Celica 1993 At200 Series

@ToYoTA & B O D Y
I M A N U A L F O RC H A S S I S
R E P AR
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FOREWORD
This repairmanualhas beenprepared to provideinformation

covering general irs
repa
service for the c hassisand bodyof the
T O Y O T AC E L I C A ,
Aooltcablemodels: AT2O0series
ST2O2.204 series
For the servicespecifications and repairplocedureof the

abovemodelotherthanthoselistedin thismanual,referto the
f o l l o w i n gm a nu a l s .
M a n u a lN a m e P u b .N o
a 7 A - F EE n g i n eR e p a i M r anual RM325E
a 3 S - F EE n g i n eR e p a rM r anual RM395E
o 3 S - G EE n g i n eR e p a i M r anual RM396E
a 35-GE,35-GTE,55-F EE n gi n e R e p a i r RM164E
Manual
S S - F EE n g i n eR e p a i M r anual RM267E
Supplement
A14OEAutomaticTransaxle Repair RM248E
Manual
a a l i r i n gD i a g r a m
C e l i c aE l e c t r i c W EWDI98Y
a C e l i c aN e w C a r F eatures N C F 10 3 E
All informationin this manualis basedon the latestproduct

informationat the time of publication,However,spectfica-
tions and procedures aresublectto changewithout notice
TOYOTA MOTOR CORPORATION
o 1995 TOYOTA MOTOR CORPORATION

Thisbookmaynot be repro-
A I rightsresefved.
d u c e d o r c o p i e d ,i n w h o l e o r i n p a f t , w i t h o u t t h e
wr tten permrssionof Toyota Motor Cofporation.

I N T R O D U C T I O$fifiiliffiff
N
CLUTCH
C52 MANUALTRANSAXLE.
S54 MANUALTRANSAXLE.Hffi.ffiff
E56MANUALTRANSAXLE*$nxilifq
AUTOMATIC TRANSAXLEffi$Jiritilr
SUSPENSIO AN N DA X L E il#{*ffi
BRAKESYSTEMffi:Hffi
STEERING ffi,ff
SUPPLEMENTAL RESTRAINT SYSTEMtHsllrltffi
BODYELECTRICAL SYSTEM
BODY ,'#ffi
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A I RC O N D I T I O N I N Y S T E Mi'ffi-,ffiffi
ELECTRICAL WIRINGDIAGRAMSriHstu#

tN-1
INTRODUCTION
H O WT O U S ET H | SM A N U A L . . . . . . . . . ' . . . . .l.N .-
t D E N T t F t C A T |TONNF O R M A T T.O . .N. . . ' . . . . . l N -
, .S. . . . . . ' " .I N - b
;ffi
G E N E R ARL E P A I R INSTRUCTION
PRECAUTTON . ' .' . . . . .. ' . . . . . IN - 1 0
VEHICLE L I F TA N D S U P P O R T
LOCATTONS . . . . . . . . . . . . . . l. N
' . - 12
A B B R E V I A T I O NUSS E DI N T H I S
MANUAL . . . . . . . . . . . . . . . |. N . . -. .
STANDAROB O L TT O R O U
E
SPEC|F|CAT|ONS . . . . . . . . . .|.N - t4

lN-2
I N T R O D U C T I O_N H O WT O U S ET H I SM A N U A L
H O W T O U S ET H I SM A N U A L
INDEX
An INDEXis providadon the first page of each sectionto guideyou to the item to be repaired.
To assistyou in finding your way through the manual,th€ SectionTitle and major headingare
ffio given at the top of 6very Page.
rffiil["
4 ' - 1 CG E N E R A L D E S C R I P T I O N
A t t h e b o g i n n i n go f e a c h s e c t i o n ,a G e n e r a lD e s c r i p t i o ni s g i v e n t h a t p 6 r t a i n st o a l l r e p a i r
operationscontainedin that s6ction.
Readthese pr6cautionsbofors startingany rspalrtask.
TROUBLESHOOTING
TROUBLESHOOTIN t h e p r o b l e ma n d
t aGb l e sa r e i n c l u d e df o r e a c hs y s t e mt o h e l py o u d i a g n o s e
find the cause.Be sure to readthis beforeperformingtroubleshooting.
PREPARATION
Preparationlists the SST (SpecialServiceTools).recommandedtools, equipment,lubricantand
S S M ( s p e c i aS t h e o p e r a t i o na n d
l e r v i c eM a t e r i a l sw) h i c h s h o u l db e p r e p a r e db e f o r eb e g i n n i n g
e x p l a i n st h e p u r p o s eo f e a c ho n e .
PROCEDURES
REPAIR
Most repair operationsbegin with an overview illustration.lt identifiesthe componentsand
shows how the parts fit togethar.
Example:
(_-.c-rf-.,
-'- -l - --frlrer uao
-_:7 ulevrs
a-
-Float
" r
a lGasket
IJ CliP
Boot I I II
Tank I ^l
II /1) s
qWR
*YYo
a Grommet (,A\ i\
,"..(Nl t)v/
, l I
to//
Cl€vis
I
lsnarl ) Ring
Lock N u t
Rod
Cylinder
N.rn (ksi;"annn torque

: specified
a N o n - r e u s a bpl ea r t

- HOW TO USETHISMANUAL tN-3
INTRODUCTION
The proceduresara presentedin a step-by-stop format:

o The illustrationshows what to do and whsrs to do it.
r The task headingtslls what to do.
. The detailed text tells how to perform the task and gives other informationsuch as
sp6cifications and warnings.
Exam ols:
Ttsk ha,dlng :
piston a3 showd in the illustration'
rrs*
technicianwith a FASTTRACKto the informationneeded.

This format orovidesthe exoerienced
The upper case task headingcan be read at a glancewhen necessary,and the text below it
orovidesd6tailedinformation.lmportantspecifications and warningsalways stand out in bold
ty pe.
REFERENCES
, h e n t h e y a r e r e q u i r e dy o u a r e g i v e nt h e
. o w e v e rw
Referenceshave been kopt to a m i n i m u m H
^.â r^ ra{.r t^
SPECIFICATIONS
Specifications a16prssentedin bold type throughoutthe text where needed.You neverhave to
leavethe procedureto look up your specifications. They arealsofound at the end of eachsection,
for q u i c k reference.

lN-4
I N T R O D U C T I O_N H O W T O U S ET H I SM A N U A L
C A U T I O N SN, O T I C E SH, I N T S :
. CAUTIONSar€ presentedin bold type, and indicatethere is a possibilityof injury to you or
other 06oolo.
. NOTICESare also presontodin bold typ6, and indicatothe possibilityof damageto the
componentb s e i n gr e p ai r e d .
r HINTS are separatedfrom the text but do not appear in bold. They provide additional
informationto help you performthe repairefficiently.
SIUNIT
The UNITSgiven in this manualare primarilyexpressedaccordingto the Sl UNIT (lnternational
Systemof Unit),and alternatolyexpressedin the metricsystemand in tho EnglishSystem.
Example:
Torque:30 N.m(310kgf.cm,22 ft.lbf)

- IDENTIFICATION
INTRODUCTION INFORMATION
I D E N T I F I C A T I OI N F O R M A T I O N
NN
IDENTIF]CATIO
VEHICLE UMBER
The vehicleidentificationnumber is stamp€don th€
vehicleidentificationnumberplateand manufacture's
plate.
A. VehicleldentificationNumberPlate
B. Manufacture'sPlate
7A-FE Engine S E R I A LN U M B E R
ENGlNE
The engine serial number is stampedon the engine
block as shown.
55- FE
3 5 - F E ,3 S - G EE n g i n e s

tN-6 _ GENERALREPAIRINSTRUCTIONS
INTRODUCTION
,-€F GENERAR
L EPAIR
INSTRUCTIONS
1. Use fender,seat and floor coversto teep tfre vd-fficie
c lean and preventdamage.
2. During disassembly,keep parts in the appropriata
order to facilitatereassemblv.
3. Observethe following:
(a) Before performing electrical work, disconnect
the negativeterminalcablefrom the battery.
(b) lf it is necessaryto disconnsctthe battery for
inspectionor repair,alwaysdisconnsctthe cable
fromthenegative ( - ) t e r m i n a lw h r c hi s g r o u n d e d
to the vehiclebodv
(c) To preventdamageto th€ batteryterminalpost,
l o o s e nt h e t e r m i n anl u t a n d r a i s et h e c a b l es t r a r -
ght up without twisting or pryingit.
(d) Cleanthe batteryterminalposts and cabletermi-
nals with a clean shop rag. Do not scrapethem
with a file or othar abrasiveobjects.
(a) Installthe cableterminalto the batterypost with
the nut loose,and tighten the nut after installa-
t i o n . D o n o t u s e a h a m m a rt o t a o t h e t e r m i n a l
onto the post.
(f) Be su16the coverfor the positive(*) terminalis
properlyin place.
4. Checkhose and wiring connactorsto make sure that
they ars sgcureand correct.
5. Non- reusableparts
(a) Always replacecotter pins.gask6ts,O - ringsand
oil sealsetc. with new onos.
( b ) N o n - r a u s a b l ap a r t sa 1 6i n d i c a t e di n t h e c o m p o -
"1"
nent illustrationsby ths symbol.
A Pra^îra.l n.rtc
Precoated parts are bolts and nuts, etc. that are

coated with a seal lock adhesiveat the factorv.
(a) lf a precoated part is retightened. loosened or
caused to move in any way, it must be recoated
w i t h t h e s o e c i fi e d a d h e s i v e .
S e a l L o c kA d h e s i v e

_ GENERALREPAIRINSTRUCTIONS
tN-7
INTRODUCTION
(b) When r€usingprecoatedparts,clean off the old
adhesiveand dry with compressedair. Then
applythe specifiedseallock adhesiveto ths bolt,
nut or th rsads.
(c) Precoatedparts are indicatedin the component
nt rTi.ry..f
u,*"* topreve
* ^"l'l"J::::l;:lJ: J; :lTnooJ
leaks.
8. Carefullyobservsall spacifications for bolt tightening
torquss.Always use a torqua wrench.
o Use of specialservicetools (SST)and specialservice
materials(SSM)may be required,dependingon the
nature of the rspair. Be sure to uss SST and SSM
where specifiedand follow the proper work proce-
d u r e .A l i s t o f S S T a n d S S M c a n b e f o u n d i n t h s
preparationpart at the front of each section in this
m an u a l .
M e d i u m C u r r e n t Fuse and High Current 10. When replacing f u s e s ,b e s u r s t h e n e w f u s e h a s t h e

E q u a lAmperage Rating corr€ctamperagorating.DO NOTexceodthe ratingor
'l
l;1ji\-,.1
I lrii
f,.rFa'nfl uss one with a lower rating.
pI Fr r.l -
TL- 11
c-)
l|;t l;t I
tL]LJ
" f
8E1367
lllustraiion Symbol Part Nam€ Abb16vi8tion
------\_'z'rc- FUSE FUSE

8E5594 tN0365
---4- C U R R E NFTU S E
MEDIUM M.FUSE
8E5595 1N0366
--@- H I G HC U R R E NFTU S E H-FUSE

a€5596 rNo367
-_@- F U SI B L EL I N K FL
885597 lNo367
CIRCUIT BREAKER CB
4E5598

tN-8
I N T R O D U C T I O_N G E N E R A R
L EPAIR
INSTRUCTIONS
1 1 .C a r €m u s t b e t a k e nw h e n j a c k i n gu p a n d s u p p o r t i n g
the vehicle.86 sur6 to lift and supportthe vehicleat
the prop6rlocations(Seepage lN - 12).
(a) lf the vehicleis to be jacked up only at th6 front
or rear snd, be surs to block ths wheels at the
oppositeend in order to ensurasafety.
IN (b) After th6 vehicleis jackedup. be sureto support
it on stands.lt is extremelydangerousto do any
work on a vehicleraisedon a jack alone.evenfor
a s m a l lj o b t h a t c a n b e f i n i s h e dq u i c k l y .
1 2 . Observethe followingprecautionsto avoiddamagato
tho followingparts:
(a) Do not open the cover or caseof the ECUunless
absolutolynecessary. (lf the lC terminalsare tou-
ched,the lC may be destroyedby static electric-
ity.)
( b ) To disconnectvacuumhoses.pull on the snd, not

WRONG CORRECT
the middleof the hose.
.L -' ( c ) To pull apart electricalconnoctors,pull on the
'...' connectoritself,not the wires.
:- ./
(d) Ba careful not to drop electrrcalcomponants.
,//).=:=-- )-1"
e- ':* such as sensorsor relays.lf they are droppedon
/'" /z a hard floor. they should be replacedand not
reusod.
(e) W h e n s t e a mc l e a n i n ga n e n g i n ep. r o t o c tt h e d i s -
tributor,air filter,and VCV from water.
(f) Neverusa an impactwrench to removeor install
WRO NG CORRECT tomperatureswitch6sor temperaturessnsors.
(sl When checkingcontinuityat the wire connector,
ins6rtthe tosterprobecarefullyto prsventtermi-
P4-l--l nals from bending.
"" ll (h) W h e n u s i n g a v a c u u m g a u g e ,n e v 6 r f o r c e t h s
ll hosa onto a connoctorthat is too large. Use a
stsp-down adapterinstead.Once the hose has
beenstretched,it may leak.
pl6 Tag hosesbeforedisconnectingthem:

(a) When disconnectingvacuum hoses,use tags to
identifyhow thoy should be reconnectod.
(b) After completinga job, double check that the
A vacuum hoses ars properlyconnected.A label
? underthe hood shows the propsr layout.

I N T R O D U C T I O- N G E N E R A R INSTRUCTIONS
L EPAIR
14. Unlessotherwisestat€d,all resistanceis measuredat

an ambienttomperatureof 20'C (68"F).Becausethe
rosistancemay be outsidespscificationsif measured
at high tempsraturesimmediatelyafter the vehicle
has been running, measuromentsshould be made
when the 6nginehas cooleddown.

tN-10 _ PRECAUTION
INTRODUCTION
PRECAUTION
S O U I P P EW
F O RV E H I C L E E D I T HS R SA I R B A G
The TOYOTA CELICAis equippedwith an SRS (Supplemental RestraintSystem)airbag as an
option.
,:.. . Failureto carry out serviceoperationsin the corrscts6quoncecouldcausethe SRSto unexpect-
ITI
rrr e d l y d e p l o yd u r i n gs e r v i c i n gp, o s s i b l yl e a d i n gt o a s e r i o u sa c c i d e n t .
Further.if a mistakeis madein servicingthe SRS,it is possiblethe SRSmay fail to op6ratewhen
required.
Before performingservicing(includingremovalor installationof parts, inspectionor replace-
ment),be sure to readthe followingitems carefully.then follow tho correctproceduredescribed
i n t h i s m a nu a l .
Location of Components
S en s o r L o c k
R e l e a s eB o l t
A i r b a gS e n s o r
S t e e r i n gW h e e lP a d S t e e r i n gW h e e l
R097r2

tN-11
I N T R O D U C T I O_N P R E C A U T I O N
'I
. N e v e rd i s a s s e m b lt eh e s t e e r i n gw h e e lp a d a s s e m b l y .
2. Do not subjectthe steeringwheel pad to shocksor bring magnetscloseto it.
3. Do not exposethe st€eringwheel pad to high temperaturesor fire.
4. lf grease,cleaner,oil or water gets on ths steoringwheel pad, promptlywipe it off with a dry
cl o t h .
5. Do not drop the steeringwheel pad. Neveruse a steeringwheel pad which has been dropped.
6 . N e v e ri n s t a ltl h e s t e e r i n gw h e e la n d p a d i n a n o t h e rv e h i c l e .
7. When the steeringwheel pad is removed,store it on a stable,flat place with the pad surface
f a c i n gu p w a r d s .N e v e rp l a c ea n y t h i n go n t o p o f t h e p a d .
8 . W h e n w o r k o n t h e v e h i c l ew i l l p r o d u c et o o s t r o n ga s h o c k .f i r s t I o o s e nt h e s e n s o rl o c k r e l e a s e
bolt until it turns freelyand performthe work after sensorlock occurs.
9 . E v e ni n c a s e sw h e r et h e v e h i c l ei s i n a l o w - i m p a c ta c c i d e nw t h a r ot h e a i r b a gi s n o t a c t i v a t e d ,
always checkthe pad surfaceand airbagsonsorpart. lf dents.cracksor deformationis visibla,
r e p l a c et h e S R Sw i t h a n e w a s s e m b l y .
1 0 . W h e n d i s p o s i n go f t h e v e h i c l eo r s t e e r i n gw h e e l ,a l w a y sd e p l o yt h e S R Sf i r s t .
1 1 . T h e d e p l o y e di n f l a t o ri n s r d et h s s t e 6 r i n gw h e e lp a d i s h o t , s o d i s p o s eo f i t a f t e r i t h a s n a t u r a l l y
cooleddown to ambienttemperature.Neverapply watsr to cool it down.
W I T H A C A T A L Y T I CC O N V E R T E R
F O RV E H I C L E SE O U I P P E D
CAUTION: ll large amounts of unburned gasoline flow into the converter, it may overheat and create
a fire hazard. To prevent this. observe the following precautions and explain them to your customer.
1. U s e o n l y u n l e a d e dg a s o l i n e .
2. Avoid prolongedidling.
A v o i d r u n n i n gt h e e n g i n ea t i d l es p e o df o r m o r et h a n 2 0 m i n u t a s .
3. Avoid spark jump test.
(a) Performsparkjump test only when absolutelynecessary. Performthis test as rapidlyas possible.
( b ) W h i l et e s t i n g n
, 6 v e rr a c et h e € n g t n e .
4. Avoid prolonged engine compressionmeasurement.
E n g i n ec o m p r e s s i otne s t sm u s t b e d o n ea s r a p i d l ya s p o s s i b l e .
5- Do not run engine when fuel tank is nearly empty.
T h i s m a y c a u s et h e e n g i n et o m i s f i r ea n d c r e a t ea n e x t r al o a do n t h e c o n v e r t e r .
6. Avoid coastingwith ignition turned off and prolongedbraking.
7. Do not disposeof used catalyst along with parts contaminatedwith gasolineor oil.

lN-12
r N T R o D U c r r o -N v E H t c L E
L I F TA N Ds u p p o R TL o c A T l o N S
V E H I C L EL I F TA N D S U P P O R LTO C A T I O N S
JACK POSITION
F r o n t . . . . . . . . . . . . . , . .F. .r o n tc r o s s m e m b e r
R e a r. . . . . . . . . . . . . . . . . .R. e a ra x l eb e a m
C A U T I O N : B e f o r ej a c k i n g - u pt h e r e a r a n d f r o n t , m a k e s u r e t h e c a r i s
not carrying any extra weight'
JACK POSITION
PANTOGRAPH
POSITION
SUPPORT
o
Saiety stand and swing arm type lift
ffi
N r0 0 0 5

- ABBREVIATIONS rN-13
INTRODUCTION USEDIN THISMANUAL
A B B R E V I A T I O NUSS E DI N T H I S
MANUAL
ABS Anti-Lock BrakoSvstgm

ALR AutomsticLockingRotractor
APPROX. Approximat6ly
A/-l AutomaticTransaxle
ATF AutomaticTransaxloFluid
CircuitBrosk€r
compact Disc
cRs Child RestrsjntSystem
ECU El€ctronicControlUnit
Em6rgencyLocking Retractor
FTFI ElectronicTurningRsdio
EX Exhaust
Ex. Exc6pt
FIPG Form€din PloceGask6t
F u s i b l oL i n k
tl Front
H- Fuso High CurrentFuso
IG l gni t i o n
JB Junction Block
rFn Light EmittingOiode
LH L6ft-Hand
LSO Limitod Slip Ditforential
Max. Marimum
Multipurpos6
M/r ManualTransaxl€
o/D Ov6rdriv€
P&BV Proportioningand By-p656 Va vg
PS Pow€r Steering
RH Right*Hand
sRs Suppl6m6ntalR66traintSystom
ssM Spoci6lSorviceMatorials
ssT SpocialSorvicoTool6
SID St6ndard
sw Switch
T EtvlP. Temp€raturo
without

tN-14 - STANOARDBOLTTOROUESPECIFICATIONS
INTRODUCTION
S T A N D A R DB O L TT O R O U E
SPECIFICATIONS
HOW TO DETERMINE
B O L TS T R E N G T H
Mark Class Mark Class
Hexagon 4- 4f stud bolt

headbolt 5T
B ol t 6- 6T
- headNo.
7 7r
8- 8T
9- 9T 4I
10- 107
' I1 T
No mark 4r
hexa9on
llange bolt
No mark 4r Grooved
w/ washer
hexagon bolt
6T
rlexagon
h e a db o l t 2
protruding 5T
lines
Hexagon
{ l a n g eb o l t 2
prolrudrng 6T Welded bolt
ltnes
h e x a g o nb o l t
|| exagon
headbolt 3
prorruorn9 7r
lrnes 41
trexagon
h e a db o l t 4
protrudrng 8T
lrnes

rN-15
I N T R O D U C T I O_N S T A N D A R D
B O L TT O R O U E
SPECIFICATIONS
S P E C I F I ETDO R O U EF O B S T A N O A R DB O L T S
Sp€citiedtorque
Oiamete, Pitch ,n head bolt
Class 69on flang€ boh
mm mm
N.m cm tt.lbt N.m kot.cm ft.lbt
6 1 5 55 48 in. lbf 6 60 52 in. lbf

B 1.25 12.5 130 I 14 145 10
10 26 260 19 29 290 21
12 1. 2 5 41 480 35 53 540 39
14 L C 74 760 55 84 850 61
L C 115 1,150 83
'l
6 o.c oc 5b rn..tDt 7.5 75 65 in..lbf
8 1. 2 5 15 . 5 160 12 11.5 115 13
10 1.25 32 330 24 36 360 26
5T
12 59 600 43 65 670 48
1.5 91 930 61 100 1, 0 5 0 76
16 1.5 140 1,400 101
6 1 8 80 69 in..lbt 9 90 78 in..lbt
8 1.25 '19 195 14 21 210 15
10 1.25 39 400 29 44 440 32
6T
12 1.25 71 730 53 80 810 59
1.5 110 1,100 80 125 1,250 90
t o 1.5 170 1.750 121
,l
6 10.5 110 8 12 120 9
B 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
12 1.25 95 970 10 105 ],050 76
t . 5 145 1,500 108 165 1,700 123
16 230 2,300 166
8 1. 2 5 29 300 22 33 330 24
8T 10 1.25 61 620 45 68 690 50
1 a 1.25 110 1,100 80 120 1,250 90
1.25 34 340 25 3't 380 21

9T 10 lo 110 51 78 790 57
12 1. 2 5 125 1,300 94 140 1,450 105
8 38 390 28 42 430 31
107 10 7a 800 58 88 890 64
140 1,450 105 155 1,600 116
8 42 430 31 47 480 35
10 '7
117 87 890 64 97 990 2
12 155 1,600 116 175 '130
1,800

- MEMO -

cL-l
CLUTCH
DESCR|PT|ON..... . . . . . . " .C L - 2
PREPARATTON . . . . . . . . . . . . C L -4
T R o U B L E S H O O T T.N
CLUTCH SYSTEM
. .G
. . . . ' . . . . . ' . . . .... . . . . .C L - 5
B L E E D I N G, . . ' . . . . ' ' " . . . . "C L - 6
ffi
CLUTCH PEDAL.. . . , . . . . . . .C L - 7
CLUTCH MASTER CYLINDER . . . . . . . . . . . ' . . .C
. . L. - 9
CLUTCH R E L E A SCEY L I N D E .R. . . . . . , . . . . .C L - 1 3
c L U r c uHN r T ' . . . . .. . . . . c 1 -1 8
S E R V T CSEp E C l F l C A T t O N S . . ..'.....'.... . . . , . .C L - 2 2

cL-2 C L U T C H_ D E S C R I P T I O N
DESCRIPTION
The diaphragmspringturnovertype clutch providinglighterreleaseperformance.
CLUTCHASSEMBLY
3S.FEEngine
55-FEEngine 74-FEEngine 3S-GEEngine(w/ LSD)
35-GE Engine
RELEASECYLINOER
35-FEEngine
5 5 - F EE n g i n e
3 S . G EE n g i n e
o 0 5 0 7 0 0 5 0 70
10 5 2 r 8
o05582005583
o05584

cL-3
CLUTCH- DESCRIPTION
MASTERCYLINDER
LHD
CL
RHD
OO50,l9
o05309

cL-4 CLUTCH- PREPARATION
PREPARATION
ssT(sPEcrAL TOOLS)
SERVtCE
0 9 0 2 3 - 0 0 1 0 0 L J n i oNr u lw r 6 r c h1 0m m Clutchlino
0 9 3 0 1 - 0 0 1 1 0 c l u t c hG u i d T
oool 7A-FE.ngino
0 9 3 0 1 - 0 0 2 1 0 c l u t c hG u i d T
oool 35-FE ongino
c5-rts angrne
3 5- G E o n o i n o
09333-00013 Clutch0 rphrrgmSpringAlioner
R E C O M M E N D ETD
OOLS
'g& 09082-00050 ToYoTAEloctric.l
T.!t6rsrt
09905-00013 SnepRingPliers
EOUIPMENT
Calipers
Dial indicator
Torquo wrench

cL-5
CLUTCH- TROUBLESHOOTING
TROUBLESHOOTING
Usoth6 tabl€belowto helpyou find the causeof the problom.Thenumbersindicatethe prlSiit'i
r€placethsssparts.
of the likelycauseof the problsm.Checkeachpartin ordsr.lf necessary,
a') @ 6 @ @
t--
See Page ) J J ) ) J ) ) )
u I (-) () () I O I I o (J (J O (J o (J
PartsNam€ 3 E
o
o
E E
o
3
c o 3
J
3 o) E
E
Q) c o
'; J
E _l (l)
-t
Trouble 3 8 ti I
o E o
ll) E
'
q)
: (J () (J (J ^ o
Clutchgrabs/chatters 1 2 2
Clutchped6lspongy
1 ?
Clutchnoisy
Clutchslips 1
Clutchdoes not disengago 1 4 6 o 7 7 8
* r S e eC 5 2 M a n u a lT r a n s a x l e
o n p a g eM X - 3 8
o n p a g eM X - 3 3
S e eS 5 4 M a n u a lT r a n s a x l e
S e eE 5 6M a n u a l T r a n s a x loen p a g e M X - 3 4

cL-6
CLUTCH_ CLUTCHSYSTEMBLEEDING
C L U T C HS Y S T E MB L E E D I N G
HINT:lf anyworkis doneon the clutchsysremofffJir
is suspectedin the clutchlines,bleedthe systemof
atr.
N O T I C E :D o n o t l o t b r a k e f l u i d r e m a i n o n a p a i n t o d s u r -
face. Warh it otf immodiately.
:,cl:i': 1. F I L L C L U T C HR E S E R V O IW R I T H B R A K EF L U I D
2. C O N N E C TV I N Y L L I N ET O B L E E D E R PLUG
I n s e r t h 6 o t h e r6 n d o f t h e l i n ei n a h a l f - f u l l c o n t a i n e r
of brakef luid.
3. BLEEDCLUTCH LINE
HINT: Check the reservoirfrequentlv.Add fluid if
n€cessary.
(a) Slowly pump tho clutch pedalseveraltimes.
(b) While pressingon th6 p6dal,loosenthe bleederplug
until the fluid startsto run out. Then closethe bloeder
plug.
s s T0 9 0 2-3 0 0 10 0
(c) Repeat this procedureuntil there are no more air
bubblesin the f luid.

cL-7
CLUTCH- CLUTCHPEDAL
C L U T C HP E D A L
C L U T C HP E D A LC H E C KA N D
P u s hR o d P l a y
A d j u s tP o i n t ADJUSTMENT
ISCORRECT
1 . C H E C KT H A TP E D A LH E I G H T
Pedal hoight from asphalt shoat:
LHD 144.9- 154.9mm (5.705-6.098 in.)
*ffit"'
R H D 1 4 1. o - 1 5 1 . 0 m m ( 5 . 5 5 1 - 5 . 9 4 5i n . )
2. IF NECESSARY, ADJUSTPEDALHEIGHT
Loosenthe locknutandturnth€ stopperboltuntilthe
PushBod heightis corroct.Tightenthe locknut.
Play '\, \,
3. CHECKTHAT PEDALFREEPLAY AND PUSHROD
PLAYARECORRECT
Padalfreeplay:
P u s h i n o n t h e p e d a l u n t i l t h s b e g i n n i n go f c l u t c h
rosistanc€is felt.
Pedal freeplay:
5 . 0- 1 5 . 0 m m ( 0 . 1 9 7 - 0 . 5 9 1i n . )
Purh rod play:
Push in on th€ psdal with a finger softly until the
r o s i s t a n c o b e g i n s t o i n c r o a s ea l i t t l e .
Purh rod play tt Pedal top:
1 . 0 - 5 . 0 m m ( 0 . 0 3 9 - 0 ' 1 9 7i n . )
4, IF NECESSARY,ADJUST PEDAL FREEPLAYAND
PUSH ROD PLAY
(a) Loosenthe lock nut and turn the push rod until tho
P e d a lH e i g h t
Adjust Point freeplayand push rod play are correct
(b) Tightentho lock nut.
(c) After adjustingthe pedal freeplay,check the pedal
height.
P u s hR o d P l a Y (d) Connectthe air duct and installlhe lower finishpanel.
5. CHECKCLUTCH RELEASEPOINT
(a) Pull the parkingbrakeleverand installwheel stopper.
(b) Start the engineand idle tho ongin€.
(c) Without depressingthe clutch pedal,slowly shift the
P e d a lH e i g h t shift lever into reversepositionuntil th€ goars con-
tact.

cL-8
CLUTCH- CLUTCHPEDAL
(d) Graduallydepressthe clutch pedal and measurethe
stroko distanc€from the point th6 gear noise stops
(releasepoint)up to the full stroke end position.
2 5 m m ( 0 . 9 8i n . )o r m o r e Standsrddistanco:
Releose 25 mm (0.98in.)or more
Point
lf the distancenot as specified,performthe following
operatron.
1*l F u l lS t r o k e o Checkpedalheight.
E n dP o s i t i o r Checkpush rod play and p6dalfreeplay.
. Bl€edth€ clutch line.
r Checkthe clutch cover and disc.

cL-9
CLUTCH- CLUTCHMASTERCYLINDER
C L U T C HM A S T E RC Y L I N D E R
COMPONENTS
LHD
/_e-\
|
\7
- )-- Frller LaP
Clip ilidu:'..
II
-q Or
Slotted N-Reservoirrank ^ôl v
U#
I
Sp r i ng
I
-^-\Md??@T
Clevis
Pin Pin
Clevis
Nut
ffi#iMf,il,"1^-*lr!:"'ff'. S pr i ng
'F
f 15ns5l1l
RHD
ag-)- Firrercap
Q-,tou, CliP
S l o t t e dS P r i n g
Reservoir
Tank
Boot
I
Pin
M a s t e rC y l i n d e r
Bo d y a Grommet
"].,J",,
,n*ffi Qr\
I
Clevi
Pin
-ockNut
S n a pR i n g
Washer
P u s hR o d
1 5 ( 1 5 5 ,1 1
OO50'15
N . m ( k q f. c m , f t . l b f ) : S p e c i f i e dt o r q u e o05308
I N o n - r e u s a bpl ea r t

cL-10 CLUTCH- CLUTCHMASTERCYLINDER
REMOVAL
MASTERCYL]NDER
1 . D R A WO U TF L U I DW I T HS Y R I N G E
2, DISCONNEC CTL U T C HL I N E
UsingSST,disconnect the clutchline.Usea container
to catchthe brakefluid.
s s T0 9 0 2 3 - 0 0 1 0 0
3. REMOVECLIPAND CLEVISPIN
4 . R E M O V E2 M O U N T I N GN U T S A N D P U L L O U T
MASTERCYLINDER
M A S T E RC Y L ] N D E D
RI S A S S E M B L Y
1. REMOVE CLEVIS
2. REMOVERESERVOIR TANK
(a) Usinga pinpunchanda hammer,
driveout the slotted
spflng prn.
( b ) R e m o v e t h e r e s e r v o i rt a n k a n d g r o m m e t .

cL-11
C L U T C H_ C L U T C HM A S T E RC Y L I N D E R
3. REMOVEPUSH ROD
Pull back the boot,and usingsnap ring pliers,remove
tho snap ring.
4. REMOVEPISTON
CL
o05039
o05587
M A S T E RC Y L I N D E IRN S P E C T I O N
Dartswith compressed
HINT:Cleanthe disassambled
a ir.
'1. INSPECTMASTERCYLINDERBOREFOR SCORING
o Rc o R R o s l o N
lf a problemis found,cleanor replacathe cylinder.
2. INSPECT PISTON ANDCUPSFORWEAR,SCORING,
CRACKSOR SWELLING
lf sitheronerequiresreplacsmsnt,usethe partsfrom
th€ cylindorkit.
3. INSPECT PUSHRODFORWEAROR DAMAGE
lf necessary,replacethe pushrod.
M A S T E RC Y L I N D E A
RS S E M B L Y
1. COATPARTSWITHLITHIUMSOAPBASEGLYCOL
GREASE, AS SHOWN
2. INSERTPISTONINTOCYLINDER
3. INSTALLPUSHROD ASSEMBLYWITH WASHER
A N DS N A PR I N G

cL-12 CLUTCH_ CLUTCHMASTERCYLINDER
4, INSTALLRESERVOIR TANK
LHD
tankand a now grommet.
(a) lnstallthe reservoir
(b) Usinga pin punchand hammer,drivein ths slottod
springpin.
Protrusion
1 . 5- 3 . 5m m 5. II{STALLCLEVIS
{ 0 . 0 5 -9 0 , 1 3 8i n . )
RHD
Protrusion
1 . 5- 3 . 5m m
( 0 . 0 5 -9 0 . 1 3 8i n . )
o05040
o05588
INSTALLATION
MASTERCYLINDER
1. INSTALLMASTERCYLINDER
Installth€ 2 mountingnuts,andtorqusthem.
T o r q u e : 12 I { . m ( 1 2 0 k s f . c m , I f t . l b f)
2, COI{I{ECT CLUTCHLINE
UsingSST,connectthe cluchline.
ssT 09023- 00100
T o r q u e :1 5 I { . m ( 1 5 5 k g f . c m , 1 1 f t . l b f )
3, CONNECT PUSHRODAND INSTALLPIN
Installths clipin the pushrod pin.
4, BLEEDCLUTCHSYSTEM
(SeepageCL-6)
5. ADJUSTCLUTCHPEDAL
(SeepageCL-7)

cL-13
CLUTCH_ CLUTCH CYLINOER
RELEASE
CYL IN DER
C LUTC HRELE ASE
COMPONENTS
3S-GEEngino
1 5 ( 1 5 5 ,1 1 )
Cylinder
Ralease
Body
Spring
tH
6 ,)'-q/,'
l,,.,on
d5v@,;_ I P u s hR o d
Boot
'BlsedorPluo
'r==-,:----;;;t
| 8.3 185,1il In..lbf)|
\((
\\/
,/1)
\
I
@
tN.m (rjJ-rmJt l6iil : Specified

torque

cL-14
CLUTCH_ CLUTCHRELEASE
CYLINDER
7A-FEEngine
33:FFElSlllcrutch Brsckst
Lin€
al
1 5 t 1 5 5 ,1 1 1
B l e e d ePr l u g
R e l e a s eC y l i n d e r
toi'^n
_\h pisron
^ h
v%@h"'l*'o'j'
l l r l
JJ' t {\\\-/,/
/ i |
Zn^ I
|
I
-:i-{
...\-._*ql
_.. _SmA
-)' -----_ \(((9
>
@s
,'1
1 5 { 1 5 5 ,1 1 1
C l u t c hL i n eB r a c k e t
N ' m { k g f. c m , f t . l b t} : S p e ci fi e d t o r q u e

cL-15
CLUTCH- CLUTCHRELEASE
CYLINDER
RELEASE REMOVAL
CYLINDER
1. REMOVE 2 B O L T SA N DH E A TI N S U L A T O R
(3S-GE)
2, REMOVEBOLTAND LINECLAMP
3. DISCONNECTCLUTCH LINE
UsingSST,disconnsctthe clutchline.Use a container
to catch the brakefluid
ssr09023-00100
4, REMOVERELEASE CYLINDER
Removethe 2 boltsand pullout r€l€ase
cylinder.
DISASSEMBLY
CYLINDER
RELEASE
1. REMOVEB L E E D EP
RL U G
2, PULLOUT BOOT WITH PUSHROD

cL-16 CLUTCH- CLUTCH CYLINDER
RELEASE
3. REMOVEPISTON
Usingcompressed air, removethe pistonwith the
springfrom the cylinder.
R E L E A SC INSPECTION
EY L I N D E R
oartswith compr€ssed
HINT:Cleanthe disassembled
air.
1. INSPECT RELEASE CYLINDERBOREFORSCORING
oR coRRosroN
lf a problemis found,cleanor replaceths cylinder.
2. INSPECT PISTON ANDCUPSFORWEAR,SCORING,
CRACKSORSWELLING
lf eitheronerequiresreplacement,useth€ partsfrom
th6 cylinderklt.
3. INSPECT PUSHRODFORWEARORDAMAGE
lf necessary,replacsthe pushrod.
RELEASE ASSEMBLY
CYLINDER
1. COAT PISTON WITH LITHIUM SOAP BASE
GLYCOLGREASE,AS SHOWN
2. INSTALLPISTONWITH SPRING
INTOCYLINDER
3. INSTALLBOOTWITH PUSHRODTO CYLINDER
4. INSTALLBLEEDERPLUG
RELEASE INSTALLATION
CYLINDER
1 . I N S T A L LR E L E A SC
EY L I N D E R
(a) Installrelease cylinderwith 2 bolts.
T o r q u c : I 2 N . m ( 12 0 k g f . c m , I f t . l b f )

cL-17
CLUTCH- CLUTCHRELEASE
CYLINDER
2. C O N N E CC T L U T C HL I N E
UsingSST,conn€ctthe clutchline.
s s T0 9 0 2 3 - 0 0 1 0 0
Torqur: 15 N.m (155 kgf.cm, 11 ft'lbf)
3. INSTALL LINE CLAMP

Installlineclampwith the bolt to the line clampbrack'
et.
Torquc:4.9N,m(50 kgf.cm,t13in..lbf)
4. INSTALLHEATINSULATOR
5. WITH BRAKE FLUID
FILL CLUTCHRESERVOIR
ANO BLEEDCLUTCHSYSTEM
(SeepageCL-O)
6. CHECKFORLEAKS

cL-18 C L U T C H_ C L U T C HU N I T
C L U T C HU N I T
COMPONENTS
Clutch Cover
R e l e a s eF o r kS u p p o r t
Flywheel
ClutchDisc
R e l e a s eF o r k
Boot
tffillsiim;iii-6itl i Specified tofque
C L U T C HU N I TR E M O V A L
1. REMOVE T R A I { S A X LFER O ME N G I N E
( S e ep a s eC 5 2 M X - 1 0 . S 5 4M X - 8 , 9 , E 5 6M X - B )
2. REMOVECLUTCH COVERAND DISC

(a) Placematchmarkson the flywheeland clutch cover.
(b) Looseneach sot bolt one turn at a time until spring
te nsion is released.
(c) Removethe set bolts, and pull off the clutch cover
with the clutch d isc.
NOTICE: Do not dropthe clutchdisc.
Matchmarks

cL-19
C L U T C H_ C L U T C HU N I T
3. REMOVERELEASEBEARINGAND FORK FROM

TRANSAXLE
Removethe releasebsaringtogetherwith the fork
\F them.
andthenseparate
-\
CLUTCHPARTSlNSPECTION
1. INSPECT CLUTCHDISCFORWEAROR OAMAGE
th€ rivotheaddepth.
m6asuro
Usingcalipers,
Minimumrivot dopth:
0.3 mm (0.012in.)
lf necessary,replacethe clutch disc.
2. INSPECT CLUTCHDISCRUNOUT
checkthe discrunout.
Usinga dialindicator,
Marimumrunout:
0.8 mm (0.031in.)
lf necessary,replacethe clutch disc.
3. INSPECT FLYWHEEL RUNOUT

checkthe flywheelrunout.
Usinga dialindicator,
Maximumrunout:
0.1 mm (0.004in.)
lf necessary,replacethe flywheel.
4. INSPECTDIAPHRAGMSPRINGFOR WEAR
Using calipers,measure ths diaphragm spring for
depth and width of wear.
Maximum:
A: Depth
0.6 mm (0.024in.)
B: Width
5.0 mm (0.197 in.)
lf necessary, replacethe clutch covor.

cL-20 CLUTCH_ CLUTCH
UNIT
5. INSPECT RELEASE BEARING
Turnthe bearingby handwhileapplyingforcoin the
axialdirection.
HINT:The baaringis permanently and re-
lubricated
quiresno cleaningor lubrication.
replacethe releasebearing.
lf necessary.
7A-FEEngine C L U T C HU N I TI N S T A L L A T I O N
I
Flyw heeI 1 . I N S T A L LC L U T C HD I S CA N D C L U T C HC O V E RO N
,{ Si d s FLYWHEEL
vf
r)
(a) Insertthe SSTin the clutchdisc,and then set them
i l andth6 clutchcoverin oosition.
'$l S S T0 9 3 0 1- 0 0 1 1 0 ( 7 A - F Ee n g i n e )
0 9 3 0 1- 0 0 2 10 ( 3 S - F E5, 5 - F E ,
I 3 5- G Ee n gi n e )
3S-FE En g i n e
sS-FE Eng i n e
3 5 - G EEn g i n €
$ \
AJFlywhsel
side
iif
.'N(-'l +
()
'*
fi
o0!110
o 0 ! 1 a lc L o l 3 l
(b) Align th6 matchmarkson the clutch cover and fly-

wheel.
(c) Torque th€ bolts on tho clutch cover in the ord€r
shown.
HINT:Temporarilytightenthe No.1 and No.2 bolts.
2. C H E C KD I A P H R A G MS P R I N GT I P A L I G N M E N T
Usinga dial indicatorwith rollerinstrument,checkthe
diaphragm s p r i n gt i p a l i g n m e n t .
Mlxlmum non - !lignment:
0.5 mm (0.020in.)

cL-21
CLUTCH- CLUTCH
UNIT
lf alignment is not as specified, usingSST,adjustthe
d i a p h r a g smp r i n gt i p a l i g n m e n t .
ssT 09333- 00013
3. APPLY MOLYEDENUMDISULPHIDELITHIUM
BASEGREASE (NLGINO.2)TO FOLLOWING PARTS
r point
fork and hub contact
Release
. fork and pushrod contactpoint
Release
. fork pivotpoint
Releas€
o Clutchdisc spline
4, INSTALLRELEASE EEARING AND FORKTO TRA.

NSAXLE
Installths bearingto the rsleasefork,andthen install
th6mto tho transaxle.
5. INSTALLTRANSAXLE TO ENGINE
( S e ep a s eC 5 2M X - 1 0 ,S 5 4M X - 8 9 , E 5 6M X - g )

cL-22 CLUTCH_ SERVICE
SPECIFICATIONS
SPECIFICATIONS
SERVICE
DATA
SERVICE
Pedalheightlrom asphaltshoot LHD 144.9- 154.9mm {5.705-6.098in.)
Pedalheightfrom asphaltsh6€t LHD 1 4 1 . 0 -1 5 1 . 0m m{ 5 . 5 5 1 - 5 . 9 4i n5. )
Push rod play at p€daltop 1 . 0 - 5 . 0m m ( 0 . 0 3 9 - 0 . 1 9 i7n . )
Pedal f106play 5 . 0 - 1 5 . 0m m ( 0 . 1 9 -70 . 5 9 1 i n . )
ii:: C utch 16sas6 point from pedaliull stroke end position 25 mm (0.98 in.)or mor6
Disc rivet head d6pth Minimum 0 . 3m m ( 0 . 0 1 2i n . )
D i s cr u n o u t Maximum 0.8 mm (0.031in.)
Diaphragmspringtip non-alignmont Maximum 0.5 mm (0.020in.)
Diaphragmspringfinger woar Maximum dopth 0.6 mm (0.024in.)
Oisphragmspringfinggr w6ar Marimum width 5 . 0m m ( 0 . 1 9 7i n . )
Flylvheelrunout Maximum 0.1 mm (0.004in.)
TOROUE
SPECIFICATIONS
Part tightoned N m kgf cm ft lbl
C utch lino l5 155 1 l
Master cy ind6r Installation nut 12 120

B o o d 6 rp l u g 8.3 74 i^.lbf
Releasocylind€rinstallationbolt 120
Clutchtube clamp 4.9 50 4 3 i n .l b l
C utch cover x Flywheel 19 195 14
R6l€as€fork suoport 7A FE ongina 375

55-FE engine 400
35-FE €n9ino 39 400
33-GE €ngino 400
3 S - G E e n g i n e( L S D ) 47 480

MX-1
C52 MANUAL TRANSAXLE
DESCRIPTION MX- 2
OPERATION MX_ 3
PREPARATION MX_ 4
MX_ 8
TROUBLESHOOTING
PRECAUTION..".. MX_ 9 frffix
ASSEMBLY R E M O V A A
L N D
INSTALLATION MX_10
C O M P O N E NPTA R T SR E M O V A L . . . . . . . . . . . .
MX_ 23
I N P U TS H A F T MX* 38
OUTPUS T HAFT . . . . . " . . MX- 44
S H I F TA N OS E L E C T L E V E RS H A F T . . . . . . . . .MX_51
D T F F E R E N TC I AALS E . ' . . ' . . . " " " MX_56
C O M P O N E NPTA R T SI N S T A L L A T I O N . . " . . l'4X- 64
A
S H I F TL E V E R N D C O N T R O CL A B L E . . . " ' MX- 73
S E R V I CS
EP E C I F I C A T I O N S MX- 74

MX-2 _ DESCRIPTION
C 5 2 M A N U A LT R A N S A X L E
DESCRIPTION
GENERAL
. Transaxlstype C52 usesconstantmeshsynchronizars for forwardgears,and a slidingm6sh
reverse9ear.
. The input shaft is composedof the l st and 2nd spesdgsarsand the revsrs€drivegear,and
the output shaft is composedof the drive gear (for use with ring gear).
Typo ol Transaxle c52

Type of Engin6 7A_FE
Gear R6tio 1st Gear 3.166
2ndG€ar 1.904
3rdG6ar 1,310
4th Gear 0.969
sth Gsaf 0,815
RovorsoGo6r 3.250
Diff6r6ntialG6ar Ratio 4.058
Oi Capacity 2 . 8 l i t e r s( 2 . 7 U S q t s , 2 . 3 l m p .q t s )
Oil Viscosity sAE 75W- 90
A P I G L- 4 o r G L - 5

MX-3
C52 MANUALTRANSAXLE- OPERATION
OPERATION
r T h e i l l u s t r a t i o n sb e l o w s h o w t h s e n g a g e m e n t so f t h e t r a n s a x l eg e a r s '
1 s tD r i v eG € a r 2 n d D r i v eG e a r
Differe ntial Differential

D r i v eG e a r D r i v eG e a r
1st
J r o u r v eb e a r
Dilferential Di f f e r e n t i a l
Di f f e r e n t i a l Differential
Assembly Assembly
4rh
o-l R e v e r sDe r i v eG e a r
-
S t h D r i v e nG e a r - - . -r A --
fleverseUr!ve \rea
^-.,.-\
r*v"1
u
| ! Reverse
\ - / l d l e rc e a r
Di f f e r e n t i a l Y i
Assembly
5rh

MX-4
C52 MANUALTRANSAXLE_ PREPARATION
PREPARATION
SST(SPECIAL
SERVICE
TOOLS)
09250-10011Replecorset'A'
(09253-10010)connecting Romovor
RodBushing & sth driv6ng6ar
e Roplacor
09308-00010 oil S€alPull€r Output sheft Ironl b6ering
09309-12020 sth DrivenGearRopl.cer
09310-35010 countorshsftBoaring
Rophcer Outputshalt front bearing
09316-60010 Transmission
& Transfer
Boaring
P8* Replacer
Ee
(09316-00020)R6plac6r'A'
ro)
v
09350-32014 ToYoTA AutomaticTransmission Diflorontialsid6oals6al
ffi Tool Sot
(09351-321 I 1) S,doEearinsRsc€R€plac€r
-32r30)
(093s1
-32150) oil soll Roplacsr

(09351
/Ar
a r q O 09550-10012 Ropl.cor
s6t'B' Diff.rentialsid€bearing
@ 3.;"t'
(09252-10010) No. I ReplecerH.ndle
{tf

MX-5
C52 MANUAL TRANSAXLE- PREPARATION
(09556-lOOlO) DiflorontialDrivoPinionFront
EoaringRomov€r
@
(09560-10010) Knuckl€outer BoaringRoplacor
I
09564-32011 Difforenti.lProldd Adaptor
09608-12010 FrontHub & DrivoPinion866ring Inputshaft front boaring

r=-5- - {D ,r
)t-q=J . tr^ ReplacorSot Inputshatt front oil soal
d-;= {;, g L?
(09608-00020)Romover
& R€placor
Hsnd16
(09608-00030)
(09608-00080)
R6plecer
I
(_)
09608-20012 Front Hub & DrivsPinionBearing Inputshatt r6arbea ng

Tool Set 0illerontialsid€ be6ringout€r
(09608-03020)
(09608-03060)Roplacer
(09608-03070)Reptacer
(09608-03090)Replacer
Pullor
worm Boaring
09612-65014 St€orin€ Inputshaft front b6aring
sideb€aringout6r
Diff6r6ntial
@"b 09628-62011 BallJointPullsr

raco
sth driv6nOear

MX-6
C52 MANUALTRANSAXLE_ PREPARATION
09636-20010 Upp.rBrllJointDu.tcovor No.3 hub 5l6ev6rsaombly
Raohcrr
09950-00020 BrlrinsRomovor
0S950-00030 BolringR.movorAttlchmont Dittorenti.lsid6 boaring
09950-30010 PullorA sol N o . 3 c l u t c hh u b

@-s+44\
@8gepisft4
-03010) l,pporPlato
(0S951
(09954-03010)
Arm

- PREIAEATIoN MX-7
c52 MANUALTRANSAXLE
OOLS
pfoload
Difforontlal
0 9 0 2 5 - 0 0 0 1 0s m a l l T o r q u e w r s n c h
0 9 0 3 1 - 0 0 0 3 0 P i nP u n c h
09905-00012 snrp RinsNo l Expsndor
EOUIPMENT
Dial indicatorwith magneticbasg
F o e l e rg a u g e
N,4icrometer
Torque wrench
LUBRICANT
It6m Cap6city Classification
M a n u a lt r a n s a x l o i l GL-4 or GL-5
2.8 litor6(2.7 US qts, 2,3 lmP qts)
(w/Ditf€rentialoil) s A E7 5 W - 9 0
ssM (sPEclALSERVICE
MATERIALS)
08826-00090 So.lPeckins1281, Trsnsmissioncasgx
EO N 0l 2 8 l o r e q u r v a l e n t
T H R EB Tfansarl€casg
(FIPG) Transmissioncasox
Casecov6r
08833-00080 Adh€sive 1s44, Trsnsmssioncasocov6f bolt

T H R EB 1344,
EO N O Strsightscrowplug
LOCTITE 242or equiv6lent Contfolshatt coverbolt

MX-8 _ TROUBLESHOOTING
C 5 2 M A N U A LT R A N S A X L E
TROUBLESHOOTING
Use the table below to helovou find the causeof tho probl€m.Thenumbers indicatethe priiffit?
. h e c ke a c hpart jn order.lf necessary,
o f t h e l i k e l yc a u s eo f t h e p r o b l s mC roplace theseparts.
(t
i
See Page X ; X i X X X X x:- x - -
>g
I
!
Parts E E
E o E o
Name ? E E
.9 o -o 9 R
; c o
E n
6 o 3 _o o 3
: o) 3
3 5 E
Trouble c €
o o o
o
Q @ ;5 lt)
l:'"___ I 1 2 3 3
Oilleakage I 1 2 2 3
H a r dt o s h i f t o r w i l l n o t s h i f t 1 2 3
J u m p so u t o l g e a r 1 2 3 3

MX.9
C52 MANUALTRANSAXLE_ PRECAUTION
PRECAUTION
W h e n w o r k i n gw i t h F I P Gm a t e r i a ly. o u m u s f o b s e r v et h e f o l l o w i n g .
o Usinga razorbladaandgaskatscraper, removeall the old FIPGmaterialfromths gasketsurfaces.
o T h o r o u g h l yc l e a n a l l c o m p o n o n t st o r a m o v ea l l t h e l o o s em a t e r i a l '
. C l e a n b o t h s e a l i n gs u r f a c e sw i t h a n o n - r e s i d u o s o l v o n t .
o A p p l y t h e s e a l p s c k i n g i n a n a p p r o x , 1 m m ( 0 . 0 4 i n . )w i d a b e a d a l o n g t h o s o a l i n gs u r f a c o .
. p a r t m u s t b s a s s e m b l o dw i t h i n 1 0 m i n u t e so f a p p l i c a t i o n O . t h e ? w i s at,h e F I P G m a t e r i s lm u s t b e
r e m o v e da n d r e ap p l i e d .

Mx-10 - ASSEMBLy
cs2 MANUALTRANsAXLE REM.'AL ANDTNSTALLATT.N
A S S E M B L YR E M O V A LA N D
INSTALLATION
Back'upLishtswit;i:"ttt|'"""""'
RHDriveshaft
.l*i*: s&;
wire
Ensine
lr,uuu,'
S*t",.!,iigro,,
-\*
"i'l'i Nmr
d*&S{1,'
il ,[.$:,.'"'
Rr]
,R -
.""*"-r-cvrino".---)A*\'^î
"nl-L'nue,""i"i'
% -T'
\; .;':
Z'QRI ,rr.-,* ;
'#=-wi-W.R.
f=*r-@,*ffi: ^";;#;ft
#
F?t?ro.s1 -------J
e?ffi;ffi :\b\f,[$|+l -..\-.
'6.^
E.sire RearMoJnlrnsInsdlator
-
-=--@
^\ \l \" 1 Lc^^:^^RearMou'lt .ls Bracket
| "-"*-, /A \:-l $95-Ensine
Ens;;T;;i-Mo, Ing ---------------rY,z
miry-----Y/'^
Englne l-ront M o u nt
''-,r<
.6 rransaxte
lransaxle
- "%_
Bracket (h \ uo,u*ol
Mount'sffi
t,J,,,,,X;[",i,'""t 'rotector--\PT
Transaxlecasee'otutto']@
l3ftora (\.
centercrossmemb"' 1l---? *
4
,4/fl t s4{650..t
80 (820,59)
S-Grommet .:
20 l2OO,111
q,- a Cotter Pin
E x ha u s tF r o n tP i P e L o c kN u t
,f so,sroit.-.l
O x y g e nS e n s or M?.Trufffi
) Gasket-------@
br,,.{", trjt-loo,r5rtl
\\ E x h a u s tF r o n tP i p e
d R H En gi n e U n d e rC o v e r
a Gasket
?
f stg3q 40I
1sf
t ,5{r5o,
L H En gi n e U n d e r C o v e r
N m ( k g fc m , f t t b f ) : S p s c i f i e dt o r q u e
a N o n - . e u s a b lp €8 n

- ASSEMBLY MX-11
C 5 2 M A N U A LT R A N S A X L E ANDINSTALLATION
REMOVAL
T R A N S A X LR
EEMOVAL
( - } T E R M I N A LC A B L E
1 . D I S C O N N E CNTE G A T I V E
FROMBATTERY
C A U T I O N :W o r k m u s t b e s t a r t o d a f t o r 9 0 s e c o n d r f r o m
'LOCK'
the time tha ignition switch is turned to tho
p o s i t i o na n d t h e n e g a t i v e( - ) t e r m i n a l c a b l e i r d i s c o n -
nacted from thg battery.
2. R E M O V EA I R C L E A N E R WITH
C A S EA S S E M B L Y
A I RH O S E
(a) Disconnect ths intakearrtemp.ssnsorconnEctor.
ry/
vl
(b) Loosen the bolt and disconectthe air cleanerhosg

f rom the throttle bodv.
( c ) D i s c o n n e ct th o 4 a i r c l e a n e cr a p c l i p s .
( d ) R s m o v et h 6 a i r c l e a n e cr a p a n d e l e m e n t .
(e) Removethe 3 bolts and air cleansrcase.
3. REMOVECLUTCHRELEASE CYLINDER
LINEBRA-
C K E TA N DR E L E A SC
EY L I N D E R
(a) Removetho bolt and clutchreleasecylinderlinEbra-
cket.

Mx'l2
c b 2 M A N U A LT R A N S A * L E- A S S E M B L yR E M ' ' A L A N D T N S T A L L A T T . N
(b) Removeth6 2 bolts and clutch releasecylinder.
4. BTA C K - U PL I G H T S W I T CCHO N N E C -
DISCONNEC
TOR
5. REMOVEGROUNDCABLE
Removeths boltandgroundcablefromth6 transaxle.
6. R E M O V EE N G I N EW I R E SC L A M P
R e m o v et h e b o l t a n d e n g i n ew i r e s c l a m p f r o m t h e
transaxls.
7, T O N T R O LC A B L E S
D I S C O N N E CC
(a) Removethe 2 clips and washers.
(b) Removeth6 2 clipsfrom the cables.
(c) Disconnectthe 2 controlcablssfrom the controllever
housingsupportb racket.

- ASSEMBLY
c52 MANUALTRANSAXLE REMOVM
8. SENSOC
STP E E D
DISCONNEC RONNECTOR
9. REMOVESTARTER'S SETBOLT
thestarter's
Remove upper
set boltfromthe transaxle
slds.
U P P E RS I D E M O U N T I N G
1 0 . R E M O V ET R A N S A X L E
BOLTS
Removethe 3 transaxle mountingbolts.
FIXTURE
SUPPORT
11. INSTALLENGINE
12. REMOVE F R O N TW H E E L S
13. RAISE HICLE
V E
N O T I C E :B e s u r e t h o v e h i c l ei s s e c u r e l ys u p p o r t e d .
14. REMOVE UNDER COVERS
1 5 . D R A I NT R A N S A X LO
EI L
16. REMOVE L E F TA N DR I G H TD R I V ES H A F T S
(SeepageSA- 76)

MX'14
cs2 MANUALTRANsAxLE- ASSEMBLy
REMovALANDTNSTALLATToN
17. REMOVEEXHAUSTFRONTPIPE,SUPPORT BRA-
C K E TA N DO X Y G E N
SENSOR
(a) Removetho 2 boltsfrom the oxhaustfront pipesup-
port brack€t.
(b) Removelhe 2 nuts,oxygensensorand gasket.
(c) Removethe 3 nuts and 2 gasketsfrom tha sxhaust

manifold.
1l
Ji
6,
(d) Removethe 2 bolts and nuts.

(e) Removethe gasketand oxhaustfront pipe.
(f) Removethe 2 bolts from the suspensionmember.

(S) Removeth6 nut from the enginerearmountinginsula-
tor.
(h) Removethe front pips support bracket.
@4848

MX.l5
C52 MANUAL TRANSAXLE_ ASSEMBLYREMOVALAND INSTALLATION
18. REMOVESTARTER
(a) Disconnectths connsctorand wire from the starter
(b) Removeth€ starter'sset bolt from the lower side.
(c) Removethe starter.
,/ 19. REMOVECENTERCROSSMEMBER
(a) Rsmovethe 2 grommets.
(b) Removethe enginerear mountinginsulator'sset bolt
and 2 n uts.
(c) Removeth€ grommet.

(d) Removethe enginefront mounting insulator's2 set
bolts.
(a) Removethe 2 bolts and center crossmember.
20. REMOVEENGINE REARMOUNTING BRACKET AND

INSULATOR
Removethe3 bolts,enginerearmountingbracketand
insulator.
2 1 . R E M O V E E N G I N EF R O N T M O U N T I N G B R A C K E T
AND INSULATOR
(a) Removetho bolt,nut and enginefront mountinginsu-
lator.
(b) Removstho 2 bolts and enginefront mountingbrack-

MX-16
cs2 MANUAL TRANsAXLE- ASSEMBLyREMovAL AND TNSTALLATT.N
22. DISCONNECTENGINELEFT MOUNTINGBRACKET

F R O ME N G I N EL E F TM O U N T I N GI N S U L A T O R
(a) Raisethe transaxleand engineleft side slightlywith a
-'t-+_
.---)
E ) \: lack.
Y I (b) Removg the engine left mounting bracket and
/1 1_\ J_
---,'/ P:-.-.----- t - ) insulator's3 set bolts.
--< i -n
-_ |,/.i4a
"', :: (,t/
23. JACK UP TRANSAXLESLIGHTLY

jack, supportthe transaxle.
Usinga transmission
24. REMOVETRANSAXLEMOUNTINGBOLTS
ENGINER E A RE N DP L A T ES I D E
tq\
@\\
Removethe 4 transaxle mountingbolts.
jrl ^,
a@ ,l
7 <
\\\
25. REMOVETRANSAXLECASE PROTECTOR

Removethe 2 bolts and transaxlecas6 orotector.
26. REMOVE TRANSAXLE

Lowerthe engineleft sideand removethe transaxls
f rom the 6ngine.

C52 MANUALTRANSAXLE- ASSE
INSTALLATION
TRANSAXLE
1. INSTALL TRANSAXLE
(a) Raisethe engineright stde.
(b) Alisn the input shaft splinewith tho clutch disc and
w/ Ground Cable installth6 transaxleto the engine.
(c) Torquethe 3 transaxlemountingboltsfrom the upper
side.
Torque:64 N'm (650kgf'cm'47 ft lbf)
2. TNSTALLTRANSAXLECASE PROTECTOR
Installand torqueths transaxlecase protector's2 set
bolts.
'-=-1.,-" Torque:13 N m (130 kgf'cm.9 ft'lbf)
l\ I )
s=--/4.
3. TNSTALLAND TOROUETRANSAXLEMOUNTING
R E A RE N DP L A T ES I D E
B O L T ST O E N G I N E
Installandtorquotho 4 transaxle mountingbolts.
Torque:
Bolt A 23 N m (230 kgf cm, 17 ft'lbf)
Bolt B 46 N.m (470 kgf 'cm' 34 ft lbf)
4. C O N N E C TE N G I N EL E F TM O U N T I N GB R A C K E TT O
E N G I N EL E F TM O U N T I N GI N S U L A T O R
(a) Raisethe transaxl€and engineleft side slightlywith a
-'t--€--- L- jack.
--_ ]) 6 ) )
- { t (b) Installand torque tha sngine lsft mounting bracket
/. -- J:
__/ !.J--..__-I "-) and insulator's3 set bolts.
_-.._ |t---{:
,/'l^l
Torque:64 N m (650 kgf'cm, 47 ft lbf)
i / ^tv=r
==; t//E
5. I N S T A L LE N G I N EF R O N TM O U N T I N GB R A C K E T
A N DI N S U L A T O R
(a) Installthe enginefront mountingbracketand torque
the 2 bolts.
Torque:77 N.m(790kgf cm, 57 ft'lbf)
( b ) I n s t a l tl h e e n g i n ef r o n t m o u n t i n gi n s u l a t oar n d t o r q u e
the bolt and nut.
Torque:87 N m (890kgf cm, 64 ft lbt)

MX-l8 - A s s E M B L yR E M . ' A L A N D T N S T A L L A T T ' N
c 5 2 M A N U A LT R A N S A X L E
6. I N S T A L LE N G I N R E E A RM O U N T I N B GR A C K EATN D
INSULATOR
I n s t a lal n d t o r q u st h e e n g i n er e a rm o u n t i n g
bracket
and insulator's 3 set bolts.
Torque:
Bolt A 87 N.m (890 ksf.cm,64 ft.lbf)
Bolt B 77 N.m (790 kgf.cm,57 ft.lbf)
7 . I N S T A L LC E N T E RC R O S S M E M B E R
(a) Installthe center crossmember.
(b) Installand torque tho 2 bolts.
T o r q u e : 3 5N . m( 3 6 0k g f . c m , 2 6f t . l b f )
(c) Install and torque the engine front mounting
insu iator's2 set bolts.
Torque:80 N.m(820kgf.cm,59ft.lbf)
(d) Install the grommet.
( e ) I n s t a l al n dt o r q u st h s e n g i n er e a rm o u n t i n gi n s u l a t o r ' s
s e t b o l ta n d 2 n u t s .
(f) Installtho 2 grommets.
8. INSTALL STARTER
(a) Installths starter.
(b) Installand torque the startor'ss6t bolt to the lower
Wf/
/z$-
sloe.
Torque:39N.m(400kgf.cm,29tt.lbf)
(c) Connecttha connectorand wira to the starter.
9. INSTALL EXHAUST FRONT PIPE,SUPPORTBRA.

C K E TA N O O X Y G E NS E N S O R
(a) Installthe exhaustfront pipe support bracket.
( b ) I n s t a l al n d t o r q u et h e n u t t o t h e e n g i n e1 6 a rm o u n t i n g
rnsulator.
(c) Install and torque the 2 bolts to the suspension
msmosr.
014848
Torque:19 N.m(195kgf.cm,14 ft lbf)

C52 MANUALTRANSAXLE- ASSEMBLYREMOVALAND INSTALLAT
(d) Installthe exhaustfront pipe.
(e) Installand torque the 2 bolts and 2 new nuts with a
n6w gasket.
Torque:42 ltrl'm(430 kgf cm, 3l ft'lbf)
(f) Installand torque 3 new nuts with 2 new gaskststo

the exhaustmonifold.
Torqua:62 N m (630 kgf cm, 46 ft'lbf)
I
Fi
(s) Installthe oxygonsensorwith a now gasket'
(h) lnstalland torquoth€ 2 nuts.
Torque:20 N.m(200kg{ cm, 14 tt'lbf)
(i) Installand torquethe 2 boltsto ths exhaustfront pipe

suDDortbracket.
Torque:25 N.m(250kgt'cm't 8 tt lbt)
10. INSTALL LEFT AND RIGHTDRIVESHAFTS

(Seepage SA - 82)
1 1 , F I L L T R A N S A X L EW I T H G E A RO I L
Oilg rade:
A P IG L - 4 o r G L - 5
Viscosity:
s A E7 5 W - 9 0
Cap8city:
2.6 litors (2.7 US qts' 2.3 lmp. qts)

MX-20
c52 MANUALTRANSAxLE- ASSEMBLyREM''AL AND TNSTALLATT.N
1 2 . I N S T A L LU N D E RC O V E R S
13. INSTALLFRONTWHEELSAND LOWERVEHICLE
14. REMOVEENGINE SUPPORT FIXTURE
MX
15. INSTALLAND TOROUESTARTER'SSET BOLT
lnstalland torouBthe starter'sset bolt to the transaxle
upperside.
Torque:39N.m(400kgf.cm,29ft.lbf)
1 6 . C O N N E C TS P E E DS E N S O RC O N N E C T O R
1 7 . C O N N E C TC O N T R O LC A B L E S
(a) Connect the 2 control cables to the control lover
housing.
(b) Installthe 2 clipsto the cables.
(c) Installthe 2 clips and washsrs.
1 8 , I N S T A L LE N G I N W
E I R E SC L A M P
Installandtorqu6tha enginewiresclamp'sset boltto
tho transaxls.

c52 MANUALTRANSAXLE- ASSEMBLYREMOVALAND INST4!!4r!9r\1---MX-21
CABLE
1 9 . I N S T A L LG R O U N D
Install and torqus the groundcable'sset bolt to the
transaxle.
2 0 . C O N N E C TB A C K - U P L I G H T S W I T C H C O N N E C .
TOR
EY L I N D E A
2 , I. I N S T A L LC L U T C HR E L E A SC RN D L I N E
BRACKET
(a) Placethe clutch relsasecylinderand torquethe 2
b ol t s .
T o r q u e :1 2 N . m ( l 2 0 k g t c m , I f t ' l b f )
( b ) I n s t a l la n d t o r q u o t h s c l u t c h r e l e a s ec y l i n d e rl i n e
bracket'sset bolt to the transaxle.
22. INSTALLAIR CLEANERCASE ASSEMBLYWITH

A I RH O S E
(a) Installandtorquethe air clsanercase's3 set bolts.

Mx-22 - ASSEMBL'REMovALANDtNsrALLATtoN
c52 MANUALTRANsAXLE
(b) Installthe air cleanerelem€ntand cap.
(c) Connectthe 4 air cleanercap clips.
(d) Torque th€ bolt and connect the air cleansrhose to
ths throttls body.
(e) Conn6ctthe intakoair t€mp. sensorconnector.
23. CONNECT NEGATIVE ( - ) T E R M I N A LC A B L ET O

BATTERY
24, INSPECT FRONTWHEELALIGNMENT
(SeepageSA-7)
25. PERFORM ROADTEST
Chackfor abnormalnoisesandsmoothshifting.

- COVPOruTNT
MX-23
C52 MANUALTRANSAXLE PARTW
C O M P O N E NPTA R T SR E M O V A L
COMPONENTS
C l u t c hR e l e a sBee ar i n g
l C l u t c nR e l e a sFeo r kA s s o m b l y
c r u t . nR e l e a sFeo r kB o o t
I
I l c l u t c hR e l e a sFeo r kS u P P o r t
I I lr;aa4
i T
@\.9 I "-Fr'1s8'
€--- so"ed Ssnsor
oV
g-- speedsensorDrivenGear
o O i lS e a l H
B ^ft?11- controlLeverHousing
Fnnto-l c/ qb (u "$J suonortBracket
l-%R>
\tS,-a\ "/
v
I
I 1 l 1 1 1 5 , 8|)
l- r9 l aa s eR e c e i v e r
TransaxC
I
F r o n tB e a r i n gR e t a a
t------..-
t-'-..-- I S i d eB e a r i n g
a Differentia
uuter Face
Case
Transaxle
fr4agnet------\ PlateWasher
a O i lS e a l J vrA
a Input ShaftFront Bearing---------\9r' D i f f e r e n t i aCl a s eA s s e m b l Y
outputShaftcou",-----:@ ffu
i) output shaft FrontBearing-----------{(9
BearingLockprate
cb=-Fn1'-a
Q01575
N m ( k q fc m , f t l b i ) : S p e c i t i e dt o r qu €
a N on - r e u s a b l P e art

MX-24
C52 MANUALTRANSAXLE- COMPONENT
PARTSREMOVAL
N o . 1S h i f t
ReverseS h i f t F o r k
* Screw Plug
S n a pR i n g
fl-spring Seat
t r ? { 1 ? r r el
ReverseShift Arm Bracket

trl Ball
N o . 1S h i f t F o r kS h a t t
E-Ring - - -----fi
R e v e r s eS h i f tA r m S ho e
o.3 Shift Fork Shaft
N o . 3S h i f t F o r k
S h i f tH e a d
S n a pR i n g
Output Shaft AssemblY N o . 2S h i f t

N o . 2S h i f tF o r k
S n a pRing
5th D r i v e nG e ar
Lock Nut
ln put Shaft
S n a pR i n g
R e a rB e ar i n g R e t a i n e r
Spacer
5th G e a r
N e e d l eR o l l e rB e a r i n g N o . 3H u b S l e e v e
S y n c h r o n i z eRr i n g
K e yS p r i n g
6r-- snap Hrng
N o . 3C l u t c hH u b
N m {kgf cm, ft lbi) : Specifiedtorque

a N o n - r e u s a bpl e
art
* Precoated part

- COMPONENT MX-25
C52 MANUALTRANSAXLE PARr! BEt"l9v4!
Back-Up Light Switch
F,;$a
-T**
R e v e r s eR e s t r i cP
t in Pipe
o,, Receiver
S l o t t e dS p r i n gP i n
* S c r e wP l u g
L 1 3{ 1 3 0 , 9 )l JI $-*
* L o c kB a l lA s s e m b l y
f:g{4oqrra
ScrewPlug
181 l
25 1250,
FEoo,za I
i'-------€
fut 14al
ro{roo,
Shift and Select
Lever Shaft Assembly
a Ou t e rR a c e
P l a t eW a s h e r-
i dE5orsrl
?--
t*.:g'rf&NW
N o . 1o i l
u
/\
Jrc Selecting
Bellcrank
Assembly
Receiver PiPe-----' u 5eal

FilleP
r lug
I
@sail-- -s Transmission
CaseCover
'!i--4,
(\-
Case
Transmission
N m (kqt cm, ft lbf) : S p e c i f i e dt o r q u e

a N o n - r e u s a b l pe ar t
* Precoatedpart

Mx-26
cs2 MANUALTRAN'A'LE - coMpoNENTpARTsREM.'AL
B A S I CS U B A S S E M B LSYE P A R A T I O N
1. REMOVEC L U T C HR E L E A SFEO R KA N D B E A R I N G
2. REMOVESPEEDSENSOR
3. REMOVEB A C K _ U PL I G H TS W I T C H
4, REMOVESELECTING BELLCRANK ASSEMBLY
5. R E M O V E C O N T R O LL E V E R H O U S I N GS U P P O R T
BRACKET
Rgmoveth6 3 boltsand controlleverhousingsupport
brac ket.
6. F R O N TB E A R I N R
REMOVE GE T A I N E R
Using a lorx wrsnch. remove the 3 torx screws and
front bearingrstainsr.
(TorxwrenchT30 09042- 00010)
7. REMOVETRANSMISSION
CASECOVER
(a) Remove the I bolts.
\-n i
(b) Carefullytap lhe projectionof the transmissioncase

cover with a brass bar and hammer to remove the
transmissioncase cover from the transmissioncase,
and removethe transmissioncase cover.

c 5 2 M A N U A LT R A N S A X L-E C O M P O N E P
NATRTS
d
8. REMOVESHIFTAND SELECTLEVERSHAFTAS.
SEMBLY
(a) Removethe lockbolt.
(b) Rsmovethe 4 bolts and pull out the shift and solect
,/'
,{&V.
levershaft assemblv.
, ,/fS
9, REMOVE L O C KN U T
(a) Usinga screwdriver,engagetho goardoublemeshing.
(b) Usinga hammerand chisel,loosenthe stakedpart of

t h e nu t .
(c) Removeths lock nut.
(d) Usinga screwdrivsr,disengageth€ geardoublemash-
Ing.
1 0 . R E M O V EN O . 3 H U B S L E E V EA N D N O . 3 S H I F T
FORK
(a) Removethe boltfrom the No.3shiftfork'
(b) Removetho No.3hubsleeveand shiftfork.

MX.28
C52 MANUAL TRANSAXLE_ COMPONENT
PARTSREMOVAL
1 1 . I N S P E CsTT H G E A RT H R U S T
CLEARANCE
Usinga dialindicator, measure the thrustclearance
Standaid claarance:
0 . 1 0 - 0 . 5 7 m m ( 0 . 0 0 3 9 - 0 . O 2 2 4i n . l
Maximumcl6arance:
0 . 6 5 m m ( 0 . 0 2 5 6i n . )
12. INSPECT sTH GEARRADIALCLEARANCE

r , s a s u rt6h e r a d i acl l e a r a n c e .
U s i n ga d i a li n d i c a t om
Standard clearance:
0.015-0.058 mm (0.0006-0.0023in.)
Moximumclearance:
0.070mm (0.0028in.)
lf the clearanceexceedsthe maximum,replacethe
gear,needlerollerbearingor shaft.
E3640 zor58
1 3 , R E M O V EN O . 3C L U T C HH U B A N D s T H G E A R
(a) Using2 screwdriversand a hammer,tap out the snap
ring.
(b) Usinga screwdriver,removetho key spring.
(c) lnstalla bolt and washerto th6 tip of tho inputshaft

and usingSST,removethe No.3clutchhub.
s s T 0 9 9 5 0 - 3 0 001 ( 0 9 9 5-10 3 0 10 , 0 9 9 5 3 -0 3 0 10 ,
0 9 9 5 4- 0 3 0 10 )
N O T I C E :S s l s c t a b o l t w h o s e o u t e r d i a m s t e r i s s m a l l o r
than thB screw hole of tho input shaft so that it can be
turned sasily,
(d) R e m o v e t h e s y n c h r o n i z e r r i n g , s t h g e a r a n d n e e d l e
r o l l er b e a r i n g .

MX-29
C52 MANUAL TRANSAXLE- COMPONENT
PARTSREMOVAL
14, REMOVEsTH DRIVENGEAR

UsingSST,remov€tho sth drivengsar.
s s T0 9 6 2 8 - 6 2 011,0 9 2 5 0 - 1 0 011( 0 9 2 s 3 - 1 0 0 1 0 )
15. REMOVEREARBEARING RETAINER

Removeths 5 boltsand rearbearingrstain6r.
16. REMOVEBEARINGSNAP RINGS

Usinga snap ring expander,rsmovethe 2 snap rings.
HINT:lf it is difficulrto romovethe snap rings,pull up
th6 shafts.
17. REMOVEREVERSEIDLER GEAR SHAFT LOCK

BOLT
1 / l/ r l r , L
w ! i l \\i q\ *
-L)it
=_\*\
18. REMOVE N O . 2 S H I F TF O R KS H A F TS N A PR I N G
Using2 screwdrivers anda hammer, tap out the snap
ring.

MX-30
c52 MANUALTRAN'AXLE- coMpoNENTpARTSREM''AL
19. REMOVESCREWPLUGS,SPRINGSEATS,SPR.
I N G SB
, A L L SA N D L O C KB A L LA S S E M B L Y
(a) Usinga hexagon wrench,rsmoveths 3 plugs.
(b) Usinga magneticfinger,rsmoveths 3 springseats,
springa s n db a l l s .
20. REMOVE L O C KB A L LA S S E M B L Y
n r e n c h1, 6 m o vtsh e l o c kb a l la s s e m -
U s i n ga h e x a g ow
otv.
2 1 . R E M O V ET R A N S M I S S I OC
NA S E
(a) TransaxleCaseSide:
Removethe 3 bolts.
(b) TransmissionCaseSide:
Removeth6 13 bolts.
(c) Carefullytap the projectionof the transmissioncase

with a plastic hammer to remove the transmission
case from the transaxlecase,and removethe trans-
m tsstoncase.
22, REMOVEREVERSE IDLERGEAR,THRUSTWASHER

AND IDLERGEARSHAFT

MX-31
C52 MANUALTRANSAXLE_ COMPONENT PARTSREMOVAL
23. REMOVEREVERSE SHIFTARM BRACKET

Removethe 2 boltsand reverseshiftarm bracket'
24. REMOVE SHIFTFORKSAND SHIFTFORKSHAFTS

(a) Using2 screwdrivers and a hammsr,tap out the 3
s n a pr i n g s .
(b) Removethe 3 set bolts.
(c) Pull up the No.3shift fork shaft,removethe No'2 shift

fork shaft and shift head.
(d) Usinga magneticfinger,removethe 2 ballsfrom the

reverseshift fork.

MX-32 - COMPONENT
C52 MANUALTRANSAXLE PARTSREMOVAL
(e) Removethe No.3 shift fork shaft and reverseshift
fork.
(f) Pull out the No.l shift fork shaft.
(s) Removethe No.1and No.2 shift forks.
25. REMOVEINPUTANDOUTPUTSHAFTSASSEMBLY
TOGETHERFROMTRANSAXLECASE
26. REMOVEDIFFERENTIAL
CASEASSEMBLY

MX-33
C52 MANUALTRANSAXLE_ COMPONENT
PARTSRE
CASE
27. REMOVEMAGNETFROMTRANSAXLE
C O M P O N E N TP A R T SI N S P E C T I O N
1. INSPECTsTH GEARSYNCHRONIZER RING
(a) Checkfor wear or damag6'
(b) Checkthe brakingeffect of the synchronizerring'
Turn the svnchronizer ring in one directionwhile push-
ing it to tho gear cone.Checkthat the ring locks'
lf ths braking effect is insufficient,apply a small
amount of fine lappingcompoundbetweenthe syn-
choronizerring and gear cone.
Lightly rub the synchronizerring and gear cons to-
gethsr.
NOTICE: Ensursths fins lappingcompound is completely
washodotf atter rubbing.
(c) Check again the braking effect of the synchronizer
ring.lf it doos not lock,replacethe synchronizerring'
(dI Usinga feelergauge,measursthe cloarancebstween

t h e s y n c h r o n i z er irn g b a c ka n d g e a rs p l i n ee n d '
Minimumclearance:
0.6 mm (0'024in.)
HINT:
r When replacrngsither a synchronizerrlng or
g e a r ,a p p l ya s m a l la m o u n to f f i n e l a p p i n gc o m -
pound between the synchronizerring and gear
cong.
Lightly rub the synchronizerring and gear cone
togsther.
r When replacingboth the synchronizerring and
gear,lhere is no needto apply any compoundor
to rub them together.
NOTICE: Ensursthe tinelappingcompound is complstely
washedoff after rubbing.

MX-34
PARTSREMOVAL
2. I N S P E CC
T L E A R A N CO
EF S H I F TF O R KA N D H U B
SLEEVE
Usinga feelergauge,measure the clearance between
th6 hubslseveand shiftfork.
Maximumclearance:
1. 0 m m ( 0 . 0 3 9 i n . )
l f t h s c l e a r a n c ee x c s e d s t h e m a x i m u m . r e o l a c e t h e
shift fork or hub sleeve.
3. REMOVT E R A N S A X LC
EA S ER E C E I V E R
Removethe 2 boltsandtransaxle casereceiver,
4. IF NECESSARY,REPLACEINPUT SHAFT FRONT

BEARING
(a) U s i n gS S T ,p u l l o u t t h e b e a r i n g .
ssT 09612-65014
-
' ^-\-.--l \
..: --
---
l- -
(b) U s i n gS S Ta n d a p r e s s i, n s t a l al n e w b e a r i n g .
s s T 0 9 6 0 8 - 1 2 0 1 0( 0 9 6 0 8 - 0 3 0 2 00, 9 6 0 8 - 0 0 0 3 0 )
5. IF NECESSARY, REPLACE OUTPUTSHAFTFRONT

BEARING
( a ) Removethe bolt and bearinglockplate.

MX.35
C52 MANUAL TRANSAXLE- COMPONENT
PARTSREMOVAL
(b) UsingSST,pull out the bearing.

s s T0 9 3 0 8 - 0 0 0 1 0
(c) Removethe output shaft front cover.
Case Cover (d) Installthe output shaft front cover.

HINT: Installthe output shaft front covor proJactlon
into the caseside hollow.
(e) UsingSST and a press,installa new bearing

1- 3 5 0 1
ssr 0930 0
M T O O ' SC M O o r 6
(f) Installthe bearing lock plate and torqus the bolt

T o r q u e :1 1 N . m ( 11 5 k g f ' c m .8 f t l b f )
6. I F N E C E S S A R YR, E P L A C EI N P U T S H A F T F R O N T
OILSEAL
(a) Usinga screwdriver,pry out the oll ssal.

MX-36 - coMpoNENTpARTSREMoVAL
c52 MANUALTBANsAXLE
(b) UsingSST,drivein a new oil seal.
s s T 0 9 6 0 8 -1 2 0 1 0( 0 9 6 0 8 - 0 0 0 2 0 ,9 6 0 8 - 0 0 0 8 0 )
(c) Coatthe lip of the oil sealwith MP grease.
7. IF NECESSARY, REPLACEREVERSERESTRICTPIN
(a) Usinga hexagonwrench, removethe straightscrew
plu9.
(b) Usinga pin punch and hammer,drive out the slotted

s p r i n gp i n .
(c) Replacethe reverserestrictpin.
(d) Using a pin punch and hammEr,drive in the slotted

springpin.

MX-37
C52 MANUALTRANSAXLE- COMPONENT
PARTSREMOVAL
(e) Apply sealantto the screw plug threads.

Sealant:
Part No. 08833-00080,THREEBOND1344,LOC-
TITE 242 or equivalent
(0 Usinga hexagonwrgnch,installand torquo ths strai-
ght screw plug.
Torque:13 N.m(130kgf.cm,9 ft lbt)
8, INSTALL TRANSAXLECASE RECEIVER

Installthe transaxlecase receiverand torque the 2
bolts.
Torque:11 N.m(115 kgt'cm,8 ft'lbf)

MX.38 - INPUTSHAFT
C52 MANUALTRANSAXLE
I N P U TS H A F T
COMPONENTS
InputShaft
3 r dG e a r
No. 2 Hub Sleeve
$- ShiftingKev
$- shilting Key spring
N e e d l eR o l l e r
Be ar i n g N e e d l eR o l l e rB e a r i n g
S y n c h r o n i z eR
r ing
No. 2 ClutchHub
SnapRing S n a pR i n g
R e a rB a l l B e a r i n g
I N P U TS H A F TD I S A S S E M B L Y
1. INSPECT 3 R D A N D 4 T H G E A RT H R U S TC L E A R .
ANCE
U s i n ga f e e l e g
r a u g em
, o a s u rteh € t h r u s tc l e a r a n c s .
Standard clearanco:
3rd gear
0 . 1 0- 0 . 3 5 m m ( 0 . 0 0 3 9 - 0 . 0 1 3 8i n . )
4th gear
0 . 1 0- 0 . 5 5 m m ( 0 . 0 0 3 9 - 0 . 0 2 1 7 i n . )
Maximumcloarancg:
3rd gorr
0 . 4 0 m m ( 0 . 0 1 5 7i n . )
4th gasr
0 . 6 0 m m ( 0 . 0 2 3 6i n ' )

- INPUTSHAFT MX-39
C52 MANUALTRANSAXLE
2. INSPECT3 RD AND 4 TH GEARRADIALCLEAR.
ANCE
Usinga dial indicator,msasur€the radialclearance
betweenthe gearandshaft.
S t a n d a r dc l e a r a n c e :
0 . 0 15 - 0 . 0 5 8 m m ( 0 . 0 0 0 6- 0 . 0 0 2 3 i n . )
Maxlmumcloaianco:
0.070 mm (0.0028 in.)
" ' '"''""
lf th6 clearanceexceedsthe maximum, '"" *
replacethe
gear, bearing
rotter
needte "; ff;. m
3. REMOVE SNAPRING
tap out the snap
anda hammer,
Using2 screwdrivers
ring.
4. REMOVE REAR BALL BEARING,4 TH GEAR,

NEEDLEROLLER BEARINGS, SPACER ANDSYNCH-
RI N GF R O MI N P U TS H A F T
R O N I Z ER
(a) UsingSSTanda press,removoths rearballbearing.
ssr 09950-00020
(b) Removethe 4th g€ar.needlerollerbearings, spacer
andsynchronizer ring.
5. REMOVESNAPRING
s da h a m m e tr a, p o u t t h es n a p
U s i n g2 s c r e w d r i v ear n
ring .
6. R E M O V EN O . 2 H U B S L E E V EA S S E M B L Y3, R D
G E A R , S Y N C H R O N I Z ER I N G A N D N E E D L E
ROLLER BEARINGS
UsingSSTand a press,removsthe No.2hub sleave
a s s e m b l y , 3gr d
e a rs, y n c h r o n i zrei nr ga n dn e e d l reo l l e r
bearings.
ssT 09950- 00020

MX-40
C52 MANUALTRANSAXLE_ INPUTSHAFT
7. REMOVE N O . 2H U BS L E E V ES,H I F T I N G
K E Y SA N D
S P R I N GFSR O MN O . 2C L U T C HH U B
Removeths 3 shiftingkeysandspringsfromthe No.2
c lutchhub.
]tlllilffi
I N P U TS H A F TC O M P O N E NPTA R T S
INSPECTION
1 . I N S P E C TS Y N C H R O N I Z ERRI N G
(a) Checkfor wear or damage.
(b) Checkthe brakingoffect of the synchronizerring.
Turn the synchronizer ring in one directionwhile push-
ing it to th€ gear cone.Checkthat the ring locks.
lf brakingsff6ct is insufficient,apply a small amount
of fine lappingcompoundb€twe6nthe synchronizer
n n g a n d g e a rc o n e .
Lightly rub the synchronizerring and gear con6 to-
gether.
NOTICE: Ensuretha fine lappingcompound is completely
washed off after rubbing.
(c) Check again ths braking effect of the synchronizer
ring.lf it doss not lock,replacethe synchronizerring.
(d) Usinga feelergauge,measurothe clearanceb€twesn

tho synchronizerring back and gear splineend.
Minimumcloarancs:
0.6 mm (0.024in.)
HINT:
o When replacingoither a synchronizerring or
cons.
Lightly rub the synchronizerring and gear cone
together.
r When replacingboth the synchronizerring and
gear,there is no needto apply any compoundor
NOTICE: Ensurothe fina lappingcompound is completely
washedoff aftar rubbing.

- INPUTSHAFT MX.41
C52 MANUALTRANSAXLE
2, INSPECTCLEARANCE OF SHIFTFORKAND HUB
SLEEVE
Usinga feelergauge,msasure betw€en
the clgarancs
th6 hubsleeveandshiftfork.
Maximumclearanca:
1.0 mm (0.039in.)
l f t h e c l e a r a n c eg x c e e d st h e m a x i m u m ,r e p l a c et h e
3. INSPECTINPUTSHAFT
(a) Checkths input shaft for wear or damage.
(b) Using a micrometsr,msasurethe outor diameterof
the input shaft journalsurface.
Minimumoutordiamater:
PartA 24.870mm (0.9791in.)
Part B 28.970mm (1.1405in.)
PartC 30.970mm (1.2193in.)
PartD 24.970mm (0.9831in.)
l f t h o o u t e rd i a m e t eirs l e s st h a nt h e m i n i m u mr,s p l a c e
the inutput shaft.
( c ) U s i n ga d i a li n d i c a t o rc, h s c kt h o s h a f t r u n o u t .
Maximumrunout:
0.05 mm (0.0020in.)
l f t h e r u n o u te x c e e d st h e m a x i m u mr, e p l a c et h e i n p u t
shaft.
I N P U TS H A F TA S S E M B L Y
H
,<\ HINT:Coatall of the slrdingand rotatingsurfaceswith
?
A^
t\.
rA \\
.!
rlEl gear oil beforeassembly.
!i::'*16l
""6R%D 1 . I N S T A L LN O . 2 C L U T C H H U B I N T O N O . 2 H U B
SLEEVE
v. rgr 7 (a) Install the 3 springs and shifting keys to the No.2
LJ--L c l u t c hh u b .
(b) Installthe No.2 hub sleeveto tho No.2 clutch hub.
2. INSTALL 3RD GEAR,NEEDLEROLLERBEARINGS,

S Y N C H R O N I Z ERRI N GA N D N O . 2H U B S L E E V EA S .
@
\r--.2
SEMBLYTO INPUTSHAFT
wcl (a) Apply gear oil to the needlerollerbearings'

(b) Placeth6 synchronizerring on th€ goar and alignthe
t-] ring slots with the shiftingkeYs.
\s:n/
Y,fl
.]-'1

MX-42
C52 MANUALTRANSAXLE- INPUTSHAFT
(c) Usinga press,installthe 3rd gearand No.2 hub sleeve

assemDtv.
3. INSTALL SNAP RING

( a ) S e l e c ta s n a pr i n g t h a t w i l l a l l o wm i n i m u ma x i a lp l a y .
Mark Thicknoss mm (in.i T h i c k n 6 s sm m ( i n . )
2.30(0.0906) 2.48(0.0976)
2.36(0.0929) 4 2.s4 (0.1000)
2.42(0.0953) 5 2 . 6 0{ 0 . 1 0 2 4 )
( b ) U s i n ga s c r e w d r i v earn d h a m m e rt,a p i n t h e s n a pr i n g .
4. I N S P E C3TR DG E A RT H R U S T CLEARANCE
U s i n ga f e e l e rg a u g e m
, e a s u r teh e 3 r d g e a rt h r u s t
clearancg.
0 . 1 0- 0 . 3 5 m m ( 0 . 0 0 3 9 - 0 . 0 1 3 8i n . )
5. I N S T A L LS Y N C H R O N I Z ERRI N G ,N E E D L ER O L L E R
B E A R I N GS , P A C E R4 , TH GEARAND REARBALL
BEARING
(a) Apply gaar oil to the needlerollerbearing.
( b ) P l a c et h e s y n c h r o n i z er irn g o n t h e g o a ra n d a l i g nt h e
ring slots with the shiftingk6ys.

MX-43
C52 MANUALTRANSAXLE- INPUTSHAFT
(c) UsingSST and a press,installthe rear ball bearing.
B s s T 0 9 6 0 8- 2 0 0 12 ( 0 9 6 0 8- 0 3 0 7 0 )
6 . I N S T A L LS N A PR I N G
( a ) S e l e c ta s n a pr i n g t h a t w i l l a l l o wm i n i m u ma x i a lp l a y .
Mark Thickness mm (in,) Mark Thickn688 mm (in.)
2.29{0.0902) o 2.41 \0.0972)
2.35(0.0925) 2.s3{0.0s96)
2.41(0.0349) F 2 , 5 9( o . 1 o 2 o )
(b) Usinga screwdriverand hammer,tap in the snap ring.
7, INSPECT4TH GEARTHRUSTCLEARANCE
Using a feeler gauge, measur€thg 4th gear thrust
clearance.
Standardclearance:
0 . 1 0 - 0 . 5 5m m ( 0 . 0 0 3-9 0 . 0 2 1 7I n . )

MX-44
C52 MANUALTRANSAXLE- OUTPUTSHAFT
O U T P U TS H A F T
COMPONENTS
T h r u s tW a s h e r
Output Shaft
N e e d l eR o l l e r
Bearing
S y n c hr o n i z e rR i n g
N o . 1H u b S l e e v e
N o . 1C l u t c hH u b
S y n c hr o ni z e rR i n g
ShiftinS Key------Q?..
J S n a pR r n g
S hi f t i n gK e y S p r i n g
N e e dl e R o l l e rB e a r i n g
3 r d D r i v e nG e a r
r B a l lB e a r i n g
2nd Gear
lst G6ar OUTPUTSHAFTDISASSEMBLY

1 . I N S P E C T1 S T A N D 2 N D G E A RT H R U S TC L E A R -
ANCE
U s i n ga f a e l e g
r a u g 6m
, s a s u rtsh e t h r u s tc l e a r a n c e .
S t s n d a r dc l e a r a n c e :
l st gear
0 . 1 0 - 0 . 4 0 m m ( 0 . 0 0 3 9- 0 . 0 1 5 7i n . )
2nd gear
0 . 1 0 - 0 . 4 5 m m ( 0 . 0 0 3 9- 0 . 0 1 7 7i n . )
2nd Gear Maximumclearanca:
lst gaar
0 . 4 5 m m ( 0 . 0 17 7 i n . )
2nd gear
0 . 5 0 m m ( 0 . 0 19 7 i n . )

MX-45
2, INSPECT1 ST AND 2 ND GEARRADIALCLEAB-

ANCE
Usinga dial indicator,maasuretho radialclearance
botw€enthe goarandshaft.
Standardclearanco:
- 0.0023in.)
0.015-0.058mm (0.0006
Maximum clealanc6:
0.070mm (0.0028in.)
lf the clearanceexceedsthe maximum,replacaths ,**o**rretr
gear,needlerollerbearingand shaft. lWXf$
3. REMOVEREARBALLBEARING,4TH DRIVENGEAR
AND OUTPUT GEAR SPACER FROM OUTPUT
SHAFT
( a ) UsingSSTand a press,removethe rearballbearing
and4th drivengear.
ssT 09950- 00020
(b) Removg tha outputspacor.
4. REMOVE3RD DRIVENGEAR,2ND GEAR,NEEDLE

ROLLERBEARING,SYNCHRONIZER RING AND
SPACER
'l
(a) Shiftthe No.1hub sleeveintotho st gear'
(b) UsingSST and a press,removethe 3rd drivengear.

ssr 09950-00020
(c) Remove th6 2 nd gear, needla roller bearing,syn-
chronizerring and sPacer.
5. REMOVESNAPRING
anda h a m m a rt,a p o u t t h o s n a p
Using2 screwdrivers
ring.

MX.46
6. REMOVENO. 1 HUB SLEEVEASSEMBLY,1 ST

G E A R ,S Y N C H R O N I Z ERRI N G .N E E D L ER O L L E R
BEARING, THRUSTWASHERANO BALL
(a) Usinga press,romov€the No.1hubsleevsassemblv,
1st gearandsynchronizer ring.
(b) Removethe needlerollerbearing, thrustwasherand
ball.
7. REMOVENO.1 HUB SLEEVE,SHIFTINGKEYS AND

SPRINGS F R O MN O . 1C L U T C HH U B
Removatho 3 shiftingkeysand springsfrom ths No.1
c l u t c hh u b .
""."
OUTPUTSHAFTCOMPONENT
PARTS
INSPECTION
1 . I N S P E C TS Y N C H R O N I Z ERRI N G S
(b) Checkthe brakingeffect of the synchronizerring.
Turn the synchronizer ring in one directionwhile push-
ing it to the gear cone.Checkthat th6 ring locks.
lf the braking effsct is insufficient,apply a small
amount of fine lappingcompoundbetwsen th€ syn-
chronizerring and gear cone.
Lightly rub th6 synchronizerring and gear cone to-
gsthsr,
NOTICE: Ensuiotho line lappingcompound is completely
(c) Check again the braking effoct of the synchronizer
ring.lf it do€s not lock,replacethe synchronizerring.
(d) Usinga feelergauge,measurethe clearancebetw66n
t h e s y n c h r o n i z er irn g b a c ka n d g e a rs p l i n ee n d .
Minimumcleorance:
0,6 mm (0.024In.)
HINT:
o When replacingeither a synchronizerring or
gear,apply a small amount of fine lappingcon-
cone.
Lightly rub the synchronizerring and g€ar con6
tog6ther.

_ OUTPUT MX-47
C52 MANUALTRANSAXLE SHAFT
o When replacingboth the synchronizerring and
gear.thsr€ is no needto apply any compoundor
to rub thsm togothor.
NOTICE:Ensurethe fine lappingcompound is completely
washadoff after rubbing.
2, INSPECTCLEARANCE OF SHIFTFORKAND HUB

SLEEVE
Usinga feelergaugE,measure between
the clearance
the hubsleEveandshiftfork.
Morimumclealanca:
1.0 mm (0.039in.)
lf the clearanceexceedsthe maximum,replacethe
3. INSPECTOUTPUTSHAFT
(a) Ch€ckthe output shaft for wear or damage.
(b) Using a micrometer,moasurethe outsr diameterof
the output shaft journalsurfacE.
Minimumoutei diamgtsr:
PartA 32.970mm (1.2980in.)
Part B 37.970mm (1.4949in.)
ParrC 3t .970mm (1.2587in')
lf the outerdiameteris lessthan tho minimum,replace
th€ outout shaft.
(c) Usinga dial indicator,check the shaft runout.
Maxlmumiunout:
0.05 mm (0.0020in')
lf the runout exceeds the maximum, replace the
output shaft.
OUTPUTSHAFTASSEMBLY
,. {=
HINT:Coatall of the slidingand rotatingsurfaceswith
lL I
""@ffi
I gear oil beforeassemblY.
- E
!tii'+ iIt-lE 1. INSTALL NO. 1 CLUTCH HUB INTO NO. 1 HUB
SLEEVE
5Et'
r\l ( a ) Install the 3 springs and shifting keys to the No.1
clutch hub.
(b) lnstallthe No.1 hub sleeveto the No.l clutch hub.

MX-48
2. INSTALL BALL, THRUST WASHER, l ST GEAR,

NEEDLEROLLERBEARING.SYNCHRONIZER RING
AND NO.1 HUB SLEEVEASSEMBLY TO OUTPUT
SHAFT
(a) Installthe ball to the shafr.
(b) Fit ths thrustwashergroovesecurelyover the locking
ball when installingthe thrust on ths shaft.
(c) Apply gear oil to the needlerollerbearing.
(d) Install the needle roller bearing,1st gear and syn-

chronizerring.
(+
iq
M]
v
grt
Y Notch
"q
FS
(e) Placethe synchronizerring on the gear and align the

clutch hub grooveswith the projectionson the syn-
chronizerring.
(f) U s i n ga p r e s si,n s t a l l t h e1 s t g e a ra n d N o . 1h u bs l e e v s .

(a) Selecta snap ring that will allow minimumaxial play.
Mark T h i c k n o s sm m ( i n . ) M ark Thickn€ssmm (in.)
2.50(0.0984) 2 . 6 8{ 0 . 1 0 5 5 )
B 2 . 5 6( 0 . 1 0 0 8 ) E 2.74\0.10791
2 . 6 2{ 0 . 1 0 3 1 ) 2 . 8 0( 0 . r1 0 2 )

MX.49
(b) Usinga screwdriverand hammer.tap in the snap ring'
4. INSPECT1ST GEARTHRUSTCLEARANCE
Using a feelar gauge, measuretho 1st gear thrust
c learance.
Standardclearance:
0.10- 0.40 mm (0.0039-0.0157in.)
5. INSTALL SYNCHRONIZER RING,SPACER'NEEDLE

R O L L E RB E A R I N G2, N D G E A R A N D 3 R D D R I V E N
@ GEAR
(a) Placeth€ synchronizerring on the gear and align the
clutch hub grooveswith tho projectionson the syn-
@ c hronizer ring.
I (b) Installths spacor.
(c) Apply gear oil to the needlerollerbearing.
(d) Installthe 2nd gear.
(e) Usinga press,insrallths 3rd drivengear.
6. I N S P E C T2 N D G E A RT H R U S TC L E A R A N C E
Using a feelar gauge, measurethe 2nd goar thrust
clearanca.
Standardclaaranca:
0 . 1 0- 0 . 4 5m m ( 0 . 0 0 3 9 - 0 ' 0 1 7i7n . )

MX-50
7. INSTALL OUTPUT GEAR SPACERAND 4 TH

ORIVENGEAR
(a) Installthe outputgearspacer.
(b) Usinga press,installthe 4th drivengear.
8. INSTALL REARBALL BEARING

UsingSST and a press,installthe rear ball bearing.
s s T 0 9 3 16 - 6 0 0 10 ( 0 9 3 16 - 0 0 0 2 0 )

- SHIFTIruO SETCCT
C52MANUALTRANSAXLE SgI
TEVEN
S H I F TA N D S E L E C TL E V E RS H A F T
COMPONENTS
l| Oil Seal
No. 1 SelectSpring
Shift and SelectLever

Spring Shaft
S e l e c tI n n e r
Lever I
No.2 Shift
lnnef Lever SnaPRing ControlShatt Cover
N o . 2 Select I
Spring Seat A
--,.1
lwv
60 1
.</
|
I
Shift Inlerlock
qi(
T
SlottedSpring Pin
| Prate
F Spring I
I
S p n n gP i n N o 1 S h i h I n n e rL e v e t
_ ,.i.
t-Hrng
a Non-reusablepart
SHIFTAND SELECTLEVERSHAFT
DISASSEMBLY
1. REMOVE N O , 2S H I F TI N N E RL E V E R
(a) Using2 screwdrivers and hammer,tap out the E-
ring.
(b) Removeths springand No.2sel€ctspringseat.
(c) Usinga pin punch and hammer,drive out the slotted

springpin from the No.2 shift inner lever.
(d) Removethe No.2 shift innsr lever.

MX-52 - sHrFTANDsELEcrLEVER
c52 MANUALTRANSAXLE sHAFT
2, REMOVE SHIFT INTERLOCKPLATE AND NO. 1
S H I F TI N N E RL E V E R
(a) Usinga pin punch and hammer,drive out the slotted
springprnfrom the No.1 shift inner lever.
(b) Rsmovsthe shift intorlockplat€ and No.1 shift inner
lsver.
3. REMOVESELECTINNERLEVER
(a) Usinga pin punch and hammer,drive out the slottsd
springpin from th6 selectinner l6ver.
(b) Removethe selectinner lever,springand No.1 select
spflng seat.
4. R E M O V ES N A PR I N G
Using2 screwdriversand a hammsr,tap out tho snap
r i ng .
5. SHAFTCOVERAND BOOT
REMOVECONTROL
6. IF NECESSARY,REPLACE CONTROL SHAFT

COVEROIL SEAL
(a) Usinga screwdriver,
removethe oil seal.

C52 MANUAL TRANSAXLE- SHIFTAND SELECTLEVERSHAF
(b) Usinga socketwrenchand hammer,drivein a new oil
seal.
Drivain dapth:
1.0- 2.0 mm (0.039- 0.079in.)
(c) Coat the lip of the oil seal wrth MP grease.
E3876 CM0060
L E V E RS H A F T
S H I F TA N D S E L E C T
ASSEMBLY
TO PARTS,AS SHOWN
1. APPLYMP GREASE
6) ON@
\J9
t f \
^rE*@Q /11 - l-
aV<1qi.-\
h)J
r'
I
2. INSTALL SHIFTAND SELECTLEVERSHAFT

lnstallthe boot and shift and selectlevarshaft to the
controlshaft cover.
HINT: Maks surs to installthe boot in correct direc-
tion.
Positionthe air bleedof the boot downward.
3. I N S T A L LS N A PR I N G
U s i n ga s c r a w d r i v ae nr dh a m m e tr a, p i n t h es n a pr i n g .

MX-54 _ SHIFTANDSELECT
LEVER
SHAFT
C52 MANUALTRANSAXLE
4. INSTALLSELECTINNERLEVER
(a) Installthe No.1selectspringseat,springand select
innerlever.
(b) Using a pin punch and hammer,drive in the slotted

springpin to the selectinner lever.
Drivoin depth:
0 + 0.5 mm (0 + 0.020in.)
826E0 E367€ \@16-
INSTALLSHIFT INTERLOCKPLATE AND NO. 1

SHIFTINNERLEVER
( a ) lnstallthe No.1shift innerleverto the shift int6rlock
olate.
(b) Using a pin punch and hammer,drivo in th€ slotted

0 + 0 . 5m m
springpin to tho No.1 shift inner lever.
Drivein depth:
0 + 0.5 mm (0 + 0.020in.)
(c) Checkthat the shift interlockplateturns smoothly.
6. INSTALLNO.2SHIFTINNERLEVER
(a) lnstallth€ No.2shift innerlever.
/s,
sE3E72

MX.55
C52 MANUALTRANSAXLE- SHIFTAND SELECTLEVERSHAFT
(b) Usinga pin punchand hammer,drivein the slotted
springpin to the No.2shiftinnerlever.
Drive In depth:
3.5 i 0.5mm(0'138+ 0.020in.)
7, INSTALLSPRING, NO.2SELECT SPRING SEATAND

E-RING
(a) Installthe springand No.2selectspringseat
RlNN
!/,
( b ) U s i n ga s c r e w d r i v ear n d h a m m e rt,a p i n t h e E - r i n g ,

MX-56
C52 MANUALTRANSAXLE_ DIFFERENTIAL
CASE
D I F F E R E N T I ACLA S E
COMPONENTS
a O i lS e a l
a O u t e rR a c e
P i n i o nT h r u s tW a s h e r
\5 j ,'."r"".'nn I
vrh l "4.
\.: y
I\qffi
shim A
l,(.lt /4,
@-einion
Gear
,- - -'-
'-'-
- -----Y-t'
-a I o c k Plate
Lock Plate
:W_ *nrn"u
//,-t fl
W RFS,Alra
"N '6 ,-, s, t sr.rl
S i d e B e ar i n g
tr t@n
ffi)Y
@ l
Drrerenla'
Dirrerentiar
case
y gk
';,",^KS sidecear
i
,.- . o,,," S i d e G e a rT h r u s tW a s h e r
strashtPinl* |
(tO
SpeedSensorD.iuecea)Y
@ A"1-^ ,^ r
U A
(ktfrm, ft1bf) 'outerRace
iN ",,,,,,,,,,,,,,, n l : specifiedtorque W sMo272
a N o n - r e u sbal e p ar t
2119n9
DIFFERENTIA
C LA S ED I S A S S E M B L Y
M a t c h m ar k s
1. REMOVE
R I N GG E A R
(a) Place matchmarks on the ring gear and differential
(b) Loosenth6 staksd part of th6 lock plate.

MX.57
CASE
(c) Removgthe 8 bolts and 4 lock plates'
(d) Using a copper hammer, taP on the ring gear

removeit from tho differentialcasg.
SPEEDSENSOR(DRIVEGEAR SIDE):
R E M O V E S I D E B E A R I N GF R O M D I F F E R E N T I A L
CASE
( a ) UsingSST,removethe side bearing.
s s T 0 9 9 5 0- 0 0 0 2 0 ,0 9 9 5 0- 0 0 0 3 0
H I N T :A p p l yt h e c l a wo f S S Tt o t h e b e a r i n gi n n e rr a c e
at the oositionwhere the speedsensordrive gear is
indant6d.
(b) Removethe speodsensordrive gear.
3. SPEEDSENSOR(RINGGEARSIDE):
R E M O V E S I D E B E A R I N GF R O M D I F F E R E N T I A L
CASE
UsingSST,rsmovethe side bearing.
s s T 0 9 9 5 0- 0 0 0 2 0 ,0 9 9 s 0- 0 0 0 3 0
H I N T :A p p l yt h e c l a wo f S S Tt o t h e b e a r i n gi n n e rr a c e
at the oositionwherethe differentialcaseis indented,
INSPECTSIDE GEARBACKLASH
Using a dial indicator,moasuretho backlashof one
s i d eg e a rw h i l eh o l d i n go n e p i n i o nt o w a r dt h e c a s s .
Standard backlash:
0.05- 0.20 mm (0.0020-0'0079in.)
installthe
lf the backlashdoesnot meet specification,
corr6ctthrust washsr to the sids g€ars.

MX-58
C52 MANUALTRANSAXLE- DIFFERENTIAL
CASE
5. DISASSEMELE DIFFERENTIAL CASE

( a ) U s i n ga p i n p u n c ha n d h a m m e rd, r i v eo u t t h e p i n i o n
shaftstraightpin.
(b) Removethe pinionshaft from the differentialcase.

(c) Removethe 2 pinionsand sidegearswith the 4 thrust
washersfrom each g ear.
6. TRANSMISSIO CN A S ES I D E :
IF NECESSARY R .E P L A C E
OIL SEALAND SIDE
BEARINO G U T E RR A C E
(a) Usinga screwdriver and hammer,driveout the oil
seat.
8 5 9 8 7E 3 8 2 2
( b ) U s i n gS S T ,p u l lo u t t h € o u t e rr a c oa n d s h i m .
s s r 0 9 6 1 2 - 6 54
0't
(c) Placethe shim into the differentialcase.
(d) UsingSST and a hammer,drive in a new outer racs.

s s T 0 9 6 0 8 - 2 0 0t 2 ( 0 9 6 0 8 - 0 3 0 2 00, 9 6 0 8 - 0 3 0 9 0 )

MX-59
- DIFFEBENTI4!
c52 MANUALTRANSAXLE JASE
(e) UsingSSTanda hammer.drivein a new oil seal'

s s r 0 9 3 5 0 - 3 2 0 1(40 9 3 5-13 2 1 1 1 0' 9 3 5 1 - 3 2 1 3 0 )
2.4 1 0.3 mm Drivein depth:
2.4 t 0.3 mm (0.094I 0.012in.)
(f) Coat the lip of the oil seal with MP grease.
E382A
3 5913
7. T R A N S A X LCEA S ES I D E :
tF NECESSARY OIL SEALANO SIOE
R ,E P L A C E
BEARING O U T E RR A C E
(a) Usinga scrswdriverand hammer,drivaout the oil
seal.
( b ) U s i n gS S T ,p u l lo u t t h e o u t e rr a c ea n d s h i m .
ssr09612-65014
(c) Placethe shim into the differentialcas6.
(d) UsingSST and a hammer,drive in a new outer rac6'

s s T 0 9 6 0 8 - 2 0 0 12 ( 0 9 6 0 8 - 0 3 0 2 0 0, 9 6 0 8 - 0 3 0 6 0 )
(e) UsingSSTanda hammer,drivein a new oil seal'

s s T 0 9 3 5 0 - 3 2 041 ( 0 9 3 5 -13 2 1 3 0 ,0 9 3 5 1- 3 2 1 5 0 )
2 . 4 + 0 . 3m m Drivein dopth:
2.4 + O.3mm (0.094+ 0.012in')
(f) Coat the lip of the oil seal with MP grease.

MX-60
C52 MANUALTRANSAXLE- DIFFERENTIAL
CASE
DIFFERENTIAL
CASEASSEMBLY
1 . A S S E M B L ED I F F E R E N T I ACLA S E
(a) Installthe correctthrust washersand side gears.
Referringto the tab16below, select thrust washers
which will ensursthat ths backlashis within soecifica-
flon.
Standafd backlash:
0.05- 0.20 mm (0.0020-0.0079in.)
Thicknoss mm (in.) Thickness mm (in.)
0.95(0.0374) 1 . 1 0( 0 . 0 4 3 3 )
L00 (0.0394) 1. 1s ( 0 . 0 4 s 3 )
1 , 0 5( 0 . 0 4 1 3 ) 1.20 lO.O472l
(b) Installthe thrust washersand side gearsin the differ-

e ntiaI case.
(c) Installthe pinionshaft.
( d ) U s i n ga d i a l i n d i c a t o rc,h e c kt h e s i d eg e a rb a c k l a s h
M a a s u r et h e s i d e g e a r b a c k l a s hw h i l e h o l d i n go n e
piniongear toward the case.
Standard backlash:
0.05- 0.20 mm (0.0020-0.0079in.)
lf the backlashis not within specification,install a
thrust washerof differentthickness.

MX-61
CASE
(e) Using a pin punch and hammer,drive in the straight

pin throughthe differentialcaseand hold in the pinion
shaft.
(f) Stakethe differentialcase.
2, SPEEDSENSOR(RINGGEARSIDE):
I N S T A L LS I D EB E A R I N G
UsingSST and a press,installthe side bearing.
s s T 0 9 5 5 0 - 10 0 12 ( 0 9 2 5 2 - 10 0 10 , 0 9 5 5 6 - 10 0 10 )
3. SPEEDSENSOR (DRIVEGEARSIDE):
INSTALL SIDE EARING
B
(a) Installth€ speedsensordrivegear.
V
CaseSide
(b) UsingSSTanda press,installtho sidebearing.

s s r 0 9 5 5 0 -1 0 0 1 2( 0 9 2 5 2 -1 0 0 1 00, 9 5 5 6 -1 0 0 1 0 ,
09560-10010)

MX-62
C52 MANUAL TRANSAXLE- DIFFERENTIAL
CASE
4. INSTALL RING GEARON DIFFERENTIAL CASE

(a) Cleanthe contact surfaceof ths difforontialcase.
(b) Hoat the ring gear in boilingwater.
(c) Carefullyrsmoveth6 ring gearfrom the water.
(d) After the moistureon the ring gear has completaly
evaporated,quicklyinstallthe ring gear to ths diffsr-
I ntraI caso.
HINT:Align the matchmarkson the differentialcase

and contactthe ring gear.
(e) Temporaryinstallthe 4lock platesand 8 bolts.
NOTICE: The ringgoarsat boltsshouldnot be tightensd
untiltha ringgaarhascooladsufficiantly.
(f) Aft6r th6 ring gaar has cooledsufficiently,torque the
ring gear'ssat bolts.
(s) U s i n ga h a m m e ra n d d r i f t p u n c h ,s t a k e t h e l o c k i n g
plate.
HINT:Stakeone claw flushwith the flat surfaceof the
nut. For the claw contactingthe protrudingportionof
the nut, stake only th6 half on the tighteningside.
5. INSPECTDIFFERENTIAL SIDE BEARINGPRELOAD

(a) Installthe differantialcase assemblyto tho transaxlo
case.
(b) lnstallth€ transmissioncas€.
(c) Installand torque the bolts.
tr--
\
cM0061

_ DIFFERENTIA! MX-63
C52MANUALTRANSAXLE t49!
(d) Using SST and a small torque wrench, msasurethe
preload.
s s T0 9 5 6 4 - 3 2 0 1 1
Preload (at starting):
New bearing
0.8-1.6 N.m(8-16 ksf'cm,6.9-13'9 in.'lbf)
Reusedbearing
0.5-1.0 N.m(5-10 kgf'cm,4.3-8'7 in.'lbf)
lf the preload is not within specification, removg the qlrqrlarwp
casesidsouterraceof thesidobearingffiilXffi
transmission
wrrn JJ | .
( S e ep a g eM X - 5 8 a n d M X - 5 9 )
Selecta nothershim.
H I N T :T h e p r e l o a dw i l l c h a n g eb y a b o u t0 . 3 - 0 . 4 N ' m
( 3 - 4 k g f . c m ,2 . 6 - 3 . 5 i n " l b f ) w i t h e a c h 0 . 0 5 m m
changein shim thickness.
Mark Thicknoss mm (in.) Mark Thicknossmm (in.)
2,r0 (0.0827) 2 . 6 0( 0 , 1 0 2 4 )
t 2.15(0.0846) 2 . 6 5( 0 . 1 0 4 3 )
c 2.20(0.0886) N 2 . 7 0( 0 . 1 0 6 3 )
2.25(0.0886) 2 . 7 5( 0 . r 0 8 3 )
E 2,30(0.0906) 2 . 8 0( 0 , 1 1 0 2 )
F 2.35(0.0925) t( 2 . A 5p , 1 1 2 2 1
2.40(0.0945) 2 . 9 0( 0 . 11 4 2 )
H 2.45(0.0985) T 2.9s(0.r16r)
J 2.50(0.0984) u 3 . 0 0( 0 . 1l 8 r )
K 2.5s(0.1004)

MX-64 - coMpoNENTpARTSTNSTALLATToN
c52 MANUALTRANSAxLE
C O M P O N E NPTA R T SI N S T A L L A T I O N
B A S I CS U B A S S E M B LRYE A S S E M B L Y
gear oil beforeassembly.
1. INSPECTDIFFERENTIAL SIDE BEARINGPRELOAD
2. INSTALL MAGNET TO TRANSAXLECASE
3. INSTALL DIFFERENTIAL
CASE ASSEMBLY
4. INSTALL INPUTAND OUTPUTSHAFTS

Installth6 input and output shaftstogether.
5. INSTALLREVERSE IDLERGEAR,THRUSTWASHER
A N D I D L E RG E A RS H A F T
lnstalltho reverseidlergoar,thrustwasherand idler
gaar shaft, as shown.
A l i g nA l i g n m e n M
t ark

PARTSINSTALLATIO
6. INSTALL REVERSESHIFT ARM BRACKET

(a) Installthe reverseshift arm bracket,as shown.
(b) Installand torque tha 2 bolts.
Torque:17 N'm (175 kgf'cm, 13 ft lbf)
7. INSTALL SHIFT FORKSAND SHIFT FORK SHAFTS

(a) Placethe No.1and No.2shift forks into the grooveof
No.1 and No.2 hub sleeves.
( b ) l n s t a l tl h e N o . 1s h i f tf o r k s h a f ti n t ot h o N o . 1s h i f tf o r k
hols.
(c) lnstallths 2 baltsinto ths revsrseshift fork hole'
(d) Installths No.3 shift fork shaft and reverseshift fork

Mx-66 - coMpoNENTpARTSTNSTALLATToN
c52 MANUALTRANsAXLE
(e) lnstallthe No.2 shift fork shaft and shift head.
(f) lnstalland torquethe No.1,No.2 and No.3 shift fork's

3 set bolts.
Torque:16 N.m(160 kgf'cm, 12 ft.lbf)
(g) Using a screwdriverand hammer,tap in the 3 snap

rings.
8. INSTALL TRANSAXLECASE
(a) Removeany FIPGmaterialand be carefulnot to drop
oil on th6 contactingsurfaceof the transmissioncase
and transaxlecase.
(b) Apply FIPG to tho transaxlecase, as shown in the
illustration.
FIPG:
Part No.08826-00090,THREE BOND1281or equi.
valont
(c) Installand torqu€ the 16 bolts.


MX.67
C52 MANUALTRANSAXLE_ COMPONENT
PARTSINSTALLATION
9. INSTALLLOCKBALLASSEMBLY
threads.
(a) Applysealantto the lockballassembly
Soalant:
PaTrNo.08833-00080, THEEBOND1344, LOC-
flfE 242 or oquivalent
(b) Usinga hexagonwrench,tightenth6 lock ball assem-
blv.
Torque:39 N.m (400 kgf'cm, 29 ft lbf)
10. INSTALL BALLS, SPRINGS,SPRINGSEATS AND

SCREWPLUGS
(a) lnstall the balls, springs and spring soats into the
holes.
(b) Apply sealant to the plugs threads.

Sorlant:
P a r t N o . 0 8 8 3 3 - 0 0 0 8 0 , T H R E EB O N D 1 3 4 4 . L A C '
l AIE 242 or equivalont
(c) Using a hexagon wrench, tighten the 3 plugs.
T o r q u e :2 5 N . m ( 2 5 0 k g f ' c m , 1 8 t t ' l b f )
I D L E RG E A R
1 1 . I N S T A L LA N D T O R O U ER E V E R S E
SHAFTLOCKBOLT
T o r q u e :2 9 N m ( 3 0 0 k g f ' c m , 2 2 t t ' l b f )
1 2 . I N S T A L LB E A R I N GS N A PR I N G S
Usinga snap ring expander.installth€ 2 snap rings.
H I N T :l f i t i s d i f f i c u l t o i n s t a ltl h e s n a pr i n g s ,p u l lt h e
shafts up.

Mx-68
c52 MANUAL TRANsA*LE - coMpoNENT pARTSTNSTALLATToN
13. INSTALLSNAP RINGTO NO.2 FORK SHAFT

U s i n ga s c r e w d r i v sarn d h a m m e rt,a p r n t h e s n a pr i n g .
1 4 . I N S T A L LR E A RB E A R I N GR E T A I N E R
Install and torquo the rear bearing rstainar's5 set
bolts.
f orque:27N.m(280kgf.cm,20 ft.lbf)
15. INSTALLsTH DRIVENGEAR

UsingSST,installths sth drivengsar.
ssr 09309-12020
16. INSTALLSPACER, NEEDLE ROLLERBEARINGS,

s T H G E A RA N DS Y N C H R O N I ZR
EIRN G
(a) Install the spacer.
(b) Applygearoil to the naedlerollerbearings.
(c) Installthe needlerollerbearings.
(d) Installthe 5th g€ar and synchronizerring.

MX.69
PARTSINSTALLATION
1 7 . I N S T A L LN O . 3 C L U T C HH U B I N T O N O . 3 H U B
SLEEVE
g (a) Installthe 3 keyspringsand shiftingkeys.
-A\ Tr ( b ) I n s t a lt lh e N o . 3h u bs l e e v e
t o t h a N o . 3c l u t c hh u b .
-{ati'.%Dr''ln"^"+E
n
') a* J{
ffl
1 8 . I N S T A L LN O . 3 H U B S L E E V EA S S E M B L YW I T H
N O . 3S H I F TF O R K
U s i n gS S Ta n da h a m m e rd, r i v ei n t h e N o . 3h u b s l e e v e
assemblywith the No.3 shift fork.
ssT09636-20010
NOTICE:Align the synchronizerring slots with the shift-
ing koys.
1 9 . I N S P E C5TT H G E A RT H R U S T CLEARANCE
r , e a s u rteh e t h r u s tc l e a r a n c e .
Standaid clearance:
0.10 - 0.57 mm (0.0039- 0.0224 in.)
20. INSTALLSNAPRING
axiap
( a ) S e 1 6 cats n a pr i n gt h a tw i l la l l o wm i n i m u m l lay.
M ark Thickn6ss mm (in.) Mark T h i c k n e s sm m ( i n . )
2.2510.0886) E 2.49(0.0980)
2.3r (0.0909) F 2 . 5 s( 0 . 1 0 0 4 )
2.37(0.0933) 2 . 6 1( 0 . 1 0 2 8 )
D 2.43(0.0957)
(b) Usinga screwdriverand hammer,tap in ths snap ring.

MX-70
c52 MANUAL TRANSA'LE - coMpoNENT'ARTS TNSTALLATT'N
21. INSTALLAND TOROUENO.3 SHIFTFORK'SSET

BOLT
T o r q u e :1 6 N . m ( 1 6 0 k g f ' c m , 1 2 f t . l b f )
22. INSTALLLOCKNUT
engagethe goardoublemeshing.
(b) lnstalland torque a new lock nut.

Torque:I 18 N.m(1,200kgf.cm,87 {t.lbf)
(c) Usinga screwdriver, disengagethe geardoublemesh-
ing.
(d) Stakethe lock nut.
q{(]aS
23. INSTALL SHIFT AND SELECT LEVER SHAFT AS.

SEMBLY
(a) Placea new gasket in positionon the control shaft
cover.
(b) Apply sealantto the bolt threads.
sgalant:
Part No.08833-00080.THREEBOND1344. LOC-
TITE242 or equivElont
(c) Installtha shift and select lever shaft assemblyand
torque the 4 bolts.
24. INSTALLANO TOROUELOCK BOLT

TRANsAxLE
c52 MANUAL plnrs rd
- coMPoNENT
25. TNSTALL TRANSMISSIONCASECOVER

casecover,as shown
(a) ApplyFIPGto the transmission
in th6 illustration.
FIPG:
P a r t N o . 0 8 8 2 6 - 0 0 0 9 0 , T H R E EB O N D 1 2 8 1 o r e q u i -
valent
(b) Installand torquethe 9 bolts.

Torque:18 N'm (185kgf'cm.13 ft lbf)
(o'.,,
26. INSTALLFRONTBEARING RETAINER

Usinga torx wrench,installand torque the front
3 set torx screws.
bearingretainer's
T o r q u e : 1 I N . m ( 11 0 k g f. c m .8 f t ' l b f )
(TorxwrenchT30 09042- 00010)
27. INSTALLCONTROLLEVERHOUSINGSUPPORT
BRACKET
Installand torquothe controllevorhousingsupport
bracket's3 set bolts.
Torque:1 I N.m(115 kgt.cm,8 ft'lbt)
28. INSTALL SELECTINGBELLCRANKASSEMBLY
Installand torquethe selectingbellcrankassembly's2
sst bolts.
Torque:25 N m (250kgf cm, 18 ft'lbf)
2 9 , I N S T A L LB A C K _ U P L I G H TS W I T C H
Inslalland torque ths back- up light switch.
Torque:40 N m (410kgf'cm, 30 ft'lbf)
30. INSTALLSPEEDSENSOR
Installand torquetho speedsensor.
Torque:1 1 N.m(115 kgf.cm,I ft'lbf)

cs2 MANUALTRANSAxLE
31. INSTALLCLUTCH RELEASEFORK AND BEARING
(a) Apply molybdenumdisulphidelithium basegreasoto
the f ollowingparts.
o Reloassfork contactsurtaco
I Releasefork and pushrod contact point
r Relsasatork pivot point
. Input shaft spline
(b) Installthe clutch releasefork and bearingto ths trans-

axle.
8214J

MX.73
C52 MANUALTRANSAXLE_ SHIFTLEVERAND CONTROLCABLE
CABLE
S H I F TL E V E RA N D C O N T R O L
COMPONENTS
A'eF
\-/" center cluster F,'rishPanel
C o n s o l eU p p e r P an e l
H e a t e rC o n l r o lP a n e l
G l o v eC o m p a n m e n t C o n s o l eB o x
& g
Scuff Plate
L o w e r C e n t e rF i n i s hP a n e l
4a
L o w e rL H F i n i s hP a n e l
C o w lSi d e P a n e l
Cl i p
Bracket
S e l e c tC o n t r o lC a b l e
Grommet
lA 12l12O,9l
Bushing-- -8
S hi f t C o n t r o lC a b l e
dJ
g-[ 4, (5o13r".1btt--l
a 5 . 4( 5 5 , 4 ei n I
Clip
PaintedMark
H e a tl n s u l a t o r
N m ( 'cm, ft lbf) : S p e c i f i e dt o r qu e

MX-74
C52 MANUAL TRANSAXLE_ SERVICE
SPECIFICATIONS
SERVICE
SPECIFICATIONS
DATA
SERVICE
Input shalt roll6rb6aringjournaldiamotor Limit 24,970mm (0.9831in.)
Input shaft srd g6Erjourn8l diametor Limit 3 0 , 9 7 0m m ( 1. 2 19 3 i n . )
Input lhaft 4th g6ar journal diametgr Limit 2 8 . 9 7 0m m ( l . 1 4 0 5i n . )
Input 8h!ft sth goar Journaldi6mster Lrmrt 24.870mm (0.9791in,)
Input lhrft runout Limit 0.05mm (0.0020in,)
OJtput shaft roll6rbEaringjournaldiamst€r Limrt 3 2 . 9 7 0m m ( 1 . 2 9 8 0
in.)
Output shaft lst ggar tournaldiamot€r Limit 3 7 . 9 7 0m m ( 1 . 4 9 4 9i n . )
Output shalt 2nd goar journaldiamotor Limit 3 l . 9 7 0 m m { 1 . 2 5 8 7I n . J
Output shaft runout Limit 0.05 mm (0.0020in.)
G6arthru3t clearanco l6t sTD 0 . 1 0 0 . 4 0m m 1 0 , 0 0 3-9 0 . 0 1 5 7i n . )
-
Limit 0 . 4 5m m ( 0 , 0 1 7 7 in.)
Gearthrustcloaranco2nd STD - -
0 . 1 0 0 . 4 5m r r ( 0 . 0 0 3 9 0 . 0 1 7 7i n . )
Limit 0 . 5 0m m ( 0 . 0 1 9 7in.)
G€arthrustclosranco3rd STO -
0 . 1 0 0 . 3 5m m ( 0 . 0 0 3 "
9 0 . 0 1 3 8r n . )
L t mt t 0.40 mm (0.0157in.)
Gea. thrust c .aranc6 4th STD 0.10 - 0.55mm {0.0039- 0.0217in.)
Lrmit 0.60mm (0.0236in.)
Gsar thrust cloaranc6 sth STD 0.10 - 0.57mm (0.0039- 0.0244i^.1
Limit 0 . 6 5m m ( 0 . 0 2 5 6
in.)
G6ar radialcl6aranc6 1st, 2nd, 3rd, 4th snd sth STD 0.015 0.058mm (0.0008- 0.0023in.)
-
Limit 0.070mm (0.0028in.)
Shift to.k to hub sl66vecloarancs Limit 1 . 0 m m ( 0 . 0 3 9i n . )
Synchronizerring to g€ar cloarancs Limit 0.8 mm (0.024 in.)
Drivs in dopth
Controlshaft cov6r oil seal 1 . 0- 2 . 0m m ( 0 . 0 3 9- 0 , 0 7 9i n . )
Tran6mis6ion
case oil soal 2 . 4 i 0 . 3( 0 . 0 9 4t 0 . 0 1 2i n . )
Transax6 cas6 oil 6oal 2 . 4 t 0 , 3( 0 , 0 9 4l : 0 , 0 1 2i n . )
S6l6ctinn6r l6v6rslott6d spring pin 0 t 0.5 mm (0 t 0.020in.)
No. 1 6hift innor lever slottodspring pin 0 t 0 . 5m m ( 0 I 0 . 0 2 0i n . )
No. 2 !hift Innar lov6rs ottod spflng prn 3.5 t 0.5 mm (0.138 i 0.020in.)
Input 8h.ft Bnapring thickn6ss
No.2 clutch hub Mark 0 2.30mm (0.0906in.)
Mark1 2.36mm (0.0929in.)
Msrk2 2.42mm (0.0953in.)
M a r k3 2.48mm (0.0976in.)
M a r k4 2 . 5 4m m ( 0 . 10 0 0 i n . )
M a r k5 2 . 6 0m m ( 0 . 10 2 4 i n . )
R6arboaring Mark A 2 . 2 9m m ( 0 . 0 9 0 2
in.i
Mark B 2 . 3 5m m( 0 . 0 9 2 5
in.)
M a r kC 2.41lnm (0.0949in.)
MarkD 2.47mm (0.0972in.)
MarkE 2.53mm (0.0998in.)
Mark F 2 , 5 9m m ( 0 . 1 0 2 0
in.)

MX.75
c52 MAI{UAL TRANSAXLE- SERVICE
SPECIFICATION9
Output shaft snap ring thickness

N o . 1c u t c h h u b M a r kA 2,50mm (0.0984in.)
M a r kB 2 . 5 6m m ( 0 . 1 0 0 8
in.)
M a r kC 2 . 6 2m m ( 0 . 1 0 3 1
in.)
MarkD 2 . 6 8m m ( 0 . 1
0 5 5i n . )
MarkE 2 . 7 4m m( 0 . 1 0 7 9in.)
MarkF 2.80 m m ( 0 . 1 1 0 2
in.)
N o . 3c l u t c hh u b M a r kA 2.25mm (0.0888in.)
M a r kB 2.31mm (0.0909in.)
M a r kC 2.37mm (0,0933in.)
MarkD 2.43mm (0.0957in.)
MarkE 2.49mm (0.0980in.)
MarkF 2.55mm (0.1004in.)
M a r kG 2 . 6 1m m ( 0 . 1 0 2 8
in,)
Diffs16ntiaside bearingproload(at startlng)
Now bearing 0.8 - 1.8 N.m 8 - 18 kgf cm 8.9 - I 3.8 in..lbf
Rousedbearing 0.5 - 1.0N.m 5 - l0 kgt.cm 4.3 - 8.7 in.lbl
D ' f f e . € n t r a lp r n r o nt o s i d o g € a r b a c k a s h 0,05 - 0.20mm (0.0020- 0.0079in.)
Diff€r6ntialsid6 gear thrust washerthickn€ss
Nono Mark 0.95mm (0.0374in.)
N o n eM a r k 1.00mm (0.0394in.)
None Mark 1 . 0 5m m ( 0 , 0 4 1 3
in,)
N o n eM a r k 1 . 1 0m m( 0 . 0 4 3 3in.)
N o n 6M a r k 1 . 1 5m m( 0 , 0 4 5 3
in.)
N o n 6M 6 r k 1.20mm (0.0472in.)
Oiff6r6nti€lsido bearingadiustingshim thicknoss
2 . 1 0m m ( 0 . 0 8 2 7
in.)
M a r kB 2.15mm (0.0848in.)
M a r kC 2.20mm (0.0886in,)
MarkD 2.25mm (0.0886in,)
MarkE 2.30mm (0.0908in.)
MerkF 2.35mm (0.0925in.)
M a r kG 2.40mm (0.0945in.)
MarkH 2.45mm (0.0985in.)
M s r kJ 2.50mm (0.0984in.)
MarkK 2 . 5 5m m ( 0 . 1 0 0 4
in.)
M a r kL 2 . 8 0m m ( 0 . 1 0 2 4
in.)
MarkM 2.65mm (0.1043in.)
M a r kN 2 , 7 0m m( 0 . 1 0 6 3
in.)
M a r kP 2.75mm (0.1083in.)
M 6 r kO 2 . 8 0m m ( 0 . 1 l 0 2i n . )
M a r kR 2 . 8 5m m ( 0 . 11 2 2i n . )
M d r kS 2 . 9 0m m ( 0 . 11 4 2i n , )
M a r kT 2 . 9 5m m( 0 . 1 1 6i1n , )
MarkU 3 . 0 0m m( 0 . 11 8 1i n . )

MX-76
C52 MANUALTRANSAXLE- SERVICE
SPECIFICATIONS
TOROUE
SPECIFICATIONS
Part tightened N.m kgf cm ft.tbf
T r s n s a x xl €E n g i n o 1 2 m mb o l t 64 650 41
1 0m mb o l t 46 470 34
Transaxlox Engine(Roar6nd plate side) 17
Engin6l€ft mountingbrack6tx Engin6lo{t mountinginsulator 64 850 47
Engin€lront mountingbrackotx Transaxle 77 790 57
Engin6tront mountingbrack€t)( En9in6front mountinginsulator a7 890 64
E n g i n 6r 6 a rn o J n t r n gb r s c k € tx T r a n s a x l e 77 790 57
Engin6r6ar mountingbrack€tx Enginersar mountinginsulator 87 890 64
Contercrossmsmb6rx Eody 35 360
Centercrossmemberx Engin€lront nounting insulstor 80 420 59
C6ntercrossmomb6rx Engin€rear mountinginsulator 80 820 59
Start6rx Transaxlo 400
Exhaustpip6 support brack6tx Engin6rear mountinginsulator l9 t95 14
Erh6ost pipo sopport brack6tx Susp6nsionm6mbor 195 14
Exhsusttront pipo x Exhaustconter papo 42 430
Exhaustfront oi06 x Exhaustmanifold 46
Oxygens6nsorx Erhausttroht pip6 20 200 14
Exhaustfront pip6 x Exhaustpip6 support brack€t 25 250 t8
Clutch r€leas6cylind6rx Transsxle 120 9
Shift ovor assemblvx Eodv 120 s
Grommotx Body 4.9 50 43 in..bt
Transmissioncontrol cable brackotx Body 4.9 50 43 in..bt
Heatlnsulstorx Body 5.4 48 in. lbf
Transmissioncaso x Trsnsaxlocas6 300 22
transmrsstoncas6 x transmtsstoncas6 cov€r 18 185
Output shaft front boaringlock plato 11 115
Straightscrew plug (Rev6rso16strictpin) 130 I
Straightscrow p ug 250 18
Transaxlecase r6c6iv6rx Trans6xl€cas6 l l 115 I
Differontialcas€ x Ring g€ar 97 71
R6ver56shift arm brackotset bo t t1 175
N o . 1 . N o . 2 a n d N o . 3 s h i f tf o r k s o t b o l t 160
Lock ball assembly 400 29
Rovers6idl€r g6ar shsft Iock bolt 29 300
Rearb6aringretainerx Transmissioncase 2ao 20
5th driven gear ock nut 1,200 a7
Shift snd select lsver shatt assomblyx Transmissaon
cas€ 20 200 l4
Shift and s€1ectlev€r shaft assemblylock bo t 300

Front bearingr6tainerx Clutch housing 1 l 110 8
Contro 6v6r housingsupport bracketx Transaxlocas6 1 1 115 8
No. 1 and No. 2 oil receivorDio6sot bolt 17 175
Seloctingbellcrankassofibly x Transmissioncase 250 18
Back-up light switch 40 410 30
Sp66d6ensor 1 1 115
Filler6nd Drain plugs 39 400 29
C utch relsasofork suooort 375

MX-1
S 5 4 M A N U A LT R A N S A X L E
A N D I N S T A L L A T I O.N. . . . . " . . . ' ' " MX- 8

C O M P O N E NPTA R T SR E M O V A L MX- 20
I N P U TS H A F T MX- 33
o u r P U TS H A F T . . . . . . . ' MX- 40
S H I F TA N D S E L E C TL E V E RS H A F T . . . , . . . . '
MX- 48
D T F F E R E N TC I AALS E . . . . . . . . . . . . ' . . MX- 53
C O M P O N E NPTA R T SI N S T A L L A T I O N . ' ' ' . . N4X-61
A N D C O N T R OCL A B L E. ' ' " . M X - 7 0
S H I F TL E V E R
S E R V I CSEP E C I F I C A T I O N S MX- 71

MX-2
S54 MANUALTRANSAXLE- DESCRIPTION
DESCRIPTION
GENERAL
. A triplo-cons typo synchromoshmechanismis used in the 2nd gear to improvoth€ shift
feelingcharacteristics, This helpsto r€ducethe shiftingeffort.
. A rev€rsesynchromeshmechanismis used to suppressg6ar engag€montnoise in reverse
g e a rs h i f t i n g .
Typ. ot Tr.ns8xle s54

Typeof Engins
G o a rR a t i o lst g6ar 3.285
2nd 966l l 960
3rd gsar 1.322
4th goar 1.028
sth g€ar 0.820
Rov6rsoggar 3.1s3
q3.736
Difto16ntialG68r Ratio 3.94! ''4.118
Oil Capocity 2.8 litors (2.7 US qt6,2.3 lmp. qt6)
O i lV i s c o s i t y s A E7 5 W - 9 0
A P IG L - 3 , G L - 4 o r A T FD E X R O N ' I I
' ' : F o rA u s t r a l i a
'r: For G.C,C.

MX.3
S54 MANUALTRANSAXLE_ OPERATION
OPERATION
o T h e i l l u s t r a t i o nb e l o w s h o w t h o e n g a g g m 6 n t so f t r a n s a x l eg e a r s '
1 s t Dr i v eG e a r 2 n d D r i v eG e a r
Differential
Dr i v eG e a r
2 n dD r i v e n
Gear
Differential Di f f e r e n t i a l
Assembly A s s em b l y
lst 2nd
3 r d D r i v eGe a r 4 t h D r i v eG e a r
i
DiffBrential
D r i v eG e a r
4th Driv€n
Gear
Differential Di f f e r e n t i a l
Assembly Assembly
R e v e r s eD r i v eG e a r
ReverseDrivenGearj'<
5 t h D r i v e nG e a r
- "'"-"'% l
t.f z
J$ftc%*Jc I
Oi f l e r e n t i a l f ?
L i E D ifterential
Assembly
Re v , A s s em b l y
"hr"d
A.A'

MX-4
S54 MANUALTRANSAXLE. PREPARATION
PREPARATION
ssT (sPEcrAL
SERV|CE
TOOLS)
09308-00010 OrlS€alPullor Inputshaft front b€aring
Outputshaft front bearing
09309-12020 sth OrivenG€arRoplac€r
09310-35010 Count6rshaftBsaring
R€plecer Inputsheft front bsaring
Outputshaft front b€aring
w:s- 09316-60010 Transmission

R€placer
& TrrnsferBearing
- 0 0 0 1 0 ) R o p r a c oP,i p e
(09316
ffiF (09316-00040)R€placor'c'
/@i\
09350-32014 ToYoTAAutomstic
T
-32120) ovordrveBsanng
(09351 Roplacer 0ifferentialsrdobearng
( 0 9 3 5- 3r 2 1 3 0 )
( 0 9 3 5 1 - 3 2 1 5o0i )lS o a l R€placer D r f f 6 r € n t r a ls i d e b 6 a r i n g

Oil s6al firansaxl€ case side)
[S:2
09564-3201I 0iffer€ntialPr€loadAdaptor
0 9 6 0 8| -2 0 1 0 FrontHub & oriv€ PlnionBsaring

iltq;,rtl & Replac€r
s€t
*: - c_9 g I
(09608-00070) DrivePinon R6arBearns Cone lnput shaft r€ar bearing
Roplacgr 4th driv€ 96ar and r€ar b6aring

MX.5
S54 MANUALTRANSAXLE- '*SP4PNTION
-20012
09608 Front Hub & Drive Pinion Bearing
-@o
e:e-
(09608-00080)
R€pLac6r Input shaft front oil s€al
I Control shaft covor oil seal
g
(09608-03020)Handl€
64
(09608-03060)RePlacer 0iff€r6ntialtapsr rollerbearrng
l ( - \
\7
Roplecor
Boaring
09612-22011 TiltHendlo Outp!t shaft r€ar b€aring
No.3clutchh!b
09950-00020 BearingRemover
09950-00030 BoaringRomoverAttachment
09950-30010 Pull6rA sot

3. t I:.2.^=F
{-+tf!---;"- -a !'
"e"WY*:- 0 9 9 5 0 - 4 0 0 1 0P ! l l e B
r s€t

MX-6
S54 MANUALTRANSAXLE_ PREPARATION
OOLS
09025-00010 srnallTorqueWronch 0itl€rsntrel preload
09031-00030
0 9 9 0 5 - 0 0 0 1 2 S n a pR n s N o 1 E x p a n d e r
EOUIPMENT
D i a li n d i c a t o r
T o r q u ew r e n c h
F e e l e rg a u g e
LUBRICANT
Item Cspscity Classification
APIGL- 3, GL 4 or ATF DEXRON'
II
Manualtransax6 oil 2.6 lito.s (2.7 US qts,2.3 lmp.qts)
s A E7 5 W - 9 0
ssM (sPEctALSERVICE
MATERIALS)
0 8 8 2 6 - 0 0 0 9 0 S 6 aPl a c kn s 1 2 8 1 . T r e n s r n i s s r o nc a s e x T r a n s a x l 6
T H R E8EO N 01 2 8 1o r e q uv a l € n t
(FtPG) T r a n s m i s s r o nc a s e x C a s e c o v e r
08833-00080 Adh€siv€
1344. Straighrscrewplug
THREEBOND' 344, Controlshaft cov€rbolt
LOCTITE
242or equiv6l€nt

- TROUBLESHOOTINd
s54 MANUALTRANSAXLE
TROUBLESHOOTING
Use the table beiow to helpyou find the causeof the problem.The numbersindicatetne prlli'iit'V
of the likelvcauseof the problem.Checkeach part in order.lf necessary,replacethese parts.
(' C'
SeePage a N
X X X X x x x i x X
Pa.ls
E
Name E o
c '.
c
d)
' E
= o 3 3 c
3 o)
Trouble ) 3
(J ) q I
Noise 1 2 3 3
O leakage 1 2 2 3
Hard io shift or will not shift 2 3
J umpsoul ol gear 2 3 3
PRECAUTION
When workingwith FIPGmatorial,you must observethe following'
o Using a razor bladeand gasket scraper,removeall the old FIPGmaterialfrom the gasket
s u rfacgs.
r T h o r o u g h l cy l e a na l l c o m p o n e n ttso r e m o v ea l l t h s l o o s om a t e r i a l '
. Cl6anboth sealingsurfacss with a non- residuesolvent.
o A p p l yt h e F I P Gi n a n a p p r o x .1 m m ( 0 . 0 4i n . )w i d e b e a da l o n gt h e s e a l i n gs u r f a c e .
. p a r t sm u s t b e a s s e m b l e d w i t h i n 1 O m i n u t e so f a p p l i c a t i o nO. t h e r w i s et ,h e F I P Gm a t e r i a l
must be removedand reaPPlied.

MX-8 _ ASSEMBLY
S 5 4 M A N U A LT R A N S A X L E R E M . V A LA N D I N S T A L L A T I . N
INSTALLATION
Removeand installthe parts as shown below.
5 S - F E/ 3 S - F EE n g i n e
? r-f w/ cruisecontrol:
I conlrol
Actuator A i r C l e a n er
clutchRe'ease
cvtinder,F [-, /-c'uise
,*fu( 4W> e
? A s s em bl y
| ,/ M, "4--
@'
MX :._4v
Clip
o
-r!_ P
l
-L-g*%]
*%"er
D r i v eS h a f l( F i H )
* ' - 1I
II
6 was
D r i v eS h a l t ( L H )
S t i f f e n eP
r lale
Nq @'l
Starter 4 9( s 0 0 , 3 6 )
e
I
l\l
\5
t-
E n g i n eU n d e rC o v e r( F t H l
l€ @-;
s
&
I g*@
T
P i p e( 5 S - F E )
I szrsso.ger
I
:F<)
43 (440,32)
E n g i n eU n d e rC o v e r( L H )
FronE t xhaust
P i p e( 3 S - F E )
N r n ( k g fc m , t l l b f ) : S p e c i l i e dt o r q u e
a N o n - r e u s a b lpea r l

"*-N
S54 MANUAL TRANSAXLE_ ASSEMBLYREMOVALAND INSTALLATION
3 S - G EE n g i n e
D r i v eS h a f t( B H )
Batlery
D r i v eS h a f t( L H )
Tie RodEnd
Starter
l.^ r@ ---a l4,(sooJ6tl
\\ #(.> , al C-o t t e Pr i n
S'Y S u p p o rBt r a c k e t
t fl
L o c kN u t C a p
e
I
I
lLl lI
\l
L
Engine Under Cover (RH)
t
tr -Qr- '
E n g i n eU n d e rC o v e r( L H )
F r o n tE x h a u sPl i p e
N m ( k g lc m , l t l b l ) ; S p e c i l i e dl o r q u e
a N o n - r e u s a bpl a
er t

MX-10
ss4 MANUALTRANsAxLE- AssEMBLyREMovALANDINSTALLATIoN
REMOVAL
TRANSAXLE
( _ ) T E R M I N A LC A B L E
FROMBATTERY
CAUTION: Work must be startad alter 90 saconds from
'LOCK'
tha timo the ignition switch is turned to tha
p o s i t i o na n d t h e n e g a t i v s ( - ) t e r m i n a l c a b l e i s d i s c o n -
nected from the battory.
2. REMOVEBATTERYAND AIR CLEANERCASEAS.
SEMBLYWITHAIR HOSE
3. CONTROL:
w/ CRUISE
REMOVECRUISECONTROLACTUATOR
(a) Disconnectthe connector.
(b) Removethe 3 bolts and cruisecontrol actuatorwith
brac ket.
4. REMOVE STARTER
(a) th6 connectorandwire from the starter,
Disconnsct
(b) Removeth6 2 boltsandstart6r.
5. REMOVE C L U T C HR E L E A SCEY L I N D EA
RN DT U B E
CLAMPS
5 5 - F E , / 3 S - F EE n gi n e :
ta) Removethe 2 boltsand release cylindsr.
(b) Removethe 2 boltsand 2 tube clamps.
35-GE Engine:
(a) Removeth6 2 bolts and heat insulator.
(b) Removethe 2 bolts and releasecylinder.
(c) Removethe 2 bolts a nd 2 t u b e c l a m p s .

S54 MANUAL TRANSAXLE- ASSEMBL
6. REMOVE CABLE
GROUND
;Q
7, BTA C K - U P L I G H T S W I T CCHO N N E C .
DISCONNEC
M
TOR
8. DISCONNECT CONTROL CABLES

(a) Removethe 2 cliPsand washers.
(b) Removethe 2 clipsfrom the cablas.
9. SENSOC
STP E E D
DISCONNEC RONNECTOR
1 0 , R E M O V ET R A N S A X L EM O U N T I N GB O L T S
5 S- F E l 3 S- F E E n g i n e :
Removethe 3 bolts of transaxlscase upperside.
35-GE Engine:
Removeth6 4 bolts of transaxlecase upperside.

MX-l2
ss4 MANUAL TRANsAxLE- ASSEMBLyREM.'AL AND TNSTALLATT'N
1 1 . R E M O V EE N G I N EL E F T M O U N T I N GB O L T A N D
NUTS
Removethe bolt and 2 nutsof engineleft mounting
u o o o sr r d e .
1 2 . I N S T A L LE N G I N E
S U P P O RFTI X T U R E
13. REMOVE FRONT WHEEL
1 4 . R A I S EV E H I C L E
N O T I C E :B a s u r e t h e v e h i c l ei s s e c u r e l ys u p p o r t e d .
15. REMOVE UNDER COVERS
1 6 . D R A I NT R A N S A X LO EI LO R F L U I D
17. REMOVE L H A N DR H D R I V ES H A F T S
( S e ep a s eS A - 6 1 )
18. REMOVE F R O N TE X H A U S P
T IPE
(a) Removeths 2 nutsand2 bolts.
(b) Removeth6 nut, 4 bolts and exhaust pipe support

b rac ket.
(c) 5S-FE Engine:

Removethe 3 nuts and front exhaust oioe with the
gasket.

- ASSEMBLY MX 13
s 5 4 M A N U A LT R A N S A X L E ANDINSTALLATION
REMOVAL
35-FE Engine:
R e m o v et h e 3 n u t s a n d f o r n t s x h a u s tp i p €w i t h t h e 2
gaskets.
3S-GEEngine: ^ F
R e m o v et h e 3 n u t s a n d f r o n t e x h a u s tp i p ew i t h t h e 2 ffi
gasl(€1s.
F R O N TM O U N T I N G
19. REMOVE NGINE
( a ) R s m o v et h e h o l ep l u g .
(b) Removethe nut and bolt.
( c ) R e m o v et h e 4 b o l t sa n d e n g i n af r o n t m o u n t i n g .
20. R E M O V EE N G I N ER E A RM O U N T I N G
(a) R e m o v st h e 2 h o l ep l u g s .
(b) R e m o v et h e t h r o u g hb o l t .
(c) R e m o v et h e 4 b o l t s ,2 n u t sa n d e n g i n er e a rm o u n t i n g
21. REMOVE NGINE L E F TM O U N T I N G BOLT

R e m o v teh e b o l to f e n g i n el e f t m o u n t i n lgo w e rs i d e

Mx'14
sE4 MANUAL TRANSA*LE- ASSEMBLyREM''AL AND TNSTALLATT'N
22. REMOVE CENTER MEMBER

(a) Removethe bolt and pipebracket.
(b) Removeths 2 boltsandcentermsmber.
23. REMOVE S T I F F E N EPRL A T E

Removethe 6 bolts,nut and stiffenerplate.
24. JACK UP TRANSAXLESLIGHTLY

U s i n ga t r a n s m i s s i oj n
a c k ,s u p p o r t h e t r a n s a x l e .
25. REMOVT
ER A N S A X L E
( a ) R e m o v et h e t r a n s a x l em o u n t i n gb o l t s .
( b ) L o w e rt h e e n g i n el e f t s i d e a n d r e m o v et h e t r a n s a x l e
f romthe engine.

- ASSEMBLY MX.15
S 5 4 M A N U A LT R A N S A X L E ANDINSTALLATION
REMOVAL
t5-f E / J5-rE Englne T R A N S A X LIEN S T A L L A T I O N

( S e ep a g eM X - g )
1 . I N S T A L LT R A N S A X LTEO E N G I N E
A l i g nt h e i n p u ts h a f ts p l i n ew i t h t h e c l u t c hd i s ca n d
i n s t a ltlh e t r a n s a x lteo e n g i n e .
Bolt A
T o r q u e :6 4 N . m ( 6 5 0 k g f . c m , 4 7 f t . l b f )
o04961 Bolt B
T o r q u e :4 6 N . m ( 4 7 0 k g f . c m , 3 4 f t l b f )
3 S - GE E n g i n e
Bolt C
2. I N S T A L LS T I F F E N E R PLATE
Install the stiffener plate with the 6 bolts and nut.
Alternatalytightenths boltsand nut in soveralpasses.
Engineside
Transaxle side
T o r q u e : 2 1N . m{ 2 1 0k g f . c m 1, 5 f t . l b f )
3 . I N S T A L LC E N T E R MEMBER
( a ) I n s t a lt lh e c e n t e m
r a m b ear n dt o r q u et h e 2 b o l t s ,
(b) Installth6 pipe bracket with a bolt.
4. L E F TM O U N T I N G
I N S T A L LE N G I N E BOLT
Torquethe boltof enginalaft mountinglowersids.
T o r q u e :6 4 N m ( 6 5 0 k g f . c m . 4 7 f t . l b f )

MX-16
s 5 4 M A N U A LT R A N s A x L E- A S S E M B L yR E M o v A LA N D T N S T A L L A T T o N
R E A RM O U N T I N G
5 . I N S T A L LE N G I N E
(a) Installthe enginerear mounting,torquethe 4 bolts
and 2 nuts.
T r a n s a x l es i d e :
T o r q u e : 7 7N . m ( 7 9 0 k g f . c m , 5 7f t . l b f )
C e n t e r m e m b e rs i d a :
T h r o u g hb o l t :
T o r q u e :8 7 N . m ( 8 9 0 k g l . c m , 6 4 f t l b f )
( b ) I n s t a l lt h e 2 h o l e p l u g s .
6 . I N S T A L L E N G I N EF R O N T M O U N T I N G
( a ) I n s t a l lt h e e n g i n e f r o n t m o u n t i n g a n d t o r q u e t h e 4
b ol t s .
T r a n s a x l ss i d o :
T o r q u e :7 7 N . m ( 7 9 0 k g f . c m . 5 7 f t . l b f )
C e n t e r m e m b e rs i d e :
T o r q u e :8 7 N . m ( 8 9 0 k g f . c m , 6 4 { t . l b f )
( b ) I n s t a l lt h e h o l e p l u g .
7. INSTALL FRONT EXHAUST PIPE
5S-FE Engine:
(a) Install the front oxhaust pipe with a new gasket
and torqueths 3 nuts.
35-FE Engine:
Installthe front exhaustpipe with 2 now gasketsand
t o r q u et h 6 3 n u t s ,
Torque:62 N.m(630kgf.cm,46lt.lbf)
35-GE Engine:
\ Installthe front exhaustpipe with 2 new gasketsand
torqus th6 3 nuts.
T o r q u e : 6 2N . m( 6 3 0k g t . c m , 4 6t t . l b f )

lT
S54 MANUAL TRANSAXLE- ASSEMBLYREMOVALAND INSTALLATIO
(b) Installthe exhaust pipe support bracket,torque the
nut and 4 bolts.
Torque:19 N.m(195kgf cm, 14 ft lbf)
(c) Installa nsw gasket,torquo tho 2 bolts and 2 nuts

Torque:43 N.m(440kgf'cm. 32 ft lbf)
8. INSTALL LH AND RH DRIVESHAFTS

( S e eP a s eS A - 7 0 )
9. FILL TRANSAXLEWITH GEAROIL
Oil grade:
A P IG L - 3 , G L - 4 o r A T F D E X R O N ' U
Viscosity:
sAE 75W- 90
Above- 18"C(0"F)SAE90
Below- 18'C (0'F)SAE75W
Capacity:
2.6 liters(2.7US qts,2.3 lmP.qts)
1 0 . I N S T A L LU N D E RC O V E R S
1 1 . I N S T A L LF R O N TW H E E LA N D L O W E RV E H I C L E
1 2 . R E M O V EE N G I N ES U P P O R T FIXTURE
1 3 . I N S T A L LE N G I N EL E F T M O U N T I N GB O L T A N D
NUTS
T o r o u et h e b o l t a n d 2 n u t so f e n g i n el e f t m o u n t i n g
u D o asr i d e .
T o r q u e :6 4 N . m ( 6 5 0 k g f ' c m , 4 7 f t l b f)

MX-l8
ss4 MANUAL TRANSAxLE- ASSEMBLyREMovAL AND TNSTALLATToN
1 4 . C O N N E CS
TP E E D
SENSOC
RONNECTOR
1 5 . C O N N E C TC O N T R O LC A B L E S
(a) Installthe 2 clipsto the cables.
(b) Connectthe 2 cablesto th6 linkagewith washersand
cl i o s .
,I6. CONNECT
B A C K_ U P L I G H TS W I T C HC O N N E C -
TOR
CABLE
T o r q u e :2 l N . m ( 2 1 0 k g f c m , 15 f t . l b f )
a,c../
o
1 8 , I N S T A L LC L U T C HR E L E A SC
EY L I N D EA
RN DT U B E
CLAMP
55-FE,/3S-FE Engine:
(a) Installthe 2 tube clampsandtorquethe 2 bolts.
(b) Installthe ralease cylinderand torqueth6 2 bolts.
T o r q u e :1 2 N . m ( 1 2 0 k g f . c m , 9 f t . l b f )

MX.19
_ ASSEMBLY
S 5 4 M A N U A LT R A N S A X L E ANDINSTALLATION
REMOVAL
35-GE Engine:
(a) Installthe 2 tube clampsand torque the 2 bolts.
(b) Installthe releasecylinderand torque ths 2 bolts
Torque:12 N.m(120kgf'cm,I ft'lbf)
(c) lnstallthe heat insulatorand torque tho 2 bolts
Torqua:12 N'm (120kgf cm, g ft lbf)
19. INSTALLSTARTER
(a) Installthe starlarandtorquethe 2 bolts.
T o r q u e :3 9 N . m ( 4 0 0 k g f c m , 2 9 f t ' l b f )
(b) Connect ths connoctor and wire to ths startsr.
20. w/ CRUISE CONTROL:

INSTALLCRUISE CONTROL ACTUATOR
(a) Installthe cruisecontrolactuatorwith bracketand
toraue tha 3 bolts
(b) Connecttho connector.
2.I. INSTALLAIR CLEANERCASE ASSEMBLYWITH

AIR HOSEAND BATTERY
BATTERY
2 3 . I N S P E CFTR O N TW H E E LA L I G N M E N T
(SeepageSA-7)
Checkfor abnormal noisesand smoothshifting.

MX-20
S54 MANUAL TRANSAXLE- COMPONENT
PARTSREMOVAL
C O M P O N E NPTA R T SR E M O V A L
COMPONENTS
t z mmF+ toso,+ztl S h i f t a n d S e l e c tL e v e rA s s e m b l y
r---------------
1 Om m
1
Y(
A ^
Y)
A )
. 7 . 4 -/ .:7 56, a i n . . l b t l K L y ' 'WI
' .'- >
H e l e a s e l , e a r l n g_
Retainer
e c t r n gB e l l c r a n k
.1-%
eI rr',
i'.@ l\s
\aa..,..
F
t-5
YQn Irw
si,^1fffr
-'/A t r
R e l e a s eB e a r i n g-1(t(n) o o-Rino {,.
\v.^ _l I
# ^9X'-n SiaeK
riner
FS O Y
II T r a n s m i s s i o nC a s e P r o t e c t o r
R e l e a s eF o r k
Boot
R e a r B e a r i n gR e t a i n e r
"-
\ -
ttl
T2sr3oo, SnapRing
oi-
l r
'@^
5th Driven
t l
Gear
sth Gear ]
a L o c kN u t
No.3 ClutchHub Assembly
No.3HubSleeve
N o . 3 S h i J tF o r k
Transmission
C a s eC o v e r
N ' m ( k s f. c m , t t . l b f) : S p e c r f i e dt o r q u e
a N o n - r e u s a b l pe a r t
\o--------------*
lrt r..". ra
* P r e c o a t e dp a r t

MX-21
S54 MANUAL TRANSAXLE_ COMPONENT
PARTSREMOVAL
T r a n s a x lC
e ase
N o . 2 S h i i t F o r kS h a f t
T r a n s a x l eC a s e O i l R e c e i v e r
ReverseShift Fork
O Oil Seal
I
I
I No,1 Shift Fork
I
i
N o . 2 S h r ft F o r k
@r No.1 Shift Fork Shaft
7.4 (75,65 in.,lbf)
Shift Head
Y/'
/l(o :
\?# D i f f e r e n t i aA
l ssemblY
InputShaft FrontBearing
lnput Shaft
R e v e r s eS h i f t A r m
Output Shaft
R e v e r s el d l e r G e a r a n d S h a f t
Shaft FrontBearing
C o v er
N , m ( k q f . c m ,f t . l b f ) : S p e c i f i e dt o r q u e
, t N o n - r e u s a b l pe a r t

Mx-22 - coMpoNENTpARTsREMovAL
s54 MANUALTRANSAXLE
( S e ep a s eM X - 2 1 a n d M X - 2 2 )
1 . R E M O V ER E L E A S E F O R K ,B E A R I N GB A C K- U P
L I G H TS W I T C HA N DV E H I C L E
S P E F DS E N S O R
2. R E M O V ER E L E A S E
B E A R I N GR E T A I N E R
3. REMOVE ENGINE M O U N TB R A C K E A TNDSELEC.

T I N GB E L L C R A N K
(a) Removeth6 3 boltsand enginemountbracket.
( b ) R e m o v teh e 2 b o l t sa n ds e l e c t i nhge l l c r a n k .
4 . R E M O V ET R A N S M I S S I OC
NA S EC O V E R
(a) Removethe 8 bolts.
(b) Usinga plastichammer,tap off the transmissioncase
c over.
5. REMOVELOCKBALLASSEMBLY
AND PI."UG
(a) Removethe lockball.

MX-23
PARTSREMOVAL
(b) Usinga hexagonwrench,removeths plug.
'
6. REMovEsHtFrANDsELEcrLEVER
ASSEMBLY
{&i-}
7. REMOVEOUTPUTSHAFTLOCKNUT
(a) Unstakeths nut.
( b ) E n g a g teh e g s a rd o u b l em e s h i n g .
(c) Removethe lock nut clockwiseand removeit.

H I N T :T h e l o c k n u t h a s L H t h r e a d s .
( d ) D i s e n g a gteh e g e a rd o u b l em e s h i n g .
8. R E M O V EN O . 3 H U B S L E E V EA N D N O , 3 S H I F T
FORK
(a) Removethe No.3shiftfork set bolt.
l,'i

Mx-24 - coMpoNENT'ARTSREMovAL
ss4 MANUALTRANsAXLE
(b) Removethe No.3 hub sleevsand No.3 shift fork.
9. REMOVE s T HD R I V E N
GEAR
UsingSST.removethe Sth drivengear.
s s T0 9 9 5 0 - 4 0 0 1 0
1 0 . M E A S U RsET H G E A RT H R U S T CLEARANCE
r , e a s u rteh e t h r u s tc l e a r a n c e .
Standard clearance:
0.20-0.40 mm (0.0079-0.0157 in.)
Maximum clearance:
0 . 4 5 m m ( 0 . 0 17 7 i n . )
1 1 . M E A S U R5ET H G E A RR A D I A LC L E A R A N C E
r , e a s u rteh e r a d i acl l e a r a n c e .
S t a n d a r d c l e a r an c s :
0.009- 0.050mm (0.0004-0.0020in.)
Maximumcloaranca:
0.07mm (0.0028in.)
lf the clearancsexceedsthe maximum,replacethe
gear.needlerollerbearingor input shaft.
1 2 . R E M O V EN O . 3C L U T C HH U B A N D s T H G E A R
(a) Using2 screwdriversand a hammer,tap out the snap
ring.

MX-25
PARTSREMOVAL
( b ) U s i n g S S T , r e m o v et h e N o - 3 c l u t c h h u b w i t h s y n -
c h r o n i z erri n g .
ssT09950-30010
(c) Removethe 5th gear.
1 3 . R E M O V EN E E D L ER O L L E RB E A R I N G
S o c k e tW r e n c h
1 4 . R E M O V ER E A RB E A R I N GR E T A I N E R
1 5 . R E M O V EB E A R I N GS N A PR I N G S
U s i n ga s n a pr i n ge x p a n d e rr,e m o v et h e 2 s n a pr i n g s .
HINT:lf it is difficultto removethe snap rings,pull up
tha shafts,
I D L E RG E A R S H A F T L O C K
1 6 . R E M O V ER E V E R S E
BOLT
17. REMOVD E I F F E R E N T IS RETAINER

A ILD EB E A R I N G
A N DS H I M

MX-26 - coMpoNENTpARTSREMovAL
s54 MANUALTRANSAXLE
18. REMOVE TRANSMISSION CASE
(a) Rsmovethe 17 bolts.
(b) Usinga plastichammsr,
tap off the transmission
case.
19. REMOVEREVERSE IDLERGEARAND SHAFT

(a) Pullout the shaft.
(b) Removethe idl6rgearandthrustwasher.
20. REMOVEREVERSE SHIFTARM

(a) Shiftthe fork shaftinto reverse.
(b) Removeths 2 boltsandoulloff the reverseshiftarm.
2 1 . R E M O V EN O . 1S H I F TF O R KS H A F T ,N O . 1S H I F T
H E A D ,N O . 1A N D N O . 2S H I F TF O R K SR , EVERSE
KI N ,I N P U TA N D
S H I F TF O R KW I T H I N T E R L O CP
OUTPUTSHAFTSASSEMBLY
Removethe inout shaft assemblvand outout shaft
assambly togstherwithth6 No.1fork shaft,shifthsad
and shiftforkswith the interlockpin from ths trans-
axlecase.
CASEASSEMBLY
22, REMOVEDIFFERENTIAL

MX-27
_ COMPONENT
S54 MANUALTRANSAXLE PARTSREMOVAL
CASE
23. REMOVEMAGNETFROMTRANSAXLE
24. REMoVENo.2 FoRKSHAFT *t\r11:

E#s'se*4
(a) Using a hexagonwrench, romovethe straightscrew
plug.
(b) U s i n ga p i n p u n c ha n d h a m m e r d, r i v eo u t t h e s l o t t o d
springprn.
( c ) Pull out ths s haft.
25. SEPARATE NO.1FORKSHAFT'NO.1SHIFTHEAD,

N O . 1 ,N O . 2 S H I F TF O R K SA N D R E V E R SS EH I F T
FORK
( a ) M o u n t h e s h i f tf o r k st o t h e v i s e .
( b ) U s i n ga p i n p u n c ha n dh a m m e rd. r i v eo u t t h o s l o t t e d
springpinfrom the No.1fork shaft
(c) Usinga pin punch and hammer,drive out the slottad

s p r i n gp i n f r o m t h e N o . 1f o r k s h a f t a s s h o w n i n t h e
i l l us t r a t i o n .

MX-28 - coMpoNENTpARTsREMo'AL
ss4 MANUALTRANSAxLE
(d) Separatethe No.'l shift fork shaft, No.1 shift head.
No.1. No.2 shift forks and reverseshift fork.
2 6 , R E M O V EN O . 5 S Y N C H R O N I Z ER RI N G W I T H K E Y
S P R I N GF R O M N O . 3C L U T C HH U B
r
rA
:\-/.
( a ) R s m o v et h a N o . 5 s y n c h r o n i z erri n g w i t h k e y s p r i n g
f r o m N o . 3c l u t c hh u b .
'1 /l
i,l
li
(b) Usinga screwdriver,removethe snap ring.

HINT:Wrap vinyl tape on the screwdriverto prevent
d a m a g i n gt h e s y nc hr o ni z er r i n g .
(c) Removethe synchronizerrings.

MX.29
S54 MANUALTRANSAXLE_ COMPONENT
PARTSRETIOVAL
C O M P O N E NPTA R T SI N S P E C T I O N
1 . T N S P E CN T O . 5S Y N C H R O N I Z ERRI N G S
( a ) C h e c kf o r w s a r o r d a m a g s .
(b) Checkthe brakingeffect of the synchronizerring.
T u r n t h e m i d d l eN o . 5 s y n c h r o n i z er ri n g i n o n e d i r e c -
t i o n w h i l e p u s h i n gi t t o t h o o u t e r N o . 5 s y n c h r o n i z e r
r i n g .C h e c kt h a t t h e r i n g l o c k s .
l f t h e b r a k i n ge f f e c t i s i n s u f f i c i e n tr ,e p l a c et h e s y n -
c hr o ni z a rr i n g .
oF No.3sHlFrFoRKAND iiflilftW
GLEARANCE
2. lNsPEcr
N O . 3H U BS L E E V E
Usinga feelergauge,maasurethe clearancebstween
th6 hub slssveand shift fork.
Maximumcl6arance:
1. 0 m m ( 0 . 0 3 9 i n . )
l f t h e c l e a r a n c es x c e e d s t h a m a x i m u m , r e p l a c o t h e
3. IF NEGESSARY, REPLACEINPUTSHAFT FRONT

EEARING
{ a ) R e m o v teh e b o l ta n dt r a n s a x lcea s er e c e i v e r .

s s T0 9 3 0-8 0 0 0 1
0
(c) UsingSST,pressin a new bearing.

ssr09310-35010
2 9 2 2 r8 2 6 8 8

Mx-30 - coMpoNENTpARTSREM'vAL
ss4 MANUALTRANsAXLE
( d ) I n s t a l tl h e t r a n s a x l e
c a s er s c s i v e ar n d t o r q u et h e b o l t .
Torque:7.4 N.m(75 kgf.cm,65in..lbf)
4. IF NECESSARY, REPLACE OUTPUTSHAFTFRONT

BEARING
(a) Removethe bolt and bearinglockplate,
( b ) U s i n gS S T ,p u l lo u t t h e b e a r i n g .
s s T 0 9 3 0 8- 0 0 0 10
( c ) U s i n gS S T ,p r e s si n a n e w b e a r i n g .
1- 3 5 0 0
ssr 0930 1
ll
Ffont
I
s M 0 2 0 aM T 0 6 6 4
(d) Installthe bearinglock plateand torque the bolt.

T o r q u e1: 8 N . m( 1 8 5k g f. c m ,1 3 f t l b f )

_ C O M P O N E NPTA R T SR E M O V A L MX.31
S 5 4 M A N U A LT R A N S A X L E
5. IF NECESSARY, REPLACEINPUTSHAFT FRONT

O I LS E A L
pry out the oil seal.
( a ) Usinga screwdriver,
, r i v ei n a n e wo i l s e a l .
( b ) U s i n gS S T d
0-0.5mm s s r 0 9 6 0 8 - 2 0 021 ( 0 9 6 0 8 - 0 0 0 8 0 ,9 6 0 8 - 0 3 0 2 0 )
Drivein deoth:
0 - 0 . 5 m m ( 0 - 0 . 0 2 0i n . )
(c) Coat ths lip of tho oil seal with MP grease.
'--l
6 . I F N E C E S S A RREPLACE
Y, REVERSE RESTRICT PIN
g o n
( a ) U s i n ga h e x a wrsnch.ramovethe straight
screw
plug.
(b) U s i n ga p i n p u n c hand hammer.drive out the slottod

s p r i n gp i n .
(c) Replacetho reverserostrictptn.

MX-32
PARTSREMOVAL
( d ) U s i n ga p i n p u n c ha n d h a m m e r d
, r i v ei n t h e s l o t t e d
s p r i n gp i n .
Drivein depth:
' l3 . 5 + 0 . 5m m 13.5+ 0.5 mm (0.531+ 0.020in.)
(s) A p p l y s e a l a n tt o t h e p l u g t h r e a d s .
Sealant:
P a r t N o . 0 8 8 3 3 - 0 0 0 8 0 , T H R E EB O N D 1 3 4 4 . L O C -
TITE242 or oquivalant
(f) Using a hexagon wrench, install and torque the strai-
ght screw plug.
T o r q u e :1 3 N . m ( 1 3 0 k g f. c m ,9 f t . l b f)

MX-33
S54 MANUALTRANSAXLE_ INPUTSHAFT
I N P U TS H A F T
COMPONENTS
N e e d lRe o l l eBr e a r i n g
I
4rhGear
' , ,f l(\ . I I
RearEearins
ilL | |
Y@GM. l'n"0,''
,_ synchronizerRins WiU)/h
wo I
InputShatt
3rd Goal
NeedleRoller Bearing
No. 2 Hub Sleeve

@"
Koy Spring
3rd Gear INPUTSHAFTDISASSEMBLY

3 R D A N D 4 T H G E A RT H R U S TC L E A R -
1. INSPECT
ANCE
U s i n g a f e e l e rg a u g e . m e a s u r et h e c l e a r a n c e .
S t a n d a r dc l e a r an c e :
3rd gsar
O.1O - O ' 2 5m m ( 0 . 0 0 3 9 - 0 . 0 0 9 8i n . )
4th gear
O.2O - 0 . 4 5 m m ( 0 ' 0 0 7 9 - 0 . 0 1 7 7i n ' )
Maximumclearanca:
4th Gear
3rd gear
0 . 3 0 m m ( 0 . 0 11 8 i n . )
4th gear
0 . 5 0 m m ( 0 . 0 1 9 7i n . )

MX-34
S54 MANUALTRANSAXLE- INPUTSHAFT
2, INSPECT 3 R D A N O 4 T H G E A RR A D I A LC L E A R .
ANCE
U s i n gd i a li n d i c a t om
r , 6 a s u 1t 6
h e r a d i acl l e a r a n cbee -
tws6nthe gearandshaft.
Standardcleara nce:
0.009- 0.053mm (0.0004-0.0021in.)
Maximumclaaranca:
0.070mm (0.0028in.)
l f t h e c l e a r a n c e x c e e d st h e m a x i m u m ,r e p l a c et h e
3. REMOVESNAP RING
Using2 screwdriversand a hammsr,tap out ths snap
flng.
4, REMOVEREAR BEARING,4 TH GEAR, NEEDLE

ROLLEREEARINGS, SPACER AND SYNCHRONIZER
R I N GF R O MI N P U TS H A F T
(a) UsingSSTanda press,removethe 4th g6arand rear
b6anng.
s s T0 9 9 5 0 0
- 0020
(b) Removethe needlerollerbearings,
spacerand syn-
c h r o n i z er irn g .
5. REMOVE S N A PR I N G
U s i n ga s n a pr i n ge x p a n d erre, m o v et h s s n a pr i n g .
6. R E M O V EN O . 2 H U B S L E E V EA S S E M B L Y3, R D
G E A RS Y N C H R O N I ZREIR N GA N DN E E D L R E OLLER
BEARINGS
UsingSSTanda press,rgmovethe No.2hub sleeve,
3 r dg a a rs, y n c h r o n i zrei nr ga n dn e e d l e
r o l l eb
r earings.
-
s s T0 9 9 5 0 0 0 0 2 0
N O T I C E :B e c a r e f u l n o t t o m i s t a k o t h e 3 r d g e a r s y n .
c h r o n i z e rr i n g f o r t h a 4 t h g e a r s y n c h r o n i z e r i n g .

MX-35
7. REMOVE K E Y SA N D
N O . 2H U BS L E E V ES,H I F T I N G
S P R I N GFSR O MN O . 2C L U T C HH U B
1A Usinga screwdriver, removethe 3 shiftingkeysand2
iw"erc- \-' r(g

s p r i n g fsr o mt h e N o . 2c l u t c hh u b .
rNPUT
SHAFT INSPECTION
COMPONENTS ffi,ffi:
1 . I N S P E C TS Y N C H R O N I Z ERRI N G S
(b) Check the braking effoct of the synchronizorring.
Turn th6 synchronizer ring in one dirEctionwhile push-
ing it to tho gear cone.Checkthat the ring locks'
lf the braking 6ffect is insufficient,apply a small
a m o u n to f f i n e l a p p i n gc o m p o u n db s t w e e nt h e s y n -
c h r o n i z erri n ga n d g e a rc o n e .
Lightly rub tho synchronizsrring and gsar cone to-
gethor.
NOTICE: Ensuretho fine lappingcompound is completaly
washed off Efter rubbing.
(c) Check again the brakingeffsct of the synchronizer
nng.
(d) Usinga feelergauge,m€asursthe clearancebstween
t h e s y n c h r o n i z or irn g b a c ka n d g e a rs p l i n ee n d .
Minimumclearance:
0.6 mm (0.024in.)
HINT:
o When replacing6ithsr a synchronizerring or
cone.
Lightly rub the synchronizorring and gear cons
tog6ther.
. When replacingboth the synchronizerring and
g e a r ,t h e r ei s n o n e e dt o a p p l ya n y c o m p o u n do r
NOTICE: Ensuretho finelappingcompound is completoly

MX-36
S54 MANUALTRANSAXLE- INPUTSHAFT
2. I N S P E CC T L E A R A N COEF N O . 2S H I F TF O R KA N D
H U BS L E E V E
Usinga feelergauge,measurs the clearance
between
t h e h u bs l e e v e
a n ds h i f tf o r k .
Maximum clearancs:
1.0 mm (0.039in.)
lf ths clearanceexceedsthe maximum,reolaceshift
fork or hub sleeve.
{rid. 3 . I N S P E C TI N P U TS H A F T
( a ) C h e c kt h e i n p u ts h a f tf o r w s a r o r d a m a g e .
(b) Using a micrometer,measureths outer diameterof
the input shaft journalsurfacs.
Minimumoutardiamster:
Part A
26.970mm (1.0618 in.)
Part B
32.470mm (1.2783 in.)
Part C
33.090mm (1.3028in.)
Part D
2 9 . 9 7 0m m ( 1. 1 7 9 9i n . )
l f t h e o u t e rd i a m e t eirs l e s st h a nt h e m i n i m u mr.e o l a c e
the input shaft.
( c ) U s i n g a d i a l i n d i c a t o r ,c h e c k t h e s h a f t r u n o u t .
Maximumrunout:
0 . 0 5 m m ( 0 . 0 0 2 0i n . )
l f t h e o u t e r d i a m e t e re x c e e d st h e m a x i m u m . r e o l a c e
t h e i no u t s h a f t .

- tNlul s!-Alf MX.37
s54 MANUALTRANSAXLE
INPUTSHAFTASSEMBLY
( S e ep a s eM X - 3 3 )
Engine
Side HINT:Coatall of the slidingand rotatingsurfacewith
+ gear oil beforeassembly.
1 . I N S T A L LN O . 2C L U T C HH U B I N T O H U B S L E E V E
(a) Installthe clutch hub and shifting keys to the hub
steeve.
(b) Installth6 shiftingkey springsunderthe shiftingkeys.
NOTICE: Installthe key springspositionod so that thair
gaps not line.
end ars
INSTALL 3RD GEAR,NEEDLEROLLERBEARINGS,
,lMx'
SYNCHRONIZER RINGAND NO.2 HUB SLEEVEAS-
SEMBLYTO INPUTSHAFT
(al Apply gear orl to the needlerollerbearings.
(b) Placethe synchronizerring (for 3rd gear)on the gear
and alignthe ring slots with the shiftingkeys.
NOTICE: Oonot instsllthe aynchronizor ringfor 4th gasr.
(c) Using a press, install tho 3rd gear and No.2 hub
sleeve.
3. INSTALLSNAP RING
(a) Selecta snap ring that will allow minimumaxial play.
Mark Thickness mm (in.)
r . 9 s - 2 . 0 0{ 0 . 0 7 8 8 - 0 . 0 7 8 7 )
2.00-2.05 (0.0787-0.0807)
2.05-2.r 0 (0.0s07-0.0827)
4 -0.0846)
2.10- 2.15(0.0827
5 2.15-2.20 (0.0846-0.0866)
6 2.2O-2.25 (0.0866-0.0886)
(b) Usinga snap ring expander,installtha snap ring.

MX-38
4. INSPECT 3RDGEARTHRUSTCLEARANCE
Usinga feelergauge,measurethe 3rd gear thrust
c t e ar an c g .
0 . 1 0- 0 . 2 5 m m ( 0 . 0 0 3 9 - 0 . 0 0 9 8 i n . )
5. I N S T A L LS Y N C H R O N I Z ERRI N G .N E E D L ER O L L E R
B E A R I N G SS, P A G E R . 4 T HG E A RA N D R E A RB A L L
V' BEARING
(a) Apply gaar oil to ths needlerollerbearings.
FJ ( b ) I n s t a ltl h 6 s p a c e ra n d n e e d l er o l l e rb e a r i n g s .
c
tt
(c) Placethe synchronizerring on the gear.

H I N T :A l i g nt h e r i n g s l o t sw i t h t h e s h i f t i n gk e y s .a n d
the ring projectionswith the hub slots.
(d) UsingSST and a press,installthe rear ball baaring.

s s T 0 9 6 0 8 - 1 2 0 1 0( 0 9 6 0 8 - 0 0 0 7 0 )
6. INSTALLSNAPRING
( a ) S e l e cat s n a pr i n gt h a tw i l la l l o wm i n i m u m
a x i ap
l lay.
M6rk Thickness mm (in.)
2.15 - 2.20(0.0848-0.0866)
2,20- 2.25(0.0868 -0.08861
c 2 . 2 5 - 2 . 3 0( 0 . 0 8 8-60 . 0 9 0 6 t
2.30-2.35 (0.0906-0.0925)
2.35- 2.40(0.0925-0.0945)

MX-39
S54 MANUAL TRANSAXLE_ INPUTSHAFT
7. INSPECT4TH GEARTHRUSTCLEARANCE
U s i n ga f e e l a rg a u g s ,m e a s u r e4 t h g e a rt h r u s tc l e a r -
ance.
Standard clearanco:
-0.45 mm (0'0079-0.0177in.)
O.2O

MX.4O
S54 MANUAL TRANSAXLE_ OUTPUTSHAFT
COMPONENTS
Output Shalt
1 s t G e ar
MX
No.1 ClutchHub
il- qw/-
, _*-.,
a
N e e d l eR o l l e rB e a r i n g j - ' 6
,a<SS"'. I
sfil Barl
spacer
=( ,,jA
<W R9a "$>1
I ...*. ]I
| \_/ RearBearing
S y n c h r o ni z e r R i n g I I €t//.Ari I
I B(plA I
2ndcear I Y(r#l
-g(aja l
I
2 n dG e a ' B u s h iIn s \ff(@)
\>/
3rd Driven Gear
l st Gaar O U T P U TS H A F TD I S A S S E M B L Y
1. I N S P E C T1 S T A N D 2 N D G E A R T H R U S T C L E A R -
ANCE
Usinga feelergauge,measurethe thrust clearance.
l st gear
0 . 1 0 - 0 . 2 9 m m ( 0 . 0 0 3 9 - 0 . 0 1 1 4i n . )
znd gesr
O . 2 O - 0 . 4 4 m m ( 0 . 0 0 7 9- 0 . 0 1 7 3 i n . )
2nd Gear Maximumclearanca:
l st goar
0 . 3 5 m m ( 0 . 0 1 3 8i n . i
znd gear
0 . 5 0 m m ( 0 . 0 1 9 7i n . i

MX.41
S54 MANUALTRANSAXLE_ OUTPUTSHAF]
2. I N S P E C T1 S T A N D 2 N D G E A R R A D I A L C L E A R -
ANCE
be-
, e a s u r et h e r a d i a cl l e a r a n c e
U s i n gd i a l i n d i c a t o rm
tw6en the gear and shaft.
Standard clearance:
0.009- 0.053mm (0.0004-0.0021in.)
Maximum clearance:
0.070mm (0'0028in.)
l f t h e c l e a r a n c e x c e e d st h e m a x i m u m ,r e p l a c et h e
3 . R E M O V ER E A RB A L L B E A R I N G , 4 T H D R I V E NG E A R
MX
A N D O U T P U TG E A R S P A C E R
( a ) U s i n gS S T a n d a p r e s s ,r a m o v et h e r e a r b a l l b e a r i n g
a n d 4 t h d r i v e ng e a r .
s s T 0 9 9 5 0- 0 0 0 2 0
( b ) R e m o v et h e o u t p u tg e a rs p a c e ra n d b a l l .
4. REMOVE G E A R , 2 N DG E A RN
3 R DD R I V E N . EEDLE
BEARINA
ROLLER GN DS Y N C H R O N I Z E IRN G
R
{ a ) S h i f t t h e N o . 1 h u b s l e e v si n t o t h B l s t g e a r .
(b) Using SST and a press,remove the 3rd driven gear

and2ndgear.
ts s s T 0 9 9 5 0- 0 0 0 2 0
( c ) R a m o v et h e n e e d l er o l l e r b e a r i n ga n d s y n c h r o n i z e r
rings.
5. REMOVE NO. 1 HUB SLEEVE ASSEMBLY' 1 ST

GEAR, SYNCHRONIZER ING, NEEDLEROLLER
B E A R I N GT, H R U S TW A S H E RA N D L O C K I N GB A L L
( a ) U s i n ga p r e s s r, e m o v et h s N o 1 h u b s l e e v e l, s t g e a r
and svnchronizerring.
(b) Removethe needlerollerbearingand lockingball.

MX-42 - OUTPUT
S54MANUALTRANSAXLE SHAFT
(c) Usinga screwdriverand hammsr,driveout the thrust
wash€r,
6. REMOVENO.1HUBSLEEVE, SHIFTINGKEYSAND
€ S P R I N GFSR O MN O . 1C L U T C HH U B
E
**.-@, @

- OUtUr tltaET MX-43
TRANSAXLE
s54 MANUAL
PARTS
OUTPUTSHAFTCOMPONENT
INSPECTION
1 . I N S P E C T1 S T G E A RS Y N C H R O N I Z ERRI N G
(a) Checkfor wsar or damage.
(b) Check the braking effect of the synchronizerring.
w h i l ep u s h '
T u r n t h e s y n c h r o n i z er irn gi n o n ed i r e c t i o n
ing it to tho gear cone.Checkthat ths ring locks.
lf the braking effect is insufficient,apply a small
amount of fine lappingcompoundb€tweenthe syn'
chronizerringandgearcone,
ring and gear coneto- J8
Lightlyrub th6 synchronizer Wt
gelh6r.
NOTICE: Ensurstho fins lappingcompound ia complataly
washedoff aftoi rubbing.
(c) Check again the brakingeffect of th€ synchronizer
nng.
(d) Usinga feelergaugs,measurethe clearancsbetwsan
t h e s y n c h r o n i z er irn g b a c ka n d t h e g a a rs p l i n se n d .
Minimumclearance:
0.6 mm (0.024in.)
HINT:
r W h e n r e p l a c i n ge i t h o r a s y n c h r o n i z erri n g o r
p o u n d b e t w e a nt h e s y n c h r o n i z erri n g a n d g e a r
con€,
L i g h t l yr u b t h e s y n c h r o n i z er ri n g a n d g e a r c o n e
together.
o W h e n r e p l a c i n gb o t h t h e s y n c h r o n i z erri n g a n d
g e a r ,t h s r e i s n o n e e dt o a p p l ya n y c o m p o u n do r
to rub thom togethsr.
NOTICE: Ensurethe finelappingcompound is completely
washedofl a{ter rubbing'
2 . I N S P E C T2 N D G E A RS Y N C H R O N I Z ERRI N G
( a ) C h e c kf o r w e a r o r d a m a g e .
(b) Checkthe brakingeffsct of the synchronizer direction
w h i l ep u s h i n gi t t o t h e g e a rc o n e .C h e c kt h a t t h e r i n g
l o cks .
lf tha brakingeffsct is insufficient,replacethe syn-
c h r o n i z erri n g .

MX-44
S54 MANUALTRANSAXLE_ OUTPUTSHAFT
(c) Measursthe clearancebotweenthe synchronizerring

b a c ka n d g e a rs p l i n ee n d .
Minimumclearance:
0.7 mm (0.028in.)
lf the clearanceis less than the limit, reolacethe
synchronizer ring.
3. INSPECTSHIFTFORKSAND HUB SLEEVESCLEAR-

ANCE
Usinga feelergaugs,measurethe clearancebstween
th6 hub sleeveand shift fork.
Maximumclearance:
I . 0 m m ( 0 . 0 3 9i n . )
l f t h e c l e a r a n c ee x c s e d s t h e m a x i m u m . r e o l a c e t h a
4 . I N S P E C TO U T P U TS H A F T
(a) Using a micrometer.measurethe outer diameterof
the output shaft journalsurface.
Minimumouterdiameter.
PartA
3 1. 9 7 0m m ( 1 . 2 5 8 7 in.)
Part I
37.970mm (1.4949in.)
Part C
3 1 . 9 9 0m m ( r . 2 5 9 4i n . )
l f t h 6 o u t 6 rd i a m e t eirs l e s st h a nt h e m i n i m u mr.e o l a c e
the output shaft.
(b) Usinga dial indicator,check the shaft runout.
Maximumrunout:
0.05 mm (0.0020in.)
lf the runout exceeds the maximum. rsolace the
outout shaft.

MX.45
S54 MANUAL TRANSAXLE_ OUTPUTSHAFT
O U T P U TS H A F T A S S E M B L Y
( S e ep a g e M X - 4 0 )
q HINT:Coatall of the slidingand rotatingsurfaceswith
o
A @ *dI
-Vr
d
Front
1,
(a)
gear oil bsfore ass6mblY.
I N S T A L LN O . l C L U T C HH U B I N T O H U B S L E E V E
Installthe 3 springsand shifting koys to tho clutch
hub.
(b) Installtho hub sleeveto tho clutch hub
HINT: Positionthe identificationgroovs of the hub
slo€veto the front of the transmission. ffit
ff
;- --l
2. I N S T A L LT H R U S TW A S H E R ,1 S T G E A R ,N E E D L E
r; R O L L E RB E A R I N GS, Y N C H R O N I Z ERRI N GA N D
N O . l H U B S L E E V ET O O U T P U TS H A F T
(a) UsingSST and a press,installthe thrust washer.
s s T 0 9 3 16 - 6 0 0 10 ( 0 9 3 16 - 0 0 0 4 0 )
(b) Apply gear oil to the needlerollerbearing.
(c) Placethe synchronizerring on thE gear and alignthe

ring slots with the shiftingkeYs.
( d ) U s i n ga p r e s si,n s t a l l t h e1 s t g e a ra n d N o . 1h u b s l e s v e .
- T I
3. INSPECTlST GEARTHRUSTCLEARANCE
Using a feeler gauge, measurothe lst g€ar thrust
clearance.
Standard clearanca:
0 . 1 0 - 0 . 2 9m m ( 0 . 0 0 3-9 0 . 0 1 1 4i n ' )

MX-46
S54 MANUALTRANSAXLE_ OUTPUTSHAFT
4. I N S T A L LS Y N C H R O N I Z ERRI N G S ,2 N D G E A R ,
NEEDLE R O L L EB RE A R I NA GN D3 R DD R I V E NGEAR
(a) Install ths ball.
(b) Fit the 2ndgearbushinggroovesecurely ov6rtho batl
w h e ni n s t a l l i nt gh e 2 n d g e a rbushinog n t h es h a f t .
(c) Placethe synchronizerrings on ths 2nd gear.
( d ) A p p l yg e a ro i l t o t h e n e e d l er o l l e rb e a r i n ga n d i n s t a lilt .
g ( e ) l n s t a l tl h e 2 n d g e a r .
t l
NOTICE: Align the clutch hub grooveswith the projec.
tionson the synchronizer ring.
( f ) U s i n gS S Ta n d a p r e s s i, n s t a l tl h e 3 r d d r i v e ng e a r .
s s T 0 9 3 16 - 6 0 0 10 ( 0 9 3 6 1 - 0 0 0 10 )
5. I N S P E C T2 N O G E A RT H R U S TC L E A R A N C E
U s i n ga f e e l e rg a u g e ,m e a s u r et h e 2 n d g 6 a r t h r u s t
c laarance.
Standardcl6ara nce:
-
0.20 0.44 mm (0.0079-0.0173in.)

MX-47
S54 MANUAL TRANSAXLE- OUTPUTSHAFT
6. INSTALLOUTPUTGEARSPACER,4 TH DRIVEN
GEARAND RADIALBALLBEARING
(a) Installthe outorgearspacor.
( b ) U s i n ga p r e s si ,n s t a ltlh o 4 t h d r i v e ng e a ra n db e a r i n g .
7. T N S T A LRLE A RB E A R I N G
H UsingSSTanda press,installthe rearbearing.
ln[ - l u50 | z- zzv | |
s55555
A
q.v
fi3
-\J

Mx-48
ss4 MANUALTRANsA'LE- sHrFTANDsELEcrLEVER
sHAFT
COMPONENTS
Shift and Select Lever Shaft
Serect
Sprins
,""1-1'^n I
Compression
Sprins
|
| )--O
r nt er loc kPla telAk 6
C o m p r e s s i o nI 'o''"LGfti@P;"'
E-Rino - l
I f@-*u.n",
w**1,"0 pin Dust --A\
Boot
Lmde
"t-
qY Sprins
{ *J ffi
..,tNqNJ/ t h -
I s h i r r r n n e r L e v e r r r\o) \l / l
S h i f t I n n,erLeverNo.2
Y I
q
l
LeverLockpin
S e l e c tS p r i n gS e a t N o ,'
I o oirlear cont'or
slirt1"u".
C o n t r oS
l h a f tC o v e r
I
O O-Ring
aii-----;_-;--- _---;--'-, -
N . m r k g t . c m ,t t . l b r ) ] : S p e c r l e dt o r o u e
O N o n - r e u s a b lp ea r t
DISASSEMBLY
1 . R E M O V EC O N T R O LS H I F TL E V E R D
, USTBOOT
A N DC O N T R OSL H A F TC O V E R
(a) Removethe nut andwashar.
(b) R e m o v et h s l e v e rl o c k p i n .
(c) Removeths controlshift lever.
(d) Removethe dust boot.
(e) Removathe controlshaft cover.
2. R E M O V ES E L E C TS P R I N GS E A T N O . 2 A N D S H I F T
I N N E RL E V E RN O . 2
(a) Usinga screwdriver,pry out the E- ring.

MX.49
S54 MANUAL TRANSAXLE_ SHIFTAND SELECTLEVERSHAFT
(b) Removethe reverserestrictpin holder,springand
shift inner leverNo.2
3. REMovEsHtFTtNTERLocK s6trr TNNER

eLATE.
SEAT
LEVERNO.1AND SELECTSPRING
ffi
( a ) U s i n ga p i n p u n c ha n d h a m m e r d, r i v eo u t t h e s l o t t s d
s p r i n gp i n .
(b) Removethe shifi interlockplats,shift innerleverNo 1

and selectsPringseat.
4. R E M O V EE - R I N G F R O M S H I F TA N D S E L E C T
LEVERSHAFT
U s i n ga s c r e w d r i v eprr,yo u t t h e E - r i n g .

Mx-50 - sHrFTANDsELEcrLEVER
sE4 MANUALTRANSAxLE 'HAFT
ASSEMBLY
( S e ep a s eM X - 4 8 )
1. APPLYMP GREASE
TO PARTS,AS SHOWN
-p*sE@@
\ \
ONCIN%
2. IF NECESSARY.REPLACE CONTROL SHAFT
C O V E RO I LS E A L
(a) Usinga screwdriver, pry out the oil seal.
(b) UsingSSTanda hammer. tap in a newoil sealuntilits

surfacais flushwith the shaftcoversurface.
s s T 0 9 6 0 8 - 2 0 0 21 ( 0 9 6 0 8 - 0 0 0 8 0 ,9 6 0 8 - 0 3 0 2 0 )
(c) Coatthe lip of th6 oil sealwith MP grease.
3. I N S T A L LE - R I N G T O S H I F TA N D S E L E C TL E V E R
SHAFT

MX.51
S54 MANUAL TRANSAXLE- SHIFTANO SELECTLEVERSHAFT
4, INSTALL SELECTSPRINGSEAT, SHIFT INNER
L E V E RN O . 1A N DS H I F TI N T E R L O CPKL A T E
(a) Installthe selectspringseatandspring.
(b) InstalltheshiftinnerlevarNo.1with tho shiftinterlockiiiitjix

Plat6.
HINT:One of the splineteeth of the shift and select
levershaft has beeneliminated.Therefore,be certain
to corractlyalignthis portionto the matchingportions
on the parts duringassemblY.
, r i v ei n t h e s l o t t e d
( c ) U s i n ga p i n p u n c h a n d h a m m e r d
spring p t n .
.,--{.^..-.-- Dfivoin dapth:
' .i'
l r A \ '1 23.5 + 1.0 mm (0.925+ 0.039in.)
..1 I
iYlL'
, , \
2 3 , 5i 1mm
m2543
5. I N S T A L LS H I F TI N N E RL E V E RN O . 2A N D S E L E C T
SPRING SEATNO.2
( a ) I n s t a ltl h e s h i f t i n n e rl e v e rN o . 2 ,s p r i n ga n d s e l e c t
s p r i n gs e a tN o . 2 .
(b) Usinga screwdriverand hammer,tap in tho E- ring.

MX-52
s54 MANUALTRANsAXLE- sHrFTAND sELEcr LEVER.HAFT
6. INSTALLCONTROLSHAFTCOVER.DUST BOOT
AND CONTROL SHIFTLEVER
(a) Installthe controlshaftcoverand dust boot.
HINT:Makesureto installthe boot in correctdirec-
tion.Positionthe air bleedof ths bootdownward.
(b) Installthe control shift lever.

iM*i (c) Installthe leverlock pin to th€ controlshift lever.
(d) Installtha washerand lock nut.
Torque:6.N 4 . m( 6 5k g f . c m , 5 6i n , . l b f )

MX.53
S54 MANUAL TRANSAXLE_ DIFFERENTIAL
CASE
COMPONENTS
S hi m
Outer Race
P i n i o nT h r u s tW a s h e r
I t'0"'""''nn
L
I
R i n gGe a r
@b6 6 MX:r,
S r d eGe a r
S i d e Ge a r T h r u s tW a s h e r
(krr.".nLt'ril)-
: S p e c i f i e dt o r q u e O u t e rR a c e
tr;
a N o n - f e u s a b l ep a r t
D I F F E R E N T I ACLA S ED I S A S S E M B L Y
1. R E M O V E S I D E B E A R I N GF R O M D I F F E R E N T I A L
C A S E( S P E E DS E N S O RD R I V EG E A RS I D E )
(a) UsingSST.remov€the bearingfrom drivegearside of
lh6 CaS6.
ssT 09950- 00020,09950- 00030
(b) Remove the speedsensordrivegear.
2. REMOVE R I N GG E A R
Matchmarks {a) Placematchmarks on the ringgearandthe case

MX-54
S54 MANUAL TRANSAXLE_ DIFFERENTIAL
CASE
( b ) U s i n ga c h i s e a
l n d h a m m e r u, n s t a k ot h e l o c k p l a t e s .
( c ) R e m o v et h e 8 b o l t sa n d 4 l o c k p l a t e s .
(d) Using a coppar hammer. tap on tha ring gear to

remove it from the case.
3. R E M O V E S I D E B E A R I N GF R O M D I F F E R E N T I A L
c A s E( R t N G
GEAR
StOE)
UsingSST,removeths bearingfrom r i n g g 6 a r o f s i d e
of the case.
s s T 0 9 9 5 0- 0 0 0 2 0 ,0 9 9 5 0- 0 0 0 3 0
4. I N S P E C TS I D EG E A RB A C K L A S H
U s i n ga d i a l i n d i c a t o rm
, e a s u r st h e b a c k l a s ho f o n e
s i d eg e a rw h i l eh o l d i n go n e p i n i o nt o w a r dt h e c a s e .
Standard backlash:
0.05- 0.20 mm (0.0020-0.0079in.)
lf the backlashdoesnot meet spocification,
installthe
correctthrust washerto the sids gears.
5 . D I S A S S E M B L E D I F F E R E NCTAI A SLE
( a ) U s i n ga p i np u n c ha n dh a m m e rdrive
, out the straight
prn.

MX-55
S54 MANUALTRANSAXLE- DIFFERENTIAL
CASE
(b) Removethe pinionshaft from tho case.

(c) Removethe 2 pinions and 2 side gears with the 4
thrust washsrsfrom each gear.
6. TRANSMlssloNCASESIDE: ;t4i- i
IF NECESSARY,REPLACEDIFFERENTIAL ]
SIDE IiBE''i'-
B E A R I N GR E T A I N E R OILSEAL
(a) UsingSST and a hammer,drive out the oil seal from
the retainor.
s s T 0 9 6 0 8 - 2 0 0 12 ( 0 9 6 0 8 - 0 3 0 2 0 0, 9 6 0 8 - 0 3 0 6 0 )
( b ) U s i n gS S Ta n d a h a m m e rd, r i v ei n a n e w o i l s e a lu n t i l
its surfaceis flush with the case surface.
s s T 0 9 3 5 0 - 3 2 0 14 ( 0 9 3 5 1- 3 2 1 3 0 , 0 9 3 5 1- 3 2 1 5 0 )
(c) Coat the lip of the oil seal with MP grease.
7. TRANSAXLECASE SIDE:
IF NECESSARY. REPLACESIDE OIL SEAL
( a ) U s i n ga s c r e w d r i v ear n d h a m m e r ,d r i v e o u t t h e o i l
seal.
s\ }( e\(
t'\9 lR
( b ) U s i n gS S Ta n d a h a m m s r d, r i v ei n a n e w o i l s e a lu n t i l
its surfaceis flush with the case surface.
s s T 0 9 3 5 0 - 3 2 0 14 ( 0 9 3 5 1- 3 2 1 3 0 , 0 9 3 5 1- 3 2 1 5 0 )
(c) Coat the lip of oil seal with MP grease.

MX-56
S54 MANUALTRANSAXLE_ DIFFERENTIAL
CASE
8. TRANSMISSIO GNA S ES I D E :
I F N E C E S S A RR YE, P L A CSE I D EB E A R I N G OUTER
RACE
( a ) U s i n ga b r a s sb a ra n dh a m m e rd,r i v eo u t t h e b e a r i n g
outerrace.
( b ) I n s t a l tl h e b e a r i n gr s t a i n s rw i t h o u ta n O - r i n g .
( c ) I n s t a l al n d t o r q u et h e 6 b o l t s .
Torque:18 N.m(185 ksf cm. 13 ft.lbf)
( d ) P l a c et h e t h i n n e s ts h i m i n t o t h e c a s e .
(e) Using SST and a press,installa n6w bearingouter
racs.
s s T 0 9 6 0 8 - 2 0 0 12 ( 0 9 6 0 8 - 0 3 0 2 0 0. 9 6 0 8 - 0 3 0 6 0 )
(f) Ramovathe 6 bolts.

(s) R s m o v et h e b e a r i n gr e t a i n e ar n d s h i m .
9. TRANSAXLE CASESIDE:
I F N E C E S S A RR YE , P L A CS
E I D EB E A R I N G OUTER
RACE
( a l U s i n ga b r a s sb a ra n dh a m m e rd,r i v eo u t t h e b e a n n g
o u t e rr a c ea n ds h i m .

MX-57
CASE
(b) Placsthe shim into the case.
(c) Using SST and a press,install a now boaringouter
racg.
s s T 0 9 6 0 8 - 2 0 0 12 ( 0 9 6 0 8 - 0 3 0 2 0 0, 9 6 0 8 - 0 3 0 6 0 )
DIFFERENTIA C LA S EA S S E M B L Y MX
(Seepase MX-53)
1 . A S S E M B L ED I F F E R E N T I ACLA S E
(a) Installthe corrsct thrust washersand side gears.
Referringto the table below, select thrust washers
which will 6nsurethat the backlashis within specifica-
tion. Trv to select washersof the same sizefor both
sides.
Standardbacklash:
0.05- 0.20 mm (0.0020-0.0079in.)
Thicknoss mm (in.) Thickness mm (in.)
0.9s (0.0374) 1.r0 (0.0433)
1.00(0.0394) 1 . 1 5( 0 . 0 4 5 3 )
L05 (0.0413) 1.20(0.0472)
Installthe thrust washersand side gearsin the differ-

e ntraI case.
(b) Installthe pinionshaft.
(c) Inspecttho side gear backlash.

Measurethe side gear backlashwhile holding one
pinrongear toward the case.
Stsndsrdbacklash:
0.05- 0.20 mm (0.0020-0.0079in.)
lf th€ backlashis not within specification,install a
thrust washerof differentthickness.
(d) Using a pin punch and hammer,drive in the straight

pin throughth€ casoand hole in the pinionshaft.

MX-58
S54 MANUAL TRANSAXLE- DIFFERENTIAL
CASE
(e) Stakethe differentialcase.
2. INSTALL RINGGEARON DIFFERENTIAL CASE

(a) Cleanthe contactsurfac6of tho difforentialcase and
the threadsof tho ring gear and differentialcasa.
(b) Heat the ring gear in boilingwater.
(c) Carefullyrsmovsthe ring gearfrom the water.
(d) After moistureon the ring gearhas completelyevapo-
rat6d,quickly installthe ring gear to the differential
case.
HINT:Align the matchmarkson the differentialcase
and contact the ring gear.
( e ) T e m p o r a r i liyn s t a l tl h e 8 b o l t sa n d 4 l o c k p l a t e s .
NOTICE: The ring gearsst boltsshouldnot be torqusd
until tho ring gear has cooled sufficiently.
(f) After ths ring gear has cooledsufficiently,torque the
ring gear set bolts.
( S ) U s i n ga p i n p u n c ha n d h a m m e rs, t a k et h e l o c k p l a t e s .
HINTS : t a k eo n e c l a wf l u s hw i t h t h 6 f l a t s u r f a c oo f t h e
bolt.For th€ claw contactingthe protrudingportionof
the bolt, stake only the tightenedside.
3 . I N S T A L LS I D EB E A R I N T GO D I F F E R E N T I C
AAL SI
(a) UsingSSTand a press,installa new sids bsaringto
the transmission caseside.
s s T 0 9 3 16 - 6 0 0 10 ( 0 9 3 6
1 - 0 0 0 10 )
0 9 3 5 0 - 3 2 041 ( 0 9 3 5-13 2 12 0 )

MX-59
CASE
(b) Installthe spesd sensor drive gear to ths transaxle
mf?
casoside.
i l
<-lli
cas6
sidell
I
lifl
-t
s M 0 2 8 8s M 0 2 2 7 z6r6
(c) UsingSSTand a press,rnstalla new sidebearinS to

ffiil
the transaxl€ caseside'
6 - 6 0 0 10 ( 0 9 361- 0 0 0 1o )
s s T0 9 3 1
0 9 3 5 0 - 3 2 041( 0 9 3 5-13 2 12 0 )
N O T I C E :I n s t a l l t h e b l a c k c a g e b e a r i n g o n t h o s p o e d
s e n c o rd r i v e g e a r s i d e .
4. A D J U S TD I F F E R E N T I ACLA S ES I D EB E A R I N GP R E -
LOAD
( a ) I n s t a ltl h e d i f f e r e n t i at ol t h o t r a n s a x l ec a s 6 .
(b) Installthe transmissioncase.
(c) Installand torque the case bolts.
Torque:29 N m (300kgf cm, 22 {t'lbf)
( d ) l n s t a l tl h s s h i m i n t o t h e t r a n s m i s s i ocna s o .
( e ) I n s t a ltl h e b e a r i n gr e t a i n ew r i t h o u ta n O - r i n g .
( f ) I n s t a l al n d t o r q u e t h e r e t a i n ebr olts.
Torque:18 N'm (185 kgf cm. ft lbf)
13

MX-60
S54 MANUAL TRANSAXLE- DIFFERENTIAL
CASE
( S ) U s i n g S S T a n d t o r q u e m e t e r , m e a s u 1 6t h e p r e l o a d .
s s T0 9 5 6 4 - 3 2 0 1 1
Preload(at starting):
0 . 8 - 1 . 6 N . m( 8 - 1 6 k s f . c m . 6 . 9 - 1 3 . 9i n . . l b f )
lf the preloadis not within specification,removethe
t r a n s m i s s i ocna s es i d e b e a r i n gr e t a i n e r .
Selecta nother shim.
H I N T :T h a p r e l o a dw i l l c h a n g eb y a b o u t0 . 3- 0 . 4 N . m
( 3 - 4 k g f . c m ,2 . 6 - 3 . 5 i n . ' l b f )w i t h e a c h 0 . 0 5 m m
c h a n g ei n s h i m t hi c kn e s s .
Mark T h i c k n e s sm m ( i n . ) Mark T h i c k n e s sm m ( r n . )
l 1.90 (0.0748) t1 2.40(0.0945)
2 1 . 9 5( 0 . 0 7 6 8 ) 2 . 4 5( 0 . 0 9 6 5 )
3 2.00(0.0787) 2.50(0.0984)
2.05(0.0807) 14 2 . 5 5( 0 . 1 0 0 4 )
5 2 . 1 0( 0 . 0 8 2 7 ) 15 2 . 6 0( 0 . 1 0 2 4 )
6 2 . 1 s( 0 . 0 8 4 6 ) 2 . 6 5( 0 . 1 0 4 3 )
l 2.20(0.0866) 17 2 . 7 0( 0 . 1 0 6 3 )
I 2.25(0.0886) l8 2 . 7 s( 0 . 1 0 8 3 1
9 2.30(0.0906) 19 2 . 8 0( 0 . 11 0 2 )
t0 2 . 3 5( 0 . 0 9 2 5 )
(h) Ramovsthe 6 bolts.

( i ) R g m o v et h e b e a r i n gr e t a i n e ar n d s h i m .
( j ) R e m o v et h e 1 7 b o l t s .
(k) Removetha transmissioncase.

MX-61
PARTSINSTALLATION
coM PoNENT PARTSINSTALLATI_O-l!..

B A S I CS U B A S S E M B LRYE A S S EB ML Y
( S e ep a g eM X - 2 1 a n d M X - 2 2 )
gear oil bsforeassembly.
1. I N S P E C TD I F F E R E N T I ASLI D EB E A R I N GP R E L O A D
(Seestep 4 on PageMX - 60)
CASE
TOTRANSAXLE
2. rNsrALLMAGNET
ffi
3. CASEASSEMBLY
INSTALLDIFFERENTIAL
4. A S S E M B L EN O . 1S H I F TF R O KS H A F T 'N O . 1S H I F T
H E A D ,N O . l A N D N O . 2S H I F TF O R K S
(a) Assemblethe No.1 shift fork shaft, No.1 shift hsad,
N o . 1a n d N o . 2s h i f t f o r k s .
(b) Mount tho shift forks to the vise.

(c) Using a pin punch and hammer,drive in the slotted
s p r i n gp i n t o t h e N o . l f o r k s h a f t a s s h o w n i n t h e
i l l us t r a t i o n .

MX'62 - coMpoNENTpARTSTNSTALLATToN
ss4 MANUALTRANsAXLE
(d) Coat the interlockpin with MP grease.
(e) Usinga screwdriver,installthe intsrlockpin into the
reverseshift fork hole.
(f) Install the reverssshift fork to the No.1 shift fork
shaft.
HINT:When installingthe reverseshift fork with int6r-
l o c k p i n t o t h e N o . 1 s h i f t f o r k s h a f t ,m a k e s u r e t h e
interlockpin does not drop out.
NOTICE: Be carefulnot to damagetha bushing.
( S ) U s i n ga p i n p u n c h a n d h a m m e r d , nvs in th6 slotted

spring p i n t o t h e N o . 1f o r k s h a f t .
5. I N S T A L LN O . l S H I F T F O R K S H A F T ,N O . l S H I F T
H E A D ,N O . l , N O . 2 S H I F TF O R K S .R E V E R S E SHIFT
F O R KW I T H I N T E R L O C K P I N ,I N P U TA N D O U T P U T
SHAFT ASSEMBLY
I n s t a l tl h e i n p u t a n d o u t p u t s h a f t a s s e m b l yt o g e t h e r
with tho No.l fork shaft. shift head and shift forks
with the int€rlockpin to the transaxlecase.
6 . I N S T A L LN O , 2 F O R KS H A F T
( a ) I n s t a l tl h 6 N o . 2 f o r k s h a f t t o t h e t r a n s a x l ec a s et h r -
o u g h t h e r e v e r s es h i f t f o r k .
( b ) U s i n ga p i n p u n c ha n d h a m m e r d
. r i v ei n t h e s l o t t e d
s p n n gp r n .

MX.63
PARTSINSTALLATION
( c ) A p p l ys e a l a n t o t h e p l u gt h r a a d s .
Sealant:
Part No.08833-00080,THBEEBOND1344, LOC'
f lTE 242 or equivslent
(d) Using a hexagonwrench, installthe straight scrow
-,:;-.r]1---1i
plug.
Torque:13 N.m(130kgf cm, I ft lbf)
7. TNSTALL SHIFTARM
REVERSE ffi
(a) Put the reverseshift fork pivot into th€ rsvorseshift wt
arm and installthe reverseshift arm to th€ transaxle
cas6.
(b) Shift the reverseshift arm into the rev6rso.
(c) Installand torque the 2 bolts.
Torqua:18 N.m(185 kgf cm, 13 ft'lbf)
(d) Shift the rev€rseshift arm to the nautralposition.
8. INSTALL REVERSEIDLERGEARAND SHAFT

( a ) I n s t a ltl h e w a s h e ra n d r e v e r s ei d l e rg e a rt o t h e s h a f t .
sMo128
(b) Inslalltho reverseidlergear and shaft as shown.
s M 0 29
t
9 . I N S T A L LT R A N S M I S S I OC
NA S E
(a) Removeany FIPGmaterialand be carafulnot to drop
oil on the contactingsurfaceof the transaxlecaso or
t r a n s m r s s r ocna s 6 .
o,---t\ ) (b) Apply FIPGto the transmissioncas€ as shown.
/ F/-,
\ -/ "fv FIPG:
PartNo.08833-00090. THREEBOND1281or equi-
valent

MX-64
PARTSINSTALLATION
(c) Installand torque the 17 bolts.

Torque:29 N.m (300 kgf.cm. 22 ft.lbf)
1 0 . I N S T A L L S H I M A N D S I D E B E A R I N GR E T A I N E R
WITHO-RING
( a ) I n s t a l al n e w O - r i n g o n t h e r e t a i n e r .
( b ) I n s t a l tl h e s h i ma n d r g t a i n s r .
{w
(c) Apply sealantto ths bolt threads.
Saalant:
P a r t N o . 0 8 8 3 3 - 0 0 0 8 0 , T H R E EB O N D 1 3 4 4 , L O C -
TITE242 or oouivalent
( d ) lnstall and toroue the 6 bolts.
T o r q u a :1 8 N . m ( 1 8 5 k g f . c m , 1 3 f t . l b f )
1 1 .INSTALL AND TOROUEREVERSEIDLER GEAR

SHAFTLOCKBOLT
1 2 . I N S T A L LB E A R I N GS N A PR I N G S
U s i n ga s n a pr i n g e x p a n d e ri ,n s t a l tl h e 2 s n a pr i n g s .
H I N T l: f i t i s d i f f i c u l t o i n s t a l l t h es n a pr i n g .p u l lu p t h e
s hafts.

MX.65
PARTSINSTALLATION
RETAINER
1 3 . I N S T A L LR E A RB E A R I N G
(a) Applysealantto the boltthreads.
Sealant:
P a r t N o . 0 8 8 3 3 - 0 0 0 7 0 ' T H R E EB O N D1 3 2 4 o r e q u i '
valgnt
(b) Installand torquo the 5 bolts.
Torqua:42 N.m (430 kgf cm,31 ft'lbf)
14. INSTALL5TH DRIVENGEAR

UsingSST,installths 5th drivengear'
s s r 0 9 3 0 9 -1 2 0 2 0
1 5 . I N S T A L LS P A C E RN , E E D L ER O L L E RB E A R I N G S ,
s T H G E A RA N D S Y N C H R O N I Z ERRI N G
(a) Installthe s pacer.
(b) Apply gear oil to the needlerollarbearings.
( c ) I n s t a ltl h e 5 t h g s a rw i t h t h e n e e d l er o l l e rb e a r i n g a
snd
svnchronizerring.
1 6 . I N S T A L LN O . s S Y N C H R O N I Z ERRI N G SW I T H K E Y
S P R I N GT O N O . 3C L U T C HH U B
(a) Assembletho No.5 synchronizerrings.
( b ) U s i n ga s c r e w d r i v e irn, s t a ltl h e s n a pr a n g .
HINT:Wrap vinyl tape on ths screwdrivarto prev€nt
d a ma g i n gt h e s y n c h r o n i z er irn g .
(c) Installtho No.5synchronizar ringswith key springsto

t h e N o . 3c l u t c hh u b .
H I N T :A l i g n t h e h o l e s o f t h e c l u t c h h u b w i t h k e y
sp r i ng .

MX'66 - coMpoNENT'ARTSrNsrALLATroN
s54 MANUALTRANSAXLE
1 7 . I N S T A L LN O . 3C L U T C HH U B
U s i n gS S T a n d a p r e s s ,i n s t a l lt h e N o . 3 c l u t c h h u b
assembly.
s s T0 9 6 1 2 - 2 2 0 1 1
: l i g n t h e h o l s so f t h s 5 t h g e a r a n d s y n c h r o n i z e r
N O T I C EA
ring.
1 8 . I N S T A L LS H I F T I N GK E Y R E T A I N E R AND SNAP
RING
(a) Install th6 retainer.
( b ) S e l e cat s n a pr i n gt h a tw i l la l l o wm i n i m u m
axiap
l lay.
T h i c k n 6 s sm m ( i n . ) Mrrk T h i c k n € s sm m ( i n . )
2,20-2,25
21
(0.0866-0.0886) 1 0 . 1 0 2- 40 . 1 0 4 3 )
2.25-2.30 2.65-2.70
t4
-0.0906)
(0,0886 ( 0 . 10 4 3- 0 .r 0 6 3 )
2 . 7 0- 2 . 7 5
15
(0.0906-0,0925) ( 0 . 1 0 6-30 . r 0 8 3 )
2.35- 2.40 2 . 75 - 2 . 4 O
16 24
( 0 . 0 9 2-s0 . 0 9 4 5 ) (0,1083-0.1102)
2.40-2.45 2.80-2.85
17
(0.0945-0.0965) (0.1102-0.1122)
2.45-2.50 2 . 8 5- 2 , 9 0
18
(0.0s6s-0.0984) (0.1122-O.1142)
2 . 9 0- 2 . 9 5
19 27
(0.0984-0.1004) { 0 . 11 4 2- 0 . 116 1)
2.55- 2.60
20
( 0 . 10 0 4- 0 . 1 0 2 4 )
( c ) U s i n ga s c r e w d r i v earn d h a m m e rt,a p i n t h e s n a pr i n g .
1 9 . I N S P E CsTT H G E A RT H R U S T CLEARANCE
r , o a s u rt6h 6 t h r u s tc l e a r a n c e .
Standard clearance:
0 . 2 0- 0 . 4 0 m m ( 0 . 0 0 7 9 - 0 . 0 1 5 7 i n . )
1l.=--
7/-^

S54 MANUAL TRANSAXLE_ COMPONE
2 0 . I N S T A L LN O . 3 H U B S L E E V EW I T H N O . 3 S H I F T
FORK
(a) lnstallthe No.3hubsleevewith No.3shiftfork to the
N o . 3c l u t c hh u b .
(b) Installand torquetho s€t bolt.

Torque:18 N m (185kgf'cm,13 ft lbf)
ilM#1;
l l
r9-
21. INSTALLOUTPUTSHAFTLOCKNUT
the geardoublemeshing.
(a) Engage
(b) Installand torque tho now lock nut.

Torque:123 N.m(1'250 kgf'cm, 90 ft lbf)
H I N T :T h e l o c k n u t h a s L H t h r e a d s .
(c) Staketho locknut.

(d) Disengage the goardoublemeshing.

MX-68 - coMpoNENTpARTSTNSTALLATToN
s54 MANUALTRANSAxLE
22. INSTALLSHIFT AND SELECTLEVERASSEMBLY

(a) Apply FIPGto the undersideof the flangedportionof
the controlshaft cover.
FIPG:
Part No.08826-00090,
THREEBONDl28l or eqrrr-
valent
(b) Installthe shift and sslect lsver assamblyand torque
th6 controlshaft cover.
T o r q u e : 3 7N . m( 3 7 5k g f . c m . 2 7f t . l b f )
i:irMxi 23. INSTALL PLUG

(a) Apply sealantto plug thrsads.
Sealant:
P a r t N o . 0 8 8 3 3 - 0 0 0 8 0 , T H R E EB O N D 1 3 4 4 , L O C -
Tlf E 242 or souivalent
( b ) U s i n g a h e x a g o nw r e n c h , i n s t a l la n d t o r q u e t h o p l u g .
T o r q u e :2 3 N . m ( 2 3 0 k g f . c m , 1 7 t t . l b f)
24. INSTALLLOCKBALL
I n s t a lal n dt o r q u ot h s N o . 1l o c kb a l l .
Torque:29 N.m (300 kgf.cm,22 ft.lbf)
25. INSTALL TRANSMISSION CASE COVER

(a) Removethe FIPGmaterialand be carefulnot to droo
oil on the contactingsurfaceof the transmissioncase
or transmissioncase cover.
(b) Apply FIPGto the transmissioncase cover as shown.
FIPG:
Psrt No.08826-00090, THREEEOND1281or equ,-
v a l en t
(c) Installthe transmissioncasa cover.

(d) Apply sealantto the bolt threads.
Sealant:
P a r t N o . 0 8 8 3 3 - 0 0 0 8 0 . T H R E EB O N D 1 3 4 4 . L O C .
TITE242 or equivalent
( e ) I n s t a l la n d t o r q u e t h e 8 b o l t s .

MX-69
_ PARTSINS
S54 MANUALTRANSAXLE COMPONENT
26, INSTALL SELECTINGBELLCRANK AND ENGINE
l7-;DX1, 'aa- M O U N TB R A C K E T
F:-t1 >--
y',l)Nfur
- l*; (a) Installthe selectingbellcrankand 2 bolts'
Torque:37 N'm (380kgf'cm, 27 ft lbf)
9 -l /:-l- (b) Install ths engine mount bracket and torque the 3
bolts.
Torque:52 N m (530kgf'cm.38 ft lbf)
27. INSTALL RELEASEBEARINGRETAINER MX

lnstallthe releasebearingretainerand torque the 3
bolts.
Toroue:7.4 N m (75 kgf cm, 65 in. lbf)
2 8 . I N S T A L LB A C K - U P L I G H TS W I T C H
Torque:44 N'm (450kgf cm. 33 ft lbf)
2 9 . I N S T A L LV E H I C L ES P E E DS E N S O R
3 0 . I N S T A L LR E L E A S E F O R KA N D B E A R I N G
( a ) A p p l ym o l y b d e n u m i s u l p h i d lei t h i u mb a s eg r e a s et o
d
t h s f o l l o w i n gP ar t s :
. InputshaftsPline
o R e l e a s ef o l k c o n t a c t s u r f a c e
(b) Apply MP greaseto the front surfaceof the release
bearing.

MX-70 _ S H I F TL E V E RA N D C O N T R OC
S 5 4 M A N U A LT R A N S A X L E L ABLE
S H I F TL E V E RA N D C O N T R O C
L ABLE
COMPONENTS
S h i f t L e v e rKn o b
sc"ff Plate
c o n s o l e{ r p p s 1e a n e rf \
It
C o w ls i d e
C e n t e rC l u s t e rF i n i s hP a n e l
H e a t e rC o n t r o l P a n e l
Compartment
Scuff Plate
F i n i s hP a n e l €4
w e r C e n t e rF i n i s h
L O ! 1 r ' t5 t O e I n m
12 tl20, 9)
P a i n t e dM a r k
S h i ft L e v e r A s s e m b l y
Washer-----O {-- Ctip 5 . 4 1 5 5 ,4 8 I n . l b f )

Heat lnsulator
N . m ( k g f. c m , f t . l b l ) : S p e ci fi e d t o r q u e

MX-71
S54 MANUALTRANSAXLE_ SERVICE
SPECIFICATIONS
SPECIFICATIONS
SERVICE
DATA
SERVICE
Roler beanng lo!ral drametor

2 9 . 9 7 0m m { 1 . 17 9 9 i n . )
3 r d g e a rl o u r n a d
l iameter
3 3 . 0 9 0m m ( 1 . 3 0 2 8
in.)
4 t h g 6 a rl o u r n a d r a m € t e r
3 2 . 4 7 0m m ( 1 . 2 7 8 3
in,)
5th gear lournaldrametor
2 6 . 9 7 0m m ( 1 . 0 6 1 8i n . )
Limit 0.05 mm (0.0020in.)

O u t p u ts h a f t
R o l l e rb s a r i n gl o u r n a d
l lametgr
3 1 . 9 7 0m m ( 1 . 2 5 8 7i n . )
1 s t g e a rl o u r n a d
l rarneter
3 7 . 9 7 0m m ( 1 . 4 9 4 9i n . )
3 1 . 9 9 0m m ( 1 . 2 5 9 4i n . )
0.05mm (0.0020in.)
G e a rl h r u s tc e a r a n c e 1 s t
0 . 1 0 - 0 . 2 9m m ( 0 . 0 0 3 9 - 0 , 0 1 1i 4
n.)
Limit 0 . 3 5m m( 0 . 0 1 3 8 in.)
Gear thrust clearanc€ 2nd
4 m{ 0 . 0 0 7 9 - 0 . 0713 i n . )
O . 2 O - O . 4m
0 . 5 0 m m ( 0 . 0 1 9 7i n . )
G€arthrust c sarance 3rd

0 . 1 0 - 0 . 2 5m m ( 0 . 0 0 3-90 . 0 0 9 8i n . )
0 . 3 0 m m ( 0 . 0 11 8 i n . )
G 6 a rt h r u s tc l e a r a n c e 4 t h
STD 0 . 2 0 - 0 . 4 5m m{ 0 . 0 0 7 9 - 0 . 0 1 7i 7
n.)
0 . 5 0 m m ( 0 . 0 19 7 i n . i
G € a rt h r u s lc a a r a n c e 5 t h
0 . 2 0 - 0 . 4 0m m ( 0 . 0 0 7 9 - 0 . 0 1 5i 7
n)
0 . 4 5 m m 1 0 . 0 1 7 7i n . )
G 6 a rr a d i a cl 6 a r a n c e 1 s t ,2 n d , 3 r d a n d 4 t h
0 . 0 0 9- 0 . 0 5 3 m m ( 0 . 0 0 0 4 - 0 . 0 0 2i 1
n,)
0.070mm (0.0028in.)
G e a rr a d i a c € a r a n c s5 t h
0 . 0 0 9 - 0 . 0 5 0m m ( 0 . 0 0 0 4 - 0 . 0 0 2i n
0)
0 , 0 7 0m m( 0 . 0 0 2 8 in.)
S h i f l l o r k t o h u b s l e e v ec l e a r a n c o
1 . 0 m m ( 0 . 0 3 9i n . )
S y n c h r o n i z 6i nr g t o g s a r c l e a r a n c e1 s t ,3 r d a n d 4 t h
0 . 6 m m ( 0 . 0 2 4i n . )

MX-72 ' S E R V I CS
S 5 4 M A N U A LT R A N S A X L E EP E C I F I C A T I O N S
S y ' l c h r o r . z e rn r g t o g e a r c l e a , a n c p 2 n d
Lrmrt 0 . 7m m ( 0 . 0 2 8i n . )
Input shaft snap ring thickness
No.2 clutch hub Mark I 1 . 9 5 2 . 0 0 m m ( 0 . 0 7 6 8 - 0 . 0 7 8 7i n . )

No.2 clutch hLrb Matk 2 2 . 0 0 2 . 0 5m m1 0 . 0 7 8 7 - 0 . 0 8 0i n7. l
N o . 2c u t c h h u b M a r k3 2 . O 5 - 2 . 1 0 n m ( 0 . 0 8 0 7- 0 . 0 8 2 7 i n . l
N o . 2c l u t c hh u b M a r k4 2 . 1 0 - 2 . 1 5 m m ( 0 . 0 8 2 7 0 . 0 8 4 6i n . )
N o . 2c l u t c hh u b lrark5 2 . 1 5 2 . 2 Om m ( 0 . 0 8 4 6 - 0 . 0 8 6l n
6.)
N o . 2c l u t c hh u b M a r k6 2 . 2 0 2 . 2 5m m{ 0 . 0 8 6 6 - 0 . 0 8 8i 6
n.l
MX No.3 c utch hub M a r k1 3 2 . 2 O 2 . 2 5m m( 0 . 0 8 6 6 - 0 . 0 8 8i 6
n.)
N o . 3c u t c h h u b Mark14 2 . 2 5 2 . 3 Om m ( 0 . 0 8 8 6 - 0 . 0 9 0i 6
n.)
N o . 3c l u t c hh u b Mark15 2 . 3 0 2 . 3 5m m ( 0 . 0 9 0 6 - 0 . 0 9 2 5
in.)
N o . 3c l u t c hh u b Mark16 2 . 3 5 - 2 . 4 0m m{ 0 . 0 9 2 5 0 . 0 9 4 5i n . l
N o . 3c u t c h h u b M a r k1 7 2.4O 2.45 mm (0.0945-0.0965 in.l
N o . 3c u t c h h u b Mark18 2 . 4 5 - 2 . 5 0 m m ( 0 . 0 9 6 5 0 . 0 9 8 4i n . )
N o . 3c l u t c hh u b Mark19 2 . 5 0 - 2 . 5 5m m ( 0 . 0 9 8 4 - 0 . 1 0 0i n
4.)
N o - 3c l u t c hh u b M a r k2 0 2 . 5 5 2 . 6 0m m ( 0 . 1 0 0 4 - 0 . 1 0 2i n 4.)
N o . 3c l u t c hh u b Matk21 2 . 6 0 - 2 . 6 5m m( 0 . 1 0 2 4 - 0 . 1 0 4i 3
n.)
No.3 c utch hlb Mark 22 2 . 6 5 - 2 . 7 Om m ( 0 . 1 0 4 3 0 . 1 0 6 3i n . )
N o . 3c u t c h h u b M a r k2 3 2 . 7 O 2 . 7 5m m ( 0 . 1 0 6 3 - 0 . 1 0 8i 3
n.)
N o . 3c l u t c hh u b M a r k2 4 2 . 7 5- 2 . 4 O m m 1 0 . 1 0 8 3 - 0 . 1 1 0i n
2.l
No-3 clutch hLrb M a r k2 5 2 . 8 0- 2 . 8 5 m m ( 0 . 110 2 - 0 . 112 2 i n . )
N o . 3c u t c h h u b M a r k2 6 2 . 8 5 - 2 . 9 0m m( 0 . 11 2 2- 0 . 11 4 2i n . )
N o . 3c u t c h h u b Matk 27 2 . 9 0 2 . 9 5m m ( 0 . 1 1 4 2 - 0 . 1 1 6i1n . )
2 . 1 5 - 2 . 2 0m m{ 0 . 0 8 4 6 - 0 . 0 8 6i 6
n.)
MarkB 2 . 2 O - 2 . 2 5m m ( 0 . 0 8 6 6 0 . 0 8 8 6i n . )
2.25 2.30mm (0.0886 0.0906in.)
2 . 3 0 2 . 3 5m m 1 0 . 0 9 0 60 . 0 9 2 5a n . )
2.35 2.4O mm (0.0925-0.0945 in.)
Differentialside bearingadjustingshim thrckness
Mark 1 1 . 9 0m m 1 0 . 0 7 4 8i n . )
1 . 9 5 m m ( 0 . 0 7 6 8i n . )
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2 . 1 0m m ( 0 . 0 8 2 7
in.)
2 . 15 m m 1 0 . 0 8 4 6i n . )
2.20mm (0.0866in.)
2 . 2 5 m m ( 0 . 0 8 8 6I n . )
Mark I 2.30mm (0.0906in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45mm (0.0965an.)
2.50mm (0.0984in.)
2 . 5 5 m m ( 0 . 1 0 0 4i n . )
2 . 6 0 m m ( 0 . 1 0 2 4i n . )
2 . 6 5 m m ( 0 . 1 0 4 3I n . )
M a r k 17 2 . 7 0 m m ( 0 . 10 6 3 ' n . )

MX.73
S54 MANUALTRANSAXLE- SERVICE
SPECIFICATIONS
Mark 18 2 . 7 5 m m ( 0 . 1 0 8 3i n . )
M a r k1 9 2 . 8 0m m( 0 . 110 2 i n . )
S h i f tl e v e rp r eo a d a d i u s t i n gs h i mt h i c k n e s s
0.5 mm (0.020in.)
MarkB 0.6 mm (0.024in.)
M a r kC 0 . 7 m m ( 0 . 0 2 8i n . )
M a r kD 0 . 8 m m ( 0 . 0 3 1i n . )
MarkE 0.9 mm (0.035 in.i
MarkF 1 . 0 m m ( 0 . 0 3 9i n . )
Mark G 1 . 1m m ( 0 . 0 4 3i n . )
M a r kH 1.2 mm (0.047 in.)
1. 3 m m ( 0 . 0 5 1i n . )
;rs&
MarkK 1 . 4 m m ( 0 . 0 5 5i n . )
MarkL 1 . 5 m m ( 0 . 0 5 9i n . )
MarkM 1 . 6 n m { 0 . 0 6 3i n . )
N4arkN 1 . 7 m m ( 0 . 0 6 7i n . )
Differentaacase side bearingpreload(at starting) 0 . 8 1 . 6 N . m( 8 1 6 k g f . c m ,6 . 9 - 1 3 9 i n l b t )
l r n i o nt o s r d e g e a t b a c k a s h
D , f f e r e n t r ap 0.05 0.20mm (0.0020-0.0079in.)
Differentialside gear thrust washer thickness
N o n sM a r k 0 . 9 s m m ( 0 . 0 3 7 4i n . i
N o n eM a r k L00 mm {0.0394 in.)
N o n eM a r k 1 . 0 5m m ( 0 . 0 4 13 i n . )
N o n €M a r k 1 . 1 0 m m ( 0 . 0 4 3 3i n . )
N o n eM a r k 1. 15 m m( 0 . 0 4 5 3
4n.)
None Mark 1 . 2 0 m m ( 0 . 0 4 7 2i n . )

MX-74
S54 MANUAL TRANSAXLE- SERVICE
SPECIFICATIONS
TOROUE
SPECIFICATIONS
Part tight€n€d N.m kgf cm ft.tbf
Transmissioncas6 x Transaxlgcasa 300
Transmissioncase x Casocover 29 300
Transmissioncase prot6ctor 18 185
R s a rb e a r i n gr o t a i n e r 210
Output shatt front b€sringlock plato 18 185
transax e case olt r6c6tv6r oD tn. oT
5th dflvon gear lock nut 123 1,250 90

R6v6rseidL€rshaft ock bolt 29 300 22
Controlshaft cov6r 37
Controlshift levorx lev6r shaft 6.4 5 6 i n . .b f
Ring gear x Dift6rentialcas6 97 985 71
Selectingbeilcrankx Transmissioncas6 3J 380
Rev6rseshift arm brack6t 18 185
No.3 shift fork x Shitt fork shaft t8 185
No.1 lock ball ass€mbly 300
No.2 lock bai assembly 230 17
F r l l op
r lug 49 500
D r a i np l u g 49 500
E a c k- u p l i g h ts w i t c h 44 450
Sid€o6a ng r6tatner 18 185
Clutch roleasoboaringrst6inor 7.4 75 65 in. bf
Straightscr€w plug (Shiftfork shaft) 130
Straightscr6w plug {R6verser€strictpin) 13 130 I
Straightscrsw p ug (Shilt and s€l6ct 1€vorsh€ft) 1 7
T r a n s a x l xe E n g i n e( 1 2 m mb o i t ) 64 650 41
T r a n s a x l xe E n g i n €( 1 0 m mb o l t ) 46 470 34
Stiffen€rplate x Engrne 43 440
Stiffenerplat€ x Transaxl€ 21 210
Exhaustpipe support brack6t 19 195 14
Enginelsft mountingset bolt and nut 64 650 47
Csnt€rmemb6rx Body 52 530 38
Cent6rm6mb6rx EngineMounting 64 650 41
Transsxl6
x E n 9 i n 6m o L r n l i n g 77 790 57
Engin6 mounting th.ough bolt 87 890 64
Front €xhaustpip€ (Bolt) 43 440
F r o n t€ x h a u s p
t i p €( N u t ) 46
G r o u n dc a b l €s 6 t b o t 210 t 5
Clutchrsleas6cylind€rx Transaxg 120

Start6rx Transaxl6 400 29

MX-1
E 5 6 M A N U A LT R A N S A X L E
DESCRIPTION MX_ 2
OPERATION MX- 3
PREPARATION MX_ 4
TROUBLESHOOTING . ' . . ' . . . . . . . . . . . . . . . . . . . '
MX- 7
PRECAUTION MX- 7
ASSEMBLY REMOVAL
ANDINSTALLATIO . .N" . . . . . . . . . ' . . . ' ..... M X - 8
C O M P O N E NPTA R T SR E M O V A L. . " . . . . . . . M ' X- lJ
MX-
34
ffi
I N P U TS H A F T
o U T P U TS H A F T . . . . . . . .
. . , . MX-
40
O I LP U M P MX-
47
S H I F TA N D S E L E C LTE V E R SHAFT . " . . ' " . MX-
52
D T F F E R E N TC .
I AALS E. . . . . . . ' . . . ' . . MX-
58
C O M P O N E NPTA R T SI N S T A L L A T I O N . " . . ' MX-
70
S H I F TL E V E RA N O C O N T R O C L ABLE . . . . . . MX-
83
S E R V I CS
EP E C I F I C A T I O N S MX- 84

MX-2 _ DESCRIPTION
DESCRIPTION
GENERAL
r h e c h a n i s mi s u s e di n t h o 2 n d g e a ra n d a d o u b l e - c o n e
A t r i p l e - c o n at y p e s y n c h r o m e sm
type synchromeshmechanismis usedin the 3rd gearto improvethe shift feelingcharacter-
istics.This helpsto reducethe shiftingeffort.
. A roversesynchromeshmechanismis us6d to suppressgear engagomentnoise in reverse
gear shifting.
oo5580
Typa ot Tran!!xlo
Typ! of Engino
G6arRstio lrt Goar
2nd Geer 2.045
3rd Grar
4th Ge.r r.028
sth Go.r 0.820
Revers!Gg!r 3.583
Oiff.rntial Ge6r Ratio 3.944
Oil C.pscity 3.5 lit.r! (3.7 US qt!,3.t lmp. qts)
Oil Vi6cosaty s A E7 5 W - 9 0
Oil Gred€ APIGL-3. GL-4 or GL-5

MX-3
E56 MANUALTRANSAXLE_ OPERATION
OPERATION
r T h e i l l u s t r a t i o n sb e l o w s h o w t h e e n g a g e m s n t so f t r a n s a x l eg e a r s '
2 n d D r i v eG e a r
Di f f e r e n t i a l Differential
D r l v eG e a r D r i v eG e a r
2nd Driven
1 s tD r i v e n
Gear
Differential Differential
Assembly A s s em b l y
lst 2nd
3 r d D r i v eG e a r 4 t h D r i v eG e a r
D l f f er e n t i a l Di f t e r e n t l a
3rd Driven
Gear
Differential
Assembly
e r i v eG e a r
ReversD
Differenrlal
D r i v eG e a r
Re v e r sDe r i v eG e a r
Reverse
Differential
D i f f e r e nita ldler
Assembly
Assembly
Rev.

MX-4
E56 MANUAL TRANSAXLE_ PREPARATION
PREPARATION
SST(SPECIAL
SERVICE
TOOLS)
0 9 2 2 3 - 1 5 0 1 0c r r n k s h a f t o i l S€rl 0iff6r6ntisl cas6 orl seal
R€plec€r
0 9 3 0 8 - 0 0 0 1 0 o i l s s s lP u l l o r
u u . t t o - z u u tI r r a n s r €Er 6 a n l gH e p r r c 0 r Inputsheft b€aring

Sidoboaring
uY.tto-ouutu rra'1smrssd
ron
t r a n s l 0 BearinO
r No.l hub sleeve
R6plsc6r 0 i t f € 1 6 n t i a lc a s e t a p € r r o l l € r
ooann€ outgr fac€
T r e n s s x l € c a s 6 c o v € r o 1 ls 6 a l
( 0 9 3 1 6 - 0 0 0 1 0R) o p l s cP
€ irp e
( 0 9 3 1 6 - 0 0 0 2 0R) 6 p l s c e r ' A
aa)
v
(09316-00040)Replacer
( 0 9 3 1 6 - 0 0 0 7 0R) € p l a c e r ' F '

@
\v
09506-30012 0iffersntialOriv€PinionRear Outputshaft reaf b€aring
BearingConoR6plac6r
0 9 5 0 6 - 3 5 0 1 0 0 i f f € r o n t i sDl r i v €P i n i o nR s a r No.2 hub sle€ve

B€aringR€plac6r Sido bearing
Input shaft boar|ng
5 0 9 6 0 8 - 1 2 0 1 0 F r o n tH u b& D r i v €P n i o nB o a r i n g Inputsh€ftoil s€al

R--g'\-
i!+;tU o & RoplEcer Sot
--6?e e
(09608-00020) R€mover& R€plac6rHendle
(09608-00060)Driv€P nionFrontBearins
Cup
R€plac€r
N--7/-,

MX.5
E56 MANUAL TRANSAXLE- PREPARATION
(09608-00080)RePlacer
aa;\
t-h
\:=
0 9 6 1 2 - 6 5 0 1 4 s t o e r i nwgo r mB e a r i nPgu l l e r Inp!t shoft boaring

Oiff6rentisltap€r roll6r
@F,b 09620-30010 st€.rinsGoarBoxReplecor

set
b€rringouterracg
Controlshaft cov6roil !r!l

@.
#-'
-00020) Handle
(09631
09950-00020 Bo!rinsRemov€r
09950-00030 BearingRomovorAttachment
t-.
'1{"
09950-30010 Pulle,A S6t
:.:;ii*:€>
,.€;.$:ffi-*- 0 9 9 5 0 - 4 0 0 1 0 P u l l €Bf S € t
OOLS
0 9 0 2 5 - 0 0 0 1 0 S m s lTl o f q uW
o rench pfolotd
Oifforontlal
0 9 0 3 -10 0 0 3 0 P r nP u n c h
â 09042-00040 TofxsockotT50
09042-00050 Torxsock€tT45

MX-6
E56 MANUAL TRANSAXLE_ PREPARATION
0 9 9 0 5 - 0 0 0 1 2 S n a pR i n gN o .1 E x p d n d 6 r
EOUIPMENT
D i a li n d i c a t o rw i t h m a g n e t i cb a s e
F e e l e rg a u g e
lMic ro mete r
i},[{r{ S t r a i g h te d g e
LUBRICANT
llem Capscity Classafication
M s n u a t r s n s a x l 6o i l A P IG L - 3 , G L - 4 o r G L - 5
3 . 5 l i t s r s{ 3 . 7 U S q t s , 3 , l l m p ,q t s )
(w,/Diflerentiaoil) S A E7 5 W - 9 0 o r 8 0 W - 9 0
s s M ( s P E c r ASLE R V t CM
EA T E R I A L S )
0 8 8 2 -60 0 0 9 0 S e aPl a c k i n1s2 8 1 , Transaxlecasgx Casecover
T H R EB EO N D1 2 8 1o r e q u i v a l o n t Transmrssioncassx Transaxle
(FIPG)
Transmss on casex case cover
0 8 8 3 3 - 0 0 0 8 0 A d h € s i v1e3 4 4 , T r a n s a x l ec a s s c o v e r b o l t
T H R EE EO N O 1344, Stra ght scr6w plug
LOCTITE 242or oqurv6lent Control shaft cover bolt

_ TROUBESHOOTIN
MX-7
E 5 6 M A N U A LT R A N S A X L E PRGE
, CAUTION
TROUBLESHOOTING
Use the table below to helpyou find the causeof tha problem.The numbersindicatethe priority
of the likslv causeof the problem.Checkeach part in order.lf necessary,r€placetheso parts'
l'r
See Page x
Pafts o
E E
Name E o € o
E
c
'.
i
t i
: oJ
o)
o .E
Trouble ) -)
c
(9 (J o
Noise 1 2 3 3
Oil leakage 1 2 2
Hard to shift or will not shilt 2 3
J u m p so u t o f g e a r 2 3 3
\,It'_r,r
I !r
PRECAUTION
When working with FIPGmaterial,you must observethe following.
o U s i n ga r a z o rb l a d ea n d g a s k e ts c r a p e rr, e m o v ea l l t h e o l d F I P Gm a t 6 r i aflr o m t h e g a s k o t
surfaces.
o T h o r o u g h l cy l e a na l l c o m p o n e n t tso r e m o v ea l l t h e l o o s em a t e r i a l '
o C l e a nb o t h s e a l i n gs u r f a c e sw i t h a n o n- r e s i d u es o l v e n t .
o A p p l yt h e F I P Gi n a n a p p r o x .1 m m ( 0 . 0 4i n . )w i d e b e a da l o n gt h e s e a l i n gs u r f a c e .
o partsmust be assembled w i t h i n 1 O m i n u t e so f a p p l i c a t i o nO. t h e r w i s et,h e F I P Gm a t e r i a l
m u s t b e r e m o v e da n d r e a P P l i e d .

Mx-8
E 5 6M A N U A LT R A N S A X L-E A S S E M B LRyE M o v A L
A N Dr N s r A L L A T r o N
INSTALLATION
""'-"'
Removeand installthe parts as shown b"low.
A i rC l e a n eAr s s e m b l y
D r i v eS ha l t
C o n l r o lC a b l 6
il
'/
W'""'o T i € R o dE n d
\
Y-=_
X@
s,"w,r--,i:._orqs?tlF oroFrf-l
o>-- F?
, M ioborrerpin
*
? ---r-:- t(fild
I gerroo,zgt
I f 'l^ ;r- \\!lF@^ /
\Nx.
En g i ne U nd e r C o v e r( R H )
' |0 8 ( 1 , 1 0 08, 0 )
6 4( 6 s 0 , 4 7 )
H o l eP l u g
od_,
En g i n eUn d e rC o v e r
i N m ( k g r ' c ml ,l l b f ) : S p e c i f i e dl o r q u e
art

MX-9
-
E56 MANUAL TRANSAXLE ASSEMBLYREMOVALA
REMOVAL
TRANSAXLE
( _ } T E R M I N A LC A B L E
1 . D I S C O N I { E CNTE G A T I V E
FROMBATTEBY
CAUTION: Work must be started after 90 seconds from
'LOCK'
tho time the ignition switch is tuined to the
p o s i t i o na n d t h s n e g a t i v e ( - ) t e r m i n a l c a b l e i s d i s c o n '
noctad from the battory.
2. REMOVEBATTERYAND AIR CLEANER CASEAS-
S E M B L YW I T HA I RH O S E
3. REMOVESTARTER
andwirefrom the starter'
(a) Disconnect
(b) Remove
tho connector
tho 2 boltsandstartor.
rfix;
4. R E M O V EC L U T C HR E L E A S E AND TUBE
CYLINDER
CLAMPS
(a) Removethe 2 bolts and heat insulator.
(b) Removethe 2 bolts and releasecylinder'
(c) Removethe 2 bolts and 2 tube clamps'
5. CABLE
REMOVEGROUND
6. BTA C K _ U PL I G H TS W I T C HC O N N E U -
DISCONNEC
TOR

MX-10
E 5 6 M A N U A LT R A N s A ^ L E- A S S E M B L yR E M o v A LA N D T N S T A L L A T T ' N
7, DISCONNECT CONTROL CABLES

(a) Removethe 2 clipsandwashers.
(b) Removsthe 2 clipsfrom the cables.
8. D I S C O N N E CV
T E H I C L ES P E E DS E N S O RC O N N E C .
' 't' TOR
-.a
MX
i/
9. REMOVETRANSAXLEMOUNTINGBOLTS
Removethe 4 bolts of transaxlecase upperside.
1 0 . R E M O V E E N G I N EL E F T M O U N T I N G B O L T A N D
NUTS
R e m o v et h e b o l t a n d 2 n u t s o f e n g i n el e f t m o u n t i n g
u o o e rs t d o ,
1 1 . I N S T A L LE N G I N S
E U P P O RFTI X T U R E

MX-11
E56 MANUALTRANSAXLE- ASSEMBLYREMOVALAND INSTALLATION
V
13. RAISE E H I C L E
N O T I C E :B e s u r e t h e v a h i c l ei s s e c u r e l ys u p p o r t e d .
14. REMOVE U N D E RC O V E R S
1 5 . DRAINTRANSAXLE OIL
1 6 . REMOVELH AND RH DRIVESHAFTS
(SeepaseSA-42)
TIPE
(a) Ramovethe 2 nutsand 2 bolts.
(2
(b) R e m o v et h s n u t , 4 b o l t s a n d e x h a u s tp i p e s u p p o r t
brackst.
(c) Removethe 3 nuts and exhaustfront pipe with the 2

gaskets.
18. R E M O V EE N G I N EF R O N TM O U N T I N G
(a) R e m o v et h e h o l e P I u g .
( (b) Removethe nut and bolt
(c) R e m o v et h e 4 b o l t sa n d e n g i n ef r o n t m o u n t i n g

MX-12 - A S S E M B L yR E M o v A LA N D T N S T A L L A T T o N
E s 6 M A N U A LT R A N S A X L E
19. R E M O V EE N G I N ER E A RM O U N T I N G
(a) Removethe 2 hole plugs.
(b) Removethe through bolt.
(c) R e m o v et h e 4 b o l t s ,2 n u t sa n d e n g i n er e a rm o u n t i n g .
2 0 . R E M O V EE N G I N EL E F TM O U N T I N GB O L T
R e m o v et h 6 b o l t o f e n g i n el 6 f t m o u n t i n gl o w e rs i d e .
MX
21. REMOVE CENTER MEMBER

(a) Removethe bolt and pipebracket.
t b ) R s m o v tgh e 2 b o l t sa n dc e n t e m
r ember.
22. JACKUP TRANSAXLE SLIGHTLY

U s i n ga t r a n s m i s s i o n k ,s u p p o rtth s t r a n s a x l 6 .
j a c
2 3 . R E M O V ET R A N S A X L E
(a) Removethe transaxlemountingbolts.
(b) Lower the engineleft side and removethe transaxre
from the engine.

MX.13
- ANDINSTALLATION
REMOVAL
E 5 6 M A N U A LT R A N S A X L E A S S E M B L Y
TRANSAXLE INSTALLATION
( S e ep a g eM X - 8 )
1. INSTALL T R A N S A X LTEO E N G I N E
A l i g nr h e r n p u ts h a f ts p l i n ew i t h t h e c l u t c hd i s ca n d
installthe transaxle to ongine.
Bolt A
T o r q u e :6 4 N ' m ( 6 5 0 k g f ' c m , 4 7 f t l b t )
Bolt B
Torque:46 N'm (470 kgf'cm,34 ft lbf)
Bolt C
T o r q u a :2 1 N ' m ( 2 1 0 k g f c m , 1 5 f t l b t )
Bolt D ;**
Torque:43 N'm (440 kgf'cm,32 lt lbf)
MEMBER
2 . I N S T A L LC E N T E R
(a) Installthe centermemberandtorquethe 2 bolts'
Torque:52 N'm (530kgf cm,38 ft'lbt)
(b) Installtho pipa bracketwith a bolt
3. I N S T A L LE N G I N EL E F TM O U N T I N GB O L T
T o r q u et h e b o l t o f e n g i n el a f t m o u n t i n gl o w e rs i d e '
Torque:64 N m (650kgf cm, 47 ft lbf)
4 . I N S T A L LE N G I N ER E A RM O U N T I N G
( a ) I n s t a l rl h e e n g i n er e a r m o u n t i n g t, o r q u et h e 4 b o l t s
a n d 2 nu t s .
T r a n s ax l e s i d e :
T o r o u e :7 7 N m ( 7 9 0 k g f c m , 5 7 f t l b f )
C e n t e r m e m b e rs i d e :
T o r q u e :6 4 N ' m ( 6 5 0 k g l c m , 4 7 f t l b t )
T h r o u gh b o l t :
T o r q u a :8 7 N ' m ( 8 9 0 k g f ' c m . 6 4 f t l b f )
( b ) l n s t a l lt h e 2 h o l e P l u g s '
5. F R O N TM O U N T I N G
I N S T A L LE N G I N E
( a ) I n s t a l lt h e e n g i n e f r o n t m o u n t i n g a n d t o r q u a t h e 4
b ol t s .
T r a n s a x l es i d e :
T o r q u e :7 7 N m ( 7 9 0 k g f c m , 5 7 f t l b f )
C e n t e rm o m b e ts i d o :
T o r o u s :6 4 N m ( 6 5 0 k g f c m , 4 7 t t l b f )
T o r o u e :8 7 N m ( 8 9 0 k g f c m , 6 4 f t l b f )
( b ) I n s t a l lt h e h o l e P l u g .

MX-14 - A S S E M B L yR E M o v A LA N D T N S T A L L A T T o N
6 . I N S T A L LF R O N TE X H A U S TP I P E
(a) Installthe front exhaustpipe with 2 new gasketsand
)-
torque the 3 n uts.
ffi,
t)i
Torque:62 N.m(630kgf.cm.46ft.lbl)
\ll
tl
( b ) Installthe sxhaust pipe support bracket,torquo thg

n u t a n d4 b o l t s .
MX Torque:19 N.m (195 kgf.cm, 14 ft.lbf)
( c ) Installa new gasket,torqu6t h e 2 b o l t sa n d 2 n u t s .

Torque:43 N m (440kgf.cm,32 ft.tbf)
7. INSTALL LH AND RH DRIVE SHAFTS

(See pase SA-54)
8. F I L L T R A N S A X L EW I T H G E A R O I L
Oil grade:
APIGL-3. GL-4 or GL-5
Viscosity:
sAE 75W- 90
A b o v e - 1 8 ' G ( 0 ' F )S A E 9 0
B e l o w - 18 " C ( 0 ' F ) S A E 7 5 W
Capacity:
3.5 liters(3.7 US qts,3.1 lmp.qts)
9. INSTALLUNDERCOVERS
11, REMOVE NGINE S U P P O RFTI X T U R E

_ ASSEMBLY MX-15
E 5 6 M A N U A LT R A N S A X L E ANDINSTALLATION
REMOVAL
1 2 . I N S T A L L E N G I N EL E F T M O U N T I N G B O L T A N O
NUTS
T o r q u et h e b o l t a n d 2 n u t s o f e n g i n el e f t m o u n t i n g
u o o e rs i d e .
Torque: 64 N.m (650 kgf .cm, 47 f t.lbf)
1 3 . C O N N E C TV E H I C L ES P E E DS E N S O RC O N N E C T O R
MX
T O N T R OC
1 4 . C O N N E CC LABLES
( a ) I n s l a l lt h e 2 c l i p s t o t h e c a b l e s .
( b ) C o n n e c tt h o 2 c a b l s st o t h s l i n k a g ew i t h w a s h e r s a n d
..a&rt clios.
ii
ttal:1
1 5 . C O N N E C TB A C K - U P L I G H T S W I T C H C O N N E C -
TOR
CABLE
T o r q u o :2 1 N m ( 2 1 0 k g f . c m , 1 5 f t l b f )

Mx-l6 - AssEMBLyREMovALANDTNSTALLATT'N
E56MANUALTRANSAXLE
1 7 . I N S T A L LC L U T C HR E L E A SCEY L I N D EA
RN DT U B E
CLAMPS
(a) Installthe 2 tube clampsandtorquethe 2 bolts.
(b) Installtho releasa cylinderand torqusths 2 bolts.
Torque:12 N.m(120kgf.cm,I ft.lbf)
(c) Installthe heat insulatorand torque the 2 bolts.
Torque:I 2 N.m (120kgf.cm,9 ft.lbf)
18. INSTALLSTARTER
(a) Installths starterandtorquetho 2 bolts.
rMX T o r q u e :3 9 N m ( 4 0 0 k g f . c m , 2 9 f t . l b f )
(b) Connect th€ conn6ctor and wire to ths starter.
1 9 . I N S T A L LA I R C L E A N E R C A S EA S S E M B L Y WITH
AIR HOSEAND BATTERY
BATTERY
(SeepageSA-5)
C h e c kf o r a b n o r m anlo i s e as n ds m o o t hs h i f t i n g .

MX-17
- COMPONENT
E56MANUALTRANSAXLE PARTSREMOVAL
TA R T SR E M O V A L
C O M P O N E NP
COMPONENTS
* f;(4oo,rr)k
l - \ ' , '
S l i l l e n e rP l a l e
\ _
-l' G-* tt.,rt.r.tl
. o I seal-{h T r a n s a x lCe a s eC o v e r
lgr*__6
\^--FC*]"-l
r4.,, ^ r------]
C l u t c hF l e l e a s e fr-11!ls'131-i
CrOr.-Jful S p e e dS e n s o D
r r i v e nG e a r
Conrror --1v
SupportBracket
t) o-Ring
_47_{480,
_35Lr
%
T r a n s a x lC
ea s e
TA B e a r i n gO u t e rR a c e
e a s eB e c e i v e r
T r a n s a x lC
7 , 4 ( 7 5 , 6 5 i n l,b f )
Transmission
O i lP i p €
M a gn e t 1 7 ( 1 7 5 ,1 3 )
k/-*o"
(
O i lP u r n p
l a s eA s s e m b l Y
D l l e r e n t i aC
ir'/ioa \'
lrt?;\
VAl'I
N m ( k g fc m , l l l b l ) : S p e c ilfe d t o r q u e
Y"Vi"l
a N o nr-e u s a b lpea r l
r t P r e c o a t epda r l

MX-l8
E s 6M A N U A LT R A N s A x L -E c o M p o N E NpTA R T SR E M o V A L
I S n a pF i n g
B e v e r s eS h i l t F o r k
MX
* P Lg
-\\j'
2 5{ 2 s 0r. s )
:+,,WA IDK
-\ / l t //,F ,-
€ J*",r" s r i r t A -, .. n
. -, . \\ _ ,
e1 -"
s p , l n gs e a t - - 1 J r z ( r z s r, s )
,' ]
* e t u sl r s ( z s o ' r e )
I
s'{rFo'<sha'rNo3
\\tt""ot"n\$1
Ba.'(.JD
rierrt
sw,r.*{f-\
x>*"'ffi u/
) )flli
* p r u sf r 3 ( 1 3 0 , t l b a A / " n " F o r k N o 3& t n r r F o r k N o 2
1
v,/
V-)
d ^"'.', f
-_
--- -
s h i f ta n dS e t e cLt e v e r
s l o t t e ds p r i n gP n g
\ r - L13'
Fl a ta Gaskpr | "an
\ \ A = a
Heverse ct_N-o ' - \
qeverseHeslr
Reslrcr ^ fljx {s!1 J6)_]
qj
1 7( 1 7 51, 3 ) O i l R e c e l v ePr l p e
S e l e c t i n gB e l l c r a kn
O l l R e c e i v ePf i p e
T r a n s m i s s i oC
n a s eC o v e r
* Plug 49(500,36)
T f a n s mi ss i o n C a s e
N r ' , q f 6 l . - ' l l b f ) : S o e c ' | e dt o r q u o

I
a No n -r e u s a b lpea r t
l t P r e c o a t epda r t

MX-19
_ COMPONENT
E 5 6 M A N U A LT R A N S A X L E PARTSREMOVAL
I n p u tS h a l l A s s e r n b l } /
""o"".,,'.@NmX-----
o""l ""'h- ili:;:'\K@-,,'
$i;" a B e a rn g O u l er F a c e
29 (3O0,22)
O u l p u tS h a f tA s s e m b l y
* F G3ort'l
y;ffix^,.f1"*,.Tn
l'""'7"1;::::"' K e yS p r i n g
lre/-4 I /*';i:"":sync,ronizerRinsNos
"/@fA
-l
R e a r B e af i n g R e t a i n e r
i / AiootesvncrroniTerFrrnsNo5
-S^ *W4-/ QdN(::":::,":::ili;"'

I
,.(.,", \.f}
sun"r'n^7prRinor
**@qffiY**J#"'"n
sthDrivenc""-{^9f
*l@ vUl).o'
K e yS p r i n g
C l u l c hH u b N o . 3
H u bS l e e v eN o . 3
S n a pF i n g
N m ( k g fc m , f t l b l ) : S p e cl l e d t o r q u e
. N o n - r eu s a b l eP a r t
* P f e c o a t e dp a r l

Es6 MANUALTRANSAXLE
( S e ep a g e sM X - 1 7 t o M X - 1 9 )
1. REMOVE
R E L E A SFEO R KA N D B E A R I N G
2. REMOVE
B A C K _ U PL I G H TS W I T C H
3. REMOVEVEHICLESPEEDSENSOR
(a) Removetha set bolt and lock plate.
Mi' (b) Removelhe vehiclespeedsensor.
4. R E M O V E3 B O L T SA N D S H I F TC O N T R O LB R A C K E T
5. REMOVESELECTING
BELLCRANK
ASSEMBLY
6, REMOVE
B R E A T H EPRL U G
7. R E M O V ES H I F TA N D S E L E C TL E V E RS H A F TA S -
SEMBLY
(a) Removethe lockbolt.

MX-21
_ C O M P O N E NPTA R T SR E M O V A L
( b ) R e m o v et h e 4 b o l t sa n d p u l l o u t t h e s h i f t a n d s s l e c t
levershaft assemblv.
8. REMOVETRANSMISSIONCASE COVER
R e m o v et h e 1 0 b o l t sa n d t r a n s m i s s i ocna s ec o v s r .
9, REMOVE L O C KN U T
(a) Unstakethe locknut.
( b ) E n g a g et h e g e a rd o u b l em e s h i n g .
(c) Removethe lock nut.

( d ) D i s e n g a gteh e g e a rd o u b l em e s h i n g ,

Mx-22
Es6 MANUALTRANsAxLE- coMpoNENTpARTSREMovAL
1 0 . R E M O V EN O . 3 H U B S L E E V E
AND NO.3 SHIFT
FORK
(a) Removethe No.3shiftfork set bolt.
(b) Removethe No.3 hub sleeveand No.3 shift fork.
11. REMOVE sTHDRIVEN GEAR

UsingSST,romovethe Sth drivengear.
s s T 0 9 9 5 0 - 3 0 00' 1
12. MEASURE 5 T H G E A RT H R U S TC L E A R A N CAEN D

R A D I A LC L E A R A N C E
( a ) U s i n ga d i a li n d i c a t om
r , a a s u 1t 6
h e t h r u s tc l e a r a n c e .
S t a n d a r dc l s a r an c e :
0.10-0.57 mm (0.0039-0.0224 in.J
Maximumclearance:
0 . 6 5 m m ( 0 . 0 2 5 6i n . )
( b ) U s i n ga d i a l i n d i c a t o rm
, e a s u r et h e r a d i a lc l e a r a n c e .
Standardcleara nce:
0.009- 0.050mm (0.0004-0.0020in.)
Maximumclearanca:
0.070mm (0.0028in.)

MX-23
- COMPONENT
E56MANUALTRANSAXLE PARISB!l/19v4!
13. REMOVE N O . 3C L U T C HH U BA N Ds T H G E A R
s da h a m m e tr a, po u t t h es n a p
( a ) U s i n g2 s c r e w d r i v ear n
ring.
(b) Using SST, remove the No 3 clutch hub with syn-

c h r o n i z erri n g a n d s t h g e a r .
s s r 0 9 9 5-0 3 0 0 0
1 l,1ilx,
(c) Removethe sth gear.
1 4 . R E M O V EN E E D L ER O L L E RB E A R I N G
15. REMOVE R E A RB E A R I N G RETAINER

(a) Usinga torx wrench,removethe 7 torx screwsand
bearingretainer.
(TorxwrenchT45 09042- 00050)
( b ) R e m o v teh o a d j u s st h i m .
1 6 . R E M O V ES N A PR I N G
( a ) U s i n ga s n a pr i n g e x p a n d e rr,e m o v et h e s n a pr i n g .
( b ) U s i n g2 s c r s w d r i v e r as n d a h a m m e r .r a m o v et h e 3
s n a pn n g s .

Mx'24
Es6 MANUALTRANsAxLE- coMpoNENTpARTSREMoVAL
1 7 . R E M O V EP L U G ,S E A T , S P R I N GA N D L O C K I N G
BALL
( a ) U s i n ga h e x a g ow
n r e n c hr.e m o v et h e p l u g .
(b) Using a magnetic fingar, remove the spring s6at,

s p r i n ga n d l o c k i n gb a l l .
1 8 . R E M O V ER E V E R S IED L E RG E A RS H A F TR E T A I -
N I N GB O L T
19. REMOVE TRANSMISSIO CN

ASE
(a) Removathe 3 boltsfrom transaxle
caseside.
(b) Removsthe 14 bolts from th6 transmissioncaseside

and tap off the casowith a plastichammer.

MX.25
E 5 6M A N U A LT R A N S A X L-E C O M P O N E P
NA REMOVAL
TRTS
20. REMOVEOUTPUTSHAFTREARTAPERED ROLLER
BEARING OUTERRACE
, p o u t t h s o u t e rr a c s .
U s i n ga p l a s t i ch a m m e rt a
2 1 . R E M O V EN O . 2O I L P I P E
(a) Removethe gasket.
(b) Removethe 2 bolts and oil pipe. MX
22. REMOVEREVERSE SHIFTARM BRACKET

tho bolt and pulloff the bracket.
Remove
23. REMOVEREVERSE IDLERGEARAND SHAFT

Pullout the shaft,removethe reverseidlergearand
thrustwasher.
24. REMOVESTRAIGHTSCREW PLUGS, LOCKING

BALLSAND SPRINGS
(a) Usinga hexagonwrench,removethe 2 plugs.

MX-26 - coMpoNENT'ARTSREMovAL
Es6 MANUALTRANsAXLE
(b) Using a magneticfinger, rsmove th6 2 spring seats.
s p r i n g sa n d b al l s .
-l', 'T:'
ci!
25. REMOVENO.l SHIFT FORKSHAFT
(a) Removetha set bolt.
(b) Pull up th€ No.3shift fork shaft,removethe No.1shifr

fork shaft.
2 6 . R E M O V EI N T E R L O C K ROLLER
U s i n ga m a g n e t i cf i n g e r ,r e m o v et h e i n t e r l o c kr o l l e r
from the reverseshift fork.
2 7 . R E M O V EN O . 2S H I F TF O R KS H A F T S
, H I F TH E A D
A N DN O . l S H I F TF O R K
(a) Removsthe 2 set bolts.

MX-27
- coMPoNENTP4EI9,BEt'i-qv4!
E56 MANUALTRANSAXLE
{b) Pull out the No.2 shift fork shaft.
{c) Removethe shift head and No.1 shift fork.
28. REMOVENO.3SHIFTFORKSHAFTWITH REVERSE

S H I F TF O R KA N D N O . 2S H I F TF O R K
(a) Pull out tha No.3 shift fork shaft with reverseshift MX
fork.
(b) Removethe No.2 shift fork.
2 9 . R E M O V ES N A PR I N G S
( a ) U s i n g2 s c r e w d r i v g rasn d a h a m m e rr, € m o v et h e s n a p
ring and reverseshift fork from the No.3 shift fork
shaft.
( b ) U s i n g2 s c r e w d r i v e rasn d a h a m m e rr,e m o v st h e s n a p
r i n g sf r o m t h e N o . 1 ,N o . 2a n d N o . 3s h i f t f o r k s h a f t .
30. REMOVE S H A F TA S S E M B L Y
I N P U TA N DO U T P U T
(a) Laaningths output shaft to the differentialside
removethe inputshaftassemblY
(b) Lift up the differentialcase assembly,remove the

output shaft.

MX-28 _ C O M P O N E NPTA R T SR E M O V A L
31. REMOVE D I F F E R E N T IA S LSEMBLY

( a ) R e m o v teh e o i l p u m pd r i v eg e a r .
(b) Removethe differentialcase assembly.
MX
32. REMOVE
M A G N E TF R O MT R A N S A X L EC A S E
33. REMOVE O I LP U M PA S S E M B L Y
(a) Removethe 2 b o l t sa n do i l p i p e .
(b) Removeth6 2 b o l t sa n d o i l o u m o .

MX-29
E 5 6M A N U A LT R A N S A X L-E C O M P O N E P
NA REMOVAL
TR T S
34. REMOVENO,5 SYNCHRONIZER RINGWITH KEY
SPRING F R O MN O . 3C L U T C HH U B
(a) Rsmovethe No.5synchronizer ring with key spring
@ f r o mN o . 3c l u t c hh u b .
(b) Usinga screwdriver,removethe snap rang.

HINT:Wrap vinyl tape on the scrswdriverto pravsnt ...- ,-
d a m a g i n gt h e s y n c h r o n i z er irn g . 'MX
(c) Removethe synchronizerrings.
C O M P O N E NPTA R T Sl N S P E C T I O N
1 . I N S P E C TN O , 5S Y N C H R O N I Z ERRI N G S
(a) Checkfor woar or damage.
( b ) C h e c kt h e b r a k i n ge f f e c t o f t h e s y n c h r o n i z erri n g .
T u r n t h e m i d d l sN o . 5s y n c h r o n i z er ri n g i n o n e d i r e c -
t i o n w h i l e p u s h i n gi t t o t h e o u t e r N o 5 s y n c h r o n i z 6 r
r i n g .C h e c kt h a t t h e r i n g l o c k s .
l f i t d o e sn o t l o c k ,r e p l a c et h e s y n c h r o n i z er ri n g
2. M E A S U R ES H I F TF O R K SA N D H U BS L E E V EC L E A R .
ANCE
U s i n ga f e e l e rg a u g s m, e a s u r et h e c l e a r a n c b eetween
the hub sleeveand shift fork.
Maximumcloarance:
1 . 0m m { 0 . 0 3 9i n . )
l f t h e c l e a r a n c se x c e e d st h e l i m i t , r e p l a c et h e s h i f t
f o r k o r h u bs l e e v e .
3. I F N E C E S S A R YR,E P L A C EI N P U TS H A F TB E A R I N G
AND OILSEAL
(a) Removethe 3 bolts and transaxlecase receaver.
E8475

MX-30
E 5 6 M A N U A LT B A N ' A X L E- c o M p o N E N Tp A R T SR E M . ' A L

s s T0 9 6 1 2 - 6 5 0 1 4
(c) Usinga screwdriver,removethe oil seal.
MX
(d) UsingSST,drivein a new oil seal.

s s T 0 9 6 0 8 -1 2 0 1 0( 0 9 6 0 8 - 0 0 0 2 0 .9 6 0 8 - 0 0 0 8 0 )
{ e ) C o a t t h e l i p o f s e a lw i t h M P g r e a s 6 .
(f) UsingSST,drive in a new bearing.

s s T 0 9 6 0 8- 12 0 10 ( 0 9 6 0 8- 0 0 0 2 0 ,0 9 6 0 8- 0 0 0 6 0 )
(9) Installthe transaxlecaso r€caiver.

(h) Installand torque the 3 bolts.
Torque:7.N 4 . m( 7 5k g f . c m . 6 5i n . . l b f )

MX-31
- CO@
(i) UsingSST and a press,removethe Innerrace'
ssr 09950-00020
(j) UsingSSTand a press,installa new input shaft front

b e a r i n gi n n e rr a c e . tt: ..,
ssr 09316-60010 ( 0 9 3 1 6 - O O O 2 O ) ' ..MX
4. IF NECESSARY, REPLACEOUTPUTSHAFT FRONT

B E A R I N GA N D U T P U TS H A F TF R O N TC O V E R
O
(a) Using SST, pull out ths output shaft front bearing
outer race.
ssT09308-00010
(b) Removethe output shaft front cover.
(c) Installa new output shaft front cover.

HINT: Inslallthe output shaft front cover projection
into the case side groove
(d) UsingSSTand a hammer,drive in a new output shaft

front bearingoutar race
s s T 0 9 3 16 - 6 0 0 l 0 ( 0 9 3 16 - 0 0 0 1 0 , 0 9 3 16 - 0 0 0 2 0 )

E56MANUALTRANSAXLE
(e) Using SST and a socket wrench, ramoveths output
shaft front bearing.
- 00020.
ssr 09950 - 00030
09950
(f) UsingSSTand a press,installa naw output shaft front

bearing.
.MX ssr 0931 1 ( 0 9 361- 0 0 0 7 0 )
6- 6000
5. IF NECESSARY, REPLACE REVERSE RESTRICT PIN

(a) Usinga hexagon
wrench,rsmoveths screwplug.
( b ) U s i n ga p i n p u n c ha n d a h a m m e rd, r i v eo u t t h e s l o t t 6 d
s p r i n gp i n .
(c) Replacethe rsversorestrictpin.

( d ) U s i n ga p i n p u n c h a n d h a m m e r d
, rivsin the slotted
s p r i n gp i n .

MX-33
- COMPONENT
E56MANUALTRANSAXLE PARTSREMOVAL
(a) Apply sealantto the scrsw plug throads.
Sealant:
PEit No.08833-OOO8O, THREEBOND1344,LOC-
f fiE 242 o? 6quivalont
(f) Usinga hexagonwrench,installthe screw plu9.

MX-34 - I N P U TS H A F T
I N P U TS H A F T
COMPONENTS
Spacer
4,hcear
'''"*'.n,.5ffi@Pb\) I'ffi--''-"'
N e e d l eR o l l e rB e a r i n g
Mx 3rdGear
I- n \ \ ) ] l B i r I I
N e " d r eR o e r B e a ' i n q
;Z
)@@e
R e a rB e a r i n g
s p Irn g
?
S n aR
Pinsl
I
I
L
vl
.-1d4
Y
\\ nl @
Y% S y n c h r o n i z eRri
I n p u tS h a f tF r o n tB e a r i n gI n n e rR a c e
I N o .2 H u b S l e e v e
N o . 2 C u t c hH u b
ShiftinqKey
I n p u tS h a t t
I N P U TS H A F TD I S A S S E M B L Y
1. MEASURE 3 R D A N D 4 T H G E A RT H R U S TC L E A R -
ANCE
U s i n ga f e e l e g
r a u g em
, s a s u rteh e t h r u s tc l e a r a n c e .
3rd gear
0.10 - 0.45 mm (0.0039- 0.0177 in.)
4th gear
0 . 1 0 - 0 . 5 5 m m ( 0 . 0 0 3 9- 0 . 0 2 1 7i n . )
Maximumclearance:
3rd gear
0 . 5 0 m m ( 0 . 0 19 7 i n . )
4th gasr
0 . 6 0 m m ( 0 . 0 2 3 6i n . )

- I N P U TS H A F T MX-35
2. C H E C K3 R D A N D 4 T H G E A RR A D I A LC L E A R A N C E
, e a s u r et h e r a d i a lc l e a r a n c b
U s i n gd i a l i n d i c a t o rm ee-
tween the gear and shaft.
Standardclsarance:
3rd gear
0.009 - 0.053mm (0.0004- 0.0021in.)
4th g 6a?
0.009 - 0.051mm (0.0004- 0.0020in.)
Maximumclsarance:
3rd and 4th gear
0.070mm (0.0028in.)
l f c l e a r a n ceex c e e d st h e l i m i t ,r e p l a c et h e g e a r ,n e e d l e
rollerbearingor shaft.
Using2 screwdrivsrsand a hammer,tap out the snap
r l ng .
4. REMOVERADIALBALLBEARING AND 4TH GEAR

UsingSST and a press, remove the radialbearing.
-
ssT 09950 00020
5, R E M O V EN E E D L ER O L L E RB E A R I N G SS, P A C E R
A N DS Y N C H R O N I ZR
EIRN G
6. REMOVESNAP RING
U s i n g2 s c r e w d r i v e rasn d a h a m m e rt,a p o u t t h s s n a p
ring.
7. REMOVE N O . 2C L U T C HH U BA S S E M B L YS,Y N C H -
RONIZER RINGSAND 3RDGEAR
U s i n ga p r e s sr,e m o v et h s N o . 2h u bs l e e v e , 3 rgde a r ,
synchronizerrings.
8. REMOVE NEEDLE ROLLER BEARINGS

MX-36 _ I N P U TS H A F T
I N P U TS H A F TC O M P O N E NPTA R T S
INSPECTION
1 . I N S P E C T3 R D G E A RS Y N C H R O N I Z ERRI N G
( a ) C h s c kf o r w e a r o r d a m a g e .
w h i l ep u s h -
T u r n t h e s y n c h r o n i z er irn gi n o n ed i r e c t i o n
i n g i t t o t h e g e a rc o n e .C h e c kt h a t t h s r i n g l o c k s .
l f i t d 0 6 sn o t l o c k ,r e p l a c et h e s y n c h r o n i z er irn g .
( c ) M e a s u r et h e c l a a r a n c be e t w e e nt h e s y n c h r o n i z er irn g
Minimumclearanca:
0.7 mm (0.028in.)
l f t h 6 c l e a r a n c ei s l e s s t h a n t h o l i m i t , r e o l a c et h a
synchronizer ring.
2 . I N S P E C T4 T H G E A RS Y N C H R O N I Z ERRI N G
( a ) C h e c kf o r w e a r o r d a m a g e .
w h i l ep u s h -
T u r n t h s s y n c h r o n i z er irn gi n o n ed r r s c t i o n
i n g i t t o t h 6 g 6 a rc o n e .C h e c kt h a t t h e r i n g l o c k s .
l f t h e b r a k i n ge f f e c t i s i n s u f f i c i e n ta, p p l y a s m a t l
a m o u n to f f i n e l a p p i n gc o m p o u n db e t w e e nt h e s y n -
c h r o n i z erri n g a n d g 6 a rc o n e .
L i g h t l yr u b t h e s y n c h r o n i z er ri n g a n d g a a r c o n e t o -
gether.
NOTICE: Ensurathe line lappingcompound is completely
w a s h e do f f a f t e r r u b b i n g .
(c) Check again the braking effect of the synchronizer
ring.
( d ) M e a s u r et h e c l a a r a n c eb s t w e e n t h e s y n c h r o n i z e r i n g
b a c k a n d s p l i ne e n d .
Minimumclsarance:
0 . 6 m m ( 0 . 0 2 4i n . )
l f t h s c l 6 a r a n c ei s l e s s t h a n t h s l i m i t , r e p l a c € t h e
s y n c h r o n i z e r i n g a n d g e a r c o n e b y a p p l y i n ga s m a l l
a m o u n t o f f i n e l a p p i n gc o m p o u n d .
N O T I C E :E n s u r at h e l i n a l a p p i n gc o m p o u n di s c o m p l 6 t e l y
washed ofl after ru bbing

- I N P U TS H A F T MX.37
3. MEASURE N O . 2 S H I F TF O R KA N D H U B S L E E V E
CLEARANCE
U s i n ga f e e l egr a u g sm
, g a s u 1t h 6 6 c l e a r a n cbee t w e o n
t h e h u bs l e e v ea n ds h i f tf o r k .
Maximumclearanca:
1 . 0m m ( 0 . 0 3 9i n . )
l f t h e c l e a r a n c e x c e e d st h e l i m i t . 1 6 o l a c 6t h e s h i f t
f o r k o r h u bs l e e v e .
4 . I N S P E C TI N P U TS H A F T
( a ) C h e c kt h e i n p u ts h a f tf o r w e a r o r d a m a g e .
(b) Usinga micrometer,
m6asure " ffilt,;
the out€rdiam6ter
--. t h e i n p u ts h a f tj o u r n a ls u r f a c e .
Fs- gR'rg'r -i-el M i n i m u m o u t e r d i am s t o r
Part A
2 7 . 9 5 0m m ( 1 . 1 0 0 4I n . )
Part B and C
3 5 . 9 5 0m m ( 1. 4 1 5 4i n . )
( c ) U s i n g a d i a l i n d i c a t o r ,c h e c k t h e s h a f t r u n o u t .
M a x i m u m r un o u t :
0 . 0 5 m m ( 0 . 0 0 2 0i n . )
I N P U TS H A F TA S S E M B L Y
,--..4
/ /a,o ( S e ep a g e M X - 3 4 )
\
r'---z/ ' -r-
=F
"-w
,-.<\ {
c /A\\ HINT:Coatall of the slidingand rotatingsurfaceswith
.L
-
E-]
i i I
r f n
1. I N S T A L LN O . 2C L U T C HH U B I N T O H U B S L E E V E
F,^^r !E l
r,6rrn (a) I n s t a l tl h e 3 s p r i n g sa n d s h i f t i n gk e y s t o t h e c l u t c h
iFL
..i--
nuo.
u:il3t1 (b) I n s t a ltl h e h u b s l e e v et o t h e c l u t c hh u b .
HINT:Directidentification groovsof tha hub sleeveto
front of the transaxle.
2. I N S T A L LN E E D L ER O L L E RB E A R I N G S , 3 R D GEAR,
S Y N C H R O N I Z ER RI N G S A N D N O . 2 H U B S L E E V E
A S S E M B L YT O I N P U TS H A F T
(a) A p p l yM P g 1 6 a s 6 t o t h 6 n s 6 d l ar o l l e rb e a r i n g .
(b) A s s e m b l et h 6 n e a d l ar o l l e rb e a r i n g si n t ot h e 3 r d g e a r .
(c) P l a c et h e s y n c h r o n i z er irn g so n t h s g o a ra n d a l i g nt h e
ring slots with the shiftingkeys.

MX-38 - I N P U TS H A F T
(d) UsingSST and a press,installthe 3rd gear and No.2
hub sleeve.
s s T 0 9 5 0 6 - 3 5 0 10
axiap
l lay.
Mark Thicknoss mm (in.) Mark T h i c k n e s sm m ( i n . )
n 2.30(0.0906) 2.50(0.0984)
J 2.35(0.0925) N 2 . 5 5( 0 . 1 0 0 4 )
K 2.40(0,0945) 2 . 6 0( 0 . 1 0 2 4 )
L 2.45(0.0965)
( b ) U s i n ga s c r e w d r i v aarn d h a m m e rt,a p i n t h e s n a pr i n g .
4. M E A S U R3ER DG E A RT H R U S T CLEARANCE
U s i n ga f e e l e rg a u g e m
, e a s u r toh e 3 r d g e a rt h r u s t
clearancg.
0 . 1 0 - 0 . 4 5 m m ( 0 . 0 0 3 9- 0 . 0 1 7 7i n . )

MX-39
E56 MANUALTRANSAXLE- INPUTSHAFT
5. INSTALL SPACER,SYNCHRONIZER RING,NEEDLE

ROLLER B E A R I N G S , 4 T G
H E A R A N D R A D I A LB A L L
BEARING
(a) I n s t a ltl h e s p a c e r .
(b) A p p l yM P g r e a s et o t h s n s o d l er o l l e rb e a r i n g s .
(c) P l a c et h e s y n c h r o n i z er irn g o n t h e g e a ra n d a l i g nt h e
ring slots with tho shiftingkeys.
(d) Installthe 4th gsar.
SST
(e) U s i n gS S Ta n d a p r e s s i, n s t a l tl h e r a d i a lb a l lb e a r i n g .
s s r 0 9 5 0-6 3 5 0 0
1
( a ) S e l e c ta s n a pr i n g t h a t w i l l a l l o w m i n i m u ma x i a lp l a y . - , .
trw
r r -a. Lr k
M I T hh, i^cL k
T ^ 6n.e d mm (r ri nnI. )
. s sm M eark
M rk m nm (l lrnn, l. )
TI hhr ci ck kn onsoss sm
2.35(0.0925) 5 2 . 5 5( 0 . 1 0 0 4 )
2 2.40(0.0945) 2 . 6 01 0 . 1 0 2 4 )
2.45(0.0965) 7 2 . 6 5( 0 . r 0 4 3 )
4 2.50(0.0984) 8 2 . 7 0( 0 . 1 0 6 3 )
7, M E A S U R E4 T H G E A RT H R U S TC L E A R A N C E
U s i n g a f e e l e rg a u g e .m e a s u r et h e 4 t h g e a r t h r u s t
clearance.
S t a n d a r d c l a a l an c a :
0.10 - 0.55 mm (0.0039 - 0'0217 in.)

MX-40
E56 MANUAL TRANSAXLE- OUTPUTSHAFT
COMPONENTS
':,eW@: N e e d l eR o l l e rB e a r i n g
I
-f
r'iix, \V
f
Spacer
''nnrn,u,nn
W
,^.",-.t"ffiryW 2nd Gea,

Needre Bearing
[-
aOutp
L
r"v spring
i
^(NQ@' ttnct"onize'p
)VY N o .cr r u t c h H u b
@
I I
S y n c h r o n i z eR
r ing aOutput Shaft F r o n t B e a r i n g
OutputShaft
a Non-reusable
Part
OUTPUTSHAFTDISASSEMBLY
1. MEASURE l S T A N D 2 N D G E A RT H R U S TC L E A R .
ANCE
Usinga feelergauge,measure tho thrustclearance.
S t a n d a r dc l e o r a n c e :
lst g6ar
0.10 - 0.35 mm (0.0039- 0.0138 in.)
2nd g6ar
0 . 10 - 0 . 4 5 m m ( 0 . 0 0 3 9 - 0 . 0 17 7 i n . )
Maximumclearrnce:
l st gsar
0 . t 1 0m m ( 0 . 0 15 7 i n . )
2nd gosf
0 . 5 0 m m ( 0 . 0 1 9 7i n . )

MX-41
2. C H E C K1 S T A N D 2 N D G E A RR A D I A LC L E A R A N C E
, e a s u r et h e r a d i a lc l e a r a n c e
betwsenthe goar and shaft.
Standardcleatance:
1st gear
0.009 - 0.051mm (0.0004- 0.0020in.)
2nd gaar
0.009 - 0.053mm (0.0004- 0.0021in')
Maximumclsaranco:
1st and 2nd gear
0.070mm (0.0028in.)
lf the clearanceexceedstho limit, raplaceths goat' e,,*-^*
needlerollerbearingor shaft. t:] ttlx
3. REMOVEOUTPUTSHAFT REARBEARING,4 TH
DRIVENGEARAND SPACER
and4th drivengsar.
(a) Usinga press,remov€the bearing
(b) Removethe spacer.
4. REMOVE3RDDRIVENGEARAND 2ND GEAR

Usinga press,r€movethe 3rd drivengearand 2nd
g€ar.
5. REMOVENEEDLE ROLLER SPACER
BEARING, AND
S Y N C H R O N I ZB
EIRN G S
6. REMOVESNAPRING
romovethe snapring.
Usinga snapringexpander,

MX-42
E56 MANUALTRANSAXLE_ OUTPUTSHAFT
7. R E M O V EN O . 1 H U B S L E E V EA S S E M B L YA N D 1 S T
U
E GEAR
f,a Using a press,remove the No.1 hub sleeveand 1st
ffi gear.
8. R E M O V E S Y N C H R O N I Z E RR I N G A N D N E E D L E
R O L L E RB E A R I N G
9, REMOVE OUTPUT S H A F TF R O N TB E A R I N G
UsingSST,removethe outputshaftfront bearing.
MX s s T 0 9 9 s 0- 0 0 0 2 00. 9 9 5 0- 0 0 0 3 0
SST
lrla
O U T P U TS H A F TC O M P O N E NPTA R T S
INSPECTION
1 . I N S P E C T1 S T G E A RS Y N C H R O N I Z ERRI N G
T u r nt h e s y n c h r o n i z e r irn gi n o n ed i r e c t i o nw h i l ep u s h -
i n g i t t o t h e g e a rc o n e .C h e c kt h a t t h e r i n g l o c k s .
l f t h e b r a k i n ge f f e c t i s i n s u f f i c i e n ta, p p l y a s m a l l
a m o u n to f f i n e l a p p i n gc o m p o u n db e t w e e nt h e s y n -
c h r o n i z erri n g a n d g e a rc o n o .
L i g h t l yr u b t h e s y n c h r o n i z erri n g a n d g e a r c o n 6 t o -
gother.
NOTICE: Ensurathe finelappingcompound is completely
washedoff stter rubbing.
(c) Check again tha braking effect of the synchronizer
ring.
( d ) M e a s u r et h e c l e a r a n cbes t w 6 6 nt h e s y n c h r o n i z er irn g
Minimumclaarance:
0.6 mm (0.024in.)
l f t h e c l e a r a n c ei s l e s s t h a n t h e l i m i t , r a p l a c et h e
s y n c h r o n i z er ri n g a n d g e a r c o n s b y a p p l y i n ga s m a t t
a m o u n to f f i n e l a p p i n gc o m p o u n d .
NOTICE: Ensurethe fine lappingcompound is complstely
washedoff stter rubbing.

MX.43
E56 MANUALTRANSAXLE- OUTPUTSHAFT
2 . I N S P E C T2 N D G E A RS Y N C H R O N I Z ERRI N G
( a ) C h e c kf o r w s a r o r d a m a g e .
(b) Checkthe brakingeffect of the synchronizer direction
w h i l ep u s h i n gi t t o t h e g s a rc o n e .C h e c kt h a t t h e r i n g
locks.
lf it does not lock, replacethe synchronizerring.
(c) Msasurethe clgarancebotwsenthe synchronizerring

b a c ka n d g e a rs P l i n es n d .
Minimumclearance: MX
0.7 mm (0.028in.)
lf the clearanceis Iess than the limit, replacethe
sYnchronizer ring.
3. M E A S U R EN O . l S H I F T F O R K A N D H U B S L E E V E
CLEARANCE
Usinga feelgrgaugo.measurethe clearancebetween
th6 hub slaeveand shift fork.
Maximumclearance:
1.0 mm (0.039in.)
l f t h e c l e a r a n c e x c e e d st h o l i m i t , r o p l a c et h B s h i f t
fork or hub sleeve.
4. INSPECTOUTPUTSHAFT
(a) Chsckthe output shaft for wear or damage.
(b) Using a micromstsr,measurethe outer diameterof
lho output shaft journalsurface
Minimum outel diameter:
38.950 mm (1.5335 in.)
( c ) U s i n ga d i a l i n d i c a t o rc,h e c kt h e s h a f t r u n o u t .
Maximumrunout:
0.06mm (0.0024in.)

MX-44 _ OUTPUT
E56MANUALTRANSAXLE SHAFT
OUTPUTSHAFTASSEMBLY
( S e ep a s eM X - 4 0 )
HINT:Coatall of the sliding and rotatingsurfaceswith
1. I N S T A L LN O . 1C L U T C HH U B I N T O H U B S L E E V E
(a) I n s t a l lt h s c l u t c h h u b a n d s h i f t i n gk e y s r o t h e h u b
sleeve.
(b) I n s t a l tl h 6 s h i f t i n gk e y s p r i n g su n d e rt h e s h i f r i n gk e y s .
I{OTICE:Installthe key apringspositionod so that thoir
endsare not in line.
2. I N S T A L L N E E D L ER O L L E RB E A R I N G ,1 S T G E A R .
MX S Y N C H R O N I Z ERRI N GA N D N O . 1 H U B S L E E V ET O
OUTPUTSHAFT
(a) Apply MP greas6to ths needlerollar bearing.
(b) l n s t a l tl h e I s t g e a r .
(c) Placothe synchronizerring (for 1st gear)on the gaar
and aligntha ring slots with the shiftingkeys.
( d ) U s i n gS S T a n d a p r e s s ,i n s t a l tl h e l s t g e a ra n d N o . 1
hub sleeve.
s s T 0 9 3 16 - 6 0 0 10 ( 0 9 3 16 - 0 0 0 4 0 )
a x i ap
l lay.
Mark Thickn€6! mm (in.) Thicknoss mm (in.)
2 . 8 0( 0 , 1 1 0 2 ) 3 . 0 0( 0 . r1 8 1 )
2 . 8 5( 0 . 1 2
r 2) 3 . 0 5( 0 . 1 2 0 1 )
c 2 . 9 0( 0 . 114 2 ) 3 . 1 0( 0 . 1 2 2 0 )
D 2 . 9 5( 0 . 1 6 1 )
(b) Usinga snap ring expander,installth6 snap ring.

MX.45
E56 MANUALTRANSAXLE_ OUTPUTSHAFT
4. M E A S U R El S T G E A RT H R U S TC L E A R A N C E
U s t n ga f e e l e rg a u g e ,m e a s u r et h e 1 s t g e a r t h r u s t
clearance.
Standrrdclearance:
0 . 1 0- 0 . 3 5m m ( 0 . 0 0 3 9- 0 . 0 1 3 8i n . )
5, INSTALL SPACER, NEEDLE ROLLER BEARING,

S Y N C H R O N I Z E R I N G S ,2 N D G E A R A N D 3 R D , , .
fi\rmnffi
[\tJft,]\a)vp'a
D R I V E NG E A R
(a) Installthe spacer.
(b) Apply MP greaseto lhe needlerollerbearing.
(c) Plac6 the synchronizerrings (for 2nd gear) on the
;MX
\\}/\Y/vW gear.
NOTICE: Do not installthe synchronizer ring for ihe lst
goar,
( d ) I n s t a ltl h e 2 n d g e a r .
(e) Usinga press,installtho 3rd drivengear.
NOTICE: Alignthe clutchhub groovaswith the projec'
tions on thg synchronizar ling.
6. M E A S U R2EN DG E A RT H R U S T CLEARANCE
g
U s i n ga f e e l e r a u g e ,
m e a s u r t
e h e 2 n d g e a rt h r u s t
clearance.
0 . 1 0 - 0 . 4 5 m m ( 0 . 0 0 3 9- 0 . 0 ' l 7 7i n . )
7 . I N S T A L LS P A C E R A N D4 T H D R I V E N
GEAR
(a) Insta l l t h es p a c e r .
(b) Usinga press,installthe 4th drivengear.

MX-46
8. INSTALLOUTPUTSHAFTREARBEARING
U s i n gS S Ta n da p r e s si ,n s t a ltlh e b e a r i n g .
s s T0 9 5 0 6 - 3 0 0 1 2
9. I N S T A L LO U T P U TS H A F TF R O N TB E A R I N G
UsingSSTand a press,installa new output shaft front
MX bearing.
s s T 0 9 3 16 - 6 0 0 10 ( 0 9 3 16 - 0 0 0 7 0 )

- O I LP U M P MX-47
O I LP U M P
COMPONENTS
,i o-R i n g
II
r --- d
Oil Strainer
ffi-o''"ô
V M
D r i v e nR o t o r
O i l P um p D r i v eF o t o r
O i l P u m pC a s e o r'^ P u m p D r i v eG e a r
\r2\-- Ret el Vatve \z
v r.'- o,,'
" ,rrrrr|,__
sr,,ng
spt ns Holder
Q
' qô.ifi6d
N m ( k g fc m , i l t^r^, o O i l P u m pC o v e r
a N o n - r e u s a b lpea r l
O I L P U M PD I S A S S E M B L Y
1. OF OIL PUMP
C H E C KO P E R A T I O N
Installtha oil pump drivegearto the driverotor,check
that the drive rotor turns smoothlv.
2. REMOVEGASKETFROM OIL PUMP CASE

MX-48
E56 MANUALTRANSAXLE- OIL PUMP
3. REMOVEOIL STRAINER
SETBOLT
4, REMOVEOIL PUMPCOVER
(a) Holdthe pumpcov€r,removethe 2 boltsandcover.
MX
ri ( b ) R e m o v et h e s p r i n gh o l d e rs, p r i n g b, a l la n d r e l i e fv a l v e
ssat.
5. CHECKROTORBODY CLEARANCE
(a) Installthe oil pump drive gear to the drive rotor.
(b) Using a feeler gauge, measurethe body clsarancs
betwosnth6 driv6 rotor and oil oumo case.
Standardcleara nce:
0.10 - 0.16 mm (0.0039- 0.0063in.)
Maximumclearsnce:
0.30 mm (0.0118 in.)
6 . C H E C KR O T O RT I P C L E A R A N C E
(a) Installthe oil pump drivegear lo tho driva rotor.
( b ) U s i n ga f e e l e rg a u g e ,m e a s u 1 t6h e t i p c l e a r a n c eb e -
tween th6 drive and drivenrotors.
Standsrdclearance:
0.08 - 0.15 mm (0.0031- 0.0059in.)
Maximumclearanca:
0 . 3 0m m ( 0 . 0 1 8 i n . )

MX-49
E56 MANUALTRANSAXLE_ OIL PUMP
7. C H E C KS I D EC L E A R A N C E
Usinga precisionstraightedgeand feelargauge,mea-
sure tha side clearanceof both rotors,
Standardcleara ncg:
0.03 0.08 mm (0.0012- 0.0031in.)
-
Maximumcloatanca:
0 . 1 5m m ( 0 . 0 0 5 9i n' )
8. REMOVEOIL PUMPORIVEROTORAND DRIVEN

ROTOR
9. IF NECESSARY, REPLACE O-RING

removetho O-ring.
( b ) A p p l yg e a ro i l t o a n e w O - r i n g .
( c ) I n s t al l t h e O - r i n g .
O I L P U M PA S S E M B L Y
( S e ep a g eM X - 4 7 )
A N D D R I V ER O T O R
ROTOR
1 . I N S T A L LD R I V E N
F 6 92r E 6 9 1 3

MX-50 _ O I LP U M P
2 . I N S T A L LO I L P U M PC O V E R
( a ) I n s t a lt lh er e l i evf a l v eb, a l ls, p r i n ga n ds p r i n gh o l d etro
t h e o i l p u m pc a s e .
(b) Hold the oil pump cover, temporarilyinstall the 2

bolts.
MX
3. I N S T A L LO I LS T R A I N E R
I n s t a ltlh eo i ls t r a i n et o
r t h eo i lp u m pc a s et.e m p o r a r i l y
installths bolt.
4. TOROUE OIL PUMPCOVERBOLTS

Torquethe 3 boltsevenly.
T o r q u e :1 0 N . m ( 1 0 5 k g f . c m , 8 f t . l b t )
5. C H E C KO P E R A T I OONF O I L P U M P
Installthe oil pumpdrivegearto th6 driverotor,check
that the driverotorturnssmoothlv.

_ O I LP U M P MX-51
6. I N S T A L LG A S K E T
I n s t a lal n e wg a s k etto t h e o i l p u m pc a s e .

MX-52 - sHrFTANDsELEcrLEVER
Es6 MANUALTRANsAXLE sHAFT
COMPONENTS
C o n t r o lS h a f t C o v e r
a O i lS e a l
D u s tE o o t
i
S h i J tI n t e r l o c kP l a t e
iA_"
I
I
S " t u " tI n n e rL e v e r
I N o . 1C o m P r e s s i oSnP r i n g
@v
A
t
Mqt-
m \90!ueisnao
I
-J 1
,^qqNA/
'<ft
ugw.':l*,:::,:;^,,",,
l t ( e
Rins
S-l
r:]Tjt_
I srotleoso,insern Y\-.--r",,".
N o 2S h i l fnt n Le er v e r
L - " ' , - 4 -
o m p r e s s i oSnp n n g i
I
S p r i n gS e a t
I
I
N o 1 S h i f t I n n e rL e v e r
S h i f t a n d S e l e c tL e v e rS h a f t
S H I F TA N D S E L E C T
L E V E RS H A F T
DISASSEMBLY
1 . R E M O V EN O . 2S H I F TI N N E RL E V E R
( a ) U s i n ga p i n p u n c ha n d h a m m e r d, r i v eo u t t h e s l o t t e d
s p n n gp r n .
( b ) U s i n g2 s c r e w d r i v e rasn d a h a m m e rr. e m o v et h e s n a p
r r ng .

_ S H I F TA N D S E L E C T MX.53
E 5 6 M A N U A LT R A N S A X L E L E V E RS H A F T
( c ) R e m o v et h e N o . 2 s e l e c ts p r i n gs o a t ,N o . 2 c o m p 1 6 s -
s i o n s p r i n ga n d N o . 2s h i f t i n n e rl e v e r .
2. R E M O V ES H I F T I N T E R L O C KP L A T E A N D N O . 1
(a) Usinga pin punch and hammer,drive out the slotted ffi
s p r i ng p i n .
t6972
( b ) R e m o v et h e s h i f t i n t e r l o c kp l a t ea n d N o . 1s h i f t i n n e r
lever.
3. REMOVE SELECT I N N E RL E V E R
( a ) U s i n ga p i n p u n c ha n dh a m m e rd, r i v eo u t t h o s l o t t e d
s p r i n gp i n .
(b) Remove the select inner lever, No. 1 compression

s p r i n ga n d N o , 1s e l e c ts p r i n gs e a t .
€69r5

MX-54
856 MANUALTRANsAxLE- sHrFTANDsELEcrLEVER
sHAFT
4. REMOVESNAP RING
Using2 screwdriversand a hammer,ramovethe snap
ring.
5. REMOVE CONTROL SHAFT COVER AND DUST

BOOT
(a) Rsmovs the control shaft with dust boot from the
shaft.
(b) Removeths dust boot from the control shaft cover
6. IF NECESSARY,REPLACE CONTROL SHAFT

C O V E RO I LS E A L
(a) Usinga screwdriver, pry out tha oil seal.
( b ) U s i n gS S Ta n da h a m m e rd,r i v ei n a n e wo i l s e a l .
s s T0 9 6 2 0 - 3 0 001( 0 9 6 2 7 - 3 0 0 1009, 6 3 -10 0 0 2 0 )
Drivein dopih:
O - 1 0 m m ( 0 - 0 . 0 3 9i n . )
(c) Coatthe oil seallip with MP grease.

MX-55
E56 MANUALTRANSAXLE- SHIFTAND SELECTLEVERSHAFT
ASSEMBLY
( S e ep a s eM X - 5 2 )
1. AS SHOWN
COATSHAFTWITHMP GREASE,
.MX
2. I N S T A L LD U S T B O O T A N D C O N T R O LS H A F T
COVER
(a) lnstalltha dust boot to the controlshaft coveras
@ shown.
(b) Installths controlshaft to the control shaft cover'
U s i n ga b r a s sb a r a n d h a m m e r i,n s t a l tl h e s n a pr i n g

MX-56
E56MANUALTRANsAxLE- sHrFTANDsELEcrLEVER
SHAFT
4. INSTALL SELECT I N N E RL E V E R
( a ) I n s t a ltlh o N o . 1s e l e c st p r i n gs e a t ,N o . 1c o m p r e s s i o n
s p r i n ga n ds e l e c itn n g rl e v e r .
( b ) U s i n ga p i n p u n c ha n d h a m m e r d , r i v ei n t h e s l o t t e d
0 + 0 . 5m m
( 0 a 0 . 0 2 0i n . s p f l n gp r n .
MX Driv6in doDth:
0 + 0.5 mm (0 + 0.020in.)
( c ) C h e c kt h a t t h € N o . 1s e l e c ts p r i n gs e a ts l i d s ss m o o t h -
lv.
5. INSTALL SHIFT INTERLOCKPLATE AND NO. 1

( a ) I n s t a l lt h o s h i f t i n t e r l o c ko l a t e a n d N o . 1 s h i f t i n n 6 r
leveras shown.
(b) Using a pin punch and hammer,drive in the slotted

s p r i n gp i n .
0 + 0 . 5m m
( 0 + 0 . 0 2 0i n . ) Drivein depth:
0 t 0.5 mm (0 + 0.020in.)
6. INSTALLNO.2SHIFTINNERLEVER
( a ) I n s t a ltlh e N o . 2s h i f t i n n e rl e v e r N
, o . 2c o m p r e s s i o n
springand No.2selectspringseat.

MX-57
E56 MANUALTRANSAXLE_ SHIFTAND SELECTLEVERSHAFT
(b) Compressthe spring and installthe snap ring with
ollgrs.
, r i v oi n t h s s l o t t e d
( c ) U s i n ga p i n p u n c ha n d h a m m e r d
s p r i n gp i n . *iili*
0 * 0.5mm Drivein depth:
( 0 + 0 . 0 2 0i n , ) 0 I 0.5 mm (0 + 0.020in.)
(d) Checkthat the No.2 selectspringseat slidessmooth-
tv.

MX-58
E56 MANUAL TRANSAXLE_ DIFFERENTIAL
CASE
COMPONENTS
* [ 5a{550.
aorl ---
G
TransaxleCaseCover
,f oil seal- \ ^
(rut550'ao) n P i n i o nS h a f tH o l d e r
ftfX @
Shaft
@6 @ ^ 'x a?-Pinion
Ag:- Differentia
I Pinion
fu=- D;ffe
r e n r iIaS i d eG e a r
tig'( side,cear Th,ust
O/--
G-rq) \-./ vvasner
.H P i n i o nT h r u s tW a s h e r
tg
R i gh t S i d e B e ar i n g
V e h i c l eS p e e dS e n s o r
D r i v eG e a r
S n a p Ri n g
D l f f e r en t i a l
R i n gG e ar
Lett S ide Bearing
'9
t1t,1r6opil I
'un
/,',b"3-
|/'52
N m (kqfcm, ft lbf) : S p e c i f i e dt o r qu e
a N o n - r e u s a b lpea n
P r e c o a t e dp a r t

MX-59
E56 MANUALTRANSAXLE- DIFFERENTIAL
CASE
C LA S ED I S A S S E M B L Y
DIFFERENTIA
1. REMOVS E I D EB E A R I N G
(a) UsingSST,removethe RH sidebearing'
s s T0 9 9 5 0 - 4 0 0 1 0
(b) UsingSST,removethe LH side baaring.

09950-00030
ssT09950-00020, : trrtx
2. REMOVE R I N GG E A R
Malchmarks caseand
(a) Placematchmarks on both the differential
ringgear.
( b ) R e m o v st h e 1 6 b o l t s .
( c ) U s i n ga p l a s t i ch a m m e rt,a p o u t t h e r r n gg e a r .

MX-60
E56 MANUALTRANSAXLE_ DIFFERENTIAL
CASE
3. REMOVE VEHICLS EPEED SENSOD R R I V EG E A R

removethe snapring.
(b) Removethe vehiclespeedsensordrivegear.
4 . D I S A S S E M B LD EI F F E R E N T I ACLA S E
Matchmarks
( a ) P l a c em a t c h m a r k so n t h s d i f f e r e n t i arli g h t a n d l e f t
MX casa.
(b) Removeth6 2 screws.
(c) Disassemble
the differentialcase.side gearand thrust
wasner,
A\
v
r@)
( d ) U s i n ga p i n p u n c h d
, r i v eo u t t h e 3 s l o t t e ds p r i n gp i n s .

- DIFFERENTIA
MX-61
E 5 6 M A N U A LT R A N S A X L E C IA S E
( e ) R e m o v et h e 3 p i n i o ns h a f t s , 4 p i n i o ng e a r s . 4 p i n i o n
4s.r-''&s washersand shaft holder'
n a.v- ! .%a
"€-5.,-
(:;)
a\==\
(f) Removetho side gear and thrust washer from the

rishtcass.
differenriat
i:"iilfi-
5. TRANSMISSION CASESIDE:
I F N E C E S S A RR
YE, PLACO E I L S E A LA N D T A P E R
ROLLER BEARINO G U T E RR A C E
(a) Usinga screwdriver, removethe oil seal.
(b) R6movothe transmission oil baffle.
( c ) U s i n ga b r a s sb a r a n d h a m m e r d, r i v eo u t t h e b e a r i n g
;-r--Vl
S:<,
o u l e r r a c s l i g h t l ya n d e v e n l Y .
\:-\,
( d ) R e m o v et h e s h i m .
\ 1 1
.. <-\
'--'="Ns*
4\ \ .:.!
\\, _-{
E8815
( e ) I n s t al l t h e s h i m .
(Seepage MX- 58)
HINTF t n d i n s t a lal s h i mo f l e s s e tr h i c k n e s s
: i r s ts e l e c a
than before.

MX-62
CASE
(f) Using SST and a press, install a new taper roller
beanng outor race.
s s T 0 9 3 16 - 6 0 0 10 { 0 9 3 6
1 - 0 0 0 10 , 0 9 3 16 - 0 0 0 4 0 )
(S) Installthe transmissionoil baffle.

H I N T :I n s t a l l t h e
t r a n s m i s s i ooni l b a f f l eo r o t e c t i o ni n t o
MX the case side c utout.
( h ) U s i n gS S Ta n da h a m m s rd, r r v ei n a n e wo i l s e a l .
s s T 0 9 2 2 3- 15 0 10
( i ) C o a t h e l i po f o i l s e a lw i t h M P g r e a s e .
6. TRANSAXLECASE SIDE:
I F N E C E S S A R YR. E P L A C EO I L S E A L A N D T A P E R
R O L L E RB E A R I N GO U T E RR A C E
(a) Removeth€ 4 bolts and 3 nuts.
1-3le',-,2i .l-
hFryqi
\'- \3/ ll
(b) Usinga plastichammer,tap the stud boltsand remove

the transaxlecase cover.

MX-63
CASE
( c ) U s i n ga s c r e w d r i v ear n d h a m m e r ,d r i v e o u t t h e o i l
seat.
( d ) U s i n gS S T ,a b r a s sb a ra n d h a m m e rr.e m o v et h e t a p e r
r o l l e rb e a r i n go u t e rr ac e .
s s T 0 9 6 12 - 6 5 0 14 ;MX
( e ) U s i n gS S T a n d a h a m m e r ,i n s t a l la n e w t a p e r r o l l e r
b e a n n go u t e rr a c e .
s s r 0 9 3 16 - 6 0 0 10 ( 0 9 316 - 0 0 0 10 , 0 9 3 16 - 0 0 0 4 0 )
-.3.=
E83?0 i r:1.
( f ) U s i n gS S Ta n da h a m m e rd,r i v ei n a n e wo i l s e a l .
s s T0 9 3 16 - 6 0 0 10 ( 0 9 361- 0 0 0 10 )
( g ) C o a t h e o i l s e a l i pw i t h M P g r e a s e .
(h) Removethe FIPGmaterialand be carefulnot to drop

oil on the contactingsurfacssof ths transaxlecasoor
case covor.
(i) Apply FIPGto the transaxlecase cover,as shown.
FIPG:
Part No.08826-00090. THREEEOND1281or equi-
valsnt
H I N T :I n s t a l tl h s t r a n s a x l oc a s ec o v e r ,a s t h 6 F I P Gi s
ao ol i a d .

MX-64 - DIFFERENTIAL
E56MANUALTRANSAXLE CASE
U) Apply sealantto th6 bolt threads.

Sealent:
Part No.08833-00080,THREEBOND1344, LOC-
TITE242 or aquivalont
te./ ( T
-,- t\ | (k) Installand torque the 4 bolts and 3 nuts.
r-2r'\ l-ll Torque:54 N.m(550kgf.cm.40ft.lbf)
t- -- t I

- DIFFERENTIAL MX-05
E56MANUALTRANSAXLE qASE
DIFFERENTIAL CASEASSEMBLY
( S e ep a g eM X - 5 8 )
1, ASSEMBLEDIFFERENTIAL CASE
(a) Installthe thrust washorand differentialside gear to
th€ diff6r6ntialright case.
(b) Installthe 3 pinionshafts,4 pinions,4pinionwashErs

and shaft holder.
(c) Usinga pinpunch,drivein the 3 slottodspringpinsto

I rightcase.
the differentia
(d) Usinga dial indicator,measurethe backlashof pinion

g e a rw h i l eh o l d i n gt h e N o . 2s h a f th o l d e r .
Standardbacklach:
0.05- 0.20 mm (0.0020-0.0079In.)
HINT: Push tha pinion g€ar of th€ l€ft side of the
differentialcase.
(e) Installtho side gear, pinion shafts and shaft holdor
with the 4 pinionsto the right sido of the differential
casg,
And check tho side gear backlash.
(f) Referringto tha table below,selectthe thrust washer
which will snsurethat the backlashis within specifica-
tion. Try to selecta washerof th€ samo sizg.
Thickn{r mm (in.) Thicknrlr mm (in.)
0.80 {0.0315) t.zo lo.o472l
0.90(o.o3s4) L30 (0.051
2)
1.00(o.o3s4) L40 (0.0551)
r.10(0.0433)

MX-66 - D I F F E R E N T IC
E 5 6 M A N U A LT R A N S A X L E ALASE
(g) Assemblathe differentialcase,side gear and thrust
washer.
rA\
v
1@\
\a6Ar
(h) Align the matchmarkson the differntialcases.

M a t c h ma r ks
(i) Installand tighlen the 2 screws.
2 . I N S T A L LV E H I C L ES P E E DS E N S O RD R I V EG E A R
(a) Install the vehicle speed sensor drive g6ar to the
differentialright case.
( b ) I n s t a ltl h e s n a pr i n g .
3. INSTALL RINGGEAR
(a) Cl6anthe contactsurfaceof th€ difforentialcase and
the threadsof the ring gear and differentialcase.
(b) Hsat the ring gear in boilingwater.
(c) Carefullyremoetho ring gear from the water.
(d) After the moisturs on the ring gear has completely
evaporated,quicklyinstallthe ring gear to the differ-
6 ntiaI case.

MX.67
CASE
HINT: Align tha matchmarkson the differentialleft

case and contactthe ring gear.
( e ) T e m p o r a r i liyn s t a l l h o 1 6 b o l t s .
NOTICE: The ringgaarsat boltsshouldnot be tightanod
untilthe ringgearhascool6dsufficiently.
(f) After the ring gear has cooledsufficiently,torque the
ring gear set bolts.
Torque:124 N m (1,260kgf.cm,91 ft lbf)
4 . I N S T A L LS I D EB E A R I N G
( a ) U s i n gS S Ta n d a p r e s s i,n s t a l al n e w R H s i d e b e a r i n g .
s s T 0 9 3 16 - 2 0 0 11
(b) UsingSST and a press.installa new LH side bearing.

t, o ( 0 9 361- o o o 1o )
s s r 0 9 3 61 - 6 0 0 1
n
-'l SHAFTASSEMBLY PRELOAD
5. ADJUSTOUTPUT
l (Seepase MX-70)
6. INSTALLDIFFERENTIAL CASEASSEMBLY
to tho transaxls
caseassemblv
lnstalltha differential
case.
7. INSTALLOUTPUTSHAFTASSMBLY
case,installtho input shaft
Lift up th6 differential
assemotv.

MX-68
E56 MANUAL TRANSAXLE_ DIFFERENTIAL
CASE
8 . I N S T A L LT R A N S M I S S I OG NA S E
( a ) I n s t a ltl h e t r a n s m i s s i ocna s a .
HINT: lf nscsssary,tap on the case with a plastic
hammer.
( b ) I n s t a l al n d t o r q u et h e 1 7 b o l t s .
Torque:29 N m (300kgt.cm.22 ft.lbt)
9. I N S T A L L O U T P U TS H A F T R E A R T A P E R R O L L E R
B E A R I N GO U T E RR A C E
U s i n gS S T a n d a h a m m e r i, n s t a l a
l n e w o u t p u ts h a f t
rear taper rollerbearingouter race.
s s T 0 9 3 16 - 6 0 0 10 ( 0 9 3 6
1 - 0 0 0 10 )
1 0 , I N S T A L LS H I M
( S e ep a s eM X - 7 0 a n dM X - 7 1 )
H I N T I: n s t a ltlh e p r e v i o u ssl ye l e c t esdh i m .
1 1 . I N S T A L LR E A RB E A R I N GR E T A I N E R
U s i n g a t o r x w r e n c h ,i n s t a l la n d t o r q u e t h e 7 t o r x
screws.
(Torxwrench T45 09042 - 00050)
1 2 . A D J U S TD I F F E R E N T I ACLA S ES I D EB E A R I N GP R E -
LOAD
(a) Installa new lock nut to the output shaft.
( b ) T u r n t h e o u t p u t s h a f t r i g h t a n d l e f t 2 o r 3 t i m e st o
a l l o wt h e b e a r i n g tso s e t t l 6 .

_ D I F F E R E N T IC MX-69
E 5 6 M A N U A LT R A N S A X L E ALASE
( c ) U s i n ga s m a l lt o r q u ew r e n c h ,m e a s u r ot h e p r e l o a d .
Preload{at starting):
New baaring(Addoutputshaftpreload)
0.2 - 0.4 N.m(2.0 - 4.1 kgf'cm,1.7 - 3.6 In..lbf)
Raused bearing(Addoutputshaftpreload)
0 . 1 - 0 . 2 N m ( 1 . 3- 2 . 5k s f . c m 1 , . 1 - 2 . 2I n . . l b f )
l f t h e p r s l o a di s n o t w i t h i n s p e c i f i c a t i o ns,e l e c ta n
a p p r o p r i a taed j u s t i n gs h i m .
H I N T :T h e t o t a l p r e l o a dw i l l c h a n g ea b o u t0 . 1 - 0 , 2
N . m ( 1 - 2 k g f. c m , 0 . 9 - 1 . 7 f t . l b f )f o r e v e r y0 . 0 5
m m c h a n g ei n a d j u s t i n gs h i mt h i c k n e s s .
Mark T h i c k n 6 s sm m ( i n . ) T h i c k n € s 6m m ( i n . )
0 2 00 (0.0787) 9 2.45(0,0965)
2.05(0.0807) 2.50(0,0984)
2 2 . 1 0( 0 . 0 8 2 7 ) E 2 . 5 5( o , 1 o 0 4 )
3 2 . 15 ( 0 . 0 8 4 6 ) 2 , 6 0( 0 . 1 0 2 4 1
4 2 . 2 0( 0 . 0 8 6 6 ) 2 . 6 5( 0 , 1 0 4 3 )
5 2 . 2 5( 0 . 0 8 8 6 ) E 2 . 7 0( 0 .r 0 6 3 )
6 2 . 3 0( 0 , 0 9 0 6 ) F 2 . 7 5( 0 r, 0 8 3 )
l 2 . 3 5( 0 . 0 9 2 5 ) 2 , 8 0( 0 . 1r 0 2 )
I 2 . 4 0( 0 . 0 9 4 s ) n 2 . 8 5\ O . 1 1 2 2 )
1 3 . R E M O V ER E A RB E A R I N GR E T A I N E R
Using a torx wrench. removethe 7 torx screws and
rear bearingretainer.
(TorxwrenchT45 09042- 00050)
1 4 , R E M O V ES H I M
1 5 . R E M O V ET R A N S M I S S I OC NA S E
( a ) R e m o v st h e 1 7 b o l t s .
( b ) U s i n ga p l a s t i ch a m m e rt,a p t h 6 t r a n s m i s s i ocna s e .
16. REMOVE
OUTPUT S H A F TA S S E M B L Y
17. REMOVE
D I F F E R E N T IC
AAL S EA S S E M B L Y

E56MANUALTRANSAXLE
C O M P O N E NP
TA R T SI N S T A L L A T I O N
BASICSUBASSEMBLY REASSEM BLY
( S e ep a g e sM X - 1 7 t o M X - 1 9 )
H I N T :C o a ta l l o f t h e s l i d i n ga n d r o t a t i n gs u r f a c ew i t h
1. INSTALL MAGNET TO TRANSAXLECASE
2 . I N S T A L LO I L P U M PA S S E M B L YA N D O I L P I P E
( a ) l n s t a l tl h e o i l p u m pa s s e m b l y .
( b ) I n s t a ltl h 6 2 b o l t s .
H I N T :B a c a r 6 f u n l o t t o d r o pt h a o i l p u m pg a s k e t .
( c ) I n s t a ltl h e o i l p i p ea n d 2 b o l t s .
IW
(d) Torquethe 4 bolts.
T o r q u e1: 7 N . m( 1 7 5k g f . c m 1, 3 f r . l b f )
3. ADJUSTOUTPUTSHAFTPRELOAD
( a ) I n s t a lt lh e o u t p u ts h a f ta s s e m o t y .
9g_

- coMPoNENT
TRANSAXLE
E56MANUAL PARrsINSTALLATIoLYI1
( b ) l n s t a l tl h e t r a n s m i s s i ocna s e .
HINT: lf necsssary,tap on ths case with a plastlc
hammer.
i-
ll ( c ) I n s t a l al n d t o r q u ot h e 1 7 b o l t s .
Torque:29 N.m(300kgf'cm,22tt lbf)
( d ) l n s t a l tl h e o u t p u ts h a f tr e a rt a p e rr o l l a rb e a r i n go u t e r
race.
( e ) I n s t a l tl h 6 a d j u s t i n gs h i m .
H I N T :W h e n r e - u s i n g t h e o u t p u ts h a f t b e a r i n gf,i r s t
i n s t a l la s h i m o f t h e s a m e t h i c k n e s sa s b e f o r e .l f MX
i n s t a l l i n ag n e w t a p e r e dr o l l e rb e a r i n gf,i r s ts e l e c ta n d
i n s t a l al s h i m o f l e s s e tr h i c k n e s st h a n b e f o r e .
(f) Installthe bearingretainer.

( s ) U s i n ga t o r x w r e n c h ,i n s t a l al n d t o r q u et h e 7 b o l t s .
(TorxwrenchT45 09042 00050) -
Torque:42 N.m(430kgf.cm,31 ft lbl)
( h ) I n s t a l al n e w l o c k n u t t o t h e o u t p u ts h a f t .
( i ) T u r n t h e o u t p u t s h a f t r i g h t a n d l e f t 2 o r 3 t i m e st o
allow the bearingsto settle.

Mx-72 - coMpoNENTpARTsTNSTALLATToN
E56MANUALTRANSAxLE
(j) Usinga smalltorque w16nch,measurethe preload.
Preload(at starting):
New bearing
0 . 8 - 1 . 6N . m( 8 - 1 6 k g f . c m6, . 9 - 1 3 . 9i n . . l b f )
Reusedbearing
0.5 - 1.0 ll.m (5 - 10 kgf.cm,4.3 - 8.7 in..lbf)
lf the preloadis not within specification,s6l6ct the
a d j u s t i n gs h i m s .
H I N T :T h e p r e l o a dw r l l c h a n g ea b o u t0 . 4 - 0 . 5 N ' m
( 4 - 5 k g f . c m , 3 . 5 - 4 . 3 i n . . l b f f)o r e v e r y0 . 0 5 m m
c h a n g ei n s h i mt h i ck n e s s .
T h i c k n e s Em m ( i n . ) Mork T h i c k n 6 s sm m ( i n . )
MX 0 1. 3 0{ 0 . 0 521) 1 . 9 5( 0 . 0 7 6 8 )
1 , 3 5( 0 . 0 s 3 1 a 2.00(0.0787)
1 , 4 0( 0 , 0 5 5 1 2.0s(0.0807)
1 . 4 5( 0 , 0 5 7 1 2.r0 (0.0827)
4 1 . 5 0( 0 . 0 5 9 1 n 2 . 1 5( 0 . 0 8 4 6 )
5 r.ss(0.0610) J 2.20(0.0866)
1 . 8 0( 0 . 0 8 3 0 ) K 2.25(0.0886)
7 1 . 8 5( 0 . 0 8 5 0 ) L 2.30(0.0906)
1.70(0.0689) 2.3s(0.0925)
I 1 . 7 5( 0 , 0 6 8 9 ) 2.40(0.0945)
r . 8 0( 0 . 0 7 0 9 ) 2.4s (0.0985)
1 . 8 s( 0 . 0 7 2 8 ) 2.50(0.0984)
1.90(0.0748)
(k) Removethe lock nut.

(l) Using a torx wrench, 16mov6the 7 torx screws and
rear bearingretainer.
(TorxwrenchT45 09042- 00050)
(m) Removethe shim.

(n) Rsmovethe 17 bolts and transmissioncase.
(o) Removethe output shaft assembly.

MX.73
E56 MANUALTRANSAXLE_ COMPONENT
PARTSINSTALLATION
4. CASEASSEMBLY
INSTALLDIFFERENTIAL
5. OIL PUMPDRIVEGEAR
TNSTALL
6. INSTALLOUTPUTSHAFTASSEMBLY
case,installth€ outputshaft
(a) Lift up the differential
assemblv.
(b) Leaningth6 output shaftto the differentialside,inslall

the input shaft assemblY.
7, INSTALLSNAPRINGS
(a) Usinga plastichammsr,installthe snapringsto the
No.1, No.2and No.3shiftfork shafts.

MX-74 - coMpoNENTpARTSrNsrALLATroN
Es6 MANUALTRANsAXLE
(b) Using a plastic hammer,the reverssshift fork and
s n a pr i n gt o t h € N o . 3s h i f t f o r k s h a f t .
8. I N S T A L LN O . 2S H I F TF O R KA N DN O . 3S H I F TF O R K
S H A F TW I T HR E V E R SSEH T F F TO R K
MX ( a ) I n s t a ltlh e N o . 2s h i f tf o r kt o t h e N o . 2h u bs l e e v e .
(b) Installth6 No.3shift fork shaft with reverseshift forx.
9. I N S T A L LN O . 1S H I F TF O R K ,S H I F TH E A D A N D
N O . 2S H I F TF O R KS H A F T
( a ) l n s t a l tl h e N o . l s h i f t f o r k t o t h e N o . l h u b s l e e v e .
( b ) P u t s h i f t h e a do n l o t h e N o . l s h i f t f o r k .

MX-75
- COMPONENT
E56MANUALTRANSAXLE PARTSINSTALLA
{c) lnstallthe No.2 shift fork shaft to tho transaxlecase.

t h r o u g ht h e s h i f t h e a da n d N o . 1s h i f t f o r k
t8610
1 0 . I N S T A L LI N T E R L O C K ROLLER
U s i n ga m a g n e t i cf i n g e r ,i n s t a l tl h o i n t e r l o c kr o l l e rt o
the reversashift fork. MX
1 1 . I N S T A L LN O . l S H I F TF O R KS H A F T
l n s t a l lt h 6 N o . 1s h i f t f o r k s h a f t t o t h e c a s e ,t h r o u g h
the No.1 shift fork and reverseshift fork.
HINT:When it is difficult to push the fork shaft thr-
o u g ht h e r e v e r s es h i f tf o r k ,p u l lu p t h e N o . 3s h i f t f o r k
shaft.
1 2 . I N S T A L LS E T B O L T S
I n s t a l al n d t o r q u ot h e 3 s e t b o l t s .
1 3 . I N S T A L LL O C K I N G B A L L SS , PRINGS S,E A T SA N D
PLUGS
s n ds e a t s .
( a ) l n s t a ltlh e 2 l o c k i n gb a l l ss, p r i n g a

Mx-76
E 5 6M A N U A LT R A N s A x L -E c o M p o N E N pr A R T ST N S T A L L A T T o N
( b ) A p p l ys e a l a n t o t h e 2 p l u g s .
Sealant:
Part No.08833-00080.THREEBOND1344, LOC-
Tlf E 242 or aauivalsnt
( c ) U s i n ga h e x a g o nw r s n c h ,r n s t a lal n d t o r q u e2 p l u g s
Torqua:25 N.m(250kgf.cm,18 ft.lbf)
1 4 . I N S T A L LR E V E R SIE
D L E RG E A RA N DS H A F T
(a) Installth6 raverseidlergearshaftand thrustwasher
MX t o t h e sh a f t .
(b) Installthe reverse idler gear shaft into the case hole.
( c ) A l i g n m a t c h m a r kas s s h o w n .
1 5 . I N S T A L LR E V E R S E
S H I F TA R M B R A C K E TA N D
NO.z OIL PIPE
(a) Put the reverssshift fork pivot into the reverseshift
arm installthe reverseshift arm bracketio the trans-
axre case.
(b) Install the bolt.
(c) Installthe No.2 oil pipe and 2 bolts.

(d) Torquethe reverseshift arm and oil pump bolts.
Torque:17 N.m(175kgt.cm,13 ft.lbf)

E56 MANUAL TRANSAXLE_ COMPONENT
PARTSINSTALLATIO
(e) Installa new gasketto the No.2 oil pipe.
.=.'...
1 6 . I N S T A L LT R A N S M I S S I OC NA S E
(a) Removsths FIPGmaterialand be carefulnot to drop ,.,,....... .
o i l o n t h s c o n t a c t i n gs u r f a c e so f t h e t r a n s m i s s i o n M X
case or lransaxlecase.
S e a lb r e'1a d t h
approx mm (0 04 in ) (b) Apply FIPGto the transmissioncase as shown in the
illustration.
FIPG:
Part No.08826-00090. THREEBOND1281or equi'
vslent
H I N T :I n s t a l tl h e t r a n s m i s s i ocna s ea s s h o w n a s t h e
F I P Gi s a p p l i e d .
( c ) I n s t a l la n d t o r q u e t h o 1 4 b o l t s t o t h 6 t r a n s m i s s i o n
casgsld€.
T o r q u e :2 9 N m ( 3 0 0 k g f ' c m . 2 2 f t l b f )
(d) Install and torque the 3 bolts to the transaxle cass
side.
T o r q u e :2 9 N m ( 3 0 0 k g f ' c m , 2 2 f t l b f )
I D L E RG E A R
1 7 I N S T A L LA N D T O R O U ER E V E R S E
SHAFT R E T A I N I NBGO L T
Torque:29 N,m(300kgf cm' 22 {t lbf)
1 8 . I N S T A L L L O C K I N G B A L L , S P R I N G ,S E A T A N D
PLUG
( a ) l n s t a l tl h 6 l o c k i n gb a l l .s p r i n ga n d s e a t .
(b) Apply soalantto tho Plug.

Saalant:
P a r t N o . 0 8 8 3 3 - 0 0 0 8 0 , T H R E EB O N D 1 3 4 4 . L O C '
f llE 242 or equivalant
( c ) U s i n g a h e x a g o nw r e n c h , i n s t a l la n d t o r q u e t h e p l u g .
T o r q u e :2 5 N m ( 2 5 0 k g f c m , 1 8 f t l b f )

MX-78
E s 6M A N U A LT R A N s A X L-E c o M p o N E N pTA R T ST N S T A L L A T T o N
1 9 . I N S T A L LS N A PR I N G S
U s i n ga p l a s t i ch a m m e r i,n s t a l tl h e 3 s n a pr i n g s .
2 0 . I N S T A L LO U T P U TS H A F TR E A RT A P E RR O L L E R
BEARINO G U T E RR A C E
MX U s i n ga p l a s t i ch a m m a rt a
, p i n t h e o u t e rr a c o .
2 1 . I N S T A L LS H I M
H I N T :I n s t a l tl h e p r e v i o u s lsye l e c t e ds h i m .
2 2 . I N S T A L LS N A PR I N G
U s i n ga s n a pr i n ge x p a n d e ri n
, s t a ltlh e s n a pr i n gt o t h e
input shaft rear bearing.
23. INSTALL REARBEARINGRETAINER

(a) Cleanthe threadsof th6 torx screws.
(b) Using a torx wrench, install and torque the 7 torx
screws.
(TorxwrenchT45 09042- 00050)

MX.79
E56 MANUALTRANSAXLE_ COMPONENT
PARTSINSTALLATION
2 4 . I N S T A L LN E E D L ER O L L E RB E A R I N GA N D 5 T H
GEAR
2 5 . I N S T A L LN O . s S Y N C H R O N I Z ERRI N G SW I T H K E Y
S P R | N GT O N O . 3C L U T C HH U B rr
( a ) A s s e m b l et h e N o . ss y n c h r o n i z er irn g s . MX
( b ) U s i n ga s c r e w d r i v e irn, s t a l tl h e s n a pr i n g .
HINT:Wrap vinyl tape on the screwdriverto prevent
d a ma g i n gt h e s y n c h r o n i z er irn g .
(c) Installthe No.5synchronizer ringswith key springsto

t h e N o . 3c l u t c hh u b .
H I N T :A l i g n t h e h o l e s o f t h e c l u t c h h u b w i t h k e v
spring.
2 6 . I N S T A L LN O . 3C L U T C HH U B
U s i n g S S T , i n s t a l lt h o N o . 3 c l u t c h h u b w i t h s v n -
c h r o n i z erri n g a n d k e y s p r i n g .
s s T 0 9 9 5 0- 3 0 0 10
27. INSTALLSNAPRING
a snapringthat will allowminimumaxialplay.
(a) Se16ct
Mark Thicknsss mm {in.} Thickn6ss mm {in.)
o 2.25(0.0886) 2.s0 (0.0984)
2 . 3 0( 0 . 0 9 0 6 ) 2 . 5 5( 0 . 1 0 0 4 )
2.35to.o92s) X 2 . 6 0( 0 . 10 2 4 )
T 2.40(0.0945) Y 2 . 6 s( 0 . 1 0 4 3 )
2.45(0.0965)

MX-80
E56 MANUAL TRANsAxLE- coMpoNENT pARTSTNSTALLATToN
( b ) U s i n ga b r a s sb a ra n d a h a m m e ri,n s t a ltl h e s n a pr i n g .
2 8 . I N S P E C Ts T H G E A RT H R U S TC L E A R A N C E
, e a s u r st h e s t h g e a r t h r u s t
clearance.
Stsndardclearance:
0.10 - 0.57 mm (0.0039-0.O224in.l
29. INSTALLsTH DRIVENGEAR

UsingSST,installtho Sth drivengear.
s s T 0 9 9 5 0 -3 0 0 1 0
3 0 . I N S T A L LN O . 3 H U B S L E E V EW I T H N O . 3 S H I F T
FORK
3 1 . I N S T A L LS E TB O L T
Installandtorquatha set bolt.
T o r q u e :2 4 N . m ( 2 4 0 k g f . c m , 1 7 t t . l b f )

MX.81
E56 MANUAL TRANSAXLE- COMPONENT
PARTSINSTALLATION
32. INSTALL LOCK NUT

( a ) E n g a g €t h a g e a rd o u b l em e s h i n g
( b ) I n s t a l al n d t o r q u et h o l o c k n u t .
Torque:123 N.m(1.250kg{.cm,90 ft'lbf)
( c ) D i s e n g a gteh e g € a rd o u b l em e s h i n g .
(d) Stakethe lock nut.
33. INSTALL TRANSMISSION CASE COVER

(a) Removethe FIPGmaterialand be carefulnot to drop
o i l o n t h e c o n t a c t i n gs u r f a c e so f t h e t r a n s m i s s i o n
case cover.
( b ) A p p l yF I P Gt o t h o t r a n s m i s s i ocna s ea s s h o w ni n t h e
figure.
FIPG:
P a r tN o . 0 8 8 2 6 - 0 0 0 9 0T.H R E E B O N D1 2 8 1o r e q u i '
v a I gn t
H I N T :l n s t a l tl h e t r a n s m i s s i ocna s ec o v o ra s s o o n a s
t h e F I P Gi s ap p l i e d .
(c) I n s t a l al n d t o r q u et h e 1 0 b o l t s .
Torqu6:29 N.m(300kgf.cm,22 ft'lbt)
34. INSTALL SHIFT AND SELECT LEVER SHAFT AS-
SEMBLY
(a) Placea new gasket in positionon the control shaft
cover.
(b) lnstallthe controlshaft cover.
lc, Apply sealantto ths bolt threads.
Sealant:
Pari No.08833-00080,THREEBOND1344,LOC'
Tlf E 242 or equivalent
(d) lnstalland toroue ths 4 bolts.
Torque:20 N m (200kgf'cm.14 ft lbf)
35. I N S T A L LA N D T O R O U EL O C K B O L T
T o r q u e : 4 9N . m( 5 0 0k g f c m , 3 6 f t ' l b f )

MX'82
E56 MANUAL TRANsAxLE- coMpoNENT pARTSTNSTALLATToN
3 6 . I N S T A L LB R E A T H E R
PLUG
Torque:49 N.m(500kgf.cm,36ft'lbf)
3 7 . I N S T A L LA N D T O R O U ES E L E C T I N B
GE L L C R A N K
' '7 ASSEMBLY
'5j'\-... T o r q u e :2 0 N . m ( 2 0 0 k g f . c m , 1 4 f t . l b f )
MX -'!
3 8 . I N S T A L LB A C K _ U PL I G H TS W I T C H
T o r q u e :4 0 N m ( 4 10 k g f . c m , 3 0 t t . l b f)
.J:--\
39. INSTALL SPEEDSENSORORIVENGEAR

40. INSTALL RELEASEFORKAND BEARING

A p p l ym o l y b d e n u m d i s u l p h i d lei t h i u mb a s eg r e a s et o
the f ollowingparts:
. I no u t s h a f ts o l i n e
r Releasefork contact surface
I

MX.83
_ S H I F TL E V E RA N D C O N T R OC
E 5 6 M A N U A LT R A N S A X L E L ABLE
CABLE
S H I F TL E V E RA N D C O N T R O L
COMPONENTS
S h i tf L e v e rKn o b
scuffPlate Uppereu"",
console
$
cowlsider,,"-4reP M
C e n t e rC l u s t e rF i n i s hP a n e l
H e a t e rC o n t r o l P a n e l
G ove Compartment
re I Scuff Plate
F i n i s hP a n e'H*P
--r
L o w e r C e n t e r F i n i s hP a n e l
u o w l S r o e l r lm
t--l--
1, tlro5l Ietarner
't
P a i n t e dM a r k
7
tu
S h i f tL e v e rA s s e m b l y
Washer----€t- Clip
Heat Insulator
N . m ( k 1 . c m ,f t . l b l ) : S p e c i f i e dt o r q u e

MX-84
E56 MANUALTRANSAXLE_ SERVICE
SPECIFICATIONS
SERVICE
SPECIFICATIONS
S E R V I CD
EATA
I n p u tB h a f t3 r d a n d 4 t h g 6 a rj o u r n a d
l iam6t6r
Limit 3 5 . 9 5 0m m ( 1 . 4 15 4 i n . )
Input shatt sth 906r journal di.m6ter
Ltm |l 2 7 . 9 5 0m m ( 1 . 1 0 0 4i n . )
l n p u ts h a f tr u n o u t
Llmrt 0.05 mm (0.0020in.)
O u t p u ts h a f t l 6 t 6 n d 2 n d g 6 a rl o u r n a d i a m g t e r
Limit 3 8 . 9 5 0m m ( 1 . 5 3 3 5i n . )
Output shsft funout
MX Lrmrt 0.06 mm (0.0024 in.)
G € a rt h f u s tc l € a r 6 n c o l s t
STD 0 . 1 0- 0 . 3 5n m { 0 . 0 0 3 9- 0 . 0 1 3 8i n . )
L i mi t 0 . 4 0m m ( 0 . 0 1 5 7
in.)
G o 6 rt h r u s tc o 6 r a n c o 2 n d
STD 0 . r 0 - 0 . 4 5 m n ( 0 . 0 0 3 9- 0 . 0 1 7 7 i n . )
Ltmtt 0 . 5 0m m ( 0 . 0 1 9 7
in.)
G o a rt h r u s tc l s s r 6 n c q 3 r d
STD 0 . 1 0- 0 . 4 5m m ( 0 . 0 0 3 9- 0 . 0 1 7 7i n . )
Ltm t! 0 . 5 0 m m ( 0 . 0 19 7 i n . )
G s a rt h r u s tc a a a a n c o4 t h
STD 0 . 1 0- 0 . 5 5r " n ( 0 . 0 0 3 9- 0 . 0 2 1 7i n . )
Lrmrt 0 . 6 0 m m ( 0 . 0 2 3 6i n . )
G € a rt h r u s tc l € s r a n c e 5 t h
STD 0.10 - 0.57mm (0.0039 O.A224i^.)
Lrmrt 0 . 6 5 m m ( 0 . 0 2 5 6i n . )
G 6 a fr a d i a c 6 a r a n c o l s t
STD 0 . 0 0 9- 0 . 0 5 1m m ( 0 . 0 0 0 4 0 . 0 0 2 0i n . )
Lrmrt 0 . 0 7 0m m( 0 . 0 0 2 8
in.)
G € o rr a d i a cl l € a r a n c 6 2 n d
STD -_9:o!!'19!991_i ooSL
^)
9oo'
LIMII 0 . 0 7 0m m{ 0 . 0 0 2 8
in.)
G66r radialc oaranc€ 3rd
STD 0.009- 0.053mm (0.0004- 0.oo21in.)
Lrmrt 0 . 0 7 0m m ( 0 . 0 0 2 8
in.)
G 6 a rf s d i a c l 6 a r a n c 6 4 t h
STD 0 . 0 0 3- 0 . 0 5 I m m ( 0 . 0 0 0 4- 0 . 0 0 2 0i n . )
Limit 0 . 0 7 0m m( 0 . 0 0 2 8
in.)
G€ar radrrl cloarance sth
STD 0.009- 0.050mm (0.0004- 0.0020in.)
Limit 0 . 0 7 0m m( 0 . 0 0 2 8
in.)
S h i f tl o r k t o h u b s l 6 o v 6c o s r a n c s
Llrn t 1 . 0m m ( 0 . 0 3 9i n , )
Shynchronizerring to g6ar cloarancs 1st, 4th and sth
Lrmrt 0 . 6m m ( 0 . 0 2 4i n . )
S y n c h r o n i z er irn g t o g e a rc l € s r a n c € 2 n d a n d 3 r d
0 . 7 m m { 0 . 0 2 8i n . )

MX.85
E 5 6 M A N U A LT F A N S A X L E_ S E R V I CSEP E C I F I C A T I O N S
I n p u ts h a f t s n a pr i n gt h t c k n o s s
N o . 2c l u t c hh u b MarkH 2.30mm (0.0906in.)
No2 c utchhub M a r kJ 2 . 3 5r n m( 0 . 0 9 2 5
in.)
N o . 2c l u t c hh u b M a r kK 2.40mm (0.0945in.)
N o . 2 c l u t c hh u b MarkL 2 . 4 5 m m ( 0 . 0 9 6 5' n . )
N o . 2c l u t c hh u b MarkM 2 . 5 0 m m ( 0 . 0 3 8 4i n . )
N o . 2c l t c h h u b M a r kN 2 . 5 5 m m 1 0 . 1 0 0 4i n . )
N o . 2c l u t c hh u b M a r kP 2 . 6 0 m m ( 0 . 10 2 4 i n . )
N o . 3c l u t c hh u b M a r kO 2 . 25 m m( 0 . 0 8 8 6
'n.)
N o . 3c u t c h h u b MarkR 2 . 3 0m m( 0 . 0 9 0 6
in.)
N o . 3c L r t c hh u b M a r kS 2 . 3 5m m( 0 . 0 9 2 5
in.)
N o . 3c l u t c hh u b M a r kT 2.40mm (0.0945in.)
N o . 3c l u t c hh u b Marku 2 . 4 5m m( 0 . 0 9 6 5
in.)
N o 3 c l u t c hh u b M a r kv 2 . 5 0 m m ( 0 . 0 9 8 4i n . )
N o . 3c u t c h h u b M a r kW 2 . 5 5m m ( 0 . 1 0 0 4
in.)
N o . 3c l u t c hh u b M a r kX 2 8 0 . n n 1 0 . I0 2 4 i n . l
N o 3 c l u t c hh u b M a r kY 2 . 6 5 m m ( 0 . 10 4 3 i n . )
OLltputshaft snap ring thrckness

N o . 1c l L r t c h u b M a r kA 2 . 8 0m m ( 0 . 11 0 2i n . )
No.l clutch hub Msfk I 2 . 8 5m n l 0 1 1 2 2 i ^ . 1
N o . l c l u t c hh r . r b MsrkC 2 . 9 0 m m ( 0 . 11 4 2 i n . )
N o . 1c u t c h h u b MsrkD 2 . 9 5m m ( 0 . 1 1 6 1i n . )
No.l c utchhub MarkE 3 . 0 0 m m ( 0 . 1 1 8 1i n . )
N o l c l u t c hh u b MarkF 3 . 0 5 m m ( 0 . 1 2 0 1i n . )
N o . 1c l u t c hh u b M a r kG I S . to . r ( 0 . 1 2 2i 0
n.)
O r p u m p b o d yc l o a r a n c o I
STD 0 . 1 0- 0 . 1 6m m ( 0 . 0 0 4- 0 . 0 0 5i n . )
Ltm |l 0 . 3 0m m ( 0 . 0 1 2i n . )
Orl pump tip c166rance
STD 0 . 0 8- 0 . 1 5m m ( 0 , 0 0 3- 0 . 0 0 6i n , )
Limit 0 . 3 0m m ( 0 . 0 1 2i n . )
O r lp u m p s i d ec l e a r a n c e
STD 0.03 - 0.08mm (0.001- 0,003in.)
L i mi t 0 , 15 m m ( 0 . 0 0 6i n . )
Contro shaft covor oil s€al drive in depth 0 - 1 . 0m m { 0 - 0 . 0 3 9i n , )

MX-86
E56 MANUALTRANSAXLE- SERVICE
SPECIFICATIONS
D'fferentra prnronto srdegear back ash 0 . 0 5- 0 . 2 0m m 1 0 . 0 0 2 0 - 0 . 0 0 7i n9. l

i Ditforentialsido goar thrust washer thjcknoss
Non6 Mark 0 . 8 0m m ( 0 . 0 3 1 5
in.)
Non6 Mark 0.90 mm (0.0354 in.)
N o n oM a r k 1.00mm (0.0394in.)
N o n oM a r k 1 . 1 0m m ( 0 . 0 4 3 3
in.)
N o n 6M a r k 1 . 2 0m m ( 0 . 0 4 7 2
in.)
N o n 6M a r k 1 . 3 0m m( 0 . 0 5 1 2in.)
Non6 Mark 1.40 mm (0.0551in.)
Diff6rentialcas6 sid6 b6aringpre oad (at starting)
Now bearing(add output shaft pre oadj 0 . 2 - 0 , 4 N m ( 2 . 0 - 4 . 1 k s f . c m ,1 . 7 - 3 . 6 i n .l b f )
Re.rsed beaflng (add oJtpJt shaft pr€lo6d) 0.1 - 0.2 N m (l .3 - 2.5 kgf.cn,1.1 - 2.2 in.lbll
Diff616ntialside b6aringadjustingshim thicknoss
Mark0 2.00mm (0.0787in.)
MarkI 2.05mm (0.0807In.)
M6rk 2 2 . 1 0 m m ( 0 . 0 8 2 7i n . )
Mark 3 2 . 1 5m m ( 0 . 0 9 4 6
in.)
M a r k4 2.20mm (0.0855in.)
M a r k5 2.25mm (0.0886in.)
M a r k6 2.30mm (0.0906in,)
M a r k7 2 . 3 5 m m ( 0 . 0 9 2 5i n . )
M a r k8 2.40mm (0.0945in.)
M a r kI 2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
Mark B 2 . 5 5 m m ( 0 . 10 0 4 I n . )
M a r kC 2 . 6 0m m ( 0 . 1 0 2 4
in.)
MarkD 2 . 5 5m m ( 0 . 1 0 4 3
in.)
MarkE 2 . 7 0 m m ( 0 . 1 0 6 3i n , )
Mark F 2 . 7 5 m m ( 0 . 1 0 8 3i n . )
Mark G 2 . 8 0m m( 0 . 110 2 i n . )
Mark H 2 . 8 5m m( 0 . 112 2 i n . )
Output shaft b6aringpr€load(at starting)
N6w b€aring 0 . 8 - 1 . 6N m ( 8 - 1 6 k g t c m . 6 . 9- 1 3 . 9 , n . l b t )
Reus€dbearing 0 . 5 - 1 . 0 N . m ( 5 - 10 k s f c m , 4 . 3 - 8 . 7 i n . . l b f )

MX.87
E56 MANUAL TRANSAXLE_ SERVICE
SPECIFICATIONS
OLrtputshaft roar bearingadjustingshirnthicknoss

M a r k0 in.)
1 . 3 0m m{ 0 . 0 5 1 2
Mark1 1.35 mm (0.0531 in.)
M a r k2 1 . 4 0 m m ( 0 . 0 5 5 1i n . )
M a r k3 1 . 4 5m m ( 0 . 0 5 7 1i n . )
M a r k4 1. 5 0m m ( 0 . 0 5 9 1
in.)
M a r k5 1 . 5 5 m m ( 0 . 0 6 1 0i n . )
M a r k6 1 . 6 0 m m ( 0 . 0 6 3 0i n . )
Mark 7 1 . 6 5m m ( 0 . 0 6 5 0
in.)
Mark 8 1 . 7 0 m m ( 0 . 0 6 6 9I n . )
M a r k9 1.75 mm (0.0689 in.)
1 . 8 0 m m ( 0 . 0 7 0 9i n , )
M a r kB 1 . 8 5m m( 0 . 0 7 2 8
in.)
M a r kC 1 . 9 0m m ( 0 . 0 7 4 8i n . )
MarkD 1 . 9 5 m m ( 0 . 0 7 6 8' n . )
M a r kE 2 . 0 0m m( 0 . 0 7 8 7
in.)
M a r kF 2.05 mm (0.0807 in.)
M a r kG 2 . 1 0m m ( 0 . 0 8 2 7
in.)
MarkH 2 . 1 5m m ( 0 . 0 8 4 6
in.)
M a r kJ 2 . 2 0 m m ( 0 . 0 8 6 6i n . )
M a r kK 2 . 2 5 m m ( 0 . 0 8 8 6i n . )
M a r kL 2.30mm (0.0906in.)
2 . 3 5 m m ( 0 . 0 9 2 5i n . )
MarkN 2.40 mm (0.0945 in.)
2 . 4 5 m m ( 0 . 0 9 6 5i n . )
M a r kO 2 . 5 0m m( 0 . 0 9 8 4
in.)
Shift eve. preload 0 . 4 9 - 1 . 4 7N . m ( 6 0 1 5 0 k s f ' c m ,0 1 - 0 3 t t l b f )
Shift l6v6r preloadadlustingshim thickness

0 . 5 m m ( 0 . 0 2 0i n . )
M a r kB 0,6 mm (0.024in.)
MErk C 0.7 mm (0.028in.)
M a r kD 0 . 8m m ( 0 . 0 3 1i n . )
MarkE 0 . 9 m m ( 0 . 0 3 5i n . )
MarkF L 0 m m ( 0 . 0 3 9i n . )
M a r kG L 1 mm (0.043in.)
Msrk H L2 mm (0.047 in.)
M a r kJ 1 . 3 m m ( 0 , 0 5 1i n . )
Mark K 1 . 4 m m ( 0 . 0 5 5i n . )
MarkL 1 . 5 m m ( 0 . 0 5 9i n . )
1 . 6 m m ( 0 . 0 6 3i n . )
Mark N 1 . 7 m m ( 0 . 0 6 7i n . )

MX-88 - S E R V I CS
E 5 6 M A N U A LT R A N S A X L E EP E C I F I C A T I O N S
TOROUE
SPECIFICATIONS
Part ti9t6n6d N m kgf.cm ft. bt
TransaxoxEngne
12 mmbolt 64 47
10 mm bolt 4E 470
Contormemborx Body 530
E n g i n ol o f t m o u n t i n gx T f a n s a x l e 64 6s0 47
E n g i n gr g 8 rm o u n tn g x T r s n s a x6 77 790 57
E n g , r 9 ' e 8 fr r o u n t , n gx C o n t g r r 6 m b 6 r 64 650 47
E n g i n €r e 6 rm o u n t i n gx t h r o u g hb o t a1 890 64
E n g i n 6l r o n t m o u n t i n gx T r a n s s xo 77 790
E l g n 6 f r o . l t r o ! n t r n g x C e n t s rm e n b 6 r 64 650 47
E n gn 6 f r o n t m o u n t i n gt h r o u g hb o t 890 64
F r o n te x h S u s ot i o sx E x h a u s m
t anifold 62 630 46
E x h a u s pt p 6 s u p p o r tb r s c k o ts 6 t b o t 6 n d n u t 19 |95 t4
F'ont oxh6Jst pipe x Ro6rexhaJst pip6 43 440
G r o u n dc a b l ex T r s n s a xe 2\O t5
C u t c h r o o a s oc y i n d o rx T r a n s a x l o 120
H o a t I n s ! a t o r x C l u t c hr o € a s 6c y l i n d o r 120 I
S t a f t o rx T r a n s a x9 39 400
Transax6 x Transsxlecaso rec6iv6f 7.4 b5 tn. tot
OlpumpxCov€r 105
Transaxl6cas6 x Transaxo case cover 54 40
Diff616ntialright cas€ x Ditforenti8ll6ft caso 640 46
Oiffsrontlalrlng g6ar x Difle16nti6lcaso 124 1.260 sl
T r a n s a x6 c a a 6x O i l o u m o t7 175
Transaxl€cas6 x Taan6mission
c6ss 300
Rovorlo id16rgea. lock bo t 300
TranSmission
case x R€ar boaringrotain6r 42 430 3l
s t h d r i v 6 n9 6 a r o c k n u t 1,250
t t a n s m t S 6 t ocn6 s 6x t r 6 n s m t s s r ocna s oc o v o r 29
Shift snd seloct l6v€r shaft ock bolt 20 200 14
Shift l6v6r ock bolt 49
Ereathsrp l.lg 49
56 octing bel c.ank lock bolt 20 200 t4
B a c k- u p l i g h tl w i t c h 40 410 30
Vshicls8p.od 3€n8orlock bolt 7.4 65 in..bf
Shilt ov6r ba I cov6r lock bolt 43 in,lbt

AX-1
TRANSAXLE
AUTOMATIC
DESCR|PT|oN . . . . . . . . . . . .A. .X _ 2
opERATtON . . . . . . . . . . . . . . . . . A X4 _
PREPARATION " " "" AX- I
T R o U B L E S H O O T t .N. .G. . . . . . . . . . . . . . . . . . . . .A. .X. ._. .l 1
o N _ v E H t c L ER E p A t R. . . . . . . . . . . . . . . . . . . . . .A. .X. ._. 4 7
ASSEMBLY R E M O V A LA N D
TNSTALLATTON . . . . . . . . . .A. X _ 5 4
s E R V t c Es P E c l F l c A T l o N s . " " " "" " AX- 70

AX-2
AUTOMATICTRANSAXLE_ DESCRIPTION
DESCRIPTION
PRECAUTIONS
W h e n w o r k i n gw i t h F I P Gm a t e r i a ly. o u m u s t o b s e r v et h e f o l l o w i n g .
o U s i n g a r a z o rb l a d ea n d g a s k e ts c r a p e r ,r e m o v ea l l t h e o l d F I P Gm a t e r i a lt r o m t h o g a s k e ts u r f a c e s ,
o T h o r o u g h l yc l e a n a l l c o m p o n e n t i t o r e m o v ea l l t h g l o o s em a t e r i e l .
. C l e a n b o t h s e a l i n gs u r l a c a sw i t h a n o n - r e s i d u a s o l v o n t .
o A p p l y t h e F I P Gi n a n a p p r o x . 1 m m ( 0 . 0 4 i n . ) w i d e b e a d a l o n g t h e s e a l i n gs u r f a c e .
. P a r t s m u s t b e a s s e m b l a dw i t h i n 1 0 m i n u t e so f s p p l i c a t i o n O
. t h a r w i s a ,t h e F I P Gm a t o r i a lm u s t b e
r € m o v a da n d r e a p p l i e d .
lf the vehicle is equippedwith a mobile communicationsystem, r6fsr to the precaution in the lN
s ec t r on .
. . . . . -G
" E N E R AD
L ESCRIPTION
ri^
The A140E Electronically ControlledTransaxle(hereaftercalledECT)describedin this AX section
i s a l o c k - u p f o u r - s p e e da u t o m a t i ct r a n s a x l e
d e v e l o p e ed x c l u s i v e lf yo r u s ew i t h t r a n s v e r s e l y -
m o u n t e de n g i n e s .
Sectional Vi€w

AX-3
AUTOMATICTRANSAXLE_ DESCRIPTION
SPECIFICATIONS
Typ€ of Transaxl€ A 14 O E
Type of Engine
Torqu€ Convort€rStall Torque Ratio 2.0.1
Torqu6 Conv6rt€rLock - up Mechanism Equippsd
G 6 a rR a t i o lst G68r 2.810

2nd G6ar 1.549
3rd Gear 1.000
O/D Geor 0.706
Rgvors6G€ar 2.296
Numborof Discs / Plat€s O/D DaroctClutch(CJ 2/2
ForwardClurch(C,) 4/4
Oir6ct Clutch(C,
2nd Brake(8t AX
l st & Rev6rs6Brako{8,) 6/5
o,/D Brako(Bo) 2/4
2nd Coast Brak6(8,) Band Width mm (in ) 25 (0.98)
ATF Typ6 ATF DEXRON.tr
Capacityliter (US qts, lmp.qts) Totel 5 . 6( 5 . 9 , 4 . 9 )
Droin & Retill 1 . 6( 1 . 7r, . 4 )

AX-4
AUTOMATICTRANSAXLE_ OPERATION
OPERATION
P l a n e t a r yG o a r U n i t
SecondErake( Br)
O/D Direct
C u t c h( C o )
O n e- W a yC l u t c h
O / D B r a k e( 8 o ) No 2 (F
AX
I
O / D O n e- W a y \
N o . 1 ( F j) I I n p u tS h a f r
C l u t c h( F o )
l n t e r m e d l a t e R e a fP l a n e t a r y
I
Ffont Planetary
Shaft Ge a r Gear
O..... Operating
S h i t tl e v e r
G e a rP o s r t i o n Co c1 c2 Bo B3 F,
p o s r t rno
P Parking o
R Reverse c a
N Neutral C
1st C C o
D
C c o c
3rd a a o o
o/o o o l
1st c o o
2 2nd o o a o o
c a c l
L
1st C o o -.
'2nd
o C o o o
' D o w n - s h i fot n l y- n o u p - s hf t

AX-5
1. F U N C T I O NO F C O M P O N E N T S
COMPONENT FUNCTION
O / D D i r e c tC l u t c h( C o ) Connectsoverdrivesun gear and overdrivecarrier'
O , / D B r a k e( B o ) overdrivesun gearfrom tufningeitherclockwiseor countetcockwtse

Prevents
Whentransaxleis beingdrivenby eng ne, connectsoverdrivesun gearand
C l u t c h( F o )
O/D One-WaY ovefdrve carlet.
F r o n rC l u r c h( C i) Connectsinput shaftand intermediate

shalt
R e a rC i u t c h ( C ? ) C o n n e c t isn p u ts h a f ta n d f r o n t a n d r e a rp l a n e t a r yg e a r '
AX
P r e v e n t fsr o n t a n d r e a rp l a n e t a r sy u n g e a rf r o m t u r n i n ge i t h e rc l o c k w i s eo r
N o 1 B r a k e( B r )
countetclocKwrse.
outerraceof F. from lurningeitherclockwiseor counterclockwlse,
Prevents lhus
N o 2 B r a k e( 8 r )
f r o n t a n d r e a rp l a n e t a r sy u n g e a rf r o m t u r n i n gc o u n t e r c l o c k w i s e
preventing
N o . 3 B r a k e( 8 3 ) Prevents se
front planetatycarrierfrom 1!rningeitherclockwiseor counterclockw
W h e n 8 2 i s o p e r a t i n gp, r e v e n t sf r o n t a n d r e a rp l a n e t a r ys u n g e a rf r o m t u r n i n g
N o . 1 O n e - W a yC l u t c h( F .)
counterclockwise.
N o . 2 O n e - W a yC l u t c h( F : ) P r e v e n lfsr o n tp l a n e l a rcya r r i efrr o mt u r n i n gc o u n t e r c l o c k w t s e

Q / D PlanetatyRing Gear lntermedrate F r o n ta n d R e a f P l a n e t a r yS u n G e a r
a n d C o u n t e rD r v e G e a r Shaft R e a rP l a n e t a r y Front PlanetaryCarrier
Ri n g G e a r I n p u tS h
Carrier
O,/D Planetary
O / D P a n e t a f yS u n G e a r
F r o n t P l a n e l a r yR n g G e a r
B e a rP a n e t a r yC a r i e r
.'tl a

AX-6 _ OPERATION
AUTOMATIC
TRANSAXLE
Power from the enginetransmittodto the inputshaftvia the torquoconv6rtsris then transmitted
to the planetarg y e a r sb y t h e o p e r a t i o n of the clutch.
By operation -
o f t h e b r a k ea n d o n e w a y c l u t c h ,e i t h e rt h e p l a n e t a r cy a r r i s ro r t h e p l a n e t a r sy u n
g e a ra r c i m m o b i l i z e da ,l t e r i n gt h e s p e e do f r e v o l u t i o n
of the planetarg y e a ru n i t .
S h i f tc h a n g ei s c a r r i e do u t b y a l t e r i n gt h e c o m b i n a t i oonf c l u t c ha n d b r a k eo p e r a t i o n .
E a c hc l u t c ha n d b r a k eo p e r a t e sb y h y d r a u l i cp r e s s u r oG. e a rp o s i t i o n sa r e d e c i d e da c c o r d i n gt o
t h e t h r o t t l eo p e n i n ga n g l ea n d v e h i c l es p e e d a, n d s h i f t c h a n g ea u t o m a t i c a l o
l yc c u r s ,
The conditionsof operationfor each gear positionare shown in tho followingillustratrons:
D or 2 Rang6 1st Gsar 2 R a n g o2 n d G o s r
AX --.---14\
-q--*rkr |7l-r(F9 -4--?icF-r | \ 4 '|i{--'l"l
/:\r\I I
r-J \-/ I t
lr\*
.\.+
--.I l
t--l'
')L
--r.- I
F a0C(tflq:1f,1fi(plA
Lc-J\\-r j\wt]vz Pr
?J\- .l.vr-r rgr ij €p
lK,, A'*i\'n /)t{a\ |
, , \ l n
*
*'6:I
/F\r| o
O U -T E ]O A
r ! _ L
ET OUT M |.i ,1\
* _ _ T _ l
T1102
D Rang€ 2nd G6ar L R a n g s1 s t G e e r
D Range3rd Gear RangsRevsrso
-=---:ffi--rfD-rdl
AO(( ( t(,' prru
(:q{{::::S
t-j\- -r:r-1fEJ'\J
)t(<
l/ \\.t_-l :to
our et:r]+I 19
D RangeO/O G6ar

_ OPERATION AX-7
AUTOMATIC
TRANSAXLE
2. H Y D R A U L I CC O N T R O LS Y S T E M
The hydrauliccontrol system is composedof the oil pump,the valve body,the solenoidvalves,
t h e a c c u m u l a t o tr h, e c l u t c h e sa n d b r a k e sa, n d t h e g o v e r n o vr a l v ea s w e l l a s t h e f l u i d p a s s a g e s
w h i c h c o n n e c ta l l o f t h s s ec o m p o n e n t s .
Basedon the hydraulicp16ssurecreatedby the oil pump.the hydrauliccontrol systemgoverns
the hydraulicpressursactingon tho torqueconverter,clutchesand brakesin accordancewith ths
v e h i c l ed r i v i n gc o n d i t i o n s .
There are three solenoidvalveson the valvebody.
T h e N o . 1a n d N o . 2s o l e n o i d v a l v e sa r et u r n e do n a n do f f b y s i g n a l sf r o m t h e E n g i n ea n d E C TE C U
t o o p e r a t et h e s h i f t v a l v e sa n d c h a n g et h e g e a rs h i f t p o s i t i o n .
T h e N o . 3 s o l e n o i dv a l v s i s o p e r a t s db y s i g n a l sf r o m t h e E n g i n ea n d E C T E C U t o e n g a g eo r
d i s e n g a g teh e l o c k- u p c l u t c ho f t h o t o r q u ec o n v e r t a r .
:.AX
- H Y D R A U L I CC O N T R O LS Y S T E M
VALVEBODY - -r
I
pressurecontrol
Torqueconverter
S O L E N O IVDA L V E S

AX.8
3. ELECTRONICCONTROLSYSTEM
Tha electroniccontrolsystomfor controllingthe shift timing and th6 operationof ths lock-up
clutch is composedof tho followingthros parts:
( a ) Ssnsors:ThesesEnsethe vehiclespeedand throttlepositionand sendthis datato the Engineand
ECTECU in the form of electronicsignals.
(b) E n g i n ea n d E C TE C U T : h i sd e t e r m i n etsh e s h i f t a n d l o c k - u p t i m i n gb a s e du p o nt h e s i g n a l sf r o m
the ssnsors.
l c , Actuators:Solenoidvalvesdiverthydraulicpressurefrom one circuitof the hydrauliccontrolunit
t o a n o t h e rt,h u s c o n t r o l l i n sg h i f t i n ga n d l o c k - u p t i m i n g .
SENSORS Engineand ECTECU ACTUATORS

R P MS E N S O R
NEUTRALSTARTSWITCH
SPEEDSENSOR
Sslt.diagnostic
3y3tem
Brck.up systqm

- PREPARATION AX-9
TRANSAXLE
AUTOMATIC
PREPARATION
SST(SPECIAL TOOLS)
SERVICE
09308-00010 OilSoelPullor Removo.ida oo!r.h.ft oil torl.
09350-32014 TOYOTA Autom.ticTr!n3mi'aion

ToolSet
(09351-i20tO) ono-wrv clltch To.t Tool
-32020) statorstopPor
(09351
( 0 9 s 5- 1
32130)
-32lsOi olrt""r ."or""l'

(09351
lA\
09843- 18020 0iagnosis

chockwir6
09992-00094 O'l
AutomlticTrlnsmrssron Lrnapr033ur0
Q* Gr!ge Sot
Pr6sauro
OOLS
'93 Tost€rsot
09082-00050 ToYoTAEloctrical

AX-10
AUTOMATICTRANSAXLE_ PREPARATION
EOUIPMENT
S t r a i g h te d g e Chocktorquoconverter
installation.
V e r n i e rc a l i p e r s Ch€cktorqu€converter
rnstallation.
D i a li n d i c a t o o
r r d i a li n d i c a t o w
r i t h m a a n e t i cb a s e M€asures drive plat€ runout.
LUBRICANT
Itsm Capacity Classification
A u i o m a t r ct r a n s a xe t l u i d
w/o Differontialoi :
AX A T FD E X R O N . I I
Dryf iil 5 . 6 l i t 6 r s( 5 . 9U S q t s , 4 . 9 m p . q t s )
D r a i na n d r s f i l l 2 . 5 l i t o r s( 2 . 6U S q t s , 2 . 2 l m p . q t s )
Differenta oi
1 . 6 l i t e r s( 1 . 7 U S q t s , 1 . 4 m p . q t s ) A T FO E X R O N . I I
(w,/ A!tomatic transat 6)
s s M ( s P E c r AS
LERVTC
MEA T E R T A L S )
08833-00070 Adhosive1324, I Torqueconvertermountinsboh
T H R E E8 O N 0 1 3 2 4o r o q u i v a l o n t

_ TROUBLESHOOTING AX-1 1
TRANSAXLE
AUTOMATIC
TROUBLESHOOTING
G E N E R AILN F O R M A T I O N
T r o u b l eo c c u r r i n gi n t h e E C Tc a n s t e mf r o m o n e o f t h r e es o u r c e st;h e e n g i n et,h e E C To l s c t r o n i c
c o n t r o lu n i t o r t h e t r a n s a x l ei t s e l f . B e f o r et r o u b l e s h o o t i ndge, t e r m i n oi n w h i c h o f t h e s et h r s e
s o u r c e st h e p r o b l e ml i e s .a n d b e g i n t r o u b l e s h o o t i nwg i t h t h e s i m p l e s to p e r a t i o ng, r a d u a l l y
w o r k i n gu p i n o r d e ro f d i f f i c u l t Y .
B A S I CT R O U B L E S H O O T I N G
e h 6 t h e rt h e p r o b l e mi s e l e c t r i c aol r m e c h a n i c a l .
g e E C T f, i r s t d e t e r m i n w
B e f o r et r o u b l e s h o o t i nt h
To do this, just refer to the basictroubleshooting flow-chart providedbelow'
l f t h e c a u s ei s a l r e a d yk n o w n ,u s i n gt h e b a s i ct r o u b l e s h o o t i ncgh a r tb e l o wa l o n gw i t h t h e g o n B r a l
t r o u b l e s h o o t i ncgh a r to n t h e f o l l o w i n gp a g es h o u l ds p 6 o dt h e p r o c e d u r e
Bad
P r e l i m i n a rCy h e c k
{ S e ep a g eA X 1 4 )
OK R e p a ior r
Replace
Read DiagnosticCode
( S e ep a g eA X - T7 )
OK
Bad M e c h a n i c aSl y s t e mT e s t s
M a n u a lS h i f t i n gT e s t
( S e ep a g eA X 2 2 ) ( S e ep a g eA X 3 4 )
OK Bad
ElectricalControl System Check F e p a i rT r a n s a x l e

l S e ep a g eA X 2 3 )
OK 8ad
Bad R e p a i ro r R e p l a c e
\reu PdgY h^-ee,

AX-12 _ TROUBLESHOOTING
A U T O M A T I CT R A N S A X L E
G E NE R A LT R O UB L E S H O O T I N G
r a n u a (l .P u bN
* : R e f e tro A 1 4 0 EA u t o m a t iTc r a n s a x lRs e p a iM . o .R M 2 4 8 E )
Pfoblom Possiblecauss Remedy Page

F l u i dd i s c o l o r e do r F l u i dc o n t a m i n a t e d R e p l a c et l u i d AX-,14
s m e l l sb u r n t Torque converter f aulty R e p l a c et o r q u ec o n v e r t e r AX-54
T r a n s a x l ef a u l t y D i s a s s e m b laen d i n s p e c t
l r a n s a xl e
V e h i c l ed o € s n o t S h i f t c a b l eo u t o f a d j u s t m e n t A d j u s ts h l f t c a b l e AX 15
movein any forward V a l v e b o d y o r p r i m a f yr e g u l a t otra u l t y I n s p e c tv a l v eb o d y
rang€ or reverse
P a r k i n gl o c k p a w l f a u l t y I n s p e c tp a r k i n gl o c k p a w l
T o r q u ec o n v e r t € rf a u l t y R e p l a c et o r q u ec o n v e r t e r AX.54
C o n v e r t e rd r l v ep l a t e b r o k e n R e p l a c ed r i v ep l a t e AX-54
O i l s t r a i n e ri n t a k es c r e e nb l o c k e d C l e a ns c r e e n
T r a n s a x l ef a u l t y Di s a s s e m b l a
en d i n s p e c t
transaxle
S h i f t l e v e rp o s i t l o n S h i f t c a b l eo u t o f a d j u s t m e n t A d j u s ts h i f t c a b l e AX '15
incorrect N 4 a n u avla l v ea n d l e v e rf a u l t y I n s p e c tv a l v eb o d y
T r a n s a x l ef a u l t yt r a n s a x l e D i s a s s e m b laen d i n s p e c t *
H a r s h6 n g a g e m e n t T h r o t l l ec a b l eo u t o f a d j u s t m e n t A d j u s tt h r o t t l ec a b l e AX 15
I n t oa n y o r v e r a n g e V a l v e b o d y o r p r i m a r yr e g u l a t ofra u l t y I n s p e c tv a l v eb o d y *
A c c u m u l a t o fp s t o n sl a u l t y I n s p e c ta c c u m u l a t opr i s t o n s *
T r a n s a x l ef a u l t y Di s a s s e m be andinspect
I r a ns a xt e
D e l a y e d1 - 2 , 2 - 3 o r E l e c t r o n i c o n t r o lf a u l t y I n s p e c te l e c t r o n i c o n t r o l AX 23
3 - O / Du p - s h i J to, r
V a l v eb o d y l a u l t y I n s p e c tv a l v eb o d y
d o w n - s h i t t st r o m
!Jtu-J ot 5-z ano S o l e n o i dv a l v et a u l t y I n s p e c ts o l e n o i dv a l v e AX 31
shift bsckto O/D or
3 T h r o t t l ec a b l eo u t o f a d j ! s t m e n t A d j u s tt h f o t t l ec a b l e AX 15
'l-2,
S l i p so n 2-3 or S h i . f ct a b l eo u t o l a d j u s t m e n t A d j u s ts h i f t c a b l e AX,15
3 - O / Du p - s h i f t ,o r T h r o t t l ec a b l eo u t o l a d j u s t m e n t A d j ! s t t h r o t t l ec a b l e AX-15
s l i p so r s h u d d e r so n
a c c el er a t o
| n V a l v eb o d y f a u l t y I n s p e c tv a l v eb o d y
S o l e n o i dv a l v ef a u l t y I n s p e c ts o l e n o i dv a l v e AX 3,]
T r a n s a x l ef a u l t y D i s a s s e m b laen d i n s p e c t
t r an s ax l e
D r a g ,b i n d i n go r S h i f t c a b l eo u t o l a d j u s t r n e n t A d j u s ls h i f tc a b l e ,]5
AX
t i e - u po n 1 - 2 , 2 - 3 , o r Valvebodyfau ty I n s p e c tv a l v eb o d y
3-0/D up-shitt
T r a n s a x l ef a u l t y Di s a s s e m b l a
en d i n s p e c t t
transaxle

AX-13
AUTOMATICTRANSAXLE_ TROUBLESHOOTING
R e p a i rM a n u a l (. P u b .N o . R M 2 4 8 E )
* : R e f a rt o A 1 4 0 E A u t o m a t i cT r a n s a x l e
Problem Possiblecause Romody Pagc

N o l o c k - u pi n 2 n d , E l e c t r o n i c o n t r o lf a u l t y I n s p e c te l e c t r o n i c o n t r o l AX.23
3rd or O/D Valvebodytaulty I n s p e c tv a l v eb o d y *
S o l e n o i dv a l v el a u l t y l n s p e c ts o l e n o i dv a l v e AX.31
T r a n s a x l et a u l t y D isassembleand inspect trsn- t
s a xl e
H a r s hd o w n - s h i f t Throttle cable out of adjustment Adjust throttle cable AX-,15
T h r o t t l ec a b l ea n d c a m l a u l t y I n s p e c t h r o t t l ec a b l eB n dc a m AX.15
A c c u m u l a t o rp i s t o n sf a u l t y I n s p e c ta c c u m u l s t opr i s t o n s *
Valvebodyfaulty Inspectvalve body *
T r s n s a x l ef a u l t y D i s a s s e m b laen d i n s p a c t r s n - *
saxle
N o d o w n - s h i f tw h e n Valve body faulty Inspectvalv€ body
coasting S o l e n o i dv s l v e t a u l t y I n s p e c ts o l e n o i dv a l v e AX.31
Electroniccontrol faulty Inspectelectroniccontrol AX.23
D o w n - s h i l to c c u r s Thrott!e cable faulty I n s p e c t h r o t t l ec a b l e AX.15
t o o q u i c k l yo r t o o V a l v eb o d y f a u l t y lnspect valve body *
l a t ew h i l e c o a s t i n g
T r a n s a x l ef a u l t y D i s a s s e m b la€n d i n s p € c tt r a n - *
saxt€
S o l e n o i dv a l v el a u l t y Inspectsolenoidvalve AX.31
E l e c t r o n i c o n t r o lf a u l t y Inspect€lectroniccontrol AX.23
N o O / D - 3 ,3 - 2 o r 2 - 1 S o l € n o i dv a l v el a u l t y I n s p e c ts o l e n o i dv a l v € AX.31
k i ck - d ow n E l e c t r o n i c o n t r o lJ a u l t y Inspectel€ctroniccontrol 4X.23
Vslvs bodyfaulty I n s p € c tv a l v eb o d y *
T h r o t t l ec a b l eo u l o f a d j u s t m e n t Adjust throttle cable AX-15
No engine braking in S o l e n o i dv s l v e f a u l t y lnspect solenoidvalve AX.31
2 or L range E l e c t r o n i c o n t r o lf a u l t y Inspectelectroniccontrol AX-23
V a l v e b o d yf a u l t y Inspectvalve body *
T r a n s a x l ef a u l t y D i s a s s e m b l 8e n d i n s p e c tt r s n - t
saxie
Vehicle does not hold Shift cable out of adjustment A d j u s ts h i f t c a b l e AX.15
in P range P a r k i n gl o c k p a w l a n d s p r i n gf a u l t y I n s p e c tc a m a n d s p r i n g *

AX-14
AUTOMATICTRANSAXLE- TROUBLESHOOTING
P R E L I M I N A RCYH E C K
1. CHECKTRANSAXLEFLUID LEVEL
HINT: The vehiclemust have been drivenso that the
engineand transaxlear€ at normaloperatingtempor-
ature.Transaxlofluid temDerature: 70-80'C (158-
176" F)
(a) Park the vehicloon a level surface,set the parking
brake.
(b) With the engineidlingand the brakepedaldoprssssd,
shift tho shift leverinto eachgearfrom the P rang€to
L rangesmoothlyand returnto P rangs.
(c) Pull out tho transaxledipstickand wipe it clean.
(d) Push it back fully into the pipe.
(e) Pull it out and checkthat th6 fluid levelis in ths HOT
range.
lf the levelis at the low sideof the hot range,add fluid.
Fluidtypo:
ATF DEXRONO II
NOTICE:Do not ovorfill.
2, CHECK FLUID CONDITION
lf th6 fluid smellsburnt or is black,replaceit.
3. REPLACEATF
NOTICE: Do not overfill.
(a) Using 10 mm h€xagonwr€nch r€movsthe drain plug,
gaskstand drain ths fluid.
(b) Installa now gasketand the drain plug secursly.
(c) Add new fluid throughthe filler pipe,

l-Fl 6;\
H @ '
Fluid:
ATF DEXRONO II
Dry fill:
| ,---..-, (---\- 5.6 litor. (5.8 US qtr, 4.9 lmp.qtr)
I J 7E:-.--/ \ t)/- Drrln and refill:
_:_:l!l_:_- _r):{NC1/
T %1., 2.5 literr (2.6 US qt., 2.2 lmp.qrs)

(d) Start the engineand shift th€ soloctorinto all posi-
tions from P through L and then shift into P range.
(e) With the enginoidling,chocktho fluid level. Add fluid

up to tho COOLlevelon tho dipstick.
(f) Checkthe fluid levelwith the normalfluidtemperature
" C ( 1 5 8 - 1 7 6 ' F ) a n da d d a s n e c e s s a r y
70 - 80
NOTICE:Do not ovarfill.

AX.15
4. INSPECTAND ADJUST THROTTLECABLE

(a) Checkthat the throttle valve is fully closed.
(b) Checkthat the innercable is not slack.
(c) Loosenthe adjustmsntnuts.
(d) Adjust the outor cabls so that the distancebotw€en
the end of the boot and stopper on the cable is as
standard.
Standsrdboot snd cablestopperdigtance:
AT4252 0 - I mm (0- 0.04 in.)
(e) Tightenthe adjustingnuts.
(f) Recheckthe adjustments.
5. ADJUST SHIFT CONTROLCABLE
(a) Loosenthe nut on the lever.
(b) Push the manuallever fully toward th€ right side - mam
- - - nf
t h ov o h i c l e . ffi
(c) Returnthe lever2 notchEsto the NEUTRALrange.

(d) Set tho shift leverin N range.
(e) While holdingtha lever lightly toward the'R' range
side,tightenthe shift levernut.
Y cosrm
6. ADJUST NEUTRALSTART SWITCH

lf the enginewill start with the shift selectorin any
rangeotherthan N or P range,adjustmentis r€quirsd.
(a) Loosenthe neutralstart switch boltsand set the shift
selectorto the N range.
(b) Align the grooveand neutralbasicline.
(c) Hold in positionand tighton the bolts.
Torque: 5.4 N.m (55 kgf.cm,48 In..lbl)
7, INSPECTIDLE SPEED
ldlerpeed:
750 t 50 rpm
(ln N rangeand air conditionerOFF)

AX-16
A U T O M A T ITCR A N S A X L_E T R O U B L E S H O O T I N G
DIAGNOSIS YSTEM
't. oEscRrPTtoN
( a ) A s e l f - d i a g n o s i sf u n c t i o ni s b u i l t i n t o t h e e l e c t r i c a l
controlsystem.Warningis indicatedby the overdrive
OFF indicator,
H I N T :W a r n i n ga n d d i a g n o s t icco d e sc a n b e r e a do n l y
when ths overdriveswitch is ON.lf OFF,the overdrive
O F Fr n d r c a t oi sr l i t c o n t i n u o u s lavn d w i l l n o t b l i n k .
lf a malfunctionoccurswithin tha speedsensors

or solenoids,the overdriveOFF light will blink to
warn the driver.
However,there will be no warningof a malfunc-
AX tion with lock- up solenoid.
The diagnosticcode can be read by the number
of blinks of the overdriveOFF indicatorwhsn
t e r m i n a l sT E 1 a n d E 1 a r e s h o r t - c i r c u i t e d(. S e e
p a g eA X - 1 7 )
. The throttlo positionsonsor or brake signal are
not indicated,but inspectioncan be made by
checkingthe voltageat terminalTT of the check
connoctor.
. The signals to each gear can be checked by
measuringths voltage at torminal TT of tho
check connectorwhile driving.
(b) The diagnostic (malfunction)code is retained in
m€moryby the ECU and dua to back- up voltage,is
not canceledout when th6 ongin€ is turned OFF.
Consequently, after repair,it is necessaryto turn the
ignitionswitch OFFand removeth6 EFIfuse (15 A) or
disconnectthe ENGINEand ECT ECU conn6ctorto
cancel out the diagnostic(malfunction)code. (See
p a g eA X - l 8 )
HINT:
. Low battory voltage will cause faulty operation
of the diagnosissystom.Th€refore,alwayscheck
ths batteryfirst.
. Uso a voltmeterand ohmmeterthat have an im-
pedanceof at least 10 k Q,/V.
2. CHECKO/D OFF INDICATORLIGHT
d
tl
'1
o/D (a) Turn the ignitionswitch ON.
OFF (b) The OrzDOFFlightwill coma on when the O/D switch
ON i s p l a c e da t O F F .
(c) When the O/D switch is s€t to ON.the O,zDOFF light
q :o /D"
ÔFF^
shouldgo out.
lf the O/D OFF light flasheswhen th6 O/D switch is
s6t to ON,the electroniccontrolsystem is faulty,
OFF I v t
@?:g

AX-17
_ TROUBLESHOOTING
TRANSAXLE
AUTOMATIC
3. READ DIAGNOSTICCODE
(a) Turn ignitionswitch and O/D main switch to ON. Do
n
'-1 OFF
not start tho engine.
HINT: Warningand diagnosticcodescan be readonly
wh6n the overdriveswitch is ON.lf OFF,the ovordrive
fl O N
'1
O F Fl i g h tw i l l l i g h tc o n t i n u o u s layn d w i l l n o t b l i n k .
( b ) U s i n gS S T ,s h o r t t e r m i n a l sT E l a n d E l o f t h e c h o c k -
connector.
s s T0 9 8 4 3 - 1 8 0 2 0
r,4L
(c) Readthe diagnosticcode as indicatedby the number

of tim€s the O/D OFF indicatorflash6s.
DiagnorticCod! Indicstion
o lf the systomis operatingnormally,the light will
blink once everY0.25 seconds.
. ln tho event of a malfunction,the light will blink

once 6very 0.5 seconds. The number of blinks
0.5seconds 2 . 5s€conds For
w i l l e q u a lt h o 1 s t n u m b € ra n d ,a f t e r 1 . 5 s e c o n d s
Next
t l Code pause,the 2nd numberof the 2 digit diagnostic
ON
t l code. lf there are 2 or more codes.there will be
a 2.5 secondsPaus€bgtween6ach.
OFF
HINT: ln the 6vontof severaltroublecodesoccurring
simultaneously. indicationwill beginfrom the smaller
4 o s e c o n d s1 . 5 s e c o n d s4 . 5 s e c o n d s
valueand continueto the larger.
(d) RemoveSST.

AUTOMATIC
TRANSAXLE
4. DIAGNOSTIC ODES
HINT:lf codes62, 63 or 64 appear,there is an electri-
c a l m a l f u n c t i o inn t h e s o l e n o i d .
C a u s s sd u a t o m e c h a n i c afla i l u r e ,s u c h a s a s t u c k
valve,will not appear.
Code No. Light Pattern DiagnosisSystem
Normal
Delective s p e e ds e n s o r( i n A T M I - s e v e r e dw i r e h a r n e s s
42
o r s h o r tc i r c u i t
S e v e r e dN o . ' ls o l e n o i do r s h o r tc i r c u i -t s e v e r e dw i r e
62
h a r n e s so r s h o r tc i r c u i t
S e v e r e dN o . 2s o l e n o i do r s h o r tc i r c u i t- s e v e r e dw i r e
S e v e r e dl o c k - u ps o s l e n o i do r s h o r tc i r c u i t- s e v e r e dw i r e
5 . C A N C E LO U T D I A G N O S T I C O D E
(a) After repairof the trouble ar€a,lho diagnosticcode
r e t a i n e di n m e m o r yb y t h e E n g i n ea n d E C TE C Um u s t
b e c a n c e l e db y r e m o v i n gt h e E F I f u s e ( 1 5 A ) f o r 1 0
s a c o n d so r m o r s ,d e p e n d i n o gn ambient emperaturo
(the lower the temporature,the longerthe fuse must
be left out) with tho ignitionswitch OFF.
HINT:
Y.ljIl:l
r C a n c e l l a t i ocna n b e a l s o d o n e b y r e m o v i n gt h e
battory nogative (-) terminal,but in this case
other m6morysystomswill be also canceledout.
Engineand ECTECU . Th6 diagnosticcode can be also canceledout by
d i s c o n n e c t i ntgh e E n g i n ea n d E C TE C Uc o n n e c -
to r.
. lf the diagnosticcode is not canceledout, it will
be retained by the Engine and ECT ECU and
appear along with a new code in the event of
f u t u r et r o ub l e .
(b) After cancsllation, performa roadtest to confirmthar
a "normalcode' is now rsad on tho O/D OFF light.

AX.19
_ TROUBLESHOOTING
TRANSAXLE
AUTOMATIC
CO D ET R O U B L E S H O O T IFNLGO W _ C H A R T
D I A G N O S T IC
HINT:
to
. lf diagnosticcodes 42,62 or 63 are output,the overdriveoFF indicatorlight will begin
to
blink immediatelyto warn the driver.However,an impactor shockmay causethe blinking
ECUmemory untiI out.
cance|ed
stop;but th€ codewi|| sti||ba retainedin the Engineand ECT
. There is no warningfor diagnosticcoda 64
appear
. ln the event of a simultaneousmalfunctionof speedsensor,no diagnosticcode will
in the D rang€,the
and the fail- safe system will not f unction. However when driving
transax|ewi||notup_shiftfromfirstgear,regard|essofthevehic|espeed'
1. DIAGNOSTICCODE42 (SPEEDSENSORCIRCUITRY)
flAi
Checkcontinuity belween Engineand ECTECU
c o n n e c t o r sS P Dt e r m i n a la n d b o d y g r o u n d .
( S e ep a g eA X - 3 0 )
S u b s t i t u t ea n o t h e rE n g i n ea n d E C TE c U .
c h e c ks p e e ds e n s o r (. S e ep a g eB E - 6 5 ) R e p a i ro r r e p l a c es p e e ds e n s o r .
C h e c kw i r i n g b e t w e e nE n g i n ea n d E C TE C Ua n d
c o m b i n a t i o nm e t e r .

AX.2O _ TROUBLESHOOTING
AUTOMATIC
TRANSAXLE
2. D I A G N O S T ICCO D E6 2 ( N O . 1S O L E N O IVDA L V EC I R C U I T R Y }
R e m o v et h e o i l p a n a n d c h e c kr e ss t a n c eo f N o 1
s o l e n o i dv a l v ec o n n e c t o a
f nd bodygfound R e p l a c eN o 1 s o l e n o i dv a l v e
Resistance: 11 - 15 O
3. D I A G N O S T ICCO D E6 3 ( N O . 2S O L E N O IVDA L V EC I R C U I T R Y )
R e m o v et h e o i l p a n a n d c h e c kr e s i s t a n coei N o 2
s o l e n o i dv a i v ec o n n e c t o a
r nd bodyground 2 s o l € n o , dv a l v e .
Resistance: 11 -15o
C h e c kw i r i n g b e t w e e nN o . 2 s o e n o d v a v e a n d E n g r n e
a n d E C TE C U

_ TROUBLESHOOTING AX-21
TRANSAXLE
AUTOMATIC
4. CODE64 (LOCK-UPSOLENOTO
DTAGNOSTIC VALVECIRCUITRY)
Remove t h e o r l p a n a n d c h e c kr e s i s t a n coef l o c k - u p
solenoidv a l v ec o n n e c t oar n d b o d yg r o u n d R e p i a c el o c k u p s o l e n o r dv a l v e .
Resistanco: 11 -15')

AX-22 AUTOMATICTRANSAXLE- TROUBLESHOOTING
M A N U A LS H I F T I N G
TEST
HINT: With this test, it can be determrnedwhether
the trouble lies within the electricalcircuit or is a
mechanicaloroblemin tha transaxla.
1. D I S C O N N E CS
TO L E N O I D
WIRE
2. INSPECT MANUAL DRIVING OPERATION
Check that tha shift and gear positionscorrespond
with the table below.
Shilt position Goar position
D ran96 o/D
2 rang6 Jro
L rsngs lst
R rang6 Rgvgrs€
P range Pawl Lock
HINT: lf ths L, 2 and D rango g€ar positionsare

difficult to distinguish,perform the following road
test.
o W h i l e d r i v i n g ,s h i f t t h r o u g h t h e L , 2 a n d D
ranges.
Checkthat th6 gear changecorrespondsto the
shift position.
lf any abnormalityis found in the above test, the
problemlies in transaxleitself.
3. CONNECTSOLENOIDWIRE
4. C A N C E LO U T D I A G N O S T I C O D E
( S e ep a g eA X - 1 8 )
REFERENCE:Possible
gearpositionsin accordance
with solenoidoperating
conditions.
No.1 SOLENOID No. 2 SOLENOID BOTHSOLENOIOS
NORMAL
MALFUNCTIONING MALFUNCTIONING MALFUNCTIONING
Solonoid V6lve Gear Solenoid Valve Gear Solenoid Valve G e a r Solenoid Valve Gear
Range No. 1 No.2 Position N o . 1 N o .2 Position N o . 1 N o ,2 Position N o . ' 1 N o . 2 Position
'lst
ON OFF 1st X ON 3rd ON X X X o/o
ON ON 2nd X ON 3rd OFF X o/D X X o/D
D rang€
OFF ON 3rd X ON 3rd OFF X o/D X X o/o
OFF OFF o/o X OFF o/o OFF x o/D X x o/D
ON 1st x ON 3rd ON X 'I
st x X 3rd
2 range ON ON 2.'d X ON 3rd OFF X 3rd X X 3rd
OFF ON 3rd X ON Jto OFF X 3rd X X
ON OFF lst X OFF 1st ON X 1st X 1st

L rang€
ON ON 2nd X ON 2nd ON X lst X X lst
X Mallunctions

- TROUBLESHOOTING AX.23
TRANSAXLE
AUTOMATIC
I CO N T R OC
ELECTRONC L IRCUIT
D o n o t o p e nt h e c o v s ro r t h e c a s eo f t h e E C Ua n d o t h e rc o m p u t e r su n l e s sa b s o l u t e l ny e c € s s a r y .
(lf the lC terminalsare touched,the lC may be destroyedby static electricity)
f
3 Q
:
2 a
E o
!
o
o
o o o 6 a
(J
-9 -q c-
3 & I (J
ci (, a >
z z I
6 h
O
f i d :.AX
F
()
L!
.g
c
Lr.l
.9
o
o
o)
o
I
E

AX-24
E L E C T R O NC
I CO N T R O C
L OMPONENTS
O / D M a i nS w i t c h
E n g i n ea n d E C TE C U * PatternSolectSwitch
ThrottlePositionSensor O / D O F FI n d i c a t o rL i g h t
Sensor
WaterTemperature
AX:: Vehicl6Speed Sensor
S L S o l e n o i dV a l v e S t o p L i g h tS w i t c h
NeutralStart Switch
N o . 2S ol e n o i dV a l v e
N o . ' 1S o l e n o i dV a l v e
* R H DM o d e l O n l y

AX-25
T R O U B L E S H O O T IFNLGO W - C H A R T
TroubleNo.1 No shifting
Warmup engine
C o o l a n t e m p . r 1 7 6 "F { 8 0 " C )
ATFtemp.; 122- 116"F(50- 80"C)
C o n n e c at v o l t m e t e tr o c h e c kc o n n e c t otre r m i n a l sT T a n d
E 1 .D o e sT T t e r m i n a vl o l t a g ev a r yw i t h c h a n g e si n t h r o t t l e
o p e n i n g ?( S e ep a g eA X - 2 9 )
Yes No
l s v o l t a g eb e t w € e nE n g i n ea n d E C TE C Ut e r m i n a l s No B r a k es i gn a l
B / K a n d E 1a s f o l l o w s ? fs u lty
0 V: Brak€pedal released
10 - 14 V: Brakeoedal deDressed
Yes
a E C Up o w e rs o u r c sa n d g r o u n df a u l t y
o T h r o t t l ep o s i t i o ns e n s o rs i g n a lf a u l t y
a TTt8rminaw l i r e o p e no r s h o r t
D i s c o n n e csto l e n o i dw i r e c o n n e c l o a r n d r o a dt e s t .
D o e st h e t r an s a x l eo p e r a t ei n t h e r e s p e c t i vgee a rw h e n i n
l h e f o l l o w l n gr a n g e sw h i l e d r i v i n g ? No
( M a n u aS l h i f t i n gT e s tS e ep a g eA X - 2 2 ) Transaxlefaulty
D range ,,,,.., Overdrive
2 r a n g e . . . . . . . .3 r d g e a r
L r a n g e . . . . . . . . ' l s tg e a r
Yes
C o n n e c st o l e n o i dw i r e c o n n e c t oar n d . o a dt e s t . 0-7V . Transaxlefaulty
D o e sT T t e r m i n a vl o l t a g er i s ef r o m 0 V t o 7 V i n s e q u e n c e ? . S o l e n o i df a u l t y
0-4V P r o c e e dt o t r o u b l eN o . 3
( S e ep a g eA X - 2 7 )
ov I o-zv A r et h e r e1 O- 1 4V b e t w e e e n" g i * " " ; l

E C TE C t jt e r m i n a l2s- E! w h e ni n t h eD
range? I
---T-_r* --f-^*
'10
A r et h e r e - 1 4V b e t w e e nE n g i n ea n d E C TE C U
t e r m i n a l sL - E 1w h e n i n t h e D r a n g e ?
No Yes
. N e u t r aI s t a r ts w i t c hc i r c u i tf a u l t y
. N e u t r a sl t a r ts w i t c hf a u l t y
T r y a n o t h e rE n g i n ea n d E C TE C U

AUTOMATIC
TRANSAXLE
T r o ub l e N o . 2 Shift point too high or too low
Warmup engine
C o o l a n t e m p . r 1 7 6 ' F( 8 0 ' C )
A T Ft e m p . i 1 2 2- 1 1 6 ' F( 5 0- 8 0 " C )
C o nn e c ta v o l t m e t e rt o c h e c kc o nn e c t o rt e r m i n a l s T aT n d E1 .
D o e sT T t e r m i n a lv o l t a g ev e r y w i t h c h a n g e si n t h r o t t l e
o p e n i n g ?( S e ep a g eA X - 2 9 )
l s v o l t a g eb e t w e e nEn g i n ea n d E C TE C Ut e r m i n a l s
B / K a n d E 1a s f o l l o w s ?
0V: Erakepedal released
' 1 0-
1 4 V : B r a k ep e d a l d e p r e s s e d
. E C Up o w e rs o u r c ea n d g r o u n df a u l t y
. T h r o t t l ep o s i t i o ns e n s o rs i g n a lf a u l t y
. TT terminaw l i r e o p e no r s h o r t
C h e c kv o l t a g eb e t w e e nE n g i n ea n d E C TE C U . F a u l t yE n g i n ea n d E C TE C U
t e r m i n a l sP W Ra n d E 1 . . F a u l t yt r a n s a x l e
P o w e rp a t t e r n : 1 0 - 1 4 V
N o r m a lp a t t e r n : l V Faulty patternselectswitch system

- TROUBLESHOOTING AX-27
TRANSAXLE
AUTOMATIC
T r o u b l eN o . 3 N o u o - s h i { t t o o v e r d r i v e( A J t e rw a r m - u p )
No
F o a dt e s tw h i l e s h i f t i n gm a n u a l l yw i t h s o l e n o i dw i r e F a u l t yt r a n s a x l e
c o n n e c t o dr i s c o n n e c t e d .
l s t h e r eo v e r d r i v eu p - s h i i ti n t h e D r a n g ew h e n
s h i f t i n gf r o m L t o 2 t o D ? ( S e ep a g eA X - 2 2 )
C o n n e c st o e n o i dw i r e c o n n e c t o ra, n d w h i l e d r i v i n gd o e s 0 -7 V a F a u l t yt r a n s a x l e
T T t e r r n i n avl o l t a g er i s ef r o m 0 V t o 7 V i n s e q u e n c e T a F a u l t ys o l e n o i d
0-4V OV
0*2V A r e t h e r e1 0 - l 4 V b e t w e e nE n g i n € 8 n d
E C TE C Ut € r m i n a l s2 a n d E1 w h e n i n t h e
D r an g e ?
Yes No
'10
A r €t h e r e - 1 4V b e t w e e nE . 1 g i naen d
EC-I E C Ut e r m i n as L a n dE 1w h e ni n t h e
rnge?
No Yes
F a u l t yn e u t r a sl t a r ts w i t c hc i r c u i t
a F a u l t yn e u t r a sl t a r ts w r t c h
T r y a n o t h e rE n g i n ea n d E C TE C U
l s v o t a g e b e t w e e nt e r m i n a l sO D 2a n d E 1 a s f o l l o w s ? o F a u l t yO / D s w i t c hh a r n e s s
O / D s w i t c ht u r n O N r 1 0 - 1 4 ' . F a u l t yO / D s w i t c h
O / D s w i t c ht u r n O F F : 0 V
l s v o l t a g eb e t w e e nt e r m i n a l sO D 2a n d E 1 a s f o l l o w s ? T r y a n o t h e rE n g l n ea n d E C TE C U
A p p r o x .5 V
l sv o l t a g eb e t w e e nEn g i n ea n d E C TE C Ut e r m i na l sO D1 a n d F a u l t yc r u i s ec o n t r o lE C U
E 1n o r r n aw l C Uc o n n e c t opr u l l e do u t ?
l i t ht h ec r u i s ec o n t r oE
. F a u l t yE n g i n ea n d E C TE C U
. F a u l t yc r u i s ec o n t r o lw i r e h a r n e s s

AX-28
TroubleNo.4 No lock- up (After warm - up)
Warm up engine
C o o l a n t e m p , 1 7 6 "F ( 8 0 ' C )
A T Ft e m p : 1 2 2- 1 7 6 ' F( 5 0- 8 0 " C )
Road tsst . Lock-upsolenoidstuck

C o n n e ca t v o l t m e t e rt o c h € c kc o n n e c t otre r m i n a l sT T a n d . F a ul t y t r a n s a x l e
E 1 .l s t h e r e7 V i n t h e l o c k - u pr a n g ew h i l e d r i v i n g ? . F a u l t yl o c k - u pm e c h a n i s m
l s v o l t a g Bb o t w € e nE n g i n ea n d E C TE C UB / K a n d E ' l F a ut y b r a k es i g n a l
term inals as follows?
B r a k ep e d a ld e p r s s s e d : 1 0 - 1 4 V
B r a k ep e d a lr e l e a s e d i 0 V
. F a u l t yE C Up o w e r s o u r c ea n d g r o u n d
. F a u l t yt h r o t t l ep o s i t i o ns i g n s l

_ TROUBLESHOOTING AX-29
TRANSAXLE
AUTOMATIC
T T T E R M I N A ILN S P E C T I O N
1 . I N S P E CTTH R O T T LP NE N S O S
EO S I T I OS RI G N A L
( a ) T u r nt h e i g n i t i o sn w i t c hO N .
Do not start tho ongin6.
( b ) C o n n e c t a v o l t m e t € rt o t e r m i n a l sT T a n d E 1 .
(c) While slowly depressingth€ acceleratorpedal,chack

t h a t T T t e r m i n avl o l t a g er i s e s a
, s shown.
z
lf the voltage does not changa in proportionto the
throttle op6ningangle,thero is a malfunctionin tho q?":
.d throttlo positionsensoror circuit. *- " - '
.E
2 , I N S P E C TB R A K ES I G N A L
(a) Depressthe acce16rator pedal until the TT terminal
E i n d i c a t e Is V .
Va ve Ope'ng A^gle(Ooa^)
(Close)Throtrle
(b) Depresstho brake psdal and ch€ck the voltageread-
i n gf r o m t h e T T t e r m i n a l .
Brakepedaldepressed
0v
Brakepedalreleased
8V
lf not as indicated,there is a malfunctionin eitherthe
stop light switch or circuit.
3 . I N S P E CE TA C HU P - S H I F TP O S I T I O N
( a ) W a r mu p t h e e n g i n e .
Cool!nttemDeraturo:
r_lO F F
-1
80'c (178' F)
(b) Turn the O/D switch Ol',t.
11O N
'1
(c) Placethe shift leverinto the D range.
(d) Duringa road tost (above10 kmlh or 6 mph) chack
that voltageat the TT terminalis as indicatedbelow
f o r e a c h u p- s h i f t p o s i t i o n .
lf the voltage increasedfrom 0 V to 7 V in the se-

quenceshown,the controlsystem is okay.
T T T e r m l n a(l V ) | G e a rP o s i t i o n
The charl on th6 left showsthe voltmeterreadingand
0 | lst
corresponding g ears.
2 | 2nd
HINT: Determin6the gearpositionby a light shock or
4 3td
6 0/D c h a n g ei n e n g i n er p m w h o n s h i f t i n g .
7 O/D Lock

AX-30
E L E C T R O NC L O M P OE
I CO N T R O C NN T S
Engineand ECT ECU
INSPECTION
1 . I N S P E C TV O L T A G EO F E N G I N EA N D E C T E C U
CONNECTOR
(a) Turnthe ignitionswitchON.
(b) Do not disconn€ct Engineand ECTECUconnector.
Measure the voltageat sachterminal,
EngineandECTECUTarminals 51 SL TT THW VC SpD OD2 B/K BATT

t t t r
',;i* I
1 TE,1 VTA E2 NSW OD1 2

Tcrminsl Mearuring condition Voltage (V)
s 1- E r l g n i t i o ns w i t c ht u r n e dO N 10 14
>2,5L-El l g n i t i o ns w i t c ht u r n e dO N 1 or less
Braks oedal is deoressed 10 14
B / K- E 1
Brakepedal is released 1 or less
THW - E2 W a t e rl e m o . 1 7 6 " F{ 8 0 " C ) 0 . 1- 0 . 8
T h r o t t l ev a l v ef u l l y c l o s e d 1 or less
IDL- E2
Throttlevalve open 4 . 5- 5 . 5
T h r o t t l ev a l v ef u l l y c l o s e d 0 . 1- 0 . 8
VTA - E2
Th rottlevalve open 4 . 5- 5 , 5
4 . 5- 5 . 5
oDl - E1 1 0- 1 4
O / D m a i n s w i t c ht u r n e dO N 1 0- 1 4
O / D m a i n s w i t c ht u r n e dO F F 1or less
C r u i s ec o n t r o l S t a n d i n gs t i l l 1 or less
S P D_ E l
m a i n s w i t c hO F F V e h i c l em o v i n g R e p e a t :0 * 4 . 5 - 5 . 5
P,N range l0 14
N S W- E l
R ,D . 2 ,L r a n g e I or l€ss
2 .ange 10 14
2-E1
Except2 range 1 or less
L range 10-14
L - E1
ExceptL r8ng6 1 or less
+B - E'] l g n i t i o ns w i t c ht u r n s d O N 1 0- ' t 4
BATT_ E1 All conditions 1 0- 1 4

AX-31
Wlre harnessside 2 . I N S P E C TS O L E N O I D S
{a) Disconnectthe connectorfrom Engineand ECTECU.
(b) Measurethe resistancobetwe€nS1. 52, SL and body
g round.
S Lb l Resista nca:
11-15c)
S2
(c) Apply batteryvoltageto each terminal.
Checkthat an opsrationnoiss can be heardfrom the
r ql5,l85 solenoid.
SEALS
C H E C KS O L E N O I D
lf ther6 is foreignmatorialin the solenoidvalv6.there
will be no f luidcontrol€venwith solenoidoporation.
C h e c kN o . 1, N o . 2a n d S L s o l e n o i dv a l v e s liAi
e Applying 490 kPa (5 kgflcm', 71 psi) of com-
pressedair.checkthat th6 solenoidvalvesdo not
leak lhe air.
r When battery voltags is suppliedto the sole-
noids,check that tho solenoidvalvesopen.
4. INSPECTNEUTRALSTART SWITCH
U s i n ga n o h m m e t e rc, h s c kt h e c o n t i n u i t yo f t h e t e r m i -
nals for each switch position shown in the table
below.
6 5 1 8 10 9 2
P
R
N
D
2
L

AX-32
5. INSPECT THROTTLE POSITION

SENSOR
Usingan ohmmotor,checkthe resistance between
s a c ht e r m i n a l .
Throttl€ valve
Resistance(kO)
TerminaI control
F ul l y c l o s e d 2.3
IDL - E2
Open
Y tttt 2 . 5- 5 . 9
F u l l yc l o s e d o . 2- 5 . 7
VAT - E2
F u l l yo p a n 2.0- 10.2
n$142
6. INSPECTSPEEDSENSOR
I \ (SeepageBE- 65)
I'd I
)n
ifit
9-t
fv-
^\_./-+3q tt o
lc
7. INSPECTPATTERN SELECTSWITCH
Checkthat there is continuitybetweenterminals2
and 3.
T6ster conditionto
Switchposition Spocifiodvalue
t6rminalnumber
NORM Continuity
PWR No continuity
z|178
8. INSPECT O,/DMA|N SWTTCH

Inspoctthat thereis continuitybetweenterminals2
and 4.
Taslar conditionto
Switch po!ition Spscitiodv.luo
tarminolnumbor
ON 2 - 1 Continuity
OFF 2 - 1 No continuity
711719

AX-33
_ TROUBLESHOOTING
TRANSAXLE
AUTOMATIC
9. INSPECT STOPLIGHTSWITCH
lnsoectthat thsre is continuitybotweenterminals1
and2.
Tostsr conditionto
Switch po6ition valuo
spocitiod
torminalnumber
ON Continuity
OFF No continuity

4X.34
STALLTEST
The object of this test is to check the overall performanceof the transaxleand engine by
m e a s u r i n tgh s s t a l ls p e e d si n t h e D a n d R r a n g e s .
NOTICE:
. Perfoimthe tost at normaloperstionfluid tomporature 50-80 "C |.122-176"F).
. Do not continuously run this test longerthan 5 seconds.
o To ensure safety, conduct this tast in a wide, clear, level area which provides good traction.
o The stall test should always be carried out in pairs. One should observe the condition of whaels
or wheel stoppers outside the vehicle while th6 oth6r is performing the tast.
MEASURESTALL SPEED
( a ) C h o c kt h e f r o n t a n d r e a rw h s e l s .
( b ) C o n n € ca t t a c h o m e t etro t h e e n g i n e .
aw ( c ) F u l l ya p p l yt h e p a r k i n gb r a k e .
rtl\ (d) Keep your left foot pressedfirmly on the brakepedal.
( e ) S t a r tt h s 6 n g i n e .
(f) Shift into the D range. Step all the way down on the accelsratorpedal with your right foot.
O u i c k l yr e a dt h e s t a l ls p 6 e da t t h i s t i m e .
Stsll speed:
2 , 4 5 0 +I 5 0 r p m ( 3 S - F E , 5 5 - F E )
(S) Perform the same test in R rangs.
EVALUATION
(a) lf the stall speed is tho sams for both rangeswithout the rear wheelsrotating but lower than
soecified value:
o E n g i n so u t p u t m a y b 6 i n s u f f i c i e n t
. Stator on€-way clutch is not oporatingproperly
(b) lf the stall sp6odin D rangeis higharthan specified:
o Line pressuretoo low
r F o r w a r dc l u t c hs l i p p i n g
o N o . 2o n e - w a y c l u t c hn o t o p s r a t i n gp r o p e r l y
. O / D o n s - w a y c l u t c hn o t o p e r a t i n gp r o p e r l y
( c ) l f t h e s t a l ls p e e di n R r a n g ei s h i g h e rt h a n s p e c i f i e d :
o Line pressuretoo low
. D i r e c tc l u t c hs l i p p i n g
. First and reversebrakeslipping
. R e a rc l u t c hs l i p p i n g
( d ) l f t h e s t a l ls p e e di n b o t h R a n d D r a n g e sa r e h i g h e rt h a n s p e c i f i e d :
. Line pressurstoo low
o l m o r o o e fr l u i d l e v e l
. O/D direct clutch not operatingproperly

AX-35
STALLTEST
P a r k i n gB r a k e
AX
T I M EL A G T E S T
l a p s eo r l a g
W h e n t h e s h i f t l e v 6 r i s s h i f t e d w h i l e t h e e n g i n e i s i d l i n g ,t h e r e w i l l b e a c € r t a i nt i m e
forward
before the shock can be felt. This is used for checkingth6 condition of the o/D clutch,
clutch. direct clutch and first and reverse brake
NOTICE:
.Parformthetestatnorma|operatingf|uidtemPorature50_80"ct122_176.F|.
. B e s u r e t o a l l o w o n e m i n u t e i n t e r v a l b e t l Y e e nt e s t s -
o M a k e t h r e e m e a s u l e m e n t sa n d t a k s t h e a v a r a g ev a l u e '
M E A S U R ET I M E L A G
( a ) F u l l y a p p l y t h e P a r k i n gb r a k e .
( b ) S t a r t t h a e n g i n ea n d c h e c k t h e i d l e s p o e d
ldle speed:
7 5 0 + 5 0 r p m ( l n N r a n g e a n d a i r c o n d i t i o n e rO F F )
it takes from
{c) shift the shift lever from N to D range. Using a stop watch, m6asure the tim6
shifting tho lever until the shock ls felt.
Time lag:
Lsssthan 1.2 seconds
( d ) I n t h e s a m e m a n n e r .m e a s u r et h s t i m o l a g f o r N t o R '
Timelag:
Lsssthsn 1.5 seconds

AX.36
TIMEtAG TEST
S h o c kN o i s e
# @
A-@
0
AX
q/',*W
ShockNoise
EVALUATION
( a ) l f N - D t i m e l a g i s l o n g e rt h a n s p e c i f i e d :
. Lin6 prossuretoo low
o Forwardclutch worn
. O/D on6-way clutch not operatingproperly
(b) lf N--*Rtims lag is longerthan specified:
r Line pressuretoo low
. Direct clutch worn
. First and reversebrakeworn
. O/D one-way clutch not oporatingproperly

AX-37
AUTOMATICTRAilSAXLE- TROUBLESHOOTING
H Y D R A U L IT
CE S T
PREPARATION
(a) Warm up the ATF.
(b) Removethe transaxlocasetast plug and connecttho hydraulicpressuregaugo
SST09992-00094 (Oilpressuregauge)
C AU T I O N :
. porformtho tast 8t normaloperltingfluid temperature 50-80 "c 1122-176'Fl.
r The linepressure tort shouldalwayrbe carriedout in pairs,Oneshouldobservethe conditions
of
wheelsor whoel stoppersoutside tho vehiclawhile tho othor is performingthe test.
ssT 09992-00094
GaugeAssy
w2
CurvedAdaPtor
4 T 5 1 6 3A T 2 0 7 9

AX-38
M E A S U R EL I N EP R E S S U R E
( a ) F u l l ya p p l yt h € p a r k i n gb r a k ea n d c h o c kt h e f r o n t w h e e l s .
( b ) S t a r tt h e e n g i n ea n d c h e c ki d l i n gr p m .
(c) Step down stronglyon the brakepedalwith your left foot and shrft into D range.
( d ) M e a s u r et h e l i n e p r e s s u r e
w h e n t h o e n g i n ai s i d l i n g .
( e ) P r e s st h e a c c e l e r a t opre d a al l l t h ew a y d o w n . O u i c k l yr e a dt h e h i g h e s lti n ap r e s s u r w
e h e ne n g i n e
s o e e dr e a c h e s t a l ls o e a d ,
(f) In the same manner.performths tast in R range.
35 _ FE:
Automatic Transaxle ldling kPa (kgflcm' , psi) Stall kPa (kgfilcm', psrl
363- 422 736-863
D Range
(3.7-4.3,53-61) ( 7 . 5- 8 . 8 , 1 0 6 - 1 2 5 )
530-706 1 , 1 5 8 -1 , 3 4 4
YTff R Range
15.4-7.2,16- 102) { 11 . 8 - 1 3 . 71, 6 8 - 1 9 5 )
5S_ FE:
A u t o m a t i cT r a n s a x l e ldling kPa (kgflcm', psi) Stall kPa (kgflcm', psi)
363 422 736 863
D Range
(3.7 4.3,53 61) ( 7 . s- 8 . 8 ,t 0 6 - 1 2 5 )
618 794 1,373 1,608
R Rangs
i a ? a 1 0 n - t 1 q l ( 1 4 . 0 1 6 . 4 ,1 9 9 2 3 3 )
l f t h e m e a s u r e d p r e s s u r 6 sa r e n o t u p t o s p e c i f i e dv a l u e , r e c h e c k t h s t h r o t t l o c a b l e a d j u s t m g n t a n d
perform a retest.
EVALUATION
(a) lf the measuredvaluesat all rangesare higherthan specified:
. Throttlecableout of adjustment
. Throttle valvedefective
. R€gulator valve dafective
(b) lf the msasuredvaluesat all rangesare lower than specified:
r Throttlacab16out of adjustment
o Throttle valve defective
r Regulatorvalve defective
. Oil pump defective
. O/D direct clutch defactive
(c) lf pressureis low in the D rangeonly:
o D r a n g ec i r c u i tf l u i d l e a k a g e
. Forwardclutch defeclive
(d) lf pressureis low in the R rangeonly:
o R r a n g ec i r c u i tf l u i d l e a k a g e
. Dir6ct clutch dofective
o First and reversebrakedefective

AX.39
ROADTEST
trlOTlCE:Parform the test 8t normsl oporating fluid tem'
p o r a t u r e5 0 - 8 0 ' C 1 1 2 2 - 1 7 6 ' F l .
1. D RANGE TEST IN NORM AND PWR PATTERN
RANGES
Shift into the D rangeand hold the acceleratorpedal
constantat tho full throttlo valvs openingposition.
Checkthe following:
(a) 1 - 2 , 2 - 3 a n d 3 - O l D u p - s h i f t s s h o u l dt a k e p l a c e ,
and shift oointsshouldconformto those shown in the
D Range automaticshift schedule.(Seepage AX- 421
-)@
F u l lO p e n
HINT:
. T h € r 6i s n o O / D u p - s h i f t a n d l o c k - u p w h e n t h o; ^ w
water tomp. is below 55" C (13 1 F).
" I T 'n'
. There is not lock- up when the vehiclespeedis
10 km/h (6 mph) lessthan tho set cruisocontrol
so€eo.
EVALUATIOI{
(1) l f t h e r ei s n o 1 * 2 u p - s h i f t :
. No.2 solenoidis stuck
o 1 -2 shift valve is stuck
(2) lf there is no 2*3 uP- shift:
. No.1 solenoidis stuck
. 2-3 shift valve is stuck
(3) lf there is no 3-OlD up-shift:
. 3-4 shift valve is stuck
(4) lf the shift point is defective:
. T h r o t t l ov a l v e ,1 - 2 s h i f t v a l v e , 2 - 3 s h i f t v a l v e ,
3 - 4 shift valveetc.,are defective
(5) lf th6 lock-up is defactive:
. Lock- up solenoidis stuck
O+@ (b)
r
In th6
L o c k - u p r e l a yv a l v ei s s t u c k
samemanner,ch€ckthe shockand slip at the 1
@+@ -2, 2*3 and 3-OlD up-shifts.
EVALUATION
@+@ Slippage?
lf the shock is excessive:
. Line pressureis too high
Shock? . Accumulatoris defective
r Checkball is defective
(c) Run at the D range lock-up or O/D gearand check
AbnormalNoiseT
D Range Vibration? for abnormalnoisesand vibration.
HINT: The checkfor the causeof any abnormalnoise
and vibrationmust be made with extremocar€ as it
could also be due to lossof balancein lhs drive shaft,
tire. torouo converter,atc.
LOCK-UP

TRANSAXLE
AUTOMATIC
d n dO / D g e a r s ,
(d) W h i l Er u n n i n gi n t h e D r a n g e , 2 n d , 3 r a
"tt" check to s6o that the oossiblekick-down vehicle
Fu,opening sp€odlimitstor 2*1 ,3*2 and O/D.--3 kick-downs
€)
conform to thoso indicatedon tho automatic shift
r;l@G'S
El
\r3'/ \
schedufe.(See page AX- 42}
(€) Checkfor abnormalshock and slio at kick- down.
6
Checkfor th€ lock- up mechanism.
(1) Drive in D range.O/D gear,at a steady speed
(lock-up ON) of about 75 km/h (47 mph).
(2) Liehtly depresslhe acc€l€ratorpedal and check
N G I
that the enginerpm does not chang6abruptly.
lf th6ro is a big jump in enginerpm,there is no lock-
uo.
2 RANGETEST
2 Rangc Shift into th€ 2 rang6 and, while driving with the
KO acceloratorpedal held constantlyat the full throttle
t
valve opening position,push in one of th6 pattern
;4n n selsctorsand check on the followingpoints.
U V (a) Checkto s66 that tho 1"*2 up-shift takes placeand
@ that the shift point cnforms to that shown on the

automaticshift schedule.(SeePage AX- 42]r
(b) While runningin the 2 rangeand 2nd gear,releasethe

2 Range acc€l€ratorpedalandcheckthe enginebrakingeffect.
EVALUATION
lf there is no enginebrakingeffect:
fle=G r Second coast brake is defective
(c) Check for abnormalnoises during accelerationand

deceleration,
and for s h o c ka t u o - s h i f t a n d d o w n -
AbnormalNoissT
shift.
O+€).^^^,,
e{)--""

AX.41
- TROU4ESl99rll9
TRANSAXLE
AUTOMATIC
3. L RANGETEST
No-Up-Shifi (a) Whilerunningin the L range,checkto seothat thore
Range
i s n o u p - s h i f tt o 2 n dg e a r .
rlz
t oale
(b) While runningin the L range,releasoth€ accelerator
oedaland check the enginebrakingeffect.
L Rang€
EVALUATION
lf there is no onginebrakingeffect:
. First and reversebrakeis defective
E n g i n eE r a k i n g ?
(c) Check for abnormalnoises during accelerationand

deceleration.
AbnormslNoise?
R RANGETEST
R Range Shift into R range and, while startingat full throttle,
F u l lO p e n
RI--^
c h e c kf o r s l i p p i n g .
CAUTION:Beforeconductingthis test snsurothat tha
te3t aroais free from personneland obstructions.
EI w
N\c\ ( I
loa -,/
Slippage?
P RANGETEST
P Range StoDth€ v6hicleon a gradient(morethan 5') and after
Vehicleon Gradient shiftinginto tho P range,releasethe parkingbrake.
Then checkto s6ethat the parkinglock pawl holdsthe
-) 0=') vehiclein olace.
\-,/
rarxrng LocK
Pawl Acting
ar280(

AX-42 - TROUBLESHOOTING
AUTOMATIC
TRANSAXLE
AUTOMATIC
S H I F TS C H E D U L E
S H I F TP O I N T
L H DM O D E L( 3 S _ F E )
Shift range Shiftingpoint V6hicl6speedkmlh (mph)
Throtlle valvefu ly openod 1 -2 5s-64 (34 40)
2-3 1 0 0 -1 1 5( 6 2 , 7 1 )
3-o/D r 3 6 - 1 s 3( 8 5- 9 5 )
o/D-3 1 2 9 - 1 4 5( 8 0 - 9 0 )
D rsng6
3-2 9 2 - 1 0 6( 5 7 6 6 )
2-1 3 3- 4 6 ( 2 4 - 2 9 )
Thfotil€vave fullyclossd 3-O/O 32-38 (20-241
* 3
O'zD t5-20 (9 12)
AX 2 r6ng6
Throttle valvefu ly openod 1-2 s5 64 (34-40)
39-46 (24- 29)
L rang€ T h r o t to v a l v ef u r l vo o s n o d 2 ,1 41-54 |29-341
R H DM O D E L( 5 S _ F E )
N O R MM O D E
S h i f tr s n g e S h i f t i n gp o i n t Vohiclesp€odkm,/h (mph)
Throtts valvefullyopsned l-2 (1-EO /11 i_rI
2-3 9 9 - 1 0 8( 6 2 - 6 8 )
3-o/o 1 4 2 - 1 5 2( 8 9- 9 5 )
o/D'3 1 3 2 - 1 4 2{ 8 3 - 8 9 )
D rsng6
89 98 (s6-61)
2-1 41-46 126-29)
Throttleva ve fu ly closod 3-O/O 39- 44 124-27)
o/o-a 19-23 (12-14)
Thrott o valve fully oponod 1-2 53-s9 (33-37)
2 tang6
41-46 t26-29)
L range Throttle valv6 fJl y oo€ned 2-1 45-50 (28-31)
P W RM O D E
Shift rang€ Shiftingpoint Vehicl€spoodkmlh (mph)
Throttlevalv€fullyoponod 1-2 53-59 {33-37)
2-3 9 9 - 1 0 8( 6 2 - 6 8 )
3*o/D | 42 - r s2 (89-95)
o/D+3 1 3 2 - r 4 2( 8 3 - 8 9 )
D rang€
3-2 89-98(56-6r)
4r -46 (26-29)
Throttlsvslvefullyclosod 3*O/D 53-58 (33-36)
o /D+3 1 S - 2 3( 1 2 -1 4 )
Throttl€v. ve fully op6n6d 1-2 El-EO rea_ar\
2 rang6
4r -46 (28-29)
L rango Throttlo valve fully opened 2-1 45-50 (28-3r)

- TROUBLESHOOTING
AX.43
TRANSAXLE
AUTOMATIC
L O C K - U PP O I N T
L H O M O D E L( 3 S - F E )
D range km/h (mph)
L o c k- u p o N k m , / hl m p h ) Lock-0p OFF
Throtlle valve oPoning3%
' s 6 - 6 4 ( 3 5- 4 0 )
59-68 (37-42)
A/O G.* 70 80 (43 s0) 58-6/t (3s-40)
R H D M O O E L( 5 S - F E )
N O R MM O D E
D range km,/h (mph)
Lock- up ON km,/h (mPh) Lock up OFF
Throttlo valve oPening3%
' 6 5 - 7 1 ( 4 0- 4 4 ) ' 60-85 (37-40)
O/DGear 6 5 - 7 1 ( 4 0- 4 4 ) 6 0 - 6 5 ( 3 7- 4 0 )
PWRMODE
D ranga Lock- up oFF kmlh (mph)
Lock- up ON km,/h (mph)
T h r o t t l €v a l v eo p s n i n g3 %
' 6 0 - 6 5 ( 3 8- 4 1 )
3rd G€ar 65-71 (41-44)
O/D G6ar 7 6- S 2 1 4 8 - s r ) 70-75 \44-471
' O l D m a i ns w i t c h O F F
HI N T :
( l ) fn t h e 2 a n d L r a n g e a , l l s t a g e sl o c k - u p i s O F F
( 2 ) I n t h e f o l l o w i n gc a s e s t, h s l o c k - u p w i l l b e r e l a a s e rde g a r d l e sosf t h e l o c k - u p p a t t s r n .
o W h e n t h e t h r o t t l ei s c o m p l € t 6 l cy l o s s d
o W h e n t h e b r a k es w i t c hi s O N .
( 3 ) S h i f t u p t o O / D w i l l n o t o c c u rw h e n t h e w a t e rt € m p i s b e l o w5 5 ' C ( 1 3 1 ' F ) '

AX-44 _ T R O UB L E S H O O T I N G
A U T O M A T I CT R A N S A X L E
T R O U B L E S H O O TM
I NAGT R I XC H A R T
U s et h e t a b l eb e l o wt o h e l py o u f i n d t h e c a u s eo f t h e p r o b l e mT. h s n u m b e r si n d i c a t et h 6 p r i o r i t y
o f t h e l i k e l yc a u s eo f t h e p r o be m C h e c ke a c hp ar t i n o r d e r .l f n e c e s s a r y r, ep l ac e t h e s e p a r t s .
S € eP a g e
i
r +
: -:
P a r t sN am e e 2
I :
; e = € )
5 i : I : !
:
i
o
: s 5a
: r : - a 9 a 6
: t ;
E z z
5 I
i ! :
AX Trouble :
:
E ; f t
a a
i
; ;
d o
c : t
o o z ': s
D o e sn o t m o v e i n a n y f o r w a r d T I
1 5 2
r an g e
D o e sn o t m o v e i n t e v e r s er a n g e I
D o e sn o t m o v e i n a n y f o r w a r d 7 1 2
r ar g e o r r e v e r s er a n g e 3 3 6
lsi -- 2no 3
N o u Ds h f t 2 n d- 3 r d
3rd--OiD
O'D-.3rd
sh , l l
3rd - 2nd
Sh fr pornttoo hrgh or too l.v.
UD shifts3rd -. O iD wlth O, i)
"
swltcf OFE"
U p s h i f t s3 f d - . O / D w h e n E G
scod
h ar s n -
engagemenr 1 s t- , . , i
Tsl ,2nd
l2rangel
1st-2nd-3.d
R e o a i rM a n u a l (. P u b .N o . R M 2 4 8 E )
* R e f e rt o A u t o m a t i cT r a n s a x l e

- TROUBLESHOOTING 4X.45
TRANSAXLE
AUTOMATIC
i _
seepase j].
- > 1 6 > Y I E l >

6 E . € ! ;
!
) i 9
' E ] E
o ri llî
o i 5 t E l z
lst - 2nd -t
3 r d- O / D
2nd-. 3rd
engagement 3 r d' O / D
N o I o c k - u pO F F
Forward& Reverse
(Afterw6rm-up)
Forward& Reverse
(Oirectryafter E/G start)
snuooer
2 n d+ 3 r d
(up'shift)
R e p a i rM a n u a l(. P u b .N o . R M 2 4 8 E )
* R e f e rt o A u t o m a t i cT r a n s a x l e

AUTOMATIC
TRANSAXLE
S e ep a g e * * * * x * * * t( *
E
PartsNam€
a
- : :
:
; E a
Trouble o :
o o o o
L ar g e s h o c kd u r i n gl o c k - u p 1 2
.Tff E / G s t a l l sw h e n s t a r t i n g
off and stooping
1 2
No kick-down 1 2 3
'l
A l l - r an g e s
o/D 1 2
O t h e rt h a n O / D 1 2
P o or 'l
O t h e rt h a n 2 n d 2
a c c e r e r a In
|o
1 s ta n d 2 n d
1 s ta n d " R "
"R"
\,tr5155
* e e p a i rM a n u a l (. P u b .N o . R M 2 4 8 E )
R e f e rt o A u t o m a t i cT r a n s a x l R

_ O N - V E H I C L ER E P A I R
AX-47
A U T O M A T TT
CR A N S A X L E
ON_VEHICLR
E EPAIR
VALVEBODYREMOVAL
a Work must ba startod90 secondsfrom the
CAUTION:
'LOCK' position
.) t i m o t h s i g n i t i o ns w i t c h i 3 t u r n e d t o t h e
and tho nsgativo (- ) termin8l csble is disconnoctedfrom
the battorY.
1. CLEAN TRANSAXLEEXTERIOR
To help preventcontamination,clean tho exteriorof
th€ transaxle.
2. DRAIN ATF
R e m o v et h e d r a i np l u gw i r h 1 0 m m h e x a g o nw r e n c h ,
0 0 a n d d r a i nt h e f l u i d i n t o a s u i t a b l ec o n t a i n e r .
3. R E M O V EO I L P A N A N D G A S K E T
NOTICE: Somefluid will remainin the oil pan.
I]
Removeall pan bolts, and carefullyremov€ the pan
a s s e m b l yd i s c a r d i n tgh e g a s k e t .
4. EXAMINEPARTICLESIN PAN
Ramove the magnets and use thom to collect any
steel chips.Look carefullyat the chipsand particlesin
th€ Danand on the magnotto anticipat€what type of
wear you will find in tho transaxle.
. Steol(magnetic): bearing,gear and plats wear
. -
B r a s s( n o n m a g n e t i c )b:u s h i n gw e a r
m m ( i n .) 5. REMOVEOIL STRAINERAND APPLY PIPEBRACK.

ET
(a) Removethe 3 bolts and tho oil strainer.
20 NOTICE:Be carafulas oil will comoout of tha strainsr
( 0 . 78 7) 50
(1.969) when it is removed.
45 (b) Removethe 2 bolts and the apply pipe bracket.
( 1. 1 1 2 )
AT3336
6. D I S C O N N E CSTO L E N O I DC O N N E C T O R S
f-'--''-No.l"Solenoid,Vatve
N o . 2S o l e n o i dV a l v e

AX-48
A U T O M A T ITCR A N S A X L-E O N - V E H I C LREE P A I R
7. REMOVEOIL PIPES
Pry up both ths 4 pip€ends with a largescrewdriver
and removethem,
8. REMOVEMANUALD E T E N T
SPRING
9. REMOVEM A N U A LVALVEAND MANUALVALVE
BODY
IiXfl
10. REMOVE VALVEBODY

R e m o v tsh o 1 2 b o l t s .
11. REMOVE T H R O T T LC
EA B L E
(a) Disconnect
the throttlecable.
(b) Removethe valvebody.
12, REMOVE
SECONDBRAKEAPPLYGASKET

- oN-vEHICLElEl4!! AX-49
TRANSAXLE
AUTOMAT|C
V A L V EB O D YI N S T A L L A T I O N
1. INSTALLSECONDBRAKEAPPLYNEWGASKET
2. INSTALLVALVE BODY
( a ) W h i l e h o l d i n gt h e c a m d o w n w i t h y o u r h a n d ,s l i pt h e
cablo into ths slot.
(b) Bringvalve body into place. *^r.
wire. Fr'\
NOTICE:Be carefulnot to entanglethe solenoid
3. INSTALL BOLTSIN VALVE BODY

Hand tighton the 12 bolts first, then torque with a
torqua wrench.
Torque:10 N.m(100 kgf'cm. 7 ft'lbf)
Boli lsngth:
A: 20 mm (0.79in.)
B: 25 mm (0'98in.)
C : 3 6 m m ( 1 . 4 2i n . )
D: 50 mm (1.97 in.)
4. CONNECTSOLENOIDWIRING
(a) Connecttho No.1solenoidvalvoconnoctor(whiteand
N o . 2S o l e n o i dV a l v e short6rwiro).
(b) Connectthe No.2solenoidvalveconn€ctor(blackand
longorwifs).
m m( i n . ) 5. INSTALL MANUAL VALVE BODY DETENTSPRING

36 (a) Align the manualvalve with th€ pin on ths manual
1.417\
shaft lever.
(b) Lowsr tho manualvalve body into place.
(c) Hand tightenthe 4 boltsfirst.Then,tightanthem with
a toroue wronch.
Torquo:10 N.m(100 kgf'cm, 7 ft lbf)

AX-50 _ ON_VEHICLR
A U T O M A T I CT R A N S A X L E E EPAIR
m m ( r n). (d) Placeth6 detentspringon the manualvalvebody and

hand tightenthe 2 bolts firsr.
Then,tightenthem with a torqus wrench.
*,._!: Torque:10 N.m(100kgf.cm.7 ft.lbf)
'--, ( e ) C h e c kt h a t t h e m a n u a lv a l v e l e v a r i s t o u c h i n gt h e
_)
center of ths detent springtip roller.
1 4 ( 0 . 5 5)1 l
6. I N S T A L LO I L P I P E S
T a p t h e p i p e sw i t h a p l a s t i ch a m m e rt o i n s t a l tl h e m
i n t o t h e o o s i t i o n si n d i c a t e di n t h e i l l u s t r a t i o n .
NOTICE: Be carefulnot to bendor damagethe pipes.
AX
m m ( i n ). 7. INSTALLOIL STRAINER AND APPLYPIPEBRACK-

ET
(a) Installthe oil strainerandtorouethe 3 bolts.
20 (b) Installth€ applypipebracketandth6 2 bolts.
( 07 8 7 ) T o r q u e : 1 0 N . m ( 10 0 k g f . c m . 7 f t . l b f )
8. I N S T A L LM A G N E T SI N P A N
Installtho 2 magnetsin the indentationsof the pan.
.l\ | ij li
.r I r
lq))
z
'1 -r . )I
'l Magnets
9. INSTALLOIL PANWITH NEWGASKET

N O T I C E :M a k e s u r e t h a t t h e m a g n e t d o e s n o t i n t s r f e r e
with the oil pipes.
T o r q u e :4 . 9 N . m ( 5 0 k g f . c m , 4 3 i n . . l b f )
1 0 . I N S T A L LD R A I NP L U GW I T HN E WG A S K E T
U s i n g1 0 m m h e x a g o w
n r e n c hi,n s t a ltlh e d r a i np l u g
w i t h a n e w g a s k e ta n d t i g h t e n i t .

AX-51
_ ON_VEHICLR
TRANSAXLE
AUTOMATIC E EPAIR
11. FILLTRANSAXLE WITHATF

A d do n l va b o u t2 l i t e r so f A T F .
N O T I C E :D o n o t o v e r t i l l .
F l u i dt y p e :
ATF DEXRON'tr
1 2 . C H E C KF L U I DL E V E L
(SeepageAX- 14)
.AX
E A B L ER E M O V A L
T H R O T T LC
1. DISCONNEC TTH R O T T LC
EA B L E
the cablehousingfrom the bracket'
(a) Disconnect
the cablefrom the throttlelinkage'
(b) Disconnect
2. REMOVENEUTRALSTART SWITCH
(a) Removsthe clipsand disconnectthe transaxlecontrol
cablefrom manualshift lever.
(b) Removethe manualshift lsver'
(c) Rsmovatho neutralstart switch.
3, REMOVEVALVE BODY
( S e ep a g eA X - 4 7 )
4. PULL THROTTLECABLE OUT OF TRANSAXLE

CASE
{a) Removethe bolt and rataining plate.
case.
{b} Pullthe cableout of the transaxle

AX-52 - O N - V E H I C L ER E P A I R
AUTOMATIC
TRANSAXLE
T H R O T T LC
E A B L EI N S T A L L A T I O N
1. I N S T A L LC A B L EI N T R A N S A X LC
EA S E
(a) Be sureto pushit in all the way.
(b) Installthe retaining plateandthe bolt.
2. INSTALLVALVEBODY
(SeepageAX-49)
3. IF THROTTLECABLEIS NEW, STAKESTOPPERON

I N N E RC A B L E
(a) Bond the cableso there is a radiusof about 200 mm
( 7 . 8 7i n . ) .
AX
(b) Pull the inner cable lightly until a slight resistanceis

0 . 8- 1 . 5m m
felt, and hold it.
( c ) S t a k 6 t h e s t o p p e r0 . 8 - 1 . 5 m m ( 0 . 0 3 1- 0 . 0 5 9 i n . )
from the end of outer cable,as shown.
4. CONNECT THROTTLE CABLE

(a) Connectthe cableto the throttl€linkage.
(b) Connectthe cablehousingto th€ brack€t.
5. ADJUSTTHROTTLE CABLE
(SeepageAX- 15)
6. INSTALL NEUTRALSTART SWITCH

(a) Installth€ noutralstart switch.
(b) Installthe manualshift lever.
,+ (c) Adjust th6 neutralstart switch.

( S e ep a g eA X - 1 5 )
(d) Connectthe transaxl6control cable.
oo
*J;t'3

AX-53
- ON_VEHICLR
A U T O M A T I CT R A N S A X L E E EPAIR
OLI L S E A LR E M O V A L
DlFFERENTIA
1. REMOVE B O T HD R I V ES H A F T S
( S e ep a g eS A - 6 1 )
2. REMOVEBOTHSIDEGEARSHAFTOIL SEALS
UsingSST,pullout the oil seal.
ssr 09308- 00010
OLI L S E A LI N S T A L L A T I O N
DIFFERENTIA
1 . I N S T A L L E F TS I D EG E A RS H A F TO I LS E A L
( 1 ) U s i n gS S Ta n da h a m m e rd,r i v ei n a n e wo i l s e a l .
s s T 0 9 3 5 0 - 3 2 041 ( 0 9 3 5-13 2 1 3 0 .0 9 3 5 1- 3 2 1 5 0 )
Oil teal dapth:
2.7 + O.5mm (0.11 + 0.02 in-)
(2) Coat the lip of oil seal with MP grease.
2. INSTALL RIGHTSIDE GEARSHAFT OIL SEAL

( 1 ) U s i n gS S Ta n d a h a m m e r d, r i v ei n a n e w o i l s e a l .
s s r 0 9 3 5 0 - 3 2 041( 0 9 3 5-13 2 13 0 ,0 9 3 s -13 2 1s 0 )
Oil real depth:
0 i 0.5 mm (0 t 0.02 in.)
(2\ Coatthe oil ssal lip with MP grease.
3. INSTALL BOTH DRIVESHAFTS
(Seepage SA-70)
4 . C H E C KF L U I DL E V E L
(Seepase AX- 14)

AX-54
T R A N s A X L E- A S S E M B L yR E M o v A LA N D T N S T A L L A T T . N
AUToMATTC
INSTALLATION
ASSEMBLY
COMPONENTS
D r i v eS h a f t( R H )
46 {470.34)
f 64G9o,4t]
Gr o u Cleaner
Battery Assembly
C ab l r
$
1 2 7( 1 , 3 0 O , 9 4 )
Gr o un d C a b l e
Converter =
e t
N o . 1 M a n i f ol d
S ta y
S t i f f en e r
,=a""'
J v,/
o n t n-oo ;
D r i v eS h a f t( L H l !
- S h i f tC o n t r o lC a b l e
F r o n tL o w e rS u b - fr a m e
i i
A 9
Yt l
I
L o w e rC e n t e r r30l
|-iEnêoq
Lql- l t.{t,q*a
En g i n eU n d e r C o v e r
,7-",'"J'- T F r o n tE x h a u s t/ '
Pipe
@'
a Gas
N m ( k g l c m ,f t l b f ) : S p e c i f i e dt o r q u e
rt Precoatedpart

jx-55
- ASSEMBLY
TRANSAxLE
AUTOMATTC AND!N!f4!!4I!9r{---
REMOVAL
T R A N S A X L ER E M O V A L
C A U T I O N :W o r k m u s t b o s t a r t e d 9 0 s e c o n d sf r o m t h e
t i m e t h 6 i g n i t i o ns w i t c h i s t u r n e d t o t h e ' L O C K ' p o s i t i o n
a n d t h e n e g a t i v e( - ) t e r m i n a l c a b l e i s d i s c o n n e c t e df r o m
the battory.
1. R E M O V EB A T T E R Y
2. D I S C O N N E CTTH R O T T L EC A B L E
w/ CruiseControl System:
3. REMOVECRUISECONTROLACTUATOR
(a) Removethe cruisecontrol actuatorcover.
(b) Disconn6ctths connoctorfrom the cruisecontrol u"- tj
iX"-
tuator.
(c) Removsthe 3 bolts and the cruisecontrol actuator.
4. REMOVE AIR CLEANER ASSEMELY

(a) Disconnect
the connector.
(b) Removethe air cleanerassombly.
5. GROUND
REMOVE BOLT
C A B L EM O U N T I N G

AX-56 - ASSEMBLy
TRANSAxLE
AUToMATTC REMovALAND TNSTALLATToN
6. REMOVEENGINELEFT MOUNTINGUPPERSIDE
BOLT
7, REMOVESTARTER
(a) Removetho nutanddisconnect
the connector
andthe
terminal.
h\w (b) Removeth6 2 bolts and the starter.
',Wn vz,'v\\
ffl-.---...--
8, D I S C O N N E CVTE H I C L E
SPEEO
SENSOR
CONNEC-
TOR
9. DISCONNECT
NEUTRAL
STARTSWITCHCONNEC-
TOR

^. ^" - 5 5
A U T O M A T ITCR A N S A X L-E A S S E M B LRYE M O V AA! N DI N S T A L L A T I O N
TRANSAXLEREMOVAL
C A U T I O N :W o r k m u s t b s s t a r t a d 9 0 s e c o n d st r o m t h e
t i m e t h 8 i g n i t i o ns w i t c h i s t u r n e d t o t h e ' L O C K ' p o s i t i o n
a n d t h e n e g a t i v e( - ) t e r m i n a l c a b l ei s d i s c o n n e c t o df r o m
the bsttery.
1. R E M O V EB A T T E R Y
2. D I S C O N N E CTTH R O T T L EC A B L E
w/ CruiseControl System:
3. R E M O V EC R U I S EC O N T R O LA C T U A T O R
(a) Removsthe cruisacontrolacluatorcover.
(b) Disconnecttho connectorfrom the cruisecontrol ""
AX
tualor.
(c) Rsmoveth6 3 bolts and the cruisecontrol actuator
4. REMOVEAIR CLEANER ASSEMBLY

(a) Disconnect
lhe connector.
(b) Removethe air cleanerassombly.
5. GROUND
REMOVE BOLT

AX-56 - ASSEMBLy
TRANSAxLE
AUToMATTC REMoVALANDrNsrALLATroN
6. REMOVEENGINELEFT MOUNTINGUPPERSIDE
BOLT
7, REMOVESTARTER
(a) Removeth6 nutanddisconnect andthe
theconnector
terminal.
';i'ii1
(b) Removethe 2 bolts and the start6r.
8. D I S C O N N E CVTE H I C L E
S P E E DS E N S O R
CONNEC-
TOR
9. DISCONNECT
NEUTRAL
STARTSWITCHCONNEC-
TOR

^" 57
A U T O M A T ITCR A N S A X L-E A S S E M B LRYE
2 TS O L E N O IC
10. DISCONNEC DO N N E C T O R S
3 T R A N S A X LM
11. REMOVE BOLTS
EO U N T I N G
12. DISCONNEC HOSES

PTSO I LC O O L E R
Loosan the 2 clips and disconn€ctthe 2 oil coolor
hoses.
ENGINE
13. TNSTALL FIXTURE
SUPPORT
1 4 , R A I S EU PV E H I C L E
15. REMOV ENGINE UNDER COVERS
1 6 . D R A I NA T F
17. REMOVE L E F TA N D R I G H TD R I V ES H A F T S
( S e ep a g eS A - 6 1 )
1 8 . J A C KU PT R A N S A X L E

Ax'58
A U T o M A T TTCR A N s A x L -E A S S E M B LRyE M o v A L
A N DT N S T A L L A T T o N
19, DISCONNEC STH I F TC O N T R OC
LABLE
(a) Remove
the nut from lhe controlshaftlever.
(b) Remove the clip and disconnectthe shift control

cable.
AX
20, REMOVE NGINE

R E A RM O U N T I N G
BOLT
TIPE
(a) Remove
th6 2 bolts.
(b) Removethe 2 bolts.th6 nut and the 6xhaustpipe stay

from th€ susoensionmember.
%t
+:a .-

^"'59
^^.
- ASSEMBLY
TRANSAXLE
AUTOMATIC ANDINSTALLATION
REMOVAL
(c) Removetho 2 bolts and the nuts'
(d) Disconnecttho front exhaust pipe and remove the
gasket.
(e) Removethe 3 nuts, the front exhaust pip€ and tho

gasl(et.
22. REMOVESUSPENSION MEMBERS

(a) Removethe 2 shiftcabl6mountingbolts.
(b) Disconnectthe air conditionerpipe bracket'
(c) Removetho 2 poworsteeringgoarassembly

set bolts
and nuts.

AX.60
AUTOMATICTRANSAXLE- ASSEMBLYREMOVALAND INSTALLATION
(d) Removeth€ 3 grommets.
Grommet
Gt t8
(e) Romovethe 13 bolts and the 2 nuts.
c05119
23. REMOVESTIFFENER PLATE

(a) Removethe nut,tho boltandthe No.1manifoldstay.
(b) Removethe 6 boltsandthe stiffenerplate.
24. REMOVETRANSAXLE
(a) Turn the crankshaftto gain accessto the bolts.
Rsmovetha 6 bolts.
(b) Removethe 3 bolts and the transaxle.

(c) Removethe bolts and ths transaxl€.

AX-61
- ASSEMBLY
TRANSAXLE
AUTOMATIC ANDINSTALLATION
REMOVAL
T R A N S A X LIEN S T A L L A T I O N
1 . I N S T A L LT O R O U E C O N V E R T ECLUTCH
R IN TRA-
NSAXLE
lf the torqueconverterclutchhas b e e nd r a i n e da n d
l i t h n e wA T F .
w a s h e dr.e f i lw
F l u i dt y p s :
II
ATF DEXRONO
2. C H E C KT O R O U EC O N V E R T E C R L U T C HI N S T A L L A -
TION
t d g e .m e a s u r ef r o m t h e
U s i n gc a l i p e r sa n d a s t r a i g h a
installedsurfaceto the front surfaceof ,1'tett.ns"tl"
h ou si n g . ffi
Corractdistanco:
Morethan 22.8 mm (0'898in.)
3 . J A C KU PT R A N S A X L E
4 , I N S T A L LT R A N S A X L E
(a) Alignthe 3 knockpinson the blockwith the convorter
houstng.
( b ) T e m p o r a r iilnys t a ltlh e b o l t .
( c ) lnstall the transaxlewith the 3 bolts.

T o r qu e :
1 2 m m h e a d b o l t : 6 4 N m (650 kgf.cm, 47 ft lbf)
1 0 m m h e a db o l t : 4 6 N m ( 4 7 0 k g f . c m , 3 4 f t . l b { )
5, INSTALLTOROUECONVERTER CLUTCHMOUNT-
I N GB O L T S
(a) Cleanthe throadsof boltswith ths gasolino.
(b) Coattho threadsof th6 boliswith tho sealor'
t9 scalant
THREEBOND1324or rqul'
Part No.08833-00070,
valsnt
(c) lnstallths 6 boltswhile turningtho crankshaftto gain
access.

Ax'62 - ASSEMBLy
REMoVAL
ANDtNsrALLATtoN
TRANSAxLE
AUToMATTC
(d) Tightenthe bolts evenly.
6 . I N S T A L L S T I F F E N E RP L A T E
(a) Installthe stiffoner plate with the 6 bolts.
Alternatelytight€n the bolts in several passes.
T o r ou e :
i:A{i, 1 2 m m h e a db o l t : 2 1 N . m ( 2 1 0 k g l c m , 1 5 f t . l b f )
1 4 m m h a a db o l t : 4 3 N . m ( 4 4 0 k g f c m , 3 2 f t . l b l )
( b ) I n s t a l lt h e m a n i f o l ds t a y w i t h t h e n u t a n d t h e b o l t .
Torque:
Bolt:21 N m (210 kgf.cm, 15 ft.lbf)
N u r : 4 3 N m ( 4 4 0 k s f . c m , 3 2 t t l b f)
7 . I N S T A L L S U S P E N S I O NM E M B E R S
( a ) T e m p o r a r i l yi n s t a l lt h 6 1 3 b o l t s a n d t h e 2 n u t s .
(b) Torque the bolts and nuts.
T o r qu 9 :
A bolt: 35 N.m (360 ksf.cm,26 ft.lbf)
D B b o l t : 8 0 N . m ( 8 2 0 k g f . c m , 5 9f t . l b f )
C b o l t : 1 7 5 N . m ( 1 , 8 0 0k g f . c m , 1 3 0 f t . l b f )
E E
D b o l t : 1 2 7 N . m ( 1, 3 0 0 k g f . c m , 9 4 f t l b f)
t1i34!
E b o l t : 1 6 7 N . m ( 1 . 7 0 0k g f . c m ,1 2 3 f t . l b f )
Nut: 80 N.m (820 kgf.cm.59 ft.lbf)
(c) Installthe 3 grommets.
Grommet
(d) Installthe power steeringgearassemblywith 2 bolts.

Torque:127 N.m(1,300kgf cm, 94 f t.lbf)
ffi
H \\--l

AX.63
AUTOMATICTRANSAXLE- ASSEMBLYREMOVALAND INSTALLATION
(e) Connectth6 air conditionerpipe bracket.
(f) lnstallthe 2 shift cablemountingbolts.
8. INSTALLFRONTEXHAUSTPIPE
(a) Installa now gaskst.
(b) Installthe front €xhaustpipewith the 3 nuts.
Torque: 82 N.m (630 kgf .cm, 46 ft.lbf)
(c) Installa n€w gasket.

(d) Installthe 2 bolts and nuts.
Torque:42 N.m (430 kgf .cm,31 ft'lbf)
c(6111
(e) Installthe oxhaustpipe stay with th6 2 bolts and nut.

Torque:1I t{.m(195 kgf.cm,14 ft lbf}
_*'-_
%t
\< (-
/;./-_-,\
\
,.''---\
() >---'-''
----"--)

Ax-64
TRANsA'LE- AssEMBLyREM.'AL ANo TNSTALLATT.N
AUToMATTC
(f) Installth6 2 bolts.
Torque:25 N.m(250ksf cm. 18 ft.lbf)
9, I N S T A L LE N G I N ER E A RM O U N T I N GB O L T
:'AX
1 0 . C O N N E CS
TH I F TC O N T R OC
LABLE
(a) Connectth6 controlcablewith th6 clio.
(b) Install the nut.
1 1 . I N S T A L L E F TA N D R I G H TD R I V ES H A F T S
(SeepageSA- 70)
U N D E RC O V E R S
13. R E M O V E
J A C KA N DL O W E RV E H I C L E

- ASSEMBLY
TRANSAXLE
AUTOMATTC ANDINSTALLAT!oNl,-lx-65
REMOVAL
S U P P O RFTI X T U R E
14. REMOV ENGINE
HOSES
T I LC O O L E R
1 5 . C O N N E CO
Connectthe oil coolerhoseswith tho 2 clips.
1 6 . I N S T A L L3 T R A N S A X LM BOLTS
EO U N T I N G
T o r q u e :6 4 N . m { 6 5 0 k g f c m , 4 7 f t ' l b t )
BOLT
Torquc: 64 N.m (650 kgf .cm, 47 ft'lbf)

AX-66
AUToMATTCTBANSAxLE- ASSEMBLyREMovAL AND TNSTALLATT'N
1 8 . C O N N E C2T S O L E N O IC
DO N N E C T O R S
1 9 . C O N N E CN
T E U T R A L S T A R T S W I TCCOHN N E C T O R
AX
2 0 . C O N N E CVTE H I C L E
SPEED
SENSOC
RONNECTOR
2 1 . I N S T A L LS T A R T E R
(a) Installthe starterwith the 2 bolts.
T o r q u a : 3 9N . m ( 4 0 0 k g f . c m . 2 9t r . l b f )
(b) Connect ths connector.

(c) Connect ths tsrminal with ths nut.

AX-67
A U T O M A T ITCR A N S A X L_E A S S E M B LRYE M O V
2 2 . I N S T A L LE N G I N EL E F TM O U N T I N GU P P E RS I D E
BOLT
Torque: 64 N m (650 kgf cm, 47 ft'lbf)
23. INSTALLAIR CLEANER ASSEMBLY

( a ) l n s t a ltlh € a i rc l e a n sar s s e m b l y .
(b) Connectthe connoctor.
lx
24. INSTALL CRUISECONTROLACTUATOR

(a) Installthe cruisecontrolactuatorwith the 3 bolts'
{b} Connectconnectorfrom cruisecontrolactuator'
(c) Installcruisecontrolactuatorcovsr'
25. INSTALLBATTERY
26. INSTALLAND ADJUSTTHROTTLE CABLE
( S e eP a g eA X - 1 5 )
2 7 . A D J U S TS H I F TC O N T R OC
LABLE
(SeePageAX 15) -
28. AOJUSTNEUTRALSTARTSWITCH
(SeepageAX - 15)
29. FILLATF
I-'!-Tl 6A\\ F l u i di y p e :
Kil Ery
|| l ,|f -,-=--.- (----r--
Dry fill:
ATF DEXRON,II
5.6 litors(5'9 US qts,4'9 lmp.qts)
rluF-.]- /ffi
---.-/ \ \-)/-
l:l- W^

AX-68 - ASSEMBLy
AUToMATTC
TRANSA*LE REMovALANDrNsrALLATroN
3 0 . C H E C KF L U I DL E V E L
(SeepageAX - 14)
(SeepageSA-7)
TOROUE
C O N V E R T ECRL E A N I N G
lf the transaxleis contaminatad, the torque converter
a n d t r a n s m i s s i ocno o l e rs h o u l db e t h o r o u g h l fyl u s h e d
' .:.
with ATF.
TOROUEC O N V E R T EARN D D R I V EP L A T E
INSPECTION
1 . I N S P E CO T N E _ W A YC L U T C H
t' ( a ) I n s t a lSl S Ti n t ot h s i n n e r a c eo f t h eo n e - w a v c l u t c h .
'>) s s T 0 9 3 s 0 - 3 3 0 41 ( 0 9 3 5 -13 2 0 10 )
(b) InstallSSTso that it fits in the notch of ths convert6r

hub and outsr race of the one- way clutch.
s s T0 9 3 s -0 3 2 0 4
1 ( 0 9 3 5-13 2 0 2 0 )
4 ^r\1
- 5 /
(c) With th6 torqu€ convorterstandingon its side, the

clutch locks when turned counterclockwise,and rot-
ates freelyand smoothlyclockwisa.
lf necessary,clsanthe converterand retestth6 clutcn.
Lock Replacetho converterif the clutch still fails the tssr.
tTp rr€€

AX-69
- ASSEMBLY
A U T O M A T I CT R A N S A X L E REM()VALAND|NSTALL
2. MEASURE D R I V EP L A T ER U N O U TA N D I N S P E C T
R I N GG E A R
S€t up a dial indicatorand measursthe drivoplate
runout.
r@A MaximumTunout:
0.20 mm (0.0079in .
lf runout exceeds0.20 mm (0.0079 in.)or if the ring
N o-.9 gear is damaged,replacetho drivs plate.lf Installinga
new drive Dlato,note the ori€ntationof spacersand
tighten the bolts.
Torque:83 N'm (850kgf'cm,61ft lbf)
3. MEASURETOROUECONVERTER SLEEVERUNOUT
(a) Temporarilymount the torquo converterto the drive
plate.Set uP a dial indicator.
Maximumrunout: io{l :
0 . 3 0m m ( 0 . 0 1 8 i n . )
lf runoutexceeds0.30 mm (0.01l8 in.),try to corroct
by reorientingthe installationof the convsrter'lf ox-
cessive runout cannot be corrected, replace the
torous converterc lutch .
HINT: Mark the positionof lho converterto ensure
correctinstallation.
(b) Removethe torque converter.

AX.7O
AUTOMATICTRANSAXLE_ SERVICE
SPECIFICATIONS
S E R V I C ES P E C I F ! C A T I O N S
S E R V I CDEA T A
L ne pressur€(whe I locked) Engineid ing
D range 363- 422 kPa 3.1 4.3 ket/cm' 53 - 61 psi
R range 618-794 kPa 6 . 3- 8 . 1 k g f l c m ? 90 11 5 p s i
AT stall (Throttlsvalve fully opsn6d)
D rang6 7.5 8.8 kgl/cm' 107 125 psi
R rang€ 1 , 3 7 3- 1 , 6 0 8k P a 1 4 . 0 1 6 . 4h s f / c ' . 1 r I99- 233 psl
Engrnestal revolution 2,450t 150 rpm
Timelag NrangerDrango Less than 1.2 s€conds
Nrange-Rrange L e s st h a n 1 . 5 s o c o n d s
Engineidle speed(Coolinglan and A/C OFF)
AX N rang6 750 t 50 rpm

Betweonboot and face and inner cab e stooo€r
Throttle cab e adjustm6nt(Throttlevalv6fully op6nod)
O l m m 0 0.04 in.
Torqueconverterrunout Limit 0 . 3 0m m 0 . 0 1i 8 i n .
D r i v ep a t e r u n o u t Limit 0 . 0 0 7 9i n .
AUTOMATIC
S H I F TS C H E D U L E
S H I F TP O I N T
L H D M O D E L( 3 S _ F E )
Shift range S h i f t r n gp o r n t V o h i c l es p e e d k m / h ( m p h )
Throttlevalv6fuilyop6n6d 1-2 55 64 (34 40)

2-3 1 0 0 - 1 1 5( 6 2 7 1 )
3-O/D 114- I qa rAE-OEr
o/D -3 1 2 9 1 4 5( 8 0 , 9 0 )
D r€nge
92 1 0 6 ( 5 7- ' 6 6 )
2-1 39 46 124 291
Thrott6 vslvefu ly clossd 3-O/D 32 3A \2O 24)
o/D-3 15 20(9-12)
Throttle valvo ful y oponsd 1-2 55..64 (34 40)
2 rangs
2-*1 39 - 46 (24 29)
L rang6 Throttl6valve tuJlvoooned 2-1 47 54129 34)

AX-71
_ S E R V I CSEP E C I F I C A T I O N S
TRANSAXLE
AUTOMATIC
R H D M O D E L( 5 S _ F E )
N O R MM O D E
Shilt range Shiftingpoint Vehicl€spoodkmlh (mph)
Throttlovslvefullyoponed 1-2 53 s9 (33 37)

2-3 9 9 1 0 8( 6 2 - 6 8 )
3*o/o 1 4 2 - 1 5 2( 8 9 - 9 s )
o/O'3 1 3 2 1 4 2( 8 3 - 8 9 )
D range 89-98(s6-61)
2-l 41 46 (26 29)
Throttlev6lvefulY closed 3'O/D 39 44 \24 27)
o/D'3 1 9 2 3 ( 1 2- 1 4 )
ra qo rl'l -17\
Thrott s valvelully opened 1-2
2 range 2.-1 41 - 46 \26- 29)
Throttlevalve lully oponod 2'1 45 5 0 ( 2 8- 3 1 ) tAx
L range
P W RM O D E
Shiftingpoint V6hicl6spsod kmlh {mPh)
Shift rang6
Throtts valvofullyopenod 1'2
2-3 9 9 1 0 8( 6 2 - 6 8 )
3-O,/D 1 4 2 1s 2 ( 8 9- 9 5 )
o/o'3 132 r42 (83 89)
D rang€ 89-98 (56-61)
2-1 41 46 (26 29)
E'r Ea iil ?41
Throttlevslvof ullyclosod 3'O/O
o/o'3 19 23(12 141
Throlt s valvofJlry opsnod 1-2
2 rango 4r 46 126-29)
Throttl€ valve fu ly open€d 2-1 45-50 (28-31)
L range

AX-72
AUTOMATICTRANSAXLE- SERVICE
SPECIFICATIONS
L O C K - U PP O I N T
L H D M O D E L( 3 S - F E )
D rang6
Lock-up ON km/h (mph) Lock-up OFF km,/h(mph)
Throttlovaive op6ning396
3rd Gear ' 5 9 - 6 8 ( 3 7- 4 2 ) ' 5 6 - 6 4 ( 3 s- 4 0 )
O/D Gosr 70-80 (43-s0) 5 6 - 8 4 ( 3 5- 4 0 )
R H DM O D E L( 5 S - F E )
N O R MM O D E
D rsng6
Lock-up ON km,/h(mph) Lock-up OFF kmilh (mph)
Throttlo volvs opening3%
3rd Goa. ' 65-7r (40-44) '60-65 (37 40)
O/O Gaal 6 5- 7 r ( 4 0 - 4 4 ) 80 6s (37 40)
li*, P W RM O D E
D ran96
Lock-up ON km,/h(mph) Lock - up OFF kmlh (mph)
Throttlovalv6 op6ning396
3rd Gear ' 6 5 - 7 r ( 4 r- 4 4 ) ' 6 0 - 6 5 ( 3 8- 4 1 )
O,/OG6ar 76-82(48-5r) 70-75 \44- 47)
' O l D m a i ns w i t c hO F F

- SERVICE AX-73
TRANSAXLE
AUTOMATIC SPEClFlC4rl9NlS
SPECIFICATION
TOROUE
Part tightonod N.m kgf.cm It.lbf
43 in..lbt
Air cl6ansrassomblY
83 850 61
Driv6 plate x Crankshaft
250 18
Torqueconv6rtorx Drivo Plato
1t 110 8
Valv6 body x Transaxleca36
7.4 85 in..lbf
Testing plug
4.9 50 43 in,lbt
Oilpan
O i l p a n d r a i np l u g 49 500
1 l 110 I
Oii strainor
Shift control cablo t2 125
400 29
Startor
RH Or|v€shaft x Erackot 64 E60 47
19 14
Front lowor sub-framo with 6terring96arhousingx Exhaustpipo 6tay
49 500 36
Tie rod end x Stooringknucle
a2 630 46
Front 6xhaustpipo
Front 6xhaustpioe x Exhaustpipo stoy 250 18
Front 6xhaustpio6 x csnter exhaustplpe 42 430 3t

l9 14
En9in6roor mountingx Exhaustpipo stay
Driv6 shaft x Sto€ringknuck16 218 2,200
127 1,300 94
Pow6r stoeringgear sSsomblyx Front sub_framo
Engineloft mounting a4 47
66 890 64
Enginor6ar mounting)( Transa)(lo
Bolt 55 48 in..lbf
N€utrslstart switch x Transaxlgc86a
Nut 8.9 70 8 1 i n .l b l
N o . l m a n i f o l ds t a y Bolt 210 t5
Nut 43 440
Stittenorplate 12 mm bolt 21 210

l4mmbot 43 440
10 mm bolt 4A 170 34
Trensaxlehousingx Engino
12 mm bolt 64 850
Suspensionmomb6rs A bolt 35
B bolt 80 820
C bolt 1,800 130
D bolt 127 1,300 94
E bolt 187 1,700
NUt 80 820

- MEMO -

sA-1
N DA X L E
S U S P E N S I OAN
' sA-I 11
TROUBLESHOOTING " SA- 2
SA- 3 F R O N TS H O C KA B S O R B E R sA- 112
G E N E R A ILN S P E C T I O N
SA- 5 L O W E RS U S P E N S I O AN RM sA-118
W H E E LA L I G N M E N T
T HE E LA L I G M
F R O NW NE N T SA- 5 LOWER B A L LJ O I N T . . . . . . . . '
. . sA-125
(Super StrutType) " " "' SA- 5 STABILIZE BR A R. . . . . . sA- 128
FR o N Tw H E E LA L I G N N , I E N T SA- ] sA- l3l
( M a c P h e r s oSnt r u tT Y P o ) SA- 7 sA- 131
R E A RW H E E LA L I G N M ENT SA- 9 PREPARATION sA- 132
SA_ I1 R E A RA X L EH U B . . . " . . . ' " . . . . . sA- 133
F R O N TA X L E
(SuperStrut Type) " " ' sA- 1t R E A RA X L EC A R R I E R sA- 137
D E S C R I P T I"O. .N. SA- I1 REARSUSPENSION"
DESCRIPTION.....
" "" sA- 141
sA- 141
ffi
PREPARATION SA- 12
F R O N TA X L EH U B " ' SA- 14 PREPARATION sA- 142
SA- 26 R E A RS H O C KA B S O R B E R sA-143
FRONTAXLE
( M a c P h e r s o nS t r u t T Y P o ) ' sA- 26 L O W E RS U S P E N S I O N
SA- 26 A R M A N D S T R U TR O D sA- 149
DESCRIPTION'....
sA- 27 S T A B I L I Z EBRA R . . . . . . . ." " s A -1 5 4
PREPARATION
SERVICE SPECIFICATIONS sA- 157
FRONA T X L EH U B ' " . . . . , . . . . . . "
F R O N TD R I V ES H A F T . " , . . . . . . . " SA- 38
/2Q - /: tr\ sA- 38
DESCRIPTION'.... SA_38
PREPARATION sA- 39
F R O N TD R I V ES H A F T. . . . " . . . ' " sA- 41
F R O N TD R I V ES H A F T . . . . . . " . . ' " SA- 57
/?Q _ Etr qq_
\vv
FF\ SA- 57
DESCRIPTION.,... sA- 57
PREPARATION sA- 58
F R O N TD R I V ES H A F T. . " . . . . . " . " sA- 60
F R O N TD R I V ES H A F T . . . . . . " . ' ' " sA- ?3
i7A_FF\ SA_73
DESCRIPTION..... sA- 73
PREPARATION sA- 74
FRONT DRIVE SHAFT ''".......... SA_]5
. ..
F R O N TS U S P E N S I O N. ' " . . . SA- 85
" " " " ' S A _8 5
{ S u p e rS t r u t T Y P e )
DESCRIPTION..'" SA- 85
PREPARATION SA- 86
F R O N TS H O C KA B S O R B E R S A _8 7
L O W E RS U S P E N S I O N
A R M W I T H B A L LJ O I N T sA- 98
s r A B l L l z E RB A R . . . " " " ' s A -1 0 7
F R O N TS U S P E N S I O N " " " sA-110
( M a c P h e r s o nS r r u t T Y P e ) " sA-ll0
DESCRIPTION.... sA-110

sA-2 S U S P E N S I OANN D A X L E - T R O U B L E S H O O T I N G
TROUBLESHOOTING
U s et h € t a b l st o h s l py o u f i n d t h e c a u s eo f t h e p r o b l e mT. h e n u m b e r si n d i c a t et h e t h e p r i o r i t yo f
the likelycass of the problem.Checkeach part in order.lf necessary.replacethese parts.
SeePage oo'
? c r
a1
Parts
c
Name E
6 !
c
d,
!
Trouble
F E .o I ln 3
Wander/pulls 1 2 ? 5 6
Bottoming 2 3
Sways/pitches 2
Front wheel sl.i.nmy 1 4 3 5 6 7 8 )
A b n o r m at li r ew e a r 1 2 4 J

sA-3
AND AXLE _ GENERALINSPECTION
SUSPENSION
G E N E R AILN S P E C T I O N
1 . I N S P E C TT I R E
(a) Checktha tires for wear and for the proper inflation
orgssu r€.
Coldtire inflationPresruro
Front Raar
Ti16 size
kPs (kgflcm', p6i) kPa (kcl,/cm!, pti)
l4 89H
195,/65R 220 12.2,321 220 12.2,32)
2 0 5 , / 5 5 R 1857 V 24O12.4,35) 24O 12.4,36],
( b ) C h e c kt h e t i r e r u n o u t
Tirarunout:
Lesgthan 1.4 mm (0.055in.)
2, ROTATING TIRES
Rotatothe left and right,or front and roartires,
3 . I N S P E C TW H E E LB A L A N C E
( a ) C h e c ka n d a d j u s tt h o O f f - t h e - c a r b a l a n c e .
( b ) l f n e c e s s a r yc,h e c ka n d a d j u s tt h e O n - t h € - c a r b a l '
ance.
Unbalancesfter adjustment:
8.0 g (0.018lb) or lerr
4, CHECKWHEELBEARING LOOSENESS
(a) Checkthe backlash
in bearingshaftdirection,
Maximum:
0 . 0 5 m m ( 0 . 0 0 2 0i n . )

sA-4 S U S P E N S I OANN D A X L E - G E N E R A ILN S P E C T I O N
(b) Checkthe axle hub deviation.
Maximum:
0.05 mm (0.0020in.)
5. CHECKFRONTSUSPENSION FOR LOOSENESS

6. L I N K A G EF O RL O O S E N E S S
C H E C KS T E E R I N G
7. CHECKBALL JOINT FOR EXCESSIVELOOSENESS

(a) Jack up the front of the vehicle.
(b) Move the wheel up and down, and checkthat tho ball
joint has not excessivoplay.
8. CHECKSHOCKABSORBERS WORK PROPERLY

r Checkfor oil leak
o Checkmountingbushingsfor wear
. Bouncefront and rear of the vehicle

sA-5
ANDAXLE- WHEEL
susPENSloN A!!9!-U!!I
W H E E LA L I G N M E N T
W HEELAL IGNMENT
FRO N T
(SuperStrut TyPe)
1 . M E A S U RV HEIGHT
EE H I C L E
Vahicle height:
1 8 2 . 8m m ( 7 . 1 9i n . )
M€asuringpoant:
Measurefrom the groundto the c6ntorof the suspen-
sion lower No.1 arm mountingbolt.
NOTICE:Beforeinrpectionthe whoelalignment,adjust
the vahiclehsight to spacification.
lf the vehicleheightis not standard,try to adjust it by K
pushingdown on or liftingthe body.
2. INSPECT AXIS
CAMBER,CASTERAND STEERING
Ccmber Catter
INCLINATION
Camber:
-0'13'+ 45'
Left-tight 917or:
45' or less
C!at3r:
2" 38' + 45'
Left - right error:
45' or lerr
Sioerlng Axit Inclin!tlon
Steerlngrxis inclination:
2'50' t /15'
HINT:Camber,casterand steeringaxis inclinationare
not adiustable.lf measurements aro not within sp€ci-
fication, inspect th€ suspensionparts for damaged
andlor worn out partsand replacethem as nocessary'
3. TOE-IN
INSPECT
T06- In (total):
A+B = 0'12't 12'
(C-D = 2 t 2 mm, 0.08 t 0'08 in.)
adjust it
lf tho to€-in is not within the spocification,
at th€ tie rod end.

sA-6
S U S P E N S I OANN D A X L E - W H E E LA L I G N M E N T
4. A D J U S TT O E _ I N
(a) Removetha boot clamps.
(b) Loosenthe tie rod end lock nuts.
(c) Turn the left and right tie rod endsan equalamountto
adjust the toe - in.
Toc- in (total):
A*B = 0'12'+ 6'
(C-D = 2 t 1 mm, 0.08 + 0.04 in.)
HINT:Measurethat the lengthsof the l6ft and right tie
rod end lengthare the same.
Tic rod cnd lcngth difference:
I .5 mm (0,059in.)or loss
(d) Torquethe tie rod end lock nuts.
Torquc:56 N.m (570 kgf.cm,42 ft.lbf)
(e) Plac6th6 boot on the seat and installthe clamp.
SA HINT:Make sur6 that the boots ar6 not twisted.
5. I N S P E CW
T H E E LA N G L E
Whrcl rngle
Outsidowho6l
ln!idc wh6ol
(r6f6r6nc6)
31" 28' X 2" 2A'22'
lf ths whselangl€sdifforfromthe specification, check

the differenceof the laft andrightti6 rod €nd length.
Tio rod end length dlffrrencc:
1 . 5 m m ( 0 , 0 5 9 I n . )o r l c r

sA-7
ANDAX!E-: rryHlurc$4Elf
susPENsloN
WHEE LAL IGNMENT
FRONT
Strut TYPe)
(MacPherson
HEIGHT
1 . M E A S U RVEE H I C L E
Vchicb hoight:
1 8 2 . 8m m ( 7 ' 1 9i n . )
MeasuringPoint:
Measurefrom the ground to the centor of th€ front
side lower arm mountingbolt.
NOTICE:Boforoinspection the wheelllignment'tdjust
ihe vohiclohoight to rpecification'
lf the vehiclehoightis not standard,try to adjustit by
pushingdown on or liftingthe body'
.sA
2, INSPECT AXIS
CAMEER,CASTERAND STEERING
Caster
Cambor
INCLINATIOI{
C!mbcr:
- 0"[6' t tts'
Lcft-tight orrof:
45' or lots
C.ttrt:
2"05' I tt5'
-
Lclt tight cirot:
45' or lott
Stoering arir inclination:
StosringAxis lnclination
14'58' i 45'
H I N T : C a m b e r ,c a s t o r a n d s t e e r i n g a x i s i n c l i n a t i o n a r e
n o t a d j u s t a b l e .l f m e a s u r e m e n t s a r e n o t w i t h i n s p € c i -
fication, inspect the suspension parts for damaged
a n d l o r w o r n o u t p a r t s a n d r e p l a c et h e m a s n e c € s s a r y '
3. TOE-IN
INSPECT
Toc - in (tot!l):
A+8 = 0't 12'
(C-D = 0 a 2 mm'0 + 0.08in.)
adjust it
lf the to6-in is not wilhin th6 spocification,
at tho tie rod end.
sA32r3

sA-8 AND AXLE - WHEELALIGNMENT
SUSPENSION
4, A D J U S TT O E - I N
(a) Removetho boot clamps.
(b) Loosenthe ti€ rod snd lock nuts.
(c) Turn the left and right tie rod endsan equalamountto
adjustthe toe- in.
Toe- in (iotal):
A*B : 0' + 6'
( C - O : 0 t I m m , 0+ 0 . 0 4 i n . )
HINT:Measurethat the lengthsof the lsft and right tre
rod end lengthare the same.
Tie rod end lengthdifference:
1,5 mm (0.059in.)or lerr
(d) Torquethe tie rod end lock nuts.
(e) Placethe boot on tho soat and installth€ clamp.
SA HINT:Make sure that the boots are not twisted.
5. INSPECT
WHEELANGLE
Whoel angle
Front Outsidewh6ol
t lnsidowhool
36"54' a 2"
(rof6renc6)
30'44'
A : Inside
B : Outside lf th€ wh6elanglesdiffarfrom tho specification, check
the differenceof the loft and right tie rod end length.
Tie rod end length difference:
1.5 mm (0.059 in.) or less

sA-9
ANDAXLE lryF|lE! i!!9!!!!r
susPENsloN
R E A RW H E E LA L I G N M E N T
HEIGHT
1 . M E A S U RVEE H I C L E
Vohiclehoight:
250.0mm (9.84in.)
MeasuringPoint:
Measurefrom the ground to ths centor of the strut
rod mountingbolt.
NOTICE: Boforeinspocting tho rYhaelslignment'adjust
the vehicleheightto specification.
lf the vehicl6heightis not standard,try to adjust it by
pushingdown on or liftingtho body.
2, I N S P E CC
TA M B E R
Camber
- 1 "1 1 't 4 5 '
3s-GEen0ino
-1'11' 145'
3S-FE engine
- 1 "r 0 ' a 4 5 '
5S-FE ongino
-1"t6' ! 45'
7A-FE 6ngin€
Left - right orror:

45' or less
HINT:Camberis not adjustable,if msasuramentis not
inspectand replacetho suspon-
within specification,
sion oarts as necessarY.
3. I N S P E CTTO E - I N
Too- in (tot8l):
A + I 3 0 " 2 1 ' +1 2 '
( C - D 3 . 5 t 2 m m ,0 . 1 4+ 0 ' 0 8 i n ' )
lf the toe - in is not within the specification,adjust it
at the No.2 lowgr susPenston arm.

sA-10
S U S P E N S I OANN D A X L E _ W H E E LA L I G N M E N T
4. A D J U S TT O E - I N
Toe- in (total):
A + B 0 "2 1 ' + 6 '
( C - D 3 . 5 t 1 m m , 0 . 1 4+ 0 . 0 4i n . )
(a) M e a s u r et h e l e n g t ho f t h e l o f t a n d r i g h t N o . 2 l o w e r
s u s p g n s r oanr m .
Left- iight d ifference:
1 mm (0.04in.)or less
lf the l6ft- right djfferenceis greaterthan the specifi-
cation,adjustthe langth.
(b) Loossnthe lock nuts.
(c) T u r n t h e l e f t a n d r i g h ta d j u s t i n g
t u b ea n e q u a la m o u n t
to adjusttoe in. -
H I N T :O n et u r n o f t h s e a c ha d j u s t i n gt u b e w i l l a d j u s t
t h e t o e - i n a b o u t0 . 7 ' ( 7 . 0m m , 0 . 2 8i n . ) .
SA (d) Torquethe lock nuts.
Rr0t64
R10165
lir{{

SUSPENSION
FRONTAXLE
( S u p e rStrut Type)
DESCRIPTION
The wheel bearingsare double-row angularball bearingscombinedwith the oit seals nli,irib
s m a l lr o l l i n gr e s i s t a n caen d a r s m a i n t o n a n cfer e e .
T h e p r e l o a do f t h e b e a r i n g sc a n b e d e t e r m i n e o d n l y t i g h t e n i n gt h o a x l e h u b n u t t o a s p e c i f i e d
t o r q u e ,i m p r o v i n gs e r v i c e a b i l i t y .
'bA
AxlsHub
Doubls-RowAngular
BallBearing

sA-12
AND AXLE - FRONTAXLE(Super
SUSPENSION Strut Type)
PREPARATION
SST(SPECIAL
SERVICE
TOOLS)
0 9 3 0 8 - 0 0 0 1 0o l s s a l P u l l o r
d}fw'
09316-60010 Transms s l o n& T r a n s f 6Er 6 a r i n g
' .-1-
)e8* R€placsr
KIlee
( 0 9 3 1 6 - 0 0 0 1 0 ) R e p l a c €Pr p €
ffi) ( 0 9 3 1 6 - 0 0 0 4 0R) e p l a c e r ' c '
09520-00031 R6arAxlo ShaftPullsr
ll .-.
0 9 6 0 8 - 1 2 0 1 0 F r o n tH u b& D r ; v eP i n o nE e a r i n s
;J, Rsplac6rSet
lr?.rt'
(09608-00020) R€mover& Replac€rHandr€
e5:
(09608-00040)Replacer
(09608-00060) DrlvePinionFrontB€arinsCup
('- " ') Replac6r
0 9 6 0 8 - 2 0 0 1 2 F r o n rH u b& D r v o P i n r o n
B6aring
^\@- Tool Set
(09608-03020) Hanate
6^
(09608-03060)Replacer
\=/

S U S P E N S I OANN D A X L E - F R o N TA X L E ( S u
(09608-03090)RePlacer
l':- .";'1
09608-32010 SteeringKnuckleo I soal B€afing installation

Roplacer Axl€ hub installation
Dust defl€ctor installation
0 9 6 1 0 - 2 0 0 1 2 P i t m s nA r m P ! l l e r Tie rod end nstallation
#9 0 9 6 2 0 - 3 0 0 1 0 s t e e r i n sG € a r8 o x R o p l a c €sre t
\.2e"
1 ? e
( 0 9 6 2 5 - 3 0 0 1 0 ) s t e e r i n gM a l ns h a f t B 6 a r n g
@)
l\'---//J
Replacer
;5'r'1
0 9 6 2 8 - 1 0 0 1 1 B a l lJ o i n tP u l l € r Hub bolt rsmoval
@ 0 9 6 2 8 - 6 2 0 1 1 B a l lJ o n t P u l l € r
09950-00020BeernsFemov€r
d1f€<@
\€5e
R E C O M M E N D ET
DO O L S
09042-00010 TorxSocketT30
0 9 9 0 5 - 0 0 0 1 3 s n a PR i n sP l i o r s
EOUIPMENT
Torque wrench

sA-14 ANDAXLE- FRoNT
suspENstoN AXLE(super
strutType)
F R O N TA X L E H U B
COMPONENTS
o-------] 80 (800,59)
Shock Absorbar with

StabilizsrBar Steering Knuckle
Tie Rod End

-.ra,--
xY
i------trcr999.!9!
CotterPin
,-F-tE=;'rt,]
^0It/ ^rt t""*
-=[*- s"n"oi
Y
Clip
tI ?
L a CotterPin
o CotterPinI
Lock C8
Y?rl
oisc r-ocrcao
a Dust Oiflector I
ttlo rz'zoo=rl
., O Oil Seal
I rrt"uu
Plx"Jil3.5r{
.?*d
| -/-i7
t :
F.g18676firbd
R09877
N . m ( k q f. c m , f t ' l b t ) I S p e c i f i e dt o r q u e
a N o n - r e u s a b lp ea r t

SUSPENSION AXLE - FRONTAXLE(SuPer
Strut T
S H O C KA B S O R B EW
R I T HS T E E R I N G
KNUCKLE REMOVAL
1 . J A C KU PV E H I C L ER, E M O V E F R O N TW H E E L
2 . C H E C KB E A R I N G B A C K L A S A N D A X L EH U BD E -
H
VIATION
(a) Removethe 2 brakecaliperset bolts.
( b ) S u s p e ntdh e b r a k ec a l i p esr e c u r e l y .
(c) Placematchmarkso n t h e d i s c a n d a x l e h u b .
(d) Removethe disc.
( e ) P l a c et h e d i a li n d i c a t onr s a rt h e c e n t e ro f t h e a x l eh u b
a n d c h e c kt h e b a c k l a s h i n t h e b e a r i n gs h a f td i r e c t i o n .
Maximum:
0.05 mm (0'0020in.)
l f g r e a t e rt h a n t h e s p e c i f i e dm a x i m u m ,r e p l a c et h e
b ear t ng .
(f) Using a dial indicator,chack tho deviation at t h e

surfaceof the axle hub outsidetha hub bolt
M a x i mm u:
0.05 mm (0.0020in.)
l f g r e a t e rt h a n t h e s p e c i f i e dm a x i m u m ,r e p l a c et h s
a x l eh u b .
(s) A l i g nt h e m a t c h m a r k as n d i n s t a l tl h e d i s ct o t h e a x l 6
hub.
( h ) I n s t a l tl h e b r a k ec a l i p e tro t h e a x l e h u b .

sA-16
S U S P E N S I OANN D A X L E _ F R O N TA X L E ( S r b r r u t I
3, REMOVE D R I V ES H A F TL O C KN U T
( a ) R e m o vteh e c o t t e rp i na n dl o c kc a p .
( b ) W h i l ea p p l y i ntgh e b r a k e sr ,e m o v o
thenut.
4. w/ ABS:
ii1 /.
REMOVEABSSPEEDSENSOR
Rsmoveth6 ABSspeedsensorset bolt.
-1,i
SA
tliI N
5. OISCONNEC BTR A K EH O S E
I (a) Remove ths clipfrom the brakebracket.
I (b) Pulloff the brakahosefrom the shockabsorber.
6. REMOVE B R A K EC A L I P E R
(a) Rsmovethe 2 brak6caliperset bolts.
(b) Suspendths brakecalipersecusely.
( c ) P l a c em a t c h m a r kos n t h e d i s c a n d a x l e h u b .
(d) Removethe d isc.

SUSPENSION
7 . D I S C O N N E CTTI E R O D E N D
(a) Removethe cotter pin and removethe nut'
(b) UsingSST,disconnectthe tie rod end from ths stoar-
ingknuckle.
s s T 0 9 6 10 - 2 0 0 12
8. D I S C O N N E CS TT A B I L I Z E R BARLINK
R s m o v et h e n u t a n d d i s c o n n e ct th e s t a b i l i z ebr a r l i n k
f rom shock absorber'
H I N T :l f t h s b a l l j o i n st t u dt u r n st o g e t h e rw i t h t h 6 n u t ,
u s ea h e x a g o nw r e n c ht o h o l dt h e s t u d .
9. DISCONNECT LOWERBALLJOINTATTACHMENT
Removethe nut and2 boltsanddisconnect tha steer-
i n gk n u c k l fer o ml o w e rb a l lj o i n ta t t a c h m s n t .
T A M B E RC O N T R O LA R M
1 0 , D I S C O N N E CC
(a) Removoths cottar pin and lock cap, romovetha nut'
' ?
(b) Using SST,disconnectthe camber control arm from

shock absorber.
s s T 0 9 6 2 8- 6 2 0 11

sA-18 AND AXLE - FRONTAXLE(Super
1 1 , D I S C O N N E CD T R I V ES H A F T
( a ) U s i n ga p l a s t i ch a m m e r d
, i s c o n n e ctth e d r i v e s h a f t
f r o m t h o a x l eh u b .
NOTICE: Coverthe driveshaftbootwith clothto Drotect
it from damage.
(b) Placewoodenblockon the jack and supportthe lower

b a l lj o i n t a t t a c hm e n t .
1 2 . R E M O V ES H O C K A B S O R B E R WITH STEERING
KNUCKLE
(a) Remove t h e 3 n u t so n u p p 6 rs i d eo f t h s s h o c k a b -
sorbsr.
( b ) R e m o v teh s s h o c ka b s o r b awr i t h s t e e r i n kgn u c k l e .
KNUCKLE DISASSEMBLY
D I S C O N N E CS TT E E R I N G K N U C K L EF R O M S H O C K
ABSORBER
( a ) R e m o v et h e c o t t e rp i n a n d t h e n u t .
( b ) U s i n g S S T , d i s c o n n e c t h o s t 6 6 r i n gk n u c k l e f r o m
shock absorber.
s s T 0 9 6 2 8- 6 2 0 1I

SUSPENSION AXLE - FRONTAXLE(SuPer
Strut T
F R O N TA X L EH U BD I S A S S E M B L Y
1. REMOVE D U S TD E F L E C T O R
Usinga screwdriver,removethe dust deflector.
2. R E M O V EI N N E RO I L S E A L
U s i n gS S T ,r s m o v et h e i n n e ro i l s e a l .
s s T0 s 3 0 8 - 0 0 0 1 0
3. REMOVE S N A PR I N G
U s i n gs n a pr i n gp l i e r sr,o m o v o
t h e s n a pr i n g .
4. REMOVA E X L EH U B
(a) UsingSST,removethe axlehub.
s s r 0 9 5 2 0- 0 0 0 3 1
(b) UsingSSTand a pross,removethe innerraco(outsida)

from the axla hub.
ssr 096203 - ooo 1 ( 0 9 6 2-53 0 0 1o ) ,
0 9 9 s -0 0 0 0 2 0

sA-20 AND AXLE - FRONTAXLE(Super
5. REMOVEDUSTCOVER
Usinga torx wrench,removethe 4 bolts and dust
cover.
T o r xw r e n c hT: 3 O( P a r tN o . 0 9 0 4 2 - 0 0 0 1 o
0r locally
manufactured tool)
REMOVEOUTEROIL SEAL
UsingSST,remov6the outeroil seal.
s s r 0 9 3 0 8 -0 0 0 1 0
'$Sl
7, REMOVE BEARING F R O MS T E E R I NKGN U G K L E

UsingSSTand a press, removethe bearingfrom the
stearingknuckle.
s s T 0 9 6 0 8 -12 0 10 ( 0 9 6 0 8 - 0 0 0 2 0 ,9 6 0 8 - 0 0 0 6 0 ) ,
0 9 5 2 7 -1 7 0 1
F R O N TA X L EH U BA S S E M B L Y
1 . INSTALLBEARING
(a) Removelhe innerracesfrom a new bearing.
( b ) UsingSST and a press,installtho bearingto the
st€eringk nuckle.
s s r 0 9 6 0 8 - 2 0 0 12 ( 0 9 6 0 8 - 0 3 0 2 0 0, 9 6 0 8 - 0 3 0 9 0 )
( c ) I n s t a ltl h e i n n e rr a c e s .
I{OTICE: It th6 innorrrce rnd bellscomeloosofrom tho
besringoutoi race,be suroto installtham on tho sama
ridc ar before.
2 . I N S T A L LO U T E RO I L S E A L
UsingSST,installa new outor oil seal.
s s r 0 9 6 0 8 - 2 o o21( 0 9 6 0 8 - 0 3 0 2 0 ) ,
0 9 6 0 -8 3 2 0 0
1

sA-21
AND AXLE _ F R O N TA X L E ( S
SUSPENSION Strut T
3. INSTALL DUST COVER

Usinga torx wrench,installthe dust cover with ths 4
bolts.
T o r x w r e n c h :T 3 0 ( P a r tN o . 0 9 0 4 2 - 0 0 0 1 0 o r l o c a l l y
manufactursdtool)
Torque:8.3 t{.m(85 kgf cm. 74 in. lbf)
4. INSTALLAXLEHUB
UsingSSTanda press.installthe axlehub.
s s r 0 9 6 0 8 - 12 0 1 0( 0 9 6 0 8 - 0 0 0 2 0 ,9 6 0 8 - 0 0 0 4 0 )
09608-32010
5. INSTALLSNAPRING
U s i n gs n a pr i n gp l i e r si ,n s t a ltlh o s n a pr i n g .
6. I N S T A L LI N N E RO I L S E A L
l n e w i n n e ro i l s s a l .
U s i n gS S Ta n d a h a m m e r i,n s t a l a
s s T0 9 6 0 8 - 2 0 02r( 0 9 6 0 8 - 0 s 0 2 0 ) ,
09608-32010
7. INSTALLDUSTDEFLECTOR
UsingSSTanda hammer, installa newdustdeflector.
s s T 0 9 3 16 - 6 0 0 10 ( 0 9 3 6 - 0 0 0 10 . 0 9 3 16 - 0 0 0 4 0 )
1

sA-22 suattnsroNANDAxLE- FRoNT
KNUCKLE ASSEMBLY
CONNECT SHOCKABSORBER TO STEERING KNU-
CKLE
(a) Clampthe steeringknucklein a vise.
(b) Installth6 upperballjoint with shockabsorberand
tightenthe nut.
Torque:99 N.m(1,010kgf.cm,73 ft'lbf)
(c) Installa now cottor pin.
KNUCKLE INSTALLATION
1. INSTALL SHOCK ABSORBERWITH STEERING
KNUCKLE
and installthe 3 nuts.
Placathe shockabsorber
Torque: 80 N.m (800 kgf .cm, 59 fr'lbf)
2. CONNECTDRIVESHAFT
(a) Installth6 drive shaft to the axla hub.
(b) Temporarilyinstallthe lock nut.
NOTICE: Becarcfulnot to d8mag.tho boot. ondInneroil
real.
3. CONNECTCAMBERCONTBOLARM
(a) Connect the camber control arm to tho shock ab-
sorberand tighEnthe nut.
Torque:171 N.m(1,754kgf.cm,129 ft.lbf)
(b) Installthe lock cap and a now cotter pin.
Y'
1. CONNECTLOWERBALL JOINT ATTACHMENT
Connectthe lower ball joint attachm€ntto tho st€er-
ing knuckleand tightenthe 2 bolts and nut.

SUSPENSION
5 . C O N N E C TT I E R O D E N D
(a) Connectthe ti6 rod end to the steeringknuckleand
tightenthe nut.
Torque:49N.m(500kgf.cm,36tt lbf)
(b) Installa new cottor pin.
6. I N S T A L L LS T A B I L I Z E R B A RL I N K
C o n n 6 c t h e s t a b i l i z ebr a r l i n k t o t h e s h o c k a b s o r b e r
and tighenthe n ut.
Torque:44 N.m(450kgf.cm,33 lt lbt)
H I N T :l f t h e b a l l j o i n st t u dt u r n st o g e t h e rw i t h t h e n u t ,
use a haxagonwrench to hold the stud.
tsA..
7 . I N S T A L LF R O N TB R A K EC A L I P E R
( a ) A l i g nt h e m a t c h m a r kasn di n s t a ltlh o d i s ct o t h e a x l e
hub.
(b) lnstallth6 brak6caliperwith 2 bolts.

Torqua:107 N.m(1,090kgf cm, 79 ft'lbf)
L w/ ABS:
INSTALLABSSPEEDSENSOR
T o r q u e :8 . 0 N . m ( 8 2 k s f . c m . 7 1 i n . . l b f )
'fl
9 . I N S T A L LB R A K EH O S E
(a) Runthe brakehosethroughthe brakehosebracket.
( b ) U s i n gp l i e r si .n s t a ltlh o c l i p .
1 0 . I N S T A L LD R I V ES H A F TL O G KN U T
(a) While applyingthe brakes,installthe nut.
Torque:21N 6 . m( 2 . 2 0 0k g f . c m 1. 5 9f r . l b f )
(b) Installthe lock cap and a new cotter pin.
SA Torque:103 N.m(1,050kgf.cm,76 ft.lbf)
1 2 , C H E C KF R O N TW H E E LA L I G N M E N T
(Seepage SA-5)
13. w/ ABS:
C H E C KA B S S P E E DS E N S O RS I G N A L
(Seepage BR- 93)
H U BB O L TR E P L A C E M E N T
1. J A C K U P V E H I C L EA N D R E M O V EF R O N TW H E E L
2. R E M O V EF R O N TB R A K EC A L I P E RA N D D I S C
(a) Removeths 2 brakecaliperset bolts.
(b) H a n gu p t h e b r a k ec a l i p e ru s i n gw i r a ,e t c .
( c ) P l a c em a t c h m a r k os n t h e d i s ca n d a x l eh u b .
Malchmarks
(d) Removsthe disc.

SUSPENSION
3. REMOVE H U BB O L T
UsingSST.removoths hub bolt.
s s r 0 9 6 2 8 - 1 0 0I1
4. INSTALL HUB BOLT

l n s t a lw l a s h e ra n d n u t t o t h e h u b b o l t ,a s s h o w ni n t h e
i l l u s t r a t i o na,n d i n s t a l lt h e h u b b o l t b y t o r q u i n gt h o
nut.
5. INSTALLFRONTDISCAND BRAKECALIPER
( a ) A l i g nt h e m a t c h m a r kasn di n s t a ltlh e d i s ct o t h e a x l s
nuo.
( b ) Installths brakecaliperwith 2 bolts.

Torque:107 N.m(1.090kgt'cm,79 ft lbf)
6. I N S T A L LF R O N TW H E E LA N D L O W E RV E H I C L E
Torque:103 N m (1,050kgf cm, 76 ft lbf)

sA-26
AND AXLE - FRONTAXLE(MacPherson
SUSPENSION Strut T
F R O N TA X L E
( M a c P h e r s oS
ntrut Type)
DESCRIPTION
T h e w h e e l b e a r i n g sa r e d o u b l e - r o w a n g u l a rb a l l b e a r r n g cs o m b i n e dw i t h t h a o i l s e a l sn i i l # g
s m a l lr o l l i n gr e s i s t a n cas n d a r e f r e e f r o m m a i n t e n a n c e .
T h e p r e l o a do f t h s b o a r i n g sc a n b e d e t e r m i n e od n l y b y t i g h t e n i n g
t h e a x l eh u b n u t t o a s p e c i f i e d
torque,improvingserviceability.
SteeringKn u c k l e
A x l eH u b
D o u b l s - R oA wn g u l ra
B a l lB e a r i n g

AND AXLE - FRONT
SUSPENSION cPhersonStrut T
PREPARATION
ssT (sPEcrAL TOOLS)
SERVICE
09308-00010 Oils68lPuller
d€-€3
09316-60010 Tr!nsmission& Transf€rB€aring DuBt d€lloctor install.tion
RgPlecor
/@|.'
09520-00031 RoarAxlsshsftPullor
dC:reF
09527-17011 R€arAxl€ ShaftB€arin€Remover
0 9 6 0 8 - 1 2 0 1 0 F r o n tH u b& D r r v oP i n i o nB 6 a r i n s
''.:L3--tt-' i o ,€-,
RsPl6cor Set
.s-;J (t {-, "

(09608-00020) Romover& Replec6rHandl€
-00040)
(09608
Cup
(09608-00060)DrivoPinlonFrontB6arins
R€pl!c6r
oil seal
Knucklo
09608-32010 steoring Be6rng installatron
,A\ RoPlacor Axl€ hub installation
v4 0ust d6fl€ctorinstallation
0 9 6 1 0- 2 0 0 1 2 P t m a nA r m P u l l o r

sA-28
suspENstoNANDAXLE- FRoNTAXLE(MacPherson
strut Type)
09620-30010 Steerlns set

GearBoxRoplac€r
@_
a_.? 6
(09625 30010) Steerns Main ShaftE6aring
1@) R€placer
0 9 6 2 8 -1 0 0 1 1 B a lJl o i n P
t uller Hub bolt removal
0 9 6 2 8 - 6 2 0 1 1 B a l lJ o i n tP u l l o r
@
09950-00020 Bsarns Rsmovor
R E C O M M E N D ET
DO O L S
09042-00010 Torx SocketT30
0 9 9 0 5 - 0 0 0 1 3 s n s pR i n sP l i g r s
EOUIPMENT
Dial indicator
Torque wrench

SUSPENSION Strut T
F R O N TA X L E H U B
COMPONENTS
\
\r'
E'
I
tro1z?,zoo,lst'l
l-r**,t'"
*g'
fj n."'*,r-+b
k
u,x'c"p/{' /7"-\
a\ \
t\q,
\s..I1,,,"
\yz
-..'.or\- o l{l (b.C!)/-ei56
-"""'1".',.""
a DustDeflector
I
f gT I a SnaoRino
-
--
f-
,A I f fl'rrJ 3ool4,l
tnnernace steerinsKnuckle
: aA
K@ ]
Q) Dusrrcover
DustCover
*@
6*':-^'flN'/
S-\" -J.--t'-=----*
.""*ffit ),&%,$'iiiili""",
I
Low€rBa,,Jont_W
ffiZ a" -q@
i N m (kgtcm, ft lbf) | :Specifiedlorque Hub Bolt
a Non-reusable parl

sA-30
susPENstoNANDAXLE- FRoNTAxLE(Macpherson
strut Type)
S T E E R I NK
GN U C K L E
W I T HA X L EH U B
REMOVAL
1. J A C K U P V E H I C L EA N D R E M O V EF R O N TW H E E L
2, C H E C KB E A R I N GB A C K L A S HA N D A X L E H U B D E -
VIATION
(a) Ramovethe 2 caliperset bolts.
(b) S u s p e n dt h e b r a k ec a l i p e rs e c u r a l y .
(c) Removeth6 d isc.
(d) P l a c at h 6 d i a li n d i c a t onr e a rt h e c e n t e ro f t h e a x l eh u b
a n d c h e c kt h e b a c k l a s h i n t h e b e a r i n gs h a f td i r a c t i o n .
Maximum:
0.05mm (0.0020in.)
l f g r e a t e rt h a n t h 6 s p e c i f i e dm a x i m u m ,r e p l a c et h e
b6aring.
SA
( e ) U s i n g a d i a l i n d i c a t o r c, h e c k t h e d € v i a t i o na t t h o
surfaceof the axle hub outsidathe hub bolt.
M aximum:
0.05mm (0.0020in.)
lf g r e a t e rt h a n t h e s p e c i f i e dm a x i m u m ,r e p l a c et h e
a x l eh u b .
3. R E M O V ED R I V ES H A F TL O C K N U T
(a) I n s t a ltl h e d i s ca n d c a l i p e r .
(b) R e m o v et h e c o t t o rp i n a n d l o c kc a p .
(c) W h i l ea p p l y i n gt h e b r a k a sr, e m o v et h e n u t .
(d) Removsthe caliperand disc.
4. w/ ABS:
REMOVA E B SS P E E D SENSOR
R e m o vteh s A B Ss p e e ds e n s osr e t b o l ta n dc l a m p .

ANO AXLE - FRONT
SUSPENSION Strut T
acPherson
5. LOOSEN N U T SO N L O W E RS I D EO F S H O C KA B S -
ORBER
HINT:Do not removethe bolts.
6. KNU.
D I S C O N N E CTTI E R O DE N DF R O MS T E E R I N G
CKLE
(a) Removethe cottsr pin and removetho nut.
(b) UsingSST,disconnecttha tio rod end from the stoer-
i n g k nuc k l e .
s s T0 9 6 1 0 - 2 0 0 1 2
7, D I S C O N N E C TS T A B I L I Z E RB A R L I N K F R O M
L O W E RS U S P E N S I OAN RM
Remove the nut.
8. D I S C O N N E CLT O W E RB A L LJ O I N TF R O ML O W E R
ARM
R e m o v teh e b o l ta n dt h o 2 n u t s .
9. REMOVESTEERING KNUCKLW E I T HA X L EH U B
(a) Removethe 2 nuts and bolts on lower side of the
shockabsorber.

sA-32
suspENstoNANDAXLE- FRoNTAXLE(MacPherson
strut Type)
( b ) R e m o v et h e s t e e r i n gk n u c k l ew i t h a x l eh u b .
F R O N TA X L E H U B D I S A S S E M B L Y
1. REMOVE O U S TD E F L E C T O R
Usinga screwdriver,removethe dust deflector.
2. REMOVE O I LS E A L
UsingSST.removethe inneroil seal.
s s T0 9 3 0 8 - 0 0 0 1 0
3 . R E M O V EL O W E RB A L L J O I N T
( a ) R e m o v et h e c o t t 6 rp i n a n d n u t .
(b) UsingSST,rsmovetha lowar ball joint.
ssr09628-62011
4. REMOVA E X L EH U B
(a) UsingSST.removeths axlehub.
s s T 0 9 5 2 0- 0 0 0 31

sA-33
S U S P E N S I OANN D A X L E - F R O N TA X L E ( M a c P h e r sSotnr u tT
( b ) U s i n gS S Ta n da p r e s sr, e m o v et h o i n n e rr a c e( o u t s i d e )
f r o m t h e a x l eh u b .
s s T 0 9 6 2 0- 3 0 0 10 ( 0 9 6 2 s- 3 0 0 10 ) ,
0 9 9 5 0- 0 0 0 2 0
5. R E M O V ED U S TC O V E R
Using a torx wrench. remove tho 4 bolts and dust
cover.
: 3 0 ( P a r tN O .0 9 0 4 2 - 0 0 0 1 0 o r l o c a l l y
T o r xw r e n c h T
manufacturodtool)
U s i n gs n a pr i n g p l i e r s r, e m o v et h e s n a pr i n g .
7. REMOVE OUTER O I LS E A L
UsingSST,removetho outeroil seal.
s s T 0 9 3 0 8- 0 0 0 10
8. REMOVE BEARING F R O MS T E E R I NKGN U C K L E

UsingSSTand a press, removsthe bearingfrom the
s t e e r i n kgn u c k l € .
s s r 0 9 5 2 7 -I 7 0 11 .0 9 6 0 8 -12 0 10 ( 0 9 6 0 8 - 0 0 0 2 0 .
0 9 6 0 8- 0 0 0 6 0 )

sA-34
SUSPENSION Strut T
F R O N TA X L EH U BA S S E M B L Y
1 . I N S T A L LN E WB E A R I N G
(a) UsingSSTand a press,installa new bearingto the
steeringknuckle.
s s T 0 9 6 0 8 -12 0 10 ( 0 9 6 0 8 - 0 0 0 2 0 ) ,
0 9 6 0 8- 3 2 0 10
( b ) U s i n gs n a pr i n g p l i e r si,n s t a l a
l n e w s n a pr i n g .
,ffii
2. INSTALL D U S TC O V E R
U s i n ga t o r xw r e n c hi .n s t a ltlh e d u s tc o v e rw i t ht h e 4
bolts.
T o r xw r e n c h T: 3 0 ( P a r tN O .0 9 0 4 2 - 0 0 0 1 0 o r l o c a l l y
m a n u f a c t u r etdo o l )
Torque:8.3 N m (85 kgf.cm,74in..lbf)
3. I N S T A L LF R O N T A X L EH U B
U s i n gS S Ta n da p r e s si ,n s t a ltlh e a x l eh u b ,
s s T 0 9 6 0 8 -12 0 10 ( 0 9 6 0 8 - 0 0 0 2 0 .9 6 0 8 - 0 0 0 4 0 ) ,
09608-32010
4 . I N S T A L L O W E RB A L LJ O I N T
( a ) I n s t a ltlh e l o w e rb a l lj o i n ta n dt o r q u et h e n u t .
T o r q u e :1 0 3 N m ( 1 , 0 5 0k g f . c m , 7 6f t . l b f )
(b) Installa nsw cotter pin.

S U S P E N S I OANN D A X L E - FRONTAXLE(MacPherson
Strut T
5. INSTALLNEWDUSTDEFLECTOR
UsingSSTanda hammer, installa newdustdefloctor'
s s r 0 9 3 16 - 6 0 0 1O ( 0 9 3 6 - 0 0 0 10 , 0 9 3 16 - 0 0 0 4 0 ) ,
1
0 9 6 0 8- 3 2 0 10
H I N TA: l i g nt h s h o l e sf o r t h e A B Ss p e s ds s n s oirn t h o
dustdeflectorandsteoringknuckle.
S T E E R I NK W I T HA X L EH U B
GN U C K L E
INSTALLATlON
1 . I N S T A L LS T E E R I NKGN U C K L E
(a) Placetho steeringknuckleandtemporarily installtho
2 boltsand nutson lowersideof shockabsorber,
HINT:Coatthe thrsadsof nutswith engineoil,
(b) Connect the lower arm to the lower ball joint and
tighten the bolt and 2 nuts,
Toiquo:127 N.m(1,300kgl cm' gtl ft lbf)
2, CONNECTSTABILIZERBAR LINK
Conn€ctthe stabilizerbar link to the lowor susponsion
arm and tightentho nut.
Torqus:44N.m(450kgf cm,33 tt'lbf)
3. CONI{ECTTIE ROD END TO STEERINGKNUCKLE

(a) Connectth€ tie rod 6nd to th€ steeringknuckleand
tighten th€ nut.
Torquo:49 N m (500kgf cm, 36 ft'lbf)
( b ) I n s t a l al n o w c o t t o rP i n .

sA-36 AND AXLE - FRONTAXLE(MacPherson
4. TOROUEBOLTSON LOWERSIDEOF SHOCKABS-

ORBER
T o r q u e : 15 3 N . m ( 1 , 5 6 0 k g f . c m . 1 1 3 f t . l b f)
9A1
5. w/ ABS:
INSTALLABS SPEEDSENSOR
Installthe clampandtorqu6th6 ABSspeedsensorset
bolt.
T o r q u e : 8 , 0t { . m ( 8 2 k g f . c m , 7 1 i n . . l b f )
6. INSTALLDISCAND CALIPER
Installthe discandcaliper.
T o r q u a :1 0 7 N . m ( 1 , 0 9 0k g f . c m . 7 9 f t . l b f )
7. INSTALLDRIVESHAFTLOCKNUT
(a) Whileapplying the brakes.installthe nut.
(b) lnstallthe lock cao and a new cotter oin.
8 . INSTALL FRONTWHEEL AND LOWERVEHICLE
Torqua:103 N.m(1,050kgf.cm,76 ft.lbf)
9. INSPECT FRONTWHEELALIGNMENT
(SeepageSA-7)
10. w,/ ABS:
I N S P E CATB SS P E E D
S E N S OS
RI G N A L
(SeepageBR- 93)

sA-37
AND AXLE - FRoNTAXLE(\4q9!!989!Jt'4 l
SUSPENSIoN
F R O N TW H E E L
A N DR E M O V E
1 . J A C KU PV E H I C L E
2. REMOVE CALIPEA R N DD I S C
3. REMOVE H U BB O L T
UsingSST,removethe hub bolt.
s s T0 9 6 2 8 - 1 0 0 1 1
ffiiiiLi
I N S T A L LH U B B O L T
l n s t a lw l a s h a ra n d n u t t o t h e h u b b o l t ,a s s h o w ni n t h e
i l l u s t r a t i o na,n d i n s t a l lt h e h u b b o l t b y t o r q u i n gt h e
nut.
5. I N S T A L LD I S CA N D C A L I P E R
Torque:107 N m (1,090kgf cm. 79 ft lbf)
Torque:103 N.m(1,050kgf cm' 76 ft lbf)

ANDAXLE- FRONTDRIVESHAFT(3S-G
SUSPENSION
FRONTDRIVESHAFT
(3S- GE)
DESCRIPTION
The front drive shaft has a double-offset CVJ (ConstantVelocityJoint) on the d itferential*Jici'e
and Rzeppatype CVJ on tho whe€l sid6.
LH DBIVESHAFT
Double-Offset
Type CVJ
Diff6renti
Si d e
$["' t a
RH DRIVESHAFT
w/ LSD
Diffsr e n t i a l
Si d e
f
C e n t e rB e a r i n g D y n a m iD
c Emper
Tvoe CVJ
Double-Offset RzeppaTypeCVJ
w/o LSD
Wh€e
Si d e
t
3lX:'""t''' t
C e n t eB
r earing D y n a m iD
c amper
RzeppaTyp€CVJ
Oouble-Offser
Type CVJ
i 10166
B:r0l
c7
810r
a8

ANDAXLE- FRoNTDRIVE
susPENsroN SHAETI!!-s
PREPARATION
ssT (sPEclAL TOOLS)
SERVICE
09506-35010 D ttarontial0r v6 PinionR6tl
I 09608- 12010
866ringR€plac6r
FrontHub & Driv€PinionB€aring

---=- 19 n
-Fa- "F' eP sot
R€plac€r
(?
F---- ,:) '9
,t
-ooo2o)Romover&
(09608 R€placerHandlo
Ef"-""
cup
(09608-00060)Driv€PinionFrontBoaring
RsPlac€r
l'::--=:,
09608-16041 FrontHub B€aringAdjustingTool
rd)
09628-6201I Blll Joint Pullef Tic rod €nd
@
.---! 09710-30020 susponsion Tools€t
Bushlng
{H='--}-
ee-&:q_-
( 0 9 7 1 0 - 0 3 1 4 0 ) L l t o r t l R o dB u s h i n s
Ronoviis B!!o
f_ei
f_,
09950-00020 EoarrnsR€movsr C€ntordrivoshalt duStcovgf

sA-40
S U S P E N S I OANN D A X L E _ F R O N TD R I V ES H A F T ( 3 S _ G E }
OOLS
0 9 0 3 1 - 0 0 0 3 0P n P u n c h
0 9 9 0 5 - 0 0 0 1 2 s n s p R i n sN o . 1 E x p a n d e r F o r r e m o v i n g a n d i n s t a l l i n gs n a p
nng
EOUIPMENT
r:,,gALUBRICANT
Item Capacity Classification
Outboardjoint grsase w/ LSD 1 0 4 - 1 1 6 s ( 3 . 6 4 . 0o z . )
w/o LSD 100- 120 g \3.5 4.2 oz.)
Inboardloint greas6 w/ LSD 104 I 16 s (3.6-4.0 oz.)
w/o LSD 100- 120 9 (3.5 4.2 oz.)

AND AXLE _ FRONTDRIVESHAFT(3S_G
SUSPENSION
FRONTDRIVESHAFT
COMPONENTS
rY/ LSo
LH DriveShaft
i'sl$].,,
RH DriveShaft
w iiA\
a ConerPin
locrruur
flrl
I
LockNutCap ,
..-./1 Arm
LowsrSusPension
N-\-
a Bootclamp
DynamicDampor(RHDriveShaft) Yr '|
i ctamp 1Pg orive Shalt)
FAilrm,lon
C6nt€rBearing
t' a Dustcovef
[f->.
I@Ail^?
w
Pu!|f,'o'o'n' 6
N.m (kgtcm,ft lbf) | r Specifiedtorque
a Non-reusablepart

sA-42
S U S P E N S I OANN D A X L E _ F R O N TD R I V ES H A F T ( 3 S _ G
F R O N TD R I V ES H A F TR E M O V A L
N O T I C E :T h e h u b b e a r i n gc o u l d b e d a m e g e di f i t i s s u b -
j e c t e d t o t h e v e h i c l ew s i g h t . s u c h a s w h s n m o v i n g t h e
vehicl6 ryith the drive shsft removod. Therefore, if it rs
a b s o l u t e l yn o c o s s a r yt o p l a c e t h o v o h i c l er v e i g h t o n i h e
h u b b e a r i n g ,f i r s t s u p p o r t i t w i t h S S T .
s s T 0 9 6 0 8 - 1 6 0 4 1( 0 9 6 0 8 - 0 2 0 2 0 , 0 9 6 0 8 - 0 2 0 4 0 )
w/ABS:
After disconnectingthe drivs shaft from the axle hub,
work carefullyso as not to damagethe sensorrotor
serrationson the drive shaft.
1 . J A C KU PV E H I C L A
E N DR E M O V E
F R O N TW H E E L
2. REMOVE NGINE UNOER COVERS
3. D R A I NT R A N S A X LOEI L
4. REMOVE COTTER P I N ,L O C KN U TC A PA N D L O C K
NUT
( a ) Removsth6 cottorpin and locknut cap.
(b) L o o s e nt h e b e a r i n gl o c k n u t w h i l a d e p r e s s i ntgh e
brakeoedal.
5 . D I S C O N N E CTTI E R O D E N D
(a) Remove th6 cottsr pin and nut from the steering
knuckle.
(b) UsingSST,disconnectthe tie rod end from th6 ste6r-
i n g k nu c kl e .
s s T0 9 6 2 8 - 6 2 0 1 1
6. DISCONNECTSTABILIZERBAR LINK
Rsmoveth6 nut and disconnectthe stabilizerbar link
f rom shock absorber.
H I N T :l f t h e b a l l j o i n ts t u dt u r n st o g e t h e rw i t h t h s n u t .
use a haxagonwrench to hold the stud.

suspe
Remove tho nut and2 boltsanddisconnectths lower
balljoint attachmentfrom steeringknuckle'
8. DISCONNECT CAMBERCONTROL ARM

pin
(a) Removeth€ cotter and lockcap,removetha nut'
*i#,5r,
(b) Using SST,disconnectthe cambercontrol arm from

shock absorber.
s s T0 9 6 2-8 6 2 0 1
9, DISCONNECTDRIVESHAFT
Using a plastic hammer,disconnectthe drive shaft
f rom axle hub.
NOTICE:Coverthe driveshatt boot vYithcloth to prolect
it from damage.
10. REMOVE L H D R I V ES H A F T
( a ) U s i n gh u b n u t w r o n c ha n d h a m m e rh a n d l eo r a n
eouivalent, pullout the driveshaft,as shown'

sA-44
S U S P E N S I OANN D A X L E _ F R O N TD R I V ES H A F T ( 3 S _ G E )
(b) Usinga screwdriver,rsmovethe snap ring.
1 1 . R E M O V ER H D R I V ES H A F T
(a) w/ LSD:
U s i n ga h a m m e ra n d a s c r e w d r i v e r e
, m o v et h 6 s n a p
ring from tho bearingbracket.
(b) Removethe bolt from the bearrngbracket.
SA (c) Removethe RH drive shaft with center drive shaft.
NOTICE: Bscarelulnot to damagothe dilferentialsideoil
sgal,
H I N T : l f i t i s h a r d t o 1 6 m o v et h e b e a r i n g ,u s e a b r a s s
b a r a n d a h a m m e ra n d t h e d r i v ef l a n o ee n d o f t h e d r i v e
s ha f t .
(d) Removeths 2 bolts and baaringbracket.
(a) w/o LSD:

Removeth6 2 boltsof th€ c€nterbearingbracket,and
pull out th6 RH drive shaft togetherwith the center
bearingcaseand csnter driveshaft.

ANDAXLE- FRoNr!ryYEJralf.€L!
susPENsloN
FRONTDRIVESHAFTDISASSEMBLY
1 . C H E C KD R I V ES H A F T
(a) Check to s€e that there is no play in the outboard
joint.
(b) Checkto se€that the inboardjoint slidessmoothlyrn
tho thrust direction.
(c) Check to see that thare is no noticeableplay in the
radial directionof the inboardjoint.
( d ) Checkfor damageto boots.
2. REMOVEINBOARDJOINT BOOT CLAMPS
(a) Usinga screwdriver,removethe 2 boot clamps.
(b) Slidethe inboardjoint boot toward joint.
:i$hn
DISASSEMBLEINBOARDJOINT TULIP
Placematchmarkson the driveshaft and inboardjoint
Matchmarks
tulio or conterdrive shaft.
NOTICE: Do not punchthe marks.
4. REMOVESNAPRING
(a) removethe snapring.
Usinga screwdriver,
(b) Removeinboardjoint tulipfrom driveshaft.
5. DISASSEMBLE INBOARD JOINT

on tho driveshaft.innerrace
(a) Placethe matchmarks
and cage.
(b) Remove tho 6 balls and cage.

sA-46
AND AXLE - FRONTDRIVESHAFT(3S-GE}
SUSPENSION
(c) Usinga snap ring expander,r€mov€the snap ring.
(d) Usinga brassbar and hammer,removethe innerrace.
O. REMOVESNAPRING
(a) Usinga snapringexpander,
rsmoveths snapring.
7, REMOVEINBOARD JOINTBOOT
x4685
8. RH Drive rhaft:
REMOVEDYNAMICDAMPER
removetheclampof th€dynamic
o a m0 6 r .
(b) Remove the dynamic damper.
9. REMOVEOUTBOARDJOINT BOOT
(a) Usinga screwdriver,removethe 2 bool clamps.
(b) Removethe outboardjoint boot toward the inboard
joint.

ANO AXLE - F R O N TD R I V ES H A F T ( 3 S - G
SUSPENSION
10, REMOVEDUSTCOVER
LH Driveshalt
Usinga screwdriver,removstho dust cover from
inboardjoinrtuliP.
11. REMOVE D U S TC O V E R
RH Driverhaft
Usinga pross,pressout tho dust cover from tho
centerdrivoshaft.
12. w,/o LSD:

REMOVS E N A PR I N G
(a) Usinga screwdriver, removethe snapring.
(b) Usinga press.pressout the bearingcase.
13. REMOVEDUSTCOVER
UsingSSTanda press,pressout the dustcover.
s s T 0 9 9 5 0- 0 0 0 2 0

sA-48
ANDAxLE- FRoNT
suspENsroN DRrvE
sHAFT(3s-GE)
14. REMOVE BEARING
(a) Usinga snapringexpander,
removetho snapring.
(b) Usinga pr6ss.pressout the b€aring.

(c) Removethe snap ring.
SA
15. w/o LSD:

REMOVE STRAIGHT PIN
Usinga pinpunchanda hammer,
tap out straightpin.
FRONTDRIVESHAFTASSEMBLY
1. w/o LSD:
INSTALLSTRAIGHT PIN
(a) Installthe straightpin intothe bearingcase.
(b) UsingSSTand a press,prssstho new bearinginto the

bearingcase.
s s T 0 9 6 0 8 - 1 2 0 10 ( 0 9 6 0 8 - 0 0 0 2 0 0, 9 6 0 8 - 0 0 0 6 0 )

S U S P E N S I OANN D A X L E _ F R O N TD R I V ES H A F T ( 3 S _ G
w/o LSD:
I N S T A L LS N A PR I N G
Usinga screwdriver,installa new snap ring,
3. w,/ LSD:
I N S T A L LB E A R I N G
( a ) I n s t a l tl h e n e w s n a Pr i n g .
( b ) U s i n ga p r e s s ,i n s t a ltl h e b e a r i n g .
4. w/o LSD:
I N S T A L LB E A R I N GC A S E
B r a s sb a r
UsingSSTand a press,installthe bsaringcaseassem-
bly to the centerdrive shaft
s s T 0 9 7 10 - 3 0 0 2 0 ( 0 9 7 0
1 - 0 3 14 0 )
4 Usinga snap ring expander,install a new snap ring.
j
w/ LSD 6. INSTALL DUST COVER

UsingSST and a press,pressinto a new dust cover
'..----'---"---- 1 ssT 09506-35010
--t
(94 a- HINT:Tha clsarancebetwoenthe dust covor and the
rF--F' bearingshould be kept in the rangesshown in the
' -:i t--/, +€':
illustralion.
''€i-- ; . - r 1 . 0m m
( 0 . 0 3 9i n )
' i - )
p10l4l

sA-50 AND AXLE _ FRONTDRIVESHAFT(3S_GE)
SUSPENSION
wrlo LSD
1 . Om m
{ 0 . 0 3 9i n , l
7, I N S T A L LD U S TC O V E R
Using a steel plate and press,press in a now dust
cover until th6 distancefrom the tio of the center
as shown in the illus-
drive reachesthe specification,
tration.
mm
I n ,J
w/o LSD
lr1
+'lT
fl leo-er.."
m_L
TEMPORARILYINSTALL BOOTSAND DAMPER
Vinyl Tape HINT: Before installingth€ boot. wrap vinyl tape
aroundthe splineof the driveshaft to preventdamag-
ing th6 boots and damper.
( a ) Temporarilyinstalla new outboardbool to tha drive

shaft.
(b) w/ Dynamicdamper:
Temporarilyinstallthe dynamic damper to the drive
shaft.
(c) Temporarilyinstall a new inboardjoint boot to the
drive shaft.

S U S P E N S I OANN D A X L E - F R O N TD R I V ES H A F T ( 3 S - G
O u t b o a r dJ o i n tB o o t
U s i n ga s n a pr i n g e x p a n d e ri ,n s t a l a
1 0 . INSTALLCAGE
Thesidewith rmallardlamot.rmutt f rcc out'
i{OTICE:
bo!rd.
(a) Align the matchmarksplacedbeforeromov€.

(b) Usinga brassbar and hammer,tap in the innerraceto
th€ cent€r drive shaft.
NOTICE: Be carafulnot to dlmag. lhc Inncrt!cc.
installa new snapring.

(c) Usinga snapringexpander,

sA-52 AND AXLE - FRONTDRIVESHAFT(3S-GE)
SUSPENSION
1 1 . I N S T A L LB O O TT O O U T B O A RJDO I N T
Beforeassembling the boot,fill greaseinto the out-
boardjoint and boot.
HINT:Usethe greasesuppliedin the boot kit.
Grease capacity:
w/ LSD;
104- 116g (3.6-4.0 oz.)
w/o LSD:
100-120 g (3.5-4.2 oz.)
G r e a s ec o l o r :
Black
1 2 . I N S T A L LI N B O A R DJ O I N TT U L I PT O F R O N TD R I V E
SHAFT
P a c ki n t h e g r e a s el o t h e b o o t a n d i n b o a r dj o i n t t u l i p .
H I N T :U s et h € g r e a s es u p p l i e di n t h e b o o t k i t .
Greasacapacity:
w/ LSD:
1 0 4 - l l 6 g ( 3 . 6 - 4 . 0o z . )
w/o LSD:
100 - 120 s (3.5- 4.2 oz.)
Graasecolor:
Yellow ocher
13. I N S T A L LC A G E
(a) A l i g nf h e m a t c h m a r k ps l a c e db e f o r ea s s e m b l y .
(b) I n s t a l tl h s c a g et o t h e i n n s rr a c e .
(c) I n s t a l tl h e 6 b a l l s .
H I N T :A p p l yg r 6 a s eo n t o t h e b a l l st o k 6 e pt h e m f r o m
falling.

ANDAXLE- FRoNTQE!!!JlAll(ls-
susPENsroN
1 4 . I N S T A L LI N B O A R DJ O I N T T U L I P
(a) Align the matchmarksplacedbeforeassembly.
Matchmarks
(b) Installthe inboardjoint tulip or centar drive shaft to
the driv€ shaft.
(c) Temporarilyinstallthe boot to the inboardjoint tulip.
15, INSTALLSNAPRING
Installa new snaPring.
lffilri
w/ LSD 16. ASSEMBLEBOOT CLAMPS TO BOTH BOOTS

(a) Be sur€ th€ boot is on tho shaft groovo.
(b) Ensusethat th€ boot is not stretchodor contracted
when the driveshaft is at standard16ngth'
Driveshaft rtandardlength:
w,/ LSD:
LH: 573.2+ 5.0 mm (22.567+ 0.197 in.)
R H :8 6 1 . 5+ 5.0 mm (33.917t 0.197 in.)
w/o LSD:
LH: 576.2+ 5.0 mm (22.685I 0.197 in.)
w/o LSO RH:863.8t 5.0 mm (34.007a 0.197 In.)
(c) Using a screwdriver,bend the band and lock it, as

shown in tho illustration.
Y R1C637

sA-54 S U S P E N S I OANN D A X L E - F R O N TD R I V ES H A F T ( 3 S _ G E }
1 7 .A S S E M B LD
EA M P E R
CLAMP
(a) Be surethe damperclampis on the shaftgroove.
(b) Checkthe drstance, as shown.
Distanco:
w/ LSD:
205.0 + 3.0 mm (8.070+ 0.118 in.)
w/o LSD:
2 0 0 . 0 + 3 . 0 m m ( 7 . 8 7 4+ 0 . 1 1 8 i n . )

shown in the illustration.
ii sA
F R O N TD R I V ES H A F TI N S T A L L A T I O N
1 . I N S T A L LL H D R I V ES H A F T
( a ) U s i n gp l i e r s i,n s t a l al n e w s n a pr i n g .
(b) Coat gear oil to the inboardjoint tulip and differential
case slidings urface.
(c) Usinga brassbar and hammer,tap in tho drivo shaft
until it makescontactwith ths oinionshaft.
HINT:
. Beforeinstallingthe driveshaft,set the snap ring
openingside facing downward.
. Wh€thoror not th€ driveshaft is makingcontact
with tho pinionshaft can be known by the sound
or feelingwhen drivingit in.
2 . C H E C KI N S T A L L A T I O N O F L H D R I V ES H A F T
( a ) C h e c kt h a t t h e r ei s 2 - 3 m m ( 0 . 0 8 - 0 . 1 2i n . )o f p l a yi n
axialdirection.
(b) Checkthat the driveshaft will not come out by trying
to pull it completelyout by hand,
3. INSTALL RH DRIVESHAFT
(a) w,z LSD:
Installthe bearingbracketwith 2 bolts.
fti
Torque:84N.m(650kgf.cm,47tt.lb{)
(b) Apply MP greaseto the transaxleoil lip.
(c) Insertthe centerdriveshaft with the RH driveshaft to
the transaxlethroughthe bearingbracket.

SUSPENSION
( d ) Installthe bolt to the bearingbracket.
Torque:32 N m (330 kgf.cm.24 ft lbf)
( € ) U s i n g p l i e r s ,i n s t a l la n e w s n a p r i n g t o t h a b e a r i n g
brackt.
(a) w/o LSD:

Coat gear oil to the inboard joint and differential
slidingsurface.
(b) Installth€ center drive shaft with th€ RH drive shaft
to tho transaxlothrough the bearingbracket.
(c) Usingpliers,installa n€w snap rang.
(d) Installtho 2 bolts and tighten them.
Torque:64 N.m(650kgf cm' 47 ft lbf)
4. CONNECTDRIVESHAFT
Installthe outboardjoint sido of tho drivoshaft to the
axle hub.
NOTICE: Be carefulnot to damagethe inneroil seal'
5. CONNECTCAMBERCONTROLARM
(a) Conn€ctthe cambercontrol arm to the steeringknu-
ckle and tighten th6 nut.
Torque:172 I{.m(1,750kgf cm' 127 ft lbf)
(b) Installths lock cap and a new cottsr pin.
t.^,
6, CONNECTLOWERBALL JOINT ATTACHMENT

Connectthe lower ball joint attachm€ntto tho stoer-
i n g k n u c k l ea n d t i g h t e nt h e 2 b o l t sa n d n u t .
Torque:108 N.m(1,100kgf'cm, 80 ft'lbf)

sA-56
ANDAXLE- FRoNTDRrvE
suspENsroN sHAFT(3s-GE)
7. CONNECTTIE ROD END
(a) Connoctthe tie rod end to ths steeringknuckleand
torquo th€ nut.
Torquc:49 N m (500kgf'cm,36 tt.lbf)
(b) Installa n6w cottor pin.
HINT:lf the cottor pin holedoesnot line up, correctby
tighteningth€ nut by the smallestamount possible.
8. CONNECTSTABILIZERBAR LINK
Connectthe stabilizerbar link to the shock absorbar
and tighten the nut.
HINT:lf the balljointstud turns togetherwith the nut,
SA use a hexagonwrench to hold th6 stud.
9. INSTALLBEARINGLOCK NUT, LOCK NUT CAP

AND NEWCOTTERPIN
(a) Installandtorquethe bearinglocknut.
Torque: 228N.m(2.300kgf.cm,166fr.lbf)
(b) Installth€locknut capandsecureit with a n€wcotter
pin.
10, FILLTRANSAXLE WITH FLUID
UNDER COVERS
1 2 . C H E C KF R O N TW H E E LA L I G N M E N T
(SeepageSA-5, 7)
13. w/ ABS:
CHECKABSSPEEDSENSOR SIGNAL
(SeepageBR- 93)

S U S P E N S I OANN D A X L E _ F R O N TD R I V ES H A F T ( 3 S _ F E , 5 5 _
F R O N TD R I V ES H A F T
(3S- FE,55- FE)
DESCRIPTION
The drivehasa tripodtype CVJ (ConstantVslocityJoint)on the differentialsideand n.eppa'Tif,e
CVJ on the wheel side.
RH DRIVESHAFT
w / D v n a m i cD a m p e r
Tripod Type CVJ TypeCVJ

Rzeppa
C e n t e rB e a r i n g D y n a m i cD a m p e r

sA-58
A N DA x L E - F R o N TD R r v Es H A F T ( 3 s - F E , 5 s - F E )
suspENsroN
PREPARATION
S S T( S P E C I ASLE R V I C T
EO O L S )
09506-35010 Diff€rontial
DrivoPinionRo6r
BoafingR€plac6r
0 9 6 0 8 - 1 2 0 1 0 F r o n tH u b& 0 r i v 6P i n i o nB o s r i n g
ilta;t.'
6...j a';)
i.r 19,
' 7 -
Roplac€r S€t
(09608-OOO2O)Remove.& ReplacerHandle
Orivo P nion Front 806r ng Cup

Rophcor
SA
09608-16041 FrontHub B€arinsAdjustingTool
@..roJ\
(09608-02020)Bort& Nut
0O d@
(09608-02040)Rstsinor
0
09610- 20012 Pitman
ArmPullsf Ti6 rod €nd
09710-30020 Susp€nsion
BushingTool S€t
e
(09710-03140)L!t.f!l RodBushins
R6moving Bas6
09950-00020 BornnsRomovor C€nt6r driv€ shaft dust cov6r

AND AXLE _ FRONTDRIVESHATT
SUSPENSION
OOLS
09031-00030 PinPunch
09905-00012 SnapRingNo.1 Exp.ndor For r6movingand instsllingsnrP

nng
EOUIPMENT
LUBRICANT
Itom Capacity Classitication
Outboardloint gre8se 1 2 0 - 1 3 0g 1 4 . 2 - 4 . 6o z ' )

lnboardjoint greaso
1 8 0 - 1 9 0s ( 5 . 3 - 6 , 7o z . )
M/-l 232-242 s (8.2- 8.5 oz.)

sA-60
S U S P E N S I OANN D A X L E _ F R O N TD R I V ES H A F T ( 3 S _ F E . 5 5 _
COMPONENTS
R H D r i v eS ha f t
.-a.r
e!(i.l:@
---l
SA
\ H Cotter Pin
En gi n e U n d e r
C o v er
w / D y n a m i cD a m o e r
D y n a mi c
a Boot Damper
l - -
wf
cta-
T r i p o dJ o i n t
C e n t e rD r i v eS h a f t
, ) S n a pR i n g
a D u s tC o v e r
i S n a pR i n g
O u t b o ar d J o i n t
w i t h D r i v eS h a f t
LH Side
Z--C S n a pR i n g
Dustcover
&.-t
'ks C e n t e rB e a r i n gC a s e
t n 6 6 6 ' 6 . . 1 6 i a\1@ [
N'rr1(kg6'nnlbtl : Specifiedtorque
a No n - r e u s a bpl ea r t

S U S P E N S I OANN D A X L E _ F R O N TD R I V ES H A F T ( 3 S _ F E , 5 5 _
FRONTDRIVESHAFTREMOVAL
N O T I C E :T h e h u b b e a r i n gc o u l d b e d a m a g e di f i t i s s u b -
j e c t e d t o t h e v e h i c l 6w e i g h t , s u c h a s w h e n m o v i n g t h e
v e h i c l ew i t h t h a d i i v e s h a t t r e m o v e d .T h e r e f o r e ,i f i t i s
a b s o l u t e l yn e c a s s a r yt o p l a c o t h e v e h i c l ew e i g h t o n t h e
h u b b e a r i n g ,f i r s t s u p p o r t i t w i t h S S T .
s s T 0 9 6 0 8 -1 6 0 4 1( 0 9 6 0 8 - 0 2 0 2 0 ,9 6 0 8 - 0 2 0 4 0 )
w/ABS:
After disconnectingths driveshaft from the axle hub,
work carefullyso as not to damagethe ssnsor rotor
serrationson the drive shaft
l€A
1. J A C KU PV E H I C L A F R O N TW H E E L
E N DR E M O V E
2. REMOVE NGINE UNDER COVERS
3. DRAINGEAROIL (M,/T)ORATF (A,/T)
4. REMOVEDRIVESHAFTLOCKNUT
(a Removeth6 cotter pin and lock nut cap.
(o Loosen the bearing lock nut while deprsssingths
brakeoedal.
5. DISCONNECTTIE ROD ENOFROM STEERINGKNU-

CKLE
( a ) Rsmovethe cotter pin and nut.
( b ) UsingSST,disconnectths tie rod end from the steer-
i n g k n uc k l e .
s s r0 9 6 1 0 - 2 0 0 1 2
DISCONNECT STABILIZER BAR LINK FROM

LOWERARM
Removeth6 nut and disconnectthe stabilizerbar link
from lowar arm.
HINT:lf the balljointstud turns togetherwith the nut,
use a hexagonwrench to hold the stud.

sA-62 ANDAXLE- FRoNT
suspENsroN sHAFT(3s-FE,
DRrvE ss-FE)
7. DISCONNECT LOWERBALLJOINTFROMLOWER
ARM
(a) Removeth6 bolt and2 nuls.
(b) Disconnect
the lowerballjointfrom lowersuspension
arm.
8. D I S C O N N E CD
T R I V ES H A F TF R O MA X L E H U B
Using a plastic hammer,disconnectthe drive shaft
from the axle hub.
NOTICE:Coveithe driveshaft boot with cloth to Drotoct
it f rom damage.
r SAil
9. REMOVELH DRIVESHAFT
( a ) U s i n gh u bn u tw r e n c ha n dh a m m ehr a n d l eo r e q u i v a -
lent,pullout the driveshaftas shown.
t{oTtcE:
r B e c a r e f u l n o t t o d a m a g st h a d u s t c o v e r .
. C o v o r t h a h u b n u t w r s n c h o r e q u i v a l e n tw i t h c l o t h
8 0 a s n o t t o d a m a g gt h e t r a n s a x l eb o d y .
(b) Usinga screwdriver,removetho snap ring.
1 0 . R E M O V ER H D R I V ES H A F T
(a) Removathe 2 boltsof the contsrbearingbracket,and
pull out the RH drive shaft togetherwith the center
bearingcase and cent6r driveshaft.
(b) Removethe centerdriveshaft with the RH driveshaft
to the transaxlethrough ths bsaringbracket.

sA-63
ANDAXLE_ F R O N D
SUSPENSION S H A F T ( 3 S - F5E5. -
T RIVE
(a) Check to ses that there is no play in the outboard
jo int.
(b) Checkto soothat the inboardjoint slidessmoothlyin
the thrust direction.
(c) Checkto seo that there is not noticeableplay in the
radialdirectionof the inboardjoint.
(d) Checkfor damageto boots.
(a) Usinga screwdriver,removeths 2 inboardjoint boot
clamps.
(b) Slidethe inboardjoint boot toward the outboardjoint.
3. DTSASSEMBLE INBOARD JOINTTULIP

(a) P l a c em a t c h m a r ko snt h et r i p o da n di n b o a rjdo i n tt u l i p
or centor driveshaft.
NOTICE: Do not Punchths marks'
(b) Removethe inboardjoint tulip or conter drive shaft
f rom th6 drive shaft.
4. REMOVE TRIPODJOINT
( a ) U s i n ga s n a pr i n ge x p a n d er re m o v ot h s s n a pr i n g .
(b) Usinga snapring expander,temporarilyslidethe snap

ring toward the outboardjoint side.

sA-64
AND AXLE - FRONTDRIVESHAFT(3S-FE,55_FE}
SUSPEITISION
(c) Placethe matchmarkson the driv6 shaft and tripod.

NOTICE: Do not punchtho mrrks.
Matchmarks (d) Using a brass bar and a hammer,removethe tripoo
joint from the drive shaft.
i{OTICE: Do not tEp the roller,
(e) Usinga snap ring expander,removethe snap ring.

5. REMOVEOUTBOARDJOINT BOOT
6. w,/ DYNAMICDAMPER(RHDRIVESHAFT):
REMOVEDYNAMICDAMPER
(a) Usingscrewdrivor,
removeth6 clampof th€ dynamic
oamp€r.
(b) Remove the dynamicdamper.
7. REMOVEOUTBOAROJOII{T EOOT
(a) Using screwdrivor,romov€the 2 clamps of the out-
boardjoint boot.
(b) Removethe boot from th€ outboardjoint.
NOTICE:Do not diras3omblctho outboardjoint.
F A lt t 5
8. REMOVEDUST COVER
LH Drive Shaft:
Using SST and press,prossout th6 dust cover from
the inboardjoint tulip.
ssT09950-00020

S U S P E N S I OANN D A X L E _ F R O N TD R I V ES H A F T ( 3 S - F E5,5 - F
RH Drive Shaft:
t-,
_gu _ ] L \
Usrng a press, press out the dust cover from the
centordrive shaft.
I
r: l .1,
9. RH DRIVESHAFT:
DISASSEMBLE CENTER DRIVESHAFT
removetho snaprang.
(a) Usinga screwdrivsr,
(b) Usinga press,pressout the b€aringcase.
(c) UsingSST and a press,pressout th6 dust cover.

s s T 0 9 9 5 0- 0 0 0 2 0
(d) Usinga snap ring expander,removethe snap ring.

sA-66 ANDAxLE- FRoNT
suspENsroN oRrvEsHAFT(3s-FE,
ss-FE)
(e) Usinga press,prossout th€ boaring.
(f) Removethe snap ring.
sA145t
( S ) U s i n ga p u n c ha n d a h a m m e rt.a p o u t t h s s t r a ; g h pt i n .
iiis
F R O N TD R I V ES H A F TA S S E M B L Y
.I. RH DRIVESHAFT:
A S S E M B LC EE N T E R D R I V ES H A F T
( a ) I n s t a ltlh e s t r a i g hpt i ni n t ot h e b e a r i n cga s e .
(b) UsingSST and a press,prsss a now bearinginto the

b e a n n gc a s e .
s s T 0 9 6 0 8- 12 0 10 ( 0 9 6 0 8- 0 0 0 2 0 ,0 9 6 0 8- 0 0 0 6 0 )
(c) Usinga screwdriver,installa new snap ring.

S U S P E N S I OANN D A X L E _ F R O N TD R I V ES H A F T
(d) UsingSSTand a press,prossa new bearinginto the
bearingcaseassembly to tho centsrdriveshaft.
(
s s r 0 9 7 10 - 3 0 0 2 0 0 9 7o
1 - 0 3 14 0 )
( e ) U s i n ga s n a pr i n g e x p a n d e ri ,n s t a l a
(f) UsingSST and press,pressin a now dust covsr.

s s T0 9 s 0 6 - 3 5 0 1 0
HINT:The clearancebetweenthe dust cover and t h 6
bearingshould be kept in th6 ranges shown in t h s
illustration.
1,0mm
(0.039
in.
INSTALLDUSTCOVER
LH DriveShaft:
Usinga press,installa new dust cover.
sA1459
RH Drive Shaft:
Using a steel plate and press,press in a new dust
cover until the distancofrom the tip of tho center
drive shaftto th6 dust coverreachesthe specification,
a s s h o w ni n t h e i l l u s t r a t i o n .
86-87mm
( 3 . 3 9- 3 . 4 3i n . )

sA-68
S U S P E N S I OANN D A X L E _ F R O N TD R I V ES H A F T ( 3 S - F E , 5 5 _ F E )
3. TEMPORARILY INSTALL BOOTS AND DAMPER

(w,/ DYNAMICDAMPER)
HINT:Beforeinstallingthe outboardjoint boot,wrap
vinyl tape aroundthe splineof the drive shaft to
preventdamaging the bootsanddamper.
( a ) Temporarilyinstalla new outboardboot to the drive

l n b o a r dJ o i n t B o o t O u t b o a r dJ o i n t E o o t
shaft.
(b) w/ Dynamicd a m p e r :
Temporarilyi n s t a l tl h e d y n a m i cd a m p s rt o t h e d r i v e
shaft.
{4--:*;l: ( c ) Temporarilyinstall a new inboardjoint boot to the
drive shaft.
4 , I N S T A L LT R I P O DJ O I N T
( a ) U s i n ga s n a pr i n g e x p a n d e ri ,n s t a l a
(b) Placethe beveledside of the tripod jornt axial spline
toward the outboardjoint.
S A i4 a : l S A 1 4 6 2
(c) Align the matchmarksplacedbeforeremoval.

Matchmarks
sar463
( d ) U s i n ga b r a s sb a r a n d h a m m e rt,a p i n t h 6 t r i p o dj o i n t
to the drivs s haft.
NOTICE: Do not t8p the roller.
f4*

sA-69
AND AXLE _ FRONTDRIVESHAFT3 5 _ F E , 5 5 _
SUSPENSION
l n o w s n a pr i n g
( e ) U s i n ga s n a pr i n g e x p a n d e ri ,n s t a l a
5. INSTALL BOOT TO OUTBOARDJOINT

Bsfore assemblingthe boot, fill greasointo the out-
HINT:Use the groasesuppliedin the boot kit.
Greasecapacity(Color= Black):
120-130 g (4.2-4.6 oz.)
6. TNSTALLINBOARDJOINT TULIP TO FRONTDRIVE

SHAFT
la, P a c ki n t h e g r o a s et o t h o b o o t a n d i n b o a r dj o i n t t u l i p .
HINT:Use tho greas€suppliedin the boot kit.
Greasecapacity(Color= Yollowochsr):
A/r
18 0 - 19 0 g ( 6 . 3- 6 . 7 o z . )
M/r
232-242 s (8.2- 8.5 oz.)
(b) Align the matchmarksplaced before removal,and

installthe inboardjoint tulip to the drive shaft.
( c ) l n s t a l tl h e b o o t t o t h e i n b o a r dj o i n t t u l i p .

sA'70 s u s p E N s r oANN DA x L E- F R o N D
T R r v sEH A F T ( 3 s - FsEs,- F E )
7. ASSEMBLEBOOT CLAMPS TO BOTH BOOTS
(a) Be sure the boot is on ths shaft groove.
{b) Ensurethat th€ boot is not stretchedor contracted
when the drive shaft is at standardlength.
Driveshaftstandardlength:
A/r
L H :5 7 6 . 7t 5 . 0 m m ( 2 2 . 7 1 3+ 0 . 1 9 7i n . )
RH:862.0t 5.0 mm (33.937a 0.197in.)
M/r
LH: 572.4t 5.0 mm (22.535+ 0.197in.)
RH:857.5t 5.0 mm (33.760t 0.197in.)
s h o w ni n t h e i l l u s t r a t i o n .
SA
8. w/DYNAMIC DAMPER(RH DRIVESHAFT):

ASSEMBLEDAMPERCLAMP
(a) Be sure the damperclamp is on th€ shaft groove.
( b ) C h e c kt h e d i s t a n c ea, s s h o w n .
Dirtrnco:
200.0+ 5.0 mm (7.874+ 0.197 in.)

FRONTDRIVESHAFTINSTALLATION
1 . I N S T A L L H D R I V ES H A F T
(a) Usinga snapringexpander, installa new snapring,
(b) Coatgearoil to the inboardjointtulipand differential
caseslidingsurface.

SUSPENSION
(c) Usinga brassbar and hammer,tap in tho driv€ shaft
until it maksscontactwith the pinionshaft.
HINT:
. Beforoinstallingths drivs shaft,set ths snap ring
openingside facing downward.
r Whetheror not the driveshaft is makingcontact
with the oinionshaft can be known by the sound
or feelingwhen drivingit in.
2. CHECKINSTALLATIONOF LH DRIVESHAFT
( a ) C h s c kr h a tt h a r si s 2 - 3 m m ( 0 . 0 8 - 0 1 2 i n . )o f p l a vi n
the axial d irection.
(b) Checkthat ths driveshaft will not come out by trying
to pull it comPletelyout bY hand.
3. INSTALL RH DRIVESHAFT
(a) Coat gearoil to the inboardjoint tulip and differential
case slidings urface.
(b) Installthe contardrivoshaftwith the RH drivs shaftto
the transaxlethroughthe bearingbracket.
NOTICE: Do not damagetha oil real lip.
(c) Installthe 2 bolts and tighten tham.
Torqua:64 N.m(650kgf'cm,47ft'lbf)
CONNECTDRIVESHAFT TO AXLE HUB

lnstallth6 outboardjoint side of the driveshaft to the
axle hub.
NOTICE:Be carefulnot to drmage the inner oil real,
bootr and ABS apoed 3en3or ?otor.
CONNECTLOWER BALL JOINT TO LOWER SUS.

PENSIONARM
Connectthe lower balljoint to lower arm and tighten
th6 bolt and 2 nuts.
Torque:127 N'm (1,300ksf'cm,94 ft lbf)

sA-72
ANDAxLE- FRoNT
suspENsroN DRrvE
sHAFT(3s-FE,
ss-FE)
6, CONNECT
STABILIZER
BARLINKTO LOWERARM
Torque:44N.m(450kgf.cm.33ft.lbf)
HINT:lf the balljointstud turns togethorwith ths nut,
7 . C O N N E C TT I E R O D E N DT O S T E E R I N G
KNUCKLE
(a) Connectthe tie rod end to the steeringknuckleand
torque tho nut.
Torque:49 N.m (500kgf.cm.36 fr.lbf)
(b) Installa new cottsr pin.
HINT:lf the cotter pin holedoesnot lineup, correctby
tighteningthe nut by the smallestamount possible.
8. INSTALLBEARINGLOCK NUT. LOCK NUT CAP

AND NEWCOTTERPIN
(a) Installandtorquethe locknut.
T o r q u e :2 1 6 N . m ( 2 , 2 0 0 k g f . c m , 1 5 9 t t . l b f )
(b) Installthe lock nut cap and sscure it with a new cotter
ptn.
9. FILL TRANSAXLE
WITH GEAROIL (M/T) OR ATF
(A/r)
U N D E RC O V E R S
T o r q u e :1 0 3 N . m ( 1 . 0 5 0 k s f . c m , 7 6 f t . l b f )
I 2 . C H E C KA N DA D J U S TF R O N TW H E E LA L I G N M E N T
(SeepageSA-7)
13. w/ ABS:
CHECKABSSPEEDSENSOR SIGNAL
(SeepaseBR- 93)

sA-73
AND AXLE - F R O N TD R I V ES H A F T
SUSPENSION
(7A- FE)
DESCRIPTION
The front drive shaft has a slidabletripod typo CVJ (ConstanlVelocityJoint) on the differentia I
side and Rzeppatype CVJ on the wheel side.
A d y n a m i cd a m p e rh a s b e e n m o u n t e do n t h e r i g h t - h a n d d r i v es h a f t t o r s d u c ev i b r a t i o na n d
nolse.
R H D R I V ES H A F T
Tripod Type CVJ TypeCVJ

Rzeppa
D i t f e r e n t iIa
s r de
<F
D y n a m i cD a m p e r

sA-74
ANDAxLE- FRoNT
suspENsroN DRrvE
sHAFT(7A-FE)
PREPARATION
ssT (sPEcrAL
SERVICE
TOOLS)
09608-16041 Frort Hub Esal'ngAdiustingTool
@'5o3\
(09608*02020)Eolt& Nut
@o@
(09608-02040)Retainer
0 09610-20012 Pitman
ArmPuller
SA
09950-00020 B€eringRsmover
OOLS
09905-00012 SnapRingNo.1 Expandor For r6movingand installingsnap
ring
EOUIPMENT
Torque wrench
LUBRICANT
Itom Capacity Classific6tion
Outboardjoint gr€as€ | 20- 130s 14.2-4.8oz.l
inboardjoint g16as6 1 8 0 - 1 9 0g ( 6 . 3 - 6 . 7o z . )

ANDAXLE- FRONT
SUSPENSION DRIVESHAFT(7A-F
COMPONENTS
R H D r i v eS h a f t
E n gi n e U n d e rC o v e r
R H s l d eo n l y :
O y n a m i cD a m p e r
w i t h D r i v eS h a f t

sA-76
S U S P E N S I OANN D A X L E _ F R O N TD R I V ES H A F T
FRONTDRIVESHAFTREMOVAL
N O T I C E :T h e h u b b e a r i n gc o u l d b e d a m a g e di f i t i s s u o -
j e c t e d t o t h e v e h i c l ew e i g h t , s u c h a s w h e n m o v i n g t h e
v e h i c l e w i t h t h e d r i v e s h a f t r e m o v e d .T h e r e f o r e ,i f i t r s
a b s o l u t e l yn e c e s s a r yt o p l a c s t h e v e h i c l ew o i g h t o n t h o
h u b b e a r i n g .t i r s t s u p p o r t i t w i t h S S T .
s s T 0 9 6 0 8 - 1 6 0 4 1( 0 9 6 0 8 - 0 2 0 2 0 0, 9 6 0 8 - 0 2 0 4 0 )
w/ABS:
After disconnectingthe driveshaft from the axle hub,
work carefullyso as not to damagethe sensortotor
ssrrationson the driveshaft.
1. J A C KU PV E H I C L A
E N DR E M O V E F R O N TW H E E L
2. REMOVE NGINE UNDER COVERS
3. DRAINGEAROIL (M/T) ORATF (A/T)
4. REMOVE D R I V ES H A F TL O C KN U T
(a) Removsthe cott6r pin and lock nut cap.
(b) Loosen ths bearing lock nut while depressingthe
brakepedal.
5. DISCONNEC
TTI ER O DE N OF R O MS T E E R I NKGN U -
CKLE
( a ) Removeth6 cotter pin and nut.
( b ) UsingSST,disconnectthe ti6 rod end from the stser-
i n g k nu c k l e .
ssT09610-20012
DISCONNECT STABILIZER BAR LINK FROM
n))\ LOWERARM
Removethe nut and disconnectthe stabilizerbar link
f rom lower arm.
Uz H I N T :l f t h e b a l l j o i n st t u dt u r n st o g e t h e rw i t h t h s n u t .
use a hexagonwrench to hold lhe stud.

S U S P E N S I OANN D A X L E - F R O N TD R I V ES H A F T
O W E RB A L LJ O I N TF R O ML O W E R
D I S C O N N E CLT
ARM
( a ) Remove the bolt and2 nuts
( b ) Disconnect the lowerballjointfrom lowersuspension
ar m .
8. D I S C O N N E CD T R I V ES H A F TF R O MA X L E H U B
Using a p l a s t i ch a m m e r ,d i s c o n n e ctth e d r i v o s h a f t
f r o m t h e a x l eh u b .
NOTICE: Be carafulnot to damagethe inneroil saal.
9. R E M O V ED R I V ES H A F T
L H D R I V ES H A F T :
U s i n ga h a m m e ra n d h u b n u t w r e n c ho r a n e q u i v a l e n t ,
16moveths d rive shaft.
RH DRIVESHAFT:
removothe
Usinga hubnut wrenchor an equivalent,
drivsshaft.
E N A PR I N G
10. REMOVS

sA-78 ANO AXLE _ FRONTDRIVESHAFT(7A-FE)
SUSPENSION
(a) Checkto s6e that thsre is no play in ths outboard
joint.
(b) Checkto se6that the inboardjoint slidessmoothlyin
th6 thrust direction.
(c) Check to see that there is no noticeableplay in the
radialdirectionof the inboardjoint.
(d) Checkfor damageto the boots.
(a) Usinga screwdriver,removethe 2 boot clamps.
(b) Slidethe inboardjoint boot toward the outboardjoint.
3 . R E M O V EI N B O A R DJ O I N T T U L I P
(a) Place matchmarkson the inboardjoint tulip, tripod
and drive shaft.
(b) Removethe inboardjoint tulip from lhe drive shaft.
4. REMOVETRIPODJOINT
( a ) U s i n ga s n a pr i n g e x p a n d e rr,e m o v 6t h 6 s n a pr i n g .
(b) Placematchmarkson the shaft and tripod.

(c) Usinga brassbar and hammer,removethe tripodjoint
f rom the driveshaft.
NOTICE: Oo not tap the roller.
5 . R E M O V EI N B O A R DJ O I N T B O O T

ANDAXLE- FRoNr9rlYEa_u_AfIOA:
susPENSroN
w,/DYNAMICDAMPER(RHDRIVESHAFT):
REMOVEDYNAMICDAMPER
removeths clampof th€dynamic
(a) Usinga scrawdriver,
oamogr.
(b) Removsthe dynamicdamPer.
7. REMOVEOUTBOARD JOINTBOOT
(a) Usinga screwdriv€r,remov€th€ 2 boot clampsfrom
joint
the outboard boot.
(b) Removethe bootfrom the outboardjoint.
t h o o u t b o a r di o i n t '
N O T I C E :D o n o t d i s a s s e m b l o
REMOVEDUSTCOVER
UsingSSTand press,pressout th€ dust coverfrom
t h e i n b o a r jdo i n tt u l i P .
s s r 0 9 9 5 0- 0 0 0 2 0
FRONTDRIVESHAFTASSEMBLY
1 . I N S T A L LN E WD U S TC O V E R
Usinga press,prsssin a nowdustcovorto ths inboard
j o i n tt u l i p .
INSTALLBOOTSANDDAMPER(RH
TEMPORARILY
oRrvEsHAFT)
HINT:Beforeinstallingthe outboardjoint boot, wrap
vinyl tape around the spline of the drive shaft to
prov€ntdamagingtho boots and damper.

sA-80 S U S P E N S I OANN D A X L E _ F R O N TD R I V ES H A F T ( 7 A _ F E )
(a) Temporarilyinstalla new outboad joint boot to lhe
l n b o a r dJ o i n t B o o t O u t b o a r dJ o i n t B o o t
drive shaft.
.--<
, / l (b) w/ Dynamicdamper:
ea. -r..'1 14' Temporarilyinsrallthe dynamicdamperto th€ drive
tl "1-\/\"-j shaft.
LJ..JJ^r
(c) Temporarilyinstall a new inboad joint boot to the
driva shaft.
3 . I N S T A L LT R I P O DJ O I N T
B e v e l € dS i d e (a) Placethe beveledside of th6 tripod joint axial spline
toward the outboardjoint.
SA
(b) Align the matchmarksplacedbeforeremoval.
(c) Usinga brassbar and hammer,tap in the tripod jornt

to ths driv6shaft.
NOTICE: Do not tap the roller.
( d ) U s i n ga s n a pr i n g e x p a n d e ri ,n s t a l a

SUSPENSION
4. INSTALL BOOTTO OUTBOARDJ O I N T

Before assemblingthe boot, fill greaseinto th6 out-
HINT:Uss lhe greas€suppliedin the boot kit.
Grotsocapacity(Color: Black):
120- 130 s 11.2-4.6oz.l
INSTALL INBOARDJOINT TULIP TO FROI{TDRIVE

SHAFT
( a ) Pack in greaseto the inboardjoint tulip and boot.
HINT:Use the greasesuppliedin the boot kit.
Greasecapacity(Color= Yellowocher):
1 8 0 - 1 9 0 g ( 6 . 3 - 6 . 7o z . )
(b) Align the matchmarksplacedbeforedisassembly.

( c ) Installtho inboardjoint tulip to the driva shaft.
(d) Temporarilyinstallthe boot to the inboardjoint tulip'
6. ASSEMBLYBOOT CLAMPS TO BOTH BOOTS

( a ) Be sure the boots are on tha shaft groovo.
( b ) Set the driva shaft longthto the standard.
Standardlength:
LH shaft
559.2+ 5.0 mm (22.016+ 0.197 in.)
RHshaft
854.9+ 5.0 mm (33.657A 0 . 1 9 7i n . )
(c) Using a screwdriver,b€nd the band and lock it, as

shown in tho illustration.

sA-82 S U S P E N S I OANN D A X L E - F R O N TD R I V ES H A F T ( 7 A - F E )
7, RH ORIVESHAFT:
ASSEMBLY DAMPERCLAMP
(a) Be surethe damperclampis on the shaftgroove.
(b) Checkthe distance,
as shown.
Distanca:
4 1 8 . 0 m m t 5 . 0 m m ( 1 6 . 4 6 1+ 0 . 1 9 7 i n . )
(c) Using a screwdriver,bend the band and lock it as

shown in the illustratio
n.
F R O N TD R I V ES H A F TI N S T A L L A T I O N
1 . I N S T A L LN E W S N A PR I N G
( a ) U s i n ga s n a pr i n g e x p a n d e ri ,n s t a l al n e w s n a pr i n g .
(b) Coat gearoil to the inboardjoint tulip and differential
c as e s l i d i n gs ur f ac e .
2. I N S T A L LD R I V ES H A F T
L H D R I V ES H A F T :
Usinga brassbar and hammer,installthe drive shaft
to the transaxls.
NOTICE: 86 caretul not to damage the boots.
R H D R I V ES H A F T :
Usinga screwdrivsa r n d h a m m e r ,i n s t a l lt h e d r i v e
shaft to tha transaxle.
NOTICE: Be careful not to damago tha boots.
3 . C H E C KI N S T A L L A T I O N O F F R O N TD R I V ES H A F T
( a ) C h e c kt h a t t h o r ei s 2 - 3 m m ( 0 . 0 8 - 0 . 1 2 i n .o) f p l a yr n
a x i a ld i r e c t i o n .
( b ) C h e c kt h a t t h e d r i v es h a f tw i l l n o t c o m eo u t b y t r y i n g
t o p u l l i t c o m p l e t e l oy u t b y h a n d .

S U S P E N S I OANN D A X L E - F R O N TD R I V ES H A F T ( 7 A -
4. C O N N E C TD R I V ES H A F TT O A X L E H U B
Installthe outboardjoint side of the driveshaft to tho
axle hub.
NOTICE:Be carefulnot to damagothe inner oll rcal,
boots and ABS speed 86n8or rotor,
CONNECTLOWERBALL JOINT TO LOWERARM

Connect the lower ball joint to th6 lower arm and
tighton th6 bolt and 2 nuts.
6. CONNECT BARLINKTO LOWERARM

STABILIZER
H I N T :l f t h e b a l l j o i n st t u dt u r n st o g e t h e w
r iththg nut,
ry
use a hexagonwrench to hold the slud.
7 , C O N N E C TT I E R O D E N D T O S T E E R I N G
KNUCKLE
(a) Conn6ctth6 lio rod end to steeringknuckleand tight-
6 n t h e nu t .
(b) Installa n6w colter pin.
8, INSTALL DRIVESHAFT LOCK NUT

(a) Tightenth€ lock nut.
Torque:216 N m (2,200kgf.cm,159 ft.lbf)
(b) Installthe lock cap and a n6w cotter pin.

sA-84
suspENsroNANDAxLE - FRoNTDRrvE'HAFT(7A-FE)
9. WITH GEAROIL (M/T) OR ATF
FILL TRANSAXLE
(A/r)
UNDER COVERS
11 . I N S T A L LF R O N T W H E E LA N D L O W E RV E H I C L E
T o r q u e : 10 3 N . m ( 1 , 0 5 0 k g f . c m , 7 6 f t . l b f )
1 2 . C H E C KA N DA D J U S TF R O N TW H E E LA L I G N M E N T
(SeepageSA-7)
13. w,/ ABS:
C H E C KA B SS P E E D
S E N S OSRI G N A L
(SeepageBR- 93)

sA-85
AND AXLE - FRONTSUSPENSIOI!
SUSPENSTON Strut T
F R O N TS U S P E N S I O N
(SuperStrut Type)
DESCRIPTION
The superstrut type suspensionfitted on the modelsusingthe 3S-GE engineis simitarin ?'Jihr
to tho MacPhorson type.Th6 superstrut typ6 suspensionhasgreatergeometricfreedomthan tho
a g a i n s t h e g r o u n d . T h be o d yc a n
d o u b l ew i s h b o n et y p a ,a n d t h u s e x s r t sl e s sc a m b e rf l u c t u a t i o n
be sharadbv the conventionalMacPhersontype
C o i lS p r i n g
S u s p e n s i oUnp p e rS up p o r t
S t a b i l i z eBr a r
S h o c kA b s o r b ar
C a m b e rC o n t r o lA r m
N o . 1 L o w e rA r m
N o . 2L o w e rA r m

sA'86
ANDAXLE- FRoNT
suspENsroN suspENsroN(super
strutType)
PREPARATION
ssT (sPEcrAL
SERVICE
TOOLS)
09506-35010 Diffof.ntillDrivePinionRorr
BorringRophcor
09608-35014 Axl6 H!b & DrivoPinionB6!ring

Tool Sgt
(09608-06040) Front Hub Inn€rBolrinsCono

R6plac€r
0 9 6 1 0 - 2 0 0 1 2 P i t m aA
n r mP u l l € r
@ 0 9 6 2 8 - 6 2 0 1 1 E r l lJ o i n P
t ullor
vttzt -,'wtv Lo r sprn9 Lompr€3ror
OCl2S-2203'l FrontSpf:ngUgp6rSo.t Holdo.
OOLS
09025-00010 SmlllTorqueWr€nch
EOUIPMENT

S U S P E N S I OANN D A X L E - F R O N TS U S P E N S I O N
uoer StrutT
F R O N TS H O C KA B S O R B E R
COMPONENTS
9- caP
gr- a f4?f-.ll,61
support
@-susp€nsion
@r-- DustSeal
/-R\
springseat
V-uPPer
sorins
$}y'-l'"3o€rcoil
LJ
I Rod
Ti6 Rod End
End
. Q-ao,, .onnn
l40(5oo,3c)l
]>-:a)
x@
g- Bumper
Spring
LowerCoil
SpringInsulator
@ r
t {
| | Cotter
-ockCap
@-- <l SnapRing
p- YSRi'""
e-l rorrr,
ofitl
\-a pin
Cotter
torque
-"lnt l!,st:g..!Dti : Specilied
a Non-reusable Parl

sA-88
suspENsroNANDAXLE- FRoNTsuspENsroN(super
strutType)
KNUCKLE REMOVAL
END REMOVE F R O N TW H E E L
2. REMOVE D R I V ES H A F TL O C KN U T
(a) Removsthe cotterpin and lockcap.
(b) Whileapplyingth€ brakss,removethe nut.
3. w/ ABS:
R E M O V EA B S S P E E DS E N S O R
Removethe ABS spaedsensorfrom the steeringknu-
cKt6.
SA
4. D I S C O N N E CB
T R A K EH O S EF R O MS H O C KA B S O R .
BER
(a) Removethe clip from the brakebracket.
(b) Pull off the brakohosefrom tha shock absorber.
5. REMOVEBRAKECALIPER
(a) Removgthe 2 brakecaliperset bolts.
( b ) S u s p e n dt h e b r a k ac a l i p e sr e c u r e l y .
( c ) P l a c em a t c h m a r kos n t h e d i s ca n d a x l eh u b .
flatchmarks
(d) Removethe d isc.

sA-89
AND AXLE - FRONTSUSPENSION(SuPer
SUSPENSION Strut T
6. DISCONNECT TIE RODEND

(a) Removethe cotterpin and removetho nut.
il"il,( (b) UsingSST,disconnect

i n gk n u c k l e .
s s T 0 9 6 10 - 2 0 0 12
the tie rod endfrom the stser-
-l ,
Removethe nut and disconnectthE stabilizorbar link
f rom shock absorber,
HINT:lf the balljointstud turns tog€therwith the nut,
use a hexagonwrench to hold tho stud.
i:sA
Removethe nut and2 boltsanddisconnect tho low€r
balljoint attachmont
from steeringknuckle.
9. DISCONNECT CAMBERCONTROL ARM

(a) Removethe cott€rpin,lockcap and romoveth6 nut.
i"
(b) Using SST,disconnectthe camber control arm from

shcck absorber.
s s T 0 9 6 2 8 - 6 2 0 11

sA-90
S U S P E N S I OANN D A X L E - F R O N TS U S P E N S I O N
1 0 . D I S C O N N E CD
T R I V ES H A F T
(a) Using a plastic hammer.disconnectthe drive shaft
f rom the axle hub.
NOTICE: Covorthe drivo.haftbootwith clothto protect
it from damago.
(b) Placewoodenblockon th6 jack and supportthe lower

balljoint attchment.
i S A
1 1 . R E M O V ES H O C K A B S O R B E R
WITH STEERING
KNUCKLE
(a) Removetho 3 nuts on uppersideof the s h o c ka b -
sorber.
(b) Removethe shockabsorber with stoerinok n u c k l e .
KNUCKLE DISASSEMBLY
DISCONNECT STEERING KNUCKLEFROMSHOCK
ABSORBER
(a) Rsmovetha cotterpin andthe nut.
(b) Using SST, disconnect the steering knuckle from

shock absorber.
s s T0 9 6 2 8 - 6 2 0 1 1

AND AXLE - FRONTSUSPENSION
SUSPENSION Strut I
B A L LJ O I N TI N S P E C T I O N
UPPER
1..4,'i
inj
l-,-l
I N S P E C T I OBNA L LJ O I N TF O RR O T A T I O C
NO N D I .
TION
(a) As shown,flip the ball joint stud back and forth 5
timesbeforeinstalling tho nut.
(b) Usinga torquegauge,turn tho nut continuously one
turn avory2-4 secondsand take the torquo reading
on the sth turn.
Torque:
1 . 0 - 2 . 9 N . m ( 1 0 - 3 0 k g f ' c m '8 . 7 - 2 6 i n . l b f )
B A L LJ O I N TR E M O V A L
UPPER
R E M O V EU P P E RB A L L J O I N T
(a) Usinga snap ring expander.removsthe snap ring.
(b) Using a vise and a hammer,remove the upper ball

joint form shock absorber.
B A L LJ O I N TI N S T A L L A T I O N
UPPER
I N S T A L LU P P E R B A L LJ O I N T
(a) UsingSST and a hammer,installa new upperbatt
joint.
s s T 0 9 5 0 6 -3 5 010 , 0 9 6 0 8 - 3 5 041 ( 0 9 6 0 8 - 0 6 0 4 0 )

sA-92
suspENstoNANDAXLE- FRoNTsuspENsroN(super
strut Type)
(b) Usinga snap ring expander,installa new snap ring.
FRONTSHOCKABSORBER
DISASSEMBLY
R E M O V EC O I L S P R I N G
(a) Installthe brack€tat the lower portion of tho shock
absorberand and secureit in a vise.
SA
(b) UsingSST,compressthe coil spring.

- 30020
ssr 09727
N O T I C E :D o n o t u s o a n i m p a c t w r e n c h .
I t w i l l d a m a g et h e S S T .
(c) UsingSST to hold the springseat.remov€tho nut.

s s T0 9 7 2 -9 2 2 0 3 1
('-- | (d) Removethe followingparts.

--'--'i
@',6fi I e o
.
Suspensionsupport
Dust seal
@ l : - ' @ r Upperspringseat
| /€=9) |
. Uppercoil springinsulator
o Coil spring
o Springbumper
. Lower coil springinsulator

AND AXLE _ F R O N TS U S P E N S I O N r Strut T
SUSPENSION
F R O N TS H O C KA B S O R B EIR
NSPECTION
I N S P E C TS H O C KA B S O R B E R
Compressand extsnd the shock absorberrod and
c h e c kt h a t t h e r ei s n o a b n o r m arle s i s t a n coer u n u s u a l
operationsounds.
lf thereis any abnormality, replacethe shockabsorber
wrtha new one.
NOTICE: When discardingthe shockabsofber,use tha
following procedure.
DISPOSAL
1. F U L L YE X T E N DS H O C KA B S O R B E R O D
2. DRILL HOLETO REMOVEGAS FROM CYLINDER
U s i n ga d r i l l ,m a k ea h o l ei n t h e c y l i n d e ra, s s h o w nt o
removsthe gas inside.
CAUTION: Thegascomingout is harmlass, but bo careful
ol chips which may fly up when drilling.
F R O N TS H O C KA B S O R B EARS S E M B L Y
RN T OS H O C KA B S -
1 . I N S T A L LL O W E RI N S U L A T OO
ORBER
2. TO PISTONROD
INSTALL SPRINGBUMPER
INSTALL COIL SPRING AND SUSPENSIONSUP-

PORT
( a ) UsingSST,comprsssthe coil spring.
s s T 0 9 7 2 7- 3 0 0 2 0
NOTICE: Do not usoan impactwronch.
It will damagetho SST.

sA-94
ANDAXLE- FRoNT
suspENsroN suspENstoN(super
strutType)
(b) Installthe coil springto th6 shock absorber.
HINT:Fit ths lowor end of the coil springinto tha gap
of the springseat of shock absorber.
(c) Installthe upperinsulator.

(d) Installth6 uppersoat.
ii
(e) Installthe dust seal and suspensionsupport.
@
@
(f) UsingSST to hold th6 springseat,installa new nut.

s s T0 9 7 2-9 2 2 0 3 1
(S) Remove the SST.
M PG r e a s e (h) Pack MP greaseinto the suspensionsupport.

(i) Installthe cap.

ANDAXLE- FRONT
susPENsroN tLJ!!!l\'|9l9N
KNUCKLE ASSEMBLY
CONNECT SHOCKABSORBER TO STEERING KNU-
CKLE
(a) Clampthe steeringknucklein a vise'
(b) Installth6 upporballjoint with shockabsorborand
tight€ntho nut.
Torque:99 N.m(1,010kgf'cm,73 ft'lbf)
(c) Installa new cottor Pin
KNUCKLEINSTALLATION
1, INSTALL SHOCK ABSORBERWITH STEERING
KNUCKLE
and installths 3 nut.
Placethe shockabsorber
Torquo: 80 N.m (800 kgf 'cm, 59 ft'lbf)
2. CONNECTDRIVESHAFT TO AXLE HUB

(a) lnstallthE drive shaft to thE axle hub.
(b) Temporarilyinstallthe lock nut.
NOTICE:Becarefulnot to damagothe bootr and inneroil
!o!1.
(a) Connect the cambsr control arm to ths shock
sorberand tighten th€ nut.
Torquc:172 N.m(1,780kgf'cm,127 fr'lbt)
(b) lnstallthe lock cap and a new cott€r pin.
Y\'
CONNECTLOWERBALL JOINT ATTACHMENT
Connectthe lower ball joint attachmentto tho st€er-
ing knuckleand tight€n the 2 bolts and nut.

sA-96
S U S P E N S I OANN D A X L E _ F R O N TS U S P E N S I O N
5 . C O N N E C TT I E R O D E N DT O S T E E R I N G
KNUCKLE
(a) Connectthe tie rod end to the steeringknuckleand
t i g h t e nt h e n u t .
(b) Installa new cotter pin.
6. INSTALLSTABILIZERBAR LINK
C o n n e c t h 6 s t a b i l i z ebr a r l i n k a n d t i g h t e nt h e n u t .
Torquo:44N.m(t150kgf.cm.33ft.lbf)
SA
7. w/ ABS:
INSTALLABS SPEEDSENSOR
Toroue:
A B S s p e a ds e n s o r :8 . 0 l { . m ( 8 2 k g f . c m , 7 1 i n . . l b f )
Wire clamp: 5 . 0 N . m ( 5 1 k g f. c m ,4 4 i n . . l b f )
8. INSTALL FRONTBRAKECALIPER
(a) Install th6 disc.
(b) Installth6 brakocalip6r.
Torque:107 N.m(1,090kgf.cm,79 tt.lbl)
9. INSTALLBRAKEHOSE
(a) Runthe brakelinethroughthe brak6hosebracket.
(b) Usingpliers,installthe clip.

AND AXLE - FRONTSUSPENSION(Stt
SUSPENSION
1 0 . INSTALLDRIVESHAFTLOCKNUT
, s t a ltlh e n u t .
W h i l ea p p l y i ntgh e b r a k e si n
Torque:216 N.m(2,200kgf cm, 159 ft lbf)
(b) lnstallthe lock cap and a new cotter pin.
1 1 . TNSTALLFRONTWHEEL AND LOWERVEHICLE
Torquo:103 N.m(1,050kgf cm, 76 lt'lbf)
W H E E LA L I G H M E N T
1 2 . C H E C KF R O N T
(SeepageSA-5)
13. w,/ ABS:
CKECKABSSPEEDSENSOR SIGNAL
(SeepaseBR- 93)

sA'98
ANDAXLE- FRoNT
suspENstoN suspENstoN(super
strutType)
L O W E RS U S P E N S I OANR M W I T H
B A L LJ O I N T
COMPONENTS
ABSSpeed
Sensor
Susoension
LowerNo.2Arm
*iconerpin
.i"J,",I-J\ff
" F ozso,lrtl
nilktr cnrTiSt-l: speciried

torque
part
a Non-reusable

LOWERARM REMOVAL
1 . J A C KU PV E H I C L EA N DR E M O V E
F R O N TW H E E L
2. R E M O V E N G I N E
U N D E R
C O V E R S
3. w/ ABS:
REMOVE A B SS P E E DSENSOR
Removethe ABS speedsensorfrom th€ staaringknu-
ckle,
O W E RB A L LJ O I N TA T T A C H M E N T
4 . D I S C O N N E CL T
(a) Removethe nut and2 bolts.
(b) Disconnect the lowerballjointattachment from axle.
5. DISCONNEC CTA M B E R
C O N T R OAL R M
(a) Removethe cott6rpin and lockcap,removetho nut.
(b) Using SST,disconnectthe cambercontrol arm from

shock absorbgr.
s s T0 9 6 2 -8 6 2 0 1
6. DISCONNECTSTABILIZERBAR LINK FROM STABI-

LIZER
(a) Removeth6 nut and disconnectthe stabilizerbar link
from stabili26r,
H I N T :l f t h e b a l l j o i n st t u dt u r n st o g € t h e rw i t h t h s n u t ,

sA-l00 ANDAXLE- FRoNT
suspENsroN strutType)
susPENstoN(super
(b) Removsboth the stabilizer
bar bushingrstainerset
boltsandromov€the stabilizer
bar.
7. REMOVE3 BOLTS
8. REMOVE F R O N TS U B - F R A M E
(a) Supportth6 transaxle with a jack.
(b) Removethe 5 boltsfrom centermember.
(c) Removethe 2 exhaustpip6 supportbracketset bolts.
(d) Removeth€ 2 grommetsand the contor msmberset

bolt.
(e) Removeth6 2 cantermemb€rset nuts and disconnect
the c€nter membsr.

sA-101
AND AXLE _ F R O N TS U S P E N S I O N r Strut T
SUSPENSION
(f) Ramovethe 2 power st66ringgearassemblyset bolts
and n uts.
'}..---..rA_,-./ (s) Supporttho f ront sub-

f rame with a j a c k .
(h) Removethe 2 bolts and lower the f r o n t s u b - f r a m e
with lower arms.
9. REMOVELOWERARM
(a) Rsmovethe bolt and disconnectthe lower arm'
(b) Removeths collar.
(c) Removetho lowor arm.
L O W E RA R M A N D C A M B E RC O N T R O L
A R MI N S P E C T I O N
1 . O I S C O N N E CCTA M B E RC O N T R O LA R M F R O M
L O W E RN O . 1A R M
( a ) R e a r r a n gt hee l o w e ra r m ,a s s h o w n .

sA-102
ANDAXLE- FRoNT
suspENsloN suspENstoN(super
strutType)
(b) Removeths cottor pin, lock cap and nut.
( c ) U s i n gS S T ,d i s c o n n e ct th s l o w s rb a l l j o i n ta t t a c h m e n t
f rom lower No.1 arm.
s s T0 9 6 2 -8 6 2 0 1
(d) Removethe cotter pin, lock cap and nut.

(e) Using SST,disconnectthe cambercontrol arm from
lower No.1 arm.
s s T 0 9 6 2 8 - 6 2 0 11
2, I N S P E CLTO W E RN O . 1A R M B A L LJ O I N T
Rotatsballjointarm in all directions.lf the movement

is not smooth and f rEe, replacethe lower No.1 arm
assembly.
3. INSPECTCAMBERCONTROLARM BALL JOINT

Rotateballjointarm in all directions.lf the movemenr
is not smooth and free, reolacethe camb6r control
arm assembly.

sA-103
AND AXLE _ FRONTSUSPENSIO
SUSPENSION Strut T
4. CONNECTCAMBERCONTROLARM TO LOWER
N O . 1A R M
(a) Tightenthe nut.
Torque: 152 N.m(1,550kgf cm,112 ft'lbf)
(b) lnstallthe lockcap anda naw cotterpin.
LOWERBALLJOINTATTACHMENT
5. DISCONNECT
FROMLOWERNO.2ARM
th€ cotterPinand nut.
(a) R€mov€
Torquc:118 l{.m (1,205kgf'cm'87 ft lbf)
(b) UsingSST,disconnecttho lowsr balljoint attachment
from lowErNo.2 arm.
- 10011
ssr 09628
6. INSPECT LOWERNO.2ARM BALLJOINT

'i..4/l Rotateballjointarmin alldirections.
lf the movement
is not smoothand froe,roplacothe lower No.2arm
(?q"> assembly.
7. CONNECT LOWERBALLJOINTATTACHMEf{T TO
LOWERNO.2 ARM
(a) Tightonthe nut.
Torquc:118 I{.m(1,205kgf'cm,87 ft'lbf)
(b) Installa n€w cotterPin.
a
ARM INSTALLATION
LOWERSUSPENSION
1, INSTALLLOWERARM
lnstallth€ bolt and collar.

sA-104
suspENsroNANDAXLE- FRoNTsuspENsroN(super
strut Type)
2 . I N S T A L LF R O N TS U B - F R A M E
(a) Jack up the front sub-frame with lower arms.
(b) Positionthe f ront sub-f rameand tightenthe 2 bolts.
Torque:127 N.m(1,300kgf cm, 94 ft.lbf)
SA
(c) Installthe power steeringgearassemblywith 2 bolts.

(d) Installthe cont6r msmberwith the bolt and 2 nuts.

(e) Installthe 2 grommats.
(f) Installtho exhaustpipe supportbracketwith 2 bolts.


sA-105
AND AXLE - FRONTSUSPENSION
SUSPENSION StrutT
(g) Installthe contor member.

Torque:
A: 35 t{.m (360 kgf 'cm, 26 {t'lbf)
B: 39 N.m (400 kgf'cm, 29 ft'lbf)
3. INSTALL3 BOLTS
TEMPORARILY
:.r=- .
rsA
4. INSTALL STABILIZERBAR LINK

(a) Install the both stabilizerbar bushing retainers
bolts.
Torque:1I N.m(195 kgt'cm.14 ft'lbf)
(b) Connectthe stabilizerbar link and tigh€n the nut'

Torque:44 N.m (450 kgf'cm, 33 tt'lbf)
HINT:lf the balljointstud turns tog€therwith the nut,
(a) Connect the camber control arm to the shock ab-
sorberand tighenthe nut.
Torque:172 N'm (1'780kgf'cm, I 27 tt'lbf)
(b) Installthe lock cap and a n€w cotter pin'

sA-106
6. CONNECTLOWERBALL JOINT ATTACHMENT

Connectthe lower balljoint attachmentto th6 stoer-
i n g k n u c k l ea n d t i g h t e nt h e 2 b o l t sa n d n u t .
Torque:108 N.m(1,100ksf.cm,80 f t.tbf)
7. w/ ABS:
INSTALL
A B SS P E E D
SENSOR
T o r qu e :
A B S s p e e ds e n s o r :8 . 0 N . m ( 8 2 k s f . c m , 7 1 i n . . l b f )
Wire clamp: 5.0 N.m (51 ksf cm, 44 in..lbf)
lsA 8. I N S T A L LE N G I N E
U N D E RCOVER
9. STABILIZE SUSPENSION
(al Installtho front wheeland lowervehicle.
Torque:103 N.m(1,050kgf.cm.76 fi.tbt)
(b) Bounce the vehicle up and down severaltimes IO
stabilizethe suspension.
1 0 . TOROUEBOLTS
Torque:
BoltA: 157 N.m(1,600ksf.cm,116 f t.tbf)
BolrB: 167 N.m(1.700ksf .cm,t 23 fr.tbf)
Bolt c: 175 N.m(l ,800kgf.cm,t 30 ft.tbf)
1 1 .C H E C KF R O N TW H E E LA L I G N M E N T
(Seepage SA - 5)
12. w/ ABS:
C H E C KA B S S P E E DS E N S O RS I G N A L
(See pase BR- 93)

AND AXLE - FRONTSUSPENSION(sq
SUSPENSION
S T A B I L I Z EB
RA R
COMPONENTS
N m (kqfcm, tt
a Non-reusable
Dart
BARREMOVAL
STABILIZER
1. REMOVELEFTANDRIGHTSTABILIZER BARLINKS
Removethe nuts and stabilizerbar links from the
arm
bar and lowersusponsion
stabilizer
REMOVELEFTANDRIGHTSTABILIZER BARBUSH.
INGS
(a) Removeth6 boltsand bushingrotainors.
(b) Remove barbushings.
the stabilizer

sA-108
suspENstoNANDAXLE- FRoNTsuspENsroN(super
strut Type)
(c) R e m o v e t h e s t a b i l i z e rb a r .
BARLINK INSPECTION
STABILIZER
I N S P E C TB A L L J O I N TF O RR O T A T I O NC O N D I T I O N
(a) Flip the balljoint stud back and forth 5 times as
s h o w ni n t h e i l l u s t r a t i o nb,e f o r er n s t a l l i ntgh e n u t .
( b ) U s i n ga t o r q u eg a u g e ,t u r n t h 6 n u t c o n t i n u o u s loy n e
t u r n e v e r y2 - 4 s e c o n d sa n d t a k e t h e t o r q u er e a d i n g
on th6 sth turn.
T u r n i n gl o r q u e :
0.05-1.0 N.m(0.5-10 kgf.cm,0.4-8.7 in..lbf)
lf not within specification,replace the stabilizer bar
l i nk .
S T A B I L I Z E RB A R I N S T A L L A T I O N
1. I N S T A L LL E F TA N D R I G H TS T A B I L I Z E R
B A RB U S H -
INGS
(a) Positionthe stabilizerbar.
(b) lnstallth6 stabilizerbar bushings.

(c) Installth6 bushingretainersand bolts.

SUSPENSION
2, INSTALL LEFTAND RIGHTSTABILIZERBAR LINKS
Conn6ctthe stabilizerbar link to the lower suspension
arm and stabilizerbar.
Torque:rl4 N.m(450kgf.cm,33ft lbf)
{ijl.ili.ill{r-,Y'"1
r.lSAr.,:

sA-l10
suspENsloNANDAXLE- FRoNTsuspENstoN(Macpherson
strut Type)
F R O N TS U S P E N S I O N
(MacPherson Strut Type)
DESCRIPTION
The front suspensionis MacPhersonstrut type suspensionwith L-shape lowar arm.
S h o c kA b s o r b e r
L o w e rS u s p e n s i oAnr m

AND AXLE - FRONTSUSPENSION(MacPherson
SUSPENSION StrutT
PREPARATION
ssT (sPEclAL TOOLS)
SERVICE
& TrlnlforBe!ring
09316-60010 Tr!nsmission D'J3tdofl€ctorinst!lhtion
P8* R6olac6r
99
(09316-00010)Rcplrcer
Pipo
(09316-00040)
/@\
09608-32010 st.oringKnucklo
oil Sorl Dult dofloctorinatallation
RoPlacor
09610-20012 PitmtnArmPullor
09628-6201I BallJointPullor
0 9 7 2 7 - 3 0 0 2 0c o i l s p r i n g c o m p r o s . o l
09729-22031 FrontspringUpporso.t Holdor
OOLS
0 9 0 2 5 - 0 0 0 1 0S m s l l T o r q ! e w r o n c h
EOUIPMENT

sA-112
AND AXLE - FRONTSUSPENSIO
SUSPENSION PhersonStrut T
COMPONENTS
€).- r l-Ji-iiEi--iEi--1
sl
Upp€rSpringSeat
U p p e rC o l lS p r h g t
i:
S p r i n gB u m p e r
C o i lS p r i n g
Lower Coil
Sprhg lnsulator
S h o c kA b s o r b e r
D u s tC o v e r
t l a S h o c kA b s o r b e r
SA\
\
s/.--l
i - t
L--'
N . m ( k s f . c m ,l t . l b t ) : S p e c i t i e dt o r q u e
a part
Non-reusable

S U S P E N S I OANN D A X L E - F R O N TS U S P E N S I O N cPhersonStrut T
F R O N TS H O C KA B S O R B ERRE M O V A L
1 . J A C KU PV E H I C L A F R O N TW H E E L
E N DR E M O V E
2. REMOVEBRAKELINE AND ABS SPEEDSENSOR
WIRE(w,z ABS)FROMSHOCKABSORBER
DISCONNEC STH O C KA B S O R B EFRR O MS T E E R I N G

KNUCKLE
Removethe 2 nuts and bolts and disconnectthe
from the steoringknuckle,
shockabsorber
W I T H C O I LS P R I N G
4 . R E M O V ES H O C KA B S O R B E R
(a) Removethe 3 nuts on upper sid€ of tho shock ab-
sorber.
(b) Removethe shock absorberwith coil spring.
5 . R E M O V EC O I L S P R I N G
(a) Installa bolt and 2 nuts to the bracketat the lower
oortionof the shock absorberand secureit in a vise.
(b) UsingSST,compr€ssthe coil spring.

s s T0 9 7 2-7 3 0 0 2 0
N O T I C E :W h e n h o l d i n gt h a s h o c k a b r o r b e r w i t h t h o c o l l
rpring removed. do not hold it by the spring lower reat.
Also, do not knock tho spring lower seat.

sA-l14
ANDAXLE- FRoNT
suspENsroN suspENstoN(Macpherson
strutTyDe)
(c) UsingSSTto holdthe suspension
supportremovethe
nut.
s s T 0 9 7 2 9- 2 2 0 31
(d) Removetho followingparts.

r Suspansionsupport
@ o
.
Bearing
U pper springseat
r6i
GE
i'1 .
o
Uppercoil springinsulator
Coil spring
\s#/ r Shock absorberdust cover
lB'
r"--l o S p r i n gb u m p e r
i
@ I . Lowor coil spring insulator

NOTICE: Whenremoving or installing
tho shockabsorber,
l l if the bearingbecomerreparatodin any way, it must be
rA\ replacedby a new bearing.
i____) \/
v,\+/
g
l
l l
,.t I
U N
tm7?!
FRONTSHOCKABSORBER
INSPECTION
INSPECTSHOCKABSORBER
Compressand extend the shock absorber rod and
check that there is no abnormalresistanceor unusual
operationsounds.
lf th€reis any abnormality,
replacethe shock absorber
with a new one.
NOTICE:When dircardingthe rhock absorber,use tho
followingproceedure,
FRONTSHOCKABSORBER
DISPOSAL
1. FULLYEXTENDSHOCKABSORBER ROD
2. DRILLHOLETO REMOVEGASFROMCYLINDER
Usinga drill,makea holein the cylinder,
as shownto
removethe gas inside,
CAUTION:Thc gar coming out ir harmlerr, but be caroful
of chipr which may f ly up when drilling,

S A ' 11 5
S U S P E N S I OANN D A X L E - F R O N TS U S P E N S I o N ( M a c P h eSr st rountT y p e )
FRONTSHOCKABSORBER
INSTALLATION
1 . I N S T A L L O W E RC O I LS P R I N G
I N S U L A T OO
RN T O
S H O C KA B S O R B E R
2 . I N S T A L LC O I LS P R I N G
(a) UsingSST,comprosstho coil spring.
s s T0 9 7 2-7 3 0 0 2 0
(b) Installthe coil springto the shock absorbor.

HINT:Fit tho lowor end of the coil springinto the gap
of the lower seat.
3. INSTALLSPRING BUMPER ANO DUSTCOVER

-r (a) Installthe springbumperto pistonrod,
I
I Y
\-j
(b) Positionth6 upp€rcoil springinsulatorto tho uppsr

spnngsgat.

sA'l16
ANDAXLE- FRoNT
suspENsroN suspENstoN(Macpherson
strutType)
(c) Positiontho dust cover to tho upperspringseat.
(d) Installtho upper spring seat with dust cover to ths
shock absorber.
(e) Align the mark on the upper spring seat to point

outward from the vehiclein its installedooisition.
(f) Installthe bearingand suspensionsupport.
(S) Using SST to hold the suspensionsupport,install a

now nut.
s s T0 9 7 2 9 - 2 2 0 3 1
Torque:47 N.m (480 kgf.cm, 35 fr.lbf)
(h) Removethe SST from thE coil spring.
NOTICE:Chockthrt the boaiingfits into the recossin the
rusponsionruppo?t.
4, INSTALLSHOCKABSORBER WITHCOILSPRING
Placethe shockabsorberand installth€ 3 nuts.
mo65J

s A - l1 7
AND AXLE - FRONTSUSPENSION(l\4!4irerson
SUSPENSION Strut T
5. C O N N E CSTH O C KA B S O R B ETRO S T E E R I NKGN U -

CKLE
(a) Coatthe threadsof the nutswith engineoil.
(b) Installthe 2 boltsand nuts.
T o r q u a :1 5 3 N . m ( 1 , 5 6 0 k g f c m , I 1 3 f t l b f )
INSTALLBRAKELINE AND ABS SPEEDSENSOR

WIRE(w/ ABs)TO sHoCK ABSoRBER
Torque:
B r a k el i n e : t 9 I I . m ( 1 9 2 k g f ' c m . 1 4 f t l b f )
ABS wire: 5.4 N.m (55 kqf cm,48 in. lbf)
Torque:103 N.m(1,050kgf.cm.76 ft lbf)
I N S P E C TF R O N TW H E E LA L I G N M E N T
(Seepage SA - 7)

AND AXLE - FRONTSUSPENSTON(MacPherson
SUSPENSION Strut T
L O W E RS U S P E N S I OANR M
COMPONENTS
Slabilizer
Bar
6
-T-tl,- flrt nn
ir
Front
Sub.Fram€
JrTe,rooJstl
ti Cotter
- Pin
I
6oI
e-=-@
o.-aCotterPin
*RT
LowerSusoension
Arm
EngineUndsrCover
dAlrl';iilliiitatl : specified
torque
part
a Non-reusable

S U S P E N S I OANN D A X L E - FRONTSUSPENSION(MacPherson
StrutT
L O W E RS U S P E N S I OANR M R E M O V A L
1. A N DR E M O V E
J A C KU PV E H I C L E F R O N TW H E E L
2. REMOVE NGINE U N D E RC O V E R S
3. REMOVEDRIVESHAFTLOCKNUT
(a) Remove the cottsrpin and lockcap.
(b) Whileapplyingthe brakes,r€moveth6 nut,
4. KNU.
D I S C O N N E CTTI E R O DE N DF R O MS T E E R I N G
CKLE
(a) Removethe cotter pin and the nut.
(b) UsingSST,disconnectth€ tie rod end from the stoer-
i n g k n uc k l e .
ssr 09610-20012
DISCONNECTSTABILIZERBAR LINK
LOWERARM
DISCONNECT LOWERARM FROM LOWERBALL

JOINT
Removethe bolt and 2 nuts.
7, REMOVE3 BOLTS
t=xr-=s()
\\!Y \
--_-,
\ >\
-{
\\

sA-120
SUSPENSION N(MacPhersonStrut T
8. REMOVE F R O N TS U B - F R A M E
(a) Supportthe transaxle with a jack.
(b) Removethe 2 exhaustpipesupportbracketset bolts.
( c ) Removethe 2 grommetsand the centsr membsrset

bolt.
( d ) Removethe 2 centermemberset nuts.
(e) Removeth6 2 pow6rsteeringgearassemblys6t bolts

and n uts.
(0 Supportthe front sub-frame with a jack.

(s) Removsths 2 bolts and lower th6 front sub-frame
with lower arms.

sA-121
{h) Removeboth stabilizerbar bushingretainorset bolts.
9. REMOVELOWERARM
(a) Removethe collar.
(b) Removethe bolt and disconnactths lower arm.
si'
L O W E RS U S P E N S I OANR M INSTALLATION
1. INSTALLLOWERARM
l n s t a ltlh e b o l ta n dc o l l a r .
2. INSTALL FRONTSUB- FRAME

( a ) J a c k u p t h s f r o n t s u b - f r a m e w i t h l o w e ra r m s .
( b ) Installboth stabilizsrbar bushingretainersset bolts.
Torque:19 N.m(195 kgt.cm,14 ft.lbf)
(c) Positionthe f r o n t s u b - f r a m ea n d t i g h t e nt h e 2 b o l t s .
Torquer127 N.m(1.300kgf.cm,94 ft.lbf)

sA-122
AND AXLE - FRONTSUSPENSTO
SUSPENSION N(Macpherson
Strut T
(d) Installth6 pow6r staeringgearassemblywith 2 bolts.

Torque:127 N.m(1,300kgf.cm.94 ft.lbf)
(e) Installthe center memberwith the bolt and 2 nuts.

T o r q u e : 8 0N . m( 8 2 0k g f . c m , 5 9f r . l b f )
(0 I n s t a ltl h e 2 g r o m m e t s .
(s) Installth6 oxhaustpipe supportbracketwith 2 bolts.

Torque:19 N m (195kgf.cm,14 ft.lbt)
3, TEMPORARILY
INSTALL3 BOLTS

sA-123
4, CONNECT LOWERARM TO LOWERBALLJOINT

Tightenthe bolt and 2 nuts.
T o r q u e :1 2 7 N . m ( 1 , 3 0 0 k g f . c m , 9 4 f t ' l b f )
5. B A R L I N K T O L O W E RA R M
C O N N E C TS T A B I L I Z E R
\>'
':-"'=
r.5;"'
6 . C O N N E CTTI ER O DE N DT O S T E E R I NKGN U C K L E
(a) Tightenth6 nut.
(b) Installa new cottar pin.
HINT: lf the cottsr pin hole does not line up, correct
by tighteningthe nut by the smallsstamountpossible.
7, INSTALL DRIVESHAFT LOCK NUT

(a) Installand torquetho lock nut.
Torque:216 N.m(2,200kgf.cm,159 ft lbt)
( b ) I n s t a l tl h e l o c kc a pa n ds e c u r ai t w i t h a n e w c o t t e rp i n .
8 . I N S T A L LE N G I N EU N D E RC O V E R S
9. STABILIZESUSPENSION
( a ) I n s t a lt lh a f r o n tw h e e a
l n dl o w e rv e h i c l e .
--ZR*
tffil ( b ) B o u n c et h e v e h i c l au p a n d d o w n s e v e r a lt i m a s t o
stabilizethe suspension

sA-124
suspENstoNANDAXLE- FRoNTs u spENStoN
(Macpherson
strut Tvpe)
10. TOROUE B O L T SA N ON U T
Torquo:
B o l t A : I 5 7 N . m ( 1 , 6 0 0 k g f . c m , 1 16 f t . t b f )
B o l t B : 16 7 N . m ( 1, 7 0 0 k s f . c m , 1 2 3 f r . l b f)
B o l t c : I 7 5 N . m ( 1 . 8 0 0k s f . c m . 1 3 0 f t . l b f )
11 . I N S P E CFTR O N TW H E E LA L I G N M E N T
(SeepageSA-7)
12. w/ ABS
INSPECT ABS SPEEDSENSOR SIGNAL
(SeepageBR- 93)
SA

sA-125
ATIIDAXLE - FRONTSUSPENSION PhersonStrut T
SUSPENSION
LOWERBALL J O I N T
COMPONENTS
FrontDriveShatt
Y*
ABS SpeodSensor
'-T-
a,2oo:i6rl
z, 1116
i/
OCottsr Pin
i @^l
I Y
Lock Cap
,-
rt\
/7
T
CotterP i n
)l91!9S.!91i
taq,
L o w e r B s l lJ o i n t
N ' m ( k q l . c m ,t t . : S p s c i f i e dt o r q u e
part
a Non-r€usable

sA-126
suspENstoNANDAXLE- FRoNTsuspENSroN(Macpherson
strut Type)
LOWERBALLJOINTREMOVAL
1. REMOVS E T E E R I NKGN U C K L W
E I T HA X L EH U B
(SeepageSA-30)
2. REMOVELOWERBALLJOINT
(a) Usinga scrawdriver,
removetho dust deflector.
SA
(b) Removethe cotter pin and nut.

(c) UsingSST,remov6tho lower balljoint.
ssT09628-62011
L O W E RB A L LJ O I N TI N S P E C T I O N
I N S P E C TB A L L J O I N T F O RR O T A T I O NC O N D I T I O N
( a ) F l i pt h 6 b a l lj o i n t s t u d b a c ka n d f o r t h 5 t i m e s b e f o r e
i n s t a l l i n tgh 6 n u t .
( b ) U s i n ga t o r q u eg a u g e ,t u r n t h e n u t c o n t i n u o u s loyn e
t u r n e v 6 r y2 - 4 s e c o n d sa n d t a k o t h a t o r q u er e a d i n g
on the sth turn.
Turningtorque:
1 . 0 - 4 . 9 N . m( 1 0 - 5 0 k g f . c m , 8 . 7 - 4 3i n . . l b f )
L O W E RB A L L J O I N T I N S T A L L A T I O N
1. INSTALLLOWERBALLJOINT
( a ) I n s t a lt lh o l o w e rb a l lj o i n ta n dt i g h t e nt h e n u t .
T o r q u a :1 0 3 N . m ( 1 . 0 5 0k g f . c m , 7 6 f t . l b f )
(b) Installa new cotter pin.

AND AXLE - FRONTSUSPENSION(MacPherson
SUSPENSION Strut T
INSTALL NEWDUSTDEFLECTOR
Using S S Ta n da h a m m ei rn,s t a l lnae wd u s td e f l e c t o r ,
ssr 0931 6 - 6 0 0 10 ( 0 9 361- 0 0 0 10 ,0 9 3 1
6-00040)
-
0 9 6 0 83 2 0 0 1
H I N T :A l i g nt h e h o l e sf o r t h e A B S s p e e ds e n s o ri n t h e
dust deflectorand steeringknuckle.
INSTALL STEERINGKNUCKLEWITH AXLE HUB
(Seepage SA-35)

sA-128
S U S P E N S I OANN D A X L E - F R O N TS U S P E N S I O N ( M a c p h eSr tsrountT
S T A B I L I Z EB
RA R
COMPONENTS
??
@- Bushing
SA
\'"/z
,,,F
, t--\r
N . m ( k q f . c m t, t . l b )f : S p e cf e d t o r q u e
S T A B I L I Z EBRA RR E M O V A L
.I. DISCONNECT LEFTAND RIGHTSTABILIZER
BAR
LINKS
'_t--..a Removetho nuts.
2. REMOVELEFTAND RIGHTSTABILIZERBAR BUSH-

INGS
( a ) Removethe bolts and bushingr6tainors.
( b ) Rsmovethe stabilizerbar bushings.

sA-129
{c) Removethe stabilizerbar'
BARLINK INSPECTION
STABILIZER
INSPECTBALL JOINT FOR ROTATIONCONDITION
(a) Flip the ball joint stud back and forth 5 tim€s as
shown in the illustration,beforeinstallingthe nut.
(b) Usinga torque gau96,turn the nut continuouslVone
"ffi
t u r n s v e r y2 - 4 s e c o n d sa n d t a k a t h e t o r q u er e a d a n g
o n t h e 5 t h t ur n .
Tuiningtorque:
0 . 0 5 - 1 . 0N . m( 0 . 5 - 1 0 k g f c m , 0 . 4 - 8 . 7i n " l b f )
lf not within specification,replacethe stabilizerbar
link.
S T A B I L I Z E RB A R I N S T A L L A T I O N
1. BARBUSH-
INSTALLLEFTANDRIGHTSTABILIZER
INGS
(a) Positionthe stabilizer
bar.
(b) Installthe stabiliz€rbar bushings.

(c) Installth6 bushingretainorsand bolts.
Torque:19 N.m(195 kgf.cm,14 ft.lbf)
----\

sA']10
ANDAXLE- FRoNT
suspENstoN suspENstoN(Macpherson
strutType)
2. CONNECTLEFT ANO RIGHT STABILIZERBAR
't) LINKS
Connectth€ stabilizsr barlinkto the lowersusoension
a r ma n ds t a b i l i z ebra r .
t T o r q u a :4 4 N . m ( 4 5 0 k g f . c m , 3 3 t t . l b f )

S4.131
S U S P E N S I OANN D A X L E _ R E A RA X L EH U BA N D C A R R I E R
R E A RA X L EH U BA N D C A R R I E R
DESCRIPTION
The rear axle also uses oil-s6alod double-row angularball bearingsfor wheel O"aringsafili'e
front axle.
There is no need for bearinggr6asemaintenanceor preloadadjustment.
Hub Bolt
R e ar A x l e
Carrier
D o u b l e - R oA wn g ul a r
B a l lB e a r i n g

sA-132
A N DA x L E - R E A RA X L EH U BA N Dc A R R T E R
suspENsroN
PREPARATION
EOUIPMENT
Torque wrench

SA.133
ANDAXLE_ REARAXLEHUBANDCARRIER
SUSPENSION
R E A RA X L E H U B
COMPONENTS
B r a k eC a l i p e r
R e a rA x l e H u b
with Bearing
I N ' m ( k g i c m , f t l b f ) I : S p e c i f i e dt o r q u e
art

SA-134
s u s p e r s r o NA N DA X L E- R E A RA X L EH U BA N Dc A R R T E R
R E A RA X L EH U BR E M O V A L
1 , J A C KU PV E H I C L E
A N DR E M O V E
R E A RW H E E L
2. REMOVEBRAKECALIPER AND OISC
(a) Removethe 2 brakecaliperset bolts.
(b) Supportthe brakecalipersecurely.

(c) Removethe disc.
3. CHECK BEARINGBACKLASHAND AXLE HUB DE-

VIATION
(a) Placethe dial indicatornearthe conterof the axle huo
and checkthe backlashin tho b€aringshaft direction.
Marlmum:
0.05 mm (0.0020in.)
lf gr6ator than tho specifiedmaximum,replacethe
axle hub with bearing.
(b) Using a dial indicator,check th€ deviation at rhs

surfaceof the axle hub outsidetha hub bolt.
Mtrlmum:
0.07 mm (0.0028In.)
lf greater than the specifiedmaximum,replacethe
axle hub with bearing.
1. REMOVEREARAXLE HUB
(a) Removetho 4 boltsand rearaxlehub.
(b) Removetha O- ring.

sA-135
ANDAXLE- REABIXLE-!-UI-AND
susPENSloN CABRIE!
REARAXLE HUBINSTALLATION
1. INSTALLREARAXLEHUB
(a) Installa new O-ring.
HINT:Coatthe O-ring with MP grease.
(b) Installth€ rear axle hub with th€ 4 bolts.

Torquc:80 N m (820 kgt cm' 59 ft lbf)
l.$6
2. INSTALL DISC AND BRAKECALIPER

(a) Installthe disc.
(b) Install the brake caliper with the 2 bolts.
Torquc:r[7 N.m (475 kgf cm, 34 ft'lbf)
3. INSTALLREARWHEELAND LOWERVEHICLE
Torqur: 103 t{'m (f ,050 kgf cm, 76 ft'lbf)

sA-136
S U S P E N S I OANN D A X L E _ R E A RA X L EH U BA N D C A R R I E R
E N DR E M O V E
R E A RW H E E L
2, REMOVEBRAKECALIPER AND DISC
(a) Removeths 2 brakecaliperset bolts.
(b) Supporrthe brakecalipersecurely.
(c) Removethe disc.
3, REMOVEHU8 BOLT
UsingSST,rsmovethe hub bolt.
s s T 0 9 6 2 8- 10 0 11
SA
INSTALL NEW HUB BOLT

7 Installwasherand nut to the hub bolt,as shown in the
M
Vr illustration,and installthe hub bolt by tighteningth6
{{9 nut.
sJr
5. I N S T A L LB R A K ED I S CA N D C A L I P E R
( a ) lnstallthe disc.
( b ) Installth6 brakecalioerwith the 2 bolts.
Torque:47N.m(475kgf'cm,34{t.lbf)
6. I N S T A L LR E A RW H E E LA N D L O W E RV E H I C L E
Torque:103 N.m(1,050kgf'cm,78 ft.lbf)

sA-137
ANDAXLE- REABAxlE-ltJBIND CAREI$
susPENsloN
R E A RA X L EC A R R I E R
COMPONENTS
'$i
B r a k eC a l i p e r
a O-Ring
R e a rA x l e H u b
with Bearing
l-Nm (kjj-Jxorcrr-qGnrEtbf-l
: Specifiedtorque
a N o n - r e u s a b lD
e an

sA-138
ANDAXLE- REARAXLEHUBANOCARRIER
SUSPEI{SION
R E A RA X L EC A R R I E R E M O V A L
A N DR E M O V E
R E A RW H E E L
2, REMOVEREARAXLEHUB
(SeepageSA- 134)
3. DISCONNECT BACKINGPLATEFROMREARAXLE
CARRIER
(a) Disconnect the backingplatefrom rearaxlecarrier.
(b) Supportthe backingplatesecurely.
4. w,/ ABS:
DISCONNECT ABS SPEEDSENSOR
Disconnect
the ABSspeedsensorfrom rearaxlecar-
rier.
SA
5. REMOVEREARAXLECARRIER
(a) Removeths boltandnut anddisconnect
the strut rod
from the rearaxlecarrier.
(b) Removethe 2 nuts from shock absorberlower set

bolts.
HINT:Do not remov6the bolts.
(c) Removethe bolt, nut and disconnectthe lower sus-
oensionarms from axle carrier.
(d) Pull out the 2 bolts from the shock absorberano
removerear axle carrier
REARAXLE CARRIER
INSTALLATION
1. INSTALL REARAXLE CARRIER
(a) Temporarilyconnect th6 lowor suspensionarms to
the axle carrierwith the bolt and nut.
(b) Temporarilyconnect the shock absorberio th6 axlo
carrierwith the 2 bolts and nuts.

sA-l39
AXLEHUBANDqAESIIE
ANDAXLE- REAR
susPENsroN
(c) Temporarilyconnect th€ strut rod to the roar axl€
carrierwith th6 bolt and nut.
(d) Torquethe 2 shock absorbers€t nuts.

Torque:255 t{.m (2,600kgf cm, 188 ft lbt)
2. w/ ABS:
CONNECT ABSSPEEDSENSOR
Connecttho ABSspeedsensorto the rearaxlecarrier.
N.m(82kgf'cm,71in"lbf)
Torque:8.0
3. INSTALL BACKINGPLATE AND REARAXLE HUB

(a) Placathe backingplate,
(b) lnstalla new O-ring.
HINT:Coatthe O-ring with MP grease.
(c) Installtho rear axle hub with the 4 bolts.

Torque:80 N.m (820 kgf'cm, 59 ft'lbf )

sA-140
AND AXLE - REARAXLE HUB AND CARRIER
SUSPENSION
4. INSTALL BRAKEDISC AT'IDCALIPER

(a) Installths disc.
(b) Installthe brakecaliperwith the 2 bolts.
Torque:47N.m(475kgf.cm,34fr.lbf)
(a) Installthe rearwheeland lowerthe vehicle.
(b) Bounce the vehicle up and down soveraltimes to
stabilizethe suspension.
6. TOROUEBOLTSAND NUT
(a) Jack up vehicleand supportbody with stands.
(b) Removethe rear wheel.
(c) Supportth6 rear axle carrierwith a jack.
(d) Torquethe bolts and nuts.
Torque:
Strut rod: I 13 N'm (1,150kgf.cm,83 ft.lbf)
Lowerarm: 197 N.m(2,010kgf.cm,145 ft.lbt)
7. INSTALL REARWHEEL AND LOWERVEHICLE
8. INSPECTAND ADJUST REARWHEEL ALIGNMENT
(See page SA-9)

sA-141
S U S P E N S I OANN D A X L E _ R E A RS U S P E N S I O N
R E A RS U S P E N S I O N
DESCRIPTION
T h e r e a rs u s p e n s i o rns dual- Iink strut independentsuspensioncomposedof two lower arms in
o a r a l l eal t t h e s i d e ,a n d strut rods which extendforward.
S t a b i l i z e rB a r L i n k
N o . 1L o w e r
S u s p e n s i o nA r m S t a b i l i z eBra r
S t r u tR o d

sA-142
AND AXLE _ REARSUSPENSION
SUSPENSION
PREPARATION
ssr (sPEcrAL
sERVtcE
TooLs)
09727-30020 CoilSplascomprossor
49729-22031 Front Spring Upp€r Soat Holder
OOLS
0 9 0 2 5 - 0 0 0 1 0S m a l l T o r a u o W r e n c h
EOUIPMENT
Torque wrench

sA-143
ANDAXLE- REARSUSPENSION
SUSPENSTON
REARSHOCKA BSO RBE R

COMPONENTS
g,-aF 600,36il
e
Susp6nsion
upper
ShockAbsorber
withCoilSpring
lltt..
o Bumper
Spring
t-J-
ffi) Ar Low6r
lnsulalor
dFe-
- -!/ // V
II
ft[rr-]tl
Absorber
Shock
Jtlbil : specifiedtorque
tNLnlkgacm
a Non-reusable
Darl

sA-144
AND AXLE _ REARSUSPENSION
SUSPENSION
REARSHOCKABSORBER
REMOVAL
A N DR E M O V E
R E A RW H E E L
2. DISCONNECTABSSPEED
SENSORWIRE(w/ ABS)
AND BRAKEHOSEFROMSHOCKABSORBER
Removethe nut and disconnectth6 stabilizerbar linK
f rom shock absorber.
HINT:lf the balljointsiud turns togetherwith the nut,
use a hexagonwrench to hold th6 stud.
4. REMOVESHOCKABSORBER WITH COILSPRING

(a) Loosenthe 2 nuts on lower side of the shock ab-
sorber.
HINT:Do not remov€the bolts.
(b) Supportthe r€araxlecarrierwirh a jack.

sA-145
AND AXLE - REARSUSPENSION
SUSPENSION
(c) Removethe 3 uppersupport nuts.
(d) Low6r ths rear axle carrierand removethe 2 bolts.

(e) Removetho shock absorberwith coil spring.
DISASSEMBLY
REARSHOCKABSORBER
1. IN VISE
C L A M P S H O C KA B S O R B E R
lnstalla bolt and 2 nuts to th6 bracketat the lowor
oortionof the shock absorberand secureit in a vise.
2, REMOVECOILSPRING
(a) UsingSST,compr6ss
the coil spring.
-
ssr 09727 30020
NOTICE:Do not us. an impact wronch.
It will dsmage thc SST.
(b) UsingSSTto holdthe upporsupport,removethe nut.

s s T0 9 7 2 9 - 2 2 0 3 1

sA-146
SUSPENSION
(c) Removethe followingparts:

o Collar
. Suspsnsionu ppsr support
r Coil spring
o S p r i n gb u m p e r
. Lower insulator
"."
REARSHOCKABSORBER
INSPECTION
I N S P E C TS H O C KA B S O R B E R
Comprassand extend the shock absorberrod and
c h e c kt h a t t h e 1 6i s n o a b n o r m arle s i s t a n coer u n u s u a l
operationsounds.
lf there is any abnormality, replacethe shockabsorber
with a newone.
NOTICE:When discarding the shockabsorbsr,use the
f ollowing procedure.
R E A RS H O C KA B S O R B EDRI S P O S A L
1 . F U L L YE X T E N D S H O C KA B S O R B ERRO D
2 . D R I L LH O L ET O R E M O V E G A SF R O MC Y L I N D E R
U s i n ga d r i l l m
, a k ea h o l ei n t h e c y l i n d e ar ,s s h o w nt o
removethe gas inside.
C A U T I O NT : h e g a r c o m i n go u t i s h a r m l e s s b, u t b s c a r o t u l
o f c h i p sw h i c h m a y f l y u p w h e n d r i l l i n g .
R E A RS H O C KA B S O R B EARS S E M B L Y
1. I N S T A L LL O W E RC O I LS P R I N GI N S U L A T O R ONTO
S H O C KA B S O R B E R
H I N T :F i t t h 6 g a p o f t h e i n s u l a t o ra, s s h o w n .
2. INSTALLSPRING
BUMPER
TO PISTONROD
&-
IT
l
de*

sA-147
S U S P E N S I OANN D A X L E _ R E A RS U S P E N S I O N
3. INSTALLCOILSPRING
(a) UsingSST,compress the coil spring.
-
ssr 09727 30020
NOTICE:Donot uso8n impactwrench.
I t Y Y i l ld a m a g 6 t h e S S T .
(b) Installthe coil springto tho shock absorber.

HINT:Fit the low6r end of the coil springinto th€ 9ap
of the lower s€at.
4, INSTALLDUSTCOVERAND UPPER SUPPORT

(a) Installthe dust covorand uppersuportto ths piston
rod.
(b) Install the collar.

(c) UsingSSTto holdthe uppersupport,installa now nut'
s s T0 9 7 2 9 - 2 2 0 3 1
(d) Rotate the uppor support and set it in the direction

shown in the illustration,
(e) Removeth6 SST.
HINT:After removingSST,again check the direction
of the uppersupport.
Outside

sA-148 AND AXLE - REARSUSPENSION
SUSPENSION
R E A RS H O C KA B S O R B EIR
NSTALLATION
1 . I N S T A L LS H O C KA B S O R B EW
RI T HC O I LS P R I N G
Placethe shock absorber and installthe 3 uooer
suDoortnuts.
Rrl9347
2, CONNECT SHOCKABSORBER TO REARAXLECAR.

RIER
Jack up the r6araxlecarrierand connectshockab-
sorberwith the 2 boltsand nuts.
Torque:255N.m(2,600ksf.cm,188ft.lbf)
3. CONNECT STABILIZER BARLINKTO SHOCKABS-

ORBER
Connectthe stabilizer
bar linkwith the nut.
To.quo:44 N.m (450 kgf'cm, 33 ft lbf)
HINT:lf ths balljoint stud turns togethorwith the nut,
4. INSTALLABSSPEED SENSOR WIRE(w,z ABS)AND

B R A K EH O S ET O S H O C KA B S O R B E R
Torquc:
Brake hose: 19 N.m (t 92 kgf .cm, I tl ft'lbf)
A B S w i r e : 6 , 4 N ' m ( 5 6 k g f. c m ,4 8 i n . . l b f )
5. INSTALLREARWHEELAND LOWERVEHICLE
T o r q u e :1 0 3 N . m ( 1 , 0 5 0k g f . c m , 7 6 t t . l b f )

sA-149
S U S P E N S I OANN D A X L E - R E A RS U S P E N S I O N
L O W E RS U S P E N S I OANR M A N D
S T R U TR O D
COMPONENTS
N o . 2L o w e r
Suspension Arm
o,r4tl
FrJ-,r-jr-r
d\
- Y'1.
20(195,141
(^\o
67'4'-
N o . ' lL o w e r
S u s p e n s i o nA r m
e46
S t r u tR o d
N m ( k g fc m , t t l b f ) ; S p e c i f i e dt o r q u e

sA-150 S U S P E N S I OANN D A X L E _ R E A RS U S P E N S I O N
L O W E RS U S P E N S I OANR M A N D S T R U
T
RODREMOVAL
E N DR E M O V E
R E A RW H E E L
2. REMOVESTRUTROO
(a) Removeth6 2 boltsand nuts.
(b) Remove the strut rod.
3. REMOVENO.2LOWERSUSPENSION ARM
(a) Removethe 2 nutsandwashers.
(b) Removeth€ No.2lowersusoension
arm.
4. REMOVENO.1LOWERSUSPENSION ARM
(a) Supportthe suspension
memberwith a jack.
(b) Removeth6 4 nuts from suspensionmember.
(c) Removetha 2 bolts.
-------1

sA-151
(d) Lower the suspensionmemberto pull out the lowor
susoensionarm set bolt.
(e) Rsmovethe No.1 lower suspensionarm with the 2

bolts and the washer.
ARM
NO.2LOWERSUSPENSION
DISASSEMBLY
DISASSEMBLENO.2 LOWERSUSPENSION ARM
(a) Loosonthe 2 lock nuts.
(b) Turn the adjustingtube and disassemblethe No.2
lower suspensionarm.
(c) Removeths lock nuts from the arms.
ARM
NO.2LOWERSUSPENSION
ASSEMBLY
ASSEMBLE NO.2LOWERSUSPENSION ARM
(a) Installth€ locknutsto th€ arms.
(b) Turnthe adjusting the No.2lower
tubeandassemble
susoension arm.
HINT: When asssmblingthe No.2 lower suspension

arm, try to make dimensionsA and B shown in the
illustrationas closeas possible.
Marimumdifferenc.:
3 mm (0.12in.)

( c ) A d j u s tt h e N o . 2l o w e rs u s p e n s i oanr m l e n g t hb y t u r n -
ing the adjustingtu be.
Arm length:
493.3 + 1.5 mm (19.421+ 0.059in.)
( d ) T e m p o r a r i ltyi g h t e nt h 6 2 l o c k n u t s .
HINT: After adjusting the rear wheel alignment,
torque the lock n uts.
L O W E RS U S P E N S I OANR M A N D S T R U T
......_:-.=-::7 R O DI N S T A L L A T I O N
1 . I N S T A L LN O . 1L O W E RS U S P E N S I OAN RM
I n s t a lt lh eN o . 1l o w e rs u s p e n s i oanr mw i t ht h s w a s h e r
and th6 2 bolts.
HINT: Face th€ paint mark to tho outer rear.
2 . I N S T A L LS U S P E N S I OM N E M B E RT O B O D Y
(a) Jack up the suspsnsiom n ember.
( b ) I n s t a ltl h e s u s p e n s i om
n e m b e rw i t h t h e 4 n u t s .
Torqua:137 N'm (1.400kgf.cm,102 ft.lbf)
(c) Installthe 2 bolts.

\.=-- -,-----=
3 . I N S T A L LN O . 2 L O W E RS U S P E N S I OA NR M
( a ) I n s t a l lt h s N o . 2 l o w e r s u s p e n s i o na r m w i t h t h a 3
washars.
HINT:Facethe oaint mark to the outer rear.
( b ) T e m p o r a r i liyn s t B ltlh e 2 l o c k n u t .

sA-l53
SUSPENSION
4. INSTALLSTRUTROD
installthe 2 bolts
Placethe strut rod andtsmporarily
and nuts.
(a) lnstallthe rear wheel and lower the vehicle.
Torque:103 N'm (1,050kgf'cm. 76 ft lbf)
,ft (b) Bounco the vehicle up and down severaltimes to
tffil stabilizethe suspenslon

sA
M
6. TOROUEBOLTSAND NUTS
(a) Jack up the vehicleand supportthe bodywith stands.
(b) Removeths rear wheel.
(c) Supportthe rsar axle carrierwtth a 1ack.
(d) Torqua the nuts of lower arm and the strut rod set
bolts.
Toroua:
Lowerarm nut: 197 N'm (2,010kgf'cm,145 tt lbf)
s t r u t r o d b o l t : 1 1 3 N . m( 1 , 1 5 0k g f ' c m , 8 3f t ' l b f )
7. I N S T A L LR E A RW H E E LA N D L O W E RV E H I C L E
Torque:103 N'm (1,050kgf'cm. 76 ft lbf)
8. I N S P E C TA N D A D J U S TR E A RW H E E LA L I G N M E N T
(Seepage SA - 9)
9. TOROUE NO.2 LOWER SUSPENSIONARM LOCK
NUTS
Torque:75 N'm (760kgf cm, 55 ft'lb{)

sA-154
S T A B I L I Z EB
RA R
COMPONENTS
.Gask€r -*-*Y
BarLink
Stabiliz€r
1*$-"-.-A
o*6Y I
Exnausltaitpipe
d )
e-----i ! !{9441
.- RH FuelTankBend
SA StabilizorBar Link
@- cusnion
4f- t,".*",
m fr' : Specitiedtorqua e-------@
a Non-reusable
oart t {92?2
STABILIZER
BARREMOVAL
T. REMOVEEXHAUSTTAILPIPE
(a) Removethe 2 boltsanddisconnet
exhausttailpipe.
(b) Removeth6 gasket.
2. REMOVEFULETANK BAND
Removethe bolt and disconnectthe RH fuel tank
band.
3. REMOVEEOTHSIDESTABILIZER BARLINKS
Removethe 4 nutsand 2 stabilizer bar links.
HINT:lf th6 balljointturnstogothorwith the nut,use
a hexagon wrenchto holdthe stud.

sA-155
4. REMOVESTABILIZER BAR
barfrom the body.
Removethe 4 boltsand stabilizer
5. REMOVEBOTHSIOECUSHIONS AND BRACKETS
Removethe cushionsandbrackets from the stabilizsr
bar.
S T A B I L I Z EBRA RL I N KB A L LJ O I N T
,-t-: INSPECTION
15 INSPECTBALL JOINT FOR ROTATIONCONDITION
(a) Flip the ball joint stud back and forth 5 times, as
shown in th€ illustration,beforeinstallingthe nut.
(b) Usinga torquewrench,turn tho nut continuouslyone
turn every2 - 4 secondsand take the torque roading
on tho sth tu rn.
Torque(turning):
0.05 - I .0 N.m(0.5 - t 0 kgf'cm, 2.6 - 8.7 in.'lbf)
lf not within specification,replacethe stabilizErbar
link.
BARINSTALLATION
STABILIZER
P a i n tL i n e
I. INSTALL STABILIZERBAR
(a) Installtho 2 cushionsto th€ stabiliz€rbar.
HINT: Installthe cushionto the outside of the paint
line.
(b) lnstallthe brackats.
(c) Installth6 stabilizerbar with the brackets,cushions
and bolts.
Torquc:19 N.m(195kgf.cm,14 ft'lbf)
2. INSTALL BOTH SIDE STABILIZERBAR LINKS
lnstallth€ stabilizerbar linksto the stabilizerbar and
shock absorber.
Torquo:44 l{.m (450 kgf.cm, 33 ft'lbf)
HINT:lf the balljoint Ftudturns tog€therwith the nut,
3. INSTALL RH FUEL TANK BAND
Connectthe RH fuel tank band and installthe bolt.
To:quc:40 N.m (400 kgf'cm, 30 ft'lbf)

4. INSTALL EXHAUSTTAILPIPE
(a) Installthe new gasket.
(b) Connectth6 6xhausttailpipeand installthe 2 bolts.
SA

sA-157
AND AXLE _ SERVICE
SUSPENSION SPECIFICATIONS
SPECIFICATIONS
SERVICE
DATA
SERVICE
Cold tire Pressure

inflation Tlre Size
Front Rear
pr€ssure
220 kPa 22okPa
19s/65R14 89H 12.2kgf lcm2. 32 psil 12.2kgt/cm2,32 psi)
240 kPa 24O kPa
205/55R15 87V ( 2 . 4k g f / c m 2 , 3 5p s i ) ( 2 . 4k g f / c m 2 , 3 5p s i )
Vehicle He i gh t
h e i gh t Tlre Size
Front Rear
1 9 5/ 6 5 R1 4 1 8 2 . 6m m ( 7 . 1 9i n . ) 2 5 0 . 0m m ( 9 . 8 4i n . )
205/55R 15
F r o n tw h e e l Toe in- (total) Super Strut Typs 0 " 1 2 ' t 6 ' ( 2 1 1 m m , 0 . 0 8t 0 . 0 4i n . )
al i gn m e n 0 ' t 6 ' ( 0 t 1 m m , 0 1 0 . 0 4i n .)
MacPhersonStrut Type
W h e e la n g l e O u t s i d ew h € e l
l n s i d eW h e e l (reference)
tsfi", st'rt Typ" 3 4 "2 4 ' ! 2 ' 24. 22'
Fr"Pl*".rr-Strrt Type 36" 54' 1 2' 30" 44'

Camber SuperStrutType -0" 13' 1 45'
MacPhersonStrut Type 4" 46' x 45'
L€ft- right error 45'or less
Caster Sup€r Strut Type 2" 36' ! 45'
MacPhersonStrut Typ€ 2' 05' X 45'
Left- right error 45'or less
S t € e r i n ga x i s Sup€rStrutTypo 2' 50' ! 45'
inclination 14' 58' r 45'
M a c P h e r s oS
n t r u tType
F r o n ta x l o Axls bearinobacklash 0 . 0 5m m ( 0 . 0 0 2i0n . )o r l e s s
Axle hub deviation 0 . 0 5m m ( 0 . 0 0 2i0n . )o r l e s s
Front Driv6 shaft w/ LSD LH 573.2f 5.0 mm 122.561 t O.19'lin.l
drive shaft standard RH 8 6 1 . 5i 5 , 0m m ( 3 3 , 9 1 t7 0 . 1 9 7i n .)
lengtn
w/o LSD LH 5 7 6 . 2t 5 . 0m m ( 2 2 . 6 8 5
t 0 . 1 9 7i n . )
RH 8 6 3 . 8t 5 . 0m m ( 3 4 . 0 0 7
1 0 . 1 9 7i n . )
3S.FE Atr LH 5 7 6 . 7 1 5 . 0m m 1 2 2 . 7 1t3 0 . 1 9 7i n . l
and
55-t- E
RH 8 6 2 . 0t 5 . 0m m ( 3 3 . 9 3 7
f 0 . 1 9 7i n . )
LH 5 7 2 . 4t 5 . 0m m ( 2 2 . 5 3 5i 0.'197 in
RH 8 5 7 . 5I 5 . 0 m m ( 3 3 . 7 6 0 :0t . 1 9 7i n .
LH 559,21 5 . 0m m { 2 2 . 0 1t60 . 1 9 7i n ,
RH 8&.9 r 5.0mm (33.657 r 0.197in.
Front Lower ball joint turning torque 1 . 0- 4 . 9 N m ( ' 1 0- 5 0 k g fc m , 8 . 7- 4 3 i n . l b t )
susp€nsion 0 . 0 5- 1 . 0N m ( 0 . 5- 1 0 k g t c m ,0 , 4- 8 . 7 i n . l b f )
S t a b i l i z ebr a r l i n kt u r n i n gt o r q u e

sA-158 AND AXLE _ SERVICE
R e a rw h e e l Toe- in (total) 0 " 2 1 't 6 ' ( 3 . 5t 1 m m , 0 . 1 4t 0 . 0 4i n .)

argmenl
Camber 35.GE - t - 11' 145'
11' ! 45'
5S.FE -1' 10' I 45'
-1' 16' 1 45'
Left- right error 45'or less
R e a ra x l e Axle bearingbacklash 0 . 0 5m m ( 0 , 0 0 2i0n . )o r l e s s
Axlehub deviation 0 . 0 7m m ( 0 . 0 0 2i8n . )o r l e s s
R e a rs u s p e n s i o n S t a b i l i z ebr a r l i n kt u r n i n gt o r q u e 0 , 0 5- 1 . 0N m ( 0 . 5- 1 0 k g fc m , 0 . 4- 8 . 7 i n . l b f )

sA-159
ANDAXLE- SERVICE
TOROUESPECIFICATIONS
(FRONT)
Part tighton6d N.m kgt.cm it.tbt
STRUT
{SUPER S U S P E N S I )O N
Tio rod end lock nut 760
Sto€ringknucklox Shock !blorbor (Upporball joinl) 103 1, 0 1 0 73
Stsoringknucklgx Brak€caliPer 107 1,0s0 7g
St6oringknucklox Tis rod 6nd 49 600 38
Axlehub nut (Drivoshaftlocknut) 214 2,200 159
Driv.6haft x Orivo shaft contsr b6.ring br.ck!t a4 650 17
It8 I ,205 a'l
Lowor No.1 arm x Lower bsll joint atlachmont
St€€ringknuckl6x Lowor ball Jointattochmont 108 1,t00 80
Lowor No.2 arm x Low6r bsll joint attachmont 118 1,205 87
Lowg.No.1armx Cambo.controlarm 152 1,560 112
Cambgrcontrol srm x Shock abSorbsr 1,750 127
Low6r No.1 arm x Front aub-fram€ 157 1,600 ll6
Lower No.2 arm x Front sub-froms ta7 1,700 123

Front 6ub-framo x BodY t75 1,800 130
Si6oringknucklox Du6t covor 8.3 5b 74 in.,lbt
AgS spo€dsensor86t boli 8.0 82 7 1 i n .l b t
EI 44 in. lbf
ABS spe6ds€nsorwirc clamp 3ot boit
Su6ponaionuppor support x Body 80 800 OU
Su6pensionuppor 6upportx Pi6tonrod 17 476 34

Stabiliz6rbsr x Stabiliz€rbar link 44 450
Stabilizerbsr link x Shock !bsorb€r 44 450 33
Strbiliz6rbar bushingrot6in6rt Front !ub-fflmc t9 195 14
Front Bub-lram6 x Body r,300 94
Front 8ub-frama x Clntar mambar 80 420 50
Contormemb€rx Enginamounting 400 29
Centorm€mb€rx Body 380 2A
Front aub-froms x Gear housing 5g 690 43
( MACPHERSONSTRUTSUSPENSIOA
Tio rod ond lock nut 760
St€€ringknuckl. x Shock absorb€f 153 I ,560 113
St€€ringknuckl6x Brskg cslipor 107 r ,090 7e
St€oringknucklox Tie rod ond 49 500
Axlo hub nut (Driv68haft lock nut) 214 2,200 l59
Low6r ball joint x Lowor orm r,300 s4
't,050
Lowor ball joint x St66ringknucklo
Lower arm (Front)x Front 6ub-lramo 1,600 lt8
Low6r lrm (R€arlx Front 8ub-frrmr 187 1,700 123
Front aub-frame x Body t75 | .800
Sto€ringknuckl6r Dust cov€r 85 74 in. lbl

sA-160
AND AXLE - SERVICE
Part tightened N.m kgf.cm it.tbt

Suspsnsionupp6r suppo.t x Body 80 420
Susponsion
upporsupportx Pistonrod 11 480
Brake hoas r Shock absorb6r 19 192 l4
ABS wire x Shock ob6orb€r 5.il 48 in..lbf
Stabiliz.rbar x Stabilizorb8. link 41 450
St6bilizerbar link x Lower lrfi 44 450
Stabiliz6rbar bushingr6tainorr Front sub-frsmo to l4
Front sub-framo r Body 121 1,300 94
Contsr mgmberx Front 6ub-lramo 80 820
ABS !p66d 6onsorsot bolt 8.0 a2 7 l i n .l b t
ExhaustDip6brack6tt Front sub-lramo t9 195 14
(REAR)
Part tightoned N m kgt cm fr.tbf
8r!ko calip6rx Ro6rrxls caraior 47 475 34
Axl6 b.aring 3oi bolt 80 820
Shock rbsorber x Re6rrxle carri6r 255 2,800 188
Srakg ho6ox Shock sbsorber 19 l4
ABS 6p€€d66nsorsot bolt 8.0 7 1 i n .l b f
ABS lpaad aanaorwir6 r Shock absorbor 5.4 cc 48 in. lbf
Su!p.nsion upp6r rupport x Body 39 400 29
Su!prnsion upp6r support x Pistonrod 49 500 38
Lowgr lu6p6nsionNo.1, No.2 srm x Susponsionmomber 197 2,010 145
Lowor !u6pan6ionNo.l, No.2 6rm x R6araxlo carrior 197 2.010 t45
Strutrod x Body 3 1,150 83
Stautaod x Rear gxlo carri€r t , t5 0 e?
Sus06nsionm€mb6rr Bodv 1,400 101

St.bili2.r b!r bu6hingrgt6in6r 19 r95 l4
Strbilizorbar link 66t nul 41 4s0 33
RH full tank blnd x Bodv 40 400 30
Exh6u6tt.ilpip. x Exhaustpip6 43 440

BR-1
B R A K ES Y S T E M
G E N E R A L D E S C R I P T I.O
. .N . . . . ' . . . . . ' . . . . . .B. .R. '- 2
DESCRtplON...' . ' . . . . . . . .B. .R - 2
opERATtON . . . . . . . . . ' . . ' . .B. .R - 2
PREPARATION . . . ' . . . . . . .B . R- 4
T R O U B L E S H O O T.I'N. .G
" ' . . . . . . . . . . . . . . . . .B. R . . -. . 6
c H E C KA N D A D J U S T M E N T . . . . ' . . . . . . . . . . . . '
B R. -
. . 7
MASTER C Y L I N D E R . ' . . . . . . . . . . . . . . " . " " . . .B . .R. .-. .I.I
B R A K EB O O S T E R . . . . . . . . ' .B R - 2 1
F R O N TB R A K E " , . . . . . . . . . .B R - 2 7
(7A_FE.3S_FE) . . . . . . .B. R _ 2 7
F R O N TB R A K E . . . . . . . . . . . .8. .R - 3 5
( 5 S - F E . 3 S - G E w / o S u p e rS t r u tT y p e )" ' B R - 3 5
F R O N TB R A K E . . . ' . . . . . . . .B " R- 44 ffi
( 3 S - G E w / S u p e rS t r u tT y p e ) " " " BR- 44
R E A RB R A K E . . . . . . . . . . . . ' . .B. 'R - 5 2
( D i s cB r a k e ) """"" " " " BR- 52
R E A RB R A K E . . . . . . . . .
. .. . . . BR- 60
(Parking B r a k ef o r R e a rD i s cB r a k e ) " " " 8R- 60
p R o p o R l o N r N GV A L V E( PV A L V E ). . " . . . . .B R - 6 7
A N T I - L O C K B R A K E S Y S T E M ( A B S ). . " . . B R - 6 9
DESCRIPT|ON..... . . . . . . . . . .B. R - 6 9
D I A G N O SS I SY S T E M . ' . . . . . ' . . . . . . , . . . . . . . ' . .B. .R - 7 3
S P E E DS E N S O R AND DECELERATION
S E N S OD R T A G N O SSTYSS T E M. . . . . . . . . . . . .B. R - 8 2
OECELERATIO SN ENSOR OPERATION
D t A G N O SS t SY S T E M . . . . . . . . . . .. .. .. .. . . . . . . . .B. .R - 8 6
A B SA C T U A T O R ... ..... BR- 87
A B SR E L A Y . ' . . . . . . . . . . . . . . . . .B. R - 9 2
FRONT SpEED SENSOR . . . . . . . . . . . . . . . . . . . ' . .B ' .R
. . -. 9 3
R E A RS P E E D S E N S O R . . . . . . . .. .. .. .. .. . . ' . . . . . .8 R - 9 7
A N T I - L O C KB R A K ES Y S T E MC I R C U I T " . . .B. R _l O I
S E R V t CSEp E C t F t C A T t O N S . . . . . . . . .....'.....B. .R. - 1 0 3

BR-2 B R A K ES Y S T E M_ G E N E R A D
L ESCRIPTION
GENERAL
DESCRIPTION
1. Caremust be takento replaceeach part properlyas it could affect the performanceof the 6%iL
systsm and result in a driving hazard.Replacethe parts with parts of the same part numberor
equ ivalent.
2, lt is vary importantto ke6p parts and tho areacleanwhsn repairingthe brakesystem.
3. w i t h a m o b i l ec o m m u n i c a t i osny s t e m r, e f s rt o t h o p r e c a u t i o n
l f t h e v e h i c l ei s e q u i p p e d in the lN
sect ion.
DESCRIPTION
The servicebrakesconsistof a foot brakewhich changesrotationalenergyto thermalenerilio
stop tho vohicl€whils it is beingdrivenand a parkingbrak6to keepthe vehiclefrom movingwhile
it is parked.
ffi orrrAroN
FOOTBRAKE
W h e n t h e b r a k ep e d a li s d e p r e s s e da,v a c u u mb u i l d su p i n t h e b o o s t e rw h i c ha m p l i f i e tsh e p e d a l
force, pressingon the piston in the mastarcylinder.The piston movementraisesthe hydraulic
pr€ssu16in the cylinder.This hydraulicpressureis then appliedto sach respectivebrakecylinder
and wheel cylinder,and acts to prsss the brake pads and shoesagainstthe rotatingdiscs and
brakedrum.The resultingfrictionconvertsthe rotationalenergyto thermalenergy,stoppingthe
vehicle.
E r a k eB o o s t e r
R e a rD i s cB r a k e
P r o p o r t i o inn g V a l v e
A B S A c t u a t or
a.....--- lf,r
B r a k eP e d a l
*
--l
F r o n tD i s cB r a k e \.--1.-

BR.3
B R A K ES Y S T E M- G E N E R A D
L ESCRIPTION
BRAKE
PARKING
W h e n t h e p a r k i n gb r a k el e v e ri s p u l l e dt h e p a r k i n gb r a k es h o el e v e ri s p u l l e dv i a t h e p a r k i n gb r a k e
wire.This causasthe shoestrut to pushthe front shoe,which expandsand is pressedagainstth6
d i s c .l f t h e p a r k i n gb r a k el e v e rc o n t i n u e tso b e p u l l e dt,h e c o n t a c tp o i n to f t h e p a r k i n gb r a k es h o e
l e v e ra n d s h o es t r u t t h e n b e c o m e st h e f u l c r u ms o t h a t t h e p a r k i n gb r a k es h o el e v e rc a u s g st h o
rear shoeto expand.This resultsin the disc beinglockedby the front shoe and r€ar shoe.
S h o eS t r u t
F r o n tS h o e
R e a rS h o e
Adjuster

BR-4
BRAKESYSTEM_ PREPARATION
PREPARATION
SST(SPECIAL
SERVICE
TOOLS)
0 9 0 2 3 - 0 0 1 0 0 U n i o nN u tW r e n c lh0 m m
09709-29017 LSPVGausosot
@-
F'
09737-00010 BrakoBoostorPushRodGaug6
0 9 7 5 -13 6 0 11 BrakL
6 i n €U n i o nN u t1 0r l 2 m m
Wronch
09843- 18020 Dirgnosis

checkwir6
09990-00150 ABS ActuatofCh€ckofand

Sub-harnsss
09990-00163 ABS Actlator Chock€rSh6€t-A'
09990-00250 ABs ActustorCheckor

sub-harngss
'G'
09990-00300 ABS ActuetorCheckors!b-harnoss

't'
09990-00360 ABS Actuatorch€ckersub-harness

'L'

BR-5
BBAKESYSTEM_ PREPARATION
EOUIPMENT
Brak6 disc
M icrometer
D i a li n d i c a t o r Erakod sc
Vernier calipers Brakedrum
LUBRICANT
It6m Capacity Classilacation
Brakelluid N o . 1 1 6o O T3
S A E J1 7 0 3o r F M V S S

BR-6
BRAKESYSTEM- TROUBLESHOOTING
TROUBLESHOOTING
Us6the tablebelowto helpyou find the causeof the problem.Thenumbersindicatetireprililiiv
of the likelycauseof the problem,Checkeachpartin order,lf necessary,
replacethes€parts.
(r)
to
l.) Lat |.l) ,i lr)
,^ ,^ '; @
Soepage
d @ @ @ @
-. N @ N N N N c! N N c\l
cr E G, t E E G cc E E (r E cc G,
.o co ao co @ .o lo @ co co @ @ .o o o
c
o
c I
6
E
P s r tN a m e t! o q)
E o)
= E
o
o
E o G G I
o !
E
o E o E o
; o
o o) q) E E
a) ) o o
': o
o !
t!
'a o) o) o) o J t
E
q)
J
3 (J
E
o
E E 3 IL
a a) E q, a) 3
o 0)
E
r! o) o
6)
v, E
c .; c
o) q) o o -
Troubls o q) a
o o
o : 6 : c ; l
!
o o (!
ol o c o l
o o
@ @ o- co o- co o cc o- I I
L o wp s d a o
l r s p o n g yp s d a l 1 2 o
B r a k od r a g 'll
4 9 8 5 o 7 10
E r a k ep u l l 1 5
H E r dD e d a lb u t b r a k ei n e t f i c i s n t ,l
5 10 I 7
N o i s ef r o m b r a k e s 'l
4 3 7 Y 10

BR-7
B R A K ES Y S T E M- C H E C KA N D A D J U S T M E N T
C HECKANDADJ USTMEN T
StopLight B R A K EP E D A LC H E C KA N D A D J U S T M E N T
cn
1 . C H E C KT H A T P E O A LH E I G H TI S C O R R E C TA, S
SHOWN
P e d a lh e i g h t { r o m s s p h a l t s h e o t :
LHD Vehicle:
1 5 1 . 9 - 1 6 1 . 9m m ( 5 . 9 8- 6 . 3 7 i n . )
RHDVehicle:
1 4 0 . 0 - 15 0 . 0 m m ( 5 . 5 0 - 5 . 9 1 i n . )
lf the pedal hoight is incorrect.adjust it.
2, IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Ramovethe instrumentfinish lower paneland heater
to 169isterNo.2 duct.
(b) Disconnectthe connectorfrom tho stop light switch.
(c) Loosenthe stop light switch lock nut and removethe
stop light switch.
( d ) Loosenthe push rod lock nut.
(e) Adjust th€ pedalheightby turningthe pedalpush rod.
(f) Tightenthe push rod lock nut.
Torque:25 N.m(260kgf.cm,19 ft'lbf)
(s) Installthe stop light switch and turn it until it lightly
contactsths pedalstopper.
( h ) Turn the stop light switch back one turn.
(i) Checkthe clearance(A)betweenstop light switch and
pedal.
Clearance:
O.5- 2.4 mm (0.02- 0.09 in.)
(i) Tightonthe stop light switch lock nut.
(k) Connectlhe connectorto the stop light switch,
(t) Checkthat the stop lights come on when the brake
pedalis depressed, and go off when the brakepedalis
released.
( m ) After adjustingthe pedalheight,checkthe pedalfree-
plav.
( n ) Installthe instrumentfinish lower paneland heaterto
registerNo.2 d uct.
HINT: lf clearance(A) betweenthe stop light switch
and the brake pedalstopp€r has been adjustedcor-
rectly,the pedalfreeplaywill meet the specifications.
CHECK THAT PEDAL FREEPLAYIS CORRECT,AS
SHOWN
(a) Stop the engineand depressths brake pedalseveral
times until there is no moro vacuum loft in the boost-
PedalFreeplay er,
(b) Push in ths pedal by hand until the b€ginningof tho
resistanceis felt, thon moasurs the distance, as
shown.

BR.8
B R A K ES Y S T E M- C H E C KA N D A D J U S T M E N T
Pedal freeplay:
1 - 0 mm (0.04- 0.24 in.)
lf incorrect,check the stop light switch c learance.
A n d i f t h e c l e a r a n c ei s O K , t h e n troubleshootthe
brakesystem.
4. CHECKTHAT PEDALRESERVE DISTANCEIS COR-

RECT
Releasethe parkingbrake.
W i t h t h 6 e n g i n er u n n i n gd, e p r e s st h e p e d a la n d m e a s -
ure the pedalreservedistance,as shown.
Pedalreservedistancolrom asphaltsheBtat
490 N (50 ksf, 1 10.2lbf):
BR 7A_FE,33-GE
LHDVehicle:Morethan 90 mm (3.54in.)
BHDVehicle:Mor6than 80 mm (3.14in.)
5S_FE
Morethan 80 mm (3.14in.)
35-FE
LHDVehicle:Morethan 90 mm (3.54in.)
RHDVehicle:Morothan 80 mm (3.14in.)
lf the reservedistanceis incorrect.troubleshootths
brakesvstem.
*
BRAKEBOOSTER
OPERATIONAL
TEST
A
l( ffi;,ll
\\ \-_,/.n //
/A\
'ii'3.(,@1ir,
\\1- \-\7./a ,
1. OPERATING CHECK
(a) Depressthe brakepedalseveraltimoswith the engine
^\7 \/
lo I off and check that thsrs is no change in the pedal
K , / R reservsdistance.
\lr\*
'\,N\Y,,',.t \\. ,/ ' ( b ) D e p r s s st h e b r a k sp e d a la n d s t a r t t h 6 e n g i n e l. f t h e
\\Nx----
)Jr Y pedalgoes down slightly,operationis normal.
GOOD NO GOOO
2 . A I RT I G H T N E S S CHECK
(a) Start the engine and stop it after 1 or 2 minutes.
Depressthe brake pedal severaltimes slowly. lf ths
pedalgoes down farth6stths 1st time, but gradually
risesafter the 2nd or 3rd time,th€ boostoris air tight.
( b ) D e p r e s st h a b r a k ap e d a lw h i l et h e 6 n g i n ei s r u n n i n g ,
and stop the enginewith the pedaldepressed.lf there
is no changein the pedalraservstraval after holding
the pedalfor 30 seconds,ths boostoris air tight.

BR-9
BRAKESYSTEM_ CHECKAND ADJUSTMENT
BRAKESYSTEMBLEEDlNG
HINT:lf anv work is doneon the brakesystemor if atr
in the brakelinesis suspected,bleedthe systsmof aar.
NOTICE: Do not let brakefluid remainon a paintodsur-
faca.Washit otf immediataly.
1. F I L L B R A K ER E S E R V O IW R I T H B R A K EF L U I D
F l u i d :S A E J 1 7 0 3o r F M V S SI { o . 1 1 6D O T 3
\w (
2. BLEEDMASTERCYLINDER
H I N T :l f t h e m a s t e rc y l i n d o hr a sb e e nd i s a s s e m b l eodr
if the reservoirbecomesempty,bl6€dthe air from the
mastercylindor.
{a) Disconnactthe brakelinesfrom the mastercylinder.
(b) Slowlydepresstho brake pedaland hold it.
.BR
(c) Block off the outlet plug with your finger and rslease
the brakeoedal.
(d) Repeat(b) and (c) 3 or 4 times.
3 . B L E E DB R A K EL I N E
(a) Connectthe vinyl tube to the caliper.
(b) Depressthe braka pedal severaltimss, then loosen
the bleederplug with the pedalheld down.
(c) At the point when fluid stops comingout, tightsn the
bleederplug,thsn r€l€assths brakepsdal.
(d) Repeat(b)and (c) until all the air in the fluid has been
blad out.
(e) Repeatthe aboveproceduroto bleedtho air out of the
b r a k el i n ef o r e a c hw h e e l .
HINT: Start bleedrngfrom the caliper the farthest
awav from th€ mastercylinderand finish at tho clo-
sest.
4 . C H E C KF L U I DL E V E LI N R E S E R V O I R
C h e c kt h e f l u i d l e v e la n d a d d f l u i d i f n e c e s s a r y .
Fluid:SAEJ1703 or FMVSSNo.1I 6 DOT3

BR-10
B R A K ES Y S T E M_ C H E C KA N D A D J U S T M E N T
PARKING
B R A K EC H E C KA N D
ADJUSTMENT
1 . C H E C KT H A TP A R K I N G B R A K EL E V E RT R A V E LI S
CORRECT
P u l lt h e p a r k i n g
b r a k el e v e a
r l lt h ew a y u p ,a n dc o u n t
t h e n u m b eor f cl i ck s .
Parkingbrakalevertravel at 196 N (20 kgf,44.1 lbf):
4-7 clicks
lf incorrect,adjustthe parkingbrake.
2. IF NECESSARY, ADJUST PARKINGBRAKE
HINT: Beforeadjustingth6 parkingbrake,make sure
that the rear brakeshoeclsarancahas beenadjusted.
For shoeclearanceadjustment,see step 9 on pageBR
-66.
(a) Removethe consolebox.
( b ) L o o s e nt h e l o c k n u t a n d t u r n t h e a d j u s t i n gn u t u n t i l
del
the Isvsr travel is correct.
(c) Tightenthe lock nut.
Torque:5.N 4 . m( 5 5k g f . c m . 4 8i n . . l b f )
(d) lnstallthe consolebox.

BR-11
BRAKESYSTEM- MASTERCYLINDER
M A S T E RC Y L I N D E R
REMOVAL
MASTERCYLINDER
LHD Vehicle
S u s p e n s i oUnp p e rB r a c e
BrakeBooster
L e v e lW a r n i n g
Switch Connector
Air Cleaner
A s s e mb l y
w/o ABS
-l
Fs rlr
1158.
3-Way U naon
R H DV e h i c l e
Brak€Booster
L e v e lW a r n i n g
Switch Connector
w/o ABS
N m ( k g fc m , f t l b f) ; Specifiedtorque 809353
a N o n - r eu s ab l e P a r t

BR-12
BRAKESYSTEM_ MASTERCYLINDER
1 . R E M O V ES U S P E N S I OU
NP P E RB R A C E
(a) Removethe 2 bolts,4 nuts and upper brace.
(b) Temporarilyfasten the shock absorberwith the 4
NUIS.
2. R E M O V EA I R C L E A N E RA S S E M B L Y
3. LHD Vehicle(w,/o ABS):

REMOVEWIRE HARNESSCLAMP
BR
4. DISCONNECT
LEVELWARNINGSWITCHCONNEC-
TOR
5, DRAWOUTFLUIDWITHSYRINGE
N O T I C E :D o n o t l o t b r a k a f l u i d r e m a i n o n a p a i n t e d s u r -
f a c e .W a s h i t o t f i m m o d i E t o l y .
6. LHDVehicle:
DISCONNEC BTR A K EL I N E S
w,/o ABS:
UsingSST,disconnectthe brakelinesfrom ths master
c y l i n d ea
r n d3 - w a y u n i o n .
s s T0 9 0 2 3 - 0 0 1 0 0
w/ ABS:
UsingSST.disconnectthe brakelinesfrom th6 master
c y l i n d ea
r n d2 - w a y u n i o n .
s s T0 9 0 2 -3 0 0 1 0 0

8R.13
7. RHDVehicle:
DISCONNEC BTR A K EL I N E S
.r", w/o ABS:
UsingSST,disconnectthe brakelinesfrom the master
c y l i n der a n d 3 - w a y u ni o n .
s s T0 9 0 2 3 - 0 0 1 0 0
w/ ABS:
UsingSST,disconnectthe brakelinesfrom the master
cvlinder.
s s r 0 9 0 2-3 0 0 10 0
8 . R E M O VM EA S T EC RY L I N D E R
Removethe mounting nuts and pull out ths master
c yl i nd e r a n d g ask e t .
"'i"i"Hi

8R.14
BRAKESYSTEM- MASTER
CYLINDER
COMPONENTS
(LHDVehicle)
w/o ABS
cap
I
/.9{
v
w
Strainer f-'a
---\J
S n a pR i n g
'':',1',Fi* No.2
Piston
a n dS p r i n g
I
I
I jm_aoot
Grommet
l^*e@*ul,
o))D)rY<" I
No.'l Piston
C y l i n d e rB o d y and Spring
a Gasket
ReservoirSet Screw
I
P i s t o nS t o p p egr o t t 1 . 71 1 7 . 51,5 . 2 I n . l b f )
w/ ABS
,et\ cap
v
I v 4 - -
ffi
L,/- Strainer
Sn a pR i n g
No.2Piston I
andsPrins
J. ,N-- ,oo,
Grommet
C y l i n d e rB o d y
t-bryCIw N o , 1P i s t o n
andSpring
a Gasket----------------
t ReservoirSet Screw
N m (kof cm, ft lbf) : S p e c i f i e dt o r q u e

a N o n . r e u s a b lp
ea r t

8R.15
BRAKESYSTEM- MASTEEJYlll'llEE
(RHDVehicle)
w/o ABS cap
I
rO)
\_7
Strainer G
)r. z{
\J.l/
5napRing
N o . 2P i s t o n
a n dS p r i n g
N o , 1P i s t o n
and ng
II
ReservoirSet Screw
[l';n?5,15fi.il4----@-
Grornmet
d9
Boot
CYlinder
tsooY
B-piston Bolt
sropper
w/ ABS z-tr)-r
cap---€y'
1Q--s,,'u,nu,
Ng
n a pR ni g
N o . 1P i s t o n
N o . 2P i s t o n
andSpring
II
q
and Spring
fieservoir Set Screw

t7 l1?5j521',.lbfr --------{4.
r$q_
- . A9
r---------
@
-------Grommet
Nd
Boot
I
Cylinder
Body
@-O Gasket
4Piston S t o p p eB
r olt
m ( k g fc m , : S p e c i f i etdo r q u e
a N o n - r eu s a b l eP a r t

BR-16
BRAKESYSTEM_ MASTER
CYLINDER
M A S T E RC Y L I N D E D
RISASSEMBLY
1. REMOVE MASTER C Y L I N D EB
RO O T
Usinga screwdriver,
removethe mast6rcylinderboor.
2. REMOVERESERVOIR
(a) Remov6the set screw and pull out ths reservoir.
(b) R6movsthe cap and strainerfrom the reservoir.
3. R E M O V E2 G R O M M E T S
4. P L A C EC Y L I N D E RI N V I S E
BR
5. REMOVEPISTONSTOPPERBOLT
Using a screwdriver.push the pistonsin all the way
and removetha pistonstopperbolt and gasket.
HINT:Tape the screwdrivertio beforeuse.
6. REMOVEPISTONS
(a) Push in th6 pistonwith a screwdriverand removethe
snap ring with snap ring pliers.
( b ) R e m o v et h e N o . 1 p i s t o na n d s p r i n gb y h a n d ,p u l l i n g
straightout, not at an angle.
NOTICE:lf pulledout at an angle.thero is 8 possibility
that the cylinder boie could be damaged,
(c) Placea rag and 2 wooden blockson ths work tabt6

and lightly tap the cylinderflange againsttho block
edgasuntil th6 pistondrops out of the cylinder.
HINT:Make sure the distance(A) from th6 rag to th6
t o p o f t h a b l o c k si s a t l e a s tI 0 0 m m ( 3 . 9 4i n . ) .

BR.17
B R A K ES Y S T E M- M A S T E RC Y L I N D E R
M A S T E RC Y L I N D E C
RO M P O N E N T S
INSPECTION
HINT:Cleanthe disassomblod partswith compressed
a ir.
1. B O R EF O RR U S TO R S C O R I N G
I N S P E C TC Y L I N D E R
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
lf necessarv, cleanor replacethe cylinder'
M A S T E RC Y L I N D E A
RS S E M B L Y
w/oABS t TO
+€) 1. APPLYLITHIUMSOAPBASEGLYCOLGREASE
\
RUBBER BY ARROWS
PARTSINDICATED
+€)
*
*
*
*
wi ABS I
\
.>9
+€)
*
* k
*
@@tr'r'
2. INSTALL PISTONS
NOTICE: Bacarefulnot to damagetho fubbeilipson tho
pirtons.
(a) Insertthe 2 pistonsstraightin, not at an angl6.
NOTICE: It insorted8t 8n angle,thereis a possibility
that
tho cylinderborocouldbe damaged.
(b) Push in the pistonwith a screwdriverand installthe
snap ring with snap ring Pliers.
HINT:Tape tho screwdrivsrtip beforeuse.
3, INSTALL PISTONSTOPPERBOLT
Usinga screwdriver, pushthe pistonin all the way and
install th€ pislon stopper bolt ovar a new gasket.
Torquetho bolt.
Torque:10 N.m(100 kgf.cm,7 ft'lbf)
4. I N S T A L L2 G R O M M E T S

8R.18
BRAKESYSTEM- MASTERCYLINDER
5. INSTALL RESERVOIR
(a) Installthe cap and strainerto lhe reservoir.
(b) Pushthe reservoironto the cylindar.
(c) lnstallth€ sst screw while pushingon the reservoir.
Torqus:1.7 N.m(17.5kgf.cm,15.2in..lbf)
6. INSTALL MASTERCYLINDERBOOT
Align the grooves on the master cylindarboot and
mastercylind€rflange as shown, installthe cylinder
boot on the mastercvlinder.
M A S T E RC Y L I N D E IRN S T A L L A T I O N
1 . A D J U S TL E N G T HO F B R A K EB O O S T EPRU S HR O D
B E F O R IEN S T A L L I NM
GA S T E RCYLINDER
( S e ep 6 s e B R- 2 5 )
2. INSTALL MASTERCYLINDER
l n s t a l lt h e m a s t e rc y l i n d a ra n d a n e w g a s k e to n t h e
brakeboosterwith 2 nuts.
Torque:13 N m (130 kgf.cm,I ft.lbt)

BR-19
3. LHDVehicle:
TR A K EL I N E S
C O N N E CB
w/o ABS:
UsingSST,connectthe brakelinesto ths master
c y l i n d ear n d3 - w a y u n i o nT. o r q u et h o u n i o nn u t s .
ssr 09023-00100
T o r q u e1: 5 N . m{ 1 5 5k g f . c m 1. 1 f t l b f }
w/ ABS:
Using SST. connect thg brake lines to the master
c y l i n d e ra n d2 - w a y u n i o n .T o r q u st h o u n i o nn u t s .
s s T0 9 0 2 -3 0 0 10 0
T o r q u e : 15 N . m ( 15 5 k g f . c m , 1 1 f t l b f)
4. RHDVehicle:
C O N N E CB
TR A K EL I N E S
w/o ABS:
) U s i n g S S T . c o n n e c tt h e b r a k e l i n e s t o t h e m a s t e r
r n d 3 - w a y u n i o n .T o r q u et h e u n i o nn u t s '
c y l i n d ea
s s r 0 9 0 2-3 0 0 10 0
Torque:15 N.m(155kgf.cm,11 fr'lbf)
W,/ ABS:
Using SST, connoct the brak6 lines to th€ mast6r
cylindar.Torquethe union nuts.
s s T0 9 0 2 3 - 0 0 1 0 0
T o r q u a :l 5 N . m ( 1 5 5 k g f . c m , 1 1 f t . l b f )
5, LHD Vehicle:
C O N N E CW
T I R EH A R N E SC
SL A M P

BR-20
ERAKESYSTEM_ MASTERCYLINDER
6. CONNECT
LEVELWARNING
SWITCHCONNECTOR
7. INSTALLAIR CLEANER
ASSEMBLY
8. FILL BRAKERESERVOIR
WITH BRAKEFLUIDAND
BLEEDBRAKESYSTEM
( S e ep a g e B R- 9 )
9 . C H E C KF O RL E A K S
1 0 . C H E C KA N DA O J U S TB R A K EP E D A L
( S e s p a g e B R- 7 )

BR-21
BRAKESYSTEM- BRAKEBOOSTER
B R A K EB O O S T E R
BRAKEBOOSTER REMOVAL
(LHDVehicle)
w/ABS
S u s p e n s i oUnp p e rB r a c e
C l e v i sP i n
Jcr"ut"
t l cliP
-d
=-r |
l
|
||
fh#i
,YJ1
t l
lfr3,1so,e-l
t-
Gasket
BrakeBooster
f l
-g ,,
lsfu,'rr;x
l $\ ,\ lI
frs{1ii,nr_lI
! _ l
Lower Pad
: S p e c i f i e dt o r qu e
tN;(kgf-cr',rcrpfttut)l
a Non-reusablePart

8R.22 BRAKESYSTEM- BRAKEBOOSTER
(RHDVehicle)
w/ ABS
Lower Pad
HH'
sensor
Vacuum
Assembly
C l e v i sP i n
BrakeBooster Gasket
a Gasket '-'
a T
^,J*'''o
t $mogr_l
lvlaster
Cylinder
\-!?inr
connector
v
T
I- ls t1s5,
rfl
w/ o ABS 3-WayUnion M/T Modal
.""......-----------l Clutch / C l e v i sP i n
13 (130,9t MasterCylinder /
-------.r--.----| | |
./ ,Washer
i
ft
\[ rlhl w-/
6-Hy il
I
1fi*- 15(' r55,
11t
LIp
: S p e c i f i e dt o r qu e
a N o n - r e u s a bpl ser t

8R.23
NP P E RB R A C E
I . R E M O V ES U S P E N S I OU
(a) Removeths 2 bolls,4 nuts and upperbrace
(b) Temporarilyfasten the shock absorberwith the 4
nuts.
2. REMOVELH FRONTWHEEL
3. LHDVehicle:
REMOVE N O I LA N D I G N I T E R
I G N I T I OC
4. RHDVehicle:
REMOVEVACUUMSENSOR ASSEMBLY
5. REMOVEMASTERCYLINDER
( S e ep a g e B R - I I )
Boo- ffffi:'T;
vAcuuMHosEFRoMBRAKE
6. DrscoNNEcr
STER
7. REMOVELOWERPAD
8. REMOVEPEDALRETURN SPRING
9. REMOVECLIPAND PIN
CLEVIS
B R A K EL I N E
10. REMOVE
LHD Vehicle:
(a) Using SST and spanner,disconnectthe brake tubo
from the flexiblehoseof LH front brake,
s s T 0 9 7 5 1- 3 6 0 11
(b) Removethe braketub6 grommotfrom tho body.
(c) Removethe 3 braketubes.as shown in the illustration

f r o m t h e N o . 1b r a k et u b e c l a m p .
-s

8R.24
BRAKESYSTEM_ BRAKEBOOSTER
R H DV e h i c l e :
Remove the bolt from the bodv.
11. REMOVE B R A K EB O O S T E R
1_-/ (a) Removethe 4 nuts.
,qr oc (b) Pullout the brakeboosterand gask€t.
-)/"-
BR
B R A K EB O O S T EIRN S T A L L A T I O N
1. I N S T A L LB R A K EB O O S T E R
(a) Installboosterand a new gasket.
t:-, (b) Connectthe 2 hoses.
'-
(c) Installthe clevisto the operatingrod.
e (d) Installand torque the boosterinstallationnuts.
Torque:13 N.m(130kgf.cm,I ft.lbf)
( s ) I n s e r tt h e c l e v i sp i n i n t o t h e c l e v i sa n d b r a k ep e d a l ,
a n d i n s t a ltl h e c l i p t o t h e c l a v i sp i n .
(0 Installths pedalreturn spring.
2 . I N S T A L LB R A K EL I N E
LHDVehicle:
( a ) I n s t a l tl h e 3 b r a k at u b e st o t h 6 N o . 1b r a k et u b ec l a m o .
Torque:5.N 0 . m( 5 0k g f . c m , 4 3i n . . l b f )
( b ) U s i n gS S Ta n d s p a n n e rc.o n n e c t h 6 b r a k et u b et o t h a
flexiblehoseof LH front brake.
s s T0 9 7 5 1 - 3 6 0 1 1
T o r q u e :1 5 N . m ( 1 5 5 k g f . c m , 1 l f t . l b f )
(c) Installthe brake tube gromm€t to the body.

8R.25
BRAKESYSTEM_ BRAKEBOOSTER
3. I N S T A L LB R A K EL I N E
RHDVehicle:
Installthe bolt to the bodY
Torque:5.0 N.m(50 kgf cm,43 in. lbf)
4. ADJUST LENGTHOF BOOSTERPUSH ROD

(a) Installthe gasketon tho mastsr cylinder.
{b) Set the SSTon th6 gasket,and lower the pin until its
tip slightlytouchssthe Piston.
s s T0 9 7 3 7 - 0 0 0 1 0
.BR
(c) Turn the SST upsidedown, and set it on the booster.

s s T0 9 7 3-7 0 0 0 1
0
(d) Measurethg clearancabotweentho boosterpush rod
and pin head (SST).
Claarance:
0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod
s l i g h t l yt o u c h e s t h a p i n h o a d .
H I N T :W h e n a d j u s t i n gt h e p u s h r o d , d e p r e s st h e b r a k a
pedal enough so that the push rod sticks out.

BR-26
5. LHDVehicle:
INSTAIIIGNITION COILAND IGNITER
6. RHDVehicle:
INSTALLVACUUMSENSOR ASSEMBLY
7, INSTALLMASTERCYLINDER
( S e op a g oB R - 1 1 )
8. CONNECT VACUUMHOSETO ERAKEBOOSTER
9. FILL BRAKERESERVOIR WITH BRAKEFLU]DAND
BLEEDBRAKESYSTEM
(See pagc BR- 9)
10. CHECKFORLEAKS
1 1 . C H E C KA N DA D J U S TB R A K EP E D A L
(SacpagcBR-7)
Check and adjust th6 brake pedal,then tighten the
clevislock nut.
Torquc:25N.m(260kgf'cm,19 ft.lbf)
12. PERFORMOPERATIONALCHECK
!la
E r'r (Seo pago BR-8)

B R A K ES Y S T E M- F R O N TB R A K E ( 7 A _ F E , 3 5 -
F RO NTBR AKE
(7A-FE,35-FE)
COMPONENTS
8 . 3( 8 5 , 7 4i n . l b t )
t""l:
Ir _ l S'l i d i n gP i n
'*fA{ $ l
ir
-.. @{- |
ousteoot
to'o'i
-@
* )sl
I
::-;.
)
\NJ./[i-. -T
r
t-,otniffii..lr-{ -q*
10?
,t
t1,090,79)
|
z
|.
:?* e lll
' \ F )
4^ \ l)I Disc
SetRing " q g 77-\

I
I
'@h a Sliding
Bushing
Pad Su pport
/{"a"-"\
W7
[--
-arr
-\rr7 i
r I
w/l a €b
n l A I I ///) .r,
I 3S-FE(RHD)Vehicle
l ' l /-( , H / / o j n
x{}n,fr
Boot
L " &
S q u eV
al l\l 7t i"l l / l
Ant -
spr n s -ls
\$l
Pad
T
l/
A n t i - S que
S hi m
"
'vw"/{+n
. 9- c $ l=/ll
r {
I n n e rA n t i - S q u e aSl h i m
tN- (kgi""1 ftlbfl] : Specifiedtorque

a N o n - r e u s a bpl ear t
B R A K EP A D SR E P L A C E M E N T
Remove th6 whe€l fastsn tho disc
and temporarily
with tho hub nuts.

BR-28
B R A K ES Y S T E M- F R O N TB R A K E ( 7 A _ F E , 3 5 _ F E )
2. I N S P E C TP A D L I N I N GT H I C K N E S S
C h e c kt h e p a d t h i c k n e s st h r o u g ht h e c a l i p e ri n s p e c -
tion hole and replacetho pads if it is not within the
specification.
Minimum th ickness:
1.0 mm (0.039in.)
3. LIFT UP CALIPER
( a ) H o l d t h s s l i d i n gp i n o n t h e b o t t o m a n d l o o s e nt h e
installation bolt.
(b) Removetha installationbolt.
BR
(c) Lift up and securelysuspendthe caliper.

H I N T :D o n o t d i s c o n n e ctth e f l e x i b l €h o s e f r o m t h e
b r a k ac a l i p e r ,
7 A - F E , 3 S _ FLEH D 4. REMOVEFOLLOWINGPARTS:
7A_ FE,35_ FE LHD:
rl., (a)
tu 2 a n t i - s q u e a sl p r i n g s
K#ffiffi{) € €
(b)
(c)
(d)
(a)
2 brakepads
2 a n t i- s q u e a sl h i m s
4 pad supportplates
33 _ FE RHD:
2 a n t i - s q u s a sl p r i n g s
(b) 2 brakepads
3 S _ F ER H D (c) 3 a n t i - s q u e a sl h i m s
(d) 4 pad support plates
r#pg#il 5. C H E C KD I S CT H I C K N E S S
(SaepageBR- 32)
AND RUNOUT

BRAKESYSTEM
6. INSTALL PAD SUPPORTPLATES

I n s t a l tl h 6 4 p a d s u p p o r tp l a t e s .
cs ,,r\l
7. INSTALL NEW PADS

HINT:lf a brakepad needsreplacing,the front brak6
oads must be replacedas a set.
(a) Apply disc brakegreaseto both sidesof the innerantl
-squealshim.
(b) I n s t a l tl h e a n t i - s q u e a ls h i m so n e a c hp a d .
(c) Install insida pad with the pad wear indicatorplate
f acing downward.
(d) I n s t a l ol u t s i d ep a d .
NOTICE: Thereshouldba no oil or graaseadheringto the
friction surfaces of the pads or the disc.
( e ) l n s t a l tl h 6 2 a n t i - s q u e a ls p r i n g st o t h e p a d s .
8. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the
rgssrvotr.
( b ) P r e s si n t h 6 p i s t o nw i t h a h a m m e rh a n d l eo r a n € q u i v -
al6nt.
H I N T :l f t h e p i s t o ni s d i f f i c u l t o p u s h i n . l o o s e nt h e
bleederplug and push in tho pistonwhile lettingsome
brakefluid escapa.
(c) Installthe caliper.
(d) Hold the slidingpin and torque the installationbolt.

Torque:34 N.m(350kgf.cm.25 ft lbf)
9. INSTALL FRONTWHEEL
1 0 . C H E C KT H A T F L U I DL E V E LI S A T M A X L I N E

BR.3O
B R A K ES Y S T E M_ F R O N TB R A K E ( 7 A - F E , 3 5 - F E )
CALIPERREMOVAL
1 . D I S C O N N E CF
TL E X I B L EH O S E
(a) Removethe union bolt and 2 gasketsfrom the brake
caliper.then disconnectthe flexible hoso from the
calioer.
(b) Use a containerto catch the brak6fluid as it drains
out.
2, REMOVECALIPER
(a) Hold the slidingpin and loosenthe 2 installationbolts.
(b) Removeth6 2 installationbolts.
(c) Removeth6 calip6rfrom tha torque plate.
3. REMOVE2 BRAKEPADS
Removethe insideandoutsideoads.
CALIPERDISASSEMBLY
1. REMOVE C Y L I N D EB
RO O TS E TR I N GA N D C Y L I N .
DERBOOT
Usinga screwdriver, removethe cylinderbootset ring
andcylinderboolfrom the caliper.
2. REMOVEPISTON
(a) Placea piece of cloth or similararticlo betwoenthe
pistonand the caIiDsr.
(b) Use compressedair to remove the piston from th6
cvlind er.
CAUTION: Do not placeyourfingarsin tront of ths piston
when usingcompressed air.

BRAKESYSTEM_ FRONT
BRA
3. REMOVEPISTONSEAL
removethe pistonsealfrom the
Usinga screwdrivgr,
cylind6r.
4, REMOVESLIDINGPINSAND DUSTBOOTS
(a) Removethe 2 slidingpinsfrom tho torqueplate.
and hammer,tap out ths 2 dust

(b) Usinga screwdriver
boots.
F R O N TB R A K EC O M P O N E N T S
I N S P E C T I OANN D R E P A I R
1 . M E A S U RP EA DL I N I N GT H I C K N E S S
, o a s u rteh e p a dl i n i n gt h i c k n e s s
U s i n ga r u l e rm
Standardihicknosr:
12.0mm (0.472in.)
Minimumthickness:
I .0 mm (0.039in.)
Replacethe padsas a set if a pad'sthicknessis at tho
minimumthicknessor less,or if the pad has sevsre
unevenwear.

BR-32
s y s r E M - F R o N TB R A K E ( 7 A - F E , 3 s - F E )
BRAKE
2. M E A S U R ED I S CT H I C K N E S S
U s i n ga m i c r o m e t a rm, e a s u r et h e d i s ct h i c k n e s s .
Standardthickness:
25.0mm (0.984in.i
Minimumthickness:
23.0mm (0.906in.)
Replacethe disc if the thicknessof the disc is at the
m i n i m u mt h i c k n e s os r l e s s R
. e p l a c teh e d i s co r g r i n di t
on a laths if it is scor€dor is worn unevenlv.
3. M E A S U R ED I S CR U N O U T
M e a s u r sd i s cr u n o u t1 0 m m ( 0 . 3 9i n . )f r o m t h 6 o u t € r
edge of the d isc.
Maximumdisctunout:
0.05mm (0.0020in.,
lf runout greatsrthan maximum,attempt to adjustto
b e l o wt h i s m a x i m u mf i g u r e .
BR HINT:Beforemeasuringthe runout,confirmthat the
front bearingplay is within specification.
4. I F N E C E S S A R YA,D J U S TD I S CR U N O U T
(a) Removethe torque platefrom the knuckle.
(b) R e m o v et h e 5 h u b n u t sa n dt h e d i s c .R e i n s t atl hl e d i s c
1/5 of a turn round from its originalpositionon the
h u b .I n s t a l al n d t o r q u et h e 5 h u b n u t s .
Remeasure the disc runout.Makea note of the runour
and the disc'spositionon the hub.
(c) Repear(b) until the disc has been installedon the 3
remaining hubposition.
(d) l f t h e m i n i m u mr u n o u tr e c o r d e di n ( b ) a n d ( c ) i s l e s s
than 0.05 mm (0.0020 in.), install the disc in that
postflon.
(e) lf the minimumrunoutrecordedin (b)and (c)is greater
than 0.05 mm (0.0020in.),replacethe disc and repeat
stop 3.
(0 Installthe torqueplatoand torquethe mounting


BRAKESYSTEM- FRONTBRAK A_FE,35_F
ASSEMBLY
CALIPER
TO
SOAPBASEGLYCOLGREASE
1. APPLYLTTHIUM
WITHARROWS
PARTSINDICATED
2. INSTALL DUST BOOTSAND SLIDINGPINS

( a ) U s i n ga 1 9 m m s o c k s tw r e n c ha n d h a m m e rt,a p i n 2
new dust boots into the torque plate.
(b) Confirmthat the metal plate portionof th€ dust boot
fits snuglyin tho torque Plate.
(c) Ins€rtth6 2 slidingpins into th€ torqu€ plate.

NOTICE:Inse?ttho rlidingpin with tho clidingbushing
into tha bottom side'
3. INSTALLPISTONSEALAND PISTONIN CYLINDER
4. INSTALLCYLINDER BOOT
EOOTAND CYLINDER
SETRING

8R.34 BRAKE - FRONB
SYSTEM T RAKE(7A_FE.35-FE}
CALIPERINSTALLATION
1 . I N S T A L L2 B R A K EP A D S
Installth6 insideandoutsid€oads.
2. INSTALL CALIPER
(a) Temporarilyinstallth€ caliperon the torqueplatewith
the 2 installationbolts.
(b) Hold the slidingpin and torque the installationbolt.
Torque:34 t{'m (350kgf.cm.25ft.lbf)
C O N N E C TF L E X I B L EH O S E
Installthe flexiblehose on the brake calioerwith 2
new gaskots.
Torque:30 N m (310 kgf.cm,22 ft.lbf)
4. FILL BRAKERESERVOIR WITH BRAKE FLUID AND
BLEEDBRAKESYSTEM
(SeepageBR- 9)
5. C H E C KF O RL E A K S

B R A K ES Y S T E M- F R O N TB R A K E ( S S - F E
35, -GE w/o Su
F R O N TB R A K E
( 5 S - F E , 3 5 - G E w / o S u P e rS t r u t
Tvpe)
COMPONENTS
l
S e t Ri n q F
.J
-------S-
- Prn
Slidrno -..\-\
Pad SupportPlare
a Bus|.i-g ---------=-O 12!
)to
a D u s tB o o t
pad Wear Ind,cator p tate
J;___________@f oÂ
l| 6 hu) r{il^:"j,:.-,
u u l# fll/ n ) shm
W lf -
l/:l rl
Anti-squear
sprins------/] t| lJ
4'r
.Nt'i- (kgicm,ft'|Itl i specifiedtorque
a Non-reuse
a bP a r t

BR-36
BRAKEsysrEM - FRoNTBRAKE(5S-FE,
3s-GE w/o superstrut Type)
BRAKEPADSREPLACEMENT
1. REMOVE F R O N TW H E E L
Removeth€ wh6sl and temporarily fastenthe disc
w i t h h u bn u t s .
tion hole and replacethe pads if it is not within the
specification.
Minimumthickness:
1.0 mm {0.039in.)
3. LIFT UP CALIPER
(a) Hold the sliding pin on the bottom and looson the
installationbolt.
(b) Removethe installationbolt.
(c) Lift up and securelysuspendtha caliper.

HINT: Do not disconnectthe flexiblehose from the
ca oer.
t* 4. REMOVEFOLLOWINGPARTS:
ft xLo (a) 2 a n t i - s q u e a ls p r i n g
v(#ffi,h (b)
(c)
2 brakepads
4 a n t i- s q u e a sl h i m s
(d) 4 pad supportplat6s
ry :.uHil 5, C H E C KD I S CT H I C K N E S S
( S e ep a g e B R - 4 0 , 4 1 )
AND RUNOUT

BRAKESYSTEM_ FRONTBRAK 3S-GE w/o Su
INSTALLPADSUPPORT PLATES
Installtho 4 padsupportPlatss.
7. |I{STALL NEW PADS

(a) Installa pad wear indicatorplateon the insidepad.
(b) Apply disc brakegreassto both sidesof the inneranti
-squealshim.
( c ) I n s t a ltl h e a n t i - s q u e a ls h i m so n e a c hp a d .
luh
(d) Install inside pad with the pad wear indicatorplate
facing upward.
(e) lnstalloutsidapad.
N O T I C ET : h e r es h o u l db e n o o i l o r g r o a s os d h e i i n g t o t h e
friction surlaces ot tha pads or the disc.
(f) I n s t a l lt h e 2 a n t i - s q u s a l s p r i n g s
8 . I N S T A L LC A L I P E R
reservolr.
(b) Pressin tho piston with watsr pump pliersor similar
implement.
H I N T :l f t h o p i s t o ni s d i f f i c u l t o p u s h i n , l o o s e nt h e
b l e e d e pr l u ga n d p u s hi n t h e p i s t o nw h i l el e t t i n gs o m e
brakefluid escapo.
(c) lnstallthe caliper.

( d ) H o l dt h e s l i d i n gp i n a n d t o r q u et h o i n s t a l l a t i obno l t .
Torque:34 N.m(350kgf'cm. 25 ft lbf)
9 . I N S T A L LF R O N TW H E E L

BR-38
BRAKEsysrEM - FRoNTBRAKE(5S-FE,
35-GE w/o superstrut Type)
CALlPER
REMOVAL
1 . D I S C O N N E CF
TL E X I B L EH O S E
(a) Removethe unionbolt and 2 gasketsfrom the caliper,
then disconnectthe flexiblehosefrom the caliper.
(b) Use a containsrto catch th6 brakefluid as it drains
out,
2. REMOVECALIPER
(a) Hold the slidingpin and loosenthe 2 installationbolts.
(b) Removethe 2 installationbolts.
(c) Removethe caliperfrom the torque plate.
3. REMOVE2 BRAKEPADS
Rsmovethe insideandoutsideoads.

BR-39
BRAKESYSTEM- FRONTBRAKE(SS-FE,
35-GE w/o SuperStrutT
DISASSEMBLY
CALIPER
1. REMOVE A N DC Y L I N .
C Y L I N D EBRO O TS E TR I N G S
DERBOOT
Usinga screwdriver, removethe cylinder bootsetring
andcvlinderbootfrom the cylinder'
2 . REMOVEPISTON
(a) Placea piece of cloth or similararticle botwosn tho
pistonand lhe caliper.
(b) Use compressedair to remove the piston from the
cvlinder.
CAUTION: Donot plscoyourfingersin tront of tho piston
when usingcompressed air'
REMOVEPISTONSEAL
removethe pistonsoalfrom the
Usinga screwdriver,
cylinder.
4, REMOVE SLIDINGPINSAND DUSTBOOTS

(a) Removethe 2 slidingpinsfrom tho torqueplate.
and hammer,tap out the 2 dust

(b) Usinga screwdriver
boots.

BR-40
BRAKEsysrEM - FRoNTBRAKE(5S-FE,3s-GEw/o superstrut Type)
1 . M E A S U RP
EA DL I N I N GT H I C K N E S S
Usinga ruler,m6asure rhe padliningthickness.
S t a n d a r dl h i c k n o s s :
1 1. 0 m m ( 0 . 4 3 3 i n . )
M i n i m u mt h i c k n e s s :
I . 0 m m ( 0 . 0 0 3 9i n . )
R e p l a c et h e p a d i f t h e p a d ' s t h i c k n e s s i s a t t h e m i n i -
m u m t h i c k n e s s o r l e s s ,o r i f t h a p a d h a s s e v e r e u n e v e n
wsar.
:.-BR
2. M E A S U RD E I S CT H I C K N E S S
U s i n ga m i c r o m e t 6mr ,e a s u rteh e d i s ct h i c k n o s s .
Standardthickness:
2 8 . 0m m ( 1 . 1 0 2i n . )
Minimumthickness:
2 6 . 0m m ( 1 . 0 2 4i n . )
R e p l a c et h e d i s c i f t h e t h i c k n e s so f t h e d i s c i s a t t h e
m i n i m u mt h i c k n e s os r l e s s R . e p l a c teh e d i s co r g r i n di t
on a lathe if it is scoredor is worn unavenlv.
3. M E A S U R ED I S CR U N O U T
M e a s u r sd i s cr u n o u tl 0 m m ( 0 . 3 9i n . )f r o m t h s o u t e r
edge of ths disc.
Maximumdiscrunout:
0.05 mm (0.0020in.)
lf runoutgroatorthan maximum.altempt to adjustto
b e l o wt h i s m a x i m u mf i gu r e .
H I N T :E e f o r em e a s u r i n tgh e r u n o u t ,c o n f i r mt h a t t h e
f r o n t b e a r i n gp l a y i s w i t h i ns p e c i f i c a t i o n .

BR-41
BRAKESYSTEM- FRONTBRAKE(sS-FE,33-GE w/o SuperStrut Type)
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Removethe toruqe platefrom tho knuckle'
(b) Removethe 5 hub nuts and tha disc Reinstallthe disc
hub. Installand torquetho 5 hub nuts'
Torque:103 N m (1,050kgf cm, 76 ft'lbf)
Remaasure the disc runout.Makea notoof this runout
a n d t h e d i s c ' sP o s i t i o no n t h e h u b .
(c) Repeat(b)until tho disc has installedon the 3 rsmain-
ing hubPosition.
(d) lf the minimum runout recordedin (b) and (c) is less
t h a n 0 . 0 5 m m ( 0 . 0 0 2 0i n . ) ,i n s t a l lt h e d i s c i n t h a t
posltlon.
(e) lf the minimumrunoutrecordedin (b)and (c)is greator
than 0.05 mm (0.0020in.),replacetho disc and repeat
steP 3.
,BR
(f) lnstalllhe torqueplatoand torquetho mountingbolts.

Torque:107 N m (1.090kgf'cm'79 tt lbf)

BRAKESYSTEM_ FRONTBRAK 3 5- G E w / o S u
CALIPER
ASSEMBLY
cr{x 1. APPLYLITHIUMSOAPEASEGLYCOLGREASE
TO
666; PARTSINDICATED
WITH ARROWS
h8q
2 . I N S T A L LD U S T B O O T SA N D S L I D I N GP I N S
( a ) U s i n ga 1 9 m m s o c k e tw r e n c ha n d h a m m e r t, a p i n 2
nsw dust boots into the loroue Dlata.
(b) Confirmthat the motal plato portionof the dust boot
fits snuglyin th6 torque plate.
(c) Insert2 slidingpins into th€ torqu6 plate.

NOTICE:Insortthe rlidingpin with slidingbushingI n t o
the bottom sida.
3. INSTALLPISTONSEALAND PISTONIN C Y L I N D E R
I N S T A L LC Y L I N O E B
RO O TAND CYLINDER
BOOT
S E TR I N G

BRAKESYSTEM_ FRONTERAK 3S-GE w/o Su StrutTvpe
CALIPERINSTALLATION
lnstallthe insideandoutsidepads.
2, INSTALLCALIPER
(a) Temporarilyinstallthecalip6ron tho torqus platewith
2 installationbolts.
(b) Hold the slidingpin and torque the installationbolt.
C O N N E C TF L E X I B L EH O S E
lnstall the flexible hose on the caliper with 2 new
gaskets.
Torque:30 t{.m(310kgf.cm,22 ft'lbf)
HINT:Installthe flexiblehoselock securelyin the lock
h o l ei n t h e b r a k ec a l i p e r .
FILL BRAKERESERVOIR WITH BRAKEFLUIDAND

BLEEDBRAKESYSTEM
(SeepageBR-9)
C H E C KF O RL E A K S

BR-44
BRAKEsysrEM - FRoNTBRAKE(3S-cE
w/ superstrut Type)
F R O N TB R A K E
( 3 S - G E w / S u p e rS t r u t T y p e )
COMPONENTS
BR
Removelha wheoland temporarily
fastonthe disc
with tho hub nuls.

B R A K ES Y S T E M- F R O N TB R A K E ( 3 S - G w
E/ S u
I N S P E C TP A D L I N I N GT H I C K N E S S
tion hole and replacethe pads if it is not within the
soecification.
Minimumthickness:
1.0 mm (0.039in.)
3, LIFT UP CALIPER
(a) Hold the slidingpin and loosenthe 2 installalionbolts.
(b) Removethe installationbolts.
:BR
(c) Removethe caliperand suspendit securely.Ensure

that hose is not stretcheo.
HINT: Do not disconnoctthe flexiblehose from the
calroer.
c6q.**
4. REMOVEFOLLOWINGPARTS:
(a) 2 a n t i - s q u e a ls p r i n g s
(b) 2 brakepads
(c) 4 a n t i - s qu e a ls h i m s
o
(d) 4 pad support plates
(e) Pad wear indicator
5. C H E C KD I S CT H I C K N E S S AND RUNOUT
( S e e p a g e B B- 4 9 )
8. INSTALLPADSUPPORT PLATES
Installthe 4 padsupportplates.

BR-46
BRAKEsysrEM - FRoNTBRAKE(3s-cE
w/ superstrut Type)
7, INSTALL NEW PADS
HINT:lf a brake pad needsreplacing,the front brake
pads must be replacedas a set.
(a) Installthe pad wear indicatorplateon a new pad.
(b) Apply disc brakegreas6to both sidesof the inneranti
-squealshim.
( c ) I n s t a l tl h e 2 a n t i - s q u e a ls h i m so n e a c hp a d .
(d) Install insido pad with the pad wear indicatorplate

f acing upward.
(e) Installoutsidspad.
NOTICE: Thercshouldbe no oil or greaseadheringto the
friction surfacorof the padr or the disc.
BR
( f ) I n s t a l tl h e 2 a n t i - s q u e a ls p r i n g st o t h e p a d s .
8 . I N S T A L LC A L I P E R
r€servorrtank.
(b) Press in the pistons with a hammer handle or an
eourva lent.
HINT:lf th6 pistonsare difficultto push in, loosenthe
bleeder plug and push in the pistons while letting
some brakefluid escape.
(c) Install the caliper.

(d) Hold the slidingpin and torque ths installationbolts
Torque:34 N.m(350kgf'cm.25 ft'lbf)
9, INSTALL FRONTWHEEL

BRAKESYSTEM- FRONTBRAKE(3S-GE
w/ SuperStrutT
CALIPERREMOVAL
I . D I S C O N N E CFTL E X I B LH
EO S E
(a) Remove ths unionboltand2 gasketsfromthe caliper,
th€ndisconnect the flexiblehosefrom the caliper.
(b) Usaa containerto catchth€ brakofluid as it drains
o ul .
2. REMOVECALIPER
(a) Hold the slidingpin and loossnthe 2 installationbolts.
(b) Rsmovethe 2 installationbolts'
(c) Removethe caliperfrom the torque plate'
REMOVE2 BRAKEPADS
Removethe insideandoutsidepads.
CALIPERDISASSEMBLY
1. REMOVE C Y L I N D EB A N DC Y L I N .
RO O TS E TR I N G S
DERBOOTS
Usinga screwdriver, romoveth€ cylinderboot set
ringsand cylinderbootsfrom the cylinder.
2. REMOVEPISTONS
{a) Placea piece of cloth or similararticle betweonthe
pistonsand the caliper.
(b) Use compressedair to removethe pistonsfrom the
cylinder,
CAUTION: Do not placeyourfingeruin front of tho piston
when usingcomprassad air.

8R.48
B R A K ES Y S T E M- F R O N TB R A K E ( 3 S - c Ew / S u o e rS t r u tT
3. REMOVEPISTONSEALS
removethe pistonsealsfromthe
Usinga screwdriver,
cvlinder.
4. REMOVE SLIDING P I N SA N DD U S TB O O T S
(a) Removeth6 2 slidingpinsfrom the torqueplato.
(b) Usinga screwdriverand hammer,tap out the 2 dust

boots.
1 . M E A S U RP EA DL I N I N GT H I C K N E S S
, s a s u rteh e p a dl i n i n gt h i c k n e s s .
U s i n ga r u l e rm
S t a n d s r dt h i c k n g s s :
1 2 . 0 m m ( 0 . 4 7 2i n . l
1. 0 m m ( 0 . 0 3 9 i n . )
Replaceth6 pads as a set if the pad'sthicknessis at
the minimum thickness or less, or if the oad has
severeunov6nwoar.

B R A K ES Y S T E M- F R O N TB R A K E ( 3 S - G w
E/ S u Strut T
2. M E A S U RD E I S CT H I C K N E S S
U s i n ga m i c r o m 6 t emr ,e a s u rteh e d i s ct h i c k n e s s .
S t s n d s r dt h i c k n e s s :
2 8 m m ( 1 . 1 0 2i n . )
2 6 m m ( 1 . 0 2 4i n . )
R e p l a c et h e d i s c i f t h o t h i c k n e s s o f t h e d i s c i s a t t h e
m i n i m u m t h i c k n a s so r l e s s .R e p l a c et h e d i s c o r g r i n d i t
on a lathe if it is scorad or is worn unevenly.
3. M E A S U RD E I S CR U N O U T
M e a s u rdei s cr u n o u t1 0 m m ( 0 . 3 9i n . )f r o mt h o o u t e r
e d g eo f t h a d i s c .
Maximumdiscrunout:
0.05 mm (0.0020in.)
lf runoutgreaterthan maximum,atlsmpt to adjustto
below this maximumfigure. re, $
HINT:Beforameasuringtho runout,confirmthat the &B.nI
front bearingplay is within speclfication.
4. IF NECESSARY. ADJUST DISC RUNOUT
(a) Removethe torque platefrom the knuckle.
(b) R e m o v et h e 5 h u b n u t sa n dt h e d i s c .R e i n s t a l l t hdei s c
hub. Installand torquethe 5 hub nuts.
Torqua:107 N m (1,090kgf.cm.79 ft'lbf)
Rsmeasurethe disc runout.Makea note of th6 runout
and the disc'soositionon the hub.
(c) Repeat(b) until ths disc has been installedon th€ 3
remaining hubposition.
(d) lf the minimum runout recordedin (b) and (c) is less
t h a n 0 . 0 5 m m ( 0 . 0 0 2 0 i n . ) ,i n s t a l lt h e d i s c i n t h a t
oosition.
(e) lf the minimumrunoutrocordedin (b)and (c)is greater
than 0.05 mm (0.0020in.),replacethe disc and r6peat
steo 3.
(f) Installthe torquoplateand torquethe mountingbolts.

Torque:107 N.m(1.090kgf'cm. 79 ft lbf)

BR'60
BRAKEsysrEM - FRoNTBRAKE(3s-cE
w/ superstrut Type)
ASSEMBLY
CALIPER
1. APPLYLITHIUMSOAPBASEGLYCOLGREASE
TO
t
@* r PARTSINDICATED
WITHARROWS
@:oo
t
o
,)\?o
I
2. INSTALL DUST BOOTSAND SLIDINGPINS

( a ) U s i n ga 1 9 m m s o c k e tw r s n c ha n d h a m m e r t, a p i n 2
new dust boots into the torque plate.
(b) Confirmthat the metal plate portionof the dust boot
fits snuglyin the torque plate.
(c) Insertthe 2 slidingpins into the torque plate.

NOTICE: Insert the sliding pin ryith tho sliding bushing
into the bottom side.
3, I N S T A L LP I S T O NS E A L SA N D P I S T O N SI N C Y L I N -
DER
4. INSTALLCYLINDERBOOTSAND CYLINDER
BOOT
S E TR I N G S

BRAKESYSTEM- FRONTBRAKE(3S-GEw/ SuperStrut T
C Y L I N D E IRN S T A L L A T I O N
l n s t a ltlh e i n s i d ea n do u t s i d ep a d s .
2 . I N S T A L LC Y L I N D E R
(a) Temporarilyinstallthe caliperon ths torqu€platewith
t h e 2 i n s t a l l a t i obno l t s .
(b) Hold the slidingpin and torque the installationbolt'
Torque:34 N.m(350kgf.cm,25ft,lbf)
C O N N E CFTL E X I B LH
EO S E
Installthe flexible hose on the caliperwith 2
gaskets.
T o r q u e :3 0 N m ( 3 1 0 k g f . c m , 2 2 f t . l b f )
WITHBRAKEFLUIDAND
F|LL BRAKERESERVOIR
BLEEDBRAKESYSTEM
( S a ep a g e B R- 9 )
C H E C KF O RL E A K S

BR-52
BRAKEsysrEM - REARBRAKE(Disc
Brake)
R E A RB R A K E
(DiscBrake)
COMPONENTS
B l e e d e rP l u g
a Gasket
--_%{ h
C al i p er
snri
@-M"in P i nB o o t
S l i d i n gB u s h i n g - - - \
Pad
I
a€P-- tad SupoonPlate
l
SrA
\
llhJ
,m-'"'
(1 I Dust
)( Boot IU l] I ft a.., J,ffil^nti.squeal
\\2,, w il!lftr',;""""
"F "F1W
Pad Support Plate
Nm(kgicm,ftlbf) : S p e c i f i e dt o r q u e
a No n - r eu s a b l ep a n
1. REMOVE R E A RW H E E L
Removeth€ wh6el and temporarily
fastenth€ disc
with the hub nuts.

BR-53
Checkthe pad thicknessthrough the caliperinspec-
tion hole and replacepads if not within specificalion.
Minimumthickness:
1.0 mm (0.039in.)
3. LIFT UP CALIPER
(a) Removetho flexibl€hoss bracket.
(b) Removeth6 insrallationbolt.
(c) Lift up and securalysuspendthe caliper.

HINT: Do not disconnectthe flexiblehose from t h e
calio6r.
4. REMOVEFOLLOWINGPAFTS:
(a) 2 brakepads
r[pTmt (b)
(c)
5.
3 a n t i - s q u e a ls h i m s
2 pad suPPortPlates
C H E C KD I S CT H I C K N E S S
(SeepageBR- 57)
AND RUNOUT

BR-54
BRAKESYSTEM- REARBRAKE(Disc
Brake)
6. INSTALLPADSUPPORT PLATES
Installthe 2 pad plates.
support
7. INSTALL NEW PADS

HINT: lf a brake pad needsreplacing,the rear brake
pads must be replacedas a set.
(a) Apply disc brakegreaseto both sidesof the inneranti
-squealshim.
(b) I n s t a ltl h e 2 a n t i - s q u e a ls h i m st o t h a o u t s i d op a d .
(c) I n s t a ltl h e a n t i - s q u e a ls h r mt o t h o i n s i d ep a d .
(d) Install2 padswith the pad waar indicatorplatefacing
downward.
NOTICE: Thererhouldbe no oil or groa3eadheringto the
triction rurflcas of thc padr oi the disc.
8. INSTALLCALIPER
(a) Draw out a small amountof brakefluid from the
reservoir.
(b) Pr6ssin the pistonwith a hammarhandleor an equiv-
a l6nt,
HINT: lf the piston is difficult to push in, loosenthe
bleederplugand push in th6 pistonwhile lettingsome
brake fluid escape.
(c) Installthe caliperand torquethe installationbolt.

Torquc:20 N.m(200kgf.cm,14 ft.lbf)

(d) Installthe flaxiblehose bracket.
Torque:19 N.m(192kgf'cm.14 ft lbf)
9 . I N S T A L LR E A RW H E E L
CALIPER EMOVAL
1 . D I S C O N N E CFTL E X I B L EH O S E
(a) Removethe unionbolt and 2 gasketsfrom the caliper,
then disconnectthe flexiblehosefrom the caliper.
(b) Use a containerto catch the brakefluid as it drains
o ut.
2. REMOVECALIPER
(a) Removethe installation
bolt.
(b) Removetho caliperfrom the torqueplate.
3. REMOVE2 PADS
REMOVEMAIN PIN
Loosenthe mainpin installation
bolt and removotho
m a i no i n .

BRAKESYSTEM_ REARBRAKE
CALIPER
DISASSEMBLY
1. REMOVE SLIDING BUSHING A N DD U S TB O O T S
Pullout the slidingbushingand removethe 2 boots.
R E M O V EM A I N P I N B O O T
P u l lo u t t h e m a i no r nb o o t .
BR
REMOVECYLINDER BOOTSETRINGAND CYLIN-

D E RB O O T
Usinga screwdrivsr,
removethe cylinderbootset ring
and cylinder boot from the cvlinder.
4. REMOVEPISTON
(a) Placaa piece of cloth or similararticle betweenthe
p i s t o na n d t h e c a l i p e r .
(b) Use compressedair to remove the piston from the
cvlinder.
CAUTION: Do not placoyourfingersin front of the piston
when usingcompressed air.
REMOVEPISTONSEAL
Usinga screwdriver,rsmoveths pistonseal from the
cvlinder.

8R.57
R E A RB R A K EC O M P O N E N TI N
SSPECTION
A N DR E P A I R
EA DL I N I N GT H I C K N E S S
1 . M E A S U RP
Usinga ruler,m€asura the pad liningthickness.
S t a n d a r dt h i c k n a s s :
1 0 . 0 m m ( 0 . 3 9 4i n . )
1 . 0 m m ( 0 . 0 3 9i n . )
R e o l a c et h e p a d s a s a s e t i f t h e p a d t h i c k n e s s i s a t t h e
minimum thickness or less,or if the pad has severe,
uneven wear.
:.BR
2. MEASURE DISCTHICKNESS
moasursthe discthickness
Usinga micromoter,
S t a n d a r dt h i c k n a s s :
1 0 . 0 m m ( 0 . 3 9 4i n . )
9 . 0 m m ( 0 . 3 5 4 i n' )
R e p l a c et h e d i s c i f t h o t h i c k n e s s o f t h e d i s c i s a t t h e
m i n i m u m t h i c k n e s so r l e s s .R e p l a c et h e d i s c o r g r i n d i t
on a lathe if it is scor€d or is worn unevenly.
3. E I S CR U N O U T
M E A S U RD
'l
Measure the discrunoutat 0 mm (0.39in.)f romthe
outor edg€ of the disc.
Maximumdiscrunout:
0.15 mm (0.0059in')
l f t h e r u n o u ti s g r e a t e trh a nt h e m a x i m u mr,e p l a c et h e
disc.
HINT:Beforemeasuringthe runout,confirm that the
h u b b e a r i n gp l a yi s w i t h i ns p e c i f i c a t i o n
4. IF NECESSARY, REPLACEDISC
(a) Removetho torque Plats.
( b ) R e m o v et h e h u b n u t so f t h € t e m p o r a r i liyn s t a l l e d i s c
a n d p u l lo f f t h e d t s c .
{c) Installa new disc and looselyinstallthe hub nuts.

Brake
(d) Install tho torque plate and tighten the mounting
bolts.
Torque:47 N.m (475 kgf.cm, 34 fr.lbf)
CALIPER
ASSEMBLY
t 1. APPLYLITHIUMSOAPBASEGLYCOLGREASE
TO
@ PARTSINDICATED
WITHARROWS
F \aix e
BR
P*@o
R3,!59
2, INSTALLPISTONSEALAND PISTONtN CYLINDER
INSTALLCYLINDER
BOOTAND SETRII{GIN CYL.
INDER
4. INSTALLMAIN PINBOOT

Brake
5. INSTALLSLIDINGBUSHING AND DUSTBOOTS

2
Install nsw bootsandthe bushing.
sliding
C A L I P E RI N S T A L L A T I O N
1. I N S T A L LM A I N P I N
Installthe main pin and torque the main pin installa-
tion bolt.
Torque:27 N.m(270kgf'cm, 19 ft'lbf)
t'di
INSTALL2 PADS
r l a t ef a ci ng
Installpadswith the pad wear i n d i c a t o p
downward.
NOTICE: Thereshouldbe no oil or groaseadheringto the
trictionsurtacesof ihe padsor the disc'
INSTALLCALIPER
bolt.
Installth€ caliperandtorqu€the rnstallation
T o r q u e :2 0 N . m ( 2 0 0 k g f . c m , 1 4 f t ' l b f )
4. C O N N E C TF L E X I B L EH O S E
Install th€ flexible hose on the calipor with 2 new
gaskets.
Torque:30 N.m(310kgf'cm, 22 ft lbf)
HINT:Insertthe flexibl6hoselock securelyin ths lock
hole in the caliper.
R I T H B R A K EF L U I DA N D
F I L L B R A K ER E S E R V O IW
BLEEDBRAKESYSTEM(See PageBR-9)
6. C H E C KF O RL E A K S

BR-60
BRAKEsYsTEM - REARBRAKE(Parking
Brakefor RearDisc Brake)
R E A RB R A K E
(ParkingBrakefor RearDisc Brake)
COMPONENTS
G ui dee P lla t e
lr
I ll "l i ng
S h o eS t r u t
Shim
r k i n g B r a k eS h o e
h) u l s
Lever
S h o eR e t u r n
Pin
_f
c-W a s h e r - q, I
II
Pin-- --\
F r o n tS h o e
R e ar
(*9w^
HoldDown
S pr i ng
@
T e n s i o nS p r i n g
i IrL; (kgGro tf ilrttl : Specified

torque
S h o eH o l d - D o w n
cap
?
Plug
art
PARKING
B R A K ED I S A S S E M B L Y
1. REMOVE R E A RW H E E L
2. REMOVEREARDISCBRAKEASSEMBLY
(a) Rsmovsthe 2 mountingbolts and removethe disc
brakeassembly.
(b) Suspendths discbrakesecurely.
Ensur6
that the hose
i s n o t s t r € t ch 6 d .
3. REMOVEDISC
HINT:lf th6 disccannotbe removedeasily,returnthe
shoaadjusteruntilthe wheelturnsfreely.

BRAKESYSTEM- REARBRAKE(Parking
Brakefor RearDisc Brake
4. R E M O V ES H O ER E T U R NS P R I N G S
U s i n gn e e d l e - n o s ep l i e r s r, e m o v st h e 2 s h o e r e t u r n
spnngs.
REMOVESHOESTRUTWITH SPRING
]BR
6. REMOVEFRONTSHOEAND ADJUSTER
( a ) Slideout the front shoeand removethe shoeadjustor.
( b ) Disconnectthe tensionspring and ramovethe front
snoe.
7. R E M O V ER E A RS H O EA N D T E N S I O NS P R I N G
( a ) Slideout the raar shoe.
( b ) Removeths tsnsionspringfrom the raar sho€.
(c) Disconnectthe parkingbrakecablefrom the parking

brakeshoe lever.
(d) R e m o v et h e s h o e h o l d - d o w n s p r i n gc u p s , s p r i n g s
andDins.

8R-62
BRAKESYSTEM- REARBRAKE(Parking
PARKING B R A K EC O M P O N E N T S
1. INSPECT DISASSEMBLED PARTS
parts for wear, rust or
Inspectthe disassembled
damage.
M E A S U R EB R A K ES H O EL I N I N GT H I C K N E S S
Using a scale, measurethe thickness of tho shos
l i ni n g .
Stsndafdthickness:
2.0 mm (0.079in.)
M i n i m u mt h i c k n o s s :
1 . 0 m m ( 0 . 0 3 9i n . )
l f t h e l i n i n gt h i c k n e s si s a t t h e m i n i m u m t h i c k n e s so r
less, or if there is uneven woar. reolac6 the braka
snoe.
MEASUREDISC INSIDEDIAMETER
Usinga verniercaliper,measurethe insidediameterof
ths disc.
Standardinsidediameter:
170.0mm (6.69in.)
Marimuminsidediameter:
17 1 . 0m m ( 6 . 7 3i n . )
Replacethe disc if the insidediameteris at th6 maxi-
m u m v a l u ao r m o r e .R e p l a c teh o d i s co r g r i n di t w i t h a
lathe if the disc is scoredor is worn unevenlv.
4. I N S P E C TP A R K I N GB R A K EL I N I N GA N D D I S C F O R
PROPERCONTACT
Apply chalk to the inside surface of the disc, then
grind down the brakeshoe liningto fit. lf the contact
betweenthe disc and the brak6shoe liningis improp-
er, repairit using a brakashoe grinderor replacethe
brakeshoe assembly.
Shim MEASURE CLEARANCE BETWEEN PARKING

BRAKESHOEAND LEVER
Usinga feelergaugs,moasu16
the clearancs.
Str ndard clsarance:
L e s s t h a n 0 . 3 5 m m ( 0 . 0 1 3 8i n , )
l f t h e c l e a r a n c ei s n o t w i t h i n t h e s p e c i f i c a t i o n ,r e p l a c e
the shim with one of the correct size.

BRAKESYSTEM- REARBRA Brakefor RearDisc Brake
Thiokncr! mm(an.) Thickn$. mm(in,)
0.3 {0.012) 0.9 (0.035)

0,8 (0.024)
6. IF NECESSARY. REPLACE SHIM

(a) Removethe brakeshoelever,and installthe
parking
correctsizeshim.
(b) Installthe parkingbrakeshoeleverwith a new C-

wasner.
nce.
the cleara
(c) Remeasure

BR-64
BRAKEsysTEM - REARBRAKE(parking
PARKING
B R A K EA S S E M B L Y
HINT:Assemblethe parts in the correctdirection,as
snown.
<F r)
Front Front
BR Left Wheel R i gh t W h e e l
1. APPLY HIGH TEMPERATUREGREASEON BACK.

ING PLATE
Apply hightamperaturogreas€to the slidingsurfaces
shadedof the sho6.
2. APPLYHIGHTEMPERATURE TO AOJUST.
GREASE
ER
<h
aJ!
I
tu
3. CONNECP T ARKING B R A K EC A B L ET O P A R K I N G
BRAKELEVER
( a ) I n s t a lt lh e s h o eh o l d - d o w ns p r i n g sc,u p sa n dp i n s .
(b) Connectthe parkingbrakecableto the parkingbrake
shoeleverof the rearshoe.

BBAKESYSTEM_ REARBRAK arkinqBrakefor RearDisc Brake
4. INSTALL REARSHOE
tr* Slidain the raar shoe botweonthe shoe hold-down
--t- s p r i n gc u p a n d t h o b a c k i n gp l a t e .
//
ilt NOTICE: Do not sllowoil or greaseto got on tho rubbing
\F facg.
..45i" P,
5. INSTALLTENSIONSPRING,FRONTSHOEAND AD.
JUSTER
Front Shoe BearShoe ( a ) I n s t a ltl h e t e n s i o ns p r i n go n t h e r e a rs h o e .
(b) lnstallth6 front shoe on tho t€nsionspring.
(c) Installthe adjustorbetweenthe front and rear shoes.
(d) Slidein the front shoe betweenthe shoe hold-down

s p r i n gc u p a n d t h e b a c k i n gp l a t e .
INSTALLSTRUTWITHSPRING
lnstallthe strutwith the springforward.
7. INSTALLSHOERETURN SPRINGS
pliers,
Usingneedle-nose installtho shoereturnspr-
ings.

BR'66
BRAKEsYsTEM - REARBRAKE(parking
8. INSTALL DISC
(a) Before installing,polish the disc and shoe surfaces
@^
with sandoaDer.
(b) Align tha holaon the rearaxlehub and serviceholeon
th6 disc.
/'r.i=\
f\@/
9. ADJUST PARKINGBRAKESHOECLEARANCE
(a) Temporarilyinstallthe hub nuts.
(b) Removeth6 hole plug.
(c) Turn the adjust6rand expandthe shoesuntil th6 disc
locks.
(d) Returnthe adjuster8 notches.
( e ) I n s t a ltl h o h o l ep l u g .
10. INSTALL REARDISC BRAKEASSEMBLY

Installth6 disc brakeassemblyand torque the 2 mou-
nting bolts.
1 1 . I N S T A L LR E A RW H E E L
1 2 . S E T T L I N GP A R K I N GB R A K ES H O E SA N D D I S C
(a) Drivethe vehicleat about50 kmlh (31 mph)on a sate,
leveland dry road.
(b) With the parkingbrakereleasebutton pushedin, pull
on the leverwith 98 N (10 kgf, 19.8 lbf) of force.
(c) Driveths vehiclefor about 400 meters(0.25 mile)in
this cond ition.
(d) Repeatthis procedure2 or 3 times.
1 3 , C H E C K A N D A D J U S T P A R K I N GB R A K E L E V E R
TRAVEL
(Seepage8R- t0)

BRAKESYSTEM_ PROPORTIONING
VALVI
VALVE(PVALVEJ-.
PROPORTIONING
F L U I DP R E S S U RCEH E C K
1. TNSTALLLSPVGAUGE(SST)
ssr 09709-29017
GAUGE
2. BLEEDAIR FROMFLUIDPRESSURE
3. RAISEMASTERCYLINDER ANOCHECK
PRESSURE
PRESSURE
REARWHEELCYLINDER
-
7A FE Engine:
M.rtar cylindar Prlaaurt Rarr wharl oYllndaroraatulr
2,162 kPr 1.26kel,/cmr,358 pri) 2,1A2kP. 125kcl,/cm',356 P.l)
7,845kPr (80 kstlom',I,l38 p.l) 5,374 kP. (6.1.8ksflomr, 779 p.l)

BR'68
sysrEM - pRopoRTroNrNG
BRAKE vALVE(pvALvE)
35-FE Engine:(LHD)
Mastor cylind6rpralaura Rcrr whgsl cvlindorDrgssurg
2,452 kPa 125kotlcm', 350 pti) 2,152kP.|'25kgf,/cm',358 p6i)
7,845kP. (80 kgt,/cmr,
l,l 38 p.i) 5,374kPa(54.8ksllcm'.779 psi)
3S-FE Engine:(RHD)
Maatcr cylindarpraarur! Roar whc6l cYlind6r pr6ssu16
2,162 kP, 126kgllcm', 350 plil 2,152 kP. (25 kgt,/cm', 358 p6i)
7,845kP! (80 kgt,/cmr,l,l 38 psi) 4,447 kPr (/t5.35kgtlcmr, 645 psi)
55-FE Engine:
M6star cylindarpraltua! Ro!r whool cYlindargr6saura
2,462 kP. \26 kgllcmr, 358 ptil 2,452 kP, 125kgl,/cm',356 p!i)
7.845 kP. (80 kgf,/cm',1,138 pri) 4,4/17kP! (45.35ksl,/cm',845 p.i)
3S-GE Engine:
M!3iar cylindarpralrura Rcrr whool cYlindorDr6ssu16
2,942 kPt l3Oksl/cmt, 127 p.tl 2,942 kPr (30 kgl/cm',127 p6il
7,845kP! (80 kcllcm', 1,138pei) 4,447 kP! (45.35ksflcm', 645 psi)
When inspectingthe fluid pressure,inspoct tho left

front and right rear togethor,and the right front and
left r€ar tog€ther.
lf the r€arwheelcylinderpressur€is incorrect,replace
the P valveassembly.
1. BLEED BRAKE SYSTEM
5. CHECK FOR LEAKS

BR-69
BRAKESYSTEM_ ANTI_LOCKBRAKESYSTEM(ABS)
A N T | - L O C KB R A K ES Y S T E M( A B S )
DESCRIPTION
. This ABS is a brakesystemwhich controlsthe brakecylinderhydraulicpr€ssureof all 4 wheels
during suddenbrakingand brakingon slipperyroadsurfaces,preventingthe wheelsfrom locking.
This ABS providestho followingbenefits:
(1) Enablesstsoring round an obstaclewith a graaterdegreeof certaintyeven when panic
braking.
(2) Enablesstoppingin a panicbrakewhile keepingthe effect upon stabilityand steerabilityto
a m i n i m u m€, v e no n c u r v e s .
. Th6 function of the ABS is to help maintaindirectionalstabilityand vehiclesteerabilityon most
road conditions.However,the syst€mcannot preventthe vehiclefrom skiddingif the cornering
s p e e dl i m i ti s e x c e e d e d .
o The ABS has a deceleration sensorfor superstrut type front suspensionmode['
. In case a malfunctionoccurs,a diagnosisfunctionand fail-safe systemhavo boen adopt€dfor
lh€ ABS to increasoserviceability.

BR.7O
BRAKESYSTEM- ANTI_LOCKBRAKESYSTEM
(ABS)
C O M P O N E N TFSU N C T I O N
Componrnt Function
FrontSoardSrnaor D.bct thc whlcl rp!.d of.rch ot th! l.ft rnd richt front wh!!l!.
RrarSp.!d S!nror O.tcct th! whcll |pr.d of ..ch ol th! lllt lnd rieht r!!r whrllr.
Lieht up to rlrrt thr drivrr whrn troubl. hlr occur.d in thr Anti-Lock
ABSW!rnlngLlght
Bruk! Svrtam.
Control. ih. br.k.lluid pratauru to arch diac brak. cylindcr through .ignrl.
Aoturtor
lrom th. ECU.
Fromthc wharl rpcrd aignrh lrom lrch rlnror. it crlcullirt !cc.l.r!iion,
ABSECU dlcllrrltion lnd alip valur| and rcndr rign.lr to thr lctulior to control
bruk! fluid Drcrrur!.
' Dlorlrrrtlon Slnror D.t.ot th. longitudlnalrnd ht..!l dccrlar|tion vrlu. ol th. v.hiolr .nd !rnd.
! llenrl lccordlngly lo th. ABS ECU.
'For SuperStrutTypeSuspension
Model
SYSTEMPARTSLOCATION
BR
ABSWarningLight
Sonsor
D€c6l€rstion
Sgngor Rotor
ABSActustor
ControlR6l8y
ReerSoeedSansor
S6nsorRotor
FrontSossdSensor
'For SupcrStrutTypcSuspenrion
Model

BRAKESYSTEM- ANTI-LOCK BRAKESYSTEM
W I R I N GD I A G R A M
N E8N
' r - X h E iT &X nE EE
r X h
EE l C O
'rurd 'r - 6
t 5
i..l,d6 866 a th 0,
o 6t: .x
-j
() !6
E E E
nc? x
g :
F
: i a
d) = = ;
c0
Y
I
o
TL
g t
6 ;
d a

tJR.72
BRAKESYSTEM- ANTI_LOCKBRAKESYSTEM
CONNECTORS
ABS Actuator
C O N N E C T OA
R
ABSRslay(R/BNo.s)
CONNECTO
BR
SR +BS GND
SolenoldB6lay Molor Relay
F r o n tS p e e dS e n s o r{ L H ) F r o n tS p e e dS e n s o r( R H ) D E C E L E R A T I OSN
ENSOR
, B R
R e a rS p e e dS e n s o rl L H ) R e a rS p e e dS e n s o r( R H )
A B SE C U
SFLR lGl RL+ FR+ SFRR

SFLH GND PKB RL- MT FR_ MR SFRH
n n
't '1 1 0
E
I n -L; l n
lr--f.--+-{
n
il
LI 8 7 6 3 1 6 5 2
I^^
L': 24
IJ
20 1 9 1 8 1 7
u
to t5
tr IJ
14 12 1 1 10
IJ
il
SRRH GND BAT Tc GGND RR- FSS FL+ | WA SRLR
I
JN RR RR F FL SRLH
e . 8 . 1l e g 5 1 . B i l O 3 € 7
e 2 - l T 1 . . 2 , 1 . Tt h 5 1
F09042

8R.73
BRAKESYSTEM_ ANTI_LOCKBRAKESYSTEM
D I A G N O S IS Y S T E M
DESCRIPTION
lf a malfunctionoccurs,the system will identify the
oroblem and the ECU will store the codss for the
trouble items.
At the samo time, the system informsthe driverof a
m a l f u n c t i o vn i a t h e ' A B S ' w a r n i n gl i g h ti n t h e c o m b i -
nation mater.
By turning on the ignitionswitch, disconnectingthe
short pin of ths ch€ck conn€ctor 1 and use SST to
0.25siL0.25s connectTc and Er of the check connector,the trouble
Lisht oNflfl1.1;1fl code
Normar
1.1fl
1;'1;111; can be identifiedby the numberof blinks(diagnostic
O F FI U U U U U U U U U U U
troublEcode)of the warning light.
0.5s TroubleCod€ ln the ev€nt of two or more codes,that having the
(ln Csss cods 23) smallestnumberedcode will be identifiedfirst'
HINT:The warninglight does not show tho diagnostic r$-
troublecodeswhile the vehicleis running.
SYSTEMINSPECTION
DIAGNOSIS
1. INSPECTBATTERYVOLTAGE
Inspectthat tho batt€ryvoltageis 10- 14 V.
2, CHECKTHAT WARNING LIGHT TURNSON
(a) Turn the ignitionswitch ON.
(b) Check that the 'ABS' warning light rurns on for 3
seconos.
lf not, inspectand repairor replacethe fuse, bulb and
wire harness.
3. READ DIAGNOSTICTROUBLECODE
S h o nP i n Tc
(a) UsingSST,connectterminalsTc and Er of the check
connoctor.
ssr 09843-18020
(b) Pull out the short pin trom the terminalsWA and WB
of ths chock conn€ctor
(c) Turn th€ ignitionswitch ON.
(d) In evEntof a malfunction.4secondslatertho warning

1stDigil 2nd Digit light will beginto blink.Readthe numberof blinks'
(Seepage BR- 75)

BR-74
BRAKE SYSTEM - ANTI-LOCK BRAKESYSTEM(ABS)
HINT: The first number of blinks will equal the first

digit of a 2 digit diagnosticrroublecode. After a 1.5
secondpause,th6 2nd numberof blinkswill equalthe
2nd numberof a 2 digit code. lf there are 2 or more
codes,therewill be a 2.5 secondoausebetweeneach.
Indicationwill start from the smallestand finishat the
largestnumberedcode.This sequencewill be repeat-
ed after a 4 secondsoause.
0.25 (e) lf the syst6m is operatingnormally(no malfunction),

the warning light will blink once every 0.5 seconds.
(f) Repairtha system.
(g) Aft6r the malfunctioningcompon€ntshas been repai-
red, clear the diagnostictrouble codes stored in the
ECU.
(Seepage BR- 76)
BR HINT:lf you disconnecttho batterycablewhile repair-
o.25 ing.all diagnostictroublecodesin the ECUwill erased.
(h) Remove the SST from terminals Tc and E, of tha
check connector.
ssT09843-r 8020
(i) Installth6 short pin to tho terminalsWA and WB.
0) Turn the ignitionswitch on, and checkthat the'ABS'
warning light goesoff after the warning light goes on
for 3 seconds.

BRAKESYSTEM- ANTI-LOCK BRAKESYSTIM
D I A G N O S T ITCR O U B L C
E ODE
Q P.= 6 =
! ? :
. l3 o 9 l
! ;
o,
}
c -l
P E
; 9 ! I i 6 = E
t e > h 9
v a !
c 9.i
3 P b ; - : o
E ; - ; ! - ; 9 :
' Y E 9 6 r t ! 6 . E ;
3 3 e F I e 9 ? l
i(;BE i > - E T;; s ; ;: : ; : ;
.9
3 ] .9 .E
3 ' i
E E ' t
I ! E
.9' I
!
o g
g
E E
! i
I o
o
.g ': = :
o
E f
'd 6
6 ;
i e E
!
E
3 ;
3
5 > o)
o p o 6
o o o o o o o o o
g 3 J 3
g g g g E
6
g
6 6 6
s f i H -
q = q
= =
J -
q ;=
-- =
- ::::. =
= = = = = .'l
C':
c= = = q =
:- ]=] l=-
q =
=-
:= = =
- = = =
*--l --]]l l _-) =
:::) = = = =
---l - = - = = = - q =
- q q = = =
_]]] = = =a
= =
_-l q =
__.l q
= = = = - =
-
z i
oo
z
i c

8R-76
B R A K ES Y S T E M_ A N T I _ L O C KB R A K ES Y S T E M( A
E O D E SC L E A RNI G
C L E A RD I A G N O S T I C
T R O U B L EC O D E S
( a l Turn the ignitionswitch ON.
HINT:Keepthe vehiclestationary.
(b) UsingSST,connsctterminalsTc and Er of the ch€ck
connector.
s s T 0 9 8 4 3- l 8 0 2 0
( c ) Clear the diagnostictrouble cod€s stored in ECU by

depressingthe brake pedal8 or more times within 3
s€conos.
o25 (d) Checkthat the warninglight shows the normalcode.

-! t- (e) Removethe SST from terminalsTc and Er of the
chsck connector.
ssT09843-18020
(f) Checkthat the warninglight goes off.
HINT:Cancellation can also be done by removingthe
-
ECU B fuse,but in this case,other memorysystems
will also be cancelledout.

BR-77
B R A K ES Y S T E M_ A N T I _ L O C KB R A K ES Y S T E MA B S
TROUBLESHOOTING
Problom No.
A l w a y sc o m e so n a f t e ri g n i t i o ns w i t c h e dO N
D o e sn o t c o m e o n f o r 3 s e c o n d sa f t e ri g n i t i o ns w i t c h e dO N 2
" A B S" w a r n i n gl i g h t
G o e so n a n d o f l . 3
C o m e so n w h i l e r u n n i n g .
&"k". p|'ilL X
B r a k i n gi n e f f i c i e n tX. 4
A B S o p e r a t e sd u r i n g n o r m a lb r a k ' n g 4
B r a k ec o nd i t i o n justbeforestopp]Igj{|ngj:,.19!I|ng
ABSoperates
B r a k eo e d a lD U l s a t easb n o r m a l l vw h i l e A B S i s o p e r a t i n g 4
S k i d d i n gn o i s eo c c u r sw h i l e A B S o p e r a t i n g . 5
( A B So p e r a l e si n e f f i c i e n t l Y )
X A l s o c h e c kt h e P a r t so f t h e b r a k es y s t e m( b r a k ec y l i n d e r sp, a d s ,h y d r a u l i cl i n e s ,e t c . )
n o t s p e c i f i c a l lpYa r t o f t h e A B S . ./t3?7

BR-78
BRAKESYSTEM- ANTI-LOCK BRAKESYSTEM(ABS}
" A B S " w a r n i n gl i g h t
1 c o m e sO N .
P u l lo u t t h e s h o r t o i n a n d c o n n e c t e r m i n a l sT c
a n d E r o f t h e c h e c kc o n n e c t o r .
D o e sw a r n i n g l i g h ts h o w t h e l r o u b l ec o d e ? S e ed l a g n o s t i ct r o u b l ec o d e .
( l gn i t i o n s w i t c h e dO N )
D o e sw a r n i n gl i g h t s h o w t h e d i a g n o s t i cn o r m a l . I n s p e c st o l e n o i dr e l a y ,a n d r e p l a c ei f n e c e s s a r y ,
c o d e ?( l g n i t i o ns w i t c h e dO N ) . S h o r tc i r c u i ti n w i r e h a r n e s sb e t w e e ns e r v i c e
c o n n e c t o tre r m i n a lW B a n d s o l e n o i dr e l a V
t e r m i n a lW .
A r ec o n n e c t o rosf E C Up r o p e r l cy o n n e c t e d ? F a u l t yE C Uc o n n e c t o r .
Bi A n da r ea l l t e r m i n a lisn t h ec o n n e c t o r ?
l s t h e r e 1 0- 1 4 V b e t w e e nt e r m i n a ll G l 1 S P o n F a u l t yp o w e r c i r c u i t .
E C Uw i r e h a r n e s ss i d ec o n n e c t o ra n d b o d y
g r o un d ? ( l g n i t i o ns w i t c h e dO N )
NO
D o e sw a r n i n gl i g h t g o o f f w h e n b o t h t h e E C U ( S t a y os n l S h o r tc i r c u i ti n w i r e h a r n e s sb e t w e e nE C U
c o n n e c t o r sa n d s h o r t p i n a r e d i s c o n n e c t e d T t e r m i n a l W Aa n d s h o r t p i n o r w a r ni n g l i g h t .
{ l g n i t i o ns w i t c hO N )

8R.79
BRAKESYSTEM- ANTI-LOCKBRAKESYSTEM
" A B S " w a r n i n gl i g h t d o e s n o t c o m e o n f o r 3 s e c o n d sa f t e ri g n i t i o ns w i t c h e dO N
P u l lo u t t h e s h o r t p i n a n d g r o u n dt h e t e r m i n a l
WA of the checkconnector.
{ l gn i t i on s w i t c h e dO N )
D o e sw a r n i n gl i g h t c o m e o n ? B u l bb u r n e do u t o r o p e nc i r c u iitn w i r eh a r n e s s
betweew n a r n i n gl i g h ta n dG A U G E fuse.
D i s c o n n e cct o n n e c t o r sf r o m E C Ua n d g r o u n d
t e r m i n a lW A o f E C Uw i r e h a r n e s ss i d e
c o n n e c t o r(.l gn i t i o ns w i t c h e dO N )
D o e sw a r n i n gl i g h t c o m e o n ? O p e r c i r c u i ti n w i r e h a r r e s sb e t w e e nE C U
t e r m i n a lW A a n d w a r n i n gl i g h t .
W i t h i g n i t i o ns w i t c ho l f , d i s c o n n e cct o n t r o lr e l a y
c o n n e c t o r sa, n d c h e c kc o n t i n u i t yb e t w e e n
t e r m i n a l sW B a n d G N D o n s o l e n o i dr e l a y .
R e v e r s et e s t e rl e a d sa n d c h e c ka g a l n S h o r tc i r c u i ti n s o l e n o i dr e l a yi n s i d ed i o d e .
l s t h e r eo n e w a y c o n t i n u i t yb e t w e e nt e r m i n a l s T
H I N T : l f t h e d i o d e i s s h o r t - c i r c u i t e da, m a l f u n c t i o na t
E C Ut e r m i n a lW A w i l l o c c u r W . h e n i n s p e c t i n gt h e t e r m i '
n al ,c o n 4 e c t h e E C Uc o n n e c t o ra, n d p ur lo u t t h e s f ' o n p i n '
T h e n t u r n t h e i g n i t i o ns w i t c h O N , a n d c h e c kt h a t t h e
w a r n i n gl i g h tg o e s o n . l f i t d o o s ,t h e E C Ut e r m i n a li s O K ,

BR-80
BRAKESYSTEM_ ANTI-LOCK BRAKESYSTEM(A
3 " A B S " w a r n i n gl i g h tg o e s
o n a n dO F F .
. C h e c kf o r s h o r tc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a T
l c o r T s a n d E 1o f c h e c kc o n n e c t o r .
B r a k e sp u L
a B r a k i n gi n e l f i c i e n t .
4 a A B S o p e r a t e sd u r i n gn o r m a lb r a k i n g .
A B S o p e r a t e sj u s t b e f o r es t o p p i n gd u r i n gn o r m a lb r a k i n g .
B r a k ep e d a p u l s a t e sa b n o r m a l l yw h i l e A B S i s o p e r a t i n g .
P u l lo u t t h e s h o r tp i n a n d c o n n e c t e r m i n a l sT c
a n d E t o f t h e c h e c kc o n n e c t o r .
D o e sw a r n i n gl i g h ts h o w t h e n o r m a lc o d e ? S e ed i a g n o s t i tcr o u b l ec o d e .
( l g n i t i o ns w i t c h e dO N )
Bi
l s e a c hs p e e ds e n s o ri n s t a l l e di n p l a c e ? Speedsensorinstallationfaulty.
A n d i s e a c hi n s t a l l a t i o bn o l tt i g h t e n e ds e c u r e l y ?
T r ys p e e ds e n s o ra n d d e c e l e r a t i osne n s o r Inspectspeedsensor.and replaceif necessary.

d a g n o s i ss y s t e m .l s s e n s o rs i g n a ll e v e lO K ?
T r y s p e e ds e n s o ra n d d e c e l e r a t i osne n s o r Inspectsensorrotor,and replaceif necessary.

d i a g n o s i s y s t e m .l s s e n s o rs i g n a lc h a n g eO K ?
D i s c o n n e ccto n n e c t o rtsr o m E C U ,i n s p e c t
c o n t r n u i t yb e t w e e ne a c hs p e e ds e n s o rt e r m i n a l s
o n w i r e h a r n e s ss i d e .
YES
D o e sa n y a b n o r m a cl h a n g eo c c u ri n c o n t i n u i t y F a u l t yw i r e h a r n e s s .
w h e n t h e c o n n e c t o r os r w i r e h a r n e s so f t h e ( A b no r m aI
s p e e ds e n s o ra n d i n t e r m e d i a tceo n n e c t o r as r e change)
twisted or bent?
NO
( N oc h a n g e )
C o n t i nu e d o n n e x tp a g e .

BR-81
C o n t i n u e fdr o m p r e v i o u sp a g e
l s t h e r ef o r e i g nm a t e r i aol r f e r r i cc h i p so n t h e C l e a nc h i o sf r o m t h e s p e e ds e n s o r .
s e n s o rt i p ?
Try speedsensorand deceieration sensoropera- F a u l t yd e c e l e r a t i osne n s o ro r s e n s o ri n s t a l l a t i o n

t i o n d i a g n o s i s y s t e m l.s s e n s o o OK?
r peration faulty,
I n s p e ctth e a c t u a t oor p e r a t i o n .
l s a c t L r a t oor p e r a t i o nO K 7
5 k r a k es y s t e mo p e r a t i o nisn e f ifc i e n t l y .
A n t i - l o cb
P u l l o u t t h e s h o n p i n a n d c o n n e c tt e r m i n a l sT c
a n d E r o I t h e c h e c kc o n n e c t o r .
D o e sw a r n i n g l i g h t s h o w t h e n o r m a l c o d e ? S e e d i a g n o s t i ct r o u b l e c o d e .
( l g n i t i o ns w i t c h e dO N )
l s t h e r eb a t t e r yv o l t a g eb e t w e e nE C Ut e r m i n a l O p e nc i r c u iitn s t o pl i gh t s w i t c ha n d /o r w i r Bh a r n e s s .
S T Pa n d b o d yg r o u n dw h e nd e p r e s s i nbgr a k e
p e d al 7
lnspectactuator.

BR-82
sysrEM - ANTr-LocKBRAKE
BRAKE sysrEM(ABs)
S P E E DS E N S O RAND DECELERATION
SENSOR D I A G N O S IS Y S T E M
DIAGNOSIS
SYSTEMINSPECTION
PRECAUTION
While checking the rpeed renror diagnoris system, ABS
doos not oporats and brako system operates as normal
broke systsm.
1, INSPECTBATTERYVOLTAGE
Inspectthat the batteryvoltageis 10- |4 V.
2. CHECKTHAT WARNINGLIGHT TURNSON
(a) Turn the ignitionswitch ON.
(b) Check that the 'ABS' warning light turns on for 3
seconds.
lf not inspoctand repairor replacethe fuse, bulb and
wire harness.
(c) C h e c kt h a t t h 6 ' A B S ' w a r n i n gl i g h tt u r n s O F F .
(d) Turn the ignitionswitch OFF.
3. PERFORMFOLLOWINGSTEPS
(a) UsingSST,connoctterminalsTs and Er of the check
connector.
ssr 09843-18020
(b) Start lhe engine.
(c) Check that the warning light blinks about 4 times

w/ o Dsc.l.rstionS€n3or every 1 second,as shown.
0.5s0.13s0.135
w/ DccalarutlonSon3ot
0 . 5 s0 . 5 s0 . 1 3 5 0 . 1 3 5

8R.83
B R A K ES Y S T E M- A N T I - L O C KB R A K ES Y S T E M
4. I N S P E C TD E C E L E R A T I O N S E N S O RA N D S P E E D
N o r m s lS i g n a l SENSOROPERATION
( a ) Stoo the vehicleona levelplacefor 1 secondor more.
0 kn /h -- 45krn/h . g0km/h -0 km/h (SuperStrut Type SuspensionModel)
l 0 m p h ) ( 2 8m p h ) ( 5 0m p h ) l 0 m p h )
( b ) Driv€ the fastor than 45 kmlh (28 mph) for several
seconds.
( c l C h e c kt h a t t h 6 w a r n i n gl i g h ts i g n a tl u r n s O F F .
ON
l f t h e w a r n i n gl i g h t s i g n a li s a b n o r m a lp, o r f o r mt h o
Lrgnt
s t e o s6 a n d 7 .
oFFJrJ"L--i- HINT:
---..l]f- !f- . lf the decelerationsensor operation in stop 4
0 .t 3 s 0.13s 0.135 doss not occur,an abnormalsignalis output.
Abnormal Signal
r T h e h i g h - s p e e d c h e c k i s p o s s i b l ea t 8 0 k m / h
( 5 0 m p h )o r h i g h t e r .
ON
Light
OFF
5. READ DIAGNOSTICTROUBLECODE
(a) Stop the vehicleand the warning light will begin to
blink.
(b) UsingSST,connectthe terminalsTc and Er of check
conn0ctor.

BR-84
BRAKESYSTEM- ANTI_LOCKBRAKESYSTEM(ABS)
(c) R6adth€ numberof blinksof the ABS warning light.

(Seepage BR- 84)
H I N T :l f n o r m a lt,h e w a r n i n gl i g h tb l i n k sa b o u t2 t i m e s
every 1 second.
lf 2 or more malfunctionsare indicatedat the sam6
tim€, the smallestnumberedcode will be displayed
1st.
Code (ExampleCode72' 76)

l\4allunction
,- -:.>-=-\
2
ON
OFF
0 . 5s e c
6. REPAIRMALFUNCTIONINGPARTS
Repairor replacethe malfunctioningparts.
HINT: When reparringor replacingparts, turn the
ignitionswitch to OFF.
7. REMOVESST
Removeth6 SST from terminalsTc. Ts and E' of ths
check conn6ctor.
ssT09843-18020

BRAKESYSTEM- ANTI-LOCK BRAKESYSTEM
EODE
o - . 9 .9 o
o- o ! o o
H !
c
o
- 9 c
c - o
9 x b o o : ;
i 0 Y
r O
t! .Y' ; o) 0 . )o . Y .Y';i !) o o (ri a 6,6
E d, th E 6, tn aci J i
= a a o a a
a a a a a a o a a
E c o
C
c C
q) c o
'6
o
o !
o o) c
1'
!
o o o =
o o.
'. .9
! ;
o o o
'- _9
o C c
o o
c') .9
! z
o o
c)(! ;
3 3 ; 3 -o o)
)o J J < d < a < 6 < a
z i
z F. o)
.) F. F F. t'- F. 1.. F.

8R.86
BRAKESYSTEM_ ANTI-LOCKBRAKE (ABS)
SYSTEM
D E C E L E R A T I OSN
ENSOR
OPERATION
D I A G N O S IS
SY S T E M
PRECAUTION
W h i l e c h e c k i n gt h e d o c e l e r a t i osne n s o ro p e r a t i n gd i -
agnosissystem, the Anti-lock Brake System does
not work and braka system works as normal brake
svstom.
DECELERATIO
SNENSOR
INSPECTION
C H E C KO F D E C E L E R A T I OSNE N S O RO U T P U T
(a) Connect3 dry batteriesof 1.5V in series.
(b) ConnectVGS terminalto the battorios'positive(*)
t e r m i n a la, n dG G N Dt e r m i n a l t ot h e b a t t e r i e sn' e g a t i v e
(-) terminal,apply tension of about 4.5V between
BR V G S - G G N Ot e r m i n a l s .
( c ) C h e c kt h e o u t p u tt e n s i o no f G L I a n d G L 2 t e m i n a l s
Symbols Condition StandardValu6
Hofizontal about2.3V
GLI Lgan lorward 0-about 2.3V
ffill RearSido
Lean raarward
Horirontal
Lorn torwsrd
6bout2.3V-4,5V
6bout 2.3V
about2.3V-4.5V
LSanroarw6ro 0 - a b o u t2 . 3 V
(qb6 HINT:
F r o n tS i d o o lf leanedlargely,the sensormay show the wrong
vatue.
. lf droppsd,the sensorshouldbe replacedwith a
n6w on€.
. The sensorremovedfrom the vehicleshould not
be placedupsidsdown.

A B SA C T U A T O R
ABSACTUATORREMOVALAND
INSTALLAT!ON
Removeand installths parts,as shown.
Br a k eT u b eC I a m p
5.4tss,48In. lbl)
Cushion
I
. l
) \ta-
h B r a k eA c t u a t o r
N o . 3B r 6 c k e t
r->
q9-_
Cushion
B r a k eA c t u a t o r t.----------------.--_
s . . ( 5 5 , 1 8 l nl b, 0
I I
l--T---
@d
Brek€ActuatorBracket
f rr r1r5,r.L-------9
tN- (kgf""anrbfl : Spscified

torque

BR-88
BRAKE sysrEM(ABs)
M A I NP O I N T S
OFREMOVAA
L ND
INSTALLATION
1. DISCONNEC ATN D C O N N E CB
TR A K EL I N E S
UsingSST,disconnect and connectthe brakelines
f rom/lo tho ABSactuator.
s s T0 9 0 2 3 - 0 0 1 0 0
2. BLEEDBRAKESYSTEM
(SeepageBR- 9)
'6ii.

BR-89
BRAKESYSTEM- ANTI_LOCKBRAKESYSTEM(A
ABSACTUATORINSPECTION
1. BATTERY
INSPECT VOLTAGE
POSITIVE
Batterypositivsvoltage:
t0-14 v
2, DISCONNECTCONNECTORS FROM ACTUATOR
Disconnect ths 2 connectors from the actuator.
3. CONNECTACTUATORCHECKER(SST)TO ACTUA-
TOR
( a l Connectths actuator checker(SST)to the actuator
side wire harnessesvia the sub - wire harnesses
(SST),as shown.
s s T 0 9 9 9 0 - 0 0 1 5 0 ,0 9 9 9 0 - 0 0 2 5 0 .0 9 9 9 0 - 0 0 3 0 0 .
0 9 9 9 0- 0 0 3 6 0
(b) Connsct the red cable of ths chsckerto the battery
positive(*) terminaland black cabloto tho negative
( - ) t e r m i n a lC. o n n e ctth o b l a c kc a b l eo f t h e s u b - w i r e
( - ) t e r m i n a lo r b o d y
i:'BR '
h a r n e s s etso t h o b a t t e r yn e g a t i v o
g round.
S u b - W i r eH a r n e s sG ( S S T )
S u b - W i r eH a r n e s sL { S S T )
S u b - W i r eH a r n e s sl {
"SHEETA" (SST)on the actuatorchecker.

{c) Plac6the
TOYOTA ssr 09990-00163
A 3 5 (Anli€k &.r. sv.l.m)
ACrrJ^roRcNtcr(f' ' ,
Lsx€Er
l\
-MOYOR\r-sol€|roo-
/ww / h e i
--- *'4" :-.1
n
v v/ \-/i
.ilq,..:l:;l:':li-'-.,

BR-90
BRAKESYSTEM- ANTI_LOCKBRAKESYSTEM(ABS)
4. INSPECTBRAKEACTUATOROPERATION
TOYOTA (a) Start the engine,and run it at idle.
A A S ( A n tr e r & . r . s Y . l . n )
lclrJAToR ch€o(€R -
sxEEtAi (b) Turn the selectorswitch of th6 actuatorcheckerto
"FRONT
RH" position.
(c) Push and hold in the MOTORswitch for a few sec-
onds.Make sure that you can hearthe motor run.
(d) Depressthe braka pedal and hold it for about 15
seconds,and checkthat the pedaldoes not go down.
(e) With your foot still appliedonto the brakepedal,push

MOTORswitch and check that the brake oedaldoes
not oulsato.
o
F*6=
\=z \v
o
BR
(f) Depressthe brake pedaland hold it. As you hold the

pedaldown,pushand hold in the POWERswitch for a
few seconds.Checkthat the p€daldoes not go down.
NOTICE:Do nol keepthe power switch pushingmore
than 10 seconds.
(s) With your foot still applied onto the brake pedal,
releasethe POWERswitch and check that th6 oedal
goes down.
( h ) With your foot still appliedonto the brakepedal,push

lhe MOTOR switch and check that the brake oedal
returns.
( i ) R6l6asethe brakepedal.
8 R 1 E 1ar2 a O 9
5. EXCEPT'FRONTRH' POSITION:
TOYOTA (a) Turn the selectorswitch to'FRONT LH" position.
Aa a tl.t.l..r ld(. t.rrt'l
lctultd clrlcxtl -
ilrrr A I (b) Repeating(c) to (i) to the stop 5, check the actuator
o operationsimilarly.
-ffi (c) S i m i l a r l yi n, s p e c t ' R E A R

RH'and
-REAR
LH"position.

BRAKESYSTEM- ANTI-LOCK BRAKESYSTEM(A
6. PUSH MOTORSWITCH
TOYOTAs v . l . t l
A S S l A r t i . r a r& . t .
(a) Push and hold in the MOTORswitch for a few sec-
^cluAfoi chfcr(tr , ,
lsHErrA onds.
- MOIOa I a-- SO!E||qO-------J
(b) Stop the engine.
wt r-.1 I
*/#*i
-(, /\ I
V",':i" l-i I
-'*-l
d4:r* I
7. DTScoNNECT ACTUATORCHECKER (SST)FROM

ACTUATOR
(a) Disconn6ct tho actuatorchecker(SST)andsub-wire
harnesses (SST) from tha actuator.
s s r 0 9 9 9 0 -0 0 15 0 ,0 9 9 9 0 - 0 0 2 5 00,9 9 9 0 - 0 0 3 0 0 ,
09990- 00360
(b) Connectthe actuatorconnectors. "dii'*r
(c) Clearthe diagnostic troublecodes.
(SeepageBR-75)

BR-92
BRAKESYSTEM_ ANTI-LOCK BRAKESYSTEM(ABS)
A B SR E L A Y
ABS RELAYINSPECTION
1. INSPECTCONTINUITYOF MOTORRELAYCIRCUIT
(a) Checkthat there is no continuitybetweenterminalsl
and 2.
(b) Check that there is continuity bstween terminals3
and 4.
lf continuityis not as specified,replacethe relay.
2 . INSPECTOPERATIONOF MOTOR RELAY CIRCUIT

(a) Connect th6 positivo (*) lead from ths battory to
terminal3 and negative(-) leadto terminal4.
(b) Check that th6re is continuitv between t€rminals 1
and 2.
lf operationis not as specified,replacethe relay.
3. INSPECTCONTINUITYOF SOLENOIDRELAY CIR-

CUIT
(a) Checkthat thero is no continuityb6tw6enterminals1
and3.
(b) Check that there is continuity betweon t6rminals2
and 3.
(c) Check that there is continuity botw€on terminals4
and6.
4. INSPECTOPERATIONOF SOLENOIDRELAY CIR.

CUIT
(a) Connect th6 positivo (+) lead from the battery to
terminal4 and negative(-) lead to t€rminal6.
(b) Check that thsrs is continuity b€tw6€n terminals 1
and3.
(c) Checkthat there is no continuitybetwe€nterminals2
and3.
lf operationis not as specified,r6placethe rolay.

B R A K ES Y S T E M_ A N T I _ L O C KB R A K ES Y S T E M
F R O N TS P E E DS E N S O R
COMPONENTS
w/ o Super Strut Type w/ Super Strut Type
8 . 0{ 8 2 , 7 2i n . l b f l 8.0(82,72in.lbr)
'iic.i
F r o n tS e n s o rR o l o r F r o n tS p e e d F r o n tS e n s o rR o t o r Front Speed Sensor

Sensor
N m (kqfcm, ft lbf) : S p e c i f i e dt o r q u e
INSPECTION
FRONTSPEEDSENSOR
1. INSPECTSPEEDSENSOR
(a) Disconnsctthe speedsensorconnector.
(b) Measureth6 r€sistanceb6twoenterminalsFR+ a n d

F r o n tL H F r o n tR H F R - , a n dF L * a n dF L -
S p e e dS e n s o r S p e e dS e n s o r
Rosistanco:
FL+ FL- FR+ FR- 0 . 6 - 1 . 8k Q
\ --.-,/ lf resistancevalue is not as specified,replacet h e
e . 21 l r e 2 . 1 T
W 112\$
sensor.

BR-94
BRAKESYSTEM_ ANTI_LOCK (ABS)
ERAKESYSTEM
(c) Checkthat th6re is no continuitybotwoeneachtermt-
nal and sensorbody.
lf there is continuity,replacethe sensor.
(d) Connecttho sp€gdsonsorconn6ctor.
2, INSPECTSENSORINSTALLATION
Check that the s6nsor installationbolt is tight6ned
properly.lf not, tighten ths bolt.
:tr-,:u:t:.111.r.-
f"':3R
3. VISUALLY INSPECTSENSORROTORSERRATIONS
(a) Removethe drive shaft
( S e ep a g eS A - 4 1 , 6 0 , 7 5 )
(b) Inspect the ssnsor rotor serrationsfor scratches,
cracks,warpingor missingt€eth.
(c) Installthe drive shaft.
( S e ep a g eS A - 4 1 , 6 0 , 7 5 )
4. PERFORMSPEEDSENSORSIGNAL CHECK
(Seepage BR- 82)
FRONTSPEEDSENSOR
REMOVAL
HINT:When replacingth6 sensoror sensorharngss,
replacethe sensorand sensorharnssstogetheras a
s6t.
1 . D I S C O N N E CSTP E E DS E N S O RC O N N E C T O R
(a) Removethe fsnder shiald,
(b) Disconnectthe speodsensorconnector.
2, REMOVESPEEDSENSOR
w/o SuparStrut TypoSuspension:
(a) Removetho 3 clamp bolts holdingtho sensorharness
from tha bodv and shock absorber.

8R.95
BRAKESYSTEM- A N T I - L O C K SYSTEM
BRAKE
bolt from the
(b) Removethe speedsensorinstallation
stesringknuckle.
(c) Rgmovethe clamPandsp€edsensor.
w/ SupcrSlrut TYPcSurpcndon:
(a) Removethe 3 bolts from the lower suspensionarm.
(b) Removethe speed sensor installationbolt from the
steeringk nuckle.
INSTALLATION
FRONTSPEEDSENSOR
L INSTALL SPEEDSENSOR
w/o SuperStrut Typc Surpenrlon:
( a ) Installthe speedsonsorto tho steeringknuckle'
Torque:8.0l{.m (82 kgf.cm,71in.'lbl)
I{OTICE: Makoruro thrt-
. Thsr6 are no foreignobjectson the sensoror th€
oart of the knuckleto which the sensoris to be
installed.
. The sensor is install6dflat againstthe knuckle
when you thightenthe bolt.
(b) Installthe clamp to the shock absorberbracketuntil

the clickingsound can be heard.

BR-96
BRAKESYSTEM_ ANTI_LOCKBRAKESYSTEM(ABS)
(c) Installthe sensorharnesswith tho 3 bolts.
w/ SuporStrut Type Suspeneion:

(a) lnstallthe speedsensorto the st€eringknuckle.
Torque:8.0N.m(82 kgf.cm.7l in..lbf)
NOTICE: Mlko rure that-
. Thereare no foreignobjectson the sensoror th6
part of the knuckleto which th6 sensoris to be
installed.
r*En'l r The sensor is install€dflat againsttho knuckt6
when you thightenthe bolt.
(b) Installthe 3 bolls to the lower suspensionarm.
2, CONNECTSPEEDSENSORCONNECTOR
3. PREFORMSPEEDSENSORSIGNAL CHECK
(See page BR- 82)

BRAKESYSTEM- ANTI-LOCKBRAKESYSTEM
(A
R E A RS P E E DS E N S O R
COMPONENTS
8.0182,t2 In. lbt,
Nm ft.rbf) : Specified
torque
INSPECTION
REARSPEEDSENSOR
(-\ I
1. INSPECT SPEEDSENSOR
J
--)
(a) Removethe roarseatbackand decktrim sidepanel'
(b) Disconnectthe spe€dsonsorconnsctor, and pullout
I
e
^
th€ sensorwire harnesswith grommet.
I
R!9418
(c) MeasurE betweenterminals.

tho rEsistanc€
R68r LH R€ar RH Rcdrtanc!:
Soeed Sensor Soeed Sensor 0.8-2.05ko
lf resistanvevalu€ is not as specifiod,replacethe
sonsor.
RL+ RL- RR+ RR-

6-2 2-4.-2-2-R

BRAKESYSTEM- ANTI-LOCKBRAKE
SYSTEM
(d) Checkthat there is no continuitybotweeneachtermi-
nal and sensorbody.
(e) Connecttho sp6sd sensorconnector.
2. INSPECT SENSOR INSTALLATION

Checkthat the sensorinstallationbolt is tight€ned
properly.
lf not,tightonthe bolt.
Torque:8.0 N.m (82 kgf'cm,71 In..lbf)
3. VISUALLY INSPECTSENSORROTORSERRATIONS
(a) Removethe axle hub.
(Seepage SA - 133)
(b) Inspect tho sonsor rotor serrationsfor scratches,
cracks,warpingor missingteeth.
(c) Installth€ axle hub.
(Seepage SA - 133)
NOTICE:To prevent damageto the rorrationr, do not
.t?iko th. axlc hub.
4, PERFORMSPEEDSENSORSIGNAL CHECK
(Seepage BR- 82)

8R.99
BRAKESYSTEM- ANTI_LOCK (ABS}
BRAKESYSTEM
REMOVAL
REARSPEEDSENSOR
(-)
1 . DISCONNECT SPEEDSENSOR CONNECTOR
J
-)
(a) Rsmovethe rsarsoatbackandd6cktrim sidopanol.
(b) Disconn€ctthe soeadsensorconn€ctor, and pullout
I
e
)
the sensorwire harnesswith grommet.
I
P@418
(c) Removethe 2 clamp bolts holding the sensor wira

harnessfrom tho body and shock absorb€r.
REMOVESPEEDSENSOR
the soeedsensorfrom the axlecarri6r,
REmove

BR'100
BRAKE sysrEM(ABS)
REARSPEEDSENSOR
INSTALLATION
1. INSTALLSPEEO SENSOR
Installthe soeedsonsorto tho axlecarrier.
Torque:8,0 N'm (82 kgf.cm,71 In.'lbf)
N O T I C E :M a k e s u r o t h s t -
. Thora lio no to?oign objoctr on the sensor or tho
part of the knucklo to ryhich tho sensoi is to be
installad.
r The renror ll Installodflat against tho knucklo when
you tighton tho blot.
(-) 2, CONNECTSPEEDSENSORCONNECTOR
(a) Feed the sensor harnessconn€ctor back inside the
--) J vehicle,connectths connector.

(b) Installthe deck trim side pansl and roar s€at back.
(-
l )
t rc9418
(c) Installthe gromm€tsecurely.
(d) Installthe sensorharness

with 2 clampsand bolts.
3. PERFORM
SPEEDSENSOR
SIGNALCHECK
(SeepaseBR-82)
\N\\WA!J-A=
1r\\\ -//tm,

BR-101
BRAKESYSTEM- A N T I _ L O CB (A
SYSTEM
KR A K E
A N T I - L O C K B R A K ES Y S T E M
CIRCUIT
SYSTEMCIRCUITINSPECTION
1. INSPECTSYSTEMCIRCUITWITH CONNECTOR
CONNECTED
( a ) Rsmoveth6 ABS ECU.
( b ) Using a voltmetor with high impedance(10 k O/V
3F13!2 minimum),maasurethe voltageat each terminaland
body ground.
SFLR IG1 S,R SFRH

SFLH I GNO ] MR S F R RI
-l_L-L-..]-
rffi -f-f
l lnl I
lr'll#++r rFrfr'-]ff.fil
l l l l l l l
|l-]-1-# r-r-t-l I lt
It-trfrf++r
*T--r-
l4-4#F
+++H+l
i I t-r-r
| I SRLH
I S R R RI R S S
Ft- | AST
SRRH GND WA SRLR Roeoc2
_---':=---1-
"ou",l'J!"" t""
t.ouon
J.""J"%;F;;] Condition
I
Actuator
SFRH "ABS" wa'ning light go€s OFF 1 0- 1 4 V Solenoidrslay
Voltage lG switch ON ard
SFRR wiringharn€ss
"ABS" warning light goes ON ABSECU
lG switch ON and
Voltags Solenoidrslay
"ABS" warning light goes OFF 9 - 14V wiringhErn6ss
lG switch ON and
A B SE C U
FR_ Conlinuity Continuity wiringharness
SRLH "ABS warning l,ghtgoes OFF r0- 14v Solenoidrelay

Voltage t G s w i l c r -O N a r d
wiringherness
SRLR
"ABS"warninglightgoesON A
lG switchON and B e l o w1 . 5V " ABBSE
SC' wUa r n i n g
voltage
l G s w t c hO N a n d" A B S "w a r . i n gl : g h g
t o e sO F F 1 0- 1 4 V lightwiringharness
FL-
R- Continuity
Contlnuity l G s w i t c h O F F
A 8 SE C U
wrnngharness
RL-
l G s w i t c h O N a n d c h e c k c o n n e c t o rT s E r n o l c o n n e c t e d 1 0 - 1 4V
Voltage B e l o w1 . 0V
l G s w i t c h O N a n d c h e c k c o n n e c t o rT s E 1c o n n e c l e d
lG switch ON and PKBlever Pulled E e l o w 1 . 5V P a r k i n gb r a k o
PKA Voltage s w r t c hb r a k e w a l n l n g
lG switch ON and PKBlever returned 1 0- 1 4 V light wiring herness
rG1 vollage lG switch ON 1 0- 1 4 V Fuse

ECU-lG
Conlinuity lG switch OFF Conlinuity W i r i n gh a r n e s s
GND
Acluator
SFLR "ABS" warnlng light goes OFF 1 0- 1 4 V Solenoidrelay
Voltage lG swilch ON and
SFLH wiringharness
RR- Continuity l G s w i l c h O F F C o n t iuni l y
l G s w i t c h O N a n d c h e c kc o n n e c t o rT c E r n o l c o n n e c t e d 10-'t4v
Tc Voltage ------------G A 8 S€ C U
swrtct" otl a"d checr co"necro. rc- r'connecr€o Ab*r 0 V wrnngnarness
lG switch ON and
"ABS" warnrng lights goes OFF 1 0- 1 4 V
Voltag6 "ABS" warning lights goes ON
lG swilch ON end Abort OV

BR-102
BRAKESYSTEM- ANTI_LOCKBRAKE (A
SYSTEM
T.|tar Ch.ck Condltlon Sprclti.d

Conn.cllon Itam Troubl.P.rt
l G s w i t c h O F Fe n d b r a k €p 6 d a t d s p r o s s e d 8 - 14V StoDIoht sw tch
STP volt0ge Stopldhr wlrlng
l G s w i t c h 0 F F a n d b r 6 l € p € d e lr e r u r n € d Eslow1.5V harn6ss
Voltlge l0 - 14v
Conliruily l G 3 w i l c hO F F Conrinuity ABSECU,wiring
GND Continuky l G s w i t c hO F F Continuity Wiring harn6ss
SRRH
voltegs l G s w i t c hO N e n d " A B S " w a r n l n g l i g h t g o € s O F F 1 0- l 4 v Solenoid
relaywiring
\,{6}55
2, INSPECTSYSTEMCIRCUITWITH CONNECTOR
DISCONNECTED
(a) Disconnect th€ connectors
from th6 ECU,inspectat
the wire harnesssideconnector.
Trtiar
Connactlon Ch.ck lt.m sRli',i!o Tro!bl. Prrl Trrlar Chockhrm Se.cltl.d Troublo P!,t
Connac{lon Vrlu.
8ôdy
spr r _ (lrouno Resistanco About5.0tl Acluator saan- [7j;no Re3lstance About 5,0O Actuator
srr n - (lrouno
QodY Rasistanca Aboui 2.2O Actuator snnn* [9j;"0 R€sistance About 2.2 O Aclu6tor
MRgR- Rg3iStanco 56-68n Controlrelsy R6sist!nco 0 , 6- 1 . 8k n FrontLH
spoeds€nsor
Re!lst!nca 06-1.8kO F r o nR
t H ' v , ' H Bodv
speedsensor Ground Conlinuity Continuity Actuator
ResiEtance 7 2 - 8 8 n Controlrelay RR+* RR- Rssistsnce 0.8- 2,05kn R e s rR H
spoedaonsor
Reristanca 0.8- 2,05ko R e a Lr H * [9jy"o RosigtancE
snLa
speedsensor About2.2O Actuator
srnn* [7$ynoR6Sistanco About2.2n Actu6tor snLr* [7j;no RgSistanc6 About 5.0O Actuator
srnx* [7$;"0Ra3istanco About 5.0n Actuator
lf the circuitis not as specified,

checkand repairor
replacoth6 troublepartshownin the tableabov€.
{b) Connsctthe connectors, and installthe ECUin olace.

BR-103
BRAKESYSTEM_ SERVICE
SPECIFICATIONS
S E R V T CSEP E C I F I C A T I O N S
DATA
SERVICE
Brakop6d.l hight from .sphllt.h.6t (LHD) | 5l.9 - 16l.S mm (5.98- 8.37in.)
Br.k. p.d6l hight from ..ph!lt rh..t (RHD) 140.0- 160.0mm (5.50- 5.91in.)
Bruk6 p.dal frolplry I - 0 mm (0.04 - 0.24 in.)
Brak€p.dal res€rvedistanco!t 490 N (50 kgt, | | 0.2 lbf)
Morr th.n 90 mm (3.54 in.)
7 A _ F E ,3 5 _ G E( L H D )
gr!k. p.dal r!!crv. diltanc..l 490 N (50 kgf, 110.2 lbf)
Morcth.n 80 mm {3.14in.)
7A-FE,35_GE (RHD)
8rak6 Dodolro.6rv! dist.nc. !t 490 N (50 kgt, | | 0.2 lbtl
Mor. thln 80 mm (3.14in.)
Brak. p.d6l r.sorv. dist.nc. .t 490 N (50 kot, I I0.2 lbf)

Mor. th.n 0Omm (3.54In.l
35-FE {LHD)
Br.k. pcdalre!.rvc di!t!nc. .l 490 N (50 kof. 110,2lbf)
Mor! thln 80 mm (3.14in.)
35-FE IRHD)
Brak. boostgr DUlh .od to pilton clrlrrnc. (w/ SST) 0 mm (0 in.l
Front brtk. prd thickn...
12.0mm (0./t72in.)
7A-FE,3S-FE STD
Frontbrukopadthicknc8r
l.o mm (0.039in.l
7A-FE'3s-FE Limit
Front brakc pad thickng!!
I 1.0mm (0.433in.)
5s-FE,35-GE (w,/o supor strul Sulp.mion Typa) STD
Front br.k. pad lhickn6.a

1.0mm (0.039in.)
55-FE,35-GE (w/o Suplr Strul Sulp.n.ion Tvp!) Limit
Front br.k. p.d thickn.!.
12.0mm 10.472in.l
3S-GE (w/ Suplr Strut Susprnlion Typ.) Sfo
Front br.ka prd thioknc!!

1.0mm (0.039in.)
3S-GE (w/ Supor Strut Sulpcnlion TYp.) Limit
Front br.k. dirc thickn... 7A-FE, 3S-FE STD 26.0mm (0.984in.)
Front br.k. di.c thickn.!. 7A-FE,3S-FE Limlt 23.0mm (0.906in.)
Frontbr.k. dilo thickno!. sS-FE,3S-GE SfD 2 8 . 0m m( 1 . 1 0 2i n . )
Frontbrrkr dirc thickn$. ES-FE,3S-GE Limit 28.0mm (1.024in.)
Front b.k. dilc runout Limlt 0.05 mm (0.0020in.)
tterr b.rko p.d thicknoss STD | 0.0 mm (0.394in.l
R..r br.ka D.d thicknc!! Limit 1.0mm (0.039in.)
R6.r br.k6 dilc thickno.s STD 10.0mm (0.394in.)
R6ar br.k. di.c thickne.t Limit 9.0 mm (0.364in.)
R..r brlkr dilc insidc thickn.!. STD | 70.0 mm (6.89 in.)
Re!. brlkc dirc inridr ihicknllt Llmit | 71,0mm {8.73in.)
Plrking br.kc liningthickn.[ for rclr dilc brlkc STD 2.0 mm (0.079in.)
Plrkine br.k. lininc thickn.$ tor rclr di.c b.!kr Limit 1.0mm (0.03Sin.)
Psrkin€brak6 .djurting .him thickncaa 0.3 mm (0.012in.)
0.6 mm 10.024In.)
0.9 mm (0.035in.)

BR-104
BRAKESYSTEM_ SERVICE
SPECIFICATIONS
TOROUE
SPECIFICATIONS
Part tightoned N m kgf.cm fr.tbt
Mast6r cylinderx Pistonstoppor bolts l0 100
Mast€r cylind6rr R6sorvoir 1.7 1 5 . 2 i n .l b f
Mastor cylindorx Brake boostsr 130 9
Brske lin€ union nut t5 lt
Brakeboostorclovis lock nut 260 r9
Brakeboost€rx Pedalbracket l3 130 I
Front disc broks cylinderinstallatiohbolt 34 350 25
8 1 s 6 d opr l u g 6 8.3 74 in..lbl
Flexiblehos6 brackotr Shock absorb€r 19 192 l4
Front disc brak€to.quo plats t Ste6ringknuckl€ 900 65
Front disc brakocylindorx Floxiblohose 30 3lo
Rea. drum b.ak6 wheel cylindorx Back|ngplate 10 100 7
R6ar disc brako torauo olat6 x Axle carn6r 47 475 34
R66rdisc brako cylind6rx Floxibl6ho6o 30 3t0
ABS actuator brackot x Bodv io 195 l4
ABS actuator x ABS actuator br.ck6t 5.4 cc 48 in..lbf
Front so6edsensorinstallationbolt 8.0 a2 7l in..lbf
R6arsp66dsonsorinstallationbolt 8.0 g2 7l in..lbt

SR.1
STEERING
G E N E R ADL E S C R I P T I O N . " . ' SR- 2

TROUBLESHOOTING """ " "" SR_ 2
O N- V E H I C L E
INSPECTION JFI _ Z
COLUMN
STEERING
.....5|.l-
PREPARATION."....' 3
ASSEMBLY R E M O V A LA N D
INSTALLATION.,....." Dn- |
N O N- T I L T S T E E R I NC
GO L U M N sR- 10
T I L TS T E E R I N C
GO L U M N )i{ - lO
STEERING
POWER
DESCRIPTION " sR- 27
OPERATION DN_ JI
PREPARATION )n- Jo
O N- V E H I C L IEN S P E C T I O N SR- 39
P O W E RS T E E R I N P
GU M P
(7A_FE)............ . . . . . , . . .s. .R _ 4 6
P O W E RS T E E R I N PGU M P
( 3 S - G E , 3 5 - F E . 5 5 - F E )" " " " " sR- 58
G E A RH O U S | N G . . . . . . . . . . . . .s.R _ 7 0
" "s
s E R V l csEP E c l F l c A T l o N "" sR-99

sR-2 - O N _ V E H I C L IEN S P E C T I O N
STEERING
GENERAL
DESCRIPTION
. Care must be taken to replace parts proporly bacause thoy could affoct tho p"rfotlnance dTili'e
stearing system and result in a driving hazard.
o T h e s t o e r i n g w h e e l p a d h a s a n a i r b a g b u i l t i n , s o t a k e a l l d u e p r a c a u t i o n aw h o n h a n d l i n gi t . F o r
more details, 8ee the RS sgction.
TROUBLESHOOTING
Useths tablebelowto helpyou find the causeof the problem.
Thenumbersindicatetne prilfiii'v
of the likelycausoof the problem.
Checkeachpartin ord€r.lf necessary,
r€plac€thes6parts.
l'.
@ N o
See page rt) C'
cc cc E E
@ r/)
Parts .g ;
Namo c o
q)
E '6
q, .:
' o
q, E E
o --) ) J
o
c E
: o
E
; '- ,
Trouble .z
t
F o U) o a
Hardsteering 1 a 5 5 6 1 8
Poor return 1 5
play
Excessive 1 5
Abnormalnoise
!{q114
ON_VEHICLE
INSPECTION
CHECKSTEERINGWHEEL FREEPLAY
With tho vehiclestopped and tires pointsd straight
ahoad,rock the steeringwho6l gently back and forth
with light finger pressure.
Freeplayshouldnot exceodthe maximum.
Maximumfreeplay:30 mm (1.18 in.)
lf incorrect,repair.

sR-3
STEERING_ STEERING
COLUMN
S T E E R I NC
GO L U M N
N O N- T I L T S T E E R I NC GO L U M N :
column.
T h i ss t e e r i n cgo l u m ni s a n o n - t i l t s t s s r i n g
C o l u m nU P P eBr r a c k e l
Ste€ring
Wheel
C o l u m nC o v e r
C o l u m nU P P eCr l a m P
lntermediale
Shaft
R09696
R09697

_ S T E E R I NC
STEERING GO L U M N
T I L TS T E E R I NC GO L U M N :
T h i ss t e e r i n cgo l u m ni s a m a n u atli l t s t e e r i ncgo l u m n .
C o l u m nU p p e rB r a c k e t
l g n i t i o nS w i t c h
T i l t L e v e rR e t a i n e r
T i l t N o . 2B o l t
o-
C o l u m nU p p e T
r ube
I
I E I E
$'n O-
M a i nS h a l t
A ss e mb l y
/ / Compression
M a i nS h a f i Bearing / Spring S t e e r i n gW h e e l
Bushing
C o l u m nL o w e r
BearinT
g h r u sC
t ollar
Tube
T i l t L e v e rA s s e m b l y
T € n s i o nS p r i n g
C o mp r e s s i oS
npring
lnlermediate C o l u m nU p p e rC l a m P
S ha l t

_ STEERING sR-5
STEERING COLUMN
PREPARATION
ssT (sPEcrAL TOOLS)
SERVTCE
0 9 6 1 2 - 2 2 0 1 1 T i l tH a n d lBoo s r i nRgo p l s c o r Main shatt bushing
(Non-tilt sto6ringcolumn)
Set
G€arBoxRoplacor
09620-30010 Steorins
@.
ffi*'
( 0 9 6 2 4 - 3 0 0 1St6€ring
0) SoctorShaftOil S6al Main sheft bushing
@. R€plac€r (Tiltsteer;ngcolumn)
\7
-3ooro)
(09626 StseringWorm FrontBoaring Main shrft bushin€
I Rgplac€r Oilt steeringcolumn)
(09631-00020) Main shaft bushing

Oilt stooringcolumn)
€--<'
09904-00010 ExpsndorSet
Snapring
(09904-00040) Snapring
-rys
drF 0 9 9 1 0 - 0 0 0 1 5 P u l l oSr € t
(09912-00010)PullorslidoHsmmor Tih No.2 bolt

sR-6 STEERING- STEERING
COLUMN
09950-40010Pullor
B sot
(09957-04010)Att chmont Main shrfl asssrnbly
g Cfiltstooringcolumn)
(09958-04010)flolder M.in 3h!ft assombly

Oilt .tooringcolumn)
09950-50010Pullor
c sst
€<-:.6P
(09951-05010)Hlnsorts0 Stosringwheel
(09952-05010)sl;deArm St6oringwhs€l
uLtll
€ <9
(09953-05020)c€nt6rBolt150 Ste6ringwhool
(09954-05020)ctawHo.2 Stoeringwh6ol
%
RECOMMENDED
TOOLS
09042-000'10 TorxsockotT30 Stoeringwhool pad
(w/ SRSAirb8g)
EOUIPMENT
Torquowrench

- STEERING sR-7
STEERING COLUMN
A SSEMBLREMOVA
Y AN
L D
INSTALLATION
COMPONENTS
w / SRsAirbag S l s €r i n gW h e e l
Bolt
r o c kR e l e a s e
S e n s oL Pad
8 . 8 ( 9 0 ,7 8 1 n . ' l b f )
n f..(3so'r5)'l
No.3Cover\ \, N o . 2C o v e r
S S l e e r i n gW h e e l S t e e r i nW
g heel
Torx Screw Pad
S t € e r i n gC o l u m nA s s e m b l Y C o l u m nU p p e r
Cluster Lower
Finish Cover
Panel
R e g i s l eNr o . 2D u c t
C o m b i n a t i o nS w i t c h
C o w lS i d eT r i m
B o a r dL H
C o l u m nL o w e r
-6
F r o n tD o o rS c u l lI n s i d eP l a t eL H
N m ( k g fc m ,l t l b f) : S p e c i l i etdo r q u e

sR-8 _ S T E E R I NC
STEERING GO L U M N
M A I NP O I N T S
OFREMOVAL
AND
INSTALLATION
1. REMOVESTEERING WHEELPAD
w/o SRSAirbag:
(a) Remove ths screw.
(b) Remove the 3 clips.
w/ SRSAirbas:
CAUTION:Whon the steeringwheel pad is removed,
alwaysplaceit on I stableflat placawith the pad surface
facingupwards.Neverplaceanythingon top of tha pad.
W
(a) U s i n g a s c r e w d r i v e rr,e m o v e t h e N o . 2 a n d N o . 3
covars.
li) 'i HINT:Tape the scrswdrivertip beforeuse.
(b) Using a torx socket wrsnch, loosenthe sensor lock
:
,r,,$R releasebolt until it turns freelv.
(c) Slidethe bolt cap downwaros.
(d) Usinga torx socketwrench,loosenthe 2 torx screws.
HINT: Loosenth6 screws until the groova along the
screw circumferencecatchoson the screw case.
(e) Pull the stoering wheel pad out from tho steering
wn6st.
CAUTION:
. Whon storingthe wheolpad,keepthe upper3urface
of the psd facing upward.
. Neverdisastembletho steeringwhael pad.
Replacetho ste6ringwheel pad with a new one if:
(SeeRS section)
. Th€ SRS has deployed.
t- . The pad surface,airbag sensor or inflator has
dents,cracksor deformation.
r The SRS has been droooed.
2, REMOVESTEERINGWHEEL
[,4atchmarks
(a) Removeth6 wheol set nut.
(b) Placematchmarkson the whool and main shaft.
(c) UsingSST,remov6the who€|.
s s T 0 9 9 5 0 - s 0 0 10 ( 0 9 9 5 1- 0 5 0 1 0 )
( 0 9 9 5 2- 0 5 0 10 )
(099s3- 05020)
( 0 9 9 s 4- 0 5 0 2 0 )

sR-9
STEERING- STEERING
COLUMN
3. DISCONNECT AND CONNECT INTERMEDIATE

SHAFT
(a) Placematchmarkson the intermediatsshaft and intsr-
mediateNo.2 shaft.
(b) Removeths bolt.
(c) Disconnectthe intermediateshaft.
(d) Align the matchmarkson ths intermediateshaft and
intermsdiateNo.2 shaft, and connectthem.
(e) Torquetho bolt.
Torqua:35 N.m(360kgf cm, 26 ft'lbf)
4. INSTALL STEERINGWHEEL
(a) s n t h e w h e s l a n d m a i ns h a f t ,
A l i g nt h e m a t c h m a r k o
and installit.
(b) Torquethe wheel sat nut.
Torque:34 N'm (350 kgf'cm. 25 ft'lbf)
5. INSTALLSTEERING WHEELPAD
w,/o SRSAirbag:
Installthe padwtth the screw.
w/ SRS Airbag:
N O T I C E :N o v e r i n s t a l l a p a d w h i c h h a s b o a n u s e d i n
a n o t h o r v e h i c l o ,W h s n r o p l a c i n gI p a d , a l w a y s i n s t a l l a
now pad.
(See RS section)
( a ) C h e c k t h a t t h 6 s e n s o r l o c k r e l e a s eb o l t i s l o o s e n e d s o
that it turns without resistance.
(b) Set tha pad in th€ stoering wh€el.
(c) Using a torx socket wrench, torqu€ the 2 torx screws.
Torque:8.8 N.m (90 kgf'cm,78 in. lbf)
N O T I C ED : o n o t p i n c ht h o h o r n b u t t o n o f w i r a h a r n e s sf o r
ths cruiso contlol system.
(d) Cover tho torx screw with the bolt cap.
(e) Using a torx socket wrench, torque the sonsor lock
r e l e a s eb o l t .
Torque:8.8 N.m (90 kgf cm,78 in.'lbf)
W
lr) .-i
(f) Installthe No.2 and No.3 covers.
NOTICE:Confirm lhat tho lowor covera ars properly in'
rtalled.
6. CHECKSTEERING POINT
WHEELCENTER

sR-10 - STEERING
STEERING COLUMN
N O N - T I L TS T E E R I NC
GO L U M N
COMPONENTS
Aff :
Key Interlock
Sol6noid
q-.
U n l o c kW a r n l n g
Switch
lgnltion
K e yC y l i n d e r
llluminalion
C o l u m nU p p € Ksy Cylind€r
Bracket C o l U mT
nube
lgnitlon
Swilch
a M a l nS h a f tBu s h i n g ColumnProtector
I
ffi eoir
-i$h
O Tapered-Head 1u
b-l-l., (50,4t",tbr) I
'%a .----{4.
<} Snap ning -J---$\l
T
lnterm6diats
Shaft
N.m tl : Speclfiedtorque
part
a Non-rousable
+ Molybdenum
disulphld6
lithiumbaseg16ase

_ S T E E R I NC sR-11
STEERING GO L U M N
GO L U M ND I S A S S E M B L Y
S T E E R ] NC
1. REMOVE NE YC Y L I N D EIRL L U M I N A T I O N
I G N I T I OK
2, REMOVE I N T E R M E D I AS HAFT
TE
(a) Removethe bolt.
(b) Shiftthe shaft.
(c) Placematchmarks on the intormediate shaftandmain
shaft.
lVatchmarks
(d) Removethe shaft.
3, C O L U M NP R O T E C T O R
REMOVE
Remove the bolt.
4. REMOVE COLUMN UPPER BRACKET AND

CLAMP
C O L U M NU P P E R
(a) Securethe columntube ana vis6.
NOTICE: Do nqt tightsnths visetoo tight.
(b) Using a centeringpunch, mark the centsr of the 2
taoered-head bolts.
( c ) U s i n ga 4 - b m m ( 0 . 1 6 - 0 . 2 0 i n . )d r i l l ,d r i l li n t o t h e 2
bolts.
(d) Usinga screw extractor,removethe 2 bolts.
5. R E M O V EM A I N S H A F T A S S E M B L YW I T H M A I N
S H A F TB U S H I N G
c ( a ) S e c u r et h e c o l u m nt u b e i n a v i s a .
NOTICE: Oo not tightonths visotoo tight.
( b ) U s i n gs n a pr i n g p l i e r s r. E m o v et h e s n a pr i n g .
\

GO L U M N
STEERING
(c) Using a brass bar and hammer, tap out the shaft
assemblywith ths bushing.
NOTICE:Takecara not to drop tho shaft assembly.
Y
MainShaft
B u s hi ng
MainSh8ft
Assembly
( d ) Socuretho shaft assemblyin a vise.

NOTICE:Do not tightenthe visetoo tight.
(e) Usingsnap ring pliers,removethe snap ring.

- STEERING
sR-13
STEERING COLUMN
GO L U M NI N S P E C T I OANN D
S T E E R I NC
REPLACEMENT
T E YC Y L I N D E R
1 . I N S P E CK
opsratospro-
Checkthatths steeringlockmechanism
PerlY.
2. IF NECESSARY, REPLACEKEY CYLINDER

(a) Placothe ignitionkey at the ACC position.
(b) Push down ths stop pin with a screwdriver.and pull
out the cylindsr.
(c) Installa new cylinder.
HINT:Make suro the ignitionkey is at the ACC posi-
t ion.
FO96o9
IF NECESSARY,REPLACE U N L O C K W A R N I N G
swtrcH
( a ) Removethe 2 scrsws.
( b ) Tightenthe 2 screws.
4. IF NECESSARY, REPLACE SOLE-

KEY INTERLOCK
NOID
A/Tt
(a) Rgmovethe 2 screws.
(b) Tightenthe 2 scrsws.

sR-14
STEERING- STEERING
COLUMN
5. IF NECESSARY, REPLACE
IGNITIONSWITCH
(a) Removethe 2 screws.
(b) Tightenthe 2 screws.
6. I N S P E C TC O L U M NT U B EB E A R I N G
Check the bearingrotation conditionand check for
a bnormalnoise,
lf the bearingis worn or damaged,replacethe column
tube.
S T E E R I NC
GO L U M NA S S E M B L Y
N 1 . C O A TW I T HM O L Y B D E N UDMI S U L P H I DLEI T H I U M
B A S EG R E A S(ES a ep a g eS R - 1 0 )
2. INSTALLMAIN SHAFTASSEMBLY
f / . \ - (a) Securethe shaftassembly in a vise.
\ l NOTICE:Do not tightontho visetoo tight.
(b) Usingsnap ring pliers,installa new snap ring.
.'tVl)
(c) Installtha shaft assemblyto the columntube.
(d) Securethe columntubo in a vise.

NOTICE:Do not tlghtcn tho viso too tight,
(e) Usingsnapringpliers,installa new snapring.

_ STEERING sR-15
STEERING COLUMN
3. INSTALLMAIN SHAFTBUSHING
UsingSST,pressthe bushingintothe tubo.
s s T0 9 6 1 2 - 2 2 0 1 1
N O T I C E :G e n t l y p r e r l t h o P l l s t i c b u r h i n g i n t o t h e t u b e .
4. INSTALL COLUMN UPPER BBACKET AND

COLUMNUPPER CLAMP
(a) Securothe columntubo in a vise'
I{OTICE:Do not tighten the visc too tight.
(b) Tighten2 new tapered-head bolts until ths bolt head
breaks off.
5. INSTALLCOLUMNPROTECTOR
Torqu6th€ bolt.
Torquo:4.9 N.m (50 kgf.cm,43 in.'lbf)
6. INSTALL If{TERMEDIATESHAFT
(a) Align the matchmarkson ths intermsdiatsshaft and
controlvalvoshaft,and installthe shaft.
(b) Torquethe bolt.
Torquc:35 I{.m (360 kgf.cm' 26 ft'lbf}
7. INSTALL IGI{ITIOT{ KEY CYLINDERILLUMINATION

sR-16 _ STEERING
STEERING COLUMN
TILTSTEERINC
GO L U M N
COMPONENTS
t"'f'nn't"*'
a E'Ring-.@ ^ a .n"o.r'*$
^
"o,,^,-/'66! -:d{_!;'r]':'"'J$/ rurnsisnal
Bracke,
T*Y,.)ry(p, &ir--r**;,n
T i l tL € v e rL o c kS h a l l .l'il;.Qffi*:;.-y
--.">\r11',>PiU -t--q\}_ ,_ _,
L " T i l rL e { tP a w l - + 9 -
Bearing
t--
rI T r l tL e v e rA s s e m b l y
M a i nS h a l tA s s e m b l y t - r
Compression-\\
Spring
B e a r i n gT h r u s tC o l l a r
Tension
Spring
T i l tL e v e rR i g h lR € l a i n e r
Key Cylinder
6. T i l rN o . 2B o l l
tr'd
- cornpressiont"'^'^sru"?'
U n l o c kW a r n l n g
h
'd, i
" " -!-' u'n'nn
I;l**lf; /' 1i^--^b,.4.--.-..1ffi
-
.,/Main.sharr\ZRZÎ.--..\.<f--.- . i _Jôe_n,ns
"-^p''
ro*)t-
corulnn --l d
rube w<@
s t
I
ColumU
n p p eB
l g n i t i oS
nwilch
r racket
#*pZPkffu
.,'corumn
,4.
p.i".to,
|
t'o':"'u'....<P
-.1s,
},so
-
sptng
t
Tensro4
Clamp Wiring
H a r n e sCs l a m P
,:' V7
N m ( k d l c m , l t l b l ) I Specilied lorque
? N o n - r e u s a b pl ea r l
<. Molybdenum D i s u l p h i dLei l h i u mB a s eG r e a s e

SR-17
- STEERING
STEERING COLUMN
GO L U M ND I S A S S E M B L Y
S T E E R I NC
1. ILLUMINATION
R E M O V EI G N I T I O NK E YC Y L I N D E R
2. R E M O V EI N T E R M E D I A TSEH A F T
(a) Removethe bolt.
(b) Shift the s haft.
(c) Placematchmarkson the intermodiatsshaft and main
shaft.
(d) Rsmovgthe shaft.
3. CLAMP
R E M O V EW I R I N GH A R N E S S
ii$,:$ill
4. C O L U M NP R O T E C T O R
REMOVE
//\
/ l : \ R e m o v e t h e b ol t .
\
,/ r/'ffi..a
5. REMOVE COLUMN UPPER BRACKET AND

COLUMNUPPER CLAMP
in a vise'
(a) Securethe steeringcolumnassembly
S c r e wE x t r a c t o r NOTICE: Do not tightenthe visetoo tight.
(b) Using a contsringpunch, mark the center of ths 2
ta pered- head bolts.
( c ) U s i n ga 4 - 5 m m ( 0 . 1 6- 0 . 2 0 i n . )d r i l l ,d r i l li n t o t h e
2 bolts.
(d) Usinga screw extractor.removethe 2 bolts.
6 . R E M O V EC O M P R E S S I OSNP R I N G
(a) Usinga torx socketwrsnch.removethe torx bolt.
( b ) R e m o v et h s s p r i n ga n d 2 b u s h i n g sf r o m t h e s p r i n g

STEERING GO L U M N
7. REMOVE3 TENSION
SPRINGS
8. REMOVETURN SIGNAL BRACKET

Removeths 2 bolts.
9. REMOVE2 TILT LEVERRETAINERS

R e m o v teh e n u t a n dE - r i n g .
10. REMOVERIGHTAND LEFTTILT PAWLSTOPPERS
11. REMOVETILT RIGHTPAWLAND TILT LEVER

)v> Removeth6 nut,washerand bolt.
\>..\)
>
I C'U
TiltLever

sR-19
STEERING- STEERING
COLUMN
12. REMOVETILT LEFTPAWL,TILT SUBLEVER,TILT

\')Y<Z LEVERASSEMBLY ANOTILT LEVERLOCKSHAFT
w \.t -1
Removerhe bolt.
"o "^ r' ,- T .'"'id} -
t.-i'1 Tilt Lever
k Shaft
T i l t N o . 2B o l t 1 3 . R E M O V EC O L U M N U P P E RT U B E W I T H M A I N
SHAFTASSEMBLY
(a) Securethe columnlowertube in a vise.
NOTICE: Do not tightenthe visotoo tight.
( b ) S e t S S T ,t h e n u t ( 1 0 m m n o m i n adl i a m e t e r1, . 2 5 m m
pitch).platewasher (36 mm outer diameter)and bolt
( 1 0 m m n o m i n a ld i a m e t e r ,1 . 2 5 m m p i t c h , 5 0 m m
length),as shown in the illustration. 'si,
s s T0 9 9 1 0 - O O 0( 10 s9 911- O O O11)
(09912-00010
Reference
Nut: 90170- 10004
Plat6washer: 90201 - 10201
Bolt: 9 11 1 1 - 5 1 0 5 0
(c) Remove th6 2 tilt No.2 bolts by using the sliding
hammsron SST.
(d) Rsmovethe uppertubo with tho shaft assemblyfrom

the lower tu be.
14. REMOVEMAIN SHAFTASSEMBLY

(a) Securethe columnuppertube in a vise.
NOTICE: Do not tightonthe visotoo tight.
(b) UsingSST,compr€ssthe compressionspring
s s T 0 9 9 5 0 - 4 0 0 10 ( 0 9 9 5 7- 0 4 0 1 0 )
(09958-04010)
NOTICE: Do not bend the univarsaljoint of the shaft
assemblymorethan 20".
(c) Usingsnap ring pliers,removeths snap ring.

sR-20 - STEERING
STEERING COLUMN
Compression (d) Removeth6 shaft assemblyfrom the uppertube.

S pr i n g
6ar3.&",-"
\^lat(+@ - -- _
upper
(e) Removethe springand bearingthrust collarfrom the
shaft assomblv.
ain Shatt
S T E E R I NC
GO L U M NI N S P E C T I OANN D
REPLACEMENT
1 . I N S P E CK
T E YC Y L I N D E R
Checkthatthe stesringlockmechanism pro-
operatss
perly.
2. IF NECESSARY. REPLACEKEY CYLINDER

(a) Placethe ignitionkey at the ACC position.
(b) Push down th6 stop pin with a thin rod, and pull out
the cylinder.
(c) Installa new cylinder.
HINT:Make sure the ignitionkey is at the ACC posr-
tion.
R09609
3. REPLACEUNLOCK WARNING
IF NECESSARY,
swtTcH
(a) Removeths 2 scrsws.
(b) Tightenthe 2 scrsws.

sR-21
STEERING- STEERING
COLUMN
4. IF NECESSARY, KEY INTERLOCK

REPLACE SOLE.
NOID
A/fz
( a ) Remove the 2 screws.
( b ) Tightenthe 2 screws.
5. IF NECESSARY, IGNITION
REPLACE SWITCH
(a) Removethe 2 screws.
(b) Tightenthe 2 screws.
6. IF NECESSARY, REPLACE MAIN SHAFTBUSHING

(a) Securethe columnlowertube in a vise.
NOTICE: Do not tightenthe visetoo tight.
( b ) U s i n gS S Ta n d a h a m m e rt,a p o u t t h e b u s h i n g .
s s r 0 9 6 2 0 - 3 0 0 10 ( 0 9 6 2 4 - 3 0 0 10 )
(09631 - 00020)
( c ) U s i n gS S Ta n d a h a m m s r t, a p i n a n e w b u s h i n g .
1 ( 0 9 6 2 6 - s 0 0 1)
- 000
s s T0 9 6 2 0 3
SST
I
(09631-00020)

sR-22 - STEERING
STEERING COLUMN
7, INSPECT MAIN SHAFTBEARING
Checkthe bearingrotationconditionand checkfor
abnormal noise.
is wornor damaged,
lf the bearing replace
the bearing.
409607
8. I N S P E C TC O L U M NU P P E RT U B EB E A R I N G
Check the bearingrotation conditionand check for
abnormalnoise.
lf th€ b€aringis worn or damaged,replacethe column
uppertu be.
GO L U M NA S S E M B L Y
S T E E R I NC
1. C O A TW I T H M O L Y B D E N U M D I S U L P H I DL
EI T H I U M
B A S EG R E A S E( S e ep a g e S R - 1 6 )
2, INSTALL MAIN SHAFT ASSEMBLY
(a) Install the bearing thrust collar and compression
ain Shaft springto ths shaft assembly.
(b) Installthe shaft assemblyinto th6 columnuppsrtube.
(c) Securethe uppertube in a vise.

NOTICE: Do not tightentho visetoo tight.
( d ) U s i n gS S T ,c o m p r e s st h e s p r i n g .
s s T 0 9 9 5 0 - 4 0 0 10 ( 0 9 9 5 7- 0 4 0 1 0 )
(099s8-04010)
NOTICE: Donot bendthe univarsaljoint of the mainshaft
assembly morethan 20',
( e ) U s i n gs n a pr i n g p l i e r s i,n s t a l a

_ STEERING
STEERING COLUMN
3. SELECTTILT NO.2BOLTS
Selectthe bolt with the hollow-tippedthrEadend
w h € nt h 6 c o l u m nu p p s rt u b em a r ki s 1 , a n dt h o b o l t
with the olainthreadendwhenthe markis 2.
NOTICE: Soloct the bolt typo to match cach number
marked in tho squaToron thc uppor tubo.
Hollow-Tipped
4. INSTALL COLUMN UPPERTUBE WITH MAIN

SHAFTASSEMBLY
intoth€
(a) Installthe uppertubewith the shaftassembly
lowgrtube.
(b) Usinga vise,pressin the 2 tilt No.2bolts'

N O T I C E :D o n o t t i g h t o n t h e v b e t o o t l g h t .
5. INSTALLTILT LEVERLOCK SHAFT,TILT LEVER

ASSEMBLY,TILT SUBLEVERAND TILT LEVER
Tilt Sub L€v€r
6. INSTALL RIGHTAND LEFT TILT PAWLS

(a) Temporarilytighton the nut'
HINT:Installthe pin of the pawlsinto the long hole of
the tilt levorand tilt sub lev€r.
(b) Tightentho tilt lEverassemblyset bolt.
Torque:2.9 N.m(30 kgf'cm,26In.'lbf)

STEERING GO L U M N
7. ENGAGE AND ADJUST RIGHT AND LEFT TILT

PAWLS
(a) Engagethe left pawl to the centerof the ratchet.
( b ) U s i n ga s p a n n e (r 1 7 m m ) ,w h i l et u r n i n gt h s r i g h tp a w l
side collar,completelyengagethe right pawl to the
ratc hot.
NOTICE:Do not turn the collaraftar tho right pawl is
engaged.
(c) Torque the nut.
Torque:5.N 9 . m( 6 0k g f . c m . 5 2i n . ' l b f )
8. SELECTRIGHTAND LEFT TILT PAWL STOPPERS
(a) With the tilt pawl and ratchet engaged,install the
A l i g n m e n tm a r k s pawl stoppers.
(b) Checkthat th6 alignmentmarks on the pawl stopper
and pawl align when the pawl stopper is lightly rot-
ated to th€ oawl side.
l f t h e a l i g n m e nmt a r k sd o n o t a l i g n ,s s l e c tt h s p a w l
stoppersaccordingto the followingtable.
-A-
Dimension
Right paw stoppor Loft pawl stopp6r
mm {rn.,
12.64 - 12.74
( 0 . 4 9 9 2- 0,5016)
12.61- 12.61
(0.4985- 0.4988)
12.54- 12.60
3 c
( 0 . 4 9 3 7- 0 . 4 9 6 1 )
12.47 - 12.53
4 D
(0,4909 - 0.4933)
12.40- 12.46
5 E
(0.4882* 0.4906)
F
(0.4854- 0.4878)
12.28- 12.32
7
- 0.48s0)
(0./1827
(c) After selectingthe pawl stoppers,checkthat on both

sidesthe pawl and ratchetare fully engaged.
9. INSTALLRIGHTAND LEFTTILT PAWLSTOPPERS

- S T E E R I NC sR-25
STEERING GO L U M N
1 0 . I N S T A L L2 T I L T L E V E RR E T A I N E R S
( a ) I n s t a l al n e w E - r i n g .
(b) Torqueth€ nut.
Torque:15 N.m(150ksf.cm.11 ft.lbf)
@
R e t aa ne r
1 1 . I N S T A L LT U R NS I G N A LB R A C K E T
Torquethe 2 bolts.
T o r q u e :5 . 4 N . m ( 5 5 k g f . c m . 4 7 i n . l b { )
1 2 . I N S T A L L3 T E N S I O NS P R I N G S
1 3 . I N S T A L LC O M P R E S S I OSNP R I N G
( a ) I n s t a l tl h e 2 b u s h i n g st o t h e s p r i n g .
( b ) U s i n ga t o r x s o c k s tw r e n c h ,t o r q u et h e t o r x b o l t .
Torque:7.8 N.m(80 kgf.cm,69in. lbf)
14. INSTALL COLUMN UPPER BRACKET AND

C O L U M NU P P E R CLAMP
( a ) S e c u r tah e s t e e r i ncgo l u m na s s e m b liyn a v i s e .
NOTICE: Do not tightonthe visetoo tight.
(b) T i g h t e n2 n e w t a p e r s d - h e a db o l t su n t i lt h e b o l t h e a d
breaksoff.

sR-26 STEERING- STEERING
COLUMN
1 5 . I N S T A L LC O L U M NP R O T E C T O R
Torouethe bolt.
T o r q u e :4 . 9 N . m ( 5 0 k g f . c m , 4 3 i n . . l b f )
1 6 . I N S T A L LW I R I N GH A R N E S SC L A M P
Tightenthe screw.
1 7 , I N S T A L LI N T E R M E D I A TSEH A F T
( a ) A l i g nt h 6 m a t c h m a r k o s n t h e i n t e r m e d i a tseh a f t a n d
main shaft, and installthe shafr.
(b) Torque th6 bolt.
T o r q u e : 3 5N . m( 3 6 0k g f . c m , 2 6f t . l b { )
1 8 . C H E C KT I L T S T E E R I N G OPERATION
( a ) C h e c kt h a t t h 6 r ei s n o a x j a lp l a ya t t h e e n d o f t h e m a r n
shaft.
( b ) W i t h t h 6 m a i ns h a f ti n t h e n e u t r apl o s i t i o np, u l l t h st i l t
l e v e ra n d c h a c kt h a t t h e m a i ns h a f tr i s a st o t h e u p p e r -
most position.
(c) Lower the main shaft, and check that it locks in the
lowermostposition.

_ POWERSTEERING sR-27
STEERING
POWERSTEERING
DESCRIPTION
P R I N C I P L EOSF P O W E RS T E E R I N G
Power steoring is a hydraulicdevice which utilizesengine power to reduce steering affort.
Consequently, the engineis usedto drivea pumpto developfluid pressure,and this prsssureacts
on a pistonwithin the powercylinderso that th6 pistonassiststhe rack effort.The amountof this
assistancedependson the extent of pressureacting on the piston.Therefore,if mors st€ering
force is required,the pressuremust be raised.The variationin the fluid pressureis accomplished
by a controlvalve which is linkedto the main shaft of tho stsoring.
35-GE:
S t e e r i nC
g olumn S t e e r i n gW h B B I
Oil Reservoir
P SV a n eP u m p
P SG e a rH o u s i n g

sR-28 _ POWERSTEERING
STEERING
S E C T I O N AVLI E W
PS VANE PUMP
7A-FE:
SnapRing
Woodruft
Key
R e a rH o u s i n g
Wavs Washer
S i d e R e a rP l a t e Vane Pump
Rotor
Vane Plate
CamRing
Side Front Plste
Vans PumpPulley
F l o w C o n t r o lV a l v e P r e s s u r eP o r t U n i o n
U n i o nS e a t
R 0 9 6 4 5R 0 9 0 4 8
i09660

sR-29
STEERING_ POWERSTEERING
VIEW
SECTIONAL
PS VANEPUMP
3S-GE,3S-FE,SS.FE:
p Ring
Woodruff
Key Rear Housing
Wave Washer
Vane
Plate
Van8 PumpRotor
S i d eF r o n t P l a t e Side Cam Ring
V a n eP u m pP u l l e y
F l o w C o n t r o lV a l v e
Port Union
Pressure
U n i o nS e a t
n09646 R096,17
R09649

sR-30 - PowERSTEERTNG
STEERTNG
SECTIONAL
VIEW
LHD:
,1.RHOis th€ symmelrical
opposlteof LHD
ControlValveAssembly
D u s tC o v e r
Oll S6al
B€arln9
UnlonSoat
TeflonRlng
RackGuldeSprlngCap B€arlng
LockNut
Oll S€al
RackGuldeSprlng
cap
R a c kH o u s i n g
RackGuld6Sprlng
Eearing
RackGulda
RackHoushgCapLockNut
RackGuldsS€at
Houslng
Cap
S t 6 e r i nR
g ack
RackHouslng
Cyllndsr
EndStopper
Blng
L___
Rack
N o , 2B r a c k o t
F0etll
F09652

- POWER sR-31
STEERING STEERING
OPERATION
OPERATION
NEUTRAL(STRAIGHT _AHEAD) POSITION
Fluidfrom the pump is sent to the controlvalve.lf the controlvalve is in thE noutralposition,all
the fluid will flow throughthe controlvalveinto the reliefport and backto the pump.At this timo,
hardlyany prossursis createdand becauseth€ pressureon the cylinderpiston is equalon both
s i d e s t, h e p i s t o nw i l l n o t m o v e i n e i t h e rd i r e c t i o n .
W H E NT U R N I N G
When the steeringmain shaft is turned in eithsrdirection,the controlvalve also moves,closing
one of the fluid passages.The other passag€then openswider. causinga changein fluid flow
volumeand,at th€ sametime,a differentialpressureis cr€atodbetweenboth sidesof the piston.
Consequently, the piston moves in the directionof the lowor pressur€so that ths fluid in the
cvlinderis forced back to the pump throughthe controlvalve.

STEERING
SERVICH
EINT
Troubleswith the powersteeringsystemare usuallyconcernedwith hardsteeringdue to the fact
that there is no assistance.In such cases,bsfore attsmptingto make repairs,it is necessaryto
determinewhetherthe troublelieswirh th6 pump or with the gear housing.To do this. an on-
vehicleinspectioncan be made by usinga pressuregauge.
O N _ V E H I C L EI N S P E C T I O N
Power steeringis a hydraulicdeviceand problemsare normallydue to insufficientfluid pressure
acting on tho piston.This could be causedby eitherthe pump not producingthe specifiedfluid
pressureor the controlvalvein the gear housingnot functioningproperlyso that ths properfluid
pressurecannot b6 obtained.
lf the fault lies wirh the pump, th6 sams symptomswill generallyoccur whethar the stoering
wheel is turnedfully to th6 right or left.On the othor hand,if the fault lieswith the controlvalvs.
there will generallybe a differencebetwesnthe amountof assistance wh6n ths stesringwheel is
turned to the left and right, causinghardersteering.However,if the piston seal of the power
cylinderis worn, therewill be a lossof fluid pressurewhetherthe steeringwheel is turnedto ths
right or left and the symptomswill be the same for both.
Before performingan on -vehicle inspection,a check must first be made to confirm that the
power steeringsystemis completelyfree of any air. lf there is any air in the syst6m,the volume
of this air will changewhen the fluid pressureis raised,causinga fluctuationin the fluid prossure
so that the power steoringwill not function properly.To determineif there is any air in the
systsm,chsck to see if there is a changeof fluid level in tho ressrvoirtank wh6n the stsering
wheel is turned fully to the right or lsft.
F o r e x a m p l ei,f t h e r e i s a i r i n t h e s y s t e m ,i t w i l l b e c o m p r e s s etdo a s m a l l e rv o l u m ew h e n t h e
steeringwheel is turned.causinga considerable drop in the fluid level.lf ths systsm is free of air,
there will be vsry littls changein the levelsvsn when the fluid pressureis raised.This is because
the fluid,beinga liquid,does not changevolumewhen compressed. Th€ little changein the fluid
level is due to expansionof the hosesbetweanth6 pump and gear housingwhen pressurerises.
Also, arr in the syst6m will sometimesresultin abnormalnoisescomingfrom the pump or gsar
housingwhen the steeringwheel is fully turned in eitherdirection.
This on -vehicle inspectionmust be parformedevery time to ensur6that ths powsr steering
system is working properlyafter overhaulingor repairingth6 pump or gear housing.
W h e nT u r n i n g N e u t r aI

- POWERSTEERING
STEERING
V A N EP U M P
Thamaincomponsntpartsofth€vanepump,suchasthecamring,rotor,vanesandf|owcontro|
pump produces
valve are high precisionparts and must be handledcarefully.Also, becausethis
the pump,
a very high fluid pressure,o-rings are usedfor sealingeach part.When reassembling
alwavs use new O - rings.
pump'
ln the flow controlvalve,thereis a reliefvalvewhich controlstho maximumpressureof the
The amountof this maximumpr€ssureis very important;if it is too low, there will be insufficient
power steeringassistanceand if too high,it will havean adverseeffect on the pressurehoses,oil
not
seals,etc. lf the maximumpressur€is eithertoo highor too low due to a faulty reliefvalve,do
disassemble or adjustthe reliefvalve,but replacethe flow control valva as an assembly'
The clearancebetweenthe flow controlvalveand pump body installationhole is very important.
Aft6r manufacture, the factory measuresthe sizeof the installationholeand outer circumference
the flow
of the flow control valve,and punchesa mark accordingly.Therefore,when replacing
propor
control valve, be sur6 to do so with one havingths samo mark in order to ensurethe
clearance.
Mark gr',
(7A-FE)
(3S.GE,3S.FE,5S-FE)
RO942tF09370 SR2674
and vanes,
The functionalpartsof the pump which producefluid pressursarg the cam ring,rotor
each is not within standard when
and theseshouldbe checkedfor wear.lf the clearancebetween
reassembling, any worn parts shouldbe replaced.
( h a v et h e s a m e m a r k ; ,
In this case,the replacedcam ring and rotor shouldbe of the samel e n g t h
and the vanes should be replacedwith thoso having a longth c o r r e s p o n d i n gt o t h a t m a r k .
otherwisethe properthrust clearancocannotbe obtained'lf there i s t o o m u c h t h r u s t c l e a r a n c € ,
it maY
there will be insufficientfluid pressureat low speeds.lf thsrs is too l i t t l 6 t h r u s t c l a a r a n c e ,
resultin seizureof the vanes.
l n s c r i b e dM a r k
s A 3 1 9 1S F 2 0 7 3

G E A RH O U S I N G
l f t h 6 g e a rh o u s i n gi s s e c u r s ddirectlyin a vise duringoverhaul,thera is dang6rof deformingit,
so alwaysfirst secureit in the SST provided(rack& pinionstosringrack housingstand)before
placingit in the vise.
The oil sealson both sides of the power cylinderare for tho preventionof leakageof the high
pressurofluid which acts on tho piston.Always uso new oil sealswhen reassembling ano oe very
carefulnot to scratchor damagsthem.
Becauseof the high pressure,6v6n tho slightestscratchwill causefluid leakage,resultingin an
inoperativepower steering syslom.
Also, be very carefulnot to scratchthe slidingportionof the rack which makescontactwith the
oil seals.When removingthe rack endsfrom the rack,it is very easyto causea burr when holding
tho tip of the rack with a wrench.Therefore,beforeassemblingthe rack,frrst check the tip for
burrs and removeany with an oil stone.
Teflon rings are used for the piston and control valve.These teflon rings are highly durable
againstwear, but if it is nsc€ssaryto replacethem, be carefulnot to strotchthe new onos.
Aftsr installinga teflon ring into its groov€,snug it down into the groovebeforeassemblyof the
cylinderor housingto proventpossibledamage.
Teflon Ring

_ POWERSTEERING
sR-35
STEERING
As with the rack and piniontype steoring,preloadis v6ry important. lf the oreloadis not corr6ct,
it could result in such troubleas stoeringwheel play or shimmYor lack of durability,so always
make sure that it is corroct.
Hexagon Wrench
I D L E _U P D E V I C E
The pump producesthe maximumfluid pressurewhsn the steoringwheel is turned fully to the
r i g h to r l e f t a n d ,a t t h i s t i m 6 ,t h a r ei s a m a x i m u ml o a do n t h o p u m pw h i c h c a u s e sa d e c r e a s ai n
w i t h a n i d l e - u p d e v i c ew h i c ha c t s
s r ee q u i p p e d
e n g i n ei d l er p m .T o s o l v st h i s p r o b l e mv, e h i c l e a
to rais€the engineidle rpm wheneverthere is a heavyload on the pump
On EFIengines,when the pistonof rhe air controlvalveis pushedby fluid pressure,the air valvs
opensand the volumeof air by-passing th€ throttlovalveis increasedto regulateenginerpm.
P S V a n €P u m P
PSG€ar
Housing
T h e i d l e - u p d e v i c ef u n c t i o n sto raiseenginei d l er p m w h e n p u m pf l u i d p r e s s u r e
a c t so n t h e a l r
controlvalve,installedto the pump body,to controlthe flow of air.

STEERING
PREPARATION
SST(SPECIAL
SERVICE
TOOLS)
0 9 6 1 0 - 2 0 0 1 2 P i t m aA
n r mP u l l s r Ti6 rod 6nd
& 09612-00012 Rsck& PinionSteerinsR6ck

Housin€Stand
09612-30012 Ste6ringWorm BearingPullor Rack housing oil seal
@F
09616-00010 stesring
WormEearins
Adjustins Ch6ckingbearingpr€load
Socket Checkingtotsl pr6lo6d
09620-30010 stoeringc6ar Box R€plecorsot

@-
€ e
(09624-30010)sto€rins
soctorsheftoil soal Rackhousingoil seal
@. Roplace.
\7
(09631-ooo2o)
Handre Controlvalvehousingoil s6el
and boaring
€-'-€" R6ckhousingoil s6al
0 9 6 2 8 - 6 2 0 1 1B allJoint P!llor Camborcontrolarm
09630-24013 st€eringRsckOil SealTool Sst

eee
(09620-24010) Valv€CupO'l S6alR€movor Control vslv6 housing oil seel

ano beanng
(09620-24020)ValveCupoil soalRoplacor ControlvalvEhousingoil soal
(09620-24030)vrlve cup BerringR6plecer Controlvrlv6 houaingb€ering
09631- 12020 Handlo Rackhousingoil ssal

sR-37
STEERING- POWERSTEERING
R a c kO i ls € s lT € s tT o o l
09631-12071 St€o'ing Air tightnoss test
'B'
0 9 6 3 1 - 2 0 0 3 1 o 1 sl e a l R s m o v o r Rackhousingoil ssal
'8" R€Plac€r Rsck housing oil s63l

09631-20040 Oil S€al
09631-20081 s€alRinsTool Control valv6 t6flon rings
'C'
09631-20051 St66rinsRackCovsr
-------_]
dl
09631-22020 Powerst€oringHos6Nut P r 6 s s u 1 6f o o d s n d r s t u r n t u b o s
1 4 x 1 7 m m w r € n c hS € t Roturn tube No.1 sub-assembly
09633-00020 PoworSte€ringHos€Nut Wronch Turn pr6ssur6tube
09922- 10010 Variebl€OpenWronch Rack€nd

Rackhousingcap lock nut
Reckguidospringcap lock nut
Pinwf€nchsst
09960-10010 Variable Van6 pumppull€y

STEERING
OOLS
09025-00010 Sm6llTo,quewronch M6asuringvan€ pumpshaft
fotrting torquo
Chockingboaringprsload
Ch6ckingtotal proload
09216-00021 BoltTonsion
G.uso Chockingdrivob€lt tonsion
09216-00030 B6ltTenrionGaugo
C.blo Checkingdriv€ b6lt t€nsion
09905-00012 SnapRingNo. 1 Exp.nd6r Snapring
09905-00013 snapRinoPliors Snapring
LUBRICANT
Item Capscity Classificstion
Pow€r stoeringfluid
0.8 liters (0.85 US qts,0.70 lmp.qts) A T FD E X R O N . I I
EOUIPMENT
Calipergauge Morsuringpumpoil cloa16nc€
Calipers Mersuring spf ng fre6 16ngth
Dial indicator Chockingste6ringrack runout
F e e l e rg a u g e M6asuring rotor groov€ and van6

Pl6te clearance
M icrometer M€esuring pump oil cl6srsnc6
M€esuflng vane plate
O i l p r e s s u r eg a u g e PS oil pr6ssu16
M6asurinO
Torque wrench
ssM (sPEclALSERVtCE
MATERIALS)
08833-00080 Adhosivo 1344, Reckhougingcap
T H R EB
EO N DI 3 4 4 , Rackhousingcap lock nlt
LOCTITE 242or equivalent Rackguid€springcap
Rsckguidespringcap lock nut

- POWER sR.39
STEERING STEERING
O N - V E H I C L EI N S P E C T I O N
98 N (10 kg|,22tbtl,," CHECK
D R I V EB E L TT E N S I O N
the driveb6ltdefl€ction.
Measure
Crank Drfve belt tonslon: [8t gB N (10 kel ' 22 lbfl)
Pulley
New bslt
7A-FE: 5 - 6 m m ( 0 ' 2 0 - 0 . 2 4I n . )
V a n eP u m pP u l l e y 3 3 - G E , F E : 8 - 1 0 m m ( 0 . 3 1 - 0 , 3 9I n . )
53-FE: 8 - 1 0 m m ( 1 . 3 1 - 0 . 3 9I n . )
Usodbolt
7A-FE: 8-8 mm (0.24-0.31in')
3 3 - G E , F E : 1 0 - 1 3 m m ( 0 ' 3 9 - 0 . 5 1I n . )
5S- FE: 10- I 3 mm (0.39- 0.51 In.)
tw^JNJL^N HINT:
. "New belt'refers to a belt which has been less
t h a n 5 m i n u t e so n a r u n n i n ge n g i n e '
. "Usedbelt' refersto a belt which has been used
on a runningenginefor 5 minutesor mor€.
. tho drivobelt,checkthat it fits
Aftorinstalling
properlyin ths ribbedgrooves. ffi
&
Reference:
o Using a belt tention gauge,check the drive belt
tension.
Drivebelt tenribn: 7A-FE, 35-GE, 33-FE, 55-FE
Now bolt
441-539 N (45-55 kgf, 99-121 lbf)
Ured belt
198-343N (20-35 kg{,44-77 lbf)
I D L E _ U PC H E C K
1. W A R MU P E N G I N E
2. TURNAIR CONDITIONER SWITCHOFF
3. C H E C KI D L E - U P
(a) Fullyturn tha ste6ringwheel.
(bI Checkthat the snginorpm decreases when the atr
control valvg hose is pinched.
(c) Checkthatthe enginerpmincreases whenthe hoseis
3S-GE.35-FE,sS.FE: released.
Air ControlValveHose

sR-40 _ P O W E RS T E E R I N G
STEERING
F L U I DL E V E LC H E C K
t1i6\oFr;?
{'-r}Booc
1 . K E E PV E H I C L EL E V E L
_,\<; ffio*ô rv/ , ,\v, ) \I
2 . BOOSTFLUID TEMPERATURE
W i t h t h e e n g i n ei d l i n ga t 1 , 0 0 0r p m o r l e s s ,t u r n t h s
6
steering wheel from lock to lock several times to
boost f luid temperature.
Fluidtemperaturo:
80"c (176'F)
3. S T O PE N G I N E
4. C H E C KF O RF O A M I N GO R E M U L S I F I C A T I O N
Normal Abnormal H I N T :F o a m i n ga n d e m u l s i f i c a t i oi n d i c a t ea i t h e rt h e
axistenceof air in the systemor that the fluid levelis
too low.
5. CHECKFLUIDLEVELIN OIL RESERVOIR

ffi. Checkthe fluidleveland addfluidif necessarv.
Fluid:
A T F O E X R O N CI ]
HINT:7A-FE
Checkthat the fluid levelis within the HOT LEVELof
the dipstickof the reservoircap. lf th6 fluid is colo,
c h e c k t h a r i t i s w i t h i n t h e C O L D L E V E Lo f t h e d r o -
st ick.
HINT: 35-GE,35-FE.55-FE
(7A-FF)
Checkthat the fluid levelis within the HOT LEVELof
l:]S-GF iq-trtr cc.Etr r
RtataT the reservoir.lf ths fluid is cold,checkthat it is within
the COLD LEVELof the reservorr.
POWERSTEERING
FLUIDREPLACEMEIi?"
1 . J A C K U P F R O N TO F V E H I C L EA N D S U P P O R ITT
WITHSTANDS
2. REMOVEFLUIDRETURNHOSEFROMOtL RESER.
V O I RA N DD R A I NF L U I DI N T OC O N T A I N E R
Return N O T I C E :T a k e c a r e n o t t o s p i l l t l u i d o n t h e d r i v e b e l r .
n ose

sR-41
3. TURN STEERING WHEELFROMLOCK TO LOCK

WHILED R A I N I N FLUID
G
4. WITH FRESHFLUID
FILLOIL RESERVOIR
Fluid:
A T F D E X R O N OI I
5. START ENGINEAND RUN IT AT l,OOORPM

After 1 or 2 seconds,fluid will beginto dischargefrom
th€ r6turn hose.Stop the enginaimmediatelyat this
time.
NOTICE:Takecarethat romo fluid remainrleft In tho oil
retervoir.
6. REPEATSTEPS 4 AND 5 FOUR OR FIVE TIMES
UNTIL THEREIS NO MORE AIR IN FLUID
7. CONNECTRETURIIIHOSETO OIL RESERVOIR
8. BLEEDPOWERSTEERINGSYSTEM
SYSTEMBLEEDING
POWERSTEERING
I, CHECKFLUIDLEVELIN OIL RESERVOIR
Checkthe fluid levelandaddfluidif necessary.
Fluid:
ATFDEXROI{O tr
HINT: 7A- F E
Checkthat th6 fluidlevelis withinthe HOTLEVELof
\/A-TE/ l.tD_(,E,,rD'Ttr,CJ_rE/
R10107 the dipstickof the reservoircap.lf th€ fluid is cold,
checkthat it is withinthe COLDLEVELof the dip-
stick.
H I N T : 3 5 - G E ,3 5 - F E ,5 S - F E
Checkthartho fluidlevelis withintho HOTLEVELof
ths reservoir. lf the fuildis cold,checkthat it is within
th6 COLDLEVELof the reservoir.

sR-42
B
2, START ENGINEAND TURN STEERINGWHEEL
FROMLOCKTO LOCK3 OR4 TIMES
With the enginespeedbelow 1,000 rpm, turn the
steeringwhsel to right or left full lock and keepit
thsrsfor 2 - 3 seconds, thsn turn the whealto the
,s\ oppositefull lockandkeeoit therefor 2 - 3 seconds.
&)
3. CHECK THAT FLUID IN OIL RESERVOIRIS NOT
FOAMY OR CLOUDY AND DOES NOT RISEOVER
M A X I M U M W H E N E N G I N EI S S T O P P E D
Measurethe fluid levelwith the onginerunning.Stop
t h s e n g i n ea n d m e a s u r et h e f l u i d l s v s l .
Maximumrise:
5 mm (0.20in.)
lf a problem is found, repeat 'POWER STEERING
F L U I D R E P L A C E M E N To "n p a g € sS R - 4 0 a n d 4 1 .
Repairthe PS if the problempersists.
O I L P R E S S U RCEH E C K
1 . C O N N E CO T I LP R E S S U RGEA U G E
-
7A FE:
(a) Disconnect ths returnhosefrom the oil reservoir,
and
d r a i nf l u i d .
NOTICE: Takscarenot to spillfluid on the drivebett.
(b) Removethe union bolt, gasket and disconnectthe
pressure feed tube.
Oil Pressure (c) Connectth6 gaugsovera new gasket,as shown in the

Gauge illustration.
P r s s g u rTeu b e
ln (d) Connectthe return hose.
(o) Bleedth6 powor steeringsyst6m.
( S e ep a g eS R - 4 1 )
Out
a n eP u m p cos3
Pressure Feed
35-GE,35-FE,55_FE:
Tube (a) UsingSST,disconnect
the pressure
feedtube.
ssT 09631-22020

sR-43
( b ) R e m o v et h e t u b e c l a m p .
( c ) C o n n e ct h e g a u g ea
, s s h o w ni n t h a i l l u s t r a t i o n .
(d) Bleedthe power steeringsyst€m.
(Seepage SR- 41 )
2. S T A R TE N G I N E A N D R U NI T A T I D L E
3, BOOSTFLUIDTEMPERATURE
,176\oFt
/rr-l8oac i9 W i t h t h e e n g i n oi d l i n ga t 1 , 0 0 0r p m o r l e s st,u r nt h a
steeringwheel from lock to lock soveraltimos to
-J<; 6ffiy^,
\---.-./ r
v/
l..
\v/
)\
I
boostf luidtemperature.
Fluidlemperature:
80'c (176'F)
4. CHECK FLUID PRESSUREREADINGWITH VALVE
CLOSED
Clossthe valveof tha oil pressurogaugeand observe
t h 6 r o a d i n go n t h s g a u g e .
Mlnlmumpressuro:7A-FE
8,865kPa(7Okgl/cm',998 Pri)
Minimumpressuro:35-GE, 3S-FE, 53-FE
8,828 kPa (90 kgf,/cmr,I ,280 Prl)
NOTICE:
. Do not koop tho valve cloted for moro thrn 10
!econd8.
CIosed . Do not let the fluid tempgratu;o bBcome too hlgh,
lf pressureis low,rapairor rsplaceths PSvanepump.
5. OPENVALVEFULLY
6. CHECK ANO RECOROPRESSURE READINGAT
r t 1 , O OR
OP M
l2\ 7, CHECK AND RECORDPRESSURE READINGAT
-L-'Kj) 3.000RPM
+ Checkthatthe pressure difference betweenthe 1,000
rpm and 3,000 rpm checksis lessthan 490 kPa (5
\ ; \
kgl/cm",71psi),lf th6 difforsncais excessive,repair
or reDlaceth€flow controlvalveof the PSvanspump.
N O T I C E :D o n o t o p o r a t ot h e s t a o r l n gw h e e l .

sR-44
8. CHECK PRESSUREREADINGWITH STEERING

(@ W H E E LT U R N E D T O F U L LL O C K
Be sure the valv6of the oil pressuregaugeis fully
o p e n e da,n dt h e e n g i n ei d l i n g .
Mlnimumpressurel 7A - FE
6,865 kPa (70 ksl/cm',9S6 psi)
L o c kP o s i t i o n M i n i m u m p r e s s u r e : 3 5 - G E ,3 5 - F E , 5 5 - F E
8,826 kPa (90 kgf,/cm", 1,280 psi)
NOTICE:
. Do not maintain lock position for more than 10
aoconds.
. D o n o t l e t t h e f l u i d t e m p s r a t u r ab e c o m et o o h i g h .
l f p r e s s u r ei s l o w , t h e P S g e a r h o u s i n g h a s a n i n t e r n a l
leak and must bo repairedor replaced.
9. D I S C O N N E COTI LP R E S S U RGEA U G E
1
R e t u r nH o s €
7A- FE:
(a) Removethe returnhose,and drainfluid.
NOTICE: Takecars not to spillfluid on the drivebelt.
Pressur€ (b) Di s c on n e c tt h e g a u g e .
F e e dT u b e (c) Connectthe pressurefeed tubo with the union bolt
/-{4' with 2 new gaskets.
" i*J H I N T :M a k e s u r s t h e s t o p p o ri s t o u c h i n gt h e p u m p
lrt-\(
housing,as shown,thon torque the bolt.
Torque:52 N.m(525kgf.cm.38 ft.lbf)
(d) Connectthe return hosa.
(e) Bl6edthe power steeringsystem.
( S e ep a g eS R- 4 1 )
RQ9022
FO963t
35-GE,35_FE,55_FE:
( a ) I n s t a lt lh e t u b ec l a m p .

(b) Using SST, connect ths tube to the control valve
housing.
ssT09631-22020
HINT: Use a torque wrench with a fulcrum length of
3 0 0 m m ( 11 . 8 1 i n . ) .
(c) Bl6sdthe powor steeringsyst€m.
( S e ep a g eS R- 4 1 )
E T E E R I NE
M E A S U RS GF F O R T
1. CENTER S T E E R I NW AT
G H E E LA N D R U NE N G I N E
IDLE
ET E E R I NEGF F O R T
2 . M E A S U RS
(a) Removethe steeringwheelpad.
(SeepageSR- 8)
(b) Measure the steoringeffortin both directions'
Maximumstearingeffort:
6.9 N.m(70 ksf.cm.61in..lbf)
lf steeringeffort is excessive,ropairthe power steer-
I n gu n r t .
H I N T :8 e s u r et o c o n s i d etrh e t i r o t y p e ,p r e s s u r sa n d
contact surfacsbeforemakingyour diagnosis.
(c) Torquethe stssringwheel set nut.
(d) Installthe stosringwheel pad.
(Seepage SR- 9)

sR-46 - POWERSTEERING
STEERING
P O W E RS T E E R I N G
PUMP
(7A- FE)
COMPONENTS
UnionBolt
PS VanePump
Assembly
O Gasket
w. Bracket
Fe60oreTl
V
1 2 m mB o l t
arTll€r..14-ll
1 4 m mB o l t
--==@
Eo600,tsTl
Engin
e UnderCov€r
N m ( k g f c m , f t l b: t Speclf
iedtorque
part
a Non-reusable

sR-47
AND
OFREMOVAL
M A I NP O I N T S
INSTALLATION
1. REMOVE D R I V EB E L T
Loos€n 2 bolts.
th6
2. DISCONNECTRETURN HOSE AND PRESSURE

FEEDTUBE
(a) Disconnect and drain
tho hossfrom the oil reservoir,
fluid.
Takecarenot to spillfluid on the drivebelt.
NOTICE:
(b) Removetho union bolt, gasket,and disconnectthe
tube.
3. REMOVEPSVANEPUMPASSEMBLY
Removethe 4 bolts.

STEERING
B e t u r nH o s e 4, CONNECT PRESSUREFEED TUBE AND RETURN
,Il HOSE
Torqusthe union bolt over 2 new gaskets.
I
H I N T :M a k e s u r e t h e s t o p p B ri s t o u c h i n gt h e p u m p
Pressure housing,as shown,then torque ths bolt.
F e e dT u b e Torque:52N.m(525kgf.cm,38ft.lbf)
5. ADJUST DRIVEBELT TENSION
t ? l (See page SR- 39)
( S e ep a s e S R - 4 1 )
R09622
809631

sR-49
COMPONENTS
/7--\ caP
,Vt---- Reservoir
U
Oil Reservoir
O-Ring
Bracket
41 {420,301
lValve
P r e s s u r eP o r t U n i o n
n t H o us r n g
5T-l
t 6, r?oo,
t
woodrulfKey' 'sS\$lA
'\ tN rN\\
seat
. union ^-f> f Yi Vd\
Y.\
--1$ $ \ ^n-^\\\\\ \J
\) klu
vu,u"
Aircontrot ^\ \ ll I v
ov
r 3o{3?oi?,
| , \2. I o,,,"r,
? Ull )eal o o_Ring
Vane PumpPulleY W a v eW a s h e r
, ' A
1 4st44o,32t
\ snapR,ns
" .-. - a Longer Straight Prn
I _-1N\
fA\\\ \\\,/
)\_.
' t\\ \\v
- o s n a pR i n g it Rear Housins
^.JNQN/-
i,ffY o o-nine
J
Vane PumpShatt
N m ( k q t . c m ,f t . l b f) : S p e c i i i e dt o r q u e
r) Non-reusable part
# P o w e r s t e e r i n gt l u i d

STEERING
PS VANEPUMPDISASSEMBLY
1 . S E C U RP
ESV A N EP U M PA S S E M B L IYN V I S E
N O T I C E :D o n o t t i g h r e n t h e v i s e r o o t i g h t .
2. REMOVEVANEPUMPPULLEY
(a) UsingSSTto stopthe pulleyrotating,remov€the nut.
s s T 0 9 9 6 0- 10 0 10
(b) Removethe woodruffkev.
3. REMOVEAIR CONTROL VALVE

Removeth€ unionsaat.
4, REMOVEBRACKET AND OtL RESERVOIR

(a) Removethe 4 bolts.
(b) Removethe O-ring from the reservoir.
5. REMOVEPRESSURE PORTUNION
R e m o v teh o O - r i n g f r o mt h e u n i o n .

sR-51
6. VALVEAND SPRING
REMOVEFLOWCONTROL
7. REMOVEREARHOUSINGAND WAVE WASHER

(a) Using2 screwdrivers,removethe snap ring.
Screwdriver
(b) Using a plastic hammer, tap out the housing and

washer.
(c) Removethe O-ring from the housing.
8. REMOVESIDEREARPLATE
(a) , po u t t h e p l a t e .
U s i n ga p l a s t i ch a m m e rt a
(b) R e m o v teh e O - r i n g f r o mt h e p l a t € .
9. REMOVECAM RINGAND 1OVANEPLATES
Removethe ringand platesfrom tho shaft.
10. REMOVE V A N EP U M PS H A F TW I T H V A N EP U M P
ROTORAND SIDEFRONTPLATE
S T R A I G HP
LONGER
11. REMOVE TI N

STEERING
Screwdriver 12. REMOVE V A N E P U M PR O T O RA N D S I D EF R O N T

PLATE
(a) Usinga screwdriver, removethe snapring.
( b ) R e m o v teh e 2 O - r i n 9 sf r o mt h e p l a t e .
(c) Secureth€ plats in a vise.

Vinyl Tape
NOTICE:
r Placeshopragsbetweenth9 visoand tho plate.
. Do not tightenthe visotoo tight.
(d) Using pliers with vinyl tape wound around the jaw
ends,removethe shorterstraightpin from the plate.
| #..,ni
P SV A N EP U M PI N S P E C T I OANN D
Micrometer REPLACEMENT
1 . M E A S U R EO I L C L E A R A N C E OF VANE PUMP
S H A F TA N D F R O N TH O U S I N G
BUSHING
C a l i p e rG Usinga micrometer andcalipergauga,measure the oil
clearance.
Standard clearance:
0.01-0.03 mm (0.0004-0.0012in.)
Maximum clearance:
0.07 mm (0.0028in.)
lf more than maximum,r€placethe entire PS vane
oumo.
2. I N S P E C TV A N E P U M P R O T O RA N D 1 0 V A N E
PLATES
l-
H eo h t I
(a) Usinga micrometer, measurethe height,thickness
I and length of ths plates.

M i n i m u m h e i g h t : 8 . 1 m m ( 0 . 3 1 9i n . )
M i n i m u m t h i c k n e s s : 1 . 7 9 7 m m ( 0 . 0 7 0 7i n . )
M i n i m u m l a n g t h : 1 4 . 9 8 8 m m ( 0 . 5 9 0 0 8i n . )

STEERING
(b) Usinga feelergauge,measurathe clearancebetween
the rotor grooveand vane plate.
Maximumclearance:
0 . 0 3m m ( 0 . 0 0 1 2
in.)
l f m o r e t h a n m a x i m u m .replace the plates and/or
rotor with one havingthe s a m em a r ks t a m p e do n t h e
cam nng.
lnscribedmark:
1, 2, 3, 4 or None
H I N T :T h e r e a r s 5 v a n e l en g th s w i t h t h e f o l l o w i n g
rotor and cam ring marks:
Rotor and cam
Van6 l6ngth mm (in.)
flng mark
Non6 14.996- 14.998 {0.59039-0.59047}
1 4 . 9 9 -4 1 4 . 9 9 6( 0 . 5 9 0 3 1 - 0 . 5 9 0 3 9 )
14 . 9 9 2- 14 . 9 9 4( 0 . s 9 0 2 4 - 0 . 5 9 0)3 1
1 4 . 9 9 -0 1 4 . 9 9 2{ 0 . 5 9 0 1-60 . 5 9 0 2 4 }
L n s c r i b e dM a f k
4 1 4 . 9 8 8 -1 4 . 9 9 0{ 0 . 5 9 0 0-80 . 5 9 0 1 6 )
t*.
3. INSPECTFLOW CONTROLVALVE
(a) Coat the valve with pow€r steeringfluid and check
that it falls smoothlvinto ths valve hole of the front
housingby its own weight.
(b) Check the valve for leakage.Closeone of the holes

a n d a p p l yc o m p r o s s eadi r [ 3 9 2 - 4 9 0 k P a ( 4 - 5 k g f , /
cm' ,57 -71 psi)l into the oppositeside,and confirm
that air doss not come out from the end hole.
lf necessary,replacethe valve with one having the

sam6 letter as inscribedon ths front housing.
lnscribedmark:
Msrk A,B,C,D,EOTF

STEERING
4. INSPECT SPRING
Usinga calipers,
measure
thefreelengthof thespring.
Sprlngfree length:
36 mm (1.42in.)
lf not to specification,
replacethe spring.
5. IF NECESSARY, REPLACE OIL SEAL

N O T I C E :B e c a r e f u l n o t t o d a m a g et h o f r o n t h o u s i n g .
(b) Coat a new oil seal lip with power steeringfluid.

(c) Usinga socketwrench (23 mm) and hammer.drive in
the oil seal.
NOTICE:Make sure you install tho oil soal facing the
corrgctd irection.
P SV A N EP U M PA S S E M B L Y
1. COAT WITH POWERSTEERINGFLUID
(Seepage SR-49)
2. INSTALL SIDE FRONTPLATE
(a) Installa new shorterstraightpin to the plate.
(b) Coat 2 new O - ringswith power steeringf luid.
(c) I n s t a ltl h e 2 O - r i n g s t o t h 6 p l a t e .
(d) Installthe plateto the vane pump shaft.
3. INSTALL VANE PUMP ROTOR

(a) Install ths rotor to the vane pump shaft with the
inscribedmark facing outward.
(b) Insralla new snap ring.

sR-55
4. INSTALLNEWLONGER PIN
STRAIGHT
5. INSTALLVANE PUMPSHAFTWITH VANE PUMP

Alignthe holeof the plateandlongerstraightpin,and
tao in the shaftwith a plastichammer.
N O T I C E :B e c a r e f u l n o t t o d a m a g o t h o o i l . e e l a n d O -
nnga,
6. I N S T A L LC A M R I N G
Align the hol6sof th€ cam ring and 2 straightpins,and
install the ring with the inscribedmark facing out'
ward.
lnscribodMErk
7, INSTALL1OVANEPLATES
l n s t a ltlh Eo l a t ew i t h t h o r o u n de n df a c i n go u t w a r d .
Round
End
8, INSTALL SIDE REARPLATE

(a) Coat a new O - ring with powsr st€eringfluid.
(b) Installthe O-ring to the plate.
(c) Align th€ holes of the plate and 2 straight pins, and
installthe Dlat6.

STEERING
9. INSTALLWAVE WASHERAND REARHOUSING

(a) Installtha washer so that its protrusionsfit into the
slots in the side rear plate.
(b) Coat a new O-ring with power stosringfluid.
( c ) l n s t a l tl h e O - r i n g t o t h 6 h o u s i n g .
(d) Usinga plastichammer,tap in the housing.
(e) Installa new snap ring.
10. MEASURE VANE PUMP SHAFT ROTATING

TOROUE
(a) Using a torque metsr, check that ths shaft rotates
smoothlvwithout abnormalnoise.
(b) Temporarilyinstallthe vane pump pulleysot nut, and
check the rotatingtorquo with a torque met6r.
Rotatingtorque:
0.3 N.m(2.8kgl.cm,2.4in..lbf)or less
1 1 . I N S T A L LS P R I N GA N D F L O W C O N T R O LV A L V E
12, I N S T A L LP R E S S U RPEO R TU N I O N
(a) Coat a new O-ring with power steeringfluid.
(b) I n s t a l tl h e O - r i n g t o t h 6 u n i o n .
(c) Torquethe union.
13. I N S T A L LO I L R E S E R V O IARN D B R A C K E T
(a) Coat a new O - ring with power steeringfluid.
(b) Installthe O-ring to the reservoir.
(c) Torqueth6 4 bolts.
Torque:
12 mm headbolt
13 N.m(130kgt.cm.9 fr.tbt)
14 mm head bolt
41 N.m (420 ksf.cm,30 ft.lbf)

sR-57
1 4 . I N S T A L LA I R C O N T R O LV A L V E
( a ) I n s t a l al n e w u n i o ns e a t .
(b) Torquetho valvs.
Torque:36 N.m(370kgf'cm, 27 ft lbf)
1 5 , I N S T A L LV A N E P U M PP U L L E Y
(a) Installthe woodruff key to the vans pump shaft
(b) UsingSSTto stop ths pulleyrotating,torque ths nut.
s s r 0 9 9 6 0 1- 0 0 1 0
Torque: 43 N.m (440 kgf 'cm, 32 ft'lbf)

sR-58
PO W ER ST EERING P UMP
( 3 S - G E , 3 5 - F E5, 5 - F E )
COMPONENTS
S u p o rS l r u t S u s p e n iso n : U n i o nB o l t
\7
4il
2 1 6( 2 , 2 0 01, 5 9 ) (ffi
*wr
PressureFeedTube
tA
,'- i Gasket I
@
L o c kN u t
/' qg
Pin !n7 ,.---o
) R'l -r
\N9/f;il--j
Rerurn/)
. Hose /
1 0 8( 1 , 1 0 0 , 7 9 )
V i
P.:t
f;::'-6t*, DrveBe,
P S V a n e P u m pA s s e m b l y
2 1 6( 2 , 2 0 01, 5 9 )
3 S - G E: w / L S D
F r o n lD r i v eS h a t tA s s e m b l y S n a pF in g
n I
RH
b
lc
I L o c kN u tC a p
o t l e rP l n
N m ( k g l . c mf,t . l b t ) : S p e c i f i etdo r qu e
a N o n . r € u s a bpl ea r t
,1.For use with SST

STEERING
MAIN POINTSOF REMOVALAND

INSTALLATION
1 . D I S C O N N E CPTR E S S U RFEE E DT U B E
UsingSST.disconnect thetubofromthe controlvalvo
housing.
JJfUYOJt-ZZVZV
2. W I R I N GH A R N E S S
R E M O V EA B S S P E E DS E N S O R
CLAMP
w/ ABS:
Removetho bolt.
3. REMOVEDRIVESHAFT
(SeeSA section)
4. REMOVEDRIVEBELT
Loosonthe 2 bolts.
5, REMOVEPSVANEPUMPASSEMBLY
Rsmovethe 4 bolts.

STEERING
6. REMOVE AND INSTALLPRESSURE FEEDTUBE

(a) Securethe PSvanepumpassembly
in a vise.
NOTICE: Do not tightonthe vis6too tight.
(b) Removethe union bolt, gasketand tub6.
(c) Torquethe union bolt over a new gasket.
Pressure H I N T :M a k e s u r € t h e s t o p p e ri s t o u c h i n gt h e p u m p
F e e dT u b e
h o u s i n ga, s s h o w n ,t h e n t o r q u et h e u n i o nb o l t .
Torque:52N.m(525kgf.cm,38ft.lbt)
R10194
809632
7. CONNECTPRESSURE FEEDTUBE
PressureFeed
Tube Using SST, connect the tube to ths control valve
h ou s i n g .
ssr 09631-22020
HINT:Use a torque wrench with a fulcrum length of
3 0 0 m m ( 11 . 8 1i n . )
8. ADJUST DRIVEBELT TENSION
(See page SR-39)
( S e ep a g eS R - 4 1 )
1 0 . C H E C KA B S S P E E DS E N S O RS I G N A L
w/ ABS:
(SeeBR section)

STEERING
COMPONENTS
U n i o nB o l l
'n#
a S n a pR i n g
R e a rH o u s i n g
N . m ( k g f' c m , f t ' l : S p e c i f i e dt o r q u e
a N o n - r e u s a b lp
ea r t
<v--J r-Owersteerrng Flurd
P SV A N EP U M PD I S A S S E M B L Y
ESV A N EP U M PA S S E M B L IYN V I S E
1 . S E C U RP
N O T I C E :D o n o t t i g h t e n t h e v i s s t o o t i g h t .
2. REMOVE V A N EP U M PP U L L E Y
(a) UsingSSTto stopthe pull6yrotating,removetho nut.
s s T0 9 9 6 0 -1 0 0 1 0
(b) Removethe woodruffkeY.

sR-62
3. REMOVE AIR CONTROL VALVE

Removethe unionseat.
4. REMOVE P R E S S U RFEE E DN O . 2T U B E
Rgmovethe unionboltand 2 gaskets.
5. REMOVE
SUCTION
P O R TU N I O N
i l
( a ) Remove
the bolt.
(b) Remove the O- ringf romth6 union.
REMOVEPRESSURE PORTUNION
R e m o v teh e O - r i n g f r o mt h e u n i o n .
7. REMOVEFLOWCONTROL
VALVEAND SPRING

- POWERSTEERING
sR-63
STEERING
8. REMOVEREARHOUSING AND WAVEWASHER

removethe snapring.
(a) Using2 screwdrivers,
Screwdriver
(b) Using a plastic hammer,tap out the housing and

wasner.
(c) Removethe O-ring from the housing.
9. REMOVE SIDEREARPLATE
(a) Usinga plastichammsr,tap out the plate.
(b) Removethe O-ring from tha plate.
10. REMOVE C A M R I N GA N D 1 OV A N EP L A T E S
Removethe ringand platesfrom the shaft.
11. REMOVE V A N EP U M PS H A F TW I T H V A N EP U M P
Removethe longerstraightpin from the front hous-
ing.
12, REMOVE V A N E P U M PR O T O RA N D S I D EF R O N T
PLATE
(a) Usinga screwdriver,removethe snapring.
?mffi (b) Removethe 2 O-rings from the plate.
ffi#gy*

STEERING
(c) Secure the plate in a vise.

V i n y lT a p e
NOTICE:
o Placeshopragsbetwoenthg viseand the plata.
. Do not tighton tho vise too tight.
(d) Using pliers with vinyl tape wound around the jaw
ends,removethe shorterstraightpin from ths plate.
C a l i p e rG a u g e P SV A N EP U M PI N S P E C T I OANN D
REPLACEMENT
1 . M E A S U R EO I L C L E A R A N C EO F V A N E P U M P
S H A F TA N DF R O N TH O U S I N G
BUSHING
Usinga micrometer andcalipergauge,measure the oil
crearancs.
Standard clearance:
26770 R09381 0.01-0.03mm (0.000a
- 0.0012in.)
Maximumclearanca:
0.07mm(0.0028in.)
lf more than maximum,reolacethe entire PS vane
pump.
2. I N S P E C TV A N E P U M P R O T O RA N D 1 0 V A N E
PLATES
l-
H e i o h tl
(a) Usinga micrometer,
and lengthof the plato.
measurethe height,thickness
I M i n i m u m h e i gh t :
8 . 1 m m ( 0 . 3 19 i n . )
Minimum thickness:
1.797mm (0.0707in.)
Minimumlength:
14.988mm(0.59008in.)
(b) Usinga feelergauge,measurethe clearanc6batween
the rotor grooveand plate.
Maximumclearance:
0.03mm(0.0012in.)
l f m o r e t h a n m a x i m u m ,r e p l a c et h e p l a t e s a n d / o r
rotor with one havingthe same mark stampedon the
cam flng.
I n s c r i b e dm a r k :
1, 2, 3. 4 or None

HINT: There are 5 vane lengths with the following
rotor and cam ring marks:
Rotor and cam
Vano l€ngth mm (in.)
ring mark
-0.59047)
14.996- 14.998(0.59039
None
14.994- 14.996 -0.59039)
(0.s9031
1 4 . 9 9 2 -1 4 . 9 9 4( 0 . s 9 0 2-40 . s 9 0 31)
Mark
lnscribed 1 4 . 9 9 0 -1 4 . 9 9 2( 0 . 5 9 0 1-60 . 5 9 0 2 4 )
4 14.988- 14.990(0.59008-0.5901
6)
3, INSPECTFLOW CONTROLVALVE
(a) Coat the valve with power steeringfluid and check
that it falls smoothlyinto the valve hole of the front
housingby its own weight.
(b) Check the valve for leakage.Closeone of ths holss

air [392-490kPa (4-SkSI/
a n d a p p l yc o m p r e s s a d
cm', 57 -71psi)l into the oppositeside,and confirm
that air does not come out from the end hole.
Air
Compressed
lf necessary,raplacethe valve with one having the

same letter as inscribedon ths front housing.
lnscribedmark:
A,B,C,D,EOTF
4. INSPECTSPRING
Usinga calipers,msasurethe free lengthof the spring'
S p r i n gf r a e l e n g t h :
3 6 m m ( 1. 4 2 i n . )
l f n o t t o s p e c i f i c a t i o n ,r e p l a c e t h e s p r l n g .

sR-66
5. IF NECESSARY, REPLACE OIL SEAL

N O T I C E :B e c a r e f u l n o t t o d a m a g et h e f r o n t h o u s i n g .

(c) Usinga socketwrench (23 mm) and hammer,drive in
the oil seal.
NOTICE:Make sure you installthe oil seal fscing tho
correctdirection,
P SV A N EP U M PA S S E M B L Y
1. COAT WITH POWERSTEERINGFLUID
(Seepage SR- 61)
2, INSTALL SIDE FRONTPLATE
(a) Installa n6w short€rstraightpin to the plate.
(b) Coat 2 new O - ringswith power st6eringf luid.
(c) Installthe 2 O-rings to the plate.
(d) lnstallthe plat€to the vane pump shaft.
3. INSTALL VANE PUMP ROTOR

(a) Install th€ rotor to the vane pump shaft with the
inscribedmark facing outward.
(b) lnstalla new snap ring.
4, INSTALLNEWLONGER
STRAIGHT
PIN

5. INSTALLVANE PUMPSHAFTWITH VANE PUMP

ROTOBAND SIDEFRONTPLATE
Alignthe hol6of the plateandlongerstraightpin,and
tap in the shaftwith a plastichammer.
NOTIGE:Be careful not to damago the oil seal and O-
rings.
E. INSTALL CAM RING

Align the holesof the cam ring and 2 straightpins,and
install th€ ring with the inscribedmark facing out-
wa rd.
7. INSTALL1OVANEPLATES
Installthe platswith the roundendfacingoutward,
R o u n dE n d
8. INSTALL SIDE REARPLATE

(a) Coat a new O-ring with powor stoeringfluid.
(b) lnstallthe O-ring to the plats.
(c) Align the holes of the plate and 2 straight pins, and
installthe olat6.
,y
9. INSTALLWAVEWASHER
lnstallth6 washerso that its protrusions
fit lnto the
slotsin the siderearplate.

SR-68
10. I N S T A L LR E A RH O U S I N G
(a) Coat a new O - ring with power steeringf Iuid.
(b) l n s t a l tl h e O - r i n g t o t h e h o u s i n g .
(c) Usinga plastichammer.tap in the housing.
(d) Installa new snap ring.
T o r q u eM e t e r 11. MEASURE VANE PUMP SHAFT ROTATING

TOROUE
(a) Using a torque meter, check that the shaft rotates
s m o o t h l vw i t h o u ta b n o r m anl o i s e .
(b) Temporarilyinstallthe vans pump pulleysst nut, and
check the rotatingtorque with a torqus m6ter.
Rotatingtorque:
0.3 N.m(2.8kgl.cm,2.4in..lbf)or less
ii:qBil
12. INSTALL SPRINGAND FLOW CONTROLVALVE
13. INSTALL PRESSURE PORTUNION

(a) -
Coat a new O ring with power steeringf luid.
(b) lnstallthe O-ring to th€ unron.
(c) Torquethe union.
Torque:69 N.m(700kgf.cm.51ft.lbf)
14. INSTALLPRESSURE FEEDNO.2TUBE

Torquethe unionbolt over2 new gaskets.

sR-69
HINT: Pressurefeed No.2 tube installationangle is

35'.
15. I N S T A L LS U C T I O NP O R TU N I O N
(a) Coat a new O - ring with powor steeringf luid.
,
(b) I n s t a ltl h e O - r i n g t o t h e u n i o n .
(c) Installthe unionwith the bolt.
Torque:13 N.m(130kgf.cm,I tt.lbf)
ffi
1 6 . I N S T A L LA I R C O N T R O LV A L V E
( a ) I n s t a l al n a w u n i o ns e a t .
(b) Tightenthe valve.
1 7 . I N S T A L LV A N E P U M PP U L L E Y
(a) Installths woodruff key to the vane pump shaft.
(b) UsingSSTto stop the pulloyrotating,torque the nut.
- 10010
ssT09960
T o r q u e : 4 3 N . m ( 4 4 0 k g f ' c m , 3 2f t ' l b f )

sR-70 STEERING- POWERSTEERING
G E A RH O U S I N G
C O M P O N E N T( L
SH D )
MacPherson Strut Suspension:
PressureFeed
a n dR s t u r nT u b e s
I n t e r m e d i a tN
e o . 2S h a f l
P S G e a r H o u s i n gA s s e m b l y
a CotteP
r in
o@
1 2 7 ( 1, 3 0 0 ,9 4 )
F r o n lS u b - F r a m € I 1 7 s( 1 , 8 0 01,3 0 )
a
CenleN
r rember
r 2 7 ( 1 , 3 0 09, 4 )
F r o n l E x h a u s tP i p e
E n g i n eU n d e rC o v e r
N m ( k g f , c m l,t l b f ) : S p e c i l i e dt o r q u e
a N o n ' r e u s a bpl ea r l
{ <F o ru s ew i t hS S T ts/

- POWER
sR-71
STEERING STEERING
COMPONENTS (LHD)
SuperStrut SusPension:
Feedand FleturnTubes
Pressure
t so , 2S h a f t
l n l e r m e d l aN
P S G e a rH o u s l n A
g ssembly #---@, FsG6fi6)-l
I
..i dr,'
solP---6
I as1soo, tr
, ? l t '
a CotlerPin- i
3 9 ( 4 0 0 , 2 9 )I
@
)a ' |7 5 ( 1
, 8 0 0 1, 3 0 )
FrontSub'Frame
Ga sk e t
t-,
t l , \
6a I Gasket
t
@
NQ-,'
e\\F?r(1,'s
C e n t eM
r ember
a CotterPin Li.;N,t;
F r o n tE x h a u sPt i P e
Cover
Under
Englne
N . m ( k g fc m , f l l b f ) : Specie
f dl o r q u e
a Non-reusable
Part
* ForusewllhSST

STEERING
COMPONENTS (RHD)
MacPherson
Strut Suspension:
PressureFeedTube
i a t eN o . 2
.ev
,#v
Ptsoo';;-l--e
/
r
a C o t t e rP i n
P S G e a rH o u s i n A
g ssembly 6a
@ '
r 1 7 5( 1 , 8 0 01, 3 0 )
FronS
t ub-Frame .,'A
Gasket
I ;r i g-.F,'"'*lt'l
l_
t l
ss
@
-@
nlerMember
t27(1,300,94)
F r o n tE x h a u sPt i p e
E n g i n eU n d e rC o v e r
N . m ( k g lc m , l l ' l b f ) S p e c r l r e tdo r q u e
a N o n - r e u s a bPl ea r t
* F o ru s ew i t hS S T

sR-73
C O M P O N E N T( R
SHD)
SuperStrut Suspension:
PressureFeedTube
l n t e r m e d l a tN
e o.2
R e t u r nH o s e
a CotterPin
P S G e a rH o u s i n A
g ssembly @
a__,4-
1 7 s( r , 9 0 0 1
, 30)
FronS
t ub-Frame
'@
C e n t eM
f ember
a CotteP
r in
F r o n tE x h a u sPt i p e
E n g l n eU n d e cr o v e r
N m ( k g fc m , f t l b f ) : S p e c i l i e dt o r q u e
part
a Non-reusable
* ForusewithSST
g

sR.74 STEERING- POWERSTEERING
M A I NP O I N T S
OF REMOVAA
L ND
INSTALLATION
N O T I C E :l f t h o c o n t o r i n g i s d o n o w i t h o u t r e m o v i n g t h e
s t o s r i n g w h e e l , u s e t h e p r o c e d u r ab e l o w t o m a k e s u r e
t h o s t o e r i n gw h e e l i s l i r m l y f i x e d i n p o s i t i o na n d c a n n o t
turn.
1 . D I S C O N N E CTTI E R O D E N D S
(a) Removethe cotter pin and nut.
(b) UsingSST,disconnectthe tie rod end from the knuck-
le arm.
s s T0 9 6 1 02- 0 0 21
2 . D I S C O N N EIC NTT E R M E D I ANTOE. 2S H A F T
(a) Positionthe front wheelsfacing straightahead.
(b) Usingthe seat belt of the driver'sseat,fix the st€ering
wheel so that it does not turn.
( c ) P l a c em a t c h m a r kosn t h e N o . 2s h a f ta n d c o n t r o vl a l v e
shaft.
(d) Loossnbolt A and removebolt B.
3. D I S C O N N E CP
TRESSURE FEED AND RETURN
TUBES
UsingSST,disconnect the tube.
ssT 09631 -22020

- POWERSTEERING sR-75
STEERING
4, S U P P O RETN G I N E
E n g i n eS u p p or t F i x t u r e
U s r n ga n e n g i n es u p p o rfti x t u r es, u p p o rtth e e n g i n e .
5. D I S C O N N E CRTI G H TA N D L E F TL O W E RA R M S
MacPherson Strut Suspension:
(a) Removethe bolt and2 nuts.
(b) Disconnect the armfrom the lowerballjoint.
Super Strut Suspension:

( a ) R e m o v et h 6 n u t a n d 2 b o l t s .
( b ) D i s c o n n e ctth e s t o e r i n gk n u c k l ef r o m t h a l o w e r b a l l
joint attachm€nt.
(c) Removeths cottor pin and lock nut cap,

(d) Removethe n ut.
( e ) U s i n gS S T ,d i s c o n n e ctth e c a m b e rc o n t r o la r m f r o m
the shock absorber.
55t UYOZ6- OZU | |

STEERING
(f) Removethe nut and disconnectth6 stabilizerbar link
f rom tho stabilizer.
H I N T :l f t h e b a l l j o i n st t u dt u r n st o g e t h e rw i t h t h e n u t ,
6. D I S C O N N E C2T E N G I N EM O U N T I N G S
Front sido:
Removethe bolt and nut.
R e a rs i d e :
Rsmovetho bolt.
B e a rS i d e
9r \
7. REMOVE FRONT S U B - F R A M EW I T HP SG E A RA S .
SEMBLY
R e m o v teh s 1 0 b o l t s .
g
I
I
____--a

_ POWERSTEERING
sR-77
STEERING
8. IT.ISTALL PS GEAR HOUSINGASSEMBLY

(a) Set the housing assembly so that it matches th€
dimensionsshown below,with the housingasssmbly
at the center Polnt.
Dimension A: 30'5 mm (1.20in.)
D i m e n s i oBn: 4 5 1 . 5m m ( 1 7 . 7 8i n . )
( b ) l n s t a l tl h s h o u s i n ga s s e m b l yt o t h e f r o n t s u b - f r a m e
with the 2 bolts and nuts.
Torque:127 N'm (1,300kgf cm' 94 ft lbf)
9. C O N N E C TP R E S S U RFEE E DA N D R E T U R NT U B E S
UsingSST,connocttha tube
ssT09631-22020
Torque:36 N m (365kgf'cm,26 ft lbf)
H I N T :U s e a t o r q u ew r e n c hw i t h a f u l c r u ml e n g t ho f
3 0 0 m m ( l 1 . 8 1i n . )

sR-78
1 0 . C O N N E CITN T E R M E D I A N
TEO . 2S H A F T
(a) Alignthe matchmarks on the No.2shaftand control
valveshaft.andconnectthem.
(b) Torquetha 2 bolts.
1 1 . B L E E DP O W E R S T E E R I NSGY S T E M
( S e ep a s eS R - 4 1 )
1 2 . C H E C KS T E E R I NW GH E E LC E N T E R
POINT
1 3 . C H E C KF R O N TW H E E LA L I G N M E N T
(SeeSA section)

_ POWER
sR-79
STEERING STEERING
C O M P O N E N T( L
SH D )
Clamp
Clip
Lock Nut
i d 6
tffi?o,41tl
-f-
fiD /-/^\
--{5.i- Tie Rod End
\J
'.i-il-..-
i RackEnd
l- s3 (880.61tl
l'60 (612,44)l
aOil Sesl
+g
fle
- l
b l f d i \ i
O-Ring
Teflon Ring aw -;-ffim-j
f5r"Y
1 3 9( 4 O 0 , 2 9I 1I R a c kH o u s i n gN o . 2 G r o m m e t
RackHousingNo. 2 Brack€t
- -
C y l i n d e rE n d S t o P P € r -
I .o,,r".,
i
. l q
@ n
L
I Y
I
i S n a PHrng
d-: \)
F'o
I
N . m ( k q f. c m , f t . l b J) : S p e c i f i e dt o r q u e
a Non-reusable Part
For use with SST e P o w e r s t e e r i n gJ l u i d t d i s u l p h i d el i t h i u m b a s e g r e a s e
N4olybdenum

sR-80
Dust Cover
a U n i o nS e a t
Turn Pressure
Tube
C o n t r o lV a l v e
Housing
. o,,,"",_Slo
,"",,nn_e)*
r
a Control Valve
Assembly
O Union Seat
Q - -
tf Tef lon Ring
Bearing
aO,,a""'N c)(VO O - R i n g * R a c kG u i d eS p r i n gC a p
\)
'u,b0-y
RackGuide
RackGuide
Spring 1
2^b
II fAt
nr
* R a c k G ui d e S p r i n g
@-48 R a c kG u i d e
Cap Lock Nut
, \
R a c kG u i d eS e a t
N ' m ( k q t . c m ,l t . l b l) ' S p e c i f i e dt o r q u e
a N o n - r e u s a b l ep a r t
* Precoated part
For use with SST
t M o l y b d e n u md i s u l p h i d el i t h i u m b a s e g r e a s e
P o w e r s t e e r i n gf l u i d

sR-81
C O M P O N E N T( R
SHD)
''"*oo'nox*
d FiackrBoot
I-\ ffi
I
I Y qaH c,amp
I c,p\K@
(/._
A
R a c kE n d
. C l a wW a s h e r
R a c kH o u s i n gN o . 2
Bracket
a OilSeal I
I
I
f\
t"- I
l.
.-t.-
O T e fl o n F i n O - @
^\
.o,,r"",.\6yl?^--.-_ 6 f fle
6 ls
t-.-- I o-nins
c y r ; n 0r"i @
, ,\
S t o' p
' per
-
#?*
Y
,/
I S n a pn i n g
a^
ICI
i _-ocr.*,|,.r)
-!
\ - - ;|
N m (kgi cm, ll lbf) : S p e c i l i e dt o r q u e ( \
a N o n - r e u s a b lpea r t
* F o r u s ew i l hS S T
+ N 4 o l y b d e n uDmi s u l p h i dLei t h i u mB a s eG r e a s e
€ P o w e rS t e e r i n gF l u i d

sR-82
a U n i o nS e a t
--t--
- 3l 1 ( 3 1 5 , 2 3 )
I II
D u s tC o v e r
h C o n l r oVl a l v eH o u s i n g
g b '
\ a U n i o nS e a l
T u r nP r e s s u rTeu b e
t oirsear---@€
eeartno---@a
Control Valv€
A ss e mb l y
:----
Bearing
a T e fl o n R i n g
a 9- a unionseat
* R a c kG u i d eS p r l n g
cap
cap I
f o-Fins
+Q- Rack
Guide I
+@-
' oilseal
:r:ilitJ 6$ -b4d% * R a c k G u i d eS p r i n g
C a pL o c kN u t
eearins-@f
* RackHouslno
@-
@-' * RackHousingcap
L o c kN u l
N m ( k g f c m , f t l b f) : S p e c i l i e dl o r q u e
a N o n - r e u s a bpl ea r t
F6.(too,so)
* s 0( 5 1 13, 7 )
I
I |
* Pr€coatedparl
,. For use with SST
+N.4olybdenum Disulphide LithiumBas€Grease
+ P o w e r S l e € r i n gF l u i d

DISASSEMBLY
P S G E A RH O U S I N G
1. REMOVE RETURN T U B EN O , 1S U B - A S S E M B L Y
RHD:
UsingSST.removeths tubs.
ssT 09631-22020
2, S E C U R EP S G E A RH O U S I N GA S S E M B L YI N V I S E
U s i n gS S T ,s e c u r st h e h o u s i n ga s s e m b l yi n a v i s e .
s s T0 9 6 1 2 - 0 0 0 1 2
3. REMOVE2 TURNPRESSURE TUBES

(a) UsingSST,removethe tub€.
s s T 0 9 6 3 3- 0 0 0 2 0
(b) Removethe 2 unions€atsfrom the rackhousing.
4, REMOVE T I ER O DE N D SA N D L O C KN U T
( a ) P l a c em a t c h m a r kosn t h e t i e r o de n da n dr a c ke n d .
(b) Loos6nthe locknut.
5. REMOVERACK BOOTS
(a) Removethe clip.
(b) Loosenthe clamp.
(c) Removsthe boot.
NOTICE:Bs carefulnot to damsgsths bootsand rack
housing.
(d) Ramovethe clamp from the boot
{e) Mark the right and lsft boots,

STEERING
6. REMOVERACKENDSAND CLAWWASHERS
Screwdriver (a) Securethe rackend in a vise.
(b) Usinga screwdriverand hammer,unstakethe washer.
NOTICE:Avoid any impact to ths stesring rack.
(c) Using a spanner122 mml to hold the steering rack

sleady,and using SST,removethe rack end.
s s r 0 9 9 2-2 1 0 0 1 0
N O T I C E :U s e S S T 0 9 9 2 2 - 1 0 0 1 0 i n t h e d i r e c t i o ns h o w n
in the illustration.
(d) Mark the right and left rack ends accordingly.
7. REMOVE R A C KG U I D ES P R I N G
C A PL O C KN U T
UsingSST,rsmovethe nut.
s s T0 9 9 2 2 -l 0 0 1 0
R a c kG u i d eS p r i n g
C a p L o c kN u t
8. REMOVE R A C KG U I D ES P R I N G
C A P ,R A C KG U I O E
SPRING A N DR A C KG U I D E
Usinga hexagon wrench(24 mml,removethe cap.

- P O W E RS T E E R I N G sR-85
STEERING
9. REMOVERACKGUIDESEAT
removethe seatfrom the rack
Usinga screwdriver.
guide.
10. REMOVE C A PL O C KN U T
R A C KH O U S I N G
UsingSST,romovotho nut.
s s T0 9 9 2 -2 1 0 0 0
1
N O T I C E :U s a S S T 0 9 9 2 2 - 1 0 0 1 0 i n t h e d i r e c t i o ns h o w n
in ths illustration.
11. REMOVE R A C KH O U S I N G
CAP
Usinga hexagon wrench124mml,r€movethe cap
12. REMOVE BEARING
R a c k H o u s i n gC a p
13. REMOVE C O N T R OV L A L V EH O U S I N G W I T HC O N -
TROLVALVEASSEMBLY
(a) Remove the dustcovor.
rks
N,4atchma ( b ) P l a c em a t c h m a r kosn t h e v a l v eh o u s i n ga n d r a c k
houslng.
(c) Remove ths 2 bolts.
(d) Removethe O-ring from the rack housing.
't
'A

sR-86 STEERING- POWERSTEERING
14. REMOVECONTROLVALVE ASSEMBLY

(a) To preventoil seal lip damage,wind vinyl taps on ths
Vinyl Tape
serratedoart of the valve shaft.
(b) Using a plastichammer,tap out the valve assembly
from the valve housing.
% R09540
NOTICE:8e carefulnot to damagetho oil soallip.
15. REMOVE N O . zB R A C K E T
R A C KH O U S I N G
(a) Placematchmarks on the brackatand rackhousing.
Matchmarks
(b) Removetho bolt.

1 6 . R E M O V ER A C K H O U S I N GN O . 2G R O M M E T
Remove th6 grommet from the rack housing No.2
brackot.
17. REMOVE C Y L I N D EE
RN DS T O P P E R
(a) Usingsnapringpliers,removethe snapring.
--6@ (b) Removethe stoppsrfrom the rack housing.

sR-87
18. BEMOVE S T E E R I NRGA C KW I T HO I LS E A L

Usingan extension bar,pressout the rackwith the oil
ssal.
NOTICE:Takecarenot to droptho rack.
19. REMOVE O I LS E A L
Using SST, prossout the oil sEal.
s s r 0 9 6 3 1 1 2 0 2 00, 9 6 3 1- 2 0 0 3 1
-
I N S P E C T I OANN D
P SG E A RH O U S I N G
r
D i aI I n d i c a t o REPLACEMENT
1 . I N S P E CS TT E E R I NRGA C K
( a ) U s i n ga d i a li n d i c a t ocr ,h e c kt h e r a c kf o r r u n o u ta n d
for t€othwearanddamage.
Marimumrunout:0.15 mm (0.006in.)
( b ) C h e c kt h e b a c ks u r f a c ef o r w e a r a n d d a m a g €
lf faulty.replacsit.

sR-88
2. IF NECESSARY. REPLACE CONTROL VALVEHOUS-

I N GO I LS E A LA N D B E A R I N G
(a) UsingSST,pressout the bearingand oil seal.
s s T 0 9 6 2 0 - 3 0 0 1 0( 0 9 6 3-10 0 0 2 0 )
0 9 6 3 0 -2 4 0 13 ( 0 9 6 2 0 - 2 4 001)
(b) Coata new oil seallip with powsrsteoringfluid.

(c) UsingSST,pressin the oil seal.
s s T0 9 6 2 0 - 3 0 0 1(00 9 6 3-10 0 0 2 0 )
0 9 6 3 0 - 2 4 031 { 0 9 6 2 0 -2 4 0 2 0 )
N O T I C E :M a k e s u r e y o u i n s t a l l t h e o i l s e a l f a c i n g t h e
correct d irection.
(d) UsingSST,pressin a new bearing.

s s T 0 9 6 2 0 - 3 0 0 1 0( 0 9 6 3-10 0 0 2 0 )
0 9 6 3 0 -2 4 0 13 ( 0 9 6 2 0 - 2 4 0 3 0 )
3. IF NECESSARY.REPLACE RACK HOUSING OIL

SEAL
(a) Set the SST as shown in the illustration.
ssT 09612-30012
(b) Turn A clockwiseand engagethe tips of C on the oil
seat.
HINT:Apply the tips of C to the cutouts in the rack
housing.
( c ) U s i n ga s p a n n e r( 8 m m ) ,k e e p A f i x e d w h i l e t u r n i n g
nut B clockwise,and removethe oil seal.
NOTICE: Be carefulnot to damagetha rack housing.
Cutouts

STEERING
SST
(d) Coata newoil seallip with powerstsoringfuild
(e) UsingSST,pressin the oil seal.
U Seat)
s s T 0 9 6 2 0- 3 0 0 10 ( 0 9 6 2-4 3 0 0 10 )
U (0963 1- 0 0 0 2 0 )
N O T I C E :M a k e s u r a y o u i n s t a l l t h e o i l s o a l f a c i n g t h e
corrgct d irgction'
4. I F N E C E S S A R YR, E P L A C ET E F L O NR I N GA N D O -
RING
(a) Using a screwdriver,removethe tef lon ring and O -
ring from the stoeringrack.
NOTICE:8o caretulnot to damagetho groovafor the
taflonring.
( b ) C o a t a n a w O - r i n g w i t h p o w e r s t e s r i n gf l u i d , a n d
i n s t a l il t .
(c) Expanda new teflon ring with your fingers.

NOTICE:Bs carefulnot to over-expandthe 7in9.
(d) Coat tho ring with power steeringfluid.

(e) Installthe ring to th6 stseringrack,and snug it down
with your fingers.
5. IF NECESSARY. REPLACE4 TEFLONRINGS

(a) Usinga screwdriver,removethe rings from the con-
trol valveassembly.
NOTICE:Be carefulnot to damagothe groovasfor the
ring.

sR-90 - P O W E RS T E E R I N G
STEERING
(b) Expand4 naw teflon ringswith your fingers.
NOTICE:Bs carsfulnot to ovor-axpandthe rings.
(c) Coat the ringswith power steeringfluid.

(d) Installthe rings to the control valve assembly,and
snug them down with your fingers.
'",-ffi (e) Carafullyslide the taperedend of SST over the rings

to seat them.
s s T 0 9 6 3 1- 2 0 0 8 1
NOTICE: Be carefulnot to damagethe rings.
6. IF NECESSARY, REPLACE4 UNION SEATS

(a) Securethe controlvalve housingin a vise.
(b) Using a screw extractor,remove the seats from the
controlvalvghousing.
Un i o n S e a t
(c) Usingan Extensionbar,tap in 4 new seats.

sR-91
7. INSPECT CONTROL VALVEBEARING

Checkthe bearingrotationconditionand checkfor
abnormal noise.
roplacethe control
lf the b€aringis wornor damaged,
valveassembly.
8. INSPECTCYLINDEREND STOPPERBUSHING
(a) Check for wear and damage on the inside of the
bushing,
lf tha bushingis worn or damaged,replacathe cylin-
der gnd stopper.
(b) Coat inside of the bushing with molybdenumdis-
u l p h i d el i t h i u mb a s eg r e a s e .
ASSEMBLY
PS GEARHOUSING
1. COATWITHPOWERSTEERING FLUIDORMOLYB-
OENUMDISULPHIDE LITHIUMBASEGREASE
(SeepasesSR-79 to SR-82)
2, INSTALLOIL SEAL
(a) Coata new oil seallip with powersteeringfluid.
(b) UsingSST,pressin tho oil seal.
ssr 09631- 12020,09631-20040
ITIOTICE:
r Makc !ur! you Inttlll thr oll rcal faclng thr co?rcct
dlrcctlon.
r Takc c!rc thlt tho oll tcal doga not got itycrrgd !r
you Inrtall lt.

STEERING
3. INSTALLSTEERINGRACK
(a) InstallSST to th6 rack.
HINT:lf necessary, scrapethe burrsoff the rack teeth
e n da n d b u r n i s h .
s s T0 9 6 3-1 2 0 0 5 1
sR2178
(b) Coat SST with power steeringfluid.

( c ) I n s t a l tl h e r a c k i n t o t h e r a c k h o u s i n g .
(d) RemovaSST.
4, INSTALL OIL SEAL

( a ) T o p r e v e n to i l s e a l l i p d a m a g e .r n s t a l lS S T t o t h e
steeringrack,and apply power steeringfluid.
s s T 0 9 6 3 1- 2 0 0 5 1
HINT: Install SST to the steeringrack side without
teeth.
{ c ) l n s t a l tl h e o i l s e a l .
NOTICE: Make sura you install the oil seal facing the
correct d irection.
(d) RemoveSST.
H I N T :H o l d t h e o i l s e a l d o w n w i t h v o u r h a n dt o o r e -
v6nt it comingout togetherwith SST.
5. INSTALL CYLINDEREND STOPPER
\ -*K@@*"
A (a) Installthe stopperinto the rack housing,

sR-93
( b ) U s i n gs n a pr i n g p l i e r si,n s t a l a
6. AIR TIGHTNESSTEST
( a ) I n s t a lSl S Tt o t h o u n i o n so f t h e r a c k h o u s i n g .
ssr 09631- 12071
( b ) A p p l y5 3 . 3 k P a ( 4 0 0 m m H g , | 5 . 7 5 i n . H g )o f v a c u u m
for a bout 30 seconds.
( c ) C h e c kt h a t t h e r ei s n o c h a n g ei n t h e v a c u u m .
l f t h e r ei s c h a n g ei n t h e v a c u u m c, h e c kt h e i n s t a l l a t i o n
o f t h e r a c k h o u s l n go i l s e a l s .
7. I N S T A L LR A C K H O U S I N GN O , 2 G R O M M E T
l n s t a l tl h s g r o m m s t o t h e r a c k h o u s i n gN o 2 b r a c k e t .
8 . I N S T A L LR A C K H O U S I N GN O . 2 B R A C K E T
(a) Align the matchmarkson the bracketand rack hous-
Ing.
Matchmarks
(b) Torqueths bolt.

Torque:39 N.m(400kgf cm. 29 ft'lbf)
9 . I N S T A L LC O N T R O LV A L V E A S S E M B L Y
( a ) T o p r e v e no , i n d v i n y lt a p e o n t h e
t i l s e a ll i p d a m a g ew
serratedpart of the valveshaft.
(b) Coat tho teflon ringswith power steeringfluid.
(c) Securaths controlvalve housingin a vise.
( d ) U s i n ga p l a s t i ch a m m e rt,a p i n t h e v a l v ea s s e m b l yi n t o
t h e v a l v eh o u s i n g .
NOTICE: Becarefulnot to dsmagethe teflonringsandoil
s e al .

sR-94
1 0 . I N S T A L LC O N T R OV
L A L V EH O U S I N G
W I T HC O N -
TROLVALVEASSEMBLY
( a ) Coat a new O - ring with power steeringfluid.
( b ) I n s t a l tl h s O - r i n g t o t h s r a c k h o u s i n g .
(c) A l i g nt h e m a t c h m a r k os n t h e v a l v eh o u s i n ga n d r a c k
housing.
(d) Torquethe 2 bolts.
(e) lnstallthe dust cover.
11 . I N S T A L LB E A R I N G
1 2 . I N S T A L LR A C KH O U S I N G
CAP
(a) Applysealantto 2 or 3 threadsof th6 cap.
Ssalant:
PartNo.08833-00080, THREEBOND1344.
LOCTITE242 or equlvalent
(b) Temporarilyinstallth6 cap.
(c) Use SSTto measur€ths rotationaltorque of th€ con-
trol valveshaft,and makea note of the torque value.
1- 0 0 0 1
s s T0 9 6 6 0
(d) Usinga hexagonwrench (24 mm),torque ths cap.
Torque:t 5 N.m(150kgf.cm,11 ft'lbf)
R 8 c kH o u s i n gC a p
(e) Using SST,a torque m6ter and hexagonwrench (24

mm),loosenthe cap until tho prsloadis within specifi-
cation.
1- 0 0 0 1
ssr 0966 0
Prcload(turning):
Torqucvrluc from (c)above * 0.1 - 0,2 N.m
(1 - 2 ksf'cm,0.9 - 1.7 in..lbf)

- POWER
STEERTNG STEERINq
1 3 . I N S T A L LR A C KH O U S T NCGA PL O C KN U T
R a c kH o u s i n gC a P
L o c kN u t (a) Applysealantto 2 or 3 throadsof the nut.
Sealant:
PartNo.08833-00080,THREEBOND1344,
LOCTITE 242 or equivalent
(b) Using a hexagonwrench (24 mm) to stop the rack
He x a g on
housingcap rotating,and using SST.torque the nut
Wrench s s T0 9 9 2 2 - 1 0 0 1 0
T o r q u e :5 0 N ' m ( 5 11 k g f ' c m . 3 7 f t l b f)
N O T I C E :U s e S S T 0 9 9 2 2 - 1 0 0 1 0 i n t h e d i r a c t i o ns h o w n
in tho illustration.
HINT: Use a torqus wrench with a fulcrum lsngth of
F u l c r u mL e n g t h
3 4 0 m m ( 13 . 3 9i n . ) .
14. INSTALLRACKGUIDESEAT,RACKGUIDE,RACK
CAP
G U I D ES P R T NAGN D R A C KG U I D ES P R I N G
(a) Installth6 soatto the guide.
(b) Applysealantto 2 or 3 threadsof ths cap.
Sealant:
PartNo.08833-00080, THREEBONO1344.
LOCTITE 242 or equivalent
installths caP.
(c) TemporarilY
15. ADJUST TOTAL PRELOAD

R a c kG u i d eS p r i n g (a) Using a hexagonwrench (24 mm), torque the rack
g u i d es p r i n g c a P .
Torqua:25ttrl.m (250kgf'cm,18 ft'lbf)
wrench(24 mm),returnthe cap 12'.

(b) Usinga hexagon

sR-96
STEEBING_ POWERSTEERING
(c) UsingSST,turnthe controlvalveshaftrightandleft 1

or 2 times.
s s T0 9 6 1 6 - 0 0 0 1 0
( d ) U s i n ga h e x a g o nw r e n c h( 2 4 m m ) ,l o o s e nt h e c a p u n t i l
R a c kGu i d e S p r i n g
t h g r a c kg u i d es p r i n gi s n o t f u n c t i o n i n g .
( e ) U s i n gS S T ,a t o r q u em s t s r a n d h e x a g o nw r e n c h( 2 4
m m ) ,t i g h t e nt h e c a p u n t i lt h e p r e l o a dj s w i t h i ns p e c i -
fication.
ssT09616-00010
Praload(turning):
1 . 2 - 1 . 5 N . m{ 1 2 - 1 5 k s f . c m 1 . 0 . 4 - 1 3 . 0i n . . l b f )
1 6 . I N S T A L LR A C KG U I D ES P R I N GC A P L O C K N U T
(a) Apply sealantto 2 or 3 threadsof the nut.
Sealsnt:
Part No.08833-00080, THREEBOND1344,
LOCTITE 242 or eouivalent
(b) Using a hexagonwrench (24 mm) to stop th6 rack
guide spring cap rotating,and using SST,torque the
NUI.
R a c kG u i d eS p r i n gC a p L o c kN u t s s T 0 9 9 2 2- 10 0 10
T o r q u e :5 0 N m ( 5 11 k g f . c m , 3 7 f t . l b f )
N O T I C EU : s e S S T 0 9 9 2 2 - 1 0 0 1 0 i n t h e d i r e c t i o ns h o w n
3 4 0 m m ( 1 3 . 3 9i n . ) .
(c) UsingSST and a torque meter,recheckthe total
preload.
s s T 0 9 6 16 - 0 0 0 10
P r e l o a d( t u r n i n g) :
1 . 2 - 1 . 5 N . m ( 1 2 - 1 5 k s f . c m ,1 0 . 4 - 1 3 . 0i n . . t b f )

_ POWERSTEERING
sR-97
STEERING
1 7 . I N S T A L LC L A W W A S H E R SA N D R A C K E N D S
, n d t € m p o r a r i l iyn s t a l tl h e r a c k
( a ) I n s t a l al n e w w a s h e r a
ono.
H I N T :A l i g nt h s c l a w so f t h e w a s h e rw i t h t h e s t e e r i n g
rack grooves.
(b) Using a spanner(22 mml to hold ths steeringrack

steady,and using SST,torqus the rack end.
s s T0 9 9 2-2 10 0 10
T o r q u e :6 0 N . m ( 6 1 2 k g f c m , 4 4 f t ' l b f )
in the illustrttion.
3 4 0 m m ( 1 3 . 3 9i n . ) .
( c ) Socurethe rack end in a vise.

NOTICE: Do not tightsnths visetoo tight.
( d ) U s i n ga b r a s sb a r a n d h a m m e r s, t a k et h e w a s h e r .
NOTICE: Avoidany impactto tho rack.
1 8 . T N S T A L LR A C KB O O T S C , L A M P SA N D C L I P S
(a) Ensurethat the steeringrack hole is not cloggedwith
grsase.
H I N T :l f t h e h o l e i s c l o g g e dt,h o p r e s s u r ei n s i d et h e
b o o t w i l l c h a n g ea f t e ri t i s a s s e m b l eadn d t h e s t e e r i n g
wheel turned.
( b ) lnstallthe boot.
NOTICE: Ba carefuln o t t o d a m s g e o r t w i s t t h e b o o t .
(cl T i g h t e nt h e c l a m p ,a s s h o w ni n t h e i l l u s t r a t i o n .
( 0 . 0 8- 0 . 2 0 n . )

sR-98
1 9 . I N S T A L LT I E R O D E N D SA N D L O C K N U T S
(a) Screw th6 lock nut and ti6 rod end onto the rack end
until the matchmarksare aligned,
(b) Adjust the dimensions.
(SeepageSR- 77)
(c) Torquethe nut.
20. INSTALL 2 TURN PRESSURE TUBES

(a) Install2 new union seatsto the rack housing.
(b) UsingSST,insrallth6 tube.
- 00020
ssT09633
Torque:l9 N.m(195kgf.cm,14 ft.lbf)
HINT:Use a torquo wrench with a fulcrum length of
250 mm (9.84 in.).
2 1 , I N S T A L LR E T U R N
T U B EN O . 1S U B - A S S E M B L Y
RHD:
UsingSST,installth€ tuoe.
ssT 09631-22020
HINT: Use a torque wrench with a fulcrum length of
250 mm (9.84 in.).

sR-99
STEERING- SERVICE
SPECIFICATIONS
SPECIFICATIONS
SERVICE
DATA
SERVICE
ON_VEHICLE
INSPECTION
Stooringwhsol fr66plsy Maximum 3 0 m m ( 1 . 1 8i n . )
S T E E R I NCGO L U M N
Tilt pawl stoppor - Mark
12.6A- 12.74mm (0.4992- 0.5016in )

2orB 12.81- 12.67mm (0.4965- 0.4988in )
50ru 1 2 . 5 4- 1 2 . 6 0m m ( 0 . 4 9 3 7- 0 4 9 6 1i n . l
4o.D 12.47 - 12.53 mm (0.4909 - 0.4933 in.)
5orE 12.40- 12.46mm (0.4882- 0.4906in.)
6orF 12.33- 12.39mm (0.4854- 0.4878in )
12.28- 12.32mm (0.4827- 0.4850in.)
P S O N_ V E H I C L EI N S P E C T I O N
7A- FEI
Driv€ bolt tensiohat 98 N (10 kgl,22 6t) Now be t 5 - 6 mm (0.20- 0.24in.)
D r i v ob e l t t o n s i o na t 9 8 N ( 1 0 k g f , 2 2 l b f ) U s e db 6 l t 6 - I m m ( 0 . 2 4- 0 . 3 1i n . )
'Drive b6lt tension N€w b€lt 441 - 539 N (45 - 55 ksf,99 - 121 lbf)
'Driv€ be t tsnsion us€d b6lt 196 - 343 N (20 - 35 kst,44 - 77 bt)
Oil lovol ris€ Maximum Bolow 5 mm (0.20 in.)
Oil prossuroat idl6 spoedwith valvo closod Minimum 6,865 kPa {70 kst,/cmr,996 p6i)
St66ringoffort at idle sp66d Maximum 6 . 9 N , m ( 7 0 k g f . c m , 6 1i n . . l b f )
3 5 _ G E3, 5 _ F E , 5 5 _ F :E
Drivo belt tensionst 98 N (10 kgf, 22 lbf) Now bolt 8 - 1 0 m m ( 0 . 3 1- 0 . 3 9 i n . )
Drivo b6lt t€nsionat 98 N (10 kgf, 22 lbt) Us€d b€lt 1 0 - 1 3 m m ( 0 . 3 9- 0 5 ! i n . )

'Driv6 bolt tension New bolt 4 4 1 - 5 3 9 N ( 4 5 - 5 5 k s f , 9 9 - 1 2 1l b f )
'Driv6 belt t€nsion Used b6lt 196 - 343 N (20 - 35 ksl,44 - 77 lbl)
Oil l€vsl rise Maximum Below 5 mm (0.20 in.)
Oil or6ssursat jdl6 speodwith valvo c osed N4inimum 8,826kPa(90 ksf,/cm',1,280Psi)

St€€ringeflort at idl6 spe€d Maximum 6.9 N.m (70 ksf cm, 6l in. lbf)
P SV A N EP U M P
7 A _ F E ,3 5 _ G E ,3 5 _ F E ,5 5 _ F E
Pump shsft / lront housingbushingoil cloaranco STD 0 . 0 1- 0 . 0 3m m ( 0 . 0 0 0 4- 0 0 0 1 2i n . )
Pump shaft / front housangbushingoil clearanc€ Maximum 0.07 mm (0.0028 in.)
V a n s p l s t eh e i g h t Minimum 8 . 1m m ( 0 . 3 1 9a n . )
V a n op l s t €t h i c k n e s s Minimum 1 . 7 9 7m m ( 0 . 0 7 0 7i n , )
Van6 plat€ l€ngth Minimum 14.988 mm (0.59008 in.)
vane plate / pump rotor groovoclssranc€ Maximum 0 . 0 3m m ( 0 . 0 0 1 2

in.)
Vano longth - Pump rotor and cam rlng mark
NONE 14.996- 14.998mm (0.59039- 0 59047in.)
1 1 4 . 9 9 4- 1 4 . 9 9 6m m { 0 . 5 9 0 3 1- 0 . 5 9 0 3 9i n . )
2 14.992- 14.994mm (0.59024- 0.59031in )
1 4 . 9 9 0- 1 4 . 9 9 2m m ( 0 . 5 9 0 1 -6 0 . s 9 0 2 4i n , )
4 1 4 , 9 8 8- 1 4 . 9 9 0m m ( 0 . 5 9 0 0 -8 0 . 5 9 0 1 6i n . )
Springlr€e l€ngth Minimum 3 6 m m ( 1 . 4 2i n . )
Vane pump rotatingtorquo Msxifium 0 . 3 N m ( 2 . 8k g f c m , 2 . 4 i n . . l b fo) r l 6 s s
' : F o r u s ew i t h b e l tt e n s i o ng a u g s

sR-100 _ S E R V I CSEP E C I F I C A T I O N S
STEERING
S E R V I C ED A T A
PS G E A RH O U S I N G
Steeringrack runout Maxrmum 0 . 1 5 m m ( 0 . 0 0 6i n . )
Total pre oad 1.2- 1 . 5N m ( 1 2 - 1 5 k q f c m , 1 0 . 4 - 1 3 . 0i n . . l b f )
TOROUE
SPECIFICATIONS
Part tightonod N m kgf cm ft.tbf
STEERING
COLUMN
Steeringwheel set nut 34 350 25
w/ SRS Airbag :
Sensor ock reloas€bo t 8.8 90 /6 tn..ot
Steenngwheel pad set screw (Torx screw) 8.8 90 78 in..lbf

Ste6ringcolumn assemblysst nut 25 260 19
Intermediat6shaft x IntsrmediatoNo.2 shalt 35 360 26
Intermediateshaft x Main shaft 35 360
Co umn protoctors€t bolt 4.9 50 43 in..lbf
T i t s t s e r i n gc o l u m n:
Compr6ssron
spflng set scrow 7.8 80 69 in..lbf
T u r ns r g n ab r a c k e ts e t b o l t 5.4 47 in..lbf
Trlt ever retainerset nut r50 l l
Ti t pawl set bo t x nut 5.9 60 5 2 i n .l b l
T i t l e v e ra s s e m by s e t b o l t 2.9 30 2 6 i n .l b f
P S V A N E P UM P
7A FE:
U n i o nb o l t 525
Drive belt adjustingbolt 400 29
PS vane pump assemblyset bolt 400
E r a c k e st s t b o l t 12 mm Bolt 19 195
l4 mm Bolt 400 29
V a n € p u m p p u l l e ys e t n u t 43 440 32
Air control valv€ 36 370 27
Eracketx Oil roservoirx Front housing 12 mm Bolt 130 9
I4 mm Bolt 41 420 30
Pressur€port union 69 700
Pressurefesd tube x Controlvalve housing 44 (36) 450 (36s) 32 t26l

Drivo bslt adlustingbolt 43 440
PS vane pump assemblys€t bolt 43 440
Brackets€t bolt 440
Union bolt x prossuref6ed tub€ 52 525
V a n €p u m p p u i l 6 ys e t n u t 43 440
Air contro valv€ 370 27
Union bolt x Pressurefeed No.2 tub6 700
Suction port union s6t bolt 130
Prossur€port union 700 5l
( ): For use with SST

sR-101
STEERING- SERVICE
SPECIFICATIONS
SPECIFICATIONS
TOROUE
Part tightonod N.m kgfcm tt.tbt
PS GEAR HOUSING
Tie rod 6nd x Stooringknucklo 4S 500
Controlvalvs shalt x Int€rm€diatoNo.2 shaft 360
Pressurel66d and return tubes x Controlvalvo housjng 4/t (36) 4so (365) 32 126l
Tub6 clamp sot bolt 130
PS goar housingasssmblysot bolt x nut 121 I,300 94
RHO:
Roturntube No.l sub-assembly 44 (36) 450 (365) 32 {26)
Turn pr6ssu16tube 2 s( 1 9 ) 2 s 0( 1 9 5 ) r8(14)
Ti6 rod ond lock nut 570 4l
Rsck ond 83 (60) 8 5 0( 6 1 2 ) 61 (44)
Rackguid6 springcap lock nut 69(so) 700 ( 5 1l ) 50 (37)
Rrck housingcap lock nut 69 (s0) 700 ( s l r) 50 (37)
Controlvalv6 housingsot bolt 315
Rack housingNo.2 bracketset bolt 400 29
( ): For use with SST cp

- MEMO -

RS-1
RLE S T R A I NSTY S T E M
SUPPLEMENTA
G E N E R ADL E S C R I P T I O N . . ". ." '"."" " " " " ' R S - 2

PREPARATTON . . . . . . . . . . . .B. .S _ 4
S T E E R I NW
G H E E LP A O .. RS- 5
GH E E LP A D D I S P O S A 1 . . . . . . . R
S T E E R I NW . . ,S. -. 8
" " "
S E R V | CSEP E C I F I C A T I O N S . ' . . . . , . " "" RS- 12

RS-2
S U P P L E M E N T ARLE S T R A I NSTY S T E M_ G E N E R A D
L ESCRIPTION
G E N E R AD
L ESCRIPTION
The CELICAis equippedwith as SRS lSupplemffi'il
R 6 s t r a i nSt y s t e m a
) i r b a ga s a n o p t i o n .
The SRS togather with the seat belt, is designedto
help prot6ctthe driver.In a collision,the airbagsensor
d e t e c t st h e s h o c k ,a n d i f t h e f r o n t - t o - r e a r s h o c ki s
greatarthan a specifiedvalue,an SRS stored in the
st66ringwheel pad is inflatedinstantansously to help
reducethe shock to the driver.
LOCATION
OFCOMPONENTS
ltrt.a.I I
i,,RS.
S e n s o rL o c k
R e l e a s eB o l t
S t € e r i n gW h e e l P a d S t e e r i n gW h e e t
409)12

RS-3
SYSTEM- GENERALDESCRIPTION
RESTRAINT
SUPPLEMENTAL
CONSTRUCTION
The supplementalrestraintsystem consistsof the airbagsensor,inflatorand bag which ara all
i n s t a l l e di n t h e s t e e r i n gw h e e lp a d .
This supplementalrestraintsystsm is a mechanicalactivationtype. The decelerationof the
v e h i c l ei m p a c td u r i n ga c o l l i s i o ni s d e t e c l o db y t h e f l o a t i n gb a l li n s i d et h e a i r b a gs o n s o rw
, hich
pushesdown on the triggershaft.Thistriggsrsthe firing pin linkedto the triggsrshaft and ignitss
t h e s q u i bo f t h e i n f l a t o r .
F l r i n gP i n F i r i n gP i n
Tr ggerShaft
Spring
iasSpring F i r i n gS p r i n g
T r i g g e rS h a f t i s e n g a g e dw i t h f i r i n g p i n a n d f i r i n g p i n T r i g g e rs h a f t i s d l s e n g a g e df r o m f i r i n g p i n a n d f i r i n g
s stopped. Aossd? pin ls ejected
in sucha way that th" ffim

The steeringwhs6landthe ste€ringwheelpadareremovedandinstalled
sonsor locatedat the left side of the steeringwheol must be loosenedfirst. This automatically
activatesthe safoty dsvice.
H A N D L I N GP R E C A U T I O N S
Failureto carry out serviceoparationsin ths corroct sequencecould cause tho supplemental
restraintsystamto unoxpectedlydeployduringservicing,possiblyleadingto a seriousaccidont
Further,if a mistakeis madein servicingth6 supplsmontalrsstraintsyst6m,it is possiblethe SRS
may fail to oparatewhen required.Beforeperformingservicing(includingremovalor installation
of parts,inspectionor replacement), be sureto readthe followingitemscarefully,th€n follow tho
correct proceduredsscribedin th€ ropairmanual.
L Neverdisassemble tho stosringwheelpadassembly.
2. Do not subjoctthe stesringwheel pad to shocksor bring magnetsclosoto it.
3. Oo not oxposa tho steering wheel pad to high tamperaturos or fire.
4. lf greasa,cleansr, oil or watei gots on the stoaring wheel pad,promptly wipo it off with a dry cloth.
5. D o n o t d r o p t h o s t e a r i n gw h e o l p a d . N a v e r u s o a s t o e r i n gw h e e l p a d w h i c h h a s b e e n d r o p p e d '
6. N e v e r i n s t a l lt h e s t e o ? i n gw h o e l a n d p a d i n a n o t h e r v o h i c l e .
7. Wh6n tho stsaring whesl p8d ir removsd, stoie it on a stable, flat plsco YYiththe pad rurface
f a c i n g u p w a r d s .N e v e r p l a c e a n y t h i n g o n t o p o f t h e p E d '
8. When work on tha vehicle will produca too rtrong ! rhock, first loosenth. senror lock releale bolt
until it turns freely and perform the work aftar sensor lock occurl.
g. E v a n i n c a g e s w h e r a t h a v e h i c l e i s i n a l o w - i m p a c t a c c i d e n tw h e i a t h o S R S i s n o t a c t i v a t e d .
a l w a y s c h e c k t h e p a d s u r f a c e a n d a i r b a g s a n s o i p a r t . l f d e n t s . c r a c k t o r d o f o r m s t i o ni s v i s i b l e ,
i e p l a c et h e S R Sw i t h a n e w a s s e m b l y .
1 0 . W h e n d i s p o s i n go f t h e v e h i c l eo r s t o e ? i n gw h e e l , a l w a y s d e p l o yt h e S R Sf i r s t .
I 1. The deployed intlator insido the steering whael pad is hot. so disposeof it after it has boen cooled
by atmospheric air. Never apply wator to cool it down.

RS-4
SUPPLEMENTAL SYSTEM- PREPARATION
RESTRAINT
PREPARATION
RECOMMENDED
TOOL
09042-00010 TorxSockot
T30 Stooringwhoolprd
EOUIPMENT
T o r q u 6w r e n c h St6erlngwhsel pad
B o l t : L e n g t h3: 5 m m ( 1 . 3 8i n . )P i t c h 1
: . 0 m m ( 0 . 0 3 9i n . ) Airbagdisposel
D i a m ,6: , 0 m m ( 0 . 2 3 6i n . )
Bope (no projoctions,difficult to break) Airbagdispos€l
T i r e W i d t h :1 8 5 m m ( 7 . 2 8i n , ) I n n e rd i a m .3: 6 0 m m( 1 4 . 1
7 in.) Airbegdisposal
T i r e w i t h d i s cw h e e l W i d t h : 18 5 m m ( 7 . 2 8i n . ) Airbagdisposal
I n n e rd i a m .3: 6 0 m m ( 1 4 . 1 7i n . )
Wir€ or string Allbag disposal
Vinyl bag Airbag dispos6l

l=
SYSTEM- STEERING
RESTRA|NT
suppLEMENTAL WHEEllAq------
G H E E LP A D
S T E E R I NW
COMPONENTS
S e n s or L o c kR e l e a s eB o l t SteeringWh6el Pad
8 . 8{ 9 0 , 7 8i n . l b t ) Torx Screw
8 . 8( 9 0 , 7 8i n . l b f )
SteeringWheel Lower
C o v e rN o . 2
8 . 8{ 9 0 , 7 8 I n , l b f l
'm( m, ft lbf) : S p e c i f i e dt o r qu e E09713

2"2351
WHEELPAD REMOVAL
STEERING
CAUTIOtI: Whon the steering whcel pad rcmoved,
rlwryr place lt on ! rtablo flrt pbcc with th! pad ru?flcr
faclng upwardr. Nevcr placc anythlng on toP of thc prd.
REMOVESTEERING WHEELPAO
(a) Usinga screwdrivar, removeth€ sto€ringwh63llowor
coverNo.2and No,3.
HINT:Tapethe screwdriver tip beforeuss.
(b) Usinga torx socketwrsnch,loosanthe sensorlock
W
ll) -l
roleasebolt untilit turnsfreely.
(c) Slidethe bolt cap downwards.

RS-6
SUPPLEMENTAL SYSTEM_ STEERING
RESTRAINT WHEELPAD
(d) Usinga torx socketwrench,removo2 torx scrsws.

(e) Pull the steering wheel pad out from the ste€ring
wheel.
S T E E R I NW
G H E E LP A D] N S P E C T I O N
INSPECT
EXTERIOR WHEELPAD
OF STEERING
CAUTION: Neverdisarsemblo tho stoeringwhaalpad.
Roplacathe steeringwheel pad with a new one i{:
(a) The SRS has deployed.
(b) The pad surface,airbagsensoror inflator has dents,
cracksor deformation.
(c) The SRS has been dropped.
iid'" S T E E R I NW
G H E E LI N S P E C T I O N
INSPECT
EXTERIOR WHEEL
OF STEERING
Replacetho rto€ring wheel with a new one if:
(a) The st€oringwheel metal bracketis deformed.
(b) The new steoringwheel pad cannotb€ installedwith-
out forcing it.

RS-7
SYSTEM- STEERING
RESTRAINT
SUPPLEMENTAL WHEELPAD
WHEELPAD INSTALLATION
STEERTNG
(SeepageRS-5)
NOTICE:
. lf ths pad assembly har been dropPed or damaged,
roplaco it with a new one.
. Novor instlll ! pad which har been ured in snother
v e h i c l e .W h e n r e p l a c i n ga p a d , a l w a y r i n r t s l l a n 6 w
pod.
INSTALLSTEERINGWHEEL PAD
(a) Checkthat th€ sensorlock releasebolt is loosenedso
that it turns without resistance.
(b) Set the stsoringwh€el pad in the steeringwheel and
use a torx sockotwrenchto installthe 2 torx screws.
Torque:8.8t{.m(90 kgf.cm,78 in. lbf}

NOTICE:Do noi Dinchtho hornbutton oi wire harnossfor
the cruisecont?olsystem.
(c) Cover the steoring whe€l sot bolt with the bolt cao, ii,;flS
th€n tightenthe sensorlock releasebolt.
Torque:8.8 N m (90 kgf'cm, 78 in.'lbf)
(d) Install2 stoeringwheel lower covers.
HINTI Confirm that the lower covers are proporly
tlrw4
lf)-
installed.

RS-8
SUPPLEMENTAL SYSTEM_ STEERING
RESTRAINT WHEELPADOISPOSAL
STEERINW
G H E E LP A D D I S P O S A L
When scrappinga vehicleequippedwith an suffii8-
mental rsstraint syst€m or disposingof a ste€ring
wheel pad (with airbag),alwaysfirst r6mov€the ste6r-
ing wheel pad from the vehicleand deploythe SRS in
accordancewith th6 oroceduredescribedbelow.
lf any abnormalityoccurs with th€ SRS deployment,
CONIACt tho SERVICEDEPT.Of tho DISTRIBUTOR.
Never dispose of a vehicle or steoring wh€el pad
which has an undeployedSRS.
PRECAUTION S AIRBAGDISPOSAL
FOR
1 . Deploy the SRS in a safe place outdoors, on a llat
concrototret.
2 . lf tho lt.oring wheel pad is going to be 3tored,
RS.i rlways placo th6 pad facing upwards.
3 . After the 3onlor lock it released,handlo tho st6er-
ing wheel pad with great care.
4. Always !t.nd at lealt 5 m (16 ft) away from the SRS
when deployingit.
5. The inllator insidethe rteering wheel pad becomes
very hot whon th6 SRS ir deployed,so lllow it to
cool for 30 minuter lftor tho SRS ir deployed. Never
apply wlter to tho inflrtor or deployedSRS,
6 . When handlingtho deployedSRS,wear 3af6ty gla-
!re3 and glover.
7. Put thc deployed SRS in a vinyl b!9, loal tho bag
tightly and dirpore of it ar indugtrialwatte.
8 . Alwayr wash your h!nd! with water aftor complet-
ing dirporal of tha SRS.

RS-9
SYSTEM_ STEERING
RESTRAINT
SUPPLEMENTAL WHEELPADDISPOSAL
WHEELPAD DISPOSAL
STEERING
CAUTION:
. Alwayr deploythc SRSin a safe placeoutdoort,on
a tlat concrotoala!.
o lf tho rteeiing wheel pad i3 rtoi9d for even r short
while, always keep ths pad surface facing upwards'
r Attor the gensorlock is released,handle tho stoering
wheel pad with groat c8to'
I. REMOVESTEERING WHEELPAD
(SeepagesRS-5 to 6)
2. PREPAREFOR AIRBAGDEPLOYMENT
(a) Install2 bolts approx.|0 mm (0.39 in') into the holes
in the st66ringwheel pad.
Bolt dimensionr:
Length35 mm (1.38in')
Pitch1.0 mm (0.038in')
Diam.8.0 mm (0.238in')
(b) Attach ropes to the ste€ringwhe6l pad so that it is

susoendedlever,as shown in the illustration.
(c) Usinga wireor string,unlockthe sensorlock.

CAUTIOI{: Aft!? ronror lock b rcloaled tho SRS will
d e p l o y i f d r o p P e df T o m ! h o i g h t o f 5 0 m m ( 1 . 9 7 i n . ) ,
rerulting in highly drngerour jumping up of the pad.
Handla thr pad cxlremcly carcfully to avoid any shockr
to it,

Rs-l0
suppLEMENTAL sysrEM - sTEERTNG
RESTRATNT wHEELpAD DrsposAL
(d) As shown in the illustration, enclose the st6sring
wheel pad within 4 tirss and tire with disc wheer,
p a s s i n gt h e r o p e t h r o u g h t h e w h e e l h o l e .
T i r e s i z e :M u s t e x c a e dt h e f o l l o w i n g d i m e n s i o n s
Width 185 mm (7.28in.)
I n n e rd i a m . 3 6 0m m ( 1 4 . 1 7i n . )
C A U T I ON :
o Oo not use tires with disc wheels.
. D o n o t s u b j e c tt h o s t o e r i n gw h e e l p a d t o a n y s h o c k s
at all.
. Tio the tiras together so that they do not movs,
I { O T I C E :T h a t i r e s m a y b e m a r k e d b y t h e a i r b a g d e p l o y .
mant, so uss redundant lires.
RS 3. AIRBAGDEPLOYMENT
5m (16ft) (a) Stand 5 m (16 ft) away from the steeringwheel pad
and pull the pad up 200 mm (7.87 in.).
CAUTION: Beforepullingthe padup,check898inthat the
surrounding area is safe,
(b) Releasethe rope to drop th6 stseringwheel pad and

deploythe SRS.
CAUTION: Beforedeployment, warn everyonenearbyin
a loudvoico.
HINT:The SRSmay not doployif the sansorlock was
not fully releasedor the pad was not horizontalwhen
s u s p e n d e dl f. t h i s o c c u r s ,a v o i da p p l y i n gi n s h o c kt o
the pad and perform the procedurefrom the starr
again.

RS-11
sUPPLEMENTALRESTRA|NTsvsreu_srreR|NGwHEELPADDlS
4, AIRBAGDISPOSAL
CAUTION:
e The steering wheel pad is very hot when the SRS is
deploYed,so leava it alone for at least 30 minutos
altor dePloYmont.
. UEo gloves and safoty. glassss whan handling a
steoring whoel pad with deployed airbag'
o Do not spply water, stc' to a stesring wheel pad
with deploy€d airbag.
. Alwtys wash your hands with water altor complet-
i n g t h e o p e r a t i o n'
Put he deployed SRS in a vrnyl bag, seal the bag
t
t i g h t l y a n d d i s p o s e o f i t a s i n d u s t r i a lw a s t e .
:n3,a

RS-12
SUPPLEMENTAL SYSTEM- SERVICE
RESTRATNT SPECIFICATIONS
SERVICE
SPECIFICATIONS
TOROUE
SPECIFICATIONS
Part tightensd N.m kgf.cm ft.tbt

S t 6 6 r a n gw h e € i 26
Steeringwh6el pad 8.8 90 78 in..lbt
Sensorlock 16leesebolt 8.8 90 7 8 i n ,l b f
RS

BE.1
B O D YE L E C T R I C ASLY S T E M
G E N E R A ILN F O R M A T I O N
PRECAUTION
PREPARATION ItE - tt/
P O W E RS O U R C E
swlrcH ...'."'
rGNrloN E'E- tb
H E A D L I G HATN D
T A I L L I G HSTY S T E M. . " . . . ' ' " RF- 1O
F R O N TF O GL I G H TS Y S T E N { BE- 31
R E A RF O GL I G H TS Y S T E M BE- 34
T U R NS I G N A LA N D H A Z A R D
WARNING S Y S T E M. . . . . . . .
B A C K - U P L I G H TS Y S T E M
S T O PL I G H TS Y S T E M ..'"....... aa- A,
H E A D L I G HCTL E A N E RS Y S T E I ' / " . . " . . . . . " . ' B E _4 4

WIPER A N D W A S H E S
R Y S T E N ' "
I " . . ' ' " . " . Etc-.lt
c o M B t N A T I OMNE T E R . ' . . . . . . . .
O E F O G G ESR Y S T E M. . . . . . . . . . irHE
;i
P O W E RW I N D O W
SYSTEM
coNTROL . . . . . . . . . .".
POWEROOORLOCK
C O N T R OSLY S T E M. . . . . . . . ' ' BE- 84
sLrDrNG R O O FS Y S T E M . . . . . . . . . ' . ' eE- on
P O W E RM I R R O R
C O N T R OSLYSTEN,I oE- 50
S Y S T E M. ' ' " . . . ' "

S E A TH E A T E R BE- 99
CRUISE C O N T R OS LYSTEM
.
A UD I OS Y S T E M . BE- 123
CLOCK BE 145
BE-147

BE.2
B O D YE L E C T R I C ASLY S T E M_ G E N E R A ILN F O R M A T I O N
Example: G E N E R A ILN F O R M A T I O N
W I R I N GC O L O RC O D E
Wire colorsare indicatedby an alphabeticalcode.
B :8lack L :Blue R :Red
BR :8rown LG :Lisht GreenV :Violet
G :Green O :Orange W :White
GR :Grav P :Pink Y :Yellow
Gr e e n Tho first letter indicatssths basicwire color and the
secondletter indicatesthe color of the strioe.
E x am p l e : CONNECTOR
1 . P I NN U M B E R
O F F E M A L EC O N N E C T O R
Numbered in orderfrom upperleft to lowerright.
2 , P I NN U M B E B
O F M A L EC O N N E C T O R
Numbered in orderfrom upperrightto low6rleft.
Examplel HINT: When connoctorswith different or the same

"A"
e.g.A7=No,7 pin ol connector number of terminalsars used with the sams parts,
each connsctorname (letterof the alphabet)and pin
"B" numberis specified.
Connector
"B"
Connector
"A"
Connector
Connector
Example: 3. D I S T I N C T I O NO F M A L E A N D F E M A L E C O N N E C -
TORS
Male and femaleconnectorsare distinguishedby the
shaoeof their internaloins.
(a) All connectorsare shown from the open end, and the
lock is on too.
(b) To pull apart ths conn6ctors,pull on th6 connector
Female Male itself, not the wires.
HINT: Checkto se6 what kind of connectoryou are
disconnectingbeforepullinga part.
Example:
B t 1 7 3 2B E t r S l

BE-3
SYSTEM_ GENERALINFORMATION
BODYELECTRICAL
R e f e r en c e : H O WT O R E P L A CTEE R M I N A L
(with terminal retaineror secondarylockingdevice)
1. PREPART E H E S P E C I A LT O O L
HINT: To remove the terminal from the connector,
pleaseconstructa specialtool or usean objectsimilar
to that shown on the l6ft.
2. D I S C O N N E CCTO N N E C T O R
3. DISENGAGE T H E S E C O N D A R YL O C K I N GD E V I C E
R a i s eU p
O R T E R M I N A LR E T A I N E R
(a) Lockingdevicemust be disengagedbeforethe termi-
nal lockingclip can be releasedand th€ terminalro-
movedfrom the connector.
(b) Use a specialtool or th€ terminalpick to unlock the
secondarylockingdeviceor tsrminalretainer.
NOTICE: Do not removethe terminalretainerfrom con-
T e r m i n aRl e t a i n e r
nector body.
@ For Non-Waterproof Type Connector

Retainerat Full Lock Position HINT:The needleinsertionpositionvariesaccording
ffi$
T e r m i n a lR e t a i n e r to the connector'sshape (numberof terminalsetc.), ffi
so check the positionbeforeinsertingit.
" C a s e1 "
Raisethe terminalretainerup to the temporarylock
oosition.
"Case 2"
Exsmple; Secondary
2)
{CasE L o c k i n gD e v i c e Openthe secondarylockingdevice.

BE.4
BODYELECTRICAL
@ For WaterproofType Connector

Terminal HINT:Terminalretainercolor is differentaccordingto
Retainer
connectorbody.
Examole:
TerminalRetainer:ConnectorBodv
Blackor White: Gray
Blackor White: Dark Gray
Gray or White: Black
IMalel l F s m al eI
" C a s e1 "
Type where terminalretaineris pulledup to tha tom-
porarylock position(PullType).
Insertthe specialtoolinto th6 t6rminalretaineraccess
hole and pullthe torminalr€tain€rup to the temporary
lock oosition.
R e t ai n € r
HINT:The neodlsinsertionpositionvariesaccording
at FullLock to the conn6ctor'sshape(Numberof terminalsetc.),
Position so check the positionbeforeinsertingit.
a t T e m D o r a r vL o c k P o s i t i o n
"Case2"
Example: l e t a i nre
T e r m i n aR
(Case2) Typewhichcannotbe pulledas far as PowerLock.
l M a l e l P r e s sD o w n
N02{07

BE-5
- Gl!!84!l-N-loRMArloN
SYSTEM
BoDYELECTRIGAL
Insertthetoolstraightintothe accessholoof terminal
as shown.
retainer,
Pushtheterminalrstainerdownto the temporary lock
Dosition.
F ul l L o c k P o s i t i o n
Temporary Lock Position

{ F e m al e )
(c) Releasetho locking lug from torminal and pull the

terminalout from the roar'
4. INSTALL TERMINALTO CONNECTOR

(a) Insertthe terminal.
HINT:
') 1 . M a k es u r €t h e t s r m i n a il s p o s i t i o n s d
corrsctly
'@)tr 2. lnsertthe terminaluntil th€ lockinglug locksfirmly'

3. lns6rtthe terminalwithtorminalretainerin the
tomporarylock Position
(b) Pushthe secondarylockingdeviceor terminalretainsr

in to tho full lock Position.
5 . C O N N E C TC O N N E C T O R

BE-6
BODYELECTRICAL
Fusible F U S ER E P L A C E M E N T
A m P d r a g ei d e n t i q u e
HINT:lf replacing
the fuss be sureto replaceit with a
f--T*l f-ie-l fusewith an equalamperago rating.
t u s ea n d H r g hCufient
l v l e d i u mC u r r e nF
Eq!al AmperageRatin g
t'ntl\n
NOTICE:
r Turn off all electrical components and the ignition
switch befors roplacing a fuso or fusibls link. Do not
P ul l e r
excead the fusa or fusible link amperage rating.
. Alwsys use a fuse puller for removing End inserting
a fuse. Removs and insort stfaight in and out with-
out twisting. Twisting could force open the tarmi-
nals too much, resulting in a bad connection.
681365 lf a fusa or fusible link continues to blow. a short
c i r c u i t i s i n d i c a t e d .T h e s y s t e m m u s t b e c h e c k e d b y a
q u a l i fi e d t e c h n i ci an .
HINT: The ouller is located at Relav Block No.2.

BE.7
BODYELECTRICAL
CHECK
VOLTAGE
T o l g n i t l o nS w i t c h
lG Terminal
la, Establishconditionsin which voltageis presentat tho
check point.
Example:
@ - l g n i t i o nS W O N
@ - l g n i t i o nS W a n d S W 1 o n
@- lgnitionSW, SW I and Relayon (SW 2 off)
(b) Usinga voltmater,connectths negative(-) lead to a
good ground point or negativs(-) battery torminal
and the positive(+) leadto the connectoror compo-
n o n tt e r m i n a lT. h i sc h e c kc a n b e d o n ew i t h a t o s t b u l b
insteadof a voltmeter.
K
C O N T I N U I TAYN D R E S I S T A N CCEH E C
Ohmmeter
.7
7t ) ;5 ns ffi
(a) Disconnsctthe battsryterminalor wire so 11'1616
-o- voltagebetweenthe check Points.
(b) Contactthe 2 leads of an ohmmeterto each of the
ch6ck Doints.
SW
lf the circuithas diodes,rovorsethe 2 leadsand check

again.
Ohmmeler When contactingthe negative(-) lead to tho diode
positive (+) side and ths positive (+) lsad to tho
negative(-) side,thsrs should be continuity.When
contactingthe 2leads in reverse,thero should bo no
continuity.
HINT:Specifications may vary dependingon the type
of tester, so rofer to the tostor's instructionmanual
beforeperformingthe inspsction
C h e c kL E D( L i g h tE m i t t i n gD i o d e i)n t h o s a m €m a n n e r
as that for diodes.
HINT:
Ohmmeler
. Usa a testsr with a power source of 3 V or
greaterto overcomethe circuit resistance.
. lf a suitabletester is not available,apply battsry
positivevoltageand checkthat the LED lightsup.

BE-8
BODYELECTRICAL
Analog Typ€ Digital Type (c) Use a voltlohmmeterwith high impedance(10 k Q,/V
minimum)for troubleshootingthe Electricalcircuit.
n-::;*:i
lT- 11
l:nnnn
il
Lr___.__.__-__-rl
@9ed
T TA+A ;"*,-\-
-1:
il,oY -a I
\)
N0901N
6 09201
B U L BC H E C K I N G
Ohmm€t€r (a) Removethe bulb.
(b) There should be continuity botween the respective
terminalsof the bulb togetherwith a certainamount
of resistance.
Euib ( c ) A p p l y t h e 2 l e a d s o f t h e o h m m o t e rt o e a c h o f t h e
terminals.
(d) Apply battarypositivevoltageand checkthat the bulb
l i gh t s u p .
S H O R TC I R C U I T
CHECK
(a) Removeth6 blown fuse and eliminateall loads from
T o l g n i t i o nS w i t c h th6 fuse.
lG Termtnal (b) Conneca t t e s t b u l b i n p l a c eo f t h e f u s s .
( c ) E s t a b l i s cho n d i t i o n isn w h i c ht h 6 t e s t b u l bc o m e so n .
Test Light FuseCase
Example:
@ - l g n i t i o nS W O N
@ - l g n i t i o nS W a n d S W 1 o n
Short (t, @ - l g n i t i o nS W , S W 1 a n d R e l a yo n ( C o n n e c t h e
Relay)and SW 2 off (or DisconnectSW 2)
{ d ) D i s c o n n e cat n d r s c o n n e ctth e c o n n e c t o r w s h i l ew a t -
c h i n gt h e t e s t b u l b ,T h e s h o r t l i e s b e t w s e nt h e c o n -
Disconn6ct nectorwherethe tast bulb stavslit and the connector
w h e r et h e b u l bg o e so u t .
( e ) F i n dt h e e x a c tl o c a t i o no f t h e s h o r t b y l i g h t l ys h a k i n g
t h e p r o b l e mw i r e a l o n gt h e b o d y .
S ol e no i d

BE.9
SYSTEM_ PRECAUTION
BOOYELECTRICAL
PRECAUTION
when performing
Take careto obs€rvethe foltowingprscautions or,r'"touui''5,id
inspections
replacementof bodyelectrical parts.
relatod
SYSTEM
HEADLIGHT
. Halog6nbulbs have pressurized gas insideand requirespecialhandling,They can burst if
scratchgdor dropped.Hold a bulb only by its plasticor motal case.
Don't touch the glasspart of a bulb with bare hands.
SRS(SUPPLEMENTAL
RESTRAINT
SYSTEM)
Failureto carry out serviceoperationsin the cor€ct sequ€ncecould causethe airbagsystsm to
unexpectedlydeployduring servicing,possiblyleadingto a seriousaccident'
Further,if a mistakeis made in servicingthe airbagsyst€m,it is possibletho airbagmay fail to
operatewhen required.Before performingservicing(includingremovalor installationof parts,
inspectionor replacement), be sure to roadthe followingitems carefully,then follow the corrsct
proceduredescribedin the repairmanual.
. NevErdisassemble the stoeringwheel pad assembly.
. Do not subjecttha stoeringwheel pad to shocksor bring magnetsclosoto it.
. Do not sxposethe steeringwheel pad to high temperaturesor fire.
o lf grease,
cleaner, wheelpad.promptlywip€it off with t dry
oil or watergetson the ste€ring
cloth. m
. Do not dropthe steeringwheelpad.Neverusea st€eringwheel padwhich has beendropped,
. Neverinslallthe steeringwheel and pad in anothervehicle,
. Wh6n th6 st€eringwheel pad is removed,store it on a stable,flat placewith tho pad surface
facing upwards.Neverplaceanythingon top of the pad.
. Wh6n work on th6 vehiclowill producetoo strong a shock,first loosenthe sensor lock
16l6asebolt until it turns freelyand performth€ work after sensorlock occurs.
. Evon in casss where the vehicle is in a low- impact accident whare th€ airbag is not
activat€d,alwayscheckthe pad surfacgand airbagsensorpart.lf dents,cracksor deforma-
tion is visible,replacethe airbagwith a new assembly.
r When disposingof the vehicleor steeringwheel,alwaysdeploythe airbagfirst.
. Tho deployedinflatorinsideth€ stseringwheel pad is hot. so disposeof it after it has been
cooledby atmosphericair. Nov€rapplywater to cool it down'
AUDIOSYSTEM
. (-)terminalcableis disconnected
lf tha n6gative the presetAM, FM 1 and
fromthe batt€ry,
FM 2 stationsstorodin memoryar€srased,so be sureto not€the stationsand resetthom
aftgrthe batteryterminalis reconnected.
M O B I L EC O M M U N I C A T I OSNY S T E M
. system,r6farto pr€cautionsin tho lN
lf th6 vehicleis equippedwith a mobilscommunication
soct ton.

BE-10
SYSTEM- PREPARATION
BODYELECTRICAL
PREPARATION
ssr (sPEcrAL
sERVtcE
TooLs)
09843-18020 0iagnosis
ch€ckwir€
'-29"
09609-20011 sto€rins
Who6lPuller For rghoving steering whe€l
OOLS
ee 09082-00015 TOYOTAEloctrical
T6st€r
\qa
09041-00030 TorxDrivsrT30 For r€moving snd installing
st€€ring wheel pad
09042-00010 TorxSock€tT30 For r€movingand installing

st6oringwh€elpad
EOUIPMENT
Voltm€ter
Amm€t6r
Ohmm6tsr
Tost load
Syphon Braksfluid levelwarnrngswitch
B ub 1 3 . 4W ) Fu€ ssndergaug€,Soat bolt warning relay
B ub ( 2 1W ) T u r ns i g n a fl l s s h € r e a y
Dry csll b6ttery F u 6 ls o n d s rg a u g 6
Toaqu6wrench
Maskingt8p€ R6sr wandowdofogg€rwir€
Tin foil Rearwindow dotogg6rwirg

BE-11
SYSTEM- PREPARATION
BODYELECTRICAL
SSM(SPECIAL MATERIAL)
SERVICE
ouPontPastoNo.4817 or Roarwindowdefogg€r
equiv.l€nt

BE.12
SYSTEM- POWER
BODYELECTRICAL SOURCE
POW ER
SO UR CE
PARTSLOCATION
R e l a yB l o c kN o . 2
R e l a yB l o c kN o . 5 and JunctionBlock
No.2
.- R e l a yB l o c k N o , 6
\ )
ILHD]
D o o r L o c k C o n t r o lR e l a y J u n c t i o nB l o c k N o . 3 R e l a yB l o c k N o , 4
E n g i n €C o n t r oM
l odule
I n p E n Js u n c t i o nB l o c k
%
, , i t ,
D a y t i m eR u n n i n gL i g h t R e l a y
{ N o r w a y ,D e n m a r k ,S w e d e n )
J u n c t i o nB l o c kN o . 1
IntagrationR6lay
N11121
N10082

BE-13
SYSTEM_ POWERSOURCE
BODYELECTRICAL
tRHDl
J u n c t i o nB l o c kN o . 3 D o o rL o c kC o n t r oR
l elaY
R e l a yB l o c k N o . 1
E n g i n eE C U
I n p a n eJ u n c t i o n
Block
%
R e l a yB l o c k N o , 4
I n t e g r a t i o nR e l a y
J u n c t i o nB l o c k
C r u i s eC o n t r o E
l CU
(Australia)

BE-14
SYSTEM- POWERSOURCE
BODYELECTRICAL
I n p a n eJ u n c t i o n B l o c k
RELAY
A . T a i l i g h tR e l a y
B. PowerMain Relay
C . D e f o g g e rR e l a y
[]r--r FUSE
M e d i u mC u r r e n tF u s e s
cl l-t
a. AN41 4OA
b. DooR 30A
c. DEF 30A
d. POWER 3OA
t__lr_l Fu s e s
1 . P A N E L( E x .G e r m a n y ) 7.5A
l-;-tFl
t l t I
T A I L - R H( G e r m a n y )
2. IGN
3 . T A I L ( E x .G e r m a n y )
10A
7.5A
15A
ttr
I
T A I L - L H( G e r m a n y ) 10A
4. STOP 15A
5, WIPER 2OA
6. HTR 1OA
7. ECU-IG 15A
8. FOG 20A
9, MIR-HTR 1OA
10.GAUGE 1OA
11.SEAT.HTR 2OA
1 2 . C t G& R A D 15A
13.TURN 1OA
1 4 ,S T 7.5A
N1 0 2 9 7
N.0298

8E.15
SYSTEM_ POWERSOURCE
BODYELECTRICAL
RelayBlock No. 2 and Junction Block No. 2
RELAY
A . F a nN o . 1 R e l a Y
B . E n g i n oM a i nR e l a y
C . H e a d l i g hR
t €lay
D. Horn Relay
E. StartorRelay
F. EFIMain R€lay
FUSE
HighCurrontFusos
c. HTR 40A
ALT 100A
MAIN 60A
f. A B S 50A
M€diumCurrontFuses
a. RDI 30A
b. cDs 30A
Fuses
1. AM2 30A
2. HAZARO 10A
3. HORN 7.5A
,1. ShortPin BE
5. RADIONo. 1 204
D. ELU-O 15A
7. DOME 10A
8. HEAD(LH)(Ex.Gsrmany) 15A
HEAD(LH)Lo (Gsrmany) 15A
9. HEAD(RH){Ex.GermanY) 15A
HEAD(RH)Lo (Germany) 15A
10. ALT-S 7.5A
11.EFI 15A
E
E
l e l l I
l'l
l l
E!E

8E.16
SYSTEM_ POWERSOURCE
BODYELECTRICAL
R s l a vB l o c kN o . 1
RELAY
A . T u r n S i g n a lF l a s h e R
r elay
B . F r o n tF o g L i g h t R e l a y
C . R e a rF o g L i g h t
lr:r^ I
lI l I- - JI lImlu-rl
lmqTL--lll
I L.Y-----U I ttl
a---:--\ /----,.........----\
l-J !ll-J ql
lt Lt _ t' _i J lltl Lt _t ' J l
-___-/ -___-/
\---_ \____
r:-)
| -rl
lq o Pl
tI=J
N1 1 1 7 6
N 1 11SO
Nrr151

8E.17
SYSTEM- PowERs9U,BqE
BODYELECTRICAL
R e l a y B l o c kN o . 5
RELAY
A . A B S S o l e n o i dR e l a Y
B . F a n R e l a yN o . 2
C . A / C M a g n e t i cC l u t c h R e l a Y
r-,-
|| I|tr-
ar-ll -'tl D. ABS lMotor Belay
E . F a n R e l a yN o . 3
l1-:llll'fl r:rur ------_:-

ll L ll
f.--,--r I lJ et-l t: t-l I

l| d| D !I lI llt--1l r"l
ll
t| L - - l
t t I| r| || ||
\---
BE
Relay Block No.6
FUSE
Fuses
1 . H E A DH t ( R H )
[m [rr] t . ' . . . . . . . . . . -t 1 l
tt t t \ t t - r--
2 . H E A DH I ( L H)
lt -iJ l l l L = l l t - J t
IL
L l
-_
N11152
N10300

BE-18
SYSTEM_ IGNITION
BODYELECTBICAL SWITCH
IGNITION
SWITCH
PARTSLOCATION
l gn i t i o n S w i t c h
BE
I G N I T I O NS W I T C HI N S P E C T I O N
I N S P E CITG N I T I O S
N W I T C HC O N T I N U I T Y
Testerconnectionto
S w i t c hp o s i l r o n Sp6citredva ue
t 6 r m i n an u m b e r
LOCK No continuity
5 - 7 Conlrnuity
4 5 - 7
8 E 3 5 8 2€ I 2 ON Continuity
4 - 7 - A
START Continuity
l f c o n t i n u i t y i s n o t a s s p e c i f i e d ,r e p l a c e t h e s w i t c h .

B E -. 1 9
--
SYSTEM- HEADLIGHT
BODYELECTRICAL AND TAILLIGHTSYSTEM
TNDTAILLIGHT
H E A D L I G HA
SYSTEM
PARTSLOCATION
R e l a yB l o c k N o . 6 .,
. H E A D H I ( R H }F u s e
. H E A D H l ( L H )F u s e
. H e a d l i g h tR e l a y
. H E A D ( R H )F u s e
o H E A D ( R H )L o F u s e
. H E A D ( L H) F u s e
. H E A D { L H )L o F u s e
Headlight
lisfrs
I n p a n eJ / B
. T a i l l i g h tR e l a y
. TA,ILFuse
. G A U G EF u s e
L i g h t C o n t r o lS w i t c h
T ai l l i gh t
N r1 2 4 9
N10046

BE-20
sysrEM - HEADLTGHT
BoDy ELEcTRTCAL sysrEM
ANDTAILL'GHT
TROUBLESHOOTING
Tho table below will be useful for you in troubleshootingthese electricalproblems.The most
likelycausesof the malfunctionare shown in the order of their probability.Inspecteach part in
the ordsr shown, and replacethe part when it is found to bs faulty.
W,/O Daytime RunningLight RelaySystem
Troubl€ Part6name Seo pago
1.MAINFL
2 . H E A DF u s €( L H , R H ) (BE-14 and 15)
3. HoadlightControlRolay (BE-27)
Hesdlight does not iight 4 D i m m e rs w i t c h (BE-26)

( T a i li g h t i s n o r m a l ) 5 . L i g h tC o n t r o S
l witch (BE-26)
6 . I n t e g r a t i oR
n elay (BE-28)
7, Wire Harn€ss
L HeadlightBulb
1. Light ConlrolSwitch (BE-28)
Headlightdoes not light 2, IntogrstionR€lay (BE-28)

(Taillightdo6s not light up) 3, Wirs Horn066
4. HEad'ightBulb
L H E A DF u 6 s( L H , R H ) ( B E 1 4 a n d 15 )
O n l yo n e s i d el i g h td o e sn o t i g h t 2 . H € a di g h t B u l b
3. Wir6 Harn€ss
1 . L i g h tC o n t r o S
l witch (8E-26)
"Lo Boam"does not ight
2. Wiro Harnoss
1. Headight DimmerSwitch (8E- 26)
' H i - B e a m -d o e sn o t l i g h t
2. Wiro Harnass
l . H s a d l i g hD
t i m m o rS w i t c h ( B E- 2 6 )
'Flash" doos not light
2. Wi16Harness
W,/ Daytime RunningLight System

Troubl€ Part6name (S€€page)
I, FLMAIN
2. HoadlightControlRolay \AE-271
3. DaytimoRunningLight Relay (8E 29)
Headlightdoes not light
4. HeadlightDimmorSwitch (BE- 26)
(Taillightis norma)
5. Light ControlSwitch (88-26)
6. Wir6 Harnoss
7. HeadlightBu b
l. Light Contro Switch (BE-26)
H6adlightdoos not light 2 . D a y t i m oR u n n i n gL i g h t R e l a y (BE-29i
(Tailight do6s not light up) 3. IntogrationRelay (8E- 28)

4. WireHarnoss
L H 8 a d l i g h8t u b
Only on6 sid6 light does not light
2, Wire Harnoss

8E.21
SYSTEM- HEADLIG@
BODYELECTRICAL
Troublc P!rt. nlmr (srr P!gr)

1. H.ldlightDimmcrSwitch (BE-28)
'Lo-B!!m'dors 2. Olylimr RunningLightR!l!y (BE-20)
not light (ALL)
3. Wir! H..ntrr
1 . H E A D( L H )L o F u t ! (BE-15)
2 . H E A o( R H L
) oFutr (BE-16)
'Lo-Bo.m'do.r not lieht (ONESIDE)
3. HeldlightEulb
4. Wir. Harnra.
'1.HoldlightDimmrrSwitch (BE-28)
'Hi-Boam'do€. not light (ALL) 2. Dlytim! RunningLightR.hY (BE-29)
3. Wirc H!rn!..
1. HEADHl (LH)Fur. (BE- 16)
2. HEADHl (RH)Furc (BE-15)
'Hi-B!.m'do.! not light (ONESIDE)
3. H.!dliehtBulb
,1.Wira Hrrn.x
1. Hlldlighi OimmlrSwitch (BE-28)
'Flash'doo! not light 2. Dlytim. RunnineLightR.l.Y (BE-29)
3, Wifa H!rn..t
l. Intcar.tionRclry (BE-28)
2 GAUGEFur (BE- 14)
'Auto Turn-olt Sy.t!m'do.. not oplrltl 3. Dlytim. Runnin€LightRlhy (BE-29)
a. Wirr Hrrnal
5, DoorCou.t..ySwitch(drivr/r) (BE-71)
l. lnilgrltlon Rllry (BE-28)
2. Light ControlSwitch (BE-26)
Hr.dlightdo.r not lightwith lightcontrolSW in HEAD. (BE-2S)
3. D.ytimr RunningLightRchy
4. Wir. Hrrnaar
l. HlrdlightControlRchy (8E-27)
2. DlytlmcRunningLightRal.Y (BE-29)
H.sdlight do6. not Oo out with lighl control SW in OFF
3. Wir. Hlrn!||
l. TrilliehtR.hy (88-27)
2. Light ConlrolSwitch (BE-26)
Tlillight do.. nor lioht with lighi control SW in TAIL
3. DrytimcRunningLightRclly (BE-29)
t. TrifliohrRrhY (BE-271
2. D.ytlm. RunningLiChtR.hy (88-29)
Trillieht do.. not 9o out with light control SW in OFF (8E-26)
3. LightControlrwitch
4. Wir! Hrrn.tt
l. GAUGEFurl (BE- 14)
2. Drytim. RunnincLightR.l!y (BE-29)
H.ldlight lnd Tlillight do not light with lnein. running lnd light
3, Wiro Hrrn...
control Sw in OFF
4. Altarn.ior L Tcrmin.l
5. Prrking Brrk. Switch (BE-701

BE22
sysrEM - HEADLT.HT
BoDy ELECTRT.AL ANDTATLLTGHT
sysrEM
H E A D L I G HATI M A D J U S T M E N T
High Beam Vertical Lo Beam Horizontal

Adjusting Scr6w Adjusting Screw Lo Beam Vertical
Adiusting Scrow
H i gh B e a m H o r i z o n t a l
Adju sting Screw
,KY

8E.23
SYSTEM_ HEADLIGHT
BOOYELECTRICAL AND TAILLIGHTSYSTEM
AN
L W I T C HR E M O V A L
L I G H TC O N T R OS
INSTALLATION
1. REMOVE C O L U M NC O V E R
(a) Remove3 screws.
(b) Removecolumn cover.
2. S W I T C HB O D Y
R E M O V EC O M B I N A T I O N
w,/ Tilt Steering:
Remove3 screws.
HINT:Usa a long nosedriver.
3. R E M O V EL I G H TC O N T R O LS W I T C H
(a) Disconnect the connector.
{b) Remove 2 screws.
(c) Removetho switch.
HINT:W/ Tilt Steering:
Lrft uo the switch bodv beforeremovingthe switch.
INSTALL PARTSOF LIGHT CONTROLSWITCH IN

REVERSS EEOUENCO E F REMOVAL

BE-24
BoDy ELEGTRT'ALsysrEM - HEADLTGHT
AND TATLLTGHT
sysrEM
W I P E RA N DW A S H E R S W I T C HR E M O V A L
A N DI N S T A L L A T I O N
1. REMOVE C O L U M NC O V E R
(a) Remove3 screws.
(b) Removathe columncovsr.
.=
2. R E M O V EW I P E RA N D W A S H E RS W I T C H
(a) Disconnectthe connector.
t^
(b) Remove2 screws.
(c) Removeswitch.
ii
\,
I N S T A L LP A R T SO F L I G H TC O N T R O LS W I T C HI N
REVERSS EEOUENCO E F REMOVAL

BE-25
SYSTEM- HEADLIGHT
BODYELECTRICAL AND TAILLIGHTSYSTEM
C O M B I N A T I OSNW I T C HD I S A S S E M B L Y
AND ASSEMBLY
L i g h t C o n t r o lS w i t c h W i p e ra n dW s s h e rS w i t c h

BE'26 sysrEM - HEADLTGHT
BoDyELEcTRTcAL ANorArLLrcHT
sysrEM
C O M B I N A T I OSNW I T C HI N S P E C T I O N
1 . I N S P E CLTI G H TC O N T R OSL W I T C HC O N T I N U I T Y
LHD Models:
ToSt!r connectionio
Switch po!ition Spocitiodvalu€
trrminal numbcr
No continuity
TAIL 14 15 Continuity
HEAD 13 t4 - 15
- Continuity
lf continuityis not as specified,

replacethe switch.
2, INSPECT DIMMERSWITCHCONTINUITY
LHD Models:
I I 1 1
Tartar connection to
Switch position Sp6cifiodvaluc
1 8 1 7 16 14 t3 11 tormin!l numblr
Flr!h 8 - I - t6 Continuily
Low balm 1 6- t 7 Cohtihuity
N1 0 0 1 6 High b€rm 8 - 16 Continuity
N11229
lf continuityis not as specified.replacethe switch.
3. INSPECT
LIGHTCONTROL
SWITCHCONTINUITY
RHDModelr:
Tartrr oonnoction to
Switch porition Sp6ciliodvalu.
tarminalnumbar
OFF No continuity
TAIL l6 17 Continuity
HEAD 1 5- 1 6- 1 7 Continuity

replacethe switch.
1, INSPECT DlMMERSWITCHCONTINUITY
RHDModeb:
Taataaconnrction to
Switch po.ition Spociti.d v.lu.
tarminalnumbar
I 7 6 1 I
Flrrh Continuity
Low Brrm l0 Continuity
IA 17 18 15 14 13 1 2 l 1 10
High 8..m 2-10 Continuity
lf continuityis not as specified,roplacetho switch.

N11231
Nl1229

8E.27
SYSTEM- HEADLIGHT
ANDTAILLIGET
HEADLIGHTCONTROLRELAY
INSPECTION
HEADLIGHT
INSPECT RELAYCONTINU.
CONTROL
ITY
To8terconncctaon
to
Condition Speciti.d v.lut
torminalnumbor
Con!tani 3 - 1 Continuity
Apply +B b6tw.cn
| - 2 Continuily
tcrminal3 cnd4.
lf continuityis not as specified,replac€the r€lay.
RELAYINSPECTION
TATLLIGHT
TAILLIGHTRELAYCONTINUITY
INSPECT
Taatar conneotion to
Condition Splcifi.d v.lu.
tarmin!l number
Conatant 1 - 2 Continuity
Apply +B b.tw..n
Continuily
t.rmin.l. | lnd 2.
lf continuityis not as sp€cified,r€placethe r€lay.

BE-28
sysrEM - HEADLTGHT
BoDy ELECTRTcAL ANDTATLLTcHT
sysrEM
Junction Block Side I N T E G R A T I ORNE L A YI N S P E C T I O N

INSPECT INTEGRATION RELAY
C o nn e c t o r" A " Light Auto Turn Of{ Systsm/ Circuit
Wire HarnessSide
Removethe relayfromjunctionblockandinspectthe
connectors on ths wi16harnessand junctionblock
side,as shownin the chart.
s.12,1,A
"B"
Connector ? ri r 5 7
T66torconngctionto
Condition Sp6cifi6dv€lue (Continuity)
t 6 r m i n anl u m b o r
A4 - Ground Passsnggr'sdoor courtesyswitch ON Contrnurty
A8 - Ground Driv€r'sdoorcourtssyswitchON Continuity
A10- Ground Constant Continuity
Bl - Ground LightcontrolswitchpositionOFFor HEAD No continuity
B1 - Ground Light control switch positionTAIL Continuity
84 - Ground Light control switch positionOFF or TAIL No continuity
84 - Ground Light control switch positionHEAD Continuity
T6starconn€ctionto
Condition Sp.cifiod valu€ {Voltago)
t6rmtntl numb6r
A1 - Ground Constant Brtteryvoltag.
A7 - Ground lOnitionswitch positionLOCKor ACC No voltae.
A7 - Ground lgnition6witchpositionON Batteryvoltsg6
82 - Ground Constant B!tt6ry voltrg6
83 - Ground Constant 8!ttory voltag.
lf the circuit is as specified,trying replacingthe relay

wtth a new ono.
lf the circuit is not as specified,inspectthe circuits
connectedto other parts.

SYSTEM-
BODYELECTRICAL
Wirs Harno3tSid€ L I G H TM A I N R E L A Y
D A Y T I M ER U N N I N G
INSPECTION
1. I N S P E C TP A R K I N GB R A K ES W I T C H
(SeePase BE-70)
2. INSPECTDAYTIME RUNNINGLIGHT MAIN RELAY
Gircuit
Disconnectthe connoctorfrom relayand inspectthe
connectoron wire harnessside,as shown'
Testerconn€ctionto Specifiod valu€ (ContinuitY)

Condition
t e r m i n a nl u m b o r
Headlight dimmer switch position Low
16 - Ground No continutty
baam
Headlightdimmer switch position Flssh or
16 - Ground Continuity
H i g hb € a m
8 - Ground Parkingbrakoswitch PositionOFF No continuity
8 - Ground Parkingbrakoswitch PoritionON Continuity
13 - Ground Constant Continuity
T€storconn€ctionto Specifi6dvalu€ (Voltago)

Condition
t 6 r m i n a nl u m b e r
2 - Ground lgnitionswitch positionLOCK or ACC No voltago
2 - Ground lgnrtionswitch PositionON Batt6ryvoltago
11 - Ground Engin6Stop No voltlge
11 - Ground Engin€Running Batt.ry voltag6

15 - Ground Constant Bstt0ryvoltago
17 - Ground Constant Battoryvoltago
lf circuitis as specified,trying replacingthe relaywith

a n6w one.lf tho circuitis not as specified,inspactthe
circuit connectedto other Parts.

BE-30
sysrEM - HEADLTGHT
BoDy ELEGTRTCAL ANDTATLLTGHT
sysrEM
H E A D L I G HBTE A ML E V E LC O N T R O L
INSPECTION
1 . I N S P E C TH E A D L I G H TB E A M L E V E L C O N T R O L
SWITCHCONTINUITY
Testorconnectionto
Switch positron Specifiedvalue
terminalnumbor
0 4 - 10 C o n t r un r t y
3E.369 S r0 2
1 4 - 9 Contrn(]ity
4 - 8 Continuity
4 - 7 Continuity
4 4 - 6 Continurty
4 - 5 Continuity
lllumination Continuity
lf continuityis not as specified,replacethe switch.
2. INSPECTACTUATOROPERATION
(a) Connsct the positiva (*) lead from th6 battary to
( - ) l e a dt o t e r m i n a5l .
t e r m i n a 6l a n dt h e n e g a t i v e
( b ) G r o u n de a c ht e r m i n a l a n cd h a c kt h a t e a c hm o d eo p e r -
a t e sa s s h o w ni n t h e c h a r ta n d i l l u s t r a t i o n .
T€rminal HsadlightBeam Level
I - Ground "0"
2 Ground
3 - Ground '2'
4 - Ground '3'
5 Ground
6 - Ground
l f o p e r a t i o n i s n o t a s s p e c i f i e d .r e o l a c e t h e a c t u a t o r .

BE-31
SYSTEM- FRoNIleGllGl]r
BODYELECTRICAL {trE!
F R O N TF O GL I G H TS Y S T E M
PARTSLOCATION
F r o n tF o g L i g h t S w i t c h
7
il
R e l a yB l o c k
. FrontFog
l n p a n eJ / B
o FOGFuse
FrontFog Light

BE-32
sysrEM - FRoNTFoc LIGHTsysrEM
BoDy ELECTRTcAL
TROUBLESHOOTING
The table below will be useful for you in troubleshootingthsse electricalproblems.The most
likelycausesof the malfunctionare shown in the order of thsir probability.Inspecteach part in
ths order shown,and replacethe part wh€n it is found to be faultv.
T r o u be Parts'nams (5€6 pagg)
1 . F O GF u s o (BE- 14)
Front Fog light does not iqht with light contro switch HEAD. 2. Front Fog Light R6lay (BE-33)
( H 6 a di g h t i s n o r m a l ) 3 . F r o n tF o g L i g h tS w i t c h (8E-32)
4, Wi16Harness
Front Fog Light do€s not light with light control switch HEAD. 1. InspocH
t e a d l i g hSt y s t e m { B E - 19 )
(Headight do6s not light up) 2. Wire Harness
1 .B u l b (BE-8)
O n i yo n 6 i g h t d o € sn o t l i g h tu p .
2. WiroHarn€ss
FrontFog Lighl
F R O N TF O GL I G H TA I M A D J U S T M E N T
AdjustScrew
\_-,,--,"'- Adjust Screw: Vertical Diroction
F R O N TF O G L I G H TS W I T C HI N S P E C T I O N
1 . I N S P E CFTR O N T
F O GL I G H TS W I T C H
CONTINUITY
LHD Models:
Testgrconn6ctionto
Switch position Spocifiedvalu€
terminalnumber
No continuity
ON 1 0- 1 1 Continuity
lf continuityis not as specified,replacethe switch,
7 o 5 1
1 8 1 7 16 14 11 10
N10017
N11229

BE-33
- FRoxllecll9lr
SYSTEM
BODYELECTRICAL JEIEM
2, FOGLIGHTSWITCHCONTINUITY
INSPECT
RHDModels:
T€storconn6ctionto
Switch position Sp6cifigdvaluE
torminalnumb€r
OFF No continuity
ON Continuity
lf continuitvis not as specified,replacethe switch.
9 7 5 4
't3 1 l 10
18 17 16 15 14
N 11 2 3 1
N1122S
FRONTFOGLIGHTRELAYINSPECTION
FRONTFOGLIGHTRELAYCONTINUITY
INSPECT
Tosterconn€otionto
Condition Sp€citiedvalu€
torminalnumb€r
Constant Continuity
Apply+B botwoon
3 - C Continuity
terminal1 and2.
8E.049 8E1840
lf continuitvis not as specified,replacethe relay.

BE-34
SYSTEM_ REARFOGLIGHTSYSTEM
BODYELECTRICAL
R E A RF O GL I G H TS Y S T E M
PARTSLOCATION
R e a rF o g L i g h tS w l t c h
:t:,r'PE
,4
a\ -----.-
t l
rf4v rr-
..Vr\\\ FT\
R e l a yB l o c kN o . ' 1
. R e ar F o g L i g h tR e l a y
C1r
R e a rF o g L i g h t

8E.35
SYSTEM_ REARFOGLIGHTSYSTEM
BODYELECTRICAL
TROUBLESHOOTING
The table below will be usefulfor you in troubleshootingthes€ electricalproblems.The most
likelvcausesof the malfunctionare shown in the order of their probability.Inspecteach part in
ths ordor shown, and rsDlacelhe part when it is found to be faulty.
Troubla P.rts'nam. (s€o Pege)
1 . F o GF u . . {88- 14)
Rear Fog Light do.6 not light wirh light control switch HEAD. 2. Ro6rFos LightRelay (BE-35)
(Hoadlightis normal) 3. RorrFogLightSwirch (BE-35)
4. Wir. Hrrn.6.
R.ar Fog Light doe. not liOhtwith light control switch HEAD. l. H.adlishtSyetem (BE- 19)
(Ho6dlightdo.s not light up) 2. WiraH6.n63.
1 .B u l b ( 8 E- 8 )
Only on. li€ht doos nol light up.
2. WiroHarn.6!
REARFOGLTGHTSWITCHINSPECTION
REARFOGLIGHTSWITCHCONTINUITY
INSPECT
Taatar connoction to
Swilch po.ition Speciliedv.lu6
t.rminrl numbgr
OFF No continuity
ON 3 - E Continuity
lllumin!tion I - 4 Continuity
lf continuity is not as specified,replacethe swit!!.-",

REARFOGLIGHTRELAYINSPECTION
REARFOGLIGHTRELAYCONTINUITY
INSPECT
Toatar connaciton to
Condition Soocitird v.lu.
tarminalnumbar
Conatant Continuity
Apply +B b.tw..n
J - 5 Continuiiy
tormin.lI and2.
r€placothe relay.

BE_36 SYSTEM- TURNSIGNALANDHAZARD
BODYELECTRICAL WARNING
SYSTEM
T U R NS I G N A LA N D H A Z A R D
W A R N I N GS Y S T E M
PARTSLOCATION
F r o n tT u r nS i g n a Ll i g h t
o T u r n S i g n a lF l a s h e r
H a z a r dW a r n i n g L i g h t S w j t c h
. HAZD Fuse
l n p a n eJ / B
. TURNFuse
T u r nS i g n aS
l witch
R e a rT u r n S i g n a lL i g h t

SYSTEM_ TURNSIGNALAND HAZARDWARNING
BODYELECTRICAL
5 l
TROUBLESHOOTING
I problems.
thesoslectrica
The tablebelowwill be usefulfor you in troubleshooting
Ths most
areshownin the orderof theirprobability.
Inspectaachpartin
likelycausesof tho malfunction
the ordershown,and replacethe partwhenit is foundto be faulty.
psrts nam6 (SesPag6)
Trouble
L Hazard warningSwitch (8E- 39)
- H a z a r d ' a n d ' T u r nd" o n o t l i g h tu P 2 , T u r nS i g n aFl l a s h o r (BE-39)
3. WiroHarness
1 ,E u l b
2 . T u r nS i g n aFl l a s h o r (BE-3S)
Tho flashingfroquencyis sbnormsl
3. Wi16Harn6ss
Fu66
1 .H A Z A R D (8E-15)
Hazardwarning light doos not light up
(Turn is norma ) 2. Wir€Harn€ss
1 . H a z a r dW o r n i n gS w i t c h (BE-39)
Hazardwarning light doos not light up in one diroction 2, wire Horn6ss
1 . l s n i t i o nS w i t c h (BE- 18)
2 . T U R NF u s e ( B E- 1 4 )
' ' T u r ns i g n a d
l o o sn o t l i g h tu P (8E-38)
3, Turn SignalSwitch
4. Wir€ Harness
1 .T U R NF u s o ( B E- 1 4 )
" Turn signs doos not light uP 2. TurnSignalSwitch (BE-38)
3. wiro Harnoss
1 . T u r nS i g n aS
l witch (BE-38)
Turn signaldoes not light up in one direction 2. Wi16Harnsss
1.B0lb
On y on6 bulb do6s not light uP 2. Wir6 Harness
CombinationMeter,WiPer and Washardo not oPorate'

CombinationM eter, Wipsr a n d W a s h e ra r e n o r m a l .

BE_38 S LY S T E M- T U R NS T G N AA
B O D YE L E C T R T C A L N D H A Z A R DW A R N T N G
SYSTEM
T U R NS I G N A LS W I T C HI N S P E C T I O N
1 . I N S P E CTTU R NS I G N A LS W I T C HC O N T I N U I T Y
L H DM o d e l s :
Test6rconnectionto
Switch position Spocifi€dvalu€
terminalnumbor
L€ft turn Contrnuity
NeLrtral No continuity
Right turn Continuity
7 1
1 8 1 7 '16 1 5 l4 13 1l
'10
N1 0 0 1 7
N11229
2. I N S P E C TT U R NS I G N A LS W I T C HC O N T I N U I T Y
R H DM o d e l s :
T6sterconnoctionto
Switch position Specifi6dvalue
t a r m i n anl u m b e r
Lsft turn Conrinurty
Neutral No continuity
R i g h tt u r n Continuity
lf continuitvis not as specified,reolacsthe switch.
I 7 5 1
1 8 '17 1 6 '15 1 4 1 3 11 10
N11231
N1t229

B O D YE L E C T R I C ASLY S T E M_ T U R NS I G N A LA N D H A Z A R DW A R N I N G 8E.39
M
S W I T C HI N S P E C T I O N
H A Z A R DW A R N I N G
T A Z A R DW A R N I N G
I N S P E CH S W I T C HC O N T I N U I .
TY
Test6rconnectionto
Condition Spocifiodvalue
terminalnumber
S w i t c hO F F 7 - 10 Continuity
7 - A
N 0 9 9 9S2- r 0 . 2 Switch ON Continuity
4 - 5 - 6 - 9
l l u m i n a t i o nc i r c u i t Continuity
INSPECTION
T U R NS I G N A LF L A S H E R
I N S P E C TT U R NS I G N A LF L A S H E RO P E R A T I O N
(a) Connect the positive (*) lead from the battery to
t e r m i n a 2l a n d t h 6 n e g a t i v e( - ) l e a dt o t o r m i n a 3l .
( b ) C o n n e c t h e 2 t u r n s i g n a l i g h t b u l b sp a r a l l etlo e a c h
o t h e rt o t e r m i n a l s1 a n d 3 , c h e c kt h a t t h e b u l b sf l a s h .
H I N T :T h e t u r n s i g n a ll i g h t ss h o u l df l a s h 6 0 o r 1 2 0
Turn Sien.l Lighr 8|llbr (21w)
t i m e sp e r m i n u t e .
lf ona of the fronl or r6arturn signallrghtshasan open
c i r c u i t t. h e n u m b e ro f f l a s h e r sw i l l b e m o r et h a n 1 4 0
permrnute.
lf operationis not as specified,raplacethe flashar.

8E-40
SYSTEM- BACK-UP LIGHTSYSTEM
BODYELECTRICAL
B A C K _ U PL I G H TS Y S T E M
PARTSLOCATION
L i g h tS w i t c h1 M/ T )
______--__,._
i I -\
P a r k /N e u t r a l
P o s i t i oS
nwitch
/\'--' .-- =<-7
',
(A/T) 1l
\/
\\ \ \-\:-: L-'--
l
/=\
I n p a n eJ / B
. G A U G EF u s e
B a c k - U pL i g h t

SYSTEM- BACK-UPLIGHTSYST!I\4-BE1
BOOYELECTRICAL
TROUBLESHOOTING
The tablebelowwill be usefulfor you in troubleshooting problems.
thosselectrical The most
Inspecteachpartin
areshownin the orderof thoirprobability.
likelycausesof the malfunction
the ordershown,and replacothe partwhenit is foundto be faulty.
Troubl6 Prd. n!m. Saa Prga
l. GAUGE
Futo ( B E -| 4 )
2. Srck-Up LiqhrSwitch(M/r) (8E-41)
Brck-Up Light do68 not light uP Noulr.l Strrt Switch(A/f)

3. Wir! H!rna!!
4. Bulb
Bsck-Up Light r.maina.lw8Y6 on l. Wirc H.rn.!!
l. WiruHtrn...
Only onc light docs not light uP
2.8ulb
B A C K - U P L I G H TS W I T C HI N S P E C T I O N
BACK-UP LIGHTSWITCH
INSPECT
Tartar conncctionto
Switchpo.ition SD.oltbdvrlu.
tcrmin!lnumbar
Fr|. | - 2 No oontinulty
Puth 1 - 2 Contlnulty
roplacothe switch,
lf continuityis not as sp€cifi€d,
STARTSWITCHINSPECTION''.-.
NEUTRAL
INSPECT NEUTRALSTARTSWITCHCONTINUITY
Scc AX rcction

8E.42
SYSTEM_ STOPLIGHTSYSTEM
BODYELECTRICAL
S T O PL I G H TS Y S T E M
PARTSLOCATION
w/o Rear Fog Light
I n p a n eJ / B
. S T O PF u s e
Stop LightSwitch
w/ RearFog Light
Stop Light

BE-43
SYSTEM- STOPLIGHTSYSTIM
BODYELECTRICAL
TROUBLESHOOTING
The table below will be usefulfor you in troubleshootingthese eleclricalproblems Tho most
the ordsr shown,and replacethe part when it is found to be faulty.
Troubl6 Parts nam€ See Page
1.sroP Fuss (BE 14)
2 . S t o pL i g h tS w i t c h (BE-43)
Stop light does not llght uP
3. WireHarnoss
4. Bulb
1 . s t o p L i g h tS w i t c h (BE-43)
Stop light r6mainsalways on
2. Wire Harness
1.Wir€Hsrnoss
Only one ight does not light uP
2. Bulb
S T O PL I G H TS W I T C HI N S P E C T I O N
STOPLIGHTSWITCHCONTINUITY
INSPECT iip,ltl
Tost6rconnectionto
Switch position Specifiedva us
t€rminalnumbar
Switch pin lree
Contlnuity
(P€daldepressed)
Switch pin pushedin
8 E 6 ? 3 88 E 6 2 3 4 Continuity
(P€dal16leased)

BE44
sysrEM - HEADLT.HT
BoDy ELEcTRTcAL .LEANERsysrEM
H E A D L I G HC
T LEANER
SYSTEM
PARTSLOCATION
H e a d l i gh t C l e an e r C o n t r o lR e l a y
I n p a nJe/ B
o WIPER Fuse
H e a d l i g hC
t l 6 € n e rM o t o r
H e a dl i g h tC l e a n € rN o z z l e
(%lt
\\ulr
H 6 8 d i i g hC
t l e a n e rS w i t c h

8E.45
SYSTEM- le@
EODYELECTRICAL
TROUBLESHOOTING
The table below will be usefulfor you in troubleshootingthes6 electricalproblems.The most
part in
likelycausesof the malfunctionare shown in the order of their probability.Inspecteach
the order shown, and rsplacethe part wh€n it is found to be faulty'
1. Cleangrhose or nozzloclogged
2. WIPERFuso {BE- 14)
3. Ctean6rMotor (BE-46)
4 . C l s a n oS
r witoh (BE-45)
Haadight cleansrdo€s oP€rato
5. Cl6sn6rControlR6lay (BE-46)
6. Light ControlSwitch (BE-26)
7. Wire Harnoss
HEADLIGHT SWITCH
CLEANER
INSPECTION
CLEANERSWITCHCONTI-
INSPECTHEADLIGHT
NUITY
Testerconnoctaonto
Switch position Speciliodva uo
terminalnumb6r
No continuity
B F 4 r8 9 S - 4 2 C ON 1 - 4 Continuity
lllumination Continuity

BE-46
SYSTEM_ HEADLIGHT
BOOYELECTRICAL CLEANER
SYSTEM
H E A D L I G HC
TL E A N E R
C O N T R OR
L ELAY
INSPECTION
INSPECTHEADLIGHTCLEANERCONTROLRELAY
OPERATION
(a) Checkthat there is no continuityb€tweenterminals2
and 5.
(b) Connect the positive (+) lead from the battery to
terminals1 and 5, th€ n€gative(-) leadto terminal3.
(c) Connect the negative(-) lead from th€ battery to
torminal 4, check that th€r€ is continuity betweon
terminals2 and 5 for 0.4 - 0.6 seconds.then there is
no continuity.
lf operationis not as specified.replacethe relay.
HEADLIGHT MOTOR
CLEANER
INSPECTION
INSPECTHEADLIGHT CLEANERMOTOROPERA-
TION
Conn€ctthe positivo(+) lead from the batteryto
(-) leadto terminal2, checl
terminal1 and negative
that the motoroDorates.
NOTICE:Th.r. tert murt bc pcitoimed quickly (within 3
- 5 rccondr) to pioycnt thr coil lrom burning out.
lf operation is not as specified, replac€ the motor.

BE-47
SYSTEM- WIPERANDwAqll8 JvsrEM
BODYELECTRICAL
W I P E RA N D W A S H E RS Y S T E M
PARTSLOCATION
W i p e ra n d W a s h e r
Switch
F r o n tW i p e rM o t o r
W a s h e rT a n ka n d
Motor
I n p a n eJ / B
. W I P E RF u s e
EE
R e a rW i p e r M o t o r
N10049
N10050

BE-48
SYSTEM_ WIPERAND WASHERSYSTEM
BODYELECTRICAL
TROUBLESHOOTING
T h e t a b l e b e l o w w i l l b e u s e f u lf o r y o u i n t r o u b l e s h o o t i nthsso
g e lectricaI p r o b l e m sT. h e m o s t
likelycausesof the malfunctionare shown in the order of thsir probability.I n s p e c e t a c hp a r t i n
the order shown. and replacethe oart when it is found to be faulty.
Trouble Parts nam6 (Se€pag6)
1.ALT Fuse (BE 15)
2. AM1 Fuse (BE-14)
3 . W I P E RF u s e (BE- 14)
Wioors and washersdo not ooerate
4 . l s n i t i o nS w i t c h (BE- 18)
5. Wipor and WasherSwitch (BE-49)
6. Wire Harn6ss
L Front Wipsr and WasherSwitch (BE-49)
Front wioer dogs not oosrate. 2 , F r o n tW i p o r M o t o r (BE-52)
3. Wir6 Harnoss
1 . R € s rW i p e ra n d W s s h e rS w i t c h (BE-50)
Rearwioer do6s not oo€ratg. 2 . R s a rW i p e rM o t o r a n d R 6 l a y (BE-53)
3. Wir6 Harnoss
1 . F r o n tW i p e r a n d W a s h € rS w i t c h (8E-49)
Front washef do6s not operat€. 2. Washer Motor (8E- 54)
3. Wiro Harness
L RoarWip€randWashorSwitch (BE-50)
R€arwashor does not operate. 2. WashsrMotor (8E- 54)
3. Wir€Harnoss

BE-49
SYSTEM- WIPERAND WASHERSYSTEM
BODYELECTRICAL
WIPERAND WASHERSWITCH
INSPECTION
1. INSPECTFRONTWIPERAND WASHERSWITCH
CONTINUITY
LHD Models:
Inspectthe switchcontinuitybetweenterminals.
T6st€rconn€ctionto
Switch position Sp€cifiedva ue
t6rmanalnumbar
WipsrOFF 7 - 1 6 Contanuity
Wipor OFF and MIST 7 - 1 7 Continuity
WiporINT Continuaty
Wipor INT and MIST Continuity

2 ,|
I 7 5 WiporLO Continuity
Wip€r LO and MIST 7 - 17 Continuity

18 17 16 15 l4 12 11 1 0
W i p o rH l Continuity
- 7 - 8 - 1 7
W i p 6 rH l a n d M I S T Continuity
WasherON Continuity
N10019
N11230
replacethe swrtch
2. INSPECTFRONTWIPERAND WASHERSWITCH
CONTINUITY
RHDModels:
lnsoecttha switchcontinuitybetweontorminals.
Testerconnoctionto
Switch position Sp€cifi€dvalue
t g r m i n anl u m b o r
w i p s rO F F Continuity
Wiper OFF and MIST 3 - 1 l Continuity
Wip6r INT Continuity
wip6r INT and MIST Continuity
Wip€rLO Continuity
Wip6r LO and MIST Continuity
W i p 6 rH l Continuity
I 8 7 t) 5 4 3 W i p 6 rH l a n d M I S T Continuity
WasherON 8 - 1 7 Continuity
1 8 1 7 't6 1 5 1 4 12 11 10
lf continuityis not as specified,replacotho switch.
N11232
N11230

BE-50
sysrEM - wrpERAND*ASHERsysrEM
BoDy ELEcTRTcAL
3. INSPECTINTERMITTENTOPERATION
(a) Turn the wiper switch to INT position.
(b) Turn the intsrmittenttime control switch to FAST
position.
(c) Connect the positive (+) lead from the battery to
t e r m i n a l 6 ( 1 2 ) a n d t h e n e g a t i v o( - ) l e a dt o t e r m i n a l
2(8).
(d) Connectthe positive(*) lead from tho voltmeterto
t e r m i n a 7l ( 3 )a n d t h e n e g a t i v e( - ) l e a dt o t e r m i n a 2
l
(8), check that the meter needle indicat6s battery
voltag e.
( ): RHDModels
INT time control

Voltags
switch position
, , A p p r o x .1 - 3 s e c .
FAST
Baftervvortase
L]----
N11243 A D p r o x .' 1 0 - 1 5s e c .
N11244 SLOW
Banelyvortase
t]ff
.Bu lf operationis not as specified,replacethe wiper and

washerswitch.
4. I N S P E C TR E A R W I P E R A N D W A S H E R S W I T C H
CONTINUITY
LHD Models:
Inspectthe switch continuitybetweentsrminals.
T€st6rconn6ctionto
Switch position Spocifi6dvalue
tsrminalnumbor
W i p s rO F F No continuity
Wiper INT Continuity
W i p o rO N 2- 10 Continuity
washerON Continuity
lf continurtyis not as specified,replacsths switch.
N1 0 0 1 8
N11230

8E.51
SYSTEM_ WIPERANDWASHER
5. INSPECTREAR WIPER AND WASHERSWITCH

CONTINUITY
RHDModels:
Inspocttho switchcontinuitybetw€ent€rminals.
Toat6r connection to
Switch po.ition Spocifi6dvrlu.
tarminalnumbar
WiporOFF No continuity
wipor INT s - l5 Continuity
WiporON I - l8 Continuity
W66h6rON 8 - 16 Continuity
lf continuityis not as specified,roplacethe switch.
I 7 o 1 3 1
18 17 16 15 14 12 11 10
N11233
N11230
6. INSPECTWASHERLINKEDOPERATIOI{
(a) Connect th€ positiv€ (*) lead from the battory to
terminal16(12)and the nogative(-) lead to terminal
2(81.
(b) Connectthe positive(+) lead from the voltmeterto
terminal7(3) and the negative(-) lead to t€rminal2
(8).
(c) Push in the washer switch, check that th6 voltago
changesas shown in the table.
( ): RHDModol.
Lessthan 1soc
BaneryVoltage
Nl't243
Nl12il4 zr20t3
is not as specified,replacethe wiperand

lf operation
washerswitch.

BE-52
SYSTEM- WIPERAND WASHERSYSTEM
BODYELECTRICAL
W I P E RM O T O RI N S P E C T I O N
1. I N S P E C TF R O N TW I P E RM O T O R
Low SpeedOperation:
Connect the positive (+) lead from the battery to
t e r m i n a l3 a n d t h e n e g a t i v €( - ) l e a d t o t e r m i n a l1 ,
check that the motor operatesat low speed.
lf operationis not as specified,replacsthe motor.
High SpeedOperation:
t e r m i n a l2 a n d t h e n e g a t i v e( - ) l e a d t o t e r m i n a l1 ,
check that the motor op6rat6sat high spead.
lf operationis not as specified,roplac€the motor.
Stoppingat Stop PositionOperotion:

(a) Oporatethe motor at low speedand stop the motor
operation anywhere by disconnectingpositlve (-r-/
leadf rom terminal3.
( b ) C o n n e c t e r m i n a l s3 a n d 5 .
t e r m i n a6l a n d n e g a t i v e( - ) l e a dt o t e r m i n a l1 , c h e c k
that the motor stops runningat the stop positionafter
the motor op€ratesagain.
lf operationis not as specified,replacethe motor.

- wIPERA!!lrya!-E!!-9Isril BE-53
SYSTEM
BoDYELECTRICAL
2, INSPECT REARWIPERMOTORAND RELAYOPER-
ATION
(a) Connectths positivs(+) lead from ths batt€ryto
t e r m i n a1l ,a n dt h en s g a t i v(e- ) l e a dt o t E r m i n a3la n d
th6 motorbody,checkthat the motorop€rates.
(b) Disconnectthe nogativ€(-) lead from terminal 3,

ch6ck that tho motor stops runningat the stop posi'
tion.
lf operationis not as specified,replacethe motor and
relay.
lntermittent OPeration:
Connsct the positiva (+) lead from the batt8ry to
t€rmina1 ( - ) l e a dt o t o r m i n a2l a n d
l ,a n d t h e n o g a t i v o lF,#;.'
th6 motor body, checkthat ths motor operatesInter-
m i t t e n t l yf o r 9 - 1 5 s s c o n d s
lf ooerationis not as specified,replacethe motor and
relav.

BE-54
sysrEM - wrpERAND*ASHERsysrEM
BoDy ELE.TRTcAL
W A S H E RM O T O RI N S P E C T I O N
INSPECTWASHERMOTOR(W/ RearWiper)
FrontWasherOperation
Connect the positive (+) Iead from the battery to
check that th6 motor operates.
NOTICE: Thesetests must be performedquickly(within
20 seconds) to prsventthe coilfrom burningout.
Rear Washer Operation
check that tho motor ooerates.
NOTICE: Thasotests mustba performedquickly(within
20 seconds) to preventthe coilfrom burningout.
lf operationis not as specified,replacsthe motor.
INSPECT WASHERMOTOR(W/O RearWiper)

Ooeration
terminal 2 and the negativs(-) lead to terminal 1,
check that the motor oparates.
N O T I C E :T h e s et e s t s m u s t b e p e r f o r m e dq u i c k l y ( w i t h i n
2 0 s e c o n d s )t o p r e v e n t t h e c o i l f r o m b u r n i n go u t .
l f o p e r a t i o n i s n o t a s s p e c i f i e d ,r e p l a c e t h e m o t o r .

J=
SYSTEM- COMBINATIoN
BODYELECTRTCAL MErEE -------
C O M B I N A T I OM
NETER
PARTSLOCATION
P a r k i n gE r a k eS w i t ch
B r a k eF l ui d L e v e lW a r n i n g
Switch Door Court€sySwitch
. D O M EF u s e
I n p a n eJ / B
o G A U G EF u s e
. IGNFuse
o T A I LF u s e
Door Courtesy Switch

BuckleSwitch

BE-56
SYSTEM- COMBINATION
BODYELECTRICAL METER
5 S - F EE n g i n e 7 4 - FE E n g i n e
W a t e r T e mp e r a t u r e Water Temperature
S e n d e rG a u g e S e n d e rG a u g e
S p e e dS e n s o r
P r e s s u rW
s arning
Switch
Low Oil Pressure
W a r n i n gS w i t c h
S p e e dS e n s o r
N e u t r a lS t a r t S w i t c h N e u t r a lS t a r t S w i t c h
N 1 0 0 2 9N 1 0 0 3 0

BE-57
SYSTEM- COMBINATION
BODYELECTRTCAL METEE
M E T E RC I R C U I T
Europe Connoctor
"A"
B1
B2 Conngctor"B"
B3
B5
c9 "C"
c12 Connector
A14
W i r i n gC o n n e c t roS i d o
1 T u r nS i g n a lS w i t c h
2 E n g i n eE C U
3 Alt6rnator
4 H a z a r dS w i t c h
5 L o w O i l P r e s s u rWe a r n i n gS w i t c h
OilPressure 6 B r a k eF l u l dL B V eW I a r n i n gS w i t c h
C h e c kEn qi n e 7 Gr o un d
8 Ground
H E A DF u s e
10 H e a dl i g h tD i m m e rS w i t c h
11 DolvlEFuse
1t Door Co! rtesySwitch
810 14 S p e e dS e n s o r
'15 Turn Signal Switch
RearFoq Liqht Gr o un d
B4
2 F u e lS e n d e rG a u g €
A'10 A9
3 W a t e rT s m p e r a t u rSs e n d e rG a u g e
A15 R e a rF o g L i g h tR e l a Y
A16 5 Gr o un d
l l l u mi n a t i o n 7 F u e lS e n d e rG a u g e
c1
8 E n g i n oE C U
A11
1 0 ABSECU
1 T a i l l i g hC t ontroR l €lsy
2 L i g h tC o n t r o R l heostat
,r_ i Fu e l B e c e i v eG
r auge 3 I P a r k i n gE r a k eS w i t c h
v I W a t e rT e m p e r a t u rR
e e c e i v eG
r auge 4 I G NF u s e
e: Tachometer 5 E n g i n eO i l L e v e lS e n s o r
o, I Speedometer r.16.1 9 l g n i t i o no r l l A
l-10.1
N l 1 1 a r6. 1 3 . 1 . A 1 2 G A U G EF u s e

BE-58
B O D YE L E C T R I C ASLY S T E M- C O M B I N A T I OMNE T E R
General
"A" "8" "C"

Connoctor Coonector Connector
A14
B2
B4
c10
A13
W i r i n gC o n n e c t oS
r ide
Turn SignalSwitch
E n g i n eE C U
G A U G EF u s €
A7 Ground
Gr o un d
H E A DF u s e
A H e a d l i g hD
t i m m e rS w i t c h
D O M EF u s e
Door Courtesy Switch
c1 S p e e dS e n s o r
87 FuelSenderGaug€
810 T u r nS i g n a l S w i t c h
B8 Ground
E n g i n ea n d E C TE C U
A9 A8
WaterTsmperatureSenderGauge
A'15
Ground
A16 F u e lS g n d e rG a u g e
B1 En g i n eE C U
l l l um i n a t i o n O / D O F FS w i t c h
c2
A B SE C U
411 A10
Light ControlRheostat
T a i l l i g hC
t ontroR l elay
Alternator
F u e lR e c e i v eG
r au g e L o w O i l P r e s s u rWe a r n i n gS w i t c h
@ WaterTemperatureR6ceiverGauge I G NF u s e
o Tachometer
B r a k eF l u i dL e v e W
l a r n i n gS w i t c ha n d
S p e e d o m o tre ParkingBrakeSwitch
I 1 6 . 1 r ' i 0r.113 . 1 . 4
N11147 l gn i t e ro r l l A

8E.59
SYSTEM- COMBINATION
S a u d iA r a b i a
Conn€ctor
"A" Connoctor
"B" Conngctor"C"
B6
414
A6
82
B4
c10
BE
A13 W i r i n gC o n n e c t oS
r ide
Turn Signal Switch
E n g i n eE C U
G A U G EF u s e
G r o un d
A7 Gr o u n d
H E A DF u s e
c6 H e a d l i g hD
t i m m e rS w l t c h
D O M EF u s e
c9 Door CourtesySwitch
Low Oil Pressure
c1
C h e c kE n q i n e F u e lS e n d e rG a u g e
B7 Turn SignalSwitch
810 G.ound
S e a tB e l tR e m i n d e r
Watsr T€mperaturo S€nderGauge
A9 A8 G r o un d
A15 F u e lS e n d e rG a u g e
E n g i n eE C U
A16
lllumination ABS ECU
c1 c2
A10 L i g h tC o n t r o R l heostat
c11
t o n r r oR
T a i l l i g hC l elay
S e a tB e l tB u c k l eS w i t c h
Alternator
u-, F u e lR e c e i v eG
r auge LowOilPrsssure W a r n i n gS w i t c h
@ WaterTemperature ReceiverGauge I G NF u s e
o Tachometer B r a k eF l u i dL e v e Wl a r n i n gS w i t c ha n d
i>, Speedometer ParkingBrakeSwitch
f161i10rj131A
N1 1 1 4 € l g n i t s ro r l l A

BE-60
SYSTEM- COMBINATION
BODYELECTBICAL METER
Connector"A" Connector"B" Connector"C"
E,O
B,]
A7
B3
c9
c12
A14
W i r i n gC o n n e c t oS
r ide
'I
T u r nS i g n a lS w i t c h
2 E n g i n eE C U
Alternator
H 4 H a z a r dS w i t c h
5 LowOilLeveW l a r n i n gS w i t c h
,^. CHG 6 B r a k eF l u i dL e v e Wl a r n i n gS w i t c h
7 Ground
Brake,a. 8 Gr o un d
LOWU l.ressure 2\ H E A DF u s e
A5 1 0 H e E d l ihgt D i m m e rS w i t c h
C h e c kE n g i n e!
97 l ' l DON,IE Fuse
B'10 1 2 Door CourtesySwitch
P a r k i nB
g r a k !e
c3 1 4 S p e € dS e n s o r
H i g hB e a m! T u r nS i g n s l S w i t c h
810
turn n ,-\ 1 6 G r o un d
415
turnL,-\ 1 F u e lS e n d a rG a u g e
PWRX 2 Ground
A16 OJ
WaterTemporatureSenderGauge
o / Do F Fx
E n g i n €a n d E C TE C U
l l l um r n a l r on ^
6 F u e lS e n d e rG a u g e
DOOR
X 1 E n g i n sE C U
412
B9
cRUtSE
x 8 Oi D OFFSwitch
9 C r u i s eC o n t r o E
l CU
'10 A B S E C U
1 T a i l l i g hCt ontroR l elay

c, F u B lR e c e i v eG
r auge 2 L i g h rC o n t r o R l heostat
g W a t e rT e m p e r a t u rR
e e c e i v eG
r auge P a r k i n gB r a k eS w i t c h
3
o Tachometer
4 I G NF u s e
Sp€€dometer l g n i t e ro r l l A
9
i.r3.1.A
[10.1i.1or 12 GAUGE
Fuse

8E.61
sYsrEM- c!t'4-q!-N4I!oN
BoDYELEGTRIGAL M.EIE!
TROUBLESHOOTING
The table below will be usefulfor you in troubleshootingthese electricaI problems.The most
eachpart in
likelycausesof th6 malfunctionare shown in the order of their probability.Inspect
the order shown,and replacethe part whan it is found to be faulty.
METER,GAUGESAND ILLUMINATION
Part8nomo Soopago
Trouble
Fuee
l. GAUGE ( B E -1 4 )
Tachometor,Fuol Gaugeend Wator TomperaturoGaugodo not op'r_ 2. Mat.. CircuitPlrt. (BE-57)
ato 3. Wirr H!rnl8.
1. Spr.d Sonsor (BE-65)
2, MotorCircuitPlate {BE-57)
Speodomotordoes not oPora!€
3. Wirr H.rno88
1. lgnitor(5S - FE)or llA (7A - FE)
2. A/1i Enginoand ECTECU
Tachomot6rdoos not oporal6 MA: EnginoEcU
3. M€rorcircuitPllte (BE-57)
4. wirr Hlrnrt!
l. FuelRrc.ivcrGrug€ (BE-88)
2. Fu.l Scnd..Glugo (BE-68)
Fuol Gaugodoaa not oporatoor abnormaloparltion 3. M.t.r circuitPl!t. (BE-57)
4. Wirr H!rnt!.
l. Wrbr T.mprrllurr RrclivcrG.ugr (BE-68)
2. Wat.r Tampor.tur.SrnderGaug. (BE-89)
Gaugodossnot op€rtl€or tbnormrlopgrution
Wat.r Tomporatur€ (BE-57)
3. Mct€rCircuilPlatc
4. WiraHtrna!!
l. TAILFulr (SE- | 4)
2. LightControlRh.o!t.t (BE-71)
All illuminationlight5 do not light up 3. M.t.r CirouitPl.t. (BE-57)
rl. Wirc Harncac
l. Bulb
Only ono illuminationlight doos not light op 2. M.tor circuit Phto (BE-57)

8E.62
SYSTEM_ COMBINATION
W A R N I N GL I G H T S
Troub I Parts namo Soo page
1 .B u l b
2 . I G NF u s € (BE- 14)
Warning ight do not light up 3. tgnitionSwitch (BE- I 8)
(Exc€ptDischargeand Door Op6n) 4. M€ter CircuitPlat€ (BE-57)
5. Wiro Harness
6. Altgrnator
1.Bulb
2. Brak€Fluid Lovsl Warning Switch (BE-70)
3 . P a r k i n gB r a k eS w i t c h (BE-70)
BrakeWarning Lrght does not light up
4. Eulb Ch€ck Relay
5. N,leterCircuitPlato (8E-57)
6. Wire Harn€ss
LBub
2. Soat86lt Euckl€Switch
Seat Eelt Warning Light doos not rrghtup 3. lnt€gration
Rolay IBE 721
4. MeterCircuitPlate (BE-57)
5. WireHarnoss
l. Bulb
2. Low Oil PressuroWarning Switch (BE-69)
Low Oil Pressur6Warning Light does not light up
3 . M € t € rC i r c u i tP l a t e (BE-57)
1.Eulb
2 . D O M EF u s o (BE 15)
3 . D o o rC o u r t e s yS w i t c h (BE-71)
Door Open Warning Light do6s not tght up 4. Luggag€Room Light Switch
5. lntogrationRelay BE 72]'
6 . M s t e rC i r c u i tP a t e (BE-57)

BE-63
SYSTEM_ COMBINATION
BODYELECTRICAL METffi
I N D I C A T O RL I G H T S
Paatsnamo S e op a g e
Trouble
L Bulb
ABS IndicatorLight does not lrght tlp 2. Wire H6rn€ss
l Bulb
Check EngineWarning Light does not laghtup 2. Engine€CM

3. Wrre Harnsss
1 .B u L b
2. Eneineand ECTECU AX Section
PWR IndicatorLight doos not llght up.
3. WireHarnoss
1 .B u l b
2. O/D Main Switch
3. EngineECM
O/D OFF IndicatorLight does not light up
4. Meter CircuitPlate ( B E- 5 7 )
5. Wirs Harn€ss
II t. e,rtu
2. Turn Signaland HazardWarning System (BE-36)
Turn IndicatorLight does not lrght up 3 . M 6 t e rC i r c u i tP a t e ( 8 E- 5 7 )
I
4. WireHarness
r. il;---
I
I 2. HeadlightSystem
High Beam IndicatorLight does noi light up 3. Moter CircuitPlate (BE-s7)
I 4. Wir6 Harn€ss
1.8lrlb
2. Cruis6Contro ECU (BE-118)
CRUISEIndicalorLight does not Lrghtup 3. Meter CircuitPlate
4. Wi16 Harness

BE-64
SYSTEM- COMBINATION
SPEEDOMETE
I NRS P E C T I O N
I N S P E C TS P E E D O M E T EORP E R A T I O O
NNVEHICLE
(a) Usinga speedomet€r tsster,inspactthe speedometer

f o r a l l o w a b l ien d i c a t i o e
n r r o ra n d c h e c kt h a o o e r a t i o n
of the odometer.
H I N T :T i r e w e a r a n d t i r e o v e r o r u n d e ri n f l a t i o nw i l l
increassthe ind icationerror.
lf error is excessive,replacethe speodometer.
(b) Checkthe speedometorfor pointervibrationand ab-
normaI norse.
EUROPE
Stsndardindicstion(km/h) Allowablerangs (km/h) Standardindication(mph) Allowablerang€ (mph)

20 20 -26 20 20 - 24.5
40 40-4a 40 40 - 46.5
60 60-70 60 60 - 68.5
80 80-92 80 80 90.5
100 1 0 0- 1 1 4 100 1 0 0- 1 1 2 . 5
120 1 2 0, 1 3 6
140 1 4 0- 1 5 8
160 1 6 0- 1 8 0
GENERAL
Standardindication(kmlh) Allowabjsr6n9o (kmlh) Standardindication{mph) A lowablorang6 (mph)

20 1 7- 2 7 20 1A-24
40 38-46 40 38-44
60 57,5- 67 60 58-66
80 77 -88 80 78-88
100 96 - 109 100 98- 110
120 ll5 130 120 118 132
140 -
134 151,5
160 1 5 3- 1 7 3
AUSTBALIA
Standardindicotion (km,/hl Allowabl€rang6 (kmlh)

40 36-44
60 54-68
80
100 9 0- 1 1 0
120 108
140 1 2 6- 1 5 4
180 144 176

BE-65
sYsrEM- co!4qlN-4Il-q-Nl!!IER
BoDYELEcrRlcAL
INSPECTION
SENSOR
SPEED
INSPECTSPEEDSENSOROPERATION
(a) Connectthe positive(+)lead from battsryto terminal
1 a n d n e g a t i v e( - ) l e a dt o t o r m i n a 2l .
(b) Connecttho positive(+) leadfrom tost€rto terminal3
a n d n e g a t i v e( - ) l e a dt o t e r m i n a 2l .
(c) Rotateshaft.
(d) Checkthat thers is a voltagechangefrom approx 0 V
to 1 1 V or more betwesnterminals2 and 3.
HINT:The voltagechangeshouldbe 4 times for every
revolutionof the speedsensorshaft.
lf oDorationis not as spacified,replaceth6 sensor.
T A C H O M E T El R
NSPECTION
INSPECTTACHOMETER
ON_VEHICLE
(a) Connect a tuns-up tsst tachometer,and start the
e n gi n e .
NOTICE: Raversing the connection of the tachomater will
damagetha transistors and diodes inside.
( b ) C o m p a r et h e t s s t e ra n d t a c h o m e t eirn d i c a t i o n s .
lf error is excessive,replacethe tachometer'
DC 13.5V,25"C(77'F)
Standardindication(rPm) Allowabl€rang€(rpm)
700 630 - 770
1000 9 0 0- 1 1 0 0
2000 1 8 5 0- 2 1 5 0
3000 2800 - 3200
4000 3800 - 4200
5000 4800 - 5200
6000 5 7 5 0- 6 2 5 0
7000 5700 - 7300

8E.66
SYSTEM_ COMBINATION
F U E LR E C E I V EGRA U G EI N S P E C T I O N
ruer -l/
baugell ll 1 . I N S P E CFTU E LR E C E I V EGRA U G EO P E R A T I O N
// '\- \ ll
ll
.4:a +-z})
- (a) Disconnect ths connoctor from the sendergaugeas-
lgnrtion
S wi t ch semDly.
I (b) Turn the ignitionswitch ON, check that the receiver
i Battery gaugeneedleindicatesEli4PTY.
T
{c) Connecttsrminals2 and 3 on the wire harnessside

connsctorthrougha 3.4 W t6st bulb.
( d ) T u r n t h s i g n i t i o ns w i t c hO N ,c h e c kt h a t t h 6 b u l bl i g h t s
F u e lG au g e up and receivergauge needlemoves toward ths full
srds.
H I N T :B e c a u s eo f t h e s i l i c o no i l i n t h e g a u g e ,i t w i l l
taks a short tima for the n6edleto stabilize.
lf operationis not as specified,inspect the receiver
8 E r 2 0 6e 5 1 A gaugeresistance.
2. I N S P E C TF U E LR E C E I V E G
R A U G ER E S I S T A N C E
Measuretha resistancebetweenterminals,
BE
Eetweont6rminals Resistance(Q)
A _ B Approx. 154.3
A p p r o x .1 2 6 . 2
Approx.280.5
lf resistancevaluais not as specified,replacethe fuel

receivergauge.
G A U G EI N S P E C T I O N
F U E LS E N D E R
1 . I N S P E C TF U E LS E N D E RG A U G EO P E R A T I O N
(a) Connecta seriesof three 1.5 V dry csll battories.
(b) Connectthe positive(+) leadfrom the dry coll batte-
ries to terminal2 through a 3.4 W tost bulb and the
negativs(-) leadto tarminal3.
(c) Chsckthat the voltagerisesbetweenlerminals3 and
2 as the float is movedfrom the too to bottom posi-
tion.

BE-67
SYSTEM- COMBINATION
2. R A U G ER E S I S T A N C E
I N S P E CFTU E LS E N D E G
Measure tho resistance between terminals 2 and3 f or
eachf loatPosition.
Float position mm (in.) R e s i s t a n c e( Q )
F A p p r o x . 2 7 .{61 . 0 9 ) Approx.3.0
1/2 A p p r o x . 3 3(.17. 3 3 ) A p p r o x .3 1 . 6
E Approx.92.7{3 65) A p p r o x .I 1 0 . 0
lf resistancevalue is not as specified.replacethe

s e n d e rg a u g e .
F U E LL E V E LW A R N I N GL I G H T
."+ lgnlt!on
INSPECTION
Switch Warning
I N S P E C TF U E LL E V E LW A R N I N GL I G H T
( a ) D i s c o n n e ct th e c o n n e c t o frr o m t h e s e n d e rg a u g e .
Battery (b) Connectterminals1 and 3 on the wire harnessside
T connecror.
( c ) T u r n t h e i g n i t i o ns w i t c h O N , c h e c kt h a t t h e w a r n i n g
B E I 2 1 7 l 5e 1 . A l |81 l i g h ti i 9h t s u p .
l f t h e w a r n r n gl i g h td o e sn o t l i g h tu p .t e s t t h e b u l bo r
inspectwire harness.
SWITCH
F U E LL E V E LW A R N I N G
INSPECTION
INSPECTFUEL LEVELWARNINGSWITCH
(a) Apply battsry voltage between terminals 1 and 3
through a 3.4 W test bulb,chock that the bulb lights
up.
HINT:lt will take a short timo for the bulb to light up.
(b) Submergetha switch in fuel,checkthat ths bulb goes

out.
lf operationis not as specified,replacethe sender
g au g s .

8E.68
SYSTEM_ COMBINATION
EngineCoolant Temperature Gauge REE C E ] V EGRA U G E

W A T E RT E M P E R A T U R
INSPECTION
...
l\
tt 2t
"rffiffi-
-rW-
1. INSPECT WATER TEMPERATURE RECEIVER
Gffi;-,{/_-\.'2../ GAUGEOPERATION
(a) Disconnectth6 connectorfrom the ssndsr gauge.
(b) Turn tho ignitionswitch ON. check that the receiver
gaugeneedleindicatesCOOL.
( c ) G r o u n dt e r m i n a ol n t h e w i r e h a r n a s ss i d e c o n n e c t o r
E n g i n eC o o l a n tT e m p e r a t u r eG a u g e
througha 3.4W test bulb.
( d ) T u r n t h o i g n i t i o ns w i t c hO N ,c h e c kt h a t t h e b u l bl i g h t s
Test Bulb up and the receivergauge needlemoves toward the
( 3 . 4W ) hot side.
lf operationis not as specifiad,replacethe sender
gaug8.
Then recheck the system.
lf operationis not as specified,measurethe receiver
gaugeresistanc€.
2. INSPECT WATER TEMPERATURE RECEIVER
G A U G ER E S I S T A N C E
Bg Measurethe resistancebetwesnterminals.
HINT:Connectthe test leadsso that the currentfrom
the ohmmet6rcan flow accordingto the chart order.
Betwo€ntorminsls R6sistanco(O)
A _ B Apptox,229.7
Approx.54.0
N10004 B - C A p p r o x .1 7 5 . 7
lf resistancevalue is not as spscified,rsplace the

e n g r n ec o o l a n t s m p e r a t u r rss c s r v egr a u g e .

BE.69
qer4l!t{AreI-!4EIE!
BoDYELECTRICALsYsrEM
T E M P E R A T USREEN D EG
WATER RA U G E
INSPECTION
I N S P E CW SENDER
T A T E RT E M P E R A T U R GAUGE
Measure tha resistance botw66n and
terminal gauge
bodY'
oC R6sistanc6(O)
T6mp€raturo ('F)
5 0 ( r2 2 . 0 ) 1 6 0- 2 4 0
1 2 0{ 2 4 8 . 0 ) 1 7 . 1- 2 1 , 2
lf resistancevalue is not as specified, replacothe

enginecoolant te mPorature s gnd e r g au9 6 .
SWITCH
L O WO I L P R E S S U RWEA R N I N G
INSPECTION
1 . I N S P E C TL O W O I L P R E S S U RW E A R N I N GS W I T C H
(a) Check that there is continuity between terminaland
groundwith tho enginestoPPed
(b) Check that thore is no continuity between terminal
a n d g r o u n dw i t h t h e a n g i n er u n n i n g
HfNT: Oil pressureshould be over 20 kPa (0.2 kgf/
cm',2.9 psi)
lf ooerationis not as specifisd,rsplacoths switch'
2 . I N S P E CLTO WO I LP R E S S U RWEA R N I N G LIGHT

(a) Disconnect the connectorfrom t h e w a r n i n gs w i t c h
a n dg r o u n dt e r m i n aoln t h ew i r eh ar n e s ss i ds c o n n s c -
ror.
( b ) T u r n t h e i g n i t i o ns w i t c h O N , c h e c kt h a t t h e w a r n i n g
light lightsup.
l f t h e w a r n i n gl i g h td o e sn o t l i g h tu p ,t a s t t h e b u l b o r
insDectwir€ harnsss.

BE-70
sysrEM - coMBrNATroN
BoDy ELEcTRTcAL METER
B R A K EF L U I DL E V E LW A R N I N G
SWITC
H
INSPECTION
1. I N S P E C TB R A K EF L U I DL E V E LW A R N I N GS W I T C H
(a) Removethe reservoirtank cap and strainer.
(b) Disconnectthe connector.
(c) Chsck that thors is no continuitybatwe€nterminals
with the switch OFF (float up).
(d) Use syphon,etc.to take fluid out of the res6rvoirtank.
(e) Checkthat there is continuitybetweentorminalswith
th€ switch ON (floatdown).
(f) Pour the fluid back in the roservoirtank.
lf operationis not as specified,replacethe switch.
2, INSPECTBRAKEWARNINGLIGHT
(a) Disconnectthe connectorfrom the brakefluid warn-
ing switch.
(b) Releasethe parkingbrakelever.
(c) Connect terminalson the wir6 harnesssrde of the
levelwarningswitch conn6ctor.
(d) Srart th€ engine,check that th6 warning light lights
up.
lf the warninglight doss not lighr up. t€st the bulb or
wire harnass.
PARKINGBRAKESWITCHINSPECTION
1. INSPECTPARKINGBRAKESWITCH
(a) Check that ther6 is continuitybetweenterminaland
switch body with the switch ON (switchpin released).
(b) Check that ther6 is no continuity betweon terminai
and switch body with tha switch OFF (switch pin
pushedin).
lf operationis not as specified.replacethe switch or
inspectgroundpoint.
2, INSPECTBRAKEWARNINGLIGHT
(a) Disconnectthe connector from th€ parking brake
switch and the brakefluid warningswitch.
(b) Groundterminalon the wire harnessside conn6ctor.
(c) Start the engine,check that the warning light lights
up.
lf the warninglight does not light up, test the bulb or
insoectwire harn6ss.

BE-71
SYSTEM_ COMBINATION
D O O RC O U R T E SSYW I T C HI N S P E C T I O N
F-il l:)
l u | - 1 . I N S P E C TD O O RC O U R T E S Y SWITCH
\ab:=z- ( a ) C h 6 c kt h a t t h e r o i s c o n t i n u i t yb e t w e s nt e r m i n a a
l nd
-- \ d switch body with the switch ON

(b) Check that thero is no continuity botween terminal
(swrtch pin releasad)'
\
Ji
-r.l
_ l
,,--\
\_/ 14
r _ and switch body with the switch OFF (switch pin
pushed).
3
lf continuityis not as specified,replacethe switch'
2. I N S P E C TO P E ND O O RW A R N I N GL I G H T
Disconnectthe connector from the door courtesy
switch, and ground tarminal 1 on the wire harness
s i d ec o n n e c t oar n d c h e c kt h a t t h e w a r n i n gl i g h tl i g h t s
up.
l f t h e w a r n i n gl i g h td o e sn o t l i g h tu p , i n s p e c t h e b u l b
or wire h arness.
L H E O S T AITN S P E C T I O N
L l G H TC O N T R O R
I N S P E C TL I G H TC O N T R O LR H E O S T A T
(a) Connect ths positive (+) lead from the battery to
t e r m i n a l1 a n d n e g a t i v el e a d( - ) t o t e r m i n a 3l '
(b) Connectthe positiva(+) lead from the voltmeterto
t e r m i n a 2l a n d n e g a t i v el e a dt o t e r m i n a 3l .
(c) Turn the rheostatknob and check that ths voltage
cnangos.

8E.72
SYSTEM_ COMBINATION
I N T E G R A T I ORNE L A YI N S P E C T I O N
1 . I N S P E C TU N L O C KW A R N I N GO P E R A T I O N
(a) Connect tha positive (*) lead from ths battery to
terminal1 and 7, the negativeleadto terminals5 and
10.
(b) Checkthat the buzzersoundswhon th6 n69ativs(-)
lead from the batteryis connectedto terminal6.
lf operationis not as specified,replacethe ralay.
2. INSPECTSEAT BELT WARNINGOPERATION

torminals1 and 7.
(b) Connect the positive (*) lead from the battery to
t o r m i n a 9l t h r o u g ha 3 . 4 W t e s t b u l b .
(c) Checkthat the test bulb lights up and buzzersounds
l o r 4 - 8 s e c o n d sw h e n t h e n e g a t i v e( - ) l e a df r o m
t h 6 b a t t e r yi s c o n n s c t e dt o t e r m i n a l1 0 .
( d ) C h e c kt h a t t h e b u z z esr o u n d i n gi n ( c )s t o p sw h a n t h e
negative(-) lead from the battery is connactsdto
t e r m i n a8l .
lf operationis not as specified,replacethe intsgration
relav.

BE.73
SYSTEM_ DEFOGGER
D E F O G G ESRY S T E M
PARTSLOCATION
D e f o g g e rS w i t c h
R e a rW i n d o wG l € s s
o WindowDefogger
I n p a n eJ / B !--'---
. DefoggerRelay
. O E FF u s e
r H T RF u s e

BE-74
SYSTEM- DEFOGGER
TROUBLESHOOTlNG
The table below will be useful for you in troubleshootingthese electricalproblems.The most
the order shown,and replacethe part when it is found to be faulty.
Troublo Part6nam€ (56€ pago)
1 . H T RF u s € ( 8 E- 1 4 )
2 . D E FF u s o (8E 14)
A I dofog€orsystgmsdo not op6rat6 3 . D € f o g g eRr o l a y (8E-75)
Switch
4. Dotogger (BE- 74)
5. WiroHarness
1 . D € t o g g eWr i r s s (BE-75)
Rs6awindow d€foggordoes not operato
2. WireHarness
SWITCHINSPECTION
DEFOGGER
INSPECTDEFOGGERSWITCH
(a) Connectthe positive(+) lead from the voltmeterto
l a n d t h e n e g a t i v e( - ) l e a d f r o m t h e v o l t m e -
t s r m i n a5
ter to terminal4.
(b) When the switch is off, the voltageshouldbe approx.
1 2V .
(c) When the switch is on. check that th6 indicatorlight

l i g h t su p a n d t h a t t h s v o l t a g ei s l e s st h a n 1 V .
(d) W/ Timer:
After 15 minutes.checkthat ths switch is off and the
voltageis approx.12 V.

BE-75
SYSTEM_ DEFOGGER
RELAYINSPECTION
DEFOGGER
T E F O G G ERRE L A YC O N T I N U I T Y
I N S P E CO
3 r f]1- T6ster connoctionto
Condition Spscifiedvalue
}- sl torminslnumber
I F-l r\ Constant Continuity
Apply +B b€tween
Continuity
t6rminalsI and 2.
8 E 1 0 4 98 E 1 8 { 0
l f c o n t i n u i t yi s n o t a s s p e c i f i e dr,e p l a c et h e r e l a Y - , - -
RI R EI N S P E C T I O N
D E F O G G EW
NOTICE:
r W h e n c l e a n i n gt h e g l a s s ,u s e a s o f t , d r y c l o t h ' 8 n d
w i p e t h e g l s s si n t h e d i r e c t i o no f t h e w i r a ' T a k e c a r e
n o t t o d a m a g st h e w i r e s .
. D o n o t u s o d s t e r g e n t so r g l a s s c l o a n e r sw i t h s b r a -
s i v a i n gr a d i e n t s .
. w h o n m e a s u r i n gv o l t a g e , w i n d I p i s c a o f t i n f o i l
a r o u n d t h o t o p o f t h e n e g a t i v ep r o b e a n d p r a s s t h e
f o i l a g a i n s tt h a w i r e w i t h y o u r f i n g e r , a s s h o w n .
(a) T u r n t h s i g n i t i o ns w i t c h O N .
(b) T u r n t h e d e f o g g e r s w i t c h O N . $ii.$lri
(c) I n s p e c t t h e v o l t a g e a t t h e c e n t o r o f e a c h h e a t w i r e , a s
snown.
Voltag€ Condition
Approx.5V Okay (No br6ak in wrre)
A p p r o x .1 0 V o r 0 V Brok6nwiro
HINT:lf there is approximatel1 y0 V, tha wire is

brokenbetweenthe contor of the wire and the posi-
t i v e ( * ) e n d .l f t h e r ei s n o v o l t a g et,h a w i r e i s b r o k e n
b€twssnths centerof the wir€ and ground.

BE-76
SYSTEM- DEFOGGER
(d) Placethe voltmeterpositive(*) leadagainstthe def-

Several
Its Volts o g g e rp o s i t i v e( + ) t e r m a n a l .
(el Place the voltmoter negativ€(-) lead with the foil
strip againsttha heatwire at the positive(* ) terminal
e n d a n d s l i d ei t t o w a r dt h e n e g a t i v o( - ) t e r m i n a l e n d .
(f) The ooint where the voltm€t€rdeflectsfrom zero to
severalV is the olacewhere the heat wire is broken.
HINT: lf the hsat wire is not broken,the voltmetor
indicate0 s V a t t h e p o s i t i v e( * ) e n d o f t h e h s a t w i r e
b u t g r a d u a l l yi n c r e a s e tso a b o u t 1 2 V a s t h 6 m e t e r
orobEis movedto the other end.
D E F O G G EW
RI R ER E P A ] R
(a) Clean the broken wire tips with a g r e a s e w
, ax and
silicone ramover.
(b) Placeth6 maskingtape alongboth sidesof the wire to
be repaired.
(c) Thoroughlymix the repair agent (DuPontpaste No,
t\,4€sking
TapE
4817).
(d) Using a fine tip brush,apply a small amount to ths

/'1
U wire.
-r- (e) Aftor a f6w minutgs,romovotho maskingtape.

(f) Allow the repairto stand at least 24 hours.

BE-l7
-- ,
SYSTEM_ POWERWINDOW CONTROLSYSTEM
BODYELECTRICAL
P O W E RW I N D O W C O N T R O L
SYSTEM
PARTSLOCATION
Power Window Switch
I n p a n eJ / B PowerWindowMotor
o P O W E RF u s e
P o w e rW i n d o w
Motor
Power Window Nlaster

Switch

BE-78
BODYELECTRICAL
TROUBLESHOOTING
The table below will be usefulfor you in troubleshootingthese electricalproblems.The most
likelycausesof the malfunctionare shown in the order of their probability.I n s p e c e
t a c hp a r t i n
the order shown, and reolacethe oart when it is found to bs faultv.
Trouble Partsnam€ (S€opago)
l . P O W E RF u s e (8E 14)
2 . G A U G EF u s 6 ( B E- l 4 i
3 . P o w e rM s i n R 6 l 6 y (BE-81)
Power Window does not op6rate.
4. lgnitionSwitch (BE- 18)
5. Power Window Master Switch (BE- 79)
6. Wire Harn6ss
"One (BE-79t
Touch Power Window Systom"doos not op€rat€. l. Powor Window Master Switch
1 . P o w e rW i n d o wM a s t e rS w a t c h (BE-79)
2 . P o w s rW i n d o wS w i t c h (8E-81)
Only on€ wrndow g ass do€s not mov6.
3. Pow6r Window Motor (88-82)
4. Wiro Harness
"Window (BE 79)
Lock Syst6m'does not op6rat6. 1, Power Window Master Switch
llluminationdoes not hght up. L Powsr window MasterSwitch {BE-79)

8F,79
B O D Y E L E C T R I C A LS Y S T E M - P O W E R W I N D O W C O N T R O
POWERWINDOWMASTERSWITCH
INSPECTION
{-a l-lllfil-l INSPECTPOWERWINDOWMASTERSWITCHCON.
---"ir-_ffil TINUITY
E!9LWJ lnsooctthe switchcontinuitybetweenterminals.
Driver'r Switch
T6at€rconnectronto
Switch po6ition Speciliodvalu.
tgrminalnumbor
UP Continuity
7- e
OFF Continuity
8(6)- I
DOWN Continuity
Parrenger't Switch (Window unlock)

To6t6rconnoctionto
N10430 Switch po6ition Spocifi€dvaluo
.'10-2-A t6rminalnumbor
il(l) - 9(8)
UP Continuity
7(s)- r 0(8)
/t(l) - 9(8) BE
Continuity
9 ( s )- 1 0 ( 6 )
4(1)- 7(8)
DOWN Continuity
9(5)- r 0{6)
Pallenger'r Switch (Window lock)

Tgst6r connsction to
Switch posataon Spocifiedvalu6
t6rminalnumbor
UP 7(8)- rO(5) Continuity
4 ( 5 )- r 0 ( r ) Continuity
oowN 4(8) 711) Continuity
( ): RHDModelr
l f c o n t i n u i t v i s n o t a s s p e c i f i e d ,r e p l a c e t h e s w i t c h .

BE-80
SYSTEM- POWERWINDOWCONTROL
One Touch Power Window System / Cw.tent ol
Circuit
Inspoctlon using an !mmgtor,
(a) Disconnectth€ conn€ctorfrom the masterswitch.
(b) Connectthe positivo(+) lead from the amm6t6rro
terminal8(7I on the wire harnessside connectorand
the nogativo(-) lead to the negativ6terminalof the
battsry.
8E2654Nlo43z 211245 (c) Conn€ct the positive (+) lead from th6 battery ro
terminal6(9) on the wire harnessside connector.
(d) As the window goes down, check that th€ current
flow is approximately7 A.
(e) Ch€ckthat th€ curr€ntincreasesup to approximately
14.5 A or more when the window stops going down.
( ): RHDModcl.
HINT:The PTCopenssome 4 - 90 secondsafter the
window stops going down, so that chock must ba
made beforeth€ PTCoperat€s.
8E2C5tN104t2 lf the operationis not as specified,r€placothe mastEr
switch.
,*.' lntpaction uring an lmmoto? wlth ! current- measuring

probc.
(a) R€mov€ th€ master switch with connector connected.
( b ) A f t a c h a c u r r € n t- m e a s u r i n g p r o b e t o t e r m i n a l 6 ( 9 ) o f
tho wire harness.
(c) Turn th6 ignition switch ON and set tho power
window switch in th6 down oosition.
(d) A8 the window goes down, check that the curront
BE265ztNtO434
21fj/47 flow is approximately7 A.
(e) Checkthat the currentincreasesup to approximately

14.5 A or more when the window stops going down,
HINT:The PTCopenssome 4 - 90 secondsafter the
window stops going down, so that check must be
made before th€ PTC operates.
lf operationis not as specified,replacethe master
switch.
8E2654NlOa!. ^12l{

8E.81
SYSTEM- POWERWINDOW CONTROLSYSTEM
BODYELECTRICAL
POWERWINDOWSWITCHINSPECTION
INSPECT POWERWINDOWSWITCHCONTINUITY
switch
lnsoect continuitybetwesnterminals.
Tester connectionto
Switch position Spooifi€dvslua
torminelnumbor
1 - 4
UP Continuity
OFF Continuity
DOWN Contrnuity
l f c o n t i n u i t yi s n o t a s s p e c i f i e dr,e p l a c et h s s w i t c h
N10431
a'5 2
P O W E RM A I NR E L A YI N S P E C T I O N
BE
I N S P E C TP O W E RM A I N R E L A YC O N T I N U I T Y
Inspectrelaycontinuitybetwe€nterminals
T6storconnoctionto
Condition value
Specifisd
t o r m i n anl u m b € r
Constant Contin0itY
Apply +B botwoon
J - C Continulty
B E 4 o / r89E 1 8 4 0 t€rminals1 and 2.
l f c o n t i n u i t vi s n o t a s s p e c i f i e dr 'e p l a c et h s r e l a y

BE-82
SYSTEM_ POWER WINDOW CONTROLSYSTEM
BODYELECTRICAL
POWER
W I N D O WM O T O RI N S P E C T I O N
1 . INSPECT
DRIVER'S
SIDEPOWER
WINDOWMOTOR
OPERATION
(a) Connect tho positive (+) lead from the battery to
t e r m i n a l1 a n d t h s n e g a t i v e( - ) l e a d t o t e r m i n a l2 .
check that the motor turns clockwise.
(b) Reversethe polarity,checkthat tho motorturns coun-

terclockwise.
2. I N S P E C TD R I V E R ' S S I D EP T C T H E R M I S T O R OPER-
::,BE ATION
(a) Disconnectth6 connectorfrom the masterswitch.
./
z.:7 li
(b) Connectths positive(*) lead from the ammetsr to
tsrminal6(9) on the wirs harnessside connsctorand
ths negative (-) lead to negative terminal of the
batt6ry.
(c) Connoct the positive (+) lead from the battery to
8 E 2 6 5 9N 1 0 4 3 3 terminal8(7)on the wire harnessside connector,and
raisethe window to the fully closedposition.
(d) Continueto apply voltage, check that th6 curront
c h a n g e sf r o m a p p r o x i m a t e l1y4 A t o l e s st h a n 1 A
:n w i t h i n4 t o 9 0 s e c o n d s .
t t/-
,/ +l (e)
(f)
Disconnectthe leadsfrom terminals.
Approximately90 secondslater,connectthe positive
i i (+) leadf rom the batteryto terminal6(9)and nsgativ€
\
(-) lead to terminal 8(8), check that tha window
begins to descend.
8 E 2 6 5N
9r0439 ( ) : R H DM o d e l s

BE-83
BODY ELECTRICAL
I N S P E C TP A S S E N G E RS' SI D E P O W E RW I N D O W
MOTOROPERATION
( a l Connectthe positive(*) lead from the batteryto
t e r m i n a1l a n d t h e n e g a t i v (€- ) l e a dt o t e r m i n a2l ,
checkthat the motorturnsclockwise.
(b) Reverssthe polarity,checkthat tha motorturns coun-

terclockwise.
lf operationis not as specified.replacethe motor.
4. INSPECT PASSENGER'SSIDE PTC THERMISTER

'.i:-
OPERATION BE i
{a) Disconnecttho connsctor from the powar wlndow
swrtch.
(b) Connectthe positive(*) lead from tha ammeterto
terminal3 on the wire harnessside connectorand the
negative(-) leadto negativeterminalof the battery.
8 E 2 6 5 9N 1 0 4 4 2 terminal 1 on the wire harnesssids connector,and
raisethe window to the fully closedposition.
(d) Continueto apply voltage, check that the current
changesfrom approximately14 A to l6ss than 1 A
within 4 to 90 seconds.
zq (e)
(f)
D i s c o n n e ct th e l e a d sf r o m t h e t € r m i n a l s .
Approximately90 secondslater.connectthe positive
i (*) leadfrom the batteryto terminal3 and tha nega-
L i t i v e { - ) l e a d t o t e r m i n a l1 . c h e c k t h a t t h a w i n d o w
beginsto descend.
B E 2 6 5 9N 1 0 4 4 3 lf ooerationis not as specified,rsplacothe motor.

BE-84
sysrEM - powERDooRLocKcoNTRoL
BoDyELECTRTCAL sysrEM
PO WE R
DOORLOC KCO NT ROL
SYSTEM
PARTSLOCATION
D o o r K e y L o c ka n d U n l o c kS w i t c h
l np a n eJ / B
o POWER Fuse Door Lock control Switch
. O O O RF u s e
. G A U G EF u s e D o o r L o c kC o n t r o lR e l a y D o o r K e y L o c ka n d U n l o c kS w i t c h
. POWER MAINRelay
rilliff.
D o o r L o c kC o n t r o lS w i t c h
( P o w e rW i n d o w
M a s t e rS w i t c h )
D o o r L o c kM o t o r a n d D o o r U n l o c k
DetectionSwitch
D o o r C o ur t e s yS w i t c h

BE-85
SYSTEM- POWERffi
BODYELECTRICAL
TROUBLESHOOTING
I p r o b l e m sT.h e m o s t
The table below will be useful for you in troubloshootingtheseslsctrica
likelycausesof the malfunctionare shown in the order of thoir Inspecteachpart in
probability.
the order shown,and replacethe part when it is found to be faulty.
Portsnomo (ssgPago)
Troubl6
1. Door Lock ControlRelay (BE-88)
2 . D o o RF u s € ( B E -1 4 )
"Door lock control 6yst€m' do6s not oporate (All) Fuse
3.GAUGE ( B E- 1 4 )
4, WireHarness
5, OthorParts
1. Door Lock ControlSwitch (BE-86)
Mallunctionin Door Lock / Unlock 2, Wire Harn6ss

3. Door Lock ControlRelay (BE-88)
(Usingdoor manualswitch)
4. oth.r Part6
Maltunctionin Ooor Lock / Unlock l. WireHarngss

(Usingdoor manu6lswitch and key) 2. OtherParts
1. Door Unlock D6t€ctionSwitch (EE-a/)
Ms lunction in Door Lock / Unlock. 2. Wiro Harnoss

3 . D o o rL o c k C o n t r o R
l 6lay (BE-88)
(UsingKoy)
4, Othor Parts
Switch
1. DoorUnlockDetoction (BE-87)
Fault in 2 - Oporationunlock function of Driv€r'ssid6 door k6y Lock 2. Wir€Hornoss

3, DoorLockControlRslay (BE-88)
and Unlock switch.
4. OthorPart8
1. Door Unlock DetoctionSwitch (BE-87)
2 , D o o r C o u r t o s yS w i t c h (BE-71)
3, Door Lock ControlSwitch (8E-86)

Faolt in k6y conlan€prov6ntlonoporatlon.
4. Wir6 Harnoss
5. Door Lock ControlRslsy (BE-88)
6. Other Parts
I D o o rL o c k M o t o r (BE-87)
Only ono door lock do€s not op€rato.
2. Wir€ Hsrn6ss

BE-86
sysrEM - powERDooRLocKcoNTRoL
BoDyELEcTRTcAL sysrEM
D R I V E R 'D
SO O RL O C KC O N T R O S
LWITCH
INSPECTION
'/-;;:\ INSPECT DRIVER'S DOOR LOCK CONTROL
€l
r F / .i , \ l SWITCHCONTINUITY
. E\L/i oool
\jJLll]r:-l
I
Testerconnectionto
Switch position Spocifi€d va ue
t e r m r n anl u m b € r
LOCK s ( 6 )- 9 ( r0 ) Contin
uity
OFF No Continurty
UNLOCK I (4) s(6) C o nt r n u r t y
RHD Models
lf continuityis not as specified,roplaceth6 switch.
P A S S E N G E RD' S
O O RL O C KC O N T R O L
S W I T C HI N S P E C T I O N
I N S P E CP
T A S S E N G E RD' O
S O RC O N T R OS
LW I T C H
l:dFli
lt"a"r _.1!u_ CONTINUITY
T6st€rconn€ctionto
Switch position Specifedvalue
tsrmrnalnLtmD0r
LOCK 3 4 Contrnuity
OFF No continuity
U NLOCK Continuity
l f c o n t i n u i t vi s n o t a s s o e c i f i e dr,o D l a c e
the switch.
Nr0431
o a 2 0

BF-87
SYSTEM- POWE
BODYELECTRICAL
D O O RL O C KM O T O RI N S P E C T I O N
I N S P E C TD O O RL O C K M O T O R
Operation
check that the door lock link movesto UNLOCKposi-
tion.
(b) Removs ths polarity,check that the door lock link
movesto LOCKPosition.
lf operationis not as specified,replacethe door lock
assemblv.
D O O RU N L O C KD E T E C T I OSNW I T C H
INSPECTION
SWITCH
I N S P E C TD O O R U N L O C KD E T E C T I O N
CONTINUITY
Tester conn€ctionto
Switch position Specili6dvalu6
t6rminalnumber
OFF
No Continuity
(LOCKposition)
ON
4- 6 Continuity
position)
(UNLOCK
lf continuitvis not as specified,replacethe door lock

assembly.

BE-88
SYSTEM_ POWERDOORLOCKCONTROL
POWERMAIN RELAYINSPECTION
I N S P E CPTO W E R
M A I NR E L A YC O N T I N U I T Y
Inspectrslaycontinuitybetwe€nterminals.
T6stsr connectionto
Condation Spscifi€d
terminalnumber
Constant Contin
uity
App y +B b€tws€n
B E a o a8oE 1 8 4 0 C o nt i nu l t y
t o r m i n a l s1 a n d 2 .
lf continuityis not as specified,replac6the relay.
D O O RC O U R T E SSYW I T C HI N S P E C T I O N
I N S P E C TD O O RC O U R T E S Y
S W I T C HC O N T I N U I T Y
(at C h e c kt h a t t h e r a i s c o n t i n u i t yb e t w s e nt e r m i n a al n d
switch bodywith the switch ON (switchpin released).
(b) C h e c kt h a t t h e r s i s n o c o n t i n u i t yb e t w e e nt e r m i n a l
a n d s w i t c h b o d y w i t h t h e s w i t c h O F F ( s w i t c hp i n
oushed).
l f c o n t i n u i t yi s n o t a s s p e c i f i e dr,e p l a c et h e s w i t c h ,
Wire HrrnsBsSid6 D O O RL O G KC O N T R O LR E L A Y
INSPECTION
I N S P E C TD O O RL O C KC O N T R O LR E L A Y
D i s c o n n e ct th o c o n n e c t o frr o m t h e r e l a va n d i n s o e c t
t h e c o n n e c t o or n t h e w i r e h a r n e s ss i d e a s s h o w n i n
the c hart.
l f c i r c u i ti s a s s p e c i f i e di ,n s p e c t h e d o o r l o c k s i g n a l .
l f t h e c i r c u i ti s n o t a s s p e c i f i e di ,n s p e c t h e c i r c u i t s
connectedto other parts.
T6!t€r connectionto
Condition Sp€cifi€d va ue (Voltag€)
t€rminalnumb6r
I - G.ound Constant Batteryvoltage
1 - Ground lgnitionswitch positionLOCKor ACC No voltagg
1 - Ground lgnitionswitch positionON Batteryvoltage

BE-89
SYSTEM- POWERDOORLOCKCONTROL
T e s t e rc o n n e c t i o tno
C o n di t i o n Sp€ciliodvalu6 (Continuity)
t € r m r n an u m o g r
Passsngsr'sdoor courtssy switch position
No continuity
O F F ( D o ocr o s e d )
Pass6ng6r'sdoor courtosy switch position
ON(Dooropenod)
Passeng€r's
door lock s€t to LOCK No continuity
5 Ground Passenger's
door lock set to UNLOCK Continuity
6 - Ground Drivgr'sdoor lock s6t to LOCK No continuity
6 - Ground Dnv6r'sdoor lock sot to UNLOCK Continuity
9 - Ground Driv6r'sdoor lock switch positionUNLOCK Continuity
I - Ground Onvsr'sdoor'ock sw'tch po6rtronLOCK No continuity
10 - Ground Door lock control switch positionUNLOCK N oc o n t i n u i t y
10 - Ground Door lock control switch positionLOCK Continuity
11 Ground D o o rl o c k c o n t r o ls w i t c hp o s i t i o nU N L O C K Continuity
l1 Ground Door ock co'1rrolswrtch posrtronLOCK N oc o n t i n u i t y
D o o r k 3 v o c k a n d u n o c k s w i t c hp o s i t i o n
12 - G r o u n d No continuity
UNLOCK
Door kov lock ond unlock switch oosition
12 - G r o u n d Continuity
LOCK
Door k€v lock and unlock switch oosatron
13 - G r o u n d Contin0ity
UNLOCK
Doof kev lock and unlock 6witch oosition
13- Ground No continuity
LOCK
Dnvor'sdoor courtesvswrtch oos't'on OFF
14 Ground No continuity
(Doorclosod)
Driv€r'sdoor courtsev switch position ON
( D o o ro p o n o d )
15 - Ground Constsnt Continuity
16 - Ground Constsnt Continuity
lgnitionswitch positionLOCK Continuity

BE-90
SYSTEM- SLIDINGROOFSYSTEM
BODYELECTRICAL
S L I D I N GR O O FS Y S T E M
PARTSLOCATION
S l i d i n gR o o tC o n t r o lR e l a y
S l i d i n gR o o fM o t o r
I n p a nJe/ B
. P o w e rf M a
in Relay
o POWER Fuse
. GAUGE Fuse

BE-91
sYsrEM- s!lq!-N-9-E99M9I!M
BoDYELEcTR|cAL
TROUBLESHOOTING
problems The most
The table below will be usefulfor you in troubleshootingthese electrical
probabilitylnspecteach part in
likelvcausesof the malfunctionare shown in the order of their
the order shown,and replacethe part when it is found to be faulty'
parts namo (Soopage)
Troubl€
1 . D o O RF u s o l B E- 1 4 )
2 , l g n i t i o ns w i t c h (BE- 18)
'' Slading
roof systemdoosnot operata (BE-88)
3. Door Lock ControlRelay
4, wirg Harnoss
1 . G A U G EF u s € (8E- 14)
2, PowER Fus€ (BE- 14)
3. Door Lock ControlRelay (8E-88)
4 . S i d i n gR o o fC o n t r o R
l elav (BE-93)
" Slidingroof systemdo€s nol oporate
5 . S l i d i n gR o o fS w i t c h (BE-92)
6. SiidingRool Motor (BE-92)
7. Wirs Harn€ss
L SlidingRoof ControlRolay (BE-93)
2 Limit switch (BE- 94)

s,tdrngrool svsl6r'l op€rat€sabnormaLly 3. SlidinsRoof Switch lBE-92)
4. Wir6 Ha.ness
1 . S l i d i n gR o o tC o n t r o R
2. Limit Switch
l €lsv (BE-93)
(BE- 94)
ffil
S iding roof system stops oporationhalf way 3 . s l i d i n gR o o lS w i t c h (BE-92)
4 . S i d i n gR o o fM o t o r (BE-92)
1.PowER Fuss (8E- 14)
2 . D o o rL o c k C o n t r o R
l elay (BE-88)
3 G A U G EF u s € ( B E- 1 4 )
"K€y-off SlidingRoof'operationdoes not operat€ (BE- 18)
4 . I g n i t i o nS w i t c h
5 . D o o r U n l o c kD e l € c t i o nS w i t c h (BE-87)
6. Wire Harness
'tt Door Lock does not operate.

": Door Lock is normal.

8E.92
EODYELECTRICAL
SLIDING
R O O FS W I T C HI N S P E C T I O N
I N S P E CSTL I D I N G
R O O FS W I T C HC O N T I N U I Y T
Insp6cttho switchcontinuitvbotwsont6rminals.
Testorconnoctionto
Switch position Sp6cafaed
valus
t6rminalnumber
SLIDE
OPEN Continuity
S L I D EO F F No continuity
S L I D EC L O S E 4 - 8 Continuity
T I L TD O W N 6 - 8 Contrnuity
T I L TO F F No continuity
T I L TU P Continuity
lf continuityis not as specified,replacethe swttch.
8E2857
0.8.2.8
SLIDING
R O O FM O T O RI N S P E C T I O N
1 . I N S P E C TS L I D I N GR O O FM O T O RO P E R A T I O N
(a) Conn€ct ths positive (*) lead from the battsry to
t e r m i n a l1 a n d t h e n s g a t i v e( - ) l e a d t o t e r m i n a l3 ,
chack that the motor turns clockwise.
\ 0 2 € . 3N 0 1 0 5 7
(b) Reverseth6 polarity,checkthat the motor turns coun-

tsrclockwise.
g-*
@[ge-
N02843N0105t
2. INSPECT CIRCUITBREAKER OPERATION

(a) With the slidingroofin the fullyopenedposition,
hold
the slidingroof switchin 'OPEN'positionand check
that th€reis a circuitbreakerooerationnoisewithin
1 0t o 6 0 s a c o n d s .
+
wiihin Front
_ f-<l e u o t o 6 0
^_---
EEu'diigerss:- seconds

8E.93
BODYELECTRICAL
(b) With the slidingroof in the fully openedposition,hold
\-------./4? t h e s l i d i n gr o o f s w i t c hi n ' C L O S E "p o s i t i o na n d c h e c k
rf-l-i r that the sliding roof beginsto close within 60 sec-
I @
i L-Il-..,r r onds.
"r'-------\\- tl lf ooerationis not as specified,roplacoths motor'
t.A I
T-JJ-
+ Fr o n t
_t-4 60seconds
8E4323
3 E 2 6 1 r8 F 3 9 8 2
il l t9rl
R O O FC O N T R O R
SLIDING L ELAY
Wire HarnessSide
INSPECTION
INSPECT S L I D I N GR O O FC O N T R O LR E L A YC I R .
CUIT
Disconnect the connector from the relayand inspect
ths connsctor on the wire harnessside,as shownin
the chart.
Toster connoctionto Spgcitiodvaluo (ContinuitY)

Condition
t€rminalnumber
Slidingroof control switch position(SLIDE)
1 - Ground No continuity

O PE N
Slidingroof contro switoh position(SLIOE)
O F Fo r O P E N
CLOSE
Sliding root control switch position (TILT)
O F Fo r D O W N
Sliding roof control switch position (TILT)
UP
4 - Ground Constant No continuity
4 - 5 Constant Continuity
5 - Ground Constant No continuaty

Sliding roof control €witch position (TILT)
O F Fo r U P
Sliding root control switch position (TILT)
DOWN
No. 1 limit switch positionOFF (Slidingroof
8 - Ground No continuatY
tiltod up or opon 6pprox.200 mm (7.87in.))
No. I limitswitchpositionON (Exc€ptfor
I - Ground Continuity
obove)
montioned
conditions

BE-94
SYSTEM_ SLIDINGROOFSYSTEM
BODYELECTRICAL
Test6rconnectionto
Condition valu6 (Continuity)
Sp€cifaod
t e r m t n anl u m D o r
No.2 limit swatchpositionOFF (Slidingroof
I - Ground No continulty
clos6d)
No. 2 limit switch positionON (Slidingroof
Continuity
op6n)
Tsster connsctionto
Condition Spociti€dvalu€ (Voltags)
terminalhumber
6 Ground lgnrtionswitch positionLOCK or ACC 'No vo tago
6 - Ground lgnitionswitch positionON Batteryvoltag€

12 - Ground Constant Batteryvoltag6
': Exceptions:Durrng60 secondperiodafter ignition

s w i t c h O N - O F F ( A C C )o r u n t i ld r i v e ro r p a s s e n g e r
door is openedafter ignitionswitch ON - OFF (ACC).
lf circuit is as specified.replacethe relay.
ii$HI
L I M I T S W I T C HI N S P E C T I O N
ON No.1 I N S P E C TL I M I T S W I T C HC O N T I N U I T Y
L r m i tS w i t c h f-l I n s p e c t h e s w i t c hc o n t i n u i t yb e t w e e nt 6 r m i n a l s .
/'-) | l-\
/ No2 l/ rl'it ll Testerconn6ctionto

L i m i tS w i t c h l t l T t t l l l Switch position Specified valu6
OFF ltlqtl t€rminalnumbgr
\-./
N o . 1l i m i ts w i t c hO F F
No contlnuily
(SW pin re eas€d)
8E2859e428
No.1 lirnitswitch ON
1 - 4 Conrinuity
(SW pin pushodin)
N o . 2 i n i t s w i t c hO F F
No contlnuity
(SW pin relsas€d)
No.2 limit switch ON
2 4 Continuity
(SW pin push€din)
lf continuityis not as specified,replaceth€ switch.

BE-95
sYsrEM - sllQl-N-q-Eeo!
BoDYELECTRICAL sYSIErvl
POWERMAIN RELAYINSPECTION
I N S P E CP TO W E R M A I NR E L A YC O N T I N U I T Y
c
I n s o e crte l a y o n t torminals'
i n u i tbye t w e e n
Testorconnectionto
Condition Specifi6dvaluo
terminalnumber
Constant Contrnuity
Apply +8 b€tween
Continuity
B E { 0 1 9B E 1 S 4 0 torminals1 and 2.
lf conrinuitvis not as specifiad,replacethe relay

BE'96
B o D y E L E C T R T csAyLs r E M - p o w E RM T R R . R
c o N T R o Ls y s r E M
P O W E RM I R R O RC O N T R O L
SYSTEM
PARTSLOCATION
R HM i r r o r
. M i r r o rM o t o r
M i r r o rS w i t c h
(w/oPoweW r indow)
\
L Ht M i r r o r \
. MirroM r otor
\
V.
M i r r o rS w i t c h
( w / P o w e rW i n d o w )

BE-97
SYSTEM_ POWERMIRRORCONTROL
TROUBLESHOOTING
The table below will be usefulfor you in troubl€shootingthos€ electricalproblems.The most
likelvcausesof th6 malfunctionars shown in the order of their probability,Inspecteach part in
the order shown, and replacethe part when it is found to be faulty'
Troubl. Ped6 namo (So. Page)
l . c l c & R A DF u 6 e (BE-14)
2. Mirrorswitch (BE-97)
Mirror do€s not op€rate (BE- 98)
3, MirrorMolor
4. WirgHarnoss
l. Mirrorswitch (BE-97)
2. MirrorMotor (BE-98)
Mirror oporat6sabnormallY
3, WiraHarn6ss
lw/ Pow6r window)

MIRRORSWITCHINSPECTION
B'a
INSPECT MIRROR SWITCHCONTINUITY
w/ POWER WINDOW
'L'
Master Switch Position
T66terconnoctionto
Switch position Sp.cifi6d valug
l6rminal numbor
No continuity
UP Continuity
3 - 4
DOWN Continuity
4 - l0
Continuity
3 - 4
I - 3
RIGHT Continuity
/t-g
'R'
Ma3terSwitch Position
T66terconnoctionto
Switch position Sp6cifigdv.lu6
lorminal numbor
No continuity
I - 6
UP Continuity
3 - 4
1 - 3
DOWN Continuity
4 - 0
Continuity
3 - 4
RIGHT Continuity
2 - 4

BE-98
sysrEM - powERMTRRoR
BoDy ELEcTRTcAL coNTRoLsysrEM
{ w / o P o w e rW i n d o w }
w,/o POWERWINDOW:
MasterSwitchPosition'L'
Testerconn€ctionto
Switch position Specafaed
valuo
lsrminal numb6r
OFF No continuity
UP Continuaty
DOWN Continuity
3 - 8
LEFT Continuity
RIGHT Continuity
3 - 8
'R'
Master Switch Position
Tsster connectionto
Switch position Spocifi6d valu6
t e r m t n an u m b e r
OFF No continuity
UP Continurty
1 - a
DOWN Continuity
E'E 7 - 10
LEFT Continuity
3 - 8
RIGHT Continuity
5 - 7
lf continuityis not as specified,replacethe switch,
M O T O RI N S P E C T I O N
MIRROR
INSPECTMIRRORMOTOROPERATION
( ): W/ Mirror Heater
(a) Connect the positive (+) lead from the battery to
termina3 l ( 6 ) a n d n e g a t i v e( - ) l e a dt o t e r m i n a 2
l (5),
check that the mirrorturns upward.
(b) Reversethe polarity,checkthat the mirrorturns dow-
nward.
(c) Connect the positive (*) lead from the battery to

t e r m i n a l1 ( 4 )a n d n e g a t i v s( - ) l e a dt o t e r m i n a l2 ( 5 ) ,
check that the mirrorturns to left side.
(d) Reversethe polarity,check that the mirror turns to
right side.
lf operationis not as specified,replacathe mirror.

BE-99
SYSTEM- SEAI EIAIEB JTSTEM
BODYELECTRICAL
SEATHEATERSYSTEM
PARTSLOCATION
./t'
h
o'
\J
-==- BE
\_----
Seat Heater
I n p a nJe/ B
. SEAT-HTR Fuse
Seat HeaterSwitch
N1 1 2 5 8
N11261

BE-100
SYSTEM- SEATHEATER
BOOYELECTRICAL SYSTEM
TROUBLESHOOTING
The table below will be usefulfor you in troubleshootingth6so 6lectricalproblems.The most
th6 ordsr shown and roDlacothe oart when it is found to b6 faulty.
Troubl. Prrir n!m. (Se. p.ge)
Soat hoatlr. do not opor!ia L SEAT HTR F|l.. (BE-14)
(Drivor'5 and Passongcr'!) 2, Wi.a H.rn.!a
1. S.!t H..t.r Switch (D.iv.r'!) (BE-IOO)
Drivor'! loat h.!tcr doo! not opcrlt! 2.Srrr Hcrrcr (88- 101)
3.WircHarnra!
l. ScatHolt.r Switch(P.ssongor'!) (8E- | O0)
Paaaenger'8ra6t haatar doa! not oparata 2. S..t H..t.r (BE- | 0l )
3. Wirr H!rnct.
Seat hcltcr temDarrtura ia too hot l. S..t H..i.r ( B E -1 0 1 )
SEATHEATERSWITCHINSPECTION
r--l
|lEil| f\€-l
1. INSPECT
SEATHEATERSWITCHCONTINUITY
|tMil
|t:lt
|I @ Switch po.ition
Taatar connaction to
t.rminrl numbar
2 - 1
Sp.cili.d v.lu.
I t tr l e t i l | HI
3 - 8
Continuity
L":J OFF No continuity

LO 3 - 4 Continuity
t--l lllumin.tionci.cuii 1 - 5 Continuiiy
t i l m i 1l l lf continuityis not as specified,replacethe switch or

til-il
|il vlil| Hf the bulb.
I
-
I l ll r o l l lI
I
r@l
[\:l
N 1 1 3 2 46 - C - 2
N 1 1 1 6 9. - 0 - 2 . H

BE-101
SYSTEM_ SEATHEATER
BODYELECTRICAL SI9IEM
2, INSPECT SEATHEATERINDICATOR LIGHT

(a) Connecttho positivo (+) leadfrom lhe battoryto
t e r m i n a l2s a n d6 , t h on e g a t i v(o- ) l E a dt o t o r m i n a1l .
(b) Pushths switchos, checkthat the indicatorlightup.
lf operation is not as specified, replacothe switchand
inspectthe circuitsconnected to othsrparts,
N 1 1 3 2 5. ' 6 ' 2
N1li68e62H
SEATHEATERINSPECTION
"A"
Connoctor connoctot"B"
INSPECT SEATHEATERCONTINUITY
(a) Heatths thormostatwith a light.
(b) lnsoectthe seatheatorcontinuity betweent€rminals.
. a-2-G.2-2.4
Tost6r connoctionto
Condition Sp.cili€d v!1ue(Continuiiy)
t€rminalnumbor
AI _A3 Const6nt Continuity
A2_82 Constant Continuity

S6at horlar t6mporalura
A1_43 'C (77 'F)
Continuity
bolow 25
Soal hoatortemporaturo
A3_BI Continuity
b o l o w2 5 ' C ( 7 7 ' F )
Seath.atsrtgmp€r8tu.o
AI _43 No continuity
. b o v o4 5 ' c ( l l 3 ' F )
Soat hertor temPqraturo
A3_81 No continuaty
' c ( 11 3 ' F )
a b o v g4 5
lf continuityis not as specified,r€placotho seat cush'

ton cover.

BE'102
s yLs r E M - c R U r s E
B o D yE L E c T R T c A c o N T R o Ls y s r E M
C R U I S EC O N T R O L
SYSTEM
PARTSLOCAITON
S p e e dS e n s or
. E CU - B F u s e
N e u t r aI S t a n S w i t c h
::+.EF I _>-22
la^\t'
tF,// \ C r ui s e C o n t r o lA c t u a t o r
S t o p L i g h tS w i t c h
c l u t c hs w i t c h
C o n t r o lS w i t c h
I n p an e J / B
. G A U G EF u s e
. S T O PF u s e
. E C U - I GF u S e
u r u r S eL o nt r o t E U U
P a r k i n gB r a k eS w i t c h
N11260
N1r255

BE-103
SYSTEM_ CRUISECONTROL
Check Conn6ctor
SYSTEM
CHECKDIAGNOSIS
l c
I
1 . READ DIAGNOSTICTROUBLECODE
1
1 I 9
t, ol' i _ '
ttT\\
1tl9/
Type A:
( a ) lf while drivingwith the cruisecontrolon, the system
rt l,----.' is canceledby a malfunctionin 6ith€r the actuator,
[1 l122l2rJ
speed sensor or cruise control switch circuit, the
'CRUISE'will blink.
cruisecontrol indicatorlight
0: Fc=r
D (b) While sropped,connact terminals3 and 11 of th€
check conn€ctor.
HINT:lf the ignitionswitch is turned off, the diagnos-
tic troublecode will not bo erasedfrom the computer
memory.
(c) Read the diagnostictrouble code on ths indicator
light'CRUISE'.
DTC CRUISEMAIN Indlcetor Light Blinklng Patt.rn Dhgnorlr
Normal
ON (short)in motorcircuit.
11 . Overcurrsnt
OFF
ON (short)in mEgnetclutchclrcult,
Ov6rcurrent
12 Op6nin magnetclutchcircultfor 0.83€c.
OFF
ON
'!e . Positionssnsordetoctsabnormalvoltage.
OFF
ON Ooonin actuatormotorcircuit.
14 Positionssnsorsignalvalusdoosnot chango
L'FT wh6n the motor opargtgS.
ON . Speedsignali8 not inputto the ECUwhilecruise
21 controlis s€t.
OFF 8E3132
ON Actualvohiclespeedhas droppedby 16 km/h

z3 (10mph)or morebslowth€ sat sposd.
OFF SDeodSonsorPulsais Ebnormrl.
32 . Shortin controlswitchcircuit.
ON
3'[ . Voltag€ abnormality in control switch.
OFF
ON . Duty rstio of 100%outputto motor 8ccsl€ration
41 side.
OFF
ON
12 . Sourc€voltEgedrop.
OFF
HINT:
. Indication codasappearin orderfrom N o . 11 .
. lf thsrs is no indicationcode,performt r o u b l s s h o o t i n ga n d i n s p e c t i o n .

BE-104 sysrEM - cRUrsE
BoDyELEcTRTcAL coNTRoL
sysrEM
2, I N P U TS I G N A LC H E C K
Type B:
Output of Cod6
(^ I. ( a ) F o r c h e c k sN o . I- N o . 3
f T u r n t h e i g n i t i o ns w i t c hO N .
.T (b) For check No.4

O Jack up tho vshicl6.
O Start th6 engin6.
@ Shift to D range.
2. Turn the control switch to SET/COASToositionor
RES/ACCpositionand hold it down or up O.
3. Pushthe main switch on O.
4. C h e c kt h a r t h e C R U I S EM A I N i n d i c a t o rl i g h t b l i n k s
twic6 ropsatedly.
5. Turn th6 SET/COASTswitch or RES/ACCswitch off.
6. Ooerateeach switch as listedin the table below.
7. R€adrhe blinkingpaiternof tho cRUlsE MAIN indica-
tor light.
8. After performingthe check,turn th€ main switch off.
HINT:When 2 or mora signalsare input to the ECt,,
only the lowest-numberedcode is displayed.
CRUISEMAIN Indicsior Light

No. Op.retlon Mcthod Disgnosis
Bllnking Pattern
1 Turn SET/COASTswitch ON.

Light ON --r 0.25Ff
I 3ec I
seroosOFF |.-_-..'i L tflr.r_ normal.
switchcircuit is
SET/COAST
RES/ACCswitch circuit is
Turn RES/ACCawitch ON.
normat.
I C A N C E Ls w i t c hc i r c u i ti s
Turn CANCELswitchON.
,Lioht normat.
ovaricn \Jrr
T u r ns t o pl i g h ts w i t c hO N . ''t Stop light switch circuit is
,
( D s p r 6 sbs r a k €p s d a l ) I s w i t c hO t ' t normat.
OFF________
Turn parklngbrakoswitchON, Parking brake switch circuit
( P u l lu p t h 6 p a r k i n gb r a k sl € u u r ) is normal,
uu.oou
Turn nautralstart switchOFF. Switch ON Neutral stan switch circuit is
(Shiftto EXCEPT ON
D RANGE) normSt.
SwitchOFF
Turn clutchswitchOFF. Clutchswitchcircuitis
(Doprsssclutchpedal) normat,
BEa006
Driv€at 40 km/h(25 mph)or LentoNl

higher. [l I n I n I | [l l
errooeOFF tl U LJ L-.1Ll L-.1tl U L-l L
4 S p € e ds € n s o irs n o r m a l .
Drlveat 40 km/h (25mph) or L i g h tO N -
b9low.
vc615

BE-105
TROUBLESHOOTING
indicatethe priority
Use the lable below to help you find the causeof the problsm.Thenumbers
rsplacethsseParts.
of tho likelycauseof the problem.Checkeach part in order.lf n€csssary,
ChartNo. o c c F H,I K
f z i
Inspectionltem
E . i n
'tE ' '!€ E
o-
( h ^ o 6 '
Db"""tlt tt*rbla tud" \
\ npeA\ 'ryooB\ t 5.5 a o
Problem \ \ \
>€ ! t a F = ;
tl 3 2
12 4 2 3
13 3 2
"CRulSE
" I n d i c a t ol ri g h tb l i n k s . 14
CruisecontrolsystemOoesnot set. 21 3
Cruis€controlsystemdoes not
operate. 3 2
34
41
42 Sourcevoltagedrop
Indicatorlight does not light up.
Largespeeddrop whon the cruiseconlrolswitch ,1
turngdto SET.
Vehiclespe€dfluctuateswhen cruiseconlrol 1
switchturn6dto SET.
Sot sp€€ddevisteson high or low side.
Accel€rationresponseis sluggishwhen cruise ,l
"ACCEL"oT"RESUME"
controlewitchturnodto
Cruisocontrolsvstemooesnotsot. OK 7 I
4
Cruisecontrolsvstemdoesnotop€role, NG
S9t speeddogs no cancelwhenbrakepedal OK
3
oepresseo. NG 2
S€t spooddo65not canc€lwhen parkingbrake OK
lev€rpullod. NG 2 1
Cruisecontrolnot cancell€d,evenwhen OK
3
transmiseionis shift€dto EXCFPTD qANGE. NG 2 1
Set sp€6ddoes not cancelwhen clutchpedsl OK

oopres66o, NG l
S6t speoddo€s not cancolwhen crursecontrol OK

3
switchturnedto CANCEL NG 2 l
Vehicl6gpo€ddoes not decreasewhen crurse OK

l
controlswitchturnodto COAST. NG 2 1
when cruas€
V6hiclesp€eddoes not accelerats OK
2
controlswitchtufnod to ACCEL. NG 1
Vehicl€sp€oddoes not raturnio msmorired OK

2 ,l
cruiS€when control3witchturnedlo REStIIVE NG
Spoodc8n be set below about40 km/h OK 1
( 2 5m p h , ) 4
NG 1
Cruigocontrolgoos not disengagoevon at ebout OK 2
40 km/h (25 mph) or l6ss. NG 2 1

BE-106
SYSTEM- CRUISECONTROL
A POWERSOURCECIRCUIT
HlNt Whilecarryingout the followinginspection,
makecertainthat the connectors
and terminalsare
nr^narl\/.^nna^forl
l s E C U - l GF u s en o r m al ? Replace f u s ea n d t u r n i g n i t i o n Fusefaulty.
s w i t c hO N .
l s f u s en o r m a l T
CC ECU
D i s c o n n e ccto n n e c t ofrr o m C C Disconnect connectors from CC S h o r t c i r c u i t i n w i r e h a r n e s so n
E C Ua n d i n s p e c ct o n n e c t o o. n EC U . v e h i c l es i d e .
w i r e h a r n e s ss i d ea s f o l l o w s . Replace f u s ea n d t u r n i g n i t i o n
s w i t c hO N .
R e o l a c eC C E C U .T h e r e c h e c sk v s t e m .
INSPECT
GROUNDCONNECTION r O p e nc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l' 1 3o f
l s t h e r ec o n t i n u i t yb e t w e e nt e r m i n a l1 3 a n d g r o u n d ? C C E C Ua n d g r ou n d ,
o G r o u n df a u l t y
INSPECTPOWERSOURCE '14
O p e nc i r c ! i t i n w i r e h a r n e s sb e t w e e nt e r m r n a l o f
T u r ni gni t i o ns w i t c hO N . No g
C CE C Ua n d r o u n d ,
i s t h e r e b a t t e r yv o l t a g e b e t w e e n t e r m i n a l 1 4 a n d
ground?
R e D l a cC
e C E C U .T h e n r e c h e c ks v s t e m . C r u i s eC o n t r o l

BE-107
BOOYELECTRICAL SYITEM
CONTROL
CRUISE CIRCUIT
INDICATOR
and termlnalsare
HINT: Whilecarryingout the followinginspection,
properlyconnected.
Replace f u s ea n d t u r n i g n l t i o n Fu s ef a u l t y .
l s G A U G Ef u s en o r m a l ?
s w i t c hO N .
lslusenormal?
COMBINATION
METER
"C" from S h o r tc i r c u i ti n w i r e h a r n e s so n
Disconnectconnector
o m e t e ra n d I n s p e c t
c o m b i n a t in v e hi c l es i d e .
c o n n e c t oor n w i r e h a r n e s ss i d e
asfollow.
"C" and
INSPECT POWER SOURCE O p e nc i r c u i ti n w i r e h a r n e s st e r m i n a l
T ur n i g n i t i o ns w i t c hO N G A U G Ef u s e .
l s t h e r eb a t t e r yv o l t a g eb e t w e e nt e r m i n a lC - 1 2a n d
ground?
Yes
INSPECTBULB CONDITION R e pa c eb u l b .T h e n r e c h e c ks y s t e m
l s b ul b c o n d i t i o n o r m a l T
aa trat I Yes
lnstalb l u l b a n d c o n n e c ct o n n e c t otro c o m b i n a t i o n
meter.
D l s c o n n e ccto n n e c t ofrr o m C CE C Ua n d i n s p e c t
c o n n e c t oor n w i r e h a r n e s ss i d ea s t o l l o w s
INSPECTINDICATORCIRCUIT . S h o r tc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m l n a l s
l st h e r ec o n t i n u i tbye t w e etne r m i n a7l a n dg r o u n d ? 7 o f C C E C Ua n d A - 9 o f c o m b i n a t i o nm e t e r '
. S h o r tc i r c u i ti n c i r c u i tp l a t eo f c o m b i n a t i o nm e t e r
b e t w e e nt e r m i n a A l - 9a n d C Ci n d i c a t o b r ulb
T ur n i g n i t i o ns w i t c hO N . . O p e nc i r c u i tl n w i r e h a r n e s sb e t w e e nt e r m n a l s .
l s t h e r eb a t t e r yv o l t a g eb e t w e e nt e r m i n a 7 a n d 7 o f C C E C Ua n d A 9 o t c o m b i n a t l o nm e t e r .
ground? . O p e nc i r c u i ti n c i r c u i tp l a t eo { c o m b i n a t i o nm e t e r
b e t w e e nt e r m i n a l A - 9a n d C C i n d i c a t o b r ul b o r
b e t w e e nt e r m i n a l C - 1 2a n d C C i n d i c a t o b
r ulb
C C r C r u i s eC o n t r o l

8E.108
c CIRCUIT
C O N T R OSLW I T C H
o u tt h e f o l l o w i n gi n s p e c t i o m
H I N T : W h i l ec a r r y i n g t h a tt h e c o n n e c t o rasn dt e r m l n a las r e
n ,a k ec e r t a i n
properlyconnected.
CONTROL
SWITCH
D i s c o n n e ccto n n e c t ofrr o m c o n t r o ls w i t c ha n d i n s p e c t
c o n n e c t o or n v v i r eh a r n e s ss i d ea s f o J o w s .
INSPECT G R O U N DC O N N E C T I O N O p e nc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l
l st h e r ec o n t i n u i tbye t w e 6tne r m j n a3l a n dg r o u n d ? o f c o n t r o ls w i t c ha n d g r o u n d .
G r o u n df a u l t y .
INSPECT SWITCH
CONTROL Replac€control switch,Then rechecksystem.
l s c o n t r o ls w i t c ho p e r a l i o nn o r m a l ?
aa Eal I
C o n n e c ct o n n e c t otro c o n t r o ls w i t c h .
D i s c o n n e ccto n n e c t o r fsr o m C C E C Ua n d i n s p e c t
s n w i r e h a r n e s ss i d ea s f o l l o w s ,
c o n n e c t o ro
MAINSWITCHCIRCUIT
INSPECT S h o r tc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l sl 9 o f
'19
i s t h e r sc o n t i n u i t yb e t w e e nt e r m i n a l s n d g r o u n d C C E C Ua n d 5 o f c o n t r o ls w i t c h .
w i t h m a i n s w i t c hO F F ?
s t h e r ec o n t i n u i t yb e t w e e nt e r m i n a l1 9 a n d g r o u n d O p e nc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l s1 9 o f
w i t h m a i n s w i t c hO N 7 C C E C Ua n d 5 o f c o n t r o ls w i t c h .
INSPECT CIRCUIT
SWITCH
CONTROL S h o r tc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l s1 8 o f
l s t h e r ec o n t i n u i t yb e t w e e nt e r m i n a l1 88 n d g r o u n d C C E C Ua n d 4 o { c o n t r o ls w i t c h .
w i t h c o n t r o ls w i t c hO F F ?
l s t h € r er e s i s t a n caes s h o w ni n t a b l eb e l o wb e t w e e n O p e nc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l s1 8 o f
t e r m i n a i1 8 a n d g r o u n dw h e n c o n t r o ls w i t c hi s t u r n e d C CE C Ua n d 4 o f c o n t r o ls w i t c h .
t o e a c ho o s i t i o n ?
Approx.68
SET/COAST A p p r o x1. 9 8
CANCEL Approx.418
C C : C r u i s eC o n t r o l

BE-109
sYsrEM - cRUlsEq!uB9!-AY9IEM
BODYELEGTRIGAL
D r ACTUATORCIRCUIT
makecertainthat the connectorsand terminals

HINT: While carryingout the followinginspection,
are properlyconnected.
ACTUATOR
Disconnectconnectortrom sctuatorand lnspect

conn€ctoron wirs harnessside as follows.
INSPECTGROUND CONNECTION o Oo€ncircuitin wir€ harnessb€tweentsrmanal

4 of actuatorand ground.
l s t h s r e c o n t i n u i t yb e t w e e nt e r m i n a l 4 a n d g r o u n d ?
. Groundfaulw.
INSPECTACTUATOR R€placeactuator.Then rechocksystem.

ls actuatoroperationnormal?
STOPLIGHT
SWITCH
INSPECTSTOPLIGHTSWITCHINSTALLATION Reinstsllstop Iight switchpropsrly.Th€n rschsck

ls stop llght switchinstall€dproperly? system,
Connoctconnoctorto Sctuator.
Disconnectconnoctorfrom stop light switchand
inso€ctconnsctoron wire harnssssideas follows.
TNSPECT MAGNETCLUTCHCIRCUIT Openor shortcircuitin wirs harnsssbetw€en

ls thor6 apDrox.38.5O betwsent€rminal4 and tarminals4 of stop light and 5 of actuator.
ground?
INSPECTSTOPLIGHTSWITCH Replacestop light switch. Th€n rochecksystem.

ls slop light switchoperationnormal?
CONTINUED PAGE

BE-10
CONTINUED
F R O MP R E V I O UP
SA G E
CC ECU
C o n n e c ct o n n e c t otro s t o p l i g h ts w i t c h .
Disconnectconnectorsfrom CC ECUand insoect
c o n n e c t oor n w i r e h a r n e s ss i d ea s f o l l o w s .
INSPECT M A G N E TC L U T C HC I R C U I T No O p e no r s h o r tc i r c u i ti n wire harnessbetween

l s t h e r ea p p r o x3. 8 . 5Q b e t w e etne r m i n a' 1
l 0a n d t e r m i n a l s1 0o f C C E C Ua n d 4 o f a c t u a t o r .
q r o un d ?
INSPECT M O T O RC I R C U I T S h o r tc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l s1 2 o f
l s t h e r ec o n t i n u i tbye t w e etne r m i n a' 1
l 2a n dg r o u n d ? CC ECUand 6 of actuator.
s there continuity betweenterminal 11 and ground? S h o r tc i r c u i ti n w l r e h a r n e s sb e t w e e nt e r m i n a l s1 1 o f

CC ECUand 7 of actuator.
l s t h e r ec o n t i n u i t yb e t w e e nt e r m i n a l s1 1a n d 1 2 w i t h O p e nc i r c u i tj n w i r e h a r n e s sb e t w e e nt e r m l n a l s1 2 o f
a c t u a t oar r m l n a p o s i t i o ne x c e p tm a x .o p e no r m a x . C C E C Ua n d 6 o f a c t u a t o o r r b e t w e e nt e r m i n a l s1 1 o f
BE cl o s e ? C C E C Ua n d 7 o f a c t u a t o r .
INSPECT POSITION CIRCUIT S h o r tc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l s2 3 o l

l s t h e r ec o n t i n u i tbye t w e etne r m i n a2l 3a n dg r o u n d ? C C E C Ua n d 1 o l a c t u a t o r .
No
l s t h e r ea p p r o x .2 k O b e t w e e nt e r m i n a l s2 3 a n d 2 5 ? . O p e nc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l s2 5
ol CC ECUand 3 of actuator.
. O p e nc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l s2 3
o f C C E C Ua n d I o f a c t u a t o r .
D o e sr e s i s t a n cceh a n g ee v e nb e t w e e nt e r m i n a l s2 4 O p e no r s h o r tc i r c u i ti n w i r e h a r n e s sb e t w e e n
a n d2 5 7 t e r m i o a l s2 4 o f C C E C Ua n d 2 o f a c t u a t o r .
B e p l a c eC CE C U .T h e n r e c h e c ks v s t e m . C C : C r u i s eC o n t r o l
,.

BE-11
sYsrEM- cBullE-qor'[Eo!ry!]EU
BoDYELECTRIGAL
S P E E DS E N S O RC I R C U I T
andterminalsare
makecertainthatthe connectors
properlyconnected.
SENSOR
SPEED
Disconnectconnectorfrom speedsensorand
i n s p e c ct o n n e c t oor n w i r e h a r n e s ss i d ea s f o l l o w s
. O p e nc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l2 o f
INSPECTGROUNDCONNECTION
s p e e ds e n s o ra n d g r o u n d .
l s t h e r ec o n t i n u i tbye t w e etne r m i n a2l a n dg r o u n d ?
o G r o un d f a u l t y .
SENSOR
SPEED
INSPECT Reolacespeedsensor'Then rechecksystem'
l s v e h i c l es p e e ds e n s o ro p e r a t i o nn o r m a l ?
BE
INSPECTSPEEDSENSORCIRCUIT O p e no r s h o r tc i r c u i ti n w i r e h a r n e s sb e t w e e n
l s t h e r ec o n t i n u i trYe p e a t e dbl ye t w e etne r m i n a2l 0a n d t e r m i n a l s2 0 o f C CE C Ua n d 2 o f s p e e ds e n s o r '
qround?
C C E C U .T h e n r e c h e c ks y s t e m
Replace C C : C r ui s e C o n t r o

BE-112
F I STOPLIGHTSWITCHCIRCUIT
and terminalsare
properlyconnected.
INSPECTSTOPLIGHTSYSTEM t C E C Uo n n e x tp a g e .
I n s p e cC
l s s t o p l r g h ts y s t e m o p e r a t i o n n o r m a l ?
l s S T O Pf u s en o r m al ? Replace fuse, F u s ef a u l t y .
D i s c o n n e ccto n n e c t ofrr o m C C S h o r tc i r c u i ti n w i r e h a r n e s s
E C Ua n d r e p l a c ef u s e . b e t w e e nt e r m j n a lI o f s t o p
l s f u s en o r m a l ? l i g h ts w i t c ha n d S T O Pf u s e ,
S h o r tc i r c u i ti n w i r e h a r n e s s
b e t w e e nt e r m i n a l1 o f C C
E C Ua n d S T O Pf u s e .
Replace f u s ea n d d e p r e s sb r a k e S h o r tc i r c u i ti n w i r e h a r n e s s
p e o ar . betweenterminal 3 of stop
l s f u s e n or m a l ? l i g h ts w i t c ha n d s t o p l i g h t .
S h o r tc i r c u i ti n w i r e h a r n e s s
b e t w e e nt e r m i n a l s1 6 o f C C
E C Ua n d 3 o f s t o pl i g h ts w i t c h .
Replace
C C E C U .T h e n r e c h e c ks y s t e m .
STOPLIGHT
SWITCH
INSPECTSTOPLIGHTSWITCHINSTALLATION R e i n s t a lsl t o p l i g h ts w i t c hp r o p e r l yT. h e n r e c h e c k

l s s t o pl i g h ts w i t c hi n s t a l l epdr o p e r l y ? syslem.
Yes
C C : C r u i s eC o n t r o l
C O N T I N U EODN N E X TP A G E
(Tr--:

BE-13
STOPLIGHT R O MP B E V I O UPSA G E
C O N T I N U EFD
SWITCH
D i s c o n n e ccto n n e c t ofrr o m s t o p l i g h ts w i t c ha n d
i n s p e c ct o n n e c t oor n w i r e h a r n e s ss i d ea s f o l l o w s
INSPECTPOWERSOURCE O p e nc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l1 o f s t
'1 l i g h ts w i t c ha n d S T O Pf u s e .
terminal andground?
lstherebatteryvo tagebetween
INSPECTSTOPLIGHTCIRCUIT . O p e nc i r c u i ti n w i r e h a r n e s sb e t w o e nt e r m i n a l3 o f
C o n n e ct et r m i n aIl a n d3 . s t o p l i g h ts w i t c ha n d g r o u n d
D os t o pl i g h tl i g h t su P ? . Ground faulty.
STOPLIGHTSWITCH
INSPECT s t o p l i g h t .T h e n r e c h e c ks y s t e m
Replace
l s s t o os w i t c ho o e r a t i o nn o r m a l ?
CC ECU
Connectconnectorto stop light switch l f s t o p l i g h ts y s t e mo p e r a t i o ni s n o r m a l ,s t a r t
D i s c o n n e ccto n n e c t ofrr o m C C E C Ua n d a n s p e c t inspectiontrom this step.
c o n n e c t oor n w i r e h a r n e s ss i d ea s f o l l o w s
BE
INSPECTSTOPLIGHTSWITCHCIRCUIT O p e nc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l1 o f C C
e e t w e etne r m i n a1l a n dg r o u n d ?
l st h e r eb a t t e rvyo l t a g b E C Ua n d S T O Pf u s e .
No O p e nc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l s1 6 o f
l s t h e r eb a t t e r yv o l t a g eb e t w e e nt e r m i n a l1 6 a n d
o r o un d w h e n b r a k ep e d a l d e p r e s s e d ? C C E C Ua n d 3 o f s t o p l i g h ts w i t c h .
R e p l a c eC CE C U .T h e n r e c h e c ks y s t e m C C r C r u i s eC o n t r o l

BE-114
G PARKINGBRAKESWITCHCIRCUIT
HlNl Whilecarryingout the followinginspection,
makecertainthal the connectors
and terminalsare
properlyconnected.
INSPECTPARKINGBRAKESWITCH R e p l a c ep a r k i n gb r a k es w i t c h .T h e n r e c h e c ks y s t e m .
ls parking brakeswitch operationnormal?
CC ECU
C o n n e c ct o n n e c t otro p a r k i n gb r a k es w i t c h .
D i s c o n n e ccto n n e c t ofrr o m C C E C Ua n d i n s p e c t
INSPECTPARKINGBRAKESWITCHCIRCUIT S h o r tc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a 3
l of CC
s t h e r ec o n t i n u i tbye t w e etne r m i n a3l a n dg r o u n d E C Ua n d p a r k i n gb r a k es w i t c h .
w h e np a r k i n g b r a k el e v e ri s r e l e a s e d ?
l s t h e r ec o n t i n u i t yb e t w e e nt e r mi n a l3 a n dg r o u n dw h e n O p e nc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a 3
l of CC
p a r k i n gb r a k el e v e ri s p u l l e d ? E C Ua n d p a r k i n gb r a k es w i t c h .
R e p l a c eC C E C U .T h e n r e c h e c ks y s t e m .

BE-115
CLUTCHSWITCHCIRCUIT(with M/T)
and termlnalsare
properlyconnected.
SWITCH
CLUTCH
INSPECTION CLUTCHSWITCHINSTALLATION R e i n s t a l l c l u t cshw i t c hp r o p e r l yT. h e n r e c h e c ks y s t e m

l s c l u t c hs w i t c hi n s t a l l epdr o p e r l y ?
D i s c o n n e ccto n n e c t ofrr o m c l u t c hs w i t c ha n d i n s p e c l
INSPECT G R O U N DC O N N E C T I O N . O p e nc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l1 o f
l s t h e r ec o n t i n u i tbye t w e etne r m i n a1l a n dg r o u n d ? c l u t c hs w i t c ha n d g r o u n d ,
. Ground laulty.
INSPECTCLUTCHSWITCH Replace . h e n r e c h e c ks y s t e m .
c l u t c hs w i t c h T
1 sc l u t c hs w i t c ho D e r a t i onno r m a l ?
CC ECU
:riBfil,
C o nn e c tc o n n e c t otro s w t t c h .
D i s c o n n e ccto n n e c t ofrr o m C C E C Ua n d l n s p e c t
c o n n e c t oor n w i r e h a r n e s ss i d ea s f o l o w s .
INSPECTCLUTCHSWITCHCIRCUIT O p e nc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l2 o f
l s t h e r eb a t t e r vy o l t a g eb e t w e etne r m i n a2l a n d C C E C Ua n d 2 o f G A U G Ef u s e .
g r o u n d w h e n c l u t c h P e d a lr e l e a s e d ?
R e pa c eC C E C U .T h e n r e c h e c ks y s t e m .
C C r C r u i s eC o n t r o l

BE-16
SYSTEM- CRUISE
CONTROL
STARTSWITCH(A/T Models)
NEUTRAL
HINT: Whilecarryingout the followingir,spection, and terminalsare
^r^â rl\, ^^ n n o^to.l
INSPECTSTARTINGSYSTEM R e p a i rs t a n i n gs y s t e m T
. h e n r e c h e c ks y s t e m .
ls startingsystemnormal?
D i s c o n n e ccto n n e c t ofrr o m C C E C Ua n d i n s p e c t
NEUTRALSTARTSWITCHCIRCUIT O p e nc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l s2 o f
ls therebatterypositivevoltagebetweenterminal2 C C E C Ua n d 2 o i p a r k / n e u t r apl o s i t i o ns w i t c h .
a n dg r o u n dw h e ns h i f tl e v e ri s s h i f t e d
to D range?
R e o l a c eC C E C U .T h e nr e c h e c ks v s t e m .
ELECTRONICALLY TRANSMISSION
CONTROLLED No.2
SOLENOID
J
B,Hi C I R C U I(Tw i t hA / T )
and terminalsare
HlNl Whilecarryingout the followinginspection,
properlyconnected.
INSPECTELECTRONIC CONTROLLED R e p a i re l e c t r o n ic o n t r o l l e dt r a n s m i s s i o sny s t e m .

TRANSMISSIONSYSTEM T h e nr e c h e c ks y s t e m .
v s t e mn o r m a l .
l s e l e c t r o nci co n t r o l l et dr a n s m i s s i os n
D i s c o n n e ccto n n e c t ofrr o m C C E C Ua n d i n s o e c t
INSPECT N o . 2S O L E N O I D
CIRCUIT O p e no r s h o r tc i r c u i it n w i r e h a r n e s sb e t w e e nt e r mi n aI
ls thereapprox.13Q betweente(minal22 andground? 2 2 o l C C E C Ua n d N o . 2s o l e n o i d .
R e o l a c eC CE C U .T h e n r e c h e c ks v s t e m .

BE-17
IDLSIGNALCIRCUIT
and terminalsare
properlyconnected.
SENSOR
POSITION
THROTTLE
SENSOR
POSITION
THBOTTLE
INSPECT A d j u s tp o s i t i o ns e n s o rp o s i t i o nT. h e n r e c h e c k
ADJUSTMENT system,
l s t h r o t t l ep o s i t i o ns e n s o ra d j u s t m e nnt o r m a l ?
INSPECTTHROTTLEPOSITIONSENSOR t h r o t t l ep o s i t i o nT. h e n r e c h e c ks y s t e m
Replace
l s t h r o t t l ep o s i t i o sne n s oor p e r a t i onno r m a l ?
Connectconnectorto throttle positionsensor'

Disconnectconnectorfrom CC ECUand inspect
cgnnectoron wire harnessside as follows.
CIRCUIT
IDLSIGNAL
INSPECT O o e nc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l s2 1 o f
l s t h e r ec o n t i n u i t yb e t w e e nt e r m i n a 2l 1 a n dg r o u n d C CE C Ua n d 2 o f t h r o t t l ep o s i t i o ns e n s o r '
w h e na c c e l e r a t i o n p € d a ll s r e l e a s e d ?
l l a n dg r o u n d
l s t h e r ec o n t i n u i t yb e t w e o nt e r m i n a 2 S h o r tc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r m i n a l s2 1 o f
w h e n a c c e l e r a t i oDn e d a il s d e p r e s s e d ? C CE C Ua n d 2 o f t h r o t t l ep o s i t i o ns e n s o r .
R e p l a c eC C E C U .T h e n r e c h e c ks y s t e m C r ui s e C o n t r o l

BE-18
SYSTEM- CRUISE
BODYELECTRICAL CONTROL
SYSTEM
W i r e H ar n € s s S i d e C O N T R OE
CRU!SE L C UI N S P E C T I O N
I N S P E CC C O N T R OE
TR U I S E L C UC I R C U I T
Disconnact connsctorand insogctconnectoron wire
harness sideas shownin ths chart.
v d . 2 6 . 1B
T6storconnectionto
Condition Spocified value (Continuity)
terminalnumbor
Parkingbrakolovor positionreleas6d No continuity
3 - Ground Parkingbrakel6v€r positionpull6d Continuity
Main switch positionr€leasod No continuity
19 - Ground Main switch oositiondeorosssd Contrnuity
Actu€tor €rm positionmax. OPEN ( 1 2* 1 1 ) N oc o n t i n u r t y
Actuator arm positionmax. OPEN (11- 1 2 )C o n t r n u i t y
Actuator arm positionmax. CLOSE ( 11 - l2) No continurty
Actuator arm positionmax. CLOSE ( 1 2* 1 1 )C o n t i n u i t y
Actuator arm is any positionoxcopt abovo
1 1- 1 2 ( 11 - l2) Continuity
posrttons
12 - Ground Constant No contanuity
8rak6 pedalrol€as€d No continuity
Erake oedaldeorsssed Continuity
T€st€r connsctionto
Condition S p € c i fi 6 d v a l u 6 ( R € s i s t a n c o )
t 6 r m i n anl u m b s r
18 - Ground Control6wrtchpo6itionOFF No continuity
18 - Ground Controlswitch oositionRES/ACC Approx. 58 O
18 - Ground Controlswitch oositionSET./COAST Approx. 198 Q
1g - Ground Controlswitch positaonCANCEL Approx.418 O
Constant A p p r o x .1 3 Q
23-25 Constant A p p r o x . 2k Q
25 Actuator arm turned Resistanc6 chang€ [near

BE-119
Tastor conngctionto
Condition valu€(Voltogo)
Spsciliod
t6rminalnumbor
1 - Ground Constant B6ttoryvolt6ge
lgnitionswitch positionON
2 - Ground Batt€ryvoltage
Clutch p€dsl positionrolea6od(M/f)
tgnitionswitch porition ON
2 - Ground No voltag6
Clutch podalpo6itiond6presssd(M/t)
2 - Ground Shift l.v6r positionet D (A/f) Battsry voltago
2 - Ground Shift l6ver positionoxcopttt D (A/f) No voltag6
7 - Ground lgnitionswitch positionat LOCKor ACC No voltago
7 - Ground lgnitionswitch positionON Batt6ryvoltags
14 - Ground lgnitionswitch positionat LOCK or ACC No voltag6
14 - Ground lgnitionswitch positjonON Brtteryvolt.9.

18 - Ground Brak6p6d8lrel€ssod No voltag€
16 - Ground Br.ko oodgld.Dr6ssod Batteryvoltago

With ignition6witch ON, spoodometershalt
20 - Ground Voltagochangssrspoat€dlY
or soe6d8onsorthatt turngd,
L W I T C HI N S P E C T I O N
C O N T R OS
CRUISE
INSPECTCRUISE CONTROL SWITCH
(a) Checkcontinuitybetw66nterminals
3 and 5.
Main switch position Condition
No continuity
ON Continuity
(b) Measurerosistanceb€twe€nterminals3 and 4.

Controlswitch position Rosistance(Q)
UI. F co (No continuity)
RES/ACC Approx.68
sET/COAST Approx,198
CANCEL Approx,418
lf resistancevalue is not as sp€cifisd,replacethe

controlswitch.
gEloog
.-6.1.C

BE'120
sysrEM - cRUrsE
BoDyELECTRTGAL coNTRoL
sysrEM
PARKING
B R A K ES W I T C HI N S P E C T I O N
INSPECTPARKING BRAKESWITCH
SeeBrakeWarningSystemon pageBE-70.
STOPLIGHTSWITCHINSPECTION
I N S P E CSTT O PL I G H TS W I T C HC O N T I N U I T Y
Tost€r connoctionto
Switch position S p o c i f i e vd a l u €
torminalnumbgr
Switch pin fr66
Continuity
(P6d6ldepress6d)
Switch pin pushodin
g E r 4 4 48 E 6 2 3 4 3 - 4 Continuity
(Pedal16loassd)
lf continuityis not as specified,replacathe stop light

swrtch.
C L U T C HS W I T C HI N S P E C T I O N
I N S P E CC
T L U T C HS W I T C HC O N T I N U I T Y
Testerconnectionto
Switch position Sp€citiedva u€
t e r m t n anl u m b 6 r
Switch pin fr€e
No continuity
(Pedaldeprossodi
Switch pin pushedin
Contin
uity
(Pedalrel68s6d)
lf continuitvis not as specified,replacethe switch.

8E.121
B O D YE L E C T R I C ASLY S T E M- C R U I S E
C O N T R OSL Y S T E M
L T A R TS W I T C HI N S P E C T I O N
N E U T R AS
INSPECTNEUTRALSTARTSWITCH
SeeAX Section
INSPECTION
SENSOR
SPEED
I N S P E C TS P E E DS E N S O R
See page BE- 65
INSPECTION
ACTUATOR
1 . I N S P E CATC T U A T O M
R AGNETICLUTCH
(a) Checkthat the arm can be movedsmoothlyby hand.
(b) Connect ths positiva (+) lead from the battery to

t e r m i n a5l a n d t h e n o g a t i v (e- ) l e a dt o t s r m i n aO
l .
( M a g n e t iCcl u t c ht u r n e dO N ) ffi
F
(c) Checkthat the arm cannot be movod bv hand.
lf operationis not as specified,rsplacethe motor.
N 1 1 0 5 68 E . 3 7 6
2 . I N S P E C TA C T U A T O RM O T O R
(a) With the magneticclutch ON, connect the positive
(+) leadfrom tho batteryto terminal6, and tho naga-
tive (-) leadto terminal7, check that th€ arm movos
t o t h e o p 6 ns i d e .
(b) When the arm reachsdto th6 opon position,check
that the motor operationstops.
(c) With the magneticclutch ON, connoct the positive

(*) leadfrom the batteryto terminal7 and the nega-
tive (-) l6adto terminal6, checkthat th€ arm mov€s
to the clos€sido.
(d) When the arm reachesto the closedposition,check
that the motor op€rationstops.
N 1 1 1 7 08 4 4 3 7 9

BE-122 sysrEM - cRUrsE
BoDyELEcTRTcAL coNTRoL
sysrEM
3. INSPECT POSITION SENSOR
(a) Measure betweenterminals1 and 3.
the resistanc6
Ro3i.tanco:Appror. 2.0 kQ
(b) When the arm movingfrom the closedto opon posr-

tion. checkthat resistanc€betweent€rminals2 and 3
increasesfrom approx.530 Q to 2.0 kO
lf operationis not as specifiod,r€placeths motor.
THROTTLEPOSITION
SENSOR
INSPECTION
INSPECTTHROTTLEPOSITION
SENSOR
Manual
Repair
SeeEngine

BE-123
SYSTEM_ AUDIOSYSIEM
BODYELECTRICAL
AUDIOSYSTEM
PARTSLOCATION
Twgeter Speaksr
Front Door Speaksr
R e l a yB l o c kN o . 2 R e a rS p 6 a k o r
o RADIONo. 1 Fus€
F r o n tD o o rS p e a k e r
PoworAmplifi€r
Motor Antsnna

BE-124
SYSTEM- AUDIOSYSTEM
BODYELECTRICAL
SYSTEMDESCRIPTION
1 . R A D I OW A V EB A N D
T h e r a d i o w a v e b a n d s u s e d i n r a d i o b r o a d c a s t i n ga r e a s f o l l o w s :
Fr€quency 30 kHz 300kHz 3 MHz 30 MHz 3 0 0M H z
De6ignation LF MF F!F VHF
Radio wav€
N,lodulationmethod A m p l i t u d em o d u l a t r o n Frequencymod! lation
LF:low Frequency MF: MediumFrequencyHF:HighFrequencyVHF:Very High Frequency
2. SERVICEAREA
Thsre are graat differencasin th6 size of the service
,KUA FM (Stefeo)
araalor AM, FM monaural,and FM stereobroadcasts
cannot be recsivedevsn though AM comes in very
c learly.
Not only do6s FM stereo hav€ the smallsstservice
F M (M o n o u r a l area, but it also picks up static and other types of
interfe16nce ("noisE')Easily.

BE-125
SYSTEM- AUDIOSYSTEM
BODYELECTRICAL
R E C E P T I OPNR O B L E M S
Besides the problem of static,there are also the prob-
"fading","multipath"and "fadeout".These
lems called
problemsare causednot by €lsctricalnoisebut by the
natureof the radiowaves themselves
Fading
Fading
ionosphefe
Besid€selectricalinterference,AM broadcastsare
espe-
also susceptibleto other typss of interference,
cially at night. This is because AM radio waves
bounceoff the ionosphere at night.Theseradiowaves
thon interferewith the signalsfrom the same trans-
mitt€r that reachthe vehicle'santennadirectly.This
"fading".
typo of interferenceis called
Multipath
Multi
bv
caused
Onetypeof interference il",?:-r::iT,j
"multipath"' #$
radio waves off of obstructionsis callad
Multipath occurs when a signal from the broadcast
transmitt6rantennabouncesoff buildingsand moun-
tains and interfereswith tho signal that is received
d irectly
Fade Out
FadsOut
BecauseFM radio waves are of higher fraquencies
than AM radiowaves,thoy bounceoff buildings,mou-
ntains.and other obstructions.For this reason,FM
signals often seam to graduallydisappearor fade
away as the vehiclegoes behinda buildingor othor
"fade out".
obstruction.This is called
MAINTENANCE
Tage Player/Head Cleaning
(a) Raisetho cass€ttedoor with your finger.
Next usinga pencilor like objoct,push in the guide'
(b) Using a cleaningpen or cotton applicatorsoaked in
cleaner,clean the head surface, punch rollers and
caostans.

BE-126
SYSTEM_ AUDIOSYSTEM
BODYELECTRICAL
TROUBLESHOOTING
NOTICE:When replacing the internal mechanism(computer part) of the audio systom, bo careful that
no part of your body or clothing comes in contact with ths torminals of the lgads from the lC, etc. of
the replacoment part (sparo part).
H I N T : T h i s i n s p e c t i o n p r o c e d u r e i s a s i m p l e t r o u b l e s h o o t i n gw h i c h s h o u l d b e c a r r i e d o u t o n t h e
vehicle during systsm operation and was prepared on the assumption of system componsnt
troublgs (except for the wires and connectors,etc.).
Always inspect th6 trouble taking th6 following items into consideration.
. ODanor short circuit of the wire harness
o Conn€ctor or terminal connection fault
Problem No.
Radio No powor coming in.
Powor coming in, but radio not oporating.
Noise present,but AM - FM not oporating.
Either3oeakordoos not work. 4
EithorAM or FM does noi work. 5
Rocoptionpoor (Volum6taint),
Fow prs86ttuning b6nds.
Soundquality poor. 6
Cannotsot stations6loct button. 7
ffitr€; Tops Play6r

Pra66tmemory disappears.
Cas6attatopa cannot be inserted.
7
8
Casa€tta top6 insert!, but no powor. o
Power coming in, but tape pl6y6rnot oporaiing. 10

Eitharspeokerdoa! not work. 1 l
Sound quolity poor (Volumr taint),
Tapg jrmmod, mallunctionwith tap6 spoodor auto-rsv€rse. l3
APS,SKIP,RPT buttons not opereting. 11
CEs6ott6taoa will not siect. t5
Antann6 Ant6nna - relatad. 16
'l',
Noiso Noiseproducodby vibrrtion or shock whilo driving.
Nois6produc6dwh6n anginastarts. 18

BE-I27
SYSTEM- AUDIOSYSTEM
BODYELECTRICAL
NO POWERCOMINGIN
p: Radio- Tap. Pteyer(Sep.l.tel pl: Radio- TapcPllYerUnit
@ : w/o TapePlayer
tru
l s t a p € p l a y e rO p e r a t i n gn o r m s l l Y ?
utr
f8ulty.
Radioassembly
trtr9
Checkif CIGfuseis OK?
ls ACC aopliedto redio?
ls ACC oppli6dto tapo plsyor? ACCwirc harneeefaulty.
ls ACC 8ppliodto power amPlifier?

rsa
Checkif GND (wire harneaeside)to redio OK?
Chsckif GND (wirs harnessside)to t8p€ plEyeri8 OK?
Checkif GND (wire harnsssside)to power amplifierie OK?
OK
utr
ls ACC apDliodto radio assembly? PoworamDlifiorfaulW
Checkif GND (wirc harncsssido)

to radio is OK?

BE-128
SYSTEM- AUDIOSYSTEM
BODYELECTRICAL
POWERCOMINGIN, BUT RAD]ONOT OPERATING
@: w/o Tape Player @: Radio- Tape Player{separate} @: Radio- Tapo player Unit
Do speakers pop when ths volume switch

ls power for th€ ant6nna
is turn€dto msximum and then tho oower R a d i of a u l t y .
b6ing output from the radio?
is switched OK?
lf radio side fau lty

G ot o N o .1 6 .
ls powerfor the ant€nna

R a d i oo r r a d i o
l s t a p e p l a y € ro p e r a t i n gn o r m a l l y ? b e i n go u t p u tf r o mt h e
a s s e m b l yf a u l t y .
radioor radioassembly?
tru
ls powerfor the
Pow€r
a n t 6 n n ab e i n go u t p u t
amplifier
from the power
faulty.
a mp l i f i € r ?
trtru
l s t h e r €c o n t i n u i t yi n s p e a k ewr i r e
h ar n e s s ?
T s mp o r a r i l yi n s t a l a
l nother
sp€aker.FunctionsOK?
trE lf radio fa u Ity
Go to No. 16.
trE
H i s s i n gs o u n df r o m s p e a k e r ? Radioassemblyfaulty. Rechecksystematt€r repair.
Pow€r amplifier faulty. Rechecksyst€m after ropair.

BE-129
SYSTEM_ AUDIOSYSTEM
BODYELECTRICAL
Radio BUTAM.FMNOTOPERATING
NOISEPRESENT,
- ptayu{separrrel lTl: Fedio-Trp.Pl.y.] Untt
JE-]:w/oTapr player [El: Rsdto T.p.
ls power for tho rntsnn! bsing output from
the radio or radio sssombly?
Eg
ls pow6rtor th€ sntenneboingoutput
from the pow€rrmPlifier?
G o t o N o .1 6 .
lf rsdio sids fEUlty
EU gE
Rsdio or radio asssmblYfEulty.
l8 tape plsyor oPsratingnormsllY? Radioor redio rssemblYfaulty
Eg
Hissingsound from sP€8lor? Poworsmptifi€rfaulty,Rochecktyitsm Ettorropsir'
Radioass€mblvfrulty. Rochocksyltem !fter repeir.

BE-130
SYSTEM_ AUDIOSYSTEM
BOOYELECTRICAL
EITHERSPEAKER
DOESNOT WORK
[]: w/o Tape Player p: Fadio- Tape Player{separate} @: Radio- TapePlayerUnit

tru Yes
l s t a p e p i a y e ro p e r a t i n gn o r m a l l y ? Radio or radio assemblvlaultv.
No
trtru Yes
ls hissproduc€d by non-functioningspeak€r? R Radio faulty.
No
Radioasssmbly faulty.
U
No
l s t h € r e c o n t i n u i t yi n s p e a k e rw i r e h a r n e s s ? Sp€akerwir€ harness faulty.
Yos
Yes
T e m p o r a r i l yi n s t a l la n o t h e rs p e a k e r . Speaker
F u n c t i o n sO K ? faulty.
No
R R a d i of a u l t y .
s
R a d i oa s s e m b l yf au l t y .
U
5 | Radio
EITHERAM OR FM DOESNOT WORK,RECEPTION
POOR
(VOLUMEFAINT},FEWPRESET
TUNINGBANDS
@: w/o Tape Player p: Radio- Tape Player(ssparate) p: Radio- TapeptayerUnit
P r o b l s mw i t h r a d i o w a v e s i g n a l so r
P o o rs i g n a l s p
, oor location.
l o c a t i o n ?{ S e e ' S Y S T E MD E S C R I P T T O N ' }
Are both AM and FM defective? R a d i oo r r a d i oa s s e m b l yf a u l t y .
l s p o w o r f o r t h e a n t o n n ab e i n g o u t p u t f r o m
l h e r a d i o o r r a d i oa s s e m b l y ?
C O N T IU
N E DO N N E X TP A G E

- Auqle JYSIEM BE-131
SYSTEM
BODYELEcTRtcAL
DR O MP R E V I O UPSA G E
C O N T I N U EF
tr tru No
s ls po\v e r f o r t h e a n t e n n ab e i n g Power a m plifier
o u t P Lt f r o m t h e p o w e r a m P l i f i e r T U fa u lty.
Yes
G ot o N o .1 6 .
tf r a d i o s i d e f a u l t y
tr ,EU
r y e r o p e r a t i n gn o r m a l l y ? R a d i oo r r a d l o a s s e m b l yf a u l t Y ,
T e m p o r a r i l yi n s t a l l a n o t h e r Speaker
s p e a k e r . F u n c t i o n sO K ? faulty.
No
UE tr
R R a d i ot a ul t y .
trtr i t!l^ --
H i s s i n gs o u n df r o m s p e a k e r ? l_]]Ll Poweramolifierfaulty. Rechecksystemafter repair'
Yss
R a d i oa s s e m b l fya u l t y . R e c h e csky s t e ma f t e rr e p a i r .
6 Radio SOUNDOUALITYPOOR
@: w/o Tape
player p: Radio- Tape Player{separate} lu.J: Radio- Tape PlayerUnit
l s s o un d q u a l i t ya l w a y s No l s s o u n d q u a l i t yb a d i n Yes Poorsignals,poor
bad? c e n a i n a r e a so n l y ? location.
Yes No
EU t l
t'-.,.r" rrr* t P E I d ! j | | 9 | | v | | | | o | | Y ' - ]

-'^ *-^-^"-",.|^,
R a d i oa s s e m b l yo r p o w e r a m p l i f i e rf a u l t y .
U
C O N T I NU E D O N N E X T P A G E

BE-132
SYSTEM- AUDIOSYSTEM
BODYELECTRICAL
FROMPREVIOUS
CONTINUED PAGE
trg
ls powertor tho lnlgnna
R a d i oo r r a d i o
ls tspe playor opsrEtingnormElly? b€lngoutputfrom thr
EEs€mbly fsulty,
radioor rsdioasssmblyT
trtr
b powor lor th. Power amp-
!ntonn! boing output lifier laulty.
from thr powar
rmplificr?
Temporsrilyinstall anoth6r
sp€8ker FunctionOK?
trg
Radios6somblyor power amplifi6r
ls pow€r for ths anlenne boing

output from th6 t8dio7
Go to No, 16.
CANNOTSETSTATIONSELECTBUTTON,PRESET
7 Radio MEMORYD]SAPPEARS
fJ: w/o TapcPlayor lTl: Radio- TaprPbyrr(srprrrtcl @: Radio-TrprPlayo:Unit
Cancasssttotapobs inssrt€din trpe pl8y6r?
Checkif RADIONo.1f useis OK?
CONTINUEOON NEXTPAGE

8E.133
SYSTEM- AUDIOSYSTEM
BODYELECTRICAL
R O MP R E V I O UPSA G E
C O N T I N U EFD
f;t T,-il
lL.llj.l
l s B + a p p l i e dt o p o w e r No B +w i r e h a r n e s s
S faulty.
assembly?
Yes
C h e c ki f G N D ( w i r eh a r n e s ss l d e )t o p o w e r NG
G N Df a u l t y .
S amplifier?
l s B + a D D l i e tdo r a d i oo r r a d i oa s s e m b l y ? B +w i r e h a r n e s sf a u l t y .
P o w e ra m p l i if s r f a u l t y .
C h e c ki t G N D ( w i r eh a r n e s ss i d e )t o r a d i o G N Df a ul t y .
o r r a d i oa s s e m b l y ? Poweramplifier fa u lty.
R a d i oo r r a d i oa s s e m b l yf a u l t y
TAPECANNOTBEINSERTED
TapePlayer CASSETTE
[3]: Radio- TapePlaver(separate] ltl: Radio- TapePlaverunit
l s t h e r ea i o r e l g no b i e c ti n s i d et a p e p l a y e r ? R e m o v ef o r e i g no b j e c t .
T a p ep l a y e rf a u l t y .
I
E
ls auto searchbutton of radio operating Ye5 R a d i oa s s e m b l y
n o r m al l y ? faulty.
No
NG
C h e c ki t R A D I ON o . 1f u s el s O K ? tuse.
Replace
rL:JmI l o K
No
l s B + a p p l i e dt o p o w e ra m p l i f i e r ? B + w i r e h a r n e s sf a u l t y .
Yes
c h e c ki f G N D { w i r e h a . n e s ss i d e r, @
OK
C O N T I N U EODN N E X TP A G E

BE-134
SYSTEM- AUDIOSYSTEM
BODYELECTRICAL
N T I N U E DF R O MP R E V I U
OS P A G E
l s 8 + a p p l i e dt o r a d i oa s s e m by ? P o w e ra mp l i f i e rf a u l t y .
C h e c ki f G N D ( w i r eh a r n e s ss i d e )
Powera mplifierfaulty.
t o r a d i oa s s e m b l yi s O K 7
9 TapePlayerI CASSETTE
TAPEINSERTS,
BUTNO POWER
[Sl: Radio- TapePlayer(separate] lU l: Radio- TapePlayerUnit
l s r a di o o p e r a t i n gn or m al l y ? R a d i oa s s e r n b lfya u l t y .
C h e c ki f C I Gf u s e i s O K ?
l s A C Ca p p l i e dt o p o w e ra m p l i f i e r ? A C Cw i r e h a r n e s sf a u l t y .
l s A C Ca p p l i e dt o r a d i oa s s e m b l y ?
A C Cw i r e h a r n e s sf a u l t y .
R a d i oa s s e m b l yf a L r l t y .

BE-135
SYSTEM_ AUDIOSYSTEM
BODYELECTRTCAL
Tape Player POWERCOMINGIN, BUT TAPEPLAYERNOT OPERATING
l5l: Radio- Tape Player(separate) I U l: naaio - Tape PlayerUnit
Functions OK if different cassefte Cassettetape faulty.

tape inserted?
normally?
l s r a d i oo p e r a t i n g Radioassemblvfaulty.
l s t h e r e c o n t i n u i t yi n s p e a k e rw i r e Soeakerwire harnessfaulty.
harness?
T e m p o r a r i l yi n s t a l la n o t h e rs p e a k e r .
Functions OK?
R a d i oa s s e m b l fva u l t y .
EU
H i s s i n gs o u n df r o m s p e a k e r ? PoweramDlifisrfaulty. Rochscksystomaft€r r€pair.
Radioassemblyfaully. Rechocksystemafter rspair.
11 Tape Player EITHER DOESNOTWORK

SPEAKER
l5l R"aio- TapePlayerlseparate) I Ul; Radio- TapePlayerUnit
l s r a d i oo p e r a t i n gn o r m a l l y ? Radioassemblyfaulty.
l s h i s s p r o d u c e db y n o n - f u n c t i o n i n g R a d i oa s s e m b l Yf a u l t y .
speaker?
l s t h € r ec o n t i n u i t yi n s p e a k ewr i r e
harness?

BE-136 SYSTEM- AUDIOSYSTEM
BODYELECTRICAL
C O N T I N U EFD
R O MP R E V I O UPSA G E
T € m p o r a r i l iyn s t a l a
l nother Y€S
S p e a k efra u l t y .
speaker.FunctionsOK7
No
S Tapeplayerfaulty.
R a di o a s s e m b l yf a u l t y .
12 TapePlayer SOUNDOUALITYPOOR(VOLUMEFAINT)
l S l : R a d i o- T a p e P l a y e r{ S e p a r a t a ) U l : R a d i o- T a p eP l a y e rU n i t
FunctionOK if differentcassette
t a p ei n s e r t e d ?
O p s r a t e sn or m a l l ya f t e rc l e a n i n g
t h e h e a d s ?( S e eM A I N T E N A N C E )
l s r a d i oo p e r a t i n gn o r m a l l y ? R a di o a s s e mb l y f a u l t y .
ls speakep
r r o p e r l yi n s t al e d ? I n s t a lpl r o p e r l y ,
T e m p o r a ryi i n s t a l al nother
s p e a k e rF. u n c t i o n sO K ?
No
l-.1 aro'osssembty
fautty.

8E.137
SYSTEM- AUDIOSYSTEM
BOOYELECTRICAL
WITHTAPESPEED
TAPEJAMMED,MALFUNCTION
13 TapePlayer ORAUTO.REVERSE
fil: Radio- TapePlayer(Separate)ltl: Radio- TapePlavorUnit
s K i f d i f f e r e ntta p e( l € s s
F u n c t i o nO Cassettetape faulty.
t h a n 1 2 0m i n s . )i s i n s e r t e d ?
l s t h e r ea f o r e i g no b i e c ti n s i d et a p e
player?
O p e r a t e sn o r m a l l ya f t e rc l e a n i n g
t h e h e a d s ?( S e eM A I N T E N A N C E )
Radioassembly faulty.
TapePlayer APS,SKIPRPTBUTTONSNOTOPERATING
FunctionsOK is differentcassette
t a p ei n s e d e d ?
Cassettetaoe faulty.(less than 3 s€cs.of silencebetweensongs (APS,RPT)'or lsrt thln 15 33cs.of silencc{SKIP)}.
TAPEWILLNOTEJETCT
TapePlayer CASSETTE
[d: Radio- TapePlEyer(sapsratet @: Radio-Tapo Play.r Unit
l s t a p €p l a y e ro P e r a t i n gn o r m a l l Y ?
ls auto searchbutton of radio Radiosssemblylsulty.

o p e r a t i n gn o r m a l l y ?
C h e c ki l R A D I ON o . 1t u s ei s O K ?
CONTINUEDON NEXTPAGE

BE-138
SYSTEM- AUDIOSYSTEM
BOOYELECTRICAL
C O N T I N U EFDR O MP R E V I O UPSA G E
u t. a* rppt,"6
t o power arnplif;€r?|
ô
.] B+ wire harnesslaulty.
I
Yes
ls B+appliedto radioassembly?l !9! S

B+ wire harnossfaultv.
Yes U
R a d i oa s s e m b l yf a u l t y .

BE-139
SYSTEM- AUDIOSYSTEM
BODYELECTRICAL
Antenna ANTENNA.RELATED
[F]: Antennaw/o Motor lfrl : MotorAntennt
TemporarilyinstallEnother
Entenna.FunctionsOK?
H$
Tgmporsrilyinstall8ôthorantgnnS.
FunctionsOK?
Inspactant€nnamotor.
I n s p o cat n t € n n am o t o r c o n t r o lr e l 8 v .
(Relaycircuit)
l9 pow6rrelstcdtolhe antennebeing
Relaycircuitfaulty.
inouttothe antennsmotorcontrolrelsv?
Ch€ckcontinuitybetweenantenna
motor control relay and radio.

BE-140
SYSTEM- AUDIOSYSTEM
BODYELECTRICAL
NOISEPRODUCEDBY VIBRATIONOR SHOCK

17 i Noise WHILEDRIVING
l s s p e a k e pr r o p e r l yi n s t a l e d T I n s t a lpl r o p e r l y ,
l s e a c hs v s t e mc o r r e c t l vi n s t a l l e d ?
Yes
W i t h v e h i c l es t o p p e dl,i g h ty t a p e a c hs y s t e m l.s
Eachsyst€mfaulty,
n o i s €p r o d u c e d ?
No
N o i s ep r o d u c e db y s t a t i ce l e c t r i c i tayc c u m u l a t i nign t h e v € h i c l eb o d y .
18 Noise NOISEPRODUCED
WHENENGINE
STARTS
W h i s t l i n gn o i s ew h i c h b e c o m e sh i g h ' p i t c h e d
w h e n a c c e l e r a t osrt r o n g l yd e p r e s s e dd,i s a p p e a r s
s h o r t l ya f t a r6 n g i n ss t o p s .
No
W h i n i n gn o i s so c c u r sw h e n A / C i s o p e r a t i n g . A/C nolse.
Scrstching n o i s eo c c u r sd u r i n gs u d d e n
€ c c e l B r a t i odnr,i v i n go n r o u g hr o a d so r w h e n F u Bg
l a u g en o i s e .
i g n i t i o ns w i t c hi s t u r n e do n .
NO
Clicking s o u n dh e s r dw h e n h o r n b u t t o ni s
p r € s s a dt ,h e n r s l e E s e dW. h i r r i n g/ g r a t i n gs o u n d H o r nn o i s e .
w h e n o u s h o dc o n t i n u o u s l v ,
No
M u r m u r i n gs o u n d ,s t o p sw h e n e n g i n es t o p s , l g n i t i o nn o i s e .
Tick-tocknoise,occursin co-ordination
with T u r ns i g n a ln o i s e ,
blinkingof flasher.
o c c u r sd u r ; 4 9w i n d o ww a s l ' e ro p e r a t i o n .
Scratchinn g o i s €o c c u r sw h i l ee n g i n ei s r u n n i n g , E n g i n ec o o l a n t e m p .
c o n t i n u e sa w h i l e e v 6 na f t e re n g i n es t o p s , g € u g en o i s e ,
S c r a p i n gr o i s e i n t i m e w i t h w p e . b e a r .

BE-141
SYSTEM- AUDIOSYSTEM
BODYELECTRICAL
A N T E N N AM O T O RI N S P E C T I O N
I N S P E C TA N T E N N AM O T O R
(a) Connectthe positive(*) leadfrom batteryto terminal
1 a n d t h e n e g a t i v e( - ) l e a dt o t e r m i n a 4l
(b) Checkthat the motor turns (movesupward).
NOTICE: Thasetastsmustba performed quickly(within3
- 5 seconds) to proventthg coilfrom burningout.
(c) Then,reversethe polarity,checkthat the motor turns
the oppositeway (movesdownward)
NOTICE: Thoset6stsmustbe performed quickly(within3
- 5 seconds) to prsvsnttha coilJromburningout'
4E4121
aa412A
#$

BE-142
SYSTEM- AUDIOSYSTEM
BODYELECTRICAL
Wire HarnessSide ANTENNAMOTORCONTROLRELAY

INSPECTION
I N S P E C TA N T E N N AM O T O RC O N T R O LR E L A Y
RelayCircuit
Disconnectth6 conn€ctorfrom the relayand inspect
t h e c o n n s c t o ro n w i r s h a r n e s ss i d e ,a s s h o w n i n t h e
chart below.
T€st6r conn€ction to
Condition Sp6cified valuo (Continuity)
t € r m i n a ln u m b e r
Cohstant Continuity
Constant Continuity
Testerconnectionto
Condition Sp€cifisdvalu€ (Vo tage)
terminalnLrmber
Constant Batt€ryvoltags
5 Ground lgnitionswitch positionLOCK No voltage
#ii 5 - Ground
6 - Ground
lgnitionswrtch positionACC or ON
lgnitionswitch positionLOCK
8attery vollag€
No vo tags
lgnitionswitch positionACC or ON
6 - Ground No voltags
(Radioswitch and cassstteOFF)
6 Ground Batteryvo tage
(Radioswitch or cassetteON)
8 Ground lgnitionswitch positionLOCK No voltage
8 - Ground No vo tag6
(Radioswitch OFF or cassetteON)
8 - Ground Batteryvo tage
(Radioswitch ON and cass€tt€OFFi
I - Ground lgnitionswjtch positionLOCK or ACC No voltago
9 - Ground s w r t c hp o s r t r o O
lgnrtron nN Eatt€ryvoltago
l f c i r c u i t i s a s s p e c i f i e d ,r e p l a c et h e r e l a y .

BE-143
SYSTEM- AUDIOSYSTEM
BODYELECTRICAL
ANTENNARODREMOVALAND
AntennaNut
INSTALLATION
1. REMOVEANTENNAROD
HINT: Perform this operationwith the negative(-)
terminalcableconnectedto the battery.
'LOCK' position.
(a) Turn the ignitionswitch to
(b) Removethe antonnanut.
(c) Pressthe'AM, FM'buttons on tho radio receiverand

simultaneously turn tho ignitionswitch to'ACC'posi-
tton.
HINT:
r The rod will extendfullv and be releasedfrom tho
motor antonna.
. After removingthe antennarod, leavethe ignl-
'ACC'.
tion switch at
NOTICE:To preventbodydamagewhen the lntonnr rod
lr releared,hold thc rod while it comot out.
2. INSTALLANTENNA ROD
(a) Insert the cable of the rod until it reachesthe bottom. AE
HINT:
r When insertingtho cabl6,the teoth on tho cable
must face toward the f ront of the vehicle.
. Insertth€ antennaapprox.300 mm (11.8 in.)

BE-144
SYSTEM_ AUDIOSYSTEM
BODYELECTRICAL
(b) Wind the cable to retract the rod by turning the

ignitionswitch to "LOCK"position.
HINT:
. lf tho ignitionswitch is alreadyin "LOCK"posi-
tion, porformstep 1 (c)first,then turn the ignition
switch to "ACC"position.
. In casethe cabl6is not wound,twist it as shown
. Evsn if the rod has not retractedfully, installthe
a n t e n n an u t a n d I n s p o c t h e a n t e n n ar o d o p e r a -
tion. lt will finallyratractfully.
( c ) I n s p e c tt h e a n t e n n ar o d o p e r a t i o nb y p u s h i n gt h e
radiowave band selectbuttons.
G L A S SP R I N T E A
DN T E N N A
GLASS PRINTEDANTENNA INSPECTION
1. I N S P E C TG L A S SP R I N T E DA N T E N N A
( U s e s a m e p r o c e d u r ea s f o r " I N S P E C TD E F O G G E R
wtREs".)
2. REPAIR GLASSPRINTED ANTENNA
( U s 6s a m ep r o c e d u r ae s f o r " R E P A I RD E F O G G E R
wrREs".)

BE-145
SYSTEM_ CLOCK
BODYELECTRICAL
CLOCK
TROUBLESHOOTING
the c l o c ka c c o r d i n gt o t h e t a b l e
HINT:Troublsshoot
bslow.
Clockwill not op€rato 1
Clock lososor gajns ttmo 2
CLOCKWILLNOTOPERATE
( a l C h e c kt h a t t h e b a t t e r yv o l t a g €i s 1 0 - 1 6 V .
l f v o l t a g ei s n o t a s s p e c i f i e dr,e p l s c et h e b s t t e r y .
( b ) C h e c kt h a t t h o D O M Ef u s 6 i s n o t b l o w n .
l f t h e t u s e i s b l o w n ,r e p l a c et h e f u s e 8 n d c h e c kf o r s h o r t .
(c) Troubleshootthe clock as follows.
H I N T : I n s o e c t h e c o n n e c t o ro n t h e w i l e h a r n e s ss i d e '
+B GNO
HHII
l s t h e r eb a t t e r yv o l t a g eb e t w e e nt e r m i n a l O p e no r s h o r tc i r c u i ti n w i r e h a l n e s sb e t -
+ B and bodvground? w e e n t e r m i n a l+ B 8 n d D O M Ef u s e
l s t h e r ec o n t i n u i t yb e t w e e nt e r m i n a l O D e nc i r c u i ti n w i r e h a r n e s sb e t w e e nt e r -
G N D a n d b o d Yg r o u n d? m i n a lG N D a n d b o d y g r o u n d
R e o l a c ec l o c ka s s e m b l Y .

BE-146
SYSTEM_ CLOCK
BODYELECTRICAL
2 C L O C KL O S E SO R G A I N ST I M E
( a ) C h e c k t h a t t h e b a t t e r yv o l t a g e i s 1 O - 1 6 V .
l{ voltage is not 8s specitied, replac€ the battery.
( b ) Inspect the error of the clock.
Allowable error {per daY); t2.O secondg
lf the error exceeds ths allowable erlor, replace the clock
ess€mbly.
( c , Check if the clock adiusting button is sticking in position
a n d h 8 s t a i l e dt o r e t u r n ,
lf the button has not returned, repair or r€place the clock
assemory.
( d ) T r o u b l e s h o otth e c l o c k a s f o l l o w s .
.r -EI- .,
H I N T : I n s D e c t h e c o n n e c t o ro n t h e w i r o h a r n e s ss i d e
aw$
+B GND
l s t h e r e 1 O - 1 6 V b e t w e e nt e r m i n a +
l B L o c a t ec a u s e . 8 n dr e p a i ro r r e c h a r g eb a t -
BE
A d j u s t o r r e p l a c ec l o c k a s s e m b l y ,

BE-147
SYSTEM_ SERVICE
BODYELECTRICAL SPECIFICATIONS
SPECIFICATIONS
SERVICE
DATA
SERVICE
INTEGRATION
RELAY
Al - Ground(Constsntl B6tt6ry voltags
A7 - Ground(lgnitionswitch positionLOCKor ACC) No voltage
A7 - Ground{lgnitionswitch positionON) 8att6ry voltage
82 - Ground (Constant) Brtt.ry voltag€
83 - Ground (Constant) Batt6ry voltage
E U N N I N LGI G H TM A I NR E L A Y
DAYTIMR
2 - Ground (lgnitionlwitch po.ition LOCKor ACC) No voltag6
2 - Ground (lgnitionlwitch po6itionON) B.ttory voltago

l1 - Ground(Enginostop) No voltago
| 1 - Ground(Enginorunning) 8rttery voltago

l5 - Groundlcon€tant) Batt6ry voltago
l7 - Ground(Constantl Irttory voltag6
TURNSIGNALFLASHER
Fhsho!,/Minut. 80 - 120
(USINGA SPEEOOMETER
SPEEDOMETER TESTER)
EUROPE
St.ndln indication(kmlh) Allow.bl. rang. (kmlh) Standsrtindication(mph) Allowablorang6{mph)
20 20-24 20 20 - 24.5 Bi'ii

40 40 - /18 10 40 - 46.s
80 60-70 60 60 - 68.5
80 80-92 80 80 - 90.5
100 1 0 0- 1 1 4 lo0 loo- 112.5
120 1 2 0- 1 3 6
140 1 4 0- 1 5 8
t00 1 8 0- 1 8 0
GENERAL
st.nd.rd indication {kmlh) Allowable renge St.ndard indication (mphl Allowablo rongo (mph)
20 17-27 20 18-21
40 38 - /to 40 38 - il4
80 57.5 - 87 B0 58-88
s0 7 7- 8 so 78-88
100 s6 - los lO0 98 - 110
120 1 1 5- 1 3 0 120 1 1 8- 1 3 2
140 134- 151.5
180 t53 - 173
AUSTRALIA
Stlnd.rd indic!tion (kmlh) Allow!bb f!no. (lmlh)
40 3A-11
80 54-86
8o 72-AA
roo 90- lt0
't
I 08 - 32
140 t28 - 154
160 14 - 176

BE-148
SYSTEM_ SERVICE
EODYELECTRICAL SPECIFICATIONS
(ON-VEHICLE)
TACHOMETER
Standardindication(rpm) Allow.bl. r.ng. (rpm)
700 830 - 770
| 000 9 0 0- 1 1 0 0
2000 t 850- 2150
3000 2800 - 3200
4000 3800 - 4200
5000 /1800- s20O
6000 5750 - 6250
7000 8700 - 7300
FUEL RECEIVERGAUGE
A _ B Approx.I 5.1.3O
Approx.126.2O
B - C App.ox.280.5 O
FUELSENDERGAUGE
Floatposition:
F Approx.3.0 O
Float position:1,/2 A p p r o x . 3 l . €O
Float position:E Approx.110.0O
WATERTEMPERATURERECEIVER
GAUGE
A - 8 Approx.229.7O
A - C Approx.54.0 O
Approx.175.7O
WATERTEMPERATURE
SENDERGAUGE
s 0 " c ( 1 2 2 ."0F ) 160 - 240 0
1 2 0" c ( 2 4 8 . 0' F ) 17.'t - 21.2 Q
ROOFCONTROL
SLIDING RELAY
6 - Ground (lgnitionswitch polition LOCK or ACC) No volt.g.
6 - Ground (lgnitionswitch polition ON) Bltl.ry volt.O.
l2 - Ground lconlt.nt) Brtl.ry volt.g.
CRUISE
CONTROL
ECU
I - l6 (Br!k. p.d6l positionr.l.!..d) Agprox.38.5 O
l8 - Ground (Controlrwitch DositionRES/ACC) Approx.8g O
18 - G.oond lControl lwitch po.ition SET,/COAST) Approx.| 99 O
18 - Ground (Controllwitch poiition CANCEL) Approx.alS O
22 - Ground {Constant) Approx.13 O
23 - 25 (Conrtlntl Approx.2 kO
24 - 25 {Actu.torlrm turn.dl Rarilttnca changa linarr
I - Ground{Conltrnt) B!tt!ry volt!C!
2 - Ground (lgnition8witch po.ition ON lnd clutch pcdll
8!ttory voltr0!
16lorsrd): M/f
2 - Ground (lOniiion.wilch porition ON.nd clutch p.d.l
No voltlgc
doprorlcd): M,/T
2 - Ground(Shilt lrv!. polition D):A/r B.ttrry volt.C!
2 - Ground (Shilt l.vcr poriiion.xc.pt O): A/I No voltlCa
7 - Ground (lgnitionlwitch porition LOCKor ACC) No volt!g.
7 - Ground (lgnitionlwitch po.iiion ON) 8!lt.ry volt.e.
l4 - Ground(lgnition.witch polition LOCK or ACC) No voltlga
l4 - Ground(lgnition.witch polition ON) Blticry voltloc

BO-1
BODY
Fffi
-* *i.r!-l

BO-2
B O D Y_ G E N E R A ILN F O R M A T I O N
Exampl6
G E N E R A ILN F O R M A T I O N
PRECAUTIONS
HANDLING
Taping
When it is possiblethat th6 body or parts may be
scratchedduringth6 operation,apply protectiv6tapo
K before starting work.

Examols:
1. Before starting work, apply protectivotape to
body surfacesaround parts to be removedand
installed.
2, Before prying parts loose with a screwdriveror
scraperetc., apply protectivetape to tha tip of
the tool to avoid scratchingparts or paintedsur-
faces of the bodv.
ProtectiveTape
B0:t110
302.88
Brtteiy
In orderto prevsnta short circuitwhile doingwork on
tho oloctricalcircuitsuch as disconnoctinga connec-
,tBO tor, first turn off the ignitionswitch and disconnect
the n€gativo (-) terminal cable from the battery
before starting work.
HINT:When battoryvoltag€is requiredfor operation
of a functioningpart,connectthe cableto the battery
loat lt when needed,and promptly disconnectit when no
longernecessary.
CAUTION:
I To rvoid craring thc momory of cach momory
ayatam,noygr urc r back-up power rupply from
outrid. thc Yohiclc.
Fitting Adjurtmontt
When removingand installingbody panelswhich have
a preloadvaluo, aftor installationrefer to lhe pago
containingthe installationadjustmentm€thods,and
make adjustmentsaccordingto the r6quiredspecifi-
cations.
HINT:When makingadjustments,do not completely
loosen the bolts and nuts of th6 part being adjusted.
Tighten them appropriately, and move the panelsby
hand to alignthem.

BO-3
B O D Y_ G E N E R A ILN F O R M A T I O N
Example A N T I _ R U S TT R E A T M E N T
A n t i - r u s t t r e a t m e n tu s e d o n t h e v e h i c l eb o d y i n -
cludesbodysealer,undercoat,rust inhibitorand paint.
HINT: Refer to the Body CollisionDamage Repair
Manualf or detailsof which parts havereceivodanti-
rust treatment.
Cracks BodySealer
lf the body sealeris damaged(peeling,cracks,etc.)
duringthe operation,replaceit with new body sealer'
HINT: lf body sealergets on othsr parts, promptly
wipe it off with a cleancloth dippedin a removerfor
g rease,wax or silicone.
Example Undercoat
lf the undercoat is damagedduring the operation,
apply new u ndercoat.
HINT:
. Coverthe surroundingarea with maskingpaper
to avoid applying undercoat whor€ it is not
needed.
Undercoat
. Do not apply undercoat to high tomperature
BO41l3
parts such as th6 tailpip6,or to drive parts such
as the driveshaft.
Fust Inhibitor
After removingand re- installinghinges and outer
panelparts,apply rust inhibitorto the parts.
HINT: lf rust inhibitor gets spilled on other parts,
promptly wrpo it off with a clean cloth dipped in a
greaso,wax and silicon16mover.
Touch- Up Print
lf a smallscratchis madein ths body surface,corrsct
t h e s c r a t c hu s i n gt o u c h - u p p a i n tt h 6 s a m ec o l o ra s
tho body color.
T o u c h . U pP ai n t

BO-4
B O D Y- G E N E R AI N
L FORMATION
CLIPS
The removaland installationm6thodsof typicalclips
used in body parts are shown in the table below.
H I N T : l f t h e c l i p i s d a m a g e dd u r i n g t h e o p e r a t i o n ,
alwaysreplaceit with a n6w clip.
Shlpc (Extmpl.) Ramov!l/ln.tallatlon
L---) t
----'1
T
il - - - - J i

BO-5
B O D Y- G E N E R A ILN F O R M A T I O N
CLIPS(Cont'd)
Shep. (Ex8mplol R.mov!l/lnrt6llrtion
Romovll lnrtlllatton
R.moval Inttallltlon

BO-6
BODY- PREPARATION
PREPARATION
ssT (sPEcrAL TOOLS)
SERVTCE
09812-00010 DoorHingos6t Boltwrench Ooo. sid€hingobolt adjustment
09806-30010 windshiold Removor

Mouldins
09631-22020 PoworSt.eringHos6Nut Fuellinofler6nut

l4 x l7 rnmWronchSot
LUBRICANT
It6m C.pacity Clas5itication

MP gr6as6
SSM (SPECIAL MATERIALS)

SERVICE
;rHd
08833-00090 Adhotivo1131, Frontdooa
1I3I,
T H R ESEO N D Brck door
LOCTITE 518or oquivrl€nt
08850-00070 wind3hieldghss tdhosivs6€t WindBhield

N o . 1 5o r . q u i v a l o n t Ouartorwindowglass
Brck door mouldingand glass
(0- l5'C or 32-59"F)
08850-00080 Windshioldgltss !dh€sivosot Windshiold

No.35or oquivalont Ourrtorwindow glass
Eackdoor mouldingand glass
(15 35'Cor 59 95'F)
08850-00090 windrhioldsb3t ldhosivoset Windshi6ld

No.45or aouiv6lont Ouart6rwindow g16ss
Backdoor mouldingand glasg
( 3 5 - 4 5 ' C o r 9 5 - t 1 3 "F )
08833-00030 Auto gh$ re.l.r or 6quivll6nt Wind3hi.ldmouldingand glsss

Ou!rtor window mouldingand glass
Backdoor mouldingand gless
08850-00085 gutvlTtp6set RooI.id. rril woath€rstrip
-00080
08826 56tl packingor aquivrlgnt Rootdrip sidofinishmoulding
Rool3id6rail woltherstrp rot6i
nor

BO-7
B O D Y- P R E P A R A T I O N
1 . C H O O SS E U I T A B LA ED H E S I VSEE T
P.rt No. U s ea n a d h e s i vsee ts u i t a b lfso r t h e a m b i e ntte m p e r -
lamp6r6l!ra
Wind3hicld
ature.
08850-00070 Olrir !dharavc
{32 - 59'F) s.t No. 15
15- 35"C 08850-O0080 0 1 6 ! r ! d h a 3 i v a

!.t No 35
35 - 45'C 08850-OOO90 g h s a r d h a 3 i v a
( 9 5- r 1 3 " F '
s.l No.45
!i:il5
(min.) 2. C H E C KA D H E S I V E ' S U S A B L ET I M E
Windshield Glsss Adh€siv6 Aftermixing m a i n a n d hardening a g e n t s f, i n i s hg l a s s
o 9 0 -No,4
tims asshown.
i n s t a l l a t i owni t h i nt h e s p e c i f i e d
E t N o . 1 5 \ l o.3'5\
t r o o E x a m p l eF: o rg l a s si n s t a l l a t i oi n a n a m b i e n t e m p e r a -
-9 ture of 25'C (77"F), applvadhesiveset No.35 within
S 3 0 45 m inutes.
10
fc)
AmbientT€moorstur€ 6 0 0 1l 9
3. C H E C KA D H E S I V EH A R D E N I N G TIME
After mainand hardeningagontsare mix6d,leaktests
s h o u l d b e m a d e o n l y a f t e r t h e h a r d e n i n gt i m e h a s
elapsed. BO
E x a m p l eT: h e h a r d e n i n tgi m e f o r a d h e s i v es e t N o . 3 5
with an ambienttemperatureot 25" C (77"F) is 2 and
1/2 hours.
NOTICE: Do not drivethe vehicleuntil8t loastdoublathB
fc)
AmbiontT€mD€rature loor 20 hardening tims haselaPsed'

BO.8
B O D Y_ F R O N TB U M P E R
F R O N TB U M P E R
COMPONENTS
F r o n tF e n d e rL i n e rR H
M u dG u a r dR H
F r o n tF e n d eLr i n e rL H
eK.ion !
artpu,.
i,bd
EnSine
Under No.3
Cover
I M u d Gu a r d L H
ll.iffifA C o o lA i r I nl e t N o . ' 1
\"e H o o dt o F r o n tE n d P a n e lS € a l
U p p e rR e t a i n e r
tt--{f
sidssupport
TurnSisna,l nX tf
r-lerrt n e r g yA b s o r b e r
-$ E mb l e m
*rN SF--Y=- fl
(
€
B u m p €C r o v e r dl
I ]
T ur n S i g n aLl i g h tL H
ll-*
l-
\ s i d eS u p p o rLt H
/r'erRetai n e r
N m (kgi cm, ft lbf) | : S p € c i f i e dt o r q u e

BO-9
B O D Y- R E A RB U M P E R
R E A RB U M P E R
COMPONENTS
5 4 (55,48in. lbf)
Packag€TrayTrimPanel
Mat
LuggageComPanment
!f '
,)
t -
' "7 r ,
3"
i^
DeckTrimR€arCover o -J
LowerBackFinlsh
CenterPanel
Reinforcement
7dL ^-..1
En€rgyAbsorber
A#
\JLJAJ
l
LighlLH
RearCombinaiion
ffi -Rear Combination
LightRH
5.4 (55,48in.lbf)
SidoSupportLH
BH
N.m ( 'cm, tt . lbf) ; Sp€cifi€dlorque

BO-10
B O D Y- H O O D
HOOD
H O O DA D J U S T M E N T
HINT: Since the centoringbolt is used as tho hood
hingeand lock s6t bolr,rhe hood and lock cannot be
adjustedwith it on. Substitutethe standardbolt for
th6 centsringbolt.
C e n t e r i n gB o l t S t a n d a r dB o l t
1 . A D J U S TH O O DI N H O R I Z O N ADLI R E C T I O N S
Adjust tho hood by loosening th6 hood side hinge
b ol t s .
T o r q u e : 1 3 N . m ( 13 0 k g f . c m , 9 . 4 t t . l b f )
2. ADJUSTFRONTEDGEOF HOODIN VERTICALDI.

RECTION
A d j u s t h 6 h o o db y t u r n i n gt h e c u s h i o n s .
irBo
-c---'-t
-',-,-,'--------
3. ADJUST REAR EDGE OF HOOD IN VERTICALDI-

RECTION
Adjust the hood by increasingor decreasingthe
numberof the washers.
4. ADJUSTHOODLOCK
Adjustthe lockby loosening
the bolts.
T o r q u e : 7 . 8N . m ( 8 0 k g f . c m , 6 9i n . l b f )
-.n,----

BO-11
BODY - FRONTDOOR
F R O N TD O O R
COMPONENTS
DoorGlass
OutorRearVigwMirror
OutsidoHandl€
"*r,*-"r;;,
DoorBeltMoulding
DoorWindowUpporSlop
K A
BO
Llnk Protgctor DoorHings
€
6el/ s Window Regulator
€
LockingLinkNo I InsideHandlo
LocklngLink
lnsid€ Pan6l Fram€
WindowGukJ€Low€rPlats
SnapRing\ S€rvicoHol6 Covgr
\ )"" &
d/ t_ @
FronlDoorSogaker
,,/ Counesy Light
N m (ko cm, lt lbl) : SpocitiEd

torqu€
* part
Procoated

BO-12
BODY _ FRONTDOOR
F R O N TD O O RA D J U S T M E N T
1 . A D J U S TD O O RI N F O R W A R D / R E A R W A R
ADND
V E R T I C AD LI R E C T I O N S
UsingSST,adjustths doorby loosening the bodyside
h i n g eb o l t s .
s s T 0 9 8 12 - 0 0 0 10
2. ADJUST DOOR IN LEFT,/RIGHTAND VERTICAL

DIRECTIONS
UsingSST,adjustthe door by looseningthe door sid€
hingebolts.
2- 0 0 0 0
ssr 0981 1
HINT:Substitutetho standardbolt for tho centering
bolt. (Seepage BO- 10)
Torque:28 t{.m(290kgf cm. 2l ft.lbf)
3. ADJUST DOORLOCK STRIKER

(a) Check that the door fit and door lock linkagesare
adjustedcorrectly.
BO (b) Loosenthe strikermountingscrews.
(c) Usinga plastichammer,tap th6 strikerto adjusrit.
CAUTION: Do not tap the st?ikertoo hard.
Torque:26 N.m(260kgf.cm.19 ft.lbf)

BO-13
BODY - FRONTDOOR
FRONTDOORDISASSEMBLY
1. REMOVETWEETER COVER
SPEAKER
2. w/o PowerWindow:
REMOVEREGULATOR HANDLE
Pulloff the snapringwith a shopragand rsmovethe
rogulatorhandloand Plato'
3. REMOVE]NSIDEHANDLEBEZEL
Removethe screwandpullthe insidehandlebezelas
shownon the illustration.
BO
(a) Power window switch
(b) Courtssylight
(c) Trim board
(d) Front speakers
(e) Insidehandle
(f) Service hole cover
(g) Weatherstrip
t
ut2n
(h) Door belt moulding
(i) Insidepanelframe
0) Door window upp€rstop
( ) : Lllp (k) Door glass
(l) Window guid6 lower plate
P (m) Window regulator
(n) Door lock with link
(o) Outsidehandlewith door lock cylinder
(p) Outer rear viaw mirror
(q) Tweeterspoaker
(r) Mirror bracket

BO-14
B O D Y- F R O N TD O O R
F R O N TD O O RA S S E M B L Y
A S S E M B L EF R O N TO O O RP A R T SB Y F O L L O W I N GD I S -
A S S E M B L YS E O U E N C E
IN REVERSE
B E F O R IEN S T A L L I NPGA R T SC. O A TT H E MW I T HM P

GREASE
(a) ApplyMP graaseto the glassguideandrollersof the
window regu lator.
(b) Apply MP greaseto the slidingand rotating parts of

the door lock.
INSTALLDOORLOCK
(a) Apply adhesiveto 3 screws.
PartNo.08833-00090. THREEBOND1324
(b) lnstallthe door lock with 3 screws.
T o r q u e : 5 . . t 1N . m ( 5 5 k g f . c m , 4 8 i n . . l b f )
(c) w/ Power Door Lock:
Connect the connoctor.
( d ) C o n n e c t2 l i n k st o t h e o u t s i d eh a n d l ea n d d o o r l o c k
cylinder.
(e) Connec2 t l i n k s c o n n e c t e dw i t h t h o i n s i d eh a n d l e .
w/o Power Window:
INSTALL REGULATORHANOLE
With door window fully closed,installthe plate and
regulatorhandlewith tho snap ring as shown on the
illustratron.

BO-15
B O D Y_ F R O N TD O O R
F R O N TD O O RG L A S SA D J U S T M E N T
1, C H E C KF R O N TD O O RG L A S S
Check the following items. lf the conditionsare not
met, readjustthe glass.
(a) When you closethe door with the glassfully closed,
t h e A - A . B - B s e c t i o n sa r e i n t h e s a m ec o n d i t i o na s
s h o w ni n t h o i l l u s t r a t i o n .
(b) W h e n y o u p u s ht h e g l a s sf i r m l yf r o m i n s i d et,h e g l a s s
s t o p sa t t h e r o o f d r i p m o u l d i n ga n d d o e sn o t m o v e .
(c) When you closethe door with the glassfully closed,
t h e g l a s si s n o t c a u g h ti n t h e o u t s i d el i p o f t h e w e a t h -
erstripand doss not touch the roof drip moulding.
(d) With the door closed,the glassmovessmoothly.
(e) The upper edge of the glass cannot be seen from
outside of the vehicle (edgetouching roof side rail
weatherstrio).
(f) When tho glassrs beingraissd,the glassand roof side
rail weatherstrioare parallel,and th€ front and rear
d o o rw i n d o wu p p e rs t o p st o u c h a t t h e s a m ot i m e .
1 0 6t 1 . 5
BO
( 0 . 4 r 7t 0 . 0 5 9 )
mm(in.)
r ^,-.,u,l

BO-16
B O D Y_ F R O N TD O O R
ADJUST FRONTDOORGLASS
Upper side of glass - in/out
(a) Removethe 2lower plate bolts and lower plate.
(b) Adjust tho glassby turningthe setting nut.
( c ) Rainstallthe lower olateand 2 bolts.
Torque:7.8 l{ m (80 kgf.cm. 69 in..lbf)
( d ) In cas6the glassdoes not fit the mirror bracket:

Loosenthe lower nut of the mirror bracket.Using a
hexagonwrench,adjust the mirror bracketto in/out
directionby turningthe stud bolt.
Torque:7.8N.m(80 kgf.cm,69in..lbf)
Lower side of glass - in/out

( a ) Loosenthe 2 nuts for the window regulator.
/ ( b ) Usinga shim,adjusttha glassto in/out direction.
BO
4lF"- ;H(
{l /,Ta:---__l
b\ Shimthicknoss:
1.0 mm (0.039in.)
;)f--\r^ i 2.0 mm (0.079in.)
tj , ,,,*t,l
Position(lorward/rearward) and attitude of glass

Loosen3 bolts of the carrierplate and adjust.
Torque:7.8 N.m(80 kgf cm, 69 in..lbf)
Its> \
o
Position(vertical)and attitude of glass

(when glass fully closed)
Adjust the door window upperstops.
Torque:5.4 N.m(55 kgf cm,48 in,.lbf)
g o
-:o ^)-.
, - l i r-.*

BO-17
BODY- BACKDOOR
B A C KD O O R
COMPONENTS
W l p e rA r m a n d B l a d e
BackOoorTrim Board
D o o r L o c kS t r i k e r
F-High t t o pL i g h t
M o u . rS
e%,
Door Lock
S'' D o o rL o c kC y i n d e r
uecK rflm n€ar Lover
) z- - \ - , L l
31r2,;
l t l r l ' oL
Nm(kqfcm,ftl : S p e c i f i e dt o r q u s

BO-18
BODY - BACKDOOR
B A C KD O O RA D J U S T M E N T
HINT:Sinceth€ centeringbolt is used the back door
side hingebolt,th€ backdoor cannotbs adjust6dwtth
it on. Substitutethe standardbolt for the centsrino
bolt.
C e n t e r i n gE o l t S t a n d a r dB o l t
1. ADJUST DOORIN HORIZONTALDIRECTION

Adjust tho door by looseningthe back door side hinge
Horizontal
Dir€ction bolts.
R
T o r q u e : 1 4N . m( 1 4 5k g f . c m 1, 1 f t . l b f )
2. ADJUSTDOORIN VERTICAL DIRECTION

(a) Removeth6 roofheadlining.(SeepagesBO-68 ro BO
-701
BO (b) Loosenthe bodysidehing6nutsand adjustthe door
by increasing
or decreasing
the numberof the shims.
T o r q u e : 2 1N . m( 2 1 0k g f . c m 1, 5 f t . l b f )
(c) Reinstallthe removed parts in tho reverseorder to
their removal.
3. ADJUST DOORLOCK
(a) Removeth€ dock trim rear cover.
(b) Adjust th6 lock positionby slightlylooseningthe lock
mountingbolts, and hitting the lock with a hammer
and brassbar.
CAUTION: Oo not tap the locktoo hard.
( c ) Installthe deck trim rsar cover.

BO-19
BODY- BACKDOOR
BACKDOORDAMPERSTAYREMOVAL
1 0 0m m ( 3 . 9 4i n .) ANDINSTALLATION
STAY
DAMPER
1. REMOVE
N O T I C E :W h e n h a n d l i n gt h e d a m P e r .
e D o n o t d i s a s s e m b l teh e d a m P e rb e c a u : et h e c y l i n d e r
H o l eH e r e is tilled wirh prossurizodgas.
o l f t h e d a m p e ri s t o b e r e p l a c e d d , rilla 2.0 - 3.0 mm
(0.079 - 0,118 in.) hole in the bottom ot tho ro'
moved damper cylinder to complEtely 7el9o36tho
high - pressure gar before disposing of it.
. W h e n d r i l l i n g ,c h i p s m 8 y f l y o u t 8 0 w o r k c a r e t u l l y .
r T h e g a s i s c o l o r l e s so, d o t l e s sa n d n o n - t o x i c .
. W h e n w o r k i n g , h a n d l et h e d a m p e r c a r e f u l l y .N e v e r
scoro or scralch tho oxpored part of thg Piston rod,
and ngver allow paint of oil to gst on it'
. Do not tuin tho piston rod and cylinder with tho
d a m p e rf u l l y e x t e n d o d '
2. INSTALLDAMPERSTAY
to the boltsbeforetightening.
Applyadhesive
Port No. 08833 - 00090 or equivalont
T o r q u e : 8 . 8N . m ( 9 0 k g f . c m , 7 8i n . ' l b f )

BO-20
B O D Y- W I P E RA N D W A S H E R
W I P E RA N D W A S H E R
COMPONENTS
FrontWipcr
W i p e rA r m a n d B l a d e
CowlTopVentilator
Louver
WiperN4otor
I
?I
W i p e rL i n k
tN:m (ksGF;ftlEitl : specified

torque

BO-21
(Cont'd)
COMPONENTS
R e a rW i p e r
BackDoorTrimBoard
N m ( k g fc m , f t l b f) ; S p e c i f i e dt o r q u e

BO-22
BODY - WIPERAND WASHER
F R O N TW I P E RM O T O RA N D L I N K
ASSEMBLY REMOVAL
1. POSITION W I P E RA R M
For easy removal of the wiper arms, operato tho
wipers and turn the ignition switch OFF when the
wiper arms are about half-way on the downward
swe€p.
(a) Front wiper arm
(b) Cowl top ventilatorlouver
3. REMOVE FRONT WIPER MOTOR AND LINK AS-
SEMBLY
(a) Remove6 bolts of the wiper link.
(b) Disconnectths connoctor,then loosen4 bolts of the

motor.
(c) Clip the claw of the wiper link on to the panel.
r,-q,ff- (d) Disconnectthe motor from the wiper link and remova
the motor.
\
N1]zt
(e) Removethe wiper link throughthe servicehole.

BO-23
F R O N TW I P E RM O T O RA N D L I N K
ASSEMBLYINSTALLATION
1. INSTALL W I P E RM O T O RA N DL I N KA S S E M B L Y
(a) Placethe linkthroughthe servicehole.
(b) lnstall6 boltsof rhe link.
(c) Clip the claw of th€ wiper link on to the panel.

(d) Connectthe motor to the wiper link.
(e) Tighten4 bolts.
2. INSTALL COWL TOP VENTILATORLOUVER
3. INSTALL FRONTWIPERARMS
(a) Op€ratethe wipers once and turn ths wiper switch
O F F .a n d i n s t a ltl h e w i p e ra r m sa n d b l a d e s
*
N]C?G
(b) Adjust the installationpositionsof th€ wiper arms to

the positionsshown in the figure.
@ Approx.36.1 mm (1.42in.)
@ Approx.20.6mm (0.81in.)
(c) Torquethe nut.
Torque:2l N.m(205kgf cm, 15 ft'lbf)

BO-24
B O D Y_ W I P E R
A N DW A S H E R
NOZZLE
F R O N TW A S H E R ADJUSTMENT
1. I N S P E C TF R O N TW A S H E RN O Z Z L E
While operatingthe washer, check that the point
where tha washer fluid hits the windshieldis within
the rangeindicatedby the hatchedarea.
@ Appror.150 mm (5.91in.)
@ A p p r o x5. 0 m m ( 1 . 9 7i n . )
r N.::'2 @ W i t h i n5 0 m m ( 1 . 9 7i n . )
@ Approx.425 mm (16.73in.)
@ Appror.250 mm (9.84in.)
(D Approx.100 mm (3.94in.)
@ Approx.260mm (10.24in.)
2. ADJUST FRONTWASHERNOZZLE
2-2.5mm
( 0 , 0 7 9- 0 , 0 9 8i n ) Usinga tool like that shown in the figure,changethe
directionof ths nozzlohole to adjustthe point whero
ao w a s h e rf l u i ds t r i k e st h e w i n d s h i e l d .
0 , 7 - 0 . 75 m m
( 0 , 0 2 8- 0 . 0 3 0i n ,)

BO-25
!:;= 14 clps REARWIPERREMOVAL

1, REMOVE R E A RW I P E RA R M
2. REMOVEBACKDOORTRIMBOARD
3. REMOVEREARWIPERMOTOR
{a) the connector,
Disconnect then loosen3 bolts'
(b) Removethe motor.
REARWIPERINSTALLATION
1. INSTALL FOLLOWINGPARTS:
(a) Rearwiper motor
(b) Back door trim board
2. INSTALLREARWIPERARM
(a) Operatethe wiper oncs and turn the wiper switch
O F F ,a n d i n s t a l tl h e w i P e ra r m .
(b) Adrust the top of tha wiper bladeto the installation l$iff
mark printedon th6 glass.
(c) Torquathe nut.
Torque:5.4 N'm (55 kgf'cm.48in. lbf)
ADJUSTMENT
NOZZLE
R E A RW A S H E R
1. I N S P E C TR E A RW A S H E RN O Z Z L E
While operatingthe washer, ch€ck that the point
where the washer fluid hits th€ back door glass 's
within tho rangeindicatedby the hatch€darea'
@ Approx.50 mm (1.97in.)
@ Approx.200 mm (7.87in.)
O Approx'I 04 mm (4.09in.)
2. ADJUST REARWASHERNOZZLE
(Seestep 2 on FRONTWASHERNOZZLEADJUST-
MENT)

BO-26
B O D Y_ R O O FD R I PS I D EF I N I S HM O U L D I N G
R O O FD R I PS I D EF I N I S HM O U L D I N G
COMPONENTS
R o o tD r i p S i d e F i n i s hM o u l d i n g
R o o fS i d eR a i l
WeatherstripRetainer
BO
R o o fS i d e R ai l W e a t h
a O u t s i d eG ar ni s h S e a l
F r o n tP i l l a rL o w e rG a r n i s h
I N o n - r e u s a b l pe a r t

go-27
REMOVAL
1. REMOVEFRONTPILLARLOWERGARNISH
2. REMOVEROOFSIDE RAIL WEATHERSTRIP

Usinga clip romover,remove5 clipsof the weatherst-
rio and removethe woatherstriP.
3. REMOVE ROOF SIDE RAIL WEATHERSTRIPRE-
TAINER
Remove3 screwsand the retainer.
4. REMOVEROOFDRIPSIDE FINISHMOULDING
RemoveI screws and the moulding.
lBO
INSTALLATION
1. INSTALLROOFDRIPSIDEFINISHMOULDING
Installth€ moulding with 8 screws.
2. INSTALLROOF SIDE RAIL WEATHERSTRIP RE.
TAINER
lnstallthe retainerwith 3 screws.
3. INSTALLOUTSIDE GARNISH SEAL

Installths garnish to
seal th6 as shownin tho
retain6r
illustration.

BO-28
1 Om m ( 0 . 3 9 i n . )o r m o r e 4. APPLY SEAL PACKING

A p p l y s e a l p a c k i n gt o t h e m o u l d i n ga n d r e t a i n e ra s
T: 3 mm (0,12 in,)or more
PartNo.08826- 00080
{ u . / Y I n . JO r m o r e
5. INSTALL ROOFSIDERAIL WEATHERSTRIP

(a) Installthe butyl tape to the weatherstripas shown in
the illustration.
(b) Installth6 weatherstrip.
6. INSTALL FRONTPILLARLOWERGARNISH
Bu t y l T a p e
BO

BO-29
B O D Y- W I N D S H I E LM
DO U L D I N G
W I N D S H I E LM
DO U L D I N G
COMPONENTS
O u t s i d eM o u l d i n g
iBo
Cowl Top VentilatorLouver
tN"n (ktft|r', ftlbfl] : Speciliedtorque

BO-30
B O D Y_ W I N D S H I E LM
DO U L D I N G
W I N D S H I E LM REMOVAL
DO U L D I N G
1. REMOVE F O L L O W I NP
GA R T S :
(a) Wiperarm
(b) Cowltop ventilatorlouver
2 . R E M O V EW I N D S H I E L D
MOULDING
(a) Usinga knife,cut off the mouldingas shown.
(b) Cut away the adhesiveat the moulding installation
areaas much as possible.
NOTICE; Do not damagethe bodywith the knife.
W I N D S H I E LM
DO U L D I N G
INSTALLATION
1. C U T A D H E S I V EA T M O U L D I N G I N S T A L L A T I O N
BO AREA
Usingthe knife,cut off the adhesivearoundtho mou-
lding installationarea.
2. APPLY ADHESIVEAT MOULDINGINSTALLATION
AREA
3, INSTALLWINDSHIELDMOULDING
Placelhe mouldrngonto tha body and tap it by hand.
4. INSTALL FOLLOWINGPARTS:
(a) Cowl top ventilatorlouver
(b) Wiper arm
Torque:21 t{.m(205kgf'cm, 15 tt.lbf)

BO-31
B O D Y_ W I N D S H I E L D
WINDSHIELD
COMPONENTS
l nn e r R e a rV i e w M i r r o r
----€F tl
a Slopper -- -
@
G>-----a Stopper
a O u t s i d eM o u l d i n g
Windshield
I Dam
F
\ 2 tio
Spacer
*:-frr,.-";.1
F r o n tr r l l a r u a r n t s nF { n
W i p e rA r m a n d B l a d e F r o n tP i l l a rG a r n i s hL H
F r o n tP i l l a r
F r o n tP i l l ar Lower Garnish LH
L o w e rG a r n i s hR H
Cowl Top VentilatorLouver
N m (kgf cm, ft lbf) : Specifiedtorq ue

an

BO-32
B O D Y- W I N D S H I E L D
W I N D S H I E LR
DE M O V A L
1. REMOVEFOLLOWING PARTS:
(a) Innerrearview mirror
(b) Sunvisorand holder
(c) Frontpillarlowergarnish
(d) Front pillargarnish

(e) Hood
(f) Wiper arm
(g) Cowl top ventilatorlouver
2. REMOVW E I N D S H I E LM
DO U L D I N G
Usinga knife,cut off the mouldingas shown.
NOTICE: Oo not damage the body with the knif€.
3. REMOVEWINDSHIELDGLASS
(a) Push pranowire throughfrom the interior.
(b) Tie both wire ends to a wooden block or similar
object.
HINT: Apply adhesivetape to the outer surfaca to
keepthe surfacefrom beingscratched.
N O T I C E :W h e n s e p a r a t i n gt h o g l a s s , t a k a c a r e n o t t o
d a m a g at h e p a i n t a n d i n t o r i o ra n d o x t o r i o ro r n s m e n t s .T o
p r e v o n t s c r a t c h i n gt h g i n s i r u m s n t p a n a l w h e n r e m o v i n g
t h e w i n d s h i e l d ,p l a c e a p l a s t i c g h a e t b e t w s e n t h g p i a n o
w i r e a n d i n s t r u m o n tp a n g l ,
(c) Cut th€ adh€siveby pulling the piano wire around it.
(d) Remove the glass.
N O T I C E :L e a v e a s m u c h o f t h e a d h e s i v ao n i h e b o d y o s
p o s s i b l ew h a n c u t t i n g o t f t h e g l a s s .

INSTALLATION
WINDSHIELD
z
\ \ /
6"-" 1 . C L E A NA N D S H A P EC O N T A C TS U R F A C EO F B O D Y
(a) Usinga knife,cut away any rougharaason ths body.
HINT:Leaveas much of the adhosiv€on tho body as
possible.
(b) Cleanth€ cuttingsurfaceof th€ adhesivewith a piece
of shop rag saturatedin cleaner.
ao4a2o HINT:Evenif alltho adhesivehas beenr€moved,cl6an
the body.
2, CLEAN REMOVEDGLASS
(a) Usinga scraper,removethe adhesivestickingto the
glass.
(b) Cleanthe glasswith cleaner.
NOTICE:Oo not touch tho gllss sfter cloaninglt.
3. INSTALL STOPPERS
(a) Removeadhesivecover from stopper.
(b) Apply 2 stopperswith doublestick tape to tho glass
as shown in the illustration.
L: 14.8mm (0.583in.)
fl$ul-
4, INSTALLSPACERS
(a) Removeadhesivecover from spacer.
(b) Apply 8 spacerswith doublestick tape to the glassas
i g shown in tho illustration.
l<F
o l o@ *
5. POSITIONGLASS
(a) Placeglassin corrsct position,
(b) Check that all contactingparts of the glass rim are
perfectly even and do not mako contact with th€
fasteners.
(c) Placereferencemarksbetweenthe glassand body.
(d) Removetho g Iass.

BO-34
B O D Y- W I N D S H I E L D
6. C L E A NC O N T A C TS U R F A C EO F G L A S S
Using a cleaner,clean the contact surface black-
coloredareaaroundthe entireglassrim.
NOTICE: Do not touchthe glassfaceafter cleaningit.
7. I N S T A L LD A M
I n s t a l lt h e d a m w i t h d o u b l es t i c k t a p e a l l t h e w a y
around tha glass except where the stoppgrsare in-
stallsdas shown in the illustration.
NOTICE: Do not touchthe glass{8ceafter cleaningit.
Ll: 7 mm (0.28in.)
L2: 25 mm (0.98in.)
8. COAT CONTACT SURFACE OF BODY WITH

PrimorM PRIMER'M'
-d'u, Usinga brush,coat th6 contact surfaceon tha body
w i t h P r i m a rM .
NOTICE:
r Let tho primercoatingdry for 3 minutesor more.
rimsrM Adh6sivs
. Do not keepany of tha opgnedprimer M and G for
latgr u8o.
acoo.2BooorI
9, COAT CONTACT SURFACE OF GLASS WITH

PRIMER'G'
(a) Using a brush or sponge,coat tho edge of the glass
and the contactsurfacewith PrimerG.
(b) Beforsths Primerdries,wipe it off with a cleanshop
rag.
NOTICE:Lat tha p?imofcoatingdry for 3 minutesor
mor9.
1 0 . M I X A D H E S I VC
EO A T I N G
NOTICE:
o Be sure that instsllation ol the moulding is finished
within tho adhesive's ussble tims. (See step 2 on
p a g e B O- 7 )
o T h o m i x t u r o s h o u l d b e m a d e i n 5 m i n u t a so r l e r s ,
(a) Thoroughly clean the glass plate and putly spatula
with solvent.

BO-35
( b ) T h o r o u g h l ym i x 5 0 0 g ( 1 7 . 6 4o z . )o f t h e m a i n a g e n t
and 75 g (2.65oz.)of ths hardeningagent on a glass
plateor like object with a putty spatula.
1 1 . A P P L YA D H E S I V E
(a) Cut off tho tip of the cartridgenozzle.Fillthe cartridge
with adhesive.
(b) Load the cartridgeinto the sealergun.
(c) Coat the glasswith adhesiveas shown.
H: 12 mm (0.47in.)
T-A
\na
:-tiii?7i t
1 2 . I N S T A L LG L A S S
(a) Positiontho glass so that the referoncemarks are
l i n e du p , a n d p r e s si n g e n t l ya l o n gt h e r i m .
(b) Usinga spatula,apply adhesiveon ths glassrim

HINT:Confirmthat tho dam is attachedto the body
panelas shown in th6 illustration.
.Y ,&z@
..Y
(c) Use a scraperto ramoveany excessor protruding
adhesive.
sots.
(d) Fastenglasssecurelyuntilthe adhosive

BO-36
13. INSTALL W I N D S H I E LM
DO U L D I N G
Placeths mouldingonto th€ body and installit by
hand.
1 4 . I N S P E C TF O RL E A K SA N D R E P A I R
(a) P6rforma leak test after the hardeningtime has ela-
psed.
(b) Sealany loak with auto glasssealer.
Part No.08833- 00030
1 5 . I N S T A L LF O L L O W I N GP A R T S :
(a) Cowl top ventilatorlouver
(b) Wiper arm
Torque:21 N.m(205kgf.cm,15 tt.lbf)
(c) Hood
Torque:13 N.m(130 kgf.cm,9.4 ft.lbf)
(d) Front pillargarnrsh
(e) Front pillarlower garnish
(f) Sunvisorand holder
(s) Innerrearview mirror

BO-37
B O D Y_ O U A R T E R
W I N D O WG L A S S
W I N D O WG L A S S
OUARTER
COMPONENTS
RoolSidelnn€rGarnish
v" N O€ckTrlmR6arCov€r
e'-
D6ckTrlmSld€Pen€l
:l,Tl::ii-H\\
.**",.,1,:{] RaarSeatback
LockSlrlksr
SldeBall
TrimPanel
Ouarter q.. Woath€rsklp
R€telner
OuarlorWlndowGlalr
8 . 0 ( 8 2 . 7 1i n . l b l )
v'
e'
v
W
FronlOoorScultlnsidePlate a outsldeGsrnlsh
s€81
18 (185,13) Roof Slds Rail W68th6r8klp
<- Peckage
TrayTrlmP8n€l
R€arSeaback
RearSsalCushion
N . m ( k o f c m ,t l : Specified
torqus
part
a Non.reusablo

BO-38
BODY - OUARTER
WINDOWGLASS
O U A R T EW
R I N D O WG L A S SR E M O V A L
( S e ep a g e sB O - 6 9 t o B O - 7 0 )
(a) Packagetray trim panel
(b) Luggagecompartmentmat
(c) Rearseat back
(d) Rearseat cushion
(a) Deck trim r6ar cov6r
(0 Deck trim side panel
(g) Front door scuff insideplate
(h) S p e a k egr r i l l e
(i) Rearseatbackhingeand lock striker
U) Rearseat outer belt floor anchor
(k) Ouartertrim panel
(l) Front seat outer belt shoulderanchor
(m) Roof side innergarnish
2. REMOVEROOFSIDERAIL WEATHERSTRIP
(a) Usingth6 clip remover,remove3 clips from the rear
side of the w€athsrstrip.
(b) Removethe r€ar sido of th6 weatherstripfrom the
16tainer.
Butyl Tape 3. REMOVE ROOF SIDE RAIL WEATHERSTRIPRE-
TAINER
4. REMOVEOUARTERWINDOW GLASS
(a) Push pianowire throughfrom the interior.
(b) Tie both wire ends lo a wooden block or similar
object.
HINT: Apply adhesivetape to th6 ouler surface to
keepthe surfacefrom beingscratched.
NOTICE:When saparatingtho glass,take care not to
damagetho psintand extarior.
(c) Cutthe adhesive b y p u l l i n gt h e p i a n ow i r e a r o u n di t .

BODY - OUARTER
WINDOWGLASS
HINT:Cut the adhesiveareasas shown in the illustra-

tion, leavingthe adhesivewhere the pins are.
(d) Using pranowire as shown in the illustration,cut off

the rest of the adhesive
(e) Removethe g lass.
NOTICE: Leaveas muchof the adhesive on tho bodyas
possiblewhencuttingotf the glass.
OUARTERWINDOWGLASS
z
\ \
6"-"
/
INSTALLATION
1. CLEAN E O N T A CSTU R F A COEFB O D Ym
A N DS H A P C
(a) Usinga knife,cut away any rough aroason the body.
HINT:Leaveas much of tho adh€siv6on the body as
possible.
(b) Cleanthe cuttingsurfaceof the adhesivewith a piece
!o:la2c of shop rag saturatedin cleaner.
HINT:Evenif all th€ adhesivehas beenremoved,clean
the body.
2. CLEAN REMOVEDGLASS
(a) Usinga scraper,removetho adhosivestickingto the
g lass.
(b) Cleanthe glasswith cleaner.
NOTICE: Do not touchtha glassafter cleaningit.
3. INSTALL SPACER
Install 3 spac€rsto th€ body panel by double stick
ta06 as shown in the illustration.
HINT:lt is not nscessaryto installpins to tho glass.
Pins are only used for positioningthe glass on the
orodu ction line.

BO-40
B O D Y- O U A R T EW
RI N D O W
GLASS
4. COAT CONTACT SURFACE OF BODY WITH
P r i m oM
r PRIMER'M'
Usinga brush,coat the contact surfaceon the body
w i l h P r i m e rM .
NOTICE:
. Lot tho primercoatingdry for 3 minutesor moro.
o Oo not kaepany of the openadprimer M and G for
Iatoru3e.
!oooa2l@oa1
5. COAT CONTACT SURFACE OF GLASS WITH

PRIMER'G'
(a) Using a brush or spongs,coat the edge of tho glass
and th€ contactsurfacewith PrimerG.
(b) Beforethe primerdries,wipe it off with a cleanshop
tag,
NOTICE:Let thc primercorting dry for 3 minutesor
mo70.
-@
--.---.<Jt
F'@\
+l \ d
I rto338
6. MIX ADHESIVE
COATING
NOTICE:
. Bc turc thlt Inrtalhtion of thc mouldingit finirhed
within thc adherlvc'r urablo time. (Seoltep 2 on
pagcBO- 7)
o Thc mixturc rhould be madein 5 minutesor legr.
(a) Thoroughlyclean the glass plats and putty spatula
with solvent.
(b) Thoroughlymix 500 g (17,64 oz.)of the main agent
and 75 g (2.65oz.)of tho hardoningagent on a glass
platoor similarobject with a putty spatula.

BO-41
BODY_ OUARTER
WINDOWGLASS
7, APPLY ADHESIVE
(a) Cut off the tip of tho cartridgenozzle.Filltho cartridg€
with adhesivs.
(b) Load the cartridgeinto tho sealergun.
(c) Coat the glasswith adhesiveas shown.
H: 12 mm (0.47in.)
B.B
_Nt
#t
d
-l
\_:t
r
___ffi
\
\
8. INSTALL OUARTERWINDOW GLASS

(a) Installtho glassto the bodY.
HINT: First fit tha glassto the mouldingand then to
the body panelas shown in tho illustration.
(b) Use adhesivetape to koepthe glasstight againstthe
body.
9. INSPECTFOR LEAKS AND REPAIR
(a) Performa leak test after ths hardeningtim€ has 6la-
psed.
(b) Sealany leak with auto glassseal6r.
Prit No. 08833- 00030
10. INSTALL REMOVEDPARTSIN REVERSE ORDERTO
REMOVALORDER
(a) Installthe garnishsealto the retainaras shown in the
illustration.
1Omm (0.39 in.) or more (b) Applysealpackingto the mouldingand retainoras

shownin the illustration.
T : 3 m m ( 0 . 1 2i n . ) o r m o r e
Parl No.08826-00080
{ 0 . 7 9 i n .) o r m o r e

BO-42
B O D Y_ B A C KD O O RM O U L D I N G
ANDGLASS
B A C KD O O RM O U L D I N G
ANDGLASS
COMPONENTS
O u t s i d eM o u l d i n g
\
oW*:
BackDoor Glass
B a c kD o o r T r i m B o a r dU p p e r
BackDoorTrimCover
II
B a c kD o o r T r i m B o a r d
l N m ( k g i c m , f t l b f )| : S p e c i f i etdo r q u e

BODY - BACKDOORMOULDINGAND GLA!!
REMOVAL
1. REMOVE R E A RW I P E RA R M
2. REMOVE B A C KD O O RM O U L D I N G
(a) Usinga cut off the mouldingas shown.
knife.
(b) Cut away the adhesiveat the mouldinginstallation
areaas muchas Possible.
N O T I C E :D o n o t d a m a g ot h a b o d y w i t h t h e k n i t e .
INSTALLATION
1 . C U T A D H E S I V EA T M O U L D I N GI N S T A L L A T I O N
AREA
Usingthe knife,cut off the adhesive aroundthe mou-
ldinginstallation area.
2. APPLY ADHESIVE AT MOULDINGINSTALLATION
AREA
3. INSTALLBACKDOORMOULDING
Plac6the mouldingontothe bodyandtap it by hand'
4. TNSTALL REARWIPERARM ,Bi
T o r q u e :5 . 4 N m ( 5 5 k g f c m , 4 8 i n " l b f ) BO
B A C KD O O RG L A S SR E M O V A L
1, D I S C O N N E CD TE F O G G E R CONNECTOR
, crio {a) B a c kd o o rt r i m b o a r da n d b o a r du p p e r
[-]
i'r : Clip (b) Back door trim cover LH and RH
(c) Rearwiper arm
3. REMOVE B A C KD O O RM O U L D I N G
Usinga knife,cut off the mouldingas shown.
t r l O T l C ED: o n o t d a m a g et h o b o d y w i t h t h a k n i f e .

BO-44
B O D Y- B A C KD O O RM O U L D I N G
ANDGLASS
4. REMOVEBACK DOORGLASS
H I N T :R e m o v et h e g l a s si n l h e s a m e m a n n e ra s t h e
quarter window glass. Cut the adhesivear6as as
shown in the illustration,leavingthe adhesivewhere
t h e p i n sa r e .( S e ep a g e sB O - 3 8 a n d B O - 3 9 )
BACKDOORGLASSINSTALLATION
H I N T : I n s t a l lt h e g l a s s i n t h 6 s a m o m a n n o ra s t h 6
q u a r t € rg l a s s (. S e ep a g e sB O - 3 9 t o B O - 4 1 )
1. INSTALLSTOPPERAND PIN
Positioningat marks printed on the glass. install 8
-4 stopp€rs and 2 pins with double stick tap6 to the
BO,
@ f\ tr lm
J/
\ g rass.
S,,/
\/
2. INSTALLBACKDOORGLASS
(a) Coatcontactsurfaceof tho glasswith primer'G'.
L: 7 mm (0.28in.)
(b) Apply adhesive.
3a^
+ 3.
H: 12 mm (0.47In,)
L : 3 m m ( 0 . 1 2I n . )
INSTALLREARWIPERARM
? Torquc:5.4 N.m (55 kgf.cm,48 in..lbf)
4, CONNECT DEFOGGER CONNECTOR
5. INSTALLFOLLOWING PARTS:
(a) Backdoortrim coverLH and RH
(b) Backdoortrim boardand boardupper

BO-45
B O D Y_ S L I D I N G
ROOF
S L I D I N GR O O F
COMPONENTS
S l i d i n gR o o fG l a s s
Shim
F r o n tG a r n i s h
R e a rG a r n i s h
Wind DeflectorPanel
S l i d i n gR o o f P a n e lS t o p p e r
.BO
S un s h a d eT r i m
GuideBlock--- -#
D r i v eR a i l
R o o f D r i p C h a n n eI
C a b l eG u i d e
-S l i-d i nv gR--o o f
-dr- P an e l S t o P P e r
D r i v eG e a r D r i v eR a i l
f s-rrrJ-.1fi]rst_l----,,------d
S l i d i n gR o o fC o n t r o lR e l a y
rt 5.4(55,18in.lbf)
N'm (kqf cm, ft lbf) : S p e c l f i e dt o r q u e

* P r e c o a t e dp a n

BO-46
B O D Y_ S L I D I N GR O O F
C O M P O N E N T (SG o n t ' d )
Sliding
RoofHousing
RootHeadlining
Opening| f l m
?-Stopper
S€atback
LookStriker
-fi-Rear
-ts,,5
w. PackageTrayTrim Panel
BO
{lto'o"n'"n'u"'
lnn6rGamish 8.0 (82.71in.

R€ar Soalback
ai-cjs,14f
Rear S€at Cushion
Fronl SeaI
Outer Bell OeckTrim Side Panol
F,onrPilla,- fl
' 6 0
Lowef
uarnlsn U Seat
Outer
B€lt
fi-near
W l
SpoakerGrillo
-ro---l
43 (440,32)
Quad€r rirnPangl
FrontDoorScull
lnsidePlale
N . m . c m .l t . l b f : specilied lofque
I rtt282

BO-47
INSPECTION
ON_VEHICLE
R O O FG L A S SA L I G N M E N T
I N S P E CSTL I D I N G
(a) Startthe engineand checkthe oparation timo of the
sliding roof.
O D o r a t i o nt i m e :
Appror. 6 secs.
( b ) C h e c k f o r a b n o r m a ln o i s eo r b i n d i n gd u r i n go p e r a t i o n .
(c) With the sliding roof fully closed. check for wator
leakage.
( d ) C h e c k f o r a d i f f e r e n c ei n l € v € lb e t w e e n t h e s l i d i n g r o o f
w6atherstrip and roof panel.
Front 9nd:
011.5 mm (0t0.059 in.)
R e a re n d :
0 t 1. 5 m m ( 0 + 0 . 0 5 9 i n . )
lf the slidingroof does not op€rats:

(e) Rsmoveths controlswitch cover.
(f) Removethe largescrew inside.
(g) Manuallyoperatoth€ slidingroof by inserting" ."r"*- ffH$""
driverinto the hole and turningthe drive shaft.
S L I D I N GR O O FA D J U S T M E N T
1. REMOVE SLIDING R O O FG A R N I S H E S
Beforemakingadjustments, removethe left andright
slidingroof garnishes.
HINT:After adjustment,reinstallth6 slidingroof gar-
nrshes.
2, TO ADJUSTLEVELDIFFERENCE
or decreasing
Adjust by increasing the numberof
shimsbetweenthe bracketand slidingroof.

BO-48
3. TO ADJUSTFORWARD OR REARWARD
(a) Adjustby loosening nuts,
tho slidingroof installation
and moverheslidingroofbracketforwardsand back-
wards.
(b) When the front or rear alignment is not correct,

r€mov3the glassand adjust th6 drive rail.
(c) Using a screwdriver,slide the link forwardsor back-
wards to alignths marks as shown.
;.6d'
4. TO ADJUSTRIGHTOR LEFT
Adjustby looseningthe slidingroof glassinstallation
nuts,and mov6the slidingroofto tho rightand left
m
-2r+--
5. TO ADJUSTCLEARAITICE
(Difforcncr In leli rnd rlght clearonco)

BO-49
B O O Y- S L I D I N GR O O F
Adjustby loosening nuts

the slidingroof installation
and readjustthe slidingroof to the proporposition.
-
I r aI
t t
|I ll l l ll l t
\ ll..-)ll
S L I D I N GR O O FR E M O V A L
( - ) T E R M I N A LC A B L E
1 , D I S C O N N E CNTE G A T I V E
FROMBATTERY
2, REMOVESLIDINGROOFGARNISHES
removstha followinggarnishes.
Usinga screwdriver,
tip beforeuse'
HINT:Tapea screwdriver
(a) Sidegarnish
(b) Frontandreargarnish
3. REMOVESL]DINGROOFGLASS
(a) Remove4 screws.
r-] : oip (b) Pullthe glasEupwardsto romoveit.
1. REMOVEROOFHEADLITTIING
(Soepager BO- 69 to BO- 70)
(a) Slidingroof controlrelay
(b) Drivegear
(c) Roofdripchannel
(d) Wind deflectorpanel

BO-50
6. R E M O V EC A B L EG U I D EC A S I N GA S S E M B L Y
(a) Slidethe drive cableforwards.
(b) Remove12 screws.
(c) Apply adhesivetape to prot6ctthe body.
r t:
(d) Pull the cable guide casing assembly forward to

remove.
SLIDING
R O O FD I S A S S E M B L Y
s6 (a) Slrdingroof panelstopper
( b ) S u n s h a dt e
rim
(c) Cableguide casrng
2, REMOVEDRIVECABLE
(a) Remove2 screwsandthe cableguideblock.
(b) Pullthe drivecablefrom the guiderail.

BO-51
B O D Y_ S L I D I N G
ROOF
R O O FA S S E M B L Y
SLIDING
ASSEMBLE SLIDING BOOFPARTSBY FOLLOWING DIS-
ASSEMBLY SEOUENCE IN BEVERSE
H I N T : W h e n i n s t a l l i n gt h o c a b l e g u i d e c a s i n g ,u s e
butyl tape to cover the cut positionof the woatherst-
ra1e rip at the connactionbetwsen tha guide casingand
S. ,.-ButYl
s- g u i d er ai l .
S L I D I N GR O O FI N S T A L L A T I O N
I N S T A L L S L I O I N GR O O F P A R T S B Y F O L L O W I I { GR E .
MOVAL SEOUENCE IN REVERSE
1 , A D J U S TD R I V ER A I L
(a) Operatethe drive rail to a closedand tilted down
posr on.
slidethe link forwardor rearw"rd ffi
(b) Usinga screwdriver,
to alignthe marksas shown.
2. INSTALL ORIVEGEAR
Point L/arks (a) Removethe screw and cam platecover.
(b) R€movotho largescrew,washersand shims.
(c) Turn the driveshaft by screwdriverto alignthe hous-
ing and gear point mark as shown.
(d) Installthe cam plat6cover with th6 scr€w.

BO-52 B O D Y- I N S T R U M E NPTA N E L
I N S T R U M E NPTA N E L
COMPONENTS
S t e e r i n gC o l u m nC o v e r
Combinatin
o Switch
S t e e r i n gW h e e l
No . 2 C o v e r
@
abr/
SJ F r o n tP i l l a rG a r n i s hR H
w-17 S t e e r i n gW h e e l P a d
^
N o , 3C o v e r
FrontPillarLower
GarnishRH
H g a t e rT o R e g i s t e D
r u c tN o . 2 8 . 8 1 9 0 , 7 8 lI bn f, J
LOWt >toe | flm
F i n i s hP a n e lL o w e r N o . 1 Board RH
'q
C o n s oPl a n eU
l pper FrontDoorScutf
I n s i d eP l a t 6R H
Register
L o w e rN o . 1
-j?@
ConsoleBox Carp€t
F u s eB o x O p e n i n gC o v e r
F r o nP i l l a rL o w e r
G ar n i s hL H
F r o n tP i l l ar G a r n i s hL H
Box
Console
Front Door Scuff Inside Plate LH
N ' m ( k q f. c m , t t . l b f ) : S p e c i l i e dt o r q u e

BO-53
B O D Y- I N S T R U M E NPTA N E L
C O M P O N E N T (SC o n t ' d )
C o w l T o p l nn e r B r a c e
B r a k eS p r i n g e r a k eSt up p o r t
r onsolB
C e n t eC
\t
S t e e r i n gC o l u m n
NozzlN
e o.2
I n s i r u m e nPt a n a l
ControlAssorn
Ay'C bly
t a n e lB o x
l n s t r u m a nP
'k
@I
C om b i n a t i o nM e t a r
I
GloveComponmontDoor
f i ni s hP a n e l
*fficru*e'Finish
g -.6@
C l u s t €Fr i n i s hP a n 6C
l antor
l"/
\a,u.,", F i n i s hP a n e lL o w e r
R e g i s t eN
r o.'l
. m { k q f . c m ,f t ' l b t ) : S p e c i f i e dt o r q u e
Nlll53

BO-54
(Cont'd)
COMPONENTS
r o z z l eG ar n i s h
D e f r o s t eN Pi
\d
Pin Side DetrosterNozzleDuct No.2

"9X
DefrosterNozzle
HeaterTo Rigister
Side DefrosterNozzleDuct No. l D u c tN o . 2
r u c tN o . l
H e a t e rT o R e g i s t e D
l n s t r um e n t P a n e l
N4ounting Bracket
No.1
t a n e lW i r e H a r n e s s
l n s t r u m e nP
Si d e N o z 2 l eN o . 1
/,1 @
\lJ'| Register
l n s t r u m e nP
t anel

B O D Y_ I N S T R U M E NPTA N E L
HINT:Bolts,nuts and screwsin ths illustrationon the

previouspagosarg indicatedusingthe code belowfor
removaland installationof instrumsntpanel.
mm (in.)
Size Shap€ Shape Siz€

Shape
8
(0.24) (0.31)
@ @ @ (0.31)
L= 20 22
(0.79) (0.98)
5.22
(0.20) (0.20551
@ \0.24)
14 @
16
(0.63)
8 l: 5.22
(0.31) (0.20) (0.20ss)
@ 15
@ o
(0.59) (0.ss) (0.79)
lle-o.
4.5
(0.177)
o
t ro::to

8O.56
I N S T R U M E NPTA N E LR E M O V A L
( - } T E R M I N A LC A B L E
1 , D I S C O N N E CNTE G A T I V E
FROMBATTERY
2. REMOVESTEERING WHEEL
(SeoSR tection)
CAUTION:
r Whcn rtorlng iho whool p8d, koop tho upper rurface
of th. prd faclng upward.
o Nevcr dberremblc thr .tooring wheel pad.
HINT:Tapea screwdriver tip beforeuse.
(a) Frontpillarlowergarnish
ir''6Noii
(b) Frontpillargarnish
(c) Frontdoorscuffinsidoplate

BO-57
(d) Cowl side trim board
(e) Steeringcolumn cover
(f) ConsolepanalupPer
(g) Consolebox
(h) F i n i s hp a n € l o w € r N o . 1
(i) Finish panel
(j) H6aterto registerduct No.2
(k) Combinationswitch
(l) Clusterfinish panellower

BO-58
(m) Clusterfinish panel
\\
\\
\\\
(n) Regist6rNo.1
(o) Combinationmstsr
(p) Clusterfinish panelcenter

(q) Audio receiverassembly
iid6'''
4. REMOVEA/C CONTROLASSEMBLY
(a) Disconnecttho cab16to the air mix damDercontrol.
(b) Disconnectth€ cableto the watsr valve in the engine

compartmont.
(c) Remove2 screwsand the A/C control assembly.

5. REMOVEINSTRUMENTPANELBOX
(SeeRS section)
HINT:Tape a screwdrivsrtip beforeuse.
(a) Remove the glove compartment door finish plate
insid€th€ instrumontPanelbox.
NOTICE: take care
Whanhandlingtho Eirbagconnector,
E- not to damage lho Eirbag wire harness'
(b) Pull up and disconnectthe airbagconnector.
(c) Removatho instrumentpanelbox.
(d) Removetha lower pad insert LH and RH
(a) Finishpanellow6r centor
(b) SidedefrostornozzleNo.2
(c) Steeringcolumn(4 nuts and 1 bolt)
'go
7. REMOVE I N S T R U M E NPTA N E L
nectthe connectors.
(a) Discon
pan6l.
(b) Rsmove2 nuts,7 boltsandthe instrument
I N m (kgl.cm,tl.lbl) : SpociliodTofqug

BO-60
8. REMOVECENTERCONSOLEBRACKETSUPPORT
(a) Removea bolt,2 nuts and the centerconsolebracket
N o . 1.
(b) Rsmovea bolt, a nut and the instrumsntpanelbrace
No.2.
(c) Removea brakespring,6bolts,3 nuts,and tho c€nter
consolebrackatsupport.
(d) Rsmovea bolt, 2 nuts and the cowl too inner brace.
I N S T R U M E NPTA N E LD I S A S S E M B L Y
(a) Defroster nozzlegarnish
(b) Defrosternozzle
(c) Sidedefrosternozzleduct No.1 and No.2
(d) Strikerplate
(e) Heat€rto registerduct No.1
(f) InstrumentpanelmountingbracketNo.1
(g) InpaneJ/B and bracket
(h) Pin
(i) SidedefrosternozzleNo.1
(j) R6gist6rNo.2
BO 2. REMOVEFOLLOWINGPARTS:
(a) H6aterto registerduct No.3
(b) RadiomountingbracketNo.2
3. REMOVEINSTRUMENTPANELWIRE HARNESS

BO-81
I N S T R U M E NPTA N E LA S S E M B L Y
ASSEMBLE PANELPARTSBY FOL-
INSTRUMENT
LOWINGDISASSEMBLY IN REVERSE
SEOUENCE
I N S T R U M E NPTA N E LI N S T A L L A T I O N
INSTALL INSTRUMENTPANEL PARTS BY FOr-'
LOWING REMOVALSEOUENCEIN REVERSE
HINT:When installingth€ A/C controlassembly,refer

to page AC- xx.
TOROUEFOLLOWINGBOLTS:
(a) Steeringcolumn
(b) Steeringwheel
Torque:34 N.m (350 kgf'cm, 25 ft.lbf)
(c) Steeringwheel pad
Torque:9,0N.m(92 kgf.cm,80in.'lbf)
lBo

BO-62
B O D Y_ F R O N S
T EAT
F R O N TS E A T
COMPONENTS
BO
SeatTrackCover
S e a tT r a c kC o v e r
N m (kgl cm. ft lbf) | r Specified tofque

BO-63
BODY _ FRONTSEAT
(Cont'd)
COMPONENTS
H e a d r e sStu p p o r t
S e a tC u s hi o n C o v e r
-T'HosRins
''ii'd
S e a tC u s h i o nP a d
S e a tC u s h i o nF r am e
F r o n tS e a tC u s h i o n
I n n e rS hi e l d
F r o n tS e a tC u s h i o nI n n e rS h i e l d
L-111119.1?l R e c l i ni n g A d i u s t e rl n s i d eC o v e r
F r o n tS e a t
I n n e rB e l t
S e a tA d j u s t e r
)),7 \ u/a- Rerease

Reclrnins
. L4t Handle
"
@--verticat A d i u s t eK
r nob
N m l k g i c m , f t l b f ) : S p e c i f i e dt o r qu e
a N o n - r e u s a b lPe art

BO-64 BODY- REARSEAT
REARSEAT
COMPONENTS
ub
fl
8 . 0 ( 8 2 ,7 ' l l n . l b f )
N m ( k g fc m , f t l b f) : S p e c iife d t o r q u e

BO-65
BODY_ REARSEAT
(Cont'd)
COMPONENTS
SeatbackBoard
6\-'
lsLJ- LockEezel
L o c kB e z e l
I
-a I
*.r-,
-@ a rglj
' . @
SeatbackLock
KnobHotder
S-t_oct
S e a t b a c kP a d
.n
{
)) Knob
fr-Lock
K n o bH o l d e r
"$? Seatback
\)
-(t
d'
1 9{ 1 9 5 1
, 4)
Locr-)
Seatback
"A:'*
HosRins =]
-tr
e'
fc(G,r.rl
S e a tC u s hi o n P a d
N m (kgi cm, ft lbf) : S p e c i f i e dt o r qu e


BO-66
EODY_ SEATBELT
SEATBELT
COMPONENTS
FrontS6atOut€rB€ll
FrontS€atInnsrB€lt
'@--l-$r_..o,rzl
N m (kgf'cm,lt lbf) : Spsclfl€d

torqu€

BO-67
BODY _ SEATBELT
SEATBELTINSPECTION
EmergencyLockingRetractor(ELR)type
T E S T( I NS A F EA R E A )
1, RUNNING
(a) Fastenthe front s€at b6lts.
( b ) D r i v et h e c a r a t 1 O m p h ( 1 6 k m / h ) a n d m a k e a v e r y
hard stoo.
(c) Checkthat the b6lt is lockedand cannot ba extondod
a t t h i st i m e .
HINT:Conductthis test in a safe aroa.lf the belt doos
not lock. rsmov€ the belt mechanismassemblyand
conduct the following static check. Also, whenever
installinga naw belt assembly,verify the properopor-
ation boforeinstallation.
2, STATIC TEST
(a) Verify that the belt lockswhen pulledout quickly'
(b) Removethe lockingrotractorassembly. mffi
(c) Tilt th€ retractorslowly. ffi'
**"
(d) Verify that the belt can be pulled out at a tilt of 15
degreesor less,and cannot be pulledout at over 45
degreesof tilt.
lf a problemis found, replacethe assembly'

BO-68
B O D Y- R O O FH E A O L I N I N G
R O O FH E A D L I N I N G
COMPONENTS
RoolHeadlining
Op€nin9Trim
-r--StoPPer
BearSeatbackLookSlriker
19 (195,14)
PackagoTrayTrimPanel
l-,nn,:1""'o"n'"
CoatHook
Inn€rGemlsh 8.0 (82,71in. lbl)

RearSeatback
Tir-iiGl4f
RoarSealCushion
FrontSEat
Oul€rB6lt DeckTrimSidePanel
----ffi1=-0""*r.,.n
/
FtonrPtttae-------/// Rearcover
Garnlsh "\NN'
I Cr-.2
N
Insid€ Plat€
N . m ( k o f . c m f, t . l b f : Specified iofque

BO-69
B O D Y- R O O FH E A D L I N I N G
R O O FH E A D L I N I NR
GE M O V A L
(a) P a c k a g et r a y t r i m p a n e l
(b) Luggagecompartmentmat
(c) Rearseatback
{d) Rearseat cushion
(e) Deck trim rear cov€r
(f) Deck trim side panel
1\'
/ l P
( g ) F r o n tp i l l a rl o w e rg a r n i s h
( h ) F r o n tp i l l a rg ar ni s h
(i) Front door scuff insideplate

(j) Speakergrille
(k) Rearseatbackhingeand lock striker
(l) Rearseat outer belt floor anchor

BO-70
B O D Y- R O O FH E A D L I N I N G
(m) Ouartertrim panel
(n) Front seat outer belt shoulderanchor
(o) Roof side inner garnish

(p) Controlswitch and cover
(q) Innerrear view mirror
(r) Sunvisorand holder
2 . REMOVEROOFHEAOLINING
(a) Remove3 clipsand 2 stoppers.
r-'l !
! : Fastn€r
(b) Removetho roof headlining.
! . ( only lor sliding rool )
.) 1 : Clip
Slidingroot
r ur:9t
R O O FH E A D L I N I NIG
NSTALLATION
INSTALLROOFHEADLINING PARTSBY FOLLOWING
REMOVAL SEOUENCE IN REVERSE
HINT:Torquefollowingparts:
(a) Front seat outer belt shoulderanchorbolt
Torque:43N.m(440kgf.cm.32ft.lbf)
(b) Rearseat outer belt floor anchorbolt
(c) Rearseatbacklock strikerx Body
Torque:19 N.m(195 kgf.cm,14 ft.lbf)
(d) Rearseatbackhingex Body
Torque:8.N 0 . m( 8 2k g f . c m , 7 1i n , . l b f )
(e) Rearseatbackx Rearseatbackhinge

BO-71
B O D Y_ F U E LT A N KA N D L I N E
F U E LT A N KA N D L I N E
COMPONENTS
F u e lT a n kC u s h i o n
g9 I l nl e t
P i p eS h i e l d
FuelTankCap
Gasket
\ \ \
uelInlet
t-N
3 \
Pipe Protector
\,'t t s
'-r
--i-,-t B r e a t h eTr u b e
F u e lI n l e tH o s €
u"",t,o".---..-...-__...--__..-,ko
Evaporation
Fuer ----]
*
a Gasket
--{D i L^,),
/p f
a Gasket
ruer
cutorrvarve___ ={ 6/
] J,fygfi-',",
Gauge-- +':1'=
Fuel Pump and SenderGauoe r-? _=4--_li
---:e l r.iffi-_i###'"
'--- "rt-lg:' t t i
, fuir-
-
-1135' 3
,r)---@ 3 . 5 1 3 5 , 3I n1. l b t ) a.]Y--------.-..-.--.-..-..-.--.ar*,
Assembly
Fuet e,-- -(P'

out i(*l,qi'r9-_-('9---\<' ..)>
Pipe
F u e lT a n k
ClamP---S
\
F u e lR e t u r n
Tube
C l a mp
F u e lT a n kB a n d
N m ( k g l c m ,f t l b f ) : Specifiedtorque
* F o r u s ew i t h S S T

BO-72
E O D Y- F U E LT A N KA N DL I N E
PRECAUTIONS
1. Always use new gasketswhen replacingthe fuel
tank or componentparts,
2. Applythe propertorqueto all partstightened.
F U E LL I N E SA N D C O N N E C T I O N S
INSPECTION
l-Leakage (a) Check the fuel lines for cracks or leakage,and all
connectionsfor deformation.
(b) Check the fuel tank vapor vent syslem hoses ano
c o n n s c t i o nfso r l o o s e n e s s ,h a r pb a n d so r d a m a g e .
(c) Checkthe fuel tank for deformation,cracks,fuel leax-
D € t or m a t i on
a g e o r t a n k b a n dl o o s e n e s s .
( d ) C h e c kt h e f l l l e rn e c kf o r d a m a g eo r f u e l l e a k a g e .
(e) Hoseand tubs conn6ctionsare as shown in the illus-
u s es l I
30Nm tration.
( 3 1 0k g fc m ,2 2 ft.rbf) lf a problem is found, repair or r€placethe part as
3'gb: nec€ssa rv.
Fulcrum
L6ngth
30 cm
{ 11 . 8 1i n . )
S S T: 0 9 6 3 1 - 2 2 0 2 0
zm5
2 - 7 m m ( 0 . 0 8- 0 . 2 8i n . )
0 - 3 m m( 0 - 0 . 1 2i n , )
FU00a1

BO-73
BODY _ SERVICE
SPECIFICATIONS
SPECIFICATIONS
SERVICE
SPECIFICATIONS
TOROUE
P.rt tightsned N m kgf.cm tt.tbt

FRONT
BUMPER
R6intorc6mentx Body t3 9.4
Froni bumporcovar t Body 6.4 48in. lbf
REARBUMPER
Rainforcamsntx Body 96 970 70
Rear bumo€r covar x BodY 5.4 bo 48in..lbt
HOOD
Hood hinoo x Hood l3 130 9.4
Hood lock x Body 1.4 80 89 in..lbt
FRONTDOOR
Door hin€. x Body 2A 290 21
Ooorhing. x Doorp.n.l 2A 290
Door ch.ok r Eody 330 24
Door chack x Door panol 60 52in..lbl
Doorlockrtrikrr x Body 2A 2EO t9

Door lock x Ooor ptnal 5..4 /|8 in..lbt
DoorOlr.. x Windowr99ul.tor 7.8 80 69in. lbf

i,i,Bor:
Window ragulatorr Door panal 5.9 60 52 in..lbf
Window guida towar pllta x Ooor panel 7.8 80 89 in.'lbf
Door window uppor ltop x Door panal 5.4 48in..lbl
Mirrorbr.ckotx OoorP.nrl 7.8 80 69in..lbf
BACKOOOR
B.ck door hing. x Body 21 2to
B.ck door hing. x B.ck door l4 t45
Door lock x Body l9 t95 t4
't9 195 11
ooor lock llrik.r x Back door
Erck door d.mp.r .t!v x Eody 8.8 90 78in. lbf
B.ck door dlmg.r !t!Y x B.ck door 8.8 90 78in. lbf
WIPERANOWASHER
Front Wipor
Wiolr.rm x Wigrr link 2l 206
R... Wiprr
Wigar arm x WiDar motor 5.4 55 48in.'lbf
ROOF
SLIDING
Driv. g.!r r Body 6.4 55 4gin..lbf

BO-74
BODY - SERVICE
SPECIFICATIONS
(Cont'd)
TOROUESPECIFICATIONS
Part tight6n6d N m kgf.cm tt.tbf

INSTRUMENT PANEL
Sto6ringcolumn x Centorconsolebracketsupport 25 280 t9
Stooringwhool x Steorang
column 31 350 25
Steoringwhool pad x Stoaringwheol 8.8 90 78in..lbt
FRONTSEAT
Seat sdjuster x Body 375 21
Soat adlust6rx Seatbsck '18
t85 13
506t adlust€rx Seat cushion t8 t85 t3
REARSEAT
Soatbackhingo LH ond RH x Body 8.0 a2 7l in..lbf
S6etbackhrng€c6ntor x Body t8 195 t3
Seotbackr Soatbackhingo t8 186
Seatbacklock 3trik€rx Eody t9 196 l4
Soatbacklock x Soatback io 195 l4
S€ATEELT
Front S66t Bolt
Out6r bolt shouldoranchor x Bodv 43 40
Outor b€lt tloor lnchor x Body 43 uo
Rotractorx Body (UpporSide) 80 69 in..lbt
R.t6ctor x Body (Low€r Sidel 43 40
'tB'6.l lnnar belt x Seot 43 110 32
R6arS.at Eoll
Outcr b6lt should6rrnchor x Bodv 43 140 32
Outar balt tloor anchor x Eodv 13 4/10
R€trrctor x Body 43 140
Innar balt x Body /13 140
F U E LT A N K A N D L I N K
Fuel tonk bsnd x Body 40 400
Fuel oullot pipa x Fusl pump .nd send6r9rug6 a55€mbly 24 210 17

AC-1
A I R C O N D I T I O N I NSGY S T E M
GENERAD L ESCRIPTION
DESCRIPTION.'... AC- I
PREPARATION AC- 13
G A U G ES E T . . . . . . . . . . . .A. .C
U S EO F M A N I F O L O . - 15
TROUBLESHOOTING . . . . . . . ."." ' A C - l8
REFRIGERAN VT OLUME AC- 25
O R I V EB E L TT E N S I O N . . " . . . " . ' AC- 26
-
tDLE UPSPEED . . " " " " " AC- 27
R E F R I G E R ALNI T NES . . . " . " . . . . . . ' AC- 28
cooLlNG uNlr . . . . . . . . ... "" ' AC- 3l
H E A T E RU N I T AC- 34
BLOWER UNlr . ' . . . . . ' . ' . " ' AC- 38
COMPRESSOR AC- 41
RECEIVER Ac- 58
CONOENSER AC- 60
EVAPORATOR AC- 62
HEATER AOlATOR . . . . . . . . . . . '.. " ' AC- 62
WATERVALVE AC- 63
EXPANSION V A L V E . "
' . ' " . . " " AC- 64
V A C U U MS W I T C H I N V
B L O W EM R OTOR......"'."
GA L V E( V S V ) . . . . . . ' ' ' AC- 65
AC- 67 ffi
E L E C T R IC CO O L I N G FAN . " . " " " " " " ' AC- 68
A I R I N L E TC O N T R OS L E R V O M O T O R . " . . "A . .C - 7 0
A I R O U T L E TC O N T R O S L E R V O M O T O R . . . . .C A . - 71
BLOWER RESISTO " .R. . . . . . '
P R E S S U RSEW l r C H . . . . ' . . . ' . " AC- 74
. . .
E V A P O R A T OTRE M P E R A T U RSEE N S O R A C - 7 6
R E V O L U T I ODNE T E C T I NSGE N S O R" . . . . " . AC- 17
R E L A Y. ' . . . . . . . . . . AC- 78
A I RC O N D I T I O N E AR
MPLIFIER AC- 80
A I RC O N D I T I O N ECRO N T R O L
ASSEMBLY AC- 82
S E R V I CS EP E C I F I C A T I O N S Ac- 89

AC-2
SYSTEM_ GENERALDESCRIPTION
AIR CONDITIONING
,_t,
",'li
G E N E R AD
L ESCRIPTION
zr"
U l t r a v i o l e tR a y s \ NEWAIR CONDITIONING
SYSTEMWtTii."
HFC134a
Refrigerant CFC 12 (R 12), previously used in
automobil6s'airconditioningsystems is believedto
contributs towards the deoletionthe earth's ozone
layer.The ozonelayer help to protect us againstthe
harmfulultravioletravs of the sun.
A newly developedrefrigera nt, H F C13 4 a ( R 1 3 4 a ) ,

does not the destroythe ozonerayer.
"
PRECAUTION FSO RS E R V I C I NH
GF C l 3 f d
R1 3 4 a A I RC O N D I T I O N I N G S
A/C SYSTEM
1. U S EO F N E W R E F R I G E R A NHTF C l 3 4 a
The very differentcharacteristics of refrig6rants
H F C 1 3 4 aa n d C F C l 2 h a v ed o t e r m i n e d t h e d e s i g no f
their r€spectiv6air conditioningsystgms.Under no
c i r c u m s t a n c eas l l o w C F C 1 2 t o e n t e r a n H F C I 3 4 a
system,or vice versa,becauseseriousdamagecould
occur.
2, USE OF PROPERCOMPRESSOR OIL
Compressoroil usedin conventionalCFC12air conor-
tioning systamscannotbs usedin HFC134aair condi-
tioning systoms.
Always usegenuineToyota HFC134a air conditioning
oil ND-OlL 8, madeexpresslyfor use with HFC134a.
N D - O I 8L
lf even a smallamountof th€ wrong oil is changed,it

't j1 will resultin cloudingof th6 r€frigorant.
A largeamountwill causethe compr€ssorto seizoup.

AC-3
AIR'CONDITIONING
3. USEOF PBOPER O_RINGSAND SEALS

CFC12air
O-rings and sealsusodfor convontional
syst€mscannotb€ us6dfor HFC134aair
conditioning
O-Ring
systems.
conditioning
Always use genuineToyota HFCl34a systemO-
ringsandsealsfor HFC134a systems.
airconditioning
f f O - r i n g s a n d l o r s e a l sf o r C F C | 2 a i r c o n d i t i o n i n g
systomsare usedby mistakein the connectionsof an
HFC134a air conditionrngsyst6m, the O - ring and
G a s ( R1 3 4 a )L e a k a g €
o
i!
nl2 O-Ring
lloamingsnd
swslling)
sealswill foam and swell resultingin leakageof refrig-
orant.
4, TIGHTENCON]tIECTING PARTSSECURELY
Securelytightenthe connectingpartsto prsventleak-
nt gas.
ing of rofrig€ra
. Apply a few drops of compressoroil to O - ring
andto prevent
reakins
C o mp r e s s o rO i l It:::..',#:??":shtenins ffi
ND-OIL8 CAUTIOI{: Applyonly ND- OILI compressor oil.
o Tightentho nuts using2 wrenches1oavoidtwist-
ing the tube.
o Tighten th€ O-ring fittings or the bolted type
fittingsto the specifiedtorque.
5. INSERTPLUG IMMEDIATELYIN DISCONNECTED
PARTS
Inserta plug immediatelyin the disconnectedpartsto
provontth6 ingressof moisturoand dust.
6, DO NOT REMOVEPLUG FROM NEW PARTSUNTIL
IMMEDIATELYBEFOREINSTALLATION
acr,oa
7, DISCHARGE GAS IN NEW COMPRESSOR FROM

CHARGING VALVEBEFORE INSTALLING IT
lf the gas in the new comprossor is not discharged
first.compressor oil will sprayout with gaswhentho
plugis removod.

AC-4
SYSTEM_ GENERALDESCRIPTION
AIR CONDITIONING
TOOLSFORHFC134aAIR
SERVICE
CONDITIONING
When servicing HFC134a air conditioningsystoms
always use th6 HFC134adedicatedmanifoldgaugos,
gas leak d6t6ctorand vacuum pump adaptor.
1. USEMANIFOLDGAUGESFORHFC134aAIR CoN-
DITIONING
Alwaysuse HFC134adedicatedmanifoldgaugosto
preventCFC12 and CFC12 compressoroil con-
Ouick Link the HFC134asyst€m.
taminating
Connector
,&?
2. USE HFGl34a GAS LEAK DETECTOR

zrî Similarly,always use an HFC 134 a dedicated leak
\-/ detect or. The CFC12leak detectoris not suffici€ntly
sensitive.
.-'oi
-l
- -L
ii .'ii:', I . 1
\\::7-4
R'134a 3. USE VACUUM PUMP

Connection Port The vaccumepump has 2 connectionports, one for
R12
Connection Port
CFC12and one for HFC134a.
CAUTIOT{:
Be 3ureto clolc off rh6 mecifoldgeugevalveimmediately
rftcr cvlcurting tho rystem. Thrn you may rwitch off
the ylcuum pump. lf thir ordcr b rcversed,tho line will
be temporarilyoponto atmosphoie.

AC.5
AIR CONDITIONING
FOR
HANDLINGPRECAUTIONS
REFRIGERANT
IN AN ENCLOSED
1. DO I{OTHANDLEREFRIGERANT
AREAOR NEARAN OPENFLAME
2. ALWAYSWEAREYEPROTECTION
3. BE CAREFULTHAT LIOUIDREFRIGERANT DOES

NOTGETIN YOUREYESOR ON YOUR SKIN
getsin youreyesor on yourskin:
lf liquidrefrigerant
(a) Washthe ar6awith lots of coolwater.
CAUTION:Do not rub your eyesor lkin.
(b) Apply cleanpetrolaumjelly to th€ skin.
(c) Go imm€diatelyto a physicianor hospitalfor profes-
sionaltrsatmsnt.
FOR
HANDLINGPRECAUTIONS
REFRIGERANCT
ONTAINER
1. NEVERHEAT CONTAINEROR EXPOSEIT TO
NAKEDFLAME
2. BE CAREFUL AND NOT
ilOT TO DROPCONTAINER
TO APPLYPHYSICAL SHOCKSTO IT
CHARGINA METHOD
GN D L E A K _ C H E C K
Evacuat€the refrigerationsystom accordingto the
f ollowingprocedures.
1 Om i n . L e a v ef o r 5 m i n .
Fill refrigerantin gas stat€ until

gauge pressurereads 1 kg/cm2
Abnormal indicationot
manitold

AC-6
SYSTEM_ GENERAL
AIRCONDITIONING DESCRIPTION
GAUTION:
. 8o suro to connecl both tho high and low pressure
quick - connoctors onto th6 A/C system when eva-
culting. lf only one sido is connectod. tho systom
would bc opon to atmosphere through the othor
connactor, making it impossible to maintain
vacuum.
r Be lure to iurn olf the manilold gauge valve imme-
V a c u u mPump
fll0g)2 diltely rlto? ovlcusting the systam. Then you may
swltch ofl tho vrcuum pump.
PRECAUTIONS
WHENCHARGING
REFRIGERANT
1. DO NOT OPERATECOMPRESSOR WITHOUT
ENOUGH REFRIGERANT IN REFRIGERANT
SYSTEM
lf there is not €noughrefrigerant in the refrigerant
system,oil lubrication will be insufficient
and com-
pressorburnoutmayoccur,so takscareto avoidthis.
2. DO NOTOPENHIGHPRESSURE MANIFOLDVALVE
WHILSTCOMPRESSOR IS OPERATING
lf the highpressurovalveis opened,refrigerant flows
in th€ reversedirectionandcouldcauseth6 charging
cylinderto rupture,so openand closathe low pres-
surevalveonly.
3. 8E CAREFULNOT TO OVERCHARGE SYSTEM
WITH REFRIGERANT
it causesproblemssuch
lf refrigerantis overcharged,
as insufficientcooling, poor f u e l e c o n o m y ,e n g i n e
overheating6tc.
ELECTRICAL
PARTS
Before removingand inspectingthe electricalparts,
set th€ ignition switch to th6 LOCK position and
disconnectths nogativo(-) terminalcablefrom bat-
te ry.
CAUTION:Work must be startadafter 90 sgcondsfrom
tho timo tho ignitionswitch is turned to tho 'LOCK'
positionand the nrgativo(-) terminalcablais discon-
nectod from ths battoiy.

AC-7
SYSTEM- GENERAL
AIRCONDITIOilING DESCRIPTION
SRSAIRBAG
Failureto carryout s€rvic€oporations in thg corrsct
sequoncscouldcauseth€ airbagsystemto deploy,
possiblyleadingto a seriousaccident.
lf duringromovalor installationof th€ partsand th€
yellowwire harnessand connactorfor tho airbagis
necessary, r€f€rto tho precautionary
notic€sin the Rs
s€ctionboforoperforming the op€ration.
CAUTIO : Work murt bc rtartld !lt.? 90 tccondl from
tho tlmc th. lgnltlon rwltch b tuincd to thr'LOCK'
porltlon and th. n.gltlvc (-) tcimlnal cablo lr dlrcon'
nactcd Irom thc b!ttcty.

AC-8
SYSTEM- DESCRIPTION
AIR CONDITIONING
DESCRIPTION
PARTSLOCATION
LHD Models
PressureSwitch
R/8 No.s
. M a g n e t i cC l u t c h
R el a y
. C o n d e n s eFr a n
R el a y N o . 2
. C o n d e n s eFr a n
R e l a yN o . 3
Compressor
Condenser
B l o w e rU n i t
. Blower Motor
. Air Inlet
H e a t e rU n i t Servomotor
. HeaterRediator
. A i r O u t l e tS e r v o m o t o r
R/B No.4
. H e a t e rM s i n R e l a y
C o o l i n gU n i t
. Evaporator
. ExpansionValve
. A/C Amplifiter
. Thermistor
. Blower Resistor
N1od06
N10!58

AC-9
SYSTEM_ DESCRIPTION
, AIR CONDITIONING
R H DM o d e l s
Water Valve
re Switch
R / B No . 5
. M a gn e t i c
Relay
C o n d e n s eFr a n
R e l a yN o . 2
C o n d e n s eFr a n
R e l a yN o . 3
Compr6ssor
B l o w e rU n i t
. Blower Motor
. Air Inlet
Servomotor
R / BN o . 4
. H e a t e rM a i n
Relay
C o o l i n gU n i t
. Evaporator
. ExpansionVElv€ HeaterUnit
a A / CA m p l i f i e r . HeatBrRadiator
o Thermistor . Air OutlotServomotor
a Blow€rResistor
N10969
N10829

AC-10 , SYSTEM- DESCRIPTION
AIR CONDITIONING
ELECTRICAL WIRlNGDIAGRAM
7 A - F E E n g i n eM o d e l s :
O e , o @ o rO
(@) Itrtr
l 4 o !
I
I lFFbl l#nd fr-z\r r l l 2|
[E.m l ar 6 T t r l 9 l o l
\*az I' I-l
t 1 . l I t - r ] . t t - T n t \ \ : J 4 l IFI f';f'['!']l!-ElEl
a\ o,-_ @' @
h r.q l 1 6 1 9 l l ' o { |2| r ! r . 5 l 1 5|
lFtr,Etr-ffiHl
t:i mtr
lL4_t-plFETilIN
I tiL]1;T'E1
|
t!.1!t5t7tal
lr rrr Ell

, A I R C O N D I T I O N I NSGY S T E M_ D E S C R I P T I O N AC-11
5 5 - F E , 3 5 - F E a n d 3 5 - G E E n g i n eM o d e l s :
].BD FHD
O"***''
o @ o @ o @ o @
@)ffii
\s!z N4z ffil
-= | ffil
t-E i rffir
t-ro | Aiffit
\v Hffi
ryt = ry
o i o _ @ @ @
...:
|\ +i r-.c-Fr J!=. l_!L!.1_ tll l:ffil
H .' H lF9elgq4gl
- fu+lrr
" , t.rrt. ,.t tffirstill
r!-;?:Tr-d lLl?_JuJ.i lrl!..11 | !:r=r: rr
.-..:. sl

Ac-12 y s r E M- D E S c R t p r t o N
A r Rc o N D r r l o N t NsG
D A M P E RP O S I T I O N S
AirMix
C o n t r o lD a m p e r
Air lnlet
C o n t r o lD a m p e r
A i r F l o w C o n t r o lD a m p e r
o.r--\
---'r l-l
'l, l'
t'.f,1
iFace
-l
( Si d e)
Air Flow Vents

N4ode
Control
A i r O u t l e tM o d e
DsmperPosition Cent€r Si d s Foot Defroster
Faca a.
,t @ @@ @ o o
a)
Bi-L€vel
i; @ @ o@
Foot rp @ @ @@ o
Foot/
Oefrost€r ,Y @ @ @@ o o
Defroster
@ @o@@ a) o
Nt0072 T h e s i z eo f c i r c l €( O ) i n d i c E t e tsh e p r o p o r t j o no t t h e a i r f l o w v o l u m s .
N10459

AC-13
SYSTEM_ PREPARATION
AIR CONDITIONING
PREPARATION
TOOLS)
SERVICE
ssr(sPEclAL
Toolsot
sorvic€
07110-58060 Air condition€r
charsinsGa,rse
tOif fl-ieOSOl Relriger.nt
(07117-88060)Retrigortnt
chrrginsHo36 Oischrrg6(R.d)
(07117-88070)Rofris.rant Hoso
Charsins Suction(Bluo)
(071l7-88080) Rofrisorlnt Ho36

charsino Utility(Groon)
Vslvo
Drtinsorvice
(071| 7-58060) Rolrigor.nt
Adapti'
(O7l1i-58080) ourckDircooncct Oi.chlrge(di!m. t0 mm)
fOf f i -Sg09O)ori"i oi."ln*"t na"pt* Suction(di.m. 13 mm)
/ll'tl l7-Ecn7n\ T- l^'^r
0 7 1 1 2 - 7 6 0 6 0 M . g n o t ,ccl u t c h s t o p p o r
clutchRsmovor
07112-66040 Magnotic
0 7 1 1 -48 4 0 1 0 s n . PR i n sP l 6 r s
0 7 1 1 4 - 8 4 0 2 0 s n . PR i n sP l i o r r

AC-14
SYSTEM- PREPARATION
AIR CONDITIONING
07116-38360 c.r Lo.kDot€ctor
A.s.mblv
0 7 1 1 0 - 6 1 0 5 0 w r . n c hs 6 t
e/////
07112-15020 scalPl.tcB6mov6r
0 7 1 1 2 - 8 5 0 3 0 L i ps . ! l B . m o v . r
07112-85020 LipSo.lPr.ror
07112-85010 Lips.!l Prot.ctor
P u m(p2 2 0V )
0 7 1 1 7 - 4 8 1 3 v0 . c u u m
07117-18140 VlcvurnPump(240V)
OOL
s&
+:Ja
0S082-00050 ToYOTAEloctricllT.dar S.t.
LUBRICANT
Itam C!p!city Cl!!!ificrtion
Comprrlroroil ND-OlL I or rouiv.lont
Whrn rupl!olngraoaivrr l0 cc (2.9fl.or.)
Wh!n rrplroingoondonrcr 40 cc (1.4tl.oz.)
Wh!n frpl!olngavrporrtor 40 co (1.4ll.or.)
Whln rapl!cinecomprlttor 120 cc (4.1tl.oz.)

AC-15
SYSTEM- USEOF MANIFOLDGAUGESET
AIR CONDITIONING
U S EO F M A N I F O L DG A U G ES E T
"'
MANIFOLDGAUGESETINSTALLATIOI\i'."
1, CONNECT CHARGINGHOSES TO MANIFOLD
GAUGESET
Tightenthe nutsby hand.
CAUTION: Do not connoct ths wrong hoses.
2. TO CHARGING
CONNECTOUICK COI'INECTORS
HOSES
Tightenthe nutsby hand.
3. CLOSE BOTH HAND VALVES OF MANIFOLD
GAUGESET
4. REMOVECAPS FROMSERVICEVALVESON RE-
FRIGERANT LINE
Low Pressure HighPressu re

C h ar g i n g H o s e C h a r g i n gH o s e
r
N1 0 3 5
Low Pressure HighPr€ssu rs

CharginHg o s e C h a r g i nH
g ose
t11096?
5, CONI{ECTOUICK CONilECTORSTO SERVICE

VALVES
HINT:Pushthe quick connoctoron to the sorvic€
valv6,then slidethe sl6ev€of the quick connector
downwardto lockit.

Ac-I6 sysrEM - usEoF MANTFoLD
ArRcoNDrnoNrNG GAUGE
sET
1"v
"1 MANIFOLDGAUGESETREMOVAL
IY 1. CLOSE BOTH HAIIID VALVES OF MANIFOLD
A
et GAUGESET
A
v
B 2. D|SCO[{[{ECTOUTCKCOI{I{ECTORSFROM SER-
VICEVALVESOI{ REFRIGERAT{T LINE
HINT:Slidethe sleeveof tho quickconnectorupward
_lt_ to unlocktha connectorand removeit from the ser-
vicevalve.
3. INSTALLCAPSTO SERVICE VALVESON REFRIG-
ERAT{TLINE

jc-17
AtRcoNDrloNtNG SYSTEM- USEOFMANIFOLD
GAUq JEI -----
_MEMO-

Ac-18
ArRcoNDtrrontNcsysrEM - TRouBLESHooflNG
TROUBLESHOOTING
Use the table below to help you find the causeof the problem.The numbersindicatethe pri8iiv
ofthe likelycauseof the problem.Checkeach part in order.lf necessary.replacethese parts.
g AC-25 A C - 2 0 A C . 2 6 AC,7 4 AC-71 AC 78 AC 79
x
Pr(5 n,
Nams ' E ; !
^
3i E .at
:;
- 6 ,.c: ' ID
o
E ; o r x
g t!
R R
(|t
B I
x x ! x o
'6
ti
Trouble
9 (
:r,
t I I
No blow6r operation
No bloworcontrol
No lir tlow mod€control
N o l i r i n l e tc o n t r o l
Insuffici€^tllow ol cool air
lnsullicientflow ol werm sir
No cool ,ir comgSout ,l

4 t 't3 9
Coolrlr comesout {nt6rmlttenlly 4
Coolair comerout only rl high

1
angrnolpegcl
Inruflicient cooling 1 12
No warm 6if coms8out
Aif tomp.conlfolnot funclioning
No €nginsldle up when A/C

switchon
vo504l

AC-19
SYSTEM_ TROUBLESHOOTING
AIR CONDITIO'{ING
AC-73 AC-70 AC,67 Ac-68 AC,82 AC-80 AC-41 AC-60 AC-62 AC-60 AC-58 AC-64
!,
t 6
i
o
= t o
o :
I a 6 o 7
o h
: I 3
U)
t 6 a
I
t
g 'd
x x
3 E a E
I o E 8
@ a a o E T
J
I 3 4
2 t J
10 12 8 7 14
c 7 8
I 11 10 13 I 14
,|
I 2

AC-20
AIR CONDITIONING
REFRIGERAN
SYT S T E MI N S P E C T I OWNI T HM A N ! F O L D
G A U G ES E T
This is a method in which the troubleis locatedby usinga manifoldgaugeset.
( S e e" U S EO F M A N I F O L DG A U G ES E T "o n p a g eA C - 1 5 )
Readthe manifoldgaugepressurewhen the followingconditionsare 6stablished:
is 30 - 35'C (86 - 95'F)
( a ) T e m p e r a t u raet t h e a i r i n l e tw i t h t h s s w i t c hs e t a t R E C I R C
( b ) E n g i n er u n n i n ga t l , 5 O Or p m
(c) Blowerspeedcontrol switch sot at high
(d) Temperaturecontrolset at max. cool
HINT:lt shouldbe notedthat tho gaugeindicationsmay vary slightlydue to ambienttemperaturo
conditions.
1. NORMALLYFUNCTIONINGREFRIGERATION SYSTEM
Gaugereading:
Low prassuresida:
0.15 - 0.25 MPa (1.5 - 2.5 kgl/ cm' l
Highpressureside:
1.37 - 1.57MPa(14 - 16 ksl/cm'J
Rt gtcr

AC-21
SYSTEM- TROUBLESHOOTING
AIR CONDITIONING
2. SYSTEM
MOISTUREPRESENTIN REFRIGERATION
C o n d i t i o n : P e r i o d i c a l l yc o o l s a n d t h € n l a i l s t o c o o l
Svmptomseenin cause
Probable Disgnosig Remody
svstem
refrigeration
Duringoperstion,pres- Moislu16anteredin re- . Drierin oversStursl€d {1} Roplscerecaivar/drief
state (2) R€movemoistur€in
sure on low pressure lrig€rstion3ystem
sidesometimes freezes8t cxpEnsion I cycl6 through roPeat-
b e c o m e s8 v a c u u m valv€orificeandlempo- . MolsturoIn relrig€rEtlon ldly ovacu8tlngEir
and sometimesnormal rarilvstopscycle,but system trs€zss sl gxpan- (3) Chargonaw r€trigersnt
normElstEt€ is reslored slonvalv€oritico8nd lo proparamount
sfter a tlmg whonths lco blocks circulttlon of re-
mells frlg€r8nt
3. I N S U F F I C I E NRTE F R I G E R A N T
Condition: Insufficientcooling
Symptom seen in R6mody

Prob6blo
c6us€ Di6gno6i8
refrigeration system
. Pressurelow on both Gss lo6k6goat Bomo Insufliciantrof.igerantin { 1 ) C h 6 c k f o r g a 3 l e o k a g e
low snd highpressuro placoin retrig6retion with lssk d6t6ctor and
stdes tem rspair if nocsssary
. Bubbless€enin sight Relrigorsnt
leaking t2l C h 6 r g e r o f r i g 6 r 6 n tt o
glasscontinuously
. nsuflicientcoolingpof- ( 3 t ll p r e s s u r 6i n d i c a t g d
v6luo i3 noar O wh6n
connoctod to gaug€,
cr6at6 th6 vlcuum af-
t o r i n 3 p e c t i n o6 n d r e -
priring lho localion of
th6 lerk

AC-22
AIRCONDITIOI{ING
4, POORCIRCULATION
OF REFRIGERATTT
Condition: Insuffici€ntcooling
SymPtoms€€nin
Probablo
causo Diagnosig Romody
refrigerotion
iyst€m
Pressurslow on both . Rofriggront flow ob- R6c€iv€r clogg€d . Roplac€ rec6iv6r
low Endhigh pre6sur€ slructod by dirt in 16-
std6s coivet
Froston tubesfrom ro-
5. REFRIGERANT
DOESNOTCIRCULATE
Condition: Does not cool (Coolslrom tim€ to time in some cases)
Symptom segn in
Prob8blocaus€ Oiagnosis Rem€dy
retriger6tionsystem
Vacuum indicatedon Re{rigerantflow ob- Retrigerontdo€s not cir' (1) Check heat sensing
low pressureside, v€ry structed by moiatureor c0late tub€, expansionvalve
low pressureindicatad dirt in rotriger6tionsys-
on hjgh pressu.esid6 rem (2) Cle€noul dirt in expan-
Frost or dew seen on Refragerant flow ob- sion valve by blowing
piping b6fore and 6ttor strl.rct9d by ga8 leakage with gir
receiver/dri€ror expan- lrom 6xpansionvalv6 lf not ablo to remove
sion valv€ heat s€nsingtubo din, replaceexpansion
(3) Replscereceiver
(4) Evacusteair and
chargenew reffigeranl
to proper Smount.
For gas leakagefrom
he6t s€nsingtube, re-
place expansionvalve.

AC-23
SYSTEM- TROUBLESHOOTING
AIRCONDITIONING
6. OR INSUFFICIENT
OVERCHARGE
REFRIGERANT OF COI{DENSER
COOLIITIG
Condition: Do€s cool suffici€ntly
Symptomssenin
Probabl€csus6 Dlagnosis R€medy
reJrigeration
system
Pressur€too highon Unableto developsutli- . Excessiv€ r€irigersnlin ( 1 1 C l 6 8 nc o n d E n s o r
both low and high cient padormanceduo to cycl6 - r€trig€rgntover- 121Chcckfan motor oper.
pregsur€srdaa 6xcsSsiv€ rolriggrantin cnErg€o Etion
No €ir bubblgsseen sy9t€m . Condonsor coolinginsut- { 3 ) l f ( 1 ) a n d( 2 ) a r ei n n o r '
throughth€ sight glass Insullici6ntcoolingof ticient- cond€nserfins mrl 8t€to, chock
even when th€ €ngine condenser cloggedor t8n molor Emountof relrigsrant
rpm is lowered. lsulty Chargeprop€r6mount
ol rgtrlg€rant
7. IN REFRIGERATION
AIR PRESENT SYSTEM
Conditionr Does not cool down suflicisntlv
NOTE: Th€segsugs indicationsare shown wh€n th€ ra-

lrigerstionsystem hss b6onopsn€d8nd th€ refrig-
erant chargedwithout vBcuumpurging.
Symptom 6oenin
Probablec6use DiBgnosis Romody
refrig€rationsystem
. Pressuretoo high on Air enteredin relrigers- . Air pr€s€ntin rgfrig€ra- ( 1 ) Chsck compre880roil
both low and high tion systom tion 8y3t€m to s€€ it diny or insufti-
pressuf€srdgs I cient
. The low pressurepiping . lnsufficigntvEcuum t2l Evscuat€air snd
is hot to ths touch pLrrgang charg6n6w rofriOerant
. Eubblesseen in sight
glass

AC-24 SYSTEM- TROUELESHOOTING
AIR CONDITIONING
8. EXPANSION VALVEIMPROPERLY
M O U N T E D / H E ASTE N S I N T
GU E ED E F E C T I V E
( O P E NT
SO OW I D E )
Condition: I n s u f f i c i e n tc o o l i n g
NO4!52
S y m p t o ms e e n i n
Probablecause Di s g n o s i s Remedy
r e t r i g e r a t i osny s t e m
. P r e s s u r et o o h i g h o n Troublein expansion Excessiverefrigerantin{ 1 ) Check heat sensing
both low and high valve or heat sensing low pressurepiping tube installedcondition
p r e s s u r es r o e s tube not installedcor- r t2l l f ( 1 ) i s n o r m a l ,c h e c k
' F r o s to r l a r g ea m o u n t rectly Expansionvalve opened expansionvalve
o f d e w o n p i p i n go n l o w too wtoe Replaceil defective
pressurestde
\,t]l0lt
9. DEFECTIVECOMPRESSIONCOMPRESSOR
Co n d i t i o n : D o e s n o t c o o l
S y m p t o ms e € n i n Rem6dy
Probabl€csuse Oiegnosis
relrigerationsystem
Pressuretoo high on . Internalleak in compres- Compressiondefoctivs . R€pairor replacecom-
l o w p r e s s u r €s i d e sor .t pressor
Pressuletoo low on Valve leakingor broken,
h i g h p r e s s u r es i d e slidingparts

AC.25
SYSTEM_ REFRIGERANT
AIR CONDITIONING VOLUME
VTO L U M E
REFRIGERAN
VOLUMEINSPECTION
REFR]GERANT
1 . R U NE N G I N A
E T I D L ES P E E D
2. OPERATEA/C AT MAXIMUM COOLINGFOR A
FEWMINUTES
3. INSPECT AMOUNTOF REFRIGERANT
Observe sightglasson th6 liquidtube.
the
It€m Symptom Amount of rafrigoront Remody

(1) Chock tor gas leakag. with ga6
lgak tgstgr and ropairif n6c666ary
Bubbl€spr6s6ntin sight gl6ss lnsufficient'
(2) Add refrigorant until bubbl08 di8-
ap6ar
2 No bubblosp.ss6nt ansight glass Non6.suffici€ntor too much Rglgr to items 3 .nd 4
(1) Ch€ck for ga8 lsakago with gaE
No temporatur€ drtf6r€ncs botwoon loak t6st€r end rop6irif necsactry

3 Empty or noarly6mpty
compressorinlgt and outl€t {2) Add r6frig6rantuntil bubblosdi8ap-
p€6r
Tsmperatur6 b€twgon comProaso.

4 Propgror too much Rsfgr to itgms 5 and I
inlot and outl€t is notic66blydiff6rent
lmmediat6ly after air conditionsr i6 (1) Oischargcr6trigrant
5 turned off, rofrigerant in srght glass Too much (2) Evacuato air and chargo proper
stays cl€ar amount of purifiodretdg€rant

Wh€n air conditionoris turn€d off, ro
Proper
trigorantfoams and then Slay cl6ar
': Bubblesin the sight glasswith ambienttemp€ratu-

ers higher than usual can be consideradnormal if
coolingis sufficient.
REFRIGERAC
NH VOLUME
T ARGE
Spocifiod amount:
650 + 50 s (22,92t 1.76oz.)

AC-26
SYSTEM_ DRIVEBELTTENSION
AIR CONDITIONING
CHECK
M bsd 1. INSPECTDRIVE BELT'S INSTALLATION

TION
CONDI.
Checkthat the drivobelt fits properlyin the ribbed

CORRECT WRONG
groov6s.
7A-FE lnglnr 2. INSPECTDRIVEBELT DEFLECTIN

UsingSST,apply a load 9.8 N (10 kgf,22 lbfl.
Measuredrive belt deflection.
7A- FE Engine:
6.0 - 7.0 mm (0.23- 0.27 in.)
-
55 FE and 35 - FE Engine:
6.0 - 9.0 mm (0.23- 0.35 in.)
Cr.nk!heft Pulloy -
35 GEEngine:
9.0 - I I .0 mm (0.35- 0.43 in.)
Refarence
5S-FE 3S-FE Ensine Using SST, check the driva belt tension.
Orive bolt tonsion
7A - FE Engine:
New blet: 520 - 755 N (53 - 77 kSl)
Used belt: 264 - 353 N (27 - 36 kgf)
- -
55 FE and 35 FE Engine:
Naw belt: 617 - 853 il (63 - 87 kgf)
Cornp.egsor Used balt: 441 - 530 N (45 - 54 ksf)
Nr0t 34 35-GE Engine:
ll6w belt: 617 - 853 N (83 - 87 ksf)
Used bslt: 333 - 422 N (34 - 43 kgf)
3S-GEEnglnc
HINT:
r 'New
bslt" refers to a b6lt which has been used
l e s s t h a n 5 m i n u t e s o n a r u n n i n ge n g i n e .
r 'Used
belt" rsfsrs to a b6lt which has been on a
running engine for 5 minutes or more.
. Aftor installing the drive belt. check that it fits
properly in the ribbed grooves.
N0439a
Nippond€nso Eorroughs
tc0003lcooot

4C.27
SYSTEM- IDLE_UPSPEED
AIR CONDITIONING
I D L E _ U PS P E E D
I D L EU P S P E E DI N S P E C T I O N
1 . W A R MU P E N G I N E
2. INSPECT IDLESPEEO
7A_FE
Magn€ticclutch conditaon Strndard idl. .pc!d (rpm)
Not 6ngagod Approx.TO0
Engagod Approx.9O0
55_FE
Magn6ticclutch condition St!nd.rd idl! .p!rd (rpm)
Not.nOaood Approx.760
Engagod Approx.850
3S-FE
Magnoticclutch condition Strnd!rd idl. lp!!d {rpm)
Not !ngagod Appfox. 800
Engagod Approx.900
3S-GE
Magnoticclutch condition Sbnd.rd ldlr !p!rd (rpm)
Not ongrg.d Approx.850
Eng!g!d Approx.950

Ac-28 sysrEM - REFRTGERANT
ArRcoNDtrtoNtNG LtNEs
R E F R I G E R A NLT
INES
O F R E F R I G E R A T I LOIN
T I G H T E N I NTGO R O U E NES
LHDModels
E x p a n s i o nV a l v e
7 A - F EEn g i n eM o d e l s
N m ( k g fc m , f t l b f ) | : S p e c i f i e dl o r q u e

AC-29
SYSTEM- REFRIGERANT
AIR CONDITIONING LINES
RHDModels
Nm { m, I S p e c i f i e dt o r q u e
1 . T N S P E CHT O S EA N D T U B E C O N N E C T I O NFSO R
LOOSENESS
2. INSPECT HOSESAND TUBESFORLEAKAGE
Usinga gasleaktester,checkfor leakageof refriger'
ant.

AC-30
SYSTEM- REFRIGERANT
AIR CONDITIONING LINES
REFRIGERANT
LINESREPLACEMENT
1. DISCHARGEREFRIGERANT IN REFRIGERATION
SYSTEM
(Seepase AC- 15)
2. REPLACE FAULTYTUBEOR HOSE
HINT:Capthe openfittingsimm6diatoly to keepmois-
ture or dirt out of the syst€m,
3, TOROUE CONNECTIONS TO SPECIFIEDTOROUE
N O T I C EC
: o n n e c t i o n r h o u l d n o t b e t o r q u e dt i g h t o r t h a n
thc rpcclflcd torquc.
4. EVACUATEAIR IN REFRIGERATION
SYSTEMAND
CHARGEWITH REFRIGERANT
Soccificd .mount:
650 t 50 s (22.92+ 1.76o2.)
6. INSPECTFOR LEAKAGEOF REFRIGERANT
Usinga gas lsak tester,check for leakageof refriger-
ant.
6. INSPECTAIR CONDITIONINGOPERATION

AC-31
SYSTEM- COOLINGUNIT
AIR CONDITIONING
C O O L I N GU N I T
U N I TR E M O V A L
COOLING
NEGATIVE(-) TERMINALCABLE
1. DISCONNECT
FROMBATTERY
CAUTION: Wotk must bo rttrted rttor 90 reconda from
'LOCK'
tha tlmo tho lgnltion switch lr turnod to the
porition end tho ncgttivo (-) terminal cable ir di3con'
nected from tho b!tt.ry.
2, DISCHARGEREFRIGEFANT FROM REFRIGERA-
TIONSYSTEM
(SeepageAC- 15)
3. DISCONNECT SUCTIONTUBEAND LIOUIDTUBE
FROMCOOLING UNITFITTING
HINT:Capthe open to keepmois-
fittingsimmodiately
tur€ out of the system.
4. REMOVEGROMMETS FROMINLETAND OUTLET
FITTINGS
5. REMOVEDRAINPIPEGROMMET
6. REMOVEINSTRUMENT PANELAND BEINFORCE-
MENT
(SeepaseBO-52)
7, DISCONNECTCONNECTORS
8, REMOVECOOLING UNIT
Remove3 nuts and 4 screws.

AC-32 SYSTEM_ COOLINGUNIT
AIR CONDITIONING
COOLINGUNITDISASSEMBLY
Upper Unit Case

Packing
Expansion Valve
Lower Unit Case
Drain Hose
S"..* --{
clip_+t--
Packing
Amplifier
1. REMOVELOWERAND UPPERUNIT CASES

(a) Disconnectthe connectors.
(b) Removethe 4 clips.
(c) Rsmovethe 4 screws.
(d) Removathe upper unit case.
(e) Removeth€ thermistorwith th€rmistorholder.
(f) Rsmovethe lower unit case.
2. REMOVEEXPANSIONVALVE
(a) Removeth6 packingand h6at sensingtube from suc-
tion and liouidtu bes.
(b) Using a hexagon wrench, remove the 2 bolts and
separatethe 6vaporatorand expansionvalve.

AC-33
SYSTEM- COOLINGUNIT
AIR CONDITIONING
Hexagon wrench U N I TA S S E M B L Y
COOLING
INSTALLCOMPONENTS ON EVAPORATOR
valve
(a) Usinga hexagonwrench,installthe €xpansion
Torquethe 2 bolts.
to the evaporator.
Torque:5.4 N.m(55 kgf cm,48 in"lbf)
HINT:Be surothat tha O - ringsare positionodon tho
tub€ fitting.
(b) Installth6 lower unit caseto the 6vaporator.
(c) lnstallthe thormistorto the evaporator.
(d) Installthe upperunit case.
(e) Installtho 4 screws.
(f) Installthe 4 cliPs.
(g) Connectthe connectors.
U N I TI N S T A L L A T I O N
COOLING
UNIT
1 . I N S T A L LC O O L I N G
Installthe cooling unit with 3 nutsand4 screws.
2. CONNECT CONNECTORS **l*#
""Eq
3. INSTALLINSTRUMENT PANELAND REINFORCE.
MENT
(SeepageBO- 52)
4, INSTALLDRAINPIPEGROMMET
5. INSTALLGROMMETS ON INLETANDOUTLETFIT.
TING
U N I TI N L E T
6 . C O N N E CLTI O U I DT U B ET O C O O L I N G
FITTING
T o r q u e :1 0 N . m ( 1 0 0 k g f ' c m , 7 f t ' l b t )
7, CONNECTSUCTIONTUEE TO COOLINGUNIT
OUTLETFITTING
T o r q u e :1 0 N . m ( 1 0 0 k g f ' c m . 7 f t l b f )
8. IF EVAPORATOR ADDCOMPRES.
WAS REPLACED,
SOROIL TO COMPRESSOR
Add 40cc (1.4tl.oz.)
C o m p r o S s oo?i l :
ND OIL 8 or oquivalent
9. CONNECTNEGATIVE(-) TERMINALCABLETO
BATTERY
SYSTEMAND
10. EVACUATEAIR IN REFRIGERANT
Specified amount:
650 + 50 g (22'92 + 1.76 oz.)
1 1 . T N S P E CAT, / C O P E R A T I O N

AC-34
SYSTEM- HEATERUNIT
AIR CONDITIONING
H E A T E RU N I T
HEATER
U N I TR E M O V A L
FROMBATTERY
CAUTION: Work must be started after g0 recondr from
th€ tims the ignition switch is turnod to the'LOCK'
p o s i t i o na n d t h e n e g r t i v e ( - ) t e r m i n s l c a b l e i s d i s c o n -
nected lrom tho battory.
2. REMOVEINSTRUMENT PANEL
(SeepaseBO- 52)
3. REMOVECOOLING UNIT
(SeepaseAC- 31)
4. DRAINENGINECOOLANTFROMRADIATOR AND
ENGINE D R A I NC O C K S
5. REMOVE WATERHOSEFROMHEATERUNIT
(a) Rsmov6the controlcablefrom the watervalve.
(b) Removeths bolt andth6 watorvalve.
(c) Gripthe clawsof tho hoseclipwith pliersandslidethe
clipalongthe hoseto a placewhareit doesnot clamo
the hoseto th6 pipo.
(d) Disconnect th6 waterhos6s.
6. REMOVEPIPEGROMMETS
7. REMOVEHEATERUNIT
(a) Disconnectth6 conn€cter.
(b) Removeth€ wire harness.
(c) Removeth6 4 nuts and a screw.
(d) Removethe heatorunit.

SYSTEM_ HEATERUNIT
AtR CONDITIONING
HEATERUNITDISASSEMBLY
H e a t e rR e t u r nP i p e
Air Vent Duct

I
A i r O u t l e tD a m p e r
C o n t r o lS e r v o m o t o r

AC-36
SYSTEM_ HEATERUNIT
AIR CONDITIONING
1. REMOVE AIROUTLETDAMPERCONTROL SERVO-

MOTOR
Removethe 2 screwsandthe air outletdamoercon-
trol servomolor.
2. REMOVEHEATERAIR DUCT
{a) Removethe 2 screws.
{b) Disconnecttho 2 claws and remove the heater alr
duct.
3. REMOVEHEATERRADIATOR
(a) Removethe 3 screwsand th€ pipe clamps.
(b) Pull out the h€ater radiator unit with h€at€r r€turn
pipe.
.Jxc
eater

AC-37
SYSTEM_ HEATERUNIT
AIR CONDITIONING
U N I TA S S E M B L Y
HEATER
1. INSTALL HEATERRADIATOR
2. INSTALL HEATERAIR DUCT
3. INSTALL AIR OUTLETDAMPERCONTROLSERVO-
MOTOR
(a) Insertthe bushof the air outlot dampercontrolservo-
motor to the lever.
(b) Installthe air outlet dampercontrol ssrvomoterwith
the 2 screws.
HEATERUNITINSTALLATION
1 . I N S T A L LH E A T E R
UNIT
Installby followingthe removalprocedure
in reverse
oroer.
2, CONNECTWATER VALVE CONTROLCABLE

(a) Set the TEMP switch to Max Cool.
(b) Set the water valve lever on Max Cool,connoct the
water valv€controlcableand lock tho clamp.
3. INSTALL COOLINGUI{IT
(See page AC - 33)
HINT:
. When the water valve control cable is installed,
ovacuatetho air in th€ systemand chargesystem
with refrigerant.
Specifiedamount:
650 a 50 s (22.92+ 1.76oz.)
. After operationsare completed,check for leak-
age of refrigarantand checkth€ op€rationof tho
A/c.
4, REFILLWITH ENGINE COOLANT
T E G A T I V(E- ) T E R M I N A LC A B L EF R O M
5 . C O N N E CN
BATTERY
6. INSPECT A,/C OPERATION

AC-38 SYSTEM- BLOWERUNIT
AIR CONDITIONING
UN IT
BLOW ER
BLOWERUNITREMOVAL
1. REMOVECOOLING UNIT
(SeepaseAC- 13)
2, REMOVEBLOWERUNIT
(a) Disconnectthe connsctorfrom the blower motor.
(b) Disconnectthe connoctorfrom tho air inlet damper
control sgrvomotor.
(c) Removewire harness.
(d) Removethe 2 nuts,a bolt and the blower unit.

AC-39
SYSTEM- BLOWER
AIRCONDITIONING UNIT
UNITDISASSEMBLY
BLOWER
Hest€rBlower
Css6
A i r I n l e tD a m p e r
Control Servomotor
Blower Motor

AC-40
SYSTEM_ BLOWERUNIT
AIR CONDITIONING
1. REMOVEAIR INLETDAMPERCONTROLSERVO.
MOTOR
Removethe 2 screwsandthe air inletdamoercontrol
servomotor.
2, REMOVEBLOWERMOTOR
(a) Removethe screwandwire harnessclamp.
(b) Removethe 3 screwsandthe blowormotor.
BLOWERUNITASSEMBLY
Assembleby followingthe disassomblyprocedurein
reverseorder.
BLOWERUNITINSTALLATION
1. INSTALLBLOWERUNIT
procedure
Installby followingtho 16moval in reverse
order.
2, INSTALLCOOLII{GUNIT
(SeepaseAC-33)

AC-41
SYSTEM- COMPRESSOR
AIR CONDITIONING
COMPRESSOR
ON_VEHICLE INSPECTION
MagneticClutch:
1. MAKE FOLLOWING V I S U A LC H E C K S
r Leakageof grease from th€ clutch bearing.
. Signsof oil on tho pressureplato or rotor.
Repairor reolace,as necessarv.
2. INSPECT MAGNETIC CLUTCH BEARING FOR

NOISE
(a) Start 6ngine.
(b) Checkfor abnormalnoise from near the compressor
when the A/C switch is oFF.
lf abnomalnoiseis beingemitted,replacethe magn€t-
ic clutch.
3. INSPECTMAGNETICCLUTCH
(a) Disconn6ctth6 connectorfrom the magnaticclutch.
(b) Connectthe positive(+) leadfrom tho batt€ryto th6
terminal on tho magn€ticclutch connectorand the
Ex,cept7A-E t, negative(-) leadto the body ground.
(c) Checkthat the magneticclutch is energized.
lf operationis not as specified,16placetho magnetic
clutch.
Compressor:
1. INSTALL MANIFOLDGAUGESET
(Seepage AC - 15)
2, START ENGINE
3. INSPECTCOMPRESSOR FOR METALLIC SOUND
Ch6ckif thereis a metallicsoundfrom the comoressor
when the A/C switch is ON.
lf metallicsound is heard, replacethe comDressor
assembly.
4. INSPECTPRESSURE OF REFRIGERATION SYSTEM
"
See RefrigerantSystem Inspectionwith Manifold
GaugeSet" on pag€ AC-20.
5. STOPENGINE
6. IilSPECTVISUALLY FOR LEAKAGEOF REFRIGER.
ANT FROM SAFETYSEAL
lf thereis any leakage.replacethe compressorassem-
bty.

AC-42
SYSTEM- COMPRESSOR
AIRCONDITIONII{G
COMPRESSOR
REMOVAL
7A-FE Englnc
l d l eP u l l e ya n d
Compressor Brsckst
' m ( k o t . c m ,f t ' l b f ) : Spscifi€dtorqug

AC.43
SYSTEM- COMPRESSOR
AIR CONDTTIONING
N . m { k q f . c m .f t ' l b f r l : S D e c i f i etdo r q u e
35-FEEngine
N . m { k g f . c m , f t . l b f ) I : S p e c i f i e dt o r q u e

AC-44
SYSTEM- COMPRESSOR
AIR CONDITIONING
3S-GEEnglns
g
Compressor
N . m ( k g t . c m ,t t . l b f ) : S p e c i l i e dt o r q u e
L RUNENGINEAT IDLESPEEDW|TH A,/C ON FOR

A P P R O X1.OM I N U T E S
2. STOPENGINE
3. ( _ ) T E R M I N A LC A B L E
D I S C O N N E CNTE G A T I V E
FROMBATTERY
GAUTION:Work must bo startod after 90 seconds from
the tims the lgnltion switch is turnad to tho 'LOCK-
p o r i t i o n a n d t h o n o g a t i v e( - ) t e r m i n a l c a b l e i s d i s c o n -
nocted from tha bsttery.
4. DISCHARGEREFRIGERANT
FROM REFRIGERA-
TIONSYSTEM
(SeepageAC- 15)

AC-45
SYSTEM- COMPRESSOR
AIR CONDITIONING
5. DISCONNECT DISCHARGE HOSEAND SUCTION

HOSEFROMCOMPRESSOR
6. REMOVE NGINE U N D E RC O V E R
7 . REMOVECOMPRESSOR
( a ) Loosendrivebelt.
( b ) 7 A - F EE n g i n e :
Removethe 4 boltsand compressor.
E x .7 A - F EE n g i n e :
Removethe 3 boltsand comPressor.

Ac-48
sysrEM - coMpRESsoR
ArRcoNDrnoNrNG
M A G N E T I C L U T C HD I S A S S E M B L Y
Bolt
I
I
dP
Prsssure
Plate
paft
Non-reuErblo
1. REMOVEPRESSURE PLATE
(a) UsingSSTandsocketwrench,remov€ths shaftbolt.
ssr07112-76060
(b) InstallSSTon the pressure

plate.
ssT07112-66040

AC-47
SYSTEM- COMPRESSOR
AIR CONDITIONING
(c) Using SST and socket wrench, removethe oressure
plat€.
ssr07112-76060
(d) Removethe shimsfrom th6 pressureplate.
''-@i1\
ty
2. REMOVEROTOR
(a) UsingSST,romoveth6 snapring.
ssr 07114-84020
(b) Usinga plastichammer,tap ths rotor off tho shaft.

]{OTICE:8c carcfulnot to dlmrgc tho pulloywh.n tapp.
Ing on tho rotor.
3. REMOVESTATOR
(a) Disconnect
the statorleadwirefrom the compressor
housing.

AC-48
SYSTEM- COMPRESSOR
AIR CONDITIONING
(b) UsingSST.removethe snap ring.

s s T0 7 1 1 4 - 8 4 0 2 0
(c) Removatho stator.
S H A F TS E A LR E P L A C E M E N T
f2j l2-50.-l l_ ,- P
c
ServiceValve
--
o SealRine -Q1
R e ar H o us i n g
I
a Gasket
Discharge ReedValve
D i s c h a r g eR e e dV a l v e
S n a pR i n g
S u c t i o nR e e dV a l v e
_k-f\ ] varveerat
s6\<i1 - - , oG
a Gjsker
asket
r .-
-O- awasher
FettHotde7(
,<t'I " l
L fllT:18)
E1111q111@ : Specified
rorque

AC-49
SYSTEM- COMPRESSOR
AIR CONDITIONING
1. REMOVE S E R V I CVEA L V E
(a) Using SST,removefour bolts holdingth€ service
vatve.
ssT07110-61050
(b) Removsthe seal ring from the cylinderblock'

Discardthe seal ring.
2, DRAIN COMPRESSOROIL INTO MEASURING

FLASK
Measurethe quantityof drainedoil becauseth€ same
amount shouldbe replacedlater.
3. REMOVEFRONTHOUSING
(a) UsingSST,remove5 throughbolts.
NOTICE:Do not rouse 5 warherr.
ssT07110-61050
(b) Usinga screwdriv€r,romoveth€ front housing.

NOTICE:Be carefulnot to 3cratchthe sealingrurfaca of
tho fiont housing.

AC-50
SYSTEM- COMPRESSOR
AIR CONDITIONING
(c) Removethe f ront O - ring.
D i s c a r dt h e O - r i n g .
(d) Removethe 2 pins.
(e) Removefront valvo platewith reedvalves.
(f) Removeand discardthe gasket.
Gasket
4. REMOVE FELT
(a) S€t SST on the folt,
s s T0 7 1 1 2 - 1 5 0 2 0

AC-51
SYSTEM_ COMPRESSOR
AIR CONOITIONING
(b) Pull the fslt with felt holderout of front housing.
ssr07112-15020
5. REMOVE SHAFTSEAL
(a) UsingSST,removethe snapringfrom th6 front hous-
ing.
s s T0 7 1 1 4 - 8 4 0 1 0
(b) Set SST on the shaft seal.

s s T0 7 1 1 2 - 8 5 0 3 0
Front
Housi
(c) UsingSST,put the shaft sealout of the front housing.

s s r 0 7 11 2 - 8 5 0 3 0
(d) Removethe O - ring from the shaft seal.
Discardthe O - ring.
6. INSTALL SHAFT SEAL

( a ) Installa new O-ring to shaft seal.
( b ) Fit shaft sealon SST.and installth€ shaft sealinto the
front housing.
s s T0 7 11 2 - 8 5 0 2 0
HINT: Clean uo the surface of the shaft seal with
comorossoroil.

AC-52
SYSTEM_ COMPRESSOR
AIR CONDITIONING
(b) UsingSST.installthe snapring into the front housing.

s s T0 7 1 1 4 - 8 4 0 1 0
7, INSTALL FRONTHOUSING
(a) Install2 pins in the front cylindsr.
(b) Lubricate a new O - ring with compressoroil and
installit in ths front housing.
(c) Installthe front suctionreedvalveoverth6 pinson the
front cvlinder.
(d) lnstallthe front valve plato with the dischargereed

valveover the oins on the front cylinder.
HINT:The front valve plate is markedwith an 'F".
V al v e P l a t e
AC
D i s c h a r g eV al v e
AC1112
(e) Lubricatea new gasketwith compressoroil and install

the gaskeron the valve plate.
Gasket
(f) Set SSTon th€ shaft to protoctth6 lip seal.

s s T0 7 11 2 - 8 5 0 1 0

AC-53
SYSTEM- COMPRESSOR
AIR CONDITIONING
(g) Installthe front housingon the front cylinder.
8. TIGHTEN5 THROUGHBOLTS
UsingSSTand torquewrench,graduallytightenthe 5
through bolts in 2 or 3 passes.
s s T0 7 1 1 0 - 6 1 0 5 0
9. INSTALLFELT
(a) Setthe felt with felt holderto th€ front housing.
try*44
,/@,...
la-E'\
-R..%)
\+#l
Rh
\r2*ryi-l
(b) Using pressureplate of magneticclutch, installth€

f6lt.
P r € s s u r eP l a t e
10. POURCOMPRESSOB OIL INTO COMPRESSOR

Add the sam€ quantityof oil as was remove,plus 20
cc (0.7 fl.oz),into the compressor.
Compressor oil:
ND OIL 8 or equivalont

AC-54
SYSTEM- COMPRESSOR
AIRCOT{DITIONING
11. INSTALLSERVICE VALVE
(a) Lubricatenew sealring with compressor
oil. Instatt
the s6alringin the servicsvalve.
(b) Installth6 servicevalveon th6 compressor.UsingSST

and torque wrench,tighten th€ bolts.
s s T0 7 1 1 0 - 6 1 0 5 0
T o r q u o :2 5 N ' m ( 2 5 0 k g f . c m , 1 8 f t . l b f )
12. CHECKSHAFTSTARTIilGTOROUE
Torque: 2.9 l{.m (30 kgf .cm, 26 in.'lbf) or less
MAGNETIC
CLUTCHASSEMBLY
1. IT{STALL STATOR
(a) Installth6 statoron the compr6ssor.
(b) UsingSST,installa new snap ring.

ssr07114-84020

AC-55
SYSTEM- COMPRESSOR
AIR CONDITIONING
NOTICE:Th. rn.p rlng rhould b. Inri.llcd .o thlt ltr
bcvclcdrldc facor up.
S n a pR i n g
(c) Connectthg statorleadwireto th€ comoressor

hous-
ing.
2. II{STALL ROTOR
(a) Installthe rotor on th6 comprossorshaft,
(b) UsingSST,installa new snap ring.
ssr 07114-84020
N O T I C E :T h c r n a p r l n g rhould bc Inrt!llcd ro thrt lis

beveled rido faccr up.
Sn a pRing
R -S h a p e
I
3. INSTALLPRESSURE PLATE
(a) Putthe shimsto the pr€ssure
plate.

AC-56
SYSTEM- COMPRESSOR
AIR CONDITIONING
(b) UsingSST and torque wrench,installthe shaft bolt.
ssT07112-76060
4. CHECKCLEARANCEOF MAGNETICCLUTCH
(a) set tho dial indicatorto the pressureplate of the
magneticclutch.
(b) Connectthe magn€ticclutch leadwire to the positive
(+) terminalof th€ battery.
(c) Checkthe clearancebetweenth€ prossuroplat€ and
rotor, then conn6ct the nogative(-) terminalof the
battery.
Stande?d clssrance:
0.5 + 0.15mm (0.020+ 0.0059in.)
lf the clearanceis not within standard clearance,
adjustthe clearanceusingshimsto obtainthe stand-
ard clearance.
Shimthickncar:
0.1 mm (0.004in.)
0.3 mm (0.012in.)
0.5 mm (0.020in.)

AC-57
SYSTEM_ COMPRESSOR
AIR CONDITIONING
INSTALLATION
COMPRESSOR
1 . I N S T A L LC O M P R E S S O R
7 A - F EE n s i n o :
Installcompressor with the 4 bolts.
T o ? q u e :2 5 N . m ( 2 5 0 k g f . c m . 1 8 f t . l b f )
Ex. 7A - FE Engine:
lnstall compressor with the 3 bolts.
T o r q u e :2 5 t { . m ( 2 5 0 k g f . c m , 1 8 f t . l b f}
2. INSTALLDRIVEBELT
3. INSPECTDRIVEBELTTENSION
(SeepageAC-26)
N
>.t-\
4.
5.
INSTALLENGINE
CONNECT
UNDERCOVER
DISCHARGE
TO COMPRESSOR
HOSEANDSUCTIONHOSE
NOTICE: Hoser should bo conncctrd immcdiltoly lftci

tha caps havs been romovad.
T o r q u e :1 0 N . m ( 1 0 0 k g f . c m , 7 f t . l b f )
O. CONNECTCONNECTOR TO MAGNETICCLUTCH
7, EVACUATE SYSTEMAND
AIR IN REFRIGERATION
E x c e o t7 A - F E WITH REFRIGERANT
CHARGE
Specifiedamount:
650 + 50 e (22.92+ 1.76oz.)
" n". leakt6ster,checkfor leakasEof refrioer-
p
:;:n
lf there is leakage,ch6ck th€ tighteningtorquo at the
joints.
9, CONI{ECT NEGATIVE(_) TERMINAL CABLE TO
BATTERY
10. |NSPECTA,/C OPERATION

AC-58
SYSTEM- RECEIVER
AIRCONDITIONING
RECEIVER
INSPECTION
ON_VEHICLE
INSPECT FITTINGFORLEAKAGE
Usinga gas leaktester,checkfor leakage.
lf thereis leakage,checkthe tightening
torqu6at th€
joints.
RECEIVER
REMOVAL
1. DISCHARGEREFRIGERANT FROM REFRIGERA-
TIOITI
SYSTEM
2. REMOVEBATTERY
CAUTION:Workmurt bo strrtcd rftor g0 seconds
from
the tim. tho ignitlon .wltch i. turned to rho'LOCK'
porition and tho nogrtivr (-) tarminal cable is discon.
nrctcd from thc blttrry.
3. REMOVEENGINECOOLANTRESERVOIR TANK
4. REMOVERECEIVER
(a) Removeth€ 2 boltsand both tubes from the receiver.
(b) Removsthe bolt, then remov€the receiverfrom the
receiver holder.
NOTICE: Csptho oponf itting3immediatelyto koepsmoi-
sture out of ihe sy3tom.

SYSTEM_ RECEIVER
AIR CONDITIONING AC-59
RECEIVER
INSTALLATION
1. INSTALLRECEIVER INTORECEIVER HOLDER
Installthe receiverinto the receiverholderwith tns
bolt.
2. INSTALL2 LIOUIDTUBESTO RECEIVER
Install2 liquidtubesto th€ r€ceiv6r
with 2 bolts,
T o r q u a :5 . 4 N . m ( 5 5 k g f . c m . 4 8 i n . . l b f )
NOTICE: Do not removr tho clpr untll thc tubct trc
connocted.
3. INSTALLCOOLANTRESERVOIR TAI{K
4. INSTALLBATTERY
5. IF RECEIVER WAS REPLACED,
ADD COMPRESSOR
OIL TO COMPRESSOR
Add 1Occ(2.9fl.oz.)
Comprecror oll:
ND OIL 8 o?equlvllcnt
6. EVACUATEAIR IN REFRIGERATTON
SYSTEMAND
CHAGEWITHREFRIGERANT
Specifiedamount:
650 + 50 g (22.92a 1.76 oz,)
7. INSPECTFOR LEAKAGEOF REFRIGERAI{T
Usinga gas laketester,checkfor leakageof refriger-
ant.
t leakage'
checkthetishtonins
torquoat,n"
jl,*:"
;
8. INSPECT
A,/C OPERATION

AC-60
A I R C O N D I T I O N I NSGY S T E M- C O N D E N S E R
CONDENSER
INSPECTION
ON_VEHICLE
1. INSPECTCONDENSER FINS FOR BLOCKAGEOR
DAMAGE
lf the fins areclogged,washthemwith wateranddry
with comoressed air.
NOTICE: Be carefulnot to damagetho fins.
lf the fins ar6 bont,straightonthem with a screwdriver
or pliers.
2. INSPECTCONDENSERAND FITTINGSFOR LEAK.
AGE
Usinga gas leak tester,check for leakage.
lf th6re is leakage,checkthe tightoningtorque at the
ioints.
C O N D E N S ERRE M O V A L
1. DISCHARGEREFRIGERANT FROM REFRIGERA.
TIONSYSTEM
(Seepase AC- I 5)
2. REMOVERADIATOR UPPERMOUNTINGS
Removethe 2 boltsandthe 2 uppermountings.
3. REMOVE2 TUBES
Remove2 boltsand2 tubes.
NOTICE:Cap the open f ittingr immediately to keop mois-
turo out of tho rystsm.

AC-61
SYSTEM- CONDENSER
AIR CONDITIOilING
4. REMOVECOIIIDENSER
(a) Remove the 2 nutsfrom condenser uppermounting.
(b) Pushthe radiatorto engineside.
(c) Pushthe condenser sideandpullit upward.
to radiator
INSTALLATION
CONDENSER
1, INSTALLCONDENSER
with 2 bracketsand 2 nuts.
lnstallthe condenser
2, INSTALLLIOUIDTUBES
Installbothtubeswith 2 bolts.
T o r q u e :9 . 8 N . m ( 1 0 0 k g f . c m , 7 f t . l b f)
NOTIGE:Do not romove caps until the tube is installed.
3. INSTALLUPPER SUPPORT
lnstallthe 2 boltsand 2 uppersupports.
4, REPLENISH COMPRESSOR OIL IF CONDENSER
HASBEENREPLACED
Add 40cc (1.4 f l.oz.)
Compressoroil:
NO OIL 8 or oquivalent
5. EVACUATE SYSTEMAND
AIR IN REFRIGERATION
WITH REFRIGERATION
CHARGE
Specifiedamount:
650 a 50 s (22.92+ 1.76oz.)
Usinga gas l6ak tester,check for leakageof refriger-
anl.

SYSTEM- EVAPORATO HEATERRADIATOR
AIR CONDITIONING
EVAPORATOR
EVAPORATOR
INSPECTION
1, CHECK
EVAPORATOR
FINSFORBLOCKAGE
lf the fins are clogged, clean them with compress€d
atr.
NOTICE:Never ule wrtor to claln the evrporator,
2. CHEAKFITTINGS FORCRACKSORSCRATCHES
Repairas nocessary.
EVAPORATORREMOVALAND
INSTALLATION
(SeepaseAC-32)
HEATER
RADIATOR
HEATERRADIATOR
REMOVAL
I. REMOVE HEATER UNIT
(SeepaseAC-34)
2. REMOVEAIR DUCT
(Seepasc AC- 35)
3. REMOVEHEATERRADIATOR
(SecpaseAC-35)
HEATERRADIATOR
INSPECTION
INSPECT FINSFORBLOCKAGE
lf the fins are clogged,cleanthem with compr€ss6d
atf .
HEATERRADIATOR
INSTALLATION
1. INSTALLHEATERRADIATOR
(Scc pagc AC- 37)
2. INSTALLAIR DUCT
(SeepageAC-37)
3. INSTALLHEATERUNIT
(SeepaseAC-37)

SYSTEM- WATERVALVE
AIR CONDITIONING AC-63
WATERVALVE
WATERVALVEREMOVAL
1, DRAIN ENGINECOOLANTFROM RADIATOR
HINT:lt is not necassaryto drain out all the coolant.
2, REMOVEWATER VALVE
(a) Disconn6ctthe water valve control cable.
(b) Disconnectthe water hose from the hoaterradiator
ptpe.
(c) Disconnectth6 wat6r hosefrom th6 wat€r valve.
(d) Removethe bolt and the water valve.
WATERVALVEINSTALLATION
H o s eC l i p
R a d i a t o rP i p s 1. INSTALLWATER VALVE
(a) Pushth€ water hoseonto th6 heaterradiatorpipe as
far as th6 ridgeon the pips and installthe hos€ clip.
(b) Installwater valvewith the bolt.
2. CONNECTHEATERHOSETO WATER VALVE
Water Hose 3. CONNECT WATER VALVE CONTROL CABLE TO
WATER VALVE
(a) Set the temperaturecontrolswitch to'COOL'.
COOL HOT
(b) Set the water valveleverto'COOL', installthe control
cableand lock the clamp.
HINT:Lock the clamp while lightlypushingthe outer
cable in the directionshown by th€ arrow.

Ac-64
sysrEM - EXpANSToN
AtRcoNDrrroNrl{c vALVE
EXPANSION
VALVE
1, CHECKOUANTITYOF GAS DURINGREFRIGERA.
TIONCYCLE
2, INSTALLMAt{IFOLDGAUGESET
3. RUNEI{GINE
Runthe engineat 1,500rpm for at least5 minutes.
Thencheckthatthe highpressuer is 1.37 - 1.53 MPa
( 1 4 - 1 6 k g / c m ' , 1 9 9- 2 2 8 p s i ) .
4. CHECKEXPANSION VALVE
lf the expansionvalve is faulty,th€ low pr€ssure
readingwill dropto O kPa(0 kglcm',0 psi).
HINT:Whenthe low prossure dropsto 0 kPa(0 kgl
cm',0 psi),f€el the r€ceivor's lN andOUTsidesfor no
t€mperatursdifference.
VALVEREMOVAL
EXPANSION
,1, REMOVEEVAPORATOR
(SeepasaAC-32)
2. REMOVEEXPANSION VALVE
(SeepaseAC-33)
E X P A N S I O NV A L V E I N S T A L L A T I O N
1. INSTALLEXPANSION
VALVE
(SeepageAC-33)
2. INSTALLEVAPORATOR
(SeepaseAC-33)

SYSTEM- VACUUMSWITCHING
AIR CONDTTTONING VALVE
V A L V E( V S V )
V A C U U MS W I T C H I N G
Ex. 7A-FE EngineModels:
VACUUMHOSECIRCUIT
VSV INSPECTION
1. REMOVE VSV
2, CHECKVACUUM CIRCUIT IN VSV BY
CONTII{UITY
BLOWII{GAIR INTOPIPES
(a) Connecttho VSV t€rminalsto th€ batteryt€rminalsas
illusstrated.
(b) B l o w i n t o p i p e ' A ' a n d c h e c k t h a t a i r c o m o so u t o f
pipe "B'.
(c) Disconnectthe battery.

(d) Blow into pipe "A" and check that air doss not coms
'8".
out of pipe
lf a problemis found, replacethe VSV.
C H E C KF O RS H O R TC I R C U I T
Usingan ohmmeter,checkthat there is no continuity
betwegneachterminaland tho VSV.
lf ther6 is continuity,roplacethe VSV.
4. CHECK FOR OPENCIRCUIT

Usingan ohmmetsr,m€asurethe resistancebotwoen
th6 two terminals.
Resistance:
30 - 34 Q 8t 20'C (68"F)
valueis not as specified,replacethe VSV.
lf resistance

AC-66
sysreu - vlcuunlswrrcHrrue
ltn conorrrortnc vntvevsv)
VSV INSPECTION
7 A - F EE N G I N E
MODEL:
1. INSPECTVACUUM CIRCUITCONTINUITYIN VSV

BY BLOWINGAIR INTO PIPES
(a) Connectthe VSV terminalsto the battorytsrminalsas
illustrated.
(b) Blow into pipe 'A" and check that air comes out of
pipe 'C".
2. IilSPECTFOR OPENCIRCUIT
Usingan ohmmeter,moasurothe resistancebetween
th6 2 terminals.
Roristlnco:30 - 34 O !t 20 'C (88'F)
lf the r6sistanceis not within sp€cification,replace
tho VSV.

AC-67
SYSTEM_ BLOWER
AIBCONDITIONING MOTOR
MOTOR
BLOWER
BLOWERMOTORREMOVAL
1. NEGATIVE(_} TERMIITIAL
DISCO]IIIIIECT CABLE
FROMBATTERY
GAUTION: Work mu.t bc .tlitcd after 90 tccondr from
the tlme the lgnition swltch l. turned to the'LOCK'
posltlon and thr ncgrtlv. (-) tcrmlnal cable is discon.
noctcd from tho batt.ry.
2. REMOVEGLOVEBOXASSEMBLY
(SeepageBO-52)
3. REMOVEBLOWERMOTOR
(a) Disconnect from the blowermotor.
tho connoctor
(b) Removethe 3 screwsandthe blowermotor.
LHDModsls BLOWERMOTORINSPECTION
INSPECT BLOWERMOTOROPERATION
Connecttho positivo(*) leadfrom the batteryto
terminal 1 and the negativo(-) lead to terminal 2, ffi
then check that tho motor oD€rationis smooth.
RHD Models
BLOWERMOTORINSTALLATION
1, INSTALLBLOWERMOTOR
(a) Installthe blowermotorwith the 3 screws.
(b) Connecttho connector to the blowormotor.
2. INSTALLGLOVEBOXASSEMBLY
(SeepaseBO- 52)
3. CONITECT NEGATIVE (-) CABLEFROMBATTERY

AC-68
SYSTEM- ELECTRIC
AIR CONDTTIONING COOLINGFAN
( - ) T e r m r nIaC a b l e E L E C T R IC O O L I N G
FAN
O N _ V E H I C L IEN S P E C T I O N
Inspection Condenser Fan Operation:
NTE G A T T V(E- ) T E R M T N ACABLE
1. DTSCONNEC L
FROM BATTERY
CAUTION: Work must be startsd after 90 seconds from
the time tha ignition switch ir turned to the'LOCK'
p o s i t i o na n d t h o n o g a t i v o( - ) t e r m i n a l c a b l e i s d i s c o n -
nectod from ths battery.
2. INSPECTCOf{DENSER FAN
(a) Disconnectthe fan conn6ctor.
(b) Connectbattoryand ammeterto the coolingfan con-
noctor.
(c) Check that the condenserfan rotatossmoothly,and
check the readingon th€ ammetor.
Standard amperago:
e.o - 7.4A
(d) Conectthe coolingfan connector.
( _ ) T E R M I N A LC A B L ET O
3 . C O N N E C TN E G A T I V E
BATTERY
l n s p e c t i o nR a d i a t o rF a n O p e r a t i o n :
1. DISCONNECNTE G A T I V(E_ ) T E R M I N AC
L ABLE
FROMEATTERY
CAUTION: Work must bo startod after 90 secondr from
the timo ths ignition lwitch ir turned to tho'LOCK'
posilion and ths nogative (-) terminal cabla ir discon-
noctod from tha battery.
2. INSPECTRADIATORFAN
(a) Disconnectthe coolingfan connector.
Ammelar (b) Connectbatteryand ammeterto the coolingfan con-
noctor.
(c) Check that the cooling fan rotates smoothly, and
check the readingon the ammeter.
Strndrrd amper!go:
5.7 - 7.7 A
(d) Connectthe coolingfan connector.
3. CONT{ECTNEGATIVE(-) TERM]NAL CABLE TO
BATTERY

AC.69
SYSTEM_ ELECTRIC
AIR CONDITIONING COOLINGFAN
F A N R E L A Y SI N S P E C T I O N
COOLING
(See page AC - 79)
Water TemperatureSwitch
WATERTEMPERATURE SWITCH
INSPECTION
1 . D R A I NE N G I N C
E OOLANT
2, REMOVEWATERTEMPERATURE SWITCH
3. INSPECTWATER TEMPERATURE SWITCH

(a) Usingan ohmmeter,check that there is no continuity
betweenthe tsrminalswhen the coolanttemoerature
is above93" C (199' F).
(b) Using an ohmm6t6r,chsck that thera is continuity o$w$sw
betwe€nthe terminalswhen the coolantt€mp€rature ffi
'
i s b e l o w8 3 ' C ( 18 1 F ) .
4. REINSTALLWATER TEMPERATURE SWITCH

5, REFILLWITH ENGINECOOLANT
6. START ENGINEAND CHECK FOR COOLANT
LEAKS

AC-70
SYSTEM- AIR INLETCONTROL
AIR CONDITIONING SERVOMOTOR
A I R I N L E TC O N T R O L
SERVOMOTOR
AIR INLETSERVOMOTOR
REMOVAL
1, REMOVEGLOVECOMPARTMENT
PARTS
(SeepageBO-52)
2. REMOVESERVOMOTOR
(a) Disconnct
th€ conn€ctor.
(b) Removethe 2 screwsandthe servomotor.
AIR INLETSERVOMOTOR
INSPECTION
ld32ll ll
,ffi\ INSPECTSERVOMOTOROPERATION
'lf
f )
terminal1 the nogative(-) lead to t€rminal3, check
that th€ arm rotatosto the'FRESH'side smoothly.
E_3 Nl0l42
(b) Connect the positive (*) lead from the battery to

terminal 1 and th6 negative(-) lead to terminal 2,
ch€ck that tho arm rotatasto the'RECIRC-side smo-
othly.
lf operationis not as specified,replacethe sorvomo-
tor.
INSTALLATION
AIR INLETSERVOMOTOR
1. INSTALLSERVOMOTOR
(a) Installthe servomotor
with 2 screws.
(b) Connectthe conn€ctor.
2. INSTALLGLOVECOMPARTMENT PARTS
(SeepageBO- 52)

4C.71
SYSTEM- AIR OUTLETCONTROL
AIR CONDITIONING SERVOMOTOR
A I R O U T L E TC O N T R O L
SERVOMOTOR .,
AIROUTLET SERVOMOTOR REMOVAL.'"
1 . R E M O V EI N S T R U M E N T
L O W E RN O . 1 F I N I S H
PANEL
(Seepage BO- 52)
2. REMOVEINSTRUMENT PANELFINISHPANEL
(SeepageBO- 52)
3. REMOVEHEATERDUCTNO.2
(SeepaseBO-52)
4, REMOVESERVOMOTOR
(a) Disconnect the connector.
(b) Removetho 2 screwsandthe servomotor.
AIR OUTLETSERVOMOTOR
INSPECTION
INSPECTSERVOMOTOROPERATION
(a) Connect the positive (*) lead from the batt€ry to
terminal5 and the negative(-) leadto terminal6.
(b) Connect the negative(-) lead from the battory to
each terminaland check that th€ arm rotatesto each
position,as shown below.
Conngct6dtgrminrl Porition
FACE
s/L
FOOT
4 FOOf/ OEF
7 |.lEE
lf operationis not as specified,replacethe sorvomo-

tor.

Ac'72
sysrEM - ArRourLETcoNTRoL
ArRcoNDrtoNrNG sERVoMoroR
AIR OUTLETSERVOMOTOR
INSTALLATION
1. INSTALLSERVOMOTOR
(a) with 2 screws.
lnstallthe sorvomotor
(b) Connectthe connoctor.
2. INSTALLHEATERDUCT
3. INSTALLINSTRUMENT FINISHPANEL
4. INSTALL INSTRUMENTLOWER NO. 1 FINISH
PANEL

AC-73
SYSTEM- BLOWERRESISTOR
AIR CONDITIONING
BLOWERRESISTOR
BLOWERRESISTOR
REMOVAL
NEGATIVE(_) TERMINALCABLE
1, DISCONNECT
FROMBATTERY
CAUTION: Work must bo startod Eftcr 90 rccondr from
tho time tho ignition switch i8 turned to tho'LOCK'
p o s i t i o nr n d t h 6 n o g r t i v o ( - ) t o r m l n a l c a b l c l s d b c o n -
noctod trom thc battcry.
2. REMOVEGLOVEBOXASSEMBLY
(Seepase BO- 52)
3. REMOVEBLOWERRESISTOR
(a) Disconnect
th6 connector
from the blowerresistor.
(b) Removeth€ 2 screwsandthe blowerresistor,
BLOWERRESISTOR
INSPECTION
INSPECT
BLOWERRESISTOR
CONTINUITY
Testar conhgction to
Condition Spccificd vrluo
torminalnumber
Constant 1 - 2 - 3 - 4 Continuity
lf continuity is not as specified,replacethe blower

resistor.
BLOWERRESISTOR
INSTALLATION
1. INSTALLBLOWERRESISTOR
(a) Installthe blowerresistorwith the 2 screws.
(b) Connectthe connsctorto th€ blow6rresistor,
2. INSTALLGLOVEBOXASSEMBLY
(ScepageBO-52)
3. CONNECT f{EGATIVE(_)TERMINALCABLEFROM
BATTERY

AC-74
SYSTEM- PRESSURE
AIR CONDITIONING SWITCH
PRESSURE
SWITCH
1. INSTALLMANIFOLDGAUGESET
(SeepageAC- 15)
2. DISCONNECTCONNECTORFROM PRESSURE
swtTcH
3. RUT{ENGINE
AT APPROX.
2,OOO
RPM
4. INSPECT
PRESSURE
SWITCHOPERATION
M!gnctic ClutchCont?ol:
( M a g n e t i cC l u t c hC o n t r o l i
(a) Conn€ctth6 positiva(+) lead from the ohmmeterto
Low Pressur€Side High PressureSide
t e r m i n a4l a n d n e g a t i v e( - ) l e a dt o t € r m i n a l1 .
O N ( C o n r i n u i t)y
(b) Checkcontinuitybetw€snt€rminalswhen refrigerant
prossureis changed,as shown.
lf operationis not as specified,replacethe prossure
3 , 1 4 0k P a
1 2 . 0k g f / c m ' , 2 8 p s i ) ( 3 2 . 0k g t / c m 2 ,4 5 5 p s i ) swrtch.
O F F ( N o C o n t i n u i t y ) O F F ( N oC o n t i n ! l t y )
Nol l '1
^)<L,,
CoolingFan Control:
(CoolingFan Controt) (a) Connectth6 positive(*) lead from the ohmmet6rto
1 5 2 0k p ! t e r m i n a 2l a n d n e g a t i v e( - ) l e a dt o t e r m i n a 3l .
( 1 5 . 5 k g f l c h 2 , 2 2 0p s t )
(b) Checkcontinuitybetweonlerminalswhen refrigerant
prossursis changed,as shown.
lf operationis not as specified,raplacethe pressure
1.?26kpr
switch.
(No continuity)
( 1 2 . 5k q f / q h :1, 7 8p s l ) 5 . S T O P E N G I N EA N D R E M O V EM A N I F O L DG A U G E
SET
6. CONNECTCONNECTORTO PRESSURE SWITCH

SYSTEM_ PRESSURE
AIR CONDITIONING 4C.76
SWITCH
PRESSURE
SWITCHREMOVAL
1. DISCHARGE REFRIGERANTFROM REFRIGERA.
TION SYSTEM
(Seepage AC - 15)
2. REMOVEPRESSURE SWITCH
(a) Disconn€cttho connector.
(b) Ramovethe pressureswitch from the liquidtube,
HINT: Lock the switch mount on ths tube with an
open end wrench, being careful not to deform the
tube, and r6movethe switch.
PRESSURE
SWITCHINSTALLATION
I. INSTALL PRESSURE SWITCH
(a) Installthe pressuroswitch to tho liquidtub€.
Torque:9.8 N.m(100kgt'cm,7 ft.lbt)
HINT: Lock th6 switch mount on th€ tub6 with an
open end wrench, being careful not to deform tho
tuba, and installtho switch.
(b) Connectth6 connector.
2. EVACUATEAIR IN REFRIGERATIOT{ SYSTEM AND
Spoclflcd!mount:
660 + 50 s (22.82+ 1.76oz.)
Usinga gas leak test6r,check for leakageof refriger-
ant from th6 pressufeswitch mount.
4. INSPECTA/C OPERATTON

Ac-76
ArRcoNDrloNr{c sysrEu - EVApoRAToR
TEMpERATURE
sENSoR
EVAPORATOR
TEMPERATURE
SENSOR "'
TEMPERATURE
EVAPORATOR SENSOR*,"
REMOVAL
1. REMOVE COOLING UNIT
(SeepageAC-31)
2. REMOVEEVAPORATOR
(SeepageAC-32)
3. REMOVEEVAPORATOR TEMPERATURE SENSOR
Pullout the 6vaporator
temperature
sensorfrom eva-
DOrator.
Thermometer
EVAPORATORTEMPERATURE
SENSOR
INSPECTION
Check resistanc€betweon terminal of evaporator
t€mp€ratu16 sensorconnectorat each t€mperatu16
Borirt!nca:
rr 0 'c (32 'F) 4.6 - 5.0 kQ
a r 1 5 ' C ( 5 9 ' F )2 . 1 - 2 . 6k Q
10 cm {3.94 in,) Aco,76 (As temperaturoas t6mp€ratureincreases,the resist-
ance decraasesgradually.)
"'
EVAPORATORTEMPERATURE
SENSOR^","
INSTALLATION
1. IilSTALL EVAPORATOR TEMPERATURE SENSOR
Installthe evaporatortomperaturesensorto evapora-
to r.
2. INSTALL EVAPORATOR
(See page AC-33)
3. INSTALL COOLINGUNIT
(Seepage AC-33)

A C.77
SYSTEM_ REVOLUTION
AIR CONDITIONING SENSOR
DETECTING
R E V O L U T I OD
NE T E C T I N S
GE N S O R
E x .7 A - F E E n g i n eM o d e l s :
FROMBATTERY
CAUTION: work must bo started after 90 secondr from
the time tho ignition .withch is turned to tha'LOCK-
position and the nogstiva (-) terminal cable ir dircon-
nected from tho battery.
2. DISCONNECT CONNECTOR OF REVOLUTION DET-
ECTINGSENSOR
3. INSPECT REVOLUTION DETECTINGSENSOR
b6tw66n
Checkthe resistance terminals1 and2 of the
sensor.
Specified iesistancoi
'G (68'F)
165 - 205 Q at 20
l f t h e r o s i s t a n c ev a l u e i s n o t a s s p e c i f i e d , r e p l a c € t h e
revolution dotscting sensor.
DETECTING
REVOLUTION SENSOR
REMOVAL
1. REMOVECOMPRESSOR
(Seepage AC- 42)
2, REMOVEREVOLUTION DETECTING SENSOR
(a) Removo2 bolts.
(b) Removethe revolution
d€tectings€nsor.
REVOLUTIONDETECTING
SENSOR
INSTALLATION
1. INSTALLREVOLUTION DETECTING SENSOR
Usinga torquewrench,tightenthe bolts.
Torque:6.9 N.m (60 kgf.cm,52 in..lbf)
2. INSTALLCOMPRESSOR
(SeepageAC-57)

AC-78
SYSTEM- RELAY
AIRCONDITIONING
R / BN o , 5
C o n d e n sr eF a n
RELAY
R e l a yN o , 2 RELAYREMOVAL
1, NEGATIVE(-) TERMINALCABLE
DISCONNECT
FROMBATTERY
CAUTIOI{: Work must be ltlrtod lltoi 90 reconds from
\ thc tlmc th. ignition rwilch ir iurnod to the'LOCK'
Condens€r poritlon and tho nogativo (-) tsrminal cable is discon-
R e l a yN o . 3
nccted fiom thc battcry.
2. REMOVERELAY
RELAYINSPECTION
1 1. INSPECTMAGNETICCLUTCHRELAYCONTINUI-
TY
5 Tlltar oonnaction to
Condition Spocificd
vrluo
tarminalnumb!r
Conrt!nt 1 - 2 Continuity
E E a 0 4lgl r l 4 0
ApplyB+ brtwccn
Continuity
tlrmlnll! | lnd 2.

roplaceth6 r6lay.

AC.79
SYSTEM_ RELAY
AIRCONDITIONING
2. HEATERMAIN RELAYCONTINUITY
INSPECT
Tostorconn6ctionto
Condition Spociliedvaluo
l6tmtnalnumo€r
Constant Continuity
2 - 4
Apply B+ b6twoon
4 - 5 Continuity
torminalsI and 3.
850 Bt!8aa
lf continuityis not as specified,replacethe relay.
3. I N S P E C TC O O L I N GF A N R E L A YN O ,1 C O N T I N U I T Y
Tgstorconn€ctionto
Condition Sp6cifisdva u6
l 6 r m t n an u m 0 6 r
; r.-'1i--.J2) Con6tant Continuity

3 - 4
ApplyB+ bstween
3 - 4 No continuity
terminals1 and2.
N O ? 9 9 1N O 8 l 1 0
lf continuityis not as specified, replacoth6 relay.

4. T O N D E N S EFRA N R E L A YN O , 2 C O N T I .
I N S P E CC
NUITY
Testorconn6ctionto
Condition Specified v€i(J€
t€rminalnumber
Con6tant Continuity
3 - 4
ApplyB+ b€tw€on
ContinLrity
t€rminols1 and2.
lf continuityis not as specified,replacetho relay.

5. INSPECTCONDENSERFAN RELAY NO. 3 CONTI-
NUITY
Tostorconn6ctionto
Condition Specifi€dvalus
t o r m i n enl u m b € r
Constant Continuity
Apply B+ botwoen
Continuity
t€rminalr I and 2.
8 8 4 0 4 98 E 1 8 4 0 lf continuityis not as specified,replacethe relay.
RELAYSINSTALLATION
1 . I N S T A L LR E L A Y S
BATTERY

Ac-80
A r Rc o N D r r o N r N sGy s r E M- A r Rc o N D r r o N EARM p L T F T E R
W i r e H a r n e s sS i d e A I RC O N D I T I O N EAR
MPLIFIER
A I RC O N D I T I O N EARM P L I F I E R
INSPECTION
INSPECT A M P L I F I E RC I R C U I T
(a) Disconnectthe amplifierand inspectthe connectoron
the wi16 harnessside,as shown in the chart below.
Test conditions:
r lgnitionswitch ON
. Temoeraturecontroldial MAX COOL
o Blowerdial Hl
Tester connectionto
Condition Speciliodvalu6 (Continuity)
t€rminalnumbor
6 Ground Constant Continuity
T€aterconnectionto
Condition Spocified valus (Resistance)
tsrminalnumbor
t1 Constant r . 5 K O a r 2 0 " C ( 6 8" F )
l5 l8 {Ex7
. A-FE) Constant A p p r o xI. l 5 O a t 2 0 " C ( 6 8 ' F )
7 - Ground Constant 1 . 2K O a t 2 0 " C ( 8 8 ' F )
T6st6r connoctionto
Condition Specifi€d valu€ (Voltago)
lorminal number
4 - Ground{RHD only) ECON6witch on Bstteryvoltags
4 - Ground (RHOonly) ECONswitch oft No voltago
5 - Ground Constent Approx, l0 - 14 V
10 - Ground A,/C switch on 8att6ry voltago
l0 - Ground A/C dwitch otf No vollaga
12 - Ground A/C switch on B6tteryvoltage
12 - Ground A/C switch olf No voltago
14 - Ground Cohstant Batt€ryvoltag.
lf circuit is as specified,try replacingthe amplifier

wilh a new one. lf the circuit is not as specified,
insp€ctths circuitsconnectedto oth6r parts.

4C.81
A I R C O N D I T I O N I NSGY S T E M- A I R C O N D I T I O N E
ARMPLIFIER
F r o m B a c kS i d e (b) Connectthe connectorto A/C amplifierand inspect

wire harnessside connectorfrom the back side, as
shown.
Testercondition:
e lgnitionswitch ON
. Temp€ralurecontroldial MAX COOL
r Blowsr dial Hl
T€st6r connectionto
Condition Specitiodvalue (Voltago)
t6rminalnumbor
Rofrigorantpr€ssure
3 Ground Bait6ryvolt6go
I 9 6 - 3 , 1 4 0k P a
Refrigerantpr6ssur€
3 - Ground No voltago
1666than 196 or moro th6n 3,140 kPa
lf circuit is not as specified.replacethe amplifier.

Ac-82
sysrEM - ArRcoNDrroNER
ArRcoNDrnoNrNG coNTRoL
ASSEMBLy
A I RC O N D I T I O N ECRO N T R O L
ASSEMBLY
A I RC O N D I T I O N ECRO N T R OA
LSSEMB[V''
REMOVAL
( _ } T E R M I N A LC A B L E
FROMBATTERY
CAUTIOi{: Work must be stsrted rf tar g0 seconds f rom
the time the ignition switch is turned to the 'LOCK'
p o s i t i o na n d t h o n o g a t i v a( - ) t e r m i n a l c a b l a i s d i s c o n -
noctod from tho brttory.
2. REMOVEINSTRUMENTLOWERFINISHPANEL
(Seepage BO- 52)
3 . R E M O V EH E A T E RA I R D U C T N O . 2
Removethe scrsw and heaterair duct No. 2.
4. DISCONNECTWATER VALVE CONTROLCABLE
5 . D I S C O N N E C TM A X C O O L D A M P E R C O N T R O L
CABLE
(a) Removethe water valve control cable guide.
(b) Disconnectthe max cool damoerconntrolcablefrom
tho hoaterunit.
6 R E M O V EU P P E RC O N S O L EP A N E L
(Seepage BO- 52)
7 . R E M O V EC E N T E RC L U S T E RP A N E L
(See pase BO- 52)
8, R E M O V EA I R C O N D I T I O N EC
RO N T R O LA S S E M B L Y
(a) Removethe 2 scraws.
(b) Disconnetth€ connector.
(c) Removethe air condition6rcontrol assembly.

4C.83
SYSTEM_ AIR CONDITIONER
AIR CONDITIONING ASSEMBLY
CONTROL
A I RC O N D I T I O N I NCGO N T R OA
LSSEMBLY
INSPECTION
LHD
@,o*
RHD
Conngctor'B'
"A"
Connector Connector" 8"
N 1 0 1 4N
31 1 0 8 5
h-22.2.9a2
"A" lllumination:
C o nn e c t o r
INSPECTILLUMINATION
LHD Models:
(a) Connsct th€ positivo (*) lead from th€ battery to
l - 8 a n d t h e n e g a t i v s( - ) l e a dt o t e r m i n aA
t e r m i n aA l
-zt.
(b) Checkthat the illuminationlights up.
lf th€ illuminationdoos not light up, test th6 bulb.

Ac-84
sysrEM - ArRcoNDrroNER
ArRcoNDrnoNrNc coNTRoLASSEMBLy
"A" RHD Models:
Connector
(a) Connoct the positive (+) lead from the battery to
tsrminaA l - 1 9 a n d t h e n e g a t i v e( - ) l e a dt o t e r m i n a l
A- 17.
(b) Checkthat th€ illuminationlights up.
lf the illuminationdoes not light up, t6st the bulb.
C o n n e c t o "r A " lndicators:

1. TNSPECT A/C INDICATOR
LHD Models:
(a) Conn€ct the positive (+) lead from the battery to
t e r m i n aA l - l 9 a n d t h e n e g a t i v e( - ) l e a dt o t e r m i n a l
A- 18.
(b) Push the A/C button in and check that the indicator
l i g h tu p .
lf operationis not as specified,replacetho A/C con-
"A" trol assembly.
Connector
RHD Models:
(a) Connoct tho positive (+) lead from the battery to
terminal A-12 and the negative(-) lead to tsrminal
A- 18.
;AC. (b) Push the A/C button in and check that the indicator
l i g h ru p .
lf operationis not as specified,replac6th6 A/C con-
trol assembly.
C o n n e c t o r" A " 2. INSPECTMODE INDICATOR

LHD Models:
(a) Connoct the positive (+) lead from the battery to
l - 1 9 a n d t h e n € g a t i v s( - ) l e a dt o t e r m i n a l
t e r m i n aA
A-22.
(b) Push eachof the mod€ buttonsin and checkthat their
indicatorslight up.
ff operationis not as specified,replacethe A/C con'
trol assembly.
Connector"A,, RHD Models:

terminalA- 18 and the negativo(-) lead to terminal
A-9.
(b) Push eachof th€ modebuttonsin and checkthat their
indicatorslight up.
lf operationis not as specified,replacethe A/C con-
trol assemblv.

4C.85
SYSTEM_ AIR CONOITIONER
AIR CONDITTONTNG CONTROL
ASSEMBLY
"A"
Connector 3. INSPECTAIR INLET INDICATOR
LHD Models:
(a) Connect the positivo (*) lead from th6 battory to
terminalA- 19 and the negative(-) leadto terminal
A-22.
(b) Checkthat the FRESHand RECIRCindicatorslight up
alternatolyeach time th€ air inlet control switch
button is oressed.
Nr0t3 lf operationis not as specified.replacethe A/C con-
trol assembly.
C o n n e c t o "r A " RHD Models:
(a) Connect the positive (+) lead from th6 battery to
l - 1 8 a n d t h e n e g a t i v e( - ) l e a dt o t 6 r m i n a l
t e r m i n aA
A-9.
(b) Checkthat th6 FRESHand RECIRCindicatorslight up
alternatelyeach time the air inlet control switch
button is pressed.
ff operationis not as specified,replacethe A/C con-
trol assemblv.
C o nn e c t o r" A " 4. INSPECTINDICATORDIMMIf{G OPERATION

LHD Modelg:
(a) Connect th6 positive (*) lead from the battery to
terminalA- 19 and th6 negativo(-) leadto terminal
A-21 and A-22.
(b) Connect the positive (*) lead from th6 battery to
terminal A - 8 and check that th€ mode indicator
dims.
lf operationis not as specified,replacethe A/C con-
trol assemblv.
RHD Models:
C o n n e c t o "r A "
(a) Connect the positive (+) lead from the batt€ry to
t6rminalA- 18 and the negative(-) lead to terminal
A - 1 7 a n dA - 9 .
(b) Connect th€ positivo (+) lead from the batt€ry to
torminal A - I 9 and check that the mode indicator
dims.
ff operationis not as specified.replaceth6 A/C con-
trol ass€mblv.

Ac-88
sysrEM - ArRcoNDrnoNER
ArRcoNDrroNrNG coNTRoL
ASsEMBLy
C o n n e c t o "r A " 5. INSPECTA/C SWTTCH

CONTTNUTTY
LHD Modeb:
T6st.r conngctionlo
Switch po!ition Spocitiod
valu6
trrminal numbor
OFF No continuity
ON Al5 - A20 Continuity
ff continuityis not as specified,replacethe A/C con-

h 22.2 trol assembly.
RHD Modeb:
Tast6r connactiohto
Switch po!itioh Specili.d voluo
torminalnumbor
OFF No continuity
ON Al0-Atl Continuity

trol assembly.
Connector "A" 8. INSPECTMODECONTROL

SWITCHCOt{TINUITY
LHD Models:
To6terconnoctionto
Switch po6ition Sp6cifi6dvalue
tsrminalnumb6r
FACE A7 - 422 Continuity
B/r A6 - 422 Continuity
FOOT A5 - A22 Continuity
FOOT,/DEF A4 - A22 Continuity
h222
A3 - 422 Contanuity
lf continuityis not as specified,replacethe A/C con-

trol assembly.
RHD Modelg:
Toster connectionto
Switch po.ition Spocifiod valu6
terminelnumbar
FACE At3 - A9 Continuity
B/L AI_49 Continuity
FOOT A5_A9 Continuity
FOOT/OEF A8-49 Continuity
A7 - 419 Continuity
lf continuityis not as specified,replac6th€ A/C con-

trol assemblv.

AC-87
A I R C O N D I T I O N I NSGY S T E M_ A I R C O N D I T I O N ECRO N T R OA
LS S E M B L Y
C o n n e c t o r" A " 7. I N S P E CATI RI N L E TC O N T R OSL W I T C HC O N T I N U -

ITY
L H DM o d e l s :
Tester conn6ctointo
Switch position Specifiodva uo
t6rmrnalnufiber
RECIRC Continuity
FRESH A16 Continuity
lf continuityis not as specified,replacethe A/C con-

trol assembly.
RHD Models:
T€st€rconnoctointo
Switch position Specifiedvalue
t€rmanalnumber
RECIRC A3_A9 Continuity
FRESH A4_A9 Contrnurty
f f c o n t i n u i t y i s n o t a s s p e c i f i e d ,r e p l a c e t h e A / C c o n -
t r o l a s s e mb l y .
C o n n e c t o r" A " 8. I N S P E CE
T C O NS W I T C HC O N T I N U I T(YR H DO n l y )
T€sterconnectionto
Switch posrlron Specifiedva ue
t e r m i n anl u m b e r
OFF
ON A2- At0
No conUnLJr!y
Contrnuity
Ae:i
trol assembly.
9. INSPECTBLOWERSPEEDCONTROLSWITCHCON.
TINUITY
lf continuityis not as specified,replacethe A/C

trol assembly.

Ac-88 A r Rc o N D r n o N r NsGy s r E M- A r Rc o N D r r o N EcRo N T R oA
LssEMBLy
*'".'
A I RC O N D I T I O N I NCGO N T R O C
L ABLE
ADJUSTMENT
1 . A O J U S TA I RM I X D A M P E R
C O N T R OC
LABLE
Set the air mix damoerand ths controlswitch to
"COOL"
oosition,installthe controlcableand lock the
c l a m p w h i l e l i g h t l yp u s h i n gt h e o u t e r c a b l e i n t h a
drrectionshown bv arrow.
cooL 2. ADJUST WATER VALVE CONTROLCABLE

"COOL"
\l
- -,i.\
S6t the water valve and control switch to
position.installthe control cable and lock tho clamp
l*7 w h i l e l i g h t l yp u s h i n gt h e o u t 6 r c a b l ei n t h e d i r e c t i o n
shown bv the arrow.
A I RC O N D I T I O N I NCGO N T R OA
LSSEMdLV
INSTALLATION
1. INSTALLA/C CONTROL PANEL
(a) Connectthe connector to A/C controlpanel.
r."fr-9 (b) Installthe A/C colntrolpanelwith 2 screws.
2. INSTALLCENTER CLUSTER PANEL
3. C O N N E CM T A X C O O LD A M P E R C O N T R OC LABLE
4. CONNECT WATERVALVECONTROL CABLE
5. I N S T A L LH E A T E R
D U C TN O . 2
6. INSTALLINSTRUMENT LOWERFINISHPANEL
7. CONSOP
I N S T A L LU P P E R L ANEL
BATTERY
9. INSPECT A,/C OPERATION

AC-89
A I R C O N D I T I O N I NSGY S T E M' S E R V I CS
EP E C I F I C A T I O N S
SPECIFICATIONS
SERVICE
DATA
SERVICE
Refrigerantchargevoiume 650 i 50 s (22.92X 1.76ozl
Drive bslt deflection
7A_FE 6 . 0 - 7 . 0 m m ( 0 . 2 3- 0 . 2 7 I n . )
55 Ft ano JJ rE 6.0 9 . 0m m ( 0 . 2 3- 0 . 3 5i n . )
9 . 0 - 1 1 . 0m m ( 0 . 3 5- 0 . 4 3 i n . )
Drive belt tension lReference)

IA FE New bolt 520 - 755 N (53 77 kst)
Us€d bs t 2 6 4 - 3 5 3N ( 2 7 - 3 6 k s f )
55 FE and 35 FE New b€lr 6 1 7 - 8 s 3 N ( 5 3- 8 7 k s f )
Usod b6lt 441 530 N (45 - 54 ksf)
35 GE N e wbolt 617 - 853 N (63 - 87 ksf)
Us€d belt 333 - 422 N (34 - 43 ksf)
ldl€ speed
IA-FE Magn€ticclutch not engagod Approx.700 rpm

Magnetic clutch engaged A p p r o x . 9 0 0r p m
55-FE and3S-FE M s g n € t i cc l u t c hn o t e n g a g e d Approx.750 rpm

Magnetic clutch engaged A p p r o x . 8 5 0r p m
3S-GE M€gneticclutch not sngagod A p p r o x . 8 5 0r p m

Magnetic clutch ongag€d A p p r o x . 9 5 0r p m
Magnelrcc utch clearance 0 . 5 t 0 . 1 5m m1 0 . 0 2 a

0 0 , 0 0 6i n . )
T O R O U ES P E C I F I C A T I O N S ffi
Part tightoned N.m kgf cm It.tbf
Suctionhose x Compressor 10 100 7
Dischargghose x Compressor l0 100 7
Compressorx Engine 25 250 18
Sorvice valv€ x Compr€ssor cylinder 250 la

Front housrng)( Compressorcylindor 250 18
Liquid tub6 x R€c€rvsr 5.4 48 in..lbf
Liquid tubo x Condens€r l0 100 7
Exoansionvalve x EvaDorator 5.4 55 48 in..lbf
Suctrontub€ x A/C unit 10 100 7
L i q u r dt u b € x A / C u n i t 10 100 7
Pressur€switch x Liquid tubo t0 100 7

Revolutiond€tectings€nsorx Comprossor 60 5 2 i n .l b f

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Celica 1993 At200 Series

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Celica 1993 At200 Series

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@ToYoTA & B O D Y

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This repairmanualhas beenprepared to provideinformation

For the servicespecifications and repairplocedureof the

All informationin this manualis basedon the latestproduct

TOYOTA MOTOR CORPORATION

o 1995 TOYOTA MOTOR CORPORATION

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N.rn (ksi;"annn torque

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The proceduresara presentedin a step-by-stop format:

piston a3 showd in the illustration'

technicianwith a FASTTRACKto the informationneeded.

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Precoated parts are bolts and nuts, etc. that are

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M e d i u m C u r r e n t Fuse and High Current 10. When replacing f u s e s ,b e s u r s t h e n e w f u s e h a s t h e

lllustraiion Symbol Part Nam€ Abb16vi8tion

------\_'z'rc- FUSE FUSE

--@- H I G HC U R R E NFTU S E H-FUSE

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( b ) To disconnectvacuumhoses.pull on the snd, not

pl6 Tag hosesbeforedisconnectingthem:

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14. Unlessotherwisestat€d,all resistanceis measuredat

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ABS Anti-Lock BrakoSvstgm

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Mark Class Mark Class

Hexagon 4- 4f stud bolt

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6 1 5 55 48 in. lbf 6 60 52 in. lbf

1.25 34 340 25 3't 380 21

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09333-00013 Clutch0 rphrrgmSpringAlioner

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Clutchdoes not disengago 1 4 6 o 7 7 8

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tN.m (rjJ-rmJt l6iil : Specified

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3. INSTALL LINE CLAMP

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tffillsiim;iii-6itl i Specified tofque