GENERAL INFORMATION 0A-1

0A
SECTION 0A

GENERAL INFORMATION
CONTENTS
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A- 2
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A- 3
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A- 3
Precautions for Catalytic Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A- 5
Precautions for Electrical Circuit Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A- 6
Electrical Circuit Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A- 7
Intermittent and Poor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-10
Precaution for Installing Mobile Communication Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-11

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IDENTIFICATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-11
Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-11
Engine Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-11
Transmission Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-11
VEHICLE LIFTING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-12
ABBREVIATIONS MAY BE USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-14
METRIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-16
Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-16
Fasteners Strength Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-16
Standard Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-16
0A-2 GENGERAL INFORMATION

HOW TO USE THIS MANUAL

1) There is a TABLE OF CONTENTS FOR THE WHOLE MANUAL
on the third page of this manual, whereby you can easily find the
section that offers the information you need. Also, there is a
CONTENTS on the first page of EACH SECTION, where the
main items in that section are listed.
2) Each section of this manual has its own pagination. It is indi-
cated at the top of each page along with the Section name.
3) The SPECIAL TOOL usage and TORQUE SPECIFICATION
are given as shown in figure below.

6) Install oil pump. Refer to “Oil pump”.

7) Install flywheel (for M/T vehicle) or drive plate (for A/T vehicle).

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Using special tool, lock flywheel or drive plate, and tighten
flywheel or drive plate bolts to specified torque.

Special Tool
(A): 09924-17810
Tightening Torque
1. Flywheel bolts or drive plate bolts for A/T vehicle (c): 78 N.m (7.8 kg-m, 56.0 lb-ft)

4) A number of abbreviations are used in the text.

For their full explanations, refer to “ABBREVIATIONS MAY BE
USED IN THIS MANUAL” of this section.
5) The SI, metric and foot-pound systems are used as units in this
manual.
6) DIAGNOSIS are included in each section as necessary.
7) At the end of each section, there are descriptions of SPECIAL
TOOLS, REQUIRED SERVICE MATERIALS and TIGHT-
ENING TORQUE SPECIFICATIONS that should be used for
the servicing work described in that section.
 GENERAL INFORMATION 0A-3

PRECAUTIONS
GENERAL PRECAUTIONS
The WARNING and CAUTION below describe some general precautions that you should observe when servicing
a vehicle. These general precautions apply to many of the service procedures described in this manual, and they
will not necessarily be repeated with each procedure to which they apply.

WARNING:

Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING
POINTS” on SECTION 0A.

When it is necessary to do service work with the engine running, make sure that the parking brake
is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for auto-
matic transmission vehicles), Keep hands, hair, clothing, tools, etc. away from the fan and belts
when the engine is running.

When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.

Do not perform service work in areas where combustible materials can come in contact with a hot
exhaust system. When working with toxic or flammable materials (such as gasoline and refriger-

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ant), make sure that the area you work in is well-ventilated.

To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold,
tailpipe, muffler, etc.

New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new
or used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory ani-
mals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil,
wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing
engine oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any
clothing or rags if wet with oil, recycle or properly dispose of used oil and filters.

Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly
during driving, obstructing your view and resulting in an accident.

CAUTION:

Before starting any service work, cover fenders, seats and
any other parts that are likely to get scratched or stained
during servicing. Also, be aware that what you wear (e.g,
buttons) may cause damage to the vehicle’s finish.

When performing service to electrical parts that does not

require use of battery power, disconnect the negative cable
of the battery.
0A-4 GENGERAL INFORMATION

When removing the battery, be sure to disconnect the nega-

tive cable first and then the positive cable. When reconnect-
ing the battery, connect the positive cable first and then the
negative cable, and replace the terminal cover.

When removing parts that are to be reused, be sure to keep

them arranged in an orderly manner so that they may be re-
installed in the proper order and position.

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Whenever you use oil seals, gaskets, packing, O-rings,
locking washers, split pins, self-locking nuts, and certain
other parts as specified, be sure to use new ones. Also, be-
fore installing new gaskets, packing, etc., be sure to remove
any residual material from the mating surfaces.

Make sure that all parts used in reassembly are perfectly

clean.

When use of a certain type of lubricant, bond or sealant is
specified, be sure to use the specified type.

“A”: Sealant 99000-31150

Be sure to use special tools when instructed.

Special Tool
(A): 09917-98221
(B): 09916-58210
 GENERAL INFORMATION 0A-5

When disconnecting vacuum hoses, attach a tag describ-

ing the correct installation positions so that the hoses can
be reinstalled correctly.

After servicing fuel, oil, coolant, vacuum, exhaust or brake

systems, check all lines related to the system for leaks.

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For vehicles equipped with fuel injection systems, never
disconnect the fuel line between the fuel pump and injector
without first releasing the fuel pressure, or fuel can be
sprayed out under pressure.

PRECAUTIONS FOR CATALYTIC CONVERT-

ER
For vehicles equipped with a catalytic converter, use only un-
leaded gasoline and be careful not to let a large amount of un-
burned gasoline enter the converter or it can be damaged.
– Conduct a spark jump test only when necessary, make it as
short as possible, and do not open the throttle.
– Conduct engine compression checks within the shortest
possible time.
– Avoid situations which can result in engine misfire (e.g.
starting the engine when the fuel tank is nearly empty.)
0A-6 GENGERAL INFORMATION

PRECAUTIONS FOR ELECTRICAL CIRCUIT

SERVICE

When disconnecting and connecting coupler, make sure to
turn ignition switch OFF, or electronic parts may get dam-
aged.

Be careful not to touch the electrical terminals of parts

which use microcomputers (e.g. electronic control unit like
as ECM, PCM, P/S controller, etc.). The static electricity
from your body can damage these parts.

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Never connect any tester (voltmeter, ohmmeter, or whatev-
er) to electronic control unit when its coupler is discon-
nected. Attempt to do it may cause damage to it.

Never connect an ohmmeter to electronic control unit with
its coupler connected to it. Attempt to do it may cause dam-
age to electronic control unit and sensors.

Be sure to use a specified voltmeter/ohmmeter. Otherwise,
accurate measurements may not be obtained or personal
injury may result. If not specified, use a voltmeter with high-
impedance (M
/V minimum) or a digital type voltmeter.

When taking measurements at electrical connectors using

a tester probe (2), be sure to insert the probe from the wire
harness side (backside) of the connector (1).

When connecting meter probe (2) from terminal side of cou-

pler (1) because it can’t be connected from harness side,
use extra care not to bend male terminal of coupler of force
its female terminal open for connection.
In case of such coupler as shown connect probe as shown
to avoid opening female terminal.
Never connect probe where (3) male terminal is supposed
to fit.
 GENERAL INFORMATION 0A-7

When checking connection of terminals, check its male half

for bend and female half for excessive opening and both for
locking (looseness), corrosion, dust, etc.

Before measuring voltage to check for electrical system,

check to make sure that battery voltage is 11V or higher.
Such terminal voltage check at low battery voltage will lead
to erroneous diagnosis.

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ELECTRICAL CIRCUIT INSPECTION
PROCEDURE
While there are various electrical circuit inspection methods, de-
scribed here is a general method to check its open and short circuit
by using an ohmmeter and a voltmeter.

OPEN CIRCUIT CHECK

Possible causes for the open circuit are as follows. As the cause
is in the connector or terminal in many cases, they need to be
checked particularly carefully.

Loose connection of connector

Poor contact of terminal (due to dirt, corrosion or rust on it, poor
contact tension, entry of foreign object etc.)

Wire harness being open

When checking system circuits including an electronic control unit

such as ECM, TCM, ABS control module, etc., it is important to per-
form careful check, starting with items which are easier to check.
1) Disconnect negative cable from battery.
2) Check each connector at both ends of the circuit being checked
Sensor
ECM
for loose connection. Also check lock condition of connector if
equipped with connector lock.

1. Check for loose connection

0A-8 GENGERAL INFORMATION

3) Using a test male terminal, check both terminals of the circuit

Check contact tension by being checked for contact tension of its female terminal.
inserting and removing just for Check each terminal visually for poor contact (possibly caused
once
by dirt, corrosion, rust, entry of foreign object, etc.).
At the same time, check to make sure that each terminal is
locked in the connector fully.

4) Using continuity check or voltage check procedure described in

the following page, check the wire harness for open circuit and
poor connection with its terminals. Locate abnormality, if any.

1. Looseness of crimping

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2. Open
3. Thin wire (single strand of wire)

Continuity check
1) Measure resistance between connector terminals at both ends
of the circuit being checked (between A-1 and C-1 in the figure).
If no continuity is indicated (infinity or over limit), that means that
the circuit is open between terminals A-1 and C-1.

2) Disconnect the connector included in the circuit (connector-B in

the figure) and measure resistance between terminals A-1 and
B-1.
If no continuity is indicated, that means that the circuit is open
between terminals A-1 and B-1. If continuity is indicated, there
is an open circuit between terminals B-1 and C-1 or an ab-
normality in connector-B.

Voltage check
If voltage is supplied to the circuit being checked, voltage check
can be used as circuit check.
1) With all connectors connected and voltage applied to the circuit
being checked, measure voltage between each terminal and
body ground.
 GENERAL INFORMATION 0A-9

If measurements were taken as shown in the figure at the left and

results were as listed below, it means that the circuit is open be-
tween terminals B-1 and A-1.

Voltage Between:
C-1 and body ground: Approx. 5V
B-1 and body ground: Approx. 5V
A-1 and body ground: 0V

Also, if measured values were as listed below, it means that there

is a resistance (abnormality) of such level that corresponds to the
voltage drop in the circuit between terminals A-1 and B-1.

Voltage Between:
0V
C-1 and body ground: Approx. 5V
B-1 and body ground: Approx. 5V 2V voltage drop
A-1 and body ground: Approx. 3V

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SHORT CIRCUIT CHECK (wire harness to ground)
1) Disconnect negative cable from battery.
2) Disconnect connectors at both ends of the circuit to be checked.
NOTE:
If the circuit to be checked is connected to other parts, dis-
connect all connectors of those parts.
Otherwise, diagnosis will be misled.
3) Measure resistance between terminal at one end of circuit (A-1
terminal in figure) and body ground. If continuity is indicated, it
means that there is a short to ground between terminals A-1 and
C-1 of the circuit.

1. Other parts

4) Disconnect the connector included in circuit (connector B) and

measure resistance between A-1 and body ground.
If continuity is indicated, it means that the circuit is shorted to the
ground between terminals A-1 and B-1.

1. To other parts
0A-10 GENGERAL INFORMATION

INTERMITTENT AND POOR CONNECTION

Most intermittent are caused by faulty electrical connections or wir-
ing, although a sticking relay or solenoid can occasionally be at
fault. When checking it for proper connection, perform careful
check of suspect circuits for:

Poor mating of connector halves, or terminals not fully seated in

the connector body (backed out).

Dirt or corrosion on the terminals. The terminals must be clean
and free of any foreign material which could impede proper ter-
minal contact. However, cleaning the terminal with a sand paper
or the like is prohibited.

Damaged connector body, exposing the terminals to moisture

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and dirt, as well as not maintaining proper terminal orientation
with the component or mating connector.

Improperly formed or damaged terminals.

Check each connector terminal in problem circuits carefully to
ensure good contact tension by using the corresponding mating
terminal.
If contact tension is not enough, reform it to increase contact ten-
sion or replace.

1. Check contact tension by inserting and removing just once

2. Check each terminal for bend and proper alignment

Poor terminal-to-wire connection.

Check each wire harness in problem circuits for poor connection
by shaking it by hand lightly. If any abnormal condition is found,
repair or replace.

Wire insulation which is rubbed through, causing an intermittent

short as the bare area touches other wiring or parts of the ve-
hicle.

Wiring broken inside the insulation. This condition could cause
continuity check to show a good circuit, but if only 1 or 2 strands
of a multi-strand-type wire are intact, resistance could be far too
high.
If any abnormality is found, repair or replace.
 GENERAL INFORMATION 0A-11

PRECAUTION FOR INSTALLING MOBILE

COMMUNICATION EQUIPMENT
When installing mobile communication equipment such as CB (Cit-
izens-Band)-radio or cellular-telephone, be sure to observe the fol-
lowing precautions.
Failure to follow cautions may adversely affect electronic control
system.

Keep the antenna as far away as possible from the vehicle’s
electronic control unit.

Keep the antenna feeder more than 20 cm (7.9 in) away from
electronic control unit and its wire harnesses.

Do not run the antenna feeder parallel with other wire har-
nesses.

Confirm that the antenna and feeder are correctly adjusted.

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IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER
The number is punched on the front dash panel in the engine room.

ENGINE IDENTIFICATION NUMBER

The number is punched on the cylinder block.

5 speed only TRANSMISSION IDENTIFICATION NUMBER

The identification number of the 5 speed transmission is located on
the transmission case.
The identification number of the 4 speed transmission is not avail-
able.
0A-12 GENGERAL INFORMATION

VEHICLE LIFTING POINTS

WARNING:

Before applying hoist to underbody, always take vehicle balance throughout service into consider-
ation. Vehicle balance on hoist may change depending of what part to be removed.

Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe,
fuel pipe, bracket or any other part.

When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up
the vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by trying
to move vehicle body in both ways. Work can be started only after this confirmation.

Make absolutely sure to lock hoist after vehicle is hoisted up.

When using frame contact hoist:

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: Support position for frame contact hoist and safety stand.

1. Front left tire
2. Rear left tire
3. Front : Floor jack position
 GENERAL INFORMATION 0A-13

When using floor jack: In raising front or rear vehicle end off the floor by jacking, be sure
to put the jack against the center portion of front cross member (1)
or rear axle (2).

WARNING:

Never apply jack against suspension parts (i.e., stabi-
lizer, etc.) or vehicle floor, or it may get deformed.

If the vehicle to be jacked up only at the front or rear
end, be sure to block the wheels on ground in order to
ensure safety.
2 After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on
the vehicle raised on jack alone.

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Front To perform service with either front or rear vehicle end jacked up,
be sure to place safety stands (1) under body so that body is se-
curely supported. And then check to ensure that body does not
slide on safety stands and the vehicle is held stable for safety’s
sake.

Rear
0A-14 GENGERAL INFORMATION

ABBREVIATIONS MAY BE USED IN THIS MANUAL

A E
ABS : Anti-lock Brake System EBCM : Electronic Brake Control
ATDC : After Top Dead Center Module, ABS Control
API : American Petroleum Institute Module
ATF : Automatic Transmission Fluid ECM : Engine Control Module
ALR : Automatic Locking Retractor ECT Sensor : Engine Coolant Temperature
AC : Alternating Current Sensor (Water Temp.
A/T : Automatic Transmission Sensor, WTS)
A/C : Air Conditioning EGR : Exhaust Gas Recirculation
ABDC : After Bottom Dead Center EGRT Sensor : EGR Temperature Sensor
A/F : Air Fuel Mixture Ratio (Recirculated Exhaust Gas
A-ELR : Automatic-Emergency Temp. Sensor, REGTS)
Locking Retractor EFE Heater : Early Fuel Evaporation
Heater (Positive Temperature
B Coefficient, PTC Heater)
B+ : Battery Positive Voltage ELR : Emergency Locking Retractor
BTDC : Before Top Dead Center

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EPS : Electronic Power Steering
BBDC : Before Bottom Dead Center EVAP : Evaporative Emission
C EVAP Canister : Evaporative Emission
CKT : Circuit Canister (Charcoal Canister)
CMP Sensor : Camshaft Position Sensor F
(Crank Angle Sensor, CAS) 4WD : 4 Wheel Drive
CO : Carbon Monoxide
CPP Switch : Clutch Pedal Position Switch G
(Clutch Switch, Clutch Start GEN : Generator
Switch) GND : Ground
CPU : Central Processing Unit
CRS : Child Restraint System H
HC : Hydrocarbons
D HO2S : Heated Oxygen Sensor
DC : Direct Current
DLC : Data Link Connector I
(Assembly Line Diag. Link, IAC Valve : Idle Air Control Valve (Idle
ALDL, Serial Data Link, SDL) Speed Control Solenoid
DOHC : Double Over Head Camshaft Valve, ISC Solenoid Valve)
DOJ : Double Offset Joint IAT Sensor : Intake Air Temperature
DRL : Daytime Running Light Sensor (Air temperature
DTC : Diagnostic Trouble Code Sensor, ATS)
(Diagnostic Code) ICM : Immobilizer Control Module
IG : Ignition
ISC Actuator : Idle Speed Control Actuator
(Motor)
 GENERAL INFORMATION 0A-15

L T
LH : Left Hand TBI : Throttle Body Fuel Injection
LSPV : Load Sensing Proportioning (Single-Point Fuel Injection,
Valve SPI)
TCC : Torque Converter Clutch
M TCM : Transmission Control Module
MAF Sensor : Mass Air Flow Sensor (A/T Controller, A/T Control
(Air Flow Sensor, AFS, Air Module)
Flow Meter, AFM) TP Sensor : Throttle Position Sensor
MAP Sensor : Manifold Absolute Pressure TVV : Thermal Vacuum Valve
Sensor (Pressure Sensor, PS) (Thermal Vacuum Switching
Max : Maximum Valve, TVSV, Bimetal Vacuum
MFI : Multiport Fuel Injection Switching Valve, BVSV)
(Multipoint Fuel Injection) TWC : Three Way Catalytic
Min : Minimum Converter (Three Way
MIL : Malfunction Indicator Lamp Catalyst)
M/T : Manual Transmission 2WD : 2 Wheel Drive
N V

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NOx : Nitrogen Oxides VIN : Vehicle Identification
O Number
OBD : On-Board Diagnostic System VSS : Vehicle Speed Sensor
(Self-Diagnosis Function) W
O/D : Overdrive WU-OC : Warm Up Oxidation
OHC : Over Head Camshaft Catalytic Converter
P WU-TWC : Warm Up Three Way
PNP : Park/Neutral Position Catalytic Converter
P/S : Power Steering
PSP Switch : Power Steering Pressure
Switch (P/S Pressure Switch)
PCM : Powertrain Control Module
PCV : Positive Crankcase Ventilation

R
RH : Right Hand

S
SAE : Society of Automotive
Engineers
SDM : Sensing and Diagnostic
Module (Air bag controller,
Air bag control module)
SFI : Sequential Multiport Fuel
Injection
SOHC : Single Over Head Camshaft
0A-16 GENGERAL INFORMATION

METRIC INFORMATION
METRIC FASTENERS
Most of the fasteners used for this vehicle are metric. When replac-
ing any fasteners, it is most important that replacement fasteners
be the correct diameter, thread pitch and strength.

FASTENER STRENGTH IDENTIFICATION

Most commonly used metric fastener strength property classes are
4T, 7T and radial line with the class identification embossed on the
head of each bolt. Some metric nuts will be marked with punch
mark strength identification on the nut face. Figure shows the dif-
ferent strength markings.
When replacing metric fasteners, be careful to use bolts and nuts
of the same strength or greater than the original fasteners (the
same number marking or higher). It is likewise important to select
replacement fasteners of the correct size. Correct replacement

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METRIC BOLTS-IDENTIFICATION CLASS NUMBERS OR
MARKS CORRESPOND TO BOLT STRENGTH-INCREAS-
ING NUMBERS REPRESENT INCREASING STRENGTH.
bolts and nuts are available through the parts division.

STANDARD TIGHTENING TORQUE

Each fastener should be tightened to the torque specified in each section of this manual. If no description or specifi-
cation is provided, refer to the following tightening torque chart for the applicable torque for each fastener. When
a fastener of greater strength than the original one is used, however, use the torque specified for the original fas-
tener.
NOTE:

For the flanged bolt and nut, add 10% to the tightening torque given in the chart below.

The chart below is applicable only where the fastened parts are made of steel or light alloy.

STRENGTH

THREAD
Conventional bolt “4T” bolt “7T” bolt
DIAMETER
(mm) N.m kg-m lb-ft N.m kg-m lb-ft
4 1.5 0.15 1.0 2.3 0.23 2.0
5 3.0 0.30 2.5 4.5 0.45 3.5
6 5.5 0.55 4.0 10 1.0 7.5
8 13 1.3 9.5 23 2.3 17.0
10 29 2.9 21.0 50 5.0 36.5
12 45 4.5 32.5 85 8.5 61.5
14 65 6.5 47.0 135 13.5 98.0
16 105 10.5 76.0 210 21 152.0
18 160 16 116.0 240 24 174.0