1989 240sx FSM
1989 240sx FSM
1989 240sx FSM
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240SX
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1989
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GI
MAINTENANCE ENGINE MECHANICAL ENGINE LUBRICATIONCOOLING & SYSTEMSENGINE FUEL EMISSION & CONTROLYSTEMS ENGINE CONTROL, FUEL EXHAUST YSTEM& S CLUTCH
MA
EM LC
EF
&EC
FE CL MT AT PD FA RA SR ST SF HA EL
NISSAN
j
24DSX
-
MODEL
S13
SERIES
PROPELLER SHAFT DIFFERENTIAL & CARRIERFRONT AXLE& FRONT SUSPENSION REAR AXLE& REAR SUSPENSION BRAKE SYSTEM STEERING SYSTEM
BODY
,
cg 1988 NISSAN MOTOR CO., LTD.
..
Printed in U.S.A.
Motor Company Ltd., Tokyo, Japan.
Not to be reproduced in who~e or in part without the prior written permission of Ni~n < ""
FOREWORD
This manual contains maintenance and repair procedures for the 1989 Nissan 240SX. In order to assure your safety and the efficient functioning of the vehicle, this manusl should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task. All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at a~y time without notice.
NISSAN MOTORCo.,LTD.
Overseas Service Department Tokyo, Japan
GI
GI- 2 GI- 5
~
CONTENTS
PRECAUTIONS HOW TO USE THIS MANUAL
GI- 7
GI-10
GI-13
LIFTING POINTS AND TOW TRUCK TOWING TIGHTENING TORQUE OF STANDARD BOLTS
GI-17 GI-20
PRECAUTIONS
Observe the following precautions ~o ensure safe and proper servicing. These precautions are not described in each individual section.
1. Do not operate the engine for an extended period of time without proper exhaust ventilation. Keep the work area well ventilated and free of any inflammable materials. Special care should be taken when handling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials. Do not smoke while working on the vehicle.
SGI285
2. Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting and towing before working on the vehicle. These operations should be done on a level surface. 3. When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder.
SGI231
4. Before starting repairs which do not require battery power, always turn off the ignition switch, then disconnect the ground cable from the battery to prevent accidental short circuit.
SGI232
5. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe and muffler. Do not remove the radiator cap when the engine is hot.
SGI233
GI-2
PRECAUTIONS
6. Before servicing the vehicle, protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons on your person do not scratch the paint.
SGI234
7. Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly. 8. Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. 9. Replace inner and outer races of tapered roller bearings and needle bearings as a set. 10. Arrange the disassembled parts in accordance with their assembled locations and sequence. 11. Do not touch the terminals of electrical components which use microcomputers (such as electronic control units). Static electricity may damage internal electronic components. 12. After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. 13. Use only the lubricants specified in MA section. 14. Use approved bonding agent, sealants or their equivalents when required. 15. Use tools and recommended special tools where specified for safe and efficient service repairs. 16. When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks. 17. Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner.
SGI291
GI-3
GI-4
r;~'~
Torque
member
~
~
,/I
J~
~
~.
::;:;:::
~
.
5~ 641556.5.40
/
/
r-
471
Main pin
IE!
to sliding portion
Pin boot
Outer shim
SBR364A
6. THE SMAll IllUSTRATIONS show the important steps such as inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustrations. Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle or transmission, etc. are presented in a step-by-step format where necessary. 7. The followings SYMBOLS AND ABBREVIATIONS are used:
~
E1I
~ rJ ~ ~
EaI~
@>
"f:l
:
:
Tightening torque Should be lubricated with grease. Unless otherwise indicated, use recommended multi-purpose grease. Should be lubricated with oil. Sealing point Checking point Always replace after every disassembly. Apply petroleum jelly. Apply A.T.F. Select with proper thickness. Adjustment is required. Service Data and Specifications Left-Hand, Right-Hand
Manual Transaxle/Transmission Automatic Transaxle/Transmission Special Service Tools Left-Hand Drive Right-Hand Drive Automatic Transmission Fluid Drive range 1st gear Drive range 2nd gear Drive range 3rd gear Drive range 4th gear Overdrive 2nd range 2nd gear 2nd range 1st gear 1st range 2nd gear 1st range 1st gear
",.
GI-5
. . .
GI-6
n
~
~B~
'-LAMP -!
.
I
lG~
A/T model
~
~ CLG~ ~B-S
~
@
: MfT model : AfT model
1m
~~
---
SWITCH This shows that continuity exists between terminals CD and CID, when the switch is turned to ON position.
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~ 2
~Whi"~
G
.rn '""".~
'"" ~ ~
lyw IiliJ
l-l
~
SWITCH
ABBREVIATIONS
LOCATION NUMBER This number shows where the connector is located. See HARNESS LAYOUT in EL section. The number is identical with the one in HARNESS LAYOUT. I
-b
BODY D GROUN
'WIRE
COLOR CODING
BR
B -BI,,'
W R G Y L LG ~ ~ ~ ~ ~ White Red Green Blue Yellow
. ht Green
OR
P PU GY SB I
~@!
I: Instrument harness
. d the base is stripe, . When. the iven first, or wire co followe d by the stripe color as g IS shown below: Example: L/W
~
~ Llg
SWITCH POSITIONS
Normally open
~~
0---
Wiring diagram switches are shown with the vehicle in the following condition. Ignition switch "OFF", Doors, hood and trunk lid/back door closed. Pedals are not depressed and parking brake is released.
. . .
Normally closed
........
~
SEL764E
GI-7
CONNECTOR SYMBOLS All connector symbols in wiring diagrams are shown from the terminal side.
..4:
Example
Connector SG 1362
EE
.
Efj
M.~ te,m;nal
Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams.
Connector symbol
G";d'-[~ Connector
Female terminal
Guide
MULTIPLESWITCH The continuity of the multiple switch is identified in the switch chart in wiring diagrams.
Example
WIPER SWITCH
-W/B -L/Y
-B.
-yo
-R.
B E C (f)
1 5 @ 2
LO HI WASH
Continuity circuit:
CID terminal
- Wiperswitch (@ - @:
SG 1365
GI-8
Example
STARTING
SYSTEM
w
'"
rnIJ ~
],
liJ
[ ,=fd:0CI~ crhKk 0
,~
r
Dm3
g
FF
0 0 0
Check
.-::
:=
y--R
.S.M.J.
L--S
't
( (Foldout
r-R~
~B
(Main harness)
DO
L---1
BR~ (Instrument harness)
+-+
r-B
(Main harness)
(Instrument
harness)
BR---l.
SEL653F
GI-9
m"
(
~m
INSPECTION START)
rill
I
-=-
SG I561
iii
~ lu
_MECT
iii
CHECK POWER SUPPLY. Check the following items. 1) Turn ignition switch "ON" .~ [ IN.G. 1) Harness continuity betWeen 2) Check voltage between crank angle sensor and battery. terminal @ and ground. 2) E.C.C.S. relay-1 (See page EF & T~Battery voltage should exist. EC-106.) 3) "BR" fusible link O.K. 2 4) Power source for E.C.U. (See page EF & EC-104.) 5) Ignition switch Check the following items. 1) Harness continu ity betWeen crank angle sensor and I N.G~ grou nd 2) Ground circuit for E.C.U. (See page EF & EC-104.)
[ill
~ ~ 00
SG 1562
2) Disconnect crank angle sensor harness connector. 3) Check resistance betWeen terminal @ and ground. Resistance: Approximately
I
on
O.K.
NOTICE The flow chart indicates work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. 1) Use the flow chart after locating probable causes of a problem following the "Preliminary Check" or the "Symptom Chart". 2) After repairs, re-check that the problem has been completely eliminated. 3) Refer to Component Parts Location and Harness Layout for the Systems described in each section for identification/location of components and harness connectors. 4) Refer to the Circuit Diagram for Quick Pin Point Check. If you must perform circuit continuity between harness connectors more detail, such as in case of sub harness is used, refer to Wiring Diagram and Harness Layout in EL section for identification of harness connectors. 5) When checking circuit continuity, ignition switch should be "OFF" . 6) Before checking voltage at connectors, check battery voltage. 7) After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as it was.
GI-10
HOW TO FOllOW
.--
Check
voltage between
Procedure,
steps or
results
measurement
Required results are indicated in bold type in the corresponding block, as shown below. These have the following meanings: Battery voltage ~ 11 14V or approximately 12V Voltage: Approximately OV ~ Less than 1V
Cross reference of work symbols in the text and illustrations Illustrations are provided as visual aids for work procedures. For example, symbol m indicated in the left upper portion of each illustration corresponds with the symbol in the flowchart for easy identification. More precisely, the procedure under the "CHECK POWER SUPPLY" outlined previously is indicated by an illustration m .
@] Symbols used in illustrations Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol. Direction mark A direction mark is shown to clarify the side of connector (terminal side or harness side). Direction marks are mainly used in the illustrations indicating terminal inspection.
Connector symbol
Direction
mark
~
View from harness side
Connector symbol
.
.
View f,om lermlnel side n' r.s. All connector symbols shown from the terminal side are enclosed by a single line.
~:
~:
View f,omhernessside .n
H.S.
Connector
~ [it
Direction mark
All connector symbols shown from the harness enclosed by a double line.
side are
SGI364
GI-11
IV
) @CONNECT
..-cT
Check after connecting the connector to be measured. Insert key into ignition switch. Turn ignition switch to "OFF" position.
Turn ignition switch to "ON" position. Turn ignition switch to "START" position.
00 00
OOACC
Fan switch is "ON". (At any position except for "OFF" position)
Fan switch is "OFF".
OOF
Drive vehicle.
0
trJ
or check
with engine
Depress
brake
pedal.
CffH
l!V
La)
Le1J
II CIUIIT-foi
II
Pin terminal check for S.M.J. type E.C.U.and AIT control unit connectors. For details regarding the terminal arrangement, refer to the foldout page.
'
GI-12
IDENTIFICATION INFORMATION
Model Variation
Destination Body Coupe Fastback Non-California Coupe Fastback Coupe Fastback California Coupe Fastback Coupe Fastback Canada Coupe Fastback HLS13AN RE4R01A RHLS13AN HLS13AV RE4R01A RHLS13AV HLS13FN FS5W71 C RHLS13FN HLS13AU RE4R01A RHLS13AU HLS13FV FS5W71C RHLS13FV KA24E R200 Model HLS13FU FS5W71C RHLS13FU Engine Transmission Differential carrier
0: R : H: L:
Coope Fastba~
KA24E engine L.H. drive
0 : means no indication.
GI-13
IDENTIFICATION
INFORMATION
Identification Number
Vehicle identification plate
Vehicle identification
label
SGI547
VEHICLE IDENTIFICATION
IT
Manufacture plant W: Kyushu Model year K: 1989 year model Check digit (0 to 9 or XI The code for the check digit is determined by mathematical computation. Restraint system S: Standard P: Automatic
. Vehicle line
S: NISSAN 240SX Model change (0 to 91 Body type 4: Coupe 6: Fastback
GI-14
IDENTIFICATION
INFORMATION
PLATE
~:it
CHASSIS NO NO DE CHASIS MODEL MOOElO
~i:J
&"
ill
.&
",-COlOR TRiM f 'Jk COlOR GUMNICION
0
I ;,.0
ffi& &&
0
CC
ENGIN[
MOTOR
'/;,.0
& &
I tf; ::::A
MADEINJAPAN
1 2 3 4 5 6 7 8 9
SGI315
Type Vehicle identification number (Chassis numbed Model Body color code Trim color code Engine model Engine displacement Transmission model Axle model
TL 1006M
MANUAL TRANSMISSION
NUMBER
AUTOMATIC
TRANSMISSION
NUMBER
SGI274
SGI513
GI-15
IDENTIFICATION INFORMATION
Dimensions
Coupe
Overall length Overall width Overall height Front tread Rear tread Wheelbase 4,520 (178.0) 1,690 (66.5) 1,290 (50.8) 1,465 (57.7) 1,460 (57.5) 2,475 (97.4)
Unit: mm (in)
Fastback
4,520 (178.0) 1,690 (66.5) 1,290 (50.8) 1,465 (57.7) 1,460 (57.5) 2,475 (97.4)
GI-16
LIFTING POINTS AND TOW TRUCK TOWING Garage Jack and Safety Stand
WARNING: Never get under the vehicle while it is supported only by the jack. Always use safety stands to support the frame when you have to get under the vehicle. Place wheel chocks at the front wheels when the rear wheels are raised and place wheel chocks at the rear wheels when the front wheels are raised. CAUTION: Place a wooden or rubber block between safety stand and vehicle body when the supporting body is flat.
. .
SGI552
GI-17
Sill
Put the sill in the slit of the lift pad to prevent the sill from deforming. If the pad does not have lift pad
//
a suitable
attachment
with slit.
SGI553
All applicable state or Provincial (in Canada) laws and local laws regarding the towing operation must be obeyed. It is necessary to use proper towing equipment to avoid possible damage to the vehicle during towing operation. Towing is in accordance with Towing Procedure Manual at dealer. When towing with the rear wheels on the ground, release the parking brake and move the gearshift lever to neutral (UN" position).
~ ~
NISSAN recommends that vehicle be towed with the driving (rear) wheels off the ground as illustrated.
'i::ij,iiii. ii;~1',,,';1tiii:.; 2
-.
SG 1383
GI-18
LIFTING
POINTS
TOWING
Front
Tow Truck Towing (Cont'd) TOWING AN AUTOMATIC TRANSMISSION MODEL WITH FOUR WHEELS ON GROUND OR TOWING WITH FRONT WHEELS RAISED (With rear wheels on ground) Observe the following restricted towing speeds and distances. Speed: Below 50 km/h (30 MPH) Distance: Less than 65 km (40 miles) If the speed or distance must necessarily be greater, remove the propeller shaft beforehand to prevent damage to the transmission. TOWING POINT Alwayspull the cable straightout from the vehicle.Never pull on the hook at a sidewaysangle.
Rear
CE1 DD9M
GI-19
Grade
Bolt size
Bolt
meter* mm
Pitch mm N.m
Tightening torque (Without lubricant) Hexagon head bolt kg-m 0.52 1.3 1.3 2.5 2.6 4.3 4.7 7.5 0.86 2.1 2.2 4.2 4.4 7.2 7.9 13.0 1.2 3.0 3.2 6.0 6.3 10.0 11.0 18.0 ft-Ib 3.8 9 9 18 19 31 34 54 6.2 15 16 30 32 52 57 94 9 22 23 43 46 72 80 130 Hexagon flange bolt N.m ft-Ib kg-m 6.1 15 16 29 30 51 56 88 10 25 26 48 51 84 92 147 15 35 37 70 74 118 137 206 0.62 1.5 1.6 3.0 3.1 5.2 5.7 9.0 1.0 2.5 2.7 4.9 5.2 8.6 9.4 15.0 1.5 3.6 3.8 7.1 7.5 12.0 14.0 21.0 4.5 11 12 22 22 38 41 65 7 18 20 35 38 62 68 108 11 26 27 51 54 87 101 152
6.0 8.0 10.0 12.0 14.0 6.0 8.0 10.0 12.0 14.0 6.0 8.0 10.0 12.0 14.0
1.0 1.25 1.0 1.5 1.25 1.75 1.25 1.5 1.0 1.25 1.0 1.5 1.25 1.75 1.25 1.5 1.0 1.25 1.0 1.5 1.25 1.75 1.25 1.5
1. Special parts are excluded. 2. This standard is applicable to bolts having the following marks embossed on the bolt head.
Grade 4T 7T 9T Mark 4 7 9
*: Nominal diameter M
6
""""L-
GI-20
'..~
MAINTENANCE
.J
SECTION
MA
l1li
CONTENTS
PERIODIC MAINTENANCE ... GENERAL MAINTENANCE. RECOMMENDED LUBRICANTS AND FLUIDS ENGINE MAINTENANCE "'"'''''''''''' CHASSIS AND BODY MAINTENANCE SERVICE DATA AND SPECIFICATIONS (S.D.S.) :" MA- 2 MA- 4 MA- 6 MA- 8 MA-14 MA-20",
PERIODIC MAINTENANCE
The following charts show the normal maintenance schedule. Under severe driving conditions, additional or more frequent maintenance will be required. Refer to "Maintenance under severe driving conditions". The periodic maintenance schedule is repeated beyond the last mileage and period shown by returning to the first 15,000 miles (24,000 km) or 12 months. EMISSION CONTROL SYSTEM MAINTENANCE
MAINTENANCE. OPERATION Perform at number of miles, kilometers or months, whichever comes first. Drive belts
Air cleaner filter Miles x 1,000 (km x 1,000) Months
7.5 (12) 6
Vapor lines Fuel lines Fuel filter Engine coolant Egnine oil
Engine oil filter (Use Nissan PREMIUM type or equivalent.)
15 (24) 12 I I I
60 (96) 48 I I I I I
Reference page
NOTE: (1) After 60,000 miles (96,000 km) or 48 months, inspect every 15,000 miles (24,000 km). (2) If vehicle is operated under extremely adverse weather conditions or in arees where ambient temperatures are either extremely low or extremely high, the filters might become clogged. In such an event, replace them immediately. (3) Maintenance items and intervals with "." are recommended by NISSANfor reliable vehicle operation. The owner need not perform such maintenance in order to ~aintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required.
Abbreviations: R = Replace. I = Inspect. Correct or replace if necessary.
MA-2
PERIODIC MAINTENANCE
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS
The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance is required to. be performed on the following items as shown in the table. Severe driving conditions A - Repeated short trips less than 5 miles (8 km) and outside temperatures remain below freezing B - Extensive idling and/or low speed driving for a long distance such as police, taxi or door-to-door delivery use C - Driving in dusty conditions D - Driving on rough, muddy, or salt spread roads E - Towinga trailer, usinga camper or a car-top carrier
Maintenance operation
Maintenance
item
Maintenance interval
Reference
page
R R
More frequently'
Every 3,000 miles (5,000 km) or 3 months Every 7,500 miles (12,000 km) or 6 months
MA-10 MA-11
A.
C D E
MA-17
D E
Manual and automatic transmission & differential gear oil Steering gear & linkage, and axle & suspension parts Steering linkage ball joints & front suspension ball joints Exhaust system I = Inspect. Correct or replace if necessary. R
MA-14, 15, 16
D . . A. . CD. .
D E
MA-18,FA-4
MA-14
Maintenance operations:
= Replace.
MA-3
GENERAL MAINTENANCE
General maintenance includes those items which should be checked during the normal day-to-day operation of the vehicle. They are essential if the vehicl~isto continue operating properly. The owners can perform the checks and inspectionsthemselvesor they can have their NISSANdealers do them for a nominal charge.
Item
OUTSIDE THE VEHICLE The ma!ntenance items listed here should be performed from time to time, unless otherwise specified. Tires Check the pressure with a gauge periodically when at a service station, including the spare, and adjust to the specified pressure if necessary. Check carefully for damage, cuts or excessivewear. Wheel nuts When checking the tires, make sure no nuts are missing,and check for any loose nuts. Tighten if necessary. Tire rotation Tires should be rotated every 12,000 km (7,500 miles.) Wheel alignment and balance If the vehicle should pull to either side while driving on a straight and level road, or if you detect uneven or abnormal tire wear, there may be a need for wheel alignment. If the steering wheel or seat vibrates at normal highway speeds, wheel balancing may be needed. Windshieldwiper blades Check for cracks or wear if they do not wipe properly. Doors and engine hood Check that all doors and the engine hood operate smoothly as well as the trunk lid and back hatch. Also ensure, that all latches lock securely. Lubricate if necessary. Make sure that the secondary latch keeps the hood from opening when the primary latch is released. When driving in areas using road salt or other corrosive materials, check lubrication frequently. INSIDE THE VEHICLE The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc. Lights Make sure that the headlights, stop lights, taillights, tUrn signal lights, and other lights are all operating properly and installed securely. Also check headlight aim. Warning lights and buzzers/chimes Make sure that all warning lights and buzzers/chimes are operating properly. Windshield wiper and washer Check that the wipers and washer operate properly and that the wipers do not streak. Windshield defroster Check that the air comes out of the defroster outlets properly and in sufficient quantity when operating the heater or air conditioner. Steering wheel Check that it has the specified free play. Be sure to check for changes in the steering condition, such as excessivefree play, hard steering or strange noises. Free play: Lessthan 35 mm (1.38 in) Seats Check seat position controls such as seat adjusters, seatback recliner, etc. to ensure they operate smoothly and that all latches lock securely in every position. Check that the head restrains move up and down smoothly and that the locks (if so equipped) hold securely in all latched positions. Check that the latches lock securely for folding-down rear seatbacks. . Seat belts Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and retractors) operate properly and smoothly, and are installed securely. Check the belt webbing for cuts, fraying, wear or damage. MA-19 MA-18 MA.17 FA-6 RA-6
Reference page
MA-19
MA-4
GENERAL MAINTENANCE
Item Clutch pedal Make sure the pedal operates smoothly and check that it has the proper free travel.
Brakes Check that the brake does not pull the vehicle to one side when applied. Brake pedal Check the pedal for smooth operation and make sure it has the proper distance under it when depressed fully. Check the brake booster function. Parking brake Check that the lever has the proper travel and confirm that your vehicle is held securely on a fairly steep hill with only the parking brake applied. Automatic transmission "Park" mechanism Check that the lock release button on the selector lever operates properly and smoothly. On a fairly steep hill check that your vehicle is held securely with the selector lever in the "P" position without applying any brakes. BR-7 Reference page
CL-5
BR-23
UNDER THE HOOD AND VEHICLE The maintenance items listed here should be checked periodically (e.g. each time you check the engine oil or refuel). Windshieldwasher fluid Check that there is adequate fluid in the tank. Engine coolant level Check the coolant levelwhen the engine is cold. Radiator and hoses Check the front of the radiator and clean off any dirt, insects, leaves, etc., that may have accumulated. Make sure the hoses have no cracks, deformation, rot or loose connections. Brake and clutch fluid levels Makesure that the brake and clutch fluid levelsare between the "MAX" and "MIN" lines on the reservoir. Engine drive belts Makesure that no belt is frayed, worn, cracked or oily. Engine oil level Check the level on the dipstick after parking the vehicle on a level spot and turning off the engine. Power steering fluid level and lines Check the level when the fluid is cold and the engine is turned off. Check the lines for proper attachment, leaks, cracks, etc. Automatic transmission fluid level Check the level on the dipstick after putting the selector lever in "P" with the engine idling. Exhaust system Make sure there are no loose supports, cracks or holes. If the sound of the exhaust seems unusual or there is a smell of exhaust fumes, immediately locate the trouble and correct it. Underbody The underbody is frequently exposed to corrosive substances such as those used on icy roads or to control dust. It is very important to remove these substances, otherwise rust will form on the floor pan, frame, fuel lines and around the exhaust system. At the end of winter, the underbody should be thoroughly flushed with plain water, being careful to clean those areas where mud and dirt can easily accumulate. Fluid leaks Check under the vehicle for fuel, oil, water or other fluid leaks after the vehicle has been parked for a while. Water dripping from the air conditioner after use is normal. If you should notice any leaks or gasoline fumes are evident, check for the cause and correct it immediately. MA-14,16 MA-8 MA-11 MA-18 MA-15 MA-9
MA-14
MA-5
Imp measure
Genuine Nissan Motor Oil*1 or equivalent (Energy Conserving Oils of API SF or SG)*2, *3
Automatic transmission fluid Power steering fluid Brake fluid Multi-purpose grease
8.3
0.9
TM
Genuine Nissan Brake Fluid*1 or equivalent DOT 3 (US FMVSS No. 116) NLGI No.2 (Lithium soap base)
*1: Available in mainland U.S.A. through you Nissan dealer. *2: For further details, see "SAE Viscosity Number". *3: Energy Conserving Oils These oils can be identified by such labels as energy conserving, energy saving, improved fuel economy, etc.
MA-6
Range
C",OF
140 .
----+16111+60---
+4011+104"'--+30111+86
+10111
+50
0111+32
-181110
-29111-20- -5W-30
T10002
T10003
10W-30 is preferable if the ambient temperature is above -18C (0 F). 20W-40 and 20W-50 are usable if the ambient temperature is above 10C (50 F) for all seasons.
MA-7
ENGINE MAINTENANCE
lAJQ'
Crank pulley T : Tension checking points IAJ: Adjusting bolts
l:~:o,
lAJA;,,ood;,;oo",
compressor
8MAOO2C
Alternator Air conditioner compressor Power steering oil pump Applied pushing force
11 (0.43)
12 (0.47)
- 0.28)
13 (0.51)
~~~
[~O1234
~ ~
.-
WARNING: To avoid being scalded, never change the coolant when the engine is hot. 1. Move heater "TEMP" control lever all the way to "HOT" position.
8M AOO3C
2. Open drain cock at the bottom of radiator, and remove radiator cap.
MA-8
"'.
6. Fill radiator with water and close air relief plug and radiator cap. 7. Run engine and warm it up sufficiently. 8. Race engine 2 or 3 times under no-load. 9. Stop engine and wait until it cools down. 10. Repeat step 2 through step 9 until clear water begins to drain from radiator. 11. Drain water.
12. Open radiator cap and air relief plug. 13. Fill rafdiator with coolant up to specified level. Follow instructions attached to anti-freeze container for mixing ratio of anti-freeze to water. Coolant capacity. (With reservoir tank) 6.7 Q (7-1/8 US qt, 5-7/8 Imp qt) Pour coolant through coolant filler neck slowly to allow air in system to escape.
MAX. MIN.
14. Close air relief plug. 15. Remove reservoir tank, drain coolant, then clean reservoir tank. 16. Install reservoir tank and fill it with coolant up to "MAX" level and then install radiator cap. 17. Run engine and warm it up sufficiently. 18. Race engine 2 or 3 times under no-load. 19. Stop engine and cool it down, then add coolant as necesary.
SMA412B
MA-9
3 mm 10.12 in)
~--,'-'
--T-+-+--J__J.-_J
Tightenhigh-pressurerubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end. Ensure that screw does not contact adjacent parts.
SMA804A
1. Remove fuse for fuel pump. 2. Start engine. 3. After engine stalls, crank engine two or three times to make sure that fuel pressure is released. 4. Turn. ignition switch off and install fuse for fuel pump.
5. Loosen fuel hose clamps. 6. Replace fuel filter. Be careful not to spill fuel over engine compartment. Place a shop towel to absorb fuel. Use a high-pressure type fuel filter. Do not use a synthetic resinous fuel filter.
. .
Changing
Air Cleaner
Filter
The viscous paper type filter does not need cleaning between renewals.
MA-10
ENGINE MAINTENANCE
Front SMAOO9C
CAUTION:
Be sure to clean drain plug and Install with new washer. Drain plug:
tOJ: 9 - 39 N.m 2
4. Check oil level. 5. Start engine and check area around drain plug and oil filter for oil leakage. 6. Run engine for a few minutes, then turn it off. After several minutes, check oil level.
SMA042C
Changing
Oil Filter
Be careful not to burn yourself, as the engine and the engine oil are hot.
2. Before installing new oil filter, clean the oil filter mounting surface on cylinder block, and coat the rubber seal of oil filter with a little engine oil.
~
---
SMA010
MA-11
SMA229B
O.K.
N.G.
Changing
Spark Plugs
1. Disconnect ignition wires from spark plugs at boot. Do not pull on the wire.
SMA017
R
16mmV1
'o.um~
SEM294A Side electrode
2. Remove spark plugs with spark plug wrench. Spark plug: Standard type ZFR5D-11 Hot type ZFR4D-11 Cold type ZFR6D-11
iii
SMA476
3. Check plug gap of each new spark plug. Gap: 1.0 - 1.1 mm (0.039 - 0~043 in) 4. Install spark plugs. Reconnect ignition wires according to nos. indicated on them. Spark plug:
~:20
- 29
N.m
MA-12
ENGINE MAINTENANCE
"
MA-13
Check exhaust pipes, muffler and mounting for improper attachment and for leaks, cracks, damage, loose connections, chafing and deterioration.
SMA211A
SMA941B
Checking
M/T Oil
,
SMA429A
2. If leakage is found, check oil level. Never start engine while checking oil level. Filler plug: ~: 25 - 34 N.m (2.5 - 3.5 kg-m, 18 - 25 ft-Ib)
SMA103
Changing
M/T Oil
~~~
~.;. ~"~
.,.
1. Drain oil and refill with new gear oil. 2. Check oil level. Oil capacity: 2.4 Q (5-1/8 US pt, 4-1/4 Imp pt) Drain plug: ~: 25 - 34 N.m (2.5 - 3.5 kg-m, 18 - 25 ft-Ib)
SMA255A
MA-14
Checking
AIT Fluid
.
SMA430A
O.K.
2. If leakage is found, check fluid level. Fluid level should be checked using "HOT" range on dipstick at fluid temperatures of 50 to 80C (122 to 176F) after vehicle has been driven approximately 5 minutes in urban areas after engine is warmed up. But it can be checked at fluid temperatures of 30 to 50C (86 to 122F) using "COLD" range on dipstick for reference after engine is warmed up and before driving. However, fluid level must be rechecked using "HOT" range. 1) Park vehicle on level surface and set parking brake. 2) Start engine and then move selector lever through each gear range, ending in "P". 3) Check fluid level with engine idling. 4) Remove dipstick and wipe it clean with lint-free paper. 5) Reinsert dipstick into charging pipe as far as it will go. 6) Remove dipstick and note reading. If level is at low side of either range, add fluid to the charging pipe. Do not overfill.
3. Check fluid condition. Check fluid for contamination. If fluid is very dark or smells burned, or contains frictional material (clutches, band, etc.), check operation of AlT. Refer to section AT for checking operation of AlT.
Changing
AIT Fluid
1. Drain fluid by removing oil pan. 2. Replace gasket with new one. 3. Refill with fluid and then check fluid level. Oil capacity (With torque converter): 8.3 Q (8-3/4 US qt, 7-1/4 Imp qt)
SMA921B
MA-15
SMA012C
2. If leakage is found, check oil level. Filler plug: ~: 59 98 N.m (6 10 kg-m, 43 - 72 ft-Ib)
SMA257 A
Changing
~~
0,,;" PI~
1. Drain oil and refill with new gear oil. 2. Check oil level. Oil capacity: 1.3 Q (2-3/4 US pt, 2-1/4 Imp pt) Drain plug: ~: 59 98 N.m (6 10 kg-m, 43 - 72 ft-Ib)
~
SMA363A
MAX
MIN
Check brake fluid lines and parking brake cables for improper attachment and for leaks, chafing, abrasions, deterioration, etc.
SMA732A
MA-16
. Check condition of disc brake components. ROTOR . Check condition and thickness.
Unit: mm (in) Front
Disc brake type
SMA260A
CALIPER
SMA922A
Unit: mm (in)
Rear CL9H
9.5 (0.374)
Minimum thickness
SMA847B
2.0 (0.079)
Balancing
Wheels
MA-17
FRONT
Do not include the T-type spare tire when rotating the tires. Wheel nuts: ~: 98 - 118 N.m (10.0 - 12.0 kg-m, 72 - 87 ft-Ib)
A!
SMA650B
. . .
.
.
Q
SMA940B
SST107B
MA-18
lEI
=~~
m.
SMA999B
CAUTION: 1. AUseat bait a..mblies, including retractors and attaching hardwares such as guida rail set, etc" should ba inspacted after any collision. Ni...n recommends that aUseet bait ...amblies in use during a collision ba replaced unless the collision was minor and the baits show no damage and continue to operete properly. Seat bait assemblies not in use during a collision should allO ba inspacted and replaced if eithar damage or improper operation is noted. 2. If tha condition of any component of a seat bait is questionable, do not have seat bait repaired, but raplaced as a bait 8118mbly. 3. If wabbing is cut, frayed, or damaged, replace bait assembly. 4. Do not spill drinks, oil, etc. on inner lap bait buckle. Never oil tongue and buckle. 5. Use a NISSAN genuine ..at bait assembly.
SMAOO1 C
MA-19
Spark plug
Standard type Hot type Cold type Plug gap
ZFR5D-11
ZFR4D-11 ZFR6D.11 1.0 - 1.1 mm (0.039 . 0.043 in)
Alternator
11 (0.43)
7-8 6-7 (0.28 - 0.311 I (0.24 - 0.28) 6-7 7-8 (0.28 - 0.311 I (0.24 - 0.28)
Ignition wire
Resistance kS1
Less than 30
12 (0.47)
8-9
I
7-8
TIGHTENING
Unit Spark plug Drain plug
Engine block
TORQUE
N'm 20- 29
34 44
Oil pan
29-39
3.0-4.0
Coolant capacity
Unit: 2 (US qt, Imp qt)
With reservoir tank
6.7 (7-118,5-7/8)
MA-20
Brake
Unit: mm (in) Disc brake Pad Standard thickness CL22VB CL9H
- 196 (7.32.7.72)
-43 /33
CL9H
Pedal Free height M/T A/T
*: Tankful of fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools, mats in designated position.
177
Free play Depressed hElight [under force of 490 N (50 kg, 110 Ib) with engine running] Parking brake Number of notches [at pulling force 196 N (20 kg, 44 Ib)]
*: Tankful of fuel, radiator coolant and engine oil full. Spare tire,
jack, hand tools, mats in designated position.
6-8
Wheel bearing
Front Wheel bearing axle end mm (in) play Wheel bearing lock nut Tightening torque N.m (kg-m, ft-Ib) 0.03 (0.0012) or less Rear 0.05 (0.0020) or less
Wheel balance
Wheel balance (Maximum allowable unbalance at rim flange) g (OZ) Tire balance weight g (OZ) 10 (0.35)
108- 159)
174- 231)
MA-21
TORQUE
N'm kg-m ft-Ib
16 22 12 25
- 15 - 34
12 - 16 9 - 11 18 - 25 43-72 43-72
Drain and filler plugs Final drive Drain plug Filler plug Front axle and front
suspension Tie-rod lock nut Camber adjusting pin Rear axle and rear suspension Toe adjusting pin Camber adjusting pin Brake system Air bleed valve Brake lamp switch lock nut Brake booster input rod lock nut Wheel and tire Wheel nut
59 -98 59 -98
37 - 46
124
27 - 34 91 - 106
- 143
- 15 -22
98 - 118
10.0 - 12.0
72 -87
MA-22
ENGINE MECHANICAL
SECTION
EM
EM- 2 EM- 3 EM- 6 EM- 7 EM- 8 EM-10 EM-16 EM-18 EM-32 EM-34
EM
CONTENTS
PRECAUTION PREPARATION OUTER COMPONENT PARTS COMPRESSION PRESSURE OIL PAN TIMING CHAIN OIL SEAL REPLACEMENT CYLINDER HEAD ENGINE REMOVAL CYLINDER BLOCK
SERVICE DATA AND SPECIFICATIONS (S.D.S.)
"""'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' EM-46
PRECAUTION
LIQUID GASKET APPLICATION PROCEDURE
~~
Groove
'
I~r Side
Bolt hole
SEM371C
a. Before applying liquid gasket, remove all traces of old liquid gasket from mating surface using a scraper. b. Apply a continuous bead of liquid gasket to mating surface. (Use Genuine Liquid Gasket or equivalent.) c. Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) wide (for oil pan). Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) wide (in areas except oil pan). d. Apply liquid gasket to inner sealing surface around hole perimeter area. (Assembly should be done within 5 minutes after coating.) e. Wait at least 30 minutes before refilling engine oil and engine coolant.
EM-2
PREPARATION
SPECIAL SERVICE TOOLS
Tool number (Kent.Moore No.) Tool name ST0501S000
(
Description
~
CI<
CD
KV10109210
~
3
KV10110300
(
Piston pin press stand assembly CD KV10110310 ( ) Cap @ KV10110330 ( ) Spacer @ ST13030020 ( ) Press stand @ ST13030030 ( ) Spring @ KV10110340 ( ) Drift @ KV10110320 ( ) Center shaft
~
?~~
EM-3
PREPARATION
Tool number (Kent-Moore No.) Tool name EM03470000 (J8037 ) Piston ring compressor
Description
KV10111100
(
Seal cutter
WS39930000
( ) Tube presser
~ T
~
EM-4
PREPARATION
COMMERCIAL SERVICE TOOLS
Tool name Spark plug wrench
Description
Q
16mm
(0.63 in)
Pulley holder
c:Y
~
Removing and
spark plug
installing
r
Valve seat cutter set
--
~
\
~~.-
~
A:~
---A B
mm (in) Intake 10.5 (0.413) 6.6 (0.260) Exhaust 11.5 (0.453) 7.6 (0.299)
Reaming valve guide (CD) or hole for oversize valve guide (@) Diameter:
Intake 01 Os 7 (0.28) 11.2 (0.441) mm (in) Exhaust 8 (0.31) 12.2'(0.480)
~D.
EM;.5
OUTER COMPONENT
KA24E ENGINE
PARTS
16
-21
(1.6
-21 .
, 12-15)
16 21 (1.6.2.1_,12
-15)
LI-I~~
I.-L ~
rA'..
3.6-4.3)
(0.5 -0.6,
,r"
Adjusting bar
142
~~
10-12 (1.0-1.2,7 - 9)
EM-6
COMPRESSION
PRESSURE
Measurement of Compression
1. 2. 3. 4. 5. Warm up engine. Turn ignition switch off. Disconnect fusible link for injectors. Remove all spark plugs. Disconnect distributor center cable.
Pressure
Q)
6. Attach a compression tester to NO.1 cylinder. 7. Depress accelerator pedal fully to keep throttle valve wide open. 8. Crank engine and record highest gauge indication. 9. Repeat the measurement on each cylinder as shown above. Always use a fully-charged battery to obtain specified engine revolution. Compression pressure: kPa (kg/cm2,. psi)/rpm Standard 1,324 (13.5, 192)/300 Minimum 981 (10, 142)/300 Difference limit between cylinders 98 (1.0, 14)/300 10. If cylinder compression in one or more cylinders is loyi. pour a small amount of engine oil into cylinders through spark plug holes and retest compression. . If. adding oil helps compression, piston rings may be worn or damaged. If' so, replace piston rings after checking piston. If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to S.D.S.) If valve or valve seat Is damaged excessively, replace them. If compression in any two adjacent cylinders is low and if adding oil does not help compression, there is I,akage past the gasket surface. If so, replace cylinder head gasket.
SEM 113B
.
.
EM-7
OIL PAN
Removal
1. Raise vehicle and support it with safety stands. 2. Drain engine oil. 3. Remove front stabilizer bar securing bolts and nuts from side member. 4. Lift engine.
Front
0 @
...Q...
2SEM337C
6. Remove oil pan. (1) Insert Tool between cylinder block and oil pan. Do not drive seal cutter into oil pump or rear oil seal retainer portion, or aluminum mating face will be damaged. Do not insert screwdriver, or oil pan flange will be deformed.
. .
(2) Slide Tool by tapping its side with a hammer, and remove oil pan.
SEM884A
EM-8
SEM338C
2. Apply a continuous bead of liquid gasket to mating surface of oil pan. Use Genuine Liquid Gasket or equivalent.
SEM339C
Cut here.
~
Liquid gasket
:J
SLC906
7 mm 10.28
in)
--Lt-.
Inner side Groove
Bolt hole SEM909B
3. Apply liquid gasket to inner sealing surface as shown in figure. Attaching should be done within 5 minutes after coating. 4. Install oil pan. Wait at least 30 minutes before refilling engine oil.
. .
EM-9
TIMING CHAIN
r
~
~
118.
,6 - 1161 5787
'
Camshaft sprocket
(1:~ain'tenSioner
7-8
(0.7.
08 5.'-5.81
. ,
rJ
L--.
Qj
Front cover
.,
.
.~
13-1.
Crankshaft sprocket
L.
SEM578C
After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads.
EM-10
. . .
5. Remove all spark plugs. 6. Set NO.1 piston,at T.D.C. on its compression stroke.
Q
Front
SEM199C
7. Remove the following parts. Power steering pump, idler pulley and power steering pump brackets Compressor idler pulley Crankshaft pulley Oil pump with pump drive spindle
. . . . .
Rocker
cover
SEM200C
SEM201C
EM-"
SEM202C
10. Remove the following parts. . Chain tensioner . Chain guides . Timing chain and sprocket
Crank~h3ft sprocket
SEM203C
Inspection Check for cracks and excessivewear at roller links. Replace if necessary.
Jf) ~
,~
'
SEM204C
EM-12
TIMING CHAIN
crankShaft Crankshaft ~prOCket
~ ~
~
Installation
.
"4~
1. Install crankshaft sprocket, oil pump drive gear and oil thrower. . Make sure that mating marks of crankshaft sprocket face engine front. .
O;I:;:~~~ '\ n 0 ~
Front.
SEM205C
~~~
'/0
(O@
\000 ~.
'~ " \\
))
"
2. Install camshaft sprocket. 3. Confirm that NO.1 piston is set at T.D.C. on its compression stroke. 4. Install timing chain. Set timing chain by al.igning its mating marks with those of crankshaft sprocket and camshaft sprocket.
~
II ~ Can ,",ocke<
"
ii
~r C"ok .p-"
e: Punchmark
SEM206C
EM-13
-3.0 mm
9. Install front cover. Be careful not to damage cylinder head gasket. Do not forget 011seal.
. .
SEM453C
10. Install rubber plug. (Refer to "Installation" HEAD.) 11. Install oil pan. (Refer to Oil PAN.)
of CYLINDER
12. Install oil pump and distributor driving spindle with new gasket in front cover. (1) Assemble oil pump and driving spindle, aligning punchmark on driving spindle with oil hole.
Punchmark
SEM212C
EM-14
Front
SEM136C
13. Install distributor. 14. Make sure that NO.1 piston is set at T.D.C. and that distributor rotor is set at NO.1 cylinder spark position.
Q
Front
SEM199C
EM-15
(J36467)
KV10980010
(
4. Apply engine oil to new valve oil seal and install it with Tool. Before installing valve oil seal, install valve spring seat.
Unit: mm (in)
SEM246C
Engine inside
SEM715A
FRONT OIL SEAL 1. Remove radiator shroud and crankshaft pulley. 2. Remove front oil seal. Be careful not to damage crankshaft.
EM-16
9i-
SEAL REPLACEMENT
3. Apply engine oil to new oil seal and install it using suitable tool.
SEM115B
REAR OIL SEAL 1. Remove flywheel or drive plate. 2. Remove rear oil seal retainer. 3. Remove traces of liquid gasket using scraper.
it
.J'I;
5. Apply engine oil to new oil seal and install it using suitable tool.
~ (0.079
0.118 in)
EM-17
CYLINDER HEAD
~~-8
.,'0.. ---Valve rocker cover-
'~w,
Oilseal
springseatA
V"Wg";..~~
Valve seat
,\;~ ~ , \ ~J
@
~~
@
E'M":~
.
\\
\J @<~ 'b@cg
Cylinder head
Head bolt
~:
EM-18
CYLINDER HEAD
CAUTION: When installing sliding parts such as rocker arms, camshaft and oil seal, be sure to apply new engine oil on their sliding surfaces. . When tightening cylinder head bolts and rocker shaft bolts, apply new engine oil to thread portions and seat surfaces of bolts.
O.K.
Hydraulic valve lifters are installed in each rocker arm. If hydraulic valve lifter is kept on its side, even when installed in rocker arm, there is a possibility of air entering it. After removal, always set rocker arm straight up, or when laying it on its side, have it soak in new engine oil.
Ii
SEM878B
N.G.
. .
Do not disassemble hydraulic valve lifter. Attach tags to valve lifters so as not to mix them up.
SEM868B
Removal 1. Drain coolant from radiator and drain plug of block. 2. Remove the following parts. Power steering drive belt Power steering pump, idler pulley and power steering brackets Vacuum hoses of S.C.v. and pressure control solenoid valve Accelerator wire bracket 3. Disconnect E.G.R. tube from exhaust manifold. 4. Remove bolts which hold intake manifold collector to intake manifold. 5. Remove bolts which hold intake manifold to cylinder head while raising collector upwards. 6. Remove rocker cover. When removing rocker cover, do not hit rocker cover against rocker arm.
. . . .
EM-19
-5/0
5 10 15 20
Red painted
~
Front
SEM199C
8. Loosen camshaft sprocket bolt. Support timing chain by using Tool as shown in figure.
SEM218C
EM-20
SEM2106
<ID
CID
11. Remove cylinder head. Head warpage or cracking could result from removing in incorrect order. Cylinder head bolts should be loosened in two or three steps.
. .
- SEM220C Disassembly'
0
10
@
0
@
0
@
0
@
01
(Q
~ (])
~ @
~ @
Q) CD
SEM445C
1. Remove rocker shaft assembly. a. When loosening bolts, evenly loosen from outside in sequence. b. Bolts should be loosened in two or three steps. 2. Remove camshaft. Before removing camshaft, measure camshaft end play. (Refer to "Inspection".)
KV10109210 ( )
3. Remove valve components with Tool. 4. Remove valve oil seals. (Refer to OIL SEAL REPLACEMENT.)
EM-21
~ ~~~
CAMSHAFT VISUAL CHECK Check camshaft for scratches, seizure and wear.
CAMSHAFT RUNOUT 1. Measure camshaft runout at the center journal. Runout (Total indicator reading):
0 - 0.02 mm (0 - 0.0008 in) 2. If it exceeds the limit, replace camshaft.
CAMSHAFT CAM HEIGHT 1. Measure camshaft cam height. Standard cam height:
Cam wear limit: 0.2 mm (0.008'in) 2. If wear is beyond the limit, replace camshaft.
in)
SEM549A
CAMSHAFT
JOURNAL
CLEARANCE
"
- 1.3002
in)
EM-22
Camshaft journal clearance: Standard 0.045 - 0.090 mm (0.0018 - 0.0035 in) Limit 0.12 mm (0.0047 in) CAMSHAFT END PLAY
1. Install camshaft in cylinder head. 2. Measure camshaft end play. Camshaft end play: Standard 0.07 - 0.15 mm (0.0028 - 0.0059 in) Limit 0.2 mm (0.008 in)
SEM228C
CAMSHAFT
SPROCKET
RUNOUT
1. Install sprocket on camshaft. 2. Measure camshaft sprocket runout. Runout (Total indicator reading): Limit 0.12 mm (0.0047 in) 3. If it exceeds the limit, replace camshaft sprocket.
SEM232C
VALVE GUIDE CLEARANCE 1. Measure valve deflection in a right-angled direction with camshaft. (Valve and valve guide mostly wear in this direction.) . Valve deflection limit (Dial gauge reading): 0.15 mm (0.0059 in)
SEM449C
2. If it exceeds the limit, check valve to valve guide clearance. a. Measure valve stem diameter and valve guide inner diameter. b. Check that clearance is within specification. Valve to valve guide clearance: Standard 0.020 - 0.053 mm (0.0008 - 0.0021 in) (Intake) 0.040 - 0.070 mm (0.0016 - 0.0028 in) (Exhaust) Limit 0.1 mm (0.004 in) c. If it exceeds the limit, replace'valve or valve guide.
EM-23
\ \ \
CYLINDER HEAD
Inspection (Cont'd)
VALVE GUIDE REPLACEMENT 1. To remove valve guide, heat cylinder head to 150 to 160C (302 to 320F).
2. Drive out valve guide with a press [under a 20 kN (2 t, 2.2 US ton, 2.0 Imp ton) pressure] or hammer and suitable tool.
.'
SEM223C
3. Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): Intake 11.175 - 11.196 mm (0.4400 - 0.4408 in) Exhaust 12.175 - 12.196 mm (0.4793 - 0.4802 in)
4. Heat cylinder head to 150 to 160C (302 to 320F) and press service valve guide onto cylinder head. Projection "L": 14.9 - 15.1 mm (0.587 - 0.594 in)
SEM225C
5. Ream valve guide. Finished size: Intake 7.000 - 7.018 mm (0.2756 - 0.2763 in) Exhaust 8.000 - 8.018 mm (0.3150 - 0.3157 in)
"
EM-24
REPLACING
I
Recess diameter
I
SEM795A
1. Bore out old seat until it collapses. The machine depth stop should be set so that boring cannot continue beyond the bottom face of the seat recess in cylinder head. 2. Ream cylinder head recess. Reaming bore for service valve seat Oversize [0.5 mm (0.020 in)): Intake 36.500 - 36.516 mm (1.4370 - 1.4376 in) Exhaust 42.500 - 42.516 mm (1.6732 - 1.6739 in) Reaming should be done to the concentric circles to valve guide center so that valve seat will have the correct fit.
SEMOO8A
"::I SEM892B
4. Cut or grind valve seat using suitable tool at the specified dimensions as shown in S.o.S. 5. After cutting, lap valve seat with abrasive compound. 6. Check valve seating condition. Seat face angle" a ": 45 deg. Contacting width "W" Intake 1.6 - 1.7 mm (0.063 - 0.067 in) Exhaust 1.7 - 2.1 mm (0.067 - 0.083 in)
EM-25
cr d
VALVE DIMENSIONS Check dimensions in each valve. For dimensions, refer to S.O.S. When valve head has been worn down to 0.5 mm (0.020 in) in margin thickness, replace\lalve. Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or less.
L
SEM188A
Jdi-----SEM288A EM113
VALVE SPRING Squareness 1. Measure "s" dimension. Out-of-square: Outer Intake Less than 2.5 mm (0.098 in) Exhaust Less than 2.3 mm (0.091 in) Inner Intake Less than 2.3 mm (0.091 in) Exhaust Less than 2.1 mm (0.083 in) 2. If it exceeds the limit, replace spring. Pressure Check valve spring pressure. Pressure: N (kg, Ib) at height mm (in) Standard Outer Intake 604.1 (61.6, 135.8) at 37.6 (1.480) Exhaust 640.4 (65.3, 144.0) at 34.1 (1.343) Inner Intake 284.4 (29.0, 63.9) at 32.6 (1.283) Exhaust 328.5 (33.5, 73.9) at 29.1 (1.146) Limit Outer Intake 567.8 (57.9, 127.7) at 37.6 (1.480) Exhaust 620.8 (63.3, 139.6) at 34.1 (1.343) Inner. Intake 266.8 (27.2, 60.0) at 32.6 (1.283) Exhaust 318.7 (32.5, 71.7) at 29.1 (1.146) If it exceeds the limit, replace spring.
EM-26
CYLINDER
HEAD
Inspection (Cont'd) ROCKER SHAFT AND ROCKER ARM 1. Check rocker shafts for scratches, seizure and wear. 2. Check outer diameter of rocker shaft. Diameter mm (in): 21.979 - 22.000 mm (0.8653 - 0.8661 in)
3. Check inner diameter of rocker arm. Diameter mm (in): 22.012 - 22.029 mm (0.8666 - 0.8673 in) Rocker arm to shaft clearance mm (in): 0.012 - 0.050 mm (0.0005 - 0.0020 in) Keep rocker arm with hydraulic valve lifter standing to prevent air from entering hydraulic valve lifter when checking.
SEM234C
Assembly 1. Install valve component parts. Always use new valve oil seal. Refer to OIL SEAL REWide pitch
Narrow
pitch
. . . .
PLACEMENT.
Before installing valve oil seal, install inner valve spring seat. Install outer valve spring (uneven pitch type) with its narrow pitch side toward cylinder head side. After installing valve component parts, use plastic hammer to lightly tap valve stem tip to assure a proper fit.
SEM6388
2. Mount camshaft onto cylinder head, placing knock pin at front end to top position. Apply engine oil to camshaft when mounting onto cylinder head.
SE M236C
SEM273C
EM-27
'"
Front
Intake
Exhaust
Exhaust SEM579C
Front
Cutout SEM274C
(j)
@
0
~
[Q: @
CD 0
@ 0
@ Q)
.Q.
.Q.
.Q.
QJ @)
SEM445C
EM-28
CYLINDER HEAD
Installation
1. Set No.1 piston at T.D.C. on its compression stroke as follows: (1) Align mark on crankshaft pulley with "0" position and confirm that distributor rotor head is set as shown in figure.
-5~ 0:5 10 15 20
Red painted
Q
Front
SEM199C
SEM442C
.
2. Install cylinder head with new gasket and tighten cylinder
CD @
I I
. Do not rotate crankshaft and camshaft separately, valves will hit piston heads. . Tightening procedure (1) Tighten all bolts to 29 Nom (3.0 kg-m, 22 ft-Ib).
(2) Tighten all bolts to 78 Nom (8.0 kg-m, 58 ft-Ib). (3) Loosen all bolts completely. (4) Tighten all bolts to 29 Nom (3.0 kg-m, 22 ft-Ib).
(5) Turn all bolts 80 to 85 degrees
SEM238C @
I
order.
or
(j)
CID
clockwise
with an angle
wrench, or if an angle wrench is not available, tighten all bolts to 74 to 83 Nom (7.5 to 8.5 kg-m, 54 to 61 ft-Ib).
EM-29
Silver
5. Install rubber plugs as follows: (1) Apply liquid gasket to rubber plugs.
Rubberplugsshouldbe replacedwithnewones.
Rubber plugs should be installed within 5 minutes of applying liquid gasket.
(2) Install rubber plugs. then move them with your fingers to uniformly spread the gasket on cylinder head surface. Rubber plugs should be installed flush with the surface. Do not start the engine for 30 minutes after installing rocker cover. Wipe clean excessive liquid gasket from cylinder head top surface.
. . .
--N.G.
o/!I!IIJl
Good
SEM933B
EM-30
(2) If valve lifter moves more than 1 mm (0.04 in), air may be inside of it. (3) Bleed air off by running engine at 1,000 rpm under no-load for about 20 minutes. (4) If hydraulic valve lifters are still noisy, replace them and bleed air off again in the same manner as in step (3).
between
rocker
cover
and
~:J
@
SEM546C
8. Tighten bolts as follows: (1) Tighten 2 bolts to 3 N.m (0.3 kg-m, 2.2 ft-Ib) temporarily in order shown in figure.
@ @\
.g,
@ @
,0,
(2) Then tighten bolts to 7 to 10 N.m (0.7 to 1.0 kg-m, 5.1 to 7.2 ft-Ib) in order shown in figure. 9. Install any parts removed.
-""6'CD @
.-JJ@
SEM547C
EM-31
ENGINE REMOVAL
M/T model
tC!] 3 -16 1
(1.3- 1.6.9.12)
tC!]3-55 4
(4A-5.6.32-41)
~ j
0 ~ ~
tC!] 3-55 4
(4.4.5.6.32
- 41)
~
,
r ~
'-, ~
tC!]2 -28 2
(2.2 2.9. 16.21)
.I?:
L~
-28
43-55
(4.4
LtC!] 22
-5.6.32-41)
//'
'''"'
~/
EM-32
..
ENGINE REMOVAL
WARNING: a. Situate vehicle on a flat and solid surface. b. Place chocks at front and back of rear wheels. c. Do not remove engine until exhaust system has completely cooled off. Otherwise, you may burn yourself and/or fire may break out in fuel line. d. For safety during subsequent steps, the tension of wires should be slackened against the engine. e. Before disconnecting fuel hose, release fuel pressure from fuel line. Refer to "Releasing Fuel Pressure" in section EF & EC. f. Be sure to hoist engine and transmission in a safe manner. g. For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS CATALOG. CAUTION: When lifting engine, be careful not to strike adjacent parts, especially accelerator wire casing, brake lines, and brake master cylinder. In hoisting the engine, always use engine slingers in a safe manner.
. .
"5
:1,; ",.
.,"'"
EM-33
CYLINDER BLOCK
Main bearing
cg
~
.
rJ
EM-34
CYLINDER BLOCK
Disassembly
PISTON AND CRANKSHAFT 1. 2. 3. 4. 5. 6.
SEM744
/;~y
,
I I.~'
~
~\ ~ I~(
II
~105~O1
ST0501 5000
Place engine on a work stand. Remove timing chain. Drain coolant and remove water pump. Drain oil. Remove oil pan and oil pump. Remove cylinder head.
-)
7. Remove pistons. When disassembling piston and connecting. rod, remove snap rings, then heat piston to 60 to 70C (140 to 158F) or use piston pin press stand at room temperature.
SEM877B
KV10110300
EM156
8. Remove main bearing beam and crankshaft. Before removing main bearing beam, measure crankshaft end play. Bolts should be loosened in two or three steps.
. .
Inspection PISTON AND PISTON PIN CLEARANCE 1. Measure inner diameter of piston pin hole "dp".
Standard diameter "dp": 20.987 - 20.999 mm (0.8263 - 0.8267 in)
;
..
SEM149B
EM-35
dp - Dp = 0 - 0.004mm (0 - 0.0002In)
If it exceeds the above value, replace pi!3ton assembly with pin.
SEM821 B
SEM249C
2nd ring 0.03 - 0.07 mm (0.0012 - 0.0028 In) 011 ring 0.065 - 0.135 mm (0.0026 - 0.0053 in) Max. limit of side clearance: 0.1 mm (0.004 in) If out of specification, replace piston and/or piston ring assembly.
SEM250C
EM-36
Measuring points
in)
CYLINDER BLOCK DISTORTION AND WEAR 1. Clean upper face of cylinder block and measure the distortion. Limit: 0.10 mm (0.0039 in) 2. If out of specification, resurface.it. The resurfacing limit is determined by cylinder head resurfacing in engine. Amount of cylinder head resurfacing is "A" Amount of cylinder block resurfacing is "B" The maximum limit is as follows: A + B = 0.2 mm (0.008 in) Nominal cylinder block height from crankshaft center: 246.95 247.05 (9.7224 - 9.7264 in) mm 3. If necessary, replace cylinder block.
SEM255C
-_N O!CD""
MM
ffi
,
I I I
ON--0 '00
I I I
. . ~.
N ... CD ...
, ,
Unit: mm (in)
PISTON-TO-BORE CLEARANCE 1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper. Standard inner diameter: 89.000 - 89.030 mm (3.5039 - 3.5051 in) Wear limit: 0.2 mm (0.008 in) Out-of-round (X-V) limit: 0.015 mm (0.0006 in) Taper (A-B) limit: 0.015 mm (0.0006 in) If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary. 2. Check for scratches and seizure. If seizure is found, hone it.
EM-37
CYLINDER BLOCK
.
Q
Front
SEM257C
Inspection
(Cont'd)
If both cylinder block and piston are replaced with new ones, select piston of the same grade number punched on cylinder block upper surface.
3. Measure piston skirt diameter. Piston diameter" A": Refer to S.D.S. Measuring point "a" (Distance from the top): 52 mm (2.05 in) 4. Check that piston-to-bore clearance is within specification.
a
SEM258C
5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to S.D.S. 6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter "A". Rebored size calculation: D= A+B-C where, D: Bored diameter A: Piston diameter as measured B: Piston-to-bore clearance C: Honing allowance 0.02 mm (0.0008 in) 7. Install main bearing caps, and tighten to the specified torque to prevent distortion of cylinder bores in final assembly. 8. Cut cylinder bores. When any cylinder needs boring, all other cylinders must also be bored. . Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time. 9. Hone cylinders to obtain specified piston-to-bore clearance. 10. Measure finished cylinder bore for out-of-round and taper. Measurement should be done after cylinder bore cools down.
A B
CRANKSHAFT cracks. 2. With a micrometer, measure journals for taper and out-ofround. Out-of-round (X-Y): Main journal Less than 0.01 mm (0.0004 in) Crank pin Less than 0.005 mm (0.0002 in) Taper (A-B): Main journal Less than 0.01 mm (0.0004 in) Crank pin Less than 0.005 mm (0.0002 in) EM-38
x
y
Taper: Out-of-round: A- B X- Y SEM316A
BEARING
CLEARANCE
Method A (Using bore gauge and micrometer) Main bearing 1. Set main bearings in their proper positions on cylinder block and main bearing cap.
SEM448C
2. Install main bearing cap to cylinder block. Tighten all bolts in correct order in two or three stages. Refer to "Assembly". 3. Measure inner diameter "A" of each main bearing.
4. Measure outer diameter "Dm" of each crankshaft main journal. 5. Calculate main bearing clearance. Main bearing clearance = A - Dm Standard: 0.020 - 0.047 mm (0.0008 - 0.0019 in) Limit: 0.1 mm (0.004 in) 6. If it exceeds the limit, replace bearing. 7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing. a. When grinding crankshaft journal, confirm that "L" dImension In fillet roll is more than the specified limit. "L": 0.1 mm (0.004 In) b. Refer to S.D.S. for grinding crankshaft and available service parts.
SEM964
EM-39
,Q
rg
Front
bl
roJ
[5j
rd
8. ;If crankshaft is reused, measure main bearing clearance and select thickness of main bearing. If crankshaft is replaced with a new one, it is necessary to select thickness of main bearings as follows: a. Grade number of each cylinder block main journal is punched on the respective cylinder block.
SEM266C
SEM272C
c. Select main bearing with suitable thickness according to the following table. Main bearing grade number:
0 1
1 2 3
2 3 4
For example: Main journal grade number: 1 Crankshaft journal grade number: 2 Main bearing grade number = 1 + 2 =3
Connecting rod bearing (Big end) 1. Install connecting rod bearing to connecting rod and cap. 2. Install connecting rod cap to connecting rod. Tighten bolts to the specified torque. 3. Measure inner diameter "C" of each bearing.
EM-40
8.
If crankshaft is replaced with a new one, select connecting bearing according to the following table.
rod
Method B (Using plastigauge) CAUTION: -Do not turn crankshaft or connecting rod while plastigage is being inserted. When bearing clearance exceeds the specified limit, ensure that the proper bearing has been installed. Then if excessive bearing clearance exists, use a thicker main bearing or undersized bearing so that the specified bearing clearance is obtained.
. .
EM142
CONNECTING ROD BUSHING CLEARANCE (Small end) 1. Measure inner diameter "c" of bushing.
SEM151B
EM-41
rod assembly
REPLACEMENT
OF CONNECTING
ROD
BUSHING
(Small end) 1. Drive in small end bushing until it is flush with end surface of rod. Be sure to align the oil holes. 2. After driving in small end bushing, ream the bushing so that clearance between small end bushing and piston pin is specified valve. Clearance between small end bushing and piston pin: 0.005 - 0.017 mm (0.0002 - 0.0007 in)
SEM062A
FLYWHEEL/DRIVE
PLATE RUNOUT
Runout (Total indicator reading): Flywheel (M/T model) Less than 0.1 mm (0.004 in) Drive plate (A/T model) Less than 0.1 mm (0.004 in)
SEM261 C
Dial gauge
Assembly PISTON 1. Install new snap ring on one side of piston pin hole.
SEM166B
2. Heat piston to 60 to lOoC (140 to 158F) and assemble piston, piston pin, connecting rod and new snap ring. Align the direction of piston and connecting rod. . Numbers stamped on connecting rod and cap correspond to each cylinder. After assembly, make sure connecting rod swings smoothly.
Cylinder number
SEM262C
EM-42
KV10110300 (
EM156
,'..."
g;r
'
rn::::
expander
..
Front
*
i?
V-
~ -""'-.) K'
.8
8 Top ring
upper rail
Ojl ring
/"')
-:::
!/ "~
Oil ring
lower rail
SEM 1606
CRANKSHAFT
~~
t2
Front
1. Set main bearings in their proper positions on cylinder block and main bearing beam. Confirm that correct main bearings are used. Refer to "Inspection" of this section.
~ ~~:O.5 50 ~ ~
No.3 No.1 No.2
SEM44BC
2. Install crankshaft and main bearing beam and tighten bolts to the specified torque. Prior to tightening bearing cap bolts, place bearing cap in its proper position by shifting crankshaft in the axial direction. '. Tighten bearing cap bolts gradually in two or three stages. Start with center bearing and move outward sequentially. After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.
. . .
EM-43
J
SEM159B
. connecting rod caps. bearings are used. Confirm that correct Refer to "Inspection". . Install bearings so that oil hole in connecting oil hole of bearing.
5. Install pistons with connecting rods. a. Install them into corresponding cylinders with Tool. Be careful not to scratch cylinder wall by connecting rod. Arrange so that front mark on piston head faces toward front of engine.
. .
b. Install connecting rod bearing caps. Tighten connecting rod bearing cap nuts to the spe.cified torqu~. . Connecting rod bearing nut: (1) Tighten to 14 to 16 N.m (1.4 to 1.6 kg-m, 10 to 12 ft-Ib). (2) Tighten bolts 60 to 65 degrees clockwise with an angle wrench, or if an angle wrench is not available, tighten them to 38 to 44 N.m (3.9 to 4.5 kg-m, 28 to 33 ft-Ib).
6. Measure connecting rod side clearance. Connecting rod side clearance: Standard
- 0.016
in)
Limit 0.6 mm (0.024 in) If beyond the limit, replace connecting rod and/or crankshaft.
EM-44
CYLINDER
BLOCK
Assembly (Cont'd) REPLACING PILOT BUSHING 1. Remove pilot bushing (M/T) or pilot convertor (A/T).
Crankshaft side
..
M/T
A/T
SEM163.B
EM-45
General Specifications
Engine model Cylinder arrangement Displacement Bore x stroke Valve arrangement Firing order Number of piston rings Compression Oil Number of main bearings Compression ratio cm' (cu in) mm (in) KA24E 4, in-line 2,389 (145.78) 89 x 96 (3.50 x 3.78) O.H.C. 1-3-4-2
2 1 5 9.1
Unit: kPa (kg/cm2 ,psi)/rpm Compression pressure Standard Minimum Differential limit between cylinders
1,324
(13.5,
192) /300
981 (10,142)/300
98 (1.0, 14)/300
EM-46
(S.D.S.)
60 (2.36)
120 (4.72) H
Standard Distortion
Grade 1 Inner diameter Cylinder bore Out-of-round (X-V) Taper (A-B) Difference in inner diameter between cylinders Piston-to-cylinder clearance Cylinder block height (From crankshaft cented
* Wear limit ** Total amount of cylinder head resurfacing and cylinder block resurfacing
89.000 - 89.010 (3.5039 - 3.5043) 89.010 - 89.020 (3.5043 - 3.5047) 89.020 - 89.030 (3.5047 - 3.5051) Less than 0.015 10.0006) Less than 0.010 (0.0004) Less than 0.05 (0.0020) 0.020 - 0.040 (0.0008 - 0.0016) 246.95 - 247.05 (9.7224 - 9.7264) Grade 2 Grade 3
0.2 (0.008)*
0.2 (0.008)
0.2 (0.008)**
CYLINDER
HEAD
Unit: mm (in)
EM-47
tL
Standard Intake
Length (L) 52.6 (2.071)
Service Exhaust
56.0 (2.205)
Limit Exhaust
56.0 (2.205)
Intake
52.6 (2.071)
Outer diameter (D) Inner diameter (d) (Finished size) Cylinder head hole diameter Interference fit Stem to guide clearance Tapping length (Q)
11.023 - 11.034 (0.4340 - 0.4344) 7.000 - 7.018 (0.2756 - 0.2763) 10.975 - 10.996 (0.4321 - 0.4329)
12.023 - 12.034 (0.4733 - 0.4738) 8.000 - 8.Q18 (0.3150 - 0.3157) 11.975 - 11.996 (0.4715 - 0.4723)
11.223 - 11.234 (0.4418 - 0.4423) 7.000 - 7.018 (0.2756 - 0.2763) 11.175-11.196 (0.4400 - 0.4408)
12.223 - 12.234 (0.4812 - 0.4817) 8.000 - 8.Q18 (0.3150 - 0.3157) 12.175 - 12.196 (0.4793 - 0.4802)
EM-48
Standard
Service
I
D1
I
D1
SEM177
SEM178
Unit:
mm (in)
Standard Intake Cylinder head seat recess diameter Valve seat outer diameter (D1 ) 36.000 - 36.016 (1.4173 - 1.4179) 36.080 - 36.096 (1 .4205 - 1.4211) 45 Exhaust 42.000 - 42.016 (1.65:35 - 1.6542) 42.080 - 42.096 (1.6567 -1.6573) 45 Intake 36.500 - 36.516 (1.4370 - 1.4376) 36.580 - 36.596 (1.4402 - 1.4408) 45
Service Exhaust 42.500 - 42.516 (1.6732 - 1.6739) 42.580 - 42.596 (1.6764 - 1.6770) 45 1.7- 2.1 (0.067 - 0.083)
1.6 - 1.7
(0.063 - 0.067)
1.7 - 2.1
(0.067 - 0.083)
1.6 - 1.7
(0.063 - 0.067)
EM-49
T (Margin thickness)
SEM188A
Standard Limit
Unit: mm (in)
In.
Ex.
In.
Ex. In. Ex. In.
Valve face angle (01) Ex. In. Valve head margi n (T) Ex.
VALVE SPRING
Unit: mm (in)
Standard Intake Outer Free height (H) Inner Pressu re N (kg,lb) at height Outer 53.34 (2.1000) 604.1 (61.6, 135.8) at 37.6 (1.480) 284.4 (29.0,63.9) at 32.6 (1.283) 47.95 (1.8878) 640.4 (65.3, 144.0) at 34.1 (1.343) 328.5 (33.5, 73.9) at 29.1 (1.146) 567.8 (57.9,127.7) at 37.6 (1.480) 266.8 (27.2,60.0) at 32.6 (1.283) 2.5 (0.098) 2.3 (0.091) 57.44 (2.2614) Exhaust 53.21 (2.0949) Intake -
Limit Exhaust
620.8 (63.3, 139.6) at34.1 (,.343) 318.7 (32.5,71.7) at 29.1 (1.146) 2.3 (0.091) 2.1 (0.083)
Inner Outer
Out-of-square Inner
EM-50
..
;#
. DC
EM120 Unit: mm (in)
SEM568A
Standard Cam height (A) Valve lift (h) Wear limit of cam height Camshaft journal to bearing clearance Inner diameter of camshaft bearing 44.839 - 45.029 (1.7653 - 1.7728) 10.4 (0.409)
limit
Outer diameter of camshaft journal (D) Camshaft f1Inout Camshaft end play ) a b c Valvetiming (Degreeon crankshaft! d e
f
0 -0.02 (0 -0.0008)
0.07 - 0.15 (0.0028 - 0.0059) 248 240 3 57 12 56
0.2 (0.008)
EM-51
=::::::::::::=
Top
d
Side clearance 2nd
- 0.070
-0.0028)
-
0.1 (0.004)
a
Oil
0.1 (0.004)
Top
0.28 - 0.43
(0.0110
- 0.0169)
0.5 (0.020)
Ring gap
2nd
0.5 10.020)
Grade No.1 Standard Piston skirt diameter (A) Grade No.2 Grade No.3
88.970 - 88.980 (3.5027 - 3.5031) 88.980 - 88.990 (3.5031 - 3.5035) 88.990 89.000 (3.5035 - 3.5039) 89.470 - 89.500 (3.5224 - 3.5236) 89.970 - 90.000 (3.5421 - 3.5433)
- 0.0236)
0.5 (0.020)
CONNECTING
ROD
0.5
Service (Oversize) (0.020) 1.0 (0.039)
Piston pin
Unit: mm (in) Standard Piston pin outer diameter Interference fit of piston pin to piston pin hole limit
=::::::::::::=
Center distance IS)
limit
0.1510.0059)
0.3 (0.012)
0.023 (0.0009)
21.000 - 21.012
10.8268
- 0.8272)
53.000 12.0866
- 53.013 - 2.0871)
0.6 10.024)
* Without
bearing
EM-52
(S.D.S.)
Out-of-round
@- Ci)
Taper@ .@
~. Om
Op
SEM394 Unit: mm (in) No.O Main journal diameter (Dm) Grade No.1 No.2 No.O Pin journal diameter (Op) Grade No.1 No.2 Center distance (r) Standard Journal Taper of journal and pin I@ - @] Pin Journal Pin 59.967 - 59.975 (2.3609 - 2.3612) 59.959 - 59.967 (2.3606 - 2.3609) 59.951 - 59.959 (2.3603 - 2.3606) 49.968 - 49.974 (1.9672 - 1.9675) 49.962 - 49.968 (1.9670 - 1.9672) 49.956 - 49.962 (1.9668 - 1.9670) 47.97 - 48.03 (1.8886 - 1.8909) Limit 0.01 (0.0004) 0.005 (0.0002) 0.01 (0.0004) 0.005 (0.0002) 0.10 (0.0039) 0.3 (0.012)
\J57
EM715
Out-of-round of journal and pin I@ -Ci)] ---, Runout IT.I.R.] * Free end play Fillet roil
* Total indicator reading
Standard Main bearing clearance Connecting rod bearing clearance 0.020 - 0.047 (0.0008 - 0.0019) 0.010 - 0.035 (0.0004 - 0.0014)
0.09 (0.0035)
EM-53
2 3
4
1.829 - 1 .833 10.0720 - 0.0722) 1.833 - 1.837 10.0722 - 0.0723) 1.837 - 1.841 10.0723 - 0.0725)
Undersize (service)
Unit: mm (in) Thickness Crank pin journal diameter "Dp"
Undersize
(service)
Unit: mm (in) Thickness
Mein journal diameter "Dm" 0.08 10.0031 ) 0.12 (0.0047) 1.540 - 1.548 (0.0606 - 0.0609) 1.560 - 1 .568 10.0614 - 0.0617) 1.625 - 1.633 10.0640 - 0.0643)
0.25 10.0098)
0.25 10.0098)
MISCELLANEOUS
COMPONENTS
Unit: mm (in)
EM-54
SECTION
LC
;..... lC- 2
,.. lC- 3
lClC-12
CONTENTS
PREPARATION
...
."..
""''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''"""''''''''''''''''''''''''''''''''
''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''
""
lC-16
PREPARATION
SPECIAL SERVICE TOOLS
Tool number (Kent-Moore No.) Tool name ST25051 001 (J25695-1 ) Oil pressure gauge
Description
U!!
EG17650301
(
a
[j
LC-2
+-..-
-- ------------
--
---<i=
r0-
O I
W
Cam ;Urlace I
'" r
(') co I\)
:r>
. .
3. Install pressure gauge. 4. Start engine and warm it up to normal operating temperature. 5. Check oil pressure with engine running under no-load.
ST25051 001 (J25695-1)
Engine rpm
Approximate discharge pressure kPa (kg/cm2, psi) More than 78 (0.8, 11) 412-481 (4.2-4.9,60-70)
If difference is extreme, check oil passage and oil pump for oil leaks. 6. Install oil pressure switch with sealant.
LC-4
~tOJ
6. 10 (0.6 - 1.0,4.3.7.2)
body Gasket
--.::> /pump
tOJ:
.
.
iT.
~~1~
Punchmark
Oil
~AU) ~~"4A
Always replace with new oil seal and gasket. When removing oil pump, turn crankshaft so that No.1 piston is at T.D.C. on its compression stroke. When installing oil pump, align punchmark on drive spindle and oil hole on oil pump.
hole
Front
~
REGULATOR VALVE INSPECTION
1. Visually inspect components for wear and damage. 2. Check oil pressure regulator valve sliding surface and valve spring. 3. Coat regulator valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If damaged, replace regulator valve set or oil pump assembly.
EL076
LC-5
Rotor
tip clearance CD
If it exceeds the limit, replace gear set or entire oil pump assembly.
SLC732
LC-6
Thermostat: Thermostat:
Open Closed
Radiator
Thermostat
SLC186A
System Check
WARNING: Never remove the radiator cap when the engine is hot; serious burns could be caused by high pressure fluid escaping from the radiator. Wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow built-up pressure to escape and then turn the cap all the way off. CHECKING COOLING SYSTEM HOSES
Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration.
LC-7
CHECKING RADIATORCAP To check radiator cap, apply pressure to cap with a tester. Radiator cap relief pressure:
78
SLC613
Water Pump
~
::~~~.~.~.m~
12'~'
\
~',P/
)!!7
.
SLC187A
(f
SLC738
INSTAllATION Remove liquid gasket from mating surface of pump housing using a scraper.
. . .
Remove liquid gasket from mating surface of cylinder block. Clean all traces of liquid gasket using white gasoline.
SLC188A
LC-8
. .
Cut off tip of nozzle of liquid gasket tube at point shown in figure. Use Genuine Liquid Gasket or equivalent.
Cut here.
~
KP510-00150 Diameter of liquid gasket: 2.0.3.0 mm 10.079.0.118 in)
]
SLC822
of pump housing as shown. a. Be sure diameter of liquid gasket Is within 2.0 to 3.0 mm (0.079 to 0.118 In) dla. range. b. Attach pump housing to cylinder block within five minutes of applying liquid gasket. c. After Installing pump housing, walt at least 30 minutes before starting engine.
SLC189A
Thermostat INSPECTION 1. Check for valve seating condition at ordinary temperatures. It should sea.ttightly.
Water inlet
SLC192A
Upward
A~
~~
Jiggle valve
--~
SLC097
temperature.
After Installation, run engine for a few minutes, and check>., for leaks.
SLC343
LC-9
(Cont'd)
. .
Remove liquid gasket from mating surface of thermostat using a scraper. Similarly, remove liquid gasket from mating surface of cylinder block. Clean all traces of liquid gasket using white gasoline.
SLC790
Cut here.
. .
KP510.()0150
Cut off tip of nozzle of liquid gasket tube at point shown in figure. Use Genuine LiqLJidGasket or equivalent. ..~
]
SLC822
Apply a continuous bead of liquid gasket to mating surface of water inlet. a. Be sure diameter of liquid gasket is within 2.0 to 3.0 mm (0.079 to 0.118 in). b. Attach water inlet to cylinder block within five minutes after applying liquid gasket. c. After installing water inlet, wait at least 30 minutes before refilling coolant and starting engine.
SLC824
'( .~
LC -1 0
Radiator
A/T model only ~3 2 -4.2 10.33-0.43,
2.4-3.1)
7 ~
@I
Automatic transmission
~
~
LJ
~:
N-mIkg-m,ft-lb)
Cooling Fan
DISASSEMBLY AND ASSEMBLY
-~
'\"
Fan
<1( L-.J
~:
N'm (lrg-m;ft-Ibl
SLC558
\~ ~o.~~ 1.0,4.3-7.2)
INSPECTION Check fan coupling for rough operation, oil leakage or bent bimetal.
SLC072
LC-11
BATTERY fus Ib I e
FUSE
@D~
36
AIR RELAY
CONDI TI ON
r(")
I ~
t'1 P P
!fI
11 41 THERMOSWITCH
n a z -I ::0 a r c z .... -I
To ther-mo
contro
I amp.
M
41
-=
36
@4Ib
0
!II r 0 I\,) w m
=
(Sub-h arness) CONNECTOR-ll
~ -
CONDENSER F AN MOTOR
@)
lR;l ~ 't1H
~ "
I ~::;CD
Ii [!t
L/OR
~ mIi]
y..>r;;;,
@
S. M. J.
Ii]
~
<ff~
'"
CD
I
IGNITION ON or SWITCH START
UP
CONNECTOR-I
~13Id
~
~CD
0
>-
G
~
@)
(Main harness)
[!t
lBIB@
~
[EttBr;;--,
r--
@l@)
(E. F. I. harness)
1i
BODY GROUND
, '" ,
>I
'" '"
,, CD...) , , ...
To thermo
contro
I amp.
'"...
E. ~ ~ S (Refer to
SLC191A
SLC238A
LC-13
Trouble Diagnosis
@i5
'+ L:::
00
-
Even though air conditioner operates normally under high engine temperature conditions [above 9SoC (20SoF)] the condenser fan motor does not rotate.
m
CHECK CONDENSER FAN MOTOR. 1) Turn ignition and air conditioner switch "OFF". 2) Disconnect condenser fan motor harness connector-I. 3) Check continuity between connector-H terminal @ and connector-I terminal @. Continuity should exist. If N.G. replace condenser fan motor-. O.K. [!] CHECK GROUND CIRCUIT. Check harness continuity between motor harness connector-I terminal @ and ground. Continuity should exist. If N.G., repair harness.
000
m
_MEeT
-= SLC239A
Iu
CHECK POWER SUPPLY (Motor side). 1) Disconnect condenser fan motor harness connector-H. 2) Turn ignition switch, air conditioner switch and blower switch "ON". 3) Check voltage between fan motor harness connector-II terminal @ and ground. Battery voltage should exist.
O.K.
[ill
iJ
SLC240A
N.G.
Ii
CHECK POWER SUPPLY (Motor side). 1) Turn ignition switch "OFF" 2) Disconnector fan motor harness connector-I. 3) Turn ignition switch "ON". 4) Check voltage between terminal @ and ground. Battery voltage should exist.
[!]
@i5
[]I]
Ii]
O.K.
SLC241A
lo.K.
N.G. Repair or replace harness between terminals @ and @.
Ii]
'
CHECK THERMOSWITCH. Check continuity between thermoswitch terminals @ and CD. Condition ContinuitY Above Yes 92 -98C (198 -2OSF) Below No 92 -98C (198 -2OSF)
lu
Ii
DISCONNECT
iii
CHECK POWER SUPPLY (Relay side). 1) Turn ignition "OFF". 2) Disconnect air conditioner relay. 3) Turn ignition "ON". 4) Check voltage between terminals @, @ and ground. Battery voltage should exist. O.K. CHECK RELAY. Refer to HA section. @is
O.K.
Check sub-harness for thermoswitch continuity. If N.G., repair or replace them.
SLC242A
EB
i5
.
00
EB
00
O.K.
-= SLC243A
r Replace relay.
LC-14
iii 34
~ lOK
i5l
0
[it
-=
SLC244A
CHECK HARNESS CONTINUITY, 1) Turn ignition switch "OFF", 2) Check continuity between relay harness connector terminal @ and fan motor harness connector-I terminal @. Continuity should exist.
N.G.
[R]
~i5@
SLC245A
"-
LC-15
Oil pump
Unit: mm (in)
Rotor tip clearance Outer rotor to body clearance Side clearance (with gasket)
412.481 (4.2.4.9,60
- 70)
Radiator
c (OF) (infF) 76.5 (170) 8/90 (0.31/194) Cap relief pressure Leakage test pressure
78
.psi)
mmfc
lC-16
/"
SECTIONEF
&
EC
... EF & ECEF & ECEF & ECEF & EC2 3 4 9 EF & EC- 16 EF & EC- 26 EF & EC- 31 EF & EC-153 EF & EC-155 EF & EC-157 EF & EC-158
CONTENTS
PREPARATION PRECAUTIONS """""""""""""""'"'''''''''''''''''''''''''''''''''''' ENGINE AND EMISSION CONTROL OVERALL SYSTEM ENGINE AND EMISSION CONTROL PARTS DESCRIPTION ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATIO INSPECTION TROUBLE DIAGNOSES FUEL INJECTION CONTROL SYSTEM INSPECTION EVAPORATIVE EMISSION CONTROL SYSTEM CRANKCASE EMISSION CONTROL SYSTEM SERVICE DATA AND SPECIFICATIONS (S.D.S.)
When you read wiring diagrams: . Read GI section, "HOW TO READ WIRING DIAGRAIVIS". See El section, "POWER SUPPLY ROUTING" for power distribution circuit.
When you perform trouble diagnoses, read GI section, "HOW TO FOllOW FLOW CHART IN TROUBLE DIAGNOSES".
PREPARATION
SPECIAL SERVICE TOOL
Tool number (Kent-Moore No.) Tool name EG11160000
( Description
EF & EC-2
PRECAUTIONS
E.C.U. Do not disassemble E.C.C.S. control unit. (E.C.U.) Do not turn diagnosis mode selector forcibly.
. .
. .
.
If a batteryterminalis disconnected, the memory will return to the ROM value. The E.C.C.S.' will now start to self-control at its initial value. Engine operation can vary slightly when the terminal is disconnected. However, this is not an indication of a problem. Do not replace parts because of a slight variation.
Do not apply undue force to mounting bracket. Before connecting or disconnecting E.C.U. connector, make sure red and green LEOs are off after turning ignition key off. Always install the properly specified E.C.U. on car; otherwise, erroneous engine operation may result. Disconnect connector by pulling it (not the harness) straight out. Before connecting connector, make sure all pins are straight.
Do not disconnectbattery
cables while the engine is running. Do not reverse polarity of battery when connecting it. Otherwise, E.C.U. and/or injectors may be burned.
INJECTOR Do not disconnect injector har~ ness connectors with engine running. Do not apply battery power directly to injectors; otherwise injectors will be damaged.
WIRELESS EQUIPMENT When installing a C.B. ham radio or a mobile phone, be sure to observe the following, as installation location may affect the electronic control systems. 1) Keep antenna as far as possible away from electronic control units. 2) Keep antenna feeder line more than 20 cm (7.9 in) away from harness of electronic controls. Do not let them run parallel for a long distance. 3) Adjust antenna and feeder line so that standing-wave ratio can be kept smaller. 4) Be sure to ground radio to vehicle body.
. .
FUEL PUMP Do not operate fuel pump when there is no fuel in lines. Do not reuse fuel hose clamps. Tighten fuel hose clamps to the specified torque.
. . . .
E.C.C.S. PARTS HANDLING Handle air flow meter carefully to avoid damage. Do not disassemble air flow meter. Do not clean air flow meter with detergent. . Do not jolt or jar the crank angle sensor.
. . .
~~
WHEN STARTING Do not depress accelerator pedal when starting. Immediately after starting, do not rev up engine unnecessarily. . Do not rev up engine just prior to shutdown.
. .
SEF121H
E.C.C.S. HARNESS HANDLING Securely connect E.C.C.S. harness connectors. A poor connection can cause extremely high voltage to develop in the coil and condenser, resulting in damage to ICs. Keep E.C.C.S. harness at least 10 cm (3.9 in) away from adjacent harnesses, to prevent an E.C.C.S. systerri malfunction due to receiving external noise, degraded operation of ICs, etc. Keep E.C.C's' parts and harnesses dry. Before removing parts, turn off ignition switch and then disconnect battery ground cable.
.
. .
EF & EC-3
. Fuelpumprelay
E.C.C.S.relay
Fuel pump
-E.G.R. control valve Exhaust gas temperature sensor (For California model) Pressure regulator Pressure regu lator control solenoid valve
~~b
~
~'iWIW
S.C.V.control
LA.A. unit
~.~,
Fuel filter
~
~
A'I'V'
I
.
0 a
"
Distributor
~~
G
~.,~. ~"
A;,flowm.'"
SEF122H
EF & EC-4
solenoid valve7
"\
Ignition
switch
Throttle valve
: r---~-L- -'
.sensol 7
m
m (")
I C1I
"TI J20
\
Transmission
temperatu re sensor
\'1'
\.Spark \1 plug '11
C.
lSJ
~
Q:
Carbon canister
Air flow me
en m
...:
Exhaustgasflow
'"
:I
"TI
r
Fuel injection & mixture ratio control
Injectors
Crankanglesensor
.
Ignition timing control Power transistor
Ignition switch
.
A.I.V. control
Starter switch
.
. .
~
Idle switch
Throttle sensor
E.C.C.S.
control unit
,"
Fuel pump
"
[
Air regulator
Neutral switch (M/T) Inhibitor switch (AiT) Acceleration cut control Air conditioner relay
Battery
Fail-safe function
EF & EC-6
@-b
E.G.R. control valve
~TWI~ @ @
Air regurator
tJi)
@ ./"'1
Canister
@/
1
SEF355H
EF 8r. EC- 7
FUSIBLE LINK
-c8J-
( ( FUSE J-----rs}
34 382336
Ij/]
CK
CONNECTOR
r<:::"7I
NJ. NlOR
E. C. C. S. RELAY
<t ::BA TTERY
No.2
No.3
= =
10 I
110
CONTROL
SOLENOID
PRESSURE
REGULATOR VALVE
106
IDS
102
rm J>r -<
103 112 4 47
109
E. G. R. CONTROL SOLENOID VALVE A. 1. V. CONTROL SOLENOID VALVE S. C. V. CONTROL SOLENOID VALVE A. A. C. VALVE L.:::T L..::..:J
lIB;
!:
...----J
L::...J L..::J
AIR REGULATOR FUELL..:....J
METER
I
AI R FLOW
r --------1 -------T
I
I
>--
m
." f20
To tachometer
gAUST
::SENSOR
mm-
I "-------1
16 17 39 48 19
3
I
>J >J
en
116 --<
45
43 44
PUMP ::-
M
THROTTLE
VALVE
SWITCH
I NHIB RELA
-=
m
(")
I
RESISTOR
{O
I
PDWER
TRANSISTOR
6
13
co
I GNITI ON COIL
DISTRIBUTOR
W
CONDENSER 3D 31 11
Z -i ;0 0 r c Z .... -i
("") 0
NEUTR
' SWITC
21-29
18
ENGINE TEMPERATURE
SENSOR EXHAUS T GAS
coco- co-
co- co-
SPARK PLUG
: :
For
A/T
Cal ifornla
model
ANGLE SENSOR
CRANK
For U. S. A.
$
( MJ
tt
22 4D
- ------__n_--_nn _n--_--_--_----
SENSOR C TEMPERA@URE
2D @:
37
THROTTLE
f
r---
SENSOR
CONT
M/T model
@:
For
Canada
lIS 28
32
1 I I
A/T UNIT CONTR&L
: A/T modeI wi th A.S. C.D. : A/T mode I without (/) m " w 0 .....
:x:
A.S. C.D.
I
With heaa-up display
Without
head-up
display
'--
SENSOR
ENGINE AND EMISSION CONTROL PARTS DESCRIPTION E.C.C.S. Control Unit (E.C.U.)
The EC.U. consists of a microcomputer, inspection lamps, a. diagnostic mode selector, and connectors for signal input and output and for power supply. The unit controls the engine.
Rotor plate
SEF853B
SEF285H
Temperature compensation
resistor
.. r-f
RH;:~-Hot wire
The air flow meter measures the mass flow rate of intake air. Measurements are made so that the control circuit will emit an electrical output signal corresponding to the amount of heat dissipated from a hot wire placed in the stream of intake air. The airflow past the hot wire removes the heat from the hot wire. The temperature of the hot wire is very sensitive to the mass flow rate. The higher the temperature of the hot wire, the greater its resistance value. This temperature change (resistance) is determined by the mass air flow rate. The control circuit accurately regulates current (I) in relation to the varying resistance value (RH) so that VA always equals VB. The air flow meter transmits a voltage value VA to the control unit where the output is converted into an intake air signal.
RH RK RA. RB
EF & EC-9
SEF903D
>
Not used
~
:5 ~ 0
~
~
.,---0'--2 3 )
switch)
(Full throttle
terminal
NO.4 and 6)
~
. 4.0
6}
~ '" ! '" -0
f2.0
~
5
9" 0
g ... "
135
SEF287D
Fuel Injector
The fuel injector is a small, elaborate solenoid valve. As the E.C.U. sends injection signals to the injector, the coil in the injector pulls the needle valve back and fuel is released ,into the intake manifold through the nozzle. The injected fuel is controlled by the E.C.U. in terms of injection pulse duration. Brass wire is used in the injector coil and thus the resistance is higher than a conventional injector.
SEF359H
EF &. EC-10
Pressure Regulator
The pressure regulator maintains the fuel pressure at 299.1 kPa (3.05 kg/cm2, 43,4 psi). Since the injected fuel amount depends on injection pulse duration, it is necessary to maintain the pressure at the above value.
SEF6058
Holder
?:
;; '" 0> ~ 0
C.
The exhaust gas sensor, which is placed into the exhaust manifold, monitors the amount of oxygen in the exhaust gas. The sensor has a closed-end tube made of ceramic zirconia. The outer surface of the tube is exposed to exhaust gas, and the inner surface to atmosphere. The zirconia of the tube compares the oxygen density of exhaust gas with that of atmosphere, and generates electricity. In order to improve the generating power of the zirconia, its tube is coated with pratinum. The voltage is approximately 1V in a richer condition of the mixture ratio than the ideal air-fuel ratio, while approximately OV in leaner conditions. The radical change from 1V to OV occurs at around the ideal mixture ratio. In this way, the exhaust gas sensor detects the amount of oxygen in the exhaust gas and sends the signal of approximately 1V or OV to the E.C.U.
> ... :J
8 0I
Rich
---
~ I
Ideal ratio Mixture ratio --Lean SEF288D
Outlet 0
Fuel Pump
Fuel damper
The fuel pump with a fuel damper is a submergible type, and are located in the fuel tank.
Motor
1) Inlet
SEF043C
Power Transistor
The ignition signal from the E.C.U. is amplified by the power transistor, which turns the ignition coil primary circuit on and off, inducing the proper high voltage in the secondary circuit. The ignition coil is a small, molded type.
SEF125H
EF & EC-11
The air regulator provides an air by-pass when the engine is cold for a fast idle during warm-up. A bimetal, heater and rotary shutter are built into the air regulator. When the bimetal temperature is low, the air by-pass port opens. As the engine starts and electric current flows through a heater, the bimetal begins to turn the shutter to close the by-pass port. The air passage remains closed until the engine stops and the bimetal temperature drops.
SEF636B
The I.A.A. unit is made up of the AA.C. valve, F.I.C.D. solenoid valve and idle adjust screw. It receives the signal from the E.C.U. and controls the idle speed at the preset value. The F.I.C.D. solenoid valve compensates for changes in idle speed caused by the operation of. the air compressor. A vaCl/um control valve is also installed in this unit to prevent an abnd'rmal rise in intake manifold vacuum pressure during deceleratton.
SEF126H
Air SEF040E
SEF286H
Magnetic
line
\ /'
~SWitch N S
Reed
N
N) switch M;;Qnetic \ I. me I
Fieldplate
0 : G
The vehicle speed sensor provides a vehicle speed signal to the E.C.U. The speed sensor consists of a reed switch, which is installed on the transmission unit and transforms vehicle speed into a pulse signal.
"{
t;\
y-/
SEF624B
Fieldplate
EF & EC-12
SEF632B
B.P.T. Valve
Vacuum signal source
".'.1' ~~~'ff'
The B.P.T. valve monitors exhaust pressure to activate' the diaphragm, controlling throttle chamber vacuum applied to the E.G.R. control valve. In other words, recirculated exhaust gas is controlled in response to positioning of the E.G.R. control valve or to engine operation.
t
Exhaust pressure
EC344A
\.
EF & EC-13
ENGINE AND EMISSION CONTROL PARTS DESCRIPTION A.I.V. Control Solenoid Valve
The A. LV. control solenoid valve cuts the intake manifold vacuum signal for A.I.V. control. It responses to the ON/OFF signal from the E.C.U: When the solenoid is off, the vacuum signal from the intake manifold is cut. When the control unit sends an ON signal, the coil pulls the plunger downward and feeds the vacuum signal to the A.I.V. control valve.
The E.G.R. system is controlled only by the E.C.U. At both lowand high-speed engine revolutions, the solenoid valve turns on and accordingly the E.G.R. valve cuts the exhaust gas leading to the intake manifold.
vacuum signal.
Fuel Filter
The specially designed fuel filter has a metal case in order to withstand high fuel pressure.
SEF256A
Carbon Canister
The carbon canister is filled with active charcoal to absorb evaporative gases produc~d in Jhe fuel tank. These absorbed gases are then delivered to the intake manifold by ,manifold vacuum for combustion purposes. The vacuum in the intake passage upstream of the throttle valve increases in response to the amount of the intake air. When the vacuum of the intake passage is higher than a preset value, the 2nd purge control valve opens and the absorbed gases are sucked into the intake passage for combustion purposes.
EF & EC-14
ENGINE AND EMISSION CONTROL PARTS DESCRIPTION Check Connector for E.C.C.S. Checker Box
The check connector for E.C.C.S. checker box is beside fuse
box.
SEF296H
SEF072G
\.
EF &. EC-15
Engine temperature Engine temperature sensor Density of oxygen in exhaust gas Exhaust gas sensor
Throttle
sensor
Idle switch
Gear position
Ignition switch
CONTROL
The amount of fuel injected from the fuel injector, or the length of time the valve remains open, is determined by the E.C.U. The basic amount of fuel injected is a programmable value mapped in the E.C.U. ROM memory. In other words, the programmable value is preset by engine operating conditions determined by input signals (for engine rpm and air intake) from both the crank angle sensor and the air flow meter.
~i
Low
Water temperature
High SEF923C
VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION In addition, the amount of fuel injection is compensated for to improve engine performan~e under various operating conditions as listed below: <Fuel increase> 1) During warm-up 2) When starting the engine 3) During acceleration 4) Hot-engine operation <Fuel decrease> 1) During deceleration
EF & EC-16
ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Fuel Injection Control (Cont'd)
CLOSED LOOP CONTROL ~ E.C:C.S.' control ~nit / . ection pulse ~ InJ
MIXTURE RATIO FEEDBACK CONTROL Mixture ratio feedback system is designed to precisely control the mixture ratio to the stoichiometric point so that the three-way catalyst can reduce CO, HC and NOx emissions. This system uses an exhaust gas sensor in the exhau,st manifold to check the air-fuel ratio. The control unit adjusts the injection pulse width according to the sensor voltage so the mixture ratio will be within the range of the stoichiometric air-fuel ratio. This stage refers to the closed-loop control condition. The open-loop control condition refers to that under which the E,C.U. detects any of the following conditions and feedback control stops in order to maintain stabilized fuel combustion. 1) Deceleration 2) High-load, high-speed operation 3) Engine idling 4) Malfunctioning of exhaust gas sensor or its circuit 5) Insufficient activation of exhaust gas sensor at low engine temperature 6) Engine starting MIXTURE RATIO SELF-LEARNING CONTROL
combusti~
e
Injector injection
SEF639B
The mixture ratio feedback control system monitors the mixture ratio signal transmitted from the exhaust gas sensor. This feedback signal is then sent to the E.C.U: to control the amount of fuel injection to provide a basic mixture ratio as close to the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. This is due to manufacturing errors (e.g., air flow meter hot wire) and changes during operation (injector clogging, etc.) of E.C.C.S. parts which directly affect the mixture ratio. Accordingly, a difference between the basic and theoretical mixture ratios is quantitatively monitored in this system. It is then computed in terms of "fuel injection duration" to automatically compensate for the difference between the two ratios. FUEL INJECTION TIMING
No.1 CYlinder
fL
Injection pulse
Fuel is injected once a cycle for each cylinder in the firing order.
rL n
n
1---1 enginecycle--j When engine starts, fuel is injected simultaneously twice a cycle. into all four cylinders
n
n n
1 engine cycle
j
1L1LfLf"LSEF841D
EF & EC-17
ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Fuel Injection Control (Cont'd)
FUEL SHUT-OFF
Enginetemperature sensor
Idle switch Throttle valve idle position E.C.C.S. control unit
Power transistor
Throttle sensor
Neutral position
,
E.
EF & EC-18
ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Ignition Timing Control (Co nt' d)
SYSTEM DESCRIPTION The ignition timing is controlled by the E.C.U. in order to maintain the best air-fuel ratio in response to every running condition of the engine. The ignition timing data is stored in the ROM located in the E.C.U., in the form of the map shown below. The E.C.U. detects information such as the injection pulse width and crank angle sensor signal which varies every moment. Then responding to this information, ignition signals are transmitted to the power transistor. e.g. N: 1,800 rpm, Tp: 1.50 msec A S.T.D.C. In addition to this, 1 At starting 2 During warm-up 3 At idle 4 At low battery voltage 5 During swirl control valve operates 6 Hot engine operation 7 At acceleration the ignition timing is revised by the E.C.U. according to the other data stored in the ROM.
Tp (msec)
I I 1.75
1.25 I
1.00 I
0.75 I
600
---
1,000
- ---
- --1,400
1,800
N 2,200
EF & EC-19
.1
Enginetemperature sensor
1
I
Engine temperature
.
.
E.C.C.S.
I
1 Neutral
I
I
A.A.C. valve
position
control unit
Powersteeringoil pressureswitchI
Battery Battery voltage
I
.
Vehicle speed
1 I
This system automatically controls engine idle speed to a specified level. Idle speed is controlled through fine adjustment of the amount of air which by-passes the throttle valve via AAC. valve. The A.AC. valve repeats ON/OFF operation at a rate of 100 to 200 Hz according to the signal sent from the E.C.U. The crank angle sensor detects the actual engine speed and sends a signal to the
E.C.U. The E.C.U. then controls the ON/OFF time of the A.AC. valve so that engine speed coincides with the target value memorized in ROM. The target engine speed is the lowest speed at which the engine can operate steadily. The optimum value stored in the ROM is determined by taking into consideration various engine conditions, such as noise and vibration transmitted to the compartment, fuel consumption, and engine load.
EF & EC-20
Engine speed
Start signal
SYSTEM DESCRIPTION The E.C.U. activates the fuel pump for several seconds after the ignition switch is turned on to improve engine startability. If the E.C.U. receives a 1 signal from the crank angle sensor, it knows that the engine is rotating, and causes the pump to perform. If the 1 signal is not received when the ignition switch is on, the engine stalls. The E.C.U. stops pump operation and prevents battery discharging, thereby improving safety. The E.C.U. does not directly drive the fuel pump. It controls the ON/OFF fuel pump relay, which in turn controls the fuel pump.
Condition Ignition switch is tunred to ON. Engine running and cranking When engine is stopped Except as shown above
Stops
Air regulator
SYSTEM DESCRIPTION The air regulator is controlled by the E.C.U. at the same time as fuel pump ON-OFF control.
Condition
Air regulator operation Operates for 5 seconds Operates OFF in 1 second OFF
Ignition switch is turned to ON While engine is running and cranking When engine is stopped Except as shown above
EF
8r. EC-21
ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Air Induction Valve (A.I.V.) Control
INPUT/OUTPUT SIGNAL LINE Enginetemperature
Engine temperature sensor
Idle switch Throttle valve idle position
SYSTEM DESCRIPTION The air induction system is designed to send secondary air to the exhaust manifold, utilizing the vacuum caused by exhaust pulsation in the exhaust manifold. The exhaust pressure in the exhaust manifold usually pulsates in response to the opening and closing of the exhaust valve and decreases below atmospheric pressure periodically. If a secondary air intake pipe is opened to the atmosphere under vacuum conditions, secondary Water temperature c (oF) Between 28 (82) and 115 (239)
air can be drawn into the exhaust manifold in proportion to the vacuum. The air induction valve is controlled by the E.C.C.S. control unit, corresponding to the engine temperature. When the engine is cold, the A.I.V. control system operates to reduce HC and CO. In extremely cold conditions, A.I.V. control system does not operate to reduce after-burning. This system also operates during deceleration for the purpose of blowing off water around the air induction valve. A.LV. control solenoid valve ON
EF
8r.
EC-22
-.
E.C.C.S.
control unit
1
I
Engine temperature
Enginetemperature sensor
Ignition switch
..,..
Start signal
I
I
SYSTEM
DESCRIPTION In addition, a system is provided which precisely cuts and controls port vacuum applied to the E.G.R. valve to suit engine operating conditions. This cut-and-control operation is accomplished through the E.C.U. When the E.C.U. detects any of the following conditions, current flows through the solenoid valve in the E.G.R. control vacuum line. E.G. R. control solenoid valve operation
Condition
This causes the port vacuum to be discharged into the atmosphere so that the E.G.R. control valve remains closed. 1) Low engine temperature 2) Engine starting 3) High-speed engine operation 4) Engine idling
When starting Below 60 (140) Water temperature Idle & heavy load conditions Other conditions OFF c (oF) Above 105 (221) ON
E.G.R. system operation E.G. R. system operates under only the following conditions.
B.P.T. valve Water temperature c (oF) Exhaust gas pressure High Throttle position Operation E.G.R. control solenoid valve E.G.R. system
Closed
Partially open
OFF
Operates
EF & EC-23
ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Fuel Pressure Regulator Control
INPUT/OUTPUT SIGNAL LINE Engine temperature
E.C.C.S.
Ignition switch
Start signal
control unit
SYSTEM DESCRIPTION The fuel "pressure-up" control system briefly increases fuel pressure for improved starting performance of a hot engine. Under normal operating conditions, manifold vacuum is applied to the fuel pressure regulator. When starting the engine, however, the E.C.U. allows current to flow through the ON/OFF solenoid valve in the control vacuum line, opening this line to the atmosphere. As a result, atmospheric pressure is applied, throttling the fuel passage to increase fuel pressure.
START
Ignition switch
OFF
n
I
ON
ON
P.R.control
solenoid
valve
OFF
.. Approx. 3 min
SEF741B
0<' -r,
Idle signal
Start signal
I
Ignition switch
Engine speed
Engine temperature
This system has a swirl control valve (S.C.V.) in the intake passage of each cylinder. While idling the S.C.V. closes. Thus the velocity of the air in the intake passage increases, promoting the vaporization of the fuel and producing a swirl in the combustion chamber. Because of this operation, this system tends to increase the burning speed of the gas mixture, Idle switch ON Water temperature Above 35C (95F) Except above
improve fuel consumption, and increase the stability in running conditions. Also, except when idling, this system opens the S.C.v. In this condition, this system tends to increase power by improving intake efficiency via reduction of intake flow resistance, intake flow. The solenoid valve controls S.C.v.'s shut/open condition. This solenoid valve is operated by the E.C.U. Solenoid valve ON OFF S.C.V. Close Open
EF & EC-24
Cut Control
Air conditioner
relay
SYSTEM DESCRIPTION When accelerator pedal is fully depressed, air conditioner is turned off for a few seconds. This system improves acceleration when air conditioner is used.
Fail-safe System
AIR FLOW METER MALFUNCTION If the air flow meter output voltage is above or below the specified value, the E.C.U. senses an air flow meter malfunction. In case of a malfunction, the throttle sensor substitutes for the air flow meter. Though air flow meter is malfunctioning, it is possible to drive the vehicle and start the engine. But engine speed will not rise more than 2,400 rpm in order to inform the driver of fail-safe system operation while driving. Operation
System E.G.R. control system Idle speed control system Fixed condition OFF Except as shown above A duty ratio is fixed at the preprogrammed value. Fuel is shut off above Fuel injection control system 2,400 rpm. (Engine speed does not exceed 2,400 rpm.)
SENSOR
When engine temperature sensor output voltage is below or above the specified value, water temperature is fixed at the preset value as follows: Operation Condition
Just as ignition switch is turned ON or Start
Engine temperature decided 20C (68F) 80C (176F) 20. 80C (68 - 176F) (Depends on the time)
THROTTLE
SENSOR
MALFUNCTION
When throttle sensor output voltage is below or above the specified value, throttle sensor output is fixed at the preset value.
EF & EC-25
. . . .
Battery
Fuses
. E.C.U.harnessconnector . Vacuumhoses
. Air intakesystem
. .
. .
Overall inspection
INSPECTION START
N.G.
Perform self-diagnosis.
/
Repair or replace.
N.G.
O.K.
N.G.
Check idle mixture ratio by using E.C.U. inspection lamps (Red and Green) [in diagnostic mode II] .
N.G.
I Repair or replace harness.
O.K.
Check base idle CO. N.G.
O.K.
Replace exhaust gas sensor.
INSPECTION END
EF & EC-26
INSPECTION START
Visually check the following: . Air cleaner clogging . Hoses and ducts for leaks . E.G.R. control valveoperation . Electrical connectors
~
3
. Gaskets
. Throttle valveand throttle valveswitch operation
~
SEF457C 4
Start engine and warm it up until water temperature indicator points to the middle of gauge.
Open engine hood and run engine at about 2,000 rpm for about 2 minutes under no-load.
2 ,~,,\""\""L"""):
"'~ 1{ 0; .1OOO,/m,"
...'.6 "!:-\ ~1 f -8
I
O.K. Check, correct or replace malfunctioning parts.
SEF477B
I
Check and clean injectors, and replace injectors if necessary.
Race engine two or three times under no-load, then run engine at idle speed.
Check idle speed. M/T: 750:!:50 rpm AfT: 750:!:50 rpm (in "N" position) O.K.
N.G.
N.G.
EF & EC-27
IDLE SPEED/IGNITION
A
TIMING/IDLE
Check ignition timing with a timing light. 1S:t2 B.T.D.C. O.K. N.G. Adjust ignition timing by turning distributor after loosening bolt which secures distributor. 1S:t2 B.T.D.C.
Adjust idle speed by turning idle speed adjusting screw. M/T: 700:tSOrpm AfT: 70O:tSOrpm (in "N" position)
1'1'
3 4 2 '*"""~"""'" 5 '~"-.(6 ~
0=
,'000""';"
~7
I 1.8
Run engine at about 2,000 rpm for about 2 minutes under no-load.
SEF477B
~r\
~/~
~V~~J
SEF450H
Make sure that inspection lamp (Green) on E.C.U. goes IN.G. on and off periodically more than 5 times during 10 seconds at 2,000 rpm under no-load. O.K. Set the diagnosis mode of E.C.U.to mode II. Check inspection lamps (Red and Green) on E.C.U. blink at 2,000 rpm. They should blink simultaneously. Yes INSPECTION END
No
~r\
~V ~~/-i~/ '--'~Jf)) ,
@
r,' ' ~
iDIY
"-'"
J~
SEF292H
D'
C'
EF &. EC-28
~~'!
E.C.C.S. harness
19
~i
nl'-'~'
SEF353H
Check exhaust gas sensor harness: 1) Turn off engine and disconnect battery ground cable. 2) Disconnect harness connector from E.C.U. 3) Disconnect exhaust gas sensor harness connector and connect terminal for exhaust gas sensor harness connector to ground with a jumping wire. 4) Check for continuity between terminal No. 19 of E.C.U. harness connector and ground metal on vehicle body.
O.K.
N.G.
Repair or replace E.C.C.S.harness and connect battery ground cable. Connect harness connector to E.C.U. and disconnect jumping wire from exhaust gas sensor.
Disconnect engine temperature sensor harness connector. . Connect a resistor (2.5 kil) between terminals of engine temperature sensor harness connector. . Disconnect A.I.V. hose and install a suitable plug in A.I.V. pipe. . Connect battery ground cable.
Start engine and warm it up until water temperature indicator points to the middle of gauge. (Wait more than 5 minutes after starting.)
Race engine two or three times under no-load then run engine at idle speed.
Check "CO"% and if engine runs smoothly. Idle CO: Less than 5% After checking CO% 1) Turn off engine. 2) Disconnect the resistor from terminals of engine temperature sensor harness connector. 3) Connect engine temperature sensor harness connector to engine temperature sensor. 4) Connect A.I.V. hose.
O.K.
EF & EC-29
N.G. Run engine at 2,000 rpm and make sure that green
inspection lamp on E.C.U.goes ON and OFF more than 5 times during 10 seconds.
. O.K.
EF & EC-30
EF & EC- 33
EF & EC- 37
,
-
1. Impossible to start
2. Impossible to start 3. Impossible to start 4. Impossible to start 5. Hard to start 6. Hard to start 7. Hard to start 8. Hard to start 9. Abnormal idling 10. Abnormal idling 11. Abnormal idling 12. Unstable idling 13. Unstable idling 14. Poor driveability 15. Poor driveability 16. Poor driveability 17. Poor driveability 18. Engine stall 19. Engine stall 20. Engine stall 21. Engine stall 22. Engine" stall 23. Engine stall 24. Backfire 25. Backfire
no combustion
partial combustion partial combustion (not affected by throttle position) partial combustion (throttle position changes combustion quality) before warm-up after warm-up every time morning after a rainy day no fast idle low idle (after warm-up) high idle (after warm-up) before warm-up after warm-up stumble (while accelerating) surge (while cruising) lack of power detonation during start-up while idling while accelerating while cruising while decelerating/just after stopping " while loading (power steering, air conditioner, headlamps, etc.) through the intake through the exhaust
EF & EC- 38
EF & EC- 39 EF & EC- 40 EF & EC- 41 EF & EC- 42 EF & EC- 43 EF & EC- 44 EF & EC- 45 EF & EC- 46 EF & EC- 47 EF & EC- 48 EF & EC- 49 EF & EC- 50 EF & EC- 51 EF & EC- 52 EF & EC- 53 EF & EC- 54 EF & EC- 55 EF & EC- 56 EF & EC- 57 EF & EC- 58 EF & EC- 59 EF & EC- 60 EF & EC- 61 EF & EC- 62
Self-diagnosis-
Description
"
.."..
"
EF & EC- 63
EF EF EF EF EF EF & & & & & & ECECECECECEC67 67 68 74 76 82
Self-diagnosis -- Mode I (Exhaust gas sensor monitor) Self-diagnosis - Mode II (Mixture ratio feedback control monitor) Self-diagnosis - Mode III (Self-diagnostic system) : Self-diagnosis - Mode IV (Switches ON/OFF diagnostic system) Self-diagnosis - Mode V (Real-time diagnostic system) Diagnostic Procedure Diagnostic Procedure 1 MAIN POWER SUPPLY AND GROUND CIRCUIT Self-diagnostic item Diagnostic Procedure 2 CRANK ANGLE SENSOR Diagnostic Procedure 3 AIR FLOW METER Diagnostic Procedure 4 ENGINE TEMPERATURE SENSOR Diagnostic Procedure 5 VEHICLE SPEED SENSOR Diagnostic Procedure 6 . IGNITION SIGNAL Diagnostic Procedure 7 ENGINE CONTROL UNIT.: Diagnostic Procedure 8
"
EF & EC- 84
EF & EC- 86
,
~ ~
EF & EC- 88 EF & EC- 90 EF & EC- 92 EF & EC- 94 EF & EC~ 98
~ ~ E.G.R. FUNCTION Diagnostic Procedure 9 ~ EXHAUST GAS SENSOR Diagnostic Procedure 10 ~ EXHAUST GAS TEMPERATURE
"
EF & EC-100
EF & EC-31
DiagnosticProcedure12
INJECTOR LEAK Switch ON/OFF diagnostic item Diagnostic Procedure 13 IDLE SWITCH Diagnostic Procedure 14 START SWITCH Not self-diagnostic item Diagnostic Procedure 15 FUEL PUMP Diagnostic Procedure 16 PRESSURE REGULATOR (P.R.) CONTROL SOLENOID VALVE Diagnostic Procedure 17 INJECTORS Diagnostic Procedure 18 SWIRL CONTROL VALVE (S.C.v.) CONTROL SOLENOID VALVE Diagnostic Procedure 19 AIR REGULATOR Diagnostic Procedure 20 AUXILIARY AIR CONTROL (A.A.C.) VALVE " Diagnostic Procedure 21 LA.A. CONTROL (F.LC.D. CONTROL) Diagnostic Procedure 22 AIR INDUCTION VALVE (A.LV.) CONTROL SOLENOID VALVE
~ ~
EF & EC-110
.
EF & EC-120 EF & EC-124 EF & EC-126 EF & EC-128 EF & EC-130 EF & EC-134 EF & EC-136 EF & EC-138
;
EF & EC-140
EF & EC-142
EF 8r. 'EC-32
TROUBLE DIAGNOSES
~~
~ .~.~ :A
~wol """
SEF232G
INTRODUCTION The engine has an electronic control unit to control major systems such as fuel control, ignition control, idle speed control, etc. The control unit accepts input signals from sensors and instantly drives actuators. It is essential that both kinds of signals are proper and stable. At the same time, it is important that there are no conventional problems such as vacuum leaks, fouled spark plugs, or other problems with the engine. It is much more difficult to diagnose a problem that occurs intermittently rather than continuously. Most intermittent problems are caused by poor electric connections or faulty wiring. In this case, careful checking of suspicious circuits may help prevent the replacement of good parts. A visual check only may not find the cause of the problems. A road test with a circuit tester connected to a suspected circuit shou Id be performed. Before undertaking actual checks, take just a few minutes to talk with a customer who approaches with a driveability complaint. The customer is a very good supplier of information on such problems, especially intermittent ones. Through the talks with the customer, find out what sy.mptoms are present and under what conditions they occur. Start your diagnosis by looking for "conventional" problems first. This is one of the best ways to troubleshoot driveability problems on an electronically controlled engine vehicle.
SE F234G
EF & EC-33
TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont'd) WORK FLOW
CHECK
IN
STEP 1
LISTEN TO CUSTOMERCOMPLAINTS
------
-----Can not be performed CHECK MAIN POWER SUPPLY AND GROUND CIRCUIT
<
---
<'
STEP 3
PROBLEM
STEP 4
r. I
I I I I I I I I I I I I I I I J I
<
INSPECTION ON THE BASE OF EACH COMPONENT
~~~~~~;able
Diagnostic Procedure EF & EC-86
STEP 5
-------
STEP 6
REPAIR/REPLACE
STEP 7
CHECK OUT
EF & EC-34
TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont'd)
DIAGNOSTIC WORKSHEET There are many kinds of operating conditions that lead to malfunctions on engine components. A good grasp of such conditions can make trouble-shooting faster and more accurate. In general, feelings for a problem depend on each customer. It is important to fully understand the symptoms or under what conditions a customer complains.. Make good use of a diagnostic worksheet such as the one shown below in order to utilize all the complaints for trouble-shooting. Worksheet sample
Customer name Engine # Incident Date MR/MS Model & Year Trans. Manuf. Date VIN Mileage In Service Date
KEY POINTS WHAT WHEN WHERE HOW Vehicle & engine model Date, Frequencies Road conditions Operating conditions, Weather conditions, Symptoms
0 Startability
0 No combustion 0 Partial combustion 0 Impossible to start 0 Partial combustion affected by throttle position 0 Partial combustion NOT affected by throttle position 0 Possible but hard to start 0 Othl!rs [ 0 No fast id Ie 0 Others [ 0 Stumble 0 0 Intake backfire 0 Others [ 0 Unstable 0 High idle ] 0 ] 0 0 While idling While decelerating 0 Low idle
Lack of power
0 Engine stall
0 At the time of start 0 While accelerating 0 Just after stopping 0 Just after delivery 0 In the morning 0 All the time 0 Not effected 0 Fine 0 Hot 0 Cold 0 0 0 Raining Warm
I
0 - While loading
0 Recently 0 0 At night In the daytime 0 Sometimes
0 0
Snowing 0 0
I
0 Cold
Others [ 0 Humid
I
] of J 8,000 rpm
Cool
I
Vehicle speed
'
10
20
30
40
50
I 60 MPH
0 Turned on
Not turned on
EF & EC-35
TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont'd)
INTERMITTENT PROBLEM SIMULATION In order to duplicate an intermittent problem, it is effective to create similar conditions for component parts, under which the problem might occur. Perform the activity listed under Service procedure and note the resu It.
'
Variable factor 1 Mixture ratio Influential part Pressure regulator Made rich Advanced 2 Ignition timing Distributor Retarded 3 Mixture ratio feedback control Exhaust gas sensor Control unit I.A.A. unit Lowered Electric connection (Electric continuity) Poor electric connection or faulty wiring Cooled 6 Temperature Control unit Warmed Turn idle adjusting screw clockwise. Tap or wiggle. Race engine rapidly. See if the torque reaction of the engine unit causes electric breaks. Cool with an icing spray or similar device. Heat with a hair drier. [WARNING: Do not overheat the unit.] Wet. [WARNING: Suspended Operation check Raised 4 Idle speed Rotate distributor counterclockwise. Disconnect exhaust gas sensor harness connector. Perform self-diagnosis (Mode I/II) at 2,000 rpm. Turn idle adjusting screw counterclockwise. Remove vacuum hose and apply pressure. Rotate distributor clockwise. Target condition Made lean Service procedure Remove vacuum hose and apply vacuum.
Moisture
Electric parts
Damp
Load switches
Loaded
Turn on head lights, air conditioner, rear defogger, etc. Perform self-diagnosis (Mode IV). Try to flash timing light for each cylinder.
9 10
EF &. EC-36
TROUBLE DIAGNOSES Diagnostic Table To assist with your trouble diagnoses,some typical diagnostic procedures for the following symptoms are. described.
REMARKS
In the following pages, the numbers such as 0, . in the above chart correspond to those in the serviceprocedure described below. Possiblecauses can be checked through the serviceprocedure shown by the mark "0".
EF 8r. EC-37
TROUBLE DIAGNOSES
1 II mpossible start to
no combustion
POSSIBLECAUSES
SPECIFICATIONS Mixture ratio (too lean) Ignition sparks (weak, missing) Ignition timing FUEL SYSTEM Fuel pump (no operation) Fuel pump relay (open circuited) Injectors (no operation, clogged)
.. 8 8 0
0 0 0
"
0
0 8
0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
IGNITION
SYSTEM
Ignition switch Main relay Power transistor Ignition coil Center cable (ignition leaks) Ignition wires (ignition leaks) Spark plugs
CONTROL SYSTEM
SERVICE PROCEDURE
LISTEN
LISTEN
I
,,\
---+
N.G. Check fuel pump and/or related circuits. [See page EF & EC-120.J
f)
~~
../ Fuel pump
CHECK
'-
~
//11II .
--+Check
N.G.
injector circuit.
.,
SE
Injector F280G
8
2l'
START
N.G -.:
[0 .! Timinglight . CHECK
--+ ,.
N.G.
MEASURE
o-~
' 5
-6 /.
Tachometer
@
~
I.*
Ignition switch SEF283G Check flashes of timing light for weak ness.
\.
SEF281G)
~ \UyJ
N.G. --+
---+
O.K.
,0
CHECK
.~
ignition
--+
((@S""~G
Check timing.
EF &. EC-38
Table (Cont'd) 0 f)
0 0
"
0
0
0
"
0
SERVICE PROCEDURE
LISTEN
N.G. Check fuel pump and/or related circuits. [See page EF & EC-120.J
f)
LISTEN
-.~
.1
Fuel pump
SEF279G
~
~
//11II
N.G.
Checkinjectorcircuit.
[See page EF & EC-126.J
Injector
SEF280G operating
..
L
~K
.1
APPL Y
,.
~.VACUUM
Improved
:J
r. D
.
,
~
\.
PRESSURE
SEF291G..I
.
,
Remove vacuum hose from pressure regulator, and apply vacuum and/or pressure, and try to start. CHECK
'SE".6G
~
~~~:ng
sm~G
"<
EF & EC-39
Table (Cont'd)
(not affected by throttle position)
. . .. . . . . . 0 .
0 0 0 0
- partial combustion
SERVICE PROCEDURE
LISTEN
N.G. Check injector circuit. [See page EF & EC-126.J
//11 InJector ' , " . , SEF280G Listen for injector operating sound. . lo.K. CHECK
--+
N.G.
throttle
Check throttle chamber ports and valve for clogging. 'A REMOVE MEASURE
s~
1---+
O.K.
Pressureregulator
Improved ,.
Fuel pressure Connect vacuum hose to pressure regulator and measure fuel pressure.
SEF291G Remove vacuum hose from pressure regulator, and try to start.
2.
1 N.G.
Repair or replace the hose.
CHECK
~
~
PERFORM
CHECK
MEASURE N.G.
, , Timing light
(!)
Ignition wire
O.K.
CHECK
~.
- (r@.<..~ ""'~G
Check ignition timing. 1 N.G. Adjust ignition timing. [See page EF & EC-26.J
G> Self-diagnosis Mode IV Perform self-diagnosis Mode IV (for start signal).
if?rn
SEF315G Measure
-~
resistance
of
Spark plug SEF282G Remove spark plugs and check their ignition sparks by cranking.
'","oct'"}~~' ;
Replace the wires.
N.G.
EF &.EC-40
Table (Cont'd)
partial combustion (throttle position changes combustion qu~lity)
10
0 0 0 0 0 0 0
41 Impossibleto start
POSSIBLE CAUSES INTAKE SYSTEM Throttle chamber (with ports clogged) Throttle valve (clogged) Air regulator (stuck closed) IdIe speed control valve CONTROL SYSTEM Engine temperature sensor Idle switch Neutral switch
SERVICE PROCEDURE
CHECK
r. N.G.
Throttle chamber
Clean theports.
CHECK
Throttle chamber
---+
..~
Check throttle chamber ports for clogging. r. CHECK
.
SEF290G
Check throttle valvefor clogging.
~.
..
jj
N.G. START
,
Check air regulator and/or its circuit. [See page EF & EC-130.J
SEF293G
CHECK .,~"
N.G. C.hec~ idle speed control Circuit. [See page EF & EC-134.J
@*
SEFOO6H Check terminal voltage of A.A.C. valve while cranking.
EF & EC-41
Table (Cont'd)
I
51 Hard to start
before warm-up
0 0 0
POSSIBLE CAUSES Mixture ratio Ignition switch (no start signal) Air regulator Engine temperature sensor Idle switch Neutral switch
0 f) 8 0 0
0 0 0 0 0 0 0 0
OTHERS
SERVICE PROCEDURE
0
"
CHECK
N.G. START 1 +
f)
MEASURE
N.G. (less than 12V) --+Charge the battery.
"i,. ;5 o-~ -6
Tachometer
SEF281G
@
~ ~
I.*
'0
CHECK
N.G. + Check air regulator and/or its circuit. [See page EF & EC-130.J
N.G.
--+ Check the malfunctioning switches and/or circuits. [See page EF & EC-118 (start signal). page EF & EC-116 (idle switch).]
if
Make sure air regulator open before warm-up.
SEF293G
stays
SEF285G Perform self-diagnosis Mode IV (for start signal and idle switch!.
g i)~
.
"
CRANK
Engine tempera- switch -!ure sensor SEF292G. Start with engine temperature sensor connector disconnected.
~ @
~
sensor circuit.
[See page EF & EC-90.J
Ignition
EF & .EC-42
Table (Cont'd)
0
after warm-up
POSSIBLE CAUSES SPECIFICATIONS Mixture ratio Fuel pressure FUEL SYSTEM Fuel line (hot fuel) Pressure regulator (low fuel pressure) Pressure regulator vacuum hose (clogged) Pressure regulator control solenoid Pressure regulator control solenoid vacuum hose Fuel temperature sensor (open circuited) IGNITION SYSTEM CONTROL SYSTEM Ignition switch (no start signal) Engine temperature sensor Air flow meter OTHERS Starter (operation too slow) Battery (voltage too low)
.
0 0 0
00
0 0 0 0
..
0
0 0 0 0
0 0 0
SERVICE PROCEDURE
CHECK '0 STARTI~ 2~' N.G. MEASURE
f)
CRANK
,,' o-~
SEF281G
I ",5 /. -6
~ @
,*
No change ~ Proceed to other steps. Improved + Proceed to other steps. If everything is O.K., check fuel vapor pressure.
FUEL
LINES
Tachometer
Ignition switch
SEF296G Measure battery voltage. N.G. (less than 12V) Charge the battery. N.G.
SEF374G Cool fuel lines with wet rags, etc. and try to start.
PERFORM
S eIf-diagnosIs Mode IV
'
~
171~
SEF285G Perform self-diagnosis Mode IV (for start signal),
0\
START
N.G. --+
0'
Ignition '-SEF294G switch Check terminal voltage of pressure regulator control solenoid while cranking.
i;.~
Listen for clicking sound from pressure regulator control solenoid when applying battery voltage. o.K. ~ N.G. Replace the solenoid. Check the solenoid circuit. [See page EF & EC-124.]
clogging.
1 N.G.
EF & EC-43
Table (Cont'd)
I
71 Hard to start
every time
0
POSSIBLE CAUSES
. . . o . (I). G . . . .
0 0 0 0 0 0 0 0 0 0 0 0 0 0
FUEL SYSTEM
Fuel pump (improper operation) Fuel line (clogged) Canister (air leaks)
Pressure regulator (low fuel pressure) Ignition wires (ignition leaks) Spark plugs (improper gap) Crank angle sensor Engine temperature sensor Idle switch Neutral switch 0 0 0 0 0
0 0
OTHERS
SERVICE PROCEDURE
LISTEN N.G. ---+Check fuel pump and/or related circuits. [See page EF &I;C-120.] START --+ Battery rMEASUREl
, SEF279G Listen for f.uel pump operating sound. No change Distributor -+ Proceed to other steps. Advance ST ART ~ Retard ~
~
CRANK
Tachometer Ignition
switch SEF281G Make sure tachometer indicates about 300 rpm while cranking. CHECK
@
~ ~
/.*
N.G.
Measurebattery voltage.
N.G.
I
Charge the battery.
..
SEF297G feedback system. Advance/retard ignition [See page EF & EC-26.] timing and try to start. Improved
~
-
Ignition
~*
switch
Check mixture
ratiO
.--
REMOVE
SEF291 G
Remove vacuum hose from pressure regulator, and try to start. CHECK3 , 1 Timing light
ro---MEASURE,
+\
Fuel pressure
;]
O.K. --+
..
Connect vacuum hose to Pressure regu Iat or pressure regulator and measure fuel pressure. Replace the wires. tN,G. MEASURE Ignition wire
. Check the malfunctioning circuits. [See page EF & EC-116 (idle switch).]
N.G. --+
I>
MEASURE
--+
O.K.
I.
CHECK
if?rn
SEF283G Check flashes of timing light for weakness. SEF315G Measure resistance of suspect ignition wires.
S~'k'~G~
Spark plug SEF299G SEF282G Check ignition sparks.
-~
EF &. EC-44
POSSIBLECAUSES
SPECIFICATIONS
8 f) 8 0
0 0 0 0 0 0 0 0 0 0 0
"
0 0 0 0 0 0 0
IGNITIONSYSTEM
Center cable (ignition leaks) Ignition wires (ignition leaks) Distributor cap (ignition leaks) Spark plugs (improper gap)
SERVICE PROCEDURE
CHECK MEASURE
8"
---+,
N.G.r.
Ignition
wire
N.G. --+
~rn
SEF315G Check flashes of timing Iight for weak ness.
.~
of
8
Distributor
DRY
'-
~~,
~0
(0
---+
O.K.
Ie
CHECK
1 Gap
~~pa'k P'"'
SEF282G Check ignition sparks.
EF & EC-45
POSSIBLECAUSES SPECI ICATIONS F INTAKE SYSTeM CONTROL SYSTEM Mixture ratio Ignition timing Blow-by hose (clogged) Air regulator (stuck closed) Engine temperature sensor
0 f)
0 0
.
0
0 0
0
0 0 0
SERVICE PROCEDURE
CHECK
~
APPLY
N.G. Check air regulator and/or its circuit. [See page EF & EC-130.J
CHECK
, N.G.
SEF293G
~ ~~
I
SEF300G Check blow-by clogging. hose for
BIOW-bY'
.
,
~
~~~:ng
1)
CHECK
""9~G
'- SEF284G
Apply vacuum pressure to pressure regulator after disconnecting vacuum hose, and check idling.
N.G. Check mixture ratio feedback system. [See page EF & EC-26.J
VACUUM PRESSURE
Engine tempera- switch tu~e sensor SEF292G Start with engine tem. perature sensor connector disconnected.
g ~. is; 9
...
"
CRANK
.
N.G.
!
START
Ignition
EF & EC-46
TROUBLE DIAGNOSES
SYMPTOM & CONDITION
POSSIBLE CAUSES SPECIFICATIONS INTAKE SYSTEM CONTROL SYSTEM Mixture ratio Ignition timing (too retarded) Throttle chamber (with ports clogged) Throttle valve (clogged) Crank angle sensor Air flow meter Engine temperature sensor
0 0 0 0
Loadswitches(remaining OFF)
SERVICE PROCEDURE
CHECK
f)
CHECK
BIOW-bY
~
~~~;ng
,SEF300G
rm ~
I 1
system.
IN.G.
SEF290G
~.
"
-
APPLY
~
-
VACUUM
feedback
PRESSURE 1
Pressure regulator
SEF291G
[SeeELsection.]
SEF285G
Self-diagnosis Mode V
Apply vacuum pressure to pressure regulator after disconnecting vacuum hose, and check idling.
'A RUN
lNG
~ ~'
g IT
II
::
,~
Ignition
@1
EF & EC-90
Engine tempera- switch ture sensor SEF292G . Start and run engine with engine temperature sensor connector disconnected.
EF & EC-47
Table (Cont'd)
...
0 0
8e
0
0
0
0
0
G>
\
\
0 0
0
0
0 0 0 0 0 0 0
CONTROL SYSTEM
Engine temperature sensor Idle switch (remaining OFF) Load switches (remaining ON)
OTHERS
Check ignitiontiming.
~
~
~~~tg
CHECK
~sm~
1 N.G.
SE F301 G Check intake system for air ~ O.K. N.G' leaks. Check throttle wire for rough sliding. Repair/replace the part.
() III~
SEF293G Make sure air regulator stays closed after warm-up. ~N.G. Check air regulator and/or its circuit. [See page EF & EC-130.J CHECK
Check throttle chember ports and valve for clogging. ~ N.G. Clean the ports and/or throttle valve.
s~
REMOVE
MEASURE Fuel pressure Connect vacuum hose to pressure regulator and measure fuel pressure. Check mixture ratio feedback system. [See page EF & EC-26.] PERFORM Self-diagnosis Mode IV Perform self-diagnosis Mode IV (for idle switch).
. SEF291G
Remove vacuum hose from pressure regulator, and try to start. CHECK
~
F
.
Pressu re regulator
N.G. --+
~.
C)
I)
CRANK
N.G.
START
((
SEF981
N.G.
Engine tempera- switch ture sensor SEF292G Start with engine temperature sensor connector disconnected.
i5 ;U~ ~
Ignition
(l]
circuit.
EF & EC-48
POSSIBLE CAUSES
SPECIFICATIONS Mixture ratio Ignition timing INTAKE SYSTEM Air regulator (not open enough) Idle speed control valve (remaining OFF) CONTROL SYSTEM Engine temperature sensor
f) 8
0
0 0
0 0 0 0 0
E.G.R. SYSTEM
~...
SERVICE PROCEDURE
.-CHECK N.G. --+Adjust ignition timing. [See page EF & EC-26.J
f)
Check ignition
~
~~~:ng
~
~ ""':G
timing.
iit
g
/
SEF293G
APPLY
~
-
Improved
VACUUM
--
CHECK
Does not turn ON +Check its circuit. [See page EF & EC-134.J
PRESSURE
SEFOO7H
Apply vacuum pressure to pressure regulator after disconnecting vacuum hose, and check idling.
CHECK
(j"E.G.R. I! control valve , SEF547A...J Check E.G.R. control valve for operation.
~ ~
a ~
Stays
/A
~rw
RUN
ST ~*ART
]
N.G
r
Check senso [S
$
'
"
~Ui6~
u
,l:c;\ :::
S'J
~"~ SEF303G
Engine tem pera- S Ignition t ure sensor witch SEF292G Start and run engine with engine temperature sensor connector disconnected.
CircUit
:.Ji!J "
p'"
EF & EC-90.]
1
Check the solenoid circuit. [See page EF & EC-100.J
EF & EC-49
POSSIBLE CAUSES
8
0
8
0
0
0
0
0
0
0
8
0
G) 4D f)
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Ignition wires INTAKE SYSTEM CONTROL SYSTEM E.G.R. SYSTEM Blow-by hose (leaks) Air duct (leaks) Idle switch Load switches
E.G. R. control valve
E.G.R. solenoid
SERVICE PROCEDURE
CHECK
.
Engine
CHECK Leak
11/"-'
CHECK
~ ~
CHECK
Timing light
BIOW_bY hose
r~
~
'.
~";f:t
SEF298G Check purge line for leaks.
~
U
~.=. SEF303G
1 N.G.
Repair/replace the part. N.G. --+
1 N.G.
Repair/replace the hose.
0.,
0
I
CHECK
O.K.
.0
+ N.G. Check the solenoid circuit. [See page EF & EC-124.J CHECK
~ru
SEF283G Check flashes of timing light for weakness. SEF315G
~~
o~
SEF282G Remove spark plugs and check their ignition sparks.
~"""~G
Check ignition timing. ~ N.G. Adjust ignition timing. [See page EF & EC-26.J PERFORM
MEASURE
COMPRESSION PRESSURE
N.G.
E.G.R' control valve , SEF547A/ Check E.G.R. control valve for operation.
n
~ ~
CHECK
6~
~
Stays
I~'"
(~
f)
Self-diagnosis Mode IV
1
Check cylinder head and gasket. [See EM section.]
~ N.G.
Check the solenoid circu it. [See page EF & EC-100.J
1 N.G.
Check the idle switch circuit. [See page EF & EC-116.J
EF & EC-50
TROUBLE DIAGNOSES
Diagnostic Table (Cont'd)
SYMPTOM & CONDITION
POSSIBLECAUSES
SPECIFICATIONS Mixture ratio Fuel pressure FUEL SYSTEM Fuel filter (clogged) Fuel line (clogged) Injectors (clogged) IGNITION SYSTEM Power transistor Ignition coil Ignition wires (ignition leaks) Spark plugs (ignition leaks, improper gap) INTAKE SYSTEM CONTROL SYSTEM Air'duct (leaks) Crank angle sensor Air flow meter Engine temperature Exhaust gas sensor Idle switch (remaining OFF) OTHERS Fuel (poor quality) sensor
. f) 8 0
0 0 0 0 0 0 0
(;)
.
0 0
0
0
0 0 0 0 0
0 0 0
0 0
0 0 0
SERVICE PROCEDURE
"
0,
CHECK
Timing light
--
N.G.
CHECK
SEF315G
\{I i
"
GJ -'}
of
--
N.G.
Repair/replacehe part. t
PERFORM
N.G.
Self-diagnosis
SEF301G
() III~
ModeIV
for
MEASURE
.--
Improved
. I0
SEF291G Remove vacuum hose from pressure regulator, and try to drive. PERFORM
!)
~.
~V
Connect vacuum hose to pressure regulator and measure fuel pressure while driving.
DISCONNECT
Self-diagnosis
N.G.
II!
1:8
-.."
Improved
U%'~
SEF285G Perform self-diagnosis Mode V (for air flow meter).
SEF307G
EF & EC-51
15 Poor driveability
POSSIBLE CAUSES SPECI FICA TIONS Mixture ratio (too lean) Fuel pressure (low) Ignition timing IGNITION SYSTEM (missing) Air duct (leaks) Throttle chamber (air leaks) Intake manifold (gasket) (air leaks) CONTROL SYSTEM Crank angle sensor Air flow meter Exhaust gas sensor Idle switch E.G.R. SYSTEM E.G. R. control valve (stuck open) E.G.R. solenoid (remaining OFF) E.G.R. vacuum hose (removed) INTAKE SYSTEM
0 f)
0
. e
0 0 8 fi) "
0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0
SERVICE PROCEDURE
~CHECK leak
Engine
() 11/
Check
.~ ~ p!
CHECK
'
Stays lifted (
. e
E.G.R.
valve
iki
U
(t@s"'~a
ignition timing.
II
~-~SEF303G
Check terminal Voltage of E.G.R. solenoid. ~N.G. Check the solenoid circuit. [See page EF & EC-100.J PERFORM Self<liagnosis Mode IV
N.G.
1 N.G.
Adjust ignition timing. [See page EF & EC-26.1 MEASURE Fuel pressure gauge
REMOVE
SEF291G Remove vacuum hose from pressure regulator, and try to drive.
~.
PERFORM
Pressure regulator
Improved
. 0
Connect vacuum hose to pressure regulator and measure fuel pressure while driving,
t
~
fj
'",,,.,a
SEF285G
Perform self<liagnosis Mode IV (for idle switch). ~N.G. Check the idle switch circuit. [See page EF & EC-116.J Improved . Replace the sensor. No change . Check mixture ratio feedback system. [See page EF & EC-26.J
0'
'0
N.G.
DISCONNEC!.-"
SEF285G Perform self-diagnosis Mode V (for crank angle sensor, air flow meter, ignition signal.!
Self-diagnosis . Check the malfunctioning parts and/or circuits. [See page EF & EC-86 (crank angle sensor), page EF & EC-88 (air flow meter), page EF & EC-94 (ignition signa!).!
Exhaust ga sensor
C1O'.:
, Disconnect connector,
10 ,"
/'~
EF & EC-52
Table (Cont'd)
. . . 0 . .. . .. 0 . .
I
SERVICE PROCEDURE
CHECK
.
,
CHECK
Check ignition timing with a timing light. ~ N.G. Adjust ignition timing. (See page EF & EC-26.J --+ Check cylinder head and gasket. [See EM section.]
~
~~~tg ~
Throttle
CHECK
chamber
~ ."':0-
~~
MEASURE
N.G.
CHECK
.
O.K.
I
~N.G. MEASURE
lgnitionWire
COMPRESSION PRESSUR-E
.-SEF315G
SEF282G Remove spark plugs and check their ignition sparks. MEASURE PERFORM CD Fuel pressure gauge Improved
@
.,
G:I
@
-.
~
~.
Self-diagnosis
c5:
71~
SEF286G Connect vacuum hose to pressure regulator and measure fuel pressure while driving. 1 Check mixture ratio feedback system. [See page EF & EC-26.]
SEF285G Perform self-diagnosis Mode V (for air flow meter).
Exhaustges sensor
~4"l
lv.iU
~
) '.'
SEF291G
~
l'
IIP=
SEF307G
~ N.G. Check the malfunctioning parts and/or circuit. [See page EF & EC-88.J
Nochange
ed mprov
EF & EC-53
detonation
POSSIBLECAUSES
SPECIFICATIONS Mixture ratio (too lean) Fuel pressure (low) Ignition timing (too advanced) FUEL SYSTEM Fuel filter (clogged) Fuel line (clogged) Injectors (clogged) CONTROL SYSTEM Crank angle sensor (improper 1-signals) Air flow meter Engine temperature sensor OTHERS Water temperature (too high) Fuel (low octane rating, poor quality)
.
0
6) e
0 0 0
0 0 0 0 0 0 0
SERVICE PROCEDURE
CHECK
Water temperature
,
~r;~~
CHECK
N.G. ~
8~ ~"'.~~
Check ignition timing.
.
.
REMOVE
Pressu re regu lator
Improved
~.
PERFORM
.I 0
SEF291G Connect vacuum hose to pressure regulator, and measure fuel pressure while driving.
N.G.
_SEF285G
Self-diagnosis
. Check the malfunctioning parts. [See page EF & EC-86 (crank angle sensor). page EF & EC-88 (air flow meter).]
Perform self-diagnosis Mode V (for crank angle sensor and air flow meter).
EF &. EC-54
during
start-up
POSSIBLECAUSES
SPECIFICATIONS Mixture ratio (too rich/too lean) Ignition sparks (weak) Ignition timing Compression pressure (too low) FUEL SYSTEM IGNITION SYSTEM Canister (too much evaporation to intake) Ignition wires (ignition leaks) Spark plugs (wet with fuel, improper gap) INTAKE SYSTEM Throttle valve (not open enough)
0 f) 8 e 41) 0
0 0 0 0
.
0
(i) 0
0 0
0 0 0 0 0 0
SERVICE PROCEDURE
CHECK CHECK
~
,
-TRY
Timing i9ht
--+
N.G.
Adjust ignition timing.
~ sm.:G
N.G. --+
'
~ttl: SEF290G
~
the wires.
N.G. --+Repair/replace
the part.
valve
C) ,, Timinglight
Ignition wire
--+Replace
N.G.
0
CHECK
MEASURE
SEF315G
~rn -~
O.K. --+ ,.
-
COMPRESSION . PRESSURE
Spark plug SEF282G Remove spark plugs and check their ignition sparks.
SEF309G
Measure resistance of ignition wires. Improved --+ Replace the canister and/or the hoses.
No change
Measure compression
Canister purge 'SEF314G Shut evaporated fuel to intake valve and try to drive.
L1X
0
-
APPLY Improved
VACUUM PRESSURE Pressu re regulator
1
No change f . Check mixture ratio .feedback system. [See page EF & EC-26.] Replace the sensor.. Improved
.,
DISCONNECT
SEF291G Apply vacuum pressure to pressure regulator after disconnecting vacuum hose, and try to drive.
\11
ij
sensor
CJQu E'h,""'i~'f"=
~
SEF307G
EF & EC-55
Table (Cont'd)
while idling
0 0
POSSIBLECAUSES
SPECIFICATIONS Mixture ratio (too rich/too lean) Fuel pressure (low) Ignition sparKs(weak, missing) Idle speed (low) FUEL SYSTEM IGNITION SYSTEM INTAKE SYSTEM CONTROL SYSTEM Fuel line (clogged) SparKplugs (wet with fuel, improper gap) Idle speed control valve (improper operation) F.I.C.D. solenoid (improper operation) Idle switch (remaining OFF) Neutral switch (remaining OFF)
. f). e 8 . . .. .
I
0 0
0 0 0 0 0 0 0 0 0 0 0 0 0
Loadswitches(remaining OFF)
SERVICE PROCEDURE
'.
REMOVE
~.
.
Tachometer
Pressure regulator
Improved
'f)
SEF291G
'."286G Connect vacuum hose to pressure regulator and measure fuel pressure. .
t
~
MEASURE
CHECK
, , Timinglight
N.G.
o-~
1\ '"
I I
.
,
.1
CHECK
.
and/or
-6
SEF283G Check flashes of timing light for weakness.
SEF316G
Measure idle speed. !N..G. Adjust idle speed. [See page EF & EC-26.J
!.EF8G
Check spark plugs for being foul or wet with fuel.
CHECK
C)
CHECK 4;)
N.G.
Checkthe idleswitchcircuit.
[See page EF & EC-116.J
SEFOO7H
Check terminal voltages of A.A.C. valve. ~ N.G. Check the part and/or circuit. [See page EF & EC-134.J
SEF981 F Check terminal voltage of F.I.C.D. solenoid. ~ N.G. Check the part and/or circuit. [See HA section.]
SEF285G
EF & EC-56
Table (Cont'd)
I
20 Engine stall
I
while accelerating
POSSIBLE CAUSES
SPECIFICATIONS Mixture ratio Ignition sparks (weak, missing) Compression pressure (low) CONTROL SYSTEM Crank angle sensor Air flow meter Exhaust gas sensor
0 f} 8 0
0 0 0 0 0
0 0
0 0
0 0 0 0
SERVICE PROCEDURE
,
0 , Timing
CHECK
light
N.G.
f)
'.
. Replacethe wires.
CHECK
~Hjl
SEF283G Check flashes of timing light for weakness during acceleration.
SEF31~
O.K.
Measure resistance of suspect wires. SEF282G N.G. Check cylinder head and gasket. [See EM section.! Remove spark plugs and check their ignition sparks.
MEASURE
COMPRESSION PRESSURE
'0
N.G.
DISCONNECT
Cf
PERFORM
IV '"
N.G.
sensor
5 times or
'
~
7I~
Self-diagnosis
C10u~r,fF Exhoon
~
[See page EF & EC~6 (crank angle sensor). page EF & EC-88 (air flow meter).]
SEF307G
SEF285G
Perform self-diagnosis Mode V (for cra n k ang Ie senso r and air flow meter!.
EF & EC-57
.
0
0
0
..
0 0 0
Mixture ratio Ignition sparks (weak, missing) Crank angle sensor Air flow meter 0 0
SERVICE PROCEDURE
'0 CHECK. Timing light N.G.
.!
..
SEF315G
MEASURE
Ignitio n wire
CHECK
N.G. . Replace the wires. O.K.
~rn
SEF283G Check flashes of timing light for weakness at constant engine revolution. (1,000 - 2,000 rpm).
.
SEF282G Remove spark plugs and check their ignition sparks.
-~
of
.-CHECK , Self-diagnosisMode II
N.G.
" .
{'')~ l-.,~-
DISCONNECT
~
,:
"~ 11\
ED
No change . Check mixture ratio feedback system. [See page EF & EC-26.]
SEF307G
Self-diagnosis Move V
N.G.
.Check the circuits. [See page EF & EC-86 (crank angle sensor), page EF & EC-88 (air flow meter).]
SEF285G Perform self-diagnosis Mode V (for air flow meter and crank angle sensor).
EF 8r. EC-58
Table (Cont'd) 0 f)
POSSIBLE CAUSES
SPECIFICATIONS
0 0
0 0
SERVICE PROCEDURE
."
CHECK
N.G.
'Q
N.G. ~
Check the malfunctioning parts and/or circuits. [See page EF & EC-94 (ignition siglal), page EF & EC-86 (crank angle sensor).]
SEF285G Perform self-diagnosis Mode V (for ignition signal and crank angle sensor).
MEASURE N.G. ~
Tachometer
0
Adjust idle speed. [See page EF & EC-26.J
CHECK
SEFOO7H voltage of
CHECK
Self-diagnosisMode
I~
N.G.
~
8
DISCONNECT
""""''' Improved
18
gas
Exhaust sensor
5 times or
(~)
C~,.:
~
\I~ 11\
No change
--+
Checkmixtureratio
feedback system. [See page EF & EC-26.J
EF & EC-59
.. f) 8 o
CONTROL SYSTEM
SERVICE PROCEDURE
MEASURE
Tachometer
2
I ...
.
,
CHECK
0-&.. ~
Measure
,,'
-6
~
~~~tg
~
---+Adjust
N.G.
ignition timing.
~ ""~G
CHECK Check the part and/or circuit. [See HA section.]
CHECK N.G. ~ Check the part and/or circuit. [See page EF & EC-134.]
PERFORM Self-diagnosis
N.G.
Mode IV
~)
SEF285G Perform self-diagnosis Mode IV (for idle switch).
EF &. EC-60
Table (Cont'd)
I
Backfire
POSSIBLE CAUSES
Mixture ratio (too lean) Ignition timing (too retarded) FUEL SYSTEM INTAKE SYSTEM Injectors (clogged) Air duct (air leaks) Intake manifold (gaskets) (air leaks) CONTROL SYSTEM Air flow meter Exhaust gas sensor
0 f) 8 8
0
.
0
0
0
0 0 0 0 0 0
SERVICE PROCEDURE
CHECK
0
Engine
f)
T iming
light
s:1i~ duct~
Check intake system for air leaks. .
(')
r&~
Improved + Check mixture ratio feedback system. [See page EF & EC-26.] '0 or
REMOVE
~.
1
SEF291G
sm~G
CLEAN
SEF317G
Remove vacuum hose from pressure regulator, and try to drive. No change
.--
Self<liagnosis Mode II
PERFORM------N.G.
DISCONNECT
\II
IV
"
CHECK Improved . Replace the sensor. No change . Check mixture ratio feedback system. [See page EF & EC-26.]
sensor
5 times or .["ore/10 sec. SEF373G Check mixture ratio by flashes of inspection lamps.
~
:w~
Self<liagnosis
C~,.; E'h'".";~'~
SEF307G
SEF285G
Perform self-d iagnos is 'Mode V (for air flow meter). 1 N.G. Check the circuits. [See page EF & EC-88 (air flow meted.]
EF &. EC-61
Table (Cont'd)
I
Backfire
POSSIBLE CAUSES
Mixture ratio (too rich) Injectors (fuel leaks) (missing) Air cleaner element (clogged) A.I.V. (always operating) A.I.V. solenoid (remaining ON) CONTROL SYSTEM Idle switch (remaining OFF)
. 8 .. 0 0 ..
0 0 0 0 0 0 0 0 0
INTAKE SYSTEM
SERVICE PROCEDURE
APPLY
PRESSURE
Improved
-+ Check mixture ratio feedback system. [See page EF & EC-26.1
~.P'~M'
~
SEF320G Check air cleaner element for clogging.
regulator
SEF291G Apply pressure to pressure regulator after disconnecting vacuum hose, and try to drive.
PERFORM
Self-diagnosis
N.G.
Mode IV
SEF285G
. Check idle switch and/or its circuit. [See page EF & EC-116.J
PERFORM Self-diagnosis Mode V N.G. -+ Check the malfunctioning part and/or circuit. [See page EF & EC-94 (ignition signal).J
SEF285G Perform self-d iagnosis Mode V (for ignition signal!. Keeps flowing
CHECK SEF375G
0 .'(0:
"
Left ON . Check the solenoid circuit.
[See page EF & EC-138.1
~
u
t~ "~mG
EF
&
EC-62
Description
SEF297H
The self-diagnosis is useful to diagnose malfunctions. in major sensors and actuators of the E.C.C.S. system. There are 5 modes in the self-diagnosis system. 1. Mode I (Exhaust gas sensor monitor) During closed-loop operation: The green inspection lamp turns ON when a lean condition is detected and goes OFF under rich condition. During open-loop operation condition: The green inspection lamp remains OFF or ON. 2. Mode n (Mixture ratio feedback control monitor) The green inspection lamp function is t!1e same as Mode 1. During closed-loop operation: The red inspection lamp turns ON and OFF simultaneously with the green inspection lamp when the mixture ratio is controlled within the specified value. During open-loop operation: The red inspection lamp remains ON or OFF. 3. Mode In (Self-diagnostic system) This mode is the same as the former self-diagnosis in self-diagnosis mode. 4. Mode N (Switches ON/OFF diagnostic system) During this mode, the inspection lamps monitor the switch ON-OFF condition.
. . .
Idle switch
Starter switch Vehicle speed sensor The moment the malfunction is detected, the display will be presented immediately. That is, the condition at which the malfunction occurs can be found by observing the inspection lamps during driving test.
..
EF &. EC-63
Q .~ Gr' r:~i
~/~)jFlashint gN
'
1. Turn ignition switch "ON". 2. Turn diagnostic mode selector to E.C.U. (fully clockwise) and wait for inspection lamps to flash. 3. Count the number of flashes, and after the inspection lamps have flashed the number of the required mode, immediately turn diagnostic mode selector fully counterclockwise.
'--~Cij\ '
Imes
Mode N
SE F288H
SEF989D
When the ignition switch Is turned off during diagnosis In any mode and then turned on again (after power to the E.C.U. has dropped completely), the diagnosis will automatically return to Mode L The stored memory will be lost if: 1. Battery terminal is disconnected. 2. After selecting Mode ill, Mode IV is selected. However, if the diagnostic mode selector is kept turned fully clockwise, it will continue to change in the order of Mode I ~ IT ~ ill ~ IV ~ V ~ I ... etc., and in this state the stored memory will not be erased. This unit serves as an idle rpm feedback control. When the diagnostic mode selector is turned within the "diagnostic mode OFF" range, a target engine speed can be selected. Mark the original position of the selector before conducting self-diagnosis. Upon completion of self-diagnosis, return the selector to the previous position. Otherwise, engine speed may change before and after conducting self-diagnosis.
EF & EC-64
Description (Cont'd)
~~E~
CHECK ENGINE LIGHT
'SEF924F
CHECK ENGINE LIGHT (For California only) This vehicle has a check engine light on the instrument panel. This light comes ON under the following conditions: 1) When ignition switch is turned "ON" (for bulb check). 2) When systems related to emission performance malfunction in Mode I (with engine running). This check engine light always illuminates and Is synchronous with red L.E.D. Malfunction systems related to emission performance can be detected by self-diagnosis, and they are clarified as self-diagnostic codes in Mode IlL 3) Check engine light will come "ON" only when malfunction is sensed. The check engine light will turn off when normal operation is resumed. Mode ill memory must be cleared as the contents remain stored.
. .
Code No. 12 13 14 31 32 33 35 43 45
Malfunction
Air flow meter circuit Enginetemperature sensor circuit Vehicle speed sensor circuit E.C.U. (E.C.C.S.control unit) E.G.R. function
Exhaust gas sensor circuit Exhaust gas temperature Throttle sensor circuit Injector leak sensor circuit
Use the following diagnostic flowchart to check and repair a malfunctioning system.
DIAGNOSIS START
)
N.G.
Replace bulb.
r
Turn ignition switch "ON" and make sure that check engine light comes "ON".
O.K.
Perform self-diagnosis and check which code is displayed in Mode III.
Check electronic control system of affected code No. to locate faulty part.
EF & EC-65
Description (Cont'd)
. Methods of erasing memories differ with systems. Read the manual before diagnosing systems: . After repairs, test drive to check that check engine light does not come on. . Test driving modes differ with systems. Read the manual before test driving.
Perform driving test. Make sure that check engine light does not come "ON" during this test.
DIAGNOSIS
END
EF & EC-66
This mode checks the exhaust gas sensor for proper functioning. The operation of the E.C.U. L.E.D. in this mode differs with mixture ratio control conditions as follows:
Engine stopped (Ignition switch "ON") ON Engine running Open loop condition *Remains ON or OFF Except for California model
8
Mode
L.E.D.
Closed loop condition Blinks For California model 8 ON: when the CHECK ENGINE LIGHT ITEMS are stored in the E.C.U. 8 OFF: except for the above condition
Red
ON
OFF
CHECK
If the number of L.E.D. blinks is less than that specified, replace the exhaust gas sensor. If the L.E.D. does not blink, check exhaust gas sensor circuit. EXHAUST GAS SENSOR CIRCUIT CHECK See page EF & EC-104.
Mode
L.E.D.
Green
Remains ON
If the red L.E.D. remains on or off operation, the mixture ratio may not Using the following procedures, check or adjust the mixture ratio. COMPONENT CHECK OR MIXTURE ADJUSTMENT See page EF & EC-26.
EF & EC-67
TROUBLE DIAGNOSES
Self-diagnosis system)
The EC.U. constantly monitors the function of these sensors and actuators, regardless of ignition key position. If a malfunction occurs, the information is stored in the E.C.U. and can be retrieved from the memory by turning on the diagnostic mode selector, located on the side of the EC.U. When activated, the malfunction is indicated by flashing a red and a green L.E.D. (Light Emitting Diode), also located on the E.C.U. Since all the self-diagnostic results are stored in the E.C.U.'s memory even intermittent malfunctions can be diagnosed. A malfunction is indicated by the number of both red and green flashing L.ED.s. First, the red L.ED. flashes and the green flashes follow. The red L.E.D. corresponds to units of ten and the green L.ED. corresponds to units of one. For example, when the red L.ED. flashes once and the green L.ED. flashes twice, this signifies the number "12", showing that the air flow meter signal is malfunctioning. All problems are classified by code numbers in this way. When the engine fails to start, crank it two or more seconds before beginning self-diagnosis. Before starting self-diagnosis, do not erase the stored memory before beginning self-diagnosis. If it is erased, the self-diagnosis function for intermittent malfunctions will be lost.
. .
Detected items Crank angle sensor circuit Air flow meter circuit Enginetemperature sensor circuit Vehicle speed sensor circuit Ignition signal missing in primary coil E.C.U. IE.C.C.S.control unit) E.G.R. function Exhaust gas sensor circuit Exhaust gas temperature sensor circuit
Throttle sensor circuit Injector leak
California X X X X X X X X X
X X
NonCalifornia X X X X X X
55
X: Available -:
EF 8r. EC-68
RETENTION OF DIAGNOSTIC RESULTS starter is operated fifty times after a diagnostic item has been judged to be malfunctioning. The diagnostic result will then be cancelled automatically. If a diagnostic item which has been judged to be malfunctioning and stored in memory is again judged to be malfunctioning before the starter is operated fifty times, the second result will replace the previous one. It will be stored in E.C.U. memory until the starter is operated fifty times more.
RETENTION
I
TERM
CHART
I Code No.
100
150
200
50 times
11
-------------------------
t?//////// J'd
If the same diagnostic item is judged to be malfunctioning before the starter is operated fifty times, it will be stored in E.C.U. memory until the starter is operated fifty times from this point in time.
: Retention term
SEF793D
EF &. EC-69
SELF-DIAGNOSTIC PROCEDURE
.~
Start engine and warm it up to normal engine operating temperature. (Drive vehicle for about 10 min.)
Flashing 3 times
After the inspection lamps have flashed 3 times, turn diagnostic mode selector fully counterclockwise.
~ ..~
~r\
&i~~) \~t ~~
. Flashin g 4 t Imes
Make sure that inspection lamps are displaying Code No. 55. O.K.
Mode III
-- -- -- -- ----
,
After the inspection lamps have flashed 4 times, turn diagnostic mode selector on E.C.U. fully countercl.ockwise.
I I I I
I
I I I
---------
- -- ---
)
SEF288H
(
CAUTION:
DIAGNOSIS
END
Check malfunctioning parts and/or perform real time diagnosis system inspection. If malfunction part is found, repair or replace it.
During display of a code number In self-diagnosis mode (Mode m), If another diagnostic mode is to be performed, be sure to note the malfunction code number before turning diagnostic mode selector on E.C.U. fully clockwise. When selecting an alternative, select the diagnosis mode after turning switch "OFF". Other. wise, self-diagnosis Information in the E.C.U. memory will be lost. Return the DIAGNOSTICMODE selector to the previous position.
EF & EC-70
.
Code No. 11
.Q
Red
(0.
(I
-\
-V
often enough while the engine speed is higher than the specified rpm.
Green
.
Code No. 12
The air flow meter circuit is open or shorted. (An abnormally high or lowvoltage is entered.)
.Q
. """. Red
--..
'",,,'
Air flow meter circuit
-\
-V
SYSTEM INSPECTION See page EF & EC.g8.
SEF043F
(I
..
Green
ENGINE TEMPERATURE
~
"!!'"
Engine temperature sensor circuit
-D
Red
--..
(I
...
,Green
) V
SYSTEM INSPECTION See page EF & EC-90.
SEF044F
. Signalcircuit is open.
CodeNo. 14
. ....
Red Green
-'\
vi
SYSTEM INSPECTION See page EF & EC-92.
SEF074G
EF & EC-71
CONTROL UNIT SHOWS A MALFUNCTION SIGNAL WHEN THE FOLLOWING CONDITIONS ARE DETECTED.
.
Code No. 21
mm .".
The ignition signalin primary circuit does not enter to E.C.U.during engine cranking or running.
Red
.. .
..
CO$
,iiim ,.....
-\
.-VI
SYSTEM INSPECTION See page EF & EC-94.
SEF045F
Green
.
-
CodeNo.31
... .
Red
".,. '.
.,=, {tQ)
.;,.
, .,.". CQ'j)
Green
E.C.U.calculation function
)
SYSTEM INSPECTION See page EF & EC-98. SE F076G
E.G.R. function
Code No. 32
. ... ..
{f0
'iiii"
.
E.G.R. function
E.G.R. valve does not operate. (E.G.R. valve spring does not lift.)
0-
, 'mii'
Red
Green
~ -I
SYSTEM INSPECTION See page EF & EC-100. SEF077G
.
Exhaust gas sensor circuit
CodeNo.33
... ...
Red Green
''''O {iQ)
'ii'"
, "",.
)
SYSTEM INSPECTION See page EF & EC-104.
SEF078G
EF &. EC-72
TROUBLE DIAGNOSES
Self-diagnosis
DISPLAY CODE MALFUNCTIONING PARTS
system) (Cont'd)
CIRCUIT OR
~
CodeNo.35
"H'" Red
Signalcircuit is open.
... .....
...
.0
Code No. 43
b .0 ... ....
Red
.
Throttle sensor circuit
short.
Green
11
I
SYSTEM INSPECTION See page EF & EC-110.
SEF079G
~ . ..... ....
D
~
[ )-
""'" ,..,..
Injector
leak
Red
Green
Code No. 55
~ {fQ
Red
'$
,..
...9.
SEF984F
Green
EF &. EC-73
diagnostic system)
In switches ON/OFF diagnosis system, ON/OFF operation of the following switches can be detected continuously.
The switches ON/OFF status in mode IV is stored in E.C.U. memory. When either switch is turned from "ON" to "OFF" or "OFF" to "ON", the red L.E.D. on E.C.U. alternately comes on and goes off each time switching is performed. (2) Vehicle Speed Sensor The switches ON/OFF status in mode IV is selected is stored in E.C.U. memory. The green L.E.D. on E.C.U. remains off when vehicle speed is 20 km/h (12 MPH or below), and comes ON at higher speeds.
"
EF & EC-74
DIAGNOSIS
START
~
Pull out E.C.U. from under the assist kick panel.
~ ~C" ~
~S""'H
After the inspection lamps have flashed 4 times, turn diagnostic mode selector fully counterclockwise.
Flashing 4 times
~0 ) <q '-~
Mode IV
SE F288H
. >~
r:~
Make sure that a red inspection lamp goes "ON" when depressing accelerator pedal.
-.----O.K.
Accelerator pedal
Make sure that a red inspection lamp goes "ON" during turning ignition switch "ST ART"*. O.K. Lift the rear of the vehicle.
~SE'29.H
S;~~T
i~
Drive vehicle. Make sure that a green inspection lamp goes "ON" when vehicle speed is 20 km/h (12 MPH) or faster. O.K. Turn ignition switch "OFF".
N.G.
(
CAUTION:
DIAGNOSIS
END
For safety, do not drive rear wheels at higher speed than required.
EF & EC-75
TROUBLE DIAGNOSES
Self-diagnosis
system)
In real-time diagnosis, if the following items are judged to be working incorrectly,a malfunction willbe indicated immediately. . Crank angle sensor (180 signal & 1 signal) output signal
Mode V
(Real-time diagnostic
Ignition signal Air flow meter output signal very effectively determines the malfunction, real-time during whether test. senitems in
.
the
Consequently, above
driving is very
self-diagnosis, detect
diagnosis
malfunctions
instantly.
However, not
as
malfunctions
in this diagnosis
are
stored
E.C.U. memory.
SELF-DIAGNOSTIC PROCEDURE
DIAGNOSIS START
I
Pull out E.C.U. from under
the assist seat.
Start engine.
Turn
diagnostic
mode
selector
on
E.C.U.
fullyclockwise.
After the inspection lamps have flashed times, turn diagnostic mode counterclockwise.
selectorfully
~r\ ~V ~(~~
(
)
Mode V
SEF288H
'-~C0
Make
lamps
are not
N.G.
idling or racing.
O.K.
Turn ignition switch "OFF". Turn ignition switch "OFF".
SE F292 H
See
decoding
chart.
(
CAUTION:
In real-time diagnosis, pay attention to
DIAGNOSIS END
Perform
system
If malfunction
inspectio.n
lamp
flashing.
E.C.U.
displays
the
malfunction
code
only
once
the inspection.
EF &. EC-76
- Mode III.)
The 10 or 1800 signal is momentarily missing, or, multiple, momentary noise signals enter.
RED L.E.D.
3.2
3.2
'9' ON-[
0 OFF
.
GREEN LED
..
3.2
3.2
:0: ','
ON
0 OFF
LI1.6lnl1.61
0.4 0.6
1.6
-V
REAL-TIME DIAGNOSTIC INSPECTION See page EF & EC-88.
SEF048F
IGNITION SIGNAL
Unit: sec
~~ r
Malfunction of ignition signal 1.8 0.2
REAL-TIME DIAGNOSTIC INSPECTION See page EF & EC-94. SEF049F
EF & EC-77
TROUBLE DIAGNOSES
Self-diagnosissystem) (Cont'd)
I
Mode V (Real:-timediagnostic
INSPECTION X : Avallab Ie -: Not available
.
REAL-TIME DIAGNOSTIC
Check parts
Check conditions
Middle connectors
Tap harness connector or component during realtime diagnosis. Check harness continuity
Go to check item 2.
at connector. Disconnect harness connector, and then check dust adhesion to harness connector. Check pin terminal bend. Reconnect harness connector and then recheck harness continuity at connector. Tap harness connector or component during realtime diagnosis.
stopped Engine stopped Engine stopped Engine stopped During real-time diagnosis
Go to check item 3.
Replace terminal.
CJ L J
EF & EC-78
-E.C.U.
harness connector
SEF130H
TROUBLE DIAGNOSES
Self-diagnosissystem) (Cont'd)
I
I
Check parts Check items Check conditions Middle connectors Sensor & actuator E.C.U. harness connector
Check sequence
Tap harness connector or. component during realtime diagnosis. Check harness continuity at connector. Disconnect harness connector, and then check dust adhesion to harness connector. Check pin terminal bend. Reconnect harness connector and then recheck harness continuity at connector. Tap harness connector or component during realtime diagnosis.
Go to check item 2.
Go to check item 3.
Engine stopped
Engine stopped
Engi ne stopped
Replace terminal.
=-l
E.C.U. harness connector
.. I"~
,<1/A
SEF131H
EF & EC-79
TROUBLE DIAGNOSES
Self-diagnosissystem) (Cont'd)
I
Ignition Signal
Check sequence
Check parts Check items Check conditions Middle connectors Sensor & actuator E.C.U. harness connector X If malfunction, perform the following items.
Tap harness connector or component during realtime diagnosis. Check harness continuity at connector. Disconnect harness connector, and then check dust adhesion to harness connector. Check pin terminal bend. Reconnect harness connector and then recheck harness continuity at connector. Tap harness connector or component during realtime diagnosis.
During real-time diagnosis Engine stopped Engine stopped Engine stopped Engine stopped During real-time diagnosis
Go to check item 2.
Go to check item 3.
Replace terminal.
EF & EC-80
TROUBLE DIAGNOSES
NOTE
EF &. EC-81
TROUBLE DIAGNOSES
Diagnostic Procedure
CAUTION:
1. Before connecting or disconnecting the E.C.U. harness connector to or from any E.C.U., be sure to turn the ignition switch to the "OFF" position and disconnect the negative battery terminal in order not to damage E.C.U. as battery voltage is applied to E.C.U. even if ignition switch is turned off. Failure to do so may damage the E.C.U.
SEF289H
2. When performing E.C.U. input/output signal inspection, remove connector protector to insert tester probe into connector.
SEF290H
3. When connecting or disconnecting pin connectors into or from E.C.U., take care not to damage pin terminals. 4. Make sure that there are not any bends or breaks on E.C.U. pin terminal, when connecting pin connectors.
SEF291H
5. Before replacing E.C.U., perform E.C.U. input/output signal inspection and make sure whether the E.C.U. unit functions properly or not. (See page EF & EC-142.)
SEF330D
6. After performing this "Diagnostic Procedure", E.C.C.S. self-diagnosis and driving test.
perform
SEF292H
EF & EC-82
TROUBLE
DIAGNOSES
Diagnostic Procedure (Cont'd) 7. When measuring E.C.U. controlled components supply voltage with a circuit tester, separate one tester probe from the other. If the two tester probes accidentally make contact with
each other during measurement, the circuit will be shorted,
'
Solenoid valve
SEF599D
EF 8r. EC-83
head-up display
I GNI T! ON SWITCH ON or START
COMBINATION METER
~,
E. C. C S
CONTR'OL'
[rmef-H-iJ [gOO:!]
I
UNIT
@ ;;
107-B.'--108-B
116-B
In EL section.)
Iii
~
tWh I te)
~ottt-O
CID
1""'00arness)
..
@)eo@
'Fi'r;;n'\
4-R/B 6-B 13-B
(E. F. J.
jI
harness)
-~
~
~
~~
12
I (~~strument
rness)
harness)
"II"
24-R
~I"I~
room
EE
UTI
@@
B/W~ ~~~~ine
@)lMJ
@)
~~
'1:
"481391
48-B
'1! 1391481
~~ @)
E.
~
C. C.
OFFACCON ST J J 1 J J 2 J 3 4 11m 5
I GNI T! ON
~
~
..
Iffl
~
~:~
~@)
(J RELAY BOX) n
S.
RELAY
ENGINE GROUND
SWITCH
BATTERY
SEF261H
Component location
I \ link /"BR;' fusible ~"G" fusible link ~.
EF
&
EC-84
TROUBLE DIAGNOSES
"-
='
INSPECTION START
<tITD
SEF153D
CHECK DIAGNOSTIC MODE ON THE E.C.U. Verify that diagnostic mode selector on the E.C.U. is turned "OFF".
O.K.
Ii)
N.G. rcheck voltage between E.C.U.
terminals @, @ and ground. Battery voltage should exist.
Ii) -
CHECKPOWER SOURCE
II
Cl'UNIT
is
Ef CONNECTOR
3647
II
00
00
FOR E.C.U. 1) Turn ignition switch "ON". 2) Verify that red and green inspection lamps on the E.C.U. illuminate.
@N.G.
@N.G.
O.K.
iZJ
[i
II
SEF259H
Check following items. 1) "G" fusible link 2) Harnessor connectors between terminal @ and battery. 3) Ignition switch If N.G., replaceaffectedparts.
c..'UN1T 116107108136
CONNECTOR
3948
~ ~
e\ srt.J
Check following items. 1) "s R" fusible link 2) Harnessor connectors between terminal @ and battery
3) Harness or connectors
[R]
00
SEF260H
[i
CHECK GROUND CIRCUIT. 1) Turn ignition switch "OFF". 2) Disconnect E.C.U. harness connector. 3) Check continuity between terminals @, @, ~, @, @, @, @ and ground. Continuity should exist. N.G.
INSPECTION END
EF &. EC-85
TROUBLE DIAGNOSES
Diagnostic Procedure 2
CRANK ANGLE SENSOR (Code No. 11)
E. C. C. S. CONTROL fF2\ UNIT I...:::..)
4-R/B
(E. F. 1harness)
B/W~ ~B/W
(Eng Ine
room
harness)
@@)
22-G/B 3031-G/Y 40-G/Y G/B
~'
,- "" \
, ,
I: , , , ,
,,
~
W R
R/B~
~R/B
@@)
:G~
147
:47
47-B/W
d. j ,.. ..
"'..'" ..
~.. " ..0: 0:0:
ij , , ,
~
@ ~~
FUSE AND
~:~
@)~
@)~
FUSIBLE LINK
FUS IBLE LI NK (ln RELA Y BOX)
~m
i@)
ENGINE GROUND
@lMJ
161~
CRANK ANGLE SENSOR
m IiIln1
E.
~
C. C.
S.
RELAY
~ BATTERY
SEF221H
Component location
-Crank
angle sensor
~harness
SEF147H
connector
~-'~
EF & EC-86
TROUBLE DIAGNOSES
fa
COIIIET
INSPECTION START
fa
Ii]
O.K.
I
)
@J
(lli)
SEF142H
~0 ~~
Ii]
II
ClUNIT
8'
CONNECTOR II
~ i5
00
SEF143H
CHECK E.C.U. INPUT SIGNAL (Crank angle sensor side). 1) Start engine. 2) Check that pulse signals exist in crank angle sensor harness connector terminals @ and @ with logic probe. Pulse signals should exist. @: 1800 signal @: 10 signal N.G.
22303140
[ill
[!J
CHECK HARNESS CONTINUITY BETWEEN CRANK ANGLE SENSOR AND E.C.U. 1) Stop engine. 2) Disconnect crank angle sensor harness connector. 3) Disconnect E.C.U. harness connector. 4) Check continuity between terminals @ and @. @. 5) Check continuity between terminals @ and @. @. Continuity should exist.
N.G. Repair harness or connectors between crank angle sensor and E.C.U.
i5~
CYJ
:
[!J
IV 00
(!1
_T
CHECK POWER SUPPLY (Crank angle sensor side). 1) Stop engine. 2) Disconnect crank angle sensor harness connector. 3) Turn ignition switch "ON". 4) Check voltage between terminal @ and ground. Battery voltage should exist.
N.G.
O.K.
f~
(!1
I
Repair or replace harness or connectors between crank angle sensor harness connector terminal @ and E.C.U. harness connector terminal @.
SEF144H
CHECK GROUND CIRCUIT. 1) Turn ignition switch "OFF". 2) Check resistance between terminal @ and ground. Continuity should exist. O.K. CHECK COMPONENTS. Check crank angle sensor. (See page EF & EC-147.)
DlSCGIINt:CT
lu
[:tI~
[ill
+:
~
SEF146H
O.K.
N.G.
INSPECTION END
1) Perform E.C.U. input/output signal inspection test. 2) If N.G., recheck the E.C.U. pin terminals for damage or the connection of E.C.U. har~ess connector.
EF & EC-87
TROUBLE DIAGNOSES
Diagnostic Procedure 3
E. c. c. s.
CONTROL
Ii)
@2
UNIT III'
f1
CE. . 1F
1D9-8/W
hsrness)
g
~@) ~"'. '"
fff1 I
, , I I ,
I , , I I I I I I I , ,
"
,.?7I!i1Ii1IUJ
, , , , ,
8/W$
@@
4-R/8
Wd
16-W
17-8
, I I , '
uJ
, , , , ,
: -J
, , , , ,
, I I I I
R/8--;
~R/8
@@
w
WJ
~~ "'''' "''''
. @)~
@)
~~
FUSIBLE LINK
FUSE AND FUSI BLE LI NK <I n RELA Y BOX)
@)lMJ
~@)
ENGINE GROUND
E. C.C.S. RELAY
;1
~
BATTERY SEF222H
Component location
EF &. EC-88
CONNECT
E)
f
.
~[Y]
:E
SEF136H
TROUBLE DIAGNOSES
INSPECTION START
m
CHECK E.C.U. INPUT SIGNAL (Air flow meter side). 1) Start engine. 2) Check that voltage between air flow meter harness connector terminal @ and ground changes by racing engine with accelerator pedal. Output voltage should change. 1.0 Approximately 3.0V
I;]
O.K.
CHECK HARNESS CON. TINUITY BETWEEN AIR FLOW METER AND E.C.U. 1) Stop engine. 2) Disconnect irflowmeter a harness connector. 3) DisconnectE.C.U.harness
@)
,IV~
I;]
~r,
~u
IU 00
SEF137H
_IECT
N.G.
N.G.
Repair or replace harness or connectors between terminals @ and @.
[ill
[!J
i5~~
[Y]
:E
I
[!J~~
CONNECT
E)
CHECK POWER SUPPLY (Air flow meter side). 1) Stop engine. 2) Disconnect air flow meter harness connector. 3) Turn ignition switch "ON". 4) Check voltage between terminal @ and ground. Battery voltage should exist.
N.G.
Repair or replace harness or connectors between air flow meter harness connector terminal @ and E.C.U. harness connector terminal ~.
@)
Ii]
O.K.
{D
Ii]
_IECT
SEF138H
~
[ill
CHECK GROUND CIRCUIT. 1) Turn ignition switch "OFF". 2) Check resistance between terminal @ and ground. Resistance: Approximately on
lu
00
SEF141 H
O.K.
N.G.
CHECK COMPONENTS. Check air flow meter. (See page EF & EC-147.) ,
O.K.
N.G.
O.K.
INSPECTIONEND
1) Perform E.C.U. input/output signal inspection test. 2) If N.G., recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.
EF & EC-89
1821-8 29-8
L/OR
(E. F. I. harness)
m[;]
.rb@)
jf!
SEF223H
\mm
Component location
SEF150H
EF & EC-90
TROUBLE DIAGNOSES
Fa
~
r1I
INSPECTION START
eJ
[ill
21 29
~
Ii]
CHECK COMPONENTS. Check engine temperature sensor. (See page EF & EC-147.) Fa
II
O.K.
i5[II
a
C;'UNIT
CONNECTOR
SEF148H
CHECK GROUND CIRCUIT. 1) Disconnect E.C.U. harness connector. 2) Check continuity bet~ engine temperature sensor terminal @ and E.C.U.terminals @,~. Continuity should exist.
N.G.
r1I
i5
[ill
r-ClUNIT 18 CONNECTOR II SEF149H
1) Repair harness or connectors between terminals @ and @,~. 2) Check engine ground.
00
Ii]
O.K.
~i5u
CHECK INPUT SIGNAL CIRCUIT. Check continuity between terminals @ and @. Continuity should exist.
O.K.
Reinstall any part removed.
Perform driving test and then perform self-diagnosis(ModeIII) again. O.K. INSPECTION END
N.G.
1) Perform E.C.U. input/output signal inspection test. 2) If N.G.; recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.
EF & EC-91
TROUBLE DIAGNOSES
Diagnostic Procedure 5
VEHICLE SPEED SENSOR (SwitchON/OFF diagno~tic item) (Code No. 14)
IGNITION SWITCH ON or START
~
U I' 28
COMBINATION METER
I!]
~Ii I@
~ (ReferBLOCK FUSE to "POWER
SUPPL
I
~
" " iiD
'">-
~@ "
.....
>->.
~ GD~~
>-
~~~
>- >-
@"..QD
E. C. C. S.
ROUT
I NG"
8S7iROL
In EL sect Ion. )
@@
8
r-=-. @@
@~<)
BODY GROUND
11
.~o
~
".II,~.
(E. F. I.
G Y/8
y/G
G .
Y/l
" ~0 ~
Y/l
Y/8
harness)
(Main)
tI
~ ~
, ,
... ..
harness
@
@D
3'Y/G
[t!J
:
-
>- >-
<Foldou ReferiOpa~e).
S. M. Y' st
age
::
' ,
>>I
Y/l Y/8~
@@])
harness
I ne
room
no. 2)
.....
" >->-
@:D~
@
~,
SPEED SENSOR
SE F224H
EF
&
EC-92
TROUBLE DIAGNOSES
PI INSPECTION START
No
Is speedometer
working
properly?
Yes
PI
SEF804F
Ii]
II
ClUNIT
]CONNECTORII
32
~i5
&a
SEF151H
[ill
Ii]
CHECK INPUT SIGNAL. 1) Perform switch ON/OFF diagnosis (in Mode IV). 2) Make sure green inspection lamp on E.C.U. comes "ON" when vehicle speed reaches 20 km/h (12 MPH). , N.G.
O.K.
INSPECTION END
CHECK CONTINUITY BETWEEN E.C.U. AND VEHICLE SPEED SENSOR. 1) Turn ignition switch "OFF". 2) Disconnect E.C.U. harness connector. 3) Check continuity between E.C.U. terminal @ and ground by rotating rear wheel by hand. Continuity should come and go. O.K. Reinstall any part removed.
N.G.
Erase the self-diagnosis memory. Make sure Code No. 55 is displayed in Mode III.
1) Perform switch ON/OFF diagnosis (in Mode IV) again. 2) Make sure green inspection lamp on E.C.U. comes "ON" when vehicle speed reaches 20 km/h (12 MPH).
N.G.
1) Perform self-diagnosis and find malfunction code. 2) According to displayed code No., perform diagnosis.
EF & EC-93
p:leJ
FUSE
@)!
(E. F. 1harness) - -- - - - - - - - - -- -- - ---, I' , I' I' "
~
bill
@@
bID
(Eng Ine room
"' , "I I
I I I I I
I I I I I I
harnesS>
B/R~
~B/R
-w
,, "
" "
I"
@)g
fJ
G
G cn
FUSIBLE LINK
f1
IGNITION
ii ~ ~@
"
'"
I
III
~~
~~
~ @)
III
@)L8
@)i - i@) .
@I~
LQ
~111~
ENGINE GROUND
CONDENSER RESISTOR
~ ij
~mm[i] 1Ir!1
POWER
TRANSISTOR
'" '\
III
BATTERY
~
DISTRIBUTOR
.
([@~ 111]
1 2 3 4 5
OFFACe ON ST c 0 C :J 0
- - - SPARK PLUG
I GNI TI ON SWITCH
SEF225H
Componentlocation l
SE F34 7H
EF & EC-94
TROUBLE DIAGNOSES
mLit~
~
CGIIBT
"..
....,
INSPECTION START
./
I
Battery
00
---.
<f>
ID
IE)
SEF370H
~ ~i5
[ill
n
CHECK E.C.U. INPUT SIGNAL (Power transistor side). 1) Start engine. 2) Verify that pulse signal exists between power transistr harness connector terminal @ and ground with logic probe. Pulse signal should exist. N.G. [!] CHECK E.C.U. OUTPUT SIGNAL (Power transistor side). Verify that pulse signal exists between power transistor harness connector terminal @ and ground with logic probe. Pulse signal should exist. O.K.
O.K.
CHECK E.C.U. INPUT LINE. 1) Stop engine. 2) Disconnect harness con. nectors from power transistor and E.C.U. 3) Check continuity between terminals @ and @. Continuity should exist. If N.G., check following. 8 Resistor 8 Harness or connector
Ii]
N.G. CHECK E.C.U. OUTPUT SIGNAL (E.C.U. side). Verify that pulse signal exists between E.C.U. harness con-
~Jur
CCNECTOR II SEF444H
~i5
nectorterminal CD andground
with logic probe. Pulse signal should exist. If N.G., check the E.C.U. pin terminals for damage or the E.C.U. harness connection.
[!]
CGIIBT
lo.K.
00
Ii]
1$ 81
ID ~[ ~ 00.
CONIIECT
I'
e
SEF152H
II
CHECK POWER SUPPLY. 1) Stop engine. 2) Disconnect harness connector from ignition coil. 3) Turn ignition switch "ON". 4) Check voltage between ignition coil harness connector terminal @ and ground. Battery voltage should exist. O.K. N.G. CHECK HARNESSCONTINUITY BETWEEN BATTERY AND IGNITION COIL. Check the following items. 8 Harness 8 "G" fusible link 8 Ignition switch
ClUNIT 1
'8
CONNECTOR
II
Battery
<f>
tID
Ii!lCoili~i5
e Logic probe
SEF153H
00
w
::E
~
~
SEF154H
EF & EC-95
TROUBLE DIAGNOSES
Ii
ffi
cilltv~i5 [ill
Ii
CHECK HARNESS CONTINUITY BETWEEN IGNITION COIL AND POWER TRANSISTOR. 1) Turn ignition switch "OF F". 2) Disconnect power transistor harness connector. 3) Che9k continuity between ignition coil harness connector terminal @ and power transistor harness connector terminal @.
[!1 O.K.
N.G.
~i5~
[!1
SEF366H
cillE>~i5~
[ill
-=-
SEF156.H
CHECK GROUND CIRCUIT. Check continuity between power transistor harness connector terminal @ and ground. Continuity should exist. O.K. CHECK COMPONENTS. Check ignition coil and power transistor. (See page EF & EC-148.) O.K. Reinstall any part removed.
N.G.
Perform driving test and then perform self-diagnosisagain. O.K. INSPECTION END
N.G.
1) Perform E.C.U. input/output signal inspection test. 2) If N.G.. recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.
EF & EC-96
TROUBLE DIAGNOSES
NOTE
EF & EC-97
TROUBLE DIAGNOSES
Diagnostic Procedure 7
ENGINE CONTROL UNIT (Code No. 31)Q
INSPECTIONSTART
INSPECTION END
EF & EC-98
TROUBLE DIAGNOSES
NOTE
EF & EC-99
TROUBLE DIAGNOSES
Diagnostic Procedure 8
E. C. C. s. CONTROL UNIT
P
105-
81
...I"
]
LG
FUSE
till
@@)
(E. F. I. harness) (Eng I ne room harness)
B/R
8R-'
'-B
BR
B~
~
~
~:~ ~
(ill) [IJI
Un
~ ..
OFFACC ON ST 1 2 3 4 5
J C
@)Q
:J
( c
I GNITI ON SWITCH
=~~
BATTERY SE F269H
EF & EC-100
TROUBLE DIAGNOSES
m
m
SEF445H
Ii]
CHECK E.G.R. CONTROL VALVE OPERATION. 1) Start engine and warm it up sufficiently. 2) Make sure E.G.R. control valvespring responds to your touch (use your fingers) and also when engine is raced.
INSPECTION END
Ii]
SEF157H
[i
~-
CHECK VACUUM SOURCE TO E.G.R. CONTROL VALVE. 1) Stop engine. 2) Disconnect vacuum hose connected to E.G.R. control valve and B.P.T. valve. 3) Start engine. 4) Make sure vacuum exists when racing engine.
O.K.
CHECK COMPONENT. Check E.G.R. control valve. (See page EF & EC-148J
I
~~
Clagg'og
=='--
~
SEF816F
[i
N.G. N.G.
If necessary, replace vacuum hose or reconnect vacuum hose firmly.
CHECK VACUUM HOSE. 1) Stop engine. 2) Check vacuum hose for clogging, cracks, and proper connections.
.:C\ ~ ""
. Improper connection
Ii]
I
O.K.
Ii]
CONNECT
100
CHECK E.C.U. OUTPUT SIGNAL (Solenoid side). 1) Start engine and warm it up sufficiently. 2) Check voltage betwen E.G.R. control solenoid valve harness connector terminal @ and ground. Engine condition
Idle Voltage
Battery voltage
(I
N.G. CHECK E.C.U. OUTPUT SIGNAL (E.C.U. side). Check voltage between E.C.U. harness connector terminal @) and ground.
Engine condition Idle Raci ng Voltage
Battery voltage
SEF158H
Temporarily dropstoO-1V
(I
CONNECTOR
II
Racing
Temporarily drops to 0 - 1 V
)
00
!
O.K.
If N.G., check the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.
O.K.
UW
C.f'H
SEF159H
tD
EF &. EC-101
TROUBLE DIAGNOSES
Ii
Test condition
Drive vehicle under the following conditions with a suitable shift position. . Engine speed:
3,100:1:300 3,000:1:400 rpm (AfT) rpm (MfT)
1
CHECK COMPONENT. 1) Stop engine. 2) Check E.G.R. control solenoid valve. (See page EF & EC-149J
N.G.
O.K. CHECK COMPONENT. Check E.G.R. control valveand B.P.T. valve. (See page EF & EC-148J O.K. For California N.G.
Valve spring may be stuck. Clean if necessary. If this does not correct trouble, replace E.G. R. control valve.
Driving mode
Test condition 16 seconds or more @
Vehicle driving
Idling ----.
Ignition'JLj Time switch: I IC)) 0 F F -+-t----Until green and red inspection lamps go off. CD Start engine and warm it up sufficiently. @ Turn off ignition switch and keep it off until green and red inspection lamps go off. CID Start engine and make sure that air conditioner switch and rear defogger are turned "OFF" during driving test. @ Shift to suitable gear position and drive in "Test condition" for at least 16 seconds. CID Decrease engine revolution to less than 2,000 rpm. @ Repeat steps @ through CID at least 1 time.
SEF037H
Check resistance of exhaust gas temperature sensor. (See page EF & EC-149.)
Erase the self-diagnosis memory. Make sure Code No. 55 is displayed in Mode III.
Ii
Perform driving test under the following conditions. 1) Warm up engine sufficiently. 2) Use test driving modes indicated in figure Ii.
[!1
~~E~
CHECK ENGINE LIGHT
SEF924F
[!1
Comes
Perform self-diagnosis and find malfunction code. According to displayed code No., perform diagnosis.
Make sure check engine light does I"ON" not come "ON" during driving test. Does not come "ON" INSPECTION END
EF & EC-102
TROUBLE DIAGNOSES
NOTE
EF &. EC-103
(E. F. 1harness)
19-W
:~:
nnn
nnnnnnnnn_nn
ii
I I I I I I I
,m
mmmm
m__m
m_:::::::::~I
1:_'
~
I I I I I I I
(ill)
m
@-=<> Ii]
i@
"::"
0
EXHAUST GAS SENSOR SEF226H
ENGINE GROUND
Component
location
EF & EC-104
TROUBLE DIAGNOSES
':)
INSPECTION START
O.K.
INSPECTION END
([IT))
SEF153D
CHECK INPUT SIGNAL. 1) Start engine and warm it up sufficiently. 2) Make sure green inspection lamp on E.C.U. blinks at 2,000 rpm.
I;]
.-cT
I;]
II
N.G. N.G.
Repair or replace harness.
eJ
Exheust ges sensor
~IT
'8 CONNECTOR
19
II
~
=
[ill
connector
SEF446H
~ .-cT eJ
CHECK EXHAUST GAS SENSOR CIRCUIT. 1) Stop engine. 2) Disconnect E.C.U. harness connector. 3) Disconnect exhaust gas sensor harness connector. 4) Connect a jumper wire from exhaust gas sensor harness connector to ground. 5) Check continuity between E.C.U. harness connector terminal @ and ground. Continuity should exist.
O.K.
Replace exhaust gas sensor.
Erase the self-diagnosis memory. Make sure Code No. 55 is displayed in Mode III.
1) Start engine and warm it up sufficiently. 2) Set diagnosis mode to Mode I. 3) Makesure that green inspection lamp on E.C.U. goes on and off periodically more than 5 times during 10 seconds at 2,000 rpm. O.K. INSPECTION END
N.G. .
Perform IDLE SPEED/IGNITION TIMING/IDLE MIXTURE RATION INSPECTION. (See page EF & EC-26J
EF & EC-105
(E. F. 1harness)
8-R/L
@
(Eng I ne room
harness)
R/~j t:/L
(Eng I ne harness
room no. 2)
21-8
I:IR/~::ft) ~~/LII:
@@
..J "aiD<
F7
Ii1[!]
@E)Q?~
~
1i1[!]
0
@
:A/T :M/T
mode I
model
~
EXHAUST GAS TEMPERATURE SENSOR
SEF204H
Component
location
(/ /rv SEF~73H
A/T mOde;
EF & EC-106
TROUBLE DIAGNOSES
INSPECTION START
m~~
CONNECT
m [Y]
:+:
~
~0 I~~
Ii)
SEF201
~~i5
[ill
'+:. ,-
CHECK INPUT SIGNAL (Exhaust gas temperature sensor side). 1) Start engine and warm it up sufficiently. 2) Keep engine speed at approximately 2,000 rpm. 3) Check voltage between exhaust gas temperature sensor harness connector terminal @ and ground under the following conditions.
Condition
Wh~n vacuum is not applied to E.G.R. control valve
O.K. EBEB
~i{)u
[i
00
~
CIUN!:!:8COtNECTOR
SEF202H
When vacuum
II
is
applied control
to E.G.R. valve
0 - 1.0V
~i5
[ill
'+
A sufficient vacuum applied with a hand vacuum pump may cause the engine to stall.
Ii)
,
N.G.
00 ~i5u
21
CHECK HARNESS CONTINUITY BETWEEN E.C.U. AND EXHAUST GAS TEMPERATURE SENSOR. 1) Stop engine. 2) Disconnect E.C.U. harness connector.
3) Disconnect
N.G.
1) Check harness and middle harness connector connection between terminals @ and @. 2) If necessary, repair or replace harness.
exhaust gas
[i
O.K. CHECK GROUND CIRCUIT. Check continuity between terminals @ and @. Continuity should exist. N.G. 1) Check middle harness connector connection. 2) If necessary, repair or replace harness.
O.K.
EB
EF & EC..'07
TROUBLE DIAGNOSES
CHECK COMPONENTS. Check exhaust gas temperature sensor. (See page EF & EC-149.)
N.G.
O.K.
Erase the self-diagnosis memory. Make sure Code No. 55 is displayed in Mode III.
N.G.
.....-O.K.
INSPECTION END
1) Perform E.C.U. input/output signal inspection test. 2) If N.G., recheck the E.C.U. pin terminals for damageor the connection of E.C.U. harnessconnector.
EF & EC-108
TROUBLE DIAGNOSES
NOTE
EF & EC-109
TROUBLE DIAGNOSES
Diagnostic Procedure 11
UNIT
~~eu~es
I:t.., nil
(E. F. 1harness)
20-W 21-8 29-8
~_nnnn__u-
33-Y/
44
1371
37H-Y LG
/R
------- U___n-n- --n- -_n- --nn --- n- nn- -- un ---u" , ----- -_n- ----- -_n n- _n- -_nn --U_- -,, , ,, , ,, ,, ,, ,, , ", ,, ,, , , ,, , , ",
B--.
t
@~
0: "
,, ,, ,, I' i I' ,
@ CfP fl
W ...J
PI Ii][!]Ii
THROTTLE
SENSOR
@i
ENGINE
GROUND
THROTTLE VALVE
SWITCH
~
~
...J
~ ~
SEF211H
EF &. EC-110
TROUBLE DIAGNOSES
,-
db ~
:f
i)
[2]
i3~
r;) cllitD
CHECK POWER SOURCE. 1) Turn ignition switch "ON". 2) Check voltage between terminal @ and ground. Voltage: Approximately 5.0V
SEF207H
N.G.
O.K.
IIISCOIIIlECT
18
[ill
HARNESS CONTINUITY BETWEEN THROTTLE SENSOR HARNESS CONNECTOR AND E.C.U. 1) Turn ignition switch "OF F". 2) Disconnect throttle sensor harness connector. 3) Disconnect E.C.U. harness connector. 4) Check continuity between terminals @ and @. Continuity should exist. If N.G., repair or replace harness or connector.
~i5[[
[i1
r---o ClUNIT
37 CONNECTOR II SEF208H
~ ~.) ~
CONNECT
[Y]
+
Ii] [i1 O.K. CHECK INPUT SIGNAL CHECK INPUT SIGNAL r----+ (Throttle sensor side). (E.C.U. side). Makesure that voltage between Makesure that voltage between terminal @ and ground changes terminal @ and ground changes when accelerator pedal is dewhen accelerator pedal is depressed. pressed. Voltage: Voltage: Approximately 0.5 -4.0V Approximately 0.5 - 4.0V
N.G.
lo.K.
Repair or replace harness or connectors between terminals @ and @.
i3~
Ii]
II
SEF209H
81
c.;uNIT
CONNECTOR ~
riI i)
20
00.
[Y]
+, ,-
i3
81 clliID
SEF367H
CHECK GROUND CIRCUIT. 1) Turn ignition switch "OF F" and disconnect E.C.U. harness connector. 2) Disconnect throttle sensor harness connector. 3) Check continuity between terminal CD and E.C.U. terminals @, @. Continuity should exist. O.K.
N.G.
1) Check harness continuity between throttle sensor and ground. 2) E.C.U.ground circuit.
~ i5
[ill
r---o ClUNIT 21 29 CONNECTOR II SEF210H
00 i5~[[
Ej
EF & EC-111
TROUBLE DIAGNOSeS
N.G.
Replace throttle sensor.
iii
SE F346H
O.K.
N.G.
ADJUST IDLE SWITCH OFF -+ ON SPEED. 1) Loosen throttle sensor securing screws. 2) Set idle switch OF F -+ ON speed to the specified value by turning throttle sensor body.
CHECK IDLE SWITCH OFF -+ ON SPEED. 1) Reconnect throttle valve switch harness connector. 2) Disconnect idle switch harness connector. 3) Start and warm up engine sufficiently. 4) Check idle switch OFF -+ ON speed with circuit tester, closing throttle valve manually. Idle switch OFF -+ ON speed: M/T: 1,oOO:t150 rpm AJT: 1~O:t150rpm (UN" range)
O.K.
Reinstall any part removed.
N.G.
1) Perform E.C.U. input/output signal inspection test. 2) If N.G., recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.
EF & EC-112
TROUBLE DIAGNOSES
NOTE
EF & EC-113
TROUBLE DIAGNOSES
INJECTOR LEAK (Code No. 45)
Diagnostic Procedure 12
INSPECTION START
SEF832F
Make sure engine runs smoothly at idle after warming. Does not run " smoothly Set the diagnosis mode selector of E.C.U. to Mode I.
Runs smoothly
Ii)
Engine racing mode
@ : 10 seconds or more
Race engine two or three times under no-load, then run engine at idle speed.
Check if the green inspection lamp stays off during 10 seconds at idle condition.
Stays off
Time
Set diagnosisto Mode II and check that red and green inspection lamps on E.C.U. blink almost simultaneously at 2,000 rpm under no-load. Do not blink
Check idle CO%. (See page EF & EC-26.)
CD Start engine and warm it up sufficiently. @ Race engine revolution higher than 2,000 rpm under no-load. CID Keep engine at idle speed for at least 10 seconds. @ Repeat steps @ through CID least 10 times. at
m
1) Stop engine. 2) Remove all spark plugs from intake manifold. Are plugs wet with fuel? No Yes
INSPECTION END)
SEF392G
Replace the injector in which cylinder spark plug is wet with fuel.
[+J
~~E~
CHECK ENGINE LIGHT
SEF924F
Remove injector assembly. (See page EF & EC-154,) Keep all injectors connected to injector tube.
Turn ignition switch "ON". IDrips Make sure fuel does not drip from injector.
Does not drip
EF & EC-114
TROUBLE DIAGNOSES
r
Erasethe self-diagnosismemory by following the procedure. 1) Start engine and warm it up sufficiently. 2) First disconnect air flow meter connector, and start and run engine for at least 30 secondsat 2,000 rpm. 3) Stop engine and reconnect air flow meter connector. 4) Make sure Code No. 12 is displayed in Mode III. 5) Erasethe self-diagnosis memory. Make sure Code No. 55 is displayed in Mode III.
Ii]
Perform engine racing by the use of indicated in figure
Ii].
Comes
[i
Make sure check engine light does I "ON" 1) Perform self-diagnosis and find malfunction code. not come "ON" during engine racing. 2) According to displayed Code Does not come "ON" INSPECTION END
No., perform diagnosis. 3) If Code No. 45 is displayed again, replace all injectors, then perform diagnosis.
EF & EC-115
33- Y/W
(E.F. 1harness)
44
TI'
H-Y
J nmm
@)r@~
THROTTLE
VALVE
SWI TCH::J LL
m
j
W
..J 0
SEF369H
SEF212H
EF & EC-116
m[lt
CONNECT
[Y]
SEF375H
TROUBLE DIAGNOSES
INSPECTION START
O.K.
O.K.
INSPECTION END
~
I!J~
@J
N.G. Repair or replace harness or connector between throttle valve switch harness connector terminal @ and E.C.U. harness connector terminal @.
IV 00
.--r
@ID
CHECK E.C.U. INPUT SIGNAL. 1) Turn ignition switch "ON". 2) Check voltage between throttle valveswitch harness connector terminal @ and ground.
Accelerator pedal condition
Fully closed Voltage
Approximately
[Y]
-= SEF449H
8- 10V OV
Open
I!J
N.G. O.K. Check continuity of harness or connectors between throttle valve switch harness connector terminal @ and E.C.U. harness connector terminal @. If N.G., repair or replace them.
CHECK POWER SUPPLY. 1) Turn ignition switch "OFF". 2) Disconnect throttle valve switch harness connector. 3) Turn ignition switch "ON". 4) Check voltage terminal @ and ground. Batteryvoltageshould exist.
N.G.
Replace throttle valve sensor/ switch.
CHECK COMPONENT. Check idle switch. O.K. ADJUST IDLE SWITCH. (See page EF & EC-112.)
Replace E.C.U.
EF 8r.EC-117
TROUBLE DIAGNOSES
Diagnostic Procedure 14
START SIGNAL (Switch ON/OFF diagnostic item)
tf2'I ~
m
FUSE BLOCK (Refer to npOWER SUPPLY ROUTINGn In El sect Ion. )
UP
@@
(E. F. 1.
@
(M In h arness ) a
OR
I
m
..
,
>-
FUSE
harness)
OR
JI
rnJ
~
, m
>-
~nglne
room harnes~
w w
BR~ ~
@])
cD
>-
...
, m
~:~ @)
~~
,
34-0R
, m
>-
FUSIBLE LINK
~~
1m
OFFACC ON ST c 0 I c 0 2 0 3 4 5
I GNITI ON
@)g
~
-
SWITCH
BATTERY
SEF214H
EF & EC-118
TROUBLE DIAGNOSES
m
II
lit is
CAJNIT
8 CONNECTORII
34
INSPECTION START
INSPECTION END
00
SEF213H
N.G. N.G. Check the following items. 1) "G" fusible link 2) Ignition switch 3) Middle harness connector
CHECK INPUT SIGNAL. 1) Turn ignition switch "START". 2) Check voltage between terminal @ and ground. Battery voltage should exist. If N.G., repair harness and connectors.
EF & EC-119
UNIT @~....
IU-8/P
r=I r=I
@J){i@5)
BODY GROUND
rffi3l~ >..
107-8
,
I
>-
, ..
@
(E. F. 1.
harness)
(Ma I n
harness)
m ,
>..
S.M.J.
[Refer to 'ast (Fa I dout page).)
FUSE page
8/R
~
8~
@@
8/P-ffi. .tB- 8/P
8/Y~ ~8/Y
0:
, ~ ..
, .... @)
>-
,~ .... ~~
@Y~
I'
~ \!!!I
~:~
[DJ~
@lMJ
IIlnii if Ifm
FUEL PUMP RELAY
III
OFFACC N ST 1 2 3 4 5
I GNI TI ON SWITCH
@)Q
AIR REGULATOR
BATTERY
SEF236H
Component location
SEF268H
EF & EC-120
TROUBLE DIAGNOSES
m~~ ~tttill1
INSPECTION START
i5
O.K.
~
(2J
[Y]
SEF264H
I!J
IImtalV
~~_r
(Fuel pump side). 1) Disconnect fuel pump harness connector. 2) Turn ignition switch "ON". 3) Check voltage between terminal @ and ground. Battery voltage indication should appear for 5 seconds after turning ignition switch "ON".
CHECK COMPON~NTS. 1) Turn ignition "OFF". 2) Check fuel pump. (See page EF & EC-149,) If N.G., replace fuel pump.
L
I!J
O.K.
[ill
00
SEF266H
N.G.
CHECK GROUND CIRCUIT. Check continuity between terminal @ and ground. Continuity should exist. If N.G., repair harness or connectors.
[!J CHECK POWER SUPPLY (Relay side). 1) Turn ignition switch "OFF". 2.) Disconnect fuel pu,,",prelay. 3) Turn ignition switch "ON". 4) Check voltage between terminals @, @ and ground. Battery voltage should exist. O.K.
N.G. CHECK HARNESSCONTINUITY BETWEEN BATTERYAND FUEL PUMP RELAY. Check following. . Harness or connectors
[!J
10
[:iI .--r
:filiL @"l)]
. "BR" fusiblelink
[Y]
lZJOO
Ii]
=
SE F377H
~ _r
illTI:0"'lII
CHECK COMPONENTS. 1) Turn ignition "OFF". 2) Check fuel pump relay. (See page EF & EC-150,)
N.G.
IV
rnJ
Ii]
O.K.
00
i5[:i1~
SEF379H
N.G.
harnessconnectorterminal CD
and fuel pump harness connector terminal @. O.K.
EF & EC-121
TROUBLE DIAGNOSES
Ii
CONNECT 104
IT B" CONNECTOR II
Ii
CHECK E.C.U. OUTPUT SIGNAL (E.C.U.side). 1) Reconnect fuel pump harness connector and fuel pump relay. 2) Turn ignition switch "ON". 3) Check voltage between E.C.U. harness connector ~ and ground. Battery voltage indication should appear after 5 seconds. O.K. N.G.
Ii
CHECK HARNESS CONTINUITY. 1) Turn ignition switch "OFF". 2) Disconnect E.C.U. harness connector. 3) Check continuity between terminal (jQ!) and relay harness connector terminal
If)
00
l
SEF266H
0
Ii
II
104
'liiV ~
_r ~
00
@.
[ill
Continuity should exist. If N.G., repair or replace harness and connectors between terminals ~ and
@.
O.K.
Recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.
INSPECTION END
1211 4R3
SEF267H
IV
~ _r
EF & EC-122
TROUBLE DIAGNOSES
NOTE
EF & EC-123
TROUBLE DIAGNOSES Diagnostic Procedure 16 , PRESSURE REGULATOR (P.R.) CONTROL SOLENOID VALVE (Not self-diagnostic item)
PRESSURE REGULATOR CONTROL SOLENOID VALVE
go~'T~;l
UNIT
@~
/7
[;]
~
@W~ml!J[;]
LID ]
I06-PU
FUSE
@@)
(E. F. 1.
harness)
8RJ t8R
8/R
(=m::~
~
I@l~~ ~ ~
FUSIBLE , LINK FUSE AND FUSI BLE LI NK <In RELA Y BOX)
~
ID
@)~
=~~
BATTERY SEF267H
Component location
EF &. EC-124
TROUBLE DIAGNOSES m
IllsalllllECT
.q:ffip
INSPECTION START
18
@) LjCYJ
m
I
0
Ii] [11
CONNECT
SEF253H
CHECK POWER SOURCE. 1) Disconnect P.R. control solenoid valve harness con. nector. 2) Turn ignition switch "ON". 3) Check voltage between terminal @ and ground. Battery voltage should exist.
. Fuse
O.K.
00
U ID
[f]
ffiiJ)
cc
UCYJ
CfH
SEF255H
18
IllsalllllECT
Ii]
CHECKCOMPONENTS. 1) Turn ignition switch "OFF". 2) Check P.R. control solenoid valve. (See page EF & EC-149J O.K. CHECK OUTPUT SIGNAL. 1) Reconnect P.R. control solenoid valve harness connector. 2) Start engine and warm it up sufficiently [until more than 90C (194 F) of c'oolant temperature] . 3) Turn ignition switch "OFF" and then start engine again. 4) Check voltage between terminals @ and ground. Voltage: 0.5 - 1.0V (for 3 minutes after starting)
[f] N.G. ~HECK HARNESS CONTINUITY BETWEEN P.R. CONTROL SOLENOID VALVE AND E.C.U. 1) Stop engine. 2) Disconnect P.R. control solenoid valveharness connector. 3) Disconnect E.C.U. harness connector. 4) Check continuity between terminals @ and @. Continuity should exist. If N.G.. repair harness or connector.
[ill
SEF256H
106
[I
CoIUNIT
[1I_T 18 ~
CONNECTOR
II
O.K.
INSPECTION END
O.K.
1) Perform E.C.U. input/output signal inspection test. 2) If N.G., recheck the E.C.U. pin terminal @ for damage or the connection of E.C.U. harness connector.
EF & EC-125
TROUBLE DIAGNOSES
Diagnostic Procedure
INJECTORS (Not self-diagnosticitem)
NO.1 NO.2 INJECTOR ANO.3 NO.4
17
E. C. C. S.
CONTROL UNI T
f'""F2I ~
(iJIJ
jJ
101-W/B 103110112-L/B G/B Y/B
~ ~ ~ ~
IImIJ IIm[ill
V
"'~
W@
m
W@
m~
"'ci
"'~ ~
!!L 1
mIJ
II mIJ
FUSE
rnJ UTI
(E.F. I.
harness)
RiiR
@ @)
~
[TI]~
@)
FUSIBLE LINK
FUSE AND FUSI BLE LI NK (1 n RELA Y BOX)
@)~
i46
(61
H-R
BAHERY
SEF251H
Component
location
Harness connector
------
EF & EC-126
TROUBLE DIAGNOSES
INSPECTION
START
)
N.G.
CHECK HARNESS CONTINUITY BETWEEN INJECTORS AND BATTERY. Check following.
eJ
-CSZJ
m
CHECK POWER SOURCE (Injector side). 1) Disconn,ect injector harness connectors. 2) Turn ignition switch "ON". 3) Check voltage between terminal @ and ground. Battery voltage should exist.
'+
OO
SE F247 H
. "G"fusible link
. Harness
I;)
eJ
00
I~~ ~~
II
No.1 No.2 No.3
~ ~
ClUNIT
19111,0193112
O.K.
CONNECTOR ~
[Y]
:+:..CHECK COMPONENTS. 1) Turn ignition "OFF". 2) Check injectors. (See page EF & EC-150.)
N.G.J
1 Replace injectors.
SEF249H
No.4~
~-.r ~
[ill
Ii)
O.K.
II
N.G.
CHECK HARNESS CONTINUITY BETWEEN INJECTORS AND E.C.U. 1) Stop engine. 2) Disconnect injector harness connectors. 3) Disconnect E.C.U.harness connector. 4) Check continuity between terminals @ (No.1) and <D, @ (No.2) and @, @ (No.3) and @, @ (No.4) and @. Continuity should exilt. If N.G., repair harness or connector.
eo ~
-.r
SEF250H
CHECK OUTPUT SIGNAL. 1) Reconnect injector harness connector. 2) Start engine and warm it up sufficiently. 3) Check voltage between E.C.U. terminals <D, @, <!!Q), @ and ground. Battery voltage should exist. O.K.
INSPECTION END
lO.K.
Recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.
EF &. EC-127
ECC.S.
C'ONTROL UNI T
[iJ
f"'F2'\ ~
~ f!ruuI Weill)
>-'" "CD
FUSE
@
12-GY
@)
~nglne
room harnes~
rnJ
8/R
8RJP '-BR
~. F. 1.
harness)
8R w w
8q] ~
~:~
@)
'"
,~ CD
(illY~ 1m
1 2 3 4 5 OFFACC ON ST c c J J
@)~
~ BATTERY SEF231H
Component location
EF & EC-128
TROUBLE DIAGNOSES
INSPECTION START
m
eJ.
[Y]
CH ECK POWE R SOU RCE. N.G.
L.:::
SEF227H
1!1
CIIIIET
1) Disconnect S.C.V. control solenoid valve harness connector. 2) Turn ignition switch "ON". 3) Check voltage between terminal @ and ground. Battery voltage should exist.
. Harness
O.K.
) 00
l
CH
YJ
+
ID
IJ
SEF229H
N.G. CHECKCOMPONENTS. 1) Turn ignition switch "OFF". 21 Check S.C.V. control solenoid valve. (See page EF & EC-149.)
~~i5
[ID
Ii)
O.K.
N.G.
[!J
00' ~i511
CHECK OUTPUT SIGNAL. 1) Reconnect S.C.V. control solenoid valveharness connector. 2) Start engine and warm it up sufficiently. 3) Check voltage between terminal @ and ground.
Voltage between terminal @ and grou nd
engine.
2) Disconnect S.C.V. control solenoid valve harness connector and E.C.U. harness connector. 3) Check continuity between
terminals @ and @
Engine speed
Lass than "approx. 1,400 rpm More than approx. 1,400 ';Pm
0.5 - 1.0V
Battery voltage
O.K.
O.K. 1) Perform E.C.U. input/output signal inspection test. (Terminal @) 2) If N.G., recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.
CHECK COMPONENT.
Check swirl control valve actuator. (See page I
and
INSPECTION
END
EF & EC-129
(Not self-diagnosticitem)
FUEL PUMP
nil nil
@D~@])
10'-B/P
~~
~
rffBl@) ...
.0
107-B
BODY GROUND
,
.0
@
(E. F. r.
harness)
@iD
GJ ...
, .0
FUSE page
B/R
~
~
@@
B/P-ffi B/Y~ ffi-B/P ~B/Y
(Eng I ne harness)
room
B/W W
BR~ 0:
, ;t ..
[!]1]1i
... , .0.0
@)
d;fh
m(;]1] WJ .
Component location
~~
1m
OFF ACC ON ST :) :) 1 :J 2 3 4 5 I GNITI ON SWITCH
;t
I"
rru\ ~
~:;
cn~
@)~
@i ENGINE
;1
~ BATTERY SEF240H
'I
EF & EC-130
TROUBLE DIAGNOSES
11
[:it~ eJ
_CT
C 11
[Y]
INSPECTION START
@a
8
[;]
SEF236H
10 00
[!J
.'2J1l
[:it ..-cT
CHECK POWER SUPPLY (Air regulator side). 1) Disconnect air regulator harness connector. 2) Turn ignition switch "ON". 3) Check voltage between terminal @ and ground. Battery voltage indication should appear for 5 seconds after turning ignition switch "ON".
O.K.
CHECK COMPONENTS. 1) Turn ignition "OFF". 2) Check fuel pump relay. (See page EF & EC-150.) If N.G. replace air regulator. [;] 1
[ill
[!J
-= SEF237H
N.G.
CHECK GROUND CIRCUIT. 1) Turn ignition switch "OFF". 2) Check continuity between terminal @ and ground. Continuity should exist. If N.G., repair harness or connectors. N.G.
eJ
[:it _T
m=ru
00
:+'
-=
CHECK POWER SUPPLY (Relay side). 1) Turn ignition switch "OFF". 2) Disconnect fuel pump relay. 3) Turn ignition switch "ON". 4) Check voltage between terminals @, @ and ground. Battery voltage should exist. O.K.
. Fuse
~oo
I]
SEF377H
~~ IV
00
CHECK COMPONENTS. 1) Turn ignition "OF F" 2) Check fuel pump relay. (See page EF & EC-150.)
N.G. J
N.G.
I]
~IV
[:it
harnessconnectorterminal CD
-and fuel pump harness connector terminal @.
SE F380H
O.K.
EB
EF &. EC-131
TROUBLE DIAGNOSES
ffi
iii
[1t
[[
U 00
COllECT
ClUNIT 104
f CONNECTOR
II
iii
[SLJ +,
~
Ii
II
SEF238H
CIWIIT"8 104
CONNECTORII
~ I..dI rw St:J
CHECK E.C.U. OUTPUT SIGNAL (E.C.U. side). 1) Reconnect fuel pump harness connector and fuel pump relay. 2) Turn ignition switch "ON". 3) Check voltage between E.C.U. harness connector C@ and ground. Battery voltage indication should appear after 5 seconds.
N.G.
I
Ii
CHECK HARNESS CONTINUITY. 1) Turn ignition switch "OFF". 2) Disconnect E.C.U. harness connector. 3) Check continuity between terminal ~ and relay hat-
[ill
00
IIISaIIIIECT
ness connector terminal @. Continuitysho\lldexist. If N.G., repair or replace harness and connectors between terminal ~ and
@. O.K.
Recheck the E.C.U.pin terminals for damage or the connection of E.C.U. harness connector.
1211 4R3
SEF267H
I()
EF & EC-132
TROUBLE DIAGNOSES
NOTE
EF &. EC-133
TROUBLE DIAGNOSES
Diagnostic Procedure 20
AUXILIARY AIR CONTROL (A.A.C.) VALVE
A.A.C. SOLENOID VALVE
(Not self-diagnosticitem)
FUSE
E C c. S.
CON'TROl
UNIT
~
<i:DJ
Wd
B/R
n~-:-
(ill)
BR
113-SB~
~ mliJ[!J
@@) BR~ BR~ ~ BR ~BR
(Eng Ine 'oom harness
w w
B~
~B:~
@
[DJ~ FUSIBLE , LINK FUSE AND FUSI BlE LI NK (1n RELAY BOX)
BR' @
(E. F. I.
harness)
;1
@tI)
BR
@)
BR'-
d c IJJ IJJ 4) C
'3-BR
~~
1m
OFF ACC ON ST J 1 ") 2
g@) lB
@)
@1) B ""'lOR l
.c E 0 0
''"
'-
~[!J
() :A/T @ :M/T
Component location
model model
3 4 5
IGNITION SWITCH BATTERY
!i@)
.",
GROUND STEERI NG OIL PRESSURE SWITCH -SEF218H
EF & EC-134
TROUBLE DIAGNOSES
~~i5
[Y]
o~
Ii]
CONNECT
m
-= SEF215H
O.K. N.G. CHECK CONTINUITY BETWEENA.A.C. VALVE AND BATTERY. Check following.
~[11)
~
+
CHECK POWER SOURCE. 1) Disconnect A.A.C. valve harness connector. 2) Turn ignition switch "ON". 3) Check voltage between terminal @ and ground. Battery voltage should exist. If N.G., repair harness or connectors.
. . . .
O.K.
~~ ~
[I
t\\-Y1
Cf'~H
';
SEF217H
~i5
ill]
I
Ii]
CHECK INPUT SIGNAL. 1) Turn ignition switch "OF F". 2) Reconnect A.A.C. valve harness connector. 3) Start engine and warm it up sufficiently. 4) Check voltage between terminal @ and ground. "voltage: Approximately 7 10V N.G.
[I
CHECK CONTINUITY BETWEEN E.C.U. AND A.A.C. VALVE. 1) Stop engine. 2) Disconnect E.C.U.harness connector. 3) Disconnect A.A.C. valveharness connector. 4) Check continuity between terminals @ and @. Continuity should exist. If N.G., repair or replace harness connectors.
~
8 E
CONNECTOR
I
L.dII WiiV
IW
~c;\ _CT
II
113
c.-uNIT
SEF452H
O.K.
1) Perform E.C.U. input/output signal inspection test. (Terminal @.) 2) If N.G. recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.
EF & EC-135
F. 1. C. D. SOLENOID VALVE
IiJ
E.C.C.S.
CONTROL
~
@)
.J
UNI T
~ -<>
. [!J 1!1
BATTERY
'" a
, .J
'" a
I
(Ma In
harness)
II:
I
UP
, .J
(ill)
N
[Refer
S. M.J.
to
last
(E. F. 1. harness)
ll-G/Y
G/Y~
@@
~G/Y
ffi
w L/G
!Eng I ne room harness)
cD '" a ,J .
'" >-"'0 a "",
::
(Fo I dout
page).
age
L/G e:r
, '" .J "'.J.J
@~
i@)
ENGINE GROUND
I.
Component location
EF 8r. EC-136
TROUBLE DIAGNOSES
m
A/C
\.
m
INSPECTION START
.. Yes
up
PU
sufficiently. 2) Does engine revolution rise when air conditioner switch is turned "ON"? No
SEF129GI
CHECK IDLE SPEED WHEN AIR CONDITIONER SWITCH IS "ON". M/T: 1,OOO:t50 rpm A/T: 1,OOO:t50rpm (at uN" range) If out of specification, adjust idle speed. (See page EF & EC-26J
r;]
!f eJ
oo
I O.K. ( O.K.
INSPECTIONEND
I
r;]
1) Stop engine.
7
I
CHECK POWERSOURCE. Disconnect F.I.C.D. solenoid valve harness connector. 3) Turn ignition switch and air
2)
ilJ
[i
SEF447H
CHECK COMPONENTS. Check F.I.C.D. solenoid valve. (See page EF & EC-151J If N.G., repair or replace F.I.C.D. solenoid valve.
-, eJ
[:it
[i
IO.K. HECKGROUNDCIRCUIT.
nal @ andground.
Battery voltage should exist.
rEIDl
N.G.
.
I
00
I;]
CONNECT
'
7
SEF448H
filii
ClUNIT
11
CONNECTOR II
II
relay.
I;]
O.K.
N.G.
00
lEL
JJ
I O.K. Recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.
O.K.
INSPECTIONEND
EF & EC-137
TROUBLE DIAGNOSES
Diagnostic Procedure 22
AIR INDUCTION VALVE (A.I.V.) CONTROL SOLENOID VALVE (Notself-diagnostictem) i
E. C.c. s. CONTROLtf2)
UNIT ~
/'
~
102-P
[i
~nglne
P
FUSE
room harnes~
(E. F. 1. harness)
ii
@)
B/R
BR
:re q]
G=I] G=I]
[ll]
(ill)
'" , ~ ID
FUSIBLE LINK
'" lDo.
@)&
(@)~
1m
rims?
OFFACCON ST 1 0 C 2 c 3 4 5
IGNITION SWITCH
BATTERY
SEF234H
Component location
EF & EC-138
TROUBLE DIAGNOSES
II
INSPECTION START
18
II
[Y]
&
m
I;]
COllECT
SEF227H
CHECK POWER SOURCE. 1) Disconnect A.I.V. control solenoid valve harness connector. 2) Turn ignition switch "ON". 3) Check voltage between terminal @ and ground. Voltage: Battery voltage
O.K.
N.G.
CHECK HARNESSCONTINUITY BETWEENA.I.V. CONTROL SOLENOID VALVE AND BATTERY. Check harness or connector.
W
if)
ool
tID
, [!] @}
CYH
SEF229H
CHECK COMPONENTS. ' N.G. 1) Turn ignition switch "OFF". 2) Check A.I.V. control solenoid valve. (See page EF & EC-149.)
l1t
[ill
i5
I;]
O.K.
N.G.
[!]
CHECK HARNESS CONTINUITY BETWEEN A.I.V. CONTROL SOLENOID VALVE AND E.C.U. 1) Stop engine. 2) Disconnect A.I.V. control solenoid valve harness connector. 3) Disconnect E.C.U.harness connector. 4) Check continuity between terminals @ and @. Continuity should exist. If N.G., repair harness or connector.
~
~
DlSCGltIlt:CT 102
1811
CHECK OUTPUT SIGNAL. 1) Reconnect A.I.V. control solenoid valve harness connector. 2) Start engine and warm it up sufficiently. 3) Check voltage between terminal @ and ground.
ClUNIT
Ef C~CTOR
II
SEF233H
Voltage
0.5 - 1.0V
Battery voltage
O.K. CHECK COMPONENT. Check air induction valve. (See page EF & EC-151.) , O.K.
N.G.
1) Perform E.C.U. input/output signal inspection test. 2) If N.G., recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.
INSPECTION END
EF & EC-139
E. C. c. S. CONTROL UNIT
0
@ @ @
with
A. S. C. D. A. S. C. D.
FUSE BLOCK (Refer to "POWER SUPPL Y ROUT! NG" 1n EL sect Ion. )
mode I without
I
(MaIn harness) age
page).
..
...J
UP
, "
...J
, "
@)@)
W-G/OR (~a~;"' I:Ss)
[Refer
S. M.J. to Iast
(Fa I dout
QJ 0
, '"
...J
" <>
@)
G/OR-Im
~ngine
room
harnes~ (Eng i ne
35- G/OR 35
j[[
--"
A
0:
ID
room no. 2)
G/OR
-ffi. .ffi.@83"~@3)
B
G/
::r'0:
"ID
r:=I
ell
J;!;II ~
QD
m[l<==-~@)
~~~~
@@)
M
IDID
@)
81
=arness
II 0: 0
lMJ@)
~dP
~~
, "'ID
1;]81
INHIBITOR
I NHI BI TOR
IJ
L,WJ = I~I
I NHI BI TOR
-=-=-= @!@)
BODY GROUND
ft i@
m~~
SWITCH
RELAY
RELAY
i5 [:it
CSZJ
OO(D
-=
SEF350H
EF & EC-140
TROUBLE DIAGNOSES
INSPECTION START
I;]
~[@b)
IIISCOIIIlECT
EO
N.G.
~
[!J
[ill
CHECK COMPONENTS. Check neutral switch (M/T) or inhibitor switch and inhibitor relay (A/T). (Seepage EF & EC-152.)
SEF242H
O.K. (A/T)
O.K. (M/T)
~~_IIECT~
taEO~
[ill
CHECK CONTINUITY BETWEEN SWITCH AND GROUND.
M/T model
, CHECK POWER SUPPLY FOR INHIBITOR SWITCH. 1) Turn ignition switch "ON". 2) Check voltage between terO.K. minal @ and ground. Battery voltage should exist.
SEF243H
(;]
I;]
~C@Th)
IIISCOIIIlECT
EO
[ill
~
i5~[[
131~
r="'
between terminal @ and ground. [!J A/T model 1) Turn ignition switch "OFF". 2) Check continuity betWeen terminals @, CD and ground. Continuity should exist.
Check continuity
. Fuse . S.M.J.
O.K.
35 CONNECTOR II SEF244H
Cf'UNI T
N.G.
(;] M/T
model
i5
I1Cf'U
00
NI T
T CONNECTOR
" ~i5
II
Check continuity between @ and @. 131A/T model Check continuity between inhibitor relay connector CDand @ @ and @. (A.S.C.D. model) Continuity should exist O.K.
INSPECTION END
SEF245H
131
~; i5 ~
-~
n
[ill
~
35
liI
IIISCOIIIlECT
SEF349H
ClUNJ
CONNECTOR II
E0
EF
&.
EC-141
TROUBLE DIAGNOSES
*Dataare referencevalues.
*DATA
0.3 - 0.6V
Ignition signal
1.2 - 1.5V
Engine speed is 2,000 rpm
Ignition check
- 12V
0 -1V 4 E.C.C.S.relay (Mainrelay) Within approximately 1 second after turning ignition switch "OF F"
- ,
E.G.R. system is operating.
0 -1.0V
0 -1.0V
0 - 1.0V 12 S.C.V. control solenoid valve Engine speed is 2,000 rpm. BATTERY VOLTAGE (11 . 14V)
EF & EC-142
EF & EC-143
TERMINAL NO.
ITEM
CONDITION
*DATA
OV BATTERY VOLTAGE
(11
- 14V)
5V
37 38 47
Approximately
OV
II
.~~o~ers~~~chl re "ON". a
Air conditioner switch is "OFF". ne is running.1 S .
43
I 11::11\:1"'1:: I~IUII'"II\:I.I .
- 10V
BATTERY VOLTAGE
(11
- 14V)
45
..
rOV I
6-8V
46
I I Ignition
switch "OFF"I
BATTERY
(11
- 14V)
VOLTAGE
EF & EC-144
TERMI. NAL
NO.
ITEM
CONDITION
*DATA
Injector No.1
Injector No.3
Engine is running.
0.7.0.9V
104
Engine is running.
"
Engine is cold.
0.7.0.9V
is below
105
solenoid
Water temperature
60C (140F).
]
BATTERY VOLTAGE (11.14V)
After warming up
Water temperature is between
[ (221F).
EF & EC-145
ITEM
CONDITION
*DATA
Stop and restart engine after warming it up. Water temperature 90C (194F) is above
106
7 -10V
113
A.A.C. valve
Steering wheel is being turned. Air conditioner is operating. Rear defogger is "ON". Headlamps are in high position.
4-7V
TERMINAL LAYOUT
~i)
SEF419H
EF & EC-146
CID
and
CID.
Continuity Yes No
CRANK ANGLE SENSOR 1. Remove distributor from engine. (crank angle sensor harness connector is connected.) 2. Turn ignition switch "ON", 3. Rotate crank angle sensor shaft slowly and check voltage between terminals @, @ and ground.
SEF364H
(I
SEF176E
for dust.
SEF365H
[ill
SE F536H
EF & EC-147
TROUBLE
DIAGNOSES (Cont'd)
[ill
@-@
SEF332H
POWER TRANSISTOR
[ill
Check continuity between power transistor terminals. Terminal No. @ @ Tester polarity
EB
Continuity No
8 8
EB
@
SEF333H
Yes
@
@
EB
No
8 8
EB Yes
@
@
E.G.R. CONTROL VALVE Apply vacuum to E.G.R.vacuum port with a hand vacuum pump. E.G.R. control valve spring should lift.
SEF820F
B.P.T. VALVE Plug one of two ports of B.P.T. valve. Apply a pressure above 0.490 kPa (50 mmH20, 1.97 inH2O) to check for leakage. If a leak is noted, replace valve.
13
t
EC381A
EF & EC~148
TROUBLE
DIAGNOSES
Electrical Components Inspection (Cont'd) E.G.R. CONTROL SOLENOID VALVE, A.I.V. CONTROL SOLENOID VALVE, P.R. CONTROL SOLENOID- VALVE AND S.C.V. CONTROL SOLENOID VALVE Check air passages continuity.
Condition Air passage continuity between @ and @ Yes Air passage continuity between @ and @
@
SEF335H
No
terminals
No supply
CD
and @
No Yes
SENSOR
Check resistance change and resistance value at 100C (212F). Resistance should decrease in response to temperature increase. Resistance: 100C (212F) 85.3 :t 8.53 k n
THROTTLE SENSOR Make sure that resistance between terminals changes when opening throttle valve manually. Resistance should change.
and CD
FUEL PUMP Check continuity between terminals @ and @. Continuity should exist.
EF & EC-149
betweenterminalsCID and @
No supply
SEF537H
INJECTORS
Check injector resistance. Resistance: Approximately 10 15n Remove injector and check nozzle for clogging.
SWIRL CONTROL VALVE Supply vacuum to actuator and check swirl control valve operation.
Condition Swirl control valve
Close
Open
SEF371H
AIR REGULATOR
.
[ill
SEF339H
Check air regulator resistance. Resistance: Approximately 75 n Check air regulator for clogging.
SEF538H
A~ve'--GV
EF & EC-150
TROUBLE DIAGNOSES
. .
SEF381H
F.I.C.D. SOLENOID
VALVE
Check that clicking sound is heard when applying 12V dirct current to terminals.
SEF341H
L l:I"(~
Plunger
~
SEF342H
AIR INDUCTION VALVE Apply vacuum to vacuum motor, suck or blow hose to make sure that air flows only towards the air induction side.
IDLE SWITCH
terminals
@ and
Continuity
Yes
@ while
No
EF & EC-151
[:it
NEUTRAL SWITCH
[ill c;JJ
~~
Shift to Neutral
Shift to other position
INHIBITOR
SWITCH
SEF344H
INHIBITOR
RELAY
Check continuity between terminals @ and CD (Without A.S.C.D.), @ and @ (With A.S.C.D.). Continuity between terminals @ and @ (Without A.S.C.D.). @ and @ (With A.S.C.D.)
Condition
Battery
CD and
W (WithoutA.S.C.D.),
Yes
[ill
Battery
SEF348H
EF & EC-152
Fuel Pressure
Pressure regulator
Check
a. When reconnecting fuel line, always use new clamps. b. Make sure that clamp screw does not contact adjacent parts. c. Use a torque driver to tighten clamps. d. Use Pressure Gauge to check fuel pressure. e. Do not perform fuel pressure check while fuel pressure regulator control system is operating; otherwise, fuel pressure gauge might indicate incorrect readings. 1. Release fuel pressure to zero. 2. Disconnect fuel hose between fuel filter and fuel tube (engine side). 3. Install pressure gauge between fuel filter and fuel tube. 4. Start engine and check for fuel leakage.
SEF135H
5. Read the fuel pressure gauge indication. At idling: When fuel pressure regulator valve vacuum hose is connected. More than 226 kPa (2.3 kg/cm2, 33 psi) When fuel pressure regulator valve vacuum is disconnected. Approximately 294 kPa (3.0 kg/cm2, 43 psi) 6. Stop engine and disconnect fuel pressure regulator vacuum hose from intake manifold. 7. Plug intake manifold with a rubber cap. 8. Connect variable vacuum source to fuel pressure regulator.
EF & EC-153
vacuum changes.
Fuel pressure should decrease as vacuum increases. If results are unsatisfactory, replace fuel pressure regulator.
to
pressure regulator
SEF718B
. .
B.P.T. valve
EF & EC-154
Fuel tank
()
0~
Carbon canister
Q
..
: Air
: Fuelvapor
SEC544A
The evaporative emission control system is used to reduce hydrocarbons emitted to the atmosphere from the fuel system. This reduction of hydrocarbons is accomplished by activated charcoals in the carbon canister. The fuel vapor from the sealed fuel tank is led into the canister which contains activated carbon and the vapor is stored there when the engine is not running. The canister retains the fuel vapor until the canister is purged by the air drawn through the bottom of the canister to the intake manifold when the engine is running. When the engine runs at idle, the purge control valve is closed. Only a small amount of stored vapor flows into the intake manifold through the constant purge orifice. As the engine speed increases, and the throttle vacuum increases, the purge control valve opens and the vapor is sucked into the intake manifold through both the main purge orifice and the constant purge orifice.
Q@
@c)
Inspection CARBON CANISTER Check carbon canister as follows: @: Blow air and ensure that there is no leakage. @: Blow air and ensure that there is leakage.
EF &. EC-155
EVAPORATIVE
EMISSION Inspection
CONTROL (Cont'd)
SYSTEM
..
~
FUEL CHECK VALVE 1. Blow air through connector on fuel tank side. A considerable resistance should be felt and a portion of air flow should be directed toward the canister. 2. Blow air through connector on canister side. Air flow should be smoothly directed toward fuel tank. 3. If fuel check valve is suspected of not properly functioning in steps 1 and 2 above, replace it.
..
Air
Fuel vapor
SEC309A
\ l'
EF & EC-156
{t9t=R:/lL '--Seal
SEF156E
lBJ
.. C:?
..
Inspection P.C.V. (Positive Crankcase Ventilation) With engine running at idle, remove ventilation hose from P.C.V. valve; if valve is working properly, a hissing noise will be heard as air passes through it and a strong vacuum should be felt immediately when a finger is placed over valve inlet.
, '1
SEC137A
VENTILATION HOSE 1. Check hoses and hose connections for leaks. 2. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace.
ET277
EF &.
EC-157
(S.D.S.)
General Specifications
IGNITION TIMING
S.T.D.C.
rpm
M/T 750%50
15%2
IDLE SPEED
Inspection
,
and Adjustment
ENGINE TEMPERATURE SENSOR 20C (68F) Thermistor resistance k11 2.1 -2.9 IDLE SWITCH Engine speed when idle switch is changed from "OFF" to "ON" rpm FUEL PRESSURE at idling (Measuring point: between fuel filter and fuel pipe) Vacuum hose is connected kPa (kg/em' ,psi) Vacuum hose is disconnected kPa (kg/em' , psi) FUEL INJECTOR Coil resistance AIR REGULATOR Resistance EXHAUST GAS TEMPERATURE SENSOR 100C (212F) Therm istor resistance k11 85.3:t8.53 11 M/T A/T 0.30 - 0.33 80C (176F)
Approximately
10 15
11
Approximately 75
EF & EC-158
FE
~~I~~~~!~
FUEL SYSTEM '... EXHAUST SYSTEM
SYSTEM
, .
FE-2
FE-3 FE-4
. . . . .
Lock nut
tOJ 8
- 11 (0.8 -1.1,5.8
- 8.01
-8.01 A.S.C.D. actuator
tOJ3 -4
~-.
o:~
Locknut
tOJ 8 12 (0.8 -1.2, 5.8 -8.7) Adjusting nut Accelerator wire bracket Accelerator pedal
Throttle drum
SFE012A
FE-2
FUEL SYSTEM
WARNING: When replacing fuel line parts, be sure to observe the following:
. Put a "CAUTION: INFLAMMABLE" sign in workshop. . Do sure smoke while servicing fuel system. Keep open flames and sparks away from work area. not . Be to disconnect battery ground cable before conducting operations. . Put drained fuel in an explosion-proof container and put licit on securely. CAUTION: . For electric fuelFilter Replacement" in disconnecting fuel hose, release fuel pressure from fuel line. pump model, before Refer to "Fuel MA section. . Do not disconnect any fuel lineto unless absolutely dust or dirt. necessary. . Plug hose and pipe openings prevent entry of . Always replace O-ring and clamps with new ones. . Do not kink or twist hose and tube when they are installed. . Do not tighten hose clamps excessively to avoid damaging hoses. . Whenengine and fuel check leaks at connections. its designated direction. (Refer to section EF & EC.) . Run installing check for valve, be careful of
tDJ 2.0 - 2.5 10.20 - 0.26'
1.4 -1.9)
:"i
~~~
I
A
I
L!
"-tDJ
!
26 -36 12.7 -3.7,20 -27) tDJ : N.m (kg-m, ft-Ib) SFE013A
FE-3
EXHAUST SYSTEM
CAUTION:
.
. .
Always replace exhaust gaskets with new ones when disassembling. Check all tube connections for exhaust gas leaks, and entire system for unusual noises, with engine running. After installation, check that mounting brackets and mounting Insulator are free from undue stress. If any of above parts are not installed properly, excessive noise or vibration may be transmitted to vehicle body.
Catalytic
conve'rter
13-16(1.3-1.6,9-121
SFE014A
FE-4
CLUTCH I SECTION
CL
CL- 2
CONTENTS
PRECAUTIONSAND PREPARATION
CLUTCH SYSTEM INSPECTION AND ADJUSTMENT
,
HYDRAULICCLUTCH CONTROL
CLUTCH RELEASE MECHANISM CLUTCH DISC AND CLUTCH COVER SERVICE DATA AND SPECIFICATIONS (S.D.S.)
III
. .
.
~
GG9431 0000 (
. . .
Recommended fluid is brake fluid "DOT 3". Never reuse drained brake fluid. Be careful not to splash brake fluid on painted areas. When removing and installing clutch piping, use Tool.
) SBR500
WARNING:
After cleaning the clutch disc, wipe it with a dust collector. Do not use compressed air,
. -,:,
~
., :',
, ,
.
t"'
. - ~"., . ,
~'::..
"
,.- :
@~
\!II
~m .
-@:j
-~
==-p
Installing clutch cover and clutch disc
~
~ ~
CL-2
SERVICE TOOLS
Description
Bearing drift
~
a~
a: 50 mm (1.97
in) dia.
In".mn, "I
be,,;n,
CL-3
~ ~f
c
,~
r~
16- 22
h ~
~~8-11
~ ~-,
1/
~ ~ ~
----",. '~
~ . Clutch switch
12-15 (1.2-1.5,9-111 . Pedal stopper
-~
16-22(1_6-2.2,1
Clutch switch
Pedalstopper
0
I
r~
c'"";, p;" m~-//
Release bearing
Clutch pedal
EI(b)
III (')
.A:
r to) en I\)
Lock nut
- 11
1/
~ . Clutch switch
.-
~' , "-
1. Adjust pedal height with pedal stopper or clutch switch. Pedal height "H": 186 - 196 mm (7.32 - 7.72 in) 2. Adjust pedal free play with master cylinder push rod. Then tighten lock nut. Pedal free play "A": 1.0 - 3.0 mm (0.039 - 0.118 in) Pedal free play means the following total measured at position of pedal pad: Play due to clevis pin and clevis pin hole In clutch pedal.
. .
- U.S.A. model only 3. Adjust clearance "C" between pedal stopper rubber and threaded end of clutch interlock switch while depressing clutch pedal fully. Clearance C: 1.0 - 2.0 mm (0.039 - 0.079 in)
SCL274
CL-5
SCL288
6. Repeat steps 3 through 5 above until brake fluid flows from air bleeder valve without air bubbles.
SCL203
CL-6
Return spring
Piston assembly
Reservoir
cap
Reservoir
EI @
Rubbing
Dust cover
lEI @
Packing . Apply brake fluid when assembling. Stopper ring
Valvestopper
1.6 - 2.9 (0.16 - 0.3,1.1 - 2.21 . Remove this stopper, when removing piston and return spring.
EI
DISASSEMBLY AND ASSEMBLY Push piston into cylinder body with screwdriver when removing and installing valve stopper.
. .
IJJJ.JJJJJJJJJj
Align groove of piston assembly and valve stopper when installing valve stopper. Check direction of piston cups.
em
--
--
~11J)
Groove
n
SCL214
CL-7
. . . . .
Check cylinder and piston rubbing surface for uneven wear, rust or damage. Replace if necessary. Check piston with piston cup for wear or damage. Replace if necessary. Check return spring for wear or damage. Replace if necessary. Check reservoir for deformation or damage. Replace if necessary. Check dust cover for cracks, deformation or damage. Replace if necessary.
Operating Cylinder
Piston assembly
~ l
. . . .
~I Operating
lEI @
Piston spring
Piston cup
IEI@
lEI @ :
INSPECTION Check rubbing surface of cylinder for wear, rust or damage. Replace if necessary. Check piston with piston cup for wear or damage. Replace if necessary. Check piston spring for wear or damage. Replace if necessary. Check dust cover for cracks, deformation or damage. Replace if necessary.
CL-8
~~I[';:':
~
~
Damper rubber
Damper cover
\\ \ \
Spring
L Bleeder screw
lEI @
~ ..,.,
@
Piston cup EI
,.o.U-721
EI @
EI
INSPECTION Check cylinder and piston rubbing surface for uneven wear, rust or damage. Replace if necessary. Check damper rubber and piston cup for cracks, deformation or damage. Replace if necessary.
. .
CL-9
:;:d'~"7 r~~~:~?~
m(Q
m(Q
---
~ ~
~-.
~
~
10
.J -~-
c;7 ;6e:z . ~
'
Release sleeve Release bearing
m (b):
-~
-.
(')
~~!)
U)o///~..
SCL217
CL145
.
Drift
with suitable
drift.
SC L222
CL-10
. .
Check release bearing to see that it rolls freely and is free from noise, cracks, pitting or wear. Replace if necessary. Check release sleeve and withdrawal lever rubbing surface for wear, rust or damage. Replace if necessary.
LUBRICATION
Apply recommended grease to contact surface and rubbing surface. Too much lubricant might damage clutch disc facing.
Pack this recess
IEEI(!): Apply
mOlybdenum
CL-11
jJ
:
~
sa I E
C') ci
Clutch Disc INSPECTION Check clutch disc for wear of facing. Wear limit of facing surface to rivet head: 0.3 mm (0.012 in)
SCL229
.
SCL221
Check clutch disc for backlash of spline and runout of facing. Maximum backlash of spline (at outer edge of disc): 0.9 mm (0.035 in) Runout limit: 1.0 mm (0.039 in) Distance of runout check point (from hub center): 107.5 mm (4.23 in) Check clutch disc for burns, discoloration or oil or grease leakage. Replace if necessary.
INSTAllATION
portion. Too much lubricant
CL-12
. .
AND ADJUSTMENT
. .
A
Set Tool and check height and unevenness of diaphragm spring. Diaphragm spring height "A": 33.0 - 35.0 mm (1.299 - 1.378 in) Check thrust rings for wear or damage by shaking cover assembly and listening for chattering noise, or lightly hammering on rivets for a slightly cracked noise. Replace clutch cover assembly if necessary. Check pressure plate and clutch disc contact surface for slight burns or discoloration. Repair pressure plate with emery paper. Check pressure plate and clutch disc contact surface for deformation or damage. Replace if necessary.
SCL219
ST20050240
Adjust unevenness of diaphragm spring with Tool. Uneven limit: 0.7 mm (0.028 in)
FLYWHEEL INSPECTION
Flywheel
. .
Check contact surface of flywheel for slight discoloration. Repair flywheel with emery paper. Check flywheel runout. Runout (Total indicator reading): Less than 0.15 mm (0.0059 in)
burns
or
SCL349
INSTAllATION
/(c) ~
Q)J
Insert Tool into clutch disc hub when installing clutch cover and disc.
CL-13
CLUTCH CONTROL
Type of clutch control
SYSTEM
Hydraulic
CLUTCH DISC
Model Facing size (Outer dia. x inner dia. x thickness) mm (in) 15.87 (5/8) Thickness of disc assembly With loed mm (in) 225 LTD
225 x 150 x 3.5 (8.86 x 5.91 x 0.138)
mm (In)
CLUTCH OPERATING
. Inner diameter mm (In)
CYLINDER
17.46 (11/16)
CLUTCH COVER
Model C225S N (kg,lb) 4.413 (450,992)
CLUTCH DAMPER
Inner diameter mm (in) 19.05 (3/4)
Fuilioed
CLUTCH COVER
Unit: mm (in) Model
Diaphragm spring height
186.196
(7.32.7.72)
Clearence between pedel stopper rubber and threeded end of clutch interlock
0.7 (0.028)
1.0-2.0 (0.039.0.079)
CLUTCH DISC
Unit: mm (In) Model Wear limit of facing surface to rivet heed Aunout limit of facing Distance of runout check point (from the hub center)
Maximum beck lash of spline (at outer edge of disc)
0.9 (0.035)
CL-14
MT
MT- 2 MT- 4 MT- 5 MT- 6 MT- 9 MT-14 MT-16 MT-26
CONTENTS
PREPARATION ON-VEHICLE SERVICE REMOVAL AND INSTAllATION... MAJOR OVERHAUL DISASSEMBLY INSPECTION ASSEMBLY SERVICE DATA AND SPECIFICATIONS (S.O.S.) ""'"''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''
PREPARATION
SPECIAL SERVICE TOOLS
Tool number (Kent-Moore No.) Tool name
ST2381 0001
(
Description
KV31100401
(
w ~
~
~
'Or;",~ mm 11.50.' do. I
::: :mm (1.30 in)dia.
9 ~
..
VW . ..
Pressing counter gear and mainshaft
Removing and installing 1st gear bushing Removing main drive gear bearing Measuring wear of baulk rings
ST23860000 ( ) Drift
MT-2
PREPARATION
Tool number (Kent-Moore No.) Tool name ST33400001 (J26082) Drift
Description
~
~
r~7mmC3'.3;")d'"
~
ST30720000 ( ) Drift
LS
iJ
Installing counter rear bearing Installing 3rd & 4th synchronizer assembly
Description
Puller
;!V/
MT-3
ON-VEHICLE SERVICE
INSTAllATION
----
Continuity Yes
No
NEUTRAL SWITCH
Check continuity.
Gear position Neutral Except neutral Continuity Yes
No
SMT384B
O.D. SWITCH
Check continuity.
Continuity Yes No
MT-4
~ ~
Removal
. . .
.
. . .
Remove propeller shaft. - Refer to section PD. Insert plug into rear oil seal after removing propeller shaft. Be careful not to damage spline, sleeve yoke and rear oil seal, when removing propeller shaft. Support engine by placing a jack under oil pan. Do not place jack under oil pan drain plug. Remove transmission from engine. Support manual transmission, while removing it.
Installation
~
@
SMT381 B
MT-5
r4 Thread
of bolts
3:
I
-I
~
C/)
s: -i w
to
(II to
---------------------
~
Main drive gear
'ftJ}~J
sh''''n''n~7i~-J .j "
m
Steel roller
,/
~ \~~3ro&4Oh
1
~'
<oooUn, .I,~ synchronizer hub -(:r 3rd & 4th Spread sprin g
'.
[
~' ballr/~
/ ~'l
M,'",h."
main
lu -,
j"'
r.:>.
gear ~
/ (~
~
I
,
mOUWMh"
,- M,,",hof.b,II bw'...
~1
ring (~)~J
2nd outer baulk ring Synchronizer cone 2 n d Inner baulk
~
~ ~~
'0
jI
I
(
,
,
/
~
M
r'/
~
Ins~rt ""on.
"'.JY
\
N d
~
~
~
"
N"dI,""''''
IU & 2n'
~
//
"'"'
" "
;J
,
~
' "
synchronizer
hub-(:r - ~ :\
~~ ~
'
,"~
R)
0.0
~ ~
l\\f'\' \J
main gear
I
~~MainShaftIOC~
Thrust
;?j~) 1 '
~~'
~= ~~~'
~Q
.
Snap ring
Snapring*
(W
~ " ""
washe
n 137.'.7 ."
r
Countershaft
'
~\1
-
10.0. 13.0,
72.941
/"<
In~ ffi1a'n"
j
'
W oo'ru" k"
.-; I~
'oJ'
. -'
'>/
ffinn' r
in.
~',"", I
~~\ )j \
Coon'" .h,,, J front bearing Snap r',n,
* ~ ""
\\; \(
S
~
,
.Y L
'- R
t..
~,~y geer oil .h." idl" P synchronizers, to geers ,~heft., .end be Ap I S e Iect with * :
_mbllng.
", : Payatt ,proper thickness. I'n'I : N'm (k g-m, ft-Ib)"''''' d' Irectlon. entlon to its WhM . SMT037B
MT-7
spring plug
of bolts
Thread
~
~
RM"';~~??\
If)
Returnspring
'i
Select check plunger
Striking arm J
rr@
Lockpin <::A
/'
I ~I
Striking lever
r ~/ ;:
\
\~
~ ~
1
CII"" "",..
., ( "V"@@
s:
I
-I
00
tDJ 9.12',9.'..,
2 ...8.7
~
~
~
~,
""C'
CII",' boil 1.
D TII,.., ofbo",
@. /
~; "2.0
i1 I
~
\
R...,";~ pl.
C.."o' 110..'..--\ \
Spring
Interlock plunger
Retainingpin ~/
~ ~
3rd & 4th fork rod ~
'6."", ,..,d
~
a.D. & reverse shift fork
"";
~
~
~\Y/~~
a.D. & reverse fork rod
49 59 (5 - 6, 36 - 431
~ ~T~
II) s: -I w C '-I C
~/
~:
f.4
: Ap ge eq
SMT982
Soft hammer
SMT320B
:r
2. Remove front cover, gasket, shim of countershaft front bearing, and snap ring of main drive gear ball bearing.
')
//
0~
SMT011
TM753
,. ~.
SMT035
MT-9
ST2381 0001 ( )
TM754
3. Drive out retaining pins. Then drive out fork remove interlock balls.
ST23540000 (J25689-A)
rods and
""
SMT984
MT -1 0
.~ SMT792A
_1
~
Gear
Mainshaft
EndPlaY
Gear Components
1. Before removiQg gears and shafts, measure each gear end play. Gear end play: Refer to S.D.S. If not within specification, disassemble and check contact surface of gear to hub, washer, bushing, needle bearing and shaft.
bushing
or
~, ~
SMT025
2. Mesh 2nd and reverse gear, then draw out counter front bearing with suitable puller. 3. Remove snap ring and then remove sub-gear bracket, sub-gear spring and sub-gear.
Suitable
puller SMT174A
4. Draw out counter drive gear with main drive gear assembly with suitable puller. When drawing out main drive gear assembly, be careful not to drop pilot bearing and baulk ring.
a. Release staking on countershaft nut and mainshaft nut and loosen these nuts. Mainshaft nut: Left-hand thread
MT -11
DISASSEMBLY Gear Components (Cont'd) b. Pull out 0.0. counter gear with bearing with suitable puller. c. Draw out reverse counter gear and spacer. d. Remove snap rings from reverse idler shaft and draw out reverse idler gear, thrust washers and reverse idler gear bearing. e. Remove speedometer drive gear and steel ball.
Suitable puller
f. g. h. i. j. k.
Remove snap ring and pull out overdrive mainshaft bearing, then remove snap ring. Remove mainshaft nut. Remove steel roller and washer. Remove roller bearing and washer. Remove 0.0. main gear, needle bearing and baulk ring (0.0.). Remove 0.0. coupling sleeve, shifting inserts and shifting insert springs.
SMT040B
I. Press out mainshaft and counter gear alternately. Make sure to alternate pressing of mainshaftand counter gear so as not to allow the frontsurface of one to contact the rear surface of the other.
SMT751A
6. Remove front side components on mainshaft. a. Remove 1st gear washer and steel ball. b. Remove 1st main gear and 1st gear needle bearing.
c. Press out 2nd main gear together with 1st gear bushing and 1st & 2nd synchronizer assembly. d. Remove mainshaft front snap ring.
ST30031000 (J22912-01 )
SMT384A
MT-12
SMT385A
7. Remove main drive gear bearing. a. Remove main drive gear snap ring and spacer. b. Press out main drive gear bearing.
SMT420A
MT -13
INSPECTION Shift Control Components Check contact surface and sliding surface for wear, scratches, projections or other damage.
SMT137
Gear Components
GEAR AND SHAFT
. .
Check shafts for cracks, wear or bending. Check gears for excessive wear, chips or cracks.
SYNCHRONIZERS
. .
. .
t
SMT387A
Check spline portion of coupling sleeves, hubs and gears for wear or cracks. Check baulk rings for cracks or deformation. Check shifting inserts for wear or deformation. Check insert springs for deformation.
MT -14
Clearance between baulk ring and gear (1st, 3rd, main drive and O.D. baulk ring):
Dimension 1st
3rd and main drive
SMT140
(Cont'd)
Standard 1.2 - 1.6 (0.047 - 0.063) 1.2 - 1.6 (0.047 - 0.063) 1.2 - 1.4 (0.047 - 0.055)
0.8 (0.031)
a.D.
If the clearance is smaller than the wear limit, replace baulk ring.
ST30031000
~~r
~
B 2nd outer baulk ring
Measure wear of 2nd baulk ring. a. Place baulk rings in position on synchronizer cone. b. While holding baulk rings against synchronizer cone as far as it will go, measure dimensions "A" and "B"
Unit: mm (in) Dimension A Standard 0.6 - 1.1 (0.024 - 0.043) 0.2 (0.008) B 0.7 - 0.9 (0.028 - 0.035) Wear limit
(J22912-01) SMT041 B
Feeler gauge
!5"
""
Synchronizer cone
SMT042B
BEARINGS
Make sure bearings roll freely and are free from noise, crack, pitting or wear.
SMT418A
MT -1 5
ASSEMBL Y
Mainshaft ball bearing in adapter plate
Gear Components
1. Install bearings into case components.
)
lJ')
ST30720000
(
~"-
2. Assemble adapter plate parts. Install oil gutter on adapter plate and expand on rear side.
Upper
~
Front
'*
Install bearing retainer. a.. Insert reverse shaft, then install bearing retainer.
SMT028
MT-16
c. Select proper main drive gear snap ring to minimize clearance of groove and install it. . Allowable clearance of groove: 0 - 0.13mm (0 - 0.0051 In) Main drive gear snap ring: Refer to S.D.S.
SM T 426A
1 ~Insert
spring
H
Hub Ind coupling .leeve
CoupJ.ing sleeve
Front.id.
SMT045B
MT -1 7
SMT046B
SMT047B
.
Coupling sleeve Synchronizer hub
/
(
- -, ,
I
Shi~t~g}l!sert
0.0. synchronizer
SMT095A
5. Install front side components on main shaft. a. Assemble 2nd main gear, needle bearing and 1st & 2nd synchronizer assembly, then press 1st gear bushing on mainshaft. b. Install 1st main gear.
SMT752A
MT -1 8
SMT403A
6. Install mainshaft and counter gear on adapter plate and main drive gear on mainshaft. a. Press mainshaft assembly to adapter plate with Tool.
KV31100401 ( )
TM439
I
ST33200000 (J26082)
I
b. Press counter gear into adapter plate with Tool. c. Install 3rd main gear and then press 3rd & 4th synchronizer assembly.
KV31100401 ( )
\\
.
Coupling sleeve Synchronizer hub
/ r
- --,
, I
Shi!ti~9_il}sert
d. Install thrust washer on mainshaft and secure it with mainshaft front snap ring. Select proper snap ring to minimize clearance of groove in mainshaft. Allowable clearance of groove: 0 - 0.18mm (0 - 0.0071 in) Mainshaft front snap ring: Refer to S.D.S. e. Apply gear oil to mainshaft pilot bearing and install it on mainshaft.
TM441
MT -1 9
KV311OO401 ( ),
TM442
Front.
SMT620A
g. Install sub-gear components. (1) Install sub-gear and sub-gear bracket on counter drive gear and then select proper snap ring to minimize clearance of groove in counter gear. Allowable clearance of groove: 0 - 0.18mm (0 - 0.0071 In) Counter drive gear snap ring: Refer to S.D.S. (2) Remove snap ring, sub-gear bracket and sub-gear from counter gear. (3) Reinstall sub-gear, sub-gear spring and sub-gear bracket. h. Install selected counter drive gear snap ring.
TM366
i.
ST22360002 (J25679-01 )
KV311OO401 ( )
TM443
MT-20
Front
L-~
TM451
b. Install insert retainer and 0.0. synchronizer to mainshaft. Pay attention to direction of hub.
SMT095A
Gear bushing
c. Install 0.0. gear bushing with Tool. d. Install 0.0. main gear and needle bearing. e. Install spacer, reverse counter gear and 0.0. counter gear. O.D. main gear and O.D. counter gear should be handled as a matched set. f. Install washer, roller bearing, steel roller and thrust washer. g. Tighten mainshaft lock nut temporarily. Always use new lock nut.
. .
SMT531
SMT043
8. Mesh 2nd and reverse gears, then tighten mainshaft lock nut with Tool.
ST22520000 IJ263481
SMTOO3A
MT - 21
ASSEMBLY
Tool Torque wrench
Use the left chart when deciding the reading torque. (Length of torque wrench vs. setting or reading torque) 9. Tighten countershaft lock nut. . Always use new lock nut.
L m (ft)
(kg-m) 157
(16) 147 (15) 137
'" ::J
c-
'" '" a:
(100)
(14)
.
SMTOO4A Mainshaft (1.5) L: Length
0.6
0.7
I
0.8 m
(2.0) of torque
Countershaft
11. Measure gear end play. For the description, ASSEMBLY for Gear Components.
1. Install shift rods, interlock plunger, interlock balls and check balls.
SMT992
SMT989
MT-22
SMT990
c. a.D.-reverse
SMT991
2. Install 0.0. and reverse fork shaft by rotating 0.0. and reverse bracket clockwise.
SMT791 A
MT-23
SMT036
SMT013
MT-24
7. Select counter front bearing shim. Counter front bearing shim: Refer to S.D.S. 8. Install gasket and front cover.
9. Install return spring plugs, check ball, return springs and select check plunger. 10. Install control housing and gasket.
SMT982
MT-25
(S.D.S)
FS5W71C 5
I
4
.
Synchromesh type Gear ratio 1st 2nd 3rd 4th O.D. Reverse
I.
Warner 3.321 1.902 1.308 1.000 0.759 3.382
Drive 1st 2nd 3rd O.D. Reverse Drive 1st 2nd 3rd O.D. Reverse
Countershaft
Reverse idler gear Oil capacity Q (US pt, Imp pt) Sub-gear Mainshaft braking mechanism Double baulk ring type synchronizer
Remarks
2nd synchronizer
MT-26
Mainshaft front
Allowable clearance Thickness mm (in) 2.4 (0.094) 2.5 (0.098) 2.6 (0.102) 0 -0.18 mm (0 -0.0071 in) Part number
32263-V5200 32263-V5201 32263-V5202
Part number
32228-20100 32228-20101 32228-20102 32228-20103
Standard 1st 3rd and main drive 1.2-1.6 (0.047 - 0_063) 1.2 - 1.6 (0.047 - 0.0631
Wear limit
0.8 (0.031)
AVAILABLE SHIMS
Inner baulk ring Synchronizer cone Dimension A Standard 0.6 - 1.1 (0.024 - 0.043) 0.2 (0.008) B
SMT0448
Unit:
mm (in)
Wear limit
0.7 - 0.9
(0.028 - 0.035)
Thickness mm (in)
1.73 1.80 1.87 1.94 2.01 2.08 (0.0681) (0.0709) (0.0736) (0.0764) (0.0791) (0.0819)
Part number
32204-78005 32204-78000 32204-78001 32204-78002 32204-78003 32204-78004
-4.51 (0.1740 -4.41 (0.1701 -4.3110.1661 -4.21 (0.1622 -4.11 (0.1583 -4.01 (0.1543
MT-27
AUTOMATIC TRANSMISSION
SECTION
/
/
AT
2 3
CONTENTS
PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-. . . . . . . . . . . . . . . . . . . .. ATPRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ATAfT CONTROL DIAGRAM TROUBLE DIAGNOSES REMOVAL AND INSTALLATION MAJOR OVERHAUL AT4
"
AT-165
When you read wiring diagrams: Read GI section, "HOW TO READ WIRING DIAGRAMS". See EL section, "POWER SUPPLY ROUTING.. for power distribution circuit. When you perform trouble diagnoses, read GI section, "HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES".
. .
Description
/CD
ST25051 001
( ) Oil pressure gauge
@ ST25052000
( )
'
U!!
"
~.:.
~ ~ ---@
CID
Hose
CID
ST25053000
o/~~
Disassembling and assembling AfT Checking one-way clutch in torque converter
Adapter
ST25055000
( Adapter
KV31102100 (J37065) Torque converter oneway clutch check tool ST25850000 (J25721-A) Sliding hammer
~
~, 0
Installing oil pump housing oil seal Installing rear oil seal
Ir;==:J
1?1/li ~~
~T~t~~
AT-2
Selecting oil pump cover bearing race and oil pump thrust washer
. . . . .
Before proceeding with disassembly, thoroughIy clean the outside of the transmission. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter. Disassembly should be done in a clean work area.
.
.
It is very important to perform functional tests. whenever they are indicated. The valve body contains precision parts and requires extreme care when parts are removed and serviced. Place removed parts in order on a parts rack so they can be put back in the valve body in the same positions and sequences. Care
. .
becoming scattered or lost. Properly installed valves, sleeves, plugs,~ will slide along their bores in the valve body under their own weight. Before assembly, apply a coat of recommended A.T.F. to all parts. Petroleum jelly may be applied to O-rings and seals and used to hold small bearings and washers in place during reassembly. Do not use grease. Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling. After overhaul, refill the transmission with new A.T.F.
AT-3
I
Lock-up solenoid
/'011 [cooler
g
Servo changer valve Modifier accunlulator
L'
lubrlcalion
/;;;'t
converter
relielvalve
~~~,~
i
,
,'
~
~
I
L~r
lubrication
I~'ve
m,
~~
II"Lr-
Ii
Ii
'-
I=;
J lIT:Jill:JUL ~~~~
J[
--
II=::II"
1 1 1 I I I I I I I I I I ,
~:~
I Pilot valve Line pressure solenolo
r
II ~
PRND21 "~"
--'~
USh~
solenOIOB
-J~
1m;~~oiO A Z Overrun
solenoid
I I I I
I/)
w
r~
'Manual valve
~
Co)
-- -
x
n --
~~-
Vehicle signal Speed sensor Overdrive switch Kickdown switch Power supply Engine AfT
Control signal'
Idle switch
Full-throttle
- - - - _.~
SAT8178
Mechnical Operation
Band servo Shift position Reverse clutch High clutch Forward clutch Overrun clutch 2nd apply 3rd re lease 4th apply Forward one-way clutch Low one-way clutch Low & reverse brake Lock-up Remarks
p R
PARK
0
1st
REVERSE NEUTRAL
D
*4
2nd
3rd
.,
0
*20
*30
. . .
0
0
0
0
0
0
0 0
Automatic shift
1-2-3-4
4th
2
1
1st 2nd
1st
2nd
*
0 0
0 0 0
0 0
. . .
.
0
0
Automatic shift
1-2
speed 1 ..... 2
*2. Oil pressure is applied to both 2nd "apply" side and 3rd "release" side of band servo piston. However, because oil pressure area on the "release" side is greater than that on the "apply" side, brake band does not contract. *3. Oil pressure is applied to 4th "apply" side in condition *2 above, and brake band contracts. *4. A/T will not shift to 4th when overdriveswitch isset to "OFF" position.
.
0
. Operates.
. Operates when throttle opening is less than 1/16. Engine brake activates.
. Operates during "progressive" acceleration. . Operates but does not affect power transmission. . Operates4l/llhen throttle opening is less than 1/16 but does not affect engine brake.
AT-5
/~
Lock-up
piston
Torque
Transmission case
~
I
0)
\00 \0
\
010
0
en :I> j
I\J C1 III
Input shaft
Oil pumlJ
Control
valve
Outpu
ON-VEHICLE SERVICE
3. Remove control valve assembly by removing fixing bolts and disconnecting harness connector.
Bolt length and location Bolt symbol @ @ Length mm (in) 37 (1.46) 50 (1.97)
""
4. Remove solenoids and valves frbm valve body if necessary. 5. Remove terminal cord assembly if necessary.
6. Remove accumulator A, S, C and D by applying compressed air if necessary. Hold each piston with rag. 7. Reinstall any part removed. Always use new sealing parts.
. .
AT-7
ON-VEHICLE SERVICE
3. Remove revolution sensor from AIT assembly. 4. Reinstall any part removed. Always use new sealing parts.
3. Install rear oil seal. Apply A.T.F. before installing. 4. Reinstall any part removed.
'\
AT-8
SAT133B
4. Insert pin into adjustment holes in both inhibitor switch and manual shaft of AIT assembly as near vertical as possible. 5. Reinstall any part removed. 6. Check continuity of inhibitor switch. - Refer to "Electrical Components Inspection".
,\
--1\
SAT081B
3. Tighten lock nut @ until it touches trunnion pulling selector lever toward "R" range side without pushing button. 4. Back off lock nut @ 1 turn and tighten lock nut (!) to the specified torque. Lock nut: ~: 11 - 15 N.m (1.1 - 1.5 kg-m, 8 - 11 ft-Ib) 5. Move selector lever from "P" range to "1" range. Make sure that selector lever can move smoothly.
Lock nut (!) Luck nut @ SAT788B
AT-9
ON-VEHICLE SERVICE
NOTE
AT-'O
AT-11
(Cont'd)
AT-59
AT-60
Diagnostic Procedure 16
(SYMPTOM: (SYMPTOM:
to "OFF"
Vehicle Vehicle
Diagnostic Procedure 17
does not shift from D4 on D3 when changing
""""""""""" "'"'''''''''''''''''''''''''''' position.)
AT-'60
Diagnostic Procedure 18
(SYMPTOM:AfT does not shift from D3on D2when changing selector lever
from" D" to "2" range.) """""""""" """'''''''' ""'''''''''''''''''''''' """"""""""
AT-61
Diagnostic Procedure 19
(SYMPTOM: Vehicle does not shift from 22 on 11when changing selector lever from "2" to ",1" range.) """" Diagnostic Procedure 20 (SYMPTOM: Vehicle does not decelerate by enigne brake when shifting from 22 (12) to 1,.) AT-61 AT-61 AT-62 . AT-68
,
Inspection
"""""""""""""""
""""""'" """"""""'" "" """"""""""""""
,.
AT-72 AT-75
AT-75 AT-76 AT-77
\
AT-78
(SYMPTOM: Ignition key cannot be removed when selector lever is set to "P" position or LOCK removed UNIT INSPECTION SHIFT can be CONTROLwhen selector lever is set to any position except "P".) SHIFT LOCK CONTROL UNIT INSPECTION TABLE COMPONENT CHECK
'"''''''''''''''''''''''''''''''''
\
'"''''''''
AT-84
AT-12
TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accura,e Repair WORK FLOW
CHECK IN
<
Reference item
LEVEL
r-----I
I I I I I I I I
--
--~I
. .
I I I I I I I I I I I I I I
I
REPAI R/REPLACE.
L- --------N.G.
FINAL CHECK
AT-13
TROUBLE DIAGNOSES
Preliminary Check
~ ~Q
,
81
~~
e
SAT767B
for example, mating surface of converter housing and transmission case. 2. Start engine, apply foot brake, place selector lever in "0" range and wait a few minutes. 3. Stop engine.
SAT801A
SA T638A
AT-14
0
I
2. Check at idle.
0
I
3. Cruise test.
SAT786A
. .
Before road test, familiarize yourself with all test procedures and items to check. Conduct tests on all items. Troubleshoot items which check out No Good after road test. Refer to "Self-diagnosis" and "Diagnostic Procedure".
SA T639A
AT-15
TROUBLE DIAGNOSES
--
0
Park vehicle on flat surface.
SAT787A
fA
Move selector lever to "P" range.
fA
fir:)
~
IJ .
SA T768B
Does O.D. OFF indicator lamp. come on for about 2 seconds? Yes Does O.D. OFF indicator lamp flicker for about 8 seconds?
I
No
~
SAT836B
a:J\
AT-16
2. Check at idle
0
Park vehicle on flat surface.
6
SA T787 A
Is engine started?
Yes
NI
SAT7698
BJ
II II
Move selector lever to "P" range.
SA T7688
~
Yes
Does vehicle move when it is pushed forward or backward? I No
Go to DiagnosticProcedure 3.
SAT796A
AT-17
~
I
SAT771B
fJ
Brake peda I
~
."';"";"
~t,ST
~
I
~
Yes I Go to Diagnostic Procedure 4.1
SA T797 A
fJ
m
[NO
Yes
Is there large shock when changing from "N" to "R" range?
I
m
SAT772B
No
Brake pedal
Go to Diagnostic Procedure 6.
iii]
Yes
Move selector lever to "D", "1" and "2" range and check if vehicle creeps forward.
iii]
I
SAT773B
AT-18
TROUBLE DIAGNOSES
AfT control~it
~ ~
terminal
\Atfull
Preliminary Check (Cont'd) 3. Cruise test Check all items listed in Parts 1 through 3. Throttle position can be controlled by voltage across termi-. nals (jJ)and @ of AfT control unit.
. .
\throttleopen
~~I.J~
SAT802A 0
Cruisetest - Part 1 0
Warm up engine until engine oil and A.T. F. reach operating temperature after vehicle has been driven approx. 10 minutes. A.T.F. operating temperature: 50 80C (122 176F)
SAT779A
II
i]
II
Set overdrive switch to "ON" position.
-.
SAT7748
II
~
II
Move selector lever to "D" range.
m
Accelerate vehicle by constantly depressing accelerator pedal halfway.
SAT7758
Go to Diagnostic Procedure 8.
SA T803A
AT-19
6
'll N II
m ,...Does AfT shift from D1 to D2 at the specified speed? Specified speed when shifting from D1 to D2: Refer to Shift schedule. . Yes Does AfT shift from D2 to D3 at the specified speed? Specified speed when shifting from D2 to D3 : Refer to Shift schedule.
No Go to Diagnostic Procedure 9.
6
0/8 .. , .. SA T804A
Nb
m
8/811 II
IU
?l
0/8
~~
l~ ~I
m .
Yes
~l
SAT805A
Does AfT shift from D3 to D4 at the specified speed? Specified speed when shifting from D3 to D4 : Refer to Shift schedule.
Yes
No Go to Diagnostic Procedure 12.
IEm
Does AfT perform lock-up at the specified speed? Specified speed when lock-up occurs: Refer to Shift schedule. , Yes
~
0/8
81) T------------0
1
SA T806A
IE m
I Yes
IE II]
8/8
~
...(" I I I
8,
I ,..,.."
'I _..?l
" ,..'"
0/8
O~O
("--
--- --
,..-----
'I)
~) SA T807 A
IE
I
.I Yes
II]
Does engine speed return to idle smoothly when AfT is shifted from D4 to D3 ? Yes
No Go to DiagnosticProcedure 15.
Stop vehicle.
I
Part 2".
I Go to "Cruise test
AT-20
Check (Cont'd)
Part 2
SA T803A
Hlilf-way
0 .
/
Accelerate vehicle by half throttle again.
8/8
No
6
0/8
Yes
SAT808A
II
Accelerato~ pedal
II
8/8
O ta O-.!.:T 21 W
/
II
Does AfT shift from D4 to D2 as soon as accelerator pedal is depressed fully?
/ Depress fully
No
Go to Diagnostic Procedure 9.
Release
.!}
/.
Release
m
8/81,
Does AfT shift from D2 to D3 at the specified speed? Specified speed when shifting from D2 to 03 : Refer to Shift schedule. Yes
------
6
SAT810A
Does AfT shift from D3 to D4 and does vehicle decelerate by engine brake? Yes
[;)6
II Accelerator pedal
Stop vehicle.
03
~ 04
I
Go to "Cruise test
Part 3".
0/8 S~
~s
SATB11A
AT-21
TROUBLE DIAGNOSES
.0
SAT812A
Confirm overdrive switch is in "ON" position. Confirm selector lever is in "D" range.
Accelerate vehicle using halfthrottle to D4.
fA
.'-
fA
Release accelerator pedal.
I]
Set overdrive switch to "OFF" position while driving in D4 range.
II
I
No
~
m
+-
I]
( D3 (O.D. OFF))
Yes Moveselector lever from "D" to "2" range while driving in D3.
6
I
~ Yes
Does AfT shift from D3 to 22 ?
"ED
G)
Engine brake
SAT776B
m m
Yes
6(;]
Does vehicle decelerate by engine brake? Yes Move selector lever from "2" to
CD3 (0.D.OFF0
@
SAT777B
. "1" range while ~riving in 22, II!] . Does AfT shift from 22 to 11 range? Yes
...
Engine brake
m
,~
IIDII
0
I
~19
~
@
SAT778B
Stop vehicle.
....
AT-22
D,
Full throttle
-+
D,
D, --> D,
95 - 101 (59 - 63) 72 -78 (45-48)
D, -+ D.
146 - 156 (91 - 97) 111-121 (69 -75)
D.
-+
D,
D, -+
D.
D,
-+
D,
1,
-+
1,
Half throttle
Full throttle
Half throttle
AT-23
Check (Cont'd)
-- - - 8/8
I
Downshift
7/8 6/8
, Kickdown range
I-
I I
0/8
~
(0)
(10)
20
30
L,
(20)
40 I
50
60
70
(30)
(40)
(50)
80
90
I'
100
110
"
120
'
130
.'
140
"
150
'
160
170
','
180
190
,,
200
'
(60)
(70)
(80)
(90)
(100)
(110)
(120)
SAT804B
- - - -8/8
Downshift
.
I
Kickdown range I I I
I
1-;-2
I
I /
8- 4/8
/,
..
.c 3/8 I2/8
CD
I I
L_I
I I I I
10
/
Lock~p "ON"
1/8I0/8 0
I
(0)
'
, '
(10)
20
30
"
40 I
60 '
60 '
70 '
80 I
(60)
90 "
100 I
(60)
110 'r
(70)
120
I
130
I
140
160
160
170
180
190
200
"
(90)
'
I
(100)
I'
(110)
"
(120)
'
(20)
(30)
(40)
(80)
SA T805B
AT-24
TROUBLE DIAGNOSES.
Control
valve
upper body
)
SAT806B
AT-25
1;Inhibitor
switch
~
~~
SAT8258
AT -26
0 [SIEE] 0 ffiHBJ
To distributor
@!j ~
IGNITION
COIL
@
@
35213
@
." r
c
0
crb
THROTTLE SENSOR
a@0~
INHIBITOR SWITCH we
POWER TRANSISTOR
'2112 15
-i
db
:u m <
0
@crb
-=
@I
m ::I
"lJ
-i
r c
0
Z
m :u
(fI m
@T 2 :u
m m Z (fI
0
r.-:1t; 0
I I I
@~ .:;;
~c
(fI
;U
r
16
1;U I I
..0
:r.. -or
.. -
, Q
..
-i . (fir ~ :Em
.. -i 0
- m-i . <0
(")
.
15 10 17 4
:r
:I
~
I
N
......
~(t)
6 8 9
26 19 20 I 2
24
29 30 28 A/T
12
CONTROL UNIT 35 22 21 34 33
23
36
II 27 25 31 32
s~
@~
S
I/)
r-
0 ;U 0
"lJ "lJ
Z
0
-=
-=
Cl(t) ;U m < m r Z
-i 0 ;U
@)
O. D. OFF INDICATOR
~v.XcgONTROL
01
- 6 @
A
(")
(fI :I
."
-i
."
(fI :I
-i
E!!3
ION
IOFF
@;
@)
-= -=
m~
~ -i
(") :I -=
(fI 0 r m Z 0
(fI 0 r m Z 0
;U ;U C Z
m "lJ
;U
(")
r C -i (") :I (fI 0 Z 0 -= 0
0
-=
-=
tD
Z 0
0
r m
-=
r m
Z 0 0
-I 00
w 00
,/
SWITCH START
O. D.
CONTROL SWITCH
HEAD-UP CONTROL
DI SPLA UNIT
[Jffi@II]
[J-t-W.H-t-j]
~
ID
~~ll~o~~
" >>->- ,
co
~
III' co " >>->-
@
f)3\ \.!::.J -'III
~
co
I
co
FUSE BLOCK (Refer toP POWER ;;:~ SUPPLY ROUTINGp co", in EL section.)
n ~t;J
@)~
co, co .. .. ..
Vi
GD
Y/G
Y/8
Y/L G (J nstrument
harness)
II
o.
MIh i te) (Black)
@
Y/G.
Y/8.
Y/L. G
C?
IGNITION ON or SWITCH START
J I~
@IIIII~I~
co
IDIII iii
@jj)fi@}}
BODY GROUND co
@ 11111~11IIl
~
11S-L 1-W
(E. F. 1. harness)
L LG/R Y/W Y/G W/L 8 LG/8 L Y/R
@
-{]II
:::::::::::::
Y/R
3-
I
@
:: ,,
1
,"
--_n
nn nn__nn_n
_n
n_nnnn-
~ I~~: co
..JID~
III
1111 , ~ co ,
1
'" , co
~
0
~@)
~@)
bJ~@)
@)
$.~
..J>->-
..J~ID
III..J
@)ii
ENGINE GROUND
00
RESISTOR
~
" ::> ~ c
...
THROTTLE SENSOR
THROTTLE
VALVE SWITCH
AT-28
in!
DROPPING RESISTOR
@m :Wlth
@)~@I~II~I
"''''
,
...
~ ~ ~
head-up display :Wlthout head-up display :Wlth anti-lock braking system :Wlthout system anti-lock braking
<;J;>@)
L' E 0
To back-up
lamp
I
~
!
L___n_--5B -G/R -G/R -R/B -G/L -Y/B -Y/L B9 B7 CB AB ClD Hll 111 5B G/R G/R R/B G/L Y/B Y/L
b
1
.E~~E ~
a
E.
'"
EE~
~~'~E'" ~
L'~""
.
a..
..a E"''''o
""""~L"'''''''~''
J
-
=...
=N
=0
BRG/W
BR G/W BR G/L G/B
@
S. M. J.
(@)
page). )
last page
(ill)
I
GY R B W L Y G
=Z
'---
=0..
@) G~W
1'i"W
@
OR/L B PU GY/R L/Y L/W
P/L
rJil ~~!~Dr
lJU
(Subharness)
harness)
a:::J-
L
LG/R Y/W Y/B W/L B LB/B L Y/R
I
.
ii
()
:;a
"E
~ ~
.....
.. ~
" l6!B@)
......
@)!i@)
BODY GROUND -= -= 1: U I::I ..J < U 0 0 ... z... 0 ::10 It:Z I-Z It:W U.UI UI..J .....J >0 1:0
OU) U)U)
~
0 n.... ::10 IZ )lUl u..J '")0 'JI m 0 ... 0 I-Z u.w .....J 1:0 -= UI It: ::I U) U) UlO It:... 0..0 Z UIUI Z..J
..JU)
~(@) "
...... .....
It: 0 U) Z UI
U)
2) Y/L-Lh Y/B-G"
==O
SPEED SENSOR
U)U)
...0
(@)
SAT101C
AT-29
TROUBLE DIAGNOSES
Self-diagnosis
SELF-DIAGNOSTIC PROCEDURE
DIAGNOSIS START Start engine and warm it up to normal engine operating temperature.
~SAT774B
(g
II
0
, PJ
fa
Set overdrive switch in "ON" position.
fifif:j
SAT779B
Does 0.0. OFF indicator lamp come on for about 2 seconds? Yes fNo
i ~
.'
~
.
.
'
'
I Go to
I]
Move selector lever to "0" range. position.
II
-CD
SA T780B
fifif:j
~ ~
m
0
I
..&\ OVER
m
~ve
I."
SAT781 B
fit 6
m
Accelerator pedal
;;;:
m
Depress accelerator pedal fully and release it.
Depress
Release
SAT754A
AT-30
TROUBLE DIAGNOSES
II!]
Self-diagnosis (Cont'd) A
II!]
~SAT782B
Check O.D. OFF indicator lamp. Refer to JUDGEMENTOF SELF-DIAGNOSISCODEon next page. DIAGNOSIS END
'---
AT-31
(Cont'd)
Damaged circuit
CODE.
,&
OlD OFF
Self-diagnosis start
f-tl
- -
Shade
t, t,t, t, t, t, t, t, t, t, t,
SAT723B
OlD
OFF
--,..--r---
-\
Lig ht 16 Shade
15
.. Go to REVOLUTION
SAT724B
SAT140B
2nd judgement flicker is longer than others. ~()~ OlD //1\' OFF
Speed sensor
- - .....--.-
- - Light
24 Arr control unit
1---1-
,-'
Shade
SAT726B
SAT760A
3rd judgement flicker is longer than others. ~).l(~ OlD /)r\' OFF --R-M-. - - Light -
.",.
15
11 AfT control
10 unit
- Shade
SA T726B tl
..
= 2.5 seconds
t2
= 2.0
seconds
t3
=1.0 second
AT-32
(Cont'd)
Damaged circuit
-=
- Shade
SA T727 B
A/T
control
unit
-----
:;/1\'
':()/
--
OFF
OlD
--
-'
Light
36
- Shade
SAT728B
SAT767A
-----
---
Light
21
Terminal assembly
cord
- Shade
SA T729B
SAT768A
~~
//1\'
OlD
OFF Terminal cord assembly -=
--
-- Light
22
---
- Shade
SAT730B
AT-33
Damaged circuit
Fluid temperature sensor is disconnected or AfT control unit power source circuit is damaged.
OlD
OFF
Self-diagnosis start
--
- Light
Shade SAT731 B
Go to FLUID TEMPERATURE SENSOR CIRCUIT AND AfT CONTROL UNIT POWER SOURCE CI RCUIT
..
CHECK.
SAT143B
-0-
,\1// //1\'
- -....--.~-
- - Light
Shade
SAT733B
SIGNAL CIRCUIT
SAT624B
is longer than
- - ...--.I '
- Light
34 33 control
Dropping resistor
4-- Shade
SAT732B
AfT
unit
CHECK.
SAT776A
Battery power is low. Battery has been disconnected for a long time. Battery is connected conversely. (When reconnecting AfT control unit connectors. is not a problem.)
- Light
This
- - Shade
t.
SAT734B
t4
= 1.0
second
AT-34
010 OFF
Inhibitor switch, overdrive switch, kickCtown SWltchOT idle switch circuit is disconnected or AIT control unit is damaged.
- - - - - - - - - - -.- - -
Light
---
Shade
.<: ~ .~ .. '"
-=-
SAT157C
Overdrive switch
ION
Kickdown switch.
)
..
-=
/
\
.....
'\
AT-35
Self-diagnosis
(Cont'd)
N.G.
.Components
Inspection".
PI
16 15
O.K. N.G.
I!
m
-~,
~
f"
t:;!
",:"",.,.
,
ST
.'' '.-'
>}
trJ
I~
. Harness continuitybetween
A/T control unit and revolution sensor (Main hamess)
. Harness continuitybetween
revolution sensor andE.C.U. (Mainharness) . Ground circuit for E.C.U. - Refer to section EF & EC.
'/
.-~
O.K.
Perform self-diagnosis again after driving for a while.
N.G.
. O;K.
00
INSPECTION END
1. Perform A/T control unit input/output signal inspecti~n. 2. If N.G., recheck AfT control, unit pin terminals for damage or connection of A/T cORtrol unit harness connector.
"
-=-
SAT737B
PI
Speed sensor
-= 24 A/T contrOl unit
CHECK
PI
CHECK INPUT SIGNAL. 1.
N.G.
'(,~I
~I
2.' Check voltage between A/T control unit terminal @ and ground while driving at 2 to 3 km/h (1 to 2 MPH)for 1 m (3 ft) or more. Voltage: Varies from OV
,
Check the following items. . Speed sensor and ground circuit for speed sensor - Refer to section El. . Harnesscontinuity between A/T control unit and speed sensor (Main harn,ss)
---.-O.K.
Perform self-diagnosis again after driving for a while.
t05V
N.G.
O.K.
INSPECTION END
SA T738B
1. Perform A/T controlu~it input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of A/T control unit harness connector.
AT-36
TROUBLE DIAGNOSES
Throttle sensor
II
";"
15
11
10 unit SAT761A
N.G.
AfT control
II
1.1 2. Check voltage between AlT controlunit terminals @ and @ while accelerator pedal is depressed slowly. Voltage: Fully-closed throttle:
13
Check harness continuity between E.C.U. and A/T control unit regarding throttle sensor circuit. (Main harness)
0.2- 0.6V
Fully-open throttle:
2.9- 3.9V
[iI
COllET
O.K.
Perform self-diagnosisagain after driving for a while. 'O.K. INSPECTION END N.G. 1. Perform A/T control unit input/output signal inspection. 2. If N.G.. recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.
SA T739B
AT-37
m
CHECK GROUND CIRCUIT. N.G. 1. Remove control valve assem-
bly. - Referto "ON-VEHI1.1 I 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal @ and ground. Resistance: 20. 30il
13
CLE SERVICE". 2. Check the following items. 8 Shift solenoid A Referto "Electrical Components Inspection". 8 Harnesscontinuity of terminal cord assembly
m
Sub-harness connector
(@)~
is
-=-
I!)
CIRCUIT.
1.1
SA T740B
13
I!)
DISCONNECT
[:it
18
2. Disconnect A/T control unit 16-pin connector. 3. Check resistance between terminal @ and A/T control unit terminal @. Resistance: Approximately Oil 4. Reinstall any part removed. 1 O.K. Perform self-diagnosisafter driving for a while.
."
N.G.
lo.K.
INSPECTION END
[ill
SAT741B
AT-38
m
CHECK GROUND CIRCUIT. N.G. 1. Remove control valve assem-
~ lu
IIIKOIIIIECT
1.1 I 2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal @ and ground. Resistance: 20 - 30n
bly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. 8 Shift solenoid B Referto "Electrical Components Inspection". 8 Harnesscontinuity of terminal cord assembly
[;]
O.K.
N.G.
-;:-
"1
Repair or replace harness between A/T control unit and terminal cord assembly. (Main harness)
16-pin connector.
[;]
~ IV
_IIECT
terminal @ and A/T control unit terminal @. Resistance: Approximately on 4. Reinstall any part removed.
O.K.
N.G.
1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck AfT control
unit pin terminals for damage
END
I
SAT743B
AT-39
TROUBLE DIAGNOSES
Self-diagnosis
Overrun clutch solenoid
- (Cont'd)
m
CHECKGROUNDCIRCUIT.
1.1
18
~
IV
-=
~
2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal @ and ground. Resistance: 20 - 30n
I!]
CIRCUIT.
1 O.K. N.G.
Repair or replace harness
I CHECK POWERSOURCE
betweenAlTcontrolunit and
1.1
SA T744B
18
I!]
eJ
Subharness connector
2. Disconnect AIT control unit 16-pin connector. 3. Check resistance between terminal @ and AIT control unit terminal @. Resistance: Approximately on 4. Reinstall any part removed. 1 O.K. Perform self-diagnosisafter driving for a while.
N.G.
lo.K.
INSPECTION END
1. Perform AfT control unit input/output signal inspection. 2. If N.G.. recheck AfT control unit pin terminals for damage or connection of AfT control unit harness connector.
P/L
[ill
SAT745B
AT-40
m
CHECK GROUND CIRCUIT. 1.
N.G.
m
IIISQIIIIECT
2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal @ and ground. Resistance: 2.5 5n
Ia
Ii)
EO
~ ~
-=-
SA T746B
Ii]
IIISCONIIECT
[:iI
fm'I
IV
Sub22 connector J
harness E1tE1
GY/R
2. Disconnect AfT control unit 16-pin connector. 3. Check resistance between terminal @ and AfT control unit terminal @. Resistance: Approximately on 4. Reinstall any part removed. O.K.
Perform self-diagnosis after driving for a while.
N.G.
. O.K.
[:ill{)
INSPECTION END
1. Perform AfT control unit input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of AfT control unit harness connector.
EEfHm
[ill
SAT747B
AT-41
FLUID TEMPERATURE SENSOR CIRCUIT AND AIT CONTROL UNIT POWER SOURCE CIRCUIT CHECKS
m
CHECK AfT CONTROL UNIT POWER SOURCE. 1. I N.G. Check the following items.
SAT143B
~
CIINNECT
2. Check voltage between AfT control unit terminals @ , @ and ground. Battery voltage should exist.
Harnesscontinuity between ignition switch and AfT con. trol unit (Mainharness) . Ignition switch and fuse - Refer to section EL.
I!]
O.K. 1. Remove oil pan. 2. Check the following items. . Fluid temperature sensor - Refer to "Electrical Com. ponents Inspection". . Harnesscontinuity of terminal cord assembly
)
AfT control unit terminal
N.G. CHECK FLUID TEMPERA. TURE SENSOR WITH TERMINAL CORD ASSEMBLY 1.
SAT748B
I!]
Subharness connector
EW3 @
yo12 15~ ~
~
IIISCOIINECT
18
SAT749B
[ill
2. Discpnnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminals @ and @ when AfT is cold. Resistance: Cold [20C (6SoF)] Approximately 2.5 kil 4. Reinstall any part removed. O.K.
AT-42
N.G.
~
CONNECT
! 13
G ' ON '}
, ,",
:," ~.'
2; lD
,)I;,
II
Check the following items. . Harness continuity between A/T control unit and terminal cord assembly (Mainharness)
2. Check voltage between A/T control unit terminal @ and ground while warming up A/T. Voltage: Cold [20C (6SoF)] -+ Hot [SOC (176F)] : 1.56V -+ O.45V
O.K.
Perform self-diagnosis after driving for a while. N.G. 1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of A/T control unit harness connector.
O.K.
"::"
SAT750B
INSPECTION END
N'~I
Check ignition signal circuit for engine control. - Refer to section EF & EC.
O.K. N.G. Check the followingitems. . Harnesscontinuity between A/T control unit and ignition coil.
SA T624B
"13
2. Check voltage between A/T control unit terminal @ and ground. Voltage: 9.5 - 12V
. Resistor
. Ignition oilc
Refer to
m~
0HHm:B l1t
AfT control unit terminal
sectionEF&EC.
CONNECT
O.K.
1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of AfT control unit harness connector.
O.K.
-=-
SAT751B
INSPECTION END
AT-43
m
CHECK GROUND CIRCUIT. N.G.
-.. 1.
1.1
2. Disconnect terminal cord assembly connector in engine compartment. 3. Check resistance between terminal @ and ground. Resistance: 2.5- 5il
1!1
AfT control
bly.- Refer to "ON-VEHICLE SERVICE". 2. Check the following items. 8 Line pressure solenoid Refer to "Electrical Components Inspection"-. 8 Harnesscontinuity of terminal cord assembly
m Sub-
harness connector
34\
@ID)
~
IV
~
!O.K. N.G. Checkthe following items. 8 Dropping resistor - Referto "ElectricalComponents Inspection" .
8 Harnesscontinuity between
=-
SAT762B
1.1
1!1[!]
~i5
terminal @ and AfTcontrol unit terminal@. Resistance: 11.2- 12.ail [!] CIRCUIT 1O.K. N.G. Repair or replace harness betweenAfTcontrolunit @
CHECK POWERSOURCE
em
2. Check resistance between terminal @ and AfT control unit terminal @. Resistance: Approximately Oil 3. Reinstall any part removed. 1 O.K. Performself-diagnosisafter driving for a while.
1.1
I
N.G.
SA T763B
O.K.
INSPECTION END
AT-44
m
CHECK INHIBITOR SWITCH CIRCUIT. 1. I N.G.
. Inhibitor witch s -
SAT7368
2. Check voltage between AfT control unit terminals CD.@. @. @, @ and ground while moving selector lever through each range. Voltage: B: Battery voltage 0: OV
No. @ @
B 0 0 0 0 0 B 0 0 0
fi/f:J..
"Electrical Components Inspection". . Harnesscontinuity between ignition switch and inhibitor switch (Mainharness) . Harnesscontinuity between inhibitor switch and AfT control unit (Mainharness)
@ CD CV
0 0 B 0 0 0 0 0 B 0 0 0 0 0 B
1!1
BR
O.K.
SWITCH
BR/W
IN.G.
1.
-=SAT7838
~
ON OFF
t!(g
to
1!1
~_caD
2. Check voltage between AfT control unit terminal @ and ground when overdrive switch is in "ON" position and in "OFF" position.
Switch position Voltage Battery voltage 1V or less
Harness continuity between AfT control unit and overdrive switch (Main harness)
O.K.
lit
e
-=-
CIIIIIECT
~
~G/R
IV n
~10~
A/T control unit terminal
(t'l
SA T7848
AT-45
[!II!]
[!1
@
CHECK KICKDOWN SWITCH CIRCUIT. N.G. Check the following items.
1.1
~
-
. .
~
t)
CONNECT
I!]
2. Check voltage between AfT control unit terminal (j) and ground while depressing accelerator pedal slowly. (after warming up engine) Voltage: When releasing accelerator pedal: 3 8V When depressing accelerator pedal fully: 1V or less , O.K.
Kickdown switch Harnesscontinuity between AfT control unit and kick. down switch (Mainharness) . Harnesscontinuity of ground circuit for kickdown switch
IN.G. CHECK IDLE SWITCH CI RCUIT. SAT754S1 I. Check voltage between AfT control unit terminal @ and ground in the same way as kickdown switch circuit. Voltage: When releasing accelerator pedal: 8 15V When depressing accelerator pedal fully: 1V or less , O.K.
Perform self-diagnosis (Mode IV) for engine control. Check idle switch circuit. O.K. Check harness continuity between AfT control unit and idle switch. (Main harness) N.G. Check id Ie switch circuit for engine
Perform
self-diagnosis
again after
I N.G.
1. Perform AfT control unit input/output signal inspection. 2. If N.G., recheck AfT control
-
unit pin terminals for damage or connection of AfT control unit harness connector.
AT-46
TROUBLE DIAGNOSES
Diagnostic Procedure 1
SYMPTOM: 0.0. OFF indicator lamp does not come on for about 2 seconds when turning ignition switch to "ON".
0 ,
CHECK AfT CONTROL UNIT POWER SOURCE. 1.
-=-
SAT755B
11
t8
2. Check voltage between AfT control unit terminals @, ~ and ground. Battery voltage should exist.
6
I
O.K.
N.G.
SAT756B
I]
Ignition switch
Fuse
2. Disconnect AfT control unit 16-pin connector. 3. Check resistance between AfT control unit terminals @ , @ and ground. Resistance: Approximately on
[:tI
([ill)
I]
1.
O.K.
N.G.
[ill
2. Disconnect AfT control unit . 16-pin connector. 3. Check resistance between AfT control unit terminals @ and @. Resistance: 50 -100n 4. Reinstall any part removed. O.K.
. 0.0. OFF indicator lamp - Refer to section EL. . Harnesscontinuity between ignition switch and 0.0. OFF indicator lamp (Main harness) . Harnesscontinuity between 0.0. OFF indicator lamp and AfT control unit
N.G.
Check again. O.K. INSPECTION END
1. Perform AfT control unit input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of AfT control unit harness connector.
AT-47
TROUBLE DIAGNOSES
OlD OFF
Diagnostic Procedure 2
SYMPTOM: Enginecannot be started with selector lever in "P" or "N" range or engine can be started with selector lever in "0", "2", "1" or "R" range.
Self-diagnosis start
D
Does self-diagnosis show damage to inhibitor switch circuit?
Yes
fA
No
Check continuity of inhibitor switch 2-pin connector. - Refer to "Electrical Components Inspection" .
O.K.
Check starting system. - Refer
to sectionEL.
O.K.
SA T838B
INSPECTIONEND
Diagnostic Procedure 3
SYMPTOM: Vehicle moves when it is pushed forward or backward with selector lever in "P" range.
D
Check parking components. Refer to "ON-VEHICLE SERVICE".
SAT133B
N.G'I
O.K. INSPECTIONEND
AT-48
TROUBLE DIAGNOSES
0
start
010 OFF
Diagnostic Procedure 4
SYMPTOM: Vehicle moves forward or backward when selecting "N" range.
Self -diagnosis
0
Does self-diagnosisshow damage to inhibitor switch after cruise test ? No Check manual control linkage. - Refer to "ON.VEHICLE SERVICE". N.G. Yes
Check inhibitor switch circuit. - Refer to "Self.diagnosis".
- - - - - - - - - - - - - - Light - - Shade
SAT157C
f)
"P" range
O.K.
Check AfT fluid level again. Refill A.T.F.
II
Lock nut
O.K.
N.G. 1. 2. . . . . DisassembleAfT. Check the following items. Forward clutch assembly Overrun clutch assembly Reverseclutch assembly Accumulator piston D
00
O.K.
11
Check again.
O.K. INSPECTIONEND
SA T638A
1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.
II
SAT171 B
AT-49
~O' /1 \
\1//
OFF
Self-diegnosis start
Throttle sensor circuit Fluid temperature sensor circuit Line pressu re solenoid circuit Light Shade
0
Does self-diagnosis show damage to throttle sensor, line pressure solenoid or fluid temperature sensor circuit? Yes
._-----
SAT7588,
fJ
Fluid 'temperature sensor E.C.U.
I) .
No
Dropping
resistor
Check line pressure at idle with selector lever in "0" range. Refer to "PRESSURE TESTING".
O.K.
SA T0888
1. Remove control valve assembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. . Valves to control line pressure ~Pressure regulator valve, modifier valve, pilot valve and pilot filter)
. Linepressuresolenoid
0
N.G.
Check again.
O.K. INSPECTIONEND
1. Perform AfT control unit input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of AfT control unit harness connector.
SA T643A
AT-50
TROUBLE DIAGNOSES
0 0
N.G'.f RefillA.T.F.
SA T638A
O.K. N.G. in both "1" and" R" range r fA Check stall revolution with selector lever in" 1" and" R" range. O.K. O.K. in "1" range N.G. in "R" range.
II
1. Remove.control valveassembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. 8 Valvesto control line pressure (Pressure regulator valve,pilot valveand pilot filter)
8
Check line pressure at idle with selector lever in "R" range. - Refer to "PRESSURE TESTING".
SA T642A
N.G.
Line pressure solenoid 3. Disassemble A/T. 4. Check the following items. 8 Oil pump assembly 8 Torque converter
II
O.K. N.G.
8 Reverseclutch assembly 8 High clutch assembly 8 Low & reverse brake assembly 8 Low one-way clutch
r Check again.
O.K.
SA T643A
r
I
IN.G., 1. Perform AfT control unit input/output signal inspection. 2. If N.G., recheck A/T control
unit pin terminals for damage or connection of A/T control unit harness connector.
INSPECTION END
SAT171B
AT-51
TROUBLE DIAGNOSES
0
I
N.G.
.1
Refill A.T.F.
B1
N.G. Check stall revolution with selector lever in "0" range. - Refer to "STALL TESTING". . O.K.
Check line pressure at idle with selector lever in "0" range. Refer to "PR.ESSU RE TESTING".
N.G.
IA
1. Remove control valveassembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. . Valvesto control line pressure (Pressure regulator valve, modifier valve, pilot valveand pilot filter)
. Linepressuresolenoid
II
O.K.
SA T642A
B1
O.K.
1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.
II
SAT171B
AT-52
TROUBLE DIAGNOSES
~~ /11\'
OlD OFF
Self-diagnosis start
Diagnostic Procedure 8
Cruise test Is Diagnostic Procedure 7 O.K.?
Part 1.
Go to Diagnostic Procedure 7.
Light
Yes
--- --~Shade
SA T760B
Does self-diagnosis show damage to revolution sensor, speed sensor, shift solenoid A or B after cruise test?
Yes
No
7""
Refer to I N.G.
Check line pressure at stall point with selector lever in "D" range. - Refer to "PRESSU RE TESTING".
N.G.
1. Remove control valveassembly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. O.K.
I]
II
N.G.
O.K.
O.K. O.K.
. . . . . .
3. 4. . . . . . .
SA T643A
II
N.G.
Check again.
O.K. INSPECTIONEND
SAT171B
1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of A/T control unit harness connector.
AT-53
TROUBLE DIAGNOSES
D 0
OlD OFF
Diagnostic Procedure 9
SYMPTOM: AfT does not shift from D, to D2 at the specified speed. AfT does not shift from D4 to D2 when depressing accelerator pedal fully at the specified speed.
Are Diagnostic 8 O.K.?
Procedures 7 and Yes Go to Diagnostic Procedure 7 or :
Self-diagnosis start
- - - - - - - - - - - - - - Light
- - Shade
SA T157C
8. Yes
m
Revolution sensor
m
Speed sensor Speedometer Check revolution "Self-diagnosis" .
speed sensor circuit.
No sensor and
N.G.
Refer to
SA T629B
iJ
O.K.
Repair or replace throttle sensor.
O.K. N.G. 1. Remove control valve.Referto "ON-VEHICLE SERVICE". 2. Checkthe following items. . Shift valveA . Shift solenoidA . Pilot valve . Pilot filter
3. 4. . . . DisassembleA/T. Check the following items. Servo piston 'assembly Brake band Oil pump assembly
O.K.
O.K. O.K.
m
Check again.
SAT171B
N.G. O.K.
INSPECTION END
8/8
8/8
Dl.:TD2"/ Depress
fully
/
+".
1. Perform AfT control unit input/output signal inspection. .2. If N.G., recheck AfT control unit pin terminals for damage or connection of AfT control unit harnessconnector.
6)
0/8
SAT118B
~ /(
0
Release
D27D3 ( 0/8
AT-54
TROUBLE DIAGNOSES
DID OFF
Diagnostic Procedure 10
SYMPTOM: AIT does not shift from D2to D3 at the specified speed.
Are Diagnostic Procedures 7 and BO.K.?
5elf-diagnosis start
- - - - - - - - - - - - - - Light
Go to Diagnostic Procedure 7 or B.
D
- - Shade
SAT157C
Yes
Yes
Check throttle sensor. - Refer to section EF & EC. O.K. 1. Remove oil pan. 2. Check A/T fluid condition. N.G.
.O.K.
BJ
O.K.
O.K.
.
.
1. Remove control valveassembly. - Refer to "ON-VEHI. CLE SERVICE". 2. Check the following items. . Shift alve v B Shift solenoid B
Pilot valve
. Pilotfilter
3. 4. . . . DisassembleAlT. Check the following items. Servo piston assembly High clutch assembly Oil pump assembly
SAT1718
II
Check again. O.K. INSPECTION END
N.G.
II
8/8
II
Jl
0
0/8 l
'1
SAT1198
AT-55
TROUBLE DIAGNOSES
D
.
/~
\1/
OlD
Revolution sensor
OFF
r:I
I
Diagnostic Procedure 11
SYMPTOM: AIT does not shift from D3to D4at the
specified speed.
Are Di~gnostic Procedures 7 and 8 O.K..
Self-diagnosis start
/ / r .-
::;;~ature Light
I IINo
Yes
- ---_M_M_-M-M---M--uShadel . SAT761B
light
I
D
I
Yes
Ch~ck da~aged ~~~cUit.- Refer
I
Does self-diagnosisshow damage to inhibitor switch, overdrive . h . .d SWltC,s h Ift soIenol, A B, revolution sensor, speed sensor or fluid temperature sensor . . f . "1 t
to Self-diagnosIs.
10
" - mUH H
~.
. O.K.
N.G.
11
I!I
./
/'
O.K.
Checkthe following items. Shift valveB Overrunclutchcontrolvalve Shift solenoidB Pilotvalve Pilotfilter
3. DisassembleA/T.
SAT171BI I
I
I.
I
II .
8/8 U
II
II
Check again.
I
I0 .K .
~
I
I
1. Perform AfT control unit 2. If N.G., recheck AfT control unit pin terminals for damage or connection of AfT control unit harness connector.
input/output signal inspection.
0/8
II
SAT120B
INSPECTION END
AT -56
TROUBLE DIAGNOSES
,\1//
OlD
Diagnostic Procedure 12
SYMPTOM: AIT does not perform lock-up at the specified speed.
:;8,'" OFF
Self.<Jjagnosis
start - -- Light
0
Does self-diagnosis show damage to lock-up solenoid circuit after cruise test?
Yes
- Shade
PJ
1. Removecontrol valve. - Refer to "ON-VEHICLE SERVICE". 2. Check following items. . Lock-up control valve
N.G.
. Shuttleshiftvalve D
.
II
8/8
l~
IJ
Check again.
O.K.
N.G.
O.K. INSPECTION END
1. Perform AfT control unit input/output signal inspection. 2. If N.G., recheck A/T control unit pin terminals for damage or connection of AfT control unit harness connector.
0/8 II
~l
SAT121B
AT-57
TROUBLE DIAGNOSES
Diagnostic Procedure 13
~C5~ 010
/11\'
OFF
Self-diagnosis start
SYMPTOM: AIT does not hold lock-up condition for more than 30 seconds.
0
-Light
- Shade
Does self-diagnosis show damage to engine revolution signal circuit after cruise test?
Yes
fA . fA
,No N.G.
. O.K.
1. Remove control valveassem-bly. - Refer to "ON-VEHICLE SERVICE". 2. Check the following items. . Lock-up control valve . Pilot valve
O.K.
O.K.
SAT171B
. Pilotfilter
3. Disassemble A/T. 4. Check torque converter and oil pump assembly.
N.G.
1. Perform AfT control unit input/output signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or connection of A/T control unit harness connector.
010 OFF
Diagnostic Procedure 14
SYMPTOM: Lock-up is not released when accelerator pedal is released.
Self-diagnosis start
0
Light
---- --- - - - - - - -
Does self-diagnosis show damage to idle switch circuit after cruise test?
Yes
- Refer
--
Shade
SAT157C
fA
Check again.
No N.G. O.K. INSPECTION END 1. Perform AfT control unit input/output signal inspection. 2. If N.G.. recheck A/T control unit pin terminals for damage or connection of A/T control unit harness connector.
fA
'1'~
j~
0/8
~
.
------------ff
SA T806A
AT-58
TROUBLE DIAGNOSES
~\ l/-::: 010
no
Light
--Shade
SA T7648
Diagnostic Procedure 15 SYMPTOM: Engine speed does not return to idle smoothly when AfT is shifted from D4to D3 with accelerator pedal released. Vehicle does not decelerate by engine brake when changing overdrive switch to "OFF" position with accelerator pedal released. Vehicle does not decelerate by engine brake when changing selector lever from "D" to "2" range with accelerator pedal released.
0
Does self-diagnosis show damage to overrun clutch solenoid circuit after cru ise test? Yes Check overrun clutch solenoid circuit. - Refer to "Self. diagnosis".
No Check throttle sensor. - Refer to section EF & EC. . O.K. 1. Remove oil pan. 2. Check AIT fluid condition. N.G. 1. Removecontrol valveassem. bly. - Refer to "ON-VEHI. CLE SERVICE". 2. Check the following items. . Overrun clutch control valve . Overrun clutch reducing valve . Overrun clutch solenoid 3. 4. . .
~
II
O.K.
O.K.
SAT1718
O.K. DisassembleAlT. Check the following items. Overrun clutch assembly Oil pump assembly
II
8/8
/'"
I //
(
.../
"'"
//
"'" .... "" ""
...'"
...//
I I I
0/8
8~O
--~(
II
Check again.
N.G.
O.K.
~
INSPECTION END
1. Perform AfT control unit input/outPut signal inspection. 2. If N.G., recheck AfT control unit pin terminals for damage or conneCtion of AfT control unit harness conneCtor.
( D3 (O.D. OFF))
+
C0
Engine brake
SAT7658
AT -59
TROUBLE DIAGNOSES
OlD OFF
Diagnostic Procedure 16
SYMPTOM:Vehicle does not start from 01 on Cruise test - Part 2.
D
- - light -- Shade
SAT7668
Does self-diagnosis show damage to revolution sensor, speed sensor, shift solenoid A or B after cruise test? 1 No Check again.
Yes
1 N.G.
I lo.K.
1. Perform AfT control unit input/output signal inspection. 2. If N.G., recheck AfT control
Go to Diagnostic Procedure 8.
unit pin terminals for damage or connection of AfT control unit harness connector.
010 OFF
Diagnostic Procedure 17
SYMPTOM: AIT does not shift from 04 to 03 when changing overdrive switch to "OFF" position.
Self-diagnosis start
- - - - - - - - - - - - - - light
--Shade
SAT157C
D
Does self-diagnosis show damage to overdrive switch circuit after cruise test? Check overdrive switch circuit. - Refer to "Self-diagnosis".
AT-GO
TROUBLE DIAGNOSES
OlD OFF
Diagnostic Procedure 18
SYMPTOM: AfT does not shift from D3 to 22 when changing selector lever from "D" to "2" range.
Self-diagnosis start
- - - - - - - - - - - - - - Light - - Shade
SAT157C
D
Does self-diagnosis show damage
Yes
to inhibitor switch
circuit after
cruise test?
No .
Go to Diagnostic Procedure
9.
OlD OFF
Diagnostic
Procedure
19
Self-diagnosis start
SYMPTOM: AfT does not shift from 22to 11when changing selector lever from "2" to "1" range.
- - - - - - - - - - - - - - Light
- - Shade
SAT157C
D
Yes
Does self-diagnosis show damage to inhibitor switch after cruise
Refer
to
"Self-diagnosis".
test?
No
11
11
,~
0
I
~~
~.
I
Check again.
~
rO.K.
f
I
fT
recheck AfT
.
I
INSPECTION END
of AfT connector.
@
Engine brake
SAT778B
Diagnostic Procedure 20
SYMPTOM: Vehicle does not decelerate by engine
11.
Procedure
6.
Yes
Go to Diagnostic Procedure 15.
AT-61
.u
CONNECT
SA T842 B
20-pin connector
16-pin connector
SAT818A
T"
No.
Item
Condition When setting selector lever to "0" range. When setting selector lever to other ranges. When setting selector lever to "1" range. When setting selector lever to other ranges.
1V or less
Battery voltage
)
1V or less
--1
4
When releasing accelerator pedal after warming up engine. When depressing accelerator pedal after warming up engine.
8 -15V
1Vorless
-+5
A.S.C.O. D.O.
When releasing" ACCE L" set switch on A.S.C.O. cruise. When applying" ACCE L" set switch on A.S.C.O. cruise.
5-8V
1V or less
cut signal
AT-62
Inspection (Cont'd)
Judgement standard 3-SV
I Kickdown switch
, .""'_..,,
I 1
I
'\
I
0
I
I 1V or less
Battery voltage
When not performing A.S.C.D. cruise. I 1V or Iess ("CRUISE" light does not come on.)
When setting overdrive switch in "ON" position. When setting overdrive switch in "OF F" position.
I Battery
voltage
Overdrive switch
I 1V or less
10
I Throttle sensor
(Power source)
I
I
I
When depressing accelerator pedal slowly after warming up engine. 11 I Throttle sensor
0.2 - 0.6V
Voltage rises gradually in response to throttle opening angle. , is 20C Fully-open throttle: 2.9 - 3.9V 1.56V
12
I
I
13 14 15
I-
WhenA.T.F.temperatureisSOC (176F).
0.45V
16
OV
AT-63
Inspection (Cont'd)
Judgement standard
- 15V
17
1Vorless
19
20
Battery voltage
21
1V or less
8- 15V
1V or less Battery voltage
22
Lock-up solenoid When AfT does not perform lock-up. When setting overdrive switch to "ON" position. When setting overdrive switch to "OFF" position.
23
1V or less
24
Speed sensor
~
~
When moving vehicle at 2 to 3 kmfh (1 to 2 MPH) for 1 m (3 ft) or more. When engine runs at idle speed.
Vary from 0 to 5V
25
When engine runs at 2,500 rpm. When setting selector lever to"R" range. When setting selector lever to other ranges.
26
27
AT-64
Inspection (Cont'd)
Judgement standard
Battery voltage
28
When turning ignition switch to "OFF". When turning ignition switch to "ON". When turning ignition switch to "ON".
~o,
29 30
Battery voltage
3f
32
33
Linepressuresolenoid
(with dropping resistor)
- 14V
O.5V or less
1.5 - 2.5V
O.5V or less
34
Battery voltage
35
Shift solenoid A
Battery voltage
36
Shift solenoid B
When shift solenoid B does not operate. (When driving in "03" or "04 ".)
lV or less
OVERDRIVE SWITCH
Yes
SA T785 8
AT-6S
~~~~~~tr ~{~c@
CD CV @
Lever position p
R
(j)
0- -0
v -0
N
0
-0 0 0
-0
SAT843B
2. If N.G., check again with manual control linkage disconnected from manual shaft of AIT assembly. - Refer to step 1. 3. If O.K. on step 2, adjust manual control linkage. - Refer to "ON-VEHICLE SERVICE".
4. If N.G. on step 2, remove inhibitor switch from AIT and check continuity of inhibitor switch terminal. - Refer to step 1. 5. If O.K. on step 4, adjust inhibitor switch. - Refer to "ONVEHICLE SERVICE". 6. If N.G. on step 4, replace inhibitor switch.
SAT851
e~ ~\
SA T844B
p::-~
~[ill
REVOLUTION SENSOR For removal and installation, refer to "ON-VEHICLE SERVICE". Check resistance between terminals CD, @ and @.
. .
Terminal No.
~ GPt)
OJ:
CD
CV CD
@
@ @
AT-66
. .
For removal and installation, refer to "ON-VEHICLE SERVICE". Check resistance between two terminals while changing temperature as shown at left.
Temperature
c tF)
Resistance
20 (68) 80 (176)
. .
For removal and installation, refer to "ON-VEHICLE SERVICE". Check resistance between two terminals.
SAT846B
Ground
. .
For removal and installation, refer to "ON-VEHICLE SERVICE". Check resistance between terminals of each solenoid. Solenoid Terminal No. @ @ @ Ground terminal 20 - 30n Resistance
IV~
,',' / /,// ,,I I ( ,
"'-'
_T~
"
/'
mJ
SAT847B
"'---
l:tI
_tT
18
~
'
SAT848B
AT-67
TROUBLE DIAGNOSES
Final Check
STALL TESTING Stall test procedure 1. Check AIT and engine fluid levels. If necessary, add. 2. Warm up engine until engine oil and A.T.F. reach operating temperature after vehicle has been driven approx. 10 minutes. A.T.F. operating temperature: 50 - 80C (122 - 176F)
SA T779A
~ ~Q
~~)
~~-
.
~
3. Set parking brake and block wheels. 4. Install a tachometer where it can be seen by driver during test. It is good practice to put a mark on point of specified engine rpm on indicator.
SA T597
5. Start engine, apply foot brake, and place selector lever in "0" range.
.- ': I
SAT767B
6. Accelerate to wide-open throttle gradually while applying foot brake. 7. Quickly note the engine stall revolution and immediately release throttle. During test, never hold throttle wide-open for more than 5 seconds. Stall revolution: 2,050 - 2,250 rpm
SA T598
8. Shift selector lever to "N". 9. Cool off A.T.F. Run engine at idle for at least one minute. 10. Perform stall tests in the same manner as in steps 5 through 9 with selector lever in "2", "1" and" R", respectively.
SAT771B
AT-68
Judgement L L L L 0 0 0 H H H 0 H 0 : Stall revolution is normal. H : Stall revolution is higher than specified. L : Stall revolution is lower than specified.
1 R
L
Damaged components
---1
/
----=>
Forward clutch
//
-
Overrun
clutch
UWJ f p
b
;= 7
,-j::
..
L- D.
,J
t-
--:511
'>i<I1.-iF=5Jr'lr'dl- .'In
II
to;
II
I!.
=::J l oMwdtth
-
II"
r"'\'
I
..t1'" -1UJ
==J
.I
-\
linepressurecontrol
.\
I
t
.
Clutches and brakes except high clutch and brake band are O.K. (Condition of high clutch and brake band cannot be confirmed by stall test.)
H H 0 0
H H H 0
H H H H
0 0 0 0
Judgement
SAT107B
AT-69
. . .
Location of line pressure test port Line pressure plugs are hexagon headed bolts. Always replace line pressure plugs as they are selfsealing bolts.
SAT782A
Line pressure test procedure 1. Check AfT and engine fluid levels. If necessary, add. 2. Warm up engine until engine oil and A.T.F. reach operating temperature after vehicle has been driven approx. 10 minutes. A.T.F. operating temperature: 50 BOoC (122 176F)
~~'I
~~-=~
SAT779A
R range -
4. Set parking brake and block wheels. Continue to depress brake pedal fully while line pressure test at stall speed is performed.
SA T597
AT-70
Line pressure kPa (kg/cm2, psi) D, 2 and 1 ranges 471 510 (4.8 - 5.2, 68 - 74) 1,020 - 1,098 (10.4 - 11.2, 148 - 159) R range 657 696 (6.7 -7.1, 95 -101) 1.422 - 1,500 (14.5 - 15.3,206 - 218)
SA T643A
JUDGEMENT
8 Fluid pressure leakage between manual valve and particular clutch. 8 For example; If line pressure is low in "R" and "1" ranges but is normal in "D" and "2" range, fluid leakage exists at or around low & reverse brake circuit. 8 Mal-adjustment of throttle sensor 8 Fluid temperature sensor damaged 8 Line pressure solenoid sticking 8 Short circuit of line pressure solenoid circuit 8 Pressure modifier valve sticking 8 Pressure regulator valve or plug sticking 8 Mal-adjustment of throttle sensor 8 Control piston amaged
8 8
t:
IV
Line pressure solenoid sticking Short circuit of line pressure solenoid Pressure modifier valve sticking Pilot valve sticking
circuit
....
AT-71
TROUBLE DIAGNOSES
Symptom Chart
ON vehicle
OFFvehicle
67
7, 67
~
~
~ .. ! ~
9, 14
66
66 !5 !
70
67, 106
67
90,
101
120' 126'
124
1
137
144
W .. :I c
Numben ere arrenged in order of probability. Perform inspections starting with number one end working up. Circled numben indicate thet the transmillion must be removed from the vehicle. .c
- I
C
,! ~ '.. ~ 'tI ..
-c
s.~!5c';;~ ..= ';;! I.=~!
E1-
:?
.D
:!1
:!1
~ 6
g
ID~
ic(
~
48 48
.1
cs? .-::1
::!1 z g ~.!!
g ..
i
c I
..
it-1;: ,
8.. u~ .. E I.i! &~ i~
.c 5.c
i:.!!' et:J:
S ~z iii ~ O.c
~
~ , '5~ :
"E"E~! 2
ILl'-
.c ~ .= U > ..
E- ]1!!]11 ..::I
~ g 2,
0
f .. c 0 .. ~ u ~ i.. IS.
~ ~~ ~,g
::1::1 ::I C
!5:: 1-0
ce..
i~ ~.!
.
.
1.. . .<V@
48
:g)
49
.
214
.
3
@ . lev . I<ID
<ID@I<v . I@ . I@
61
62
1 2
31 6
4, .
@I@.!@
4 8
<V
.
1
61 1 31 7
6, .
@.
ev
.
31.
214
. 3,.
. .
31.
6,.
.
7 8
@ <v1@@1 . @
61,62
1 21.
.1.
4 6
@@@.
@.I.
.I(j])
.
1
21 1 .16
211
211
1
2 3
.1. .14
.,. .
No creep at all, Failure to change gear from "0, " to "0, ". Failure to change gear from "0," to "0.".
.16
64, 66, 66
Failure to change gear from "O~" to "0. ", TO'ohigh e geer change point from "0, " to "0, ", from "0," to "0, ", from "0," to ".", Gaar change directly from "0, " to "0," occu rs, Engine stopswhan shifting lever into "A", "0", "2" and "1", , Too sharp a shock in change from "0, " to "0,". Too sharp a shock in changa from "0, " to "0,
.I 4 .
112
. @<IDI. .I .1. .1. .1. .1. .1. .1. .1. . . . . -@ .1. .1. .1. . I. .1. . I. @. <V 6 . .@
3 4
.
2 @ @ @ 3 2
1
1
3
214 214
.1. .1.
6 3
.<ID
AT-72
ON vehicle
OFF vehicle
~
~
~
Reference pege (A T-
9, 14
66
66
70
67, 106
67
67
7, 67
90, 101
120' 124
126, 137
144
c: ! of II::
i fI .
Numbers are arranged in order of probability. Perform inspections starting with number one and working up. Circled numbers indicate thet the trensmission must be removed from the vehicle.
c:
S > :0
0.
t: i
c:
-~~lIg~ I-o.';:;~
~ .. .c -N -fi -fi' ~~ ! :;;5505.~ ; ~!~:2:!!!!S =!1~~!au 0.c: ~~~~~I :J c: ~ 5.c.2! uO .:! i ."2 80.u~ :2 .:J :J:J ~!~.!
IIIO:!!.
<:'
i.
:!!
II
g.!!
:!! i g S
0
c:
-. ~.
~
1::
~ II
;9 :;;z
~E
z 1;;
~1 M.c
Eo
.c ~ :J U >
.c U ~
.:! .0
II .>< I!!
~ c:
II c: 0
0.
ij:;;
EE
.EII.ai!i!
20
4111 II
~ ~
. 0..
~ u
to
31 5
@I 4
31 5
.<;
4
01 0
@ICID
31 5
.<;
@@I
to
Vehicle braked by gear change from "D, .. to "D,". Vehicle braked by gear change from "D," "D.". to
.@
@
5 3 4 6 4 5 3
CIDI@
..
@@
Maximum speed not attained. Acceleration poor. Failure to change gear from "D." Failure to change gear from "D," Or from "D." to "D, ". Failure to change gear from "D," Or from "D," to "D. ". to "D," to "D,"
$
1 1
Qj)'@1 @0
.. ..
@ .10
15
3 4
@I .(j;
01 @I. @I
to "D."
5 3 4
.
3
Gear change shock felt during deceleration by releasing accelerator pedal. Too high a change point from ~'D." to "D, ", from "D," to "D, ", from "D," to "D, ". Kickdown does not operate when depressing within kickdowII vehicle speed.
112
pedal in "D."
31 4
Kickdown
depressing pedal in "D. " beyond k ickdown vehicle speed limit. Races extremely fast or slips in changing from "D." to "D," when depressing pedal. Races extremely fast or slips in changing from "D." to "D," when depressing pedal. 1 1
31 4
8 0
@. . . .0
Races extremely fast or slips in changing from "D," to "D," when depressing pedal. Races extremely fast or slips in changing from "D." or "D," to "D," when depressing pedal. Vehicle will not run in any range. Transmission noise in "D", ranges. "2", "1" and "R"
@0. . . . @
@0.@
@"l ,. .1.
@
I OJ
AT-73
TROUBLE DIAGNOSES
Symptom Chart (Cont'd)
ON vehicle
OFF vehicle 67
~
.. i' a. 8 c: ! of .. tr
Reference
pege (A T-
9, 14
66
66
70
67, 106
67
7, 67
90, 101
120' 124
1
126' 137,
126'1130 134
144
..:. ~
Numbers ere errenge<! in order of probebilitV. Perform inspections starting with number one and working up. Circled numbers indicate that the trensmission must be removed from the vehicle.
~ c:
~ E .. ~"ii S"2a. '0 ...;;;
~
i01
-~~&gg ~=
001
?: .Q E
'tI .g
0 c: 01 'tI M .- '0
:2
~ c:
01 M e :J
.. -I: a: ~
~~ ... ..
M.c: o.~ 1;j ~
'5 c: E 0 :J';
.c: ~ .: u
.c:" u '"
~
~ ~ 0'
~ I
.c:
~~ ~~ (I)..J
(I)
g~ .ag ..JOIL
3
8 8 g'c .!!!
8a.~~
ILIL
~~
O..J ..Ja)
~~ ~e
@
015 01
M E 01 c: 0 a. E 0 u '" c: i.. IL
514
@.
61 -
Engine brake does not operete in "I" Geer chenge from "I, "to Does not chenge from "1," "1," in "I"
@.I@.
.'
..
@ .Icv
@
416
@cvl@@I@.I@ .I@@
@<IDICID
57 -
A.T.F. shoots out during operetion. White smoke emitted from exheust pipe during operation. Offensive smell et fluid charging pipe. Torque converter is not locked up. Lock-up piston slip Lock-up point is extremelv high or low. AfT does not shift to "D. " when driving with overdrive switch "ON", Engine is stopped at "R". "D", renges, "2" end "I"
.I@ .Icv@
1 3 1 2 4
1 2 1 2 2 1 3 8
6 3
8 6 4 5
7 4 3
4
.
2
543
"
AT-74
TROUBLE DIAGNOSES
/---------
",
\,
SAT8358
AT-75
"
11
5
SWITCH
~~ ~~
2
3
FUSE
To stop lamp
I GN IT ION SWITCH 8
I...,
ON or START
S
8
m" 5 19
...
SHI FT LOCK
@
SOLENOID,
~ ~
"::" SAT815B
AT-76
I GNI TI ON
SWI TCH
1
ON or START
BA TTERY
UP
*
@
I
GI:U
~~
@D@
(Eng ine room harness) R/W L 9 He" G9 R/W L L/R Y/R
(Ma In
harness)
KEY LOCK
!i I
..... .....
.~
r::o- L ~L/R
SOLENOID
~
.
L/R Y/R
KEY
SWITCH
G
~
I
ill
H9
S. M. J.
@J)
ffieferto
(Fo Idout
last page
page).]
~~~:
To time control
unit
BA TTERY
:u
, ~
@)
L Y [C]]
L L
[
FUSE
!II
[C]]
~~~~~ ~ ~ ~ II II III
GI GI GI
p
~
ID
LI NK
@fi@J)
BODY GROUND
TROUBLE
DIAGNOSES
AfT Shift Lock System (Cont'd) DIAGNOSTIC PROCEDURE 1 SYMPTOM: Selector lever cannot be moved from "P" range when applying brake pedal or can be moved when releasing brak,e pedal.
R/W
0
CHECK POWER SOURCE.
N.G.
Check the following items:
1.1
-=SAT818B
. Fuse
. Ignitionswitch
@i)[9 ~EIDJ
[Y]
~
LIB
6
CHECK INPUT SIGNAL (Detention switch).
N.G. Check the following items: . Detention switch - Refer to "COMPONENTCHECK". . Key switch - Refer to "COMPONENTCHECK". . Harnesscontinuity between detention switch and control unit.
-=-
SAT819B
I]
1.1
OJ
RIG'
2. Check voltage between control unit terminal @ and ground while setting selector lever in "P" position.
Selector lever release butto n Not pressed Voltage
Battery voltage
-=-
SA T820B
I]
CHECK INPUT SIGNAL (STOP LAMP SWITCH).
N.G.
1. I
fI!if::j
O.K.
AT-78
II
i5~ ~
A:
LIT1D 1
L/G
@TIY
II
I
!YJ
'"
CHECK
OUTPUT SIGNAL
N.G.
1. I
fiIiif:j
SAT821B
Check harness continuity between control unit and shift lock solenoid:
terminal
CD
O.K.
Check shift lock solenoid. (Refer to "COMPONENT CHECK".) N.G. Replace A!T shift lock control device assembly.
O.K.
N.G. Recheck shift lock operation. 1. Perform control unit input! output signal inspection test. 2. If N.G., recheck harness connector connection.
O.K.
INSPECTION END
AT-79
TR~OUBLE DIAGNOSES
, 'AIT
D
R/W
Shift Lock System (Cont'd) DIAGNOSTICPROCEDURE2 SYMPTOM: Ignition key cannot be removed when selector lever is set to lOP"position or can be removed when selector lever Is set to any position except lOP".
D
-=SAT818B
N.G..
1.
@i)~
[Y)
:+' Control unit terminal
(g
VIR
mm~
6
SAT822B
2. Check voltage between control unit terminals @, @, @ and ground. Battery voltage should exist. O.K. N.G.
CHECK INPUT SIGNAL (Key switch). 1. Insert ignition key into ign ition .switch. 2. Check voltage between control unit terminal (j]) and ground. Battery voltage should exist.
.1
Check the following items: . Harnesscontinuity between battery and control unit
. Fuse
. Ignitionswitch
-=I]
@i)[iI rtiBL~
[Y)'
:+: Control unit terminal
LIB
O.K. I]
CHECK INPUT SIGNAL (Detention switch).
N.G.
-::-
SAT819B
"I
(g.
Voltage
Battery voltage
Check the following items: . Detention switch - Refer to "COMPONENTCHECK". . Harnesscontinuity'betWeen detention switch and control unit.
2. Check voltage between control unit terminal @ and ground while setting selector lever in "P" position.
Selector lever release button Release
3. Check voltage between control unit terminal @ and ground while setting selector lever in any position except "P" . ov O.K.
A AT-SO
II
iVr:it
II
N.G.
Check harness.continuity between control unit and key lock solenoid.
[Y]
SA T823B
Ia
2. Check voltage between terminals @ and @ of key lock solenoid harnessconnector when turning detention switch ON and OFF. Battery voltageis momentarily produced. (Refer to "SH IFT LOCK CONTROL UNIT INSPECTION TABLE".)
O.K.
N.G' Check key lock solenoid. (Refer to "COMPONENT CHECK".)
Replace key lock solenoid.
I
O.K.
N.G. Recheck key lock operation.
1. Perform control unit input/ output signal inspection test. 2. If N.G., recheck harness connector connection.
O.K.
INSPECTION END
AT-81
12-pin connector
ITIiliI::QJ:ill
~
SA T824B
Measure voltage between each terminal and terminal @ by following "SHIFT LOCK CONTROL UNIT INSPECTION TABLE". Pin connector terminal layout.
AT-82
Item
Condition
Judgement standard
~
Except above
When setting selector lever in "P" position and releasing brake pedal
Battery voltage
ov
Power source
Battery voltage
3
9
Battery voltage
ov
Power source
Battery voltage
Detention switch
When setting selector lever in "P" position and releasing selector lever release button
Battery voltage
When setting selector lever in "P" position and pushing selector lever release button
ov
Ignition signal
Battery voltage
Battery voltage
I
I
91
10 I
I Ground
When turning detention switch ON with ignition switch set to LOCK,OFF or ACC Except above
11
I Key switch
I
I
Battery voltage
OV
AT-83
i5~
Shift lock harness connector
COMPONENT CHECK Shift lock solenoid Check operation by applying battery voltage to shift lock harness connector.
Detentionswitch Check continuity between terminals @ and @ of shift lock harness connector.
Condition
When setting shift lever to "P" position with release button released. Except the above
SAT832B
Continuity Yes
No
[ill
Key lock solenoid . Check operation by applying battery voltage to key lock solenoid harness connector. Operating sound must be emitted.
SAT833B
i5~
~
Key switch Check continuity between terminals @ and CDof key switch harness connector.
~ Key switch
Continuity Yes No
[ill G~~-SAT834B
AT-84
~~~ J~Q~
Removal
. .
. .
Installation
Drive plate runout Maximum allowable runout: 0.5 mm (0.020 in) If this runout is out of allowance, replace drive plate with ring gear.
SA T718
. . .
When connecting torque converter to transmission, measure distanc:;e"A" to be certain that they are correctly assembled. Distance "A": 26 mm (1.02 in) or more Install converter to drive plate. Reinstall any part removed.
After converter is installed to drive plate, rotate crankshaft several turns. and check to be sure that transmission rotates freely without binding.
CD
. Tighten bolts
CD ~: AfT -+ Engine @'\ ~ : Engine (gusset) to AfT
securing
transmission.
SAT111C
. . .
.
Reinstall any part removed. Check fluid level in transmission. Move selector lever through all positions to be sure that transmission operates correctly. With parking brake applied, rotate engine at idling. Move selector lever through "N" to "D", to "2", to "1" and to "R". A slight shock should be felt by hand gripping selector each time transmission is shifted. Perform road test. - Refer to "ROAD TESTING".
SA T638A
AT-85
MAJOR OVERHAUL
~: ~:
N.m (kg-m, ft-Ib) Apply recommended sealant (Nissan genuine part: KP610.(0250) or equivalent. Apply A.T.F. : Select with proper thickness. : Adjustment is req~ired. OiIPumPhOUSingOilseal~~
S 'lde seal
Side seal
~:
*
*
~
, ,J,
./
S pnng seat
l~.
~/./ ..~
1
I
~ iP':>..~ \\})
o-ring~~
61 64
~~ ,V:.::-J~
x~
/'
/ '.
~~ ~~
'~
:i~~
<:\
Friction ring/
"":<:'i~ ,
~VaneElq./ Vanering.,/
,,/
Input shaft
/'
O-ring~EI
./5 ,~
i'>
/
0
0
~ ~TOrqUeConverter
39 -49 /
~~~ \~
\
.tJPJ
1\
o.,;",~/
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..
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m q /
Needle bearing
Needle bearing
. .
EI ~
Beari~grace'
Overrunclutch hUb
m q.
Thrust washer mq
Retaining plate*/
~ ~,~
~
E.nd bearing
//
,
./
BearingraceElq (with rear planetary carrier) Front internal gear
Ealq
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-
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.
I
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7
:e
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AT-86
\ Snap ring
Thrust washer
m q
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Front planetary carrier
MAJOR OVERHAUL
D-ring
~~
Oilseal ~~
'1
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Overrun clutch
OilN" t:!"'Ti"
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Parkin 0
"".m" flow,
."
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-1 >
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~ 7. 9 '.7-0.9,6., .
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...
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n Oil pan
/"
3.6- , ~,;.: 5.8) Oil 000'" TUbe b,,,,.:0.7 . "9, S.1 . 6.S'
AT-87
Torque converter pressure (lock-up released) Reverse clutch pressure Torque converter pressure (lock-up applied) Oil pump feedback pr.essUre Oil pump suction hole Oil pump discharge hole Front lubricating hole High-clutch pressure Torque converter pressure /lock-up released) . Forward clutch pressure Oil pump suction hole Torque converter pressure (lock-up applied) Reverse clutch pressure
-~r/
-==
-.S/
L Oil cooler tube (OUT) and rear lubricating hole 3 -+ 4 & N -+ R accumulator back pressure Servo 4th apply chamber pressure Servo 2nd apply chamber pressure SAT186B
AT-SS
Oute CD
<ID
(j)
Ite num
@ @ @ @
(j)
It, num
CD
<I
~
I
co
CD
Out
In
-i 0'1
. ....
@ @ @
DISASSEMBLY!
Disassembly
1. Remove torque converter by holding it firmly and turning while pulling straight out.
2. Check torque converter one-way clutch. a. Insert Tool into spline of one-way clutch inner race. b. Hook bearing support unitized with one-way clutch outer race with suitable wire. c. Check that one-way clutch inner race rotates only clockwise with Tool while holding bearing support with wire.
SAT0198
_._~
._~-
._-~--
4. Remove oil pan. a. Drain A.T.F. from rear extension. b. Raise oil pan by placing wooden blocks under converter housing and rear extension. c. Separate the oil pan and transmission case. Always place oil pan. straight down so that foreign particles inside will not move.
SAT1868
5. Place transmission into Tool with the control valve facing up.
II-:cr.IWl-.
SAT1878
AT-90
.
/
SAT171B
7. Remove lock-up solenoid' and fluid temperature connectors. Be careful not to damage connector.
sensor
8. Remove oil strainer. a. Remove oil strainer from control valve assembly. Then remove O-ring from oil strainer.
SATOO8B
V(g)
~---~ SAT025B
'-.
9. Remove control valve assembly. a. Straighten terminal clips to free terminal cords then remove terminal clips.
~~~I
SATOO9B
AT-91
@ @
10. Remove terminal cord assembly from transmission case while pushing on stopper. Be careful not to damage cord. . Do not remove terminal cord assembly unless It Is damaged.
AT-92
SAT999A
b. Remove O-rings from converter housing. c. Remove traces of sealant. Be careful not to scratch converter housing.
SAT995A
13. Remove oil pump assembly. a. Attach Tool to oil pump assembly and extract it evenly from transmission case.
SA T027 B
b. Remove O-ring from oil pump assembly. c. Remove traces of sealant from oil pump housing. Be careful not to scratch pump housing.
AT-93
DISASSEMBLY
Disassembly
SAT108B
15. Remove brake band and band strut. a. Loosen lock nut and remove band servo anchor end pin from transmission case.
SAT029B
SA T655
AT-94
DISASSEMBLY Disassembly
16. Remove a. Remove sun gear) from
(Cont'd)
and gear components. high clutch and front pack (reverse clutch, case. transmission
b. Remove c. Remove
front bearing race from clutch pack. rear bearing race from clutch pack.
d. Remove
e. f.
Remove Remove
Ir~
g.
~
Remove
case. '
~--(~
\~ r
'" Oil groove SAT974A
.~~~~ ~"~\~) 1
.
~c:::-'::'
,',,;:;:.
')"
l~/
~'
<'~ ~:JP~
.
:::.. ll--=:.I
0/
'
/:
~~
AT-95
DISASSEMBLY
~
Disassembly (Cont'd)
17. Remove rear extension. a. Remove rear extension from transmission case. b. Remove rear extension gasket from transmission case.
c. Remove oil seal from rear extension. Do not remove oil seal unless it is to be replaced.
SA T190B
d. Remove revolution sensor from rear extension. e. Remove O-ring from revolution sensor.
18. Remove output shaft and parking gear. a. Remove rear snap ring from output shaft.
b. Slowly push output shaft all the way forward. Do not use excessive force. c. Remove snap ring from output shaft.
AT-96
DISASSEMBLY Disassembly (Cont'd) d. Remove output shaft and parking gear as a unit from
----
f.
19. Remove rear side clutch and gear components. a. Remove front internal gear.
AT-97
SAT951A
SA T034B
f.
Remove overrun clutch hub from rear internal gear and forward clutch hub.
SAT035B
SAT037B
AT-98
SAT038B
b. Apply compressed air to oil hole until band servo piston comes out of transmission case. Hold piston with a rag and gradually direct air to oil hole. c. Remove return springs.
d. Remove springs from accumulator pistons S, C and D. e. Apply compressed air to each oil hole until piston comes out. Hold piston with a rag and gradually direct air to oil hole.
A a
B b
C c
D d
SAT040B
f.
(2~3) Accumulator Front. (3--+4,N--->R)
Accumulator piston A
~fi
t? ~~b'
SA T937 A
21. Remove manual shaft components, if necessary. a. Hold width across flats of manual shaft (outside the transmission case) and remove lock nut from shaft.
AT.. 99
Transmission
\:
case
SA T042 B
c. While pushing detent spring down, remove manual plate and parking rod from transmission case.
\
e. Remove spacer and detent spring from transmission case.
f.
-In~
~~.~ '0_L
-/
-~j-/c ~
,)
@~~\I \ I
r yj-
~ SAT044B
AT -1 00
Oil Pump
Friction ring O-ring Oil pump housing Oil seal O-ring
EI. ~
~ <@
Side seal
Pivot pin
EI ~
Side seal
Control
~<@
,~~
lEal~
Vane ring
.M-~EI~
SA T648A
DISASSEMBLY 1. Loosen bolts in numerical order and remove oil pump cover.
SAT649A
Inscribe
identification
mark
2. Remove rotor, vane rings and vanes. Inscribe a mark on back of rotor for Identification of fore-aft direction when reassembling rotor. Then remove rotor.
3. While pushing on cam ring remove pivot pin. Be careful not to scratch oil pump housing.
AT-101
. .
oil pump
6. Remove pivot pin from control piston and remove control piston assembly.
7. Remove oil seal from oil pump housing. Be careful not to scratch oil pump housing.
SAT655A
INSPECTION Oil pump cover, rotor, vanes, control piston, side seals, cam ring and friction ring Check for wear or damage.
SA T656A
AT -1 02
Vane
SAT657A
Side clearances Measure side clearances between end of oil pump housing and cam ring, rotor, vanes and control piston in at least four places along their circumferences. Maximum measured values should be within specified ranges. Before measuring side clearance, check that friction rins~, O-ring, control piston side seals and cam ring sprinb are removed. Standard clearance: Cam ring 0.01 - 0.024 mm (0.0004 - 0.0009 in) Rotor, vanes, control piston 0.03 - 0.044 mm (0.0012 - 0.0017 in) If not within standard clearance, replace oil pump assembly except oil pump cover assembly.
. .
Clearance
lr
Seal ring
Seal ring clearance Measure clearance between seal ring and ring groove. Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 in) Wear limit: 0.25 mm (0.0098 in) If not within wear limit, replace oil pump cover assembly.
. .
SA T658A
ASSEMBLY 1. Drive oil seal into oil pump housing. Apply A.T.F. to outer periphery and lip surface.
2. Install cam ring in oil pump housing by the following stops. a. Install side seal on control piston. Pay attention to its direction - Black surface goes toward control piston. Apply petroleum jelly to side seal. b. Install control piston on oil pump
. .
AT-1 03
d. Assemble cam ring, cam ring spring and spring seat. Install spring by pushing it against pump housing.
3. Install rotor, vanes and vane rings. Pay attention to direction of rotor.
SAT662A
4. Install oil pump housing and oil pump cover. a. Wrap masking tape around splines of oil pump cover assembly to protect seal. Position oil pump cover assembly in oil pump housing assembly, then remove masking tape. b. Tighten bolts in a criss-cross pattern.
AT -104
E!!I@
Large dia. seal rings
j~~~
--::::~>
.
~~
YL~
~==,/- ~--:-,
5. Install seal rings carefully after packing ring grooves with petroleum jelly. Press rings down into jelly to a close fit. . Sealrings come in two different diameters. Check fit carefully in each groove. Small dia. seal ring: No mark Large dia. seal ring: Yellow mark in area shown by arrow Do not spread gap of seal ring excessively while installing. It may deform ring.
SA T663A
AT -1 05
Harness clips
Harness clips
Lower body
Orifice check spring Orifice check valve Reamer bolt Reamer bolt Pilot filter Lower separate gasket
~. -
~. -'
Separator plate
Side plate
Upper body
O-"og~
\ '~ ~. ~~\Q
-~
~\
.
-;~
\ O-'og~
(overrun clutch solenoid and
shift ,o'oooid ,,,"mb'y 3-00" solenoids A and B)
AT-106
SAT194B
c. Remove line pressure solenoid from upper body. d. Remove a-ring from solenoid.
SA T667 A
e. Remove 3-unit solenoid assembly from upper body. f. Remove a-rings from solenoids.
SAT668A
2. Disassemble upper and lower bodies. a. Place upper body facedown, and remove bolts, reamer bolts and support plates. b. Remove lower body, separator plate and separate gasket as a unit from upper body. Be careful not to drop pilot filter, orifice check valve, spring and steel balls.
c. Place lower body facedown, and remove separate gasket and separator plate. d. Remove pilot filter, orifice check valve and orifice check spring.
SA T670A
AT-107
REPAIR FOR COMPONENT PA.RTS Control Valve Assembly (Cont'd) e. Check to see that steel balls are properly positioned in upper body and then remove them from upper body.
SAT671A
Check to see that there are pins and retainer plates in lower body.
SAT672A
.
.
Check to see that there are pins and retainer plates in upper body. Be careful not to lose these parts.
SAT673A
Tube connector
.
.
Check to make sure that oil circuits are clean and free from
0 00
O'o'--.r 0000 0
o~ o~0 0 0 0 oo ~
) ~ 00
0 0 00
Separator plates . Check to make sure that separator plate is free of damage and not deformed and oil holes are clean.
0
0
'0
0
0
0
0 0
0 C ' 00 0
00
cc" 0' 0
'0
0 '" 0 0 0",", o~ 0
00
0
'0 0 Do 0
0 0 I
~
= ,[l
=
0' 0
= 0, 0 c"g 0 g c? 0 00 OC "go
~ ,00
"0
Co 0
OC 0
gD"c"5 0 0
0
0
"",,,00
0 c
0
0
g
0 0
0 .0.
DOO
00
SAT675A
AT - t08
SA T676A
Lock-up solenoid Check that filter is not clogged or damaged. Measure resistance. - Refer to "Electrical Inspection".
. .
Components
SAT091
Line pressure solenoid Check that filter is not clogged or damaged. Measure resistance. - Refer to "Electrical Inspection".
. .
Components
SAT092B
3-unit solenoid assembly (Overrun clutch solenoid and shift solenoids A and B) Measure resistance of each solenoid. - Refer to "Electrical Components Inspection".
SAT095B
Refer to "Electrical
Components
SAT196B
AT -1 09
b. Install reamer bolts from bottom of upper body and install separate gaskets.
c. Place oil circuit of lower body face up. Install orifice check spring, orifice check valve and pilot filter.
SAT682A
d. Install lower separate gaskets and separator plates on lower body. e. Install and temporarily tighten support plates, fluid temperature sensor and tube brackets.
AT-110
SAT198B
g.
Install
and
a 70 (2.76)
b 50 (1.97)
c 33 (1.30)
d 27 (1.06)
@--
Side plate
2. Install solenoids. a. Attach a-ring and install lock-up solenoid and side plates onto lower body.
SA T200B
SAT668A
c. Attach a-ring and install line pressure solenoid onto upper body. 3. Tighten all bolts.
SAT667A
AT-111
CD R
/
Sleeve
Lock-up control valve Upper body
.~
Pin
\
Retainer Plate/
crm1rn
\ \ ~
i\
((((O '\)
~
~
0
13 Return spring
\
' ~
' ~9--'
"W~#' \
J
e
@"'7/
~/~?7
cV - cJI-/ /
/0~
'" ~
!i
I II II
@ Return spring
~/
--.I
0 1 ~
.
'
1 1;
'
!~ct
P",~""",~" "',,
'(Cf)
CID
CV Return s
-r
,r-'-~
Return spnng
~Pi Plug
//
~
~
G1
CL.' C-L-.
~~/ ~
. . ~
#.
(j])eturn R
.r-..,~
~12 ;t fl L!: ~o Ar I , ~
. .
;; 77 // ~~~GG/~/ \
~fjYP
Z
.
SI
eeve
0Cf
mPlug~
'\
crnQ
@R"'"
I~
j@R"''''':",mkco P'" ~
Shift valve B
~
'
Sho
'
Retainer pl
Pin
L
!II ~ ~ CD W .... CD
/ ,
/ '1" R 11;(<0
(7)
amL
Plug
C
Shift
,
\U
valve
~ ~
[((0
@ Return spring
'
A
({{((((CQ".
<tV
Retainer plate
'B" R t
'''
~e~~
~~n
=yd]
P'"'
~~Pin
Plug Numbers preceding valve springs correspond shown in Spring Chart on page AT-115,
SAT834A
b. Remove parallel pins while pressing their corresponding plugs and sleeves. Remove plug slowly to prevent internal parts from jumping out.
~'~)(S:f/ v~-:::::y~ ") ) ,L"/~ ~~"~---"-S -":;)'--~' 7'(\ "~ ~u-~d':.7"-' ' '-J' (J '~ \ ~<:::;;~~J~-'-'CJ~-'0r ~~ ('\\\ -~
/ u -7~::: i::::/-S-,Y
.,<:2?C::::::'0~1:,:::;-<:::7"
/e~~~I\\~,-, ~ ,u--"u!(-'l--.l~~
~---~~0
"\
-42/b4Q)2)0;,)y ~
~ r
I ' v( /-C:::;'
~~~
~~
c. Place mating surface of valve facedown, and remove internal parts. If a valve is hard to remove, place valve body facedown and lightly tap it with a soft hammer. Be careful not to drop or damage valves and sleeves.
. .
-@/~j,~'it
'
Soft hammer
SA T824A
2. Remove valves at retainer plates. a. Pry out retainer plate with wire paper clip.
Retainer plate
SAT825A
AT-113
SA T826A
. .
Soft hammer
SAT827A
.
-
.--::.-~ /~..-
'~~
~l
I~ Parallel :r--~//( .~ (~
i~
( '(0:;'
pin
.
(S;
4-2 sequence valve and relay valve are located far back in upper body. If they are hard to remove, carefully push them out using stiff wire. Be careful not to scratch sliding surface of valve with wire.
~,,~
:",-.J~~6/.-S
/.//.::~~;-~
~(~\\IJ~IJ\\
Shiftw~
~~
SAT828A
AT-114
i5 ~ :; 0
0
'"
~
-
--r\
\\\ \
-
Valve springs Measure free length and outer diameter of each valve spring. Also check for damage or deformation. Numbers of each valve spring listed in table below are the same as those in the figure on AT-112.
. .
Q . Free length
SAT829A
Inspection standard
Item Parts CD CV
CID
Unit: mm (in) Part No. 31742-41X18 31742-41X16 31742-41 X19 31762-41XOO 31756-41 XOO 31762-41 X01 31756-41XOO 31762-41 X01 31762-41X03 31742-41 X20 31762-41X04 31742-41X13 31742-41X22 Q 32.3 (1.272) 61.5 (2.421) 31.95 (1.2579) 26.5 (1.043) 29.1 (1.146) 25.0 (0.984) 29.1 (1.146) 25.0 (0.984) 23.6 (0.929) 32.5 (1.280) 51.0 (2.008) 25.7 (1.012) 18.5 (0.728) D 9.0 (0.354) 8.9 (0.350) 6.8 (0.268) 6.0 (0.236) 6.95 (0.2736) 7.0 (0.276) 6.95 (0.2736) 7.0 (0.276) 7.0 (0.276) 7.0 (0.276) 5.65 (0.2224) 9.1 (0.358) 13.0 (0.512)
Torque converter relief valve spring Pressure regulator valve spring Pressure modifier valve spring Shuttle shift valve D spring 4-2 sequence valve spring Shift valve B spring 4-2 relay valve spring Shift valve A spring Overrun clutch control valve spring Overrun clutch reducing valve spring Shuttle shift valve S spring Pilot valve spring Lock-up control valve spring
@
CID
<@
m
@ @ @ ([j) @ @
. .
AT -11
Wrap a small screwdriver with vinyl tape and use it to insert the valves into proper position.
~ ' ':;'" -
~I I
~
~~
r
Sleeve
Y-'--"';
II
~.
--.J::::
~
'\'\';!
C)J~"
~ij
0
I~
~
~ r
""
If pressure
regulator
properly,
sleeve
II u71)) 7~
p.,'h ',"~
/
'r'
) If
!
cannot be inserted into bore in upper body. If this happens, use vinyl tape wrapped screwdriver center sleeve until it can be inserted. Turn sleeve slightly while installing.
to
I ""'l7<\
"Center plug
r--:-~'CZ~ ! II ~_I"~)
-I
I SAT832A
Accumulator control plug . Align protrusion of accumulator control sleeve with notch in plug. Align parallel pin groove in plug with parallel pin, and install accumulator control valve.
~~
,=
~I
)
I
Notch
/"
~~f~ ,
, -----------
1(0:; ~JJ
+---rr~)~ l~.
SA T833A
/
2. Install parallel pins and retainer plates.
SA T834A
AT-116
REPAIR FOR COMPONENT PARTS Control Valve Upper Body (Cont'd) . Whilepushing plug,installparallelpin.
I,
~. ,
Parallel
,~}p!n~
:::2...y-/---uO-..:::::J
~ rE v/:\
':>
~
II
4-2 sequence valve and relay valve Push 4-2 sequence valve and relay valve with wire wrapped in vinyl tape to prevent scratching valve body. Install parallel pins.
~ ':::::::::::
~-'--&
Wire
I.//. '--
~(j~~~~;:;fS
Cj\\C) ~
,:J,,&~
~-:
if1-J-:G .
GG
SAT835A
.
00
Retainer plate
SAT836A
AT-117
Lower body
Pin
!i
... ...
co
I
Retainer plate
~
3-2 timing valve
@ Return spring
--,
~Pin
~
~--
CD
Retainer late---\cl P
f!!!j-- Plug
Manual valve
(I) to>
en ~ -i
" ~
SA T838A
INSPECTION
:;; Qj E as '6 :;; '5 0
0
.~
.-
\\\ \
Q : Free length
Valve springs Check each valve spring for damage or deformation. Also measure free length and outer diameter. Numbers of each valve spring listed in table below are the same as those in the figure on AT-118.
. .
SAT829A
Inspection standard:
Item Parts CD '@
CID
Unit: mm (in) Part No. 31742-41X15 31756-41X05 31742-41 X08 31742-41X06 Q 30.5 (1.201) 25.4 (1.000) 20.55 (0.8091) 23.0 (0.906) D 9.8 (0.386) 6.75 (0.2657) 6.75 (0.2657) 6.7 (0.264)
Modifier accumulator piston spring 1st reducing valve spring 3-2 timing valve spring Servo charger valve spring
. .
Control valves Check sliding surfaces of control valves, sleeves and plugs for damage.
ASSEMBLY Install control valves. For installation procedures, refer to "ASSEMBLY" of Control Valve Upper Body.
SA T838A
AT -11 9
Reverse Clutch
For the number of clutch sheets (drive plate and driven platel. refer to the below cross-58ction.
~:
R.~~. d"Iohd,"m~
Dish plate
SAT839A
SA T840A
2. Check operation of reverse clutch. a. Install seal ring onto oil pump cover and install reverse clutch. Apply compressed air to oil hole. b. Check to see that retaining plate moves to snap ring. c. If retaining plate does not move to snap ring, D-ring or oil seal may be damaged or fluid may be leaking at piston check ball.
SAT841A
AT -1 20
SAT842A
4. Remove snap ring from clutch drum while compressing clutch springs. Do not expand snap ring excessively. 5. Remove spring retainer and return spring.
SAT843A
6. Install seal ring onto oil pump cover and install reverse clutch drum. While holding piston, gradually apply compressed air to. oil hole until piston is removed. Do not apply compressed air abruptly. 7. Remove D-ring and oil seal from piston.
INSPECTION Reverse clutch snap ring and spring retainer Check for deformation, fatigue or damage.
SAT844A
Q; E <II
.-
~
Thickness
~
.
Reverse clutch return springs Check for deformation or damage. Also measure free length and outside diameter.
\\ ;
~ SAT829A
Inspection standard:
Unit: mm (in) Parts Spring Part No. 30505-41 X02 fl 19.69 (0.7752) D 11.6 (0.457)
fl . Free length
Facing
Reverse clutch drive plates Check facing for burns, cracks or damage. Measure thickness of facing. Thickness of drive plate: Standard value: 2.0 mm (0.079 in) Wear limit: 1.8 mm (0.071 in) If not within wear limit, replace.
. . .
Core plate
SA T845A
AT-121
Reverse clutch piston Shake piston to assure that balls are not seized. Apply compressed air to check ball oil hole opposite the return spring to assure that there is no air leakage. Also apply compressed air to oil hole on return spring side to assure that air leaks past ball.
. . .
SA T846A
Oil seal
C@
ASSEMBLY 1. Install O-ring and oil seal on piston. Apply A.T.F. to both parts.
SAT847A
@)
2. Install piston assembly by turning it slowly and evenly. Apply A.T.F.to inner surface of drum.
SA T848A
SAT849A
SAT843A
AT-122
5. Install drive plates, driven plates, retaining plate and dish plate.
Drive plate
Driven plate
Di,h I'''/\:~~J! P
SAT851A
7. Measure clearance between retaining plate and snap ring. If not within allowable limit, select proper retaining plate. Specified clearance: Standard 0.5 - 0.8 mm (0.020 - 0.031 in) Allowable limit 1.2 mm (0.047 in)
/ Retaining plate: Refer to S.D.S.
SAT841A
AT-123
~
~ @
~
I" D-ring(Large)
I I
~~
Driven plate
,.
'"
Snap ring
R"um",,;,,)
Spring retainer Drive plate
~
*
: ApplyA.T.F.
Service procedures for high clutch are essentially the same as those for reverse clutch, with the following exception:
AT -1 24
I.
SA T855A
.... CI)
.
-
'i'i
Q; E 01
....
CI)
'5 0 c
~
.-
-~
. .
Inspection standard:
I
\\,
\ \
Part No.
31505-21 X03
D 11.6 (0.457)
Q : Free length
SAT829A Thickness
Facing
Inspection of high clutch drive plate Thickness of drive plate: Standard 1.6 mm (0.063 in) Wear limit 1.4 mm (0.055 in)
Core plate
SA T845A
Measurement 9f clearance between retaining plate and snap ring Specified clearance: Standard 1.8 - 2.2 mm (0.071 - 0.087 in) Allowable limit 3.0 mm (0.118 in) Retaining plate: Refer to S.D.S.
SA T858A
AT -1 25
Retaining plate *
Drive plate
@t>
- Driven plate
---IJ
Dish plate
'
~lutchPlate
Forwad
'
I
,
'
O"'o,~@P
r <m,~@P
If
.-,it" JI-'C
"" \\
'H"
.. N
"'" w
II ...
"" II ~ IRII 11
II \
,~
JV
Return spring
~
I
"-/
..
, ,"'"
"'"
~~'-- Fm
So.."0'
.J
retainer
0 ~ I seal ~~ ~
"
,.':'~
'
Driven plate
@
*
: Apply A.T.F.
: Selectwithproperthickness.
SAT810B
AT-126
Removal of forward clutch drum Remove forward clutch drum from transmission holding snap ring.
case by
Removal of forward clutch and overrun clutch pistons 1. While holding overrun clutch piston, gradually apply compressed air to oil hole.
SAT862A
SA T863A
AT -127
... Q)
Q; E <II '5
0
.
-
Inspection springs
of forward
clutch
and overrun
clutch
return
:;
c
... Q)
~
.-
~.
-
\\,, .
\
Inspection standard:
Part
No. Q
Unit: mm (in)
D 9.7 (0.382)
31505.41 X01
35.77 (1.4083)
Q : Free length
SAT829A Thickness
.
Facing
Inspection of forward clutch drive plates Thickness of drive plate: Standard 2.0 mm (0.079 in) Wear limit 1.8 mm (0.071 in)
Core plate
SAT845A Thickness
.
Facing
Thickness of drive plate: Standard 2.0 mm (0.079 in) Wear limit 1.8 mm (0.071 in)
Core plate
SAT845A
Installation of forward clutch piston and overrun clutch piston 1. Install forward clutch piston by turning it slowly and evenly. Apply A.T.F. to inner surface of clutch drum.
AT-1 28
Align notch in forward clutch piston with groove in forward clutch drum.
SA T867 A /'
2. Install overrun clutch by turning it slowly and evenly. Apply A.T.F. to inner surface of forward clutch piston.
SA T868A
Measurement of clearance between retaining plate and snap ring of overrun clutch Specified clearance: Standard 1.0 - 1.4 mm (0.039 - 0.055 in) Allowable limit 2.0 mm (0.079 in) Retaining plate: Refer to S.D.S.
Measurement of clearance between retaining plate and snap ring of forward clutch Specified clearance: Standard 0.45 - 0.85 mm (0.0177 - 0.0335 in) Allowable limit 1.85 mm (0.0728 in) Retaining plate: Refer to S.D.S.
AT -1 29
Driven plate
Direction
of oil seal
m~: *
: Apply A.T.F. Driveplate Apply petroleum jelly. : Select with proper thickness.
SAT811B
a. Install seal ring onto oil pump cover and install reverse clutch. Apply compressed air to oil hole. b. Check to see that retaining plate moves to snap ring.
c. If retaining plate does not move to snap ring, D-ring or oil seal may be damaged or fluid may be leaking at piston check ball.
2. Remove snap ring, low and reverse brake drive plates, driven plates and dish plate.
SAT873A
AT-130
REPAIR FOR COMPONENT PARTS Low & Reverse Brake (Co nt' d)
3. Remove low one-way clutch inner race, spring retainer and return spring from transmission case.
4. Remove seal rings from low one-way~clutch inner race. 5. Remove needle bearing from low one-way clutch inner race.
SAT875A
6. Remove low and reverse brake piston using compressed air. 7. Remove oil seal and O-ring from piston. INSPECTION Low and reverse brake snap ring and spring retainer Check for deformation, or damage.
'" '5
t :; 0
0
OJ E
~
Thickness
Low and reverse brake return springs Check for deformation or damage. Also measure free length and outside diameter.
. .
\\
\
Inspection standard:
SAT829A
Part No.
31521-21XOO
Q : Free length
Low and reverse brake drive plates Check facing for burns, cracks or damage.
Facing
. .
Measure
thickness
of facing.
Core plate
.
SAT845A
Thickness of drive plate: Standard value 2.0 mm (0.079 in) Wear limit 1.8 mm (0.071 in) If not within wear limit, replace.
AT-131
REPAIR FOR COMPONENT PARTS Low &, Reverse Brake (Cont'd) Low one-way clutch inner race Check frictionalsurface of inner race for wear or damage.
SAT877A
1
~ng
r Clearance
. . .
.
SAT878A
Install a new seal rings onto low one-way clutch inner race. Be careful not to expand seal ring gap excessively. Measure seal ring-to-groove clearance. Inspection standard: Standard value: 0.10 - 0.25 mm (0.0039 - 0.0098 in) Allowable limit: 0.25 mm (0.0098 in) If not within allowable limit, replace low one-way clutch inner race.
C)-m
...
(!>J
ASSEMBLY 1. Install bearing onto one-way clutch inner race. Pay attention to its direction - Black surface goes to rear side. Apply petroleum jelly to needle bearing.
SAT112B
Oil seal
2. Install oil seal and D-ring onto piston. Apply A.T.F. to oil seal and D-ring.
D-ring <:@
SAT879A
t 3. Install piston by rotating it slowly and evenly. Apply A.T.F. to inner surface of transmission case.
AT -1 32
Driven plate
5. Install dish plate, low and reverse brake drive plates, driven plates and retaining plate. 6. Install snap ring on transmission case.
Drive plate
SAT812B
7. Check operation of low and reverse brake clutch piston. Refer to "DISASSEMBLY".
SAT872A
8. Measure clearance between retaining plate and snap ring. If not within allowable limit, select proper retaining plate. Specified clearance: Standard 1.1 - 1.5 mm (0.043 - 0.059 in) Allowable limit 2.5 mm (0.098 in) Retaining plate: Refer to S.D.S.
I
'
~J
(;-~
",]
"
/\
'
~ I\
I
/"
t/.
,
(
~'-
'\
,,*'/,~.
~=
,
f
,
~~
,
=~
I
"
-(
~- U
~,
17
/
.
I~
~
:
"
. .
'\: IC
\
..
Apply petroleum jelly to seal ring. Make sure seal rings are pressed held by petroleum jelly.
~
,
"
~\
\
".
/1
[\ \
\ r.
~r
;;'.
\
~ I,
(
(
AT -1 33
"
~
I
..
II.
( \0 SAT884A
I~N
Needle bearing Snap ring Low one-way clutch Side plate Snap ring
~
~ ~
~"
-''''''''
0.., -.
J;J -. '> -.
-!. .., I
(
-. -.
SAT886A
0.
SA T888A
\/
SA T889A
AT -1 34
SAT891A
~~
...~
INSPECTION Forward clutch drum Check spline portion for wear or damage. Check frictional surfaces of low one-way clutch and needle bearing for wear or damage.
. .
SAT892A
Needle bearing and low one-way clutch Check frictional surface for wear or damage.
SAT893A
SAT113B
AT-135
3. Install low one-way clutch onto forward pushing the roller in evenly.
clutch drum by
SAT894A
SAT895A
)
4. Install side plate onto forward clutch drum. 5. Install snap ring onto forward clutch drum.
AT -1 36
REPAIR FOR COMPONENT PARTS Rear Internal Gear and Forward Clutch Hub
Thrust washer
lEI @
Forward clutch hub (with forward one-way clutch outer race) Snap ring Forward one-way clutch
6ri~
End bearing
lEI
DISASSEMBLY 1. Remove rear internal gear by pushing forward clutch hub forward.
SA T897 A
f)
SAT898A
SAT899A
AT-137
REPAIR FOR COMPONENT PARTS Rear Internal Gear and Forward Clutch Hub (Cont' d)
4. Remove end bearing.
IIT'n,,,
~ B/
~
~...~
-~0'GIi)~
SAT900A
5. Remove forward one-way clutch and end bearing as a unit from forward clutch hub.
...
"-
:::=-~!)
SAT955A
Illh I-~~,f),
SAT901A
..
..
..
SAT902A
INSPECTION Rear internal gear and forward clutch hub Check gear for excessive wear, chips or cracks. Check frictional surfaces of forward one-way clutch and thrust washer for wear or damage. Check spline for wear or damage.
. . .
oc) 00
SAT903A
AT -1 38
REPAIR FOR COMPONENT PARTS Rear Internal Gear and Forward Clutch Hub (Cont'd)
ASSEMBLY 1. Install snap ring onto forward clutch hub. 2. Install end bearing.
SAT901A
3. Install forward one-way clutch onto clutch hub. Install forward one-way clutch with flange facing rearward. 4. Install end bearing. 5. Install snap ring onto forward clutch hub.
6. Install thrust washer onto rear internal gear. Apply petroleum jelly to thrust washer. Securely insert pawls of thrust washer into holes in rear internal gear.
. .
8. After installing, check to assure that forward clutch hub rotates clockwise.
SAT905A
AT-1 39
~~
Gasket
O-ring
~ <&V
O-ring
I
,
~ <&V
O-ring
~
0.0. servo piston retainer
~ @V
~ <&V
SAT908A
DISASSEMBLY 1. Block one oil hole in 0.0. servo piston retainer and the center hole in 0.0. band servo piston. 2. Apply compressed air to the other oil hole in piston retainer to remove 0.0. band servo piston from retainer. 3. Remove O-ring from 0.0. band servo piston.
SAT909A
4. Remove band servo piston assembly from servo piston retainer by pushing it forward.
SAT910A
5. Place piston stem end on a wooden block. While pushing servo piston spring retainer down, remove E-ring.
E-ring
SAT911A
AT-140
"e
n_@
SAT912A
SAT913A
8. Remove servo cushion spring retainer from band servo piston. 9. Remove O-rings from band servo piston. 10. Remove Q-rings from servo piston retainer.
SAT914A
~
INSPECTION
..
....
Pistons, retainers and piston stem Check frictional surfaces for abnormal wear or damage.
..
Spring B
Return springs . Check for deformation or damage. Measure free length and outer diameter.
Inspectionstandard:
Spring A
Unit: mm (in)
Free length 45.6 (1.795) 53.8 (2.118) 29.0 (1.142) Outer diameter 3.3 (1.350) 40.3 (1.587) 27.6 (1.087)
SAT916A
Spring C
AT-141
PARTS
. .
SAT919A
5. Install servo piston spring retainer, return spring C and piston stem onto band servo piston.
'@&
~@
SAT912A
AT-142
SAT921 A
7. Install band servo piston assembly onto servo piston retainer by pushing it inward.
SAT922A
SAT923A
9. Install 0.0. band servo piston onto servo piston retainer by pushing it inward.
SAT924A
AT-143
24
- 29 N.m
17
- 22 ft-Ib)
Rear extension
2. Remove return spring, pawl spacer and parking pawl from rear extension. 3. Remove parking pawl shaft from rear extension.
SAT927A
4. Remove parking actuator support and rod guide from rear extension.
AT-144
'"
SAT929A
ASSEMBLY 1. Install rod guide and parking actuator support extension. 2. Insert parking pawl shaft into rear extension. onto rear
3. Install return spring, pawl spacer and parking pawl onto parking pawl shaft.
SAT927A
AT-145
ASSEMBL Y
Assembly
1. a. . . b. Install manual shaft components. Install oil seal onto manual shaft. Apply A.T.F. to oil seal. Wrap threads of manual shaft with masking tape. Insert manual shaft and oil seal as a unit into transmission case. c. Remove masking tape.
SAT931 A
\
e. Align groove in shaft with drive pin hole, then drive pin into position as shown in figure at left.
SA T933A
f.
g. While pushing detent spring down, install manual plate onto manual shaft.
AT -146
ASSEMBL Y
Assembly (Cont'd)
h. Install lock nuts onto manual shaft.
SAT936A
Front. .
Accumulator
piston B
Accumulator
Apply A.T.F. to O-rings. Unit: mm (in) B 32 (1.26) 50 (1.97) C 45 (1.77) 50 (1.97) D 29 (1.14) 45 (1.77)
AE..o,
piston A
tJ tr{'Ob
Accumulator
A 29 (1.14) 45 (1.77)
piston C
SA T937 A
b. Install return spring for accumutator case. Free length of return spring:
Accumulator
Free length
A onto transmission
Unit: mm (in) A
43 (1.69)
c.
Install accumulator
pistons
A, S, C and D.
3. Install band servo piston. a. Install return springs onto servo piston.
SAT941 A
AT -14 7
4. Install rear side clutch and gear components. a. Place transmission case in vertical position.
ST07870000
(J37068)
SAT943A
.;:I
b. Slightly lift forward clutch drum assembly and slowly rotate it clockwise until its hub passes fully over the clutch inner race inside transmission case.
SAT944A
-----------------
SAT945A
AT ~ 148
SAT946A
SAT947A
f.
Install needle bearing onto rear of overrun clutch hub. Apply petroleum jelly to needle bearing.
SAT948A
hub rotates
as shown while
SAT949A
SAT950A
AT-149
j.
Install needle bearing onto rear internal gear. Apply petroleum jelly to needle bearing.
k. Install bearing race onto rear of front internal gear. Apply petroleum jelly to bearing race. . Securely engage pawls of bearing race with holes in front internal gear.
I.
AT -1 50
ASSEMBL Y
Adjustment
When any parts listed in the following table are replaced, total end play or reverse clutch end play must be adjusted.
Total end play case clutch hub gear carrier inner race 8 8 8 8 8 8 carrier 8 8 8 8 8 drum Reverse clutch end play 8 8 8 8 8 8 8 8 8 8 8
8
High clutch
1. Install front side clutch and gear components. a. Install rear sun gear on transmission case. Pay attention to its direction.
b. Install needle bearing on front of front planetary carrier. Apply petroleum jelly to needle bearing. c. Install needle bearing on rear of front planetary carrier. Apply petroleum jelly to bearing. Pay attention to its direction - Black side goes to front.
. . .
SAT967A
AT -151
..,
SAT969A
.
F rant planetary carrier
Check that portion A of front planetary carrier protrudes approximately 2 mm (0.08 in) beyond portion B of forward clutch assembly.
,
Portion A
'.-=
...:::.'.
Portion B SAT970A
O---El~ ~~
e. Install bearing races on rear of clutch pack. Apply petroleum jelly to bearing races. Securely engage pawls of bearing race with hole In clutch pack.
. .
~f}Jj ~ r~:
""--~-L
'
//
/
SA T204B
f.
SAT973A
AT -1 52
a. With needle bearing installed, place J34291-1 (bridge), J34291-2 (legs) and the J34291-5 (gauging cylinder) ente eil pump. The leng ends ef legs sheuld be placed firmly en machined surface ef eil pump assembly and gauging cylinder sheuld rest en tep ef the needle bearing. Leck gauging cylinder in place with set screw.
c. With eriginal bearing race installed inside reverse clutch drum, place shim selecting gauge with its legs en machined surface ef transmissien case (no. gasket) and allew gauging plunger to. rest en bearing race. Leck gauging plunger in place with set screw.
d. Remeve To.el and use feeler gauge to. measure gap between gauging cylinder and gauging plunger. This measurement sheuld give exact tetal end play. Total end play "T,": 0.25 - 0.55 mm (0.0098 - 0.0217 in) If end play is eut ef specificatien, decrease er increase thickness ef eil pump cever bearing race as necessary. Available oil pump cover bearing race: Refer to S.D.S.
SAT979A
AT -1 53
a. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gauging cylinder) on machined surface of transmission case (no gasket) and allow gauging cylinder to rest on front thrust surface of reverse clutch drum. Lock cylinder in place with set screw.
SAT981A
c. With original thrust washer installed on oil pump, place shim setting gauge legs onto machined surface of oil pump assembly and allow gauging plunger to rest on thrust washer. Lock plunger in place with set screw.
Lock
d. Use feeler gauge to measure gap between gauging plunger and gauging cylinder. This measurement should give you exact reverse clutch drum and play. Reverse clutch drum end play "12": 0.55 - 0.90 mm (0.0217 - 0.0354 in) If end play is out of specification, decrease or increase thickness of oil pump thrust washer as necessary. Available oil pump thrust washer: Refer to S.D.S.
AT-154
ASSEMBL Y
Assembly
1. Install output shaft and parking gear. a. Insert output shaft from rear of transmission case while slightly lifting front internal gear. Do not force output shaft against front of transmission case.
;~T216B b. Carefully push output shaft against front of transmission case. Install snap ring on front of output shaft. Check to be sure output shaft cannot be removed in rear direction.
c. Install needle bearing on transmission case. Pay attention to its direction - Black side goes to front. . Apply petroleum jelly to needle bearing.
e. Install snap ring on rear of output shaft. Check to be sure output shaft cannot be removed in forward direciton.
SA T960A
AT -1 55
SAT219B
b. Install O-ring on revolution sensor. Apply A.T.F. to O-ring. c. Install revolution 'sensor on rear extension.
SAT191B
SA T963A
f.
SAT189B
AT-156
b. Make sure needle bearing is on front of front planetary carrier. Apply petroleum jelly to needle bearing. c. Make sure needle bearing is on rear of front planetary carrier. Apply petroleum jelly to bearing. Pay attention to its direction - Black side goes to front.
. . .
SAT967A
d. While rotating forward clutch drum clockwise, install front planetary carrier on forward clutch drum.
SAT969A
Front planetary
carrier
Check that portion A of front planetary carrier protrudes approximately 2 mm (0.08 in) beyond po.rtion B of forward clutch assembly.
Portion A Portion B
SAT970A
e. Make sure bearing races are on front and rear of clutch pack. Apply petroleum jelly to bearing races. Securely engage pawls of bearing races with holes in clutch pack.
. .
Front
Rear SAT971A
AT-157
SAT220B
4. Install brake band and band strut. a. Install band strut on brake band. Apply petroleum jelly to band strut.
SAT985A
b. Place brake band on periphery of reverse clutch drum, and insert band strut into end of band servo piston stem.
c. Install anchor end bolt on transmission case. Then, tighten anchor end bolt just enough so that reverse clutch drum (clutch pack) will not tilt forward.
5. Install input shaft on transmission case. Pay attention to its direction - O-ring groove side is front. 6. Install gasket on transmission case.
AT-158
. .
SA T989A
c. Carefully install seal rings into grooves and press them into the petroleum jelly so that they are a tight fit.
m~
Seal ring
a-ring
lEI ~
SAT991A
e. Apply petroleum jelly to mating surface of transmission case and oil pump assembly.
SAT992A
f.
Install oil pump assembly. Install two converter housing securing bolts in bolt holes in oil pump assembly as guides.
SAT993A
AT-159
Insert oil pump assembly to the specified position in transmission, as shown at left.
SAT114B
b. Apply recommended sealant (Nissan genuine part: KP610-00250 or equivale.nt) to outer periphery of bolt holes in converter housing. Do not apply too much sealant.
SAT997A
c. Apply recommended sealant (Nissan genuine part: KP610-00250 or equivalent) to seating surfaces of bolts that secure front of converter housing.
SA T998A
AT -1 60
10.Adjust brake band. a. Tighten anchor end bolt to specified torque. Anchor end bolt:
~: 4
- 6 N.m
11. Install terminal cord assembly. a. Install O-ring on terminal cord assembly. Apply petroleum jelly to O-ring. b. Compress terminal cord assembly stopper and install terminal cord assembly on transmission case.
12. Install control valve assembly. a. Install accumulator piston return springs B, C and D. Free length of return springs: Item
Free length
Unit: mm (in) 8
c
45 (1.77)
D
58.4 (2.299)
66 (2.60)
AT-161
ASSEMBL Y
Assembly (Cont'd)
b. Install manual valve on control valve. Apply A.T.F. to manual valve.
SATOO58
c. Place control valve assembly on transmission case. Connect solenoid connector for upper body. d. Install connector clip.
e. Install control valve assembly on transmission case. f. Install connector tube brackets and tighten bolts @ and @. Check that terminal assembly harness does not catch.
Bolt @ @
Length
37 mm (1.46 in) 50 mm (1.97 in)
g. Install O-ring on oil strainer. Apply petroleum jelly to O-ring. h. Install oil strainer on control valve.
SAT2218
AT -1 62
tI::~~1
SATOO98
j.
Connector
SAT0118
b. Install oil pan gasket on transmission case. c. Install oil pan and bracket on transmission case. Tighten four bolts In a criss-cross pattern to prevent dislocation of gasket.
SAT0128
II
14. Install inhibitor switch. a. Check that manual shaft is in "1" range. b. Temporarily install inhibitor switch on manual shaft. c. Move manual shaft to "N".
SAT0138
AT -163
\\
--\\
SAT014B
15. Install torque converter. a. Pour A.T.F. into torque converter. Approximately 2 liters (2-1/8 US qt, 1-3/4 Imp qt) of fluid are required for a new torque converter. When reusing old torque converter, add the same amount of fluid as was drained.
. .
SAT015B
SAT016B
c. Measure distance A to check that torque converter is in proper position. Distance "A": 26 mm (1.02 in) or more
AT-164
General Specifications
Engine Autorriatic transmission model Transmission model code number Stall torque ratio Transmission gear ratio 1st . 2nd Top O.D. Reverse Recommended oil Oil capacity II (US qt, Imp qt) KA24E RE4R01A 45X06 2.0: 1
2.785 1.545 1.000 0.694 2.272 Automatic transmission fluid Type DEXRONTM 8.3 (8-3/4,7-1/4)
AND
STALL
REVOLUTION
Stall revolution 2,050 rpm
Vehicle speed km/h (MPH) Lock-up "ON" 146 - 156 (91 -97) Lock-up "OFF" 140 - 150 (87 -93) 89-95 (55-59) 102-110 (63 -68) 71 -79 (44 -49)
-2,250
LINE PRESSURf;
Engine speed rpm Idle line pressure kPa (kg/em' , psi) D,2 and 1 ranges 471 .510 ' (4.8 - 5.2, 68 - 74) 1,020 . 1,098 (10.4 -11.2,148 -159) R range 657 . 696 (6.7 -7.1,95 -101) 1.422 - 1,500 (14.5 - 15.3,206 - 218)
-101
-84
(47 - 52)
Stall
AT-165
31605-41X10
31605-41 X09
31605-41X06
-------------------
27.6 (1.087)
AT-166
IForward
5 5
Thickness of drive plate mm(in) Standard Wear limit Clearance mm (in) Standard Allowable limit
IReverse clutch/
Number of drive plates Number of driven plates Thickness of drive plate mm(in) Standard Wear limit Clearance mm (in) Standard Allowable limit 2 2
0.45 - 0.85 (0.0177 - 0.0335) 1.85 (0.0728) Thickness mm (in) 8.0 8.2 8.4 8.6 8.8 9.0 9.2 (0.315) (0.323) (0.331) (0.339) (0.346) (0.354) (0.362) 3 5 Part number
31537-41 XOO
0.5 - 0.8 (0.020 - 0.031) 1.2 (0.047) Thickness mm (in) 4.6 4.8 5.0 5.2 5.4 5.6 5.8 (0.181) (0.189) (0.197) (0.205) (0.213) (0.220) (0.228) 4 4 Part number 31537-21XOO 31537-21 X01 31537-21X02 31537 -21 X03 31537-21X04 31567-41X13 31567-41 X14
IOverrun
Thickness of drive plate mm (in) Standard Wear limit Clearance mm(in) Standard Allowable limit
IHigh clutch I
Number of drive plates Number of driven plates Thickness of drive plate mm (in) Standard Wear limit Clearance mm(in) Standard Allowable limit
1.0 - 1.4 (0.039 - 0.055) 2.0 (0.079) Thickness mm (in) 4.0 (0.157) 4.2 (0.165) 4.4 (0.173) 4.6(0.181) 4.8 (0.189) 5.0 (0.197) 5.2 (0.205) Part number 31537-41X79 31537-41 X80 31537-41X81 31537-41 X82 31537-41X83 31537-41 X84 31537-41 X20
1.8 - 2.2 (0.071 - 0.087) 3.0 (0.118) Thickness mm(in) 3.6 3.8 4.0 4.2 4.4 4.6 4.8 5.0 (0.142) (0.150) (0.157) (0.165) (0.173) (0.181) (0.189) (0.197) Part number 31537.41X61 31537-41X62 31537-41X63 31537-41X64 31537-41 X65 31537-41X66 31537-41 X67 31537-41X68
AT-167
0.55
- 0.90 mm
Part number
31528-21 XOO' 31528-21 X01 31528-21X02 31528-21 X03 31528-21 X04 31528-21 X05 31528-21 X06
1.1 - 1.5 (0.043 - 0.059) 2.5 (0.098) Thickness mm (in) Part number 31667-41X03 31667-41X04 31667-41X05 31667-41X06 31667-41X09 31667-41 X10
I
Brake band Anchor end bolt tightening torque N.m (kg-m, ft-Ib) Number of returning revolutions for anchor end bolt
(1.1-1.5
Distance between end of clutch housing and torque converter Drive plate runout limit
Rotor, vanes and control piston - oil.pump housing Standard Seal ring clearance mm (in) Standard Allowable limit
0.03
TOTAL
END PLAY
0.25 - 0.55 mm (0.0098 0.0217 in)
Thickness mm (in) 0.8 1.0 1.2 1.4 1.6 1.8 2.0 (0.031) (0.039) (0.047) (0.0551 (0.063) (0.071) (0.079)
Part number
31429-21 XOO 31429-21 X01 31429-21 X02 31429-21 X03 31429-21X04 31429-21 X05 31429-21 X06
AT-168
PD
."
0 0 0.. 0"'" 0 PDPD0''''' 0...0"""0" PD-11
CONTENTS
PREPARATION... PROPELLER SHAFT """"""""""" ""'''''''''''''''''''0'''''''''''''''''''' "'..0 0'"'''' """'"'''''''''''''''''''' 0"
2 5
ON-VEHICLE
SERVICE
(Final drive)
..
0 """""'''''''''''''...0 """"""'"'''''''''' '"'''''''''''' 0'"''''''''''''0''' "'''''''''''''''''''''' 0'"'''' 0..""'''''''...0.0 0'0'"'''''''''''''' 0 ...".
PD- 9
PD-12
''''''''''''''''''''''''''''''''''''''''''''''''''''''
"'"'''''''''''''''''''''''''''''''''''''' """"'''''''''''''''''''''''''''' 0
DISASSEMBLY
PD-13
0. PD-17 PD-18 PD-25
INSPECTION
ADJUSTMENT ASSEMBLY 0 0 o.0
"""''''''0'''''''''''''0''''''''
PD-30
PREPARATION
SPECIAL SERVICE TOOLS
Tool number (Kent-Moore No.) Tool name ST38060002 (J34311) Drive pinion flange wrench
KV38100800
(
Description
~
V
Removing and installing propeller shaft lock nut, and drive pinion lock nut.
ST30031000
(J22912-D1) Puller
@ ST30901000
(
~
~
Removing and installing differential side bearing inner cone
Equivalent tool (J22888) Body @ ST33061 000 (J8107-2) Equivalent tool (J26010-D1) Adapter ST30611000 (J25742-1) Drift
Q}fi
~~
~~ ~~\~.;II';~J..i'Hi1tlI'itr;;;'WJJ
PD-2
PREPARATION
Tool number (Kent-Moore No.) Tool name ST30613000 (J25742-3) Drift
Description
~.
KV381 00200 (J26233) Gear carrier side oil seal drift KV38100500
(
KV38100600 (J25267) Side bearing spacer drift ST3127S000 (See J25765-A) Preload gauge CD GG91030000 (J25765) Torque wrench @ HT62940000
(
~ roo ~ ~
CD
r;==~
~-~
Socket adapter @ HT62900000 ( ) Socket adapter HT72400000 ( ) Slide hammer Removing differential case assembly
PD-3
PREPARATION
Tool number (Kent-Moore No.) Tool name (J34309) Differential shim selector
Description
PD-4
PROPELLER SHAFT
~
.~
3S63A-T
Washer Apply a coat of multi-purpose lithium grease containing molybdenum disulfide to the end face of the center bearing and both sides of the washer.
25-39
'fh<i'-"\\l-/
~QjoJ~
r
~
lJi~
~~
~~
34 -4413.5 -4.5,25-33)
Companion flange
3S63A-R
Washer Apply a coat of multi-purpose lithium grease containing molybdenum disulfide to the end face of the center bearing and both sides of the washer. Center bearing upper mounting bracket
25
- 30,
181
-217)
39
Companion flange
Center bearing assembly Install center bearing with "F" mark t!)ward ~ront of vehicle.
25
19 - 29)
PD-5,
PROPELLER SHAFT
On-vehicle Service
,~
PROPELLER SH~FT VIBRATlON ( If vibration is present at high spee,d, inspect propeller shaft runout first. 1. Raise rear wheels. 2. Measure propeller shaft runout at indicated points by rotating final drive companion flange with hands. Runoutlimit: 0.6 mm (0.024 in)
~i"'
3S63A-R
ABC
Center
~~"m"
Journal
Coupling.
c
SPD872
ABC
3. If runout exceeds specifications, disconnect propeller shaft at final drive companion flange; then rotate companion flange 180 degrees and reconnect propeller shaft. Runout limit: 0.6mm (0.024 in) 4. Check runout again. If runout still exceeds specifications, replace propeller shaft assembly. 5. Perform road test. APPEARANCE CHECKING
. .
Inspect propeller shaft tube surface for dents or cracks. If damaged, replace propeller shaft assembly. If center bearing is noisy o~ damaged, replace center bearing.
/
Transmission
Removal
Draw out propeller shaft from transmission and plug up rear end of transmission rear extension housing.
SPD359
PD-6
PROPELb.ER SHAFT
.Installation.
~nted ~rk-j~ Painted mark;;::
.
.
Temporarily install differential companion flange and flange yoke so that their alignment marks are located as close to each other as possible. Turn propeller shaft until alignment marks face straight upward. Securely fasten propeller shaft so that lower side wall of concave flange yoke will touch lower side wall of convex companion flange.
Inspection
Inspect propeller shaft run'out. If runout exceeds specifications, replace propeller shaft assembly. Runout limit: 0.6 mm (0.024 in)
~
SPD106
.
// /~~
Inspect journal axial play. If the play exceeds specifications, replace propeller shaft assembly. Journalaxial play: 0 mm (0 in)
SPD874
Disassembly CENTER BEARING 1. Put matchmarks on flanges, and separate 2nd tube from 1st
tube.
/\
SPD109
SPD110
PD-7
SPD 111
SPD112
5. Remove center bearing with Tool and press. Tool number: ST30031000 (J22912-01)
. .
When installing center bearing, position the "F" mark on center bearing toward front of vehicle. Apply a coat of multi-purpose lithium grease containing molybdenum disulfide to the end face of the center bearing and both sides of the washer.
. .
Stake the nut. Always use new one. Align matchmarks when assembling tubes.
SPD117
~'\
pl1:8
5. Apply multi-purpose grease to sealing lips of oil seal. Press front oil seal into carrier. 6. Install companion flange and drive pinion nut. 7. Install propeller shaft.
Side Oil Seal Replacement 1. Remove drive shafts. Refer to RA section. 2. Remove oil seal.
P.D-9
-)
3. Apply multi-purpose
PD-'O
. . . . .
Installation
Filler opening
:C!;' :
SPD882
PD-11
~
bearing spacer
er
Spe
Side
", "
,h,f<-
' , mate
Pinion
Breath
?
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l~O
Sidel?e
""
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\:
.
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.
I Inner
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CI
e,,,"'"
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R", ,.,,,
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t
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P' , "',,'" ''''' ,moo ' spacer* g adJusting P,,'oo b""O" washer* g adJusting
,
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,
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a
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;PIQtn 0
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.et
,IJI Differential
case
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Companion
""",,
bea
flange
en
DISASSEMBLY
Pre-inspection
Before disassembling final drive, perform the following inspection. Total preload 1) Turn drive pinion in both directions several times to set bearing rollers. 2) Check total preload with Tool. Tool number: ST3127S000 (See J25765-A.) Total preload: 1.4 - 1.7 N.m (14 - 17 kg-em, 12 - 15 in-Ib)
SPD884
Ring gear to drive pinion backlash Check ring gear-to-drive pinion backlash with a dial indicator at several points. Ring gear-to-drive pinion backlash: 0.10 - 0.15 mm (0.0039 - 0.0059in)
SPD513
. .
0../"/11
Ring gear runout Check runout of ring gear with a dial indicator. Runout limit: 0.05 mm (0.0020 in) Tooth contact Check tooth contact. (Refer to Adjustment.)
Side gear to pinion mate gear backlash Measure clearance between side gear thrust washer and differential case with a feeler gauge. Clearance between side gear thrust washer and differential case: 0.1 - 0.2 mm (0.004 - 0.008 in)
SPD887
Differential Carrier
1. Using two 45 mm (1.77 in) spacers, mount carrier on Tool.
Tool number:
KV38100800
PD-13
Bearing caps are line-board during manufacture. Replace them in their proper positions.
SP D889
out with
Tool.
)
PD344
6 ?
~.
SPD527
Keep the side bearing outer races together with inner cone do not mix them up.
flange.
SPD890
PD-14
SPD891
6. Take out drive pinion (together with rear bearing inner race, bearing spacer and adjusting washer). 7. Remove oil seal. 8. Remove front bearing inner race. 9. Remove side oil seal.
PD349 /.'-~ I
11. Remove pinion rear bearing inner race and drive pinion
height adjusting washer with suitable tool.
\ ""'-7
./
<.~.
.Tool
_H..
.--. .
---- --
-- -PD179
PD-15
SPD529
SPD022
2. Loosen ring gear bolts in a criss-cross fashion. 3. Tap ring gear off the differential case with a soft hammer. Tap evenly all around to keep ring gear from binding.
4. Drive out pinion mate shaft lock pin, with punch from ring gear side. Lock pin is calked at pin hole mouth on differential case.
SPD025
PD-16
SPD909
Bearing 1. Thoroughly clean bearing. 2. Check bearings for wear, scratches, pitting or flaking. Check tapered roller bearing for smooth rotation. If damaged, replace outer race and inner cone as a set.
SPD715
PD-17
ADJUSTMENT
For quiet and reliable final drive operation, the following five adjustments must be made correctly. 1. Side bearing preload 2. Pinion gear height 3. Pinion bearing preload 4. Ring gear-to-pinion backlash (Refer to ASSEMBLY.) 5. Ring and pinion gear tooth contact pattern
6
011
1. Make sure all parts are clean and that the bearings are well lubricated with light oil or DexronTMtype automatic transmission fluid. 2. Place the differential carrier, with side bearings and bearing races installed, into the final drive housing.
~ ~
SPD527
3. Put the side bearing spacer in place on the ring gear end of the carrier.
4. Using the. J-25267 side bearing spacer drift, place both of the original carrier side bearing preload shims on the carrier end, opposite the ring gear.
PD-18
7. Measure the turning torque of the carrier at the ring gear retaining bolts with a spring gauge, J-8129. Specification: 34.3 - 39.2 N (3.5 - 4 kg, 7.7 - 8.8 Ib) of pulling force at the ring gear bolt.
L--I
I I
.---i., ,
'-, ,
8. If the carrier turning torque is not within the specification range, increase or decrease the total thickl1ess of the side bearing adjusting washers until the turning torque is correct. If the turning torque is less than the specified range, install washers of greater thickness; if the turning torque is greater than the specification, install thinner washers. See the S.O.S. section for washer dimensions and part numbers. 9. Record the total amount of washer thickness required for the correct carrier side bearing preload.
10. Remove the carrier from the final drive housing, saving the selected preload washers for later use during the assembly of the final drive unit.
PD344
- iPt= I
I!DIiIIIIIIIIII
1. Make sure all parts are clean and that the bearings are well lubricated.
I- ~
!:J
SPD769
2. Assemble the pinion gear bearings into the pinion preload shim selector Tool, J-34309.
18
PD-19
ADJUSTMENT
3. Place the pinion preload shim selector Tool, J-34309-1, gauge screw assembly with the pinion rear bearing inner cone installed into the final drive housing.
~!
C' /'
1\1 SPD893
4. Assemble the front, pinion bearing inner cone and the J-34309-2 gauge anvil together with the J-34309-1 gauge screw in the final drive housing. Make sure that the pinion height gauge plate, J-34309-16, will turn a full 360 degrees, and tig hten the two sections together by hand.
SPD770
6. Measure the turning torque at the end of the J-34309-2 gauge anvil using torque wrench J-25765A. 'Turning torque specification: 1.0 - 1.3 N.m (10 - 13 kg-em, 8.7 - 11.3 in-Ib)
PD-20
8. Place the solid pinion bearing spacer, small end first, over the J-34309-2 gauge anvil and seat the small end squarely against the tip of the J-34309-1 gauge screw in the tool recessed portion.
9. Select the correct thickness of pinion bearing preload adjusting washer using a standard gauge of 3.5 mm (0.138 in) and your J-34309-101 feeler gauge. The exact measure
you get with your gauges is the thickness of the adjusting washer required. Select the correct washer from the
following chart. Drive pinion bearing preload adjusting washer: Refer to S.D:S.
10. Set your selected, correct pinion bearing preload adjusting, washer aside for use when assembling the pinion gear and bearings into the final drive.
SPD774
PD-21
11. Now, position the side bearing discs, J-25269-4, and arbor firmly into the side bearing bores. Install the side bearing caps and tighten the cap bolts to proper torque.
12. Select the correct standard pinion height adjusting washer thickness using a standard gauge of 3 mm (0.12 in) and your J-34309-101 feeler gauge. Measure the distance between the J-34309-10 pinion height adapter and the arbor.
SPD775
14. Correct the pinion height washer size by referring to the "pinion head number." There are two numbers painted on the pinion gear. The first one refers to the pinion and ring gear as a matched set and should be the same as the number on the ring gear. The second number is the "pinion head height number," and it refers to the ideal pinion height from standard for quietest operation. Use the following chart to determine the correct pinion height washer.
SPD542
PD-22
ADJUSTMENT
15. Select the correct pinion height washer from the following chart. Drive pinion height adjusting washer (R200):
Thickness mm (in) 3.09 3.12 3.15 3.18 3.21 3.24 3.27 3.30 3.33 3.36 3.39 3.42 3.45 3.48 3.51 (0.1217) (0.1228) (0.1240) (0.1252) (0.1264) (0.1276) (0.1287) (0.1299) (0.1311) (0.1323) (0.1335) (0.1346) (0.1358) (0.1370) (0.1382)
Part No.
38164-P60 17 38154-P6Q 18 38154-P60 19 38154-P6020 381 54-P6021 38154-P6022 38154-P6023 38164-P6024 38154-P6025 38154-P6026 38154-P6027 38154-P6028 38154-P6029 38154-P6030 38154-P6031 38154-P6032 38154-P6033 38154-P6034 38154-P6035 38164-P6036
16. Remove the J-34309 pinion preload shim selector Tool from the final drive housing and disassemble to retrieve the pinion bearings.
PD-23
ADJUSTMENT
Tooth Contact
Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion. Hypoid gear sets which are not positioned properly may be noisy, or have short life, or both. Low noise and a long life can be assured with a pattern check.
1. Thoroughly clean ring gear and drive pinion teeth. 2. Sparingly apply a mixture of powdered ferric oxide and oil or equivalent to 3 or 4 teeth of ring gear drive side.
SPD357
3. Hold companion flange steady and turn the ring gear in both directions.
Usually the pattern will be correct if you have calculated the shims correctly and the backlash is correct. However, in rare cases you may have to use trial-and-errorprocessas until you get a good tooth contact pattern. The tooth pattern is the best indication of how well a differential has been set up.
Heel contact
Face contact
Toe contact
Flank contact
~~
~
.
To correct, increase thickness of pinion height adjusting washer in order to bring drive pinion close to ring gear.
~~
~
To correct, reduce thickness of pinion height adjusting washer in order to make drive pinion go away from ring gear.
CM""-..
When adjustment is completed, be sure to wipe off completely the ferric oxide and oil or their equivalent.
~
PD-24
v-t~
SPDOO7
ASSEMBLY
Differential Case
1. Install side gears, pinion mate gears, thrust washers and thrust block into differential case.
SPD552
2. Fit pinion mate shaft to differential case so that 'it meets lock pin holes.
SPD553
3. Adjust clearance between rear face of side gear and thrust washer by selecting side gear thrust washer. Refer to S.O.S. Clearance between side gear thrust washer and differential case: 0.10 - 0.20 mm (0.0039 - 0.0079 in)
SPD828
4. Install pinion mate shaft lock pin with a punch. Make sure lock pin is flush with case.
SPD030
5. Apply oil to gear tooth surfaces and thrust surfaces and check that they turn properly.
Gear oil
SPD322
PD-25
Tool@
7. Press~fit side bearing inner cones on differential case with Tool. Tool number: @ KV38100300 (J25523) @ ST33061000 (J8107-2)
Tool @
PD353
Differential Carrier
1. Press-fit front and rear bearing outer races with Tools. Tool number: @ 5T30611000 (J25742-1) @ 5T30613000 (J25742-3) @ 5T30701000 (J25742-2) 2. Select pinion bearing adjusting washer and drive pinion bearing spacer, referring to Adjustment.
~/~
if
Pinion front bearing outer race
w~
@
SPD679
Press
Adjusting washer
3. Install drive pinion height adjusting washer in drive pinion, and press-fit pinion rear bearing inner cone in it, using press and Tool. Tool number: 5T30901000 (
SPD377
PD-26
~
)~
r-"
E!!I
SPD581
Pinion be' arlng adjDrive Pinion ust' lng spacer Pinion be'
ad'
arlng
JuH;"~~'~~ @
J' ~
E:
lIE!
SPD897
5. Set drive pinion assembly (as shown in figure at left) in differential carrier and install drive pinion, with press and suitable tool. Stop when drive pinion touches bearing. Apply multi-purpose grease to pinion rear bearing inner race, pinion front bearing inner race and front pilot bearing.
SPD896
6. Apply multi-purpose grease to cavity at sealing lips of oil seal. Install front oil seal with Tool. Tool number: KV38100500 (
SPD557
7.: Install companion flange, and tighten pinion nut to specified torque with Tool. Ascertain that threaded portion of drive pinion and pinion nut are free from oil or grease. Tool number: ST38060002 (J34311)
Tool
PD416
PD-27
SP D884
9. Select side bearing adjusting washer. Refer to Adjustment. 10. Install differential case assembly with side bearing outer races into gear carrier.
5'
SPD527
11. Insert left and right side bearing adjusting washers in place between side bearings and carrier.
~~~
, ~( ::;..;;-..f\:i{;! Tool
~
~~'
12. Drive in side bearing spacer with Tool. Tool number: KV38100600 (J25267)
bo,,'"
SPD559
13. Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier.
PD-28
ASSEMBL Y
SP0560
gear-to-drive
pinion
backlash with
a dial
SP 0884
16. Check total preload with Tool. When checking preload, turn drive pinion in both directions several times to seat bearing rollers correctly. Total preload: Value more than 0.29 N.m (3.0 kg-em, 2.6 in-Ib) added on measured value of drive pinion preload If preload is too great, remove the same amount of shim to each side. If preload is too small, add the same amount of shim to each side. Never add or remove a different number of shims for each side as it will change ring gear-to-drive pinion backlash. 17. Recheck ring gear-to-drive pinion backlash because increase or decrease in thickness of shims will cause change of ring gear-to-pinion backlash.
. .
SP0524
18. Check runout of ring gear with a dial indicator. Runout limit: 0.05 mm (0.0020 in) If backlash varies excessively in different places, foreign matter may be caught between the ring gear and the differential case. If the backlash varies greatly when the ring gear runout is within a specified range, replace the hypoid gear set or differential case. 19. Check tooth contact. Refer to Adjustment. 20. Install rear cover and gasket.
PD-29
SPECIFICATIONS
Unit: mm (in)
SPECIFICATIONS
Propeller shaft model
AND ADJUSTMENT
Unit: mm (in) 3S63A-R
1
0 (0)
3S63A- T
A/T 3S63A-T
0.6 (0.024)
75.0 (2.953) 75.0 (2.953) ... Large side 63.5 (2.500) ... Small side
2nd
75.0 (2.953)
/~
PD-30
Final drive model Ring gear pitch diameter mm (in) Gear ratio Number of teeth (Ring gear/Drive pinion) Oil capacity (approx.) Q (US pt, Imp pt)
Thickness mm (in) 1.8 (3-7/8,3-1/8) 3.80 - 3.82 3.82 - 3.84 3.84-3.86 3.86 - 3.88 3.88 - 3.90 3.90 - 3.92 3.92 - 3.94 3.94-3.96 3.96 - 3.98 3.98 - 4.00 4.00-4.02 4.02 - 4.04 4.04 - 4.06 4.06 - 4.08 4.08 - 4.10 (0.1496 - 0.1504) (0.1504 - 0.1512) (0.1512 -0.1520) (0.1520 - 0.1528) (0.1528 - 0.1535) (0.1535 - 0.1543) (0.1543 - 0.1551) (0.1551-0.1559) (0.1559 - 0.1567) (0.1567 - 0.1575) (0.1575-0.1583) (0.1583 - 0.1591) (0.1591 - 0.1598) (0.1598 - 0.1606) (0.1606 - 0.1614)
Part number
38125-61001 38126-61001 38127-61001 38128-61001 38129-61001 38130-61001 38131-61001 38132-61001 38133-61001 38134-61001 38135-61001 38136-61001 38137-61001 38138-61001 38139-61001
(R200)
3.09 (0.1217) 3.12 3.15 3.18 3.21 (0.1228) (0.1240) (0.1252) (0.1264)
Part number
38165-B4002 38165-B4003 38165-B4004 38165-61001 38166-61001
3.24 (0.1276) 3.27 (0.1287) 3.30 3.33 3.36 3.39 3.42 3.45 3.48 3.51 3.54 3.57 3.60 3.63 3.66 (0.1299) (0.1311) (0.1323) (0.1335) (0.1346) (0.1358) (0.1370) (0.1382) (0.1394) (0.1406) (0.1417) (0.1429) (0.1441)
PD-31
Total preload
0.03
-0.0910.0012
- 0.00351
Part number
38453-N3100 38453-N3101 38453-N3102 38453-N31 03 38453-N3104 38453-N3105 38453-N3106 38453-N3107 38453-N3108 38453-N3109 38453-N3110 38453-N3111 38453-N3112 38453-N3113
Part number
38424-40FOO 38424-40F08 38424-40F01 38424-40F09 38424-40F02 38424-40F10 38424-40F03 38424-40F 11 38424-40F04 38424-40F12 38424-40F05 38424-40F13 38424-40F06 38424-40F 14 38424-40F07
---------
PD-32
SECTION
FA
FA- 2
FA4
CONTENTS
PRECAUTIONS AND PREPARATION CHECK AND ADJUSTMENT FRONT AXLE FRONT AXLE FRONT AXLE Wheel Hub and Knuckle Baffle Plate Coil Spring and Strut Assembly
; ,'
... """""'"'' "'"''
"
FA-18 FA-19
. .
SBR500
When installing each rubber part, final tightening must be carried out under unladen condition * with tires on ground. * Fuel, radiator coolant and eRg!ne oil full. Spare tire, jack, hand tools and mats in designated positions. When removing each suspension part, check wheel alignment and adjust if necessary. Use Tool when removing or installing brake tubes.
Preparation SPECIALSERVICETOOLS
Tool number (Kent-Moore No.) Tool name HT72520000 (J25730-A) Balljoint remover
Description
~ e5E
HT71780000
(
Spring compressor
ST35652000
(
Strut attachment
~ ~
~ ~
GG94310000
(
FA-2
OO)!
Wheel bearing drift
2J
~
B
A: 75 mm (2.95 in) dia. B: 66 mm (2.60 in) dia. c: 62 mm (2.44 in) dia. D: 25.55 mm (0.98.2.17
in) dia.
FA-3
Final tightening for rubber parts requires to be carried out under unladen condition* with tires on ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. Strut mounting insulator (with strut mounting bearingl
Coil spring
Strut assembly
46 52
"'.$. ~
I ,
c:::?
Front
~
Tension rod
~
Brake disc roter
~
FA~4
On-vehicle
SMA525A
(2) Retighten all nuts and bolts to the specified torque. Tightening torque: Refer to S.O.S. (3) Make sure that cotter pin is inserted.
(4) Check front axle and front suspension parts for wear, cracks
or other damage.
SFA541A
(shock
absorber)
Check suspension ball joint for grease leakage and ball joint dust cover for cracks or other damage.
FA'" 5
On-vehicle
"
SFA543A
. . . .
\
Check axial end play. Axial end play: 0.03 mm (0.0012 in) or less If axial end play is not within specification or wheel bearing does not turn smoothly, replace wheel bearing assembly. Refer to FRONT AXLE - Wheel Hub and Knuckle.
Inside
. . .
~.
SFA575S
Refer
. .
. .
CAMBER, CASTER AND KINGPIN INCLINATION Caster and kingpin inclination are preset at factory and cannot be adjusted.
SFA894
90
SFA573B
FA-6
On-vehicle
(Cont'd)
SFA103A Camber:
-130' to 0
Camber
90
SFA574A
If camber is not within specification, adjust by turning adjusting pin as follows: (1) Remove adjusting pin Adjusting pin is installed with flat portion facing downward.
SFA105A
(2) Next replace adjusting pin with flat portion facing upward. (3) Turn adjusting pin to adjust. Camber changes about 5' with each graduation of adjusting pin. (4) Tighten adjusting pin to specified torque.
~: 124
Adjusting pin
SFA106A
TOE-IN
1. Draw a base line on tread surface of tires. After lowering front of vehicle, move it up and down to eliminate friction, and set steering wheel in straight-ahead position.
SMA123
FA-7
On-vehicle
(Cont'd)
2. Measure toe-in. Measure distance "A" and "B" at same height as hub center. Toe-in:
Front
SFA234A
8M~
t#
9 Toe-in =A Total toe-in
-B
= 29 3. Adjust toe-in by varying length of steering tie-rods. (1) Loosen lock nuts. (2) Adjust toe-in by turning forward and reverse tie-rod.
~,
-~
-,
~
SFA545A
Make sure both tie-rods are the same length. Standard length "L" - reference data: 174.8 mm (6.88 in) (3) Fix lock nuts, then tighten them designed torque.
FRONT WHEEL TURNING ANGLE 1. Set wheels in straight-ahead position and then move vehicle forward until front wheels rest on turning radius gauge properly.
SMA 127
2. Rotate fully steering wheel to the right or left; measure turning angle.
't
Front
A: Inside B: Outside
33
SFA898
FA-8
FRONT AXLE
Snap ring
Wheel hub
FA-'9
FRONT AXLE
Removal
SFA090A
Remove brake caliper assembly. Brake hose need not be disconnected from brake caliper. Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted.
SFA547A
SF,o,571 B Adjusting'pin
FA-10
FRONT AXLE -
Installation
. .
SFA114A
Check wheel bearing axial end play. Axial end play: 0.03 mm (0.0012 In) or less
SFA543A
Disassembly CAUTION: When removing wheel bearing from wheel hub, replace wheel bearing assembly (outer race, inner races and grease seal) with a new one. . Remove circular clip with suitable tool.
SFA215A
.press.
. Check wheel dyeingfortest.any cracks by hub exploration or CIRCULAR CLIP . Check circular clip for wear or cracks. Replace if necessary.
FA-11
using a magnetic
FRONT AXLE
Assembly
1. Press new wheel bearing assembly into wheel hub from inside of rotor disc (with wheel hub). Maximum load P: 29 kN (3 t, 3.3 US ton, 3.0 Imp ton)
CAUTION:
. .
Do not press inner race of wheel bearing assembly. Do not apply oil or grease to mating surfaces of wheel bearing outer race and wheel hub. Be careful not to damage grease seal.
Grease seal
Circular clip
2. Install circular clip into groove of wheel hub. 3. Apply multi-purpose grease to sealing lip.
SFA218A
FA-12
FRONT AXLE
Baffle Plate
Mark match marks on baffle plate before removing. If baffle plate raplacement requires removal of knuckle spindle. separate it equally using a screwdriver. Be careful not to scratch knuckle spindle.
Matchmarks
. .
Removal
SFA548A
Installation
Align matchmarks previously marked on baffle plate and install baffle plate by lightly tapping with a copper hammer and suitable tool.
SFA549A
FA-13
FRONT SUSPENSION
cap
~~
59 78 (6.0
- 8.0,~"(
43 - 58)
~~
39 54 (4.0
-5.5,29- 40)
GaSket~
Strut mounting insulator
~~
Bound bumper
Lock washer~
Coil spring
u""''''''~
Strut assembly
suspension
member
fi
I V
~~88-108
f)~ }~"""J
"
J)
Transverse
link
L~~46-52 (4.7-5.3,
34-38)
'
r
If ~
~\
'
4-/r/~>\
"~:J
a~~\
@
",
"-Tension
rod
/
~:
N.m (kg-m, ft-Ib)
l'\1~
FA-14
When inStalling Stabilizer bar, tension rod and transverse link, final tightening requires to be carried out under unladen condition* with tires on the ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated position.
SFA550A
FRONT SUSPENSION
Strut upper portion
Removal
I~
Suitable bar
. . .
Adjusting pin
Remove strut assembly fixing bolts and nuts (to hoodledge). Do not remove piston rod lock nut on vehicle. Put match marks on strut lower bracket and camber adjusting pin.
Disassembly 1. Set strut assembly on vise with Tool, then loosen piston rod lock nut. Do not remove piston rod lock nut.
SFA134A
HT71780000 ( )
2. Compress spring with a Tool so that strut mounting insulator can be turned by hand.
SFA135A
ST35652000 ( ) SFA136A
. . .
Check for smooth operation through a full stroke, both compression and extension. Check for oil leakage occuring on welded or gland packing
portion.
Check piston rod for cracks, deformation or other damage. Replace if necessary.
FA-15
Inspection (Cont'd)
STRUT MOUNTING INSULATOR Check cemented rubber-to-metal portion for separation or cracks. Check rubber parts for deterioration.
Top
Assembly
When installing coil spring, be careful not to reverse top and bottom direction. (Top end is flat.)
Bottom
SFA760
~
\,
.
\
Fl.. .."
r=sA"
~"'"d
{}
Left Front
Right
SFA'"
Install upper spring seat with its cutout facing the inner side of vehicle.
Cutout
(Inner side of vehicle) Upper seat
"
SFA576A
FA-16
FRONT SUSPENSION
SFA552A
Press.
. .
When removing tension rod bushing, place one drift on lower side of bushing and the other on upper side, as shown at left, and press bushing out. Place arrow mark on bushing facing tension rod before installing bushing.
~D"ft
, SF A553A
Front
Install stabilizer rear side bushings, then install front side bushings. When installing stabilizer bar clamp, make sure direction is correct (as shown at left.)
SFA554A
SFA555A
.
View from B
mA~
~~
~~
N.G.
SFAOO2A
O.K.
FA-17
FRONT SUSPENSION
. . .
Remove stabilizer, tension rod, ball joint and transverse link assembly. During installation, final tightening must be carried out at curb weight with tires on ground. After installation, check wheel alignment. Refer to "Front Wheel Alignment" of CHECK AND ADJUSTMENT - On-vehicle.
SFA552A
Inspection
TRANSVERSE
. .
LINK
Check transverse link for damage, cracks or deformation. Replace it if necessary. Check rubber bushing for damage, cracks and deformation. Replace transverse link if necessary.
Check ball joint for play. If ball stud is worn, play in axial direction is excessive or joint is hard to swing, replace transverse link assembly if necessary.
Measuring
turning
torque
Swing force and turning torque Before checking, turn ball joint at least 10 revolutions so that ball joint is properly broken in. Swing force: (measure point: cotter pin hole of ball stud) 7.8 - 55.9 N (0.8 - 5.7 kg, 1.8 - 12.6 Ib) Turning torque: 0.49 - 3.43 N.m (5.0 - 35 kg-em, 4.3 - 30.4 in-Ib)
SFA757
~\(
Dial indicator
//:%
SFA556A
Vertical end play (On-vehicle) (1) Jack up front of vehicle and set the stands. (2) Clamp dial indicator onto transverse link and place indicator tip on lower edge of brake caliper. (3) Make sure front wheels are straight and brake pedal is depressed. (4) Place a pry bar between transverse link and inner rim of road wheel. (5) While pushing and releasing pry bar, observe maximum dial indicator value. Vertical end play: 0 mm (0 In) (6) If not within above specification, replace transverse link.
FA-18
...
COIL SPRING
Model Item Wire diameter
Except Sports package mm (in) mm (in) mm (in) 13.3 (0.524) 170 (6.69) 326 (12.83)
Sports package
25 10.98) Orange
311 (12.24)
19.6 (2.0, 112) N/mm (kg/mm, Ib/in) Identification color Orange x 1, Purple x 1
Pink x 1, Purple x 1
STRUT
Model Item Piston rod diameter mm (in) Stroke mm (in) Except Sports package Sports package
Damping force [at 0.1 m (0.3 ft)/sec.] N (kg,lb) 412-608 (42 - 62,93 - 137)
I
Expansion
Compression
912 - 1,245 (93 - 127,205 - 280) 392 - 588 (40 - 60,88 - 132)
FA-19
degree degree
-130' 6 00'
- 7 30'
- 0.091)
Swing force (Measuring point: cotter pin hole of ball stud) N (kg, Ib)
mm (in) degree Kingpin inclination Front wheel turning angle Full turn*2 inside/outside d egree degree
7.8 - 55.9 (0.8 - 5.7,1.8 - 12.6) 0.49 - 3.43 (5.0 - 35, 4.3 - 30.4)
0 (0)
Turning torque
N'm (kg-cm, in-Ib)
-43 /33
mm (in)
*1: Tankful of fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools, mats in designated position. *2: On power steering models, wheel turning force (at circumference of steering wheel) .of 98 to 147 N (10 to 15 kg, 22 to 33'lb) with engine idle.
lateral runout
Aluminum wheel
WHEEL BEARING
Steel wheel Wheel bearing axial end play mm (in) Wheel bearing lock nut Tightening tirque N'm (kg-m, ft-Ib) 0.03 (0.0012) or less
mm (in)
(0.031) or less
FA-20
SECTION
RA
RA2
CONTENTS
PRECAUTIONS AND PREPARATION REAR AXLE AND REAR SUSPENSION CHECK AND ADJUSTMENT REAR AXLE REAR AXLE On-vehicle REAR 'AXLE AND REAR SUSPENSION ASSEMBLY Wheel Hub and Axle Housing Drive Shaft Coil Spring and Shock Absorber Stabilizer Bar Multi-link and Lower Ball Joint
"'"''.'''''''''''''''''''''''''''''''
III
~,
GG9431 0000
(
. . .
When installi~ each rubber part, final tightening must be carried out under unladen condition. with tires on ground. . Fuel, radiator coolant and .engine oil full. Spare tire, jack, hand tools, and mats in designated positions. Use Tool when removing or installing brake tubes. When removing each suspension part, check wheel alignment and adjust if necessarY. Do not jack up at the lower arm.
SBR500
Preparation SPECIALSERVICETOOLS
Tool number (Kent-Moore No.) Tool name HT71780000
(
Description
Spring compressor
GG94310000
(
~ ~ ~
~ ~----.
ST38280000
(
~ ~
RA-2
}aJJ} lIID)
1:EID J
mm (in)
Removing rear wheel hub A: 26 mm (1.02 in) dia. B: 40 mm (1.57 in) dia.
rED
RA-3
It
~
~
69 -88
;:.E- 19
Shock absorber
69 -88
Lower link
I~
~
L~43 -55 . (4.4 - 5.6,32 -41) ~98-118 I
110.0
- 12.0,72
- 871
-8.71.
Final tightening for rubber parts requires to be carried out under unladen condition* with tires on ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
~:
N.m (kg-m,ft-Ib)
SRA093A
RA-4
CHECK ANDADJtlSTMENT -
On-vehicle
wear or
SMA525A
(2) Retighten all nuts and bolts to the specified torque. Tighteningtorque: Refer to S.D.S. (3) Make sure that cotter pin is inserted. (4) Check rear axle and rear suspension parts for wear, cracks or other damage.
SMA113
Check suspension ball joint for grease leakage and ball joint dust cover for cracks or other damage.
RA-5
On-vehicle
. . .
SRA107A
Inside
~.
SFA575S
Make following checks. Adjust, repair or replace if necessary. Check tires for wear and for improper inflation. Check rear wheel bearings for looseness. Check wheel runout. Refer to S.D.S. Check that rear shock absorber works properly. Check rear axle and rear suspension parts for looseness. Check vehicle posture (Unladen). ' "Unladen" : Fuel tank, radiator and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
. . . . . .
CAMBER
Measure camber of both right and left wheels with a suitable alignment gauge and adjust in accordance with the following procedures.
SRA096A
Camber: -136'
to -036'
'/
SRA097A
RA-6
On-vehicle (Cont'd)
If camber is not within specification, adjust by turning the adjusting pin. (1) Turn the adjusting pin to adjust. Camber changes about 5' with each graduation of the adjusting pin. (2) Tighten to the specified torque.
TOE-IN 1. Draw a base line across the tread. After lowering rear of vehicle, move it up and down to eliminate friction.
and "B"
1.5' - 12.5'
Front
~
SFA234A
Toe-in = A
6
Total toe-in = 26
-B
3. Adjust toe-in by turning adjusting pins. Toe changes about 1.5 mm (0.059 in) [One side] graduation of the adjusting pin. 4. Tighten to the specified torque.
~:69
with each
- 88 N.m
Drive Shaft
Check boot and drive shaft for cracks, wear, damage or grease leakage.
SRA796
RA-7
SRA 100A
. .
Remove brake caliper assembly. Brake hose need not be disconnected from brake caliper. Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted.
SFA110A
Remove upper end nuts of shock absorber. Do not remove piston rod lock nut. Remove suspension member fixing nuts. Then draw out rear axle and rear suspension assembly.
. .
SRA101A
RA-8
REAR AXLE
Adjusting cap
L.~
Wheel bearing
with flange~
~ : N'm(kg-m, t-Ib) f
SRA102A
Removal
Remove brake caliper assembly and rotor. Brake hose need not be disconnected from brake caliper. Be careful not to depress brake pedal, or piston will pop out. Make sure brake hose is not twisted.
SFA110A
RA-9
REAR AXLE
SFA181A
SRA104A
Remove wheel bearing with flange, and wheel hub from axle housing.
SRA105A
Installation
. .
Install axle housing with wheel hub. Tighten wheel bearing lock nut.
tOJ: 35 2
- 314N.m
SRA106A
Check wheel bearing axial end play. Axial end play: 0.05 mm (0.0020 in) or less
SRA107A
RA-10
REAR AXLE
SRA108A
. . . WHEEL HUB . Remove wheel housing before flange) and wheel hub as one bearing (with unit from axle disassembling.
Press.
WHEEL BEARING Using a press and drift as shown in figure at left, press wheel bearing out. Discard old wheel bearing assembly. Replace with a new wheel assembly.
. .
SRA109A
CAUTION:
ST30031 000 (J22912-01 )
a. Do not reuse o!d inner race although it is of the same brand as the bearing assembly. b. Do not replace grease seals as single parts.
SRA110A
RA-11
REAR AXLE
SRA111A
. .
Ensure axle housing bore is free from scratches or deformities before pressing bushing into it. Attach bushing to chamfered bore end of axle housing and press it until it is flush with end face of axle housing.
SRA112A
. .
Check wheel hub and axle housing for cracks by using a magnetic exploration or dyeing test. Check wheel bearing for damage, seizure, rust or rough
operation.
Drift
Assembly . Place hub on a block. Attach a drift to inner race of wheel bearing and press it into hub as shown in figure at left. Be careful not to damage grease seal.
Block SRA113A
RA-12
REAR AXLE
Drive Shaft
Drive shaft
~I
~"'''~-~ 174 (24.32, ~ 235.314 - 231)
Insulator
@)~
Adjusting cap
SRA114A
Removal
When removing drive shaft, cover boots with waste cloth to prevent damage to them.
WHEEL SIDE Remove drive shaft by lightly tapping it with a copper hammer. To avoid damaging threads of drive shaft, install a nut while removing drive shaft.
Installation
. .
.
Insert drive shaft from wheel hub and temporarily tighten wheel bearing lock nut. Tighten side flange mounting bolts to specified torque.
RA-13
REAR AXLE
Drive Shaft
~
IE!
Spider assembly
m
Wheel hub side
;>
Boot band
SRA117A
Disassembly
FINAL DRIVE SIDE 1. Remove plug seal from slide joint housing by lightly tapping around slide joint housing.
2. Remove boot bands. 3. Put match marks on slide joint housing and drive shaft before separating joint assembly. 4. Put match marks on spider assembly and drive shaft.
SRA118A
RA-14
Shaft
Disassembly (Cont'd)
5. Pry off snap ring, then remove spider assembly. CAUTION: Do not disassemble spider assembly. 6. Draw out slide joint housing. 7. Draw out boot. Cover drive shaft serration with tape to prevent damage to the boot.
SRA119A
WHEEL SIDE
SFA963
4. Pry off snap ring "A" with a screwdriver, and pull out slide joint housing.
SRA120A
5. Pry off snap ring "B", then remove spider assembly. CAUTION: Do not disassemble spider assembly. 6. Draw out boot. Cover drive shaft serration with tape to prevent damage to the boot.
SFA964
Inspection Thoroughly clean all parts in cleaning solvent, and dry with compressed air. Check parts for deformation or other damage. DRIVE SHAFT Replace drive shaft if it is twisted or cracked. BOOT Check boot for fatigue, cracks, or wear. Replace boot with new boot bands.
RA-15
REAR AXLE
Drive Shaft
(Cont'd)
spider assembly for bearing, roller and washer
Inspection
JOINT ASSEMBLY
. .
Check
Slide joint
When replacing only spider assembly, assembly from among those listed in the number stamped on sliding joint stamped on new part. Housing alone cannot be replaced. It together with spider assembly. Stamped number 00
SRA121A
select a new spider table below. Ensure is the same as that must be replaced
01 02
Assembly
. .
After drive shaft has been assembled, make sure it moves smoothly over its entire range without binding. Use Nissan Genuine Grease or equivalent after every overhaul.
1. Install new small boot band, boot and slide joint housing to drive shaft. Cover drive shaft serration with tape to prevent damage to boot during installation.
Tape
SFA800
RA-16
REAR AXLE -
Drive Shaft
Assembly (Cont'd)
{r
*"{E;=
~ ~
<
2. Install spider assembly securely, making sure marks are properly aligned. Press-fit with spider assembly serration chamfer facing shaft. 3. Install new snap ring.
Su itable tool
Chamfer
SFA397
4. Install coil spring, spring cap and new plug seal to slide joint housing. Press plug seal. Apply sealant to mating surface of plug seal.
CAUTION:
a. When pressing plug seal into place, hold it horizontal so that spring inside it does not tilt or fall down. b. Move shaft in axial direction to ensure that spring is installed properly. If shaft drags or if spring is not installed properly, remove plug seal and install a new one. Discard plug seal after removal.
.
SRA123A LI
5. Pack drive shaft with specified amount of grease. Specified amount of grease: 185 195 g (6.52 - 6.88 oz) 6. Set boot so that it does not swell and deform when its length is "L,". Length" L1": 110.5 - 112.5 mm (4.35 - 4.43 in) Make sure that boot is properly installed on the drive shaft groove.
SRA124A
SFA395
RA-17
REAR AXLE
Drive Shaft
(Cont'd)
Assembly
7. Lock new larger boot band securely with a suitable tool, then lock new smaller boot band.
Suitable tool
SFA472
~
~"
{I
WHEEL SIDE 1. Install new small boot band and boot on drive shaft. Cover drive shaft serration with tape to prevent damage to boot during installation.
Tape
SFA800
05=
~ ~
Suitable tool Chamfer
SFA397
2. Install spider assembly securely, making sure marks are properly aligned. Press-fit with spider assembly serration chamfer facing shaft. 3. Install new snap ring.
0
SRA125A SFA395
4. Pack drive shaft with specified amount of grease. Specified amount of grease: 145 - 155 g (5.11 - 5.47 oz) 5. Install slide joint housing, then install new snap ring "A". 6. Set boot so that it does not swell and deform whe'n its length is "L2". Length "L2": 110.5 - 112.5 mm (4.35 - 4.43 in) Make sure that boot is properly installed on the drive shaft groove. 7. Lock new larger and smaller boot bands securely with a suitable tool.
RA-18
REAR SUSPENSION
'
11.6.1.9,12.14)
C;~ 17,.,"..".061Suspension m
ember
43.55
(4.4 . 5,6,
'" '"
~
,
32 - 41)
~~
]
~
'
.. -'
~ Ao'I'
fi/
~
~~18.24
(1.8.2.4,13.11) Upper plate
Gasket
~
~
Bushing
Upper spring seat
Upper rubber seat
11. 98
(1.9.10,51.12)
\ ~' Ii ~
~ ~
..@I
Bushing Plate
K
N--><
8
Mem';',
~
'
~ ~'~~i 1'
<:I'
~Dustcover
0
c;~I:~"~,2.6," 8.7~
-~~ 69-88 (1.0.9.0,61.66)
~21
26
(2.;.2.1,16.20)
c;
~
~98.118
"."2.72.871
:j);
'
vr
I"
~
I
'
i
.
'",
@
I
~
.
Connecting
~
(6.0 -1.0,36 - 51)
~A49'69
~ 71...
~ '\~ )
h
,
/~
- '-"""Mm
I
21.26(2.1.2.1,16.20) Differential
f0 Y/!
~(~
.@
(et,I
:"
,
~~88.108
(9.0.11,86.80)
Drive shaft
'
Shock absorber
-'---t :
~. 98.118110.12,12.81)
Stabilizer BUShingA
@@.l 34. ~
(3.5.4.5,
L
!
1
~
Axle assembly -
q"
26. 33)
~ ~
'.
rod
>B~
43.55 (4.4.5.6,32.41)
e @ ~~
A ~
9.12
(0.9.1.2,6.5.8.1)
Insulator cap
~ J7 I !
Adjusting
CAUTION: Do not jack up at lower arm. When installing each rubber part, final tightening must be carried out under unladen condition* with tires on ground. * Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
SAA 132A
RA-19
REAR SUSPENSION
Removal
. .
Remove shock absorber upper and lower fixing nuts. Do not remove piston rod lock nut on vehicle.
Disassembly 1. Set shock absorber on vise with attachment, then loosen piston rod lock nut. . Do not remove piston rod lock nut.
SRA782
2. Compress spring with Tool so that the strut upper spring seat can be turned by hand.
SRA783
SRA784
Check for smooth operation through a full stroke, both compression and extension. Check for oil leakage occuring on welded or gland packing portion. Check piston rod for cracks, deformation or other damage. Replace if necessary. UPPER RUBBER SEAT AND BUSHING Check rubber parts for deterioration or cracks. Replace if necessary.
. . .
ASSEMBLY
RA-20
RI;ARSUSPENSION -Coil
Inspection (Cont'd)
COIL SPRING
Top
Assembly
When installing coil spring, be careful not to reverse top and bottom direction. (Top end is flat.)
Bottom
SFA760
r==A,.FI""" \
\,
When installing coil spring on strut, it must be positioned as shown in figure at left.
~"~d
Bigger inner diameter side of lower bushing
,,,.,,
Vehicle front
When installing upper spring seat, make sure that it is positioned as shown.
Outside of vehicle
RA-21
Stabilizer Bar
Inspection
. .
Check stabilizer bar for deformation or cracks. Replace if necessary. Check rubber bushings for deterioration or cracks. Replace if necessary.
Installation
When installing connecting rod, make sure direction is correct (as shown at left).
Connecting rod
Stabil izer
SRA128A
RA-22
REAR SUSPENSION
Before removing, put matchmarks on adjusting pin. When installing, final tightening must be carried out at curb weight with tires on ground. After installation, check wheel alignment. Refer to "Rear Wheel Alignment" of CHECK AND ADJUSTMENT - On vehicle.
. .
SRA129A
J;
Inspection REAR SUSPENSION Replace suspension member assembly if cracked or deformed or if any part (insulator, for example) is damaged. UPPER AND LOWER LINKS
MEMBER
Replace upper or lower link as required deformed or if bushing is damaged. LOWER BALL JOINT
if cracked
or
SUSPENSION
. .
Measure swing force, turning torque and vertical end play in axial direction. (Use same measurement procedures as that of FA section.) If ball stud is worn, play in axial direction is excessive, or joint is hard to swing, replace lower arm.
12.7 - 90.2 N Swing force (1.3 - 9.2 kg, 2.9 - 20.3 Ib) 0.5 - 3.4 N.m Turning torque Vertical end play (5 - 35 kg-em, 4.3 - 30.4 in-Ib) 0 mm (0 in)
RA-23
General Specifications
COIL SPRING
Model
SHOCK ABSORBER
Except Sports package
11.0 (0.433)
Item
Wire diameter
Sports package
11.3 (0.445)
Model Item Piston rod diameter Stroke Damping force [at 0.1 m (0.3 ftl/sec.] Expansion mm (in) 'mm (in) N (kg, Ib)
Sports package
I 367.5
(14.47)
355 (13.98)
314 - 471 (32 -48, 71 - 106) 157 - 235 (16 -24, 35 -53) N (kg,lb)
392 . 588 (40 -60, 88 - 132). 196 - 294 (20 -30, 44 -66)
Compression
647 - 902 (66 .92, 146 - 203) 363 - 539 (37 - 55, 82 -1211
DRIVE
SHAFT
Final drive side TS82F TS82C mm (in) 30 (1.18) SRA133A
Joint type Final drive side Wheel side Diameter Wheel side D I Grease name Final drive side
Wheel side
Wheel side Specified amount of grease g (oz) Final drive side Wheel side Boot length mm (in) Final drive side (LI) Wheelside (L2 )
L2 SRA134A
REAR STABILIZER
BAR
. Except Sports package Sports package 17 (0.67) Light blue
RA-24
and Adjustment
WHEEL RUNOUT (Radial and lateral)
Radial runout .mm (in)
I
(Unladen*)
-136' to -036'
Lateral runout
or less
0.3 (0.012)
* Tankful of fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools, mats in designated position.
Swing force (Measuring point: cotter pin hole of ball stud) N (kg, Ib) 0.05 (0.0020) or less Turning torque N.m (kg-cm, in-Ib)
I 235 -314
(24
-32, 174.231)
mm (in)
RA-25
BR
BR- 2 BR- 3 BR- 4 BR- 6 BR- 8 BR-10
CONTENTS
PRECAUTIONS CHECK BRAKE BRAKE BRAKE VACUUM AND PREPARATION AND ADJUSTMENT HYDRAULIC PEDAL AND LINE """"""".'.""'.'"''''''''''''.'''''''''''''''''''
BOOSTER PIPING
MASTER CYLINDER FRONT DISC BRAKE (CL22VB, CL25VA) FRONT DISC BRAKE (CL22VB, CL25VA) REAR DISC BRAKE (CL9H) REAR DISC BRAKE (CL9H) PARKING BRAKE CONTROL ANTI-LOCK BRAKING SYSTEM TROUBLE DIAGNOSES SERVICE DATA AND SPECIFICATIONS (S.D.S.) Caliper Rotor Caliper Rotor
all
.
. .
. .
Recommended fluid is brake fluid "DOT 3". Never reuse drained brake fluid. Be careful not to splash brake fluid on painted areas. To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use clean brake fluid. Never use minerai oils such as gasoline or kerosene. They will ruin rubber parts of hydraulic system.
WARNING: . Clean brake pads and shoes with a waste cloth, then collect dust with a dust collector.
SBR500
Preparation
SPECIAL SERVICE TOOL
Tool number (Kent-Moore No.) Tool name GG94310000 ( ) Flare nut torque wrench
Description
~ ~
0 @ @ @
0
c
o.
0
BR-2
MAX
. .
Check fluid level in reservoir tank. It should be between Max. and Min. lines on reservoir tank. If fluid level is extremely low, check brake system for leaks.
MIN
6/@ *"
SMA 732A
.
.
Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts. If leakage occurs around joints, retighten or, if necessary, replace damaged parts. Check for oil leakage by fully depressing brake pedal.
valve.
SBR992
. . .
Use same procedure as in bleeding hydraulic system to refill brake fluid. Refer to Bleeding Procedure. Refill with recommended brake fluid "DOT 3".
BR-3
: N.m (kg-m, ft-Ib) 0 : Flare nut 15 -18 /1.5 -1.8, 11 -13) : Connecting bolt 17 .20/1.7 - 2.0,12.14)
SBR471A
Bleeding
CAUTION:
Procedure
. .
Carefully monitor brake fluid level at master cylinder during bleeding operation. Fill reservoir with r~commended brake fluid. Make sure it is full at all times while bleeding air out of system.
Bleed air according to the following procedure. Without Anti-lock Braking System: Left rear caliper ,j, Right rear caliper
With Anti-lock Braking System: Left rear caliper ,j, Right rear caliper ,j, Left front caliper ,j, Right front caliper
BR-4
remove flare nut securing brake lock spring. entrance of dirt whenever disexcessive bending, twisting and check for oil leakage by fully
Inspection
Check brake lines (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts. If leakage occurs around joints, retighten or, if necessary, replace damaged parts.
BR-5
~16
S; !@j"
/,/<
(1.6-2.2 12
,-161
-22
A (1.2-1.5,9-111 12-15
Brake pedal
Replace clevis pin if plastic stopper. which is located at the end of clevis pin, is deformed or damaged.
A
Inspection
Check brake pedal for following items. Brake pedal bend
. .
.
BR-6
Floor carpet Dash insulator Melt sheet ~: N'm (kg.m, ft.lbl SBR153A
1. Adjust pedal free height with brake booster input rod. Then tighten lock nut. Make sure that tip of input rod stays inside.
SBR930
2. Adjust clearance "C1" and "C2" with stop lamp switch and A.S.C.D. switch respectively. Then tighten lock nuts. 3. Check pedal free play. Make sure that stop lamp is off when pedal is released. 4. Check brake pedal's depressed height while engine is running. If depressed height is below specified value, check brake system for leaks, accumulation of air or any damage to components (master cylinder, wheel cylinder, etc.); then make necessary repairs.
BR-7
(
'"
"
I
//
/ ,\ ~-- -\
\
\
) ,
,
\
,"""
\. ~
.../ / /
/
v..~,'"..-,
,:..~
./
......-
~;,~"
, "'"
~:>\ ,... ,
(~'>r---
/-<:~, \;.,.........-
-...--
''!
~:
Inspection
OPERATING
. .
CHECK
Depress brake pedal several times with engine off, and check that there is no change in pedal stroke. Depress brake pedal, .then start engine. If pedal goes down
SBROO2A
AIRTIGHT
O.K.
N.G.
. .
CHECK
and stop it after one or two minutes. Depress
Start engine,
~
SBR365A SBR281A
brake pedal several times slowly. If pedal goes further down the first time and gradually rises after second or third time, booster is airtight. Depress brake pedal while engine is running, and stop engine with pedal depressed. If there is no change in pedal stroke after holding pedal down 30 seconds, brake booster is airtight.
OUTPUT ROD LENGTH CHECK 1. Supply brake booster with vacuum of -66.7 kPa (-500 mmHg, -19.69 inHg) using a handy vacuum pump. 2. Check output rod length. Specified length: 10.275 - 10.525 mm (0.4045 - 0.4144 in)
BR-8
3. Adjust rod length if necessary. 4. If rod length is without specification, replace brake booster.
BR-9
VACUlfM PIPING
~~~{a
Chod< ..w
~
DJ
IJ.
Brake booster CAUTION: Do not apply any oil or lubricants to vacuum hose end check valve.
Intake manifold
.
'''_J)-=I
SBR474A
E=;=-;=:3
.. side booster or vacuum pump side .. Brake Intake anifold m
SBR202A
Check vacuum lines, connections and check valve for airtightness, improper attachment chafing and deterioration.
BR-'O
When pressure is applied to brake booster side of check valve and valve does not open, replace check valve with a new one.
Manifold side
..
SBR475A
BR-11
MASTER CYLINDER
cap
0;' fil'''~
Float~
Reservoir tank
Primary
piston assembly
Seal
~
\
~
\
);.
Piston cup.
*: Lubricate piston cup with brake fluid or rubber grease when assembling master cylinder.
SBR476A
. .
~
. .
..
f!. 1
.. .
."; ~. I '
I
)
':
':
!;
. .
Pay attention to direction of piston cups in figure at left. Check parts for wear or damage. Replace if necessary.
Primary ,. ;
'Ii 11II=II
,.
SBR012A
BR-12
Caliper
IEI@
Dust seal~lEI@
Outer shim Torque member fixting bolt 72 97
(7.3
Pin bolt
22
-31
-
lEI @
-9.9,
53
- 72)
.~
CL25V A Torque member fixing bolt
(7.3
A: N.m (kg-m, ft-Ib) lEI @ : P.B.C. (Poly Butyl Cuprysil)grease or silicone-based \lrease point IE! @ : Rubber grease points SBR477A @ : Brake fluid point
22
-31
(2.2
- 3.2,
16
- 23)
A 72 -97
- 9.9, 53 - 721
Air bleeder A7-9 (0.7.0.9, 5.1 -6.5) Connecting bolt A17-20 (1.7 - 2.0,12 - 14)
Brake hose
lEI
lEI
A:
: :
BR-13
Caliper
Pad Replacement
1. Remove pin bolt.
SBR453A
2. Swing cylinder body upward. Then remove pad retainer, and inner and outer shims. CAUTION: . When cylinder body is swung up, do not depress brake pedal because piston will pop out. Be careful not to damage dust seal or get oil on rotor. Always replace shims when replacing pads.
SBR220A
Disassembly Push out piston with dust seal using compressed air.
SBR772
BR-14
Caliper
Inspection
CYLINDER Check inside surface of cylinder for scoring, rust, wear, damage or foreign materials. Replace if any such condition exists. Eliminate minor damage from rust or foreign materials by polishing surface with fine emery paper. CAUTION: Use brake fluid to clean. PISTON
. .
BODY
Check piston for scoring, rust, wear, damage or foreign materials. Replace if any condition exists. CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign materials are stuck to sliding surface.
Assembly
. .
Place piston boot over rear of piston. Fit piston boot's lip properly in corresponding groove on cylinder body. Insert piston into cylinder body and fit boot's lip properly in corresponding groove on piston.
SBR480A
Inspection (On-vehicle)
INSPECTION OF BRAKE DRAG FORCE
1. Swing cylinder body upward. 2. Make sure that wheel bearing is adjusted properly. Refer to section FA. 3. Measure rotating force (F1).
SBR456A
4. 5. 6. 7. 8.
Install caliper with pads to original position. Depress brake pedal for 5 seconds. Release brake pedal and rotate disc rotor 10 revolutions. Measure rotating force (F2). Calculate brake drag force by subtracting F, from F2. Maximum brake drag force (F2 F1): 59.8 N (6.1 kg, 13.5 Ib) If it is not within specification, check main pins and retainer boots in caliper.
SBR457A
BR-15
- Caliper
Check disc pad for wear or damage. Pad standard thickness (A): 10.0 mm (0.394 in) Pad wear limit (A): 2.0 mm (0.079 in)
SMA364A
BR-16
Rotor
RUNOUT Adjust wheel bearing preload. Check runout using a dial indicator. Rotor repair limit: Maximum runout (Total indicator reading at center of rotor pad contact surface) 0.07 mm (0.0028 in)
SBR826
THICKNESS Standard thickness: 20.0 mm (0.787 in) Minimum thickness: 18.0 mm (0.709 in)
SBR827
BR-11
Caliper
7 .9 (0.7 .0.9,5.1
- 6.5)
~ -3.2,
/'
16-23)
":>, ,/
~ }
e
0
~ j--~
/
17 20 (1.7.2.0,12
r-
~. Gl..//
(v
~
'
Cam
m@ Cam bolt
- ,S2)'" I /' . ,~
/'.
I
"I
~,
B @ : Rubber "'@:Brakefluid U
~.:
~~
-
J..~ .
Seat
~
/
~\
/'
'~
Rod
m@
,/
~
!
Y
(!,
1.
Lever
Return spring
Spring washer
~
dI
'"
.(/
~
~
Cable stay
Torquemember
O-ring
m@
!--tC:J26 -36
/'--,
IE!I@
Spring
,~Spacer
A~wavewasher '~D_:-spacer Ball bearing
>
Piston seal
~ m@
i~~RingA >-.J)
,/~'
~
~..oo boo'
/~
Adjusting nut
Cup~m@
&~"OO
I'J@OO'OCOh'mj!?,-
~
~
v
~ ~ ~~ ~ ))
R padr;.tainerm In
pad
0
~
Pin
E!@
Inner'
' ,:.;a@, .
'-., ~
uter pa
.
Pad "";OM EII@~
EII@
~/' "
~
/
'~~
'
/'
W,
~"N'4)
~
Torque member
~/
saR48' A
Pad Replacement
CAUTION: When cylinder body is swung up, do not depress brake pedal because piston will pop out. Remove parking cable stay fixing bolt, pin bolts and lock spring. Then remove pad retainers, pads and shims.
. .
When installing pads, retract piston into cylinder body by turning it clockwise. Be careful not to damage piston boot or get oil on rotor. Always replace shims when replacing pads.
SBR641
BR-18
Caliper
SBR482A
Disassembly
1. Remove piston by turning it counterclockwise longnose pliers. with suitable
SBR646
2. Pry off ring A from piston with suitable pliers and remove adjusting nut.
SBR648
3. Disassemble cylinder body. Pry off rings Band C with pliers, then remove spring cover, spring and seat.
SBR891
SBR485A
BR-19
Caliper
Disassembly (Cont'd)
4. Remove return spring and lever.
..
SBR877
Inspection
CYLINDER Check inside surface of cylinder for score, rust, wear or other damage. Minor damage from rust of foreign materials may be eliminated by polishing surface with a fine emery paper. Replace if necessary. CAUTION: Use brake fluid to clean. TORQUE MEMBER
. .
BODY
Check for wear, cracks or other damage. Replace if necessary. PISTON Check piston for score, rust, wear or other damage. Replace if necessary . CAUTION: Piston sliding surface is plated. Do not polish with emery paper even if rust or foreign matter is stuck to sliding surface.
PIN AND PIN BOOT Check for wear, cracks or other damage. Replace if necessary. Assembly Install cup securely in the specified direction.
::::::::::::::
~f\t1t
1 I::::::::::::::
SBR849
.
Convex portion
Fit push rod into square hole in key plate. Also match convex portion of key plate with concave portion of cylinder.
@
SBR893
BR-20
Caliper
Keyplate
c~
"1B'>
(Cont'd)
~.h
,oo-j
fi) SB R878
Rod
.
Tool
Install seat, spring, spring cover and ring B with suitable press and drift.
SBR492A
Inspection
(On-vehicle)
.
FI
INSPECTION OF BRAKE DRAG FORCE 1. Swing cylinder body upward. 2. Make sure that wheel bearing is adjusted properly. Refer to section RA. 3. Measure rotating force (F,).
SBR227A
4. 5. 6. 7. 8.
Install caliper with pads to original position. Depress brake pedal for 5 seconds. Release brake pedal, rotate disc rotor 10 revolutions. Measure rotating force (F2). Calculate brake drag force by subtracting F, from F2. Maximum brake drag force (F2 F,): 86.3 N (8.8 kg, 19.4 Ib) If it is not within specification, check pins and pin boots in caliper.
DISC PAD Check disc pad for wear or damage. Standard thickness (A): 9.5 mm (0.374 in) Pad wear limit (A): 2.0 mm (0.079 in)
SMA364A
BR-21
Rotor
..
RUNOUT
. .
Check runout using a dial indicator. Make sure that axial end play is within the specifications before measuring. Refer to section RA. Rotor repair limit: Maximum runout (Total Indicator reading at center of rotor pad contact surface) 0.07 mm (0.0028 In)
SBR845
SBR847
BR-22
m
.
~
~
l. H. rear cable
Ell
SBR487A
REMOVAL Before removing parking brake control, remove console box. Loosen cable using control lever adjuster, and separate front and rear cables. Break clinched portion of control lever using a hammer and chisel as shown in figure at left, and replace cables with new parts. Apply multi-purpose grease to areas between control lever drum and cables.
. . .
SBR488A
INSTALLATION
Be careful not to damage boot and inner cable. When installing parking brake cable at rear caliper, make sure to align matchmark on parking cable stay and cable.
Cable guide
Matchmark
SBR489A
Inspection
1. Check control lever for wear or other damage. Replace if necessary. 2. Check parking brake cables, lamp and switch. Replace if necessary . 3. Check parts at each connecting portion for deformation or damage. If found, replace.
BR-23
Box wrench
Adjustment
1. Ensure that parking brake releases when control lever is pulled down completely. If control lever does not release parking brake, proceed as follows: Pull control lever up by 4 or 5 notches. Insert a box wrench into opening in control lever and loosen. self-lock adjusting nut to slacken cables. Completely push control lever down. 2. Forcefully depress brake pedal about five times (so that caliper is automatically set in position.). 3. Pull lever up by 4 or 5 notches. 4. Turn adjusting nut as shown in figure at left and adjust lever stroke to specified value. 5. Completely push control lever down and ensure that: Parking brake is released completely. Rear brakes are free from dragging.
. .
SBR490A
. .
6. Pull control lever with specified amount of force. Check lever stroke and ensure smooth operation. Number of notches: Center lever type 6 8
SBR491 A
7. Bend parking brake warning lamp switch plate so that brake warning light comes on when ratchet at parking brake lever is pulled "A" notches and goes out when fully released. Number of "A" notches: 1
SBR493A
BR-24
Hydraulic Circuit
Master cylinder
,'
I
SBR517 A
BR-25
ACTUATOR
]0
;01/1
R. H.
;0
I: : :
;o",,
t
m::o;o< 00 ;0 Z Zr -i -i< ;0 rm ;r ;r
mo rr
m -<Z 0
0
3 -<
"
< r < m
~P @~
..~ I I I I , I ,
I ,
: :
BODY GROUND
*
UP
@
R/Y~
~
...'"
G/L
-i
III c+ 0 "C
OJ 3 "C
II
9@
~".)
6
8
6 6 6
]1 3 2
017>
::-
Et
"'..,.....
21 9 7
(E. F. 1-
harness)
n
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r:-
Ii l_mn
:
en
OJ :IJ I N
..
"',...,...
lmum-
..."',
"..
....
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, ...
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:
"1
(B I ack)
n_nnn_~
o.
--:
I I I I I
:
' I
I I I I I
I
:
(Ma in
S. M. J.
harness)
[Refer to
~ngine
room
harnes~
Iast page:
R/GG/L-
,"-un_un_nnn~mmn__nmnm
@
8R/Y R/Y L/Y YG/Y L/R LG/R GY/R LW/LOR/L W/R
rnnn~
@
1
:IE:IE
I I I I I I I I I I I I
rnI I I I I I I I I I
L -W/L OR/L
EI E2 DI DII FI 83 U G2 85 G6 H5 16 18
8 W 8 8 8
~- u- - - - n - - - -_h- ---n-
_n_-
- - - _n_-
- - - -. -- - - _u- - ---
8R/Y R/YL/Y-
W/R
iW/R :IE
, ..
Y/L Y /G
I I I
@
(J n
FUSE
[j
"'..
FUSIBLE
.."''''
~
BODY GROUND
~@)
.~ ~~ ,...,...
, ,
I I I I I I
II
c;;p
rEtffi@Y :IE
,
..
(Engine harness room no. 2)
..
@) (
W/R
RELAY BOX)
LINK
::BODY
~u_-~
GROUND VJ CD :0
0> II) U1 :I>
"_n-n_-
Y/L Y/G-f
@ -
..
:IE
BATTERY
WHEEL
SENSOR
FRONT
i3J~
ALTERNATOR
L. H.
Be careful not to damage sensor edge and sensor ro,or teeth. FRONT WHEEL SENSOR
...,
"
~
~ : N.m(kg-m, t-Ib) f
SBR519A
REAR SENSOR
-294 -30,137.217)
.-///
Sensor rotor
Companion flange
SBR520A
Remove rear sensor rotor with companion propeller shaft removal. Refer to PD section.
flange after
BR-27
. . .
Disconnect 3 connectors and brake tubes. Remove relay bracket. Remove actuator by removing 3 nuts fixing actuator bracket.
to
BR~28
...
Preliminary Check2
Preliminary Check 3, 4 ... Self-diagnosis Component Parts Location ... Harness Connector Location Ground Circuit Check Circuit Diagram for Quick Pinpoint Check Diagnostic Procedure 1 .. Diagnostic Procedure 2 .
......
...
""'''.' ,
BR-36
BR-37 ...: BR-38 BR-39
BR-40
BR-41
BR-42
BR-43
'..'...".."""""""""'.""'.""."" BR-44
DiagnosticProcedure3
."."."""""""""'.""""".'."""""""'.'...'..'."...'
Diagnostic Procedure 4 """.. Diagnostic Procedure 5 Diagnostic Procedure 6 Diagnostic Procedure 7 Diagnostic Procedure 8 Diagnostic Procedure 9 Diagnostic Procedure 10 . Diagnostic Procedure 11 Diagnostic Procedure 12 Electrical Components Inspection
...
... BR-44
...
... ... ... ... ... ... ...
BR-45
BR-45 ...... BR-46 BR-47 BR-48 BR-49
...
...
BR-50
BR-51 ... BR-52
BR-29
TROUBLE DIAGNOSES
SEF234G
BR..30
"
TROUBLE DIAGNOSES How to Perform Trouble Diagnoses for Quick and Accurate Repair (Cont'd)
WORK FLOW
CHECK IN
<Reference
item
INVESTIGATE ITEMS YOU SHOULD CAR RY OUT RELATED TO EACH SYMPTOM AND NOTE
I I I I I I I I I I I ,I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I
1
r--------------------
Self-diagnostic item
DIAGNOSTIC WORKSHEET (Seepage BR-32.) ELIMINATE GOOD PART(S), HARNESS(ES) OR CONNECTOR(S) THROUGH ELECTRICALL Y TESTING Malfunctioning harness(es) and connector(s)
. HarnessConnectorLocation
Malfunctioning parts
REPAIR OR REPLACE
N.G. -- -- -- -----
FINAL CHECK
BR-31
TROUBLE DIAGNOSES
MRIMS
0 Warning activates
Engine conditions
0 When starting 0 Engine speed: 5,000 rpm or more 0 Low friction road (0 Snow 0 Protrusion 0 0 0 0
0 After starting
Road conditions
0 Gravel 0 Other)
Drivingconditions
High speed cornering Vehicle speed: Greater than 10 kmlh (6 MPH) Vehicle speed: 10 km/h (6 MPH) or less Vehicle is stopped
0 Suddenly 0 Gradually 0 Operation of electrical equipment 0 Large pedal stroke 0 Operation of clutch
Other conditions
BR-32
-HS
tJ:J
I n
~
~
0
~. OJ < . I en
"!> OJ
.. .
... CD .c c::
CD ::I
m0 ~
~
0
::I 0
CT 3 ~
CD
..
a.
b ::I ce '" ..
0 " "
:E I
5' ce I n ..
... ::I
"'tI CD
en
CT c:: ..
"
a. ~ < CT ...
I ~, 0 ::I g;o ::I 0 iii' CD
-< s: "'tI
-I 0 s:
a.
~ I n ..
<:
... ::I 5 ce
~ I
~ 0 ... 7':'
5' ce a.
<5" ::I
I ::I
~.
<' I .. CD '"
G')
fa
0
0
0
0
0 0 0 0 0
Preliminary Check 1 Preliminary Check 2 Preliminary Check 3 Preliminary Check 4 Diagnostic Procedure 1 Diagnostic Procedure 2 Diagnostic Procedure 3 Diagnostic Procedure 4 Diagnostic Procedure 5 Diagnostic Procedure 6
BR-34 BR-35 BR-36 BR-36 BR-42 BR-43 BR-44 BR-44 BR"-45 BR-45 BR-46 BR-47 BR-48 BR-49 BR-50 BR-51 BR-40 BR-40
iiii
"'tI
~ 3
-<
(') ::I" CD n 7':'
::I I ...
0
0 0
0 iii' ce ::I 0
'" ..
0 0
CD
0 0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0 0
--. (I)
-"'::I
CD CD ~9. -. I ::Ice 0
Motor ground
Actuator inspection
BR-52
-"
.::.~
1-18'1:>WOldw'<S
S3S0NDVIO 3'SnOH~
TROUBLE DIAGNOSES
Preliminary
CHECK
Check
=
=
MAX
MIN
CHECK
O.K.
.
. N.G. Repair b rake system. +--
&@
."
10K
CHECK
SMA732A
CHECK
..
O.K.
SBROO2A
Check brake booster operation and airtightness. Refer to "Inspection" of BRAKE BOOSTER.
Check brake pads and rotor. Refer to "Inspection" of FRONT and REAR DISC BRAKE.
BR-34
SBR522A CHECK.
B = Clearance
SBR523A
N.G.
. Check sensor for the following items: . Dust, foreign materials, etc., at fastening portion . Improper installation
. Breakage
O.K.
N.G.
N.G. ---+ Replace sensor rotor with wheel hub or companion flange as a set.
SBR525A
/
BR-35
c=
O.K.
.
SBR528A
Check warning lamp activation. When ignition switch is turned on, warning lamp turns on. O.K. 1 N.G. Check fuse. Check bulb condition and remedy.
CHECK
N.G.
SBR529A
.
L.E.D.
Check warning lamp for deactivation. When engine starts, warning lamp deactivates.
~O.K. DRIVE
Controller
SBR681A
. Keep engine on and running. . Remove rear side finisher. . Count the number of L.E.D. flashes during 5 to 10 second "OFF" period. 1
~ __FF
SBR530A
N.G.
SBR529A
O.K. ---+ If Preliminary Check 2 is not performed and there is abnormal A.8.S. operation, perform Preliminary Check 2.
BR-36
TROUBLE DIAGNOSES
Self-diagnosis
CHECKING THE NUMBER OF L.E.D. FLASHES When a problem occurs in the A.B.S., the warning light on the instrument panel comes on. As shown in the Table, the control unit performs self-diagnosis. To obtain satisfactory self-diagnosing results, the vehicle must be driven above 30 km/h (19 MPH) for at least one minute before the self-diagnosis is performed. After the vehicle is stopped, the number of L.E.D. flashes is counted while the engine is running. The L.E.D. is located on the control unit, identifying a malfunctioning part or unit by the number of flashes. Both the warning light and the L.E.D. persistently activate, even after a malfunctioning part or unit has been repaired, unless the ignition switch is turned "OFF". After repairs, turn the ignition switch "OFF". Then start the engine and drive the vehicle over 30 km/h (19 MPH) for at least one minute to ensure that the malfunctioning part or unit has been repaired properly. If more than two circuits malfunction at the same time, the L.E.D. will flash to indicate one of the malfunctioning circuits. After the circuit has been repaired, the L.E.D. will then flash to indicate that the other circuit is malfunctioning.
1 2 30r4 5 6 7 or 8 9 10 16
Left front actuator solenoid circuit Right front actuator solenoid circuit Rear actuator solenoid circuit Left front rotor sensor circuit Right front rotor sensor circuit Rear rotor sensor circuit Actuator motor, motor relay circuit Actuator solenoid valve relay Control unit
Warning activates and Power supply or ground circuit for control unit l.E.D. "OFF"
Repeat
1 - 2 sec.
5 - 10 sec.
SBR631A
//
SBR532A
BR-38
TROUBLE DIAGNOSES
SBR533A
BR-39
TROUBLE DIAGNOSES
Check
resistance
between
both terminals.
Resistance: on
Resistance: on
Resistance: on
BR-40
TROUBLE DIAGNOSES
I GNI TJ ON
SWI TCH
ON or START
~ ~
t'fD ~ FRONT L H.
To stop
lamp
SA TTERY
FRONT R.H.
FRONT L ~ H. FRONT R. H.
-=
REAR
REAR SOLENOID
~.~
-=
-=
-=
ALTERNATOR
8The unit side connectors with a double clrcle"~"are connected to the harness side connectors shown in the"Harness Connector Locat ion". (See page BR-39.) 8The terminal numbers in the connector coincide with the circuit numbers surrounded by a single circlepO".
SBR698A
BR-41
TROUBLE DIAGNOSES Diagnostic Procedure 1 SYMPTOM: Pedal vibration and noise Refer to worksheet results.
Check whether brake is applied suddenly in normal driving conditions. No
SA T797 A
Brake pedal
Yes
When brake is normally applied, A.B.S. works and produces pedal vibration or noise.
Yes
00
Speedometer
SBR539A
~~
No
00
Yes Check whether the symptom disappeared within 5 seconds.
Check whether the symptom appeared when the vehicle speed is within 10 km/h (6 MPH) after starting engine.
,.
Yes
--=-
No A.B.S. may sometimes operate when load is high and voltage is low due to insufficient alternator output.
Check whether the symptom appeared while the vehicle was driven. 1 Yes No
SBR530A
I
I No
gradually. Check whether b'rake is applied
I
Yes
Brake pedal
. Shifting
. Operating clutch . Passingprotrusion NO @ For such condition, if there is considerable wheel speed variation and, A.B.S.will work normally. Check if there were any conditions, among those listed below, when symptom appeared. . Low friction road . High speed cornering . Passingprotrusion Yes
SA T797 A
Yes
For such conditions, if wheel speed is considerably different between front and rear or left and right, A.B.S. will work normally.
BR-42
T
Check whether engine speed is over 5,000 rpm with vehicle stopped. No Check whether electrical equipYes Yes Vibration related to sensor may cause A.B.S. operation.
Check front wheel sensor shielded ground. Refer to Ground Circuit Check. N.G. Remedy. O.K. Replace control unit.
--===-
Diagnostic Procedure 2
SYMPTOM: Long stopping distance Refer to worksheet results.
Check if road condition is slippery with snow or gravel. No Yes Stopping distance may be longer than vehicleswhich are not equipped wih A.B.S.
SBR530A
Disconnect actuator connector and check whether stopping distance is still long. 1 No Perform Preliminary Check 1 and air bleeding.
Yes
'--
BR-43
TROUBLE DIAGNOSES
Diagnostic Procedure 3
SYMPTOM: Abnormal pedal action Refer to worksheet results.
Check whether brake pedal stroke is abnormally large. No Yes Vehicle equipped with A.B.S. may have a tendency for large pedal strokes.
SBR540A
Yes
Normalcondition.
I
I
Disconnect actuator connector and check whether brake is effective. No Perform Preliminary Check 1.
SBR541A
IEJ
C:I
Yes
Refer to Preliminary Check 4 result. Go to Self-diagnosis. (See page BR-37.) A.B.S. doesn't work in this condition.
SBR52BA
(I
Check whether vehicle speed is under 10 km/h (6 MPH). . No Refer to Preliminary Check 2 result.
.........
'~
Ma in switch
(I
Harness: KV999P1010
Motor switch 3.4 select switch (
) SBR660A
Check actuator by referring to Electrical Components Inspection - ACTUATOR. (See page BR-52.)
BR-44
TROUBLE DIAGNOSES
Diagnostic Procedure 5
SYMPTOM: A.B.S. works but warning activates.
Check whether alternator produces proper output. Refer to EL section.
.
No Remedy.
No
Remedy.
.Yes
B
CHECK BRAKE FLUID
N.G.
Perform Preliminary Check 1.
~
\
PR ESSU R E.
--d--.
77
Q Front
..~)
PI =P, \"" , ,,'
SBR642A I!J
,,'
.
O.K.
Yes Remedy.
5 -~l
E
.. " a:~
B ..
No
D,
L~_--_--nn~
.5::0 .>l
~
PI kPa (kg/em'. psi) Front brake fluid pressure SBR643A
I!J
SMA626A
(\ BR-45
TROUBLE DIAGNOSES
Diagnostic Procedure 7
ACTUATOR SOLENOID (L.E.D. flashing number 1 - 4)
INSPECTIONSTART Remove battery negative terminal connector.
-)J _T
[ill
iii
Actuator connector
eJ ~
m
I
SBR544A
O.K.
Replace control unit.
~ \:ill!
SBR545A
Disconnect control unit connector. Check resistance between control unit connector (vehicle side) terminals. Flashing number 1: Terminals @ and (t) Flashing number 2: Terminals @ and @ Flashing number 3 or 4: Terminals @ and @ Resistance: 0.7 - 1.60
iii
N.G.
O.K. Repair harness between actuator connector and control unit connector.
Disconnect actuator connector. Check resistance between actuator connector (actuator side) terminals. Flashing number 1: Terminals @ and CD Flashing number 2: Terminals @ and (t) Flashing number 3 or 4: Terminals @ and @ Resistance: 0.7 - 1.60
N.G.
Replace actuator.
BR-46
tROUBLE
DIAGNOSES
)J
[:iIi5
m
SBR546A
O.K.
Replace control unit.
CHECK SPEED SENSOR RESISTANCE Disconnect control unit connector. Check resistance between control unit connector (vehicle side) terminals. Flashing number 5: Terminals @ and @ Flashing number 6: Terminals @ and @ Flashing number 7 or 8: Terminals (j) and @
Resistance: 0.8
- 1.2
kil
N.G. Refer to Preliminary Check 3 result. Check whether sensor has 0.8 1.2 kQ resistance.
N.G.
Replace sensor.
N.G.
Re~air harness between sensor connector and control unit connector.
BR-47
TROUBLE DIAGNOSES
Diagnostic Procedure 9
ACTUATOR MOTOR RELAY (L.E.D. flashing number 9)
INSPECTION START Remove battery negative terminal connector. Fa
SBR547 A
~i5
Ii)
Actuator connector
[i] N.G. ~isconnect actuator connector. Check resistance between actuator connector (actuator side) terminals @ and @. Resistance: 38 - 45n O.K. Repair harness between actuator and control unit.
Effij
i5 ~
[ill
CHECK MOTOR RELAY SOLENOID RESISTANCE. Disconnect control unit connector. Check resistance between control unit connector (vehicle side) terminals @ and @. Resistance:38 -45n
II
N.G.
RELAY
DEACTIVATION. Disconnect actuator connector. Check continuity between actuator connector (actuator side) terminals @ and @. No
0
[i]
No
~ -, eJ
\:mEY
~~
. Yes
Perform Electrical Components Inspection - ACTUATOR. (See page BR-52.) N.G. .O.K. Replace actuator.
[ill
SBR550A
Motor rela;
0 ~
~
SBR688A
BR-48
TROUBLE DIAGNOSES
m
[
Diagnostic Procedure 10
ACTUATOR SOLENOID number 10) INSPECTION START Remove battery negative terminal connector. VALVE RELAY (L.E.D. flashing
~~
rnJ
_CT
18
m
SBR552A
Ii
N.G. rcheck resistance between actuator connector (actuator side) terminals (j) and 00. Resistance: 80 - 90Q O.K.
Repair harness between actuator and control unit
Ii)
@)
Actuator connector
~)
IVr:II~
[ill I
SBR553A
CHECK SOLENOID VALVE RELAY RESISTANCE. Disconnect control unit connector. Check resistance between control unit connector (vehicle side) terminals @ and @. Resistance. 80 - 90Q
[i
N.G.
Ii)
CHECK SOLENOID VALVE RELAY MOVEMENT. Disconnect actuator connector. Check continuity between actuator connector (actuator side) terminals @ and @. No
Check if solenoid valve relay fuse is blown. Yes Yes
r~
L~eplace solenoid valverelay.
[i
No
N.G.
O.K.
Replace controlunit.
Replacefuse.
Ii
Actuator connector
-,
@~eo~
[ill
SBR556A
BR-49
BR-50
TROUBLE DIAGNOSES
()
)J
ij~
PI
-=SBR557A
Ii)
()
I~
[Y]
1
CHECK CONTROL UNIT POWE SUPPLY. R Disconnect control unit connector. Check voltage between control unit connector (vehicle side)
[:iI ij
Ii)
O.K. N.G.
SBR55BA
()
CHECK ALTERNATOR L TER~INAL VOLTAGE. Disconnect control unit connector. Check voltage between control unit connector (vehicleside) terminal @ and body ground after engine starting. Voltage: 6V or more O.K. (!J Check continuity between control unit connector (vehicle side) terminal @ and body ground with ignition switch "OFF" .
SBR559A
O.K.
Replace control unit.
BR-51
TROUBLE DIAGNOSES
Motor relay indicator Power supply indicator
item)
'"'$SUR' DEC
~/
(
in switch
Connect A.B.S. checker to actuator connector and vehicle harness with battery terminal connected and all checker switch turning off. Check that battery' voltage is at least 12 volts. Use harness for 3 channel. Set select switch to 3 channel.
No
Turn checker power supply switch on. Check power supply indicator for coming on. Yes Check checker valve relay indicator for coming on. Yes Select one valve. Select pressure decreasing position by switch then turn motor switch on. Turn motor switch off. Select pressure increasing position.
Replace battery with fully charged new one, if checker connection is correct.
CAUTION: Do not hold switch at the pressure decreasing position for more than 5 seconds. Otherwise, solenoid valve may be overheated and damaged.
Check motor relay indicator for coming on while motor switch is turned on. Yes Check motor for operational sound beside the actuator in a quiet place. Yes
No
No
Replace actuator as assembly. if Diagnostic Procedures 7 - 12 are already performed and checker connection is correct.
Bring checker in the vehicle and depress the brake pedal. Repeat step
~.~
~~R691A
Valve select switch position RR is used for 4 channel checking. In the case of 3 channels, brake pedal vibration or depression will not occur in position RR. It will occur, however, in position RL.
BR-52
O.K.: Vibration
N ..: G
I' . N 0 VI ration b
BR-53
CL9H 33.96 (1.3370) 75.0 x 40.0 x 9.5 (2.953 x 1.575 x 0.374) 258 x 9 (10.16 x 0.35)
mm lin)
22.22 (7/8)
23.81 (15/16)
Center lever
BR-54
BRAKE PEDAL
CL25VA Free height MfT mm (in) 177.0
- 187.0
(6.97.7.36)
18.0 (0.709)
20.0 (0.787)
0.07 (0.0028)
1.3
(0.04.0.12)
2.0 (0.079)
PARKING BRAKE
8.0 (0.315) Item 0.07 (0.0028) Number of notches [under force of 196 N (20 kg, 44 Ib)) Number of notches (when warning switch comes on)
Center lever
6-8
BR-55
STEERING SYSTEM
SECTION
ST
ST- 2
ST - 3 ST- 5 ST- 7 ST-10 ST-14 ST-27
CONTENTS
PRECAUTIONS
PREPARATION ON-VEHICLE ON-VEHICLE STEERING POWER POWER SERVICE INSPECTION INSPECTION WHEEL (Power steering) COLUMN (Model PR24SC)
""""""'"''
"
STEERING STEERING
LINKAGE
ST-31
IDI
PRECAUTIONS
Before disassembly, thoroughly clean the outside of the unit. Disassembly should be done in a clean work area. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter. When disassembling parts, be sure to place them in order "in a parts rack so they can be reinstalled in their proper positions. Use nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might interfere with their operation. Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable solvent. Before assembly, apply a coat of recommended A.T.F.* to hydraulic parts. Vaseline may be applied to a-rings and seals. Do not use any grease. Replace all gaskets, seals and a-rings. Avoid damaging a-rings, seals and gaskets during installation. Perform functional tests whenever designated. *: Automatic transmission fluid
. . . . . .
ST-2
PREPARATION
SPECIAL SERVICE TOOLS
Tool number (Kent-Moore No.) Tool name KV48100700 (J26364) Torque adapter
Description
~n ~
~@ ~@
KV48102500
(
~
CD-fJ
CJI@
Measuring turning torque
~
Reforming teflon ring
@~ @-o
Socket adapter
KV481 04400
(
ST-3
PREPARATION
COMMERCIAL SERVICE TOOLS
Tool name
Description
~"'di'
Pinion oil seal drift
Installing pinion oil seal
v:2.,.,dg
Oil pump attachment
Welding ,\1-\O.a.1\ 40 11.57) 12 .;.~fb~10.47) "".
ST-4
ON-VEHICLE INSPECTION
Checking . Steering Wheel Play
35 mm (1.38
.
If it is assembly. not within
in) or less
specification, check rack' and pinion
Checking
. Check that the steering wheel is in the neutral position when driving straight ahead. . If it is not in the neutral and reinstall it correctly. neutral lock position nut and is between move tie-rod two serrated teeth, loosen direction position, remove the steering wheel
.
SST104B
If the tie-rod
in the
opposite
by the same
compensate
amount
on
right sides to
. Rotatesteering wheel
turning angle.
right
and
left;measure
SMA 127
. If it is not within specification, check rack stroke.
SST086B
ST-5
Check the movement of steering gear housing during stationary steering. The maximum allowable movement is as follows:
Movement of gear housing: . :t 2 mm (:t 0.08 in) (on dry paved surface) or less Apply a force of 49 N (5 kg, 11 Ib) to steering wheel to check the gear housing movement. On models equipped with power steering, turn off ignition key while checking.
If movement
exceeds
mount
insulator
after
ST~6
Checking
CAUTION:
Fluid Level
. .
Transmission
Fluid
Checking
Fluid Leakage
Check the lines for improper attachment and for leaks, cracks, damage, loose connections, chafing or deterioration. 1. Run engine at idle speed or 1,000 rpm. Make sure temperature of fluid in oil tank rises to 60 to 80C (140 to 176F). 2. Turn steering wheel right-to-Ieft several times. 3. Hold steering wheel at each "lock" position for five seconds and carefully check for fluid leakage.
CAUTION:
SST107B
Do not hold the steering wheel in a locked position for more than 15 seconds. 4. If fluid leakage at connectors is noticed, loosen flare nut and then retighten. Do not overtighten connector as this can damage O-ring, washer and connector.
4. Check steering wheel turning force with engine idling when steering wheel has been turned 360 from neutral position. Steering wheel turning force: 39 N (4 kg, 9 Ib) or less
ST-8
ST27091000(J26357)
...
Low-pressure hose
. .
SST834
ST-9
~~~
Steering tube assembly
~
~L"!]~:'o ~.o.
22 - 291
~N~
\L"!]
13'
- 19
(1~
- >,9 - 13]
to.) : N.m (kg-m, ft-Ib) SST109B
to.) 13.1811.3.1.8,9.13)
Removal
STEERING
WHEEL
SST110B
SST275B
ST -1 0
WHEEL
When installing steering wheel, apply multi-purpose grease to entire surface of turn signal cancel pin (both portions) and also to horn contact slip ring.
SST112B
STEERING
COLUMN
When installing steering column, fingertighten all lower bracket and clamp retaining bolts; then tighten them securely. Do not apply undue stress to steering column.
'
When attaching coupling joint, be sure tightening bolt faces cutout portion.
CAUTION: After installing steering column, turn steering wheel to make sure it moves smoothly and that the number of turns from the straight forward position to left and right locks are equal. Be sure that the steering wheel is in a neutral position when driving straight ahead.
Lower joint SST800A
ST -11
Hole cover
. . .
SST428A
When disassembling and assembling, unlock steering lock with key. Ensure that rounded surface of snap ring faces toward bearing when snap ring is installed. Install snap ring CD before inserting shaft into jacket tube.
.
---n
Upper shaft
SST770A
ST -1 2
and Assembly
(Cont'd)
Tilt mechanism
Tighten adjusting nut to specification. ~: 4 - 5 N.m (0.4 - 0.5 kg-m, 2.9 - 3.6 ft-Ib)
SST114B
Steering
lock
~~ i
Self-shear screw
SST742A
b) Install self-shear type screws and then cut off self-shear type screw heads.
Inspection
When steering wheel can not be rotated smoothly, check the steering column for the following matters and replace damaged parts. a. Check column bearings for damage or unevenness. Lubricate with recommended multi-purpose grease or replace steering column as an assembly, if ecessary. b. Check steering column lower sh ft for deformation or breakage. Replace if necessary. When the vehicle is involved in a light collision, check steering column length "L1" and steering column lower shaft length "L2". If it is not within specifications, replace steering column as an assembly. Steering column length "L1": 653.1- 654.5 mm (25.71 - 25.77 in) Steering column lower shaft length "L2": 323.7 - 325.3 mm (12.74 - 12~81 in)
F~-
L,
:1
SST098B
L2
SST115B
L.
After installing steering column, check tilt mechanism operation. L1: 9.8 mm (0.386 in) L2: 19.5 mm (0.768 in) . L3:29.3 mm (1.154 in) L.: 58.2 mm (2.291 in)
SST116B
ST -1 3
POWER STEERING GEAR AND LINKAGE (Model PR24SC) Removal and Installation
V,",". "00'
~
..,.I>
~
~
~
~
~o
:
I
~
~I\
'
18
Gear and linkage assembly tOJ 88 . 108 (9.0 . 11.0, 66 .80) tDJ: N.m (kg-m, ft.lb) 124B
SST783A
SST080B
ST -14
POWER STEERING GEAR AND LINKAGE (Model PR24SC) Removal and Installation (Cont'd)
. .
Observe specified tightening torque when tightening highpressure and low-pressure pipe connectors. Excessive tightening can damage threads or damaged connector O-ring. The O-ring in low-pressure pipe connector is larger than that in high-pressure connector. Take care to install the proper O-ring. .
Initially, tighten nut on tie-rod outer socket and knuckle arm to 29 to 39 N.m (3 to 4 kg-m, 22 to 29 ft-Ib). Then tighten further to align nut groove with first pin hole so that cotter pin can be installed. CAUTION: Tightening torque must not exceed 49 N.m (5 kg-m, 36 ft-Ib).
arm
SST824A
. .
Before removing lower joint from gear, set gear in neutral (wheels in straight-ahead position). After removing lower joint, put matching mark on pinion shaft and pinion housing to record neutral position of gear. To install, set left and right dust boots to equal deflection, and attach lower joint by aligning matching ~arks of pinion shaft and pinion housing. \
ST -1 5
POWER STEERING GEAR AND LINKAGE (Model PR24SC) Disassembly and Assembly
The table below lists four ways to repair oil leaks in the steering gear, depending on the location of the leak. See the following figure for oil leak locations.
CD Rear housing cover and rear housing
Operation
@ Boot
@ Boot
@ Cylinder tube
.
.
. . .
Replacement
. Replacement
Rack oil seal Boot clamp
. .
. Replacement
Rack oil seals Rack oil seal O-ring Back-up collar
Boot clamp
. . . . .
. Replacement
Cylinder tube
. .
Copperwasher
I I Replacecylinder
I I
tube.
kit
. .
SST117B
ST -1 6
be
~r~ l ~ 0r
O'@J ~@
~
~.
~16-21
(1.6-2. 1 , 12-15)
R~
Adjusting screw
----~:9n_U~9
(40-6.0,
SP~;r~ng disc
29-43) 1J
rWasher
%@@
evli.",,," 40"""\ /
CenterbUShing\
Rack oil seal~
So"og
Retainer
~
~
-.!
<::::::>--O-ring
"'"
Pinion assembly
\\\)~
m
R~kO'I_'~
l
43 -54'
Tie-rod
~ \
rn:
~JL. Bo",",m,
Rack spacer
~
socket
rJ
~:
N.m (kg-rn,ft-Ib)
ssn1SB
ST -1 7
. . .
SST1198
3. Remove tie-rod outer sockets and boots. 4. Loosen tie-rod inner socket by prying up staked portion, and remove socket. 5. Remove retainer. 6. Remove pinion assembly.
SST881
7. Drill staked portion of cylinder end cover with drill of 2 to 2.5 mm (0.079 to 0.098 in) diameter, until the staking is eliminated.
SST450A
8. Remove gear housing end cover assembly with Tool. 9. Draw out rack assembly.
SST0818
. . .
rack seal ring. heat gun, heat rack seal to approximately 40C rack seal ring. Be careful not to damage rack. rack seal ring and O-ring with new ones.
SST0828
ST -18
+1:''''0
"" 29mm..ok"
SST472A
Assembly
1. Using a heat gun, heat rack seal ring (made of Teflon) to
approximately 40C (104F) and install it onto rack with your hand.
~R"'k
",' cO",
SST083B
KV481 04400 ( )
Using Tool, compress periphery of rack seal ring (made of Teflon) to position and secure it on rack. Always insert the tool from the rack gear side.
Rack teeth
~lIJIfi11lJJJ11II11IIiIJ!I.
SST084B
.~
.~--
2. Insert rack oil seal. Place plastic film into rack oil seal to prevent damage by rack teeth. Always remove plastic film after rack oil seal is positioned properly. Make sure lips of rack oil seal face each other.
.
. .
Film~~
Rack oil seal j
SST201A
3. Install center bushing and rack oil seal with rack assembly.
SST830A
ST -1 9
6. Set rack gear in neutral position. Measured length "L": Refer to S.D.S.
SST086B
...
Suitable tool
7. Coat seal lip of oil seal with multi-purpose grease and install new pinion oil seal to pinion housing with suitable tool. Make sure lip of oil seal faces up when installed.
Oil seal
SST381
8. Install pinion bearing adjusting shim(s). Whenever pinion assembly, gear housing and rear housing are disassembled, replace shim(s) with new ones. Always use the same number of shim(s) when replacing.
SST074B
ST -20
. .
SST085B
10. Apply a coat of multi-purpose grease to needle bearing roller and oil seal lip before installing pinion assembly in gear housing.
SST075B
11. Install pinion assembly to pinion housing. Be careful not to damage pinion oil seal.
SST552
Gear housing
SST121B
- Protrusion
13. Install rear cover cap so that protrusion of rear housing cover is positioned as shown in figure at left. Be careful not to damage worm ring and oil seal.
ST -21
. .
SST087B
~(
@
r{ ~
<1;",h.
@ <ID
. Attach lock plate to side rod inner socket . Apply locking socket into inner socket threads @.to sealant to Screw inner rack @ and tighten torque. . Clinch two places of lock plate at rack's groove. CAUTION:
CV CD.
specified
'-CD
SST123B
16. Tighten inner socket and securely bend lock plate at 2 cutout portions of inner socket. To prevent damage to boot, remove burrs after bending lock plate.
SST 435
~'L~"~
~
SST093B
L'
SST086B
ST -22
SST967A
.~
20. Install boot clamps. To install, wrap boot clamp around boot groove twice. Tighten clamp by twisting rings at both ends 4 to 4-1/2 turns with screwdriver while pulling with a force of approx. 98 N (10 kg, 22 Ib).
SST097B
Install boot clamp so that it is to the rear of the vehicle when gear housing is attached to the body. (This will prevent interference with other parts.)
(0.20
- 15 mm - 0.59
in)
y
Vehicle front SST125B
~ \.
SST440A
After twisting boot clamp, bend twisted and diagonally so it does not contact boot.
0 CI M
SST126B
\
ST-23
Adjustment
Adjust pinion rotating torque as follows: 1. Set gears to Neutral without fluid in the gear.
2. Coat the adjusting screw with locking sealant and screw it in. 3. Lightly tighten lock nut. 4. Tighten adjusting screw to a torque of 4.9 to 5.9 Nom (50 to 60 kg-em, 43 to 52 in-Ib). 5. Loosen adjusting screw, then retighten it to 0.05 to 0.20 Nom (0.5 to 2 kg-em, 0.43 to 1.74 in-Ib). 6. Move rack over its entire stroke several times.
SSTOB9B
Adjusting screw
7. Measure pinion rotating torque within the range of 1800 from neutral position. Stop the gear at the point of maximum torque. 8. Loosen adjusting screw, then retighten it to 4.9 to 5.9 Nom (50 to 60 kg-em, 43 to 52 in-Ib). 9. Loosen adjusting screw by 40 to 60.
SST072B
10. Prevent adjusting screw from turning, and tighten lock nut to specified torque.
SST557A
11. Check steering gear for rack sliding frictional force. Around neutral point of rack stroke :t5.5 mm (:to.217 in): 122.6 - 166.7 N (12.5 - 17 kg, 27.6 - 37.5 Ib) Except for neutral point: 122.6 - 186.3 N (12.5 - 19 kg, 27.6 - 41.9 Ib) If sliding frictional force is out of specification, repeat the adjustment procedure, starting from NO.4. After the readjustment, if sliding force is still out of specification, steering gear is damaged.
SST090B
12. Measure pinion rotating torque within the range of :t 100 from the neutral point. Average rotating torque [(Max. measured value + Min. measured value) x 0.5]:
0.8
SST072B
Maximum torque increment: Less than 0.4 Nom (4 kg-em, 3.5 in-Ib) Except for above mentioned measuring range: Maximum rotating torque 1.9 Nom (19 kg-em, 16 in-Ib) Maximum torque incremen~ Less than 0.6 Nom (6 kg~m, 5.2 In-Ib) ST -24
If pinion rotating torque is not within specification, readjust it. After the readjustment, if pinion rotating torque is still out of specification, steering gear is damaged.
Inspection
Thoroughly clean all parts in cleaning solvent or automatic transmission fluid "DEXRONTMType", and blow dry with compressed air, if available. BOOT Check condition of boot. If cracked excessively, replace it.
RACK Thoroughly examine rack gear. If damaged, cracked or worn, replace it. PINION ASSEMBLY
.
.
Ci CO)
ri
0 CD
~!
Unit: *: Measuring points
TIE-ROD OUTER AND INNER SOCKET Check ball joint for swinging force. Tie-rod outer ball joint: 9.12 - 91.30 N (0.93 - 9.31 kg, 2.05 - 20.53 Ib) Tie-rod inner ball joint: 8.14 - 122.6 N (0.83 - 12.5 kg, 1.83 - 27.6 Ib)
mm (in)
SST750A
Check ball joint for rotating torque. Tie-rod outer ball joint: 0.29 - 2.94 N.m (3.0 - 30.0 kg-em, 2.~ - 26.0 in-Ib) Tie-rod inner ball joint: 7.4 N.m (75 kg-em, 65 in-Ib) or less
SST751A
ST -25
Check ball joint for axial end play. Tie-rod outer ball joint: 0.5 mm (0.020 in) or less Tie-rod inner ball joint: 0 mm (0 in) Check condition of dust cover. replace it.
If cracked
excessively,
SST435A
CYLINDER
TUBES
ST -26
Oil seal
~ lEI
(qJ 27 . 35
(2.8
-3.6,
20 . 261
Pre-disassembly Inspection
Disassemble the power steering oil pump only if the following items are found. Oil leak from any point shown in the figure. Deformed or damaged pulley.
. .
SST12BB
ST-27
. . . .
Remove snap ring, then draw pulley shaft out. Be careful not to drop pulley shaft.
Extension bar
SST010B
SST034A
Front housing
of
SST036A
. . .
If pulley is cracked or deformed, replace it. If an oil leak is found around pulley shaft oil seal, replace the seal. If serration of pulley or pulley shaft is deformed or worn, replace it.
ST-28
Assembly
Assemble oil pump in the reverse order of disassembly, noting the following instructions. Before installation, coat the a-rings and oil seal with A.T.F.* Make sure a-rings and oil seal are properly installed. When assembling vanes to rotor, rounded surfaces of vanes
. . . .
.
.
must face cam case side. Always install new a-rings and oil seal.
SST289A
.
Faces inside
Flat portion
SST843A
SST499A
Spring
.
*:
ApplyA.T.F.*to a-ring.
Automatic Transmission Fluid
SST536A
ST-29
CID
as shown at left.
D,
SST497A
ST -30
GENERAL
Steering wheel axial play mm (in) Steering wheel play mm (in)
0
- 35
(0
- 1.38)
STEERING
Steering column
COLUMN
length "L, " mm (in)
mm(in)
N (kg, Ib)
Rotating torque
N'm (kg-em, in-Ib)
mm (in)
)1~J
L,
SST098B
*: Measuring point
~'L~"J
~
SST093B
0.78
L2
- 1.27
mm (in)
~~
,'\ ".' --, ',,',',
d:P
~:-
",
'p'
SST086B
ST-31
Steering wheel turning force (Mesured at one full turn from neutral) N (kg, Ib) Normal operating temperature
39 (4,9) or less
of power steeringfluid
C (0 F)
Fluid capacity (Approximate) J2(US qt, Imp qt) Oil pump maximum presure kPa (kg/cm2, psi)
0.9 (1,3/4)
6,865
(70, 995)
ST -32
. .
BF- 2 BF- 6
CONTENTS
GENERAL BODY END DOOR
(Including "Power Window" & "Power Door Lock")
SERVICING
.............................
B F-12
INSTRUMENT INTERIOR
PANEL.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BF-18
AND
EXTERIOR
................................... .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B F-32
TROUBLE DIAGNOSES................................................... SUN ROOF.............................................................. WINDSHIELD AND WINDOWS............................................. MIRROR - Door Mirror................................................... REAR COMBINATION LAMP...............................................
FRONT AND
BODY
.........................................
ALIGNMENT
................................................
Read GI section, "HOW TO READ WIRING See EL section, "POWER SUPPLY ROUTING"
--
When you perform trouble diagnoses, read GI section, "HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES".
GENERAL SERVICING
Precautions When removing or installing various parts, place a cloth or padding onto the vehicle body to prevent
scratches. Handle trim, molding, instruments, grille, etc. carefully during removing or .installation. Be careful not to soil or damage them. Apply sealing compound where necessary when installing parts. When applying sealing compound, be careful that the sealing compound does not protrude from parts. When replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust prevention measures.
.
.
. .
. .
CD
SBF092B
SBF109B
='0=
SBF094B
CD
T
SBF113B
SBF114B
1f
5."3'.
b
Removal: Pull up by rotating.
SBF115B
::
Removal:
W
SBF141B
y
SBF142B
SBF143B
BF-2
GENERAL SERVICING
Clip and Fastener No. I Symbol
I
(Cont'd)
Removal & Installation
Removal: Removewith a flat-bladed screwdriversor plier.
Shape
(VI
W
SBFOS9B
o
I I
"t
T
-
=1
CS@
SBF090B
I
SBF091B
Push center pin to catching position. (Do not remove center pin by ... Push hitting it.! Push
2j)DI
!
SBF31SC SBF319C
...
Pi "
Installation:
E
SBF320C
cO])
-!SBF103B
I
R__".
SBF104B
SBF147B
I
Removal:
Clip
/\)
/
SBF653B
Then bend up
CD ..E([
Push
SBF654B
I
<f01
\ )
SBF 1730
\U U)
SBF1740
'T'
SBF1750
BF-3
Symbol
Shape
Clip-A
\
<f~1})
SBF035C
SBF036C
~
~CUP~
Clip-B (Grommet)
<fF21])
Sealing washer
...
Clip-B (Grommet)
~
Body panel SBF652B
SBF150D
-<f
SBF151D
c~~
SBF768B
~)Q~
SBF770B
i
(~op
~
SBF138B
~
SBF139B
l4
(~ 0])
s
SBF363B
~
BF-4
T
SBF364B
SBF140B
i
CfO:V
T
SBF361B SBF362B
SBF140B
BF-5
BODY END
Body Front End
. .
~'
@@@
@@
Bumber height
At vehicle center
~ Ground
BF-6
Hood lock adjustment . Adjust lock so that hood primary lock meshes at a position where hood is 1 to 1.5 mm (0.039 to 0.059 in) lower than fender. . After hood lock adjustment, adjust bumper rubber. . When securing hood lock, ensure it does not tilt. Striker must be positioned at the center of hood primary lock. . After adjustment, ensure that hood primary and secondary lock operate properly. Hood lock secondary latch hooking length More th8n Hood adjustment
5 mm (0.20 inl
C1G: ~
Hood
Secondary latch
Bumper rubber adjustment . Adjust so that hood is aligned with fender. [Bumper rubber free height is approx. 20 mm (0.79 in).]
* : Bumper assembly mounting bolts and nuts tOJ : N.m (kg-m, ft-Ib) SBF174E
BF-7
B,ODY END
. . .
/
Back door adjustment: Adjust at hinge-body portion for proper back door fit.
Back door lock system adjustment: Adjust lock & striker so that they are in the center. After adjustment, check back door lock operation. Trunk lid adjustment:Adjust at hinge-trunk lid portion for proper trunk lid fit. Trunk lid lock system adjustment: Adjust striker so that it is in the center of the lock. After adjustment, check trunk lid lock operation.
WARNING:
a. Be careful not to scratch back door stay when installing back door. A scratched stay may cause gas leakage. b. The contents of the back door stay are under pressure. Do not take apart, puncture, apply heat or allow fire near it. . Opener cable: do not attempt to bend cable using excessive force. After installation, make sure that trunk lid/back door and fuel filler lid open smoothly.
FASTBACK Before removing rear bumper, remove right drafter which is secured with two upper nuts and butyl seal.
15-20)
\
""\".
\
[Hinge-body (Behind rear roof rail garnish)] ~12.1-2.7,15-20)
c,.~
~
21
-26
/
BF-8
BODY END
Body Rear End and Opener (Cont' d)
\
*
tOJ: : Bumper assembly mounting bolts and nuts N.m (kg-m. ft-Ibl SBF176E
BF-9
BODY END
COUPE
II
\""
~ iii
/
//
//
~~'
I
Trunk lid torsion bar removal & installation WARNING: When removing and installing torsion bar, be careful as it is under tension.
iii
BF-10
Ii)
[!J
\OCk nu~
~d
.
~
~/~
".
~~:::~~ t;r~
\/ 7 I
Trunk lid lock
,-Striker adjustment
.l~
Ii
Ii]
Bumper height
556.7
-606.7
mm
TI
in)
(21.92.23.89
SBF~
SF-11
DOOR
Bencrank
adjustment
Regulator assembly
adjustment
Ii]
tOJ 5.1 -6.5
handla
Ii)
BF-12
DOOR
Ii)
Outside handle escutcheo~)//
1/ '
Holder
U--
Outside
handle adjustment
-"
t
Striker adjustment
[+J
tOj13-16 (1.3_1.6'
9 -12)
..
...
Ii]
. Removeweatherstrip from retainer.
Glass portion
~~ .
@
t~
.
in)]
'{~d~";~"~:'m
(0.039
. .
Door glass-to-retainer clearances A and B Adjust so that clearances A and B are equal. Ensure door glass is not tilted.
Weatherstrip retainer
Outside
c=>
Glass portion
fA
SBF177
BF-13
Upward
Downward
~@ r-",
(Main harness)
W/B
W/R"""4..l.I L/R-;::n,
BREAKER . I CIRCUI T
I
@
(Door harness
L.H.)
W/B R~B~ R/W~
~
.
R~B
R/W
:;!~I~ :U~I
R/W
R/B W/B
I GN I TI ON
RELAY
g,
."
I ~
@ 8
. D
(Door harness
R/W R/B W/B
R. H. )
~~
R/W
W~B
R/B L
.@
rr-~~ ,,,,r-"'OI' ~
01"""
~@
DRIVER SIDE LOCK ONESWITCH TOUCH MANUAL U N 0 U N D ON OFF a 1 a a 2 :3 0 0 a 4 5 6 7 PASSENGER SIDE U N 0
MOTOR
POWER WINDOW
AMPLI F I ER
.
~:a~:ar-r:a0l0l~0I~
POWER W
(Passen
a <> 0 0 a
CIRCUIT BREAKER
Wi ope di
CJI
m "11
w W I'J m
Connections
AMP AMP
AMP
~~ 9
~
Ground
-=-
VOLTMETER Window operating direction Upward Downward FRONT DRIVER SIDE POWER WINDOW REGULATOR
f I Current
flow
I\.1
direction
AMP.
OPERATION
Connections
\
51 52 -53 54 55
Operations
56
Manual operation One-touch (Autol Operation Power source OGNI 12V 12V 12V 12V 12V 12V Ground Gmund Ground Gmund Gmund Gmund Ground ON or ST ON or ST ON or ST ON or ST ON or ST From ignition SW(ON or STI ON or ST To FR driver side power OFF OFF OFF OFF OFF ON window SW (AUTO) Q) '0; To FR driver side power OFF ON OFF OFF , OFF OFF window SW (UP) @ To FR driver side power OFF ON OFF OFF OFF ON window SW(DOWN) CV
57 58
. I
FR driver side regulator (Upward power source) FR driver side regulator (Downward power source)
Approx. OV Approx. OV
Regulator
Operating
Condition
Stop
Starting
Keeping opera. tion until fully open, then "ops automatically. operation
Downward
CIRCUIT
BREAKER
INSPECTION
'
For example, when current is 30A, the circuit is broken within 8 to 20 seconds. This circuit breaker is also used in the power door lock system.
1 0 SBF284E
10 20 30 40 50 60 70 Current (A)
BF-15
.
ORB'L
PASSENGER
SID~ D
Between
lock"
~t
([ill)
@
CIRCUIT~ BREAKER~ rn::;-L/R
~W/R
un lock n a
@@D
<Therm
breaker
",{eli",{e
(Sub harness)
W(GR
@
ORs"B
@
C
(Main harness)
W(GR
LG
L G/B
~~
. C @ @)
LG L G/B
L
harness
L G/B
(Door R.H.)
LG I8:I8l.I
:::rTLn
gJ ."
I ~
~
.
ORs"B LG/B
OR/L
Lockwa~d
0')
1~~~1
OR/L
@
<Door harness L. H. )
OR/L
~~
@
~ ~
"IJ
~@)
OR/B=EI3
EE}:OR/B
(ill)
unlock,
to lock,
(Front H. dash R.
[:J
LG LG;S
@)
s I de)
.,
(II m ." w W w m
@fi@Y
BODY GROUND
INSPECTION
OPERATION
OFF OFF
Turns ON OFF
ON
OFF Turns ON
OFF
OFF
Turns ON
Turns OFF
OFF
ON
After SW-A Turns operation, Turns OFF immediately OFF turns ON OFF ON... OFF OFF ... ON... OFF
OFF
Carry out the complete inspection in this chart from left to right. Do not carry out any switch operations that are not described in the above chart so as to avoid breaking the door lock timer.
Lighting period of test lamp differs according to SW-B operation. Moreover, test lamp may come on once or it may not come on at all. If this occurs, do not judge it fau Ity solely from th is step.
--BATTERY
TEST LAMP
SW-B
=
=
-::-
-=-
SW-A
DOOR LOCK TIMER
CIRCUIT CONNECTIONS 31 32 Power source (BAT) To/From actuators (Lock power source & Unlock ground) To/From actuators (Unlock ground & Lock power source) To lock-unlock switches (Input signal for lock) Ground To lock-unlock switches (Input signal for unlock)
- +
+ -
33 34 35 39
SBF377E
BF-17
INSTRUMENT PANEL
f
.
.
When removing instrument panel assembly, remove defroster grille, combination meter, A/C or heater control, cluster lid C and S.M.J. first.
HEAD-UP DISPLAY (H.U.D.) When removing H.U.D. finisher, be extremely careful not to scratch H.U.D.'s reflective surface. To avoid scratching, cover H.U.D.'s reflective surface or finisher with a cloth or vinyl sheet. II
~
-~
Ii)
;;;.
* ~
.'
rPawl (I
-~*
/~
~
.
~P8WI
Ii]
~~
Combination meter
~~
Cluster lid C
~.Metal
~
*
: Instrument panel assembly mounting bolts
cliPIJ
'1'"
~/
BF-18
INSTRUIYIENT PANEL
(j]
@J
'
--
Ii]
II
Ii
[!1
1:1
IJ
Ia
II
Metalclip
SBF178E
BF-19
~ 0
-;?o,;',
--~:. fT ."."- ~
Speaker
panel
Ii]
Metal clip
iii
~ U-:!
\I
[!I
BF-20
Ii]
[!]
;t=.~~~
Garnish
Ii]
(I
Pawl
Ii
Pawl
Pawl
[!I
SBF179E
BF-21
Coupe
~=,1J~\
Garnish SBF180E
LUGGAGE
ROOM TRIM
Coupe
Clip removal
Ii)
Ii)
J-~
Removal
SBF181E
Bf=-22
Coupe
.~~
U
Ii)
Roof panel Back door window
~R~f
"'m ~,.". m
r-
/)
1ass
g
HoodnO;"'
M""<"p ~l
~ ~
r-.~
\ r)}. 0/
7
SBF182E
~~tXL\
BF-23
INTERIORAND EXTERIOR
Exterior
@>
(j)
SBF192E
BF-24
Method 1
Cut off top portion of molding and clean glass and panel surfaces.
~.q~ ~"~,
.
...
<@J;
to top portion of
~9
~.,.,.,.,.,.,..: ~~;~ Cut off lower portion of new molding.
~()
':1:--4
/
CID
SBF211E
SEV
.',','.'.','. ." ':i/":::: 'J
'r"~
Method 2 1. Cut off sealant at glass end. 2. Clean the side on which panel was mounted. 3. Set molding fastener and apply sealant & primer to body panel, and apply primer to molding.
Apply primer."\ Glass~ Dam rubber
-,
~
(
4. Install molding by aligning the molding mark located on center with vehicle center. Be sure to install tightly so that there is no gap around the corner.
SBF519B
s"u"'~"h7 ~.
Grommet
'
BF-25
~
II
m
ButYl tape Double-faced adhesive tape
: Butyl tape
[!) Coupe
Removal
.--;
Ii]
Windshield pi liar garn ish Body side welt Body side weatherstrip
II
Weatherstrip retainer
Ii
Seal
SBF214E
BF-26
t""h"
W,""
\ SBF215E
SBF217E
@ Back window upper and side molding (Coupe) Basically the same as windshield upper and side molding. (j]) Back window lower molding (Coupe) It is mounted with screws. @ Trunk lid weatherstrip
@ Back door window upper and side molding (Fastback) Bonded on back door glass side. @ Back door window lower molding (Fastback)
Molding ~ clip
~ "
Trunk lid
' weatherst . . .;. np
(9 places)
SBF401B SBF216E
adhesive tape (When install ing fastener. heat body panel and fastener to approx. 30 to 40C (86 to 104 F)).
BF-27
(Cont' d)
(j]) Sun roof lid weatherstrip
Manual sun roof
Butyl seal
Sealant
Body panel
SBF757Q
SBF873C
SBF218E
@ Sun roof lid weatherstrip and sun roof frame weatherstrip (Coupe)
Sun roof lid weatherstrip is bonded to lid. Apply primer before bonding it. Front // Roof panel ./ Sun roof lid
.///j
'
SBF824D
BF-28
BF-29
SEAT
Front Seat
IRJ
SBF183E
BF-30
Seat back
adjustment
I!J
I!J ~
Bushing ~Grommet
~ '3.,.~1-::lli (1.3-1.6 j
9-12)'
(10
I
SBF184E
..
)
BF-31
[!J
Pawl
Drive motor
Lap belt
(Installation
Ii) )
~43
-55 14.4- 5.6,32 - 411 Shoulder belt assembly (Installation m) 14.4- 5.6, 32 - 41)
~~43-55 ~.
oD
i~. Lap belt buckle (L.H. only) switch
Control unit
BF-32
I~
rA
43-55
(4.4-5.6,32 -41)
~I
~
A43 - 55 (4.4 - 5.6, 32 - 41)
Ii]
retractor
Lap belt
~~t~
(4.4 - 5.6, 32 - 41)
[!J
Guide rail assembly Rear limit switch (Bottom color: Green) Guide cable
~ ~
J>ff
.~.~
A
: N.m (kg-m. ft-Ib)
SBF185E
BF-33
'" ~@})
E1
..J ~
j
WARNING CHIME
I ast
page)
page
.J
m ,
u:
'"
I
@D
~
"''''
..J
~.
R/B
(Mai n harness)
@
G
I
'iii U) Q)
(Ma I n harness)
'" EEIBHEE @
CWh te) i (B lack)
'" ,
>-
~@ ~@
c
III .c Q. E III E 0 0 0:
~
@
tHHHffil@ '"
, >..J
>'III
'-
@
'"
(J nstrument harness)
WI)
EW
~@
'"
, >-
'"
"" >-
'"
~QD
[Sffi:B]@
I
92
~
91 o
@--<>
:
I
~
91 o @ o 92 SEAT BELT WARNING LAMP
METER
0
1
[g
R. H. SIDE
FRONT LIMIT SWITCH
COMBINATION
BF-34
~ ~
~:Without
head-up
~~@V
m~~~~~~
""",m
~~~~~~~
m ~
,~~
',m"~~m"
~~ ~~~~
~m
~~~~
~~ ~~ R. H. SIDE
~
~~~
G;R G/B
CD
~L/W~~ D
j1
~Lr~
w ~
"'~Rl ~
Shoulder
~
'53 rst
buckIe condItlon
FR IFR and RRIRR
belt
Shoulder
belt condl t Ion IUnfastened I I Belt ope rat In9 dl rect Ion
rlFrontward Raarward
L. H. SIDE
@E)
~~~
LG;R LG/B
jl
SHOULDER BELT
BUCKLE SWI TCH 55 54
L
~ ~ ~
m'
,m
dIdI
@Y~
@~
~ ~
171
j
@}) BODY GROUND
m
II J ~ II 1: ~
W ~
. 0
i=9
~ FID ~
11
@D
-0..
R:~
~M18 fn.) DI ~ ~
@ ii
@D(@@~
BODY GROUND SBF784E
1121
LAP BELT
BUCKLE
(L. H. s I de
SWITCH
on I y)
BF-35
1 ';;;
:; 0.
o!:
Ignition
switch
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF ON
ON
OFF ON
OFF
OFF ON
OFF
ON ON
OFF
ON OFF
ON
ON OFF
ON
ON ON
ON
OFF ON
OFF
OFF ON
OFF
ON ON
OFF
ON OFF
OFF
ON OFF
ON
ON OFF
ON
ON ON
ON
OFF ON
OFF
OFF ON
Rear limit switch Drive motor power source for frontward operation
1
';;;
OV
OV
OV
OV
OV
12V
12V
OV
OV
OV
OV
OV
12V
12V
OV
OV
:; 0. :; 0
Drivemotor power
source for rearward OV OV 12V 12V OV OV OV OV 12V 12V OV OV OV OV OV operation Function Stop Stop Start to move Start to move Start to move Start to move OV
Stop
Stop
Stop
Stop
Stop
Stop
Shoulder buckle
belt Position Front Front Front Rear Rear Front Front Rear Rear
Rear
Front
Front
TIMER
If limit switch does not operate (when accomplishing frontward operation, front limit switch can not be turned "OFF" or when accomplishing rearward operation, rear limit switch can not be turned "OFF"), control unit will continue to supply power to drive motor for 15 secondsand control unit will stop supplying power. QUICK WARNING (Ignition switch "ON")
If front limit switch is not turned "OFF" after accomplishingfrontward operation, control unit will stop supplying power 15 seconds later and warning lamp will flash and chime will operate rapidly for approximately
seconds.
REAR LOCK If quick warning functions twice successively while ignition switch is "ON", shoulder belt buckle will move to rear position when the door is closed as normal but will remain in rear position even if door is opened. This function is canceledwhen ignition switch is "OFF".
BF-36
(Cont'd)
Lamp
Chime
OFF -* ON
I Lamp Chime
.
And,", R'~I - _h"
Lamp Chime
n..
I Shoulder belts
are not fastened.
I
ON
I
t::
I
Within 6 sec.
100 sec.
ON OFF
ON
.me Belts
OFF -* ON
Lamp
Chime Belts Lamp Chime Belts
O~~
ON OFF Unfastened Fasten~~.I~ec.
r-aSIenea
OFF -* ON
Lamp
Chime
ON OFF
O~~
~
I
Within 6 sec.
6 sec.
BF-37
BF-38
BF-46 BF-48 BF-49 BF-52 BF-54 BF-56 ..".. BF-58 BF-60 BF-62 BF-63 BF-64
Since left and right component parts are basically the same, harness layout and methods for electronic components inspection are shown for one side only. Although methods for checking component parts on both sides are described in the flow chart, making it easier to trouble-shoot, apply checking procedures to either side that have problems during trouble diagnoses. For those methods enclosed by double rectangulars,however,component parts on both sides must be checked as problems occurring on either side cannot be easily determined by a symptom.
BF-39
TROUBLE DIAGNOSES
Symptom Chart
BF-64 BF-64 BF-64 BF-64 BF.64 BF-65 co :i Ii Motor Shoulder belt buckle switch 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
c: 0
of;
co
.. ... c: .. c:
8
BF-64 iii
BF-64
Motor
0 0
0 0 0 0
.
0
0 0 0 0 0 0
t ..
" -0
0;;; :i ....i
0 0
Warning chime
0 0 0 0 0
e a.
i i5
u ji; 0 c:
0 0
0 0
0 0 0 0
0 0
0 0
a.;'G c: 0. -0.00
.. "E o.><
e o!::6
.><
0 0 0 ..
.!! '><-o
.E a.
'f
0 .. ..
iu
0
e ;,
Q:
c: " j! ..
co i 0. .. u
Ia.
>CI)
:>< 0
>..c
u..
.. "..
ij 0 ;'''.011" 11 ... ..
.. - c:
...
g
.2.. -0 >
g-
a:
zE
0-00
c:
...:.. :2.. f
;, ...
EE
3:: 000
'" c: .: 02 E0
.. u ;:... ;,
.. .
0. 0 '" c: of co
0
05
! ..
... u
BF-40
Turn ignition switch and all other electrical switches "OFF", and close door.
Open door.
Move shoulder belt buckle to center (not rear lock position and not front stop position) by wrench supplied in tool bag or equivalent.
Close door.
r
Connect battery cable. STEP 1 Does shoulder belt buckle move frontwards? No Yes
Open door.
STEP 2
I
Yes
Close door, and turn ignition switch "ON". STEP 3 No Does shoulder belt buckle move rearwards? Yes END
BF-41
Yes
Go to PROCEDURE 2 of Main Power Supply and Ground Circuit Check. (See page BF-45.) Then go to Diagnostic Procedure 1. (See page BF-49.)
BF-42
Turn ignition switch "ON". STEP 1 Does warning chime sound for 6 seconds after switch is turned on? No
Yes STEP 2
Is warning lamp flashing now? Yes Close both doors. STEP 3
I
No
Is warning lamp flashing although shoulder belt buckles reached rear lock position? No Unfasten L.H. shoulder belt.
Yes
Does warning chime sound for 6 seconds and warning lamp glow after belt is unfastened?
.
No
Yes
Unfasten R.H. shoulder belt. STEP 5 Does warning chime sound for 6 seconds and warning lamp glow after belt is unfastened? Yes Fasten R.H. shoulder belt. No
Bf-43
Does warning chime sound and warning lamp glow for 6 seconds after the switch is turned on?
No
Yes
END
BF-44
TROUBLE DIAGNOSES
Terminals
Ignition switch "ON"
@ - Ground
SBF336E
@ @
- Ground - Ground
<@) Ground -
i5~ I~I ~
C.U. connectors
l~
-=-
~
B
- Ground
@ - Ground @ - Ground
SBF337E
IV [it
~
_T
PROCEDURE
<@)
- Ground
- Ground
Yes Yes
SBF33BE
-=-
BF-45
TROUBLE DIAGNOSES
Harness Layout
m
--------------------@ R.H. front limit switch
@
Body ground
I;]
@
r.
.
~
~
18 Warning (without
lamp
Warning chime
head-up
B F -46
SBF368E
BF-47
FUSE
1/1 FUSE
G)@
(WIth head-up
d I sp lay)
0~
(WI thout
@!
BELT WARNING
d I sp lay)
SEAT
@
' @
;
@
WARNING
CIRCUIT
BREAKER
S@
52
51
head-up
LAMP
CHI E M
0~
22
30 29 37 46 25
@!
I
[IJ
M @
SEAT BELT
\5
w6 en:
.> I.11::
I/)W
11::0
AUTOMATIC
34
2]
/
9 0
I
33
CONTROL UNIT
39
44 4] 45
40 38
26
26 42
'36
43
@ nlO1
3 9 H3'
'0 HH
3] 32 36 35
I 11::0
I I I
@Y @})
I ,1/);2
I 0 I--
5...J : G) @
51/)
CD @
I/)
0 I--
@@
O:J
-m
I...J .W ...Jm
I/) .1--
IW WO
Ei
@
I 11::0 WI-...J :JI/) 0 IW
0-...J
W:E
I--
.11:: I .w ...JII::
11lIM
I--
I/)W
...JO
.> .11::
@
I 0 I-
I 0
i
I
IO .0 -10
I/)
0I/)...J
I 0
(0
I/) .II::
.Z IO .11:: -ILL
wO...J
1/)1--
I-:E
0@
@
0@
Ei
@
WO O:J
I/)
-m
W:E
.1-I...J .W !r:m
.11:: I .W !r:1I::
0-...J I/)
I--
I 0
@i)
:JO
OC
@)
I-@
I/)
WI-0 -...J I/) .11:: IO .0
11::0
0 I--
: ...J-
I 0
(0
@I
Will m. I Q...
:E WO...J 1/)1-.Z IO
.11:: II::LL
I--
5d
@!D-::!:~
@-::!:@Y
@!D-::!:~
SBF7B5E
BF-48
TROUBLE DIAGNOSES
Fa
@p
IU
_T
Diagnostic Procedure 1
START
LHo"iwl
~40
tt4~ aHHo"d'
Fa CHECK MOTOR CIRCUIT. 1) Disconnect 10-pin connector from control unit. 2) Check continuity.
N.G.
~'Gm
SBF339E
m
@p
C.U. 10-pin connector
IU
~
~ ~
@
@-@ @-@
LG/S
C.U.10-pin
"IJ
L.H. ide s
R.H. side
[!]I I
@ - Ground
@
- Ground
O.K.
[!]I~
connector
i5~
Frontward operation Rearward operation
N.G. Go to DRIVE MOTOR ASSEMSLY of Electrical Components Inspection. (See page SF-64.) N.G.
Replace drive motor assembly.
LG/R
O.K.
SBF341E
BF-49
Ii]
1) Disconnect connector from drive motor assembly. 2) Check continuity.
Terminals
N.G.
Repair harness.
LG/B
LG/R
~ Drive motorconnector
R.H. side
~i5
SBF342E
O.K.
Check drive motor harness for open circuit. Repair drive motor harness.
O.K.
G/R
r.I_CT
ellU
~
~
D
52 LG/B 4~'
fill
~ Drivemotor
-.Eer
52
tEJ
Drivemotor connector
1) Disconnect connector from drive motor assembly. 2) Does continuity exist in at least one point?
Terminals L.H. side
Yes
@ - Ground
<@ - Ground
SBF343E
":"
-=-
R.H. side
@ - Ground
<@ - Ground
N.G.
Repair drive motor harness.
BF-50
TROUBLE DIAGNOSES
_NEeT
Ii <p
Eu
N.G.
SBF344E
-=-
@ - Ground @ - Ground
III
Rearward operation
N.G.
LG/R
RH. side
@ @
- Ground - Ground
O.K.
Yes . Replace control unit.
I
Rearward operation
SBF341 E
III ~
IJISCOIINEeT
18
Go to PROCEDURE 1 (START) of Preliminary Check. (See page BF-41.)
-=
SBF345E
BF-51
lu
_IECT
~
~
L
(
m
START
)
O.K.
(Go to @ on next page.)
SBF346E
-=
CHECK DOOR SWITCH CIRCUIT. 1) Disconnect 16-pin connector from control unit. 2) Check continuity.
Ii)~
_T~
TerC.U. 16-pin
connector
switch connector
IU ~
L.H. side
lu ~
_IEtT~
~1a1
~
nfFOil~
Ii)
N.G.
N.G.
LEvB
c.@9>
Door latch
IIISCIIIIIECT
lu
_IEtT ~
~
L
switch connectorlU
~
L
Repair harness.
I~R.H.side
rmJ
&
~
L.H. side
Terminals
R.H. side
1
[;]
_IECT
Ug~IJ~[;]
SBF347E
O.K. Yes
Connector Terminals @ - Ground @ - Ground
12J
~ ~
~
Harness color L.H. side: R R.H. side: L SBF348E
Repair harness. There will be incorrect grounding between terminals @ and (j]) or @ and (j]).
-::-
O.K.
Check door latch switch harness for open and short circuit. . O.K. Replace door lock assembly.
BF-52
SF-53
TROUBLE DIAGNOSES
_CT
~C.U.10-pin connector
,8:~
WiV
[it
m
Diagnostic Procedure 3
START
CHECK FRONT LIMIT SWITCH CI RCUIT. 1) Disconnect 10-pin connector from control unit. 2) Check continuity.
O.K.
(Go to @ on next page.)
SBF344E
-=
i5~
Frontward operation Rearward operation
LG/R
\
L.H. side R.H. side
Terminals
Shoulder belt .buckle position At front Not at front At front Not at front
@Ground
@Grou nd
R.H. side
~ -~~NB
G/R W/L \:.J U
[!] <&1~v 10-pin C.U.
Rearward
operation
1) Disconnect connector from front limit switch. 2) Check continuity. L.H. side R.H. side
Terminals
IE)
connector
[ill
<&1~1). C.U. 10-pln
connector
IE)~ m
B
O.K.
eJ fit D'
IlELJ
,Q -=
~m
.
Front
rtffiB EEE
H' side R8
limit
-[II ~
0
Y/L
CID~;,'" 00""':,',.',
II,Q II
~
(Go to @ on next page.)
SBF349E
SF-54
Ii]
A)
_MECT
':c;\
~V
~
~
Ii]
Does continuity exist?
Yes Terminals
Repair harness. There will be incorrect grounding between terminals @ and CD or @ and CD.
@g)
@) No
CD
- Ground
CD - Ground
-::"
C@Front
O.K.
Replace guide rail assembly.
N.G.
Check front limit switch harness for open and short circuit.
N.G.
Repair front limit switch harness.
O.K.
SBF350E -=-
Yes
Replace control unit.
1 (START)
BF-55
TROUBLE DIAGNOSES
m
C~V
C.U. 16-pin connector
[it
Diagnostic Procedure 4
START
m
CHECK REAR LIMIT SWITCH CIRCUIT. 1) Disconnect 16-pin connector frdm control unit. 2) Check continuity.
Shoulder Terminals
I
O.K.
-=-
SBF345E
tinuity Con-
L.H. side
@ GrOud
@Ground
at rear At rear
o Yes
No I Yes
Rearward operation
LG/R
R.H. side
Not at rear
iii Refer
[!J
N.G. N.G.
Repair harness.
~
L.H. side
SBF341E
~)
(~. (~.
[!J
IIISC8IIIECT
EO
[it
I
connector
12J
I~
rn ~
o
~
[it
R.H. side
@-(@ @ Ground
<ill>)
O.K.
_CT
,0;\ ~
[it
()
Rear
switch
IIISQIIIIIECT
[it
0 LM
I~J
~~j)CU.I.~;"
oonMctor SBF352E
~
=
LlLillJ
[ill
fJ ~
tfj
L
BF-56
TROUBLE DIAGNOSES
DiagnosticProcedure4 (Cont'd)
Ii]
m
SBF353E
CIDor()
i5~
LID
Connector L.H. side: CID R.H. side: () Harness color L.H. side: L/W R.H. side: L/W
Ii]
Does continuity
1
exist? Terminals - Ground - Ground No CID CID
Yes
----- Connector
L.H. side R.H. side
Repair harness. There will be incorrect grounding between terminals @ and ~ or @ and ~.
-=-
~
Check rear limit switch harness for open or short circuit. O.K. Repair rear limit switch harness.
1
Is this the second time? No Reinstall any part removed.
Go to PROCEDURE 1 (STEP 3) (See page BF-41.) or PROCEDURE 2 (STEP 3) (See page BF-43.) of Preliminary Check.
BF-57
TROUBLE DIAGNOSES
~
C.U. 16-pin connector
[
IV
-,
rw
~
Diagnostic Procedure 5
START
Y/B
, CHECK SHOULDER BELT BUCKLE SWITCH CIRCUIT. 1) Disconnect 16-pin connector from control unit.
-::SBF354E
O.K.
(Go to @ on next page.)
l.H. side
i5~
RH. side
Ter-Shoulder
minals l.H. side R.H. side @Ground beit Fasten Unfasten Fasten Unfasten
@Ground
[;) If shoulder
SBF355E
belt buckle is
[i
N.G.
N.G.
Repair harness.
~
l.H. side
Terminals
@-~
~
C.U. 16-pin connector
CID Rear switch assembly connector
RH. side
Continuityshouldexist.
Ii]
O.K. Yes Repair harness. There will be incorrect grounding between terminals @ and ~ or @ and ~.
Connectorerminals T
<ID CID - Ground - Ground
No
Ii]
~
SBF357E
[JlJ
Connector l.H. side: CID R.H. side: CID Harness color l.H. side: B R.H. side: B
Go to SHOULDER BELT BUCKLE SWITCH of Electrical Components Inspection. (See page BF-64.)
N.G.
-=
BF-58
TROUBLE DIAGNOSES
DiagnosticProcedure5 (Cont'd)
T
Check shoulder belt buckle switch harness for open or short circuit. O.K.
Replace rear switch assembly.
BF-59
TROUBLE DIAGNOSES m
,c:;>,
_T
1I8v ~
Diagnostic Procedure 6
connector
~C.U.16-pin
ST ART
I
LAP BELT BUCKLE
CIRCUIT (L.H.only).
m
CHECK
SWITCH
)
O.K. (Go to
on next
page.)
SBF358E
-=
[;)i5
~E)
Lap belt DISCONNECT
~ cV
~ 18
S8"S9'
C.U. 16-pin
connector
~
~
l..m
L/R
[]l]
L/R
Ii]
N.G. N.G.
Repair harness.
[!]
~ 1180
~~~
connector
~
L/R
[ill
[!]
O.K. Yes
Repair harness. There will be incorrect grounding.
No
Go to LAP BELT BUCKLE
SWITCH of
Electrical
Com-
ponents Inspection.
Check lap belt buckle switch harness for open and short circuit.
O.K.
N.G.
BF-60
T
Is this the second time? No Reinstall any part removed.
../
BF-61
Diagnostic Procedure 7
START m
I
iS~
~GM N~"
Ground intermittently.
1
-=-
SBF361E
CHECK WARNING CHIME CIRCUIT. 1) Disconnect 16-pin connector from control unit. 2) Check warning chime.
Terminals Method Result Ground interI Sound mittently.
O.K.
(Go to @ below.)
ijril
ij[il
-Ground
~
SBF362E
m
GM GM
I!J
N.G.
N.G.
Repair harness.
[!]
is [iI
[Q]
-=
[!]
O.K. Ves
Repair harness. There will be incorrect grounding.
SBF363E
Ii]
No
Ii]
is~
Check battery voltage existence. Terminals @ Ground Battery voltage should exist.
N.G.I Repairharness.
For details, refer to POWER SUPPLV ROUTING in EL section.
O.K. r.
Is this the second time?
r-@
Replace control unit.
BF-62
TROUBLE DIAGNOSES
DISCOIINECT
Diagnostic Procedure 8
E~ ,
~ ~
I~
SBF365E
C m
START
)
O.K. (Go to @ below.)
T'G
CHECK WARNING LAMP CIRCUIT. 1) Disconnect 16-pin connector from control unit. 2) Check warning lamp. Terminals
Resu It Glow
Ii)
@ - Ground
Ii)
N.G.
N.G.
Repair harness.
[
ffiJl f
i5
Y/G
<ID
6
Y/G
fO'WID7
Ii)
CIDfor Y/G
O.K. Yes
Repair harness. There will be incorrect grounding.
[ill
[i
SBF366E
-=-
@ - Ground
No
N.G.
[ii5~
91 0
~ [tmOO
~CIDforW/D
O.K.
Is warning lamp bulb burn out? Replace bulb.
~VJ
-=
No
A
rR=fcHEl
~forE/D SBF367E
BF-63
TROUBLE DIAGNOSES
i5l11
L.H.side Push
~/.
i5l11
Bottom color: Black
Released
SBF369E
REAR LIMIT
SWITCH Continuity
/ No Yes
SHOULDER
IU~
_IIECT~
SBF371E
i5r:i1
[ill
SBF290E
Continuity
Yes No
Open Closed
i5~ ~
-52~--1511!~
1 I
I I I I I I I I I
EB (@ @
e
@ (@
-~
SBF373E
BF-64
i5~
184is6!.
WARNING CHIME
Condition
A
Operation Sounds
SBF373E
i5~
~
[ill
SBF374E
LAP BELT BUCKLE SWITCH (Built-in lap belt buckle for L.H. side) Condition Fastened Unfastened Continuity No Yes
SF-6S
SUN ROOF
Electrical Sun Roof
Do not move or remove limit switch unless it is necessary. After any adjustment, check sun roof operation and lid alignment.
~GUide rail (Attached with screws and sealant) Link guide bracket
Urethane
forming
1:~
m:
Grease-up points
BF-66
Remove guide rail cover and pull up pawl, then draw out finisher plate with sun roof lid open.
I!J
Link & wire assembly
.
.
Pulling up pawl
.c-
l
"
Draw out
finisher
Removal: Raise pawl of retainer bracket, shift finisher plate and remove locating pins from retainer bracket. Then remove finisher plate.
[;)
Link & wire adjustment Ii] Movelink & wire assembly to closed lid position and after closingfully (as shown in figure below). install motor.
Link & wire assembly
rLink bJ.i
guide
bracket
Front stoppe~
..
SBF187E
BF-67
SUN ROOF
Wiring Diagram
(Ma i n harness)
IGNITION
I~u: 1/i::~! ~ @
RELAY M9 I GNITI ON SWITCH ON or START
*
I 2 3
@@
-CI II:]W/B
J:EI]W/B W:BD ~~
fi156\ ~ r.;;)
~:'i~
R/L
SLI DE RELAY-Close
@
B-[Jp}-,
-~
BODY
-:!:- GROUND
BATTERY (Via
'\ rI RCUIT
@) R~L::!;DJ
\REAKER
Lid operBt in9 direct Ion
fusible I ink-Gree~
@ e-B
C I2f3:: P/B SB
~: ~
SLI DE
~y::ent
I
direction
Openward CIoseward
W/B
@)
SAFETY RELAY
:~: P
~ 'i~
@
LIMIT
Fully opened Between approx. IODmm (3.94InJ opened and fully opened
RELAY-Open SWITCHCSafety)
OUTER LID POSITION Approx. IOOmm (3.94InJ opened Between fully closed and approx. IOOmm (3. 941nJ opened
!:l@ ~~'~1
@
PU8'W~
i
II 12
Fully closed
0 6
0 <5-
0 0
SBF334E
BF-68
SUN ROOF
Manual
Sun Roof
Handle adjustment
Female hinge
Hinge bracket
Air deflector adjustment Drain hose . After installation of drain hoses, make sure water drains smoothly.
SBF186E
BF-69
INSTALLATION
. Use genuine Nissan Sealant kit or equivalent. Follow instructions furnished with it. . After installation, the vehicle should remain stationary for about 24 hours. . Do not use sealant which is more than 12 months past its production date. . Do not leavecartridge unattended with its cap open. . Keep primers and sealant in a cool, dry place. Nissan recommends that they are stored in a refrigerator. . Be lure to install moldings.
Clean bonding surface thoroughly. Glass side
Body side
SBF413B
Body side
Install spacers to panel with double-feced tape.
Glass side
~
(19.09)
i~OO
spacer
Body panel
~
~
<>:
vehicle center
Unit: mm (in)
center
~~~
.I.~ Vehicle
SBF1 96E
Install molding fastener. When installing it, heat body panel and fastener to approx. 30 to 40C (86 to 104F). . . upper & side molding fastener
Apply primer A.
,/1
(
SBF197E
'
~
"-
Fastener
Panel
of glass
SBF719C
CAUTION: Allow primers to dry for 10 to 15 minutes before proceeding to the next step.
BF- 70
1
Apply primer E.
Apply sealant evenly.
Morethan 12 (0.471
SBF038B
SBF199E
CAUTION: Allow primers to dry for 10 to 15 minute, before proceeding to the next step.
CAUTION: Windshield glass should be installed within 15 minu18sof applying 88alant 88alant starts to harden 15 minu18l at18r it is applied.
Set glass in position and press glass lightly and evenly.
Apply sealant additionally to Io_r portion of gland make it uniform as shown below: Glass
SBF720C
CAUTION: For sealant drying time, refer to "Drying Time for Sealant".
CAUTION: Molding must be installed securely 10 that it is in position and I88V8I o gap. n
BF-71
Back Window-Coupe
. . .
Construction and removal/reinstallation methods of back window are basically the same as those of windshield. For details of service procedures, refer to "Windshield". The difference between windshield and back window is as follows: For sealant drying period, refer to "Drying Time for Sealant", For details of moldings, refer to "Exterior",
Sealant quantity
"
:
/ " ,( I
--
~-
'I
II 1I II II I I II II 1I I I
II , I
Ii]
m
More than 12 (0,471
Ii)
~N_'than More
7 (0281
Unit: mm (in)
~
420i (16,54) Unit: mm (in) Vehicle center
fastener, When installing it, heat body panel and fastener to approx. 30 to 40C (86 to 104 F).
Ii] double-facedrubber and tape. (Body side) Install dam spacers with adhesive
Lower portion
SBF200E
BF- 72
. . . .
Construction and removal/reinstallation method of back door window are basically the same as those of windshield. Major differences are that sealant & dam rubber are instailed to back door panel instead of glass surface. Spacer position is also changed. Moreover, there are locating pins in lower portion of glass. For details, refer to following figure. For sealant drying period, refer to "Drying Time for Sealant". For details of moldings, refer to "Exterior",
Locating pin
(Left and right) 1m
xx:
Spacer
.:
0:
Locating pin
Molding clip
Lower molding
1m
(;J
fastener installing it, heat body & fastener to approx. 40C (86 to 104FI.
[!)
Spacer
Unit: mm (in)
Ii]
=
Backdoor glass 7 (0,28)
Welt
Morethan 12 (0.47) ~n
~u_~
BF- 73
Wire
Side window
Body panel
Wire
SBF376E
FASTBACK
Sealant portion
I)
I)
(;]
Morethan '12 (0.47)
Body panel Body panel More than 7 (0.28)
Unit: mm (in)
Unit: mm (in)
Unit: mm (in)
J SBF203E
BF- 74
"
Seelent portion
I]
Clip
Ii]
E1
Ii]
[I
Dam rubber 30 (1.181
Unit: mm (in)
Sealant quantity
I]
Morethen 710.281
Unit: mm (in)
SBF202E
BF- 75
WINDSHIELD
AND WINDOWS
Drying Time for Sealant \ Reference: Time required for sealant to dry to desired hardness.
Unit: days 90 'c (oF) 40 (104) 25 (77) 5 (41) 1.5 2.5 5.0 2.5 4.0 13.0 5.0 7.5 20.5 50 25
CAUTION: Advise the user of the fact that vehicle should not be driven on rough roads or surfaces until sealant has properly vulcanized.
Repairing Water leaks for Windshield and Back Window (Coupe)/Back Door Window (Fastback)
leaks can be repaired without removing and reinstalling glass. If water is leaking between caulking material and body or between glass and caulking material, determine the extent of the leak by applying water while pushing glass outward. To stop the leak, apply primer and then sealant to the leak point.
T,;m~
.~
..,.
,V,,:
""
Apply sealant.
.-Flat stick
..
1!f!/
4'
4~60 /~
Work into joints.
POlysulphide
or polyurethane
sealant
SBF543B
BF-76
~ ('
Fa
WIRING DIAGRAM
I GNI TI ON SWITCH ACC or ON
FUSE BLOCK
ITIIJI]]]
@
@
Y/B ,-PyU:: Pu/w====-.rL/B L/B
(Door
~..
@
L/W
II
@ @
~ Leftward
~
R. H. )
Rightward
harness
(Main harness)
III' ...J
~'"
~, J
'" >-> J
_JlI>O:
~~
~~15~~1
MIRROR SW. CHANGE SW. OVER
II
@
Y/L PyU:;:: PU/W===-.sL/R L/R (Ooor harness L. H. )
,-
~ Leftward i Rightward
Mirror operat Ing dl rect Ion
~ Downward i Upward
6 7
(1)A~
~~
SWITCH BODY GROUND SBF335E
DOOR MIRROR
BF-77
Rear combination lamps are installed with nuts and butyl sealant.
Removal
Installation
Butyl seal
. .
Apply butyl seal evenlyas it tends to become thin in the corners. Warmup lamp assemblyarea to a tem~rature of a little below 60C (140F).
SBF189E
BF-78
. .
When installing, make sure that there are not gaps or waves at ends of air spoiler. Before installing spoiler, clean and remove oil from surface where spoiler will be mounted. /
~
Double-faced adhesive tape
'----.
r;7~~~
!
'-~
~~~_/-o
r;1;:;;J/
I~J
,
~/~
~"'" ""'
I
W~-
r;-r r-.~
Double-faced adhesive tape SBF190E
SBF191E
BF- 79
BODY ALIGNMENT
. . . .
. .
All dimensions indicated in figures are actual ones. When a tram tracking gauge is used, adjust both pointers to equal length and check the/pointers and gauge itself to make sure there is no free play. When a measuring tape is used, check to be sure there is no elongation, twisting or bending. Measurements should be taken at the center of the mounting holes. An asterisk (*) following the value at the measuring point indicates that the measuring point on the other side is symmetrically the same value. The coordinates of the measurement points are the distances measured from the standard line of "X", "Y" and "Z".
"X" "V"
@)
(:J
"X"
=JQ
"Z"
Q
"Z" I-)
... I ...
''V''
1+1 "X" : Vehicle center "V" : Center line of front axle "Z" : Imaginary base line [200 mm below datum line I"OZ" at design plan)]
@:
L.H.side
R.H. side
@:
Engine Compartment
MEASUREMENT
Unit: mm
SBF193E
BF-80
BODY ALIGNMENT
I'
SBF223E
" '
() <::)
()
<)
'CID1
.
()
CJ
~
<')
6dia.~
()
SBF220E
SBF224E
SBF221E
SBF225E
SBF222E
SF-81
BODY ALIGNMENT
Underbody
MEASUREMENT
~1J
E E
... 'c
:J
8
1
cq.~
~ ...
i
* * coM ... GI 'It M
1
:2 <II
. J: .J
..
an GI
...
~ 'It
~,t
0 0
q~
0 @
0
a:
]~
SBF194E
BF-82
(Cont'd)
~u
0 0
CD "0 0
0 0
0 CD
~y .J
~~.
~;
a::
J::
..@
0
J~
u.
~0
SBF196E
BF-83
BODY ALIGNMENT
Underbody
Front and rear strut tower centers
Coordinates: @,@ X: 542.2 Y: 63.5 z: 725.7 CD ,CD X: 474.5 Y: 2,500 z: 658.9
(Cont'd)
Unit: mm
I
Rear: CD.
Coordinates: @,@ X: 132.9 Y: -582 z: 189 @,@ X: 370 Y: -304 z: 255 @,@ X: 384.2 Y: 32 z: 255 @.@ X: 375 Y: 700 z: 106.2 ~,@ X: 420 Y: 1,150 z: 1'06.2
F~n1::!/
CD
48
die.
]D
SBF271E SBF226E Center side member. Rear suspension end Coordinates: Q),CD X: 303 Y: 2,635 z: 65.8 member rear mounting bolt threaded Coordinates: rear side member and rear extension
@,CD
X: 422.5 Y: 1,650
Z: 104
:nO ~ ~ U /~ r'
ChJ, CD
12 die.
~
-
r.1', I I L ),~) I 1/ I \
@'@
X:
380
rK' \!y.'JY
r.1',~_1
16 die.
L , \" \ '" \
\ \
Y: 2 ,030 @,@ x: 520 Y: 3,050 z: 398.8 ChJ X: 528 Y: 3,221 z: 386 (1) X: 528 Y: 3,200 z: 400
z: 195.8
~ \
SBF227E
0
0
BF-84
SECTION
HA
HAHAHAHAHA-13
CONTENTS
AIR FLOW AND COMPONENT LAYOUT DOOR CONTROL DESCRIPTION - PushControl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUSH CONTROL UNIT
HEATER ELECTRICAL CIRCUIT
2 5 7 9
. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . .
HA-12
PRECAUTIONS.
. .. .. . . .. . .. .. . .. . .. . .. .. . .. .. . .. . .. . .. .. . .. . .. .. .. . .. . .. .
PRECAUTIONS FOR REFRIGERANT CONNECTION. . . . . . . . . . . .. . . . . . . .. . . . . . . PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISCHARGING, EVACUATING, CHARGING AND CHECKING DESCRIPTION OF AIR CONDITIONER SERVICE PROCEDURES AIC PERFORMANCE TEST COMPRES5>OR OIL - For NVR 140S (ATSUGI make) COMPRESSOR Model NVR 140S (ATSUGI make) " . . . .. .. . .. .. . .. . .. .. .
HA-33
HA-35
HA-42 HA-44
HA-73
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HA-40
When you read wiring diagrams: Read GI section, "HOW TO READ WIRING DIAGRAMS". See EL section, "POWER SUPPLY ROUTING" for power distribution circuit. Whenyou perform trouble diagnoses,read GI section, "HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES".
mil
if
Floor and defroster
~~~
0123~1
~
10
.'"";'
if
To floor
CD To ventilator
Bi-Ievel
'O~~~ ~..~
CD To ventilator
if
.Ie
To defroster
if
To floor :>
...
: Airpassedthroughheatercore +~ )
HA-2
VENT
.. .. ".. "
B/L
I I I I I I I I I I I VENT I
I I I I I I I I I I
FOOT
F/D
'4;1
I I DEF I I I I I
I
DEF
(%)
100
80
I I I I - I
I
I
50 40
I
I I I I I I I I
0 RHA372A
HA-3
~
~--~..
.'
J:
I
~
.
Jl
H."""""
Cooling unit (Air conditioner)
:II :r ~ w
.... w ~
':
When disconnecting control cable, remove E-ring and take off cable while pushing cable outer.
MODE DOOR 1. Move side link with hand and hold mode door in VENT mode. 2. Install mode door motor on heater unit and connect it to body harness. 3. Turn ignition switch to ACC. 4. Turn VENT switch ON. 5. Attach mode door motor rod to side link rod holder. 6. Turn DEF switch ON. Check that side link operates at the fully-open position. Also turn VENT switch ON to check that side link operates at the fully-open position.
~
Mode door motor
CONNECT
)
RHA894A
(2J
WATER COCK CONTROL ROD When adjusting water cock control rod, first disconnect temperature control cable from air mix door lever. Reconnect and readjust temperature control cable.
'"
door lever
Air mix
~
~
Link lever
~
/PuSh.
r---J
( w--/ RHA375A
/\\U\\<
1. Push air mix door lever in direction of arrow. 2. Pull control rod of water cock in direction of arrow so as to give a clearance of about 2 mm (0.08 in) between ends of rod and link lever. Connect control rod to door lever. After connecting control rod, check it operates properly.
Clamp cable while pushing cable outer and air mix door lever in direction of arrow.
After
"
\ \
'-.
"
RHA376A
HA-5
RHA895A
HA-6
DESCRIPTION
Push Control
FUSE
m ~
RES! S TOR
@ @ @
:2'8 =
I[j
f@;1
-~
RHA378A
This push control system operates the intake and mode door motors to activate their corresponding doors.
FUNCTIONS
Indicator illuminates
AIC I
..;
... ...... J
I
. ...-..
I I I I I
Air outlet
Intake air
Compressor
AIC
-
I 0
I I 0
I I
ON*1 B/L
- .. Q I
...
......
...
I 0 I I I I I I 0 I I I
0
I
I I
I I
0
I I
I I
FOOT
F/D
DEF
-fJ
FRE
FRE
ON*1
I
.
b:2: --------I.
.REC
HA-7
DESCRIPTION
Push Control
MP---1
-
~
To push control.
~I
door
llntake motor
{
RHA379A
*: Current flows as VENT indicated by the arrow, motor actuates as indicated by the words.
1
To push control
Mode door motor Mode door 9peration Stop VENT--DEF DEF --VENT Direction of linkage rotation Stop Clockwise Counterclockwise
@ 8
EB 8
8 8
EB
RHA380A
HA-8
~gj" fR92~1
BB8 0,
Cluster lid C
\/
RHA384A
2.
Push control If asse'mbly )U[f
Remove
audio
(radio).
===1 ,
3. Remove four screws of push control unit. 4. Remove temperature control cable. 5. Disconnect push control unit harness connectors. 6. Remove push control unit. 7. Installation is in the reverse order of removal. Refer to Control Cable Adjustment for temperature control cable.
Overhaul
Co""o' "..~
Control knob
1- -
',-
"-
1/'1~ v' ~~
~
L 0
Coa,ro' ,,,...
A
,~84
J
'\
Temperature control cable
RHA386A
L E-ring
Control
box
'",,-- Finisher
plate
'/L
Temperature ontrollever c
HA-9
Overhaul -
1. Remove control knobs. Wrap knobs with a cloth and pull in direction indicated by arrow as shown in figure at left. Be careful not to scratch knobs during removal.
Small flat-bladed
,
screwdriver
:J~
Illumination harness
3. Remove control base. Undo hook at each end of control box and remove control base from control box by moving it in direction indicated by arrow.
"-
AHA390A
HA-10
Overhaul -
6. Remove control knobs. Wrap finisher with a cloth and remove knobs using pliers or . similar tool. Be careful not to scratch finisher's surface. 7. Re ove control case. 8. Rem ve illumination plate. Be care ul not to scratch control amp. when removing illumination plat " . 9. Remov finisher plate. 10. Remov control amp. Be careful not to damage substrate when removing, '11. Discon -ect temperature control cable. 12. Install tion is in reverse order of removal.
..
-.
"
\
'"
HA-11
,.,..
Wiring Diagram
BLOWER MOTOR
I GNIT ION SWITCH ACC or ON L/R L/R L/OR
~
@)~ , 0:: , ..J ..J
1J
Iii
FUSE BLOCK (Refer to "POWER SUPPLY ROUTING" in EL section.) MODE G/Y
V B/L FOOT F/D DEF
DOOR
MOTOR
li)
UI Q)
@
INTAKE DOOR MOTOR
G/Y
G/B L/OR
alai 5.:
.- L
cc
j
0
@)
To A/C system
~1J0::>-II> ~~~~~II>
1J
(Subharness)
o~J
"" ..J..J..J..J
0::
>-11>
@lffiJ
@)~~~ ~~~
'" OFF 4 25 26 27 23 28 21 20 1 If 1 2 3 4 From
illumination
[]
RESISTOR
@)~(@)
BODY GROUND
RHA392A
I LLUMI
HA-12
PRECAUTIONS
WARNING:
.
.
. .
.
. Keep refrigerantaway from open flames because poisonDo not increase can temperature beyond 40C (104F) in charging. Do not heat refrigerant can with an open flame. There is a danger that can will explode. Do not use steam to clean surface of condenser or evaporator. Be sure to use cold water or compressed air. Compressed air must never be used to clean a dirty line. Clean with refrigerant gas.
. . .
CAUTION:
N.G. \3
SHA919A
. .
Do not over-tighten service valve cap. Do not allow refrigerant to rush out. Otherwise, compressor oil will be discharged along with refrigerant.
HA-13
Gradually loosen discharge side hose fitting, and remove It after remaining pressure has been released.
CAUTION:
After disconnecting tubes, plug all openings Immediately to prevent entrance of dirt and moisture.
Plug SHA058
.
.
011.
When connecting tube, apply compressor oil to portions shown in illustration. Be careful not to apply 011 to threaded portion. O-ring must be closely attached to Inflated portion of tube.
portion
O.K. SHA897A
.
No'
~~~ ~
D
After connecting line, conduct leak test and make sure that there is no leakage from connections. When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten connections of seal seat to the specified torque.
I~
&
SHA898A
~4)
HA-14
PREPARATION
SPECIAL SERVICE TOOLS Tool number (Kent-Moore No.) Tool name
KV998VROO1
(
Description
KV99231010
(
\\Y
HA-15
PREPARATION
SERVICE TOOLS Tool name
Manifold gauge Description
Charging hose
Charge valve
. 0
. .;
C'-
"
Dischargingand charging refrigerant
Thermometer
Checking temperature -3
Vacuum pump
Evacuating refrigerant
..
HA-16
*1 When it is necessary to replace pa rts + Check the spot where malfunction occurs. Point-'
Discharging
When it is not necessary to replace parts + Check the spot where refrigerant leaks.
i.
Replace parts.
Repair.
t
Add refrigerant
I
I
J
N.G.
Point-4 Repair.
Twice evacuating On condition that pump operates below -98.6 kPa (-740 mmHg, -29.13 inHg) and with high humidity on a rainy day.
Point-6 Charging , Open high-pressure valve of manifold gauge and charge refrigerant into system. When low-pressure gauge reading is 98 kPa (1.0 kg/cm2 , 14 psi), completely close high-pressure valve of manifold gauge and stop charging. Point-3 Checking airtightness Point-5 1 O.K. Evacuating Run pump for over 20 minutes.
On condition that pump operates over -98.6 kPa (-740 mmHg, -29.13 inHg) and with low humidity on a clear day. Point-5
!
Evacuating
N.G.
Point-7
Charging
Checkingrefrigerantleaks
I
*1: Depending on the det *2: Working operation dep pump and the weather. When servicing AIC sys done under any condition.
In
N.G.
l O.K.
Checkoperationof AICsystem.
HA-17
Point-1 Discharging
I
Slowly open the valves to discharge only refrigerant. If they are opened quickly, compressor oil will also be discharged.
.
SHA240B
Point-21
Low
~I
.
-
Vacuum
pump
SHA241 B
-,
Elevation m (ft)
0 (0) 300 (1,000) 600 (2,000) 900 (3,000)
Vacuum of system* kPa (mmHg, inHg) 101.3 (760,29.92) 98.0 (735,28.94) 94.61710,27.95) 91.3 (685,26.97)
1. Close both low and high-pressure valves and leave them unattended for approx. 5 to 10 minutes. 2. Make sure the pointer of the low-pressure gauge does not deflect toward the "0" direction. 3. If the pointer deflects, gas leakage is present. Repair as outlined under POint-41.
I I
Point-4
Repair
If a problem is noticed under IPoint-31 above, locate and repair the leaking point using the following table as a guide.
Leak at/around pipe connection Leak at/around gauge manifold
. a-ring fouled, damaged or deformed . Oil not applied to pipe connections during installation . Pipe connections not properly tightened (too tight or too loose)
. . . .
Malfunctioning charging hose Gauge improperly installed Malfunctioning valve Malfunctioning packing, etc.
HA-18
pOint-51
10
~I:
='
)
.
fU
Close
Evacuating the System 1. Close manifold gauge valve securely and disconnect charging hose from refrigerant can. 2. Connect center charging hose to vacuum pump. 3. Start pump, then open both valves and run pump for over 20 minutes.
Vacuum pump
SHA241B
I Point-61
~
Close
Charging
1. Close manifold gauge valves securely and disconnect charging hose from vacuum pump. 2. Purge air from center charging hose. 1) Connect center charging hose to refrigerant can through charge valve. 2) Break seal of refrigerant can and purge air. 3. Charge refrigerant into system.
WARNING:
SHA242B
To high-pressure
service valve
Ensure that engine is off. 1) Open high-pressure valve of manifold gauge and charge refrigerant into system.
Open
LR~
RHA278 CAUTION: To low-pressure service valve
To high-pressure service valve
~
SHA244B
If charging liquefied refrigerant into the system with the can turned upside down to reduce charging time, charge it only through high-pressure (discharge) service valve. After charging, the compressor should always be turned several times manually. 2) When low-pressure gauge reading is 98 kPa (1.0 kg/cm2, 14 psi), completely close high-pressure valve of manifold gauge and stop charging.
HA-19
e
-..
Point-71 Charging
Turn
In or out
IL~ n ~
#>~f r
Ii:) Close
H.h
II
SHA245B
Fan lever mode and temperature dial: Maximum cold and speed
1. Open manifold gauge low-pressure valve and charge refrigerant into system. WARNING: Ensure that engine is off. 2. When refrigerant charging speed slows down, start engine air conditioning system ON, maximum cold temperature set, maximum blower speed set, can in upright position. Monitor sight glass. Charge is complete when sight glass is clear. Cycling clutch systems will produce bubbles in sight glass when clutch engages. Therefore, allow 5 seconds after clutch engages to determine if bubbles continue, and, if so, add refrigerant to clear sight glass. WARNING: Never charge refrigerant through high-pressure side (discharge side) of system since this will force refrigerant back into refrigerant can and it may explode. 3. Charge refrigerant while controlling low-pressure gauge reading at 275 kPa (2.8 kg/cm2,40 psi) or less by turning in or out low-pressure valve of manifold gauge. Be sure to purge air from charging hose when replacing can with a new one.
RHA504
HA-20
IPoint-71
Charging (Cont' d)
The state of the bubbles in the sight glass can only be used for checking whether the amount of charged refrigerant is small or not. The amount of charged refrigerant should be correctly judged by means of the discharge pressure. 5. After charging, be sure to install valve cap on service valve. 6. Confirm that there are no leaks in system by checking with a leak detector.
When refrigerant charging is performed with a charging cylinder, charging station, or automatic charging equipment with engine off, charge only through high pressure side. After specified refrigerant amount has entered the system, close high-pressure valve on gauge set. Start engine, return to idle speed, operate AIC at maximum temperature setting, high blower. Observe sight glass to confirm complete charge. Overcharging will result in increased high pressures, and reduced performance.
HA-21
DISCHARGING,
. . . .
.
CONDITION Door window: A/C switch: TEMP. lever position: FAN lever position: Check sight glass after a minutes.
no refrigerant
Insufficient
Suitable
Almost no difference between high-pressure and low-pressure side temperature. Bubbles flow continuously. Bubbles will disappear al)d something like mist will flow when refrigerant is nearly gone.
AImost transparent. Bubbles may appear when engine speed is raised and lowered.
AC256
AC257
AC258
Pressure
of system.
Both pressures on high and low-pressure sides are slightly low. Check for gas leakage, repair as required, replenish and charge system.
Repair.
a.
The bubbles seen through the sight glass are influenced by the ambient temperature. Since the bubbles are hard to show up in comparatively low temperatures below 20 C (68 F), it is possible that a slightly larger amount of refrigerant would be filled, if supplied according to the sight glass. Recheck the amount when it
exceeds 20C (68 F). In higher temperature the bubbles are easy to show up. b. When the screen in the receiver drier is clogged, the bubbles will appear even if the amount or refrigerant is normal. In this case, the outlet side pipe of ,~he receiver drier becomes considerably cold. '~
HA-22
SHA733A
UNION TYPE
GENERAL PRECAUTIONS FOR HANDLING LEAK DETECTOR Place the probe on connection fitting and wait for 5 seconds or more. To check cooling unit, wait for 10 seconds or more. If a leak is detected, keep the probe as still as possible for one more minute.
RHA279
PLATE TYPE
~~L
RHA280
MEASUREMENT
STAN.DARD
If any leak is noted with a detector having a nominal sensitivity of 15 to 25 g (0.53 to 0.88 oz)/year, that leak must be repaired. The nominal sensitivity of the detector is determined under the assumption that all the leaking gas is collected by the detector. Accordingly, the quantity of gas actually leaking can. amount to five to ten times the indicated value. Generally speaking, leakage of 150 to 200 g (5.29 to 7.05 oz) of refrigerant can cause insufficient cooling. Oil deposited during assembling must be wiped off before inspection. Refrigerant easily dissolves in oil, and the presence of oil can cause an error in measurement. This precaution is important when checking a used car for refrigerant leakage. If oil is noted at or around connections, it indicates that refrigerant is leaking.
HA-23
DESCRIPTION
Acceleration
This system is controlled by the E.C.C.S. control unit. When the engine is heavily over loaded (throttle sensor judges that throttle valve is at full throttle position), the compressor is turned off for approx. 4 seconds to reduce overloading. Additionally when the temperature of engine coolant rises above approx. 113C (235F), the compressor is turned off.
To condenser fan motor via thermo-
switch
COMPRESSOR
~
~
HA-24
~
t '
~
I,':':':':':':':d
Low-pressure liquid
Low-pressu re
gas
lill
Outside air
Compressor
u
0
Blower motor
Condenser
.
Expansion valve Receiver drier Fusible plug Dual-pressure switch
RHA393A
HA-25
~ ~
10.20 7.14)
(1.0.2.0,
rg
[]]J[1J
Expansion
valve
Ie] ~~
*: For removal, it is necessary to remove condenser.
-12.3)
20
-29
(2.0
-3.0,
14
-22)
~:
HA-26
co;J 45
"
. ~.
~~
,
co;J: N'm (kg-m, ft-Ib)
RHA395A
Remove screws, which secure thermistor locating stay, from front of cool~ng unit. Replace thermo control amp. assembly with a new one. (Without removing cooling unit, thermo control amp. can be replace.)
RHA396A
Belt Tension
Refer to MA section.
HA-27
-;
TEST READING
Recirculating-to-discharge air temperature table
Inside air (Recirculating air) at blower assembly inlet Relative humidity % Air temperature c (oF) 20 (68) 25 (77) 50 - 60 30 (86) 35 (95) 40 (104) 20 (68) 25 (77) 60 -70 30 (86) 35 (95) 40 (104)
Ambient air temperature-to-compressor Ambient air Relative humidity % Air temperature c tF) 20 (68) 25 (77) 50 -70 30 (86) 35 (95) 40 (104) pressure table
1.6 - 2.7 (35 - 37) 4.4 - 6.0 (40 - 43) 9.2 - 11.3 (49 - 52) 14.8 - 17.0 (59 - 63) 18.1 - 20.3 (65 - 69) 2.7 -4.3 (37 - 40) 6.0 - 8.2 (43 - 47) 11.3 - 13.8 (52 - 57) 17.0 - 19.5 (63- 67) 20.3 - 22.8 (69 - 73)
High-pressure (Discharge side) kPa (kg/cm2 , psi) 1,030 - 1,255 (10.5 - 12.8, 149 - 182) 1,196 - 1,471 (12.2 - 15.0, 173 - 213) 1,402
Low-pressure (Suction side) kPa (kg/cm2 , psi) 98.1 - 142.2 (1.0 - 1.45, 14.2 - 20.6) 122.6 - 171.6 (1.25 - 1.75,17.8- 24.9) 161.8 - 210.9 (1.65 - 2.15, 23.5 - 30.6) 205.9 - 259.9 (2.1 - 2.65, 29.9 - 37.7) 259.9 - 318.7 (2.65 - 3.25, 37.7 - 46.2)
- 247)
1,608 - 1,971 (16.4 - 20.1, 233 - 286) 1,844 - 2,256 (18.8 - 23.0, 267 - 327)
HA-28
In the following table, the portion smeared with ink on each gauge scale indicates the range showing that the air conditioning system is in good order. This range is described in Performance Chart.
Probable cause
Corrective action
INSUFFICIENT 'REFRIGERANT
CHARGE
I.
Refrigerant is low, or leaking slightly.
AC352A
ALMOST NO REFRIGERANT
No cooling action. A lot of bubbles or something like mist appears in sight glass.
Stop compressor immediately. 1. Leak test. 2. Dischargesystem. 3. Repair leak(s). 4. Replace receiver drier if necessary. 5. Check oil level. 6. Evacuate and recharge system.
AC353A
Expansion valve restricts refrigerant flow. . Expansion valve is clogged. . Expansion valve is inoperative. Valve stuck closed. Thermal bulb has lost charge.
If valve inlet reveals sweat or frost: 1. Discharge system. 2. Remove valve and clean it. Replace it if necessary. 3. Evacuate system. 4. Charge system. If valve does not operate: 1. Discharge system. 2. Replace valve. 3. Evacuate and charge system.
AC354A
HA-29
(Cont'd)
Corrective action Check valve for operation. If suction side does not show a pressure decrease. replace valve.
AC356A
IAIR
IN SYSTEM
AC359A
MOISTURE IN SYSTEM
After short operation, suction side may show vacuum pressure reading. During this condition, discharge air will be warm. As a warning of this, reading vibrates around 39 kPa (0.4 kg/cm2 , 6 psi).
Drier is saturated with moisture. Moisture has frozen in expansion valve. Refrigerant flow is restricted.
1. Discharge system. 2. Replace receiver drier (twice if necessary). 3. Evacuate system completely. (Repeat 30minutes evacuating three times.) 4. Recharge system.
AC360A
HA-30
Test Diagnoses
Probable cause
(Cont'd)
Corrective action
MALFUNCTIONING CONDENSER
No cooling action: engine may overheat. Bubbles appear in sight glass of drier. Suction line is very hot.
. Check fan belt and fluid coupling . Check condenser fan motor. (U.S.A. model only) . Check condenser for dirt accumulation. . Check engine cooling
. system for overheating. Check for refrigerant overchargi ng.
"
@
AC361A
If pressure remains high in spite of all above actions taken, remove and inspect the condenser for possible oil clogging.
HIGH PRESSURE
LINE BLOCKED
1. Dischargesystem. 2. Removereceiver drier or strainer and replace it. 3. Evacuate and charge system.
AC362A
MALFUNCTIONING
COMPRESSOR
Insufficient cooling.
1. Discharge system. 2. Remove and check compressor. 3. Repair or replace compressor. 4. Check oil level. 5. Replace receiver drier. 6. Evacuate and charge system.
AC363A
HA-31
Test Diagnoses
Probable cause Too much oil circulates with refrigerant, causing the cooling capacity of the system to be reduced.
(Cont'd,)
Corrective action
Insufficient cooling.
AC364A
HA-32
COMPRESSOR OIL -
'I
Checking
is
with the refrigerant. replacing any component of the syslarge amount of gas leakage occurs, maintain the original amount of oil.
OIL CAPACITY
Unit: mQ (US fl OZ, Imp fl oz) Applied model Capacity Total in system Amount of oil which can be drained Compressor (Service parts) charging amount All models Above 90 (3.0, 3.2) *
Oil levelmay be low. Pour in 90 mQ(3.0 US fl OZ, 3.2 Imp fl oz) of oil.
If amount of oil drained is much greater than under normal circumstances, flush air conditioner system with refrigerant. Then pour in 200 mQ (6.8 US fl OZ, 7.0 Imp fl oz) of oil into air conditioner system.
OIL RETURN OPERATION Before checking and adjusting oil level, operate compressor at engine idling speed, with controls set for maximum cooling and high blower speed, for 20 to 30 minutes in order to return oil to compressor.
(b) When oil contains chips or other foreign material; After air conditioner system has been flushed with refrigerant, replace receiver drier. Then pour in 200 m Q (6.8 US fl oz, 7.0 Imp fl oz) of oil into air conditioner system.
CHECKING AND ADJUSTING FOR COMPRESSOR REPLACEMENT CHECKING AND ADJUSTING FOR USED COMPRESSOR 1. After oil return operation, stop the engine and discharge refrigerant, and then remove compressor from the vehicle. 2. Drain compressor oil from compressor discharge port and measure the amount. Oil is sometimes hard to extract when compressor is cooled. Remove oil while compressor is warm [maintained to 40 to 50C (104 to 122F.
3. If the amount is less than 90 m Q (3.0 US fl OZ, 3.2 Imp fl oz), some refrigerant may have leaked out. Conduct leak tests on connections of each system, and if necessary, repair or replace malfunctioning parts.
200 m Q (6.8 USfl OZ, 7.0 Imp fl oz) of oil is charged in compressor (service parts). So it is necessary to drain the proper amount of oil from new compressor. Follow the procedure below. 1. After oil return operation, drain compressor oil from used compressor and measure the amount. (It is the same procedure as CHECKING AND ADJUSTING FOR USED COMPRESSOR.)
HA-33
COMPRESSOR OIL
Draining amount of oil from new compressor 200 (6.8, 7.0) - [Amount of oil drained + 20 (0.7, 0.7)] 90 (3.0, 3.2)
*: If amount of oil. drained is greater than under ". normal circumstances, flush air conditioner system with refrigerant. Then install new compressor. [200 mi! (6.8 US fl oz, 7.0 Imp fl oz) of oil is charged compressor service parts.] .
Example:
Unit: mi! (US fl OZ,Imp fl oz) Amount of oil drained from used compressor Draining amount of oil from new compressor 70 (2.4,2.5) 90 (3.0, 3.2)
"
(b) When oil contains chips or foreign material; After air conditioner system has been flushed with refrigerant,. replace receiver drier. Then install new compressor. [200 m Q (6.8 US fl OZ, 7.0 Imp fl oz) of oil is charged in compressor service parts.]
HA-34
COMPRESSOR
. . . . . .
Whel\ s~ring a compressor, be sure to fill it with refrigerant \to prevent rust formation. Add refrigerant at the low-pressure side and purge air at the high-pressure side, while rotating shaft by hand.
HA-35
COMPRESSOR
Key
Adjusting shim
tOJ 29
-39
tOJ:
HA-36
COMPRESSOR
. .
When removing center bolt, hold clutch disc with clutch disc wrench. Using clutch disc puller, clutch disc can be removed.
SHA052B
.
.
Bend down pawl of lock washer. When removing pulley, remove lock nut with nut wrench.
SHA053B
INSPECTION Clutch disc If the contact surface shows signs of damage due to excessive heat, the drive plate and pulley should be replaced.
Clutch disc Pulley Coil
~
SHA703B
Pulley Check the appearance of the pulley assembly. If the contact surface of the pulley shows signs of excessive grooving due to slippage, both the pulley and drive plate should be replaced. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation. Coil Check coil for loose connection or cracked insulation.
0.3 -0.6 Adjusting shim (0.012 -0.024) [Thickness - 0.1, 0.3, 0.5, 0.8
(0.004,0.012,0.020,0.031)]
ADJUSTMENT . When assembling clutch disc, adjust disc-to-pulley clearance with shims. OPERATION
BREAK-IN
When replacing compressor clutch assembly, do not forget break-in operation, accomplished by engaging and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.
~ ~
Unit: mm (in)
RHA843
HA-37
COMPRESSOR
. .
Thermal protector
SHA055B
HA-38
COMPRESSOR NOTE
HA-39
n U
PROTEC1OR
THERMO-
SWITCH
~
~(SUb
"
7
AIR
"
0 (J
h.cn.s~
CONDENSER FAN MOTOR
~i
@)~ to
~],I
CAN]""
"
@)
u.s.A.
111
~~
, '" III
~III
....
<ff@)
@)A@)
DUALPRESSURE SWITCH ~ ~LG/R
>- to
BODY GROUND
~nglne room
harnes~
~~
i)-LG -
"
to
'"
III
""
@~ @~
@) ~~~/G
F. I. C. D.
SOLENOID VALVE
to
>- to
"
'" ,
III
l
ENGINE GROUND
III
~@ (E. F. I. harness)
'" ,
li :~~~~~~~~~~~~-------------- ~ --f~
I
~:
to ""~III
@@
~o: 1-0
OVJ O:Z ILU I-VJ
~ I~ ::J III.... , I-
ffi@)
0 Z ::J 0 0: (!Jill
@~I~~IIIFNlbb1Ii
~o: zo
wO@ z~ (!J7
Z W
III ~ I~ II~
~ ~ ~ & (Refer to
HA-40
BLOWER
@~
~
~
31' I>: '\ '\ ..J ..J
Iii
FUSE BLOCK (Refer to "POWER SUPPLY ROUTING" in EL sect ion. ) MODE DOOR MOTOR
G/Y G V B/L FOOT F/D DfF
@
INTAKE DOOR MOTOR
G/Y
G/B
S. M. J.
ffiefer to last
L/OR
j
@
age
(Main harness)
(@)
-L/OR -LG -LG/R 112 HI2 HID
@)
L/OR LG LG/R
:W
~RM'STOR
()
I'" @)
- LG
G/YR/Y-
1314 1211
169
815 17 87 65 43 2 1
L/Y
L/W
G L
L/OR
L/B L/R
~3:I>:>-'"
@)
@~
~~~ ~~~
'\. OFF 1 24 2 26 27 2 8 21 20 1 1 2 3 4 (
(Subharness)
,
19 0 21 PUSH CONTROL UNIT
From
} system FAN SWITCH
illumination
(tJ(tl-\....,
'"
RESISTOR
~:
For For
U. S. A.
@@~
BODY GROUND
(CAN):
Canada
RHA398A
I LLUMI NATI ON
HA-41
Resistor
Inteke door motor
Engine compartment
\ Ther';'oswitch\
(U:S.A. onl\)
-'.~:
::
\\
...1.--\'~
~/
RHA403A
HA-42
HA-43
TROUBLE DIAGNOSES
Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair Symptom Chart Preliminary Check PRELIMINARY CHECK 1 (Intake door is not set at "FRESH" in DEF or FOOT mode.) PRELIMINARY CHECK 2 (A/C does not blow cold air.) '"'''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' PRELIMINARY CHECK 3 HA-45 HA-46 HA-48 HA-48 HA-49
HA-50
in DEF
mode.)
"
PRELIMINARY CHECK 4 (Air outlet does not change.) PRELIMINARY CHECK 5 (Noise) Main Power Supply and Ground Circuit Check Harness Layout for AIC System Circuit Diagram for Quick Pin Point Check Diagnostic Procedure 1 (SYMPTOM: Blower motor does not rotate.) Diagnostic Procedure 2 (SYMPTOM: Air outlet does not change.) Diagnostic Pfocedure 3 (SYMPTOM: Intake door does not change in VENT, B/L or FOOT mode.)
HA-51 HA-52 HA-53 HA-55 HA-56 HA-57 HA-59 HA-61 HA-62 HA-66
HA-70
Diagnostic Procedure 4
(SYMPTOM: Magnet clutch does not engage with A/C switch and fan switch are ON.)
Diagnostic Procedure 5
(SYMPTOM: Illumination or indicators of push control unit do not come on.)
Electrical Components
Inspection
HA-44
TROUBLE DIAGNOSES
<
LISTEN TO CUSTOMER COMPLAINTS AND CONFIRM.
Reference item
----------------I
I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I
Preliminary Check (See page HA-48 - 52.) Main Powerf.;upplY and Ground Circuit Check (See page HA-53 - 54.)
Diagnostic procedure(s) (See page HA-57 - 69.) . Circuit diagram for quick pin point check (See page HA-56.)
REPAIR/ REPLACE.
/1
I I L
-- -- - -
----
N.G.
HA-45
TROUBLE DIAGNOSES
Symptom Chart
DIAGNOSTIC TABLE
PROCEDURE
Preliminary Check a)
I"'It)
Diagnostic Procedure
0 <0
It)
It)
<0
REFERENCE
PAGE
a)
:I: :I:
< < :I: :I: < :I: :I: < < :I:
It)
.It)
It)
M
It)
It)
,< :I:
It)
..SYMPTOM
CJ II) .J:; CJ > IV c: N .J:; CJ M .J:; CJ V CJ II) .J:; CJ It) CJ II) .J:; CJ
II)
::::s
N
II)
M
II)
::::s
'i CJ
" II)
::::s
>
IV c:
>
IV c:
>
IV c:
>
IV c:
0 Q,
CJ
Q,
e
::::s
It)
II)
..
::::s
...
'c :I
II) ... ::::s '0 51 ::::s
ci E IV
'0 ... c: 0 CJ 0
E
'ii
'E
'ii
E
'ii
'E
'ii
E
'ii
Q.
Q.
Q.
Q.
Q.
.+:; ... 0 c: C) IV i5
.+:; ... 0 c: C) IV
.+:; ... 0 c: C) IV
CJ
.+:; ... 0
CJ
c:
Q, CJ .+:; ... 0
...
C)
c:
IV
C)
IV
u.
i5 i5
i5 0
i5
u. It) 0 .- .0
Q.
I-
0 0
.. ..
0
0 0
0
Air outlet does not change. Intakedoor does not changein VENT,
B/L or FOOT mode, Intake door is not set at "FRESH" in DEF or FOOT mode. Magnet clutch does not engagewhen AIC switch and fan switch are ON.
0
0
0
0 ..
..
0
Magnet clutch does not engage in DEF mode. Illumination or indicators of push
0, ..: The numbermeanscheckingorder, 0 : Asfor checkingorder, referto eachflowchart, (It dependson malfunctioning portion.)
HA-46
\\
0 0 0 0 0
0 0
0 0 0
0
0 0 0 0 0 0 0 0
0
0 0 0 0 0 0 0
VENTswitch BILswitch
FOOT switch FID switch DEF switch
Fanswitch
Modedoor motor
0
0
0 0 0 0 0 0
0
0 0 0 0 0 0
Intakedoor motor
A/C relay Thermo control amp. Dual-pressur, switch Compressor (Magnetclutch) Thermal protector E.C.C.S.control unit Illumination system Knob illumination Compressor
::I: I ~ "'-01
0 0 0 0 0 0 0 0
& R E
Harness
TROUBLE DIAGNOSES
Preliminary Check
PRELIMINARY CHECK 1 Intake door is set at "FRESH" in DEF or F/D mode.
No Is intake door in "Fresh" position when REC switch is turned from ON to OFF at VENT, B/L or FOOT mode with ignition switch at. ACe and fan speed at 4? (Can you hear air moving from the intake unit?)
Yes
Go to DiagnosticProcedure 3.
No
Is intake door in "REC" position when REC switch is turned from OFF to ON at VENT, B/L or FOOT mode with ignition switch at ACC and fan speed at 4? (Can you hear air moving from the intake unit?
Go to Diagnostic Procedure 3.
I
Yes
Is intake door in "Fresh" positionl when F/D switch or DEF switch is pushed? (Can you hear air moving from the intake unit?) Yes INSPECTION END No
HA-48
TROUBLE DIAGNOSES
PRELIMINARY CHECK 2 A/C does not blow cold air.
Preliminary "
Check (Cont'd)
N.G.
DOES AIR FLOW FROM VENTS? Condition . Ignition switch, AIC switch,
and fan switch are ON.
O.K.
CHECK COMPRESSOR BELT TENSION. Refer to MA section. N.G. CHECK COMPRESSOR OPERATION. O.K. CHECK REFRIGERATION CYCLE PRESSURE WITH MANIFOLD GAUGE CONNECTED. Refer to Performance Chart.
O.K.
TN.G. Adjust or replace compressor belt
CHECK FOR EVAPORATOR I- COIL FREEZE UP. Remove intake unit. Check if evaporator freezes. N.G. (F reeze up) O.K. (Does not freeze up)
,.
N.G.
Go to Performance Diagnoses. Test
O.K.
O.K.
N.G.
CHECK FOR REFRIGERANT LEAKS
Go to Diagnostic Procedure 4
I. O.K.
I CHECK EVAPORATOR
HA-49
With engine running, does magnet clutch engage normally when A/C switch and fan switch are ON? Yes Push A/C switch and turn A/C system OFF. Make sure that magnet clutch is disengaged.
No Go to Diagnostic Procedure 4.
With engine running, does magnet clutch engagenormally when DEF switch and fan switch are ON? Yes INSPECTION END
No
HA-50
Go to Diagnostic
Procedure 2.
Indicator illuminates
....1
. ........
Air outlet
. ....I
........
,..
... ,1 ...
.
0
0 0 0
0
VENT
FOOT & VENT
...
F/D
I
DEF
(%) 100
'''
80
50
40
I I
0
Yes
INSPECTION END
HA-
51
TROUBLE DIAGNOSES
, ------
Belt
Replace compressor.
(
Readjust belt tension. Refer to ENGINE MAINTENANCE in MAsection. The pully center does not match. Readjust the pully center.
HA-52
amp.
THERMO
CONTROL
AMP. CHECK
~~
L/OR
i5
00
':"
Check power supply circuit for thermo control amp. with ignition switch ON. 1. Disconnect thermo control amp. harness connector. 2. Connect voltmeter from harness side. 3. Measure voltage across terminal No. @ and body ground. Voltmeter terminal Voltage
EB @
8
Body ground
RHA406A
Approx. 12V
(
.,
Thermo con trol amp. ne ctor @
'O"~
LG/B
[ill
-=
~ i5 .~
00
RHA509A
Check body ground circuit for thermo control amp. with ignition switch OFF, AIC switch ON and fan switch ON. 1. Disconnect thermo control amp. harness connector. 2. Connect ohmmeter from harness side. 3. Check for continuity between terminal No. @ and body ground.
Ohmmeter terminal
EB
8
Body ground
Continuity Yes
HA-53
TROUBLE DIAGNOSES
lit IV 00
Push control unit connector @
..-cT
~
RHA431A
~n
Check power supply circuit switch at ACC. 1. Disconnect push control 2. Connect voltmeter from 3. Measure voltage across
Voltmeter terminal
Ei1
~!
e
Body ground
Voltage
Approx.12V
litij~
Push control unit connector @
[ID
Check body ground circuit for push control unit with ignition switch OFF. 1. Disconnect push control unit harness connector. 2. Connect ohmmeter from harness side. 3. Check for continuity between terminal No. @ and body ground.
::
IBffiEHEI
B
RHAB96A
HA-54
TROUBLE DIAGNOSES
@
@
Engine compartment
'.
@: Mode door motor @) : Push control unit @: Fan switch @: Thermo control amp. @: Resistor @: Blower motor @: Intake door motor
RHA404A
HA-55
BATTERY
(Via
fusible IInk-Green)
~ I
FUSE
~ FUSE
30 I'm
'N
BLOWER
MOTOR
~rcr
INTAKE DOOR MOTOR
0)'
@3
<8
@ 10
I
m m
@
::E:
I
@ @ @
DUALPRESSURE~ SWITCH @W
~
246
O~@@
PUSH
CONTROL _UNI T
THERMISTOR
U1 en
ED
RESI STOR
~ ~
8
~
MODE DOOR MOTOR
VENT
E. CO UN
1
J
2
<8
2 2 2
,;:~
'---1'1
~
EF OEF;o F/0
B/L
'~ \1
m
;0
~~ 6
~
~
en."." , ~
~
21
'
(1
I
(J: ) ---1(2
en en FOOT 0
~ I@ ~ ~
~ ~
~
\1-1
zo 0' <
~ m'
~ M
:1
zz
::I
~~u ILLUMINATION
From
g~
~~ or.
;0
Ci\ am 6 ;0
-I
O::Y;:
{
' '
~: (~):
U. S. A.
For Canada
l ~
11>1
.
connectors shown
I
-::!..
"-
~
~
~
~ ~
:D :I ~ ~ 0 (,II ~
The unit 'side connectors with a double circle" 0 " are connected to the harness side connectors shown in the "Harness Layout for A/C System", (See page HA-55,1 . The terminal numbers in the connector coincide with the circuit numbers surrounded by a single circle" .: These switches are built in push control unit and mechanically linked to corresponding switches.
.
.
All
in this illustration
TROUBLE DIAGNOSES
Flow chart No.
INCIDENT
Diagnostic Procedure 1
SYMPTOM: Blower motor does not rotate. ! Perform PRELIMINARY CHECK 2 befor~ referring following flow chart.
1 2 3 4 5
Fan fails to rotate. Fan does not rotate at 1 peed. Fan does not otate at 2peed. Fan does not rotate at 3peed. Fan does not rotate at 4peed.
rn
to the
L1J
Check if blower motor rotates properly at each fan speed. Conduct check as per flow chart at left. Fa
rn
~
B)
L1J
~
(g
Fa
Blower motor connector @
\&",l1tis
~
"cfi' 2 3 4, RHA407A
CHECK POWER SUPPLY FOR BLOWER MOTOR. Disconnect blower motor harnessconnector. Do approx. 12 volts exist between blower motor harness terminal No. @ and body ground?
(Q)
(Go to next page.) N.G. Check 15A fusesat fuse block. (Refer to "POWER SUPPLY ROUTING" in EL section and AIC ELECTRICAL CIRCUIT.)
[;J
O.K.
N.G.
Reconnect blower motor harness connector.
[;J
connector @
;l1tiJ Blower4m~ 1
II
Check circuit continuity between blower motor harness terminal No. @ and body ground.
O.K.
Q
I
00
-
"~~
N.G.
Replace blower motor.
[i]
Resistor@
~m l1t i)
00
-=
[i]
CHECK BLOWER MOTOR CIRCUIT BETWEEN BLOWER MOTOR AND RESISTOR. Do approx. 12 volts exist between resistor harnessterminal No. @ and body ground? O.K. N.G.
Disconnect blower motor and resistor harness connectors.
Ii]
Check circuit continuity between blower motor harness terminal No.
Note
"0'
23 4
RHA408A
Ii]
l1tu
L/W
harness terminal
Resistor
connector @
A (Go to next page.) Note: If the result is N.G. after checking circuit continuity, repair harness or connector.
Y~~lfOO
L/W
[ill
RHA518A
HA-57
D'
~
CHECK RESISTOR AFTER DISCONNECTING IT. (Refer to Electrical Components Inspection.)
~
RHA409A
':"
O.K.
-eft' 2 3 .
Reconnect resistor harness connector.
iii
~~i5
00
Continuity exists: O.K.
AHA897 A
':"
[]J
II
I
CHECK FAN SWITCH CIRCUIT. Do approx. 12 volts exist between each fan switch harness terminal and body ground? Flow chart No.
Terminal No.
II
e
@ @
Voltage
LIB
[itij
O.K.
~
Body Approx. ground 12V
@ @
--,
Lffl
.-. L/R
27---,
L/Y
-'
00
RHA519A
~ ~ ~
[2]
CHECK FAN SWITCH AFTER DISCONNECTING IT. (Refer to Electrical Components Inspection.)
II
N.G.
Note
Resistor connector @
iii
O.K.
Note
Check circuit continuity between fan switch harness terminal No. @and body
ground .
O.K.
Replace blower motor.
Note: If the result is N.G. after checking circuit continuity, repair harnessor connector.
HA~58
TROUBLE DIAGNOSES
Diagnostic Procedure 2
Push control unit connector @)
SYMPTOM:
eJ
00
m
RHA410A
_lET
Air outlet does not change. Perform PRELIMINARYCHECK 4 and M;:ttn Power Supply and Ground Circuit Check before referrir:tg to the following flow chart.
Disconnect mode door motor harness connector. (;) Note
t
-=
(;)
connector@
.-r Eu
00
RHA411 A
CHECK MODE DOOR MOTOR POSITION SWITCH. 1. Turn VENT switch ON with ignition switch at ACC position. 2. Turn ignition switch OFF. Disconnect push control unit connector. 3. Check if continuity exists
II
between terminal No. CD or @ of push control unit harness connector and body ground. 4. Using above procedures, check for continuity in any other mode. as indicated in chart.
Mode switch VENT
B/L Terminal No.
CHECK BODY GROUND CIRCUIT FOR MODE DOOR MOTOR. Does continuity exist between mode door motor harness terminal No. @ and body ground?
II
O.K.
Note
Check circuit continuity between each terminal on push control unit and on mode door motor.
Terminal No.
Conti-
(f)
CD or @ @ or CID CIDor @ @ or <ID <IDor @
nuity
(f)
ContJ-fltlity-..
00
\
Body ground
Yes
@
CID
@'
CID
,-,.-r-r , ,
,(..,
\
---
,~\(' 'O\(..,'-,~
~~~:,
654 321 7 8
, Q>'
,.
,---,
>,
Yes @ @
<ID
O.K.
SHA297C
<ID @ (j) @
@ (j) @
@ (Go to next page.) Note: If the result is N.G. after checking circuit continuity, repair harness or connector.
HA-59
TROUBLE DIAGNOSES
IJ]
lit
COI8ECT
00
( \
Reconnect control unit and push mode door motor harness connectors.
~
Push control unit connector @ G/Y
IJ]
I~
[2J
CSZJ
CHECK FOR OUTPUT OF PUSH CONTROL UNIT. Do approx. 12voltsexist between push control unit harness terminal No. (j) and @when modeis switchedfrom "VENT" to "DEF" or when mode is switched from "DEF" to "VENT"?
Terminal
No. Mode door motor
N.G.
RHA412A
(])
8 8
8 ffi
Stop
Stop
----------
VENT -- DEF
DEF --VENT
Clockwise
Counterclockwise
ffi 8
-
O.K.
J
HA-60
TROUBLE DIAGNOSES
Diagnostic Procedure 3
SYMPTOM:
IV 00
1
I;]
RHA414A
_r
Intake door does not change in VENT, B/L or ! FOOT mode. Perform PRELIMINARYCHECK 1 and Main ~ower Supply and Ground Circuit Check before referring to 'the following flow chart.
m
CHECK POWER SUPPLY FOR INTAKE DOOR MOTOR. Disconnect intake door motor harness connector. Do approx. 12 volts exist betWeen intake door motor harness terminal No. @and body ground?
.eJ
dih
G/B
-=
N.G. ICheck 10Afuses at fuse block. (Referto "POWE SUPPLY R ROUTING" in ELsectionandAIC ELECTRICALCIReUIT.)
I;]
O.K. N.G.
Disconnect push control unit harness connector.
~
Continuity should exist when test leads are connected as
":"
CHECK BODY GROUND CIRCUIT FOR INTAKE DOOR MOTOR. Does continuity exist betWeen intake door motor harness terminal No. @ and body ground when REC switch is ON? Does continuity exist betWeen intake door motor harness terminal No. (j]) and body ground when REC switch is OFF?
[!]
Note
Check circuit continuity be 'tWeen push control unit harness terminal No. @ ((j])) and intake door motor harness terminal No. @ ((j])).
RHA415A
'
[!]
[8E5J;i8] ij ~ 00 ~kill
r ,G/YIIQ
I
II
G~~~
,. RHA898A
Note: If the result is N.G. after checking circuit continuity, repair harness or connector.
HA-61
TROUBLE DIAGNOSES
Diagnostic Procedure 4
SYMPTOM: Magnet clutch does not operate when A/Q switch and fan switch are ON. ( Perform PRELIMINARY CHECK 2 before referring" to the following flow chart.
~ lit is
L/G
00
m
I
CHECK POWERSUPPLY
N.G.
~
1!1 Thermal protector connector @-2
RHA416A
1~i5~
B
FOR COMPRESSOR. Disconnect compressor harness connector. Do approx. 12 volts exist betWeencompressor harness terminal No. @ and body ground?
1!1
5 (Goto !)extpage.)
O.K.
N.G. Replace thermal protector.
[ill
"
RHA899A
CHECK THERMAL PROTECTOR. Disconnect thermal protector harness connector. Does continuity exist betWeen thermal protector harness terminal No. @ and body ground?
O.K.
Check magnet clutch coil.
O.K.
Replace magnet clutch. Refer to COMPRESSOR Model
HA~62
E)
A/C relay
~ ~[
m1
For U.S.A.
connector 42@) For Canada ~LIG
RHA418A
~
~
L/G
[Y]
CHECK AIC RELAY OPERATION. Do approx. 12 volts exist between AIC relay harness terminal No. @ and body ground? O.K.
Disconnect AIC relay harness connector.
II
N.G. 'CHECK POWE~UPPL Y FOR AIC RELAY. 0 isconnect AIC relay. Do approx. 12 volts exist between AIC relay harness terminal No. @. @J and body ground? O.K. N.G.
Ii]
rl;]or
L/G
~
Compressor
connector
LIG
~ _T eJ
00
Canada
Ii]
Check circuit continuity between AIC relay harness terminal No. @ and compressor harness terminal No. @.
Note
@
LIG
181
RHA523A
II
~eJ
conm.L/OR
IIISCIIIIIIECT
00
~
CHECK AIC RELAY AFTER DISCONNECTINGIT. (Refer to Electrical Components Inspection.) O.K. Reconnect AIC relay. N.G.
Replace AIC relay.
~~~.A. ~
RHA522A
iii
iii
~i)
II
((g~
unit
CHECK COIL SIDE CIRCUIT OF AIC RELAY. Do approx. 12 volts exist between E.C.C.S.control unit harness terminal No. @ and body ground?
O.K.
N.G.
RHA419A
(C
Note: If the result is N.G. after checking circuit continuity, repair harness or connector.
HA-63
I
G/Y 43
tft\I
III
II I RHA524A
fo1 CONNECTOR
~~i)
L/G
CHECK VOLTAGE FOR THERMO CONTROL AMP. Do approx. 8 to 9 volts exist between thermo control amp. harnessterminal No. @ and body ground?
IJ N.G.r::
Note
.. .. Check circuit continuity b etween E.C.C.S. control unit harnessterminal No.@ and thermo control amp. harnessterminal No. @.
O.K.
O.K.
00
RHA420A
[
&] [It
LGtB
CHECK POWER SUPPLY FOR THERMO CONTROL AMP. Go to Main Power Supply and Ground Circuit Check.
i5 ~
"o,,~~
D
CHECK BODY GROUND CIRCUIT FOR THERMO CONTROL AMP. Disconnect thermo control amp. harnessconnector. Does continuity exist between thermo control amp. harness terminal No. @ and body ground?
N.G.
unit
II
Check circuit continuity between thermo control amp. harness terminal No. @ and push control unit harness terminal No. @.
Note
=u
~ RHA900A
'
IJ
LtG
44
IV 00
II RHA525A
~,
O.K.
I
O.K.
II
ClUNIT
101 COIMCTOR
II
connector
lit, lu 00
113 RHA901 A
unit
Note: If the result is N.G. after checking circuit continuity, repair harness or connector.
HA-64
TROUBLE DIAGNOSES
DiagnosticProcedure4 (Cont'd)
II
~i5(
[ill
1'2113
II
CHECK PUSH CONTROL UNIT. Does continuity exist between push control unit terminals No. @ and @?
N.G.
RHA422A
lO.K.
Disconnect dual-pressure switch.
III
@)
[1t
III
Check circuit continuity between dual-pressure switch harness terminal No. @ and push control unit harness terminal No. @.
Note
~ij
~oo lEEHEHB
III
/
I
III
O.K. N.G.
Replace dual-pressure switch.
[
~i5
Continuity exists: O.K.
CHECK DUAL-PRESSURE SWITCH Does continuity exist between dual-pressure switch terminals?
O.K.
Disconnect fan switch harness connector.
)
Note
m
RHA423A
U~
eJ
[it -,
Check circuit continuity between dual-pressure switch harness terminal No. @ and fan switch harness terminal No. @.
Ii
O.K.
Note
CHECK BODY GROUND CIRCUIT FOR FAN SWITCH. Does continuity exist between fan switch harness terminal No. @ and body ground?
O.K.I
RHA903A
Ii
'\
[ill
Note: If the result is N.G. after 'checkingcircuit continuity, repair harness or connector.
::-
RHA904A
HA-65
..
TROUBLE DIAGNOSES
Diagnostic Procedure 5 SYMPTOM: Illumination or indicators of push control unit do not come on. . Perform Main Power Supply and Ground Circuit Check
KNOB ILL.
)
/
CHECK IllUMINATION AND INDICATORS. . Turn A/C, REC and fan switches ON. . Push VENT, B/l, FOOT, F/D and DEF switches in order. . Check for incidents and follow the repairing methods as shown:
INCIDENTS
"Ho to repair"
ILL. VENT
AIC
/
Go to DIAGNOSTIC PROCEDURE 5-1.
0
0
0
0
0
0
0
0
0
0
0
0 X
Go toDIAGNOSTIC
PROCEDURE 5-2. ...
RHA427A
'\
0
Go to DIAGNOSTIC
PROCEDURE 5-3.
'\
0 X X X
D.
Go toDIAGNOSTIC
PROCEDURE 5-4.
0: Illumination orindicator comes on, X: Illumination or indicator does not come on. D.: Some indicators for VENT, B/L, FOOT, FID, DEF or REC come on,
DIAGNOSTIC
PROCEDURE
I
5-1
N.G. CHECK IllUMINATION SYSTEM. Refer to illumination/Wiring Diagram in E l section.
CHECK THE OTHER llUMINATION SYSTEMS EXCEPT FOR A/C SYSTEM. Do the other illumination come on with ignition switch and lighting switch ON?
.O.K.
m
I
m
CHECK IllUMINATION BULB. Remove push control unit and disconnect,harness connectors-. Remove illumination bulb(s) and check them.
N.G.
Replace illumination bulb(s).
O.K.
A
(Go to next page.)
HA-66
IV 00
[E)
~
A H A428A
"
CHECK POWER SUPPLY FOR ILLUMINATION WITH LIGHTING SWITCH ON. Do approx. 12 volts exist between push control unit harness terminal No. @ and body ground?
N.G.
CHECK POWER SUPPLY FOR AIC tLLUMINATION SYSTEM. ! Refer to Illumintion/Wiring Diagram in EL section.
[I
[I
O.K.
CHECK BODY GROUND CIRCUIT FOR ILLUMINATION.
Note
[It 15
Push control unit connector
[ill
I'R/Y
Does contunity exist between push control unit harness term i::-
IEEEEmm00
:/
RHA429A
'-
~i5
Push control unit connector
[ill
I
~ ~
CHECK MAGNET CLUTCH OPERATION. Does magnet clutch operate normaly when engine ON, AIC switch, fan switch are ON?
Go to Diagnostic Procedure 4.
Continuity should exist when test leads are connected as shown, it should not exist when test leads are reversed.
RHA430A
O.K.
of
N.G.
Replace control amp. built-in push control unit.
Note: If the result is N.G. after checking circuit continuity, repair harness or. connector.
HA-67
TROUBLE DIAGNOSES
~ eJ 00
_IIECT
~
RHA431A
~n
~!
@
m
CHECK POWER SUPPLY FOR PUSH CONTROL UNIT. Do approx. 12 volts exist between push control unit harness terminal No. @ and body ground?
N G r..\ .
I!)
~i5~
Push control unit connector
[JlJ
I!)
::
O.K.
Note ----
IEHBHEBI
B
RHAB96A
CHECK BODY GROUND CIRCUIT FOR PUSH CONTROL UNIT. Does continuity exist between push control unit harness terminal No. @ and body ground? O.K. Replace control amp. built-in push control unit.
repair harness or
HA-68
TROUBLE DIAGNOSES
~ij~
B
[ill
IEHffiHEI
m
RHA896A
Note
CHECK BODY GROUND CIRCUIT FOR PUSH CONTROL UNIT. Does continuity exist between push control unit harness terminal No. @ and body ground? \ O.K.
Replace control amp. built-in push control unit.
repair harness or
HA-69
2 I 3 I 4
RHA399A
BLOWER MOTOR Confirm smooth rotation of the blower motor. Ensure that there are no foreign particles inside the intake unit.
Coh"h";"
oh~k
HA- 70
TROUBLE DIAGNOSES
connector
~
Switch condition AIC ON ON OFF DEF ON OFF ON
~ ~
~
LElJ
Terminal No.
0
@
e
@
Continuity
Yes
RHA469A
DUAL-PRESSURE SWITCH
High-pressure side line pressure kPa (kg/cm2, psi) Decreasing to
177 - 216 (1.8 - 2.2, 26 - 31) Increasing to 2,452 . 2,844 (25 . 29, 356 . 412)
Operation
Continuity
Turn OFF
Increasing to 177 - 235 (1.8 - 2.4, 26 - 34) Decreasingto 1,863 . 2,256 (19 . 23, 270 - 327)
Turn ON
Exists
1 i
i
/
THERMAL PROTECTOR
Temperature of compressor c (oF) Increasing to approx. 135 -145 (275.293) Operation Turn OFF Turn ON
HA-71
Thermo
control
I
II I Voltmeter
THERMO
CONTROL
AMP.
amp. connector
~I~/G
1. Run engine, and operate AIC system. 2. Connect the voltmeter from harness side. 3. Check thermo control amp. operation shown in the table. Evaporator outlet air temperature c (oF) Decreasing to 1.5 - 2.5 (35 - 37) Thermo amp. operation Turn OFF Turn ON Tester Approx.12V Approx.OV
~) ) ~1
\
For Canada
1111
II
II
1---------
Check circuit continuity between terminals by supplying 12 volts to coil side terminal of AIC relay.
For U.S.A.
SHA128C
THERMOSWITCH
[ill
r
~
CD
Thermoswitch
85 - 91 (185 - 196)
Increasing to 92 - 98 (198 -208)
Decreasingto
~connector ~_"CT
~eJ
SHA129C
HA- 72
(S.D.S.)
General Specifications
~MPRESSOR
Model
LUBRICATION
ATSUGI meke
NVR 140S Vane rotary Model
OIL
ATSUGI make
NVR 140S
Type Capacity mQ (US fl oz, Imp fl oz) Total in system Amount of oil which can be drained Compressor (Service parts) charging amount
SUNlsa 5GS
of rotation
200 (6.8,7.0)
REFRIGERANT
Type
Capacity kg (lb) R-12
and Adjustment
COMPRESSOR
Model
Clutch disc-pulley clearance
mm lin)
..
'--...
HA-
73
~~
ELECTRICAL SYSTEM
I
SECTION
EL
EL- 3 EL- 5 EL- 7 EL- 15 EL- 17 EL-.23 EL- 25 EL- 33 EL- 35 EL- 46 EL- 52 EL- 54 EL- 61 EL- 65 EL- 75 EL- 81 EL- 82 EL- 85 EL- 88 EL- 97 EL- 99 EL-117
When you read wiring diagrams: . Read GI section, "HOW TO READ WIRING DIAGRAMS".
CONTENTS
HARNESS CONNECTOR... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .'. . . . . . . . . . . . . . . . . . EL- 2
STANDARDIZED RELAY................................................. POWERSUPPLYROUTING............................................... BATTERY.. .,. . .. . ., . . . . .. ... .. . .. . .. . .. . . .. .. . . .. . . . . . .'. . . . .. . . . .. STARTINGSYSTEM..................................................... STARTINGSYSTEM-Starter '... CHARGING SYSTEM .....................
CHARGING SYSTEM -Alternator -........................................ COMBINATIONSWITCH.................................................. HEADLAMP EXTERlOR LAMP
, ';"""""""""""""""""
INTERIOR LAMP
WARNING LAMPS AND CHIME
METERAND GAUGES...................................................
TIME CONTROL SYSTEM.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIPER AND WASHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .,. . . . . . . . . . . . . . HORN, CIGARETTE LIGHTER AND CLOCK 1 .~,: ....... REAR WINDOW DEFOGGER.............................................. AUDIO AND ANTENNA ........................................ ..
.,/t.;. . .\ . . .
..~ ..
.
"
I!II
Q.D. CONTROL.. . . . . . . . . . . . . . . . . . . . . . ..
LOCK-UP ONTROL. . . . . . . . . . . . . . . . . . . . . . C
AT SECTION
AT SECTION ELECTRIC DOOR MIRROR,SUN ROOF, DOOR LOCK, POWER WINDOW AND AUTOMATIC SEAT BELT. . . . BF SECTION HEATER AND AIR CONDITIONER. . . . . . . . . . . . . HASECTION
~ARNESS
'----
CONNECTOR
Description
HARNESS CONNECTOR All harness connectors have been modified to prevent accidental looseness or disconnection. The connector can be disconnected by pushing or lifting the locking section.
. .
CAUTION:
~ the connector.
[Example]
LIFT
PUSH
~
PUSH PUSH
PUSH
$J
/'
(For r.l.y)
SEL769D
EL-2
u.
u. 9
.
Does flow not c:>
.
I
I =
)
0 SW 1 Flows
I
BATTERY
=
::>
SW 1
I.-J
BATTERY
0 SW 1
BATTERY
I I
Z
I
I
IL'
-1'""1 sw 1
I
BATTERY
SW 1
I
BATTERY
s
SW 1 BATTERY SEL881H
I'
2M 1M.l B
1 Make 1 Transfer
," (
,--- r', ,.
(
2M
'.
...
...
----
~~) ,
"
1T
lM.1B
1T ,
'I'
...
I I \
?---
'
'
t 0',': \ \ ~ 1\
'-r,
"
'
1'
1B \
,'
I I
\ I
,\
"
1M
SE L882H
EL-3
STANDARDIZED RELAY
Type
"<V
Outer view
Circuit
Casecolor
1T
BLACK
@
t:==I
1M @
BLUE
<ZL 2M @
<D@@
=
BROWN
CD
1M.1B
GRAY
SEL883H
EL-4
/--~
I 2 3 4 5 Bulb
relay Fue I pump. All' regulator
OFFACC ON ST 0 0 0 0 0
ACCESSORY
RE I GNITI ON T JON
~ ci'
~~
G/Y
CheCk
)
""H I-I
... l'fl'l
...
..,c
.-
@,
~ II ::
~
~
I
LAY
A. S
~ @~
, '"
"''''1'' \,RELAY"'
~! ~~
",
Me
G/W L -
Tur
Sh I ft
Key
lac k
]
L/WlG
@)~@)
Rea was
Win
OR/B-
Ciga
Retract
relay
GROUND
BODY
(@) W~L~
AII' conditioneI'
l/OR-
Heat
t~~ ~ IBlo
.~
FUSE BLOCK
m rI
Front Horn.
fog
lamp
A. S. C. D.
U1
(@)
@)
R/B l
.l
IRe
Jnte
'"
U.f r=r
" ~...
...",
" ~~
'"
m ;>J m r-z 0 -<." tDC
0(1)
~." -c :J(I)
"''''
~@ ~@
I
. ~o ~
~ ..
Rn
G/l
~@~@
FUSE
x~tD :;;@) rz
'"
"
~
-
~~
n
U3
4 3
SB
CJ RCUJ T BREAKER
@@j)~
BODY
~;
G/R
Stop unit.
Haza
Head Not
BATTERY
GROUND
OR G/l -
Exter
rn m r en
.... Q)
s:
Fuse a. If fuse
O.K.
Blown
SEL954J
is blown, be sure to eliminate cause of problem before installing new fuse. b. Use fuse of specified rating. Never use fuse of more than specified rating. c. Do not install fuse in oblique direction; always insert It into fuse holder properly. d. Remove fuse for clock if vehicle is not used for a long period of time.
Fusible Link
A melted fusible link can be detected either by visual inspection or by feeling with finger tip. If its condition is questionable, use circuit tester or test lamp. CAUTION: a. If fusible link should melt, it is possible that critical circuit (power supply or large current carrying circuit) is shorted. In such a case, carefully check and eliminate cause of problem. b. Never wrap periphery of fusible link with vinyl tape. Extreme care should be taken with this link to ensure that it does not come into contact with any other wiring harness or vinyl or rubber parts.
SEL387L
15 20 30 35 40
El-6
BATTERY
CAUTION: a. If it becomes necessary to start the engine with a booster battery and jumper cables, use a 12-volt booster battery. b. After connecting battery cables, ensure that they are tightly clamped to battery terminals for good contact. c. Never add distilled water through the hole used to check specific gravity.
SEL711E
METHODS OF PREVENTING OVER-DISCHARGE The following precautions must be taken to prevent over-discharging a battery. The battery surface (particularly its top) should always be kept clean and dry. If the top surface of a battery is wet with electrolyte or water, leakage current will cause the battery to discharge. Always keep the battery clean and dry.
When the vehicle is not going to be used over a long period of time, disconnect the negative battery terminal. (If the vehicle has an extended storage switch, turn it off.)
/
SEL712E Hydrometer
Check the charge condition of the battery. Periodically check the specific gravity of the electrolyte. Keep a close check on charge condition to prevent overdischarge.
SEL442D
EL-7
BATTERY
How to Handle
Battery
(Cont'd)
LEVEL
'\
/
Do not allow battery fluid to come in contact with skin, eyes, fabrics, or painted surfaces. After touching a battery, do not touch or rub your eyes until you have thoroughly washed your hands. If the acid contacts the eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention. Normally the battery does not require additional water. However, when the battery is used under severe conditions, adding distilled water may be necessary during the battery life.
. .
Removethe cell plug using a suitable tool. Add distilled water up to the MAXlevel.
SELOO1K
Charging voltage
1
Normal battery
Sulphated battery
Charging current
~
"-'
Charging
voltage
SULPHATION When a battery has been left unattended for a long period of time and has a specific gravity of less than 1.100, it will be completely discharged, resulting in sulphation on the cell plates. Compared with a battery discharged under normal c.onditions, the current flow in a "sulphated" battery is not as smooth although its voltage is high during the initial stage of charging, as shown in the f~gureat the left.
SPECIFIC GRAVITY
CHECK
SE L442D
EL-8
Hydrometer ~I~
/'
When electrolyte level is too low, tilt battery case to raise it for easy measurement.
TI"~o-'
SEL710E
2. Convert into specific gravity at 20 C (68 F). Example: . When electrolyte temperatu re is 35 C (95 F) and specific gravity of electrolyte is 1.230, converted specific gravity at 20 C (68 F) is 1.240. When electrolyte temperature is 0 C (32 F) and specific gravity of electrolyte is 1.210, converted specific gravity at 20C (68F) is 1.196.
Converted
specific gravity
(5201
1.30
en
1.28
1.26
a
I!
II Q
II
1.2"
e ti
.. II
>
1.22
1.20
1.18
1.16 1.1"
1.12
20 1681
c (0 F) SE L042D
temperature
_/
EL-9
BATTERY
~
/
Chart I
VISUAL INSPECTION . Check battery case for cracks or bends. . Check battery terminals for damage. . If the difference between the max. and min. electrolyte level in cells is within 10 mm (0.39 in), it is O.K. O.K.
N.G.
Replace
battery .
.
STANDARD CHARGE Refer to "B: Standard Charge" .
QUICK CHARGE Refer to "C: Quick Charge" . CAPACITY TEST Refer to "Chart II".
N.G. Ready for use . Mount battery again and check loose ter. minals. Also, check other related circuits.
RECHARGE Refer to "C: Quick Charge". .If battery temperatUre rises above 60C C14O"F), stop charging. Always charge battery when its temperatUre is below 60C (140FI.
CAPACITY TEST Refer to "Chart II". O.K. Ready for use N.G. Replace battery.
N.G.
Replace battery.
. "STANDARDCHARGE" is recommended in -
EL-10
Chart II
1//
.
Test using load tester.
Check battery
type and
Type 28B19R(l) 34B19R(l) 46B24R(l) 55B24R(l) 50D23R(L) 55D23R(l) 65D26R(l) 80D26R(l) 75031 R(L) 95031 R(L) 95E41 R (l) 130E41R(L)
Current (A) 90 99 135 135 150 180 195 195 210 240 300 330
Read load tester voltage when specified discharging current (Refer to Fig. 1.1 flows through battery for 15 seconds. N.G.
Go to next step.
Go to next step.
~~ ..
0
6010
SE L697 B
/"
EL-11
A: SLOW CHARGE
Fig. 2 INITIAL CHARGING CURRENT :i:i SETTING :i:i
a:a:
(Slow charge) :i
a:
:i:i
a:a:
a:a:
:i:i
a: a:
:i
a:
- IDID
..,...,.
MM NN 00 Oln Inln
NN 00 1n0 <OlD
<0<0
M 0 In
.....
M..,. Ow In In
0101
- -
..,. W
Determine initial charging current from specific gravity referring to Fig. 2. Below 1.100 . Charge battery. . Check charging voltage 30 minutes after starting the battery charge.
4.0 (A)
5.0 (A)
7.0 (A)
8.0 (A)
9.0 (A)
10.0 (A)
14.0 (A)
. .
Check battery type and determine the specifiedcurrent using the table shown above. After starting charging,adjustment of chargingcurrent is not necessary.
Fig. 3 ADDITIONAL CHARGE (Slow charge) O.K. N.G. Replace battery. Continue to charge for 12 hours.
Charge for 5 hours. at initial charging current setting. Charge for 4 hou rs at initial charging current setting. Charge for 2 hou rs at initial charging current setting.
Below 1.150
1 .1 50 - 1 .200
Above 1 .240
CAUTION:
Conduct additional charge as per Fig 3. if necessary.
a.
Go to "CAPACITY
TEST".
Set charging current to value specified in Fig. 2. If charger is not capable of producing specified current value, set its charging current as close to that value as possible. b. Keep battery away from open flame while it is being charged. c. When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this may cause a spark. If battery temperature rises_above. 60C (140 F), stop charging. Always charge battery when its temperature is below 60C (140F).
d.
EL-12
BATTERY
~
Battery
Fig.4
Chart (Cont'd)
B: STANDARD ~
CHARGE
CDNVERTED
Determine specific initial charging current to Fig. 4. from SPECIFIC gravity. referring
::;::; a:a:
vv
NN alai COLtl VLtl
......
coco
a:a:
::;
a:
::;::;
"''''
alai
LtILtI
NN 00 LtlO COal
M 0
a:a:
Mv Ow mm
LtILtI
::!
a:
W
,..
LtI
4.0 (A) 5.0 (A) 6.0 (A) 7.0 (A) 8.0 (A) 9.0 (A) 13.0 (A) 3.0 (A) 4.0 (A) 5.0 (A) 6.0 (A) 7.0 (A) 8.0 (A) 11.0 (AI 2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A) 6.0 (A) 7.0 (A) 9.0 (A) 2.0 (A) 2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A) 5.0 (A) 7.0 (A)
.
CHECKING SPECIFIC GRAVITY Refer to "Specific Gravity Check".
Check battery type and determine the specifiedcurrent usingthe table shown above. After starting charging,adjustment of chargingcurrent is not necessary.
Conduct
additional
charge as per
Fig. 5. if necessary.
~
Charge for 3.5 hours at initial charging current setting. Charge for 2.5 hours at initial charging current setting. Charge for 1.5 hours at initial charging current setting.
Go to "CAPACITY TEST".
Above 1 .240
CAUTION:
a. Do not use standard charge method on a battery whose specific gravity is less than 1.100. b. Set charging current to value specified in Fig. .4. If charger is not capable of producing specified current value, set its charging current as close to that value as possible. c. Keep battery away from open flame while it is being charged. d. When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this may cause a spark. e. If battery temperature rises above 60C (140 F), stop charging. Always charge battery when its temperature is below 60 C (140 F).
EL-13
BATTERY Battery
C: OOICK CHARGE
Chart (Cont'd)
Fig.6
Determine initial charging current setting and charging time from specific gravity. referring to Fig. 6.
:J:J a: a: mm
IDID
-IDv NM 10 (A)
--MMv Oow
:J a:
coono vonon
on on on r-mm
; W !i! -
15 (A)
20 (A)
30 (A)
40 (A)
1.100-1.130
1 . 130 - 1.160
2.5 hours 2.0 hours 1.5 hours 1.0 hours 0.75 hours (45 minJ
Charge battery
. .
Check battery type and determine the specifiedcurrent using the table shown above. After starting charging.adjustment of chargingcurrent is not necessary.
CAUTION: a. Do not use quick charge method on a battery whose specific gravity is less than 1.100. b. Set initial charging current to value specified in Fig. 6. If charger is not capable of producing specified current value, set its charging current as close to that value as possible. c. Keep battery away from open flame while it is being charged. d. When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this may cause a spark. e. Be careful of a rise in battery temperature because a large current flow is required during quick-charge operation. If battery temperature rises above 60C (140 F), stop charging. Always charge battery when its temperatu re is below 60 C (140 F). f. . Do not exceed the charging time specified in Fig. 6, because charging battery over the charging time can cause deterioration of the battery.
Service
Applied area Type CapaciW V-AH U,S.A.
(S. D. S.)
Canada 65D26R
12-65
55D23R 12-60
EL-14
STARTING SYSTEM
MfT MODEL
/
SWITCH
Wiring Diagram
IGNITI ON
WI
INTERLOCK
CLUTCH
1 2 3 4 5
OFFACC ON ST :J 0 :J
~@Y
~~
'"
Q ~" <f?
~>-
W@
~~
"''''
"
"
~(@) ~
~'" '"
'"
",0: '"
@)ft@)
BODY GROUND
(Eng i ne harness)
room ~8/W-'Q'
~8/Y...o,.0 "O-8/Y
(Eng i ne harness room no. 2) >-
@)@)
@,
For
U. S. A.
~
@),
For Canada
@)g
I
, '"
@.?)O
888 88J
cr:=::o cr:=::o
FUSE AND FUSIBLE lINK CIn RElA Y BOX)
]
FUSE
~M
BATTERY STARTER MOTOR
7
(ill)
SEl466L
AfT MODEL
INHIBITOR IGNITION SWITCH SWITCH
1 2 3 4 5
OFFACC ON ST :J C ()
N IP
WI
~@Y
~~
'"
~@
....
~~
~@)
room
(Eng Ine
harness)
en ~ 8/Y-o' "O-8/Y
@)1f2W ~
(Eng I ne harness room no. 2)
]
~
@)Q
, '"
8/R
>-
@.?)O
888 88J
cr:=::o cr:=::o
lINK
]
FUSE
(ill)
SA HERY
STARTER
MOTOR
SE L67BM
EL-15
Replace
Does starter
motor
turn?
No
O.K.
Check battery for charging condition and battery terminals for connections and corrosion. O.K.
.1
N.G.
. .
VIS
Ch Re
batt
N.G.
Check wir ing of starting system.
O.K.
Check reduction geer. armature and gear shaft for damage. Replace if necessary.
Rep
m rI
.... 0')
N.G.
.
.
Adju
O.K. Remove starter motor from engine. Does starter motor turn under no load by connecting battery (jJ terminal to M terminal of starter motor and battery terminal to starter motor body?
Ves N.G.
Ch and Re
.,
Ch Re
O.K.
Does engine turn by replacing motor with a new one7 starter
1
i
No
Check inside of engine.
I
I
<Che
If an
~:on
6.4-8.3
(0.65 - 0.85. 4.7 - 6.1)
Dust cover
\ I
'
IEI@
.~ ~
m
I ~
@
Spring
r'"
~m L J~
Pinion assembly Washer Brush holder
\\ ~
c<.w bn."k..(A)
en
ro~
/
Lrmature
~~"
0
J
Yoke assembly
I!J
:
;:
A
lEI @
Unit:
mm Iinl
(kg-m. ft-Ib)
: N'm
Throug h-bolt
4.9-6.4
: High-temperature
grease points
Magnetic
switch assembly
Packing
Sleeve bearing
mCBJ
m
~ I
CO
-'
Gear case
mCBJ
Pinion assembly
mCBJ ~
~m
[;;
Unit: mm (inl co:J : N'm (kg-m. ft-Ibl CBJ: High-temperature grease point
STARTING SYSTEM
Starter
/
Magnetic Switch Check
~
Ohmmeter
. . 1. .
Before starting to check, disconnect battery ground cable. Disconnect "M" terminal of starter motor. Continuity test (between "8" terminal and switch body). No continuity... Replace.
QJ
SEL036H
2. Continuity test (between "8" terminal and "M" terminal). No continuity... Replace.
SEL038H
Pinion/Clutch Check
~
1. Inspect pinion teeth. Replace pinion if teeth are worn or damaged. (Also check condition of ring gear teeth.) 2. Check to see if pinion locks in one direction and rotates smoothly in the opposite direction. If it does not lock (or locks) in either direction or unusual resistance is evident. ... Replace.
. .
~-
Vernier
caliper
SEL626B
EL-19
STAFtTING SYSTEM
;
Starter
-.
J
M1T72781
.
. .
S114-519A
SEL568B
\
.SEL558E
Armature Check
1. Continuity test (between two segments side by side). No continuity... Replace.
Ohmmeter
SE L625B
2. Insulation test (between each commutator bar and shaft). Continuity exists. ... Replace.
SEL 104E
EL-20
STARTING SYSTEM
'.
- Starter -
4. Check diameter of commutator. Commutator minimum diameter: Refer to S.D.S. 8 Less than specified value ... Replace.
Vernier caliper
Commutator SEL418A
5. Check depth of insulating mold from commutator surface. 8 Less than 0.2 mm (0.008 in) ... Undercut to. 0.5 to 0.8 mm (0.020 to 0.031 in)
u""'"'",.OC"'"'..~ .
Round
0.5 . 0.8 mm
10.020.0.031 inl
Correct
-e=\.
Commutator
~~Old Incorrect
EE021
Assembly
Apply high-temperature grease to lubricate the bearing, and frictional surface when assembling the starter. Carefully observe the following instructions. 8 Gear case metal 8 Moving portion of shift lever 8 Plunger of magnetic switch 8 Internal gear 8 Planetary gear 8 Shaft
gears
EL-21
STARTING SYSTEM
Starter
Assembly (Cont'd)
PINION PROTRUSION LENGTH ADJUSTMENT
r
T
Switch
-'-
I Battery
With pinion driven out by magnetic switch, push pinion back to remove slack and measure clearance" Q" between the front edge of the pinion and the pinion stopper. Clearance" Q": Refer to S.D.S.
SE L299E
Clearance
"Q"
Adjusting
plate
.
I
~
\
SEL633B
(S.D.S.)
HITACHI make
Reduction gear type Applied model System voltage No-load Terminal voltage Current Revolution V All 12
-4,000
Minimum diameter of commutator mm (In) Minimum length of brush mm (in) Brush spring tension N (kg, Ib)
28.8 (1.134)
11.0 (0.433) 17.7-21.6 (1.8 - 2.2,4.0 - 4.9) 0.2 10.008) 0.3 -1.5 (0.012 - 0.059)
12.0 (0.472) 13.7 -25.5 (1.4 -2.6,3.1 -5.7) 0.5-2.0 (0.020 - 0.079)
Clearance of bearing metal and armatUre shaft mm (in) Clearance "Q" between pinion front mm(in) edge and pinion stopper
EL-22
(ill)
IGNITION SWITCH ON or START
FUSIBLE
LINK
1rinrnr r
G1 G1" G1
FUSE
]
.. '"
;j
@)~..:(
""
a::::::IJ
:(:(
@J
[D-w
::BATTERY (Eng ine room harness)
~
WI
BR~BR W/R~W/R
'"
@])@
(Ma in harness)
m
rI
S. M. J.
ffiefer to last page (Fo Idout page). J
N W
~ '" I @~II~P4111
(Black)
IIII
QD~llfbdlll I
:(
IlIl
, '"
BODY GROUND
i@
J:1~
..:(
:(
, '"
:(
(@)~
@c;9 @9~
:(
~@)
:( , '"
~@]) @
(Eng ine room harness no. 2)
we
:(
QDG1
@V
[!::I:Em
~: ~:
With head-up display display Without head-up
O::HHH:
2
rJJ
m r
ij
B
<eo- B <eo- w
I 7 o----@---ol
rB=W~R
CHARGE
(IT CD ~ ~
ALTERNATOR
COMBINATIO
.~
@
Ignition switch "ON"
I I I I
Dim light Light fl ickers Bright light
I (MITSUBISHI
:~a~e~
Check or replace drive belt. Engine idling
Use fully charged battery. Light: Charge warning light A.C.G. : Alternator parts except IC regulator IC-RG : IC regulator O.K. : IC alternator is in good condition. 3) When reaching "Damaged A.C.G.", remove alternator from vehicle and disassemble, inspect and correct or replace faulty parts. 4) *Method of grounding F terminal (HITACHI make only) Gasoline engine model Contact tip of wire with brush and attach wire to alt~rnator body.
1) 2)
-- --E.
SEL766D
5)
Terminals "S", "L", "8" and "E" are marked on rear cover of alternator.
EL-24
CHARGING SYSTEM -
Alternator
Construction
Front cover Rotor *Rear bearing
~,:;~(
Front bearing Condensor~
"
..,-.
.'-./,
-," -'->'
i--
hrOU9h-bOlt
Rear cover
A2T14094
I~~
t:>
IC voltage assembly
regulator
Stator
A:
*Rear bearing CAUTION: Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. Be careful not to
'
EL-25
Alternator
REAR COVER REMOVAL CAUTION: Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. To facilitate removal of rear cover, heat just bearing box section with a 200W soldering iron. Do not use a heat gun, as it can damage diode assembly.
SEL628D Ohmmeter
Replace rotor.
Ohmmeter
2. Insulator test
3. Check slip ring for wear. Slip ring minimum outer diameter: Refer to S.D.S.
SE L630D
Brush Check
1. Check smooth movement of brush. Not smooth ... Check brush holder and clean.
2. Check brush for wear. Replace brush if it is worn down to the limit line.
SE L631 D
2 mm 10.08 inl
3. Check brush lead wire for damage. Damaged... Replace. 4. Check brush spring pressure. Measure brush spring pressure with brush projected proximately 2 mm (0.08 in) from brush holder.
ap-
.
E E049
Spring pressure: Refer to S.D.S. Not within the specified values ... Replace.
EL-26
CHARGING,SYSTEM
Stator
AI.ternator
Check
To test the stator or diode, separate them by unsoldering the connecting wires.
CAUTION:
SE L587
[HITACHI
make]
[MITSUBISHI make]
EL-27
CHARGING SYSTEM
Alternator
Continuity
exists.
'" Replace
stator.
SE L384L
EL-28
-~
Alternator -
MAIN DIODES
Use an ohmmeter to check condition of diodes as indicated in chart below: If any opthe test results is not satisfactory, replace diode assembly.
Ohmmeter probes Positive (fJ
Negative e
Diode terminals
Positive diode plate Diode terminals Negative diode plate [MITSUBISHI make] Sub-diodes
Continuity
Yes No
No Yes
Diode terminals
Negative diode plate Diodes check (Negative side) Diode terminals
[HITACHI make]
SE L768D
EL-29
--~
CHARGING SYSTEM
Diode
SUB-DIODES
Alternator
(Cont'd)
Check
[MITSUBISHI make]
. .
SE L494H
[HITACHI make]
(~:1 \ !I
{(
,J
(- J
1/)
;'//.' /.-
~
.~
. . ~
- (]Do
0
~ .4..L c--
Assembly
Carefully observe the following instructions.
When soldering
each stator
WHEN SOLDERING
Wear limit line-,
[MITSUBISHI make] Position brush so that its wear limit line protrudes 2 mm (0.08 in) beyond end face of brush holder.
SEL386L
[HITACHI make] (1) Position brush so that it extends 10.5 to 11.5 mm (0.413 to 0.453 in) from brush holder.
SEL595A
EL-30
CHARGING SYSTEM
Soldering points
Alternator
Assembly (Cont'd)
(2) Coil lead wire 1.5 times around terminal groove. Solder outside of terminal. When soldering, be careful not to let solder adhere to insulating tube as it will weaken the tube and cause it to break.
/
After soldering. place insulating tube on terminal.
1 mm 10.04 inl SE L596A
Fix ring into groove in rear bearing so that it is as close to the adjacent area as possible.
REAR COVER INSTAllATION (1) Before installing front cover with pulley and rotor with rear cover, push brush up with fingers and retain brush by inserting brush lift wire into brush lift hole from outside. (2) After installing front and rear sides of alternator, pull brush lift wire by pushing toward the center. Do not pull brush lift wire by pushing toward outside of rear cover as it will damage slip ring sliding surface.
SE L766D
/
EL-31
CHARGING SYSTEM
-"-
Alternator -
Alrpm V mm (in)
14.1 -14.7 6.0 (0236) 1.471 - 3.334 (150 -340, 5.29 - 11.99) 26.8 (1.055) 8.0 (0.315) 3.040 -4217 (310-430, 10.93 -15.17) 22.1 (0.870)
N (g, oz)
EL-32
COMBINATION SWITCH
Check
----
,
A
{[
WASH HI
"
C
n:,(j
2nd OFF
<}
L
I
22 4
~
~
For lighting switch
LIGHTING QFF A B CA 5 0 0 6 7 8 0 0 9 10 11
SWITCH 1 2 B C A B C 100 0
OO
.Q.
HORN SWITCH
12 25 26 27
~
EL-33
rq II
RNL 2 3
28
SEL388L
,~
COMBINATION SWITCH
Wiper and
washer switch
Replacement
.~
,
Lighting switch
SEL389L
.
Attaching screw
To remove combination switch base, remove base attaching screw and turn after pushing on it.
SE L390L
EL-34
FUSE
~
I~A TTERY
I
-0
RETRACTOR SWITCH
OFFI ON I
RETRACT RELAY-4
6
I~
<;>
...
To
i I Ium
inat
I r+- }
system
r1S
I--
-=-
@5
.RETRACT RELAY-l ,---
RETRACT RELAY-3
f--
.--vm=;:
[of
~
RE TRAC
I
T
-=-
~OJ ..L-
H
1I
RELAY-2
m
rI
W
(J'I
-l--
cnc
::Err
~~
~rr, nn :r~ , ~ Z G1
~ ~~--
l -~,
4 3
--4-3
-
~~~ ~- --d,
~U~
~D~W~ ~P~
4'~ 3
-~O~N ~ ~~ ~
1-
>
t1!
G1
[L1J
:~f*
: I
@t,
---
<
<
IS
-=-
5'
..L
~!
~
R. H.
I I
L--
TIMER
-~
-~~
HEADLAMP
MOTOR
HEAD LAMP
~
m r
HEADLA~P
MOTOR L.H.
HEADLAMP MOTOR R. H.
(D
RETRACT RELAY-]
RETRACT RELAY-2
RETRACT RELAY-3
RETRACT RELAY-4
HEADLAMP TJ MER
iii[l@~
~@) ..
~
~@) ..
~@) c..
rftl@
~> ~~~:"
OFF ON 1 a 2 a 3 4 5 6 B
@ -~@)
~,,~~~..~~~~ ~~ ". ~.. ..
1.1
..~
".
~~
..:~ ~~
.. .....
~~~
..:~
X
9
jj
To Illumination system
BR/W PU/W OR B BR
O~
m rI HEADLAMP R. H.
@])@)
EA 'iff!:2 ORR B - PU mBR/W
@
BR PU EA ORBR/W m OR P/B P/B R/G BR/ Y .ffi R/l G/R
en
rE~?LAMP
HEADLAMP MOTOR L. H.
~ ~
@)
P/B ~G/l 't}: R/G
"'
E2 FI
BR/Y
@ ~G/Y
~R/B
....
(Eng I ne harness) room
01 A2 AS C3 Cl El 02 F2
..
BR/Y
(D1.~P:f
cc ..,,"''''
..,". ......
~@!)
Ii
LIGHTING SWITCH
'"
'" "''''
FUSE
~~@)
[3[
@
~~
BATTERY
Ii
@)@)
BODY GROUND
en m r UI CIO UI
s:
HEADLAMP
Description
BASIC OPERATION
Cond ition Lighting switch OFF 1ST 2ND 1ST 1ST 2ND 1ST OFF Retractor switch OFF OFF OFF OFF OFF ON
CIRCUIT OPERATION.
Operation C/O* Headlamp motor No operation [A) Open Held to open position [B) [C) [D) Closed Opened and closed after headlamps go off. Open Headlamps OFF ON after headlamp motor reaches fully open position. OFF OFF Momentarily ON after headlamp motor reaches fully open position, and go off. OFF
EL-37
"2ND"
)
RETRACT RELAY-4
To Illumination system
RETRACT RELAY-!
~
c-" .m
--.J
'
~~ ij"
" "
~~
A-2:
MEADLAMP MOTOR L. H.
HEADLAMP MOTOR R. H.
7!J
---~
HEADLAMP Tl MER
SEL657L
RETRACT RELA Y- 4
J system
To
Illumination
RETRACT RELAY-3
RETRACT RELAY-!
RETRACT RELAY-2
"" "
I
I
'" ...m
~~
/
~!J
HEADLAMP MOTOR R. H.
HEADLAMP
TIMER
HEADLAMP MOTOR L. H.
SEL658L
EL-38
HEADLAMP Description
[B]
(Cont'd) "OFF"
} system
RETRAC RELAY-4 T
To
Illumination
RETRACT RELAY-I
RETRACT RELAY-2
..~
I
r~ .m ~ .~ " ..
"'~ ;,~ .0
r " "
r~ ~~ .. ;:~ "" ..
TIHER
_.~
+oJ
.
I
SEL659L
[C] C-1:
When lighting switch is switched to "PASSING" While operating the head lamp motor to open position
FUSE
} system
RETRACT RElAY-4
To Illumination
RETRACT RELAY-3
RETRACT RELAY-2
.:J
HEADLAMP MDTDR L. H. HEADLAMP MOTOR R. H.
--.J
.
I
r~ .m ~ .~ ~
..~ r~ ~~ ..
;:~ "" ..
..
SEL660L
EL-39
)
RETRACT RELAY-'
To Illuolna<lon system
RETRACT RElAY-3
RETRACT RELAY-I
RETRACT RElAY-2
r", O~
I
~ r:::
HEADlAHP HDTDR l.
H.
HEADlAHP HDTDR R. H.
~!J
L-_~HEADlAHP TI
HER
.. "" ..
SEL661L
[D]
When retractor switch is turned ON (While operating the headlamp motor to open position)
FUSE
)
RETRACT RELAY-'
RETRACT
RElAY-'
~~
r", O~ r~
I
I
--.J
'
~~ ':e ~
~ 'm
". :e .
'" rm
..
" ~
~"
HEADlAMP HDTDR l.
H.
HEADlAMP HDTDR R. H.
~!J
HEADLAHP
T)MER
--_=:J
SEL662L
EL-40
HEADLAMP
-" ...~tin"e.
.
Headlamp motor . Headlamp motor should be removed together with the headlamp bracket as an assembly. Link B
\-~:w, 1--~-~-
-~
c::=
~
~
~
Headlamp bracket
Finisher
SEL391 L
!I
EL-41
HEADLAMP
Assembly
1. Install headlamp motor, ball joint and link A (as one unit) on headlamp bracket. 2. While turning link S, install link A's ball joint on headlamp housing's ball joint. 3. Set distance between centers of upper and lower ball joints as shown in figure at left, and tighten lock nuts. 4. Assemble head lamp, finisher and lid.
SEL392L
Lock nut
Motor side
Approx. 6.8 (0.2681
SEL393L
I,
~~I
l
lllll.
I
lllllllllllli I
---------
-----------
LLLlLlllll [
Adjust lid, hood and fender for alignment while opening and closing headlamp with motor manual knob. Use motor manual knob to open and close headlamp, and adjust alignment while checking that lid is not interfering with hood.
SEL395L
~-
~~_isflush.
Ad;""ro,,4
S~L396L
EL-42
1. Disconnect battery ground cable. 2. Disconnect the headlamp motor connector. 3. Use an ohmmeter to check for continuity in headlamp motor circuit while rotating motor with manual knob.
LSE L399 L Up
INSTALLING HEADlAMP RUBBER CAP When installing the rubber cap, set the "TOP" or " ..." mark so that it is facing up.
SEL495G
Press the rubber cap firmly so that the lip makes contact with the head lamp body.
~
Bulb
Press
SEL841 H
EL-43
HEADLAMP
Aiming Adjustment
When performing headlamp aiming adjustment, use an aiming machine, aiming wall screen or headlamp tester. For operating instructions of any aimer, it should be in good repair, calibrated and used according to respective operation manuals supplied with the unit. If any aimer is not available, aiming adjustment can be done as follows: For details, refer to the regulations in your own country. -----CAUTION:
a. Keep all tires inflated to correct pressures. b. Place vehicle and tester on one and same flat surface. c. See that there is no-load in vehicle (coolant, engine oil filled up to correct level and full fuel tank) other than the driver (or equivalent weight placed in driver's position).
WL = 1.067
(42.01)
. .
H "H" : Horizontal center line of head lamps
Adjust headlamps so that upper edge and left edge of high intensity zone are within the acceptable range as shown. Dotted lines in illustration show center of headlamp.
lamp centers I
7lZ.
I"':
~pper
edge of
1100
(4) 100 (4) f.iOOfWo (4) (4) Left edge of high intensitY zone 100 (4) 100 (4)
'" ""
~igh
intensitY zone
Unit: mm lin)
~ = ACCEPTABLE
RANGE
SEL914D
ADJUSTING SCREWS
lU
lU
7.)
\\1illtlllllllllllllllll i
SEL400L
EL-44
1LHorizontal
SE L401 L
side: 4
\
LVertlcal
side: 2
---------
EL-45
LAMPR. H.
I
UP
BATTERYI
LAMP SWITCH
STOP
@D
<t;>@) '"
'III ,..
t
@
(Refer
FUSE BLOCK
I
F2
R~L=Q]]
L..J
JII
"'''' "
"'-<
@Y
@
"'''' "
-<'"
I
R/L~
~
FRONT COMBI NATI ON LAMP R. H. <Eng Ine harness)
SUPPLY ROUTINGH.)
to
HPOWER
R:G~
R/Lj:b
R~G=1:P 18
II
room
0
G/R
@)
D2 R/L
G/R
@V
(Ma i n harness)
I"..can,. ~, ~
m
R/L
B [},~ R/L-D'
page).
page
@9
(Bac k harne
r~
en
FRONT COMBI NATI ON LAMP L. H. LI GHTI NG SWITCH
I
R~G=83fi:R~G f
~
1\ OFF 1ST 2ND A B C A B C A Be 5 6 7 8 9 10 II 12 2S 26 27 28
B --0, R/L-D'
@
@!O) R/Lj:b R~G=1:P
I "..c.n,.
~
I '"
~,
'" III' ,.. ~@)
;~m
R/L~
R:G~ @IV
R/L
@)~@)
(fj
m r
BODY GROUND
:. -.j
'"
@jJ
B:
~
@@
'R
... r
BODY ~ROUND
STOP
LAMP SWITCH
<f?@) '"
'III r-
*
UP @
L-....fT5A
~'"
~~
Il
@)~ "''''
~
"
j -<~
@D
R~L::ern
B FRONT
COMBI LAMP NA TI ON R. H.
j
@9
(Eng i ne
~
I
m
~
Clearance
~@
~R:L
room harness) -
@D@
G/R R/L
F2 D2 to
G/R R/L
(Ma in harness)
B -Q, R/L-Q'
S. M. J.
Iast
page
[Re fer
~
R/G=EB B
rI
~
~
"
FRONT
COMBINATI ON LAMP L. H. LI GHTI NG SWI TCH
()
OFF 1ST 2ND ABCABCAB C
B --0, R/L-Q'
Clearance
~@
R:L
:~m
III' r-
'"
5 6 7 8 9 10 11 12 25 26 27 28
@
B
@ill)
R/L B ::ern
~@
@)~@)
en m r
I\) r
BODY GROUND
~
FRONT SIDE MARKER
LAMP L. H.
@),,@
" ...
BODY GROUND
~~
ON or START
il @I l
FUSE BLOCK
@!) _G/w-Q ~
'z:1 --E:J B ~
BACK-UP
LAMP R. H.
--------
@)~
(Eng Ine
..J
()
~~ '" '"
<illY
G/L G/W
G/L
room
@)
harness)
0:
@: @:
.
=[9
10 HI H2
J
~
~IG;I~-UP
REAR
COMB LAMP
I NA TI ON R. H.
(Main harnesS>
@D
G/w-p~
B --E:J ~
BACK-UP
LAMP L K
~~ "''''
(@)
@:
I~IG;I ~-UP
(Eng Ine harness room no. 2)
REAR
COMB I NA TI ON
G/L-{}, G/W--QJ
BACK-UP LAMP
LAMP
L H.
SWITCH
~rii@
BODY GROUND
SEL679M
El-48
-g9" TO
H
25 26 27
0 ir
. c
'" '" , ,
R/G R/W G/L
~@
DIODE
'" -<
I 28
FOG
LAMP n RELAY U
D~
trn'I rr;;;\
@D@)
OR/B
OR/L
R/G
~
S. M. J.
R/G
G/L OR
OR/L~OR/L
(MaIn harness)
m
~
rI
CD
@
FRONT FOG ~ LAMPR. H. \bL FRONT FOG ~
LAMP L.H.
CI[8::Ot/B
CI[8::OR/B
~ B
\bL
J=
(Sub-harness)
~ ~
OR~B~
[8::ot/B
::IE
Ifr Ifr
@ii@)
m r '" ...,
(f)
~~
"'co '"
Ifr rr rr
co"'''' '"
BODY GROUND
'" r
r..,C/1
-<
0-c 3
2 c 3 4 5 6 7
IX
OFF ON
L HAZARD SWITCH
COMBI NATI ON FLASHER UNIT
COMBINATION
TURN R. H.
(D
-@ m@
r
",:;; ",,,,,,,,,,
. ~
~ .. ~ ..
:~3
TURN
L. H.
~'PH
, :e
@)
, r
'"
30
:J
~~~~~~~~
..
@ QD
~oW1@
,~,
G/B~
(Main harness)
f'i
~G/B~
.~,
(J
nstrument
harness)
m rI
@ii()
S.M.J.
[Refer to Iast page
c.n
@ill)
(Fa Idout
page). J
GEJ
~
E!81:;?;
rr ",,,,"'''' c..
IjIG~Y =EfI
~.
,,"
~
~
@
(Eng Ine harness) room
I~@ I~@
TURN TURN
";1
B J{:G/Y 't::J
. r
-ffi
~t:Y~
4J
0
B J{: G/B 't::J
LG/B G/Y G/B
Jj
- 1m
m
display braking system braking
@IV
jIG~B=EfI
. ~
@'
@: @: @: @' @'
Fast
Back
Coupe
With head-up display
-ffi ~
~IG:B~~
Without With
head-up
@)ii@) - en m r
BODY GROUND UI (X) 01 ~
anti-lock
Without
anti-lock
system
. .
Before checking, ensure that bulbs meet specifications. Connect a battery and test lamp to the combination flasher unit, as shown. Combination flasher unit is properly functioning if it blinks when power is supplied to the circuit.
---
Battery
SEL122E
)
Bulb Specifications
Item Headlamp (Sealed) Front clearance lamp Front turn signal lamp Front side marker lamp Rear side marker lamp Turn signal lamp Stop/Tail lamp Back-up lamp License plate lamp Wattage (W) 65/35 8 27
3.8 3.8
27 27/8 27
7.5 10 8 3.4 3 5 18
Interior lamp Spot lamp Trunk room lamp Foot well lamp Luggagecompartment lamp High-mounted stop lamp
EL-51
METER
BATTERY
UP
TIME
(Refer
CONTROL UNIT
to
I1TIME
CONTROL SYSTEMI1.)
\
1 2 3 4
".
r....
*
@
r FUSE BLOCK
ffiH31 ~M
"',,'" ,c:", r
III~@ @
X
5
@.
-<
~
R/Y R/L L
1'1'~
lD~*1
@)
R/y
~~
QD r ~
y.;j'
R/L L
(Sub-harness)
(Main harness)
m rI
n "''''
~@)
IR~L=83 ffi::=/L
1
""
'"
@)@
~@)
ii
@~
"'., 0... " -n
::: @ :;; BODY GROUND
r,
.~
rt
0
Unstrument
harnes~
~:
With
~:
*1
:
Witho
(J1 N
8
5 6 7 8 10 11 12 2S 26 27 28
~
~G/R
S6 PU
~:u 'THII
. CD0 ~
~
iD
@)
(IT)
i
"''''
Conn
displ
S6 PU
CASSETTE DECK
r",
C'11 "''''
(ill?)
- "'., ~ GD
" r",
R/L
g ~en
100
-<
~I
IDIDL
~
dBim W
X
'"0 ~ID
<g
@~ ~@ ~ ,
'" "'''' "
r-<
(Engine
room
h.cn.s~
'"
en m
G; 01 01
@D@@ BODY
-=- -
n ,
]
'" '"
'" '"
"''''
III'
~
rcn
r::I:
....
EffiJ@?) ~~ r-t
::I .... Z -t .... 0 z
@~ @~ @ @~ @ ~
HAZARD SWITCH
FRONT FOG LAMP SWI TCH PER REAR AND W SHER SWITCH
~ ~~
-t
LI GHTI NG SWITCH
GROUND
~~m~EI ~
SPO
:l I
UP, (Refer
FUSE
INTERIOR LAMP A
INTERIOR LAMP
BLOCK
@:@~ @:@;o;a
" ..'"
EH
w@ ,..,
:G "
tiS
:G
'" ..
, . S
(Ma In harness)
R/B R/W
m
I
r(J1 W
R.H. FOOT
LAMP
0 ~. ~
r.ct\ ~
f'Dt\ ~
R/B R/W
~ ~
~
!g)R/B-'1 R ={j
L. H. FOOT LAMP
@
I9I:D= R/W R/B
[
, '"
:G
~ ~
-c:IJ
~
@})
:gf)R/B-'1 R ={j
~0
DOOR SWI TCH
(Or I ver
!II m r CI CI
, '"
:G
Q@V
@~()
I
@l) 1 @])
(Y [ :~~ @:
@:
@: ~: ~:
s I de)
@
BODY GROUND
-=-=-
@
BODY-GRO~
.....
@:
s:
"BRAKE"
-~
0 )
20
11
17
14
16
30
12
24
I
ZI01/) ....>1-0::
@:
:J
Z 0 ....
Ii
m I Z Z C3 0 -I U 0 I u I-I w :J LL a:
:J:J -lei
Hl 1il2
I (!) ....
:.: u
gj I-
I-
gj
J
6 10 6 26
m I
18
15
6 28
6 7
6 19
1
25
i] g] ]
21 22 23
W I/)
] i]
] I]
9 27
-I I .... IZ 6 2
SEL577M
EL-54
CJ
[
10 0 0 03 21 10 0 0101
0
(j;)
(j;)
(j;)
8) (FUel~
~
Head-up display unit
10
1, 14
23
21
18
17 con *1:To
d-up display
I unit
@:
For
Ca I Iforn
I a
Y .
Z
0
@)
if if
)
W
u....,
*1
0 20
0 8
6 9
6 15
6 19
I
7
j
13
IZ uw
W(!J
:I<:
...: a::
gj
11
j
16
Ij
12
j
24
CD 5 SEL403L
EL-55
r---, Inn
I,u,-,
DISPLAY
I
~--j
HEAD-UP DISPLAY UNIT
METER
DIGITAL
COMBINATION
HEAD-UP ON-OFF
Dl SPLA Y SWITCH
II
FUSE
MPH
HEAD-UP CONTROL DISPLAY UNIT 6 2 3 8 9 II
km/h
5 1 7 4
To
}
Illumination
-=
SPEED SENSOR
SEL480L
EL-56
I GNITI ON SWITCH
ON or
G L
...
START
.~
@
R/B
@~~
-
BODY GROUND
(@Y @)
~ng a
"
FB
rness)
Ine room
Y/L
. (Main
Y/L
III
harness)
km/h
r-I
Y/B
HII
r'"
m rI C1'I
J . .
Y/B
",'" r ",...r
.....
@@~ -<-<
" r",
@) EHHEEB
(81 ack)
a:amm
WVh I te) 'H-<
(IT) EEEffiHB1
...
@~
",,,, r ",...r
:rm
ED::I "1(c ::1!II::I 01 !II 01 "1 ::10 00
(Jnstrument
harness)
. 3
w@])
(
ToE.
C. C. S.
control
III
unit
m r OJ OJ
IX)
SPEED SENSOR
To
I I lumlnatlon
control
system
[
COMBINATION I GNI TI ON SWITCH ON or START FUEL TANK GAUGE UNIT HEAD-UP DISPLAY
ME 12
17
*
UP
A
'" (Refer
, 1
I/DDI
~
@E)$ '"
,'" ,...
0h~
!9!!9!
HEAD-UP DISPLAY CONTROL UNIT
BODY GROUND
~@)
m m 0 0 :J: m -i m ::u
'" -u
-i
>c cm r m
C:J:
IS
19
~
@
~~
we
\'" ::0
~ @ ,...
~~~
m en
~ I @
(E.F. I. harness)
@@
CO
IW
3-Y/R
[!]
[Q]
~rm
,'
-< ,... '" ::0 '"
--nnn,
:
L/B Y/R Y/G
I I n__- m__mn--:lfI I
II
COIL
SPARK
(Ma i n
harness)
~ 1
Y/L Y/B Y/R Y/G G/L L/B
<Wh l
. 0
~;u
'"
,... ~"':e
,... ",'"
",::0
~C'D
i
te)
\
0?
Y/LY/B' Y/RY/GG/L' L/B'
"
0-..
Q~@
@'"
32-Y/G
'"
-(11 a., 0
<
(Q en'
1J ;I 1;;
-:I:
11@
(B lack)
GROUND
@tb
E. C. C. S
l{j@)
@)CtP
. 1J -I
(Q
(11
,...'"
"
-<-<
'"
~:
@h@TI)
!9!!9!
::-::-@ BODY GROUND Y/B
@:
m SYSTEMin'
b; EF&EC
m
. .
sect
ion,
~ ~
POWER TRANSISTOR
IGNITION
::-
J~
\
@I
RESISTOR
PLUG
::-
'\
SEL404L
Needle type
. @ and @:
@ and@:
~ ~
@ (Temp.)~
o.
@ (Temp.)
~
oo
2) Ignition relay
----------
E!) (Fuel)
O.K.
N.G.
~~
~
[Y] \tt:m:IU
CHECK GAUGE OPERATION. 1) Turn ignition switch "ON". 2) Connect terminals @ (Fuel). @ (Temp.) and ground with wire for less than 10 seconds. 3) Check operation of gauge. Gauge should move smoothly to full scale. O.K. N.G. Check harness continuity between component and combination meters @ (Fuel). @ (Temp.). O.K.
CHECK COMPONENT. Check gauge units and harness. Refer to "Fuel Tank Gauge Unit Check" or "Th~rmal Transmitter Check". O.K. Reinstall any part removed.
I .Y.
Repair or replace.
~
and @:
@ (Temp.)
Fuel gauge
INSPECTION
END
EL-59
~
*3
SEL407L
*2 *3
Resistance
of oil pressure
Continuity
NO
Engine stop
':' SEL748K
YES
Voltmeter
11 rId M
+ -
App<ox.05V
EL-60
Warning Lamps/Schematic
TIME CONTROL UNIT
I'
III -
E 41 +' In >In C! C
I'
.JI::
III t. .c C t. 0 -0
.JI::
BELT
ANTI-LOCK
I'
<.
uj
:j t. 0 u.
III "tJ tJ
0 ....
-I
+'
III
~ a ~
CHECK ENGINE
CL
CONTROL UNIT
t. 0 u.
t. 0 u.
.c. +'
I'
-.
..
-.
..
~ ~ ~ ~ OIL
I' OIL PRESSURE SWITCH II FUEL TANK GAUGE UNIT
@@@@
CONTROL UNIT
FUEL
WASHER I'
WASHER FLUID LEVEL SWITCH
1 I II
DOOR
DOOR
SWI TCH
COr iver
s Ide)
=
UI
'" :J U.
I'
side)
DOOR
SWITCH
<Passenger
BRAKE
I'
BRAKE
FLUID
LEVEL
.
SWITCH
.1
II
'"
PARKING UI
BRAKE SWITCH
:J U.
'"
=
BULB CHECK
I.
RELAY
CHARGE
ALTERNATOR
I'
SE L578M
EL-61
BULB
CHECK
RELAY
AUTOMATICSEAT BELT
(Refer to BF sect Ion. )
@)IWI
~I
B ~ = ~
":::~III:.
~
I~I
~
~
~
,III
~I
B @ ~~
~
"" ,m
en.."
~
I
ICI:I?PI
",
UP
,
en
~@
@@
Y/G R/W illl/R R/B W/R
W/R Y/W
R/W Y/pu
~~ ~
~I
G R
t
0 0 0
Y/G
..
PARKI
NG
(Me In harness)
Y/w
'1 ~ f'
Y/wY/GR/WL/R CM.: R/BW/R-
R/B
BO~Y-=-
~
~~ -=-
~
IT:rY/pu
r.Cr-R/L
(!!,
@ @
GROUND
m
N
WASHE~G
roI
en
WARNI LAMP
IGNITION
~
TART
I
~~
"0- G \0
S SWITCH ON or
h
B/R
-.. I~,~ ~~
-n.. 0 ...
Y/pu
r,
. 53 0
.. n ,..
~/~
R Y/pu
@)~@
-I>en g."
C<+' <+0;I "0 -L' enen::-en ;;;;;0111..
@
(6) l=.J ::rm 3~. I>:J OIl> OI ~., 0
~
Wj
FUSE
BR
:J
J
. "0
-..
~~ ~
~~~~
i~~! "
DOOR SWITCH I> ~/
[
f.ill\
\ KJ ~..
@ ~ 6
BODY
GROUND
;u
[( 11'1~1~"J~II9~I~~1
~ & & (Refer
-=P
~ :
~
III
()..
.
I>
[b :R~
rrn1
~ :R; ~
;U
,
.. ..
Y/W
~
FUSE (J n AND
..r
c:..
ILIJ
FUSIBLE LINK
FUSIBLE
@)
LINK
RELAY
BOX)
LEVEL SWITCH
~ ~
=
m@
~~
head-up
anti-lock
f]
@~
fi R To k
BODY GROUND
".@ n"
W/R
~ I" Q~ ~
@!V;u f?ri1 ;I)
0
l9
~
(E F h;'rn
g~~~ector
@
-mr en
;I)
WIth
With
~28~ND@ , WIthout
~jJ8
@'
r@J
~ ?i
;I)-=-
~ ~~
m
m r U1
.... ID s:
\ \
LI GHTI NG SWITCH
OFF 1ST 2ND A BCAB CA B C 5 6 7 B 9 10 11 12 2S 26 27 28 I lie Inl I I(
t@
I~I
r~
IDA
~@
'"
@f
'"
FUSE BLOCK "'~ (Refer to pPOWER \.\. SUPPL Y ROUTI NGp. ) ~'"
~I
~~0 m'
~R/L
G/R
KEY SWITCH
(Eng i ne harness)
room
m
I
~@V
r0) W
tl
~~~~
@D@
0
2 D2 H9
(Ma i n harness)
$E
$E
\.
$E$E
I I
II
$E
a::::IJ
o::::::IJ
.L1
I
FUSIBLE OJ
-< LINK
g@
I
0ii
=
DOOR SWITCH (Dr iver side) GROUND
BODY
CB[EE
FUSE
f/) m
Hr '" '"
I!I
..... 0
, en
s:
LINK
BATTERY
Diode Check
. .
.
SEL901F
Check continuity using an ohmmeter. Diode is functioning properly if test results are as shown in the figure at left.
\
Diodes for warning la~s meter printed circuit. are built into the combination
~JJl
Diode
SEL409L
EL-64
Schematic
(0
lJJ V)
::J LL
u (0 C (0 U L 0 LL
=
I U 1-1~o:: =:~ REAR WINDOW
To rear
window
defogger
I
--
:::(OQ) I')~ CE
C\I~ 'e+:;
L
Q)'t-
1-0
DEFOGGER R~LAY
--t
If'I
I')
>D
0
If'I
I'
I'
WARNING CHIME
0'
I>0:: W lI~
I.
.
I'
::J ...J
aJ
KEY
SWITCH
>D I LLUMI
NA TI ON
0 0::
Iz 0
U
lJJ I: I-
LI GHTI NG
(J LL. )
SWI TCH
C\J
I NTERMI
TTENT
WIPER VOLUME
I U I~Z
--t
I'
=:0 V)
L Zo 0 ~U I-U ~~ Z t!I
C\J
I')
lJJ V) ::J LL
L
FRONT WASHER MOTOR.
INTERMITTENT SWITCH
I'
~IO: ~
FRONT WIPER AMP.
I'
}TO front wiper motor
I'
SEL486L
EL-65
a
~
WARNI NG CHI ME
TIME
CONTROL UNIT
imWmI ~
@J)~.... ~ , '"
~@~
~
GH
T .
"'~
~ ~ ;0 OJ
AzI
@~ ~I
~
I
"'''' c
'"
~@ ""
g: ~
~ rri z
I
I~I
@
--i
ilia 3
TI
-.
C 3
i
1 1
4 5
I~I
" ... a OJ
OJ
27
28
Ii
@j)~
BODY GROUND
'-!.
cEtE
~
0
\
3'"R/l G/R
@})
(Eng
KEY SWITCH
r---l
02 F2 H9 812 Al1 811 AIO 810 012
page). J
R/l G/R Y/R PU P l/Y l G/8 8 lG
(Main harness)
m rI
~~
~~ c
en m
~Y/R
R/W
LINK
en
en
@) @
W
0
l p--.riTl G-'::j"JJ
@
WASHER FRONT MOTOR
~
I
Ii
@()
BODY
(Main harness)
, '"
~
R/W
1111~II1JJ~~D (BIackJ
~ ~8GRdJ
lE~8
8R
1
@'@ @'@
0
"'""
AND
1"'~"9@
(jnstrument harness)
~ ~:R~
FUSIBLE LINK
::j
ID-w @
[
@)Ii@)
8R
\G:'
lG/R PU
~ 8
~
-=III m r C11 OJ -.J
J
[
BODY GROUND
It
([ill)
FRONT WASHERW1:fR
.@
-< ""
eft
~ ,
~
'"
'"
~@
[liHE3ifI]
13
~
24 0---@---02 SEAT BELT
WARNING LAMP
I
" ~,
~,
3 ' 17 o---@---o
BATTERY
19
"YJ
@' @'
To front
wiper motor
COMBINATION
s:
_L
Time control
functions. Details of control Regulates intermittent time from approximately 3 to 12 seconds depending on the intermittent wiper volume setting.
Intermittent
wiper control
2 3
control
Wiper is operated in cojunction with washer switch. Regulates brightness of illumination in 16 stages depending on the illumination control switch setting. When driver's door is opened with ti9ht switch ON and ignition switch OFF, warning chime sounds. Seat-belt warning lamp blinks for about 7 seconds when ignition switch is turned to "ON" Sounds warning chime for about 7 seconds if ignition switch is turned "ON" when seat belt switch is "ON" (seat belt is unfastened).
OPERATING
CONDITIONS
,'
OOt/) tertrJifli31 t ter. trJ/fli31 CD
Power
source from battery
Light switch
Washer
Item
@
ON
@
ON
\@
(j) or @
Intermittent wiper
/
ON ON ON
@
(fJ)
ON ON ON
@
@ @
ON
ON
timer
ON
OFF or ACC ON
ON
*1 Door switch is turned ON when door is opened. *2 Seat belt switch is turned ON when driver's side seat belt is unfastened.
EL-67
Wiper and washer activate individually but not in combination Illumination Illumination control system does not actuate. Light warning chime does not activate. Seat belt warning chime does not activate. Warning Seat belt warning lamp does not go off nor come on. Ignition key warning chime does not activate. Rear defogger Rear defogger does not activate, or does not go off.
[it
9
PREPARATION FOR TROUBLE-SHOOTING 1. Remove driver's side dash side cover. 2. Remove time control unit with harness connected. POWER SUPPLY CIRCUIT CHECK 1. Connect ohmmeter from harness side. 2. Check continuity between terminal @ and body ground. ~
Ohmmeter terminals
Continuity
(+) SEL689L
(-)
Body ground
Yes
~
@'@~
SEL690L
terminals
(-)
Ignition
switch position
OFF
Approx. 12V OV OV
ACC
Approx. 12V OV Approx. 12V
ON
Approx. 12V Approx. 12V Approx. 12V /
@
@ @
@
@ @
EL-68
T.C.U. OUTPUT FOR WIPER RELAY CIRCUIT CHECK Measure voltage across CD and @. 8191101
1
1181i915<1
~ ~
~ ~
~
+
O.K.
Check T.C.U. output for wiper relay circuit.
[Y]
-
Ii)
CIRCUIT between
CHECK @ and @.
Ii)
N.G.
O.K.
Check harness between T.C.U. and wiper relay.
~oo
@ @
TifT
I w;p" ~;",h
"ONT"
O.K.
Check harness between T.C.U. and wiper switch
N.G.
Replace wiper switch.
SEL653L
@
#1kn
taJ
[Q]
~~
Approx 1kna;"L"
~@?]
Intermittent
Replace T.C.U.
EL-69
O.K. N.G. Check T.C.U. output for wiper motor. O.K. Replace T.C.U.
[
~oo
@
Approx.12V
m
Check T.C.U. output for light switch circuit. O.K.
Check IIIumi nati on circuit. Check for loose harness connector. Check harness betWeen T.C.U. and light switch.
Light switch
... ON
SEL648L
O.K.
[1100
[!]
kJ
IllUMINATION
SEL649L
CONTROL CIRCUIT
CHECK
1E5L---,
III 00
@@
[aJ
[ill
+ on Excep. on
EL- 70
O.K.
N.G.
Go to "PowerSupply Check". Circuit Check harness for T.C.U. power supply circuit.
O.K.
Go to "T.C.U. output for light switch circuit check". (Refer to back page.) O.K.
Replace T.C.U.
T.C.U. OUTPUT FOR CHIME CIRCUIT CHECK Measure voltage across (j]) and @ when driver's door is opened and closed.
DIAGNOSTIC
PROCEDURE-6
~oo
@
@ . Approx.12Vwhen Light switch ... 1ST driver's side door is closed. . Voltmeter needle swings (0 -12V) when driver's
f\Tl LY'.J + -
SEAT BELT SWITCHCIRCUIT CHECK 1. Unfasten driver's seat belt. 2. Check continuity between (j]) and @. 3. Fasten driver's seat belt. 4. Check to determine if continuity does not exist between (j]) and@.
W
[ill
+ -
. ~oo
SEL643L
EL-71
DIAGNOSTIC
PROCEDURE-7
Seat belt warning lamp does not go off nor comes on. Go to "Power Supply Circuit Check". 1 O.K.
SEL651L
~oo
@
N.G.
~ooJ il~
N.G.
Check T.C.U. oUtpUtfor belt warning lamp circuit. Voltmeter needle keeps sWinging (approx. 0 +-+ 12V) for about 7 seconds after ignition switch is turned ON. 1 O.K. Check warning lamp, and harness between T.C.U. and warning lamp.
Replace T.C.U.
EL-72
(Cont'd)
DIAGNOSTIC
PROCEDURE-8
~oo
w
.
DRIVER'S Check continuity
O.K.
Check key switcQ circuit~
k I Checkey
. O.K.,
switch or harness.
O.K.
Check T.C.U. output for chime circuit. N.G. Check driver's door switch circuit. N.G ' .~ Check harness between T.C.U. . and seat belt switch.
Check chime and harness between T.C.U. and chime.
Approx. 12Vwhen
SEL639L
O.K.
~oo
Replace T.C.U.
LaJ
Driver's side door KEY SWITCH CIRCUIT Measure voltage across CHECK
... Open
SEL640L
@ and@.
[it
@
laJ
@-~
'A
SEL641L
EL-73
(Co nt' d)
DIAGNOSTIC PROCEQURE-9 Rear defogger does not activate, or does not go off. Go to "Power Supply Circuit Check". N.G. Check harness for T.C.U. power supply circuit.
00
switch
~
Rear defogger
lNJ
[Y]
+ -
ON
N.G.
[ilOO
0 @.
Rear defogger switch "OFF": Except on Rear defogger switch "TIMER": on
I
O.K.
"f'
Check defogger switch, and harness between T.C.U. and defogger switch.
Replace T.C.U.
~d- j
SEL645L
-,
EL-74
~: ~:
With
anti-lockbraking system
Cill:@
~
~
I
WIPER UP
LG L
@:@I~I
J
(MaIn harness)
~
WIPER
/
S. M.J.
m rI
.r -=
(Eng I ne harness) LG OR
room
ffiefer to last page (Fo I dout page). J LG/B LG PU PAIl B L/Y AI0 012 BI2 BIO BII LG/B LG PU P B L/Y
..... UI
~
M ~
@
~LG ~ P
LG~B LG/R
i i
@])@
WIPER ([@)
BR LG/B L/Y
WASHER
, L
AND
MOTOR WASHER
LGfR
PU
I
[]
14 0
IS 16 17 18
19
c c
,....
i'
1 0
20
111
en m r
@)@@)
BODY GROUND
U1 OJ OJ
s:
REAR WIPER
AMP.
*
, ~
r-
UP
IDA
[;]
@
~~
FUSE BLOCK
(Main harness)
@ill)
L/W
(Back
L/W harness)
door
@
L~W
m rI
L/W
I::"l
L/W
.....
en
(Eng I ne harness)
room
LG/B~LG/B
(Main harness)
B -B.3 ffi~@
:[
2 3 ~ 4
Lg~R
@@
" ~...
rr-",
'
L/R R/Y
LGB"B R/LI
le.~ ~
~@
L
(/)
m r a>
"
~
';
..
Before removing front wiper motor link, turn wiper switch OFF and disconnect motor leads at connectors. 1. Remove wiper ,arm. 2. Remove cowl cover. 3. Remove bolts which secure wiper motor. , 4. Extract wiper motor so that wiper motor link comes out of hole in front cowl top panel. Then, pull motor straight;out to disconnect ball joint which connects motor link and wiper link. Wiper motor can then be removed. SEL411L 5. Remove wiper link pivot blocks on driver and passenger sides. 6. Extract wiper link and pivot blocks (as one unit) from oblong hole on left side of cowl top.
~
r
FRONT WIPER INSTAllATION Cowltop front panel 1. Position wiper link and pivot blocks (as one unit) in cowl top through oblong hole. 2. Before installing pivot blocks on cowl top, hold end (motor link side) of wiper link at hole in front cowl top panel and insert motor link's ball pin into hole in wiper link. 3. Install front wiper in reverse order of above removal procedures. Apply a small amount of grease to ball joints before installation.
~
.:. /'
,\
~
""
Insert securely.
SEL412L
EL- 77
-"-"~
1. Prior to wiper arm installation, turn on wiper switch to operate wiper motor and then turn it "OFF" (Auto Stop). 2. Lift the blade up and then set it down onto glass surface to set the blade center to clearance "L1" & "L2" immediately before tightening nut. 3. Eject washer fluid. Turn on wiper switch to operate wiper motor and then turn it "OFF". 4. Ensure that wiper blades stop within clearance "L1" & "L2". Clearance "L/': 17.5 - 32.5 mm (0.689 - 1.280 in) Clearance "L2": 25 35 mm (0.98 - 1.38 in) Tighten wiper arm nuts to specified torque. Front wiper: 17 - 23 N.m (1.7 - 2.3 kg-m, 12 - 17 ft-Ib) Rear wiper: 13 - 18 N.m (1.3 - 1.8 kg-m, 9 - 13 ft-Ib)
50 (1.971 28 (1.101 43 (1.691 21 (0.831 144 (5.671 155 (6.101 273 (10.751 385 (15.161
0
Clearance "L,"
Clearance"
rt
L1"
~
~
Unit: mm (in)
* All the diameters of these circles are less than 80 (3.151.
*7
'8
Glass end
SEL425L
93 85 38 25
Nozz~e1~b
Unit: mm {inl
SEL414L
EL- 78
SEL415L . Before reinstalling wiper arm, clean up the pivot area as illustrated. This will reduce possibility of wiper arm looseness.
SEL024J
This will prevent "rounding out" the small female square in the center of the nozzle.
SEL117K
Check Valve
reservoir
':;0
F'om
.
c~ ".I~ ..
~ D";'e
SEL411H
EL- 79
To
A check valve is provided in the washer fluid line. Be careful not to connect check valve to washer tube in the wrong dir~ction.
~~
:4;
SEL6S1 I
EL-80
~
HORN RELAY
~
.
- -: :
~
LlGHTER
CIGARETTE
I GNI TI AC
RES~ME/ACCEL
~ @~
"'''''''
SLl
RI NG
~
P
'
I
~
~~~~~~~
HORN
:, :
+t=
4
= 0 SWITCH
0
. (3
SET/COAST
SWI TCH
. .
,
(
fl
@~
III 0 :oJ
III
2
I
I
- n .~
~=SWITCH -
P0
, :E
'"
,.
,, :E'III
en
(Ma In
harness)
@: :oJ
III
III
HORN- HIGH
@: ~: ~:
m rI 00
~
rr\--.@)
~[D-G -=
(Eng Ine room harness)
@
rJoIhite)
III
EEHHE:EJ EHffiIrn @)
ii
[D- G
LOW
ii
@)
GROUND
@~I
~
III
~QD :oJ
(Black)
rr\--. ~@)
HORN-
@J) @~
BODY
.~
'"
'
:E
, III
'"
, :E
:E
Q0
HORN
SWITCH
FUSE
o=:::IJo::::IJ
'" III
g@)
II
[
en m r 0> .... "-I
s= <In
:oJ
'" '"
FUSIBLE
t
BATTERY
UP
*
FUSE BLOCK (Refer to "POWER SUPPLY ROUTING".)
A
I
r rr
@
Ii1
~@
Ii1 r
'rli1 ;0
,r' -<;0
[[J-L/R
L/R-cD
()
@ill)
m rco
I
~
-=
CO
@
(Ma in harness)
~
CP)L/R-cD
J~~n~~~ym~~~i~~n -=
\
CONDENSER
(1@
'IDID'"
;o;or
1 2 3
OFFON 0 0
@~(
!II m r
BODY GROUND
X (P
4 5 X (
6
'" -.I W
~
BODY
I-]
Filament Check
1. Attach probe circuit tester (in volt range) to middle portion of each filament.
SE L263
[-J
SEL264
~
0 volts
[+]
r'n
r/
Burned-out point
SE L265
3. To locate burned out point, move probe to left and right along filament to determine point where tester needle swings abruptly.
~
(VI S E L266
EL-83
Heat wire
Drawing
pen
Unit:
mm (in) BE540
REPAIRING PROCEDURE 1. Wiper broken heat wire and its surrounding area clean with . a cloth dampened in alcohol. 2. Apply a small amount of conductive silver composition to tip of drawing pen. Shake silver composition container before use. 3. Place ruler on glass along broken line. Deposit conductive silver composition on break with drawing pen. Slightly overlap existing heat wire on both sides [preferably 5 mm (0.20 in)] of the break. 4. After repair has been completed, check repaired wire for continuity. This check should be conducted 10 minutes after silver composition is deposited. Do not touch repaired area while test is bei",gconducted.
Repaired
point
~
[0
@
SEL012D
Repaired
point
5. Apply a constant stream of hot air directly to the repaired area for approximately 20 minutes with a heat gun. A minimum distance of 3 cm (1.2 in) should be kept between repaired area and hot air outlet. If a heat gun is not available, let the repaired area dry for 24 hours.
SE L013D
EL-84
DECK
DIN CODE
,UP
FUSE BLOCK (Refer to "POWER SUPPLY ROUTING".)
*
,...
:0
0-c
~
.... "",... III""
I~
:J
@1Mll~@
:0.. .. ~""""" ~>,... ~ ~~~:o""""'" RD
@~
:0
" -<
~@ @1Mll~@
" ..
(Main harness)
m r-
co
c.n
@: @): @: @:
only
type deck type type MJII ..,...,,:;; -<:IE eM: .. ..,...:;; :IE
speaker
@)ii@JJ
BODY GROUND
@)
@
III""":;; -<:IE
@ @D
rnl 11>'1 III III"":;; :IE (Ai @ill) mBR/W~ U BR ~ @ill)
@
DOOR
L/W m'
L. H. SPEAKER
[D=ru
tl.j~L/Y1
'
DOOR SPEAKER
L. H.
en m r 01 .... ~ ~
~I
AMP.. UNIT
@
0
DOOR
SPEAKER R ~
L/W L/Y
LG
i
LG
.:1
BR/W
BR
I~
o.
AMP. UNI T
L
~~
Loosen~~
~2N~
~ ~ ,-( \\
~1 \ \ \ \ \ \ \
--
J
SEL416L
\ \ \ \ \ \ )f/~.
r[~
Radio (For AM/FM electronic tuning)
\ ~
EL-86
Ohmmeter
[TI
@
SEL2501
Ohmmeter
[TI
No continuity
@. ---'
SEL251\
Continuity
exist
SEL2521
3. To locate broken point, move probe to left and right along element to determine point where tester needle swings abruptly.
Ohmmeter
[TI
@
SEL2531
EL-87
FUSE
FUSE
-@
A. s. C. D. SWI
I
TCH
OFFI
A. S. C. D. STEERING
I
N ON
SWITCH
I
=
To horn
RESUME/ACCEL
SWITCH
A. S.
C. D.
HOLD RELAY
-=-=-
A. S. C. D.
A.
S.
C.
D.
rI
co co
7 13
~ ~ ~ ~ 12
2
CONTROL
11
4
I
CANCEL SWITCH
I I
CLUTCH SWITCH
UNIT
10
5 9 8 -r-'
0 ;0 c Ct1 m
To
i I Iu
A. S. C. D. ACTUATOR
control
--i ~
a z
~
-=-
-=-
SPEED SENSOR
To
rJ)
-=-
i IlumlnatiOn
-=[
control
system
m r
0, A/T @' M/T @), With @), Witho @' With syst @' Witho syst
I 0 >-->--
-", ,>-", P
P", c >-
"'"'
C C1
'" C
+' C1
COMBINATIONMETER
1_~~
~.. Z CJ
@@
HEAD-UP
CONTROL UNI
01SPLA Y
T
10 ILL
~
~
CRUI SE
3
ILL
II
20
.1 (LIQUID CRYSTAL>
ILL.
~
(LIQUID
CRUI SE
'
. CRYSTAL>
ILL.
I~I
@~
.", ~ "~~m :i ~~
m~
~~~--~
~
~ ~ ~ ~ m ~,,~ ~
~
@,
m" m
0~ ,
~~-
@
'-a.
~-
>'"
~Til- lid
.
(J
U U
v v '"
n
U I V U .c
is
., " .,
:J
V +-'
nstrument
harness)
@~!
~~~~
, ,
bIIII
(White)
0
::;
(Black)
~ ~ rrr
>-- >-- P P
J ~~ ~
"
U 111'4 b II E:j
@@@@
Y/G
@~I,~II,II~
:i:ild,,~~
~m
~111,d~IIE:j
m
---------
~
.
I ) "
r
-r O/B---o'"
G/W G/R
R/G
z <>
W
~ . N .
I,
0 0 U;
@ ,G/L--{'k
O/B--o..
II
.
'--A, SWI
@
0
Y/G
G/W
R/G
G/R
..J
W
I'
>--
I<
'
>--
~
V)
ti
I
~ ' ~~~~;::,~~
;;::
WI..JI OI LO UJO 00
>--
I 0
11
~ ~ @
. .
S, C, 0, T CH
CLUTCH
A,
S, C. 0,
U CANCEL SWITCH
Q
Ai:
u; "' v C L '" r
u: !!!
@~ffi
UJ:;:..:;: UJ:;:0:;:
~
d
..
~
,
L .~
t
[;!J
"'~O~V)r~
~
' " ,: -
~.
~ ~
~~I
@)
'~I' '-~I'
~ffim~
Ln.'
~G/OR
G/Y
@m " """
@ @
G/W
SLI P RING
UB. G/OR G/Y-
O..J
o~ ~~~ O:::J
>-~
[1]
5
..J '
~~~:
G/R-
('<i) a @ \:::)
Y/' Y/L
50
Y/L
L/WG/LY G/W-
='
8
'= Y/'
@
(.;) ~
l
W
~~
B~
L-
~~! '-"'''
..~
(j
I
\;,;;!
@
Y G/W1< 0 u;
@ ~@)~
.~::~ @
~
0
OJ
A U
...J '" 000
~UJv) IUJZ UJQ.UJ > V) V)
<
SE L590M
EL-89
f".-
.~r
~
CAUTION:
-SEL419L
. .
Be careful not to twist A.S.C.D. wire when removing it. Do not tense A.S.C.D. wire excessively during adjustment.
After confirming that accelerator wire is properly adjusted, adjust the tension of A.S.C.D. wire in the following manner. (1) After adjusting the length of the accelerator wire, turn a securing nut by 1/2 to 1 turn from throttle open starting position to the wire loosening direction to fix. (Must be securing carried out to prevent response delay of operation of the A.S.CD.) (2) Securely tighten lock nut to hold adjusting nut in place. For A.S.C.D. stop switch and clutch switch adjustment, refer to SR and CL sections.
EL-90
Trouble Diagnoses
Symptom A.S.C.D. control unit cannot be set properly. Resume switch will not operate. Cancel switch will not operate. Engine hunts. Large difference between set vehicle speed and actual speed. Set speed cannot be cancelled. 8 When A.S.C.D. is set while vehicle is operating in "0.0." range, 0.0. will be cancelled and shifting to 0.0. cannot be made thereafter. 8 0.0. will not be cancelled even if actual vehicle speed is 6 km/h (4 MPH) lower than set speed. (Set speed cannot be ,maintained.) 8 0.0. will not be cancelled even if accelerator switch is turned "ON". DIAGNOSTIC PROCEDURE 1 2 3 4 5 6
PREPARATION FOR TROUBLE-SHOOTING 1. Remove R.H. dash side cover. 2. Remove A.S.C.D. control unit with harness connected. 3. Perform check from harness side using circuit tester, with harness connector connected.
A.S.C.D. control
unit
Q)I
~
SEL418L
CID
EL-91
~oo
Approx. (4) @ 12V
[Y]
Voltmeter CUT-OFF CIRCUIT CHECK 1. Step on brake pedal. 2. Turn A.S.C.D. main switch to "ON". . 3. Check voltage between (j]) and CID
N.G.
O.K.
Check AS.C.D. cancel switch, clutch switch (M/T model), inhibitor relay and inhibitor switch (A/T model).
[ilOO
:11
Approx. 12V
Brake pedal
Step on.
O.K.
Check speed sensor circuit.
SET SWITCH CIRCUIT CHECK 1. Push A.S.C.D. set switch. 2. Check voltage between @ and CID .
O.K.
Check speed sensor and harness betWeen A.S.C.D. control unit and speed sensor signal output terminal of combination meter.
Approx.
[iI@a
Replace actuator.
l5J
Voltmeter SPEED SENSOR CIRCUIT CHECK 1. Disconnect speed sensor from transmission. 2. Connect a voltmeter between (j) and CID . 3. Slowly turn speed sensor by hand to make sure voltmeter pointer deflects. . Voltmeter pointer deflects twice per rotation of pinion.
~@a
J~\ Lfi-J
Voltmeter Approx.O.5V
SEL630L
EL-92
DIAGNOSTIC
PROCEDURE-2 N.G.
rilOO
Q)
1
::~rox. @
lilJ
[YJ
+ Voltmeter
Resume-switch
- ON
SEL636L
/
CANCEL SWITCH CIRCUIT CHECK 1. Turn cancel switch to "ON". 2. Check voltage between @ and @ or CD and @ .
DIAGNOSTIC
PROCEDURE-3
riI~
Q)or@ Approx.
Cancel switch
- ON
Voltmeter
~~~
j
SEL637L
EL-93
PROCEDURE-4
O.K. Does A.S.C.D.wire move smoothly? O.K. Go to "Actuator Check". O.K. Replace A.S.C.D. control unit. N.G. [ Replace actuator. Repair or replace wire.
DIAGNOSTIC
PROCEDURE-5
/
Replace wire or actuator.
N.G.
O.K.
Check vacuum hose for breakage, cracks or fracture. Repair or replace hose.
O.K.
Go to "Actuator Check".
I~
I~
Replace actuator.
O.K.
Replace A.S.C.D. control unit.
EL-94
DIAGNOSTIC
PROCEDURE-6
CID
~
@
~oo
3 Brake pedal-> Step on. Clutch pedal (M/T)-> Step on. AfT control-> "N" range lever (A/T)
CHECK
CID
OV
[JZJ + -
Voltmeter
Replace actuator.
~
Approx. 12V
[JZJ
Voltmeter SEL631L
O.D. CANCEL CIRCUIT CHECK FOR A.S.C.D. CONTROL UNIT 1. Turn 0.0. control switch to "ON"
2. MeasurevOltageacross @ and
CID
. . .
When A.S.C.D. is set while vehicle is operating in "O.D." range, O.D. will be cancelled and shifting to O.D. cannot be made thereafter. O.D. will not be cancelled even if actual vehicle speed is 6 kmfh (4 MPH) lower than set speed. (Set speed cannot be maintained.) O.D. will not be cancelled even if accelerator switch is turned "ON". N.G. Check harness betWeen0.0. cancel solenoid, 0.0. control switch and A.S.C.O. control unit.
0.0. control
switch -> ON
O.K.
Voltmeter SEL640M
EL-95
Actuator Check
~
234
'~~ [ill
+
-1'0
DISCONNECT
18
1. Disconnect connector of actuator from main harness. 2. Check actuator operations as shown.
Check actuator.
~
~
'\
/ \ /J
m
SEL423L CD
O.K.
N.G.
Replace actuator.
and @. O.K.
~
SE L691 L
Ii)
Check to see if A.S.C.D. wire is pulled when 12V D.C. is applied and @ . across CD. CV.:ID
N.G.
Replace actuator.
[!)
I;)
~ I
N.G.
!
Replace actuator.
1/
(;]
~
SEL692L
[!)
~
SEL693L
(;]
~
SE L694L
EL-96
~
[AJ
FRONT
Accessory relay-2 (Blue) A.S.C.D. hold relay (Blue) Air conditioner relay
[eJ
(Canada: Blue )
(
U.S.A.:
BrOwn
~ ~";'
f?' ,/
Fuse block
Headlamp
/~
'
I ~ "/
'~
~
relay-1
SEL420L
EL-97
Passenger Compartment
Accessory relay-1 (Blue)
Circuit breaker Ignition relay With power window: Brown Without power window: Blue) Bulb check relay (Blue) Rear window defogger relay (Black) S.M.J.
\I
Combination flasher unit Chime Headlamp timer Time control unit A.S.C.D. cancel switch Stop lamp switch Shift lock control unit Automatic seat belt control unit
SEL421L
EL-98
Instrument harness
\
Engine room harness no. 2
E.F.I. harness.
SEL496L
Coupe
EL-99
HARNESS LAYOUT
Main Harness
EL-100
@
@ @ @ @ @ @ @ @ @) @ @ @ @ @ @ @ @ @ @ @ @ @ @ @) @ @ @ @ @ @ @ @ @ en m r UI CD ~
s:
@ @ @ @ @) @ @ @ @ @ @
m rI ~
0
~
: Time control unit : Headlamptimer : Check connector : Warningchime : Fuse block : Accessoryrelay-' : Circuit breaker (Modelwith power window system) : Circuit breaker (For U.S.A.I : Ignition relay (Modelwith power window system) : Ignition relay (Modelwithout power window system) : To engine room harness 0 : To engine room harness (Blue) : To engine room harness ([ill) (Black) : Bulb check relay : Rear window defoggerrelay : A.S.C.D.clutch switch (M/T model with A.S.C.D.I : To door harness L.H. @) : To door harness L.H. @ : Drillerside front limit switch (For U.S.A.) : Kickdownswitch (A/T model) : A.S.C.D.cancel switch (Modelwith A.S.C.D.I : Stop lamp switch : A.S.C.D.main switch (Modelwith A.S.C.D.I : Headlampretractor switch : Illuminationcontrol switch : Front fog lamp switch : Shift lock control unit (A/T model) : Combination flasher unit : Modedoor motor : Foot lamp L.H. : O.D. off indicator lamp (A/T model) : Rear wiper and washer switch : Rear window defoggerswitch : Hazard switch : Radio : Radio : Cassettedeck : Cassettedeck : Push control unit : Fan switch : Diode : To sub-harness @ : To main harness @ : Glovebox lamp : Glovebox lamp switch
@ @ @) @ @ @ @ @ @ @ @ @ @ @) @ @
: : : : : : : : : : : : : : : :
To instrument harness @ (Black) To instrument harness @(White) Thermo control amplifier Heater resistor Blowermotor Foot lamp R.H. To E.F.I. harness @ To door harness R.H. @ill) To door harness R.H. @ill) To room lamp harness @ Body ground Intake door motor To sub-harness @ To main harness @ Door lock timer Washerwarninglamp (Modelwith Anti-lock Brak
Diode
@
Lighting switch
~
~
I
L-
Retractor re Headlamp ti
Lighting swi
Brake warning lamp Brake fluid level switch Parking brake switch Seat belt warning lamp
r
~
Time control
L-
Seat belt sw
Bodyro""~ g
m rI
...a
0 N
: : : : : : : : : : : : : : : :
Body ground Lap belt buckle switch (For U.S.A.) Seat belt switch (For Canada) Ash tray illumination Cigarette lighter Door mirror control switch Automatic seat belt control unit (For U.S.A.) Parking brake switch AfT device (AfT illumination and O.D. control switch) (AfT model) Shift lock solenoid (AfT model) Door switch L.H. Automatic seat belt motor assembly L.H. (For U.S.A.) Body ground (For U.s.A.) Body ground Rear speaker L.H. Rear side marker lamp L.H. Rear combination lamp L.H.
m rI
Rear combination lamp L.H. Back-uplamp L.H. Rear wiper amplifier Licenselamp L.H. Licenselamp R.H. Body ground Luggageroom lamp switch Back-uplamp R.H. Luggageroom lamp Rearcombination lamp R.H. Rear combination lamp R.H. Rear side marker lamp R.H. Fuel tank gaugeunit Rear speaker R.H. To back door harness @ill) To back door harness ~ To back door harness @ Automatic seat belt motor assembly R. Door switch R.H. A.B.S.control unit (For Anti-lock Brak Body ground (For Anti-lock BrakingSy Rear sensor (For Anti-lock BrakingSys
...a
0
Co\)
~
C/J m
r-
U1 II) 0
s:
rI
...\ 0 ~
--
@:
~ ~
@B) :
Body ground Lap belt buckle switch (For U.S.A.) Seat belt switch (For Canada) Ash tray illumination Cigarette lighter Door mirror control switch Automatic seat belt control unit (For U.S.A.) Parking brake switch AfT device (AfT illumination and a.D. control switch) (AfT model) Shift lock solenoid (AfT model) Door switch L.H. Automatic seat belt motor assembly L.H. (For U.S.A) Body ground (For U.S.A.) Body ground Rear speaker L.H.
~ ~
Rear side marker lamp L.H. Licenselamp L.H. Licenselamp R.H. Body ground Rear side marker lamp R.H. Fuel tank gaugeunit Rear speaker R.H. Automatic seat belt motor assembly Door switch R.H. Trunk room lamp switch Trunk room lamp High-mountedstop lamp Rear window defogger Rear combination lamp L.H. Rear combination lamp R.H. Not used
m
~
,... I
0
U'I
en m r
(II 00
--------
s:
HARNESS LAYOUT
Instrument Harness
CID : To main harness @ (Black) @ : To main harness @ (White) @ : Head-updisplaycontrol unit
@: @: @:
Combination meter (Model with head-up display) Combination meter (Model without head-up display) Combi nation meter (Model with head-up display)
QD :
@
Combination meter (Model without head-up display) : Combination meter (Model without head-up display)
SE L501 L
EL-106
EL-107
HARNESS LAYOUT
'U C ::I 0
.. 01
>
'U 0 ID
EL-108
@
@
@
@ @ @
.
: : : : : :
Windshield wiper motor A.S.C.D. actuator (Model without Anti-lock Braking System) Rear washer motor Front washer motor Washer fluid level switch To E.F.I. harness @ (White) To engine room harness no. 2 (@D (MfT model) Inhibitor switch (AfT model) Revolution sensor (AfT model) Inhibitor switch (AfT model) (Gray) To solenoid valve sub-harness (AfT model) (Brown)
@
@
@ @
@D @) @ @ @ @
m rI
~
Low.pressureswitch Battery .Battery Bodyground Clutch interlock relay (MfTmodel for U.S.A.) Front side marker lamp R.H.
@ @ @) @ @ @ @ @': @ @ @ @ @ @ @ @ @ @ @
: : : : : : : : : : : : : : : : :
To front fog lamp sub-harness@ HeattlampR.H. Headlamp motor R.H. Front combination lamp R.H. Horn-high Condenserfan motor Horn-low Headlamp motor L.H. Headlamp L.H. Front combination lamp L.H. Front side marker lamp L.H. Body ground Relay box (Refer to page EL~7.1 Dropping resistor (AfT model.) Compressor A.I.V. control solenoidvalve Brake fluid levelswitch Windshieldwiper amplifier (Modelwithout A
@ @
@ @ @) @ @
0 CD
: : : : :
Front wheel sensor L.H.(For Anti-lock Bra Body ground (For Anti-lock BrakingSystem Actuator (For Anti-lock BrakingSystem) Windshieldwiper amplifier (Modelwith Ant A.S.C.D.actuator (Modelwith Anti-lock Br
en m r UI (XI
I\)
m r..a ..a 0
I
~~
~
@)
1t.7ii'\
"'P
(@j)
E112 El11
0 0
: : : To main harness @ To main harness @ (Blue) To main harness @ (Black) Clutch switch (M/T model for U.S.AJ Key lock solenoid (AfT model) Key switch ([8)
0 0 B
(fJ m
@j) : @3) :
0 ~
r~
UI CD N
0: @
0
@Y
@ @ @
Body ground
(MfT mo
: To engine
m r@) : @ : @ : @ : @) : @ : @ : @ : @ : @ : @ : @) : @) : @ : @ : @ : @) : @ : @ : @ : @ : @ :
@ @
;:
en m r UI co W
A.A.C.va Injector n Air regula Injector n Pressurere S.C.V. con Exhaust g Injector n Injector no Enginegro Crank ang Enginetem Thermal tr Throttle v Throttle se E.G.R. con Air flow m Resistor Condenser Ignition co Power tran Front whe
m rI
...a ...a
@D : To engine room harness @D (M/T model! ~ : To engine room harness @ ~ : To engine room harness @ @! : To engine room harness @ : Battery @) : Power steering oil pressure switch @V : Alternator : Oil pressure switch @J : Starter motor @!9 : Exhaust gas temperature sensor @ : Vehicle speed sensor : Back-up lamp switch (M/T model!
~
~
~
en m r
01 0 ....
HARNESS LAYOUT
: : : : : : @ : @D : ~ : @ill) :
~ ~
@D (Qlli) @ill) ~
To main harness @ill) To main harness ~ To main harness @E) Rear window defogger High-mounted stop lamp To rear wiper sub-harness @D (White) (Brown) To rear wiper sub-harness To back door harness ~ (White) To back door harness @ (Brown) Rear window wiper motor
SEL505L
EL-113
Body ground
m rI
-' -' ~
In m r
U1 0 ~ r
Room @ : @) : @ : @ : (~ : @ : @ :
lamp harness To main harness @ To sun roof harness @ Spot lamp (Model with sun roof) Interior lamp (Model without sun roof) Interior lamp (Fastback with sun rootl Interior lamp (Coupe with sun roof) Automatic seat belt front limit switch (For U.S.A.)
Sun ro : @ : @ : @ : @ : @ : @ : @ :
@ @
@)
@ @ @ @ @D
: : ; : :
Power window main switch Power window amplifier Door lock actuator Door lock switch Door latch switch (For U.S.A.)
SEL503L
R.H.
~8 .@ill)~
@B
@) @) : To main harness @ : To main harness @ : Door speaker (Active speaker type) : Door speaker (Standard speaker type) : Door mirror motor
0
: : .~ : @:IV : @IV : @
8 ~
Power window regulator Power window sub switch Door lock actuator Door lock switch Door latch switch (For U.S.A.)
SEL504L
EL-115
HARNESS LAYOUT
NOTE
j
l, ~
r
l , I
, ~ r
I
I
EL-116
. .
S.M.J. is located on left side of dash. To disconnect S.M.J., loosen fixing bolt.
To install S.M.J., tighten bolts until orange "full-tight" mark appears and then retighten to specified torque as required. ~: 3 - 5 N.m (0.3 - 0.5 kg-m, 2.2 - 3.6 ft-Ib) CAUTION: Do not overtighten bolts, otherwise, they may be damaged.
S.M.J.
SEL422L
EL-117
HARNESS
/
AlA2A3 AS A4 A6 A7 A9 11 A8 AliA A12
BIB2B3B4BsB6 CIC2C3C4CsC6 01 02 El E2 Fl F2 Gl G 2G3G4 G6 Gs HIH21H3 HsH6 H4 11121314IS16 B7B8B9BID B12 B 11 C7C8C9CID C12 C 11
011 012
LJ
Ell E12
F11 F12
~
~
ENGINE ROOM HARNESS
[11
View from harness side
EL-118
;&
OUiCKREFERENCE CHART:24081
/
I 1989
'
I,'FRONT WH-EEL BEARING---Wheel bearing lock nut Tightening torque N.m (kg-m, ft-Ib) mmtinl ,. 147 - 216 (15 . 22, 108 - 159) 0.03 (0:00121 or less Wheel bearing end pray
KA24E 1.3-4-2 750tSO 750tSO 15'2 Idle mixtUre screw is preset and sealed at facto,:\" .", Non-adjustable Less than 30 ZFR5D-11 ZFR4D-11 cl
IREARWHEELALIGNMENT (Unladen.)
Camber Toe-in ': degree mmtinl degree -136' to -036' 0.5 - 4.5 (0.020 - 0.177) 1.5'.12.5'
.
I
,
; High tension
,; Spark plug Type
.
Set dellection of new belt
Tankful of fuel, rediator coolant and engine oil full. Spare tire, jack, hand tools, and mats in designated positions.
I Gap
..
Alternator Air conditioner compressor Power It;'ering pump '
.'
., if
I,
~
Unit: mm tinl "i
dellection 7.8 (0.28 . 0.31) 7,,8 (0.28 - 0.311 8.9 (0.31 . 0.35) 98 (10, 22) kg.m 2.0.3.0
I .,
6.7 (0.24 . 0.28) 6.7 (0.24.0.281 7.8 (0.28 . 0.311 ft.lb 14,.22 22.29
I
)' I, N (kg,lb,!'
BRAKE"
Disc brake Pad repair limit Rotor thickness ..I!'pairlimit Pedal free height MIT model AIT model Pedal depressed height' 1 Front side Rear side . 2.0 (0.019! 18.0 (0.709) 8.0 (0.315) 177. 187 (6.97 - 7.36) . 186 - 196 (7.32 -7.721 / 100 (3.841or more
{ Tightening torque
<
3.0.4.0
,j
,,'.,( I'CLUTCHPE"AL ~
. 1''Ped~!."e~ .I' Pedal free play
186
Unit:
mm (in I
- 196
Parking brake Number of notches'2 '1: Under foree of 490 N (50 kg, 110 Ib) with engine running '2: At pulling force: 196 N (20 kg, 44lb)
6-8
1- 3 (0.04-
REFILL CAPACIT'ES,.'
Unit Engine model Fuel tank Coolant
Engine With reservoir tank With oil filter
600' -730'
0.3 - 2.3 (0.012 - 0.091) l' - 6.5' (Total toe-inl
KA24E 60 6.7 3.&'3.2 2.4 8.3 1.3 0.9 Refrigerant 0.9 - 1.0 kg 15-7/8 gal 7-1/8 qt 3-3/4 qt 3.3/8 t 5-1/8 P. 8-3/4 qt 2-3/4pt 1 qt 2.0 - 2.21b .,
J
,'/
mmtin} degree
Innerwheel
Outer wheel
i I
38 .43
33
.:
Tankful of fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools,and mats. in designated positions. .~'
,I
--~.
.
~!
"';"1\
Edition~ August 1988 Printing~ February 1989 (02) Publication No. SM9E.OS13UO Printed in U.S.A.
~. mmm!I ,..
~
~--
--
....
Box 191 ' 90247-7638
IN U:S.A. "~
(213) 532-3111
'
J'SERVICE BULLETIN
Classification:
EF&EC89-004
Reference:
Models:
1989 240SX
Date:
number KA24-012039*
SERVICE INFORMATION
.
~
The following
Compression
. . .
Compressionratio has been changed (9.1 to 8.6). Air temperature sensor has been added. E.C:U. has been changed.
Idle speed. Self-diagnosis pages reflect ~or E.G.R. these changes.
CONTENTS
Pressure
- Measurement
General
2
3
!
Specifications
System
4
"
5 ................................... 6
7 Description
~
Engine and Emtssion Control System Description Igni tioll Timing Control Swirl Control Valve" (S.C. V.) Control Fail-safe System Idle Speed/Ignition Timing/Idle Mixture Ratio Inspection Trouble Diagnoses Self-diagnosis - Mode III (Self-diagnostic System) Diagnostic Procedure 8
Diagnostic Procedure 24
~
.........................\............
9 .11 .12 13 15
16
~lectrical
Components Inspection
.,.19 21
Service Data and Specifications ..~ Please reference this Bulletin on the Contents Sections of the 1989 24USXService Manual. *Vehicles .modified with an Air Temperature engine. Sensor 1/23 on the
;... .23
pages air of the EM and EF&EC
f'
,t
cleaner
I ~
-It'
COMPRESSION
PRESSURE
Measurement
1. 2. '3. 4. 5.
of Compression
Pressure
Warm up engine. Turn igr;1ition switch off. Disconnect fusible link for injectors. Remove all spark plugs. Disconnect distributor center cable.
g
6. Attach a compression tester to NO.1 cylinder. 7. Depress accelerator pedal fully to keep throttle valve wide open. 8. Crank engine and record highest gauge indication. 9. Repeat the measurement on each cylinder as shown above. Always use a fully-charged battery to obtain specified engine revolution.
Compression pressure:
kPa (kg/cm2, psi)/rpm Standard 1,206 (12.3, 175)/250 Minimum 1,010 (10.3, 146)/250 Difference limit between cylinders 98 (1.0, 14)/250
SEM113B
10. If cylinder compression in one or more cylinders is low, pour a small amount of engine oil into cylinders through spark plug holes and retest compression. If adding oil helps compression, piston rings may be worn
.
.
or damaged. If so, replace piston rings after checking piston. If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to S.D.S.) If valve or valve seat is damaged excessively, replace them. If compression in any two adjacent cylinders is low and if adding oil does not help compression, there is leakage past the gasket surface. If so, replace cylinder head
gasket. '
",.
. 2/23
oil'
~
Engine model Cylinder arrangement Displacement Bore x stroke Valve arrangement Firing order Number of piston rings Compression Oil Number of main bearings em' leu in) mm lin) KA24E 4, in-line 2,3891145.78) 89 x 9613.50 x 3.78) O.H.C. 1-3-4.2
2 1 5 8.6
Compression ratio
"
3/23
v.:
0\;, ;j
ENGINE AND EMISSION CONTROL OVERALL SYSTEM E.C.C.S. Component Parts Location
E.C.C.S.control unit
.
.
E.C.C.S.relay,
Fuelpump
E.G.R. control
valve
Pressure regulator
t~
~ ~
~"o,
s.c.v.contrOI
I.A.A. un"it
fijif~ ~
Fuel filter
t9
Throttle chamber
~
)
~
Engine
ankangle
cr
iT
~"'o,
temperatu re sensor
'"~
Jec or
o;?J ~
Exhaust gas sensor
1 SEF4601
4/23
--
Ignition switch
, , ,
r Air regulator
Throttle valve sensoi
8a
-)" : r--L J
-,
--N W
01
Ignition coil S.C.V. control--solenoid valve Cran k angle sensor built-in distributor Neutral switch (M/T) Inhibitor switch (AfT)
Swirl control""'"
,
Fuel pressure
regulator
/
/
I Engine
'\
,
"- Spark plug {}
valve
Transmission
temperature sensor
g
=
':;. speed
Vehiclesensor
Carbon canister Exhaust gas sensor " A.I. V. control solenoid valve
A.I.V.
- Air flow me
en m " ~ C>
Q
..
: Exhaustgasflow
E.C.C.S. CONTROLSYSTEM
I
'System Chart
.1
I
I
I
I
Fuel injection&
~
~
I
Injectors
I
.I
I
I
I
I
)f Power transistor
Exhaust gassensor
I
I
.1
~.
I
)1
)I
Ignition switch
--1
~I
AJ.V. control
[ Starter switch
J
I
~I
~
~
,/1
~
Idle switch
Fuel pump
I
I
Air regulator control
Air conditioner
switch
Air regulator
I
I
~I I
I
I valve) control
, switch
S.C.V.(Swirl control
S.C.V.control
solenoid valve
Battery
~I
~
I
~I
8 8 Fail-safe function 8 8
Air flow meter Throttle sensor Engine temperature sensor Air temperature sensor
6/23
~
FUSIBLE LINK
IGNITION
SWITCH
{8J-
OFFIACCION I ST
CHECK CONNECTOR r-
FUSE
f--1S}
-0
E. C. C. s.
1
INJECTOR
...:-. iii
RELAY SATTERY
-=-
U ffi3
~ ~ ~ ~
I ~--_m-7
25 106
105
a a a a
~:~[ff:i!I:i: ~~
INHIBITOR SWI TCH @ RELAY
I A~~E~LOW
A.A.C. VALVE -a
AIR REGULAT~ FUEL PUMP
-=-
INHIBIr
To tachometer
-=-
n---__n_-1...
m48
19
!'1 P 1] 6 P
'R
THROTTLE VALVE SWITCH
"'p
45
L
6
Y'
n 0 Z --i ;u 0 r c z --i
~=~ ~SWITCH
RESISTORm
_n--nn
n_-
13
43
SWITCH
44 33 35 4] 11 21LL 29
~LL IDLE
$
-= -= -= -= CRANK
CONDENSER
~
..:::::::.J
ENGINE TEMPERATURE
S ENS 0 R
cn__m_-T
<n__n
3D 31
18
SPARK PLUG
ANGLE SENSOR
i-+-I
22 40
8
I 20 I
~
H
--~:::::::::::::::~
01SPLAY eo HEAO-IE
@
(0
For
Ca I Iforn Ia
: :
@:
@:
For U.S.A.
37 32
@
@:
For Canada
115 28
A. S. C. D.
A. S. C. D.
26
I] I ~
L->
~~~~6~LE
I'.tI
en
m
"T1 ~ C'I '"
@: ~:
A/T mode
With
wi thout
II
.,!,.
head-up
display display
SPEED SENSOR
~:
Without
head-up
The air temperature sensor is used to control ignition timing when the temperature of the intake air is extremely high, in order not to cause predetonation.
+~I
SEF1651
~ .
8/23
DESCRIPTION
INPUT/OUTPUT
Crank angle sensor
I
SIGNAL LINE E .
I
d Dist
'ti on
Amount
of intake air
I Engine temperature
Engine temperature
Air temperature
sensor
Throttle
Idle switch
I
Throttle sensor Neutral switch (M/T) Inhibitor switch (A/T) Ignition switch
Neutral position
Start signal
I
~
9/23
'--
ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Ignition Timing Control (Cont'd)
SYSTEM DESCRIPTION The ignition timing is controlled by the E.C.U. in order to maintain the best air-fuel ratio in response to every running condition of the engine. The ignition timing data is stored in the ROM located in the E.C.U., in the form of the map shown below. The E.C.U. detects information such as the injection pulse width and crank angle sensor signal which varies every moment. Then responding to this information, ignition signals are transmitted to the power transistor. e.g. N: 1,800 rpm, Tp: 1.50 msec A S.T.D.C. In addition to this, 1 At starting 2 During warm-up 3 At idle 4 At low battery voltage 5 During swirl control valve operates 6 Hot engine operation 7 At acceleration 8 When intake air temperature is extremely high the ignition timing is revised by the E.C.U. according to the other data stored in the ROM.
Tp (msec) 1.75i
1.25i
1.00I
0.75
600
1,000
1,400
- ---
1,800
2,200
10/23
ENGINE AND EMISSION CONTROL SYSTEM DESCRIPTION Swirl Control Valve (S.C.V.) Control
INPUT/OUTPUT SIGNAL LINE
~
Idle switch
I I
Idle signal
. .
E.C.C.S.
control unit S.C.V. control solenoid valve
Start signal
I
Ignition
switch
Engine speed
Enginetemperature
This system has a swirl control valve (S.C.V.) in the intake passage of each cylinder. While idling the S.C.V. closes. Thus the velocity of the air in the intake passage increases, promoting the vaporization of the fuel and producing a swirl in the combustion chamber. Because of this operation, this system tends to increase the burning speed of the gas mixture, Idle switch ON ~ Water temperature Above 3SoC (9SoF) Except above
improve fuel consumption, and increase the stability in running conditions. The solenoid valve controls S.C.V.'s shut/open condition. This solenoid valve is operated by the E.C.U.
This table shows the control when starting enginetemperatureis above 10C (50F).
~
11/23
SENSOR
When engine temperature sensor output voltage is below or above the specified value, water temperature is fixed at the preset value as follows:
Operation Condition Just as ignition switch is turned ON or Start More than 6 minutes after ignition ON or Start Except as shown above Engine temperature decided 20C (68F)
OFF
A duty ratio is fixed at the preprogrammed value. Fuel is shut off above
THROTTLE
SENSOR
MALFUNCTION
When throttle sensor output voltage is below or above the specified value, throttle sensor output is fixed at the preset value. AIR TEMPERATURE MALFUNCTION SENSOR
When air temperature sensor is below or above the specified value, air temperature value is fixed at the preset value [20C (68F)].
12/23
..
..
--
--~
-~~
INSPECTION START
Visually check the following: . Air cleaner clogging . Hosesand ducts for leaks . E.G.R. control valve operation . Electricalconnectors
. Gaskets
. Throttle valveand throttle valveswitch operation
I~~I
SEF457C 2
Start engine and warm it up until water temperature indicator points to the middle of gauge.
Open engine hood and run engine at about 2,000 rpm for about 2 minutes under no-load.
1..!
)!'
""
0::
."""',,"',"
3 4 ~,."..~",L../" 5
'~<I,6 +(
\
O.K.
~1
fI -8
SEF477B
Check idle speed. Mrr: 700:tSOrpm Arr: 7S0:tSOrpm (in "N" position)
O.K. Check ignition timing with a timing light. 1S:t2 B.T.D.C. N.G.
~ ~
O.K.
N.G.
~~~--,-'-~ fj
Ensure that engine speed is below 800 rpm. O.K. Adjust idle speed to less than 800 rpm by turning idle speed adjusting screw.
SMA189A
~~~.,
@ @ 13/23
1 ~
Check ignition timing with a timing light.
N.G.
Adjust ignition timing by turning distributor after loosening bolt which secures distributor. 15:t2 B.T.D.C.
3
2
0:
1~ =
.""""Im;n
>,.",,,,,,~,,,,,,. 5
'v"-(6
~ ~
~1 ~ ~8
Run engine at about 2,000 rpm for about 2 minutes under no.load.
SEF477B
~~\
~V
j\.(r)J
SEF450H
Make sure that inspection lamp (Green) on E.C.U. goes IN.G. on and off periodically more than 5 times during 10 seconds at 2,000 rpm under no.load. O.K. Set the diagnosis mode of E.C.U.to mode II. Check inspection lamps (Red and Green) on E.C.U. blink at 2,000 rpm. They should blink simultaneously. Yes
INSPECTION END
~/~
No
~r\
~~
d~,/i~~
'--~(r)
)
SEF292H
j
D
14/23
The E.C.U. constantly monitors the function of these sensors and actuators, regardless of ignition key position. If a malfunction occurs, the information is stored in the EC.U. and can be retrieved from the memory by turning on the diagnostic mode selector, located on the side of the E.C.U. When activated, the malfunction is indicated by flashing a red and a green L.ED. (Light Emitting Diode), also located on the E.C.U. Since all the self-diagnostic results are stored in the E.C.U.s memory even ' intermittent malfunctions can be diagnosed. A malfunctionis indicated by the number of both red and green flashing L.ED.s. First, the red L.ED. flashes and the green flashes follow. The red L.ED. corresponds to units of ten and the green L.ED. corresponds to units of one. For example, when the red L.E.D.flashes once and the green L.ED. flashes twice, this signifies the number "12", showing that the air flow meter signal is malfunctioning. All problems are classified by code numbers in this way. . When the engine fails to start, crank it two or more seconds before beginning self-diagnosis.
11 12 13 14 21 31 32
Crank angle sensor circuit Air flow meter circuit Engine temperature sensor circuit Vehicle speed sensor circuit Ignition signal missing in primary coil E.C.U. IE.C.C.S. control unit) E.G.R. function
33
Exhaust gas sensor circuit Exhaust gas temperature sensor circuit Air temperature sensor circuit
Throttle sensor circuit Injector leak No malfunction in the above circuit
X X X
X X X
35 41
43 45 55
X
X
15/23
E. G.R. CONTROL
SOLENOID VALVE
E. C. C. S. CONTROL
UNI T
@)
Iij
IDS-LG
FUSE
WJ
@)@)
(E. F. I. harness)
B/R
BR-' tBR
(Eng I ne harness)
room
BR
w
BR~
I~ ~:~
CDJ~
FUSIBLE LINK
"1
2 3 4 5
~
<II
@g
OFF ACC ON ST
n 0 -('r --0 :J
~8~
1m
I GNITI ON SWITCH
~
BATTERY SEF4631
Component
location
16/23
--'-
'1
INSPECTION START
B
CHECK E.G.R. CONTROL VALVE OPERATION. 1) Start engine and warm it up sufficiently. 2) Make sure E.G.R. control valve spring responds to your touch (use your fingers) and also when engine is raced.
INSPECTION END
SEF445H
(;]
[!)
~-
CHECK VACUUM SOURCE TO E.G.R. CONTROL VALVE. 1) Stop engine. 2) Disconnect vacuum hose connected to E.G.R. control valve and B.P.T. valve. 3) Start engine. 4) Make sure vacuum exists when racing engine.
O.K.
CHECK COMPONENT. Check E.G.R. control valve. (See page EF & EC-148.)
I
~$\
aoggi.,
=='---
~
SEF816F
[!)
N.G.
N.G.
If necessary, replace vacuum hose or reconnect vacuum hose firmly.
. -::C'\
"Ii]
"
Improper connection
I
CHECK VACUUM HOSE. 1) Stop engine. 2) Check vacuum hose for clogging, cracks, and proper. connections.
Ii]
O.K.
CONNECT
oo
tD
CfH
ClUNIT 105 '8 CONNECTOR II
":"
CHECK SIGNAL (Solenoid side). 1) Start engine and warm it up sufficiently. 2) Check voltage betwen E.G.R. control solenoid valve harness connector terminal @ and ground. Engine condition
Idle Voltage
Battery voltage
. E.C.U. OUTPUT
~
N.G. CHECK E.C.U. OUTPUT SIGNAL (E.C.U.side). Check voltage between E.C.U. harness connector terminal @) and ground.
Engine condition Idle Racing Voltage Battery voltage
SEF158H
~~u
CONNECT
Racing
Temporarily drops to 0 1V
O.K.
If N.G., check the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector. O.K.
Repair harness or connectors between terminals @ and @.
00 ?~ ~L:t-r-J Cf~H
[Y]
+'
SEF159H
17/23
,
y
. .
O.K. CHECK COMPONENT. Check E.G.R. control valve and B.P.T. valve. (SeepageEF & EC-148.) O.K. For California N.G. Valve spring may be stuck. Clean if necessary. If this does not correct trouble, replace E.G.R. control valve.
Driving mode
Test condition 16 seconds or more @ Vehicle driving
@
Idling ---u Ignition l.ILJ switch: I I,'f Time OF F +---+-Until green and red inspection lamps go off. CD Start engine and warm it up sufficiently. @ Turn off ignition switch and keep it off until green and red inspection lamps go off. @ Start engine and make sure that air conditioner switch and rear defogger are turned "OFF" during driving test. @ Shift to suitable gear position and drive in "Test condition" for at least 16 seconds. <ID Decrease engine revolution to less than 2,000 rpm. @ Repeat steps @ through <ID at least 1 time.
SEF037H
(
Check resistance of exhaust gas temperature sensor. (See page EF & EC-149,)
INSPECTION END
Erase the self-diagnosis memory. Make sure Code No. 55 is displayed in Mode III.
(j
Perform driving test under the following conditions. 1) Warm up engine sufficiently. 2) Use test driving modes indicated in figure (j.
~~E~
CHECK ENGINE LIGHT
SE F924F
Make sure check engine light does not come "ON" during driving test.
"ON"
Perform self-diagnosis and find malfunction code. According to displayed code No., perform diagnosis.
/'
'-
18/23
(E. F. I. harness)
26-L 21-B 2'-B
at;]
~@)
~mf
~ ala]
Component ~ location
AIR
~
SEF4641
TEMPERATURE SENSOR
19/23
""'"
lu
~,
INSPECTION START
(bla
f
CHECK COMPONENTS. Check air temperature sensor. (See page 20.)
<=' 2"' 29
N.G.
~ i5~u
I;]
bla
CoIUNIT fo1 CONNECTOR II
SEF3121
O.K.
N.G.
1)
~i5
[ill
r=Cl'UNIT
minals @. @.
Continuity should exist.
~ ~i5n
I;]
O.K.
N.G. Repair or replace harness or connectors between terminals @ and@.
_6
CONNECTOR II
SEF3131
O.K.
Reinstall any part removed.
N.G.
O.K.
INSPECTION END
1) Perform E.C.U. input/output signal inspection test. 2) If N.G.. recheck the E.C.U. pin terminals for damage or the connection of E.C.U. harness connector.
20/23
SIGNAL INSPECTION
*Data are reference values.
CONDITION
*DATA
1.0- 3.0V
16 Air flow meter
I
Engine is running.
1.0- 5.0V
18 Engine temperature sensor
I
Engine is running.
19
0.4 - Approximately 4V
20 Throttle sensor Ignition switch "ON" Output voltage varies with the throttle valve opening angle.
22 30
Engineis running.I
Do not run engine at high speed under no-load.
0.2 - 0.5V
1.0 - 1.5V
Air temperature is 20C (68F). 26 Air temperature sensor Approximately 0.3V Air temperature is 80C (17SoF). 28 Throttle opening signal Ignition switch "ON" Engine is running.
I
0.3 - Approximately3V
31 40
2.0 - 3.0V
Approximately9 - 10V
Throttle valve: idle position
33
Idle switch (
e side)
Throttle valve: except idle position
OV
Any position
34
Start signal
Cranking
8 - 12V
OV
35
21/23
+
SEF2651
Temperature c (oF)
20 (68)
80 (176)
22/23
(S.D.S.)
General Specifications
~
IGNITION TIMING
B.T.D.C. rpm
M/T 700:t50 A/T 750:t50
15:t2
IDLE SPEED
Inspection
ENGINE TEMPERATURE SENSOR 20C (68F) Therm istor resistance kn 2.1 -2.9 AIR TEMPERATURE SENSOR 20C (68F) Resistance kn 2.1.2.9 IDLE SWITCH Engine speed when idle switch is changed from "OFF" to "ON" rpm FUEL PRESSURE at idling (Measuring point: between fuel filter and fuel pipe) Vacuum hose is connected kPa (kg/cm' ,psi! Vacuum hose is disconnected kPa (kg/cm' , psi) FUEL INJECTOR Coil resistance AIR REGULATOR Resistance EXHAUST GAS TEMPERATURE SENSOR 100C (212F) Therm istor resistance kn 85.3:1:8.53 n 0.27 - 0.38 80C (176F) 0.30 -0.33 80C (176F)
and Adjustment
M/T A/T
1,OOO:t150
1 ,OOO:t 150
Approximately
10 15
Approximately 75
NISSAN
MOTORORPORATION U.S.A. C IN
Publications Department
Technical
23/23