page) .
101 102 103 104 105 106

107 lOB 109 110 111 112
113 114 115 116 117 l1B
HEC075
EC-153
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS ffiJ
INSPECTION START
OK
1. Start engine and warm it up suffi-
ciently.
2. Check idle speed.
If NG, adjust idle speed.
~ 3.• Perform "AAC VALVE
~ ADJ" or "IACV-AACIV
ADJ" in "WORK
SUPPORT" mode with
CONSULT.
• Disconnect throttle posi-
tion sensor harness con-
nector.
4. Make sure that idle speed drops.
~ SEF142NC NG Check the following.

CHECK POWER SUPPLY.
Ii) 2. Disconnect IACV-AAC valve harness QD,@orQD,
connector. @
~i5~i5 3. Turn ignition switch "ON".

• 10A fuse
short between IACV-AAC
dfu CillffuID or G) and ground.
Voltage: Battery voltage valve and fuse
OK connectors.
CD : For Europe and Israel

NG
@ : Except for Europe and Israel 1. Turn ignition switch "OFF". nectors.
SEF233R
(ij\ 2. Reconnect IACV-AAC valve
~ harness connector and then
• IACV-AACNSYSTEM. start engine.
3. Perform "IACV-AACIV
LET ENGINEIDLE SYSTEM" in "FUNCTION
THEN TEST" mode with CONSULT.
TOUCHSTART OR
(AiC SW-UGHT SW OFF) (F.I\ 3. Perform "IACV-AACIV
~ OPENING" in "ACTIVE TEST"
mode with CONSULT.
OR
!:::=====mul=== M 2. Disconnect ECM harness con-
I NEXT" START I
MEF176E
~ nectar.
3. Check harness continuity
between ECM terminal (ill)
or @ and terminal @, ECM
• ACTIVETEST. o terminalGID
terminal @.
or @ and
IACV-AACN 34% Continuity should exist.

OPENING If OK, check harness for short.
========== MONITOR ==========
CMPS-RPM(REF) 712rpm OK
MASAIRIFLSE 1.13V @
COOLANTEMPtS 92°C
illU--illU
~[]fl[OOWN][Qill
SEF484Q
EC-154
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS [ill
[!J For Europe and Israel
1=1
~io
=E=CM=19'CONNECTORII
~io
cffu
@
113 CHECK COMPONENT NG Replace IACV-AAC valve.

(IACV-AAC valve).
below.
Except for Europe and Israel OK
~io
•
II Trouble is not fixed.

nector and retest.
SEF150R
IACV-AAC valve - Except for Europe and Israel
Disconnect IACV-AAC valve harness connector.
• Check resistance between terminals @ and CID, CID and
@.
Resistance:
50 - 1000 [at 25°C (7rF)]
AEC845
IACV-AAC VALVE - For Europe and Israel

• Check IACV-AAC valve resistance.
Resistance:
Approximately 100 [at 25°C (77°F))
• Check plunger for seizing or sticking.
EC-155
Cooling Fan Control

SYSTEM DESCRIPTION
Vehicle speed
EGM
Gooling
Engine coolant temperature (EGGS
Engine coolant temperature sensor fan
control
relay(s)
module)

MIT MODELS
The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, and
air conditioner ON signal. The control system has 2-step control [ON/OFF].
Operation
For Europe with daytime light system
Air conditioner switch Is "OFF". ~ iL Air conditioner switch Is "ON".

E~
::J 0 /,
~Z; :v () /'/"
!~~ 11'l1/1~~~
2io 100 (212) 0.0
E E
~ ~
95 (203)
95 (203)
~
'0
o
o
Gl
r r
c 20 80 .~ 20 80
'0>
c
w
(12) (50) ill (12) (50)
Vehicle speed km/h (MPH) Vehicle speed km/h (MPH)
D :Cooling fans do not operate. EZ2l : Cooling fans operate.
SEF902P
For Europe without daytime light system and Australia
Gl_ Air conditioner switch Is "OFF", Air conditioner switch Is "ON",

., -
2~
:v0.0() 105 (221)
E
~
95 (203) 100 (212)
~
'0 91 (196)
o
o
Gl
c 20 80
'0> 20 80
c (12) (50) (12) (50)
w
D :Cooling fans do not operate. ~ : Cooling fans operate. SEF649MB
EC-156
Cooling Fan Control (Cont'd)
AIT MODELS
The ECM controls the cooling fan corresponding to thevehicle speed, engine coolant temperature, and
air conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF],
Operation
For Europe with daytime light system
Air conditioner switch Is "OFF". ~ iL Air conditioner switch Is "ON".

::J 0
105 (221) e;-

~o
105 (221)
100 (212) E 100 (212)
~
•
C 95 (203) C 95 (203)
<tl <tl
'0 '0
o o
() ()
Q) Q)
c
'0> ~ 00 i 00~
c
UJ (12) (50) tD (12) (50)
o: Cooling fans do not operate. ~: Cooling fans operate at "Low" speed. ~: Cooling fans operate at "High" speed.
SEF904P
For Europe without daytime light system and Australia
Air conditioner switch Is "OFF". ~~ Air conditioner switch is "ON",

::J 0
(;j-
105 (221) 0 105 (221)
....
~o
100 (212) E 100 (212)
2
95 (203) C 95 (203)
~ <tl
'0 '0
o 91 (196) o
()
()
Q) Q)
c
'0> ~ 00 i 00~
c (12) (50) tD (12) (50)
UJ
o: Cooling fans do not operate. l22a: Cooling fans operate at "Low" speed. ~: Cooling fans operate at "High" speed.
SEF905P
EC-157
EC-COOL/F-01
IGNITION SWITCH BATTERY (Via
ON or START fusible link)
(1): LHD models
(8): RHO models
FUSE Refer to
10A BLOCK EL-POWER. @: LHD AIT models
30A for Europe without
1251 (JIB)
daytime light system
(E106) IT]
@: Except @
IQ~OI GY
BR
9-I--@-------------
-
t:}
I -
-----0--<\])---------- GY
BR ~
Next page
I!' '$1
SR
lki=U~rn>
GY
nU FAN
COOLING
RELAY-1
LG/R G/B
I ' --------0--<1»-------
.. G/B -i9> Next page
00 L~
1$ ~ (E10t)
T---
G~B G!B
1I1¥J1 I~I rFh m
<BID LG/R LG/R <BID ~ COOLING
FAN
~ COOLING
FAN
~ M MOTOR-1 M MOTOR-2
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~ 0 ~ ll4JI
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I B B
I------~-= -@>
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m
RFRL
ldoll
RFRH
ECM
(ECCS
-: Detectable
for DTC
line
MODULE) line for DTC
I
-----------CED
Refer to last page
(Foldout page) .
+2
5
1
@
L
@)
W @
@~
GY , GY
<BID , (E10t)
(E106)
HEC044
EC-158
EC-COOL/F-02
Preceding {: ::
-
~L:.. @: LHD A/T models
for Europe without
page _
<&SR~ @: Except@
-: Detectable line
II!II~II:!
SR GY LG/S
for DTC
-: Non-detectable
rI
•
line for DTC
COOLING
~~~AY-2 ~ ~
I4J
IGCB_ -j--T=====I,
rn:@ ~ ~
(E10f) n l!F Ii GIS G/Y GIS G/Y

CHIDLG IcP~- t~1 :~~~ IcP~- ~$I :~~~
t GIS G/Y GIS G/Y
LG
I rt=n
La
m Hi COOLING
rm m
La Hi COOLING
(M49) II : II (+) (+) FAN (+) (+) FAN
@ 6 MOTOR-1 MOTOR-2
Hi La (E303): /LA' Hi L ~ /i'"A'..
LG H (-) ~ H (~ ~: ~
~ ~ ~ ~
LG/B B LG/B B
IYJr - -1$1(E3Ot)
~
iCiJr- i$1 (E302)
<rn>
.!_! -
LG/B S LG/B
I ~
B
----0------0-'.
B B
-!- -!-
~ (E51)
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(Foldout page) .
<BID , (El0t)
lmf
2
57
3 6
rn
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~
\mJ
@
GY ,
@Z)
GY ,
(E303)
GY ,
(E304)
GY
HEC045
EC-159
Cooling Fan Control (Cant' d)
EC-COOL/F-01
IGNITION SWITCH BATTERY (Via
ON or START fusible link)
@: AIT models
FUSE Refer to EL-POWER. <H>: M/T modeIs
10A BLOCK 30A <ID: Models with
1251 (JIB)
(Ei06) o air conditioner
IQ~OI GY
BR -
<}- I-(A)--------------
O--cF)---------
I
::t} Next page
II!I~ I
BR GY
n FAN
COOLING
u RELAY-1
~~~
I ..'--------0---<:£)-------
LG/R G/B
G/B ~ Next page
LG/R
Utili (Ei0!)
2rL CHID
~
'-----1
(~II (il
G/B G/B
LG1/R FAN
COOLING FAN
COOLING
M MOTOR-1 M MOTOR-2
LG/R ~: <ID ~: <ID
Iml (M49) U4=!J U4=!J <ID
+@ B B
LG1/R I
."-...-:(£))01-----------
~ :
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LG
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Next page
LG/R LG
rIT4iJ 1r@1 ECM _. Oetectab Ie line
RFRL RFRH (ECCS for DTC
MODULE) line for OTC
------------ I <:ED
+2
~ 5
1 L clli:> ~~
GY , GY
Refer to last page
(Foldout page) .
@ (EIOn
~
,
101 102 103 104 105 106

107 108 109 110 111 112
113 114 115 116 117 118
HEC076
EC-160
EC-COOL/F-02
Preceding
page {: :: ~A
-
_•
@: A/T models
~SR~
@: MIT models
SR GY LG/S
@: Models with
II!I~nII~n I air conditioner

COOLING
FAN
RELAY-2
@: @ I!4=Jl Ibi=Jl
LG
I L
G/Y
U
4J
8
U
-:
-:
Detectable line
for DTC
Non-detectable
line for DTC
,
•
CBID I!I
~r=b, LG _ I
1- -----
LG
It GIS
mm
La
G/Y
Hi COOLING COOLING
@ r=b, (+) (+) FAN FAN
@1'4J1 MOTOR-1 MOTOR-2
LG ~:<:D ~:<:D
@
<€}- LG A
.....
-
Preceding A A A
page
<m- -<ID 0 0
,-,
0
S
1
S 8
-!- ~
<m (E51)
Refer to last page

(Foldout page) .
if57
36
ID
SR
~~,~
3 4 GY GY
CHID , (ElOO
HEeD??
EC-161
m With air conditioner DIAGNOSTIC PROCEDURE
Coolingfan
INSPECTION START
CHECK COOLING FAN LOW SPEED NG Check cooling fan low

OPERATION. speed control circuit.
I With air conditioner I (Go to
1. Start engine. I PROCEDURE A I.)
2. Set temperature lever at full cold
Without air conditioner position.
Coolingfan
3. Turn air conditioner switch "ON".
4. Turn blower fan switch "ON".
5. Run engine at idle for a few minutes
with air conditioner operating.
6. Make sure that cooling fan operates
at low speed.
I Without air conditioner I
1. Start engine.
2. Keep engine speed at about 2,000
MEC340B rpm until engine is warmed up suffi-
ciently.
3. Make sure that cooling fan begins to
Coolingfan operate at low speed during warm-
Engine coolant
up.
~ ~ ~a~~:;:t:a::;'~~' OK
~~ eN
Q
lDoo CHECK COOLING FAN HIGH SPEED NG Check cooling fan high
150n Resistor
~ ~ OPERATION. speed control circuit.
~ ~ 1. Turn air conditioner switch "OFF". (Go to
SEF492Q 2. Turn blower fan switch "OFF". IPROCEDURE B I.)
(Steps 1) and 2) are only performed
for models with air conditioner.)
3. Stop engine.
4. Disconnect engine coolant tempera-
ture sensor harness connector.
5. Connect 1500 resistor to engine cool-
ant temperature sensor. harness con-
nector.
6. Restart engine and make sure that
cooling fan operates at high speed.
OK
INSPECTION END
EC-162
PROCEDURE A
INSPECTIONSTART

SEF193R
1. Stop engine. • 10A fuse
•
2. Disconnect cooling fan relay-1. • 30A fusible link
3. Turn ignition switch "ON". • Harness for open or
4. Check voltage between terminals G), short between cooling
@ and ground. fan relay-1 and fuse
Voltage: Battery voltage • Harness for open or
short between cooling
OK
fan relay-1 and battery
connectors.
MEC342B
CHECK GROUND CIRCUIT. NG Repair harness or con-
2. Disconnect cooling fan motor-1 har-
ness connector and cooling fan
motor-2 harness connector.
I!l 3. Check harness continuity
between terminal CD and termi-
nal @.
Ii 4. Check harness continuity
between terminal @ and body
ground or terminal @ and body
ground.
OK
EC-163
@
Ii 1
~
1. Disconnect ECM harness connector. • Harness connectors
2. Check harness continuity between aD,@
ECM terminal @ or @ and terminal • Harness connectors
@. @,@D
OK Ian relay-1 and ECM
connectors.
NG
CHECK COMPONENT Replace cooling fan
---+
(Cooling fan relay-1). relay.
Refer to "COMPONENT INSPECTION".
(See page EC-167.)
OK
[!1
* 1 : 2-step control models CHECK COMPONENTS
NG
Replace cooling fan
* 2 : 3-step control models SEF195R (Cooling fan motors-1 and -2).
---+
motors.
00 1. Reconnect cooling fan relay-1,

cooling fan motor harness
connectors and ECM harness
connector.
3. Perform "COOLING FAN
CIRCUIT" in "FUNCTION
TEST" mode with CONSULT.
OR
* 1 : 2-step control models

00 3. Perform "COOLING FAN" in
"ACTIVE TEST" mode with
* 2 : 3-step control models SEF175R

CONSULT.
OR
Ii @ Refer to " COMPONENT
~i5 INSPECTION". (See page

EC-167.)
II ECM
9
ECONNEc@1
14
OK

nectors in the circuit. Then. retest.
@: For Australia Check ECM pin terminals for damage

(2): Except lor Australia SEF234R or the connection 01 ECM harness con-
nector and retest.
• COOLING FAN CIRCUIT.
DOES
COOLING FAN INSPECTION END
ROTATE AND STOP
EVERY 3 SECONDS ?
NEXT II NO 11 YES I
MEF311F
EC-164
• ACTIVE TEST. o PROCEDURE B
COOLING FAN OFF

INSPECTIONSTART
= = = MONITOR = = =
COOLAN TEMP/S 88°C
1:1
NG
CHECK POWER SUPPLY.
1. Stop engine.
----.. Check the following.
2. Disconnect cooling fan relay-2. short between cooling
3. Turn ignition switch "ON". fan relay-2 and fuse
•
4. Check voltage between terminals G), • Harness for open or
@ and ground. short between cooling
Voltage: Battery voltage fan relay-2 and fusible
. link
OK
connectors.
NG
----.. Repair harness or con-
nectors.
1:1 o 3. Check harness continuity
~i5 3
between terminal @ and termi-
nal @.
7 5
~2 1 If OK, check harness for short.
II 4. Check harness continuity
nal @, terminal (!) and body
ground.
MEC346B
OK
II
NG
----.. Check the following.
2. Check harness continuity between @,@
ECM terminal @ or @l and terminal • Harness connectors
@. @,@D
If OK, check harness for short. short between ECM
and cooling fan relay-2
OK
connectors.
EC-165
o @
~i5 CHECK COMPONENT NG Replace cooling fan

~-
m=m (Cooling fan relay-2).
relay.
on next page.
OK
SEF226R
II
CHECK COMPONENTS NG Replace cooling fan
~ IDlsco~
~i5 I...s1 0
(Cooling fan motors-1 and -2).
~ 1. Rec~nnect cooling fan relay-2,
motors.
:~ ~ \J!} cooling fan motor harness

rn=m QW connectors, engine coolant
temperature sensor harness
connector and ECM harness
connector.
SEF227R
OR
~i5 ~i5 00 3
3. Perform "COOLING FAN" in
II ECM
13
El'CONNECTORII
10 Jm1 2
7 5
1
~
CONSULT.
OR
Refer to " COMPONENT
~ INSPECTION" on next page.
OK
@: For Australia
II • COOLING FAN CIRCUIT. Trouble is not fixed .
DOES Check ECM pin terminals for damage

COOLING FAN
ROTATE AND STOP nector and retest.
EVERY 3 SECONDS 7
NEXT II NO II YES I
MEF311F
INSPECTION END
II • ACTIVE TEST.
COOLING FAN OFF
== = MONITOR ---
ggoC
COOLAN TEMPjS
CJ5_N_I~ MEF312F
EC-166
= Cooling fan relay-1
Check continuity between terminals @ and CID.
12V direct current supply between

Yes
terminals G) and @
SEF511P
Cooling fan relay-2

Check continuity between terminals
Conditions
between terminals G) and @
@ and CID, @ and (f).
Continuity
Yes
•

SEC2028
Cooling fan motors-1 and -2

MIl models:
1. Disconnect cooling fan motor harness connectors.
2. Supply cooling fan motor terminals with battery voltage and
check operation.
Terminals
(EB) (8)
Cooling fan
SEF499QA motor
Cooling fan motor should operate.

If NG, replace cooling fan motor.
EC-167
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS @]
~ IDISCD~ AfT models for Australia and LHD AfT models for Europe with-
~ c'J out daytime light system
check operation.
Terminals
Speed
(EB) (8)
Cooling fan Low G) @
SEF500QA motor-1 High @ @

motor-2 High @ @

EC-168
Power Steering Oil Pressure Switch
EC-PST/SW-01
ECM
(ECCS (0: LHD models
CONTROL
MODULE) @: RHO models
PWST em @: LHD models with ABS or
dual air bag or rear door
1~31 power window
PU/W <fID : LHO models except @
I
•
-: Detectable line
for DTC
-: Non-detectable
PU/W line for DTC
14J1<m
~
PU/W
+~--------~'-@--------I
I
PU/W PU/W
1$11 (El0n
CHID 1c}J1~(8113)
PU/W PU/W
rh rh
POWER STEERING POWER STEERING POWER STEERING
ON OIL PRESSURE ON OIL PRESSURE ON OIL PRESSURE
SWITCH SWITCH SWITCH
OFF.....--
@:@ ~: <fID OFF.....-- (8102): @
~ ~ ~
B B B
+
O~ J
~
,.
B
~
B
,.
I
~
B B
~
m (E51) @~
Refer to last page

(Foldout page) .
~
W
,..Q...
UJ.g)
@ ~ (8102)
GY , GY , GY
ffiIl' I lfij
45678
(8113)
W
CHID , (El0n
HEC046
EC-169
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS @J
Power Steering Oil Pressure Switch (Cont'd)
EC-PST/SW-01
ECM
(ECCS
CONTROL -: Detectable line
MODULE) for DTC
PWST
(IT) -: Non-detectable
line for DTC
12•51
PU/W
I
PU/W
Iml@
=r~
PU/W
I
PU/W
1$11 <BID
~
PU/W
I
POWER STEERING
ON OIL PRESSURE
SWITCH
OFF'--- @
~
B
I
,-,
B B
..L. ..L.
do ~1)
Refer to last page

(Foldout page) .
~@
W,g) GY <BID ,m
101 102 103 104 105 106

107 108 109 110 111 112
113 114 115 116 117 118
HEC078
EC.170
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS @[]
Power steering oil ___ COMPONENT DESCRIPTION
pressure switch
- ~ The power steering oil pressure switch is attached to the power
to steering high-pressure tube and detects a power steering load.
When a power steering load is detected, it signals the ECM. The
ECM adjusts the IACV-AAC valve to increase the idle speed and
adjust for the increased load.
• PW/ST SIGNAL CIRCUIT.
HOLD STEERING WHEEL
LOCKED
IN A FULL
THEN
POSITION
INSPECTION START
CHECK OVERALL FUNCTION. OK INSPECTION END

•
TOUCH START fiii\ 1. Turn ignition switch "ON".
~ 2. Perform "PW/ST SIGNAL
NEXT II START CIRCUIT" in "FUNCTION
MEF023E
OR
(F.i\ 1. Start engine.
* MONITOR * NO FAIL 0 ~ 2. Check "PW/ST SIGNAL" in
PW/ST SIGNAL OFF
CONSULT.
Steering is in neutral
position:
OFF
Steering is turned:
ON
RECORD OR
SEF591I 1. Start engine.
terminal @ or @ and ground.
~i)~ Voltage:
When steering wheel is
II ECM
43
Ef
25
CONNECTOR II turned quickly.
Approximately OV
Except above
Approximately 5V
NG
@): For Australia

EC-171
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS @K]
@

1 Repair harness or con-
2. Disconnect power steering oil pres-
sure switch harness connector.
AEC760 If OK, check harness for short.
~i5 ~i5 [i
II ECM Ef CONNECTOR II c:ITb CHECK INPUT SIGNAL CIRCUIT.
NG
......---.. Check the following .
43 25
2. Check harness continuity between aD, (MID
ECM terminal @ or @ and terminal • Harness connectors
G). @,@or@,
Continuity should exist. <!ill)
If OK, check harness for short. • Harness for open or
@: For Australia short between ECM and
OK
power steering oil pres-
sure switch
connectors.
NG
CHECK COMPONENT
(Power steering oil pressure switch).
--... Replace power steering
oil pressure switch.
below.
OK


and retest.
INSPECTION END
[At IV ID Power steering oil pressure switch

1. Disconnect power steering oil pressure switch harness con-
nector then start engine.
2. Check continuity between terminals <D and @.
Steering wheel is being turned Yes

~ Steering wheel is not being turned No
AEC762
If NG, replace power steering oil pressure switch.
EC-172
Park/Neutral Position Switch
EC-PNP/SW-01
reM
(ECCS
CONTROL
MODULE)
NEUT
CED <D: LHD models
I~I
G/OR
: RHO mode1s
<:A>:
I¥J'@ ~
<E>:
A/T mode1s
M/T models
G/OR @: For Europe and Israel
•
I @: Except @
@: A/T models except for
Europe and Israel
<!>
G/OR
<!>
G/OR
@:
*1"'@1
Except @
, @2
1$1 ~~~1) 1$1~~~1) *2"'@1
-:
, @6
Detectable line
G/OR G/OR for DTC
*_.I _T ~(E201)
-: Non-detectable
line for OTC
O--<D--- G/DR ~ G/OR ---
t
G/DR
I[b (E23) ..
• INHIBITOR
1 SWITCH
=r='@QD ...- 2 W>: <:A>
G/DR
m NEUTRAL
N
l4=Jl
0
POSITION B
SWITCH
OTHER - ~ @:<E>
4J
,.
B A
(E20f) ~
I--------(H)-O- B ~ B
B B
~ ~
@rn
Refer to last page

(Foldout page) .
~ (E20t) ~ (E222) <BID ,(E10t)
~ B ~ GY
HEC047
EC-173
Park/Neutral Position Switch (Cont'd)
EC-PNP/SW-01
ECM
(ECCS
CONTROL
MODULE) ill : AIT models
NEUT (IT) @: MIT models
-: Detectable line
12•21 fa/"'DTC
G/OR -: Non-detectable
I line for DTC
G/OR
1$11 @
CEID
G/OR
1$1 ~<BID
G/OR
I
O-<D--- G/OR
~@D
-ca G/OR ---
t
G/OR
[b,~ P __
• INHIBITOR
.. 1 SWITCH
=r@D
G/OR R N--D 2 ~: ill
I
G/OR l4=Jl
m B
I
OTHER --
NEUTRAL
POSITION
SWITCH
(E220): @
Qj: B
<f
-cM>--O--'-, B B
~ ~
~ @D
Refer to last page

(Foldout page) .
~ (222) fTIffiI<E"W CHID ,(E10t)
~ GY ~B
101 102 103 104 105 106

107 108 109 110 111 112
113 114 115 116 117 118
HEC079
EC-174
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS @J
Park/Neutral Position Switch (Co nt' d)
When the gear position is "P" (A/T models only) or "N", parkl
neutral position switch is "ON",
ECM detects the park/neutral position when continuity with
ground exists,
• NEUTRAL SW CIRCUIT.
OUT OF
SHIFT
NIP-RANGE
THEN
INSPECTION START
•
TOUCH START
OK
__ II START (ijJ\ 1. Turn ignition switch "ON".
SEF206L
~ 2. Perform "NEUTRAL SW
CIRCUIT" or "NEUTRAL POSI
SW CKT" in "FUNCTION
i,MONITOR *NO FAIL 0 TEST" mode with CONSULT.
OR
START SIGNAL ON rF.I\ 2. Check "NEUTRAL SW" or
CLOSED TH/POS ON ~ "NEUT POSI SW" signal in
/lIR COND SIG OFF
NEUT POSI SW ON
CONSULT.
Neutral position: ON
Except above: OFF
OR
fff\ 1. Set shift lever to the neutral
[ RECORD ~ position.
MEF983E
2. Disconnect ECM harness con-
nector.
~ CONNECT ~ JA between ECM terminal @ or
L41E)~~ @ and body ground.
1=1 =E=CM~ECONNECTOR!' If OK, check harness for short.
35 22
NG
Turn ignition switch "OFF".
@: Fo' Australia
@: Except for Australia SEF236R r:'I
.;,
1. Disconnect neutral position switch • Harness connectors
harness connector. @,(@)
2. Check harness continuity between • Harness for open or
terminal @ and body ground. short between neutral
Continuity should exist. position switch and
If OK, check harness for short. body ground
OK connectors.
SEF5020
EC-175
~io ~iV @
Il ECM E[coNNECTORII m Disconnect ECM harness con-

35 22
nector.
NG
CHECK INPUT SIGNAL CIRCUIT. Check the following.
@: For Australia 1. Check harness continuity between • Harness connectors
ECM terminal @ or @ and terminal @,@
35 : Except for Australia SEF177R
CD. • Harness connectors
Continuity should exist. @,@!)
If OK, check harness for short. • Harness connectors
@),CmD
OK • Harness for open or
short between ECM
and neutral position
switch
" NG, repair harness or
connectors.
NG
CHECK COMPONENT Replace neutral position
(Neutral position switch). switch.
Refer to "Check of Position Switch" of
"ON-VEHICLE SERVICE" in MT section.
OK


nector and retest.
INSPECTION END
EC-176
• PARKJNEUTPOSI SW CKT • Inhibitor switch
SHIFT
INSPECTION START
OUT OF NIP-POSITION
THEN
TOUCH START
1!1
OK
(ij\ 1. Turn ignition switch "ON".
I NEXT II__ ST:_A_RT

__ I
MEC7318
~ 2. Perform "NEUTRAL POSI SW
CKT" in "FUNCTION TEST"
•
mode with CONSULT.
OR
~rMONITOR ~NO FAIL 0 rF.I\ 2. Check "NEUTRAL SW" or
SlART SIGNAL ON ~ "NEUT POSI SW" signal in
CLOSED TH/POS ON "DATA MONITOR" mode with
'!\IR COND SIG OFF CONSULT.
NEUT POSI SW ON
"N" or "P": ON
Except above: OFF
OR
1. Shift selector lever to "P"
position.
[ RECORD
2. Disconnect ECM harness con-
MEF983E nector.
~i5@a between ECM terminal @ or

@ and body ground.
II ECM 19' CONNECTOR TI

If OK, check harness for short
G ...._ CD 35 22 4. Shift selector lever to "N"
position.
between ECM terminal @ or
~~ @ and body ground.
@ : For Australia
@ : Except for Australia SEF178R
NG
~io@a Turn ignition switch "OFF"
6iB
1. Disconnect inhibitor switch harness • Harness connectors
connector. @D,@])
terminal G) and body ground. short between inhibitor
SEF228R
Continuity should exist. switch and body ground
connectors.
OK
Disconnect ECM harness con-

nector.
EC-177
iii
~i5 ~i5
II ECM
35
E
22
CONNECTOR II Effij iii
NG
1. Check harness continuity between • Harness connectors
ECM terminal @ or @ and terminal QD,@)
@. • Harness connectors
Continuity should exist. @,@D
@: For Australia
@),@D
@: Except for Australia SEF237R OK • Harness for open or
short between ECM
and inhibitor switch
connectors.
NG
CHECK COMPONENT Replace inhibitor switch.
(Inhibitor switch).
Refer to "Electrical Components
Inspection" of "TROUBLE DIAGNOSES"
in AT section.
OK

Check ECMpin terminals for damage

nector and retest.
INSPECTION END
EC-178
EVAP Canister Purge Control Solenoid Valve

GA16DE MIT models except for Europe, Israel and
Australia
SYSTEM DESCRIPTION
Camshaft position sensor Engine speed
•
Amount of intake air ECM
Mass air flow sensor EVAP canister
(ECCS
purge control
control
Throttle position sensor Throttle position solenoid valve
module)
Ignition switch Start signal
This system cuts and controls the port vacuum This causes the port vacuum to be discharged
applied to the EVAP canister purge control sole- into the atmosphere so that the EVAP canister
noid valve to suit engine operating conditions. purge line remains closed.
This cut-and-control operation is accomplished • Engine starting
through the ECM. When the ECM detects any of • Closed throttle position
the following conditions, current flows through • Low and high engine coolant temperature
the solenoid valve in the EVAP canister purge • During deceleration
control solenoid valve control vacuum line. • Engine stopped
• Vehicle speed: below 10 km/h (6 MPH)
• Mass air flow sensor malfunction
The EVAP canister purge control solenoid valve responds to
signals from the ECM. When the ECM sends an ON (ground)
signal, the coil in the solenoid valve is energized. A plunger will
W> then move to cut the vacuum signal (from the intake manifc,ld
Vacuum to the EVAP canister purge control solenoid valve).
signal
When the ECM sends an OFF signal, the vacuum signal passes
through the solenoid valve. The signal then reaches the EVAP
canister purge control solenoid valve.
SEF240PG
EC-179
(Cont'd)
MIl models except for Europe and Israel
EC-PGC/V-01
IGNITION SWITCH
ON or START

10A BLOCK
1251 (JIB)
~
_. Detectable line
for DTC
-: Non-detectable
line for DTC
BR
IlIDl
',=@
<MW
BR
BR
I
OCIEVAP
PURGE CANISTER
CONTROL
SOLENOID VALVE
'4=JlCW
P
~
I
P
PURGE ECM
(ECCS
CONTROL
MODULE)
. (ill
Refer to last page

(Foldout page) .
~cm fmjl I I~ CEID
a:IID G 45678 W
HEC041
EC-180
(Cont'd)
INSPECTION START
m
CHECK VACUUM SOURCE TO EVAP OK CHECK COMPONENT
CANISTER.
L---. (EVAP canister).
1. Jack up drive wheels. (See page EC-29.)
MEC296BB 2. Start engine and warm it up suffi- If NG, replace EVAP can-
•
ciently. ister.
~i5
ECMB CONNECTOR II
3. Perform diagnostic test mode II (Self-
diagnostic results). Make sure that
9iagnostic trouble code No. 55 is dis-
played.
4. Disconnect vacuum hose to EVAP
'f ~VV1 canister.

5. Set shift lever to 1st position.
6. Make sure that vacuum exists under
the following conditions.
At Idle:
MEC325B Vacuum should not exist.
Racing engine from Idle to 3,000 rpm:
Vacuum should exist.
~ Crack NG
Ii) [!J
CHECK CONTROL FUNCTION. OK Check vacuum hose for
Clogging
1. Check voltage between ECM terminal
--.. clogging, cracks or
@ and ground with CONSULTor improper connection.
=:5---
tester under the following conditions.
~ Improper connection Voltage:
SEF816F
At idle
Approximately OV
Engine speed is about 2,000 rpm
Battery voltage
~i5 NG
I!l
1. Stop engine.
I-----. • Harness connectors
2. Disconnect EVAP canister purge con- QD,@
~ trol solenoid valve harness connector. • 10A fuse
SEF488Q 4. Check voltage between terminal @ short between EVAP
and ground with CONSULTor tester. canister purge control
Voltage: Battery voltage solenoid valve and fuse
@
r K
connectors.
EC-181
(Cont'd) @
~io ~io 1
II ECM E
105
CONNECTOR II dfu CHECK OUTPUT SIGNAL CIRCUIT.
nectors.
ECM terminal Gill and terminal G).
SEF489Q If OK, check harness for short.
OK
CHECK COMPONENT NG Replace EVAP canister

(EVAP canister purge control solenoid purge control solenoid
valve). valve.
OK


and retest.
INSPECTION END
EVAP canister purge control solenoid valve
Check air passage continuity.
Air passage Air passage

Condition . continuity continuity
between @ and CID between @ and @
12V direct current sup-

ply between terminals Yes No
MEC488B G) and @
No supply No Yes
If NG, replace solenoid valve.
EC-182
EGR Valve and EVAP Canister Purge Control

Solenoid Valve
For Europe, Israel and Australia, and GA 15DE MIT
models
SYSTEM DESCRIPTION
•
Amount of intake air ECM EGR valve &
(ECCS EVAP canister
control purge control
module) solenoid valve
Ignition switch Start signal
This system cuts and controls the port vacuum This causes the port vacuum to be discharged
applied to the EGR valve and EVAP canister into the atmosphere so that the EGR valve and
purge control solenoid valve to suit engine oper- EVAP canister purge line remains closed.
ating conditions. • Engine starting
This cut-and-control operation is accomplished • Closed throttle position
through the ECM. When the ECM detects any of • Low and high engine coolant temperature
the following conditions, current flows through • During deceleration
the solenoid valve in the EGR valve and EVAP • Engine stopped
canister purge control solenoid valve control vac- • Vehicle speed: below 10 km/h (6 MPH)
uum line. • Mass air flow sensor malfunction
Exhaust gas recirculation (EGR) valve
The EGR valve controls the amount of exhaust gas routed to the
intake manifold. Vacuum is applied to the EGR valve in
response to throttle valve opening. The vacuum controls the
movement of a taper valve connected to the vacuum diaphragm
in the EGR valve.
SEF783K
EGR valve and EVAP canister purge control solenoid

valve
The EGR valve and EVAP canister purge control solenoid valve
responds to signals from the ECM. When the ECM sends an ON
l# (ground) signal, the coil in the solenoid valve is energized. A
Intake
plunger will then move to cut the vacuum signal (from the throt-
manifold
vacuum tle body to the EGR valve and EVAP canister purge valve).
signal When the ECM sends an OFF signal, the vacuum signal passes
through the solenoid valve. The signal then reaches the EGR
valve and EVAP canister.
SEF240PF
EC-183
Solenoid Valve (Cont'd)
EC-EGRC/V-01

BLOCK
(JIB)
~
IN~91
BR
SR
dJ~
I -:
-:
Detectable line
for DTC
Non-detectable
line for DTC
~Cffi
SR
BR
I
([) EGR VALVE & EVAP
CANISTER PURGE
CONTROL SOLENOID
VALVE
I4=!ICW
P
I
p
~
EGR ECM
(ECCS
CONTROL
MODULE)
em
Refer to last page

(Foldout page) .
~CW
(ill) B B1~II(ij
3456 @W
HEC042
EC-184
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS @K]
EC-EGRC/V-01
IGNITION SWITCH
ON or START

10A BLOCK
1251
•
(JIB)
~
-: Detectable 1ine
for DTC
BR -: Non-detectable
IITJ,@ line for DTC
=r='@
BR
I
I!i
BR
EGR
EVAP VALVE
CANISTER
&
PURGE CONTROL
SOLENOID
II111 VALVE
=r=' <ll)
P
I
P
~
EGR ECM
(ECCS
CONTROL
MODULE)
em
till I Ifij em
3456 W
~(ffi
<II]) G
Refer to last page
(Foldout page) .
101 102 103 104 105 106

107 108 109 110 111 112
113 114 115 116 117 118
HEC074
EC-185
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS []K]
INSPECTION START
m
1) Jack up drive wheels. ~
Cf~H 2) Start engine and warm it up suffi-
MEF51BE ciently.
3) Perform diagnostic test mode II (Self-
diagnostic results).
Make sure that diagnostic trouble
code No. 55 is displayed.
4) Set the shift lever to 1st position.
5) Make sure that EGR valve spring
moves up and down (Use your fin-
ger) under the following conditions.
At idle:
SprIng does not move.
RacIng engIne from idle to 3,000
rpm:
Spring moves up and down.
NG
l!1
OK
CHECK VACUUM SOURCES TO EGR
VALVE AND EVAP CANISTER.
-----... CHECK COMPONENTS
(EGR valve, EGRC-BPT
1) Disconnect vacuum hoses to EGR valve and activated EVAP
valve and EVAP canister. canister).
2) Make sure that vacuum exists under Refer to "COMPONENT
the following conditions. INSPECTION". (See page
At idle: EC-188.)
Vacuum should not exist.
Racing engine from idle to 3,000 lNG
rpm:
~I) ~ID Vacuum should exist.
NG
Replace malfunctioning
component(s).
II ECM -gcoNNEcTORII ~ [!J I!l

103 105 ~.1 OK
CHECK CONTROL FUNCTION.
1) Check voltage between ECM terminal
----.. CHECK VACUUM HOSE.
1) Check vacuum hose
@ or GID and ground under the for clogging, cracks or
following conditions. improper connection.
Voltage:
@ : For Australia At Idle
@ : Except for Australia SEF179R
Approximately OV
~=.
Engine speed is 2,500 rpm
Battery voltage
Crack ~NG
Clogging
~
~ Improper connection
SEFB16F
EC-186
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS [QK]
~i8 @

1) Stop engine. • Harness connectors
~ 2) Disconnect EGR valve & EVAP canis- @,@
ter purge control solenoid valve har- • 10A fuse
SEF488Q ness connector. • Harness continuity
•
3) Turn ignition switch "ON". between EGR valve &
Ii 4) Check voltage between terminal @ EVAP canister purge
~i5 ~i8 and ground.

and fuse
II ECM ]gCONNECTORII dfu OK
103 105
connectors.
Ii
CHECK OUTPUT SIGNAL CIRCUIT. NG Repair harness or con-
@: For Australia 1) Turn ignition switch "OFF". nectors.
@: Except for Australia SEF238R 2) Disconnect ECM harness connector.
3) Check harness continuity between
ECM terminal Gill or @ and ter-
minal G).
OK
CHECK COMPONENT NG Replace EGR valve &

(EGR valve & EVAP canister purge con- EVAP canister purge con-
trol solenoid valve). trol solenoid valve.
OK


nector and retest.
INSPECTION END
EC-187
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS @KJ
EGR valve
Apply vacuum to EGR vacuum port with a hand vacuum pump.
EGR valve spring should lift.
If NG, replace EGR valve.
MEF137D
EGRC-BPT valve
1) Plug one of two ports of EGRC-BPT valve.
2) Vacuum from the other port and check for leakage while
applying a pressure above 0.981 kPa (100 mmH20, 3.94
inH20) from under EGRC-BPT valve.
3) If a leakage is noted, replace the valve.
+ Apply pressure
SEF083P
EGR valve and EVAP canister purge control solenoid

valve
Check air passage continuity.

Condition continuity continuity
between @ and @ between @ and @
12V direct current sup-

ply between terminals Yes No
G) and @
MEC4888
No supply No Yes
If NG, replace solenoid valve.
EC-188
Heated Oxygen Sensor (H02S)

EC-H02S-01
IGNITION SWITCH
ON or START

10A BLOCK
mJ (J/B)
•
~
IN~OI
BR/Y -: Detectable line
for DTC
.I -: Non-detectable
BR/Y line for OTC
I[~]I~
'=r='@
BR/Y
I
BR/Y
rn HEATED
OXYGEN
SENSOR
I4=Jl I4=Jl <rn>
- OR W
F -;
tl I
I
I
I
W.~-~In
I JOINT
I CONNECTOR-6
: @
OR
~ mn
02H 02S ECM
(Eg~iROL
MODULE)
B
I
..J
...1..
__
8
18
(IT) (ffi)(ffi)
Refer to last page

(Foldout page) .
Bjl
3456
Illjj @
W
~<rn>
~GY
~cw
[I[I]1]I[ill] GY
HEC048
EC-189
Heated Oxygen Sensor (H02S) (Co nt' d)
GA16DE for Australia (A/T models)
EC-H02S-01
IGNITION SWITCH
ON or START

10A BLOCK
rnJ (J/B)
~
IN~OI
BR/Y -: Detectable line
for DTC
I -: Non-detectable
BR/Y line for DTC
I$I~
@
BR/Y
I
BR/Y
rn HEATEO
OXYGEN
SENSOR
<0
~ Ibi=ll
- OR W
~ ;
tl I
I
I
I
W.~~~
I JOINT
I CONNECTOR-6
: CW
OR
uil5il
02H
rr16il
02S ECM
In
B B B
(~g~¥ROL
MODULE)
,_I.J
-L
1_
(IT) <ETI>~
Refer to last page

(Foldout page) .
~III'ti}
3456 @
W
~cw
IIITIIII[ll!] GY
101 102 103 104 105 106

107 108 109 110 111 112
113 114 115 116 117 118
HEeDBD
EC-190
Heated Oxygen Sensor (H02S) (Cont'd)
The heated oxygen sensor is placed into the exhaust manifold.
It detects the amount of oxygen in the exhaust gas compared
to the outside air. The heated oxygen sensor has a closed-end
tube made of ceramic zirconia. The zirconia generates voltage
from approximately 1V in richer conditions to av in leaner con-
ditions. The heated oxygen sensor signal is sent to the ECM.
The ECM adjusts the injection pulse duration to achieve the
ideal air-fuel ratio. The ideal air-fuel ratio occurs near the rad-
L Isolalion
Healer pad
Zirconia
ical change from 1V to av.
bearing tube
SEF406H
2:
:>
Q)
Ol
~
0
>
::;
1
•
c.
::;
0
0
Rich-
,,"--
Ideal ratio
Mixlure ratio
-_ Lean
SEF288D
m • MIXTURE RATIO TEST.

INSPECTION START
ACCELERATE TO 2000
RPM AND HOLD THEN
TOUCH START
OK
I£J
1800 2000 2200
CHECK OXYGEN SENSOR CIRCUIT.
1) Start engine and warm it up suffi-
ciently.
INSPECTION END
NEXT
II START ~J (F.i\ 2) Perform "MIXTURE RATIO
~ TEST" in "FUNCTION TEST"
SEF815L mode with CONSULT.
OR
m * MONITOR * NO FAIL D
(F.i\
~
2) Make sure that "M/R FIC
MNT" in "DATA MONITOR"
mode indicates "RICH" and
CMPS.RPM (REF) 2000rpm "LEAN" periodically more
MIR FIC MNT RICH than 5 times during 10 sec-
onds at 2,000 rpm.
OR
fti>\ 2) Stop engine and set ECM
~ Diagnostic Test Mode /I
(Heated oxygen sensor moni-
tor).
RECORD I
SEF522Q
3) Restart engine and run it at
about 2,000 rpm for about 2
........
e",/
4) Keep engine speed at 2,000
rpm and make sure that the
\ I / malfunction indicator lamp on
the instrument panel goes on
and off more than 5 times dur-
- CHECK- ing 10 seconds.
",/ ........ NG
/ I \ @
lamp
SEF051PA
EC-191
@
I;) 1 NG
1. Stop engine.
--. Repair harness or con-
nectors.
and heated oxygen sensor harness
connector.
~ 3. Check harness continuity between
ECM terminal @ or @ and terminal
@.
~ SEF180R
I;) ~i5 ~i5 1 0K
Il ECM 'QcoNNECTORII cilltD CHECK HEATED OXYGEN SENSOR
OK
--. Go to "CHECK
46 19
HEATER CIRCUIT. COMPONENT".
1. Reconnect harness connectors.
2. Start engine.
@ (For Europe and Israel) or @
(For Australia AfT models) and
@: For Australia NT models ground with CONSULTor tester
under the following conditions.
@: For Europe and Israel SEF181R
Voltage:
Engine speed is below 3,200 rpm
Approximately OV
Engine speed is above 3,200 rpm
Battery voltage
NG
[!J
NG
CHECK POWER SUPPLY. Check the following.
~
2. Disconnect heated oxygen sensor aD,@
harness connector. • 10A fuse
SEF646P
4. Check voltage between terminal @ short between heated
and ground. oxygen sensor and
For Europe and Israel, and GA15DE.L.J
Voltage: Battery voltage fuse
engine models Engine ground @, @
----- \ ~ ~ OK connectors.
\ '1
.~
NG
-----... Repair harness or con-
nectors.
3, Check harness continuity between
terminal G) and ECM terminal @
(For Europe and Israel) or Gill (For
Australia AfT models) .
tOK
,~\ C/
Power steering",
fluid reservoir __\ ~
W~ :'C"",,
EC-192
@

screws.
OK
NG
CHECK COMPONENT Replace heated oxygen
(Heated oxygen sensor heater). sensor.
below.
•
OK

ne~tors in the circuit. Then retest.

nector and retest.
Replace heated oxygen sensor.
Heated oxygen sensor heater
Check resistance between terminals @ and CD.
Resistance: 2.3 - 4.3Q at 25°C (77°F)
DISCONNECT Check continuity between terminals @ and CD, @ and @.
I~J Continuity should not exist.
If NG, replace the heated oxygen sensor.
CAUTION:
00 SEF586Q
• Discard any oxygen sensor which has been dropped from
a height of more than 0.5 m (19.7 in) onto a hard surface
such as a concrete floor; use a new one.
EC-193
Oxygen Sensor (02S)

EC-02S-01
_. Detectable line
ECM for DTC
(ECCS
MODULE) line for DTC
02S em
~
w
(- ....
~,------
1
1
I
I
I
1
1
I
I
I
1
1
I
1
I
I
1
rn
I JOINT
I
I
CONNECTOR-6
I @
I
I 1
I
I
I
1
I
I
-
- _I
n
-)
w
rn 8 8 8
OXYGEN
SENSOR
@ i.J
m m
1
~@
rn:II.ITIIillJ GY
HEC049
EC-194
Oxygen Sensor (02S) (Coni' d)
GA16DE for Australia (M/T models)
EC-02S-01
-: Detectable line
ECM for OTC
(ECCS
MODULE) line for OTC
~-
1
~
02S
1~61
-1
w
<ED
•
I I
I I
1 1
1 I
1 1
I I
1 I
1 I
I
I
I
I
I
1
1
1
rn
I JOINT
I CONNECTOR-6
1
I @
1
1 1
1
I
I
1 I
1 I
I I
1- _I
r
~
- )
w
m B
n
B B
~...J
1
OXYGEN
SENSOR
~ -!-
(F13) (F14)
-
~cw
ITIIIITill.IIJ GY
101 102 103 104 105 106

107 10B 109 110 111 112
113 114 115 116 117 llB
HEC081
EC-195
Oxygen Sensor (02S) (Cont'd)
Oxygen sensor The 028 is placed into the exhaust manifold. It detects the
Louver amount of oxygen in the exhaust gas compared to the outside
Zirconia tube air. The sensor has a closed-end tube made of ceramic zirco-
nia. The zirconia generates voltage from approximately 1V in
richer conditions to OVin leaner conditions. The sensor signal
Holder
Contact
Isolation
plate
r
Connector
bushing
is sent to the ECM. The ECM adjusts the injection pulse dura-
tion to achieve the ideal air-fuel ratio. The ideal air-fuel ratio
occurs near the radical change from 1V to OV.
AEC854
~
:>
Q)
OJ
.!!1
~
'5
0-
'5
o ,'--
o
_ Lean
Rich --- Ideal ratio
Mixture ratio
SEF288D
m • MIXTURE RATIOTEST.
ACCELERATETO 2CXXJ INSPECTION START

RPM AND HOLD THEN
TOUCH START
OK
CHECK OXYGEN SENSOR CIRCUIT. INSPECTION END
~ 1. Start engine and warm it up suffi-
1800 2CXXJ 2200
ciently.
NEXT II START ~J (F.i\ 2. Perform "MIXTURE RATIO
~ TEST" in "FUNCTION TEST"
SEF815L mode with CONSULT.
OR
m 1;{ MONITOR 1;{ NO FAIL D
(F.i\ 2. Make sure that "M/R FIC
\..!!J MNT" in "DATA MONITOR"
CMPS.RPM (REF) 2000rpm
"LEAN" periodically more
MIR FICMNT RICH than 5 times during 10 sec-
onds at 2,000 rpm.
OR
~ 2. Stop engine and'set ECM
~ Diagnostic Test Mode II (Oxy-
gen sensor monitor).
3. Restart engine and run it at
RECORD I
SEF522Q
4. Keep engine speed at 2,000
rpm and make sure that the
malfunction indicator lamp on
\ I / the instrument panel goes on
and off more than 5 times dur-
'~/' ing 10 seconds.
- CHECK-
NG
/ "- @
I I \
lamp
SEF051PA
EC-196
Oxygen Sensor (02S) (Conl'd)
@
NG
and oxygen sensor harness connec-
tor.
ECM terminal @ or @ and terminal
CD.
•
~Io
19' II
~iV OK
II ECM CONNECTOR @ Loosen and retighten engine ground

46 19 screws.
OK

@: For Australia M/T models
@: Except for Europe and Israel SEF182R

nector and retest.
Replace oxygen sensor.
CAUTION:
• Discard any oxygen sensor which has been dropped from
a height of more than 0.5 m (19.7 in) onto a hard surface
such as a concrete floor; use a new one.
EC-197
Valve Timing Control (VTC)

SYSTEM DESCRIPTION
Mass air flow sensor Amount of intake air

ECM
Valve timing
(ECCS
control solenoid
control
valve
Engine coolant temperature sensor Engine coolant temperature module)
The valve timing control system is utilized to increase engine performance. Intake valve opening and
closing time is controlled, according to the engine operating conditions, by the ECM.
Engine coolant temperature signals, engine speed, amount of intake air, throttle position, vehicle speed
and gear position are used to determine intake valve timing.
The intake camshaft pulley position is regulated by oil pressure, which is controlled by the valve timing
control solenoid valve.
Valve timing control ~

'o'""oid ,,',"
»
Ii
Intake air signal (From mass air flow sensor)
EGM (EGGS Engine speed signal (From camshaft position sensor)
control Engine coolant temperature (From engine coolant temperature sensor)
module)
Throttle valve idle position (From throttle position sensor)
Vehicle speed (From vehicle speed sensor)
Drain ..
Piston
"'- Camshaft (Intake side)
/
Return spring
/
Camshaft sprocket
MEF572DA
EC-198
Valve Timing Control (VTC) (Co nt' d)
OPERATION
Valve timing control Intake valve opening
Engine operating condition Valve overlap Engine torque curve
solenoid valve and closing time
• Engine coolant temperature

is 70"C (158"F) or more .
• Engine load is high .
• Engine speed is between ON Advance Increased @
1,500 rpm and 5,100 rpm .
• Engine speed is 6,800 rpm or

more.
CD
•
Those other than above OFF Normal Normal
CD Valve timing control (VTC) solenoid valve is OFF. @ Valve timing control (VTC) solenoid valve is ON.
Effr
t
f __~
Torque ~
L__ _
Engine speed --+-

Overlap (18°)
Exhaust valve Intake valve

open time open lime
Intake closes
BOC
CD @
For Australia
I~ Overlap (-12°)
TOC
, Intake opens
Exhaust valve Intake valve

open time open time
intake cioses
BOC
CD @ SEF183R
EC-199
Valve Timing Control (VTC) (Cont'd)
GA16DE engine models except for Europe and Israel
EC-VTC-01
IGNITION SWITCH
ON or START

10A BLOCK
1251 (JIB)
<fill)
IN~91
BR
Irn@)
8R
-:
-:
Oetectable line
for DTC
Non-detectable
line for DTC
U4Jl@
BR
BR
I
VTC
SOLENOID
VALVE
14=JJ~
~
Y/R
Y/R
I
~
VTC ECM
(ECCS
CONTROL
MODULE)
ill)
Refer to last page

(Foldout page) .
fill I
45678,~@W
~<E:IID
Y.1.J.gjJ B
HEC050
EC-200
EC-VTC-01
IGNITION SWITCH
ON or START

10A BLOCK
1251
•
(JIB)
~
IN~gl
BR
BR
dJ@
I -:
-:
Detectable
for DTC
Non-detectable
line for DTe
line
lkfdI
SR
cru
SR
I
VTC
SOLENOID
VALVE
l4=JI(ffi)
~
Y!R
Y/R
I
nffin
VTC ECM
(ECCS
CONTROL
MODULE)
(ill
Refer to last page

(Foldout page) .
fIll I I~ em
3456 W
~ffi)
ll..!.@jJ B
101 102 103 104 105 106

107 108 to9 110 111 112
113 114 115 116 117 118
HEC082
EC-201
Valve Timing Control (VTC) (Cant' d)
• ACTIVETEST. 0
INSPECTION START
VALVE TIMING SOL OFF
==========
MONITOR
========== m
AAC VALVE 16% CHECK OVERALL FUNCTION. INSPECTION END
~
00 1. Start engine and run it at idle.
2. Perform "VALVE TIMING
ON IION/OFF IEDI SEF523Q

SOL" in "ACTIVE TEST"
mode with CONSULT and
make sure that improper idle
condition occurs.
~£) OR
II ECM ~CONNECTORII
12 114 00 1. Connect a suitable jumper
wire between ECM terminal
@ or @ and body ground.
2. Start engine and make sure
that improper idle condition
occurs.
~ NG
@): For Australia
iii
CHECK ELECTRICAL CONTROL FUNC- OK CHECK COMPONENTS
~i)~ID~ TION.
1. Stop engine.
-+
(VTC solenoid valve and
VTC valve).
II ECM NCONNECTORII 2. Jack up drive wheels. Refer to "COMPONENT
A~fl"'" M/T<p~~
@@
ciently.
4. Shift gear to 1st position.
INSPECTION" on next
page.
NG
~ @ or @ and ground under the

@): For Australia following conditions.
@: Except for Australia SEF185R Voltage:
Racing engine quickly from idle to
4,000 rpm
Approximately OV Replace malfunctioning
At idle component(s).
Battery voltage
NG
.
[!J
~
2. Disconnect VTC solenoid valve har- QD,@or@,
ness connector. @
3. Turn ignition switch "ON". • 10A fuse
~r5 4. Check voltage between terminal @

and ground.
short between VTC
solenoid valve and fuse
OK
connectors.
SEF507Q
EC-202
~i5 ~i5
II ECM
12
E
114
CONNECTOR II ~ I!]
CHECK OUTPUT SIGNAL CIRCUIT. NG Repair harness or con-
~
ECM terminal @ or (ill) and termi-
114 : For Australia nal CD.
Conlinuity should exist.
•
• VALVE TIMING SN CKT.
OK
DOES THE SOLENOID
(I .
VALVE MAKE NG
CHECK COMPONENT Replace VTC solenoid
AN OPERATING SOUND
~
(VTC solenoid valve). valve.
Perform "VALVE TIMING SIV
EVERY 3 SECONDS?
@) CKT" in "FUNCTION TEST"
mode with CONSULT.
NEXT II NO II YES I OR
MEF813D
@ Refer to "COMPONENT
INSPECTION" below.
OK


nector and retest.
INSPECTION END
Valvetiming control COMPONENT INSPECTION

solenoidvalve
Plunger VTC solenoid valve
1. Supply VTC solenoid valve terminals with battery voltage.
i 2. Make sure that inside plunger protrudes.

If NG, replace VTC solenoid valve.
~ AEC889
EC-203
IACV-FICD Solenoid Valve

LHD models
EC-FICD-01
FUSE
<D: LHD models
BLOCK <ID: RHO models
(JIB) Aefer to EL-POWEA. -: Detectable line
~ L/Y for DTC
(E106) -: Non-detectable
line for DTC
1QlI
LIS
I LG/A -B> Next page
LIB L/Y
1_~_1 I~_!_~I~~~TIONER
dJY
~~
L/R
I •1 L/A
To compressor
+ (Aefer to
HA-A/C.)
o~
~L
..
I
O-<C>-
(HOt)
L/A ~
CHID
L/A -<O-O~
():100
(MID ~
k l
I~I
tElOO
CMID
~ L/R ~ L/R ~ m~ L/R
~9
Y Y (E100 CHID qJ CEID
r.l~ L/R
~OL R ~ ~~2~-
SOLENOID
I VALVE
Y Ibi=!lffi
d::,~ B
ICiJI @ 1 To ECM
+ (ECCS
I ~
Y .-- SlY control
module)
IfTI;J I I
ACRLY
(
ECM
(ECCS
CONTROL
MODULE)
B/Y
tl...1
B
1
B
~________ em ill (F13)
Aefer to last page

(Foldout page) .
+2
5
1
<ill>
L
IZlffi
CITID PU
CHID , (~fo})
,
<fi@ (E106)
HEC051
EC-204
IACV-FICD Solenoid Valve (Cont'd)
EC-FICD-02
Preceding ~ LGIR _
page ~ <D: LHO models
: RHO models
*1 ... <D G/B , <ID GY
-: Detectable line
for OTC
•
THERMO -: Non-detectable
CONTROL line for DTC
THERMISTOR AMPLIFIER
Q1W
... (El0n CHID

;:-- SB -l@}- SB
0/ <rnD CHID *1 + To AIC
(Refer
switch
to HA-AlC.)
0-<lD- SB ~ SB
I
SB
rm
OUAL-
--
LOW HIGH PRESSURE
.... ..., SWITCH
NORMAL ~
~
G
I <rnD CHID ~
0-<1>- G ~ G
L ~
G
(El0l)
~
CHID
G
~
-<ID-O-
~@
G -[D G
it G
fi4TI
ARCON
IEeM
(ECCS
CONTROL
MODULE)
em
Refer to last page
(Foldout page) .
~ CHID , (ElM
2 W
~3
HEC052
EC-205
RHO models
EC-FICD-03
FUSE
BLOCK
(JIB) Refer to EL-POWER.
-: Detectable line
for DTC ~ L/Y
I
-: Non-detectable (EI06)
line for DTC IN.21
LG/R L/Y
AIR
~I~~~~~TIONER
~ru>
~
Ir---------
L L/R
I •
tt-- ...- L/R
+TO compressor
(Refer to HA-A/C.)
•
L/R
ukll (EIOn
L THERMO ~CBID
m ~
THERMISTOR
CONTROL
AMPLIFIER
<8[D
L/R
r=!:::,@
IqJlcm
DUAL- L/R
... .......
LOW
~
HIGH PRESSURE
SWITCH
m ~ ~ I
l4JJ
G
NORMAL
Ir~'Rll(Elan
fG"A'i"\\
~r.:::b,
1f6"1~1
~R/L
R IL G.Y I
,
tt- GY + (Refer to
GY
_
r.:::b,@
To A/C
-
HA-A/C.)
switch
m
L/R
IACV-
FICO
SOLENOID
VALVE
~<BID .... .... I~I @) ~CfID
G
d=~
1C4Jlcm
wm
G
~
RIL
14.41 Ii4TI
•
GY
---- B
•
tt----
I r-1
B/Y +
1~C~~M
control
module)
B/Y B B
ACRLY THAMP ARCON
1
ECM
(ECCS
CONTROL
MODULE)
ill)
t...l
m 0:13)
Refer to last page
T
2
5
1
U])
L 2
~3
cgw
W
~
<:!IillHIID
CfID
BR
(Foldout page) .
<BID , (Elan
@g) , (EI06)
HEC053
EC-206
_.
-:
Detectable line
for DlC
Non-detectable FUSE
EC-FICD-01
line for DTC BLOCK

(J/B) Refer to EL-POWER.
~ L!Y
I
CE106)
I ....
THERMO
CONTROL
.
AMPLIFIER
IN.21
~G/R
~
-------I
L!Y
AIR
~12~~~VIONER
i-
~.......
I@
•
~ L/R
•1 --- L/R
+TO compressor
(Refer to HA-A/e.)
1
To A/e Y L!R
SWitch
+ (Refer to 11i=!l;ll (El0!) ukll CE101)
HA-A/C .J
~CBID ~CBID
Y L/R
r=b~
OUAL-
IqJ'cru
LOW HIGH PRESSURE L/R
....
--
NORMAL
SWITCH
<rn>
•
L/R
I
lk¥J
G
1r!R1I CE101)
Y
r=b~
Il4Jl <£[)
Y
It I FICO
lACV-
SOLENOID
VALVE
~CHID ~@
d:,~
G
ICiJI <£[)
G
IDilt
I
Y
Irfffil
B
•1-
I n B/Y
+~~CE~M
control
module)
B/Y B B
1
ARCON ACRLY ECM
(ECCS
CONTROL
MODULE) t-J
------------------ I
(IT) ill <ffi)
A,@ ~ ~ CEID
Refer to last page
(Foldout page) .
T L 2
~3
W ~BR CHID , (El0!)
cH:W , CE106)
101 102 103 104 105 106

107 108 109 110 111 112
113 114 115 116 117 118
HEC083
EC-207
When the air conditioner is on, the IACV-FICD solenoid valve
supplies additional air to adjust to the increased load.
MEC289BA
GA 6DE except for Europe and Israel DIAGNOSTIC PROCEDURE

'""k, mM,o"l\ INSPECTION START
m
' ~. CHECK OVERALL FUNCTION. O~L.- __ I_N_S_P_E_CT_I_O_N_E_N_D
__
[
iAcv-AAC
~
valve (with /
ciently.
IACV-FICD solenoid valve)
{
harness connector MEC286BA 2. Check idle speed.
Refer to EC-36.
GA14DE, GA16DE for Europe an If NG, adjust idle speed.
3. Turn air conditioner switch and
Israel ~'IACV_FIICI~'~O~~'d~
(\ ~valve harness~ blower fan switch "ON".
~ connector 4. Recheck idle speed.
/ 900 rpm or more (AIT in "N" posi-
tion)
NG
Check if air conditioner compressor NG Refer to "TROUBLE

functions normally. DIAGNOSES" in HA sec-
tion.
OK

1. Turn air conditioner switch "OFF" • Harness connectors
and stop engine. QD,@
2. Disconnect IACV-AAC valve or IACV- • Harness connectors
FICO solenoid valve harness connec- @,@
tor. • Harness for open or
3. Restart engine, then turn air condi- short between IACV-
tioner switch and blower fan switch AAC valve or IACV-
MEF634E
"ON". FICO solenoid valve
4. Check voltage between terminal (1) harness connector and
and ground with CONSULTor tester. air conditioner relay
Voltage: Battery voltage If NG, repair harness or
connectors.
OK
* 1 : For Europe and Israel ~

~n t
* 2: Except for Europe and Israel SEF187R
EC-208
[!J
~i5~i5 @a
dfu c:illffiID NG
CHECK GROUND CIRCUIT. Repair harness ~
_J
J
o. E",0p, "d ,,,,~

terminal @ or @ and body ground.
o : Except for Europe and Israel SEF239R If OK, check harness for short.
•
OK
CHECK COMPONENT NG Replace IACV-FICD sole-

(IA"CV-FICD solenoid valve). noid valve.
below.
OK


nector. Then retest.
INSPECTION END
r14 10 IACV-FICD solenoid valve -

Israel
CITfl:B 1. Disconnect IACV-AAC valve harness connector.

2. Check resistance between terminals G) and CID.
Resistance: 75 - 125Q [at 25°C (77°F)]
If NG. replace the solenoid valve.
AEC896
IACV-FICD solenoid valve - Europe and Israel

• Check for clicking sound when applying 12V direct current
to terminals.
EC-209
• Check plunger for seizing or sticking .
• Check for broken spring.
• ~ho~
a::?\SPriOg
[PlUnger
SEF163N
EC-210
Electrical Load Signal
LHD MODELS EC-LOAD-01

ECM
(ECCS
75A CONTROL
m Refer
EL-POWER.
to H/FAN
MODULE)
<ED
W BIR 1~51
G/Y
CEID
•
~O-(QD-~
I I$I
*1 G/Y@
rrffil
2ND LIGHTING
SWITCH
I
G/Y
I ~
JUNCTION
rn
~T (E107)
OFF'- BOX NO.2
(JOINT
CONNECTORS)
~
*2 4=U~
I G/Y
O-<QD----w I
r.l. RIL BIR G/Y
~ r=:b, r=:b,
111111 II 1 II 6
WIR TAIL/L TAIL
DAYTIME FAN
10A SW FUSE LIGHT ON SWITCH
1451 TAIL/L UNIT OFF-- @
--' ~
~
R/Y L..-.,.,:..,OU;,.,...T....-
~
~
l4dJ
B
~ RIB
O--<ID>---l <QD: With daytime 1ight
I system
@: Without daytime
*3
light system
I Q(E106)
(I)
1 3 *1 ... <QDB/R @ W
FUSE
BLOCK *2 .. '@RIL '@W/R
(JIB) *3 ... <QDR/B '@R/Y
,
I~BI ~ -: Detectable line
for DTC
RIG
-: Non-detectable
line for DTC
1 RIG .fA-. Next
~page
Refer to last page

(Foldout page) .
~<mID ~ , CE106)
~GY
~
~@
~w
HEC054
EC-211
Electrical Load Signal (Cont'd)
EC-LOAD-02
.------ FUSE Refer to

20A 20A 10A BLOCK EL-POWER.
(JIB)
m [[] 1251 ~
(106)
I Pl' IQ~OI
rn!
~120)
LIB BR
REAR
WINDOW
DEFOGGER
~1~
ONU
In I ~~r~~GER
REAR
WINDOW
-1-i~'---I-i"""""l m:@)
L
SWITCH OFF--
@:@ 11211
.,= L/R G/R
m
L/R IrJPl CHID
<E1QD
L/R To rear window
~g~~~CTOR-2 ~ L/R ..J G/R ~~~~~~~e~otimer
@) I.4=JI
~
EL-DEF .)
L/R
DIOOE-1
~
2
~ @: With daytime light
page ~
~
Preceding ---At- RIG ~
OIOOE-2~
R
-.m@R
I
I
R
@:
-:
-:
system
Without daytime
light system
Detectable line
for OTC
Non-detectable
!!4Jl@ line for OTC
R
13'31
LOAD ECM
(ECeS
CONTROL
MODULE)
(fD
+
Refer to last page
(Foldout page) .
CHID , m
f1Till1~
1m W
rrrITrl@
ITlIl] GY
~~
W,gJ'
~ 2 1
m
L
(!IIII~
3 4 5 6
@
W ~ , (106) , @Q)
5
HEC055
EC-212
RHO MODELS EC-LOAD-03
FUSE
BLOCK Refer to EL-POWER.
(JIB)
~
•
~
LIB
1 @: For Europe
REAR WINDOW 2ND LIGHTING
ON DEFOGGER SWITCH @: Except@
SWITCH (E10?) -: Detectable line
OFF-- , ~ for DTC
~ -: Non-detectable
~ ~ line for DTC
L~R ~R:~ ~
DIODE-1 FUSE
~ BLOCK
OO 2
R DIODE-2 ~
(JIB)
UN.BI ~
e- R {#Jjf{I} RIG
RIG
..J
6~ 6
LG/B
<$>
R
I
R
FAN
rn~ rn~
~R em I!4=lJ @
OFF--
ON SWITCH
~
LG/BIGA"?i\
R r=b~
~
l4=!J
~ I IU/JI@
LG/B
B
O~
I
R
It
LG/B
IT3n 1@5J1 rI I I
B B B B B
LOAD H/FAN ECM
------------------- I
(ECCS
CONTROL
MODULE)
(IT)
L~ L~
-!-
(M68)
-!-
(M60) CM28)
1
~---------------------~ Refer to last page
(Foldout page') .
~@
F1Tffi~ ~w ~ , (E106)
rn:rn:rn W L ~
HEC056
EC-213
EC-LOAD-01
lOA FUSE
1361
m
20A BLOCK
(JIB)
Refer to EL-POWER.
BIR ~
BIR
I ~
LIB
LIB
I
-: Detectable line
rrffil l
for DTC
2ND LIGHTING REAR WINDOW -: Non-detectable
l1JJ
SWITCH line for DTC
~ ON DEFOGGER
OFF ...._1ST <E1Q?) SWITCH
OFF-- ~
~ lbi=ll
RIL L/R
R/L
I
Q'3 I (EiOS)
FUSE BLOCK
(JIB) LG/B
~IN181~ 6
RIG FAN
ON SWITCH
RIG
I LIR LG/B
OFF-- @
r=:b,~
IU"ArI\
r::::b@
~
I4J
'RIG
Uil' CEID I$I@
@ IlJlll CEID B
L/R LGIB
RIG
I L/R
I LG/B
It
~ 115'51 1351 I
B B B B B
H!LMP R/DEF H/FAN ECM
(ECCS
CONTROL
MODULE)
em
L~ L~
~
-!- -!-
(M60) @
1
Refer to last page
~~
tiliIiI W lll' III~~
3456 W
~@
~W
(Foldout
<M@ ([@
page) .
101 102 103 104 105 106

107 108 109 110 111 112
113 114 115 116 117 118
HEC084
EC-214
* MONITOR * NO FAIL 0
INSPECTION START
LOADSIGNAL OFF
m
CHECK OVERALL FUNCTION-I. NG Check rear window
----+
1) Turn ignition switch "ON", defogger circuit.
I I,)
___ RE_C_O_R_D __ I
MEC212B
00 2) Check "LOAD SIGNAL" in
CONSULT.
(Go to Procedure A
II ECM
~15@a0
33 55
ECONNECTORII
@
.
Rear window defogger switch
is "ON": ON
Rear window defogger switch
is "OFF": OFF
OR
2) Check voltage between ECM
terminal @ or @ and
•
ground under the following
conditions.
Voltage:
@: For Australia
33 : Except for Australia SEF240R Rear window defogger
switch is "ON".
Ii]
Battery voltage
Rear window defogger
LOADSIGNAL OFF switch is "OFF".
Approximately OV
OK
Ii]
CHECK OVERALL FUNCTION-II. NG Check lighting switch cir-
----+
L,__ R_E_CO_R_D__ I 1) Turn rear window defogger switch cuit.
MEC212B "OFF", (Go to I Proceduffil?J)
00 2) Check "LOAD SIGNAL" in

~15~ CONSULT.
Lighting switch is "ON": ON
II ECM €I' CONNECTOR II Lighting switch is "OFF": OFF
33 60
OR
@ 2) Turn ignition switch "OFF"

3) Check voltage between ECM
terminal i@J or @ and
ground under the following
@: For Australia cond itions.
Voltage:
~15~ Battery voltage

Lighting switch is "OFF".
II ECM E CONNECTOR II Approximately OV

45 35
r-(A)
@: For Australia
45 , Except for Australia SEF197R
EC-215
@
CHECK POWER AND GROUND CIRCUIT NG Check the following.

2. Check continuity between ECM termi- QD,@
nal @ or @ and ground. • Joint connector
Blower fan switch "ON" @
Continuity should exist. • Harness continuity
Blower fan switch "OFF" between ECM and fan
Continuity should not exist. switch, fan switch and
ground
OK
connectors.


or loose connection of ECM harness
connector. Reconnect ECM harness
connector and retest
INSPECTION END
EC-216
~ 15 ~ 15 I P_RO_CE_DU_RE_A _
ECM ECON NECTORII INSPECTION START

55 33
Check if rear window defogger func- NG Check rear window

tions normally. defogger circuit. (Refer to
"REAR WINDOW
@: For Australia OK
DEFOGGER" in EL sec-
@: Except for Australia SEF19SR
tion.)
I;J
1. Turn rear window defogger switch
"OFF".
NG
@,@orQI),
@
•
3. Disconnect ECM harness connector • Diode@
and rear window defogger switch • Joint connector
harness connector. @
ECM terminal @ or @ and terminal short between ECM
@. and rear window defog-
Continuity should exist. ger switch
connectors.
OK


nector and retest.
INSPECTION END
EC-217
II Except for Australia I PROCEDURE B
~Io ~io ----~ INSPECTION START

II ECM E!'CON NECTOR II
33
Check if lamps light when lighting NG Check lighting switch cir-

-----..--..
switch is turned "ON". cui!. (Refer to "COMBI-
NATION SWITCH" in EL
OK
section.)
Ii
~15 ~i5 CHECK INPUT SIGNAL CIRCUIT. NG
-----..--.. Check the following.
II ECM 19" CONNECTOR II 1. Turn ignition switch "OFF".
CID,@or@,
33
and lighting switch harness connec- @orQD,@
tor. • Harness connectors
3. Check harness continuity between @,@ID
ECM terminal @ or @ and terminal .Diode@
* 1 : LHD models and RHD models for Europe
* 2 : RHD models except for Europe
@.
• 10A fuse
• Daytime light unit
SEF188R If OK, check harness for short. • Harness for open or
short between lighting
II For Australia OK
switch and diode
~&5 ~15 connectors.
1=' =E=CM===IE[ CONNECTOR II Disconnect and reconnect harness con-

60

SEF199R
nector and retest.
INSPECTION END
EC-218
Torque Converter Clutch Solenoid Valve
EC-LKUP-01
IGNITION SWITCH -: Detectable line
ON or START for DTC
-: Non-detectable
line for DTC
10A BLOCK
rn
•
(JIB)
(Ef06)
IQ.61
y
I
y
1l1J1 ffi
=r (E202)
y
I
y
r::b, TORQUE
3 CONVERTER
CLUTCH
SOLENOID
II 111 VALVE
~
=r (E223)
PIB
I
PIS
r::b,@i)
Il4Jlm
PIB
L PiS ~
(E10!) CHID (M49)
PIS -- PIS ~~
CEID
P/S"""l
PIS
Ii1N
LKUP ECM
(ECCS
CONTROL
MODULE)
em
Refer to last page

(Foldout page) .
~~~~ ~~
~ S w.g@> S ~S
HEeD5?
EC-219
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS em
Torque Converter Clutch Solenoid Valve (Cont'd)
GA16DE for Australia (A IT models)
EC-LKUP-01
IGNITION SWITCH
ON 01" START
_. Detectable line
fol" DTC
FUSE Refel" to EL-POWER. -: Non-detectable
10A BLOCK line fol" DTC
rn (JIB)
<E106)
UQj611
y
$=y
y
I
I
r=!::, TORQUE
3 CONVERTER
CLUTCH
SOLENOID
~
~~E
P/B
I
P/B
r=!::, CE201)
1C4J1~
P/B
L PIS ~
~CM8)
PIS -- PIS ~~
@@
PiS ~
P/B
Ii3tiJ
LKUP ECM
(ECCS
CONTROL
MODULE)
em
Refer to last page

~~ ~~ FmB1~ (Foldout page) .
lIDIDZIID B w.g@) B ~ B
101 102 103 104 105 106

107 108 109 110 111 112
113 114 115 116 117 118
HEC085
EC-220
SYSTEM DESCRIPTION
Throttle position sensor Throttle valve opening angle
ECM
(ECCS Torque converter
control clutch solenoid
module) valve
The AfT lock-up is controlled by the ECM through • Throttle position is open .
the torque converter clutch solenoid valve. When
the ECM detects any of the following conditions,
• Engine coolant temperature is 60°C (140°F) or •
more.
the ECM switches the torque converter clutch
solenoid valve OFF to accomplish lock-up Dpera-
• Vehicle speed is 58 kmfh (36 MPH) or more .
tion. While the vehicle is in conditions other than

below, the torque converter clutch solenoid valve
is always set to ON, releasing the lock-up oper-
ation.
m ~ i3~ INSPECTION START
II ECM HCONNECTORII
30 115
OK CHECK COMPONENT
CHECK CONTROL FUNCTION.
1. Jack up drive wheels. (Torque converter clutch
ID cf6~H 2. Start engine and warm it up suffi-

ciently.
solenoid valve).
Refer to "Electrical Com-
ponents Inspection" in
~i3~ 3. Shift selector lever to "D" position.
GID
AT section.
II ECM E
30
CONNECTOR
115
II
or @ and ground under the
following conditions.
If NG, replace torque
converter clutch solenoid
Voltage: valve.
Accelerator pedal is depressed
iIJ [Vehicle speed is above

58 km/h (36 MPH).]
OK
ID cf6~H
@> :
AIT models for Australia
Battery voltage
Accelerator pedal is fully
released
INSPECTION END
@: AlT models except for Europe
ApprOXimately OV
and Israel, and Australia SEF189R
NG
MEC279BA
EC-221
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS @]
@
~i5 I!J 1 NG
CHECK POWER SUPPLY.
1. Stop engine.
--.--.. Check the fol/owing.
2. Disconnect torque converter clutch @),<mY
solenoid valve harness connector. • 10A fuse
~ 4. Check voltage between terminal @ short between torque
and ground. converter clutch sole-
Voltage: Battery voltage noid valve and fuse
SEF513Q
" NG, repair harness or
OK connectors.
rilio [;J
NG
II ECM HCONNECTORII CHECK OUTPUT SIGNAL CIRCUIT. --.--.. Check the following.
115 30
2. Disconnect ECM harness connector. aD,@
ECM terminal (ill) or @ and termi- @,@!)
nal (D. • Harness connectors
Continuity should exist. @),@D
@ : AIT models for Australia
" OK, check harness for short. • Harness for open or
@: NT models except for Europe short between ECM
and Israel, and Australia SEF190R OK and torque converter
clutch solenoid valve
connectors.
NG
CHECK COMPONENT Replace torque converter
~
(Torque converter clutch solenoid clutch solenoid valve.
valve).
Inspection" in AT section.
OK


nector and retest.
.
INSPECTION END
EC-222
MIL & Data Link Connectors

LHD models
EC-MIL-01
IGNITION SWITCH
ON or START

7.5A BLOCK @: Models with tachometer
IT]
•
(JIB) @: Models without tachometer
~ *1"'@30 , @40
*2' .. @32 ,@ B
-: Detectable 1ine
for DTC
I -: Non-detectable
I~
G line for DTC
COMBINATION
METER
(MALFUNCTION
INDICATOR
I DATA LINK
CONNECTOR
FOR CONSULT
LAMP)
<fill)
@)
1*.21
ORIL
@ L+J
G/B
Li-J
GY/L
L-iJ
G/W
l4-J
G/R
~
B
G/B
It
I~ GY/L G/W
I~ ~
(t~1 II;~I 'D~I

~3~~~~~~
CONNECTORS) _
(ffi]) ~ ~ ~
ORIL @) G/B GY IL G/W G/R
I$~
(F~9)- - - - - - - - - - ~$J
--~$~
--~$~
--~$I
ORIL G/B GY IL G/W G/R
I I I I I
ORIL G/B GY IL G/W G/R
u*iI
LCHK
m
SCI
rrf5n
SCI
u=!4fl
SCI
~
CHECK ECM
R ~ U Q (ECCS
CONTROL
MODULE)
CID
Refer to last page

(Foldout page) .
HEC058
EC-223
MIL & Data Link Connectors (Cont'd)
RHO models
EC-MIL-02

BLOCK @: Models with tachometer
(JIB) @: Models without tachometer
<M@ *1... @30 , @40
*2... @32 ,@ 8
-: Detectable 1 ine
for DTC
i -: Non-detectable
G line for DTC
COMBINATION
m
METER DATA LINK
(MALFUNCTION CONNECTOR
INDICATOR FOR CONSULT
I
LAMP)
~ 1 .~
1*.21
ORIL
@ LiJ!4J
G/B GYIL
~LiJ ~
G/R G/W B
I~GY/LIt ~ ~
tt 'DJOINT
G/B
l
CONNECTOR-5
~~~
ORIL @ G/B GYIL G/R G/W
1~~{F~5----------~~~-~~~---------~qp~-~~1
ORIL G/B GYIL G/R G/W
I I I I I
ORIL G/B GY/L G/R G/W
~
LCHK
mum
SCI SCI
~wrn
CHECK SCI ECM
R RX TX CL (ECCS
CONTROL
MODULE)
em
Refer to last page

(Foldout page) .
~~
~OR
HECOS9
EC-224
MIL & Data Link Connectors (Cont'd)
IGNITION SWITCH EC-MIL-01

ON or START
Refer to EL-POWER.
FUSE -: Detectable line
7.5A BLOCK
m (JIB)
-:
for OTC
Non-detectable
~ line for OTC
Y G
•
1;01
COMBINATION
m
METER
(MALFUNCTION
INDICATOR
I DATA LINK
CONNECTOR
FOR CONSULT
LAMP) ~
@ 1
13•21 Li-JL4J LiJ l4J
ORIL G/B GY/L G!W B
It
I~GYIL ~
tt 'D
G/B
l
CONNECTOR-5
JOINT
lbi=U~~
ORIL G/B GYIL G!W
1~~~F~~----------4~~-~~~---------4~1
ORIL c:E.ID G/B GYIL G!W
I I I I
OR!L G/B GY!L G!W
!rOO
LED-R
~~
SCI SCI
m
SCI ECM
RX TX CL (ECCS
CONTROL
MODULE)
(ill
@
Refer to last page
W (Foldout pagel.
~(@)
~OR
101 102 103 104 105 106

107 108 109 110 111 112
113 114 115 116 117 118
HEC086
EC-225
Circuit Diagram
'"I"
U
~U COOLING
F~LAY-1
(!) ~
Z I
f- f- H 0:
H H -' 0
3:f- 3: OZf-
(f]0: (f] 0<t0
--ttt
<t UIL::E
ZI- ZZ
O(f] SO
H
~ .c
l
I-L f- COOLING u
HO H
FAN RELAY-2 ,I' L
'"~
~r
Z Z 0 .M
(!)Z (!)
HO
~ H r=-1 "'"' 0:
0
REf"
r-
'"a
L "'
r Z(!) ru U
T~
::EO: H "-
I
E
0 ~ od
O:f-'
UJza.
::E <t
I H 0: U II
COOLING oz~@
-' 0
0:
0
f-
0
0
FAN RELAY-3 8i1~ « f-
~[j~ ~~ r=-1 ~
H
rf=~I' ~
O:Z-'
f-
H>-
O<t r
= HOW
<tUo:
C;::A
M
A (!)
Z
0: HW
0.
W -@---11' 0:0:
W:::>
OD~~O ~ ij!
W(f]
o
::E Z

Z-' I (f] <tHI
o
HO:
f-O
@
uw -tBt_ H
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OZf-
0:
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o:I
o:o.u
f- o ~
a:I-U
f-Hf-
::>(/)o-<
'"'"'"
a: CLc5 c--- 0<t0 3-'H H
W03:
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:::>u
wo
f-H
<t(f)
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uu.::E OH3:
0.0(f]
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o.I
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ILH 0:0 WWO <t
E
0
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<tH
W-' f-(!)(f] -'
-'0 WZ 0 '-"-' .c o
<tZ >w "'0:
<t>-Z ZW -@---11' U
II ~
aD
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-
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ru S eno N ::: ;; ~ II)
r-- '"
~~ffi
Hf-Z
~
--IUO Q)
wu ECM (ECCS CONTROL MODULE)
<tZ
f-ZO:
<tOO '"
N ~J
OUIL
::';
...
(D en
;::: ~ffi~ ...
(T) ;::: ;:::
'"
S ~ !;:l ...;::: (T)
r--Q)(D
......
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(T)(T) :;:; 0
ru
en~Q)
"IN-
r--
N
rLJ I I I 11 I
-
0
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(\J
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0
ro
Z
0
...
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Z
L j
-
i
I
c.-U U J
I
I
I
II
II
,U
II
II. I ~D
>- I II II
~
III
(f]<t
U--I
UW
wo: 0 I
I
I
I
L-
a:
II
II
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i~@ --
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HQj- 0
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f- --I a:~
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f- f-
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m u.o. r--:l 0:0:
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(f] l::':.J f-O
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u.
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f-
om
@@@
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H
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W
BATTERY 0:
HEC001
EC-226
System Diagram
~
.3
o
(/)
Q;
C
Ol
C
0 .~
.0
C
~
"
Ql
""'5 Ql ::J
o
(/)~
0
(/)
"0
Ql
C
0
tl (/)
(/)
.c Q;
o
C
Ql.o
en .~
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C.
(/)
0
~ B ~ ~£
0
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SEF306R
EC-227
ECCS Component Parts Location
EGR valve
IACV.air regulator
EGRC-BPT valve
Injector
IACV.AAC valve
Pressure
IACV.FICD solenoid valve regulator
Engine coolant temperature sensor Camshaft position sensor,

ignition coil and power
Knock sensor Heated oxygen transistor built into distributor
sensor
SEF307R
EC-228
ENGINE AND EMISSION CONTROL OVERALL SYSTEM ~
ECCS Component Parts Location (Cont'd)
IACV.FICD solenoid valve

•
IACV.air regulator
Knock sensor
SEF308R
EC-229
ECCS Component Parts Location (Cont'd)
Camshaft
L
position
sensor
Metal tip of ignition coil tower

(Terminal of secondary coil circuit)
Terminal for ignition coil
NOTE: Power transistor, camshaft position sensor,
and ignition coil have to be replaced as a
distributor assembly.
SEF853NA
EC-230
Vacuum Hose Drawing
EGR valve
•
Pressure regulator
VIEW A VIEW B
/- Vacuum gallery
A
Throttle body ~
EGR valve
5
EGR valve & EVAP canister
purge control solenoid valve
SEF309R
(1) Pressure regulator to vacuum @ Throttle body to EGR valve & @ Intake manifold collector to
gallery EVAP canister purge control vacuum gallery
@ Air duct to vacuum gallery solenoid valve @ EGRC-BPT valve to EGR tube
@ EVAP canister (vacuum line) to @ EGR valve & EVAP canister @ EGRC-BPT valve to vacuum
vacuum gallery purge control solenoid valve to gallery
vacuum gallery
@ EVAP canister (purge line) to @ EGR valve to EGRC-BPT valve
intake manifold collector (J) EGR valve & EVAP canister
vacuum gallery
EC-231
System Chart
Camshaft position sensor Fuel injection & mixture ratio • I

I Injectors
control

I
Distributor ignition system ~1Power transistor
r
Engine coolant temperature .

sensor
I IACV-AAC valve and
Idle air control system
IACV-FICD solenoid valve

I
IACV-air regulator control ~--..j IACV-air regulator

I
Ignition switch
I
I Throttle position sensor

~-+
Fuel pump control Fuel pump relay
ECM
(ECCS
control
Neutral position/Inhibitor . module) Heated oxygen sensor
switch ~-+ Malfunction indicator lamp
monitor & on-board diagnos-
(On the instrument panel)
tic system
I Air conditioner switch

t~ EGR valve & EVAP canister 1---+ EGR valve & EVAP canister
purge control purge control solenoid valve
Knock sensor .....
Front heated oxygen sensor Front heated oxygen sensor

Battery voltage
I
. heater control
. heater
Power steering oil pressure

switch
~ Cooling fan control
-- Cooling fan relay
Vehicle speed sensor ..... Air conditioning cut control Air conditioner relay
EC-232
Multiport Fuel Injection (MFI) System


•
Density of oxygen in exhaust gas

Front heated oxygen sensor
Throttle position ECM

Throttle valve idle position (ECCS
control
Injector
Gear position module)
Neutral position/lnhibitor switch
I Vehicle speed sensor I Vehicle speed
Start signal
Ignition switch
Air conditioner operation

Battery voltage
Battery
BASIC MULTIPORT FUEL INJECTION VARIOUS FUEL INJECTION

SYSTEM INCREASE/DECREASE COMPENSATION
The amount of fuel injected from the fuel injector In addition, the amount of fuel injected is com-
is determined by the ECM. The ECM controls the pensated to improve engine performance under
length of time the valve remains open (injection various operating conditions as listed below.
pulse duration). The amount of fuel injected is a < Fuel increase>
program value in the ECM memory. The program • During warm-up
value is preset by engine operating conditions. • When starting the engine
These conditions are determined by input signals • During acceleration
(for engine speed and intake air) from both the • Hot-engine operation
camshaft position sensor and the mass air flow • When selector lever is changed from "N" to
sensor. "0" (AfT models only)
• High-load operation
< Fuel decrease>
• During deceleration
EC-233
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION [][]
Multiport Fuel Injection (MFI) System (Cont'd)
CLOSED LOOP MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP
CONTROL CONTROL)
The mixture ratio feedback system provides the best air-fuel
Feedback signal mixture ratio for driveability and emission control. The three
way catalyst can then better reduce CO, HC and NOx emissions.
This system uses a heated oxygen sensor in the exhaust man-
ifold to monitor if the engine operation is rich or lean. The ECM
adjusts the injection pulse width according to the sensor volt-
age signal. For more information about the heated oxygen
sensor, refer to EC-362. This maintains the mixture ratio within
MEF025DD the range of stoichiometric (ideal air-fuel mixture).
This stage is referred to as the closed loop control condition.
OPEN LOOP CONTROL
The open loop system condition refers to when the ECM detects
any of the following conditions. Feedback control stops in order
to maintain stabilized fuel combustion.
• Deceleration and acceleration
• Engine idling
• Malfunction of heated oxygen sensor or its circuit
• Insufficient activation of heated oxygen sensor at low
engine coolant temperature
• High-engine coolant temperature
• After shifting from "N" to "0"
• During warm-up
• When starting the engine
MIXTURE RATIO SELF-LEARNING CONTROL
The mixture ratio feedback control system monitors the mixture
ratio signal transmitted from the heated oxygen sensor. This
feedback signal is then sent to the ECM. The ECM controls the
basic mixture ratio as close to the theoretical mixture ratio as
possible. However, the basic mixture ratio is not necessarily con-
trolled as originally designed. Both manufacturing differences
(Le., mass air flow sensor hot wire) and characteristic changes
during operation (Le., injector clogging) directly affect mixture
ratio.
Accordingly, the difference between the basic and theoretical
mixture ratios is monitored in this system. This is then com-
puted in terms of "injection pulse duration" to automatically
compensate for the difference between the two ratios.
EC-234
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION ~
Multiport Fuel Injection (MFI) System (Cont'd)
..--./ Injection pulse FUEL INJECTION TIMING
NO.1 cylinder ---1 0/1 _
Two types of systems are used.
No.2 cylinder rL Sequential multiport fuel injection system

Fuel is injected into each cylinder during each engine cycle
NO.3 cylinder ~n~ _ according to the firing order. This system is used when the
engine is running.
NO.4 cylinder ~n~ _
~ 1 engine cycle ----j
Sequential multiport fuel injection system
MEF522D
No. 1 cylinder jl
No. 2 cylinder jl
No. 3 cylinder ]l
NO.4 cylinder D
n
n
n
n
rL-
rL-
rL-
fL-.
Simultaneous multipart fuel injection system
Fuel is injected simultaneously into all four cylinders twice each
engine cycle. In other words, pulse signals of the same width
are simultaneously transmitted from the ECM.
The four injectors will then receive the signals two times for
each engine cycle.
•
This system is used when the engine is being started and/or if
~- 1 engine cycle ---1 the fail-safe system (CPU) is operating.
Simultaneous multi port fuel injection system
FUEL SHUT-OFF
MEF523D
Fuel to each cylinder is cut off during deceleration or operation
of the engine at excessively high speeds.
Distributor Ignition (DI) System




Throttle position
Throttle valve idle position ECM
I Vehicle speed sensor I Vehicle speed (ECCS

control
Power
transistor
module)
Start signal
Ignition switch
Engine knocking
Knock sensor
Gear position
Battery voltage
Battery
EC-235
Distributor Ignition (01) System (Cont'd)
Tp SYSTEM DESCRIPTION
(msec)
1.75 The ignition timing is controlled by the ECM to maintain the best
A air-fuel ratio for every running condition of the engine.
~ 1.50
.~ The ignition timing data is stored in the ECM. This data forms
3l 1.25 the map shown.
:;
a. The ECM receives information such as the injection pulse width
c: 1.00
.Q and camshaft position sensor signal. Computing this
~ 0.75 information, ignition signals are transmitted to the power tran-
E sistor.
N
600 1,000 1,400 1,800 2,200 e.g., N: 1,800 rpm, Tp: 1.50 msec
Engine speed (rpm) SEF742M AOBTDC
During the following conditions, the ignition timing is revised by
the ECM according to the other data stored in the ECM.
• At starting
• During warm-up
• At idle
• Hot engine operation
• During acceleration
The knock sensor retard system is designed only for emergen-
cies. The basic ignition timing is programmed within the anti-
knocking zone, if recommended fuel is used under dry condi-
tions. The retard system does not operate under normal driv-
ing conditions.
If engine knocking occurs, the knock sensor monitors the con-
dition. The signal is transmitted to the ECM (ECCScontrol mod-
ule). The ECM retards the ignition timing to eliminate the k.nock-
ing condition.
Air Conditioning Cut Control


Throttle valve opening angle

ECM Air
Engine speed (ECCS condi-
control tioner
module) relay

Start signal
Ignition switch
SYSTEM DESCRIPTION
This system improves acceleration when the air conditioner is used.
When the accelerator pedal is fully depressed, the air conditioner is turned off for a few seconds.
When engine coolant temperature becomes excessively high, the air conditioner is turned off. This con-
tinues until the coolant temperature returns to normal.
EC-236

speed)
Vehicle speed
Neutral position
Neutral position/lnhibitor switch
ECM
Throllle position (ECCS
Throllle position sensor control Injectors
•
module)
.
Engine speed
If the engine speed is above 3,950 rpm with no load (for

example, in neutral and engine speed over 3,950 rpm) fuel will
be cut off after some time. The exact time when the fuel is cut
off varies based on engine speed.
Fuel cut will operate until the engine speed reaches 1,150 rpm,
then fuel cut is cancelled.
NOTE:
This function is different than deceleration control listed under
"Multipart Fuel Injection (MFI) System" on EC-233.
EC-237
Description
EGR valve & EVAP canister purge control

solenoid valve
-
Vapor vent line
t
Fuel filler cap
with vacuum
-
relief valve
Fuel tank EVAP canister yAir

.. Fuel vapor
MEF609DC
The evaporative emission system is used to reduce hydrocar-

bons emitted into the atmosphere from the fuel system. This
reduction of hydrocarbons is accomplished by activated char-
coals in the EVAP canister.
The fuel vapor from sealed fuel tank is led into the EVAP can-
ister when the engine is off. The fuel vapor is then stored in the
EVAP canister. The EVAP canister retains the fuel vapor until
the EVAP canister is purged by air.
When the engine is running, the air is drawn through the bot-
tom of the EVAP canister. The fuel vapor will then be led to the
intake manifold.
When the engine runs at idle, the purge control valve is closed.
Only a small amount of vapor flows into the intake manifold
through the constant purge orifice.
As the engine speed increases and the throttle vacuum rises,
the purge control valve opens. The vapor is sucked through
both main purge and .constant purge orifices.
Inspection
EVAP CANISTER
Check EVAP canister as follows:
1. Blow air in port @ and ensure that there is no leakage.
2.
• Apply vacuum to port @. [Approximately -13.3 to -20.0 kPa
(-133 to -200 mbar, -100 to -150 mmHg, -3.94 to -5.91 inHg)]
• Cover port CID with hand.
• Blow air in port @ and ensure free flow out of port @.
SEF312N
EC-238
Inspection (Conl'd)
FUEL CHECK VALVE
+
0:> Check valve operation
Fuel lank side
1. Blow air through connector on fuel tank side.
A considerable resistance should be felt and a portion of air
QAir
flow should be directed toward the EVAP canister side .
.. Fuel vapor
2. Blow air through connector on EVAP canister side.
..
EVAP canister side Air flow should be smoothly directed toward fuel tank side.
<? 3. If fuel check valve is suspected of not properly functioning
in steps 1 and 2 above, replace it.
MEC744B
FUEL TANK VACUUM
4.
RELIEF VALVE
1. Wipe clean valve housing.
Suck air through the cap. A slight resistance accompanied
by valve clicks indicates that valve A is in good mechanical
condition. Note also that, by further sucking air, the resis-
tance should disappear with valve clicks.
•
3. Blow air on fuel tank side and ensure that continuity of air
passage exists through valve B.
4. If valve is clogged or if no resistance is felt, replace cap as
an assembly.
Fuel tank side
SEF427N
EC-239
Description
This system returns blow-by gas to the intake into the crankcase. In this process the air passes
manifold collector. through the hose connecting air inlet tubes to
The positive crankcase ventilation (PCV) valve is rocker cover.
provided to conduct crankcase blow-by gas to the Under full-throttle condition, the manifold vacuum
intake manifold. is insufficient to draw the blow-by flow through
During partial throttle operation of the engine, the the valve. The flow goes through the hose con-
intake manifold sucks the blow-by gas through nection in the reverse direction.
the pev valve. On vehicles with an excessively high blow-by, the
Normally, the capacity of the valve is sufficient to valve does not meet the requirement. This is
handle any blow-by and a small amount of venti- because some of the flow will go through the
lating air. hose connection to the intake manifold collector
The ventilating air is then drawn from the air duct under all conditions.
PCV valve operation
Oil separator Engine not running

or backfiring Cruising
Baffle plate
~~ .0
.~
Idling or Acceleration or
q Fresh air
decelerating high load
.. Blow-by gas
ct> Blow-by gas during
high-load operation -~--
AEC923
Inspection
PCV (Positive Crankcase Ventilation)
With engine running at idle, remove PCV valve from rocker
cover. A properly working valve makes a hissing noise as air
passes through it. A strong vacuum should be felt immediately
when a finger is placed over the valve inlet.
AEC911
VENTILATION HOSE
2. Disconnect all hoses and clean with compressed air. If any
hose cannot be freed of obstructions, replace.
ET277
EC-240
~U5e box
Fuel Pressure Release
Before disconnecting fuel line, release fuel pressure from fuel
line to eliminate danger.
~ 1. Turn ignition switch "ON".
~~~ \J!I} 2. Perform "FUEL PRESSURE RELEASE" in "WORK
SUPPORT" mode with CONSULT.
~11~1-
Data link connector ~"
3. Start engine.
for CONSULT
t=====/
• FUEL PRES RELEASE.
FUEL PUMP Will STOP BY

TOUCHING START DURING
IDLE.
ENGINE STALL
D
•
---S-T~-RT--
SEF823K
Remove fuse for fuel pump.

@ ~: Start engine.
4. Turn ignition switch off and reconnect fuel pump
fuse.
SEF921P
Fuel Pressure Check

• When reconnecting fuel line, always use new clamps.
• Make sure that clamp screw does not contact adjacent
parts.
• Use a torque driver to tighten clamps.
• Use Pressure Gauge to check fuel pressure.
• Do not perform fuel pressure check with system operating.
Fuel pressure gauge may indicate false readings.
2. Disconnect fuel hose between fuel filter and fuel tube
(engine side).
3. Install pressure gauge between fuel filter and fuel tube.
4. Start engine and check for fuel leakage.
5. Read the indication of fuel pressure gauge.
At idling:
With vacuum hose connected
With vacuum hose disconnected
If results are unsatisfactory, perform Fuel Pressure Regula-
tor Check.
SEF034K
EC-241
Fuel Pressure Regulator Check

Vacuum Fuel pressure 1. Stop engine and disconnect fuel pressure regulator vacuum
hose from intake manifold.
2. Plug intake manifold with a rubber cap.
.... 3. Connect variable vacuum source to fuel pressure regulator.

4. Start engine and read indication of fuel pressure gauge as
vacuum is changed.
LTo pressure regulator
Fuel pressure should decrease as vacuum increases. If results
are unsatisfactory, replace fuel pressure regulator.
SEF718B
Injector Removal and Installation

2. Disconnect vacuum hose from pressure regulator.
3. Disconnect fuel hoses from fuel tube assembly.
4. Disconnect injector harness connectors.
5. Remove injectors with fuel tube assembly.
• Push injector tail piece.

• Do not pull on the connector.
'nsu'a,or~7
a-ring~1~OJ'
InsUlalor~7
~> ~
Om~riJ$ _.
~lnjeCIOr
SEF310R
6. Install injectors.
Insulator
kJ
11+- 1
• Clean exterior of injector tail piece.
• Use new O-rings.
'I" Locale plate
•. on this side.
a-ring . I
~
FuellUbe~i '.
assembly , .
~'nsulator
I SEF616N
7. Install injectors with fuel tube assembly to intake manifold.

8. Install fuel hoses to fuel tube assembly.
9. Reinstall any parts removed in reverse order of removal.
CAUTION:
After properly connecting fuel hose to injector and fuel tube
assembly, check connection for fuel leakage.
MEC710B
EC-242

Adjustment
PREPARATION • On models equipped with air conditioner,
checks should be carried out while the air
• Make sure that the following parts are in
good order. conditioner is "OFF".
(1) Battery • On models equipped with automatic
transaxle, when checking idle speed, ignition
(2) Ignition system
(3) Engine oil and coolant levels timing and mixture ratio, checks should be
(4) Fuses carried out while shift lever is in "N" position.
(5) ECM harness connector • When measuring "CO" percentage, insert
•
(6) Vacuum hoses probe more than 40 cm (15.7 in) into tail pipe.
(7) Air intake system • Turn off headlamps, heater blower, rear
defogger.
(Oil filler cap, oil level gauge, etc.)
(8) Fuel pressure • Keep front wheels pointed straight ahead.
(9) Engine compression • Make the check after the cooling fan has
stopped.
(10) Throttle valve
Overall inspection sequence
INSPECTION
Perform diagnostic test mode II NG Repair or replace.

(Self-diagnostic results).
OK
Check & adjust ignition timing.
Check & adjust idle speed.
Check heated oxygen sensor NG Check heated oxygen sensor NG Repair or replace harness.
function. harness.
OK OK
Check CO%. OK Replace heated oxygen sensor.
NG
NG Check heated oxygen sensor OK

Check emission control parts
and repair or replace if neces- function.
sary.
INSPECTION END
EC-243
BASIC SERVICE PROCEDURE Em
Adjustment (Cont'd)
START
Visually check the following:

• Hoses and duct for leaks
• Electrical connectors
• Gasket (intake manifold, cylinder head, exhaust system)
• Throttle valve and throttle position sensor operation
SEF455Q
m
\ I / Start engine and warm it up until engine coolant temperature indicator
points to the middle of gauge.
'~,,/ Ensure engine speed stays below 1,000 rpm.
- CHECK-
,,/ ........ 1
/ I \ Open engine hood and run engine at about 2,000 rpm for about 2 minutes
under no-load.
lamp
SEF051PA
Ii]
Perform the Diagnostic Test Mode 1\ (Self-diagnostic results).
OK ~NG
Repair or replace components as neces-

sary.
[!J
SEF248F Run engine at about 2,000 rpm for about 2 minutes under no-load.
Rev engine two or three times under no-load, then run engine at idle
Ii] • IGN TIMING ADJ. D speed for about 1 minute .
IGNITION TIMING FEEDBACK

CONTROL WILL BE HELD BY
TOUCHING START. li]1!I
AFTER DOING SO, ADJUST
IGNITION TIMING WITH A
TIMING LIGHT BY TURNING
THE CAMSHAFT POSITION
00 1. Select "IGNITION TIMING ADJ" in WORK SUPPORT mode.
2. Touch "START" . .
OR
I
SENSOR.
START I
00 1. Turn off engine and disconnect throttle position sensor harness
connector.
2. Start engine.
SEF546N
Rev engine (2,000 - 3,000 rpm) 2 or 3 times under no-load, then run engine
at idle speed.
@
t
harness connector SEF785KA
EC-244
BASIC SERVICE PROCEDURE []K]
Adjustment (Cont'd)
Ii @
Ii L
Check ignition timing with a timing light.
M/T: 15°::l:2° BTDC

A/T: 15°::l:2° BTDC (in UN" position)
NG
Adjust ignition timing to the specified value by turning

AEC804
distributor after loosening bolts which secure distribu-
•
tor.
• IGN TIMING ADJ. 0
IGNITION TIMING FEEDBACK M/T: 15°::l:2° BTDC
CONTROL WILL BE HELD BY . A/T: 15°::l:2° BTDC (in UN" position)
TOUCHING START
AFTER DOING SO, ADJUST @
IGNITION TIMING WITH A ~IIJ ~
SENSOR 00 1. Select "IGN TIMING ADJ" in "WORK
SUPPORT" mode.
2. Touch "START".
OR
START
SEF546N @ 1. Stop engine and disconnect throttle position
sensor harness connector.
2. Start engine.
0
Check idle speed.
@ Read idle speed in "IGN TIMING ADJ" in

"WORK SUPPORT" mode.
OR
@ Check idle speed.
M/T: 750::l:50 rprn
A/T: 750::l:50 rprn (in UN" position)
OK NG
Rev engine (2,000 - 3,000 rpm) 2 or 3 times under

o • IGN TIMING ADJ. 0 no-load, then run engine at idle speed.
I- - CONDITION SETIING - - 1.1

IGN/T FEEDBACK HOLD Adjust idle speed by turning idle speed adjusting
screw.
=== MONITOR === M/T: 750::l:50 rpm

CMPS.RPM (REF) 762rpm A/T: 750::l:50 rprn (in UN" position)
IGN TIMING 15BTDC
CLOSED TH/POS ON
SEF548N
II
00 Touch "BACK".
OR
@ 1. Turn off engine and connect throttle position

2. Start engine.
L
Rev engine (2,000 - 3,000 rpm) 2 or 3 times under
/ / I no-load, then run engine at idle speed.
\
Throttle position sensor-
harness connector / I
\ SEF788LA
-.
EC-245
BASIC SERVICE PROCEDURE mJ
Adjustment (Cont'd)
@
II 1
Check idle speed.
00 Read idle speed in "DATA

MONITOR" mode with CONSULT.
OR
SEF913J
@ Check idle speed.
II M/T: 800:l: 50 rpm

~MONITOR ~NO FAIL 0 A/T: 800:l: 50 rpm (in uN" position)
CAS-RPM (REF) 825rpm ~NG

OK
Check IACV-AAC valve and replace if nec-
essary.
~
Check IACV-AAC valve harness and repair
if necessary.
RECORD
SEF135K
~
Check ECM function- by substituting
1< MONITOR 1< NO FAIL D another known good ECM.

MIR FIC MNT RICH - ECM may be the
cau se of a
pro blem, but this
is r arely the case
1II111[!]
(j) 1. See "M/R FIC MNT" in "DATA
MONITOR" mode.
RECORD I
MEC7118
no-load.
3. Maintain engine at 2,000 rpm
under no-load (engine is warmed
~
up sufficiently). Check that the
monitor fluctuates between
~~r "LEAN" and "RICH" more than 5
@~
times during 10 seconds.
~~V
1 cycle: RICH -> LEAN -> RICH
2 cycles: RICH -> LEAN -> RICH
->LEAN -> RICH
NG
- -~ OR ~@
with a suitable harness)
(j) 1. Set "Heated oxygen sensor
monitor" in the Diagnostic Test
Mode II.
(See page EC-252.)
SEF909P
no-load.
3. Maintain engine at 2,000 rpm
under no-load. Check that the
\ I / malfunction indicator lamp goes
on and off more than 5 times dur-
ing 10 seconds.
......... ~/"
- CHECK- ~OK
/ ...... END
/ I \
SEF051P
EC-246
BASIC SERVICE PROCEDURE [][]
Adjustment (Cont'd)
Heated oxygen sensor @
harness connector
Check heated oxygen sensor harness:

1. Turn off engine and disconnect battery ground
cable.
2. Disconnect ECM harness connector from ECM.
3. Disconnect heated oxygen sensor harness con-
nector. Then connect harness side terminal for
MEF031DB
heated oxygen sensor to ground with a jumper
•
wire.
4. Check for continuity between terminal @ of ECM
~io harness connector and body ground.
Continuity exists OK
II ECM TIcoNNECTORl1
19 Continuity does not exist NG
LEn MEC712B
OK
Repair or replace harness.
Connect ECM harness connector to ECM.
• ACTIVE TEST. 0
COOLANT TEMP 20°C
1. Connect battery ground cable.
===MONITOR=== 2. Select "ENG COOLANT TEMP" in
CMPS.RPM (REF) Orpm "ACTIVE TEST" mode.
INJ PULSE O.7msec 3. Set "COOLANT TEMP" to 20"C (68"F) by
IGN TIMING 5BTDC touching "Qu" and "Qd" and "UP",
"DWN".
OR
AEC681 Disconnect engine coolant temperature

2. Connect a resistor (2.5 kQ) between termi-
DISCONNFCT Engine coolant nals of engine coolant temperature sensor
10 temperature sensor
harness connector
harness connector.
3. Connect battery ground cable.
~ Ii
Start engine and warm it up until engine coolant
00 ~
2.5 k 0 resistor
temperature indicator points to middle of gauge.
(Be sure to start engine after setting "COOLANT
'-- A_E_C6_8-l2 TEMP" or installing a 2.5 kQ resistor.)
Ii
SEF455Q
EC-247
BASIC SERVICE PROCEDURE mJ
Idle Speed/Ignition Timing/ldle Mixture Ratio
Adjustment (Cont'd)
CID
m 1
Rev engine two or three times under no-load, then run
engine at idle speed.
m
Check "CO"%.
SEF248F
Idle CO: Less than 10% and engine runs smoothly.
After checking CO%.
00 1. Touch "BACK".
OR
(j) 1. Disconnect the resistor from terminals of engine

coolant temperature sensor harness connector.
2. Connect engine coolant temperature sensor har-
ness connector to engine coolant temperature
sensor.
SEF913J
NG
1 0K
* MONITOR * NO FAIL D Replace heated oxygen sensor.

MIR F/C MNT RICH fa an
00 1. See "MIR FIC MNT" in "Data
monitor" mode.
2. Maintain engine at 2,000 rpm under
no-load (engine is warmed up suffi-
ciently.). Check that the monitor fluc-
RECORD I
MEC7118
tuates between "LEAN" and "RICH"
more than 5 times during 10 sec-
onds.
1 cycle: RICH --> LEAN -. RICH
w=jr
2 cycles: RICH --> LEAN --> RICH
-->LEAN --> RICH
~~:?_-~ .
~~~~"v
~~ -~
(j)
OR
1. Set "Heated oxygen sensor monitor"
in the Diagnostic Test Mode II.
(Refef'to EC-253)
2. Maintain engine at 2,000 rpm under
no-load. Check that the malfunction
with a suitable harness)
indicator lamp goes ON and OFF
more than 5 times during 10 sec-
SEF909P
onds.
I NG OK
\ I /
......... ~/'
- CHECK-
/ .......
/ I \
SEF051P
EC-248
,$
BASIC SERVICE PROCEDURE []K]
Adjustment (Cont'd)
CD
1
Connect heated oxygen sensor harness connec-
tor to heated oxygen sensor.
Check fuel pressure regulator.

(Refer to EC-242.)
Check mass air flow sensor and its circuit.

Refer to TROUBLE DIAGNOSIS FOR DTC 12.
(Refer to EC-293.)
•
Check injector and its circuit.
Refer to TROUBLE DIAGNOSIS FOR NON
DETECTABLE ITEMS.
(Refer to EC-324.)
Clean or replace if necessary.
Check engine coolant temperature sensor and

its circuit. Refer to TROUBLE DIAGNOSIS FOR
DTC 13.
(Refer to EC-297.)
Check ECM function' by substituting another

known good ECM
•. ECM may be the c ause of a problem, but

It1IS IS rarely the case.
EC-249
Malfunction Indicator lamp (Mil)

1. The malfunction indicator lamp will light up when the igni-
\ I / tion switch is turned ON without the engine running. This is
a bulb check.
'~/' • If the malfunction indicator lamp does not light up, refer to
- CHECK-
EL section ("WARNING LAMPS AND CHIME") or see
/ .......
EC-370.
/ I \ 2. When the engine is started, the malfunction indicator lamp
should go off.
SEF051P Diagnostic Diagnostic

Condition
Test Mode I Test Mode II
Engine
stopped SELF-DIAGNOSTIC
Ignition BULB CHECK
switch in
"ON" posi-
0 RESULTS
Engine
tion HEATED OXYGEN
running MALFUNCTION
SENSOR MONI-
~
ID WARNING
TOR
EC-250
Malfunction Indicator Lamp (MIL) (Cont'd)
HOW TO SWITCH DIAGNOSTIC TEST MODES
~ Turn ignition switch "ON". (Do not

~ start engine.)
Diagnostic Test Mode I- BULB CHECK Diagnostic Test Mode I -

I
MALFUNCTION WARNING
1 Start engine.
~yW~r
~-~
•
Wait at least 2 seconds.
CHK IGN
~J/~l
~-~
DIAGNOSTIC TEST MODE II Diagnostic Test Mode II

- SELF-DIAGNOSTIC RESULTS - HEATED OXYGEN
:~~-~
Start engine. SENSOR MONITOR
~
w;ir
f!i~
l~mv -~
• SWitching the diagnostic test mode is not possible when
the engine is running.
• When ignition switch is turned off during diagnosis, power
Wait at least 2 seconds. to ECM will drop after approx. 1 second.
The diagnosis will automatically return to Diagnostic Test
~ Mode I.
~/~~N
~-~
EC-251
ON-BOARD DIAGNOSTIC SYSTEM DESCRIPTION ~
Malfunction Indicator Lamp (MIL) (Cont'd)
DIAGNOSTIC TEST MODE I-BULB CHECK
In this mode, the MALFUNCTION INDICATOR LAMP on the instrument panel should stay ON. If it remains
OFF, check the bulb. Refer to EL section ("WARNING LAMPS AND CHIME") or see EC-370.
DIAGNOSTIC TEST MODE I-MALFUNCTION WARNING
MALFUNCTION INDICATOR LAMP Condition
Engine coolant temperature sensor circuit malfunction is detected, or the ECM's CPU
ON
is malfunctioning.
OFF No malfunction.
• These Diagnostic Trouble Code Numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOS-
TIC RESULTS).
DIAGNOSTIC TEST MODE II-SELF-DIAGNOSTIC RESULTS
In this mode, a diagnostic trouble code is indicated by the number of blinks of the MALFUNCTION INDI-
CATOR LAMP as shown below.
Example: Diagnostic trouble code No. 12 and No. 43
0.6 0.3 0.6 0.3
ON 1111
OFF
~
0.9 0.3
--I~
2.1 0.6 0.9 Unit: second
Diagnostic trouble code No. 12 Diagnostic trouble code No. 43

AEC490
Long (0.6 second) blinking indicates the number of ten digits, and short (0.3 second) blinking indicates
the number of single digits. For example, the malfunction indicator lamp blinks 4 times for about 2.5
seconds (0.6 sec x 4 times) and then it blinks three times for about 1 second (0.3 sec x 3 times). This
indicates the DTC "43" and refers to the malfunction of the throttle position sensor.
In this way, all the detected malfunctions are classified by their diagnostic trouble code numbers. The
DTC "55" refers to no malfunction. (See DIAGNOSTIC TROUBLE CODE CHART, refer to EC-268.)
HOW TO ERASE DIAGNOSTIC TEST MODE II (Self-diagnostic results)
The diagnostic trouble code can be erased from the backup memory in the ECM when the diagnostic
test mode is changed from Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer to "HOW TO
SWITCH DIAGNOSTIC TEST MODES" on previous page.)
• If the battery terminal is disconnected, the diagnostic trouble code will be lost from the backup
memory within 24 hours.
• Be careful not to erase the stored memory before starting- trouble diagnoses.
• If the MIL blinks or "NATS MALFUNCTION" is displayed on
• SELF-DIAG RESULTS. 0 "SELF-OIAG RESULTS" screen, perform self-diagnostic
FAILURE DETECTED TIME results mode with CONSULT using NATS program card
NATS MALFUNCTION 0 (NATS-E940). Refer to EL section.
• Confirm no self-diagnostic results of NATS is displayed
before touching "ERASE" in "SELF-DiAG RESULTS" mode
with CONSULT.
• When replacing ECM, inltialisation of NATS V2.0 system and
registration of all NATS V2.0 Ignition key IDs must be car-
I
ERASE PRINT II
SEF288Q
ried out with CONSULT using NATS program card (NATS-
E940).
I
Therefore, be sure to receive all keys from vehicle owner.
Regarding the procedures of NATS initialisation and NATS
manual, NATS V2.0.
EC-252
ON-BOARD DIAGNOSTIC SYSTEM DESCRIPTION []K]
DIAGNOSTIC TEST MODE II-HEATED OXYGEN SENSOR MONITOR
In this mode, the MALFUNCTION INDICATOR LAMP displays the condition of the fuel mixture (lean or
rich) which is monitored by the heated oxygen sensor.
MALFUNCTION INDICATOR LAMP Fuel mixture condition in the exhaust gas Air fuel ratio feedback control condition
ON Lean
Closed loop system
OFF Rich
Remains ON or OFF Any condition Open loop system
To check the heated oxygen sensor function, start engine in Diagnostic Test Mode II. Then warm it up
until engine coolant temperature indicator points to middle of gauge.
Next run engine at about 2,000 rpm for about 2 minutes under no-load conditions. Make sure that the •
MALFUNCTION INDICATOR LAMP comes ON more than 5 times within 10 seconds with engine running
at 2,000 rpm under no-load.
EC-253
CONSULT
CONSULT INSPECTION PROCEDURE
1. Turn off ignition switch.
2. Connect "CONSULT" to Data link connector for CONSULT.
(Data link connector for CONSULT is located behind the fuse
box cover.)
for CONSULT
t======/
3. Turn on ignition switch.
+: Program card
CONSULT AE930: For Australia
EE940 +
~
START
I I
I SUB MODE I
SEF253Q
5. Touch "ENGINE",
~ SELECT~S=Y=S=TE=M====
ENGINE
SEF895K
6. Perform each diagnostic test mode according to each ser-

~ SELECT DIAG MODE [i] vice procedure.
WORK SUPPORT For further information, see the CONSULT Operation Manual.
SELF-DIAG RESULTS
DATA MONITOR
ACTIVE TEST
ECM PART NUMBER
FUNCTION TEST
SEF136P
EC-254
CONSULT (Coni' d)
ECCS COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
DIAGNOSTIC TEST MODE
SELF.
Item WORK DlAG. DATA ACTIVE FUNCTION
SUPPORT NOSTIC MONITOR TEST TEST
RESULTS
Camshaft position sensor X X
Mass air flow sensor X X
Engine coolant temperature sensor X X X
•
Heated oxygen sensor X X
Vehicle speed sensor X X
Throttle position sensor X X X X

INPUT
Knock sensor X
lJ)
~ Ignition switch (start signal) X X
a:
<
0-
Air conditioner switch X
~
z
w Park/Neutral position switch X X
z
0 Power steering oil pressure switch X X
0-
:!
0 Battery voltage X
0
lJ) Injectors X X X
0
0
w X (Ignition
Power transistor (Iynition timing) X X X X
signal)
IACV-AAC valve X X X X
OUTPUT Air conditioner relay X
Fuel pump relay X X X X
Cooling fan X X X
EGR valve & EVAP canister purge

X X X
X: Applicable
EC-255
CONSULT (Cont'd)
FUNCTION
Diagnostic test mode Function
A technician can adjust some devices

Work support faster and more accurately by following
indications on CONSULT.
Self-diagnostic results can be read and
Self-diagnostic results
erased quickly.
Data monitor Input/Output data in the ECM can be read.
CONSULT drives some actuators apart

Active test from the ECM's and also shifts some
parameters in a specified range.
ECM part numbers ECM part numbers can be read.
Conducted by CONSULT instead of a tech-

Function test nician to determine whether each system
is "OK" or "NG".
WORK SUPPORT MODE

WORK ITEM CONDITION USAGE
THRTL POS SEN ADJ CHECK THE THROTTLE POSITION SENSOR SIGNAL. When adjusting throttle position
ADJUST IT TO THE SPECIFIED VALUE BY ROTATING sensor initial position
THE SENSOR BODY UNDER THE FOLLOWING CONDI-
TIONS .
• IGN SW "ON"
• ENG NOT RUNNING
• ACC PEDAL NOT PRESSED
IGNITION TIMING ADJ • IGNITION TIMING FEEDBACK CONTROL WILL BE When adjusting initial ignition
HELD BY TOUCHING "START". AFTER DOING SO, timing
ADJUST IGNITION TIMING WITH A TIMING LIGHT BY
TURNING THE CAMSHAFT POSITION SENSOR.
IACV-AAC VALVE ADJ SET ENGINE SPEED AT THE SPECIFIED VALUE UNDER When adjusting idle speed
THE FOLLOWING CONDITIONS .
• ENGINE WARMED UP
• NO-LOAD
FUEL PRESSURE RELEASE • FUEL PUMP WILL STOP BY TOUCHING "START" When releasing fuel pressure
DURING IDLING. from fuel line
CRANK A FEW TIMES AFTER ENGINE STALLS
EC-256
CONSULT (Cont'd)
SELF-DIAGNOSTIC MODE
Regarding items detected in "SELF-DiAG RESULTS" mode, refer to "Diagnostic Trouble Code (DTC)
Chart". (See page EC-268.)
DATA MONITOR MODE

Monitored item ECM
Main
signals
signals
CMPS.RPM • Indicates the engine speed computed • Accuracy becomes poor if engine
(REF) [rpm] from the REF signal (180' signal) of speed drops below the idle rpm.
0 0 the camshaft position sensor. • If the signal is interrupted while the
MAS AIR/FL SE [V]
COOLAN TEMP/S
rOC]or rF]
0 0
• The sig~al voltage of the mass air
flow sensor is displayed.
• The engine coolant temperature

(determined by the signal voltage of
engine is running, an abnormal value
may be indicated .
• When the engine is stopped, a certain

value is indicated .
• When the engine coolant temperature
sensor is open or short-circuited,
•
0 0 the engine coolant temperature sen-
sor) is displayed.
ECM enters fail-safe mode. The
engine coolant temperature deter-
mined by the ECM is displayed .
02 SEN [V] • The signal voltage of the heated oxy-

0 0 gen sensor is displayed.
M/R F/C MNT • Display of heated oxygen sensor sig- • After turning ON the ignition switch,
[RICH/LEAN] nal during air-fuel ratio feedback con- "RICH" is displayed until air-fuel mix-
trol: ture ratio feedback control begins.
RICH ... means the mixture became • When the air-fuel ratio feedback is
0 0 "rich", and control is being affected

toward a leaner mixture.
clamped, the value just before the
clamping is displayed continuously.
LEAN ... means the mixture became
"lean", and control is being affected
toward a rich mixture .
VHCL SPEED SE • The vehicle speed computed from the

[km/h] or [mph] 0 0 vehicle speed sensor signal is dis-
played .
SATTERY VOLT [V] • The power supply voltage of ECM is

0 0 displayed .
THRTL POS SEN [V] • The throttle position sensor signal

0 0 voltage is displayed.
START SIGNAL • Indicates [ON/OFF] condition from the • After starting the engine, [OFF] is dis-
[ON/OFF] 0 0 starter signal. played regardless of the starter sig-
nal.
CLSD THLIPOSI • Indicates the closed throttle position

[ON/OFF] [ON/OFF] determined by the throttle
position sensor signal.
0 0 ON: Closed throttle position
OFF: Other than closed throttle
position
NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display auto-
matically.
EC-257
CONSULT (Conl'd)
Monitored item ECM
Main
signals
signals
AIR COND SIG • Indicates [ON/OFF] condition of the

[ON/OFF] 0 0 air conditioner switch as determined
by the air conditioning signal.
PIN POSI SW • Indicates [ON/OFF] condition from the

[ON/OFF] 0 0 park/neutral position switch signal.
PW/ST SIGNAL • Indicates [ON/OFF] condition of the
[ON/OFF] power steering oil pressure switch
0 0 determined by the power steering oil
pressure signal.
INJ PULSE [msec] • Indicates the actual fuel injection • When the engine is stopped, a certain
0 pulse width compensated by ECM
according to the input signals.
computed value is indicated.
IGN TIMING [BTDC] • Indicates the ignition timing computed

nals.
IACV-AACIV [%] • Indicates the idle air control valve

(AAC valve) control value computed
nals.
A/F ALPHA [%J • Indicates the mean value of the air- • When the engine is stopped, a certain
fuel ratio feedback correction factor value is indicated.
0 per cycle. • This data also includes the data for
the air-fuel ratio learning control.
AIR COND RLY • Indicates the air conditioner relay

[ON/OFF] 0 control condition (determined by ECM
FUEL PUMP RLY • Indicates the fuel pump relay control
[ON/OFFJ 0 condition determined by ECM accord-
ing to the input signals.
COOLING FAN • Indicates the control condition of the
[HI/LOW/OFFJ cooling fans (determined by ECM
0 HI ... High speed operation
LOW ... Low speed operation
OFF ... Stopped
EGRC SOLIV • Indicates the control condition of the
[ON/OFFJ EGR valve & EVAP canister Purge
control solenoid valve (determined by
ECM according to the input signal).
0 ON ... EGR and EVAP canister purge
operation cut-off
OFF ... EGR and EVAP canister purge
operation not cut-off
VOLTAGE • Voltage measured by the voltage
[V] probe.
PULSE • Pulse width, frequency or duty cycle • Only "#" is displayed if item is
[msec] or [Hz] or measured by the pulse probe. unable to be measured.
[%] • Figures with "#"s are temporary
ones. They are the same figures as
an actual piece of data which was just
previously measured.
EC-258
CONSULT (Conl'd)
ACTIVE TEST MODE
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
trouble condition If trouble symptom disappears,
FUEL INJECTION • Fuel injectors
• Change the amount of fuel see CHECK ITEM.
• Heated oxygen sensor
injection using CONSULT.
• Engine: After warming up, idle
the engine.
IACV-AACIV Engine speed changes according • Harness and connector
• Change the IACV-AAC valve
OPENING to the opening percent. • IACV-AAC valve
opening percent using CON-
•
SULT.
trouble condition
ENG COOLANT If trouble symptom disappears, • Engine coolant temperature
• Change the engine coolant .
TEMP see CHECK ITEM. sensor
temperature indication using
• Fuel injectors
CONSULT.
trouble condition
IGNITION TIMING • Timing light: Set • Adjust initial ignition timing
see CHECK ITEM.
• Retard the ignition timing using
CONSULT.
• Engine: After warming up, idle • Harness and connector
the engine. • Compression
POWER • AIC switch "OFF" • Injectors
Engine runs rough or dies.
BALANCE • Shift lever "N" • Power transistor
• Cut off each injector signal one • Spark plugs
at a time using CONSULT. • Ignition coils
COOLING FAN • Turn the cooling fan "ON" and Cooling fan moves and stops.
• Cooling fan motor
"OFF" using CONSULT.
• Ignition switch: ON (Engine

stopped)
FUEL PUMP Fuel pump relay makes the oper- • Harness and connector
• Turn the fuel pump relay "ON"
RELAY ating sound. • Fuel pump relay
and "OFF" using CONSULT
and listen to operating sound .
EGRC
• Turn solenoid valve "ON" and Solenoid valve makes an operat- • Harness and connector
SOLENOID
"OFF" with the CONSULT and ing sound. • Solenoid valve
VALVE
listen to operating sound .
SELF-LEARNING • In this test, the coefficient of self-learning control mixture ratio returns to the original coefficient by
CONT touching "CLEAR" on the screen.
EC-259
CONSULT (Conl'd)
FUNCTION TEST MODE
FUNCTION TEST
ITEM
SELF-DIAG (Engine stopped)
RESULTS • Displays the results of on-
- Objective system
board diagnostic system .
(Engine stopped)
Throttle valve: opened OFF • Throttle position sensor
• Closed throttle position is
CLOSED THROTTLE tested when throttle is
adjustment
POSI opened and closed fully.
• Throttle linkage
(Closed throttle position is
Throttle valve: closed ON • Verify operation in DATA
selected by throttle posi-
MONITOR mode.
tion sensor.)
(Engine stopped)
Range (Throttle valve fully • Throttle position sensor
THROTTLE POSI • Throttle position sensor More than
opened - Throttle valve adjustment
SEN CKT circuit is tested when 3.QV
fully closed) • Throttle linkage
throttle is opened and
• Verify operation in DATA
closed fully.
MONITOR mode .
(Engine stopped) Out of N/P positions OFF
• Neutral position switch or
PARK/NEUT POSI • Inhibitor/Neutral position
inhibitor switch
SW CKT switch circuit is tested
• Linkage or inhibitor switch
when shift lever is manip- In N/P positions ON
adjustment
ulated .
• Ignition. switch: ON
(Engine stopped)
• Fuel pump
FUEL PUMP • Fuel pump circuit is tested There is pressure pulsation on the fuel
• Fuel pump relay
CIRCUIT by checking the pulsation feed hose.
• Fuel filter clogging
in fuel pressure when fuel
• Fuel level
tube is pinched .
(Engine stopped)
• EGR valve & EVAP canis-
EGRC SOLIV The solenoid valve makes an operating • EGR valve & EVAP canis-
ter purge control solenoid
CIRCUIT sound every 3 seconds. ter purge control solenoid
valve circuit is tested by . valve
checking solenoid valve
operating noise .
COOLING FAN The cooling fan rotates and stops every
• Cooling fan circuit is • Cooling fan motor
CIRCUIT 3 seconds.
tested when coaling fan is • Cooling fan relay
rotated.
EC-260
CONSULT (Cont'd)
FUNCTION TEST
ITEM
• Ignition switch: ON ->
START
• Start signal circuit is
tested when engine is
started by operating the
starter. Before cranking,
START SIGNAL battery voltage and engine • Harness and connector
Start signal: OFF -> ON
CIRCUIT coolant temperature are • Ignition switch
•
displayed. During
cranking, average battery
voltage, mass air flow
sensor output voltage and
.
cranking speed are dis-
played .
(Engine running) Locked position ON
• Power steering circuit is
PW/ST SIGNAL • Power steering oil pres-
tested when steering
CIRCUIT sure switch
wheel is rotated fully and
Neutral position OFF • Power steering oil pump
then set to a straight line
running position .
• Vehicle speed sensor cir-
VEHICLE SPEED cuit is tested when vehicle Vehicle speed sensor input signal is
• Vehicle speed sensor
SEN CKT is running at a speed of 10 greater than 4 km/h (2 MPH)
• Electric speedometer
km/h (6 MPH) or higher .

engine.
• Adjust ignition timing (by
• Ignition timing adjustment
moving crankshaft position
is checked by reading The timing light indicates the same
IGN TIMING ADJ sensor or distributor)
ignition timing with a tim- value on the screen.
ing light and checking
drive mechanism
whether it agrees with
specifications.
• INJECTION SYS (Injector,

fuel pressure regulator,
harness or connector)
• IGNITION SYS (Spark
• Air-fuel ratio feedback cir-
plug, power transistor,
cuit (injection system, igni-
ignition coil, harness or
tion system, vacuum
connector)
MIXTURE RATIO system, etc.) is tested by Heated oxygen sensor COUNT: More
• VACUUM SYS (Intake air
TEST examining the heated oxy- than 5 times during 10 seconds
leaks)
gen sensor output at 2,000
• Heated oxygen sensor cir-
rpm under non-loaded
cuit
state.
• Heated oxygen sensor
operation
• Fuel pressure high or low
EC-261
CONSULT (Cont'd)
FUNCTION TEST
ITEM
engine.
• Injector operation of each • Injector circuit (Injector,
cylinder is stopped one harness or connector)
after another, and result- • Ignition circuit (Spark
Difference in engine speed is greater
ant change in engine rota- plug, power transistor,
POWER BALANCE than 25 rpm before and after cutting off
tion is examined to evalu- ignition coil, harness or
the injector of each cylinder.
ate combustion of each connector)
cylinder. (This is only dis- • Compression
played for models where a • Valve timing
sequential multi port fuel
injection system is used.)

engine.
• IACV-AAC valve
• IACV-AAC valve system is
Difference in engine speed is greater • Air passage restriction
IACV-AACIV tested by detecting change
than 150 rpm between when valve open- between air inlet and
SYSTEM in engine speed when
ing is at 80% and at 20%. IACV-AAC valve
IACV-AAC valve opening
• IAS (Idle adjusting screw)
is changed to 0%,20%
adjustment
and 80%.
EC-262
CONSULT (Cont'd)
REAL TIME DIAGNOSIS IN DATA MONITOR MODE
CONSULT has two kinds of triggers and they can be selected by touching "SETTING" in "DATA
MONITOR" mode.
1. "AUTO TRIG" (Automatic trigger):
• The malfunction will be identified on the CONSULT screen in real time.
In other words, DTC and malfunction item will be displayed at the moment the malfunction is
detected by ECM.
DATA MONITOR can be performed continuously until a malfunction is detected. However, DATA
MONITOR cannot continue any longer after the malfunction detection.
2. "MANU TRIG" (Manual trigger):
• DTC and malfunction item will not be displayed automatically on CONSULT screen even though a
malfunction is detected by ECM. •
DATA MONITOR can be performed continuously even though a malfunction is detected.
Use these triggers as follows:
1. "AUTO TRIG"
• While trying to detect the DTC by performing the "DTC CONFIRMATION PROCEDURE", be sure to
select to "DATA MONITOR (AUTO TRIG)" mode. You can confirm the malfunction at the moment
it is detected .
• While narrowing down the possible causes, CONSULT should be set in "DATA MONITOR (AUTO
TRIG)" mode, especially in case the incident is intermittent.
Inspect the circuit by gently shaking (or twisting) suspicious connectors, components and harness
in the "DTC CONFIRMATION PROCEDURE". The moment a malfunction is found the DTC will be
displayed. (Refer to GI section, "Incident Simulation Tests" in "HOW TO PERFORM EFFICIENT
DIAGNOSIS FOR AN ELECTRICAL INCIDENT".)
2. "MANU TRIG"
• If the malfunction is displayed as soon as "DATA MONITOR" is selected, reset CONSULT to
"MANU TRIG". By selecting MANU TRIG you can monitor and store the data. The data can be
utilized for further diagnosis, such as a comparison with the value for the normal operating con-
dition.
I~ SELECT MONITOR ITEM I~ SET RECORDING COND
ECM INPUT SIGNALS AUTO TRIG I MANU TRIG MANU TRIG
I MAIN SIGNALS HI SPEED I LONG TIME HI SPEED
I SELECTION FROM MENU
1 _
1========
l-SE-TI-IN-G ll--S-T.-AR-T--
__ "SETIING"
1__
"AUTO TRIG" "MANU
J
TRIG"
A malfunction can be A malfunction can not be
displayed on "DATA displayed on "DATA
MONITOR" screen MONITOR" screen
automatically if detected. automatically even if
detected.
SEF6740
EC-263
Introduction
Sensors The engine has an ECM to control major systems such as fuel
control, ignition control, idle air control system, etc. The ECM
~ ECM Actuators accepts input signals from sensors and instantly drives actua-
~~.~
tors. It is essential that both input and output signals are proper
and stable. At the same time, it is important that there are no
problems such as vacuum leaks, fouled spark plugs, or other
problems with the engine.
It is much more difficult to diagnose a problem that occurs
MEF036D
lems are caused by poor electric connections or improper wir-
ing. In this case, careful checking of suspected circuits may
help prevent the replacement of good parts.
A visual check only may not find the cause of the problems. A
road test with CONSULTor a circuit tester connected should be
performed. Follow the "Work Flow" on the next page.
talk with a customer who approaches with a driveability com-
plaint. The customer can supply good information about such
problems, especially intermittent ones. Find out what symptoms
are present and under what conditions they occur. A "Diagnos-
tic Worksheet" like the example on EC-267 should be used.
first. This will help troubleshoot driveability problems on an
electronically controlled engine vehicle.
SEF234G
EC-264
Work Flow
CHECK IN
Listen to customer complaints. (Get symptoms.) ............................................... STEP I
Check, print out or write down, and erase Diagnostic Trouble Code (DTC). .. STEP II
Symptoms No symptoms but
•
collected. Malfunction Code
exists at STEP II.
Verify the symptom by driving in the condition the

'1
customer described. ..................................... STEP III
Normal Code Malfunction Code

(at STEP II) (at STEP II)
Verify the DTC by performing the "DTC CONFIRMATION PROCEDURE" '1

...... STEP IV
Choose the appropriate action. . STEP V

'2
Malfunction Code Normal Code (at both STEP II and IV)
(at STEP II or IV)
BASIC INSPECTION
SYMPTOM BASIS (at STEP I or III)
Perform inspections
according to Symptom
Matrix Chart.
TROUBLE DIAGNOSIS FOR DTC XXX. STEP VI
REPAIR/REPLACE
NG FINAL CHECK
Confirm that the incident is completely fixed by performing BASIC INSPECTION
...................................... STEP VII
and DTC CONFIRMATION PROCEDURE (or OVERALL FUNCTION CHECK).
OK
CHECK OUT
*1: If the incident cannot be duplicated, refer 10 GI section ("Incident Simulation Tesls", "HOW TO PERFORM EFFICIENT DIAG-
NOSIS FOR AN ELECTRICAL INCIDENT").
*2: If the on-board diagnostic system cannot be performed, check main power supply and ground circuit. Refer 10 "TROUBLE
DIAGNOSIS FOR POWER SUPPLY", EC-286.
EC-265
Description for Work Flow
STEP DESCRIPTION
Get detailed information about the conditions and the environment when the incident/symptom occurred
STEP I
using the "DIAGNOSTIC WORKSHEET" as shown on the next page.
Before confirming the concern, check and write down (print out using CONSULT) the Diagnostic Trouble
Code (DTC), then erase the code. The DTC can be used when duplicating the incident at STEP 1/1 & IV.
STEP II
Study the relationship between the cause, specified by DTC, and the symptom described by the customer.
(The "Symptom Matrix Chart" will be useful. Refer to EC-274.)
Try to confirm the symptom and under what conditions the incident occurs.
The "DIAGNOSTIC WORK SHEET" is useful to verify the incident. Connect CONSULT to the vehicle in DATA
STEP III MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. Refer to GI section.
If the malfunction code is detected, skip STEP IV and perform STEP V.
Try to detect the Diagnostic Trouble Code (DTC) by driving in (or performing) the "DTC CONFIRMATION
PROCEDURE". Check and read the DTC by using CONSULT.
During the DTC verification, be sure to connect CONSULT to the vehicle in DATA MONITOR (AUTO TRIG)
mode and check real time diagnosis results.
STEP IV If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. Refer to GI section.
In case the "DTC CONFIRMATION PROCEDURE" is not available, perform the "OVERALL FUNCTION
CHECK" instead. The DTC cannot be displayed by this check, however, this simplified "check" is an effec-
tive alternative.
The "NG" result of the "OVERALL FUNCTION CHECK" is the same as the DTC detection.
Take the appropriate action based on the results of STEP I through IV.
If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC XX.
STEP V
If the normal code is indicated, proceed to the BASIC INSPECTION. Refer to EC-271. Then perform inspec-
tions according to the Symptom Matrix Chart. Refer to EC-274.
Identify where to begin diagnosis based on the relationship study between symptom and possible causes.
Inspect the system for mechanical binding, loose connectors or wiring damage using (tracing) "Harness
Layouts".
Gently shake the related connectors, components or wiring harness with CONSULT set in "DATA MONITOR
(AUTO TRIG)" mode.
Check the voltage of the related ECM terminals or monitor the output data from the related sensors with
STEP VI
CONSULT. Refer to EC-277.
The "DIAGNOSTIC PROCEDURE" in EC section contains a description based on open circuit inspection. A
short circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE. For details,
refer to GI section ("HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT", "Circuit
Inspection").
Repair or replace the malfunction parts.
.
Once you have repaired the circuit or replaced a component, you need to run the engine in the same condi-
tions and circumstances which resulted in the customer's initial complaint.
Perform the "DTC CONFIRMATION PROCEDURE" and confirm the normal code (Diagnostic trouble code No.
STEP VII 55) is detected. If the incident is still detected in the final check, perform STEP VI by using a different
method from the previous one.
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) DTC in ECM.
(Refer to EC-252.)
EC-266
Diagnostic Worksheet
KEY POINTS There are many operating conditions that lead to the malfunc-
tion of engine components. A good grasp of such conditions can
WHAT ..... Vehicle & engine model make troubleshooting faster and more accurate.
WHEN Date, Frequencies In general, each customer feels differently about a problem. It
WHERE Road conditions is important to fully understand the symptoms or conditions for
HOW Operating conditions, a customer complaint.
Weather conditions,
Utilize a diagnostic worksheet like the one shown below in
Symptoms
order to organize all the information for troubleshooting.
SEF907L
WORKSHEET
Customer name
Engine #
Incident Date
SAMPLE
MR/MS Model & Year
Trans.
Manuf. Date
VIN
Mileage
In Service Date
•
o Impossible to start o No combustion o Partial combustion
o Partial combustion affected by throttle position
o Startability
o Partial combustion NOT affected by throttle position
o Possible but hard to start o Others [ ]
[J Idling
o No fast idle o Unstable o High idle o Low idle
o Others [ ]
Symptoms
[J Stumble o Surge o Knock o Lack of power
o Driveability o Intake backfire o Exhaust backfire
o Others [ ]
o At the time of start o While idling

o Engine stall o While accelerating o While decelerating
o Just after stopping o While loading
o Just after delivery o Recently
Incident occurrence
o In the morning o At night o In the daytime
Frequency o All the time o Under certain conditions o Sometimes
Weather conditions o Not affected
Weather o Fine DRaining o Snowing o Others [ ]
Temperature o Hot o Warm o Cool o Cold o Humid of
o Cold o During warm-up o After warm-up

Engine conditions Engine speed I I I I I I I I I
0 2,000 4,000 6,000 8,000 rpm
Road conditions o In town o In suburbs o Highway o Off road (up/down)
o Not affected
o At starting o While idling o At racing
o While accelerating o While cruising
Driving conditions
o While decelerating o While turning (RH/LH)
Vehicle speed I I I I I I I I I I I I I
0 10 20 30 40 50 60 MPH
Malfunction indicator lamp o Turned on o Not turned on
EC-267
Diagnostic Trouble Code (DTC) Chart

ENGINE RELATED ITEMS
Diagnostic Detected items
trouble code
No. Malfunction is detected when ...
(Screen terms for CONSULT,
MIL "SELF-DIAG RESULTS" mode)
0
11 Camshaft position sensor circuit • Either 1 or 180 signal is not detected by the ECM for the first few
0
(CAMSHAFT POSI SEN) seconds during engine cranking .

0 0
• Either 1 or 180 signal is not detected by the ECM often enough
while the engine speed is higher than the specified rpm .
• The relation between 1" and 180" signals is not in the normal range
during the specified rpm .
12 Mass air flow sensor circuit • An excessively high or low voltage is entered to ECM.
(MASS AIR FLOW SEN) • Voltage sent to ECM is not practical when compared with the cam-
shaft position sensor signal and throttle position sensor signal.
13 Engine coolant temperature sen- • An excessively high or low voltage from the sensor is detected by
sor circuit the ECM.
(COOLANT TEMP SEN)
21 Ignition signal circuit • The ignition signal in the primary circuit is not detected by the ECM
(IGN SIGNAL-PRIMARY) during engine cranking or running.
34 Knock sensor circuit • An excessively low or high voltage from the sensor is detected by
(KNOCK SENSOR) the ECM.
43 Throttle position sensor circuit • An excessively low or high voltage from the sensor is detected by
(THROTTLE POSI SEN) the ECM.
• Voltage sent to ECM is not practical when compared with the mass
air flow sensor and camshaft position sensor signals .
55 No failure • No malfunction related to OBD system is detected by either ECM or
(NO SELF DIAGNOSTIC FAILURE AIT control unit.
INDICATED...)
*1: This is Quick Reference of "DTC CONFIRMATION PROCEDURE".

Details are described in each TROUBLE DIAGNOSIS FOR DTC XX.
Abbreviations are as follows:
IGN: ON : Turning the ignition switch ON is required for the ECM to detect a malfunction (if one exists).
RUNNING: Running engine is required for the ECM to detect a malfunctiQn (if one eXists).
EC-268
TROUBLE DIAGNOSIS - General Description ill]
Diagnostic Trouble Code (DTC) Chart (Cont'd)
x: Applicable
-: Not applicable
"DTC *1 *2
Check Items CONFIRMATION "OVERALL FUNC- Fail Reference Page
(Possible Cause) PROCEDURE" TION CHECK" Safe
Quick Ref. Quick Ref. System
RUNNING - - EC-289
•
• Starter motor
• Starting system circuit (EL section)
• Harness or connectors -
(The sensor circuit is open or shorted.) RUNNING RUNNING X EC-293
(The sensor circuit is open or shorted.) IGN: ON - X EC-297
• Power transistor unit RUNNING - - EC-301
(The sensor circuit is open or shorted.) RUNNING - - EC-306
• Knock sensor
(The sensor circuit is open or shorted.) - IGN: ON X EC-309
• No failure
- - - -
*2: • The "OVERALL FUNCTION CHECK" is a simplified and effective way to inspect a component or circuit.
In some cases, the "OVERALL FUNCTION CHECK" is used rather than a "DIAGNOSTIC TROUBLE CODE CONFIRMA-
TION PROCEDURE".
When no DTC CONFIRMATION PROCEDURE is available, the "NG" result of the OVERALL FUNCTION CHECK can be
considered to mean the same as a DTC detection .
• During an "NG" OVERALL FUNCTION CHECK, the DTC might not be confirmed.
EC-269
Fail-Safe Chart
The ECM enters fail-safe mode, if any of the following DTCs is recorded due to the open or short circuit.
DTC No.
Detected items Engine operating condition in fail-safe mode
MIL
12 Mass air flow sensor Engine speed will not rise more than 2,400 rpm due to the fuel cut.
circuit
13 Engine coolant tem- Engine coolant temperature will be determined based on the time after turning ignition
perature sensor cir- switch "ON" or "START".
cuit
Just as ignition switch is turned ON or Start 30'C (86'F)
More than 4 minutes after ignition ON or Start 80'C (176'F)
30 - 80'C (86 - 176'F)
43 Throttle position Throttle position will be determined based on the injected fuel amount and the engine
sensor circuit speed.
Therefore, acceleration will be poor.
Condition Driving condition

When engine i$ idling Normal
When accelerating Poor acceleration
- Start signal circuit If the ECM always receives a start signal, the ECM will judge the start signal "OFF"
when engine speed is above 1,000 rpm.
This prevents extra enrichment.
After the engine speed is below 200 rpm, start-up enrichment will be allowed until the
engine speed reaches 1,000 rpm.
- ECM Fail-safe system activating condition when ECM is malfunctioning

The computing function of the ECM was judged to be malfunctioning.
When the fail-safe system activates (i.e., if the ECM detects a malfunction condition in
the CPU of ECM), the MALFUNCTION INDICATOR LAMP on the instrument panel lights to
warn the driver.
Engine control, with fail-safe system, operates when ECM is malfunctioning
When the fail-safe system is operating, fuel injection, ignition timing, fuel pump
operation, IACV-AAC valve operation and cooling fan operation are controlled under cer-
tain limitations.
Operation
Engine speed Engine speed will not rise more than 3,000 rpm
Fuel injection Simultaneous multi port fuel injection system
Ignition timing Ignition timing is fixed at the preset valve
Fuel pump relay is "ON" when engine is running and "OFF" when
Fuel pump
engine stalls
IACV-AAC valve Full open
Cooling fan relay "ON" (High speed condition) when engine is
Cooling fans
running, and "OFF" when engine stalls
EC-270
TROUBLE DIAGNOSIS - General Descrip_ti_on 1 S_R_'
Basic Inspection
Precaution:
Perform Basic Inspection without electrical or mechanical loads
applied;
• Headlamp switch is OFF,
\\ •
•
Air conditioner switch is OFF,
Rear defogger switch is OFF,
• Steering wheel is in the straight-ahead position, etc.
~
~
m
SEF1421
BEFORE STARTING
1. Check service records for any recent •
repairs that may indicate a related
problem, or the current need for
scheduled maintenance.
2. Open engine hood and check the fol-
lowing:
• Harness connectors for improper con-
nections
• Vacuum hoses for splits, kinks, or
improper connections
• Wiring for improper connections,
pinches, or cuts

IGNITION TIMING FEEDBACK CONNECT CONSULT TO THE VEHICLE.
CONTROL WILL BE HELD BY Connect "CONSULT" to the data link
TOUCHING START connector for CONSULT and select
AFTER DOING SO, ADJUST "ENGINE" from the menu. Refer to
IGNITION TIMING WITH A EC-254.
SENSOR.
No
DOES ENGINE START? Go to (I.
START
SEF555N Yes
CHECK IGNITION TIMING. Adjust ignition timing by

(ij\ 1. Warm up engine sufficiently. turning distributor.
~ 2. Select "IGN TIMING ADJ" in
3. Touch "START".
4. Check ignition timing at idle
using timing light.
Ignition timing:
15°::f:2° BTDC
~ 1 Warm up engine sufficiently.

~ 2: Stop engine and disconnect
throttle position sensor har-
ness connector.
3. Start engine.
4. Check ignition timing at idle
using timing light.
Ignition timing:
15°::f:2° BTDC
OK
(Go to @ on next page.)
EC-271
Basic Inspection (Cont'd)
I!] @
IGNITION TIMING FEEDBACK
CONTROL WILL BE HELD BY I!]
TOUCHING START
AFTER DOING SO, ADJUST NG
IGNITION TIMING WITH A
CHECK IDLE ADJ. SCREW INITIAL SET
RPM.
---.. Adjust engine speed by
turning idle adjusting
SENSOR 00 1. Select "IGN TIMING ADJ" in
2. When touching "START",
screw.
I START I
SEF546N
does engine speed fall to
750:!: 50 rpm (AfT in "N" posi-
tion)?
Ii • THRTL POS SEN ADJ .0 OR
••• ADJ MONITOR •••

00 Does engine run at 750:!: 50 rpm
(AfT In "N" position)?
THRTL POS SEN O,52V OK
======== MONITOR ========

CMPS.RPM(REF) Orpm Reconnect throttle position sensor har-
CLSDTHUP ON ness connector.
SEF165P
Ii
NG
CHECK THROTTLE POSITION SENSOR
IDLE POSITION.
---.. Adjust output voltage to
0.50V by rotating throttle
00 1. Perform ''THRTL POS SEN

ADJ" in "WORK SUPPORT"
position sensor body.
mode.
2. Check that output voltage of
1
RESET IDLE POSITION
throttle position sensor is MEMORY.
approx. 0.35 to 0.65V (Throttle 1. Warm up engine suffi-
valve fully closes.) and "CLSD ciently.
THLIPOSI" stays "ON". "OFF" and wait at
OR least 5 seconds.
3. Disconnect throttle
00 Measure output voltage of throt-
tie position sensor using
voltmeter, and check that it is
ness connector.
4. Start engine and wait
approx. 0.35 to O.65V.(Throttle at least 5 seconds in
"N" position.
valve fully closed.) 5. Reconnect throttle
OK • ness connector while
running engine.
~ 1
,
CID
(Go to next page)
EC-272
Basic Inspection (Conl'd)
@
NG
CHECK IDLE SPEED Adjust idle speed. Refer
(ij\ Read the engine idle speed in to EC-243.
~ "DATA MONITOR" mode with
CONSULT.
MfT = 800:1: 50 rpm
AfT = 800:1: 50 rpm
(in uN" position)
OR
fiY\ Check idle speed.
~ MfT = 800:1:50 rpm
AfT = 800:1: 50 rpm
•
(in uN" posillon)
OK
After this inspection, unnecessary diag-

nostic trouble code No. might be dis-
played.
Erase the stored memory in ECM.
OK
INSPECTION END
EC-273
Symptom Matrix Chart
SYMPTOM
z
0
i=
<t:
0::
Z ill
w w w (!)
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-l
-l
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W i= 0
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page
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<t:
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II:
<t:
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O'
<t:
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u.. Z >< >< > > >
r:
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1A 18 1C 1F 1H 1R 1S 1M 1J 1L 1K 1T 1V 1N 1P 1X 1Y
Fuel Fuel pump circuit
• • • • • • 0 00 00 0 • 0 EC-327
Fuel pressure regulator system
• • • • • • • EC-241
Injector circuit
Evaporative emission system
•0 0• 0• 0• 0• 0• 0 00 0 0
0 0
•
0
EC-324
EC-238
Air Positive crankcase ventilation system 0 0
• 0 • 0 0 0 0 0 0 0 EC-240
IACV-Air regulator
Incorrect idle speed adjustment
• 0• • 0• • • 0•
0 0
0 0 0
0
EC-332
EC-243
IACV-AAC valve circuit
IACV-FICD solenoid valve circuit
• • • • • • • • 0
0 0 0 0 0 0 0 0 0
0
•
C)
0 EC-335
EC-339
Ignition Incorrect ignition timing adjustment 0 0
• 0 • • • 0 0 • EC-243
EGR
Ignition circuit
EGR valve & EVAP canister purge con-
• • • • • • • • • EC-301
trol solenoid valve circuit • • 0 • 0 • EC-319
EGR system
Main power supply and ground circuit
0
• • • 00 0 0• 00
()
0 0 0 0 C)
0
0 0
EC-319
0 EC-286
Cooling Cooling fan circuit 0 0 0 0 0 0 0 0 0 0 0 0 EC-343
Air conditioner circuit 0 0 0 0 0 0 0 0 0 0 HA section
EC-274
SYMPTOM
z
0
1=
<!
0:: W
w w W
Z
CJ
..J
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CJ W
0:: () 9 5 1=
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i=' en I :2 Q. ()
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:r: z w en 0::
SYSTEM ..J ~ 0 0 e; en z
w 0
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en w Reference
0 .... Q.
en 0 W z 0
Z
- ECCS system ~ 0:: ....
Q. ..J Z
a: 9- ()
0
2-
page
.... <!
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s: ....0
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•
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0
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0
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u-
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en en WI () () w0::>-
w en 0 I
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u u w w w 1=
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I I 0:: W I ..J Z (/) 1Il <! w w w 0 0 0 1Il
11\ 18 1C 1F 1H 1R 1S 1M 1J 1L 1K 1T 1V 1N 1P 1X 1Y
ECCS Camshaft position sensor circuit
• •
0 0
• 0 0 0 0 0 EC-289
Mass air flow sensor circuit
• • • • • • 0 0 0
• EC-293
Heated oxygen sensor circuit
• • • • 0 0 0
• EC-362
circuit • • • • • • • 0 0 0
• EC-297
Throttle position sensor circuit

Incorrect fhrottle position sensor
• • • • • • EC-309
adjustment
0
• 0 0
• 0 0 EC-272
Vehicle speed sensor circuit 0 0 0 0 EC-314

Knock sensor circuit 0 0 0 0 EC-306
ECM 0 0 0 0 0 0 0 0 0 0 0 0 0 EC-270
Start signal circuit 0 0 EC-317
Park/Neutral position switch circuit 0 0 0 0 EC-357
Power steering oil pressure switch cir-
0 0 EC-354
cuit

EC-275
TROUBLE DIAGNOSIS - General Descrip_tio_n 1 s_R_1
SYMPTOM
z
0
i=
«
a: z W
w w w CJ
....J ....J 0 Z a:
CJ w i= 0 «
a: (.) 9 8 0..
::J (.) z i= :I:
i=' en « :I: :2 0.. (.)
Q 0 f:::. a:
CJ 8 :J
w
:J
en
:2 a:
....J ~ 0 :E z en z :J w
SYSTEM
0 I- en 0.. W
0..
0
0 az w 0
en
z Cl
z
Reference
- Engine mechanical & other S:?- a:
« l-
ii.
....J
9 ~
e- (.)
....J
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(.) 2-
page
I-
a: « w z w CJ Cl
....J ....J 0 :.::: 0 ....J Z
« u. ~ :J «
I-
en
~
a:
w
....J
....J
« Z 0
I-
Z
(.)
0 W
z
:J
u..
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0
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en
I-
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a:
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Cl
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en enen>
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a: « 0 >-
Z Z l- ii: w w 0 :I: a:
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w :.::: a: z en :I: (.) (.)
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z
(.)
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a
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(.)
x
(.)
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w w
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:I: :I: a: w :I: ....J Z en (l) « w w w 0 0 0
1A 1B 1C 1F 1H 1R 1S 1M 1J 1L 1K 1T 1V 1N 1P 1X 1Y
Fuel Fuel tank 0 0 0
Fuel piping 0 0 0 0 0 0 0 0 0 0
Vapor lock 0 0
Valve deposit 0 0 0 0 0 0 0 0 0
Poor fuel (Heavy weight gasoline. Low
0 0 0 0 0 0 0 0 0 -
octane)
Air Air duct 0 0 0 0 0
Air cleaner 0 0 0 0 0
Air leakage from air duct
0 0 0 0 0 0 0 0 0 0
(Mass air flow sensor - throttle body)
Throttle body. Throttle wire
Air leakage from intake manifoldl
• • • • • • • FE section
Coliector/Gasket
0 0 0
• 0 0 0 0 0 0 -
Cranking Battery 0 0 0 0 0 0 0 0 0
Alternator circuit 0 0 0 0 0 0 0 0 0 EL section
Starter circuit
• •
Flywheel
Inhibitor switch
•0 00 -
AT section
Engine Cylinder head
• 00 • • 0• • • 0 0
Cylinder head gasket
• 0 0• 0 0• () 0 0 0 0
Cylinder block
• () 0 0 0
Piston
• 00 00 0• 00 00 • 0 0
Piston ring
Connecting rod
•
0 0 0 0 0 0
0
0
0
0
0
Bearing 0 0 0 0 0 0 0 0
Crankshaft 0 0 0 0 0 0 0 0
Valve Timing chain
• 0 0
• • 0• 0 0 0
mechanism Camshaft
• 0
• • 0• 0 0
Intake valve
• 0 0 0 0
• 0 0 0
Exhaust valve
Hydraulic lash adjuster
• 0 0 0
0 0
0
0
0
0
0
'0 0
0 0
0
0
-
Exhaust Exhaust manifoldlTube/Mulfler/Gasket 0 0 0 0 0 0 0 0 0 0
Lubrication
Three way catalyst
Oil pan/Oil strainer/Oil pump/Oil filterl
• 0 0
• 0 0 0 0 0 0
Oil gallery • 0
• 0 0 0 0 0 0
Oil level (Low)/Filthy oil 0 0 0 0 0 0 0 0 0
Cooling Radiator/Hose/Radiator filler cap 0 0 0 0 0 0 0 0 0
Thermostat 0 0 0 0 0 0 0 0 0 0 0
Water pump 0 0 0 0 0 0 0 0 0
Water gallery 0 0 0 0 0 0 0 0 0
Cooling fan 0 0 0 0 0 0 0 0 0 0 0
Coolant level (low)/Contaminated cool-
0 0 0 0 0 0 0 0 0
ant
• ; High Possibility Item

EC-276

Mode
Remarks:
• Specification data are reference values .
• Specification data are output/input values which are detected or supplied by the ECM at the connec-
tor.
* Specification data may not be directly related to their components signals/values/operations.
(Le., Adjust ignition timing with a timing light before monitoring IGN TIMING. Specification data might
be displayed even when ignition timing is not adjusted to specification. This IGN TIMING moni-
tors the data calculated by the ECM according to the input signals from the camshaft position
sensor and other ignition timing related sensors.)
• If the real-time diagnosis results are NG, and the on-board diagnostic system results are OK, when •
diagnosing the mass air flow sensor, first check to see if the fuel pump control circuit is normal.
• Tachometer: Connect Almost the same speed as the CON-

CMPS.RPM (REF)
• Run engine and compare tachometer indication with the CONSULT value. SULT value .

Idle 1.3 - 1.7V
MAS AIR/FL SE
2,000 rpm 1.7 - 2.1V
• No-load
COOLAN TEMPIS • Engine: After warming up More than 70°C (15S0F)
02 SEN 0- 0.3V .....0.6 - 1.0V

Maintaining engine speed at 2,000 LEAN +--> RICH
MIR FIC MNT rpm Changes more than 5 times
during 10 seconds.
• Turn drive wheels and compare speedometer indication with the CONSULT Almost the same speed as
VHCL SPEED SE
value the CONSULT value
BATTERY VOLT • Ignition switch: ON (Engine stopped) 11 - 14V
• Ignition switch: ON Throttle valve fully closed 0.35 - 0.65V

THRTL pas SEN
(Engine stopped) Throttle valve fully opened Approx. 4.0V
START SIGNAL • Ignition switch: ON -> START -> ON OFF -> ON -> OFF
Throttle valve:
ON
• Ignition switch: ON Idle position
CLSD THLIPOSI
(Engine stopped) Throttle valve:
OFF
Slightly open
Air conditioner switch: OFF OFF

• Engine: After warming up, idle the
AIR COND SIG Air conditioner switch: ON
engine ON
(Compressor operates)
Shift lever "P" or "N" ON

PIN POSI SW • Ignition switch: ON
Except above OFF
EC-277
TROUBLE DIAGNOSIS - General Description []K]
Mode (Cont'd)
Steering wheel in neutral

position OFF
PW/ST SIGNAL • Engine: After warming up, idle the engine (forward direction)
The steering wheel is

ON
turned

Idle 2.5 - 3.7 msec .
INJ PULSE
2,000 rpm 1.9 - 2.8 msec .
• No-load
Idle 13 - 15° BTDC

IGN TIMING ditto
2,000 rpm More than 25° BTDC
Idle 20 - 40%
IACV-AACIV ditto
2,000 rpm -
Maintaining engine speed

A/F ALPHA • Engine: After warming up 53 - 155%
at 2.000 rpm
AIR COND RLY • Air conditioner switch: OFF -+ ON OFF -+ ON
• Ignition switch is ~urned to ON (Operates for 5 seconds)

• Engine running and cranking ON
FUEL PUMP RLY • When engine is stopped (stops in 1.0 seconds)
• Except as shown above OFF

is 94°C (201°F) or less for
AfT models. and 99°C OFF
(210°F) or less for M/T mod-
els

• After warming up engine. idle the engine.
is between 95°C (203°F) and
COOLING FAN • Air conditioner switch: OFF LOW
104°C (219°F) for A/T mod-
• Vehicle stopped
els only

is 105°C (221°F) or more for
A/T models. and 100°C HIGH
(212°F) or more for M/T
models
• Engine: After warming up Idle ON

EGRC SOLIV
2.000 rpm OFF
• No-load
EC-278

Mode
The following are the major sensor reference graphs in "DATA MONITOR" mode.
(Select "HI SPEED" in "DATA MONITOR" with CONSULT.)
THRTL POS SEN, CLSD THLIPOSI

Below is the data for "THRTL pas SEN" and "CLSD THLIPOSI" when depressing the accelerator pedal
with the ignition switch "ON".
The signal of "THRTL pas SEN" should rise gradually without any intermittent drop or rise after "CLSD
THLIPOSI" is changed from "ON" to "OFF".
•
CLSD THUPOSI -00"09 THRTL POS SEN -00"09
10:22 +02"69 10:22 xO.1V +02"69
OfF ON
I
. ~
o
\
13 2,6 38 51,
Full { ~
Release
Full
Depress {
SEF673Q
CMPS.RPM (REF), MAS AIR/FL SE, THRTL POS SEN, 02 SEN, INJ PULSE
Below is the data for "CMPS.RPM (REF)", "MAS AIR/FL SE", "THRTL pas SEN", "02 SEN" and "INJ
PULSE" when revving quickly up to 4,800 rpm under no load after warming up engine sufficiently.
Each value is for reference, the exact value may vary .
.... , .
E ..... • "CMPS'RPM{REF)" should increase gradually
c. '"
-8~ ,... ..."" ..

, , while depressing the accelerator pedal and
u..~
w>< ............ should decrease gradually after releasing
0:
the pedal without any intermittent drop or rise,
~
Q. co_
o: ~ <',••""", ..,..' , d _ .
en
Q.C\j
lO ..... ,..
:EOio
()o •
/ ....
>
:;re-
><
.':
.0"
• "MAS AIRIFL SE" should increase when

w depressing the accelerator pedal and should
(J)
"'- ", ••'\o, "" , .". ~ _ ••••_ _ .
-" ....• decrease at the moment "THRTL POS SEN" is
!o!:: C')_
0: ~ closed (accelerator pedal is released),
C{LO
(J)C\j
<Coo
"",0>0
",,0 It.
SEF059P
EC-279
TROUBLE DIAGNOSIS - General Description m:J
Mode (Cont'd)
<0
,... ..-
lO
0 <0
0 ~
9 0
+
<Xl
>
l')
" • "THRTL pas SEN" should increase while

..- <0
C\l
0 depressing the accelerator pedel and should
z x
w decrease while releasing it.
en
en
0
a..
...
l')
...J
I- lO
~
0: C\l
:I: Oi 0 A
I- 0
<0 ,... m.
0 <0
C\l
~ ~+
C\l
0>
>
0 to
ci C\l
X
• ''02 SEN" may increase immediately after
.----v-. _...:-------
depressing the accelerator pedel and may
"""
<0
. decrease after releasing the pedal .
z
w
en
C\l
lO
C\l I-- ---.... ---
0 Oi 0 A
0
<0 ,...
0 <0 0
b ~ C\l
9 0
+
II)
c..>
w
en ;!-
~ :~.
• "INJ PULSE" should increase when depressing
~-
w II) the accelerator pedal and should decrease
en
when the pedal is released .
.
...J j
::>
a.. lO '.\ .-'\
~ C\l
Oi
z 0
0
A
SEF259QA
EC-280
ECM Terminals and Reference Value

PREPARATION
1. ECM is located behind the center console. For this
inspection, remove the front passenger center console
panel.
•
MEF505D

ily.
!~
Thin wire Tester probeJ
SEF3671
ECM HARNESS CONNECTOR TERMINAL LAYOUT
SEF877K
EC-281
TROUBLE DIAGNOSIS - General Description [![]
ECM inspection table
*Data are reference values.
TERMINAL WIRE
ITEM CONDITION 'DATA
NO. COLOR
[Engine is runninQ]
0.2 - 0.3V
L Idle speed
1 W/B Ignition signal
Approximately 0.7V
IEngine is running]
2 LlOR Tachometer Approximately 0.9V
L Idle speed
!Engine is running.1
3 GY/R Ignition check Approximately 13V
L Idle speed
I
Ilgnition switch "OFF"I 0- 1V

4 WIG
off) switch "OFF"
Ilgnition switch "OFF"I

BATTERY VOLTAGE
L A few seconds after turning ignition switch (11 - 14V)
"OFF" and thereafter
6 B/W ECCS ground Engine ground
L Idle speed
7 G/B Approximately 13.5V

14 G/W Data link connector for IEngine is running.1 Approximately OV
15 GY/L CONSULT L Idle speed Approximately 2.5V
23 G/R Approximately OV

L Cooling fan is not operating. (11 - 14V)
Cooling fan relay (Low
9 LG/R
speed) IEngine is running.1
Approximately OV
10 LG
Cooling fan relay
BATTERY VOLTAGE
(11 - 14V)
(High speed)
Approximately OV
L Both A/C switch and blower fan switch are Approximately OV
11 Y Air conditioner relay "ON".

13 B/W ECCS ground Engine ground
L Idle speed
EC-282
TROUBLE DIAGNOSIS - General Description [ill
TERMINAL WIRE
ITEM CONDITION *DATA
NO. COLOR
1.3 - 1.7V
L Idle speed
16 OR Mass air flow sensor
1.7-2.1V
Mass air flow sensor IEngine is running.!

W Approximately OV
•
17
ground L Idle speed
0- 5.0V
Engine coolant tem- Output voltage varies
18 BRIY IEngine is running.!
perature sensor with engine coolant
temperature.
19 W Heated oxygen sensor 0- Approximately 1.OV
L After warming up sufficiently
Ilgnition switch "ON"I (Warm-up condition)

0.35 - 0.65V
20 Y
Throttle position sen- L Accelerator pedal released
sor Ilgnition switch "ON"I
Approximately 4V
21 B Sensor's ground Approximately OV
L Idle speed
Camshaft position
22
L sensor (Reference IEngine is running.1 0.1 - O.4V
30
signal)
jlgnition switch "ON"!
Approximately 1.5V
24 ORIL
lamp IEngine is running.1 BATTERY VOLTAGE
(11 - 14V)
27 W Knock sensor Approximately 2.5V
L Idle speed
29 B Sensor's ground Approximately OV
L Idle speed
Camshaft position
31
S/W sensor (Position sig- IEngine is running.! 2.0 - 3.0V
40
nal)
32 PUIR Vehicle speed sensor t

Eng;ne "opped and ge., po,;!;on ;, "Neo-

tral position".
While rotating drive wheel by hand
Varies from 0 to 5V
Ilgnition switch "ON"!

Approximately OV
34 BIY Start signal
Ilgnition switch "START"I SATTERY VOLTAGE
(11 - 14V)
EC-283
TROUBLE DIAGNOSIS - General Description []:KJ
TERMINAL WIRE
ITEM CONDITION *DATA
NO. COLOR
/Ignition switch "ON'"
35 G/OR
Neutral position
t "N" or "P" position (A/T)
Neutral position (M/T)
OV
switch/lnhibitor switch
I'gnition switch "ON"I BATTERY VOLTAGE
L Except the above gear position (11 - 14V)
I'gnition switch "OFF"I

OV
36 B/R Ignition switch
Ilgnition switch "ON"I BATTERY VOLTAGE
(11 - 14V)
Throttle position sen- pgnition switch "ON"I

37 P/L Approximately 5V
sor power supply
38 BATTERY VOL TAGE

W/R Power supply for ECM Ilgnition switch "ON"I
47 (11 - 14V)
L Idle speed
IEngine is running.!
L Both air conditioner switch and blower fan Approximately OV
41 G Air conditioner switch switch are "ON".

OV
43 PUlW
Power steering oil L Steering wheel is being turned.
pressure switch IEngine is running.1
7 - 9V
L Steering wheel is not being turned.
Power supply BATTERY VOLTAGE
46 W/L I'gnition switch "0FFj
(Back-up) (11 - 14V)
L Idle speed
BATTERY VOLTAGE
109 W/L Current return Ilgnition switch "OFF"I
(11 - 14V)
101 RIB Injector No. 1
103 G/B Injector No.3 BATTERY VOLTAGE

110 Y/B Injector NO.2 (11 - 14V)
112 LIB Injector NO.4
EC-284
TROUBLE DIAGNOSIS - General Description []K]
'Data are reference values.
TERMINAL WIRE
ITEM CONDITION 'DATA
NO. COLOR

"ON" Approximately OV
104 B/P Fuel pump relay

BATTERY VOLTAGE
•
"ON" and thereafter
0.6 - 0.8V
EGR valve & EVAP . L Engine speed is 4,000 rpm.
105 P canister purge control
solenoid valve
L Idle speed (11 - 14V)
107 IEngine is running.j

B/Y ECCS ground Engine ground
108 L Idle speed
Approximately 0.2V
Heated oxygen sensor L Engine speed is below 3,200 rpm.
111 OR
heater IEngine is running.1 BATTERY VOLTAGE
IEngine is running.\
11 - 14V
L Idle speed
lEngine is running.1
113 SB IACV-AAC valve
~ Sle«;ng wheel ;, be;ng I"med
2 - 11V
Approximately OV
Torque converter L Idle speed
115 P/B clutch solenoid valve IEngine is running.1 (Warm-up condition)
(A/T models) BATTERY VOLTAGE
L Vehicle speed is 60 km/h (37 MPH) or (11 - 14V)
more in "D" position
L Idle speed
EC-285
TROUBLE DIAGNOSIS FOR POWER SUPPL V
Main Power Supply and Ground Circuit
EC-MAIN-01
7.5A Refer to EL-POWER. 30A

[ill OJ
W!L
d:::. (E10n
I~I (MS) Refer to EL-POWER.
W!L
*@
~@
W!L
ST IGNITION
SWITCH
~
I
e----'--, W/L W/L
~
B/R
I
IT ]1
Ibi=Jl Ibi=Jl
ECCS
~ RELAY
@
B/R
d:::.(llii)
I~I(]ID
B/R
ICDI@
+--~
WIG W/R =r@
'--I
W/L W/L WIG
I W/R W/R
B/R
B/R
I
14'61
BATT
h1~1
CRTN
m
SSOFF
';sl
VB
\171
VB
~
IGN
SW ECM
(ECCS
CONTROL
MODULE)
GNO
-C
GNO
-C
GND
-E
GND
-E
GND
-E
GND
-I
GND
-I em
13.91 I~SI 11~71 1I1~1 11~61 ~ ~
B B B/Y B/Y B/Y B/W B/W
L , I--i '-e-e-=e----lI
I I I I I
.~
B
+
L,
*
B B B/Y
-:
-:
Detectable line
for DTC
Non-detectable
line for DTC
CF13) ill
Refer to last page
3456 W
Acrn
~IIIllij @ T L
~
[mJID
(E114)
W
(Foldout page) .
em
L
HEC002
EC-286
TROUBLE DIAGNOSIS FOR POWER SUPPLY []K]
Main Power Supply and Ground Circuit (Co nt' d)
~i) INSPECTION START
Il ECM Er CONNECTOR II
No
36
Start engine. --+ CHECK POWER SUP-
Is engine running? PL V-I.
Yes "ON".
2. Check voltage between
ECM terminal @ and
ground with CONSULT
or tester.
MEC746B Voltage: Battery volt-
•
age
If NG, check the follow-
~i) ing .
@,@
II ECM EfCONNECTORI!
~$ OO,@l)
Lwt
short between ECM
and ignition switch
connectors.
MEC714B ~OK
Go to III
"CHECK
GROUND CIRCUIT" on
next page.
Il ECM ~ CONNECTOR II
NG
38' 47
"--.--'
CHECK POWER SUPPL V.II. --+ Check the following.
2. Check voltage between ECM terminals @,@
@l , (ill) and ground with CONSULT • Harness connectors
or tester. OO,@l)
• 7.5A fuse
MEC747BI OK short between ECM
and battery
connectors.
OK
CHECK POWER SUPPL V-III. --+ Go to III
"CHECK
1. Turn ignition switch "ON" and then GROUND CIRCUIT" on
"OFF". next page.
2. Check voltage between ECM terminals
@, @ and ground with CONSULT
@ or tester.
Voltage:
Case-1: Battery voltage
After turning ignition switch "OFF",
does not exist.
battery voltage will exist for a few
MEC748B Case-2: Battery voltage
seconds, then drop to approximately
exists for more than
QV.
a few seconds.
NG
Case-2
Case-1 Go to [it "CHECK ECCS
RELA Y" on next page.
EC-287
TROUBLE DIAGNOSIS FOR POWER SUPPLY [gJ
@
~IV ~i5 I!]

NG
Ie ECM E!'CONNECTORI!
38.47
+3 1
CHECK HARNESS CONTINUITY
BETWEEN ECCS RELAY AND ECM
nectors.
5 1. Disconnect ECM harness connector.
~
2. Disconnect ECCS relay harness con-
nector.
ECM terminals @, @ and terminal
@.
SEF460Q If OK, check harness for short.
@,@
OK
ts 2
5
1
3
CHECK VOLTAGE BETWEEN ECCS
RELAY AND GROUND.
Check voltage between terminals (!),
@ and ground with CONSULT or
NG
@, <illD
short between ECCS
relay and battery
connectors.
tester.
OK
Ii NG
CHECK OUTPUT SIGNAL CIRCUIT. Repair harness or con-
AEC684 Check harness continuity between ECM nectors.
terminal @ and terminal @.
Ii
~i5 If OK, check harness for short.
[!1
OK
II
•
ECM JO[CONNECTOR NG
CHECK ECCS RELAY. Replace ECCS relay.
4
1. Apply 12V direct current between
relay terminals (!) and @.
2. Check continuity between relay ter-
minals @ and @.
12V «(!) . @) applied:
Continuity exists.
No voltage applied:
AEC492 No continuity
OK
III NG
screws.
4. Check harness continulty between
ECM terminals @, @, @, @,
@, COO, GID and engine ground.
Continuity should exist. .
SEF090M OK
III Check ECM pin terminals for damage

and check the connection of ECM har-
~15@a ness connector.
II ECM ~ CONNECTOR II
. 6'13'39048'107'108'116 . INSPECTION END
LEn SEF461Q
EC-288
Camshaft Position Sensor (CMPS)

The camshaft position sensor is a basic component of the
ECCS. It monitors engine speed and piston position. These
input signals to the ECM are used to control fuel injection, igni-
tion timing and other functions.
The camshaft position sensor has a rotor plate and a wave-
forming circuit. The rotor plate has 360 slits for a 1" (POS) sig-
0
nal and 4 slits for a 180 (REF) signal. The wave-forming circuit
consists of Light Emitting Diodes (LED) and photo diodes.
Rotor plate The rotor plate is positioned between the LED and the photo
SEF6138
diode. The LED transmits light to the photo diode. As the rotor
plate turns, the slits cut the light to generate rough-shaped •
$
1800 signal slit for NO.1 cylinder
#'
';\'0\
\\\\""I"~'11111
\\\\\ d'" /11;
I//..;:
/%
:£
~
10 signal slit
1800 signal slit

pulses. These pulses are converted into on-off signals by the
wave-forming circuit and sent to the ECM.
f %
o
0
Rotor plate SEF8638
Diagnostic
Check Items
(Possible Cause)
No.
0 0
11 • Either 1 or 180 signal is not sent to ECM for the • Harness or connectors
first few seconds during engine cranking. (The camshaft position sensor circuit is open or
shorted.)
• Either r or 180" signal is not sent to ECM often • Starter motor (Refer to EL section.)
enough while the engine speed is higher than the • Starting system circuit (Refer to EL section.)
specified engine speed. • Dead (Weak) battery
~
• The relation between rand 180 signal is not in 0
the normal range during the specified engine

speed.

PROCEDURE
rif\ 1) Turn ignition switch "ON" and select "DATA
~ MONITOR" mode with CONSULT.
speed.
---------- OR ----------
@ 1) Start engine and run it for at least 2 seconds at idle
speed.
2) Turn ignition switch "OFF", wait at least 7 seconds
and then turn "ON".
results) with ECM.
EC-289
TROUBLE DIAGNOSIS FOR DTC 11 [][]
EC-CMPS-01
Refer' to EL-POWER. _. Detectable line

for' DTC
-: Non-detectab Ie
line for' DTC
W!L
I
W!L Ifii'ii\
r=b\!JQ!,
I~I (MB)
W!L
,rID'@
=r='@
DISTRIBUTOR
(CAMSHAFT
W!L POSITION
SENSOR)
I ern>
T-,
W!L W!L
u,,;J~1!.i=ll
L B!W B
---
ECCS
t ..."'J.
I!~I
!bi=UI!.i=U
~ RELAY
CEID
WIG W!R
.I--_.
JOINT
CONNECTOR-6
@
I
l'" --- .... ~==~--•
rT
WIG W!R
rhU3'sn~
SSOFF VB
" W!R
VB
L L
12~1 13.01
REF REF
"
B!W
Ii3'n1 1:0 I
POS POS
B!W
ECM
(ECCS B
...
B B
CONTROL
MODULE)
em 1..1
m m
J
(Ill I I~
3456
@
W T
~5 1 CF
L
3) ~
(11213415\6)
rn>
GY
~@
ITIIIIIIIillI GY
Refer to last page
(Foldout page) .
em
L
HEC003
EC-290
TROUBLE DIAGNOSIS FOR OTC 11 [][]
DIAGNOSTIC PROCEDURE (DETECTABLE CIRCUIT)
INSPECTIONSTART

2. Disconnect camshaft position sensor short between camshaft
harness connector. position sensor and
3. Turn ignition switch "ON". ECCS relay
•
and ground with CONSULT or tester. connectors.

1. Turn ignition switch "OFF". nector.
screws.
SEF524Q terminal @ and engine ground.
~i5 @a
( 1121\'ij151~ 1. Disconnect ECM harness connector. nectors.
terminal @ and ECM terminals @,
@l, terminal @ and ECM terminals
@,@.
SEF463Q
[!J
~15 ~15 CHECK COMPONENT

OK
NG Replace camshaft position

II ECM ECONNECTORII mmJili) (Camshaft position sensor). sensor.
f
31.40
'-.,-J Refer to "COMPONENT INSPECTION"
on next page.
~Q~ ~ OK
.---
[fiJ Disconnect and reconnect harness con-
.. - SEF462Q

ness connector. Reconnect ECM har-
ness connector and retest.
INSPECTIONEND
EC-291
~i)ID Camshaft position sensor

1. Start engine.
dID 2. Check voltage between camshaft position sensor terminals
CID, @ and ground with AC range.
Condition Terminal Voltage (AC range)
@and ground Approximately

Engine running at idle
@and ground 2.7V'
AEC689
*: Average voltage for pulse signal (Actual pulse signal can be confirmed
by oscilloscope.)
3. If NG, replace distributor assembly with camshaft position

sensor.
4. Remove distributor cap. Visually check signal plate for dam-
age or dust.
After this inspection, diagnostic trouble code No. 11 might be
displayed with camshaft position sensor functioning properly.
Erase the stored memory.
SEF887K
EC.292
TROUBLE DIAGNOSIS FOR OTe 12
Mass Air Flow Sensor (MAFS)

The mass air flow sensor is placed in the stream of intake air.
It measures the intake flow rate by measuring a part of the
entire intake flow. It consists of a hot wire that is supplied with
electric current from the ECM. The temperature of the hot wire
is controlled by the ECM a certain amount. The heat generated
by the hot wire is reduced as the intake air flows around it. The
more air, the greater the heat loss.
Therefore, the ECM must supply more electric current to main-
tain the temperature of the hot wire as air flow increases. The
SEF781K ECM detects the air flow by means of this current change .
Diagnostic
Trouble
Code No.
12
is sent to ECM.
Check Items
(Possible Cause)
• An excessively high or low voltage from the sensor • Harness or connectors

•

PROCEDURE
fiii\ 1) Turn ignition switch "ON", and wait at least 6 sec-
~ onds.
3) Start engine and wait at least 3 seconds.
---------- OR ----------
rR\ 1) Turn ignition switch "ON", and wait at least 6 sec-
~ onds.
2) Start engine and wait at least 3 seconds.
and then turn "ON".
results) with ECM.
EC-293
Mass Air Flow Sensor (MAFS) (Coni' d)
EC-MAFS-01
Refer to EL-POWER. -: Oetectable line

for DTG
-: Non-detectable
line for DTC
W!L
I
W!L iETtITI
1Fst11~
~@ W!R
W/L
,ctJ,@
W
3MASS
=r(ffi AIR
W!L FLOW
SENSOR
I
T-,
W!L W!L
lbjdJlbj:Jlm
OR W
EGGS
t "
...1
I!~I
1ki=JI1'=i=!'@
~ RELAY
WIG W!R
.I--_....
JOINT
CONNEGTOR-6
I ( ....-m=_ ~=P:1 @
SSOFF VB
"
WIG W!R W!R
wtilli1Bnd7n
VB QA+
OR
w=IT5il~
QA-
W
ECM B
11
BB
(EGCS
CONTROL
MODULE)
em t...J 1
<ill> (ffi)
~III'fil em
3456 W
~<rn>
cn.g:oo BR
~@
CDODDDJDJJJD GY
Refer to last page
(Foldout page) .
em
L
HEC004
EC-294
INSPECTION START
NG
CHECK POWER SUPPLY. Repair harness or con-
2. Disconnect mass air flow sensor har-
ness connector.
~i5~0
c:u:ffiD
Voltage: Battery positive voltage

1. Turn ignition switch "OFF"
NG
nectors.
•
screws.
MEC749B terminal @ and ECM terminal @.
If OK. check harness for short.

Check harness continuity between ter- nectors.
minal CD and ECM terminal @.
if OK, check harness for short.
NG
CHECK COMPONENT Replace mass air flow
~I() ~Io (Mass air flow sensor).

Refer to "COMPONENT iNSPECTION"
sensor.
1=' =E=CM=B II
CONNECTOR CIIfJ1D on next page.
17
OK


MEC751B

~i() ~io and check the connection of ECM har-
II ECM 'ECONNECTORII
16
(TIffiJ::J ness connector and retest.
INSPECTION END
MEC752B
EC-295
TROUBLE DIAGNOSIS FOR DTC 12 ,

1, Turn ignition switch "ON",
2, Start engine and warm it up sufficiently,
3, Check voltage between terminal CD and ground,
Conditions Voltage V
Ignition switch "ON" (Engine stopped.) Less than 1.0
Idle (Engine is warmed-up sufficiently.) 1.3 - 1.7

MEC753B
4, If NG, remove mass air flow sensor from air duct. Check hot
wire for damage or dust.
SEF881K
EC-296

The engine coolant temperature sensor is used to detect the
engine coolant temperature. The sensor modifies a voltage sig-
nal from the ECM. The modified signal returns to the ECM as
the engine coolant temperature input. The sensor uses a ther-
mistor which is sensitive to the change in temperature. The
electrical resistance of the thermistor decreases as tempera-
ture increases.
SEF594K
9
~
~
1ij
'w
20
19
6
4
2
1.0
0.8
< Reference data>
Engine coolant temper-
. ature
'C ("F)
-10 (14)
Voltage
(V)
4.4
Resistance
(kQ)
7.0-11.4
•
8! 04 20 (68) 3.5 2.1 - 2.9
0.2 50 (122) 2.2 0.68 - 1.00
0.1
.20 0 20 40 60 80 100 90 (194) 0.9 0.236 - 0.260
(-4) (32) (68) (104)(140)(176)(212)
Temperature 'C (OF)
SEF012P
Diagnostic
Check Items
(Possible Cause)
No.
is sent to ECM. (The sensor circuit is open or shorted.)

PROCEDURE
rF.i\ 1) Turn ignition switch "ON".
3) Wait at least 5 seconds.
---------- OR ----------
rm 1) Turn ignition switch "ON" and wait at least 5 seconds.
~ 2) Turn ignition switch "OFF", wait at least 7 seconds
and then turn "ON".
results) with ECM.
EC-297
(Cont'd)
EC-ECTS-01
~ENGlNE COOLANT
TEMPERATURE
SENSOR
@lID
Il:j.JJ 4=U
BR/Y B
I I
BR/Y ~
$--1--$
B
_.
-:
Detectable line
for DTC
Non-detectable
line for DTC
BR/Y U])
B
•
t
BR/Y B B
Ii1'sH ~ 12-91
TW GND GND ECM
-A -A (ECCS
CONTROL
MODULE)
em
~~ ~<rn>
@ L ~ GY
em
L
HEC005
EC-298
TROUBLE DIAGNOSIS FOR DTC 13 mJ
(Cont'd)
INSPECTIONSTART
m NG
2. Disconnect engine coolant tempera- short between ECM
MEC7188A ture sensor harness connector. and engine coolant
•
3. Turn ignition switch "ON". temperature sensor
4. Check voltage between terminal @ • Harness connectors
~io and ground with CONSULT or tester.

Voltage:
. Approximately 5V
@D,@)
connectors.
CHECK GROUND CIRCUIT. NG

~ 1. Turn ignition switch "OFF". • Harness for open or
2. Check harness continuity between short between ECM
SEF518Q terminal CD and engine ground. and engine coolant
Continuity should exist. temperature sensor
~i5 OK
@D.@)
If NG. repair harness or
connectors.
CHECK COMPONENT Replace engine coolant

(Engine coolant temperature sensor). temperature sensor.
~ Refer to "COMPONENT INSPECTION"
on next page.
SEF519Q
OK


INSPECTIONEND
EC-299
(Cont'd)
Temperature °C (OF) Resistance kQ
20 (68) 2.1 - 2.9
50 (122) 0.68 - 1.00
90 (194) 0.236 - 0.260

SEF152P
If NG, replace engine coolant temperature sensor.
EC-300
Ignition Signal
Ignition coil & power transistor (Built into distributor)
The ignition coil is a small molded type. The ignition signal from
the ECM is sent to the power transistor. The power transistor
switches on and off the ignition coil primary circuit. As the pri-
mary circuit is turned on and off, the proper high voltage is
induced in the coil secondary circuit.
Diagnostic
21
Trouble
Code No.
to ECM during engine cranking or running.

Check Items
(Possible Cause)
• The ignition signal in the primary circuit is not sent • Harness or connectors
•
• Power transistor unit.
• Resistor

PROCEDURE
Note: If both DTC 11 and 21 are displayed, perform TROUBLE
DIAGNOSIS FOR DTC 11 first. Refer to EC-289.
(F.I\ 1) Turn ignition switch "ON".
3) Start engine. (If engine does not run, turn ignition
switch to "START" for at least 5 seconds.)
---------- OR ----------
~ 1) Turn ignition switch "ON".
~ 2) Start engine. (If engine does not run, turn ignition
switch to "START" for at least 5 seconds.)
and then turn "ON".
results) with ECM.
EC-301
Ignition Signal (Co nt' d)
EC-IGN/SG-01
30A Refer to EL-POWER. -: Detectable line

for OTC
OJ -: Non-detectable
G line for DTC
OFF
m ST IGNITION
' ....
SWITCH BIR
<tlB)
ACG w+fl
~
BIR
db~
I~ICMID
t CONDENSER
BIR IGNITION DISTRIBUTOR
IUJI@
COIL
POWER m
=r<B) TRANSISTOR @
BIR
~ ~~
G W/B B/W
I'
G
t I'
.-
~
BIY +
To EC"
(EGGS contra 1
module)
RESISTOR
SPARK PLUG
W
GY/R
2
~
W/B
m
IGN
m
IGN ECM n
(EGCS BIY B B
t.J !
CK
CONTROL
MODULE)
L- ---l CED
m m
r--------------------~
I I Refer to last page
~ (E114)
fill I lfi] Cffi I I:XI m~@1
tmIID W 3456 W : (11213141516)
I
L
GY CZIID GY :
I
~
(IT)
L
HEC006
EC-302
TROUBLE DIAGNOSIS FOR DTe 21
INSPECTION START
Yes
Turn ignition switch "OFF". and restart
engine.
Is engine running?
SEF010P NG
•
2. Disconnect ignition coil harness con- QD,@
nector. • Harness connectors
3. Turn ignition switch "ON". @,@D
4. Check voltage between terminal • Harness for open or
(J) and ground with CONSULT or short between ignition
tester. coil and ignition switch
connectors.
OK
NG
AEC69a 1. Turn ignition switch "OFF". nectors.
2. Disconnect power transistor harness
connector.
~i5 @a Continuity should exist.

NG
1. Disconnect ECM harness connector. nectors.
~ 2. Check harness continuity between
SEF4690
ECM terminal G) and power transis-
tor terminal G).
~iv ~i5 OK
NG
II ECM 'gCONNECTORII (1!2IffllsI6) CHECK COMPONENTS Replace malfunctioning
(Ignition coil, power transistor). component(s).
EC-305.
OK
SEF4700 Disconnect and reconnect harness con-


INSPECTION END
EC-303
@

2. Disconnect ignition coil harness con-
nector.
3. Strip tape covering resistor.
ignition coil terminal CID and resistor
terminal (!). resistor terminal @
(;J~i5 ~i5
1
and ECM terminal @.
~~Q~ 'Cf ~ OONNlliOR~
LllJ ~i5 CHECK COMPONENT
OK
NG Replace resistor.
cffu (Resistor).
[ill Refer to "COMPONENT INSPECTION"
on next page.
SEF471Q


INSPECTION END
EC-304
Ignition coil
1. Disconnect ignition coil harness connector.
2. Check resistance as shown in the figure.
Terminal Resistance [at 25'C (77'F)]

(J) - @ (Primary coil) 0.5 - 1.0Q
(J) - @ (Secondary coil) Approximately 25 kQ
AEC902
For checking secondary coil, remove distributor cap and
measure resistance between coil tower metal tip @ and
terminal (f).
If NG, replace distributor assembly as a unit.
•
LCoiltower meta/tip MEC719B
Power transistor
1. Disconnect camshaft position sensor & power transistor
harness connector and ignition coil harness connector.
2. Check power transistor resistance between terminals CID
and @.
Terminals Resistance Result
NotOQ OK
@ and @
on NG
If NG, replace distributor assembly.

Resistor
1. Disconnect resistor harness connector.
2. Check resistance between terminals CD and CID
Resistance: Approximately 2.2 kQ [at 25°C (77°F»
If NG, replace resistor.
EC-305
Knock Sensor (KS)

The knock sensor is attached to the cylinder block. It senses
engine knocking using a piezoelectric element. A knocking
vibration from the cylinder block is sensed as vibrational pres-
sure. This pressure is converted into a voltage signal and sent
to the ECM.
PIEZO-ELEMENT
SEF598K
Diagnostic
Check Items
(Possible Cause)
No.
34 • An excessively low or high voltage from the knock • Harness or connectors

sensor is sent to ECM. (The knock sensor circuit is open or shorted.)
• Knock sensor

PROCEDURE
fiii\
1) Turn ignition switch "ON" and select "DATA
\J!} MONITOR" mode with CONSULT.
speed.
----------OR -----------
speed.
and then turn "ON".
results) with ECM.
EC-306
EC-KS-01
-: Detectable line
for DTC
ECM -: Non-detectable
(ECCS line for DTC
CONTROL
MOOULE)
KNK (IT)
12'; I
W
f .--------. •
.
I I
I I
I I
I I
I I
I I
,,:"
w~
w @Z)
rn
JOINT
CONNECTOR-6
@
fI • I 1
I I
I I
I I
I I
I I
I:: )
KNOCK
SENSOR
~
~m> ~@
~GY I.IIIIIIII1lII GY
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L
HEC007
EC-307
,,~n~( r\r~\ //\ \AY
..("'~Inlake manifold
INSPECTION START
~ ~
screws.
fa
and knock sensor harness connector.
3. Disconnect sub-harness connectors
@,@D.
terminal CD and ECM terminal @ .
If OK, check harness for shorl.
OK
m
CHECK SUB.HARNESS CIRCUIT. Repair harness or con-
1. Disconnect knock sensor harness nectors.
connector.
\ MEC7568
knock sensor harness connector ter-
fa minal @ and knock sensor sub-har-
~15 ~15 ness connector terminal CD.
II ECM ..
BCONNECTORII ~
27 \ili:tV OK
CHECK COMPONENT NG Replace knock sensor.

(Knock sensor).
below.
MEC757B OK


~~ Check ECM pin terminals for damage
\tiiliJ and check the connection of ECM har-
ness connector and retest,
INSPECTION END
Knock sensor
• Use an ohmmeter which can measure more than 10 MO.
1. Disconnect knock sensor harness connector.
2. Check resistance between terminal @ and ground.
Resistance: 500 - 620 kO [at 25°C (77°F))
CAUTION:
Do not use any knock sensors that have been dropped or phys-
ically damaged. Use only new ones.
AEC719
EC-308
Throttle Position Sensor

The throttle position sensor responds to the accelerator pedal
movement. This sensor is a kind of potentiometer which trans-
forms the throttle position into output voltage, and emits the
voltage signal to the ECM. In addition, the sensor detects the
opening and closing speed of the throttle valve and feeds the
voltage signal to the ECM.
Idle position of the throttle valve is determined by the ECM
receiving the signal from the throttle position sensor. This one
controls engine operation such as fuel cut.
SEF089K
[f~..
L
~L 1
VI
~
.~
2
&c
Supply voltage:
4.55V (Applied be~VoIee~_terminalsNO.1 and 3)
•
~ ~M
Throttle position sensor g -g

:; ~ 0.5
8~
0.
00 -~---_. 90
Throttle valve opening angle (deg.) SEF520Q
Diagnostic
Check Items
Trouble Malfunction is detected when ...
(Possible Cause)
Code No.
43 • An excessively low or high voltage from the sensor • Harness or connectors

is sent to ECM. (The sensor circuit is open or shorted.)
EC-309
OVERALL FUNCTION CHECK
"* MONITOR * NO FAIL 0 Use this procedure to check the overall function of the throttle
THRTL pas SEN 0.48V position sensor. During this check, a DTC might not be con-
firmed.
rij\ 1) Turn ignition switch "ON".
~ 2) Select "MANU TRIG" and "HI SPEED" in "DATA
MONITOR" mode with CONSULT.
3) Select "THRTL POS SEN" in "DATA MONITOR" mode
I- I~-----..l with CONSULT.
~-R-E-CO-R-D-~I 4) Press RECORD on CONSULT SCREEN at the same
SEF477Q time accelerator pedal is depressed.
5) Print out the recorded data and check the following:
NG data OK data
THFm. pos SEN 00"00 THRTL pos SEN OO~ • The voltage when accelerator pedal fully released
'~U.'3 ~v ~:' 'g;v :":' is approximately 0.35 - 0.65V .
• ~~~'3. 1
") ................. 1 • The voltage rise is linear in response to accelera-

•...•..•..• 1 tor pedal depression .
THRTl THRTL
• The voltage when accelerator pedal fully depressed
15:38 ~~~ 15:38 ~~~ is approximately 4V.
(V) (V)
00"36 214 00"46 2.88 ---------- OR ----------
00"37 2.20 00"47 3.00
00"38 2.26 00"48 3.12 1) Turn ignition switch "ON",
00"39 2.32 00"49 3.24
00"41 2.26 00"50 3.34 2) Check the voltage between ECM terminals @J and
00"42 2.20 00"51 3.46
00"43 2.58 00"52 3.56 @, @ (ground) and check the follOWing:
SEF267Q
• The voltage when accelerator pedal fully released
is approximately 0.35 - 0.65V.
~i) • The voltage rise is linear in response to accelera-

tor pedal depression.
II
LelJ
ECM El'coNNEcTORII
(9"oodl
• The voltage when accelerator pedal fully depressed
is approximately 4V,
MEC7228
EC-310
EC-TPS-01
THROTTLE
POSITION
SENSOR
@
--
-:
Detectable line
for DTC
Non-detectable
line for DTC
1I
•
(
t I~
I
I
~
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I JOINT
CONNECTOR-6
.-
I
I I @
I I
I I
'::::
~ ~
P/L
t
13-71 12.01
Y
~ i~.~
B B
12-91 n
B B B
AVCC TVO GND GND ECM
-A -A (ECCS
CONTROL
MODULE)
CED
tJ m1
0:13)
~@ ~@
<IIm BR IIIillIIIIIIl GY
CED
L
HECOOB
EC-311
INSPECTION START
NG
CHECK POWER SUPPLY. Repair harness or con-
2. Disconnect throttle position sensor
harness connector.
4. Check voltage between terminal (1)
MEC723B
Voltage: Approximately 5V
OK
NG
CHECK GROUND CIRCUIT. Check the following.
2. Loosen and retighten engine ground short between ECM
screw. and throttle position
3. Check harness continuity between sensor
terminal @ and engine ground. If NG, repair harness or
SEF480Q
OK
r~r~
,,~n~7 \ n\ \!Y
-z~lntake manifold CHECK INPUT SIGNAL CIRCUIT.
NG
[L~ 1. Disconnect ECM harness connector.

ECM terminal @) and terminal @.
nectors
OK
ADJUST THROTTLE POSITION SEN-

SOR.
Perform "Basic Inspection", EC-271.
OK
NG
CHECK COMPONENT Replace throttle position
~io (Throttle position sensor).

on next page.
sensor. To adjust it, per-
form "Basic Inspection",
EC-271.
OK •

~
SEF481Q

~io ~i5 ness connector and retest.
II ECM ~CONNECTORII o::fl\])

20 INSPECTION END
SEF482Q
EC-312
1. Disconnect throttle position sensor harness connector.
2. Make sure that resistance between terminals @ and CID
changes when opening throttle valve manually.
Throttle valve conditions Resistance [at 25'C (77'Fl)
Completely closed Approximately 1 kQ

Partially open 1 - 10 kQ
MEC7248
Completely open Approximately 10 kQ
If NG, replace throttle position sensor.

To adjust it, perform "Basic Inspection", EC-271.
EC-313
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS [][]
Vehicle Speed Sensor (VSS)
IGNITION SWITCH
ON 01" START
_. EC-VSS-01
Detectable line
for DTC
-: Non-detectable
line for DTC
10A BLOCK
[]] (,JIB)
~
COMBINATION
METER ~ R/Y .j~ R/Y
1'TIO\1iETt\i\
~11E:w'l\
,!1J- R/Y i4~VEHICLE
) SPEED
(SPEED- ~ I 'C!Qy ~ I\Ee!6I (SENSOR
OMETER)
@ @r R ,~ R , [iJ- R ~ @@
@)
~
PU/R
I
PU/R/U"Arn
r=:b~
I~I@
PUIR
PU/R
I
13'21
VSP ECM
(ECCS
CONTROL BIR
MODULE)
em -!-
@
r---------------------------------~
Refer to last page
(Foldout page) .
~@@
tW GY
~---------------------------------~
~~
mz:rnJ B
CID
L
HEC009
EC-314
The vehicle speed sensor is installed in the transaxle. It con-
tains a pulse generator which provides a vehicle speed signal
Vehiclespeed
to the speedometer. The speedometer then sends a signal to
sensor
the ECM.
AEC110
• V~HICLE SPEED SEN CKT.
AFTER TOUCH START.

DRIVE VEHICLE
AT lOkm!h (6mph) OR
MORE WITHIN 15 see
INSPECTION START •
L--- __ '~----'
-N-EX-T -1I=~_s-T_A~R=T== 1. Jack up drive wheels.

fi\ 2. Perform "VEHICLE SPEED
MEF559D ~ SEN CKT" in "FUNCTION
rif\
OR
2. Read "VHCl SPEED SE" sig-
VHCL SPEED SE 20kmlh
PIN POSI SW OFF ~ nal in "DATA MONITOR"
mode with CONSULT.
CONSULT value should be the
same as the speedometer indi-
cation.
OR
RECORD 3. Rotate drive wheel by hand.
SEF941N
terminal @ and body ground.
~ CONNECT f?Ft::J:. ~ Voltage should vary between
~£) ~~ approx. 0 - 5V.
1=' =E=CM=-g CONNECTOR II ~ NG

32 ~l NG
CHECK SPEEDOMETER FUNCTION. Check vehicle speed sen-
Make sure that speedometer functions sor and circuit.
properly. (Refer to "Inspection!
Speedometer and Vehicle
OK
Speed Sensor" of
MEC3238
"METER AND GAUGES"
in El section.)
EC-315
@
ECM @I CONNECTOR I
32 CHECK INPUT SIGNAL CIRCUIT. NG Check the following.
2. Disconnect ECM harness connector CID,@
and combination meter harness con- • Harness for open or
nector. short between ECM
3. Check harness continuity between and combination meter
MEC7598
ECM terminal @ and terminal @. If NG, repair harness or
OK


INSPECTION END
EC-316
Start Signal
EC-S/SIG-01
Refer to EL-POWER.
-: Detectable line
•
for DTC
-: Non-detectable
IGNITION line for DTC
ST SWITCH
(E114)
FUSE
7.5A BLOCK
1261 (JIB)
~
IN.41 (E106)
BIY
BIY
I
r=:b (M49)
I!¥JI CEID
BIY
SlY
I
~
ST ECM
MTR (ECCS
CONTROL
MODULE)
em
@15f1l (E114) Refer to last page

(Foldout page) .
@gN] w
em
L
HEC010
EC-317
• START SIGNAL CKT •
INSPECTION START
1 CLOSE THROTILE, SHIFT
TO P OR N RANGE
2 TOUCH START AND
START ENGINE fa
IMMEDIATELY CHECK OVERALL FUNCTION. OK INSPECTION END
(ij\ 1, Turn ignition switch "ON",
~ 2, Perform "START SIGNAL CKT"
in "FUNCTION TEST" mode
NEXT II START with CONSULT,
OR
SEF191L
rif\ 1, Turn ignition switch "ON",
~ 2, Check "START SIGNAL" in
fa -(:( MONITOR -(:( NO FAIL 0 "DATA MONITOR" mode with
STARTSIGNAL OFF CONSULT,
CLSDTH/PSW ON
IGN "ON" OFF
AfRCONDSIG OFF
IGN "START" ON
PIN POSI SW ON
OR
1, Turn ignition switch to
___ RE_C_O_R_D __ I
SEF111P
"START",
2 Check voltage between ECM
terminal @ and ground,
Voltage:
Ignition switch "START"
~i3 Battery voltage

Exceplabove
II ECM E[CONNECTORII
34
Approximately OV
CHECK INPUT SIGNAL CIRCUIT. NG Check the following,

1, Turn ignition switch "OFF", • Harness connectors
~ 2, Disconnect ECM harness connector @,@
MEC725B and ignition switch harness connec- • 7,5A fuse
tor, • Harness for open or
3, Check harness continuity between short between ECM and
~15
~
ECM terminal @ and terminal @,
ignition switch
connectors,
ECM ~CONNECTORI
34
t:1tlliJ OK
Disconnect and reconnect-harness con-

nectors in the circuit Then retest
Trouble is not fixed,

MEC760B
ness connector, Reconnect ECM har-
ness connector and retest
INSPECTION END
EC-318
Exhaust Gas Recirculation (EGR) Valve and

EVAP Canister Purge Control
SYSTEM DESCRIPTION
I Camshaft position sensor I Engine speed
EGR valve
Mass air flow sensor I Amount of intake air ECM & EVAP
I (ECCS canister
control purge con-
Engine coolant temperature sensor ~Engine coolant temperature
module) trol sole-
I noid valve
I Start signal
I Ignition switch
•
I
This system cuts and controls vacuum applied to • Low engine coolant temperature
EGR valve and EVAP canister to suit engine oper-
• Engine starting
ating conditions. This cut-and-control operation • High-speed engine operation
is accomplished through the ECM and the EGR • Engine idling
valve & EVAP canister purge control solenoid • Excessively high engine coolant temperature
valve. When the ECM detects any of the following
conditions, current flows through the solenoid
• Mass air flow sensor malfunction
valve. This causes the port vacuum to be dis-

charged into the atmosphere. The EGR valve and
EVAP canister remain closed.
EGR valve
The EGR valve controls the amount of exhaust gas routed to the
intake manifold. Vacuum is applied to the EGR valve in
response to throttle valve opening. The vacuum controls the
movement of a taper valve connected to the vacuum diaphragm
in the EGR valve.
SEF783K
EGRC-BPT valve
The EGRC-BPT valve monitors exhaust pressure to activate the
diaphragm, controlling throttle body vacuum applied to the EGR
valve. In other words, recirculated exhaust gas is controlled in
response to positioning of the EGR valve or to engine operation.
Exhaust pressure
SEF529K
EGR valve & EVAP canister purge control solenoid valve

The EGR valve & EVAP canister purge control solenoid valve
responds to signals from the ECM. When the ECM sends an ON
(ground) signal, the coil in the solenoid valve is energized. A
~ plunger will then move to cut the vacuum signal (from the throt-
Vacuum tle body to the EGR valve and EVAP canister purge valve).
signal
When the ECM sends an OFF signal, the vacuum signal passes
through the solenoid valve. The signal then reaches the EGR
valve and EVAP canister.
SEF240PE
EC-319
EVAP Canister Purge Control (Cont'd)
EC-EGRC/V-01

BLOCK
(JIB)
<till>
-: Detectable line
for DTC
SR
-: Non-detectable
1[~]1 @ line for DTC
=r=
BR
em
I
1!1~~~p
BR
v~k~iS~EA
PURGE CONTROL
SOLENOID
II 111VALVE
=r=<W
P
I
P
rrfo5u
EGR ECM
(ECCS
CONTROL
MODULE)
em
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3456I
I 'fil (ffi
W
~<fl)
@ B
Refer to last page
(Foldout page) .
Cill
L
HECD14
EC-320
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS [1[J
INSPECTION START
m
~
ciently.
MEF637B 2. Perform diagnostic test mode II (Self-
•
diagnostic results).
Make sure that Diagnostic trouble
code No. 12 is not displayed.
rpm. Make sure that EGR valve
spring moves up and down when
engine is raced to about 4,000 rpm.
EGRC-BPT valve
~)5 ~~II
(Use your finger.)
NG
~~uu~ hose
connected to EGR valve~
( ~ '
MEC761B
m
OK
CHECK VACUUM SOURCE TO EGR
VALVE.
----.. CHECK COMPONENTS
(EGR valve and EGRC-
1. Disconnect vacuum hose to EGR BPT valve).
valve. Refer to "COMPONENT
2. Disconnect vacuum hose to EVAP INSPECTION", EC-323
canister.
NG
3. Check vacuum existence under the
Engine speed is 4,000 rpm:
Vacuum should not exist. Replace malfunctioning
Engine speed is 2,000 rpm: component(s).
[!J NG
r----, ~ CONNECT
[!J (!]
II ECM ~ CONNECTORIIl.imJ £) OK
CHECK CONTROL FUNCTION. CHECK VACUUM HOSE.
105
Check voltage between ECM terminal
-----.- Check vacuum hose for
@ and ground under the following clogging, cracks or
+ - conditions. improper connection.
0.6 - O.BV
MEF955D
Battery voltage
~NG
Clogging
::::.S.-
~P"P" '00","'00
MEF521E
EC-321
_~ ~EVAPcanis:r Purge Control (Cont'd)
NG
~GR valve & EVAP

\ CHECK POWER SUPPLY.
1. Stop engine.
2. Disconnect EGR valve & EVAP canis-
ter purge control solenoid valve har-
QD,@
• 10A fuse
------ canister control solenoid
,----,
I I
----- valve harness connector
. \ \ \
MEC7638
ness connector.
and ground.
• Harness open or short
between EGR valve &
EVAP canister purge
Voltage: Battery voltage and fuse
connectors.

ECM terminal (ill) and terminal CD.
NG
Continuity should exist. Repair harness or con-
If OK, check harness for short. nectors.
MEC7648 OK
~i5
1=1 =E=CM=-g CONNECTOR
II
CHECK COMPONENT
(EGR valve & EVAP canister purge con-
trol solenoid valve).
105
(ij\ 1. Reconnect ECM harness con-
~ nector and EGR valve & EVAP
canister purge control sole-
noid valve harness connector.
3. Perform "EGRC SOLIV
CIRCUIT" in "FUNCTION NG
TEST" mode with CONSULT. Replace EGR valve &
MEC7658 OR EVAP canister purge con-
(F./) 3. Turn EGR valve & EVAP can- trol solenoid valve.
~ ister purge control solenoid
• EGR CONT S/V CIRCUIT. valve "ON" and "OFF" in
DOES THE SOLENOID
CONSULT and check operat-
VALVE MAKE
ing sound.
OR
AN OPERATING SOUND ~ Refer to "COMPONENT
EVERY 3 SECONDS?
OK
NEXT II NO II YES I Disconnect and reconnect harness con-

MEF5698 nectors in the circuit. Then retest.
Trouble is not fixed .

• ACTIVE TEST. 0
EGRC SOL/V 0N and check the connection of ECM har-
== = MONITOR = Orpm
CMPS.RPM (REF)
== ness connector and retest.
INSPECTION END
ON I_I OFFl
clEF353F
EC-322
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS []:[]
o EGR valve & EVAP canister purge control solenoid valve
1. Disconnect EGR valve & EVAP canister purge control sole-
noid valve harness connector.
2. Check solenoid valve, following the table as shown below:

Conditions continuity continuity
between @ and @ between @ and @
NEF071
12V direct current
.
supply between
terminals G) and @
No supply
If NG, replace EGR valve

solenoid valve.
Yes
No
& EVAP canister

No
Yes
purge control
•
EGR valve
Apply vacuum to EGR vacuum port with a hand vacuum pump.
EGR valve spring should lift.
If NG, replace EGR valve.
SEF820FB
EGRC-BPT valve
Plug one of two ports of EGRC-BPT valve.
Apply a pressure above 0.490 kPa (4.90 mbar, 50 mmH20, 1.97
inH20) to check for leakage. If a leak is noted, replace valve.
t
SEF807K
EC-323
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS []B]
Injector
EC-INJECT-01
-: Detectable line
for DTC
Refer to EL-POWER. -: Non-detectable
line for DTC
G
m
OFF ST IGNITION
SWITCH
'e- <tlW
ACC
~
BIR
1~I(E101)
BIR (][)
i4J@
B/R@
I
e,----e----e----I
I I I
BIR BIR BIR BIR
(~:1 ~I
I4=JJ
INJECTOR
NO.1
(ffi)
I4=JJ
INJECTOR
NO.2
rn (€ :1 ~I
I4=JJ
INJECTOR
NO.3
@
I4=JJ
NO.4
INJECTOR
ffi
RIB Y/B GIB LIB
RIB
I I
Y/B
I
GIB
I
LIB
~ 11~ol 11~31 11~21
INJ INJ INJ INJ ECM
#1 #2 #3 #4 (ECCS
CONTROL
MODULE)
(IT)
~~
tm:lID W
f!l' I IfiJ
3456
@
W @
~ (ffi) ffi) •~
B
I
B B
I ffi
B
Refer to last page
(Foldout page) .
em
L
HEC011
EC-324
Injector {Co nt' d)
The fuel injector is a small, precise solenoid valve. When the
ECM supplies a ground to the injector circuit, the coil in the
injector is energized. The energized coil pulls the needle valve
back and allows fuel to flow through the injector into the intake
manifold. The amount of fuel injected depends upon the injec-
tion pulse duration. Pulse duration is the length of time the
injector remains open. The ECM controls the injection pulse
duration based on engine fuel needs.
SEF596K
• ACTIVE TEST.
••• POWER BALANCE •••
=== MONITOR
CMPS.RPM(REF)
IACV-AACjV
= ==
737rpm
MAS AIR/FL SEN O.98V
41%
0 DIAGNOSTIC PROCEDURE
INSPECTIONSTART

•
(ij\ 1. Start engine.
~ 2. Perform "POWER BALANCE"
110Q]~~ in "ACTIVE TEST" mode with
DDDDL:::J MEF354F
CONSULT.
3. Make sure that each circuit
produces a momentary engine
speed drop.
OR
I~~ ~ 1. Start engine.
Click ~ 2. Listen to each injector operat-
ing sound.
Ct.
I~-+ Clicking noise should be
heard.
--
/1
SEF730L 1. Stop engine. • Harness connectors
2. Disconnect injector harness connec- @,@
tor. • Harness connectors
3. Turn ignition switch "ON". @,<ill!>
4. Check voltage between injector har- • Harness for open or
ness connector terminal @ and short between injector
ground with CONSULT or tester. and ignition switch
connectors.
OK
MEF960A
AEC755
EC-325
Injector (Cont'd)
@
~i5 ~i5 1
II ECM -g CONNECTOR II illb CHECK OUTPUT SIGNAL CIRCUIT. Repair harness or con-
\101'110:103'112, 1. Turn ignition switch "OFF". nectors.
injector harness connector terminal
G) and ECM terminals @. Gill,
@: NO.1 cylinder @ :No.3cylinder GID. Gill.
<::DQ): No.2cylinder @): No.4cylinder SEF485Q Continuity should exist.
OK
NG Replace injector.
CHECK COMPONENT
(Injector).
below.
OK

~ Trouble is not fixed.

INSPECTION END
Injector
1. Disconnect injector harness connector.
2. Check resistance between terminals as shown in the figure.
0
Resistance: 10 - 140 [at 25 (77°F)]
If NG, replace injector.
AEC559
EC-326
Fuel Pump
SYSTEM DESCRIPTION
I Engine speed
I Camshaft position sensor ~
ECM
Fuel
(ECCS
pump
control
Start signal relay
module)
!,gnition switch
I
The ECM activates the fuel pump for several sec-

Condition Fuel pump operation •
onds after the ignition switch is turned on to
improve engine startability. If the ECM receives Operates for
Ignition switch is turned to "ON"
0
a 180 signal from the camshaft position sensor, 5 seconds
it knows that the engine is rotating, and causes Engine running and cranking Operates
0
the pump to perform. If the 180 signal is not
When engine is stopped Stops in 1 second
received when the ignition switch is on, the
engine stalls. The ECM stops pump operation Except as shown above Stops
and prevents battery discharging, thereby
improving safety. The ECM does not directly
drive the fuel pump. It controls the ON/OFF fuel
pump relay, which in turn controls the fuel pump.
The fuel pump with a fuel damper is an in-tank type (the pump
and damper are located in the fuel tank).
AECB01
EC-327
Fuel Pump (Cont'd)
EC-F/PUMP-01
IGNITION SWITCH
ON 01"' START
-: Detectable line
tal"' DTC
-: Non-detectable
15A FUSE ReteI"' to EL-POWER. line tal"' DTC
IJI) BLOCK
(JIB)
(M15)
UN•61 I N.61
II!]I(UEL
B/L B/W
Ibi=JlIbiJCHD
n
U
PUMP
RELAY
B/P B/Y
1 B/Y ~ ~ B/Y ----_1

(@ (]I)
B/Y
m
~@
B
1
FUEL
FUEL TANK
B/P M PUMP GAUGE
r=b~ UNIT
~
I~I@ ~ (B17)
B/P ~
I m@ B
B/P ~
~
FPR ECM
(ECCS
CONTROL
MODULE)
,-, B
I
B B
...L ...L
(ffi
(811) (832)
A<BV
T L
FillJ@
m w
~@
0.J.g)
~@
I..!.@J
Refer to last page
(Foldout page) .
(ffi
L
HEC012
EC-328
Fuel Pump (Conl'd)
INSPECTION START

~
2. Pinch fuel feed hose with fingers.
aller ignition switch is turned "ON".
m .
CHECK POWER SUPPLY.
NG

2. Disconnect fuel pump relay.
NG
~
• 15A fuse
•
3. Turn ignition switch "ON". short between fuse and
4. Check voltage between terminals CD, fuel pump relay
@ and ground with CONSULTor If NG, repair harness or
tester. connectors.
OK
[!l
CHECK POWER AND GROUND CIRCUIT. NG Check the following.
1. Turn ignition switch "OFF". ~ • Harness connectors
2. Disconnect fuel pump harness con- @,Cill
nector. • Harness for open or
3 Check harness continuity between short between fuel
terminal @ and body ground, termi- pump and body ground
nal CD and fuel pump relay connector • Harness for open or
terminal @. short between fuel
SEF479P
Continuity should exist. pump and fuel pump
Under the rear seat If OK, check harness for short. relay
"--- OK
connectors.
I!]
NG
o CHECK OUTPUT SIGNAL CIRCUIT.
~
2. Check harness continuity between @,QD
ECM terminal Gill and fuel pump • Harness for open or
relay connector terminal @. short between ECM and
MEC267BA Continuity should exist. fuel pump relay
connectors.
~OK
EC-329
Fuel Pump (Coni' d)
@
~i5 1
II ECM B
104
CONNECTOR II
CHECK COMPONENT NG Replace fuel pump relay.
(Fuel pump relay).
(ij\ 1. Reconnect fuel pump relay,
~ fuel pump harness connector
and ECM harness connector.
MEC332B
3. Turn fuel pump relay "ON"
and "OFF" in "ACTIVE TEST"
mode with CONSULT and
• ACTIVE TEST. D check operating sound.
FUEL PUMP RELAY ON OR
fti>\ Refer to "COMPONENT
= = MONITOR ---
=CMPS.RPM(REFj Orpm
OK
CHECK COMPONENT NG Replace fuel pump.

(Fuel pump).
_o_N_I_' OFF I
MEF309F
on next page.
OK


INSPECTION END
EC-330
Fuel Pump (Conl'd)
= Fuel pump relay
Check continuity between terminals CID and @.).

Yes
between terminals G) and @

SEF511P
Fuel pump
1. Disconnect fuel pump harness connector.
. Resistance: 0.2 - 5.0n [at 25°C (77°F)]
•
EC-331

SYSTEM DESCRIPTION
Engine speed
ECM
(ECCS
IACV-air regulator
control
Start signal
Ignition switch module)
The IACV-air regulator is controlled by the ECM

IACV-air regulator
at the same time as fuel pump ON-OFF control. Condition
operation
Operates for 5
Ignition switch is turned to "ON"
seconds
Engine running and cranking Operates

When engine is stopped OFF in 1 second
Except as shown above OFF
Bimetal
IACV-air regulator provides an air bypass when the engine ;s
cold for a fast idle during warm-up.
A bimetal, heater and rotary shutter are built into the IACV-air
...
regulator. When the bimetal temperature is low, the air bypass
port opens. As the engine starts and electric current flows
through a heater, the bimetal begins to turn the shutter to close
the bypass port. The air passage remains closed until the
Air flow
engine stops and the bimetal temperature drops.
SEF095K
EC-332
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS []:[]
(Cont'd)
EC-AIRREG-01
IGNITION SWITCH
ON or START
<:E>: AIT models
<M>: MIT models
FUSE Refer to EL-POWER. ... : Detectable line
15A BLOCK for DTC
[ill (JIB)
<f@
---: Non-detectable
line for DTC
IN.61IN•61
B/L
I I
B/W
14> ~
B/Y B/Y B/Y
•
IT
B/L B/W r=b@}) r-!-, @ ,..-!-, @
I~ICHID ~(E203) ~(E20t)
n PUMP
I~IIFCEL B/Y B/Y B/Y
IbJdlIbiJlCBD
B/P B/Y
U RELAY
t_f
t
B/Y
I
rn
IACV-AIR
REGULATOR
Clli:4)
1
~
BIP tG"Ai'\\ B
d:::,~
IllJl C£[) I
B
B/P 1$1(ffi) (E227)
I B
B/P
~
FPR ECM
In B B B
(ECCS
CONTROL
MODULE)
(ill
fJ
mm
1
Refer to last page
ACBD ~(E203) ffiill@W .r.'T;:;,.. (Eli 4) (Foldout page) .
T L
rnrn:tzlID GY ~B LJ...1J£p GY CHID , (EJon
~
~@
~GY
em
L
HEC013
EC-333
(Cont'd)
INSPECTION START
I CHECK CONTROL FUNCTION.

NG
~
Check fuel pump control
circuit.
2. Pinch fuel feed hose with fingers. (See page EC-327.)
after ignition switch is turned "ON".
I;)
CHECK POWER SUPPLY.
1 0K

~ • Harness connectors
2. Disconnect IACV-air regulator har- @,@})
ness connector. • Harness connectors
3. Turn ignition switch "ON". @D, <lliD (M/T mod-
4. Check voltage between terminal G) els)
and ground. • Harness connectors
Battery voltage should exist for 5 sec. @, @ (A/T models)
onds after ignition switch is turned • Harness for open or
"ON". short between IACV-air
regulator and fuel pump
I
OK relay
~15 connectors.

2. Check harness continuity between Cill), @ID
terminal @ and body ground. • Harness for open or
Continuity should exist. short between IACV-air
~ If OK, check harness for short. regulator and body
ground
MEC7368
connectors.
~
~15 CHECK COMPONENT

(IACV-air regulator).
Replace IACV-air regula-
tor.
below.
OK.
~ INSPECTION END
~
MEC7378
IACV-air regulator
Disconnect IACV-air regulator harness connector.
• Check IACV-air regulator resistance.
Resistance:
Approximately 70 • 80n [at 25°C (77°F))
• Check IACV-air regulator for clogging.
EC-334

SYSTEM DESCRIPTION
Control (AAC) Valve
Engine speed
Camshaft position sensor ~
I

I

I
Ignition switch

I
I
Start signal
Throttle "position
ECM
(ECCS
•
Park/Neutral position
Inhibitor switch (A/T models)/
Neutral position switch (M/T models)
control
module)
! IACV-AAC valve I
Air conditioner operation

I Battery Battery voltage
Vehicle speed
I
l Cooling fan
I
Cooling fan operation
This system automatically controls engine idle speed to a specified level. Idle speed is controlled
through fine adjustment of the amount of air which bypasses the throttle valve via IACV-AAC valve. The
IACV-AAC valve repeats ON/OFF operation according to the signal sent from the ECM. The camshaft
position sensor detects the actual engine speed and sends a signal to the ECM. The ECM then controls
the ON/OFF time of the IACV-AAC valve so that engine speed coincides with the target value memo-
rized in ECM. The target engine speed is the lowest speed at which the engine can operate steadily.
The optimum value stored in the ECM is determined by taking into consideration various engine
conditions, such as during warm up, deceleration, and engine load (air conditioner, power steering and
cooling fan operation).
IACV-AAC valve
The IACV-AAC valve is moved by ON/OFF pulses from the ECM.
The longer the ON pulse, the greater the amount of air that will
flow through the valve. The more air that flows through the
valve, the higher the idle speed.
Air
SEF040E
EC-335
EC-AAC/V-01
Refer to EL-POWER.
BR
I @: AlT models
$-~
BR BR
<H>:
---:
MIT models
... : Detectable line
for DTC
Non-detectable
1r.fJ1@) 1$1
(E203)
rn>
(E201)
line for DTC
*_1
BR
I
SR
~I
BR
IACV-AAC
VALVE
(E213)
~
SB
I
SB
14J1 (E227)
(F12)
SB
I
SB
~
ISC ECM
(ECCS
CONTROL
MODULE)
C£I)
~<E203) ~~ ~ (E213) ~@
~GY GIIDID S @ SR ~GY
C£I)
L
HEC015
EC-336
-- CONDITION SETIING --
INSPECTION START
IGN/T FEEDBACK HOLD
=== MONITOR
CAS. RPM (REF)
---
---
800rpm CHECK OVERALL FUNCTION.
Drops
INSPECTION END
IGN TIMING 15BTDC 1. Start engine and warm it up suffi-
IDLE POSITION ON ciently.
800::1:50 rpm
SEF786KA If NG, adjust idle speed. (Refer to
•
eEC-243.)
3.
(l)
..
I!I
• Perform "IGN TIMING ADJ"
in "WORK SUPPORT"
with CONSULT.
mode
• Disconnect IACV-AAC valve

5 harness connector.
4. Ma
~ e sure that idle speed drops.
Does not drop
NG
CHECK POWER SUPPLY. Check the following .
2. Disconnect IACV-AAC valve harness @D, ([ill) (M/T mod-
connector. els)
4. Check voltage between terminal G) @, @ (A/T models)
and ground with CONSULT or tester. • 7.5A fuse
Voltage: Battery voltage • Harness for open or
short between IACV-
OK AAC valve harness con-
nector and fuse
con nectors.
[!1
NG
CHECK OUTPUT SIGNAL CIRCUIT. Check the following.
2. Check harness continuity between @,@D
MEC768B
ECM terminal CTIDand terminal (2). • Harness for open or
Continuity should exist. short between ECM and
If OK, check harness for short IACV-AAC valve
~i5 ~i5 OK
connectors.
ECM E[CONNECTORII cffb CHECK COMPONENT

NG
Replace IACV-AAC valve.
113
(IACV-AAC valve).
on next page.
OK

nectors in the circuit Then retest

ness connector and retest
INSPECTION END
EC-337
IACV-AAC valve
Disconnect IACV-AAC valve harness connector.
• Check IACV-AAC valve resistance.
Resistance:
Approximately 100 [at 25°C (77°F)]
• Check for broken spring.
MEC770B
EC-338

Valve
EC-FICD-01
FUSE
BLOCK
@
(El06) I
L/Y
I
~
~
LIB
!
-I ........
AIR
~12g~~~TIONER
~ -I --~I-~~I«@
L!Y
rn~ •
THERMO Y L/R
CONTROL
THERMISTOR AMPLIFIER
lMW I. I L/R
m
I
~ Y JA---.. Next
.",........-
page
1$l(E202)
L/R
I To compressor
.-
I
L/R + (Refer to
HA-A/C.)
L/R
GY + To(Refer
A/C switch
to
HA-A/C. )
IACV-
FICO
SOLENOID
VALVE
~t lbi=Jl
~ CE212)
OUAL- B
....~r-.
LOW HIGH PRESSURE
SWITCH 1$1(E227)
([g)
NORMAL @
~ TO ECM
~ •- (ECCS
+ contro 1
G
1 _ I B/Y
r-J module)
G ~Next page B/Y B B
_.
-:
Detectable line
for oTC
Non-detectable
line for oTC
t.J
ill)
1
<ffi)
Refer to last page
A«@
T L
~
rIDm:IID
(E202)
B
~ (E212)
UJ.g) GY
~
~
([g)
GY 2
~
W
(Foldout page) .
CHID , {EtOn
@
~3 , (El06)
JS2L~
w.g) B
EC-339 HEC021
Valve (Co nt' d)
EC-FICD-02
Preceding <@-6
page -: Detectable line
<&Y -:
for DTC
Non-detectable
line for DTC
Y 6
r=bCE101) ~
116Al~- - - - - - - - - - ~f38l1
'-T"' eM[) 'T'
Y 6
Y @ 6
II~~-~~-------~rihl
~@ T
Y 6
t
din rF41i1
ACRLY AIR ECM
CON (ECCS
CONTROL
MODULE)
em
Refer to last page
(Foldout page) .
(MS) , <lliD
em
L
HEC022
EC-340
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS []liJ
Idle adjusting
Valve (Cont'd)
screw COMPONENT DESCRIPTION
When the air conditioner is on, the IACV-FICD solenoid valve
supplies additional air to adjust to the increased load.
MEF023D
INSPECTION START
•
ciently.
MEF634E
800:1::50 rpm
If NG, adjust idle speed.
3. Turn air conditioner switch and
blower fan switch "ON".
4. Recheck idle speed.
850 rpm or more
NG
Check if air conditioner compressor NG Refer to "TROUBLE

functions normally. DIAGNOSES" i!1 HA sec-
tion.
OK

2. Disconnect IACV-FICD solenoid valve @D,@!)
harness connector. • Harness for open or
3. Start engine, then turn air conditioner short between IACV-
switch and blower fan "ON". FICO solenoid valve
4. Check voltage between terminal CD harness connector and
and ground with CONSULT or tester. air conditioner relay
AEC765
connectors.
OK
EC-341
Valve (Cont'd)
~i5 @
cf0
2. Check harness continuity between cmD,@
terminal @ and body ground. • Harness for open or
Continuity should exist. short between IACV-
If OK, check harness for short. FICO solenoid valve and
AEC766
engine ground
connectors.
NG
CHECK COMPONENT Replace IACV-FICD sole-
(IACV-FICD solenoid valve). noid valve.
below.
OK


ness connector. Then retest.
INSPECTION END
~i5@d IACV-FICD solenoid valve

Disconnect IACV-F1CD solenoid valve harness connector.
~
• Check for clicking sound when applying 12V direct current
to terminals.
SEF721Q

\ Washer • Check for broken spring.
err ~~v ~S~log
Plunger
SEF097K:
EC-342
Cooling Fan Control

SYSTEM DESCRIPTION
Cooling fan control
I Vehicle speed sensor

I Vehicle speed
Engine coolant temperature EGM

(EGGS
Engine coolant temperature sen-
sor control I
~ Goaling fan relay(s)
•
module)
I Air conditio~er "ON" signal

I Air conditioner switch
The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, and
air conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF] on A/T models and
2-step control [ON/OFF] on M/T models.
Operation
For AIT models
Air conditioner switch is "ON".
~LL ~u:
.3 ?- 105 (221) ~ ?- 105 (221)
~o ~0
2i 0 100 (212) 2i 0 100 (212)
E E
2 95 (203) 2 95 (203)
C C
o'"o o'"o
o o
OJ 20 80 OJ 20 80
c:
.0, (12) (50) .~ (12) (50)
c Vehicle speed km/h (MPH)
w Vehicle speed km/h (MPH) ~
0: Cooling fans do not operate. ~: Cooling fans operate at "Low" speed. m!lll: Cooling fans operate at "High" speed.
MEC772B
For MIT models

~u: Air conditioner switch is "OFF". ~ u: Air conditioner switch is "ON".
::J 0 ::J
Z;
0
1il ;- 105 (221) 1il 105 (221)

OJ OJ
E
0 0
~ 100 (212) 100 (212)

<1> OJ
- 95 (203) - 95 (203)
C C
'"
oo
I
o'"o
o o
OJ
20 80 OJ
20 80
c (12) (50) c (12) (50)
.0, 0,
c Vehicle speed km/h (MPH) c Vehicle speed km/h (MPH)
ill ill
0: COOling fans do not operate. m: Cooling fans operate at "High" speed. MEC773B
EC-343
M/T models EC-COOL/F-01

BATTERY (Via
fusible link)

BLOCK 30A
(JIB)
(El06) o
IIQ~OI GY
BR I
I 1--
II!]1
BR GY
1biJ1bi=Jl@
n COOLING
FAN
u 1 RELAY-1
@: Models with air conditioner
-:
for DIC
Non-detectable
line for Ole
LG/R G/B
LG/R
I 1----0--
1 I
r=::!= <lliD
I~I(][) mG/B
m
G/B
LG/R ~ COOLING ~ COOLING
LG/R
I FAN
M MOTOR-l
(E45)
M
FAN
MOTOR-2
rn
@
+@
II-t-JI(M49)
R
~
B
~
B
Lr l-------6
LG/R I
m ECM e.1
-
RFRL
I (ECCS
CONTROL
MODULE)
B
..L_
B
..L_
------ em ern> @D
Refer to last page

(Foldout page) .
+
2
5
1
<m>L ~@~
lJ.l.g) GY , GY
@ , (El0t)
(El06)
em
L
HEC016
EC-344
AIT models EC-COOL/F-02

IGNITION SWITCH
ON or STAAT
i0A
I 25 I
FUSE
~~9~f
(El06)
~.jffil 30A
IT]
30A
IT]
Refer to
EL-POWEA.
@:
-:
Models with air
conditioner
for DTC
Non-detectable
line for DTC
GY G/W
-~-,-I-FO~=-_I I SR
•--1
GY G/W SR GY LG/S SA G/W LG/R
•
COOLINGII:!:I
~~~AY-i
:!i' ~
:]JII COOLING
~ ~~~AY-2
'I :}:' ':f]1 I:[]II COOLING/I:!:I 1:f]1 ':[]II
~ ~ ~~~AY-3 ~ ~
(ffi) ~ ~ ~ rn ~ lbiJ U+!J ~iC8) ~ lbiJ ~
-tr=- !-.JI
LG/R G/8 G/A LG G/Y 8 @ LG G/OR S
I~ - _I _ I--~t t
LG ~LG/R
r:::::k,{jQj;r:::::k,
114.J I~- - - -l13.J II G/R
LG ~LG/R wT1
I I ~~~LING
MOTOR-1
~)
COOLING
FAN
MOTOR-2
LG (M49) LG/R ~
rn
1t!J~CEID
LG
-F6- ~cPl
LG/R
@ t t
I~ 1 ~
LG
rrToi1
AFAH
rm
LG/R
RFRL
ECM
(ECCS
CONTROL
____r~-, S S
MODULE) -!- -!-
(IT) ~<rn>
Refer to last page
(Foldout page) .
~ (Ei2), (Ei7), (Ei8) ~ (E40), (E46)
~ SR SR SR t::mJ GY GY
~ , (El0!)
(El06)
em
L
HEC017
EC-345
• COOLING FAN CIRCUIT. M/T models
DOES
INSPECTION START
COOLING FAN
ROTATE AND STOP

OK
EVERY3 SECONDS 7 CHECK OVERALL FUNCTION. INSPECTION END
NEXT II NO II YES I
MEF311F
~ 2. Perform "COOLING FAN
OR
• ACTIVE TEST. 0 rij\ 1. Turn ignition switch "ON".
COOLING FAN OFF \J!V 2. Select "COOLING FAN" in
=== MONITOR === CONSULT.
OR
COOLAN TEMP/S
I With air conditionerI

1. Start engine.
HI 2. Set temperature lever at full cold
position.
k C
00lin9fan
5. Run engine at idle for a few minutes
6. Make sure that cooling fan operates.
I I
Q
Without air conditioner
1. Start engine.
rpm until engine is warmed up suffi-
ciently.
~ID~ operate during warm-up.
NG
CHECK POWER SUPPLY. NG

1. Turn air conditioner switch "OFF". • 30A fusible link
2. Turn blower fan switch "OFF" • 10A fuse
(Step 1 and 2 are only performed for • Harness for open or
models with air conditi.oner.) short between fuse and
3. Stop engine. cooling fan relay
4. Disconnect cooling fan relay. • Harness for open or
5. Turn ignition switch "ON". short between battery
6. Check voltage between terminals G), and cooling fan relay
MEF277G @ and ground. If NG, repair harness or
Voltage: Battery voltage connectors.
OK
EC-346
@
NG
terminal G) and terminal @, termi-
SEF777P nal @ and body ground.
•
(!]
NG
2. Check harness continuity between (]D,@
ECM terminal @ and terminal @. • Harness connectors
short between ECM
OK
MEC775B
and cooling fan relay
connectors.
~io ~i5 NG
1=1 =EC=M=W CONNECTOR II ~
CHECK COMPONENT
(Cooling fan relay).
Replace cooling fan
relay.
EC-353.
OK
NG
CHECK COMPONENTS Replace cooling fan
SEF332Q (Cooling fan motors). motors.
EC-353.


INSPECTION END
EC-347
AlT models
INSPECTION START

1. Disconnect cooling fan re/ays-2 and (Go to
-3. IPROCEDURE A I,
• COOLING FAN CIRCUIT. 00 2. Turn ignition switch "ON".

EC-350.)
DOES TEST" mode with CONSULT.

OR
COOLING FAN
ROTATE AND STOP 3. Perform "COOLING FAN" in
EVERY 3 SECONDS I CONSULT.
OR
NEXT II NO II YES JF311F (j)

I With air conditioner I
• ACTIVE TEST. 0 2. Start engine.
3. Set temperature lever at full cold
COOLING FAN OFF position.
=== MONITOR ===
COOLAN TEMPjS 88°C 6. Run engine at idle for a few minutes
7. Make sure that cooling fan operates
at low speed.
==H=I=11 L~W I I Without air conditioner 1
2. Start engine.
rpm until engine is warmed up suffi-
lCOOtingfan ciently.
@l
operate at low speed during warm-
up.
OK
~ID~
EC-348
• COOLING FAN CIRCUIT.
DOES
Ii
COOLING FAN NG
CHECK COOLING FAN HIGH SPEED Check cooling fan high
ROTATE AND STOP OPERATION. speed control circuit.
1. Turn ignition switch "OFF". (Go to
EVERY 3 SECONDS "I
2. Reconnect cooling fan relays-2 and IPROCEDURE B I.
-3. EC-351.)
NEXT II NO II YES I 3. Disconnect cooling fan relay-1.
MEF311F
•
~ 5. Perform "COOLING FAN
Ii • ACTIVE TEST. D CIRCUIT" in "FUNCTION
COOLING FAN OFF
OR
=== MONITOR --- fiii\ 4. Turn ignition switch "ON".
~ 5. Perform "COOLING FAN" in
COOLAN TEMP/S "ACTIVE TEST" mode with
CONSULT.
1.1-
OR
4. Turn air conditioner switch
clTJI LOW
MEF314F
and blower fan switch "OFF"
(Models with air conditioner).
Ii Cooling fan
5. Disconnect engine coolant
temperature sensor harness
connector.
6. Connect 150Q resistor to
7. Restart engine and make sure
that cooling fan operates at
150(1 resistor higher speed than low speed.
OK
MEC475B
INSPECTION END
EC-349
PROCEDURE A
INSPECTION START
IJ;
2
7 5
1
3
~
I CHECK POWER SUPPLY.
NG
Cooling fan
1. Turn ignition switch "OFF". • 10A fuse
relay-1
2. Disconnect cooling fan relay-1. • 30A fusible link
SEF725QB 4. Check voltage between terminals CD, short between cooling
@, @ and ground with CONSULT or fan relay-1 and fuse
tester. • Harness for open or
Voltage: Battery voltage short between cooling
fan relay-1 and battery
connectors.

rnotor-2 harness connector.
cooling fan relay-1 terminal @ and
cooling fan motor-1 terminal CD, cool-
ing fan relay-1 terminal (J) and cool-
ing fan motor-2 terminal CD.
terminal @ and body ground.
/ 0
CHECK OUTPUT SIGNAL CIRCUIT. NG Check the following.
@D,@
~io~io~io.-fT1
3 .~
@,QD
7 5 ~ ~
~21. short between cooling
. Cooling Cooling
C00 ,Ing OK fan relay-1 and ECM
fan motor-1 fan motor-2
f an re Iay- 1 If NG, repair harness or
connectors.
NG
~ CHECK COMPONENT Replace cooling fan relay.
SEF723QA
(Cooling fan relay-1).
EC-353.
OK
@
Cooling.fan S S Cooling fan
motor-1 \lliJ ~motor-2
SEF727QA
EC-350
o ~ INNEer @
~15 Cooling ~
II ECM ~CONNECTORII fan CHECK COMPONENT Replace cooling fan
9 relay-1 (Cooling fan motors-1 and -2). motors.
illi
3
7 5 EC-353.
2 1
OK

•

ne&s connector. Reconnect ECM har-
[ INSPECTION END
PROCEDURE B
INSPECTION START

1. Turn ignition switch "OFF" • 10A fuse
2. Disconnect cooling fan relays-2 and • 30A fusible link
-3. • Harness for open or
3. Turn ignition switch "ON". short between cooling
4. Check voltage between cooling fan fan relays-2, -3 and fuse
relay-2 terminals CD, @ and ground, • Harness for open or
~i5
~-
and between cooling fan relay-3 ter-
minals CD, @ and ground with CON-
SULT or tester.
fan relays-2, -3 and bat-
tery
clf:tb Voltage: Battery voltage If NG, repair harness or
connectors.
Coolingfan OK
relay-2
~- @
ffi:b
Coolingfan
relay-3 SEF781P
EC-351
TROUBLE DIAGNOSIS FOR NON';DETECTABLE ITEMS
@
~iiO Cooling
1
6 3 fan 1. Turn ignition switch "OFF". nectors.
7 5 relay-2
2 1
1f,
3 4
2
Cooling fan
motor-1
Ia
terminal @ and terminal @, ter-
minal @ and terminal @, termi-
harness
nal CV and body ground.
connector
II 4. Check harness continuity between
terminal @ and terminal @, ter-
minal @ and terminal @, termi-
nal CV and body ground.
111
SEF782PA NG
II 2. Check harness continuity between CID.@
ECM terminal @J and terminal @. • Harness connectors
Continuity should exist. @,@
~ iifO 6 3
7 5
Cooling
fan
relay-3
OK
fan relays-2. 3 and ECM
2 1
If NG. repair harness or
connectors.
tllii
It Cooling fan
motor-2
CHECK COMPONENT
(Cooling fan relays-2, 3).
NG Replace cooling fan
relays.
harness Refer to "COMPONENT INSPECTION"
connector on next page.
OK

(Cooling fan motors). motors.
on next page.
OK

SEF783PA nectars in the circuit. Then retest.
~15 I ~Io f,:j! Cooling

II ECM ElCONNECTORI fan
relay-2, -3
10 ness connector and retest.
~
[?Ffu
INSPECTION END
MEC7788
EC-352
MIT models COMPONENT INSPECTION
Cooling fan relay (M/T models)
=
Check continuity between terminals @ and CID.

Yes
terminals CD and @
SEF511PA
•
AlT models Cooling fan relays-1, -2 and -3 (A/T models)

Check continuity between terminals @ and CID, @ and (j).

Yes
terminals CD and @

SEC202BA

For AIT Models
Cooling fan motor check operation.
harness connector
Terminals
Speed
(Ee) (8)
Low
CD @
(A/T models)
AEC715
Cooling fan High
CD,@ @,@
motor (A/T models)
For MIT models
High
CD @
(M/T models)

AEC,81
EC-353
Power Steering Oil Pressure Switch
EC-PST/SW-01
ECM
(ECCS
CONTROL -: Detectable line
MODULE) for DTC
PWST em -: Non-detectable
line for DTC
1~31
PU/W
IIrnl
PU/W
CfID
=r@
PU/W
PU/W
I
I$J'C~MID
pu/w
I
POWER STEERING
ON OIL PRESSURE
SWITCH
OFF.....-- (g)
~
B
I
,-, B B
-L -L
@ <1;51)
Refer to last page

(Foldout page) .
~@
U@ GY CHID ,m
em
L
HEC018
EC-354
The power steering oil pressure switch is attached to the power
steering high-pressure tube and detects a power steering load.
When a power steering load is detected, it signals the ECM. The
ECM adjusts the IACV-AAC valve to increase the idle speed and
adjust for the increased load.
Hoodledge RH ~
MEC730B
• PW/ST SIGNAL CIRCUIT.
HOLD STEERING WHEEL
LOCKED
IN A FULL
POSITION
INSPECTION START
•
THEN
TOUCH START
CHECK OVERALL FUNCTION.
~
INSPECTION END
I
ciently.
NEXT II START
MEF023E
00 2. Perform "PW/ST SIGNAL
OR
0
-crMONITOR
PW/ST SIGNAL
-crNO FAIL
OFF
@ 2. Check "PW/ST SIGNAL" in
CONSULT.
Steering is in neutral
position:
OFF
Steering is turned:
ON
RECORD OR
SEF5911
@ 2. Check voltage between ECM
terminal @ and ground.
m 1=' =EC=M =.,~ CONNECTORII ~ is Voltage:

When steering wheel is
43 00 turned quickly.
Approximately OV
Except above
[Y] Approximately 8 - 10V
+ -
~NG
.". MEF315F
EC-355
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS mJ
Power Steering Oil Pressure Switch (Co nt' d)
@
1 NG
--.. nectors.
2. Disconnect power steering oil pres-
sure switch harness connector.
AEC760 Continuity should exist.
OK
~i5 ~i5 [!J

CHECK INPUT SIGNAL CIRCUIT. NG
--.. Check the following.
II ECM ~CONNECTORII dIb 1. Disconnect ECM harness connector.

CID,@
43
ECM terminal @ and terminal CD. • Harness connectors

short between ECM and
OK
SEF501Q power steering oil pres-
sure switch
connectors.
CHECK COMPONENT NG Replace power steering

(Power steering oil pressure switch). oil pressure switch.
below.
OK


INSPECTION END
~ to ID Power steering oil pressure switch

1. Disconnect power steering oil pressure switch harness con-
nector then start engine.
2. Check continuity between terminals CD and @.
Steering wheel is being turned Yes

~ Steering wheel is not being turned No
AEC762
EC-356
Park/Neutral Position Switch
EC-PNP/SW-01
ECM
(ECCS
CONTROL
MODULE) (A): A/T models
NEUT ill) @: MlT models
-: Detectable line
13•51 for DTC
G/OR -: Non-detectable
I line for DTC
G/OR
I$I@
G/OR
@
1$1 CMID
G/OR
~
•
I
O---a>---
~~Qr
G/OR.j G/OR --
t
G/OR
IdJl~
=r (£201) P ..... ..
• INHIBITOR
1 SWITCH
G/OR R N-D 2 (W):(A)
I
G/OR
m NEUTRAL
POSITION
SWITCH
OTHER -- @ID: @
Refer to last page

(Foldout page) .
~~ fITilll~
tIDIDZIID GY ~ B (][)
,(E10t)
~ (E220) ~ «222)
tgJ B ~ GY
(IT)
L
HEC019
EC-357
When the gear position is in "P" (A/T models only) or "N",
park/neutral position is "ON". ECM detects the position
because the continuity of the line (the "ON" signal) exists.
m • PARKINEUTPOSI SW CKT •
Neutral position switch (M/T mod-
SHIFT els)
OUT OF NIP -POSITION

INSPECTION 8T ART
THEN
TOUCH START
OK
I NEXT II START I
MEC731B
1 Turn ignition switch "ON".
INSPECTION END
(Iii'" 2. Perform "PARK/NEUT POSI

m * MONITOR * NO FAIL 0 ~ SW CKT" in "FUNCTION
PIN POSI SW ON
OR
(F.i\ 2. Select "PIN POSI SW" in
\J!J "DATA MONITOR" mode with
CONSULT.
3. Check "PIN POSI SW" signal
Neutral position: ON
RECORD Except neulral posllion: OFF
SEF963N OR
m ~ CONNECT ~ ~
~
~
2. Check vo~ge between ECM
terminal ~ and ground under
lAID£)~~ the following conditions.
II ECM EcoNNECTORl1 Voltage:
35 Neutral position
Approximately OV
Excepl neutral position
Ballery voltage
NG
MEC779B
EC-3S8
@

1 NG Check the following.
--.. • Harness connectors
2. Disconnect neutral position switch (ill1), (ill)
harness connector. • Harness for open or
3. Check harness continuity between short between neutral
terminal @ and body ground. position switch and
AEC750 Continuity should exist. body ground
•
connectors.
OK
~Io ~Io [!] .

CHECK INPUT SIGNAL CIRCUIT. NG Check the following.
II ECM Ef
35
CONNECTOR II illDJ 1. Disconnect ECM harness connector. f----- • Harness connectors
2. Check harness continuity between @,@
ECM terminal @ and terminal CD. • Harness connectors
@),@
SEF503Q OK
neutral position switch
connectors.
CHECK COMPONENT NG Replace neutral position

(Neutral position switch).
~ switch.
Refer to MT section.
OK


INSPECTION END
EC-359
m • PARKINEUTPOSI SW CKT • I Inhibitor switch (AIr models) J
SHIFT INSPECTION START
OUT OF NIP-POSITION
THEN
TOUCH START
fiii\ 1. Turn ignition switch "ON".
I NEXT II START I
MEC7318
~ 2. Perform "PARK/NEUT POSI
SW CKT" in "FUNCTION
m * MONITOR * NO FAIL 0 rif1
OR
PIN POSI SW ON ~ 2. Select "PIN POSI SW" in
CONSULT.
3. Check "PIN POSI SW" signal
"N" or "P" position: ON
Except above position: OFF
RECORD OR
SEF963N 1. Make sure that inhibitor switch
circuit functions properly.
m~i)~0 (Refer to AT section.)

II ECM ~CONNECTORII
terminal @ and ground under
30
Voltage:
UN" or uP" position
Approximately OV
Except above position
Battery voltage
MEC7798
NG
EC-360
@
1
1. Disconnect inhibitor switch harness f----+ • Harness connectors
connector. @ill,@
terminals CD and body ground. short between inhibitor
Continuity should exist. switch and body ground
connectors.
MEF791EA OK
•
[i
NG
~i5 CHECK INPUT SIGNAL CIRCUIT.

2. Gheck harness continuity between
----. Check the following.
QD,@
@B ECM terminal @ and terminal @.
@,@[!)
@,@
OK
inhibitor switch
MEC780B
connectors.
CHECK COMPONENT NG Replace inhibitor switch.

(Inhibitor switch).
ECM ~CONNECTORI
~. Refer to AT section.
35
\:lliJ OK

MEC781B Check ECM pin terminals for damage

INSPECTION END
EC-361
Heated Oxygen Sensor (H02S)
EC-H02S-01
IGNITION SWITCH
ON or START

10A BLOCK
[l[J (JIB)
~
IN:OI
BR!Y -: Detectable line
for DTC
I -: Non-detectable
BR/Y line for DTC
,cID,@
=r@
BR/Y
I
BR/Y
m HEATED
OXYGEN
SENSOR
I4=!J ~ <W>
- OR W
F 4
tl I
I
I
I
I JOINT
I CONNECTOR-6
I em
W .~.....--~
OR
urtru u=f9l1 In
02H 025 ECM
(~g~~ROL
MODULE)
8
,_I
-L
B
-I 1
8
cw. m~
~em
!Il' I'I~
3456 @
W
~<W>
U@..@) GY CDODJDJDJDJD GY
Refe~ to last page
(Foldout page) .
CED
L
HEC020
EC-362
SYSTEM DESCRIPTION
Heated oxygen sensor heater control
ECM Heated
I Crankshaft position sensor I Engine speed ~

(ECCS ~ oxygen
control sensor
module) heater
The ECM performs ON/OFF control of the heated OPERATION •

oxygen sensor
engine speed.
heater corresponding to the --~- Heated oxygen sensor
Engine speed rpm
heater
Above 3,200 OFF
Below 3,200 ON
The heated oxygen sensor is placed into the front tube. It
detects the amount of oxygen in the exhaust gas compared to
the outside air. The heated oxygen sensor has a closed-end
tube made of ceramic zirconia. The zirconia generates voltage
from approximately 1V in richer conditions toav in leaner con-
ditions. The heated oxygen sensor signal is sent to the ECM.
i Isolation
Heater pad
Zirconia i
The ECM adjusts the injection pulse duration to achieve the
ideal air-fuel ratio. The ideal air-fuel ratio occurs near the rad-
ical change from 1V to av.
bearing tube
SEF406H
2 1
::>
<D
OJ
~
(5
>
"5
c.
"5
0
0
Rich ---
:'--
Ideal ratio
Mixture ratio
-
_ Lean
SEF288D
EC-363
• MIXTURE RATIO TEST.
INSPECTION START
ACCELERATE TO 2000
RPM AND HOLD THEN
TOUCH START.
OK
II=] CHECK HEATED OXYGEN SENSOR INSPECTION END
1800 2000 2200 ij CIRCUIT.

NEXT II START J ciently.
rF.i\ 2. Perform "MIXTURE RATIO
SEF815L \J!J TEST" in "FUNCTION TEST"
mode with CONSULT.
OR
*. MONITOR * NO FAIL 0 rF.i\
\J!J
2. Make sure that "M/R FIC
MNT" in "DATA MONITOR"
CMPSoRPM(REF) 2000rpm "LEAN" periodically more
M/RFIC MNT RICH than 5 times during 10 sec-
onds at 2,000 rpm.
OR
~ 2. Stop engine and set ECM
~ Diagnostic Test Mode II
(Heated oxygen sensor moni-
RECORD I
MEC782B
tor).
3. Restart engine and run it at
4. Keep engine speed at 2,000
\ I / rpm and make sure that the
malfunction indicator lamp on
the instrument panel goes on
'~/' and off more than 5 times dur-
- CHECK-
ing 10 seconds.
/ ......
NG
/ I \
Malfunction indicator NG
lamp
SEF051PA 1. Turn ignition switch "OFF". nectors.
'-------------------' 2. Disconnect heated oxygen sensor
harness connector and ECM harness
connector.
ECM terminal @ (or terminal @)
and ground.
~ Continuity should not exist.
if OK, check harness for short.
Heated oxygen ' ~~
sensor harness connector \ OK
ij ~I 1-''--\
SEF089PA @
~i5 ~i5
II ECM -er 19
CONNECTOR II ~
MEC735B
EC-364
@J ~i)~ID @
II ECM J9"
111
CONNECTOR II OK
CHECK HEATED OXYGEN SENSOR Go to "CHECK
HEATER CIRCUIT. COMPONENT".
1. Reconnect harness connectors.
2. Start engine.
Gill and ground with CONSULT or
tester under the following conditions.
Voltage:
MEC783B
Engine speed is below 3,200 rpm
•
Approximately OV
Engine speed is above 3,200 rpm
Battery voltage
NG
2. Disconnect heated oxygen sensor aD,@
harness connector. • 10A fuse
4. Check voltage between terminal @ short between heated
SEF646P
and ground. oxygen sensor and
Voltage: Battery voltage fuse
~i5 ~i5 OK
connectors.
ECM J9" CONNECTOR II cillID

111
NG
CHECK OUTPUT SIGNAL CIRCUIT. Repair harness or con-
terminal G) and ECM terminal Gill.
MEC784B
OK

screws.
NG
CHECK COMPONENT Replace heated oxygen
(Heated oxygen sensor heater). sensor.
on next page.
OK

Trouble is not fixed

INSPECTION END
EC-365
Heated oxygen sensor heater
Check resistance between terminals CD and CID.
Resistance: 3.3 • 6.30 [at 25°C (77°F)]
If NG, replace the heated oxygen sensor.
AEC745
EC-366
Torque Converter Clutch Solenoid Valve
EC-LKUP-01
IGNITION SWITCH
ON or START
-: Detectable line
for DTC
FUSE Refer to EL-POWER. -: Non-detectable
10A SLOCK line for DTC
[]] (J/S)
•
<E106)
I Q.61
Y
I
Y
1[~]Im
=r=~
Y
I
Y
r=b TORQUE
3 CONVERTER
CLUTCH
SOLENOID
11111VALVE
~
=r=@ID
PIS
I
PIS
r=bm
1~1@g)
PIS
L PIS ~
~(][)
PIS - PIS
@@
iJJ- PIS l
PIS
IF1I5n
LKUP ECM
(ECCS
CONTROL
MODULE)
em
~~,m Refer to last page

(Foldout page) .
~ S GY
(IT)
L
HEC023
EC-367
SYSTEM DESCRIPTION
Throttle position sensor Throttle valve opening angle
ECM
(ECCS Torque converter
control clutch solenoid
module) valve
The AfT lock-up is controlled by the ECM through • Throttle position is open .
the torque converter clutch solenoid valve. When • Engine coolant temperature is 70°C (158°F) or
the ECM detects any of the following conditions, more .
the ECM switches the torque converter clutch • Vehicle speed is 58 kmfh (36 MPH) or more.
solenoid valve OFF to accomplish lock-up opera-
tion. While the vehicle is in conditions other than
below, the torque converter clutch solenoid valve
is always set to ON, relea'sing the lock-up oper-
ation.
~i3~ INSPECTION START
II ECM E[CONNECTORII
115
OK
CHECK CONTROL FUNCTION. CHECK COMPONENT
1. Jack up drive wheels. (Torque converter clutch
2. Start engine and warm it up suffi- solenoid valve).
ciently. Refer to "Electrical Com-
3. Shift selector lever to "0" position. ponents Inspection" in
4. Check voltage between ECM terminal AT section.
GID and ground under the following If NG, replace torque
conditions. converter clutch solenoid
Voltage: valve.
Accelerator pedal Is depressed
II ECM Ef CONNECTOR II [Vehicle speed is above
58 km/h (36 MPH).]
OK
115
Battery voltage
Accelerator pedal is fully
released INSPECTION END
~~ Approximately OV
ID cf8~-H
-
MEC785B
NG
2. Disconnect torque converter clutch @,<illV
solenoid valve harness connector. • 10A fuse
4. Check voltage between terminal @ short between torque
and ground. converter clutch sole-
Voltage: Battery voltage noid valve and fuse
OK connectors.
@
MEC279BA
EC-368
TROUBLE DIAGNOSIS FuR NON-DETECTABLE ITEMS [![]
@
~i5 NG
2. Disconnect ECM harness connector. @@,@
ECM terminal @ and terminal G). @D,@
Continuity should exist. • Harness connectors
~ If OK, check harness for short. @,CID
SEF513Q OK short between ECM
•
and torque converter
~i5 connectors.
II ECM
115
Ef CONNECTOR II CHECK COMPONENT
(Torque converter clutch solenoid
NG
Replace torque converter
clutch solenoid valve.
valve).
Inspection" in AT section.
~ OK
SEF514Q
Trouble is not fixed

INSPECTION END
EC-369
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS [![J
Malfunction Indicator lamp (Mil) & Data Link

Connector (DlC) for CONSULT
IGNITION SWITCH
ON or START EC-MIL-01
Refer to EL-POWER.
FUSE -: Detectable line
7.5A BLOCK for DTC
ITJ (JIB)
~ -: Non-detectable
line for DTC
Y G
13'01
COMBINATION
m
METER
(MALFUNCTION
INDICATOR
I DATA LIN<
CONNECTOR
FOR CONSULT
LAMP) (fill)
@ 1
U3.211
ORIL
LiJLiJ~LiJ
GIS GY IL G/R G/W
~
S
It
I~GYIL ~ ~
JOINT
CONNECTOR-5
~
tt
GIS
1bi=H~
l
I~
ORIL~ G/B GY IL G/R G/W

I$~ -F~- - - - - - - - - - - ~$~-~$~-~$~-~$I
ORIL CEID GIS GYIL G/R G/W
I I I I I
ORIL G/S GY/L G/R G/W
~ mrr15il~rrtru
LED-R SCI SCI CHECK SCI ECM
RX TX CL (ECCS
(In) (Out) CONTROL
MODULE)
em
Refer to last page

(Foldout page) .
~~
~OR
em
L
HEC024
EC-370
INJECTION SYSTEM
By-pass passage (Fuel temperature is cold)
Fuel return passage
•
Fuel return control valve
(Only models for frigid areas)
Injection nozzle
Fuel temperature: Cold
To
fuel tank- From injection pump
SEF151R
SEF152R
EC-371
VE-TVPE INJECTION PUMP
G) Engine slinger @ Injection pump bracket (J) Water hoses

@ Rear back cover @ Bracket @ Injection pump
@ Injection pump sprocket @ Bracket @ Key
Removal
1. Put a matchmark across injection pump and injection pump
bracket.
2. Disconnect battery e
cable, electrical connectors and
accelerator wire.
3. Set No.1 piston at TDe on its compression stroke.

TOC: Crankshaft pulley notch without painted mark
4. Disconnect water hoses for cold start device.
5. Remove fuel hoses (supply, return and spill) and injection
tubes.
6. Remove air duct and injection pump timing belt cover.
7. Remove injection pump timing belt.
Refer to EM section ("Injection Pump Timing. Belt").
EC-372
VE-TVPE INJECTION PUMP ~
Removal (Cont'd)
8. Remove injection pump sprocket with Tool.
• Remove key from injection pump shaft and store safely .
9. Remove injection pump assembly.
•
Installation
1. With matchmarks aligned, install injection pump.
2. Install key on injection pump shaft, then install injectiol

pump sprocket.
• Use mark "A" on sprocket.
3. Install injection pump timing belt.
Refer to EM section ("Injection Pump Timing Belt").
SEF155R
4. Adjust injection timing.

Refer to "Adjustment" on the next page.
5. Install all parts removed.
EC-373
VE- TYPE INJECTION PUMP
Adjustment
INJECTION TIMING ADJUSTMENT (Plunger lift
adjustment)
Preparation of cold start device
1. Turn cold start device linkage clockwise.
2. Set a suitable block [Thickness: about 15 mm (0.59 in)]
between cold start device plunger and linkage rod.
3. Turn crankshaft 2 turns clockwise to set the device to nor-
mal position.
Checking
1. Set NO.1 piston at TDC on its compression stroke.
TDC: Without painted mark
2. Remove injection tubes and air bleeder on the back of injec-
tion pump.
3. Set dial gauge so its indicator points to somewhere between
1.0 and 2.0 mm (0.039 and 0.079 in) on the scale.
4. Turn crankshaft 1 turn clockwise and check that dial gauge
indicates the same value again.
5. Turn crankshaft counterclockwise about 20 to 25 degrees,

then set dial gauge indicator to 0 mm (0 in).
6. Turn crankshaft clockwise and set the pump timing mark to
the mark on the crankshaft pulley.
Pump timing mark: Yellow painted mark
0
Injection timing: 8 BTDC
7. Read plunger lift.
Plunger lift:
0.79 - 0.85 mm (0.0311 - 0.0335 in) at pump timing
mark
• When repeating the checking, start with step 5.
Adjusting
1. If plunger lift is not within the specified value, adjust by
turning injection pump.
• If indication is smaller than the specified value, turn pump
body away from engine.
• If indication is larger than the specified value, turn pump
body towards engine.
2. Tighten injection pump securing bolts and nuts.

Nut:
~: 13 - 18 N.m (1.3 - 1.8 kg-m, 9 - 13 ft-Ib)
Bolt:
~: 49 - 59 N.m (5.0 - 6.0 kg-m, 36 - 43 ft-Ib)
3. Remove dial gauge and install air bleeder with new washer.
4. Install injection tubes.
Flare nut:
~: 22 - 25 N.m (2.2 - 2.5 kg-m, 16 - 18 ft-Ib)
5. Bleed air from fuel system.
SEF779A Refer to "Water Draining, Fuel Filter Check and Replacement"
of "ENGINE MAINTENANCE" in MA section.
EC-374
VE-TVPE INJECTION PUMP ~
Adjustment (Cont'd)
IDLE SPEED AND MAXIMUM SPEED ADJUSTMENT
CAUTION:
• Do not remove sealing caps unless absolutely necessary.
• Never disturb full-load adjusting screw because this alters
the mixture ratio and may result in serious engine prob-
lems.
• Do not adjust maximum speed adjusting screw to a point
exceeding specifications, because exceeding the maximum
speed may cause engine damage.
• When attaching tachometer pickup, remove fuel tUbe
clamps. (Refer to tachometer instructions.)
Idle speed adjustment •
• Refer to MA section.
Idle speed: 700~ ~o rpm
SEF156R
Maximum speed adjustment

1. Start engine and warm it up until coolant temperature indi-
cator points to middle of gauge.
2. Connect tachometer pickup to NO.1 fuel injection tube.
• Refer to the instructions on tachometer.
3. Depress accelerator pedal fully under no-load and read the
tachometer indication.
Maximum engine speed (Under no-load):
5,400 rpm
4. If indication is lower than specified maximum engine speed,
adjust using maximum speed adjusting screw.
5. After adjustment, tighten lock nut securely and plug it with
a sealing cap.
Dash pot adjustment

2. Attach tachometer and adjust touch speed using adjusting
screw.
Touch speed: 1,300 rpm
EC-375
INJECTION NOZZLE
CAUTION:
Plug flare nut with a cap or rag so that no dust enters the noz-
zle. Cover nozzle tip for protection of needle.
Nozzle side Removal and Installation

1. Remove fuel injection tube and spill tube.
2. Remove injection nozzle assembly.
Also remove washers from nozzle end.
3. Install injection nozzle in the reverse order of removal.
Injection nozzle to engine:
Combustion
~: 59 - 69 N'm (6.0 - 7.0 kg-m, 43 - 51 ft-Ib)
chamber side
Injection nozzle to tube:
~: 22 - 25 N'm (2.2 - 2.5 kg-m, 16 - 18 ft-Ib)
Spill tube:
SEF668A
~: 39 - 49 N'm (4.0 - 5.0 kg-m, 29 - 36 ft-Ib)
a. Always clean the nozzle holes.
b. Always use new injection nozzle gasket.
c. Note that small washer should be installed in specified
direction.
d. Bleed air from fuel system.
SEF781A
Disassembly
1. Loosen nozzle nut while preventing nozzle top from turning.
SEF669A
older 2. Arrange all disassembled parts in the order shown at left.
:S
c:,
Adiusting
~ '~[;{~I:,""'
~
pi,",
shim
Nozzle spring
Nozzle needle ~~(''''-

Nozzle bOdyr ~
Nozzle nut) SEF670A
EC-376
INJECTION NOZZLE
Inspection
Thoroughly clean all disassembled parts with fresh kerosene or
solvent.
• If nozzle needle is damaged or fused, replace nozzle
assembly with a new one.
• If end of nozzle needle is seized or excessively discolored,
replace nozzle assembly.
• Check nozzle body and distance piece for proper contact. If
excessively worn or damaged, replace nozzle assembly or
distance piece.
• Check distance piece and nozzle holder for proper contact.
If excessively worn or damaged, replace distance piece or •
nozzle holder.
• Check nozzle spring for excessive wear or damage. If
excessively worn or damaged, replace it with a new spring.
Cleaning
a. Do not touch the nozzle mating surface with your fingers.
b. To wash the nozzles, use a wooden stick and brass brush
with clean diesel fuel.
1. Remove any carbon from exterior of nozzle body (except
wrapping angle portion) by using Tool.
SEF830
2. Clean oil sump of nozzle body using Tool.
SEF831
3. Clean nozzle seat by using Tool.

This job should be performed with extra precautions, since
efficiency of nozzle depends greatly on a good nozzle seat.
KV11290150
SEF832
EC-377
INJECTION NOZZLE ~
Cleaning (Coni' d)
4. Clean spray hole of nozzle body by using Tool.
To prevent spray hole from canting, always clean it by starting
with inner side and working towards outside.
KV11290220
SEF833
5. Decarbonate nozzle needle tip by using Tool.
SEF834
6. Check needle sinking.

(1) Pull needle about halfway out from body and then release
it.
(2) Needle should sink into body very smoothly from just its
own weight.
(3) Repeat this test and rotate needle slightly each time.
If needle fails to sink smoothly from any position, replace both
needle and body as a unit.
SEF835
Assembly
Assemble in the reverse order of disassembly, observing the
following.
KV11292010
SEF671A
If nozzle body is not installed properly, Tool cannot be removed

and nozzle body may be damaged.
Holder to nozzle nut:
(OJ: 78 - 98 N'm (8.0 - 10.0 kg-m, 58 - 72 ft-Ib)
EC-378
INJECTION NOZZLE
Test and Adjustment

WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to contact your hands or body, and make
sure your eyes are properly protected with goggles .
INJECTION
1.
PRESSURE TEST
Install nozzle to injection
flare nut.
nozzle tester and bleed air from
•
EF791A
2. Pump the tester handle slowly (one time per second) and
watch the pressure gauge.
3. Read the pressure gauge when the injection pressure just
starts dropping.
Initial injection pressure:
Used
12,259 - 13,239 kPa (122.6 - 132.4 bar,
125 - 135 kg/cm2, 1,778 • 1,920 psi)
New
12,749 - 13,534 kPa (127.5 - 135.3 bar,
SEF672A 130 - 138 kg/cm2, 1,849 • 1,962 psi)
Always check initial injection pressure using a new nozzle.
4. To adjust injection pressure, change adjusting shims.

Adjusting shim
a. Increasing the thickness of adjusting shims increases initial
injection pressure. Decreasing thickness reduces initial
pressure.
b. A shim thickness of 0.04 mm (0.0016 in) corresponds
approximately to a difference of 471 kPa (4.71 bar, 4.8
kg/cm2, 68 psi) in initial injection pressure.
Refer to SDS for adjusting shim (EC-419).
SEF673A
EC-379
INJECTION NOZZLE ~
Test and Adjustment (Cont'd)
LEAKAGE TEST
1. Maintain the pressure at about 981 to 1,961 kPa (9.8 to 19.6
bar, 10 to 20 kg/cm2, 142 to 284 psi) below initial injection
pressure.
2. Check that there is no dripping from the nozzle tip or around
the body.
Good Faulty
SEF674A
3. If there is leakage, clean, overhaul or replace nozzle.
SPRAY PATTERN TEST

1. Pump the tester handle one time per second.
2. Check the spray pattern .
•
Good I
Wrong
EF794
3. If the spray pattern is not correct, clean or replace nozzle.
EC-380
FUEL SYSTEM CHECK
Priming Pump Check

Before checking priming pump, make sure that fuel filter is
filled with fuel.
1. Disconnect fuel return hose.
Place a suitable container beneath hose end.
2. Pump priming pump and check that the fuel overflows from
the hose end. If not, replace priming pump .
Fuel Cut Solenoid Valve

1. Disconnect fuel cut solenoid
check voltage.
Ignition switch
OFF
valve harness connector
Voltage
OV
and
•
ON Battery voltage
2. Check fuel cut solenoid valve for circuit continuity.

3. Remove fuel cut solenoid valve and check that plunger
moves smoothly and that spring is normal.
EC-381
CRANKCASE VENTILATION SYSTEM
Q Fresh air
~ Blow-by gas
l J
SEF157R
Ventilation Hose
2. Disconnect all hoses and clean with compressed air.
If any hose cannot be freed of obstructions, replace.
SEC692
EC-382
Component Parts Location
Engine coolant
temperature sensor
•
relay-2
Glow plugs
SEF159R
EC-383
System Diagram
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SEF160R
EC-384
Circuit Diagram
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HEeD8?
EC-385
System Chart
Ignition key
Quick-glow system Glow relay & glow lamp

sensor
Partial load advance (PLA)
Solenoid timer
control
Engine speed sensor ECM
(Engine
control
Air conditioner switch module)
Cooling fan control Cooling fan relay
Battery voltage
Air conditioner cut control Air conditioner relays

EC-386
TROUBLE DIAGNOSES
ECM Terminals and Reference Values

PREPARATION
1. ECM is located behind the center console panel. For this
inspection, remove the center console under cover .
•
MEF603D

ily.
!~
Thin wire Tester probeJ
SEF3671 ECM HARNESS CONNECTOR TERMINAL LAYOUT
SEF162R
EC-387
TROUBLE DIAGNOSES ~
ECM Terminals and Reference Values (Coni' d)
ECM INSPECTION TABLE
-Data are reference values.
TER-
MINAL ITEM CONDITION -DATA
NO.
L Both AIC switch and blower fan switch are Approximately OV
8 Air conditioner relay "ON".


L Cooling fan is not operating. (11-14V)
Cooling fan relay (Low
9
speed) IEngine is running I
1V
10
Cooling fan relay (High
BATTERY VOLTAGE
(11-14V)
speed)
1V
0- 5.0V
15 IEngine is running.1 Output voltage varies with
sensor
engine coolant temperature.
25 BATTERY VOLTAGE
Power supply for ECM jlgnition switch "ON"I
37 (11 - 14V)

Approximately OV
28 Start signal
llgnition switch "START"I SATTERY VOLTAGE
(11 - 14V)
Ilgnition key is not inserted.1

OV
BATTERY VOLTAGE (11 -

30 Key-in switch 14V) [for 3 seconds at
Ilgnition key is inserted.1
- of approx. 60°C (140°F) or
less)
L Both air conditioner switch and blower fan Approximately OV
31 Air conditioner switch switch are "ON".

Ilgnition switch "OFF"I BATTERY VOLTAGE

38 Power supply
(11 - 14V)
106 Glow relay Refer to "Quick-glow System".
EC-388
TROUBLE DIAGNOSES ~
ECM Terminals and Reference Values (Cont'd)
TER-
MINAL ITEM CONDITION *DATA
NO.
BATTERY VOLTAGE
L Engine coolant temperature is lower than (11-14V)
we (50'F).
108 Solenoid timer
/Engine is running.1
L Engine coolant temperature is higher than Approximately OV
•
we (50'F).
EC-389
TROUBLE DIAGNOSES
Quick-glow System
SYSTEM DESCRIPTION
Key-in switch and key position
Ignition key ECM Glow relay Glow plugs
(Engine
control
Engine coolant temperature sensor module) Glow lamp
Ignition
START[~
switch
I
11
Key
switch
Key
timer
~~ [ -II-
OUT
ONe n
Ir1
T,
I
I
~
Hn
I !
JTl-
~
I I-l
.1"l....!:.1L- 1iI
Lamp
OFF
ON [
o~~
..Lfl
To
I I-.J TL I
UL
I I-l TL
HTo
I I
HT'o
I I
~
I HTL I-l T'L
Relay OFF [j I_ L- ~ r--L .f"l.-.JL ~
T. II I II ~ 1r;,1
,
"'I II I I
Glow plug
temperature
Normal operation Operation after Leaving key in Repeating key IN Repeating key ON
key timer is OFF ON position and OUT and OFF
TL = T, - T, TL =.
T, T'o ~ 80% of To T', =. T,
when T, - 0.5 T, > when To < T, when T. 5': 3 sec. T', =. T,
TL = T,
when T, - 0.5 ~ T, ;a; To
SEC550B
When the ignition key is inserted into the key While cranking, the relay remains on. The relay
cylinder, the engine control module turns on the automatically turns off after T4 seconds have
relay and the "high-level" electric current flows passed from the engine start.
through the glow plugs and heats them up
quickly. When the ignition switch is turned on, the
control module turns on the indicator. After T1
seconds have passed from key in, the control
module turns off the indicator.

Second Engine coolant tempera-' Remarks
Resistance (kQ)
ture 'C ('F)
To 3.1 - 3.9 - -
5.0 - 7.0 -25(-13) 19.7
T, 1.8 - 3.2 20 (68) 2.5
0.8 - 2.2 60 (140) 0.6
17.0 - 23.0 Lower than 60 (140) More than 0.6

T3
40 - 6.0 Higher than 60 (140) Less than 0.6
255 - 345 Lower than 60 (140) More than 0.6 When alternator is
T4
Less than 10 Higher than 60 (140) Less than 0.6 working
15 - 25 Lower than 60 (140) More than 0.6 When alternator is not

(T4)
3 - 7 Higher than 60 (140) Less than 0.6 working
T5 0.1 - 0.9 - -
EC-390
TROUBLE DIAGNOSES
Quick-glow System (Cont'd)
DESCRIPTION
Engine coolant temperature sensor (ECTS)
The engine coolant temperature sensor detects engine coolant
temperature and transmits a signal to the ECM.
Electrical resistance of the thermistor decreases in response to
the temperature rise.
Key-in switch
The key-in switch is built into the key cylinder. The ECM detects
the key position and controls the key-in glow system.
•
SEF938P
EC-391
TROUBLE DIAGNOSES
Quick-glow System (Co nt' d)
EC-GLOW-01
IGNITION SWITCH IGNITION SWITCH
START ON or START
FUSE
7.5A 10A 10A BLOCK Refer to EL-POWER.
1261 1251 IT] (JIB)
@:ID
IN.41 1Ni91 1Ni91 1I~11 : LHD models

B/Y BR BR Y
<£D: RHO models
I!i
Y
METER
COMBINATION
(GLOW LAMP)
113•31 @
OR
I
B/Y BR BR OR
~
START
~
IGN
~
IGN
m
GIL ECM
(ENGINE
CONTROL
MODULE)
GNO-C GNO-C GNO-A GNO-A TW @
12.6I 113•9 I 11~11 11~51 ~
B B B B G/B
I----.-_-.-I I
__ 1.I I To engine coolant
.-o-ee-°l
I
I
<;
-------..
A ;>
temperature sensor
(Refer to EC-COOL/F.)
B
-!-!
1---.1
.
B
-!-
Refer to last page

(Foldout page) .
HEC088
EC-392
TROUBLE DIAGNOSES
EC-GLDW-02
I
.------.
BATTERY
•
I
7.5A
FUSE
BLOCK 75A
Refer to EL-POWER.
1241 (JIB)
(106) ~ffij IT]
10.91
•
W/L B/R
(b): LHD models
1--~ I
P
<E:>: RHO models
I
P
W!L B/R
1
IN
KEY-IN
SWITCH
@
11!11~II~e~y
~m>
OUT-- ~
~
~
1!:i=Jll!:i=!J~
W/R R
BR/Y
I I
~~
BR/Y
(E10f) . ~
CHID I~I
BR/Y
~
I~I
(EiOf)
CHID
m W/L
CHID I~I
+f ~1
rA,
W/L
~(E10f)
I~I CHID CHID ~
W/R
<EIQD ~
W/R
~ (E10!)
I~ICHID ~~
R
ctJ@
BR/Y BR/Y W/L W!L W/R W/R R
t-t tJ tJ BR/Y
I I
W/L W/R
I
I
R
Q
00KEY
1001
BATT
IL@JI
G/R GLOW
!'e"
(ENGINE
CONTROL
MODULE)
(M39)
PLUG
(E213)
~---------------~
I I
Refer to last page
(Foldout page) .
~ (E115) :Fnm>~~~~:
[IIg] W :rnJ
,
G @J W l.9J W :
,
-----------------
HEC089
EC-393
TROUBLE DIAGNOSES
-"-..... 'y;-----...
Connectingplate nut:J INSPECTION START

~1.0 • 1.5 N.mr-
"(0.1 • 0.15 kg-m,- ""'-
8.7 - 13.0 in-Ib)
"" . '------ Check fuel level, fuel supplying system, ~ Correct.

~ ~ starter motor, etc.
OK
m
Check that all glow plug connecting ~ Install properly.
plate nuts are installed properly.
OK
OK
Check entire quick-glow system. (Refer
---.. CHECK COMPONENT
(Glow plug).
to "System Operation Check" on next See page EC-397.
page.)
NG
NG
CHECK POWER SUPPLY AND GROUND
CIRCUIT.
---.. Repair harness or con-
nector.
SEF939P
(Refer to "Power Supply and ground
(!] circuit for ECM", EC-396).
~io (!]
OK
NG
CHECK VOLTAGE BETWEEN GLOW
RELA Y AND GROUND.
---.. Check the following.
• 7.5A fuse
1) Check voltage between terminals • 75A fusible link
G), @ and ground with tester. • Harness continuity
Voltage: Battery voltage between glow relay
and fuse
SEF940P OK
connectors.
~ [!1
II ECM E1
106
CONNECTOR II CHECK OUTPUT SIGNAL CIRCUIT.
NG
---+
nectors.
ill] OK
~ Ii]
SEF941P
CHECK HARNESS CONTINUITY NG Repair harness or con-
---+
BETWEEN GLOW RELAY AND GLOW nectors.
Ii]
PLUG.
~i5 Glow
plug
1) Disconnect ECM harness connector.
2) Disconnect glow relay.
Eill~
@]Q] 2 0 glow relay terminal @ and glow
plug.
[ill
~OK
~
SEF942P
EC-394
TROUBLE DIAGNOSES
@
CHECK COMPONENTS NG Replace malfunctioning

(Glow relay, Glow plug, Engine coolant component(s).
temperature sensor, Key-in switch, Igni-
tion switch).
Refer to "Component Inspection" (EC-
397).
OK


•
and retest.
SYSTEM OPERATION CHECK

Set voltmeter between glow plug and engine body.
START [ 1. Key-in glow system

• Read voltage when ignition key is inserted into ignition
Ignition ON
key switch.
IN [ Voltage:
OUT ,, Battery voltage for about 3 seconds
,
,
I
JL
BATIERY [
Voltage
OV
SEC5558
2. Quick-glow (Pre-glow) system

1) Turn ignition switch "ON" 3 or more seconds after key-in.
Ignition
2) Read voltage.
key
Voltage:
Battery voltage for about 20* seconds
* Coolant temperature is lower than 60°C (140°F).
* Repeating ignition key "ON" and "OFF" may
BATIERY [ change the time.
Voltage
OV
SEC5568
EC-395
TROUBLE DIAGNOSES
J
F:
3. Quick-glow (Cranking) system
START[ 1) Disconnect "S" terminal for starter motor to prevent engine
from cranking.
Ignition ON
key IN r- j 2) Read voltage when ignition key is turned to "8T ART".
Voltage:
OUT L : Battery voltage *
I
* For about 20 seconds after returning ignition switch
vo,,:TIERYlJlfr
I
I
to "ON".
oV SEC557B
Ignition
key
STA:~[
OUT [
IN
r:JL :
!
I
I
Engine running
4. After-glow system
1) Connect "8" terminal to starter motor.
2) Start engine and read voltage.
Voltage:
Battery voltage for 5* minutes
* Coolant temperature is lower than 60°C (140°F).
Jlfi=
,
,
I
votta;ATIERY [
oV SEC558B
POWER SUPPLY AND GROUND CIRCUIT FOR ECM
~i5 1. Disconnect "S" terminal for starter motor to prevent engine

from cranking.
II ECM E CONNECTOR II 2. Disconnect ECM harness connector.
26-39101-105 3. Check terminals @, @. Gill. @ for ground continuity.
Continuity should exist (On).
• If NG, check ground harness.
SEF943P
4. Check voltage at each terminal according to the following
~i5 chart.
(D II
ECM B CONNECTOR
•5-25-28-30-37-38-106,
II Terminal No . Ignition switch position Voltage
@ OFF (Not inserted)
Battery voltage
GID . OFF (Not inserted)
OFF (Not inserted) OV
@
OFF (Inserted) Battery voltage
OFF OV
@,@
ON START Battery voltage
OFF OV
@
ON START Battery voltage
OFF ON OV
@
START Battery voltage
EC-396
TROUBLE DIAGNOSES ~
• If NG. check component parts and their related harness
according to the following chart.
Parts which should be checked

Terminal Fuse Glow in-
No. Glow Key-in Ignition
Battery IFusible dicator Harness
relay switch switch
link bulb
@ X X X
@ X X X X
@ X X X X
@,@ X X X X
@
@
X
X
X
X
X
X
X X
•
Glow relay
1. Check relay for coil continuity.
2. Check relay for proper operation.
Coil voltage Continuity Contact point
OV No OFF
12V Yes ON
Ohmmeter
SEC5648
Glow plug
1. Remove glow plug connecting plate.
2. Check each glow plug for continuity.
Continuity should exist:
Approximately 0.650
• If NG, replace glow plug.
SEF630K
EC-397
TROUBLE DIAGNOSES
~GIOwnut 3. Install glow plug connecting plate securely.
Glow harness
Connecting
plate
Spring washer
SEC5658

Check engine coolant temperature sensor resistance.
Coolant temp. °C ('F) Resistance kfl
-15 (5) 11.5
0(32) 5.6
10 (50) 3.7
40 (104) 1.2
Key-in switch
Check continuity between terminals of key-in switch connector.
Ignition key Continuity
Not inserted No continuity
Inserted Continuity should exist.
Alternator
Refer to "CHARGING SYSTEM" in EL section.
EC-398
TROUBLE DIAGNOSES
Partial Load Advance (PLA) Control

SYSTEM DESCRIPTION

ECM
(Engine
Solenoid timer
control
Engine speed module)
Engine speed sensor
This system switches the solenoid timer on and off corresponding to the engine coolant temperature and
engine speed. The solenoid timer operation advances and retards the fuel injection timing as follows:
•
•
•
The injection timing advances when the timer is ON, while it retards when the timer is OFF.
When the engine stalls or the ignition switch is in the START position, the solenoid timer is set to
OFF.
When the engine coolant temperature is lower than 10°C (50°F), the timer is set to ON.
•
DESCRIPTION
Solenoid timer
The solenoid timer switches on and off in accordance with a
signal from the ECM. This timer operation changes the pres-
sure in the injection pump, thereby controlling the fuel injection
timing.
Engine speed sensor

The engine speed sensor detects engine speed by monitoring
the rotation of drive shaft gear in the injection pump. The sen-
sor sends a signal of 37 pulses per drive shaft rotation to the
ECM.
EC-399
TROUBLE DIAGNOSES ~
Partial Load Advance (PLA) Control (Cont'd)
LHD models
EC-PLA-01
~~~~K Refer to EL-POWER.

(JIB)
<fill)
IN;91 IIN•41
BR B/Y
I
BR
I
B/Y
~ Iffsn ECM
IGN START
(ENGINE
CONTROL
MODULE)
PLR REV GND-S GND-S TW @
11~81 ~ /12.311 13.61 ~
Y L!Y B/W B/W G!B
I I f-t_I t
Y ~ L!Y B!W
1
._--~.
To engine coolant
temperature sensor
(Refer to EC-COOL!F.)
IrlsJ~ - M.-B - ~I&~

'T' (E101) L:jf'
- -- ~r;]ID1
"T'
Y L!Y B!W
1c!J~~ ~cL~
- -- ~c!J1
<=j= (E231) =r' =r'
Y L!Y B!W
! L~Y B~Wt
rrh m m
INJECTION
PUMP
SOLENOID ENGINE (E214)
TIMER SPEED
SENSOR
Refer to last page

(Foldout page) .
~~ ~ (E214)
~ GY \ill) GY
HEC090
EC-400
TROUBLE DIAGNOSES ~
RHO models
EC-PLA-02

BLOCK
(JIB)
~
•
IN;91 IN.41
BR B/Y
BR
I B/Y
I
~ Wail
IGN START ECM
(ENGINE
CONTROL
MODULE)
PLR REV GND-S GND-S TW ~
11~BI ~ 112•31 13.,61 ~
Y L/Y B/w B/W G/B
I I f-
Y ~ L/Y B/W
t-, t I
..........
To engine coolant
~. temperature sensor
(Refer to EC-COOL/F.)
I$t~
Y
_M~- ~t~
---~$I
L/Y B/W
4r=~~t---~
Y L/Y B/W
! L~Y B~Wt
m m rn
INJECTION
PUMP
SOLENOID ENGINE (E214)
TIMER SPEED
SENSOR
Refer to last page

(Foldout page) .
~(E203) M\ (~!4)
rn:rn:tIlID GY t:]lV GY
HECC91
EC-401
TROUBLE DIAGNOSES ~
INSPECTION START
~i5
D~CONNECTORII
lOB
1) Start engine.
2) Check voltage between ECM terminal
COO and ground.
Voltage:
Engine coolant temperature is
SEF040Q
lower than 10'C (50' F)
Battery voltage
Engine coolant temperature is
higher than 60'C (140'F)
OV

1) Disconnect ECM harness connector. nectors.
2) Disconnect injection pump harness
connector.
ECM terminal COO and terminal @.
~i5 Continuity should exist.
II ECM M II
CONNECTOR
OK
10B
CHECK COMPONENT NG Replace solenoid timer,
(Solenoid timer, engine speed sensor). engine speed sensor.
on next page.
OK
SEF949P

nector. Reconnect ECM h~rness con-
nector and retest.
EC-402
TROUBLE DIAGNOSES ~
Solenoid timer
1. Disconnect solenoid timer harness connector.
2. Apply battery voltage to solenoid timer terminals and listen
for operating sound.
Condition Operating sound

With battery voltage applied Yes
Without battery voltage applied No
•
Engine speed sensor
1. Disconnect engine speed sensor harness connector.
2. Check resistance between terminals @ and CID.
Resistance: Approximately 1.6Q
EC-403
TROUBLE DIAGNOSES
Cooling Fan Control

SYSTEM DESCRIPTION
Vehicle speed
ECM
Engine coolant temperature (Engine
Engine coolant temperature sensor Cooling fan
control
relay(s)
module)
The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, air
conditioner system pressure and air conditioner ON signal. The control system has 3-step control
[HIGH/LOW/OFF].
Operation
Air conditioner switch Is "OFF". Air conditioner switch Is "ON".
Q> -
...LL ~LL
:J 0 :J 0
~~ 100 (212) eZ; 100 (212)

~o ~o
E 95 (203) E 95 (203)
2 2
90 (194)
c 90 (194) C
'"
'0
o
'"
'0
o
U U
Q> Q>
c c 20 80
'5> 20 80 '5>
c: (12) (50) c (12) (50)
w w
Vehicle speed kmfh (MPH) Vehicle speed kmfh (MPH)
o: Cooling fans do not operate. 1222l: Cooling fans operate at "Low" speed. ~ : Cooling fans operate at "High" speed.
SEF953P
EC-404
TROUBLE DIAGNOSES
IGNITION SWITCH
EC-COOL/F-01
ON or START
FUSE
: LHD mode 1s
10A (JIB) <ID: RHO models
1251 <M:@
CE106)
COMBINATION
METER
1~
... ------------.
R -----------0
---------I~-LI.
BR ~TO EC-COOLlF-03
•
(SPEEDOMETER)
@
@
1~
~
R/Y
B/R ----I <j=I=(

R/Y CHID R
~
PUlA
I
B; Iu)~&~1)~u)J1
~ R/Y~ R
PU/R
rrT6TI 1$~~i~1
ECM R/Y R
VSP
A
(ENGINE
CONTROL
MODULE)
R/FAN2 R/FAN1 ~
~
LG
~
LG/R
o
It L
I0---t
O~LG/R ~LG/R;l
CHID: (EiOt)
=1
R ~~
(J
rv
VEHICLE
SPEED
SENSOR
C:
R/Y @lID
-ea::::- LG ~ LG
L LG/R. LG/R I(C:- .0- ....

-- LG/R~}
CHID:~ To EC-COOL/F-03
L LG. LG -<b:>-O-_ ....
_. LG -@>:
Refer to last page

(Foldout page) .
~~ ~~ ~~
~B ~B tW GY
HEC092
EC-405
TROUBLE DIAGNOSES
EC-COOL/F-02
iJ
ENGINE COOLANT
_ TEMPERATURE
SENSOR
~ (6): LHD models
lLj:U (B): RHO models
GIS S/W
It
o
I
(E203) ~
<W ~
GIS ~
L :>
S/W

S/W ~
d!b:. ~ d!b:.
~11lJ1 Icpt (ES-) - -1~1 IciJl <E2~)
GIS GIS S/W S/W
@QD~
I GIS
db ~
I t'ETr\'i\ S/W
I
,.,.b
S/W
I
I~I@QD
<:BID I~I
GIS
1~~-M8--~
GIS @ S/W
;,:@
to
L
o
I
GIS
t
iTlJ
S/W S/W
I@I 1l@1 100'
TW GND-S GND-S
I(ENGINE
EeM
CONTROL
MODULE)
@
Refer to last page

(Foldout page) .
~~ ~(E203) ~~
@GY rnmz:mI GY ~GY
HEC093
EC-406
TROUBLE DIAGNOSES
EC-COOL/F-03
rt~30A
LVffi ~[]]
Refer to EL-POWER.
GY G/W
I I
~g,COOL/F ~ BA =,-I-F e
,1= I I •
COOLING
FAN
RELAY-1
8R
I I:!:' I:!r
U
GY G/W
n 1:1]1n ~OOLINGI:~:I
FAN
U RELAY-2
1
8R GY LG/8
IJjI n 1:1]1n
U U1
COOLING
~~~AY-3
I
:!:
8R G/W LG/R
1:1]' 1:1]1
~ ~1
(ill) IbjJJ lbj.JJ ~ <ffi) ~ lbi=Jl ~ <m> IbjJJ lbi=Jl ~
bl=l-J
LG/R G/8 G/R LG G/Y 8 LG G/OR 8
To
EC-COOL/F {~LG/R:J
~
* _--I~- ....
- • I .... I--~t t
-01 LG
----
COOLING COOLING
FAN FAN
MOTOR-1 MOTOR-2
rn ~
i
"
-!-
S
m CE51)
8
-!-
~ (ill), (ffi) , (ffi) ~@,rn

~ 8R 8R 8R ~GY GY
HEC094
EC-407
TROUBLE DIAGNOSES
INSPECTION START

1) Turn ignition switch "OFF". I
(Go to PROCEDURE C P
2) Disconnect engine coolant tempera-
ture sensor connector.
SEF168R 3) Disconnect cooling fan relays 1, 2
and 3.
5) Reconnect cooling fan relay 1.
6) Make sure that cooling fan operates
at low speed.
OK
CHECK COOLING FAN HIGH SPEED NG Check cooling fan high

SEC163BA
1) Turn ignition switch "OFF". I
(Go to PROCEDURE D I.)
2) Reconnect cooling fan relay-2 and
cooling fan relay-3.
4) Make sure that cooling fan operates
at high speed.
OK
INSPECTION END
EC-408
TROUBLE DIAGNOSES
~i5
PROCEDURE C
3 INSPECTION START
7 5
~2 1
[!]
NG
CHECK POWER SUPPLY.
1) Turn ignition switch "OFF".
--.-. Check the following.
• Harness connector
2) Disconnect cooling fan relay-1. ~
SEF956P
3) Turn ignition switch "ON". • 10A fuse
4) Check voltage between terminals • 30A fusible links
~~----
Cooling fan motor-2
G), @, @ and ground.
OK
•
•
75A fusible link
Harness continuity
between cooling fan
relay-1 and fuse
between cooling fan
relay-1 and battery
•
connectors.
-----~_._----------
-------------------- NG
o CHECK GROUND CIRCUIT. --.-. Repair harness or con-
SEF857P 1) Turn ignition switch "OFF". nectors.
2) Disconnect cooling fan motor-1 har-
~i5
I!l ~i5.~ Cooling
I!] 3) Check harness continuity
\nY
A
3 fan between terminal (J) and termi-
7 5 motor-1 nal G) , terminal @ and termi-
2 1
nal G) .
.~ Cooling II 4) Check harness continuity
\nY fan between terminal @ and body
motor-2 ground.
SEF041Q
OK
[j
NG
f--..- • Harness connectors
~ ~ 2) Check harness continuity between @D,@
\WI \ttV ECM terminal @ and terminal (?). • Harness continuity
Cooling fan Cooling fan
motor-1 motor-2 Continuity should exist. between cooling fan
relay-1 and ECM
connectors.
SEF042Q NG
(Cooling fan relay-1).
f--..- relay.
~i5 (See page EC-412.)
ECM E CONNECTOR II ~OK
SEF958P
EC-409
TROUBLE DIAGNOSES
Cooling Fan Control (Co nt' d)
@
NG
(Cooling fan motors). motors.
(See page EC-412.)
OK


nector and retest.
I PROCEDURE D
INSPECTION START
NG
1) Turn ignition switch "OFF". • Harness connectors
2) Disconnect cooling fan relay-2 and (ill!)
SEF168R
cooling fan relay-3. • 10A fuse
3) Turn ignition switch "ON". • 30A fusible links
4) Check voltage between cooling fan • 75A fusible link
~i5 relay-2, 3 terminals (!J, @ and

ground.
between cooling fan
relay-2, 3 and fuse
~ • Harness continuity
rntJ OK between cooling fan
Coolingfan relay-2, 3 and battery
relay. 2,3
connectors.
SEF959P
EC-41 0
TROUBLE DIAGNOSES
@
1:1
~i5 1 NG
CHECK GROUND CIRCUIT. ---... Repair harness or con-
:~-
[W=ill
1) Turn ignition switch "OFF". nectors.
2) Disconnect cooling fan motor-1 har-
Coolingfan
relay-2 AG< ness connector and cooling fan
\lliJ motor-2, 3 harness connectors.
Cooling
fan motor
1:1 3) Check harness continuity
-2,3
harness nal @, terminal @ and termi-
connector
•
nal @, terminal iJ) and body
ground.
Continuity should exisl.
OK
-
0
NG
CHECK OUTPUT SIGNAL CIRCUIT
---.. Check the following.
2) Check harness continuity between @!D,@
ECM terminal @ and terminal @. • Harness continuity
Continuity should exisl. between cooling fan
relay-2, 3 and ECM
SEF960P OK If NG, repair harness or
connectors.
o
~i5 CHECK COMPONENT
(Cooling fan relay-2, 3).
NG
f----+
Replace cooling fan
relays.
II ECM ~ CONNECTOR II Refer to "COMPONENT INSPECTION"
10 on next page.
OK
NG
(Cooling fan motors).
f----+ motors.
SEF043Q
on next page.
OK


nector and retest.
EC-411
TROUBLE DIAGNOSES
Cooling fan relays-1, -2 and -3
Check continuity between terminals @ and CID, CID and (l).

Yes
terminals G) and @
SEC202B

Cooling fan motor-1
harness connector 2. Supply cooling fan motor terminals with battery voltage and
check operation.
Cooling fan motor-2 Terminals

harness connector Speed
(EB) (8)

motor-1 High @,e!) @,@
SEF044Q
Cooling fan Low e!) @
motor-2 High @,e!) @,@

EC-412
TROUBLE DIAGNOSES
Air Conditioner Cut Control

SYSTEM DESCRIPTION
Air conditioner switch A/C ON signal
ECM
Air condi-
(Engine
tioner
control
Engine coolant temperature relay
Engine coolant temperature sensor module)
The air conditioner is turned off under the following conditions:

RHO models .
• Engine coolant temperature is higher than grC (20rF)
LHD models
•
• Engine coolant temperature is higher than 105°C (221°F)
For trouble diagnoses, refer to "TROUBLE DIAGNOSES" in HA section.
EC-413
TROUBLE DIAGNOSES
Air Conditioner Cut Control (Cont'd)
LHD models
EC-A/CCUT-01
FUSE
BLOCK
(JIB) Refer to EL-POWEA.
~ L/Y
(BOO)
1~11I~211~1
OFF
II-~ --
LIB LG/R LG/R
,
LG/R
LG/R~ I
I
I
I
ON A/C
SWITCH
LIB L/Y m I OFF @
IT ~IA/C
I
THERMO
CONTROL
RIL ~ AMP.
n RELAY
~ ON
U UID
4=JJ~
._-~--_. rn
~ ~
L L/R G/B
I I
G/B G/Y
m JUNCTION
~L
THERMISTOR
BOX NO.2
To compressor (JOINT
._ L/R. (Refer to CONNECTORS)
rn
I
HA-A/C.) ~ ~
...
LOW
~~_.
n
HIGH
NORMAL
DUAL-
PRESSURE
SWITCH
~
00 ~E~N~~gD I ?iJ
G/Y
~~~TCH
I!4Jl VALVE OFF-- ~
G IkjJ (E64) ~
~~1;1$1 t B (E65) B
m
COMP
G R/L
IriDl
A/C ECM
(ENGINE
I
• ..,
r1
B B
I B
---------- I
CONTROL
MODULE)
@
1~
mm
1 i....l
~~
Refer to last page
(Foldout page) .
IQl@
~(E16) CMID , (El0n
T L
~ W
lf1@ , (E106)
~-----------.,
I I ~
JS4.ffi
(tiS) B :ITl~ ~~:
I
L ~I
HEC095
EC-414
TROUBLE DIAGNOSES
Air Conditioner Cut Control (Cont'd)
RHO models
EC-A/CCUT-02
FUSE
BLOCK
@g)
<lliID
UQ-lil I N.21 I N.21
II •
OFF
LIB LG/R LG/R
I
---Im THERMO
LG R CONTROL
LG/R~ I
I
I
I
I
ON
OFF
A/C
SWITCH
@
IT ]/,/c
LIB L/Y AMP.~ I
~
R/L ~ ~GY~
n RELAY
ON
U~
~lbi=ll IACV-FICD
~
r L..
L L/R THERMISTOR LG/B
SOLENOID
VALVE
(E101) (BID <fill) @ill) @!QD ~
LOW
...
m L HIGH
_e
OUAL-
PRESSURE
SWITCH
-
-
L/R
L/R.
~ L/R ~
To compressor
(~~~~/Ctf
L/R
~
'-B~
•
-e=~Y,
<fill)@B)
B
~~
LG/B
I
NORMAL ffi
4=U . ffi ~~:CTOR-4 OFF-- ON ~~;CH
G
db (E101)
I~I(][)
t W ~
+--, n I
B B
G R/L
m
COMP
Irfnl
A/C ECM
B B B B B
(ENGINE
I
~---------@
CONTROL
MODULE)
@
1 t..l t..l
<HW ~
Refer to last page
A~
T L
L'Ql@
[[[g@] W
(Foldout page) .
(BID , (E101)
~ , <EIQ6)
r----------.,
J I
1Ql ~ I F.1 (B10n B (B102) I ITI:illIIITIIII @ ~ ~
C!J.S) B I~ B ~ B I~ P 123456 W
I I
L .J
HEC096
EC-415
TROUBLE DIAGNOSES
Fuel Cut Control
EC-FCUT-01
IGNITION SWITCH
ON or START

10A BLOCK
1251 (JIB)
<E106)
(b): LHO mode Is
: RHD models
BR SR
~@) liJ~
1!:iJl@
~m»
BR BR
to
I
BR
m
INJECTION
PUMP
FUEL CUT ~
SOLENOID
VALVE
Refer to last page

(Foldout page) .
~~ ~~ ~~
~S m:zm GY \IDZJ GY
EC-416 HEe09?
PRESSURE REGULATOR
Regulated pressure 299 (2.99, 3.05, 43.4)
Idle speed'1 rpm

ENGINE COOLANT TEMPERATURE
SENSOR
GA14DE, GA16DE for Europe and
Israel Temperature 'c ('F) Resistance kn
•
AIT: 800:1:50
20 (68) 2.1 - 2.9
Models with daytime light system
MIT: 800:1:50 90 (194) 0.24 - 0.26
Models without daytime light system
110 (230) 0.14-0.15
M/T: 700:1:50
GA15DE
No-load'2 M/T: 630:1:50
A/T: 750:1:50
FUEL PUMP
M/T: 675:1:50
A/T: 800:1:50 Resistance [at 25'C (77'F)] n Approximately 0.2 - 5
GA16DE except for Europe and Israel,
and Australia
M/T: 650:1:50
A/T: 800:1:50
Air conditioner: ON 900 or more

IACV-AAC VALVE
GA 14DE, GA 16DE for Europe and Approximately 10 (For Europe
Israel and GA16DE except for Australia n and Israel)
Resistance [at 25'C (77'F))
10':1:2' BTDC 50 - 100 (Except for Europe and
Ignition timing GA15DE Israel)
6':1:2' BTDC
8':1:2' BTDC
Throttle position sensor INJECTOR

0.40. 0.60
idle position'3 V
Resistance [at 25'C (77'F)) n Approximately 10. 14
'1: Feedback controlled and needs no adjustments
'2: Under the following conditions:
• Electric load: OFF (Lights, heater, fan & rear defogger)
• A/T models: in "N" position
'3: Engine is warmed up SUfficiently. RESISTOR
Resistance [at 25'C (77'F)] kn Approximately 2.2
IGNITION COIL
Primary voltage V 12
THROTTLE POSITION SENSOR
Primary resistance
Approximately 0.5 - 1.0
[at 20'C (68'F)] n Accelerator pedal conditions Resistance kn [at 25'C (77'F))
Secondary resistance Completely released Approximately 0.5'

Approximately 12
[at 20'C (68'F)] kn Partially released 0.5 - 4
Completely depressed Approximately 4
': Engine is warmed up sufficiently.

MASS AIR FLOW SENSOR
Supply voltage V Battery voltage
Output voltage V 1.2 - 1.8'
': Engine is warmed up SUfficiently and idling under no-load.
EC-417
PRESSURE REGULATOR
Fuel pressure at idling
Approximately
Vacuum hose is connected
235 (2.35. 2.4. 34)
Approxi mately
Vacuum hose is disconnected
294 (2.94, 3.0, 43)
Idle speed'1 rpm

FUEL PUMP
No-load'2 Resistance [at 25'C (77'F)] n Approximately 0.2 - 5.0
800:1:50
(in "N" position)
Air conditioner: ON
850 or more
(in "N" position)
IACV-AAC VALVE
Ignition timing 15':1:2' BTDC
Resistance [at 25'C (77'F)] n Approximately 10.0
Throttle position sensor idle
0.35 - 0.65
position V
'1: Feedback controlled and needs no adjustments

'2: Under the following conditions:
INJECTOR
• Electric load: OFF (Lights, heater fan & rear defogger)
Resistance [at 25'C (77'F)) n ' 1_0_-_1_4 _
IGNITION COIL
RESISTOR
Primary voltage V 12
Resistance [at 25'C (77'F)) kn ApproXimately 2.2
Primary resistance
0.5 - 1.0
[at 25'C (77'F))
Secondary resistance
Approximately 25
[at 25'C (77'F)) kn THROTTLE POSITION SENSOR
Resistance kn
Throttle valve conditions
[at 25'C (77'F)]
MASS AIR FLOW SENSOR Completely closed Approximately 1
Supply voltage V Battery voltage (11 - 14) Partially open 1 - 10
Output voltage V 1.3 - 1.7' Completely open Approximately 10
': Engine is warmed up sufficiently and idling under no-load.
ENGINE COOLANT TEMPERATURE

SENSOR
Temperature 'c ('F) Resistance kn
20 (68) 2.1-2.9
50 (122) 0.68 - 1.00
90 (194) 0.236 - 0.260
HEATED OXYGEN SENSOR HEATER

Resistance [at 25'C (77'F)] n I 3.3 - 6.3
EC-418
VE-type Injection Pump

GENERAL SPECIFICATIONS Pump numbers
Unit: rpm
Pump assembly
Engine Part number
Engine CD20 number
Idle speed FICO: OFF 700~~O CD20 16700-75J01 104740-2610
FICO: ON 800 Pump data is not yet available.

(Pump data will be given by Technical Bulletin, or
Dash pot touch speed 1,300
refer to CALIBRATION STANDARD published by
Maximum engine speed 5,400 ZEXEL.)
INSPECTION
Plunger lift
(Injection timing)
AND ADJUSTMENT
Installation of injection pump
Engine
mm (in)
CD20
0.79 - 0.85
(0.0311 - 0.0335)
•
(equivalent to 8' BTDC)
Injection Nozzle
INSPECTION AND ADJUSTMENT Adjusting shims
Injection nozzle assembly Thickness mm (in) Parts No.
Unit: kPa (bar, kg/em', psi) 0.50 (0.0197) 16613-V0700
Initial injection pressure 0.54 (0.0213) 16613-V0702
12,749 - 13,534 (127.5 - 135.3, 0.58 (0.0228) 16613-V0704

New
130 - 138,1,849 - 1,962)
062 (0.0244) 16613-V0706
12,259 - 13,239 (122.6 - 132.4,
Used 0.66 (0.0260) 16613-V0708
125 - 135, 1,778 - 1,920)
0.70 (0.0276) 16613-V0710
0.74 (0.0291) 16613-V0712
0.78 (0.0307) 16613-V0714
0.82 (0.0323) 16613-V0716
0.86 (0.0339) 16613-V0718
0.90 (0.0354) 16613-V0720
0.94 (0.0370) 16613-V0722
0.98 (0.0386) 16613-V0724
1.00 (0.0394) 16613-V0760
EC-419
ACCELERATOR CONTROL, FUEL &
EXHAUST SYSTEMS
SECTION FE
ACCELERATOR CONTROL SySTEM
Adjusting Accelerator Wire
CONTENTS
2
2
FUEL SYSTEM
Fuel Pump and Gauge
3
4
•
EXHAUST SySTEM 5
ACCELERATOR CONTROL SYSTEM
CAUTION:
• When removing accelerator wire, make a mark to indicate lock nut's initial position.
• Check that throttle valve opens fully when accelerator pedal is fUlly depressed. Check that throttle
valve returns to idle position when accelerator pedal is released.
• Check accelerator control parts for improper contact with any adjacent parts.
• When connecting accelerator wire, be careful not to twist or scratch wire.
• For adjustment of AfT throttle wire, refer to in AT section ("Throttle Wire Adjustment", "ON-VEHI-
CLE SERVICE").
SEC. 180
~~ Iii] 3 .4 (0.3 .0.4, 26. 36)
CD20 engine models ~~~

r 1iI4.4 • 5.9
\i
~ (0.45 - 0.60, 39.1 • 52.1)
v' !il2.9 - 3.9

~ (0.30 - 0.40, 26.0 - 34.7)
A~
~' .
7C
3l~
. ~
5
, 5
SFE413A
G) Accelerator wire @ Pedal bracket CID Accelerator pedal

@ Wire bracket @ Return spring @ Dynamic damper
GA engine models Adjusting Accelerator Wire

Lock nut
1. Loosen lock nut, and tighten adjusting nut until throttle drum
~8 -11 N.m
(0.8 - 1.1 kg-m, starts to move.
69 - 95 in-Ib) 2. From that position turn back adjusting nut 1.5 to 2 turns, and
secure lock nut.
SFE249AD
SR and CD engine models
Lock nut
• 8 - 11 N.m
(0.8 - 1.1 kg-m,
69 - 95 In-Ib)
SFE411AA
FE-2
FUEL SYSTEM
WARNING:
When replacing fuel line parts, be sure to observe the following:
• Put a "CAUTION: INFLAMMABLE" sign in workshop.
• Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
• Be sure to disconnect battery ground cable before conducting operations.
• Be sure to furnish workshop with a CO2 fire extinguisher.
• Put drained fuel in an explosion-proof container and put lid on securely.
CAUTION:
• For ECCS engine models, release fuel pressure from fuel line. Refer to EC section ("Fuel Pressure
Release", "BASIC SERVICE PROCEDURE").
• Do not disconnect any fuel line unless absolutely necessary.
• Plug hose and pipe openings to prevent entry of dust or dirt.
• Always replace O-ring and clamps with new ones.
• Do not kink or twist hose and tube when they are installed.
• Do not tighten hose clamps excessively to avoid damaging hoses. •
• When installing fuel check valve, be careful of its designated direction. Refer to EC section ("FUEL
CHECK VALVE", "EVAPORATIVE EMISSION SYSTEM").
• After installation, run engine and check for fuel leaks at connections.
GA & SR engine models CD engine models

SEC. 172
r ~
~.4'22.6)
2.0 - 2.5
(0.20 • 0.26,
~ .---£l
~I
~j~ ~.
, ~o-nngt:1
.
ge.V ..., / tt'.J 28 - 35

(2.' . 3.6, 20 • 26)
, I
.
I
i
tt'.J : N. m (kg-m, It-Ib)
iii :N'm (kg-m, in-Ib) ~ tt'.J 28 • 35 (2.8 - 3.6, 20 • 26)

SFE414A
CD Fuel gauge @ Fuel pump @ Fuel tank

@ Chamber
FE-3
FUEL SYSTEM
Fuel Pump and Gauge

REMOVAL
1. Release fuel pressure from fuel line.
Refer to EC section ("Fuel Pressure Release", "BASIC SER-
VICE PROCEDURE").
2. Remove inspection hole cover located under the rear seat.
3. Disconnect fuel outlet, return tube and connectors.

4. Remove the six screws.
5. Remove fuel gauge assembly and disconnect tubes and

connector.
Connector
/
SFE145A
6. Remove fuel pump with fuel tank chamber as shown in the

figure.
a. Pull up the front of fuel pump.
b. Slide it forward.
t2Front
SFE366A
Fuel pump harness 7. Remove fuel tank chamber from fuel pump.
Fuel pump
INSTALLATION
To install, reverse the removal procedure.
CAUTION:
• Tighten to specified torque.
• Install fuel pump harness on the left side of the feed hose
as shown in the figure.
SFE366A
FE-4
EXHAUST SYSTEM
CAUTION:
• Always replace exhaust gaskets with new ones when reas-
sembling.
If gasket is left on flange surface, scrape off completely as
shown at left.
• With engine running, check all tube connections for exhaust
gas leaks, and entire system for unusual noises.
• After installation, check to ensure that mounting brackets
and mounting insulators are free from undue stress. If any
of the above parts are not installed properly, excessive
SFE180A noise or vibration may be transmitted to the vehicle body.
SR engine models
SEC. 200-208
•
toJ 13 - 16 (1.3 - 1.6, 9 - 12)
GaSket~
toJ : N'm (kg-m, ft-Ib)
SFE412A
FE-5
EXHAUST SYSTEM
GA engine for Australia models

SEC. 200-208 tOJ 13. 16 (1.3 • 1.6, 9. 12)
Ii] 4.9 • 6.9
tCJ 43 - 55 Collar
(0.50 • 0.70, 43.4 • 60.8)
(4.4 - 5.6,
32 - 41)
Ii] 5.1 - 6.5

(0.52 - 0.66,
45.1 - 57.3)
L~tCJ 43 - 55
(4.4 • 5.6,
32 • 41)
C1 tOJ 28 • 33 (2.9 - 3.4, 21 - 25)
Ii] 5.1 • 6.5

GA engine for Europe models
(0.52 - 0.66, 45.1 • 57.3) ~~
! ~
C1tOJ28-(2.9
33
• 3.4, 20.7 • 24.3)
~
i ~
GasketC1 ~
b
-~ r~ 5.1 • 6.5
V (0.52 • 0.66,
45.1 • 57.3)
Heat insulator
II] 5.1 • 6.5 (0.52 • 0.66, 45.1 • 57.3)
~ : N'm (kg-m, in-Ib) - Among Europe model!l, only GA 16DE engine model
tCJ : N.m (kg-m, fl.lb) has a heat insulator on the exhaust front tube,
MFE024A
FE-6
EXHAUST SYSTEM
~
GA engine except for Europe and Australia models
SEC. 200
ollar
13 -16
8
(1.33 - 1.63,
~ 43 _ 55 \ ~ 9.6 - 11.8)
(4.4.5.6,31.7' 40'6)'~~
o to.J 28 - 33 \ {J)f:::@
to.J
Gasket 0 ".~
(2.9 - 3.4, 20.7 -124.3)
~~ ~
30 - 39 (3.1 - 4.0, 22.1 - 28.8)
13 - 16 (1.33 - 1.63, 9.6 - 11.8)
1.. . .v. ~ 0
'''~ •
Gasket
v' •
5.1 - 6.5 (0.52 - 0.66,45.1 - 57.3)
I~ •
iii 5.1
.
Heat Insulator
- 6.5 (0.52 - 0.66, 45.1 - 57.3)
CD20 engine models
0 to.J 60 - 70 (6.1 - 7.1, 44.3 - 51.6)
~
Gasket ~
7r
o
~
:
iii :N'm (kg-m, in-Ib)

MFE023A
FE-7
CLUTCH
SECTION CL
CONTENTS
Precautions
Preparation
CLUTCH SYSTEM - Hydraulic Type
CLUTCH SYSTEM - Mechanical Type
2
2
3
4
2 Operating
Clutch Damper
Cylinder
CLUTCH RELEASE MECHANiSM

CLUTCH DISC AND CLUTCH COVER
Clutch Disc
7
8
9
11
11
•
INSPECTION AND ADJUSTMENT 5 Clutch Cover and Flywheel 12
Adjusting Clutch Pedal 5 SERVICE DATA AND SPECIFICATIONS (SDS) 13
Bleeding Procedure - Hydraulic type 5 General Specifications 13
HYDRAULIC CLUTCH CONTROL.. 6 Inspection and Adjustment 14
Clutch Master Cylinder 6
Precautions
• Recommended fluid is brake fluid "DOT 3".
• Do not reuse drained brake fluid.
• Be careful not to splash brake fluid on painted areas.
• When removing and installing clutch piping, use Tool.
• Use new brake fluid to clean or wash all parts of master
cylinder, operating cylinder and clutch damper.
• Never use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.
SBR820B
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.
Preparation
Tool number
Description
Tool name
GG94310000 Removing and installing clutch piping

Flare nut torque wrench
NT406 a: 10 mm (0.39 in)
KV30101600 (New) New Installing clutch cover and clutch disc:

KV30101000 (Former)
Clutch aligning bar
a: 15.9 mm (0.626 In) dia.

b: 17.9 mm (0.705 in) dia.
NT645 c: 40 mm (1.57 in)
ST20050240 Adjusting unevenness of diaphragm spring

Diaphragm spring of clutch cover
adjusting wrench
a: 150 mm (5.91 in)
NT404 b: 25 mm (0.98 in)
COMMERCIAL SERVICE TOOLS

Equivalent to Removing and installing clutch piping
GG94310000
CD Flare nut crows foot
@ Torque wrench
NT360 a: 10 mm (0.39 in)
CL-2
CLUTCH SYSTEM - Hydraulic Type
m (bl : Apply lithium-based grease including

molybdenum disulphide.
~ : N.m (kg-m. ft-Ib)
~ : N.m (kg-m. in-Ib)

SCL667
G) Clutch pedal bracket @ Withdrawal lever @ Clutch cover

@ Clutch master cylinder @J Release bearing @ Clutch disc
@ Assist spring @ Clutch hose @ Clutch pedal
@ Bushing @ Operating cylinder support @ Clevis pin
@ Pin bracket @ Pedal stopper
@ Stopper rubber @ Clutch lever @ Fulcrum pin
(J) Operating cylinder @ Spring pin
@ Air bleeder screw @ Operating cylinder bracket
CL-3
CLUTCH SYSTEM - Mechanical Type
SEC. 300'307.465
~ 8 - 11
(0.8 - 1.1, 69 - 95)
<D (RHO model)
\ r"" @ @m
~~~ ~ /~
to.J 16 - 22 f 77'\ -j, ~'

, (1.6.2.2, 12 - 16)~ ~ M -
. <D (LHD model) Of ~ ':,
,/ I r ';, ~~ I' @ to.J 16 • 22 (1.6 - 2.2, 12 • 16)
/ fA'l @m ~ a!',~~ I
1r
,/' ~ ~ {l ,-0 ~ be \.\~':~ @
< 01Q'?0'J:l'e..------ , d ~~
v,~
~JO
~;, 1
~, ~
a ,
i,: c
',@/
I ~
:' ~'
J ~m
..--.......
~
to.J13-16
(1.3 • 1.6, 9 - 12)
@ to.J 16 - 22 ~ be c _1 L~---- .~
C1J.~,
.Jl
(1.6 - 2.2, 12 - 16) '~d' ~ @m

'm (
@ ,
@ to.J 13 - 16 (1.3 • 1.6, 9 • 12) .~. ~ I
to.J 16 - 22 (1.6 - 2.2, 12 - 16) @ ~ ~
@ m(Q ~~@ .
-m~.
m(Q ~
~h~
(7\I~ <:.~
\ ~J;i::::;~
l"J" - 29 (2.2 - 3.0, 1. - 22)1> 0~~ <bl ~'" 'I
~
@-..........t>'"l(0.8-1.1,69-95)
/l~~
¥:11)
~ ~I!C! <bl I!C! <bl ' ApplVIlth'"m-",,' om,,, '001""00
m (Q molybdenum disulphide.
Iiii\ . [OJ ; N.m (kg-m, ft-lb)
~ IjJ ; N'm (kg-m, in-Ib)
SCL668
G) Clutch pedal bracket (1) Return spring @ Clutch pedal

@ Insulator @ Clutch lever @ Bushing
@ Assist spring @ Spring pin @ Pedal stopper
@ Withdrawal lever @J Release bearing @ Lock nut
@ Clutch cover @ Stopper rubber @ Fulcrum pin
@ Clutch disc
CL-4
Adjusting Clutch Pedal

1. Adjust pedal height with pedal stopper.
Pedal height "H":
Refer to 50S, CL-14.
Pedal stopper
Dash lower
panel (except
•
CD20 engine / /
model)
/ L Floor car-pet
L Dash reinforcement panel
(CD20 engine model)
SCL625
Lock nut - For mechanical type -

2. Adjust withdrawal lever play "8" according to the following
procedure_
B a. Push withdrawal lever by hand until resistance is felt, and
then tighten adjusting nut.
b. Turn back adjusting nut 2.5 to 3.5 turns, and then tighten lock
nut.
Withdrawal lever play "B":
Adjusting nut 2.5 - 3.5 mm (0.098 - 0.138 in)
lock nut:
SCL423 ~: 3 - 4 N'm (0.3 - 0.4 kg-m, 26 - 35 in-Ib)
- For hydraulic type and mechanical type -
3. As a final check, measure pedal free travel "A" at center of
pedal pad.
Pedal free travel "A":
Refer to 50S, CL-14.
SCL341-A
Bleeding Procedure - Hydraulic type

Bleed air according to the following procedure.
• Carefully monitor fluid level at master cylinder during
bleeding operation.
1. Top up reservoir with recommended brake fluid.
2. Connect a transparent vinyl tube to air bleeder valve.
3. Fully depress clutch pedal several times.
4. With clutch pedal depressed, open bleeder valve to release
air, then close bleeder valve.
5. Repeat steps 3 through 5 above until clear brake fluid
SCL613 comes out of air bleeder valve.
CL-5
HYDRAULIC CLUTCH CONTROL
Clutch Master Cylinder

SEC. 305
~ 2.9 • 5.9 (0.30 • 0.60, 26.0 • 52.2)
CD
/
@LHD models
(j) ~ 2.5 - 3.9 (0.25 - 0.40, 21.7 - 34.7)

(1), ~ 1'.
@m CD Rubbing surface to
~'. ~ ". @liJa-
( ~ I' 11
~f
piston assembly
(08. '.1,
,< I /@O@I1I!@(A':o'::"'1
@ m@(LHD models)
Rubbing surface to
@. Apply brake fluid when assembling. ~ (jJ) m @ (RHD models) push rod
m @ (LHD models)
* Take care of the bolt direction Contact surface to piston assembly
m@ : Apply rubber grease. ~
@~ 1.5 - 2.9 (0.15 - 0.30, 13.0 - 26.0)
m @ : Apply silicone grease, • Remove this stopper, when
m CD : Apply rubber lubricant. removing piston and return spring.
Iil : N.m (kg-m. in-Ib)

SCL669
(1) Piston assembly @ Reservoir cap @ Push rod

@ Piston cup (]) Reservoir band @ Stopper
@ Return spring @ Cylinder body @ Stopper ring
@ Reservoir tank @ Packing @ Dust cover
@ Reservoir hose @) Valve stopper @ Lock nut

• Push piston into cylinder body with screwdriver when
removing and installing valve stopper.
• Align groove of piston assembly and valve stopper when

installing valve stopper.
• Check direction of piston cups.
c;D.=: =.J3@
Groove
SCL214
CL-6
Clutch Master Cylinder (Cont'd)
INSPECTION
Check the following items, and replace if necessary.
• Rubbing surface of cylinder and piston, for uneven wear,
rust or damage
• Piston with piston cup, for wear or damage
• Return spring, for wear or damage
• Dust cover, for cracks, deformation or damage
• Reservoir, for deformation or damage
Operating Cylinder
SEC. 306
Operating cylinder m@
•
/ Piston spring ,
7:\ I
J
/ I Piston cup m~;} Always replace after every disassembly as a set.
~d / /Piston
{ 'c Bleeder screw

~ti) d
~Q ~,""d
IiIS.9 - 9.8 N.m .

(0.6 - 1.0 kg-m, 52.2 - 86.7 In-Ib)
(il@
Dust cover /
m lR): Apply rubber grease.
SCL607-B
INSPECTION
• Rubbing surface of cylinder and piston, for uneven wear,
rust or damage
• Piston with piston cup, for wear or damage
• Piston spring, for wear or damage
• Dust cover, for cracks, deformation or damage
CL-7
Clutch Damper
SEC. 306
Bleeder screw
11]5.1 - 6.5
1i15.9 - 9.8 Cylinder body (0.52 - 0.66,
(0.60 - 1.00, 52.2 . 86.7) (LHD model) 45.1 - 57.5)
m @ Rubbing surface to
piston assembly
Piston cup m @ J'

Piston assembly
- Damper cover
(RHD model)
m @ Contact surface to piston assembly
Damper rubber ~
II] 2.9 - 5.9
(0.30 - 0.60,
25.7 - 52.2)
m@ : Apply rubber grease.
II] : N'm (kg-m. in-Ib)

SCL672
INSPECTION
• Check cylinder and piston rubbing surface for uneven wear,
rust or damage. Replace if necessary.
• Check damper rubber and piston cup for cracks, deforma-
tion or damage. Replace if necessary.
CL-8
CLUTCH RELEASE MECHANISM
SEC. 321 Withdrawal lever

(Hydraulic clutch
control)
* : Pay attention
m (Q:
to direction of bearing retainer.
Apply lithium-based grease including molybdenum disulphide.

Spring pin
SCL670 •
• Remove release bearing by pulling bearing retainers out-
ward.
• Align spring pin with cavity of clutch housing and tap out
spring pin.
INSPECTION
• Release bearing, to see that it rolls freely and is free from
noise, cracks, pitting or wear
• Release sleeve and withdrawal lever rubbing surface, for
wear, rust or damage
CL-9
CLUTCH RELEASE MECHANISM
LUBRICATION
• Apply recommended grease to contact surface and rubbing
surface.
Lithium-based grease
including molybdenum
• Too much lubricant might damage clutch disc facing.
disulphide
ACL020
CL-10
SEC. 300
~1st: 10-20(1.0-2.0,7.2-14)
2nd: 22 - 29 (2.2 - 3.0 , 16 - 22)
•
Clutch disc Clutch cover
• Do not clean in solvent. m (iJ: Apply lithium-based grease including
• When installing, be careful that grease from molybdenum disulphide.
main drive shaft does not adhere to clutch disc.
~ : N'm (Kg-m, ft-Ib).
ACL019
Clutch Disc
INSPECTION
• Clutch disc, for burns, discoloration, oil or grease leakage
• Clutch disc, for wear of facing
Wear limit of facing surface to rivet head:
0.3 mm (0.012 in)
• Clutch disc, for backlash of spline and runout of facing.

Maximum backlash of spline (at outer edge of disc):
Model 180 0.7 mm (0.028 in)
Model 190 and 200 0.8 mm (0.031 in)
Model 215 0.9mm (0.035 in)
Runout limit:
1.0 mm (0.039 in)
Distance of runout check point (from hub center):
Model 180 85 mm (3.35 in)
Model 190 90 mm (3.54 in)
SCL221 Model 200 95 mm (3.74 in)
Model 215 102.5mm (4.04 in)
CL-11
Clutch Disc (Cont'd)
INSTALLATION
• Apply recommended grease to contact surface of splines.
• Too much lubricant may damage clutch disc facing.
Clutch Cover and Flywheel

• Check clutch cover, installed on vehicle, for uneven dia-
phragm spring toe height.
Uneven limit:
Model 180 1.0 mm (0.039 in)
Model 190, 200 and 215 0.7 mm (0.028 in)
• If out of limit, adjust the height with Tool.
SCL466-A
FLYWHEEL INSPECTION
CAUTION:
Dial gauge Do not allow any magnetic materials to contact the ring gear
teeth.
• Inspect contact surface of flywheel for slight burns or dis-
coloration. Clean flywheel with emery paper.
• Check flywheel runout.
Maximum allowable runout:
Refer to EM section ("Inspection", "CYLINDER
BLOCK").
AEM100
INSTALLATION
• Insert Tool into clutch disc hub when installing clutch cover
and disc.
• Be careful not to allow grease to contaminate clutch facing.
• Tighten bolts in numerical order, in two steps.
First step:
~: 10 • 20 N'm '(1.0 • 2.0 kg-m, 7 - 14 ft-Ib)
Final step:
~: 22 • 29 N'm (2.2 • 3.0 kg-m, 16 • 22 ft-Ib)
SCL616-A
CL-12
CLUTCH CONTROL SYSTEM CLUTCH MASTER CYLINDER
Engine Except for CD20 CD20 Inner diameter mm (in) 15.87 (5/8)
Type of clutch con-

Mechanical Hydraulic
trol
CLUTCH OPERATING CYLINDER
CLUTCH DAMPER Inner diameter mm (in) 17.46 (11/16)
Inner diameter mm (in) 19.05 (3/4)
CLUTCH DISC
Unit: mm (in)
Engine GA14DE GA15DE, GA16DE CD20 SR20DE
Model
Facing size
(Outer dia. x inner dia. x
thickness)
Thickness of disc assem-

bly with load
180
180 x 125 x 3.5

(7.09 x 4.92 x 0.138)
190
190 x 132 x 3.5

(7.48 x 5.20 x 0.138)
200
200 x 130 x 3.5

(7.87 x 5.12 x 0.138)
8.0 - 8.4 (0.315 - 0331) with 3,923 N (400 kg, A2 Ib)

215
215 x 140 x 3.5

(8.46 x 5.51 x 0.138)
7.6 - 8.0 (0.299 - 0.315)

with 3,923 N
•
(400 kg, 882 Ib)
CLUTCH COVER
Engine GA14DE GA15DE I GA16DE CD20 SR20DE
Model 180 190 200 215
Full-load N (kg, Ib) 3,236 (330, 728) 3,432 (350, 772)

I 3,825 (390, 860) 3,481 (355, 783) 4,413 (450, 992)
CL-13

CLUTCH PEDAL
Unit: mm (in)
Except for CD20 engine models CD20 engine models

Applied model
RHO LHD RHO LHD
Pedal height "H" 159 - 169 (6.26 - 6.65)'1 153 - 163 (6.02 - 6.42)*2 156 - 166 (6.14 - 6.54)'1 149 - 159 (5.87 - 6.26)'2
Pedal free travel "A"

11 - 15 (0.43 - 0.59) 9 - 16 (0.35 - 0.63)
(at pedal pad)
Withdrawal lever play "8" 2.5 - 3.5 (0.098 - 0.138) -

'1: Measured from surface of dash reinforcement panel to surface of pedal pad.
'2: Measured from surface of dash lower panel to surface of pedal pad.
CLUTCH DISC
Unit: mm (in)
Disc model 180 190 I 200 215
Wear limit of facing surface to rivet head 0.3 (0.012)
Runout limit of facing 1.0 (0.039)
Distance of runout check point (from hub

center)
Maximum backlash of spline (at outer edge of

85 (3.35) 90 (3.54)
I 95 (3.74) 102.5 (4.04)
0.7 (0.028) 0.8 (0.031) 0.9 (0.035)

disc)
CLUTCH COVER
Unit: mm (in)
Cover model 180 190

I 200
I 215
Uneven limit of diaphragm spring toe height 1.0 (0.039) 0.7 (0.028)
CL-14
MANUAL TRANSAXLE
SECTION MT
CONTENTS
PREPARATION 2 RS5F32A
Special
Commercial
Replacing
Position
Service
ON-VEHICLE SERVICE
Oil Seal
Switch
Tools
Service
Check
Tools
2
4
5
5
6
7
MAJOR OVERHAUl
Case Components
Gear Components
Shift Control
DiSASSEMBly " ,.,.,
Components
,
REPAIR FOR COMPONENT PARTS
,
, , ,
,
33
33
34
35
36
39
•
Removal , 7
Input Shaft and Gears 39
Installation ' 8
Mainshaft and Gears 42
TRANSAXlE GEAR CONTROL 9
Final Drive .47
Shift Control Components 49
RS5F30A & RS5F31A Case Components ' 51
MAJOR OVERHAUL 10 ADJUSTMENT , , ", 54
Case Components 10 Differential Side Bearing Preload , 54
Gear Components , 11 ASSEMBLY ', 56
Shift Control Components , 12
DiSASSEMBly , 13 '----_-JI RS5F30A & RS5F31A & RS5F32A
REPAIR FOR COMPONENT PARTS 16
SERVICE DATA AND SPECIFICATIONS (SDS) 60
Input Shaft and Gears 16
Mainshaft and Gears 19
Inspection and Adjustment - RS5F30A &
Final Drive , , 23
RS5F31 A ' 61
Shift Control Components 25
Inspection and Adjustment - RS5F32A 64
Case Components , 25
ADJUSTMENT , ,.., 28
Differential Side Bearing Preload 28
Mainshaft Bearing Preload , 29
ASSEMBly , 30
PREPARATION
Tool number
Description
Tool name
KV38105900.For F30A & Measuring turning torque of final drive
F31A assembly
KV38107700.For F32A Measuring total turning torque
Preload adapter Measuring clearance between side gear
and differential case with washer
Selecting differential side bearing
adjusting shim (Use with KV38106000.)
NT087
KV38106000 Selecting differential side bearing

Height gauge adapter adjusting shim (Use with KV38105900 or
(differential side bearing) KV38107700.)
a: 140 mm (5.51 in)

b: 40 mm (1.57 in)
c: 16 mm (0.63 in) dia.
NT418 d: M8 x 1.25P
KV32101000 Removing and installing retaining pin
Pin punch
NT410 a: 4 mm (0.16 in) dia.

8T22730000 Removing mainshafl front and rear bear-
Puller ing inner race (F30A & F31A)
Removing 5th main gear
a: 82 mm (3.23 in) dia.

NT411 b: 30 mm (1.18 in) dia.
8T30031000 Removing differential side bearing
Puller inner race (F30A & F31A)
Removing 3rd and 4th synchronizer
Measuring wear of 2nd & 3rd baulk ring
(F32A)
a: 90 mm (3.54 in) dia.

NT411 b: 50 mm (1.97 in) dia.
8T30021000 Removing 5th synchronizer
Puller
a: 110 mm (4.33 in) dia.

NT411 b: 68 mm (2.68 in) dia.
ST33290001 Removing differential oil seal
Puller Removing mainshafl front bearing outer
race (F30A & F31A)
Removing differential side bearing outer
race
a: 250 mm (9.84 in)

NT414 b: 160 mm (6.30 in)
MT-2
PREPARATION
Special Service Tools (Coni' d)
Tool number
Description
Tool name
ST33400001 Installing differential oil seal (F30A &
Drift F31A)
a: 60 mm (2.36 in) dia.

NT086 b: 47 mm (1.85 in) dia.
KV31103000 Installing differential oil seal (F32A)
Drift Right and left sides
(Use with ST35325000.)
a: 56 mm (2.20 in) dia.

NT105 b: 49 mm (1.93 in) dia.
ST35325000 Installing differential oil seal (F32A)
Drift handle a- (Use with KV31103000.)
a: 215 mm (8.46 in)

c b: 25 mm (0.98 in) dia.
c: M12 x 1.5P
•
NT417
KV38102100 Installing input shaft rear bearing

Drift
a: 44 mm (1.73 in) dia.

NT427 b: 24.5 mm (0.965 in) dia.
ST33200000 Installing mainshaft front bearing outer
Drift race (F30A & F31A)
Installing mainshaft front bearing (F32A)
a: 60 mm (2.36 in) dia.

NT091 b: 44.5 mm (1.752 in) dia.
ST22350000 Installing input shaft front bearing
Drift
a
a: 34 mm (1.34 in) dia.
NT065 b: 28 mm (1.10 in) dia.
ST22452000 Installing 1st & 2nd synchronizer
Drift Installing 3rd & 4th synchronizer (F32A)
a a: 45 mm (1.77 in) dia.

NT065 b: 36 mm (1.42 in) dia.
ST37750000 Installing 5th main gear
Drift Installing 3rd & 4th synchronizer
Installing input shaft oil seal
Installing 5th synchronizer
(F30A & F31A)
Install ing mainshaft rear bearing (F32A)
a
a: 40 mm (1.57 in) dia.

NT065 b: 31 mm (1.22 in) dia.
MT-3
PREPARATION
Special Service Tools (Coni' d)
Tool number
Description
Tool name
ST22360002 Installing rnainshaft rear bearing inner
Drift race (F30A & F31A)
a
a: 29 mm (1.14 in) dia.
NT065 b: 23 mm (0.91 in) dia.
ST30621000 Installing differential side bearing outer

Drift race
~ a
a: 79 mm (3.11 in) dia.
NT073 b: 59 mm (2.32 in) dia.

Drift handle race
a: 15 mm (0.59 in)
b: 335 mm (13.19 in)
c: 25 mm (0.98 In) dia.
NT419 d: M12 x 1.5P

Puller Removing input shaft front bearing
m:
(F30A & F31A)
Removing mainshaft rear bearing (F32A)
o 0
NT077
Drift Installing mainshaft front bearing inner

race
a: 26 mm (1.02 in) dia.
b: 21 mm (0.83 in) dia. (F30A)
a
a: 31 mm (1.22 in) dia.
NT065 b: 26 mm (1.02 in) dia. (F31A & F32A)
Drift Installing differential side bearing inner

race
a: 56 mm (2.20 In) dia.

NT065 b: 50.5 mm (1.988 in) dia.
Drift Installing striking rod oil seal
a: 38 mm (1.50 In) dia.

NT065 b: 32 mm (1.26 in) dla.
MT-4
ON-VEHICLE SERVICE
Replacing Oil Seal

DIFFERENTIAL OIL SEAL
1. Drain gear oil from transaxle.
2. Remove drive shafts. Refer to FA section ("Removal",
"FRONT AXLE - Drive Shaft").
3. Remove differential oil seal.
4. Install differential oil seal.

• Apply multi-purpose grease to seal lip of oil seal before
installing.
5.- Install drive shafts - Refer to FA section ("Installation",
F30A F31A
- F30A & F31A- •
LH and RH sides LH and RH sides
Drift
ST33400001
SMT684C
F32A Clutch housing side -F32A -

Transmission • Install differential oil seal so that dimension "A" and"B"
case side
are within specifications.
Unit: mm (in)
A B
Oil seal
5.9 - 6.1 (0.232 - 0.240) 0.5 (0.020) or less
.P SMT7388
MT-5
ON-VEHICLE SERVICE
Replacing Oil Seal (Cont'd)
STRIKING ROD OIL SEAL
1. Remove transaxle control rod from yoke.
2. Remove yoke retaining pin.
• Be careful not to damage boot.
3. Remove striking rod oil seal.
4. Install striking rod oil seal.

installing.
Position Switch Check

DISCONNECT
• Check continuity.
eJ
Neutral position Switch Gear position Continuity
switch harness
connector Reverse Yes
Back-up lamp switch
Except reverse No
Neutral Yes
Except neutral No
~
SMT715BB
MT-6
Removal
1. Remove battery negative terminal.
2. Remove air duct.
3. Disconnect clutch control cable. (Except for CD20 engine

models)
Remove clutch operating cylinder and clutch operating cyl-
inder bracket from transaxle. (CD20 engine models)
4. Disconnect back-up lamp switch, neutral position switch,
speedometer sensor and ground harness connectors.
5. Remove starter motor from transaxle.
6.
7.
8.
Remove shift control rod and support rod from transaxle.
Drain gear oil from transaxle.
Remove drive shafts. Refer to FA section ("Removal",
•
9. Jack up transaxle together with engine slightly and insert

wooden block between center member and engine oil pan.
CAUTION:
Do not place jack under oil pan drain plug.
10. Remove rear and LH mounts supporting transaxle with jack.

11. Remove bolts securing transaxle.
12. Lower transaxle.
MT-7
CD Installation
@ M/T to engine
Tighten bolts securing transaxle and install any part removed.
• GA engine models
Tightening torque
Bolt No. "C" mm (in)
N'm (kg-m, ft-Ib)
G) 30 - 40 (3.1 - 4.1,22 - 30) 70 (2.76)
@ 30 - 40 (3.1 - 4.1,22 - 30) 85 (3.35)

@ 30 - 40 (3.1 - 4.1, 22 - 30) 30(1.18)
@ 16 - 21 (1.6 - 2.1,12 - 15) 25 (0.98)
Front gusset to
30 - 40 (3.1 - 4.1,22 - 30) 20 (0.79)
engine
Rear gusset to
16 - 21 (1.6 - 2.1,12 - 15) 16 (0.63)
engine
@ M/T
Q9
to engine ~
Engine to M/T
~o". Q~.\
leV • SR engine models
Bolt No.
Tightening torque
N'm (kg-m, ft-Ib)
"C" mm (in)
--
G) 70 - 79 (7.1 - 8.1,51 - 59) 55 (2.17)
17
SMT747C
@
@
@
30 - 40 (3.1 - 4.1,22 - 30)
30 - 40 (3.1 - 4.1,22 - 30)
70 - 79 (7.1 - 8.1,51 - 59)

35 (1.38)
45 (1.77)
65 (2.56)
• CD20 engine models
Tightening torque
Boll No. "C" mm (in)
N'm (kg-m, ft-Ib)
G) 30 - 40 (3.1 - 4.1, 22 - 30) 120 (4.72)
CD @ 30 - 40 (3.1 - 4.1,22 - 30) 85 (3.35)
@ 44 - 54 (4.5 - 5.5, 33 - 40) 75 (2.95)
@ 16 - 21 (1.6 - 2.1,12 - 15) 30 (1.18)
@ 16 - 21 (1.6 - 2.1,12 - 15) 25 (0.98)

SMT740A
Front gusset to
30 - 40 (3.1 - 4.1, 22 - 30) 35 (1.38)
engine
Rear gusset to
30 - 40 (3.1 - 4.1, 22 - 30) 40 (1.57)
engine
MT-8
TRANSAXlE GEAR CONTROL
SEC. 341
m
. ..--~~
. ,39.1. 52.1)
~~O
~ 4.4.5.9 (0.45 • 060
't~~~
•
3
t"J t"J 12 • 15 (jj)~~~~l '

35 • 47
(3 6
(1.2 • 1 5
. , 9 • 11) ~~
._le' - ...--~
12
/"rIiJ 10 . 13 ~ I\~~ ~ ;~; '~.5, 9 • 11)
,{y"'''
'\ iI5J _Y (1.0 • 1.3,
87 • 113)
"",/'
I t
L, t"J"@
>
22 • 29 (2.2 . 3.0. 16 • 22)
16
-~ 18. 24 (1.8 • 2.4, 13 • 17)
~ . Nom (kg-m, in-Ib)
f?:!-
:g.~
W ~ 14. 18 (1 .4. .,
18 1O. 13)
~ : Nom (kg-m, ft-Ib)
Control lever kn b Hand Iever socket @ Collar

Boot 0 Plate bolt @ Bushing
Control lever socke Transaxle
S h 0 Ie cover @) Control rod
Control lever t upport rod @ Return spring
Bearing seat s . Plate @ Return s pring
. rubb
Seat pring Hold er
Collar @ er bracket
Bushing Bushing @ Mass dam p e r (CD20 engine
only)
O-ring Support rod bracket
MT-9
MAJOR OVERHAUL I RS5F30A & RS5F31 A I
Case Components
SEC. 320
.. -- RS5F31A---
~16 - 21
(1.6 - 2.1, 12. 15)
@ ~ Mating
surface to
transmiSSion
case ----
@ ~ 15 - 20 (1.5 - 2.0, 11 - 14)

~ Thread of bolt
@ ~20 - 29 (2.0 - 3.0, 14 - 22)-
~ Thread of bolt
Ij] : Nom (kg-m, in-I b)
tr'J : Nom (kg-m, ft-Ib)
~ : Apply recommended sealant
(Nissan genuine part: KP610-00250) or equivalent.
*: : Pay attention to its direction.
SMT755C
(1) Clutch housing @) O-ring @ Striking rod oil seal

@ Input shaft oil seal @ Case cover @J Boot
@ Oil pocket @ Back-up lamp switch @ Neutral position switch (GA
@ Bearing retainer @ Differential oil seal engine) or switch plug (CD
engine)
@ Bearing retainer @ Drain plug
@ Torx screw @l Transmission case
@ Differential oil seal
(J) Filler plug @ Oil gutter

@ O-ring
@ Air breather @ Reverse idler shaft

@ Speedometer pinion assembly
@ Welch plug @ Oil channel
MT-10
MAJOR OVERHAUL I RS5F30A & RS5F31 A I
SEC. 322
•
45 t:r
Apply gear oil to gears, shifts. synchronizers

and bearings when assembling.
~ (iJ : Apply locking sealant
*. Select proper thickness.
11 : Pay attention to its direction.
SMT686C
G) Reverse idler gear @ Spread spring @ C-ring holder @) Differential side

@ Reverse idler @ Shifting insert @ Mainshaft rear bearing adjusting
bushing @ bearing shim
5th stopper
@ Reverse idler @ Input shaft rear @ Spacer @ Differential side
spacer bearing @ Mainshaft bearing bearing
@ Snap ring @ Mainshaft front adjusting shim @ Retaining pin
@ Spacer bearing @ 4th bushing @ Pinion mate thrust
@ Input shaft front @l Mainshaft @ 3rd & 4th synchro- washer
bearing nizer hub @ Speedometer drive
@J 1st main gear
(]) Input shaft @ 3rd main gear gear
@ 1st gear needle
@ @ Speedometer
@ Oil plug bearing 2nd main gear
stopper
@ 5th gear needle @ Steel ball @ 1st & 2nd synchro-
@ Side gear
bearing @ 2nd & 3rd bushing nizer hub
@ 5th input gear @ Reverse main gear
@ Pinion mate gear
@ 4th main gear
@ Coupling sleeve (Coupling sleeve) @ Pinion mate shaft
@ 5th main gear
@ Differential case @ Side gear thrust
@ Baulk ring @ Thrust washer
@ Final gear washer
@ 5th synchronizer @ Mainshaft C-ring
hub
MT-11
MAJOR OVERHAUL I RS5F30A & RS5F31A I
Shift Control Components
SEC. 328
@*
[OJ 12 . 16
(1.2 • 1.6, 9 • 12)
~ Ch> Thread of plug
~ \~ 6.3 • U (0.64 • 0.6'. 55.6 • 13.61
~ : N.m (kg-m. in-Ib)

[OJ : N.m (kg-m. ft-Ib)
~ Ch> : Apply locking sealant.
* : Select proper length.
SMT750C
G) Reverse check spring @ 3rd & 4th shift fork @ Striking lever
@ Reverse check plug @ 1st & 2nd shift fork @ Check ball (Large)
@ Check ball plug @ Control bracket @J Check ball (Small)
@ Shift check ball @ Striking interlock @ Check sleeve
@ Shift check spring @ Retaining pin @ G-ring
@ Fork shaft support spring @) Retaining pin @ Select return spring
(J) Shifter cap @) Yoke @ Check plunger
@ Fork shaft @ Striking rod @ Stopper pin
@ 5th shift fork
MT-12
DISASSEMBL V I RSSF30A & RSSF31 A I
1. Remove transmission case while slightly tilting it to prevent

5th shift fork from interfering with case.
SMT571
2. Draw out reverse idler spacer and fork shaft, then remove
5th and 3rd & 4th shift forks.
5th shift - • Be careful not to lose shifter cap.
fork
3.
•
Remove control bracket with 1st & 2nd shift fork.
Be careful not to lose shifter cap.
•
SMT082A
4. Remove gear components from clutch housing.

- RS5F30A-
a. Remove three screws and detach bearing retainer.
Suitable • One of these three screws is torx type and should be
tool removed with a suitable tool, as shown.
SMT577
b. Remove input shaft together with mainshaft by tapping

lightly.
• Always withdraw mainshaft straight out. Failure to do so
can damage resin oil channel on clutch housing side.
• Do not draw out reverse idler shaft from clutch housing
because these fittings will be loose.
• When removing input shaft, be careful not to scratch oil seal
lip with shaft spline.
SMT579
MT-13
DISASSEMBL Y I RS5F30A & RS5F31A I
c. Remove reverse idler gear and final drive assembly.
SMT580
- RS5F31A-
a. Remove mainshaft and final drive assembly.
• Always withdraw mainshaft straight out. Failure to do so
SMT720
SMT721
b. Remove bearing retainer securing bolts.
SMT646A
c. Remove input shaft together with bearing retainer and

Soft hammer reverse idler gear by tapping lightly.
• Be careful not to scratch oil seal lip with shaft spline when
removing input shaft.
SMT722
MT-14
DISASSEMBL Y RS5F30A & RS5F31 A
5. Remove oil pocket, shift check ball, shift check spring and
check ball plug.
SMT648AA
6. Drive retaining pin out of striking lever, then remove strik-

ing rod, striking lever and striking interlock.
KV32101000 • Select a position where retaining pin does not interfere with
. clutch housing when removing retaining pin .
SMT599AA
• Be careful not to damage oil seal lip, when removing

ing rod. If necessary, tape edges of striking rod.
strik- •
SMT583
7. Remove reverse check plug, then detach reverse check

/ Reverse check plug spring and check balls,
~ " Reverse check spring
S/
V Check ball (Large)
"--_Check ball (Small)
SMT584
8. Remove check sleeve assembly.
SMT585
MT-15
REPAIR FOR COMPONENT PARTS I RS5F30A & RS5F31 A I
Input Shaft and Gears

DISASSEMBLY
1. Before disassembly, check 5th input gear end play.
Gear end play:
Refer to SOS, MT -61.
EndPlaY • If not within specification, disassemble and check contact
Gear
surface of gear, shaft and hub. Then check clearance of
snap ring groove. Refer to "ASSEMBLY", MT-17.
~ Needle bearing
SMT734A
2. Remove snap ring and 5th stopper.

3. Remove 5th synchronizer, 5th input gear and 5th gear nee-
dle bearing.
5th synchronizer hub
5th input gear
Set Tool below

5th input gear.
SMT750BA
4. Remove snap ring of input shaft front bearing and input gear
spacer.
5. Pull out input shaft front bearing.

6. Remove bearing retainer.
SMT601A
MT-16
REPAIR FOR COMPONENT PARTS I RS5F30A & RS5F31A I
Input Shaft and Gears (Cont'd)
INSPECTION
Gear and shaft
• Check shaft for cracks, wear or bending.
• Check gears for excessive wear, chips or cracks.
SMT602A
Synchronizer
Shifting insert
• Check spline portion of coupling sleeves, hubs and gears
for wear or cracks.
• Check baulk rings for cracks or deformation.
• Check shifting inserts for wear or deformation.
t
Baulk ring to
gear clearance
SMT387A
• Measure clearance between baulk ring and gear.

Clearance between baulk ring and gear:
Standard
•
1.0 - 1.35 mm (0.0394 - 0.0531 in)
Wear limit
0.7 mm (0.028 in)
SMT140
Bearing
• Make sure bearings roll freely and are free from noise,
cracks, pitting or wear.
SMT148A
ASSEMBLY
1. Assemble 5th synchronizer.
MT-17
• Be careful not to hook front and rear ends of spread spring
to the same insert.
SMT7618
2. Install bearing retainer.

3. Press on input shaft front bearing.
4. Install spacer.
~" O~0 Bearing retainer
~~ SMT731-A
5. Select and install snap ring that gives the proper clearance
of input shaft groove.
Allowable clearance of groove:
o- 0.1 mm (0 - 0.004 in)
Snap ring of input shaft front bearing:
6. Install 5th gear needle bearing, 5th input gear, 5th synchro-
nizer and 5th stopper.
7. Measure gear end playas the final check. Refer to
"DISASSEMBLY", MT-16.
5T37750000
5th synchronizer hub
SMT779AA
8. Select and install snap ring that gives the proper clearance
of input shaft groove.
0-0.1 mm (0 - 0.004 in)
Snap ring of 5th synchronizer:
SMT591
MT-18
REPAIR FOR COMPONENT PARTS I RS5F30A & RS5F31 A I
Mainshaft and Gears

DISASSEMBL Y
1. Before disassembly, check 1st, 2nd, 3rd and 4th main gear
end plays.
Gear end play:
Refer to 50S, MT -61.
• If not within specification, disassemble and check contact
surface of gear, shaft and hub. Then check clearance of
C-ring groove. Refer to "ASSEMBLY", MT-21.
2. Press out mainshaft front bearing.
ST22730000
SMT641-A
3. Press out mainshaft rear bearing. •

SMT638-A
4. Remove C-ring holder, mainshaft C-rings and thrust

~ C-ring holder
washer.
~~ Mainshaft C-ring
8--- Thrust washer
SMT592-A
5. Press out 5th main gear.
5T,22730, OOO~~""~/ i~;~<~:(

-',
'.
"~"
-----~""""."•.~,
-'::-.
>~\. J.
,---
'.~
'/ Hook tool under
flange as indicated
by arrows.
"-~, ",' .' //
" /!~'(';Y
I -\ --...
Y:<"~_. ~~w" -, ~
--...' ....~"'I "
SMT593-A
MT-19
Mainshaft and Gears (Conl'd)
6. Remove 4th main gear, 4th bushing and steel ball.
• Be careful not to lose steel ball.
Steel ball
SMT687C
7. Remove 3rd & 4th synchronizer, 3rd main gear, 2nd & 3rd
bushing, steel ball and 2nd main gear.
• Be careful not to lose steel ball.
3rd & 4th

synchronizer hub r ST30031 000
SMT780AA
8. Remove 1st & 2nd synchronizer and 1st main gear, then
remove 1st gear needle bearing.
1st & 2nd

, synchronizer
/ / 1st main
.~/\ gear
t-r=-~~'c
SMT594
INSPECTION
Gear and shaft
MT-20
Mainshaft and Gears (Cont'd)
Synchronizer
Shifting insert
for wear or cracks.
• Check shifting inserts for wear or deformation.
t
Baulk ring to
gear clearance Clearance between baulk rings and 1st-4th main gears:
Standard
1.0 - 1.35 mm (0.0394 - 0.0531 in)
Wear limit
0.7 mm (0.028 in)
SMT140
Bearing
•
• When replacing tapered roller bearing, replace outer and
inner race as a set.
ASSEMBLY
1. Assemble 1st & 2nd and 3rd & 4th synchronizers.

to the same insert.
SMT761B
MT-21
2. Install 1st gear needle bearing and 1st main gear.
3. Press on 1st & 2nd synchronizer.
ST22452000
SMT605AA
4. Install steel ball, 2nd main gear, 2nd & 3rd bushing, 3rd
main gear and 3rd & 4th synchronizer.
• Apply multi-purpose grease to steel ball before installing it.
• 2nd & 3rd bushing has a groove in which steel ball fits.
ST37750000 -
3rd & 4th
synchronizer hub
SMT085CA
5. Install steel ball, 4th bushing and 4th main gear.

• 4th bushing has a groove in which steel ball fits.
Steel ball
SMT687C
6. Press on 5th main gear.
/ 5th main gear
SMT606AA
7. Install thrust washer.

~ C-ring holder
8. Select and install mainshaft C-ring that gives proper clear-
~~ Mainshaft C-ring ance of groove in mainshaft.
@---Thrust washer 0-0.1 mm (O . 0.004 in)
Mainshaft C-ring:
9. Install C-ring holder.
SMT592-A
MT-22
REPAIR FOR COMPONENT PARTS I RSSF30A & RSSF31A I
10. Press on mainshaft rear bearing.
ST22360002
SMT607AA
11. Press on mainshaft front bearing.

12. Measure gear end playas the final check - Refer to
"DISASSEM BL y", MT -19.
SMT639
Final Drive
DISASSEMBL Y
•
1. Remove final gear.
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings.
• Be careful not to mix up the right and left bearings.
[ .
SMT647-A
4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears.
Retaining
pin
SMT147AA
INSPECTION
Gear, washer, shaft and case
• Check mating surfaces of differential case, side gears and
pinion mate gears.
• Check washers for wear.
SMT083A
MT-23
Final Drive (Conl'd)
Bearing
SPD715
ASSEMBLY
1. Attach side gear thrust washers to side gears and install in
differential case.
2. Install pinion mate thrust washers and pinion mate gears.
SMT839
3. Insert pinion mate shaft.

• When inserting, be careful not to damage pinion mate thrust
washers.
SMT087A
4. Measure clearance between side gear and differential case

with washers following the procedure below:
a. Set Tool and dial indicator on side gear.
KV381 05900
SMT610AB
b. Move side gear up and down to measure dial indicator

deflection. Always measure indicator deflection on both
side gears.
Clearance between side gear and differential case with
washers:
0.1 - 0.2 mm (0.004 - 0.008 in)
c. If not within specification, adjust clearance by changing
thickness of side gear thrust washers.
Side gear thrust washer:
SMT611A
MT-24
Final Drive (Cont'd)
5. Install retaining pin.
• Make sure that retaining pin is flush with case.
Retaining
pin
SMT147AA
6. Install final gear.

• Apply locking sealant to final gear fixing bolts before install-
ing them.
7-. Install speedometer drive gear and stopper .
1/
SMT609A
8. Press on differential side bearings. •
;? Control b~'Ck:t ,
INSPECTION
.. ~-t' • Check contact surface and sliding surface for wear,
If 0
scratches, projections or other damage.
Shift fork and shifter cap ",0
~
SMT086C
Case Components
Input shaft oil seal
1. Drive out input shaft oil seal.
MT-25
REPAIR FOR COMPONENT PARTS I RSSF30A & RSSF31A I
Case Components (Cont'd)
2. Install input shaft oil seal.
installing.
SMT751BA
Input shaft rear bearing

1. Remove welch plug from transmission case.
SMT688C
2. Remove input shaft rear bearing by tapping it from welch

plug hole.
r Welch plug hole
SMT633
3. Install welch plug.

• Apply recommended sealant to mating surface of transmis-
sion case.
4. Install input shaft rear bearing.
MT-26
Mainshaft front bearing outer race and oil channel
1. Remove mainshaft front bearing outer race.
2. Remove oil channel.
SMT636-A
3. Install oil channel.

Toward
• Ensure the oil groove faces the oil pocket.
oil pocket
SMT595
4. Install mainshaft front bearing outer race. •

Mainshaft rear bearing outer race
• Refer to "Differential Side Bearing Preload", MT -29.
Differential side bearing outer race
• Refer to "Mainshaft Bearing Preload", MT -28.
MT-27
ADJUSTMENT I RS5F30A & RS5F31 A I
Differential Side Bearing Preload

If any of the following parts are replaced, adjust differential side
bearing preload.
• Differential case
• Differential side bearing
• Clutch housing
• Transmission case
1. Remove differential side bearing outer race (transmission

case side) and shim(s).
2. Reinstall differential side bearing outer race without

shim(s).
3. Install final drive assembly on clutch housing.
4. Install transmission case on clutch housing.
• Tighten transmission case fixing bolts to the specified
torque. Refer to MT-10.
SMT646-A
5. Set dial indicator on front end of differential case.

6. Insert Tool all the way into differential side gear.
KV38106000
I"
7. Move Tool up and down and measure dial indicator deflec-
tion.
8. Select shim considering bearing preload.
Suitable shim thickness =
Dial indicat~r deflection
+ specified bearing preload
Differential side bearing preload and adjusting shims:
Refer to 50S, MT -62, 63.
9. Install selected shim(s) and differential side bearing outer
race.
10. Check differential side bearing turning torque.

a. Install final drive assembly on clutch housing.
b. Install transmission case on clutch housing.
SMT454-A
MT-28
ADJUSTMENT I RS5F30A & RS5F31A I
Differential Side Bearing Preload (Cont'd)
c. Measure turning torque of final drive assembly.
Turning torque of final drive assembly
(New bearing):
• When old bearing is used again, turning torque will be
slightly less than the above.
• Make sure torque is close to the specified range.
• Changes in turning torque of final drive assembly per rev-
olution should be within 1.0 N'm (10 kg-em, 8.7 in-Ib) with-
out binding.
Mainshaft Bearing Preload

If any of the following parts are replaced, adjust mainshaft bear-
il}g preload.
• Mainshaft
• Mainshaft bearings
• Clutch housing
~casecover
"U--0-ring
~spacer
1. Remove case cover, O-ring, spacer, mainshaft bearing
adjusting shim and mainshaft rear bearing outer race from
transmission case.
•
2. Install mainshaft assembly on clutch housing.
Mainshaft rear bearing ~ Mainshaft 3. Install transmission case on clutch housing.
outer race ~ bearing
0
- \ adjusting torque. Refer to MT-10.
shim
I ~--
SMT613AA
4. Install mainshaft rear bearing outer race on inner race.
5. Measure distance from transmission case to bearing outer

race.
• Make sure that bearing is properly seated.
6. Select shim. Refer to SDS, MT-62.
7. Check total turning torque after assembling. Refer to
"ASSEMBLY", MT-30.
SMT599
MT-29
ASSEMBLY I RS5F30A & RS5F31 A I
1. Install striking rod, lever and interlock.

• Tape edges of striking rod to avoid damaging oil seal lip
during installation.
• When taped edges of striking rod are past the oil seal,
remove tape.
2. Install reverse check sleeve assembly.

3. Install check balls, reverse check spring and check plug.
4. Check reverse check turning torque (At striking rod).

Reverse check turning torque (At striking rod):
• If not within specification, select another check plug having
a different length and reinstall it.
Reverse check plug:
5. Install selected reverse check plug.
• Apply locking sealant to thread of plug before installing it.
6. Install check ball plug, shift check ball and shift check
spring.
7. Install oil pocket.
SMT648AA
8. Install gear components onto clutch housing.

- RS5F30A-
a. Install final drive assembly and reverse idler gear.
SMT580
MT-30
ASSEMBLY I RS5F30A & RS5F31 A I
b. Install mainshaft and input gear as a set.

• Take care not to damage oil seal lip with splines of input
shaft while shaft is being inserted into clutch housing.
• Take care not to damage oil channel when inserting main-
shaft into clutch housing.
SMT737A
c. Install bearing retainer.

• One of these three screws is torx type and should be
installed with suitable tool, as shown.
Suitable
tool
d. After installing torx screw, stake it at two points. •

SMT664
- RS5F31A-
a. Install input shaft assembly and reverse idler gear.
~ "-- Soft hammer • Be careful not to damage oil seal lip with splines of input
shaft.
SMT614A
Final drive assembly b. Install final drive assembly.
/{(/
SMT721
MT-31
ASSEMBLY I RSSF30A & RSSF31 A I
c. Install mainshaft assembly.

• Take care not to damage oil channel when inserting main-
SMT720
9. Apply grease to shifter caps, then install it to control

bracket. Install control bracket with 1st & 2nd shift fork.
10. Install 3rd & 4th and 5th shift forks.
11. Insert fork shaft.

• Apply multi-purpose grease to support spring before install-
ing.
12. Install reverse idler spacer.
13. Apply recommended sealant to mating surface of clutch

housing.
15. Measure total turning torque.

Total (Final drive + Mainshaft) turning torque (New
bearing):
MT-32
MAJOR OVERHAUL I RS5F32A I
Case Components
SEC.320 ~ 3.7 • 5.0 (0.38 • 0.51, 33.0 - 44.3)
CD ~
;1 Mating surface to
transmission case
1J2»~
I
~
o//~ ~3J
d~~~
CID.:. m
. ~)
Seal lip
~
(]? i~=1D.
//\
\
\
!-~~
1~
•
~'
@~ 10.20 (1.0 - 2.0, 87 - 174)

W~ Mating surface to ~ Thread of bolt
"""mi"ioo '"" \1:.01 ~ /', J

(15,'
. WO ,,~., .,.~
~~~> '\
\
@~ Mating surface to
\L~ 6.3 . 8.3
(0.64 - 0.85, 55.6 - 73.8)
t,,~~~~
I:::t:\ ~___--
o __ ~j)\~
~.L'
*
@~Mating
~i)~/(ro\~\~)
. ------ ~~,/ ~Q~ I f""\
~~~ ..~ Q{
t~A
!13i
26 - 30 (2.7 - 3.1, 20 - 22)
~ 25 _ 34 ~ N.m (kg-m, In-Ib\
(2.5 - 3.5, 18 - 25) A N.m (kg-m, ft-Ib)

~ Thread of bolt ~ . Apply recommended sealant
(fl) to.J 20 - 29 \ (Nissan genuine part: KP610-00250) or equivalent
- (2.0 - 3.0, 14 - 22) 12)~. m Seal lip ~ ,.1..', Apply locking sealant
~ Thread of bolt * : Select proper thickness.
-tI . Pay attention to its direction,
SMT751C
G) Clutch housing (9) O-ring @ Bearing retainer

@ Reverse idler shaft @ Case cover @l Striking rod oil seal
@ Input shaft oil seal CfD Back-up lamp switch QID Boot
@ Oil pocket @ Differential oil seal @ Neutral position switch
@ Bearing retainer @ Drain plug @ Differential oil seal
@ Filler plug @ Transmission case @ O-ring
(J) Air breather @ Oil gutter @ Speedometer pinion assembly
@ Welch plug @ Oil channel
MT-33
MAJOR OVERHAUL I RS5F32A I
Gear Components
SEC. 322
u : Pay attention to its direction.

* : Select proper thickness.
~ ~) : Apply locking sealant.
• : Apply gear oil. SMT593CB
CD Reverse idler gear @ 1st main gear @ 5th main gear

@ Reverse idler bushing @ Baulk ring I[~ Spacer
@ Reverse idler spacer @ 1st gear needle bearing ~~ Mainshaft rear bearing
@ Snap ring @ Reverse main gear ~ID Mainshaft C-ring
@ Spacer (Coupling sleeve) @ C-ring holder
@ Input shaft front bearing @ Insert spring @ Snap ring
(j) Input shaft @ 1st & 2nd synchronizer hub @ Snap ring
@ 5th gear needle bearing @ 2nd outer baulk ring @ Differential side bearing
@ 5th input gear @ 2nd synchronizer cone @ Speedometer stopper
@) Baulk ring @ 2nd inner baulk ring @ Speedometer drive gear
@ Coupling sleeve @ 2nd main gear @ Differential case
@ Spread spring @ 2nd & 3rd bushing {4) Final gear
@ Shifting insert @ 3rd main gear @ Differential side bearing
@ 5th gear synchronizer hub @ 3rd inner baulk ring @ Differential side bearing
@ Spread spring @ 3rd synchronizer cone adjusting shim
@l 5th stopper @ID 3rd outer baulk ring @ Retaining pin
@ Snap ring @ Coupling sleeve @ Pinion mate thrust washer
@ Input shaft bearing @ 3rd & 4th synchronizer hub @ Pinion mate gear
@l Mainshaft front bearing @ Insert spring ~O) Thrust washer
@) Steel ball @ Baulk ring @ Side gear
@ Mainshaft @".!J 4th main gear @ Pinion mate shaft
@ 4th bushing
MT-34
MAJOR OVERHAUL I RSSF32A I
SEC. 328
~~
CV-~
~
CID~ 6~~
~~
~ ~lil6.3-8.3
(0.64 • 0.85,
~ 55.6 • 73.8)
~ 5 *~-
...12 - 16
(1.2 - 1.6, 9 - 12)
~ Cbl Plug thread
•
/
r /~
I
<Si~~
J
"@lEa!
lil: N.m (kg-m, in-Ib)
~ Cbl : Apply locking sealant.
* : Select proper length.
~ : Select proper part. Adjustment is required.
SMT695CB
CD Check plunger @ Fork shaft @ Retaining pin

@ Select return spring @ Fork shaft support spring @ Yoke
@ Stopper pin @ 5th shift fork @ Reverse check plug
@ Striking lever @ Shifter cap @ Check ball (Large)
@ Striking interlock @ 3rd & 4th shift fork @ Check ball (Small)
@ E-ring @ Shifter cap @ Check sleeve
(J) Reverse brake cam @ 1st & 2nd shift fork @ O-ring
@ Check ball plug @ Control bracket @ Reverse check spring
@ Shift check ball @J Interlock pin
@) Shift check spring @ Retaining pin
@ Reverse brake cam spring @ Striking rod
MT-35
DISASSEMBL Y I RS5F32A I
1. Remove case cover.
SMT6648
2. Remove mainshaft bearing snap ring.
3. Remove transmission case while slightly tilting it to prevent

5th shift fork from interfering with case.
SMT6668
4. Draw out reverse idler spacer and fork shaft.
SMT6678
5. Remove 5th and 3rd & 4th shift forks.

• Be careful not to lose shifter cap.
5th shift
fork
MT-36
DISASSEMBl Y I RS5F32A I
6. Remove control bracket with 1st & 2nd shift fork.
7. Remove gear components from clutch housing.

a. Remove input shaft front bearing retainer securing bolts .
b.
•
Remove input shaft with bearing retainer, mainshaft assem-
bly and reverse idler gear.
Always withdraw mainshaft straight out. Failure to do so
•
When removing input shaft, be careful not to scratch oil seal
lip with shaft spline.
SMT6708
c. Remove final drive assembly.
SMT6718
8. Remove oil pocket, shift check ball, shift check spring and
check ball plug.
SMT64BAA
MT-37
DISASSEMBL V I RS5F32A I
9. Drive retaining pin out of striking lever, then remove strik-

ing rod, striking lever and striking interlock.
• Select a position where retaining pin does not interfere with
clutch housing when removing retaining pin.
SMT599AA
• Be careful not to damage oil seal lip, when removing strik-

ing rod. If necessary, tape edges of striking rod.
SMT583
10. Remove reverse check plug, then detach reverse check

spring and check balls.
• If the smaller ball does not come out, remove it together
with check sleeve assembly.
11. Remove check sleeve assembly.
Check sleeve
assembly
SMT585
MT-38
REPAIR FOR COMPONENT PARTS I RS5F32A I
Input Shaft and Gears

DISASSEMBL Y
1. Before disassembly, check 5th input gear end play.
Gear end play:
• If not within specification, disassemble and check contact
surface of gear, shaft and hub. Check clearance of snap ring
groove. Refer to "ASSEMBLY", MT-40.
2. Remove snap ring and 5th stopper.
~
5th input gear
Set Tool below

5th input gear.
3. Remove 5th synchronizer,
dle bearing.
5th input gear and 5th gear nee- •
- r 5th synchronizer hub
/ ST30021 000
SMT417CA
4. Remove snap ring of input shaft front bearing and input gear
spacer.
Spacer
Input shaft
front bearing
SMT674B
5. Remove input shaft front bearing.

6. Remove bearing retainer.
MT-39
INSPECTION
Gear and shaft
SMT602A
5th synchronizer
Shifting insert
for wear or cracks.
• Check insert springs for wear or deformation.
SMT387A
Baulk ring to
gear clearance Clearance between baulk ring and gear:
Standard
0.90 - 1.50 mm (0.0354 - 0.0591 in)
Wear limit
0.7 mm (0.028 in)
SMT140
Bearing
ASSEMBLY
1. Assemble 5th synchronizer.
MT-40
to the same insert.
SMT761B
2. Install bearing retainer.

3. Press on input shaft front bearing.
4. Install input gear spacer.
~= Bearing retainer
SMT731-A
Snap ring
5. Select and install snap ring that gives proper clearance
input shaft groove.
of •
o- 0.1 mOl (0 - 0.004 in)
Snap rings of input shaft front bearing:
SMT708B
• Be sure to replace 5th gear synchronizer hub with new one

when it is removed.
6. Install 5th gear needle bearing, 5th input gear, 5th synchro-
nizer and 5th stopper.
• Input shaft must be vertical to press on synchronizer hub.
ST37750000 ~ 7. Measure gear end playas a final check. Refer to
5th synchronizer hub "DISASSEMBLY", MT-39.
SMT779AA
8. Select and install snap ring that gives proper clearance of

input shaft groove.
o - 0.1 mm (0 - 0.004 in)
Snap ring of 5th synchronizer:
Refer to SOS, MT-65.
SMT591
MT-41
Mainshaft and Gears

End play
DISASSEMBL Y
1. Before disassembly, measure gear end play.
Gear end play:
• If end play is not within the specified limit, disassemble and
check the parts.
2. Remove mainshaft rear bearing snap ring, Coring holder

and mainshaft C-rings.
Snap ring
C-ring holder
SMT709B
~Snapring
@--- C-ring holder
~~ Malnshaft C-r1ng
- Mainshaft rear
bearing
SMT676BB
3. Remove mainshaft rear bearing and spacer.
Puller-
./- Suitable
drift
Mainshaft rear
bearing
SMT677BA
4. Remove 5th main gear.
SMT593-A
MT-42
REPAIR FOR COMPONENT PARTS I RSSF32A I
5. Remove 4th main gear, bushing and steel ball.
• Take care not to lose steel ball.
SMT418C
6. Remove 3rd & 4th synchronizer and 3rd main gear .
2nd & 3rd~

bushing
2nd gear
-'-~)
~
SMT766BA
7.
•
Remove 2nd & 3rd bushing and 2nd main gear.
Take care not to lose the steel ball.
•
AMT053
8. Remove 1st & 2nd synchronizer hub and 1st main gear.
1st main gear
AMT056
INSPECTION
Gear and shaft
SMT604A
MT-43
Synchronizer
for wear or cracks.
• Check insert springs for deformation.
t
SMT7198
Baulk ring to • Measure clearance between baulk ring and gear.

gear clearance Clearance between baulk rings and gears,
for 1st and 4th gear only:
Standard
1st 0.95. 1.45 mm (0.0374 • 0.0571 in)
4th 0.90. 1.45 mm (0.0354 • 0.0571 in)
Wear limit
0.7 mm (0.028 in)
• 2nd and 3rd gears have inner and outer baulk rings and so
have different measurements.
SMT140
Outer baulk ring --\

Synchronizer
ST30031000
,fli 10M'
~
baolk 'fOM FA
B
SMT714CA
• Measure wear of 2nd and 3rd baulk rings.

a. Place inner baulk ring in position on synchronizer cone.
b. Hold baulk ring evenly against synchronizer cone and mea-
sure distance "A".
c. Place outer baul.k ring in position on synchronizer cone.
d. Hold baulk ring evenly against synchronizer cone and mea-
sure distance "B".
Standard:
Inner-A 0.7 - 0.9 mm (0.028 - 0.035 in)
Outer-B 0.6 - 1.1 mm (0.024 - 0.043 in)
Wear limit:
0.2 mm (0.008 in)
e. If distance "A" or "B" is smaller than the wear limit, replace
baulk ring.
MT-44
Bearing
• The mainshaft front bearing cannot be re-used. It must be
replaced once removed.
SPD715
ASSEMBLY
1. Install 1st gear needle bearing, 1st main gear and baulk
ring.
2. Press on 1st & 2nd synchronizer hub.
SMT089CA
• Ensure correct fitting of 1st & 2nd synchronizer hub . •

1stmain. 2nd main
gear • gear
SMT7018
3. Install 2nd synchronizer cone, outer & inner baulk ring and
reverse main gear (coupling sleeve).
SMT6838
4. Install steel ball, 2nd main gear, 2nd & 3rd bushing.
• Apply gear oil to 2nd & 3rd bushing before installing it.
.....
ST23860000 • 2nd & 3rd bushing has a groove in which steel ball fits.
Front
rr=DJ
KV31100401 -
SMT412CA
MT-45
5. Install 3rd main gear, synchronizer cone, outer & inner
baulk ring.
6. Press on 3rd & 4th synchronizer hub.
SMT090CA
• Ensure correct fitting of 3rd & 4th synchronizer hub.

7. Install 3rd & 4th coupling sleeve and 4th baulk ring.
4th main ..... ..... 3rd main

gear ...... .".. gear
SMT7028
8. Install steel ball, 4th bushing and 4th main gear.

~ 4th m.lo g.. ' • Apply multi-purpose grease to steel ball before installing it.
• 4th bushing has a groove in which steel ball fits.
~-
~ 4th bushing
mAr-51""'"
l(~J SMT422C
9. Press on 5th main gear.
ST3n50000
SMT091CA
10. Select proper mainshaft bearing spacer to give correct

Mainshaft rear bearing
bearing distance.
Mainshaft adjusting
spacer
Bearing distance "e":
230.15 - 230.25 mm (9.0610 - 9.0649 in)
Spacers available:
SMT6938
MT-46
11. Press on mainshaft rear bearing.
ST37750000
SMT092CA
12. Select and install mainshaft C-ring that gives proper clear-
@-Snapring
ance of groove in mainshaft.
e--- C-ring holder Allowable clearance of groove:
~~ Mainshaft C-ring
o - 0.1 mm (0 - 0.004 in)
Mainshaft C-rings:
Mainshaft rear
13. Install C-ring holder and snap ring.
bearing
14. Measure gear end playas the final check. Refer to
•
"DISASSEMBLY", MT-42.
SMT676BB
C-ring
SMT712B
Final Drive
DISASSEMBL Y
2. Remove speedometer drive gear by cutting it.
• Be careful not to mix up the right and left bearings.
SMT647-A
4. Drive out retaining pin and draw out pinion mate shaft.
MT-47
INSPECTION
pinion mate gears.
SMT083A
Bearing
SPD715
ASSEMBLY
1. Attach side gear thrust washers to side gears, then install
pinion mate washers and pinion mate gears in place.
SMT839
2. Insert pinion mate shaft.

• When inserting, be careful not to damage pinion mate thrust
washers.

with washers following the procedure below:
a. Set Tool and dial indicator on side gear.
KV381 05900
SMT610AB
MT-48
b. Move side gear up and down to measure dial indicator
side gears.
washers:
0.1 - 0.2 mm (0.004 - 0.008 in)
c. If not within specification, adjust clearance by changing
SMT611A
4. Install retaining pin.

• Make sure that retaining pin is flush with case .
5.
•
Install final gear.
Apply locking sealant to final gear fixing bolts before install-
ing them.
•
6. Install speedometer drive gear.
SMT609A
7. Press on differential side bearings.
SMT648
Striking rod Control bracket Shift Control Components
~
_.~0
.~ INSPECTION
• Check contact surface and sliding
scratches, projections or other damage.
surface for wear,
Shift fork an};Jd"

shifter cap •
s:;
'l@ SMT093C
MT-49
Shift Control Components (Cont'd)
Striking lever
Reverse brake earn
SMT099C
ADJUSTMENT OF INPUT SHAFT BRAKING MECHANISM

1. Install striking lever & rod, striking interlock assembly and
control bracket on clutch housing exactly.
• When installing control bracket on clutch housing, assure
protrusion beneath bracket is correctly seated.
SMT774B
2. Measure maximum height "H" while shifting from neutral to

reverse position.
Maximum height "H":
67.16 - 67.64 mm (2.6441 .2.6630 in)
Height
gauge
1st & 2nd shifter
Control bracket
fitting surface ~
Reverse brake carn
SMT728B
MT-SO
Shift Control Components (Cont'd)
3. Measure clearance "C" between reverse brake cam and
striking lever while shifting to reverse position.
Clearance "C":
0.05 - 0.125 mm (0.0020 - 0.0049 in)
If "H" or "C" is not within specification, replace the follow-
ing parts as a set.
• Striking lever assembly
• Striking interlock assembly (This includes reverse brake
earn.)
• Control bracket assembly
Reverse brake eam
SMT729B
Case Components
•
Input shaft oil seal
1. Drive out input shaft oil seal.
2. Install input shaft oil seal.

installing.
SMT751BA
Input shaft rear bearing

1. Remove welch plug from transmission case.
SMT705B
MT-51
2. Remove input shaft rear bearing by tapping it from welch
plug hole.
SMT704B
3. Install welch plug.

sion case.
SMT705B
4. Install input shaft rear bearing.
SMT706BA
Mainshaft front bearing and oil channel

1. Remove mainshaft front bearing retainer.
SMT707B
2. Remove mainshaft front bearing.

ST33290001 3. Remove oil channel.
SMT714BA
MT-52
REPAIR FOR COMPONENT PARTS I RSSF32A I
4. Install oil channel.
Toward
• Ensure the oil groove faces the oil pocket.
oil pocket
SMT595
5. Install mainshaft front bearing.

6. Install mainshaft front bearing retainer.
• Apply locking sealant to thread of screw before installation .
MT-53
ADJUSTMENT I RS5F32A I
Differential Side Bearing Preload

If any of the following parts are replaced, adjust differential side
bearing preload.
• Differential case
• Differential side bearing
• Clutch housing
1. Remove differential side bearing outer race (transmission

case side) and shim.
2. Install differential side bearing outer race without shim.

3. Install final drive assembly on clutch housing.
SMT646-A
5. Set dial indicator on front end of differential case.

6. Insert Tool all the way into differential side gear.
7. Move Tool up and down and measure dial indicator deflec-
tion.
8. Select shim considering bearing preload.
• Suitable shim thickness = Dial indicator deflection +

Specified bearing preload
Differential side bearing preload and adjusting shims:

Refer to SDS, MT-66.
Bearing preload:
0.25 - 0.30 mm (0.0098 - 0.0118 in)
9. Install selected shim and differential side bearing outer

race.
10. Check differential side bearing turning torque.
a. Install final drive assembly on clutch housing.
b. Install transmission case on clutch housing.
SMT454-B
MT-54
ADJUSTMENT I RS5F32A I
Differential Side Bearing Preload (Cont'd)
c. Measure turning torque of final drive assembly.
Turning torque of final drive assembly
(New bearing):
2.9 - 6.9 N'm (30 - 70 kg-em, 26 - 61 in-Ib)
• Changes in turning torque of final drive assembly per rev-
olution should be within 1.0 N'm (10 kg-em, 8.7 in-Ib) with-
out binding.
MT-55
ASSEMBLY I RS5F32A ,
1. Install striking rod, lever and interlock.

• Tape edges of striking rod to avoid damaging oil seal lip
during installation. When taped edges of striking rod are
past the oil seal, remove tape.
2. Install reverse check sleeve assembly.

J Reverse check plug 3. Install check balls, reverse check spring and check plug.
~ Reverse check spring
V Check ball (Large)
"-- Check ball (Small)
b~6
, ~
l ~---- -'.
SMT584
4. Check reverse check turning torque (At striking rod).

Reverse check turning torque (At striking rod):
4.9 - 7.4 N'm (50 - 75 kg-em, 43 - 65 in-Ib)
• If not within specification, select another check plug having
a different length and reinstall it.
Available reverse check plugs:
5. Install selected reverse check plug.
• Apply locking sealant to thread of plug before installing it.
SMT688
6. Install check ball plug, shift check ball and shift check
spring.
7. Install oil pocket.
SMT648AA
8. Install gear components onto clutch housing.

a. Install final drive assembly.
SMT671B
MT-56
ASSEMBLY I RSSF32A I
b. Install input shaft assembly with bearing retainer, mainshaft

assembly and reverse idler gear.
• Be careful not to damage oil seal lip with splines of input
shaft.
• Be careful not to damage oil channel when inserting main-
c. Install input shaft front bearing retainer.
9. Apply grease to shifter caps, then install it to control

bracket. Install control bracket with 1st & 2nd shift fork.
•
SMT666
• When installing control bracket on clutch housing, ensure

bracket is correctly seated.
10. Install 3rd & 4th and 5th shift forks.
SMT774B
11. Insert fork shaft.

• Apply multi-purpose grease to support spring before install-
ing.
12. Install reverse idler spacer.
SMT596
MT-57
ASSEMBLY I RS5F32A I
13. Apply recommended sealant to mating surface of clutch
housing.
SMT666B
15. Install mainshaft front bearing snap ring.
Snap ring
SMT665B
16. -Check mainshaft bearing end play.

Mainshaft bearing end play:
o- 0.1 mm (0 - 0.004 in)
• Make sure that bearing is properly seated. If not, tap main
shaft end with a rubber hammer.
• If not within specification, select another case cover having
a different thickness.
Available case covers:
SMT775B
MT-58
ASSEMBLY I RS5F32A I
17. Install O-ring and case cover on transmission case.
sion case.
SMT6648
MT-59
TRANSAXLE
Except for
Except for
Europe Europe and Europe Australia Europe
Europe
Australia
Applied model
GA14DE GA15DE GA16DE
Without SR20DE CD20
With catalyzer
catalyzer
Transaxle model RS5F30A RS5F31A RS5F32A RS5F31A
Number of speeds 5
Synchromesh type Warner
Shift pattern
1 3 5
~tJ
II
2 4 A
Gear ratio 1st 3.333 3.333 3.063 3.063 3.333

2nd 1.955 1.955 1.826 1.826 1.955
3rd 1286 1.286 1.286 1.286 1.286
4th 0.902 0.926 0.975 0.975 0.902
5th 0.733 0.756 0.810 0.756 0,756
Reverse 3.417 3.417 3.417 3.153 3.417
Number of Input 1st 15 15 16 16 15
teeth gear 2nd 22 22 23 23 22
3rd 28 28 28 28 28
4th 41 41 40 40 41
5th 45 45 42 45 45
Rev. 12 12 12 13 12
Main 1st 50 50 49 49 50
gear 2nd 43 43 42 42 43
3rd 36 36 36 36 36
4th 37 38 39 37
5th 33 34 34 39/
34 34
Rev. 41 41 41 41 41
Reverse idler
30 30
gear 31
3.7 - 3.9 2.9 - 3.2
Oil capacity C (Imp pt) 2.8 - 3.0 (4-7/8 - 5-1/4) 2.9 - 3.2 (5-1/8 - 5-5/8)
(6-1/2 - 6-7/8) (5-1/8 - 5-5/8)
.
39 - 44 54 - 61
Oillevel* mm (in) 58 - 66 (2.28 - 2.60) 57 - 66 (2.24 - 2.60)
(1.54 - 1.73) (2.13 - 2.40)
*: Refer to MA. section.
FINAL GEAR
Engine GA14DE GA15DE GA16DE SR20DE CD20
Final gear ratio 4.167 3.789 4.167 4.176 3.650
Final gear/Pinion 75/18 72/19 75/18 71/17 73/20

Number of
teeth Side gear/Pinion
14/10 14/10 16/10 14/10 16/10
mate gear
MT.60

RS5F31A
GEAR END PLAY AVAILABLE SNAP RINGS
Input shaft front bearing
Gear End play mm (in)
1st main gear 0,18 - 0,31 (0,0071 - 0,0122) Allowable clearance 0- 0,1 mm (0 - 0,004 in)
2nd main gear 0,20 - 0,30 (0,0079 - 0,0118) Thickness mm (in) Part number
3rd main gear 0,20 - 0,30 (0,0079 - 0,0118) 1,27 (0,0500) 32204-M8004
4th main gear 0,20 - 0,30 (0,0079 - 0,0118) 1,33 (0,0524) 32204-M8005
5th input gear 0,18 - 031 (0,0071 - 0,0122) 1,39 (0,0547) 32204-M8006
1.45 (0,0571) 32204-M8007
CLEARANCE BETWEEN BAULK RING AND

GEAR Input shaft 5th synchronizer hub
1st, 2nd, 3rd, 4th, 5th baulk ring Allowable clearance 0- 0,1 mm (0 - 0,004 in)
Unit: mm (in)
Thickness mm (in) Part number
•
Standard Wear limit
2,00 (00787) 32311-M8812
1.0 - 1.35 (0.0394 - 0.0531) 0.7 (0.028)
2,05 (0,0807) 32311-M8813
2,10 (0,0827) 32311-M8814
2,15 (0,0846) 32311-M8815

AVAILABLE CHECK PLUGS
2,20 (0.0866) 32311-M8816
Reverse check plug 2.25 (0.0886) 32311-M8817
2.30 (0.0906) 32311-M8818

Reverse check turning
4.9 - 7.4
torque (At striking rod)
(50 - 75, 43 - 65)
N'm (kg-em, in-Ib)
Thickness mm (in) Part number AVAILABLE C-RINGS

8.3 (0.327) 32188-M8001'
Mainshaft C-ring
7.1 (0.280) 32188-M8002
7.7 (0.303) 32188-M8003 Allowable clearance 0- 01 mm (0 - 0.004 in)
8.9 (0.350) 32188-M8004 Thickness Thickness

Part number Part number
mm (in) mm (in)
, Standard size check plug
3.63 (0 1429) 32348-M8800 4.12 (0.1622) 32348-M8807
3.70 (0.1457) 32348-M8801 4.19 (0,1650) 32348-M8808
3.77 (0.1484) 32348-M8802 4.26 (0.1677) 32348-M8809
3.84 (0.1512) 32348-M8803 4.33 (0.1705) 32348-M8810
3.91 (0.1539) 32348-M8804 4.40 (0.1732) 32348-M8811
3,98 (0.1567) 32348-M8805 4.47 (0.1760) 32348-M8812
4.05 (0.1594) 32348-M8806 4.54 (0.1787) 32348-M8813
MT-61
RS5F31 A (Cont'd)
AVAILABLE WASHERS Mainshaft bearing adjusting shims
Differential side gear thrust washer Thickness mm (in) Part number
• GA 16DE and CD20 engine models 0.10 (0.0039) 32137-M8000
0.15 (0.0059) 32137-M8001
Allowable clearance between
0.1 - 0.2 mm 0.20 (0.0079) 32137-M8002
side gear and differential case
(0.004 - 0.008 in) 0.25 (0.0098) 32137-M8003
with washer
0.30 (0.0118) 32137-M8004
035 (0.0138) 32137-M8005
0.75 - 0.80 (0.0295 - 0.0315) 38424-02111
0.40 (0.0157) 32137-M8006
0.80 - 0.85 (0.0315 - 0.0335) 38424-02112
0.45 (00177) 32137-M8007
0.85 - 0.90 (0.0335 - 0.0354) 38424-02113 0.50 (0.0197) 32137-M8008
0.90 - 0.95 (0.0354 - 0.0374) 38424-02114 0.55 (0.0217) 32137-M8009
0.95 - 1.00 (0.0374 - 0.0394) 38424-02115 0.60 (0.0236) 32137-M8010

0.65 (0.0256) 32137-M8011
0.70 (0.0276) 32137-M8012
• Except for GA16DE and CD20 engine models
0.75 (0.0295) 32137-M8013
Allowable clearance between 080 (0.0315) 32137-M8014
0.1 - 0.2 mm
side gear and differential case 0.85 (0.0335) 32137-M8015
(0.004 - 0.008 in)
with washer
0.90 (0.0354) 32137-M8016
095 (0.0374) 32137-M8017
076 - 0.81 (0.0299 - 0.0319) 38424-01 M10 1.00 (0.0394) 32137-M8018
0.81 - 0.86 (0.0319 - 0.0339) 38424-01 M11
0.86 - 0.91 (0.0339 - 0.0358) 38424-01 M12
0.91 - 0.96 (0.0358 - 0.0378) 38424-01M13 Table for selecting mainshaft bearing
adjusting shim
Unit: mm (in)
AVAILABLE SHIMS
MAINSHAFT AND DIFFERENTIAL SIDE Measured distance Suitable shim thickness
BEARING PRELOAD AND ADJUSTING 2.35 - 2.40 (0.0925 - 0.0945) 0.10 (0.0039)
SHIM 2.40 - 2.45 (0.0945 - 0.0965) 0.15 (0.0059)

2.45 - 2.50 (0.0965 - 0.0984) 0.20 (0.0079)
Bearing preload (Reused bearing)
2.50 - 2.55 (0.0984 - 0.1004) 0.25 (0.0098)
Unit: mm (in)
2.55 - 2.60 (0.1004 - 0.1024) 0.30 (0.0118)
Oifferential side
Mainshafl bearing 2.60 - 2.65 (0.1024 - 0.1043) 0.35 (0.0138)
bearing
2.65 - 2.70 (0.1043 - 0.1063) 0.40 (0.0157)
0.18 - 0.23 0.24 - 0.32
RS5F30A 2.70 - 2.75 (0.1063 - 0.1083) 0.45 (0.0177)
(0.0071 - 0.0091) (0.0094 - 0.0126)
2.75 - 2.80 (0.1083 - 0.1102) 0.50 (0.0197)
0.18 - 0.27 0.20 - 0.25
RS5F31A 2.80 - 2.85 (0.1102 - 0.1122) 0.55 (0.0217)
(0.0071 - 0.0106) (0.0079 - 0.0098)
2.85 - 2.90 (0.1122 - 0.1142) 0.60 (0.0236)
2.90 - 2.95 (0.1142 - 0.1161) 0.65 (0.0256)
Turning torque (New bearing) 0.70 (0.0276)
2.95 - 3.00 (0.1161 - 0.1181)
Unit: N'm (kg-em, in-Ib)
3.00 - 3.05 (0.1181 - 0.1201) 0.75 (0.0295)
Total 3.05 - 3.10 (0.1201 - 0.1220) 0.80 (0.0315)
Final drive only (Final drive +
3.10 - 315 (0.1220 - 0.1240) 0.85 (0.0335)
Mainshafl)
3.15 - 3.20 (0.1240 - 0.1260) 0.90 (0.0354)
2.0 - 7.8 3.9 - 12.3
RS5F30A 3.20 - 3.25 (0.1260 - 0.1280) 0.95 (0.0374)
(20 - 80, 17 - 69) (40 - 125, 35 - 109)
3.25 - 3.30 (0.1280 - 0.1299) 1.00 (0.0394)
2.0 - 7.8 3.9 - 13.7
RS5F31A
(20 - 80, 17 - 69) (40 - 140, 35 - 122)
MT-62
RS5F31A (Cont'd)
Differential side bearing adjusting shims
0.44 (0.0173) 38454-M8000
0.48 (0.0189) 38454-M8001
0.56 (0.0220) 38454-M8003
0.60 (0.0236) 38454-M8004
0.64 (0.0252) 38454-M8005
0.68 (0.0268) 38454-M8006
0.72 (0.0283) 38454-M8007
0.76 (0.0299) 38454-M8008
0.80 (0.0315) 38454-M8009
0.84 (0.0331) 38454-M8010
0.88 (0.0346) 38454-M8011
MT-63
Inspection and Adjustment - RS5F32A

GEAR END PLAY AVAILABLE REVERSE CHECK PLUGS AND
CASE COVERS
Gear End play mm (in)
Reverse check plug
1st main gear 0.18 - 0.31 (0.0071 - 0.0122)
2nd main gear 0.20 - 0.30 (0.0079 - 0.0118) Reverse check turning torque 4.9 - 7.4 N'm
3rd main gear 0.20 - 0.30 (0.0079 - 0.0118) (At striking rod) (50 - 75 kg-em, 43 - 65 in-Ib)
4th main gear 0.20 - 0.30 (0.0079 - 0.0118) Length mm (in) Part number
0.18 - 0.31 (0.0071 - 0.0122) 8.3 (0.327) 32188-M8001*

5th input gear
7.1 (0.280) 32188-M8002
7.7 (0.303) 32188-M8003
CLEARANCE BETWEEN BAULK RING AND 8.9 (0.350) 32188-M8004
GEAR * Standard size check plug
1st, 4th, 5th baulk ring

Unit: mm (in)
Case cover
Standard Wear limit
0.95 - 1.45 Main shalt bearing end play 0- 0.1 mm (0 - 0.004 in)
1st
(0.0374 - 0.0571)
0.90 - 1.45
4th 07 (0.028) 10.78 (0.4244) 32131-50JOO
(0.0354 - 0.0571)
10.83 (0.4264) 32131-50J01
0.90 - 1.50
5th
(0.0354 - 0.0591) 10.88 (0.4283) 32131-50J02
10.93 (0.4303) 32131-50J03
10.98 (0.4323) 32131-50J04
2nd and 3rd baulk ring 11.03 (0.4343) 32131-50J05

Unit: mm (in)
:I{ ~ '00" ',,'k ,iog

\..- Synchronizer cone SMT757C
Dimension Standard Wear limit
0.7 - 0.9
A
(0.028 - 0.035)
02 (0008)
0.6 - 1.1
B
(0.024 - 0.043)
MT-64
Inspection and Adjustment - RS5F32A (Cont'd)
AVAILABLE SNAP RINGS AVAILABLE SPACERS
Input shaft front bearing Mainshaft bearing adjusting spacer
Allowable clearance 0 - 0.1 mm (0 - 0.004 in)

Mainshaft rear bearing
Mainshaft adjusting
1.27 (0.0500) 32204-M8004 spacer
133 (0.0524) 32204-M8005
1.39 (0.0547) 32204-M8006
1.45 (0.0571) 32204-M8007

c
SMT6938
Input shaft 5th synchronizer hub 230.15 - 230.25 mm

Bearing distance "C"
(9.0610 - 9.0649 in)
Allowable clearance 0- 0.1 mm (0 - 0.004 in) Thickness mm (in) Part number
Thickness mm (in) Part number 1891 (0.7445) 32347-50JOO
2.00 (0.0787) 32311-M8812 18.98 (0.7472) 32347-50J01
2.05 (0.0807) 32311-M8813 19.05 (0.7500) 32347-50J02
2.10 (0.0827)
2.15 (0.0846)
2.20 (0.0866)
225 (0.0886)
2.30 (0.0906)
32311-M8814
32311-M8815
32311-M8816
32311-M8817
32311-M8818
1912 (0.7528)
1919 (0.7555)
19.26 (0.7583)
1933 (0.7610)
19.40 (0.7638)
32347-50J03
32347-50J04
32347-50J05
32347-50J06
32347-50J07
•
19.47 (0.7665) 32347 -50J08
AVAILABLE C-RINGS
Mainshaft C-ring
AVAILABLE WASHERS
Allowable clearance 0- 0.1 mm (0 - 0.004 in) Differential side gear thrust washer
Allowable clearance between
4.45 (0.1752) 32348-50JOO 01 - 0.2 mm
side gear and differential case
(0.004 - 0.008 in)
4.52 (01780) 32348-50J01 with washer
4 59 (0.1807) 32348-50J02 Thickness mm (in) Part number
4.66 (0 1835) 32348-50J03 075 - 0.80

38424-02111
(0.0295 - 0.0315)
473 (0.1862) 32348-50J04
0.80 - 085
480 (0.1890) 32348-50J05 38424-02112
(0.0315 - 0.0335)
487 (0.1917) 32348-50J06
0.85 - 0.90
38424-02113
4.94 (0.1945) 32348-50J07 (0.0335 - 0.0354)
0.90 - 0.95
38424-02114
(00354 - 0.0374)
0.95 - 1.00
38424-02115
(0.0374 - 0.0394)
MT-65
Inspection and Adjustment - RS5F32A (Cont'd)
INPUT SHAFT BRAKING MECHANISM AVAILABLE SHIMS
DIFFERENTIAL SIDE BEARING
Reverse brake earn
PRELOAD AND ADJUSTING SHIM
Bearing preload (Reused bearing)
Unit: mm (in)
H Differential side bearing 0.25 - 0.30 (0.0098 - 0.0118)
Turning torque (New bearing)

Unit: N'm (kg-cm, in-I b)
Reverse brake cam Final drive 2.9 - 6.9 (30 - 70, 26 - 61)
SMT735B
Maximum height "H" between

the control bracket fitting sur- 67.16 - 67.64
face and 1-2 shiller (2.6441 - 2.6330)
mm (in) Thickness mm (in) Part number
0.44 (0.0173) 38454-M8000
0.48 (0.0189) 38454-M8001
0.56 (0.0220) 38454-M8003
0.60 (0.0236) 38454-M8004
0.64 (0.0252) 38454-M8005

c
0.68 (0.0268) 38454-M8006
0.72 (00283) 38454-M8007
0.76 (00299) 38454-M8008
0.80 (0.0315) 38454-M8009
SMT736B 0.84 (0.0331) 38454-M8010
Clearance "C" between 0.88 (0.0346) 38454-M8011

reverse brake carn and striking 0.05 - 0.125
lever (0.0020 - 0.0049)
mrn (in)
MT-66
AUTOMATIC TRANSAXLE
SECTION AT
CONTENTS
PREPARATION AND PRECAUTIONS 3 MAJOR OVERHAUL.. 42
Special Service Tools 3 All Models 42
Commercial Service Tools 6 Except Model 34X81 .44
Service Notice 7 Model 34X81 45 •
Supplemental Restraint System (SRS) "AIR Shift Control Components 46 i
BAG" (Dual Air Bag System) 7 Oil Channel 47

Supplemental Restraint System (SRS) "AIR Locations of Adjusting Shims, Needle
BAG" (Single Air Bag System) 7 Bearings, Thrust Washers and Snap Rings -
DESCRIPTION 8 Except Model 34X81 .48
Cross-sectional View 8 Locations of Adjusting Shims, Needle
Hydraulic Control Circuit 10 Bearings, Thrust Washers and Snap Rings -
Shift Mechanism 14 Model 34X81 .49
Control System 15 DiSASSEMBLy 50
TROUBLE DIAGNOSES 17 REPAIR FOR COMPONENT PARTS 66
Preliminary Check (Prior to Road Testing) 17 Manual Shaft and Throttle Lever 66
Road Testing 17 Oil Pump 70
Stall Tasting 24 Control Valve Assembly 74
Pressure Testing 26 Control Valve Upper Body 86
Wiring Diagram - AT - 28 Control Valve Lower Body 90
Electrical Components Inspection 30 Reverse Clutch 93
ON-VEHICLE SERVICE 31 High Clutch 97
Control Valve Assembly and Accumulator 31 Forward Clutch and Overrun Clutch 102
Throttle Wire Adjustment.. 33 Low & Reverse Brake 108
Control Cable Installation and Adjustment 35 Rear Internal Gear, Forward Clutch Hub and
Governor Valve 36 Overrun Clutch Hub 112
Inhibitor Switch Adjustment 37 Output Shaft, Output Gear, Idler Gear,
Differential Side Oil Seal Replacement.. 37 Reduction Pinion Gear and Bearing Retainer
REMOVAL AND INSTALLATION 39 - Except Model 34X81 116
Removal 39 Output Shaft, Idler Gear, Reduction Pinion
Installation .40 Gear and Bearing Retainer - Model 34X81 121
Band Servo Piston Assembly 126
Final Drive - Except Model 34X81 131
Final Drive - Model 34X81 135
CONTENTS (Cont'd.)
ASSEMBLy 138 Adjustment 3 157

Assembly 1 138 Assembly 4 158
Adjustment 1 139 SERVICE DATA AND SPECIFICATIONS (SOS) 165
Assembly 2 147 General Specifications 165
Adjustment 2 151 Specifications and Adjustments 165
Assembly 3 155

• See EL section, "POWER SUPPLY ROUTING" for power distribution circuit.
PREPARATION AND PRECAUTIONS
Tool number
Description
Tool name
8T25058001 Measuring line pressure and governor

Oil pressure gauge set pressure
G) 8T25051001
Oil pressure gauge
@ 8T25052000
Hose
@ 8T25053000
Joint pipe
@ 8T25054000
Adapter
@ 8T25055000
Adapter
NT097
KV31103000 Installing differential side oil seal

Drift (Use with 8T35325000)
a: 59 mm (2.32 in) dia.

NT105 b: 49 mm (1.93 in) dia.
•
8T35325000 Installing differential side oil seal
Drift (Use with KV31103000)
a: 215 mm (8.46 in)

b: 25 mm (0.98 in) dia.
NT417 c: M12 x 1.5P
KV31103200 Removing and installing clutch return

Clutch spring compressor spring
a: 179 mm (7.05 in)

b: 76 mm (2.99 in) dia.
NT425 c: 174 mm (6.85 in)
8T23540000 Removing and installing parking rod plate

Pin punch and manual plate
a: 2.3 mm (0.091 in) dia.

NT442 b: 4 mm (0.16 in) dia.
KV32101000 Installing throttle lever and manual shaft

Pin punch retaining pins
Removing and installing differential pinion
mate shaft lock pin.
NT410 a: 4 mm (0.16 in) dia.
AT-3
Tool number
Description
Tool name
ST3306S001 Removing differential side bearing inner
Differential side bearing race
puller set
CDST33051001 a: 38 mm (1.50 in) dia.
Puller b: 28.5 mm (1.122 in) dia.
,~
@ ST33061000 a c: 130 mm (5.12 in)
Adapter d: 135 mm (5.31 in)
NT413 e: 100 mm (3.94 In)
KV381054S0 • Removing differential side oil seal
(ST33290001) • Removing idler gear bearing outer race
Puller - EXCEPT MODEL 34X81 -
• Removing output shaft bearing outer
race from bearing retainer
• Removing output gear bearing outer
race from bearing retainer
- MODEL 34X81 -
• Removing differential side bearing outer
race
• Removing needle bearing from bearing
retainer
a: 250 mm (9.84 in)

NT414 b: 160 mm (6.30 in)
ST27180001 • Removing idler gear
Puller • Removing output gear (Except model
34X81)
a: 100 mm (3.94 In)

b: 110 mm (4.33 in)
NT424 c: M8 x 1.25P
ST30031000 Removing reduction pinion gear bearing

Puller inner race (Except model 34X81)
a: 90 mm (3.54 In) dia.

NT411 b: 50 mm (1.97 in) dia.
ST30021000 Removing differential side bearing

Puller (Except model 34X81)
a: 110 mm (4.33 in) dia.

NT411 b: 68 mm (2.68 in) dia.
ST35272000 • Installing reduction pinion gear bearing

Drift inner race
• Installing idler gear bearing inner race
• Installing output gear bearing inner race
(Except model 34X81)
~
a: 72 mm (2.83 in) dia.
NT426 b: 35.5 mm (1.398 in) dia.
AT-4
Tool number
Description
Tool name
8T37830000 Installing idler gear bearing outer race
Drift
a: 62 mm (2.44 in) dia.

NT427 b: 39 mm (1.54 in) dia.
8T33200000 Installing differential side bearing (Except

Drift model 34X81)
a: 60 mm (2.36 in) dia.

NT091 b: 44.5 mm (1.752 in) dia.
8T35271000 • Installing idler gear

Drift • Installing output gear (Except model
34X81)
a: 72 mm (2.83 in) dia.

NT115 b: 44 mm (1.73 in) dia.
8T33400001 • Installing oil pump housing oil seal

Drift • Installing output gear bearing outer race
onto bearing retainer (Except model •
34X81)
a: 60 mm (2.36 in) dia.

NT086 b: 47 mm (1.85 in) dia.
KV40104840 Installing output shaft bearing outer race

Drift onto bearing retainer (Except model
34X81)
a: 49 mm (1.93 in) dia.
NT108 b: 42 mm (1.65 in) dia.
KV38105710 - MODEL 34X81 -

Preload adapter • Measuring turning torque of final drive
assembly
• Measuring clearance between side gear
and differential case with washer
• Selecting differential side bearing
NT087 adjusting shim
8T35321000 Installing output shaft bearing
Drift (Model 34X81)
a: 49 mm (1.93 in) dia.

NT073 b: 41 mm (1.61 in) dia.

Drift race (Model 34X81)
a: 67 mm (2.64 in) dia.

NT073 b: 49 mm (1.93 in) dia.
AT-5

Puller • Removing idler gear bearing inner race
=m
• Removing and installing band servo pis-
ton snap ring
o 0
- EXCEPT MODEL 34X81 -
• Removing output gear bearing inner
race
NT077 • Removing differential side bearing
Drift Removing idler gear bearing inner race
NT109
~ a: 34 mm (1.34 in) dia.
Drift Installing needle bearing onto bearing

retainer (Model 34X81)
NT109
~ a: 36 mm (1.42 in) dia.
Drift Removing output gear bearing inner race

NT109
~ a: 33 mm (1.30 in) dia.
Drift Removing differential side bearing (Except

model 34X81)
NT109
~ a: 38 mm (1.50 in) dia.
Drift Removing output shaft bearing inner race

a: 70 mm (2.76 in) dia.

NT110
~ b: 30 mm (1.18 in) dia.
Drift Installing output shaft bearing inner race

a: 70 mm (2.76 in) dia.
b: 34 mm (1.34 in) dia.
~d c: 30 mm (1.18 in) dia.
NT111 d: 2 mm (0.08 in)
AT-6
Service Notice
• Before proceeding with disassembly, thor- • The valve body contains precision parts and
oughly clean the outside of the transaxle. It is requires extreme care when parts are
important to prevent the internal parts from removed and serviced. Place disassembled
becoming contaminated by dirt or other for- valve body parts in order, on a parts rack, for
eign matter. easier and proper assembly. Care will also
• Disassembly should be done in a clean work prevent springs and small parts from becom-
area. ing scattered or lost.
• Use lint-free cloth or towels for wiping parts • Properly installed vales, sleeves, plugs, etc.
clean. Common shop rags can leave fibers will slide along their bores in the valve body
that could interfere with the operation of the under their own weight.
transaxle. • Before assembly, apply a coat of recom-
• Place disassembled parts in order, on a parts mended ATF to all parts. Apply petroleum
rack, for easier and proper assembly. jelly to protect O-ring and seals, or hold bear-
• All parts should be carefully cleaned- with a ings and washers in place during assembly.
general purpose, non-flammable solvent Do not use grease.
before inspection or reassembly. • Extremely care should be taken to avoid dam-
• Gaskets, seals and O-rings should be age to O-rings, seals and gaskets when
replaced any time the transaxle is disassem- assembling.
bled. • After overhaul, refill the transaxle with new
• It is very important to perform functional tests ATF.
whenever they are indicated.

The Supplemental Restraint System "Air Bag" used along with a seat belt, helps to reduce the risk or
•
WARNING:
Ii Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this

The Supplemental Restraint System "Air Bag" and used along with a seat belt, helps to reduce the risk
or severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of
an air bag module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp,
WARNING:
Service Manual.
AT-7
DESCRIPTION
Cross-sectional View
EXCEPT MODEL 34X81
Band servo piston
Reverse clutch drum Converter housing

High clutch
Brake band
Torque converter
SAT502HB
AT-8
DESCRIPTION
Cross-sectional View (Cant' d)
MODEL 34X81
Band servo piston

Reverse clutch drum
High clutch
Front planetary gear
Reverse clutch
Low one-way clutch
Oil pump assembly
Rear planetary gear Brake band
Converter housing
Forward clutch
Overrun clutch
Low & reverse brake
Torque converter •
Input shaft
c
Idler gear
... -;-
,"'I I
L_
Forward one-way clutch Reduction pinion gear
Final gear
Differential case
SAT101EA
AT-9
DESCRIPTION
Hydraulic Control Circuit

MODEL 34X68
Low & reverse
brake
Forward
High clutch clutch
4th
speed cut
valve
Overrun
clutch
control
valve
Lock-up
control
valve
1-2
shift
valve
Torque '~ ..•.•

converter
relief
>..•.••••
..••.....
valve ..
Governor
valve
Detent valve
X : Drain port
: Orifice
SAT1961
AT-10
DESCRIPTION
Hydraulic Control Circuit (Cont'd)
MODEL 34X69 AND 34X70
Torque Forward
converter High clutch clutch
Oil
pump
4th
speed
cut
valve
i
accumulator
valve
Lock-up
control
valve
Overrun
clutch II
•
control
valve
1-2
shift valve
00 cancel
solenoid
X : Drain port
=:= : Orifice
SAT509H
AT-11
DESCRIPTION
MODEL 34X80
Low & reverse
Torque brake
Oil converter Overrun Reverse Forward
,clutch High clutch Band servo clutch clutch
tJ
I g~
pump I (Jp::- (T, tf1 --;::;-;r.]O ~
4th
speed cut
~J 1 ~ (~ ~~ l] J~ ~
valve
Overrun
clutch ~iJ - N ~%~ UL "-' IU4~1~~
control-
valve C-1 -! ~frEJ! 1
Lock-up_
control
6 ~, -~
valve 1-2
accumulator
valve
cooler-
~1
i i
L- _
-
- ILJ m ~,--J
,-O...J
0
r ar xU
r::r=< I '---,~ II . ( I ' IJ
,'- ,,'
I
( -
-
=- ~tL ' , ~H
::l.
-= ~ I r
x
-
rr=- 1-2
L~
LL: J~
~ ~M~ ·
I~ shift
valve
1-
Torque x'" ~
converter
relief
i i
'
valve 2 ~ '- F= f='l .,.11
"
~I"
~ r' I L...---...l
~reducing_
3-4 shift valv~-HiliJI L 2-3 . 4-2 I ~valve= ~
Governor../l ..- shift ~ seq!!.enc~
valve ~ - valve ,-=-valve---j h 1J;;;.Q"t....
Pressure
=--=-.J II Ma~alve lJl. "~'L--.J
regulator
valve !lJF :;;; ~ I
=-.--'
II
11 U
p RNb'21
I
nn
~ II
-,
'i-VD
D ~Y&
00 cancel I
." c: I
II
modifier
Throttle
valve
I
':fj'~1
1"
.
.
";'Jnn!
If.'
l...
,
solenoid •
X : Drain port
Pressure
modifier valve
Detent valve
:=~-' Throttle valve
\~ ~ Klckdown
modifier
:::::: : Orifice valve
SAT1971
AT-12
DESCRIPTION
MODEL 34X81
Torque
High clutch
converter
Oil
pump
4th speed
cut valve
Lock-up
control valve
Overrun
clutch
control valve
1-2
•
shift valve
3-4 shift valve
X Drain port
:::::= : Orifice
SAT1981
AT-13
DESCRIPTION
Shift Mechanism
CONSTRUCTION
,:-1 18
SAT214H
ill Torque converter @ Front internal gear @ Overrun clutch

@ Oil pump @l Front planetary carrier @ Low one-way clutch
@ Input shaft @ Rear sun gear @ Low & reverse brake
@ Brake band @ Rear pinion gear @ Parking pawl
@ Reverse clutch @ Rear internal gear @ Parking gear
@ High clutch @ Rear planetary carrier @ Output shaft
o Front sun gear @ Forward clutch @ Idle gear
@ Front pinion gear @ Forward one-way clutch @ Output gear
FUNCTION OF CLUTCH AND BRAKE

Glutch and brake components Abbr. Function
Reverse clutch RIG To transmit input power to front sun gear
High clutch HIG To transmit input power to front planetary carrier
Forward clutch FIG To connect front planetary carrier with forward one-way clutch
Overrun clutch OIG To connect front planetary carrier with rear internal gear
Brake band BIB To lock front sun gear

When forward clutch is engaged, to stop rear internai gear from rotat-
Forward one-way clutch F/O.G
ing in opposite direction against engine speed
To stop front planetary carrier from rotating in opposite direction

Low one-way clutch LlO.G
against engine speed
Low & reverse brake L & RIB To lock front planetary carrier
AT-14
DESCRIPTION
Shift Mechanism (Cont'd)
OPERATION OF CLUTCH AND BRAKE
Band servo Forward Low Low &
Shift posi- Reverse High Forward Overrun
2nd 3rd 4th one-way one-way reverse Lock-up Remarks
tion clutch clutch clutch clutch
apply release apply clutch clutch brake
P PARK POSITION
REVERSEPOSI-
R 0 0 TION
NEUTRAL POSI-
N
TION
1st 0 '10
• •
D
'4
2nd
3rd 0
0
0
'10
'10
0
'2@ @
•• Automatic shift
1<-->2<-->3<-->4
4th 0 @ '3@ @ 0 0
1st 0 0
• • Automatic shift
•• •
2
1<-->2
2nd 0 0 0
1st 0 0 0 Locks (held sta-
•
1 tionary) in 1st
•
2nd 0 0 0 speed 1 <-- 2
'1 Operates when overdrive switch is sel to "OFF".

'2 Oil pressure is applied to both 2nd "apply" side and 3rd "release" side of band servo piston. However, brake band does not contract
because oil pressure area on the "release" side is greater than that on the "apply" side.
'3 Oil pressure is applied to 4th "apply" side in condition '2 above, and brake band contracts.
'4 AIT will not shift to 4th when overdrive switch is set to "OFF" position.
o Operates.
• Operates. During "progressive" acceleration.

@ Operates but does not affect power transmission.
Control System
CONTROL SYSTEM
Engine
AIT
:
Governor valve 1
1
I
1
'1: Equipped on model
Lock-up cancel 1
1 34X69, 34X70 and 34X80

solenoid'1 I
1 : Electrical signal
1
Overdrive .... : Hydraulic pressure

OD cancel solenoid :
control switch ; I
L J
SAT985HA
AT-15
DESCRIPTION
NOTE
AT-16
TROUBLE DIAGNOSES
Fluid leakage Preliminary Check (Prior to Road Testing)

AIT FLUID CHECK
Fluid leakage check
1. Clean area suspected of leaking, - for example, mating
surface of converter housing and transmission case.
2. Start engine, apply foot brake, place selector lever in "0"
position and wait a few minutes.
3. Stop engine.
4. Check for fresh leakage.
SAT288G
Fluid condition check

Fluid color Suspected problem
Oark or black with burned odor Wear of frictional material
Water contamination
Milky pink - Road water entering through
filler tube or breather
Oxidation
Varnished fluid, light to dark brown
- Over or under filling
and tacky
- Overheating
Fluid level check - Refer to MA section (CHASSIS AND

BODY MAINTENANCE).
Road Testing
Perform road tests using "Symptom" chart. Refer to page
•
AT-20.
"P" POSITION
1. Place selector lever in "P" position and start engine. Stop
engine and repeat the procedure in all positions, including
neutral position.
2. Stop vehicle on a slight upgrade and place selector lever in
"P" position. Release parking brake to make sure vehicle
remains locked.
"R" POSITION
1. Manually move selector lever from "P" to "R", and note
shift quality.
2. Drive vehicle in reverse long enough to detect slippage or
other abnormalities.
"N" POSITION
1. Manually move selector lever from "R" and "0" to "N" and
note shift quality.
2. Release parking brake with selector lever in "N" position.
Lightly depress accelerator pedal to make sure vehicle
does not move. (When vehicle is new or soon after clutches
have been replaced, vehicle may move slightly. This is not
a problem.)
AT-17
TROUBLE DIAGNOSES
Road Testing (Cont'd)
"0" POSITION
1. Manually move selector lever from "N" to "D" position, and
note shift quality.
2. Using the shift schedule as a reference, drive vehicle in "D"
position. Record, on symptom chart, respective vehicle
speeds at which up-shifting and down-shifting occur. These
speeds are to be read at three different throttle positions
(light, half and full), respectively. Also determine the timing
at which shocks are encountered during shifting and which
clutches are engaged.
SAT612GA 3. Determine whether lock-up properly occurs while driving
vehicle in proper gear position and at proper vehicle speed.
4. Check to determine if shifting to overdrive gear cannot be
made while OD control switch is "OFF".
5. Drive vehicle in "D3" position at half to light throttle posi-
tion. Keep driving at 60 to 70 km/h (34 to 43 MPH). FUlly
depress accelerator pedal to make sure transaxle down-
shifts from 3rd to 2nd gear.
6. Drive vehicle in "D2" position at half to light throttle posi-
tion. Keep driving at 25 to 35 km/h (16 to 22 MPH). Fully
depress accelerator pedal to make sure transaxle down-
shifts from 2nd to 1st gear.
SAT497G
"2" POSITION
1. Shift to "2" position and make sure vehicle starts in 1st
gear.
2. Increase vehicle speed to make sure transaxle upshifts from
1st to 2nd gear.
3. Further increase vehicle speed. Make sure transaxle does
not upshift to 3rd gear.
4. Drive vehicle in "22" position at half to light throttle position.
Keep driving at 25 to 35 km/h (16 to 22 MPH). Fully depress
accelerator pedal to make sure transaxle downshifts from
2nd to 1st gear.
5. Allow vehicle to run idle while in "2" position to make sure
that transaxle downshifts to 1st gear.
6. Move selector lever to "D" position and allow vehicle to
operate at 30 to 40 km/h (19 to 25 MPH). Then, shift to "2"
position to make sure transaxle downshifts to 2nd gear.
"1" POSITION
1. Place selector lever in "1" position and accelerate vehicle.
Make sure transaxle does not shift from 1st to 2nd gear
although vehicle speed increases.
2. Drive vehicle in "1" position. Release accelerator pedal to
make sure that engine compression acts as a brake.
3. Place selector lever in "D" or "2" position and allow vehi-
cle to run at 15 to 25 km/h (9 to 16 MPH). Then move selec-
tor lever to "1" position to make sure transaxle downshifts
to 1st gear.
AT-18
TROUBLE DIAGNOSES
SHIFT SCHEDULE
Drive the vehicle for approx. 10 minutes. Measure the oil tem-
perature. When the oil temperature becomes between 50 and
80°C (122 and 176°F), carry out this check.
VEHICLE SPEED WHEN SHIFTING GEARS

Model 34X68
Throttle posi- Vehicle speed km/h (MPH)
tion 0, ~ O2 O2 -> 03 03 -> 04 04 ~ 03 03 -> O2 O2 -> 0, 12 ~ 1,
48 - 56 88 - 96 133 - 141 80 - 88 37 - 45 45 - 53
Full throttle -
(30 - 35) (55 - 60) (83 - 88) (50 - 55) (23 - 28) (28 - 33)
31 - 39 54 - 62 102 - 110 75 - 83 44 - 52 7 - 15 45 - 53
Half throttle
(19 - 24) (34 - 39) (63 - 68) (47 - 52) (27 - 32) (4 - 9) (28 - 33)
Model 34X69 and 34X70

Throttle pasi- Vehicle speed km/h (MPH)
tion 0, ~ O2 O2 ~ 03 03 -> 04 04 ~ 03 03 -> O2 O2 ~ 0, 12 ~ 1,
Full throttle
Half throttle
51 - 60
(32 - 37)
30 - 38
(19 - 24)
94 - 102
(58 - 63)
52 - 60
(32 - 37)
-
97 - 105
(60 - 65)
136 - 144
(85 - 89)
67 - 75
(42 - 47)
85 - 93
(53 - 58)
42 - 50
(26 - 31)
40 - 48
(25 - 30)
8 - 16
(5 - 10)
48 - 56
(30 - 35)
48 - 56
(30 - 35) •
Model 34X80
tion 0, ~ O2 O2 -> 03 03 ~ 04 04 -> 03 03 ~ O2 O2 -> 0, 1" -> 1,
52 - 60 100 - 108 145 - 153 90 - 98 40 - 48 49 - 57

Full throttle -
(32 - 37) (62 - 67) (90 - 95) (56 - 61) (25 - 30) (30 - 35)
30 - 38 53 - 61 103 - 111 69 - 77 42 - 50 8 - 16 49 - 57
Half throttle
(19 - 24) (33 - 38) (64 - 69) (43 - 48) (26 - 31) (5 - 10) (30 - 35)
Model 34X81
tion 0, ~ O2 O2 -> 03 03 ~ 04 04 -> 03 03 -> O2 O2 ~ 0, 12 ~ 1,
58 - 66 107 - 115 160 - 168 96 - 104 39 - 47 48 - 56

Full throttle -
(36 - 41) (66 - 71) (99 - 104) (60 - 65) (24 - 29) (30 - 35)
33 - 41 57 - 65 105 - 113 69 - 77 45 - 53 8 - 16 48 - 56
Half throttle
(21 - 25) (35 - 40) (65 - 70) (43 - 48) (28 - 33) (5 - 10) (30 - 35)
AT-19
TROUBLE DIAGNOSES
ROAD TEST SYMPTOM CHART ~ ON VEHICLE
~
Numbers are arranged in order of probability.
Perform inspections starting with number one
and work up.
Circled numbers indicate that the transaxle Q)
Q)
must be removed from the vehicle. Ol
>
Iii
>
c:
.;: > Q) Iii
> > Q)
~ ';: C Iii
eC >
: Valve expected to be malfunctioning Iii 2 > Iii
::l "lJ
c:
"lJ
Q) Q) ~ >
0"
ro Q) "lJ
B 0
~ 0- ro <.l
~
'0 (/) od
"3 ~
"lJ
Q) .l:l
;: ~ Ol ~ Q)
>
Q)
>
Q)
> Ol
Q)
>
Q)
>
Q)
> .l:l
"lJ
0
c: :0 c: ::l
~ .2
ro ro (/) ;: (/)
Iii Iii co> Iii
>
Iii
>
Iii
> u
E
~ > >
ec s:0
(/)
Q)
<.l
~ ~ ;: ;;: ~
>
Q)
E
Q)
c: 0- ec Q)
E
::l
(/) ~ .c
c:
eQ; ::l
(/)
~e ~e
2 '0, (/) (/) (/) (/)
0 ~ c:
Q)
c: 0 ~ M C)' >
Q)
0 0 .E I- W :::i 0 l- N 0 0:
Sharp shocks in shifting from "N" to "D" position 2 5 3 4 7
When shifting from 1st to 2nd or

2 4 3 6
2nd to 3rd
When shifting from 3rd to 4th 2 4 3 5
When shifting from D to 2 and 1

Shift shocks position.
2 4 3 5
When OD switch is set from
"ON" to "OFF"
When shifting from 2nd to 1st in

2 4 3 5
"1" position
When shifting from 1st to 2nd 2 4 3 5
Shift slippage when upshifting When shifting from 2nd to 3rd 2 4 3 6
When shifting from 3rd to 4th 2 4 3 5
When shifting from 4th to 2nd 2 5 3 6
Shift slippage with accelerator When shifting from 4th to 3rd 2 4 3 6

pedal depressed
When shifting from 4th to 1st
2 5 3 6
and shifting from 3rd to 1st
When vehicle starts 2 4 3 6

Poor power/acceleration
When upshifting 2 4 3 7
When shifting from "D" to "2"

2 4 3 5
and" 1" position
When OD switch is set from

No engine braking 2 4 3 7
"ON" to "OFF"
When shifting from 2nd to 1st in

2 4 3 5
"1" position
Too Iowa gear change point

from 2nd to 3rd and from 3rd to 3 2 6
2nd.
Too high a gear change point

from 2nd to 3rd and from 3rd to 3 2 6
Shift quality 2nd.
Too Iowa gear change point

3 2 6
from 2nd to 1st in "1" position.
Too high a gear change point

3 2 6
from 2nd to 1st in "1" position.
AT-20
TROUBLE DIAGNOSES
... ON VEHICLE .. ... OFF VEHICLE ~
Q)
>
Iii
>
~0 ~
c:::
B
0
Q)
> ~0 E OJ
c:::
Iii
Q)
~ ";:
Q)
>
>
Q)
> '"
.r: '"
nl
Q)
ill "~
.r:
Qi Iii u
Iii Q)
>
Q)
> Q) > .B
~ ~ ~ "0
c::: :; .r:
>
~ Iii ~ Iii Q)
>
Iii Q)
~ "0 U 0 '"
"0
nl U .r: u
:;
tl
c:::
Q) > Q)
> ~ > >
Oi > >
~ 0
c:::
~ ~ D
c::: .r:
(j; >- .B
~ U
Q)
;;::
(; Q)
Iii
Q) Oi Q) nl .B nl c:::
>
'"'"
Q)
'6
c;; > > ~> ~ "2 > Q)
>
Q)
t Z .r: t .r: .r:
~ .r: U Q) 0
'"(; u
"~
0 Iii :; Q) Q) (5 Q)
.B
Q)
.B .B >- ~ 0-
~ "0 1: Oi > (; > ~ :; Q)
~
"2'"
E OJ u Ci nl E
c::: E
>
OJ
c:::
U
c:::
0
0
E
u
"0
0
u
c:::
~ > '"
Qj
c:::
0
~~ ~~
"~ c:::
0 u .r:
.B u
c:::
0 U ~
Q)
>
"0
c::: 0
u
~ ~ c::: ~ u Q)
0- ~
Q)
0 (; (J u
'"c:::0 1:
u 0-
E
Q) ~ "0 "0 c::: Q) ~ nl
.Q
0 (J
"E "0 Q)
~
Q) Q)
0- ~ CT c::: c::: c:::
nl ~
Q)
E E 0 ~
Q)
~ ~ u tii tii ;: c:::
0 o1S
OJ
c:::
"0
(J
nl :;:; ~ ~ ~ Q)
'"
(j; (j; (J ~ ~ E (J 0- Q)
.r: ~ ~ (j; ~
Q)
-'" ~
-'"
(J
'}' '}' ii)
CT
(; .r: '"
.r:
(J
0 N
>
0
>
0 D
CT
(;
(J
(J
(J
(J c::: D
CT
(; >
Q) OJ (; (; >
~
0 0 ~ tii
~ ~ C") ~ l- I- ::<t ..J .} ~ ~ 0 I- <{ <{ E' 0 l- (5 e:: I LL LL 0 ..J ..J lD 0..
6 9 8
5 8 7
I
8 7 6
8 7 6
• 5
7
8
8
7
6
6
•
A
4 7 8 9 10 11 13 14 15 16 17 12
5 7 8 10 11 9
4 7 11 8 10 9
5 9 7 8
5 6 9 8
6 5 8
If 6 7
4 5
4 5
4 5
I[ 4 5
AT-21
TROUBLE DIAGNOSES
Numbers are arranged in order of probability. ~ ON VEHICLE ..
Perform inspections starting with number one
and work up.
Circled numbers indicate that the transaxle
must be removed from the vehicle. (J) (J)
> >
01 0;
c: (J)
0;
. Valve expected to be malfunctioning .;:: >
> > (J)
~
0;
.~ c
(J)
0;
> eC >
0;
::J "0 "0 Q) >
rr c:
III
(J)
(J)
0.
"0
oil
.8III 0
<.>
~
'0 J::. rtl :; J::.
ii
"0
(J) £
.~ ~ 01
c:
~ (J)
>
(J)
>
(J)
>
01
(J)
>
(J)
>
(J)
> £ 0
c:
III
:0
III rtl .~
::J
rtl 0; 0; 0; ~ 0; 0; 0; ::J
(3 E
<.> ~ ~ rtl > > >
~
> > >
~
a; ~ ;: c:
>
~ eC .8
:0 E
(J)
e
(J)
.!::
0.
(J)
ec (J)
E
0
0;
::J
c:
::J
rtl
rtl
J::.
rtl
'E
J::.
rtl
;t:
:c
rtl
2
li;
::J
rtl
rtl
6
0
u
J::.
EO
J::.
~
01
c:
UJ
c:
::i
0
u
.c~ III
::E
(J)
a: "'f
C')
C')
N
C)'
0
>
(J)
a:
Failure to change gear from 4th
to 2nd with accelerator pedal 3 2 6
depressed.
Failure to change gear from 3rd

to 2nd with accelerator pedal 3 2 6
depressed.
Failure to change gear from 1st

3 2 6
to 2nd in "0" and "2" position.
Shift quality Vehicle does not start from

3 2 6
"1st" in "0" and "2" position.
Failure to change gear to 3rd

3 2 6
and 4th in "0" position.
Changes gear to 1st directly

when selector lever is set from 3 2 6
"D" to "1" position.
Changes gear to 2nd in "1"

3 2 6
position.
Lock-up point is extremely high

3 2 6
or low.
Torque converter does not lock-

Lock-up quality 3 2 7
up.
Lock-up is not released when

2
accelerator pedal is released.
Engine does not start in "P" and "N" positions or engine starts
2 3
in positions other than "P" and "N" positions.
Vehicle moves with selector lever in "P" position.
AT-22
TROUBLE DIAGNOSES
Road Testing (Conl'd)
... ON VEHICLE ~ ... OFF VEHICLE ~
QJ
>
OJ
>
"0
.0
...
0
c: (5
QJ QJ Ol
E c:
>
OJ
(5
en
QJ
en ... ..:;
>
QJ
~ .~
QJ
>
OJ QJ
>
~ QJ
> QJ
>
OJ
>
.s::
.B
::l
'"
QJ
~ ~en "0
c:
.s::
.B
::l .s::
> >
... OJ ~ OJ QJ QJ
~ "0 t3 "0
'" t3 .s:: .B .!!l
c:
QJ >
QJ
> ... > > OJ
>
> .0 0
> c: .s:: >- .B ::l
QJ
~ 2 OJ OJ ::l c:
2 Qi Cl
'" .B Qi ::l t3 c:
"0
0
.8
~
QJ
>
OJ
OJ
> Qi
>
~
"0
>
"5
e1: >
QJ
en
en
QJ
QJ
>
OJ
~0
en
Qi
>
en
0
Z
0
.s::
.B
.~
en
t
QJ
>
.s::
.B
.s::
.B
'"d>
:;: .s::
.B
t3
>-
QJ
~
0
0.
E
E > Ol ()
0. ::l ::l c: ::l
'"
c: c: .~
e1: c: QJ "0
0 ()
::l c: c: > .s:: :;:
.0
0
Q) 0 1ii 1ii 0 u t3 0 t3 > c: 0
c:
:;:
E
::l
Ol
.~ ::l
0
()
E
QJ
"0
QJ
()
0.
QJ
::l 0c: ac: ()
c:
()
::l ::l
en
c:
() 0.
E
QJ
en
.B
::l "0 "0 c: d> ~ <tl
.0
()
0 ()
E "0 QJ
E
QJ
l'
0- QJ
E E 0
QJ
t3 :a :a:;: t
c: Ol
c:
'"
QJ 0 0 o(l
"0
()
<tl :;:; ~ ::l 0.
en en Qi Qi ()
::l
::l E
::l ::l
Qi QJ
:;:
~
()
-" ::l 0- 0. .s:: :;: :;: -"
-" 2" 2 > > 2" () () > QJ
:a
m'"
()
()
'}' '}' u; 0 .s:: .s:: 0 N 0 0 Cl 0 () () c: Cl 0 QJ Ol
0 0 > 0 0
~ C') ~ f- f- ::; ..J ..,;. Cl Cl 0 f- <{ <{ ~ 0 f- <5 a: I u.. u.. 0 ..J ..J 0-
4 5
4 5
4 5
•
4 5
4 5 7 8
4 5
4 5
4 5
4 5 6 8
rr 3
1
4
AT-23
TROUBLE DIAGNOSES
Stall Tasting
STALL TEST PROCEDURE
1. Check AIT and engine fluid levels. If necessary, add fluid.
2. Drive vehicle for about 10 minutes until engine oil and ATF
reach operating temperature.
ATF operating temperature:
50 - 80 0
e
(122 - 176°F)
SAT6478
3. Set parking brake and block wheels.

4. Install a tachometer where it can be seen by driver during
test.
SAT513G
5. Start engine, apply foot brake, and place selector lever in

"0" position.
~ ~ID
~c;>
•
SAT7678
6. Accelerate to wide-open throttle gradually while applying

foot brake.
7. Quickly note the engine stall revolution and immediately
release throttle.
• During test, never hold throttle wide-open for more than 5
seconds.
Stall revolution .standard:
Refer to SDS, AT-166.
SAT514G
8. Move selector lever to "N" position.

9. Cool off ATF.
• Run engine at idle for at least one minute.
10. Repeat steps 5 through 9 with selector lever in "2", "1" and
n
"R positions.
SAT7718
AT-24
TROUBLE DIAGNOSES
Stall Tasting (Cont'd)
JUDGEMENT OF STALL TEST
Selector lever position Judgement
D H o L
o : Stall revolution is normal.
2 H o L H : Stall revolution is higher
than specified.
H o L
L : Stall revolution is lower
R o H L than specified.
Damaged components
Forward one-way
cluth
Engine
Torque converter
one-way clutch
•
Reverse clutch
Hydraulic circuit for

line pressure control Low one-way clutch
(Line pressure is low.)
Clutches and brakes except

high clutch, brake band and
D H o overrun clutch are OK.
2 H o (Condition of high clutch,
brake band and overrun
H o clutch cannot be confirmed by
R H o stall test.)
Selector lever position Judgement
SAT871H
AT-25
TROUBLE DIAGNOSES
Pressure Testing
• Location of pressure test port.
• Always replace pressure plugs as they are self-sealing
bolts.
governor pressure
Test port for
line pressure SAT565D
LINE PRESSURE TEST PROCEDURE

1. Check AfT and engine fluid levels. If necessary, add fluid.
2. Drive vehicle for about 10 minutes until engine oil and ATF
50 - 80°C (122 - 176°F)
SAT647B
3. Install pressure gauge to line pressure port.
4. Set parking brake and block wheels.

Continue to depress brake pedal fully while performing line
pressure test at stall speed.
SAT513G
5. Start engine and measure line pressure at idle and stall

speed.
Line pressure:
Refer to SOS, AT-166.
JUDGEMENT OF LINE PRESSURE TEST

• If line pressure does not rise, first check to make sure that
throttle wire is connected properly.
1) When line pressure while idling is low at all positions ("D",
"2", "1", "R" and "P"), the problem may be due to:
SAT494G • Wear on interior of oil pump
AT-26
TROUBLE DIAGNOSES
Pressure Testing (Cont'd)
• Oil leakage at or around oil pump, control valve body, trans-
mission case or governor
• Sticking pressure regulator valve
• Sticking pressure modifier valve
2) When line pressure while idling is low at a particular
position, check the following.
• If oil leaks at or around low & reverse brake circuit, line
pressure becomes low in "R" position. But line pressure is
normal in "P", "D", "2" or "1" position.
3) When line pressure is high while idling, pressure regulator
valve may have stuck.
GOVERNOR PRESSURE TESTING

1. Check AIT and engine fluid levels. If necessary, add fluid.
2.. Drive vehicle for about 10 minutes until engine oil and ATF
50 - 80°C (122 - 176°F)
'-)
~)o
( 3. Install pressure gauge to governor pressure port.
•
Front
4. Set parking brake and block rear wheels.

5. Jack up front wheels.
6. Set selector lever in D position and drive vehicle.
Be careful of rotating wheels.
SAT498G
Governor pressure:
• Governor pressure is not generated when vehicle is
stopped. (front wheels are not rotating.)
• Governor pressure rises gradually in response to vehicle
speed. (front wheel rotating speed.)
If not, check governor valve assembly. Refer to AT-36.
AT-27
TROUBLE DIAGNOSES
Wiring Diagram - AT -
AT-A/T-01
(b): LHD models
 : RHO models
@: For Europe and Israel
FUSE @: Except@
(J!B) @: GA engine
([@ @: SR engine
(El06)
l---t~'~
Y ~Next page
I
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AT-28
TROUBLE DIAGNOSES
Wiring Diagram - AT - (Coni' d)
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HAT002
AT-29
TROUBLE DIAGNOSES
Electrical Components Inspection

OVERDRIVE CONTROL SWITCH
• Check continuity between two terminals.
00 switch position Continuity
ON No
OFF Yes
SAT0761
INHIBITOR SWITCH
• Check continuity in "N", "P" and "R" positions.
• With manual shaft held in "N" position, turn manual shaft an
equal amount in both directions to see if current flow posi-
tions are nearly the same. (When manual lever is in each
position, continuity normally exists within 1S in either
direction.) If current flows outside normal position, or if nor-
mal flow position is out of specifications, properly adjust
inhibitor switch.
Position Terminal No. Continuity
SAT0771
Park/neutral position @-@ No
Reverse position @-@ Yes
Model 34X68 00 CANCEL SOLENOID VALVE AND TORQUE

CONVERTER CLUTCH SOLENOID VALVE
• Check resistance between terminals.
Solenoids Terminal No. Resistance
00 cancel solenoid
valve
@-@
Approximately 250
Torque converter
CIJ-@
SAT0781
Model 34X69, 34X70, 34X80, 34X81
~i5
Gltm
~
SAT948HA
AT-30
ON-VEHICLE SERVICE
Control Valve Assembly and Accumulator

REMOVAL
1. Drain ATF from transaxle.
2. Remove oil pan and gasket.
3. Disconnect AfT solenoid harness connector.
SAT494HB
4. Remove stopper ring from AfT solenoid harness terminal

Model
34X68 body.
5. Pull out AfT solenoid harness from transmission case by
pushing terminal body.
AT-31
ON-VEHICLE SERVICE
Control Valve Assembly and Accumulator
(Cont'd)
SAT496HB
6. Remove control valve assembly by removing fixing bolts.

Bolt length, number and location:
Bolt symbol @ @ CID @
Bolt length" C"
25.0 33.0 40.0 43.5
~Q (0.984) (1.299) (1.575) (1.713)

mm (in)
Number of bolts 2 6 5 2
Tightening torque
7 - 9 (0.7 - 0.9, 61 - 78)
N'm (kg-m, in-Ib)
• Be careful not to drop manual valve, tube connector, tubes

and 3.R accumulator return spring.
7. Disassemble and inspect control valve assembly if neces-
sary - Refer to "REPAIR FOR COMPONENT PARTS",
AT-74.
SAT700D
8. Remove 3-R and N-D accumulators by applying compressed

air if necessary.
• Hold each piston with a rag.
INSTALLATION
• Set manual shaft in Neutral position, then align manual
plate with groove in manual valve.
• After installing control valve assembly, make sure that
selector lever can be moved to all positions.
SAT497H
AT-32
ON-VEHICLE SERVICE
Throttle Wire Adjustment
SEC. 319
Model 34X68, 34X69 Model 34X70
AIT throttle wire bracket
•
Front
AIT throttle wire assembly
Model 34X81 Model 34X80
Intake manifold support bracket
NT throttle wire bracket
Throttle drum
Front
AIT throttle wire assembly
(0.45 - 0.59,
39.1 - 51.2)
iii : N.m (kg-m, in-Ib)
SAT0791
AT-33
ON-VEHICLE SERVICE
Throttle Wire Adjustment (Cont'd)
1. Turn ignition switch to OFF.
p, (Full throttle position) 2. While pressing lock plate, move adjusting tube in direction
ThrOttle drum "T" (Transaxle side).
Direction U 3. Return lock plate.
, ,-- p, t (Adjusting tube is locked at this time.)
~ I ~. (Idling 4. Move throttle drum from "P2" to "P1" quickly. Adjusting
--r ~_.) position) I tube moves in direction "U" (Engine side) while depressing
the lock plate. Ensure that throttle wire stroke "L" is within
Direction T
the specified range, between full throttle and idle.
(at P,)
Throttle wire stroke "L":
40 - 42 mm (1.57 - 1.65 in)
(at P,) • Adjust throttle wire stroke after accelerator wire is installed
and adjusted.
• When connecting throttle wire to throttle drum, do not use
Engine side" ~ Adjusting tube
bracket
tools. Manually hook it.
Lock plate • Put mark on throttle wire to facilitate measuring wire stroke.
5. Clamp throttle wire at proper positions shown in the illus-
tration after adjusting throttle wire.
6. After properly adjusting and clamping throttle wire, ensure
the parting line is as straight as possible.
SAT551D
If throttle wire stroke is improperly adjusted the following prob-

4/4
lems may arise.
'//
/
0>
c:
---------1-- ,/ I
• "P1" is the throttle drum fully-open position. When "P1" is
too far in direction "T", the shift schedule will be @ in the
C I
Q)
0-
o
Normal : figure. And the kickdown range will greatly increase.
,- .J
r-/ • When "P1" is too far in direction "U", the shift schedule will
~ I ,/
2 I / be CD in the figure. And the kickdown will not occur.
£
I-
,,~/~
o
Vehicle speed
SAT669H
AT-34
ON-VEHICLE SERVICE
Control Cable Installation and Adjustment

• Move selector lever from the "P" range to the "1" range.
You should be able to feel the detents in each range.
• The control cable needs adjustment in the following cases:
1) When the detents cannot be felt;
2) When the pointer indicating the range is improperly
aligned.
• Always adjust control cable when it is removed from selec-
tor lever or manual shaft.
SEC. 349
Front <;:::J Selector lever assembly
~ 4.4 - 5.9 (0.45 - 0.60, 39.1 - 52.1) Transax1,e

~ 4.4 • 5.9 (0.45 - 0.60, 39.1 - 52.1)
•
Cable bracket
•
~4.4 - 5.9
(0.45 • 0.60. 'I
39.1 - 52.1)
Floor panel
~ 17.5 - 23.7 (1.8 • 2.4, 13 • 17)
Sub frame \.~ 4.4 - 5.9 (0.45 • 0.60. 39.1 - 52.1)
AIT control cable assembly ~ : N.m (kg-m, in-Ib)

SAT499HA
INSTALLATION
-{' .~ 1. Place selector lever and manual shaft at "P" position.
did Selector lever 2. Connect control cable to selector lever and tighten control
I'y- Clamp ,I .
\ '4'i"" \ .,)
'OJ} "
I ,i cable lock nut. Clamp control cable to selector lever

Selector lever bracket \Vu 7/ / bracket.
( ( . tll@:::(-c/",/.I
; '''J)!I'r. cY'?1I /'
j \\-.. ) ~j '.-It
p
A( i t:J- .,'-' ,
D
t;-\ 'II/.f Lock nut ~i'.--- l~}-

'.~/;,J~
'j (,k;;. l~\.\:\ eee:::
I'
u IControl cable
/,<\,:.~ 4.4 • 5.9 N.m .. "

- (0.45 - 0.6 kg-m,
'~-39.1 - 52.1 in-Ib)
SAT230EA
AT-35
ON-VEHICLE SERVICE
Control Cable Installation and Adjustment
(Cont'd)
3. Connect control cable to manual shaft and clamp control
cable to bracket at transaxle.
4. Pull control cable in the direction of the arrow shown in the
illustration by specified force.
Specified force: 6.9 N (0.7 kg, 1.5 Ib)
5. Return control cable in the opposite direction of the arrow
for 1.0 mm (0.039 in).
6. Tighten control cable lock nut.
7, Move selector lever from "P" position to "1" position. Make
sure that selector lever can be moved smoothly without any
sliding noise.
8. Apply grease to contacting areas of selector lever and con-
trol cable. Install any part removed.
SAT576E
ADJUSTMENT
1. Loosen control cable lock nut at transaxle side.
2. Place selector lever and manual shaft at "P" position.
3. Pull control cable in the direction of the arrow shown in the
illustration by specified force.
Specified force: 6.9 N (0.7 kg, 1.5 Ib)
4. Return control cable in the opposite direction of the arrow
for 1.0 mm (0.039 in).
5. Tighten control cable lock nut.
6. Move selector lever from "P" position to "1" position. Make
sure that selector lever can be moved smoothly without any
sliding noise.
7. Apply grease to contacting areas of selector lever and con-
trol cable.
SAT577E
Governor Valve
1. Remove air duct.
2. Remove governor cap snap ring.
3, Remove governor cap,
AT-36
ON-VEHICLE SERVICE
Governor Valve (Cont'd)
4. Remove governor valve assembly from transaxle.
5. Check governor valve assembly if necessary - Refer to
"DISASSEMBLY", AT-65.
Inhibitor Switch Adjustment

1. Remove control cable end from manual shaft.
2. Set manual shaft in "N" position.
3." Loosen inhibitor switch fixing bolts.
4. Use a 4 mm (0.16 in) pin for this adjustment. •

a. Insert the pin straight into the manual shaft adjustment hole.
b. Rotate inhibitor switch until the pin can also be inserted
straight into hole in inhibitor switch.
5. Tighten inhibitor switch fixing bolts.
6. Remove pin from adjustment hole after adjusting inhibitor
switch.
7. Reinstall any part removed.
8. Adjust control cable - Refer to "Control Cable Installation
and Adjustment", AT-35.
SAT580E 9. Check continuity of inhibitor switch - Refer to "Electrical
Components Inspection", AT-30.
Differential Side Oil Seal Replacement

1. Remove drive shaft assemblies. - Refer to FA section
("Removal", "FRONT AXLE - Drive Shaft").
2. Remove oil seals.
AT-37
ON-VEHICLE SERVICE
Differential Side Oil Seal Replacement (Cont'd)
3. Install oil seals.
• Apply ATF to oil seal surface before installing.
Converter housing side (RHS)
Transmission case side (LHS)
SAT259EA
Transmission Converter housing • Install oil seals so that dimensions "A" and "8" are within
case side side specifications.
B
Unit: mm (in)
A B
Oil 5.5 - 6.5 (0.217 - 0.256) 0.5 (0.020) or less

Oil seal
seal
4. Reinstall any part removed.

A
SAT639D
AT-38
Removal
• Remove battery and bracket.
• Remove air duct.
• Disconnect AIT solenoid harness connector, inhibitor switch
harness connector and speedometer pinion harness con-
nector.
• Disconnect throttle wire at engine side.
• Drain ATF.
• Remove undercover and side cover.
• Disconnect control cable from transaxle.
• Disconnect oil cooler hoses.
• Remove drive shafts - Refer to FA section ("Removal", •

• Remove exhaust front tube.
• Remove starter motor from transaxle.
• Remove front and rear gussets and engine rear plate.

• Remove bolts securing torque converter to drive plate.
Rotate crankshaft for access to securing bolts.
• Support engine by placing a jack under oil pan.
Do not place jack under oil pan drain plug.
• Support transaxle with a jack.

• Remove LH and rear mountings from transaxle.
• Remove bolts fixing AIT to engine.
• Lower transaxle while supporting it with a jack.
AT-39
Installation
• Drive plate runout
Maximum allowable runout:
Refer to EM section ("Inspection", "CYLINDER
BLOCK").
If this runout is out of allowance, replace drive plate with
ring gear.
SAT037C
• When connecting torque converter to transaxle, measure

distance "A" to be certain that they are correctly assem-
bled.
Distance "A":
Except model 34X81
21.1 mm (0.831 in) or more
Model 34X81
15.9 mm (0.626 in) or more
SAT573D
• Install converter to drive plate.

• With converter installed, rotate crankshaft several turns to
check that transaxle rotates freely without binding.
o AIT to engine • Tighten bolts fixing transaxle

o Engine (gusset) GA engine models
to AIT
Bolt No.
Tightening torque Bolt length "e"
N.m (kg-m, ft-Ib) mm (in)
G) 30 - 40 (3.1 - 4.1,22 - 30) 50 (1.97)
@ .30 - 40 (3.1 - 4.1, 22 - 30) 30 (1.18)
@ 16 - 21 (1.6 - 2.1,12 - 15) 25 (0.98)
Front gusset to
30 - 40 (3.1 - 4.1,22 - 30) 20 (0.79)
engine
Rear gusset to
16 - 21 (1.6 - 2.1,12 - 15) 16 (0.63)
engine
AT-40
<!) AIT to engine SR engine models
@ Engine to Tightening torque Bolt length 'T'
AIT Bolt No.
N'm (kg-m, ft-Ib) mm (in)
CD 70 - 79 (7.1 - 8.1,51 - 59) 55 (2.17)
@ 70 - 79 (7.1 - 8.1, 51 - 59) 50 (1.97)
@ 70 - 79 (7.1 - 8.1,51 - 59) 65 (2.56)
@ 30 - 40 (3.1 - 4.1, 22 - 30) 25 (0.98)
@ 30 - 40 (3.1 - 4.1, 22 - 30) 40 (1.57)

SAT558DA
• Reinstall any part removed.

• Adjust throttle wire and control cable. Refer to "ON-VEHI-
CLE SERVICE", AT-33, 35.
•. Check inhibitor switch. Refer to "Electrical Components
Inspection", AT-3D.
• Refill transaxle with ATF and check fluid level, AT-17.
• Move selector lever through all positions to be sure that
transaxle operates correctly. With parking brake applied,
idle engine. More selector lever through "N" to "D", to "2",
to "1" and "R". A slight shock should be felt through the
SAT638A hand gripping the selector each time the transaxle is
shifted. •
• Perform road test - Refer to "ROAD TESTING", AT-17. i
AT-41
All Models
>-
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en
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0.
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0.
~
E
:cen
Cl
c
en::>
'0
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Cl
c
.~
Ql
.0
Ql
"0
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.0
.a
Cl
c
"in
::>
o
.c
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ill
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ill
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:!.
01
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Ql
Cl
Ql
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CI.i
SAT1991
AT-42
SEC. 315
"Q)
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Qi.x
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Q) Q)
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LL::.O
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««en
SAT932HA
AT-43
MAJOR OVERHAUL
Except Model 34X81
~ :0-
.~ .:::
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Ol
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E E
z z
~~
...ai
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co
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COO
ai.
o
e
SAT2001
AT-44
•
II)
(')
:; 0
c
....
13 (')
3~
SAT2011
AT-45
MAJOR OVERHAUL
SEC. 349 ~ 4.4 • 5.9 (0.45 • 0.6, 39.1 • 52.1)
p m
I
Return spring
'''''-y. "'.,,',,"
Control cable clamp~
". '\ Selector lever rror.;
NT "01co, "II" • S""", ,,," k,o'

'
\ -~~
Position indicator
Control lever assemblY~
~11.8 • 14.7
(1.20 - 1.50, 8.76 • 10.84)
~ 4.4 - 5.9
(0.45 • 0.6, 39.1 - 52.1) ~ : N'm (kg-m. in-Ib)
Dust cover ~ : N'm (kg-m, tt-Ib) SATOBOI
AT-46
MAJOR OVERHAUL
Oil Channel
Torque converter pressure

High clutch pressure (Lock-up released)
SIR accumulator shoulder pressure
SIR accumulator back pressure
Torque converter pressure (Reverse clutch pressure)
Reverse clutch Reverse clutch
(Lock-up released)
pressure pressure
Oil pump suction hole
Differential lubricant hole
Oil cooler tube (IN)
Torque converter pressure
(Lock-up applied)
" Servo 4th apply chamber pressure
Servo 2nd apply chamber pressure
• Servo 3rd release

chamber pressure
Oil pump discharge hole
Torque converter
pressure
(Lock-up applied) High clutch pressure
Low & reverse brake pressure
Overrun clutch pressure
Forward clutch pressure
•
Forward clutch pressure Oil cooler tube (OUT) hole
Overrun clutch pressure
Low & reverse brake
Torque converter
pressure
pressure
(Lock-up applied)
Torque converter
pressure
(Lock-up released)
High clutch pressure

Oil pump discharge hole
Reverse clutch
pressure
Oil cooler tube (IN) hole
Governor pressure Line pressure
SAT586DC
AT-47
MAJOR OVERHAUL
Locations of Adjusting Shims, Needle Bearings,

Thrust Washers and Snap Rings - Except
Model 34X81
Outer diameter and color of thrust washers Outer and inner diameter of needle bearings
Item number Outer diameter mm (inl Color Outer diameter Inner diameter
Item number
mm(in) mm(in)
@ 72.012.8351
black 47.0 (1.8501 32.0 (1.2601
@ 78.5 13.091)
35011.3781 20.1 10.7911
60.012.3621 42.00.6541
60.0 (2.362) 45.011.7721
47.011.850) 30011.1811
42.6 0.677) 26.1 0.0281
48.0 (1890) 33.511.319)
54.0 121261 40.1 11.5791
Outer & inner diameter of bearing races, adjusting shims and

adjusting spacer
Outer diameter Inner diameter
Outer diameter of snap rings
Item number
mm linl mm (in) Item number Outer diameter mm lin)
@ 48.00.8901 33.0 (1.299)

Q. 142.0 (5.591
@ 29.0 11.1421 25.0 (0.9841
CV 113.0 (4.451
@ 34.5 (358) 26.1 11.0281 @ 162.4 (6391
@ 79.5 13.1301 72.012.835) @ 135.4 15.331
~ 55.012.165) 42.0 (1.654)

CID 126.0 (4.961
*: Select proper thickness. @ 161.5 16.361

SAT510H
AT-48
MAJOR OVERHAUL
Locations of Adjusting Shims, Needle Bearings,

Thrust Washers and Snap Rings - Model 34X81
Outer diameter and color of thrust washers Outer & inner diameter of needle bearings
Outer diameter Outer diameter Inner diameter

Item number Color Item number
mm (in) mm (in) mm (in)
@ 72.0 (2.835) 47.0 (1.850) 32.0 (1.260)
Black
@ 78.5 (3.091) 35.0 (1.378) 20.0 (0.787)
60.0 (2.362) 42.0 (1.654)
60.0 (2.362) 45.0 (1.772)
47.0 (1.850) 30.0 (1.181)
42.6 (1.677) 26.1 (1.028)

48.0 (1.890) 33.5 (1.319)
55.0 (2.165) 40.5 (1.594)
60.0 (2.362) 40.1 (1.579)
Outer diameter of snap rings

Item number Outer diameter mm (in)
Outer & inner diameter of bearing race and adjusting shims CD 142.0 (5.59)
ClJ 113.0 (4.45)

Outer diameter Inner diameter
Item number
mm (in) mm (in) 0 162.4 (6.39)
@ 48.0 (1.890) 33.0 (1.299) 0 135.4 (5.33)
@ 72.0 (2.835) 61.0 (2.402) ~ 161.5 (6.36)
@ 34.5 (1358) 26.1 (1.028) @ 126.0 (4.96)

@ 68.0 (2.677) 60.0 (2.362) (j) 40.5 (1.594)
SAT106EC
AT-49
DISASSEMBL Y
1. Drain ATF through drain plug.
J!in plug
SAT007D
2. Remove torque converter.
3. Check torque converter one-way clutch using check tool as

shown at left.
/
~:e2
I ;,cr~~ar~ /
/
a. Insert check tool into the groove of bearing support built into
one-way clutch outer race.
b. While fixing bearing support with check tool, rotate one-way
clutch spline using flat-bladed screwdriver.
c. Check inner race rotates clockwise only. If not, replace
torque converter assembly.
- ~ /
Bend a wire and use
it as a check tool .
.----:-
Approx. 3.0 (0.118)
[Bend a 1.5 (0.059) die ..
g
.... wire In hall.]
2
.. Outer race
:
Approx.
15 (0.59)
One-way clutch
Unit: mm (in)
SAT009D
4. Remove oil charging pipe and oil cooler tube.
SAT586H
AT-50
DISASSEMBL Y
5. Set manual shaft to "P" position.

6. Remove inhibitor switch.
SAT620E
7. Remove oil pan and oil pan gasket.

• Do not reuse oil pan bolts.
8. Check foreign materials in oil pan to help determine cause •

of malfunction. If the fluid is very dark, smells burned, or
Waste
contains foreign particles, the frictional material (clutches,
material
band) may need replacement. A tacky film that will not wipe
clean indicates varnish build up. Varnish can cause valves,
servo and clutches to stick and can inhibit pump pressure.
• If frictional material is detected, replace radiator after repair
of AlT. Refer to LC section ("Radiator", "ENGINE COOLING
SYSTEM").
Oil pan
SAT013D
9. Remove control valve assembly according to the following

procedures.
a. Remove control valve assembly mounting bolts @, CID, @
and @.
SAT711D
AT-51
DISASSEMBL Y
Model b. Remove stopper ring from terminal body.

34X68
c. Push terminal body into transmission case and draw out

solenoid harness.
SAT496HB
10. Remove manual valve from control valve assembly.
SAT0170
11. Remove return spring from SIR accumulator piston.
12. Remove SIR accumulator piston with compressed air.

13. Remove O-rings from SIR accumulator piston.
AT-52
DISASSEMBL Y
14. Remove N-D accumulator piston and return spring with

compressed air.
15. Remove O-rings from N-D accumulator piston.
('l:,~~ 16. Check accumulator pistons and contact surface of transmis-

sion case for damage.
o \~A~~l 17. Check accumulator return springs for damage and free
u~!~~:
. length.
Unit: mm (in)
o
Contact 0 9&k .~ Spring
SIR accumulator spring

Free length
56.4 (2.220)
Outer diameter
21.0 (0.827)
'"~~~~~)(?~~
SIR accumulator piston ~. /
N-D accumulator spring 43.5 (1.713) 28.0 (1.102)
SAT023DB
18. Remove lip seals from band servo oil port.
•
SAT129E
19. Remove oil filter for governor.
20. Check oil filter for governor for damage or clogging.
SAT024D
AT-53
DISASSEMBL V
21. Remove throttle wire from throttle lever.
22. Remove throttle wire mounting bolt.

23. Draw out throttle wire from transmission case.
- All models -
24. Remove converter housing according to the following pro-
cedures.
a. Remove converter housing mounting bolts @ and CID.
b. Remove converter housing.
c. Remove O-ring from differential oil port.
AT-54
DISASSEMBL V
25. Remove final drive assembly from transmission case.

• If it is difficult to lift up by hand, tap final drive slightly with
a soft hammer (Except model 34X81).
SAT030D
26. Remove differential side bearing outer race from transmis-

sion case (Model 34X81).
27. Remove differential side bearing adjusting shim from trans- •

mission case.
SAT132E
28. Remove differential side bearing outer race from converter

KV381054S0 housing (Model 34X81).
SAT840DB
29. Remove oil seal from converter housing using a screw-

driver.
• Be careful not to damage case.
SAT133E
AT-55
DISASSEMBL Y
30. Remove side oil seal from transmission case using a screw-
driver.
31. Remove oil tube from converter housing.
SAT134E
32. Remove oil pump according to the following procedures.

a. Remove O-ring from input shaft.
b. Remove oil pump assembly from transmission case.
c. Remove thrust washer and bearing race from oil pump

assembly.
AT-56
DISASSEMBLY
33. Remove brake band according to the following procedures.

a. Loosen lock nut, then back off anchor end pin.
• Do not reuse anchor end pin.
b. Remove brake band from transmission case.
l~~
• To prevent brake linings from cracking or peeling, do not •
stretch the flexible band unnecessarily. When removing the i
brake band, always secure it with a clip as shown in the

figure at left.
Leave the clip in position after removing the brake band .
. _~
Unit: mm (in)
SAT039D
c. Check brake band facing for damage, cracks, wear or burns.
34. Remove input shaft assembly (high clutch) and reverse

clutch according to the following procedures.
a. Remove input shaft assembly (high clutch) with reverse
clutch.
AT-57
DISASSEMBl Y
b. Remove input shaft assembly (high clutch) from reverse

clutch.
SAT042D
c. Remove needle bearing from high clutch drum.

Needle bearing ~ d. Check input shaft assembly and needle bearing for damage
... or wear.
High clutch
SAT043D
35. Remove high clutch hub and needle bearing from transmis-
sion case.
36. Check high clutch hub and needle bearing for damage or
wear.
37. Remove front sun gear and needle bearings from transmis-
Front
sun gear sion case.
38. Check front sun gear and needle bearings for damage or
wear.
39. Remove front planetary carrier assembly and low one-way

clutch according to the following procedures.
a. Remove snap ring using a screwdriver.
AT-58
DISASSEMBLY
b. Remove front planetary carrier with low one-way clutch.
c. Check that low one-way clutch rotates in the direction of the

arrow and locks in the opposite direction.
d. Remove low one-way clutch from front planetary carrier by
rotating it in the direction of unlock.
Front planetary carrier

e. Remove needle bearing from front planetary carrier.
•
SAT049D
f. Check front planetary carrier, low one-way clutch and nee-

dle bearing for damage or wear.
g. Check clearance between pinion washer and planetary car-
rier using feeler gauge.
Standard clearance:
0.15 - 0.70 mm (0.0059 - 0.0276 in)
Replace if the clearance exceeds 0.80 mm (0.0315 in).
40. Remove rear planetary carrier assembly and rear sun gear
according to the following procedures.
a. Remove rear planetary carrier assembly from transmission
case.
AT-59
DISASSEMBL Y
b. Remove rear sun gear from rear planetary carrier.
c. Remove needle bearings from rear planetary carrier

assembly.
~ Needle bearing
SAT053D
Clearance d. Check rear planetary carrier, rear sun gear and needle
bearings for damage or wear.
tarn: e. Check clearance between pinion washer and rear planetary

carrier using feeler gauge.
Standard clearance:
0.15 .0.70 mm (0.0059 . 0.0276 in)
Replace if the clearance exceeds 0.80 mm (0.0315 in).
SAT054D
41. Remove rear internal gear from transmission case.
Rear internal
gear
42. Remove needle bearing from rear internal gear.

43. Check needle bearing for damage or wear.
~ N."",.."I",
I
Rear internal gear
SAT056D
AT-50
DISASSEMBL V
44. Remove forward clutch assembly from transmission case.
45. Remove thrust washer and bearing race from transmission

case.
- All models - •
46. Remove return spring from parking shaft using a screw- i
driver.
Parking shaft
SAT064D
- Except model 34X81 -

47. Remove output shaft, output gear and reduction pinion gear
according to the following procedures.
a. Remove side cover.
• Do not reuse side cover bolts.
SAT702D
b. Set manual lever to "p" position to fix idler gear and out-
put gear.
c. Unlock both idler gear and output gear lock nuts using a pin
punch.
AT-61
DISASSEMBL V
d. Remove idler gear and output gear lock nuts.

• Do not reuse idler gear and output gear lock nuts.
SAT704D
e. Remove idler gear and output gear using a puller.
f. Remove reduction pinion gear and output shaft.

g. Remove adjusting shim from reduction pinion gear.
h. Remove adjusting spacer from output shaft.
Reduction
pinion gear
SAT706DA
- Model 34X81 -
47. Remove output shaft assembly according to the following
procedures.
a. Remove side cover bolts.
b. Remove side cover by lightly tapping it with a soft hammer.

• Be careful output shaft assembly does not drop out when
removing cover.
AT-62
DISASSEMBL Y
c. Remove adjusting shim.
d. Remove output shaft assembly.
SAT439D
• If output shaft assembly is still attached to side cover, sep-

arate the two by tapping cover with a soft hammer.
•
SAT435D
e. Remove needle bearing.
48. Disassemble reduction pinion gear according to the follow-

ing procedures.
a. Set manual shaft to position "P" to fix idler gear.
b. Unlock idler gear lock nut using a pin punch.
AT-53
DISASSEMBL V
c. Remove idler gear lock nut.

• Do not reuse idler gear lock nut.
SAT061D
d. Remove idler gear with puller.
ST27180001
--"" SAT841DA
e. Remove reduction pinion gear.

f. Remove adjusting shim from reduction pinion gear.
SAT310G
- All models -
49. Draw out parking shaft and remove parking pole from trans-
mission case.
50. Check parking pole and shaft for damage or wear.
SAT065D
51. Remove parking actuator support from transmission case.

"(
~~~
~,O
0
Eh~ ~
-vf~SD\O
52. Check parking actuator support for damage or wear.
II ~ \~~--'-:c
,L.J,,=-.... ~_ CH\ 0\)
o 0 0 _ 0
Parking actuator~\ \
support C':l C':l
I-i
~~
SAT066D
AT-64
DISASSEMBL Y
53. Remove governor valve assembly according to the follow-

ing procedures.
a. Remove snap ring using a screwdriver.
b. Remove governor cap using water pump pliers.

c. Remove a-ring from governor cap.
d. Remove governor valve assembly.
•
SAT070D
e. With low primary weight closed, place top of governor valve

LOW secondary weight assembly down to make sure governor valve properly low-
Low primary weight ers under its own weight.
Governor valve
f. Place top of governor assembly down. Operate both low and
\ high secondary weights to make sure governor valve func-
tions properly.
High primary weight

High secondary weight
SAT071D
54. Remove side oil seal from transmission case using a screw-
driver.
• Be careful not to damage case.
AT-55
Manual Shaft and Throttle Lever

SEC. 319 ~ 6.4 • 7.5 N.m
Retaining pm ~~ (0.65 - 0.76 kg-m. "-
Throttle shaft ~ 56.4 - 66.0 In-Ib) f
~ 0."" ''''0'''11)
Th""'. ,,~,/ , V
~ Return spnng
~ Retaining pin ~
c&D: Apply ATF.

SAT109EB
REMOVAL
1. Remove detent spring from transmission case.
2. Pullout throttle shaft retaining pin, then draw out throttle

shaft from transmission case.
3. Drive out manual plate retaining pin.
AT-66
Manual Shaft and Throttle Lever (ConI' d)
4. Drive and then pull out parking rod plate retaining pin.
5. Remove parking rod plate from manual shaft.

6. Draw out parking rod from transmission case.
7. Pull out manual shaft retaining pin. •

8. Remove manual shaft and manual plate from transmission i
case.
9. Remove manual shaft oil seal.
SATOBOD
INSPECTION
• Check component parts for wear or damage. Replace if
necessary.
AT-67
Manual Shaft and Throttle Lever (Cont'd)
INSlALLA liON
1. Install manual shaft oil seal.
• Apply ATF to outer surface of oil seal.
2. Install throttle lever and return spring on throttle shaft.

3. Install throttle lever assembly on transmission case.
4. Align groove of throttle shaft and hole of transmission case.

5. Install throttle shaft retaining pin.
6. Move throttle lever in the direction of the arrow.

7. Install manual shaft and manual plate.
8. Align groove of manual shaft and hole of transmission case.

9. Install manual shaft retaining pin.
AT-68
Manual Shaft and Throttle Lever (Co nt' d)
10. Install parking rod to parking rod plate.
Parking rod plate
11. Install parking rod assembly to manual shaft.
View A
12. Install manual plate retaining pin and parking rod plate
Retaining Pin~
Manual plate
retaining pin.
and parking
(rod plate
" ~5 .6 mm
- (0.20 • 0.24 In)
tt
~ /1
ST2354~
~~ SAT087D
13. Install detent spring.
AT-69
Oil Pump
SEC. 313
a-ring ~@D
~ 7 -11 N.m
(0.7 - 1.1 kg-m,
61 - 95 in-Ibj
',- Ouler gear
\
o Inner gear
@V:
Seal ring ~ m C!'\ Apply ATF.
m C~) : Apply petroleum jelly.
SAT698HA
DISASSEMBL Y
1. Remove seal rings.
SAT699H
2. Loosen bolts in numerical order and remove oil pump

cover.
3. Remove inner and outer gear from oil pump housing.
AT-70
Oil Pump (Cont'd)
4. Remove O-ring from oil pump housing.
~)
SAT093D
5. Remove oil pump housing oil seal.
SAT094D
INSPECTION
Oil pump housing, oil pump cover, inner gear and outer
gear
• Check for wear or damage.
•
Side clearance
Dial gauge • Measure side clearance of inner and outer gears in at least
/ four places around each outside edge. Maximum measured
Span (180 mm values should be within specified ranges.
(7.09 In)]
Standard clearance:
0.02 - 0.04 mm (0.0008 - 0.0016 in)
• If clearance is below standard, select inner and outer gears
as a set to assure clearance within specifications.
Inner and outer gear:
Oil pump Inner gear • If clearance is more than standard, replace whole oil pump
housing assembly except oil pump cover.
*: Measuring points
SAT095D
AT-71
Oil Pump (Cont'd)
• Measure clearance between outer gear and oil pump hous-
ing.
Standard clearance:
0.08 - 0.15 mm (0.0031 - 0.0059 in)
• If not within standard clearance, replace whole oil pump
assembly except oil pump cover.
SAT0960
Seal ring clearance

• Install new seal rings onto oil pump cover.
• Measure clearance between seal ring and ring groove.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in)
Allowable limit:
0.25 mm (0.0098 in)
• If not within wear limit, replace oil pump cover assembly.
ASSEMBLY
1. Install oil seal on oil pump housing.
2. Install O-ring on oil pump housing.

• Apply ATF to O-ring.
3. Install inner and outer gears on oil pump housing.

• Take care with the direction of the inner gear.
AT-72
Oil Pump (Conl'd)
4. Install oil pump cover on oil pump housing.
a. Wrap masking tape around splines of oil pump cover
assembly to protect seal. Position oil pump cover assembly
on oil pump housing assembly, then remove masking tape.
b. Tighten bolts in numerical order.
SAT101D
5. Install new seal rings carefully after packing ring groove

with petroleum jelly.
• Do not spread gap of seal ring excessively while installing .
. It may deform the ring.
SAT699H
AT-73
Control Valve Assembly
SEC. 317
Model 34X69, 34X70,

34X80, 34X81
\ Clip
~ 6-T1ng~

'I : Model 34X68
'2 : Model 34X69, 34X70.
34X80, 34X81
SATOB11
Model DISASSEMBL Y
34X68
1. Remove tube connector and tube from control valve lower
body.
SAT603DB
Model
34X69,
34X70.
34X80,
34X81
SAT104DB
AT-74
Control Valve Assembly (Cont'd)
2. Disassemble upper, inter and lower bodies using the follow-
Model 34X68
ing procedures.
Without torque converter clutch solenoid valve
Bolt symbol @ @ @ @ CID cD

Bolt length 'T'
13.5 58.0 40.0 66.0 33.0 78.0
@ (0.531) (2.283) (1.575) (2.598) (1.299) (3.071)
~Qmm(in)
Number of bolts 4 3 6 11 2 2
@
Section Y - Y
@Bolt~ CD Plain
washer
Support plate f Nut
SAT245EB
With torque converter
Bolt symbol
Bolt length" ("
~>-,-1 Q mm (in)
13.5
(0.531)
@
58.0
(2.283)
@
40.0
(1.575)
@
66.0
(2.598)
CID
33.0
(1.299)
CD
78.0
(3.071)
•
Section Z - Z
Reamer bolt
Section y - y
(E)BOIt~
(f) Plain
washer
Support plate ~
Nut SAT515HB
Model 34X68 a. Remove bolts @, @ and CB shown in the illustration.

b. Remove oil strainer from control valve assembly.
AT-75
Model 34X69. 34X70. 34X80, 34X81
Model 34X68 c. Remove aD cancel solenoid from control valve assembly.

(Model 34X68)
Model 34X69. 34X70, 34X80. 34X81 d. Remove aD cancel solenoid and torque converter clutch
~)
Torque solenoid valve from control valve assembly. (Model 34X69,
converter
34X70, 34X80, 34X81)
clutch
solenoid
valve
SAT519HB
Model 34X68 e. Remove a-rings from aD cancel solenoid, and harness ter-
minal body. (Model 34X68)
Ori~
SAT240EB
ModeJ Overdrive cancel solenoid

f. Remove a-rings from aD cancel solenoid, torque converter
34X69. Torque clutch solenoid valve and harness terminal body. (Model
34X70. converter 34X69, 34X70, 34X80, 34X81)
34X80. clutch '0
34X81 solenoid valv~
"
o_rin~
Terminal 0
body
O-ring~ l \
SAT521HB
AT-76
g. Place upper body facedown, and remove bolts.
SAT107DA
h. Remove lower body from inter body and upper body.
Accumulator i. Turn over lower body, and remove accumulator support •

support plate plate.
SAT109D
j. Remove separating plate and separating gaskets from

Line pressure
lower body.
relief valve
spring k. Remove steel balls and relief valve springs from lower
body.
• Be careful not to lose steel balls and relief valve springs.
Section A-A
SAT110D
I. Remove inter body from upper body.
AT-77
REPAIR FOR COMPONEN
Control Val T PARTS
ve Asse b
m. Check to see that m Iy (Cont'd)
body and th steel balls ar
• Be careful n~~ ;:m ove them. e properly positioned in .
ose steel b Inter
l ails.
SAT111D
Model 34X69 and 34X70 n. Remo ve separatin

upper body
o. Check to s. 9 plate and separating gask
upper bodye:n~ht steel balls are els from

• Be careful nollo ~en remove them properly positioned.
ose steel balls. . In
Model 34X68
SAT523H
Model 34X80
Model 34X81
SAT0831
AT-78
INSPECTION
Lower and upper bodies
• Check to see that retainer plates are in proper position in
lower body.
SAT113D
• Check to see that retainer plates are in proper position in

upper body.
• Be careful not to lose these parts.
Oil strainer
• Check wire netting of oil strainer for damage.
•
Oil strainer SAT115D
Model 34X68 Overdrive cancel solenoid 00 cancel solenoid and torque converter clutch solenoid
valve
• Measure resistance - Refer to "Electrical Components
Inspection", AT-3D.
SAT608DB
Model 34X69, 34X70, 34X80, 34X81

Overdrive cancel solenoid
Torque converter
clutch
solenoid valve
SAT522HB
AT-79
REPAIR FOR COM PONE
Control Val NT PARTS
0"1 ve
I cooler reli f Asse m b Iy (Cont'd)
• Check f e valve spring
• Measureorfree
damagIe e or deformation
Inspection ngth and outer d'Iameter
Re f er tostandard" . of valve spring
50S AT.
, -167. .
Q (Length)
Model 34X69 and 34X70 ASSEMBLY

1. PI
a Install upper, inter and
. tha~e oil circuit of u lower body
elr pro per posT pper b0dY face. up. Install ste e lb' ails
I Ions. In
Model 34X68
Model 34X80
SATOB21
SATOB31
AT-SO
b. Install new upper separating gasket, new upper inter sepa-
rating gasket and upper separating plate in order shown in
illustration.
Upper
separating
gasket
SAT243E
c. Install reamer bolts (!) from bottom of upper body and

Separating install separating gaskets and separating plate as a set on
plate & upper body using reamer bolts as guides.
gaskets
SAT119DA
d. Place lower body side of inter body face up. Install steel •
balls in their proper positions.
e. Install inter body on upper body using reamer bolts (!) as

Inter body guides.
• Be careful not to dislocate or drop steel balls.
SAT121DA
f. Install steel balls and relief valve springs in their proper

Line pressure
positions in lower body.
relief valve
spring
Section A-A
SAT110D
AT-81
g. Install new lower separating gasket, new lower inter sepa-
rating gasket and lower separating plate in order shown in
illustration.
Lower separating
plate
Lower separating
gasket SAT244E
h. Install support plate fixing bolts CID from bottom of lower

Separating body and install separating gaskets and separating plate as
plate & gaskets a set on lower body using bolts CID as guides.
Lower body
> (~) Boit
SAT124DA
i. Temporarily install support plates on lower body.
SAT125DA
j. Install lower body on inter body using reamer bolts (f) as

guides and tighten reamer bolts (f) slightly.
Lower body
Inter and
upper bodies
SAT126D
Model 34X68 Overdrive cancel solenoid 7

2. Install a-rings to aD cancel solenoid, torque converter
.'
clutch solenoid valve and harness connector.
• Apply ATF to O-rings.
AT-82
Model Overdrive cancel solenoid
34X69, Torque~
34X70, converter
34X80, clutch '0
34X81 solenoid valv~
'"
o_rin~
Terminal 0
body
O-ring~ l \
SAT521HB
3. Install and tighten bolts.

Model 34X68
Without torque converter clutch solenoid valve
Bolt symbol @ @ @ @ (!) ffi

Bolt length "C"
13.5 58.0 40.0 66.0 33.0 78.0
(0.531) (2.283) (1.575) (2.598) (1.299) (3.071)
~ Q mm(in)
3.4 -
•
4.4 7 - 9
Tightening torque (0.35 - (0.7 -
7 - 9 (0.7 - 0.9, 61 - 78)
N'm (kg-m, in-Ib) 0.45, 0.9,61
Section Z - Z
30.4 - - 78)
Reamer bolt
Section y - y 39.1)
/
@Bolt~ (:E) Plain
washer
Support plate r Nut
SAT245EB
With torque converter clutch solenoid valve
Bolt symbol @ @ @ @ (!) ffi

Bolt length "C"
13.5 58.0 40.0 66.0 33.0 78.0
(0.531) (2.283) (1.575) (2.598) (1.299) (3.071)
~ Q mm (in)
3.4 -
4.4 7-9
Tightening torque (0.35 - (0.7 -
7 - 9 (0.7 - 0.9, 61 - 78)
N'm (kg-m, in-Ib) 0.45, 0.9,61
30.4 - - 78)
39.1)
Section Z - Z
Reamer bolt
Section y - y
(ElBolt -
en Plain
washer
. S"PP~
AT-83
a. Install and tighten bolts @ slightly.
SAT609D
Model 34X68 b. Install OD cancel solenoid to lower body. (Model 34X68)

c. Install OD cancel solenoid and torque converter clutch sole-
noid valve to lower body. (Except model 34X68)
d. Install and tighten bolts @ and @ slightly.
e. Remove both reamer bolts (f) previously installed as
guides. Install one reamer bolt (f) (marked in illustration)
from lower body side.
f. Tighten bolts @, @, @ and (f) to specified torque.
~: 7 - 9 N'm (0.7 - 0.9 kg-m, 61 - 78 in-Ib)
SAT525HA
00 cancel
solenoid
SAT526HB
g. Install oil strainer and the other bolt CB (marked in

illustration), then tighten bolts @, @ and CB to specified
torque.
~: 7 - 9 N'm (0.7 - 0.9 kg-m, 61 - 78 in-Ib)
Oil
strainer
SAT516HA
AT-84
Control Valve Assembly (Cant' d)
Model 34X69, 34X70, 34X80, 34X81
Model 34X68 h, Install support plates and tighten bolts CID to specified
torque.
[j]: 3.4 - 4.4 N'm (0.35 - 0.45 kg-m, 30.4 - 39.1 in-Ib)
SAT529HA
Model
34X69,
34X70,
34X80,
34X81
•
Model i. Install tube connector and tubes to lower body,
34X68 • Install oil circuit side of tube connector face up.
SAT603DB
Model
34X69,
34X70,
34X80,
34X81
SAT104DB
AT-8S
Control Valve Upper Body
SEC. 317
Ql
OJ
c: Cil
.~ c.
(J)
iii
c: u c: >
c: 0 0 <ii
-J u >
Z ~ Ql
c:
5 ~
~ <ii
>
a: Ql
@ U
c:
Ql
::J
0-
Ql
(J)
C\I
.;.
iii
0.
0.
::>
OJ
c:
';:
iit
E
::J
~
a:
e
(I)
Cil 2
c. co
iii c.
c:
'19 iii
c:
Ql
a:
yg
Ql
a:
Apply ATF to all components before their installation.

Numbers preceding valve springs correspond with those shown in Spring Chart of SDS on page AT-167,
SAT2021
AT-86
Control Valve Upper Body (Cont'd)
DISASSEMBL Y
1. Remove valves at retainer plates.
• Do not use a magnetic "hand".
SAT114D
a. Use a screwdriver to remove retainer plates.
SAT135D
b. Remove retainer plates while holding spring, plugs and •

sleeves.
• Remove plug slowly to prevent internal parts from jumping
out.
c. Place mating surface of valve face down, and remove inter-

nal parts.
• If a valve is hard to remove, place valve body face down and
lightly tap it with a soft hammer.
• Be careful not to drop or damage valves and sleeves.
SAT137D
INSPECTION
Valve spring
• Measure free length and outer diameter of each valve
spring. Also check for damage or deformation.
Inspection standard:
Refer to 50S, AT-167.
• Replace valve springs if deformed or fatigued.
Q (Length) Control valves
• Check sliding surfaces of valves, sleeves and plugs.
SAT138D
AT-87
ASSEMBLY
• Lay the control valve body down when installing valves.
• Do not stand the control valve body on edge.
SAT139D
1. Lubricate the control valve body and all valves with ATF.
Install control valves by sliding them carefully into their
bores.
• Be careful not to scratch or damage valve body.
• Wrap a small screwdriver with vinyl tape and use it to insert

the valves into their proper positions.
Screwdriver
SAT141D
1-2 accumulator valve

• Install 1-2 accumulator valve. Align 1-2accumulator retainer
plate from opposite side of control valve body.
• Install return spring and 1-2 accumulator piston.
SAT142D
2. Install retainer plates.

Retainer plate
• While pushing plug or return spring, install retainer plate.
Screwdriver J
SAT143D
AT-SS
Retainer plate:
A A
Unit: mm (in)
B
E{1}
Type B
Name of control valves
Pressure modifier valve
Lock-up control valve

Length A
6.0 (0.236)
Length B
28.0 (1.102)
Type
4-2 sequence valve
Kickdown modulator valve

3-2 timing valve A
Type A SAT611D
1st reducing valve 6.0 (0.236) 21.5 (0.846)
Throttle modulator valve

4th speed cut valve
1-2 accumulator valve 6.0 (0.236) 38.5 (1516)
Torque converter relief valve 13.0 (0.512) 17.0 (0.669) B
• Install proper retainer plates.
AT-89
Control Valve Lower Body
SEC. 317
~o
.0
Ol
::>
i5.
oo
a.
W
~Ol
::>
a:
~
Cll
m
i5.
Q;
c
'OJ
a;
a:
Apply ATF to all components before their installation.

Numbers preceding valve springs correspond with those shown in Spring Chart of SOS on page AT-167.
SAT532H
AT-gO
Control Valve Lower Body (Cont'd)
DISASSEMBL Y
1. Remove valves at retainer plate.
For removal procedures, refer to "DISASSEMBLY" in "Con-
trol Valve Upper Body", AT-B?
SAT1130
Throttle valve
o f2- • Remove throttle valve at E-ring.
SAT147D
INSPECTION
Valve springs
• Check each valve spring for damage or deformation.
measure free length and outer diameter.
Also •
• Replace valve springs if deformed or fatigued.
Q (Length) Control valves
• Check sliding surfaces of control valves, sleeves and plugs
SAT13BO for damage.
ASSEMBLY
Throttle valve
• Insert throttle valve to control valve body and then install
E-ring to throttle valve.
SAT1490
Pressure regulator valve

• Install pressure regulator valve after assembling sleeve
plug, plug A and plug B.
SAT1500
AT-91
Control Valve Lower Body (Cont'd)
3-4 shift valve and 2-3 shift valve
• Install 3-4 shift valve and 2-3 shift valve after fixing plugs to
retainer plates on the opposite side.
SAT151D
• Install control valves.

For installation procedures, refer to "ASSEMBLY in "Con-
trol Valve Upper Body", AT-8?
SAT113D
Retainer plate:
"A" Unit: mm (in)
"A" Name of control valve Length A Length 8 Type
Eli
Throttle valve & detent valve 6.0 (0.236) 7.2 (0.283) 1/
Pressure regulator valve

"B"
U
3-4 shift valve
Type II
2-3 shift valve 6.0 (0.236) 28.0 (1.102) I
Type I 1-2 shift valve

SAT153D
Overrun clutch control valve
• Install proper retainer plates.
AT-92
Reverse Clutch
SEC. 315
*
Snap ring I
Retaining plate
Driven plate
Snap ring~
Piston
Oil seal~@D
D-ring~ @:>
Drive plate
Dish plate
Snap ring~
~. Apply ATF.
SAT940HA
DISASSEMBLY •
1. Check operation of reverse clutch.
a. Install seal ring onto drum support of oil pump cover and
install reverse clutch assembly. Apply compressed air to oil
hole.
b. Check to see that retaining plate moves to snap ring.
c. If retaining plate does not contact snap ring,
• D-ring might be damaged.
• Oil seal might be damaged.
• Fluid might be leaking past piston check ball.
2. Remove snap ring.

3. Remove drive plates, driven plates, retaining plate, and dish
plates.
SAT156D
4. Set Tool on spring retainer and remove snap ring from

reverse clutch drum while compressing return springs.
KV31103200
• Set Tool directly above springs.
• Do not expand snap ring excessively.
5. Remove spring retainer and return springs.
• Do not remove return springs from spring retainer.
SAT157D
AT-93
Reverse Clutch (Cont'd)
6. Remove piston from reverse clutch drum by turning it.
SAT159D
7. Remove O-ring and oil seal from piston.
SAT13BE
INSPECTION
Reverse clutch snap ring, spring retainer and return
springs
• Check for deformation, fatigue or damage.
• Replace if necessary.
• When replacing spring retainer and return springs, replace
them as a set.
Reverse clutch drive plates

• Check facing for burns, cracks or damage.
• Measure thickness of facing.
Facing Thickness of drive plate:
Standard value 2.0 mm (0.079 in)
Wear limit 1.8 mm (0.071 in)
• If not within weC1rlimit, replace.
SAT162D
Reverse clutch dish plates

• Check for deformation or damage.
• Measure thickness of dish plate.
Thickness of dish plate:
2.89 - 3.19 mm (0.1138 - 0.1256 in)
• If deformed or fatigued, replace.
SAT163D
AT-94
Reverse clutch piston
• Make sure check balls are not fixed.
• Apply compressed air to check ball oil hole opposite the
return spring. Make sure there is no air leakage.
• Apply compressed air to oil hole on return spring side to
make sure air leaks past ball.
Check air does not flow

through ball hole. SAT164D
ASSEMBLY
1. Install O-ring and oil seal on piston.
• Take care with the direction of the oil seal.
• Apply ATF to both parts.
Oil seal
SAT138E
2. Install piston assembly by turning it slowly.
•
SAT159D
3. Install return springs and spring retainer on piston.

Spring
retainer
Piston
SAT168D
4. Set Tool on spring retainer and install snap ring while com-
pressing return springs.
KV31103200
• Set Tool directly above return springs.
SAT157D
AT-95
5. Install drive plates, driven plates, retaining plate and dish
CD plates.
• Do not align the projections of any two dish plates.
evCD
.~
~ ?
jjfu
SAT170D
6. Install snap ring.
SAT156D
7. Measure clearance between retaining plate and snap ring.

If not within allowable limit, select proper retaining plate.
Specified clearance:
Standard 0.5 - 0.8 mm (0.020 - 0.031 in)
Allowable limit 1.2 mm (0.047 in)
Retaining plate:
Refer to SOS, AT -168.
Retaining plate
SAT174D
8. Check operation of reverse clutch.

Refer to "DISASSEMBLY" in "Reverse Clutch", AT-93.
AT-96
High Clutch
SEC. 315
Fa<th. oumh" of ,Iuloh ,h.of. (d"., pI" ....
,,',' to fh' "'ow 010.... ""00.
d d,I... PI'@(if)
~ ) ~
Driven plate
Retaining plate* Input shaft assembly

(High clutch drum)
Snap ring f:1 Except model 34X81 Model 34X81

Retaining plate*- Driven plate
Retaining Driven plate 1.5 mm (0.059 in)
•
Snap ring
l Driven plate
i 2.0 mm
•.•.(0.079 in)
m @ • Apply petroleum jelly.

@. Apply ATF -- Drive plate
* ; Select proper thickness.
SAT0841
DISASSEMBLY
1. Check operation of high cl utch.
a. Apply compressed air to oil hole of input shaft.
• Stop up a hole on opposite side of input shaft.
b. Check to see that retaining plate moves to snap ring.
c. If retaining plate does not contact snap ring,
• O-ring might be damaged.
• Oil seal might be damaged.
• Fluid might be leaking past piston check ball.
Nylon cloth
SAT176D
2. Remove seal rings from input shaft.
Input shaft
1/5'" hog
SAT177D
AT-97
High Clutch (Co nt' d)
4. Remove drive plates, driven plates and retaining plate.
SAT178D
5. Set Tool on spring retainer and remove snap ring from high
clutch drum while compressing return springs.
• Set Tool directly above springs.
Snap ring,
SAT617H
7. Remove piston from high clutch drum by turning it.
8. Remove O-ring and oil seal from piston.
SAT139E
INSPECTION
Reverse clutch snap ring, spring retainer and return
springs
them as a set.
AT-98
High Clutch (Cont'd)
High clutch drive plates
Except model 34X81
Core plate Model 34X81
SAT162D • If not within wear limit, replace.
High clutch piston
• Apply compressed air to oil hole on return spring side to
make sure air leaks past ball.
I
I
Check air does not Check air flows
flow through through ball
ball hole. hole. SAT186D
Seal ring clearance

•
•
Install new seal rings onto input shaft.
Measure clearance between seal ring and ring groove.
Standard clearance:
0.08 - 0.23 mm (0.0031 - 0.0091 in)
Allowable limit:
•
0.23 mm (0.0091 in)
• If not within wear limit, replace input shaft assembly.
Input shaft
SAT187D
ASSEMBLY
1. Install O-ring and oil seal on piston.
2. Install piston assembly by turning it slowly.

• Apply ATF to inner surface of drum.
AT-99
- Spring
retainer
SAT191D
4. Set Toolan spring retainer and install snap ring while com-
Snap ring:
--j
I
SAT617H
• Do not align snap ring gap with spring retainer stopper.

Snap ring
SAT1930
5. Install drive plates, driven plates and retaining plate.

• Take care with the order and direction of plates.

Standard 1.4 - 1.8 mm {O.055 • 0.071 in}
Snap Allowable limit {Except model 34X81} 2.4 mm {O.094
ring
in}
Allowable limit (Model 34X81) 2.6 mm (0.102 in)
Feeler
Retaining plate:
gauge Refer to SOS, AT -168.
SAT1990
AT-100
8. Check operation of high clutch.
Refer to "DISASSEMBLY" in "High Clutch", AT-97.
SAT196D
9. Install seal rings to input shaft.

• Apply petroleum jelly to seal rings.
Apply petroleum jelly
SAT197D
• Roll paper around seal rings to prevent seal rings from •

spreading.
/ Thick paper
Tape
SAT198D
AT-101
Forward Clutch and Overrun Clutch
CD Snap ring
~ Retaining plate *
~ Drive plate
o Driven plate
CID Dish plate
.~
Oilseal~~
Overrun * :Select
@D: Apply x~~per thickness.
clutch
Spring retainer piston
SAT942HA
DISASSEMBLY
1. Check operat'
~: ~;t~" bearin~o~e~~i~:;ardclutch and ov
c. Ch~:k~ompressedair t~n forward ciutch,;;run clutch.
o see that retaining
011 hole of f
plate movesorwardrum.
. to sclutch d
nap ring.rum.
If r~taining plate d
D~nng might b oes not conta
• 0,1 seal m" h e damaged
ig t b d'
ct snap ring
'
• Fluid might be leak'
e amaged '
• mg past piston check ball.
Bearing
retainer
AT.102
Forward Clutch and Overrun Clutch (Cont'd)
2. Remove snap ring for forward clutch.
3. Remove drive plates, driven plates, retaining plate and dish
plate for forward clutch.
SAT203D
4. Remove snap ring for overrun clutch.

5. Remove drive plates, driven plates, retaining plate and dish
plate for overrun clutch.
SAT204D
6. Set Tool on spring retainer and remove snap ring from for- •
ward clutch drum while compressing return springs.
Snap ring
SAT205D
8. Remove forward clutch piston with overrun clutch piston

from forward clutch drum by turning it.
SAT216D
9. Remove overrun clutch piston from forward clutch piston by

turning it.
AT-103
10. Remove D-rings and oil seals from forward clutch piston
@ @ Oil seal and overrun clutch piston.
@ @'r:rY;)
, ~~o<mg
~~o:~::'"
l\~)t D-rlng
"'Ioh pi","
Overrun
clutch piston SAT140E
INSPECTION
Snap rings and spring retainer
Forward clutch and overrun clutch return springs

• Measure free length and outer diameter.
• Replace if deformed or fatigued.
Q (Length)
SAT138D
Forward clutch and overrun clutch drive plates

Forward clutch
Core plate Overrun clutch
SAT162D • If not within wear limit, replace.
Forward clutch and overrun clutch dish plates
Forward clutch 2.35 - 2.65 mm (0.0925 - 0.1043 in)
t
Overrun clutch 2.00 - 2.30 mm (0.0787 - 0.0906 in)
SAT163D
AT-104
Forward clutch drum
• Apply compressed air to check ball oil hole from outside of
forward clutch drum. Make sure air leaks past ball.
• Apply compressed air to oil hole from inside of forward
clutch drum. Make sure there is no air leakage.
Check air does not flow

through ball hole.
SAT213D
Overrun clutch piston

• Apply compressed air to oil hole on return spring side.
Make sure air leaks past ball.
Check air flows

Check air does not flow through ball hole.
through ball hole. SAT212D
ASSEMBLY
@ @ Oil seal
1. Install O-rings and oil seals on forward clutch piston
and.
overrun clutch piston.
• Take care with direction of oil seal.
@,~~~
~ O;',':'d oI"tohpi","
~'U,., Overrun
O-nng
clutch piston SAT140E
2. Install overrun clutch piston assembly on forward clutch

piston while turning it slowly.
Overrun clutch
piston
3. Install forward clutch piston assembly on forward clutch

drum while turning it slowly.
AT-105
Center---l , 4. Align notch in forward clutch piston with groove in forward
clutch drum.
5. Install return springs on piston.
..
Qrspring
retainer
6. Install spring retainer on return springs.
SAT218D
7. Set Tool on spring retainer and install snap ring while com-
/ _. Set Tool directly above return springs.
Snap ring
SAT205D
• Do not align snap ring gap with spring retainer stopper.
SAT220D

plate for overrun clutch.
9. Install snap ring for overrun clutch.
SAT204D
AT-106
Snap ring 10. Measure clearance between overrun clutch retaining plate
and snap ring.
Standard 1.0 - 1.4 mm (0.039 - 0.055 in)
Overrun clutch retaining plate:
Refer to SOS, AT-1G8.
Retaining
plate
SAT227D
plate for forward clutch.
Snap ring 12. Install snap ring for forward clutch.
\
Screwdriver
SAT203D
Retaining plate 13. Measure clearance between forward clutch retaining plate •
and snap ring.
Standard 0.45 - 0.85 mm (0.0177 - 0.0335 in)
Forward clutch retaining plate:
Refer to SOS, AT-1G8.
14. Check operation of forward clutch.

Refer to "DISASSEMBLY" in "Forward Clutch and Overrun
Clutch", AT-102.
Bearing
retainer
SAT201D
15. Check operation of overrun clutch.

Refer to "DISASSEMBLY" in "Forward Clutch and Overrun
Clutch", AT-102.
Bearing
retainer
AT-107
Low & Reverse Brake

SEC. 315
For the numb , r ven plates),
refer to the b:~O~ cross-section
clutch sheets (dri ve plates and d I
Drive plate
Retaining plate*
Driven plate
Retaining plate
Driven plate
~: * : Select
Apply x~~per thickness. Drive plate Dish plate
SAT943HA
DISASSEMBL Y
1. Check ope rat'
a. Apply co Ion of low & r
b. Check t mpressed air to o,elvherse brake
c . If retaining
0 see that
plat dretaining I ole of t ransmission
plate . ca
• D-rin . e oes n t moves t se.
• Oil g might be dama 0 contact snap .0 snap ring.
seal might be ged. ring,
• FluId might b e leak'
damaged
Ing past . piston c h eck ball
2. Stand trans . ,
3. Remove sn~l1IS~lOn case.
4. Remov . p nng.
d' e dnve plate retaining plates and
Ish plates from t ransmlssio
s, ~riven plate
n case. s,
AT-108
Low & Reverse Brake (Conl'd)
5. Set Tool on spring retainer and remove snap ring while
compressing return springs.
7. Apply compressed air to oil hole of transmission case while

holding piston.
8. Remove piston from transmission case by turning it.
•
9. Remove D-ring and oil seal from piston.
piston
SAT618H
INSPECTION
Low & reverse clutch snap ring, spring retainer and
return springs
them as a set.
AT-109
Low & Reverse Brake (Coni' d)
Low & reverse brake drive plate
• If not within wear limit, replace.
SAT162D
Low & reverse brake dish plates

3.00 - 3.30 mm (0.1181 - 0.1299 in)
SAT163D
ASSEMBLY
1. Install D-ring and oil seal on piston.
• Apply ATF to O-ring and oil seal.
2. Stand transmission case.

3. Install piston assembly on transmission case while turning
it slowly.
• Apply ATF to inner surface of transmission case.
AT-110
Low & Reverse Brake (Cont'd)
5. Install snap ring while compressing return springs.
6. Install drive plates, driven plates, retaining plates and dish

plates.
• Do not align the projections on the two dish plates.
SAT254E
•
If not within allowable limit, select proper retaining plate
(front side).
Standard 1.4 - 1.8 mm (0.055 - 0.071 in)
Allowable limit
2.8 mm (0.110 in)
Retaining plate:
/7
" gRetaining plate
\ ~\ J/.. ~6D
9. Check operation of low & reverse brake.

Refer to "DISASSEMBLY" in "Low & Reverse Brake",
AT-108.
AT-111
Rear Internal Gear, Forward Clutch Hub and

Overrun Clutch Hub
SEC. 315
Forward one-way clutch
Thrust washer m@
Forward clutch hub
Thrust washer m@
Overrun clutch hub
Rear internal gear
Bearing
m@
m@: Apply petroleum jelly.
SAT975H
DISASSEMBL Y
Overrun 1. Remove snap ring from overrun clutch hub.
clutch hub 2. Remove overrun clutch hub from forward clutch hub.
Forward
clutch hub
SAT249D
3. Remove thrust washer from forward clutch hub.
Forward
clutch hub
SAT250D
AT-112
Overrun Clutch Hub (Conl'd)
4. Remove forward clutch hub from rear internal gear.
Forward clutch
hub
Rear internal
gear
SAT251D
5. Remove end bearing from rear internal gear.
Rear internal
gear
SAT252D
6. Remove thrust washer from rear internal gear.
•
Rear
internal
gear
SAT253D
7. Remove end bearing from forward one-way clutch.
SAT254D
8. Remove one-way clutch from forward clutch hub.
O
~
[j
Forward one-way
clutch
Forward clutch
hub
SAT255D
AT-113
Overrun Clutch Hub (Cont'd)
i
INSPECTION
t Rear internal gear, forward clutch hub and overrun
clutch hub
Overrun
• Check rubbing surface for wear or damage.
clutch hub
Rear Internal
1 t
o
gear SAT256D
Snap ring, end bearings and forward one-way clutch

~~"'",'h • Check snap ring and end bearings for deformation and dam-
age.
• Check forward one-way clutch for wear and damage.
Endbeari~
SAT257D
ASSEMBLY
1. Install forward one-way clutch on forward clutch.
• Take care with the direction of the forward one-way clutch.
2. Install end bearing on forward one-way clutch.

• Apply petroleum jelly to end bearing.
3. Install thrust washer on rear internal gear.

l.r'~l ! Thrust washer
•
•
Apply petroleum jelly to thrust washer.
Align pawls of thrust washer with holes of rear internal
gear.
'] . .
, . Pawl
Rear
internal
gear
SAT143E
AT-114
Overrun Clutch Hub (Cont'd)
4. Install end bearing on rear internal gear.
• Apply petroleum jelly to end bearing.
Rear internal
gear
SAT144E
5. Install forward clutch hub on rear internal gear.

Rear internal gear • Check operation of forward one-way clutch.
Hold rear internal gear and turn forward clutch hub. Check
forward clutch hub for correct locking and unlocking direc-
tions.
• If not as shown in illustration, check installation direction of
forward one-way clutch.
Forward
clutch hub
Unlocked "'OOQ Locked

SAT713H
Pawl
Overrun
6.
•
•
Install thrust washer on overrun clutch hub.
Apply petroleum jelly to thrust washer.
Align pawls of thrust washer with holes of overrun
hub.
clutch
•
clutch
hub
SAT145E
7. Install overrun clutch hub on rear internal gear.

• Align projections of rear internal gear with holes of overrun
Rear internal gear clutch hub.
Overrun
clutch
hub
-Forward
clutch hub
SAT264D
8. Install snap ring to groove of rear internal gear.
SAT248D
AT-115
Output Shaft, Output Gear, Idler Gear, Reduction

Pinion Gear and Bearing Retainer - Except
Model 34X81
"""
..,1\
SEC. 314 Adjusting spacer
Idler gear
Idler gear bearing
(ill)
CO'.J63 • 67 (6.4 • 6.8, 46 - 49) ~~

']I~
I?:(;J~~~" ,/ (~)~'~~_
Reduction pinion gear.
bearing outer race \
'
,C~\(~~~~ljY:~
\~\ ~o/p\ __
\f _2:;!_-----~~ ), I A .. _-
\;;~\J ~~:;.- Lock nut~
~5
181 • 203)
Reduction pinion gear ~ I~(l: -:<~~)\~\.JV ~
beanng Inner race @£)\ '\ '-':" '..,-:;..?/ ,--,,~
~- ij",~l
-- I-;r l "" /
-:'l")..-
\
Output gear
...:" /" ~,/ r::- ,"";'--- -..., ~/I ;-
~ yJ ",.. \: ~~
---'-::::--..;-(~.
~~
~I':i~~/
/.1 ~ ( (
,..:J AdJusting shim *
Reduction pinion gear ' ~ _/ " 7', -.)
~
....-/ 1 o",.~) ~~;;;'~i/~
\ '-.'.=;.--'--..1'
'r'. ~t gear bearing
(~i \
;..-"" R ' .\..
A~\J))) .
yX--;;earlng;
/l
y~,._,
OutP~t gear bearing outer race
X' CO'.J16 • 20 retainer ~ /
/ ~ "\..-/
/\
(1.6. 2~"
12 • 15) %l
~ ..~ /Seal ring [ ~
(S \ V f{~
\ Y
~
\\ ~mp.
v\..
0"''"' 'h'"
- m (p)
, N.m (kg.m, tt.lb)
v Seal ring .~. : Apply petroleum jelly,

~' \ .. , Select proper thickness,
Output shaft : Apply ATF,
bearing@£)
SAT255EC
DISASSEMBL Y
1. Remove seal rings from output shaft and bearing retainer.
$\s", clog
Seal ring
-
Output shaft Bearing retainer
SAT666D
AT-116
Model 34X81 (Cont'd)
2. Press out output shaft bearing inner race.
SAT619H
3. Remove output shaft bearing outer race from bearing

retainer.
KV3B1054S0
SAT668D
Drift
4. Remove output gear bearing inner race.
•
SAT669D
5. Remove output gear bearing outer race from bearing

retainer.
KV3B1 054S0
SAT670D
6. Remove idler gear bearing inner race.
SAT648D
AT-117
7. Remove idler gear bearing outer race from transmission
case.
SAT649D
8. Press out reduction pinion gear inner race from reduction

pinion gear.
SAT650D
9. Remove reduction pinion gear bearing outer race from

transmission case.
INSPECTION
Output shaft, output gear, idler gear and reduction
pinion gear
• Check shafts for cracks, wear or bending.
• Check gears for wear, chips and cracks.
Bearings
• When replacing taper roller bearing, replace inner and
SPD715 outer races as a set.
AT-118
Clearanc.al ring
Seal ring clearance
• Install new seal rings to output shaft.
• Measure clearance between seal ring and ring groove of
output shaft.
Standard clearance:
Output shaft 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Bearingretainer Wear limit:
SAT6710
0.25 mm (0.0098 in)
• If not within wear limit, replace output shaft.
• Install new seal rings to bearing retainer .
bearing retainer.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in)
Wear limit:
0.25 mm (0.0098 in)
• If not within wear limit, replace bearing retainer.
ASSEMBLY •
1. Press reduction pinion gear bearing inner race on reduction i
pinion gear.
2. Install reduction pinion gear bearing outer race on trans-

mission case.
3. Press idler gear bearing inner race on idler gear.
AT-119
4. Install idler gear bearing outer race on transmission case.
ST37830000
5. Press output gear bearing inner race on output gear.
6. Install output gear bearing outer race on bearing retainer.
ST33400001
SAT673D
7. Press output shaft bearing inner race on output shaft.
SAT620H
8. Install output shaft bearing outer race on bearing retainer.
KV40104840
SAT675D
AT-120
Seal ring
9. Install new seal rings onto output shaft and bearing retainer.
• Apply petroleum jelly to seal rings.
Output shaft Bearing retainer

SAT222E
10. Roll paper around seal rings to prevent seal rings from
spreading.
SAT677D
•
~63-67
(6.4 - 6.8,
46 . 49)
Reduclron pinion gear
~ Thrust needle beanng !i:i!I (EJ
Seal ring ~ !i:i!I tB ~ . N.m (kg-m, ft-Ib)

a ~: Apply petroleum jelly.
Thrust needle bearing @) :Apply ATF.
SAT984HA
AT-121
Output Shaft, Idler Gear, Reduction Pinion Gear
and Bearing Retainer - Model 34X81 (Cont'd)
~}~eal DISASSEMBL Y
~ nng Seal
1. Remove seal rings from output shaft and bearing retainer.
ring
SAT644D
2. Remove output shaft bearing with screwdrivers.

Output shaft bearing ~ • Always replace bearing with a new one when removed.
• Do not damage output shaft.
3. Remove snap ring from bearing retainer.
SAT646D
4. Remove needle bearing from bearing retainer.
~ KV381054S0
Bearing retainer
NAT046
5. Remove idler gear bearing inner race from idler gear.
SAT648D
AT-122
6. Remove idler gear bearing outer race from transmission
case.
NAT047
7. Press out reduction pinion gear bearing inner race from

reduction pinion gear.
8. Remove reduction pinion gear bearing outer race from •

transmission case.
INSPECTION
Output shaft, idler gear and reduction pinion gear
• Check shafts for cracks, wear or bending.
• Check gears for wear, chips and cracks.
Bearing
• When replacing taper roller bearing, replace outer and
inner race as a set
SPD715
AT-123
Seal ring clearance
............ • Install new seal rings to output shaft.
""""'" • Measure clearance between seal ring and ring groove of
output shaft.
Standard clearance:
0.10.0.25 mm (0.0039 . 0.0098 in)
Allowable limit:
0.25 mm (0.0098 in)
Bearing retainer • If not within allowable limit, replace output shaft.
SAT652D • Install new seal rings to bearing retainer.
bearing retainer.
Standard clearance:
0.10 . 0.25 mm (0.0039 . 0.0098 in)
Allowable limit:
0.25 mm (0.0098 in)
• If not within allowable limit, replace bearing retainer.
ASSEMBLY
1. Press reduction pinion gear bearing inner race on reduction
pinion gear.
- ST35272000
NAT049
2. Install reduction pinion gear bearing outer race on trans-

mission case.
NAT048
AT-124
4. Install idler gear bearing outer race on transmission case.
5T37830000
NAT051
5. Press output shaft bearing on output shaft.
NAT052
6. Press needle bearing on bearing retainer.
•
SAT658D
7. Install snap ring to bearing retainer.
SAT659D
8. After packing ring grooves with petroleum jelly, carefully

install new rings on output shaft and bearing retainer.
SAT660D
AT-125
• Roll paper around seal rings to prevent seal rings from
B:,~
paper
Tape spreading.
0/ ~
SAT661D
Band Servo Piston Assembly

Second servo return spring
n : Adjustment is required.
cED: Apply ATF.
SAT945HA
DISASSEMBL Y
1. Remove band servo piston snap ring.
2. Apply compressed air to oil hole in transmission case to

remove 00 servo piston retainer and band servo piston
assembly.
• Hold band servo piston assembly with a rag.
AT-126
Band Servo Piston Assembly (Cont'd)
3. Apply compressed air to oil hole in aD servo piston retainer
to remove aD servo piston from retainer.
• Hold 00 servo piston while applying compressed air.
00 servo
piston
Nylon waste
4. Remove D-ring from aD servo piston.
~~----o
00 servo piston
O-ring
SAT119EB
00 servo
piston retainer
5. Remove a-rings from aD servo piston retainer.
•
SAT120EA
6. Remove band servo piston assembly from servo piston

retainer by pushing it forward.
~;!
IT Servo PiS' ~
retainer
Band servo
piston assembly
SAT293D
7. Place piston stem end on a wooden block. While pushing

servo piston spring retainer down, remove E-ring.
AT-127
8. Remove aD servo return spring, band servo thrust washer
Band servo~
and band servo piston stem from band servo piston.
stem ~
~~:~~r ~~ Band servo

~ thrust washer
~ Band servo piston
~ ~OO servo
return spring SAT295DA
9. Remove a-rings from servo piston retainer.
SAT121E
10. Remove D-rings from band servo piston.
O-ring
SAT122E
INSPECTION
Pistons, retainers and piston stem
• Check frictional surfaces for abnormal wear or damage.
Return springs
• Measure free length and outer diameter.
Q (Length)
SAT138D
AT-128
ASSEMBLY
Band servo piston
o O-ring CD
1. Install D-rings to band servo piston.
•
•
Apply A TF to O-rings.
Pay attention to the position of each O-ring.
O-rings:
Unit: mm (in)
Inner diameter
O-ring
Except model 34X81 Model 34X81
O-ring !IJ G) 53.8 (2.118) 51.9 (2.043)
SAT256E
@ 31.7 (1.248) 29.8 (1.173)
2. Install band servo piston stem, band servo thrust washer,

Band servoW OD servo return spring and spring retainer taband servo
stem?
piston.
~~:~~r ~~ Band servo

~ . thrust washer
• . Band servo piston
~ ~ 00 servo
return spring SAT295DA
3. Place piston stem end on a wooden block. While pushing •

servo piston spring retainer down, install E-ring.
SAT301D
4. Install O-rings to servo piston retainer.

Servo piston
• Apply ATF to O-rings.
retainer
• Pay attention to the position of each O-ring.
O-rings:
a-ring CD Unit: mm (in)
O-ring Inner diameter
CD 65.5 (2.579)
@ 67.0 (2.638)
a-ring @
SAT257E
5. Install band servo piston assembly to servo piston retainer

by pushing it inward.
SAT303D
AT-129
6. Install O-ring to 00 servo piston.
~---o
aD servo piston
D-ring
SAT119EB
OD servo 7. Install a-rings to aD servo piston retainer.

'piston retainer • Apply ATF to O-rings.
• Pay attention to the position of each O-ring.
O-rings:
Unit: mm (in)
O-ring Inner diameter
69.5 (2.736)
71.0 (2.795)
a-ring ,j., 73.0 (2.874)
SAT258EA
8. Install aD servo piston to 00 servo piston retainer.
aD servo
piston
9. Install band servo piston assembly and 2nd servo return

Second servo spring to transmission case.
return spring • Apply ATF to O-ring of band servo piston and transmission
case.
jJ --,~ piston assembly

SAT307DA
10. Install aD servo piston assembly to transmission case.

• Apply ATF to O-ring of band servo piston and transmission
case.
AT-130
11. Install band servo piston snap ring to transmission case.
SAT288D
Final Drive - Except Model 34X81

SEC. 381
•
OJ
I
L Final gear
\ Differential case
\ - Speedometer drive gear

~ Differential side bearing SAT680DB
DISASSEMBL Y
SAT311D
ST30021000
SAT681D
AT-131
Final Drive - Except Model 34X81 (Cont'd)
3. Remove speedometer drive gear.
4. Drive out pinion mate shaft lock pin.
SAT076E
5. Draw out pinion mate shaft from differential case.

SAT273E
INSPECTION
pinion mate gears.
SAT317D
Bearings
SPD715
AT-132
ASSEMBLY
1. Install side gears and side gear thrust washers in differen-
Pinion mate shaft tial case.
2. Install pinion mate gears and pinion mate thrust washers in
r= the differential case while rotating them.
• Apply A TF to all parts.
SAT318D

with washers.
Clearance between side gear and differential case
with washers:
0.1 - 0.2 mm (0.004 - 0.008 in)
• If not within specification, adjust clearance

by changing •

Both feeler gauges are the

same thickness.
SAT321D
4. Install lock pin.

• Make sure that lock pin is flush with case.
KV32101000
SAT077E
5. Install speedometer drive gear on differential case.

• Align projection of speedometer drive gear with groove of
differential case.
AT-133
6. Press differential side bearings on differential case.
ST33200000
SAT678D
5T33200000
SAT679D
7. Install final gear and tighten fixing bolts in numerical order.
SAT326D
AT-134
Final Drive - Model 34X81

SEC. 381 Pinion mate
thrust washer ""
Pinion mate gear~ '@

Pinion mate Shaft~
Sid, ""~
~ _ ~
Side gear
thrust washer
L~k~O~
*
)
Z
~,~
q"
@
Differential
~v.
side bearing
adjusting shim *
Differential
side bearing @)
om"""., ,Id, b"do, Final gear
Speedometer drive gear Differential case * : Select proper thickness.

@): Apply ATF.
SAT637HA
DISASSEMBL Y
•
SAT311D
SAT312D
3. Remove speedometer drive gear.

Speedometer drive gear 0
o
SAT313D
AT-135
Final Drive - Model 34X81 (Coni' d)
4. Drive out pinion mate shaft lock pin.
SAT970H
5. Draw out pinion mate shaft from differential case.

SAT316D
INSPECTION
pinion mate gears.
Bearings
• When replacing taper roller bearing, replace outer and
NAT055 inner race as a set.
'----------------'
ASSEMBLY
1. Install side gear and thrust washers in differential case.
Pinion mate shaft
2. Install pinion mate gears and pinion mate thrust washers in
differential case while rotating them.
• Apply ATF to any parts.
SAT318D

with washers using the following procedure.
Dial a. Set Tool and dial indicator on side gear.
gauge b. Move side gear up and down to measure dial indicator
side gears.
washers:
0.1 - 0.2 mm (0.004 - 0.008 in)
NAT056
AT-136
Final Drive - Model 34X81 (Cont'd)
c. If not within specifications, adjust clearance by changing
Refer to 50S, AT -170.
SMT616
4. Install lock pin.

• Make sure that lock pin is flush with case.
5. Install speedometer drive gear on differential case. •

I Speedometer:..slrive gear 0
• Align the projection of speedometer drive gear with the
groove of differential case.
~//
SAT313D
6. Install final gear and tighten fixing bolts in numerical order.
SAT326D
7. Press on differential side bearings.
Suitable
drift
SMT700B
AT-137
ASSEMBLY
Assembly 1
1. Install differential side .
converter housing 011 seals on transmiss,'on
cations. ' so that "A" and "8" are withincase and
specifi-
KV31103000 and
ST35325000
-J..
Converter housing s'd
Ie (RHS)
KV31103000
Transmission case side (LHS)
KV'"03000~ ..
SAT260EA
Transmission Converter housing Unit: mm (in)

case side side
B A B
5.5 - 6.5 (0.217 - 0.256) 0.5 (0.020) or less
Oil
Oil seal
seal
SAT6390
.. 2.
•
Install parking actuator su
Pay attention to direction Pfort t? transmission case .
o parkmg actuator support.
~
Inside
...
~
Outside
SAT328D
3. Install and fix it with

parking parking
shaft. pawl on transmission case
SAT3290
AT-138
ASSEMBLY
Assembly 1 (Cont'd)
4. Install return spring.
Adjustment 1
DIFFERENTIAL SIDE BEARING PRELOAD
-" Model 34X81 -
1. Install differential side bearing outer race without adjusting
shim on transmission case.
2. Install differential side bearing outer race on converter
housing.
3. Place final drive assembly on transmission case. •

4. Install transmission case on converter housing. Tighten
transmission case fixing bolts @ and CID to the specified
torque.
5. Attach dial indicator on differential case at transmission

case side.
6. Insert Tool into differential side gear from converter hous-
ing.
~-_./-'--.~.-l 7. Move Tool up and down and measure dial indicator deflec-
~ tion.
8. Select proper thickness of differential side bearing adjust-
1 ing shim(s) using SDS table as a guide.
I Differential side bearing adjusting shim:
Refer to 50S, AT-HO.
-~------~._--~ .
• ~KV38105710
• Wooden
block
NAT060
AT-139
ASSEMBLY
Adjustment 1 (Cont'd)
9. Remove converter housing from transmission case.
10. Remove final drive assembly from transmission case.
11. Remove differential side bearing outer race from transmis-
sion case.
12. Reinstall differential side bearing outer race and shim(s)
selected from SDS table on transmission case.
13. Reinstall converter housing on transmission case and
tighten transmission case fixing bolts to the specified
torque.
NAT033
14. Insert Tool into differential case and measure turning torque
of final drive assembly.
KV38105710 • Turn final drive assembly in both directions several times
to seat bearing rollers correctly.
Turning torque of final drive assembly (New bearing):
0.49 - 1.08 N'm (5.0 - 11.0 kg-em, 4.3 - 9.5 in-Ib)
REDUCTION PINION GEAR BEARING PRELOAD

- All models -
1. Select proper thickness of reduction pinion gear bearing
adjusting shim using the following procedures.
a. Place reduction pinion gear on transmission case as shown.
Reduction
pinion
gear
SAT332DA
b. Place idler gear bearing on transmission case.

c. Measure dimensions "8", "C" and "D" and calculate
D
dimension "A".
A = D - (8 + C)
"A": Distance between surface of idler gear bearing
inner race and adjusting shim mating surface of
Transmission
case reduction'pinion gear.
SAT333DA
• Measure dimension "8" between end of reduction pinion

gear and surface of transmission case.
• Measure in at least two places.
AT-140
ASSEMBLY
• Measure dimension "C" between surface of idler gear bear-
ing inner race and converter housing fitting surface of trans-
mission case.
• Measure dimension "D" between end of reduction pinIOn

gear and adjusting shim mating surface of reduction pinion
gear .
•. Measure in at least two places.
• Calculate dimension "A"
A = 0 - (B + C)
SAT336DA
d. Measure dimension "E" between end of idler gear and idler •

gear bearing of idler gear inner race mating surface.
Depth gauge • Measure in at least two places.
SAT337D
e. Calculate "T" and select proper thickness of reduction pin-

ion gear bearing adjusting shim using SDS table as a guide.
T=A-E
Reduction pinion gear bearing adjusting shim:
2. Install reduction pinion gear and reduction pinion gear

bearing adjusting shim selected in step 2-e on transmission
case.
4. Press idler gear on reduction pinion gear.
• Press idler gear so that idler gear can be locked with park-
ing pawl.
SAT338DA
AT-141
ASSEMBLY
5. Tighten idler gear lock nut to specified torque.
~ 245 - 275 N.m • Lock idler gear with parking pawl when tightening lock nut.
(25 - 28 kg-m, 181 - 203 ft-Ib)
SAT339D
6. Measure reduction pinion gear bearing preload.

Preload gauge
• When measuring bearing preload, turn reduction pinion
gear in both directions several times to seat bearing rollers
correctly.
Reduction pinion gear bearing preload:
0.11 - 0.69 N.m (1.1 .7.0 kg-em, 0.95 • 6.08 in-Ib)
• If not within specified range, readjust bearing preload.
OUTPUT SHAFT BEARING PRELOAD

Output shaft - Except model 34X81 -
1. Select proper thickness of output shaft bearing adjusting
spacer using the following procedures.
a. Remove paper rolled around output shaft.
b. Place bearing retainer on output shaft.
Bearing retainer
SAT682D
c. Place output gear bearing inner race on bearing retainer.

d. Measure dimensions "G" and "H" and calculate dimension
"F".
H "F": Distance between the surface of output gear bear-
F ing inner race and adjusting shim mating surface
of output shaft.
F=H-:-G
Output shaft
SAT683D
• Measure dimension "G" between end of output shaft and

surface of output gear bearing inner race.
AT-142
ASSEMBLY
• Measure dimension "H" between end of output shaft and
adjusting spacer mating surface of output shaft.
• Calculate dimension "F".
F=H-G
Straightedge
SAT685D
e. Measure distance "I" between end of output gear (adjust-

ing spacer mating surface) and bearing inner race fitting
surface .
• 0 Measure in at least two places.
..•. I
::~i~::::::..-."."...:::/i \.::;.."...;.:;:;::{\
~ Output gear
SAT686D
f. Calculate dimension "T2". •

"T 2": Distance between adjusting spacer mating surface
of output gear and output shaft
T2 = F - I
g. Select proper thickness of output shaft bearing adjusting
spacer using SOS table as a guide.
Output shaft bearing adjusting spacer:
Refer to 50S, AT -172.
2. Install bearing retainer on transmission case.
3. Place output shaft on bearing retainer.

4. Place output shaft bearing adjusting spacer selected in step
1-g on output shaft.
5. Press output gear bearing inner race on output gear.
6. Press output gear on output shaft.
AT-143
ASSEMBLY
7. Tighten output gear lock nut to specified torque.
SAT689D
8. Remove idler gear to measure output shaft bearing preload.
9. Measure output shaft bearing preload.

• When measuring bearing preload, turn output shaft in both
directions several times to seat bearing rollers correctly.
Output shaft bearing preload:
0.25 - 0.88 N'm
(2.5 - 9.0 kg-em, 2.2 - 7.8 in-Ib)
10. Install idler gear and tighten lock nut to specified torque.
11. After properly adjusting "turning" torque, clinch idler gear
and output gear lock nuts as shown.
12. Install new gasket and side cover on transmission case.

• Always replace side cover bolts.
SAT702D
AT-144
ASSEMBLY
OUTPUT SHAFT END PLAY
- Model 34X81 -
• Measure clearance between side cover and the end of the
output shaft bearing.
• Select proper thickness of adjusting shim so that clearance
is within specifications.
SAT341D
1. Install bearing retainer for output shaft.
2. Install output shaft thrust needle bearing on bearing •

retainer.
SAT438D
3. Install output shaft on transmission case.
SAT439D
4. Measure dimensions" £1" and" £2" at side cover and then

calculate dimension "A".
• Measure dimension "f/' and "f2" in at least two places.
"A": Distance between transmission case fitting surface
and adjusting shim mating surface.
A = f1 - £2 £2: Height of gauge
KV31101300
NAT064
AT-145
ASSEMBLY
5. Measure dimensions "f2" and "f3" and then calculate
dimension "8".
• Measure" f2" and" fa" in at least two places.
"B": Distance between the end of output shaft bearing
outer race and the side cover fitting surface of
transmission case.
B = £2 - fa f2: Height of gauge
6. Select proper thickness of adjusting shim so that output

shaft end play (clearance between side cover and output
shaft bearing) is within specifications.
Output shaft end play (A - B):
o- 0.5 mm (0 - 0.020 in)
Output shaft end play adjusting shim:
Refer to 50S, AT-H2.
7. Install adjusting shim on output shaft bearing.
SAT440D
3 - 5 (0.12 - 0.20) 8. Apply locking sealant to transmission case as shown in

illustration.
~ .... Locking
lide sealant
SAT441D
9. Install side cover on transmission case.

• Apply locking sealant to the mating surface of transmission
case.
SAT442D
10. Tighten side cover fixing bolts to specified torque.

• Do not mix bolts @ and CID.
• Always replace bolts @ as they are self-sealing bolts.
AT-146
ASSEMBLY
Assembly 2
- All models -
1. Remove paper rolled around bearing retainer.
2. Install thrust washer on bearing retainer.
• Apply petroleum jelly to thrust washer.
3. Install forward clutch assembly.

• Align teeth of low & reverse brake drive plates before
Forward clutch
installing.
assembly .. Make sure that bearing retainer seal rings are not spread.
Bearing race m@ -
4.
•
Except model 34X81 -
Install bearing race on bearing retainer.
Apply petroleum jelly to bearing race. •
mep,: Apply petroleum jelly. SAT698D
5. Install needle bearings on rear internal gear.

Needle bearing • Apply petroleum jelly to needle bearings.
@ • Pay attention to direction of needle bearing.
'-
(I
SAT694D
- Model 34X81 -
4. Install thrust needle bearing on bearing retainer.
• Apply petroleum jelly to thrust bearing.
• Pay attention to direction of thrust needle bearing.
AT-147
ASSEMBLY
Assembly 2 (Cont'd)
5. Install thrust needle bearing on rear internal gear.
• Apply petroleum jelly to thrust needle bearing.
~ru,t
beanng
,,,dl,
m@ • Pay attention to direction of thrust needle bearing.
/)/11/11
~I~u ,
"ill)
m@ : Apply petroleum jelly. SAT357D
Forward - All models -

clutch hub
6. Hold forward clutch hub and turn overrun clutch hub.
Overrun Check overrun clutch hub for directions of lock and unlock.
clutch hub
• If not as shown in illustration, check installed direction of
forward one-way clutch.
SAT358D
"7. Install rear internal gear assembly.

• Align teeth of forward clutch and overrun clutch drive plate.
SAT359D
8. Install needle bearing on rear planetary carrier.

• Apply petroleum jelly to needle bearing.
• Pay attention to direction of needle bearing.
" u
Rear planetary carner

~
SAT152E
9. Install rear sun gear on rear planetary carrier.

• Pay attention to direction of rear sun gear.
AT-148
ASSEMBLY
Assembly 2 (Cont'd)
10. Install rear planetary carrier on transmission case.
11. Install thrust needle bearing on front planetary carrier.

Thrust • Apply petroleum jelly to thrust needle bearing.
~.-b.. ~ needle • Pay attention to direction of thrust needle bearing.
~ bearing
Front
planetary
carrier
SAT153E
12. Install low one-way clutch to front planetary carrier by turn- •

ing it in the direction of the arrow as shown.
13. While holding front planetary carrier, turn low one-way
clutch.
Check low one-way clutch for correct directions of lock and
unlock.
14. Install front planetary carrier assembly on transmission

case.
15. Install snap ring with screwdriver.

Screwdriver • Forward clutch and bearings must be correctly installed for
snap ring to fit groove of transmission case.
AT-149
ASSEMBLY
Assembly 2 (Cont'd)
16. Install needle bearing on front sun gear.
Front
sun
gear
SAT154E
17. Install front sun gear on front planetary carrier.
18. Install needle bearing on front sun gear.

19. Install high clutch hub on front sun gear.
20. Install needle bearing on high clutch hub.

SAT156E
AT-150
ASSEMBLY
Assembly 2 (Cont'd)
21. Remove paper rolled around input shaft.
22. Install input shaft assembly.
• Align teeth of high clutch drive plates before installing.
23. Install reverse clutch assembly.

• Align teeth of reverse clutch drive plates before installing.
Adjustment 2 •
When any parts listed below are replaced, adjust total end play
and reverse clutch end play.
Item Reverse clutch

Total end play
Part name end play
Transmission case • •
Overrun clutch hub • •
Rear internal gear • •
Rear planetary carrier • •
Rear sun gear • •
Front planetary carrier • •
Front sun gear • •
High clutch hub • •
High clutch drum • •
Oil pump cover • •
Reverse clutch drum -
•
Reverse clutch TOTAL END PLAY

assembly
• Measure clearance between reverse clutch drum and nee-
dle bearing for oil pump cover.
• Select proper thickness of bearing race so that end play is
within specifications.
SAT374D
AT-151
ASSEMBLY
1. Measure dimensions "K" and "L" and then calculate
dimension "J".
Transmission
case
SAT375D
a. Measure dimension "K".
Transmission case
SAT376D
b. Measure dimension "L",

Depth
c. Calculate dimension "J".
gauge
• "J": Distance between oil pump fitting surface of transmis-
sion case and needle bearing mating surface of high
clutch drum.
J=K-L
SAT377D
2. Measure dimension "M".

a. Place bearing race and needle bearing on oil pump assem-
/ Needle bearing bly.
SAT378D
Straightedge b. Measure dimension "M".

• "M": Distance between transmission case fitting surface
and needle bearing on oil pump cover.
• M1: Indication of gauge.
Straightedge
SAT379D
AT-152
ASSEMBLY
c. Measure thickness of straightedge "t".
M = M1 - t
3. Adjust total end play "T 3'"

T3 = J - M
Total end play "T3":
0.25 - 0.55 mm (0.0098 - 0.0217 in)
• Select proper thickness of bearing race so that total end
play is within specifications.
Bearing races:
Refer to SOS, AT -173.
REVERSE CLUTCH END PLAY

•
•
Measure clearance between oil pump cover and thrust
washer for reverse clutch drum.
Select proper thickness of thrust washer so that end play is
within specifications.
•
SAT380D
1. Measure dimensions "0" and "P" and then calculate

dimension "N".
Transmission case
SAT381D
a. Place thrust washer on reverse clutch drum.

b. Measure dimension "0".
AT-153
ASSEMBLY
c. Measure dimension "P".
- Straightedge d. Calculate dimension "N".
Depth • "N": Distance between oil pump fitting surface of transmis-
gauge
sion case and thrust washer on reverse clutch drum.
N=O-P
Transmission case pack SAT383D
2. Measure dimensions "R" and "S" and then calculate

dimension "Q".
SAT384D
a. Measure dimension "R".
Straightedge b. Measure dimension "S".

c. Calculate dimension "Q".
• "0": Distance between transmission case fitting surface
and thrust washer mating surface.
O=R-S
3. Adjust reverse clutch end play "T4".

T4 = N - 0
Reverse clutch end play:
0.65 - 1.00 mm (0.0256 - 0.0394 in)
• Select proper thickness of thrust washer so that reverse
clutch end play is within specifications.
Thrust washer:
Refer to SDS, AT-173.
AT-154
ASSEMBLY
Assembly 3
1. Remove reverse clutch assembly and install needle bearing
on high clutch assembly.
2. Install reverse clutch assembly.
3. Install anchor end pin, washer and lock nut on transmission

case.
4. Place brake band on outside of reverse clutch drum. Tighten
. anchor end pin just enough so brake band is evenly fitted
on reverse clutch drum.
5. Place bearing race selected in total end play adjustment •

Bearing race
step on oil pump cover.
• Apply petroleum jelly to bearing race.
SAT158E
Thrust washer 6. Place thrust washer selected in reverse clutch end play step
on reverse clutch drum.
• Apply petroleum jelly to thrust washer.
7. Install oil pump assembly on transmission case.
AT-155
ASSEMBLY
Assembly 3 (Cont'd)
8. Tighten oil pump fixing bolts to specified torque.
9. Install O-ring to input shaft.

10. Adjust brake band.

a. Tighten anchor end pin to specified torque.
Anchor end pin:
Ill:3.9 - 5.9 N.m (0.4 - 0.6 kg-m, 35 - 52 in-Ib)
b. Back off anchor end pin two and a half turns.
c. While holding anchor end pin, tighten lock nut.
AT-156
ASSEMBLY
11. Apply compressed air to oil holes of transmission case and

check operation of brake band.
SAT397D
Adjustment 3
FINAL DRIVE END PLAY
_. Except model 34X81 -
• Measure clearance between differential side bearing and
transmission case.
• Select proper thickness of adjusting shim so that end play
is within specifications.
1. Measure dimension 'T" between side bearing fitting sur- •

face of transmission case and converter housing fitting sur-
face of transmission case.
"T/': indication of gauge
Straightedge
SAT695D
2. Measure thickness of straightedge "t".

T = T1 - t
3. Place final drive assembly on converter housing.

4. Measure dimension "U" between end of differential case
and transmission case fitting surface of converter housing.
SAT696D
AT-157
ASSEMBLY
Adjustment 3 (Co nt' d)
5. Measure dimension "V" between end of differential case
and adjusting shim mating surface of differential side bear-
ing.
6. Calculate final drive end play.
Final drive end play:
T-U+V
7. Select proper thickness of differential side bearing adjust-
ing shim so that final drive end play is within specifications.
Final drive end play:
0- 0.15 mm (0 - 0.0059 in)
SAT697D Differential side bearing adjusting shim:
Assembly 4
1. Install differential side bearing adjusting shim selected in
final drive end play adjustment step on transmission case.
2. Install final drive assembly on transmission case.
3. Install oil tube on converter housing.
SAT134E
AT-158
ASSEMBLY
Assembly 4 (Cont'd)
4. Install a-ring on differential oil port of transmission case.
3 - 5 (0.12 • 0.20)
5. Install converter housing on transmission case.
• Apply locking sealant to mating surface of converter hous-
ing.
Bolt Length mm (in)

Locking
sealant @ 32.8 (1.291)
~O'i"9
@ 40 (1.57)
w-w
Unit:
SAT405D
3-R accumulator
piston
N-D accumulator
piston
6.
a.
Install accumulator piston.
Check contact surface of accumulator piston for damage.
•
Contact
surface SAT406D
b. Install a-rings on accumulator piston.

N-D accumUlato'e
iston ~ • Apply ATF to a-rings.
SIR ~
accumulator Accumulator piston O-rings:
piston Unit: mm (in)
~C)
o Accumulator
SIR accumulator
Inner diameter (Small)
26.9 (1.059)
Inner diameter (Large)
44.2 (1.740)
N-D accumulator 39.4 (1.551)

O~ 34.6 (1.362)
O-ring
SAT135EA
c. Install accumulator pistons and return springs on transmis-

~ Return N-D ~ sion case.
~ spring accumulator ~
S/R piston • Apply ATF to inner surface of transmission case.
accumulator Return
@)
ATF . t
pISon spring~ tATi=" Return springs:
~~~ ~~'\\~ Unit: mm (in)
~U~~~-1C
.~.~
....
..
o*lf}~y)~: Spring Free length Outer diameter
~:
~ _~o_
° ~~~'
Apply ATF.
00 \\ I I~o
r
SAT408DA
SIR accumulator spring
N-D accumulator spring

56.4 (2.220)
43.5 (1.713)
21.0 (0.827)
28.0 (1.102)
AT-159
ASSEMBLY
Assembly 4 (C
7. Install ,. ont'd)
• Acase . tp seals for band servo oil holes on transmiss'Ion
pply petroleum jell y to lip seals.
8. Install oil filt

• Take care w~~ f.otr9?VernOr valve
I s dIrection. .
. to t ransm'ISSloncase.
Install throttle wIre .
10. Install thrattle wire to thrattle lever.
11. Install control

a. Insert manu valve assembl
• Apply ATF t:I~:~v:alinto conir~1 valve assembly.
valve.
AT.160
ASSEMBLY
Assembly 4 (Conl'd)
b, Set manual shaft in Neutral position.
~~~~C0\
~~ \ .---.! c. Install control valve assembly on transmission case while
~ />"0 aligning manual valve with manual plate and detent valve
\~
o <=~~ )' () with throttle lever.
Throttle lever' ~ ~ \
~ I l';-,~\ ,~\\)
,./, Manual plate 2\ (
d:----, (\, Detent
n\'\3l~w1:
; \ ~ "~
. ~ -P-' (\ valve
/- \, 'sdJ , ,
Manual valve
nd\'~~\ r:,\\)~
\(--' "'!f () ~ A~
\ ~ SAT414D
d. Pass solenoid harness through transmission case and

install terminal body on transmission case by pushing it.
e. Install clip to terminal body.
f. Tighten bolts @, @. ~ and @.

Bolt
Bolt length 'T' mm (in)

@
33,0
(1.299)
@
40,0
(1.575)
@
43,5
(1,713)
@
25,0
(0.984)
•
Number of bolts 6 5 2 2
Tightening torque
7 - 9 (0,7 - 0.9, 61 - 78)
N'm (kg-m, in-Ib)
SAT664D
12. Install oil pan.

a. Attach magnet to oil pan.
AT-161
ASSEMBLY
Assembly 4 (Cont'd)
b. Install new oil pan gasket on transmission case.
c. Install oil pan on transmission case.
• Always replace oil pan bolts.
• Tighten the four bolts in a criss-cross pattern to prevent
dislocation of gasket.
d. Tighten drain plug to specified torque.
13. Install governor valve.

a. Install governor valve assembly into transmission case.
SAT070D
b. Install O-ring to governor cap.

a-ring • Apply ATF to a-ring.
SAT160E
c. Install governor cap onto transmission case.
d. Install snap ring onto transmission case with a screwdriver.

• Align snap ring gap with the notch of transmission case.
AT-162
ASSEMBLY
Assembly 4 (Cont'd)
14. Install inhibitor switch.
a. Set manual shaft in "P" position.
b. Temporarily install inhibitor switch on manual shaft.
c. Move selector lever to "N" position.
SAT620E
d. Use a 4 mm (0.157 in) pin for this adjustment.

1) Insert the pin straight into the manual shaft adjustment hole.
2) Rotate inhibitor switch until the pin can also be inserted
straight into hole in inhibitor switch.
e. Tighten inhibitor switch fixing bolts.
f. Remove pin from adjustment hole after adjusting inhibitor
switch.
15. Install oil charging pipe and oil cooler tube to transmission •
case.
SAT586H
16. Install torque converter.

a. Pour ATF into torque converter.
• Approximately 1 liter (7/8 Imp qt) of fluid is required for a
new torque converter.
• When reusing old torque converter, add the same amount
of fluid as was drained.
SAT428DA
b. Install torque converter while aligning notches of torque

converter with notches of oil pump.
Torque
converter
AT-163
ASSEMBLY
Assembly 4 (Cont'd)
c. Measure distance "A" to check that torque converter is in
proper position.
Distance "A":
Except model 34X81
21.1 mm (O.831 in) or more
Model 34X81
15.9 mm (O.626 in) or more
AT-164
Except Europe and Except Europe and

Europe Australia Australia
Australia Australia
Applied model
GA150E GA160E
SR200E
With catalyzer Without catalyzer
Automatic transaxle
RL4F03A
model
Automatic transaxle
assembly
Model code number 34X69 34X68 34X70 34X80 34X81
Transaxle gear ratio
1st 2.861 2.8611 2.861
2nd 1.562 1.5622 1.562
3rd 1.000 1.0000 1.000
4th 0697 .0.6979 0.697
Reverse 2.310 2.3103 2.310
Final drive 3.827 4.0721 3.827
Recommended oil Genuine Nissan ATF or equivalent
Oil capacity f (Imp qt) 7.0 (6-1/8)
Specifications and Adjustments

VEHICLE SPEED WHEN SHIFTING GEARS
Model 34X68
Throttle position
Full throttle
0, -->
48 - 56
O2 O2 -->
88 - 96
03 03 -->
-
Vehicle speed km/h (MPH)
O. O. -->
133 - 141
03 03 -->
80 - 88
O2 O2 -->
37 - 45
D, 12 -->
45 - 53
1,
•
(30 - 35) (55 - 60) (83 - 88) (50 - 55) (23 - 28) (28 - 33)
31 - 39 54 - 62 102 - 110 75 - 83 44 - 52 7 - 15 45 - 53
Half throttle
(19 - 24) (34 - 39) (63 - 68) (47 - 52) (27 - 32) (4 - 9) (28 - 33)

Throttle position
0, --> O2 O2 --> 03 03 --> O. O. --> 03 03 --> O2 O2 --> 0, 12 --> 1,
51 - 60 94 - 102 136 - 144 85 - 93 40 - 48 48 - 56
Full throttle -
(32 - 37) (58 - 63) (85 - 89) (53 - 58) (25 - 30) (30 - 35)
30 - 38 52 - 60 97 - 105 67 - 75 42 - 50 8 - 16 48 - 56
Half throttle
(19 - 24) (32 - 37) (60 - 65) (42 - 47) (26 - 31) (5 - 10) (30 - 35)
Model 34X80
Throttle position
0, --> O2 O2 --> 03 03 --> O. O. --> 03 03 --> O2 O2 --> 0, 12 --> 1,
52.60 100 - 108 145 - 153 90.98 40 - 48 49 - 57
Full throttle -
(32 - 37) (62 - 67) (90 - 95) (56 - 61) (25 - 30) (30 - 35)
30 - 38 53 - 61 103 - 111 69 - 77 42 - 50 8 - 16 49 - 57
Half throttle
(19 - 24) (33 - 38) (64 - 69) (43 - 48) (26 - 31) (5 - 10) (30 - 35)
Model 34X81
Throttle position
0, --> O2 O2 --> 03 03 --> O. O. --> 03 03 --> O2 O2 --> 0, 12 --> 1,
58.66 107.115 160. 168 96 - 104 39 - 47 48 - 56
Full throttle -
(36 - 41) (66 - 71) (99 - 104) (60 - 65) (24 - 29) (30 - 35)
33 - 41 57 - 65 105.113 69 - 77 45 - 53 8. 16 48 - 56
Half throttle
(21 - 25) (35 - 40) (65.70) (43 - 48) (28 - 33) (5 - 10) (30 - 35)
AT-165
Specifications and Adjustments (Cont'd)
VEHICLE SPEED WHEN PERFORMING Model 34X81
LOCK-UP Vehicle speed
km/h (MPH)
Model 34X68 Throttle position Gear position
Lock-up "ON"
Vehicle speed
km/h (MPH) 105 - 113
Throttle position Gear position Half throttle
(65 - 70)
Lock-up "ON"
102 - 110
Half throttle
(63 - 68)
STALL REVOLUTION
Stall revolution
Engine
rpm
GA15DE Model 34X69 2,400 - 2,700
Vehicle speed
Throttle posi- km/h (MPH) Model 34X70, 34X80 2,550 - 2,850
Gear position GA16DE
tion
Lock-up "ON" Lock-up "OFF" Model 34X68, 34X80 2,450 - 2,750
112 - 120 97 - 105 SR20DE Model 34X81 1,850-2,150

Half throttle D4
(70 - 75) (60 - 65)
THROTTLE WIRE ADJUSTMENT

Model 34X80 Unit: mm (in)
Vehicle speed Throttle wire stroke 40 - 42 (1.57 - 1.65)

Throttle posi- km/h (MPH)
Gear position
tion
Lock-up "ON" Lock-up "OFF"
116 - 124 97 - 105

Half throttle D4
(72 - 77) (60 - 65)
LINE PRESSURE
Model 34X68, 34X69 and 34X70
Engine speed Line pressure kPa (bar, kg/em', psi)
rpm R position D position 2 position 1 position
Idle 883 (8.83, 9.0, 128) 637 (6.37, 6.5, 92) 1,147 (11.47,11.7,166) 1,147 (11.47,11.7,166)
Stall 1,765 (17.65, 18.0,256) 1,275 (12.75,13.0,185) 1,275 (12.75, 13.0, 185) 1,275 (12.75,13.0,185)
Model 34X80
Engine speed Line pressure kPa (bar, kg/em?, psi)
Idle 883 (8.83, 9.0, 128) 637 (6.37, 6.5, 92) 1,147 (11.47,11.7,166) 1,147 (11.47,11.7,166)
Stall 1,765 (17.65, 18.0, 256) 1,275 (12.75, 13.0, 185) 1,275 (12.75, 13.0, 185) 1,275 (12.75, 13.0, 185)
Model 34X81
Engine speed Line pressure kPa (bar, kg/em', psi)
Idle 883 (8.83, 9.0, 128) 637 (6.37, 6.5, 92) 1,147 (11.47,11.7,166) 1,147 (11.47,11.7,166)
Stall 1,765 (17.65, 18.0,256) 1,275 (12.75, 13.0, 185) 1,275 (12.75, 13.0, 185) 1,275 (12.75, 13.0, 185)
AT-166
CONTROL VALVES
Control valve return springs
Unit: mm (in)
Parts Part No. Free length Outer diameter

Model
Pressure modi-
34X69, 34X70, 34X68,
d) lier valve 31742-31X64 2502 (0.9850) 79 (0.311)
34X80, 34X81
spring
@) Kickdown modulator valve spring 31742-31 X03 40.5 (1.594) 9.0 (0.354)
34X80 31742-31X04 51.14 (2.0134) 17.0 (0.669)

1-2 accumula-
@ 34X69, 34X70, 34X68,
tor valve spring 31742-31X63 50.8 (2000) 17.0 (0.669)
34X81
@ 3-2 timing valve spring 31736-21 XOO 26.3 (1.035) 7.2 (0.283)
~ 1st reducing valve spring 31835-21X08 22.6 (0.890) 7.3 (0.287)

Upper @ Torque converter relief valve spring 31742-31X06 23.5 (0.925) 7.4 (0.291)
body
Throttle modu- 34X68, 34X81 31742-31X07 29.5 (1.161) 5.5 (0.217)
(J) lator valve
spring 34X69, 34X70, 34X80 31742-31X18 29.5 (1161) 5.5 (0.217)
34X69, 34X70, 34X80 31736-01X02 21.7 (0.854) 6.65 (0.2618)

4th speed cut
@ 34X68 31756-21X02 22.6 (0.890) 7.3 (0.287)
•
valve spring
34X81 31835-21X02 23.2 (0913) 6.2 (0.244)
@ Lock-up control valve spring 31742-31X08 39.5 (1.555) 50 (0.197)
@ 4-2 sequence valve spring 31742-31X09 39.5 (1.555) 51 (0.201)
- Oil cooler relief valve spring 31872-31XOO 17.02 (0.6701) 8.0 (0.315)
Throttle valve 34X81 31802-31 X06 32.0 (1.260) 10.0 (0.394)

d) and detent 34X69, 34X70, 34X68,
valve spring 31802-31X07 33.0 (1.299) 10.0 (0.394)
34X80
(2) Pressure regulator valve spring 31742-31XOO 5224 (2.0567) 15.0 (0.591)
34X68 31762-31XOO 52.0 (2.047) 8.0 (0.315)

Lower
3-4 shift valve
body @ 34X69, 34X70, 34X80 31762-31 X 13 52.0 (2.047) 7.45 (0.2933)
spring
34X81 31762-31X11 52.0 (2.047) 80 (0.315)
@ 2-3 shift valve spring 31762-31X01 52.7 (2.075) 7.0 (0.276)
cID 1-2 shift valve spring 31762-31X02 45.9 (1.807) 5.3 (0.209)
@ Overrun clutch control valve spring 31742-31X60 48.9 (1.925) 7.0 (0.276)
AT-167
CLUTCH AND BRAKES 34X68, 34X69,
Model 34X81
34X68, 34X69, 34X70, 34X80
Model 34X81
34X70, 34X80
I Forward cl utch I
IReverse clutch I Number of drive plates 5
Number of
2
drive plates Number of driven plates 5
Number of Drive plate thickness
2
driven plates
mm (in)
Drive plate
thickness Standard 1.8 (0.071)
mm (in)
Wear limit 1.6 (0.063)
Standard 2.0 (0.079)
Clearance mm (in)
Standard 0.45 - 0.85 (0.0177 - 0.0335)
Clearance
mm (in) Allowable limit 1.85 (0.0728)
Standard 0.5 - 0.8 (0.020 - 0.031)
Thickness
Allowable Part number
1.2 (0.047) mm (in)
limit
3.6 (0.142) 31537-31X60
4.4 (0.173) 31537-31XOO 3.8 (0.150) 31537-31X61
Thickness of retaining plate
Thickness 01 4.6 (0.181) 31537-31X01 4.0 (0.157) 31537-31X62
retaining
plates 4.8 (0.189) 31537-31X02 4.2 (0.165) 31537-31X63
5.0 (0.197) 31537-31X03
4.4 (0.173) 31537-31X64
5.2 (0.205) 31537-31X04
4.6 (0.181) 31537-31X65
IHigh clutch I IOverrun clutch I
Number 01
3 4
drive plates Number of drive plates 3
Number 01
5 6+1 Number of driven plates 4
driven plates
Drive plate Drive plate thickness
thickness mm (in)
mm (in)
Standard 1.6 (0.063)
Standard 2.0 (0.079) 1.6 (0.063)
Wear limit 1.8 (0.071) 1.4 (0.055)
Clearance Clearance mm (in)
mm (in)
Standard 1.0 - 1.4 (0.039 - 0.055)
Standard 1.4 - 1.8 (0.055 - 0.071)
- Allowable limit 2.0 (0.079)
Allowable
2.4 (0.094) 2.6 (0.102)
limit Thickness
Part number
Thickness mm (in) Part number mm (in)
31537- 31537- 3.6 (0.142) 31567-31X72

3.8 (0.150) 3.8 (0.150)
31X11 31X11
Thickness 01 retaining plate 3.8 (0.150) 31567-31X73
31537- 31537-
4.0 (0.157) 4.0 (0.157)
31X12 31X12 4.0 (0.157) 31567-31X74
.
31537- 31537- 4.2 (0.165) 31567-31X75
4.2 (0.165) 4.2 (0.165)
Thickness 01 31X13 31X13
retaining 31537- 4.4 (0.173) 31567-31X76
31537-
plates 4.4 (0.173) 4.4 (0.173)
31X14 31X14
31537- 31537-
46 (0.181) 4.6 (0.181)
31X15 31X15
31537- 31537-
4.8 (0.189) 4.8 (0.189)
31X16 31X16
31537-
5.0 (0.197)
31X17
AT-168
SERVICE OATA AND SPECIFICATIONS (50S)
34X68,
OIL PUMP
Model 34X69, 34X81 Oil pump side clear-
34X70, 34X80 0.02 - 0.04 (0.0008 - 0.0016)
ance mm (in)
ILow & reverse brake I Inner gear
Number of drive plates 5 Thickness
Part number
Number of driven plates 5 mm (in)
Drive plate thickness 9.99 - 10.00

31346-31 XOO
mm (in) (0.3933 - 0.3937)
Standard 2.0 (0.079) 9.98 - 9.99

31346-31 X01
(0.3929 - 0.3933)
9.97 - 998
Clearance mm (in) 31346-31X02
Thickness of inner (0.3925 - 0.3929)
Standard 1.4 - 1.8 (0.055 - 0.071) gears and outer gears Outer gear
Allowable limit 2.8 (0.110) . Thickness
Part number
Thickness mm (in)
Part number
mm (in)
9.99 - 10.00
31347-31XOO
36 (0.142) 31667-31X10 (0.3933 - 0.3937)
38(0150) 31667-31X11 9.98 - 9.99

Thickness of retaining 31347-31X01
(0.3929 - 0.3933)
plate 4.0 (0 157) 31667-31X12
9.97 - 9,98
4.2 (0.165) 31667-31X13 31347-31X02
(0.3925 - 0.3929)
•
4.4 (0.173) 31667-31X14 Clearance between oil
4.6 (0.181) 31667-31X15 pump housing and
outer gear
IBrake band I mm (in)
Anchor end bolt tighten-
Standard 008 - 0 15 (0.0031 - 0.0059)
ing torque 39 - 5.9 (0.4 - 06, 35 - 52)
N'm (kg-m, in-Ib) Allowable limit 015 (0.0059)
Number of returning rev- Oil pump cover seal

olutions for anchor end 2.5:1e0125 ring clearance
bolt mm (in)
Lock nut tightening Standard 0.10 - 0.25 (0.0039 - 0.0098)

31 - 36 (3.2 - 3.7, 23 - 27)
torque N'm (kg-m, ft-Ib)
Allowable limit 0.25 (0.0098)
Clutch and brake return springs INPUT SHAFT

Unit: mm (in)
Input shaft seal ring
Return spring Free length Outer diameter clearance
mm (in)
Forward clutch Inner 263 (1.035) 77 (0.303)
(Overrun clutch) Standard 0.08 - 0.23 (0.0031 - 0.0091)
(16 pes) Outer 266 (1.047) 10.6 (0.417)
Reverse clutch (16 pes) 18.6 (0.732) 80 (0.315)
High clutch (12 pes) 197 (0.776) 11.1 (0.437)
PLANETARY CARRIER
Clearance between planetary
carrier and pinion washer
mm (in)
Standard 0.15 - 0.70 (0.0059 - 0.0276)
Allowable limit 080 (0.0315)
AT-169
FINAL DRIVE Differential side bearing adjusting shims
Differential side gear clearance
Clearance between side gear
and differential ease with 0.1 - 0.2 (0.004 - 0.008) 0.48 (0.0189) 38454-M8001
washer mm (in)
0.56 (0.0220) 38454-M8003
0.64 (0.0252) 38454-M8005
0.72 (0.0283) 38454-M8007

Differential side gear thrust washers (Model
0.80 (0.0315) 38454-M8009
34X69)
0.88 (0.0346) 38454-M8011
0.96 (0.0378) 38454-M8013
0.75 - 0.80 (0.0295 - 0.0315) 38424-31 XOO
1.04 (0.0409) 38454-M8015
0.80 - 0.85 (0.0315 - 0.0335) 38424-31X01
0.85 - 0.90 (0.0335 - 0.0354) 38424-31 X02

0.90 - 0.95 (0.0354 - 0.0374) 38424-31 X03 (Model 34X81)
0.95 - 1.00 (0.0374 - 0.0394) 38424-31X04
0.40 (0.0157) 31499-21X07
0.44 (0.0173) 31499-21X08

Differential side gear thrust washers
0.48 (00189) 31499-21X09
0.52 (0.0205) 31499-21X10
0.56 (0.0220) 31499-21X11
0.75 - 0.80 (0.0295 - 0.0315) 38424-02111
0.60 (00236) 31499-21X12
0.80 - 0.85 (0.0315 - 0.0335) 38424-02112
0.64 (0.0252) 31499-21X13
0.85 - 090 (0.0335 - 0.0354) 38424-02113
068 (00268) 31499-21 X14
090 - 0.95 (0.0354 - 0.0374) 38424-02114
0.72 (00283) 31499-21X15
0.95 - 1.00 (0.0374 - 0.0394) 38424-02115
076 (0.0299) 31499-21X16
0.80 (0.0315) 31499-21X17
0.84 (0.0331) 31499-21X18

Differential case end play (Except model
0.88 (0.0346) 31499-21X19
34X81)
0.92 (0.0362) 31499-21X20
Differential case end play
0-015 (0 - 0.0059) 1.44 (00567) 31499-21X21
mm (in)
Bearing preload (Model 34X81)

Oifferential side bearing pre-
004 - 009 (00016 - 0.0035)
load 'T' mm (in)
Turning torque (Model 34X81)

Turning torque of final drive 049 _ 1 08 ( _ 11 4 _ 5)
assembly Nm (kg-em, in-Ib)' . 5.0 .0,.3 9.
AT-170
Table for selecting differential side bearing Bearing preload (Model 34X81)
adjusting shim(s)
Reduction pinion gear bearing
Unit: mm (in) 0.05 (0.0020)
preload mm (in)
Dial indicator deflection Suitable shim(s)
0.31 - 0.35 (0.0122 - 0.0138) 040 (0.0157)

035 - 0.39 (0.0138 - 0.0154) 0.44 (0.0173) Reduction pinion gear bearing adjusting
0.39 - 043 (0.0154 - 0.0169) 048 (0.0189) shims
043 - 047 (0.0169 - 0.0185) 0.52 (0.0205)
047 - 0.51 (0.0185 - 0.0201) 0.56 (0.0220)
1.74 (0.0685) 31438-31X16
0.51 - 0.55 (0.0201 - 0.0217) 060 (0.0236) 1.78 (00701) 31438-31X17
055 - 059 (0.0217 - 0.0232) 0.64 (0.0252) 1.82 (0.0717) 31438-31X18
0.59 - 0.63 (0.0232 - 0.0248) 0.68 (0.0268) 1.86 (0.0732) 31438-31X19
0.63 - 0.67 (0.0248 - 00264) 1.90 (0.0748) 31438-31 X20

0.72 (0.0283)
1.92 (0.0756) 31439-31 X60
0.67 - 0.71 (0.0264 - 0.0280) 076 (0.0299)
1.94 (0.0764) 31438-31X21
071 - 075 (0.0280 - 0.0295) 0.80 (0.0315) 1.96 (0.0772) 31439-31X61
075 - 079 (0.0295 - 0.0311) 084 (0.0331) 1.98 (0.0780) 31438-31 X22
0.79 - 083 (0.0311 - 0.0327) 0.88 (0.0346) 2.00 (0.0787) 31439-31 X62
0.83 - 0.87 (0.0327 - 0.0343) 0.92 (00362) 202 (0.0795) 31438-31 X23
2.04 (0.0803) 31439-31X63
087 - 0.91 (0.0343 - 0.0358) 048 (0.0189) + 048 (0.0189)
206 (0.0811) 31438-31X24
0.91 - 095 (0.0358 - 0.0374) 048 (0.0189) + 052 (0.0205)
2.08 (0.0819) 31439-31X64
095 - 099 (0.0374 - 0.0390) 0.52 (0.0205) + 052 (0.0205)
•
2.10 (00827) 31438-31X60
0.99 - 1.03 (0.0390 - 0.0406) 052 (0.0205) + 056 (0.0220) 2.12 (0.0835) 31439-31X65
103 - 1.07 (0.0406 - 0.0421) 056 (00220) + 0.56 (0.0220) 2.14 (0.0843) 31438-31X61
1.07 - 1.11 (0.0421 - 0.0437) 056 (0.0220) + 060 (0.0236) 2.16 (00850) 31439-31 X66
2.18 (0.0858) 31438-31X62
1.11 - 1.15 (0.0437 - 00453) 0.60 (0.0236) + 0.60 (0.0236)
2.20 (0.0866) 31439-31 X67
1.15 - 1.19 (0.0453 - 0.0469) 060 (00236) + 064 (0.0252)
2.22 (0.0874) 31438-31X63
119 - 1.23 (0.0469 - 0.0484) 064 (0.0252) + 0.64 (0.0252) 2.24 (0.0882) 31439-31 X68
1.23 - 1.27 (0.0484 - 0.0500) 0.64 (0.0252) + 0.68 (0.0268) 226 (0.0890) 31438-31X64
1.27 - 1.31 (0.0500 - 0.0516) 068 (0.0268) + 0.68 (0.0268) 2.28 (0.0898) 31439-31 X69
2.30 (0.0906) 31438-31 X65
1.31 - 1.35 (0.0516 - 0.0531) 0.68 (0.0268) + 0.72 (0.0283)
234 (0.0921) 31438-31X66
135 - 139 (00531 - 0.0547) 144 (0.0567)
238 (0.0937) 31438-31 X67
139 - 143 (0.0547 - 0.0563) 0.72 (0.0283) + 0.76 (0.0299) 242 (0.0953) 31438-31 X68
143 - 147 (0.0563 - 0.0579) 076 (0.0299) + 0.76 (0.0299) 246 (0.0969) 31438-31X69
147 - 151 (0.0579 - 0.0594) 0.76 (0.0299) + 0.80 (0.0315) 250 (0.0984) 31438-31 X70
2.54 (0.1000) 31438-31X71
151 - 155 (00594 - 0.0610) 0.80 (0.0315) + 080 (0.0315)
2.58 (0 1016) 31438-31 X72
1.55 - 159 (0.0610 - 00626) 0.80 (0.0315) + 0.84 (0.0331)
262 (0.1031) 31438-31 X73
1.59 - 163 (0.0626 - 0.0642) 084 (0.0331) j- 084 (0.0331)
266 (0.1047) 31438-31 X74
163 - 1.67 (0.0642 - 0.0657) 0.84 (0.0331) + 088 (0.0346)
1.67 - 1.71 (0.0657 - 0.0673) 088 (0.0346) + 0.88 (0.0346)
1.71 - 1.75 (0.0673 - 0.0689) 088 (0.0346) i 092 (0.0362)
1.75 - 1.79 (0.0689 - 0.0705) 092 (00362) + 0.92 (0.0362)
1.79 - 183 (0.0705 - 0.0720) 044 (0.0173) + 144 (0.0567)
1.83 - 187 (0.0720 - 00736) 048 (0.0189) + 144 (0.0567)
1.87 - 191 (0.0736 - 0.0752) 052 (0.0205) + 144 (0.0567)
1.91 - 195 (0.0752 - 0.0768) 0.56 (0.0220) + 144 (0.0567)
REDUCTION GEAR
Bearing preload (Model 34X68, 34X69,
34X70, 34X80)
Reduction pinion gear bearing
011 - 069 (11 - 70, 095 - 6.08)
preload Nm (kg-em, in-Ib)
AT-171
Table for selecting reduction pinion gear Bearing preload (Except model 34X81)
bearing adjusting shim Output shaft bearing preload
Unit: mm (in) 0.25 - 0.88 (2.5 - 9.0, 2.2 - 7.8)
Nm (kg-em, in-Ib)
Dimension'T' Suitable shim(s)
1.77 - 1.81 (0.0697 - 00713) 1.74 (0.0685)

1.81 - 1.85 (0.0713 - 0.0728) 1.78 (0.0701) Output shaft bearing adjusting spacers
1.85 - 1.89 (0.0728 - 0.0744) 1.82 (0.0717) (Except model 34X81)
1.89 - 1.93 (00744 - 0.0760) 1.86 (0.0732)
1.93 - 1.96 (0.0760 - 0.0772) 1.90 (0.0748)
6.26 (0.2465) 31437-31X16
1.96 - 1.98 (0.0772 - 0.0780) 1.92 (0.0756)
6.30 (0.2480) 31437-31X17
1.98 - 2.00 (0.0780 - 0.0787) 1.94 (0.0764) 6.34 (0.2496) 31437-31X18
2.00 - 2.02 (0.0787 - 0.0795) 1.96 (00772) 6.38 (0.2512) 31437-31X19
2.02 - 2.04 (0.0795 - 0.0803) 1.98 (0.0780) 6.42 (0.2528) 31437-31X20
2.04 - 2.06 (0.0803 - 0.0811) 2.00 (0.0787) 6.46 (0.2543) 31437-31X21
2.06 - 2.08 (0.0811 - 0.0819) 2.02 (0.0795) 6.50 (0.2559) 31437-31X22
2.08 - 2.10 (0.0819 - 0.0827) 2.04 (0.0803) 6.54 (0.2575) 31437-31X23
2.10 - 2.12 (0.0827 - 0.0835) 206 (0.0811) 658 (0.2591) 31437 -31X24
6.62 (0.2606) 31437-31X60
2.12 - 2.14 (0.0835 - 0.0843) 2.08 (0.0819)
6.64 (0.2614) 31437-31X78
2.14 - 216 (0.0843 - 0.0850) 2.10 (0.0827)
666 (0.2622) 31437-31X61
2.16 - 2.18 (0.0850 - 0.0858) 2.12 (0.0835)
6.68 (0.2630) 31437-31X79
2.18 - 2.20 (0.0858 - 00866) 2.14 (0.0843)
6.70 (0.2638) 31437-31X62
2.20 - 2.22 (0.0866 - 0.0874) 2.16 (0.0850)
6.72 (0.2646) 31437-31X80
2.22 - 2.24 (0.0874 - 0.0882) 218 (0.0858) 6.74 (02654) 31437-31X63
2.24 - 2.26 (0.0882 - 00890) 2.20 (0.0866) 6.76 (0.2661) 31437-31X81
2.26 - 2.28 (0.0890 - 0.0898) 2.22 (0.0874) 6.78 (0.2669) 31437-31X64
2.28 - 2.30 (0.0898 - 0.0906) 2.24 (0.0882) 6.80 (0.2677) 31437-31X82
2.30 - 2.32 (0.0906 - 0.0913) 226 (00890) 6.82 (0.2685) 31437-31X65
2.32 - 234 (0.0913 - 0.0921) 2.28 (0.0898) 6.84 (0.2693) 31437-31X83
234 - 237 (0.0921 - 00933) 2.30 (0.0906) 6.86 (02701) 31437-31X66

6.88 (0.2709) 31437-31X84
2.37 - 2.41 (0.0933 - 0.0949) 2.34 (0.0921)
690 (0.2717) 31437-31X67
2.41 - 2.45 (0.0949 - 0.0965) 238 (0.0937)
6.92 (0.2724) 31437-31X46
2.45 - 2.49 (0.0965 - 0.0980) 2.42 (0.0953)
694 (0.2732) 31437-31X68
2.49 - 2.53 (0.0980 - 0.0996) 2.46 (0.0969)
696 (0.2740) 31437-31X47
253 - 2.57 (0.0996 - 0.1012) 2.50 (0.0984)
6.98 (0.2748) 31437-31X69
2.57 - 2.61 (0.1012 - 0.1028) 254 (0.1000) 31437-31X48
7.00 (0.2756)
261 - 2.65 (0.1028 - 0.1043) 258 (0.1016) 702 (0.2764) 31437-31X70
265 - 269 (0.1043 - 0.1059) 2.62 (0.1031) 706 (0.2780) 31437-31X71
2.69 - 273 (0 1059 - 0.1075) 266 (0.1047) 7.10 (0.2795) 31437-31X72
7.14 (0.2811) 31437-31X73
7.18 (0.2827) 31437-31X74
7.22 (0.2843) 31437-31X75
OUTPUT SHAFT
Seal ring clearance
Output shaft seal ring clear-
ance mm (in)
Standard 0.10 - 0.25 (0.0039 - 0.0098)
Allowable limit 025 (00098)
End play (Model 34X81)

Output shaft end play mm (in) o - 0.5 (0 - 0.020)
AT-172
Table for selecting output shaft bearing BEARING RETAINER
adjusting spacer
Seal ring clearance
Unit: mm (in)
Bearing retainer seal ring
Dimension "T" Suitable spacer
clearance mm (in)
6.29 - 6.33 (0.2476 - 0.2492) 6.26 (0.2465)
Standard 0.10 - 0.25 (0.0039 - 0.0098)
6.33 - 6.37 (0.2492 - 0.2508) 6.30 (0.2480)
6.37 - 6.41 (0.2508 - 0.2524) 634 (0.2496)
6.41 - 6.45 (0.2524 - 0.2539) 6.38 (0.2512)
6.45 - 6.49 (0.2539 - 0.2555) 6.42 (0.2528)

TOTAL END PLAY
6.49 - 6.53 (0.2555 - 0.2571) 6.46 (0.2543)
Total end play mm (in) 0.25 - 0.55 (0.0098 - 0.0217)
6.53 - 657 (0.2571 - 0.2587) 6.50 (0.2559)
6.57 - 6.61 (0.2587 - 0.2602) 654 (0.2575)
6.61 - 6.65 (0.2602 - 0.2618) 6.58 (0.2591)

Bearing races for adjusting total end play
6.65 - 668 (0.2618 - 0.2630) 6.62 (0.2606)
6.68 - 670 (0.2630 - 0.2638) 6.64 (0.2614)
0.6 (0024) 31435-31X01
6.70 - 6.72 (0.2638 - 0.2646) 6.66 (0.2622)
0.8 (0.031) 31435-31X02
6.72 - 674 (0.2646 - 0.2654) 6.68 (0.2630) 1.0 (0.039) 31435-31X03
6.74 - 6.76 (0.2654 - 0.2661) 6.70 (0.2638) 1.2 (0.047) 31435-31X04
•
6.76 - 6.78 (0.2661 - 0.2669) 6.72 (0.2646) 1.4 (0.055) 31435-31 X05
6.78 - 6.80 (0.2669 - 0.2677) 6.74 (0.2654) 1.6 (0.063) 31435-31X06

1.8 (0.071) 31435-31X07
6.80 - 6.82 (0.2677 - 0.2685) 676 (0.2661)
2.0 (0.079) 31435-31X08
6.82 - 684 (0.2685 - 0.2693) 6.78 (0.2669)
6.84 - 6.86 (0.2693 - 0.2701) 6.80 (0.2677)
6.86 - 6.88 (0.2701 - 0.2709) 6.82 (0.2685)

REVERSE CLUTCH END PLAY
6.88 - 6.90 (0.2709 - 0.2717) 6.84 (0.2693)
Reverse clutch end play
6.90 - 6.92 (0.2717 - 0.2724) 6.86 (0.2701) 0.65 - 1.00 (0.0256 - 0.0394)
mm (in)
6.92 - 6.94 (0.2724 - 0.2732) 6.88 (0.2709)
6.94 - 696 (0.2732 - 0.2740) 690 (0.2717)
6.96 - 698 (0.2740 - 0.2748) 6.92 (0.2724) Thrust washers for adjusting reverse clutch
6.98 - 7.00 (0.2748 - 0.2756) 6.94 (0.2732) end play
7.00 - 702 (0.2756 - 02764) 696 (0.2740)
7.02 - 7.04 (0.2764 - 0.2772) 6.98 (0.2748)
0.65 (0.0256) 31508-31XOO
7.04 - 7.06 (0.2772 - 0.2780) 7.00 (0.2756) 0.80 (00315) 31508-31X01
7.06 - 7.09 (0.2780 - 0.2791) 7.02 (0.2764) 0.95 (0.0374) 31508-31 X02
7.09 - 7.13 (0.2791 - 0.2807) 7.06 (0.2780) 1.10 (0.0433) 31508-31X03

1.25 (0.0492) 31508-31X04
7.13 - 7.17 (0.2807 - 0.2823) 7.10 (0.2795)
1.40 (0.0551) 31508-31X05
7.17 - 7.21 (0.2823 - 0.2839) 7.14 (0.2811)
7.21 - 7.25 (0.2839 - 0.2854) 7.18 (0.2827)
7.25 - 7.29 (0.2854 - 0.2870) 7.22 (0.2843)

ACCUMULATOR
O-ring
Unit: mm (in)
Inner diameter Inner diameter

Accumulator
(Small) (Large)
SIR accumulator 26.9 (1.059) 44.2 (1.740)
N-D accumulator 34.6 (1.362) 39.4 (1.551)
AT-173
.SERVICE OAT A AND SPECIFICATIONS (SOS)
Return spring
Unit: mm (in)
Accumulator Free length Outer diameter
SIR accumulator spring 56.4 (2.220) 21.0 (0.827)
N-D accumulator spring 43.5 (1.713) 28.0 (1.102)
BAND SERVO
Return spring
Unit: mm (in)
Return spring Free length Outer diameter
2nd servo return spring 32.5 (1.280) 25.9 (1.020)
00 servo return spring 31.0 (1.220) 21.7 (0.854)

Except model 34X81
Distance between end of con- 21.1 mm (0.831 in) or more
verter housing and torque con-
verter Model 34X81
15.9 mm (0.626 in) or more
AT-174
FRONT AXLE &
FRONT SUSPENSION
SECTION FA
CONTENTS
PRECAUTIONS AND PREPARATION 2 FRONT AXLE 8
Precautions 2 Wheel Hub and Knuckle 8
Special Service Tools 2 Drive Shaft 12
Commercial Service Tools 3 FRONT SUSPENSION 24
FRONT SUSPENSION SySTEM 4 Coil Spring and Strut Assembly 25
ON-VEHICLE SERVICE 5 Stabilizer Bar 26
Front Axle and Front Suspension Parts 5 Transverse Link and Lower Ball Joint.. 27 •
Front Wheel Bearing 5 SERVICE DATA AND SPECIFICATIONS (SDS) 29
Front Wheel Alignment.. 6 General Specifications 29
Drive Shaft 7 Inspection and Adjustment 29
Precautions
• When installing rubber parts, final tightening must be car-
ried out under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine oil full. Spare tire, jack,
hand tools and mats in designated positions.
• After installing removed suspension parts, check wheel
alignment and adjust if necessary.
• Use flare nut wrench when removing or installing brake
tubes.
• Always torque brake lines when installing.
SBR820B
Tool number
Description
Tool name
HT72520000 Removing tie-rod outer end and lower ball

Ball joint remover joint
NT146
HT71780000 Removing and installing coil spring

Spring compressor
NT144
ST35652000 Fixing strut assembly

Strut attachment
NT145
GG94310000 Removing and installing brake piping

NT406 a: 10 mm (0.39 in)

KV38106700 Installing drive shaft
KV381 06800
Differential side oil seal
protector
LH: KV38106700
NT147 RH: KV38106800
FA-2
Front wheel hub drift Removing wheel hub
a: 42 mm (1.65 in) dia.

NT065 b: 33 mm (1.30 in) dia.
Front wheel bearing outer Removing and installing wheel bearing

race drift outer race
a: 76 mm (2.99 in) dia.

NT115 b: 72 mm (2.83 in) dia.
Grease seal drift Installing outer grease seal
a: 81 mm (3.19 in) dia.

NT115 b: 76 mm (2.99 in) dia.
Attachment Measuring wheel alignment

Wheel alignment
a: Screw M22 x 1.5
b: 35 (1.38) dia.
•
c: 65 (2.56) dia.
d: 56 (2.20)
e: 12 (0.47)
NT148 Unit mm (in)
Equivalent to GG94310000 Removing and installing brake piping

G) Flare nut crows foot
GV Torque wrench
NT360 a: 10 mm (0.39 in)
FA-3
FRONT SUSPENSION SYSTEM
SEC. 391-400-401
When installing rubber parts, final tightening must be carried out under unladen condition" with tires on ground .
• Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
~~25.29
~ (2.5 • 3.0, 18 • 22)
\
...\
~ 98 • 118 (10 • 12, 72 • 87)

Front
to.J : N. m (kg-m, ft-Ib)
SFA715B
CD Suspension member @ Coil spring (J) Transverse link

@ Stabilizer bar @ Strut assembly @ Front strut tower bar
@ Drive shaft @ Knuckle
FA-4
ON-VEHICLE SERVICE
Front Axle and Front Suspension Parts

Check front axle and front suspension parts for excessive play,
cracks, wear or other damage.
• Shake each front wheel to check for excessive play.
• Make sure that cotter pins are inserted.
• Retighten all axle and suspension nuts and bolts to the
specified torque.
Tightening torque:
Refer to FRONT SUSPENSION (FA-24).
SMA525A
• Check strut (shock absorber) for oil leakage or other dam-

age.
• Check suspension ball joint for grease leakage and ball
joint dust cover for cracks or other damage.
If ball joint dust cover is cracked or damaged, replace trans-
verse link.
Strut Ball joint

SFA392B
• Check suspension ball joint end play.

a. Jack up front of vehicle and set the stands.
b. Clamp dial indicator onto transverse link and place indica- •
tor tip on lower edge of brake caliper. •
c. Make sure front wheels are straight and brake pedal is
depressed.
d. Place a pry bar between transverse link and inner rim of
road wheel.
e. While raising and releasing pry bar, observe maximum dial
indicator value. Vertical end play: 0 mm (0 in)
f. If ball joint vertical end play exists, remove transverse link
and recheck the ball joint. Refer to FA-27.
Front Wheel Bearing

• Check that wheel bearings operate smoothly.
• Check axial end play.
Axial end play: 0.05 mm (0.0020 in) or less
• If out of specification or wheel bearing does not turn
smoothly, replace wheel bearing assembly.
Refer to FRONT AXLE - Wheel Hub and Knuckle (FA-B).
SFA484A
FA-5
ON-VEHICLE SERVICE
Front Wheel Alignment

Before checking front wheel alignment, be sure to make a pre-
liminary inspection (Unladen*).
SFA575B
PRELIMINARY INSPECTION
1. Check tires for wear and improper inflation.
2. Check wheel runout.
Wheel runout:
Refer to SOS (FA-30).
3. Check front wheel bearings for looseness.
4. Check front suspension for looseness.
5. Check steering linkage for looseness.
6. Check that struts work properly.
7. Check vehicle posture (Unladen).
CAMBER, CASTER AND KINGPIN INCLINATION

Camber, caster and kingpin inclination are preset at factory and
cannot be adjusted.
1. Measure camber, caster and kingpin inclination of both right
and left wheels with a suitable alignment gauge.
Camber, Caster and Kingpin inclination:
2. If camber, caster or kingpin inclination is not within
specification, inspect front suspension parts. Replace dam-
aged or worn out parts.
SFA948A
TOE-IN
Front
Measure toe-in using following procedure.
WARNING:
Hub center • Perform following procedure always on a flat surface.
height
• Make sure that no person is in front of the vehicle before
pushing it.
1. Bounce front of vehicle up and down to stabilize the posture.
2. Push the vehicle straight ahead about 5 m (16 ft).
3. Put a mark on base line of tread (rear side) of both tires at
the same height as hub center. These are measuring points.
SFA614B 4. Measure distance "A" (rear side).
5. Push the vehicle slowly ahead to rotate the wheels 180
Lines parallel to degrees (1/2 turn).
center line of body
If the wheels have rotated more than 180 degrees (112 turn), try
the above procedure again from the beginning. Never push
vehicle backward.
6. Measure distance "B" (front side).
Total toe-in
Q SFA234AC
Front
FA-6
ON-VEHICLE SERVICE
Front Wheel Alignment (Cont'd)
7. Adjust toe-in by varying the length of steering tie-rods.
a. Loosen lock nuts.
Lock nut
b. Adjust toe-in by screwing tie-rods in and out.
Standard length "L":
Refer to ST section.
c. Tighten lock nuts to specified torque.
Lock nut tightening torque:
Refer to ST section.
SFA486A
FRONT WHEEL TURNING ANGLE

1. Set wheels in straight-ahead position. Then move vehicle
forward until front wheels rest on turning radius gauge
properly.
2. Rotate steering wheel all the way right and left; measure
yf-\; turning angle.
Do not hold the steering wheel on full lock for more than 15
if
Front
-----
\mll// seconds.
Wheel turning angle (Full turn):
A Inside
B: Outside I I Refer to 50S (FA-29).
SFA439B
Drive Shaft
• Check for grease leakage or other damage .
•
SFA108A
FA-7
FRONT AXLE
10
Front
@~ 98 • 118 (10 • 12, 72 - 87)

SFA619B
CD Drive shaft (J) Snap ring @ Insulator

@ Inner grease seal @ Outer grease seal @ Adjusting cap
@ Knuckle @ Hub bolt @ Cotter pin
@ Baffle plate @) Wheel hub @ Disc rotor
@ ABS sensor @ Plain washer @ Wheel nut
@ Wheel bearing assembly @ Wheel bearing lock nut
Wheel Hub and Knuckle

REMOVAL
CAUTION:
Before removing the front axle assembly, disconnect the ABS
wheel sensor from tl1e assembly. Then move it away from the
front axle assembly area. Failure to do so may result in dam-
age to the sensor wires and the sensor becoming inoperative.
1. Remove wheel bearing lock nut.
2. Remove brake caliper assembly and rotor.
SFA110A Brake hose need not be disconnected from brake caliper.
In this case, suspend caliper assembly with wire so as not to
stretch brake hose.
Be careful not to depress brake pedal, or piston will pop out.
Make sure brake hose is not twisted.
FA-8
FRONT AXLE
Wheel Hub and Knuckle (Conl'd)
3. Separate tie-rod from knuckle with Tool.
Install stud nut on stud bolt to prevent damage to stud bolt.
4. Separate drive shaft from knuckle by lightly tapping it. If it

is hard to remove, use a puller.
Cover boots with shop towel so as not to damage them when
-removing drive shaft.
5. Remove strut lower mounting bolts.
•
6. Loosen lower ball joint tightening nut.
7. Separate knuckle from lower ball joint stud with Tool.
8. Remove knuckle from transverse link.
SFA113AA
INSTALLATION
1. Install knuckle with wheel hub.
• Replace strut lower mounting nuts.
When installing knuckle to strut, be sure to hold bolts and
tighten nuts.
~: 114 - 133 N'm (11.6 • 13.6 kg-m, 84 . 98 ft.lb)
Before tightening, apply oil to threaded portion of drive shaft
and both sides of plain washer.
2. Tighten wheel bearing lock nut.
~: 196 - 275 N'm (20 • 28 kg-m, 145 - 203 ft-Ib)
SFA114A
FA-9
FRONT AXLE
Wheel Hub and Knuckle (Cont'd)
3. Check wheel bearing axial end play.
Axial end play:
0.05 mm (0.0020 in) or less
DISASSEMBL Y
CAUTION:
When removing wheel hub or wheel bearing from knuckle,
replace wheel bearing assembly (outer race, inner races and
grease seals) with a new one.
Wheel hub
Drive out hub with inner race (outside) from knuckle with a
suitable tool.
SFA116A
Wheel bearing
When replacing wheel bearing, replace wheel bearing assem-
bly (inner races and outer race).
1. Remove bearing inner race (outside), then remove outer
grease seal.
SFA654A
2. Remove inner grease seal from knuckle.
FA-10
FRONT AXLE
4. Press out bearing outer race.
SFA496A
INSPECTION
Wheel hub and knuckle
Check wheel hub and knuckle for cracks by using a magnetic
exploration or dyeing test.
Snap ring
Check snap ring for wear or cracks. Replace if necessary.
ASSEMBLY
1. Press new wheel bearing assembly into knuckle.
Maximum load P: •
29 kN (3 ton, 3.3 US ton, 3.0 Imp ton) i
Wheel bearing
assembly CAUTION:
~ Knuckle • Do not press inner race of wheel bearing assembly.
• Do not apply oil or grease to mating surfaces of wheel
bearing outer race and knuckle.
2. Install snap ring into groove of knuckle.
SFA951A
3. Pack grease seal lip with multi-purpose grease.
SFA747
4. Install outer grease seal.

Maximum load P:
10 kN (1 ton, 1.1 US ton, 1.0 Imp ton)
Suitable tool
SFA620B
FA-11
FRONT AXLE
5. Install inner grease seal.
Maximum load P:
SFA953A
6. Press wheel hub into knuckle.

Maximum load P:
Be careful not to damage grease seal.
Wheel
bearing
assembly
7. Check bearing operation.

a. Add load P with press.
Load P:
34.3 - 49.0 kN (3.5 - 5.0 ton, 3.9 - 5.5 US ton,
3.44 • 4.92 Imp ton)
b. Spin knuckle several turns in both directions.
c. Make sure that wheel bearings operate smoothly.
Drive Shaft
REMOVAL
Brake caliper need not be disconnected.
Do not twist or stretch brake hose when moving components.
SFA090A
2. Remove strut lower mounting bolts.

3. Remove brake hose clip.
SFA1538
FA-12
FRONT AXLE
Drive Shaft (Coni' d)
4. Separate drive shaft from knuckle by slightly tapping it.
If it is hard to remove, use a puller.
When removing drive shaft, cover boots with shop towel to
prevent damage to them.
Refer to FRONT AXLE - Wheel Hub and Knuckle (FA-8).
5. Remove right drive shaft from transaxle.
6. Remove left drive shaft from transaxle.

-For MITmodels-
•
• Pry off drive shaft from transaxle as shown at left.
AfT model -For AITmodels-

• Insert screwdriver into transaxle opening for right drive
shaft and strike with a hammer.
Be careful not to damage pinion mate shaft and side gear.
SFA730
FA-13
FRONT AXLE
Drive Shaft (Cont'd)
RH
INSTALLATION
Transaxle side
1. Drive a new oil seal to transaxle. Refer to MT or AT section.
2. Set Tool along the inner circumference of oil seal.
SFA394BB
3. Insert drive shaft into transaxle. Be sure to properly align

the serrations and then withdraw Tool.
4. Push drive shaft, then press-fit circular clip on the drive
shaft into circular clip groove of side gear.
5. After its insertion, try to pull the flange out of the slide joint
by hand. If it pulls out, the circular clip is not properly
meshed with the side gear.
Wheel side
• Install drive shaft into knuckle.
• Tighten wheel bearing lock nut.
Refer to FRONT AXLE - Wheel Hub and Knuckle (FA-B).
FA-14
FRONT AXLE
COMPONENTS
GA and CD engine model
SEC. 391 Wheel side (ZF80, ZF90 type)
Circular clip:
Circular clips should be properly meshed with differential side
gear (transaxle side) and with joint assembly (wheel side).
Make sure they will not come out.
Be careful not to damage boots. Use suitable protector or cloth
during removal and installation.
8 .~ ZF90/TS79C type left side
p
Wheel ~
side
Diesel engine models only

,~ ~ Transaxle
side
\~
Wheel
side
r-J\ Transaxle
~side •
Transaxle side (TS70C, TS79C type)
SFA622B
CD Joint assembly @ Dynamic damper band @) Spider assembly

@ Boot (J) Dynamic damper @ Snap ring
@ Boot band @ Boot @ Slide joint housing
@ Circular clip @ Boot band @ Circular clip
@ Drive shaft
FA-15
~RONT AXLE
Drive Sh a f t (Cont'd)
SR20DE eng-me model
SEC. 391 Wheel side (BF83)
20
r:~~ ~'Vz~
@O '
Left drive s haft
Transa x I e side (TS83)
tOJ 25 . 35 (2 .6 • 3.6, 19 . 26)
Right drive shaft
@~ti~~o
f:~~ 2!~ ~ 30.41 (3.1.4.2,22 - 301
tOJ : N-m (kg-m, ft-Ib)
T ~ 13 - 19 (13
ransaxle side (0 . - 1.9, 9 • 14)
S83)
SFA716B
G) Jo'Int assembly @l
@ Spi'd er assembly @ Slide joint
S'
Ion shaft
houslng
' , exten-
with
@ Boot band Snap ring C
@ Boot @ Slide joint houslng
. @J Snap ring E
13' 0
@ Circular clip B \!'V ust shield @ Dust shield
@ Drive shaft @ Circular clip A @ Support bearing
@
@ Band @ Snap ring A Support bearin
@ Bracket g retainer
tJ) Dynamic dam @l Inner race
@ Boot per @ Snap ring 0
@ Cage
@ Boot band @ Ball @ Dust shield
FA-16
FRONT AXLE
OISASSEMBL Y
Transaxle side (TS70C, TS79C, TS83 type)
1. Remove boot bands.
2. Put matching marks on slide joint housing and drive shaft
before separating joint assembly.
3. Put matching marks on spider assembly and drive shaft.
SFA963
4. Pry off snap ring, then remove spider assembly.

CAUTION:
Do not disassemble spider assembly.
5. Draw out boot.
Cover drive shaft serration with tape to prevent damage to the
boot.
Transaxle side (OS83 type)

2. Put matching marks on slide joint housing and inner race, •
before separating joint assembly. i
3. Pry off snap ring "A" with a screwdriver, and pull out slide
joint housing.
SFA476
4. Put matching marks on inner race and drive shaft.

5. Remove snap ring "C", then remove ball cage, inner race
and balls as a unit.
6. Draw out boot.
Cover drive shaft serrations with tape so as not to damage the
boot.
SFA514A
Wheel side
CAUTION:
The joint on the wheel side cannot be disassembled.
1. Before separating joint assembly, put matchmarks on drive

shaft and joint assembly.
2. Separate joint assembly with a suitable tool.
Be careful not to damage threads on drive shaft.
SFA092A
FA-17
FRONT AXLE
Support bearing
1. Remove dust shield.
SFA692
3. Press support bearing assembly off of drive shaft.
4. Separate support bearing from retainer.
INSPECTION
Thoroughly clean all parts in cleaning solvent, and dry with
compressed air. Check parts for evidence of deformation or
other damage.
Drive shaft
Replace drive shaft if it is twisted or cracked.
FA-18
FRONT AXLE
Boot
Check boot for fatigue, cracks, or wear. Replace boot with new
boot bands.
Joint assembly (Transaxle side)

• Check spider assembly for bearing, roller and washer dam-
age. Replace spider assembly if necessary.
• Check housing for any damage. Replace housing set and
spider assembly, if necessary.
• When replacing only spider assembly, select a new spider

assembly from among those listed in table below. Ensure
Slide joint the number stamped on sliding joint is the same as that
stamped on new part.
Housing alone cannot be replaced. It must be replaced together
with spider assembly.
TS70C
Stamped number Part No.
00 39720-51 EOO
SRA121A 01 39720-51E01
02 39720-51 E02
03 39720-51 E03
TS79C
Stamped number
00
01
Part No.
39720-61 EOO
39720-61 E01
•
02 39720-61 E02
03 39720-61 E03
04 39720-61 E04
05 39720-61E05
06 39720-61 E06
Joint assembly (Wheel side)

Replace joint assembly if it is deformed or damaged.
ASSEMBLY
• After drive shaft has been assembled, ensure that it moves
smoothly over its entire range without binding.
• Use NISSAN GENUINE GREASE or equivalent after every
overhaul.
FA-19
FRONT AXLE
Wheel side
1. Install boot and new small boot band on drive shaft.
Cover drive shaft serration with tape so as not to damage boot
SFA800
2. Set joint assembly onto drive shaft by lightly tapping it.

r:r Install joint assembly securely, ensuring marks which were
1..--* made during disassembly are properly aligned.
- Wheel bearing
lock nut
SFA 130A
3. Pack drive shaft with specified amount of grease.

Specified amount of grease:
ZF80 95 g (3.35 oz)
ZF90 115 - 125 g (4.06 . 4.41 oz)
BF83 85. 105 g (3.00 - 3.70 oz)
4. Make sure that boot is properly installed on the drive shaft
groove.
Set boot so that it does not swell and deform when its length
is "L,".
Length "L/':
SFA4568 ZF80 90.5 - 92.5 mm (3.563 - 3.642 in)
ZF90 96 - 98 mm (3.78 - 3.86 in)
BF83 94 - 96 mm (3.70 - 3.78 in)
5. Lock new larger and smaller boot bands securely with a

suitable tool.
SFA4438
FA-20
FRONT AXLE
Gasoline engine Dynamic damper
DF83/TS83 left side 1. Use new damper band when reinstalling.
BF83/DS83 right side
2. Install dynamic damper from stationary-joint side while
ZF80/TS70C & ZF90/TS79C right side
holding it securely.
A B_1 Length:
Unit: mm (in)
.":JJ.Ci ZF80/TS70C
ZF90/TS79C
Diesel BF83/TS83,
Gasoline engine
engine DS83
ZF90/TS79C left side
RH RH LH RH
372.5 - 377.5
432 - 442 175.3 - 185.3 169 - 175
"A" (14.67 -
(17.01 - 17.40) (6.90 - 7.30) (6.65 - 6.89)
14.86)
"B" 66 (2.60) 58 (2.28) 37 (1.46) 70 (2.76)
Transaxle side (TS70C, TS79C, TS83 type)

Cover drive shaft serration with tape so as not to damage boot •
SFA800
2. Install spider assembly securely. making sure the marks

which were made during disassembly are properly aligned.
3. Install new snap ring.
FA-21
FRONT AXLE
Drive Shaft (Co nt' d)
TS70C 110 - 120 g (3.88 - 4.23 oz)
TS79C 155 - 165 g (5.47 - 5.82 oz)
TS83 130 - 150 g (4.59 • 5.29 oz)
5. Install slide joint housing.
6. Set boot so that it does not swell and deform when its length
is "L2".
Length "L2":
TS70C 95.5 - 97.5 mm (3.76 - 3.84 in)
SFA993 TS79C 101.5 - 103.5 mm (4.00 - 4.07 in)
TS83 98 - 100 mm (3.86.3.94 in)
Make sure that boot is properly installed on the drive shaft
groove.
suitable tool.
SFA395
Transaxle side (OS83 type)

Cover drive shaft serration with tape to prevent damage boot
SFA800
2. Install ball cage, inner race and balls as a unit, making sure
the marks which were made during disassembly are prop-
erly aligned.
3. Install new snap ring "C".
SFA514A

115 - 135 g (4.06 - 4.76 oz)
5. Install slide joint housing, then install new snap ring "A".
6. Make sure that boot is properly installed on the drive shaft
groove.
Set boot so that it does not swell and deform when its length
is "L2".
Length "L2":
97 - 99 mm (3.82 - 3.90 in)
SFA149A
FA-22
FRONT AXLE
Drive Shaft (Co nt' d)
suitable tool.
SFA395
Support bearing
1. Install bearing into retainer.
Suitable tool
SFA618
2. Press drive shaft into bearing.

Suitable tool
•
SFA694

4. Install new dust shield.
Transaxle side
SFA444B
FA-23
FRONT SUSPENSION
SEC. 391.400.401
When installing rubber parts, final tightening ~~ 59.74
must be carried out under unladen condition'
with tires on ground. ~.~ ::' .4: - 54)
9
• Fuel, radiator coolant a'1d engine 011full. o (2.5 _ 3.0,
Spare tire, Jack, hand tools and mats In
18 - 22)
designated positions. ~~
~~
@
9=:
~
L.~ (3.2 - 4.3, 23 • 31)

~~
1/ ~
~.
-----J
/~18-24
@
(1.8.2.4,13.17)
&1 (@
Front
~
~J~!~5 (20 - 28, 145 • 203)
59 • 74 (6.0 - 7.5, 43 • 54)
SFA624B
CD Spacer @ Lower spring rubber seat @ Knuckle

@ Strut mounting insulator @) Strut assembly @ Cotter pin
@ Strut mounting insulator @ Suspension member @) ABS sensor
bracket @ Stabilizer bar @ Plain washer
@ Thrust bearing @ Stabilizer clamp @ Wheel bearing lock nut
@ Upper spring seat @ Connecting rod @ Insulator
@ Upper spring rubber seat @ Transverse link @ Adjusting cap
(J) Bumper rubber @ Compression rod clamp @ Cotter pin
@ Coil spring @ Drive shaft
FA-24
FRONT SUSPENSION
Coil Spring and Strut Assembly

• Remove strut assembly fixing bolts and nuts (to hoodledge).
Do not remove piston rod lock nut on vehicle.
DISASSEMBL Y
1. Set strut assembly on vise with Tool, then loosen piston rod
lock nut.
Suitable
. Do not remove piston rod lock nut at this time.
bar
2. Compress spring with Tool so that the strut mounting insu-
lator can be turned by hand.
3. Remove piston rod lock nut.
•
SFA610B
INSPECTION
Shock absorber assembly
• Check for smooth operation through a full stroke, both com-
pression and extension.
• Check for oil leakage on welded or gland packing portion.
• Check piston rod for cracks, deformation or other damage.
Mounting insulator and rubber parts

• Check cemented rubber-to-metal portion for separation or
cracks. Check rubber parts for deterioration.
Thrust bearing
• Check thrust bearing parts for abnormal noise or excessive
rattle in axial direction. Replace if necessary.
Coil spring
• Check for cracks, deformation or other damage. Replace if
necessary.
FA-25
FRONT SUSPENSION
Coil Spring and Strut Assembly (Cont'd)
ASSEMBLY
• When installing coil spring on strut, it must be positioned as
shown in the figure at left.
\ '
~Ud
SFA508A
• When installing spring seat, make sure that it is positioned

Front
as shown.
Outside of
vehicle
SFA957A
Stabilizer Bar
• Remove stabilizer bar.
• When installing stabilizer, make sure that paint mark and

clamp face in their correct directions.
Inside of ..-1'.
vehicle L..y'
SFA625B
• When removing and installing stabilizer bar, fix portion A.
FA-26
FRONT SUSPENSION
Stabilizer Bar (Cont'd)
• Install stabilizer bar with ball joint socket properly placed.
View from B
OK NG
SFA449BA
INSPECTION
• Check stabilizer for deformation or cracks. Replace if nec-
essary.
• Check rubber bushings for deterioration or cracks. Replace
if necessary.
• Check ball joint can rotate in all directions. If movement is
not smooth and free, replace stabilizer bar connecting rod.
ARA027
Transverse Link and Lower Ball Joint

1. Remove wheel bearing lock nut. •
2. Remove tie-rod ball joint.
3. Remove strut lower bracket fixing bolts and nuts.
4. Separate drive shaft from knuckle by slightly tapping drive
shaft end.
Cover boots with shop towel so as not to damage them when
removing drive shaft.
SFA181A
5. Separate lower ball joint stud from knuckle with Tool.

Refer to FRONT AXLE - Wheel Hub and Knuckle (FA-8).
SFA113AA
6. Remove fixing bolts and nuts as shown at left.

7. During installation, final tightening must be carried out at
curb weight with tires on the ground.
8. After installation, check wheel alignment. Refer to ON-VE-
HICLE SERVICE - Front Wheel Alignment (FA-6).
FA-27
FRONT SUSPENSION
Transverse Link and Lower Ball Joint (Cont'd)
INSPECTION
• Check transverse link for damage, cracks or deformation.
Replace if necessary.
• Check rubber bushing for damage, cracks and deformation.
Replace transverse link if necessary.
• Check ball joint for excessive play. Replace transverse link

,............... A
assembly if any of the following exists:
• Ball stud is worn .
• Joint is hard to swing .
• Play in axial direction is excessive.
Before checking, turn ball joint at least 10 revolutions so
that ball joint is properly broken in.
Swinging force "A":
(measuring point: cotter pin hole of ball stud):
8.24 - 57.37 N (0.84 - 5.85 kg, 1.85 - 12.90 Ib)
SFA858A Turning torque "B":
0.49 - 3.43 N'm (5.0 - 35 kg-em, 4.3 - 30.4 in-Ib)
Vertical end play "e":
o mm (0 in)
• Check dust cover for damage. Replace it and cover clamp
if necessary.
FA-28
Suspension type Independent macpherson struts
Strut type Double-acting hydraulic
Stabilizer For 14- and 15-inch wheel models

WHEEL ALIGNMENT (Unladen*1)
GA engine and SR CD engine and SR

Applied model engine models with engine models with
14-inch wheels 15-inch wheels
Camber Minimum -no' (-1.33')

.
Nominal -0'35' (-0.58')
Degree minute
(Decimal degree) Maximum 0'10' (0.1r)
Caster Minimum 0'40' (0.6r)
Nominal 1'25' (1.42')

Degree minute
(Decimal degree) Maximum 2'10' (217")
Kingpin inclination Minimum 14'00' (14.00')
Nominal 14'45' (14.75')

Degree minute
(Decimal degree) Maximum 15'30' (15.50')
Total toe-in Minimum 0(0)
Distance (A - B)
Angle (left plus right)

Degree minute
(Decimal degree)
Nominal
mm (in) Maximum
Minimum
Nominal
Maximum
2 (008)
4 (0.16)
0' (0.00')
11' (0.18')
22' (0.37")
•
Wheel turning angle Minimum 38'00' (38.00') 34'00' (34.00')
Inside Nominal 4nO' (41.00') 3rOO' (37.00')

Degree minute
(Decimal degree) Maximum 42'00' (42.00') 38'00' (38.00')
Full (urn'2
Outside
Degree minute Nominal 34'00' (34.00') 31'00' (3100')
(Decimal degree)
'1' Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
'2: On power steering models, wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 Ib) with engine
idle
FA-29
DRIVE SHAFT
GA14DE, GA16DE, SA 20DE

Applied model
GA15DE CD20 AH LH Boot length
Joint type Wheel side
Transaxle side TS70C TS79C DS83 TS83
Wheel side ZF80 ZF90 BF83
Boot length mm (in)
95.5 - 97.5 101.5 - 103.5 97 - 99 98 - 100
Transaxle side L2
(376 - 3.84) (4.00 - 4.07) (3.82 - 3.90) (3.86 - 3.94)
Transaxle side
90.5 - 92.5 96 - 98
Wheel side L, 94 - 96 (3.70 - 3.78)
(3.563 - 3.642) (3.78 - 3.86)
Grease Nissan genuine grease or equivalent
Capacity g (oz)
110 - 120 155 - 165 115 - 135 130 - 150
Transaxle side
(388 - 4.23) (5.47 - 5.82) (4.06 - 4.76) (4.59 - 5.29)
115 - 125
Wheel side 95 (3.35) 85 - 105 (3.00 - 3.70)
(4.06 - 4.41) SFA3968
WHEEL BEARING WHEEL RUNOUT

Unit: mm (in)
Wheel bearing axial end play
0.05 (0.0020) or less Wheel type Aluminum wheel Steel wheel
limit mm (in)
Maximum radial
Wheel bearing lock nut 0.3 (0.012) 0.5 (0.020)
runout limit
tightening torque 196 - 275 (20 - 28, 145 - 203)
N'm (kg-m, ft-Ib) Maximum lateral
03 (0.012) 0.8 (0.031)
runout limit
Preload
N'm (kg-em, in-Ib) 0.90 (9.2, 8.0)
At hub bolt N (kg, Ib) 6.08 (0.62, 1.37)
LOWER BALL JOINT
Swinging force "A"

(Measured at cotter pin hole)
8.24 - 5737
N (kg, Ib)
(0.84 - 5.85, 1.85 - 12.90)
Turning torque "B"

0.49 - 3.43 (5.0 - 35, 4.3 - 30.4)
Nm (kg-em, in-I b)
Vertical end play limit "C"

0(0)
mm (in)
FA-30
REAR AXLE &
REAR SUSPENSION
SECTION RA
CONTENTS
PRECAUTIONS AND PREPARATION 2 REAR AXLE 6
Precautions 2 Wheel Hub 6
Special Service Tools 2 REAR SUSPENSION 8
Commercial Service Tools 2 Removal and Installation 9
REAR SUSPENSION SySTEM 3 Coil Spring and Shock Absorber 9
ON-VEHICLE SERVICE 4 Torsion Beam, Lateral Link and Control Rod 11
Rear Axle and Rear Suspension Parts 4 SERVICE DATA AND SPECIFICATIONS (SDS) 12
Rear Wheel Bearing 4 General Specifications 12
•
Rear Wheel Alignment 5 Inspection and Adjustment. 12
Precautions
• When installing each rubber part, final tightening must be
carried out under unladen condition* with tires on ground.
• Use flare nut wrench when removing or installing brake
tubes.
• After installing removed suspension parts, check wheel
alignment.
• Do not jack up at the trailing arm and lateral link.
SBR820B
Tool number
Description
Tool name
GG9431 0000 Removing and installing brake piping

Flare nut torque
wrench
NT406 a: 10 mm (0.39 in)
HT71780000 Removing and installing coil spring

Spring compressor
NT144
ST35652000 Fixing strut assembly

Shock absorber
attachment
NT145

Equivalent to Removing and installing brake piping
GG9431 0000
G) Flare nut crows foot
@ Torque wrench
NT360 a: 10 mm (0.39 in)
RA-2
REAR SUSPENSION SYSTEM
SEC. 431
When installing each rubber part, final tightening
must be carried out under unladen condition'
with tires on ground.
, Fuel, radiator coolant and engine oil full.
Spare tire, lack, hand tools and mats in
designated positions.
•
~ : N.m (kg-m, fHb)
SRA709AA
G) Shock absorber cap @ Shock absorber @ Lateral link

@ Shock absorber mounting seal @ Torsion beam (J) Control rod
@ Coil spring
RA-3
ON-VEHICLE SERVICE
Rear Axle and Rear Suspension Parts

Check axle and suspension parts for excessive play, wear or
damage.
• Shake each rear wheel to check for excessive play.
SMA525A
• Retighten all nuts and bolts to the specified torque.

Tightening torque:
Refer to REAR SUSPENSION (RA-8).
• Check shock absorber for oil leakage or other damage.
SMA113
Rear Wheel Bearing

---I • Check axial end play.
Axial end play:
0.05 mm (0.0020 in) or less
• Check that wheel hub bearings operate smoothly.
• Check tightening torque of wheel bearing lock nut.
(OJ: 186 • 255 N.m (19 - 26 kg-m, 137 • 188 ft-Ib)
• Replace wheel bearing assembly if there is axial end play
or wheel bearing does not turn smoothly. Refer to REAR
AXLE - Wheel Hub (RA-6).
SRA690A
RA-4
ON-VEHICLE SERVICE
Rear Wheel Alignment

PRELIMINARY INSPECTION
Make following checks. Adjust, repair or replace if necessary.
• Check tires for wear and for improper inflation.
• Check rear wheel bearings for excessive play.
• Check wheel runout.
Wheel runout: Refer to SOS in FA section.
• Check that rear shock absorber works properly.
• Check rear axle and rear suspension parts for excessive
SFA575B play.
• Check vehicle posture (Unladen*).
*: Fuel, radiator and engine oil full. Spare tire, jack, hand
tools and mats in designated positions.
CAMBER
Camber is preset at factory and cannot be adjusted.
Camber:
Refer to SOS (RA-12).
• If the camber is not within specification, inspect and replace
SFA948A
any damaged or worn rear suspension parts.
•
TOE-IN
Front
Toe-in is preset at factory and cannot be adjusted.
Measure toe-in using following procedure. If out of
Hub center specification, inspect and replace any damaged or worn rear
height
suspension parts.
WARNING:
• Perform following procedure always on a flat surface.
• Make sure that no person is in front of the vehicle before
pushing it.
1. Bounce rear of vehicle up and down to stabilize the posture.
SFA614B 2. Push the vehicle straight ahead about 5 m (16 ft).
3. Put a mark on base line of the tread (rear side) of both tires at
Lines parallel to the same height of hub center. This mark is a measuring point.
center line of bOdY~
4. Measure distance "A" (rear side).
5. Push the vehicle slowly ahead to rotate the wheels 180
degrees (1/2 turn).
If the wheels have rotated more than 180 degrees (1/2 turn), try
the above procedure again from the beginning. Never push
vehicle backward.
6. Measure distance "B" (front side).
Total toe-in:
Q Refer to SOS, RA-12.
Front SFA234AC
RA-5
REAR AXLE
Wheel Hub
SEC. 430
Drum brake
6 ~ 186 • 255
(19 • 26, 137 - 188)
Disc brake
~
25 - 33(2.5 - 3.4, 18 - 25)
: N.m (kg-m. ft-Ib)

r2'\
Front ~ 22 - 29 (2.2 • 3.0, 16 - 22)
SRA710A
G) Spindle @ Wheel hub bearing (J) Cotter pin

@ Baffle plate @ Washer @ Hub cap
@ Back plate @ Wheel bearing lock nut @ ABS sensor
REMOVAL
CAUTION:
• Before removing the rear wheel hub assembly, disconnect
the ABS wheel sensor from the assembly. Then move it
away from the hub assembly. Failure to do so may result in
damage to the sensor wires and the sensor becoming inop-
erative.
• Wheel hub bearing does not require maintenance. If any of
the following symptoms are noted, replace wheel hub bear-
ing assembly.
• Growling noise is emitted from wheel hub bearing during
operation.
• Wheel hub bearing drags or turns roughly. This occurs
when turning hub by hand after bearing lock nut is tightened
to specified torque.
RA-6
REAR AXLE
Wheel Hub (Conl'd)
1. Remove brake caliper assembly.
3. Remove brake rotor (models with disc brake) or brake drum
(models with drum brakes).
4. Remove wheel hub bearing from spindle.
Brake hose does not need to be disconnected from brake cali-
per.
Suspend caliper assembly with wire so as not to stretch brake
hose.
SRA711A Make sure brake hose is not twisted.
INSTALLATION
• Install wheel hub bearing.
• Tighten wheel bearing lock nut.
Before tightening, apply oil to threaded portion of rear spin-
dle and both sides of plain washer.
~: 186 - 255 N'm (19 - 26 kg-m, 137 - 188 ft-Ib)
• Check that wheel bearings operate smoothly.
SRA712A
• Check wheel hub bearing axial end play.

Axial end play:
0.05 mm (0.0020 in) or less
RA-7
REAR SUSPENSION
SEC. 431
When installing each rubber part, final tightening
must be carried out under unladen condition"
with tires on ground.
" Fuel, radiator coolant and engine all full.
Spare tire, jack, hand tools and mats In ~
designated positions. ~
~~ 18.24 (1.8.2.4, 13 -17)~
~
~A 19 • 22 (1.9 - 2.2, 14 • 16)~
~
~
:\\ '~
~;.; ~~.4,
L~'
18 • 25)
\--/
\ \ i---J
~
- ~ 98 • 118 (
I~ / 110-12,72-87) ~- ~~ ~ @
~~
~ " \..-~
~ ~ ;:;:Y ~ '-~.
--...~~ ~~98-118
~ (10 - 12, 72 • 87)
~~A 98 - 118 (10 - 12, 72 - 87)
~ : N'm (kg-m. fl-Ib)

Front
SRA694AA
(1) Shock absorber cap @ Upper spring seat rubber Q!J Shock absorber
@ Washer (J) Bushing @ Torsion beam
@ Bushing @ Bound bumper cover @ Lateral link
@ Shock absorber mounting seal @ Bound bumper Q4) Control rod
@ Shock absorber mounting @J Coil spring @) ABS sensor
bracket
RA-8
REAR SUSPENSION
Removal and Installation

CAUTION:
• Before removing the rear suspension assembly, disconnect
the ABS wheel sensor from the assembly. Failure to do so
may result in damage to the sensor wires and the sensor
becoming inoperative.
• Remove suspension assembly.
1. Disconnect brake hydraulic lines and parking brake cable at
toggle lever. (Models with drum brakes.)
• Drain brake fluid before disconnecting brake lines.
2. Disconnect parking brake cable from caliper and remove
brake caliper and rotor. (Models with disc brakes.)
hose.
Make sure brake hose is not twisted.
3. Using a transmission jack, raise torsion beam a little, and
remove nuts and bolts from the trailing arm, shock absorber
assembly (lower side) and lateral link.
4. Lower transmission jack, and remove suspension.
5. Remove luggage compartment trim. Refer to BT section.
6. Remove strut securing nuts (upper side). Then pull out strut
SRA696A
assembly.
• Install suspension assembly.
CAUTION:
Refill with new brake fluid "DOT 3".
Never reuse drained brake fluid.
1. Attach torsion beam, at trailing arm and lateral link, to vehi-
•
cle. Do not tighten bolts at this time.
SRA697A
2. Using a transmission jack, place lateral link and control rod

horizontally against torsion beam. Tighten lateral link on
Control
rod
S
vehicle.
Lateral link 3. Attach shock absorber assembly to vehicle. Then tighten the
lower side of shock absorber assembly.
~H";""I" 4. Lower torsion beam to fully extended position. Remove
transmission jack and tighten torsion beam, at trailing arm,
to specified torque. Refer to RA-8.
ITorsion beam
5. Install brake hydraulic lines and tighten flare nuts.
~: 15 - 18 N'm (1.5.1.8 kg-m, 11 - 13 ft-Ib)
SRA698A
Coil Spring and Shock Absorber

REMOVAL
Remove shock absorber upper and lower fixing nuts.
Do not remove piston rod lock nut on vehicle.
RA-9
REAR SUSPENSION
Coil Spring and Shock Absorber (Conl'd)
DISASSEMBL Y
1. Set shock absorber in vise with attachment, then loosen
piston rod lock nut.
Do not remove piston rod lock nut at this time.
2. Compress spring with Tool so that the shock absorber upper
spring seat can be turned by hand.
3. Remove piston rod lock nut.
INSPECTION
Shock absorber assembly
• Check for smooth operation through a full stroke, both com-
pression and extension.
• Check for oil leakage on welded or gland packing portions.
• Check piston rod for cracks, deformation or other damage.
Upper rubber seat and bushing
Check rubber parts for deterioration or cracks.
Coil spring
Check for cracks, deformation or other damage. Replace if nec-
essary.
ASSEMBLY
• Locate upper spring seat as shown.
LH RH
SRA699A
Top
• When installing coil spring, be careful not to reverse top and
bottom direction. (Top end is flat.)
~P"'"d
• When installing coil spring on shock absorber, it must be
Ai
-- - • Flat
tail positioned as shown in figure at left.
i ' I
~
Bottom ~l_""d
SFA4368
RA-10
REAR SUSPENSION
Torsion Beam, Lateral Link and Control Rod

DISASSEMBL Y
• Remove torsion beam assembly. Refer to Removal and
Installation in REAR SUSPENSION (RA-9).
• Remove lateral link and control rod from torsion beam.
INSPECTION
• Check for cracks, distortion or other damage. Replace if
necessary.
SRA703A Standard length:
A 207.208 mm (8.15 - 8.19 in)
B 394 - 395 mm (15.51 - 15.55 in)
C 601 - 603 mm (23.66 . 23.74 in)
Lateral link o 106 - 108 mm (4.17 - 4.25 in)
Temporary I
Ilgh"oIog ,,' d) ,
~~ • Check all rubber parts for wear, cracks
or deformation.
ASSEMBLY
~ Cootrol 100 1. Temporarily assemble lateral link and control rod.
• When installing the control rod, connect the bush with the
smaller inner diameter to the lateral link.
Large inner diameter
Torsion beam side

Small inner diameter
Lateral link side

SRA700A
•
2. Temporarily install lateral link and control rod on torsion
beam.
• When installing, place lateral link with the arrow topside.
3. Place lateral link and control rod horizontally against tor-
0"" ;;~h"0109
4.
sion beam, and tighten to the specified torque.
Install torsion beam assembly. Refer to Removal and Instal-
lation in REAR SUSPENSION (RA-9).
~ .$ Horizontal
SRA702A
RA-11
Suspension type Multi-link beam suspension
Shock absorber type Double-acting hydraulic
Stabilizer Standard equipment

WHEEL ALIGNMENT (Unladen*) WHEEL BEARING
Camber Minimum -1'45' (-1.75') Wheel bearing axial end play

0.05 (0.0020) or less
mm (in)
Nominal -1'00' (-1.00')
Degree minute
Wheel bearing lock nut tighten-
(Decimal degree) Maximum -0'15' (-0.25') 186 - 255
ing torque
(19 - 26, 137 - 188)
Total toe-in Minimum -3 (-0.12) N'm (kg-m. ft-lb)
Nominal 1 (0.04)
Distance (A-B)
mm (in) Maximum 5 (0.20)
Angle (left pius right) Minimum -16' (-0.27')
Nominal 5' (0.08')

Degree minute
(Decimal degree) Maximum 26' (0.43')
': Fuel, radiator coolant and engine oil full. Spare tire. jack, hand
tools and mats in designated positions.
RA-12
BRAKE SYSTEM
SECTION BR
CONTENTS
PRECAUTIONS AND PREPARATION 3 Inspection - Caliper 22
Precautions 3 Inspection - Rotor 23
Special Service Tools 4 Assembly '" .23
Commercial Service Tools 4 Installation 24
CHECK AND ADJUSTMENT 5 REAR DRUM BRAKE 25
Checking Brake Fluid Level 5 Removal 25
Checking Brake Line 5 Inspection - Wheel Cylinder 26
Changing Brake Fluid 5 Wheel Cylinder Overhaul 27
AIR BLEEDING 6 Inspection - Drum 27
Bleeding Procedure 6 Inspection - Lining 27
BRAKE HYDRAULIC LINE 7 Installation 27
Removal 8 REAR DISC BRAKE 29
Inspection 8 Pad Replacement 29
Installation 8
CONTROL VALVE 9 ~~s:~::~'~I~':::::::::::':::
::.::::::::.::
::::.:::::::
:::.:::::
:.::::::::~~•••
Proportioning Valve 9 Inspection - Caliper 32
BRAKE PEDAL AND BRACKET 11 Inspection - Rotor 33
Removal and Installation 11 Assembly 33
Inspection 11 Installation 35
Adjustment 11 PARKING BRAKE CONTROL 36
MASTER CYLINDER 12 Removal and Installation 36
Removal 12 Inspection 36
Disassembly 12 Adjustment ." 37
Inspection 13 ANTI-LOCK BRAKE SYSTEM 38
Assembly 13 Purpose 38
Installation 14 Operation 38
BRAKE BOOSTER 15 ABS Hydraulic Circuit 38
On-vehicle Service 15 System Components 39
Removal 15 System Description 39
Inspection 16 Removal and Installation .40
Installation 16 Wiring Diagram - ABS - .45
VACUUM HOSE 17 TROUBLE DIAGNOSES 52
Removal and Installation 17 Contents 52
Inspection 17 Component Parts and Harness Connector
FRONT DISC BRAKE 19 Location 64
Pad Replacement.. 19 SERVICE DATA AND SPECIFICATIONS (SDS) 86
Removal 22 General Specifications 86
Disassembly 22 Inspection and Adjustment 88
CONTENTS (Cont'd.)

• See El section, "POWER SUPPLY ROUTING" for power distribution circuit.
When you perform trouble diagnoses, read GI section, "HOW TO FOllOW FLOW CHART
IN TROUBLE DIAGNOSES" and "HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN
ELECTRICAL INCIDENT".
Precautions
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG"
(DUAL AIR BAG SYSTEM)
The Supplemental Restraint System "Air Bag" used along with
a seat belt, helps to reduce the risk or severity of injury to the
driver and front passenger in a frontal collision. The Supple-
mental Restraint System consists of air bag modules (located
in the center of the steering wheel and on the instrument panel
on the passenger side), a diagnosis sensor unit, warning lamp,
vice Manual.
WARNING:
• To avoid rendering the SRS inoperatiYe, which could increase the risk of personal injury or death

(SINGLE AIR BAG SYSTEM)
WARNING:
•
•
To avoid rendering the SRS inoperative, which could increase the
in the event of a collision which would result in air bag inflation, all
Improper maintenance, including incorrect removal and installation
risk of personal injury or death
maintenance must be performed
of the SRS, can lead to personal

•
Service Manual.
BR-3
Precautions (Conl'd)
BRAKE SYSTEM
For tightening flare nut
• Recommended fluid is brake fluid "DOT 3" or "DOT 4".
• Do not mix different types of brake fluids (DOT 3, DOT 4).
• Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
• To clean master cylinder parts, disc brake caliper parts or
GG94310000 or wheel cylinder parts, use clean brake fluid.
commercial equivalent • Never use mineral oils such as gasoline or kerosene. They
SBR820BA will ruin rubber parts of hydraulic system.
• Use flare nut wrench when removing and installing brake
tubes.
WARNING:
• Clean brakes with a vacuum dust collector to minimize risk
of health hazard from powder caused by friction.
Tool number
Description
Tool name
GG9431 0000 Removing and installing each brake piping

a: 10 mm (0.39 in)
NT406 ~: 16.2 N'm (1.65 kg-m, 11.9 f1-lb)
CD Flare nut crows foot Removing and installing each brake piping
@ Torque wrench
NT360 a: 10 mm (0.39 in)
Brake fluid pressure Measuring brake fluid pressure

gauge
NT151
BR-4
CHECK AND ADJUSTMENT
Checking Brake Fluid Level

Max. line
• Check fluid level in reservoir tank. It should be between
Max. and Min. lines on reservoir tank.
• If fluid level is extremely low, check brake system for leaks.
Min. line • If brake warning lamp comes on, check brake fluid level
OK switch and parking brake switch.
MIN
SBR418C
Checking Brake Line

CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for cracks, deteriora-
tion or other damage. Replace any damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running.
ABR159
Changing Brake Fluid

CAUTION:
• Refill with new brake fluid "DOT 3" or "DOT 4".
• Always keep fluid level higher than minimum line on reser-
voir tank.
• Be careful not to splash brake fluid on painted areas; it may •
cause paint damage. If brake fluid is splashed on painted : •
SBR419C
1. Clean inside of reservoir tank, and refill with new brake
fluid.
2. Connect a vinyl tube to each air bleeder valve.
3. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
4. Refill until new brake fluid comes out of each air bleeder
valve.
Use same procedure as in bleeding hydraulic system to
refill brake fluid.
Refer to "Bleeding Procedure", BR-6.
BR-5
AIR BLEEDING
Bleeding Procedure
CAUTION:
• Carefully monitor brake fluid level at master cylinder during
bleeding operation.
• If master cylinder is suspected to have air inside, bleed air
from master cylinder first. Refer to "Installation", "MASTER
CYLINDER", BR-12.
• Fill reservoir with new brake fluid "DOT 3" or "DOT 4".
Make sure it is full at all times while bleeding air out of
system.
SBR995
• Place a container under master cylinder to avoid spillage of
brake fluid.
• For models with ABS, turn ignition switch OFF and discon-
nect ABS actuator connector or battery cable.
• Bleed air in the following order:
I RHO models I
Left rear brake-+Right front brake-+Right rear brake-+Left
front brake
I LAD models I
Right rear brake-+Left front brake-+Left rear brake-+Right
SBR419C
front brake.
1. Connect a transparent vinyl tube to air bleeder valve.
2. Fully depress brake pedal several times.
3. With brake pedal depressed, open air bleeder valve to
release air.
4. Close air bleeder valve.
5. Release brake pedal slowly.
6. Repeat steps 2. through 5. until clear brake fluid comes out
of air bleeder valve.
7. Tighten air bleeder valve.
~: 7 - 9 N.m (0.7 - 0.9 kg-m, 61 - 78 in-Ib)
BR-6
BRAKE HYDRAULIC LINE
Without anti-lock brake system

(Models with dual proportioning valve built into master cylinder)
(built-in type)
Proportioning valve
(Do not disassemble.)
With anti-lock brake system
ASS actuator
L Master cylinder
= .Primary
-
line
. Secondary line
•
~ 0 : Flare nut
15 - 18 (1.5 - 1.8, 11 - 13)
• : Connecting bolt
17 - 20 (1.7 - 2.0, 12 - 14)
SBR086D
BR-7
BRAKE HYDRAULIC LINE
Removal
CAUTION:
• All hoses must be free from excessive bending, tWisting and
pulling.
1~ Connect a vinyl tube to air bleeder valve~
brake pedal.
SBR419C
3. Remove flare nut securing brake tube to hose, then with-
draw lock spring.
4. Cover openings to prevent entrance of dirt whenever dis-
connecting hydraulic line.
Inspection
Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
For tightening flare nut

Installation
CAUTION:
1. Tighten all flare nuts and connecting bolts.
Flare nut: .
~: 15 - 18 N'm (1.5 - 1.8 kg-m, 11 - 13 ft-Ib)
~GG94310000 or Connecting bolt:
commercial equivalent ~: 17 - 20 N'm (1.7 - 2.0 kg-m, 12 - 14 ft-Ib)
SBR820BA
valve.
3. Bleed air. Refer to "Bleeding Procedure", BR-6.
BR-8
CONTROL VALVE
Proportioning Valve
INSPECTION
CAUTION:
• Carefully monitor brake fluid level at master cylinder.
• Use new brake fluid "DOT 3" or "DOT 4".
cause paint damage. If brake fluid is splashed on paint
• Depress pedal slowly when raising front brake pressure.
• Check rear brake pressure 2 seconds after front brake pres-
sure reaches specified value.
• For models with ABS disconnect harness connectors from
ABS actuator relay before checking.
1. Connect Tool to air bleeders of front and rear brakes on
either LH or RH side.
2. Bleed air from the Tool.
3. Check rear brake pressure by depressing brake pedal
(increasing front brake pressure).
Unit: kPa (bar, kg/cm2, psi)
Applied models
Without ABS I With ABS
GA14DE, GA16DE, CD20 GA16DE' SR20DE
Applied pressure 7.355 6.375 5,394

(Front brake) (73.6, 75, 1,067) (63.7, 65, 924) (53.9, 55, 782)
3,432 - 3,825 2,452 - 2,844

Output pressure 5,100 - 5,492 (34.3 - 38.2, (245 - 28.4,
(Rear brake) (51.0 - 54.9, 52 - 56, 739 - 796) 35 - 39, 25 - 29,
498 - 555) 356 - 412)
* Models for Australia
If output pressure is out of specifications, replace dual pro- •••

portioning valve (separated type) or master cylinder assem-
bly (built-in type).
4. Bleed air after disconnecting the Tool. Refer to "Bleeding
Procedure", BR-5.
BR-9
CONTROL VALVE
Proportioning Valve (Co nt' d)
REMOVAL (Separated type)
CAUTION:
• All hoses must be free from excessive bending, twisting and
pulling.
1. Connect a vinyl tube to air bleeder valve.
brake pedal.
3. Loosen flare nut.
4. Remove proportioning valve mounting bolt, then remove
flare nut.
INSTAllATION (Separated type)

CAUTION:
1. Temporarily fit flare nut to proportioning valve.
2. Tighten proportioning valve mounting bolt, then tighten flare
nut with wooden block placed between proportioning valve
and dash panel.
Flare nut:
tDJ: 15 - 18 N'm (1.5 - 1.8 kg-m, 11 - 13 ft-Ib)
Mounting bolt:
11]: 5.1 - 8.8 N'm (0.52 - 0.9 kg-m, 45.1 - 78.1 in-Ib)
valve.
REMOVAL AND INSTAllATION (Built-in type)

Always replace together with master cylinder as an assembly.
• Refer to "MASTER CYLINDER", BR-12.
BR-10
BRAKE PEDAL AND BRACKET
SEC. 465
Slop lamp sWitch

SBR205D
Inspection
Check brake pedal for following items:
• Brake pedal bend
• Clevis pin deformation
• Crack of any welded portion
o • Crack or deformation of clevis pin stopper
SBR997
Adjustment
Check brake pedal free height from dash reinforcement panel
•
(RHD) and dash lower panel (LHD). Adjust if necessary.
H: Free height
Refer to 50S (BR-SS).
0: Depressed height
Refer to 50S (BR-SS).
Under force of 490 N (50 kg, 110 Ib)
with engine running
1. Loosen lock nut and adjust pedal free height by turning
brake booster input rod. Then tighten lock nut.
2. Check pedal free play.
Make sure that stop lamps go off when pedal is released.
3. Check brake pedal's depressed height while engine is run-
ning.
If lower than specification, check for leaks, air in system or
damage to components (master cylinder, wheel cylinder,
etc.). Then make necessary repairs.
SBR034D
BR-11
MASTER CYLINDER
Removal
CAUTION:
• In the case of brake fluid leakage from the master cylinder,
disassemble the cylinder. Then check piston cups for defor-
mation or scratches and replace necessary parts.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve, depressing
brake pedal to empty fluid from master cylinder.
3. Remove brake pipe flare nuts.
4. Remove master cylinder mounting nuts.
SEC. 460
Reservoir cap ----g ___Reservoir tank
Seal~
Oil strainer ----. ~
L------- -
Cylinder body
Models with ASS
'V/O-ring~(Models with ABS only)

jJ'JD~----
o l-~ '\~ /' Valve stopper
T@" ~ 1.5.2.9
N.m (kg-m, in-Ib) . .-:'J (0.15.0.3, 13.0 • 26.0)
C'9 --- Secondary piston ~ 11.7 - 14.7 \
N.m (kg-m. ft-Ib) (1.2 - 1.5, 8.7 - 10.8)
Brake fluid point
~ Stopper cap ~ assembly ~f]
SBR019DB
Disassembly
1. Bend claws of stopper cap outward.
BR-12
MASTER CYLINDER
2. Remove valve stopper while piston is pushed into cylinder
(Models with ASS only).
SBR435B
3. Remove piston assemblies.

If it is difficult to remove secondary piston assembly, gradually
apply compressed air through fluid outlet.
4. Draw out reservoir tank.
SBR939A
Inspection
Check master cylinder inner wall for pin holes or scratches.
Replace if damaged.
Secondary piston
Assembly
1. Insert secondary piston assembly. Then insert primary pis-
•
ton assembly.
• Pay attention to direction of piston cups in figure at left.
Also, insert pistons squarely to avoid scratches on cylinder
Primary piston bore.
• Pay attention to alignment of secondary piston slit with
valve stopper mounting hole of cylinder body (For models
with ABS only).
SBR012A
Models with ABS

Secondary piston
Primary piston
_-rnIJ SBR221BA
BR-13
MASTER CYLINDER
Assembly (Cont'd)
2. Install stopper cap.
Before installing stopper cap, ensure that claws are bent
inward.
3. Push reservoir tank seals into cylinder body.
4. Push reservoir tank into cylinder body.
5. Install valve stopper while piston is pushed into cylinder

(Models with ABS only).
SBR435B
Installation
CAUTION:
1. Place master cylinder onto brake booster and secure
mounting nuts lightly.
2. Torque mounting nuts.
~: 11.7 - 14.7 N'm (1.2 - 1.5 kg-m, 8.7 -10.8 ft-Ib)
3. Fill up reservoir tank with new brake fluid.
4. Plug all ports on master cylinder with fingers to prevent air
suction while releasing brake pedal.
5. Have driver depress brake pedal slowly several times until
no air comes out of master cylinder.
6. Fit brake lines to master cylinder.
7. Tighten flare nuts.
~: 15 - 18 N'm (1.5 - 1.8 kg-m, 11 - 13 ft-Ib)
8. Bleed air from brake system. Refer to "Bleeding
Procedure", BR-6."
BR-14
BRAKE BOOSTER
On-vehicle Service
OPERATING CHECK
• Depress brake pedal several times with engine off. After
exhausting vacuum, make sure there is no change in pedal
stroke.
• Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
AIRTIGHT CHECK
• Start engine, and stop it after one or two minutes. Depress
SBR002A brake pedal several times slowly. Booster is airtight if pedal
stroke is less each time.
• Depress brake pedal while engine is running, and stop
OK NG
engine with pedal depressed. The pedal stroke should not
change after holding pedal down for 30 seconds.
SBR365AA
Removal
CAUTION:
• Be careful not to deform or bend brake pipes, during
removal of booster.
SEC. 465.470
Gasket •

SBR223BB
BR-15
BRAKE BOOSTER
Inspection
OUTPUT ROD LENGTH CHECK
1. Supply brake booster with vacuum of -66.7 kPa (-667 mbar,
-500 mmHg, -19.69 inHg) using a hand vacuum pump.
2. Check output rod length.
Specified length:
M195, S205 or C205
10.275 - 10.525 mm (0.4045 - 0.4144 in)
Installation
Approx. 125 mm (4.92 In) CAUTION:
• Be careful not to deform or bend brake pipes during instal-
lation of booster.
• Replace clevis pin if damaged.
• Do nol mix different types of brake fluids (DOT 3, DOT 4).
• Due to the angle of installation, thread can be damaged by
the dash panel.
1. Before fitting booster, temporarily adjust clevis to dimen-
sion shown. (Does not apply to vehicles fitted with ABS.)
2. Fit booster, then secure mounting nuts (brake pedal bracket
to booster) lightly.
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts.
Specification:
~: 13 - 16 N'm (1.3 - 1.6 kg-m, 9 - 12 ft-Ib)
5. Install master cylinder. Refer to BR-12.
BR-16
VACUUM HOSE
----a
CAUTION:
When installing vacuum hoses, pay attention to the following
More Ih .. 24 mm points.
(0.94 In) • Do not apply any oil or lubricants to vacuum hose and check
valve.
----------r:~
---------~~~----------
• Insert vacuum tube into vacuum hose as shown.
Connect hose until it contacts

protrusion on vacuum tube.
SBR225B
• Install check valve, paying attention to its direction.

TYPE 1
Intake manifold Brake booster
; C::::::::'::::~:d q
SBR498A
TYPE 2
CAUTION
~
... ENG.
Inspection
HOSES AND CONNECTORS
•
Check vacuum lines, connections and check valve for
airtightness, improper attachment, chafing and deterioration.
BR-17
VACUUM HOSE
Inspection (Cont'd)
CHECK VALVE
Check vacuum with a vacuum pump.
~ Connect to
Booster side
booster side
Connect to
Vacuum should not exist.
engine side
SBR943A
Booster side
Engine side
Arrow indicates
engine side
SBR826B
VACUUM WARNING SWITCH (Diesel engine models)

Test continuity through vacuum warning switch with an ohmme-
ter and vacuum pump.
Vacuum condition Continuity
Less than 26.7 kPa

Yes
(267 mbar, 200 mmHg, 7.87 inHg)
33.3 kPa
(333 mbar, 250 mmHg, 9.84 inHg) or No
SBR007A
more
VACUUM PUMP
1. Install vacuum gauge.
2. Run engine at 1,000 rpm or more.
3. Check vacuum.
Specified vacuum:
86.6 kPa (8~6 mbar, 650 mmHg, 25.59 inHg) or more
BR-18
FRONT DISC BRAKE
Pad Replacement
WARNING:
Clean brake pads with a vacuum dust collector to minimize the
hazard of airborne particles or other materials.
CAUTION:
• When cylinder body is open, do not depress brake pedal or
piston will pop out.
• Be careful not to damage piston boot or get oil on rotor.
Always replace shims when replacing pads.
• If shims are rusted or show peeling of the rubber coat,
replace them with new shims.
• It is not necessary to remove connecting bolt except for
disassembly or replacement of caliper assembly. In this
case, suspend cylinder body with wire so as not to stretch
. brake hose.
1. Remove master cylinder reservoir cap.

2. Remove lower pin bolt.
3. Open cylinder body upward. Then remove pad retainers,

return spring (Except AD22VF brake model) and inner/ol,lter
shims.
•
Standard pad thickness:
CL22VD and CL22VE 11 mm (0.43 in)
CL22VF 10 mm (0.39 in)
Pad wear limit:
2.0 mm (0.079 in)
Carefully monitor brake fluid level because brake fluid will
return to reservoir when pushing back piston.
~ 0 tJ
L:{SR020D
BR-19
FRONT DISC BRAKE
SEC. 440
CL22VD AND CL22VE
<D m @ to sliding portion
t~m@
~ I 0
@~@'~I~_\ '~ 'j/0

\ ~ ~m@
tOJ 22 - 31 (2.2 - 3.2, 16 - 23) '1r ~ m'8' (fJJ;18 ~ -=a 18\

iii: N'm (kg-m, in-Ib) \!.o/WLJ\SI ~WIlI[LJ;I\OI
(OJ : N'm (kg-m, ft-Ib) 17 fJ@

m@ : Rubber grease point
(] @ : Brake fluid point
m@ : PBC (Poly Butyl Cuprysil) grease or silicone-based grease point SBR206D
CD Main pin @ Pad retainer @ Bleed valve

@ Pin boot @ Outer pad @ Cylinder body
@ Torque member fixing bolt @J Outer shim @ Piston seal
@ Torque member @ Connecting bolt @ Piston
@ Shim cover @ Copper washer @ Piston boot
@ Inner shim @ Main pin bolt @ Pad return spring
(j) Inner pad
BR-20
FRONT DISC BRAKE
SEC. 440
AD22VF
15 ~ 31 - 41 16
Ij] : N.m (kg-m, in-Ib) -I (3.2 - 4.2, 23 - 30)
to.J : N. m (kg-m, 1t-lb)

@ Ij] 7 • 9 (0.7 • 0.9, 61 • 78)
m@ : Rubber grease point

f] : Brake fluid point
•
m@ : PBC (Poly Butyl Cuprysil) grease or silicone-based grease point SBR207D
G) Plug @ Inner pad @ Main pin bolt

@ Torque member @ Inner shim @ Cylinder body
@ Torque member fixing bolt @ Shim cover @ Piston seal
@ Pin boot @ Connecting bolt @ Piston
@ Outer shim @ Brake hose @ Piston boot
@ Outer pad @ Copper washer @J Piston boot retainer
(J) Pad retainer @ Air bleeder
BR-21
FRONT DISC BRAKE
Removal
WARNING:
hazard of airborne asbestos or other materials.
CAUTION:
hose.
Remove torque member fixing bolts and connecting bolt.

It is not necessary to remove connecting bolt except for disas-
sembly or replacement of caliper assembly. In this case, sus-
pend caliper assembly with wire so as not to stretch brake
hose.
AD22VF Disassembly
1. Remove piston boot retainer with a screwdriver.
SBR776B
WARNING:
Do not place your fingers in front of piston.
CAUTION:
Do not scratch or score cylinder wall.
2. Push out piston with dust seal with compressed air.
3. Remove piston seal with a suitable tool.
SBR772
Inspection - Caliper
CYLINDER BODY
• Check inside surface of cylinder for score, rust, wear, dam-
age or presence of foreign objects. If any of the above con-
ditions are observed, replace cylinder body.
• Minor damage from rust or foreign objects may be elimi-
nated by polishing surface with a fine emery paper. Replace
cylinder body if necessary.
CAUTION:
Use brake fluid to clean. Never use mineral oil.
BR-22
FRONT DISC BRAKE
Inspection - Caliper (Cont'd)
PISTON
Check piston for score, rust, wear, damage or presence of for-
eign objects. Replace if any of the above conditions are
observed.
CAUTION:
Piston sliding surface is plated. Do not polish with emery paper
even if rust or foreign objects are stuck to sliding surface.
SLIDE PIN, PIN BOLT AND PIN BOOT
Check for wear, cracks, rust or other damage. Replace if any of
the above conditions are observed.
Inspection - Rotor
RUNOUT
1: Secure rotor to wheel hub with at least two nuts (M12 x
1.25).
2. Check runout using a dial indicator.
Make sure that wheel bearing axial end play is within the spec-
ifications before measuring. Refer to FA section ("Front Wheel
Bearing", "ON-VEHICLE SERVICE").
Maximum runout:
SBR936A 0.07 mm (0.0028 in)
3. If the runout is out of specification, find minimum runout
position as follows:
a. Remove nuts and rotor from wheel hub.
b. Shift the rotor one hole and secure rotor to wheel hub
with nuts.
c. Measure runout.
d. Repeat steps a. to c. so that minimum runout position can
be found.
4. If the runout is still out of specification, turn rotor with on-car
brake lathe ("MAD, DL-8700", "AMMCO 700 and 705" or •••
equivalent).
THICKNESS
Thickness variation (At least 8 positions):
Maximum 0.02 mm (0.0008 in)
If thickness variation exceeds the specification, turn rotor with
on-car brake lathe.
Rotor repair limit:
CL22VF 24.0 mm (0.945 in)
SBR944A
Piston boot retainer (AD22VF only) Assembly

Piston boot 1. With piston boot fitted to piston, insert piston boot into
groove on cylinder body and install piston.
2. Properly secure piston boot.
3. Secure piston boot with retainer.
Piston
seal (AD22VF model only)
Piston
SBR777B
BR-23
FRONT DISC BRAKE
Installation
CAUTION:
1. Install caliper assembly.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
BR-24
REAR DRUM BRAKE
SEC. 441
Front
m,W . Rubber grease POint

• . Brake grease point
~ : N.m (kg-m, f1-lb)
/il. N.m (kg-m, in-Ib)
•
SBR772BC
Cl) Wheel cylinder assembly (J) Return spring @ Shoe hold-down spring
@ Boot @ Adjuster @ Toggle lever
@ Piston @ Shoe @ Washer
@ Piston cup @) Adjuster lever @ Retainer ring
@ Cylinder body @ Adjuster spring @ Shoe hold-down pin
@ Spring @ Retainer @ Plug
Removal
WARNING:
Clean brake lining with a vacuum dust collector to minimize the
CAUTION:
Make sure parking brake lever is released completely.
BR-25
REAR DRUM BRAKE
Removal (Cont'd)
1. Release parking brake lever fully, then remove drum.
Wheel If drum is hard to remove, the following procedures should be
cylinder
carried out.
a. Remove plug. Then shorten adjuster to make clearance
between brake shoe and drum as shown.
Adjuster
SBR280B
b. Tighten the two bolts gradually.
Bolts
(M8 x 1.25)
SBR020A
2. After removing retainer, remove spring by rotating shoes.

• Be careful not to damage wheel cylinder piston boots.
• Be careful not to damage parking brake cable when sepa-
rating it.
3. Remove adjuster.
4. Disconnect parking brake cable from toggle lever.
SBR785BA
5. Remove retainer ring with a suitable tool. Then separate

toggle lever and brake shoe.
Inspection - Wheel Cylinder

• Check wheel cylinder for leakage.
• Check for wear, damage and loose conditions.
Replace if any such condition exists.
BR-26
REAR DRUM BRAKE
Wheel Cylinder Overhaul

• Check all internal parts for wear, rust and damage. Replace
if necessary.
• Pay attention so as not to scratch cylinder when installing
pistons.
SBR215B
Inspection - Drum
Maximum inner diameter:
181 mm (7.13 in)
Out-of-roundness:
0.03 mm (0.0012 in) or less
SBR022A
• Contact surface should be fine finished with No. 120 to 150

emery paper.
• Using a drum lathe, lathe brake drum if it shows scoring,
partial wear or stepped wear.
• After brake drum has been completely reconditioned or
replaced, check drum and shoes for proper contact pattern .
A
Inspection - Lining
Check lining thickness.
Standard lining thickness:
•
4.0 mm (0.157 in)
Lining wear limit (A):
1.5 mm (0.059 in)
SBR021A
Installation
Always perform shoe clearance adjustment. Refer to
"Adjustment" in "PARKING BRAKE CONTROL", BR.37.
1. Fit toggle lever to brake shoe with retainer ring.
BR-27
REAR DRUM BRAKE
2. Apply brake grease to the contact areas shown at left.
SBR216B
3. Shorten adjuster by rotating it.

• Pay attention to direction of adjuster.
~ ~ Vohi'" 'COol
Wheel Screw Depression
Left Left-hand thread Yes

Right Right-hand thread No
DepreSSi~~
" ~
/ 4. Connect parking brake cable to toggle lever.
5. Install all parts.
Be careful not to damage wheel cylinder piston boots.
SBR217B
6. Check all parts are installed properly.
Pay attention to direction of adjuster assembly.
7. Install brake drum.
8. When installing new wheel cylinder or overhauling wheel
cylinder, bleed air. Refer to "Bleeding procedure", BR-6.
9. Adjust parking brake. Refer to BR-37.
SBR279B
BR-28
REAR DISC BRAKE
Pad Replacement
WARNING:
CAUTION:
• When cylinder body is open, do not depress brake pedal,
otherwise piston will pop out.
• Be careful not to damage piston boot or get oil on rotor.
Always replace shims when replacing pads.
• If shims are rusted or show peeling of rubber coat, replace
them with new shims.
• It is not necessary to remove connecting bolt except for
disassembly or replacement of caliper assembly. In this
case, suspend cylinder body with wire so as nol to streich
brake hose
• Carefully monitor brake fluid level because brake fluid will
1. Remove master cylinder reservoir cap.
2. Remove brake cable lock spring.
3. Remove cable guide from caliper assembly.
4. Disconnect cable.
5. Remove lock spring from brake hose. Then remove brake
hose from bracket.
6. Remove lower pin bolt.
7. Open cylinder body upward. Then remove pad retainers,
and inner and outer shims.
Standard pad thickness:
10 mm (0.39 in)
Pad wear limit:
1.5 mm (0.059 in)
SBR023D
8. When installing new pads, push piston into cylinder body by

turning piston clockwise.
Carefully monitor brake fluid level because brake fluid will
•
Commercial
service tool
SBR868C
BR-29
REAR DISC BRAKE
SEC. 440
CL7HB AND ~ 25 - 29 (2.5 - 3.0, 18 - 22)
~
CL9HC
<l
@m@to ,Ii"" pmli"
m @ to p,d ,,,,,,, ""

J
!
@ ~~~:':'~) ~' ~ :d~ CL9HC)
,-,
"""
-
. N.m (kg-m,.
"II-'b)pom' • m@
(Model CL9HC)
@. 'f /
@(Model CL7H
B)
'i'i'
m'O' , Robb" "" d """ pom'
in @ : Bra ke fluid point Cuprysil) greas e or silicone-base
U BC (Poly Butyl SBR208D
m@ ,p @ Oo'e"him
CD Cable guide @ Piston seal
@ Cylinder @ Strut @ Snap ring
@ Toggle lever @ O-ring @ Spacer
@ Pin @ Push rod @ Wave washer
@ Pin boot @ Key plate @l Spacer
(6) Torque m ember @ Snap ring @ Bearing
(j) Retainer @ Seat @ Adjuster
@ Inner shim @ Spring @'J Cup
@ Inner pad @l Spring cover @) Piston
@ Pad retainer @ Snap ring @ Piston boot
@ Outer pad
BR-30
REAR DISC BRAKE
Removal
WARNING:
1. Remove parking brake cable lock plate.
2. Remove torque member fixing bolts and connecting bolt.
It is not necessary to remove connecting bolt except for disas-
sembly or replacement of caliper assembly. In this case, sus-
pend caliper assembly with wire so as not to stretch brake
hose.
SBR025D
Disassembly
1. Remove piston by turning it counterclockwise with suitable
long nose pliers or commercial service tool.
( I
( ~i
i
U
SBR646
•
Commercial
service tool
SBR868C!
2. Remove snap ring from piston with suitable pliers and

remove adjusting nut.
SBR889
3. Disassemble cylinder body.

a. Pry off snap ring with suitable pliers, then remove spring
cover, spring and seat.
b. Remove snap ring, then remove key plate, push rod, rod
and strut.
BR-31
REAR DISC BRAKE
c. Remove piston seal.
Be careful not to damage cylinder body.
l
--,II
~//
SBR656
4. Remove return spring, toggle lever and cable guide.
SBR026D
Inspection - Caliper
CAUTION:
Use brake fluid to clean cylinder. Never use mineral oil.
CYLINDER BODY
• Check inside surface of cylinder for score, rust, wear, dam-
age or presence of foreign objects. If any of the above con-
ditions are observed, replace cylinder body.
• Minor damage from rust or foreign objects may be elimi-
nated by polishing surface with a fine emery paper.
Replace cylinder body if necessary.
TORQUE MEMBER
Check for wear, cracks or other damage. Replace if necessary.
PISTON
CAUTION:
Piston sliding surface ;s plated. Do not polish with emery paper
even if rust or foreign objects is stuck to sliding surface.
Check piston for score, rust, wear, damage or presence of for-
eign objects. Replace if any of the above conditions are
observed.
SLIDE PIN, PIN BOLT, AND PIN BOOT

Check for wear, cracks or other damage.
Replace if any of the above conditions are observed.
BR-32
REAR DISC BRAKE
Inspection - Rotor
RUBBING SURFACE
Check rotor for roughness, cracks or chips.
RUNOUT
1. Secure rotor to wheel hub with at least two nuts (M12 x 1.25).
2. Check runout using a dial indicator.
Make sure that wheel bearing axial end play is within the spec-
ifications before measuring. Refer to "Rear Wheel Bearing" of
"ON-VEHICLE SERVICE" in RA section.
3. Change relative positions of rotor and wheel hub so that
runout is minimized.
Maximum runout:
0.07 mm (0.0028 in)
THICKNESS
Rotor repair limit:
Minimum thickness
CL7HB 6.0 mm (0.236 in)
CL9HC 8.0 mm (0.315 in)
Thickness variation (At least 8 portions)
Maximum 0.02 mm (0.0008 in)
Replace rotor if any of the above do not meet the specifications .
SBR847
Assembly
1. Insert cam with depression
inder.
facing towards open end of cyl-
•
SBR247B
2. Generously apply rubber grease to strut and push rod to

make insertion easy.
BR-33
REAR DISC BRAKE
Assembly (Cont'd)
3. Match protrusion on key plate with depression in cylinder.
Convex portion
Snap ring 4. Install snap ring with a suitable tool.

~
Keyplate~
Rod ---{[J
SBR809B
5. Install seat, spring, spring cover and snap ring while

Press
depressing with suitable tool.
Snaprjng-~
Spring cover ~
Spring-l
Seat--@
SBR810B
6. Install adjuster in the specified direction.
7. Install cup, adjuster, bearing, spacers, washers and snap

Snap ring-o
ring with a suitable tool.
Spacer ------L81
VVavewasher~
Spacer----i9'J
Ball bearmg~
AdjUSler-i
Cup---@)
P"'o0-e SBR078D
BR-34
REAR DISC BRAKE
Assembly (Cont'd)
8. Insert piston seal into groove on cylinder body.
9. With piston boot fitted to piston, insert piston boot into
groove on cylinder body and fit piston by turning it clock-
wise with long nose pliers, or suitable tool.
SBR646
Commercial
service 1001
SBR868C
10. Fit toggle lever, return spring and cable guide .
Installation
CAUTION:
•
1. Install caliper assembly.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.
BR-35
PARKING BRAKE CONTROL
SEC. 443
ItJ 3.'.'~ (0.33 .0 .... 28.6 • 38.2)~
Rear RH cable "'"
\;.., Rear drum model

,Lever assembly ~r.iil ~4.3 - 6.5
I llrJ 3.2 • 4.3 " ~ (0.44 • 0.66, 38.2 • 57.3)
~
jjf (y -
~15.7
..
- 19.6
2.0, 11.6 • 14.5) ~1iI3.2
(0.33.0.44,28.6.38.2)
• 4.3
','(5'
"""'...~)\)')'))Jl--'
..--,
Ad' t t~
IUS Ing nu ~
Parking brake
"
~/
,,~'::\'
~'
i
/, f
J,
I'
I
!cablem.
Front
e\
~\
<>
r
,
(0.33 - 0.44, 28.6 - 38.2)
Rear LH cab7e
~
I
<~
~
m
3.2 • 4.3 (0.33 - 0.44, 28.6 • 38.2)
I
warning lamp switch
JJ~? iii (~./?' ~ Boot
3.2 • 4.3 ~
/ -
3.2 .4.3 (0.33 • 0.44, 28.6 - 38.2)
~ M___ (0.33 • 0.44, 28.6 - 38.2) iii ~ci~3;~'~.44, II] 3.2 • 4.3 (0.33 • 0.44',28.6 - 38.2)
Bracket 28.6 _ 38.2) Ill: N.m (kg-m, In-Ib)
~: N.m (kg-m, ft-Ib) SBR028DA

1. To remove parking brake cable, first remove center con-
sole.
2. Disconnect warning lamp connector.
3. Remove bolts, slacken off and remove adjusting nut.
4. Remove lock plate and disconnect cable (disc brake only).

For drum brake models, refer to BR-25.
Inspection
1. Check control lever for wear or other damage. Replace if
necessary.
2. Check wires for discontinuity or deterioration. Replace if
necessary.
3. Check warning lamp and switch. Replace if necessary.
4. Check parts at each connecting portion and, if deformed or
damaged, replace.
BR-36
PARKING BRAKE CONTROL
Adjustment
Toggle lever Before or after adjustment, pay attention to the following points.
a. For rear disc brake be sure that toggle lever returns to
Stopper stopper when parking brake lever is released.
b. There is no drag when parking brake lever is released.
Front
SBR029D
1. Adjust clearance between shoe and drum/pad and rotor as

follows:
a. Release parking brake lever and loosen adjusting nut.
b.- Depress brake pedal fully at least 10 times with engine run-
ning.
2. Pull control lever 4 - 5 notches. Then adjust control lever by
turning adjusting nut.
SBR042D
3. Pull control lever with specified amount of force. Check

196 N (20 kg, 44 Ib) lever stroke and ensure smooth operation.
/ Number of notches:
Drum brake: 7 - 8
Disc brake: 8 - 9
SBR073D
4. Bend warning lamp switchplate to ensure following. Warn-

ing lamp comes on when lever is pulled "A" notches and
goes out when fully released.
•
Number of "A" notches: 1 or less
BR-37
ANTI-LOCK BRAKE SYSTEM
Purpose
The Anti-Lock Brake System (ABS) consists of electronic and hydraulic components. It allows for con-
trol of braking force so that locking of the wheels can be avoided.
The ABS:
1) Improves proper tracking performance through steering wheel operation.
2) Eases obstacles to be avoided through steering wheel operation.
3) Improves vehicle stability by preventing flat spins.
Operation
• When the vehicle speed is less than 10 km/h (6 MPH) this system does not work.
• The Anti-Lock Brake System (ABS) has self-test capabilities. The system turns on the ABS warning
light for 1 second after turning the ignition switch ON. The system performs another test the first time
the vehicle reaches 6 km/h (4 MPH). A mechanical noise may be heard as the ABS performs a self-
test. This is a normal part of the self-test feature. If a malfunction is found during this check, the ABS
warning light will come on.
• During ABS operation, a mechanical noise may be heard. This is a normal condition.
ABS Hydraulic Circuit
)(
SBR918C
G) Inlet solenoid valve @ Motor @ Check valve

@ Outlet solenoid valve @ Inlet valve @) Damper
@ Reservoir (J) Outlet valve @ Gradient switch
@) Pump @ Bypass check valve
BR-38
System Components
Dual proportioning
valve
Rear wheel sensors
For LHD models, control unit

is located on the opposite side.
SBR048DB
Control unit System Description
s::';o~'~W.
Magnetic flux ~
r<ca!bvJ
_~- Coil
steJ
SENSOR
I . I
The sensor unit consists of a gear-shaped sensor rotor and a
Tooth~ Sensor rotor sensor element. The element contains a bar magnet around
which a coil is wound. The sensor is installed on the back side
/ ~m~f one tooth of the brake rotor. Sine-wave current is generated by the sen-
sor as the wheel rotates. The frequency and voltage increase(s) •
v:~-- as the rotating speed increases. : •
V: Induced electromotive force

SBR124B
CONTROL UNIT
The control unit computes the wheel rotating speed by the sig-
nal current sent from the sensor. Then it supplies a DC current
to the actuator solenoid valve. It also controls ON-OFF opera-
tion of the valve relay and motor relay. If any electrical malfunc-
tion should be detected in the system, the control unit causes
the warning lamp to light up. In this condition, the ASS will be
deactivated by the control unit, and the vehicle's brake system
reverts to normal operation.
SBR049DA
BR-39

CAUTION:
Be careful not to damage sensor edge and sensor rotor teeth.
When removing the front or rear wheel hub assembly, discon-
nect the ABS wheel sensor from the assembly and move it
away.
FRONT WHEEL SENSOR
~!Ii 3.9 - 5.9 (0.4 - 0.6, 35 - 52)
Front wheel sensor (LH) ~: Nom (kg-m, ft-lb)

~: Nom (kg-m, in-Ib)
SBR030DA
REAR WHEEL SENSOR
\
L Rear wheel sensor (LH)
~: Nom (kg-m, ft-Ib)

~: Nom (kg-m, in-Ib)
SBR031DA
BR-40
Removal and Installation (Cont'd)
SENSOR ROTOR
Removal
1. Remove the drive shaft and rear wheel hub. Refer to FA
section ("Drive Shaft", FRONT AXLE") and RA section
("Wheel Hub", REAR AXLE").
2. Remove the sensor rotor using suitable puller, drift and
bearing replacer.
Suitable drift
SBR873CA
Installation
Install the sensor rotor. For front sensor rotor, use hammer and
wooden block. For rear sensor rotor, use suitable drift and
press.
• Always replace sensor rotor with new one .
Rear sensor rotor

SBR985C
• Pay attention to the dimension of rear sensor rotor as shown

in figure.
h: 4.5 - 5.5 mm (0.177 - 0.217 in)
•
Suitable drift
SBR986C
CONTROL UNIT
B,.,k" ~ ABS .'0"'" ","
Location: Passenger side, behind dash side lower finisher.
• Make sure that the sensor shield ground cable is secured
with mounting bolt.
Dash side ~
lower finisher ~ 3.9 _ 5.9 N.m
(0.4 - 0.6 kg-m,
35 - 52 In-Ib) SBR032DA
BR-41
---------~~~~~:A~K~EirS;V~S~T~EWo.M;(c:O;;~'dii
ANTI-LOCK BR d Installation (Cont
Removal an
ABS ACTUATOR
RHO
ASS relay
box
Actuator ground
cable
cc:J 11 - 15 . 11)
(1.1 . 1.5, 8 , ry side
linder prima
From master cy ndary side
From master cy rInder seco
~ Front
LHO
heel cylinder (RH)

To rear W c linder (LH)
To f ro nt wheel y
From master cylinder
primary side
From m aster'de
cylinder
secondary Sl (LH)
To rear Wheel cylinder
To rear Wheel cylinder (RH)
r.ii1 ' N.m (kg-m. in-Ib)

cc:J:
IX! ' N.m (kg-m. ft-Ib)
SBR033DA
BR-42
1. Disconnect battery cable.
2. Drain brake fluid. Refer to SR-5.
3. Discharge air conditioner refrigerant. Refer to HA section
("R-134a Service Procedure", "SERVICE PROCEDURES").
4. Disconnect all connectors from ASS relay bracket.
5. Remove mounting bolt for relay bracket.

6. Remove ASS relay box with bracket.
7. Remove air conditioner low-pressure tubes. Refer to HA
section, ("Refrigerant Lines", "SERVICE PROCEDURES") .
8. Disconnect brake pipes and move away from actuator.

It is not necessary to remove these pipes from vehicle.
•
9. Remove/loosen mounting nuts between actuator and

bracket.
BR-43
10. Draw out ASS actuator as shown.
ASS actuator
SBR039D
CAUTION:
After installation, pay attention to the following points:
• Refill brake fluid and bleed air. Refer to "CHECK AND
ADJUSTMENT", BR-5 and "AIR BLEEDING", BR.6, respec-
tively.
• Charge air conditioner refrigerant. Refer to HA section,
("R-134a Service Procedure", "SERVICE PROCEDURES").
• The installation procedure is the reverse of removal.

ASS actuator
_-=--=--=--=--_-_-\,_~ ""'~t"b"ok.,
SBR040D
ABS RELAYS
1. Disconnect battery cable.
2. Remove ASS relay cover.
BR-44
Wiring Diagram - ABS -
BR-ABS-01
IGNITION SWITCH
ON or START
FUSE Refer to
BLOCK EL-POWER.
(JIB)
~
<D: LHD models

STOP @: RHO models
DEPRESED LAMP
SWITCH
RELEASED
~
P!L
~
I~I
Y
COMBINATION
METER
• (ABS WARNING
LAMP)
~:I ~@
~
LIB @
P!L
rn
I JUNCTION
BOX NO.2
(JOINT
CONNECTORS) GY <fill)
I
LIB
1!:i=!J~
PIL
$-------$
GY (~) LIB
~~ I-
•lelIl e-
•
LIB ~ To BR-ABS-O?
I
PIL
<fill)
9F'~
P!L GY LIB
14-81 ffi 13-0 I
STOP IGN FAIL
LAMP SW LAMP ABS
SW CONTROL
UNIT
(B111)
Refer to last page

Fa~ ~~(B115) (Foldout page) .
l..1..@ BTI1910 W 5 6 1112
~---------------------------------,
L ~
HBR002
BR-45
Wiring Diagram - ABS - (Coni' d)
BR-ABS-02
IGNITION SWITCH
ON or START
ABS
FUSE Refer to CONTROL
7 .5A BLOCK EL-POWER. UNIT
rn (JIB) OrAG (!ID1)
L TXD RXD
~
~ 1~61 ~
ORIB ~ GY!L GIB
I$~~ ~ciJ~--- ~~I
ORIB GY/L GIB
It It
cr
GY!L GIB
l
I~ i~MO~o~?ic~g~)
~:<O
JOINT CONNECTOR-5
~ 1*.21~:<ID
GY/L GIB
ORIB GY/L
I GIB
I
rtl m r1l
DATA LINK
CONNECTOR
FOR CONSULT
----------------------- I
(M13)
<0: LHD models

<ID: RHO mode Is
@: GA engine and SR engine
@: CD20 engine
~f1 <0 10 <ID 6
*2 <0 9 '<ID, 3
Refer to last page

~~(~) (Foldout page) .
56j819101112 W
~(~24)
~OR
HBR003
BR-46
Wiring Diagram - ABS - (Cont'd)
BR-ABS-03
ABS
CONTROL
SENSOR UNIT
FR-RH
H GN02 GNO 1 GNO

~ 12.81 12.91 13•91
B
I
t B B B
Ll-l
o
..
R
- ~
R
1
----
)
I
,.
1 1
I
I I
I 1
1
I....
l
'] ----
W@1IDB .
1
1
I $---$-]1W @) 8
_.
I
I
I -----
1
I
(, -
JOINT
rn
I 1 - - I
CONNECTOR 1 I I
-7 I I I
(B109) J
1
l.... •
-]1
1 1
I
1
1
I l~t~~8}j~f
I
1 W «(1Q"n B (jJ: LHO models
1
-----
•
1 (8): RHO models
1 r-- _
1
I I I
1 I 1
I.... 1 1
t l.... 'J
~
W
rv
B
WHEEL
SENSOR
FRONT RH
(1llQj)
SPEED M W
rv
B
WHEEL
SENSOR
FRONT RH
(E 11)
SPEED
Refer to last page

(Foldoutpage).
&~(BIT5) ..In em), @ill) ~(Eli[9)
5 6 TII9ID 1112 W <..!J.g) GY GY IIlIITl.IIillJ GY
HBR004
BR-47
Wiring Diagram - ABS - (Cont'd)
BR-ABS-04
ASS
CONTROL
SENSOR UNIT
FR-LH ~
H
~
t <D: LHO models
•
L @: RHO models
,.
0 L
- -ec
L
I
I
I
-- -- )
I
I
I
I
---- 1--
)
I
I
I
I
I
t
']
$---$JR ~
----
L
1 R <MID L
1
I - - --
mJOINT CONNECTOR
I
I
1
I
I' ---- !
I I
-7 I 1 I
(B109) l-- •
1 -----
A@L ]
t -- )
I
I
,I
I
I
(
I$f---J$-J
(,
I
R L
-----
(ffi1)
- ---
.
)
1
I
I
----- -----
-
(eUO)
M R
rv
L
.>'EEL
SENSOR SPEED
FRONT LH
(8106)
M R
rv
L
WHEEL
SENSOR SPEED
FRONT LH
@
Refer to last page

(Foldout page) .
...IE. @,(~) ~(B109)
~~(@
56 iBl91<iu 12 W (tig) SR SR illIIIIIIIIIl GY
HBR005
BR-48
Wiring Diagram - ABS - (Conl'd)
BR-ABS-05
A8S
CONTROL
SENSOR SENSOR SENSOR SENSOR UNIT
RR-RH RR-RH RR-LH RR-LH <illTI)
(+) H (+) H
3 8
~ 1 • 1 lY;ll ~
J t J t
"
PU LG P L
----- -----
....
(
---- /)I
r-:l~!
I
I
I
.
JOINT
CONNECTOR-7
@QID
I
I
I
I
I
I
I
I
r
(8110)
I
1
1
I
I
I
I
I
I
I
I
I
I
•
I
I
I
,I
'I )
/
----
MPU
rv
LG
WHEEL
SENSOR
REAR RH
(!W)
SPEED M P
rv
L
WHEEL
SENSOR SPEED
REAR LH
(ffi?)
Refer to last page

(Foldout page) .
15a ([UID , @TI) ~(8109)
C!J.g) GY SR l:TIIillIIIIIJ GY
HBR006
BR-49
Wiring Diagram - ABS - (Coni' d)
BR-ABS-06
ABS
CONTROL
UNIT
FL- FL- FR- FR- RL- RL- RR- RR-
OUT IN OUT IN OUT IN OUT IN ~
13';'
GY
IbiJ
GY/R
12•61
BR
15•41
BR/W
12';'
LG
15•31
LG/R
13•41
PU
~
PU/W
t t t t t t t t
-- B
C
}Next
page
@
18 - -- 20
19 --- 21
GY GY/R BR BR/W LG LG/R PU PU/W ~
nf4ll m ~ rTI wf6n rrtll Iff7il ~
FL -OUT FL - IN FR-OUT FR- IN RL -OUT RL -IN RR-OUT RR- IN

M MOTOR ABS
ACTUATOR
(fJ103)
r-------------------------,
I Refer to last page
(Foldout page) .
~
~~ B ~
~@: B I
L I
~
HBRDD?
BR-50
Wiring Diagram - ABS - (ConI' d)
SR-ASS-07
I BAT.ERY I SOLENOID
VALVE MOTOR MOTOR
ABS
CONTROL
Refer to RELAY MOTOR RELAY RELAY UNIT
rJ:~~30A EL-POWER. CONTROL

(-)
RELAY
MONITOR
CONTROL
(+)
CONTROL
(-) ~
LtJw LtJm
BR Y
13: I
LG/R
~
L
~
Y
4=U
G/R
t t J t
Preceding{
page
~
B
--
rg.~~,~ L/B ~
t t t Lt t
m•
BR LIB LG/R Y Y G/R
ffi n=fo] rh m n=f3n rrf1iJ
*
-----<
@> @ @ @) ABS
SOLENOID MOTOR RELAY
BOX
• :.
VALVE I: RELAY
RELAY I ?
~ ) ~ UQ)
~)
(lli) I@ ~@ @> I@
~----------------------~
(Foldout page) .
: UQ) ~~
I (411'3) GY ~B
I
~----------------------~
HBRDDa
BR-51
TROUBLE DIAGNOSES
Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair SR-52
Self-diagnosis SR-53
CONSULT BR-58
CONSULT Inspection Procedure BR-59
Component Parts and Harness Connector Location BR-64
Preliminary Check BR-65
Ground Circuit Check BR-66
Circuit Diagram for Quick Pinpoint Check BR-67
Diagnostic Procedure 1 Warning lamp does not come on BR-68
Diagnostic Procedure 2 Warning lamp stays on BR-69
Diagnostic Procedure 3 ABS actuator solenoid valve BR-72
Diagnostic Procedure 4 Wheel sensor or rotor BR-74
Diagnostic Procedure 5 Motor relay or motor BR-76
Diagnostic Procedure 6 Solenoid valve relay BR-79
Diagnostic Procedure 7 Power supply BR-81
Diagnostic Procedure 8 Control unit BR-82
Diagnostic Procedure 9 Pedal vibration and noise BR-82
Diagnostic Procedure 10 Long stopping distance BR-83
Diagnostic Procedure 11 Unexpected pedal action BR-83
Diagnostic Procedure 12 ABS does not work BR-84
Diagnostic Procedure 13 ABS works frequently B R-84
Electrical Component Inspection BR-85
How to Perform Trouble Diagnoses for Quick
and Accurate Repair
INTRODUCTION
The ABS system has an electronic control unit to control major
functions. The control unit accepts input signals from sensors
and instantly drives the actuators. It is essential that both kinds
of signals are proper and stable. It is also important to check
for conventional problems: such as air leaks in booster lines,
lack of brake fluid, or other problems with the brake system.
SEF233G It is much more difficult to diagnose a problem that occurs
lems are caused by poor electric connections or faulty wiring.
In this case, careful checking of suspicious circuits may help
prevent the replacement of good parts.
A visual check only may not find the cause of the problems, so
a road test should be performed.
talk with a customer who approaches with a ABS complaint. The
customer is a very good source of information on such prob-
lems; especially intermittent ones. Through the talks with the
customer, find out what symptoms are present and under what
SEF234G conditions they occur.
first. This is one of the best ways to troubleshoot brake prob-
lems on an ABS controlled vehicle.
BR-52
TROUBLE DIAGNOSES
Self-diagnosis (For Europe)

FUNCTION
• When a problem occurs in the ABS, the warning lamp on the
instrument panel comes on.
• A maximum of three malfunctions are stored in the memory
of the ABS control unit.
Erase the self-diagnosis results stored in the control unit after
malfunctions are repaired (See next page).
• The self-diagnosis results are identified by CONSULT or
warning lamp.
SELF-DIAGNOSIS PROCEDURE
Start engine.
Dr.ive vehicle over 15 km/h (9 MPH) for at least one minute .
.=J MPH
-~s:: ~
Stop vehicle with engine running.
~~ Make sure thai the ASS warning lamp activates.
___ --- warnin:1 SBR875CA

Verify the location of the malfunction with the malfunction code chart.
Then make necessary repairs following the diagnostic procedures.
After the malfunctions are repaired, erase the self-diagnostic results

stored in the control unit.
Disconnect connectors for ASS control unit or the battery negative termi-
nal for at least one minute.
Check warning lamp for deactivation after driving vehicle over 15 km/h (9
MPH) for at least one minute. •
Test the ASS in a safe area to verify that it functions properly.
BR-53
TROUBLE DIAGNOSES
Self-diagnosis (For Europe) (ConI' d)
HOW TO READ SELF-DIAGNOSTIC RESULTS (Malfunction codes)
• Determine the code No. by counting the number of times the warning lamp flashes on and off.
• The malfunction code chart is given on the next page.
Example
Malfunction code No. 12 and 23
Warning lamp ON
a 3 seconds (Clearance between code No.)

b 0.6 second (Ten digits)
c 0.3 second (One digit)
Warning lamp OFF
c
SBR877CA
HOW TO ERASE SELF-DIAGNOSTIC RESULTS (Malfunction codes)

• Disconnect ASS control unit connectors or battery negative terminal for at least one minute.
• When using CONSULT, touch "ERASE" on the CONSULT screen with self-diagnostic results mode.
BR-54
TROUBLE DIAGNOSES
Self-diagnosis (For Europe) (Cont'd)
MALFUNCTION CODE/SYMPTOM CHART
Code No.
Malfunctioning part Diagnostic procedure
(No. of warning lamp flashes)
45 Actuator front left outlet solenoid valve 3

46 Actuator front left inlet solenoid valve 3
41 Actuator front right outlet solenoid valve 3
42 Actuator front right inlet solenoid valve 3
51 Actuator rear right outlet solenoid valve 3
52 Actuator rear right inlet solenoid valve 3
55 Actuator rear left outlet solenoid valve 3
56 Actuator rear left inlet solenoid valve 3

25 Front left sensor (open-circuit) 4
26 Front left sensor (short-circuit) 4
21 Front right sensor (open-circuit) 4
22 Front right sensor (short-circuit) 4
35 Rear left sensor (open-circuit) 4
36 Rear left sensor (short-circuit) 4
31 Rear right sensor (open-circuit) 4
32 Rear right sensor (short-circuit) 4
18 Sensor rotor 4
61 Actuator motor or motor relay 5
63 Solenoid valve relay 6
57 Power supply (Low voltage) 7
•
71 Control unit 8
Control unit power supply circuit
Warning lamp bulb circuit
Warning lamp stays on when igni-
Control unit or control unit connector 2
tion switch is turned on
Solenoid valve relay stuck
Power supply for solenoid valve relay coil
Warning lamp stays on, during
Control unit -
self-diagnosis
Warning lamp does not come on Fuse, warning lamp bulb or warning lamp circuit
1
when ignition switch is turned on Control unit
Warning lamp does not come on
during self-diagnosis
Control unit -
Pedal vibration and noise - 9

Long stopping distance - 10
Unexpected pedal action - 11
ABS does not work - 12
ABS works frequently - 13
BR-55
TROUBLE DIAGNOSES
Self-diagnosis (Except Europe)

FUNCTION
• When a problem occurs in the ASS, the warning lamp on the
instrument panel comes on. To start the self-diagnostic
results mode, ground the self-diagnostic (check) terminal
located on "Data Link Connector for CONSULT". The loca-
tion of the malfunction is indicated by the warning lamp
flashing.
Drive vehicle over 30 km/h (20 MPH)

for at least one minute.
~
Turn ignition switch "OFF".
m L
Ground terminal "L" of "DATA LINK
CONNECTORfor CONSULT" with a
suitable harness.
L
Turn ignition switch "ON" while
grounding terminal "L".
Do not depress brake pedal.
m ~
After 3.6 seconds, the warning lamp
starts flashing to indicate the malfunc-
tion code No (See NOTE.)
s~'~"\
Verify the location of the malfunction
with the malfunction code chart. Refer
to BR-57. Then make the necessary
[i repairs following the diagnostic proce-
dures.
~/''':~~
~/\\l---u~
DATA LINK CONNECTOR (D'. ct the harness)
L
After the malfunctions are repaired,
erase the malfunction codes stored in
the control unit. Refer to BR-57.
for CONSULT ~Isconne

~
~ / !/717) ') SBR054D
Rerun the self-diagnostic results mode
to verify that the malfunction codes
have been erased.
~ 1 NOTE: The indication terminates

Disconnect the check terminal from after five minutes.
the ground. The self-diagnostic results
,
However, when the ignition
mode is now complete. switch is turned from
"OFF" to "ON", the indica-
tion starts flashing again.
BR-56
TROUBLE DIAGNOSES
Self-diagnosis (Except Europe) (Cont'd)
@
Check warning lamp for deactivation

after driving vehicle over 30 km/h (20
MPH) for at least one minute.
After making certain that warning

lamp does not come on, test the ASS
in a safe area to verify that it functions
properly.
HOW TO READ SELF-DIAGNOSTIC RESULTS (Malfunction codes)

• Determine the code No. by counting the number of times the warning lamp flashes on and off.
• When several malfunctions occur at one time, up to three code numbers can be stored; the latest
malfunction will be indicated first.
• The indication begins with the start code 12. After that a maximum of three code numbers appear in
the order of the latest one first. The indication then returns to the start code 12 to repeat (the indi-
cation will stay on for five minutes at the most).
• The malfunction code chart is given on the next page.
Example: Code No. 32 REAR SENSOR SHORT-CIRCUIT

Start code: 12 CODE NO. 32
Tens digits Units digits Tens digits Units digits
ON
Warning
lamp
OFF
3.6 0.4 1.6 0.4 0.4 0.4 3.6 Unit: Second

ON
•
IGN
OFF
SBR441C
Self-diagnosis completed
HOW TO ERASE SELF-DIAGNOSTIC RESULTS
~~
"I
i
(Malfunction codes)
L
1. Disconnect the check terminal from ground (ASS warning
::J1IU
p;eck~IJi
1
i
lamp will stay lit).
2. Within 12.5 seconds, ground the check terminal 3 times.
Open -._.- Each terminal ground must last more than 1 second. The
Idlsconnect) ! ASS warning lamp goes out after the erase operation has
Ground 10---+1 I
been completed.
__. __... _--.J.. ~9rt'_ !~~_1.~:':. ... ... LJ 3. Perform self-diagnosis again. Refer to SR-56. Only the start
; 12.5 see j
Malfunction code
memory erased
code should appear, no malfunction codes.
ABR256
MALFUNCTION CODE/SYMPTOM CHART

Refer to SR-55.
BR-57
TROUBLE DIAGNOSES
CONSULT
CONSULT APPLICATION TO ASS
SELF-DIAGNOSTIC
ITEM DATA MONITOR ACTIVE TEST
RESULTS
Front right wheel sensor X X -
Front left wheel sensor X X -
Rear right wheel sensor X X -
Rear left wheel sensor X X -
Stop lamp switch - X -

Front right inlet solenoid valve X X X
Front right outlet solenoid valve X X X
Front left inlet solenoid valve X X X
Front left outlet solenoid valve X X X

Rear right inlet solenoid valve X X X
Rear left inlet solenoid valve X X X

Rear right outlet solenoid valve X X X
Rear left outlet solenoid valve X X .X

Actuator solenoid valve relay X X -
Actuator motor relay

(ABS MOTOR is shown on the Data Monitor X X X
screen.)
ABS warning lamp - X -

Battery voltage X X -
X: Applicable
-; Not applicable
ECU part number mode

Ignore the ECU part number displayed in the ECU PART NUMBER MODE. Refer to parts catalog to order
the ECU.
BR-58
TROUBLE DIAGNOSES
CONSULT Inspection Procedure

m
1) Turn ignition switch OFF.
2) Connect CONSULT to Data Link Con-
nector for CONSULT.
1) Start engine.
2) Drive vehicle over 30 km/h (20 MPH)
Ii) for at least one minute.
NISSAN
CONSULT .
r
EE940.
(;) 1) Stop vehicle with engine running
~ and touch "START" on CON-
START SULT screen.
I I, • Program card
AE950: For Australia
I SUB MODE EE940: Except Australia
SEF253Q (!] 2) Touch "ASS".
@]
lP] 3) Touch "SELF-DIAG RESULTS".
~ SELECTSYSTEM 0 • The screen shows the detected mal-
function and the times of ignition
ENGINE switch ON and OFF after it occurred.
AfT
AIRBAG
ABS Make the necessary repairs following
the diagnostic procedures.
•
IVMS
SBR104D II
After the malfunctions are repaired,
@]
I ~ SELECTDIAG MODE 01 erase the self-diagnostic results stored
I SELF-DIAGRESULTS , in the control unit by touching

"ERASE".
I DATA MONITOR I
I ACTIVETEST
I ECU PARTNUMBER Check warning lamp for deactivation
after driving vehicle over 30 km/h (20
I MPH) for at least one minute.
I
SST412B
Test the ASS in a safe area to verify

II • SELF-DiAGRESULTS. 0 that it functions properly.
FAILURE DETECTED TIME
FR RH SENSOR 0
Note: "SELF.DlAG RESULTS" screen shows the detected malfunction and
[OPEN)
the times of ignition switch ON and OFF after it occurred.
ERASE II PRINT
SBR950C
BR-59
TROUBLE DIAGNOSES
CONSULT Inspection Procedure (Conl'd)
SELF-DIAGNOSTIC RESULTS MODE
Diagnostic
Diagnostic item Diagnostic item is detected when ...
procedure
FR RH SENSOR • Circuit for front right wheel sensor is open.
4
[OPEN] (An abnormally high input voltage is entered.)
FR LH SENSOR • Circuit for front left wheel sensor is open.
4
RR RH SENSOR • Circuit for rear right sensor is open.
4
RR LH SENSOR • Circuit for rear left sensor is open.
4
FR RH SENSOR • Circuit for front right wheel sensor is shorted.
4
[SHORT] (An abnormally low input voltage is entered.)
FR LH SENSOR • Circuit for front left wheel sensor is shorted.
4
RR RH SENSOR • Circuit for rear right sensor is shorted.
4
RR LH SENSOR • Circuit for rear left sensor is shorted.
4
ABS SENSOR • Teeth damage on sensor rotor or improper installation of wheel sensor.
4
[ABNORMAL SIGNAL] (Abnormal wheel sensor signal is entered.)
FR RH IN ABS SOL • Circuit for front right inlet solenoid valve is open.
3
[OPEN] (An abnormally low output voltage is entered.)
FR LH IN ABS SOL • Circuit for front left inlet solenoid valve is open.
3
RR RH IN ABS SOL • Circuit for rear right inlet solenoid valve is open.
3
RR LH IN ABS SOL • Circuit for rear left inlet solenoid valve is open.
3
FR RH IN ABS SOL • Circuit for front right inlet solenoid valve is shorted.
3
[SHORT] (An abnormally high output voltage is entered.)
FR LH IN ABS SOL • Circuit for front left inlet solenoid valve is shorted.
3
RR RH IN ABS SOL • Circuit for rear right inlet solenoid valve is shorted.
3
RR LH IN ASS SOL • Circuit for rear left inlet solenoid valve is shorted.
3
FR RH OUT ABS SOL • Circuit for front right outlet solenoid valve is open.
3
FR LH OUT ASS SOL • Circuit for front left outlet solenoid valve is open.
3
RR RH OUT ASS SOL • Circuit for rear right outlet solenoid valve is open.
3
RR LH OUT ABS SOL • Circuit for rear left outlet solenoid valve is .open.
3
FR RH OUT ASS SOL • Circuit for front right outlet solenoid valve is shorted.
3
FR LH OUT ABS SOL • Circuit for front left outlet solenoid valve is shorted.
3
RR RH OUT ABS SOL • Circuit for rear right outlet solenoid valve is shorted.
3
RR LH OUT ASS SOL • Circuit for rear left outlet solenoid valve is shorted.
3
ABS ACTUATOR RELAY • Actuator solenoid valve relay is ON, even control unit sends off signal.
6
[FAILURE] • Actuator solenoid valve relay is OFF, even control unit sends on signal.
ABS MOTOR • Circuit for actuator motor is open or shorted.
5
[FAILURE] • Actuator motor relay is stuck.
BATTERY VOLT
• Power source voltage supplied to ABS control unit is abnormally low. 7
[VB-LOW]
CONTROL UNIT • Function of calculation in ASS control unit has failed. 8
BR-50
TROUBLE DIAGNOSES
CONSULT Inspection Procedure (Cont'd)
m NISSAN
DATA MONITOR PROCEDURE
CONSULT 1) Turn ignition switch OFF.

EE940 + 2) Connect CONSULT to Data Link Connector for CONSULT.
3) Turn ignition switch ON.
fDU
1
I
I SUB MODE
START
II m 1) Touch
Iil 2) Touch
"START" on CONSULT screen.
"A8S".
SEF253Q t!J 3) Touch "DATA MONITOR".
Iil ~ SELECT SYSTEM 01 ~

ENGINE I!l 1) Touch "SETTING" on "SELECT MONITOR ITEM" screen.
(I 2) Touch "LONG TIME" on "SET RECORDING COND" screen.
AfT I!l 3) Touch "START" on "SELECT MONITOR ITEM".
AIRBAG
ABS
IVMS
SBR104D
t!J
I ~ SELECTDIAG MODE 01
I SELF-DIAG RESULTS I
I DATA MONITOR
I
I ACTIVE TEST I
I ECU PART NUMBER
I
I!l
I~
I
I
SELECT MONITOR ITEM
ALL SIGNALS
I
ISST412B
•
SELECTION FROM MENU
SETTING II START
SBR936C
AUTO TRIG
LONG TIME
SBR937C
BR-61
TROUBLE DIAGNOSES
CONSULT Inspection Procedure (Coni' d)
Fa ACTIVE TEST PROCEDURE
NISSAN
• When conducting Active test, vehicle must be stationary.
CONSULT • When ASS warning lamp stays on, never conduct Active
test.
EE940 +
rBU 1) Turn ignition switch OFF.
START
I I 2) Connect
3) Start
CONSULT
engine.
to Data Link Connector for CONSULT.
I SUB MODE I
SEF253Q l
Fa 1) Touch "START" on CONSULT screen.
m ~ SELECT SYSTEM D m 2) Touch "ASS".
[!) 3) Touch "ACTIVE TEST".
ENGINE
AlT ~
AIRBAG £!1 1) Select active test item by touching screen.
ASS
II 2) Touch "START".
IVMS ~
I Carry out the active test by touching screen key.
SBR104D
~ SELECT DIAG MODE

OJ
SELF.DIAG RESULTS
DATA MONITOR
ACTIVE TEST
ECU PART NUMBER
SST412B
£!1
~ SELECT TEST ITEM 0
FR RH SOLENOID
FR LH SOLENOID
RR RH SOLENOID
RR LH SOLENOID
I ASS MOTOR
I
SBR976C
II • FR RH SOL TEST •
~ SELECT MONITOR ITEM
MAIN SIGNALS
SELECTION FROM MENU
START
SBR934C
BR-62
TROUBLE DIAGNOSES
CONSULT Inspection Procedure (Cont'd)
DATA MONITOR MODE
FR RH SENSOR
FR LH SENSOR Drive vehicle.
Almost the same speed as speedometer.
REAR RH SENSOR (Each wheel is rotating.)
REAR LH SENSOR
Depress the pedal: ON
STOP LAMP SW Brake is depressed.
Release the pedal: OFF
FR RH IN SOL
FR RH OUT SOL
FR LH IN SOL
FR LH OUT SOL Operating conditions for each solenoid valve are indicated.
Engine is running.
RR RH IN SOL ABS is not operating: OFF
RR RH OUT SOL .
RR LH IN SOL
RR LH OUT SOL
Ignition switch ON (Engine stops): OFF
ACTUATOR RLY
Engine running: ON
ABS is not operating: OFF
MOTOR RELAY Ignition switch is ON or ABS is operating: ON
engine is running.
Warning lamp is turned on: ON
WARNING LAMP
Warning lamp is turned off: OFF
BATTERY VOLT Power supply voltage for control unit
ACTIVE TEST MODE

TEST ITEM CONDITION JUDGEMENT
Brake fluid pressure control operation
•
FR RH SOLENOID
IN SOL OUT SOL
FR LH SOLENOID
RR RH SOLENOID UP (Increase): OFF OFF
RR LH SOLENOID KEEP (Hold): ON OFF
Engine is running.
DOWN (Decrease): ON ON
ABS actuator motor
ABS MOTOR ON: Motor runs
OFF: Motor stops
Note: Active test will automatically stop ten seconds after the
test starts. (LIMIT SIGNAL monitor shows ON.)
BR-63
TROUBLE DIAGNOSES
Component Parts and Harness Connector

Location
RHO models
Dual proportioning
valve
DABS warning lamp

1.1 ABS relay box
Brake master cylinder
X ~ Rear wheel sensors
Ii Rear right
[i1 Rear
wheel
sensor connector
left wheel
sensor connector
• For LHD models, control unit

is located on the opposite side.
SBR047DA
BR-64
TROUBLE DIAGNOSES
Preliminary Check
Max line
m
Check brake fluid level in reservoir tank.
Min line
OK Low fluid level may indicate brake pad

wear or leakage from brake line.
SBR418CB
Check brake line for leakage. NG Repair.
OK
t
Check brake booster for operation and NG Replace.
air tightness. Refer to BR-15.
OK
Check brake pads and rotor. Refer to NG Replace.

SBR389C
BR-19,29.
OK
Check brake fluid level in reservoir tank. NG Fill up brake fluid.
OK
•
Check warning lamp activation. NG Check fuse, warning
When ignition switch is turned on, lamp bulb and warning
warning lamp turns on. lamp circuit.
-,/"
'
SBR058C
OK
-~--
ASS ,:"arnlng lamp
iii,A',.!.,
NG Go to Self-diagnosis,
Check warning lamp for deactivation.
/~ ,/~ When ignition switch is turned on, BR-56.
/ / />Jf, I warning lamp turns on, then deacti.
C vates after 1 second.
i
/' " / -..,J
,J \) 003
(') ~---
OK
~"
(-ji=o - [--
~" -,--
'-,--_ ..
SBR051DA Drive vehicle at 30 km/h (20 MPH) for at

least one minute.
NG Go to Self-diagnosis,
Ensure warning lamp remains off while
driving. BR-56.
OK
END
BR-65
TROUBLE DIAGNOSES
Ground Circuit Check

ACTUATOR MOTOR GROUND
• Check resistance between actuator motor ground terminal
and body ground.
Resistance: on
SBR055D
CONTROL UNIT GROUND

[( C/UNIT CONNECTOR
28 . 29 . 39
p~ • Check resistance between the terminals and ground.
Resistance: on
15
SBR237D
~ABS relay box 6-pin connector (body side) ABS RELAY BOX GROUND
EtiD r:tt °i5

T
• Check resistance between ASS relay box harness 6-pin con-
nector (body side) terminal @ and ground.
Resistance: on
[ill
SBR931CB
BR-66
TROUBLE DIAGNOSES
Circuit Diagram for Quick Pinpoint Check
C!l
Z
H
W zo.
Ul (fJITL:
~
LL
CD<l:<l:
<l:3:-l
>-
<l:
(fJ-lX
CDWO
<l:lIeD
0
"'
H
0
W ZW>-
-l W><l:
CD -l-l-l
HY: O<l:W
UlZ
:JH @UJ>a: @ II
LL.-J 0
I-
~ <l:
:J
@ I-
U
<l:
@ @ (fJ
CD
<l:
•
~ "1 l"-
I"-
l'"J S) a
l'"J
l'"J
l'"J Ul f.D
"1 "
Ul
Ul
"1
l'"J
Ul "
l'"J f.D
.-J
0
II
1-1-
(fJZH
CDOZ
<l:U~
CO
~ co~ "
f.D f.D
~ ::": OJ ;::: ::: co
l'"J S'l ~
"
0.
L:
<l:
.-JI
U
0.1-
OH ~
1-3:
(fJUl
"-"1
I-
W .-J
>- Ul :>::II:J
II
W
~
LL
ZOUl
HI-Z
l- -lUO CO
I- WU
<l: <l:Z
CD I-ZIT
<l:00
DULL
I"-
I
U D 0 0 0
I- W W W W W
H Ul W W W W
3:1-
Ulii
~
LL
0. I
(fJ IT
0. I
(fJ .-J
0.
(fJ I
0.
(fJ I
<l: II IT II II IT.-J
ZI- -l01- -l01- .-JO .-JO
0(fJ W(fJZ WUlZ W(fJ1I W(fJ1I
H WZO WZO WZ<l: WZ<l:
1-<:... IWIT IWII IWW IWW
HO 3:(fJLL 3:(fJLL 3:(fJ1I 3:(fJ1I
Z
C!lZ
HO
HBR001
BR-67
TROUBLE DIAGNOSES
Diagnostic Procedure 1 (Not self-diagnostic item)

c( C/UNIT CONNECTOR
p~ Warning lamp does not come on when ignition switch is turned
30 on.
15 WARNING LIGHT CIRCUIT CHECK
NG
Replace fuse.
Check 10A fuse ~ for warning lamp.

For fuse layout, refer to SR-4S.
OK
NG
Check warning lamp bulb. Replace bulb.
SBR238D
OK
Ii) ASS relay box 6-pin
connector (body side) NG
1. Install 10A fuse and bulb. Repair harness and con-
~ 108 c( C/UNIT CONNECTOR P 2. Disconnect connectors from control
unit and ASS relay box.
nectors.
I...a1 30 ~ 3. Check voltage between control unit
15 l.41
connector terminal @ and ground
after turning ignition switch "ON".
Iv Battery voltage should exist after

turning ignition switch "ON".
OK
SBR239D
NG
• Check continuity between ASS relay Repair harness and con-
box 6-pin connector (body side) and nectors.
control unit terminals.
\ ASS relay box

~i5
@ID ASS relay box 6-pin
ASS relay box
@)
Control unit
@
f~~~_
connector
(ASS relay box side) <ID Ground
108 Continuity should exist.
OK
NG
1. Remove solenoid valve relay. Replace ABS relay box.
2. Check continuity between ASS relay
SBR945CB box 6-pin connector (ASS relay box
side) and ASS relay box terminals.
ASS relay box ASS relay box

connector terminals
@)\B @e
<ID @
Note: Pay attention to tester polarity",
OK
NG
SOLENOID VALVE RELAY CHECK Replace solenoid valve
relay.
Refer to SOLENOID VALVE RELAY in
Electrical Components Inspection,
BR-8S.
OK
Go to Diagnostic Procedure 7, BR-81.
": Specifications may vary depending on the type of tester.

Before performing this inspection, refer to the instrucllon manual of the
tester.
BR-68
TROUBLE DIAGNOSES
Diagnostic Procedure 2 (Not Self-diagnostic

( C/UNIT CONNECTOR item)
1
Warning lamp stays on when ignition switch is turned on.
NG
CONTROL UNIT POWER SUPPLY ----"""'(Go to (!) on BR-71.)
CIRCUIT
Check 7.5A fuse [ll] for control unit.

For fuse layout, refer to BR-45.
SBR240D m OK
NG
1. Disconnect connector from control ----....... Repair harness and con-
unit. nector.
~i5 ASS relay box
2. Check voltage between control unit
connector terminal (i) and ground
( C/UNIT CONNECTOR P 6-pin connector alter turning ignition switch "ON".
(body side) Battery voltage should exist.
2 . 37
'--v--'
E$B [;] ~OK

NG
SOLENOID VALVE RELAY COIL POWER Repair harness and con-
----+
SUPPL Y CIRCUIT nector.
1. Turn ignition switch "OFF". Discon-

SBR241D nect ABS relay box 6-pin connector.
2. Check continuity between control unit
connector terminals and ABS relay
box 6-pin connector (body side) ter-
minals.
~
~i5
@) ABS relay box 6-pin
Control unit
@
ABS relay box
@
~ connector
@ CID
(ABS relay box side)
ABS relay box

[!]
CIRCUIT CHECK
~OK
1. Disconnect solenoid valve relay.

2. Check continuity between ABS relay
box 6-pin connector (ABS relay box
~
Replace ABS relay box.
•
side) terminals and solenoid valve
~ relay box terminals.
o DO ABS relay box ASS relay box
!MJ
connector terminals
@ @
CID @

SBR969CB
OK
NG
~
relay.
BR-85.
.OK
@
(Go to next page.)
BR-69
TROUBLE DIAGNOSES
item) (Cont'd)
c( C/UNIT CONNECTOR
p~
30
15
GROUND-SHORT CHECK FOR WARN- NG Repair harness and con-
ING LAMP CIRCUIT. nector.

SBR242D
2. Disconnect connectors from control
unit and ABS relay box 6-pin connec-
EIT8 ~i5
tor.
@QD ABS relaybox 6-pin connector terminal @J and body
connector ground.
(ABS relaybox side)
Continuity should not exist.
OK
1. Disconnect actuator ground terminal NG Replace ABS relay box.

SBR971CB
and 6-pin connector.
side) terminal @ and body ground.
@ ABS actuatora-pin Continuity should not exist.
connector Note: Pay attention to tester polarity •.
(ABS actuatorside)
OK
Ii
SOLENOID VALVE CIRCUIT NG Replace ABS actuator.
SBR972CB
1. Disconnect ABS actuator 8-pi n con-
nector.
2. Check continuity between each ABS
actuator 8-pin connector (ABS actua-
tor side) terminals and body ground.
OK
Check control unit pin terminals for

damage or the connection of control
unit harness connector.
Reconnect control unit harness connec-
tor. Then retest.
•. Specifications may vary depending on the type of tester.

Before performing this inspection, refer to the instruction manual of the
tester.
BR-70
TROUBLE DIAGNOSES
item) (Cont'd)
c( C/UNIT CONNECTOR
1
p~
15 Replace 7.5A fuse.
1 ~ Inspection end
Does the fuse blowout when ignition
switch is turned "ON"?
Yes
SBR243D
[!1
NG
c( CONTROL UNIT POWER SUPPLY
---... Repair harness and con-
C/UNIT CONNECTOR
2
p~ CIRCUIT nector.
15 1. Disconnect control unit connector.

connector terminal (D and body
ground.
OK
SBR244D
III
Check continuity between control unit NG Repair harness and con-
--+
connector terminal @ and body nector.
ground.
OK
•
tor. Then retest.
BR-71
TROUBLE DIAGNOSES
Diagnostic Procedure 3
ABS ACTUATOR SOLENOID VALVE
c( C/UNIT CONNECTOR
P ASS relay box
(Malfunction code No. 41, 45, 51, 55, 42, 46, 52, 56)
2-pin connector
(ASS actuator side)
5 . 6 25. 26
,33 . 34 53 54, rO-...@ 1. Disconnect connectors from control ~ Inspection end
U!l.LJ
unit, ASS actuator and ASS relay
box. Check terminals for damage or
loose connections. Then reconnect
connectors.
2. Carry out self-diagnosis again.
SBR245D
Does warning lamp activate again?
(;) ASS actuator
a-pin connector
(ASS actuator side) ~i8
ASS relay box m
Yes
2-pin connector ABS ACTUATOR SOLENOID VALVE OK

(ASS actuator side) f---+@ (Go to next page.)
CHECK
rO-...@
U!l.LJ
unit and ABS relay box.
2. Check resistance between control
unit connector terminals and ASS
SBR246D relay box 2-pin connector @ (ABS
actuator side) terminal.
Control ASS relay Resis-

Code No.
unit box tance
41 @ @
45 @ @
4.4 - 6.0n
51 @ @
55 @ @
42 @ @
46 CID @ 85 -
52 @ @ 110n
56 @ @
NG
(;)
1. Disconnect ASS actuator 8-pin con- OK Repair harness and con-
~
nector. nector between control
2. Check resistance between ABS actu- unit connector terminal
ator 8-pin connector (ABS actuator and ASS actuator 8-pin
side) terminals and ASS relay box connector terminal.
2-pin connector @) (ABS actuator
side) terminal.
.
ASS ASS relay Resis-

Code No.
actuator box tance
41 @ @
45 @ @)
4.4 - 6.0n
51 @ @ I
55 @ @
42 @) @
46 CD @ 85-
52 (J) @ 11.0n
56 CID @
NG
Replace ABS actuator.
BR-72
TROUBLE DIAGNOSES
Diagnostic Procedure 3 (Conl'd)
@
ASS relay box
connectors
(ASS relay box side)
EffB~ 1. Disconnect ASS relay box connec- OK Go to Diagnostic Proce-

tors. dure?, SR-81.
box 2-pin connector @D (ASS relay
box side) terminal @ and 6-pin con-
nector <!ill) (ASS relay box side) ter-
SBR058D
minal @.
NG
ASS relay box

I- ASS relay box 2-pin connector
(ASS relay box side)
NG
Uw@ 1. Remove solenoid valve relay. Replace ASS relay box.
~~D~ box 2-pin connector @D (ASS relay
side) terminal @ and ASS relay box
terminal @.
SBR059D
OK
Go to Diagnostic Procedure 6, BR-79.
BR-73
TROUBLE DIAGNOSES
~i5 WHEEL SENSOR OR ROTOR
E( C/UNITCONNECTOR P (Malfunction code No. 21, 22, 25, 26, 31, 32, 35, 36 or 18)
,14.9.11 . 12, ,15.10.38.13,
unit and wheel sensor of malfunction
~ Inspection end
I
code No. Check terminals for dam-
age or loose connections. Then
reconnect connectors.
SBR247D
Yes
m
WHEEL SENSOR ELECTRICAL CHECK OK
~@ (See next page.)
1. Disconnect control unit connector.

2. Check resistance between control
unit connector terminals.
Code No. 21 or 22 (Front RH wheel)
Terminals @ and @
Code No. 25 or 26 (Front LH wheel)
Terminals @ and @
Code No. 31 or 32 (Rear RH wheel)
Terminals @ and @
Code No. 35 or 36 (Rear LH wheel)
Terminals @ and @
Resistance: 0.8 • 1.2 kD
NG
Note Note
CHECK WHEEL SENSOR. ~ Replace wheel sensor.
I
Refer to WHEEL SENSOR in Electrical
Components Inspection, SR-85.
OK
Note Note: Wheel position should

Repair harness and connectors be distinguished by
between control unit conn'ector and code No. exceplcode
wheel sensor connector. No. 18 (sensor rotor).
BR-74
TROUBLE DIAGNOSES
@
Note Note
WHEEL SENSOR MECHANICAL CHECK NG Adjust tire pressure or
replace tire(s).
Check for inflation pressure, wear and
size of each tire.
OK
Note
Check wheel bearing axial end play.
\ \ Rotor OK
\\ Sensor m "Note Note
)I
)6
Feeler gauge
Check clearance between sensor and
rotor.
Clearance:
Front
0.1 - 1.1 mm
(0.004 . 0.043 in)
NG Clean sensor fixing
portion, or replace sen-
sor.
SBR069C
Rear
0.1 - 1.1 mm
(0.004 - 0.043 in)
OK
Note Note
Check sensor rotor for teeth damage. NG Replace sensor rotor.
OK
Check control unit pin terminals for Note: Wheel position should •• •
damage or the connection of control be distinguished by
unit harness connector. code No. except code
Reconnect control unit harness connec- No. 18 (sensor rotor).
tor. Then retest.
BR-75
TROUBLE DIAGNOSES
m ASS relay box 2-pin

connector @
[it ~c:\
IJIJ
DISCONNECT Diagnostic Procedure 5
(body side) ";V MOTOR RELAY OR MOTOR
rn (Malfunction code No. 61)
NG
MOTOR POWER SUPPLY CIRCUIT
@ (Skip page.)
Check fusible link @] for ABS relay box.
For fusible link layout, refer to POWER
SUPPLY ROUTING in EL section.
OK
SBR953CC
No
1. Disconnect connectors from control Inspection end
~iv ~iV unit and ABS actuator. Check termi-

nals for damage or loose connection.
c( C/UNIT CONNECTOR P ASS relay box
6-pin connectors
Then reconnect connectors.
7 19. 2, (body side) @29 Does warning lamp activate again?
Yes
~
NG
1. Disconnect ABS relay box 2-pin con- Repair harness and COI
nector@. nectors.
2. Check voltage between connector
SBR248D
(body side) terminal @ and ground.
NG
CIRCUIT CHECK Repair harness and cor
nectors.
1. Disconnect ABS relay box 6-pin con-
nector and control unit connector.
connector terminals and ABS relay
box 6-pin connector ~ (body side)
terminals.
Control unit ASS relay box
@
@
cID
OK
NG
MOTOR RELAY CHECK Replace motor relay.
Refer to MOTOR RELAY in Electrical

Components Inspection, BR-8S.
OK
NG
ACTUATOR MOTOR GROUND CHECK Repair harness and ter-
minals.
Refer to ACTUATOR MOTOR GROUND
in Ground Circuit Check, BR-66.
OK
@
(Go to next page.)
BR-76
TROUBLE DIAGNOSES
Diagnostic Procedure 5 (Cont'd)
@
[:tI °15
T
ASS relay box connectors

(ASS relay box side) NG
MOTOR RELAY CIRCUIT Replace ASS relay box.
2~~
9 11 ~~
~
1. Remove motor relay.
~ 2. Check continuity between ASS relay
box connectors (ASS relay box side)
and ASS relay box terminals.
ASS relay box ASS relay box

connector terminal
@ @
@ @
@ @
Connector@
ASS 'relay bO @
f
@
Connector@
[ill @
[ill EJ 86
WJ 87
~
OK
SBR061D Ii]
Check continuity between ASS relay NG Repair harness and con-
box 2-pin connector @ (ASS actuator nectors.
side) terminal @ and actuator motor
ASS relay box 2-pin positive terminal.
connector @iY
(ASS actuator side)
do
131
•
MOTOR CHECK NG Replace ASS actuator.
1. Disconnect actuator motor terminals.

2. Apply battery voltage to motor termi-
nals.
Motor should operate.
Do not connect wire for more than 5
seconds.
OK
Go to Diagnostic Procedure 7, SR-81.
SBR249D
BR-77
TROUBLE DIAGNOSES
Ii ASS relay box 2-pin ~ CID
connector @
(body side)
= 1c0,
DISCONNECT
V
No
cD Replace fusible link. Inspection end
Does the fusible link blowout when
ignition switch is turned "ON"?
Ii
NG
MOTOR POWER SUPPL V CIRCUIT Repair harness and con-
nector.
SBR957CC
1. Disconnect battery cable and ASS
relay box 2-pin connector @.
box 2-pin connector @ (body side)
@) ASS relay box 6-pin terminal @ and ground.
connector Continuity should not exist.
(body side)
1. Disconnect ASS relay box 6-pin con-

NG Repair harness and con-
nector and control unit connector. nector.
2. Check continUity between ASS relay
SBR958CB box 6-pin connector @E) (body side)
III
@ @El ~ DISCONNECT
rrt\ ASS relay box ~c;"1 OK
\J.tV connectors -';;V
0U 9 (ASS relay box side)
Check continuity between ASS relay

NG Replace ASS relay box. J
side) terminal @ and ground, 2-pin
connector @ (ASS relay box side)
SBR065DB
OK
o ASS relay box 2-pin

o NG
connector 1. Remove motor ground. Replace ASS actuator.
(ASS actuator side) Remove motor 2. Check continuity between ASS relay
~@ ground. box 2-pin connector @) (ASS actua-
L1J.1J
tor side) terminal @) and ground.
OK
MOTOR CHECK
SBR250D Go to n!II in Diagnostic Procedure 5

(preceding page).
OK

tor. Then retest.
BR-78
TROUBLE DIAGNOSES
Fa Diagnostic Procedure 6
ASS relay box 2-pin DISCONNECT
connector @ ~ ~~ SOLENOID VALVE RELAY
(body side) I..lI&I ~V (Malfunction code No. 63)
ctD NG
SOLENOID VALVE POWER SUPPLY @ (See next page.)
CHECK
Check fusible link @]. For fusible link

layout, refer to POWER SUPPLY ROUT-
ING in EL section.
SBR961CC OK
No
(
~Io
C/UNIT CONNECTOR P ASS relay box
unit and ASS actuator. Check termi-
nals for damage or loose connection.
Inspection end
6-pin connector .Then reconnect connectors.

(body side) @W 2. Carry out self-diagnosis again.
2 . 30 . 37
. Does warning lamp activate again?
Efe Yes
GROUND CIRCUIT CHECK Repair harness and con-

nectors.
Refer to CONTROL UNIT GROUND and
SBR251D ACTUATOR GROUND in Ground Circuit
Check, SR-66.
OK
SOLENOID VALVE POWER SUPPLY Repair harness and con-

CHECK nector.
1. Disconnect connectors from ASS

relay box.
•
2. Check voltage between ASS relay box
2-pin connector @ (body side) ter-
minal @ and ground.
CIRCUIT CHECK Repair harness and con-

nectors.
connector terminals and ASS relay
box connector @ill (body side) termi-
nals.
Control unit ABS relay box
3T
Xi
@ @
OK

relay.
SR-85.
OK
@
(Go to next page.)
BR-79
TROUBLE DIAGNOSES
Diagnostic Procedure 6 (Co nt' d)
(!)
~i5 ~ ASS relaybox

1
SOLENOID VALVE RELAY CIRCUIT NG • Replace ASS relay box.
LI!ID c:!D ~ connectors CHECK
,2.4.~.8.18, (ASS relaybox side)
Check continuity between ASS relay ter-
minals and ASS relay box connector
(ASS relay box side) terminals.
ABS relay box terminal
~SS relay box 87a

85
~
[]QJ ~ ~
}
:~
85
@

OK
00 87a
30
I Go to diagnostic procedure 3, SR-72.
SBR068D
I;]
~i5
GD ASS relay box 2-pin connector@
Replace fusible link.
Does the fusible link blowout when
Ignition switch is turned "ON"?
No
Inspection end
(body side)
Yes
I;]
NG
[Q] RELAY UNIT POWER SUPPLY CIRCUIT Repair harness and con-
nector.
1. Disconnect ASS relay box 2-pin con-
-=- nector@.
SBR964CC 2. Check continuity between ASS relay
box 2-pin connector @ (body side)
c1!D
~i5
ASS relay box
OK
2-pin connector
(ASS relay box side) Ii
@ED NG
1. Disconnect ASS relay box connectors Replace ASS relay box.
and control unit connector.
2. Check continuity betwee"ll ASS relay
box 2-pin connector @ (ASS relay
box side) terminal @ and ground.
-=- Continuity should not exist.
SBR069D
OK
Ii Ii
~io
ABS relay box
Check continuity between ASS relay
box 2-pin connector @ (ASS actuator
NG
Replace ASS actuator.
@[) 2-pin connector side) terminal @ and ground.

(ABS actuator side) Continuity should not exist.
@
OK
Go to Diagnostic Procedure 3, SR-72.
':"
SBR252D
BR-80
TROUBLE DIAGNOSES
c( C/UNIT CONNECTOR
p~ POWER SUPPLY (Low voltage)
1
18 (Malfunction code No. 57)
1. Disconnect control unit connectors.

No
Inspection end
Check terminals for damage or loose
connections. Then reconnect connec-
tors.
SBR253D
NG
CONTROL UNIT POWER SUPPLY
---.-.@ (See below.)
CHECK

2. Check voltage between control unit
connector terminal G) and ground.
Battery voltage should exist when
ignition switch is turned ON.
OK
NG
CONTROL UNIT GROUND CHECK Repair harness and con-
nectors.
Refer to CONTROL UNIT GROUND in
Ground Circuit Check, BR-66.
OK

•
tor. Then retest.
NG
Check 7.5A fuse rj2J . Refer to POWER Replace fuse.
SUPPLY ROUTING in EL section.
OK
Check continuity between battery and

control unit connector terminal CD.
NG
Repa;, hame" aod coo-
nectors.
I
OK
Check battery. Refer to BATTERY in EL

section.
BR-81
TROUBLE DIAGNOSES
CONTROL UNIT
(Malfunction code No. 71)
Carry out self-diagnosis after erasing

self-diagnostic results, BR-56.
Yes
Does warning lamp indicate code No. Replace control unit.
71 again?
No
Inspect the system according to the

code No.
Brake pedal
SYMPTOM: Pedal vibration and noise
Yes
1. Apply brake. Carry out self-diagnosis.
2. Start engine. Refer to BR-53 (Europe)
3. Does the symptom appear only when or BR-56 (Except
engine is started? Europe).
No
No
Does the symptom appear when electri- Go to Ii1in Diagnostic
SAT797A cal equipment switches (such as head- Procedure 11, BR-83.
lamp) are operated?
Yes
Check wheel sensor shield grou.nd

secured with control unit mounting bolt.
Refer to BR-41.
OK

tor. Then retest.
Note: ABS may operate and cause vibration under any of the
• Applying brake gradually when shifting or operating clutch.
• Low friction (slippery) road.
• High speed cornering.
• Driving over bumps and pot holes.
• Engine speed is over 5,000 rpm with vehicle stopped.
BR-82
TROUBLE DIAGNOSES
SYMPTOM: Long stopping distance
Disconnect ABS relay box 6-pin connec- No Go to IiJin Diagnostic
tor and check whether stopping dis- Procedure 11. SR-83.
tance is still long.
Perform Preliminary Check and air

bleeding.
Note: Stopping distance may be larger than vehicles without

ABS when road condition is slippery.
SYMPTOM: Unexpected pedal action
m Yes
Check brake pedal stroke. Is stroke Perform Preliminary
excessively large? Check. refer to SR-65.
No
SBR540A
Disconnect ASS relay box 6-pin connec-
tor and check whether brake is effec-
tive.
Yes
Ensure warning lamp remains off while

Perform Preliminary
Check. refer to SR-65.
Carry out self-diagnosis.

•
driving. Refer to BR-53 (Europe)
or SR-56 (Except
OK Europe).
CHECK WHEEL SENSOR. Repair.
1. Check wheel sensor connector for

terminal damage or loose connec-
tion.
2. Perform wheel sensor mechanical
check.
Refer toIiJ in Diagnostic Procedure
4, BR-75.
OK

tor. Then retest.
BR-83
TROUBLE DIAGNOSES
SYMPTOM: ASS does not work.
Yes
Does the ABS warning lamp activate? Carry out self-diagnosis.
Refer to BR-53 (Europe)
No or BR-55 (Except
Europe).
Go to Ii) in Diagnostic Procedure 11,

BR-83.
Note: ABS does not work when vehicle speed is under 10 km/h
(6 MPH).
SYMPTOM: ASS works frequently.
CHECK BRAKE FLUID PRESSURE. NG Perform Preliminary

Check, refer to BR-55.
Check brake fluid pressure distribution.
Refer to proportioning valve inspection,
BR-9.
OK
CHECK WHEEL SENSOR. NG Repair.
1. Check wheel sensor connector for

terminal damage or loose connec-
tions.
2. Perform wheel sensor mechanical
check.
Refer to Ii) in Diagnostic Procedure
4, BR-75.
OK
Check front and rear axles for exces- NG Repair.

sive looseness. Refer to FA section
("Front Wheel Bearing", "ON-VEHICLE
SERVICE") and RA section ("Rear
Wheel Bearing", "ON-VEHICLE
SERVICE").
OK

tor. Then retest.
BR-84
TROUBLE DIAGNOSES

WHEEL SENSOR
Check resistance for each sensor.
Resistance: 0.8 - 1.2 kQ
ACTUATOR MOTOR RELAY

Continuity existence between
Condition
terminals @ and @
Battery voltage not applied between

No
terminals @ and @.
Battery voltage applied between
Yes
terminals @ and @.
While applying battery voltage to relay terminals, insert fuse

into the circuit.
SBR140C
SOLENOID VALVE RELAY

Continuity existence Continuity existence
Condition between terminals @ between terminals @
and@ and @
Battery voltage not

applied between termi- Yes No
nals @ and @.
SBR329B
Battery voltage applied
between terminals @
and @.
While applying battery voltage

into the circuit.
No
to relay terminals,
Yes
insert fuse
•
BR-85
BRAKE UNIT (Europe)
Without ABS With ABS
Applied model GA14DE GA16DE

I CD20 GA14DE GA16DE
I CD20
Standard Option
Front brake
Brake model CL22VD CL22VE CL22VD CL22VE
Cylinder bore diameter

54.0 (2.126)
mm (in)
Pad mm (in)
106 x 39.5 x 11.0 (4.17 x 1.555 x 0.433)
length x width x thickness
Rotor outer diameter x thickness 247 x 18 247 x 18
Rear brake
mm (in)
232 x 18 (9.13 x 0.71)
I (972 x 0.71)
232 x 18 (9.13 x 0.71)
I (9.72 x 0.71)
Brake model LT18C CL7HB

15.87 (5/8) 30.23 (1-1/4)
mm (in)
Lining or pad mm (in) 172.8 x 30 x 4 94 x 29 x 10

length x width x thickness (6.80 x 1.18 x 0.16) (3.70 x 1.14 x 0.39)
Drum inner diameter or rotor

outer diameter x thickness 180 (7.09) 234 x 7 (9.21 x 0.28)
mm (in)
Master cylinder
20.64 (13/16) 22.22 (7/8)
Cylinder bore diameter mm (in)
Control valve
Valve model Dual proportioning valve built into master cylin- Dual proportioning valve separated from master
der cylinder
Split point [kPa (bar. kg/cm2•

3.923 (39.2. 40. 569) x 0.4 3.923 (39.2. 40. 569) x 0.4
psi)] x reducing ratio
Brake booster
Booster model M195T
Diaphragm diameter Primary: 205 (8.07)

mm (in) Secondary: 180 (7.09)
Recommended brake fluid DOT 3 or DOT 4
BR-86
General Specifications (Cont'd)
BRAKE UNIT (Except for Europe)
Except for Except for
Australia Australia
Australia Australia
Without ABS With ABS

Applied model
GA15DE. GA15DE.
GA16DE SR20DE GA16DE SR20DE
GA16DE GA16DE
Standard Standard Option Option
Front brake
CL22VD CL22VE AD22VF CL22VD CL22VE AD22VF
Brake model

54.0 (2.126)
mm (in)
Pad mm (in) 106.8 x 43.8 x 106.8 x 43.8 x

106 x 39.5 x 11.0 106x39.5x11.0
length x width x thickness 10.0 (4.20 x 10.0 (4.20 x
(4.17 x 1.555 x 0.433) (417 x 1.555 x 0.433)
. 1.724 x 0.394) 1.724 x 0.394)
Rotor outer diameter x thickness 232 x 18 247 x 18 257 x 26 232 x 18 247 x 18 257 x 26
mm (in) (9.13 x 0.71) (9.72 x 0.71) (10.12 x 1.02) (9.13 x 0.71) (9.72 x 0.71) (10.12 x 1.02)
Rear brake
LT18C CL9HC CL7HB CL9HC
Brake model

15.87 (5/8) 33.96 (1-3/8) 30.23 (1-1/4) 33.96 (1-3/8)
mm (in)
Lining or pad mm (in) 89.1 x 39.5 x 89.1 x 39.5 x

172.8 x 30 x 4 94 x 29 x 10
length x width x thickness 10.0 (3.508 x 10.0 (3.508 x
(6.80 x 1.18 x 0.16) (370 x 1.14 x 0.39)
1.555 x 0.394) 1555 x 0.394)
Drum inner diameter or rotor

258 x 9.0 234 x 7 258 x 9.0
outer diameter x thickness 180 (7.09)
(10.16 x 0.354) (9.21 x 0.28) (10.16 x 0.354)
mm (in)
Master cylinder
20.64 (13/16) 22.22 (7/8) 23.81 (15/16) 22.22 (7/8) 23.81 (15/16)
Cylinder bore diameter mm (in)
•
Control valve Dual proportioning valve built into master cylin- Dual proportioning valve separated from master
Valve model der cylinder
Split point [kPa (bar. kg/cm'. 3.923 3.923 1.961 3.923 2.942 1.961
psi)] x reducing ratio (39.2. 40. 569) (39.2. 40. 569) (19.6. 20. 284) (39.2. 40. 569) (29.4. 30. 427) (19.6. 20. 284)
x 0.4 x 0.4 x 0.2 x 0.4 x 0.2 x 0.2
Brake booster
S205 or C205 M195T
Booster model
Diaphragm diameter Primary: 205 (8.07)

205 (8.07)
mm (in) Secondary: 180 (7.09)
Recommended brake fluid DOT 3
BR-87

DISC BRAKE DRUM BRAKE
Front Rear Rear

Brake model
Brake model CL22VD, LT18C
AD22VF CL7HB CL9HC
CL22VE
Lining wear limit
Pad wear limit
Minimum thickness 1.5 (0.059)
Minimum thickness 2.0 (0.079) 1.5 (0.059)
Drum repair limit
Rotor repair limit
Maximum inner diameter 181 (7.13)
Minimum thickness 16.0 24.0 6.0 8.0
Out-ai-round 0.03 (0.0012) or less
(0.630) (0.945) (0.236) (0.315)
Maximum runout 0.07 (0.0028)
Maximum thickness
0.02 (0.0008)
variation
BRAKE PEDAL
Unit: mm (in)
Applied model RHD LHD
Free height
MIT 155.0 - 1650 (6.10 - 6.50) 148.0 - 158.0 (5.83 - 6.22)
AIT 164.0 - 174.0 (6.46 - 6.85) 157.0 - 167.0 (6.18 - 6.57)
Depressed height
[under force 01 490 N (50 kg, 110 Ib) with

See below.
engine running]
Clearance between switches and pedal stopper

0.3 - 1.0 (0.012 - 0.039)
bracket
Depressed Height [Under force of 490 N (50 PARKING BRAKE CONTROL

kg, 110 Ib) with engine running]
Unit: mm (in) Brake type Drum Disc
Control type Center lever

Applied model RHD LHD
Number 01 notches
MIT 75 (2.95) or more
[under lorce of 196 N 7- 8 8- 9
AIT 85 (3.35) or more
(20 kg, 44 Ib)]
Number of notches when

1 or less
warning switch comes on
BR-88
STEERING SYSTEM
SECTIONST
CONTENTS
PRECAUTIONS AND PREPARATION 2 Removal and Installation 14
Precautions 2 Disassembly 15
Special Service Tools 3 Inspection 15
Commercial Service Tools 4 Assembly and Adjustment... 16
ON-VEHICLE SERVICE 5 POWER STEERING GEAR AND LINKAGE (Model
Checking Steering Wheel Play 5 PR24AC) 19
Checking Neutral Position on Steering Wheel 5 Removal and Installation 19
Front Wheel Turning Angle 5 Disassembly 22
Checking Gear Housing Movement 5 Inspection 22
Checking and Adjusting Drive Belts (For Assembly ,..23
power steering) 6 Adjustment 27
Checking Fluid Level 6 POWER STEERING OIL PUMP 29
Checking Fluid Leakage 6 Pre-disassembly Inspection 30
Bleeding Hydraulic System 7 Disassembly 30
•
Checking Steering Wheel Turning Force (For Inspection 31
power steering) 7 Assembly 31
Checking Hydraulic System 8 POWER STEERING OIL COOLER 33
STEERING WHEEl AND STEERING COLUMN 9 Oil Cooler (Heavy duty kit for CD20 engine
Removal and Installation 9 model) 33
Disassembly and Assembly 12 Removal and Installation 33
Inspection 13 SERVICE DATA AND SPECIFICATIONS (505) 34
MANUAL STEERING GEAR AND LINKAGE General Specifications 34
(Model R24N) 14 Inspection and Adjustment 34
Precautions
(Dual Air Bag System)
WARNING:

(Single Air Bag System)
WARNING:
Service Manual.
STEERING SYSTEM
• Before disassembly, thoroughly clean the outside of the unit.

• Disassembly should be done in a clean work area. It is important to prevent the internal parts from
becoming contaminated by dirt or other foreign matter.
• Place disassembled parts in order, on a parts rack, for e"asier and proper assembly.
• Use nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might
interfere with their operation.
• Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable
solvent.
• Before assembly, apply a coat of recommended ATF* to hydraulic parts. Vaseline may be applied to
O-rings and seals. Do not use any grease.
• Replace all gaskets, seals and O-rings. Avoid damaging O-rings, seals and gaskets during installa-
tion. Perform functional tests whenever designated.
*: Automatic transmission fluid
ST-2
Tool number
Description
Tool name
KV48100700 Measuring pinion rotating torque
Torque adapter
NT169
KV48102500 Measuring oil pressure

Pressure gauge adapter PF3/B"~ @
@
PF3/B"~ ~ x 1.5 pitch

NT542 M16 x 1.5 pitch
ST27180001
Steering wheel puller @Q'O , '250;'0' Removing and installing steering wheel
@ @ MB x 1.25 pitch
NT544 (1.14 in)
HT72520000 Removing ball joint

Ball joint remover
a: 33 mm (1.30 in)
b: 50 mm (1.97 in)
NT546 r: R11.5 mm (0.453 in)
ST27091000 To control valve Measuring oil pressure

Pressure gauge
KV48104400
Rack seal ring reformer
NT547 Shut-off valve
Reforming teflon ring
•
a: 50 mm (1.97 in) dia.
b: 36 mm (1.42 in) dia.
NT550 c: 100 mm (3.94 in)
ST3127S000 Measuring turning torque

G) GG91030000
Torque wrench
@ HT62940000 ~ 1/4" ~rque wrench
Socket adapter ~ with range of
1/4" to 3/B" 2.9 N.m
@ HT62900000
~ " " (30 kg-em,
Socket adapter 'V 'td" 3/B to 1/2 26 in-Ib)
NT541
ST-3
Rear oil seal drift Installing rear oil seal
NT063 a: 28 mm (1.10 in) dia.

Pinion oil seal drift Installing pinion oil seal
NT063 a : 35 mm (1.38 in) dia.

Oil pump attachment Welding Disassembling and assembling oil pump
12 (0.47)
40 (1.57)
---12 (0.47)
Unit: mm (in)
ST-4
ON-VEHICLE SERVICE
Checking Steering Wheel Play

• With wheels in a straight-ahead position, check steering
wheel play.
Steering wheel play:
35 mm (1.38 in) or less
• If it is not within specification, check the following for loose
or worn components.
Steering gear assembly
Steering column
Front suspension and axle
SST489B
Checking Neutral Position on Steering Wheel

OK NG
Pre-checking
• Make sure that wheel alignment is correct.
Wheel alignment:
Refer to SOS in FA section.
• Verify that the steering gear is centered before removing
the steering wheel.
Checking
SST490BA 1. Check that the steering wheel is in the neutral position when
driving straight ahead.
2. If it is not in the neutral position, remove the steering wheel
and reinstall it correctly.
3. If the neutral position is between two teeth,. loosen tie-rod
lock nuts. Turn the tie-rods by the same amount in opposite
directions on both left and right sides.
Front Wheel Turning Angle •

1. Rotate steering wheel all the way right and left; measure
turning angle.
Turning angle of full turns:
Refer to SOS in FA section.
2. If it is not within specification, check rack stroke.
Rack stroke "S":
Refer to SOS (ST-35).
SMA127
Checking Gear Housing Movement

1. Check the movement of steering gear housing during sta-
tionary steering on a dry paved surface.
• Apply a force of 49 N (5 kg, 11 Ib) to steering wheel to check
the gear housing movement.
Turn off ignition key while checking.
Movement of gear housing:
:I: 2 mm (:I: 0.08 in) or less
2. If movement exceeds the limit, replace mount insulator after
confirming proper installation of gear housing clamps.
ST-5
ON-VEHICLE SERVICE
Checking and Adjusting Drive Belts (For power

steering)
Refer to "Checking Drive Belts" for "ENGINE MAINTENANCE"
in MA section.
Checking Fluid level

Check fluid level using dipstick on reservoir cap, or referring to
the scale on reservoir tank.
Use "HOT" range for fluid temperatures of 50 to 80°C (122 to
176°F).
Use "COLD" range for fluid temperatures of 0 to 30°C (32 to
86°F).
CAUTION:
• Do not overfill.
• Recommended fluid is Automatic Transmission Fluid
''DEXRON™,, type or equivalent.
SST476C
Checking Fluid leakage
S
Check the lines for improper attachment and for leaks, cracks,
damage, loose connections, chafing or deterioration.
1. Run engine between idle speed and 1,000 rpm.
r Make sure temperature of fluid in oil tank rises to 60 to 80°C

(140 to 176°F).
2. Turn steering wheel right-to-Ieft several times.
3. Hold steering wheel at each "lock" position for five seconds
and carefully check for fluid leakage.
CAUTION:
SST681B
Do not hold the steering wheel in a locked position for more
than 15 seconds.
4. If fluid leakage at connectors is noticed, loosen flare nut and
then retighten.
Do not overtighten connector as this can damage O-ring,
washer and connector.
5. Check rack boots for accumulation of power steering fluid.
ST-6
ON-VEHICLE SERVICE
Bleeding Hydraulic System

1. Raise front end of vehicle until wheels are clear of the
ground.
2. Add fluid into oil tank to specified level. Then quickly turn
steering wheel fully to right and left and lightly touch steer-
ing stoppers.
Repeat steering wheel operation until fluid level no longer
decreases.
3. Start engine.
Repeat step 2. above.
• Incomplete air bleeding will cause the following to occur.

When this happens, bleed air again.
a. Air bubbles in reservoir tank
b. Clicking noise in oil pump
c. Excessive buzzing in oil pump
Fluid noise may occur in the valve or oil pump. This is common
when the vehicle is stationary or while turning the steering
wheel slowly. This does not affect the performance or durabil-
ity of the system.
Checking Steering Wheel Turning Force (For

power steering)
1. Park vehicle on a level, dry surface and set parking brake.
2. Start engine.
3. Bring power steering fluid up to adequate operating temper-
ature. [Make sure temperature of fluid is approximately 60
to 80°C (140 to 176°F).]
Tires need to be inflated to normal pressure.
4. Check steering wheel turning force when steering wheel
has been turned 360° from the neutral position.
SST491B
Steering wheel turning force: •
39 N (4 kg, 9 Ib) or less
5. If steering wheel turning force is out of specification, check
rack sliding force.
a. Disconnect steering column lower joint and knuckle arms
from the gear.
b. Start and run engine at idle to make sure steering fluid has
reached normal operating temperature.
c. Pull tie-rod slowly to move it from neutral position to ::l:: 11.5
mm (::l:: 0.453 in) at speed of 3.5 mm (0.138 in)/s. Check that
rack sliding force is within specification.
SST090B Average rack sliding force:
152.0 - 240.3 N (15.5 - 24.5 kg, 34.2 - 54.0 Ib)
Maximum force deviation:
98 N (10 kg, 22 Ib)
6. If rack sliding force is not within specification, overhaul
steering gear assembly.
7. If rack sliding force is OK, inspect steering column. Refer to
ST-13.
ST-7
ON-VEHICLE SERVICE
ST27091 000 Checking Hydraulic System

Before starting, check belt tension, driving pulley and tire pres-
sure.
1. Set Tool. Open shut-off valve. Then bleed air. (See "Bleed-
ing Hydraulic System" ST-7.)
2. Run engine.
Make sure temperature of fluid in tank rises to 60 to 80°C (140
to 176°F).
WARNING:
Low-pressure Warm up engine with shut-off valve fully opened. If engine is
.. : Direction of oil flow hose SST834-A started with shut-off valve closed, fluid pressure in oil pump
increases to maximum. This will raise oil temperature abnor-
mally.
3. Check pressure with steering wheel fully turned to left and
right positions with engine idling at 1,000 rpm.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds.
Oil pump maximum standard pressure:
7,649 - 8,238 kPa (76.5 . 82.4 bar,
78 - 84 kg/cm2, 1,109 - 1,194 psi)
4. If oil pressure is below the standard pressure, slowly close
shut-off valve and check pressure.
• When pressure reaches standard pressure, gear is dam-
aged.
• When pressure remains below standard pressure, pump is
damaged.
CAUTION:
Do not close shut-off valve for more than 15 seconds.
5. If oil pressure is higher than standard pressure, check oil
pump flow control valve.
6. After checking hydraulic system, remove Tool and add fluid
as necessary. Then completely bleed air out of system.
S1-8
STEERING WHEEL AND STEERING COLUMN
SEC. 484.487.488 With air bag
Without air bag
_~ ~ 4.0 - 4.9 (0.4 - 0.5, 35 - 43)
ij] :N.m (kg-m, in-Ib)

co;J : N.m (kg-m. ft-Ib)
SST538C
G) Air bag module @ Spiral cable (J) Steering column assembly

@ Horn pad @ Column cover @ Lower joint
@ Steering wheel @ Combination switch @ Boot
CAUTION (SRS models only): •

• The rotation of the spiral cable (SRS "Air bag" component
part) is limited. If the steering gear must be removed, set
the front wheels in the straight-ahead direction. Do not
rotate the steering column while the steering gear is
removed.
• Remove the steering wheel before removing the steering
lower joint to avoid damaging the SRS spiral cable.
STEERING WHEEL
With Air Bag
• Remove air bag module and spiral cable.
Refer to "Removal - Air Bag Module and Spiral Cable",
"SUPPLEMENTAL RESTRAINT SYSTEM" in RS section.
SBF812E
ST-9
• Align spiral cable correctly when installing steering wheel.
a. Set the front wheels in the straight-ahead position.
b. Make sure that the spiral cable is in the neutral position.
\ The neutral position is detected by turning left 2.5 revolu-
~ tions from the right end position. Align the two marks (~').
CAUTION:
The spiral cable may snap due to steering operation if the cable
is installed in an improper position.
Also, with the steering linkage disconnected, the cable may
snap by turning the steering wheel beyond the limited number
of turns. (The spiral cable can be turned up to 2.5 turns from the
neutral position to both the right and left.)
MBF487BA
• Remove steering wheel with Tool.
Without Air Bag

1. Remove horn pad.
Insert a crosshead screwdriver into hole on lower side of
spoke and remove clamp.
Lift horn pad off by hand.
SST502C
Three spoke type

Cross head screwdriver
SST495CA
ST-10
Two spoke type
Clamp
Crosshead screwdriver~
II
SST503C
2. Remove steering wheel with Tool.
SST122B
• When installing steering wheel, lubricate with multi-purpose

grease. Apply grease to entire surface of turn signal cancel
pins and horn contact slip rings.
Cr~I~I;~ •
SST112B
STEERING COLUMN
• When installing steering column, fingertighten all lower
bracket and clamp retaining bolts; then tighten them
securely. Do not apply undue stress to steering column.
• When attaching coupling joint, be sure tightening bolt faces
cutout portion.
~#f
~.'". Lower joint

SST800A
• Align slit of lower joint with projection on dust cover. Insert

joint until surface A contacts surface B.
CAUTION:
After installation, turn steering wheel to make sure it moves
smoothly. Ensure the number of turns are the same from the
straight forward position to left and right locks. Be sure that the
steering wheel is in a neutral position when driving straight
ahead.
SST491C
ST-11
Disassembly and Assembly

SEC. 488
~ . N.m (kg-m, in-Ib)

~ . N.m (kg-m, ft-Ib)
SST539C
G) Spiral cable !J) Steering column mounting @ Boot

@ Combination switch bracket @ Steering column shaft
@ Lock nut @ Adjust bolt @ Lower joint
@ Tilt lever CID Adjust bolt stopper @ Return spring
@ Washer @J Push nut
@ Tilt lever stopper @ Jacket tube assembly
• When disassembling and assembling, unlock steering lock

with key.
Lock nut • Install lock nut on steering column shaft and tighten the nut
to specification.
~: 25 - 34 N.m (2.5 - 3.5 kg-m, 18 - 25 ft-Ib)
II I
SST490C
ST-12
Disassembly and Assembly (Cont'd)
• Steering lock
a. Break self-shear type screws with a drill or other appropri-
ate tool.
SST741A
b. Install new self-shear type screws and then cut off self-
shear type screw heads.
Self-shear screw
SST742A
Inspection
• When steering wheel does not turn smoothly, check the
- ---
L
---_ .. _-------, steering column as follows and replace damaged parts.
a. Check column bearings for damage or unevenness. Lubri-
I cate with recommended multi-purpose grease or replace
steering column as an assembly, if necessary.
b. Check jacket tube for deformation or breakage. Replace if
Center of joint
necessary.
• When the vehicle comes into a light collision, check length
ilL",
SST334C
Column length "L": •
533.0 - 535.0 mm (20.98 - 21.06 in)
If out of the specifications, replace steering column as an
assembly.
Tilt mechanism
• After installing steering column, check tilt mechanism oper-
1510.59) ation.
15 (0.59)
Unit: mm (in)
8ST5828
ST-13
MANUAL STEERING GEAR AND LINKAGE (Model R24N)
SEC. 480
tt'J 29 • 39
(3.0 - 4.0,22 - ", ~
A : N.m (kg-m, tt-Ib) ~

@~ SST056CA
(!) Hole cover @ Manual steering gear assembly @ Rack mounting insulator
@ Lower joint @ Steering gear mounting clamp @ Cotter pin
CAUTION:
The rotation of the spiral cable (SRS "Airbag" component part)
is limited. If the steering gear must be removed, set the front
wheels in the straight-ahead direction. Do not rotate the steer-
ing column while the steering gear is removed.
• Detach tie-rod outer sockets from knuckle arms with Tool.
• Initially, tighten nut on tie-rod outer socket and knuckle arm

to 29 to 39 N'm (3 to 4 kg-m, 22 to 29 ft-Ib).
• Tighten nut further to align nut groove with the first pin hole
so cotter pin can be installed.
CAUTION:
Tightening torque must not exceed 49 N.m (5 kg-m, 36 ft-Ib).
ST-14
Disassembly
SEC. 480
~[OJ 49 - 69(5 -7,36 - 51}
@ A 39 - 59
(4 - 6, 29 .43) ""
@~~
_~
-=-
m
q= ~~~m
~
0
)!l
5
6
(j];=-@ @~
8 'Do not disassemble
WIlEi'! "-". ~9 0
13
\
24' Do not disassemble.
!ill \ [OJ 78
~~;:1'\~~~
- 98 (S - 10, 58 - 72)
Do oot d,,,,,,mbt, ~ [OJ 37 _ "

(3.8 - 4.7, 27 - 34)
SST892BA
CD
@
@
@
@
@
Guide chip
Rear cover lock nut
Dust seal
Rear cover
Pinion bearing
Pinion assembly
@)
@
@
@
@
@
Wave washer
Adjusting screw
Adjusting lock nut
Gear housing assembly
Boot clamp
Boot
@
@
@)
@
@
@
Tie-rod inner socket
Lock plate
Spacer
Rack
Spacer
Lock plate
•
(j) Retainer @J Boot band @ Tie-rod inner socket
@ Retaining spring @ Boot clamp @ Tie-rod outer socket
@ Plain washer
Inspection
BOOT
Check condition of boot. If it is cracked excessively, replace it.
RACK
Thoroughly examine rack gear. If rack gear is damaged,
cracked or worn, replace.
PINION ASSEMBLY
• Thoroughly examine pinion gear. If pinion gear is damaged,
cracked or worn, replace.
• Check that all bearings roll freely. Ensure that balls, rollers
and races in the bearing assemblies are not cracked, pitted
or worn. Replace if necessary.
ST-15
Inspection (Cont'd)
TIE-ROD OUTER AND INNER SOCKETS
...... A • Check outer and inner ball joints for swinging force" A" and
axial end play "C".
Refer to SOS CST-35).
Measuring point • Check outer ball joint for rotating torque "B".
Refer to SOS CST-35).
• Check condition of dust cover. If excessively cracked,
replace it.
SST057C
Assembly and Adjustment

STEERING GEAR
1. Insert rack gear from gear housing side.
2. Set rack gear in neutral position.
SST518A
3. Insert pinion assembly, then set guide chip at neutral posi-

GO":,%? tion as shown in figure. Pinion rack gear should be held in
place.
'~
SST6688
4. Install rear cover with Tool and secure with lock nut.
Tool number: KV48102000
• Before installing rear cover, apply locking sealant to
threaded areas. Do not allow sealant to get into pinion bear-
ing.
• Apply a coat of multi-purpose grease to sealing lips of dust
seal.
CAUTION:
Wrap cellophane tape around pinion gear end when installing
dust seal.
SST815A
5. Insert retainer, spring, plain washer and wave washer.

Then, install adjusting screw.
• Apply a coat of locking sealant to threaded areas of retainer
cover.
Adjusting screw
SST966A
5T-16
Assembly and Adjustment (Cant' d)
6. Adjust pinion rotating torque as follows:
a. Set gears to neutral position.
b. Loosen lock nut.
c. Tighten adjusting screw to a torque of 9.8 N'm (100 kg-cm,
87 in-Ib).
d. Loosen adjusting screw and retighten it to a torque of 9.8
N'm (100 kg-cm, 87 in-Ib).
e. Loosen adjusting screw within 60° until specified pinion
torque is obtained. Ensure that pinion-to-rack play is less
than 0.1 mm (0.004 in) when 15 N'm (1.5 kg-m, 11 ft-Ib) torque
is applied to pinion.
f. Prevent adjusting nut from rotating and tighten lock nut to
specified torque 39 to 59 N'm (4 to 6 kg-m, 29 to 43 ft-Ib)
Average value
= (Max. value + Min. value) x 0.5
holding adjusting screw in place.
Maximum
value
g. While slowly rotating pinion in the :f:: 100° range from neu-
tral position, make sure its rotating torque is within the
Minimum specifications.
value Pinion
rotating Within :f:: 100° from the neutral position:
torque Average rotating torque
0.7 - 1.2 N'm (7 - 12 kg-em, 6.1 - 10.4 in-Ib)
Maximum torque deviation
0.3 N'm (3 kg-em, 2.6 in-Ib)
SST272A Except for above measuring range:
Maximum rotating torque
1.5 N'm (15 kg-em, 13 in-Ib)
Maximum force deviation
0.5 N'm (5 kg-em, 4.3 in-Ib)
h. If pinion rotating torque is not within the specifications,
readjust.
If pinion rotating torque is outside the specifications after
adjustment has been made, replace retainer spring.
If pinion rotating torque is still out of specifications after replac-
ing retainer spring, replace gear assembly.
7. Install new lock plate. •

• Attach lock plate @ to side rod inner socket CD.
• Apply locking sealant to inner socket threads CID.
Screw inner socket into rack @ and tighten to specified
torque.
/)
@~~l(1)
Clinch
• Clinch two places of lock plate at rack's groove.
CAUTION:
To prevent scratching the boot, remove burrs from lock plate.
~@
SST6748
TIE-ROD AND BOOT

1. Install boot on tie-rod inner socket.
2. Apply locking sealant to threaded portion of inner socket.
Install tie-rod inner socket to rack end together with new
lock plate.
3. Install lock nut and outer socket to inner socket. Adjust tie-
rod length "L" and tighten lock nut.
Tie-rod length "L": Refer to 50S (ST-35).
Screwed length" f": 32 mm (1.26 in) or more
SST746A
ST-17
Assembly and Adjustment (Co nt' d)
4. Measure rack stroke.
Measure stroke "S":
Refer to SOS (ST -35).
AST141
5. Before installing boot, coat the contact surfaces between

boot and tie-rod with grease.
~==--
SST967A
6. Install boot clamps.

• To install, wrap boot clamp around boot groove twice. Use
a screwdriver to tighten clamps. Twist rings at both ends 4
to 4-1/2 turns while pulling them with a force of approx. 98
N (10 kg, 22 lb).
• Do not cross wire on boot.
AST137
• Bend twisted end of boot clamp as shown at left. (This will

prevent interference with other parts.)
AST138
ST-18
POWER STEERING GEAR AND LINKAGE (Model PR24AC)
~~.~
';'-------t"J 29 • 39 (3.0 • 4.0, 22~ ~.'.. ~ "'-

~ : N.m (kg-m, in-Ib) :;.
~
--f8\~
~~
~ d( ~
~
~
Vehicle front
[O.J : N. m (kg-m, ft-Ib)
[O.J 73 - 97 (7.4 • 9.9, 54 • 72) ~ '</ SST568C
CD Lower joint @ Rear cover cap (J) Gear housing mounting bracket
@ Hole cover @ Gear and linkage assembly @ Cotter pin
@ Insulator bracket @ Rack mounting insulator
CAUTION: •
• The rotation of the spiral cable (SRS "Air bag" component
part) is limited. If the steering gear must be removed, set
the front wheels in the straight-ahead direction. Do not
rotate the steering column while the steering gear is
removed.
• Remove the steering wheel before removing the steering
lower joint to avoid damaging the SRS spiral cable.
• Detach tie-rod outer sockets from knuckle arms with Tool.
• When disconnecting steering shaft lower joint, follow the
procedure shown below.
1. Remove nuts for fitting the hole cover.
2. Disconnect the lower joint while shifting the hole cover.
ST-19
• Install pipe connector.
• Observe specified tightening torque when tightening high-
pressure and low-pressure pipe connectors. Excessive
tightening will damage threads of connector or O-ring.
Connector tightening torque:
CD Low-pressure side
27 - 39 N'm (2.8 - 4.0 kg-m, 20 - 29 ft-Ib)
~ High-pressure side
15 - 25 N'm (1.5 - 2.5 kg-m, 11 - 18 ft-Ib)
• The O-ring in low-pressure pipe connector is larger than
that in high-pressure connector. Take care to install the
proper O-ring.
• Initially, tighten nut on tie-rod outer socket and knuckle arm

to 29 to 39 N'm (3 to 4 kg-m, 22 to 29 ft-Ib). Then tighten fur-
ther to align nut groove with first pin hole so that cotter pin
can be installed.
CAUTION:
Tightening torque must not exceed 49 N'm (5 kg-m, 36 ft-Ib).
• Before removing lower joint from gear, set gear in neutral

(wheels in straight-ahead position). After removing lower
joint, put matching mark on pinion shaft and pinion housing
to record neutral position.
• To install, set left and right dust boots to equal deflection.
Attach lower joint by aligning matching marks of pinion
shaft and pinion ~ousing.
• Tighten gear housing mounting bracket bolts in the order

shown.
o @
~
'--v---' ~
Temporary ..
tightening Secure tIghtening
SST6778
ST-20
SEC. 492
(SR ,,' CD ,",,", m_"'7 ~\Il~
m~ @, ~16. 21
~~'" ~ • '.1, ". 1S(
r, @ l"J ::'0',':0,
<V~!ilh, ~
1 '1 ""'---l
I
~20. 26
(2.0 • 2.7, 14 • 20)
~ ~m
tGi
@
/7' ~y @
"-~~(]
~
t:;;J
.~
I
@)(]~\-
~'
r ~to:J59' 74 20~
@~~~~
L
(6.0 • 7.5, 43 . 54)
•
_~ @Do not disas~smble. 0 ~~(SRandCD
~ ~~ engine models)
to:J 29 • 39
{3.0.4.0,22. "~~ 8 ~78. 98
(8.0 • 10.0, 58 • 72)
~ : N.m (kg-m. ft-lb)

f] :Lubrication points
GA engine model (With automatic
~ 37 • 46 (3.8 • 4.7, 27 . 34) transmission fluid
CD and SR engine models "DEXRON'u" type
M 78 . 98 (8.0 • 10.0, 58 • 72) or equivalent)
SST506CA
G) Rear cover cap @ Washer @ End cover assembly

@ Rear housing assembly @ Spring seat @ Boot clamp
@ Pinion seal ring @ Retainer @ Dust boot
@ Pinion assembly @ Gear housing @ Boot band
CID O-ring @ Center bushing @l Steering gear spacer
@ Shim @ Rack oil seal @ Lock plate
(J) Pinion oil seal @ Rack assembly @ Tie-rod inner socket
@ Lock nut @ Rack seal ring @ Tie-rod outer socket
@ Adjusting screw @) O-ring @ Cotter pin
@) Spring @ Rack oil seal @ Gear housing tube
@ Spring disc
ST-21
Disassembly
1. Prior to disassembling, measure pinion rotating torque.
Record the pinion rotating torque as a reference.
• Before measuring, disconnect gear housing tube and drain
fluid.
• Use soft jaws when holding steering gear housing. Handle
gear housing carefully, as it is made of aluminum. Do not
grip cylinder in a vise.
2. Remove pinion gear.
Be careful not to damage pinion gear when removing pinion
seal ring.
3. Remove tie-rod outer sockets and boots.
4. Loosen tie-rod inner socket by prying up staked portion, and
remove socket.
5. Remove retainer.
6. Remove pinion assembly.
7. Use a 2 to 2.5 mm (0.079 to 0.098 in) diameter drill to com-
pletely remove staked portion of gear housing end.
8. Remove end cover assembly with a suitable tool.

9. Draw out rack assembly.
10.Remove rack seal ring.
• Using a heat gun, heat rack seal to approximately 40°C
(104°F).
• Remove rack seal ring.
Be careful not to damage rack.
11. Remove center bushing and rack oil seal using tape
wrapped socket and extension bar.
Do not scratch inner surfaces of pinion housing .
.. !tension bar
29 mm socket
SST472A
Inspection
Thoroughly clean all parts in cleaning solvent or automatic
transmission fluid ''DEXRON™,, type or equivalent. Blow dry
with compressed air, if available.
BOOT
• Check condition of boot. If cracked excessively, replace it.
• Check boots for accumulation of power steering fluid.
RACK
Thoroughly examine rack gear. If damaged, cracked or worn,
replace it.
ST-22
Inspection (Cont'd)
PINION ASSEMBLY
• Thoroughly examine pinion gear. If pinion gear is damaged,
cracked or worn, replace it.
• Check that all bearings roll freely. Ensure that balls, rollers
and races are not cracked, pitted or worn. Replace if nec-
essary.
GEAR HOUSING CYLINDER

Check gear housing cylinder bore for scratches or other dam-
age. Replace if necessary.
TIE-ROD OUTER AND INNER SOCKETS

• Check ball joints for swinging force.
Inner
Us Tie-rod outer and inner ball joints swinging force "A":
ball joint +
Measuring pOin;~~ + C
• Check ball joint for rotating torque.
Tie-rod outer ball joint rotating torque "B":
/' •
Refer to 50S (ST-35).
Check ball joints for axial end play.
Tie-rod outer and inner ball joints axial end play "e":
• Check condition of dust cover. If cracked excessively,
replace outer tie-rod.
Assembly
1. Using a heat gun, heat new teflon rack seal ring to approx-
imately 40°C (104°F). Then place it onto rack.
~R"k , .. I ""9
•
SST083B
2. Using Tool, compress rack seal ring securely onto rack.

Always insert Tool from the rack gear side.
Rack seal ring
Position and
secure seal.
SST885BA
3. Insert new rack oil seal.

• Place plastic film into rack oil seal to prevent damage by
rack teeth.
• Do not forget to remove plastic film after rack oil seal is
c--.~ •
positioned properly.
Make sure lips of rack oil seal face each other.
Film
Rack ~
oil seal
SST201A
ST-23
Assembly (Conl'd)
4. Install center bushing and rack oil seal with rack assembly.
SST830A
5. Insert rack oil seal and end cover assembly to rack. Then
tighten end cover assembly.
End cover assembly
SST321B
2-3mm 6. Fasten end cover assembly to gear housing by staking.

(0.08 • 0.12 In)
SST073B
7. Set rack gear in neutral position.

Rack stroke "5":
SST086BA
8. Coat seal lip of new pinion oil seal with multi-purpose

grease. Install it into pinion housing of gear with a suitable
tool.
Suitable tool Make sure lip of oil seal faces up when installed.
Oil seal
SST381A
ST-24
Assembly (Cont'd)
9. Install pinion bearing adjusting shim(s).
• Whenever pinion assembly, gear housing and rear housing
are disassembled, replace shim(s) with new ones. Always
use the same number of shim(s) when replacing.
SST074B
10. Install new pinion seal ring (made of Teflon) on pinion gear
assembly.
• Using a heat gun, heat pinion seal ring to approximately
. 40°C (104°F) before installing it onto pinion gear assembly.
• Make sure pinion seal ring is properly settled in valve
groove.
SST085B
11. Apply a coat of multi-purpose grease to needle bearing

roller and oil seal lip.
•
SST075B
12. Install pinion assembly to rear housing.

Be careful not to damage pinion oil seal.
SST552
13. Apply a coat of multi-purpose grease to new rear oil seal lip
before installing rear housing.
Gear housing
SST133C
ST-25
Assembly (Cont'd)
14. Ensure that the rack is centered. Install rear cover cap so
that its protrusion is positioned as shown in figure.
Be careful not to damage worm ring and oil seal.
88T507C
15. Install diaphragm spring into gear housing.

• Always install retainer, spring washer and diaphragm
spring in that order.
• Make sure convex end (painted white) of diaphragm spring
faces outward when installing.
16. Install retainer spring and adjusting screw temporarily.
88T0878
17. Install new lock plate.

a. Attach lock plate @ to side rod inner socket (!).
b. Insert steering gear spacer CID to rack @.
c. Apply locking sealant to inner socket threads CID.
Screw inner socket into rack @ and tighten to specified
torque.
d. Stake lock plate at two places.
CAUTION:
To prevent scratching the boot, remove burrs from lock plate.
18. Tighten outer socket lock nut.

Tie-rod length "L":
88T0938
19. Measure rack stroke.

Rack stroke "5":
88T0868A
ST-26
Assembly (Cont'd)
20. Before installing boot, coat the contact surfaces between
boot and tie-rod with grease.
88T967A
21. Install boot clamps.

• To install, wrap boot clamp around boot groove twice. To
tighten clamp, place a screwdriver through both rings. Twist
rings 4 to 4-1/2 turns while pulling with a force of approx. 98
N (10 kg, 22 Ib).
• Twist boot clamp in the direction shown in figure at left.
88T440A
• Locate twisted end of boot clamp in the range shown. (This

will prevent interference with other parts.)
88TS09C
• After twisting boot clamp, bend twisted and diagonally so it •

does not contact boot.
88T1268
Adjustment
Adjust pinion rotating torque as follows:
1. Set rack to the neutral position without fluid in the gear.
2. Coat the adjusting screw with locking sealant and screw it
in.
3. Lightly tighten lock nut.
4. Tighten adjusting screw to a torque of 4.9 to 5.9 N'm (50 to
60 kg-em, 43 to 52 in-Ib).
5. Loosen adjusting screw, then retighten it to 0.2 N'm (2
Adjusting screw kg-em, 1.7 in-Ib).
88T0898
ST-27
Adjustment (Cont'd)
6. Move rack over its entire stroke several times.
7. Measure pinion rotating torque within the range of 180°from
neutral position.
Stop the gear at the point of maximum torque.
8. Loosen adjusting screw, then retighten it to 4.9 N'm (50
kg-em, 43 in-Ib).
9. Loosen adjusting screw by 70° to 110°.
SST072BA
10. Prevent adjusting screw from turning, and tighten lock nut
to specified torque.
SST557A
11. Check rack sliding force on vehicle as follows:

a. Install steering gear onto vehicle, but do not connect tie-rod
to knuckle arm.
b. Connect all piping and fill with steering fluid.
c. Start engine and bleed air completely.
d. Disconnect steering column lower joint from the gear.
e. Keep engine at idle and make sure steering fluid has
reached normal operating temperature.
f. Pull tie-rod slowly to move it from neutral position to :l: 11.5
mm (:l: 0.453 in) at speed of 3.5 mm (0.138 in)/s. Check that
SST090B rack sliding force is within specification.
Average rack sliding force:
152.0 - 240.3 N (15.5 . 24.5 kg, 34.2.54.0 Ib)
98 N (10 kg, 22 Ib)
g. Check sliding force outside above range at rack speed of 40
mm (1.57 in)/s.
Maximum rack sliding force:
294 N (30 kg, 66 Ib)
147 N (15 kg, 33 Ib)
• If rack sliding force is not within specification, readjust by
repeating adjustment procedure from the beginning.
• If rack sliding force is still out of specification after
readjustment, gear assembly needs to be replaced.
ST-28
POWER STEERING OIL PUMP
SEC. 493 GA engine model SEC. 490

SR engine model ~
~16-21
'Z5) [ij6.3.8.3 To engine
~
(1.6.
31 • 42
2.1, 12
@ @"
' ,..,
To engine
,
0
./'----~
"I
.'$>J
(0.64.
55.6 :/73.8)
/e;..
K@
0.85, ~26.
;~7..':ij
36
~':J ~
m'-/~/i<> ·"-
~ ,/"~
@ 'CJ!I",
1~ ........
To engine
<~~~iX':I~
J:
16_22
To engine
(1.6 • 2.2, 12 • 16)
\1f!.7~
v. Pm
~-.. 16 - 21 ~ 45 - 60 ~ 54.68
, "~ ~1.6' 2.1, 12 • 15) (4.6 - 6.1, ~
33 - 44) {5.5 - 6.9,
~ 16. 21 _~
(1.6 - 2.1, 12. 15) 40 - 50~
~ 13.3. 18.0
. (1.36 • 1.84, .G @) 0
CD engine model 9.8 _ 13.3) ../ /3 5 0
~ 16 - 21 (1.6 - 2.1, 12 - 15) l. ~
@@ , ~engine @ @Of1--! ~ 2
:r:
" ," I ~
.' "@ It. 17 0 f1 ~ ~ ~ 3 lEi! 10 ~ 69 - 78
37 • 50
(3.8. 5.1, 27 . 37)
/, '-l 18 f1
0,
..> lei 51 • 58)
19 0 ()
W ~Q @
GA16 with ASS c:> 15 7 8 0.
Except GA16 with ASS

~ 31 - 42 (3.2 - 4.3, 23 - 31)
CD engine
mo de I
~ 27 - 35
:7 ~~ f:j
- '"
-~
\) ~
()
()
0
0
0
6? ~
:\
()
,d
21
22
e7
<:>
C' 0
Pay attention
b
to its direction.
Except GA16
with ASS
I
@~ 49.69
ITh ~
-J.1; ~
.
(5.0 - 7.0,36 - 51)
(2.8 - 3.6, ~, ~ 23
20 _ 26) ri /
•
~ 13.3 - 18.0 ~~ 2~ /
1'36 • 1.84,
9.8 • 13.3) 13R engi~e model J ~ CD engine model I
~
') 26
///
~ 13.3. 18.0 Y.l~6
(1.36 - 1.84f \
9.8 • 13.3) I ()
-\:f 14
\\"- /
14
jGA16
~
with ASS
13.3 - 18.0
(1.36 • 1.84,
/ 0 9.8 - 13.3)
~ 27.35:~)-e / I \~'l ~ 27 - 35 ~l) ~ / Except GA16 with ASS
(2.8 - 3.6~ III ~..::::-- (2.8 - 3.6, ~ 27 • 35
20 • 26) \) 20 - 26) ~ (2.8 _ 3.6, 20 _ 26)
~ : N'm (kg-m, It-Ib) f]: Lubrication points (With automatic transmission
[ij : N'm (kg-m, in-Ib) fluid ''DEXRON™,, type or equivalent)
SST569C
CD Pulley @ Copper washer @ Vane

@ Snap ring @ Hose @ Rotor
@ Drive shaft assembly @ Connector boll @ Pin
@ Oil seal @ Mounting bracket @ Carn ring
@ Suction pipe @ Front housing @ Gasket
@ O-ring @l Spring @ Rear housing
0 Spring @ O-ring @ Mounting bracket

@ Control valve @ O-ring @ Adjusting bracket
@ O-ring @) Front side plate @ Adjusting boll
@) Connector
ST-29
Pre-disassembly Inspection
Disassemble the power steering oil pump only if the following
items are found.
• Oil leak from any point shown in the figure
• Deformed or damaged pulley
• Poor performance
SST984A
Disassembly
CAUTION:
• Parts which can be disassembled are strictly limited. Never
disassemble parts other than those specified.
• Disassemble in as clean a place as possible.
• Clean your hands before disassembly.
• Do not use rags; use nylon cloths or paper towels.
• Follow the procedures and cautions in the Service Manual.
• When disassembling and reassembling, do not let foreign
matter enter or contact the parts.
• Remove snap ring, then draw drive shaft out.

Be careful not to drop drive shaft.
Extension bar
SST010B
• Remove oil seal.

Be careful not to damage front housing.
• Remove connector and flow control valve with spring.

Front housing
Be careful not to drop flow control valve.
SST036A
5T-30
Inspection
• If pulley is cracked or deformed, replace it.
• If an oil leak is found around pulley shaft oil seal, replace
the seal.
• If serration on pulley or pulley shaft is deformed or worn,
replace it.
Assembly
Assemble oil pump, noting the following instructions.
• Make sure O-rings and oil seal are properly installed .
• . Always install new O-rings and oil seal.
• Be careful of oil seal direction.
• Cam ring, rotor and vanes must be replaced as a set if nec-
essary.
• Coat each part with ATF when assembling.
Rear housing side Front housing side • Pay attention to the direction of rotor.
SST289A
• When assembling vanes to rotor, rounded surfaces of vanes •

must face cam ring side.
Faces inside
./' 'I (}
~
Flat portion
SST843A
ST-31
Assembly (Cont'd)
• Insert pin CID into pin groove CD of front housing and rotor.
Then install earn ring CID as shown at left.
earn ring:
D1 is less than D2
SST472C
ST-32
POWER STEERING OIL COOLER
Oil Cooler (Heavy duty kit for CD20 engine

model)
Reservoir lank
~ 3 - 4 (0.3 - 0.4, 26 - 35)
~ Engine mounting
/~bracket
\~
~~eWB~
Details of part A
15 mm 3 mm
(0.59 in) (0.12 in) or less
Hose
Bulge
.1 I-
30 mm (1.18 in) ~ 3 - 4
Tube
(0.3 - 0.4, 26 - 35) ~ • N.m (kg-m, in-Ib)
•
SST583C

• Install heavy duty kit for power steering oil cooler as shown
in figure.
• Fill fluid and bleed hydraulic system. Refer to ST-7.
• Check fluid leakage and fluid level. Refer to ST-6.
ST-33
CD and SR
Applied model GA engine model engine
models
Manual
Steering model Power steering
steering
Steering gear type R24N PR24AC
Steering overall gear

23.2 17.1
ratio
Turns of steering wheel

4.21 3.17 2.95
(Lock to lock)
Steering column type Collapsible, tilt

GENERAL
Steering wheel axial play

0(0)
mm (in)
Steering wheel play mm (in) 35 (1.38) or less
Movement of gear housing

:!: 2 ( :!: 0.08) or less
mm (in)
STEERING COLUMN
Applied model All
Steering column length "L" 533.0 - 535.0

mm (in) (20.98 - 21.06)
'" '- Center of joint SST334C
ST-34
STEERING GEAR AND LINKAGE CD and
Applied model GA engine model SR engine
CD and models
Applied model GA engine model SR engine
models Steering gear type R24N PR24AC
R24N PR24AC Rack stroke "S" mm (in) 70 (2.76) 65 (2.56)

Steering gear type
Tie-rod outer ball joint
Swinging force at
6.9 - 64.7
cotter pin hole: "A"
(0.7 - 6.6, 1.5 - 14.6)
N (kg, Ib)
Rotating torque: "B" 0.29 - 294

N'm (kg-em, in-Ib) (30 - 30.0, 26 - 260)
Axial end play: "C"

0.5 (0.020) or less
mm (in)
Tie-rod inner ball joint

.
3.9 - 53.0
Swinging force": "A" 6.9 - 569
(0.4 - 5.4,
N (kg, Ib) (07 - 58,1.5 - 12.8)
0.9 - 11.9) POWER STEERING
Axial end play: "C"
mm (in)
0.4 (0.016) a (0)
Applied model All
Tie-rod standard length "L" Steering gear type PR24AC

187 (7.36)
mm (in)
Rack sliding force
". Measuring point [f: 137 mm (5.39 in)] N (kg, Ib)
Under normal operating oil

pressure
Range within ~.115 mm

(:1:0.453 in)
from the neutral
position at rack speed of
3.5 mm (0.138 in)/s
1520 - 2403
SST488C Average force
(15.5 - 24.5, 34.2 - 54.0)
Retainer adjustment
Maximum force deviation 98 (10, 22)
•
Adjusting screw
Except for the above range
Initial tightening
98 4.9 - 5.9 Maximum sliding force 294 (30, 66)
torque
(100,87) (50 - 60, 43 - 52)
Nm (kg-em, in-Ib) Maximum force deviation 147 (15, 33)
Retightening torque Steering wheel turning force

after loosening - 02 (2, 1.7) (Measured at one full turn from the
39 (4, 9) or less
N'm (kg-em, in-Ib) neutral position)
N (kg, Ib)
Tightening torque
after gear has Fluid capacity (Approximate)
- 49 (50, 43) 0.9 (3/4)
settled f (Imp qt)
N'm (kg-em, in-Ib)
7,649 - 8,238
Less than Oil pump maximum pressure (76.5 - 82.4,
60' kPa (bar, kg/em?, psi) 78 - 84,
[Within 1,109 - 1,194)
Returning angle play of 0.1
70' - 110'
degree mm (0.004
in)/15 N'm
(1.5 kg-m,
11 ft-Ib)]
ST-35
BODY & TRIM
SECTION BT
CONTENTS
PRECAUTIONS 2 Roof Trim 24
Service Notice 2 Trunk Room Trim 26
Supplemental Restraint System (SRS) "AIR Back Door Trim 27
BAG" (Dual Air Bag System) 2 EXTERIOR 28
Supplemental Restraint System (SRS) "AIR SEAT 35
BAG" (Single Air Bag System) 2 Front Seat 35
GENERAL SERViCiNG 3 Heated Seal... 36
Clip and Fastener 3 Rear Seat 37
BODY END 5 SUNROOF 39
Body Front End 5 WINDSHIELD AND WINDOWS 43
Body Rear End and Opener 7 Windshield and Rear Window 43
DOOR 11 Back Door Window 44
Front Door 11 Rear Side Window .45
Rear Door 12 MIRROR 46
INSTRUMENT PANEL 13 Door Mirror .46
INTERIOR TRIM 16 BODY ALIGNMENT 47
Side and Floor Trim 16 Engine Compartment 47
Door Trim 22 Underbody .49
*
•
For seat belt, refer to MA and RS section.
* For wiring diagrams of body electrical systems, refer to EL section.
PRECAUTIONS
Service Notice
• When removing or installing various parts, place a cloth or padding onto the vehicle body to prevent
scratches.
• Handle trim, molding, instruments, grille, etc. carefully during removing or installing. Be careful not
to soil or damage them.
• Apply sealing compound where necessary when installing parts.
• When applying sealing compound, be careful that the sealing compound does not protrude from
parts.
• When replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust
prevention measures.

WARNING:

WARNING:
Service Manual.
BT-2
GENERAL SERVICING
Clip and Fastener

• Clips and fasteners in BT section correspond to the following numbers and symbols.
• Replace any clips and/or fasteners which are damaged during removal or installation.
Symbol
Shapes Removal & Installation
No.
Removal:
Remove by bending up with
flat -bladed screwdrivers or
clip remover.
SBF302H SBF367BA
@D
9 T1f1f~,Q Removal:
Remove with a clip remover.
SBT095 SBF423H
Removal:
@ID
uy f ~ s""ru'
w MBF518B
l1! Finisher
SBF638C
,
@D •
MBF519B MBF520B
81-3
GENERAL SERVICING
Clip and Fastener (Cont'd)
Symbol
Shapes Removal & Installation
No.
Removal:
SBF104B
<fliP-- Removal:
Flat-bladed screwdriver
s: Finisher
..
'.
. .... ~ ~~
f
Clip-B
7~~;~met)
Sealing 0 (Grommet)
washer Clip-A
Sealing
SBF151D washers SBF259G
Removal: Installation:
/(1}"
Rotate 45°
,
to remove.
SBF145B Removal: SBF085B
Removal:
Holder portion of clip must be
spread out to remove rod.
SBF768B SBF770B
Removal:
1. Screw out with a Phillips
screwdriver.
2. Remove fema~e
~~~'l
portion with
flat-bladed
SBF078B SBF992G
BT-4
BODY END
Body Front End

• When removing or installing hood, place a cloth or other padding on hood. This prevents vehicle body
from being scratched.
• Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it.
• Hood adjustment: Adjust at hinge portion.
• Hood lock adjustment: After adjusting, check hood lock control operation. Apply a coat of grease to
hood locks engaging mechanism.
• Hood opener: Do not attempt to bend cable forcibly. Doing so increases effort required to unlock
hood.
REMOVAL - Front bumper assembly

CD Remove front air spolier. Refer to "Front air spoiler" in "EXTERIOR" for details, BT-33.
@ Remove bolts securing bumper fascia to engine undercover.
CID Remove clips @QD securing front grille.
@ Remove screws securing left and right turn signal lamps and remove the lamps.
@ Remove screws and clips @W *1, @ *2 securing left and right sides of front fender protector.
@) Remove bolts securing left and right front fenders to bumper fascia.
([) Remove bolts and clips @W securing retainer to bumper fascia.
@) Extract bumper fascia assembly.
*1: Standard bumper type
*2: Aero bumper type
•
to.J : N'm (kg-m, ft-Ib)
SBT037
B1-5
BODY END
Body Front End (Cont'd)
SEC. 261-620-623-650-656
Hood lock adjustment
• Adjust hood so that hood primary lock
meshes at a position 1 to 1.5 mm (0.039 to
0.059 in) lower than fender .
• After hood lock adjustment, adjust bumper
rubber.
• When securing hood lock, ensure it does
not tilt. Striker must be positioned at the
center of hood primary lock .
Hood adjustment r.:.1
• After adjustment, ensure that hood primary
and secondary lock operate properly.
Hood lock secondary latch hooking length
More than 5.0 mm (0.197 in)
E Secondary latch
Bumper fascia assembly

* : Bumper assembly mounting bolts, screw & clips.
[OJ : N. m (kg-m, ft-Ib)
SBT038
B1-6
BODY END
Body Rear End and Opener

4-DOOR SEDAN
• When removing or installing trunk lid, place a cloth or other padding on rear fender. This prevents
vehicle body from being scratched.
• Bumper fascia is made of plastic. Do not use excessive force and be sure to keep oil away from it.
• Trunk lid adjustment: Adjust at hinge-trunk lid portion for proper trunk lid fit.
• Trunk lid lock system adjustment: Adjust striker so that it is in the center of the lock. After
adjustment, check trunk lid lock operation.
• Opener cable: Do not attempt to bend cable using excessive force.
• After installation, make sure that trunk lid and fuel filler lid open smoothly.
REMOVAL - Rear bumper assembly

CD Remove bolts securing leH and right rear fenders to bumper fascia.
@ Remove bolts and clips @ID securing bumper lower side to bumper fascia.
@ Remove clips @ID securing rear pimel upper to bumper fascia.
@ Extract bumper fascia assembly.
rn [;I ~5.1 .6.5

(0.52 • 0.66,
(;I
'11IInff\ \W, \ \CC\\\\\\\\\\\\\\ 45.1 - 57.3)~n m

__ \.QL_OIT~~T~
o
Jf-~~
mm (0 in) Fuel filler lid opener & control
•
~ : N'm (kg-m, in-I b)
SBT039
B1-7
BODY END
Body Rear End and Opener (Cont'd)
SEC. 843-844-850-998
Trunk lid lock key cylinder rn
Trunk lid adjustment
Bumper fascia assembly@ * .Bumper assembly mounting clips and bolts.
SBT040
BT-8
BODY END
3-DOOR AND 5-DOOR HATCHBACK
• Back door adjustment: Adjust at hinge-body portion for proper back door fit.
• Back door lock system adjustment: Adjust lock & striker so that they are in the center. After
adjustment, check back door lock operation.
WARNING:
• Be careful not to scratch back door stay when installing back door. A scratched stay may cause gas
leakage.
• The contents of the back door stay are under pressure. Do not take apart, puncture, apply heat or
allow fire near it.
• Opener cable: Do not attempt to bend cable using excessive force.
• After installation, make sure that back door and fuel filler lid open smoothly.
REMOVAL - Rear bumper assembly

(1) Remove bolts securing left and right rear fenders to bumper fascia.
@ Remove bolts and clips @ill> securi-ng bumper lower side to bumper fascia.
@) Remove clips ~ securing rear panel upper to bumper fascia.
@ Extract bumper fascia assembly.
rn
~\\\\\\\\\\\\\\\\\\\\\\
I , "-
l
•
1f; omm~
(0 in)
'\ '---
Opener cable
adju~~m~nl
[O.J : N.m (kg-m, Il-Ib)
SBT041
B1-9
BODY END
SEC. 850-900-905
Back door hinge adjustment (!J
Opener handle m
Back door stay installation Gl
Fuel filler lid control fi!I
I
I
I
I '
@!@~ *
* ! <@Y
*
Bumper fascia assembly@
*: Bumper assembly mounting clips and bolls.
SBT042
B1-10
DOOR
Front Door
• For removal of door trim, refer to "Door Trim" in "INTERIOR TRIM" for details, 8T-22.
• After adjusting door or door lock, check door lock operation.
SEC. 800-803-805 Bell crank adjustment
Striker
adjustment ~
=:-/~
g3-
c1 ..
.1~.6,
.. @~\ 9 - 12)
Outside
handle
•
escutcheon --: __
/~
'. '
~~ ~
~
, -- Outside handle adjustment
(Turn holder as the clearance between
holder & rod is specified value.) Ii] : N'm (kg-m, in-Ib)
SBT044
BT-11
DOOR
Rear Door
SEC. 820-823-825
Outside handle adjustment m Inside handle installation
Door-hinge adjustment r.:.1

-';;;;Tau@
()Q .
,===W
~
m
~J'",*
~'-
~ L!il4.3 - 5.9
(0.44 • 0.60, 38.1 • 52.2)
Amll.e
m 1[0.]21 _ 28 (2.1 - 2.9, 15 - 21)
!ilS.2 - 7.0 (0.53 • 0.71, 46.0 • 62.0)
r.:.1 Door-hinge adjustment m

Outside handle ~6)
escutcheon / ~:~ _ 6) ~
_t
, / r
."..\,..- 0.5 - 2.4 mm ~
(0.020 • 0.094 in) I Release
I
ever
Holder
~
Outside handle adjustment
(Turn holder as the clearance between
holder & rod is specified value.)
Striker
adjustment ~
ill cI =-/~13
~'~3
- 16
1~;'"
~ : N'm (kg-m, ft-lb)
iii :N'm (kg-m, in-Ib)
88T045
BT-12
INSTRUMENT PANEL
CAUTION:
• Disconnect both battery cables in advance.
• Disconnect air bag system line in advance.
• Never tamper with or force air bag lid open, as this may adversely affect air bag performance.
• Be careful not to scratch pad and other parts.
REMOVAL - Instrument panel assembly

Instrument panel assembly Audio & AIC control Console box
Remove air bag module (driver's) and steering wheel.

Refer to "SUPPLEMENTAL RESTRAINT SYSTEM" in RS section for details.
CD Steering column cover and combination switch

• Remove screws.
l6l Instrument lower panel on driver side

• Remove screws.
@ Cluster lid C
• Remove screws and disconnect harness connectors.
@ Cluster lid A
• Remove screws.
@ Combination meter
• Remove screws and disconnect harness connectors.
cID Audio and AIC control unit

• Remove screws from the instrument panel.
(J) Glove box assembly

• Remove glove box pin .
• Then disconnect passenger air bag module
connector.
@ Passenger air bag module

• Refer to "SUPPLEMENTAL RESTRAINT
SYSTEM" in RS section for details.
@ AIT finisher or MIT shift lever boot
@ Rear console box

• Remove console mask and screws.
@ Front console box

• Remove screws and bolts.
•
@ Instrument mask
• Disconnect harness connector.
@ Front pillar garnish

• Refer to "Side and Floor Trim" in "INTE-
RIOR TRIM" for details, 8T-16.
@ Instrument panel and pads II

• Remove bolts and nuts.
• Remove door mirror switch and disconnect
the connector.
8T-13
INSTRUMENT PANEL
SEC. 248-251-272-487-680-685-969
8
Metal clip rn
* : Instrument panel assembly mounting

. bolts & nuts.
SBT046
8T-14
INSTRUME NT PANEL
SBT047
8T-15
INTERIOR TRIM
Side and Floor Trim

CAUTION:
Wrap the tip of flat-bladed screwdriver with a cloth when removing metal clips from garnishes.
REMOVAL - Body side trim

4-door sedan
CD Remove front and rear seats. Refer to "SEAT" for details, BT-35.
@ Remove front and rear seat belts. Refer to "SEAT BELTS" in RS section for details.
@) Remove front and rear kicking plates.
@ Remove dash side lower finishers.
@) Remove front and rear body side welts.
@ Remove front pillar garnishes.
tD Remove center pillar lower garnishes.
@ Remove center pillar upper garnishes.
@ Remove rear pillar garnishes.
@) Remove rear parcel shelf finisher.
@ Remove welt.
@ Remove seatback finisher.
SEC. 678-749-769-799
(!] Metal clip
(ilHook
Metal clip~
X : Metal clips
SBT048
8T-16
INTERIOR TRIM
Side and Floor Trim (Cont'd)
To instrument panel
8BT049
8T-17
INTERIOR TRIM
Side and Floor Trim (ConI' d)
5-door hatchback
• Remove tonneau board before removing body side trim.
@) Remove front and rear kicking plates.
CID Remove front and rear body side welts.
@) Remove front pillar garnishes.
(f) Remove center pillar lower garnishes.
@ Remove center pillar upper garnishes.
@ Remove rear parcel shelf side finishers.
@) Remove rear pillar finishers.
@ Remove rear wheelhouse finishers.
@ Remove luggage room rear plate.
@ Remove luggage room rear finisher.
@ Remove luggage room side lower finishers.
SEC. 678-749-769-799
Metal cliPGl
~: Velcro
X : Metal clip
88T050
8T-18
INTERIOR TRIM
Side and Floor Trim (Cont'd)
To instrument panel
SBT051
8T-19
INTERIOR TRIM
Side and Floor Trim (Conl'd)
3-door hatchback
• Remove tonneau board before removing body side trim.
@) Remove kicking plate.
@ Remove body side welts.
@ Remove front pillar garnishes.
(j) Remove rear parcel shelf side finishers.
@ Remove rear side finishers.
@ Remove rear pillar garnishes.
@) Remove luggage room rear plate.
@ Remove luggage room rear finisher.
@ Remove luggage room rear side lower finishers.
SEC. 678-749-769-799
~: Velcro
X : Metal clips
SBT052
8T-20
___________ s~rcN~T~E~R*IO~R~~T~RI~M~~CO':;j;;j),-
d Floor Trim (Cont d)
Side an 1
Metal clip
To instrument panel
SBT053
8T-21
INTERIOR TRIM
Door Trim
REMOVAL - Door trim
3-door hatchback
(j) Remove inside handle escutcheon.
@ Remove arm rest finisher from power window switch assembly and disconnect the connector.
@ Remove bolts, screws and clips @ securing door finisher.
@ Lift out door finisher.
SEC. 809
r ""J@
~'
SBT054
8T-22
INTERIOR TRIM
Door Trim (Coni' d)
REMOVAL - Door trim
4-door sedan and 5-door hatchback
G) Remove inside handle escutcheon.
CID Remove arm rest finisher from power window switch assembly and disconnect the connector.
@ Remove screw securing pull handle and remove pull handle.
@ Remove window regulator handle (Manual window models).
@ Remove bolts, screws and clips ~ securing door finisher.
@ Lift out door finisher.
SEC. 251-267-809-828
~ Manual window regulator handle

Hook Removal
(j) ~?
~
.P"h
Flat-bladed
{} screwdriver
@~l
Squeeze the regulator handle clip in place with a
screwdriver and remove the regulator handle from
the regulator shaft.
Set the regulator handle clip as shown in figure CD
Installation
. •
Push the regulator handle to install it onto the regulator
shaft.
Install the regulator handle in place as shown in the figure
with the window completely closed.
88T055
8T-23
INTERIOR TRIM
Roof Trim
REMOVAL - Headlining
4-door sedan
@) Remove body side trim. Refer to "Side and Floor Trim" for details, BT-16.
@ Remove sunroof switch. (Models equipped with sunroof)
@ Remove sunroof welt. (Models equipped with sunroof)
@ Remove inside mirror assembly.
([) Remove sun visors.
@ Remove interior lamp assembly.
@ Remove assist grips.
@) Remove clips @ securing headlining.
@ Remove headlining.
SEC. 264-738-963-964
Pawl'
Pawl
SBT056
BT-24
INTERIOR TRIM
Roof Trim (Cont'd)
REMOVAL - Headlining
3-door and 5-door hatchback
@) Remove body side trim. Refer to "Side and Floor Trim" for details, BT-16.
@ Remove sunroof switch. (Models equipped with sunroof)
cID Remove sunroof welt. (Models equipped with sunroof)
@ Remove inside mirror assembly.
(f) Remove sun visors.
@ Remove interior lamp assembly.
@ Remove assist grips.
@)Remove clips @ securing headlining.
(j]
Remove roof rear garnish.
@ Remove headlining.
SEC. 264-738-963-964
Pawlm
Metal clip l!1

m
Pawl
•
SBT05?
8T-25
_
__________ -:~N~T~E~R~IO~R~T~R~IM~------
Trun k Room Trim
SEC. 849
Front
Trunk room rear plate
Trunk roo m floor trim
SBT05B
BT-26
INTERIOR TRIM
Back Door Trim

REMOVAL - Back door trim
CD Remove back door side finisher.
CID Remove handle escutcheon.
@) Remove back door finisher.
@ Remove high-mounted stop lamp.
SEC. 909
x ><
Me'" 'UP~
•
G',"'~
SBTOS9
BT-27
EXTERIOR
SBT060
8T-28
EXTERIOR
CD ~ Hood front sealing rubber CID Windshield upper molding

SEC. 650 SEC. 720
Hood front sealing rubber
1 Cut off sealant at glass end.
2. Clean the side on which panel was mounted.
3. Set molding fastener and apply primer to body
panel, and apply sealant to body.
58T061
(ID @ Cowl top seal and cowl top grille

SEC. 660
4. Install molding by aligning the molding mark

located on center with vehicle center.
Be sure to install tightly so that there is no gap
around the corner.
@lJ SBF342H
Cowl top seal

58T062
(f) Drip weatherstrip
CID Windshield side molding

Mounted with screws,
Door panel
•
SEC. 720
SBT063
8T-29
EXTERIOR
@ Body side welt @ Door outside molding

SEC. 769 Front door
SEC. 800 Screw' III
~"
g.@~
d;!)de
Door outer molding
~/CIiP ~ __
~"..-/f'yoor outer panel
Rear door ~ c:?

~J
: Front door only
CID Door weatherstrip

SBT043
s,,~,~)
SEC. 820
\.~ ~' "',, mold'"

SEC. 800.820
CIIP~~
Door panel ~ --~ 0
SBT067
@ Sunroof lid weath erstnp.

SEC.736
Sun roof lid
weatherstrip
Roof panel
SBF455EA
@ Front doo r parting

. seal
r Sun roof rail
assembly
l
(\ Front
@
\\@ SBF349H
\\
~~ @
::€t)£j
......... \\ @
I.
II \\
.~) I @
II
@
u
SBT065
8T-30
EXTERIOR
@J Side guard molding @ Trunk lid weatherstrip

SEC. 766 SEC. 843
4-door and 5-door
3-door
Bonding portion
SBT069
@ Back door side sealing rubber

SEC. 909
• ; Double-faced adhesive tape
~~~~
~.:
-----~ .. .
..
~-o
~. "----' -.-/
'-
Heat gun
SBT06B
• With a vehicle coated with Hard Clear Coat, SBT070

use double-faced 3M adhesive tape Product
No. 4210 or equivalent, after priming with 3M
@ Back door window molding
primer Product No. N-200 or C-100 or equiva-
lent. SEC. 900
Back door window molding
•
@ Rear window upper molding and side
molding
Basically the same as windshield upper molding.
Refer to @ Windshield upper molding.
@ Rear window lower molding
Mounted with screws.
Removal: Remove molding by cutting around its perimeter.

Installation: Refer to "Back door window."
MBF13BAA
8T-31
@l Back door weatherstrip
SEC. 900
Vehicle center
Bonding portion
SBT072
@ Rear combination lamp. d ith nuts and butyl sealant.

• Rear com b'Ination lamps are Installe w
SEC. 265
BT-32
EXTERIOR
@ Front air spoiler
SEC. 960
8BT074
@ Front strut tower bar assembly
SEC. 401
[OJ : N.m (kg-m, ft-lb)

8BT099
•
CAUTION:
Do not remove front strut tower bar assembly while vehicle is jacked up with wheels on.
8T-33
EXTERIOR
@ Rear air spoiler

• When installing, make sure that there are not gaps or waves at ends of air spoiler.
• Before installing spoiler, clean and remove oil from surface where spoiler will be mounted.
4-door sedan
SEC. 960
Sealing rubber
SBT075
3-door and 5-door hatchback
SEC. 960 Double-laced adhesive lape
SBT076
8T-34
SEAT
• When removing or installing the seat trim, carefully handle it to keep dirt out and avoid damage.
* For Wiring Diagram, refer to "POWER SEAT" in EL section.
Front Seat
SEC. 870
l"l 43 • 55 (4.4 • 5.6, 32 . ~ \
\~4.4
t"J :' - -555.6, 32 • 41)
~ L
~~@~.
~
iTiln>__
---
m
I:
/
m ~\
'
tOJ 43 - 55 ~'}
(4.4 - 5.6, 32 • 41)
~ 21 - 26 (2.1 - 2.7, 15 . 20)
~,
•
SBT077
8T-35
SEAT
Heated Seat
• When handling seat, be extremely careful not to scratch heating unit.
• To replace heating unit, seat trim and pad should be separated.
• Do not use any organic solvent, such as thinner, benzene, alcohol, gasoline, etc. to clean trims.
Seatback heating unit removal & installation
Seat back trim
Heating
unit
Increasing to Decreasing to
Trim temperature
0C (OF) 35 - 45 15 - 25
(95 - 113) (59 - 77)
Thermostat
OFF ON
operation
SBF424H
* For Wiring Diagram, refer to "HEATED SEAT" in EL section.
8T-36
SEAT
Rear Seat
4-door sedan
SEC. 880
Rear seat hinge [!J
ifI
Bushing l ~';'
«tD-1 Ol
~ 13 - 16
~
(1.3 - 1.6,
9 - 12) ..
-=\----,
'
<J>/ t
SBT078
8T-37
SEAT
Rear Seat (Cont'd)
Hatchback
Type-l
SEC. 880
Rear seat hinge m
~ ; N. m (kg-m, ft-Ib)
SBT079
Type-2 Rear seat back striker r.i.1

SEC. 880 Rear armrest h'mge~r-'I
Bushing l
,
N7I
~~-~
~13 -16~
(1.3 - 1.6,
-I' ')
.--!
9 • 12) ~ ~ ~
)
~ ; N'm (kg-m, fHb) SBT080
BT-38
SUNROOF
ADJUSTMENT
Install motor & limit SW assembly and sunroof rail assembly in the following sequence:
1. Arrange equal lengths of link and wire assemblies on both sides of sunroof opening.
2. Connect sunroof connector to sunroof switch and positive (+) power supply.
3. Set lid assembly to fully closed positionm by operating OPEN switch and TILT switch.
4. Fit outer side of lid assembly to the surface of roof on body outer panel.
5. Remove motor, and keep OPEN switch pressed until motor pinion gear reaches the end of its rotat-
ing range.
6. Install motor.
7. Check that motor drive gear fits properly in wires.
8. Press TILT-UP switch to check lid assembly for normal tilting.
9. Check sunroof lid assembly for normal operations (tilt-up, tilt-down, open, and close).
FrontQ ri1 9 Rear

/ Tilting up & down range
- ;:: u ~ Outer body panel
~ Closing & opening range
Closing & opening range
SBF920F
81-39
SUNROOF
REMOVAL
• After any adjustment, check sunroof operation and lid alignment.
• Handle finisher plate and glass lid with care so not to cause damage.
• It is desirable for easy installation to mark each point before removal.
CAUTION:
Always work with a helper.
Link and wire Sunroof frame Shade assembly Lid assembly Motor assembly
assembly assembly
~
~
8T-40
SUNROOF
* For Wiring Diagram, refer to "ELECTRIC SUNROOF" in EL section.
SEC. 736
@Rear drain assembly
•
@Motor assembly
7 Sunroof switch bracket
SBT081
81-41
SUNROOF
m Using flat-bladed screwdriver, pry shade assembly holder

off rail. Then pull shade assembly forward to remove it from
rail.
I]IIDisengage pawls from rail, then remove window deflector

holder.
mUsing flat-bladed screwdriver, pry stopper spring off rail

groove. Then slide rear guide backward to remove it from
rail.
mRemove wire and link assembly from rail while pushing

Link assembly link back with flat-bladed screwdriver.,
MBF493B
81-42
WINDSHIELD AND WINDOWS
Cutting sealant REMOVAL

After removing moldings, remove glass,
CAUTION:
Be careful not to scratch glass when removing.
INSTALLATION
• Use genuine Nissan Sealant kit or equivalent. Follow
instructions furnished with it.
• After installing the glass, the vehicle should remain station-
ary until the sealant hardens.
WARNING:
SBF034B
Keep heat and open flames away as primers are flammable.
CAUTION:
Advise user not to drive the vehicle on rough roads until seal-
ant has properly vulcanized.
•. Do not use sealant which is past its usable term.
• Do not leave cartridge unattended with its cap open.
• Keep primers and sealant in a cool, dry place. Ideally, they
should be stored in a refrigerator.
• Molding must be installed securely so that it is in position
and leaves no gap.
Windshield and Rear Window

Body side Glass side Rear window
Install spacer to panel. Install dam Vehicle center
Windshield
rubber.
Windshield
8 (0.31)
8 (0.31)
• fj
'@8(0.31)1:@
447.2 (17.61)
8 (0.31)\
Joint
portion (J 8 (0.31)
Joint portion "
:~'
Rear window
G,,,,
t==\
O,m ,"bb"~
h¥ •
Double-laced
markmg po"II" adhesive tape 8 (0.31)
•
Apply sealant evenly.
Windshield and rear window
400 (15.75)
Install molding fastener. 7 • 8 (0.28 • 0.31)
When installing it, heat body panel and
fastener to approx. 30 to 40°C Upper & side molding lasteners
(86 to 104°F).
V
0;-.
Fastener 12 - 15
(0.47 - 0.59)
P'""~
Unit: mm (in)
Double-laced adhesive tape S8T083
REPAIRING WATER LEAKS FOR WINDSHIELD

Leaks can be repaired without removing and reinstalling glass.
If water is leaking between caulking material and body or glass, determine the extent of leakage. This
can be determined by applying water while pushing glass outward.
To stop the leak, apply primer and then sealant to the leak point.
81-43
Back Door Window
SEC. 900
.: Locating pin
• : Spacer
Spacer portion Primer portion (Body side)
Ii
pacer
:t
Spacer in;ltallation
marking S
pacer Spacer installation
marking
Back door molding Apply sealant evenly.

Back door molding
More than
joint portion
7 (0.28)
Locating pin
8 mm
(0.31 in)
primer~
Back door window molding
607.6 (23.92) 611.3 (24.07)
Back door mOld~
SBT098
BT-44
Rear Side Window
Sealant quantity
1
12 - 15
(0.47 - 0.59)
1-
7 -8
Unit: mm (in) (0.28 - 0.31)
locating pin
58T084
Sealant quantity
12 - 15
•
(0.47 - 0.59)
7 -8
(0.28 - 0.31)
Unit: mm (in)
88T085
8T-45
MIRROR
Door Mirror
CAUTION:
Be careful not to scratch door rearview mirror body.
* For Wiring Diagram, refer to "POWER DOOR MIRROR" in EL section.
REMOVAL - Door mirror

CDRemove door trim. Refer to "Door Trim" for details, BT-22.
~ Remove inner cover from front corner of door.
~ Disconnect door mirror harness connector.
@ Remove bolts securing door mirror, then remove door mirror assembly.
SEC. 963
Removal:
• Wrap flat-bladed of screwdriver with a cloth to prevent
scratching rear of door mirror. Do not insert screwdriver too far.
Pawl
Cloth
Flat-bladed
screwdriver
58T086
8T-46
BODY ALIGNMENT
• All dimensions indicated in figures are actual ones.

• When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and
gauge itself to make sure there is no free play.
• When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
• Measurements should be taken at the center of the mounting holes.
• An asterisk (*) following the value at the measuring point indicates that the measuring point on the
other side is symmetrically the same value.
• The coordinates of the measurement points are the distances measured from the standard line of
"X", "Y" and HZ".
~r
(+)
I v
L"oo" b.~ Ii"'
"2": Imaginary base line
[200 mm below datum line
~ ("02" at design plan)]
y
/H (0)
Front axle center
SBF874GB
Engine Compartment
MEASUREMENT
SBT087
8T-47
BODY ALIGNMENT
Engine Compartment (Cont'd)
MEASUREMENT POINTS
Unit: mm
SBT088
Front side
Radiato~ COrf~ ---.!upport lo~er C/
l'l
-~-
<Q 11 dia.
SBT090 SBT094
Radiator core support upper center
_~5~
~ 0
S ~
JI--------~
CDs dia....
CDs dia.
SBT091
BT-48
BODY ALIGNMENT
Underbody
MEASUREMENT
~
<lJ
0:
E
tI
E
IQ c:>J "c
::::>
1,017
@@
@@
0
(J)
(II Itl
Itl
CD .,.
CD
..,.
CD ..,.
(J)
(J)
Itl
.,.",
...
O. (II
(J)
CXlItl
CXlC!-
... @@
CXl
(j
CD
<?in
CD .... (g)@
Itl Itlltl
Itl
CD
ee
Itl
@@
...
C!-
(II
• CD
• 00
.... (II
~ co""
>£
<lJ
";;
787 127
"0
ill @@
C
"~
"
~
"
:;::
:c
Ol
<f> <lJ
..,.
Itl <lJ
I-
~Q
-l
(J)
c:>~ 0:
<Ii
<lJ
C C
.- 0
"0-
-"
<lJ
<ll-
<ll
790
•
u u
'6
.
<ll
C
-~
C
o
<lJ
Cti
(f)
<lJ
.
.,.1.ii .,.
<?
Itl
"fij :;
C ._Ol
.
<lJ
E-
•-
"0
_
<lJ
<f>
<lJ CD
0
CD
:<£ (J)
...
...
@@
.
(J) •
@@>
0
Itl
in Itl
0
....
@)@
@@
@"I 500
~{>
~{>
88T096
BT-49
BODY ALIGNMENT
Underbody (Cont'd)
MEASUREMENT POINTS
Rear
Front Rear
{t coordinates:
@.@
coordinates:
@.@ @
X : 250 X : 393.5 X : 475
Y : -632 Y : 1,460 Y : 3,082
Z : 224.8 Z : 126.9 Z : 336.8
@.@ @, @ @
X : 492 X : 572 X : -542
Y : -450 Y : 1,940 Y : 3,082
Z : 355 Z : 200 Z : 336.8
@.@ Q). CD
X : 406 X : 600
Y : 64 Y : 2,035
Z : 172 Z : 235.2
@.@ Q)
X : 352.7 X : 150
Y : 69 Y : 2,442.9
Z : 240 Z : 241
(g),@ @
X : 432 X : 300
Y : 338 Y : 2,480
Z : 128 Z : 381.8
CEJ, CD @
X : 395 X : -300
Y : 515 Y : 2,480
Z : 129.2 Z : 405.8
12 dia.@. •• @ @. @)
X : 393
LH side RH side Y : 2,560
Q Q @
Z : 365
II
Bottom X : 470
view of Y : 2,911
vehicle Z : 339.6
If @
X : -539
Y : 2,911
Z : 339.6
Unit: mm
Front and rear strut tower centers

I
@.0
~-t~
Coordinates:
Front @, 076 dia.
X : 522.2
Rear @, @62 dia.
Y : 18.1
Z : 571.7
@,@
X : 465
Y : 2,456.4
Z : 522
Front
SBT097
BT-50
RESTRAINT SYSTEM
SECTION RS
CONTENTS
PRECAUTION 2 Installation - Air Bag Module and Spiral
Supplemental Restraint System (SRS) "AIR Cable 17
BAG" (Dual Air Bag System) 2 Installation - Front Passenger Air Bag
Supplemental Restraint System (SRS) "AIR Module (Dual Air Bag System) 18
BAG" (Single Air Bag System) 2 Disposal of Air Bag Module and Seat Belt
SEAT BELTS 3 Pre-tensioner 19
Front Seat Belt 3 TROUBLE DIAGNOSES - Supplemental
Rear Seat Bel!. 5 Restraint System (SRS) 25
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 8 How to Perform Trouble Diagnoses for Quick
Precautions for SRS "Air Bag" and "Seat Belt and Accurate Repair 25
Pre-tensioner" Service 8 TROUBLE DIAGNOSES - Supplemental
Special Service Tools 8 Restraint System (SRS) - Dual Air Bag System 28
Description 9 Schematic 28
SRS Component Parts Location 10 Wiring Diagram - SRS - 29
Maintenance Items 11 Self-diagnosis 32
Removal and Installation - Diagnosis Sensor Trouble Diagnoses for Air Bag Warning Lamp 38
Unit. 12 COLLISION DIAGNOSIS - Dual Air Bag System .40
Removal and Installation - Seat Belt Pre- TROUBLE DIAGNOSES - Supplemental
tensioner (Mechanical Type) 13 Restraint System (SRS) - Single Air Bag •
Removal and Installation - Air Bag Module System 41 •
and Spiral Cable (Dual Air Bag System) 14 Schematic 41
Removal and Installation - Air Bag Module Wiring Diagram - SRS - 42
and Spiral Cable (Single Air Bag System) 14 Self-diagnosis 43
Removal - Air Bag Module and Spiral Cable 15 COLLISION DIAGNOSIS - Single Air Bag
Removal - Front Passenger Air Bag Module System .45
(Dual Air Bag System) 16 COLLISION DIAGNOSIS - Seat Belt
Pre-tensioner .46

When you perform trouble diagnoses, read GI section, "HOW TO FOLLOW FLOW CHART
PRECAUTION

The Supplemental Restraint System" Air Bag", used along with a seat belt, helps to reduce the risk or
WARNING:

wiring harness and spiral cable.
WARNING:
Service Manual.
RS-2
SEAT BELTS
CAUTION:
• For vehicles equipped with seat belt pre-tensioner, refer to "Removal and Installation - Seat Belt
Pre-tensioner (Mechanical Type)" when removing seat belt. Refer to RS-13 for details.
• Do not disassemble buckle or seat belt assembly.
• Replace anchor bolts if they are deformed or worn out.
• Never oil tongue and buckle.
• If any component of seat belt assembly is questionable, do not repair. Replace the whole seat belt
assembly.
• If webbing is cut, frayed, or damaged, replace seat belt assembly.
• When replacing seat belt assembly, use a genuine seat belt assembly.
• After any collision, inspect all seat belt assemblies, including retractors and other attached hard-
wares (i.e., guide rail set).
Front Seat Belt

4-DOOR SEDAN AND 5-DOOR HATCHBACK
CAUTION:
Before removing seat belt pre-tensioner assembly, be sure to lock safety lever to make seat belt pre-
tensioner inoperative. Do not unlock safety lever before reinstalling seat belt pre-tensioner assembly.
<D Remove front seat. Refer to "SEAT" in BT section for details.
@ Remove floor anchor bolt.
@ Remove adjuster cover.
@ Remove shoulder anchor bolt.
@ Remove center pillar upper and lower garnishes. Refer to "INTERIOR TRIM" in BT section for details.
@ Remove second sash guide.
(J) Remove the bolt securing seat belt pre-tensioner retractor, then remove seat belt and seat belt pre-
tensioner retractor.
@ Remove the bolts securing seat belt adjuster, then remove seat belt adjuster.
SEC. 769-868
rz1
•
A
~t.. ~. t;// ~>-..,\
~<:.~
~
...~ 0
~ 43 - 55 (4.4 - 5.6, 32 - 41)
toJ : N.m (kg-m, ft-Ib) toJ 43 - 55 (4.4 - 5.6, 32 - 41)
MRS107A
RS-3
SEAT BELTS
Front Seat Belt (Cont'd)
3-DOOR HATCHBACK
CAUTION:
Before removing seat belt pre-tensioner assembly, be sure to lock safety lever to make seat belt pre-
tensioner inoperative. Do not unlock safety lever before reinstalling seat belt pre-tensioner assembly.
CD Remove front and rear seats. Refer to "SEAT" in 8T section for details.
@ Remove floor anchor bolts.
@ Remove shoulder cover.
@ Remove shoulder anchor bolt.
@ Remove rear side lower garnish. Refer to "INTERIOR TRIM" in 8T section for details.
@ Remove the bolts securing second sash guide.
(!) Remove the bolts securing seat belt pre-tensioner retractor, then remove seat belt and seat belt
pre-tensioner retractor.
SEC. 769-868 [OJ 43 • 55 (4.4 • 5.6, 32 . 41)
to.J 43 • 55
>~",
~J.
~//~«;~
/ / --...""
(4.4 • 5.6, 32 . 41)
~~. 55 (44 • 5~" 32 • 41) ,
tOJ 43 -.55 (4.4 • 5.6, 32 . 41)
to.J : N'm (kg-m. ft-Ib) MRS108A
RS-4
SEAT BELTS
Rear Seat Belt

4-DOOR SEDAN
CD Remove rear seat. Refer to "SEAT" in BT section for details,
@ Remove rear pillar garnish and rear parcel shelf finisher. Refer to "INTERIOR TRIM" in BT section
for details.
@) Remove trunk room trim. Refer to "INTERIOR TRIM" in BT section for details.
@ Remove each anchor bolt.
@ Remove the bolt securing rear seat belt retractor, then remove seat belt retractor.
SEC. 869
~q.
5 '","" ~ ~
/" ~-A 43 - 55 (4.4 - 5.6, 32 - 41)
/ ---- "" \
Anchor bolt
•
~ 43 - 55 (4.4 - 5.6, 32 • 41)
~ : N. m (kg-m, ft-Ib) MRS109A
RS-5
SEAT BELTS
Rear Seat Belt (Cont'd)
3-DOOR HATCHBACK
• Before removing seat belt, open back door and remove tonneau board.
CD Remove rear seat. Refer to "SEAT" in BT section for details.
@ Remove rear parcel shelf side escutcheon and luggage side lower finisher. Refer to "INTERIOR
TRIM" in BT section for details.
@) Remove shoulder anchor cover.
CID Remove the bolt securing rear seat belt retractor, then remove seat belt retractor.
SEC. 869
---------
Anchor
.....[OJ
I'll
bolt )
43 • 55
/
~ (4.4 • 5.6, 32 - 41)
Anchor bolt
to;J43 - 55 (4.4 • 5.6, 32 - 41)
to;J : N'm (kg-m. ft-Ib)

MRS110A
RS-6
SEAT BELTS
Rear Seat Belt (Cont'd)
5-DOOR HATCHBACK
• Before removing seat belt, open back door and remove tonneau board.
CD Remove rear seat. Refer to "SEAT" in BT section for details.
@ Remove rear parcel shelf side finisher and luggage side lower finisher. Refer to "INTERIOR TRIM"
in BT section for details.
@) Remove shoulder anchor cover.
@) Remove the bolt securing rear seat belt retractor, then remove seat belt retractor.
SEC. 869
Anchor bolt
~ 43 - 55 (4.4 - 5.6, 32 - 41)

MRS111A
•
RS-7
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Precautions for SRS "Air Bag" and "Seat Belt

Pre-tensioner" Service
• Do not use a circuit tester to check SRS circuits.
• Before servicing the SRS. turn ignition switch "OFF", disconnect both battery cables and wait for at
least 10 minutes.
For approximately 10 minutes after the cables are removed, it is still possible for the air bag to
deploy. Therefore, do not work on any SRS connectors or wires until at least 10 minutes have passed.
• For single air bag system, do not separate diagnosis sensor unit from steering wheel.
• For dual air bag system. diagnosis sensor unit must always be installed with their arrow marks "Q"
pointing towards the front of the vehicle for proper operation. Also check diagnosis sensor unit for
cracks. deformities or rust before installation and replace as required.
• The spiral cable must be aligned with the neutral position since its rotations are limited. Do not
attempt to turn steering wheel or column after removal of steering gear.
• Handle air bag module carefully. Always place it with the pad side facing upward.
• Do not use old bolts after removing any SRS parts; replace with new ones. Conduct self-diagnosis
to check entire SRS for proper function.
• For dual air bag system, instrument panel assembly should be replaced after air bag inflates.
Application
Tool number Seat belt Dual Air Single
Description
Tool name pre-ten- Bag Air Bag
sioner*2 S stem S stem
KV991072So Disposing of air bag
Air bag deployment kit module
X X
KV99106400
Deployment tool
KV991065So
Deployment tool
adapters
X
For passenger
air bag module
NT353
KV99105300 Anchor the passenger
Passenger air bag air bag module
bracket
X
NT354
HT61961000and Use for special bolts
HT62152000com- [TAMPER RESISTANT
bined c TORX (Size T50))
*1 Special torx bit
a: 3.5 (0.138) dia.
X X
b: 8.5 - 8.6
(0.335 • 0.339) dia.
a c: approx. 10
(0.39) sq.
NT361 Unit: mm (in)
*1: Special tool or commercial equivalent

*2: Tools are not applicable because of its mechanical type.
RS-8
Description
The air bag deploys if the diagnosis sensor unit activates while the ignition switch is in the "ON" or
"START" position.
Single and dual air bag systems
Driver air
bag module
Ignition
Diagnosis sensor unit
switch
(ON or START)
• Auxiliary power source (condenser)
o Drive circuit
• CPU
• G sensor
Passenger air bag module
• Saling sensor (For dual air bag system)
Battery
MRS069AB
Seat belt pre-tensioner
G-Iorce when decelerating

(greater than the predetermined setting)
Mechanical sensor Mechanical trigger Piston and wire rope
Seat belt Retractor shaft
Combined into seat belt retractor

•
SRS126
RS-9
SRS Component Parts Location

Dual air bag system and seat belt pre-tensioner
SEC. 251-253-484-680-868 Spiral cable Air bag module
Single air bag system and seat belt pre-tensioner

SEC. 253-484-868 Air bag module

MRS114A
RS-10
Maintenance Items
1. Check "AIR BAG" warning lamp operation
After turning ignition key to "ON" position, "AIR BAG"
warning lamp illuminates. The "AIR BAG" warning lamp
will turn off after about 7 seconds if no malfunction is
detected.
If any of the following air bag warning lamp conditions
occur, immediately check the air bag system. Refer to RS-32
and 43 for details.
MRS115A
• The warning lamp does not illuminate when the ignition
switch is turned "ON".
• The warning lamp does not turn off about 7 seconds after
the ignition switch is turned "ON".
• The warning lamp turns off about 7 seconds after the igni-
tion switch is turned "ON", but it turns on or flashes again.
2. Visually check SRS components

(1) Diagnosis sensor unit
• Check diagnosis sensor unit and bracket for dents, cracks
or deformities.
• Check connectors for damage, and terminals for deformi-
ties.
(2) Air bag module and steering wheel

• Remove air bag module from steering wheel or instrument
panel. Check harness cover and connectors for damage,
terminals for deformities, and harness for binding.
• Install driver side air bag module to steering wheel to check
fit or alignment with the wheel.
• Check steering wheel for excessive free play .
• For dual air bag system, install passenger side air bag
module to instrument panel to check fit or alignment with the
instrument panel.
(3) Spiral cable

• Check spiral cable for dents, cracks, or deformities.
• Check connectors and protective tape for damage.
• Check steering wheel for noise, binding or heavy operation. •
(4) Main harness and air bag harness (For dual air bag system
only)
• Check connectors for poor connections, damage, and termi-
nals for deformities.
• Check harnesses for binding, chafing or cut.
CAUTION:
Replace previously used screws with new ones.
RS-11
Removal and Installation - Diagnosis Sensor

Unit
CAUTION:
• Before servicing SRS, turn the ignition switch off, disconnect both battery cables and wait for at least
10 minutes.
• The special bolts are coated with bonding agent while the other bolt is for ground. Do not use old
bolts after removal; replace with new ones.
• For single air bag system, do not separate diagnosis sensor unit from steering wheel.
• For dual air bag system, check diagnosis sensor unit for proper installation.
• Check diagnosis sensor unit to ensure they are free of deformities, dents, cracks or rust. If they show
any visible signs of damage, replace them with new ones.
• Check diagnosis sensor unit brackets to ensure they are free of deformities or rust.
• Always work from the side of air bag module.
• Replace diagnosis sensor unit if it has been dropped or sustained an impact.
SEC. 253~ REMOVAL OF DIAGNOSIS SENSOR UNIT

G r Grou~?
~~~
IT bolt ~
Fr?nt _--I d--e!

Forward mark
Dia~no:iS senSlr unit
1. Disconnect driver and passenger air bag module connec-
tors. Also, disconnect seat belt pre-tensioner connector.
2. Remove console box. Refer to "INSTRUMENT PANEL" in 8T
!
section.
3. Disconnect diagnosis sensor unit connector.
4. Remove bolt and also remove special bolts using the
TAMPER RESISTANT TORX (Size T50), from diagnosis sen-
Special bOIt~ - sor unit.
t"'J 15 - 25 N.m Then remove the diagnosis sensor unit.
(1.5 • 2.5 kg-m, 11 - 18 ft-Ib) MRS116A NOTE:
• To install, reverse the removal procedure sequence.
• After replacement, perform self-diagnosis for SRS. Refer to
"Self-diagnosis" for details (RS-32 and RS-43).
RS-12
Removal and Installation - Seat Belt

Pre-tensioner (Mechanical Type)
CAUTION:
• Do not attempt to disassemble seat belt pre-tensioner assembly.
• Do not drop or impact seat belt pre-tensioner assembly. This may cause seat belt pre-tensioner to
deploy.
• Check seat belt pre-tensioner assembly for damage or deformities.
• Replace seat belt pre-tensioner assembly that shows any visible sign of damage.
• Do not expose seat belt pre.tensioner to temperatures exceeding 80°C (176°F).
Seat belt pre-tensioner retracter For removal of seat belt pre-tensioner, refer to "Front Seat
Belt" for details (RS-3).
SEC. 868
CAUTION:
• Before removing seat belt pre-tensioner assembly, be sure
to lock safety lever to make seat belt pre-tensioner inoper-
ative. Do not unlock the safety lever before reinstalling seat
belt pre-tensioner assembly.
• After removing, place seat belt pre-tensioner assembly in a
box (such as a card board box) with the safety lever facing
down.
• After reinstalling seat belt pre-tensioner assembly, release
safety lever lock to make seat belt pre-tensioner operative.
• When installing new seat belt pre-tensioner assembly, pull
clip out to release safety lever lock. Failure to pull clip out
will result in it coming into contact with center pillar trim,
thus hampering installation.
NOTE:
(4.4 - 5.6 kg-m, • To install, reverse the removal procedure sequence.
32 - 41 fl-Ib)
MRS117AI
[i] Safety lever position
Operational range
for pre-tensioner
When installing
new pre-tensioner
(Clip is in place.)
•
When removing pre-tensioner:
Hook safety lever over the
pawl (burr) on retractor to
lock, then remove pre-tensioner.
Seat belt pre-tensioner is operative. Seat belt pre-tensioner is inoperative. SRS125
RS-13
Removal and Installation - Air Bag Module and

Spiral Cable (Dual Air Bag System)
SEC. 253-484
Special bolt ~
to:J 15.25 (1.5 • 2.5, 11 • 18)
Side lid RH
Air bag module
Horn relay switch connector
Special bolt ~ to:J 29 - 39 (3.0 - 4.0, 22 - 29)

to:J 15 - 25 (1.5 - 2.5, 11 - 18)
Lower lid
to:J : N.m (kg-m. ft-Ib) MRS118A
Removal and Installation - Air Bag Module and

Spiral Cable (Single Air Bag System)
DiagnOSiS sensor unit
SEC. 253-484
(Do not separate the diagnosis
sensor unit from steering wheel.)
Air bag module connector
Special boll ~
to:J
~~ r
Spiral cable 15 - 25 (1.5 - 2.5, 11 - 18)
~
S;d, lid RH
~ (] A;, b'9 mod",
Special bolt ~
A ' ~
t"J 15 • 25 (1.5 • 2.5, 11 • 18)- ~
Side lid LH / "-J

to:J : N. m (kg-m. ft-Ib) MRS119A
RS-14
Removal - Air Bag Module and Spiral Cable

CAUTION:
• Before servicing SRS, turn the ignition switch off, discon-
nect both battery cables and wait for at least 10 minutes.
1. Remove lower lid from steering wheel, and disconnect air
bag module connector.
SBF811E
2. Remove side lids. Using the TAMPER RESISTANT TORX

(Size T50), remove left and right special bolts. Air bag mod-
ule can then be removed.
SBF812E
CAUTION:
• Always place air bag module with pad side facing upward.
• Do not attempt to disassemble air bag module.
• The special bolts are coated with bonding agent. Do not use
old bolts after removal; replace with new ones.
MRS120A
• Replace air bag module if it has been dropped or sustained

an impact.
Air bag
• Do not expose the air bag module to temperatures exceed-
ing 90°C (194°F).
•
•
module
• Do not allow oil, grease or water to come in contact with the

air bag module.
SBF814E
3. Set steering wheel in the neutral position.

4. Disconnect horn connector and remove nuts.
5. Using steering wheel puller, remove steering wheel. Be
careful not to over-tighten puller bolt on steering wheel.
CAUTION:
• Do not tap or bump the steering wheel.
6. Remove steering column cover.
7. Disconnect connectors and remove the four screws. The
spiral cable can then be removed.
CAUTION:
SBF239F • Do not attempt to disassemble spiral cable.
• Do not apply lubricant to the spiral cable.
RS-15
Removal - Front Passenger Air Bag Module

CAUTION:
• Before servicing SRS, turn the ignition switch off, discon-
nect both battery cables and wait for at least 10 minutes.
• Always work from the side of or under air bag module.
1. Open the glove box lid.
2. Disconnect inflator connector from body harness air bag
connector.
3. Remove glove box assembly. Refer to "INSTRUMENT
PANEL" in BT section for details.
4. Remove the nuts and special bolts using the TAMPER

RESISTANT TORX (Size T50j from front passenger air bag
module.
Take out the air bag module from the instrument panel.
• The air bag module is heavy and should be supported using
both hands during removal.
MRS122A
CAUTION:
• Always place air bag module with pad side facing upward.
• Do not attempt to disassemble air bag module.
• The special bolts are coated with bonding agent. Do not use
old bolts after removal; replace with new coated bolts.
• Do not insert foreign objects (screwdriver, etc.) into air bag
module connector.
• Do not use a circuit tester to check the air bag module har-
ness connector.
• Replace air bag module if it has been dropped or sustained

an impact.
• Do not expose the air bag module to temperatures exceed-
Air bag
ing 90°C (194°F).
module
• Do not allow oil, grease or water to come in contact with the
air bag module.
SBF814E
RS-16
Dual air bag system Installation - Air Bag Module and Spiral Cable
1. Set the front wheels in the straight-ahead position.
2. Make sure that the spiral cable is in the neutral position.
The neutral position is detected by turning left about 2.5
revolutions from the right end position. Align the two marks
(~ ).
CAUTION:
• The spiral cable may snap due to steering operation if the
cable is installed in an improper position.
Also, with the steering linkage disconnected, the cable may
snap by turning the steering wheel beyond the limited num-
ber of turns. (The spiral cable can be turned up to 2.5 turns
from the neutral position to both the right and left.)
3. Connect spiral cable cOnnector and tighten with screws.
Install steering column cover.
MRS074AA
Single air bag system
•
SRS037-A
Dual air bag system 4. Install steering wheel setting spiral cable pin guides, and
pull spiral cable through.
5. Connect horn connector and engage spiral cable with pawls
in steering wheel.
6. Tighten nut.
~: 29 - 39 N'm (3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
MRS075AA
RS-17
Installation - Air Bag Module and Spiral Cable
(Cont'd)
MRS046AA
7. Position air bag module and tighten with new special bolts.
8. Connect air bag module connector.
G\\
--------~ ~\)
9.
10.
Install all lids.
Conduct self-diagnosis to ensure entire SRS operates prop-
erly. (Use CONSULT or warning lamp check.)
..~l~~
Before performing self-diagnosis, connect both battery
cables.
\\\?\\
Special bolt ~ ~ "'( \ \
11. Turn steering wheel to the left end and then to the right end
fully to make sure that spiral cable is set in the neutral
cc:J
15 - 25 N.m ~
position.
(1.5 - 2.5 kg-m,
11 - 18 ft-Ibl SBF812EA If air bag warning lamp blinks or stays ON (at the user
mode), it shows the spiral cable may be snapped due to its
improper position. Perform self-diagnosis again (use CON-
SULT or warning lamp). If a malfunction is detected, replace
the spiral cable with a new one.
Installation - Front Passenger Air Bag Module

1. Install front passenger air bag module on steering member.
• Ensure harness is not caught between rear of air bag mod-
ule and steering member.
2. Install glove box'assembly. (Glove box lid is open.)
3. Connect air bag module connector to body harness connec-

tor.
4. Close the glove box lid.
RS-18
Disposal of Air Bag Module and Seat Belt

Pre-tensioner
• Before disposing of air bag module and seat belt pre-tensioner, or vehicles equipped with such
systems, deploy the systems. If such systems have already been deployed due to an accident, dis-
pose of as indicated in "DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER" (RS-
24).
• When deploying the air bag module, always use the Special Service Tool; Deployment tool
KV99106400.
• When deploying the air bag module and seat belt pre-tensioner, stand at least 5 m (16 ft) away from
the deployment component.
• Due to heat, leave air bag module unattended for more than 30 minutes after deployment. Also leave
seat belt pre-tensioner unattended for more than 10 minutes after deployment.
• Be sure to wear gloves when handling a deployed air bag module and seat belt pre-tensioner.
• Never apply water to a deployed air bag module.
• Wash your hands clean after finishing- work.
• Do not dispose of the air bag module and seat belt pre-tensioner un-deployed.
CHECKING DEPLOYMENT TOOL
Connecting to battery
• Place the vehicle outdoors with an open space of at least 6
m (20 ft) on all sides.
• Use a voltmeter to make sure the vehicle battery is fully
charged.
CAUTION:
The battery must show voltage of 9.6V or more.
Remove the battery from the vehicle and place it on dry wood
Deployment tool blocks approximately 5 m (16 ft) away from the vehicle.
(KV99106400j SRS005-B • Wait 10 to 12 minutes after the vehicle battery is discon-
nected before proceeding.
• Connect red clip of deployment tool to battery positive ter-
minal and black clip to negative terminal.
Make sure the polarity is correct. The right side lamp in the tool,
marked "deployment tool power", should glow with a green
light. If the right side lamp glows red, reverse the connections
to the battery.
Deployment tool check

Press the deployment tool switch to the "ON" position. The left
side lamp in the tool, marked "air bag connector voltage"
•
should illuminate. If it does not illuminate, replace the tool.
Air bag deployment tool lamp illumination chart (Battery

connected)
RighI side lamp,
Left side lamp, green'
green'
Switch operation "AIR BAG CONNEC-
SBF266H "DEPLOYMENT TOOL
TOR VOLTAGE"
POWER"
OFF OFF ON
ON ON ON
,. If this lamp glows red, the 1001 is connecled to the battery incorrectly.
Reverse the connections and make sure the lamp glows green.
RS-19
Pre-tensioner (Cont'd)
15 (0.59) 15 (0.59)
•. 5~335) dl"~ DEPLOYMENT PROCEDURES FOR AIR BAG MODULE
(OUTSIDE OF VEHICLE)
°170 ('.89~ Unless the vehicle is being scrapped, deploying the air bag in
the vehicle is not recommended. This may cause damage to the
vehicle interior.
Anchor air bag module in a vise secured to a firm foundation
during deployment.
"'- Passenger air bag bracket
(KV99105300)
mm (in) SRS141
Deployment of driver's air bag module (outside of
vehicle)
1. Make an 8.5 mm (0.335 in) diameter hole in passenger air
bag bracket (SST: KV99105300) at the position shown in fig-
ure at left.
2. Using wire, secure air bag module to passenger air bag
bracket (SST: KV99105300) at two places.
CAUTION:
Passenger air Use wire of al least 1 mm (0.04 in) diameter.
bag bracket 3. Firmly secure passenger air bag bracket (SST: KV99105300)
(KV991 05300)
with air bag module attached, in a vise.
4. Connect deployment tool (SST: KV99106400) to air bag mod-

ule connector.
Passenger air
bag bracket
(KV99105300)
Air bag module 5. Connect red clip of deployment tool to battery positive ter-
6. The lamp on the right side of the tool, marked "deployment
tool power", should glow green, not red.
7. Press the button on the deployment tool. The left side lamp
on the tool, marked "air bag connector voltage", will illumi-
Deployment tool nate and the air bag module will deploy.
(KV99106400) CAUTION:
When deploying the air bag module, stand at least 5 m (16 ft)
away from the air bag module.
SRS020-A
Deployment of passenger air bag module (outside of

15 (0.59) 15 (0.59) vehicle)
1. Make an 8.5 mm (0.335 in) diameter hole in passenger air
bag bracket (SST: KV99105300) at the position shown in fig-
°'70 (.... ~ ure at left.
Passenger air bag bracket

(KV99105300)
mm (in) SRS141
RS-20
2. Firmly secure passenger air bag bracket (SST: KV99105300)
in a vise.
SRS145
3. Match the two holes in passenger air bag bracket (held in

vise) and passenger air bag module and fix them with two
bolts [M8 x 25 - 30 mm (0.98 - 1.18 in)].
CAUTION:
If a gap exists between passenger air bag module and passen-
ger air bag bracket, use a piece of wood inserted in the gap to
stabilize the air bag module.
4. Connect deployment tool adapter (SST: KV991065S0) to

deployment tool (SST: KV99106400) connector and connec-
tor on either side of air bag module.
5. Connect red clip of deployment tool to battery positive ter-
nate and the air bag module will deploy.
CAUTION:
Whwn deploying the air bag module, stand at least 5 m (16 ft)
Air bag module away from the air bag module.
8. Activate the other inflator.
Deployment tool
(KV991 06400)
CAUTION:
Always activate one inflator at a time.
•
SRS020-A!
RS-21
DEPLOYMENT OF AIR BAG MODULE WHILE MOUNTED
IN VEHICLE
When disposing of a vehicle, deploy air bag module while it is
mounted in vehicle.
CAUTION:
When deploying air bag module, ensure vehicle is empty.
1. Disconnect both battery cables and wait 10 minutes.
2. Disconnect air bag module connector.
3. Connect deployment tool (SST: KV99106400) to air bag mod-
SBF240F
ule.
4. Connect red clip of deployment tool to battery positive ter-
nate and the air bag module will deploy.
CAUTION:
Active only one passenger air bag module inflator at a time.
Deployment tool
(KV99106400) SRS006-B
DEPLOYMENT OF SEAT BELT PRE- TENSIONER

(OUTSIDE OF VEHICLE)
1. Remove seat belt unit with pre-tensioner. Refer to RS-3
fordetails.
Safety lever lock
CAUTION:
Before removing seat belt pre-tensioner assembly, be sure to
lock safety lever to make seat belt pre-tensioner inoperative.
2. Cut seat belt off at upper part of pre-tensioner.
SRS078
3. Tie a strong string at least 6 m (20 ft) long to pre-tensioner

body, with pre-tensioner cylinder facing down.
SRS079
4. Move lever in direction of arrow to unlock operation protec-

tion system. Pre-tensioner assembly is now ready for oper-
ation.
• After unlocking operation protection system, be careful not
to bump pre-tensioner assembly.
SRS080
RS-22
5. Place five used tires (four without rims and one with) on a
concrete floor, as shown in the figure, so that they encircle
pre-tensioner. Route end of the string through the center of
the rim.
• Make sure pre-tensioner is away from any of the tires to
prevent any shocks being applied.
SRS081
6. From a distance of more than 5 m (16 ft) away from tires,

5 m (16 ft) pull string until pre-tensioner is approximately 400 mm
(15.75 in) above the ground.
• Before pulling string, once again for safety, check that the
area around the tires is clear.
40 em (15.75 in)
SRS082
7. Release string to allow the pre-tensioner to hit the ground.

Pre-tensioner will now deploy.
• The pre-tensioner cylinder is too hot to touch immediately
after deployment; therefore, wait at least 10 minutes until it
cools down.
• Although the gas which is discharged during deployment is
harmless, avoid inhaling as it can cause some discomfort.
8. Before disposing of pre-tensioner, re-check that it has prop-
erly deployed. If it has not, repeat steps 3 through 7 above.
• A pre-tensioner deploying can be amply heard even at a
SRS083 distance of 5 m (16 ft).
• After pre-tensioner has deployed, the rubber cap is sepa-
rated from cylinder head by gas generated during deploy-
ment.
•
• Move screwdriver or similar ferrous metal close to the mag-
net built into the rear of sensor case. If it is attracted, pre-
tensioner has not deployed yet; if it is not attracted, pre-
tensioner has already been deployed.
CAUTION:
Be extremely careful not to apply any impacts to the pre-ten-
sioner until you are absolutely sure pre-tensioner has been
deployed.
RS-23
DISPOSING OF AIR BAG MODULE AND SEAT BELT
PRE- TENSIONER
Deployed air bag module and seat belt pre-tensioner are very
hot. Before disposing of air bag module and seat belt pre-
tensioner, wait at least 30 minutes. Seal them in a plastic bag
before disposal.
CAUTION:
• Never apply water to a deployed air bag module and seat
belt pre-tensioner.
SBF276H
• Be sure to wear gloves when handling a deployed air bag
module and seat belt pre-tensioner.
• No poisonous gas is produced upon air bag module deploy-
ment. However, be careful not to inhale gas since it irritates
throat and can cause choking.
• Do not attempt to disassemble air bag module and seat belt
pre-tensioner.
• Air bag module and seat belt pre-tensioner can not be
re-used.
• Wash your hands clean after finishing work.
RS-24
TROUBLE DIAGNOSES - Supplemental Restraint System (SRS)

and Accurate Repair
A good understanding of the malfunction conditions can make troubleshooting faster and more accurate.
In general, each customer feels differently about a problem. It is important to fully understand the
symptoms or conditions for a customer complaint.
INFORMATION FROM CUSTOMER

WHAT Vehicle model
WHEN Date, Frequencies
WHERE Road conditions
HOW Operating conditions, Symptoms
PRELIMINARY CHECK
Check that the following parts are in good" order.
• Battery [Refer to MA section ("GENERAL MAINTENANCE").]
• Fuse [Refer to EL section ("Fuse", "POWER SUPPLY ROUTING").]
• System component-to-harness connections
DIAGNOSIS FUNCTION
The SRS self-diagnosis results can be read by using "AIR BAG" warning lamp and/or CONSULT.
USING WARNING LAMP

USING CONSULT
User mode Diagnosis mode
Dual air bag system X X X
Single air bag system X
Seat belt pre-tensioner
The reading of these results is accomplished using one of two modes - "User mode" and "Diagnosis
mode".
The User mode is exclusively prepared for the customer (driver). This mode warns the driver of a sys-
tem malfunction through the operation of the "AIR BAG" warning lamp.
The Diagnosis mode allows the technician to locate and inspect the malfunctioning part.
The mode applications for the "AIR BAG" warning lamp and CONSULT are as follows:
•
User mode Diagnosis mode Display type
"AIR BAG" warning lamp X X ON-OFF operation
CONSULT X Monitoring
Seat belt pre-tensioner can not be diagnosed by using warning lamp and/or CONSULT. When seat belt
pre-tensioner is requires servicing, visually check seat belt pre-tensioner assembly. If damaged, replace
with a new one.
DIAGNOSIS MODE FOR CONSULT (For Dual Air Bag System)

• SELF-DIAG RESULTS
A current Self-diagnosis result (also indicated by the number of warning lamp flashes in the Diag-
nosis mode) is displayed on the CONSULT screen in real time. This refers to a malfunctioning part
requiring repairs.
RS-25
and Accurate Repair (Cont'd)
• ECU DISCRIMINATED No .• • ECU DISCRIMINATEDNO.
The diagnosis sensor unit for each vehicle model is
ECU No.
assigned with its own, individual classification number. This
09 number will be displayed on the CONSULT screen, as
shown at left. When replacing the diagnosis sensor unit,
refer to the part number for the compatibility. After
installation, replacement with a correct unit can be checked
by confirming this classification number on the CONSULT
screen.
SRS102 For NISSAN model N15, the diagnosis sensor unit classifi-
cation number assigned is 09.
RS-26
and Accurate Repair (Cont'd)
CAUTION:
• Do not use a circuit tester to check SRS harness connectors unless instructed to in this Service
Manual. For dual air bag system, SRS wiring harnesses are covered with yellow insulation either
just before the harness connectors or for complete harness, for easy identification.
• Do not attempt to repair, splice or modify the SRS wiring harness. If the harness is damaged, replace
it with a new one.
• Keep ground portion clean.
WORK FLOW
ACTION ITEM REFERENCE ITEM
Check in.
Listen to customer complaints and requests.
Perform preliminary check. -+-1 Preliminary check (RS-25)
Single
Perform self-diagnosis
mode
using "AIR BAG" warning lamp. - User
-+- DIAGNOSTIC PROCEDURE 1
or 7 (RS-32, 43)
air bag Dual air bag Single air bag

system system
system
Inspect malfunctioning part. - Diagnosis mode • DIAGNOSTIC PROCEDURE

2: Using CONSULT (RS-33)
Dual
Perform self-diagnosis using CONSULT. • DIAGNOSTIC PROCEDURE
air bag
OR 3: Using "AIR BAG" warn-
system
•
Perform self-diagnosis using "AIR BAG" warning lamp. ing lamp (RS-34)
Repair/Replace
NG Final check - Diagnosis mode and User mode • DIAGNOSTIC PROCEDURE

2: Using CONSULT (RS-33)
OK
• DIAGNOSTIC PROCEDURE
3: Using "AIR BAG" warn-
ing lamp (RS-34)
Check out
DIAGNOSTIC PROCEDURE 1
or 7 (RS-32, 43)
RS-27
TROUBLE DIAGNOSES - Supplemental Restraint System (SRS) -
Dual Air Bag System
Schematic
DUAL AIR BAG SYSTEM
DATA LINK
CONNECTOR FUSE FUSE
FOR CONSULT
o
COMBINA nON
METER
(AIR BAG
WARNING
LAMP)
19 2120 15
AIR BAG
DIAGNOSIS
SENSOR UNIT
3 4 5 6 2 17
SPIRAL
CABLE
-
AIR BAG AIR BAG DOOR SWITCH
MODULE MODULE DRIVER'S SIDE
DRIVER'S PASSENGER
SQUIB SIDE SQUIB SIDE
HRS002
RS-28
Dual Air Bag System
Wiring Diagram - SRS -

DUAL AIR BAG SYSTEM
RS-SRS-02
IGNITION SWITCH
ON or START
FUSE
10A (JIB)
W 1221 (M15)
~ (ll)"
*~ BRIW ~ BRIW -.
COMBINATION BRIW
METER ~
(AIR BAG 111511
WARNING WIL IGN AIR BAG
LAMP) DIAGNOSIS
(M30) SENSOR
11*.21 ~ UNIT
GNO ill)
BIR
~ <D:LHO mode Is
B
~(ll) <ID:
RHO models
C:J~
B
I ~
~g~~~CTOR-3
@: GA and SR engine
@: CD engine
@: With tachometer
rn
@: Without tachometer
~:<D ~f1... @ 30 , @ 40
JOINT *2 @ 9 @ 31
CONNECTOR-4
*3 @ 16 ,'@ 30
~~:<ID
B
I
•
,..O~O-O-ID-
I
B
<: :> I ~
B
R
B B B
: :} To AS-SAS-D.
BIR
.....
~ ~
1 L..t t.J (M60) ~
~----------------------------------~ Refer to last page

(Foldout page) .
L ~
em (IT)
y y
~(M59):<ID ITIII:illJIIIII ~ : <D

~P ~ BR
HRS004
RS-29
Dual Air Bag System
Wiring Diagram - SRS - {Co nt' d)
RS-SRS-03
AIR BAG
DIAGNOSIS
SENSOR
SQ+ SQ- UNIT
DOOR SW (DR) (DR)
SQ+
(PASS)
SQ-
(PASS) em
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ICiJI~
R
I
BOX NO.2
(..JOINT
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~~
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R
<;>
0
•
R
SPIRAL
CABLE
m DOOR
SWITCH
DRIVER'S
SIDE AIR BAG
OPEN @)
AIR BAG
MODULE MODULE
DRIVER'S PASSENGER
"=iJ
B
SIDE
(SQUIB)
SIDE
(SQUIB)
I
f.
B B
~ ~
(B11) @
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RS-30
Dual Air Bag System
Wiring Diagram - SRS - (Cont'd)
RS-SRS-04
IGNITION SWITCH
ON or START
AIR BAG
OIAGNOSIS
FUSE Refer to SENSOR
7 .5A BLOCK El-POWER.
rn (JIB) SSS SSS SSS
UNIT
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~ ~ ~ JUNCTION BOX NO.2
IIB.II 11*711 II*BII
(JOINT CONNECTORS)
<flli): <D
JOINT CONNECTOR-5
~
1*:1 II*.BI~: <ID
G/W GY/l G/B
to
G
rtl
G/W
~
• GY/L
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I I G/B
~
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To RS-SRS-02 {~
<@-B~
B ~ i
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HRS006
RS-31
Dual Air Bag System
Self-diagnosis
DIAGNOSTIC PROCEDURE 1 (@ without CONSULT)
Checking SRS operation by using" AIR BAG" warning lamp -
User mode
1. After turning ignition switch from "OFF" to "ON", "AIR
BAG" warning lamp operates.
2. Compare "AIR BAG" warning lamp operation to the chart
below.
"AIR BAG" warning lamp operation - User mode - SRS condition Reference item
No malfunction is
detected.
IGN ON
No further action is nec-
ON Ji I
essary.
OFF ~~----------------
MRS095A
The system has problem Go to DIAGNOSTIC PRO-

and needs to be repaired CEDURE 2, or 3 (RS-33
as indicated. or 34).
ON
OFF
MRS096A
Air bag is deployed. Go to COLLISION DIAG-

NOSIS (RS-40).
lGN ON
ON
OFF Jr--------------------
• Fuse, diagnosis sensor
unit or harness is mal-
Go to DIAGNOSTIC PRO-
CEDURE 4 (RS-38).
functioning and needs to
be repaired.
MRS097A
Diagnosis sensor unit or Go to DIAGNOSTIC PRO-

"AIR BAG" warning CEDURE 5 (RS-38).
IGN ON
lamp circuit is shorted or
open and needs to be
ON repaired.
OFF --------------------
MRS098A
NOTE:
If "AIR BAG" warning lamp operates differently from the oper-
ations shown above, refer to "AIR BAG" warning lamp opera-
tion - Diagnosis mode -, DIAGNOSTIC PROCEDURE3, RS-34.
Then repair as necessary.
RS-32
Dual Air Bag System
Self-diagnosis (Cont'd)
DIAGNOSTIC PROCEDURE 2 (00 with CONSULT)
Inspecting SRS malfunctioning parts by using CONSULT -
Diagnosis mode
2. Connect "CONSULT" to Data link connector.
MRS124A

CONSULT
START
SUB MODE I
SRS046
5. Touch "AIRBAG".
I~ SELECT SYSTEM 01
I ENGINE 1
AIRBAG
1-----1
1 '
I I
I 1
MRS125A
I~ SELECT DIAG MODE 01 6. Touch "SELF-DIAG RESULTS".
•
SELF-DIAG RESULTS
I ECU DISCRIMINATED NO. I

'======
1 -
1========
1 -
SRS043
7. Diagnostic codes are displayed on "SELF-DIAG RESULTS" .

• SELF-DIAG RESULTS. 0
FAILURE DETECTED
CONTROL UNIT
I ERASE II PRINT I SRS064
RS-33
Dual Air Bag System
If no self-diagnostic failure is detected on "SELF-DIAG
• SELF-DIAG RESULTS. 0 RESULTS", no further action is necessary. Touch "BACK" key
FAILURE DETECTED of CONSULT until SELECT SYSTEM MODE appears, then turn
• NO SELF DIAGNOSTIC off CONSULT.
FAILURE INDICATED.
FURTHER TESTING
MAY BE REQUIRED. **
ERASE " PR INT I

SRS044
8. Touch "PRINT".
9. Compare diagnostic codes to the CONSULT DIAGNOSTIC
CODE CHART, page RS-36.
10. Touch "BACK" key of CONSULT until SELECT SYSTEM
MODE appears, then turn off CONSULT.
11. Turn ignition switch "OFF", then disconnect CONSULT and
both battery cables.
12. Repair the system as outlined by the "Repair order" in
CONSULT DIAGNOSTIC CODE CHART, that corresponds to
the problem code. For replacement procedure of component
parts, refer to RS-12.
13. After repairing the system, conduct DIAGNOSTIC PROCE-
DURE 2 again.
If repair is completed, turn ignition switch "OFF", and dis-
connect CONSULT.Then go to DIAGNOSTIC PROCEDURE1,
page RS-32.
DIAGNOSTIC PROCEDURE 3 (00 without CONSULT)

Inspecting SRS malfunctioning parts by using "AIR BAG" warn-
ing lamp - Diagnosis mode
1. Open driver's door.
2. Turn ignition switch from "OFF" to "ON".
3. Press driver's door switch at least 5 times within 7 seconds
after turning ignition switch "ON".
SRS is now in Diagnosis mode.
4. "AIR BAG" warning lamp operates in diagnosis mode as
follows:
Door switch NOTE:
If SRS does not enter diagnostic mode, go to DIAGNOSTIC
PROCEDURE 6, page RS-39.
RS-34
Dual Air Bag System
No. "AIR BAG" warning lamp operation - Diagnosis mode - SRS condition
@ through @ are repeated. No malfunc-
IGN ON
tion is
detected.
ON
t No further
action is nec-
OFF
essary.
MRS100A
@ through @ are repeated. The system

NOTE: has problem
IGN ON
@ - Interval I and needs to
ON
I @) @ (c) @ - Start signal (Start signal be repaired.
identifies display modes)
2 @ - Interval II
OFF 7 sec. 3sec.
@ - Indicates malfunctioning
2 sec. 2 sec. Varies with malfunctioning part part (0.5 sec. ON and 0.5
sec. OFF is counted as
one flash.)
MRS099A
5. Malfunctioning part is indicated by the number of flashes

(part @). Compare the number of flashes to WARNING
LAMP FLASH CODE CHART, page RS-37, and locate mal-
functioning part.
6. Turn ignition switch "OFF", and disconnect both battery
cables.
7. Repair the system as outlined by the "Repair order" in
WARNING LAMP FLASH CODE CHART that corresponds to
the flash code. For replacement procedure of component
parts, refer to RS-12.
8. After repairing the system, conduct DIAGNOSTIC PROCE-
DURE 3 again.
If repair is completed, turn ignition switch "OFF" and then
turn "ON". Press driver's door switch at least 5 times within
7 seconds after turning ignition switch "ON".
9. The system is reset from Diagnostic mode to User mode.
Next, go to DIAGNOSTIC PROCEDURE 1, page RS-32. •
RS-35
Dual Air Bag System
CONSULT DIAGNOSTIC CODE CHART
Repair order
Diagnostic item Explanation
Recheck SRS at each replacement.
NO SELF DIAGNOSTIC • No malfunction is detected. -
FAILURE INDICATED.
AIRBAG MODULE • Driver's air bag module circuit is open. 1. Visually check the wiring harness connec-
[OPEN) (including the spiral cable) tions.
2. Replace the spiral cable.
AIRBAG MODULE • Driver's air bag module circuit is shorted
3. Replace driver's air bag module.
[VB-SHORT] to some power supply circuit. (including
(Before disposing of it, it must be
the spiral cable)
deployed.)
AIRBAG MODULE • Driver's air bag module circuit is shorted 4. Replace the diagnosis sensor unit.
[GND-SHORT] to ground. (including the spiral cable) 5. Replace the air bag harness.
AIRBAG MODULE • Driver's air bag module circuits are

[SHORT] shorted to each other.
ASSIST A/B MODULE • Front passenger air bag module circuit is 1. Visually check the wiring harness connec-
[OPEN] open. tions.
2. Replace front passenger air bag module.
ASSIST A/B MODULE • Front passenger air bag module circuit is (Before disposing of it, it must be
[VB-SHORT] shorted to some power supply circuit.
deployed.)
ASSIST A/B MODULE • Front passenger air bag module circuit is 3. Replace the diagnosis sensor unit.
[GND-SHORT) shorted to ground. 4. Replace the air bag harness.
ASSIST A/B MODULE • Front passenger air bag module circuits

[SHORT] are shorted to each other.
CONTROL UNIT • Diagnosis sensor unit is out of order. 1. Visually check the wiring harness connec-
tions.
2. Replace the diagnosis sensor unit.
3. Replace the air bag harness.
4. Replace the main harness.
* Follow the procedures in numerical order when repairing malfunctioning parts. Confirm whether malfunction is eliminated
using the air bag warning lamp (in user mode) or CONSULT each time repair is finished. If malfunction is still observed, pro-
ceed to the next step. When malfunction is eliminated, further repair work is not required.
RS-36
Dual Air Bag System
Self-diagnosis (Co nt' d)
WARNING LAMP FLASH CODE CHART
Warning Flash code @ Repair order

Explanation
lamp (# of flashes) Recheck SRS at each replacement.
0 No malfunction is detected. -
2 The driver's air bag module circuit 1. Visually check the wiring harness connections.
is out of order. 2. Replace the spiral cable.
3. Replace the driver's air bag module.
D.
E (Before disposing of it, it must be deployed.)
(Ij
- 4. Replace the diagnosis sensor unit.
en
c 5. Replace the air bag harness.
c
ca 7 The diagnosis sensor unit is out of 1. Visually check the wiring harness connections.
~
order. 2. Replace the diagnosis sensor unit.
C)
« 3. Replace the air bag harness.
OJ . 4. Replace the main harness .
cr:
;:(
8 The front passenger air bag module 1. Visually check the wiring harness connections.
circuit is out of order. 2. Replace the front passenger air bag module.
(Before disposing of it, it must be deployed.)
3. Replace the diagnosis sensor unit.
4. Replace the air bag harness.
* Follow the procedures in numerical order when repairing malfunctioning parts. Confirm whether malfunction is eliminaled
using the air bag warning lamp (in user mode) or CONSULT each time repair is finished. If malfunction is still observed, pro-
ceed to the next step. When malfunction is eliminated, further repair work is nol required.
RS-37
Dual Air Bag System
Trouble Diagnoses for Air Bag Warning Lamp

{f SYMPTOM: "AIR BAG" warning lamp does not turn off.
UP
SIDE •
T
Is air bag module deployed?
No
Replace air bag module
and diagnosis sensor
AIRBAG
EE3J unit. Refer to COLLISION

DIAGNOSIS, (RS-40).
Is SRS "Air Bag" fuse (10A) OK? Replace fuse.
Yes
I~ SELECTSYSTEM 01 00 Connect CONSULT and touch

"START".
No
----.... Replace diagnosis sensor
unit.
I ENGINE I • Is "AIRBAG" displayed on
AIRBAG CONSULT?
~Yes
Is harness connection between warning No Connect warning lamp

lamp and diagnosis sensor unit OK?
~ and diagnosis sensor unit
properly. If warning lamp
Yes
still does not go off,
MRS125A
replace harness.
[RePlace diagnosis sensor unit.
{f
UP
+
METER
SYMPTOM: "AIR BAG" warning
Is warning lamp fuse OK?
Yes
lamp does not turn on.
No Replace fuse.
SIDE
EE3J Is warning lamp LED OK?
Yes
Replace warning lamp
LED.
Is harness connection between warning Connect warning lamp

MRS127A lamp and diagnosis sensor unit OK? harness properly. If warn-
ing lamp still does not
Yes
come on, replace har-
ness.
I Replace diagnosis sensor unit.
RS-38
Dual Air Bag System
Trouble Diagnoses for Air Bag Warning Lamp
m (Cont'd)
SYMPTOM: SRS does not enter Diagnostic mode.
m
Is "AIR BAG" warning lamp blinking? No SRS is in good order. Set-
ting the CONSULT to the
Yes
Diagnosis mode is impos-
sible. No further action is
necessary.
MRS115A
Disconnect both battery cables and No Charge battery.

check battery voltage using circuit
te.ster.
• Is battery voltage more than 9V?
Remove driver's door switch and check No Replace driver's door

continuity between driver's door switch switch.
connector terminals G) and @ under
SRS058
Condition Continuity
Door switch is depressed

YES
(Door is closed).
Door switch is released

NO
(Door is open).
00
Check harness continuity between driv- No Replace or repair har-
MRS104
er's door switch connector terminal @ ness.
and body ground .
• Does continuity exist?
I
Yes
Replace diagnosis sensor unit.
Go 10 DIAGNOSTIC PROCEDURE 3.
•
SRS060
RS-39
COLLISION DIAGNOSIS - Dual Air Bag System
To repair the SRS, perform the following steps.

When SRS is activated in a collision:
CD Replace the diagnosis sensor unit.
@ Remove the air bag modules.
@ Check the SRS components using the table shown below:
• Replace any SRS components showing visible signs of damage (dents, cracks, deformation).
@ Conduct self-diagnosis. Refer to "Self-diagnosis" for details (RS-32). Ensure the remainder of the
SRS is operating properly.
<ID Install new air bag modules.
@ Conduct self-diagnosis again.
When SRS is not activated in a collision:
CDCheck the SRS components using the table shown below:
• Replace any SRS components showing visible signs of damage (dents, cracks, deformation).
@ Conduct self-diagnosis using CONSULT and "'AIR BAG" warning lamp. Refer to "Self-diagnosis" for
details (RS-32). Ensure entire SRS operates properly.
SRS inspection
Part SRS is activated SRS is NOT activated
Air bag module REPLACE 1. Remove air bag module. Check harness cover and connectors for damage,
(driver and passen- Install with new terminals for deformities, and harness for binding.
ger side) bolts. 2-1. Install driver air bag module into the steering wheel to check fit and align-
ment with the wheel.
2-2. Install passenger air bag module into the instrument panel to check fit
with the instrument panel.
3. No damage found, reinstall with new bolts.
4. If damaged-REPLACE. Air bag must be deployed before discarding.
Instrument panel REPLACE 1. Check instrument panel for bending, deformities, or cracks.
Install with new 2. If no damage is found, reinstall with new bolts.
bolts. 3. If damaged-REPLACE.
Diagnosis sensor REPLACE 1. Check case and bracket for dents, cracks or deformities.
unit Install with new 2. Check connectors for damage, and terminals for deformities.
bolts. 3. If no damage is found, reinstall with new bolts.
4. If damaged-REPLACE.
Steering wheel 1. Visually check steering wheel for deformities.
2. Check harness (built into steering wheel) and connectors for damage, and terminals for deformi-
ties.
3. Install air bag module to check fit or alignment with steering wheel.
4. Check steering wheel for excessive free play.
5. If no damage is found, reinstall with new bolts.
Spiral cable 1. Visually check lock (engagement) pins and combination switch for damage.
2. Check connectors, flat cable and protective tape for damage.
3. Check steering wheel for noise, binding or heavy operation.
Harness and Con- 1. Check connectors for poor connection, damage, and terminals for deformities.
nectors 2. Check harness for binding, chafing, cuts, or deformities.
3. If no damage is found, reinstall the harness and connectors.
4. Damaged-REPLACE damaged section of harness. Do not attempt to repair, splice or modify any
SRS harness.
RS-40
Single Air Bag System
Schematic
SINGLE AIR BAG SYSTEM
FUSE
COMBINA nON
METER
(AIR BAG
WARNING
LAMP)
8 9 10
SPIRAL
CABLE
2 7
AIR BAG
DIAGNOSIS
SENSOR UNIT
3 4
AIR BAG
MODULE
DRIVER'S
SQUIB SIDE
HRS001
RS-41
Wiring Diagram - SRS -

SINGLE AIR BAG SYSTEM
RS-SRS-01
IGNITION SWITCH
ON or START
FUSE
BLOCK
(J/B) Refer to EL-POWER.
10A 3A
rn 1211 ~
<E106)
CHID m @: With
tachometer
~BR/W~F.BR/W~ @: Without tachometer
i(f ... @ 30 @ 40
I GID@!) I *2"'@9'@31 ,
I
O-JD- BR/W .3ID)- BR/W-:E-O *3... @16 , @30
Y B!wt
Ii*llJ ":3 I t
COMBINAnON
METER
(AIR BAG
WARNING
m-~~ffl---m
BR/W ~ R/W B
LAMP)
SPIRAL
@) CABLE
~
U*.21
B/R
AIR BAG
DIAGNOSIS
SENSOR
UNIT
B/R AIR BAG

MODULE
B
rT B
-!- (SQUIB) ~ ~
~ ~ @D

I (Foldout page) .
1 ~ <E108)
I
I
lIL..m BR
I
L ~
r-----------------,
I I
1
1~*4 ~ 3*51 I
: [g]lJTIJ W 4 Y :
I
L 1
~
HRS003
RS-42
Self-diagnosis
DIAGNOSTIC PROCEDURE 7 (@ without CONSULT)
Checking SRS operation by using "AIR BAG" warning lamp-
User mode
1. After turning ignition switch from "OFF" to "ON", "AIR
BAG" warning lamp operates.
2. Compare "AIR BAG" warning lamp operation to the chart
below.
Note: CONSULT cannot be used for trouble diagnoses.
"AIR BAG" warning lamp operation - User mode
1. Normal
IGN ON
ON !--
OFF J Approx.I _
I} I sec ...
2. Abnormal - If the warning lamp shows as follows, check the SRS immediately.
e Blinking
ON
OFF
o.5~sec.
e Warning lamp does not illuminate at all.
IGN ON
,----,
•
ON
I I
I I
OFF I I
ecootiooo::JOO_IG_N_O_N _
OFF
MRS106
RS-43
REPAIR PROCEDURES
CAUTION:
Before servicing air bag, turn the ignition switch off and disconnect both battery cables and wail for at
least 10 minutes.
Warning lamp operation Explanation Repair order

Open or short in the air 1. Visually check the wiring harness and connectors.
Air bag
bag module circuit. 2. Replace air bag module.
Warning lamp blinks. has not
Malfunctioning diagnosis 3. Replace steering wheel assembly (including diag-
deployed.
sensor unit nosis sensor unit).
Warning lamp fuse is blown. 1. Check warning lamp fuse.

2. Visually check the wiring harnesses and connec-
Open in the warning lamp circuit tors.
Warning lamp does not 3. Check warning lamp LED.
Malfunctioning LED
illuminate at all. 4. Replace steering wheel assembly (including diag-
Malfunctioning combination meter nosis sensor unit).
5. Replace air bag harness assembly.
Malfunctioning diagnosis sensor unit 6. Replace combination meter.
Go to COLLISION DIAGNOSIS - Single Air Bag

Air bag has deployed:
System, page RS-45.
1. Check air bag fuse.
SRS air bag fuse is blown.
2. Visually check the wiring harnesses and connectors
Warning lamp is continu- for combination meter, diagnosis sensor unit and
ously ON. Open in air bag harness or spiral spiral cable.
cable circuit 3. Replace spiral cable.
4. Replace steering wheel assembly (including diag-
nosis sensor unit).
Malfunctioning diagnosis sensor unit
5. Replace air bag harness assembly.
*; After air bag is deployed, warning lamp illuminates until the ignition switch is turned OFF. When the Ignition switch is turned
ON again, Ihe warning lamp illuminates for approximately 7 seconds. It then blinks if malfunction is found, or goes out when
there is no malfunction.
Follow the procedures in numerical order when repairing malfunctioning parts. Confirm whether malfunction is eliminated using
the air bag warning lamp each time repair is finished. If malfunction is still observed, proceed to the next step. When malfunc-
tion is eliminated, further repair work is not required.
RS-44
COLLISION DIAGNOSIS - Single Air Bag System
To repair the SRS "AIR BAG", perform the following steps:

When SRS is activated in a collision:
CD Remove the air bag module.
@ Remove the steering wheel assembly.
@) Check the spiral cable using the table shown below:
• If the spiral cable shows any visible damage such as dents, cracks, or deformation, replace it
with a new one.
@ Install new steering wheel assembly.
CID Install new air bag module.
@ Conduct self-diagnosis using "AIR BAG" warning lamp to ensure that entire SRS operates properly.
Refer to RS-43 for details.
When SRS is not activated in a collision:
CDCheck the SRS components using the table shown below:
• If the SRS components show any visible damage such as dents, cracks, or deformation, replace
them with new ones.
@ Conduct self-diagnosis using "AIR BAG" warning lamp to ensure that entire SRS operates properly.
Refer to RS-43 for details.
SRS inspection
Part SRS is activated SRS is NOT activated

Air bag module REPLACE 1. Remove air bag module. Check harness cover and connectors for damage,
Install with new terminals for deformities, and harness for binding.
bolts. 2. Install air bag module into the steering wheel to check fit and alignment
with the wheel.
3. No damage found, reinstall with new bolts.
4. If damaged-REPLACE. Air bag must be deployed before discarding.
Steering wheel REPLACE 1. Visually check steering wheel for deformities.
assembly (includ- 2. Check harness and connectors for damage, and terminals for deformities.
ing diagnosis sen- 3. Check diagnosis sensor unit for dents, cracks or deformities.
sor unit). Do not remove diagnosis sensor unit from steering wheel.
4. Install air bag module to check fit or alignment with steering wheel.
5. If no damage is found, reinstall the steering wheel assembly.
Spiral cable 1. Check spiral cable for dents, cracks or deformities.
2. Check connectors and protective tape for damage.
3. Check steering wheel for noise, binding or heavy operation.
•
Harness and Con- 1. Check connectors for poor connection, damage, and terminals for deformities.
nectors 2. Check harness for binding, chafing, cuts, or deformities.
3. If no damage is found, reinstall the harness and connectors.
4. Damaged-REPLACE damaged section of harness. Do not attempt to repair, splice or modify any
SRS harness.
RS-45
COLLISION DIAGNOSIS - Seat Belt Pre-tensioner
Before replacing "SRS" seat belt pre-tensioner, check if seat belt pre-tensioner is activated or not as
follows.
Seat belt can be pulled - Seat belt pre-tensioner is not activated.
CD Visually check seat belt assemblies including seat belt retractors attached hardware (Le., guide rail
set) for damage.
@ If no damage is found, reinstall.
@) If damaged, install a new seat belt pre-tensioner assembly.
Seat belt cannot be pulled - Seat belt pre-tensioner is activated.
• Replace with a new seat belt pre-tensioner assembly.
RS-46
HEATER &
AIR CONDITIONER
SECTION HA
CONTENTS
PRECAUTIONS AND PREPARATION 2 Wiring Diagram - HEATER - 36
Supplemental Restraint System (SRS) "AIR Wiring Diagram - AIC - 38
BAG" (Dual Air Bag System) 2 SERVICE PROCEDURES 66
Supplemental Restraint System (SRS) "AIR HFC-134a (R-134a) Service Procedure 66
BAG", (Single Air Bag System) 2 Maintenance of Lubricant Quantity in
Precautions for Working with HFC-134a (R- Compressor 68
134a) 3 Refrigerant Lines 70
General Refrigerant Precautions 3 Compressor Mounting 75
Precautions for Refrigerant Connection 4 Belt Tension 76
Precautions for Servici ng Compressor. .. 5 Fast Idle Control Device (FICO) 76
Special Service Tools 5 Compressor - Model DKV-11D and DKV-14D
HFC-134a (R-134a) Service Tools and (ZEXEL make) 77
Equipment. 6 Compressor Clutch 77
Precautions for Service Equipment 8 Thermal Protector 80
DESCRIPTION 10 Compressor - Model CR-14 (Calsonic make) 80
Refrigeration Cycle . 10 Compressor Clutch .. 80
Component Layout 11 Thermal Protector 82
Discharge Air Flow 12 Ventilation Air Filter 83
Control Operation 13 SERVICE DATA AND SPECIFICATIONS (SDS) 84
TROUBLE DIAGNOSES 14 General Specifications 84
Contents 14 Inspection and Adjustment 84

When you perform trouble diagnoses, read GI section, "HOW TO FOLLOW FLOW CHART
•

WARNING:

WARNING:
Service Manual.
HA-2
Precautions for Working with HFC-134a (R-134a)

WARNING:
• CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These refrigerants
must never be mixed, even in the smallest amounts. If the refrigerants are mixed, compressor fail-
ure is likely to occur .
• Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. If lubricant other than that specified is used, compressor failure is likely to occur .
• The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed:
a: When removing refrigerant components from a vehicle, immediately cap (seal) the component
to minimize the entry of moisture from the atmosphere.
b: When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just
before connecting the components. Connect all refrigerant loop components as quickly as pos-
sible to minimize the entry of moisture into system.
c: Only use the specified lubricant fr.om a sealed container. Immediately reseal containers of
lubricant. Without proper sealing, lubricant will become moisture saturated and should not be
used.
d: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose
and throat. Remove R-134a from the A/C system, using certified service equipment meeting
requirements of SAE J2210 (R-134a recycling eqUipment), or J2209 (R-134a recovery equipment).
If accidental system discharge occurs, ventilate work area before resuming service. Additional
health and safety information may be obtained from refrigerant and lubricant manufacturers.
e: Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts.
Damage may result.
General Refrigerant Precautions

WARNING:
• Do not release refrigerant into the air. Use approved recoverylrecycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
• Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
• Do not store or heat refrigerant containers above 52°C (125°F).
• Do not heat a refrigerant container with an open flame; if container warming is required, place the
bottom of the container in a warm pail of water.
• Do not intentionally drop, puncture, or incinerate refrigerant containers.
• Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
• Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
• Do not introduce compressed air to any refrigerant container or refrigerant component.
HA-3
Precautions for Refrigerant Connection

WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is
less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.
CAUTION:
When replacing or cleaning refrigerant cycle components, observe the following.
• When the compressor is removed, store it in the same position as it is when mounted on the car.
Failure to do so will cause lubricant to enter the low pressure chamber.
• When connecting tubes, always use a torque wrench and a back-up wrench.
• After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
• When installing an air conditioner in the vehicle, connect the pipes as the final stage of the opera-
tion. Do not remove the seal caps of pipes and other components until just before required for con-
nection.
• Allow components stored in cool areas to warm to working area temperature before removing seal
caps. This prevents condensation from forming inside AIC components.
• Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
• Always replace used O-rings.
• When connecting tube, apply lubricant to portions shown in illustration. Be careful not to apply
lubricant to threaded portion.
Lubricant name: Nissan AIC System Oil Type R
Part number: KLHOO-PAGRO
• O-ring must be closely attached to inflated portion of tube.
• After inserting tube into union until O-ring is no longer visible, tighten nut to specified torque.
• After connecting line, conduct leak test and make sure that there is no leakage from connections.
When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten con-
nections of seal seat to the specified torque.
O-ring
Apply lubrication oil.
NG
NG
- Inflated portion
OK
SHA525DA
HA-4
Precautions for Servicing Compressor

• Plug all openings to prevent moisture and foreign matter from entering.
• When the compressor is removed, store it in the same position as it is when mounted on the car.
• When replacing or repairing compressor, follow "Maintenance of Lubricant Quantity in Compressor"
exactly. Refer to HA-68.
• Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubricant,
wipe it off by using a clean waste cloth moistened with thinner.
• After compressor service operation, turn the compressor shaft by hand more than five turns in both
directions. This will equally distribute lubricant inside the compressor. After the compressor is
installed, let the engine idle and operate the compressor for one hour.
• After replacing the compressor magnet clutch, apply voltage to the new one and check for normal
operation.

DKV-11D and DKV-14D compressors
Tool number
Description
Tool name
KV99231260 Removing shaft nut and clutch disc

Clutch disc
wrench
NT204
KV99232340 Removing clutch disc

Clutch disc puller
NT206
KV99234330 Installing pulley

PUlley installer
~
NT207
KV99233130 Removing pulley
•
Center pulley puller
NT208
C
HA-5
CR-14 compressor
Tool number
KV99106700 Removing shaft nut and clutch disc

Clutch disc wrench
NT351
KV99106800 Installing pulley

Pulley installer
NT352
HFC-134a (R-134a) Service Tools and Equipment

Never mix HFC-134a refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its
lubrication oil.
Separate and non-interchangeable service equipment must be used for each type of refrigerant/
lubricant.
Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which
handles refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This
is to avoid mixed use of the refrigerants/lubricant.
Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamina-
tion will occur and compressor failure will result.
Tool name Description Note

HFC-134a (R-134a) refrig- Container color: Light blue
erant Container marking: HFC-134a (R-134a)
Fitting size: Thread size
• large contai ner 1/2"-16 ACME
NT196
~~
Nissan A/C System Oil Type: Poly alkyline glycol oil (pAG), type R
Type R Application: HFC-134a (R-134a) vane rotary
(Part No.: KLHOO-PAGRO) compressors (Nissan only)
Lubricity: 40 me (1.4 Imp fI oz)
~
NT197
Recovery/Recycling/ Function: Refrigerant Recovery and Recy-

Recharging equipment ~ cling and Recharging
•
":' s Q"'~
==
NT195
~ t:J II
HA-6
HFC-134a (R-134a) Service Tools and Equipment
(Cont'd)
Tool name Description Note

Electrical leak detector Power supply:
• DC 12 V (Cigarette lighter)
NT19S
Manifold gauge set (with Identification:

hoses and couplers) • The gauge face indicates R-134a.
Filling size: Thread size
• 1/2"-16 ACME
NT199
Service hoses Hose color:

• High side hose • Low hose: Blue with black stripe
• Low side hose • High hose: Red with black stripe
• Utility hose • Utility hose: Yellow with black stripe or
green with black stripe
Hose filting to gauge:
• 1/2"-16 ACME
NT201
Service couplers Hose filling to service hose:

• High side coupler • M14 x 1.5 fitting is optional or
• Low side coupler permanently attached .
NT202
Refrigerant weight scale For measuring of refrigerant

.1/2"-16 ACME
•
NT200
Vacuum pump Capacity:

(Including the isolator • Air displacement: 4 CFM
valve) • Micron rating: 20 microns
• Oil capacity: 482 g (17 oz)
.1/2"-16 ACME
NT203
HA-7
Precautions for Service Equipment

RECOVERY/RECYCLING/RECHARGING EQUIPMENT
Be certain to follow the manufacturers instructions for machine
operation and machine maintenance. Never introduce any
refrigerant other than that specified into the machine.
ELECTRONIC LEAK DETECTOR

Be certain to follow the manufactures instructions for tester
operation and tester maintenance.
With isolator valve VACUUM PUMP

Hose fittings:
1/2".16ACME The lubricant contained inside the vacuum pump is not compat-
ible with the specified lubricant for HFC-134a (R-134a) AIC sys-
tems. The vent side of the vacuum pump is exposed to atmo-
spheric pressure. So the vacuum pump lubricant may migrate
out of the pump into the service hose. This is possible when the
pump is switched off after evacuation (vacuuming) and hose is
connected to it.
To prevent this migration, use a manual valve placed near the
hose-to-pump connection, as follows.
• Usually vacuum pumps have a manual isolator valve as part
of the pump. Close this valve to isolate the service hose
Without isolator valve
from the pump.
• For pumps without an isolator, use a hose equipped with a
manual shut-off valve near the pump end. Close the valve
to isolate the hose from the pump.
• If the hose has an automatic shut off valve, disconnect the
hose from the pump. As long as the hose is connected, the
valve is open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the
pump's ability to pull a deep vacuum and are not recom-
RHA270D mended.
MANIFOLD GAUGE SET

Be certain that the gauge face indicates R-134a or 134a. Be sure
the gauge set has 1/2"-16 ACME threaded connections for ser-
vice hoses. Confirm the set has been used only with refriger-
ant HFC-134a (R-134a) and specified lubricants.
~
1f2"-16ACME
SHA533D
Hose fittings to SERVICE HOSES

manifold gauge or recovery/recycling
equipment; 1/2"-16ACME Be certain that the service hoses display the markings
described (colored hose with black stripe). All hoses must
include positive shut off devices (either manual or automatic)
near the end of the hoses opposite the manifold gauge.
RHA272D
HA-8
Precautions for Service Equipment (Cont'd)
SERVICE COUPLERS
Never attempt to connect HFC-134a (R-134a) service couplers to
an CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers
will not properly connect to the CFC-12 (R-12) system. However,
M14 x 1.5 fitting
optional
if an improper connection is attempted, discharging and con-
(Hose may be tamination may occur.
permanently
attached to Shut off valve rotation AIC service valve
coupler)
Clockwise Open
Counterclockwise Close
RHA273D
REFRIGERANT WEIGHT SCALE

Verify that no refrigerant other than HFC-134a (R-134a) and
specified lubricants have been used with the scale. If the scale
controls refrigerant flow electronically, the hose fitting must be
Hose fittings:
1/2"-16ACME 1/2"-16 ACME.
To manifold gauge
RHA274D
CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant
may be vented into air from cylinder's top valve when filling the
cylinder with refrigerant. Also, the accuracy of the cylinder is
generally less than that of an electronic scale or of quality
recycle/recharge equipment.
HA-9
DESCRIPTION
Refrigeration Cycle
REFRIGERANT FLOW
The refrigerant flow is in the standard pattern. Refrigerant flows through the compressor, condenser,
liquid tank, evaporator and back to the compressor.
The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expan-
sion valve, located inside the evaporator case.
FREEZE PROTECTION
The compressor cycles on and off to maintain the evaporator temperature within a specified range. When
the evaporator coil temperature falls below a specified point, the thermo control amplifier interrupts the
compressor operation. When the evaporator coil temperature rises above the specification, the thermo
control amplifier allows compressor operation.
REFRIGERANT SYSTEM PROTECTION

Dual-pressure switch
The dual-pressure switch is located on the liquid tank. If the system pressure rises or falls out of
specifications, the switch opens to interrupt compressor clutch operation.
Fusible plug
Open at temperature above 105°C (221°F), thereby discharging refrigerant to the atmosphere. If this plug
is melted and opened, check the refrigerant line and replace liquid tank.
c:::::.J High-pressure EJ Low-pressure

gas liquid
1:-:-:-:-::-:-::-:-:1 ~~~~pressure !::i'i'i':}':J ~~:-pressure
Compressor
s
D
t
Outside air
Blower motor
Fusible plug -~ ~.. U

'" Expansion valve
Liquid tank "'-- Dual-pressure switch SHA504D
HA-10
__________ ~==D=ES=C~R~I~P~TI~O~N~~-
Component Layout
SEC. 270-271-272-273
Side defros t er nozzle
Defroster nozzle
Side defroster nozzle
Side venli.1a tor duct Center ventilator duct
Side ventilator duct
Cooling unit
•
Control assembly
. .11stration
This I u is for LH D models.
. symmetrically opp osite to this layout.
The layout for RHO models IS
RHA312F
HA-11
DESCRIPTION
Discharge Air Flow

CD; Ventilation @: Defroster Floor
@; Fool
Defroster
@ To defroster
Ventilator door
Bi-Ievel
(~ switch "OFF" )
.... ; Air passed through heater core
<$=::I : Mixed air ( ... + <;::::J )

This illustration is for LHD models. <:;:::::J ; Air not passed through heater core
The layout for RHD models is symmetrically opposite.
RHA313F
HA-12
DESCRIPTION
Control Operation
LHO models RHO models
FAN CONTROL KNOB

This knob turns the fan ON and OFF, and controls fan speed.
MODE CONTROL KNOB

This knob controls the outlet air flow.
TEMPERATURE CONTROL KNOB

This knob allows adjustment of the temperature of the outlet air.
RECIRCULATION (REC) SWITCH

OFF position:
Outside air is drawn into the passenger compartment.
ON position:
Interior air is recirculated inside the vehicle.
The indicator lamp will also light.
AIR CONDITIONER SWITCH

The air conditioner switch controls the Ale system. When the switch is depressed with the fan ON, the
compressor will turn ON. The indicator lamp will also light.
The air conditioner cooling function operates only when the engine is running.
HA-13
TROUBLE DIAGNOSES
Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair HA-15
Operational Check HA-16
Symptom Chart HA-18
Preliminary Check HA-20
PRELIMINARY CHECK 1
(A/C does not blow cold air.) HA-20
PRELIMINARY CHECK 2
(Air outlet does not change.) HA-21
PRELIMINARY CHECK 3
(Noise) HA-22
PRELIMINARY CHECK 4
(Insufficient heating) HA-23
Performance Test Diagnoses HA-24
INSUFFICIENT COOLI NG HA-24
Performance Chart HA-26
TEST CONDITION HA-26
TEST READING HA-26
Trouble Diagnoses for Abnormal Pressure HA-27
Harness Layout. HA-31
Circuit Diagram - Air Conditioner HA-34
Wiring Diagram - HEATER - HA-36
Wiring Diagram - AIC - HA-38
Main Power Supply and Ground Circuit Check HA-49
(SYMPTOM: Blower motor does not rotate.) HA-50
(SYMPTOM: Intake door does not change.) HA-52
(SYMPTOM: Magnet clutch does not operate when A/C switch and fan switch are ON.)
- For GA and SR engines HA-54
- For CD engine HA-59
Electrical Components Inspection HA-62
Control Linkage Adjustment HA-64
System Description HA-65
HA-14
TROUBLE DIAGNOSES

and Accurate Repair
WORK FLOW
_________ C_H_EI_K_I_N I +-1 Reference item
.--------------,
LISTEN TO CUSTOMER COMPLAINT AND CONFIRM BY Operational check
+-
PERFORMING OPERATIONAL CHECK. (Refer to HA-16.)
Symptom Chart (Refer
to HA-18.)
INVESTIGATE IT-EMS YOU SHOULD CARRY OUT Symptom Chart

+- (Refer to HA-18.)
RELATED TO EACH SYMPTOM.
ELIMINATE GOOD SYSTEM(S)/PART(S). +- Preliminary Check

(Refer to HA-20.)
CHECK MAIN POWER SUPPLY AND GROUND CIR- +- Main Power Supply and
CUITS. Ground Circuit Check
(Refer to HA-49.)
• Diagnostic Proce- ELIMINATE GOOD PART(S)/HARNESS(ES)/ Harness layout (Refer to

+- HA-31.)
dure(s) (Refer to CONNECTOR(S) ELECTRICALLY.
HA-50.)
• Circuit Diagram
(Refer to HA-34.) Malfunctioning Malfunctioning
harness( es)/ part(s)
connector(s)
INSPECT EACH COM- Electrical Components
+-
PONENT. Inspection
(Refer to HA-62.)
I REPAIR.
•
NG FINAL CHECK
CHECK OUT
HA-15
TROUBLE DIAGNOSES
Operational Check
The purpose of the operational check is to confirm that the sys-
tem operates as it should. The systems which are checked are
the blower, mode (discharge air), intake air, temperature
decrease, temperature increase.
CONDITIONS:
Engine running at normal operating temperature.
PROCEDURE:
1. Check blower
1) Turn fan control knob to 1-speed.
Blower should operate on 1-speed.
2) Then turn fan control knob to 2-speed.
3) Continue checking blower speed until all four speeds are
checked.
4) Leave blower on 4-speed.
RHA315F
2. Check discharge air.

1) Turn mode control knob.
RHA316F
2) Confirm that discharge air comes out according to the air

Discharge air flow
distribution table at left.
Refer to "Discharge Air Flow" in "DESCRIPTION" (HA-12).
Switch Air outlet/distribution
model RHD models LHD models
indicator Face Foot Defroster Face Foot Defroster
_e - - -
II 100% - 100%
"#Ie 60% 40% - 60% 40% -
-
"J 80% 20% 14% 65% 21%
,,<flj,; - 60% 40% 13% 57% 30%
W - - 100% - - 100%
RHA317F
HA-16
TROUBLE DIAGNOSES
Operational Check (Cont'd)
3. Check recirculation
1) Pre~s recirculation switch.
2) ~.eclrculati~n indicator should light
Isten for Intake door position ch'an
blower sound change slightly). ge (you should hear
RHA318F
4. Check temperature decrease

~~ ~~~nC~ef~~~~~~ur~cont:ol knob to full cold.
air at discharge air outlets.
RHA319F
5. Check temperature increase

~~ ~~rn ~efmperatu:e control knob to full hot
ec or hot air at discharge air outlets:
RHA320F
6. Check air conditioner switch

Turn fan control knob to the desired 1
a~? push the air conditioner 't h ( to 4-speed) position
dltlOner. SWI c to turn ON the air con-
The
ON. indicator light should com e on when air. conditioner is
RHA321F
•
HA-17
TROUBLE DIAGNOSES
Symptom Chart
DIAGNOSTIC TABLE
Main Power
Preliminary Diagnostic Supply and
PROCEDURE
Check Procedure Ground Circuit
Check
REFERENCEPAGE 0
N N C') 0 N O'J O'J O'J
N N N LO LO "'"
LO
"'.d:" "'"
.d: .d: .d: .d: .d: ~
I
.d: "'.d:" .d:

:c :c :c :c :c :c :c :c :c :c
~ N C')
Q) Q) Q)
~ N C') .... .... .... ci.
-'"
u -'"
u
-'"
u
"'-'"u" :J
"0
Q)
:J
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Q)
:J
"0
Q)
E
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u
Q)
.c
u
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Q)
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u
Q)
.c
u
Q)
.c
u
0
....
0.
u
0
....
0.
u
0
....
0.
eC
~ >.
.... ....>. u u u 0
~ «l «l «l
UJ
OJ
UJ
Q) u
c
.- c
.- c c
.- ~0 ~0 ~ UJ UJ 0
0 :J
E
.- E E .E
- c c c u.. .2 E
SYMPTOM - OJ OJ OJ ~ ....
~ OJ
.... Qj
....
Qj
.... «l «l «l ~ LO
Q)
.c
a.. a.. a.. a.. Ci Ci Ci ~
LO
r-- f-
AIC does not blow cold air. 0 0 0 0 0 0

Blower motor does not rotate. 0 fj ()
Insufficient heating 0 ()
Air outlet does not change. 0

Intake door does not change. 0 0 0
Magnet clutch does not operate when
0 fj 0 0 0
AIC switch and fan switch are ON.
Noise 0
0, fj: The number means checking order.

C : As for checking order, refer to each flow chart. (It depends on malfunctioning portion.)
HA-18
TROUBLE DIAGNOSES
Symptom Chart (Cont'd)
c c
.8 on0 .8 tl
.Q
C\J
CD
C')
CD
C')
CD
C')
CD
C\J
CD
-.r
CD
C')
CD
-.r
CD
C')
CD
.... Q)
CfJ
....
Q)
Q) Q) CfJ
I
<i: <i: <i: « <i: <i: <i: <i: <i: Qj 0 Qj -l

I I I I I I I I I a:: w a:: w I
Q)
:J
"'0
0
E
.
~
c 0
(.)
Q)
c
Ol
c
~
.... ~
0 0
CfJ W
CfJ
Q)
.... Q)
a. :J
E "'0
0 0
r. 0 E
r. ci. .B
.B E .~ .... ~ EQ)
.~ crl 0
C
.... CfJ - CfJ
tl 0
tl
>.
.... 0
c
0
.... Q)
.... Q) (.)
CfJ
0
(5
~ 0 C :J (5
.... (/J c
E
CfJ
Q)
....
r.
.B :; r.
.B >.
0
(.)
CfJ
CfJ
Q)
a. 0
0 .~
0
.... .... .~ :J .~ crl

0 .... Ci3 w c
CfJ
CfJ
~ OJ 9-
Q)
~
Q)
~ CfJ
0 (.)
CfJ
c
....
0
E
....
Q) Ci3
E
Q) ~ E
Q)
c
....
0 0
iii iii ;;: OJ
a::
crl
LL ;;: r.
I-
:J
0
r.
I-
0
W -
:J
-
-
crl
I
() 0 0 0 0 0 () 0 0 0
0 0 0 ()
0
() 0
(0) () ()
0 0 (:: 0 ()
HA-19
TROUBLE DIAGNOSES
Preliminary Check
PRELIMINARY CHECK 1
Ale does not blow cold air.
DOES AIR FLOW FROM VENTS? IS BLOWER MOTOR OPERATING
Condition NORMALLY?
• Engine running at operating tem-
perature . Yes
• Ignition switch, AIC switch, and
fan switch are ON.
CHECK BLOWER
• Mode control knob is in VENT
MOTOR OPERATION.
mode and temperature control
Go to Diagnostic Pro-
knob is in full cold position.
cedure 1. (HA-50)
Yes
CHECK COMPRESSOR BELT TEN- CHECK COMPRESSOR OPERA- CHECK FOR EVAPORATOR COIL
SION. TION. FREEZE UP.
Refer to "Checking Drive Belts" in Remove intake unit. Check if evap-
MA section. OK orator freezes.
NG OK
Adjust or replace CHECK REFRIGERATION CYCLE

compressor belt. PRESSURE WITH MANIFOLD NG OK
Refer to MA section GAUGE CONNECTED. (Freeze up.) (Does not
("ENGINE Refer to Performance Chart. (HA- freeze up.)
MAINTENANCE"). 26)
NG OK
CHECK REFRIGERANT. CHECK VENTILATOR

Connect manifold gauge then DUCT FOR AIR
check system pressure. LEAKS.
Refer to Performance Chart. (HA-
26)
Go to Performance CHECK THERMO CONTROL AMP.
OK NG Test Diagnoses. (HA- OPERATION.
24) Refer to Electrical Components
Inspection. (HA-63)
NG
CHECK FOR REFRIG- CHECK WATER COCK OPERA- Adjust or replace water cock.
ERANT LEAKS TION.
Warm up engine before checking.
Refer to HA-64.
OK
NG
Go to Diagnostic Procedure 3. CHECK TEMPERATURE CONTROL Adjust temperature control cable.
(HA-54) CABLE.
Refer to Control Linkage Adjust-
ment. (HA-64)
OK
NG
VISUALLY INSPECT AIR MIX Replace air mix door.
DOOR.
Access by removing instrument
panel.
OK
CHECK THERMO CONTROL AMP.

OPERATION.
Refer to Electrical Components
Inspection. (HA-63)
HA-20
TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
PRELIMINARY CHECK 2
Air outlet does not change.
TURN IGNITION SWITCH AND FAN SWITCH ON. DOES AIR No Adjust mode control cable. Refer to
COME OUT NORMALLY FROM EACH DUCT WHEN EACH HA-64.
MODE SWITCH IS PUSHED?
Discharge air flow
Switch Air outlet/distribution

model RHO models LHD models
indicator Face Foot Defroster Face Foot Defroster
iI 100% - - 100% - -
.
,7,./ 60% 40% - 60% 40% -
,~ - 80% 20% 14% 65% 21%
,~ - 60% 40% 13% 57% 30%
\tEl - - 100% - - 100%
res
INSPECTION END
HA-21
TROUBLE DIAGNOSES
Preliminary Check (Coni' d)
PRELIMINARY CHECK 3
Noise
Check where noise comes from. I

I
Blower motor
I Compressor Expansion valve I Refrigerant line I I Belt
I
Check for noise Inspect the com- Replace expan-

in all modes and pressor clutch sion valve.
temperature set- and pulley and
tings. idler pulley.
Noise is OK NG
constant.
Check blower Replace The line is fixed The line is not

motor for for- compressor directly to the fixed.
eign particles. clutch and body.
pulley.
Refer to
HA-77.
Check blower Check disc-to- Fix the line with Fix the line
motor and fan pulley clearance. rubber or some tightly.
for wear. Refer to HA-79, vibration absorb-
82. ing material.
OK
Check and adjust

lubricant.
Refer to HA-68.
OK
Replace com- The belt vibra- Side of belt is

pressor and tion is intense. worn out.
liquid tank.
Noise is
interm ittent. Readjust belt The pulley cen-
tension. ter does not
Check air dis- Refer to MA match.
charge ducts section ("Check- Readjust the pul-
for obstruc- ing Drive Belts", ley center.
tions, foreign "ENGINE
materials or MAINTENANCE").
air leakage.
HA-22
TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
PRELIMINARY CHECK 4
Insufficient heating
DOES AIR FLOW FROM FOOT AREA? No CHECK BLOWER MOTOR

Condition: OPERATION.
• Vehicle at operating temperature . Perform Diagnostic Proce-
• Ignition switch and fan control knob are ON. dure 1. (Refer to HA-50.)
• Mode control knob is in FOOT mode and tem-
perature control knob is in full hot position.
Check the following: NG Repair/replace as neces-

• Engine coolant level (Refer to MA section) sary .
• Hoses for leaks or kinks
• Radiator cap (Refer to LC section)
• Air in cooling system.
CHECK WATER COCK OPERATION. NG Adjust or replace water

Warm up engine before checking. cock.
Refer to HA-64.
OK
CHECK TEMPERATURE CONTROL CABLE. NG Adjust temperature control

Refer to Control Linkage Adjustment. (HA-64) cable.
VISUALLY INSPECT AIR MIX DOOR. NG Replace air mix door.

Access by removing instrument panel.
OK
Check by feel the heater inlet and outlet hoses.
Hot inlet Both hoses

Warm outlet warm
Check thermostat installa- Check heater hoses for proper

tion. installation.
to LC section
OK
Replace thermostat. Refer
("Thermostat", "ENGINE
COOLING SYSTEM").
ant. Retest.
Hot inlet
OK
Back flush heater core, drain and refill cool-
Both hoses
•
Warm outlet warm
System OK Replace heater

core.
HA-23
TROUBLE DIAGNOSES
Performance Test Diagnoses

INSUFFICIENT COOLING
INSUFFICIENT COOLING
CHECK AIR FLOW. CHECK BLOWER MOTOR OPERATION.
OK OK
@
CHECK COMPRESSOR OPERATION. Clogged blower inlet!
(Go to
Clogged duct/Loose duct
OK next
connection/Air leakage, etc.
page.)
<ID
(Go to
next page.)
OK
CHECK HIGH AND LOW SIDE PRESSURE. USE
PERFORMANCE CHART. (Refer to HA-26.)
NG
RECOVER REFRIGERANT USING RECOVERY

RECYCLING EQUIPMENT AND CHARGE SPECI-
FIED AMOUNT OF REFRIGERANT.
Note
NG
CHECK HIGH AND LOW SIDE PRESSURE.
PERFORMANCE CHART. (Refer to HA-26.)
USE
BOTH HIGH AND LOW m
PRESSURE SIDES ARE
OK TOO HIGH.
CHECK DISCHARGE AIR TEMPERATURE. USE HIGH PRESSURE SIDE IS

(;]
PERFORMANCE CHART. (Refer to HA-26.) TOO HIGH AND LOW
PRESSURE SIDE IS TOO
NG LOW.
HIGH PRESSURE SIDE IS

TOO LOW AND LOW
PRESSURE SIDE IS TOO
HIGH.
Malfunctioning temperature control operation BOTH HIGH AND LOW

Ii]
(air mix door position improperly adjusted)/ PRESSURE SIDES ARE
Malfunctioning water cock operation (incorrect TOO LOW.
valve closure)
LOW PRESSURE SIDE

SOMETIMES BECOMES
NEGATIVE.
Note: Fa-Ii correspond to those in TROUBLE DIAGNOSES FOR LOW PRESSURE SIDE
BECOMES NEGATIVE. Ii
ABNORMAL PRESSURE.
(Refer to HA-27.)
HA-24
TROUBLE DIAGNOSES
Performance Test Diagnoses (Cont'd)
@
Malfunctioning blower motor fan Malfunctioning electrical circuit Malfunctioning blower motor
internal circuit
Loose fan!lmproper contact of fan Discontinued wiring or component

and case!Deformed fan circuits or poor connection!
Malfunctioning resistor, amplifier,
etc.! Burned out fuse or low bat-
tery voltage
Magnet clutch does not engage. Magnet clutch slipping Belt slipping
CHECK MAGNET CLUTCH CHECK COMPRESSOR BELT AND

(coil circuit, disc-to-pulley clear- BELT TENSION.
ance).
CHECK ELECTRICAL CIRCUIT Malfunctioning internal parts of

(wiring, components circuit). clutch, compressor
CHECK ACTIVATION OF SAFETY! Foreign particles on clutch fric-

PROTECTION DEVICES (such as tional surface or excessive disc
pressure switch, etc.). clearance
Malfunctioning electrical circuit

(poor connection, low battery
voltage, etc.)
•
HA-25
TROUBLE DIAGNOSES
Performance Chart
TEST CONDITION
Testing must be performed as follows:
Vehicle location: Indoors or in the shade (in a well-venti-
lated place)
Doors: Closed
Door window: Open
Hood: Open
TEMP.: Max. COLD
Discharge Air: Face Vent
REC switch: (Recirculation) set
FAN speed: High speed
Engine speed: Idle speed
Operate the air conditioning system for 10 minutes before
taking measurements.
TEST READING
Recirculating-to-discharge air temperature table
Inside air (Recirculating air)

at blower assembly inlet Discharge air temperature at center ventilator
Relative humidity Air temperature .C ('F)
% .C ('F)
25 (77) 11.4 - 13.6 (53 - 56)
30 (86) 15.7 - 18.3 (60 - 65)

50 - 60
35 (95) 20.5 - 23.8 (69 - 75)
40 (104) 26.0 - 30.8 (79 - 87)
25 (77) 13.6 - 16.0 (56 - 61)
30 (86) 18.3 - 21.1 (65 - 70)

60 - 70
35 (95) 23.8 - 27.4 (75 - 81)
40 (104) 30.8 - 36.0 (87 - 97)
Ambient air temperature-to-operating pressure table
Ambient air
High-pressure (Discharge side) Low-pressure (Suction side)
Relative humidity Air temperature kPa (bar, kg/cm2, psi)
% .C ('F)
.
892 - 1,138
25 (77) 118 - 226 (1.18 - 2.26,1.2 - 2.3,17 - 33)
(8.92 - 11.38, 9.1 - 11.6,129 - 165)
1,108 - 1,393
30 (86) 137 - 265 (1.37 - 2.65,1.4 - 2.7,20 - 38)
(11.08 - 13.93, 11.3 - 14.2, 161 - 202)
50 - 70
1,344 - 1,677
35 (95) 177 - 314 (1.77 - 3.14,1.8 - 3.2, 26 - 46)
(1344 - 16.77,13.7 - 17.1, 195 - 243)
1,589 - 1,971
40 (104) 226 - 373 (2.26 - 3.73, 2.3 - 3.8, 33 - 54)
(15.89 - 19.71,16.2 - 20.1, 230 - 286)
HA-26
TROUBLE DIAGNOSES
Trouble Diagnoses for Abnormal Pressure

Whenever system's high and/or low side pressure is abnormal, diagnose using a manifold gauge. The
marker above the gauge scale in the following tables indicates the standard (normal) pressure range.
Since the standard (normal) pressure, however, differs from vehicle to vehicle, refer to HA-26 ("Ambi-
ent air temperature-to-operating pressure table").
Gauge indication Refrigerant cycle Probable cause Corrective action
Both high and low-pressure • Pressure is reduced soon Excessive refrigerant charge Reduce refrigerant until spec-
sides are too high. after water is splashed on in refrigeration cycle ified pressure is obtained.
m condenser.
Air suction by cooling fan is Insufficient condenser cooling • Clean condenser.

insufficient. performance • Check and repair cooling
! fan as necessary.
CD Condenser fins are
clogged.
@ Improper fan rotation of
cooling fan
• Low-pressure pipe is not Poor heat exchange in con- Evacuate repeatedly and
cold. denser recharge system.
• When compressor is (After compressor operation
stopped high-pressure stops, high pressure
AC359A
value quickly drops by decreases too slowly.)
approximately 196 kPa (2.0 1
bar, 2 kg/cm2, 28 psi). It Air in refrigeration cycle
then decreases gradually
thereafter.
Engine tends to overheat. Engine cooling systems mal- Check and repair each
function. engine cooling system.
• An area of the low-pres- • Excessive liquid refrigerant Replace expansion valve .
sure pipe is colder than on low-pressure side
areas near the evaporator • Excessive refrigerant dis-
outlet. charge flow
• Plates are sometimes cov- • Expansion valve is open a
ered with frost. little compared with the
specification.
1
CDImproper thermal valve
installation
@ Improper expansion valve
adjustment
HA-27
TROUBLE DIAGNOSES
(Cont'd)
High-pressure side is too Upper side of condenser and High-pressure tube or parts • Check and repair or
high and low-pressure side is high-pressure side are hot, located between compressor replace malfunctioning
too low. however, liquid tank is not so and condenser are clogged parts .
hot. or crushed. • Check lubricant for contam-
ination.
AC360A
High-pressure side is too low High and low-pressure sides Compressor pressure opera- Replace compressor.
and low-pressure side is too become equal soon after tion is improper.
high. compressor operation stops. 1
[;J Damaged inside compressor
packings
No temperature difference Compressor pressure opera- Replace compressor.

between high and low-pres- tion is improper.
sure sides 1
Damaged inside compressor
packings
AC356A
80th high- and low-pressure • There is a big temperature Liquid tank inside is clogged • Replace liquid tank.
sides are too low. difference between liquid a lillie. • Check lubricant for contam-
I!] tank outlet and inlel. Outlet ination.
temperature is extremely
low .
• Liquid tank inlet and expan-
sion valve are frosted.
• Temperature of expansion High-pressure pipe located • Check and repair malfunc-
valve inlet is extremely low between liquid tank and tioning parts.
as compared with areas expansion valve is clogged. • Check lubricant for contam-
near liquid tank. ination.
• Expansion valve inlet may
be frosted .
• Temperature difference
AC353A occurs somewhere in high-
pressure side
HA-28
TROUBLE DIAGNOSES
(Cont'd)
Both high- and low-pressure There is a big temperature Expansion valve closes a lit- • Remove foreign particles
sides are too low. difference between expansion tle compared with the specifi- by using compressed air.
l!] valve inlet and outlet while cation. • Check lubricant for contam-
the valve itself is frosted. 1 ination.
CD Improper expansion valve
adjustment
@ Malfunctioning thermal
valve
@ Outlet and inlet may be
clogged.
An area of the low-pressure Low-pressure pipe is clogged • Check and repair malfunc-
@ pipe is colder than preas or crushed. tioning parts.
near the evaporator outlet. • Check lubricant for contam-
ination.
Air flow volume is not Compressor pressure opera- Replace compressor.
AC353A enough or is too low. tion is improper.
1
Damaged inside compressor
packings
Low-pressure side some- • Air conditioning system Refrigerant does not dis- • Drain water from refriger-
times becomes negative. does not function and does charge cyclically. ant or replace refrigerant.
Ii not cyclically cool the com- 1 • Replace liqUid tank.
partment air. Moisture is frozen at expan-
• The system constantly func- sion valve outlet and inlet.
tions for a certain period of 1
time after compressor is Water is mixed with refriger-
stopped and restarted. ant.
AC354A
HA-29
TROUBLE DIAGNOSES
(Conl'd)
Low-pressure side becomes liquid tank or front/rear side High-pressure side is closed Leave the system at rest until
negative. of expansion valve's pipe is and refrigerant does not flow. no frost is present. Start it
Ii frosted or dewed. L again to check whether or
Expansion valve or liquid not the problem is caused by
tank is frosted. water or foreign particles .
• If water is the cause, ini-
tially cooling is okay. Then
the water freezes, causing
a blockage. Drain water
from refrigerant or replace
refrigerant.
• If due to foreign particles,
remove expansion valve
and remove the particles
with dry and compressed
AC362A air (not shop air).
• If either of the above meth-
ods cannot correct the
problem, replace expansion
valve .
• Replace liquid tank .
• Check lubricant for contam-
ination.
HA-30
TROUBLE DIAGNOSES
Harness Layout
ENGINE COMPARTMENT
•
RHA322F
HA-31
HA-32
TROUBLE DIAGNOSES
Harness Layout (Co nt' d)
LHD models
Thermo control amp. (M61)

\--7/
,-.....
I \
I
l~'
I \
•
RHA324F
HA-33
TROUBLE DIAGNOSES
Circuit Diagram - Air Conditioner
AIR
CONDITIONER
RELAY
M BLOWER
MOTOR IT
o
f-
U1 THERMO
H
~
IT
CONTROL
AMP.
DUAL-
AIC W PRESSURE
SWITCH I SWITCH
f-
FAN
RESISTOR
GE C
FAN SWITCH
OFF1234 GA D
IT
o
..JI-
«u
~w
IT I-
wo
To illumination IIT
f-(L
system
RECIRCULA nON IT
SWITCH o o
U1 uo
U1 HH
W [LO
IT IZW
(L >w>
~ U..J....J
1
o 404
u HUJ>
@: AIT models
@: MIT models
@: Except @
@: GA engine models
@: Except f or Europe, I srae 1 and Austra 1i a
@: GA eng ine f or Europe, Israe 1 and Austra 1 ia and SR eng Ine
@: Except @
<Q:>: LHD AIT models for Europe without daytIme light system
@: Except <Q:>
*1 @ 41. @ 44
HHA001
HA-34
TROUBLE DIAGNOSES
Circuit Diagram - Air Conditioner (Cont'd)
---------,
I
I
I
(!) ~ (!) [\J
Z I Z I I
H >- H >- COOLING
-I <l: -I <l: FAN I
OZ-I OZ-I I
O<l:W O<l:W RELAY-l
ULLCI: I
ULLCI:
I
I
I
A
I
I
A
I
Z Z I
<t <t
LL LL B I
I
(!)[\J
ZI I
HCI: I
-10
01- I
00 I
U::E
<{ I
-' M I
I
41119 10 4541 *1119 10 I

I
ECM(ECCS ECM(ECCS COOLING COOLING I
CONTROL CONTROL FAN FAN I
MODULE) MODULE) MOTOR-l MOTOR-2 I
L ~ L
@ @ ~I
(SR20DE engine AIT models) (GA engine except for Australia

and SR20DE engine MIT models)
,
Z Z Z I
<l: <l: <t I
LL LL LL
I COOLING COOLING
(!)(Tl
(!) ....
ZI
(!)(\J
ZI ZI I FAN FAN
H>-
-I<t
0-1
H>-
-I<t
0-1
H>-
-I<t
0-1
,
I RELAY-l RELAY-2
@
ow ow
UCI:
ow
ucr
I
UCI: I
I
I
I
I
I
A A
I
I
I
Z Z
<l: <t I
•
LL LL I COOLING COOLING
(!)~ (!)(\J I FAN FAN
B ZI ZI I
o MOTOR-l MOTOR-2 M
HCI: HCI:
-10
01-
-10
OI-
I @ @ COOLING
00 00 I
U::E U::E I
FAN
I MOTOR-2
I @
I
I
I
31 B 9 10 I 35 21 15 13 14
I
ECM(ENGINE I
ECMIECCS
CONTROL MODULE) CONTROL MODULE)
I
I
L J
(C020 engIne) (GAI6DE engIne for AustralIa)
HHA014
HA-35
TROUBLE DIAGNOSES
Wiring Diagram - HEATER -
HA-HEATER-01
<0: LHO models

Refer to EL-POWER. (8): RHO models
@: Except@
FUSE t LIB
15A BLOCK
T (JIB)
L..:..J ~ ~
IN31 ~~~~ST""
L!W
•
L/W
L.l L/W L/Y L/R
1
I
L/W .,--I-~r=t
t
:4
r
L/W
I
L/Y L!R
I I:31 12~1 Ii2'nJ
LIB RIG
n1=iI
RIG. To EL-m
BLOWER
M MOTOR
~ FAN
~I!.j.JJ SWITCH
@
LIB ILL. ~
~ ~
B B
~ol __ 1 I
II < ------.~o--l
 JOINT
B CONNECTOR-4
1 Li tJ Lt 1 B {J gj. B ~Next page
\~ ~/ \~ ~ ~/
<0 
~--------------------, Refer to last page
(Foldout page) .
i~@~~:
I~W
I
2 Wi
I
l1IillIITillIil ~
~P
~
L ~
I I
HHA012
HA-36
TROUBLE DIAGNOSES
Wiring Diagram - HEATER - (Conl'd)
IGNITION SWITCH
HA-HEATER-02
ON
EE
Refer to EL-POWER.
7.5A FUSE
BLOCK
III (JIB)
~
IN21
•
LG/R
(b): LHD models

@: RHO models
@: For Europe and Israe 1
@: Except@
*1 (6) GIS ViS
INTAKE
DOOR
*2 <0 G/Y ,, @ Y/R
MOTOR
~
LG/R
ffi
RECIRCULATION
SWITCH
INDICATOR ~
~
B
Preceding ~ B
I
page ~ ~O L
r-------------------, Refer to last page

(Fo'ldout page) .
1~ ~~)1
•
~~
~W
:
L (b) @ :
~
HHA013
HA-37
TROUBLE DIAGNOSES
Wiring Diagram - Ale -
HA-A/C-01
IGNITION SWITCH
ON Q: LHO models
IGNITION SWITCH Refer to EL-POWER. <ED: RHO models

ACe or ON @: For Europe and Israel
@: Except@
LIB @: CD engine RHO models
15A
IT] m
15A
FUSE
BLOCK
(JIB)
~
t ~~~~::OR -(0 Gty· LGtS
@
IN31
-
.,__LI~I_;~fr-
L/W L/W ~
L.l *1 ~TO HA-A/C-03
L/W
I .. RIG ~ To EL-ILL
1 t L/W L/Y LlR LIB *1 RIG

BLOWER 12-4 1 12-3112~I Ii2'ilI 12-51 n=tn
M MOTOR
(fill) FAN
SWITCH
I!:j:lI
~
~
LIB ILL. @
~ lbi=ll
B B
rro::::::-.--::::;8::-- --o:::: L
1
__ 1
...

B
JOINT
CONNECTOR-4
1 ~:<ED
~ {} B .--- B f> Next page
IW'ia\
\~ ~I
~
\~
~
~ ~I ~
fiI-
~
B =~ B .JC'-.- To
~-06
HA-A/C
Q <ED
(Foldout page) .
I 0 I
I
1~@1~1 ~ I
m:ITillIillIill @ ~
I~W 2 Wi ~P
I I
I I
~--------------------~
HHA002
HA-38
TROUBLE DIAGNOSES
Wiring Diagram - A/C - (Conl'd)
HA-A/C-02
Refer to EL-POWER.
FUSE
BLOCK
(JIB)
<fill)
(HOB)
LG/R ~ To HA-A/C-04
LIB -@>}
..J?-....... Next page
LG/RV
INTAKE
DOOR
MOTOR <D: LHO mode Is
~ <ID: RHO models
@: Except@
*2 ... (0 G/B , @ Y/B
*3"'(0 G/Y , @ Y/R
LG/R
m
RECIRCULATION
SWITCH
~
INDICATOR
~
B
Preceding -4 B
I
page ~ ~O L
r-------------------, Refer to last page

•
~~
:~ ~W:
I~ ~~I
~ , (~i9B)
~W
: (0 @ :
~-------------------~
HHA003
HA-39
TROUBLE DIAGNOSES
Wiring Diagram - A/C - (Cont'd)
HA-A/C-03
Refer to EL-POWER.
Preceding~ ~
page LIB' I
L/Y
:
<ID:
@:
@:
@:
LHO models
RHO models
GA engine
GA engine for
and Australia
Except@
Europe. Israel
and SR engine
IT ]1,rR
LIB L/Y
*1"'(0 G/Y , <ID LG/B
n CONOITIONAER *4"'(0 G/B , <ID GY
U RELAY *5... @Y , @L
1bi=Jl1!:l=Jlm>
*5 L/R
....
I I .... L/R -@> To
*5 ~Next
HA-A/C-06
page
-4-
Preceding~LG/R"""""'1 *4 -(t> Next page
page ~
LG/R
I
u=tru
A!C
SWITCH
~
.:., INDICATOR ~
To HA-A/C-01 ~ *1
I *1 ~ -4- *1 -e> To HA-A/C-05
O~I-O-eb:>-
•
0~O~
G/Yi8J
G/Y
~
(j
JUNCTION
BOX No.2
(~g~~~CTORS)
1
_IIIIIIC~::. • G/Y (j ~ :(0
Refer to last page

(Foldout page) .
LQl@ ~
~ W
HHA004
HA.40
TROUBLE DIAGNOSES
Preceding
page
To HA-AlC-02
~
~
*5
<e}-lG/R...,
---------O~
+ ..-----I GX l
HA-A/C-04
lG/R ~
THERMISTOR IFti
THERMO
CONTROL
~--:t>
Y
r.!" ~ ~~
Y
LOW • HIGH
... ...,.. -.
NORMAL
OUAl-
PRESSURE
SWITCH
m:@
A~~FIER "¥JICHID"~AIICHID lUll
y y =r'
I6j:JJ
*6
<;> @ I
o• 0--1,-0
~ 
_loJt t
G
I$I~II~I~
CMID '"T'
G
CBID
~
S8
S8
GX .~
G
@
G
I$I
CBID
1r$J1CMID o~o--l
*__
•
S8m
S8
1>
S8m
o
•
(b):
<iD:
....
lHO modeIs
RHO models
*7
@: GA engine for Europe, Israel

and Australia and SR engine
-B> Next page
m + R
@: Except@
@: Except for Europe, Israel
~ OUAl- 'j/ ~ and Australia
......, ..-. .l,m..l:.~

PRESSURE
lOW HIGH SWITCH *4 ... (b) G/8, GY <ID
~:@ I~I II3.eII *5',,@y ,@l
NORMAL ""'iF' CMID CHID
G G *6 ... @ S8 , @ RIL
~OL> @*7"'@Y,@G
- "1"--1 XE *8".@G ,@R/l
Preceding
page
-<!}- *4 - -------:~ 0
~O ...... -.-_. G*8 ~}
y
~
Next page
Refer to last page
•
(Foldout page) .
2
~~ W cftID~
1 2 8
(~) ,~
3
HHA005
HA-41
TROUBLE DIAGNOSES
HA-A/C-05
(b): LHD models @: GA engine for Europe, Israel and

Australia and SR engine
 : RHO models
@: GA engine @: Except@
@: CD engine *1 ... (b) G/Y LG/B
@: For Europe and Israel *7"'@ Y '@G
,
@: Except@ *8,'.@G @R/L
@: GA engine for Australia *9 ... @ 11 , @ 15
@: Except@ *1O .. @ 41 , @ 21
@: GA engine and SR engine *11"@ 45 , @ 35
@: Except for Europe, Israel *12"@ 4 @ 5
and Australia *13"@ 5:@ 4
-
I _
preCeding{:;t ::
page ~
<@- GY
To HA-A/C-03~ *1
1 ~f CDr~+
*1 GY R/L G *7 R/L G
CVl (Ij) m
1iTm~ 4.QJ -- rn
~ -- ~
IIIi21 -- ffilill
£31
111
~A/C m
COMP ECM
(ENGINE
*1 GY R/L G *7 CONTROL
It
*1
It It It I~
GY R/L G *7
MODULE)
@:@)
mmu IF4'1n Ii14iI III~oI I*-91

H/FAN ARCON THAMP ARCON ACRLY ECM
(ECCS
@ @ <ID @ CONTROL
MODULE)
CED:@
Refer to last page

(Foldout page) .
@
W
em
@
HHAO06
HA-42
TROUBLE DIAGNOSES
-. HA-A/C-06
To HA-A/C-03 ~ L/R ---'. o~o 1
ES
L/R
I ~
<C>
(EIOt)
~
~(@t)
rI!. o~14) I~I 116,.B II
~Cill> ~CHID L/R CHID
iemp
O
- Hi-
temp
THERMAL
PROTECTOR
L/R
I L/R ~, .... @
o ~m~-"!_I J
0-,
------ (E207)-1
SOLENOID
t
VALVE
SR I!:i=!l ~
a @ <0>
------. ~@ ~~
JR ~(Blu)
L/R
[4J
L/R
(ffi)
ocr rn irh
iemp
O- Hi-
temp
THERMAL
PROTECTOR
IACV-
~6E~NOIO
VALVE
• ..,
VALVE
IACV-
~ ~6E~NOIO
t67i\i\
W Mg~- SOLENOID
VALVE
------ (~)-1
~ (~). !1i=!J \!ill!!I Ill~61 m:@
J,~ 1 1 a @w a CEID:@
COMPRESSOR T'C..!.S'
IWIIE"f"\' ~?) @J) r=!=(Qill)
I~I @

(E20j) -2 a GA
~
To HA-A/C-01 ~ B
..- ._1::::::::::::::1~0
~ 'I
<D: LHO models @: Except@ To ECM
@:
@:
@:
RHO models
GA engine
GA engine for Europe
@:
@:
CD engine
CD engine RHO models
and GA engine
RHO mOdels
In
• (ECCS
• a/y ~ control
module)
and Israel
~SZR :. GA engine
~
@:
SR engine
Except@
excePt@*15
*14 .. @ E24 ,@ E27
.. @E202,@E201
*16 .. @ 2, @ 5
t
IJ l B/Y B B
@: CD engine LHO models G:14) a:1~)

Refer to last page
(Foldout page) .
~ @ID: IT! @@ill)

W5J @'@)
GY I
,
I a a
@}
@@W:
@'@)
a a
I
I
I
12:<]
(ill)
ffi
PU ~
~ CEID
BR
CHID , <illD
•
~--------------------~
~U?J
~ GY
HHA007
HA-43
TROUBLE DIAGNOSES
Wiring Diagram - A/C - (Conl'd)
COOLING FAN CONTROL
SR20DE engine MfT models, GA engine MfT models, GA engine AfT models - except for
Australia
HA-A/C-07
BATTERY (Via
fusible link)

30A BLOCK
(JIB)
m <illID
GY IQ~OI
I--I BR
I
<0:LHO mode Is
@: RHO models
GY SR @: GA engine for Australia
'X (OCLING
@: Except@
In
U~I
FAN
RELAY-1
*17"@9 @14
•
1bi=JJ1'=iJI<rn>
G/B LG/R
~ OotS)
I I O-eDoLG/RoI!jJoLG/Ri
G/B
T'---I
COOLING
G/B
COOLING
~LG/R~
~@
LGIR-eJD-O
I
LG/R~
1 FAN
M MOTOR-1
rn
~1 FAN
M MOTOR-2
m
rn
........
LG/R
@
IbiJl
I,
~ IbjJJ
B B
1_--1 LG/R
I nilln EeN
" 2
RFRL (ECCS
B B
-:!:-
mffi
-:!:-
I em
CONTROL
MOOULE)
Refer to last page

(Foldout page) .
+
2
5
1
<rn>
L
;Q..~~
~GY'GY
(MS), <ill])
~
em
HHA006
HA-44
TROUBLE DIAGNOSES
Wiring Diagram A/C (Cont'd)
GA engine AIT models for Australia
HA-A/C-08
BATTERY (Via
fusible link)

BLOCK 30A
(JIB)
CE106)
IT]
la~OI
I
GY
.II_~.-----
BA
I------...l n I
I
~
I!' J11~'1
BA GY LG/B
~ ~ COOLING
3 BA GY COOLING ~ ~ ~~~AY-2
n FAN 1/ 2 1/ tEi7\
t
. U AELAY-1 '"'iF Ibi=H ~ 'I::.!v
IbjJI Ibi=ll ~ LG G!Y B
!I
~
LGI/A G~B
--,-I -
G/B G/Y
I
LG/A
r=!:::.~ LG 1/db1 II r.:::!::"
1/ 2 II
COOLING COOLING
113.JIt-c~)-- - -- - - - - ~I~" ~) ~) FAN FAN
La MOTOA-1 MOTOA-2
LGfR LG m Hi
H
La
H ~
~4=H
LG/R
It=!:J ~~9Z________
LG/A @ -
I~t!J1
LG
LG/B
£-1
B
•I
r=!:::. LG
1IT4l1
AFAL
~
1[I3]1
RFAL Il~~CS
f,
B B
CONTROL ..... .....
(
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57
36
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BR
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(Foldout page)~age
CHID,
~
(ill
(Ei0t)
•
"
HHA009
HA-45
TROUBLE DIAGNOSES
GA engine AfT models - for Europe LHD without daytime light system (with dealer installed
towing kit)
HA-A/C-09
BATTERY (Via
fusible link)
-
BLOCK 30A
(JIB) r-e-t
(El06) ~
IQ;OI GY
SR GY LG/S
BR _ 1_
f-p:=_e:::::- ~ ~ RELAY-2
BR GY
~~~rn> t
1:Jt1 :lJIICOOLING
n
U
IbjJJ ILi=U <ill>
LG/R G/B
FAN
RELAY-1 -T-.
GIS
LG
i
G/Y
G/Y@
I '
I
S
GIS
• I G/Y ID
I
LG/R~ LG
IciJ~- t~J1@D
GIS
mm
La
1+)
G/Y
Hi
(+) COOLING
$-$@g)
mrn
La
1+)
G/Y
GIS
Hi
1+)COOLING
Li~ I
~\EJQ!I ~ FAN FAN
~M8----------~ Hi La
MOTOR-1
~ Hi La
MOTOR-2
H H~ H H ~
IkjJJ ~ ~ ~
LG/S S @D LG/S S ~
IrjJ~- $ 66 IrjJ~- i$/ 6
LG/S S @ LG/S S ID
I-I
LG/R~ LG
Iqp~-~~---------~qpl
LG/RCEID LG &-_I!__ ~.,
2 m
RFRL
ffiJl
RFRL
ECM
(ECCS
I emCONTROL
MODULE)
S
~
~~
~
S
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(Foldout page) .
¥
2 CHID, <rnD
2
@
1 L
rffi\ @ID, @?), (f303), ~ 57 @
5
t:]JY GY GY GY GY 36 SR (El06)
em
"
@
W
HHA047
HA-46
TROUBLE DIAGNOSES
Wiring Diagram - Ale - (Cont'd)
SR20DE engine AIT models
HA-A/C-10
IGNITION SWITCH
ON or START
~J9~~~.j;l
Refer to EL-POWER.
10A FUSE
125 I 30A 30A
(El06) IT] [B]
GY G/W
I I
----,-I-F.~= BR GY G/W BR GY LG/B BR
I I
G/W LG/R
COOlING(!IIZ I~IICODLING11!1 ]II~II

~~~AY-1 . ~ ~ ~~~AY-2 ~ ~
CDDLINGI:i:
FAN
RELAY-3
1
:lJ1n
U
I~II
n U
m> ~ Il:i=lI 4=Jl @ I!:i=!I Il:i=lI 4=ll ~ I!:i=!I Il:i=lI n,;JJ
LG/R G/B G/R LG G/Y B LG G/OR B
r:r- ~r=!-JI
I$~
---~$I G/B G/R
1- -
1--& t t
LG CHIDLG/R m m
I I
LG ~LG/R
[+) COOLING
FAN
MOTOR-1
[+) COOLING
FAN
MOTOR-2
1c!J~ ~c!J1
-F~: Lo rn
Hi
(-)
lLjJJ
~
tt
CEID
LG
rl.
LG/R
LG/R B
IJ I f
~
LG
RFRH
LG/R
m
RFRL
ECM
(ECCS
___ I-_!,
CONTROL B B
MODULE) -!- -!-
(ED <rn>~
~
IIDm
m>,<UZ>,(E18)
BR BR BR
~
\MJ
m,(ffi)
GY GY
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(Foldout
CHID , (El01)
(lliID
(IT)
page) .
•
HHA010
HA-47
TROUBLE DIAGNOSES
CD20 engine models
HA-A/C-11
IGNITION SWITCH
r1!Jj;1]
ON or START

10A BLOCK 30A 30A
1251 (J/B) : LHD mode 1s
(Et06) 0 [B] @: RHD models
GY G/W
1---1
_ ....
-,-I-F. BR GY G/W
,-1=BR GY LG/B
I
BR
I
G/W LG/R
I~II 1:!:::JI ::II :!J'n I~II

1
COOLING1:Jt1 1::1nU
FAN
RELAY-1
n COOLING
U
FAN
RELAY-2
n
U
n FAN
COOLING1:}:1
U RELAY-3 U
n
U
llli> I'=idI IliJI ~ ~ I'=idI Iki=ll ~ ((@ I'=idI IliJI ~
LG/R G/B G/R LG G/Y B LG G/OR B
~ 1-1_ I..J 1_ 1--1

r~-CJI::~.
971~ ~ G/B G/Y COOLING
t t
<;::J:=;>
LG Ifii\i\LG/R LG Ifii\i\LG/R
db
II 111
db FAN
II 2 II MOTOR-1
,..,Ib ~ ~ r::::!= ~ r::::!= La Hi IE"4S
~£:r
~-M-a-~
LG
O~I.
I
CHID LG/R
"1rlt-M-a-iI3.r1l
LG CHID LG/R
(+)
Hi
ijl
M
(+) ~
Hi
ijl
r'
R
t t
LI
0 LG/B B LG/R B
LG t
IFffill
R/FAN2
mt
L:/R
R/FAN1
ECM
(ENGINE
_,
L...I1.____ ...,
CONTROL B B
MODULE) -!- -!-
@ <rnlffi
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(Foldout page) .
~ llli>,@,((@ ~@,~
CHID , (EiOt)
~BR BR BR ~ GY GY <lliID
~
HHA011
HA-48
TROUBLE DIAGNOSES
Main Power Supply and Ground Circuit Check

POWER SUPPLY CIRCUIT CHECK FOR AIC SYSTEM
Check power supply circuit for air conditioning system.
Refer to "POWER SUPPLY ROUTING" in EL section and Wiring
Diagram.
THERMO CONTROL AMP. CHECK

~I()~
Thermo control amp.
Check power supply circuit for thermo control amp. with ignition
switch ON.
connector@
1~ Disconnect thermo control amp. harness connector.
Lom ~ 2. Connect voltmeter from harness side.
3. Measure voltage across terminal No. CD and body ground.
Voltmeter terminal
Voltage
EB e
CD Body ground Approx. 12V
RHA341F
Turn AIC and fan switches ON. Check body ground circuit for
~Iv~
Thermo control amp.
thermo control amp.
1. Disconnect thermo control amp. harness connector.
2. Connect ohmmeter from harness side.
connector @
LHD
models: GIS
RHD
;Uw-i
2
[][]
~~.
\...~
3. Check for continuity between terminal No. @ and body
ground.
EB
Ohmmeter terminal
e
Continuity
models: GY
@ Body ground Yes
Continuity exists: OK '=" RHA342F
HA-49
TROUBLE DIAGNOSES
Flow chart
INCIDENT
No.
SYMPTOM: Blower motor does not rotate.
1 Fan fails to rotate.
Fan does not rotate at
rn • Perform PRELIMINARY CHECK 1 before referring to the fol-
2 [2J lowing flow chart.
1-speed.
Fan does not rotate at
3
2-speed. ~ CD
Check if blower motor rotates prop-
Fan does not rotate at erly at each fan speed. @
4 [1J
3-speed. Conduct checks as per flow chart at
Fan does not rotate at [2] left. @
5
4-speed.
@
~i5~ rn (Go to next page.)
Blower motor CHECK POWER SUPPL V FOR BLOWER No Check 15A (No. rnand
connector @) MOTOR. No. [2J ) fuses at fuse
m LlW
Disconnect blower motor harness con-
nector.
Do approx. 12 volts exist between
blower motor harness terminal No. CD
block.
(Refer to "POWER SUP-
PLY ROUTING" in EL sec-
tion and Wiring Diagram.)
and body ground?
Ves
RHA343F
Check circuit continuity between blower Reconnect blower motor
~ DISCONNECT motor harness terminal No. @ and harness connector.
IV@a
Blower motor
body ground.
~OK
connector @)
CHECK BLOWER MOTOR.
(Refer to Electrical Components Inspec-
~ ~ tion.) (HA-62)
LIB NG
I Replace blower motor.
RHA344F
@J
CHECK BLOWER MOTOR CIRCUIT No Disconnect blower motor
BETWEEN BLOWER MOTOR AND and resistor harness con-
RESISTOR nectors.
Resistor
Do approx. 12 volts exist between resis-
connector@
tor harness terminal No. CD and body
[Qli1JJ ground?
Ves
LIB
Disconnect fan switch harness connec- Note

tor. Check circuit continuity
between blower motor
RHA345F harness terminal No. @
and resistor harness ter-
minal No. (1).
If OK, check harness for
Blower motor short.
Resistor connector@
connector@ @
61iJ] ~
Note:
(Go to next page.)
LIB LIB If the result is NG after checking circuit continuity, repair harness or connec-
tor.
RHA346F
HA-50
TROUBLE DIAGNOSES
@
Fan switch
connector @ 1
Check circuit continuity between fan switch
Note
harness terminal No. @ and body ground.

~
1 0K
~
@
CHECK RESISTOR AFTER DISCONNECT-
ING IT. ~
(Refer to Electrical Components Inspec- @
.". RHA347F tion.) (HA-63)
@]
@
Ii OK NG
. I Replace resistor.
@
Reconnect resistor harness connector.
ITJ ~ ~ @] ~
Ii
.". RHA348F CHECK FAN SWITCH CIRCUIT.
Do approx. 12 volts exist between each fan switch
harness terminal and body ground?
Flow chart Terminal No.

Fan switch Voltage
Resistor No.
connector@ conector@
Ell e
~ @
lQ~ [31\!:4Jli] QJ @
uy 'r'r\ LlR Body ground Approx. 12V
UBUR71JLM LI~'LI~'
\ \ \
~ @
f f I 'I __,, ~ @
I I I _.1.1
Yes No
RHA349F
[!1 Note
Check circuit continuity
between fan switch har-
ness terminal and resistor
harness terminal.
Terminal No.
Conti-
Fan Resistor nuity
switch
@ CD
@
@
@
~
CID
@

short.
Yes
•
CHECK FAN SWITCH AFTER DIS-
CONNECTING IT.
'-NG
H Replace fan switch.
(Refer to Electrical Components

Inspection.) (HA-62)
Note:
If the result is NG after checking circuit continuity, repair harness or connec-
tor.
HA-51
TROUBLE DIAGNOSES
SYMPTOM: Intake door does not change.
Intake door motor
connector @ m
CHECK POWER SUPPLY FOR INTAKE No Check 7.5A (No. ~ )
~ f-----.-
~JJ 1
DOOR MOTOR. fuse at fuse block.
Disconnect intake door motor harness (Refer to "POWER SUP-
LGIRt connector. PLY ROUTING" in EL sec-
Do approx. 12 volts exist between intake tion and Wiring Diagram.)
door motor harness terminal No. G)
RHA350F
and body ground?
Yes
~i5@a~
Intake door motor
(;J
connector@ CHECK BODY GROUND CIRCUIT FOR No Disconnect recirculation
~
INTAKE DOOR MOTOR. switch harness connector.
~ LHD models Turn recirculation switch ON. Does con-
tinuity exist between intake door motor
harness terminal @ and body ground? @J Note
GIS
Turn recirculation switch OFF. Does
Check continuity between
continuity exist between intake door
recirculation switch har-
motor harness terminal @ and body
ness terminal G) (@)
ground?
and intake door motor
Yes harness terminal @
(@).
short.
Continuity should exist when OK

test leads are connected as shown,
it should not exist when test leads
CHECK INTAKE DOOR LINKAGE.
are reversed.
RHA351F Refer to Control Linkage Adjustment.
(HA-65)
~15
Recirculation switch
OK
I Replace intake door motor. @

connector@ (Go to next page.)
~ Note:
GIS: LHO models
Y/S: RHO mOdels'
1- GIY: LHO models
VIR: RHO models
tor.
I
I
I
'"
.-
I
I
I
Y/S t Y/R G/Y t GIS
rERl-¥1Jl RHD models ~ LHO models

Intake door motor
connector@
RHA352F
HA-52
TROUBLE DIAGNOSES
@
~15
Recirculation switch
1 Note
connector ~ Check circuit continuity between recircu-

lation switch harness terminal No. @
[5b and body ground.
B
~OK
CHECK RECIRCULATION SWITCH. Replace recirculation

RHA353F
(Refer to Electrical Components Inspec- switch.
tion.) (HA-63)
Note:
tor ..
HA-53
TROUBLE DIAGNOSES
SYMPTOM: Magnet clutch does not engage when Ale
Compressor switch and fan switch are ON. - For GA and SR
connector @QD-2
engines
~ • Perform PRELIMINARY CHECK 1 before referring to the fol-
lowing flow chart.
s
m Yes
CHECK POWER SUPPLY FOR COMPRES- Check magnet clutch coil.
SOR.
RHA354F Disconnect compressor harness connec-
NG
tor.
Do approx. 12 volts exist between com-
pressor harness terminal ill and body Replace magnet clutch.
ground? Refer to HA-77, HA-80.
Thermal protector
No
connector @QD-1
[;) [;J
~ CHECK POWER SUPPLY FOR THERMAL Yes CHECK THERMAL PRO-
PROTECTOR. TECTOR.
lIR Disconnect thermal protector harness Check circuit continuity
connector. between thermal protector
Do approx. 12V exist between thermal harness terminal ill and
protector harness terminal ill and body compressor harness termi-
RHA355F
ground? nal ill.
No
shorl.
Thermal protector Compressor NG

connector @QD-1 connector@QD-2
Disconnect AIC relay. I Replace thermal protector.
~ ~
~ ~ ls CHECK CIRCUIT CONTINUITY BETWEEN

Note
AIC RELAY HARNESS TERMINAL @

~ AND THERMAL PROTECTOR HARNESS
RHA356F TERMINAL ill.
~ i5@a
Thermal
protector AIC relay

connector @-1 connector (ill) No
CHECK POWER SUPPLY FOR AIC CHECK POWER SUPPLY
,"R~~t
RELAY. CIRCUIT AND 7.5A (No.
Disconnect AIC relay. [Q] and ~ ) FUSES AT
Do approx. 12 volts exist !)etween AIC FUSE BLOCK.
[1[] lIR relay harness terminals ill, @ and Refer to EL section ("Wir-
body ground? ing Diagram", "POWER
SUPPLY ROUTING").
Yes
RHA357F
NG
CHECK AIC RELAY AFTER DISCON- Replace AIC relay.
NECTING IT.
~15~
AlC relay
Refer to HA-64.
OK
connector (ill)
@: GA engine (for Europe, Israel and
~lIY Australia) and SR engine
@: Except above
Note:
tor.
RHA358F
HA-54
TROUBLE DIAGNOSES
@
Ii ~i)@a~ ~
EGM (EGGS control
module) connector @
I Reconnect AIC relay. _
II EGM ]gCONNECTOR II Ii !
CHECK COIL SIDE CIRCUIT OF AIC
No
Disconnect A/C relay.
~
RELAY. Disconnect ECM (ECCS
Do approx. 12 volts exist between ECM control module) harness
(ECCS control module) harness terminal connector.
• : GA engine for @ or @ and body ground?
l
Australia: 15 (Y)
Others : 11 (G) RHA359F Yes ~ Note
CHECK CIRCUIT CONTI-
~&)
AlG relay
~Io
EGM (EGGS control
NUITY BETWEEN AIC
RELAY HARNESS TERMI-
NAL @ AND ECM (ECCS
CONTROL MODULE) HAR-
ci
connector@
II
module) connector@
EGM ]gCONNECTOR II
(I)
. NESS TERMINAL @ or
@.
Y short.
CHECK VOLTAGE FOR ECM (ECCS con-
tral module) .
• : GA engine for Do approx. 12 volts exist between ECM
Australia : 15 (Y) No
Others : 11 (G)
RHA360F
(ECCS control module) harness terminal
@, or @ and body ground?
-.. CHECK ECM (ECCS con-
trol module). Refer to EC
section.
Yes
III ~i) @a ~ Disconnect ECM (ECCS contra I module)

harness connector.
EGM (EGGS control
module) connector@ Disconnect dual-pressure switch har-
ness connector.
II EGM 'gCONNECTORII
.
41 or 21
o Note
CHECK CIRCUIT CONTINUITY

BETWEEN ECM (ECCS CONTROL MOD.
21: GA engine for
ULE) HARNESS TERMINAL @ or @
Australia (G)
AND DUAL-PRESSURE SWITCH HAR-
41: Others (GY)
RHA361F NESS TERMINAL @.
o Dual-
~15@a
EGM (EGGS control
pressure
switch
connector@
OK
NG
CHECK DUAL-PRESSURE SWITCH. Replace dual-pressure
module) connec1or@
Refer to HA-64. switch.
~.
II EGM E[CONNECTORII
OK
.
41 or 21 G
•
Disconnect thermo control amp. har-
ness connector.
21: GA engine for
Australia (G)
41: Others (GY)
RHA362F II Note Note:
If the result is NG after
CHECK CIRCUIT CONTINUITY BETWEEN checking circuit continuity,
DUAL.PRESSURE SWITCH HARNESS repair harness or connector.
TERMINAL @ AND THERMO CONTROL
AMP. HARNESS TERMINAL @.
Thermo Continuity should exist.
Dual-
control amp. If OK, check harness for short.
pressure
tm
switch
connector @ OOD @
OK
d)) Reconnect dual-pressure

connector.
switch harness
S8
S8
@ (Go to m .)
RHA363F
HA-55
TROUBLE DIAGNOSES
Diagnostic Procedure 3 (Co nt' d)
~ CONNECT ~ (gl ~
l41E) ~ @ ~
EGM (EGGS control
module) connector @ I Reconnect AIC relay_. _... _
II EGM J9"CONNECTORII
11 II !
CHECK COIL SIDE CIRCUIT OF AIC Disconnect ECM (ECCS
G RELAY. control module) harness
Do approx. 12 volts exist between ECM connector.
(ECCS control module) harness termi. Disconnect dual-pressure
nal @ and body ground? switch harness connector.
SHA734E
Yes
II Note
II CHECK CIRCUIT CONTINU-
ITY BETWEEN ECM (ECCS
CONTROL MODULE) HAR-
EGM (EGGS control Dual-pressure NESS TERMINAL @ AND
module) connector @ switch connector @ DUAL-PRESSURE SWITCH
HARNESS TERMINAL CD.
II ECM Ej'coNNEcTORII ~ Continuity should exist.
11 If OK, check harness for
G short.
G
~OK
NG
CHECK --+ Replace
RHA446F DUAL- dual-
PRES- pressure
SURE switch.
SWITCH.
Refer to
HA-64.
Dual-pressure switch NC relay
connector@ connector@
Note
CHECK CIRCUIT CONTINU-
L ITY BETWEEN AIC RELAY
L HARNESS TERMINAL @
AND DUAL-PRESSURE
SWITCH HARNESS TERMI-
NAL @.
RHA414F
~i)~@ short.
EGM (EGGS control II No

module) connector@ CHECK VOLTAGE FOR ECM CHECK ECM (ECCS control
(ECCS control module). module). (Refer to EC sec-
II EGM E[CONNECTORII Do approx. 12 volts exist between ECM tion.)
44 (ECCS control module) harness termi-
nal No. @ and body ground?
R/L
Yes
Disconnect ECM (ECCS control mod-

ule) harness connector.
"='RHA443F Disconnect thermo control amp. har-
ness connector.
Yes
@
Note:
If the result is NG after checking circuil continuity, repair harness or connec-
tor.
HA-56
TROUBLE DIAGNOSES
@
Thermo control
amp. connector ~
EGM (EGGS control
module) connector@ CHECK CIRCUIT CONTINUITY
t
BETWEEN
Note
ECM (ECCS CONTROL MODULE) HAR-

EGM ECONNECTORII NESS TERMINAL @ AND THERMO
~ II 44 CONTROL AMP. HARNESS TERMINAL
@.
RIL
RIL If OK, check harness for short.
~OK
Reconnect thermo control amp. harness
connector.
Thermo control
,mp;""",,, @ ~
CHECK POWER SUPPLY FOR THERMO
Note
CONTROL AMP.
Refer to HA-49.
LHD:
RHD:
G/S'~L-.D--J
GY
rrIDl rJ.1
CHECK BODY GROUND CIRCUIT FOR Replace thermo control
RHA364F THERMO CONTROL AMP. amp.
Disconnect thermo control amp. harness
connector.
Does continuity exist between thermo
control amp. harness terminal @ and
Thermo control A/G switch body ground?
amp. connector @) connector @
No
i55lJ Disconnect
tor.
AIC switch harness connec-
~
LHD: GIS LHD: GIS Note
RHD: GY RHD: GY
CHECK CIRCUIT CONTINUITY BETWEEN
RHA365F THERMO CONTROL AMP. HARNESS
TERMINAL @ AND AIC SWITCH HAR-
NESS TERMINAL @.
OK
NG switch Fan switch
connector@ connector@ Replace AIC switch.
CHECK AIC SWITCH.
62J ~
Refer to HA-63.
OK
LHD: G/Y
RHD: LG/S
LHD: G/Y
RHD: LG/B
RHA366F
Disconnect
tor.
fan switch
CHECK CIRCUIT CONTINUITY

harness
BETWEEN
AIC SWITCH HARNESS TERMINAL @
connec-
Note
•
AND FAN SWITCH HARNESS TERMINAL
@.
OK
Note:
If the result is NG or No alter checking circuit continuity, repair harness or
connector.
HA-57
TROUBLE DIAGNOSES
~iv@a CID
Fan switch
connector@ 1
CHECK BODY GROUND CIRCUIT FOR
Note
~ FAN SWITCH.
Does continuity exist between fan switch
B harness terminal @ and body ground?
Yes
NG
CHECK FAN SWITCH. Replace fan switch.
'="RHA367F
Refer to HA-62.
Note:
If the result is No after checking circuit continuity, repair harness or connec-
tor.
HA-58
TROUBLE DIAGNOSES
SYMPTOM: Magnet clutch does not engage when Ale
switch and fan switch are ON. - For CD engine
• Perform PRELIMINARY CHECK 1 before referring to the fol-
Compressor
connector @Q7>-2 lowing flow chart.
m Yes
~ CHECK POWER SUPPLY FOR COMPRES- Check magnet clutch coil.
SOR.
B OK
Disconnect compressor harness connec-
tor.
Do approx. 12 volts exist between com-
Replace magnet clutch.
RHA354F
pressor harness terminal CD and body
Refer to HA-77.
ground?
No
(;J [!]
Thermal protector CHECK POWER SUPPLY FOR THERMAL Yes CHECK THERMAL PRO-
connector @Q7>-1 PROTECTOR. TECTOR.
Disconnect thermal protector harness Check circuit continuity
connector. between thermal protector
~ Do approx. 12V exist between thermal harness terminal G) and
LlR protector harness terminal G) and body compressor harness termi-
ground? nal CD.
No
If OK. check harness for
RHA355F short.
NG
Disconnect AIC relay. I Replace thermal protector.
Thermal protector Compressor

connector@-1 connector@QD-2 Note
j. ~~1-
AIC RELAY HARNESS TERMINAL @)
AND THERMAL PROTECTOR HARNESS
TERMINAL G).
I1iJ Continuity should exist.
RHA356F
OK
No CHECK POWER SUPPLY

CHECK POWER SUPPLY FOR AIC
Thermal RELAY. CIRCUIT AND 7.5A (No.
protector AlC relay Disconnect AIC relay. ~J and 00 )
FUSES AT
connector @:>-1 connector @]) Do approx. 12 volts exist between AIC FUSE BLOCK.
~ ciP
1
relay harness terminals
body ground?
CD. @ and Refer to EL section ("Wir-
ing Diagram", "POWER
SUPPLY ROUTING").
•
Yes
~/R ~
NG
~L1R Replace AIC relay.
CHECK AIC RELAY AFTER DISCON-
NECTING IT.
RHA357F Refer to HA-64.
OK
@
(Go to next page.)
Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.
RHA358F
HA-59
TROUBLE DIAGNOSES
Ii ~i)~@ @
+
ECM (Engine control
I
r---
module) connector @ Reconnect AIC relay.
II ECM E[CONNECTORII Ii
8
CHECK COIL SIDE CIRCUIT OF AIC No Disconnect ECM (Engine
G RELAY. control module) harness
Do approx. 12 Yolts exist between ECM connector.
(Engine control module) harness termi- Disconnect dual-pressure
nal @ and body ground? switch harness connector .
....RHA370F
Yes
[iJ Note
CHECK CIRCUIT CONTINU-
ITY BETWEEN ECM
(ENGINE CONTROL MOD-
ECM (Engine control Dual-pressure ULE) HARNESS TERMINAL
module) connector ~ switch connector @) @ AND DUAL-PRESSURE
II ECM HCONNECTORII ~ NAL G).
G If OK, check harness for
G
short.
OK
RHA368F
NG
CHECK Replace
DUAL- dual-
PRES- pressure
SURE switch.
SWITCH.
Refer to
Dual-pressure switch AlC relay
HA-64.
connector@ connector@
Note
L CHECK CIRCUIT CONTINU-

L ITY BETWEEN AIC RELAY
HARNESS TERMINAL @
AND DUAL-PRESSURE
RHA414F
NAL @.
o If OK, check harness for
~i5~~ o
short.
II ECM 11
31
CONNECTOR II CHECK VOLTAGE FOR ECM (Engine
No
CHECK ECM (Engine con-
ECM control unit). trol module). (Refer to EC
(Engine control AIL
Do approx. 12 YOIts exist between ECM section.)
module)@ (Engine control module) Ilarness termi-
nal No. @ and body ground?
Yes
-= Disconnect ECM (Engine control mod-

ZHA158AA ule) harness connector.
Disconnect thermo control amp. har-
ness connector.
@
(Go to next page.)
Note:
connector.
HA-60
TROUBLE DIAGNOSES
II (!)
II ~ Note
Thermo control ECM (Engine control
amp. connector@) module) connector @
ECM (ENGINE CONTROL MODULE)
~ II ECM ?,CONNECTOOII
HARNESS TERMINAL @ AND THERMO
CONTROL AMP. HARNESS TERMINAL
IAIL ~_tR/L
@.
OK
Reconnect thermo control amp. harness

connector.
Note
CHECK POWER SUPPLY FOR THERMO
Co"NTROL AMP.
:~~~~~;;:~:@) ~ Refer to HA-49.
G/S'~ rn (l CHECK BODY GROUND CIRCUIT FOR Replace thermo control
'L-.D--J 1
LHO: THERMO CONTROL AMP. amp.
RHO: GY Disconnect thermo control amp. harness
connector.
RHA364F
Does continuity exist between thermo
control amp. harness terminal @ and
II body ground?
No
Thermo control A/C switch
amp. connector @) connector @ Disconnect AIC switch harness connec-
tor.
~
~
II Note
LHO: GIS LHO: GIS THERMO CONTROL AMP. HARNESS
RHO: GY RHO: GY TERMINAL @ AND AIC SWITCH HAR-
NESS TERMINAL @.
RHA365F
OK
CHECK AIC SWITCH. Replace AIC switch.

NC switch Fan switch Refer to HA-63.
connector@ connector @ID
OK
[ij ~
Disconnect fan switch harness connec-
tor.
LHO: G/Y
RHO: LG/S
LHO: G/Y
RHO: LG/S
RHA366F CHECK CIRCUIT CONTINUITY
@.
BETWEEN
AIC SWITCH HARNESS TERMINAL @
AND FAN SWITCH HARNESS TERMINAL
Note
•
OK
@
(Go to next page.)
Note:
connector.
HA-61
TROUBLE DIAGNOSES
~15@a @
Fan switch
connector@
1
CHECK BODY GROUND CIRCUIT FOR
Note
~ FAN SWITCH.
B Does continuity exist between fan switch
harness terminal @ and body ground?
Yes
'="RHA367F NG
CHECK FAN SWITCH. Replace fan switch.
Refer to HA-62.
Note:
connector.

FAN SWITCH
Check continuity between terminals at each switch position.
LEVER POSITION Continuity between terminals
OFF
1 @-@-@
2 @----@-@
3 @ -------@ - @
RHA325F
4 @ ----------@ - @
BLOWER MOTOR
Confirm smooth rotation of the blower motor.
• Ensure that there are no foreign particles inside the intake
unit.
HA-62
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
BLOWER RESISTOR
Check resistance between terminals.
Circuit check
Terminal No.
Resistance
EB 8
@ Approx. 1.4 - 1.6Q
@ (1) Approx. 2.5 - 2.8Q
@ Approx. 0.5 - 0.6Q
AIC SWITCH
.Switch condition Terminal No.

Continuity
A/C EB e
ON Yes
@ @
OFF No
~
AlC switch
connector
RHA328F
RECIRCULATION SWITCH
Terminal No. Recirculation

Continuity
EB e switch condition
I
ON Yes
I
(1) @
I OFF No
I
I ON No
'- @ @
OFF Yes
SHA732E
THERMAL PROTECTOR
Temperature of compressor
Compressor operation
°C (OF)
Increasing to approx. 145 - 155 (293 - 311) Turn OFF
Decreasing to approx. 130 - 140 (266 - 284) Turn ON
THERMO CONTROL AMP.

1. Run engine, and operate AIC system.
•
2. Connect the voltmeter from harness side.
3. Check thermo control amp. operation shown in the table.
Evaporator outlet air temperature Thermo amp.

Tester
°C CF) operation
Decreasing to 2.5 - 3.5 (37 - 38) Turn OFF Approx. 12V
Increasing to 4.0 - 5.0 (39 - 41) Turn On Approx.OV
HA-63
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
AIC RELAY
Check continuity between terminals <ID and CID.
12V direct current supply between terminals G)
Yes
and @
AHA233
DUAL-PRESSURE SWITCH
Dual-pressure ON OFF
switch connector kPa (bar, kg/cm2, psi) kPa (bar, kg/cm2, psi)
Increasing to Decreasing to
Low-pressure
157 - 216 (1.57 - 2.16, 157 -196 (1.57 - 1.96,
side
1.6 - 2.2,23 - 31) 1.6 - 2.0,23 - 28)
Decreasing to Increasing to
High-pressure
1,863 - 2,256 (18.6 - 22.6, 2,452 - 2,844 (24.5 - 28.4,
side
19 - 23, 270 - 327) 25 - 29, 356 - 412)
Control Linkage Adjustment

MODE CONTROL CABLE
1. For RHO models, turn the mode control knob to the VENT
position.
For LHO models, turn the mode control knob to the OEF
position.
2. For RHO models, set the side link in the VENT position by
hand.
For LHO models, set the side link in the OEF position by
hand.
3. Pullan the cable cover in the direction of the arrow, then
clamp it.
After positioning control cable, check that it operates properly.
WATER COCK CONTROL ROD

• When adjusting water cock control rod, first disconnect tem-
perature control cable from air mix door lever and then
adjust control rod. Reconnect temperature control cable
and readjust it. (Refer to TEMPERATURE CONTROL
CABLE.)
1. Push air mix door lever in direction of arrow.
2. Pull control rod of water cock in direction of arrow so as to
make clearance of about 2 mm (0.08 in) between ends of rod
and link lever and connect the rod to door lever.
SHA522E After connecting control rod, check it operates properly.
HA-64
TROUBLE DIAGNOSES
Control Linkage Adjustment (Cont'd)
TEMPERATURE CONTROL CABLE
1. For RHO models, move the temperature control knob to the
full cold position.
For LHO models, move the temperature control knob to the
full hot position.
2. For RHO models, set the air mix door lever in the full cold
position.
For LHO models, set the air mix door lever in the full hot
position.
3. Pull on the cable cover in the direction of the arrow, then
clamp it.
After positioning control cable, check that it operates properly.
INTAKE DOOR MOTOR

1. Install intake door motor on intake unit.
Ensure that the intake door motor lever is fitted into the slit
portion of intake door link.
2. Connect the intake door motor harness connector.
3. Turn ignition switch to ON.
4. Check that intake door operates properly when REC switch
is turned ON and OFF.
ZHA178A
System Description
INTAKE DOOR MOTOR
The intake door motor is installed on the intake unit. Using a
link it opens and closes the intake door.
When RECIRCULATION switch is ON, the ground line of the
motor is switched from terminal @ to @. This starts the motor
because the position switch contacts built into it make current •
flow. When RECIRCULATION switch is OFF, the ground line is •
switched from terminal @ to @. The contacts turn along with
the motor. When they reach the non-current flow position, the
LHD: u:Eh!.IJ motor will stop. The motor always turns in the same direction.
o::EhhJ
---I
RHD:
I
~----j
Intake door
molar
RHA331F
HA-65
SERVICE PROCEDURES
HFC-134a (R-134a) Service Procedure

SETTING OF SERVICE TOOLS AND EQUIPMENT
DISCHARGING REFRIGERANT
WARNING:
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat.
Remove HFC-134a (R-134a) from A/C system using certified service equipment meeting requirements
of HFC-134a (R-134a) recycling equipment or HFC-134a (R-134a) recovery equipment. If accidental sys-
tem discharge occurs, ventilate work area before resuming service. Additional health and safety infor-
mation may be obtained from refrigerant and lubricant manufacturers.
Example
I -,
I~
V ~I~e service
~ .._----~
Recovery/Recycling/Recharging equipment
SHA539DC
EVACUATING SYSTEM AND CHARGING REFRIGERANT

Example
Preferred (Best) method Alternate method

Manifold gauge set
SHA540DC
HA-66
SERVICE PROCEDURES
HFC-134a (R-134a) Service Procedure (Cont'd)
Set the recoverylrecycling equip-
ment.
Recovered lubricant (HA-68) Discharge refrigerant into recoveryl

recycling equipment.
Repair or replace parts.
Evacuate the unwanted air in charg-

ing hoses.
Evacuating (over 25 minutes).
Check air tightness. Repair.
I
Partial charging
'-1
[approx. 200 g (7.05 oz)J.
Preliminary refrigerant leak check. Repair.
, -1
Complete charging [specified
amount - 200 g (7.05 oz)J.
--H'-2
--r.---~.
'---.
---
---C-h-e-c-k-f-o-r-re-f-r-ig-e-r-a-nt-Ie-a-k-s-. Repair.
Check for AIC operation and AIC

cooling performance
Remove service couplers from AIC

service valves.
Recover refrigerant in charging

•
hoses.
Remove service tools.
Note: '-1 Before charging refrigerant, ensure engine is off.

'-2 Before checking for leaks, start engine to activate air conditioning system then turn it off.
Service valve caps must be attached to valves (to prevent leakage).
HA-67
SERVICE PROCEDURES
Maintenance of Lubricant Quantity in

Compressor
The lubricant in the compressor circulates through the system
with the refrigerant. Add lubricant to compressor when replac-
ing any component or after a large gas leakage occurred. It is
important to maintain the specified amount.
If lubricant quantity is not maintained properly, the following
malfunctions may result:
• Lack of lubricant: May lead to a seized compressor
• Excessive lubricant: Inadequate cooling (thermal exchange
interference)
LUBRICANT
Name: Nissan Ale System Oil Type R
Part number: KLHOO-PAGRO
CHECKING AND ADJUSTING
Adjust the lubricant quantity according to the flowchart shown
below.
START
~
Yes
Can lubricant return operation be per- -+ Perform lubricant return operation, proceeding as follows:
formed?
• AIC system works properly. 1. Start engine, and set the following conditions:
• There is no evidence of a large amount • Test condition
of lubricant leakage. Engine speed: Idling to 1,200 rpm
AlC or AUTO switch: ON
No Blower speed: Max. position
Temp. control: Optional [Set so that Intake air temperature is
25 to 30°C (77 to 86°F).]
2. Next item is for V-5 or V-6 compressor. Connect the manifold
gauge, and check that the high pressure side pressure is 588 kPa
(5.9 bar, 6 kg/cm2, 85 psi) or higher,
If less than the reference level, attach a cover to the front face of
the condenser to raise the pressure.
Should the compressor be replaced? 3. Perform lubricant return operation for about 10 minutes.
~ 4. Stop engine.
No Yes CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant
return operation.
@
(Go to next page.)
Yes
Is there any part to be replaced?
(Evaporator, condenser, liquid tank or in
-.. After replacing any of .the following major components, add the cor-
rect amount of lubricant to the system.
case there is evidence of a large amount Amount of lubricant to be added
of lubricant leakage.) Lubricant to be added to
system
No Part replaced
Amount of lubricant
Remarks
mf (Imp II oz)
Evaporator 75 (2.6) -
Condenser 75 (2.6) -
Add if compressor is not
Liquid tank 5 (0.2)
replaced. '1
30 (11) Large leak
Carry out the AIC performance test. In case of refrigerant leak
~ - Small leak'2
.
*1: If compressor is replaced. addition of lubricant is included in the

flow chart.
*2: If refrigerant leak is small, no addition of lubricant is needed.
HA-68
SERVICE PROCEDURES
Maintenance of Lubricant Quantity in
Compressor (Cont'd)
@
1. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into the
recovery/ recycling equipment.
2. Remove the drain plug of the "old" (removed) compressor (applicable only to V-5, V-6 or DKS-16H compressor).
Drain the lubricant into a graduated container and record the amount of drained lubricant.
3. Remove the drain plug and drain the lubricant from the "new" compressor into a separate, clean container.
4. Measure an amount of new lubricant installed equal to amount drained from "old" compressor. Add this lubricant to
"new" compressor through the suction port opening.
5. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to "new"
compressor through the suction port opening.
6. Torque the drain plug.
V.5 or V-6 compressor: 18 - 19 N'm (1.8 - 1.9 kg-m, 13 - 14 ft-Ib)
DKS.16H compressor: 14 - 16 N'm (1.4 - 1.6 kg-in, 10 - 12 ft-Ib)
7. If the liquid tank also needs to be replaced, add an additional 5 mC (0.2 Imp II oz) of lubricant at this time.
Do not add this 5 m C(0.2 Imp II oz) of lubricant if only replacing the compressor.
Lubricant adjusting procedure for compressor replacement
DO DO
Recovery/ Old New

Recycling compressor compressor
eqUipment
! Roo'" ,m,,", 1R,,,,' ,moo",

Drain lubricant
from new
,--------------------, compressor
I I into clean
I I container
II + "Y" II
I "X" mQ I
I mQ I
IL ~I
Reinstall
"X"m Q + "Y"m Q
New
of new lubricant
New
-.------- lubricant
compressor ------ L-... .J
fAdda;-addition;; "I
•
15m Q (0.2 US fl Ol,
I 0.2 Imp fl Ol) of I
I new lubricant when I
! replacing liquid I
, tank. I
1- - __I
RHA065DD
HA-69
SERVICE PROCEDURES
Refrigerant Lines
• Refer to page HA-4 regarding "Precautions for Refrigerant
Connection" .
GA ENGINE RHO MODEL

SEC. 271.274.276
fil10' 20 (1.0 . 2.0, 87 . 174)

8 mm dia.
Expansion valve
[O;J 15 - 25 (1.5 - 2.5, 11 - 18)

12 mm dia.
Low-pressure (Suction)
service valve
o (Tightening torque)
o0 (Wrench size)
o (O-ring size)
[O;J : N.m (kg-m, ft-Ib)
rn : 20 • 29 (2.0 • 3.0, 14 - 22)
fiI : N.m (kg-m, in-I b)
Condenser IBl : 8 • 11 (0.8 - 1.1, 69 - 95)
[C] : 10 - 20 (1.0 - 2.0, 87 - 174)
Liquid tank ~ : 3 - 4 (0.3 - 0.4, 26 - 35)
RHA332F
HA-70
S~~~~:~::--_~S~ER ~V~1~C~E~P;.R;O~C¥E¥,D~U~fo;;r.:i)
R ENGINE RHD MO DEL
_ Ref ngerant
" L" RES
EC. 271.274 '276 mes (Cont' d)
5
Low-pressure (Suct'Ion) se rVlce

' valve
High-pressure (0'Ischarg e ) service valve
Cooling unit
Liquid tank
Condenser
oo
o
~:
o
IiiiI
(Tightening
(Wrench size)
(D-ring size)
t orque)
N'm (kg-m, ft-Ib)
r.:.1 :
25 - 34 ( 2.5 - 3.5 18
•
~ : N.m ( ,- 25)
kg-m, in-Ib)
(SJ :. 10 - 20 (1 .0 - 2.0, 87 - 174)
'Cl . 8 - 11 (0.8 - 1.1 69

~
1)1 . ' - 95)
lMJ . 2.9 . 3 .9 ( 0.3 - 04., 26 - 35)
RHA371F
HA-71
SERVICE
R f • PROCE DURES
e ngerant L.mes (Cont'd)
CD ENGINE RHO MO DEL
SEC. 271'274-276
iii 810mm
- 20 (1.0 - 2
dia. .0, 87 - 174)
Expansion valve
[O.J 15
12 -mm
25 d'
(1.5 - 2.5, 11 - 18)
la. Hi~h-pressure
[SJ (Discharge)
service valve
\~
il!1d
Low-pressure (
service valve Suction)
I
I
D
DO (Tightening t
orque)
(Wrench size)
o (O-ring size)
Compressor [O.J : N'm (kg-m, ft-Ib)
iiia::N'm
20 - 29 (20
. - 3.0, 14 - 22)
(kg-m, in-Ib)
Condenser [SJ :: 810- 11 (0.8 - 1.1, 69 - 95)
ICl
- 20 (1.0 • 2
[Q] : 3 _4 .0, 87 - 174)
Liquid tank
(0.3 - 04
., 26 • 35)
RHA333F
HA-72
SERVICE PROCEDURES
Refrigerant Lines (Cont'd)
GA ENGINE lHD MODEL
SEC. 271. 274 .276
~ 15 • 20 (1.5 - 2.0, 11 - 14)

8 mm (0.31 in) die.
___ ==- - ~ 20 - 25
High-pressure
(2.0 - 2.5, 14 - 18)
~
."""\
~t;, 12 mm (0.47 in) dia.
Expansion valve
(Discharge) service valve
High-pressure
(Discharge) service valve
~ 10 - 20 (1.0 - 2.0, 87 - 174)
6 mm (0.24 in) dia.
Thermo control amp.
Low-pressure (Suction) service valve
~ Liquid tank
o
DD
D
~
~
(Tightening
(Wrench size)
(O-ring size)
torque)
: N'm (kg-m, ft-lb)
: 25 - 34 (2.5 - 3.5, 18 - 25)

•
rm : 10 - 20 (1.0 - 2.0, 87 - 174)

~ : 8 • 11 (0.8 • 1.1, 69 • 95)
~ : 2.9 • 3.9 (0.3 - 0.4, 26 • 35)
RHA334F
HA-73
SERVICE PROCEDURES
Refrigerant Lines (Co nt' d)
CD ENGINE LHD MODEL
SEC. 271' 274 '276
[O.J 15. 20 (1.5 - 2.0, 11 - 14)

8 mm (0.31 in) dia.
[O.J 20 - 25 (2.0 - 2.5, 14 - 18)
12 mm (0.47 in) dia.
~ 10 • 20 (1.0 - 2.0, 87 • 174)

6 mm (0.24 in) dia.
Thermo control amp.
High-pressure (Discharge) service valve
Cooling unit
Low-pressure (Suction) service valve
o (Tightening torque)
o0 (Wrench size)
o (O-ring size)
[O.J : N'm (kg-m, It-I b)

Liquid tank
B : 25 - 34 (2.5 - 3.5, 18 - 25)
[SJ :10 - 20 (1.0 - 2.0,87 - 174)
[Q : 8 - 11 (0.8 - 1.1, 69 - 95)
[Q] : 2.9 • 3.9 (0.3 - 0.4, 26 - 35)
RHA335F
HA-74
SERVICE PROCEDURES
Compressor Mounting
GA engine models
SEC. 274.275

ZHA182AB
CD engine models
SEC. 274.275
~ : N.m (kg-m, ft-Ib) ZHA183AA •
HA-75
SERVICE PROCEDURES
Compressor Mounting (Cont'd)
SR20DE engine models
SEC. 274.275 ~ 16 • 19 (1.6 • 1.9, 12 • 14)
~ 45 - 60 (4.6 - 6.1, 33 • 44)
~ : N.m (kg-m, ft-Ib) ~45.60

(4.6 - 6.1, 33 • 44)
AHA387
Belt Tension
• Refer to MA section.
Fast Idle Control Device (FICO)

• Refer to EC section.
HA-76
SERVICE PROCEDURES
Compressor - Model DKV-11D and DKV-14D

(ZEXEL make)
SEC. 274
~4 -6
(0.4 - 0.6, 35 • 52)
Thermal protector
Clutch disc ~ 15 - 18 (1.5 - 1.8, 11 • 13)

SHA927DB
Compressor Clutch
REMOVAL
• When removing center bolt, hold clutch disc with clutch disc
wrench.
Drive plate
• Remove the drive plate using Tool KV99232340.
Insert holder's three pins into the drive plate. Rotate the
•
holder clockwise to hook it onto the plate. Then, tighten the
center bolt to remove the drive plate.
When tightening the center bolt, insert a round bar
(screwdriver, etc.) between two of the pins (as shown in the
left-hand figure) to prevent drive plate rotation. After remov-
Shim ing the drive plate, remove the shims from either the drive
shaft or the drive plate.
SHA098EA
HA-77
SERVICE PROCEDURES
Compressor Clutch (Cont'd)
• Remove the snap ring using external snap ring pliers.
External snap
ring pliers
Snap ring
RHA072C
• Pulley removal
Use any commercially available pulley puller. Position the
center of it on the end of the drive shaft, and remove the
KV99233130 pulley assembly.
For pressed pulleys
To prevent deformation of the pulley groove, the puller
claws should be hooked into (not under) the pulley groove.
For machine latched pulleys
ulley puller Align the pulley puller groove with the pulley groove, and
then remove the pulley assembly.
SHA099EA • Remove the field coil harness clip using a screwdriver.
• Remove the three field coil fixing screws and remove the
field coil.
~/S"'wd""'"
g- Field coil
1J
RHA074C
INSPECTION
Shim Snap ring
Clutch disc: If the contact surface shows signs of damage due
BOll\
JJ _ ~crew to excessive heat, replace clutch disc and pulley.
Pulley: Check the appearance of the pulley assembly. Check
the contact surface of the pulley for any sign of excessive groov-
ing due to slippage. If any sign is found, replace both the pul-
~ ley and clutch disc. !he contact surfaces of the pulley assem-
~ bly should be cleaned with a suitable solvent before reinstalla-
L Clutch disc tion.
Coil: Check coil for loose connection or cracked insulation.
RHA075C
INSTAllATION
• Install the field coil.
Be sure to align the coil's pin with the hole in the compressor's
front head.
• Install the field coil harness clip using a screwdriver.
RHA076C
HA-78
SERVICE PROCEDURES
• Install the pulley assembly using the installer and a hand
Pulley assembly press, and then install the snap ring using snap ring pliers.
SHA100EA
• Install the drive plate on the drive shaft, together with the
original shim(s). Press the drive plate down by hand.
Drive plate
-Shim
RHA07BC
• Using the holder to prevent drive plate rotation, tighten the

bolt to 12 to 15 N'm (1.2 to 1.5 kg-m, 9 to 11 ft-Ib) torque.
After tightening the bolt, check that the pulley rotates smoothly.
Drive plate
holder
SHA101EA
• Check clearance around the entire periphery of clutch disc.

Disc-to-pulley clearance:
Pulley assembly
0.3 - 0.6 mm (0.012 - 0.024 in)
If the specified clearance is not obtained, replace adjusting
spacer and readjust.
BREAK-IN OPERATION
When replacing compressor clutch assembly, always conduct •
the break-in operation. This is done by engaging and disengag- i
/
Feeler gauge -.I ing the clutch about thirty times. Break-in operation raises the
level of transmitted torque.
-~~
'Spark plug gap gauge
( ~
Unit: mm (in)
RHAOBOC
HA-79
SERVICE PROCEDURES
Thermal Protector
INSPECTION
• When servicing, do not allow foreign matter to get into com-
pressor.
Compressor - Model CR-14 (Calsonic make)
Pulley assembly
Snap ring
Clutch disc
Center bolt ~12 - 15 N.m (1.2 - 1.5 kg-m, 9 - 11 ft-Ib)

RHA314E
Compressor Clutch
REMOVAL
• When removing center bolt, hold clutch disc with clutch disc
wrench.
• Take off clutch disc.
• Remove snap ring (which secures rotor pulley) by using

external snap ring pliers.
HA-80
SERVICE PROCEDURES
Compressor Clutch (Co nt' d)
• Pulley removal
Position the center pulley puller on the end of the drive
shaft, and remove the pulley assembly using any commer-
cially available pulley puller.
To prevent the pulley groove from being deformed, the
puller claws should be positioned onto the edge of the pul-
ley assembly.
RHA317E
• Remove snap ring (which secures field coil) by using exter-

nal snap ring pliers.
INSPECTION
Clutch disc
If the contact surface shows signs of damage due to excessive
heat, the clutch disc and pulley should be replaced.
Pulley
~~
\t PUlley assembly
Check the appearance of the pulley assembly. If the contact
surface of the pulley shows signs of excessive grooving due to
-Shim RHA319E slippage, both the pulley and clutch disc should be replaced.
The contact surfaces of the pulley assembly should be cleaned
with a suitable solvent before reinstallation.
Coil
Check coil for loose connection or cracked insulation .
INSTALLATION
• Position the field coil.
•
Be sure to align the coil's pin with the hole in compressor's
front head.
• Install snap ring (which secures field coil) by using external
snap ring pliers.
RHA320E
HA-81
SERVICE PROCEDURES
• Position and install pulley assembly securely by using plas-
tic hammer.
• Install snap ring (which secures rotor pulley) by using exter-
nal snap ring pliers.
KV991 06800
~ RHA321EA
• Install the clutch disc on the drive shaft, together with the
original shim(s). Press the disc down by hand.
~
s~ ~ Clutch disc
• Using the clutch wrench disc to prevent clutch disc rotation,

tighten the bolt to 12 to 15 N'm (1.2 to 1.5 kg-m, 9 to 11 ft-Ib)
torque.
After tightening the bolt, check that the pulley rotates smoothly.
RHA323E
• Check clearance around the entire periphery of clutch disc.

Pulley assembly Disc-to-pulley clearance:
0.3 - 0.6 mm (0.012 - 0.024 in)
If the specified clearance is not obtained, replace adjusting
spacer and readjust.
BREAK-IN OPERATION
When replacing compressor clutch assembly, do not forget
break-in operation, accomplished by engaging and disengaging
the clutch about thirty times. Break-in operation raises the level
of transmitted torque.
Thermal Protector
INSPECTION
• When servicing, do not allow foreign matter to get into com-
pressor.
SHA055B
HA-82
SERVICE PROCEDURES
Ventilation Air Filter

Ventilation air filter
FUNCTION
Air inside passenger compartment is kept clean at either recir-
culation or fresh mode by installing ventilation air filter into
cooling unit.
Evaporator
RHA336F
REPLACEMENT TIMING
Replace ventilation air filter every 2 years or 24,000 km (15,000
miles).
C-aution label is fixed inside the glove box.
REPLACEMENT PROCEDURES
• Remove glove box which is secured with two clips.
• Remove instrument reinforcement from instrument panel.
• Cut instrument panel as shown at left to remove ventilation

air filter.
•
Take out ventilation air filter which is secured with one clip,
from cooling unit.
Replace with new one and reinstall instrument reinforce-
•
ment on instrument panel.
• Reinstall glove box.
RHA340F
HA-83
COMPRESSOR LUBRICANT
GA15DE, ZEXEL make
CALSONIC make
SR20DE GA14DE GA16DE Model DKV-11D
CR-14
engine engine and CD20 DKV-14D
Model engines
Nissan A/C System Oil
Name
CALSONIC ZEXEL ZEXEL Type R
make make make
Part number KLHOO-PAGRO
CR-14 DKV-14D DKV-11D
CapacitymC (Imp fl oz)
Type Vane rotary
Total in system 200 (7.0) 180 (6.3)
Displacement
144 (8.79) 140 (8.54) 110 (6.71)
cm3 (cu in)/Rev Compressor (Ser-
vice parts) 200 (7.0) 180 (6.3)
Clockwise
Direction of rotation charging amount
(Viewed from drive end)
GA engine model: Poly V

Drive belt SR engine model: Poly V
CD engine model: Type A REFRIGERANT
Type HFC-134a
Capacity kg (Ib)
RHD models (Except Austra-

0.45 - 0.55 (0.99 - 1.21)
lia)
Australia (SR20DE engine) 0.50 - 0.60 (1.10 - 1.32)
Australia (GA 16DE engine)

0.60 - 0.70 (1.32 - 1.54)
and LHD models for Europe

ENGINE IDLING SPEED COMPRESSOR
When AIC is ON Model DKV-11D, DKV-14D and CR-14
Refer to EC section.
Clutch disc-to-pulley clearance 0.3 - 0.6
mm (in) (0.012 - 0.024)
BELT TENSION
Refer to Checking Drive Belts (MA section).
HA-84
ELECTRICAL SYSTEM
SECTION EL
• Read GI section, "HOW TO READ WIRING DIAGRAMS".
When you perform trouble diagnos.es, read GI section, "HOW TO FOllOW FLOW CHART
CONTENTS
PRECAUTIONS 4 Construction 55
Supplemental Restraint System (SRS) "AIR Removal and Installation 57
BAG" (Dual Air Bag System) 4 Disassembly 57
Supplemental Restraint System (SRS) "AIR Rotor Check 57
BAG" (Single Air Bag System) 4 Brush Check 58
HARNESS CONNECTOR 5 Stator Check 58
Description 5 Diode Check 59
STANDARDIZED RELAy 6 Assembly 60
Description 6 Service Data and Specifications (SDS) 61
POWER SUPPLY ROUTING 8 COMBINATION SWITCH 62
Schematic 8 Combination Switch/Check 62
Wiring Diagram - POWER - 10 Replacement 64
Fuse 19 HEADLAMP - Without Daytime light System - 65
Fusible Link 19 Wiring Diagram - H/LAMP - 65
Circuit Breaker 19 Trouble Diagnoses 67
GROUND DISTRIBUTION 20 HEADLAMP - Daytime light System - 68
BATTERy 25 Operation (Daytime light system) 68
How to Handle Battery 25 System Description 69
Battery Test and Charging Chart.. 28 Schematic 70
Service Data and Specifications (SOS) 32 Wiring Diagram - DTRL - 71
STARTING SySTEM 33 Trouble Diagnoses (Daytime Light) 74
Wiring Diagram - START - 33 HEADLAMP 75
Trouble Diagnoses 35 Bulb Replacement... 75 •
Construction 36 Aiming Adjustment. 75
Removal and Installation .45 HEADLAMP - Headlamp Aiming Control- 77
Magnetic Switch Check .46 Wiring Diagram - AIM - 77
Pinion/Clutch Check 46 Description 81
Brush Check 46 EXTERIOR LAMP 82
Yoke Check 47 Clearance, License and Tail Lamps/Schematic 82
Armature Check 48 Clearance, License and Tail Lamps/Wiring
Assembly .49 Diagram - TAILIL - 83
Service Data and Specifications (SDS) 50 Stop Lamp/Wiring Diagram - STOP/L - 92
CHARGING SYSTEM 52 Back-up Lamp/Wiring Diagram - BACK/L - 94
Wiring Diagram - CHARGE - 52 Front Fog Lamp/Wiring Diagram - F/FOG - 96
Trouble Diagnoses 54 Front Fog Lamp Bulb Replacement 101
CONTENTS (Conl'd.)
Front Fog Lamp Aiming Adjustment.. 101 Rear Wiper and Washer/Wiring Diagram
Rear Fog Lamp/Wiring Diagram - R/FOG - 102 - WIP/R - 171
Turn Signal and Hazard Warning Lamps/ Rear Wiper Amplifier Check 175
Schematic 106 Rear Wiper Installation and Adjustment.. 175
Turn Signal and Hazard Warning Rear Washer Nozzle Adjustment 175
Lamps/Wiring Diagram - TURN - 107 Rear Washer Tube Layout.. 176
Turn Signal and Hazard Warning Check Valve (for rear washer) 176
Lamps/Trouble Diagnoses 113 Headlamp Wiper and Washer/Wiring Diagram
Combination Flasher Unit Check 113 - HLC - 177
Bulb Specifications 114 Headlamp Wiper Motor Check 179
INTERIOR LAMP 115 Headlamp Wiper Installation 179
Illumination/Schematic 115 Headlamp Washer Tube Layout.. 179
Illumination/Wiring Diagram - ILL - 116 Check Valve (For headlamp washer) 179
Interior, Spot, Trunk Room and Luggage POWER WINDOW 180
Room Lamps/Wiring Diagram - INT/L - 122 System Description 180
Bulb Specifications 126 Schematic 183
METER AND GAUGES 127 Wiring Diagram - WINDOW - 185
Combination Meter 127 Trouble Diagnoses 197
Speedometer, Tachometer, Temp. and Fuel POWER DOOR LOCK 198
Gauges/Wiring Diagram - METER - 129 System Description 198
Inspection/Fuel Gauge and Water Schematic 200
Temperature Gauge 133 Wiring Diagram - D/LOCK - 202
Inspection/Tachometer 134 Trouble Diagnoses - Type 1 (For Europe and
Inspection/Speedometer and Vehicle Speed Austral ia) 212
Sensor 135 Trouble Diagnoses - Type 2 (Except for
Fuel Tank Gauge Unit Check 137 Europe and Australia) 216
Thermal Transmitter Check 137 POWER DOOR MIRROR 220
Vehicle Speed Sensor Signal Check 137 Wiring Diagram - MIRROR - 220
WARNING LAMPS AND BUZZER 138 ELECTRIC SUN ROOF 224
Warning Lamps/Schematic 138 Wiring Diagram - SROOF - 224
Warning Lamps/Wiring Diagram - WARN - 139 HORN, CIGARETTE LIGHTER AND CLOCK 226
Oil Pressure Switch Check 151 Wiring Diagram - HORN - 226
Fuel Warning Lamp Sensor Check 151 REAR WINDOW DEFOGGER AND DOOR
Diode Check 151 MIRROR DEFOGGER 230
Warning Buzzer Unit... 151 System Description (For models with daytime
Warning Buzzer/System Description 152 light system) 230
Warning Buzzer/Wiring Diagram Wirin.g Diagram - DEF - 231
- BUZZER - 154 Filament Check 235
Components Inspection - Warning Buzzer 157 Fi lament Repai r 236
WIPER AND WASHER 160 AUDIO AND ANTENNA 237
Front Wiper and Washer/System Description 160 Audio/System Description 237
Front Wiper and Washer/Wiring Diagram Wiring Diagram - AUDIO - 238
- WIPER - 162 Radio Fuse Check 243
Front Wiper Amplifier Check 166 Location of Antenna 243
Front Wiper Installation and Adjustment.. 166 Antenna Rod Replacement.. 243
Front Wiper Linkage 167 HEATED SEAT 245
Front Washer Nozzle Adjustment... 168 Wiring Diagram - H/SEAT - 245
Front Washer Tube Layout 168 NATS (Nissan Anti-Theft System) 247
Rear Wiper and Washer/System Description 169 System Description 247
System Composition 247
CONTENTS (Cont'd.)
Component Parts Location 248 Air Bag Harness 297

Wiring Diagram - NATS - 249 Room Lamp Harness 298
Trouble Diagnoses 251 Back Door Harness 299
LOCATION OF ELECTRICAL UNITS 266 Front Door Harness (LH side) 300
Engine Compartment 266 Front Door Harness (RH side) 302
Passenger Compartment 267 Rear Door Harness 304
HARNESS LAyOUT 269 SUPER MULTIPLE JUNCTION (SMJ) Foldout
How to Read Harness Layout... 269 Terminal Arrangement Foldout
Outline 270 FUSE BLOCK - Junction Box (JIB) Foldout
Engine Control Harness 271 Terminal Arrangement Foldout
Engine Room Harness 274 ELECTRICAL UNITS Foldout
Main Harness '" 280 Terminal Arrangement Foldout
Body Harness : 284 JOINT CONNECTOR (J/C) Foldout
Body No.2 Harness 292 Terminal Arrangement Foldout
Engine Harness 294
WIRING DIAGRAM REFERENCE CHART
COOLING SYSTEM LC SECTION

ECCS (Ignition syslem) EC SECTION
AUTOMATIC TRANSAXLE CONTROL SYSTEM AT SECTION
ANTI-LOCK BRAKE SYSTEM BR SECTION
SRS "AIR BAG" RS SECTION
HEATER AND AIR CONDITIONER HA SECTION
•
PRECAUTIONS

WARNING:

air bag module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp and
spiral cable. Information necessary to service the system safely is included in the RS section of this
Service Manual.
WARNING:
• Do not use electrical test equipment on any circuit related to the SRS.
EL-4
HARNESS CONNECTOR
Description
HARNESS CONNECTOR
• All harness connectors have been modified to prevent accidental looseness or disconnection.
• The connector can be disconnected by pushing or lifting the locking section.
CAUTION:
Do not pull the harness when disconnecting the connector.
[Example]
Packing
(Water-proof type)
LIFT PUSH
PUSH
PUSH
•
PUSH
(For combination meted (For relay)
SEL769D
EL-5
STANDARDIZED RELAY
Description
NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS
Relays can mainly be divided into three types: normal open, normal closed and mixed type relays.
NORMAL OPEN RELAY NORMAL CLOSED RELAY MIXED TYPE RELAY
Flows. Flows .
U.
Does not
flow. e:> = Does note:>
•
u.
9 flow.
~
(J)
I =0
I = 0 I
BATIERY SW 1 BATIERY SW 1 BATIERY
Flows .
• Does not
flow. Q
Does not
flow. Q
Z =
0
Flows.
:s:
(J)
L t L
SW 1 SW 1
I
BATIERY BATIERY BATIERY
SEL881H
TYPE OF STANDARDIZED RELAYS
1M 1 Make 2M 2 Make
1T 1 Transfer 1M.1B .................. 1 Make 1 Break
r~~-~.~_._- -~--_.-_.."..__ ._-~- _.. ----------- -------~.- -.----.-----~----

1M 2M
(ftj 1M
,
.. "
,
2M
r
;
-~~- -~.-----.-
r---~---.-------------
----
.... 1T
1T I
iM.1B
1B
(/ -', \ I
~.. - -_\_~- ~---- j

SEL882H
EL-6
51 ANDARDIZED RELAY
Connector symbol
Type Outer view Circuit Case color
and connection
1T BLACK
=
2M BROWN
1M.1B GRAY
1M BLUE
The arrangement of terminal numbers on the actual relays may differ from those shown above.
•
SEL661TA
EL-7
Schematic
CHARGE
75A [ill
>- CIRCUIT
a:
w
I--
I--
25A m BREAKER
« ILL, WINDOW, D/LOCK, SROOF

CD
30A 0
I COOl/F, A/C I
30A lliJ
COOl/F, A/C
7.5A@Q]
FICO, A/CCUT, A/C
7.5A@I]
CHARGE
UJ
..J
IGNITION SWITCH
30A ITJ OFF ACC ON ST
MAIN, IGN/SG, INJECT
START
7.5A~
7.5A~
S/SIG, GLOW, PlA, DTRl
AAC/V
15A @ill
H/lAMP, DTRl, R/FOG
15A @Q]
H/LAMP,DTRl
7.5A0J LIGHTING SWITCH
MAIN, CMPS, MAFS, GLOW, NATS OFF 1ST 2ND
ABC ABC ABC
10A ~
HORN
7.5A@]
R/FOG
FRONT FOG
lAMP SWITCH
10A 00
DR
LE 10A mI
CD
DAYTIME
LIGHT
UNIT DL
HEL001
EL-8
Schematic (Cont'd)
l5A ~
F/FOG
20A @J
LOAD, DEF
lOA [8J
ABS, SToP/L
lOA [ill
TURN
7.5A@Q]
FICO, A!CCUT,
HEATER, A!e INT/L
GLOW, AIM, BUZZER,

HORN, AUDIO, NATS
ILL, AUDIO
lOA @]
HEATER, A!e WIP/R
l5A [ill
HORN
20A [ill
WIPER
lOA ~
ACCESSORY
RELAY MIRROR, DEF
l5A ~
HLC
20A []]
@ RHO models LOAD, DEF

@ eo engine
n IGNITION
@ SR engine U RELAY LOAD, MIL, BUZZER, WINDOW,
SROOF, DEF, NATS
@ SR engine A/T models
and CO engine
@ For Europe and Israel LKUP, AIT, BACK/L,
@ Except @ METER, WARN
@ LHD models without
daytime light system TURN
@ Except @
7. 5A [ill
@ LHo models with
daytime light system ABS
@ Without daytime light system lOA [ill
@ With single air bag system H/SEAT
@) With dual air bag system lOA [ill
•
H02S
l5A @]
TAIL. F/FoG F/PUMP, AIRREG
3A IE]
LOAD, AIM, TAIL, F/FO~ SRS
ILL, BUZZER
lOA ~
SRS
PGC/V, EGRC/V, AAC/V, VTC,

COOL/F, LOAD, GLOW, PLA,
FCUT, A/C, START, DTRL, DEF
HEL096
EL-9
Wiring Diagram - POWER -
~ BATTERY
EL-POWER-01
FUSIBLE LINK AND
W/R RELAY BOX ~
~ ~
W/R~ t 30A
@: CD engine
@: LHD models without
I W daytime light system
@: SR engine AT models
and CD engine
B/R BR Y
Jt
W/R t o 1_-_-_-_- _-I::::::: BYR :} ABS
rn - B/R + GLOW
75A
- A Next page
FUSIBLE LINK
[]] AND FUSE BOX
~
~
~
Il:jdI W GY G/W L!Y RIB
!
Wt
~
1
CIRCUIT
BREAKER
(102)
I ---------
1 RIB +
L/Y +
G/W +}
CHARGE
FICO, A/CCUT,
COOL/F,A/C
A/C
~
W!L GY +
I W/L + 57tb~R~~2~bF
.--------------
1-----0---------
~
W +CHARGE
JB---- To EL -POWER
~:--. -f9>
W
~ -04
1._.- __ - W Next page
~-----------------------------------,
CE57> ~
FRONT
FRONT"
t
-----------------------------------~
HEL002
El-10
Wiring Diagram - POWER - (Cont'd)
Preceding --19- W EL-POWER-02

page ~
@: AHO models
<ID: LHO models without daytime
light system
<Illi>: Except <ID
LIGHTING
SWITCH @: LHO models with daytime light system
00): <ID @: SA engine
@: Except@
*1"'@ R/B , <ID R/Y , @ AIL
I
W/R
Preceding
page
FUSIBLE LINK
10A AND FUSE BOX
1451 <rn>
@
A/Y BIA BA R
+
•
I
R ~H/lAMP. DTRl. AIFOG
BA .. AAC/V
~
~ 0 ~ BIA ~ TAIL. F/FOG. ILL
LIGHTING
SWITCH
-
-
TAIl/l
OFF.... ~:<Illi> FUSE DAYTIME
1l12J1 LIGHT
TAIL/l UNIT
~Ol
~R/l ~ SW
(E119): @
TAIL/L
OUTPUT
LE 0-0- * 1 .JE-.
~
To El -POWER
-09
LE 01--- AIL .. TAIL, F/FOG
r---------------------------------,
<rnl
FAONT. L
~(ffiID
~
•
~GY
L _
HEL003
EL-11
Wiring Diagram - POWER - (Conl'd)
EL-POWER-03
Preceding o
page
FUSIBLE LINK
7.5A AND FUSE BOX
1431 ~
@
G R/W W/L GIS P
I
I
L- P + R/FOG
----- GIS+ HORN
-------- W/L + ~t5~:~~~~.MAFS.
R/W + H!LAMP.DTRL
G
IFh
S
IGNITION
ON.-ST ON SWITCH
OFF' OFF 'e- @
ACC ACC
ACC
~ @: For Europe and Israel

W/L @: Except for Europe
and Israel
EE
_______ S/L ~ ~glL-POWER
B/W +
START
SIP ~ To EL-POWER
~-08
.--------------- SiR -e> ~g6EL-POWER

1.--------------- B/R
W/L ~
+
MAIN.IGN/SG.INJECT
~g5EL-POWER
r-------------------~
I I
I I
<ill) , Illin @ ~ @ (EU4) I
FRONT. : tmmID
,
W tm:IID W :
L ~I
HEL004
EL-12
Wiring Diagram - POWER - (ConI' d)
EL-POWER-04
To EL-POWER4
-01 ~
W
----.---- W ~ Next page
~: LHD models with daytime light system

@: Except@
FUSE BLOCK
(JIB)
m (E12O)
10A ~
[}[] ~
(fl06)
(]V
IN;51
GIOR
EE
LG/OR+TU1N
R/Y • IL
ABS,STOP
P • GLOW.
BUZZER
P • AIM
: :} AUDIO
P .NATS
P .HORN
RIB .}
INTIL
RIB.
LIB • LOAD.DEF
OR .F/FOG
~------------------------------------------------------------,
N20
N22
([@
~@:m
B
@: (H2O)
•
@) ,.-------
I
W I
L j I
HEL005
EL-13
Wiring Diagram - POWER - (Conl'd)
EL-POWER-05
To EL-POWER-03~
Preceding page ~ W _1-,

W/L ..... ()~
W!L W
W/L ~
(b):
@:
@:
~gBEL-POWER
LHO models
RHOmodels
db db @: LHO models with daytime light system
- IIS511 IIRill
~
~}Next page
FUSE BLOCK
(.J/B)
- iOA
~
<f!@
@ID
(106)
(@
[[]
EE OL
WIP/R
PU
LG
LG
L
L
r-----------------------------------------------------------,
+ 2
5
1
{ACCD
L ~
HEL006
EL-14
Wiring Diagram - POWER - (Coni' d)
EL-POWER-06
To EL-POWER-03 ~ BIR --,
@: LHD models with daytime light system
BIR @: Without daytime light system
Is~1
Preceding { L
page
p
FUSE BLOCK
(JIB)
-
<fill)
(E105)
(f106)
@)
20A
m
@)
Y Y R R G/W G G G G GLIB
t.= L~B :} LOAD, DEF
~ G • MIL
G • NATS
G • BUZZER
G • WINDOW,SROOF
G/W • TURN
: :} H/SEAT
Y • METER,WARN
Y • LKUP, AIT
BACK!L
GY • ABS
r-----------------------------------------------------------,
+
2
5
1
(IGNl)
•
----------------------------------------------------~
HEL007
EL-15
EL-POWER-07
@: A/T models
@: With single air bag system
@: With dual air bag system
To EL-POWER-03 <Q- S/L --------------1

S/L
la-51
N
FUSE SLOCK
(J/S)
<till)
10A
1251 ~
1I~51 IN.41 IN.41

RIL S/Y s/Y
A I L S/Y • S/SIG. GLOW, PLA
L..: S/Y .DTRL
R/L .}
SRS
R/W.
SR • START
SR • COOL/F. LOAD. FCUT,

A/C,DTRL,DEF
SR • GLOW. PLA
SR • PGC/V. EGRC/V. AAC/V,

VTC, GLOW. PLA
S/W.} F/PUMP. AIRREG

SIL •
SR/Y. H02S
r-------------------------------------------------,
HEL008
EL-16
Wiring Diagram - POWER - (ConI' d)
EL-POWER-08
To EL-POWER ~ B/P ~
-03 ~ I <D:LHO models
<ID:
RHO mode Is
~g5EL-POWER ~ W/L ~() @: For Europe and Israel
@: Except @
I *2'" @W!L @B/P
*2
rrm
I
To FUSE BLOCK
EL-POWER (..)/B)
-06 (ill)
p
- m
15A 7.5A
IT]
(105)
<El06)
UN.?'
B
I
B
ln
1
JOINT
CONNECTOR-1
@
.I-()~()..,
~
B
I
<:
B
:>B
R
B
I
B
..
..
----
__
• LIB +}
LG/R +
LG/R +
FICO. A/CCUT•
A/C
HEATER, A/C
If-II
... ----- LG/R + A/CCUT. A/C
LG/R+}
HEATER.A/C
~~ @
L/W +
r-----------------------------------------------------------,
+2
• 5
1
CIGN2)
(ACC2)
r--------------------------
UITIIIIIIIIIill @
~BR
--------------------------------~
HEL009
EL-17
<D: LHD models

EL-POWER-09
@: RHO models
@: LHD models with daytime light system
To EL-POWER-02 <@- *1 qJ): LHD models without daytime light system
l
@: Except @
@: Models with tachometer
*1'" @R/B , qJ)R/Y , @R/L
*3'" (DRIG , @R/L
*4" . (DRIY , @RIL
( FUSE BLOCK
~
(JIB)
4;106)
I @)
UN: I I r:I Ir: I IIN: I UN: I UN: I IN.aI UN.al IN..aI UN.allI~al UN: I liT: I I~21
I.
*3 RIG RIG RIG RIG RIG RIG RIG RIG RIG RIG RIG *4 RIL
TN R/l" TAIL, FIFOO
..----R/G. *4 •
RIG.
TAIL
RIG.
RIG.
ILL
RIG.
RIG.
RIG.
RIG.
RIG. BUZZER
RIG. LOAD
RIG • AIM. ILL
*3 • FIFOG
r-------------------------------------------------,
-------------------------------------------------~
HEL010
EL-18
Fuse
• If fuse is blown, be sure to eliminate cause of problem
before installing new fuse.
• Use fuse of specified rating. Never use fuse of more than
specified rating.
• Do not partially install fuse; always insert it into fuse holder
properly.
• Remove fuse for clock if vehicle is not used for a long period
of time.
OK Blown
CEL083
Fusible Link
A melted fusible link can be detected by visual inspection. If its
condition is questionable, use circuit tester or test lamp.
CAUTION:
• If fusible link should melt, it is possible that critical circuit
(power supply or large current carrying circuit) is shorted.
In such a case, carefully check and eliminate cause of prob-
lem.
• Never wrap outside of fusible link with vinyl tape.
Important: Never let fusible link touch any other wiring har-
ness or vinyl or rubber parts.
ime (sec.)
Circuit Breaker
100
50
For example, when current is 30A, the circuit is broken within 8
to 20 seconds.
20 Circuit breakers are used in the following systems.
10 • Power window
8
5 • Power door lock
• Electric sun roof
SBF284E
•
EL-19
GROUND DISTRIBUTION
GROUND CONNECT TO CONN. NO. CELL CORD
E37/E51 AIR BAG DIAGNOSIS SENSOR UNIT (Single

E108 RS-SRS
air bag system)
BRAKE FLUID LEVEL SWITCH E2 EL-WARN
CLEARANCE LAMP LH E50 EL-TAILIL
CLEARANCE LAMP RH E33 EL-TAILIL
COOLING FAN MOTOR-1 (1-mode type) E45 EC-COOLIF HA-A/C
COOLING FAN MOTOR-1 (2-mode type-GA

E66 EC-COOLIF HA-A/C
engine for Europe)
COOLING FAN MOTOR-1 (2-mode type-ex-
eept GA engine for Europe)
COOLING FAN MOTOR-2 (1-mode type) E39 EC-COOLIF HA-A/C

-
COOLING FAN MOTOR-2 (2-mode type-GA
E67 EC-COOLiF HA-A/C
engine for Europe)
COOLING FAN MOTOR-2 (2-mode type-ex-

eept GA engine for Europe)
COOLING FAN RELAY-1 E12 EC-COOLIF HA-A/C
DAYTIME LIGHT UNIT E119 EL-DTRL
FRONT FOG LAMP LH E52 EL-F/FOG
FRONT FOG LAMP RH E36 EL-F/FOG
FRONT TURN SIGNAL LAMP LH E53 EC-TURN
FRONT TURN SIGNAL LAMP RH E32 EC-TURN
FRONT WIPER AND WASHER SWITCH E113 EL-WIPER
FUEL FILTER SWITCH E5 EL-WARN
HEADLAMP AIMING MOTOR UNIT LH E48 EL-AIM
HEADLAMP AIMING MOTOR UNIT RH E35 EL-AIM
HEADLAMP LH E49 EL-H/LAMP EL-DTRL
HEADLAMP RH E34 EL-H/LAMP EL-DTRL
HEADLAMP WIPER MOTOR LH E44 EL-HLC
HEADLAMP WIPER MOTOR RH E41 EL-HLC
IACV-FICD SOLENOID VALVE (LHD models .

E65 EC-A/CCUT HA-A/C
with CD20 engine)
INHIBITOR SWITCH E222 EC-PNP/SW AT-A IT EL-START
NEUTRAL POSITION SWITCH E220 EC-PNP/SW
POWER STEERING OIL PRESSURE SWITCH

E3 EC-PST/SW
(RHO models with gasoline engine)
REAR FOG LAMP RELAY E20 EL-R/FOG
REAR WIPER AND WASHER SWITCH E112 EL-WIP/R
REAR WIPER RELAY E15 EL-WIP/R
SIDE TURN SIGNAL LAMP (Driver side) E1 EL-TURN
WASHER FLUID LEVEL SWITCH E30 EL-WARN
EL-20
GROUND DISTRIBUTION
M27 COMBINATION METER (TACHOMETER) M31 EL-METER
COMBINATION METER (AIR BAG WARNING

M'1 RS-SRS EL-WARN
LAMP)
COMBINATION METER (CLOCK ILLUMINA-
M'1 EL-ILL EL-HORN
TION) (For Europe and Israel)
COMBINATION METER (FUEL GAUGE) M'1 EL-METER
COMBINATION METER (HIGH BEAM INDICA-

M'1 EL-H/LAMP EL-DTRL
TOR)
COMBINATION METER (SPEEDOMETER) M'1 EC-VSS EC-COOLIF EL-METER
COMBINATION METER (TURN) M'2 EL-TURN
COMBINATION METER (WATER TEMP.

M'1 EL-METER
GAUGE) .
M28/M68 A/T CONTROL DEVICE (OD CONTROL
M42 AT-A/T
(LHD models) SWITCH)
M28/M60/M68
A/T CONTROL DEVICE (A/T INDICATOR
(RHD models) M42 EL-ILL
ILLUMINATION)
ACCESSORY RELAY (In fuse block) M15 EL-POWER
ASHTRAY ILLUMINATION M44 EL-ILL
BLOWER RELAY (In fuse block) M15 EL-POWER
CIGARETTE LIGHTER SOCKET M43 EL-HORN
COMBINATION FLASHER UNIT M20 EL-TURN
COMBINATION METER (METER ILLUMINA- M30

EL-ILL
TION) (For Europe and Israel) M32
DATA LINK CONNECTOR FOR CONSULT M13 EC-MIL BR-ABS RS-SRS
DOOR LOCK TIMER (Type-1) M34 EL-D/LOCK
DOOR LOCK TIMER (Type-2) M35 EL-D/LOCK
DOOR MIRROR REMOTE CONTROL SWITCH M9 EL-MIRROR
ECM (ENGINE CONTROL MODULE) M39 EC-GLOW
FAN SWITCH M45 EC-A/CCUT EC-LOAD HA-A/C
FAN SWITCH ILLUMINATION M48 HA-A/C EL-ILL
FRONT FOG LAMP SWITCH M10 EL-F/FOG EL-ILL
FRONT WIPER AMPLIFIER M74 EL-WIPER
FRONT WIPER MOTOR (With ASS, dual air

M83 EL-WIPER
bag or rear power window)
GLOVE BOX LAMP SWITCH M66 EL-ILL
HAZARD SWITCH
HEADLAMP AIMING SWITCH
HEADLAMP WIPER AND WASHER SWITCH
IGNITION RELAY (In fuse block)

ILLUMINATION CONTROL SWITCH
M54
M11
M56
M15
M21
EL-TURN
EL-AIM
EL-ILL
EL-POWER
EL-ILL
EL-ILL
EL-HLC •
MIRROR DEFOGGER RELAY M17 EL-DEF
NATS IMMU M36 EL-NATS
'1: M30 (With tachometer), M32 (Without tachometer)

'2: M30 (Without tachometer), M31 (With tachometer)
EL-21
GROUND DISTRIBUTION

M28/M68 POWER STEERING OIL PRESSURE SWITCH
(LHD models) (LHD models without A8S, dual air bag and M82 EC-PST/SW
M28/M60/M68 rear power window)
(RHD models) POWER WINDOW RELAY M16 EL-ILL EL-WINDOW
REAR FOG LAMP SWITCH M55 EL-R/FOG EL-ILL EL-8UZZER
REAR WINDOW DEFOGGER SWITCH M53 EL-ILL EL-DEF
REAR WINDOW DEFOGGER TIMER M37 EL-DEF

REAR WIPER AMPLIFIER (RHD models) M21 EL-WIP/R
RECIRCULATION SWITCH M46 HA-A/C
SIDE TURN SIGNAL LAMP (Passenger side)

(GA engine without A8S, dual air bag and M81 EL-TURN
rear power window)
SUN ROOF RELAY M16 EL-SROOF

WARNING 8UZZER UNIT (For Australia) M38 EL-8UZZER
FRONT WIPER MOTOR (With A8S, dual air

8105 EL-WIPER
bag or rear power window)
-_._- -
REAR WIPER AMPLIFIER (LHD modelsl 88 EL-WIP/R
0-
IACV-FICD SOLENOID VALVE (RHD models

8102 EC-A/CCUT HA-A/C
with CD engine)
POWER STEERING OIL PRESSURE SWITCH

(LHD models with ASS, dual air bag or rear 8102 EC-PST/SW
power window)
SIDE TURN SIGNAL LAMP (Passenger side)

(Except GA engine without A8S, dual air bag 8108 EL-TURN
and rear power window)
AIR 8AG DIAGNOSIS SENSOR UNIT (Dual air

Z1 RS-SRS
bag system)
SPOT LAMP R2 EL-INT/L

DOOR LOCK ACTUATOR (Driver side) D8 EL-D/LOCK
DOOR LOCK ACTUATOR (Passenger side) D38 EL-D/LOCK
DOOR MIRROR DEFOGGER (Driver side) D4 EL-DEF
DOOR MIRROR DEFOGGER (Passenger side) D34 EL-DEF
LOCK KN08 SWITCH D9 EL-D/LOCK
POWER WINDOW MAIN SWITCH (Without
D6 EL-WINDOW
rear power window)
POWER WINDOW MAIN SWITCH (With rear

D7 EL-WINDOW EL-D/LOCK
power window)
EL-22
GROUND DISTRIBUTION
F13/F14 DISTRIBUTOR (CAMSHAFT POSITION SEN-

F24 EC-CMPS
SOR)
DISTRIBUTOR (POWER TRANSISTOR) F24 EC-IGN/SG
ECM (ECCS CONTROL MODULE) F1 EC-MAIN
IACV-FICD SOLENOID VALVE (GA16DE

F9 EC-FICD HA-A/C
engine except for Europe and Israel)
IACV-FICD SOLENOID VALVE (GA engine for
F11 EC-FICD HA-A/C
Europe and Israel and GA 15DE engine)
SHIELD WIRE (CAMSHAFT POSITION SEN-

F24 EC-CMPS
SOR)
SHIELD WIRE (HEATED OXYGEN SENSOR) F23 EC-H02S
SHIELD WIRE (KNOCK SENSOR) (GA engine) F102 EC-KS
SHIELD WIRE (MASS AIR FLOW SENSOR)

(GA engine for Europe and Israel and F12 EC-MAFS
GA15DE engine)
SHIELD WIRE (MASS AIR FLOW SENSOR)
(GA 16DE engine except for Europe and Israel F27 EC-MAFS
and SR engine)
SHIELD WIRE (OXYGEN SENSOR) F22 EC-02S
SHIELD WIRE (THROTTLE POSITION SEN-

F8 EC-TPS
SOR)
IACV-AIR REGULATOR E214 EC-AIRREG
IACV-FICD SOLENOID VALVE (SR engine) E212 EC-FICD HA-A/C
SHIELD WIRE (KNOCK SENSOR) (SR engine) E215 EC-KS
E205 ALTERNATOR E233 EL-CHARGE EL-WARN
B11/B32 FRONT DOOR SWITCH (Driver side) B9 RS-SRS EL-BUZZER

(Sedan) B17 EC-F/PUMP
FUEL PUMP
B11/B32/D105
FUEL TANK GAUGE UNIT B18 EL-METER EL-WARN
(Hatchback)
HEATED SEAT LH B12 EL-H/SEAT
HEATED SEAT RH B16 EL-H/SEAT
HEATED SEAT SWITCH LH B13 EL-H/SEAT
HEATED SEAT SWITCH RH B15 EL-H/SEAT

REAR COMBINATION LAMP LH (TAIL AND
B27 EL-TAILIL EL-STOP/L
STOP) (Hatchback)
REAR COMBINATION LAMP LH (TURN SIG-
B27 EL-TURN
•
NAL) (Hatchback)
REAR COMBINATION LAMP RH (TAIL AND

B28 EL-TAILIL EL-STOP/L
STOP) (Hatchback)
REAR COMBINATION LAMP RH (TURN SIG-
B28 EL-TURN
NAL) (Hatchback)
HIGH-MOUNTED STOP LAMP (In rear air
D112 EL-STOP/L
spoiler) (Hatchback)
HIGH-MOUNTED STOP LAMP (On rear win-
D108 EL-STOP/L
dow) (Hatchback)
LICENSE PLATE LAMP LH (Hatchback) D107 EL-TAILIL
LICENSE PLATE LAMP RH (Hatchback) D109 EL-TAILIL
EL-23
GROUND DISTRIBUTION
B11/B32 LUGGAGE ROOM LAMP SWITCH 0110 EL-INT/L

(Sedan) REAR COMBINATION LAMP LH (BACK-UP) 0103 EL-BACK/L
B11/B32/D105
REAR COMBINATION LAMP LH (REAR FOG)
(Hatchback) 0103 EL-R/FOG
(LHD Hatchback models for Europe)
REAR COMBINATION LAMP LH (TAIL)

0103 EL-TAILIL
(Hatchback except for Europe and Australia)
REAR COMBINATION LAMP RH (BACK-UP) 0111 EL-BACK/L
REAR COMBINATION LAMP RH (REAR FOG)

0111 EL-R/FOG
(RHO Hatchback models for Europe)
REAR COMBINATION LAMP RH (TAIL)
0111 EL-TAILIL
(Hatchback except for Europe and Australia)
T10/T11 HIGH-MOUNTED STOP LAMP (Sedan) T6 EL-STOP/L
LICENSE PLATE LAMP LH (Sedan) T5 EL-TAILIL
LICENSE PLATE LAMP RH (Sedan) T7 EL-TAILIL
REAR COMBINATION LAMP LH (BACK-UP)

T3 EL-BACK/L
(LHD Sedan models)
REAR COMBINATION LAMP LH (REAR FOG)
T3 EL-R/FOG
(Sedan)
REAR COMBINATION LAMP LH (TAIL AND
T2 EL-TAILIL EL-STOP/L
STOP) (Sedan)
REAR COMBINATION LAMP LH (TAIL)
T3 EL-TAILIL
(Sedan except for Europe and Australia)
REAR COMBINATION LAMP LH (TURN SIG-

T2 EL-TURN
NAL) (Sedan)
REAR COMBINATION LAMP RH (BACK-UP)
TB EL-BACK/L
(Sedan)
REAR COMBINATION LAMP RH (REAR FOG)

TB EL-R/FOG
(RHO Sedan models)
REAR COMBINATION LAMP RH (TAIL AND
T9 EL-TAILIL EL-STOP/L
STOP) (Sedan)
REAR COMBINATION LAMP RH (TAIL)

TB EL-TAILIL
(Sedan except for Europe and Australia)
REAR COMBINATION LAMP RH (TURN SIG-

T9 EL-TAILIL
NAL) (Sedan) .
TRUNK ROOM LAMP SWITCH T4 EL-INT/L
B110 SHIELD WIRE (WHEEL SPEED SENSOR
E4 BR-ABS
FRONT LH) (LHD models)
SHIELD WIRE (WHEEL SPEED SENSOR

E11 BR-ABS
FRONT RH) (RHO models)
B106 BR-ABS
FRONT LH) (RHO models)

B107 BR-ABS
FRONT RH) (LHD models)
B112 ABS CONTROL UNIT B111 BR-ABS
ABS RELAY BOX B104 BR-ABS

B204 REAR WINDOW DEFOGGER B203 EL-DEF
EL-24
BATTERY
CAUTION:
• If it becomes necessary to start the engine with a booster
battery and jumper cables, use a 12-volt booster battery.
• After connecting battery cables, ensure that they are tightly
clamped to battery terminals for good contact.
• Never add distilled water through the hole used to check
specific gravity.
How to Handle Battery

METHODS OF PREVENTING OVER-DISCHARGE
T.he following precautions must be taken to prevent over-dis-
charging a battery.
• The battery surface (particularly its top) should always be
kept clean and dry.
• The terminal connections should be clean and tight.
• At every routine maintenance, check the electrolyte level.
SEL711E
• When the vehicle is not going to be used over a long period

of time, disconnect the negative battery terminal. (If the
vehicle has an extended storage switch, turn it off.)
• Check the charge condition of the battery.

Periodically check the specific gravity of the electrolyte.
Keep a close check on charge condition to prevent overdis-
charge.
SEL459R
CHECKING ELECTROL VTE LEVEL •

WARNING:
Do not allow battery fluid to come in contact with skin, eyes,
fabrics, or painted surfaces. After touching a battery, do not
touch or rub your eyes until you have thoroughly washed your
hands. If the acid contacts the eyes, skin or clothing, immedi-
ately flush with water for 15 minutes and seek medical atten-
tion.
EL-25
BATTERY
How 10 Handle Battery (Coni' d)
• Remove the cell plug using a suitable tool.
• Add distilled water up to the MAX level.
SEL001K
Normal battery SULPHATION

SUlphated battery
Charging voltage ~_"'" ----- A battery will be completely discharged if it is left unattended
for a long time and the specific gravity becomes less than 1.100.
t~ Charging voltage This may result in sulphation on the cell plates.
To find if a discharged battery has been "sulphated", pay atten-
Charging current
tion to its voltage and current when charging it. As shown in the
, Charging current figure at left, if the battery has been "sulphated", less current
t and higher voltage may be observed in the initial stage of
charging.
Duration of charge
SEL005Z
Read top level / Hydrometer SPECIFIC GRAVITY CHECK

with scale 1. Read hydrometer and thermometer indications at eye level.
.'\U)
II~
SEL442D
• When electrolyte level is too low, tilt battery case to raise it

Hydrometer for easy measurement.
Thermal~n
gauge ]
SEL006Z
EL-26
BATTERY
How to Handle Battery (Cont'd)
2. Convert into specific gravity at 20°C (68°F).
Example:
• When electrolyte temperature is 35°C (95°F) and specific
gravity of electrolyte is 1.230, converted specific gravity at
20°C (68°F) is 1.240.
• When electrolyte temperature is O°C (32°F) and specific
gravity of electrolyte is 1.210, converted specific gravity at
20°C (68°F) is 1.196.
Converted specific gravity
1.30
Q)
1.28
:;
~
Q)
1.26
0-
E
l!l 1.24
Q)
>. 1.22
e0
Q)
a; 1.20
<;;
>, 1.18
=5
'"0, 1.16
.g
U 1.14
Q)
0-
00
1.12
1.10
-30 -20 -10 0 10 20 30 40 50

(-22) (-4) (14) (32) (50) (68) (86) (104) (122)
Electrolyte temperature °C (OF) SELOO7Z
•
EL-27
BATTERY
Battery Test and Charging Chart
Chart I
VISUAL INSPECTION
• Check battery case for cracks or bends .
• Check battery terminals for damage .
• If the difference between the max. and min. electrolyte level in cells is within 10 mm (0.39 in), it is OK.
OK
tNG
Replace
CHECKING SPECIFIC GRAVITY
battery.
Refer to "Specific Gravity Check".
I
Below 1.100 1.100 - 1.220 Above 1.220
SLOW CHARGE
. QUICK CHARGE CAPACITY TEST
Refer to "A: Slow STANDARD CHARGE Refer to "C: Quick Charge". Refer to "Chart II".
Charge". Refer to "B: Standard
CAPACITY TEST
Charge".
CAPACITY TEST
r K
Ready for use

NG
• Mount battery again

Refer to "Chart Refer to "Chart II".
and check loose termi-
II".
OK NG nals. Also check other
t t
K
Ready for
G
Replace Ready for

CHECKING SPECIFIC
related circuits.
QUICK CHARGE
use battery. use
GRAVITY Refer to "C: Quick Charge".
Refer to "Specific Gravity • Time required: 45 min.
Check".
1
RECHARGE CAPACITY TEST
Refer to "C: Quick Charge" . Refer to "Chart II".
• If battery temperature rises above 60°C (140°F),
stop charging. Always charge battery when its OK NG
temperature is below 60°C (140°F).
Ready for use Replace

CAPACITY TEST
battery.
Refer to "Chart II"
tOK
Ready
tNG
Replace
for use battery.
* "STANDARD CHARGE" is recommended if the vehicle is in storage alter charging.
EL-28
BATTERY
Battery Test and Charging Chart (Cont'd)
• Check battery type and determine the specified current
Chart II using the following table.
Fig. 1 DISCHARGING CURRENT
(Load Tester)
CAPACITY TEST
Type Current (A)
28B19R(L) 90
34B19R(L) 99
46B24R(L) 135
55B24R(L) 135
Test using load tester.
50D23R(L) 150
55D23R(L) 180
65D26R(L) 195
Follow manufacturer's Read load tester voltage
instructions to check and when specified discharging 80D26R(L) 195
determine if battery is ser- current (Refer to Fig~ 1.)
75D31R(L) 210
viceable, flows through battery for 15
seconds. 95D31R(L) 240
OK NG
115D31R(L) 240
95E41R(L) 300
Ready for use Go to next 130E41R(L) 330
step.
Above 9.6
volts
OK
Ready for use

Below 9.6
volts
Go to next
step.
NG ~mo~
SEL008Z
•
EL-29
BATTERY
I A: SLOW CHARGE
Determine initial charging current Irom specilic gravity

relerring to Fig. 2.
Fig. 2 INITIAL CHARGING CURRENT SETTING (Slow charge)
• Charge battery. BATTERY TYPE

• Check charging voltage 30 minutes after starting the CON-
battery charge. VERTED 2 ::J 2 ::J ::J2 ::J 2 ::J ::J 2 2 ::J
if
SPECIFIC r:r: if r:r: if if r:r: if r:r: r:r: if r:r:
;;; r:r: :;
en
~ en '<t
N
'<t
N "" 0""
N N
<D
N
<D
N ;;; ;;; 0 :; 1.U
GRAVITY CD CD CD CD 0 0 0 0 0
<0 '<t <D to to LO LO LO ~
to
~
1.U
LO
0
~
N
"" '<t to
0
to LO <D
0
<0 "- en en ""
Below 4.0 5.0 7.0 8.0 9.0 10.0 14.0
1.100 (A) (A) (A) (A) (A) (A) (A)
• Check battery type and determine the specified current using the
table shown above .
• After starting charging, adjustment of charging current is not nec-
essary.
Continue to charge lor 12

hours. Fig. 3 ADDITIONAL CHARGE (Slow charge)
Replace battery
Above 1.240

Reier to "Specilic Gravity Check".
Charge for 5 Charge lor 4 Charge lor 2
hours at hours at hours at
initial charg- initial charg- initial charg-
ing current ing current ing current
Conduct additional charge as per Fig. 3. if necessary.
selting. setting. setting.
Go to "CAPACITY TEST".
Go to "CAPACITY TEST"
I
CAUTION:
• Set charging current to value specified in Fig. 2. If charger
is not capable of producing specified current value, set its
charging current as close to that value as possible.
• Keep battery away from open flame while it is being
charged.
• When connecting charger, connect leads first, then turn on
charger. Do not turn on charger first, as this may cause a
spark.
• If battery temperature rises above 60°C (140°F), stop charg-
ing. Always charge battery when its temperature is below
60°C (140°F).
EL-30
BATTERY
I B: STANDARD CHARGE
Fig. 4 INITIAL CHARGING CURRENT SETTING
(Standard charge)
BATTERY TYPE
CON-
:J ~
VERTED ::J ::J ~ ::J ::J ::J ::J ::J ::J ::J :J
Determine initial charging current from er:- er:- a: er:- er:- er:- er:- er:- er:- er:- er:- a:
a:
SPECIFIC 0> 0> '1" '1" (') (') to to
;:;:; ~ ;:;:;
:; :;
specific gravity, referring to Fig. 4. GRAVITY co co'1" C'J
co
C'J
co
C'J
D
a
C'J
D
C'J
D
C'J
D
a
D
(')
D
D
~
L!) UJ
UJ
a
<Xl
C'J (')
to
'1"
L!)
L!) L!)
L!)
L!)
L!)
to <Xl
L!)
t-
L!)
O> ~ L!)
OJ ~
8.0 130
1.100 - 1.130 4.0 (A) 5.0 (A) 60 (A) 7.0 (A) 90 (A)
(A) (A)
7.0 11.0
Charge battery for 8 hours. 1.130 - 1160 30 (Al 4.0 (Al 5.0 (A) 6.0 (A) 8.0 (A)
(A) (A)
6.0 9.0
1.160 - 1.190 2.0 (A) 3.0 (Al 4.0 (A) 5.0 (Al 7.0 (A)
(A) (A)
5.0 7.0
1.190 - 1.220 2.0 (A) 2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A)
(A) (A)
Refer to "Specific Gravity Check".
• Check battery type and determine the specified current using the table shown
above .
• After starting charging, adjustment of charging current is not necessary.
Fig. 5 ADDITIONAL CHARGE (Standard charge)
Conduct additional charge as per Fig.

Below 1.150 1.150 - 1.200 1.200 - 1.240 Above 1240
5, if necessary.
Go to "CAPACITY TEST". Charge for 3.5 Charge for 2.5 Charge for 1.5
hours at initial hours at initial hours at initial
charging cur- charging cur- charging cur-
rent setting. rent setting. rent setting.
I
Go to "CAPACITY TEST".
CAUTION:
• Do not use standard charge method on a battery whose specific gravity is less than 1.100.
• Set charging current to value specified in Fig. 4. If charger is not capable of producing specified
current value, set its charging current as close to that value as possible.
• Keep battery away from open flame while it is being charged.
• When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as
this may cause a spark.
• If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its tem-
•
perature is below 60°C (140°F).
EL-31
BATTERY
I C: QUICK CHARGE
Fig. 6 INITIAL CHARGING CURRENT SETTING AND CHARGING TIME (Quick
charge)
:::J :::J
:::J :::J :::J :::J :::J :::J :::J d d d ~ :::J
Determine initial charging current setting and ~ ~ ~ ~ ~ ~ ~ a: a: a: ;;:; ~ ~
SATTERY TYPE 0> 0>
;;:; ;;:; Cl ~ ~
co co ""D:l ""
C') C') CD CD
charging time from specific gravity, referring to C\I N C\I N C\I N W
D:l Cl Cl Cl Cl Cl Cl WL() 0
Fig. 6. 0 0 L() L()
;: L()
~
to
"" "" CD L() L() L()
N C') L() L() L() CD to t- O> 0>
40
CURRENT [A] 10 (A) 15 (A) 20 (A) 30 (A)
(A)
>- 2.5 hours

I- 1.100 - 1.130
I Charge battery.
:>
<l:
a:
(!J
1.130 - 1.160 2.0 hours
0
u::
U
w 1.160 - 1.190 1.5 hours
0-
w
Go to "CAPACITY TEST". Cl
w
I- 1.190 - 1.220 1.0 hours
a:
w
>
z
0 Above 1.220 0.75 hours (45 min.)
0
• Check battery type and determine the specified current using the table
shown above .
• After starting charging, adjustment of charging current is not necessary.
CAUTION:
• Do not use quick charge method on a battery whose specific gravity is less than 1.100.
• Set initial charging current to value specified in Fig. 6. If charger is not capable of producing spec-
ified current value, set its charging current as close to that value as possible.
• Keep battery away from open flame while it is being charged.
• When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as
this may cause a spark.
• Be careful of a rise in battery temperature because a large current flow is required during quick-
charge operation.
If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its tem-
perature is below 60°C (140°F).
• Do not exceed the charging time specified in Fig. 6, because charging battery over the charging time
can cause deterioration of the battery.
Service Data and Specifications (SOS)

Applied model GA engines CD20 SR20DE
Type 26S19L 55D23L 65D26L 95D31L 34S19L
Capacity V-AH 12 - 30 12 - 60 12 - 65 12 - 80 12 - 33
EL-32
STARTING SYSTEM
Wiring Diagram - START -

MIl MODELS
EL-START-01
:J Refer to EL-POWEA.
(1): LHOmode1s
@: RHOmodels
@: GAeng ine and SR eng ine
@: CD engine
@: Except@
~: Gasoline engine models for
ST IGNITION Europe, Israel and Australia
ON SWITCH
OFF 'e- ..... @: Except~
~
ACC *1"'(1)1 , @4
U:i=ll
B/W
~~
O~ B/W ~ B/W ~Ol - B/W -(Q
LB/W~B/W.J <D:@ ~:<D

@: ~ ~:@
BATTERY
STARTER MOTOR
@TI): ~
@lID: @
~---------------------~
I
: ~@
,~mID
~ W
fTIN1@ ~:
W
I
I
~
~
R@TI)
GY I
~
GY •
~~
@lID:ID B
~oo
~GY
HEL 194
EL-33
STARTING SYSTEM
Wiring Diagram - START - (Conl'd)
AIT MODELS
EL-START-02

BLOCK
(JIB)
<E106)
IQ~OI @: For Europe and Israel
I -It
BR @: Except@
IGNITION
ST SWITCH <ID: GA engine
@: SR engine
<M'>
~H"'@3 @4
OF *2 ... <ID 2 ', @ 1
J-.
1111 -- *
SA I
n INHIBITOR
u RELAY
I
G/OR B/Y
I
lkjJIlbjdlffi) B/Y
m
lJ
B/Y~B/Y
<ID:~:~:<ID
@:~IOO:@
G/OR ~ G/OR ...
G/OR
Iftn BATTERY
STARTER MOTOR
~
INHIBITOR
SWITCH
@g)
~~
~ B ~ B
B
• B ~ B
~~

I I
(Foldout page) .
I~ FmTl I
~<rn
: @@lID
:
L W
@ tIDrnI @ @W
W
:
:
~
T L
R~
'.!J GY
~~ ~~ Iffi\m>
~B ~GY \AW GY
HEL195
EL-34
STARTING SYSTEM
Trouble Diagnoses
If any abnormality is found, immediately disconnect battery negative terminal.
Starter does not stop. Replace magnetic switch.
Engine does not start.
Does engine turn by cranking? Does engine turn normally? Check ignition/fuel system.
No No (Turns slowly.)
OK
Check battery as follows: Repair starter motor.
• Charging condition
• Terminal connections
• Terminal corrosion
NG
@
Yes
Does starter motor turn? Does gear shaft turn? Check pinion clutch.
No No
Check reduction gear, armature

and gear shaft.
Check fuse and fusible link. Replace.
OK
@
Check battery as follows:
• Charging condition
• Terminal connections NG
• Terminal corrosion • Charge battery .
• Repair connections and corro-
OK sian of battery terminals.
Check starting system wiring. Repair.
OK
No
Does magnetic switch operation Replace magnetic switch
sound occur?
Yes
OK Yes
Check condition of pinion and Does starter turn under no load Replace magnetic switch.
ring gear mesh. by connecting wires as follows?
NG
• Adjust pinion movement.

• Check pinion moving mecha-
nism .
• Check ring gear.
Repair starter motor .
•
SELOO9Z
EL-35
STARTING SYSTEM
Construction
SEC. 233 r.ii1 iii(0.17

1.7 • 2.4
S114-766A III 7.4 - 9.8 (0.75 - 1.00, 65.1 • 86.8) ~ 4.9 _ 6.4 _ 0.24, 14.8 • 20.8)
~6.4. 8.3 (0.50 - 0.65, 43.4 • 56.4)
(0.65 - 0.85, 56.4 • 73.8)

a @: High-temperature grease point
MEL779DA
G) Gear case @ Pinion shaft @ Brush spring

@ Pinion assembly (J) Planetary gear @ Brush H
@ Shift lever @ Internal gear @ Brush holder
@ Adjusting plate @ Yoke @ Rear cover
@ Magnetic switch assembly @ Armature
SEC. 233 Adjusting plate ~ -Magnetic switch assembly

MIT72087A Plate thickness:
~10 • 12 (1.0 - 1.2, 87 - 104)
0.25 (0.0098)
0.50 (0.0197)
-Planetary gear m @
Packing 0
paCking
Plate KJo
~4.4 - 7.1
o (0.45 - 0.72, 39.1 - 62.5)
~
~ Brush holder
~m@
m@
L Internal g~ar 0
Pinion stopper
Ii!2.5 - 4.4
(0.25 - 0.45,
Yoke 21.7 - 39.1)
Unit : mm (in)
Ii! : N'm (kg-m, in-Ib)
m @ : High-temperature grease point MEL234F
EL-36
STARTING SYSTEM
Construction (Cont'd)
0:
SEC. 233
M1T77281 [Magnetic SWitrChas:~::~ry gear m@
\:; ,o42 • 365 • 66.'}
paCking ~4.4 -7.1
(0.45 - 0.72,
39.1 • 62.5)
~ /'
~~;:/ ~o
C)~G ~
Gear case metal

Brush holder
m@
Brush spring
~2.5 - 4.4
(0.25 . 0.45,
21.7 . 39.1)
Unit: mm (in)
m@: lligh-temperature grease point
SEL151SA
SEC. 233 Adjusting plate
S114-769A T::~~nc::~~g~p,a~~£~~~~~fr: Magnetic switch assembly
Shift lever ), ~
m@ 02,
Gear case assembly 0 Connector stay p
': Center br<icket (P) ~
0"
o
;P ~
p;o;o~,,~
I!E!l~
~~~
\ I!E!@I\.'
7~0 I] ~ I!E!(flJ
Qo
(J , (
\
"';0'.5'.. P,",oo ,.,. ~"""
Planetary gear (x3)
Pinion stopper clip /_ Through bolt (x2) •
~cp
Pinion stopper _ ~
1i'iI14.9 • 6.4 (0.50 • 0.65, 43.4 . 56.4)
Ollll! 3J
~ l]J ~.
~m\@R"i'7m,:: '0.17 .0.24,14.'. 20.'}
Center bracket (A) ~oo Rear cover assembly

Yoke assembly Armature assembly S-washer
Unit: mm (in) Brush holder assembly
~: N.m (kg-m, in-Ib) .
m @: High-temperature grease POint SEL902RA
EL-37
STARTING SYSTEM
SEC. 233
Dust cover (Adjusting plate)
S114.568A
Plate thickness:
S114-630 0.5 (0.020)
0.8 (0.031)
• 7.4.9.8 (0.75 • 1.00. 65.1 .86.8)
• 4.9.6.4
(0.50 • 0.65. 43.4 • 56.4)
E-ring
Unit: mm (in)
fj] : N.m
(kg-m, in-Ib) Field coil
m@ :High-temperature grease point
SEL249SC

M3T37783 Plate thickness:
0.25 (0.0098)
0.50 (0.0197)
Armature
IiJ 2.5 - 4.4

r.ilI (0.25 - 0.45.
~ 4.4 • 7.1 21.7 • 39.1)
(0.45 • 0.72.
Gear case
Unit: mm (in)
Gear case metal m@ fj]: N.m (kg-m. in-Ib)
m @: High-temperature grease point
SEL464PA
EL-38
STARTING SYSTEM
SEC. 233
li!4.9 • 6.9 (0.50 • 0.70, 43.4 - 60.8)
M2T62071A
Center bracket
Armature
gear
\ Brush holder
Pinion
stopper Brush H
Brush spring
Brush (+) li!2.5 • 4.4

Reduction (0.25 - 0.45,
gearm@ 21.7 - 39.1)
Washer
SEL 153SA
•
EL-39
STARTING SYSTEM
5EC. 233
513-305
8
513-331
Iil!J '.4 . 7.8 (0.'5 - 0.80, 56.4 - 88.4) ~
6
~7.4. 9.8
(0.75 - 1.00,
65.1 - 86.8)
~ . N.m (kg-m, in-Ib)
m @ : High-temperature grease point
MEL233F
CD Bearing retainer @ Dust cover @ Brush (+)

@ Pinion shaft @ Torsion spring @) Brush spring
@ Clutch assembly @) Shift lever @ Brush H
@ Return spring @ Magnetic switch assembly @ Brush holder
@ Pinion stopper @ Armature assembly @ Rear cover
@ Stopper clip @ Field coil @) Through-bolt
(J) Gear case @ Yoke
EL-40
STARTING SYSTEM
SEC. 233
M2T61871A
~4.9. 6.9
(0.50 - 0.70,
43.4 - 60.8)

EO! CBJ: High-temperature grease point
SEL554PA
G)
@
@
@
@
@
Pinion stopper
Pinion assembly
Gear case
Pinion shaft assembly
Shift lever
Spring
(J)
@
@
@)
@
@
Holder
Reduction gear
Washer
Center bracket
Magnetic switch assembly
Armature
@
@
@
@J
@
@
Yoke
Brush (+)
Brush spring
Brush H
Brush holder
Rear cover
•
EL-41
STARTING SYSTEM
Construct" IOn (Co nt' d)
IiiiI
@ Plate
7 8
thickness' ;
~.25(......
9
.50 (0'0197)\~
.,
•
0
b ijJ325 ...
(0.25.'0.45
• 1.7. 39.1)
2
iji... 7.1
(0.4' • '.72
"'" '.1 • 7.' s;i: 39.1 • 02 ')'

(0••2. '.77 @ ijJ 10 - 12 .
(8JB ~ ':> 87.104) <, \\:~'
~ IOI!Ei!@ ,
~., Jtlj)~ EIl@ .
I~~~ 6 ,,,'
U;it: mm (in)
[iJ:
B(8J: N.m (k
Hi h- g.m, in-Ib)
9 temperature grease pOint
.
Q) Sleeve bea ring. @ Plate Armature

@ Gear case @ Packing Bush (+)
@ Stopper cr @) PI~netary gear Brush spring
P' Ip
@ p~n!on stopper @ Adjusting plate Brush holder
@ mlon assembl @ Magnetic swit h Bearing
Packing c assembly
@ Internal
, g ear Y @ Rear cover
(j) ShIft lever @ Yoke
SEC. 233
S114-806
m iji:
tj:f" N.m (kg-m, in-Ib)
\!:y' Hlgh-temp,erature
greas
e POint
MEL675EA
EL-42
STARTING SYSTEM
SEC. 233
S114-800A Magnetic switch assembly
Brush
'. spring
t Brush H
Ij] 1.7 - 2.4
Brush (+) (0.17 - 0.24, 14.8 - 20.8)
Armature
Ij]: N.m (kg-m, in-Ibl

Ij] 6.4 - 8.3 (0.65 - 0.85, 56.4 - 73.8) m @: High-temperature grease point
SEL027UA
o\:l
SEC. 233 Magnetic switch assembly Planetary
gearm@
l
MOT80281
MOT80281ZC ~4.4 - 7.1
.G::f (0.45 - 0.72, 39.1 - 62.S)
5hifll'.',\ ~~
~~
~4.1-7.. ~19
(0.42 • 0.77, 36.5 • 66.8)
l..-
•
44
(0.25 - 0.45,
21.7 - 39.1)
Brush holder
Armature m@ ~: N.m (kg-m, in-Ib)

m @: High-temperature grease point
Yoke
SEL026UA
EL-43
STARTING SYSTEM
SEC. 233 @Plate thickness:
M2T49282 0.25 (0.0098)
0.50 (0.0197)
SEL526QB
CD Gear case metal @ Shift lever @ Yoke

@ Gear case (J) Holder @ Brush (+)
@ Stopper clip @ Armature @ Brush spring
@ Pinion stopper @ Adjusting plate @ Brush (-)
)
@ Pinion assembly @) Magnetic switch assembly @ Rear cover
SEC. 233
S114-570B Dust cover (Adjusting Plate
Plate thickness:
1
~ 6.4 - 7.8 0.5 (0.020) Magnetic switch assembly
(0.65 - 0.80, 56.4 . 69.4) 0.8 (0.031)
r~7.4 - 9.8 (0.75 - 1.00,65.1 .86.8)
onnector stay set Torsion sprrng\
Dust cover 0 0
0Jl 0 0
~4.9 - 6.4
(0.50 - 0.65, 43.4 - 56.4)
E-ring
Gear case metal m@ Rear cover metal m@

Unit : mm (in)
Brush H
m (8J: High.temperature grease point
Brush (+)
MEL674E
EL-44
STARTING SYSTEM
M2T48681 Plate thickness:
0.25 (0.0098) Magnetic switch assembly
0.50 (0.0197)
~ 4.4 .7.1 (0.45 - 0.72. 39.1 - 62.5)
~ 4.1 • 7.6 (0.42 - 0.77, 36.5 - 66.8) ~2.5 - 4.4
(0.25 - 0.45. 21.7- 39.1)
J
Rear cover
Brush H
Brush spring
~ Brush (+)
Unit : mm (in)
m@: High-temperature grease point
MEL673E

~ . N.m (kg-m, ft-Ib)
~ 31 - 42 (3.2 - 4.3, 23 - 31)

SEL909T
•
EL-45
STARTING SYSTEM
Type 1 Magnetic Switch Check

• Before starting to check, disconnect battery ground cable.
• Disconnect "M" terminal of starter motor.
1. Continuity test (between "S" terminal and switch body).
• No continuity ... Replace.
2. Continuity test (between "S" terminal and "M" terminal).
• No continuity ... Replace.
Type 2
Type 3
W4
Pinion/Clutch Check
1. Inspect pinion teeth.
• Replace pinion if teeth are worn or damaged. (Also check
condition of ring gear teeth.)
2. Inspect reduction gear teeth.
• Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)
3. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
• If it locks or rotates in both directions, or unusual resistance
is evident. ... Replace.
Type 1 Type 2 Type 3 Type 4 Type 5
SEL011Z
Brush Check
BRUSH
Check wear of brush.
Wear limit length:
Refer to 50S (El-SO).
- Vernier caliper • Excessive wear ... Replace.
SEL014Z
EL-46
STARTING SYSTEM
Brush Check (Conl'd)
BRUSH SPRING PRESSURE
Check brush spring pressure with brush spring detached from
brush.
Spring pressure (with new brush):
Refer to SOS (EL-50).
/ Brush spring e Not within the specified values ... Replace.
Brush
SEL015Z
Type 1 BRUSH HOLDER

1. Perform insulation test between brush holder (positive side)
and its base (negative side).
e. Continuity exists .... Replace.
2. Check brush to see if it moves smoothly.
e If brush holder is bent, replace it; if sliding surface is dirty,
clean.
Type 2
Type 3
SEL016Z
Type 1 Yoke Check

Magnet is secured to yoke by bonding agent. Check magnet to
see that it is secured to yoke and for any cracks. Replace mal-
functioning parts as an assembly.
Holder may move slightly as it is only inserted and not bonded.
CAUTION:
Do not clamp yoke in a vice or strike it with a hammer .
Type 2
•
SEL018Z
EL-47
STARTING SYSTEM
Armature Check
1. Continuity test (b
• No continuit etween two segm .
2. Insulation t Y ... Replace. ents sIde by side)
• C . . est (between .
ontlnulty exists .... Reach
eplace. commutato r bar and shaft).
SEL019Z
•3. Check
Rough comm
S ut a~or surface.
... and lightly with N0.500 - 600 emery paper.
4. Check diameter of
Commutator ml" "commutator.
mmum dia
R e f er to SOS (EL meter:
Less than spe CI'f'led value
• -50) . ... Replace.
Vernier caliper
SEL021Z
5. Check depth of .
• Less than 0 2 Insulating mold from
(0.020 to 003'1
. ~m)
In (0.008 in) ... Undercut
commutator
to 0.5 tosurface
0.8 m'm
Round 0.5 - 0.8 ,;,;;
~""I
Correct
~File
~ Commutator
SEL022Z
EL-48
STARTING SYSTEM
Assembly
Apply high-temperature grease to lubricate the bearing, gears
and frictional surface when assembling the starter.
Carefully observe the following instructions.
PINION PROTRUSION LENGTH ADJUSTMENT

With pinion driven out by magnetic switch, push pinion back to
[,,
remove slack and measure clearance''£''
edge of the pinion and the pinion stopper.
between the front
Clearance "-E":
"T"
I
-L. Refer to 50S (EL-SO).
Clearance " !2 "
SEL026Z
Type 1
,. • Not in the specified value .., Adjust by adjusting plate.
~"'ti"g pl."
Type 2
~
~o'IJ
III III
~ A:iusting plate
Type 3
,.~
~.Adjusting plate
•
SEL029Z
EL-49
STARTING SYSTEM
Service Data and Specifications (SDS)

STARTER
S114-766A M1T72087A M1T77281 S114-769A S114-630 M3T37783 M2T62071A S13-305 S13-331 M2T61871A
MITSUB-
Type HITACHI MITSUBISHI HITACHI MITSUBISHI HITACHI
ISHI
Reduction Non-reduction Reduction
Europe
Applied model GA engines

CD20
A/T MIT
System voltage V 12
No-load
Terminal voltage V 11.0 115 11.0
Less than Less than Less than Less than

Current A 50 - 75 Less than 60 Less than 140
85 85 105 110
More
More than More than More than More than More than
Revolution rpm 3,000 - 4,000 than More than 3,900
2,950 2,950 6,500 4,030 4,100
7,000
Minimum diameter of 28.0 28.0 39.0 31.4

28.8 (1.134) 31.4 (1.236) 35.5 (1.398)
commutator mm (in) (1,102) (1,102) (1.535) (1236)
Minimum length 10.5 10.5 11.0 11.5

12.0 (0.472) 11.5 (0.453) 11.0 (0.433)
of brush mm (in) (0.413) (0.413) (0.433) (0.453)
17.7 -
16.2 14.7 - 17.7 13.7 - 25.5
Brush spring tension 13.7 - 25.5 21.6 13.7 - 25.5 28.4 - 34.3 (2.90 -
(1.65, (1.5 - 1.8, (1.4 - 2.6,
N (kg, Ib) (1.4 - 2.6, 3.1 - 5.7) (1.8 - 2.2, (1.4 - 2.6, 3.1 - 5.7) 3.50, 6.38 - 7.71)
3.64) 3.3 - 4.0) 3.1 - 5.7)
4.0 - 4.9)
Clearance between Less Less

Less than
bearing metal and - than 0.2 - than 0.2 -
0.2 (0.008)
armature shaft mm (in) (0.008) (0.008)
Clearance 'T'
0.3 - 2.5 0.5 - 2.0 0.3 - 2.0 0.3 - 0.8
between pinion front 0.5 - 2.0 0.3 - 2.5
(0.012 - (0.020 - - (0.012 - (0.012 - -
edge and pinion (0.020 - 0.079) (0.012 - 0.098)
0.098) 0.079) 0.079) 0.031)
stopper mm (in)
Movement 'T' in 0.5 - 2.0 0.3 - 1.5

height of pinion - (0.020 - - - (0.012 -
assembly mm (in) 0.079) 0.059)
EL-50
STARTING SYSTEM
Service Data and Specifications (SOS) (Co nt' d)
M1T72985A S114-806 S114-800A MOT80281ZC I MOT80281 M2T49282 S114-568A I S114-570B M2T48681
MITSUB- MITSUB-
Type HITACHI MITSUBISHI HITACHI
ISH I ISHI
Reduction Non-reduction
Australia RHD Except Europe and Australia
Applied model GA engines

SR20DE
A/T M/T
I AIT
System voltage V 12
No-load
Terminal voltage V 11.0 11.5
Less than Less than

Current A 50 - 75 Less than 90 Less than 60
53 53
3,000 -
More .
Revolution rpm than More than 2,750 More than 6,000
4,000
2,700
Minimum diameter of 28.8 314 314

280 (1.102) 28.8 (1.134) 28.0 (1.102)
commutator mm (in) (1.134) (1.236) (1236)
Minimum length 12.0 11.5 11.5

10.5 (0413) 7.0 (0.276) 90 (0.354)
of brush mm (in) (0472) (0453) (0453)
13.7 - 25.5 13.7 - 25.5 137 - 25.5

Brush spring tension 12.7 - 17.7 11.77 - 23.53 9.8 - 13.7
(14 - 2.6, (14 - 2.6, (1.4 - 2.6,
N (kg, Ib) (1.3 - 1.8, 2.9 - 4.0) (1.2 - 24, 2.6 - 5.3) (1.0 - 14, 2.2 - 31)
3.1-5.7) 3.1 - 5.7) 3.1 .5.7)
Clearance between
bearing metal and arma- Less than 0.2 (0.008)
ture shaft mm (in)
Clearance" C"
0.5 - 2.0 0.5 - 2.0
between pinion front 0.3 - 25
(0.020 - 05 - 2.0 (0.020 - 0.079) 0.3 - 2.5 (0.012 - 0.098) (0.020 -
edge and pinion (0.012 - 0.098)
0.079) 0.079)
stopper mm (in)
Movement 'T' in
heigh\. at pinion -
assembly mm (in)
•
EL-51
CHARGING SYSTEM
Wiring Diagram - CHARGE -

GASOLINE ENGINE MODELS
EL-CHARGE-01
IGNITION SWITCH
ON or START
FUSE Refer to
lOA BLOCK EL-POWER.
FUSIBLE Refer to []] (JIB)
LINK AND EL-POWER. ~
FUSE BOX
7.5A 1~11
I~
~
mJ ~
Y
RIB METER
COMBINATION
(CHARGE (0: LHD models
WARNING @: RHO models
LAMP)
(M30) @: AIT models
~ 1*.31 @: MIT models
Y/R @: For Europe
@: Except@
2 ~ Y/R -ee-~
JOINT ~
()~ CONNECTOR-l~ ~
~ ~ ()-ID-I
~ Y/R Y/R
RIB
~ ~ R/B@@
,..,JI,., ~
IJ¥!I
Irku@
(E26) '"T-' ~ In-'
4 JOINT
~ @D
RIB R/B@@
(E201)
(E203)YIR
I EU ~gNNECTOR
@l
<t <;> {(100 <BID Iy~I
Y/R
~~
~@jg) @: GA engine
RIB Y/R @: SR engine
n1-lI m ., @: With tachometer
~f1"'@ 6,@ B
B *2 @30 , @40
! *3 @40 , @ 3
ALTERNATOR ~ ~ ~ @QID
~-------------------------------, Refer to last page

(Foldout page) .
L j
@,<lliD
~
~BR
~~ ~~~@D
~ B ~ B
~~,~
rn::rm B GY
m~,
r-----------------,
:~~~~~~:
11m ~ GY ISI I
~~
~OR
I
L jI
HEL 196
EL-52
CHARGING SYSTEM
Wiring Diagram - CHARGE - (Cont'd)
DIESEL ENGINE MODELS
EL-CHARGE-02
FUSE Refer to
10A BLOCK EL-POWER.
[]] (JIB)
Refer to <f1@
EL-POWER. I N~ll
---:l,7.5A
ljJOO
RIB
IJ
~
Y
COMBlNA
METER TION
(CHARGE
WARNING
LAMP)
(1): LHO models
@: RHO models
I
O~
I ~
Y/R
f-<D-
JOINT
CONNECTOR-1~
Y/R ~--~ Y/R 1

~
RIB
I
RIB
,c!J, ~ ,ell, ~ ,c:r
Y/R
eMB)
Y/R
~ eMB)
'T"~ 'T"~ l <illD
IQl::!J I~I <illD
RIB RIB
Y/R Y/R
<;> I
J~
1~lm IclJl~
'T" eE202) 'T" ~
t~;..-__
Y/R Y/R
I
I
RIB Y/R
U+JI 1m,
., B
ALTERNATOR ~ ~ ~
!
~
•
Refer to last page
(Foldout page) .
~@QJ) ~~
~ GY ~GY
aID <illD
I
<H:@
r-----------------,
:~ ~ ,R.. ~ ~ ~: ~ ~ CillIillIillTII ~
I ~ \b:.@ GY lSJ I mz:l]:l B ~ BR
I
L ~I
HEL 197
EL-53
CHARGING SYSTEM
Trouble Diagnoses
Before conducting an alternator test, make sure that the battery is fully charged. A 3D-volt voltmeter and
suitable test probes are necessary for the test. The alternator can be checked easily by referring to the
Inspection Table.
Before starting, inspect the fusible link.
WITH Ie REGULATOR
With alternator side L terminal Burned-out
grounded. internal short occurs bulb.
@ when + diode is short-circuited. Replace and
proceed to
Ignition Light "OFF" Disconnect
"@".
switch "ON" connector (S, 'See 4) for grounding F terminal.
L) and
Light "ON" ground L Connect
lead wire. (HITACHI connector (S,
make) L) and
ground F
terminal
Dim light (MITSUBISHI

Light flickers make)
Bright light
Light "ON Check or Light "ON"

replace drive
belt.
Light "OFF"
Engine Light "ON"

speed:
1,500 rpm
Lighting Light "OFF" Engine
switch "ON" speed:
1) Use fully charged battery.
1,500 rpm
2) light: Charge warning light (Measure B
ACG : Alternator parts except I'C regulator terminal
IC-RG : IC regulator voltage)
OK : IC-alternator is in good condition.
3) When reaching "Damaged ACG", remove Make sure
connector (S, L) is
alternator from vehicle and disassembly, inspect
connected
and correct or replace faulty parts. correctly.
4) *Method of grounding F terminal (HITACHI make
only)
Gasoline engine model
Contact tip of wire with brush and attach
wire to alternator body.
~~~
;;z..'~~.~
S$.~~' s<(r~,
~~/j - Brush lift wire
;;.. ~ Q<:::z"d,l'T7.
~.. ~ ~-)o,IJ!"-f/
- -~~ C); 0 ~~/
'~-/i ~-, ~
-~j~n
- <::::; -~ \ •
~
'" 1A/-'
SEL030Z
5) Terminals "S", "l", "B" and "E" are marked on rear cover of alternator.
EL-54
:====
SE~C:-.
=23=-:.-1-----
~C~H~A~R~G=I~N=G~S~Y~S!:!T!E~M!...----
Construction
A5T06891
Bearing retainer
iii 3.9 • 5.4
(0.40 • • 47.7)'
34.7 055 Front bearing
F'om 'O~I
~mb'~
~~~ Diode assembly
fPJ 83.108
(8.5 • 11.0,
61 • 80)
IC voltage
regulator assembly
Stator
1iJ: N.m (kg-m, in-Ib)
~ : N.m (kg-m, ft-lb)
SEL252SC
IiJ3.1 • 3.9 (0.32 • 0.40, 278.• 34.7) Rotor
Retainer
Front bearing
Front cover
PUlley
assembly
1iI3.1 • 3.9• (0.32 - 0.40' 278

. - 34.7)
37
I C regulator
assembly ::; , 1i1(0.38.0.51,
. • 5.0 33.0 .44.3)
R." _'" @J' .
(5.0 • 6.5,
36 • 47) •
~_... N.m (kg-m, ft-Ib)
SEL156SB
EL-55
CHARGING SYSTE
M
Constr uct"Ion (Cont'd)
SEC. 231
LR170-746E ~ 3.14.39 . (0.320 • 0.398• 27.8 • 34.5)
Stator
Slip ring
RO'O'1
~3.14 - 3.9 (03
. 20 - 0.398• 27.8 - 34.5)
~ 7.8.10.8
Retainer \ (0.80 • 1.10 • 69 .4 - 95.5)
Front bearing
~
Front cover @
~~
~~
~#Y
@~
@, o
Brush
~ 3.14.3.9
L (0.320 - 0.398 .~8-34~
O lode assembly
•
IC regul ator assembly
l Condenser
~.
~,N.m
N.m (kg-m, in-Ib)
(kg-m, ft-Ib)
SEC. 231
A2T82491A
[ij3.9 - 5.4
(0.40 - 0.55 , 34 .7.47.7~
\~ A83.108
(8.5 • 11, 61 .80)
1jJ:
~. N.m
N (kg-m, in-Ib)
~_.. . .m (kg-m, ft-Ib)
MEL782DB
Pulley assembly @ Rotor @ Ie voltage reg I

@ Diode assemb~ ator assembly
Front cover @ R ear bearing
Front bearing (J) Stator @) Rear cover
Bearing retainer
EL-56
CHARGING SYSTEM
~ : N.m (kg-m, ft-Ib) Removal and Installation
SEL910T
Disassembly
REAR COVER REMOVAL
C~UTION:
Rear cover may be hard to remove because a ring is used to
lock outer race of rear bearing. To facilitate removal of rear
cover, heat just bearing box section with a 200W soldering iron.
Do not use a heat gun, as it can damage diode assembly.
SEL032Z
REAR BEARING
CAUTION:
• Do not reuse rear bearing after removal. Replace with a
new one.
• Do not lubricate rear bearing outer race.
Rotor Check
1. Resistance test
Resistance: Refer to SOS (EL-61).
• Not within the specified values ... Replace rotor.
2. Insulator test
• Continuity exists ... Replace rotor.
3. Check slip ring for wear.
Slip ring minimum outer diameter:
Refer to SOS (EL-61).
• Not within the specified values ... Replace rotor .
•
SEL033Z
EL-57
CHARGING SYSTEM
Type 1 Brush Check

1. Check smooth movement of brush.
• Not smooth ... Check brush holder and clean.
2. Check brush for wear.
• Replace brush if it is worn down to the limit line.
Type 2
Brush wear
limit line
SEL034Z
Type 1 Stator Check

1. Continuity test
• No continuity ... Replace stator.
2. Ground test
• Continuity exists ... Replace stator.
Type 2
I
I
------_~
I
SEL037Z
EL-58
CHARGING SYSTEM
Diode Check
MAIN DIODES
• Use an ohmmeter to check condition of diodes as indicated in chart below.
• If any of the test results is not satisfactory, replace diode assembly.
Ohmmeter probes
Judgement
Positive EB Negative e
Positive diode plate Diode terminals Diode conducts in only one
Diodes check (Positive side)
Diode terminals Positive diode plate direction.
Negative diode plate Diode terminals Diode conducts in only one

Diodes check (Negative side)
Diode terminals Negative diode plate direction.
Type 1 Type 4
Sub-diodes
Type 2
Type 5
Negative diode plate
Positive
diode
plate
Negative diode Type 6 \ Negative diode plate

plate
\ Diode
Type 3 terminals
(Stator side)
SEL039Z •
EL-59
CHARGING SYSTEM
Amount of protrusion: Assembly

Fix ring at the position
OfR~~wnlmumprotrusion. RING FITTING IN REAR BEARING
,
,,,,'
~... ~~
.
\
• Fix ring into groove in rear bearing so that it is as close to
- ,'.:' ; .', the adjacent area as possible.
, "
Eccentric ' <-'>/ CAUTION:

Do not reuse rear bearing after removal.
groovy
Rear bearing
SEL044Z
REAR COVER INSTALLATION

(1) Fit brush assembly, diode assembly, regulator assembly
and stator.
(2) Push brushes up with fingers and install them to rotor.
Take care not to damage slip ring sliding surface.
SEL048Z
SEl049Z
EL-60
CHARGING SYSTEM
Service Data and Specifications (SOS)

ALTERNATOR
A5T06891 LR170-746E LR170-504B A2T82491A
Type
MITSUBISHI HITACHI MITSUBISHI
Applied model GA engines CD20 SR20DE
Nominal rating V-A 12-70 12-80
Ground polarity Negative
Minimum revolutions
under no-load Less than Less than
Less than 1,000
(when 13.5V is applied) 1,300 1,300
rpm
Hot output current More than More than

(When 13.5V is applied) More than 22/1,300 27/1,300 More than
. 21/1,300 More than More than 22/1,300
More than 50/2,500 56/2,500 More than
50/2,500 More than More than 65/2,500
A/rpm 67/5,000 66/5,000
Regulated output
14.1 - 14.7
voltage V
Minimum length of
50(0.197) 6.0 (0.236) 5.0 (0.197)
brush mm (in)
4.609 - 5.786 1.0 - 343 0.92 - 328 4.609 - 5.786

Brush spring pressure
(470 - 590, (102 - 350, (94 - 334, (470 - 590,
N (g, oz)
16.58 - 20.81) 3.60 - 12.34) 332 - 11.78) 16.58 - 20.81)
Slip ring minimum

221 (0.870) 26.0 (1.024) 31.6 (1.244) 221 (0.870)
diameter mm (in)
Rotor coil resistance at

2.5 - 2.9 258 48 24 - 29
20'C (68'F) n
•
EL-61
COMBINATION SWITCH
Combination Switch/Check
FOR EUROPE AND ISRAEL
REAR WIPER
AND WASHER
ON
WASH~INT WIPER
....<!jOFF
WASH
LIGHT
,-A--..
WASH
A ~
III B
2ND
1~~ HI
~
C
OFF L
@JEij
(Turn)
(Rear wiper
and washer)
(Rear fog lamp)
LIGHTING SWITCH FRONT WIPER AND

- WASHER SWITCH
I~, OFF 1ST 2ND TURN SIGNAL
A B C A B C A B C SWITCH
5 r.
6
7
8
9
10
11
6
010
616 -~
0
0
WI
12 6
25
REAR WIPER AND INTERMITTENT HORN SWITCH

WASHER SWITCH WiPER VOLUME (Without air bag)
HEL011
EL-62
COMBINATION SWITCH
Combination Switch/Check (Cont'd)
EXCEPT FOR EUROPE AND ISRAEL
L
LIGHT
lJ ~
£0, ' 'B

REAR WIPER N
AND WASHER
ON INT 1ST ~
OFF
WASH~
FRONT WIPER
AND WASHER
WASH
0R
[)
OFF
C
°i ~INT VOLUME~
~ WASH
LO
~
HI
:::::.------+ fl9
(Rear wiper
and washer)
~
(Turn) ~
(Horn)
FRONT WIPER AND REAR WIPER AND

LIGHTING SWITCH WASHER SWITCH WASHER SWITCH
~
\A
OFF 1ST
B C A B CAB
2ND
C
,""
13 0
OFF INT LO HI WASH
21
WASH OFF INT ON WASH
5 0 14 6 22
6 6 166 6 15 23
7 16 0 24
8 n 17 6 0
n :> 6 6
•
9 18
10
11
12
INTERMITTENT TURN SIGNAL
WIPER VOLUME SWITCH
II
HORN SWITCH
(Without air bag)
HEL012
EL-63
COMBINATION SWITCH
Replacement
\ Wiper and washer switch For removing/installing air bag module and spiral cable, refer
to RS section.
• Each switch can be replaced without removing combination
~I!!.t:~
~~ .~
switch base.
Switch base
MEL612D
• To remove combination switch base. remove base attaching

screw.
MEL613D
EL-64
HEADLAMP -, Without Daytime Light System -
Wiring Diagram - H/LAMP -
EL-H/LAMP-01
I BATTERY I
• Refer to EL-POWER.
~ 15' 15A
4-11391
R R/W
~
m rrtil
--2NO---- 2ND
OFF'-.- .... LIGHTING

1ST SWITCH
HIGH PASS PASS - -PASS - - PASS (EtO])
,LOW .. ,LOW" , LOW , LOW
- .... HIGH - .... HIGH -.-.... HIGH -.- ....
HEADLAMP RH
~ ~~ lbi=IJ~
R/G P!L R/B R/Y
HIGH a- R/G.:JJ
~B
LOW .-
~P/L -
HIGH
~~ R/y-I
B-. -
i]- R/B- - • - R/B ~ Next page
LOW
HEADLAMP LH
,..-., B B
@: Except @
~
~ ~
(ffil @!)
•
r---------------------,
J3L<rnJ W
[ITgJ] B ' B
~---------------------~
HEL013
EL-65
HEADLAMP - Without Daytime Light System -
Wiring Diagram - H/LAMP - (Cont'd)
EL-H/LAMP-02
Preceding
page
~ RIB -o~
L. R
RIB ~
<illD <:BID
RIB ~
RIB
RIB
~
~o
R
(HOf) <:BID
i!i
RIB
METER
C~INATION
(HIGH BEAM
INDICATOR)
I*fl @
8 @
I
B
1
JOINT
CONNECTOR-1
~
~
~
8
: LHD models

@: RHO models
@: With tachometer
I
e-o-ee-o--,
@:
JU."@
Without tachometer
14 , @ 38 I <:
8 8
R :>
8
I
B
15 , @ 37
1 t-~1
*2."@
@@ ~
r---------------------------------~ I
Refer to last page
(Foldout page) .
ITITIilllIIIIIl @
~BR
HEL014
EL-66
HEADLAMP -. Without Daytime Light System -
Trouble Diagnoses
Symptom Possible cause Repair order
LH headlamps do not operate. 1. Bulb 1. Check bulb.

2. LH headlamp ground 2. Check LH headlamp ground. (Terminal @)
3. 15A fuse 3. Check 15A fuse (No. @ill , located in fusible link and
fuse box).
4. Lighting switch 4. Check lighting switch.
RH headlamps do not operate. 1. Bulb 1. Check bulb.

2. RH headlamp ground 2. Check RH headlamp ground. (Terminal @)
3 15A fuse 3. Check 15A fuse (No. ~ , located in fusible link and
fuse box).
LH high beam does not operate, 1. Bulb . 1. Check bulb.

but LH low beam operates. 2. Open in LH high beam circuit
r,
L. Check RIB wire between lighting switch and LH
head lamp for an open circuit.
LH low beam does not operate, 1. Bulb 1. Check bulb.

but LH high beam operates. 2. Open in LH low beam circuit 2. Check R/Y wire between lighting switch and LH
headlamp for an open circuit.
RH high beam does not operate, 1. Bulb. 1. Check bulb.

but RH low beam operates. 2. Open in RH high beam circuit 2. Check RIG wire between lighting switch and RH
headlamp for an open circuit.
3. Lighting switch. 3. Check lighting switch.
_.
RH low beam does not operate, 1. Bulb 1. Check bulb.
but RH high beam operates. 2. Open in RH low beam circuit 2. Check P/L wire between lighting switch and RH
head lamp for an open circuit.
High beam indicator does not 1. Bulb 1. Check bulb in combination meter.
work. 2. High beam indicator ground 2. Check combination meter ground. [Terminal @
(with tachometer) or @ (without tachometer)]
3. Open in high beam circuit 3. Check RIB wire between lighting switch and com-
bination meter for an open circuit.
•
EL-67
HEADLAMP - Daytime Light System -
Operation (Daytime light system)

The headlamps' low beam and clearance, license, tail and illu-
mination lamps automatically turn on after starting the engine
with lighting switch in "OFF" position.
Lighting switch operations other than the above are the same
as conventional light systems.
Engine With engine stopped With engine running

OFF 1ST 2ND OFF 1ST 2ND
Lighting switch
A B C A B C A B C A B C A B C A B C
High beam X X 0 X X 0 0 X 0 X X 0 X X 0 0 X 0
Headlamp
Low beam X X X X X X X 0 X 0 () 0 X X X X () X
Clearance and tail lamp X X X 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
License and instrument illumination lamp X X X 0 0 0 0 0 0 0 0 0 0 0 0 () 0 0
0: Lamp "ON"
X: Lamp "OFF"
o: Added functions
EL-68
System Description
The headlamp system on vehicles for North Europe contains a daytime light unit. The unit activates the
following whenever the engine is running with the lighting switch in the OFF position:
• Low beam head lamps
• Clearance, license, tail and illumination lamps
Power is supplied at all times
• through 15A fuse (No. @ill , located in the fusible link and fuse box)
• to daytime light unit terminal @ and
• to lighting switch terminal @.
Power is also supplied at all times
• through 15A fuse (No. ~ , located in the fusible link and fuse box)
• to daytime light unit terminal CID and
• to lighting switch terminal CID.
Power is also supplied at all times
• through 10A fuse (No. ~ , located in the fusible link and fuse box)
• to daytime light unit terminal CD and
With the ignition switch in the ON or START position, power is supplied
• through 10A fuse (No. ~ , located in the fuse block)
• to daytime light unit terminal (]).
With the ignition switch in the START position, power is supplied
• through 7.5A fuse (No. l2~ , located in the fuse block)
• to daytime light unit terminal @.
Ground is supplied to daytime light unit terminal @ through body grounds @ and @D.
HEADLAMP OPERATION (Daytime light cancel operation)

Power is supplied at all times
• through 10A fuse (No. ~ , located in the fuse and fusible link box)
When the lighting switch is turned to the 1st or 2nd position
• through lighting switch terminal @,
• to daytime light unit terminal @.
Then daytime light will be canceled. And the lighting system operation will be the same as no daytime
light system.
DAYTIME LIGHT OPERATION

With the engine running and the lighting switch in the OFF position, power is supplied
• from alternator terminal CI>
• to daytime light unit terminal @
• to daytime light unit terminal @
• through daytime light unit terminal CID
• to terminal @) of LH headlamp
to daytime light unit terminal CID
•
•
• through daytime light unit terminal @
• to terminal @) of RH headlamp
• to daytime light unit terminal CD
• through daytime light unit terminal @)
• to tail lamp and illumination.
Ground is supplied to terminal @ of each headlamp through body grounds @ and @D.
Ground is also supplied to terminal @ of daytime light unit through body grounds @ and @D.
EL-69
HEADlAMP - Daytime light System -
Schematic
HEADLAMP RH
High
Low
HIGH BEAM
INDICATOR
HEADLAMP LH
High
Low
ill
UJ ..,;
'J Ul 0
::J ..,; ..,;
.c
LL WO
(fl .....
C+'
w<o
uc
ill ..-1.rl
UJ ,...,E
>- ::J .::J
IT LL W"'"
ill u.-.
I- c .....
I- <0
« I- LD
m ill H <oc
UJ Z w<o
,...,
::J ::J (fl
LL u,...,0.
l- ..... E
I OlUlU
(9 I-+,"'"
I H
U --l
I- IJJ
H UJ IJJ
3: ::J ::E
UJ LL
H
I-
Z >-
0 «
H 0
1-1-
HIT
Z«
(91-
HUJ IJJ
UJ
::J
LL 01
aJ
I
U
I- ill
H UJ IT
3:1- ::J 0
UJIT LL I-
« «
ZI- Z
OUJ IT
H IJJ
I-L (9 I-
HO IJJZ --l
Z (9H «
(9Z ITZCL
HO «IT::E
I««
U3:--l
HEL015
El-70
HEADlAMP - Daytime Light System -
Wiring Diagram - DTRl -
EL-DTRL-01
I BATTERY I FUSE
rr::-J;::-'Jl
~I~ W~I ~1401
15A
~
10A
IT]
BLOCK
(JIB)
<fill)
(£106)
Refer to
EL-POWER.
B/R R R/W Y
I• ! •• R~W :} Next page
1
Y
----B/R~
COMBINATION
METER
GS (CHARGE
~ WARNING
LAMP)
GS
~
~
~ ~
Y IR
rn
B/Y I ~g~~~CTOR
IfWlJCMID
11:1~
-1
@
B/Y
~ @: Gasoline engine
.
Y IR @: With tachometer
II~IQID
1 @: Without
T-' (EiQD tachometer
Y IR
~
.'----- Y IR -{9> Next page
B/R R R/W B/Y BR •
IR *1 @ 30 @
TAIL
m mRH
mLH
m
ST
m
IGN
m
Y
*2 @ 40 '@
,
40
3
ALT -L DA YTIME
FUSE FUSE FUSE LIGHT
UNIT
(El1B)
<mID
•
Refer to last page
(Foldout page) .
L ~
~---------------------,
I I
: ~ (~ITB) ~ (E119) : ~~
I~GY~GYI ~ BR
I
L ~I
HEL016
El-71
Wiring Diagram - DTRL - (Cont'd)
page
{
~
~
RIW
Preceding ~----Bt- R
BIR
==I --------------
I
EL-DTRL-02
I
R LIGHTING SWITCH RIW BIR
m <U@ rn Irf1iI
@: CD engine --2NO--- --2ND-------------- 2ND

@: GA and SR OFF- .......
engine 1ST
HIGH PASS PASS - -PASS - - PASS
'-LOW --HIGH '-LOW __ '-LOW '-LOW
_.... _.... HIGH -.......HIGH - .......
Preceding .....-;::;1.
page ~ YIR 1 ~~ 1biJJ~ ~
RIL
.....
~t L._._eI
RIG PIL RIB RIY
I
YIR YIR R/Y lit>
~@ID=r
IctJl 1r1J1
=r~
~ RIG ~
Next page
Y/R Y/R
e--II- PIL -@>
tJI
Y/R
It
PIL
m m
RIY t RIL
wf1]
RIB ~
d
DIMMER DIMMER TAIL DAYTIME
LAMP LAMP LAMP LIGHT
OUTPUT OUTPUT SW UNIT
RH LH
~
ALTERNATOR (ffiID
~
Ffm~ ~~
ffi GY ~B
r---------------------,
I I
@lID : ~ @ID ~ <mID :

(~) GY I
I
L
~ GY \llLt:W GY I
I
~
HEl017
EL-72
Wiring Diagram - DTRL - (Cont'd)
EL-DTRL-03
DAYTIME
LIGHT
UNIT
TAIL LAMP (ffiID
GND OUTPUT
~ ~
B RIB
~ To clearance. license. tail

and illumination lamps
~ R/Y
.
Preceding <& RIG
page
~
<m- RIB
PIL
-.I
RIB
-.- -- -- -
- RIB
BQ
!(J
HIGH HEADLAMP
LOW
LH
m
1r$J1~ R/Y JD
@
RIB
Iit"S METER
(HIGH BEAM
INDICATOR)
INATION
1*':' ~
B @
.- RIG
sQ
!(J
JD
HIGH HEADLAMP
LOW
RH
~
W
JOINT PIL
CONNECTOR-1
1bjJ~
,.., ,..,
B
I
B
~
B
~
B
~
S
~
@: With tachometer
*3"'@ 14 , @ 38
*4"'@15 , @37
(M28) ~ @~
•
Refer to last page
(Foldout page) .
~(ffiID
~GY
~~m B
[]]JgJ] ' 8
I1IillIillIITil ~
~ SR
HEL018
EL-73
Trouble Diagnoses (Daytime Light)

DAYTIME LIGHT CONTROL UNIT INSPECTION TABLE
(Input/output operation signal)
Voltage (V)
INPUT (1)/
Terminal No. Connections Operated condition (Approximate
OUTPUT (0)
values)
Power source for

1 illumination & tail - - 12
lamp
Power source for

2
head lamp LH
- - 12
Power source for

3
head lamp RH
- - 12
ON (daytime light operating') 12

4 Headlamp RH 0
OFF 0
ON (daytime light operating') 12
5 Headlamp LH 0
OFF 0
START 12
6 Start signal I Ignition switch
ON, ACC or OFF 0
ON or START 12
7 Power source - Ignition switch
ACC or OFF 0
Alternator "L" ter- Running 12

8 I Engine
minal Stopped 0
9 Ground - - -
Illumination & tail ON (daytime light operating') 12
10 0
lamp OFF 0
1ST.2ND position 12
11 Lighting switch I
OFF 0
': Daytime light operating: Lighting switch in "OFF" position with engine running.
EL-74
HEADLAMP
Bulb cover
Bulb Replacement
The headlamp is a semi-sealed beam type which uses a
replaceable halogen bulb. The bulb can be replaced from the
engine compartment side without removing the headlamp body.
• Grasp only the plastic base when handling the bulb. Never
touch the glass envelope.
1. Disconnect the battery cable.
2. Disconnect the harness connector from the back side of the
bulb.
3. Turn the bulb retaining ring counterclockwise until it is free
from the headlamp reflector, and then remove it.
4. Pull off the rubber cap.
5. Remove the headlamp bulb carefully. Do not shake or rotate
the bulb when removing it.
6. Install in the reverse order of removal.
CAUTION:
• Do not leave head lamp reflector without bulb for a long
period of time. Dust, moisture, smoke, etc. entering head-
lamp body may affect the performance of the head lamp.
Remove headlamp bulb from the head lamp reflector just
before a replacement bulb is installed.
SEL995K
Bulb Specifications
Item Wattage (W)

Semi-sealed beam
High/Low 60/55
Aiming Adjustment
When performing head lamp aiming adjustment, use an aiming
machine, aiming wall screen or headlamp tester. Aimers
should be in good repair, calibrated and operated in accor-
dance with respective operation manuals.
If any aimer is not available, aiming adjustment can be done as
follows:
For details, refer to the regulations in your own country.
CAUTION:
• Keep all tires inflated to correct pressures.
• Place vehicle and tester on one and same flat surface.
• See that vehicle is unloaded (except for full levels of
coolant, engine oil and fuel, and spare tire, jack and tools).
Have the driver or equivalent weight placed in driver's seat.
CAUTION: •
Be sure aiming switch is set to "0" when performing aiming
f> to adjustment on vehicles equipped with head lamp aiming con-
3 2 1 0 trol.
~ nOD
o SEL226P
EL-75
HEADLAMP
Aiming Adjustment (Cont'd)
LOW BEAM
1. Turn headlamp low beam on.
2. Use adjusting screws to perform aiming adjustment.
• First tighten the adjusting screw all the way and then make
adjustment by loosening the screw.
-
Up and down adjusting screw
, \ , I / MEL614D
"H": Horizontal • Adjust headlamps so that main axis of light is parallel to

center line center line of body and is aligned with point P shown in
of headlamps illustration.
• Figure to the left shows head lamp aiming pattern for driv-
ing on right side of road; for driving on left side of road,
aiming pattern is reversed.
• Dotted lines in illustration show center of head lamp.
"H": Horizontal center line of headlamps
"WL": Distance between each head lamp center
"l": 5,000 mm (196.85 in)
"e": 65 mm (2.56 in)
Height of
Vertical centerline
ahead of headlamps -
lamp centers I
f P \
/~
d = ACCEPTABLE RANGE
SEL2541
EL-76
HEADLAMP - Headlamp Aiming Control -
Wiring Diagram - AIM -

LHD MODELS
EL-AIM-01

BLOCK
(JIB)
CE106)
(HOD <BID .....
WIG ~~
~bBIR ------ .....

BIR
WIG -----
..... WIG ~
BIR ~
Next page
r=B/L~&B/L ..... B/L ~
I~ AI. ~1~ AI. ----- RIW -w>
.I-.I=.I=.I~:.:--==--~=I-I 1-"
P WIG
HEAOLAMP
AIMING
BIR B/L RIW MOTOR LH P WIG
HEADLAMP
AIMING
BIR B/L R/W MOTOR RH
mmmrnm~ mm~rnm ~
Refer to last page •

(Foldout page) .
~ <rn (EAS)
\A:tW GY GY
HEL019
EL-77
Wiring Diagram - AIM - (Cont'd)
EL-AIM-02
I BATTERY I
•
~-113.0:.1----t!J r~AI --------- FUSE
BLOCK
(JIB)
~ I
~ Refer to
EL-POWER.
BIR W u@
*1 RIG
(f@
LIGHTING
SWITCH
~
2ND
JUNCTION
BOX NO.2
(JOINT
00 @: Models with
daytime light
system
(E10]) CONNECTORS) @: Models without
@ <fW ~ daytime light
system
RIG
RIB , @ RIY
t rn *1"'@
LIGHTING
SWITCH HEADLAMP
2ND k:i, AIMING
(E107)
SWITCH
<ID <6>J ~
~ 0- *1
BIR
RIL
R/L
I tt
RIB ~~ ~~~
rn
TAIL
ifill
TAILIL
rm
TAILIL DAYTIME LIGHT
UNIT (Refer to
WIG BIR B/L R/W B
~
I JOINT
FUSE SW
-------'
OUTPUT EL-DTRL.)
~:@
rn
Ibi=U
CONNECTOR-3
~
- B
Preceding
page
~
~
WIG
BIR -- I
i.
~
~
B/L
RIW - ~
B
(M28) ~
~
B
Refer to last page

(Foldout page) .
~(EU9)
~GY
ITIIIII::ITillT ~
~ BR
HEL020
EL-78
RHD MODELS
EL-AIM-03

BLOCK
(JIB)
..
(E106)
-------
(E10!)
WIG ~~
CHID
WIG --- __ -- WIG ~
.. -----
r=B/L~~B/L
I I=.R/W
BIR ~~
~~
BIR -----
RIW -----
-- BIR ~
BIL ~
RIW ~
Next page
T-i=i=r~
P
~mmmlFh
WIG
HEADLAMP
AIMING
BIR B/L RIW MOTOR LH
rn
HEADLAMP
AIMING
MOTOR RH
@
•
Refer to last page
(Foldout page) .
rITfu\ ~ ~
~ GY , GY
HEL021
EL-79
EL-AIM-04
FUSE]
G J
Refer to BLOCK
EL-POWER.
(JIB) Refer to
----- ~ EL-POWER.
a.
I 3-, ----I N.B I (Et06)
R/L RIG
LIGHTING
SWITCH
I
<lliD
HEADLAMP
AIMING
SWITCH
(8TI)
U:i=U ll:iJl ~ IbjJJ ~

WIG B/R B/L RIW B
I
B
~
I JOINT
.....
rn
L4=JJ
B
CONNECTOR-4
~
<€l- WIG .....

<& B/R I
Preceding
page
<@-
<@-
B/L
.....
..... T-, n
B B B B
1 !..1 1
RIW
(M2B) <MW ~
Refer to last page

(Foldout page) .
m:m:I:illIillTI ~
~P
HEL022
EL-80
+ BATIERY
Description
Reversing
relay A CIRCUIT OPERATION
o
1 [Example]
2
3
Aiming switch "0"
• When the aiming switch is set to "0", the motor will not start.
This is because the power terminals are positioned at the
nonconductive section of the sensor's rotary unit.
Thermistor
SEL465M
Aiming switch "0" -t "1"

+ BATIERY
Reversing • When the aiming switch is moved from "0" to "1", the sen-
relay
sor's conductive section activates the relay. Power is sup-
o
1 . plied through the relay to the motor. The headlamps will
2
3 then move in the "DOWN" direction.
• The motor continues to rotate while the rotary unit of the
sensor moves from point A to point B.
• The power terminals will then be positioned at the noncon-
ductive section, disconnecting the power to the motor. The
Thermistor motor will then stop.
SEL364P
Aiming switch "1" -t "0"

+ BATIERY
Reversing • When the aiming switch is moved from "1" to "0", the sen-
relay
sor's conductive section activates the relay. Power is sup-
o
1 plied through the relay to the motor. The motor will rotate
2
3 to move the headlamps in the "UP" direction.
• When the rotary unit of the sensor moves from point B to
point A, the motor will stop.
::- Thermistor
SEL365P
•
EL-81
EXTERIOR LAMP
Clearance, License and Tail Lamps/Schematic
CD
.r<
rl
CD
L LICENSE PLATE LAMP RH
.+oJ
Ul
:J
«
D
...... C
QJ CD II
CD QJ
L E ...... LICENSE PLATE LAMP LH
Ul .r< QJ
H QJ .+oJ CD
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TAIL LAMP RH(OUTER)
II
TAIL LAMP LH(OUTER)
a:
CLEARANCE LAMP RH
>-
([
t}j@)
::>0
LL
W
W ::E:
f- -'
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LLLL-.lUl
HEL032
EL-82
EXTERIOR LAMP
Clearance, License and Tail Lamps/Wiring

Diagram - TAIL/L -
LHD MODELS WITH DAYTIME LIGHT SYSTEM
EL-TAIL/L-01
Refer to EL-POWER.
BIR
@1) @)
2ND LIGHTING
SWITCH
(E107>
r
.- RIB ~
AIL ~
~SE
AIL
A/Y ...----
BLOCK
AIL ~}
A/Y -@>
Next
Page
AIL (JIB) (106)(@
I
........... A/L~-[] CLEARANCE
LAMP AH
L ........ B -0 <rn>
r
I........
A/L~~ CLEAAANCE
LAMP LH
BIR RIL AIB

t BoO
m IrITil IFfon ~
.-.
TAIL TAILIL TAILIL DAYTIME
FUSE SW OUTPUT LIGHT
UNIT
L- ---' (E119)
I
B
I
B
..I.. ..I..
(37) $51>
~<ffiZ)
~W
F.=arn
L1.l£f B ,
@
B
Aefer to last page
(Foldout page) .
•
~<lliID
~ GY
HEL023
EL-83
EXTERIOR LAMP
Diagram - TAIL/L - (Cont'd)
EL-TAIL/L-02
Preceding.-at-~
page A/Y -O~ R/Y (1j1.
?!f" R/Y ----- ..li1
R/Y "'\!d
TAIL
AEAR
COMBI-
~I~
B-o NATION
LAMP RH
(OUTER)
STOP
P!L -D (j])
Preceding
*
~ f=iL
-e- ~ LICENSE
page AIL - -O~
(HB)
i
R/L ~ R/L •
e---
-
I
RIL
B
-u:J
~
PLATE
LAMP AH
@
I e-
e- - -
R/L ~~
B ~
~t~~~SE
LAMP LH
(Th)
R!L~ AEAR
TAIL COMBI-
e- B-o NATION
e---
LAMP LH
STOP (OUTER)
P!L -D (R)
-R/L~} Next
Page ~ p/L • To a-STOP!L
@: Sedan models
@: Hatchback
----
models
R/Y -{9>
r.
B
..... B
.....
(f1D) . (f11)
~@ ~(R) (j]) [Q] (Th) CID

~W ~w' w [I[g] w ' w
HEL024
EL-84
EXTERIOR LAMP
Diagram - TAIL/L - (Cont'd)
EL-TAIL/L-03
Preceding -iJI- R/Y R/Y ..rr=1
page ~ -ud REAR
COMBI-
B-o NATION
LAMP RH
(OUTER)
.. ---------- P/L ~ ~
~ @QD
Preceding ~
page ~ RIL -.-
.- - _
-
R/L ~
@@W
.~
RIL
B -.--
It
._ R/L~
RIL
-(Q
~
-(Q~
~C~~~SE
LAMP RH
(fj109)
~C~~~SE
..rr=:: LAMP LH
.--- B"1li @QZl
-1---------11--- R/L ~ TAIL REAR

COMBI-
.-1--------1--- B
~4
~
STOP
NATION
LAMP LH
(OUTER)
i~~~~~~~~~~
..
~~~
::: ~TO a-STOP/L ~
'I
B
~
$11)
~
(32)
B
rflII' I
45678I~ @!QD
W
• ~~~
~w' w
[Q] @QZl CD 109)
IIf.g] w ' w
HEL025
EL-85
EXTERIOR LAMP
Diagram - TAIL/L - (Conl'd)
LHD MODELS WITHOUT DAYTIME LIGHT SYSTEM
EL-TAIL/L-04
Aefer to EL-POWEA.
2ND LIGHTING
SWITCH
~
W/A
I
~
r <ffi1) (]ID
AIL ~ AIL ------- AIL ~

Next
Page
i-'
W/A W/A
• •
L_--B~ AIL ~~ CLEAAANCE

LAMP AH
rn
~I';I ~t:1 t ... -.. A/L~~ CLEAAANCE

LAMP LH
"B~1 @
A/V AIL
L A/Y ~ ~
FUSE BLOCK
(JIB)
AI, ------1-1-
.-. A/V -e> Next
Page
(106) @Z)
.....
I
B
$37> $51)
I
B
Refer to last page

(Foldout page) .
~@)
~w
F.=r=t
l..!.@
rn
B
@Q)
B
,
HEL026
EL-86
EXTERIOR LAMP
EL-TAIL/L-05
Preceding --f1- R/Y -O~ R/Y ~ R/Y _
R/Y (J REAR
page -......cr ~ TAIL COMBI-
~1(iJ]) NATION
I
I
B-{Gl LAMP RH
I (OUTER)
I
I
PIL ~ GID
I
I
I
I
I
PreCeding........a
page ~ RIL - -O~
<HB) i
RIL ~
I
FiL
RIL •
•
- -e-
I B ~
~
R/L "1!:J
LICENSE
PLATE
@ RH
LAMP
I .-
.- - -
RIL ~~
B ~
~t~~~SE
LAMP LH
aID
.-e--- R/L
B-{Gl
PIL ~
(J TAIL
STOP
REAR
COMBI-
NATION
LAMP LH
(OUTER)
<:lID
____
... R/L ~}
R/Y ~
Next
Page L::- PIL • To EL -STOP/L
@: Sedan models
<Im>: Hatchback models
T.
~
S B
~
aiD) aiD
rTI2I"QIID (ill)
~w ~w'
~<:lID GID
w
[Ql
[I[gJ
GID CID
w ' w
•
HEL027
EL-87
EXTERIOR LAMP
Diagram - TAIL/L - (ConI' d)
EL-TAIL/L-06
Preceding 4 R/Y R/Y £1
page ~ ~ REAR
COMBI-
NATION
B~ LAMP RH
(OUTER)
P/L ~ ~
~ <QW
* -e- -
- ~~ -_-1-
Preceding .........,;l.
page RIL - RIL ~ RIL e- R/L~ -«:l ~C~~~SE
..IR LAMP RH
e-
I B ~ B
e
B
R/L ~~
-,bf
..IR
B -,bf
(0109)
~C~~~SE
LAMP LH
(0107)
e-
- RIL ()
B~
REAR
COMBI-
NATION
LAMP LH
(OUTER)
e PIL ~ ~
I
.1
P/L • To EL-STOP/L
B B
..... ~
0311) 0332'>
fHiI' I IIjl
4567B @QD
W
~@~
~ W ' W
[QJ @W (0109)
[I[g] w ' w
HEL028
EL-88
EXTERIOR LAMP
RHO MODELS
EL-TAIL/L-07
@: For Europe
lOA Aefer to EL-POWEA.
@: Except for Europe
1361
BIA
0----.
~
I
BIA
B IA tE1i\A\
rr=illJ
FAONT I~I 'E!QJ; ~ 2ND LIGHTING
FOG LAMP ..!i'1 CHID SWITCH
SWITCH
(fill): @ m
S/A " 1ST
OFF,_
~
~
AIL
l
FUSE BLOCK
(JIB)
(fill) (106) (]V
AIL ~3 T~ AIL ----- AIL -{t> Next Page
EE AIL ~8 Q~ AIL .... tt... A/L~ ~ CLEAAANCE

LAMP AH
-s(j @
tt-tt
r BoiO
LAMP LH
I
B
I
8
-!- -!-
~~
Refer to last page •

r---------------------, (Foldout page) .
J
f2TIffi~ Fa ~ @ID
tmm:I S l1.l.£.J S , S
HEL029
EL-89
EXTERIOR LAMP
Diagram - TAIL/L - {Cont'd}
EL-TAIL/L-OB
~CID
Preceding
page -...-'f1.
~ R/L -O~
HB "'_1.
RIL ~ :k!!" R/L ---.--- R/L .IFf
B
"'1!::::!
~
REAR
COMBI-
NATION
LAMP RH
(OUTER)
,,'1--- PIL ~ ill)
REAR
O~ R/L ~ CONBINATION
LAMP RH
I
R/L JJ-. Next
~Page 0- _ ~ B ~ ~~~ER) (TAIL)
.'---
~
I RIL -fQ~ ~C~~~SE
I
LAMP RH
-[? em
I .---
.- - --- B
RIL~ -fQ ~C~~~SE
I
LAMP LH
.- - --- B -[? aID
I O~ RIL~ ~~~~~INATION
LAMP LH
0- _ ~
t:
I._1_____
B ~
R/L
B
-0
~
~~~ER) (TAIL)
TAIL REAR
COMBI-
~~~~O~H
.1 PIL ~ STOP
(OUTER)
ill)
l::..
@: Sedan models
<tm> :
@: Except
Hatchback
Australia
models
for Europe and
,.
.....B .....B
PIL + To EL-STOP/L
(fi0) (fit)
~ill)
~w'
ill)
w
~cm CID [Q] CI[)
II[g] w '
em
w
~w' w
HEL030
EL-90
EXTERIOR LAMP
EL-TAIL/L-09
Preceding ~ RIL _. RIL ..IF"!
REAR
page ~ "'\b! TAIL COMBI-
NATION
8~ LAMP RH
(OUTER)
STOP
.. ---------- PIL -«) @
F
RIL~
E ~ ~5~~INATION
LAMP RH
~ 8 ~ (INNER) (TAIL)
.-.-- _
(824) (0101)
RIL ~ R/L -
-0---
~
-0-- RIL ~~
(0111)
~C~~~SE
LAMP RH
- 8
~
~
(0102)
8
II 0--
B
RIL ~
~ «hOg)
~C~~~SE
.1-1:: GE
8
R/L ~
~~~:: LH
CONBINATION
LAMP LH
O~ B.rrs (INNER) (TAIL)
~ ID103)
_1 11 R/L -[1
REAR
COMBI-
.-1-------11---- 8~
NATION
LAMP LH
(OUTER)
---.P/L~ ~
i ____- PIL • To EL-STOP/L
i.
B B @: Except
Australia
for Europe and
~ ~
(1311) (1332)
~I
45678
I II~w
@QD Fn
W W
(1)102) ~
~
@) (1328)
W 'W
~
~
@
W
@ill)
'W
[Q] @QZ)
[]Jg] W'
(1)109)
W
•
HEL031
EL.91
EXTERIOR LAMP
Stop Lamp/Wiring Diagram - STOP/L -

SEDAN MODELS
EL-STOP/L-01
(b): LHD modeIs
FUSE
: RHO models
(J/8)
<HB>: Models with high-mounted
stop lamp
~ *1 ... (b) R/Y, <R> R/L
+ *1
DEPRESSEDSTOP LAMP
SWITCH
To
EL-TAIL/L {• R/L
RELEASED
~
~
P!L @ (@
O~ • P!L ~3i1 P/L .,
+
'V
P!L
ctJ~ I6'iA\
Pt,
JlJ'<CTION ~tP!L(IT)
m
BOX No.2 R
(JOINT
CONNECTORS) 0-0
~ (ffi]): (b) L ~
P/L
~(M5)
~(@
P!L
I
., --
@ (j]g)
P/L ~ P/L
t 1
Y
P/L
[jJ aID
1
HIGH-
~~g~TE~MP TAIL
~
STOP
REAR ~
TAIL STOP
REAR
8 B E~~~I~~TION B E~~~I~~TION
1 I
t M.
• 0
(OUTER) av
T.
B
(OUTER)
8
<lID
..... ~
Cfl0) ql1)
Refe~ to last page

~~ (Foldout page) .
I..!.@ 8
f&~@)
56J8I9Wu12 W
m@
[I[g] 8R
~
~
@
w'
aID
w
~<lli>
~W
HEL033
EL-92
EXTERIOR LAMP
Stop Lamp/Wiring Diagram - STOP/L -
HATCHBACK MODELS (Cant' d)
EL-STOP/L-02
(1): LHD models
FUSE (8): RHO mode1s
BLOCK Refer to EL-POWER. @: Models with high-mounted
(J/B) stop lamp on rear window
<E@ ~: Models with high-mounted
stop lamp in rear air spoiler
~t1... (1) R/Y,(8) RIL
DEPRESSED STOP LAMP

SWITCH
~ + *1
RELEASED To
{
EL-TAIL/L .. R/L
~
PIL <BID <m)
•
O~P/L~P/L~
~
PIL
~
0-.
aJ
~I iJUNCTION
~@:(1)
P/L
BOX NO.2
(~g~~~CTORS)
t
L P'L
c!J ~
~
PIL
P/L
@W
I
i l
1l\.QJ1 (@
eb@)
P/L ~I 1 HIGH-
MOUNTED
STOP LAMP TAIL STOP TAIL STOP
~ <01OB): @ ~REAR ~REAR
B ~:~ a E~~~I~~nON a E~~~I~~nON
I _. I(OUTER)~
1.I
(OUTER)~
I
.-
a
a ~
<W (ij25)
a
I
f.
a a
---
(0105)
---~ ......
"="
•
Refer to last page
~~
L.iJ.gJ a
fEi)! I Ill) @W m
45678 illW
(0102)
W
(Foldout page) .
m ([HOB) ~~ ~@)@
~~@
5 6 TIIV01112 W IJ:m aR WEJ GY ~ w' W
HEL034
EL-93
EXTERIOR LAMP
Back-up Lamp/Wiring Diagram - BACK/L -
EL-BACK/L-01
FUSE
lOA BLOCK Refer to EL-POWER.
[]] (J/B) <D: LHD models
(f106) (8): RHD models
I Q.61 @: A/T models
Y @: MlT models
@): LHD models with CD engine
I
O~ y
ern
Q)
@ID
Y
@: Except LHD models with CD
engine
L ~ @QID
i>
~l -
Y Q) Y
1 t4._".)~
m
BACK-UP INHIBITOR
R LAMP SWITCH
SWITCH
@D:@ ~:@
OTHERS
~
G/W ~
 G/W
O-::E--- .....
-------,
I ~ern
O~ G/W ~ G/W -,.. .r:-- ([ill) @
G/W ~ G/W ~}
L c @@ ~
G/W ~ G/W ~O--IO~
<]=> <f t ~
G/W ~
CHID
G/W -@>
Next page
Refer to last page

(Foldout page) .
~~ @D mi\~ ~WV
rn:tilllID B cf]:g) GY ~ GY ~W
~ (E23O)
~B
HEL035
EL-94
EXTERIOR LAMP
Back-up Lamp/Wiring Diagram - BACK/L -
(Cont'd)
EL-BACK/L-02
~ G/w-eb <h> :
I
LHO models
Preceding <ID :
RHO models
page (MID@ @: Sedan models
~G/W~G/W~G/W 0 @: Hatchback models
~
HB
I
0

G/W~
~ 24
~(O101)
~t
G/W
~@
@
G/W
~@)
(IT)
G/W G/W G/W
I•I f---.t
I
Iffi •I I
I~i
G/W REAR
LAMP LH
COMBINATION
(INNER)
(BACK-UP
W
G/W
REAR
COMBINATION
LAMP RH
(INNER)
(BACK-UP
i!l
G/W REAR
LAMP LH
C~INATION
(INNER)
(BACK-UP
I!II
G/W REAR
LAMP RH
COMBINATION
(INNER)
(BACK-UP
~ LAMP) ~ LAMP) ~ LAMP) ~ LAMP)
([)103): @ @ill): @ c:IID:
B B B
@ B aID: @
~ @Qg)
I I
r B ~ B
•• I• I•
I I I
"
B
~
m@
B
~ ~
B
4>1m~
~
B
<TIQ)
~
QID
B
(MID
W ~lllllml
45678
@QD
W rr:r:g:@fi,mtIZIID (TwO ~(lli)
45678 W •
~ en:> GID (0103) QlliD m (0102)
m:z:IID w' w' W' W Ww
HEL036
EL-95
EXTERIOR LAMP
Front Fog Lamp/Wiring Diagram - F/FOG -

LHD MODELS WITH DAYTIME LIGHT SYSTEM
EL-F/FOG-01
I BATTERY I
-------rm~
I
~-t~-:-I FUSE
BLOCK
Refer to
EL-POWER.
I (JIB)
BIR
I .......R/L
~
OR
OIR
(120)
1
i
BIR 11:lt I:!JIIn FAONT
FOG LAMP
U RELAY
Ii1'1n ~ l!:i=!J (103)
LIGHTING GY/R ORIB

SWITCH
(£107)
LI GY/R~Next page
i---'
ORIB ORIB
BIR
m
RIL
Iff1n
RIB
~
t
I~II FOG
FFOOT
LAMP
LH
~rONTFOG
LAMP
1bi=H@
RH
TAIL/L TAIL/L TAIL/L ~~
FUSE SW OUTPUT DAYTIME B B
LIGHT
UNIT
<EnID I I
•I
-B
•I
B
~ ~
rn ~
~~1 4 GY
dJg)@)@
GY , GY +~103l
5 L
Refer to last page
(Foldout page) .
(120)
HEL037
EL-96
EXTERIOR LAMP
(Cont'd)
EL-F/FOG-02
precedin9-4 Y/R
page ~
G
1 1 .... R/Y +To EL-R/FOG
GY/R R/Y
1
1
1 TI
4=Jl
GY/L
1
no
U0
~
B
REAR
FOG LAMP
RELAY
@
1-----
1-------
GY/L
I
ng:AU~
GY/L
(BID
....
B +To
R/G +To
EL-R/FOG
EL-ILL
GY/L
I R/G
m m FRONT
ILL FOG
LAMP
OFF--
SWITCH
<f1!ID
~ ~
B B
1-_1
•
B
W~INT CONNECTOR-1
@
~
B
I
T.
B
-!-
B
-!-
@ ~
•
Refer to last page
2 (Foldout page) .
376 ~ ~(fill) I1III'ITillilli ~
~ 4 GY IIDIDID B ~BR
HEL03B
EL-97
EXTERIOR LAMP
(Cont'd)
LHD MODELS WITHOUT DAYTIME LIGHT SYSTEM
EL-F/FOG-03
I BATTERY I
1
FUSE Refer to
~75A 15A BLOCK EL-POWER.
LtJ[]] CD (JIB)
(E120)
I
RIL R/L
• ~
OR
LIGHTING
SWITCH ~ IlOA
441 II!I I~II"AONT
n FOG LAMP
I
(El0n U RELAY
OFF- 2ND WIR Ibi=!l IbjJI 00>
~~2
W/R
t GYIL <f!W ORIB
n9:AU (~:)
________ GY/L
1_--1---11.--------- RIG +To EL-ILL
--e
ll
RIG ~Y.1/~ ...
IT1rTI FRONT
ILL FOG
LAMP
SWITCH ORIB OR/B
~
B
.'---
1
~ I~i I~I FOG
FRONT
LAMP
LH
FOG
FA~T
LAMP
RH
• ~~ ~~
~
B B B
W
I JOINT
CONNECTOR-1
@ I I
e----e
T rl! @~ ~
I
~
B
I B
~
(51)
Refer to last page
A
TL (E103) 12i1l=.;fI@Q)
~B
~@~
~ Gy'GY
(Foldout page) .
ITlIIillIill1II @
~BR
HEL039
EL-98
EXTERIOR LAMP
(Cont'd)
RHO MODELS FOR EUROPE
EL-F/FOG-04
I BATTERY I
• FUSE Refer to
~10A EL-POWER.
L:J 1361 15A
W
BLOCK
(JIB)
(EfOO)
B/R ~ (120)
rrf1D
II!'
R!L OR
LIGHTING
SWITCH . I~In (RONT
FOG LAMP
CEW U RELAY
t ~ ~m
GY!L OR/B
117\,1~
~@)
GY/L
1-1----- RIG. To EL-ILL
~ ILL
FRONT
FOG
LAMP
SWITCH
-----ell
~ OR/B OR/B
~
.•• ---
B I!\ FOG
FRONT
LAMP
LH
i!'1 FOG
FRONT
LAMP
RH
ll¥J~ ~@9>
B B B
m
~
1 !JOINT
CONNECTOR-1
~
" n
B B B B
I
e----e
I
I I
B
1 i.l 1
- - - ~
B
~
B
A~
T L
~<MIQ)
lID[@] B
~~~
\!lSJ GY' GY
Refer ta last page
(Faldaut page) .
•
ITIillIillITIIT @
~ BR
HEL040
EL-99
EXTERIOR LAMP
(Cont'd)
RHO MODELS EXCEPT FOR EUROPE
EL-F/FOG-05
I BATTERY I
I
~1i~
~'-t3.0:.I------.I----:::~--~-rn-~-A-1 Refer to
EL-POWER.
BIR ~~l I.~I-- ~ 0;1061

I RIL RIG OR
BIR
i----I t
~
R~G ~
~
O~ ~
ILL FRONT
ffi] I~I~ FOG LAMP
JiJ1 CHID SWITCH
~L
LIGHTING
SWITCH BIR OFF ~
.....
OFF - ~
DRIB
lufl@
DRIB
m
B
L...
i --,
ORIB DRIB
rn
JOINT
CONNECTOR-1
1!,i=!J@
I!l
~
FOG
LAMP
FRONT
LH
@g)
I!i
~
FOG
LAMP
FRONT
RH
~36)
B B B
I
,..,n I I
B
1 i.Jl
B B B .----.
I I
....B
~
B
~@ ~ <rn> (51)
Refer to last page

(Foldout page) .
~ ~ IIIIJJTIIIIIITI @ <ffg) @,~
[[l[[ID B ~ BR GY GY
HEL041
EL-100
EXTERIOR LAMP
Front Fog Lamp Bulb Replacement

The front fog lamp is a semi-sealed beam type which uses a
replaceable halogen bulb.
• Grasp only the plastic base when handling the bulb. Never
touch the glass envelope.
1. Disconnect the battery cable.
2. Disconnect the harness connector from the back side of the
bulb.
3. Turn the bulb retaining ring counterclockwise until it is free
from the front fog lamp reflector, and then remove it.
GEL001
4. Pull off the rubber cap.
5. Remove the front fog lamp bulb carefully. Do not shake or
rotate the bulb when removing it.
6. Install in the reverse order of removal.
CAUTION:
.' Do not leave front fog lamp reflector without bulb for a long
period of time. Dust, moisture, smoke, etc. entering front fog
lamp body may affect the performance of the front fog lamp.
Remove front fog lamp bulb from the front fog lamp reflec-
tor just before a replacement bulb is installed.
Front Fog Lamp Aiming Adjustment

Before performing aiming adjustment, make sure of the follow-
ing.
a. Keep all tires inflated to correct pressure.
b. Place vehicle on level ground.
c. See that vehicle is unloaded (except for full levels of
coolant, engine oil and fuel, and spare tire, jack, and tools).
Have the driver or equivalent weight placed in driver's seat.
Adjust aiming by turning the adjusting screw.
•
EL-101
EXTERIOR LAMP
Rear Fog Lamp/Wiring Diagram - R/FOG -

WITH DAYTIME LIGHT SYSTEM
EL-R/FOG-01
I BATTERY I
•
~'-t3.5:.'----~'4~i Refer to EL-POWER.
R ~<EIQD
Irtn "~I CHID
LIGHTING P
SWITCH
~
(£109) JUNCTION BOX RIG • ~E-ILL
5 NO.2 (JOINT
112• 1 <BID
RI/Y r-PU/R~PU/R_PU/R~PU/R- -,
<EIQD CONNECTORS) ~
t
I Ir PU/R P PU/R RIG
R/Y PU/R GYIR J nTi1 m rm
a~W:i:II~AR ,
REAR
ILL FOG
FOG LAMP
n LAMP I~ SWITCH
U RELAY OFF
@
I!:iJI ~ ~ ~ I~JI IWI
B WIPU GY!L T T
To 1--1
.. -:~~~: } ~ -F /F:~/R + EL-BUZZER I f I
rn
JOINT
W/PU.I'f;:---.-
Next CONNECTOR-3
"........page ~
~
B
I
f.
B B
f.
B B
-!- -!- -!- -!-
~ @D ~ ~
r--------------------~
I
Refer to last page
(Foldout page) .
I
: ....R%i5<=.-I...........I-I1 (E~09) ~~
~BR
I
L ~
I1IIIIIIIIIIlII ~
~BR
HEL042
EL-102
EXTERIOR LAMP
(Conl'd)
EL-R/FOG-02
Preceding
page
----1l- W/PU
~
1
@: Sedan mode Is
@: Hatchback models
m
W/PU
~@[)
(E117)
W/PU
I
l~--I
W/PU W/PU
ICiJI~@ IciJl ~@QD

W/PU W/PU
I I
i!i I!II
W/PU W/PU
~5:INATION
LAMP LH ~ INATION
LAMP LH
(INNER) (INNER)
II 8 II (REAR FOG) II 8 II (REAR FOG)
'=r' (lli: @ =r (0103): @
8 8
I
il
~{ill),@
~W W
~I Iltil@QDW
45678
~
~
(lli, CQl03)
W W •
HEL043
EL-103
EXTERIOR LAMP
(Cont'd)
WITHOUT DAYTIME LIGHT SYSTEM
EL-R/FOG-03
I BATTERY I
.------rfl
• Refer to EL-POWER.
[jt::1 Wi;,;i (b):

(8):
LHO models
RHO models
R P
m CHID
m LIGHTING
~~
I __
P ~ P
SWITCH ~ P ~ P
~
(fl09) m CHID
m CHID
~PU/R~PU/R ~
I <EW@ I
r-
I~
O-ee-PU/R~PU/R~PU/R- ~Ot RIG .~~-ILL
JUNCTION BOX II11JI P PU~R RIG
No.2 (JOINT =r'
m m m
14
R/Y PU/R CONNECTORS)PU/R
1
]llfEAA
n
U
LAMP FOG
RELAY
~. INO
ILL
REAR
FOG
LAMP
SWITCH
Ibi=U Ibi=JI ~ OFF ~
B W/PU ~ ~
L W/PU o@> ~:~~ PU/R. ~ -BUZZER i--lB B
~
,..,
a
~
B
~ 1
a a
-I
rn
~
B ~
I JOINT
5g~~~CTOR-3 @: (b)
CONNECTOR-4@: (8)

I (Foldout page) .
~~ [JQII~
L ~ T L ~aR
IIIIIillJIlIIil ~: <D IIIIIillJIlIIil ~: <ID

~~ ~ P
HEL044
EL-104
EXTERIOR LAMP
(Conl'd)
EL-R/FOG-04
Preceding
page
4
~
w/pu..,
<C>I'001
w/pu
r::::b (illZ)
w/pu
(EfO!)
<1):
:
@:
LHO models
RHO models
Sedan models
I~I@) ~@ @: Hatchback models
w/pu ~CMID
r.l. I~I(@
~ w/pu
O~
I .
f~---I
~-----~
w/pu w/pu
~~
~ @lQD
IciJl @
wf@>wf
IrtJl ~
em t-----.~
w/pu
I!I
w/pu w/pu W/pu w/pu
I!II ~INATION
LAMP LH
(INNER)
i!11 ~~~INATION
LAMP RH
(INNER)
~~INATI~
LAMP LH
(INNER)
~ ~~INATION
LAMP RH
(INNER)
1\ 8 1\ (REAR FOG) 1\ 8 1\ (REAR FOG) 1\ 8 1\ (REAR FOG) 1\ 8 1\ (REAR FOG)
*
=r@:@ =r GID:@ =r(D103):@ =r @ill):@
8 B B B
1> ~__ 5J> 1

'-I
8
..... ~
B
~
I
B
•
Refer to last page
~W1),(f1g) (Foldout page) .
~W W
fil' I'~
45678 @QD
W
~
~
(U), GID,(0103),
W W W
(DiU)
W
HEL045
EL-105
EXTERIOR LAMP
Turn Signal and Hazard Warning Lampsl

Schematic
FRONT TURN SIGNAL LAMP LH
SIDE TURN SIGNAL LAMP LH
REAR COMBINATION LAMP LH
COMBINATION METER (TURN LH)
FRONT TURN SIGNAL LAMP RH
SIDE TURN SIGNAL LAMP RH
REAR COMBINATION LAMP RH
f-
ZH (Y)
OZ COMBINATION METER (TURN RH)
H::::>
f-
<((I
ZW nJ
HI
rJ)(f)
~ I
(f)([ u...
- ::::>
([ u...
W
f-
f-
<i
co
HEL052
EL-106
EXTERIOR LAMP
Turn Signal and Hazard Warning Lamps/Wiring

Diagram - TURN-
LHD MODELS
EL-TURN-01

BLOCK
(JIB)
~
___ RIG. To EL-ILL
RIG
m
HAZARD
ILL SWITCH
~
~
LG t JUNCTION BOX NO.2
• I (JOINT CONNECTORS)
~
G/B
~
G/Y
~
B
25 ~ 12';1 12~1
2~ LG -, 2~ G/B -G/B~
LG
~12~1 CBID~ 2~ G/Y - G/Y -@> To
LGt ml~1
EL-TURN
G/R 2~ G/Y _ G/Y ~ -03
ffl IFtiI LG
POWER OCT COMBINATION
FLASHER
I 2~ G/B -G/B~
UNIT LG 2~ - G/Y -f> Next page
. .
G/Y
GROUND @) m 12•31 12•41 JUNCTION BOX
NO.2 (JOINT
Ibj:!J TURN
SIGNAL G/B G/Y CONNECTORS)
8 LAMP ~
SWITCH L R G/B CBID G/Y
WID IriJ~----~$1
___ t.GI" ~ GIV ,
------'. - G/Y~}
_ G/B ~
~
Next
page
•
.- B ~
Refer to last page
m 11f!]~
(Foldout page) .
F1i21~ c:I:Q]] (E110)
54213 W '"TIT B ~W
HEL046
EL-107
EXTERIOR LAMP
Diagram - TURN - (Cont'd)
EL-TURN-02
@; GA engine without dual
air bag system and ABS
@; Except@
preCeding{~
page ~
:~ 1
..........
~ G/B ---I-----Ie-----.
~o
I$I::+B
G/Y
~O
•
G/Y G/B G/B G/Y
1!lfQ2~
SIGNAL
LAMP RH
1I111@:<B108)
I!ISIDE
TURN
SIGNAL
II111LAMP LH
1!IF~T 1!I~T
TURN
SIGNAL
11211LAMP LH
TURN
SIGNAL
ILall LAMP RH
'=r='@: ~ =w= (il) =w=~ '=r=' ~
B B B B
•
.L~+
~O
Icrl~ NB
Preceding ~
page ~
B
~O
...,1
~~
B B
-------Ie--i
I~B
JOINT -t-, r-t
CONNECTOR-3 B B B
~
~ ~ ..... .....B
<82B) (868) @ 4;51)
..&i ~
(tlg)
@ (B108)
GY , GY , GY
....g,~
l..!@j B '
~
B
~I
4567B
11[Il~W
lIIIIIIIIIlIIII @)
~BR
HEL047
EL-108
EXTERIOR LAMP
Diagram - TURN - (Conl'd)
EL-TURN-03
<]): Sedan models ~H"'@37. @14
@: Hatchback models *2"'@36. @12
@: With tachometer *3"'@17. @13
<8- G/Y @: Without tachometer
TO ~ GIS
EL-TURN
-01
:::-l
<Qfo GIY
~GlBl I
GIS G/Y
mITn I *~ I
COMBINATION
METER (TURN)
G/B CMID G/Y
LH RH~ I~~----------~~I
<fill)
.....
---I----I~
B/R ~3
G/S@ G/Y
@
.-----1---,0 I
< H S ~ S ?
G/S@ G/Y
~----------~
I!\ I!I ~l I!i

G/B G/Y G/S@ G/Y
~Q~INATION
LAMP LH ~~~INATION
LAMP RH ~ ~~INATION
LAMP LH ~~INATION
LAMP RH
(OUTER) (OUTER) (OUTER) (OUTER)
~ ~~~ SIGNAL) ~ ~~~~ SIGNAL) " 4" (TURN SIGNAL) /I 4 " (TURN SIGNAL)
=r <:m =r GID
.------. .------ .
B B S S
I I I I
SiR B
I IB
I
S
I
S
~ ~ ~ ~ ~
~ <B11) ~
•
~ @, ~, @, aID ~@
u::IillHJ W W W W ~W
HEL048
EL-109
EXTERIOR LAMP
RHO MODELS
EL-TURN-04
@: For Europe
FUSE Refer to EL-POWER. @: Except for Europe
BLOCK
(JIB)
Qill)
1--- RIG. To EL-ILL
RIG
m
HAZARD
SWITCH
~
~
~
LG t JOINT
L~JOINT ~
I../B CONNECTOR G/Y B
•
2
I
~
CONNECTOR-1
~
LG - ,
db
1r211~
-4
~G/B-
1_- B
G/B ~
-u>}
..J"i-..... Next page
~""iF
11211 LG:m. I G/B ~
eMS) ~ ~ G B -
G/R LGt ~~ ~G/B-
m ~ LG
I Ibi=Jl
G/B~
il
POWER OUT COMBINATION JOINT
FLASHER G/B G/Y CONNECTOR-1
To
UNIT LG ~ ~
GROUND
II 2 II
""iF
~
TURN SIGNAL
rn ~2
II 3 II II 3 II
~ G/Y -[B>
EL-TURN
-06
B LAMP SWITCH ""iF ""iF

I7 ~~~~~
~~ L R G/B <BID G/Y G/Y
1__ -
rn~ ~
1~~----i~1 G/Y ~
~g~~~CTOR-1 t_ G /B~ G.'Y•• t _

B
1 G/Y~}
-@> •. G/B Next page
1------------------ S ~
~--------------------------,
I I
Refer to last page
(Foldout page) .
fIrn' ,'IIl~
54213 W
~
lID"'
(M20)
B
I I:TIIJ
: @OI[g]
I
L
(E110) : @
W
--.CQ"l ~
rmm W
:@ I
:
~I
mm:ITI1lIIIIJJi ~ IIDIillIillIITi ~
~BR ~P
HEL049
EL-110
EXTERIOR LAMP
Diagram - TURN - {ConI' d)
EL-TURN-05
-@: GA engine without dual
~ GIS air bag system and ASS
@: Except <@)
Preceding
<efG/Y-----
I.'----..
page
~ GIS
~o
I$I~;'~
G/B
+B
~O .
•
G/B
'!II~Q~~ I~I i!'1

SIGNAL
LAMP LH
II UI @ : (8108)
G/B
TURN
FRONT
G/Y
TURN
SIDE
G/Y
I!I TURN
F RONT
9F'@:~ SIGNAL SIGNAL SIGNAL
S
~O • ILZJI LAMP LH
"=r' ~
B
II111LAMP RH
"=r' @
B
II211LAMP RH
9F' ~
B
===~+
'Cfl'@
~O
NB
I
L!---.I
S
~ I JOINT
~ B .. B ~ CONNECTOR-4
~
Preceding ~~
rT. n
il
page B-
•I-J
- li.Jl
B B B B
(M28) <MW <8W
1itl <MW @
<.!J.g) GY ,
lTIillIillIITil ~
GY ,
(8108)
GY
...g.,~
L.!..l£.J B '
~
B
•
~P
HEL050
EL-111
EXTERIOR LAMP
EL-TURN-06
ill: Sedan modeIs *1... @ 37 . @ 14
@: Hatchback models *2"'@36. @12
@: With tachometer *3"'@17. @13
<@a G/Y @: Without tachometer
To ~ G/B
<eo G/Y:;-'
EL-TURN
-04
<go G/81 I
G/B G/Y
mill! I *~I
COMBINATION G/B G/Y
LH RH METER(TURN) @
~ I~~----------~~I
B/R ~3 ~ G/B@) G/Y
1.. ----11
-----I------~
-----°1 @ ..
< HB) ~,. S ?

G/B~ G/Y
G/B G/Y
$----------$
(IT)
G/B G/Y
I!I ~:INATION~1~~~INATI,..1!1~~INATION
I!l ~~~INATION
LAMP LH
(OUTER)
LAMP RH
(OUTER)
LAMP LH
(OUTER)
LAMP RH
(OUTER)
II 4 II (TURN SIGNAL) II ~UI(TURN SIGNAL) ILA II (TURN SIGNAL) ILAJI (TURN SIGNAL)
=r~ =r@ =r@ =r CfID
B B B B
B/R
.-----.
I
I
B
I
I
B
.--
I
I
1•
I
I
~ ~ ~ ~
B
.... B
<8gz) ~ ~ CTiD) (fin
r--------------------------------------------------,
L ~
--.CQL ~, (B2B), @, GID

~ W W W W
HEL051
EL-112
EXTERIOR LAMP
Turn Signal and Hazard Warning Lamps/Trouble

Diagnoses
Symptom Possible cause Repair order

Turn signal and hazard warning 1. Hazard switch 1. Check hazard switch.
lamps do not operate. 2. Combination flasher unit 2. Refer to combination flasher unit check.
3. Open in combination flasher 3. Check wiring to combination flasher unit for open
unit circuit circuit.
Turn signal lamps do not operate 1. 7.5A fuse 1. Check 7.5A fuse (No. [ill, located in fuse block).
but hazard warning lamps oper- Turn ignition switch ON and verify battery positive
ate. voltage is present at terminal @ of hazard
switch.
2 Hazard switch 2. Check hazard switch.
3. Turn signal switch 3. Check turn signal switch.
4. Open in turn.signal switch cir. 4. Check harness between combination flasher unit
cuit terminal @ and turn signal switch terminal G)
for open circuit.
Hazard warning lamps do not 1. 10A fuse 1. Check 10A fuse (No. ffiJ ,located in fuse block).
operate but turn signal lamps Verify battery positive voltage is present at termi-
operate. nal @ of hazard switch.
2. Hazard switch 2. Check hazard switch.
3. Open in hazard switch circuit 3. Check harness between combination flasher unit
terminal @ and hazard switch terminal @ for
open circuit.
Individual turn signal lamp or 1. Bulb 1. Check bulb.

turn indicators do not operate. 2. Grounds 2. Check ground circuit for the bulb.
Test lamp (27W)

Combination Flasher Unit Check
,\ I /
/ • Before checking, ensure that bulbs meet specifications.
• Connect a battery and test lamp to the combination flasher
unit, as shown. Combination flasher unit is properly func-
tioning if it blinks when power is supplied to the circuit.
Battery
SEL 122E
•
EL-113
EXTERIOR LAMP
Bulb Specifications
Wattage (W)
Front turn signal lamp 21

Clearance lamp 5
Front fog lamp 55
Side turn signal lamp 5
Rear combination lamp
Turn signal 21
StoplTail 21/5
Tail 5
Back-up 21
Rear fog 21
License plate lamp 5
High-mounted stop lamp
Bulb type (Sedan) 5 (x6)
Bulb type (Hatchback) 21
LED type 4.6
EL-114
INTERIOR LAMP
ilium ination/Schematic
rl
Q)
ro Q)
L E
(J) .rl
H Q) +J
E > L
D .rl ro Q)
Q) C +J D +J FAN SWITCH ILLUMINATION
ra ra > Q)
L ra +J E
(J) Q) D ::J 0
H Q 0 .c
0 .c .c U COMPACT DISK DECK ILLUMINATION
D L +J +J m
c ::J .rl .rl +J
(J)
..-;
Q)
D
ro
Q)
Q
0
L
lLJ
L
0
'<-
3E
(J)+J
r-l(/)
OJ>
D(J)
Q)
3E
(J)+J
r-1(J)
OJ>
D(J)
Q)
e
W
-!
.c
+J
.rl
3
EI
REAR FOG LAMP SWITCH
ILLUMINA TION
0 ::J +J 0 0 +J (J)
E lLJ Q E+J E+J Q..-; DL
OJ .c .c OJ OJ
0 L U OOlOOlU
I.r-l I-rl
D HEADLAMP WIPER AND WASHER SWITCH
I 0 0
a: LL
X
lLJ ---1.---1 ---1.---1
X
W L: ILLUMINA TION
@@@)~ e ~@ HAZARD SWITCH ILLUMINATION
II
GLOVE BOX LAMP GLOVE BOX
LAMP SWITCH
REAR WINDOW DEFOGGER SWITCH

ILLUMINA TION
RADIO ILLUMINATION
I
U
f- lLJ
UJ
H
3: ~ ASHTRAY ILLUMINATION
UJ LL
Z
ZO
o
HL
f-O
H
AIT INDICATOR ILLUMINATION
ZU
cc:JU COMBINATION METER
H«
CLOCK
METER
METER
>- lLJ
a: L: ILLUMINA TION
lLJ Hf-
f- I-If- EE
f- >-cc:JH
« «HZ
m O-!~
lLJ
UJ
~
•
LL
ILLUMINATION
CONTROL SWITCH
FRONT FOG LAMP SWITCH

I
ILLUMINATION
I- U
Z Ilf-
Occ:JL:H
a:O«3:
LLLL-!UJ
HEL060
EL-115
INTERIOR LAMP
Illumination/Wiring Diagram - ILL -
EL-ILL-01
I BATTERY I
•
~ ::.
1361
75A
W
Refer to EL-PDWER.
BIR W
DL
I
O~------ I.- BIR ~ Next page
BIR •
rr=m
LIGHTING LIGHTING
SWITCH SWITCH
~:@) ~:@
<R>: RHOmodels
o L @: LHD models without
BIR RIL @): Except@
rmwfnJ @: LHD models with daytime
light system
TAIL TAIL/L DAYTIME
FUSE SW @: For Europe and Israel
LIGHT R
UNIT @: Except @
TAILIL
OUTPUT <mID *1'" @R/B.@R/Y.
<])RIL
~ LE
RIB
I._-:~)I__ .IO~O- *1 II@> Next page
r------------------------~
~<ffiID
~GY
L ~
HEL053
EL-116
INTERIOR LAMP
Illumination/Wiring Diagram - ILL - (Cont'd)
EL-ILL-02
Preced ing
page
{<& ~
~
~f!
BIR
FUSE
BLOCK
C Next page (JIB)
@ , (E106)
IN.81 IN.81
B/R~
I~I
CHID
*2.
I t
0- I ~
RIG
-(C:- RIG ~TO EL-ILL-05

BIR
o EI
To EL-F/FOG. OR
RIG
FRONT
FOG LAMP
SWITCH
I!I, FOG LAMP
FRONT
SWITCH
(ILLUMINA nON)
([@: @)
~([@:@
B
To EL-F IFOG .OR/B
: LHO modeIs

: RHO models
EI
@: LHO models without
@: Models with daytime
light system
@: Except @
if! . .. <QD RIB. @ R/Y. RIL JOINT
E Next page CONNECTOR-1
*2'" <DR/G.@R/L
~
•
Refer to last page
(Foldout page) .
~(fITQ) CillIIITIIITIII ~
rnJm] B ~ BR
HEL054
EL-117
INTERIOR LAMP
EL-ILL-03
FUSE Refer to
Preceding C BLOCK EL-POWER.
page (JIB)
~
RIG RIG
m METER
':31METER
ILLUMI- ILLUMI- COMBINATION
ILLUMI- NATION NATION METER
NATION @ @
ILL CONTROL
SWITCH ~
~:@
lbiJl 1*.51
IbiJI ~ *6 *6
~
<W
B B BR/Y
It
~
I @: For Europe and Israel
"'I~
~O @: Except @
o @: Models with tachometer
@: Models without
BR/Y BR/Y BR/Y tachometer
*3'" @ 27. @ 11
1_~_m_m_51 *4'"
*5 ...
@34,@
@ 29, @ 10
5
JOINT *6'" @ B.@BR/Y

CONNECTOR-5
B
~:@
m
Preceding E JOINT
page H Next page CONNECTOR-1
~
Refer to last page

(Foldout page) .
ITillJ~
~W
L ~
~~ ITIIIII1IIITIil ~
~OR ~ BR
HEL055
EL-118
INTERIOR LAMP
EL-ILL-04
FUSE
Preceding F BLOCK
page I Next page (JIB)
~
UN.BI IN:I
RIG RIG
RIG
I I
RIG RIG
4 AIT
INDICATOR
ILLUMI- II!'I ILLUMI-
A9<TRAY
m RADIO
(ILLUMI-
NATION NATION NATION)
~~@) lbi=U@) ~
B B
I I
B
Irtil
JOINT
Preceding H CONNECTOR-1
page @
I!4Jl
B
I
.-O~O...,
:
<R>:
LHO models
RHOmodels I <:
B
:> B
R
B B
I
~~
If-II ~
•
Refer to last page
~@ ~ (M44) (Foldout page) .
~W [IgJ W
ITIillIilllIITI @
~BR
HEL056
EL-119
INTERIOR LAMP
Illumination/Wiring Diagram - ILL - (Coni' d)
EL-ILL-05
FUSE
Preceding BLOCK <I:>: LHD mode 1s
page (JIB) : RHD models
@ <QD: Models with daytime
light system
IN.BI IN.BI *9 ... <I:> 13 , @ 3
RIG RIG
JUNCTION
I Ii!9TI BOX NO.2
i~i
RIG (JOINT
CONNECTORS)
Next ~:<D
DEFOGGER
REAR WINDOW page
SWITCH JOINT
(ILLUMINATION) CONNECTOR-4
~ 1*.91 ~:
~ ~
RIG RIG
t
B
~E- ILL-02 <Q}r RIG • ~o

RIG
I RIG RIG
;
2
GLOVE
BOX LAMP
~
II!'I SWITCH
HAZARD
(ILLUMI-
NATION)
~
6
HEADLAMP
WIPER AND
WASHER
SWITCH
(ILLUMI-
~L:j=' NATION)
II7 II
l!4Jl
RIW
~~
B B
(856): <QD
CLOSED
rn GLOVE
BOX LAMP
OPEN SWITCH
~
I1~_I;
B B B
m
LL
CONNECTOR-
JOINT 3
_ Next~: <D
K page JOINT
( CONNECTOR-4
---------------------' ~: <ID
~~
~ W W
~@ [Q]~
[IIg] BR
1Irn','1Il~
54213 W
alll@~
45231 BR
Refer to last page
(Foldout page) .
rIIII:ITITillTI ~: <D rIIII:ITITillTI ~: 

~~ ~ P
HEL057
EL-120
INTERIOR LAMP
EL-ILL-06
JUNCTION
~3~I~~.2
~~-ILL-03 ~ RIG
( ~~~~ed1ng ~J ~!r<DS)
- ~;--I--------II~JI ~ CONNECTOR-4
.!r ~:@
RIG RIG
RIG
I
RIG RIG
I
(!II LAMP
REAR FOG
SWITCH
(ILLUMI-
12-31 COMPACT
DISK DECK
(ILLUMI-
NATION)
(£1 FAN SWITCH
(ILLUMI-
NATION)
NATION) 1
~~:@ ~:<ID ~~
B B
I I~L
B
m JOINT
CONNECTOR-2
Preceding
page
~:<D
JOINT
CONNECTOR-4
~:@
~
B
I
<D: LHD models e-o-::c-o..,
@:
@:
RHO models
For Europe and Israe 1
I <:
B B
R :>
B
I
B B
1 1--1 i...J
@: Except @
*9 ... <D 13 ,@ 3
(M28) @ ~
•
Refer to last page
(Foldout page) .
~~ ~~
~BR Ww
IIIIlII:illIill ~: <D IIIIlII:illIill ~: @

~BR ~P
HEL058
EL-121
INTERIOR LAMP
Interior, Spot, Trunk Room and Luggage Room

Lamps/Wiring Diagram - INT/L -
LHD MODELS
EL-INT/L-01
FUSE BLOCK @: Sedan models

(JIB) Refer to EL-POWER. @: Hatchback mode Is
~ @: Models with sun roof
@) @: Models without sun roof
IN;31
IIT.311
RIB RIB @@)
I• RIB 1II1} RIB

, 0
t
O~
RIB
RIB
i~iLUGGAGE
ROOM
LAMP
t
RIB
m
Im
RIB
1~lrnu~
lbi=Jl~
ROOM
LAMP
~~
R
c!J@}
SPOT
LAMP ON OFF aID:@
INTERIOR
LAMP
1bi=Jl@Q!) ON <:BID: @)
...... <BID:@)
R R OFF.....
--
I
R
m LUGGAGE ~ ~
DOOR
$@ ROOM
OPEN LAMP B CBD = R/W
(ill)
SWITCH IQP~~i~--------~qpl
(!)
R
CLOSED @llID
c!J ~
B R/W
TRUNK
rn
ROOM B JLNCTION
BOX No.2
•••
JOINT
LAMP CONNECTOR-1 (JOINT
SWITCH <f@ CONNECTORS)
CLOSED c::ID ~<fill)
m@W
~@)
B ~
B R/W
B
I I•
B
-!-
r.
B
-!-
B
-!-
I.
B
-!-
I
B
-!-
R/W ~Next
page
<:ITID (ill) (Ql05) ~ @ ~ ~
Refer to last page

~~~ ~CID wCBID(@@ (Foldout page) .
~ W I W ~W rn::g] W' W' W
I:illliTI] @
~W fHiI'II~@WW
4567B
rh-f:l@
~ B
n.o-r:l@llID
LUQ.LgJ B
ITIillIITillIII <f@
~BR
HEL061
EL-122
INTERIOR LAMP
Lamps/Wiring Diagram - INT/L - (Cont'd)
EL-INT/L-02
Preceding ~ R/W
page ~
@: Sedan and 5-door
Hatchback models
R/W t'UE\
db~
IUJJI(Jg)
R/W
I
i---O--s -H--°:l
R/W R/W
w=h FRONT
~ FRONT
DOOR DOOR
OPEN SWITCH OPEN SWITCH
(DRIVER'S (PASSENGER
SIDE) SIDE)
CLOSED @) CLOSED @
REAR REAR
DOOR DOOR
SWITCH SWITCH
LH RH
CLOSED @ CLOSED ~
E~@
5 Sj8I91Q1112 W
~@)
'TIT S L!l
~@@
SR ' SR ' SR
•
HEL062
EL-123
INTERIOR LAMP
Lamps/Wiring Diagram - INT/L - (Cant' d)
RHD MODELS
EL-INT/L-03
FUSE BLOCK @: Sedan modeIs

(JIB) Refer to EL-POWER. <@>: Hatchback models
~ @: Models with sun roof
CID @: Models without sun roof
IIN~31
IIT.31
RIB RIB ~ CRD
I • RIB ~
,
RIB 0
t
O~
RIB
RIB
iLUGGAGE
ROOM
+
RIB
IFh
RIB
IFh
~
LAMP
1~ITRU~ROOM lbi=JI~ SPOT

INTERIOR
LAMP
LAMP R LAMP
ON OFF C8!): @
U:jJI~ c!:I~
1biJI@QD
ON aID: @
.....(][):@
R R OFF.....
-- DOOR
I
R
n=h ~ ~
LUGGAGE B = R/W
c!J@ ROOM
OPEN LAMP m CRD
rnA'\
r=:b\..B.1..l
I!:iJIcm
R SWITCH qJ~ 1[jJ1~
CLOSED @llQ) B R/W
dJ ~
4
(1)
TRUNK JOINT JOINT
ROOM B
••
. CONNECTOR-4 CONNECTOR-1
LAMP
SWITCH ~ ~
CLOSED @
•
m@QDB 4=ll
~
B
~
R/W
[jJ~
B
I
,...,
I
nB
f. B B
I.J
B
('[@ @
~
B
(0105) m
~
B
~
@
B
~
1- !
@
J
~
R/W ..sa--.
~page
Next
Refer to last page

~@~ ~am@)(][) (Foldout page) .
2 W' W ~QID
1 234 W 12 W' W ' W
I:HiII
45678
I Iii] (O101)
W
rk-O
lli!.@
Cffi
B
n-.,....c, (0110)
l..!..l2@ B
ITIII:illITIIIT @ ITIII:illITIIIT ~
~BR ~ BR
HEL063
EL-124
INTERIOR LAMP
Lamps/Wiring Diagram - INT/L - (Cont'd)
EL-INT/L-04
Preceding -Bl- R/W
page ~
@: Sedan and 5-door
Hatchback models
R/W t""TIE\
r4:,~
I~I(@
R/W
I
i---O--s -H--°:l
R/W R/W
IT=h FRONT
m FRONT
DOOR DOOR
OPEN SWITCH OPEN SWITCH
(DRIVER' (PASSENGER
SIDE) SIDE)
CLOSED @) CLOSED @
REAR REAR
DOOR DOOR
SWITCH SWITCH
LH RH
CLOSED ~ CLOSED @)
rill"lcm:>
'TIT S
A~~~
lJJ SR ' SR ' SR
•
HEL064
EL-125
INTERIOR LAMP
Bulb Specifications
Wattage (W)
Interior lamp 10
Spot lamp 10
Turn room lamp 3,4
Luggage room lamp 3,4
EL-126
METER AND GAUGES
Combination Meter
WITH TACHOMETER
Gasoline engine
Diesel engine
o
RESISTOR
DIODE (Gasoline engine)
\*" ~ o
\~\=S=I
,-,------
, \
=======~
1 8
2 9
310
411
12
@ Gasoline engine
1 13 @ Diesel engine ~
~
514 @D For Australia
615
716 @ Except for Australia
6 27 34 37 36 28 12 10 30 14
•
a:
@
z z z LlJ a:
0 0 0 I-
LlJ
0 @J
~ ~ ~ ~ ~
Z
~
Z
~
Z
~
I
--J
Z
I
a:
Z
()
0
~
0
I
()
is a:
u.
u.
0
LlJ
~
@
~
a:
LlJ
I
@
--J --J
::J ::J ::J a: a: ()
()
~ --J
0 Cl <t (J) LlJ 0 (J)
f:J
--J --J --J ::J ::J 0 a: co ::> <t
:::! :::! :::! l- I-
~ Z 0 Cl 0 co <t u.
--J
CD ~
LlJ
co
~ >--- 0
() 1=
0 @~
--J
() a:::J
LlJu.
f:J<i!
U::~
5 29 17 13 16 18 1 938 15 32 41 40 42 39 26 2 4 7 8 33 31 3
@ @
HEL065
EL-127
METER AND GAUGES
Combination Meter (Cont'd)
WITHOUT TACHOMETER
RESISTOR
11 5 14 12 6 33 15 40 38
UJ
z z UJ CJ
a:
0 0 CJ :::>
:::> <C 0
~ ~ I I ~ <C CJ ~
Z Z ....J a: u CJ
0.: U UJ
~ ~ z z 0
....J
....J
UJ
~ ~ 0 a: ~ ....J
:::> :::> a: a: U :::> UJ <C ~ 0 <C UJ
....J ....J :::> :::> u.. I- UJ UJ
....J
0 a: :::>
:::! :::! l- I- CJ
[D z CJ 5 0 [D u..
~ <C >---ffi>--- 0 a:
u [D
~ t= <C
u :I:
0
....J
u
a:
« :s: z
:::>
u
u..
....J
<C
~
10 13 32 30 36 31 4 37 8 3 2 28 35 29
HEL066
EL-128
METER AND GAUGES
Speedometer, Tachometer, Temp. and Fuel

Gauges/Wiring Diagram - METER -
LHD MODELS WITH TACHOMETER
EL-METER-01
@: Gasoline engine
FUSE @: Diesel engine
BLOCK Refer to EL-POWER. *1"'@~ @@)
(JIB) *2"'@ ~' , @) (E230)
~ *3"'@ 7 , @) 6
~ *4"'@ B , @ 7
~----.PU/R. To EC-VSS, *5"'@ 1 , @) B
I EC-COOL/F
PU/R
IFf3TI COMBINATION METER (M30)~ ~
SPEEDOMETER
~
R/Y
~
L/OR
l4=ll
G
~
PU/W
R/Y
I
db@db
R It! PU/W
I
1fffiFn@
1114FI~- - - iIT3FI1
......~
R/Y
'T"
R
to CD IciJl ~:~~
G
ITJI<rnv
PU/W
R/Y
~@~
I I R
II!@J~- - - ~lMJl
L/OR IU'Arn
db~
L/OR
I~I@
I
G
II!I TANK
FlU
GAUGE
PU/W
I$I@
I
'=r'(g)'=r'
R/Y R I Ibi=ll
UNIT
PU/W
(g)
I, RIt L/OR
2027
L/OR
1n
(818)
I
0
R/Y PU/W
8
(LeSJ
TACHO TACHO 8
SiR 8/R
VEHICLE SPEED
Ll! ECM (ECCS
CONTROL
MODULE)
ECM (ENGINE
CONTROL
MODULE)
&.J
~
8
1
8
_
~T~~ALTRANSMITTER
(E211)
SENSOR
Cf@ CTI):@@:@m:D ~
•
~
r------------------------------------------------,
Refer to last page
(Foldout page) .
L ~
@ , {W
~
~@g) ~~ em
rn:rn:IZlID 8 ~8
~
~
1 GY ~~GID
56)819101112 W
~2 HEL067
EL-129
METER AND GAUGES
Gauges/Wiring Diagram - METER - (Co nt' d)
LHD MODELS WITHOUT TACHOMETER
EL-METER-02
@: Gasoline engine
FUSE @: Diesel engine
BLOCK Refer to EL-POWER. *1 ... @m @@
(J/B) *2"'@ ~' , @) (E230)
~
I
.... PU/R~ To EC-VSS
*3 ... @ 7
*4."@
*5"'@
8
1
,@ 6
, @) 7
, @) 8
PU/R
rr=!2il
WATER COMBINATION
FUEL TEMP. METER
SPEEDOMETER GAUGE @
GAUGE
@
~ ~ ~ ~
R/Y B/R G PU/W
I I I
R/Y
db(M8) db
R
11'i4F1~- - - ifI3Fll
.......~ 'T"
m@
+@)
G PU/W
~CBID
liJI~
R/Y R G PU/W
I
R/Y
I I CED R
1
G
FUEL
TANK
GAUGE
db~
I
PU/W~
I~ICEID
I$~<ID
_*-.1_ i$1
~~
UNIT
(818)
PU/W
R/Y R I
PU/W
IJ I t B
m THERMAL
R/Y R
In TRANSMITTER
W
B B B
1...1.1
CE211)
VEHICLE
SPEED
rv SENSOR B/R
~ ~
~ w @
Refer to last page

(Foldout page) .
L ~ <:MID , ~
~
~~
rn:rnrrIID B
~~
~B &~O:ID
5 6 TI19101112 W
@IID
1 GY
~2
HEL068
EL-130
METER AND GAUGES
Gauges/Wiring Diagram - METER - (Cont'd)
RHO MODELS WITH TACHOMETER
EL-METER-03
IGNITION SWITCH @: Gasoline engine
ON or START
@: CD engine
FUSE Refer to EL-POWER. @: GA engine for Australia
lOA BLOCK
[]] (JIB) @: GA engine for Europe
Qill) @: Except @
....
r- + PU/R To EC-VSS.
EC-COOL/F
*6"'@2 , @3
PU/R
ffil COMBINATION METER (M30)~ ~
WATER
TEMP.
GAUGE
~
R
~
L/OR
4=U
G
~
PU/W
I
R/Y@R
I
0
It I
G
~CMID
PU/W
I
It.ICMID
1~~_~8_i$/ CD
t
~ ~@) (El0n
R/Y R G pu/w
I
I I
R/Y
ctJ(ffi>[f]
R
L/OR~
~
~CEID
L/OR
49
rn G
FUEL
TANK
PU/W
I
dJ (E24)
GAUGE
~~~ Ibi=Jl (E202)
R/Y
IJ
R
I UNIT
PU/W
It L/OR L/OR ~ (B18)
I
0 0 t..lI n1
R/Y R B
PU/W
TACHO TACHO
B/R B/R
B B B ~T~~AL
~
VEHICLE SPEED
LI ~
ECM(ECCS
CONTROL
MODULE)
ECM(ENGINE
CONTROL
MODULE)
TRANSMITTER
(E2u)
SENSOR
~ @ <ED:@ <M39):@ ~ @
r------------------------------------------------,
L ~
Refer to last page
(Foldout page) .
(BID
Qill)
(El0l) •
~~ ~ R~ em
rn:tIDZ:IID B ~GY L!J B @
~
1 GY
~2
HEL069
EL-131
METER AND GAUGES
Gauges/Wiring Diagram - METER - (Cont'd)
RHO MODELS WITHOUT TACHOMETER
EL-METER-04
IGNITION SWITCH
ON or START
FUSE
[]] (..)/B)
<M:@
PU/R
-
I...............
PU/R~ To EC-VSS
Iffi=n
COMBINATION
FUEL WATER METER
GAUGE TEMP. @
GAUGE
@
~
R
~
B/R
~
G
I!4J1
pu/w
I I I
R/Y R G pu/w
Ir¥~<-~ 2 ItlCMID
m i~1R IrOJl ~::~ m
R/Y G pu/w
I
I I G
I
R/Y
""!-'~r-!-.
R
IW~ - - - ~LJUI
9F~"=
R/Y
Ifit
R
W
lbj:JI
B
i FUEL
TANK
GAUGE
UNIT
(BiB)
~=
pu/w
pu/w
I
pu/w
R/Y R
In rFh THERMAL
TRANSMITTER
M
B B B (E2H)
VEHICLE
'V
SPEED
SENSOR
@ID
B/R
~
i.J.l
~ @ @
Refer to last page

(Foldout page) .
CHID , ~
<M:@
~~ ~
IIDIDlIID B 1 GY
~2
HEL070
EL-132
METER AND GAUGES
Inspection/Fuel Gauge and Water Temperature

~i5~
Combination meter connector @
Gauge
y INSPECTION START
Voltmeter
CHECK POWER SOURCE. NG Check the following

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<COMBINED EDITION>

QUICK REFERENCE INDEX

ALMERA ENGINE MECHANICAL EM

FRONT AXLE & FRONT SUSPENSION FA

REAR AXLE & REAR SUSPENSION RA

BODY & TRIM BT

HEATER & AIR CONDITIONER HA

ALPHABETICAL INDEX IDX

NISSAN EUROPE N.V.

In order to assure your safety and the efficient functioning of the

All information in this manual is based on the latest product informa-

IMPORTANT SAFETY NOTICE

pe"fl NISSAN MOTOR CO., LTD.

Observe the following precautions to ensure safe and proper

Supplemental Restraint System (SRS) "AIR

Supplemental Restraint System (SRS) "AIR

• Do not use electrical test equipment on any circuit related •

Precautions for NATS V2.0 (For Gasoline Engine

• Before starting repairs which do not require battery power:

• To prevent serious burns:

• Before servicing the vehicle:

• Clean all disassembled parts in the designated liquid or

Precautions for Multiport Fuel Injection System

Precautions for Three Way Catalyst

Do not place the vehicle on flammable material. Keep flamma-

HEALTH PROTECTION PRECAUTIONS

ENVIRONMENTAL PROTECTION PRECAUTIONS

Precautions for Fuel

It]. N'm (kg-m, in-Ib)

• The following SYMBOLS AND ABBREVIATIONS are used:

MfT models AfT models

Number Item Description

• The double line shows that this is a fusible link.

• The single line shows that this is a fuse.

• This shows that connector @) is female and connector @ is male .

• This arrow shows that the circuit continues to an adjacent page.

• This shows an internal representation of the relay. For details, refer to EL

@ Component name • This shows the name of a component.

• This shows the connector number .

@ Ground (GND) • This shows the ground connection.

View from harness side

Example • Male and female terminals

DETECTABLE LINES AND NON-DETECTABLE LINES

f' 80th switches are turned in

SWITCH POSITION CONTINUITY CIRCUIT

....... @ID .......

r-BR (Main harness)

STARTI G SYSTEM STARTING SYSTEM

Wiring Diagram Codes (Cell Codes)

Air Conditioner Cut Control LOAD EC Load Signal

CHARGE EL Charging System MIRROR EL DOOR MIRROR

CHIME EL Warning Chime NATS EL NISSAN ANTI-THEFT SYSTEM

CMPS EC Camshaft Position Sensor 02S EC OXYGEN SENSOR

COOllF EC Cooling Fan Control EVAP CANISTER PURGE CON-

--------- -------------------- STEP 5

WHEN Date, Time of Day, Weather Conditions, Frequency.

WHERE Road Conditions, Altitude and Traffic Situation.

HOW System Symptoms, Operating Conditions (Other Components Interaction).

STEP 2 Operate the system, road test if necessary.

STEP 3 Get the proper diagnosis materials together including:

POWER SUPPLY ROUTING

STEP 5 Repair or replace the incident circuit or component.

The section is broken into the six following topics: