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Ranger / Drifter RepairManual
FOREWORD This Manual has been prepared to provide information covering normal service repairs and maintenance for the RANGER / DRIFTER SERIES. As all information in this manual was the best available at the time of printing, vehicle specification and other information will be updated in Service Information. Ford/Mazda Motor Company
WARNING Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Ford/Mazda-trained technicians in mind. This manual may be useful to non-Ford/Mazda trained technicians, but a technician with our service-related training and experience will be at less risk when performing service operations. However, all users of this manual are excepted at least to know general safety procedures. This manual contains "Warnings" and "Cautions" applicable to risks not normally encountered in a general technician's experience. They should be followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that the "Warnings" and "Cautions" are not exhaustive. It is impossible to warn of all the hazardous consequences that might result from failure to follow the procedures. The procedures recommended and described in this manual are effective methods of performing service and repair. Some require tools specifically designed for a specific purpose. Persons using procedures and tools, which are not recommended by Ford/Mazda Motor Corporation, must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized. The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Ford/Mazda Motor Corporation reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation. Parts should be replaced with genuine Ford/Mazda replacement parts or with parts, which match the quality of genuine Ford/Mazda replacement parts. Persons using replacement parts of lesser quality than that of genuine Ford/Mazda replacement parts must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized. Ford/Mazda Motor Corporation is not responsible for any problems, which may arise from the use of this manual. The cause of such problems includes but is not limited to insufficient service related training, use of improper tools, use of replacement parts of lesser quality than that of genuine Ford/Mazda replacement parts, or not being aware of any revision of this manual.
CONTENTS
Ranger / DrifterRepairManual
APPLICATION:This manual is applicable to vehiclesbeginning with the Vehicle IdentificationNumbers (VIN), and related materialsshown on the following page.
Title Section
General Information GI
Engine
Lubrication System
Cooling System
Fuel and Emission Control Systems
Engine Electrical System G
Clutch H
J1
Front and Rear Axles M
Steering System N
Braking System P
Suspension R
Body S
T
U
Body Electrical System
E
D
F1
ST
TD
Special Tools
Technical Data
Manual Transmission J2
M15M–DM15MX–DR15M–DR15MX–D
LPropeller Shaft
G6
WL, WL Turbo
F2
G6
WL, WL Turbo
J3Transfer
F2
F3F2 CIS
F4F2 CARB
Heater and Air Conditioner Systems
1999 Ford/Mazda Motor CompanyAll rights reserved. Reproduction by any means, electronic or mechanical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford/Mazda Motor Company.PRINTED IN JAPAN, JAN.1999F161–10–99A
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F8/FE
ST
GI
B1
B3
B2
VEHICLE IDENTIFICATION NUMBERS (VIN) U.K. specs.
JMZ UN1B320W 100001– JMZ UN8B320W 100001– JMZ UN8F420W 100001–
European specs. JMZ UN1*620W 100001– JMZ UN1*62WW 100001– JMZ UN1*320W 100001– JMZ UN1*32WW 100001– JMZ UN8*720W 100001– JMZ UN8*72WW 100001– JMZ UN8*320W 100001– JMZ UN8*32WW 100001– General specs. (L.H.D.) MM7 UNY02100 100001– MM7 UNY021WW 100001– MM7 UNYOW100 100001– MM7 UN2*6*00 100001– MM7 UN2*6*WW 100001– MM7 UN3*6*00 100001– MM7 UN3*6*WW 100001– MM7 UN2*2*00 100001– MM7 UN2*2*WW 100001–
General specs. (R.H.D.) MM6 UNY02100 100001– MM6 UNYOW100 100001–
RELATED MATERIALS B Series Training Manual .......................................... 3333-10-99A Engine Workshop Manual WL, WL Turbo ................ 1532-10-96C Engine Workshop Manual G6 .................................... 1640-10-99A Engine Workshop Manual F2 .................................... 1641-10-99A Manual Transmission Workshop Manual M15M-D M15MX-D .............................................................. 1645-10-99A Manual Transmission Workshop Manual R15M-D R15MX-D.................................................... 1642-10-99A B Series Wiring Diagrams (European, General specs. (L.H.D.)) ..................... 5449-10-99A B Series Wiring Diagrams
(European, General specs. (R.H.D.)) .................... 5450-10-99A
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CONTINUED
MM7 UNYOW1 WW 100001–
GI–1
GENERAL INFORMATIONHOW TO USE THIS MANUAL GI-1. . . . . . . . . . . . . . .
RANGE OF TOPICS GI-1. . . . . . . . . . . . . . . . . . . . . SERVICING PROCEDURE GI-1/2. . . . . . . . . . . . . . . SYMBOLS GI-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADVISORY MESSAGES GI-3. . . . . . . . . . . . . . . . . . TROUBLESHOOTING PROCEDURE GI-3/6. . . . . .
UNITS GI-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUNDAMENTAL PROCEDURES GI-8. . . . . . . . . . . .
PROTECTION OF THE VEHICLE GI-8. . . . . . . . . . PREPARATION OF TOOLS AND
MEASURING EQUIPMENT GI-8. . . . . . . . . . . . . . SPECIAL SERVICE TOOLS GI-8. . . . . . . . . . . . . . . DISCONNECTION OF THE NEGATIVE
BATTERY CABLE GI-8. . . . . . . . . . . . . . . . . . . . . . REMOVAL OF PARTS GI-8. . . . . . . . . . . . . . . . . . . . DISASSEMBLY GI-8. . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION DURING REMOVAL,
DISASSEMBLY GI-8. . . . . . . . . . . . . . . . . . . . . . . . . ARRANGEMENT OF PARTS GI-8/9. . . . . . . . . . . . . . CLEANING OF PARTS GI-9. . . . . . . . . . . . . . . . . . . REASSEMBLY GI-9. . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENT GI-9. . . . . . . . . . . . . . . . . . . . . . . . . . RUBBER PARTS AND TUBING GI–19. . . . . . . . . . . HOSE CLAMPS GI–19. . . . . . . . . . . . . . . . . . . . . . . . . TORQUE FORMULAS GI–10. . . . . . . . . . . . . . . . . . . . VISE GI–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DYNAMOMETER GI–10. . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION OF RADIO SYSTEM GI–10. . . . . . . . ELECTRICAL SYSTEM GI–11. . . . . . . . . . . . . . . . . . . . .
ELECTRICAL PARTS GI–11. . . . . . . . . . . . . . . . . . . . CONNECTORS GI–11/13. . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL TROUBLESHOOTING
TOOLS GI–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JACKING POSITIONS GI–14. . . . . . . . . . . . . . . . . . . . . . VEHICLE LIFT (2 SUPPORTS) POSITIONS GI–14. . . SAFETY STAND POSITIONS GI–14. . . . . . . . . . . . . . . TOWING GI–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOWING HOOKS GI–16. . . . . . . . . . . . . . . . . . . . . . . . TIEDOWN HOOKS GI–16. . . . . . . . . . . . . . . . . . . . . . .
IDENTIFICATION NUMBER LOCATIONS GI–16. . . . . VEHICLE IDENTIFICATION NUMBER GI–16. . . . . . ENGINE IDENTIFICATION NUMBER GI–16. . . . . . .
NEW STANDARDS GI–17/19. . . . . . . . . . . . . . . . . . . . . . . . ABBREVIATIONS GI–19. . . . . . . . . . . . . . . . . . . . . . . . . .
HOW TO USE THIS MANUALRANGE OF TOPICS This manual contains the procedures for performing
all of the required service operations. Theprocedures are divided into the following five basicoperations.(1) Removal/Installation(2) Disassembly/Assembly(3) Replacement(4) Inspection(5) Adjustment
Simple operations which can be performed easilyjust by looking at the vehicle, such asremoval/installation of parts, jacking, vehicle lift,cleaning of parts, and visual inspection, have beenomitted.
SERVICING PROCEDUREInspection, Adjustment The procedures for inspections and adjustments
are divided into steps. Important points in regardto the location and contents of the procedures areexplained in detail and are shown in theillustrations.
SHOWS PROCEDURE ORDERFOR SERVICE
SHOWS TIGHTENING TORQUE SPECIFICATIONS
CONTINUED
TEXT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . GI-6
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-20 PRE-DELIVERY INSPECTION TABLE . . . . . . GI-20
PRE-DELIVERY INSPECTION. . . . . . . . . . . . . .GI
HOW TO USE THIS MANUAL
GI–2
Repair procedure1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only the removal/installation procedures which need tobe performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overviewillustration. In addition, symbols indicating parts which require the use of special service tools forremoval/installation are also shown.
3. The procedures are numbered and the part that is the main point of that procedure is shown in the illustrationwith the corresponding number. Occasionally, there are important points or information concerning a procedure.Refer to this information when servicing the related part.
SHOWS SERVICEITEM (S)
SHOWS TIGHTENINGTORQUESPECIFICATIONS
SHOWS PROCEDURE ORDERFOR SERVICE
SHOWS SPECIALSERVICE TOOL (SST)FOR SERVICE OPERATION
SHOWS APPLICATIONPOINTS OF GREASE, ETC.
SHOWS EXPENDABLE PARTS
SHOWS DETAILS
SHOWS TIGHTENINGTORQUE UNITS
SHOWS THEREARE REFERRALNOTES FOR SERVICE
SHOWS REFERRALNOTES FORSERVICE
Procedure
“Removal/Installation”Portion
Indicates any relevantreferences which need to befollowed during installation.
“Inspection After Installation” Portion
Install the partsby performingSteps 1—3 inreverse order
SHOWS SPECIALSERVICE TOOL (SST)NO.
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HOW TO USE THIS MANUAL
GI–3
SYMBOLS There are eight symbols indicating oil, grease,
sealant, and the use of SSTs. These symbolsshow the points of applying or using such materialsduring service.
Symbol Meaning Kind
Apply oilAppropriate newengine oil orgear oil
Apply brake fluidAppropriate newbrake fluid
Apply automatictransaxle/transmissionfluid
Appropriate newautomatictransaxle/transmission fluid
Apply greaseAppropriategrease
Apply sealantAppropriatesealant
Apply petroleumjelly
Appropriatepetroleum jelly
R Replace partO-ring, gasket,etc.
SST Use SST Appropriate SST
ADVISORY MESSAGESYou’ll find several Warnings , Cautions , Notes ,Specifications and Upper and lower limits in thismanual.
Warning A Warning indicates a situation in which
serious injury or death could result if thewarning is ignored.
Caution A Caution indicates a situation in which
damage to the vehicle could result if thecaution is ignored.
Note A Note provides added information that will
help you to complete a particular procedure.
Specification The values indicate the allowable range when
performing inspections or adjustments.
Upper and lower limits The values indicate the upper and lower limits
that must not be exceeded when performinginspections or adjustments.
TROUBLESHOOTING PROCEDUREBasic Flow of Troubleshooting
SECTION F ONLY
SECTION F ONLY
ACTUAL TROUBLESHOOTING PROCEDURES
SECTION K ONLY
IFMENTIONED
On-board diagnosis The service codes are important hints for repairing
malfunctions that are difficult to simulate. Byfollowing the service code, perform the inspectionto quickly and accurately diagnose the malfunction.
The self-diagnostic function is used duringinspection. When a service code is shown,specifying the cause of a malfunction, continue theinspection according to the items indicated by theself-diagnostic function.
Engine tune-up (Section F) Any necessary adjustments are made after starting
the engine.
Basic inspection (Section K) The basic inspection is performed to quickly
narrow down the possible causes after amalfunction occurs regardless of the symptoms.The basic inspection is performed to also locatethe region of many malfunction symptoms.
Diagnostic index The diagnostic index lists the symptoms of the
malfunctions. Select the symptoms pertaining ormost closely pertaining to the actual malfunction.
Quick diagnosis chart (If mentioned) The quick diagnosis chart lists the diagnosis and
inspection procedures to be performed specificallyrelating to the cause of the malfunction.
Symptom troubleshooting Symptom troubleshooting quickly determines the
location of the malfunction according to the type ofsymptoms.
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HOW TO USE THIS MANUAL
GI–4
Procedures For UseUsing the basic inspection
Perform the basic inspection before the symptom troubleshooting. Perform each step in the order shown. The reference column lists the location of the detailed procedure for each basic inspection. Although inspection and adjustment are performed as according to the procedures referred to in the reference
column, if the cause of the malfunction is discovered during the basic inspection, continue the procedures asindicated in the remarks column.
SHOWS INSPECTIONORDER
SHOWS ITEM NAMES FORTHE DETAILED PROCEDURES SHOW POINTS REQUIRING
ATTENTION IN REGARD TO INSPECTION RESULTS
Perform malfunction diagnosis according to No. 26“HOLD INDICATOR LIGHT DOES NOT ILLUMI-NATE WHEN HOLD SWITCH IS TURNED ON” orNo. 27 “HOLD INDICATOR LIGHT ILLUMINATESWHEN HOLD SWITCH IS NOT TURNED ON”
Using the diagnostic index The symptoms of the malfunctions are listed in the diagnostic index for system troubleshooting. The exact malfunction symptoms can be selected using the details.
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HOW TO USE THIS MANUAL
GI–5
Using the quick diagnosis chart The chart lists the relation between the symptoms and cause of the malfunction. The chart is effective in quickly narrowing down the relation between the symptoms and cause of the
malfunction and specifying the region of the common cause when multiple malfunction symptoms occur. The appropriate diagnostic inspection relating to the cause of the malfunction as specified by the symptoms can
be selected by looking down the diagnostic inspection column of the chart.
PART WHICH MAY BETHE SYMPTOM
PARTS WHICH MAY BE THE CAUSE OFPROBLEMS
CHOOSE THE ACTUALSYMPTOM
ENGINE QUICK DIAGNOSTIC CHART
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HOW TO USE THIS MANUAL
GI–6
Using the symptom troubleshooting
Symptom troubleshooting shows diagnosis procedure, inspection method, and proper action to take for eachtrouble symptom.
TROUBLESHOOTINGHINTS describespossible point ofmalfunction.
STEP shows theorder oftroubleshooting.
INSPECTIONdescribes aninspection (method) toquickly determine thefailed part.
Reference page(s) forthe detailed procedureto performINSPECTION is shown.
ACTION describes theappropriate action totake as a result(Yes/No) ofINSPECTION.
How to perform ACTIONis described in the relativematerial shown.
TROUBLE SYMPTOM
TEXT SEQUENCE The text sequence is as indicated by the arrows shown below.
Example:
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UNITS
GI–7
UNITSElectric current A (ampere)
Electric power W (watt)
Electric resistance (ohm)
Electric voltage V (volt)
Lengthmm (millimeter)
Lengthin (inch)
kPa (kilo pascal)
Negative pressure mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
Positive pressure kgf/cm2 (kilogram force per squarecentimeter)
psi (pounds per square inch)
Number ofrevolutions rpm (revolutions per minute)
N·m (Newton meter)
kgf·m (kilogram force per meter)
Torque kgf·cm (kilogram force per centimeter)
ft·lbf (foot pound) force
in·lbf (inch pound) force
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
Volume ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
Weightg (gram)
Weightoz (ounce)
Conversion to SI Units (Système International d’Unités) All numerical values in this manual are based on SI
units. Numbers shown in conventional units areconverted from these values.
Rounding off Converted values are rounded off to the same
number of places as the SI unit value. Forexample, if the SI unit value is 17.2 and the valueafter conversion is 37.84, the converted value willbe rounded off to 37.8.
Upper and lower limits When the data indicates upper and lower limits, the
converted values are rounded down if the SI unitvalue is an upper limit and rounded up if the SI unitvalue is a lower limit. Therefore, converted valuesfor the same SI unit value may differ afterconversion. For example, consider 2.7 kgf/cm2 inthe following specifications:
210—260 kPa 2.1—2.7 kgf/cm 2, 30—38 psi270—310 kPa 2.7—3.2 kgf/cm 2, 39—45 psi
The actual converted values for 2.7 kgf/cm2 are264 kPa and 38.4 psi. In the top specification, 2.7is used as an upper limit, so its converted valuesare rounded down to 260 and 38. In the bottomspecification, 2.7 is used as a lower limit, so itsconverted values are rounded up to 270 and 39.
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FUNDAMENTAL PROCEDURES
GI–8
FUNDAMENTAL PROCEDURESPROTECTION OF THE VEHICLE Always be sure to cover fenders, seats, and floor
areas before starting work.
PREPARATION OF TOOLS AND MEASURINGEQUIPMENT Be sure that all necessary tools and measuring
equipment are available before starting any work.
SPECIAL SERVICE TOOLS Use special tools when they are required.
DISCONNECTION OF THE NEGATIVE BATTERYCABLE Before beginning any work, turn the ignition switch
to LOCK, then disconnect the negative batterycable and wait for more than 1 minute to allow thebackup power supply of the SAS unit to deplete itsstored power.Disconnecting the battery cable will delete thememories of the clock, audio, and DTCs, etc.Therefore, it is neccessary to verify thosememories before disconnecting the cable.
REMOVAL OF PARTS While correcting a problem, try also to determine
its cause. Begin work only after first learning whichparts and subassemblies must be removed anddisassembled for replacement or repair. Afterremoving the part, plug all holes and ports toprevent foreign material from entering.
DISASSEMBLY If the disassembly procedure is complex, requiring
many parts to be disassembled, all parts should bemarked in a place that will not affect theirperformance or external appearance and identifiedso that reassembly can be performed easily andefficiently.
INSPECTION DURING REMOVAL, DISASSEMBLY When removed, each part should be carefully
inspected for malfunctioning, deformation,damage, and other problems.
ARRANGEMENT OF PARTS All disassembled parts should be carefully
arranged for reassembly. Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
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FUNDAMENTAL PROCEDURES
GI–9
CLEANING OF PARTS All parts to be reused should be carefully and
thoroughly cleaned using the appropriate method.
Warning Using compressed air can cause dirt and
other particles to fly out, causing injury tothe eyes. Wear protective eye wearwhenever using compressed air.
REASSEMBLY Standard values, such as torques and certain
adjustments, must be strictly observed in thereassembly of all parts.
If removed, these parts should be replaced with newones:
1 Oil seals 2 Gaskets
3 O-rings 4 Lockwashers
5 Cotter pins 6 Nylon nuts
SXU00011
Sealant, a gasket, or both should be applied to thespecified locations. When sealant is applied, partsshould be installed before sealant hardens.Hardened sealant causes leaks.
Oil should be applied to the moving components ofparts.
Specified oil or grease should be applied at theprescribed locations (such as oil seals) beforereassembly.
SXU00012
ADJUSTMENT Use suitable gauges and/or testers when making
adjustments.
SXU00013
RUBBER PARTS AND TUBING Prevent gasoline or oil from spilling on rubber parts
or tubing.
SXU00014
HOSE CLAMPS When reinstalling, position the hose clamp in the
original location on the hose, and squeeze theclamp lightly with large pliers to ensure a good fit.
SXU00015
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FUNDAMENTAL PROCEDURES, INSTALLATION OF RADIO SYSTEM
GI–10
TORQUE FORMULAS When using a torque wrench-SST combination, the
written torque must be recalculated due to theextra length that the SST adds to the torquewrench. Recalculate the torque using the followingformulas. Choose the formula that applies to you.
Torque Unit Formula
kgf·m kgf·m [L/(L+A) ]
kgf·cm kgf·cm [L/(L+A) ]
ft·lbf ft·lbf [L/(L+A) ]
in·lbf in·lbf [L/(L+A) ]A: The length of the SST past the torque wrench drive.L: The length of the torque wrench.
SXU00016
VISE When using a vise, put protective plates in the jaws
of the vise to prevent damage to parts.
SXU00017
DYNAMOMETERWhen test-running a vehicle on dynamometer : Place a fan, preferably a vehicle-speed
proportional type, in front of the vehicle. Connect an exhaust gas ventilation unit. Cool the exhaust pipes with a fan. Keep the area around the vehicle uncluttered. Watch the water temperature gauge.
INSTALLATION OF RADIO SYSTEMIf a radio system is installed improprerly or if a high-powered type is used, the CIS and other systems maybe affected.When the vehicle is to be equipped with a radio,observe the following precautions.
1. Install the antenna at the farthest point from controlmodules.
2. Install the antenna feeder as far as possible fromthe control modules harness, and perpendicular towiring harnesses.
3. Do not install a high-powered radio system.4. After installing the radio system, start and idle the
engine, then confirm that the engine is notinfluenced by output waves from the system.
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ELECTRICAL SYSTEM
GI–11
ELECTRICAL SYSTEMELECTRICAL PARTSBattery Cable Before disconnecting connectors or removing
electrical parts, disconnect the negative batterycable.
SXU00018
Wiring Harness To remove the wiring harness from the clip in the
engine room, pry up the hook of the clip using aflathead screwdriver.
CONNECTORSData Link Connector Insert the probe into the service hole when
connecting a jumper wire to the data linkconnector.
Caution Inserting a jumper wire probe into the data
link connector terminal may damage theterminal.
SXU00019
Disconnecting Connectors When disconnecting two connectors, grasp the
connectors, not the wires.
SXU00020
Connectors can be disconnected by pressing orpulling the lock lever as shown.
SXU00021
Locking Connector When locking connectors, listen for a click that will
indicate they are securely locked.
SXU00022
Inspection1. When a tester is used to check for continuity or to
measure voltage, insert the tester probe from thewiring harness side.
SXU00023
2. Check the terminals of waterproof connectors fromthe connector side, as they cannot be accessedfrom the wiring harness side.
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ELECTRICAL SYSTEM
GI–12
Caution To prevent damage to the terminal, wrap a
thin wire around the lead before inserting itinto the terminal.
SXU00024
TerminalsInspection Pull lightly on individual wires to check that they
are secured in the terminal.
SXU00025
Replacement Use the appropriate tools to remove a terminal as
shown. When installing a terminal, be sure to insertit until it locks securely.
Insert a thin piece of metal from the terminal sideof the connector, and then, with the terminallocking tab pressed down, pull the terminal outfrom the connector.
SXU00026
TYPE A
TYPE B
Sensors, Switches, and Relays Handle sensors, switches, and relays carefully. Do
not drop them or strike them against other objects.
SXU00027
Wiring HarnessWiring color codes Two-color wires are indicated by a two-color code
symbol. The first letter indicates the base color of the wire
and the second the color of the stripe.CODE COLOR CODE COLOR
B Black O Orange
BR Brown P Pink
G Green R Red
GY Gray V Violet
L Blue W White
LB Light Blue Y Yellow
LG Light Green
SXU00028
B/R BR/Y
BLACK
RED
BROWN
YELLOW
FuseReplacement
1. When replacing a fuse, be sure to replace it withone of the specified capacity. If a fuse again failsafter it has been replaced, the circuit probably hasa short and the wiring should be checked.
2. Be sure the negative battery terminal isdisconnected before replacing a main fuse.
SXU00029
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ELECTRICAL SYSTEM
GI–13
3. When replacing a pullout fuse, use the fuse puller.
SXU00030
PULLER
FUSE
ELECTRICAL TROUBLESHOOTING TOOLSJumper Wire A jumper wire is used to create a temporary circuit.
Connect the jumper wire between the terminals ofa circuit to bypass a switch.
Caution Do not connect a jumper wire from the
power source line to a body ground; thismay cause burning or other damage towiring harnesses or electronic components.
SXU00032
Voltmeter The DC voltmeter is used to measure circuit
voltage. A voltmeter with a range of 15 V or moreis used by connecting the positive (+) probe (redlead wire) to the point where voltage is to bemeasured and the negative (–) probe (black leadwire) to a body ground.
VOLTMETER POWER SOURCE LINE
BLACK LEAD
RED LEAD
GROUND
Ohmmeter The ohmmeter is used to measure the resistance
between two points in a circuit, and to check forcontinuity and short circuits.
Caution Do not connect the ohmmeter to any circuit
to which voltage is applied. This willdamage the ohmmeter.
SXU00034
POWER SOURCE LINE
GROUND LINE
OHMMETER
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JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) POSITIONS, SAFETY STAND POSITIONS
GI–14
JACKING POSITIONSWarning Improperly jacking a vehicle is dangerous.
The vehicle can slip off the jack and causeserious injury. Use only the correct frontand rear jacking positions and block thewheels.
Use safety stands to support the vehicle after it hasbeen lifted.
FRONT
REAR
VEHICLE LIFT (2 SUPPORTS)POSITIONSFRONT
REAR
SAFETY STAND POSITIONSFRONT
REAR
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TOWING
GI–15
TOWINGProper lifting and towing are necessary to preventdamage to the vehicle.Government and local laws must be followed.
Wheel dollies
Wheel dollies
Caution Do not tow with sling-type equipment. This
could damage your vehicle. Use wheel-liftor flatbed equipment.
(With Manual Transmission)If the transmission, rear axle, and steering system arenot damaged, the vehicle may be towed on all fourwheels. If any of these components are damaged, usewheel dollies.
If all four wheels are on the ground, the vehicle may betowed only forward. Do not exceed 45 km/h (28 mph)and a distance of 15 km (9.3 miles); you could damagethe transmission.
If speed must exceed 45 km/h (28 mph) or a towingdistance of 15 km (9.3 miles), use one of thesemethods:
Place the rear wheels on dollies.
Tow with the rear wheels off the ground.
Disconnect the propeller shaft.
If the transmission or rear axle is inoperative, tow withthe rear wheels off the ground.
Caution Follow these instructions when towing the
vehicle with all wheels on the ground orwith the front wheels on the ground and therear wheels raised.
(44 Model)1. Put the transfer case in 2H.2. Set the transfer case at 2H and the hubs
at FREE.
(All Models)1. Set the transmission in neutral.2. Turn the engine switch to ACC position.3. Release the parking brake.
Remember that power assist for the brakesand steering will not be available when theengine is not running.
If your Ford/Mazda has 44, change to 2-wheel drive before having the vehicle towed. If this is not possible, tow with all four wheels raised.
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(With Automatic Transmission)If excessive damage or other conditions preventtowing the vehicle with the driving wheels off the ground, use wheel dollies.
PAGES. FROM. MANUAL
TOWING, IDENTIFICATION NUMBER LOCATIONS
GI–16
TOWING HOOKS
Caution The towing hooks should be used only in
an emergency (e.g. to get the vehicle out ofa ditch or a snow bank).
When using the towing hooks, always pullthe cable or chain in a straight directionwith respect to the hook. Apply nosideways force.
FRONT44
TIEDOWN HOOKS
Caution Do not use the hook loops under the front
for towing. They are designed ONLY fortying down the vehicle when it is beingtransported. Using them for towing willdamage the bumper.
FRONT42
44
IDENTIFICATION NUMBERLOCATIONSVEHICLE IDENTIFICATION NUMBER
ENGINE IDENTIFICATION NUMBERG6
WL, WL Turbo
F2 CISF2 CARB
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NEW STANDARDS
GI–17
NEW STANDARDS Following is a comparison of the previous standard and the new standard.
New Standard Previous Standard
Abbreviation Name NameRemark
AP Accelerator Pedal — Accelerator Pedal
ACL Air Cleaner — Air Cleaner
A/C Air Conditioning — Air Conditioning
BARO Barometric Pressure — Atmospheric Pressure
B Battery Positive Voltage VB Battery Voltage
— Brake Switch — Stoplight Switch
— Calibration Resistor — Corrected Resistance #6
CMP sensor
Camshaft Position Sensor — Crank Angle Sensor
CAC Charge Air Cooler — Intercooler
CLS Closed Loop System — Feedback System
CTP Closed Throttle Position — Fully Closed
— Closed Throttle Position Switch — Idle Switch
CPP Clutch Pedal Position — Clutch Position
CIS Continuous Fuel Injection System EGI Electronic Gasoline Injection System
CS sensor Control Sleeve SensorCSP
sensorControl Sleeve Position Sensor #6
CKP sensor
Crankshaft Position Sensor — Crank Angle Sensor 2
DLC Data Link Connector — Diagnosis Connector
DTM Diagnostic Test Mode — Test Mode #1
DTC Diagnostic Trouble Code(s) — Service Code(s)
DI Distributor Ignition — Spark Ignition
DLI Distributorless Ignition — Direct Ignition
EI Electronic Ignition — Electronic Spark Ignition #2
ECT Engine Coolant Temperature — Water Thermo
EM Engine Modification — Engine Modification
— Engine Speed Input Signal — Engine RPM Signal
EVAP Evaporative Emission — Evaporative Emission
EGR Exhaust Gas Recirculation — Exhaust Gas Recirculation
FC Fan Control — Fan Control
FF Flexible Fuel — Flexible Fuel
4GR Fourth Gear — Overdrive
— Fuel Pump Relay — Circuit Opening Relay #3
FSO solenoid
Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
GEN Generator — Alternator
GND Ground — Ground/Earth
HO2S Heated Oxygen Sensor — Oxygen Sensor With heater
IAC Idle Air Control — Idle Speed Control
— Incorrect Gear Ratio — —
#1: Diagnostic trouble codes depend on the diagnostic test mode#2: Controlled by the PCM#3: In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).#6: Part name of diesel engine
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Abbreviation
PAGES. FROM. MANUAL
NEW STANDARDS
GI–18
New Standard Previous Standard
Name NameRemark
— Injection Pump FIP Fuel Injection Pump #6
— Input/Turbine Speed Sensor — Pulse Generator
IAT Intake Air Temperature — Intake Air Thermo
KS Knock Sensor — Knock Sensor
MIL Malfunction Indicator Lamp — Malfunction Indicator Light
MAP Manifold Absolute Pressure — Intake Air Pressure
MAF sensor
Mass Air Flow Sensor — Airflow Sensor
MFL Multiport Fuel Injection — Multiport Fuel Injection
OBD On-Board Diagnostic — Diagnosis/Self-Diagnosis
OL Open Loop — Open Loop
— Output Speed Sensor — Vehicle Speed Sensor 1
OC Oxidation Catalytic Converter — Catalytic Converter
O2S Oxygen Sensor — Oxygen Sensor
PNP Park/Neutral Position — Park/Neutral Range
— PCM Control Relay — Main Relay #6
PSP Power Steering Pressure — Power Steering Pressure
PCM Powertrain Control Module ECU Engine Control Unit #4
— Pressure Control Solenoid — Line Pressure Solenoid Valve
PAIR Pulsed Secondary Air Injection — Secondary Air Injection SystemPulsed injection
— Pump Speed Sensor — NE Sensor #6
AIR Secondary Air Injection — Secondary Air Injection SystemInjection withair pump
SAPV Secondary Air Pulse Valve — Reed Valve
SFI Sequential Multipoint Fuel Injection — Sequential Fuel Injection
— Shift Solenoid A— 1–2 Shift Solenoid Valve
— Shift Solenoid A— Shift A Solenoid Valve
Shift Solenoid B— 2–3 Shift Solenoid Valve
— Shift Solenoid B— Shift B Solenoid Valve
— Shift Solenoid C — 3–4 Shift Solenoid Valve
3GR Third Gear — 3rd Gear
TWC Three Way Catalytic Converter — Catalytic Converter
TB Throttle Body — Throttle Body
TP sensor Throttle Position Sensor — Throttle Sensor
TCV Timer Control Valve TCV Timing Control Valve #6
TCC Torque Converter Clutch — Lock-up Position
TCM Transmission (Transaxle) Control Module
— EC-AT Control Unit
— Transmission (Transaxle) FluidTemperature Sensor
— ATF Thermosensor
TR Transmission (Transaxle) Range — Inhibitor Position
TC Turbocharger — Turbocharger
VSS Vehicle Speed Sensor — Vehicle Speed Sensor
VR Voltage Regulator — IC Regulator
#4: Device that controls engine and powertrain#6: Part name of diesel engine
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Abbreviation Abbreviation
PAGES. FROM. MANUALTO. MODEL .INDEX
NEW STANDARDS, ABBREVIATIONS
GI–19
New Standard Previous Standard
Name NameRemark
VAF sensor
Volume Air Flow Sensor — Air flow Sensor
WU-TWC Warm Up Three Way CatalyticConverter
— Catalytic Converter #5
WOT Wide Open Throttle — Fully Open
#5: Directly connected to exhaust manifold
ABBREVIATIONSACC Accessories. . . . . . . . . . . . . . ATDC After top dead center. . . . . . . . . . . . . ATF Automatic transmission fluid. . . . . . . . . . . . . . . BTDC Before top dead center. . . . . . . . . . . . . CARB Carburetor. . . . . . . . . . . . . ELR Emergency locking retractor. . . . . . . . . . . . . . EX Exhaust. . . . . . . . . . . . . . . FIP Fuel injection pump. . . . . . . . . . . . . . . HI High. . . . . . . . . . . . . . . . HLA Hydraulic lash adjuster. . . . . . . . . . . . . . IG Ignition. . . . . . . . . . . . . . . . IN Intake. . . . . . . . . . . . . . . . INT Intermittent. . . . . . . . . . . . . . . LH Left hand. . . . . . . . . . . . . . . . L.H.D. Left hand drive. . . . . . . . . . . . . LO Low. . . . . . . . . . . . . . . LSD Limited slip differential. . . . . . . . . . . . . . LSPV Load sensing proportioning valve. . . . . . . . . . . . . M Motor. . . . . . . . . . . . . . . . MAX Maximum. . . . . . . . . . . . . . MFW Manual freewheel. . . . . . . . . . . . . MIN Minimum. . . . . . . . . . . . . . P/S Power steering. . . . . . . . . . . . . . . RFW Remote freewheel. . . . . . . . . . . . . . RH Right hand. . . . . . . . . . . . . . . R.H.D. Right hand drive. . . . . . . . . . . . SAS Sophisticated air bag sensor. . . . . . . . . . . . . . SST Special service tool. . . . . . . . . . . . . . TNS Tail number side lights. . . . . . . . . . . . . . 2WD 2 wheel drive. . . . . . . . . . . . . . 4WD 4 wheel drive. . . . . . . . . . . . . . 42 4 wheel – 2 drive. . . . . . . . . . . . . . 44 4 wheel – 4 drive. . . . . . . . . . . . . .
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Abbreviation Abbreviation
PAGES. FROM. MANUAL
PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE Following items may be done at any time prior to delivery to your customer. EXTERIOR
UNDER BONNET-ENGINE RUNNING AT OPERATING TEMPERATURE
CHECK the following items: Operation of dashpot Initial ignition timing Injection timing Idle speed Operation of throttle position sensor
ON HOIST
INSPECT and ADJUST, if necessary, the following items to the specifications:
Glass, exterior bright metal and paint for damage Wheel lug nuts Tire pressures All weatherstrips for damage or detachment Operation of bonnet release and lock Door operation and alignment Headlight aiming
INSTALL the following parts: Wheel caps
UNDER BONNET-ENGINE OFF
CHECK the following items: Operation of freewheel hubs Manual transmission oil level Transfer oil level Front differential oil level Rear differential oil level Underside fuel, coolant and hydraulic lines, fittings,
connections and components for leaks Tires for cuts or bruises Steering linkage, suspension, exhaust system and
all underside hardware for looseness or damage
ROAD TEST
INSPECT and ADJUST, if necessary, the following items to the specifications:
Fuel, coolant and hydraulic lines, fittings, connections and components for leaks Engine oil level Power steering fluid level (if equipped) Brake and clutch master cylinder fluid levels Windshield washer reservoir fluid level Radiator coolant and specific gravity Tightness of water hose clamps Tightness of battery terminals, electrolyte level and
specific gravity Drive belt tensions Accelerator cable and linkage for free movement
CLEAN the spark plugs
INTERIOR
CHECK the following items: Brake operation Clutch operation Steering control Operation of meters and gauges 3 Squeaks, rattles
or unusual noise Engine general performance Emergency locking retractors Operation of transfer
AFTER ROAD TEST
INSTALL the following parts Fuse for accessories
CHECK the operation of the following items: Seat controls (sliding and reclining) and headrest Door locks Ignition switch (Engine switch) and steering lock All lights including warning and indicator lights Horn, windshield wipers and washers (if equipped) Wiper blades performance Clean the wiper blades and
windshield Antenna Cigarette lighter and clock Tilt steering (if equipped) Air conditioner at various modes (if equipped)
CHECK the following items: Presence of spare fuse Upholstery and interior finish
CHECK and ADJUST, if necessary, the following items: Operation and fit of windows Pedal height and free play of brake and clutch pedals Parking brake
REMOVE seat and floor mat protective covers CHECK for necessary owner's information material, tools and spare tire in vehicle
Gl-20
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ENGINE (G6)
DRIVE BELT ................................................................B1-1 DRIVE BELT INSPECTION ................................B1-1/2
DRIVE BELT ADJUSTMENT .............................B1-2 COMPRESSION INSPECTION ..................................B1-2 TIMING CHAIN .............................................................B1-3
TIMING CHAIN REMOVAL/ INSTALLATION....................................................B1-3/5 CYLINDER HEAD GASKET ..................................B1-6 CYLINDER HEAD GASKET REPLACEMENT .................................................B1-6/9 HYDRAULIC LASH ADJUSTER (HLA).................B1-10
HLA REMOVAL/INSTALLATION .....................B1-10/11 HLA TROUBLESHOOTING .............................B1-12 FRONT OIL SEAL.......................................................B1-13 FRONT OIL SEAL REPLACEMENT.................B1-13 REAR OIL SEAL .........................................................B1-14 REAR OIL SEAL REPLACEMENT ..................B1-14 ENGINE .......................................................................B1-15
ENGINE REMOVAL/INSTALLATION ..............B1-15/16 ENGINE DISASSEMBLY/ASSEMBLY ..............B1-17
Deflection mm inDrive belt *New Used
Generator 10.0—12.0 0.40—0.47
12.0—14.0 0.48—0.55
P/S 6.6—7.2 0.26—0.28
7.2—8.0 0.29—0.31
A/C 8.5—10.0 0.34—0.39
10.0—11.5 0.40—0.45
*: A belt that has been on a running engine for less than five minutes. 2. If the deflection is not within the specification, adjust it.
(Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) Drive Belt Tension Check 1. Belt tension can be checked in place of belt deflection.
Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has been stopped. Using the SST, check the belt tension between any two pulleys.
N kgf, Ibf
Drive belt *New Used
Generator 491-588 50-60,110-132
393-490 40-50,88-110
P/S 412—470
42-48,93—105 354—402
36-41, 80—90
A/C 557—641
56.7—65.4, 125—143
471—556 48.0—56.7, 106—124
DRIVE BELT DRIVE BELT INSPECTION Drive Belt Deflection Check 1. Check the drive belt deflection when the engine
is cold, or at least 30 minutes after the engine has been stopped. Apply pressure 98 N 10 kgf, 22 Ibf midway between the specified pulleys.
* A belt that has been on a running engine for less than five minutes.
B1-1
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DRIVE BELT, COMPRESSION INSPECTION COMPRESSION INSPECTION
Warning • When the engine and the oil are hot, they
can badly burn. Be careful not to burn yourself during removal/installation of each component.
1. Verify that the battery is fully charged. Recharge it if necessary. (Refer to section G, CHARGING SYSTEM, BATTERY INSPECTION, Battery.)
2. Warm up the engine to the normal operating temperature.
3. Stop the engine and allow it to cool off for about 10 minutes.
4. Perform "Fuel Line Safety Procedure". Leave the fuel pump relay removed. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
5. Disconnect the igniter connector. (Refer to section G, IGNITION SYSTEM, IGNITION COIL REMOVAL/INSTALLATION.)
6. Remove the spark plugs. 7. Connect a compression gauge into the No.1 spark
plug hole. 8. Fully depress the accelerator pedal and crank the
engine. 9. Note the maximum gauge reading. 10. Inspect compression of each cylinder.
Compression kPa kgf/cm2, psi [rpm]Engine type Item G6
Standard 1255 12.8, 182 [270] Minimum 882.6 9.0, 128 [270] Maximum difference between 196 kPa 2.0 kgf/cm2, 28 psi
2. If the tension is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
DRIVE BELT ADJUSTMENT 1. Loosen mounting bolts A and B, and locknut C. 2. Adjust the belt deflection or tension by turning the
adjusting bolt D. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.)
3. Tighten mounting bolts A and B and locknut C.
11. If the compression in one or more cylinders is low or the compression difference between cylinders exceeds the maximum, pour a small amount of clean engine oil into the cylinder and recheck the compression. (1) If the compression increases, the piston, the
piston rings, or cylinder wall may be worn and overhaul is required.
(2) If the compression stays low, a valve may be stuck or improperly seated and overhaul is required.
(3) If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required.
12. Disconnect the compression gauge. 13. Install the spark plugs.
Tightening torque 15—22 N.m 1.5—2.3 kgf.m, 11—l6ft.lbf
14. Connect the igniter connector. 15. Install the fuel pump relay.
B1-2
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TIMING CHAIN
TIMING CHAIN TIMING CHAIN REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the generator. 3. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way.
(Refer to section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP REMOVAL/INSTALLATION.)
4. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way.
5. Remove the cylinder head. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.)
6. Remove the water pump. (Refer to section E, WATER PUMP, WATER PUMP REMOVAL/INSTALLATION.) 7. Remove the oil pan. (Refer to section D, OIL PAN, OIL PAN REMOVAL/INSTALLATION.) 8. Disconnect the oil strainer stay. 9. Remove in the order indicated in the table. 10. Install in the reverse order of removal. 11. Start the engine and check for engine oil and engine coolant leakage.
1 A/C compressor bracket 10
Balancer chain, idler sprocket, crankshaft sprocket Installation Note 2 Generator strap
3 P/S oil pump bracket 11
Timing chain, timing sprocket, camshaft sprocket Installation Note
4 Generator bracket 12
Chain adjuster Installation Note 5
Pulley lock bolt Removal/Installation Note 13 Key
6 Crankshaft pulley 7 Chain cover
14
Timing chain lever Installation Note
8 Spacer 15 Timing chain guide 9
Balancer chain guide Installation Note
B1-3
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TIMING CHAIN Pulley Lock Bolt Removal/Installation Note
• Hold the crankshaft using the SST.
Timing Chain Lever Installation Note
• Install the chain lever and verify that it moves smoothly in the direction indicated.
Chain Adjuster Installation Note
• Push the chain adjuster sleeve in (toward the left) and insert the pin as shown into the lever to hold the sleeve.
Timing Chain, Timing Sprocket, Camshaft Sprocket Installation Note
1. Install the timing chain and timing sprocket so that the white link of the timing chain is aligned with the timing mark of the timing sprocket as shown.
2. Assemble the camshaft sprocket to the timing chain so that the timing mark of camshaft sprocket is aligned with the white link of timing chain as shown.
3. Secure the camshaft sprocket and the timing
chain with a wire to prevent disengagement. Balancer Chain, Idler Sprocket, Crankshaft Sprocket Installation Note 1. Install the crankshaft sprocket as shown.
2. Assemble the idler sprocket on to the idler shaft.
3. Set the balancer chain on the idler sprocket so
that the timing mark of the idler sprocket is aligned with the brown link of the balancer chain as shown.
B1-4
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TIMING CHAIN 4. Install the balancer chain so that the five
alignment marks on the chain, sprocket and cylinder block align, and attach the idler sprocket to the cylinder block.
5. Hand-tighten the idler sprocket lock bolt. Balancer Chain Guide Installation Note
1. Install the chain guide A and B.
2. Install the chain guide C, and tighten the bolt D
and hand-tighten the adjusting bolt E.
3. Tighten the idler sprocket lock bolt.
4. Loosen the chain guide C by adjusting bolt E. 5. Push the chain guide C with a force of 49 N
5.0 kgf, 11 Ibf in the direction of the arrow, then pull back the chain guide 3.2—3.8 mm 0.13—0.14 in] and tighten the adjusting bolt E.
Note • The balancer chain must be replaced if chain
guide C bottoms when adjusting. 6. Measure the timing chain slack.
Specification Approx. 3.0 mm 0.12 in
B1-5
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CYLINDER HEAD GASKET
CYLINDER HEAD GASKET CYLINDER HEAD GASKET REPLACEMENT
Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F1. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, COOLING SYSTEM SERVICE WARNINGS.)
(Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 4. Remove the cooling fan. 5. Remove the front pipe. 6. Remove the air intake pipe and resonance chamber. 7. Disconnect the accelerator cable and bracket. 8. S. Disconnect the vacuum hoses, water hoses, and engine harness connectors. 9. Disconnect the fuel hoses.
(Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to section F1, FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
10. Remove the intake manifold bracket. 11. Remove the distributor.
(Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 12. Remove the high-tension lead.
(Refer to section G, IGNITION SYSTEM, HIGH-TENSION LEAD REMOVAL/INSTALLATION.) 13. Remove the spark plug. 14. Remove in the order indicated in the table. 15. Install in the reverse order of removal. 16. Inspect for fuel leakage. 17. Inspect the compression.
(Refer to COMPRESSION INSPECTION.) 18. Start the engine and
(1) check the pulleys and drive belt for runout and contact. (2) check the ignition timing and idle speed. (Refer to section F1, ENGINE TUNE-UP.)
B1-6
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CYLINDER HEAD GASKET
1 Upper radiator hose 2
Cylinder head cover Installation Note
5
Cylinder head Removal Note Installation Note
6
Cylinder head gasket Installation Note
3
Distributor drive gear Removal Note Installation Note
4
Camshaft sprocket Removal Note Installation Note
B1-7
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CYLINDER HEAD GASKET Distributor Drive Gear Removal Note 1. Turn the crankshaft clockwise so that the No.1
piston is at TDC of the compression stroke.
2. Verify that the camshaft sprocket mark is aligned
with the horizontal surface on the cylinder head.
3. Remove the seal cover. 4. Hold the crankshaft using the SST.
5. Remove the lock bolt. Camshaft Sprocket Removal Note 1. Remove the service cover on the chain cover.
2. Push the chain adjuster sleeve in (toward the left) and insert a pin as shown into the lever hole to hold the sleeve.
3. Secure the camshaft sprocket and the chain with a
wire as shown.
4. Remove the camshaft sprocket off the camshaft
dowel pin. Cylinder Head Removal Note 1. Remove the bolts A. 2. Loosen the cylinder head bolts a few turns in the
order shown.
Cylinder Head Gasket Installation Note • Apply silicone sealant to the areas shown.
Thickness Ø3.0 mm 0.12 in
B1-8
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CYLINDER HEAD GASKET Cylinder Head Installation Note
1. Tighten the cylinder head bolts a few turns in the order shown.
2. Tighten the bolts A. Camshaft Sprocket Installation Note
1. Install the camshaft sprocket onto the camshaft dowel pin.
2. Remove the wire securing the camshaft sprocket and chain.
3. Remove the retaining pin from the chain adjuster. 4. Install the service cover with a new gasket.
Tightening torque 7.9—10.7 N.m 80—110 kgf.cm, 69.5—95.4 in.lbf
Distributor Drive Gear Installation Note 1. Install the distributor drive gear with a new washer
and lock bolt. 2. Hold the camshaft with a screwdriver as shown.
3. Tighten the lock bolt. 4. Apply silicone sealant to the areas shown.
5. Install the new seal cover. Cylinder Head Cover Installation Note 1. Verify that the grooves on the cylinder head cover
are free of oil, water, and other foreign material. 2. Coat a new gasket with silicone sealant, and install
it onto the cylinder head cover. 3. Apply silicone sealant to the cylinder head as
shown.
4. Install the cylinder head cover.
B1-9
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HYDRAULIC LASH ADJUSTER (HLA)
HYDRAULIC LASH ADJUSTER (HLA) HLA REMOVAL / INSTALLATION
Caution • Removal and installation of the HLA must be carried out only when the problem cannot be solved by
the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
1. Disconnect the negative battery cable. 2. Remove the distributor.
(Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 3. Remove the cylinder head cover.
(Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Check the engine oil level,
(Refer to section D, ENGINE OIL, ENGINE OIL INSPECTION.) 7. Start the engine and
(1) check the engine oil. (2) check the idle speed, (Refer to section F1, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)
8. Check the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
2
Rocker arm Removal Note & Installation Note
3 HLA Installation Note
1
Distributor drive gear CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Distributor Drive Gear Removal Note CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Distributor Drive Gear Installation Note
B1-10
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HYDRAULIC LASH ADJUSTER (HLA) Rocker Arm Removal Note 1. Loosen the bolts a few turns in the order shown.
2. Identify the rocker arm and shaft assembly parts so that they can be reinstalled in the same locations from which they were removed.
3. Remove the rocker arm and shaft assembly together with the bolts.
HLA Installation Note 1. Place each HLA in a container filled with clean
engine oil. Caution • Do not push the pin too hard. It may damage the HLA.
2. Bleed the air from the HLA by inserting a pin into the plunger hole and pressing the plunger until it no longer moves.
3. Pour engine oil into the oil reservoir in the rocker arm.
4. Apply clean engine oil to HLA O-ring
Rocker Arm Installation Note Note
• The intake side shaft has twice as many oil holes as the exhaust side shaft.
1. Assemble the rocker arm and shaft assembly as shown in the figure according to the cap number and mark.
2. Install the rocker arm and shaft. 3. Tighten the bolts a few turns in the order shown.
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HYDRAULIC LASH ADJUSTER (HLA)
HLA TROUBLESHOOTING Problem Possible Cause Action
1. Noise when engine is started immediately after oil is changed.
2. Noise when engine is started after sitting one day or more.
Oil leakage in oil passage or in HLA
3. Noise when engine is started after new HLA is installed.
Oil leakage in HLA
Run engine at 2,000—3,000 rpm. If noise stops within 20 minutes*, HLA is normal. If not, replace HLA.
Time required for engine oil to circulate within HLA includes tolerance for engine oil condition and ambient temperature. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING, Valve Clearance Inspection.)
Insufficient oil pressure
Check oil pressure. If lower than specification, check for cause. (Refer to section D, OIL PRESSURE INSPECTION)
4. Noise continues more than 10 minutes.
Faulty HLA
Press down HLA by hand. If it does not move, HLA is normal. If it moves, replace HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.) Measure valve clearance. (Refer to HLA, HLA TROUBLESHOOTING, Valve Clearance Inspection.)
Incorrect oil amount
Check oil level. (Refer to section D, ENGINE OIL, ENGINE OIL INSPECTION.)
5. Noise during idle after high speed running.
Deteriorated oil
Replace new engine oil. (Refer to section D, ENGINE OIL, ENGINE OIL REPLACEMENT.)
Valve Clearance Inspection 1. Remove the cylinder head cover.
(Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.)
2. Measure valve clearance.
Valve clearance 0.15 mm 0.0059 in max.
3. If valve clearance is more than 0.15 mm 0.0059 in, replace the HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.)
4. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Cylinder Head Cover Installation Note.)
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FRONT OIL SEAL FRONT OIL SEAL FRONT OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Drain the engine coolant.
(Refer to section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
3. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
4. Remove the cooling fan and water pump pulley. 5. Remove the radiator cowling. 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal.
1
Pulley lock bolt TIMING CHAIN, TIMING CHAIN REMOVAL/INSTALLATION, Pulley Lock Bolt Removal/Installation Note
2 Crankshaft pulley 3
Front oil seal Removal Note Installation Note
Front Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected
with a rag.
Front Oil Seal Installation Note 1. Apply clean engine oil to the oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a
hammer.
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REAR OIL SEAL REAR OIL SEAL REAR OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the flywheel.
(Refer to section H, CLUTCH UNIT, CLUTCH UNIT REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Rear oil seal Removal Note Installation Note
Rear Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver
protected with a rag.
Rear Oil Seal Installation Note 1. Apply clean engine oil to the new oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a
hammer.
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ENGINE ENGINE ENGINE REMOVAL/INSTALLATION
Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F1. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
1. Disconnect the negative battery cable. 2. Drain the engine coolant.
(Refer to section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
3. Remove the air cleaner and fresh-air duct. 4. Remove the front pipe. 5. Disconnect the accelerator cable, bracket, heater hoses, and vacuum hoses. 6. Remove the radiator.
(Refer to section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.) 7. Remove the drive belt.
(Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 8. Disconnect the fuel hoses.
(Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to section F1, FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
9. Remove the transmission. (Refer to section J2, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION.)
10. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way. (Refer to section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP REMOVAL/INSTALLATION.)
11. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way.
12. Remove in the order indicated in the table. 13. Install in the reverse order of removal. 14. Start the engine and
(1) check the engine oil, engine coolant, transmission oil, and fuel leakage. (2) check the ignition timing, idle speed and idle mixture. (Refer to section F1, ENGINE TUNE-UP.)
15. Perform a road test.
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ENGINE
1 Engine mount nut 2 Engine
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ENGINE
ENGINE DISASSEMBLY/ASSEMBLY 1. Remove the oil cooler. (Refer to section D, OIL COOLER, OIL COOLER REMOVAL/INSTALLATION.) 2. Remove the thermostat. (Refer to section E, THERMOSTAT, THERMOSTAT REMOVAL/INSTALLATION.) 3. Remove the spark plug. 4. Remove the oil pressure switch. (Refer to section D, OIL PRESSURE INSPECTION.) 5. Remove the intake-air system.
(Refer to section F1, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 6. Remove the exhaust system.
(Refer to section F1, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 7. Remove the oil filter. (Refer to section D, OIL FILTER, OIL FILTER REPLACEMENT) 8. Remove the distributor. (Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 9. Remove the generator. 10. Disassemble in the order indicated in the table. 11. Assemble in the reverse order of disassembly.
1 Water bypass pipe 6 A/C idler2 Water inlet pipe 7 P/S idler3 A/C compressor bracket 8 Oil cooler bypass pipe 4 Generator bracket 9 Generator strap5 P/S oil pump bracket
10 Engine mount
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CONTENTS
General Information GI
Engine B
Technical Data TD
Special Tools
Engine Workshop Manual F8 FE
FOREWORD This manual explains the disassembly,
inspection, repair, and reassembly procedures for the above-indicated engines. In order to do these procedures safely, quickly, and correctly, you must first read this manual and any other relevant service materials carefully.
The information in this manual is current up to April, 1997. Any changes that occur after that time will not be reflected in this particular manual. Therefore, the contents of this manual may not exactly match the mechanism that you are currently servicing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
© 2001 Ford/Mazda Motor Corporation PRINTED IN JAPAN, APR. 1997 1570-10-97D
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Title Section
ST
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GENERAL INFORMATION HOW TO USE THIS MANUAL .............. ................ Gl- 1
RANGE OF TOPICS .................... .................... Gl- 1 SERVICING PROCEDURE .............. ................ Gl- 1/2 SYMBOLS ............................. .......................... Gl- 3 ADVISORY MESSAGES ................. ................. Gl- 3 TEXT SEQUENCE ...................... ..................... Gl- 3
UNITS ................................................................... Gl- 4 NEW STANDARDS ............................................... Gl- 5 FUNDAMENTAL PROCEDURES ........... .............. Gl- 7
PREPARATION OF TOOLS AND MEASURING EQUIPMENT .......................... Gl- 7 SPECIAL TOOLS ............................................. Gl- 7 DISASSEMBLY ................................................ Gl- 7
INSPECTION DURING REMOVAL, DISASSEMBLY ............................................. Gl- 7 ARRANGEMENT OF PARTS ........................... Gl- 7 CLEANING OF PARTS .................................... Gl- 7 REASSEMBLY ................................................. Gl- 7 ADJUSTMENT ................................................. Gl- 8 RUBBER PARTS AND TUBING ....................... Gl- 8 HOSE CLAMPS ............................................... Gl- 8 TORQUE FORMULAS ...................................... Gl- 8 VISE ................................................................ Gl- 8
ELECTRICAL SYSTEM ........................................ Gl- 9 CONNECTORS ................................................ Gl- 9
ABBREVIATIONS.................................................. Gl- 10
HOW TO USE THIS MANUAL RANGE OF TOPICS • This manual contains the procedures for
performing all of the required service operations. The procedures are divided into the following five basic operations. (1) Removal/Installation (2) Disassembly/Assembly (3) Replacement (4) Inspection (5) Adjustment
• Simple operations which can be performed easily just by looking at the vehicle such as removal/installation of parts, jacking, vehicle lift, cleaning of parts, and visual inspection, have been omitted.
SERVICING PROCEDURE Inspection, Adjustment • The procedures .for inspections and adjustments
are divided into steps. Important points in regard to the location and contents of the procedures are explained in detail and are shown in the illustrations.
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HOW TO USE THIS MANUAL Repair procedure 1. Most repair operations begin with an overview illustration, It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only the removal/installation procedures which need to be performed methodically have written instructions,
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts which require the use of special service tools for removal/installation are also shown.
3. The procedures are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or information concerning a procedure. Refer to this information when servicing the related part.
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SYMBOLS
• There are eight symbols indicating oil, grease, sealant, and the use of SSTs. These symbols show the points of applying or using such
Symbol Meaning Kind
Apply oil New appropriate engine oil or gear oil
Apply brake fluid New appropriate brake fluid
Apply automatic transaxle / transmission fluid
New appropriate automatic transaxle/transmission fluid
Apply grease Appropriate grease
Apply sealant Appropriate sealant
Apply petroleum jelly
Appropriate petroleum jelly
Replace part O-ring, gasket, etc.
Use SST Appropriate SST
ADVISORY MESSAGES You'll find several Warnings, Cautions, Notes, Specifications and Upper and lower limits in this manual.
•
Caution • A Caution indicates a situation in which damage
to the vehicle could result if the caution is ignored.
Note • A Note provides added information that will help you
to complete a particular procedure.
Specification • The values indicates the allowable range when
performing inspections or adjustments.
Upper and lower limits • The values indicate the upper and lower limits that
must not be exceeded when performing inspections or adjustments.
TEXT SEQUENCE
• The text sequence is as indicated by the arrows shown below.
Example:
HOW TO USE THIS MANUAL
Warning A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
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UNITS Electrical current A (ampere) Electric potential V (volt) Electric power W (watt)
mm (millimeter) Length
in (inch) kPa (kilo pascal) mmHg (millimeters of mercury) Negative pressure inHg (inches of mercury) kPa (kilo pascal) kgf/cm2 (kilogram force per square centimeter) Positive pressure
psi (pounds per square inch) Resistance Ω (ohm) Speed rpm (revolution per minute)
N•m (Newton meter) kgf•m (kilogram force per meter)
kgf•cm (kilogram force per centimeter)
ft•lbf (foot pound)
Torque
in•lbf (inch pound) L (liter) US qt (U.S. quart) Imp qt (Imperial quart) ml (milliliter) cc (cubic centimeter) cu in (cubic inch)
Volume
fl oz (fluid ounce) 9 (gram)
Weight oz (ounce)
• The actual converted values for 2.7 kgf/cm2 are 264 kPa and 38.4 psi. In the top specification, 2.7 is used as an upper limit, so its converted values are rounded down to 260 and 38. In the bottom specification, 2,7 is used as a lower limit, so its converted values are rounded up to 270 and 39.
Conversion to Sl Units (Système International d'Unités) • All numerical values in this manual are based on
81 units. Numbers shown In conventional units are converted from these values,
Rounding off • Converted values are rounded off to the same
number of places are the Sl unit value. For example, if the 81 unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.
Upper and lower limits • When the data indicates upper and lower limits,
the converted values are rounded down if the Sl unit value is an upper limit and rounded up if the Sl unit value is a lower limit. Therefore, converted values for the same Sl unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications:
210—260 kPa 2.1—2.7 kgf/cm2 , 30—38 psi 270—310 kPa 2.7—3.2 kgf/cm2 , 39—45 psi
HOW TO USE THIS MANUAL
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NEW STANDARDS NEW STANDARDS
• Following is a comparison of the previous standard and the new standard.
Previous Standard New Standard Abbreviation Name Abbreviation Name Remark
— Accelerator Pedal AP Accelerator Pedal — Air Cleaner ACL Air Cleaner — Air Conditioning A/C Air Conditioning — Airflow Meter VAF Volume Air Flow Sensor — Airflow Sensor MAF Mass Air Flow Sensor — Alternator GEN Generator
— ATF Thermosensor — Transmission (Transaxle) Fluid Temperature Sensor
— Atmospheric Pressure BARO Barometric Pressure VB Battery Voltage B+ Battery Positive Voltage
OC Oxidation Catalytic Converter TWC Three Way Catalytic Converter
Catalytic Converter
WU-TWC Warm Up Three Way Catalytic Converter #1
— Circuit Opening Relay FPR Fuel Pump Relay #2 — Clutch Position CPP Clutch Pedal Position — Crank Angle Sensor CMP Camshaft Position Sensor — Crank Angle Sensor 2 CKP Crankshaft Position Sensor — Diagnosis Connector DLC Data Link Connector — Diagnosis/Self-Diagnosis OBD On-Board Diagnostic — Direct Ignition DLI Distributorless Ignition
— EC-AT Control Unit TCM Transmission (Transaxle) Control Module
EGI Electronic Gasoline Injection System CIS Continuous Fuel Injection System — Electronic Spark Ignition El Electronic Ignition #3
PCM Powertrain Control Module #4 ECU Engine Control Unit
ECM Engine Control Module — Engine Modification EM Engine Modification — Engine RPM Signal — Engine Speed Input Signal — Evaporative Emission EVAP Evaporative Emission — Exhaust Gas Recirculation EGR Exhaust Gas Recirculation — Fan Control FC Fan Control — Feedback System CLS Closed Loop System — Flexible Fuel FF Flexible Fuel — Fuel Pump FP Fuel Pump — Fully Closed CTP Closed Throttle Position — Fully Open WOT Wide Open Throttle — Ground/Earth GND Ground — 1C Regulator VR Voltage Regulator
#1: Directly connected to exhaust manifold #2: In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump relay (speed). #3: Controlled by the ECM/PCM #4: Device that controls engine and powertrain
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NEW STANDARDS
Previous Standard New Standard Abbreviation Name Abbreviation Name Remark
— Idle Speed Control IAC Idle Air Control — Idle Switch — Closed Throttle Position Switch — Igniter ICM Ignition Control Module — Inhibitor Position TR Transmission (Transaxle) Range — Intake Air Pressure MAP Manifold Absolute Pressure — Intake Air Thermo IAT Intake Air Temperature — Intercooler CAC Charge Air Cooler — Knock Sensor KS Knock Sensor — Line Pressure Solenoid Valve — Pressure Control Solenoid — Lock-up Position TCC Torque Converter Clutch — Malfunction Indicator Light MIL Malfunction Indicator Lamp — Multiport Fuel Injection MFI Multiport Fuel Injection — Open Loop OL Open Loop — Overdrive 4GR Fourth Gear
HO2S Heated Oxygen Sensor With heater — Oxygen Sensor
O2S Oxygen Sensor — Park/Neutral Range PNP Park/Neutral Position — Power Steering Pressure PSP Power Steering Pressure — Pulse Generator — Input/Turbine Speed Sensor — Reed Valve SAPV Secondary Air Pulse Valve
PAIR Pulsed Secondary Air Injection Pulsed injection — Secondary Air Injection System
AIR Secondary Air Injection Inject with compressor
— Sequential Fuel Injection SFI Sequential Multipoint Fuel Injection — Service Code(s) DTC Diagnostic Trouble Code(s) — Spark Ignition Dl Distributor Ignition — Stoplight Switch — Brake Switch — Test Mode DTM Diagnostic Test Mode #5 — Throttle Body TB Throttle Body — Throttle Sensor TP Throttle Position Sensor — Turbocharger TC Turbocharger — Vehicle Speed Sensor VSS Vehicle Speed Sensor — Vehicle Speed Sensor 1 — Output Speed Sensor — Water Thermo ECT Engine Coolant Temperature
1—2 Shift Solenoid Valve Shift+A Solenoid Valve
Shift Solenoid A
2—3 Shift Solenoid Valve Shift+B Solenoid Valve
— Shift Solenoid B
— 3—4 Shift Solenoid Valve — Shift Solenoid C — 3rd Gear 3GR Third Gear — — — Incorrect Gear Ratio
#5: Diagnostic trouble codes depend on the diagnostic test mode
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FUNDAMENTAL PROCEDURES PREPARATION OF TOOLS AND MESURING EQUIPMENT • Be sure that all necessary tools and measuring
equipment are available before starting any work.
SPECIAL TOOLS • Use special tools when they are required.
DISASSEMBLY • If the disassembly procedure is complex, requiring
many parts to be disassembled, all parts should be disassembled in a way that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.
INSPECTION DURING REMOVAL, DISASSEMBLY• When removed, each part should be carefully
inspected for malfunctioning, deformation, damage, and other problems.
GI-7
ARRANGEMENT OF PARTS • All disassembled parts should be carefully
arranged for reassembly. • Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
CLEANING OF PARTS • All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
Warning• Using compressed air can cause dirt and
other particles to fly out, causing injury to the eyes. Wear protective eye wear " whenever using compressed air.
REASSEMBLY• Standard values, such as torques and certain
adjustments, must be strictly observed in the reassembly of all parts.
If removed, these parts should be replaced with new ones:
1 Oil seals 2 Gaskets 3 O-rings 4 Lockwashers 5 Cotter pins 6 Nylon nuts
FUNDAMENTAL PROCEDURES
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1. Sealant, gasket, or both should be applied to the specified locations. When sealant is applied, parts should be installed before sealant hardens. Hardened sealant causes leaks.
2. Oil should be applied to the moving components of parts. 3. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly.
ADJUSTMENT• Use suitable gauges and testers when making
adjustments.
RUBBER PARTS AND TUBING • Prevent gasoline or oil from getting on rubber
parts or tubing.
HOSE CLAMPS• When reinstalling, position the hose clamp in the
original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit.
TORQUE FORMULAS• When using a torque wrench-SST combination,
the written torque must be recalculated due to the extra length that the SST adds to the torque wrench. Recalculate the torque by using the following formulas. Choose the formula that applies to you.
Torque Unit Formula N•m N•m x [L/(L+A) ]
kgf•m kgf•m x [L/(L+A) ] kgf•cm kgf•cm x [L/(L+A) ] ft•lbf ft•lbf x [L/(L+A) ] in•lbf in•lbf x [L/(L+A) ]
A: The length of the SST past the torque wrench drive.
L: The length of the torque wrench.
VISE• When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
I
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FUNDAMENTAL PROCEDURES
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Locking Connector • When locking connectors, listen for a click that will
indicate they are securely locked.
2. Check the terminals of waterproof connectors from the connector side, as they cannot be accessed from the wiring harness side.
Caution • To prevent damage to the terminal, wrap a thin
wire around the lead before inserting it into the terminal.
ELECTRICAL SYSTEM CONNECTORS Disconnecting Connectors • When disconnecting two connectors, grasp the
connectors, not the wires.
• Connectors can be disconnected by pressing orpulling the lock lever as shown.
Inspection 1. When a tester is used to check for continuity or to measure voltage, insert the tester probe from the wiring
harness side.
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ELECTRICAL SYSTEM
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ABBREVIATIONS ABBREVIATIONS
EX ............................................ Exhaust HLA ......................................... Hydraulic lash adjuster IN ............................................. lntake MAX ......................................... Maximum SST ......................................... Special service tool
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ENGINE
ENGINE OVERHAUL SERVICE WARNING .......... B- 1 ENGINE MOUNTING/DISMOUNTING ................... B- 1
MOUNTING ....................................................... B- 1/2 DISMOUNTING .................................................. B- 2
ENGINE DISASSEMBLY/ASSEMBLY .................. B- 3 TIMING BELT DISASSEMBLY/ASSEMBLY ......... B- 3/5 CYLINDER HEAD (I) DISASSEMBLY/ ASSEMBLY .................................................... B- 6/12CYLINDER HEAD (II) DISASSEMBLY/ ASSEMBLY .................................................... B-12/13 TIMING CHAIN DISASSEMBLY/ ASSEMBLY .................................................... B-14/16 CYLINDER BLOCK (I) DISASSEMBLY/ ASSEMBLY .................................................... B-17/19 CYLINDER BLOCK (II) DISASSEMBLY/ ASSEMBLY .................................................... B-20/22
ENGINE INSPECTION/REPAIR ............................ B-23 CYLINDER HEAD INSPECTION/REPAIR ........... B-23 VALVE INSPECTION ......................................... B-23/24 VALVE GUIDE INSPECTION ............................. B-24 VALVE GUIDE REPLACEMENT ......................... B-24 VALVE SEAT INSPECTION/REPAIR ................. B-25 VALVE SPRING INSPECTION ........................... B-25 CAMSHAFT INSPECTION ................................. B-26 CAMSHAFT OIL CLEARANCE INSPECTION .................................................. B-26
CAMSHAFT END PLAY INSPECTION ................... B-26 ROCKER ARM AND ROCKER ARM SHAFT
INSPECTION ..................................................... B-26/27 CYLINDER BLOCK INSPECTION/ REPAIR ............................................................. B-27 PISTON INSPECTION ........................................... B-27 PISTON CLEARANCE INSPECTION/ REPAIR ............................................................. B-28 PISTON RING CLEARANCE INSPECTION ........... B-28 PISTON PIN CLEARANCE INSPECTION .............. B-28/29 CRANKSHAFT INSPECTION ................................. B-29 CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR ........................................ B-29/30 CRANKSHAFT END PLAY INSPECTION/REPAIR ........................................ B-30 CONNECTING ROD INSPECTION ........................ B-30 CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR ........................................ B-31 CONNECTING ROD SIDE CLEARANCE INSPECTION ..................................................... B-31 PISTON AND CONNECTING ROD INSPECTION ..................................................... B-31 TENSIONER SPRING INSPECTION ..................... B-31 GEAR CLEARANCE INSPECTION ........................ B-31/32 ROTOR CLEARANCE INSPECTION ..................... B-32/33 PLUNGER SPRING INSPECTION ......................... B-33
Warning • Continuous exposure with USED engine oil
has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work.
ENGINE MOUNTING/DISMOUNTING MOUNTING 1. Install the SST (arms and attachment) to the
cylinder block holes as shown, and hand-tighten the SST (bolts).
2. Assemble the SST (bolts, nuts, and plate) to the specified positions.
ENGINE OVERHAUL SERVICE WARNING
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3. Adjust the SST (bolts) so that less than 20 mm 0.79 in of thread is exposed. 4. Make the SST (plate and arms) parallel by adjusting the SST (bolts and nuts). 5. Tighten the SST (bolts and nuts) to affix the SST firmly.
Warning• The self-locking brake system of the engine
stand may not be effective when the engine is held In an unbalanced position. This could lead to sudden, rapid movement of the engine and mounting stand handle and cause serious injury. Never keep the engine in an unbalanced position, and always hold the rotating handle firmly when turning the engine.
6. Mount the engine on the SST (engine stand).
7. Drain the engine oil. 8. Install the oil drain plug.
Tightening torque 30–41 N.m 3.0–4.2 kgf.m, 22–30 ft.lbf
DISMOUNTING • Dismount in the reverse order of mounting.
B-2
ENGINE MOUNTING/DISMOUNTING
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ENGINE DISASSEMBLY/ASSEMBLYTIMING BELT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1
Crankshaft pulley • Refer to Disassembly Note • Refer to Assembly Note
2 Upper timing belt cover 3 Lower timing belt cover 4 Guide plate 5 Spark plug
6
Timing belt • Refer to Disassembly Note • Refer to Assembly Note
7
Tensioner, tensioner spring • Refer to Assembly Note
8 Idler
B-3
ENGINE MOUNTING/DISMOUNTING
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Crankshaft Pulley Disassembly Note • Hold the crankshaft by using the SST.
Timing Belt Disassembly Note 1. Turn the crankshaft clockwise and align the timing
marks as shown.
Camshaft pulley timing mark F8: 4 FE: 2
2. Remove the spark plug. Caution
• The following will damage the belt and shorten its life; forcefully twisting it. Turning it inside out, or allowing oil or grease on It.
3. Mark the timing belt rotation on the belt for proper reinstallation.
Tensioner, Tensioner Spring Assembly Note 1. Install the tensioner and tensioner spring. 2. Position the tensioner all the way to the intake
side and temporarily secure it by tightening the lock bolt.
Timing Belt Assembly Note 1. Turn the crankshaft clockwise and align the timing
marks as shown.
Camshaft pulley timing mark F8: 4 FE: 2
2. Install the timing belt.3. Turn the crankshaft clockwise twice and align the
timing marks. If they are not aligned, remove the timing belt and repeat from Timing Belt Assembly Note step 1.
4. Loosen the tensioner lock bolt to apply tension to the belt. Do not apply tension other than that of the tensioner spring.
5. Tighten the tensioner lock bolt. Be sure the tensioner does not move together with the bolt rotation.
6. Turn the crankshaft clockwise twice and check the timing belt deflection at the point indicated by applying moderate pressure 98 N 10 kgf , 22 Ibf If it is incorrect repeat from Timing Belt Disassembly Note.
B-4
Timing belt deflectionNew : 4.0―5.0 mm 0.16―0.19 In Used : 5.5―6.5 mm 0.22―0.25 in
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B-5
Crankshaft Pulley Assembly note • Hold the crankshaft by using the SST.
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CYLINDER HEAD(I) DISASSEMBLY/ASSEMBLY Timing belt drive type 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1
Cylinder head cover • Refer to Assembly Note
2
Rocker arm • Refer to Disassembly Note • Refer to Assembly Note
3
Camshaft pulley • Refer to Disassembly Note • Refer to Assembly Note
4
Front housing • Refer to Assembly Note
5
Camshaft • Refer to Assembly Note
6
Cylinder head • Refer to Disassembly Note • Refer to Assembly Note
7 Cylinder head gasket
B-6
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Rocker Arm Disassembly Note • Loosen the bolts in two or three steps in the order
shown.
Cylinder Head Assembly Note • Tighten the bolts in two or three steps in the order
shown.
Camshaft Assembly Note • Be certain that the knock pin of the camshaft faces
straight up.
Front Housing Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.
Camshaft Pulley Assembly Note • Install the camshaft pulley on the camshaft with
the knock pin fit into the hole at the timing mark.
Camshaft pulley timing mark F8: 4 FE: 2
B-7
Camshaft pulley Disassembly Note • Hold the camshaft by using a screwdriver.
Cylinder Head Disassembly Note • Loosen the cylinder head bolts in two or three
steps in the order shown.
Rocker Arm Assembly Note 1. Assemble the rocker arms, rocker arm shafts, and
camshaft bearing cap as shown in the figure.
2. Tighten the bolts in two or three steps in the ordershown.
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Cylinder Head Cover Assembly Note 1. Apply silicone sealant to the shaded areas.
B-8
Thickness ∅1.5―2.0 mm 0.060―0.078 in
2. Install the cylinder head cover and tighten the bolts in two or three steps in the order shown.
3. Tap in the seal cap by using a plastic hammer.
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Timing chain drive type 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1
Cylinder head cover • Refer to Assembly Note
2
Chain adjuster • Refer to Disassembly Note • Refer to Assembly Note
3
Camshaft gear • Refer to Disassembly Note
4
Rocker arm • Refer to Disassembly Note • Refer to Assembly Note
5 Camshaft
6
Camshaft sprocket • Refer to Disassembly Note • Refer to Assembly Note
7
Cylinder head • Refer to Disassembly Note • Refer to Assembly Note
8
Cylinder head gasket • Refer to Assembly Note
B-9
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Chain Adjuster Disassembly Note 1. Turn the crankshaft until the FE mark of the
camshaft pulley is at the top as shown. 2. Check that the crankshaft pulley timing mark is
aligned with the indicator pin.
Cylinder Head Disassembly Note 1. Remove the bolt A. 2. Loosen the remaining cylinder head bolts in two or
three steps in the order shown.
3. Remove the chain adjuster.
Camshaft Gear Disassembly Note 1. Pry up the washer tab.
2. Hold the camshaft with a screwdriver as shown.
Rocker Arm Disassembly Note • Loosen the rocker arm shaft bolts in two or three
steps in the order shown.
2. Tighten the remaining small cylinder head bolts.
B-10
Cylinder Head Gasket Assembly Note 1. Apply silicone sealant to the shaded area.
2. Install the cylinder head gasket. 3. Apply silicone sealant to the shaded area of the
cylinder head gasket.
Cylinder Head Assembly Note 1. Tighten the cylinder head bolts in two or three
steps in the order shown.
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Rocker Arm Assembly Note 1. Apply silicone sealant to the shaded area.
Camshaft Sproket Assembly Note 1. Install the camshaft sprocket to the camshaft,
aligning mark on the camshaft sprocket and timingchain.
2. Tighten the bolt in two or three steps in the order shown.
2. Hold the camshaft with a screwdriver as shown. 3. Tap in the new seal cap by using a plastic hammer.
3. Bent the washer tab to lock the locknut.Chain Adjuster Assembly Note
1. Lift the ratchet pawl and compress the chain adjuster sleeve fully, then lock it with the pin lock.
B-11
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Cylinder Head Cover Assembly Note 1. Apply silicone sealant to the seal cap as shown.
2. Apply silicone sealant to the shaded areas.
CYLINDER HEAD (II) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1
Valve keeper • Refer to Disassembly Note • Refer to Assembly Note
2 Upper valve spring seat 3
Valve spring (FE CIS: Single spring type)
• Refer to Assembly Note 4 Lower valve spring seat 5 Valve 6
Valve seal • Refer to Disassembly Note • Refer to Assembly Note
Valve Seal Disassembly Note • Remove the valve seal by using the SST.
B-12
3. Install the cylinder head cover and tighten the bolts in two or three steps in the order shown.
Valve Keeper Disassembly Note • Remove the valve keeper by using the SST.
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Valve Seal Assembly Note 1. Assemble the SST so that depth L is as specified.
Depth L F8, FE CARB: 19.2―19.6 mm 0.756―0.771 in FE CIS: 21.4―22.2 mm 0.843―0.874 in
2. Press the valve seal onto the valve guide by hand. 3. Tap the SST by using a plastic hammer until its
lower end touches the cylinder head.
B-13
Valve Keeper Assembly Note • Install the valve keeper by using the SST.
Valve Spring Assembly Note • Install the valve spring with the closer pitch toward
the cylinder head.
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TIMING CHAIN DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table. 2. Assemble in the order of disassembly.
1 Water pump 2
Crankshaft pulley • Refer to Disassembly Note • Refer to Assembly Note
3
Timing chain cover • Refer to Disassembly Note • Refer to Assembly Note
4
Timing chain • Refer to Assembly Note
5 Timing gear 6 Crankshaft key 7 Timing chain lever
8 Timing chain guide 9 Oil strainer 10
Oil pan • Refer to Disassembly Note • Refer to Assembly Note
11 Oil pump cover 12 Inner rotor 13 Outer rotor 14 Spring seat 15 Pressure spring 16 Control plunger
B-14
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Timing Chain Assembly Note 1. Install the timing chain as shown in the figure.
Crankshaft Pulley Disassembly Note • Hold the crankshaft by using the SST.
Oil Pan Disassembly Note • Remove the oil pan by using the separator tool.
Thickness ∅2.5―3.5 mm 0.099―0.137 in
_
Timing Chain Cover Disassembly Note • Remove the oil seal by using a screwdriver
protected with a rag.
B-15
2. Support the timing chain by using a magnetic base.
Timing Chain Cover Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.
Tightening torqueA: 19―25 N.m 1.9―2.6 kgf.m , 14―18 ft.lbf B: 38―51 N.m 3.8―5.3 kgf.m , 28―38 ft.lbf
4. Apply silicone sealant to the mounting surface along the inside of the bolt holes as shown.
Oil Pan Assembly Note • Apply silicone sealant to the oil pan as shown.
5. Tighten the timing chain cover installation bolt.
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Crankshaft Pulley Assembly Note • Hold the crankshaft by using the SST.
B-16
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CYLINDER BLOCK (I) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
2
1
Oil pan (Timing belt drive type) • Refer to Disassembly Note • Refer to Assembly Note
2 Oil strainer (Timing belt drive type) 3
Oil baffle (FE CIS) • Refer to Disassembly Note • Refer to Assembly Note
4
Timing belt pulley (Timing belt drive type) • Refer to Disassembly Note • Refer to Assembly Note
5
Flywheel • Refer to Disassembly Note • Refer to Assembly Note
6 End plate 7
Oil pump (Timing belt drive type) • Refer to Disassembly Note • Refer to Assembly Note
8 Oil pump body (Timing belt drive type) 9 Outer gear (Timing belt drive type)
10 Inner gear (Timing belt drive type) 11 Oil pump cover (Timing belt drive type) 12 Spring seat (Timing belt drive type) . 13 Pressure spring (Timing belt drive type) 14 Control plunger (Timing belt drive type) 15
Rear cover • Refer to Disassembly Note • Refer to Assembly Note
16
Water pump • Refer to Assembly Note
B-17
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Oil Pan Disassembly Note Note
• Do not insert the separator tool between the oil baffle and cylinder block.
• Remove the oil pan by using the separator tool.
Oil Baffle Disassembly Note • Remove the oil baffle by using the separator tool.
Timing Belt Pulley Disassembly Note • Hold the crankshaft by using the SST.
Flywheel Disassembly Note • Hold the crankshaft by using the SST.
Oil Pump Disassembly Note • Remove the oil seal by using a screwdriver
protected with a rag.
Water Pump Assembly Note 1. Verify that the rubber seal is securely fixed onto the water pump. 2. If not, replace the rubber seal and reapply the bonding agent. 3. Install the water pump.
Rear Cover Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.
B-18
Rear Cover Disassembly Note • Remove the oil seal by using a screwdriver
protected with a rag.
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Oil Pump Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.
Oil Pan Assembly Note• Apply Silicone sealant to the oil pan as shown.
Thickness ∅2.0―3.0 mm 0.079―0.118 in
Flywheel Assembly Note1. Hold the crankshaft by using the SST. 2. Tighten the flywheel bolt in the order shown.
Timing Belt Pulley Assembly Note • Hold the crankshaft by using the SST.
Oil Baffle Assembly Note• Apply silicone sealant to the oil baffle as shown.
Thickness ∅2.0―3.0 mm 0.079―0.118 in
B-19
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CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
B-20
1 Connecting rod cap 2 Lower connecting rod bearing 3
Piston and connecting rod • Refer to Disassembly Note • Refer to Assembly Note
4 Upper connecting rod bearing 5 Piston ring 6 Piston pin 7 Piston 8 Connecting rod
9
Main bearing cap • Refer to Disassembly Note • Refer to Assembly Note
10 Lower main bearing 11
Pilot bearing • Refer to Disassembly Note • Refer to Assembly Note
12 Crankshaft 13 Upper main bearing 14 Cylinder block
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Piston and Connecting Rod Disassembly Note1. Assemble the SST as shown.
2. Insert SST No.2 into the piston pin as shown andfully screw in SST No.1.
3. Set the piston and connecting rod on the SST as shown.
4. Press out the piston pin.
Main Bearing Cap Disassembly Note • Loosen the main bearing cap bolts in two or three
steps in the order shown.
B-21
Pilot Bearing Disassembly Note
Pilot Bearing Assembly Note
Main Bearing Cap Assembly Note 1. Tighten the bolts in two or three steps in the order shown.
Piston and Connecting Rod Assembly Note 1. Assemble the SST as shown.
• Remove the pilot bearing by using the SST.
• Install the pilot bearing by using a suitable pipe.
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10. F mark facing the front of the engine.
2. Insert SST No.2 into the piston pin as shown and fully screw in SST No.1.
8. Verify that the second ring is installed with the scraper face downward. 9. Position the end gap of the oil ring as shown.3. Set the SST (stopper bolt) so that dimension L is
as specified.
Dimension L 60.0 mm 2.36 in
4. Apply clean engine oil to the piston pin. 5. Insert the piston pin and the SST assembled in
step 2 into the piston and connecting rod.
6. Press the piston pin into the piston and connecting rod until the SST (guide) contacts the SST (stopper bolt).
7. While inserting the piston pin, check the pressure force. If it is less than the specification, replace the piston pin or the connecting rod.
Pressure force 2.94―14.70 KN 300―1500 kgf , 660―3300 Ibf
B-22
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ENGINE INSPECTION/REPAIR CYLINDER HEAD INSPECTION/REPAIR 1. Carry out cooling flaw detection on the cylinder
head surface. Replace the cylinder head if necessary.
2. Inspect for the following and repair or replace if necessary. (1) Sunken valve seats (2) Excessive camshaft oil clearance and end
play 3. Measure the cylinder head for distortion in the six
directions as shown.
Distortion 0.15 mm 0.006 in max.
4. If the cylinder head distortion exceeds the maxi-mum, repair by grinding the height or replace the cylinder head. If the cylinder head height is not within the specification, replace it.
Standard height 91.95―92.05 mm 3.621―3.624 in
Grinding 0.20 mm 0.008 in max.
5. Measure the manifold contact surface distortion as shown.
Distortion 0.15 mm 0.006 in max.
6. If the distortion exceeds the specification, grind the surface or replace the cylinder head .
Grinding 0.20 mm 0.008 in max.
B-23
VALVE INSPECTION 1. Measure the valve head margin thickness of each valve. Replace the valve if necessary.
Margin thickness FE CIS IN: 1.80―2.20 mm 0.071―0.086 in EX: 1.30―1.70 mm 0.052―0.006 in F8, FE CARB IN: 0.8―1.2 mm 0.032―0.047 in EX: 1.3―1.7 mm 0.052―0.066 in
2. Measure the length of each valve. Replace the valve if necessary.
Standard length FE CIS IN: 115.61―116.01 mm 4.552―4.567 in EX: 116.01―116.41mm 4.568―4.583 in F8, FE CARB IN: 111.69―112.09 mm 4.398―4.412 EX: 111.49―111.89 mm 4.390―4.405 in
Minimum length FE CIS IN: 115.51 mm 4.548 in EX: 115.71 mm 4.556 in F8, FE CARB IN: 111.39 mm 4.386 in EX: 111.19 mm 4.378 in
3. Measure the stem diameter of each valve in X and Y directions at the three points (A, B, and C) shown. Replace the valve if necessary.
Standard diameter FE CIS IN: 6.970―6.985 mm 0.2745―0.2749 in EX: 6.965―6.980 mm 0.2743―0.2748 in F8, FE CARB IN: 8.030―8.045 mm 0.3162―0.3167 in EX: 8.025―8.040 mm 0.3160―0.3165 in
Minimum diameter FE CIS IN: 6.920 mm 0.2724 in EX: 6.915 mm 0.2722 in F8, FE CARB IN: 7.980 mm 0.3142 in EX: 7.975 mm 0.3140 in
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VALVE GUIDE INSPECTION 1. Measure the inner diameter of each valve guide in X
and Y directions at the three points (A, B, and C) shown. Replace the valve guide if necessary.
Standard inner diameter FE CIS
IN: 7.010―7.030 mm 0.2760―0.2767 in EX: 7.010―7.030 mm 0.2760―0.2767 in
F8, FE CARB IN: 8.030―8.045 mm 0.3162―0.3167 in EX: 8.025―8.040 mm 0.3160―0.3165 in
2. Measure the protrusion height (dimension A) of each valve guide without lower valve spring seat. Replace the valve guide if necessary.
VALVE GUIDE REPLACEMENTValve Guide Removal
• Remove the valve guide from the combustion chamber side by using the SST.
Valve Guide Installation1. Assemble the SSTs so that depth L is as specified.
Depth LFE CIS: 19.8―20.3 mm 0.780―0.799 in F8, FE CARB: 19.1―19.6 mm 0.752―0.771 in
2. Tap the valve guide in from the side opposite the combustion chamber until! the SST contacts the cylinder head.
3. Verify that the valve guide projection height (dimension) is within the specification.
Standard heightFE CIS: 19.8―20.3 mm 0.780―0.799 in FB, FE CARB: 19.1―19.6mm 0.752―0.771 in
B-24
Standard height FE CIS: 19.8―20.3 mm 0.780―0.799 in F8, FE CARB: 19.1―19.6mm 0.752―0.711 in
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VALVE SPRING INSPECTION 1. Apply pressing force to the pressure spring and
check the spring height. Replace the valve spring if necessary.
VALVE SEAT INSPECTION/REPAIR 1. Measure the seat contact width.
If necessary, resurface the valve seat by using a 45° valve seat cutter and/or resurface the valve face.
Standard width IN: 1.2―1.6 mm 0.048―0.062 in EX: 1.2―1.6 mm 0.048―0.062 in
2. Verify that the valve seating position is at the cen-ter of the valve face. (1) If the seating position is too high, correct the
valve seat by using a 75° (FE CIS) or 60° (F8, FE CARB) cutter, and a 45° cutter.
(2) If the seating position is too low, correct the valve seat by using a 35° (IN) or 15° (EX) cutter and a 45° cutter.
3. Check the sinking of the valve seat. Measure the protruding length (dimension L) of the valve stem. Replace the cylinder head if necessary.
Standard dimension L F8, FE CARB: 46.5 mm 1.831 in FE CIS: 49.7 mm 1.957 in
Maximum dimension L F8, FE CARB: 47.0 mm 1.850 in FE CIS: 51.2 mm 2.016 in
B-25
Pressing forceFE CIS
IN: 203.10―229.86 N 20.71―23.44 kgf , 45.57 51.56 Ibf EX: 240.37―272.03 N 24.51―27.74 kgf , 53.93―61.02 Ibf
F8, FE CARB Inner: 117.19―136.01 N 11.95―13.87 kgf , 26.29―30.51 Ibf Outer: 243.70―267.03 N 24.85―27.23 kgf , 54.67―59.90 Ibf
Standard height FE CIS IN: 41 mm 1.614 in EX: 41 mm 1.614 in F8, FE CARB Inner: 36.5 mm 1.437 in Outer: 41.0 mm 1.614 in
2. Measure the out-of-square of the valve spring. Replace the valve spring if necessary.
Valve spring out-or-square FE CIS IN: 1.70 mm 0.067 in EX: 1.76 mm 0.069 in FB, FE CARB Inner: 1.5 mm 0.059 in Outer: 1.8 mm 0.071 in
―
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CAMSHAFT INSPECTION 1. Set the No.1 and No.5 journals on V-blocks. Measure the camshaft runout. Replace the camshaft if necessary.
Runout 0.03 mm 0.0012 in max.
2. Measure the cam lobe height at the two points as shown. Replace the camshaft if necessary.
Standard height FE CIS IN: 41.340 mm 1.6276 in EX: 41.847 mm 1.6475 in F8, FE CARB IN: 38.202 mm 1.5040 in EX: 38.202 mm 1.5040 in Fuel pump cam: 39.900 mm 1.5709 in
3. Measure the journal diameters in X and Y directions at the two points (A and B) as shown. Replace the camshaft if necessary.
Standard diameter No.1, 5: 31.940―31.965 mm
1.2575―1.2585 in No.2, 3, 4: 31.910―31.935 mm
1 .2563―1.2572 in
Minimum diameter No.1, 5: 31.910 mm 1.2563 in No.2, 3, 4: 31.880 mm 1.2551 in
CAMSHAFT OIL CLEARANCE INSPECTION 1. Position a plastigage atop the journals in the axial direction.
2. Install the camshaft cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY CYLINDER HEAD (II) Camshaft Cap Assembly Note.)
3. Remove the camshaft cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER HEAD (II) Camshaft Cap Assembly Note.)
4. Measure the oil clearance. Replace the cylinder head if necessary.
Standard clearance No.1, 5: 0.035―0.085 mm
0.00138―0.00334 in No.2, 3, 4: 0.065―0.115 mm
0.00256―0.00453 in
Maximum clearance 0.15 mm 0.006 in
CAMSHAFT END PLAY INSPECTION 1. Install the camshaft and thrust plate. 2. Measure the camshaft end play. Replace the
camshaft and/or thrust plate if necessary.
Standard end play0.08―0.16 mm 0.00315―0.00629 in
Maximum end play0.20 mm 0.008 in
ROCKER ARM AND ROCKER ARM SHAFT INSPECTION 1. Measure the rocker arm inner diameter.
Diameter FE CIS: 19.000―19.033 mm 0.7481―0.7493 in F8, FE CARB: 15.966―15.984 mm 0.6286―0.6292 in
2. Measure the rocker arm shaft diameter.
B-26
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mm in
Diameter FE CIS: 18.959―18.980 mm
0.7465―0.7472 in F8, FE CARB: 15.966―15.984 mm
0.6286―0.6292 in
3. Calculate the rocker arm-to-shaft clearance. Replace the rocker arm and/or rocker arm shaft if necessary.
Standard clearance FE CIS: 0.020―0.074 mm 0.00079―0.00291 in
F8, FE CARB: 0.016―0.061 mm 0.00063―0.00240 in
CYLINDER BLOCK INSPECTION/REPAIR 1. Measure the distortion of the cylinder block top
surface in the six directions as shown. Repair by grinding or replace if necessary.
Cylinder block distortion 0.15 mm 0.006 in max.
Cylinder block height FE: 288.93―289.07 mm 11.376―11.380 in F8: 268.43―268.57 mm 10.569―10.573 in
Grinding 0.20 mm 0.008 in max.
2. Measure the cylinder bores in X and Y directions at 65 mm 2.56 in (F8), 70 mm 2.76 in (FE) below the top surface.
3. If the cylinder bore exceeds the wear limit, replace the cylinder block or rebore the cylinder and install the oversize pistons so that the specified piston-to-cylinder clearance is obtained.
Note• Base the boring diameter on the diameter of
an oversize piston. All cylinders must be the same diameter.
Cylinder bore
Size Diameter 86.000―86.019
Standard 3.3859―3.3865 86.250―86.269
0.25 0.01 oversize 3.3957―3.3964 86.500―86.519
0.50 0.02 oversize 3.4056―3.4062
Wear limit 0.15 mm 0.006 in
PISTON INSPECTION • Measure the outer diameter of each piston at a
right angle (90°) to the piston pin, 18.0 mm 0.709 in below oil ring groove.
Piston diameter mm in Size Diameter
85.943―85.965 Standard 3.38358―3.38444
86.193―86.215 0.25 0.01 oversize 3.39342―3.39428
86.443―86.465 0.50 0.02 oversize 3.40327―3.40412
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PISTON CLEARANCE INSPECTION/REPAIR1. Calculate the piston-to-cylinder clearance.
Replace the piston or rebore the cylinders to fit an oversized piston if necessary.
Standard clearance 0.035―0.076 mm 0.0014―0.0029 in
Maximum clearance 0.15 mm 0.006 in
2. If the piston is replaced, the piston rings must also be replaced.
PISTON RING CLEARANCE INSPECTION 1. Measure the piston ring-to-ring land clearance
around the entire circumference. Replace the piston and piston ring if necessary.
Standard clearance Top : 0.03―0.07 mm 0.0012―0.0027 in Second : 0.03―0.07 mm 0.0012―0.0027 in Oil : 0.03―0.07 mm 0.0012―0.0027 in
Maximum clearance 0.15 mm 0.006 in
2. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel.
3. Measure each piston ring end gap by using a feeler gauge. Replace the piston ring if necessary.
Standard end gap Top : 0.20―0.35 mm 0.008―0.013 in Second : 0.15―0.30 mm 0.006―0.011 in Oil rail : 0.20―0.70 mm 0.008―0.027 in
Maximum end gap 1.0 mm 0.039 in
PISTON PIN CLEARANCE INSPECTION 1. Measure each piston pin hole diameter in X and Y directions at the four points (A, B, C, and D) as shown.
Standard diameter21.988―21.998 mm 0.8657―0.8660 in
2. Measure each connecting rod small end inner diameter in X and Y directions as shown.
Standard diameter 21.943―21.961 mm 0.8639―0.8646 in
3. Measure each piston pin diameter in X and Y directions at the four points (A, B, C, and D) as shown.
Standard diameter 21.974―21.980 mm 0.8652―0.8653 in
4. Calculate the piston pin-to-piston pin bore clearance. Replace the piston and/or piston pin if necessary.
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Standard clearance 0.008―0.024 mm 0.00032―0.00094 in
5. Calculate the connecting rod small end-to-piston pin clearance. Replace the connecting rod or piston pin.
Standard clearance - 0.037―0.013 mm -0.0014―0.0006 in
CRANKSHAFT INSPECTION 1. Measure the crankshaft runout. Replace the crankshaft if necessary.
Runout 0.03 mm 0.0012 in
2. Measure the journal diameter in X and Y direction at the two points (A and B) as shown. Replace the crankshaft or grind the journal and install the undersize bearing if necessary.
Main journal mm in Bearing size Diameter
Standard
No.1, 2, 4, 5 : 59.937―59.955 2.3598―2.3604 No.3 : 59.937―59.955 2.3598―2.3604
0.25 0.01 undersize
No.1, 2, 4, 5 : 59.687―59.697 2.3499―2.3502 No.3 : 59.687―59.691 2.3499―2.3500
0.50 0.02 undersize
No.1, 2, 4, 5 : 59.437―59.447 2.3401―2.3404 No.3 : 59.437―59.455 2.3401―2.3407
0.75 0.03 undersize
No.1, 2, 4, 5 : 59.187―59.197 2.3302―2.3305 No.3 : 59.187―59.205 2.3302―2.3309
Out-of-round 0.05 mm 0.002 in max.
Crank pin mm in Bearing size Diameter
Standard 50.940―50.955 2.0056―2.0060
0.25 0.01 undersize 50.690―50.705 1.9957―1.9962
0.50 0.02 undersize 50.440―50.455 1.9859―1.9864
0.75 0.03 undersize 50.190―50.205 1.9760―1.9765
Out-of-round 0.05 mm 0.002 in max.
CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR .
1. Position a plastigauge atop the journals in the axial direction. 2. Install the main bearing cap.
(Refer to ENGINE DISASSEMBLY/ASSEMBLY. CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Assembly Note.)
3. Remove the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Disassembly Note.)
4. Measure the main journal oil clearance. If the clearance exceeds the maximum, replace the main bearing or grind the main journal and install the undersize bearings so that the specified oil clearance is obtained.
Standard oil clearance No.1, 2, 4, 5: 0.025―0.074 mm 0.00099―0.00291 in No.3: 0.031―0.074 mm 0.00123―0.00291 in
Maximum oil clearance 0.10 mm 0.004 in
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mm in
mm in Bearing size Bearing thickness
Standard 2.004―2.007 0.07890―0.07901
0.25 0.01 undersize 2.129―2.139 0.08382―0.08421
0.50 0.02 undersize No.1, 2, 4, 5 : 2.254―2.264 0.08874―0.08913No.3 : 2.254―2.257 0.08874―0.08885
0.75 0.03 undersize No.1, 2, 4, 5 : 2.379―2.389 0.09367―0.09405No.3 : 2.379―2.382 0.09367―0.09377
CRANKSHAFT END PLAY INSPECTION/REPAIR1. Install the main bearing cap.
(Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Assembly Note.)
2. Measure the crankshaft end play. If the end play exceeds the maximum, replace the crankshaft bearing or grind the crankshaft and Install an undersize bearing so that the specified end play is obtained.
Standard end play 0.08―0.18 mm 0.00315―0.00708 in
Maximum end play 0.30 mm 0.012 in
Note • When replacing the No.3 crankshaft bearing
replace all of the bearing as a set.
Bearing size Bearing thickness
Standard 27.94―27.99 1.1000―1.1019
0.25 0.01 undersize 28.04―28.09 1.1 040―1.1 060
0.50 0.02 undersize 28.12―28.17 1.1071―1.1090
0.75 0.03 undersize 28.20―28.25 1.1103―1.1122
3. Remove the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Disassembly Note.)
CONNECTING ROD INSPECTION • Measure each connecting rod for bending and
distortion. Replace the connecting rod if necessary.
Bending 0.15 mm 0.006 in max. /100 mm 3.937 in
Distortion 0.180 mm 0.0071 in max. /50 mm 1.97 in
Center-to-center distance FE: 151.95―152.05 5.983―5.986 in F8: 135.95―136.05 5.353―5.356 in
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CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR 1. Position a plastigauge atop the journals in the
axial direction. 2. Install the connecting rod cap.
(Refer to ENGINE DISASSEMBLY/ASSEMBLY. CYLINDER BlOCK(II) DISASSEMBLY/ASSEMBLY,
Piston and Connecting Rod Assembly Note.) 3. Remove the connecting rod cap. 4. Measure the crankpin oil clearance. If the
clearance exceeds the maximum, replace the connecting rod bearing or grind the crankpin and use undersize bearings so that the specified clearance is obtained.
Standard oil clearance 0.027―0.067 mm 0.0011―0.0026 in
Maximum oil clearance 0.10 mm 0.004 in mm in
Bearing size Bearing thickness
Standard 1.505―1.510 0.0593―0.0594
0.25 0.01 undersize 1.630―1.635 0.0642―0.0643
0.50 0.02 undersize 1.755―1.760 0.0691―0.0692
0.75 0.03 undersize 1.880―1.885 0.0741―0.0742
CONNECTING ROD SIDE CLEARANCE INSPECTION 1. Install the connecting rod cap.
(Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY. Piston and Connecting Rod Assembly Note.)
2. Measure the connecting rod large end side clearance. Replace the connecting rod and cap if necessary.
Standard clearance 0.110―0.262 mm 0.005―0.010 in
Maximum clearance 0.30 mm 0.012 in
B-31
3. Remove the connecting rod cap.
PISTON AND CONNECTING ROD INSPECTION• Check the oscillation torque as shown. If the large
end does not drop by its own weight, replace the piston or the piston pin.
TENSIONER SPRING INSPECTION • Measure the free length of the tensioner spring.
Replace the tensioner spring if necessary.
Free lengthF8: 63.0 mm 2.48 in FE CARB: 56.9 mm 2.24 in FE CIS: 53.9 mm 2.12 in
GEAR CLEARANCE INSPECTION F8, FE CARB Timing Belt Drive Type
• Measure the following clearance. Replace the gear and/or pump body if necessary.
Standard innergear tooth tip to cresent clearance
0.267―0.380 mm 0.0106―0.0149 in
Maximum innergear tooth tip to cresent crearance
0.400 mm 0.0157 in
ENGINE INSPECTION/REPAIR
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Standard outer gear tooth tip to cresent clearance
0.200―0.320 mm 0.0079―0.0125 in
ROTOR CLEARANCE INSPECTION FE CIS
• Measure the following clearance. Replace the rotor and/or pump body if necessary.
Maximum Inner rotor tooth tip to outer rotor clearance
0.18 mm 0.007 in
Maximum outer gear tooth tip to cresent clearance
0.350 mm 0.0138 in
Standard side clearance 0.030―0.063 mm 0.00119―0.00248 in
Standard outer gear to pump body clearance 0.090―0.176 mm 0.0036―0.0069 in
Maximum side clearance 0.10 mm 0.004 in
Maximum outer gear to pump body clearance 0.20 mm 0.008 in
Standard outer rotor to body clearance 0.030―0.063 mm 0.00119―0.00248 in
Standard side clearance 0.03―0.09 mm 0.0012―0.0035 in
Maximum body clearance 0.10 mm 0.004 in
Maximum side clearance 0.10 mm 0.004 in
B-32
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FE CARB Timing Chain Drive Type • Measure the following clearance. Replace the
rotor and/or pump body if necessary.
Standard Inner rotor tooth tip to outer rotor clearance
0.044―0.084 mm 0.0017―0.0033 in
PLUNGER SPRING INSPECTION • Measure the free length of the plunger spring.
Replace the plunger spring if necessary.
Free length 46.4 mm 1.827 in
Maximum Inner rotor tooth tip to outer rotor clearance
0.18 mm 0.007 in
Standard outer gear to pump body clearance 0.090―0.176 mm 0.0035―0.0069 in
Maximum outer gear to pump body clearance 0.20 mm 0.008 in
Standard side clearance 0.03―0.09 mm 0.0012―0.0035 in
Maximum side clearance 0.10 mm 0.004 in
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TECHNICAL DATA TECHNICAL DATA ......................................... TD-1/4 TECHNICAL DATA
Item SpecificationCylinder head Height mm in 91.95—92.05 3.621—3.624 Distortion mm in 0.15 0.006 max. Grinding mm in 0.20 0.008 max.
IN 0.30 0.012 (Engine hot) Valve clearance (F8, FE CARB) mm in EX 0.30 0.012 (Engine hot) Valve and valve guide
IN FE CIS: 1.80—2.20 0.071—0.086 F8, FE CARB: 0.8—1.2 0.032—0.047 Margin thickness
mm in EX FE CIS: 1.30—1.70 0.052—0.066
F8, FE CARB: 1.3—1.7 0.052—0.066
Standard FE CIS: 115.61—116.01 4.552—4.567 F8, FE CARB: 111.69—112.09 4.398—4.412 IN
Minimum FE CIS: 115.51 4.548, F8, FE CARB: 111.39 4.386
Standard FE CIS: 116.01—116.41 4.568—4.583 F8, FE CARB: 111.49—111.89 4.390—4.405
Valve length mm in
EX Minimum FE CIS: 115.71 4.556, F8, FE CARB: 111.194.378
Standard FE CIS: 6.970—6.985 0.2745—0.2749 F8, FE CARB: 8.030—8.045 0.3162—0.3167 IN
Minimum FE CIS: 6.920 0.2724 F8, FE CARB: 7.980 0.3142 Standard
FE CIS: 6.965—6.980 0.2743—0.2748 F8, FE CARB: 8.025—8.040 0.3160—0.3165
Valve stem diameter mm in
EX Minimum FE CIS: 6.915 0.2722 F8, FE CARB: 7.975 0.3140 IN
FE CIS: 7.010—7.030 0.2760—0.2767 F8, FE CARB: 8.030—8.045 0.3162—0.3167
Guide inner diameter EX
FE CIS: 7.010—7.030 0.2760—0.2767 F8, FE CARB: 8.025—8.040 0.3160—0.3165
IN
FE CIS: 19.8—20.3 0.780—0.799 F8, FE CARB: 19.1—19.6 0.752—0.771 Valve guide protrusion height
mm in EX
FE CIS: 19.8—20.3 0.780—0.799 F8, FE CARB: 19.1—19.6 0.752—0.771
Valve seat IN 1.2—1.6 0.048—0.062 Seat contact width
mm in EX 1.2—1.6 0.048—0.062 IN 45°
Seat angle EX 45° Standard F8, FE CARB: 46.5 1.831 FE CIS: 49.7 1.957
IN Maximum F8, FE CARB: 47.0 1.850 FE CIS: 51.2 2.016 Standard F8, FE CARB: 46.5 1.831 FE CIS: 49.7 1.957
Seat sinking mm in (Valve protrusion height)
EX Maximum F8, FE CARB: 47.0 1.850 FE CIS: 51.2 2.016
TD-1
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TECHNICAL DATA
Item SpecificationValve spring
H: 41.0 mm 1.614 in (FE CIS) 203.10—229.86 20.71—23.44, 45.57—51.56
IN H Inner: 36.5 mm 1.437 in Outer: 41.0 mm 1.614 in (F8, FE CARB)
Inner: 117.19—136,01 11,95—13.87, 26.29—30,51 Outer: 243.70—267.03 24.85—27.23, 54.67—59.90
H: 41.0 mm 1.614 in (FE CIS) 240.37—272.03 24.51—27.74, 53.93—61.02
Pressing force at Valve spring height H N kgf, lbf
EX H Inner: 36.5 mm 1.437 in Outer: 41.0 mm 1.614 in (F8, FE CARB)
Inner: 117.19—136.01 11.95—13.87, 26,29—30.51 Outer: 243.70—267.03 24.85—27.23, 54.67—59.90
IN FE CIS: 1.70 0.067 F8, FE CARB: Inner 1.5 0.059 outer 1.8 0.071 Out-of-square
mm in EX FE CIS: 1.76 0.069
F8, FE CARB: Inner 1.5 0.059 outer 1.8 0.071 Camshaft Camshaft runout mm in 0.03 0.0012 max.
IN FE CIS: 41,340 1.6276 F8, FE CARB: 38.202 1.5040 Lobe height mm in
EX FE CIS: 41.847 1.6475 F8, FE CARB: 38.202 1.5040 Standard 31.940—31.965 1.2575—1.2585
No.1, 5 Minimum 31.910 1.2563 Standard 31.910—31.935 1.2563—1.2572
Journal diameter mm in No.2, 3,
4 Minimum 31.880 1.2551 No.1, 5 0.035—0.085 0.00138—0,00334 No.2, 3, 4 0.065—0.115 0.00256—0.00453 Camshaft bearing oil clearance
mm in Maximum 0.15 0.006 Standard 0.08—0.16 0.00315—0.00629
Camshaft end play mm in Maximum 0.20 0.008
Rocker arm and rocker arm shaft
Rocker arm inner diameter mm in FE CIS: 19.000—19.033 0.7481—0.7493 F8, FE CARB: 15.966—15.984 0.6286—0.6292
Rocker arm shaft diameter mm in FE CIS: 18.959—18.980 0.7465—0.7472 F8, FE CARB: 15.966—15.984 0.6286—0.6292
Rocker arm to shaft clearance mm in FE CIS: 0.020—0.074 0.00079—0.00291 F8, FE CARB: 0.016—0.061 0,00063—0.00240
Cylinder block
Height mm in FE; 288.93—289.07 11.376—11.380 F8: 268.43—268.57 10.569—10.573
Distortion mm in 0.15 0.006 max. Grinding mm in 0.20 0.008 max.
Standard 86.000—86.019 3.3859—3,3865 0.25 0.01 oversize 86.250—86.269 3.3957—3.3964 Cylinder bore diameter
mm in 0.50 0.02 oversize 86.500—86.519 3.4056—3.4062
Wear limit mm in 0.15 0,006
TD-2
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TECHNICAL DATA
Item SpecificationPiston
Standard 85.943—85.965 3.38358—3.38444
0.25 0.01 oversize 86.193—86.215 3.39342—3.39428
Piston diameter Measured at 90° to pin bore axis and 18.0 mm 0.709 in below oil ring groove mm in 0.50 0.02 oversize 86.443—86.465 3.40327—3.40412
Standard 0.035—0.076 0.0014—0.0029 Piston-to-cylinder clearance mm in
Maximum 0.15 0.006 Piston ring
Top 0.03—0.07 0.0012—0.0027 Second 0.03—0.07 0.0012—0.0027 Oil 0.03—0.07 0.0012—0.0027
Piston ring-to-ring groove clearance mm in
Maximum 0.15 0.006 Top 0.20—0.35 0.008—0.013 Second 0.15—0.30 0.006—0.011 Oil (rail) 0.20—0.70 0.008—0.027
End gap (Measured in cylinder) mm in
Maximum 1.0 0.039 Piston pin Diameter mm in 21.974—21.980 0.8652—0.8653 Connecting rod small end-to-piston pin clearance mm in - 0.037— - 0.013 -0.0014— - 0.0006 Piston-to-piston pin clearance mm in 0.008—0.024 0.00032—0.00094 Crankshaft Crankshaft runout mm in 0.03 0.0012 max.
Standard No.1, 2, 4, 5: 59.937—59.955 2.3598—2.3604 No.3: 59.937—59.955 2.3598—2.3604
0.25 0.01 undersize No.3: 59.687—59.691 2.3499—2.3500
0.50 0.02 undersize No.1, 2, 4. 5: 59.437—59.447 2.3401—2.3404 No.3: 59.437—59.455 2.3401—2.3407
Main journal diameter mm in
0.75 0.03 undersize No.1, 2, 4, 5: 59,187—59.197 2.3302—2.3305
Out-of-round mm in 0.05 0.002 max. Standard 50.940—50.955 2.0056—2.0060 0.25 0.01 undersize 50.690—50.705 1.9957—1.9962 0.50 0.02 undersize 50.440—50.455 1.9859—1.9864
Crankpin diameter mm in
0.75 0.03 undersize 50.190—50.205 1.9760—1.9765 Out-of-round mm in 0.05 0.002 max.
Standard No.1, 2, 4, 5: 0.025—0.074 0.00099—0.00291 No.3: 0.031—0.074 0.00123—0.00291 Main journal oil clearance
mm in Maximum 0.10 0.004 Standard 0.08—0.18 0.00315—0.00708
Crankshaft end play mm in Maximum 0.30 0.012
TD-3
No.1, 2, 4, 5: 59.687—59.697 2.3499—2.3502
No.3: 59.187—59.205 2.3302—2.3309
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TECHNICAL DATA
Item SpecificationConnecting rod and connecting rod bearing
Length (Center to center) mm in F8: 135.95—136.05 5,353—5.356 FE: 151.95—152.05 5.983—5.986
Bending mm in 0.15 0.006 max./100 mm 3.937 in Distortion mm in 0.180 0.0071 max./50 mm 1.97 in
Standard 0.110—0.262 0.005—0.010 Connecting rod side clearance mm in Maximum 0.30 0.012
Standard 0.027—0.067 0.0011—0.0026 Connecting rod bearing oil clearance mm in Maximum 0.10 0.004 Tensioner spring
Free length mm in F8: 63.0 2.48, FE CARB: 56.9 2.24, FE CIS: 53.9 2.12
Oil pump
Standard FE CARB Timing chain drive type: 0.044—0.084 0.0017—0.0033 Inner rotor tooth tip to outer rotor
clearance mm in Maximum 0.18 0.007 (FE CIS, FE CARB Timing chain type)
Standard FE CIS, CARB Timing chain type: 0.090—0.176 0.0035—0.0069 Outer rotor to body clearance
mm in Maximum FE CIS, CARB Timing chain type: 0.20 0.008
Standard F8, FE CARB Timing belt drive type: 0.267—0.380 0.0106—0.0149 Inner gear tooth tip to crescent
clearance mm in Maximum F8, FE CARB Timing belt drive type:
0.400 0.0157
Standard P8, FE CARB Timing belt drive type: 0.200—0.320 0.0079—0.0125 Outer gear tooth tip to crescent
clearance mm in Maximum F8, FE CARB Timing belt drive type: 0.350 0.0138 Standard 0.030—0.063 0.00119—0.00248 Outer gear to pump body clearance
mm in Maximum 0.10 0.004
Standard F8, FE CARB Timing belt drive type:
0.030—0.063 0.00120—0.0024 FE CIS, FE CARB Timing chain drive type:
0.03—0.09 0.0012—0.0035 Side clearance mm in
Maximum 0.10 0.004 Plunger spring Free length mm in 46.4 1.827
TD-4
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SPECIAL TOOLS SPECIAL TOOLS ........................................... ST-1 SPECIAL TOOLS 49 0107 680A Engine stand
49 L010 1A0 Engine hanger set
49 0636 100B Valve spring lifter arm
49 B012 0A2 Pivot
49 0221 251A Valve guide remover and installer
49 S120 170 Valve seal remover
49 L012 0A2 Valve seal and guide installer
49 L011 0A0B Piston pin setting tool set
49 E011 1A0 Ring gear brake set
49 1285 071 Needle bearing puller
49 P005 204 Oil seal installer
49 S011 103 Oil seal installer
ST-1
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B2–1
ENGINE(WL, WL Turbo)
DRIVE BELT B2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE BELT INSPECTION B2–1/2. . . . . . . . . . . . . . . . DRIVE BELT ADJUSTMENT B2–2. . . . . . . . . . . . . . .
VALVE CLEARANCE B2–2. . . . . . . . . . . . . . . . . . . . . . . . VALVE CLEARANCE
INSPECTION/ADJUSTMENT B2–2. . . . . . . . . . . . . COMPRESSION INSPECTION B2–3. . . . . . . . . . . . . . . TIMING BELT B2–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING BELT REMOVAL/INSTALLATION B2–4/5. . . . CYLINDER HEAD GASKET B2–6. . . . . . . . . . . . . . . . . .
CYLINDER HEAD GASKET REPLACEMENT B2–6/8. . . . . . . . . . . . . . . . . . . . . . . . .
ROCKER ARM B2– 9. . . . . . . . . . . . . . . . . . . . . . . . . . . ROCKER ARM REMOVAL/
INSTALLATION B2– 9/11. . . . . . . . . . . . . . . . . . . . . . . . FRONT OIL SEAL B2–11. . . . . . . . . . . . . . . . . . . . . . . . .
FRONT OIL SEAL REPLACEMENT B2–11/12. . . . . . . . REAR OIL SEAL B2–12. . . . . . . . . . . . . . . . . . . . . . . . . .
REAR OIL SEAL REPLACEMENT B2–12. . . . . . . . ENGINE B2–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE REMOVAL/INSTALLATION B2–13/14. . . . . . ENGINE DISASSEMBLY/ASSEMBLY B2–14. . . . .
DRIVE BELTDRIVE BELT INSPECTIONDrive Belt Deflection Check
1. Check the drive belt deflection when the engine iscold, or at least 30 minutes after the engine hasstopped. Apply pressure 98 N 10 kgf, 22 lbfmidway between the specified pulleys.
GENERATOR
A/C
GENERATOR
MEASURINGPOINT
WATERPUMP
CRANKSHAFTPULLEY
MEASURINGPOINT a
MEASURINGPOINT b
CRANKSHAFTPULLEY
A/C COMPRESSOR
Deflection (mm in)
Drive belt *New Used Limit
Generator7.0—9.0
0.28—0.358.0—10.0
0.32—0.3916.0
0.63
A/C
a5.0—6.2
0.20—0.246.0—6.5
0.24—0.2511.3
0.44A/C
b9.5—11.8
0.38—0.4611.0—12.5
0.44—0.4918.0
0.71
* A belt that has been on a running engine for less thanfive minutes.
2. If the deflection is not within the specification,adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
Drive Belt Tension Check1. Belt tension can be checked in place of belt
deflection. Check the drive belt tension when theengine is cold, or at least 30 minutes after theengine has stopped. Using the SST, check the belttension between any two pulleys.
WHEN SET
WHEN MEASURED
49 9200 020A
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DRIVE BELT, VALVE CLEARANCE
B2–2
Tension (N kgf, lbf)
Drive belt *New Used Limit
Generator442—63745—65,99—143
383—53939—55,86—121
17718, 40
A/C403—51941—53,91—116
354—43136—44,80—96
18118.5, 41
* A belt that has been on a running engine for less thanfive minutes.
2. If the tension is not within the specification, adjustit. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
DRIVE BELT ADJUSTMENT1. Loosen the mounting bolt and locknut A.2. Adjust the belt deflection or tension by turning
adjusting bolt B. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.)
3. Tighten the mounting bolt and locknut A.
GENERATOR
A/C
GENERATOR
WATERPUMP
CRANKSHAFTPULLEY
CRANKSHAFTPULLEY
N·m kgf·m, ft·lbf
32—463.2—4.7,24—33
A/C COMPRESSOR
B
A 19—251.9—2.6,14—18
A
B
a
A
b
38—513.8—5.3,28—38
4. Inspect the belt deflection or tension. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.)
VALVE CLEARANCEVALVE CLEARANCE INSPECTION/ADJUSTMENT
1. Remove the cylinder head cover.2. Turn the crankshaft and align the timing mark so
that the piston of the No.1 or No.4 cylinder is atTDC of compression.
3. Measure the valve clearances A with the No.1cylinder at TDC of compression, and those of Bwith the No.4 cylinder at TDC of compression.
Valve clearanceIN: 0.05—0.15 mm 0.0020—0.0059 in
[Engine cold]0.15 mm 0.0059 in
[Engine hot (Reference)]EX:0.15—0.25 mm 0.0060—0.0098 in
[Engine cold]0.25 mm 0.0098 in[Engine hot (Reference)]
ENGINEFRONT
B
A A A
B B
4. If not within the specification, adjust and recheckthe valve clearance.
5. Turn the crankshaft one full turn and measure theremaining valve clearances. Adjust if necessary.
Tightening torque (locknut)16—20 N·m 1.6—2.1 kgf·m, 12—15 ft·lbf
LOCKNUT
FEELERGAUGE
ADJUSTSCREW
6. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEADGASKET REPLACEMENT, Cylinder Head Cover Installation Note.)
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COMPRESSION INSPECTION
B2–3
COMPRESSION INSPECTIONWarning When the engine and the oil are hot, they
can badly burn. Turn off the engine and waituntil they are cool.
1. Verify that the battery is fully charged. Recharge itif necessary.(Refer to Section G, CHARGINGSYSTEM, BATTERY INSPECTION, Battery.)
2. Warm up the engine to the normal operatingtemperature.
3. Stop the engine and allow it to cool off for about 10minutes.Warning Fuel line spills and leaks are dangerous.
Fuel can ignite and cause serious injuriesor death and damage. Fuel can also irritateskin and eyes. To prevent fuel fromspurting out of the injection nozzle hole, donot ground the FCV (fuel cut valve) terminal.
4. Disconnect the FCV (fuel cut valve) connector.5. Remove all the glow plugs.
(Refer to Section F2, INTAKE AIR SYSTEM, GLOW PLUG REMOVAL/INSTALLATION.)
6. Install the SSTs into the glow plug hole.49 S010 1A0
49 S013 102
7. Crank the engine and note the maximum gaugereading.
8. Check each cylinder as above.
Compression(kPa kgf/cm 2, psi [rpm])
ItemEngine
ItemWL, WL Turbo
Standard 2942 30, 427 [200]
Minimum 2648 27, 384 [200]
9. If the compression in one or more cylinders is low,pour a small amount of clean engine oil into thecylinder and recheck the compression.(1) If the compression increases, the piston, the
piston rings, or cylinder wall may be worn andoverhaul is required.
(2) If the compression stays low, a valve may bestuck or improperly seated and overhaul isrequired.
(3) If the compression in adjacent cylinders stayslow, the cylinder head gasket may be damagedor the cylinder head distorted and overhaul isrequired.
10. Remove the SST.11. Install the glow plug.
(Refer to Section F2, INTAKE AIR SYSTEM, GLOW PLUG REMOVAL/INSTALLATION.)
12. Connect the FCV (fuel cut valve) connector.
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PAGES. FROM. MANUAL
TIMING BELT
B2–4
TIMING BELTTIMING BELT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf
38—51 3.8—5.3, 28—38
1 Timing belt cover+ Installation Note
2 Tensioner, tensioner spring
3 Timing belt+ Removal Note+ Installation Note
Timing Belt Removal Note
Caution Forcefully twisting the belt, turning it inside
out, or allowing oil or grease on it willdamage the belt and shorten its life.
FAULTY
ROTATIONARROW
25 mm 1.0 in MIN.
FAULTY FAULTY
FAULTY
1. Mark the timing belt rotation on the belt for properreinstallation.
2. Turn the crankshaft clockwise and align the timingmarks as shown.
CAMSHAFTPULLEY
TIMING MARK
TENSIONERSPRING
TENSIONER
FIP PULLEYTIMING MARK
3. Remove the tensioner and tensioner spring.
Timing Belt Installation Note1. Measure the tensioner spring free length. Replace
the tensioner spring if necessary.
Free length63.0 mm 2.48 in
FREE LENGTH
2. Turn the crankshaft clockwise and align the timingmarks as shown.
CAMSHAFTPULLEY
TIMING MARK
TENSIONERSPRING
TENSIONER
FIP PULLEYTIMING MARK
TENSIONERLOCK BOLT
Caution Overtensioning of the timing belt can cause
breakage of the belt and the camshaft.
3. Verify that the FIP attaching bolts and nuts aretightened to the specified torque. This must bedone to prevent overtensioning of the timing beltafter it has been installed.
4. Install the timing belt.5. Install the tensioner, tensioner spring, and
hand-tighten the lock bolt.6. Turn the crankshaft clockwise twice, and align the
timing marks. If they are not aligned, remove thetiming belt and repeat from Timing Belt Installation Note Step 2.
7. Loosen the tensioner lock bolt to apply tension tothe belt. Do not apply tension other than that of thetensioner spring.
8. Tighten the tensioner lock bolt. Be sure thetensioner does not move together with the boltrotation.
9. Turn the crankshaft clockwise twice, and check thetiming belt deflection as shown. If it is incorrect,repeat from Timing Belt Removal Note .
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PAGES. FROM. MANUAL
ST
TIMING BELT
B2–5
Timing belt deflection9.0—10.0 mm 0.36—0.39 in at
98 N 10 kgf, 22 lbf
CAMSHAFTPULLEY
TENSIONERSPRING
TENSIONER
FIP PULLEY
TENSIONERLOCK BOLT
DEFLECTIONCHECKINGPOINT
Timing Belt Cover Installation Note Tighten the timing belt cover bolts in the order
shown.
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PAGES. FROM. MANUAL
CYLINDER HEAD GASKET
B2–6
CYLINDER HEAD GASKETCYLINDER HEAD GASKET REPLACEMENT
Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line SafetyProcedures”. (Refer to Section F2, FUEL SYSTEM, FUEL PRESSURE AND SERVICING FUEL SYSTEM.)
1. Disconnect the negative battery cable.2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE W
,ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)3. Remove the intake manifold, air intake pipe and breather chamber.
(Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)4. Remove the injection nozzle.
(Refer to Section F2, FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.)5. Remove the turbocharger. (WL Turbo)
(Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)6. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.)7. Remove in the order indicated in the table.8. Install in the reverse order of removal.9. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
10. Check the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.)11. Bleed air in the fuel line. (Refer to Section F2, FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)12. Start the engine and
(1) Inspect for engine oil, engine coolant, and fuel leakage.(2) Inspect the idle speed. (Refer to Section F2, ENGINE TUNE-UP, PREPARATION, Idle Speed Adjustment.)
13. Inspect the compression. (Refer to COMPRESSION INSPECTION.)
18—19 1.8—2.0, 13.1—14.4
N·m kgf·m, ft·lbf
7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf
38—51 3.8—5.3, 28—38
7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf
29 3.0, 22 + (90°—105°) + (90°—105°)
5.0—8.8 N·m50—90 kgf·cm,44—78 in·lbf
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CONTINUED
ARNINGS.) (Refer to Section E
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ST
CYLINDER HEAD GASKET
B2–7
1 Drive belt
2 Cylinder head cover+ Installation Note
3 Cylinder head bolt+ Removal Note+ Installation Note
4 Cylinder head
5 Cylinder head gasket+ Installation Note
Cylinder Head Bolt Removal Note1. Remove bolts A.2. Loosen the cylinder head bolts in two or three
steps in the order shown.
A
A
Cylinder Head Gasket Installation Note Apply silicone sealant to the cylinder head as
shown.
Thicknessø2.0—3.0 mm 0.08—0.11 in
ENGINEFRONT
16.0 mm0.63 in
40.5 mm1.59 in
48.5 mm1.91 in
9.0 mm0.35 in
Cylinder Head Bolt Installation Note1. Measure the length of each bolt. Replace the bolt if
necessary.
Cylinder head bolt (mm in)
Bolt head mark Standardlength
Maximumlength
W101.2—101.8
3.985—4.007102.5 4.035
N113.2—113.8
4.457—4.480114.5 4.508
LENGTH
2. Apply clean engine oil to the threads and the seatface of each bolt and install them.
3. Tighten the bolts in two or three steps in the ordershown in the figure.
Tightening torque29 N·m 3.0 kgf·m, 22 ft·lbf
A
A
4. Put a paint mark on each bolt head.5. Using the marks as a reference, tighten the bolts
by turning each 90°—105° in the sequence shown.6. Further tighten each bolt by turning another
90°—105°.
PAINT MARK
PAINT MARK
90°—105° 90°—105°
7. Tighten bolts A.
Tightening torque18—19 N·m 1.8—2.0 kgf·m, 13.1—14.4 ft·lbf
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CYLINDER HEAD GASKET
B2–8
Cylinder Head Cover Installation Note1. Apply silicone sealant to the cylinder head as
shown.
Thicknessø1.5—2.5 mm 0.060—0.098 in
2. Tighten cylinder head cover bolts A and B.
Tightening torque1.5—2.9 N·m 15—30 kgf·cm, 14—26 in·lbf
ENGINEFRONT
A
B
3. Tighten the cylinder head cover bolts in the ordershown.
Tightening torque5.0—8.8 N·m 50—90 kgf·cm, 44—78 in·lbf
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PAGES. FROM. MANUAL
ST
ROCKER ARM
B2–9
ROCKER ARMROCKER ARM REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove the air intake pipe and breather chamber.
(Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)3. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.)4. Remove in the order indicated in the table.5. Install in the reverse order of removal.
16—20 1.6—2.1, 12—15
N·m kgf·m, ft·lbf
7.9—10.7 N·m 80—110 kgf·cm, 69.5—95.4 in·lbf
30—41 3.0—4.2, 22—30
5.0—8.8 N·m50—90 kgf·cm,44—78 in·lbf
11.3—14.2 N·m 115—145 kgf·cm, 100—125 in·lbf
123—140 12.5—14.3, 91—103
R
SST
R
1 Cylinder head cover+ VALVE CLEARANCE, VALVE CLEARANCE
INSPECTION/ADJUSTMENT+ CYLINDER HEAD GASKET, CYLINDER HEAD
GASKET REPLACEMENT, Cylinder Head CoverInstallation Note
2 Camshaft pulley+ Removal Note+ Installation Note
3 Seal plate+ Installation Note
4 Camshaft+ Removal Note+ Installation Note
5 Rocker arm+ Installation Note
6 Pivot
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PAGES. FROM. MANUAL
ROCKER ARM
B2–10
Camshaft Pulley Removal Note Hold the camshaft by using a wrench on the cast
hexagon.
Camshaft Removal Note
Note Mark the camshaft caps so that they can be
reinstalled in the position from which they wereremoved.
Loosen the camshaft cap bolts in three or foursteps in the order shown.
ENGINEFRONT
Rocker Arm Installation Note If a new rocker arm is used, set dimension as
follows.
Dimension A0—4 mm 0—0.1 in
A
Camshaft Installation Note1. Apply silicone sealant to the front camshaft cap
mounting surfaces as shown. Prevent sealant fromgetting onto the camshaft journal, oil seal surface,and camshaft thrust surface.
2. Tighten the camshaft cap bolts gradually in three orfour steps in the order shown.
ENGINEFRONT
3. Apply clean engine oil to the new oil seal.4. Push the oil seal slightly in by hand.5. Tap the oil seal into the cylinder head by using the
SST and a hammer.6. To ensure that the oil seal is installed accurately,
measure distance between the end of the cylinderhead and the face of the oil seal.
HAMMER CYLINDERHEAD OIL SEAL
0.5—1.0 mm 0.02—0.03 in
49 S010 001
Seal Plate Installation Note Tighten the seal plate bolts in the order shown.
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PAGES. FROM. MANUAL
ROCKER ARM, FRONT OIL SEAL
B2–11
Camshaft Pulley Installation Note Hold the camshaft by using a wrench on the cast
hexagon and tighten the pulley lock bolt.
FRONT OIL SEALFRONT OIL SEAL REPLACEMENT
1. Disconnect the negative battery cable.2. Drain the engine coolant. (Refer to Section E,
COOLING SYSTEM SERVICE WARNINGS.)(Refer to Section E, ENGINE COOLANT, ENGINECOOLANT REPLACEMENT.)
3. Remove the upper radiator hose.4. Remove the radiator cowling and cooling fan.
(Refer to Section E, WATER PUMP, WATERPUMP REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.6. Install in the reverse order of removal.7. Inspect the engine oil level.8. Adjust the drive belt deflection.
(Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
R
SST
SST
N·m kgf·m, ft·lbf
350—39035—40,260—280
1 Drive belt
2 Crankshaft pulley+ Removal Note+ Installation Note
3 Front oil seal+ Removal Note+ Installation Note
Crankshaft Pulley Removal Note Hold the crankshaft by using the SST.
Caution Turning the crankshaft after the crankshaft
pulley is removed can cause the timinggear to become dislocated.
Removing the key can cause the keygroove to become misaligned.
49 S011 102A
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FRONT OIL SEAL, REAR OIL SEAL
B2–12
Front Oil Seal Removal Note1. Cut the oil seal lip by using a razor knife.2. Remove the oil seal by using a screwdriver
protected with a rag.
RAG
Front Oil Seal Installation Note1. Apply clean engine oil to the new oil seal lip.2. Push the oil seal slightly in by hand.3. Tap the oil seal in evenly by using the SST and a
hammer.4. To ensure that the oil seal is installed accurately,
measure the distance between the end of the gearcase cover and the face of the front oil seal.
HAMMERFRONT OIL SEAL
0—0.4 mm0—0.01 in
GEAR CASE COVER
49 S010 301
Crankshaft Pulley Installation Note Hold the crankshaft by using the SST.
49 S011 102A
REAR OIL SEALREAR OIL SEAL REPLACEMENT
1. Disconnect the negative battery cable.2. Remove the flywheel.
(Refer to Section H, CLUTCH UNIT, CLUTCH UNITREMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.4. Install in the reverse order of removal.5. Inspect the engine oil level. (Refer to Section D,
ENGINE OIL, ENGINE OIL INSPECTION.)
RSST
1 Rear oil seal+ Removal Note+ Installation Note
Rear Oil Seal Removal Note1. Cut the oil seal lip by using a razor knife.2. Remove the oil seal by using a screwdriver
protected with a rag.
RAG
Rear Oil Seal Installation Note1. Apply clean engine oil to the new oil seal lip.2. Push the oil seal slightly in by hand.3. Tap the oil seal in evenly by using the SST and a
hammer.4. To ensure that the oil seal is installed accurately,
measure the distance between the end of the rearcover and the face of the rear oil seal.
HAMMERREAR OIL SEAL
REAR COVER
0—0.5 mm 0—0.01 in
49 S011 103
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ENGINE
B2–13
ENGINEENGINE REMOVAL/INSTALLATION
Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line SafetyProcedures”. (Refer to Section F2, FUEL SYSTEM, FUEL PRESSURE AND SERVICING FUEL SYSTEM.)
1. Remove the air intake pipe. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
2. Remove the battery. (Refer to Section G, CHARGING SYSTEM, BATTERY REMOVAL/INSTALLATION.)3. Remove the radiator. (Refer to Section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.)4. Remove the front pipe.
(Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)5. Remove the transmission.
(Refer to section J2, TRANSMISSION, TRANSMISSION REMOVAL/INSTALLATION.)6. Remove in the order indicated in the table.7. Install in the reverse order of removal.8. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)9. Bleed air in the fuel line. (Refer to Section F2, FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)
10. Start the engine and(1) Inspect the engine oil, engine coolant, and fuel leakage.(2) Inspect the idle speed.
(Refer to Section F2, ENGINE TUNE-UP, IDLE SPEED PREPARATION, Idle Speed Adjustment.)11. Perform a road test.
N·m kgf·m, ft·lbf
32—46 3.2—4.7, 24—33
7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf
20—30 2.0—3.1, 15—22
9.9—14.7 N·m100—150 kgf·cm,86.8—130 in·lbf
19—25 1.9—2.6,14—18
1 Cooling fan
2 Drive belt
3 Accelerator cable
4 A/C compressor+ Removal Note
5 P/S oil pump+ Removal Note
6 Engine mount nut
7 Engine+ Removal/Installation Note
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ENGINE
B2–14
A/C Compressor Removal Note Remove the A/C compressor with the pipe still
connected. Position the A/C compressor so that itis out of the way.
P/S Oil Pump Removal Note Remove the P/S oil pump with the oil hose still
connected. Position the P/S oil pump so that it isout of the way.
Engine Removal/Installation Note Install the engine hanger (JE48 10 561C) to the
cylinder head by using bolt (99794 0820) or (M8 1.25, 6T, length 20 mm 0.79 in) as shown.
Tightening torque19—25 N·m 1.9—2.6 kgf·m, 14—18 ft·lbf
ENGINEFRONT
ENGINE DISASSEMBLY/ASSEMBLY1. Remove the intake-air system.
(Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
2. Remove the exhaust system. (Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
3. Remove the oil cooler. (Refer to Section D, OIL COOLER, OIL COOLERREMOVAL/INSTALLATION.)
4. Disassemble in the ordre indicated in the table.5. Assemble in the reverse order of disassembly.
N·m kgf·m, ft·lbf
38—513.8—5.3,28—38
38—513.8—5.3,28—38
32—463.2—4.7,24—33 19—25 1.9—2.6, 14—18
12—17 1.2—1.8, 9—13
1 Drive belt
2 Generator
3 Idler
4 A/C compressor bracket
5 Engine mount bracket
6 Oil pressure switch+ Section D, OIL PRESSURE INSPECTION
7 Water pump pulley
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ENGINE (F2)
DRIVE BELT .................................................... B3- 1 HLA REMOVAL/INSTALLATION ................ B3-10/12 DRIVE BELT INSPECTION .......................... B3- 1 HLA TROUBLESHOOTING ........................ B3-13 DRIVE BELT ADJUSTMENT ........................ B3- 2 FRONT OIL SEAL ......................................... B3-14
TIMING BELT .................................................. B3- 4 REAR OIL SEAL ............................................. B3-15
CYLINDER HEAD GASKET ............................. B3- 7 ENGINE .......................................................... B3-16
HYDRAULIC LASH ADJUSTER (HLA) ............ B3-10
Deflection mm inDrive belt *New Used
Generator 7.0—8.0 0.28—0.31
8.0—9.0 0.32—0.35
P/S 5.0—6.0 0.20—0.23
5.5—6.5 0.22—0.25
A/C 10.0—12.0 0.40—0.47
12.0—14.0 0.48—0.55
DRIVE BELT DRIVE BELT INSPECTION Drive Belt Deflection Check 1. Check the drive belt deflection when the engine
is cold, or at least 30 minutes after the engine has stopped. Apply pressure 98 N 10 kgf, 22 Ibf midway between the specified pulleys.
* A belt that has been on a running engine for less than five minutes. 2. If the deflection is not within the specification,
adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
Drive Belt Tension Check 1. Belt tension can be checked in place of belt
deflection. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two pulleys.
B3-1
CYLINDER HEAD GASKET ENGINE REMOVAL/INSTALLATION ......... B3-16/17
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COMPRESSION INSPECTION ........................ B3- 2/3 FRONT OIL SEAL REPLACEMENT ........... B3-14
TIMING BELT REMOVAL/INSTALLATION ... B3-4/6 REAR OIL SEAL REPLACEMENT ............. B3-15
REPLACEMENT ......................................... B3- 7/9 ENGINE DISASSEMBLY/ASSEMBLY ........ B3-18
DRIVE BELT, COMPRESSION INSPECTION Tension N kgf, Ibf
Drive belt *New Used
Generator 510—588 52—60,
115—132
432—509 44—52,
97—114
P/S 393—490 40—50, 88—110
344—441 35—45, 77—99
A/C 373—490 38—50, 84—110
275—372 28—38, 62—83
COMPRESSION INSPECTION Warning • When the engine and the oil are hot, they
can badly burn. Be careful not to burn yourself during removal/installation of each component.
• Verify that the battery is fully charged. Recharge it if necessary. (Refer to Section G, CHARGING SYSTEM, BATTERY INSPECTION, Battery.)
• Warm up the engine to the normal operating temperature.
• Stop the engine and allow it to cool off for about 10 minutes.
• Perform "Fuel Line Safety Procedure". Leave the fuel pump relay removed. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
• Disconnect the igniter connector (F2 CIS) or ignition coil primary wire connector (F2 CARB).
• Remove the spark plugs. • Connect a compression gauge into the No.1 spark
plug hole. • Fully depress the accelerator pedal and crank the
engine. • Note the maximum gauge reading. • Inspect compression of each cylinder.Compression kPa kgf/cm2, psi [rpm]
Engine type Item F2 CARB F2CIS
Standard 1196 12.2, 173 [300]
1226 12.5, 178 [300]
Minimum 837 8.54, 121 [300]
858 8.75, 124 [300]
Maximum difference between cylinders
196 kPa 2.0 kgf/cm2, 28 psi
* A belt that has been on a running engine for less than five minutes.
2. If the tension is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
DRIVE BELT ADJUSTMENT 1. Loosen mounting bolts A and B, and locknut C. 2. Adjust the belt deflection or tension by turning the
generator or adjusting bolt D. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.)
3. Tighten mounting bolts A and B, and locknut C.
• If the compression in one or more cylinders is low or the compression difference between cylinders exceeds the maximum, pour a small amount of clean engine oil into the cylinder and recheck the compression. • If the compression increases, the piston, the
piston rings, or cylinder wall may be worn and overhaul is required.
• If the compression stays low, a valve may be stuck or improperly seated and overhaul is required.
• If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required.
• Disconnect the compression gauge. • Install the spark plugs.
Tightening torque 15—22 N-m 1.5—2.3 kgf-m, 11—16 ft-lbf
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COMPRESSION INSPECTION
• Connect the igniter connector (F2 CIS) or ignition coil primary wire connector (F2 CARB).
• Install the fuel pump relay.
B3-3
CONTINUED
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TIMING BELT TIMING BELT TIMING BELT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable. 2. Remove the spark plugs. 3. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 4. Remove the cooling fan and cooling fan pulley. 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Start the engine and
(1) Inspect the pulleys and drive belt for runout and contact. (2) Inspect the ignition timing.
(Refer to Section F3-F4, ENGINE TUNE-UP, IGNITION TIMING ADJUSTMENT.)
1 Generator strap 2 Cooling fan bracket
6
Timing belt Removal Note Installation Note3
Timing belt cover Installation Note 7 Tensioner, tensioner spring
Installation Note4 Crankshaft pulley 5 Guide plate
B3-4
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TIMING BELT Timing Belt Removal Note
1. Turn the crankshaft clockwise and align the timing marks.
Camshaft pulley timing mark 1
2. Loosen the tensioner lock bolt. 3. Push the tensioner in the direction of the ar
row to reduce tension of the timing belt and hand-tighten the tensioner lock bolt.
Caution • Forcefully twisting the belt, turning it
inside out, or allowing oil or grease on it will damage the belt and shorten its life.
Note • Mark the timing belt rotation on the belt for
proper reinstallation.
Tensioner, Tensioner Spring Installation Note
1. Measure the tensioner spring free length. If not as specified, replace the tensioner spring. Free length 63.0 mm 2.48 in
2. Install the tensioner. 3. Temporarily secure the tensioner with the spring
fully extended.
Timing Belt Installation Note 1. Verify that the timing belt pulley mark and
camshaft pulley mark are aligned with the timing marks as shown.
Camshaft pulley timing mark 1
2. Install the timing belt so that there is no
looseness at the tension side.
B3-5
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TIMING BELTCaution
• Applying excessive tension can break the timing belt. Be sure not to apply tension other than that of the tensioner spring.
3. Loosen the tensioner lock bolt to apply tension to the timing belt.
4. Turn the crankshaft clockwise twice and verify that the timing belt pulley mark and camshaft pulley mark are aligned with the timing marks.
5. If not, repeat from Timing Belt Removal Note. (Refer to Timing Belt Removal Note.)
Caution • Prevent the tensioner from moving with the
tensioner lock bolt as it is turned. Otherwise tension will become very high and the timing belt may break.
6. Tighten the tensioner lock bolt. 7. Inspect the timing belt deflection at the point
indicated by applying moderate pressure 98 N 10 kgf, 22 Ibf.
Timing belt deflection New : 8.0—9.0 mm 0.32—0.35 in Used : 9.0—10.0 mm 0.36—0.39 in
8. If not as specified, repeat from Timing Belt
Removal Note. (Refer to Timing Belt Removal Note.)
Timing Belt Cover Installation Note • Tighten the timing belt cover bolts in the order
shown.
B3-6
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CYLINDER HEAD GASKETCYLINDER HEAD GASKET CYLINDER HEAD GASKET REPLACEMENT
Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F3, F4. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.)
(Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the timing belt, (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 4. Remove the front pipe.
(Refer to Section F3-F4, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 5. Remove the air cleaner. (F2 CARB) 6. Remove the air hose. (F2 CIS) 7. Disconnect the PCV hose. 8. Disconnect the accelerator cable and bracket (F2 CIS). 9. Disconnect the vacuum hoses, and engine harness connector.
10. Disconnect the fuel hoses. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to Section F3-F4, AFTER REPAIR PROCEDURE.)
11. Remove the dynamic chamber bracket. (F2 CIS) 12. Disconnect the heater hoses. 13. Remove in the order indicated in the table. 14. Install in the reverse order of removal. 15. Inspect for fuel leakage. 16. Inspect the compression. (Refer to COMPRESSION INSPECTION.) 17. Start the engine and inspect the idle speed.
(Refer to Section F3-F4, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)
B3-7 CONTINUED
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CYLINDER HEAD GASKET
3 Cylinder head gasket 1
Cylinder head cover Installation Note
2
Cylinder head Removal Note Installation Note
B3-8
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CYLINDER HEAD GASKET Cylinder Head Bolt Removal Note
• Loosen the cylinder head bolts a few turns in the order shown.
Cylinder Head Bolt Installation Note • Tighten the cylinder head bolts a few turns in the
order shown.
Cylinder Head Cover Installation Note 1. Verify that the grooves on the cylinder head cover
are free of oil, water and other foreign material. 2. Apply sealant all around the cylinder head cover
side of the cylinder head cover gasket surface. 3. Install the cylinder head cover gasket into the
cylinder head cover. 4. Apply silicone sealant to the shaded area as
shown.
B3-9
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HYDRAULIC LASH ADJUSTER (HLA)HYDRAULIC LASH ADJUSTER (HLA) HLA REMOVAL/INSTALLATION
Caution • Removal and installation of the HLA must be carried out only when the problem cannot be solved by
the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
1. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 2. Remove the cylinder head cover.
(Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.) 6. Start the engine and
(1) inspect the engine oil (2) inspect the idle speed. (Refer to Section F3—F4, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)
7. Inspect the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
3 Hydraulic lash adjuster (HLA)
Installation Note1
Rocker arm component Removal Note Installation Note
2 Camshaft cap (F2 CARB) Installation Note
B3-10
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HYDRAULIC LASH ADJUSTER (HLA) Rocker Arm Component Removal Note
1. Loosen the bolts a few turns in the order shown.
2. Identify the rocker arm and shaft assembly parts
so that they can be reinstalled in the same locations from which they were removed.
3. Remove the rocker arm and shaft assembly together with the bolts.
Hydraulic Lash Adjuster (HLA) Installation Note
1. Place each HLA in a container filled with clean engine oil.
Caution • Do not push the pin too hard. It may
damage the HLA. 2. Bleed the air from the HLA by inserting a pin into
the plunger hole and pressing the plunger until it no longer moves.
3. Pour engine oil into the oil reservoir in the rocker
arm.
4. Apply clean engine oil to HLA 0-ring.
Camshaft Cap (F2 CARS) Installation Note
• Apply silicone sealant to the shaded areas of the cylinder head as shown.
Rocker Arm Component Installation Note Note • The intake side shaft has twice as many oil
holes as the exhaust side shaft. (F2 CARB)
1. Assemble the rocker arms and shaft assembly as shown in the figure.
B3-11
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HYDRAULIC LASH ADJUSTER (HLA)
2. Apply silicone sealant to the shaded areas of the
cylinder head as shown.
3. Install the rocker arm component. 4. Tighten the bolts a few turns in the order shown.
B3-12
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HYDRAULIC LASH ADJUSTER (HLA)HLA TROUBLESHOOTING
Problem Possible Cause Action 1. Noise when engine is started
immediately after oil is changed.
2. Noise when engine is started after sitting one day or more.
Oil leakage in oil passage or in HLA
3. Noise when engine is started after new HLA is installed.
Oil leakage in HLA
Run engine at 2,000—3,000 rpm. If noise stops within 20 minutes*, HLA is normal. If not, replace HLA. * Time required for engine oil to circulate within HLA includes tolerance for engine oil condition and ambient temperature. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING, Valve Clearance Inspection.)
Insufficient oil pressure
Check oil pressure. If lower than specification, check for cause. (Refer to section D, OIL PRESSURE INSPECTION.)
4. Noise continues more than 10 minutes.
Faulty HLA
Press down HLA by hand. If it does not move, HLA is normal. If it moves, replace HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.) Measure valve clearance. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING, Valve Clearance Inspection.)
Incorrect oil amount
Check oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.)
5. Noise during idle after high speed running.
Deteriorated oil
Replace new engine oil. (Refer to Section D, ENGINE OIL, ENGINE OIL REPLACEMENT.)
Valve Clearance Inspection 1. Remove the cylinder head cover.
(Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.)
2. Measure valve clearance.
Valve clearance 0.15 mm 0.0059 in max.
3. If valve clearance is more than 0.15 mm 0.0059 in, replace the HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.)
4. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.)
B3-13
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FRONT OIL SEAL FRONT OIL SEAL FRONT OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the timing belt.
(Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the engine oil level.
(Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.)
1
Timing belt pulley Removal/Installation Note
2 Key 3
Front oil seal Removal Note Installation Note
Timing Belt Pulley Removal/Installation Note • Hold the crankshaft using the SST.
Front Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver
protected with a rag.
Front Oil Seal Installation Note
1. Apply clean engine oil to the oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a
hammer.
B3- 14
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REAR OIL SEALREAR OIL SEAL REAR OIL SEAL REPLACEMENT
1. Disconnect the negative battery cable. 2. Remove the flywheel.
(Refer to Section H, CLUTCH UNIT, CLUTCH UNIT REMOVAL/ INSTALLATION.)
3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Rear oil seal • Refer to Removal Note
• Refer to Installation Note Rear Oil Seal Removal Note
1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected with a
rag.
Rear Oil Seal Installation Note
1. Apply clean engine oil to the new oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a
hammer.
B3-15
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ENGINEENGINE ENGINE REMOVAL/INSTALLATION Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F3, F4. (Refer to section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.)
(Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the air cleaner and air hose (F2, CIS). 4. Remove the front pipe. 5. Disconnect the accelerator cable, bracket (F2 CIS), heater hoses, high-tension leads, and vacuum hoses. 6. Remove the radiator. (Refer to Section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.) 7. Remove the cooling fan and cooling fan pulley. 8. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 9. Disconnect the fuel hoses. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
(Refer to Section F3-F4, FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 10. Remove the transmission.
(Refer to Section J1-J2, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION.) 11. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way.
(Refer to Section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP REMOVAL/INSTALLATION.)
12. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way. 13. Remove in the order indicated in the table. 14. Install in the reverse order of removal. 15. Start the engine and
(1) Inspect the engine oil, engine coolant, transmission oil, and fuel leakage. (2) Inspect the ignition timing, idle speed and idle mixture. (Refer to Section F3-F4, ENGINE TUNE-UP.)
16. Perform a road test.
B3-16
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ENGINE
1 Engine mount nut 2 Engine
B3-17
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ENGINEENGINE DISASSEMBLY/ASSEMBLY
1. Remove the distributor. (Refer to Section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 2. Remove the generator. 3. Remove the thermostat. (Refer to Section E, THERMOSTAT, THERMOSTAT REMOVAL/INSTALLATION.) 4. Remove the intake-air system.
(Refer to Section F3-F4, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 5. Remove the exhaust system.
(Refer to Section F3-F4, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 6. Remove the oil filter. (Refer to Section D, OIL FILTER, OIL FILTER REPLACEMENT.) 7. Remove the oil pressure switch. (Refer to Section D, OIL PRESSURE INSPECTION.) 8. Disassemble in the order indicated in the table. 9. Assemble in the reverse order of disassembly.
1 Generator strap 6 Dipstick 2 Cooling fan bracket 7 P/S oil pump bracket 3 Generator bracket 8 Gusset plate 4 Water inlet pipe 9 Engine mount5 Water bypass pipe
B3-18
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D–1
LUBRICATION SYSTEMOIL PRESSURE INSPECTION D–1. . . . . . . . . . . . . . . . ENGINE OIL D–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL INSPECTION D–2. . . . . . . . . . . . . . . . . . ENGINE OIL REPLACEMENT D–2. . . . . . . . . . . . . . .
OIL FILTER D–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL FILTER REPLACEMENT D–2. . . . . . . . . . . . . . . .
OIL COOLER D–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL COOLER REMOVAL/INSTALLATION D–3/4. . . . . OIL COOLER BODY INSPECTION D–4. . . . . . . . . .
OIL PAN D–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PAN REMOVAL/INSTALLATION D–4/5. . . . . . . . .
OIL PRESSURE INSPECTIONWarning Continuous exposure with USED engine oil
has caused skin cancer in laboratory mice.Protect your skin by washing with soap andwater immediately after this work.
When the engine and the oil are hot, theycan badly burn. Turn off the engine and waituntil they are cool.
1. Remove the oil pressure switch.2. Screw the SST into the oil pressure switch
installation hole.
F2, G6
49 0187 280
49 0187 280
WL, WL TURBO
3. Warm up the engine to normal operatingtemperature.
4. Run the engine at the specified speed, and notethe gauge readings.
Note The oil pressure can vary with viscosity and
temperature.
Oil pressureF2 : 295—392 kPa
3.0—4.0 kgf/cm 2, 43—56 psi [3,000 rpm]
G6 : 305—402 kPa 3.1—4.1 kgf/cm 2, 45—58 psi [3,000 rpm]
WL : 452—529 kPa 4.6—5.4 kgf/cm 2, 66—76 psi [3,000 rpm]
WL Turbo : 402—480 kPa 4.1—4.9 kgf/cm 2, 59—69 psi [3,000 rpm]
5. If the pressure is not as specified, inspect for thecause and repair or replace as necessary.
6. Stop the engine and wait until it becomes cool.7. Remove the SST.8. Apply silicone sealant to the oil pressure switch
threads as shown.1.0—2.0 mm0.040—0.078 in
4.0—6.0 mm0.16—0.23 in
9. Install the oil pressure switch before the sealanthardens.
Tightening torque12—17 N·m 1.2—1.8 kgf·m, 9—13 ft·lbf
10. Start the engine and inspect for oil leakage.
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ENGINE OIL, OIL FILTER
D–2
ENGINE OILENGINE OIL INSPECTION
1. Position the vehicle on level ground.2. Warm up the engine to normal operating
temperature and stop it.3. Wait for five minutes.4. Remove the dipstick and inspect for oil level and
condition. Verify that the oil level is within the F andL marks on the dipstick.
5. Add or replace oil if necessary.
ENGINE OIL REPLACEMENT
Warning When the engine and the engine oil are hot,
they can badly burn. Don’t burn yourselfwith either.
A vehicle that is lifted but not securelysupported on safety stands is dangerous. Itcan slip or fall, causing death or seriousinjury. Never work around or under a liftedvehicle if it is not securely supported onsafety stands.
Continuous exposure with USED engine oilhas caused skin cancer in laboratory mice.Protect your skin by washing with soap andwater immediately after this work.
1. Position the vehicle on level ground.2. Remove the oil filler cap and the oil pan drain plug.3. Drain the oil into a container.4. Install the drain plug by using a new washer.
Tightening torque30—41 N·m 3.0—4.2 kgf·m, 22—30 ft·lbf
5. Refill the engine oil with the specified type andamount of engine oil.
6. Refit the oil filler cap.7. Run the engine and inspect for oil leakage.8. Inspect the oil level and add oil if necessary.
(Refer to ENGINE OIL, ENGINE OIL INSPECTION.)
Note The actual oil level may vary from the specified
capacity in some cases.
Oil capacity (L US qt, Imp qt)Engine
ItemF2 G6 WL, WL
Turbo
Oil replacement3.9
4.1, 3.44.5
4.8, 4.05.6
5.9, 4.9
Oil and oil filterreplacement
4.2 4.4, 3.7
4.7 5.0, 4.4
6.3 6.7, 5.5
Total(dry engine)
4.6 4.9, 4.0
5.5 5.8, 4.8
6.7 7.1, 5.9
OIL FILTEROIL FILTER REPLACEMENT
1. Remove the oil filter by using the SST or the filterwrench.
49 9014 001
2. Use a clean rag to wipe off the mounting surfaceon the oil filter body.
3. Apply engine oil to the O-ring and tighten the filteraccording to the installation directions on the sideof the oil filter using the SST or the filter wrench.
4. Start the engine and inspect for oil leakage.5. Inspect for the oil level and add oil if necessary.
(Refer to ENGINE OIL, ENGINE OILINSPECTION.)
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OIL COOLER
D–3
OIL COOLEROIL COOLER REMOVAL/INSTALLATIONG6, WL, WL Turbo
1. Disconnect the negative battery cable.2. Drain the engine coolant. (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)3. Remove the turbocharger.
(Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) (WL Turbo model.)4. Remove the oil filter. (Refer to OIL FILTER, OIL FILTER REPLACEMENT.)5. Remove in the order shown in the figure.6. Install in the reverse order of removal.7. Fill the radiator with the specified amount and type of engine coolant.
(Refer to section E, ENGINE COOLANT,ENGINE COOLANT REPLACEMENT.)8. Inspect the engine oil level. (Refer to ENGINE OIL, ENGINE OIL INSPECTION.)9. Start the engine and inspect for engine coolant leakage.
N·m kgf·m, ft·lbf
30—39 3.0—4.0, 22—28
G6
1 Water hose
2 Nut
3 Oil cooler
N·m kgf·m, ft·lbf
R
R
19—25 1.9—2.6, 14—18R
19—25 1.9—2.6, 14—18
R
R
30—49 3.0—5.0, 22—36
7.9—10.7 N·m80—110 kgf·cm,70—95 in·lbf
WL, WL TURBO
1 Dipstick pipe
2 Radiator hose
3 Thermostat case
4 Insulator
5 Oil cooler body+ Installation Note
6 Oil cooler
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OIL COOLER, OIL PAN
D–4
Oil Cooler Body Installation NoteWL, WL Turbo Tighten the mounting bolts and nuts in the order
shown.
OIL COOLER BODY INSPECTIONWL, WL Turbo Measure the spring free length. Replace the spring
if necessary.
Standard free lengthBypass valve spring: 36.7 mm 1.44 inPressure control valve spring: 54.7 mm 2.15 in
BYPASS VALVE SPRING
PRESSURE CONTROL VALVE SPRING
OIL PANOIL PAN REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Drain the engine oil.
(Refer to ENGINE OIL, ENGINE OIL REPLACEMENT.)3. Remove in the order shown in the figure.4. Install in the reverse order of removal.5. Fill with the specified amount and type of engine
oil. (Refer to ENGINE OIL, ENGINE OIL REPLACEMENT.)
6. Start the engine and inspect for engine oil leakage.
N·m kgf·m, ft·lbf
7.9—10.7 N·m80—110 kgf·cm,70—95 in·lbf
F2, G6
38—513.8—5.3,28—38
38—513.8—5.3,28—38
30—413.0—4.2, 22—30
1 Gusset plate
2 Oil pan+ Removal Note+ Installation Note
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OIL PAN
D–5
N·m kgf·m, ft·lbf
94—1159.5—11.8, 69—85
55—805.6—8.2,41—59
7.9—10.7 N·m80—110 kgf·cm,70—95 in·lbf
WL, WL TURBO
1 Crossmember (4WD)
2 Oil pan+ Removal Note+ Installation Note
Oil Pan Removal Note1. Remove the oil pan mounting bolts.
Caution Pry tools can easily scratch the cylinder
block or oil baffle and oil pan contactsurfaces. Prying off the oil pan can alsoeasily bend the oil pan flange.
2. Use a separator tool to separate the oil pan.
SEPARATOR TOOL
Oil Pan Installation Note
Caution If the bolts are reused, remove the old
sealant from the bolt threads. Tightening abolt that has old sealant on it can causebolt hole damage.
CRACKS
OLD SEALANT
1. Apply silicone sealant to the oil pan along theinside of the bolt holes and overlap the ends.
ThicknessØ2.0—3.0 mm 0.08—0.11 in
OIL PAN
2. Install the oil pan before the sealant hardens.
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E–1
COOLING SYSTEMENGINE COOLANT E–1. . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE COOLANT LEVEL INSPECTION E–1. . . . ENGINE COOLANT REPLACEMENT E–1/2. . . . . . . . ENGINE COOLANT LEAKAGE
INSPECTION E–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR CAP E–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RADIATOR CAP INSPECTION E–3. . . . . . . . . . . . . . RADIATOR E–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RADIATOR REMOVAL/INSTALLATION E–3. . . . . . .
THERMOSTAT E–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTAT REMOVAL/INSTALLATION E–4/5. . . . THERMOSTAT INSPECTION E–5. . . . . . . . . . . . . . .
WATER PUMP E–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER PUMP REMOVAL/INSTALLATION E–6. . . .
COOLING FAN E–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING FAN REMOVAL/INSTALLATION E–7. . . COOLING FAN INSPECTION E–7. . . . . . . . . . . . . . .
ENGINE COOLANT
Warning Removing the radiator cap or loosening the
radiator drain plug while the engine isrunning, or when the engine and radiatorare hot is dangerous. Scalding coolant andsteam may shoot out and cause seriousinjury. It may also damage the engine andcooling system.
Turn off the engine and wait until it is cool.Even then, be very careful when removingthe cap. Wrap a thick cloth around it andslowly turn it counterclockwise to the firststop. Step back while the pressure escapes.
When you’re sure all the pressure is gone,press down on the cap –still using a cloth–turn it, and remove it.
When the engine and the engine coolant arehot, they can badly burn. Turn off theengine and wait until they are cool beforedraining the engine coolant.
ENGINE COOLANT LEVEL INSPECTION1. Remove the radiator cap.2. Verify that the coolant level is near the radiator filler
neck.3. Verify that the coolant level in the radiator reservoir
is between the FULL and LOW marks.4. Add coolant if necessary.
ENGINE COOLANT REPLACEMENT1. Drain the coolant in the radiator reservoir.2. Remove the radiator cap and loosen the radiator
drain plug.
DRAINPLUG
TYPE A
TYPE B
3. Drain the coolant into a container.4. Flush the cooling system with water until all traces
of color are gone.5. Let the system drain completely.6. Tighten the radiator drain plug.
Tightening torqueType A: 1.5—2.9 N·m
15—30 kgf·cm, 14—26 in·lbfType B: 0.9—1.1 N·m
9.0—12 kgf·cm, 7.9—10 in·lbf
Caution The engine has aluminum parts that can be
damaged by alcohol or methanol antifreeze.Do not use alcohol or methanol in thecooling system. Use onlyethylene-glycol-based coolant.
Use only soft (demineralized) water in thecoolant mixture. Water that containsminerals will cut down on the coolant’seffectiveness.
7. Referring to the following graph and chart, selectproper gravity of the coolant. Slowly pour thecoolant into the radiator up to the coolant filler port.
Filling pace1.0 L 1.1 US qt, 0.88 Imp qt/min. [max]
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ENGINE COOLANT
E–2
COOLANT TEMPERATURE °C °F
–10 14
0 32
10 50
20 68
30 86
40 104
50 122
60 140
70 158
80 176
90 194
0
1,000
1,010
1,020
1,030
1,040
1,050
1,060
1,070
1,080
1,090
1,100
COOLANT PROTECTIONSPECIFICGRAVITY
30%
40%
50%
Antifreeze solution mixture percentage
Coolant protectionVolume percentage Gravity
at 20°CCoolant protectionWater Coolant
at 20°C68°F
Above –16°C 3°F 65 35 1,054
Above –26°C –15°F 55 45 1,066
Above –40°C –40°F 45 55 1,078
8. Fill the coolant into the reservoir up to the FULLmark.
9. Fully install the radiator cap.10. Start the engine and let it idle for approx. 10
minutes. If the coolant temperature becomes toohigh, stop the engine to prevent it fromoverheating.
11. After the engine warms up, run it at approx. 2,500rpm for five minutes.
12. Increase the engine speed to approx. 3,000 rpmfor five seconds, then return to idle. Repeat severaltimes.
13. Stop the engine and wait until it is cool.14. Inspect the coolant level. If it is low, repeat Steps
7—12.15. Inspect for coolant leakage.
ENGINE COOLANT LEAKAGE INSPECTION1. Inspect the coolant level.
(Refer to ENGINE COOLANT, ENGINE COOLANT LEVEL INSPECTION.)
2. Remove the radiator cap.3. Connect a radiator cap tester and the SST to the
radiator filler neck.4. Apply pressure to the radiator.
PressureF2: 103 kPa 1.05 kgf/cm 2, 14.9 psiG6, WL, WL Turbo:
122 kPa 1.25 kgf/cm 2, 17.7 psi
Caution Applying more than 103 kPa 1.05 kgf/cm 2,
14.9 psi (F2) or 122 kPa 1.25 kgf/cm 2, 17.7psi (G6, WL, WL Turbo) can damage thehoses, fittings, and other components, andcause leakage.
49 9200 146
49 9200 147
5. Verify that the pressure is held. If not, inspect thesystem for coolant leakage.
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ST
RADIATOR CAP, RADIATOR
E–3
RADIATOR CAPRADIATOR CAP INSPECTION
Warning Removing the radiator cap while the engine
is running, or when the engine and radiatorare hot is dangerous. Scalding coolant andsteam may shoot out and cause seriousinjury. It may also damage the engine andcooling system.
Turn off the engine and wait until it is cool.Even then, be very careful when removingthe cap. Wrap a thick cloth around it andslowly turn it counterclockwise to the firststop. Step back while the pressure escapes.
When you’re sure all the pressure is gone,press down on the cap –still using a cloth–turn it, and remove it.
1. Attach the radiator cap to a radiator cap tester withthe SST. Apply pressure gradually.
2. Verify that the pressure becomes stable within thespecification.
PressureF2: 74—102 kPa
0.75—1.05 kgf/cm 2, 10.7—14.9 psiG6, WL, WL Turbo: 94—122 kPa
0.95—1.25 kgf/cm 2, 13.5—17.7 psi
3. If the pressure is held for 10 seconds, the radiatorcap is normal.
49 9200 147
RADIATORRADIATOR REMOVAL/INSTALLATION
1. Drain the engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
2. Remove in the order indiacted in the table.3. Install in the reverse order of removal.4. Fill the radiator with the specified amount and type
of engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
N·m kgf·m, ft·lbf
7.9—10.7 N·m 80—110 kgf·cm, 69.5—95.4 in·lbf
18—261.8—2.7, 14—19
18—261.8—2.7,14—19
1 Radiator hose
2 Lower radiator cowling
3 Radiator cowling
4 Radiator
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THERMOSTAT
E–4
THERMOSTATTHERMOSTAT REMOVAL/INSTALLATION
1. Drain the engine coolant. (Refer to ENGINECOOLANT, ENGINE COOLANT REPLACEMENT.)
2. Remove in the order indicated in the table.3. Install in the reverse order of removal.4. Fill the radiator with the specified amount and type
of engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
N·m kgf·m, ft·lbf
F2
19—25 1.9—2.6, 14—18
R
1 Upper radiator hose
2 Thermostat cover
3 Thermostat+ Installation Note
N·m kgf·m, ft·lbf
G6
19—25 1.9—2.6, 14—18
19—25 1.9—2.6, 14—18
R
1 Upper radiator hose
2 Thermostat cover
3 Thermostat+ Installation Note
N·m kgf·m, ft·lbf
7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf
R
19—25 1.9—2.6, 14—18
WL, WL TURBO
1 Dipstick pipe
2 Lower radiator hose
3 Thermostat cover
4 Thermostat+ Installation Note
Thermostat Installation NoteF2, G6
1. Install the thermostat into the cylinder head withthe jiggle pin at the top.
2. Install a new gasket with the seal print side facingthe cylinder head.
JIGGLE PINA
AA–A
WL, WL Turbo Install the thermostat into the thermostat cover,
aligning the projection on the gasket to thethermostat cover as shown.
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ST
THERMOSTAT
E–5
PROJECTION
THERMOSTAT COVER
GASKET
THERMOSTAT INSPECTION
Warning During inspection, the thermostat and water
are extremely hot and they can badly burn.Do not touch the thermostat and waterdirectly.
Inspect the thermostat for the following and replace asnecessary. Open valve in room temperature Opening temperature and lift of the valve
Initial-opening temperatureF2: 83.5—89.5 °C 183—193 °FG6: 86.5—89.5 °C 188—193 °F (Main valve)
83.5—86.5 °C 183—187 °F (Sub valve)WL, WL Turbo: 80—84 °C 176—183 °F
Full open temperatureF2, G6 : 100 °C 212 °FWL, WL Turbo: 95 °C 203 °F
Full open liftG6 : 8.0 mm 0.31 in min. (Main valve)
1.5 mm 0.06 in min. (Sub valve)F2, WL, WL Turbo: 8.5 mm 0.33 in min.
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WATER PUMP
E–6
WATER PUMPWATER PUMP REMOVAL/INSTALLATION
1. Remove the cooling fan. (Refer to COOLING FAN, COOLING FAN REMOVAL/INSTALLATION.)
2. Remove the timing belt (F2). (Refer to Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.)
3. Drain the engine coolant. (Refer to ENGINECOOLANT, ENGINE COOLANT REPLACEMENT.)
4. Remove in the order indicated in the table.5. Install in the reverse order of removal.6. Fill the radiator with the specified amount and type
of engine coolant. (Refer to ENGINE COOLANT,ENGINE COOLANT REPLACEMENT.)
N·m kgf·m, ft·lbf
F2
19—251.9—2.6, 14—18
R
38—513.8—5.3, 28—38
N·m kgf·m, ft·lbf
19—221.9—2.2, 14—16
G6
R
N·m kgf·m, ft·lbf
19—251.9—2.6, 14—18
19—221.9—2.3, 14—16
WL, WL TURBO
R
1 Water pump
2 Idler
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COOLING FAN
E–7
COOLING FANCOOLING FAN REMOVAL/INSTALLATION
1. Remove the drive belt.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.4. Adjust the drive belt (generator) deflection.
(Refer to Section B2,DRIVE BELT, DRIVE BELT ADJUSTMENT.)
N·m kgf·m, ft·lbf
F2, G6: 7.9—10.7 N·m 80—110 kgf·cm, 69.5—95.4 in·lbfWL, WL TURBO: 19—25 1.9—2.6, 14—18
1 Cooling fan
2 Water pump pulley
COOLING FAN INSPECTION1. Rotate the cooling fan by hand and inspect for
abnormal noise and looseness. Replace thecooling fan if necessary. (Refer to COOLING FAN, COOLING FAN REMOVAL/INSTALLATION.)
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FUEL AND EMISSION CONTROL SYSTEMS (G6)
ENGINE TUNE-UP ...............................................................F1-2 ENGINE TUNE-UP PREPARATION ............................F1-2
IGNITION TIMING ADJUSTMENT...............................F1-2/3 IDLE SPEED ADJUSTMENT .......................................F1-4 IDLE-UP SPEED INSPECTION ..................................F1-4/5 IDLE MIXTURE INSPECTION .....................................F1-5 INTAKE-AIR SYSTEM ........................................................F1-6 VACUUM HOSE ROUTING DIAGRAM .......................F1-6 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .................................F1-6/7 BYPASS AIR CONTROL (BAC) VALVE REMOVAL/INSTALLATION .................................F1-8 AIR VALVE INSPECTION ........................................... F1-8 IDLE AIR CONTROL (lAC) VALVE INSPECTION ........................................................F1-8 ACCELERATOR PEDAL REMOVAL/INSTALLATION ................................ F1-9 ACCELERATOR CABLE INSPECTION/ADJUSTMENT ..............................F1-9 FUEL SYSTEM .................................................................. F1-10 BEFORE REPAIR PROCEDURE ............................. F1-10 AFTER REPAIR PROCEDURE ................................. F1-10 FUEL TANK REMOVAL/INSTALLATION ............................... F1-11/13 NONRETURN VALVE INSPECTION ........................ F1-13 FUEL PUMP UNIT REMOVAL/INSTALLATION ............................... F1-13 FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY .............................. F1-13/14
FUEL PUMP UNIT INSPECTION .............................. F1-14/16 FUEL FILTER (HIGH-PRESSURE)
REMOVAL/INSTALLATION ............................... F1-16/17 FUEL INJECTOR REMOVAL/INSTALLATION ............................... F1-18/19 FUEL INJECTOR INSPECTION ................................ F1-19/21 PRESSURE REGULATOR REMOVAL/INSTALLATION ............................... F1-21 PRESSURE REGULATOR INSPECTION ...................................................... F1-21/22 PRESSURE REGULATOR CONTROL (PRC) SOLENOID
VALVE INSPECTION ................................................. F1-22 PULSATION DAMPER REMOVAL/INSTALLATION ............................... F1-22 PULSATION DAMPER INSPECTION ....................... F1-22 FUEL PUMP RELAY INSPECTION .......................... F1-23 EXHAUST SYSTEM .......................................................... F1-24 EXHAUST SYSTEM INSPECTION ........................... F1-24 EXHAUST SYSTEM REMOVAL/INSTALLATION ............................... F1-24 EMISSION SYSTEM .......................................................... F1-25 EMISSION SYSTEM (ENGINE COMPARTMENT SIDE) COMPONENT LOCATION .......................................................... F1-25
ROLLOVER VALVE INSPECTION ........................... F1-25 EVAPORATIVE GAS CHECK VALVE (TWO-WAY) INSPECTION ................................ F1-25
CHECK VALVE (TWO-WAY) INSPECTION ....................................................... F1-25/26 EVAPORATIVE CHAMBER INSPECTION ....................................................... F1-26 CHARCOAL CANISTER INSPECTION ................... F1-26 PURGE SOLENOID VALVE INSPECTION ....................................................... F1-26/27 POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION .............................. F1-27 CONTROL SYSTEM .......................................................... F1-28 CONTROL SYSTEM COMPONENT
LOCATION............................................................ F1-28 PCM REMOVAL/INSTALLATION .............................F1-29 PCM INSPECTION .............................................. F1-29/37 MASS AIR FLOW (MAF) SENSOR INSPECTION........................................................ F1-37 THROTTLE POSITION (TP) SENSOR
INSPECTION ....................................................... F1-37/38 THROTTLE POSITION (TP) SENSOR ADJUSTMENT .................................................... F1-38 THROTTLE POSITION (TP) SENSOR REMOVAL/INSTALLATION ................................ F1-38/39 CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION ....................................... F1-39 INTAKE AIR TEMPERATURE (IAT) SENSOR
INSPECTION ....................................................... F1-39 INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION ................................ F1-40 ENGINE COOLANT TEMPERATURE (ECT)
SENSOR REMOVAL/INSTALLATION ............... F1-40 ENGINE COOLANT TEMPERATURE (ECT)
SENSOR INSPECTION ...................................... F1-40/41 CAMSHAFT POSITION (CMP) SENSOR INSPECTION ....................................................... F1-41 OXYGEN SENSOR O2S) INSPECTION ....................................................... F1-41/42 OXYGEN SENSOR O2S) REMOVAL/INSTALLATION................................. F1-42 VARIABLE RESISTOR INSPECTION........................ F1-42 CLUTCH SWITCH INSPECTION .............................. F1-42/43 CLUTCH SWITCH REMOVAL/INSTALLATION ............................... F1-43 NEUTRAL SWITCH INSPECTION ............................ F1-43 NEUTRAL SWITCH REMOVAL/INSTALLATION ................................ F1-43/44 POWER STEERING PRESSURE
(PSP) SWITCH INSPECTION ............................ F1-44 MAIN RELAY INSPECTION ....................................... F1-44/45 MAIN RELAY REMOVAL/INSTALLATION ................ F1-45 ON-BOARD DIAGNOSTIC SYSTEM ............................... F1-45 READ/CLEAR DIAGNOSTIC TEST
RESULTS ............................................................. F1-45 PARAMETER IDENTIFICATION (PID)
ACCESS ............................................................... F1-45 DIAGNOSTIC SUPPORT PROCEDURE .................. F1-45 SIMULATION TEST..................................................... F1-45 ON-BOARD DIAGNOSTIC TEST .............................. F1-45/46 DTC READING PROCEDURE .................................. F1-46/48
F1-1
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PID/DATA MONITOR AND RECORD PROCEDURE ......................................................F1-48
PLAYBACK OF STORED PIDS PROCEDURE ......................................................F1-48/49
DIAGNOSTIC SUPPORT PROCEDURE ..........F1-49 SIMULATION TEST PROCEDURE ........................F1-50/51
AFTER REPAIR PROCEDURE .............................F1-51 DTC INSPECTION ..................................................F1-52/69
TROUBLESHOOTING ...................................................F1-70 FOREWORD ............................................................F1-70
TROUBLESHOOTING ITEM TABLE .....................F1-70 QUICK DIAGNOSTIC CHART ...............................F1-71/74 SYMPTOM TROUBLESHOOTING .......................F1-75/114 DIAGNOSTIC INSPECTION..................................F1-115/120
ENGINE SYSTEM INSPECTION .........................F1-120/127
ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION Using the SSTs (NGS Tester) 1. Warm up the engine to normal operating
temperature. 2. Shift the transmission into neutral. 3. Turn off all electrical loads.
• A/C switch 4. Verify that the steering wheel is at straight ahead
position. 5. Connect the SSTs (NQS tester) to the DLC and
select "PID/DATA MONITOR AND RECORD". (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TEST, NGS Tester Hook-up Procedure.)
6. Access RPM PID. Press the trigger key to enter
this selection. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, PID/DATA MONITOR AND RECORD PROCEDURE.)
7. Press SETUP (Key 8) and turn the test mode on.
8. Press CANCEL. 9. Press START.
Not Using the SSTs (NGS tester) 1. Warm up the engine to normal operating
temperature. 2. Shift the transmission into neutral. 3. Turn off all electrical loads.
• A/C switch 4. Verify that the steering wheel is at straight ahead
position. Caution
• Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only.
5. Connect a dwell tachometer to the DLC terminal IG-.
IGNITION TIMING ADJUSTMENT Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION".
(Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.)
2. Verify that the RPM PID is within the specification. Specification 730—770 (750 ±20) rpm
3. If not as specified, adjust the idle speed. (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)
4. Connect the timing light to the high-tension lead of the No. 1 cylinder.
5. Verify that the timing mark on the crankshaft pulley is within the specification. Specification BTDC 4°—6°(5° ± 1°)
F1-2
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FUEL AND EMISSION CONTROL SYSTEMS (G6)
Page 2 of 2
ENGINE TUNE-UP
6. If not as specified, loosen the distributor lock bolts and turn the distributor to make the adjustment.
7. Tighten the distributor lock bolts to the specified torque. Tightening torque 19—25 N.m 1.9—2.6 kgf.m, 14—18 ft.lbf
8. Press SETUP (Key 8) and turn the test mode off. 9. Press CANCEL. 10. Verify that the timing mark on the crankshaft
pulley is within the specification.
Specification BTDC 1°—30°
Not Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION".
(Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.)
2. If using the SST (System selector) to turn on the test mode, perform the following: (1) Connect the SST to the DLC. (2) Set switch A to position 1. (3) Set the test switch to SELF TEST.
3. If using a jumper wire to turn on the test mode,
perform the following: Caution
• Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only.
• Use a jumper wire to short terminal TEN of the DLC to body GND.
4. Verify that the idle speed is within the
specification. Specification 730—770 (750 ± 20) RPM
5. If not as specified, adjust the idle speed.
(Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)
6. Connect the timing light to the high-tension lead
of the No.1 cylinder. 7. Verify that the timing mark on the crankshaft
pulley is within the specification. Specification BTDC 4°—6° (5° ± 1°)
8. If not as specified, loosen the distributor lock bolts and turn the distributor to make the adjustment.
9. Tighten the distributor lock bolts to the specified torque.
Tightening torque 19—25 N.m 1.9—2.6 kgf.m, 14—18 ft.lbf
10. Disconnect the SST or jumper wire. 11. Verify that the timing mark on the crankshaft pulley is within the specification. Specification BTDC 1°—30°
F1-3
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ENGINE TUNE-UP IDLE SPEED ADJUSTMENT Using the SSTs (NGS Tester)
1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.)
2. Verify that the RPM PID is within the specification. Specification 730—770 (750 ± 20) RPM
Caution • The TAS is set at the factory and must not
be adjusted. Any adjustment will negatively affect the engine performance.
3. If not as specified, verify that the ignition timing is within specification according to the "IGNITION TIMING ADJUSTMENT", then adjust the idle speed by turning the AAS.
4. Press SETUP (Key 8) to turn the test mode off. 5. Press CLEAR to clear previously selected items. 6. Disconnect the SSTs.
Not Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION".
(Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.)
2. If using the SST (System selector) to turn on the test mode, perform the following: (1) Connect the SST to the DLC. (2) Set switch A to position 1. (3) Set the test switch to SELF TEST.
3. If using a jumper wire to turn on the test mode,
perform the following:
Caution • Connecting the wrong DLC terminals
may possibly cause a malfunction. Carefully connect the specified terminals only.
• Use a jumper wire to short terminal TEN of the DLC to body GND.
4. Verify that the idle speed is within the specification
using the dwell tachometer. Specification 730—770 (750 ± 20) RPM Caution • The TAS is set at the factory and must not
be adjusted. Any adjustment will negatively affect the engine performance.
5. If not as specified, verify that the ignition timing is within specification according to the "IGNITION TIMING ADJUSTMENT', then adjust the idle speed by turning the AAS.
6. Disconnect the SST or a jumper wire. 7. Disconnect the dwell tachometer. IDLE-UP SPEED INSPECTION Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION".
(Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.)
2. Press SETUP (Key 8) and turn the test mode off. 3. Press CANCEL. 4. Press START. 5. Verify that the idle speed is normal.
(Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)
6. Verify that the RPM PID is within the specification.
F1-4
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ENGINE TUNE-UP Specification
Load condition Idle-up speed (RPM)*1 P/S ON*2 A/C ON*3 700—800 (750 ± 50)
*1: Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. *2: Steering wheel is fully turned.
: A/C switch and fan switch are on. 7. If not as specified with all load conditions,
inspect the IAC valve. 8. If not as specified with some load condition,
inspect the related input switches, harnesses, and connectors.
Not Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION".
(Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.)
2. Verify that the idle speed is normal. (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)
3. Verify that the idle-up speed is within the specification.
Specification Load condition Idle-up speed (rpm)*1
P/S ON*2 A/C ON*3 700—800 (750 ± 50)
*1: Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. *2: Steering wheel is fully turned. *3: A/C switch and fan switch are on. 4. If not as specified with all load conditions, inspect
the IAC valve. 5. If not as specified with some load conditions,
inspect the related input switches, harnesses, and connectors.
IDLE MIXTURE INSPECTION Vehicles With Oxygen Sensor (O2S) 1. Perform "ENGINE TUNE-UP PREPARATION".
(Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.)
2. Verify that the idle speed and ignition timing are within the specification. (Refer to ENGINE TUNE-UP, IGNITION TIMING INSPECTION.) (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)
3. Turn the test mode off. 4. Warm up the engine by holding the engine speed
at 2500—3000 rpm for approx. 3 minutes. 5. Insert an exhaust gas analyzer to the tailpipe. 6. Verify that the CO and HC concentrations are
within the regulation. 7. If not within the regulation, inspect the following:
• On-board diagnostic system (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TROUBLE CODE INSPECTION.)
• O2S (Refer to CONTROL SYSTEM, OXYGEN SENSOR O2S) INSPECTION.)
• Intake manifold vacuum (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Intake Manifold Vacuum Inspection.)
• Fuel line pressure (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection.)
• Ignition timing control (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Ignition Timing Control Inspection.)
• If the systems and devices are normal, replace the TWC. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
Vehicles Without Oxygen Sensor O2S) 1. Perform "ENGINE TUNE-UP PREPARATION". 2. Verify that the idle speed and ignition timing are
within the specification. (Refer to IGNITION TIMING INSPECTION.) (Refer to IDLE SPEED ADJUSTMENT.)
3. Insert an exhaust gas analyzer to the tailpipe. 4. Verify that the CO and HC concentrations are
within the regulation. 5. If not, turn the adjust screw to adjust CO and HC
concentration using the SST.
6. If not adjusted, inspect the following:
• On-board diagnostic system (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TROUBLE CODE INSPECTION.)
• Variable resistor (Refer to CONTROL SYSTEM, VARIABLE RESISTOR INSPECTION.)
• Intake manifold vacuum (Refer to TROUBLESHOOTING, ENGINE SYSTEM, INSPECTION, Intake Manifold Vacuum Inspection.)
• Fuel line pressure (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel line Pressure Inspection.)
• Ignition timing control (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Ignition Timing Control Inspection.)
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INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION
Warning • When the engine and intake-air system are hot, they can badly burn. Turn off engine and wait until
they are cool before removing the intake-air system. • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
2. Drain the engine coolant from the radiator. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
3. Disconnect the negative battery cable. 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Complete the "AFTER REPAIR PROCEDURE".
(Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
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INTAKE-AIR SYSTEM
1 Air cleaner component 5 Throttle body component 2 Air intake hose 6 Dynamic chamber 3 MAP sensor 7
Fuel injector FUEL SYSTEM, FUEL INJECTOR REMOVAL/ INSTALLATION
4
Accelerator cable ACCELERATOR CABLE INSPECTION/ ADJUSTMENT
8 Intake manifold
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INTAKE-AIR SYSTEM BYPASS AIR CONTROL (BAC) VALVE REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the IAC valve connector. 3. Drain the engine coolant from the radiator.
(Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
4. Remove the BAC valve.
5. Install in the reverse order of removal. AIR VALVE INSPECTION Operation Inspection
Note 1. Perform the following test only when directed.
1. Carry out the "Idle Air Control (IAC) Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Idle Air Control (IAC) Inspection.)
2. Remove the BAC valve. (Refer to INTAKE-AIR SYSTEM, BAC VALVE REMOVAL/INSTALLATION.)
3. Add cold water into the engine coolant passage of the BAC valve to reduce the air valve temperature.
4. Verify that the air valve operates when hot water is added into the engine coolant passage of the BAC valve.
5. If not as specified, replace the BAC valve, 6. Install the BAC valve.
IDLE AIR CONTROL (IAC) VALVE INSPECTION Resistance Inspection
Note 2. Perform the following test only when directed,
1. Carry out the "Idle Air Control (IAC) Inspection", (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Idle Air Control (IAC) Inspection.)
2. If not as specified, perform the further inspection for the IAC valve.
3. Disconnect the negative battery cable. 4. Disconnect the IAC valve connector. 5. Measure the resistance between the IAC valve
terminals using an ohmmeter. Resistance 7.7—9.3 Ω [23 °C 73 °F]
6. If not as specified, replace the BAC valve.
(Refer to BAC VALVE REMOVAL/INSTALLATION.) If as specified, but IAC valve is failed, inspect for the following: Open circuit
• Power circuit (IAC valve connector terminal A and main relay terminal D)
• GND circuit (IAC valve connector
terminal B and PCM connector terminal 2W)
Short circuit • IAC valve connector terminal B and
PCM connector terminal 2W to GND 7. Repair or replace faulty areas. 8. Connect the IAC valve connector. 9. Connect the negative battery cable.
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INTAKE-AIR SYSTEM
ACCELERATOR PEDAL REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
1
Accelerator cable ACCELERATOR CABLE INSPECTION/ADJUSTMENT
2 Accelerator pedal
ACCELERATOR CABLE INSPECTION/ADJUSTMENT 1. Measure the free play of the accelerator cable.
Free play 1—3 mm 0.04—0.11 in
2. If not as specified, adjust by turning the locknut,
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FUEL SYSTEM FUEL SYSTEM BEFORE REPAIR PROCEDURE
Warning • Fuel vapor is hazardous. It can easily
ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safety Procedures".
Note • Fuel in the fuel system is under high pressure
when the engine is not running. Fuel Line Safety Procedures 1. Remove the fuel-filler cap and release the pressure
in the fuel tank. 2. Disconnect the fuel pump relay connector located
under the passenger's side front side trim.
3. Start the engine. 4. After the engine stalls, crank the engine several
times. 5. Turn off the ignition switch. 6. Reconnect the fuel pump relay connector. AFTER REPAIR PROCEDURE
Warning • Fuel line spills and leakage are dangerous.
Fuel can ignite and cause serious injuries or death and damage. When installing the fuel hose, observe "Fuel Hose Installation" and "Fuel Leakage Inspection" described below.
Fuel Hose Installation 1. Replace damaged or deformed fuel hoses, fuel
pipes, and hose clamps. 2. When installing the fuel hose onto the fuel pipe, fit
the hose onto the pipe over 25 mm 0.98 in. When the pipe has a stopper, fit the hose until it contacts the stopper.
3. Install a hose clamp over the fuel hose within the
clamp installation range as shown, avoiding the original clamp position.
CLAMP INSTALLATION RANGE
Fuel Leakage Inspection
Warning • Fuel line spills and leakage are
dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.
Caution • Connecting the wrong DLC terminal
may possibly cause a malfunction. Carefully connect the specified terminal only.
1. Short the DLC terminal F/P to body GND using a jumper wire.
2. Turn the ignition switch on to operate the fuel pump body.
3. Pressurize the system this way for at least 5 minutes to be sure of no leakage.
4. If there is fuel leakage, inspect for damaged fuel hoses, hose clamps, and fuel pipe sealing surface and replace as necessary.
5. After repair, assemble the system and repeat Steps 1 to 3.
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FUEL SYSTEM
FUEL TANK REMOVAL/INSTALLATION
Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire
may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.
1. Level the vehicle. 2. Complete the "BEFORE REPAIR PROCEDURE".
(Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Disconnect the negative battery cable. 4. Drain the fuel from the drain plug. 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Complete the "AFTER REPAIR PROCEDURE".
(Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
STRETCH CAB 2WD, DOUBLE CAB 2WD
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FUEL SYSTEM
STRETCH CAB 4WD, DOUBLE CAB 4WD, REGULAR CAB
8 Fuel pump unit1
Joint hose Installation Note 9 Fuel-filler pipe
10 Dust cover 2
Breather hose Installation Note 11 Fuel inlet pipe
3 Under guard 12 Nonreturn valve
4 Fuel hose 5 Fuel tank
13
Evaporative gas check valve (two-way) Installation Note
14 Check valve (two-way) 6
Evaporative hose Installation Note
15 Evaporative chamber 7 Rollover valve
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FUEL SYSTEM Evaporative Gas Check Valve (Two-way) Installation Note • Install the arrow mark of the evaporative gas
check valve (two-way) facing the charcoal canister.
Evaporative Hose Installation Note • Fit each hose onto the respective fittings within the
specification, and install clamps as shown. Length Evaporative hose: 25—30 mm 0.99—1.18 in
Breather Hose Installation Note • Fit each hose onto the respective fittings within the
specification, and install clamp as shown. Length Breather hose: 25—30 mm 0.99—1.18 in
Joint Hose Installation Note • Fit the joint hose onto the respective fittings
within the specification, and install clamps as shown. Length Joint hose: 35—40 mm 1.4—1.5 in
NONRETURN VALVE INSPECTION 1. Remove the nonreturn valve with the fuel inlet
pipe. 2. Verify that the nonreturn valve opening angle is
50—56° when pushed out from the fuel inlet pipe side, and the clearance between the nonreturn valve and the fuel inlet pipe end is within 1.5 mm 0.06 in when the nonreturn valve is returned to the closed position.
3. If not as specified, replace the nonreturn valve. FUEL PUMP UNIT REMOVAL/INSTALLATION 1. Remove the fuel pump unit.
(Refer to FUEL SYSTEM,FUEL TANK REMOVAL/INSTALLATION.)
2. Install the fuel pump unit. (Refer to FUEL SYSTEM,FUEL TANK REMOVAL/INSTALLATION.)
FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY
Warning • Fuel line spills and leakage are
dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.
1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
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FUEL SYSTEM STRETCH CAB 2WD, DOUBLE CAB 2WD
STRETCH CAB 4WD, DOUBLE CAB 4WD, REGULAR CAB
1 Rubber mount 2 Fuel filter (low-pressure) 3 Clamp 4 Fuel hose 5 Fuel pump body 6 Fuel gauge sender unit
FUEL PUMP UNIT INSPECTION Simulation Test 1. Carry out the "Fuel Pump Operation Inspection", "Fuel
Pump Control Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Operation Inspection.) (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Control Inspection.)
2. If not as specified, perform the further inspection for the fuel pump unit.
Continuity Inspection Note • Perform the following test only when directed.
1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
2. Disconnect the negative battery cable. 3. Remove the fuel tank. (Refer to FUEL SYSTEM,
FUEL TANK REMOVAL/INSTALLATION.) 4. Inspect for continuity between fuel pump unit
connector terminals C and D.
5. If there is no continuity, replace the fuel pump
body. If as specified but the "Simulation Test" is failed, inspect the following:
Fuel pump relay malfunction Open circuit • GND circuit (fuel pump unit connector terminal D
and body GND) • Power circuit (fuel pump relay connector terminal
D and fuel pump unit connector terminal B through common connector)
Short circuit
• Fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector to GND
6. Repair or replace faulty areas. 7. Install the fuel tank.
(Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)
8. Reconnect the negative battery cable. 9. Complete the "AFTER REPAIR PROCEDURE".
(Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
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FUEL SYSTEM Fuel Pump Maximum Pressure Inspection
Warning • Fuel line spills and leakage are dangerous.
Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.
Note • Perform the following test only when directed.
1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
2. Disconnect the negative battery cable. 3. Connect a fuel pressure gauge to the fuel hose
between the pulsation damper and fuel main hose, then plug the opening as shown.
4. Connect the negative battery cable.
Caution • Connecting the wrong DLC terminal may
possibly cause a malfunction. Carefully connect the specified terminal only.
5. Short the DLC terminal F/P to body GND using a jumper wire.
6. Turn the ignition switch on to operate the fuel
pump body. Measure the fuel pump maximum pressure. Fuel pump maximum pressure 500—630 kPa 5.0—6.5 kgf/cm2, 72—92 psi
7. Turn the ignition switch off and disconnect the jumper wire.
8. If not as specified, inspect the following: • Fuel pump relay • Fuel filter (low-pressure, high-pressure) for
clogging • Fuel line for clogging or leakage
9. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
10. Disconnect the negative battery cable. 11. Disconnect the fuel pressure gauge. 12. Connect the negative battery cable. 13. Complete the "AFTER REPAIR PROCEDURE".
(Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
Fuel Pump Hold Pressure Inspection Warning • Fuel line spills and leakage are dangerous.
Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.
Note • Perform the following test only when directed.
1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
2. Disconnect the negative battery cable. 3. Connect a fuel pressure gauge to the fuel hose
between the pulsation damper and fuel main hose, then plug the opening as shown.
4. Connect the negative battery cable. Caution • Connecting the wrong DLC terminal may
possibly cause a malfunction. Carefully connect the specified terminal only.
5. Short the DLC terminal F/P to body GND using a jumper wire.
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FUEL SYSTEM
1 Fuel hose 2 Protector 3
Fuel filter (high-pressure) Removal Note Installation Note
6. Turn the ignition switch on for 10 seconds to
operate the fuel pump body. 7. Turn the ignition switch off. Measure the fuel pump
hold pressure after 5 minutes. Fuel pump hold pressure More than 340 kPa 3.5 kgf/cm2, 50 psi
8. Disconnect the jumper wire. 9. Complete the "BEFORE REPAIR PROCEDURE".
(Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
10. Disconnect the negative battery cable. 11. Disconnect the fuel pressure gauge. 12. Reconnect the negative battery cable. 13. If not as specified, carry out the "PRESSURE
REGULATOR INSPECTION", "FUEL INJECTOR INSPECTION" (Refer to FUEL SYSTEM, PRESSURE REGULATOR INSPECTION.) (Refer to FUEL SYSTEM, FUEL INJECTOR INSPECTION.)
14. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION 1. Complete the "BEFORE REPAIR PROCEDURE".
(Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
2. Disconnect the negative battery cable. 3. Remove in the order indicated in the table. 4. Install in the reverse order or removal. 5. Complete the "AFTER REPAIR PROCEDURE".
(Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
Fuel Filter (High-pressure) Removal Note • Before removing the fuel filter (high-pressure),
paint marks on the fuel filter (high-pressure) and fuel filter bracket for correct reassembly.
Fuel Filter (High-pressure) Installation Note Replacing the fuel filter (high-pressure) 1. Paint a mark on the new fuel filter (high-pressure)
at the same spot as the removed fuel filter (high-pressure).
2. Align the paint marks and install the fuel filter (high-pressure) as shown.
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FUEL SYSTEM
Replacing the fuel filter bracket
1. Paint a mark on the new fuel filter bracket at the same spot as the removed fuel filter bracket.
2. Align the paint marks and install the fuel filter bracket as shown.
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FUEL SYSTEM
FUEL INJECTOR REMOVAL/INSTALLATION
Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
1. Complete the "BEFORE REPAIR PROCEDURE" (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Disconnect the fuel injector connectors and remove the harness from the fuel distributor. 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Complete the "AFTER REPAIR PROCEDURE." (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
1 Dynamic chamber 6
Fuel injector Installation note2 Dynamic chamber gasket
7 Grommet 3 Fuel injector connector 8 Fuel injector insulator 4 Fuel hose
5 Fuel distributor
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FUEL SYSTEM Fuel Injector Installation Note 1. Use new fuel injector O-rings. 2. Verify that the O-rings and the fuel injector sealing
surfaces are free of foreign materials. Clean with gasoline if necessary.
3. Apply a small amount of engine oil to the O-rings and into the fuel distributor.
4. Install the fuel injectors in the fuel distributor with a light twisting motion so that the O-rings will not be folded.
FUEL INJECTOR INSPECTION Simulation Test 1. Carry out the "Fuel Injector Operation Inspection".
(Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Injector Operation Inspection.)
2. If not as specified, perform the further inspection for the fuel injectors.
Resistance Inspection Note • Perform the following test only when directed.
1. Disconnect the negative battery cable. 2. Disconnect the fuel injector connectors. 3. Measure the resistance of the fuel injector using
an ohmmeter.
Resistance 12—16Ω[20°C 68°F] 4. If not as specified, replace the fuel injector.
(Refer to FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.) If as specified but "Simulation Test" is failed, inspect for the following:
Open circuit • GND circuit (No.1 cylinder fuel injector connector
terminal B and PCM connector terminal 2U) • GND circuit (No.2 cylinder fuel injector connector
terminal B and PCM connector terminal 2V) • GND circuit (No.3 cylinder fuel injector connector
terminal B and PCM connector terminal 2U) • GND circuit (No.4 cylinder fuel injector connector
terminal B and PCM connector terminal 2V) • Power circuit (No.1 cylinder fuel injector connector
terminal A and main relay connector terminal D through common connector)
• Power circuit (No.2 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector)
• Power circuit (No.3 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector)
• Power circuit (No.4 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector)
Short circuit • No.1 cylinder fuel injector connector terminal B
and PCM connector terminal 2U to GND • No.2 cylinder fuel injector connector terminal B
and PCM connector terminal 2V to GND • No.3 cylinder fuel injector connector terminal B
and PCM connector terminal 2U to GND • No.4 cylinder fuel injector connector terminal B
and PCM connector terminal 2V to GND 5. Repair or replace faulty areas. 6. Reconnect the fuel injector connectors. 7. Reconnect the negative battery cable. Fuel Leakage Test
Warning • Fuel line spills and leakage are dangerous.
Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.
Note • Perform the following test only when directed.
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FUEL SYSTEM 1. Complete the "BEFORE REPAIR PROCEDURE".
(Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
2. Disconnect the negative battery cable. 3. Remove the fuel injectors together with the fuel
distributor. (Refer to FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.)
4. Fasten the fuel injectors firmly to the fuel distributor with wire.
5. Connect the negative battery cable.
Caution • Connecting the wrong DLC terminal may
possibly cause a malfunction. Carefully connect the specified terminal only.
6. Short the DLC terminal F/P to body GND using a jumper wire.
7. Turn the ignition switch on to operate the fuel
pump body. 8. Tilt the fuel injectors approx. 60 degrees and
verify that fuel leakage from the fuel injector nozzles is within the specification.
Fuel leakage Less than 1 drop/2 minutes
9. Turn the ignition switch off and remove the jumper wire.
10. If not as specified, replace the fuel injector. 11. Complete the "AFTER REPAIR PROCEDURE",
(Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
Volume Test Warning • Fuel line spills and leakage are dangerous.
Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.
Note • Perform the following test only when directed.
1. Complete the "BEFORE REPAIR PROCEDURE", (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
2. Disconnect the negative battery cable. 3. Remove the fuel injectors together with the fuel
distributor. (Refer to FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.)
4. Fasten the fuel injectors firmly to the fuel distributor with wire.
5. Connect the SST as shown in the figure.
6. Connect the negative battery cable.
Caution • Connecting the wrong DLC terminal may
possibly cause a malfunction. Carefully connect the specified terminal only.
7. Short the DLC terminal F/P to body GND using a jumper wire.
8. Turn the ignition switch on to operate the fuel pump body.
9. Measure the injection volume of each fuel injector using a graduated container.
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FUEL SYSTEM
Injection volume 55—71 ml 55—71 cc, 1.9—2.3 fl oz/15 sec.
10. Turn the ignition switch off and disconnect the jumper wire.
11. If not as specified, replace the fuel injector. 12. Complete the "AFTER REPAIR PROCEDURE".
(Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
PRESSURE REGULATOR REMOVAL/INSTALLATION
Warning • Fuel line spills and leakage are dangerous.
Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
2. Disconnect the negative battery cable. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Complete the "AFTER REPAIR PROCEDURE".
(Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
O 1 Vacuum hose 2 Fuel hose 3 Pressure regulator
PRESSURE REGULATOR INSPECTION Simulation Test 1. Carry out the "Fuel Line Pressure Inspection".
(Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection.)
2. If not as specified, perform the further inspection for the pressure regulator.
Operation Inspection Note • Perform the following test only when directed.
1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE".)
2. Disconnect the negative battery cable. 3. Connect a fuel pressure gauge between the
pulsation damper and fuel main hose.
4. Connect the negative battery cable. 5. Start the engine and let it idle. 6. Measure the fuel line pressure after approx. 2
minutes. Fuel line pressure 210—250 kPa 2.1—2.6 kgf/cm2, 30—36 psi
7. Disconnect the vacuum hose from the pressure regulator and measure the fuel line pressure.
Fuel line pressure 270—310 kPa 2.7—3.2 kgf/cm2, 39—45 psi 8. Turn the ignition switch off. 9. Complete the "BEFORE REPAIR PROCEDURE".
(Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.")
10. Disconnect the negative battery cable. 11. Disconnect the fuel pressure gauge. 12. Reconnect the fuel main hose to the fuel
distributor. 13. Reconnect the negative battery cable. 14. If not as specified, inspect the following:
• Fuel pump maximum pressure • Fuel pump hold pressure • Fuel filter for clogging • Fuel injector for leakage • Fuel pump relay • Fuel line for improper routing, clogging, kinks
or leakage
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FUEL SYSTEM
Short circuit • PRC solenoid valve connector terminal B and
PCM connector terminal 2T through common connector to GND)
5. Repair or replace faulty areas. 6. Install the PRC solenoid valve. 7. Reconnect the negative battery cable. PULSATION DAMPER REMOVAL/INSTALLATION1. Complete the "BEFORE REPAIR PROCEDURE".
(Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
2. Disconnect the negative battery cable. 3. Remove the pulsation damper. 4. Install in the reverse order of removal. 5. Complete the "AFTER REPAIR PROCEDURE".
(Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
1 Fuel hose 2 Bolt3 Pulsation damper
If all items above are okay, replace the pressure regulator. (Refer to FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION.)
15. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
PRESSURE REGULATOR CONTROL (PRC) SOLENOID VALVE INSPECTION Simulation Test 1. Carry out the "Pressure Regulator Control (PRC)
Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Pressure Regulator Control (PRC) Inspection.)
2. If not as specified, perform the further inspection for the PRC solenoid valve,
Airflow Inspection Note • Perform the following test only when directed.
1. Disconnect the negative battery cable. 2. Remove the PRC solenoid valve.
(Refer to INTAKE-AIR SYSTEM, VACUUM HOSE ROUTING DIAGRAM.)
3. Inspect airflow between the ports under the following conditions.
4. If not as spec tied, replace the PRC solenoid valve. If as specified but the "Simulation Test" is failed, inspect for the following: Vacuum hose improper routing, kinks or leakage Open circuit • GND circuit (PRC solenoid valve connector
terminal B and PCM connector terminal 2T through common connector)
• Power circuit (PRC solenoid valve connector terminal A and main relay connector terminal D through common connector)
PULSATION DAMPER INSPECTION 1. Remove the pulsation damper.
(Refer to FUEL SYSTEM, PULSATION DAMPER REMOVAL/INSTALLATION.)
2. Visually inspect the pulsation damper for damage and cracks. Also inspect that there is no extreme rust, which will cause fuel leakage.
3. If either is observed, replace the pulsation damper.
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CONTINUED
FUEL SYSTEM FUEL PUMP RELAY INSPECTION Simulation Test 1. Carry out the "Fuel Pump Operation Inspection",
"Fuel Pump Control Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Operation Inspection.) (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Control Inspection.)
2. If not as specified, perform the further inspection for the fuel pump relay.
Continuity Inspection Note • Perform the following test only when directed.
1. Disconnect the negative battery cable. 2. Remove the fuel pump relay located under the
passenger's side front side trim.
3. Inspect for continuity between the fuel pump relay
terminals using an ohmmeter.
4. If not as specified, replace the fuel pump relay. If as specified but the "Simulation Test" is failed, inspect for the following: Fuel pump unit malfunction Open circuit • GND circuit (fuel pump relay connector terminal
B and PCM connector terminal 1H through common connector)
• GND circuit (fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector)
• Power circuit (fuel pump relay connector terminal A or C and IG switch connector terminal IG1 through common connector)
Short circuit • Fuel pump relay connector terminal B and
PCM connector terminal 1H through common connector to GND
• Fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector to GND
5. Repair or replace faulty areas. 6. Install the fuel pump relay. 7. Reconnect the negative battery cable.
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CONTINUED
EXHAUST SYSTEM
EXHAUST SYSTEM EXHAUST SYSTEM INSPECTION 1. Start the engine and inspect the exhaust system component for exhaust gas leakage. 2. If leakage is found, repair or replace as necessary.
EXHAUST SYSTEM REMOVAL/INSTALLATION
Warning • When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait
until they are cool before removing the exhaust system.
1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1 After silencer 4 Front pipe2 Main silencer 5 Insulator
TWO (Europe) 6 Exhaust manifold3 Presilencer (Except Europe)
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EMISSION SYSTEM
4. If not as specified, replace the rollover valve. EVAPORATIVE GAS CHECK VALVE (TWO-WAY) INSPECTION 1. Remove the evaporative gas check valve (two-
way). (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)
2. Inspect airflow of the valve under the following conditions.
Apply pressure below +2.9 kPa +22 mmHg, +0.87 inHg to port A No airflow
Apply pressure over +5.9 kPa +44 mmHg, +1.7 inHg to port A Airflow
EMISSION SYSTEM EMISSION SYSTEM (ENGINE COMPARTMENT SIDE) COMPONENT LOCATION
1 Charcoal canister Apply pressure over -0.98 kPa -7.36 mmHg, -0.29 inHg to port A Airflow
2 Purge solenoid valve 3 PCV valve
3. If not as specified, replace the evaporative gas check valve (two-way).
CHECK VALVE (TWO-WAY) INSPECTION 1. Remove the check valve (two-way).
(Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)
2. Inspect airflow of the valve under the following conditions.
Apply pressure of -0.98—1-13.7 kPa -7.3—1-102 mmHg, -0.28— + 4.0 inHg to port A
No airflow
Apply pressure over +18.6 kPa +140 mmHg, +5.5 inHg to port A Airflow
ROLLOVER VALVE INSPECTION 1. Remove the rollover valve.
(Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)
2. Hold the valve as shown. Blow air into port A and verify that there is airflow.
3. Turn the valve upside-down as shown. Blow
air into port A and verify that there is no airflow.
Apply pressure over -4.9 kPa -36.8 mmHg, -1.4 inHg to port B Airflow
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CONTINUED
EMISSION SYSTEM
3. If not as specified, replace the check valve (two-way).
EVAPORATIVE CHAMBER INSPECTION 1. Remove the evaporative chamber.
(Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)
2. Blow air into port A and verify that air flows out from the holes B on the evaporative chamber.
3. Visually inspect that there is no damage nor crack
on the evaporative chamber. 4. If not as specified, replace the evaporative
chamber. 5. Install the evaporative chamber. CHARCOAL CANISTER INSPECTION 1. Remove the charcoal canister. 2. Plug the atmosphere side port and purge solenoid
valve side port of the charcoal canister. 3. Blow air into the charcoal canister from the fuel
tank side port and verify that there is no air leakage.
4. If there is air leakage, replace the charcoal
canister.
PURGE SOLENOID VALVE INSPECTION Simulation Test 1. Carry out the "Purge Control Inspection".
(Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Purge Control Inspection.)
2. If not as specified, perform the further inspection for the purge solenoid valve,
Airflow Inspection Note • Perform the following test only when directed.
1. Disconnect the negative battery cable. 2. Remove the purge solenoid valve. 3. Inspect airflow between the ports under the following
conditions.
4. If not as specified, replace the purge solenoid valve.
If as specified but the "Simulation Test" is failed, inspect for the following: Vacuum hose improper routing, kinks or leakage. Open circuit • GND circuit (purge solenoid valve connector
terminal B and PCM connector terminal 2X through common connector)
• Power circuit (purge solenoid valve connector terminal A and main relay connector terminal D through common connector)
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EMISSION SYSTEM
Short circuit • Purge solenoid valve connector terminal B and
PCM connector terminal 2X through common connector to GND
5. Repair or replace faulty areas. 6. Install the purge solenoid valve. 7. Reconnect the negative battery cable. POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION 1. Remove the PCV valve. 2. Blow through the valve and verify that air flows as
specified.
Specification Condition Airflow
Air applied from port A Yes Air applied from port B No
3. If not as specified, replace the PCV valve.
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CONTINUED
CONTROL SYSTEM
CONTROL SYSTEM CONTROL SYSTEM COMPONENT LOCATION
1 PCM 8 O2S (Europe only)2 MAF sensor 9 Variable resistor (Except Europe) 3 TP sensor 10 Clutch switch 4 CTP switch 11 Neutral switch 5 IAT sensor 12 PSP switch 6 ECT sensor 13 Main relay 7 CMP sensor (In distributor)
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CONTINUED
CONTROL SYSTEM PCM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the cowl side panel (driver's side). 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1 PCM 2 PCM connector
PCM INSPECTION Using SSTs (NGS tester)
Note • PIDs for the following parts are not available
on this model. Go to the appropriate part inspection page.
1. Water temperature sender unit (Integrated with ECT sensor) (Refer to CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION.)
2. CMP sensor (Refer to CONTROL SYSTEM, CAMSHAFT POSITION (CMP) SENSOR INSPECTION.)
3. Main relay (Refer to CONTROL SYSTEM, MAIN RELAY INSPECTION.)
1. Connect the SSTs (NGS tester) to the DLC. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TEST, NGS Tester Hook-up Procedure.)
2. Turn the ignition switch on. 3. Select the "PID/DATA MONITOR AND RECORD"
function on the NGS tester display and press TRIGGER. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, PID/DATA MONITOR AND RECORD PROCEDURE.)
4. Select the appropriate PID on the NGS tester display and press START.
5. Measure the PID value. Note
• The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the PCM. Therefore, an output device malfunction is not directly indicated as a malfunction of the monitored value for the output device. If a monitored value of an output device is out of specification, inspect the monitored value of the input device related to the output control.
• For input/output signals except those of the monitoring items, use a voltmeter to measure the PCM terminal voltage.
• When measuring the following PID value, perform the following:
• TP V PID (Refer to Not Using the SSTs (NGS tester) at Constant Voltage Terminal Inspection.) (Refer to Not Using the SSTs (NGS tester) at Ground (GND) Terminal Inspection.)
6. If PID value is not within the specification, follow the instruction in action column.
Note
• Perform the SIMULATION TEST for the output device (A/C RLY, FP RLY, IACV, PRGV) after PID/DATA measurement is completed.
F1-29
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CONTINUED
CONTROL SYSTEM
PID MONITOR Table Monitor item (Definition)
Unit/ Condition Condition/Specification Action PCM
terminal
A/C RLY (A/C relay) ON/OFF
Ignition switch on: OFF A/C switch on and fan switch on at idle: ON
Inspect following PIDs: RPM, TP V, ECT V, A/C SW. Inspect A/C relay. Section U
1J
A/C SW (A/C switch) ON/OFF
A/C switch and fan switch on at ignition switch on: ON A/C switch off at ignition switch on: OFF
Inspect A/C switch. Section U 1Q
B+ (Battery positive
voltage) V Constant: B+
Inspect main relay. CONTROL SYSTEM, MAIN RELAY INSPECTION Inspect battery. Section G
1B
BARO*2
(Barometric pressure)
kPa Below 400 m 0.25 mile above sea level: 100—103 kPa 1.01—1.05 kgf/cm2
DTC P1195 is indicated. Follow DTC Troubleshooting ON-BOARD DIAGNOSTIC SYSTEM, DTC INSPECTION
-
BARO V*2
(Barometric pressure signal
voltage) V Below 400 m 0.25 mile above sea
level: 3.9—4.0 V
DTC P1195 is indicated. Follow DTC Troubleshooting ON-BOARD DIAGNOSTIC SYSTEM, DTC INSPECTION
-
BRKSW (Brake switch) ON/OFF Brake pedal depressed: ON
Brake pedal released: OFF Inspect brake switch. Section P 1O
CTP SW (Idle switch) ON/OFF Accelerator depressed: OFF
Accelerator released: ON
Inspect CTP switch CONTROL SYSTEM, CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION
1N
ECT (Engine coolant
temperature) °C °F
Engine coolant temperature 20 °C 68°F: 20°C 68°F Engine coolant temperature 60 °C 140°F: 60°C 140°F
Inspect engine coolant temperature sensor. w CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
2Q
ECT V (ECT signal
voltage)
V Engine coolant temperature 20 °C 68 °F; 2.2—2.4V After warms up: Below 1.0 V
Inspect engine coolant temperature sensor. CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
2Q
FHO2S*1 (Oxygen sensor) V
Ignition switch on: 0,1—1.0 V After warm up: 0.1—1.0 V Acceleration (after warm up): 0.5—1.0 V Deceleration (after warm up): 0—0.5V
Inspect O2S. CONTROL SYSTEM, OXYGEN SENSOR O2S) INSPECTION
2N
FPRLY (Fuel pump relay) ON/OFF Ignition switch on: OFF
Idle: ON Cranking: ON
Inspect following PID: RPM. Inspect fuel pump relay. FUEL SYSTEM, FUEL PUMP RELAY INSPECTION
1H
IACV (Idle air control
valve) ms Idle: 2.4—2.7 ms
Inspect following PIDs: IATV, RPM, ECT V, MAF V, TP V, NL SW, CLT SW, PSP SW, A/C SW, TEN. Inspect idle air control valve. INTAKE-AIR SYSTEM, IDLE AIR CONTROL (IAC) VALVE INSPECTION
2W
1: Europe only *2: Except Europe
F1-30
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CONTROL SYSTEM
Monitor item (Definition)
Unit/ Condition Condition/Specification Action PCM terminal
IATDC (Intake air
temperature (Dynamic chamber))
°C
Intake air temperature 20 °C 68 °F:20°C68 °F
Inspect IAT sensor rar -CONTROL SYSTEM, INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION
2L
IATDC V (IAT signal voltage
(Dymanic chamber))
V Intake air temperature 20 °C 68 °F: 2.5—2.7 V
Inspect IAT sensor -CONTROL SYSTEM, INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION
2L
IGT (Ignition timing)
BTC Terminal TEN (DLC) short to ground: A—6 BTC Idle: 1—30 BTC
Inspect following PIDs: MAF V, IAT V, RPM, TP V, ECT V, PSP SW, NL SW, A/C SW, TEN, Inspect CMP sensor. -CONTROL SYSTEM, CAMSHAFT POSITION (CMP) SENSOR INSPECTION Inspect idle speed and ignition timing. - ENGINE TUNE-UP.
2F
INJ (Fuel injection
duration) ms
Ignition switch on: 0.0 ms Idle: 3.0—5.0 ms
Inspect following PIDs: MAF V, IAT V, RPM, TP V, ECT V, NL SW, FHO2S, PSP SW, BRK SW, A/C SW, B+. Inspect CMP sensor. - CONTROL SYSTEM, CAMSHAFT POSITION (CMP) SENSOR INSPECTION
2U 2V
MAFV (Mass air flow signal voltage)
V Ignition switch on: 1.0—2.0 V Idle: 1.9—2.8 V
Inspect mass air flow sensor. CONTROL SYSTEM, MASS AIR FLOW (MAF) SENSOR INSPECTION
20
MT/AT*1
(MT/AT distinction signal)
ON/OFF Constant: ON - 1L
NLSW (Load/no load
condition signal) ON/OFF
Neutral position and clutch pedal depressed: ON Others: OFF
Inspect neutral switch. - CONTROL SYSTEM, NEUTRAL SWITCH INSPECTION Inspect clutch switch. -CONTROL SYSTEM, CLUTCH SWITCH INSPECTION
1V
*1: Europe only
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CONTROL SYSTEM
Monitor item (Definition)
Unit/ Condition Condition/Specification Action PGM
terminal
PRCV (Pressure
regulator control) ON/OFF
Ignition switch on: OFF Idle: OFF Engine start at hot condition: ON
Inspect following PIDs: ECTV, IAT V, RPM,TP V, B+. Inspect PRC solenoid valve. FUEL SYSTEM, PRC SOLENOID VALVE INSPECTION
2T
PRGV (Purge solenoid valve duty value)
% Ignition switch on: 0% Idle: 0%
Inspect following PIDs: IATV, RPM, ECT V, MAP V, TP V, FHO2S, B+. Inspect purge solenoid valve. EMISSION SYSTEM, PURGE SOLENOID VALVE INSPECTION
2X
PSP SW (PSP switch)
ON/OFF Steering wheel fully turned: ON Steering wheel straight ahead position: OFF
Inspect PSP switch. CONTROL SYSTEM, POWER STEERING PRESSURE (PSP) SWITCH INSPECTION
1P
RPM (Engine speed)
RPM Idle: 700—770 RPM Inspect CMP sensor. CONTROL SYSTEM, CRANKSHAFT POSITION SENSOR INSPECTION
2E
TEN (TEN terminal
(DLC)) ON/OFF
Terminal TEN (DLC) short to ground: ON Terminal TEN (DLC) open: OFF
Inspect wiring from DLC terminal TEN to PCM terminal 1L 1K
TP V (TP sensor signal
voltage) V
Closed throttle position: 0.4—0.6 V Wide open throttle: 3.4—4.7 V
Inspect TP sensor. CONTROL SYSTEM, THROTTLE POSITION (TP) SENSOR INSPECTION
2M
VRV*2
(Variable resistor) V
Turned fully clockwise: below 1.0 V Turned fully counterclockwise: Approx 4.0 V
Inspect variable resistor VARIABLE RESISTOR INSPECTION
2N
VS (Vehicle speed)
KPH
Vehicle speed 20 km/h mph: 20 km/h mph Vehicle speed 40 km/h mph: 40 km/h mph
Inspect vehicle speedometer sensor Section T, WARNING AND INDICATOR SYSTEM, INSTRUMENT CLUSTER INSPECTION Inspect vehicle speed sensor
1M
*2: Except Europe
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CONTROL SYSTEM
4. If there is no continuity, repair the related harnesses.
Not Using the SSTs (NGS Tester) at Power Supply Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connectors. 3. Measure the voltage between the PCM battery power
terminal connectors and body GND using an ohmmeter.
Power supply terminal 1A
Not Using the SSTs (NGS tester) at Constant Voltage Terminal Inspection
1. Turn the ignition switch on. 2. Measure the voltage between the TP sensor and
variable resistor (Except Europe) connector (vehicle side) terminal A and body GND using a voltmeter. (1) When measurement voltage is 0 V. ① Turn the ignition switch off. ② Disconnect the TP sensor and variable resistor (Except Europe) connector (applied to constant voltage).
③ Verify there is no continuity between the TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C and body GND using an ohmmeter. ④ If there is continuity, repair the related harnesses. ⑤ Using an ohmmeter, inspect for continuity between the PCM connector (vehicle side) terminal 2D and TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C which is applied to constant voltage. ⑥ If there is continuity, repair the related harness.
(2) When measurement voltage is B+. ① Turn the ignition switch off. ② Disconnect the battery positive harness, then battery negative harness. ③ Verify there is no continuity between the TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C and battery positive harness using an ohmmeter. ④ If there is continuity, repair the related harnesses.
(3) When measurement voltage is approx. 5V. • Constant voltage terminal of PCM is okay.
Not Using the SSTs (NGS tester) at Ground (GND) Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connectors. 3. Inspect for continuity between the PCM GND
terminals and body GND using an ohmmeter.
PCM GND terminal 2A 2B 2C
Power supply terminal voltage: B+
4. If not as specified, repair the related harnesses and replace the faulty fuses.
Not Using the SSTs (NGS Tester) at Serial Communication Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connectors. 3. Verify there is continuity between PCM connector
terminal 1 D and DLC KLN terminal.
4. If there is no continuity, repair the related
harnesses. Not Using the SSTs (NGS Tester) at Instrument Cluster (Engine speed signal) Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connector and instrument cluster
connector (26 pin). 3. Verify there is continuity between PCM connector
terminal 2F and instrument cluster connector (20 pin) terminal 3B.
4. If there is no continuity, repair the related harnesses.
F1-33
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CONTROL SYSTEM Using voltmeter
Caution • The PCM terminal voltages vary with
change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made.
1. Remove the PCM. 2. Reconnect PCM connector and battery negative
terminal.
Note • With the PCM connector connected, body
ground the voltmeter negative (-) lead and measure voltage at each PCM terminal by inserting the voltmeter positive (+) lead.
3. Measure the voltage at PCM terminal using a voltmeter.
4. If any incorrect voltage is detected, inspect related systems, wiring harnesses and connectors referring to the action column in the terminal voltage list.
PCM Terminal Voltage (Reference)
Terminal Signal Connected to Test condition Voltage (V) Action
1A Back-up power supply
Battery Constant B+ • Inspect ROOM fuse. • Inspect related harness.
Ignition switch off 0 1B Power supply Main relay
Ignition switch on B+ • Inspect related harness.
1C — — — — —
1D Serial communication
DLC (Terminal KLN)
Carry out inspection according to DTC. DTC output is a part of serial communication. Judgement by terminal voltage is not possible.
— • Inspect related harness.
No DTC stored Below 1.0 1E DTC output
DLC (Terminal FEN)
Ignition switch on and terminal TEN (in DLC) short to chassis ground DTC stored 0-B+
• Inspect related harness.
1F — — — — — 1G — —- — — —
Ignition switch on B+
Cranking Below 1.0 1H Fuel pump control
Fuel pump relay
Idle Below 1.0
• Inspect fuel pump relay. FUEL SYSTEM,FUEL PUMP INSPECTION
• Inspect related harness.
1I — — — — — A/C switch on B+ Ignition switch
on A/C switch off B+ A/C switch on Below 1.0
1J A/C control
A/C relay
Ignition switch off A/C switch off Below 1.0
• Inspect A/C relay. section U
• Inspect related harness.
Terminal TEN (DLC) open
B+
1K Diagnostic test mode
DLC (Terminal TEN)
Ignition switch on Terminal TEN
(DLC) short to ground
Below 1.0 • Inspect related harness.
1L*1 Transmission distinction
Ground Constant
0 • Inspect related harness.
*1: Europe only
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CONTROL SYSTEM Terminal Signal Connected to Test condition Voltage (V) Action
Vehicle stopped 0 or Approx. 5.0 1M Vehicle speed VSS
Vehicle running Approx. 5.0
• Inspect VSS. section T • Inspect related harness.
Accelerator pedal depressed B+
1N CTP CTP switch Ignition switch on Accelerator pedal
released Below 1.0
• Inspect CTP switch. CLOSED THROTLE POSITION (CTP) SWITCH INSPECTION
• Inspect related harness.
Brake pedal depressed B+ 1O Brake Brake switch
Brake pedal released Below 1.0
• Inspect brake switch. section P • Inspect related harness.
Steering wheel straight ahead position
B+ 1P Power steering
pressure PSP switch Idle Steering wheel fully turned Below 1.0
• Inspect PSP switch. POWER STEERING PRESSURE (PSP) SWITCH INSPECTION
• Inspect related harness.
A/C switch and fan switch on Below 1.0
1Q A/C A/C switch Ignition switch on
A/C switch off B+
• Inspect A/C switch. section U
• Inspect related harness. 1R — — — — — 1S — — — — — 1T — — — — — 1U — — — — —
Transmission neutral position or clutch pedal depressed
Below 1.0
1V Load/no load distinction
Neutral/clutch switch
Ignition switch on Other than
transmission neutral or clutch pedal released
B+
• Inspect neutral switch. NEUTRAL SWITCH INSPECTION
• Inspect clutch switch. CLUTCH SWITCH INSPECTION
• Inspect related harness.
2A Fuel injector ground Ground Constant Below 1.0 • Inspect related harness.
2B Power ground Ground Constant Below 1.0 • Inspect related harness. 2C System ground Ground Constant Below 1.0 • Inspect related harness.
2D Analog ground
MAF sensor, IAT sensor, ECT sensor, O2S,TP sensor
Constant Below 1.0 • Inspect related harness.
Ignition switch on 5.0 2E SGT
CMP sensor (integrated into distributor) Idle 1.8—2.3
• Inspect CMP sensor. CAMSHAFT POSITION (CMP) SENSOR INSPECTION
• Inspect related harness.
Ignition switch on Below 1.0 2F IGT control Ignition control
module Idle 0.35—0.5
• Inspect ignition control module. section G
• Inspect related harness. 2G — — — — — 2H — — — — — 2I — — — — — 2J — — — — —
2K Constant voltage (Vref) TP sensor Ignition switch on 4.5—5.5 • Inspect related harness.
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CONTROL SYSTEM Terminal Signal Connected to Test condition Voltage (V) Action
2L IAT IAT sensor Ignition switch on IAT 20° C 68°F 2.15
• Inspect IAT sensor. INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION
• Inspect related harness.
Accelerator pedal released 0.4—0.6
2M TP TP sensor Ignition switch on Accelerator pedal
depressed 3,4—4.7
• Inspect TP sensor. THROTTLE POSITION (TP) SENSOR INSPECTION
• Inspect related harness.
Ignition switch on 0.55 Engine cold 0.0—1.0
Idle 0.0—1.0
Acceleration After warm up 0.5—1.0 2N*1 O2S O2S
Deceleration 0.0—0.5
• Inspect O2S. OXYGEN SENSOR (O2S) INSPECTION
• Inspect related harness.
2N*2 Variable resistor Variable resistor Varies according to the variable resistor adjustment 0—4
• Inspect variable resistor. VARIABLE RESISTOR INSPECTION
• Inspect related harness.
Ignition switch on 1.45
Idle (after warm up) 2.15 2O Mass airflow MAP sensor Engine speed 3000 rpm (after warm up) 2.73
• Inspect MAF sensor. MASS AIR FLOW (MAF) SENSOR INSPECTION
• Inspect related harness.
2P — — — — —
IAT 20°C 68°F 1.02
2Q ECT ECT sensor Ignition switch on
After warm up 0.58
• Inspect ECT sensor. ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
• Inspect related harness.
2R — — — — — 2S — — — — —
For 120 sec. after ignition switch on 0 ECT above
90°C 194°F (Hot condition) For 120 sec. after
engine start 0 2T Pressure regulator control
PRC solenoid valve
Others Ignition switch on B+
• Inspect PRC solenoid valve. FUEL SYSTEM, PRC SOLENOID VALVE INSPECTION
• Inspect related harness.
Ignition switch on B+ 2U Fuel injector
No.1,No.3 Idle B+
• Inspect fuel injector. FUEL SYSTEM,FUEL INJECTOR INSPECTION
• Inspect related harness.
Ignition switch on B+ 2V
Fuel injector control
Fuel injector No.2, No.4
Idle B+
• Inspect fuel injector. FUEL SYSTEM,FUEL INJECTOR INSPECTION
• Inspect related harness.
Ignition switch on 0.2 2W IAC IAC valve
Idle (after warm up) Approx 1.0
• Inspect IAC valve. INTAKE-AIR SYSTEM, IAC VALVE INSPECTION
• Inspect related harness. *1: Europe only *2: Except Europe
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CONTROL SYSTEM Terminal Signal Connected to Test condition Voltage (V) Action
Ignition switch on B+
Idle B+ 2X Purge control Purge solenoid valve
Driving in gear
• Inspect purge solenoid valve. EMISSION SYSTEM, PURGE SOLENOID VALVE INSPECTION
• Inspect related harness.
2Y — — — — —
Ignition switch on B+ 2Z Engine speed output
Tachometer (integrated into instrument cluster)
Idle 4.9—7.0
• Inspect instrument cluster. FUEL SYSTEM, FUEL INJECTOR INSPECTION
• Inspect related harness.
MASS AIR FLOW (MAF) SENSOR INSPECTION
Note • Perform the following test only when directed.
MAF Sensor Inspection 1. Visually inspect for the following on the MAF
sensor. • Damage • Cracks • Terminal bends • Terminal rust
2. If any of the above are found, replace the MAF sensor. If the MAF sensor PID value is out of specification, inspect as follows and repair or replace as necessary:
3. Disconnect the MAF sensor connector. Open circuit • MAF signal circuit (MAF sensor connector
terminal B and PCM connector terminal 20) • Power circuit (MAF sensor connector
terminal C and main relay terminal D through common connector) • GND circuit (MAF sensor connector terminal A and PCM connector terminal 2D through common connector)
Short circuit • MAF signal circuit (MAF sensor connector
terminal B and PCM connector terminal 20 to GND)
• Power circuit (MAF sensor connector terminal C and main relay terminal D through common connector to GND) 4. Repair or replace faulty areas.
5. Reconnect the MAF sensor connector.
THROTTLE POSITION (TP) SENSOR INSPECTIONNote • Perform the following test only when directed.
Resistance Inspection 1. Verify that the throttle valve is at closed throttle
position. 2. Inspect that the accelerator cable free play is
within the specification. (Refer to INTAKE-AIR SYSTEM, ACCELERATOR CABLE INSPECTION / ADJUSTMENT.)
3. If as specified but PID valve is out of specification, measure the resistance between TP sensor terminals A and C using an ohmmeter. Specification 4—6KΩ
4. Disconnect the TP sensor connector. 5. If not as specified, replace the TP sensor. If as
specified, inspect for the following: Open circuit • Reference voltage circuit (TP sensor
connector terminal A and PCM connector terminal 2K)
• TP signal circuit (TP sensor connector terminal B and PCM connector terminal 2M)
• GND circuit (TP sensor connector terminal C and PCM connector terminal 2D)
Short circuit • Reference voltage circuit (TP sensor
connector terminal A and PCM connector terminal 2K)
• TP signal circuit (TP sensor connector terminal B and PCM connector terminal 2M)
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CONTROL SYSTEM
Specification (CTP) TP sensor terminal C
voltage (V) PCM terminal 2M voltage
TP V (NGS tester) (V) 4.5—4.9 0.4—0.6 4.9—5.1 0.4—0.6 5.1—5.5 0.4—0.6
8. Tighten the TP sensor screw. Tightening torque 1.6—2.3 N.m 16—24 kgf.cm, 14—20 in.lbf
9. Use the NGS tester ("TP V" of PID/DATA MONITOR AND RECORD function) or voltmeter to verify the TP sensor so that the voltage of PCM terminal 2M is within the specification below when the throttle valve is wide open.
Specification (WOT)
TP sensor terminal C voltage (V)
PCM terminal 2M voltage TP V (NGS tester) (V)
4.5—4.7 3.4—4.4 4.7—4.8 3.6—4.5 4.8—4.9 3.7—4.6 4.9—5.0 3.7—4.8 5.0—5.1 3.8—4.9 5.1—5.3 4.0—5.0 5.3—5.4 4.1—5.1 5.4—5.5 4.2—5.2
6. Repair or replace faulty areas. 7. Reconnect the TP sensor connector.
THROTTLE POSITION (TP) SENSOR ADJUSTMENT
Caution • Adjusting the TP sensor with the throttle
adjusting screw (TAS) can adversely affect the engine. Do not adjust the TP sensor with the TAS.
• Since the TP sensor is adjusted by the manufacturer, adjusting the TP sensor excessively can adversely affect the engine. Do not adjust the TP sensor excessively.
1. Verify that the throttle valve is at closed throttle position.
2. Disconnect the TP sensor connector. 3. Turn ignition switch on. 4. Measure and record the voltage of the
disconnected harness side connector terminal C using a voltmeter.
Specification 4.5—5.5 V
5. Reconnect the TP sensor connector. 6. Loosen the TP sensor screw.
7. Use the NGS tester ("TP V" of PID/DATA MONITOR AND RECORD function) or voltmeter to adjust the TP sensor so that the voltage of PCM terminal 2M is within the specification below when the throttle valve is at the closed throttle position.
10. If not as specified, replace the TP sensor.
(Refer to CONTROL SYSTEM, THROTTLE POSITION (TP) SENSOR REMOVAL / INSTALLATION.)
THROTTLE POSITION (TP) SENSOR REMOVAL/INSTALLATION 1. Disconnect the TP sensor connector. 2. Remove the TP sensor screws. 3. Remove the TP sensor from the throttle body.
4. Verify that the throttle valve is fully closed. 5. Install the TP sensor to the throttle body. 6. tighten the TP sensor screws.
Tightening torque 1.6—2.3 N.m 16—24 kgf.cm, 14—20 in.lbf
7. Verify that the throttle valve moves smoothly. 8. Reconnect the TP sensor connector.
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CONTROL SYSTEM
Short circuit • CTP signal circuit (CTP switch connector
terminal and PCM connector terminal 1 N to GND)
4. Reconnect CTP switch connector. INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION Resistance inspection
Note • Perform the following test only when directed.
1. Remove the IAT sensor. 2. Heat the IAT sensor using the lamp. 3. Measure the resistance of the IAT sensor using
an ohmmeter
Specification
Water temperature (°C °F) Resistance (kΩ)
9. Adjust the TP sensor. (Refer to CONTROL SYSTEM, THROTTLE POSITION (TP) SENSOR ADJUSTMENT.)
CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION
Caution • The CTP switch is set at the factory. Do not
try to adjust it. • Removing the closed throttle position
switch can negatively affect the engine. Note • Perform the following test only when directed.
1. Disconnect the CTP switch connector. 2. Inspect for continuity between the CTP switch
terminal and a GND using an ohmmeter.
Specification
20 68 2.09— 2.81
Measuring condition Continuity 80 176 0.274 —0.802
Closed throttle position Yes Others No
3. If not as specified, replace the throttle body. If the CTP switch is okay, but PI D value is out of specification, inspect as follows and repair or replace as necessary.
Open circuit • CTP signal circuit (CTP switch connector terminal
and PCM connector terminal 1N) • GND circuit (CTP switch body to GND)
4. If not as specified, replace the IAT sensor. If
IAT sensor is okay, but PID value is out of specification, inspect as follows and repair or replace as necessary.
Open circuit • IAT signal circuit (IAT sensor connector terminal
A and PCM connector terminal 2L) • GND circuit (IAT sensor connector terminal B
and PCM connector terminal 2D)
Short circuit • IAT signal circuit (IAT sensor connector terminal
A and PCM connector terminal 2Lto GND) 5. Reconnect the IAT sensor connector.
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CONTROL SYSTEM ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
Note • Perform the following test only when directed.
ECT Sensor Resistance Inspection 1. Drain the engine coolant.
(Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
2. Remove the ECT sensor. 3. Place the ECT sensor in water with a
thermometer, and heat the water gradually.
4. Measure the resistance between the ECT sensor
terminals A and B using an ohmmeter.
Specification Water temperature (°C °F) Resistance (kΩ)
20 68 2.2—2.8 80 176 0.29—0.4
INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the IAT sensor connector. 3. Remove the IAT sensor. 4. Install the IAT sensor.
Tightening torque 7.9—11.7 N.m 80—120 kgf.cm, 70—104 in.lbf
5. Connect the IAT sensor connector. 6. Connect the negative battery cable. ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION
Warning • When the engine is hot, it can badly burn.
Turn off the engine and wait until it is cool before removing or installing the ECT sensor.
1. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
2. Disconnect the ECT sensor connector. 3. Remove the ECT sensor.
4. Replace the gasket. 5. Install in the reverse order of removal,
Tightening torque 25—29 N.m 2.5—3.0 kgf.m, 19—21 ft.lbf
6. Refill the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
5. If not as specified, replace the ECT sensor. If the ECT sensor is okay, but PID value is out of specification, inspect for the following: Open circuit • ECT signal circuit (ECT sensor connector
terminal A and PCM connector terminal 2Q through common connector)
• GND circuit (ECT sensor connector terminal B and PCM connector terminal 2D through common connector)
Short circuit • ECT signal circuit (ECT sensor connector
terminal A and PCM connector terminal 2Q through common connector to GND)
• GND circuit (ECT sensor connector terminal B and PCM connector terminal 2D through common connector to GND)
6. Repair or replace faulty areas. F1-40 CONTINUED
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CONTROL SYSTEM 7. Install the ECT sensor. 8. Refill the engine coolant.
(Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
CAMSHAFT POSITION (CMP) SENSOR INSPECTION
Note • Perform the following test only when directed.
Voltage Inspection 1. Remove the distributor. 2. Disconnect the fuel injector connectors. 3. Disconnect the high-tension lead. 4. Connect the distributor connector.
Warning • Turning the ignition switch on with the
fuel injector connector still connected will actuate the fuel injector.
• Turning the ignition switch on with the distributor connector still connected will generate sparks, which can cause electrical shock. Disconnect the connector and prevent it from grounding to the vehicle body.
5. Turn the ignition switch on. 6. Verify the following signal (voltage) from the PCM
2E terminal using a voltmeter when the distributor is rotated by hand.
Specification Signal Terminal Voltage SGT 2E 4 pulses/rev. (Approx. 5.0 V)
Short circuit • SGT signal circuit (Distributor harness side
connector terminal C and PCM harness side connector terminal 2E to GND)
• Power circuit (Distributor harness side connector terminal B and main relay harness side connector terminal D to GND)
9. If the harnesses are okay, replace the distributor and adjust the ignition timing. (Refer to ENGINE TUNE-UP, IGNITION TIMING ADJUSTMENT.)
OXYGEN SENSOR (O2S) INSPECTION O2S Voltage Inspection
Note • Perform the following test only when directed.
1. Warm up the engine and run it at idle. 2. Disconnect the O2S connector. 3. Connect the voltmeter test leads to the following
O2S terminals: • (+) lead-O2S terminal A • (-) lead-O2S terminal B
4. Run the engine at 3000 rpm until the voltmeter increases 0.5—0.7 V.
5. Verify that the voltmeter needle moves when racing the engine several times.
Specification Engine condition Voltage (V)
Acceleration 0.5—1.0 Deceleration 0—0.5
7. If not as specified, inspect as follows and repair
or replace as necessary. 8. Disconnect the distributor connector.
Open circuit • SGT signal circuit (Distributor harness side
connector terminal C and PCM harness side connector terminal 2E)
• Power circuit (Distributor harness side connector terminal B and main relay harness side connector terminal D)
• GND circuit (Distributor harness side connector terminal A and engine GND)
6. If not as specified, replace the O2S. If the O2S is okay, but PID value is out of specification, inspect for following:
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CONTROL SYSTEM
Variable resistor condition Resistance (kΩ)
Turned fully clockwise 4-6 Turned fully counterclockwise Below 0.1
Open circuit • O2S signal circuit (O2S connector terminal A and
PCM connector terminal 2N) • GND circuit (O2S connector terminal B and PCM
connector terminal 2D)
Short circuit • O2S signal circuit (O2S connector terminal A and
PCM connector terminal 2N to GND) 7. Repair or replace faulty areas. 8. Reconnect the O2S connector. OXYGEN SENSOR (O2S) REMOVAL/INSTALLATION 1. Disconnect the battery negative terminal. 2. Disconnect the O2S connector. 3. Remove the O2S. 4. Install in the reverse order of removal.
Tightening torque 29-49 N.m 3—5 kgf.m, 22—36 ft.lbf
VARIABLE RESISTOR INSPECTION 1. Disconnect the connector from the variable
resistor. 2. Connect an ohmmeter between the variable
resistor terminal B and C.
3. Using the SST, verify that the resistance increases in relation to the turning amount of the variable resistor.
4. If not as specified, replace the variable resistor. 5. Adjust idle mixture. 6. If the variable resistor is okay, but PCM terminal
2N or 2K voltage is out of specification, inspect for the following:
Open circuit • Reference voltage circuit (Variable resistor
connector terminal A and PCM connector terminal 2K)
• Variable resistor signal circuit (Variable resistor connector terminal B and PCM connector terminal 2N)
• GND circuit (Variable resistor connector terminal C and PCM connector terminal 2D)
Short circuit • Reference voltage circuit (Variable resistor
connector terminal A and PCM connector terminal 2K)
• Variable resistor signal circuit (Variable resistor connector terminal B and PCM connector terminal 2N)
7. If there is an open or short circuit, repair or replace wiring harness.
8. If there is no open or short circuit, replace variable resistor.
9. Reconnect the variable resistor connector. CLUTCH SWITCH INSPECTION Continuity Inspection
Note • Perform the following test only when directed.
1. Verify that the clutch switch is installed properly. 2. Disconnect the negative battery cable. 3. Remove the clutch switch.
(Refer to CONTROL SYSTEM, CLUTCH SWITCHREMOVAL/INSTALLATION.)
4. Inspect the continuity between the clutch switch terminals A and B using an ohmmeter.
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CONTROL SYSTEM
Specification Transmission Continuity
In neutral Yes Others No
Specification
5. If not as specified, replace the clutch switch. If the
clutch switch is okay, but PID value is out of specification, inspect for the following: Open circuit • Power circuit (Clutch switch connector terminal
B and PCM connector terminal 1V through common connector)
• GND circuit (Clutch switch connector terminal A and GND)
Short circuit • Power circuit (Clutch switch connector terminal
B and PCM connector terminal 1V to GND) Neutral switch
• The neutral switch operation and related harnesses continuity (Refer to NEUTRAL SWITCH INSPECTION.
6. Repair or replace faulty areas. 7. Install the clutch switch.
(Refer to CONTROL SYSTEM, CLUTCH SWITCH REMOVAL/INSTALLTION.)
8. Connect the negative battery cable. CLUTCH SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the clutch switch connector. 3. Loosen the nuts and remove the clutch switch. 4. Install the clutch switch. 5. Adjust the clutch pedal height referring to the above
and the height specification. (Refer to Section H, CLUTCH PEDAL, CLUTCH PEDAL INSPECTION/ADJUSTMENT.)
6. Connect the clutch switch connector. 7. Connect the negative battery cable. NEUTRAL SWITCH INSPECTION Continuity inspection
Note • Perform the following test only when directed.
1. Disconnect the battery negative cable. 2. Disconnect the neutral switch connector. 3. Measure the continuity between the neutral switch
terminals A and B using an ohmmeter.
4. If not as specified, replace the neutral switch. If the
neutral switch is okay, but PID value is out of specification, inspect for the following:
Open circuit • Load/no load distinction circuit (neutral switch
connector terminal A and PCM connector terminal 1V through common connector)
• GND circuit (neutral switch connector terminal B and GND)
Short circuit • Load/no load distinction circuit (neutral switch
connector terminal A and PCM connector terminal 1V through common connector to GND) Clutch switch
• The clutch switch operation and related harness continuity. (Refer to CONTROL SYSTEM, CLUTCH SWITCH INSPECTION.)
5. Repair or replace faulty areas. 6. Reconnect the neutral switch connector. NEUTRAL SWITCH REMOVAL/INSTALLATION 1. Disconnect the battery negative cable. 2. Disconnect the neutral switch connector. 3. Remove the neutral switch. 4. Install the new washer and neutral switch.
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CONTROL SYSTEM
Tightening torque 25—34 N.m 2.5—3.5 kgf.m, 19—25 ft.lbf
5. Connect the neutral switch connector. 6. Connect the battery negative cable. POWER STEERING PRESSURE (PSP) SWITCH INSPECTION Continuity inspection
Note • Perform the following test only when directed.
1. Disconnect the PSP switch connector. 2. Start the engine. 3. Inspect for continuity between the PSP switch
terminal and GND using an ohmmeter.
Specification
Condition Continuity Steering wheel in straight ahead Yes
Steering wheel fully turned No 4. If not as specified, replace the PSP switch. If the
PSP switch is okay, but PID value is out of specification, inspect for the following: Open circuit • PSP signal circuit (PSP switch connector
terminal and PCM connector terminal 1P through common connector)
• GND circuit (PSP switch body and GND)
Short circuit • PSP signal circuit (PSP switch connector terminal
and PCM connector terminal 1P through common connector to GND) Power steering fluid (Refer to Section N, engine speed sensing power steering system.)
• Fluid level • Fluid leakage • Fluid pressure 5. Repair or replace faulty areas. 6. Reconnect the PSP switch connector. MAIN RELAY INSPECTION Continuity Inspection
Note • Perform the following test only when directed.
1. Disconnect the negative battery cable. 2. Remove the main relay connector. 3. Inspect for continuity between terminals of the
relay using an ohmmeter.
Specification
4. If not as specified, replace the main relay. If the main relay is okay, inspect for the following: Open circuit • Main relay power supply circuit (Main relay
connector terminal A and ignition switch (IG1) connector through common connector)
• PCM power supply circuit (Main relay connector terminal C and battery positive terminal through common connector)
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CONTROL SYSTEM, ON-BOARD DIAGNOSTIC SYSTEM
• GND circuit (Main relay connector terminal B and GND)
Short circuit • Main relay power supply circuit (Main
relay connector terminal A and ignition switch (IG1) connector through common connector to GND)
• PCM power supply circuit (Main relay connector terminal C and battery positive terminal through common connector to GND)
5. Repair or replace faulty areas. 6. Reconnect the main relay. 7. Reconnect the negative battery cable. MAIN RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the main relay connector. 3. Remove the main relay. 4. Install the reverse order of removal.
Tightening torque 7.9—10.7 N.m 80—110 kgf.cm, 69.5—95.4 in-Ibf
ON-BOARD DIAGNOSTIC SYSTEM READ/CLEAR DIAGNOSTIC TEST RESULTS
• This retrieves all stored DTCs in the PCM and clears the DTC.
PARAMETER IDENTIFICATION (PID) ACCESS • The PID mode allows access to certain data
values, analog and digital inputs and outputs, calculated values and system status information. Since PID values for output devices are PCM internal data values, perform the Simulation Test to identify which output devices are malfunctioning.
Note • PID monitor item "PRCV" can be selected and
"ON" or "OFF' is displayed for vehicles without the PRC system, but is not used for the inspection because the corresponding part (PRC solenoid valve) is not equipped.
DIAGNOSTIC SUPPORT PROCEDURE
• These tests are the ability of the powertrain control system to detect a change in certain input devices by following the instructions on the NGS tester. There are two options: ALL TEST and SINGLE TEST. ALL TEST takes you through all diagnostic support tests. SINGLE TEST enables you to perform specific tests that relate to the particular diagnosis that you are conducting. This test MUST follow the instructions on the NGS tester. If not, a "TEST CONDITIONS NOT CORRECT' message will appear, or else the test result will be FAULTY.
SIMULATION TEST • Output devices can be turned on and off by
sending simulation command signals from the NGS tester to the PCM. The "Idling Test" and "Ignition ON Test" are available in this test. These tests will verify the PCM status, output devices, and related circuit wiring harnesses.
Note • "PRCV" of the simulation item can be selected
for vehicles without the PRC system, but is not used for the inspection because the corresponding part (PRC solenoid valve) is not equipped.
ON-BOARD DIAGNOSTIC TEST NGS Tester Hook-up Procedure
Note • Make sure the ignition switch is at LOCK
position. 1. Insert the vehicle interface module and latest
program card into the hand-held NGS control unit.
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ON-BOARD DIAGNOSTIC SYSTEM
2. Plug the adapter harness connector into the
vehicle interface module and the DLC located at the engine compartment.
3. Plug the NGS tester power connector into the cigarette lighter. Alternatively, use a battery hook-up adapter.
4. Listen to the double beep. The NGS tester is now initialized. Begin the powertrain control system functional test.
DTC READING PROCEDURE Using the SSTs (NGS Tester)
Note • Start engine and keep it running. If the
engine will not start, turn the ignition switch on during the procedure.
1. Perform the necessary vehicle preparation and visual inspection. Hook the NGS tester up to the vehicle.
2. Move the cursor to VEHICLE & ENGINE
SELECTION. Press the TRIGGER key to enter this function.
3. Move the cursor to SELECT NEW VEHICLE YEAR & MODEL Press the TRIGGER key to enter this selection.
4. Move the cursor to B-SERIES (UN). Press the TRIGGER key to enter this selection.
EUROPE
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ON-BOARD DIAGNOSTIC SYSTEM EXCEPT EUROPE
Note
• Make sure the selected vehicle is correct. 5. A vehicle selection screen showing the selected
vehicle will be displayed. Move the cursor to the vehicle selected. Press the TRIGGER key.
6. Move the cursor to DIAGNOSTIC DATA LINK on the main menu screen. Press the TRIGGER key to enter into menu system diagnostics.
7. Move the cursor to PCM-POWERTRAIN CONTROL MODULE. Press the TRIGGER key to enter this selection.
8. Move the cursor to DIAGNOSTIC TEST MODES.Press the TRIGGER key to enter this selection.
9. Move the cursor to READ/CLEAR DIAGNOSTIC TEST RESULTS. Press the TRIGGER key to enter this selection.
10. Press START.
11. Retrieve DTCs. Not Using the SSTs (NGS Tester) Using the SST (self-diagnosis checker) 1. Connect the SSTs to the DLC located in the
engine compartment and ground the black (negative) lead to the body.
2. Set the select switch on the SST (self-diagnosis
checker) to A. 3. Turn the dial switch on the SST (system selector)
to 1, and the test switch to SELF TEST. 4. Turn the ignition switch on. 5. Verify that the buzzer sounds for approximately 3
seconds and code "88" flashes for 5 seconds. If DTC is not detected, "00" will then be indicated. Note • If the "88" does not flash, inspect +B terminal
of the DLC, and the related harnesses and connectors.
• If the "88" flashes and the buzzer sounds more than 20 seconds, inspect the harness between the PCM terminal and the DLC. If the harness is normal, replace the PCM and inspect.
6. If any DTCs is indicated, inspect the appropriate area and repair as necessary. Note • A DTC consists of four numbers. They are
flashed one by one in the right window on the display. ("1" is always shown on the left window.)
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ON-BOARD DIAGNOSTIC SYSTEM 7. After completion of repairs, erase all DTCs from
the memory. (Refer to AFTER REPAIR PROCEDURE, Not Using the SSTs (NGS tester).)
8. Remove the SSTs.
Using the Voltmeter 1. Turn the ignition switch off.
Caution • Connecting the wrong DLC terminals may
possibly cause a malfunction. Carefully connect the specified terminals only.
2. Using a jumper wire to short terminal TEN of the DLC to body GND.
3. Connect the negative battery lead of voltmeter (20V range) to the DLC terminal FEN, and the positive lead to the DLC terminal +B.
4. Turn the ignition switch on. 5. The voltmeter indicates B+ for approximately 3
seconds, then indicates 0V. 6. Read the DTCs indicated by the movement of the
voltmeter's needle. If DTC is not detected, the needle does not move.
Note • The DTC will be output as shown.
7. If any DTCs is indicated, inspect the appropriate area and repair as necessary.
8. After completion of repairs, erase all DTCs from the memory. (Refer to AFTER REPAIR PROCEDURE, Not Using the SSTs (NGS Tester).)
9. Remove the voltmeter and jumper wire PID/DATA MONITOR AND RECORD PROCEDURE 1. Perform the NGS Tester Hook-up Procedure. 2. Perform Steps 1 through 7 from the DTC
READING PROCEDURE. 3. Turn the ignition switch on or run the engine. 4. Move the cursor to PID/DATA MONITOR AND
RECORD. Press the TRIGGER key to enter this selection.
5. Move the cursor to PID values to view. Press the TRIGGER key. A star symbol will appear next to the item when it is selected. Note • Press the TRIGGER key once again to
deselect a PID. • Press the CLEAR to deselect all PIDs.
6. Press START to begin. 7. When ready to capture and store the selected
PIDs, press the TRIGGER key. 8. Press the TRIGGER key again when ready to
save information. 9. Move the cursor to STORE RECORDING AREA
1. Press the TRIGGER key.
10. Follow the instructions displayed on the NGS
tester to save the recording data. PLAYBACK OF STORED PIDS PROCEDURE
Note • Look for abnormal behavior or values that
are clearly incorrect. Inspect the signals for abrupt or unexpected changes.
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ON-BOARD DIAGNOSTIC SYSTEM • Look for agreement in related signals. • Make sure signals act in proper sequence.
1. Select VIEW RECORDER AREAS.
2. Select up to four PIDs to review in the table format or two PIDs to review in the graph mode. (1) Table format: Scroll through the PID data while analyzing the information. Look for sudden drops or peaks in the values.
(2) Graph format: Scroll through the PID data while analyzing the information. Look for sudden drops or peaks in the linear lines showing the transformation of values to the line graph.
DIAGNOSTIC SUPPORT PROCEDURE 1. Perform the NGS Tester Hook-up Procedure. 2. Perform Steps 1 through 8 from the DTC
READING PROCEDURE. 3. Move the cursor to DIAGNOSTIC SUPPORT
PROCEDURE. Press the TRIGGER key to enter this selection.
4. Move the cursor to ALL TEST or SINGLE TEST.
Press the TRIGGER key. Note • ALL TEST inspects each item according to an
established programmed order. With SINGLE TEST, enable to select and inspect any test item in any order, one at a time.
5. Follow the instructions displayed on the NGS tester and press the TRIGGER key.
Note • To skip a test item, press OMIT. • Before performing the test, the basic condition
on the test vehicle must be set up in order to get exact data. Press BASIC to view the basic condition instruction screen.
• If the screen shows PASSED, the system operates correctly.
• If the screen shows FAULTY, the system operates incorrectly.
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ON-BOARD DIAGNOSTIC SYSTEM SIMULATION TEST PROCEDURE Idling Test 1. Perform the NGS tester hook-up procedure. 2. Perform the Steps 1 through 7 from the DTC
READING PROCEDURE. 3. Start the engine and run it at idle. 4. Move the cursor to SIMULATION TEST. Press the
TRIGGER key to enter this selection.
5. Move the cursor to IDLING TEST. Press the TRIGGER key to enter this selection.
6. The screen will display a list of simulation items.
Select the appropriate simulation item for testing, then press the TRIGGER key.
Note • Only one simulation item can be selected at a
time.
7. Press START. Note • If the screen displays "TEST CONDITION NOT
CORRECT", inspect the following signal conditions and determine whether or not they are normal:
• NLSW: ON • RPM; above 550
8. Press the TRIGGER key.
9. The simulation is performed for 3 seconds, and a "SIMULATION ACTIVATED PLEASE WAIT" message is displayed during those 3 seconds.
10. To perform the simulation again, press the TRIGGER key. To exit the idling test, press the CANCEL key.
Ignition ON Test 1. Perform Steps 1 through 7 from the DTCs
READING PROCEDURE. 2. Turn the ignition switch on. Move the cursor to
SIMULATION TEST. Press the TRIGGER key to enter this selection.
3. Move the cursor to IGNITION ON TEST. Press the TRIGGER key to enter this selection.
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ON-BOARD DIAGNOSTIC SYSTEM
4. The screen will display a list of simulation items.
Select the appropriate simulation item for testing, then press the TRIGGER key.
5. Press START.
6. Press the TRIGGER key.
7. The simulation is performed for 3 seconds, and
a "SIMULATION ACTIVATED PLEASE WAIT" message is displayed during those 3 seconds.
8. To perform the simulation again, press the
TRIGGER key. To exit the ignition on test, press the CANCEL key.
AFTER REPAIR PROCEDURE Using the SSTs (NGS Tester) 1. After repairs have been made, perform the DTCs
READING PROCEDURE. 2. Press CLEAR. 3. Press the TRIGGER key. 4. Press the CANCEL key. 5. Ensure that the customer's concern has been
resolved. Not Using the SSTs (NGS Tester) 1. After repairs, disconnect the negative battery
cable for at least 20 seconds, and depress the brake pedal. Reconnect the negative battery cable.
2. Warm up the engine to normal operating temperature. Note • If the engine will not start, continue to operate
the starter for 5-6 seconds.
3. Perform the "DTC READING PROCEDURE" again.
4. Verify that the DTC is not detected.
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ON-BOARD DIAGNOSTIC SYSTEM DTC INSPECTION DTC Table
DTC No. Output pattern Display on the NGS tester Condition
P0100
MAF/VAF-CIRCUIT MALFUNCTION MAF sensor circuit malfunction
P0115
ECT-CIRCUIT MALFUNCTION ECT sensor circuit malfunction
P0120
TP-CIRCUIT MALFUNCTION TP sensor circuit malfunction
P0134
O2S 11-CIRCUITNO ACTIVITY DETECTED O2S circuit no activity detected
P0340
CAMSHAFT POS SENSOR-CKT MALFUNCTION SGT signal is not detected
P0443
EVAP SYSTEM-PURGE CTRL VALVE CKT MALF Purge solenoid valve circuit malfunction
P0505
IDLE CONTROL SYSTEM-MALFUNCTION IAC valve circuit malfunction
P1110
IATS (D/C)-OPEN OR SHORT IAT sensor circuit malfunction
P1170
HO2S 11-INVERSION O2S is stuck
P1195
EGRBS-OPEN OR SHORT Barometric pressure sensor (in PCM) malfunction
P1250
PRC-OPEN OR SHORT PRC solenoid valve circuit malfunction
P1608
PCM (CPU)-MALFUNCTION PCM internal circuit malfunction
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ON-BOARD DIAGNOSTIC SYSTEM DTC Troubleshooting
DTC P0100 Mass air flow (MAP) sensor circuit malfunction DETECTION CONDITION
Input voltage from MAF sensor is below 0.7 V or above 5.4 V when ignition switch is turned on.
POSSIBLE CAUSE
• MAF sensor malfunction • Blockage at MAP sensor • Poor connection of connectors at MAF sensor and/or PCM • Leakage in intake-air system • Short to power supply circuit in wiring from MAF sensor terminal B to PCM terminal 20 • Short to ground in wiring from MAF sensor terminal B to PCM terminal 20 • Open circuit in wiring from MAF sensor terminal B to PCM terminal 20 • Open circuit in wiring from MAF sensor terminal C to main relay terminal D • Open circuit in wiring from MAF sensor terminal A to PCM terminal 2D • Open circuit in wiring from PCM terminal 2C to engine ground.
STEP INSPECTION ACTION Yes
Inspect for open circuit in following wiring harnesses, then go to Step 12. • Main relay terminal D-purge solenoid valve, PRC
solenoid valve, IAC valve CMP sensor • PCM terminal 2D-throttle position sensor, intake-air
temperature sensor, engine coolant temperature sensor, oxygen sensor
• Between PCM terminal 2C and engine ground
1
Verify stored DTC. Have DTCs P0115, P0120, P0134, P0340, P0443, P0505, P1110, P1170, and/or P1250 been stored?
No Go to next step Yes Repair or replace connector, then go to Step 12. 2
Does MAP sensor connector or PCM connector have poor connection? No Go to next step.
Yes Go to next step 3
Is intake-air system okay? No Repair or replace faulty parts, then go to Step 12.
Yes Go to next step. 4
Disconnect MAF sensor connector. Turn ignition switch on. Is there battery positive voltage at MAF sensor harness side connector terminal C?
No
Inspect for open or short circuit in wiring harness (between main relay terminal D and MAF sensor terminal C), thengo to Step 12.
Yes
Go to next step.
5
Disconnect PCM connector. MAF sensor connector is disconnected. Is there continuity between MAF sensor harness side connector terminal A and PCM harness side connector terminal 2D?
No
Repair open circuit, then go to Step 12.
Yes Go to next step 6
Is there continuity between MAF sensor harness side connector terminal B and PCM harness side connector terminal 20 No Repair open circuit, then go to Step 12.
Yes Repair short to power circuit, then go to Step 12. 7
Is there continuity from PCM harness side connector terminals 20 to 1B? No Go to next step
Yes Repair short to ground circuit, then go to Step 12. 8
Is there continuity from PCM harness side connector terminals 20 to body ground. No Go to next step.
Yes Clean MAF sensor screen, then go to Step 12. 9
Remove MAF sensor. Is there any foreign material at MAF sensor screen?
No Go to next step. Yes
Go to next step.
10
Connect MAF sensor connector. Connect NGS tester to DLC. Turn ignition switch on. Access MAF V PID. Does MAF V PID change when air is blown into mass airflow sensor?
Note • If NGS tester is not used, measure PCM
20 terminal voltage with circuit tester.
No
Replace MAF sensor, then go to Step 12.
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ON-BOARD DIAGNOSTIC SYSTEM
STEP INSPECTION ACTION Yes Go to Step 1. 11
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
No
Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step.
Yes Go to applicable DTC inspection. 12
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
No
Troubleshooting completed.
DTC P0115 Engine coolant temperature (ECT) sensor circuit malfunction
DETECTION CONDITION
Input voltage from ECT sensor is below 0.07 V or above 4.58 V when ignition switch is turned on.
POSSIBLE CAUSE
• ECT sensor malfunction • Poor connection of connectors at ECT sensor terminal and/or PCM • Short to power supply circuit in wiring from ECT sensor terminal A to PCM terminal 2Q • Short to ground in wiring from ECT sensor terminal A to PCM terminal 2Q • Open circuit in wiring from ECT sensor terminal A to PCM terminal 2Q • Open circuit in wiring from ECT sensor terminal B to PCM terminal 2D • Open circuit in wiring from PCM terminal 2C to engine ground
STEP INSPECTION ACTION Yes
Inspect for open circuit in following wiring harnesses, then go to Step 9. • PCM terminal 2D-MAF sensor, O2S, IAT sensor,
and/or TP sensor • PCM terminal 2C-engine ground
1
Verify stored DTC. Have DTCs P0100, P0120, P0134, P1110, and/or P1170 been stored?
No Go to next step Yes Repair or replace connector, then go to Step 9. 2
Does ECT sensor connector or PCM connector have poor connection? No Go to next step
Yes Go to next step 3
Disconnect ECT sensor connector. Turn ignition switch on. Is there 5V at engine coolant temperature sensor harness side connector terminal A
No
Inspect for open or short circuit in wiring harness (between PCM terminal 2Q and ECT sensor terminal A), then go to Step 9.
Yes
Go to next step.
4
Disconnect PCM connector. ECT sensor connector is disconnected. Is there continuity between ECT sensor harness side connector terminal B and PCM harness side connector terminal 2D
No
Repair open circuit, then go to Step 9
Yes Repair short to power circuit, then go to Step 9 5
Is there continuity from PCM harness side connector terminals 2Q to 1B? No Go to next step.
Yes Repair short to ground circuit, then go to Step 9. 6
Is there continuity from PCM harness side connector terminals 2Q to body ground? No Go to next step
Yes Go to next step 7
Is ECT sensor okay? CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
No
Replace ECT sensor, then go to Step 9. CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION.
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ON-BOARD DIAGNOSTIC SYSTEM
STEP INSPECTION ACTION Yes Go to Step 1. 8
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
No
Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step.
Yes Go to applicable DTC inspection. 9
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"? No Troubleshooting completed.
DTC P0120 Throttle position (TP) sensor circuit malfunction DETECTION CONDITION
Input voltage from TP sensor is below 0.09 V or above 4.78 V when ignition switch is turned on.
POSSIBLE CAUSE
• TP sensor malfunction • Poor connection of connectors at TP sensor and/or PCM • Short to power supply circuit in wiring from TP sensor terminal A to PCM terminal 2K • Short to power supply circuit in wiring from TP sensor terminal C to PCM terminal 2D • Short to power supply circuit in wiring from TP sensor terminal B to PCM terminal 2M • Short to ground in wiring from TP sensor terminal B to PCM terminal 2M • Short to ground in wiring from TP sensor terminal A to PCM terminal 2K • Open circuit in wiring from TP sensor terminal A to PCM terminal 2K • Open circuit in wiring from TP sensor terminal C to PCM terminal 2D • Open circuit in wiring from TP sensor terminal B to PCM terminal 2M • Open circuit in wiring from TP sensor terminal 2C to engine ground
STEP INSPECTION ACTION Yes
Inspect for open or short circuit in following wiring harnesses, then go to Step 11. • PCM terminal 2D -MAP sensor, O2S, IAT
sensor, and/or ECT sensor • Between PCM terminal 2C and engine ground
1
Verify stored DTC. Have DTC P0100, P0115, P0134, P1110 and/or P1170 been stored.
No Go to next step Yes Repair or replace connector, then go to Step 11 2
Does TP sensor connector or PCM connector have poor connection? No Go to next step.
Yes Go to next step. 3
Disconnect TP sensor connector. Turn ignition switch on. Is there 5V at TP sensor harness side connector terminal A?
No
Inspect for open or short circuit in wiring harness (between PCM terminal 2K and TP sensor terminal A), then go to Step 11
Yes
Go to next step.
4
Disconnect PCM connector. TP sensor is disconnected. Is there continuity between TP sensor harness side connector terminal C and PCM harness side connector terminal 2D.
No
Repair open circuit, then go to Step 11.
Yes Go to next step. 5
Is there continuity between TP sensor harness side connector terminal B and PCM harness side connector terminal 2M. No Repair or replace wiring harness, then go to Step 11.
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ON-BOARD DIAGNOSTIC SYSTEM
STEP INSPECTION ACTION Yes Repair short to power supply circuit, then
go to Step 116
Is there continuity from PCM harness side connector terminals 2D to 1B? No Go to next step.
Yes Repair short to power supply circuit, then go to Step 11.
7
Is there continuity from PCM harness side connector terminal 2M to 1B No Go to next step.
Yes Repair short to ground circuit, then go to Step 11. 8
Is there continuity from PCM harness side connector terminals 2M to body ground? No Go to next step.
Yes
Go to next step.
9
Connect TP sensor and PCM connectors. Connect NGS tester to DLC. Turn ignition switch on. Access TP V PID. Does TP V increase linear according to throttle valve opening angle?
Note
• If NGS tester is not used, measure PCM 2M terminal voltage with circuit tester.
No
Verify TP sensor, then go to Step 11.
Yes Go to Step 1. 10
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
No
Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step.
Yes Go to applicable DTC inspection 11
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"? No Troubleshooting completed.
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ON-BOARD DIAGNOSTIC SYSTEM
DTC P0134 Oxygen sensor (O2S) circuit no activity detected
DETECTION CONDITION
O2S signal does not exceed 0.45 V after the engine is started, or stays below 0.45 V for 180 seconds after the engine has reached normal operating temperature.
POSSIBLE CAUSE
• O2S malfunction • Open or short circuit in wiring harness • Open or short circuit in wiring harness • Poor connection of connector • Fuel injector malfunction • Pressure regulator malfunction • Fuel pump malfunction • Fuel delivery hose and/or fuel filter clogging or leakage • Leakage in intake-air system • Leakage in exhaust system • Ignition coil and/or igniter malfunction Insufficient compression • MAF sensor malfunction • ECT sensor malfunction • TP sensor malfunction • Vacuum hose damage or looseness Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures.Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION ACTION Yes Inspect and repair DTC P0100, P0115, P0120 or
P1110 then go to Step 22. 1
Verify stored DTC. Have DTC P0100 P0120, P0115 and/or P1110 been stored? No Go to next step
Yes
Trouble is in process. Go to next step.
2
Clear DTC. Verify RPM, ECT and VS PIDs. Drive in normal mode for approx. 2 minutes under same condition. Is DTC P0134 stored?
Note • If NGS tester is not used, measure
follow PCM terminal voltages with circuit tester. ① SGT (terminal 2E) ② ECT sensor (terminal 2Q) ③ Vehicle speed (terminal 1M)
No
Go to 'TROUBLESHOOTING, ENGINE SYMPTOM TROUBLESHOOTING, Intermittent concerns".
Yes
Implement TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure" and repair or replace, then go to Step 22.
3
Implement PID/DATA MONITOR AND RECORD (ECT, RPM, TP V) from DIAGNOSTIC DATA LINK by using NGS tester. Is there any signal that is far out of specification when ignition switch is on, and engine is run at idle?
Note • If NGS tester is not used, measure
following PCM terminal voltages with circuit tester. ① ECT sensor (terminal 2Q) ② SGT (terminal 2E) ③ TP sensor (terminal 2M)
No
Go to next step.
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ON-BOARD DIAGNOSTIC SYSTEM
STEP INSPECTION ACTION Yes
Implement 'TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure" and repair or replace, then go to Step 22.
4
Continue monitoring items in previous step. Is there any input signal, which causes drastic changes when it is set to be in trouble condition?
No Go to next step.
Yes
Repair or replace faulty exhaust parts, then go to Step 22. EXHAUST SYSTEM, EXHAUST SYSTEM
REMOVAL/INSTALLATION.
5
Inspect exhaust system upstream from oxygen sensor. Is there any gas leakage?
No Go to next step Yes Go to next step. 6
Inspect installation of O2S. Is it okay?
No
Install O2S properly, then go to Step 22. CONTROL SYSTEM, OXYGEN SENSOR (O2S)
REMOVAL/INSTALLATION. Yes
Go to next step.
7
Implement PID/DATA MONITOR AND RECORD (O2S) from DIAGNOSTIC DATA LINK using NGS tester. Is voltage on oxygen sensor as follows while racing engine (in neutral)? • More than 0.45V when accelerator pedal is
suddenly pressed: rich condition • Less than 0.45V during fuel cut: lean condition
Note • If NGS tester is not used, measure PCM
2N terminal voltage with circuit tester.
No
Inspect and repair or replace faulty oxygen sensor harness, connector or terminal, then go to Step 22. CONTROL SYSTEM, OXYGEN SENSOR (O2S)
INSPECTION.
Yes
Repair or replace faulty harness, connector or terminal, then go to Step 22.
8
Inspect for open, poor connection, and other problems on following harnesses, connectors and terminals (for fuel injector at each cylinder): • Front main relay to fuel injector Are there any
problems? No Go to next step.
Yes
Replace faulty fuel injectors, then go to Step 22. FUEL SYSTEM, FUEL INJECTOR
REMOVAL/INSTALLATION.
9
Inspect injection amount of each fuel injector. FUEL SYSTEM, FUEL INJECTOR
INSPECTION, Fuel Injection Volume Test. Are there any fuel injectors in abnormal condition for amount or condition of injection? No Go to next step.
Yes
Repair or replace source of air suction, then go to Step 22.
10
Inspect for air suction: • From air cleaner to throttle body • From throttle body to dynamic chamber • From dynamic chamber to intake manifold Visually inspect for cracks and damage, and inspect fluctuation after spraying rust penetrating agent, then select air suction area. Can air suction be confirmed?
No
Go to next step.
Yes
Repair or replace source of air suction, then go to Step 22.
11
Inspect for suction in vacuum hose which has negative pressure on intake manifold, in the same manner as previous step. Can air suction be confirmed? No Go to next step.
Yes Go to Step 17. 12
Inspect fuel line pressure under trouble condition. TROUBLESHOOTING, ENGINE SYSTEM
INSPECTION, Fuel Pressure Inspection. Is fuel line pressure okay?
No Go to next step.
Yes Go to next step 13
Inspect fuel pump maximum pressure. FUEL SYSTEM, FUEL PUMP UNIT
INSPECTION, Fuel Pump Maximum Pressure Inspection.
Is it okay?
No
Replace fuel pump, then go to Step 22. FUEL SYSTEM, FUEL PUMP UNIT
REMOVAL/INSTALLATION. Yes Go to next step. 14
Inspect for clogging in fuel filter (high-pressure). Are there foreign materials on fuel side of fuel filter? No Go to Step 16.
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ON-BOARD DIAGNOSTIC SYSTEM STEP INSPECTION ACTION
Yes
Replace fuel filter (high-pressure), then go to Step 22. - FUEL SYSTEM, FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION.
15
Inspect inside of fuel tank for foreign materials and stains. Is inside of fuel tank okay?
No
Clean inside of fuel tank and fuel filter (low-pressure). Replace fuel filter (high-pressure), then go to Step 22. -FUEL SYSTEM, FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION.
Yes Go to next step. 16
Inspect for leakage and clogging in fuel line from fuel distributor to fuel pump. Is it okay? No Repair or replace necessary, then go to Step 22.
Yes
Replace pressure regulator, then go to Step 22.-FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION.
17
Inspect for leakage in fuel line fuel filter (high-pressure) to fuel tank (return side). Is it okay? No Repair or replace as necessary, the go to Step 22.
Yes Go to Step 19. 18
Verify blinking condition on each cylinder by setting timing light on high-tension lead under trouble condition. Does it blink regularly and stably?
No Go to next step.
Yes Go to next step. 19
Inspect resistance of ignition coil. Section G, IGNITION COIL INSPECTION. Is it okay? No Replace ignition coil, then go to Step 22.
Yes
Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant passage. Repair or replace faulty parts, then go to Step 22.
20
Warning • Removing the radiator cap when the
radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury.
• When removing the radiator cap, wrap a thick cloth around and turn it slowly.
Remove radiator cap. Implement procedure to bleed air from engine coolant, then run engine at idle. Are there any small bubbles which make engine coolant white at filling opening?
Note • Large bubbles are normal since they are
remaining air coming out from engine coolant passage.
No
Go to next step.
Yes Go to next step 21
Inspect engine compression. Section B1, COMPRESSION INSPECTION. Is it okay? No Implement engine overhaul, the go to next step.
Yes Go to applicable DTC inspection. 22
Clear DTC. Verify DTC after running vehicle. Is there any DTC stored? No Troubleshooting completed.
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ON-BOARD DIAGNOSTIC SYSTEM DTC P0340 SGT signal is not detected
DETECTION CONDITION
No SGT signal input from CMP sensor when engine is started and 2.1 seconds have passed
POSSIBLE CAUSE
• CMP sensor malfunction • CMP sensor air gap incorrect • Short to power supply circuit in wiring from CMP sensor terminal C to PCM terminal 2E • Short to ground in wiring from CMP sensor terminal C to PCM terminal 2E • Short to ground in wiring from CMP sensor terminal B to main relay terminal D • Open circuit in wiring from CMP sensor terminal C to PCM terminal 2E • Open circuit in wiring from CMP sensor terminal B to main relay terminal D • Open circuit in wiring from CMP sensor terminal A to body ground
STEP INSPECTION ACTION Yes
Inspect for open circuit in following wiring harnesses, then go to Step 11. • Main relay terminal D-purg solenoid valve, PRC solenoid valve, IAC solenoid valve, MAF sensor
1
Verify stored DTC. Have DTC PP0100, P0443, P0505, and/or P1250 been stored?
No Go to next step. Yes Repair or replace connector, then go to Step 11. 2
Does CMP sensor or PCM connector have poor connection? No Go to next step
Yes Go to next step. 3
Disconnect CMP sensor connector. Turn ignition switch on. Is there battery positive voltage at CMP sensor harness side connector terminal B?
No
Inspect for open or short circuit in wiring harness (between main relay terminal D and CMP sensor terminal B), then go to Step 11.
Yes Go to next step. 4
Disconnect CMP sensor connector. Turn ignition switch on. Is there 5 V at CMP sensor harness side connector terminal C?
No
Inspect for open or short circuit in wiring harness (between PCM terminal 2E and CMP terminal C), then go to Step 11.
Yes
Go to next step.
5
Disconnect PCM connector and CMP sensor con-nector. Is there continuity between CMP sensor harness side connector terminal C and PCM harness side connector terminal 2E?
No
Repair open circuit, then go to Step 11.
Yes Repair short to power circuit, then go to Step 11. 6
Is there continuity from PCM harness side connector terminal 2E to 1B? No Go to next step.
Yes Repair short to ground circuit, then go to Step 11. 7
Is there continuity from PCM harness side connector terminal 2E to body ground? No Go to next step.
Yes Go to next step. 8
Is there continuity from CMP sensor harness side terminal A to body ground? No Repair open circuit, then go to Step 11.
Yes
Go to next step.
9
Connect CMP sensor connector. Connect NGS tester to DLC. Turn ignition switch on. Access RPM PID. Does RPM PID change when engine is running?
Note
• If NGS tester is not used, measure PCM 2E terminal voltage with circuit tester.
No
Replace distributor and adjust ignition timing, then go to Step 11.
Yes Go to Step 1 10
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
No
Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step.
Yes Go to applicable DTC inspection. 11
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"? No Troubleshooting completed.
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ON-BOARD DIAGNOSTIC SYSTEM
DTC P0443 Purge solenoid valve circuit malfunction
DETECTION CONDITION Open or short circuit is observed in purge solenoid valve system when ignition switch is turned on.
POSSIBLE CAUSE
• Purge solenoid valve malfunction • Poor connection of connectors at purge solenoid valve and/or PCM • Short to power supply circuit in wiring from purge solenoid valve B to PCM terminal 2X • Short to ground in wiring from purge solenoid valve terminal B to PCM terminal 2X • Open circuit in wiring from PCM terminal 2B and/or 2C to engine ground • Open circuit in wiring from purge solenoid valve terminal B to PCM terminal 2X • Open circuit in wiring from purge solenoid valve terminal A to main relay terminal D
STEP INSPECTION ACTION Yes
Inspect for open circuit following wiring harnesses, then go to Step 9. • Main relay terminal D-PRC solenoid valve, IAC
solenoid valve, MAF sensor, CMP sensor • Between PCM terminal 2C and engine ground
1
Verify stored DTC. Have DTC P0100, P0505, P0340, and/or P1250 been stored?
No Go to next step Yes Repair or replace connector, then go to Step 9. 2
Does purge solenoid valve connector or PCM connector have poor connection? No Go to next step.
Yes Go to next step. 3
Disconnect purge solenoid valve connector. Turn ignition switch on. Is there battery positive voltage at purge solenoid valve harness side connector terminal A?
No
Inspect for open or short circuit in wiring harness (between main relay terminal D and purge solenoid valve terminal A), then go to Step 9.
Yes
Go to next step.
4
Disconnect PCM connector Purge solenoid valve is disconnected. Is there continuity between purge solenoid valve harness side connector terminal B and PCM harness side connector terminal 2X?
No
Repair open circuit, then go to step 9.
Yes Repair short to power supply circuit, then go to Step 9.
5
Is there continuity from PCM harness side connector terminal 2X to 1B? No Go to next step.
Yes Repair short to ground circuit, then go to Step 9. 6
Is there continuity from PCM harness side connector terminal 2X to body ground? No Go to next step.
Yes Go to next step 7
Is purge solenoid valve okay? EMISSION SYSTEM, PURGE SOLENOID
VALVE INSPECTION No Replace purge solenoid valve, then go to Step 9.
Yes Go to Step 1. 8
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
No
Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step.
Yes Go to applicable DTC inspection. 9
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"? No Troubleshooting completed.
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ON-BOARD DIAGNOSTIC SYSTEM
DTC P0505 Idle air control (IAC) valve circuit malfunction
DETECTION CONDITION
Open or short circuit is observed in idle air control, system
POSSIBLE CAUSE
IAC valve malfunction Poor connection of connectors at IAC valve and/or PCM Short to ground in wiring from IAC valve terminal B to PCM terminal 2W Short to power supply circuit in wiring from IAC valve terminal B to PCM terminal 2W Short to ground in wiring from IAC valve terminal A to main relay terminal D Open circuit in wiring from PCM terminal 2B and/or 2C to engine ground Open circuit in wiring from IAC valve terminal B to PCM terminal 2W Open circuit in wiring from IAC valve terminal A to main relay terminal D
STEP INSPECTION ACTION Yes
Inspect for open circuit following wiring harnesses, then go to Step 9. • Main relay terminal D-PRC solenoid valve, MAF
sensor, CMP sensor, purge solenoid valve • Between PCM terminal 2C and engine ground
1
Verify stored DTC. Have DTC P0100, P0340, P0443, and/or P1250 been stored.
No Go to next step Yes Repair or replace connector, then go to Step 9. 2
Does IAC valve connector or PCM connector have poor connection? No Go to next step
Yes Go to next step. 3
Disconnect IAC valve connector. Turn ignition switch on. Is there battery positive voltage at IAC valve harness side connector terminal A?
No
Inspect for open or short circuit in wiring harness (between main relay terminal D and IAC valve ter-minal A), then go to Step 9.
Yes
Go to next step.
4
Disconnect PCM connector IAC valve is disconnected. Is there continuity between IAC valve harness side connector terminal B and PCM harness side con-nector terminal 2W?
No
Repair open circuit, then go to step 9.
Yes Repair short to power supply circuit, then go to Step 9.5
Is there continuity from PCM harness side connector terminal 2W to 1B? No Go to next step.
Yes Repair short to ground circuit, then go to Step 9, 6
Is there continuity from PCM harness side connector terminal 2W to body ground? No Go to next step
Yes
Go to next step.
7
Is resistance between IAC valve component side connector A and B as specified?
Specification 8.7—10.5 Ω [23 °C 73.4 °F]
No
Replace IAC valve, then go to Step 9.
Yes Go to Step 1 8
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
No
Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step.
Yes Go to applicable DTC inspection 9
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"? No Troubleshooting completed
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ON-BOARD DIAGNOSTIC SYSTEM
DTC P1110 Intake air temperature (IAT) sensor circuit malfunction
DETECTION CONDITION
Input from IAT sensor is below 0.1 V or above 4.9 V when ignition switch is turned on
POSSIBLE CAUSE
• IAT sensor malfunction • Poor connection of connectors at IAT sensor terminal and/or PCM • Short to power supply circuit in wiring from IAT sensor terminal A to PCM terminal 2L • Short to GND in wiring from IAT sensor terminal A to PCM terminal 2L • Open circuit in wiring from IAT sensor terminal A to PCM terminal 2L • Open circuit in wiring from IAT sensor terminal B to PCM terminal 2D • Open circuit in wiring from PCM terminal 2C to engine GND
STEP INSPECTION ACTION Yes
Inspect for open circuit in following wiring harnesses, then go to Step 7. • PCM terminal 2D-ECT sensor, MAP sensor, O2S,
CMP sensor and/or TP sensor • PCM terminal 2C-engine GND
1
Verify stored DTC. Have DTC P0100, P0115, P0120, P0134, P0335, and/or P1170 been stored?
No Go to next step. Yes Repair or replace connector, then go to Step 9. 2
Does IAT sensor connector or PCM connector have poor connection? No Go to next step.
Yes Go to next step. 3
Disconnect IAT sensor connector. Turn ignition switch on. Is there 5V at IAT sensor harness side connector terminal A?
No
Inspect for open or short circuit in wiring harness (between PCM terminal 2L and IAT sensor terminal A), then go to Step 9.
Yes
Go to next step.
4
Disconnect PCM connector. IAT sensor connector is disconnected. Is there continuity between IAT sensor harness side connector terminal B and PCM harness side connector terminal 2D?
No
Repair open circuit, then go to Step 9.
Yes Repair short to power circuit, then go to Step 9. 5
Is there continuity from PCM harness side connector terminals 2L to 1B? No Go to next step.
Yes Repair short to ground circuit, then go to Step 9. 6
Is there continuity from PCM harness side connector terminal 2D to body GND? No Go to next step.
Yes Go to next step. 7
Is IAT sensor okay? CONTROL SYSTEM, INTAKE AIR
TEMPERATURE (IAT) SENSOR INSPECTION
No
Replace IAT sensor, then go to Step 9. CONTROL SYSTEM, INTAKE AIR
TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION
Yes Go to Step 1. 8
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
No
Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step.
Yes Go to applicable DTC inspection. 9
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"? No Troubleshooting completed.
F1-63
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ON-BOARD DIAGNOSTIC SYSTEM
DTCP1170 Oxygen sensor (O2S) is stuck
DETECTION CONDITION
When O2S signal stays above 0.45V for 20 seconds after engine has reached normal operating temperature.
POSSIBLE CAUSE
• O2S deterioration • Fuel injector malfunction • Pressure regulator malfunction • Fuel pump malfunction • Fuel delivery hose clogging or leakage • Fuel return hose and/or fuel filter clogging • Leakage in intake-air system or exhaust system PCV valve malfunction • Purge solenoid valve malfunction or purge solenoid hoses are hooked up incorrectly • Ignition coil malfunction Insufficient compression • MAF sensor malfunction • ECT sensor malfunction • TP sensor malfunction • Open or short circuit in wiring harness • Poor connection of connector • Vacuum hose damage or looseness Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Al-
ways keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious Injuries
or death and damage. Fuel can also Irritate skin and eyes. To prevent this, always com-plete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION ACTION Yes
Inspect and repair DTC P0100, P0110, P0115, or P0120. Go to Step 26.
1
Verify stored DTC. Have DTCs P0100, P0110 P0115, and/or P0120 been stored? No Go to next step.
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ON-BOARD DIAGNOSTIC SYSTEM
STEP INSPECTION ACTION Yes
Trouble is in process. Go to next step.
2
Clear DTC. Verify RPM, ECT and VS PIDS. Drive vehicle approx. 1 minute under same condition. Is DTC P1170 stored?
Note • If NGS tester is not used, measure
following PCM terminal voltage with voltmeter. ① SGT (terminal 2E) ② ECT sensor (terminal 2Q) ③ Vehicle speed (terminal 1 M)
No
Go to TROUBLESHOOTING, ENGINE SYMPTOM TROUBLESHOOTING, Intermittent Concerns.
Yes
Implement TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure and repair or replace then go to Step 26.
3
Implement PID/DATA.MONITOR AND RECORD (ECT, RPM, TP V) from DIAGNOSTIC DATA LINK using NGS tester. Is there any signal that is far out of specification when ignition switch is on, and engine is run at idle?
Note • If NGS tester is not used, measure
following PCM terminal voltage with voltmeter. ① ECT sensor (terminal 2Q) ② SGT (terminal 2E) ③ TP sensor (terminal 2K)
No
Go to next step.
Yes
Implement TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure and repair or replace, then go to Step 26.
4
Continue monitoring items on previous PIDs. Is there any input signal which causes drastic changes when it is set to be in trouble condition?
No Go to next step. Yes
Repair or replace faulty exhaust parts, then go to Step 26. EXHAUST SYSTEM, EXHAUST SYSTEM
REMOVAL/INSTALLATION.
5
Inspect exhaust system, upstream from O2S. Is there any gas leakage?
No Go to next step. Yes Go to next step. 6
Is O2S installed properly? No
Install heated oxygen sensor properly, then go to Step 26. CONTROL SYSTEM, OXYGEN SENSOR (O2S)
REMOVAL/INSTALLATION. Yes
Go to next step.
7
Implement FID/DATA MONITOR AND RECORD (O2S) from DIAGNOSTIC DATA LINK using NGS tester. Is voltage on O2S as follows while racing engine (in neutral)? • More than 0.45V when accelerator pedal is
suddenly pressed: rich condition • Less than 0.45V during fuel cut: lean
condition Note
• If NGS tester is not used, measure PCM 2N voltages with voltmeter.
No
Inspect and repair or replace faulty O2S, harnesses, connector or terminals, then go to Step 26. CONTROL SYSTEM, OXYGEN SENSOR (O2S)
INSPECTION.
Yes
Repair or replace faulty harness, connector or terminal, then go to Step 26.
8
Inspect for open, poor connection and other problems on the following harnesses, connectors, and terminals (for fuel injector at each cylinder): • From main relay to fuel injector • From fuel injector to PCM Is there any trouble? No Go to next step.
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ON-BOARD DIAGNOSTIC SYSTEM
STEP INSPECTION ACTION Yes
Replace faulty fuel injectors, then go to Step 26. FUEL SYSTEM, FUEL INJECTOR
REMOVAL/INSTALLATION.
9
Inspect injection amount of each injector. FUEL SYSTEM, FUEL INJECTOR
INSPECTION, Volume Test. Are there any injectors operating abnormally? (e.g. injection amount, injection condition) No Go to next step.
Yes Go to next step. 10
Inspect purge control system. TROUBLESHOOTING, ENGINE SYSTEM
INSPECTION, Purge Control Inspection. Is it okay?
No
By following system inspection, repair or replace faulty parts, then go to Step 26.
Yes
Go to next step.
11
Inspect PCV valve operation. EMISSION SYSTEM, POSITIVE CRANKCASE
VENTILATION (PCV) VALVE INSPECTION. Is it okay? No Replace PCV valve, then go to Step 26,
Yes
Inspect for leakage and injection amount. FUEL SYSTEM, FUEL INJECTOR INSPECTION.
Replace faulty fuel injector, then go to Step 26.
12
Inspect fuel line pressure under trouble condition. TROUBLESHOOTING, ENGINE SYSTEM
INSPECTION, Fuel Line Pressure Inspection. Is fuel line pressure okay? No Go to next step.
Yes Go to next step. 13
Inspect pressure regulator. FUEL SYSTEM, PRESSURE REGULATOR
INSPECTION. Is it okay?
No
Replace pressure regulator, then go to Step 26. FUEL SYSTEM, PRESSURE REGULATOR
REMOVAL/INSTALLATION, Yes
Repair or replace source of air suction, then go to Step 26.
14
Inspect air suction: • From air cleaner to throttle body • From throttle body to dynamic chamber • From dynamic chamber to intake manifold
Visually inspect for cracks and damage, and inspect fluctuation after spraying rust penetrating agent, then select air suction area.
• Can air suction confirmed?
No
Go to next step.
Yes
Repair or replace source of air suction, then go to Step 26.
15
Inspect for air suction in vacuum hose, which has negative pressure on intake manifold, in the same manner as previous step. Can air suction be confirmed? No Go to next step,
Yes Go to Step 22. 16
Inspect fuel line pressure under trouble condition. TROUBLESHOOTING, ENGINE SYSTEM
INSPECTION, Fuel Line Pressure Inspection. Is fuel line pressure okay?
No Go to next step.
Yes Go to next step. 17
Inspect fuel pump maximum pressure. FUEL SYSTEM, FUEL PUMP UNIT
INSPECTION, Fuel Pump Maximum Pressure Inspection.
Is it okay?
No
Replace fuel pump body, then go to Step 26. FUEL SYSTEM, FUEL PUMP UNIT REMOVAL/
INSTALLATION.
Yes Go to next step. 18
Inspect for clogging in fuel filter (high-pressure). Is there foreign material in fuel on fuel pump side of filter? No Go to Step 20.
Yes
Replace fuel filter (high-pressure), then go to Step 26. FUEL SYSTEM, FUEL FILTER (HIGH-
PRESSURE) REMOVAL/INSTALLATION.
19
Inspect inside of fuel tank for foreign material and stains. Is inside of fuel tank okay? No
Clean inside of fuel tank and fuel filter (low-pressure). Replace fuel filter, then go to Step 26.
Yes Go to next step. 20
Inspect for leakage and clogging in fuel line from distributor to fuel pump. Is it okay?
No Repair or replace source of fuel leakage or clogging, then go to Step 26.
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ON-BOARD DIAGNOSTIC SYSTEM
STEP INSPECTION ACTION Yes
Replace pressure regulator, then go to Step 26. FUEL SYSTEM, PRESSURE REGULATOR
REMOVAL/INSTALLATION.
21
Inspect for leakage in fuel line from fuel filter (high-pressure) to fuel tank (return side). Is it okay? No Repair or replace source of fuel leakage, then
go to Step 26 Yes Go to Step 24 22
Verify blinking condition on each cylinder by setting timing light on high-tension lead under trouble condition. Does it blink regularly and stably?
No Go to next step.
Yes Go to next step. 23
Inspect resistance of ignition coil. Section G, IGNITION COIL INSPECTION. Is it okay? No Replace ignition coil, then go to Step 26.
Yes
Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant passage. Repair or replace faulty parts, then go to Step 26.
24
Warning • Removing the radiator cap when the
radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury.
• When removing the radiator cap, wrap a thick cloth around and turn it slowly.
Remove radiator cap. Implement procedure to bleed air from engine coolant, then run engine at idle. Are there any small bubbles, which make engine coolant white at filling opening?
Note
• Large bubbles are normal since they are remaining air coming out from engine coolant passage.
No
Go to next step.
Yes Go to next step. 25
Inspect engine compression. Section B1, COMPRESSION INSPECTION. Is it okay? No Implement engine overhaul, then go to next step.
Yes Go to applicable DTC inspection. 26
Clear DTC. Verify DTC after running vehicle. Is there any DTC stored? No Troubleshooting completed.
DTC P1195 Barometric pressure (BARO) sensor (in PCM) DETECTION CONDITION
Input voltage from barometric pressure sensor is below 1.5 V or above 4.5 V when ignition switch is turned on.
POSSIBLE CAUSE • Barometric pressure sensor (in PCM) malfunction. STEP INSPECTION ACTION
_ _ _ Replace PCM CONTROL SYSTEM, PCM
REMOVAL/INSTALLATION
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ON-BOARD DIAGNOSTIC SYSTEM
DTC P1250 PRESSURE REGULATOR CONTROL (PRC) solenoid valve circuit malfunction
DETECTION CONDITION
Open or short circuit is observed in PRC solenoid valve when Ignition switch is turned on
POSSIBLE CAUSE
• PRC solenoid valve malfunction • Poor connection of connectors at PRC solenoid valve and/or PCM • Short to power supply circuit in wiring from PRC solenoid valve B to PCM terminal 2T • Short to GND in wiring from PRC solenoid valve terminal B to PCM terminal 2T • Short to GND in wiring from PRC solenoid valve terminal A to main relay terminal D • Open circuit in wiring from PCM terminal 2T and/or 2C to engine GND • Open circuit in wiring from PRC solenoid valve terminal B to PCM terminal 2T • Open circuit in wiring from PRC solenoid valve terminal A to man relay terminal D
STEP INSPECTION ACTION Yes
Inspect for open circuit in following wiring harnesses, then go to Step 9. • Main relay terminal D-IAC valve, PRC solenoid
valve, MAF sensor, CMP sensor, purge solenoid valve
• Between PCM terminal 2C and engine ground.
1
Verify stored DTC. Have DTCs P0100, P0335, P0443 and/or P0505 been stored?
No Go to next step. Yes Repair or replace connector, then go to Step 9. 2
Does PRC solenoid valve connector or PCM connector have poor connection? No Go to next step.
Yes Go to next step. 3
Disconnect PRC solenoid valve connector. Turn ignition switch on. Is there battery positive voltage at harness side connector terminal A?
No
Inspect for open or short circuit in wiring harness. (between main relay terminal D and PRC solenoid valve terminal A), then go to Step 9.
Yes
Go to next step.
4
Disconnect PCM connector. PRC solenoid valve is disconnected. Is there continuity between PRC solenoid valve harness side connector terminal B and PCM harness side connector terminal 2T?
No
Repair open circuit, then go to Step 9.
Yes Repair short to power supply circuit, then go to Step 9.
5
Is there continuity between PCM harness side connector terminals 2T and 1B? No Go to next step.
Yes Repair short to GND circuit, then go to Step 9. 6
Is there continuity from PCM harness side connector terminal 2T to body GND? No Go to next step.
Yes Go to next step. 7
Is PRC solenoid valve okay? FUEL SYSTEM, PRESSURE REGULATOR
CONTROL (PRC) SOLENOID VALVE INSPECTION
No Replace PRC solenoid valve, then go to Step 9.
Yes Go to Step 1. 8
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
No
Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step.
Yes Go to applicable DTC inspection. 9
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"? No Troubleshooting completed.
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ON-BOARD DIAGNOSTIC SYSTEM
DTCP1608 PCM internal circuit malfunction DETECTION CONDITION
PCM does not read DTC from output devices.
POSSIBLE CAUSE • PCM does not read DTC from output devices. • Short to power supply circuit in wiring from output devices (purge solenoid valve, PRC solenoid
valve, IAC solenoid valve and/or fuel injectors) to PCM
STEP INSPECTION ACTION Yes
Repair short to power supply circuit. Replace PCM. CONTROL SYSTEM, PCM
REMOVAL/INSTALLATION
1
Disconnect output devices and PCM connector. Is there continuity between the following connectors? • PCM harness side connector terminal 2X-1B • PCM harness side connector terminal 2E-1B • PCM harness side connector terminal 2W-1B • PCM harness side connector terminal 2U-1B • PCM harness side connector terminal 2V-1B
No Replace PCM CONTROL SYSTEM, PCM
REMOVAL/INSTALLATION
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TROUBLESHOOTING
TROUBLESHOOTING FOREWORD • Before proceeding with the following troubleshooting.
(1) Refer to section Gl to understand the basic troubleshooting procedure. (2) Perform the diagnostic trouble code inspection. (3) If the diagnostic trouble code is displayed, proceed with inspection steps for the code. (4) When the engine can be started, perform "ENGINE TUNE-UP".
TROUBLESHOOTING ITEM TABLE • Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart.
No. TROUBLESHOOTING ITEM DESCRIPTION 1 Melting of main or other fuses — 2 Will not crank Starter does not work.
3 Hard to start/long crank/erratic start/erratic crank
Starter cranks engine at normal speed but engine requires excessive cranking time before starting.
4 Engine stalls After start/at idle Engine stops unexpectedly at idle and/or after start. 5 Cranks normally but will not start Starter cranks engine at normal speed but engine will not run. 6 Slow return to idle Engine takes more time than normal to return to idle speed.
7 Engine runs rough/rolling idle Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively.
8 Fast idle/runs on Engine speed continues at fast idle after warm-up. Engine runs after ignition switch is turned off.
9 Low idle/stalls during deceleration Engine stops unexpectedly at beginning of deceleration or recovery from deceleration.
Engine stalls/quits Acceleration/cruise Engine stops unexpectedly at beginning of acceleration or during acceleration. Engine stops unexpectedly while cruising.
Engine runs rough Acceleration/cruise Engine speed fluctuates during acceleration or cruising. Misses Acceleration/cruise Engine misses during acceleration or cruising.
Buck/jerk Acceleration/cruise/ deceleration Vehicle bucks/jerks during acceleration, cruising, or deceleration.
Hesitation/stumble Acceleration Momentary pause at beginning of acceleration or during acceleration.
10
Surges Acceleration/cruise Momentary minor irregularity in engine output. 11 Lack/loss of power Acceleration/cruise Performance is poor under load (e.g. power down when climbing hills).
12 Knocking/pinging Acceleration/cruise Sound is produced when air/fuel mixture is ignited by something other than spark plug (e.g. hot spot in combustion chamber).
13 Poor fuel economy Fuel economy is unsatisfactory. 14 Emissions compliance Emission compliance test is failed. 15 High oil consumption/leakage Oil consumption is excessive.
16 Cooling system concerns Overheating Engine runs at higher than normal temperature/overheats.
17 Cooling system concerns Runs cold Engine takes excessive period for reaching normal operating temperature.
18 Exhaust smoke Blue, black, or white smoke from exhaust system 19 Fuel odor (in engine compartment) Gasoline fuel smell or visible leakage 20 Engine noise Engine noise from under hood 21 Vibration concerns (engine) Vibration from under hood or driveline
22 A/C does not work sufficiently A/C compressor magnetic clutch does not engage when A/C is turned on.
23 A/C is always on/A/C compressor runs continuously A/C compressor magnetic clutch does not disengage.
24 A/C is not cut off under WOT conditions A/C compressor magnetic clutch does not disengage under WOT. 25 Exhaust sulphur smell Rotten egg smell (sulphur) from exhaust. 26 Intermittent concerns Symptom occurs randomly and is difficult to diagnose. 27 Constant voltage Incorrect constant voltage.
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TROUBLESHOOTING
QUICK DIAGNOSTIC CHART Possible factor
Troubleshooting item St
arte
r mot
or m
alfu
nctio
n (M
echa
nica
l or e
lect
rical
)
Star
ter c
ircui
t inc
ludi
ng ig
nitio
n sw
itch
open
Impr
oper
eng
ine
oil l
evel
Low
or d
ead
batte
ry
Cha
rgin
g sy
stem
mal
func
tion
Impr
oper
eng
ine
com
pres
sion
Impr
oper
val
ve ti
min
g
Hyd
rolo
cked
eng
ine
Impr
oper
eng
ine
oil v
isco
sity
Impr
oper
dip
stic
k
Base
eng
ine
mal
func
tion
Flyw
heel
sei
zed
Impr
oper
tens
ion
or d
amag
ed d
rive
belts
Impr
oper
eng
ine
cool
ant l
evel
Wat
er a
nd a
nti-f
reez
e m
ixed
impr
oper
ly
Coo
ling
syst
em m
alfu
nctio
n (R
adia
tor,
hose
s, o
verfl
ow
syst
em, t
herm
osta
t, et
c.)
Engi
ne o
r tra
nsm
issi
on m
ount
s im
prop
erly
inst
alle
d
1 Melting of main or other fuses 2 Will not crank x x x x x x 3 Hard to start/long crank/erratic start/erratic crank 4 Engine stalls After start/at idle X x x 5 Cranks normally but will not start X x x 6 Slow return to idle 7 Engine runs rough/rolling idle x x 8 Fast idle/runs on 9 Low idle/stalls during deceleration
Engine stalls/quits Acceleration/cruise x x Engine runs rough Acceleration/cruise x x Misses Acceleration/cruise x x
Buck/jerk Acceleration/cruise/ deceleration
x x
Hesitation/stumble Acceleration x x
10
Surges Acceleration/cruise x x 11 Lack/loss of power Acceleration/cruise x x 12 Knocking/pinging Acceleration/cruise x x 13 Poor fuel economy x x x x 14 Emissions compliance x x x x 15 High oil consumption/leakage x x x 16 Cooling system concerns Overheating x x X x 17 Cooling system concerns Runs cold x 18 Exhaust smoke x x 19 Fuel odor (in engine compartment) 20 Engine noise x x x 21 Vibration concerns (engine) x x 22 A/C does not work sufficiently.
23 A/C is always on/A/C compressor runs continuously
24 A/C is not cut off under WOT conditions 25 Exhaust sulphur smell 26 Intermittent concerns x 27 Constant voltage
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TROUBLESHOOTING
Possible factor Troubleshooting item C
oolin
g fa
n se
ated
impr
oper
ly
Acce
lera
tor c
able
free
pla
y m
isad
just
men
t
Fuel
qua
lity
Engi
ne o
verh
eatin
g
Air c
lean
er e
lem
ent c
logg
ed o
r res
trict
ion
Air l
eaka
ge fr
om in
take
-air
syst
em (T
ubes
loos
enes
s,
crac
k, g
aske
ts b
roke
n)
IAC
val
ve im
prop
er o
pera
tion
Thro
ttle
body
mal
func
tion
Vacu
um le
akag
e (V
acuu
m h
ose
dam
aged
, mis
-rou
ting)
Igni
tion
coil
mal
func
tion
(e.g
. ope
n sh
ort o
r cra
cks)
Initi
al ig
nitio
n tim
ing
mis
adju
stm
ent (
CM
P &
cran
ksha
ft pu
lley
mis
adju
stm
ent
Spar
k pl
ug m
alfu
nctio
n
Hig
h-te
nsio
n le
ads
mal
func
tion
(Cra
cks
, ope
n, lo
w
resi
stan
ce)
CM
P se
nsor
dam
aged
(e.g
. ope
n or
sho
rt ci
rcui
ts)
1 Melting of main or other fuses 2 Will not crank 3 Hard to start/long crank/erratic star/erratic crank x x x x x x x 4 Engine stalls After start/at idle x x x x x x x x x x x 5 Cranks normally but will not start x x x x x x x x x x 6 Slow return to idle x 7 Engine runs rough/rolling idle x x x x x x x x x 8 Fast idle/runs on x 9 Low idle/stalls during deceleration x x
Engine stalls/quits Acceleration/cruise x x x x x x x x Engine runs rough Acceleration/cruise x x x x x x x x Misses Acceleration/cruise x x x x x x x x
Buck/jerk Acceleration/cruise/ deceleration
x x x x x x
x x
Hesitation/stumble Acceleration x x x x x x x x
10
Surges Acceleration/cruise x x x x x x x x 11 Lack/loss of power Acceleration/cruise x x x x x x x 12 Knocking/pinging Acceleration/cruise x 13 Poor fuel economy x x x x 14 Emissions compliance x x x x x 15 High oil consumption/leakage 16 Cooling system concerns Overheating 17 Cooling system concerns Runs cold 18 Exhaust smoke x x x 19 Fuel odor (in engine compartment) 20 Engine noise x x 21 Vibration concerns (engine) x 22 A/C does not work sufficiently.
23 A/C is always on/A/C compressor runs continuously
24 A/C is not cut off under WOT conditions 25 Exhaust sulphur smell x 26 Intermittent concerns x x x x x x 27 Constant voltage
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TROUBLESHOOTING
Fuel
pum
p bo
dy m
alfu
nctio
n (M
echa
nica
l or e
lect
rical
Pres
sure
regu
lato
r mal
func
tion
Fuel
hos
es re
stric
ted
or c
logg
ed
Inje
ctor
s m
alfu
nctio
n (L
eaka
ge o
r clo
ggin
g,
inop
erat
ive)
Fuel
leak
age
from
fuel
sys
tem
(Inc
ludi
ng in
sula
tor,
inje
ctor
O-r
ing)
Fuel
filte
rs re
stric
ted
or c
logg
ed
PRC
sol
enoi
d va
lve
impr
oper
ope
ratio
n
Impr
oper
air/
fuel
mix
ture
ratio
con
trol
Exha
ust s
yste
m re
stric
ted
or c
logg
ed
Cat
alyt
ic c
onve
rter m
alfu
nctio
n
Evap
orat
ive
emis
sion
con
trol s
yste
m m
alfu
nctio
n
PCV
valv
e m
alfu
nctio
n
V-re
fere
nce
supp
ly c
ircui
t mal
func
tion
Mai
n re
lay
mal
func
tion
(Mec
hani
cal o
r ele
ctric
al)
ECT
sens
or m
alfu
nctio
n
Possible factor Troubleshooting item
Melting of main or other fuses 1 Will not crank 2
x x x x x x x x x Hard to start/long crank/erratic start/erratic crank 3 x x x x x x x x x x After start/at idle Engine stalls 4 x x x x x x x x x x x Cranks normally but will not start 5 x Slow return to idle 6 x x x x x x x x x Engine runs rough/rolling idle 7 x Fast idle/runs on 8 x x Low idle/stalls during deceleration 9 x x x x x x x x x x x Acceleration/cruise Engine stalls/quits x x x x x x x x x x x Acceleration/cruise Engine runs rough x x x x x x x x x x x Acceleration/cruise Misses
x x x x
x x x
x x x x Acceleration/cruise/ deceleration
Buck/jerk
x x x x x x x x x x x Acceleration Hesitation/stumble x x x x x x x x x x x Acceleration/cruise Surges
10
x x x x x x x Acceleration/cruise Lack/loss of power 11x x Acceleration/cruise Knocking/pinging 12x x x x x x x Poor fuel economy 13x x x x x x x x x Emissions compliance 14 x High oil consumption/leakage 15 Overheating Cooling system concerns 16 Runs cold Cooling system concerns 17x x x x x x Exhaust smoke 18 x x x Fuel odor (in engine compartment) 19 Engine noise 20 Vibration concerns (engine) 21 A/C does not work sufficiently. 22
A/C is always on/A/C compressor runs continuously
23
A/C is not cut off under WOT conditions 24 x Exhaust sulphur smell 25x x x x x x x x Intermittent concerns 26 Constant voltage 27
F1-73 CONTINUED
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TROUBLESHOOTING
Possible factor Troubleshooting item Br
ake
switc
h an
d re
late
d ci
rcui
t mal
func
tion
Neu
tral o
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switc
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late
d ci
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func
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MAF
sen
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d ci
rcui
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func
tion
TP s
enso
r and
rela
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circ
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TP s
enso
r mis
adju
stm
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Incl
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Varia
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and
rela
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circ
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n (E
xcep
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PSP
switc
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late
d ci
rcui
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func
tion
Impr
oper
refri
gera
nt c
harg
ing
amou
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A/C
rela
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/C c
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circ
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Clu
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slip
page
VSS
and
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circ
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Impr
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ATF
leve
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Brak
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aggi
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Loos
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Whe
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and
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impr
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bal
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Driv
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Susp
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1 Melting of main or other fuses 2 Will not crank 3 Hard to start/long crank/erratic start/erratic crank x 4 Engine stalls after start/at idle x x 5 Cranks normally but will not start 6 Slow return to idle 7 Engine runs rough/rolling idle x x x 8 Fast idle/runs on 9 Low idle/stalls during deceleration x x x x x x
Engine stalls/quits acceleration/cruise x x x x x x x Engine runs rough acceleration/cruise x x x x x x x Misses acceleration/cruise x x x x x x x
Buck/jerk acceleration/cruise/ deceleration
x x x x x x x
Hesitation/stumble acceleration x x x x x x x
10
Surges acceleration/cruise x x x x x x x 11 Lack/loss of power acceleration/cruise x x x x x 12 Knocking/pinging acceleration/cruise x 13 Poor fuel economy x x 14 Emissions compliance 15 High oil consumption/leakage 16 Cooling system concerns overheating x x 17 Cooling system concerns runs cold 18 Exhaust smoke 19 Fuel odor (in engine compartment) 20 Engine noise x 21 Vibration concerns (engine) x x x 22 A/C does not work sufficiently. x x
23 A/C is always on/A/C compressor runs continuously
x
24 A/C is not cut off under WOT conditions x x 25 Exhaust sulphur smell 26 Intermittent concerns x x x x x x 27 Constant voltage x x
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SYMPTOM TROUBLESHOOTING: Symptom 1-Melting of main or other fuses FI-75 Symptom 2-Will not crank FI-76 Symptom 3-Hard to start/long crank/erratic crank FI-77-78 Symptom 4-Engine stalls-after start/at idle FI-79-81 Symptom 5-Cranks normally but will not start FI-82-84 Symptom 6-Slow return to idle FI-85 Symptom 7-Engine runs rough/rolling idle FI-86-88 Symptom 8-Fast idle/runs on FI-89 Symptom 9-Low idle/stalls during deceleration FI-90 Symptom 10-Engie stalls/quits-acceleration/cruise
- Engine runs rough – acceleration/cruise - Misses-acceleration/cruise - Buck/jerk – acceleration/cruise/deceleration - Hesitation/stumble – acceleration
I-91-93 Symptom 11-Lack/loss of power-acceleration/cruise FI-94-96 Symptom 12-Knocking/pinging-acceleration/cruise FI-97 Symptom 13-Poor fuel economy FI-98-99 Symptom 14-Emission compliance FI-100-101 Symptom 15-High oil consumption/leakage FI-101 Symptom 16-Cooling system concerns-overheating FI-102-103 Symptom 17-Cooling system concerns-runs cold FI-103 Symptom 18-Exhaust smoke FI-104-105 Symptom 19-Fuel odor (in engine compartment) FI-106 Symptom 20-Engine noise FI-107 Symptom 21-Vibration concerns (engine) FI-107 Symptom 22-A/C does not work sufficiently FI-108 Symptom 23-A/C is always on (a/c compressor runs continuously FI-109 Symptom 24-A/C does not cut off under wide open throttle (wot) conditions FI-110 Symptom 25-Exhaust sulphur smell FI-111 Symptom 26-Intermittent concerns FI-112 Symptom 27-Constant voltag e FI-113-114
- Surges – acceleration/cruise F
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CONTINUED
TROUBLESHOOTING
SYMPTOM TROUBLESHOOTING SYMPTOM 1 MELTING OF MAIN OR OTHER FUSES
Damaged Fuse Related Wiring Harness
MAIN (80 A)
MAIN fuse Generator Ignition switch Starter Ignition coil Condenser
HEAD (30 A) HEAD fuse • Generator
A/C (10A) A/C relay • Generator
WIPER (15 A)
WIPER fuse • A/C relay • A/C switch
STOP (15 A) STOP fuse • Brake switch
FUEL INJ (30 A)
Main relay • Fuel injector • PCM • PRC solenoid valve • Purge solenoid valve • IAC valve • MAF sensor • CMP sensor
ROOM (10 A) ROOM fuse • PCM
ENGINE (15 A)
ENGINE fuse • Main relay • Fuel pump relay Fuel pump relay • Fuel pump
METER (15 A)
METER fuse • PCM
F1-75
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TROUBLESHOOTING
SYMPTOM 2 WILL NOT CRANK DESCRIPTION • Starter does not work.
POSSIBLE CAUSE
• Open circuit between ignition switch and starter • Starter malfunction • Seized/hydrolocked engine or flywheel
STEP INSPECTION RESULTS ACTION Yes Go to next step. 1
Inspect for following: • Battery connection • Battery condition • Fuses Are all items okay?
No
Service as necessary. Repeat Step 1.
Yes Go to next step. 2
Is clicking sound heard from starter when ignition switch is turned to START? No Go to Step 4.
Yes
Inspect for seized/hydrolocked engine or flywheel. Section H, FLYWHEEL, FLYWHEEL
INSPECTION
3
Inspect starting system. Section G, STARTING SYSTEM,
STARTER INSPECTION Is starting system okay?
No
Repair or replace components as required.
Yes Go to next step. 4
Do any other electrical accessories work? No
Inspect charging system. Section G, CHARGING SYSTEM, GENERATOR
INSPECTIONYes
No DTC is displayed: Inspect following: • START circuit in ignition switch • Open circuit between ignition switch and starter
5
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? No
DTC is displayed: Go to appropriate DTC test. Communication error message is displayed: Inspect for following: • Open circuit between main relay and PCM
terminal 1B • Open main relay GND circuit • Main relay is stuck open. • Open or poor GND circuit at PCM • Poor connection of vehicle body GND
6 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING
SYMPTOM 3 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK
DESCRIPTION • Starter cranks engine at normal speed but engine requires excessive cranking time before starting. • Battery in normal condition.
POSSIBLE CAUSE
• Spark leakage from high-tension leads • Vacuum leakage Poor fuel quality • Starting system malfunction • Spark plug malfunction • Air leakage from intake-air system • Erratic signal from CMP sensor • Air cleaner restriction PCV valve malfunction • Inadequate fuel pressure • Purge solenoid valve malfunction • MAF sensor contamination • Restriction in exhaust system • Pressure regulator control (PRC) system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes
Go to next step.
1
Inspect for following: • Vacuum leakage • Fuel quality (e.g. proper octane, contami-
nation, winter/summer blend) • Loose bands on intake-air system • Cracks on intake-air system parts • Air cleaner restriction Are all items okay?
No
Service as necessary.
Yes
No DTC is displayed: Go to next step.
2
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No
DTC is displayed: Go to appropriate DTC test.
Yes Go to symptom troubleshooting No.16 for "Cooling system concerns - Overheating".
3
Is engine overheating?
No Go to next step. Yes Repair suspected high-tension leads. 4
Inspect for cracks on high-tension leads. Are there any cracks on high-tension leads? No Go to next step.
Yes
Spark plug is wet or covered with carbon: Inspect for fuel leakage from fuel injector. Spark plug is grayish white: Inspect for clogged fuel injector.
5
Inspect spark plug conditions. Is spark plug wet, covered with carbon or grayish white?
No Install spark plugs on original cylinders. Go to next step.
Yes Go to next step. 6
Visually inspect CMP sensor. Is CMP sensor okay? No Replace malfunctioning parts.
Yes Go to next step. 7
Remove PCV valve and inspect PCV valve. Does PCV valve rattle? No Replace PCV valve.
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TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes Go to next step. 8
Install fuel pressure gauge between fuel filter and fuel distributor. Connect a jumper wire between F/P terminal at DLC in engine compartment and GND. TROUBLESHOOTING, ENGINE SYSTEM
INSPECTION, Fuel Line Pressure Inspection
Turn ignition switch on. Is fuel line pressure correct? Fuel line pressure 270—310 kPa 2.7—3.2 kgf/cm2, 39—45 psi
No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. Inspect PRC solenoid valve and related vacuum hose and harnesses. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Yes Go to next step. 9
Is fuel line pressure held after ignition switch is turned off? Fuel line pressure More than 150 kPa 1.5 kgf/cm2,21 psi for 5 min.
No
Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.
Yes
Go to next step.
10
Disconnect vacuum hose from pressure regulator and plug hose. Start engine. Does fuel line pressure remain within ± 20 kPa 0.21 kgf/cm2, 3 psi while driving vehicle?
No
Inspect for clogged fuel filter.
Yes Go to next step. 11
Connect vacuum hose to pressure regulator. Install vacuum gauge to intake manifold. Start engine. Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or fuel pressure gauge reading decrease as vacuum gauge reading increases?
No
Connect vacuum hose to pressure regulator. Start engine. Verify fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator.
Yes
Inspect if purge solenoid valve sticks to open.
12
Disconnect a vacuum hose from purge solenoid valve and plug opening end of vacuum hose. Start engine. Is starting condition improved?
No
Go to next step.
Yes Replace MAP sensor. 13
Inspect for contaminated MAP sensor. Is there any contamination? No Go to next step.
Yes Inspect exhaust system. 14
Is there restriction in exhaust system? No Go to next step.
Yes Inspect for loose connectors or poor terminal contact. 15
Inspect starting system. Section G, STARTING SYSTEM,
STARTER INSPECTION Is starting system normal?
No Repair or replace components as required.
16 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
F1-78
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TROUBLESHOOTING SYMPTOM 4 ENGINE STALLS - AFTER START / AT IDLE DESCRIPTION • Engine stops unexpectedly at idle and/or after start.
• A/C system operation is improper. • Air leakage from intake-air system parts • Purge solenoid valve malfunction • Improper operation of IAC valve • No signal from CMP sensor due to sensor related wire or wrong installation • Vacuum leakage • Low engine compression • Spark leakage from high-tension leads • Poor fuel quality • PCV valve malfunction • Air cleaner restriction • Restriction in exhaust system • Electrical connector disconnection • Open or short circuit in fuel pump body and related harness • No battery power supply to PCM or poor GND • Inadequate fuel pressure • Fuel pump body mechanical malfunction • Fuel leakage from fuel injector • Fuel injector clogging • Pressure regulator control (PRC) system malfunction
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always • keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death • and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE • REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Go to next step.
Yes
Service as necessary. Repeat Step 11.
1
Verify following: • Vacuum connection • Air cleaner element • No air leakage from intake-air system • No restriction of intake-air system • Proper sealing of intake manifold and
components attached to intake manifold (e.g. IAC valve)
• Ignition wiring • Fuel quality (e.g. proper octane, contami-
nation, winter/summer blend) • Electrical connections • Smooth operation of throttle valve Are all items okay?
No
Go to next step. Yes
2
Turn ignition switch on. Disconnect TP sensor connector. Measure voltage at TP sensor connector VREF terminal with ignition switch on. Voltage 4.5—5.5 V Is voltage okay?
No
Go to symptom troubleshooting No.27 "Constant voltage".
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TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes
No DTC is displayed: Go to next step.
3
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or SYSTEM PASSED" displayed?
No
DTC Is displayed: Go to appropriate DTC test. Communication error message is displayed: Inspect for following: • Open circuit between main relay and PCM terminal 1B • Open main relay GND circuit • Main relay stuck open • Open PCM GND circuit (terminal 2A, 2B or 2C) • Poor connection of vehicle body GND
Yes Inspect IAC valve and wiring harness. 4
Attempt to start engine at part throttle. Does engine run smoothly at part throttle? No Go to next step.
Yes Go to next step. 5
Connect NGS tester to DLC. Access RPM PID. Is RPM PID indicating engine speed during cranking of engine?
No
Inspect for following: • Open or short circuit In CMP sensor • Open or short circuit between CMP sensor and PCM
terminal 2E • Open or short circuit in CMP sensor harnesses If CMP
sensor and harness okay, go to next step. Yes Go to next step. 6
Visually inspect CMP sensor. Is CMP sensor okay? No Replace malfunctioning parts.
Yes Repair suspected high-tension lead. 7
Inspect for cracks on high-tension leads Are there any cracks on high-tension leads? No Go to next step.
Yes
Go to next step. If symptom occurs with A/C on, go to Step 14.
8
Is strong blue spark visible at each discon-nected high-tension lead while cranking engine? No
Inspect for following: • Open or short circuit in ignition coil • Open circuit in high-tension leads • Open circuit between igniter connector GND terminal
and body GND • Open circuit between ignition switch and ignition coil • Open circuit between ignition coil and condenser • Open circuit between condenser and igniter • Open circuit between ignition coil and igniter • Open circuit between igniter and PCM terminal 2F
Yes
Spark plug is wet or covered with carbon: Inspect for fuel leakage from injector. Spark plug is grayish white: Inspect for clogged fuel injector.
9
Inspect spark plug condition. Is spark plug wet, covered with carbon, or grayish white? No Install spark plugs on original cylinders.
Go to next step.Yes Go to next step. 10
Remove and shake PCV valve. Does PCV valve rattle? No Replace PCV valve.
Yes Inspect exhaust system. 11
Is there any restriction in the exhaust system? No Go to next step.
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TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes Go to next step. 12
Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC and GND. Turn ignition switch on. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270—310kPa 2.7—3.2 kgf/cm2, 39—45 psi
No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. Inspect PRC solenoid valve, related vacuum hose and related harnesses. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Yes
Go to next step.
13
Visually inspect for fuel leakage at fuel injector, O-ring, and fuel line. Service as necessary. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure More than 150 kPa 1.5 kgf/cm2,21 psi for 5 min.
No
Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.
Yes
Go to next step.
14
Note • The following test is for stall concerns
with A/C on. If other symptoms exist, go to next step.
Connect pressure gauges to A/C low and high pressure side lines. Turn A/C on and measure low side and high side pressure. Section U, REFRIGERANT SYSTEM
SERVICE PROCEDURE, REFRIGER-ANT PRESSURE CHECK
Is pressure within specifications?
No
If A/C is always on, go to symptom troubleshooting No.23 "A/C is always on / A/C compressor runs continuously". For other symptoms, inspect following: • Refrigerant charging amount
Yes
Inspect if purge solenoid valve sticks to open. Inspect evaporative emission control system.
15
Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid side. Plug opening end of vacuum hose. Start engine. Is engine stall now eliminated?
No
Go to next step.
Yes Repair or replace. 16
Is air leakage felt or heard at intake-air system components while racing engine to higher speed? No Go to next step.
Yes Inspect valve timing. 17
Is engine compression correct? No Inspect for cause.
18 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
F1-81
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TROUBLESHOOTING
SYMPTOM 5 CRANKS NORMALLY BUT WILL NOT START
DESCRIPTION
• Starter cranks engine at normal speed but engine will not run. • Refer to "Engine stalls" if this symptom appears after engine stall. • Fuel in tank. • Battery in normal condition.
• No battery power supply to PCM • Air leakage from intake-air system • Open PCM GND or vehicle body GND • Improper operation of IAC valve • No signal from CMP sensor due to sensor related wire or incorrect installation • Low engine compression • Vacuum leakage • Spark leakage from high-tension leads • Poor fuel quality • PCV valve malfunction • Air cleaner restriction • Restriction in exhaust system • Disconnected electrical connector • Open or short circuit in fuel pump body and related harness • Inadequate fuel pressure • Fuel pump body mechanical malfunction • Fuel leakage from injector • Fuel injector is clogged. • Purge solenoid valve malfunction • Pressure regulator control (PRO) system malfunction
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service:
POSSIBLE CAUSE
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described In this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes
Go to next step.
1
Verify following: • Vacuum connection • External fuel shut off or accessory (kill
switch, alarm etc.) • Fuel quality (e.g. proper octane, contami-
nation, winter/summer blend) • No air leakage from intake-air system • Proper sealing of intake manifold and
components attached to intake manifold (e.g. IAC valve)
• Ignition wiring • Electrical connections • Fuses • Smooth operation of throttle valve Are all items okay?
No
Service as necessary. Repeat Step 11.
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TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes No DTC is displayed:
Go to next step. 2
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No
DTC is displayed: Go to appropriate DTC test. Communication error message is displayed: Inspect for following: • Open circuit between main relay and PCM terminal
1B • Open main relay GND circuit • Main relay stuck open • Open PCM GND circuit (PCM terminal 2A, 2B or 2C) • Poor connection of vehicle body GND
Yes
Go to next step.
3
Turn ignition switch on. Disconnect TP sensor connector. Measure voltage at TP sensor connector VREF terminal with ignition switch on. Voltage 4.5—5.5 V Is voltage okay?
No
Go to symptom troubleshooting No.27 "Constant voltage",
Yes Go to Step 18. 4
Does engine start with throttle closed? No Go to next step.
Yes Inspect IAC valve and wiring harness. 5
Will engine start and run smoothly at part throttle? No Go to next step.
Yes Go to next step. 6
Connect NGS tester to DLC. Access RPM PID. Is RPM PID indicating engine speed when cranking engine?
No
Inspect for following: • Open or short circuit in CMP sensor • Open or short circuit between CMP sensor and PCM
terminal 2E • Open or short circuit in CMP sensor harnesses If CMP sensor and harness are okay, go to next step.
Yes Go to next step. 7
Visually inspect CMP sensor. Is CMP sensor okay? No Replace malfunctioning parts.
Yes Repair suspected high-tension leads. 8
Inspect for cracks on high-tension leads. Is there any cracks on high-tension leads? No Go to next step.
Yes Go to next step. 9
Is strong blue spark visible at each disconnected high-tension lead while cranking engine?
No
Inspect for following: • Open or short circuit in ignition coil • Open circuit in high-tension leads • Open circuit between igniter connector GND terminal
and body GND • Open circuit between ignition switch and ignition coil • Open circuit between ignition coil and condenser • Open circuit between condenser and igniter • Open circuit between ignition coil and igniter • Open circuit between igniter and PCM terminal 2F
Yes
If spark plug is wet or covered with carbon, inspect for fuel leakage from injector. If spark plug is grayish white, inspect for clogged fuel injector.
10
Inspect spark plug conditions. Is spark plug wet, covered with carbon, or grayish white?
No
Install spark plugs on original cylinders. Go to next step.
Yes Go to next step. 11
Remove and shake PCV valve. Does PCV valve rattle? No Replace PCV valve.
Yes Inspect exhaust system. 12
Is there any restriction in exhaust system? No Go to next step.
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TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes Go to next step. 13
Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC in engine compartment and GND. Turn ignition switch on. Is fuel line pressure correct when ignition switch is cycled on/off five times? Fuel line pressure 270—3-10 kPa 2.7—3.2 kgf/cm2, 39—45 psi
No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. Inspect PRC solenoid, related vacuum hose, and har-nesses. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Yes
Go to next step.
14
Visually inspect for fuel leakage at fuel injector O-ring and fuel line. Service as necessary. Is fuel line pressure held after ignition switch is turned off? Fuel line pressure More than 150 kPa 1.5 kgf/cm2, 21 psi for 5 min.
No
Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.
Yes
Inspect if purge solenoid valve sticks to open mechanically. Inspect evaporative emission control system.
15
Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Start engine. Is starting condition improved?
No Go to next step.
Yes Repair or replace. 16
Is air leakage felt or heard at intake-air system components while racing engine to higher speed? No Go to next step.
Yes Inspect valve timing. 17
Is engine compression correct? No Inspect for causes.
18 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
F1-84
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TROUBLESHOOTING
SYMPTOM 6 SLOW RETURN TO IDLE DESCRIPTION • Engine takes more time than normal to return to idle speed.
POSSIBLE CAUSE
• ECT sensor malfunction • Thermostat is stuck open. • Throttle body malfunction • Air leakage from intake-air system
STEP INSPECTION RESULTS ACTION Yes
No DTC is displayed: Go to next step.
1
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No
DTC is displayed: Go to appropriate DTC test.
Yes Engine coolant temperature and thermostat are okay. Go to next step.
2
Remove thermostat and inspect operation. Section E, THERMOSTAT,
THERMOSTAT INSPECTION Is thermostat okay?
No
Access ECT V PID on NGS tester. Inspect for both ECT V PID and temperature gauge on instrument cluster readings. If temperature gauge on instrument cluster indicates normal range but ECT V PID is not same as temperature gauge reading, inspect ECT sensor. If temperature gauge on instrument cluster indicates cold range but ECT V PID is normal, inspect temperature gauge and heat gauge unit.
Yes Inspect for air leakage from intake-air system components while racing engine to higher speed.
3
Is throttle body free of contamination?
No Clean or replace throttle body. 4 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING
SYMPTOM 7 ENGINE RUNS ROUGH/ROLLING IDLE
DESCRIPTION • Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively. • Idle speed is too slow and engine shakes excessively. • Air leakage from intake-air system parts • A/C system operation is improper. • Spark leakage from high-tension leads • Purge solenoid valve malfunction (if equipped) • Improper operation of IAC valve • Low engine compression • Erratic signal from CMP sensor • Poor fuel quality • PCV valve malfunction • Air cleaner restriction • Restriction in exhaust system • Disconnected electrical connectors • Inadequate fuel pressure • Fuel pump body mechanical malfunction • Fuel leakage from fuel injector • Fuel injector clogging • Engine overheating • Vacuum leakage • Pressure regulator control (PRC) system malfunction
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes
Go to next step.
1
Verify following: • External fuel shut off or accessory • Fuel quality (e.g. proper octane, contami-
nation, winter/summer blend) • No air leakage from intake-air system • Proper sealing of intake manifold and
components attached to intake manifold (e.g. IAC valve)
• Ignition wiring • Electrical connections • Fuses • Smooth operation of throttle valve. Are all items okay?
No
Service as necessary. Repeat Step 1.
Yes
No DTC is displayed: Go to next step.
2
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" display? No
DTC is displayed: Go to appropriate DTC test.
Yes
Go to symptom troubleshooting No.16 "Cooling system concerns - Overheating".
3
Is engine overheating? No Go to next step.
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TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes
Go to next step.
4
Note • Following test is for engine running rough
idle with A/C on concerns. If other symp-toms exist, go to next step.
Connect pressure gauge to A/C low and high pressure side lines. Start engine and run it at idle. Turn A/C switch on. Measure low side and high side pressures. Section U, REFRIGERANT SYSTEM
SERVICE PROCEDURE, REFRIGER-ANT PRESSURE CHECK
Are reading pressures within specification?
No
If A/C is always on, go to symptom troubleshooting No.23 "A/C is always on / A/C compressor runs continuously". For other symptoms, inspect following: • Refrigerant charging amount
Yes
Inspect power steering pressure switch operation and wiring harness between power steering pressure switch connector and PCM connector terminal 1P.
5
Note • Following test is for engine running rough
with P/S on. If other symptoms exist, go to next step.
Start engine and run it at idle. Access PSP SW PID. Inspect if PSP SW PID is on while turning steering wheel right to left. Is PSP SW PID okay?
No
Go to next step.
Yes Go to next step. 6
Visually inspect CMP sensor. Is CMP sensor okay? No Replace malfunctioning parts.
Yes Repair suspected high-tension leads. 7
Inspect for cracks on high-tension leads. Are there any cracks on high-tension leads? No Go to next step.
Yes
Spark plug is wet or covered with carbon: Inspect for fuel leakage from injector. Spark plug is grayish white: Inspect for clogged fuel injector.
8
Inspect spark plug conditions. Is spark plug wet, covered with carbon, or grayish white?
No Install spark plugs on original cylinders. Go to next step.
Yes Go to next step. 9
Start engine and disconnect IAC valve con-nector. Does rpm drop or engine stall? No Inspect IAC valve and wiring harness.
Yes Go to next step. 10
Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250 kPa 2.1—2.6 kgf/cm2, 30—36 psi
No
Zero or low Inspect fuel pump circuit Inspect for open fuel pump relief valve Inspect for fuel leakage inside pressure regulator Inspect for clogged main fuel line Inspect PRC solenoid valve, related vacuum hose and harnesses High • Inspect pressure regulator for high pressure cause • Inspect for clogged fuel return line
Yes
Go to next step.
11
Visually inspect for fuel leakage at fuel injector, O-ring, and fuel line. Service as necessary. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure More than 150 kPa 1.5 kgf/cm2,21 psi for 5 min.
No
Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.
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TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes
Go to next step.
12
Connect NGS tester to DLC, Start the engine and run it at idle. Access FHO2S PID. Is FHO2S PID okay? • More than 0.45 V when accelerator pedal
is suddenly depressed: rich condition • Less than 0.45 V during fuel cut: lean
condition
No
Inspect and repair or replace faulty O2S, harness, connector or terminal, then go to next step.
Yes
Inspect if purge solenoid valve sticks open mechanically. Inspect evaporative emission control system.
13
Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Start engine. Does engine condition improve?
No
Go to next step.
Yes Go to next step. 14
Remove and shake PCV valve. Does PCV valve rattle? No Replace PCV valve.
Yes Inspect exhaust system. 15
Is there restriction in exhaust system? No Go to next step.
Yes Inspect valve timing. 16
Is engine compression correct? No Inspect for causes.
17 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING
SYMPTOM 8 FAST IDLE/RUNS ON DESCRIPTION
• Engine speed continues at fast idle after warm-up. • Engine runs after ignition switch is turned off.
POSSIBLE CAUSE
• ECT malfunction • Air leakage from intake-air system • Throttle body malfunction
STEP INSPECTION RESULTS ACTION Yes Go to next step. 1
Connect NGS tester to DLC. Access ECT PID. Start and warm up engine to normal operating temperature. Is ECT PID reading between 112°C 234°F and 82°C 180°F?
No
ECT PID is higher than 112°C 234°F: Go to symptom troubleshooting No.16 "Cooling system concerns - Overheating". ECT PID is less than 82°C 180°F: Go to symptom troubleshooting No.17 "Cooling system concerns - Runs cold".
Yes
No DTC is displayed: Go to next step.
2
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No
DTC is displayed: Go to appropriate DTC test.
Yes Repair or replace parts as necessary. 3
Is there air leakage felt or heard at intake-air system components while racing engine to higher speed? No Verify accelerator cable free play.
4 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING
SYMPTOM 9 LOW IDLE/STALLS DURING DECELERATION DESCRIPTION • Engine stops unexpectedly at beginning of deceleration or recovery from deceleration.
POSSIBLE CAUSE
• Vacuum leakage • IAC valve malfunction • Air leakage from intake-air system • MAF sensor or related circuit malfunction • TP sensor or related circuit malfunction • Brake switch or related circuit malfunction • Neutral/clutch switch or related circuit malfunction
STEP INSPECTION RESULTS ACTION Yes Go to symptom troubleshooting No.7 for "Engine runs
rough/Rolling idle".1
Does engine idle roughly?
No Go to next step. Yes
Go to next step.
2
Verify following: • Proper routing and no damage of vacuum
lines • IAC valve is connected properly. • No air leakage from intake-air system Are
all items okay?
No
Service as necessary. Repeat Step 2.
Yes
No DTC is displayed: Go to next step.
3
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No
DTC is displayed: Go to appropriate DTC test.
Yes Go to next step. 4
Does idle speed drop or stall when discon-necting IAC valve?
No
Inspect following: • Circuit from IAC valve to PCM connector terminal 2W for
open and short • IAC valve for sticking If okay, go to next step.
Yes
Inspect evaporative emission control system.
5
Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Drive vehicle. Does engine condition improve?
No
Go to next step.
Yes
Go to symptom troubleshooting No.26 for "Intermittent concerns".
6
Connect NGS tester to DLC. Access TP V, MAP V, VS, BRK SW and NL SW PIDs. Monitor each PID while driving vehicle. • TP V PID • MAF V PID • VS PID BRK • SW PID • NL SW PID Are PIDs okay? CONTROL SYSTEM, PCM INSPECTION
No
TP V PID: Inspect TP sensor. MAF V PID: Inspect MAF sensor. VS PID: Inspect VSS. BRK SW PID: Inspect brake switch. NL SW PID: Inspect neutral switch and clutch switch.
7 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING
SYMPTOM 10
ENGINE STALLS/QUITS - ACCELERATION/CRUISE ENGINE RUNS ROUGH - ACCELERATION/CRUISE MISSES - ACCELERATION/CRUISE BUCK/JERK - ACCELERATION/CRUISE/DECELERATION HESITATION/STUMBLE - ACCELERATION SURGES - ACCELERATION/CRUISE
DESCRIPTION
• Engine stops unexpectedly at beginning of acceleration or during acceleration. • Engine stops unexpectedly while cruising. • Engine speed fluctuates during acceleration or cruising. • Engine misses during acceleration or cruising. • Vehicle bucks/jerks during acceleration, cruising or deceleration. • Momentary pause at beginning of acceleration or during acceleration. • Momentary minor irregularity in engine output. • A/C system operation is improper. • Air leakage from intake-air system parts • Purge solenoid valve malfunction • Improper operation of IAC valve • Erratic signal from CMP sensor • Low engine compression • Vacuum leakage • Poor fuel quality • Spark leakage from high-tension leads • Air cleaner restriction • PCV valve malfunction • Improper valve timing due to jumping out of timing belt • Restriction in exhaust system • Intermittent open or short in fuel pump circuit • Inadequate fuel pressure • Fuel pump mechanical malfunction • Fuel leakage from fuel injector • Fuel injector clogging • Intermittent open or short of MAF sensor, TP sensor and VSS • Clutch slippage Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
POSSIBLE CAUSE
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes
Go to next step.
1
Verify following: • Vacuum connection • Air cleaner element • No air leakage from intake-air system • No restriction of intake-air system • Proper sealing of intake manifold and
components attached to intake manifold (e.g. IAC valve)
• Ignition wiring • Fuel quality (e.g. proper octane, contami-
nation, winter/summer blend) • Electrical connections • Smooth operation of throttle valve Are all items okay?
No
Service as necessary. Repeat Step 1.
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TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes
No DTC is displayed: Go to next step.
2
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No
DTC is displayed: Go to appropriate DTC test.
Yes Go to symptom troubleshooting No.16 "Cooling system concerns - Overheating".
3
Is engine overheating?
No Go to next step. Yes Go to next step. 4
Connect NGS tester to DLC. Access RPM PID, B+ PID, TP V PID, MAF V PID, and VS PID. • RPM PID • B+PID • TP V PID • MAF V PID • VS PID Drive vehicle while monitoring PIDs. Are PIDs within specification? CONTROL SYSTEM, PCM INSPECTION
No
RPM PID: Inspect CMP sensor and related harness for vibration, intermittent open/short circuit. B+ PID: Inspect for open circuit intermittently. MAF V PID: Inspect for open circuit of MAF sensor and related wire harness intermittently. TP V PID: Inspect if output signal from TP sensor changes smoothly. VS PID: Inspect for open circuit of VSS and related wire harness intermittently.
Yes Go to next step. 5
Visually inspect CMP sensor. Is CMP sensor okay? No Replace malfunctioning parts.
Yes
Spark plug is wet or covered with carbon: Inspect for fuel leakage from fuel injector. Spark plug is grayish white: Inspect for clogged fuel injector.
6
Inspect spark plug condition. Is spark plug wet, covered with carbon, or grayish white?
No
Install spark plugs on original cylinders. Go to next step.
Yes Go to next step. 7
Remove and shake PCV valve. Does PCV valve rattle? No Replace PCV valve.
Yes Go to next step. 8
Verify that throttle lever is resting on throttle valve stop screw and/or throttle valve orifice plug. Is lever in correct position?
No Adjust as necessary.
Yes Inspect exhaust system. 9
Are there restrictions in the exhaust system? No Go to next step.
Yes Go to next step. 10
Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC in engine compartment and GND. Turn ignition switch on. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270—310kPa 2.7—3.2 kgf/cm2, 39—45 psi
No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Yes
Go to next step.
11
Visually inspect for fuel leakage at fuel injector, O-ring, and fuel line. Service as necessary. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure More than 150 kPa 1.5 kgf/cm2, 21 psi for 5 min.
No
Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.
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TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes Go to next step. 12
Install vacuum gauge to intake manifold. Start engine. Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or does fuel pressure gauge reading decrease as vacuum reading increases?
No
Connect vacuum hose to pressure regulator. Start engine. Verify that fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator.
Yes
Go to next step.
13
Note • The following test is for engine stalling with
A/C on. If other symptoms exist, go to next step.
Connect a pressure gauge to A/C low and high pressure side lines. Turn A/C on and measure low side and high side pressure. Is pressure within specifications? Section U, REFRIGERANT SYSTEM
SERVICE PROCEDURES, REFRIGER-ANT PRESSURE CHECK
No
If A/C is always on, go to symptom troubleshooting No.23 "A/C is always on / A/C compressor runs continuously". For other symptoms, inspect following: • Refrigerant charging amount
Yes
Inspect if purge solenoid valve sticks open mechanically. Inspect evaporative emission control system.
14
Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Drive vehicle. Does engine condition improve?
No Go to next step.
Yes
Inspect following: • Valve timing • Clutch
15
Is engine compression correct?
No Inspect for cause. 16 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING
SYMPTOM 11 LACK/LOSS OF POWER - ACCELERATION/CRUISE DESCRIPTION • Performance is poor under load e.g. power down when climbing hills).
• Improper A/C system operation • Air leakage from intake-air system parts • Purge control solenoid malfunction • Brake dragging • Erratic signal from CMP sensor • Low engine compression • Vacuum leakage • Poor fuel quality • Spark leakage from high-tension leads • Air cleaner restriction • PCV valve malfunction • Improper valve timing due to jumping out of timing belt • Restriction in exhaust system • Intermittent open or short in fuel pump circuit • Inadequate fuel pressure • Fuel pump mechanical malfunction • Fuel leakage from fuel injector • Fuel injector clogging • Intermittent open or short of MAP sensor, TP sensor and VSS • Clutch slippage
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes
Go to next step.
1
Verify following: • Vacuum connection • Air cleaner element • No air leakage from intake-air system • No restriction of intake-air system • Proper sealing of intake manifold and
components attached to intake manifold (e.g. IAC valve)
• Fuel quality (e.g. proper octane, contami-nation, winter/summer blend)
Are all items okay?
No
Service as necessary. Repeat Step 1.
Yes No DTC Is displayed: Go to next step.
2
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTCs. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No DTC is displayed: Go to appropriate DTC test.
Yes Go to symptom troubleshooting No. 16 "Cooling system concerns - Overheating".
3 Is engine overheating?
No Go to next step.
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STEP INSPECTION RESULTS ACTION
Yes Go to next step. 4
Connect NGS tester to DLC. Access RPM PID, MAF V PID, TP V PID, and VS PID. • RPM PID • MAP V PID • TP V PID • VS PID Drive vehicle while monitoring PIDs. Are PIDs within specification? CONTROL SYSTEM, PCM INSPECTION
No
RPM PID: Inspect CMP sensor and related harness for vibration and/or intermittent open/short circuit. MAF V PID: Inspect for intermittent open circuit of MAF sensor and related wire harness. TP V PID: Inspect if TP sensor output increases smoothly. VS PID: Inspect for intermittent open circuit of VSS and related wire harness.
Yes Go to next step. 5
Visually inspect CMP sensor. Is CMP sensor okay? No Replace malfunctioning parts.
Yes
Spark plug is wet or covered with carbon: Inspect for fuel leakage from fuel injector. Spark plug is grayish white: Inspect for clogged fuel injector.
6
Inspect spark plug conditions. Is spark plug wet, covered with carbon or grayish white?
No Install spark plugs on original cylinders. Go to next step.
Yes Go to next step. 7
Remove and shake PCV valve. Does PCV valve rattle? No Replace PCV valve.
Yes Inspect exhaust system. 8
Is there restriction in exhaust system? No Go to next step.
Yes Go to next step. 9
Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC in engine compartment and GND. Turn ignition switch on. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270—310 kPa 2.7—3.2 kgf/cm2, 39—45 psi
No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Yes Go to next step. 10
Install vacuum gauge to intake manifold. Start engine. Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or does fuel pressure gauge reading decrease as vacuum reading increases?
No
Connect vacuum hose to pressure-regulator. Start engine. Verify that fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator.
Yes
Go to next step.
11
Note • Following test is for engine stalling with
A/C on concern. If other symptoms exist, go to next step.
Connect pressure gauge to A/C low and high side pressure lines. Turn A/C on and measure low side and high side pressure. Is the pressure within specifications? Section U, REFRIGERANT SYSTEM
SERVICE PROCEDURES, REFRIGER-ANT PRESSURE CHECK
No
If A/C is always on, go to symptom troubleshooting No.23 "A/C always on/ A/C compressor runs continuously". For other symptoms, inspect following: • Refrigerant charging amount
Yes Go to next step. 12
Inspect for A/C cut off operation. Does A/C cut-off work properly? No Inspect A/C cut-off system components.
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TROUBLESHOOTING
TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes
Inspect if purge solenoid valve sticks open mechanically. Inspect evaporative emission control system.
13
Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Drive vehicle. Does engine condition improve?
No
Go to next step.
Yes
Inspect following: • Valve timing • Clutch • Brake system for dragging
14
Is engine compression correct?
No Inspect for cause. 15 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING
SYMPTOM 12 KNOCKING/PINGING - ACCELERATION/CRUISE
DESCRIPTION • Sound is produced when air/fuel mixture is ignited by something other than spark plug (e.g. hot spot in combustion chamber).
POSSIBLE CAUSE
• Engine overheating due to cooling system malfunction • Inadequate engine compression • Inadequate fuel pressure Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes
Go to next step.
1
Connect NGS tester to DLC. Access ECT P1D. Verify ECT PID is less than 116°C 241 °F while driving. Is ECT PID less than specification?
No
Inspect cooling system for cause of overheating.
Yes
No DTC is displayed: Go to next step.
2
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No
DTC is displayed: Go to appropriate DTC test.
Yes Go to next step. 3
Is engine compression correct? No Inspect for cause.
Yes Go to next step. 4
Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250kPa 2.1—2.6 kgf/cm2, 30—36 psi
No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Yes Inspect ignition timing. 5
Install vacuum gauge to intake manifold. Start engine. Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or does fuel pressure gauge reading decrease as vacuum reading increases?
No
Connect vacuum hose to pressure regulator. Start engine. Verify that fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator.
6 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING
SYMPTOM 13 POOR FUEL ECONOMY DESCRIPTION • Fuel economy is unsatisfactory.
POSSIBLE CAUSE
• Contaminated air cleaner element • Engine cooling system malfunction • Improper automatic transmission fluid level • Weak spark • Poor fuel quality • Improper coolant level • Inadequate fuel pressure • Spark plug malfunction • PCV valve malfunction • Brake dragging • Improper valve timing due to jumping out of timing belt • Contaminated MAF sensor • Improper engine compression • Exhaust system clogging Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Go to next step. 1 Inspect following:
• Air cleaner element for contamination • Automatic transmission fluid level • Fuel quality • Coolant level Are all items okay?
No Service as necessary. Repeat Step 1.
Yes No DTC is displayed: Go to next step.
2 Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTCs. Is "NO CODES RECEIVED" or "SYSTEM PASSED" display?
No
DTC is displayed: Go to appropriate DTC test.
Yes Go to next step. 3 Connect NGS tester to DLC. Access ECT PID. Drive vehicle while monitoring PID. CONTROL SYSTEM, PCM INSPECTION Is PID within specification?
No Inspect for coolant leakage, cooling fan operation, or thermostat operation.
Yes Inspect for following: • Spark plug malfunction Repair or replace malfunctioning parts. If okay, go to next step.
4
Is strong blue spark visible at each discon-nected high-tension lead while cranking en-gine?
No Inspect the following: • High-tension leads • Ignition coil and connector
Yes Go to next step. 5
Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250kPa 2.1—2.6 kgf/cm2, 30—36 psi
No Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
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TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes Go to next step. 6
Remove and shake PCV valve. Does PCV valve rattle? No Replace PCV valve.
Yes Inspect exhaust system. 7
Is there restriction in exhaust system? No Go to next step.
Yes Go to next step. 8
Is brake system functioning properly? No Inspect for cause.
Yes Replace MAP sensor. 9
Inspect for contaminated MAF sensor. Is there any contamination? No Go to next step.
Yes Inspect valve timing. 10
Is engine compression correct? No Inspect for cause.
11 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING
SYMPTOM 14 EMISSION COMPLIANCE DESCRIPTION • Emission compliance test is failed.
POSSIBLE CAUSE
• Vacuum line leakage or blockage • Cooling system malfunction • Spark plug malfunction • Leakage from intake manifold • Inadequate fuel pressure • PCV valve malfunction or incorrect valve installation • Exhaust system clogging • Fuel tank ventilation system malfunction • Charcoal canister damage • Excessive carbon built up in combustion chamber • Improper engine compression Improper valve timing Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes
Go to next step.
1
Inspect following: • Vacuum lines for leakage or blockage • Electrical connections • Proper maintenance schedule followed • Intake-air system and air cleaner element
concerns: obstructions, leakage or dirt Are all items okay?
No
Service as necessary. Repeat Step 1.
Yes
No DTC is displayed: Go to next step.
2
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No
DTC is displayed: Go to appropriate DTC test.
Yes Go to appropriate symptom troubleshooting. 3
Is any other drivability concern present? No Go to next step.
Yes Go to next step. 4
Connect NGS tester to DLC. Access ECT PID. Warm up engine and run it at idle. Is ECT PID correct?
No
Inspect for coolant leakage, cooling fan operation or thermostat operation.
Yes
Inspect for following: • Spark plug malfunction Repair or replace malfunctioning parts. If okay, go to next step.
5
Is strong blue spark visible at each discon-nected high-tension lead while cranking en-gine?
No
Inspect following: • High-tension leads • Ignition coil and connector
Yes Go to next step. 6
Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250 kPa 2.1—2.6 kgf/cm2, 30—36 psi
No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
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TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes
Go to next step.
7
Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210—250kPa 2.1—2.6 kgf/cm2, 30—36 psi
No
Inspect pressure regulator for high pressure cause.
Yes Go to next step. 8
Remove and shake PCV valve. Does PCV valve rattle? No Replace PCV valve.
Yes Inspect exhaust system. 9
Is there restriction in the exhaust system? No Go to next step.
Yes Replace charcoal canister. 10
Inspect for fuel saturation inside charcoal canister. Is excessive amount of liquid fuel present in canister?
No Inspect fuel tank vent system.
11 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
SYMPTOM 15 HIGH OIL CONSUMPTION/LEAKAGE DESCRIPTION • Oil consumption is excessive.
POSSIBLE CAUSE
• PCV valve malfunction • Improper dipstick • Improper engine oil viscosity • Engine internal parts malfunction
STEP INSPECTION RESULTS ACTION Yes Go to next step. 1
Remove and shake PCV valve. Does PCV valve rattle? No Replace PCV valve.
Yes
Inspect internal engine parts such as valves, valve guides, valve stem seals, cylinder head drain passage, piston rings.
2
Inspect for following: • External leakage • Proper dipstick • Proper engine oil viscosity Are all items okay?
No
Service as necessary. Repeat Step 2.
3 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING
SYMPTOM 16 COOLING SYSTEM CONCERNS - OVERHEATING DESCRIPTION • Engine runs at higher than normal temperature/overheats.
POSSIBLE CAUSE
• Improper coolant level • Blown fuses Coolant leakage/Improper coolant level • Excessive A/C system pressure • Improper water/anti-freeze mixture • Fans reverse rotation • Poor radiator condition • Thermostat malfunction • Radiator hose damage • Improper or damaged radiator cap • Main cooling fan is inoperative. • Coolant overflow system malfunction • Improper tension of drive belt • Drive belt damage
STEP INSPECTION RESULTS ACTION Yes
Go to next step.
1
Inspect following: • Engine coolant level • Coolant leakage • Water and anti-freeze mixture • Radiator condition • Collapsed or restricted radiator hoses • Radiator pressure cap • Overflow system • Fan rotational direction • Fuses Are all items okay?
No
Service as necessary. Repeat Step 1.
Yes
No DTC is displayed: Go to next step.
2
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No
DTC is displayed: Go to appropriate DTC test.
Yes Go to Step 5. 3
Start engine and run it at idle speed. Turn A/C switch on. Does A/C compressor engage?
No
Inspect for following and repair or replace as necessary: • Refrigerant charging amount • Open circuit between A/C relay and PCM terminal 1J • Seized A/C magnetic clutch • A/C magnetic clutch malfunction If all Items are okay, go to next step.
Yes Go to next step. 4
Connect NGS tester to DLC. Access A/C SW PID on NGS tester. Start engine and run it at idle speed. Turn A/C switch on. Does A/C SW PID read ON?
No
Inspect for following: • Refrigerant pressure switch operation • A/C switch stuck open • Open or short circuit between refrigerant pressure
switch and PCM terminal 1Q • Open circuit of blower motor fan switch and resistor
(if blower motor does not operate) • Evaporator temperature sensor and A/C amplifier
Yes Go to next step. 5
Is drive belt okay? No Replace drive belt.
Yes Inspect and service heater for leakage. 6
Is there any leakage around heater unit in passenger compartment? No Go to next step.
Yes Replace malfunctioning parts. 7
Is there any leakage at coolant hoses and/or radiator? No Go to next step.
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TROUBLESHOOTING STEP INSPECTION RESULTS ACTION
Yes Engine coolant temperature and thermostat are okay, inspect engine block for leakage or blockage.
8
Cool down engine. Remove thermostat and inspect operation. Section E, THERMOSTAT,
THERMOSTAT INSPECTION Is thermostat okay?
No
Access ECT V PID on NGS tester. Inspect for both ECT V and temperature gauge readings. If temperature gauge on instrument cluster indicates normal range but ECT V is not same as temperature gauge reading, inspect ECT sensor. If temperature gauge on instrument cluster indicates overheating but ECT V is normal, inspect temperature gauge and heat gauge unit.
9 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
SYMPTOM 17 COOLING SYSTEM CONCERNS - RUNS COLD DESCRIPTION • Engine takes excessive period for reaching normal operating temperature.
POSSIBLE CAUSE
• Thermostat malfunction • Cooling fan system malfunction
STEP INSPECTION RESULTS ACTION Yes Inspect A/C and heater system. 1
Is customer complaint "Lack of passenger compartment heat" only? No Go to next step.
Yes Go to symptom troubleshooting No.8 "Fast idle/runs on". 2
Does engine speed continue at fast idle? No Go to next step.
Yes
Access ECT V PID on NGS tester. Inspect for both ECT V PID and temperature gauge on instrument cluster readings. If temperature gauge on instrument cluster indicates normal range but ECT V PID is not same as temperature gauge reading, inspect ECT sensor. If temperature gauge on instrument cluster indicates cold range but ECT voltage is normal, inspect temperature gauge and heat gauge unit.
3
Remove thermostat and inspect operation. Section E, THERMOSTAT,
THERMOSTAT INSPECTION Is thermostat okay?
No Replace thermostat. 4 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING
SYMPTOM 18 EXHAUST SMOKE DESCRIPTION • Blue, black, or white smoke from exhaust system.
Blue smoke (Burning oil): • PCV valve malfunction • Engine internal oil leakage White smoke (Water in combustion): • Cooling system (coolant loss) malfunction • Engine internal coolant leakage Black smoke (Rich fuel mixture): • Air cleaner restriction • Intake-air system is collapsed or restricted. • Fuel return line is restricted. • Excessive fuel pressure • Improper engine compression • Injector fuel leakage • Ignition system malfunction
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Blue Burning oil is indicated. Go to next step.
White Water in combustion is indicated. Go to Step 3. 1 What color is smoke coming from exhaust
system?
Black Rich fuel mixture is indicated. Go to Step 4. Yes
Inspect for following: • Damaged valve guide, stems or valve seals • Blocked oil drain passage in cylinder head • Piston rings are not seated, seized or worn • Damaged cylinder bore If other drivability symptoms are present, return to diagnostic index to service any additional symptoms.
2
Remove and shake PCV valve. Does PCV valve rattle?
No Replace PCV valve. Yes
Inspect for following: • Cylinder head gasket leakage • Intake manifold gasket leakage • Cracked or porous engine block If other drivability symptoms are present, return to diagnostic index to service any additional symptoms.
3
Does cooling system hold pressure?
No Inspect for cause. Yes Go to next step. 4
Inspect for following: • Air cleaner restriction • Collapsed or restricted intake-air system • Restricted fuel return line Are all items okay?
No Service as necessary, Repeat Step 4.
Yes No DTC Is displayed: Go to next step.
5 Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No DTC is displayed: Go to appropriate DTC test.
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TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes Go to next step. 6
Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250 kPa 2.1—2.6 kgf/cm2,30—36 psi
No
Zero or low: Inspect fuel pump circuit Inspect for open fuel pump relief valve Inspect for fuel leakage inside pressure regulator Inspect for clogged main fuel line High: Inspect pressure regulator for high pressure cause Inspect for clogged fuel return line
Yes
Go to next step.
7
Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210—250kPa 2.1—2.6 kgf/cm2,30—36 psi
No
Inspect pressure regulator for high pressure cause.
Yes Inspect spark plugs. 8
Is strong blue spark visible at each discon-nected high-tension lead while cranking en-gine?
No
Inspect following: • High-tension leads • Ignition coil and connector
9 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING
SYMPTOM 19 FUEL ODOR (IN ENGINE COMPARTMENT) DESCRIPTION • Gasoline fuel smell or visible leakage,
POSSIBLE CAUSE
• Excessive fuel pressure • Fuel tank vent system blockage • Charcoal canister malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes
Go to next step,
1
Visually inspect for fuel leakage at fuel injector O-ring and fuel line. Service as necessary. Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Then stop engine. Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on and off? Fuel line pressure 210—250 kPa 2.1—2.6 kgf/cm2, 30—36 psi
No
Inspect pressure regulator for high pressure cause.
Yes
Replace vacuum hose.
2
Inspect for blockage/restriction or open be-tween engine vacuum port and charcoal canister. Inspect for blockage in fuel tank vent system. Is fault indicated?
No
Go to next step.
Yes Go to next step. 3
Inspect purge solenoid valve. EMISSION SYSTEM, PURGE SOLENOID
VALVE INSPECTION Is solenoid operating properly?
No Replace purge solenoid valve.
Yes
No DTC is displayed: Inspect charcoal canister for fuel saturation. If excessive amount of liquid fuel is present, replace charcoal canister.
4
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No
DTC is displayed: Go to appropriate DTC test.
5 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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POSSIBLE CAUSE
Squealing, clicking or chirping noise: • Improper engine oil level • Improper drive belt tension Rattling noise: • Loose parts Hissing sound noise: • Vacuum leakage • Loose spark plug • Air leakage from intake-air system Rumbling or grinding noise: • Improper drive belt tension Rapping or roar noise: • Exhaust system looseness Other noise: • Camshaft friction gear noise
STEP INSPECTION RESULTS ACTION Yes Inspect engine oil level or drive belts. 1
Is squealing, clicking or chirping sound present? No Go to next step.
Yes Inspect drive belt. 2
Is rumbling or grinding sound present? No Go to next step.
Yes Inspect location of rattle for loose parts. 3
Is rattling sound present? No Go to next step.
Yes
Inspect following: • Vacuum leakage • Spark plug looseness • Intake-air system leakage
4
Is hissing sound present?
No Go to next step. Yes Inspect exhaust system for loose parts. 5
Is rapping or roaring sound present? No Go to next step.
Yes Go to symptom troubleshooting No.12 "Knocking/ pinging".6
Is knocking sound present?
No If noise comes from inside engine, inspect for friction gear noise.
7 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
SYMPTOM 21 VIBRATION CONCERNS (ENGINE) DESCRIPTION • Vibration from under hood or driveline POSSIBLECAU
SE • Loose attaching bolts or worn parts • Component malfunctions such as worn parts
STEP INSPECTION RESULTS ACTION Yes
Inspect following systems: • Wheels • Driveline • Suspension
1
Inspect following components for loose at-taching bolts or worn parts: • Cooling fan • Drive belt and pulleys • Engine mounts
Are all items okay? No Readjust or retighten engine mount installation position. Service as necessary for other parts.
2 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING
SYMPTOM 20 ENGINE NOISE DESCRIPTION • Engine noise from under hood
TROUBLESHOOTING
SYMPTOM 22 A/C DOES NOT WORK SUFFICIENTLY. DESCRIPTION • A/C compressor magnetic clutch does not engage when A/C switch is turned on.
POSSIBLE CAUSE
• Improper refrigerant charging amount • Open A/C magnetic clutch • Open circuit between A/C relay and A/C magnetic clutch • Poor GND of A/C magnetic clutch • Refrigerant pressure switch is struck open. • A/C relay is stuck open. • Seized A/C compressor • Open circuit between A/C switch and PCM through both refrigerant pressure switch and A/C amplifier
STEP INSPECTION RESULTS ACTION Yes
No DTC is displayed: Go to next step.
1
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No
DTC is displayed: Go to appropriate DTC test,
Yes
Inspect for GND condition of magnetic clutch on A/C compressor. If GND condition is okay, inspect for open circuit of magnetic clutch coil.
2
Disconnect A/C compressor connector. Start engine and turn A/C switch on. Is there correct voltage at terminal of A/C compressor magnetic clutch connector? Specification More than 10.5V No Go to next step.
Yes
Inspect for stuck open A/C relay. Replace as necessary.
3
Connect NGS tester to DLC. Access A/C SW PID on NGS tester. Start engine. Turn A/C switch on and set blower fan at any speed. Does A/C SW PI Dread ON?
No
Go to next step.
Yes
Inspect for following: • Refrigerant charging amount • Refrigerant pressure switch operation
4
Disconnect refrigerant pressure switch con-nector. Connect a jumper wire between terminals of refrigerant pressure switch connector. Start engine and turn A/C switch on. Does A/C work?
No
Inspect for following: • A/C switch is stuck open. • Open circuit between refrigerant pressure switch and
PCM terminal 1Q • Open circuit of blower motor fan switch and resistor (if
blower motor does not operate) • Evaporator temperature sensor and A/C amplifier • Open circuit between A/C amplifier and refrigerant
pressure switch
5 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING
SYMPTOM 23 A/C IS ALWAYS ON /A/C COMPRESSOR RUNS CONTINUOUSLY. DESCRIPTION • A/C compressor magnetic clutch does not disengage.
POSSIBLE CAUSE
• Stuck engagement • A/C relay is stuck closed. • Short to GND between A/C switch and PCM • Short to GND circuit between A/C relay and PCM • A/C relay to magnetic clutch circuit shorts to battery power
STEP INSPECTION RESULTS ACTION Yes
No DTC is displayed: Go to next step.
1
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No
DTC is displayed: Go to appropriate DTC test.
Yes
Inspect for following: • A/C relay is stuck closed. • Short to GND circuit between A/C relay and PCM
terminal 1J If both items okay, go to next step.
2
Start engine and run it at idle. Turn A/C switch on. Remove A/C relay. Does A/C magnetic clutch disengage?
No
Inspect if circuit between A/C relay and magnetic clutch shorts to battery power circuit. If circuit is okay, inspect magnetic clutch engagement or clearance.
Yes
Inspect for short to GND circuit between refrigerant pressure switch and PCM terminal 10.
3
Connect NGS tester to DLC. Access A/C SW PID on NGS tester. Start the engine and turn A/C switch on. Read A/C SW PID while disconnecting re-frigerant pressure switch connector. Note • A/C SW PID should read OFF when dis-
connecting connector. If A/C SW PID reading remains ON, short to GND circuit may be present.
Does A/C SW PID reading remain ON?
No
Go to next step.
Yes
Inspect for following: • Short to GND circuit between A/C switch and A/C
amplifier • Short to GND circuit between A/C amplifier and
refrigerant pressure switch
4
Reconnect refrigerant pressure switch connector. Read A/C SW PID while turning off A/C switch. Note • A/C SW PID should read OFF when turn-
ing A/C switch off. If A/C SW PID reading remains ON, short to GND circuit may be present.
Does A/C SW PID reading remain ON?
No
Inspect for stuck closed A/C switch.
5 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING
SYMPTOM 24 A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE (WOT) CONDITIONS DESCRIPTION • A/C compressor magnetic clutch does not disengage under WOT.
POSSIBLE CAUSE
• TP sensor malfunction • TP sensor misadjustment • TP sensor is loosely installed.
STEP INSPECTION RESULTS ACTION Yes Go to next step. 1
Does A/C compressor disengage when A/C switch is turned off?
No Go to symptom troubleshooting No.23 "A/C is always on / A/C compressor runs continuously".
Yes
No DTC is displayed: Inspect TP sensor for proper adjustment.
2
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No
DTC is displayed: Go to appropriate DTC test.
3 Verify test results. If okay, return to diagnostic index to service any additional symptoms,
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TROUBLESHOOTING
SYMPTOM 25 EXHAUST SULPHUR SMELL DESCRIPTION • Rotten egg smell (sulphur) from exhaust
POSSIBLE CAUSE
• Electrical connectors are disconnected or connected poorly • Charcoal canister malfunction • Vacuum lines are disconnected or connected improperly. • Improper fuel pressure Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Go to appropriate flow chart. 1
Are any drivability or exhaust smoke concerns present? No Go to next step.
Yes Go to next step. 2
Inspect following: • Electrical connections • Vacuum lines Are all items okay?
No
Service as necessary. Repeat Step 2.
Yes
No DTC is displayed: Go to next step.
3
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No
DTC is displayed: Go to appropriate DTC test.
Yes Go to next step. 4
Install fuel pressure gauge between fuel filter and fuel distributor. Start engine and run it at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250kPa 2.1—2.6 kgf/cm2,30—36 psi
No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Yes
Go to next step.
5
Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210—250kPa 2.1—2.6 kgf/cm2, 30—36 psi
No
Inspect pressure regulator for high pressure cause.
Yes Replace charcoal canister. 6
Inspect charcoal canister for fuel saturation. Is excessive amount of liquid fuel present in canister?
No
Inspect fuel tank vent system. If fuel tank vent system is okay, since sulfur content can vary in different fuels, suggest trying a different brand. If fuel tank vent system is not okay, repair or replace malfunctioning parts.
7 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING SYMPTOM 26 INTERMITTENT CONCERNS DESCRIPTION • Symptom occurs randomly and is difficult to diagnose.
STEP INSPECTION RESULTS ACTION Yes
Go to next step.
1
Talk to customer. Retrieve vehicle service history. Does vehicle have a number of previous repairs and components replaced for a certain symptom?
No
Go to Symptom Index.
Yes
Inspect each wire for corrosion, bent or loose terminal crimps.
2
Connect NGS tester to DLC. If input is switch-type component, turn on manually. Turn ignition switch on. Access PIDs for suspect component. Lightly tap on suspect component, wiggle and pull each wire/connector at suspect component or PCM. Are any PID values out of range, or do they suddenly change and go back into range?
No
Go to next step.
Yes
Inspect each wire for corrosion, bent or loose terminal crimps.
3
Start engine. Lightly tap on suspect component, wiggle and pull each wire/connector at suspect component or PCM. Are any PID values out of range, or do they suddenly change and go back into range?
No
Go to next step.
Yes
Fault occurred while spraying component: Replace part and verify repair. Fault occurred while spraying wiring: Inspect each wire for corrosion, bent or loose terminals and poor wire terminal crimps. Fault occurred while spraying vacuum line: Repair vacuum hoses.
4
Start engine. Accurately spray water on suspect component wire, component or vacuum line related to possible fault area. Are any PID values out of range, or do they suddenly change and go back into range, or was there a noticeable engine misfire/ stumble? No
Inspect wire and connector at suspect component for corrosion, bent or loose terminals, poor wire terminal crimps and high tension of wire. Repair as necessary.
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TROUBLESHOOTING
SYMPTOM 27 CONSTANT VOLTAGE DESCRIPTION Incorrect constant voltage
POSSIBLE CAUSE
• Constant voltage circuit malfunction Note • TP sensor and variable resistor (Except Europe) use constant voltage.
STEP INSPECTION RESULTS ACTION Yes
Repair constant voltage circuit short to power in harness.
1
Disconnect TP sensor connector. Turn ignition switch on. Measure voltage between following TP sensor and variable resistor (Except Europe) connector terminals: • Constant voltage terminal - GND terminal Is constant voltage greater than 6.0 volts?
No
Go to next step.
Yes Go to next step. 2
Is voltage across battery terminals greater than 10.5 volts? No Inspect charging system.
Yes
Go to next step.
3
Turn ignition switch off. Leave TP sensor and variable resistor (Except Europe) connector disconnected. Measure voltage between battery positive terminal and GND circuit at TP sensor connector. Is voltage greater than 10.5 volts and within 1.0 volt of battery voltage?
No
Go to Step 8.
Yes
Go to Step 7.
4
Note • The purpose of this step is to determine if
NGS tester is communicating with PCM. Turn ignition switch on. Attempt to access ECT PID. Can ECT PID be accessed?
No
Go to next step.
Yes
Go to next step.
5
Turn ignition switch off. Leave TP sensor and variable resistor (Except Europe) connector disconnected. Disconnect PCM connector. Turn ignition switch on. Measure voltage between PCM connector terminals 1B and 2B. Is voltage greater than 10.5 volts?
No
Repair open circuit between PCM terminal 1B and main relay.
Yes
Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again. If constant voltage is still out of range, replace PCM.
6
Leave TP sensor, variable resistor (Except Europe) and PCM connectors disconnected. Disconnect NGS tester from DLC. Measure resistance between PCM connector terminals 2K and 2B. Is resistance greater than 10,000 ohms?
No Repair constant voltage circuit short to GND.
Yes
Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again. If constant voltage is still out of range, replace PCM.
7
Turn ignition switch off. Leave TP sensor and variable resistor (Except Europe) connector disconnected. Disconnect PCM connector. Measure resistance between PCM connector terminal 2K and constant voltage circuit at appropriate sensor connector. Is resistance less than 5.0 ohms?
No
Repair open constant voltage circuit.
Yes
Go to next step.
8
Note • The purpose of this step is to determine if
NGS tester is communicating with PCM. Reconnect TP sensor and variable resistor (Except Europe) connector. Turn ignition switch on. Attempt to access ECT PID. Can ECT PID be accessed?
No
Go to Step 10.
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TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes
Reconnect sensor connector. Go to appropriate DTC test.
9
Turn ignition switch off. Disconnect NGS tester from DLC. Disconnect PCM connector. Measure resistance between GND circuit at appropriate sensor connector and PCM connector terminal 2D. Is resistance less than 5.0 ohms?
No
Repair open GND circuit.
Yes
Go to next step.
10
Turn ignition switch off. Disconnect PCM connector. Measure resistance between battery negative terminal and PCM terminals 2A, 2B and 2C. Is each resistance less than 5.0 ohms?
No
Repair open GND circuit.
Yes
GND circuits are okay. Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again.
11
Turn ignition switch off. Measure resistance between GND circuit at following sensor connector and GND: • ECT sensor • O2S • IAT sensor • MAF sensor • TP sensor • Variable resistor (Except Europe) Is each resistance less than 5.0 ohms?
No
Inspect for open GND circuit.
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TROUBLESHOOTING DIAGNOSTIC INSPECTION Spark Plug Condition Inspection Purpose Inspecting spark plugs condition can determine whether problem is related to a specific cylinder or to all cylinders.
Procedure 1. Remove the spark plug. 2. Inspect spark plug condition. 3. Go to appropriate troubleshooting chart for further
information. Spark plug condition Troubleshooting chart
Specific plug is wet or covered with carbon. Symptom 1 Wet/carbon stuck on specific plug Specific plug looks grayish white. Symptom 2 Grayish white with specific plug All plugs are wet or covered with carbon. Symptom 3 Wet/carbon stuck on all plugs All plugs look grayish white. Symptom 4 Grayish white with all plugs
SYMPTOM 1 Wet/carbon stuck on specific plug
POSSIBLE CAUSE
• Spark—No spark visible or spark weak • Air/fuel mixture—Excessive fuel injection volume • Compression—No compression, low compression • Faulty spark plug Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Working up and down inspect all areas related to oil. 1
Is spark plug wet/covered with carbon by engine oil? No Go to next step.
Yes
Go to next step.
2
Inspect spark plug for following: • Cracked insulator • Heating value • Air gap • Worn electrode Is spark plug okay?
No
Replace spark plug.
Yes Go to next step. 3
Inspect compression pressure at suspected faulty cylinder. Section B1, COMPRESSION INSPECTION Is compression pressure correct?
No Repair or replace malfunctioning parts.
Yes Go to next step. 4
Install all spark plugs. Carry out spark test at suspected faulty cylinder. Is strong blue spark visible? (Compare with normal cylinder)
No Repair or replace malfunctioning parts.
Yes
Inspect fuel injector for following: • Open or short in injector • Leakage • Injection volume
5
Carry out fuel line pressure inspection. TROUBLESHOOTING, ENGINE SYSTEM
INSPECTION. Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270—310 kPa 2.7—3.2 kgf/cm2, 39—45 psi
No
Zero or low: Inspect fuel pump circuit. Inspect for fuel pump relief valve open. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
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TROUBLESHOOTING
SYMPTOM 2 Grayish white with specific plug
POSSIBLE CAUSE
• Air/fuel mixture—Insufficient fuel injection volume • Faulty spark plug
STEP INSPECTION RESULTS ACTION Yes Go to next step. 1
Inspect spark plug for following: • Heating value • Air gap Is spark plug okay? No Replace spark plug.
Yes
Inspect for open circuit between suspected fuel injector terminal and PCM connector terminal.
2
Remove suspected fuel injector. Inspect for following: FUEL SYSTEM, FUEL INJECTOR
INSPECTION • Resistance • Fuel injection volume Are all above items
okay?
No
Replace fuel injector.
SYMPTOM 3 Wet/carbon stuck on all plugs
POSSIBLE CAUSE
• Spark—Spark weak • Air/fuel mixture—Too rich • Compression—Low compression • Clogging in intake/exhaust system Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death
and damage. Fuel can also Irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Go to next step. 1
Is air cleaner element free of restriction? No Replace air cleaner element.
Yes Go to next step. 2
Carry out spark test. Is strong blue spark visible at each cylinder? No Repair or replace malfunctioning parts.
Yes Go to next step. 3
Carry out fuel line pressure inspection. TROUBLESHOOTING, ENGINE SYSTEM
INSPECTION. Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270—310 kPa 2.7—3.2 kgf/cm2, 37—45 psi
No
Zero or low: Inspect fuel pump circuit. Inspect for fuel pump relief valve open. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Yes
Go to next step.
4
Inspect following PIDs: CONTROL SYSTEM, PID/DATA MONITOR
INSPECTION • MAF V • ECT • FHO2S (When engine can be started) Are PIDs okay?
No
Repair or replace malfunctioning parts.
Yes Go to next step. 5
Carry out purge control inspection. (When engine can be started) Is purge control correct? No Repair or replace malfunctioning parts.
Yes Inspect for clogging in exhaust system. 6
Carry out compression inspection. Is compression correct? No Repair or replace malfunctioning parts.
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TROUBLESHOOTING
SYMPTOM 4 Grayish white with all plugs
POSSIBLE CAUSE
• Air/fuel mixture—Too lean Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious Injuries or death
and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes
Repair or replace malfunctioning parts.
1
When engine cannot be started, inspect intake-air system for air leakage. When engine can be started, carry out intake manifold vacuum inspection. Is air sucked in from intake-air system?
No
Go to next step.
Yes
Inspect following PIDs: CONTROL SYSTEM, PID/DATA MONITOR
INSPECTION • MAF V • ECT • FHO2S (When engine can be started) Inspect for PCM GND condition.
2
Carry out fuel line pressure inspection. TROUBLESHOOTING, ENGINE SYSTEM
INSPECTION, Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270—310 kPa 2.7—3.2 kgf/cm2, 37—45 psi
No
Zero or low: Inspect fuel pump circuit. Inspect for fuel pump relief valve open. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
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TROUBLESHOOTING Inspection Using an Oscilloscope (Reference) Purpose Using an oscilloscope, inspection such as stuck solenoid valve is made possible without actually removing parts.
When normal Counter electromotive voltage A, generated when the three-way solenoid valve or the fuel injector is turned off from on, shows irregular convergence because induced electromotive voltage B, generated by the plunger return operation, is added to it.
When plunger is stuck When the plunger is stuck, pulse convergence is smooth because no induced electromotive voltage B is generated.
Input Signal System Investigation Procedure 1. Find an unusual signal. (Refer to procedures below) 2. Locate its source. (Refer to procedures below) 3. Repair or replace the defective part. 4. Confirm that the unusual signal has been erased.
Finding unusual signals While referring to the diagnostic trouble code inspection section of the on-board diagnostic system, use the PID/DATA MONITOR AND RECORD function to inspect the input signal system relating to the problem. 1. Turn the ignition on and run it at idle. You can assume
that any signals that are out of specifications by a wide margin are unusual.
2. When recreating the problem, any sudden change in monitor input signals that is not consciously created by the driver can be judged as unusual.
Locating the source of unusual signals
Caution: • Compare the NGS monitor voltage with the
measurement voltage using the DIGITAL MEASUREMENT SYSTEM function. If you use another tester, misreading may occur.
• When measuring voltage, attach the tester GND to the GND of the PCM that is being tested, or to the engine itself. If this is not done, the measured voltage and actual voltage may differ.
• After connecting the pin to a waterproof coupler, confirming continuity and measuring the voltage, inspect the waterproof connector for cracks. If there are any, use sealant to fix them. Failure to do this may result in deterioration of the harness or terminal from water damage, leading to problems with the vehicle.
Variable resistance type 1 (Throttle position (TP) sensor and variable resistor (Except Europe))
Investigate the input signal system 1. When you get an unusual signal, measure the #1 PCM
terminal voltage. (1) If the #1 terminal voltage and the NGS monitor voltage are the same, proceed to the next step. (2) If there is a difference of 0.5 V or more, inspect the following points concerning the PCM connector. • Female terminal opening loose • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.
2. When you get an unusual signal, measure the #2 sensor terminal voltage. (1) If there is a 0.5 V or more difference between the sensor and NGS voltages, inspect the harness for open or short circuits.
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(2) If the sensor and NGS voltages are the same, inspect the following points concerning the sensor connector. If there are no problems, proceed to next investigation below.
• Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.
Investigate the standard power supply system (1) Confirm that the #3 terminal is at 5 V. (1) If the measured voltage on the #3 terminal is 5 V,
inspect the following points on the sensor connector. If there is no problem, proceed to next investigation below. (3) Female terminal opening looseness (4) Coupler (pin holder) damage (5) Pin discoloration (blackness)
(2) If the #3 terminal measures other than 5 V, inspect for the following.
• Open or short circuit in harness • Harness/pin crimp is loose or disconnected.
Investigate the GND system 1. Confirm that terminal sensor #5 is at 0 V.
(1) If it is at 0 V, inspect the sensor. If necessary, replace the sensor.
(2) If not, inspect for the following. Open or short circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected.
Variable resistance type 2 (Mass air flow (MAP) sensor)
Investigate the input signal system 1. When you get an unusual signal, measure the #1 PCM
terminal voltage. (1) If the #1 terminal voltage and the NGS monitor
voltage are the same, proceed to the next step. (2) If there is a difference of 0.5 V or more, inspect
the following points concerning the PCM connector. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.
2. When you get an unusual signal, measure the #2 sensor terminal voltage.
(1) If there is a 0.5 V or more difference between the sensor and NGS voltages, inspect the harness for open or short circuits.
(2) If the sensor and NGS voltages are the same, inspect the following points concerning the sensor connector. If there are no problems, proceed to next investigation below.
• Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.
Investigate the electrical supply system 1. Confirm that the sensor #3 terminal is B+.
(1) If the measured voltage on the #3 terminal is B+, inspect the following points on the sensor connector. If there is no problem, proceed to next investigation below.
• Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness)
(2) If the #3 terminal measures other than B+, inspect for the following.
• Open or short circuit in harness • Harness/pin crimp is loose or disconnected.
Investigate the GND system 1. Confirm that terminal sensor #4 is at 0 V.
(1) If it is at 0 V, inspect the sensor. If necessary, replace the sensor.
(2) If not at 0 V, inspect for the following. Open circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected.
Thermistor type (Intake air temperature (IAT) and engine coolant temperature (ECT) sensors)
Investigate the input signal system 1. When you get an unusual signal, measure the #1 PCM
terminal voltage. (2) If the #1 terminal voltage and the NGS monitor
voltage are the same, proceed to the next step. (3) If there is a difference of 0.5 V or more, inspect the
following points concerning the PCM connector. (1) Female terminal opening looseness (2) Coupler (pin holder) damage (3) Pin discoloration (blackness) (4) Harness/pin crimp is loose or disconnected.
2. When you get an unusual signal, measure the #2 sensor terminal voltage. (3) If there is a 0.5 V or more difference between the
sensor and NGS voltages, inspect the harness for open or short circuits.
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(2) If the sensor and NGS voltages are the same, inspect for the following points concerning the sensor connector. If there are no problems, proceed to next investigation below, • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.
Investigate the GND system 1. Confirm that terminal sensor #3 is at 0 V.
(1) If it is at 0 V, inspect the sensor. If necessary, replace the sensor.
(2) If not, inspect for the following. Open circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected.
Vehicle speed sensor (VSS)
1. Measure the #1 PCM terminal voltage and confirm that it
is at 0 V or 5 V when the ignition switch is on and the engine is at idle. (1) If it is at 0 V or 5 V, proceed to symptom
troubleshooting No.26 "Intermittent Concerns". (2) If not, inspect the following points concerning the
PCM connector. If there are no problem, proceed to next step.
• Female terminal opening loose • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.
2. Measure the #2 sensor terminal voltage and confirm that
it is at 0 V or 5 V when the ignition switch is on and the engine at idle. (1) If it is at 0 V or 5 V, proceed to symptom
troubleshooting No.26 "Intermittent Concerns". (2) If not, inspect the following points concerning the
sensor connector. If there are no problems, proceed to next step.
• Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.
3. Confirm that the #3 terminal switch voltage is at 0 V.
(1) If it is at 0 V, inspect the sensor. If necessary, replace the sensor.
(2) If not, inspect for the following. • Open circuit in harness • Female terminal opening looseness • Coupler (pin holder) damage
• Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.
ENGINE SYSTEM INSPECTION Main Relay Operation Inspection 1. Verify that the main relay clicks when the ignition switch
is turned to on and off.
2. If there is no operating sound, inspect the following. • Main relay • Harness and connector between ignition switch and
main relay Intake Manifold Vacuum Inspection 1. Verify air intake hoses are installed properly. 2. Start the engine and run it at idle. 3. Disconnect the vacuum hose between the intake
manifold and purge solenoid valve on the intake manifold side.
4. Connect a vacuum gauge to the intake manifold and measure the intake manifold vacuum.
Specification More than 60 kPa 450 mmHg, 18 inHg
5. If not as specified, inspect for the following: • Air suction at throttle body, intake manifold and
PCV valve installation points • Fuel injector insulator • Accelerator cable free play • Engine compression (Refer to section B1.) Note • Air suction can be located by engine speed change
when lubricant is sprayed on the area where suction is occurring.
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TROUBLESHOOTING (3) Verify that DTC P0505 is not displayed. If DTC
P0505 is shown, carry out DTC inspection. (4) Select the SIMULATION TEST function on the
NGS display. (5) Change the duty value of the IAC valve to 100%
using the IACV PID. (6) Verify that the idle speed increases.
① If the idle speed increases, replace the PCM. ② If the idle speed does not change, inspect the following. • IAC valve air passage • Open or short circuit between IAC valve connector terminals and PCM connector terminal 2W
4. Warm up the engine to normal operating temperature and run it at idle.
5. Select the PID/DATA MONITOR AND RECORD function on the NGS display.
6. Select the following PIDs. • A/C SW • IAC V • PSP SW • RPM
7. Turn the electrical loads on and verify that the engine speed is within the specification.
Engine speed (rpm) Load condition Idle-up speed (rpm)*1
P/S ON*2 A/CON*3
700—800 (750 ± 50)
Idle Air Control (IAC) Inspection Engine coolant temperature (ECT) compensation inspection 1. Connect the SSTs (NQS tester) to DLC.
2. Select the PID/DATA MONITOR AND RECORD function on the NGS display.
3. Select the following PIDs. • ECT • IACV • RPM
4. Verify that the engine is cold, then start the engine. 5. Verify that the engine speed decreases as the
engine warms up. 6. If the engine speed does not decrease or decreases
slowly, carry out the following. • ECT sensor inspection • IAC valve inspection
Load compensation inspection 1. Start the engine and run at idle. 2. Disconnect the IAC valve connector and verify that the
engine rotation changes.
3. If the engine condition does not change, do as follows.
(1) Connect the IAC valve connector. (2) Connect the SSTs (NGS tester) to DLC.
*1 Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. *2: Steering wheel is fully turned. *3: A/C switch and fan switch are on.
Note • Excludes temporary idle speed drop just after the electrical loads are turned on.
8. If not as specified, carry out the following. • A/C switch inspection • PSP switch inspection • IAC valve inspection
Fuel Line Pressure Inspection Warning • Fuel line spills and leakage are dangerous.
Fuel can ignite and cause serious injuries or death. Fuel can also irritate skin and eyes.
• To prevent this, always complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
1. Disconnect the negative battery cable. 2. Connect a fuel pressure gauge between the fuel
filter and fuel distributor.
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3. Connect the negative battery cable.
Caution • Connecting the wrong DLC terminals may
possibly cause a malfunction. Carefully connect the specified terminals only.
4. Short the DLC terminal F/P to body GND using a
jumper wire.
5. Turn the ignition switch on and measure the fuel line
pressure. Specification 270—310 kPa 2.7—3.2 kgf/cm2, 39—45 psi
6. Turn off the ignition switch and disconnect the jumper
wire. 7. If the pressure is higher than specified, inspect the fuel
pump maximum pressure. If normal, inspect fuel return hose or the pressure regulator for clogging.
8. If the pressure is lower than specified, measure the fuel line pressure while pinching the return hose.
• If the fuel line pressure quickly increases, inspect the pressure regulator and PRC solenoid valve.
• If fuel line pressure gradually increases, inspect the fuel pump maximum pressure. If the fuel pump maximum pressure is normal, inspect for clogging between fuel pump body and pressure regulator.
Fuel Pressure Hold Inspection
Warning • Fuel line spills and leakage are dangerous. Fuel
can ignite and cause serious injuries or death. Fuel can also irritate skin and eyes.
• To prevent this, always complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
1. Disconnect the negative battery cable. 2. Connect a fuel pressure gauge between the fuel filter and
fuel distributor.
3. Connect the negative battery cable. Caution • Connecting the wrong DLC terminals may
possibly cause a malfunction. Carefully connect the specified terminals only.
4. Short the DLC terminal F/P to body GND using a jumper
wire.
5. Turn the ignition switch on for approx. 10 sec. to operate the fuel pump body.
6. Turn off the ignition switch and disconnect the jumper wire. 7. Observe the fuel pressure after 5 min.
Specification More than 150 kPa 1.5 kgf/cm2, 21 psi
8. If the pressure is lower than specified, measure the fuel
line pressure while pinching the return hose.
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• If the fuel line pressure holds, replace the pressure
regulator. (Refer to FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION.)
• If fuel line pressure does not hold, inspect the fuel leakage from fuel line and fuel injector.
Pressure Regulator Control Inspection Warning • Fuel line spills and leakage are dangerous. Fuel
can ignite and cause serious injuries or death. Fuel can also irritate skin and eyes.
• To prevent this, always complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
1. Disconnect the negative battery cable. 2. Connect a fuel pressure gauge between the fuel filter and
fuel distributor.
3. Connect the negative battery cable. 4. Measure the fuel line pressure under the following
conditions. Specifications
Condition Fuel pressure [kPa kgf/cm2, psi]
Idling
210—250 2.1—2.6, 30—36
During 120 sec. of hot start
270—310 2.7—3.2, 39—45
After 120 sec. of hot start
210—250 2.1—2.6, 30—36
210—250 2.1—2.6, 30—36
270—310 2.7—3.2, 3&—45
Judgment Normal Not Normal
(Perform Inspection 1)
Not Normal (Perform
Inspection 2)
Inspection 1
1. Connect the SSTs (NGS tester) to the DLC.
2. Start the engine and let it idle. 3. Select the SIMULATION TEST function on the NGS
display. 4. Select IDLING TEST mode. 5. Select PRCV PID. 6. Press START. 7. Turn the PRC solenoid valve from off to on and inspect if
the fuel pressure changes. (1) If the pressure changes, inspect the following.
• ECT, IATDC and TP V PIDs (Refer to CONTROL SYSTEM, PID/DATA MONITOR INSPECTION.)
(2) If the pressure does not change, do as follows. ① Select the SIMULATION TEST function on the NGS display. ② Select IDLING TEST mode. ③ Select PRCV PID. ④ Press START. ⑤ Turn the PRC solenoid valve from off to on and inspect if the operation sound of the valve is heard. ⑥ If the operating sound is heard, inspect the pressure regulator. ⑦ It the operating sound is not heard, inspect the PRC solenoid valve.
Inspection 2 1. Connect the SSTs (NGS tester) to the DLC.
2. Turn the ignition switch on. 3. Select the SIMULATION TEST function on the NGS
display. 4. Turn the PRC solenoid valve from off to on using the
PRCV PID and inspect if the operating sound is heard. (1) If the operating sound is heard, inspect for a loose or damaged vacuum hose. (Pressure regulator—PRC solenoid valve—intake manifold) (2) If the operating sound is not heard, inspect the
PRC solenoid valve)
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TROUBLESHOOTINGFuel Injector Operation Inspection
STEP INSPECTION RESULTS ACTION Yes Fuel injector operation is okay. 1
While cranking engine, inspect for fuel injector operating sound at each cylinder using a soundscope. Is operating sound heard?
No
Not heard at all cylinders: Go to next step. Not heard at some cylinders: Go to Step 3.
Yes
Inspect following: • Fuel injector power system related wiring harnesses
and connectors • PCM connectors • Fuel injector GND and related wiring harnesses and
connectors
2
Carry out main relay operation inspection. Is main relay operation okay?
No Repair or replace malfunctioning parts. Yes Go to next step. 3
Change fuel injector connector of not operating fuel injector and operating fuel injector. Is operating sound heard? No Replace fuel injector.
Yes Inspect PCM terminal voltage of fuel injector signal. 4
Are wiring harnesses and connectors of not operating fuel injector okay? (Open or short) No Repair or replace malfunctioning parts.
Fuel Cut Control Inspection 1. Warm up engine and let it idle. 2. Turn off the electrical loads and A/C switch. 3. Connect the SSTs (NGS tester) to the DLC.
4. Select the PID/DATA MONITOR AND RECORD function on the NGS display.
5. Select RPM and INJ PIDs. 6. Press START. 7. Monitor both PIDs while performing the following
steps. (1) Depress the accelerator pedal and increase the engine speed to 4000 rpm. (2) Release the accelerator pedal (brake pedal is not depressed) and inspect that the fuel injector duration time is 0 msec., and 2—5 msec. when the engine speed drops below 1200 rpm.
8. If not as specified, carry out the following. • ECT sensor inspection • Neutral/clutch switch inspection
Fuel Pump Operation Inspection 1. Connect the SSTs (NGS tester) to the DLC.
2. Remove the fuel-filler cap. 3. Turn the ignition switch on. 4. Select the SIMULATION TEST function on the NGS
display. 5. Turn the fuel pump relay from off to on using the FP
RLY PID and inspect if the operating sound is heard. 6. If no operating sound is heard, measure the voltage at
harness side fuel pump unit connector terminal B. Specification Battery positive voltage (Ignition switch on)
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TROUBLESHOOTING 7. If the voltage is as specified, inspect the following.
• Fuel pump continuity • Fuel pump GND • Wiring harness between fuel pump relay and PCM
terminal 1 H 8. If not as specified, inspect the following.
1. Fuel pump relay 2. Wiring harness and connector (Main relay—fuel
pump relay—fuel pump unit) Fuel Pump Control Inspection 1. Connect the SSTs (NGS tester) to the DLC.
2. Turn the ignition switch on. 3. Select the SIMULATION TEST function on the NGS
display. 4. Select IG ON TEST mode. 5. Select FP RLY PID. 6. Press START. 7. Turn the fuel pump relay from off to on and inspect if
the operating sound of the fuel pump relay is heard.
8. If no operating sound is heard, inspect the fuel
pump relay. 9. If the fuel pump relay is normal, inspect the
following. • Wiring harnesses and connectors (Main
relay—fuel pump relay—PCM) Ignition Timing Control Inspection 1. Connect a timing light to the engine. 2. Crank the engine. 3. Verify that the timing mark (yellow) on the crankshaft
pulley is within the specification. Specification BTDC 9°—11°(10° ± 1°)
4. Increase the engine speed and verify the ignition timing
is advanced. 5. If the ignition timing is not advanced, carry out the
following. • CMP sensor inspection • MAP sensor inspection
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TROUBLESHOOTING Spark Test
1. Remove the fuel pump relay. 2. Verify that each high-tension lead and connector is connected properly. 3. Inspect the ignition system in the following procedure.
Warning • High voltage in the ignition system can cause strong electrical shock which can result in serious injury. Avoid
direct contact to the vehicle body during the following spark test.
STEP INSPECTION RESULTS ACTION Yes Ignition system is okay. 1
Remove high-tension lead from spark plug. Hold high-tension lead with pliers installed 5—10 mm 0.20—0.39 in from GND. Crank the engine and verify that there is a strong blue spark. (Inspect each cylinder.)
No
Some cylinders do not spark: Go to next step. All cylinders do not spark: Go to Step 3.
Yes Inspect for cracks or damage of high-tension lead, distributor and Ignition coil.
2
Is high-tension lead resistance correct?
No Replace the high-tension lead. Yes Repair or replace connector. 3
Does PCM or ignition coil connector have poor connection? No Go to next step.
Yes Go to next step. 4
Is igniter okay? No Replace igniter.
Yes Go to next step. 5
Is ignition coil winding resistance okay? No Replace ignition coil.
Yes Go to next step. 6
Are distributor cap and rotor okay? No Replace distributor cap or rotor.
Yes
Inspect for open or short in wiring harness and connector of CMP sensor.
7
Are following parts okay? • CMP sensor • PCM terminal 2F voltage Specification Approx. 1.5 V
No Repair or replace malfunctioning part.
F1-126
CONTINUED
TO. MODEL .INDEXPAGES. FROM. MANUAL
BACK.TO.CHAPTER.INDEXRANG.DRFT.REPAIR MANUAL
TROUBLESHOOTING Purge Control Inspection 1. Start the engine. 2. Disconnect the vacuum hose between the purge
solenoid valve and the charcoal canister. 3. Put a finger to the purge solenoid valve and verify that
there is no vacuum applied when the engine is cold. 4. If there is a vacuum, inspect the following.
• Wiring harness and connectors (Purge solenoid valve—PCM terminal 2X)
• Purge solenoid valve 5. Warm up the engine to the normal operating
temperature. 6. Stop the engine. 7. Connect the SSTs (NGS tester) to DLC.
8. Turn the ignition switch on. 9. Select the PID/DATA MONITOR AND RECORD
function on the NGS display. 10. Select ECT PID. 11. Verify that the engine coolant temperature is above
60°C 140°F. 12. If the SSTs (NGS tester) indicates below 60 °C 140 °F,
carry out the ECT sensor inspection. 13. Select the SIMULATION TEST function on the NGS
display. 14. Select PRGV PID. 15. Press START. 16. Increase the duty value of the purge solenoid valve to
50% and inspect if the operating sound of the valve is heard. (1) If the operating sound is heard, inspect the loose
or damaged vacuum hose. (Intake manifold—purge solenoid valve—charcoal canister)
(2) If the operating sound is not heard, carry out the purge solenoid valve inspection.
A/C CUT-OFF CONTROL INSPECTION 1. Start the engine. 2. Turn the A/C switch and fan switch on. 3. Verify that the A/C compressor magnetic clutch
actuates. 4. If it does not actuate, go to symptom troubleshooting
No.22 "A/C does not work sufficiently". Note • Specification of A/C cut-off control time is from 2
to 5 seconds. 5. Fully open the throttle valve in a short period and verify
that the A/C compressor magnetic clutch does not actuate.
6. If it actuates, inspect the following. (1) Connect the SSTs (NGS tester) to DLC.
(2) Turn the A/C switch off. (3) Turn the ignition switch on. (4) Select the SIMULATION TEST function on the
NGS display. (5) Select IG ON TEST mode. (6) Select A/C RLY PID (7) Press START. (8) Turn the A/C relay from off to on and inspect if the
operating sound of the relay is heard. (9) If the operating sound is heard, inspect TP V PID. (10) If the operating sound is not heard, inspect the
following. • /C relay • Open or short to GND circuit in wiring
harnesses and connectors (Main relay—A/C relay—PCM terminal 1J)
• A/C related parts
F1-127
CONTINUED
TO. MODEL .INDEXPAGES. FROM. MANUAL
BACK.TO.CHAPTER.INDEXRANG.DRFT.REPAIR MANUAL
F2–1
FUEL AND EMISSIONCONTROL SYSTEMS
(WL, WL Turbo)ENGINE TUNE-UP F2–2. . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TUNE-UP PREPARATION F2–2. . . . . . . . IDLE SPEED ADJUSTMENT F2–2. . . . . . . . . . . . . . IDLE-UP SPEED ADJUSTMENT F2–2. . . . . . . . . . . INJECTION TIMING ADJUSTMENT F2–3. . . . . . . .
INTAKE-AIR SYSTEM F2–4. . . . . . . . . . . . . . . . . . . . . . VACUUM HOSE ROUTING DIAGRAM F2–4. . . . . INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION F2–5/7. . . . . . . . . . . . . . TURBOCHARGER INSPECTION F2–8/9. . . . . . . . . . GLOW PLUG REMOVAL/INSTALLATION F2–9. . . GLOW PLUG INSPECTION F2–9. . . . . . . . . . . . . . . GLOW PLUG RELAY
REMOVAL/INSTALLATION F2–9. . . . . . . . . . . . . . GLOW PLUG RELAY INSPECTION F2–10. . . . . . . . GLOW PLUG CORD INSPECTION F2–10. . . . . . . .
F2–10/11ACCELERATOR CABLE
INSPECTION/ADJUSTMENT F2–11. . . . . . . . . . . . IDLING KNOB, IDLING CABLE
INSPECTION F2–11. . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM F2–12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEFORE REPAIR PROCEDURE F2–12. . . . . . . . . . AFTER REPAIR PROCEDURE F2–12. . . . . . . . . . . . FUEL TANK REMOVAL/INSTALLATION F2–13/15. . . . FUEL FILTER DISASSEMBLY/
ASSEMBLY F2–15/16. . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL GAUGE SENDER UNIT
REMOVAL/INSTALLATION F2–16. . . . . . . . . . . . . . FUEL GAUGE SENDER UNIT
INSPECTION F2–16. . . . . . . . . . . . . . . . . . . . . . . . . . FUEL FILTER AIR BLEEDING F2–16. . . . . . . . . . . . . SEDIMENTOR WATER DRAINING F2–16. . . . . . . . . SEDIMENTOR SWITCH INSPECTION F2–16/17. . . . . FUEL WARMER INSPECTION F2–17. . . . . . . . . . . . FUEL INJECTION PUMP (FIP)
INSPECTION F2–17. . . . . . . . . . . . . . . . . . . . . . . . . . FUEL INJECTION PUMP (FIP)
REMOVAL/INSTALLATION F2–17/18. . . . . . . . . . . . . . INJECTION NOZZLE
REMOVAL/INSTALLATION F2–18. . . . . . . . . . . . . .
INJECTION NOZZLE DISASSEMBLY/ASSEMBLY F2–19. . . . . . . . . . . . .
INJECTION NOZZLE INSPECTION F2–19/20. . . . . . . . FUEL CUT VALVE (FCV)
REMOVAL/INSTALLATION F2–20. . . . . . . . . . . . . . FUEL CUT VALVE (FCV) INSPECTION F2–20/21. . . . . FICD SOLENOID VALVE NO.1, NO.2 INSPECTION
F2–21TIMER CONTROL VALVE (TCV)
INSPECTION F2–22. . . . . . . . . . . . . . . . . . . . . . . . . . EXHAUST SYSTEM F2–23. . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM INSPECTION F2–23. . . . . . . . . EXHAUST SYSTEM
REMOVAL/INSTALLATION F2–23/25. . . . . . . . . . . . . . EMISSION SYSTEM F2–25. . . . . . . . . . . . . . . . . . . . . . .
ROLLOVER VALVE INSPECTION F2–25. . . . . . . . . EVAPORATIVE CHAMBER INSPECTION F2–25. . . EGR VALVE INSPECTION F2–26. . . . . . . . . . . . . . . . EGR SOLENOID VALVE INSPECTION F2–26. . . . .
F2–26CONTROL SYSTEM F2–27. . . . . . . . . . . . . . . . . . . . . . .
COMPONENT PARTS F2–27. . . . . . . . . . . . . . . . . . . . POWERTRAIN CONTROL MODULE (PCM)
REMOVAL/INSTALLATION F2–28. . . . . . . . . . . . . . POWERTRAIN CONTROL MODULE (PCM)
INSPECTION F2–28/31. . . . . . . . . . . . . . . . . . . . . . . . . . NE SENSOR INSPECTION F2–32. . . . . . . . . . . . . . . ENGINE COOLANT TEMPERATURE (ECT)
SENSOR INSPECTION F2–32/33. . . . . . . . . . . . . . . . . IDLE SWITCH INSPECTION F2–33. . . . . . . . . . . . . . CONTROL LEVER POSITION SENSOR
INSPECTION F2–33/34. . . . . . . . . . . . . . . . . . . . . . . . . . ON-BOARD DIAGNOSTIC SYSTEM F2–35. . . . . . . . .
DTC READING PROCEDURE F2–35. . . . . . . . . . . . . AFTER REPAIR PROCEDURE F2–35. . . . . . . . . . . . DTC INSPECTION F2–36/38. . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING F2–39. . . . . . . . . . . . . . . . . . . . . . FOREWORD F2–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING ITEM TABLE F2–39. . . . . . . . SYMPTOM TROUBLESHOOTING F2–40/60. . . . . . . . . SYSTEM INSPECTION F2–61/64. . . . . . . . . . . . . . . . . . .
BACK.TO.MAIN.INDEX
CONTINUED
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PAGES. FROM. MANUAL
ACCELERATOR PEDAL REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . .
EGR PIPE, EGR VALVE REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . .
ENGINE TUNE-UP
F2–2
ENGINE TUNE-UPENGINE TUNE-UP PREPARATION
1. Warm up the engine to normal operatingtemperature.
2. Turn the all electrical loads off.3. Connect a tachometer.
IDLE SPEED ADJUSTMENTWL
1. Perform “Engine tune-up preparation ”.2. Verify that the idle speed is within the specification.
Specification700—740 (72020) rpm
3. If not within the specification, adjust the idle speedby turning the IAS (idle adjustment screw).
LOCKNUT5.9—8.8 N·m60—90 kgf·cm,53—78 in·lbf
IAS
4. After adjusting the idle speed, tighten the locknutsecurely.
WL Turbo1. Perform “Engine tune-up preparation ”.2. Verify that the idle speed is within the specification.
SpecificationGeneral (L.H.D.) : 760—800 (78020) rpmEurope and UK : 700—740 (720 20) rpm
Caution Turning the idle switch (Europe and UK
only) with its connector connected canbreak the harness. Be sure to disconnectthe connector when turning the idle switchmore than one rotation.
3. If not as specified, loosen the idle switch locknutand adjust the idle speed by turning the idle switch.
LOCKNUT11.8—14.7 N·m120—150 kgf·cm,104—130 in·lbf
IDLE SWITCH
4. After adjusting the idle speed, tighten the locknutsecurely.
IDLE-UP SPEED ADJUSTMENT1. Perform “Engine tune-up preparation ”.2. Turn all electrical loads off in neutral shift position.3. Apply vacuum of –53.3 kPa –400 mmHg, –15.8
inHg or over to actuator B, and measure theidle-up speed.
ADJUSTINGSCREW B
LOCKNUT B
WL
ACTUATOR B
ADJUSTINGSCREW C
ACTUATOR A
WL, WL TurboADJUSTINGSCREW B
LOCKNUT B
ACTUATOR B
ADJUSTINGSCREW C
ACTUATOR A
Specification1200—1500 (1,350150) rpm
4. If not within the specification, do as follows;(1) Loosen the locknut B.(2) Adjust the idle-up speed by turning the
adjusting screw B.(3) Tighten the locknut B.
Tightening torque5.9—8.8 N·m 60—90 kgf·cm, 53—78 in·lbf
5. Release actuator B to atmosphere and applyvacuum of –53.3 kPa –400 mmHg, –15.8 inHg orover to actuator A, and measure the idle-up speed.
SpecificationWL vehicle: 805—855 (830 25) rpmWL Turbo, WL (Europe only):
825—875 (85025) rpm
6. If not as specified, adjust the idle-up speed byturning adjusting screw C.
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PAGES. FROM. MANUAL
ENGINE TUNE-UP
F2–3
INJECTION TIMING ADJUSTMENT
Warning Fuel vapor is hazardous. It can very easily
ignite, causing serious injury and damage.Always keep sparks and flames away fromfuel.
Fuel line spills and leaks are dangerous.Fuel can ignite and cause serious injuriesor death and damage. Fuel can also irritateskin and eyes. To prevent this, alwaysobserve the “Fuel Line Safety Procedures”,“Fuel Hose Installation”.
Caution After tightening the FIP mounting nuts and
bolt after loosening them, be sure toinspect the timing belt tension. If the belttension is not inspected, the timing belt andthe camshaft may become damaged. (Referto Section B2, TIMING BELT, TIMING BELTREMOVAL/INSTALLATION, Timing BeltInstallation Note.)
1. Remove the injection pipes (Refer to FUEL SYSTEM, FUEL INJECTION PUMP (FIP)REMOVAL/INSTALLATION.)
2. Remove the cooling fan (Refer to Section E, COOLING FAN, COOLING FANREMOVAL/INSTALLATION.)
3. Turn the crankshaft pulley at slow rotation to alignthe timing mark (BTDC 0° : yellow mark) withindicator pin.
ATDC 10 ° (WHITE MARK)
INDICATOR PINBTDC 0 °(YELLOW MARK)
4. Remove the hydraulic head plug from the injectionpump.
5. Mount the SST into the plug hole on the hydraulichead so that the dial indicator probe touches theplunger end of the pump and the dial indicatorindicates approx. 2.0 mm 0.079 in .
49 9140 074
6. Turn the crankshaft counterclockwise to approx.30° BTDC. (Align the SST installation hole on thecrankshaft pulley.)
7. Turn the crankshaft lightly right and left, and verifythat the dial gauge indicator does not move. Thenset the indicator to 0 mm 0 in.
8. Turn the crankshaft clockwise to position theindicator pin to 10° ATDC (white mark) and readthe dial indicator.
INDICATOR PIN
BTDC 0°(YELLOW MARK)
ATDC 10° (WHITE MARK)
Specification0.95—1.05 mm 0.038—0.041 in
(1.00.05 mm 0.0390.019 in)
9. If not as specified, adjust by loosening the FIPmounting nut and bolt and turn the FIP.
10. Tighten the FIP mounting nuts and then the bolt.
Tightening torque19—25 N·m 1.9—2.6 kgf·m, 14—18 ft·lbf
MOUNTING NUT
MOUNTING BOLT
11. Remove the SST.12. Install the hydraulic head plug and a new gasket.
Tightening torque14—19 N·m 1.4—2.0 kgf·m, 11—14 ft·lbf
13. Connect the injection pipes. (Refer to FUEL SYSTEM, INJECTION NOZZLEREMOVAL/INSTALLATION.)
14. Bleed the air from the fuel filter. (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)
15. Inspect for fuel leakage.16. Check the timing belt tension.
(Refer to Section B2, TIMING BELT, TIMING BELTREMOVAL/INSTALLATION, Timing Belt Installation Note.)
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PAGES. FROM. MANUAL
INTAKE-AIR SYSTEM
F2–4
INTAKE-AIR SYSTEMVACUUM HOSE ROUTING DIAGRAM
WL
FICD SOLENOIDVALVE No.1
FICD SOLENOIDVALVE No.2
FICD ACTUATOR
VACUUM PUMP
TO POWERBRAKE UNIT
WL TURBO
FICD SOLENOIDVALVE No.2
TO RFWACTUATOR
4WD ONLY
TO POWERBRAKE UNIT
FICD ACTUATOR
VACUUM PUMP
EGR VALVE
FICD SOLENOIDVALVE No.1
EGR SOLENOIDVALVE
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PAGES. FROM. MANUAL
INTAKE-AIR SYSTEM
F2–5
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION
Warning When the engine and intake-air system are hot, they can badly burn. Turn off the engine and wait
until they are cool before removing the intake-air system.
WL1. Disconnect the negative battery cable.2. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.)3. Remove in the order indicated in the table.4. Install in the reverse order of removal.
R
7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf
2.0—2.9 N·m20—30 kgf·cm,18—26 in·lbf
2.0—2.9 N·m 20—30 kgf·cm, 18—26 in·lbf
7.9—11.7 N·m80—120 kgf·cm,70—104 in·lbf
8.9—12.7 N·m90—130 kgf·cm,79—112 in·lbf
N·m kgf·m, ft·lbf
7.9—10.7 N·m80—110 kgf·cm,70—95 in·lbf
18.7—25.41.9—2.6,13.8—18.8
7.9—11.7 N·m80—120 kgf·cm,70—104 in·lbf
18.7—25.41.9—2.6,13.8—18.8
1 Fresh-air duct
2 Air cleaner
3 Air hose
4 Resonance chamber
5 Air intake pipe
6 FICD solenoid valve No.1
7 FICD solenoid valve No.2
8 FICD solenoid valve bracket
9 Intake manifold
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PAGES. FROM. MANUAL
INTAKE-AIR SYSTEM
F2–6
WL Turbo1. Disconnect the negative battery cable.2. Drain the engine coolant from radiator.
(Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.)3. Remove the front mud guard.
(Refer to Section S, FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.)4. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.)5. Remove in the order indicated in the table.6. Install in the reverse order of removal.7. Refill the engine coolant to radiator.
(Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.)
STEP 1
4.9 N·m 50 kgf·cm, 43 in·lbf
4.9 N·m 50 kgf·cm, 43 in·lbf
8.9—12.7 N·m90—130 kgf·cm,79—112 in·lbf
7.9—11.7 N·m80—120 kgf·cm,70—104 in·lbf
2.0—2.9 N·m 20—30 kgf·cm, 18—26 in·lbf
7.9—11.7 N·m80—120 kgf·cm,70—104 in·lbf
4.9 N·m 50 kgf·cm, 43 in·lbf
7.9—11.7 N·m 80—120 kgf·cm,70—104 in·lbf
8.9—12.7 N·m90—130 kgf·cm,79—112 in·lbf
8.9—12.7 N·m90—130 kgf·cm,79—112 in·lbf
A
A
1 Fresh-air duct
2 Air cleaner
3 Air intake hose
4 Air hose
5 Air intake pipe
6 Air hose
7 Charge air cooler
8 Air hose
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PAGES. FROM. MANUAL
INTAKE-AIR SYSTEM
F2–7
STEP 2
7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf
19—25 1.9—2.6, 14—18
19—25 1.9—2.6, 14—18
19—25 1.9—2.6, 14—18
N·m kgf·m, ft·lbf
19—25 1.9—2.6, 14—18
R
R
1 FICD solenoid valve No.1
2 FICD solenoid valve No.2
3 EGR solenoid valve
4 FICD solenoid valve bracket
5 Air intake pipe
6 Intake manifold
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PAGES. FROM. MANUAL
INTAKE-AIR SYSTEM
F2–8
TURBOCHARGER INSPECTIONWastegate Actuator Inspection
Caution Compressed air used in the workshop is
highly pressurized and can damage theactuator. Adjust the air pressure with atransformer, and inspect the actualpressure by using an air blower beforeactual use. Stop blowing air if the rodmoved.
1. Disconnect the air hose of the wastegate actuatoron the compressor housing side.
2. Apply the compressed air using the air gun.3. Note the air pressure when the wastegate actuator
is moved.
Specification107—115 kPa
1.09—1.18 kgf/cm 2, 15.5—16.8 psiWASTEGATEACTUATOR
ROD
4. If not within the specification, replace theturbocharger. (Refer to EXHAUST SYSTEM,EXHAUST SYSTEM REMOVAL/INSTALLATION.)
Compressor Wheels Inspection1. Remove the air hose.
(Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
2. Remove the joint pipe. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
3. Set the small mirror as shown and inspect thecompressor wheel from view A.
Note To make work accurate, use a penlight to
inspect.
TURBOCHARGERMIRROR
A
4. Inspect all fins of compressor wheel while rotatingthe compressor wheel by hand.
5. If the compressor wheel is interfering with thehousing, it is likely that more than two fins aredamaged, cracked or bent. Replace theturbocharger.
Note If scratches are found inside the housing but
the fins are okay, the turbocharger is okay.Scratches are made in the turbocharger madeby factory.
Turbine Wheels Inspection1. Remove the air hose.
(Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
2. Remove the joint pipe. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
3. Set the small mirror as shown and inspect theturbine wheel from view B.
Note To make work accurate, use a penlight to
inspect.
TURBOCHARGER
MIRROR
B
4. Inspect all fins of turbine wheel while rotating theturbine wheel by hand.
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PAGES. FROM. MANUAL
INTAKE-AIR SYSTEM
F2–9
5. If the turbine wheel is interfering with the housing,it is likely that one or more fins are damaged,cracked or bent. Replace the turbocharger.
Note Grinding marks on the shaft are normal. This
mark is for adjusting the shaft balance at thefactory.
GRINDING MARK
GLOW PLUG REMOVAL/INSTALLATION
Caution Do not damage the heated section of the
glow plug. Do not reuse a glow plug that has been
dropped over a height of 10 cm 0.4 in. When removing the glow plug, first loosen
it over one pitch by using a tool, thenloosen by hand.
1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf
0.8—15 N·m8—15 kgf·cm,7—13 in·lbf
1 Glow plug cord
2 Glow plug
GLOW PLUG INSPECTION1. Remove the glow plug cord.2. Inspect the resistance between the glow plug
terminal and the cylinder head.
SpecificationGlow plug resistance
Approx. 0.75 Ω [20 °C 68 °F]
GLOW PLUG
3. If not as specified, replace the glow plug.
GLOW PLUG RELAY REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove glow plug relay.3. Install the glow plug relay.
8.9—12.7 N·m90—130 kgf·cm,79—112 in·lbf
GLOW PLUGRELAY
4. Connect the negative battery cable.
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123456567
INTAKE-AIR SYSTEM
F2–10
GLOW PLUG RELAY INSPECTIONSystem Inspection
1. Carry out the “Glow system inspection”. (Refer to TROUBLESHOOTING, SYSTEM INSPECTION, Glow System Inspection.)
2. If not as specified, perform the further inspectionfor the glow plug relay.
Continuity InspectionNote Perform the following test only when directed.
1. Remove the glow plug relay.2. Inspect for continuity between terminals C and D of
the glow plug relay under the following conditions.
C D
A B
C D
A B
: ContinuityStep A B C D
1 B+ GND
2
3. If there is no continuity, replace the glow plug relay.(Refer to GLOW PLUG RELAY REMOVAL/INSTALLATION.)
If as specified but theSystem Inspection is failed, inspect following:
Open circuit Power circuit (Glow plug relay connector terminal A
(1-pin: R/B) and battery) Power circuit (Glow plug relay connector terminal A
(2-pin) and PCM connector terminal O) GND circuit (Glow plug relay connector terminal A
(1-pin: R) and glow plug cord) GND circuit (Glow plug relay connector terminal B
(2-pin) and engine GND) Signal circuit (Glow plug relay connector terminal A
(1-pin: R) and PCM connector terminal I)
Short circuit Glow plug relay connector terminal A (1-pin: R/B)
and battery to GND. Glow plug relay connector terminal A (2-pin) and
PCM connector terminal O to GND. Glow plug relay connector terminal A (1-pin: R)
and PCM connector terminal I to GND.4. Repair or replace faulty areas.5. Install the glow plug relay.
GLOW PLUG CORD INSPECTION1. Remove the glow plug cord.
(Refer to GLOW PLUG REMOVAL/INSTALLATION.)2. Verify that the glow plug cord is not broken or bent.3. Verify there is continuity at both ends of the glow
plug cord.4. If there is no continuity, replace the glow plug cord.
ACCELERATOR PEDAL REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the column cover.
(Refer to Section N, MANUAL STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.4. Install in the reverse order of removal.
General (R.H.D.)
5.0 N·m 50 kgf·cm, 44in·lbf
RN·m kgf·m, ft·lbf
19—25 1.9—2.6, 14—18
19—25 1.9—2.6,14—18
R
1 Idling knob
2 Idling cable
3 Brake switch connector
4 Accelerator cable+ Installation Note
5 Spring pin
6 Clevis pin
7 E clip
8 Pin
9 Bushing
10 Push rod
11 Clevis
12 Nut
13 Nut
14 Pedal component+ Installation Note
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INTAKE-AIR SYSTEM
F2–11
Except General (R.H.D.)
7.9—10.7 N·m 80—110 kgf·cm,69.5—95.4 in·lbf
1 Accelerator cable+ Installation Note
2 Accelerator pedal
Pedal Component Installation Note Carry out the “BRAKE PEDAL HEIGHT
INSPECTION” procedure after installing the pedalcomponent. (Refer to Section P, BRAKE PEDAL HEIGHT INSPECTION.)
Carry out the “CLUTCH PEDAL INSPECTION”procedure after installing the pedal component.(Refer to Section H, CLUTH PEDALINSPECTION/ADJUSTMENT.)
Accelerator Cable Installation Note Carry out the “ACCELERATOR CABLE
INSPECTION/ADJUSTMENT” procedure afterinstalling the accelerator cable. (Refer to ACCELERATOR CABLEINSPECTION/ADJUSTMENT.)
ACCELERATOR CABLEINSPECTION/ADJUSTMENT
1. Warm up the engine, then turn the engine switchoff.
2. Measure the free play of the accelerator cable.
LOCKNUT
Free play1—3 mm 0.04—0.11 in
3. If not as specified, adjust by turning locknut.
IDLING KNOB, IDLING CABLE INSPECTIONGeneral (R.H.D.)
1. Verify that the accelerator pedal is in the idlingposition, when the idling knob is not turned.
2. Verify that the accelerator pedal moves in thedirection that engine speed increases, when theidling knob is turned to the right.
3. Verify that the accelerator pedal returns to theidling position when the idling knob is turned to theleft.
IDLING KNOB
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FUEL SYSTEM
F2–12
FUEL SYSTEMBEFORE REPAIR PROCEDURE
Warning Fuel vapor is hazardous. It can very easily
ignite, causing serious injury and damage.Always keep sparks and flames away fromfuel.
Fuel in the fuel system is under high pressurewhen the engine is not running.
Warning Fuel line spills and leaks are dangerous.
Fuel can ignite and cause serious injuriesor death and damage. Fuel can also irritateskin and eyes. To prevent this, alwayscomplete the following “Fuel Line SafetyProcedures”.
Fuel Line Safety Procedures Avoid fuel line spills and leaks by completing the
following procedures.(1) Remove the fuel-filler cap and release the
pressure in the fuel tank.(2) When disconnecting a fuel hose, wrap a rag
around it to protect against fuel leakage.(3) Plug the fuel hose after removal.
AFTER REPAIR PROCEDURE
Warning Fuel line spills and leaks are dangerous.
Fuel can ignite and cause serious injuriesor death and damage. When installing thefuel hose, observe “Fuel Hose Installation”described below.
Fuel Hose Installation Verify that there is no damage or deformation on
the fuel hose and fuel pipe when installing.
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FUEL SYSTEM
F2–13
FUEL TANK REMOVAL/INSTALLATION
Warning Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire
may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
1. Disconnect the negative battery cable.2. Complete the “BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)3. Remove the drain plug and drain the fuel from the fuel tank.4. Remove the rear flap.5. Remove in the order indicated in the table.6. Install in the reverse order of removal.7. Complete the “AFTER REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
STRETCH CAB 2WD, DOUBLE CAB 2WD
N·m kgf·m, ft·lbf
7.9–10.7 N·m 80—110 kgf·cm, 69.5—95.4 in·lbf
1.1–2.1 N·m 11—22 kgf·cm, 10—19 in·lbf
1.1–2.1 N·m 11—22 kgf·cm, 10—19 in·lbf
1.1–2.1 N·m 11—22 kgf·cm, 10—19 in·lbf
2.5—3.5 N·m 25—36 kgf·cm, 22—26 in·lbf
2.5—4.6 N·m 25—47 kgf·cm, 22—40 in·lbf
11.8—16.6 N·m 120—170 kgf·cm, 105—147 in·lbf
16—22 1.6—2.3, 12—16
11.8—16.6 N·m 120—170 kgf·cm, 105—147 in·lbf
16—22 1.6—2.3, 12—16
DRAIN PLUG26—32 2.6—3.3, 19—23
32—46 3.2—4.7, 24—33
R
R
R
R R
A B
WITH BOX
32—46 3.2—4.7, 24—33WITHOUT BOX
SEAL RUBBER
EXCEPT EUROPE
EUROPE
1.1—2.1 N·m 11—22 kgf·cm, 10—19 in·lbf
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FUEL SYSTEM
F2–14
STRETCH CAB 4WD, DOUBLE CAB 4WD, REGULAR CAB
N·m kgf·m, ft·lbf
1.1–2.1 N·m 11—22 kgf·cm, 10—19 in·lbf
1.1–2.1 N·m 11—22 kgf·cm, 10—19 in·lbf
1.1–2.1 N·m 11—22 kgf·cm, 10—19 in·lbf
2.5—3.5 N·m 25—36 kgf·cm, 22—26 in·lbf
2.5—4.6 N·m 25—47 kgf·cm, 22—40 in·lbf
11.8—16.6 N·m 120—170 kgf·cm, 105—147 in·lbf
16—22 1.6—2.3, 12—16
11.8—16.6 N·m 120—170 kgf·cm, 105—147 in·lbf
16—22 1.6—2.3, 12—16
DRAIN HOSE26—32 2.6—3.3, 19—23 32—46 3.2—4.7, 24—33
R
R
R
R
A B
WITH BOX
7.9—10.7 N·m 80—110 kgf·cm, 69.5—95.4 in·lbf
WITHOUT BOX
32—46 3.2—4.7, 24—33
SEAL RUBBER
EUROPE
1.1—2.1 N·m 11—22 kgf·cm, 10—19 in·lbf
EXCEPT EUROPE
1 Evaporative chamber (If equipped)
2 Joint hose+ Installation Note
3 Breather hose+ Installation Note
4 Under guard
5 Fuel hose+ Installation Note
6 Fuel tank
7 Evaporative hose+ Installation Note
8 Fuel gauge sender unit
9 Rollover valve
10 Fuel-filler pipe
11 Dust cover
12 Fuel inlet pipe
13 Check valve (two–way)
14 Evaporative chamber
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FUEL SYSTEM
F2–15
Evaporative Hose Installation Note Fit each hose onto the respective fittings within the
specification, and install clamps as shown.
LengthEvaporative hose: 25 mm 0.98 in
10 mm 0.39 in
EVAPORATIVE HOSE
Fuel Hose Installation Note Fit each hose onto the respective fittings within the
specification, and install clamp as shown.
LengthFuel hose: 25 mm 0.98 in
10 mm 0.39 in
FUEL HOSE
Breather Hose Installation Note Fit each hose onto the respective fittings within the
specification, and install clamp as shown.
LengthBreather hose: 25 mm 0.98 in
10 mm 0.39 in
BREATHER HOSE
Joint Hose Installation Note Fit the joint hose onto the respective fittings within
the specification, and install clamps as shown.
LengthJoint hose: 35 1.4 in
9—12 mm0.36—0.47 in
VIEW A
9—12 mm0.36—0.47 in
VIEW B
FUEL FILTER DISASSEMBLY/ASSEMBLY1. Disconnect the negative battery cable.2. Complete the “BEFORE REPAIR PROCEDURE”.
(Refer to FUEL SYSTEM, BEFORE REPAIRPROCEDURE.)
3. Disassemble in the order indicated in the table.4. Assemble in the reverse order of removal.5. Complete the “AFTER REPAIR PROCEDURE”.
(Refer to FUEL SYSTEM, AFTER REPAIRPROCEDURE.)
6. Bleed air from the fuel filter. (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)
7. Start the engine and verify that fuel does not leakfrom the fuel system.
8. If fuel leaks, reassemble the fuel filter.19—25 1.9—2.6, 14—18
WITHOUT FUEL WARMER
WITH FUELWARMER
N·m kgf·m, ft·lbf
R
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FUEL SYSTEM
F2–16
1 Connector
2 Fuel hose
3 Priming pump
4 Fuel filter+ Assembly Note
5 Sedimentor switch+ Assembly Note
6 Drain plug
7 Fuel warmer
Sedimentor Switch Assembly Note Apply a small amount of fuel to a new O-ring.
Tighten the sedimentor switch enough to the fuelfilter by hand.
Fuel Filter Assembly Note Apply a small amount of fuel to the fuel filter
O-ring. Tighten the fuel filter approx. 3/4 by handafter the O-ring contacts the priming pump.
FUEL GAUGE SENDER UNITREMOVAL/INSTALLATION(Refer to FUEL SYSTEM, FUEL TANKREMOVAL/INSTALLATION)
FUEL GAUGE SENDER UNIT INSPECTION(Refer to Section T, WARNING AND INDICATORSYSTEM, FUEL GAUGE SENDER UNITINSPECTION.)
FUEL FILTER AIR BLEEDING
Caution Continuously cranking the engine for over
30 seconds can damage the battery and thestarter.
Repeat cranking the engine for 30 seconds andstop for 5—10 seconds until the engine starts.
SEDIMENTOR WATER DRAINING1. Disconnect the negative battery cable.2. Complete the “BEFORE REPAIR PROCEDURE”.
(Refer to FUEL SYSTEM, BEFORE REPAIRPROCEDURE.)
3. Loosen the drain plug located at the bottom of thefuel filter.
4. Pump the priming pump and drain the water.5. After all the water has been drained, tighten the
drain plug.6. Complete the “AFTER REPAIR PROCEDURE”.
(Refer to FUEL SYSTEM, AFTER REPAIRPROCEDURE.)
7. Reconnect the negative battery cable.
SEDIMENTOR SWITCH INSPECTIONContinuity Inspection
Note Perform the following test only when directed.
1. Disconnect the negative battery cable.2. Drain fuel from the fuel filter.
(Refer to FUEL SYSTEM, SEDIMENTOR WATERDRAINING.)
3. Remove the sedimentor switch.4. Inspect continuity of the sedimentor switch by
using an ohmmeter.
Float Continuity
Up Yes
Down No
FLOAT
UP
DOWN
5. If not as specified, replace the sedimentor switch.If as specified, inspect following:Open circuit GND circuit (Sedimentor switch connector
terminal B and body GND) Power circuit (Sedimentor switch connector
terminal A and engine switch connectorterminal C)
SEDIMENTOR SWITCH
HARNESS SIDE CONNECTOR(VIEW FROM TERMINAL SIDE)
BA
ENGINE SWITCH
HARNESS SIDE CONNECTOR(VIEW FROM TERMINAL SIDE)
BA
CA
DB
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FUEL SYSTEM
F2–17
Short circuit GND circuit (Sedimentor switch connector
terminal B and body GND to power circuit) Power circuit (Sedimentor switch connector
terminal A and engine switch connectorterminal C to GND)
6. Repair or replace faulty areas.7. Install the sedimentor switch.8. Reconnect the negative battery cable.9. Bleed air from the fuel filter.
(Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)
FUEL WARMER INSPECTIONWith fuel warmer
1. Disconnect the negative battery cable.2. Complete the “BEFORE REPAIR PROCEDURE”.
(Refer to FUEL SYSTEM, BEFORE REPAIRPROCEDURE.)
3. Remove the fuel warmer. (Refer to FUEL SYSTEM, FUEL FILTERDISASSEMBLY/ASSEMBLY.)
4. Verify that the resistance between terminal A andthe fuel warmer body is within the specificationwhen vacuum of –26.6—–40.0 kPa–200—–300mmHg, –7.9—–11.8 inHg is appliedto port A of the fuel warmer.
SpecificationWater temperature °C °F Resistance ( Ω)
20 68 0.5—1.5
5. If not as specified, replace the fuel warmer.
FUEL INJECTION PUMP (FIP) INSPECTION
Caution FIP is sealed to maintain proper function.
Special tools and testers are required whendisassembling the FIP. Disassembling theFIP without special tools and testers willcause a malfunction.
Consult your distributor for disassembly if any FIPinternal parts are possibly malfunctioning.
FUEL INJECTION PUMP (FIP) REMOVAL/INSTALLATION
Caution After removing/installing the FIP, be sure to
inspect the timing belt tension. If the belttension is not inspected, the timing belt andthe camshaft may become damaged. (Refer to section B2, TIMING BELT, TIMING BELTREMOVAL/INSTALLATION, Timing Belt Installation Note.)
1. Disconnect the negative battery cable.2. Complete the “BEFORE REPAIR PROCEDURE”.
(Refer to FUEL SYSTEM, BEFORE REPAIRPROCEDURE.)
3. Remove the FICD solenoid valve bracket. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEMREMOVAL/INSTALLATION.)
4. Remove the air intake pipe. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEMREMOVAL/INSTALLATION.)
5. Set the No.1 cylinder to TDC.6. Remove in the order indicated in the table.7. Install in the reverse order of removal.8. Complete the “AFTER REPAIR PROCEDURE”.
(Refer to FUEL SYSTEM, AFTER REPAIRPROCEDURE.)
9. Inspect injection timing. (Refer to ENGINETUNE-UP, INJECTION TIMING ADJUSTMENT.)
10. Check the timing belt tension. (Refer to Section B2,TIMING BELT, TIMING BELTREMOVAL/INSTALLATION, Timing Belt InstallationNote.)
N·m kgf·m, ft·lbf
7.9—10.7 N·m 80—110 kgf·cm, 69.5—95.4 in·lbf
2.4—3.4 N·m 25—35 kgf·cm, 22—30 in·lbf
19—25 1.9—2.6, 14—18
19—25 1.9—2.6, 14—18
59—68 6.0—7.0, 44—50
A
A
R
25—29 2.5—3.0, 19—21
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FUEL SYSTEM
F2–18
1 Injection pipe
2 Accelerator cable
3 Fuel hose
4 Connector
5 Vacuum hose
6 Timing belt cover+ Section B2, TIMING BELT, TIMING BELT
REMOVAL/INSTALLATION, Timing Belt CoverInstallation Note.
7 FIP mounting bolt
8 FIP mounting nut
9 FIP+ Removal Note
10 Key
FIP Removal Note1. Remove the two FIP pulley mounting bolts.2. Loosen the FIP pulley locknut.3. Remove the pulley with the SST.
FIP PULLYLOCKNUT
49 S120 215A
INJECTION NOZZLE REMOVAL/INSTALLATION
Caution Cover the outlet of the injection pipe and
fuel hose with a rag. Catch the fuel with a rag.
1. Disconnect the negative battery cable.2. Complete the “BEFORE REPAIR PROCEDURE”.
(Refer to FUEL SYSTEM, BEFORE REPAIRPROCEDURE.)
3. Remove the FICD solenoid valve bracket. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.5. Install in the reverse order of removal.6. Complete the “AFTER REPAIR PROCEDURE”.
(Refer to FUEL SYSTEM, AFTER REPAIRPROCEDURE.)
N·m kgf·m, ft·lbf
R
25—29 2.5—3.0, 19—21
27—32 2.7—3.3, 20—23
59—68 6.0—7.0, 44—50
2.4—3.4 N·m 25—35 kgf·cm, 22—30 in·lbf
R
R
1 Injection pipe
2 Fuel leak pipe
3 Fuel leak washer
4 Injection nozzle+ Installation Note
5 Nozzle washer
6 Corrugated gasket+ Installation Note
Corrugated Gasket Installation Note Install the bead side facing combustion chamber.
Injection Nozzle Installation Note Install each injection nozzle onto the FIP, matching
their identification color rings as shown.
FIPINJECTION NOZZLE
COLOR RING
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FUEL SYSTEM
F2–19
INJECTION NOZZLE DISASSEMBLY/ASSEMBLY
Caution The injection port is very small so it must
be kept clean. Otherwise, foreign materialmay get stuck in the injection nozzle,causing damage.
1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
29—49 3.0—5.0,22—36
N·m kgf·m, ft·lbf
1 Nozzle holder body+ Disassembly Note
2 Ring
3 Shim
4 Nozzle spring
5 Spring seat
6 Spacer
7 Needle valve+ Assembly Note
8 Nozzle body
9 Retaining nut
Nozzle Holder Body Disassembly Note Secure the retaining nut in a vise and remove the
nozzle holder body.
Needle Valve Assembly Note When the nozzle body or the needle valve is
damaged, replace them as a set.
INJECTION NOZZLE INSPECTION
Caution Fuel and fuel tank used for the nozzle tester
must be kept clean. Otherwise, foreignmaterial may get stuck between the nozzleand the nozzle tester, causing damage.
Injection Starting Pressure1. Connect the injection nozzle to a nozzle tester.2. Bleed the air by pumping the nozzle tester handle
several times.3. Slowly lower the nozzle tester handle and note the
pressure when injection starts.
Injection starting pressure11.4—12.1 MPa
116—124 kgf/cm 2, 1650—1760 psi (New)More than 10.0 MPa
102 kgf/cm 2, 1450 psi (Inspection)
4. If the injection starting pressure is not within thespecification, adjust it by installing the correct shim.
Note Adding/subtracting 0.02 mm 0.0008 in
thickness shim increases/decreases thestarting pressure approx. 470 kPa 4.8kgf/cm 2, 68 psi .
ADJUSTING SHIM
Atomization1. Connect the injection nozzle to the nozzle tester.2. Bleed the air by pumping the nozzle tester handle
several times.3. Lower the handle several times as quickly as
possible so that a pulsating whistling sound isheard, and note the atomization pattern.(1) Uniform, proper atomization(2) Incorrect injection angle and direction
(1) (2)
NORMAL FAULTYANGLE
FAULTYDIRECTION
4. If necessary, disassemble and clean or replace theinjection nozzle.
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FUEL SYSTEM
F2–20
Nozzle Leakage1. Connect the injection nozzle to the nozzle tester.2. Bleed the air by pumping the nozzle tester handle
several times.3. Apply 8.8 MPa 90 kgf/cm 2, 1,280 psi pressure to
the injection nozzle, and inspect for fuel leakagefrom the nozzle spray port.
CORRECT WRONG
4. If fuel leaks, disassemble and clean or replace theinjection nozzle.
Operating Inspection1. Verify that the needle valve and nozzle body are
not damaged.2. Verify that the nozzle body is not damaged. Hold
the nozzle body upright and insert approximatelytwo thirds of the needle valve; then see if theneedle valve drops to the valve seat by its ownweight when released.
NEEDLE VALVE
NOZZLEBODY
Injection Nozzle Cleaning1. Inspect the outer and inner surfaces of the injection
nozzle for carbon accumulation.2. If carbon is observed on the outer surface, remove
it by using a hard wood chip.3. If carbon is observed inside of the nozzle, remove
it by using a toothpick.
4. Remove the needle valve from the nozzle body.5. Clean the needle valve and the nozzle body with
clean light oil.6. Verify that the needle valve moves smoothly in the
nozzle body.7. If not, replace the nozzle assembly.
FUEL CUT VALVE (FCV) REMOVAL/INSTALLATIONWithout immobilizer system
1. Disconnect the negative battery cable.2. Complete the “BEFORE REPAIR PROCEDURE”.
(Refer to FUEL SYSTEM, BEFORE REPAIRPROCEDURE.)
3. Remove the FCV.4. Install in the reverse order of removal.
NUT2.0—2.4 N·m 20—25 kgf·cm,18—21 in·lbf
N·m kgf·m, ft·lbf
FCV15—25 1.5—2.6, 11—18
FUEL CUT VALVE (FCV) INSPECTIONWithout immobilizer systemOn-vehicle Inspection
Note Perform the following test only when directed.
1. With the engine idling, disconnect the FCVconnector and verify that the engine stops.
2. If the engine does not stop, carry out the followinginspection.
Off-vehicle Inspection1. Disconnect the negative battery cable.2. Remove the FCV.3. Connect the battery positive voltage to the FCV
terminal and GND the FCV body,4. Verify that the FCV stem is drawn into the FCV.
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123456567
FUEL SYSTEM
F2–21
5. Replace the FCV if not as specified. If as specified, inspect following:Open circuit GND circuit (FCV body and engine switch
connector terminal IG1) Power circuit (FCV connector terminal and
engine switch connector terminal IG1)
ENGINE SWITCH
HARNESS SIDE CONNECTOR(VIEW FROM TERMINAL SIDE)
BA
CA
DB
Short circuit GND circuit (FCV body and engine switch
connector terminal IG1 to GND) Power circuit (FCV connector terminal and
engine switch connector terminal IG1 to GND)
6. Repair or replace faulty areas.7. Install the FCV.8. Reconnect the negative battery cable.
FICD SOLENOID VALVE NO.1, NO.2 INSPECTIONSystem Inspection
1. Carry out the “FICD System Inspection”.(Refer to TROUBLESHOOTING, SYSTEM INSPECTION, FICD System Inspection.)
2. If not as specified, perform the further inspectionfor the FICD solenoid valve No.1, No.2.
Airflow Inspection
Note Perform the following test only when directed.
1. Disconnect the negative battery cable.2. Remove the FICD solenoid valve No.1, No.2.
(Refer to INTAKE-AIR SYSTEM, INTAKE-AIRSYSTEM REMOVAL/INSTALLATION.)
3. Inspect for airflow between ports of the solenoidvalve.
: Continuity : Airflow
StepTerminal Port
StepA B A B C
1
2 B+ GND
B A
B+GND
AIR FILTER
A
B
C
4. If not as specified, replace the faulty FICD solenoidvalve.If as specified but the “System Inspection” is failed,inspect following:
Vacuum hose improper routing, kinks or leakage. Open circuit GND circuit (FICD solenoid valve No.1 connector
terminal B and PCM connector terminal C) GND circuit (FICD solenoid valve No.2 connector
terminal B and PCM connector terminal P) Power circuit (FICD solenoid valve No.1 connector
terminal A and engine switch connector terminalIG1)
Power circuit (FICD solenoid valve No.2 connectorterminal A and engine switch connector terminalIG1)
ENGINE SWITCH
HARNESS SIDE CONNECTOR(VIEW FROM TERMINAL SIDE)
BA
CA
DB
Short circuit GND circuit (FICD solenoid valve No.1 connector
terminal B and PCM connector terminal IG1) GND circuit (FICD solenoid valve No.2 connector
terminal B and PCM connector terminal P) Power circuit (FICD solenoid valve No.1 connector
terminal A and engine switch connector terminalIG1 to GND)
Power circuit (FICD solenoid valve No.2 connectorterminal A and engine switch connector terminalIG1 to GND)
5. Repair or replace faulty areas.6. Install the FICD solenoid valve No.1, No.2.7. Reconnect the negative battery cable.
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FUEL SYSTEM
F2–22
TIMER CONTROL VALVE (TCV) INSPECTIONEurope and UK
1. Carry out the “Timer Control Valve (TCV) ControlInspection”. (Refer to TROUBLESHOOTING, SYSTEM INSPECTION, Timer Control Valve (TCV) Control Inspection.)
2. If not as specified, perform the further inspectionfor the TCV.
Continuity Inspection
Note Perform the following test only when directed.
1. Disconnect the negative battery cable.2. Disconnect the FIP connector (8–pin terminal).3. Verify that there is continuity between the FIP
connector terminal D and TCV body.
FIP
A
COMPONENT SIDE CONNECTOR(VIEW FROM TERMINAL SIDE)
B
C
D
E
F
G
H
4. If not as specified, send TCV to a distributor forreplacement. If the TCV is okay, but PCM terminalvoltage is out of specification, inspect as followsand repair or replace as necessary.Open circuit Power circuit (FIP connector terminal D and
PCM connector terminal H)Short circuit FIP connector terminal D and PCM connector
terminal H to GND5. Repair or replace faulty areas.6. Reconnect the FIP connector.
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EXHAUST SYSTEM
F2–23
EXHAUST SYSTEMEXHAUST SYSTEM INSPECTION
1. Start the engine and inspect each exhaust system component for exhaust gas leakage.2. If leakage is found, repair or replace as necessary.
EXHAUST SYSTEM REMOVAL/INSTALLATION
Warning When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait
until they are cool before removing the exhaust system.
1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
WL
TURKEY and GENERAL(R.H.D., L.H.D.)
EUROPE and UK
1 Tail pipe
2 Main silencer
3 Middle pipe (Turkey and General (R.H.D.,L.H.D.)
OC (Europe and UK)
4 Front pipe
5 Exhaust manifold insulator
6 Exhaust manifold
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EXHAUST SYSTEM
F2–24
N·m kgf·m, ft·lbf
WL TURBO
TURKEY and GENERAL(R.H.D., L.H.D.)
EUROPE and UK
1 Tail pipe
2 Main silencer
3 Middle pipe (General (L.H.D.)) OC (Europe and UK)
4 Front pipe
5 Exhaust manifold insulator
6 Joint pipe
7 Turbocharger+ Removal Note
8 Oil pipe+ Installation Note
9 Exhaust manifold
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EXHAUST SYSTEM, EMISSION SYSTEM
F2–25
Oil Pipe Installation Note Be sure to confirm that the turbocharger is installed
correctly, then install the oil pipe.
Water pipe Install the water pipe and tighten to the specified
torque.
Tightening torque24—35 N·m 2.4—3.6 kgf·m, 18—26 ft·lbf
OIL PIPE
WATER PIPE
Turbocharger Removal Note Do not drop the turbocharger. Do not bend the wastegate actuator mounting or
rod. Cover the intake, exhaust and oil passages to
prevent dirt or other objects from entering.
EMISSION SYSTEMROLLOVER VALVE INSPECTION
1. Remove the rollover valve.(Refer to FUEL SYSTEM, FUEL TANKREMOVAL/INSTALLATION.)
2. Blow from port A and verify that there is airflow.
A
3. Turn the valve over and blow from port A. Verifythat there is no airflow.
A
4. If not as specified, replace the rollover valve.
EVAPORATIVE CHAMBER INSPECTIONIf equipped
1. Remove the evaporative chamber.(Refer to FUEL SYSTEM, FUEL TANKREMOVAL/INSTALLATION.)
2. Blow from port A and verify that there is airflowfrom port B.
A
B
3. If not as specified, replace the evaporativechamber.
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123456567
EMISSION SYSTEM
F2–26
EGR VALVE INSPECTIONWL Turbo for Europe and UKAirflow Inspection
Note Perform the following test only when directed.
1. Remove the EGR valve.2. Inspect for airflow between 1 and 2 when vacuum
is applied using a vacuum pump as shown in thefigure.
Vacuum (kPa mmHg, inHg) Airflow
Below –21.3—–25.3–160— –190, –6.3— –7.4
Yes
Except above No
3. If not as specified, replace the EGR valve.
EGR SOLENOID VALVE INSPECTIONWL Turbo for Europe and UKAirflow Inspection
Note Perform the following test only when directed.
1. Disconnect the negative battery cable.2. Remove the EGR solenoid valve
(Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION, WL Turbo.)
3. Inspect for airflow between ports of the solenoidvalve.
: Continuity : Airflow
StepTerminal Port
StepA B A B C
1
2 B+ GND
B A
B+GND
AIR FILTER
A
B
C
4. If not as specified, replace the EGR solenoid valve.If the EGR solenoid valve is okay, but PCMterminal voltage is out of specification, inspect asfollows and repair or replace as necessary.
Vacuum hose improper routing, kinks or leakage.
Open circuit Power circuit (EGR solenoid valve connector
terminal A and PCM connector terminal 1R) GND circuit (EGR solenoid valve connector
terminal B and body GND through commonconnector)
HARNESS SIDE CONNECTOR(VIEW FROM TERMINAL SIDE)
A B
EGR SOLENOID VALVE
Short circuit EGR solenoid valve connector terminal A and PCM
connector terminal 1R.5. Repair or replace faulty areas.6. Install the EGR solenoid valve connector.
EGR PIPE, EGR VALVE REMOVAL/INSTALLATIONWL Turbo for Europe and UK
1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
7.9—10.7 N·m 80—110 kgf·cm,69.5—95.4 in·lbf
19—251.9—2.6, 14—18
19—251.9—2.6, 14—18
35—403.5—4.0,25—29
1 EGR pipe
2 EGR valve
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CONTROL SYSTEM
F2–27
CONTROL SYSTEMCOMPONENT PARTS
WL TURBO
WL TURBO
1 Glow indicator light
2 Temperature control dial
3 Engine switch
4 PCM
5 FICD solenoid valve No.2
6 FICD solenoid valve No.1
7 EGR solenoid valve*1
8 ECT sensor
9 DLC
10 A/C relay
11 TCV*2
12 Control lever position sensor*2
13 Glow plug
14 NE sensor
15 Idle switch*2
16 Starter
17 Glow plug relay
*1: WL Turbo for Europe and UK*2: Europe and UK
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CONTROL SYSTEM
F2–28
POWERTRAIN CONTROL MODULE (PCM)REMOVAL/INSTALLATION
1. Disconnect the battery negative cable.2. Remove the driver’s side front side trim.
(Refer to Section S, TRIM, FRONT SIDE TRIMREMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.4. Install in the reverse order of removal.
8.9—12.7 N·m 90—130 kgf·cm, 78—112 in·lbf
1 PCM connector
2 PCM installation nut
3 PCM
POWERTRAIN CONTROL MODULE (PCM)INSPECTION
Caution The PCM terminal voltages vary with
change in measuring conditions andvehicle conditions. Always carry out a totalinspection of the input systems, outputsystems, and PCM to determine the causeof trouble. Otherwise, a wrong diagnosiswill be made.
1. Remove the driver’s side front side trim. (Refer to Section S, TRIM, FRONT SIDE TRIMREMOVAL/INSTALLATION.)
2. Remove the PCM with the connector connected.(Refer to POWERTRAIN CONTROL MODULE(PCM) REMOVAL/INSTALLATION.)
Note With the PCM connector connected, body
ground the voltmeter negative (–) lead andmeasure the voltage at each PCM terminal byinserting the voltmeter positive (+) lead.
3. Measure the voltage of each PCM terminals byusing a voltmeter.
4. If the output voltage is not normal while each inputvoltage is normal, inspect the related devicesystems. When they are normal, replace the PCM.
5. Install the PCM. (Refer to POWERTRAIN CONTROL MODULE (PCM)REMOVAL/INSTALLATION.)
6. Install the driver’s side front side trim. (Refer to Section S, TRIM, FRONT SIDE TRIMREMOVAL/INSTALLATION.)
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CONTROL SYSTEM
F2–29
Terminal Voltage (Reference)
O M K I G E C ABDFHJLNP
O M K I G E C A
BDFHJLNPS Q
RT
Europe and UK Turkey and General (R.H.D. ,L.H.D.)
Termi-nal
Signal Connectedto
Test condition Voltage(V)
Action
A – – – – –
A*1 Constantvoltage
Controlleverposition
Engineswitch
ON Approx.5.0
Inspect related harness.
ositionsensor
EGRvalve
OFF Below1.0
Inspect PCM. Inspect related harness.
valvepositionsensor
Idle Approx.5.0
B Systemground
Ground Constant Below1.0
Inspect related harness.
C FICD control
FICD sole-noid valveNo.1
Idle ECT is below 20°C 68°F. Below1.0
Inspect FICD solenoidvalve No.1.
+ FUEL SYSTEM, FICDSOLENOID VALVE No 1
ECT is above 20°C 68°F. B+SOLENOID VALVE No.1,No.2 INSPECTION
Inspect related harness
D Start Engineswitch
Engine switch is on. Below1.0
Inspect related harness
(Starter) While cranking Approx.10
E ECT ECT sensor Engineswitch is on.
ECT is 20°C 68°F. Approx.3.1
Inspect engine coolanttemperature sensor.
+ ECT SENSORAfter warm-up Approx.
0.8
+ ECT SENSORINSPECTION
Inspect related harness
F Enginespeed
NE sensor Engine switch is on. Approx.0
Inspect NE sensor.+ NE SENSOR
(Input) Idle Approx.0.05
INSPECTION Inspect related harness
G A/C(With A/C)
Temperaturecontrol dial
Engineswitch is on.
Temperature control dial isoff and fan switch is off.
B+ Inspect microswitch.+ Section U, CONTROL
SYSTEM, HEATERCONTROL UNITINSPECTION
Temperature control dial isat position other than offand fan switch is on.
Below1.0
Inspect fan switch.+ Section U, CONTROL
SYSTEM, HEATERCONTROL UNITINSPECTION
Inspect related harness
H – – – – –
H*1 Idle (Controllever open
Idle switch Engineswitch is on.
Accelerator pedal is de-pressed.
B+ Inspect idle switch.+ IDLE SWITCH
or close) Accelerator pedal is re-leased.
Below1.0
INSPECTION Inspect related harness.
*1: Europe and UK
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CONTROL SYSTEM
F2–30
Termi-nal
Signal Connectedto
Test condition Voltage(V)
Action
I Glow plugvoltage
Glow plug ECT is be-low 60°C140°F.
For less than approx. 15seconds after turning engine switch on.
B+ Inspect related harness
Over approx. 15 secondsafter turning engine switchon.
Below1.0
For less than 10 minutesafter starting engine.
B+
Over 10 minutes afterstarting engine.
Below1.0
While cranking B+
ECT isabove 60°C140°F.
For less than approx. 2 seconds after turning en-gine switch on.
B+
Over approx. 2 secondsafter turning engine switchon.
Below1.0
While cranking B+
J Powersupply
Engineswitch
Engineswitch
OFF Below1.0
Inspect engine switch.+ Section T, POWER
SYSTEM, IGNITIONON B+
,SWITCH INSPECTION
Inspect related harness.
J*1 Control le-ver position(Detection)
Control le-ver positionsensor
Engineswitch is on.
Accelerator pedal is fullyopen.
Approx.4.2
Inspect control lever posi-tion sensor.
+ CONTROL LEVER( )Accelerator pedal is fullyclosed.
Approx.0.8—1.5
POSITION SENSORINSPECTION
Inspect related harness.
K Enginespeed (Out
Instrumentcluster
Engine switch is on. B+ Inspect related harness.speed (Out-put)
clusterIdle 6.9—7.1
L*1 Powersupply
Engineswitch
Engineswitch
OFF Below1.0
Inspect engine switch.+ Section T, POWER
SYSTEM, IGNITIONON B+
,SWITCH INSPECTION
Inspect related harness.
L*2 A/C control(With A/C)
A/C relay Engine switch is on. B+ Inspect A/C relay.S ti U CONTROL(With A/C)
Idle A/C is not operating B++ Section U, CONTROL
SYSTEM, A/C RELAYA/C is operating Below
1.0
SYSTEM, A/C RELAYINSPECTION
Inspect related harness.
M Glow indica-tor light con-
Glow indica-tor light
Engine switch is off. Below1.0
Inspect glow indicatorlightg
trolg
Engine switch is on and within approx. 4.5sec. (25 °C 77 °F).
g+ Section T, WARNING
AND INDICATORSYSTEM, WARNING
Over 4.5 seconds (25 °C 77 °F) afterturning engine switch on.
B+ AND INDICATOR LIGHTBULB REPLACEMENT
Inspect related harness.
N*1 A/C control(With A/C)
A/C relay Engine switch is on. B+ Inspect A/C relay.S ti U CONTROL(With A/C)
Idle A/C is not operating B++ Section U, CONTROL
SYSTEM, A/C RELAYA/C is operating Below
1.0
SYSTEM, A/C RELAYINSPECTION
Inspect related harness.
N*2 – – – – –*1: Europe and UK*2: Turkey and General (R.H.D., L.H.D.)
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CONTROL SYSTEM
F2–31
Termi-nal
Signal Connectedto
Test condition Voltage(V)
Action
O Glow sys-tem
Glow plugrelay
Engine cool-ant tempera-ture is below
For less than approx. 15seconds after turning en-gine switch on.
B+ Inspect glow plug relay.+ INTAKE-AIR SYSTEM,
GLOW PLUG RELAY60°C140°F.
Over approx. 15 secondsafter turning engine switchon.
Below1.0
INSPECTION Inspect related harness.
For less than 10 minutesafter starting engine.
B+
Over 10 minutes afterstarting engine.
Below1.0
While cranking B+
Engine cool-ant tempera-ture is
For less than approx. 2 se-conds after turning engineswitch on.
B+
above 60°C140°F.
Over approx. 2 secondsafter turning engine switchon.
Below1.0
While cranking B+
P FICD control
FICD sole-noid valveNo.2
Idle Temperature control dialis not at OFF
Engine coolant temper-ature is below 60°C140°F.
Below1.0
Inspect FICD solenoidvalve No.2.
+ FUEL SYSTEM, FICDSOLENOID VALVE No.1,No.2 INSPECTION
Temperature control dialis not at OFF
Engine coolant temper-ature is above 60°C140°F.
B+ Inspect related harness.
Q – – – – –
Q*1 Timer control
TCV Engine switch is on. B+ Inspect TCV.+ CONTROL SYSTEM,
Idle Below1.0
TIMER CONTROL VALVE(TCV) INSPECTION
Inspect related harness.
R – – – – –
R*3 EGR valvecontrol
EGRsolenoidvalve
Engine switch is on. B+ Inspect EGR solenoidvalve.
+ EMISSION SYSTEMvalveIdle Below
1.0
+ EMISSION SYSTEM,EGR SOLENOID VALVEINSPECTION
Inspect related harness.
S – – – – –
S*1 Diagnostictest mode
Data linkconnector
Engineswitch is on
Open terminal TEN B+ Inspect related harness.test mode connector
(DLC) (Ter-minal TEN)
switch is on.Short terminal TEN Below
1.0
T – – – – –
T*1 DTC output Data linkconnector(DLC) (Ter
No DTC output Below1.0
Inspect related harness.
(DLC) (Ter-minal FEN) DTC output 0—B+
*1: Europe and UK*2: Turkey and General (R.H.D., L.H.D.)*3: WL Turbo for Europe and UK
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CONTROL SYSTEM
F2–32
NE SENSOR INSPECTION
Note Perform the following test only when directed.
1. Disconnect the NE sensor connector.2. Measure the resistance between the NE sensor
connector terminals A and B by using anohmmeter.
A B
Specification800—920 Ω
3. If not as specified, replace the NE sensor.
Tightening torque7.9—10.7 N·m
80—110 kgf·cm, 69.5—95.4 in·lbf
4. If NE sensor is okay, but PCM terminal F voltage isout of specification, inspect the following:Open circuit Engine speed (input) circuit (NE sensor
connector terminal A and PCM connectorterminal F)
GND circuit (NE sensor connector terminal Band PCM connector terminal B)
Short circuit NE sensor connector terminal A and PCM
connector terminal F to GND5. Repair or replace faulty areas.6. Reconnect the NE sensor connector.
ENGINE COOLANT TEMPERATURE (ECT) SENSORINSPECTION
Note Perform the following test only when directed.
1. Drain the engine coolant from the radiator. (Refer to Section E, ENGINE COOLANT, ENGINECOOLANT REPLACEMENT.)
2. Disconnect the ECT sensor connector.3. Remove the ECT sensor.4. Place the sensor in water with a thermometer, and
heat the water gradually.
A B
5. Measure the resistance between engine coolanttemperature sensor terminals A and B by using anohmmeter.
SpecificationWater temperature ( °C °F) Resistance (k Ω)
20 68 2.27—2.73
80 176 0.29—0.34
6. If not as specified, replace the ECT sensor.7. Refill the radiator with the specified engine coolant.
(Refer to Section E, ENGINE COOLANT, ENGINECOOLANT REPLACEMENT.)
8. Install the ECT sensor.
Tightening torque16—23 N·m 1.6—2.4 kgf·m, 12—17 in·lbf
9. If ECT sensor is okay, but PCM terminal E voltageis out of specification, inspect as follows:
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CONTROL SYSTEM
F2–33
Open circuit Reference voltage circuit (ECT sensor
connector terminal A and PCM connectorterminal E through common connector)
GND circuit (ECT sensor connector terminal Band PCM connector terminal B throughcommon connector)
Short circuit ECT sensor connector terminal A and PCM
connector terminal E through commonconnector to GND
10. Repair or replace faulty areas.11. Reconnect the ECT sensor connector.
IDLE SWITCH INSPECTIONEurope and UKContinuity Inspection
Note Perform the following test only when directed.
1. Disconnect the negative battery cable.2. Disconnect the 8-pin connector of FIP.3. Inspect for continuity between the idle switch
terminal E and ground using an ohmmeter.
COMPONENT SIDE CONNECTOR(VIEW FROM TERMINAL SIDE)
E
H
GCA
FDB
Specification: Continuity
Measuring Terminalgcondition E GND
Not accelerated
Other
Caution Turning the idle switch with its connector
connected can break the harness. Be sureto disconnect the connector when turningthe idle switch more than one rotation.
4. If not as specified, loosen the idle switch locknutand adjust the continuity by turning the idle switch.
5. If not as specified, replace the idle switch. If theidle switch is okay, but PCM terminal voltage is outof specification, inspect as follows and repair orreplace as necessary.
Open circuit Power supply circuit (Idle switch connector terminal
E and PCM connector terminal 2H throughcommon connector)
GND circuit (Idle switch connector terminal andbody GND)
HARNESS SIDE CONNECTOR(VIEW FROM TERMINAL SIDE)
C
B
AEG
DFH
Short circuit Power supply circuit (Idle switch connector terminal
E and PCM connector terminal H through commonconnector to GND)
6. Repair or replace faulty areas.7. Reconnect the 8-pin connector of FIP.
CONTROL LEVER POSITION SENSORINSPECTIONEurope and UKOutput Voltage Inspection
Note Perform the following test only when directed.
1. Verify that the FIP control lever is fully closed.2. Turn the engine switch on and measure the PCM
terminal J voltage.
SpecificationMeasuring condition Voltage (V)
Accelerator pedal is fullyopen.
Approx. 4.2
Accelerator pedal is fullyclosed.
Approx. 0.8—1.5
3. If not as specified, replace the control leverposition sensor. When the reading is out ofspecification, send the FIP with the control leverposition sensor to a distributor to repair. If the PCMterminal voltage is out of specification, inspect asfollows and repair or replace as necessary.
Open circuit Constant voltage circuit (Control lever position
sensor connector terminal B and PCM connectorterminal A through common connector)
Control lever position signal circuit (Control leverposition sensor connector terminal A and PCMconnector terminal J through common connector)
GND circuit (Control lever position sensorconnector terminal C and PCM connector terminalB through common connector)
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CONTROL SYSTEM
F2–34
HARNESS SIDE CONNECTOR(VIEW FROM TERMINAL SIDE)
C
B
AEG
DFH
Short circuit Control lever position sensor connector terminal B
and PCM connector terminal A through commonconnector to GND
Control lever position sensor connector terminal Aand PCM connector terminal J through commonconnector to GND
4. Repair or replace faulty areas.5. Reconnect the 8-pin connector of FIP.
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ON-BOARD DIAGNOSTIC SYSTEM
F2–35
ON-BOARD DIAGNOSTIC SYSTEMEurope and UK onlyDTC READING PROCEDUREUsing the SST (Self-Diagnosis Checker)
1. Connect the SSTs to the DLC located in the enginecompartment and GND the black (negative) lead tothe body.
49 B019 9A0
49 H018 9A1A
DLC
2. Set the select switch on the SST (self-diagnosischecker) to A.
3. Turn the dial switch on the SST (system selector)to 1, and the test switch to SELF TEST.
4. Turn the engine switch on.5. Verify that the buzzer sounds for approximately
3 seconds and code “88” flashes for 5 seconds. IfDTC is not detected, “00” will then be indicated.
Note If the “88” does not flash, inspect +B terminal of
the data link connector, and the relatedharnesses and connectors.
If the “88” flashes and the buzzer sounds morethan 20 seconds, inspect the harness betweenthe PCM terminal and the DLC. If the harnessis normal, replace the PCM and inspect.
6. If any DTCs are indicated, inspect the appropriateareas and repair as necessary.
Note A DTC consists of four numbers. They are
flashed one by one in the right window on thedisplay. (“1” is always shown on the leftwindow.)
When there are multiple malfunctions, thecodes are displayed in numerical order.
7. After completion of repairs, erase all DTCs fromthe memory. (Refer to AFTER REPAIRPROCEDURE.)
8. Remove the SSTs.
Using the Voltmeter1. Turn the engine switch off.2. Connect the DLC located in the engine
compartment terminal TEN and GND using ajumper wire.
Caution Connecting the wrong DLC terminals may
possibly cause a malfunction. Carefullyconnect the specified terminals only.
3. Connect the negative battery lead of voltmeter(20V range) to the DLC terminal FEN, and thepositive lead to the DLC terminal +B.
FEN
TENGND+B
DLC
4. turn the engine switch on.5. The voltmeter indicates the battery positive voltage
for approximately 3 seconds, then indicates 0V.6. Read the DTCs indicated by the movement of the
voltmeter’s needle. If DTC is not detected, theneedle does not move.
7. If any DTCs are indicated, inspect the appropriateareas and repair as necessary.
8. After completion of repairs, erase all DTCs fromthe memory. (Refer to AFTER REPAIRPROCEDURE.)
9. Remove the voltmeter and the jumper wire.
AFTER REPAIR PROCEDURE1. After repairs, disconnect the negative battery cable
for at least 20 seconds, and depress the brakepedal. Reconnect the negative battery cable.
2. Warm up the engine to normal operatingtemperature.
Note If the engine will not start, keep the starter
operated for 5-6 seconds.
3. Perform the “DTC READING PROCEDURE”again.
4. Verify that the DTC is not detected.
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ON-BOARD DIAGNOSTIC SYSTEM
F2–36
DTC INSPECTIONDTC Table
DTC No. Indicator Pattern Condition
09Engine coolant temperature (ECT) sensormalfunction
12 Control lever position sensor malfunction
36 Glow plug relay malfunction
DTC 09 ENGINE COOLANT TEMPERATURE (ECT) SENSOR MALFUNCTION
DETECTIONCONDITION
Input value to PCM is excessively high or low for more than 2.0 sec.
POSSIBLECAUSE
ECT sensor malfunction Open or short circuit in wiring from ECT sensor terminal A to PCM terminal E Open or short circuit in wiring from ECT sensor terminal B to PCM terminal B
STEP INSPECTION ACTION
1 Does ECT sensor or PCM connector have Yes Repair or replace connector, then go to Step 6.poor connection? No Go to next step.
2 Disconnect ECT sensor connector. Yes Go to next step.Turn engine switch on. Is there 5 V atconnector terminal A?
No Inspect for open or short circuit in wiring harness. (PCMterminal B–ECT sensor terminal B)
3 Is there continuity between connector Yes Go to next step.terminal A and PCM terminal E? No Repair or replace wiring harness, then go to Step 6.
4 Is ECT sensor okay?+ CONTROL SYSTEM, ENGINE
Yes Go to next step.
COOLANT TEMPERATURE (ECT)SENSOR INSPECTION
No Replace ECT sensor, then go to Step 6.
5 Clear DTC from memory. Yes Go to Step 1.Is same code No. present after performing“After Repair Procedure”?
No Intermittent poor connection in harnesses or connector. Repair connectors and/or harnesses, then go to next step.
6 Clear DTC from memory.Is there any DTC present after performing
Yes Go to applicable DTC inspection.Is there any DTC present after performing“After Repair Procedure”? No Troubleshooting completed.
HARNESS SIDE CONNECTOR(VIEW FROM TERMINAL SIDE)
PCM (20 PIN)ECT SENSOR
A B
HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDE)
J BE
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ON-BOARD DIAGNOSTIC SYSTEM
F2–37
DTC 12 CONTROL LEVER POSITION SENSOR MALFUNCTION
DETECTIONCONDITION
Input voltage from control lever positIon sensor is below 0.1 V or above 4.75 V when continued for 1.0sec.
When idle switch is on, input voltage from control lever position sensor is below 0.35V or above 1.39V.
POSSIBLECAUSE
Control lever position sensor malfunction Idle switch malfunction Open circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal C to PCM termi-
nal B Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal A to
PCM terminal J Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal B to
PCM terminal A Open or short circuit wiring from idle switch (FIP connector: 8pin) terminal E to PCM terminal H
STEP INSPECTION ACTION
1 Does control lever position sensor connector Yes Repair or replace connectors, then go to Step 7.or PCM connector have poor connection? No Go to next step.
2 Disconnect control lever position sensor Yes Go to next step.connector. Turn engine switch on. Is there 5 V at connector terminal B?
No Inspect for open or short circuit in wiring harness. (PCMterminal A–control lever position sensor terminal B)
3 Is there continuity between connector Yes Go to next step.terminal A and PCM terminal J? No Repair or replace wiring harness, then go to Step 7.
4 Is there continuity between connector Yes Replace control lever position sensor, then go to Step 7.terminal C and PCM terminal B? No Repair or replace wiring harness, then go to Step 7.
5 Is there continuity between connector Yes Go to next step.terminal E and PCM terminal H? No Repair or replace wiring harness, then go to Step 7.
6 Is idle switch okay?+ CONTROL SYSTEM IDLE SWITCH
Yes Go to next step.+ CONTROL SYSTEM, IDLE SWITCH
INSPECTION No Replace idle switch.
7 Clear DTC from memory. Yes Go to Step 1.Is same code No. present after performing“After Repair Procedure”?
No Intermittent poor connection in harness or connector. Repair connector and/or harness, then go to next step.
8 Clear DTC from memory.Is there any DTC present after performing
Yes Go to applicable DTC inspection.Is there any DTC present after performing“After Repair Procedure”? No Troubleshooting completed.
HARNESS SIDE CONNECTOR(VIEW FROM TERMINAL SIDE)
HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDE)
PCM (20 PIN)CONTROL LEVER POSITION SENSOR
G E C A
H F D BJ
A
B
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ON-BOARD DIAGNOSTIC SYSTEM
F2–38
DTC 36 GLOW PLUG RELAY MALFUNCTION
DETECTIONCONDITION
When the glow plug relay is on, current voltage signal of the relay below 1.0 V is inputted to the PCMcontinuously for more than 1.0 sec.
When the glow plug relay is off, signal of the relay current voltage above 4.0 V is inputted to the PCMcontinuously for more than 1.0 sec.
POSSIBLECAUSE
Glow plug relay malfunction Open or short circuit in wiring from PCM terminal O to glow plug relay terminal A (BR) Open or short circuit in wiring from PCM terminal I to glow plug relay terminal A (B) Open or short circuit in wiring from glow plug relay terminal A (R) to glow fuse
STEP INSPECTION ACTION
1 Does glow plug relay connector or PCM Yes Repair or replace connectors, then go to Step 5.connector have poor connection? No Go to next step.
2 Remove glow plug relay.Is there continuity between connectorterminal A and PCM terminal O?
Yes Go to next step.
terminal A and PCM terminal O? Is there continuity between connectorterminal A (B) and PCM terminal I?
No Repair or replace wiring harness.
3 Is there continuity between connector Yes Go to next step.terminal B and body GND? No Repair or replace wiring harness.
4 Is there continuity between connector Yes Go to next step.terminal A (R) and glow fuse? No Repair or replace wiring harness.
5 Is glow plug relay okay?+ INTAKE AIR SYSTEM GLOW PLUG
Yes Go to next step.+ INTAKE-AIR SYSTEM, GLOW PLUG
RELAY INSPECTION No Replace glow plug relay.
6 Clear DTC from memory. Yes Go to Step 1.Is same code No. present after performing“After Repair Procedure”?
No Intermittent poor connection in harnesses or connectors. Repair connectors and/or harnesses, then go to next step.
7 Clear DTC from memory.Is there any DTC present after performing
Yes Go to applicable DTC inspection.Is there any DTC present after performing“After Repair Procedure”? No Troubleshooting completed.
PCM (20 PIN)
HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDE)
A A
A
B
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
GLOW PLUG RELAY
(WIRE COLOR: R)
(WIRE COLOR: B)
IO
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TROUBLESHOOTING
F2–39
TROUBLESHOOTINGFOREWORDBefore processing with the following troubleshooting,refer to section GI to understand the basictroubleshooting procedure.
TROUBLESHOOTING ITEM TABLE Confirm trouble symptom by using the following
diagnostic index, then go to appropriatetroubleshooting chart.
If a diagnostic trouble code is displayed, proceedwith inspection steps for the code.
No. TROUBLESHOOTING ITEMS DESCRIPTION
1 Melts main or other fuse —
2 Will not crank Starter does not work.
3 Hard start/long crank/erratic start/erratic crank Starter cranks engine at normal speed but engine requiresexcessive cranking. Battery is in normal condition.
4 Engine stalls After start Engine stops unexpectedly at idle and/or after start.
At idle
5 Cranks normally but will not start Starter cranks engine at normal speed but engine will notrun.Refer to “ENGINE STALLS” if this symptom appears afterengine stall. Fuel is in tank Battery is in normal condition.
6 Slow return to idle/fast idle Engine takes more time than normal to return to idle speed.Engine speed continues at fast idle after warm-up.
7 Engine runs rough/rolling idle Engine speed fluctuates between specified idle speed andlower speed and excessive engine shake.Idle speed is too slow and engine shakes excessively.
8 Runs on Engine runs after engine switch is turned off.
9 Engine stalls/quits Acceleration/cruise Engine stops unexpectedly at beginning of acceleration dur-ing acceleration or while cruising.
Engine runs rough Acceleration/cruise Engine speed fluctuates during acceleration or cruising.
Misses Acceleration/cruise Engine misses during acceleration or cruising.
Buck/jerk Acceleration/cruise/deceleration
Vehicle bucks/jerks during acceleration, cruising, or decel-eration.
Hesitation/stumble Acceleration Momentary pause at beginning of acceleration or during ac-celeration.
Surges Acceleration/cruise Momentary minor irregularity in engine output.
10 Lack/loss of power Acceleration/cruise Performance is poor under load (i.e. power down whenclimbing hills).
11 Poor fuel economy Fuel economy is unsatisfactory.
12 High oil consumption/leaks Oil consumption is excessive.
13 Cooling system concerns Overheating Engine runs at higher than normal temperature/overheats.
14 Cooling system concerns Runs cold Engine does not reach normal operating temperature.
15 Excessive black smoke Excessive black smoke is observed in exhaust gas.
16 Engine noise Engine noise from under hood.
17 Vibration concerns (engine) Vibration from under hood or driveline.
18 A/C does not work. A/C compressor magnetic clutch does not engage when A/Cis turned on.
19 A/C always on/A/C compressor runs continuously. A/C compressor magnetic clutch does not disengage.
20 Intermittent concerns Symptom occurs randomly and is difficult to diagnose.
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SYMPTOM TROUBLESHOOTING: Symptom 1-Melts main or other fuse F2-40 Symptom 2-Will not crank F2-41 Symptom 3-Hard start/long crank/erratic start/erratic crank F2-42-43 Symptom 4-Engine stalls-after start/at idle F2-43-44 Symptom 5-Cranks normally but will not start F2-45-46 Symptom 6-Slow return to idle/fast idle F2-46 Symptom 7-Engine runs rough/rolling idle F2-47-48 Symptom 8-Runs on F2-49 Symptom 9-Engie stalls/quits-acceleration/cruise
- Engine runs rough – acceleration/cruise - Misses-acceleration/cruise - Buck/jerk – acceleration/cruise/deceleration - Hesitation/stumble – acceleration
- Surges – acceleration/cruise F2-49-50 Symptom 10-Lack/loss of power-acceleration/cruise F2-51-52 Symptom 11-Poor fuel economy F2-53 Symptom 12-High oil consumption/leaks F2-54 Symptom 13-Cooling system concerns-overheating F2-55 Symptom 14-Cooling system concerns-runs cold F2-55 Symptom 15-Excessive black smoke F2-56 Symptom 16-Engine noise F2-56-58 Symptom 17-Vibration concerns (engine) F2-58 Symptom 18-A/C does not work F2-58-59 Symptom 19-A/C is always on/a/c compressor runs continuously F2-59-60 Symptom 20-Intermittent concerns F2-60
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RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
CONTINUED
TROUBLESHOOTING
F2–40
SYMPTOM TROUBLESHOOTINGSYMPTOM 1 MELTS MAIN OR OTHER FUSE
TROUBLESHOOTING HINTSInspect the condition of the fuse.
Shorted harnessDeterioration
Repair shorted harness and replace fuseRepair shorted harness and replace fusefuse Replace fuse
Damaged Fuse Related Wiring Harness
MAIN (100 A) Main fuse Engine switch Generator PCM
Blower relay Blower fan motor
A/C relay Refrigerant pressure switch
HEAD (30 A) HEAD fuse Generator
GLOW (60 A) Glow plug relay Glow plugs
ENGINE (15 A) Engine fuse PCM FICD solenoid valve No.1 FICD solenoid valve No.2 FCV
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TROUBLESHOOTING
F2–41
SYMPTOM 2 WILL NOT CRANK
DESCRIPTION Starter does not work.
POSSIBLECAUSE
Open starter circuit between battery and starter through engine switch Starter malfunction Seized/hydrolocked engine, flywheel
STEP INSPECTION RE-SULTS
ACTION
1 Verify the following: Battery condition Battery connection
Yes Go to next step.
Battery connection Fuses
Are all items okay?
No Service as necessary and repeat Step 1.
2 Turn engine switch to START. Yes Go to next step.Is clicking sound heard from starter? No Go to Step 6.
3 Do any other electrical accessories work? Yes Go to next step.
No Inspect the charging system.+ Section G, CHARGING SYSTEM
4 Disconnect battery negative cable.Disconnect engine switch and starter connec-tors.Inspect for electrical connections, loose wire,bent or corroded terminals. Inspect for continuity on following circuits:
Yes Go to next step.
Ins ect for continuity on following circuits: Engine switch connector terminal STA and
starter terminal S Battery positive cable and starter magnet
switch terminal B.Are all circuits okay?
No Repair or replace open circuit.
5 Inspect engine switch.+ Section T, POWER SYSTEM, IGNITION
Yes Go to next step.
SWITCH INSPECTION.Is engine switch okay?
No Replace engine switch.
6 Inspect starting system.Is starting system okay?
Yes Inspect for seized/hydrolocked engine, flywheel.+ Section H, CLUTCH, FLYWHEEL INSPECTION
No Service as required.+ Section G, STARTING SYSTEM, STARTER
INSPECTION
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TROUBLESHOOTING
F2–42
SYMPTOM 3 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK
DESCRIPTION Starter cranks engine at normal speed but engine requires excessive cranking.Battery is in normal condition.
POSSIBLECAUSE
Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating Glow system malfunction
Fuel leakage Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression pressure Fuel line clogging
STEP INSPECTION RE-SULTS
ACTION
1 Verify the following: Fuel quality including water contamination Loose bands on intake-air system
Yes Go to next step.
y Cracks on intake-air system parts Air cleaner element restriction
Are all items okay?
No Service as necessary and repeat Step 1.
2 Is engine overheating? Yes Go to flowchart No.13 for “COOLING SYSTEM CONCERNS OVERHEATING”.
No Go to next step.
3 Does engine start normally after warm-up? Yes Inspect glow system operation.+ SYSTEM INSPECTION, Glow System InspectionReplace any defective parts as necessary. If quick start system is okay, go to next step.
No Go to next step.
4 Is idle speed correct? Yes Go to next step.
No Adjust idle speed.+ ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT
5 Is there any restriction in exhaust system? Yes Repair or replace as necessary.
No Go to next step.
6 Inspect for fuel leakage from fuel pipe. Yes Repair or replace as necessary.Is any fuel leakage found in fuel pipe? No Go to next step.
7 Measure engine compression. Yes Go to Step 9.Is compression okay? No Go to next step.
8 Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks
Is timing belt okay?
Yes Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket. Damaged valve seat. Worn valve stem or valve guide.
Repair or replace as necessary.
No If tension or timing of timing belt is incorrect, adjusttiming belt.If timing belt is broken, damaged or cracked, replacethe timing belt.
9 Inspect injection timing. Yes Go to next step.Is injection timing okay? No Inspect TCV (if equipped).
+ TIMER CONTROL VALVE (TCV) INSPECTIONIf TCV is okay, adjust injection timing.+ ENGINE TUNE-UP, INJECTION TIMING
ADJUSTMENT
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TROUBLESHOOTING
F2–43
STEP INSPECTION RE-SULTS
ACTION
10 Remove and inspect injection nozzle as fol-lows: Clogged nozzle
Yes Remove FIP.Inspect FIP.If FIP okay, inspect fuel line for clogging.
Incorrect valve opening pressure Faulty nozzle gasket
Is injection nozzle okay?
No Clogged nozzle or seized needle valve:Disassemble and clean or replace the injection nozzle.Incorrect valve opening pressure:Adjust injection nozzle opening pressure.Faulty nozzle gasket:Replace nozzle gasket.
SYMPTOM 4 ENGINE STALLS – AFTER START/AT IDLE
DESCRIPTION Engine stops unexpectedly at idle and/or after start.
POSSIBLECAUSE
Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating A/C system improper operation Glow system malfunction
Fuel leakage Fuel filter clogging Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression FICD malfunction
STEP INSPECTION RE-SULTS
ACTION
1 Note: The following test should be performed
on vehicles with immobilizer system.Go to next step for vehicles withoutimmobilizer system
Yes Go to “ON-BOARD DIAGNOSTIC FUNCTION” of immobilizer system.
immobilizer system.
Does immobilizer indicator light flash and indicate?
No Go to next step.
2 Verify the following: Fuel quality including water contamination Loose bands on intake-air system
Yes Go to next step.
y Cracks on intake-air system parts Air cleaner element restriction
Are all items okay?
No Service as necessary and repeat Step 2.
3 Is engine overheating? Yes Go to flowchart No.13 for “COOLING SYSTEM CONCERNS-OVERHEATING”.
No Go to next step.
4 Does engine run normally after warm-up? Yes Go to next step.
No Go to Step 6
5 Inspect glow system operation, Yes Go to next step.+ SYSTEM INSPECTION, Glow System
Inspection.Is quick start system operation normal?
No Repair or replace any defective part according to glowsystem operation results.+ SYSTEM INSPECTION, Glow System Inspection
6 Note: If the following test cannot be
performed due to engine stalls, go tonext step
Yes Go to next step.
next ste .
Connect the pressure gauge to A/C lines.Turn the fan switch on.Is pressure within specification?+ section U, REFRIGERANT SYSTEM
SERVICE PROCEDURES,REFRIGERANT PRESSURE CHECK.
No If A/C is always on, go to symptom troubleshootingNo.19 “A/C always ON/A/C compressor runs continu-ously”. For other symptoms, inspect following: Refrigerant charging amount. Cooling fan operation.
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TROUBLESHOOTING
F2–44
STEP INSPECTION RE-SULTS
ACTION
7 Inspect FICD system operation. Yes Go to next step.+ SYSTEM INSPECTION, FICD System
InspectionIs FICD operation normal?
No Inspect the following: Engine coolant temperature sensor
+ CONTROL SYSTEM, ENGINE COOLANTTEMPERATURE SENSOR INSPECTION
Vacuum pump Vacuum leakage around vacuum pump or fittings FICD solenoid valves
+ FUEL SYSTEM, FICD SOLENOID VALVE No.1,No.2 INSPECTION
FICD actuator PCM terminal voltage, J Open circuit between FICD solenoid No.1 connector
terminal B and PCM connector terminal C Open circuit between FICD solenoid No.2 connector
terminal B and PCM connector terminal PRepair or replace any defective part as necessary.If FICD system is okay, go to next step.
8 Depress accelerator pedal slightly.Crank the engine.
Yes Inspect and adjust idle speed.+ ENGINE TUNE-UP, IDLE SPEED ADJUSTMENTIf symptom still appears, go to next step.
Does engine start now? No Go to next step.
9 Inspect fuel leakage from fuel pipe. Yes Repair or replace as necessary.Is any fuel leakage found in fuel pipe? No Go to next step.
10 Measure engine compression. Yes Go to Step 12.Is compression okay? No Go to next step.
11 Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks
Is timing belt okay?
Yes Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket. Damaged valve seat Worn valve seat or valve guide
Repair or replace as necessary.
No If tension or timing of timing belt is incorrect, adjusttiming.If timing belt is broken, damaged or cracked, replacetiming belt.
12 Inspect injection timing. Yes Go to next step.Is injection timing okay? No Adjust injection timing.
+ ENGINE TUNE-UP, INJECTION TIMINGADJUSTMENT
13 Inspect fuel filter for clogging. Yes Go to next step.Is fuel filter okay? No Replace fuel filter cartridge.
14 Remove injection nozzle. Yes Go to next step.Inspect injection nozzle for the following: Clogged nozzle Seized needle valve Incorrect valve opening pressure Faulty nozzle gasket
Is injection nozzle okay?
No Clogged nozzle or seized needle valve:Disassemble and clean or replace the injection nozzle.Incorrect valve opening pressure:Adjust injection nozzle opening pressure.Faulty nozzle gasket:Replace nozzle gasket.
15 Is valve clearance correct? Yes Remove FIP.Inspect FIP.
No Adjust valve clearance.
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TROUBLESHOOTING
F2–45
SYMPTOM 5 CRANKS NORMALLY BUT WILL NOT START
DESCRIPTION Starter cranks engine at normal speed but engine will not run. Refer to “ENGINE STALLS” if this symptom appears after engine stall. Fuel is in tank. Battery is in normal condition.
POSSIBLECAUSE
Poor fuel quality Air cleaner restriction FCV malfunction Low engine compression Fuel leakage
Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction
STEP INSPECTION RE-SULTS
ACTION
1 Note: The following test should be performed
on vehicles with immobilizer system.Go to next step for vehicles withoutimmobilizer system
Yes Go to “ON-BOARD DIAGNOSTIC FUNCTION” of immobilizer system.
immobilizer system.
Does immobilizer indicator light flash and indicate?
No Go to next step.
2 Verify the following: Fuel quality including water contamination Loose bands on intake-air system
Yes Go to next step.
Cracks on intake-air system parts Air cleaner element restriction Fuses
Are all items okay?
No Service as necessary.Repeat Step 2.
3 Turn engine switch to ON. Yes Go to next step.Is FCV operation sound heard? No Inspect for the following:
Stuck FCV Open circuit in FCV Open wiring harness between engine switch and
FCV. Poor ground of FCV.
4 Measure engine compression. Yes Go to step 6.Is compression okay? No Go to next step.
5 Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks
Is timing belt okay?
Yes Inspect for the following: Burnt valve Worn piston, piston ring or cylinder Damaged cylinder head gasket. Damaged valve seat Worn valve stem or valve guide
Repair or replace as necessary.No If tension or timing of timing belt is incorrect, adjust
timing.If timing belt is broken, damaged or cracked, replacetiming belt.
6 Inspect injection timing. Yes Go to next step.Is injection timing okay? No Adjust injection timing.
+ ENGINE TUNE-UP, INJECTION TIMINGADJUSTMENT
7 Inspect fuel filter for clogging. Yes Go to next step.Is fuel filter okay? No Replace fuel filter cartridge.
8 Remove injection nozzle. Yes Go to next step.Inspect injection nozzle for the following: Clogged nozzle Seized needle valve Incorrect valve opening pressure Faulty nozzle gasket
Is injection nozzle okay?
No Clogged nozzle or seized needle valve:Disassemble and clean or replace the injection nozzle.Incorrect valve opening pressure:Adjust injection nozzle opening pressure.Faulty nozzle gasket:Replace nozzle gasket.
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TROUBLESHOOTING
F2–46
STEP INSPECTION RE-SULTS
ACTION
9 Is valve clearance correct? Yes Remove FIP.Inspect FIP.
No Adjust valve clearance.
SYMPTOM 6 SLOW RETURN TO IDLE/FAST IDLE
DESCRIPTION Engine takes more time than normal to return to idle speed.Engine speed continues at fast idle after warm-up.
POSSIBLECAUSE
Malfunction of ECT sensor Thermostat stuck open FICD malfunction
Injection timing is incorrect. Accelerator cable free play incorrect adjustment Idle speed incorrect adjustment
STEP INSPECTION RE-SULTS
ACTION
1 Inspect FICD system operation. Yes Go to next step.+ SYSTEM INSPECTION, FICD System
Inspection.Is FICD operation normal?
No Inspect the following: ECT sensor
+ CONTROL SYSTEM, ENGINE COOLANTTEMPERATURE (ECT) SENSOR INSPECTION
FICD solenoid valves+ FUEL SYSTEM, FICD SOLENOID VALVE No.1,
No.2 INSPECTION FICD actuators. PCM terminal voltage (J)
+ CONTROL SYSTEM, PCM INSPECTION Short to ground circuit between FICD solenoid valve
No.1 connector terminal B and PCM connector ter-minal C.
Short to ground circuit between FICD solenoid valveNo.2 connector terminal B and PCM connector ter-minal P
Repair or replace any defective part as necessary.If FICD system is okay, go to next step.
2 Inspect injection timing. Yes Go to next step.+ ENGINE TUNE-UP, INJECTION TIMING
ADJUSTMENT.Is injection timing okay?
No Adjust injection timing.+ ENGINE TUNE-UP, INJECTION TIMING
ADJUSTMENT
3 Remove thermostat and inspect operation.+ section E, THERMOSTAT, THERMOSTAT
INSPECTION.
Is thermostat okay?
Yes Inspect for free play of accelerator cable. Adjust freeplay as necessary. If free play is okay, inspect and adjust idle and/or idle-up speed.+ ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT
No Replace thermostat.
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TROUBLESHOOTING
F2–47
SYMPTOM 7 ENGINE RUNS ROUGH/ROLLING IDLE
DESCRIPTION Engine speed fluctuates between specified idle speed and lower speed and excessive engineshake.Idle speed is too slow and engine shakes excessively.
POSSIBLECAUSE
Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating A/C system improper operation Glow system malfunction
Fuel leakage Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression FICD malfunction
STEP INSPECTION RE-SULTS
ACTION
1 Verify the following: Fuel quality including water contamination
Yes Go to next step. Fuel quality including water contamination Air cleaner element restriction No Service as necessary and repeat Step 1.
2 Is engine overheating? Yes Go to flowchart No.13 for “COOLING SYSTEM CON-CERNS-OVERHEATING”.
No Go to next step.
3 Does engine run normally after warm-up? Yes Go to next step.
No Go to Step 5.
4 Inspect glow system operation.+ SYSTEM INSPECTION Glow System
Yes Go to Step 6.+ SYSTEM INSPECTION, Glow System
Inspection.
Is glow system operation normal?
No Repair or replace any defective part according to glowsystem operation results.+ SYSTEM INSPECTION, Glow System Inspection
5 Note: If the following test cannot be
performed due to engine stalls, go tonext step
Yes Go to next step.
next ste .
Connect the pressure gauge to A/C (ifequipped) lines. Turn the blower switch on.Is the pressure within specification?+ section U, REFRIGERANT SYSTEM
SERVICE PROCEDURES,REFRIGERANT PRESSURE CHECK.
No If A/C is always on, go to symptom troubleshootingNo.19 “A/C always ON/ A/C compressor runs continu-ously”. For other symptoms, inspect following: Refrigerant charging amount. Cooling fan operation.
6 Inspect for FICD system operation. Yes Go to next step.+ SYSTEM INSPECTION, FICD System In-
spectionIs FICD operation normal?
No Inspect the following: Engine coolant temperature sensor
+ CONTROL SYSTEM, ECT SENSOR INSPECTION Vacuum pump Vacuum leaks around vacuum pump or fittings FICD solenoid valves
+ FUEL SYSTEM, FICD SOLENOID VALVE No.1,No.2 INSPECTIONInspection
FICD actuators PCM terminal voltage (J)
+ CONTROL SYSTEM, PCM INSPECTION Open circuit between FICD solenoid valve No.1 con-
nector terminal B and PCM connector terminal C. Open circuit between FICD solenoid valve No.2 con-
nector terminal B and PCM connector terminal P.Repair or replace any defective part as necessary.If FICD system is okay, go to next step.
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TROUBLESHOOTING
F2–48
STEP INSPECTION RE-SULTS
ACTION
7 Depress accelerator pedal slightly.Crank the engine.
Yes Inspect and adjust idle speed.+ ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.If symptom still appears, go to next step.
Does engine start now? No Go to next step.
8 Inspect fuel leakage from fuel pipe. Yes Repair or replace as necessary.Is any fuel leakage found on fuel pipe? No Go to next step.
9 Note: The following test should be performed
on vehicles with EGR system. Go tonext step for vehicles without EGRsystem.
Yes Go to next step.
Carry out EGR system inspection.+ SYSTEM INSPECTION, EGR System
InspectionIs EGR system okay?
No Repair or replace as necessary.
10 Measure engine compression. Yes Go to Step12.Is compression okay? No Go to next step.
11 Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks
Is timing belt okay?
Yes Inspect follows: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket Damaged valve seat Worn valve stem or valve guide
Repair or replace as necessary.
No If tension or timing of timing belt is incorrect, adjusttiming belt.If timing belt is broken, damaged or cracked, replacetiming belt.
12 Inspect injection timing. Yes Go to next step.Is injection timing okay? No Inspect TCV (if equipped).
+ TIMER CONTROL VALVE (TCV) INSPECTIONIf TCV is okay, adjust injection timing.+ ENGINE TUNE-UP, INJECTION TIMING
ADJUSTMENT
13 Inspect fuel filter for clogging. Yes Go to next step.Is fuel filter okay? No Replace fuel filter cartridge.
14 Remove injection nozzle. Yes Go to next step.Inspect injection nozzle for the following: Clogged nozzle Seized needle valve Incorrect valve opening pressure Faulty nozzle gasket
Is injection nozzle okay?
No Clogged nozzle or seized needle valve:Disassemble and clean or replace the fuel injectionnozzle.Incorrect valve opening pressure:Adjust fuel injection nozzle opening pressure.Faulty nozzle gasket:Replace nozzle gasket.
15 Is valve clearance correct? Yes Remove fuel injection pump.Inspect fuel injection pump.
No Adjust valve clearance.
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TROUBLESHOOTING
F2–49
SYMPTOM 8 RUNS ON
DESCRIPTION Engine runs after engine switch is turned off.
POSSIBLECAUSE
FCV malfunction
STEP INSPECTION RE-SULTS
ACTION
1 Run the engine at idle speed.Disconnect the FCV connector.Verify that the engine stops.Does the engine stop?
Yes Inspect for the following: Short to power line between engine switch and
FCV.Repair or replace wire harness.
No Inspect for FCV stuck to open.
SYMPTOM 9
ENGINE STALLS/QUITS-ACCELERATION/CRUISEENGINE RUNS ROUGH-ACCELERATION/CRUISEMISSES-ACCELERATION/ CRUISEBUCK/JERK-ACCELERATION/CRUISE/DECELERATIONHESITATION/STUMBLE-ACCELERATIONSURGES-ACCELERATION/CRUISE
DESCRIPTION Engine stops unexpectedly at beginning of acceleration, during acceleration or while cruis-ing.
Engine speed fluctuates during acceleration or cruising. Engine misses during acceleration or cruising. Vehicle bucks/jerks during acceleration, cruising, or deceleration. Momentary pause at beginning of acceleration or during acceleration. Momentary minor irregularity in engine output.
POSSIBLECAUSE
Poor fuel quality Starting system malfunction Air leaks from intake-air system Air cleaner restriction Engine overheating A/C system improper operation Fuel leakage
Glow system malfunction Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression Clutch slippage
STEP INSPECTION RE-SULTS
ACTION
1 Is idle speed stable? Yes Go to next step.
No Go to flowchart No.7 “ENGINE RUNS ROUGH/ROL-LING IDLE”.
2 Is engine overheating? Yes Go to flowchart No.13 “COOLING SYSTEM CON-CERNS OVERHEATING”.
No Go to next step.
3 Does symptom disappear after warm-up? Yes Go to next step.
No Go to Step 5.
4 Inspect for glow system operation. Yes Go to next step.+ SYSTEM INSPECTION, Glow System
Inspection.Is glow system operation normal?
No Repair or replace any defective part according to glowsystem operation results.+ SYSTEM INSPECTION, Glow System Inspection
5 Connect the pressure gauge to A/C lines. Yes Go to next step.Turn the blower switch on.Is the pressure within specifications?+ section U, REFRIGERANT SYSTEM
SERVICE PROCEDURES,REFRIGERANT PRESSURE CHECK.
No If A/C is always on, go to symptom troubleshootingNo.19 “A/C ALWAYS ON/ A/C COMPRESSOR RUNSCONTINUOUSLY”. For other symptoms, inspect fol-lowing: Refrigerant charging amount. Cooling fan operation.
6 Inspect air cleaner for clogging. Yes Go to next step.Is air cleaner okay? No Clean or replace air cleaner element.
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TROUBLESHOOTING
F2–50
STEP INSPECTION RE-SULTS
ACTION
7 Note: The following test should be performed
on turbocharger equipped model. Forother models, go to Step 9.
Inspect the hose band between the followingparts:
T b h h i d i
Yes Retighten the hose band.If the concern is resolved, complete the inspection.If the concern still exists, go to next step.
Turbocharger compressor housing and aircleaner
Turbocharger compressor housing andcharge air cooler.
Is the hose band loose?
No Go to next step.
8 Inspect for improper operation, kinks, clogs,or disconnection on the wastegate actuator.
Yes Turbocharger is okay. Go to next step.
+ INTAKE-AIR SYSTEM, WASTEGATEACTUATOR INSPECTION.
Is actuator okay?
No Repair or replace as necessary.If the concern is resolved, complete the inspection.If the concern still exists, the turbocharger is okay. Go to next step.
9 Remove injection nozzle. Yes Go to next step.Inspect injection nozzle for the following Clogged nozzle. Seized needle valve Incorrect valve opening pressure. Faulty nozzle gasket.
Is injection nozzle okay?
No Clogged nozzle or seized needle valve:Disassemble and clean or replace the injection nozzle.Incorrect valve opening pressure:Adjust injection nozzle opening pressure.Faulty nozzle gasket:Replace nozzle gasket.
10 Is there any restriction in exhaust system? Yes Repair or replace as necessary.
No Go to next step.
11 Inspect for fuel leakage from pipe. Yes Repair or replace as necessary.Is any fuel leakage found in fuel pipe? No Go to next step.
12 Inspect fuel filter for clogs. Yes Go to next step.Is fuel filter okay? No Replace fuel filter cartridge.
13 Measure engine compression. Yes Go to Step 15.Is compression okay? No Go to next step.
14 Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks
Is timing belt okay?
Yes Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket Damaged valve seat Worn valve stem and valve guide
Repair or replace as necessary.
No If tension or timing of timing belt is incorrect, adjusttiming belt. If timing belt is broken, damaged or cracked, replacetiming belt.
15 Inspect injection timing.Is injection timing okay?
Yes Inspect follows: Clutch slippage FIP
No Adjust injection timing.+ ENGINE TUNE-UP, INJECTION TIMING
ADJUSTMENT
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TROUBLESHOOTING
F2–51
SYMPTOM 10 LACK/LOSS OF POWER-ACCELERATION/CRUISE
DESCRIPTION Performance is poor under load (i.e. power down when climbing hills).
POSSIBLECAUSE
Poor fuel quality Starting system malfunction Air leaks from intake-air system Air cleaner restriction Engine overheating A/C system improper operation Clutch slippage Fuel leakage
Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression pressure Turbocharger malfunction Brake system drags EGR system malfunction (WL Turbo)
STEP INSPECTION RE-SULTS
ACTION
1 Is idle speed stable? Yes Go to next step.
No Go to flowchart No.7 “ENGINE RUNSROUGH/ROLLING IDLE”.
2 Is engine overheating? Yes Go to flowchart No. 13 “COOLING CONCERNSOVERHEATING”.
No Go to next step.
3 Connect the pressure gauge to A/C lines. Yes Go to next step.Turn the fan switch on.Is the pressure within specification?+ section U, REFRIGERANT SYSTEM
SERVICE PROCEDURES,REFRIGERANT PRESSURE CHECK.
No If A/C is always on, go to symptom troubleshooting No.19“A/C ALWAYS ON/ A/C COMPRESSOR RUNSCONTINUOUSLY”. For other symptoms, inspect thefollowing: Refrigerant charging amount. Cooling fan operation.
4 Inspect air cleaner for clogging. Yes Go to next step.Is air cleaner okay? No Clean or replace air cleaner element.
5 Note: The following test should be performed
on turbocharger equipped model. Forother models, go to Step 13.
Inspect the hose band between the followingparts:
T b h h i d i
Yes Retighten the hose band.If the concern is resolved, complete the inspection.If the concern still exists, go to next step.
Turbocharger compressor housing and aircleaner
Turbocharger compressor housing andcharge air cooler.
Is the hose band loose?
No Go to next step.
6 Inspect the wastegate actuator for improper Yes Go to next step.operation, kinks, clogs, or disconnection.+ INTAKE-AIR SYSTEM, WASTEGATE
ACTUATOR INSPECTION.Is actuator okay?
No Repair or replace as necessary.If the concern is resolved, complete the inspection.If the concern still exists, the turbocharger is okay. Go tonext step.
7 Remove the parts necessary to inspect theturbocharger. Do not remove the turbocharger.Inspect if the turbocharger primary compressorwheel is bent, damaged, or interfering with the
Yes Replace the turbocharger.
, g , ghousing on the vehicle.+ INTAKE-AIR SYSTEM, TURBOCHARGER
INSPECTION.Is there any problem?
No Go to next step.
8 Inspect if the turbocharger compressor wheellocknut is loose or has fallen down inside
Yes Replace the turbocharger.
turbocharger.Is there any problem?
No Go to next step.
9 Turn the turbocharger compressor wheel byhand
Yes Go to next step.hand.Does the wheel turn easily and smoothly? No Replace the turbocharger.
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CONTINUED
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
TROUBLESHOOTING
F2–52
STEP INSPECTION RE-SULTS
ACTION
10 Inspect if the turbocharger turbine wheel isdamaged, cracked, or interfering with thehousing on the vehicles.
Yes Replace the turbocharger.
Note: Inspect all fins on each turbine wheel.
Is there any problem?
No Go to next step.
11 Is any engine oil found inside the turbochargerturbine housing?
Yes If an excessive amount of oil is found on the vehicle,replace the turbocharger.If a small amount of oil is found, wipe the oil off thevehicle. Then, go to next step.
No Go to next step.
12 Is any engine oil found inside the turbochargercompressor housing?
Yes Wipe the oil off the vehicle and install all removed partsin Step 7. Then, go to next step.
No The turbocharger is okay. Install all removed parts inStep 7. Then, go to next step.
13 Remove injection nozzle. Yes Go to next step.Inspect injection nozzle for the following: Clogged nozzle. Seized needle valve Incorrect valve opening pressure. Faulty nozzle gasket.
Is injection nozzle okay?
No Clogged nozzle or seized needle valve:Disassemble and clean or replace the injection nozzle.Incorrect valve opening pressure:Adjust injection nozzle opening pressure.Faulty nozzle gasket:Replace nozzle gasket.
14 Is there any restriction in exhaust system? Yes Repair or replace as necessary.
No Go to next step.
15 Inspect fuel leakage from pipe. Yes Repair or replace as necessary.Is any fuel leakage found on fuel pipe? No Go to next step.
16 Inspect fuel filter for clogging. Yes Go to next step.Is fuel filter okay? No Replace fuel filter cartridge.
17 Note: The following test should be performed
on vehicles with EGR system. Go to nextstep for vehicles without EGR system.
Yes Go to next step.
Carry out EGR system inspection.+ SYSTEM INSPECTION, EGR System
InspectionIs EGR system okay?
No Repair or replace as necessary.
18 Measure engine compression. Yes Go to Step 20.Is compression okay? No Go to next step.
19 Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks
Is timing belt okay?
Yes Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket Damaged valve seat Worn valve stem and valve guide
Repair or replace as necessary.
No If tension or timing of timing belt is incorrect, adjust timing.If timing belt is broken, damaged or cracked, replace timingbelt.
20 Inspect injection timing.Is injection timing okay?
Yes Inspect follows: Brake system dragging Clutch slippage FIP
No Inspect TCV (if equipped).+ TIMER CONTROL VALVE (TCV) INSPECTIONIf TCV is okay, adjust injection timing.+ ENGINE TUNE-UP, INJECTION TIMING
ADJUSTMENT
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TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
TROUBLESHOOTING
F2–53
SYMPTOM 11 POOR FUEL ECONOMYDESCRIPTION Fuel economy is unsatisfactory.
POSSIBLECAUSE
Idle speed or idle-up speedincorrect adjustment
Accelerator cable free playincorrect adjustment
Air cleaner restriction Engine cooling system malfunction Improper transmission fluid level Poor fuel quality Improper coolant level Improper engine compression
Exhaust system clogged Injection timing incorrect Injection nozzle malfunction FIP malfunction High idle speed High idle-up speed FICD malfunction Fuel leakage Brake dragging EGR system malfunction (WL Turbo)
STEP INSPECTION RE-SULTS
ACTION
1 Inspect the following: Fuel quality including water contamination Air cleaner element for restriction
Yes Go to next step.
Transmission fluid level Coolant level
Are all items okay?
No Service as necessary and repeat Step 1.
2 Inspect for idle speed and idle-up speed.+ ENGINE TUNE-UP IDLE-UP SPEED
Yes Go to next step.+ ENGINE TUNE-UP, IDLE-UP SPEED
ADJUSTMENT.Is idle-up speed within specifications?
No Go to flowchart No.6 “SLOW RETURN TO IDLE/FAST IDLE”.
3 Inspect fuel leakage from pipe.f f f ?
Yes Repair or replace as necessary.Is any fuel leakage found in fuel pipe? No Go to next step.
4 Remove injection nozzle. Yes Go to next step.Inspect injection nozzle for the following: Clogged nozzle. Seized needle valve Incorrect valve opening pressure. Faulty nozzle gasket.
Is injection nozzle okay?
No Clogged nozzle or seized needle valve:Disassemble and clean or replace the injection nozzle.Incorrect valve opening pressure:Adjust injection nozzle opening pressure.Faulty nozzle gasket:Replace nozzle gasket.
5 Is there restriction in exhaust system? Yes Inspect exhaust system.
No Go to next step.
6 Is brake system functioning properly? Yes Go to next step.
No Inspect for cause.
7 Note: The following test should be performed
on vehicles with EGR system. Go to nextstep for vehicles without EGR system.
Yes Go to next step.
Carry out EGR system inspection.+ SYSTEM INSPECTION, EGR System
InspectionIs EGR system okay?
No Repair or replace as necessary.
8 Measure engine compression.?
Yes Go to Step 10.Is compression okay? No Go to next step.
9 Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks
Is timing belt okay?
Yes Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket Damaged valve seat Worn valve stem and valve guide
Repair or replace as necessary.
No If tension or timing of timing belt is incorrect, adjusttiming belt . If timing belt is broken, damaged or cracked, replacetiming belt.
10 Inspect injection timing.Is injection timing okay?
Yes Inspect for the following: FIP
No Adjust injection timing.+ ENGINE TUNE-UP, INJECTION TIMING
ADJUSTMENT
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TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
TROUBLESHOOTING
F2–54
SYMPTOM 12 HIGH OIL CONSUMPTION/LEAKS
DESCRIPTION Oil consumption is excessive.
POSSIBLECAUSE
Improper engine oil level Improper dipstick Improper engine oil viscosity
Engine internal part malfunction Oil leak Turbocharger malfunction
STEP INSPECTION RE-SULTS
ACTION
1 Inspect the following: Proper dipstick Proper engine viscosity
Yes Go to next step.
Pro er engine viscosity Engine oil level
Are all items okay?
No Service as necessary and repeat Step 1.
2 Note: The following test should be performed
on turbocharger equipped model. Forother models, go to Step 10.
Remove the parts necessary to inspect theturbocharger. Do not remove the turbochar-
Yes Replace the turbocharger.
ger.Inspect if the turbocharger primary compres-sor wheel is bent, damaged, or interfering withthe housing on the vehicle.+ INTAKE-AIR SYSTEM, TURBOCHARGER
INSPECTIONIs there any problem?
No Go to next step.
3 Inspect if the turbocharger compressor wheellocknut is loose or has fallen down inside
Yes Replace the turbocharger.
turbocharger.Is there any problem?
No Go to next step.
4 Turn the turbocharger compressor wheel byhand
Yes Go to next step.hand.Does the wheel turn easily and smoothly? No Replace the turbocharger.
5 Inspect if the turbocharger turbine wheel isdamaged, cracked, or interfering with thehousing on the vehicles.
Yes Replace the turbocharger.
Note: Inspect all fins on each turbine wheel.
Is there any problem?
No Go to next step.
6 Is any engine oil found inside the turbochargerturbine housing?
Yes If an excessive amount of oil is found on the vehicle,replace the turbocharger.If a small amount of oil is found, wipe the oil off thevehicle. Then, go to next step.
No Go to next step.
7 Is any engine oil found inside the turbocharger Yes Wipe the oil off the vehicle. Then, go to next step.compressor housing? No Go to next step.
8 Is any engine oil found around oil pipes at-tached on the turbocharger center housing?
Yes If the oil leaked from the damaged pipe, replace the oilpipe. Then, go to next step.
No Go to next step.
9 Is any engine oil found inside the air intake Yes Wipe the engine oil off.pipes or Hoses? No The turbocharger is okay. Install all parts removed in
step 2. Then, go to next step.
10 Measure engine compression. Yes Inspect oil leakage from outside of engine.Is compression okay? No Inspect for the following:
Damaged valve seat. Worn valve stem and valve guide. Worn or stuck piston ring. Worn piston, piston ring, or cylinder.
Service as necessary.
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TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
TROUBLESHOOTING
F2–55
SYMPTOM 13 COOLING SYSTEM CONCERNS—OVERHEATING
DESCRIPTION Engine runs at higher than normal temperature/overheats.
POSSIBLECAUSE
Cooling fan malfunction Low drive belt tension Drive belt damage Improper coolant level Thermostat malfunction Radiator clogging A/C system malfunction
Water temperature gauge or sender unit malfunc-tion
Improper or damaged radiator cap Radiator hose damage Coolant leakage (engine internal, turbocharger, ex-
ternal)
STEP INSPECTION RE-SULTS
ACTION
1 Inspect the following: Engine coolant level Coolant leakage Radiator condition Collapsed or restricted radiator hoses
Yes Go to next step.
Collapsed or restricted radiator hoses Radiator pressure cap Drive belt tension Drive belt
Are all items okay?
No Service as necessary and repeat Step 1.
2 Connect the pressure gauge to A/C lines. Yes Go to next step.Turn the blower switch on.Is the pressure within specification?+ section U, REFRIGERANT SYSTEM
SERVICE PROCEDURES,REFRIGERANT PRESSURE CHECK.
No If A/C is always on, go to symptom troubleshootingNo.19 “A/C ALWAYS ON/ A/C COMPRESSOR RUNSCONTINUOUSLY”. For other symptoms, inspect thefollowing: Refrigerant charging amount Cooling fan operation
3 Inspect water temperature sender unit.Is water temperature sender unit okay?
Yes Inspect thermostat.+ section E, THERMOSTAT, THERMOSTAT
INSPECTION
No Replace water temperature sender unit.
SYMPTOM 14 COOLING SYSTEM CONCERNS—RUNS COLD
DESCRIPTION Engine does not reach normal operating temperature.
POSSIBLECAUSE
Thermostat malfunction
STEP INSPECTION RE-SULTS
ACTION
1 Remove the thermostat from vehicle.Inspect thermostat.+ section E, THERMOSTAT, THERMOSTAT
INSPECTION
Yes Inspect water temperature sender unit operation.+ section T, INSTRUMENT CLUSTER, WATER TEM-
PERATURE SENDER UNIT INSPECTIONINSPECTION.
Is thermostat okay? No Replace thermostat.
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TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
TROUBLESHOOTING
F2–56
SYMPTOM 15 EXCESSIVE BLACK SMOKE
DESCRIPTION Excessive black smoke is observed in exhaust gas.
POSSIBLECAUSE
Air cleaner element restriction Incorrect fuel injection timing Injection nozzle malfunction
FIP malfunction Low engine compression EGR system malfunction (WL Turbo)
STEP INSPECTION RE-SULTS
ACTION
1 Does any other symptom exist? Yes Go to appropriate flow chart.
No Go to next step.
2 Inspect air cleaner element for clogging. Yes Go to next step.Is air cleaner element okay? No Repair or replace air cleaner element.
3 Inspect injection timing. Yes Go to next step.Is injection timing okay? No Inspect TCV (if equipped).
+ FUEL SYSTEM, TIMER CONTROL VALVE (TCV)INSPECTION
If TCV is okay, adjust injection timing.+ ENGINE TUNE-UP, INJECTION TIMING
ADJUSTMENT4 Remove injection nozzle. Yes Go to next step.
Inspect injection nozzle for the following: Clogged nozzle. Seized needle valve Incorrect valve opening pressure Faulty nozzle gasket
Is injection nozzle okay?
No Clogged nozzle or seized needle valve:Disassemble and clean or replace the injection nozzle.Incorrect valve opening pressure:Adjust injection nozzle opening pressure.Faulty nozzle gasket:Replace nozzle gasket.
5 Note: The following test should be performed
on vehicles with EGR system. Go tonext step for vehicles without EGRsystem.
Yes Go to next step.
Carry out EGR system inspection.+ SYSTEM INSPECTION, EGR System
InspectionIs EGR system okay?
No Repair or replace as necessary.
6 Measure engine compression. Yes Inspect fuel injection pump.Is compression okay? No Inspect for the following:
Damaged valve seat. Worn valve stem and valve guide. Worn or stuck piston ring. Worn piston, piston ring, or cylinder.
Service as necessary.
SYMPTOM 16 ENGINE NOISE
DESCRIPTION Engine noise from under hood.
POSSIBLECAUSE
Engine internal damage Timing belt displacement Injection nozzle malfunction Loose attaching bolts or worn
parts
Improper drive belt tension Air leaks from intake-air system Turbocharger operating noise EGR system malfunction (WL Turbo)
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TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
TROUBLESHOOTING
F2–57
STEP INSPECTION RE-SULTS
ACTION
1 Note: The following test should be performed
on turbocharger equipped model. Forother models, go to Step 9.
Remove the necessary parts to inspect the
Yes Replace the turbocharger.
Remove the necessary arts to ins ect theturbocharger.Inspect if the turbocharger compressor wheelis bent, damaged, or interfering with the hous-ing on the vehicle.Is there any problem?
No Go to next step.
2 Inspect if the turbocharger compressor wheellocknut is loose or has fallen down inside the
Yes Replace the turbocharger.
turbocharger.Is there any problem?
No Go to next step.
3 Turn the turbocharger compressor wheel byhand
Yes Go to next step.hand.Does wheel turn easily and smoothly? No Replace the turbocharger.
4 Inspect if the turbocharger turbine wheel isdamaged, cracked, or interfering with the
Yes Replace the turbocharger.
housing on the vehicle.Is there any problem?
No Go to next step.
5 Is any engine oil found inside the turbochargerturbine housing?
Yes If an excessive amount of oil is found on the vehicle,replace the turbocharger.If a small amount of oil is found, wipe the oil off thevehicle. Then, go to next step.
No Go to next step.
6 Is any engine oil found inside the turbocharger Yes Wipe the oil off of the vehicle. Then, go to next step.compressor housing? No Go to next step.
7 Is any exhaust gas leakage found around thelocation where the turbocharger is attached tothe exhaust manifold?
Yes Remove turbocharger. Inspect for cracks on centerhousing inlet surface.If cracks are found, replace turbocharger.If no cracks are found, DO NOT replace turbocharger.Replace gaskets, bolts, and nuts only. Then, go to nextstep.
No Go to next step.
8 Are any of the attaching bolts of center hous-ing and turbine housing loose?
Yes Retighten the loose bolts.If any bolt is missing, attach the appropriate new bolt.
No Turbocharger is okay. Install all removed parts inStep1. Go to next step.
9 Is squeal, click, or chirp sound present? Yes Inspect engine oil level or drive belt.
No Go to next step.
10 Is rumble or grind sound present? Yes Inspect drive belt.
No Go to next step.
11 Is rattle sound present? Yes Inspect location of rattle for loose parts.
No Go to next step.
12 Is hiss sound present? Yes Inspect for the following: Vacuum leaks Intake-air system leaks
No Go to next step.
13 Is rap or roar sound present? Yes Inspect exhaust system for loose parts.
No Go to next step.
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TROUBLESHOOTING
F2–58
STEP INSPECTION RE-SULTS
ACTION
14 Inspect the injection timing. Yes Go to next step.Is injection timing okay? No Inspect TCV (if equipped)
+ FUEL SYSTEM, TIMER CONTROL VALVE (TCV)INSPECTION
If TCV is okay, adjust injection timing.+ ENGINE TUNE-UP, INJECTION TIMING
ADJUSTMENT15 Note:
The following test should be performedon vehicles with EGR system. Go tonext step for vehicles without EGRsystem.
Yes Go to next step.
system.Carry out EGR system inspection.+ SYSTEM INSPECTION, EGR System
InspectionIs EGR system okay?
No Repair or replace as necessary.
16 Remove the fuel injection nozzle.Inspect for the following: Clogged nozzle. Seized needle valve
Yes Inspect for the following: Metal flow Bent connecting rod Damaged valve seat
Incorrect valve opening pressure Faulty nozzle gasket Fuel dripping (fuel leakage)
Is injection nozzle okay?
No After-leakege, clogged nozzle or seized needle valve:Disassemble and clean or replace the injection nozzle.Incorrect valve opening pressure:Adjust injection nozzle opening pressure.Faulty nozzle gasket:Replace nozzle gasket.
SYMPTOM 17 VIBRATION COCNERNS (ENGINE)
DESCRIPTION Vibration from under hood or driveline.
POSSIBLECAUSE
Loose attaching bolts or worn parts Components malfunctions such as worn parts
STEP INSPECTION RE-SULTS
ACTION
1 Inspect the following components for looseattaching bolts or worn parts: Cooling fan Drive belt and pulley Engine mounts Exhaust system
Yes Inspect the following: Wheels Transmission and mounts Driveline Suspension
Service as necessary.Are all items okay? No Readjust or retighten engine mount installation posi-
tion.Service as necessary for other parts.
SYMPTOM 18 A/C DOES NOT WORK.
DESCRIPTION A/C compressor magnetic clutch does not engage when A/C is turned on.
POSSIBLECAUSE
Improper refrigerant chargingamount
Microswitch is stuck open. Open A/C magnetic clutch Open circuit in related wire har-
nesses Poor ground of A/C magnetic
clutch A/C low/high pressure switch is
stuck open.
A/C relay is stuck open. Seized A/C compressor Frost switch is stuck open. Open circuit in blower resistor Poor blower switch ground ECT sensor malfunction Improper magnet clutch clearance
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TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
TROUBLESHOOTING
F2–59
STEP INSPECTION RE-SULTS
ACTION
1 Turn engine switch on. Yes Go to next step.Set the fan switch to 1st, 2nd, 3rd, or 4th posi-tion.Verify the blower motor is operating.Is blower motor okay?
No Inspect for the following: Poor ground of fan switch Open circuit in blower resistor Poor contact of fan switch Blower relay is stuck open. Open circuit in blower relay coil Seized blower motor Open circuit in blower motor coil. Open circuit between blower motor and resistor Open circuit between fan switch and resistor
Repair or replace as necessary.
2 Turn the engine switch on. Yes Go to next step.Set the fan switch to 1st, 2nd, 3rd, or 4th posi-tion.Measure the voltage at PCM connector termi-nal G.+ CONTROL SYSTEM, PCM INSPECTIONSpecification:Less than 2.7 VIs voltage correct?
No Inspect for the following: Frost switch is stuck open. Poor contact of microswitch in heater control unit Open circuit between PCM connector terminal G
and frost switch connector terminal. Open circuit between frost switch connector termi-
nal and fan switch connector terminal.Repair or replace as necessary.
3 Start the engine and run it at idle speed. Yes Go to next step.Set the fan switch to 1st position.Measure the voltage at terminal of A/C relayconnector terminal C.Specification:More than 10.5 VIs voltage correct?
No Inspect for the following: Open circuit in A/C relay coil Poor contact in A/C relay A/C relay stuck open Open circuit between PCM connector terminal L
and A/C relay connector terminal. Open circuit in battery supply line Open circuit between engine switch and A/C relay
connector terminal Engine coolant temperature sensor malfunction
Repair or replace as necessary.
4 Disconnect the A/C magnetic clutch connec-tor, Measure the A/C magnetic clutch connectorterminal voltage.Specification:
Yes Inspect for the following: Poor ground of A/C magnetic is clutch Open circuit in magnet is clutch coil Refrigerant charging amount
Repair or replace as necessary.More than 10.5 VIs voltage okay?
No Inspect for the following: Open circuit between pressure switch connector
terminal and A/C magnetic clutch connector termi-nal
Refrigerant charging amount A/C pressure switch is stuck open. Magnetic clutch clearance A/C compressor is seized.
Repair or replace as necessary.
SYMPTOM 19 A/C ALWAYS ON / A/C COMPRESSOR RUNS CONTINUOUSLY.
DESCRIPTION A/C compressor magnetic clutch does not disengage.
POSSIBLECAUSE
Improper magnetic clutch clear-ance
Short to ground circuit betweenPCM and frost switch
Short to ground circuit betweenPCM and A/C relay
Short to power line between A/C relay and pressureswitch
A/C low/high pressure switch is stuck to close. A/C relay is stuck to close. Frost switch is stuck to close.
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TROUBLESHOOTING
F2–60
STEP INSPECTION RE-SULTS
ACTION
1 Turn the engine switch on. Yes Go to next step.Turn the blower switch off.Measure the voltage at PCM connector termi-nal G.Specification:More than 2.7 VIs voltage correct?
No Inspect for the following: Short to ground circuit between PCM connector
terminal G and frost switch Short to ground circuit between frost switch and
blower switch connector terminalRepair or replace as necessary.
2 Start the engine and run it at idle speed.Turn the blower switch off.
Yes Inspect for magnetic is clutch clearance.Adjust it as necessary.
Measure the voltage at terminal of A/C relayconnector terminal C.Specification:0 VIs voltage correct?
No Inspect for the following: Short to ground circuit between PCM connector
terminal L and A/C relay terminal C A/C relay is stuck to close. Short to power line between A/C relay connector
terminal C and A/C pressure switch Short to power line between pressure switch and
A/C compressor magnetic is clutch connectorRepair or replace as necessary.
SYMPTOM 20 INTERMITTENT CONCERNS
DESCRIPTION Symptom occurs randomly and is difficult to diagnose.
STEP INSPECTION RE-SULTS
ACTION
1 Talk to customer.Retrieve vehicle service history.Does vehicle have a number of previous re-
Yes Go to next step.
Does vehicle have a number of revious re-pairs and components replaced for a certainsymptom?
No Go to symptom index.
2 Key off.If input is switch-type component, turn onmanually.Turn engine switch off.Connect the voltmeter to the PCM terminals.Lightly tap on suspect component wiggle and
Yes Inspect each wire for corrosion, bent or loose terminalclamps.
Lightly ta on sus ect com onent, wiggle andpull each wire/connector at suspect compo-nent or PCM.Is any voltage out of range, or do they sud-denly change and go back into range?
No Go to next step.
3 Start the engine and run it at idle speed.Lightly tap on suspect component, wiggle andpull each wire/connector at suspect compo-nent or PCM
Yes Inspect each wire for corrosion, bent or loose terminalclamps.
nent or PCM.Are any voltages out of range, or do they sud-denly change and go back into range?
No Go to next step.
4 Accurately spray water on suspect componentwire, component, or vacuum line related topossible fault area.Is any voltage out of range, or suddenlychange and go back into range, or was therea noticeable engine stumble?
Yes Fault area is identified.If fault occurred while spraying on component:Replace part and verify repair.If fault occurred while spraying water:Inspect each wire for corrosion, bent, loose terminals,or poor wire terminal clamps.If fault occurred while spraying vacuum line:Repair vacuum hoses.
No Inspect wire and connector at suspect component forcorrosion, bent, loose terminals, or poor wire terminalcrimps and high tension wire. Repair as necessary.
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TROUBLESHOOTING
F2–61
SYSTEM INSPECTIONFICD System InspectionFast-Idle Function
1. Verify that the FICD actuator rod is not pulled.2. Verify that the engine is cold (ECT is below 20 °C
68 °F).3. Turn fan switch off.4. Start the engine.5. Verify that the FICD actuator rod is pulled.
6. If not, disconnect the vacuum hoses from the FICDactuator and inspect if there is vacuum as shown.
FICD ACTUATOR
Caution FIP is sealed to maintain proper function.
Special tools and testers are required whendisassembling the FIP. Disassembling theFIP without special tools and testers willcause a malfunction.
7. If there is vacuum, consult your distributor forreplacement of the FICD actuator.
8. If there is no vacuum, inspect the following. FICD solenoid valve No.1 and No.2 Loose or damaged vacuum hoses between
FICD actuator, FICD solenoid valve No.1 andNo.2, and vacuum pump.
PCM terminal C, E and P voltages (Refer to CONTROL SYSTEM, POWERTRAINCONTROL MODULE (PCM) INSPECTION.)
Wiring harness between FICD solenoid valveNo.1 and PCM terminal C.
Wiring harness between FICD solenoid valveNo.2 and PCM terminal P.
9. Warm up the engine. (ECT above 20 °C 68 °F).10. Verify that the FICD actuator rod returns for one
notch.
11. If not, disconnect vacuum hose A from the FICDactuator and inspect if there is vacuum.
VACUUM HOSE A
Caution FIP is sealed to maintain proper function.
Special tools and testers are required whendisassembling the FIP. Disassembling theFIP without special tools and testers willcause a malfunction.
12. If there is no vacuum, consult your distributor forreplacement of the FICD actuator.
13. If there is vacuum, inspect the following. FICD solenoid valve No.1 PCM terminal C, E voltages
(Refer to CONTROL SYSTEM, POWERTRAINCONTROL MODULE (PCM) INSPECTION.)
Wire harness between FICD solenoid valveNo.1 and PCM terminal C
14. Warm up the engine (ECT is above 60 °C 140°F).
15. Verify that the FICD actuator rod returnscompletely.
16. If not, disconnect vacuum hose B from the FICDactuator and inspect if there is vacuum.
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TROUBLESHOOTING
F2–62
VACUUM HOSE B
Caution FIP is sealed to maintain proper function.
Special tools and testers are required whendisassembling the FIP. Disassembling theFIP without special tools and testers willcause a malfunction.
17. If there is no vacuum, consult your distributor forreplacement of the FICD actuator.
18. If there is vacuum, inspect the following. FICD solenoid valve No.2 PCM terminal E, G and P voltages
(Refer to CONTROL SYSTEM, POWERTRAINCONTROL MODULE (PCM) INSPECTION.)
Wiring harness between FICD solenoid valveNo.2 and PCM terminal P.
A/C Idle-up Function1. Start the engine.2. Warm up the engine to normal operating
temperature and run it at idle speed.3. Set the fan switch at 1st position.4. Verify that the FICD rod is pulled for one notch.5. If not, disconnect the vacuum hose B from the
FICD actuator and inspect if there is vacuum asshown.
VACUUM HOSE B
Caution FIP is sealed to maintain proper function.
Special tools and testers are required whendisassembling the FIP. Disassembling theFIP without special tools and testers willcause a malfunction.
6. If there is vacuum, consult your distributor forreplacement of the FICD actuator.
7. If there is no vacuum, inspect the following: FICD solenoid valve No.2 PCM terminal G and P voltages
(Refer to CONTROL SYSTEM,POWERTRAIN CONTROL MODULE (PCM) INSPECTION)
Wiring harness between FICD solenoid valve No.2connector terminal B and PCM terminal P
Turbocharger Boost Pressure1. Disconnect the air hose between the intake pipe
and the boost compensator.2. Connect a pressure gauge (range of measurement
is 93.3 kPa 700 mmHg, 27.6 inHg).BOOST COMPENSATOR
PRESSURE GAUGE
TO INTAKEPIPE
3. Warm up the engine.4. With the accelerator at the wide open throttle,
increase the engine speed to 4800—5000 rpm andverify that the boost pressure is within thespecification.
Specification60.0—73.3 kPa
0.62—0.74 kgf/cm 2, 8.82—10.52 psi
5. If not as specified, inspect the exhaust system. (Refer to EXHAUST SYSTEM, EXHAUSTSYSTEM INSPECTION.)
6. If the exhaust system is normal, inspect thewastegate actuator. (Refer to INTAKE-AIRSYSTEM, TURBOCHARGER INSPECTION,Wastegate Actuator Inspection.)
7. If the wastegate actuator is normal, inspect theturbocharger. (Refer to INTAKE-AIR SYSTEM,TURBOCHARGER INSPECTION.)
TCV Control Inspection (Europe and UK)1. Crank the engine and verify that the TCV operation
sound is heard.
WL
TCV
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TROUBLESHOOTING
F2–63
WL Turbo
TCV
2. If no operation sound is heard, inspect the TCV (inthe FIP).
3. If the TCV is normal, inspect the following: PCM terminal Q voltage
(Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION)
Wire harness between TCV and PCM terminalQ
EGR System Inspection (if equipped)1. Make sure that all hoses are securely connected in
the proper position.2. Disconnect the vacuum hose from the EGR valve.3. Start the engine at cold condition.4. Verify that there is no vacuum at vacuum hose.5. If there is vacuum, inspect the following:
EGR solenoid valve PCM terminal R voltage
(Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.)
Wire harness between EGR solenoid valve andPCM terminal R
6. Warm up the engine to the normal operatingtemperature and run it at idle speed.
7. Verify that there is vacuum at vacuum hose.8. If there is no vacuum, inspect the following:
EGR solenoid valve PCM terminal R voltage
(Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.)
Wire harness between EGR solenoid valve andPCM terminal R
9. Connect the vacuum pump to the EGR valve.10. Apply the vacuum to the EGR valve and inspect if
the engine speed becomes unstable or the enginestalls.
11. If the engine speed does not change, stop theengine and inspect the EGR valve.
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CONTINUED
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
TROUBLESHOOTING
F2–64
Glow System InspectionSTEP INSPECTION RE-
SULTSACTION
1 Connect NGS tester to DTC.Turn engine switch on and retrieve DTC.Are any of the following DTCs displayed? 09 (ECT sensor)
Yes Go the appropriate DTC test.After repair is completed, go to next step.
09 (ECT sensor) 12 (Control lever position sensor) 36 (Glow plug relay)
No Go to next step.
2 Turn engine switch on while engine is cold. Yes Go to next step.Does glow indicator light illuminate for approx.1—9 seconds.?
No Inspect the following according to indication conditionof glow indicator light:1. Will not go out Short circuit between glow indicator light and PCM
connector terminal M Short circuit in instrument cluster print plate
2. Illuminates for approx. 1 second (same conditionafter engine is warmed up and cold)
Extremely low resistance of engine coolant temper-ature sensor
Short circuit between engine coolant temperaturesensor and PCM connector terminal E
3. Will not illuminate Glow indicator light Open circuit between glow indicator light and PCM
connector terminal M Open circuit in instrument cluster print plate
4. Illuminates for approx. 9 seconds (same conditionafter engine is warmed up and cold)
Extremely high resistance of engine coolant temper-ature sensor
Open circuit between engine coolant temperaturesensor and PCM connector terminal E
3 Leave engine switch on while engine is cold. Yes Go to next step.Does glow plug voltage indicate B+ forapprox. 15 seconds.?
No Inspect for open or short circuit in harnesses and con-nectors between battery, glow plug relay, and glowplug.Inspect if glow plug relay is stuck open or closed.Inspect glow plug relay ground circuit.Inspect for open circuit between glow relay and PCMterminal O.
4 Does glow plug voltage indicate B+ while Yes Go to next step.cranking engine? No Inspect for open or short to ground circuit in harness
and connectors between engine switch (starter) andPCM connector terminal D.
5 Is power supplied to the glow plug for maxi- Yes Go to next step.mum 10 minutes after engine started whenengine is cold?
No Inspect for open or short circuit in harnesses and con-nectors between NE sensor and PCM connector termi-nal F.
6 Remove the glow plug wire from glow plugs.Measure resistance between glow plug andbody ground.
Yes Glow system is okay.
y gIs glow plug resistance approx. 1 Ω or less?+ INTAKE-AIR SYSTEM, GLOW PLUG
INSPECTION
No Replace glow plug.
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CONTINUED
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
FUEL AND EMISSION CONTROL SYSTEMS
(F2 CARB) ENGINE TUNE-UP .........................................................F4-2
ENGINE TUNE-UP PREPARATION ........................F4-2 IGNITION TIMING ADJUSTMENT ...........................F4-2 IDLE SPEED ADJUSTMENT ...................................F4-2 IDLE MIXTURE ADJUSTMENT ...............................F4-2/3 DASHPOT (D/P) ADJUSTMENT ..............................F4-3 THROTTLE POSITIONER (T/P)
ADJUSTMENT ........................................................F4-3/4 A/C IDLE-UP ADJUSTMENT ...................................F4-4/5 INTAKE-AIR SYSTEM .................................................F4-6
VACUUM HOSE ROUTING DIAGRAM ...................F4-6 INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION ..................................F4-7 AIR CLEANER ELEMENT
INSPECTION ..........................................................F4-8 IDLE COMPENSATOR INSPECTION ....................F4-8 AIR THERMO VALVE
INSPECTION ..........................................................F4-8 VACUUM CONTROL DIAPHRAGM
INSPECTION ..........................................................F4-8 ACCELERATOR PEDAL
REMOVAL/INSTALLATION ..................................F4-9 ACCELERATOR CABLE
INSPECTION/ADJUSTMENT .............................. F4-9 FUEL SYSTEM ..............................................................F4-10
BEFORE REPAIR PROCEDURE.............................F4-10 AFTER REPAIR PROCEDURE ...............................F4-10 FUEL TANK REMOVAL/INSTALLATION ...............F4-11/13NONRETURN VALVE INSPECTION ......................F4-13 FUEL PUMP UNIT
REMOVAL/INSTALLATION...................................F4-13 FUEL PUMP UNIT
DISASSEMBLY/ASSEMBLY ................................F4-13/14 FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION ..................................F4-14
FUEL GAUGE SENDER UNIT INSPECTION ..........................................................F4-14
FUEL PUMP INSPECTION ......................................F4-14/15 FUEL LINE PRESSURE INSPECTION ..................F4-15 FUEL LINE FLOW AMOUNT
INSPECTION ..........................................................F4-15/16 FAST IDLE SPEED ADJUSTMENT ........................F4-16 DASHPOT (D/P) INSPECTION ................................F4-16 FUEL PUMP RELAY INSPECTION ........................F4-16/17 SERVO DIAPHRAGM
REMOVAL/INSTALLATION ..................................F4-17 CARBURETOR
REMOVAL/INSTALLATION ..................................F4-17
CARBURETOR
DISASSEMBLY/ASSEMBLY ............................... F4-18/21 CARBURETOR
INSPECTION/ADJUSTMENT .............................. F4-21/24 HIGH-ALTITUDE COMPENSATOR
INSPECTION ......................................................... F4-24 PTC HEATER INSPECTION ................................... F4-24 SLOW FUEL CUT SOLENOID VALVE
INSPECTION ......................................................... F4-24 EXHAUST SYSTEM .................................................... F4-25
EXHAUST SYSTEM INSPECTION ........................ F4-25 EXHAUST SYSTEM
REMOVAL/INSTALLATION ................................. F4-25 EMISSION SYSTEM .................................................... F4-26
N0.1 PURGE CONTROL VALVE INSPECTION ......................................................... F4-26
N0.2 PURGE CONTROL VALVE INSPECTION ......................................................... F4-26
WATER THERMO VALVE INSPECTION .............. F4-26 AIR VENT SOLENOID INSPECTION ...................... F4-26 CHECK VALVE (TWO-WAY)
INSPECTION ......................................................... F4-26 CHARCOAL CANISTER INSPECTION ................. F4-26 ROLLOVER VALVE INSPECTION ......................... F4-26/27 WATER THERMO VALVE
REMOVAL/INSTALLATION ................................. F4-27 PCV VALVE INSPECTION ...................................... F4-27 CLOSED THROTTLE POSITION (CTP)
SWITCH ADJUSTMENT ...................................... F4-27 FLANGE THERMOSWITCH
INSPECTION ......................................................... F4-27 CONTROL SYSTEM .................................................... F4-28
COMPONENT LOCATION ...................................... F4-28 PCM REMOVAL/INSTALLATION ........................... F4-29 PCM INSPECTION .................................................... F4-29 PTC HEATER RELAY INSPECTION ..................... F4-30 THROTTLE POSITIONER T/P) SOLENOID
VALVE INSPECTION ........................................... F4-30 WATER THERMOSWITCH (INTAKE
MANIFOLD SIDE) INSPECTION ......................... F4-30/31 WATER THERMOSWITCH
REMOVAL/INSTALLATION ................................. F4-31 TROUBLESHOOTING ................................................ F4-32
FOREWORD ............................................................. F4-32 TROUBLESHOOTING ITEM TABLE ...................... F4-32 QUICK DIAGNOSTIC CHART ................................. F4-33
SYMPTOM TROUBLESHOOTING ......................... F4-34/47
F4-1
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CONTINUED
ENGINE TUNE-UP
IDLE MIXTURE ADJUSTMENT 1. Attach an exhaust gas analyzer and measure the
CO concentration.
2. Perform the "ENGINE TUNE-UP PREPARATION"
and "IDLE SPEED ADJUSTMENT." 3. Verify that CO concentration in exhaust gas at the
tail pipe during idling is as specified in the table below.
For CO concentration (%) GULF 2.0—2.5 (2.0 ) General 2.0—3.0 (2.5 ±0.5)
ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION 1. Check the condition of the engine (plugs, leaks in
hoses, etc.) 2. Make sure all accessories are OFF. 3. Connect a tacho dwell tacho tester to the engine. 4. Warm up the engine and run it for three minutes
at 2,500—3,000 rpm in neutral. IGNITION TIMING ADJUSTMENT
1. Perform the "ENGINE TUNE-UP PREPARATION.2. Disconnect the vacuum hose for vacuum spark
advance between the distributor and the carburetor at the distributor side and plug it.
3. While checking the ignition timing by using a
timing light, adjust the crankshaft pulley alignment mark position (yellow paint) by turning the distributor as specified.
Specification BTDC: 5°—7°(6°±1°)
4. Reconnect the proper vacuum hose to the port. IDLE SPEED ADJUSTMENT 1. Perform the "ENGINE TUNE-UP PREPARATION.2. Verify that the idle speed is within the
specification.
3. If not within the specification, adjust the idle
speed by turning the TAS (throttle adjust screw)
4. If not within the specification, adjust the CO concentration by turning the MAS (mixture adjust screw).
5. Remove the blind cap. (GULF)
6. Remove the spring pin.
F4-2
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CONTINUED
ENGINE TUNE-UP
7. Reconfirm that the engine speed is within the
specification. 8. If not within the specification, adjust the idle
speed by turning the TAS (throttle adjust screw).
Note GULF only
• Run the engine at idle for 3—5 seconds, then fit a blind cap to the MAS (mixture adjust screw) of the vehicles for the following markets.
• Run the engine at idle for 3—5 seconds,
then tap in the spring pin as shown.
DASHPOT (D/P) ADJUSTMENT 1. Perform the "ENGINE TUNE-UP PREPARATION"
and "IDLE SPEED ADJUSTMENT" 2. Increase the engine speed to 2,500 rpm. 3. Pull the throttle lever until the rod and arm of the
dashpot separate. 4. Slowly return the throttle lever from the position
above, then verify that the engine speed is as specified when the arm contacts the rod.
Specification 1,900—2,100 (2,000 ± 100) rpm
5. If not as specified, loosen the dashpot locknut and turn the dashpot body to adjust.
6. After adjustment, tighten the locknut.
Tightening torque 9.8—17.6 N.m 100—180 kgf.cm, 87—156 in.lbf
7. Race the engine and again verify that the engine speed returns smoothly to idle speed. 8. If not, repeat the above procedure to adjust the idle speed or D/P inspect (Refer to FUEL SYSTEM, DASHPOT (D/P) INSPECTION)
THROTTLE POSITIONER (T/P) ADJUSTMENT GULF only 1. Perform the "ENGINE TUNE-UP PREPARATION"
and "IDLE SPEED ADJUSTMENT." 2. Disconnect the vacuum hose for vacuum spark
advance between the distributor and the carburetor at the distributor side and plug it.
3. Disconnect the vacuum hose from the servo diaphragm.
4. Connect the intake manifold vacuum directly to the
servo diaphragm, and verify that the engine speed is as specified.
Specification 1,050—1,250 (1,150 ± 100) rpm
F4-3
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CONTINUED
ENGINE TUNE-UP
5. If not within the specification, adjust the engine speed by the adjust screw.
6. After adjusting the engine speed, reconnect the
vacuum hose to the proper port. Verify that the servo diaphragm operates when the engine speed is raced at 2,000 rpm or more.
7. If the servo diaphragm does not operate, inspect the T/P solenoid valve.
8. If the solenoid valve is okay, replace the servo diaphragm.
A/C IDLE-UP ADJUSTMENT GULF only with, A/C 1. Perform the "ENGINE TUNE-UP PREPARATION"
and "IDLE SPEED ADJUSTMENT." 2. Disconnect the vacuum hose from port A.
3. Connect the intake manifold vacuum directly to port A, and verify that the engine speed is as specified. Specification 1,400—1,600 (1,500 ± 100) rpm
4. If not within the specification, adjust the engine speed by the adjust screw.
5. Reconnect the proper vacuum hose to port A.
6. Disconnect the vacuum hose for vacuum spark advance between the distributor and the carburetor at the distributor side and plug it.
7. Disconnect the vacuum hose from port B.
8. Connect the intake manifold vacuum directly to
port B, and verify that the engine speed is as specified. Specification 1,050—1,250 (1,150 ±100) rpm
9. If not within the specification, adjust the engine speed by the adjust locknut on the dual servo diaphragm head.
10. Reconnect the proper vacuum hose to port B. 11. After adjusting the engine speed reconnect the
vacuum hose to the proper port. Verify that the servo diaphragm operates when the A/C is operated.
12. If the servo diaphragm does not operate, inspect the A/C idle-up solenoid valve or T/P solenoid valve.
13. If the solenoid valve is okay, replace the dual servo diaphragm.
Except GULF, with A/C 1. Perform the "ENGINE TUNE-UP PREPARATION"
and "IDLE SPEED ADJUSTMENT." 2. Disconnect the vacuum hose from the servo
diaphragm. 3. Connect the intake manifold vacuum directly to
the servo diaphragm, and verify that the engine speed is as spec tied.
F4-4
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CONTINUED
ENGINE TUNE-UP
Specification 1,400—1,600 (1,500 ± 100) rpm
4. If not within the specification, adjust the engine speed by adjust screw.
5. Reconnect the proper vacuum hose to port. 6. After adjusting the engine speed reconnect the vacuum
hose to the proper port. Verify that the servo diaphragm operates when the A/C is operated.
7. If the servo diaphragm does not operate, inspect the A/C idle-up solenoid valve.
8. If the solenoid valve is okay, replace the servo diaphragm.
F4-5
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CONTINUED
INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM
VACUUM HOSE ROUTING DIAGRAM
1 Air cleaner 12 Distributor 2 Carburetor 13 T/P solenoid valve 3 Vacuum control diaphragm 14 Servo diaphragm 4 Idle compensator 15 A/C idle-up solenoid valve 5 Air thermos sensor 16 Dual servo diaphragm 6 FICB solenoid valve 17 To intake manifold 7 High-altitude compensator 18 Fuel main line (to fuel tank) 8 FICB diaphragm 19 Fuel return line (to fuel tank) 9 Charcoal canister 20 To charcoal canister or ventilation 10 No.1 purge control valve 21 To carburetor 11 Water thermo valve
22 To check valve (two-way)
F4-6
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CONTINUED
INTAKE-AIR SYSTEM INTAKE - AIR SYSTEM REMOVAL/INSTALLATION
Warning • When the engine and intake-air system are hot, they can badly bum. Turn off the engine and wait
until they are cool before removing the intake-air system. • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
1. Disconnect the negative battery cable. 2. Drain the engine coolant from the radiator. (Refer to Section E.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
8 Intake manifold 1
Air cleaner (in idle compensator, vacuum control diaphragm, shutter valve, air thermo sensor)
2 Air cleaner element 3 Carburetor
9
Water thermoswitch CONTROL SYSTEM, WATER THERMOSWITCH REMOVAL/INSTALLATION
4 Fuel hose 10 Intake manifold gasket
5 Accelerator cable 6 PTC heater gasket
11
Water thermo valve FUEL SYSTEM, WATER THERMO VALVE REMOVAL/INSTALLATION
7 PTC heater
12 Servo diaphragm
F4-7
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CONTINUED
INTAKE-AIR SYSTEM AIR CLEANER ELEMENT INSPECTION
• Visually check the air cleaner element for excessive dirt, damage or oil, replace if necessary.
IDLE COMPENSATOR INSPECTION 1. Confirm that the valve is in the closed position
when the bimetal temperature is lower than the specified temperature. Opening temperature 63—71 °C 145.4—159.8 °F
2. To check, suck air from the tube A. If excessive air leakage is found, replace the idle compensator.
3. When the bimetal temperature is more than
approx. 71 °C 159.8 °F, confirm that the valve is in the open position. If the valve is not open, replace the idle compensator as an assembly.
AIR THERMO VALVE INSPECTION Note • Perform the following test only when directed.
1. Disconnect the vacuum hose from the vacuum control diaphragm.
2. Verify that vacuum is felt at the vacuum hose when the engine is cold (below 30 °C 86 °F) and idling.
3. Warm up (above 30 °C 86 °F) the engine and verify that vacuum is not felt.
4. If vacuum condition is not as specified in Steps 2
and 3, replace the air thermo valve. VACUUM CONTROL DIAPHRAGM INSPECTION 1. Disconnect the vacuum hose from the vacuum
control diaphragm. 2. Connect a vacuum pump to the vacuum control
diaphragm. 3. Apply more than 24 KPa 180 mmHg, 7.087
inHg vacuum and verify that the shutter valve is opened to the hot position.
4. Replace the vacuum control diaphragm if not
as specified.
F4-8
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CONTINUED
INTAKE-AIR SYSTEM
ACCELERATOR PEDAL REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
1
Accelerator cable ACCELERATOR CABLE INSPECTION/ADJUSTMENT
2 Accelerator pedal ACCELERATOR CABLE INSPECTION/ADJUSTMENT
1. Verify that the throttle valve is entirely closed. 2. Measure the free play of the accelerator cable.
Free play 1—3 mm 0.04—0.11 in
3. If not as specified, adjust by turning locknut A.
F4-9
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CONTINUED
FUEL SYSTEM FUEL SYSTEM BEFORE REPAIR PROCEDURE
Warning • Fuel vapor is hazardous. It can easily
ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safety Procedures".
Fuel Line Safety Procedures Note
• Fuel in the fuel system is under high pressure also when the engine is not running.
1. Remove the fuel-filler cap and release the pressure in the fuel tank.
2. Disconnect the fuel pump relay connector located under the passenger's side front side trim.
3. Start the engine. 4. After the engine stalls, crank the engine several
times. 5. Turn off the ignition switch. 6. Reconnect the fuel pump relay connector. AFTER REPAIR PROCEDURE
Warning • Fuel line spills and leakage are dangerous.
Fuel can ignite and cause serious injuries or death and damage. When installing the fuel hose, observe "Fuel Hose Installation" and described below.
Fuel Hose Installation 1. Replace damaged or deformed fuel hoses, fuel
pipes, and hose clamps. 2. When installing the fuel hose onto the fuel pipe, fit
the hose onto the pipe over 25 mm 0.98 in. When the pipe has a stopper, fit the hose until it contacts the stopper.
3. Install a hose clamp over the fuel hose within the clamp installation range as shown, avoiding the original clamp position.
F4-10
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CONTINUED
FUEL SYSTEM
FUEL TANK REMOVAL/INSTALLATION Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous.
Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.
1. Level the vehicle. 2. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Disconnect the negative battery cable. 4. Drain the fuel from the drain plug. 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
DOUBLE CAB
F4-11
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CONTINUED
FUEL SYSTEM
REGULAR CAB
7 Rollover valve 1 Joint hose
Installation Note 8 Fuel pump unit9 Fuel-filler pipe 2 Breather hose w Installation Note
10 Dust cover 3 Under guard 11 Fuel inlet pipe
4 Fuel hose 12 Non return valve
5 Fuel tank
13 Evaporative gas check valve (two-way) Installation Note 6 Evaporative hose - Installation Note
F4-12
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CONTINUED
FUEL SYSTEM Evaporative Gas Check Valve (Two-way) Installation Note • Install the arrow mark of the evaporative gas
check valve (two-way) facing the charcoal canister.
Evaporative Hose Installation Note • Fit each hose onto the respective fittings within
the specification, and install clamps as shown. Length Evaporative hose: 25 mm 0.98 in
Breather Hose Installation Note • Fit each hose onto the respective fittings within
the specification, and install clamp as shown. Length Breather hose: 25—30 mm 0.99—1.18 in
Joint Hose Installation Note • Fit the joint hose onto the respective fittings
within the specification, and install clamps as shown. Length Joint hose: 35—40 mm 1.4—1.5 in
NONRETURN VALVE INSPECTION 1. Remove the nonreturn valve with the fuel inlet
pipe. 2. Verify that the nonreturn valve opening angle is
50—56° when pushed out from the fuel inlet pipe side, and the clearance between the nonreturn valve and the fuel inlet pipe end is within 1.5 mm 0.06 in when the nonreturn valve is returned to the closed position.
3. If not as specified, replace the nonreturn valve. FUEL PUMP UNIT REMOVAUINSTALLATION 1. Remove the fuel pump unit.
(Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)
2. Install the fuel pump unit. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)
FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY Warning • Fuel line spills and leakage are
dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.
1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
F4-13
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CONTINUED
FUEL SYSTEM DOUBLE CAB
REGULAR CAB
1 Fuel pump unit connector 2 Rubber mount 3 Fuel filter (low-pressure) 4 Clamp 5 Fuel hose
Assembly Note 6 Fuel pump body
Assembly Note 7 Fuel gauge sender unit
Fuel Pump Assembly Note • After installing the fuel pump body to the
bracket; pull the pump down so that it is tight against the bracket.
Fuel Hose Assembly Note 1. Do not apply excessive side force when pushing
the fuel hose onto the fuel pump nipple. 2. Install the clamps as shown.
FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) FUEL GAUGE SENDER UNIT INSPECTION (Refer to Section T, WARNING AND INDICATOR SYSTEM, FUEL GAUGE SENDER UNIT INSPECTION.) FUEL PUMP INSPECTION Continuity Inspection
Note • Perform the following test only when
directed, 1. Complete the "BEFORE REPAIR
PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
2. Disconnect the negative battery cable. 3. Remove the fuel tank.
(Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)
4. Inspect for continuity between fuel pump unit connector terminals C and D.
F4-14
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CONTINUED
FUEL SYSTEM
5. If there is no continuity, replace the fuel pump body. If there is continuity in the fuel pump but the fuel pump does not operate, inspect as follows and repair or replace as necessary. Open circuit • GND circuit (fuel pump unit connector
terminal C and body GND) • Power circuit (fuel pump relay connector
terminal C and fuel pump unit connector terminal D through common connector)
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
Short circuit • Fuel pump relay connector terminal C and
fuel pump unit connector terminal D through common connector to GND
6. Repair or replace faulty areas. If the harnesses are okay, inspect the fuel pump relay. (Refer to FUEL SYSTEM, FUEL PUMP RELAY INSPECTION.)
7. Install the fuel tank. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)
8. Reconnect the negative battery cable. 9. Complete the "AFTER REPAIR PROCEDURE".
(Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
FUEL LINE PRESSURE INSPECTION
Note • Perform the following test only when directed.
1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
2. Disconnect the negative battery cable. 3. Disconnect the main fuel hose (A), and connect a
fuel pressure gauge to it.
4. Connect the C and D terminals of the fuel pump relay with a jumper wire.
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
5. Connect the negative battery cable. 6. Turn the ignition switch ON, and verify that fuel
pressure is as specified. Specification 20—25kPa 0.20—0.25 kgf/cm2, 2.8—3.6 psi
7. If not as specified, perform the fuel pump inspection. (Refer to FUEL PUMP INSPECTION.)
FUEL LINE FLOW AMOUNT INSPECTION Note
• Perform the following test only when directed. 1. Complete the "BEFORE REPAIR
PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
2. Disconnect the negative battery cable. 3. Disconnect the main fuel hose (A), and insert the
end into a measuring beaker. 4. Connect the C and D terminals of the fuel pump
relay with a jumper wire.
F4-15
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CONTINUED
FUEL SYSTEM
5. Connect the negative battery cable. 6. Turn the ignition switch on. Drive the fuel pump
for a minute and verify that the fuel flow amount is within the specification. Specification More than 1.150 cc 70.2 cu in min.
7. If not as specified, perform the fuel pump inspection. (Refer to FUEL PUMP INSPECTION.)
FAST IDLE SPEED ADJUSTMENT 1. Warm up the engine to normal operation
temperature. 2. Stop the engine. 3. Plug the hoses of the idle compensator. 4. While holding the throttle valve slightly open,
push the choke fully closed; then release the choke valve after releasing the throttle valve.
5. Start the engine, but do not touch the accelerator pedal.
6. Verify that the engine speed is 3,000—4,000 rpm. If the engine speed is not as specified, turn the adjust screw to adjust.
DASHPOT (D/P) INSPECTION 1. Open the throttle valve fully then push the dash
pot rod with a finger and make sure the rod goes into the dash pot slowly.
2. Release the finger and make sure the rod comes out quickly.
FUEL PUMP RELAY INSPECTION On-Vehicle Inspection
Note • Perform the following test only when directed.
1. Remove the front left side trim. 2. Crank the engine while touching the fuel
pump relay by hand. 3. Verify that clicking sound is heard or vibration is
felt from the fuel pump relay white cranking the engine.
4. If there is no clicking sound or vibration, inspect the harness for the following,
Open circuit • Power circuit (fuel pump relay connector
terminal A, D and ignition switch IG1) • GND circuit (fuel pump relay connector
terminal B and PCM terminal H)
Short circuit • Fuel pump relay connector terminal A, D
and ignition switch IG1 to GND. 5. If the harnesses are okay, perform the following off-vehicle inspection.
Off-Vehicle Inspection 1. Remove the fuel pump relay. 2. Inspect for continuity between the fuel pump relay
terminals by using an ohmmeter.
F4-16
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CONTINUED
FUEL SYSTEM
3. If not as specified, replace the fuel pump relay. SERVO DIAPHRAGM REMOVAL/INSTALLATION 1. Loosen the servo diaphragm installation nut.
2. Remove the servo diaphragm and the servo diaphragm bracket from the intake manifold.
3. Separate the servo diaphragm from the bracket. 4. Install the servo diaphragm onto the bracket,
then hand-tighten the installation nut. 5. Install the servo diaphragm bracket to the intake
manifold. Tightening torque 19—25N.m 1.9—2.6 kgf.m, 14—18ft.lbf
6. Tighten the installation nut to the specification.
Tightening torque 9.8—24 N.m 100—250 kgf.cm-cm, 87—216 in.lbf
CARBURETOR REMOVAL/INSTALLATION (Refer to INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
F4-17
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CONTINUED
FUEL SYSTEM
CARBURETOR DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. (Refer to Carburetor After Assembly Note.)
Caution • Replace the O-rings, gaskets, and washers when assembling the carburetor. If not, it will possibly
cause a malfunction.
F4-18
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CONTINUED
FUEL SYSTEM
1 Accelerator pump connecting rod 2 Connect spring 3 Air vent solenoid valve 4 Choke rod 5 Air horn 6 Float 7 Needle valve assembly 8 Accelerator pump plunger
9
Closed throttle position (CTP) switch (GENERAL (LH.D.), high-altitude models)
10 Slow fuel cut solenoid valve 4
Air vent solenoid valve lead (separate from the connector)
11 Accelerator pump outlet check ball and spring 5 Disconnect choke rod 12 Accelerator pump inlet check ball 13 Primary slow jet 14 Secondary slow jet 15 Primary main jet 16 Secondary main jet 17 Primary venturi and nozzle 18 Secondary venturi and nozzle 19 Primary main air bleed 20 Secondary main air bleed 21 Main body 22 Vacuum diaphragm
6
Air horn and automatic choke assembly (separate from main body)
23 Throttle body 24 Mixture adjust screw
7
Air vent solenoid valve, spring, and gasket, if necessary
25 Bimetal
26 Choke breaker diaphragm 27 Power jet
Needle Valve and Float Disassembly/Assembly 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 Float and pin 2 Needle valve assembly
Air Horn and Automatic Choke Disassembly/Assembly 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 Vacuum hose 2 Accelerator pump connecting rod, spring, and lever 3 Connect spring
F4-19
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CONTINUED
FUEL SYSTEM
1 CTP switch and spring
Air Bleeds and Jets Disassembly/Assembly 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
2
Slow fuel cut solenoid valve, needle valve, spring, and gasket.
1 Secondary slow jet 2 Secondary slow air bleed (No.1) 3 Secondary main air bleed 4 Secondary main jet 5 Primary main air bleed 6 Slow jet and plug 7 Primary slow air bleed (No.1) 8 Primary main jet 9 Primary slow air bleed (No.2)
10 Power jet 3 Accelerator pump plunger assembly and spring 4 Retaining clip 5 Strainer and accelerator pump inlet check ball 6 Check valve plug 7 Accelerator pump outlet check ball and spring
Caution
• Note the size of all jets and air bleeds so that they will be reassembled in the correct position
11 Coasting richer air bleed (No.2) 12 Secondary slow air bleed (No.2) 13 Coasting richer air bleed (No.1)
Note • One bolt is inside the throttle body
14 Coasting richer jet 8 Disconnect vacuum diaphragm connecting rod9 Throttle body (separate from main body)
10 Vacuum diaphragm assembly and gasket Main Body Disassembly/Assembly
Caution • After installing the idle switch, be sure to adjust it.
1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
F4-20
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CONTINUED
FUEL SYSTEM
11 Diaphragm cover screws and cover 12 Spring and diaphragm 13 Accelerator cable hanger
Throttle Body Disassembly/Assembly
Caution • Do not remove the throttle valve and shaft, the Venturis, or the choke valve and shaft.
1. Disassemble in the following order. 2. Assemble in the reverse order of disassembly. (1)
When removing the mixture adjust screw, tap out the spring pin as shown in the figure.
Carburetor After Assembly Note • Install the carburetor in the reverse order of
removal. After installation, note the following. (1) Start the engine and check for leaks. (2) Make the idle adjustment. (3) After the idle adjustment is completed,
press in the spring pin.
(4) Adjust the CTP switch. (5) After the idle adjustment has been
completed, check the fast idle speed as follows.
CARBURETOR INSPECTION/ADJUSTMENT Body, Valve, Jet 1. Check for cracks on the air horn, distortion on the
installing surface attached to the main body, and wear on the contact surface of the choke valve shaft. If necessary, replace it.
2. Check for cracks and distortion on the throttle body, and wear on the contact surface of the throttle valve shaft. If necessary, replace it.
3. Check for deformity, bends, and wear on the levers, arms, and connecting rods. If necessary, replace it. Caution • Do not use a piece of wire to clean the
jets. The wire may scratch, crack, or deform the port of the jets and become the cause of malfunctions.
4. Check for clogging in jets and air bleeds. If necessary, clean with clean gasoline or kerosene and dry with compressed air.
5. Check the taper part of the MAS, solenoid valves, and needle valve (float) for cracks and dents, and wear. If necessary, replace it.
6. Check the rubber part of the accelerator pump for cracks and damage. If necessary, replace it.
F4-21
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CONTINUED
FUEL SYSTEM Diaphragms 1. Push the rod fully and plug the port by hand. 2. Verify that the rod does not return when the port is
plugged.
3. If the rod returns to the original position, replace the diaphragm.
Float Level Adjusting 1. Measure the clearance H between the float and air
horn.
Clearance H 8—9 mm 0.315—0.354 in
2. If not as specified, bend the float seat lip A until the proper clearance is obtained.
3. Measure the clearance L between the bottom of
the float and air horn.
Clearance L 44—45 mm 1.732—1.772 in
4. If not as specified, bend the float stopper B until
the proper clearance is obtained.
Choke Valve 1. Use a vacuum pump to apply approximately 53
kPa 400 mmHg, 15.7 inHg vacuum to the choke diaphragm.
2. Push the choke valve lightly to close it, and check the clearance R,
Clearance R 1.72—2.22 mm 0.068—0.087 In
3. If the clearance is not as specified, adjust by bending the choke lever D.
F4-22
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CONTINUED
FUEL SYSTEM Fast-idle cam
1. Set the fast-idle cam to the second highest position.
2. Adjust the throttle valve clearance G by turning the adjust screw. (The clearance becomes larger as the screw is turned clockwise.)
Clearance G 0.64—0.84 mm 0.025—0.033 in
3. Set the fast idle cam at the second highest position.
4. Check the choke valve clearance R.
Clearance R 0.60—1.20 mm 0.024—0.047 in
5. If necessary, adjust the choke valve clearance R by bending the starting arm B. If large adjustments are required, the choke rod should be bent.
Unloader system 1. Open the primary throttle valve fully. 2. Measure the choke valve clearance R.
Clearance R 2.82—3.70 mm 0.111—0.146 in
3. If the clearance is not as specified, adjust by bending tab A.
Secondary throttle valve 1. The secondary throttle valve should start to open
when the primary throttle valve opens 48 ° —52 ° and should be completely open at the same time the primary throttle valve is fully open.
2. Check the clearance between the primary throttle valve and the throttle bore when the secondary throttle valve starts to open.
3. If the clearance is not as specified, bend tab B to adjust.
F4-23
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CONTINUED
FUEL SYSTEM
Clearance R 7.35—8.25 mm 0.289—0.325 in
HIGH-ALTITUDE COMPENSATOR INSPECTION 1. Disconnect each air hose from the carburetor. 2. Check the high-altitude compensator by blowing
through each hose.
500m 1,640 ft or higher (High altitude): Air passes.
Less than 500 m 1,640 ft (Low altitude): Air does not pass.
3. If not as specified, replace the high-altitude compensator.
PTC HEATER INSPECTION 1. Disconnect the PTC heater connector. 2. Connect an ohmmeter between the
connector and the intake manifold, and verify continuity.
3. If it is not correct, replace the PTC heater.
SLOW FUEL CUT SOLENOID VALVE INSPECTION Operation Inspection
Note • Perform the following test only when directed.
1. Run the engine at idle speed. 2. Disconnect the carburetor connector (6-pin). 3. Disconnect the carburetor connector and
verify that the engine stops. 4. If the engine does not stop, replace the
slow fuel cut solenoid valve.
F4-24
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CONTINUED
EXHAUST SYSTEM
EXHAUST SYSTEM
EXHAUST SYSTEM INSPECTION 1. Start the engine and inspect the exhaust system component for exhaust gas leakage. 2. If leakage is found, repair or replace as necessary.
EXHAUST SYSTEM REMOVAL/INSTALLATION
Warning • When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait
until they are cool before removing the exhaust system.
1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
1 After pipe 4 Front pipe 2 Main silencer 5 Exhaust manifold
3 Pre-silencer
F1-25
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CONTINUED
EMISSION SYSTEM 3. Turn the ignition switch to "ON" and "OFF". If
there is a "clicking" noise, the air vent solenoid valve is working properly.
CHECK VALVE (TWO-WAY) INSPECTION 1. Remove the check valve (two-way). 2. Inspect airflow of the valve under the following
conditions. Condition Airflow
Apply pressure below +2.9 kPa +22 mmHg, +0.87 inHg to port A No
Apply pressure over +5.9 kPa +44 mmHg, +1.7 inHg to port A Yes
Apply pressure over -0.98 KPa -7.36 mmHg, -0.29 inHg to port A Yes
EMISSION SYSTEM N0.1 PURGE CONTROL VALVE INSPECTION 1. Blow through port A and verify that air does not
flow. 2. Connect a vacuum pump and apply vacuum of
-14.7 KPa -110 mmHg, -4.33 inHg or above and blow through port A again.
3. Verify that air flows from port A.
N0.2 PURGE CONTROL VALVE INSPECTION 1. Disconnect vacuum hose B from the pipe. 2. Blow into the hose and make sure air flows freely.
3. If not as specified, replace the charcoal canister. WATER THERMO VALVE INSPECTION 1. Remove the water thermo valve. 2. Put the threaded part in a water-filled container and
slowly increase the water temperature. 3. Check the airflow of the valve under the following
conditions.
Condition Port Below 50°C 122°F Above50°C 122°F
A-B No Airflow Airflow C-D Airflow No Airflow
4. If not as specified, replace the water thermo valve.
AIR VENT SOLENOID INSPECTION 1. Remove the air cleaner. 2. Touch the finger onto the air vent solenoid valve.
3. If not as specified, replace the check valve (two-way).
CHARCOAL CANISTER INSPECTION 1. Remove the charcoal canister. 2. Visually check the charcoal canister for damage
and leakage. 3. Shake the charcoal canister upside down and
verify that no pieces of charcoal falls from either nipple.
4. Replace the charcoal canister if necessary. ROLLOVER VALVE INSPECTION 1. Remove the rollover valve.
(Refer to FUEL SYSTEM,FUEL TANK REMOVAL/INSTALLATION.)
2. Hold the valve as shown. Blow air into port A and verify that there is airflow.
F4-26
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CONTINUED
EMISSION SYSTEM
CLOSED THROTTLE POSITION (CTP) SWITCH ADJUSTMENT 1. Warm up the engine and run it at idle. 2. Connect a dwell tacho tester to the engine. 3. Connect a voltmeter to the CTP switch terminal. 4. Increase the engine speed to more than 2,000 rpm;
decelerate gradually and verify that the volt meter indicates as follows. Engine speed Voltage
At idle Approx. 12 V 1,000—1,200 (1,100 ±100) rpm Less than 1.5 V
5. If not as specified, turn the adjust screw to adjust.
FLANGE THERMOSWITCH INSPECTION
Note • Perform the following test only when directed.
Continuity Inspection 1. Drain the coolant into a container.
(Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.)
2. Remove the flange thermoswitch from the carburetor.
3. Place the thermoswitch in water with a thermometer, and heat the water gradually.
4. Inspect the thermoswitch terminals by using
an ohmmeter. Specification
Water temperature (°C °F) Continuity
3. Turn the valve upside-down as shown. Blow air into port A and verify that there is no airflow.
4. If not as specified, replace the rollover valve. WATER THERMO VALVE REMOVAL/NSTALLATION1. Drain the engine coolant.
(Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
2. Remove the water thermo valve from the intake manifold.
3. Wrap sealing tape two or three times around the threaded part of the valve before installing.
4. Use a new washer and install in the reverse order of removal. Tightening torque 25—39 N.m 2.5—4.0 kgf.m-m, 19—28 ft.lbf
PCV VALVE INSPECTION 1. Remove the PCV valve. 2. Check the airflow of the valve under the following
conditions.
Below 67 153 Yes
Condition Airflow
Above 67 153 No
Blow from port A Yes Blow from port B No 3. If not as specified, replace the PCV valve.
5. If not as specified, replace the flange thermoswitch.
F4-27
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CONTINUED
CONTROL SYSTEM
CONTROL SYSTEM
COMPONENT LOCATION
1 Ignition coil 4 T/P solenoid valve (GULF only) 2 Water thermoswitch 5 PTC heater relay 3 PCM
6 Fuel pump relay
F4-28
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CONTINUED
CONTROL SYSTEM PCM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the front left side trim. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
PCM INSPECTION Caution • The PCM terminal voltages vary with
change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made.
1. Remove the PCM. 2. Reconnect PCM connector and battery negative
terminal. Note • With the PCM connector connected, body
ground the voltmeter negative (-) lead and measure voltage at each PCM terminal by inserting the voltmeter positive (+) lead.
3. Measure the voltage at PCM terminal using a voltmeter.
4. If any incorrect voltage is detected, inspect related systems, wiring harnesses and connectors referring to the Action column in the terminal voltage list.
PCM Terminal Voltage (Reference)
Terminal Signal Connected to Test condition Voltage (V) Action
Below 1500 rpm B+ *A Throttle
positioner control T/P solenoid valve Engine speed
Above 1500 rpm Below 1.0
• T/P solenoid valve
• Related wiring harnesses
B — GND Constant Below 1.0 • Related wiring harnesses
Coolant temperature Below 40°C 104°F
Ignition SW ON B+
C FICB control FICB solenoid valve
Other Below 1.0
• FICB solenoid valve
• Related wiring harnesses
Idle Approx 11V D Ignition Igniter
Ignition SW ON Below 1.0
• Igniter • Related wiring
harnessesE — — — — —
ON B+ F IG1 Ignition SW Ignition SW
OFF Below 1.0
• Ignition SW • Related wiring
harnessesG — — — — —
ON B+ H
• Fuel pump control
• PTC heater control
• Fuel pump relay
• PTC heater relay
Ignition SW OFF Below 1.0
• Fuel pump relay • PTC heater
relay • Related wiring
Below 40°C 104°F B+ I Coolant
temperature Water thermoswitch
Coolant temperature
Above 40°C 104°F 0V
• Water thermoswitch
• Related wiring harnesses
ON B+
J • Fuel pump
control • PTC heater
control
• Fuel pump relay
• PTC heater relay
Ignition SW OFF Below 1.0
• Fuel pump relay • PTC heater
relay • Related wiring
harnesses *: GULF only
F4-29
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CONTINUED
CONTROL SYSTEM PTC HEATER RELAY INSPECTION 1. Remove the PTC heater relay. 2. Inspect for continuity between the PTC heater
relay terminals by using an ohmmeter.
3. If not as specified, replace the PTC heater relay. THROTTLE POSITIONER (T/P) SOLENOID VALVE INSPECTION Voltage Inspection
Note • Perform the following test only when directed.
1. Run the engine at idle. 2. Connect a voltmeter to terminals of the T/P
solenoid valve as shown. 3. Measure the voltage as shown.
Engine speed (rpm) Voltage (V) Below 1,500 B+ Above 1,500 Below 1.0
8. If output voltage is as shown in the table above
but there is no airflow in the T/P solenoid valve, perform the following airflow inspection.
Airflow Inspection 1. Disconnect the negative battery cable. 2. Remove the T/P solenoid valve. 3. Inspect for airflow between each port under the
following condition.
4. If not as specified, replace the T/P solenoid valve.
If as specified, inspect the following: Vacuum hose improper routing, kinks or leakage.
Open circuit • Power circuit (T/P solenoid valve connector
terminal A and ignition switch IG1 through common connector.)
• GND circuit (T/P solenoid valve connector terminal B and PCM connector terminal A.) Short circuit
• T/P solenoid valve connector terminal A and ignition switch IG1 through common connector to GND
5. Repair or replace faulty areas. 6. Install the T/P solenoid valve. 7. Connect the negative battery cable. WATER THERMOSWITCH INSPECTION
Note • Perform the following test only when directed.
Continuity Inspection 1. Drain the coolant into a container.
(Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.)
2. Remove the water thermoswitch from the under side of the intake manifold.
3. Place the thermoswitch in water with a thermometer, and heat the water gradually.
4. Inspect the thermoswitch terminals by using an
ohmmeter.
F4-30
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CONTINUED
CONTROL SYSTEM
Specification Water temperature (°C °F) Continuity Below 40 104 Yes Above 40 104 No 5. If not as specified, replace the water
thermoswitch.
WATER THERMOSWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant.
(Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
3. Remove the water thermoswitch from the radiator. 4. The wrap sealing tape two or three times around the
threaded part of the switch before installing.
5. Use a new washer and install in the reverse order of removal.
Tightening torque 5.9—8.8 N.m 60—90 kgf.cm-cm, 53—78 in.lbf
F4-31
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CONTINUED
TROUBLESHOOTING
TROUBLESHOOTING FOREWORD
• Before proceeding with the following troubleshooting; (1) Refer to section Gl to understand the basic troubleshooting procedure. (2) Perform the diagnostic trouble code inspection. (3) If a diagnostic trouble code is displayed, proceed with inspection steps for the code. (4) When the engine can be started, perform "ENGINE TUNE-UP".
TROUBLESHOOTING ITEM TABLE • Confirm trouble symptom by using the following diagnostic index, then go to appropriate troubleshooting chart.
No. TROUBLESHOOTING ITEM DESCRIPTION 1 Cranks normally but won't start or hard start No combustion 2
Cranks normally but won't start or hard start (always)
Requires excessive cranking time (more than 5 seconds)
3
Cranks normally but won't start or hard start (engine cold)
Requires excessive cranking of longer than 5 seconds for more than 3 times for engine to start.
4
Cranks normally but won't start or hard start (engine warm)
Requires excessive cranking time (more than 5 seconds)
5 Rough idle/engine stalls at idle (always) — 6 Rough idle/engine stalls at idle (engine cold) Idling is stable when engine is warm. 7 Rough idle/engine stalls at idle (engine warm) Idling is stable when engine is cold. 8
Rough idle/engine stalls at idle when A/C or P/S ON (if equipped)
Engine runs normally at idle with no load, but stalls or vibrates excessively when load (A/C or P/S) is ON.
9 Engine suddenly stalls often — 10 High idle speed after warm-up — 11 Engine stalls at drive away — 12 Engine stalls on deceleration — 13 Hesitation — 14 Poor acceleration — 15 No power, fastest speed is low — 16 Knocking — 17 Afterburn occurs during deceleration — 18 Poor fuel economy —
F4-32
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CONTINUED
TROUBLESHOOTING
QUICK DIAGNOSTIC CHART
Fuel system
No Item
Inta
ke-a
ir sy
stem
Carburetor
Cont
rol
syst
em
Engi
ne
Emis
sion
sy
stem
Engine electrical system
1
Cranks normally but won't start or hard start O O O O O O O O O O O O
2
Cranks normally but won't start or hard start (always) O O O O O O O O O O O O
3
Cranks normally but won't start or hard start (engine cold) O O O O O O O O O O O O O
4
Cranks normally but won't start or hard start (engine warm) O O O O O O O O
5
Rough idle/engine stalls at idle (always) O O O O O O O O O O O
6
Rough idle/engine stalls at idle (engine cold) O O O O
7
Rough idle/engine stalls at idle (engine warm) O O O O O O O
8
Rough idle/engine stalls at idle when A/C or P/S ON (If equipped)
9 Engine suddenly stalls often O O O 10 High idle speed after warm-up O O O 11 Engine stalls at drive away O O O O O O O 12 Engine stalls on deceleration O 13 Hesitation O O O O O O O O O O O 14 Poor acceleration O O O O O O O O O O O O O 15 No power, fastest speed is low O O O O O O O O O O O O O 16 Knocking O O O O O O O
17
Afterburn occurs during decel-eration O O
18 Poor fuel economy O O O O O O O O O O O O
Clo
gged
air
clea
ner
Mis
adju
sted
acc
eler
ator
cab
le
Mal
func
tioni
ng h
oses
C
logg
ed p
rimar
y sl
ow
Clo
gged
prim
ary
mai
n C
logg
ed s
econ
dary
slo
w
Clo
gged
sec
onda
ry m
ain
Man
ufac
turin
g ac
cele
rato
r pum
p Fl
oat l
ever
M
alfu
nctio
ning
cho
ke s
yste
m
Mis
adju
sted
CO
, HC
con
cent
ratio
n M
alfu
nctio
ning
fuel
line
M
alfu
nctio
ning
fuel
pum
p
Mal
func
tioni
ng w
ater
sw
itch
Engi
ne in
tern
al d
amag
e M
alfu
nctio
ning
air
vent
sol
enoi
d va
lve
Mal
func
tioni
ng s
low
cut
sol
enoi
d va
lve
Mal
func
tioni
ng d
istri
buto
r M
alfu
nctio
ning
igni
tion
coil
Mal
func
tioni
ng s
park
plu
g M
alfu
nctio
ning
sta
rter
Batte
ry
Measure compres-sion pressure
Lower than specification
O
Spark inspection No spark O O O
F4-33
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CONTINUED
SYMPTOM TROUBLESHOOTING: Symptom 1-Cranks normally but will not start or hard start F4-34 Symptom 2-Cranks normally but will not start or hard start (always) F4-35 Symptom 3-Cranks normally but will not start or hard start (engine cold) F4-36-37 Symptom 4-Cranks normally but will not start or hard start (engine warm) F4-37 Symptom 5-Rough idle/engine stalls at idle (always) F4-38 Symptom 6-Rough idle/engine stalls at idle (engine cold) F4-39 Symptom 7-Rough idle/engine stalls at idle (engine warm) F4-39 Symptom 8-Rough idle/engine stalls at idle-when a/c or p/s on (if equipped) F4-40 Symptom 9-Engine suddenly stalls often F4-40 Symptom 10-High idle speed after warm-up F4-41 Symptom 11-Engine stalls at drive away F4-41-42 Symptom 12-Engine stalls on deceleration F4-42 Symptom 13-Hesitation F4-42-43 Symptom 14-Poor acceleration F4-43-44 Symptom 15-No power, fastest speed is low F4-44-45 Symptom 16-Knocking F4-46
Symptom 18-Poor fuel economy F4-47
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RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
CONTINUED
Symptom 17-After burn occurs during deceleration F4-46
TROUBLESHOOTING
SYMPTOM TROUBLESHOOTING SYMPTOM 1 CRANKS NORMALLY BUT WON'T START OR HARD START
POSSIBLE CAUSE
1. Air/Fuel mixture too lean • Air leak
2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily Ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and teaks are dangerous. Fuel can ignite and cause serious Injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Repair or replace appropriate parts. 1
Check if there is any air leakage. Is there any? No Go to next step.
Yes Go to next step. 2
Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder? No Refer to section G.
Yes Go to next step. 3
Check float level. Is it okay?
No
If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank.
Yes Check each jet and air bleed for clogging. 4
Open and close throttle valve 2-3 times. Does engine start? No Go to next step.
Yes Go to next step. 5
Check each spark plug. Are they okay? No Repair or replace spark plug.
Yes Go to step 8. 6
Check ignition timing at idle. Is it okay? No Go to next step.
Yes Adjust ignition timing. 7
Perform ignition timing adjustment. Can timing be adjusted? No Check both distributor and timing belt.
Yes Go to step 10. 8
Check slow fuel cut solenoid. Is it okay? No Go to next step.
Yes Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor.
9
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? No Repair or replace slow fuel cut solenoid valve.
Yes Go to step 12. 10
Check compression pressure. Is it okay? No Go to next step.
Yes Check pistons and cylinders for wear, 11
Add oil through plug hole. Does engine start?
No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
12
Check primary main, slow system. Is it okay?
No Clean or replace each jet and air bleed.
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CONTINUED
TROUBLESHOOTING
SYMPTOM 2 CRANKS NORMALLY BUT WON'T START OR HARD START (ALWAYS)
POSSIBLE CAUSE
1. Air/Fuel mixture too lean • Air leak • Fuel level incorrect • Restricted primary main, slow system
2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression 5. Air/Fuel mixture too rich
• Float level incorrect • Loose primary main jet
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. "
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Repair or replace appropriate parts. 1
Check if there is any air leakage. Is there any? No Go to next step.
Yes Go to next step. 2
Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder? No Refer to Section G.
Yes Go to Step 8. 3
Check ignition timing at idle. Is it okay? No Go to next step.
Yes Adjust ignition timing. 4
Perform ignition timing adjustment. Can timing be adjusted? No Check both distributor and timing belt.
Yes Go to next step. 5
Check float level. Is it okay?
No
If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank.
Yes Check each jet and air bleed for clogging. 6
Open and close throttle valve 2-3 times. Does engine start? No Go to next step.
Yes Go to next step. 7
Check each spark plug. Are they okay? No Repair or replace spark plug.
Yes Go to Step 10. 8
Check slow fuel cut solenoid. Is it okay? No Go to next step.
Yes Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor.
9
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? No Repair or replace slow fuel cut solenoid valve.
Yes Go to Step 12. 10
Check compression pressure. Is it okay? No Go to next step.
Yes Check pistons and cylinders for wear. 11
Add oil through plug hole. Does engine start?
No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
12
Check primary main, slow system. Is it okay?
No Clean or replace each jet and air bleed.
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CONTINUED
TROUBLESHOOTING
SYMPTOM 3 CRANKS NORMALLY BUT WON'T START OR HARD START (ENGINE COLD)
POSSIBLE CAUSE
1. Air/Fuel mixture too lean • Air leak
2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression 5. Air/Fuel mixture too rich
• Choke system malfunction • Loose primary main jet
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor Is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Repair or replace appropriate parts. 1
Check if there is any air leakage. Is there any? No Go to next step.
Yes Go to next step. 2
Disconnect high-tension lead at idle, then check engine speed, Does it decrease equally at each cylinder? No Refer to Section G.
Yes Go to next step. 3
Check float level. Is it okay?
No
If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank.
Yes Check each jet and air bleed for clogging. 4
Open and close throttle valve 2-3 times. Does engine start? No Go to next step.
Yes Go to next step. 5
Check each spark plug. Are they okay? No Repair or replace spark plug.
Yes Go to Step 9. 6
Check ignition timing at idle. Is it okay? No Go to next step.
Yes Adjust ignition timing. 7
Perform ignition timing adjustment. Can timing be adjusted? No Check both distributor and timing belt.
Yes Go to next step. 8
Check choke system. Is it okay? No Repair or replace choke system.
Yes Go to Step 11. 9
Check slow fuel cut solenoid. Is it okay? No Go to next step.
Yes Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor.
10
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? No Repair or replace slow fuel cut solenoid valve.
Yes Go to Step 13. 11
Check compression pressure. Is it okay? No Go to next step.
Yes Check pistons and cylinders for wear. 12
Add oil through plug hole. Does engine start?
No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
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CONTINUED
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
13
Check primary main, slow system. Is it okay?
No Clean or replace each jet and air bleed.
SYMPTOM 4 CRANKS NORMALLY BUT WON'T START OR HARD START (ENGINE WARM)
POSSIBLE CAUSE
1. Percolation • Air vent solenoid valve malfunction
2. Air/Fuel mixture too rich • High float level • Choke system malfunction
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage.
Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION 1 Inspect spark plugs. Yes Repair or replace Are spark plugs wet or covered with carbon? No Go to next step.
2 Check choke system. Yes Go to next step. Is it okay? No Repair or replace choke system.
3 Check air vent solenoid valve. Yes Go to next step. Is it okay? No Replace air vent solenoid valve.
4 Check float level? Yes Check for the following: Is it okay? (float level is high.) • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) No Inspect both float and needle valve.
F4-37
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CONTINUED
TROUBLESHOOTING
SYMPTOM 5 ROUGH IDLE/ENGINE STALLS AT IDLE (ALWAYS)
POSSIBLE CAUSE
1. Air/Fuel mixture too rich • High float level • Loose primary main jet • Restricted primary slow air bleed
2. Poor ignition or misfire 3. Air/Fuel mixture too lean
• Air leakage • Restricted primary main jet
4. Low engine compression Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described In this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Repair or replace appropriate parts. 1
Check if there is any air leakage. Is there any? No Go to next step.
Yes Go to next step. 2
Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder? No Refer to Section G.
Yes Go to next step. 3
Check idle-up system. Is it okay? No Repair or adjust system.
Yes Go to Step 6. 4
Check ignition timing at idle. Is it okay? No Go to next step.
Yes Adjust ignition timing. 5
Perform ignition timing adjustment. Can timing be adjusted? No Check both distributor and timing belt.
Yes Go to Step 8. 6
Check idling speed. Is it okay? No Go to next step.
Yes Adjust idling speed. 7
Perform idling speed adjustment. Can idling speed be adjusted? No Adjust or inspect idling mixture.
Yes Go to next step. 8
Check pcv valve. Is it okay? No Repair or replace pcv valve.
Yes Go to Step 11. 9
Check compression pressure? Is it okay? No Go to next step.
Yes Check pistons and cylinders for wear. 10
Drive vehicle. Does engine stop at takeoff?
No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
11
Check primary main, slow system. Is it okay?
No Clean or replace each jet and air bleed.
F4-38
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CONTINUED
TROUBLESHOOTING
SYMPTOM 6 ROUGH IDLE/ENGINE STALLS AT IDLE (ENGINE COLD)
POSSIBLE CAUSE
• Choke system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION 1
Check choke system (quick release). Is it okay?
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
No Repair or replace choke system.
SYMPTOM 7 ROUGH IDLE/ENGINE STALLS AT IDLE (ENGINE WARM)
POSSIBLE CAUSE
1. Choke system malfunction 2. Float level incorrect 3. Air vent solenoid valve malfunction
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Go to next step. 1
Start and warm engine. Check choke valve. Is it fully open? No Repair or replace choke system.
Yes Repair or replace spark plugs. 2
Inspect spark plugs. re spark plugs wet or covered with carbon? No Go to next step.
Yes Go to next step. 3
Check air vent solenoid valve. Is it okay? No Replace valve.
Yes Go to next step. 4
Check fuel check valve. Is it okay? No Repair or replace valve.
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
5
Check float level. Is it okay? (float level is high.)
No Inspect both float and needle valve.
F4-39
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CONTINUED
TROUBLESHOOTING
SYMPTOM 8 ROUGH IDLE/ENGINE STALLS AT IDLE - WHEN A/C OR P/S ON (IF EQUIPPED
POSSIBLE CAUSE
1. Idle-up system malfunction • Solenoid valve malfunction
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious Injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes
Follow steps for troubleshooting item "Rough idle/engine stalls at idle (Always)".
1
Inspect idle-up system. Is it okay? No Adjust or repair system,
SYMPTOM 9 ENGINE SUDDERLY STALLS OFTEN
POSSIBLE CAUSE
1. Disconnected starter connector 2. Poor connection of starter connector Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor Is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks
and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Go to next step. 1
Check starter connector. Is it disconnected or is it not properly con-nected?
No Properly connect connector, or repair or replace if necessary.
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
2
Check slow fuel cut valve. Is it okay?
No Go to next step. Yes Repair or replace wiring harness between slow fuel cut
solenoid valve and carburetor. 3
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? No Repair or replace slow fuel cut solenoid valve.
F4-40
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CONTINUED
TROUBLESHOOTING
SYMPTOM 10 HIGH IDLE SPEED AFTER WARM-UP
POSSIBLE CAUSE
• Idle-up system malfunction • Choke system malfunction
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks
and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Go to next step. 1
Check throttle wiring. Is there sufficient slack in wiring? No Adjust or repair accelerator cable.
Yes Go to next step. 2
Check idle-up system. Is it okay? No Adjust or repair.
Yes Go to next step. 3
Check secondary throttle valve. Is it closed? No Repair or inspect secondary diaphragm link.
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
4
Check float level. Is it okay? (float level is high.)
No Inspect both float and needle valve.
SYMPTOM 11 ENGINE STALLS AT DRIVE AWAY
POSSIBLE CAUSE
• Restricted primary main system • Accelerator pump malfunction • Poor ignition or misfire • Malfunctioning unloader system
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks
and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Repair or replace parts as necessary. 1
Check system for air leakage. Is there any? No Go to next step.
Yes Go to next step. 2
Check throttle wiring. Is there sufficient slack in wiring? No Adjust or repair accelerator cable.
Yes Go to next step. 3
Check accelerator pump. Is fuel pumped out when accelerator pump is depressed? No Repair or replace accelerator pump.
Yes Go to next step. 4
Check distributor's vacuum advance. Is it correct? No Replace distributor vacuum control unit.
Yes Go to next step. 5
Check unloader system. Is it okay? No Repair or replace unloader system.
F4-41
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CONTINUED
TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
6
Check primary main, slow system. Is it okay?
No Clean or replace each Jet and air bleed.
SYMPTOM 12 ENGINE STALLS ON DECELERATION
POSSIBLE CAUSE
• Slow fuel cut solenoid valve malfunction • Throttle positioner (T/P) malfunction (GULF only) Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Go to next step. 1
Check idle-up system. Is it okay? No Repair or replace any parts as necessary.
Yes Go to Step 4. 2
Check slow fuel cut valve. Is it okay? No Go to next step.
Yes
Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor.
3
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? No Repair or replace slow fuel cut solenoid valve.
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
4
Check dashpot's touch speed. Is it correct?
No Adjust dashpot.
SYMPTOM 13 HESITATION
POSSIBLE CAUSE
• Spark advance control malfunction • Restricted jets • Air leakage
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Repair or replace any parts as necessary. 1
Check system for air leakage. Is there any? No Go to next step.
Yes Go to next step. 2
Check throttle wiring. Is there sufficient slack in wiring? No Adjust or repair accelerator cable.
F4-42
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CONTINUED
TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes Go to next step. 3
Check centrifugal spark advance control. Is it okay?
No
Check for the following: • Over advance (Inspect for governor spring damage.) • Under advance (Inspect governor weight, cam op eration.)
Yes Go to next step. 4
Check accelerator pump. Is fuel pumped out when accelerator pump is depressed? No Repair or replace pump.
Yes Go to next step. 5
Check secondary diaphragm. Is it okay? No Replace secondary diaphragm.
Yes Go to next step. 6
Inspect spark plugs? Are they okay? No Clean or replace spark plugs.
Yes Go to next step. 7
Is linkage of primary and secondary valve smooth? No Repair or replace any parts as necessary.
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
8
Inspect every jet. Are they okay?
No
Clean or replace jets. Note • Dirt and grime can be removed from jets by covering the air horn with your hand.
SYMPTOM 14 POOR ACCELERATION
POSSIBLE CAUSE
1. Spark advance control malfunction 2. Restricted intake/exhaust system 3. Air/Fuel mixture too lean
• Low float level • Restricted jets, air bleeds • Accelerator pump malfunction
4. Secondary diaphragm malfunction • RPM limiter malfunction
5. Low engine compression 6. Poor ignition Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Go to next step. 1
Check throttle wiring. Is there sufficient slack in wiring? No Adjust or repair accelerator cable.
Yes Go to next step. 2
Inspect intake system. Is it restricted? (especially air cleaner) No Repair or replace intake system.
Yes Go to next step. 3
Check choke valve. Is it fully open after warm-up? No Repair or replace choke system.
Yes Go to next step. 4
Check distributor, (centrifugal spark advance, vacuum spark advance) It is okay? No Repair or replace distributor.
F4-43
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CONTINUED
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION
Yes Go to next step. 5
Inspect exhaust system. Is it okay? No Repair or replace exhaust system.
Yes Go to next step. 6
Inspect accelerator pump. It is okay? No Repair or replace accelerator pump.
Yes Go to next step. 7
Check float level. Is it okay?
No
If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank.
Yes Go to next step. 8
Inspect spark plugs. Are they okay? No Clean or replace spark plugs.
Yes Go to next step. 9
Check secondary diaphragm. Is it okay? No Replace secondary diaphragm.
Yes Go to Step 12. 10
Check compression pressure. Is it okay? No Go to next step.
Yes Check pistons, rings, and cylinders for wear. 11
Add oil through plug hole. Does engine start?
No
Check the following: • Cylinder heads, gaskets • Valve clearance
Yes Clean or replace each jet and air bleed. 12
Inspect all jets and air bleeds (including high speed richer) of both primary and secondary main passage. Is there blockage?
No
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
SYMPTOM 15 NO POWER, FASTEST SPEED IS LOW
POSSIBLE CAUSE
• Restricted primary main, slow system • Centrifugal spark advance malfunction • Restricted exhaust system • Restricted air cleaner
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can Ignite and cause serious Injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Go to next step. 1
Check system for air leakage. Is there any No Repair or replace any part as necessary.
Yes Stop vehicle and let it idle to cool engine. Inspect coolant and engine oil.
2
Check engine. Does it seem to be overheating? No Go to next step.
Yes Go to next step. 3
Check throttle wiring. Is there sufficient slack in wiring? No Adjust or repair accelerator cable.
Yes Go to next step. 4
Check choke valve. Is it fully open after warm-up? No Repair or replace choke valve.
Yes Go to next step. 5
Check intake system. Is it restricted? (especially air cleaner) No Repair or replace intake system.
F4-44
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CONTINUED
TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION Yes Go to next step. 6
Check exhaust system. Is it restricted? No Repair or replace exhaust system.
Yes Go to next step. 7
Check float level. Is it okay? (float level is low.)
No
If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank.
Yes Go to next step. 8
Inspect spark plugs. Are they okay? No Clean or replace spark plugs.
Yes Go to next step. 9
Check secondary diaphragm. Is it okay? No Replace secondary diaphragm.
Yes Go to next step. 10
Check centrifugal spark advance control. Is it okay? No
Check for the following: • Over advance (Inspect for governor spring damage.) • Under advance (Inspect governor weight, cam op-
eration.)Yes Go to Step 13. 11
Check compression pressure. Is it okay? No Go to next step.
Yes Check pistons and cylinders for wear. 12
Add oil through plug hole. Does engine start?
No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
Yes Go to next step. 13
Check main (primary) system. Is it okay?
No
Check the following: • Main jet • Air bleed
Note • Dirt and grime can be removed from jets by covering the air horn with your hand.
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
14
Check main (secondary) system. Is it okay?
No
Check the following: • Main jet • Air bleed Note • Dirt and grime can be removed from jets by covering the air horn with your hand.
F4-45
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CONTINUED
TROUBLESHOOTING
SYMPTOM 16 KNOCKING
POSSIBLE CAUSE
1. Air/Fuel mixture too lean • Restricted primary main, slow system • Poor ignition or misfire • Insufficient engine coolant
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious Injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Stop vehicle and let it idle to cool engine.
Inspect coolant and engine oil, 1
Check engine Does it seem to be overheating? No Go to next step.
Yes Replace fuel, 2
Inspect spark plugs. Are spark plugs electrode free of carbon ac-cumulation? No Clean or replace spark plugs.
SYMPTOM 17 AFTERBURN OCCURS DURING DECELERATION
POSSIBLE CAUSE
• Poor ignition or misfire • Slow fuel cut solenoid valve malfunction • Throttle position (T/P) malfunction (GULF only) • Dashpot malfunction
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage.
Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Go to Step 3. 1
Check ignition timing at idle. Is it okay? No Go to next step.
Yes Adjust ignition timing. 2
Perform ignition timing adjustment. Can timing be adjusted? No Check both distributor and timing belt.
Yes Go to next step. 3
Inspect distributor, (centrifugal spark ad-vance, vacuum spark advance) It is okay? No Repair or replace distributor.
Yes Go to next step.4
Check thermostat. Is it okay? No Repair or replace thermostat.
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
5
Inspect every jet. Are they okay?
No Clean or replace jets.
F4-46
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CONTINUED
TROUBLESHOOTING
SYMPTOM 18 POOR FUEL ECONOMY
POSSIBLE CAUSE
• Incorrect adjustment of main adjust screw • Incorrect adjustment of idle speed • High float level • Poor ignition or misfire
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death
and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION RESULTS ACTION Yes Go to next step. 1
Check system for air leakage. Is there any? No Repair or replace any part as necessary.
Yes Go to Step 4. 2
Check ignition timing at idle. Is it okay? No Go to next step.
Yes Adjust ignition timing. 3
Perform ignition timing adjustment. Can timing be adjusted? No Check both distributor and timing belt.
Yes Go to Step 6. 4
Check idling speed. Is it correct? No Go to next step.
Yes Adjust idling speed. 5
Perform idling speed adjustment. Can it be adjusted? No Adjust or repair any part as necessary.
Yes Go to Step 8. 6
Check slow fuel cut solenoid valve. Is it okay? No Go to next step.
Yes Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor.
7
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? No Repair or replace slow fuel cut solenoid valve.
Yes Go to next step. 8
Check both CO and HC concentration. Are they okay? No Adjust CO and HC concentrations.
Yes Go to next step. 9
Check choke valve. Is it fully open after warm-up? No Repair or replace choke system.
Yes Go to next step. 10
Check float level. Is it okay? (float level is high.)
No
Check the following: • Float • Needle valve
Yes Go to next step. 11
Check distributor, (centrifugal spark advance, vacuum spark advance) Is it okay? No Repair or replace distributor.
Yes Go to Step 14. 12
Check compression pressure. Is it normal? No Go to next step.
Yes Check pistons and cylinders for wear. 13
Add oil through plug hole. Does engine start?
No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
14
Is main jet loose?
No Clean or replace jets.
F4-47
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CONTINUED
ST
G–1
ENGINE ELECTRICAL SYSTEMCHARGING SYSTEM G–1. . . . . . . . . . . . . . . . . . . . . .
BATTERY REMOVAL/INSTALLATION G–1. . . . . . BATTERY INSPECTION G–1/2. . . . . . . . . . . . . . . . . . BATTERY RECHARGING G–2. . . . . . . . . . . . . . . . . GENERATOR REMOVAL/INSTALLATION G–2/3. . . GENERATOR INSPECTION G–3/4. . . . . . . . . . . . . .
IGNITION SYSTEM G–5. . . . . . . . . . . . . . . . . . . . . . . . IGNITER INSPECTION G–5. . . . . . . . . . . . . . . . . . . IGNITION COIL REMOVAL/INSTALLATION G–5.
IGNITION COIL INSPECTION G–5/6. . . . . . . . . . . . . DISTRIBUTOR REMOVAL/INSTALLATION G–6/7. . DISTRIBUTOR DISASSEMBLY/ASSEMBLY G–8. DISTRIBUTOR INSPECTION (F2 CARB) G–9. . . HIGH-TENSION LEAD
REMOVAL/INSTALLATION G–9. . . . . . . . . . . . . . STARTING SYSTEM G–10. . . . . . . . . . . . . . . . . . . . . . .
STARTER REMOVAL/INSTALLATION G–10. . . . . . STARTER INSPECTION G–10/11. . . . . . . . . . . . . . . . . .
CHARGING SYSTEMBATTERY REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
N·m kgf·cm, in·lbf
3.5—4.935—50, 31—43
1 Negative battery cable
2 Positive battery cable
3 Battery clamp+ Installation Note (RH)
4 Battery
5 Battery tray
Battery Clamp Installation Note (RH) Install the battery clamp as shown.
FRONT
FRONT
75D26R
BATTERY INSPECTIONBattery Inspect the battery in the following procedure.Step Inspection Action
1 Measure open circuitAbove12.4 V
Go toStep 3.
1voltage of battery. Below
12.4 VGo tonext step.
2Quick charge for 30minutes and recheck
Above12.4 V
Go tonext step.
2 minutes and recheckvoltage. Below
12.4 VReplacebattery.
3
Apply test load (see testload chart) to battery usinga battery load tester and
YesBattery isokay.
3y
record battery voltage after15 seconds. Is voltagemore than specification?
NoReplacebattery.
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CHARGING SYSTEM
G–2
Test load chartBattery Load (A)
34B19R 110
55D23R 180
75D26L 195
75D26R 195
80D26R 195
95D31R 250
Battery positive voltage with loadApproximatebattery temp.
Minimum voltage(V)
21 °C 70 °F 9.6
15 °C 60 °F 9.5
10 °C 50 °F 9.4
4 °C 40 °F 9.3
– 1 °C 30 °F 9.1
– 7 °C 20 °F 8.9
–12 °C 10 °F 8.7
–18 °C 0 °F 8.5
Back-up Current1. Verify that the ignition switch (engine switch) is at the
OFF position and that the key has been removed.2. Disconnect the negative battery cable.
Caution Operating electrical loads while measuring
the back-up current can damage the circuittester.
3. Measure the back-up current between the negativebattery terminal and the negative battery cable.
Back-up current20 mA max.
4. If the current exceeds the maximum, remove thefuse in the main fuse block and the fuse block oneby one while measuring the back-up current.
5. Inspect and repair harnesses and connectors ofthe fuse at which the current reduces.
BATTERY RECHARGING
Caution When disconnecting the battery, remove
the negative cable first and install it last toprevent damage to electrical componentsor the battery.
To avoid deformation or damage to thebattery, remove the battery plugs whilecharging the battery.
Do not quick charge for over 30 minutes. Itwill damage the battery.
1. Place a battery in a pan of water to prevent it fromoverheating. The water level should come up abouthalfway on the battery. Keep water off the top ofthe battery.
BATTERY
2. Connect a battery charger to the battery.3. Adjust the charging current as follows.
Battery type(5–hour rate)
Slow charge(A)
Quick charge(A)/(30 min.)
34B19R (27) 3.0—4.0 20
55D23R (48) 4.5—5.5 30
75D26L (52) 5.5—6.5 35
75D26R (52) 5.5—6.5 35
80D26R (55) 5.5—6.5 35
95D31R (64) 6.5—8.0 40
4. After the battery has been recharged, measure thebattery positive voltage and verify that the batterykeeps specified voltage for more than 1 hour.
SpecificationAbove 12.4 V
5. If not as specified, replace the battery.
GENERATOR REMOVAL/INSTALLATION
Warning When the battery cables are connected,
touching the vehicle body with generatorterminal B will generate sparks. This cancause personal injury, fire, and damage tothe electrical components. Alwaysdisconnect the battery before performingthe following operation.
1. Disconnect the negative battery cable.2. Remove the fresh-air duct, air intake pipe and air
hose. (WL, WL Turbo)3. Remove in the order indicated in the table.4. Install in the reverse order of removal.5. Inspect the drive belt deflection/tension.
(Refer to Section B2, DRIVE BELT, DRIVE BELT INSPECTION.)
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ST
CHARGING SYSTEM
G–3
5.0—6.8 N·m 50—70 kgf·cm, 44—60 in·lbf
N·m kgf·m, ft·lbf
38—51 3.8—5.3, 28—38
G6
19—25 1.9—2.6,14—18
5.0—6.8 N·m 50—70 kgf·cm, 44—60 in·lbf
N·m kgf·m, ft·lbf
38—51 3.8—5.3, 28—38
16—22 1.6—2.3,12—16
F2 CARB, F2 CIS
5.0—6.8 N·m 50—70 kgf·cm,44—60 in·lbf
38—51 3.8—5.3,28—38
N·m kgf·m, ft·lbf
A
B
C
38—51 3.8—5.3, 28—38
20—302.0—3.1, 15—22
A
B
C
WL, WL Turbo
1 Terminal B wire
2 Connector
3 Drive belt (generator)
4 Generator strap (G6)
5 Generator
GENERATOR INSPECTIONGenerator Warning Light
1. Verify that the battery is fully charged.2. Verify that the drive belt deflection/tension is
correct. (Refer to Section B2, DRIVE BELT,DRIVE BELT INSPECTION.)
3. Turn the ignition switch (engine switch) on andverify that the generator warning light illuminates.
4. If not, inspect the generator warning light andwiring harnesses between the battery andgenerator warning light and between the batteryand generator terminal L (G6, F2 CARB, F2 CIS), I(WL, WL Turbo).
S L
G6, F2 CARB, F2 CIS
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CHARGING SYSTEM
G–4
A S I
WL, WL Turbo
5. Verify that the generator warning light goes outafter engine starts.
6. If not, inspect the wiring harness between the Sterminals of the generator (WL, WL Turbo) and thegenerator.
GeneratorVoltage
1. Verify that the battery is fully charged.2. Verify that the drive belt deflection/tension is within
the specification. (Refer to Section B2, DRIVEBELT, DRIVE BELT INSPECTION.)
3. Turn off all electrical loads.4. Turn the ignition switch (engine switch) to START
position and verify that the generator turnssmoothly without any noise while the engine isrunning.
5. Measure the voltage at the terminals shown in thetable.
S L
G6, F2 CARB, F2 CIS
Standard voltage
TerminalIgnition switch ON (V) Idle [20 °C 68°F] (V)
TerminalG6, F2 CARB, F2 CIS G6, F2 CARB, F2 CIS
B B+ 14.1—14.7
L Approx. 1 13.0—14.0
S B+ 14.1—14.7
A S I
WL, WL Turbo
Standard voltage
TerminalEngine switch ON (V) Idle (V) [20 °C 68°F]
TerminalWL, WL Turbo WL, WL Turbo
B B+ 14.05—14.85
A B+ 14.05—14.85
S 0 7.025—7.425
I 2.0—4.0 13.00—14.85
6. If not as specified, disassemble and inspect thegenerator.
Current1. Verify that the battery is fully charged.2. Verify that the drive belt deflection/tension is
correct. (Refer to Section B2, DRIVE BELT,DRIVE BELT INSPECTION.)
3. Disconnect the negative battery cable.4. Connect an ammeter, capable of reading 120 A or
over, between generator terminal B and the wiringharness.
5. Connect the negative battery cable.6. Turn all electrical loads off.7. Start the engine and increase the engine speed to
2,000—2,500 rpm.8. Turn the following electrical loads on and verify that
the current reading increases. Headlights Blower motor Rear window defroster
Note Current required for generating power varies
with electrical loads applied.
Standard current (Reference)
Measuring conditionsRoom temperature: 20 °C 68 °FVoltage: 13.5 VEngine hot
Engine speedTerminal B current (A) *
Engine speed(rpm) G6, F2 CARB,
F2 CISWL, WL Turbo
1,000 Approx. 0—43 Approx. 0—58
2,000 Approx. 0—62 Approx. 0—74
*: Must not be 0 A.
9. If generator terminal B current will not increase,disassemble and inspect the generator.
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ST
IGNITION SYSTEM
G–5
IGNITION SYSTEMIGNITER INSPECTIONG6, F2 CIS
1. Disconnect the igniter connector.2. Turn the ignition switch on and measure the
voltage at connector terminal A using thevoltmeter.
G6, F2 CIS
SpecificationBattery positive voltage
3. Turn the ignition switch off and verify that there iscontinuity between terminal B and the bodyground.
4. While cranking the engine, measure the voltage atterminal C using the voltmeter.
SpecificationApprox. 0.5 V
5. If voltage and continuity are okay, replace theigniter. (Refer to IGNITION SYSTEM, IGNITIONCOIL REMOVAL/INSTALLATION.)
IGNITION COIL REMOVAL/INSTALLATIONG6, F2 CARB, F2 CIS
1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
8.9—12.7 90—130, 79—112
1.5—1.9 15—20, 14—17
6.87—9.80 70—100, 60.8—86.8]
N·m kgf·cm, in·lbf
G6, F2 CIS
8.9—12.7 90—130, 79—112
2.0—2.9 20—30, 18—26
6.87—9.80 70—100, 60.8—86.8]
N·m kgf·cm, in·lbf
F2 CARB
1 Center lead
2 Connector
3 Ignition coil bracket
4 Condenser
5 Ignition coil
6 Igniter
IGNITION COIL INSPECTIONG6, F2 CARB, F2 CISPrimary Coil Winding
1. Disconnect the ignition coil connector.
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IGNITION SYSTEM
G–6
2. Measure the resistance at the primary coil using anohmmeter.
Specification [20 °C 68 °F]G6, F2 CIS: 0.81—0.99 ΩF2 CARB: 1.035—1.265 Ω
G6, F2 CIS
F2 CARB
3. If not as specified, replace the ignition coil. (Refer to IGNITION SYSTEM, IGNITION COILREMOVAL/INSTALLATION.)
Secondary Coil Winding1. Disconnect the ignition coil connector.2. Disconnect the center lead.3. Measure the resistance at the secondary coil using
an ohmmeter.
Specification10—16 k [20 °C 68 °F]
G6, F2 CIS
F2 CARB
(+)
4. If not as specified, replace the ignition coil. (Refer to IGNITION SYSTEM, IGNITION COILREMOVAL/INSTALLATION.)
DISTRIBUTOR REMOVAL/INSTALLATIONG6, F2 CARB, F2 CIS
1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.4. Adjust the ignition timing.
(Refer to Section F2, ENGINE TUNE-UP, IGNITION TIMING ADJUSTMENT.)
19—25 1.9—2.6, 14—18
N·m kgf·m, ft·lbf
G6
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ST
IGNITION SYSTEM
G–7
19—25 1.9—2.6, 14—18
N·m kgf·m, ft·lbf
F2 CARB
19—25 1.9—2.6, 14—18
N·m kgf·m, ft·lbf
F2 CIS
1 Vacuum hose
2 High-tension lead+ HIGH-TENSION LEAD
REMOVAL/INSTALLATION
3 Connector
4 Distributor+ Installation Note
Distributor Installation Note Verify that the No.1 cylinder is at top dead center,
and align the distributor matching marks.
MATCHING MARKS
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IGNITION SYSTEM
G–8
DISTRIBUTOR DISASSEMBLY/ASSEMBLYG6, F2 CARB, F2 CIS
1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
F2 CARB
F2 CISG6
R
R
R
1 Cap
2 Rotor
3 Cover
4 Signal rotor
5 Pick-up coil with igniter
6 Vacuum control unit
7 Breaker
8 Coupling set
9 Governor set
10 Oil seal
11 Bearing
12 Distributor body
13 O-ring
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ST
IGNITION SYSTEM
G–9
DISTRIBUTOR INSPECTION (F2 CARB)Centrifugal Spark Advance Control
1. Warm up the engine to the normal operatingtemperature.
2. Check to be sure that the idle speed and ignitiontiming are correct. (Refer to Section F2, ENGINE TUNE-UP.)
3. Turn off all electrical loads.4. Disconnect the vacuum hose to the vacuum control
unit, and plug the end of the hose.
VACUUM HOSE
5. While gradually increasing the engine speed, usethe timing light to check the advance angle oncrankshaft pulley.
ENGINE SPEED ( rpm )
19—23
9—13
ADVANCE (DEGREE)
( ° )
0 1,200 2,200 6,0000—2
(1) Excess advance weak governor spring (if . . . the governor spring is
broken, the advance will rise very high)
(2) Insufficient advance governor weight or cam .malfunction
6. If necessary, disassemble and inspect thedistributor.
Vacuum Spark Advance Control1. Warm up the engine to normal operating
temperature.2. Check to be sure that the idle speed and ignition
timing are correct.(Refer to section F2, ENGINE TUNE-UP.)
3. Turn off all electrical loads.4. Disconnect the vacuum hose to the vacuum control
unit, and plug the end of the hose.5. Attach a vacuum pump to the diaphragm A and
check using the timing light while applying vacuum.
DIAPHRAGM A
TIMING LIGHT
ADVANCE (DEGREE)
( ° )
VACUUM ( kPa mmHg , inHg )
20 150, 5.9
11—15
53.3400, 15.7
00—2
6. If necessary, disassemble and inspect thedistributor.
Pick-up Coil With Igniter Inspection1. Connect an ohmmeter to the pick-up coil.
2. Measure the resistance.
Resistance900—1,200 Ω
3. If it is not within specification, replace it.
HIGH-TENSION LEAD REMOVAL/INSTALLATION
Caution The high-tension leads must be reinstalled
to their original positions. Incorrectinstallation can damage the leads andcause power loss, and negatively affect theelectronic components.
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STARTING SYSTEM
G–10
STARTING SYSTEMSTARTER REMOVAL/INSTALLATION
Warning When the battery cables are connected,
touching the vehicle body with starterterminal B will generate sparks. This cancause personal injury, fire, and damage tothe electrical components. Alwaysdisconnect the battery before performingthe following operation.
1. Disconnect the negative battery cable.2. Remove the battery. (WL, WL Turbo)
(Refer to CHARGING SYSTEM, BATTERYREMOVAL/INSTALLATION.)
3. Remove the intake manifold bracket. (G6)4. Remove in the order indicated in the table.5. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
9.9—11.7 N·m 100—120 kgf·cm,87—104 in·lbf
38—51 3.8—5.3, 28—38
G6, F2 CARB, F2 CIS
N·m kgf·m, ft·lbf
9.9—11.7 N·m 100—120 kgf·cm,87—104 in·lbf
38—51 3.8—5.3, 28—38
WL, WL Turbo
1 Terminal B wire
2 Terminal S wire
3 Starter
STARTER INSPECTIONOn-vehicle Inspection
1. Verify that the battery is fully charged.2. Crank the engine and verify that the starter turns
smoothly without any noise.3. If not as specified, measure the voltage at
terminals S and B when the ignition switch (engineswitch) is at START position.
SpecificationAbove 8 V
4. If the voltage is within the specification, remove thestarter and inspect the magnetic switch and thestarter.
5. If the voltage is not as specified, inspect the wiringharness, ignition switch (engine switch).
No Load Test1. Verify that the battery is fully charged.2. Connect the starter, battery, voltmeter, and
ammeter as shown.
STARTER
A
B
M
V
TERMINAL S
IGNITIONSWITCH(ENGINESWITCH)
BATTERY
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STARTING SYSTEM
G–11
3. Operate the starter and verify that it turnssmoothly.
4. Measure the voltage and current while the starteris operating.
SpecificationEngine type
ItemG6 F2 CARB,
F2 CISWL,
WL Turbo
Voltage (V) 11.5 11.5 11
Current (A) Below 100 Below 60 Below 130
5. If not as specified, repair or replace the inner partsas necessary.
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H–1
CLUTCHGENERAL PROCEDURES H–1. . . . . . . . . . . . . . . . . . . CLUTCH FLUID H–1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH FLUID INSPECTION H–1. . . . . . . . . . . . . CLUTCH FLUID REPLACEMENT/AIR
BLEEDING H–1/2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH PEDAL H–2. . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH PEDAL INSPECTION/ADJUSTMENT H–2/3. . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH PEDAL REMOVAL/INSTALLATION H–3. . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH PEDAL DISASSEMBLY/ASSEMBLY H–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH MASTER CYLINDER H–5. . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER
REMOVAL/INSTALLATION H–5. . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER
DISASSEMBLY/ASSEMBLY H–5/6. . . . . . . . . . . . . .
CLUTCH RELEASE CYLINDER H–7. . . . . . . . . . . . . . CLUTCH RELEASE CYLINDER
REMOVAL/INSTALLATION H–7. . . . . . . . . . . . . . . CLUTCH RELEASE CYLINDER
DISASSEMBLY/ASSEMBLY H–7. . . . . . . . . . . . . . CLUTCH UNIT H–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH COVER INSPECTION H–10. . . . . . . . . . . . CLUTCH DISC INSPECTION H–11. . . . . . . . . . . . . . . CLUTCH RELEASE COLLAR
INSPECTION H–11. . . . . . . . . . . . . . . . . . . . . . . . . . . FLYWHEEL H–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PILOT BEARING INSPECTION H–11. . . . . . . . . . . . . FLYWHEEL INSPECTION H–11. . . . . . . . . . . . . . . . .
GENERAL PROCEDURESClutch Pipe Removal/Installation
1. If any clutch pipe has been disconnected any timeduring the procedure, add brake fluid, bleed the air,and inspect for leakage after the procedure hasbeen completed.
2. If removing the clutch pipe, remove it using theSST (49 0259 770B). If installing the clutch pipe,modify the clutch pipe tightening torque to allow forthe use of a torque wrench–SST (49 0259 770B)combination, and then tighten the clutch pipe usingthe SST (49 0259 770B).
CLUTCH FLUIDCLUTCH FLUID INSPECTION
Note The fluid in the reservoir must be maintained
between the MIN/MAX level duringreplacement.
CLUTCH FLUID REPLACEMENT/AIR BLEEDING
Caution Clutch fluid will damage painted surfaces,
be careful not to spill clutch fluid on apainted surface. If this should happen,wash it off immediately.
Do not mix different brands of clutch fluid. Do not reuse the clutch fluid that was
drained out.1. Draw the fluid from the reserve tank with a suction
pump.2. Remove the bleeder cap from the clutch release
cylinder and attach a vinyl hose to the bleeder plug.3. Place the other end of the vinyl hose into a
container.4. Slowly pump the clutch pedal several times.5. With the clutch pedal depressed, loosen the
bleeder screw using the SST to let fluid escape.Close the bleeder screw using the SST.
BLEEDER SCREW
49 0259 770B
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CLUTCH UNIT REMOVAL/INSTALLATION . . . H–8/10
CLUTCH FLUID, CLUTCH PEDAL
H–2
1.Repeat steps 4 and 5 until only clean fluid is seen.2.Tighten the bleeder screw.
Tightening torque5.9—8.8 N·m 60—90 kgf·cm, 52—78 in·lbf
3.Add fluid to the MAX mark.4.Check for correct clutch operation.
CLUTCH PEDALCLUTCH PEDAL INSPECTION/ADJUSTMENTClutch Pedal Height
1. Measure the distance from the upper surface of thepedal pad to the carpet.
Pedal height241.6—246.6 mm 9.52—9.70 in
N·m kgf·m, ft·lbf
PEDAL HEIGHT
A 14—171.4—1.8, 11—13
B
CARPET
2.If necessary, adjust the pedal height by turningstopper bolt A and clutch switch (or adjust bolt) B.
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CLUTCH PEDAL
H–3
Clutch Pedal Free Play1. Depress the clutch pedal by hand until clutch
resistance is felt, and measure the pedal free play.
Pedal free play3.0—8.0 mm 0.12—0.31 in
PEDALFREE PLAY
N·m kgf·m, ft·lbf
D
C12—161.2—1.7, 8.7—12.3
2.If necessary, adjust the pedal free play by turninglocknut C and adjusting push rod D.
Clutch Release Point Inspection1. Without depressing the clutch pedal, slowly shift
the shift lever into reverse position until the gearscontact.
2.Gradually depress the clutch pedal and measure thestroke distance from the point the gear noise stops(release point) up to the full stroke end position.
Standard distanceA: 14.6—37.5 mm 0.58—1.47 in
(reference value)
FULLSTROKEENDPOSITION
RELEASEPOINT
A
PEDAL STROKE
3.If the clutch pedal disengagement stroke is outside ofthe specification, adjust the pedal height and pedalfree play, and verify the pedal stroke.
Pedal stroke146.5—151.5 mm 5.8—5.9 in
(reference value)
CLUTCH PEDAL REMOVAL/INSTALLATION1. Disconnect the negative battery cable.
2.Remove in the order indicated in the table.3.Install in the reverse order of removal.4.After installation, adjust the clutch pedal.
(Refer to CLUTCH PEDALINSPECTION/ADJUSTMENT)
L.H.D.
N·m kgf·m, ft·lbf
19—251.9—2.6,14—18
19—251.9—2.6,14—18
6.9—9.80 N·m70—100 kgf·cm,61—86.8 in·lbf
1 Clutch switch connector (G6, F2 CIS)
2 Spring pin
3 Clevis pin
4 Nut
5 Clutch pedal component
R.H.D.G6, F2 CIS, F2 Carb Refer to section F2, INTAKE-AIR
SYSTEM, ACCELERATOR PEDALREMOVAL/INSTALLATION.
WL, WL Turbo Refer to section F2, INTAKE-AIR SYSTEM,
ACCELERATOR PEDALREMOVAL/INSTALLATION.
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CLUTCH PEDAL
H–4
CLUTCH PEDAL DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.
Note Apply lithium-based grease to the spring and
bush when assembling.
2. Assemble in the reverse order of disassembly.
R
12—161.2—1.7, 8.7—12.3
N·m kgf·m, ft·lbf
14—171.4—1.8, 11—13
1 Clutch switch (G6, F2 CIS)
2 Adjustment bolt (WL, WL Turbo, F2 Carb)
3 Nut
4 Stopper rubber
5 Retaining ring
6 Washer
7 Bush
8 Pin
9 Fork
10 Push rod
11 Nut
12 Pedal pad
13 Clutch pedal component
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CLUTCH MASTER CYLINDER
H–5
CLUTCH MASTER CYLINDERCLUTCH MASTER CYLINDER REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
* 49 0259 770B
6.9—9.8 70—100, 60.8—86.7
SST
12.8—21.5130—220, 113—190
*
N·m kgf·cm, in·lbf
R
1 Clutch pipe
2 Nut
3 Clutch master cylinder
4 Gasket
CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
R
R
R
84—112 N·m8.5—11.5 kgf·m,61.5—83.1 ft·lbf
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CLUTCH MASTER CYLINDER
H–6
1 Snap ring+ Disassembly Note+ Assembly Note
2 Piston
3 Protector
4 Primary cap
5 Return spring
6 Tank cap
7 Reservoir
8 Bushing
9 Joint bolt
10 Gasket
11 One-way valve piston
12 Return spring
13 One way valve pin
14 Clutch master cylinder body
Snap Ring Disassembly Note Hold the piston down using a cloth-wrapped pin
punch.
Snap Ring Assembly Note Hold the piston down using a cloth-wrapped pin
punch.
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CLUTCH RELEASE CYLINDER
H–7
CLUTCH RELEASE CYLINDERCLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
22—26 2.2—2.7, 16—19
16—22 1.6—2.3, 12—16
(LITHIUM BASED GREASE)
1 E-clip
2 Clutch hose
3 Bolt
4 Clutch release cylinder
CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
R
5.9—8.8 N·m60—90 kgf·cm,53—78 in·lbf
G6
EXCEPTG6
1 Boot
2 Push rod
3 Piston and cap
4 Return spring
5 Bleeder cap
6 Bleeder screw
7 Steel ball
8 Clutch release cylinder body
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CLUTCH UNIT
H–8
CLUTCH UNITCLUTCH UNIT REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
SST
(MOLYBDENUM SULFIDE)
TRANSMISSION SIDEENGINE SIDE
18—26 1.8—2.7, 14—19
G6 :92—98 9.3—10.0, 67.3—72.3EXCEPT G6 :97—102 9.8—10.5, 70.9—75.9
N·m kgf·m, ft·lbf
SSTSST
SST
1 Transmission+ Section J1, MANUAL TRANSMISSION, MANUAL
TRANSMISSION REMOVAL/INSTALLATION
2 Clutch release collar
3 Clutch release fork
4 Clutch cover+ Removal Note+ Installation Note
5 Clutch disc+ Installation Note
6 Pilot bearing+ Removal Note+ Installation Note
7 Flywheel+ Removal Note+ Installation Note
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+ Section J2, MANUAL TRANSMISSION, MANUALTRANSMISSION REMOVAL/INSTALLATION
PAGES. FROM. MANUAL
CLUTCH UNIT
H–9
Clutch Cover Removal Note1. Install the SSTs.2. Loosen each bolt one turn at a time in a crisscross
pattern until spring tension is released.
49 E011 1A0
49 SE01 310A
Pilot Bearing Removal Note
Note The pilot bearing does not need to be removed
unless you are replacing it.
Use the SSTs to remove the pilot bearing.
49 1285 071
Flywheel Removal Note1. Hold the flywheel using the SST.2. Remove the bolts evenly and gradually in a
crisscross pattern.
ÇÁ
 ÃÄ
Å
ÆÀ49 E011 1A0
G6
EXCEPT G6
49 E011 1A0
16
42
5
3
Flywheel Installation Note1. Install the flywheel to the crankshaft.2. Hand-tighten the flywheel lock bolts.3. Install the SST to the flywheel.4. Apply sealant to the bolt threads before installing
the bolt to prevent oil leakage from the bolt.5. Gradually tighten the flywheel lock bolts in a
crisscross pattern.
49 E011 1A0
G6
4
71
5
3
82
6
EXCEPT G6
49 E011 1A0
16
42
5
3
Pilot Bearing Installation NoteG6, F2 CIS, F2 Carb Install a new pilot bearing using a pipe until depth
is as follows:
Depth4.0 mm 0.16 in
PILOT BEARINGCRANKSHAFT
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CLUTCH UNIT
H–10
WL, WL Turbo Install a new pilot bearing using a pipe until
protrusion height is as follows:
Protrusion height0—0.2 mm 0—0.008 in
PILOT BEARINGFLY WHEEL
Clutch Disc Installation Note Hold the clutch disc in position using the SST.
49 SE01 310A
Clutch Cover Installation Note1. Install the SSTs.2. Tighten the bolts evenly and gradually in a
crisscross pattern.
49 E011 1A0
49 SE01 310A
CLUTCH COVER INSPECTION1. Measure the wear of the diaphragm spring figures.
Depth0.6 mm 0.024 in min.
DEPTH
2. Measure the flatness of the pressure plate using astraight edge and a feeler gauge.
Clearance0.5 mm 0.020 in max.
3. When checking the diaphragm spring fingers,mount a dial indicator on the cylinder block.
4. Rotate the flywheel and check for misaligneddiaphragm spring fingers.
Misalignment0.6 mm 0.030 in max.
5. Replace the clutch cover if not as specified.
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CLUTCH UNIT
H–11
CLUTCH DISC INSPECTION1. Using vernier calipers, measure the thickness of
the lining at a rivet head on both sides.2. If clutch disc thickness is less than the minimum,
replace the clutch disc.
Thickness0.3 mm 0.012 in min.
0.3 mm0.012 in
3. Measure the clutch disc runout using a dialindicator.
Runout0.7 mm 0.027 in max.
4. If runout is excessive, replace the clutch disc.
CLUTCH RELEASE COLLAR INSPECTION
Caution Cleaning the clutch release collar with
cleaning fluids or a steam cleaner can washthe grease out of the sealed bearing.Otherwise, clutch release collar may notoperate properly.
1. Turn the collar while applying force in the axialdirection.
2. If the collar sticks or has excessive resistance,replace the clutch release collar.
FLYWHEELPILOT BEARING INSPECTION
1. Without removing the pilot bearing from theflywheel, turn the bearing while applying force inthe axial direction.
2. If the bearing sticks or has excessive resistance,replace it.
FLYWHEEL INSPECTION1. Install a dial indicator on the cylinder block.2. Measure the flywheel runout using a dial indicator.
Runout0.2 mm 0.079 in max.
3. If runout is excessive, replace the flywheel.
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MANUAL TRANSMISSION (M15M-D, M15MX-D)
TRANSMISSION OIL INSPECTION ................ J1-1 INSPECTION .....................................................J1-2 TRANSMISSION OIL REPLACEMENT ........... J1-1/2 MANUAL TRANSMISSION OIL SEAL (M15M-D) REPLACEMENT ............. J1-2 REMOVAL/INSTALLATION ................................J1-3/7 VEHICLE SPEEDOMETER SENSOR
REMOVAL/INSTALLATION ........................ J1-2
MANUAL TRANSMISSION TRANSMISSION OIL INSPECTION 1. Remove the check plug A.
2. Verify that the oil is at the brim of the check plug hole
as shown. If it is low, add the specified oil from the check plug hole.
Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C 50 °F) Capacity: 2.0 L 2.1 US qt, 1.8 Imp qt (M15M-D) 2.5 L 2.6 US qt, 2.2 Imp qt (M15MX-D)
3. Install a new check plug A. Tightening torque A: 25—39 N.m 2.5-4.0 kgf.m, 19—28 ft.lbf
TRANSMISSION OIL REPLACEMENT 1. Remove the drain plug B with washer and the
check plug A.
2. Drain the oil into a container. 3. Clean the drain plug B. 4. Install the drain plug B with new washer.
Tightening torque B: 40—58 N.m 4.0—6.0 kgf.m, 29—43 ft.lbf
5. Add the specified oil from check plug A port until the level reaches the brim of check plug hole.
Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C 50 °F) Capacity: 2.0 L 2.1 US qt, 1.8 Imp qt (M15M-D) 2.5 L 2.6 US qt, 2.2 Imp qt (M15MX-D)
6. Install a new check plug A. Tightening torque A: 25—39 N.m 2.5—4.0 kgf.m, 19—28 ft.lbf
J1-1
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CONTINUED
MANUAL TRANSMISSION .............................. J1-1 VEHICLE SPEEDOMETER SENSOR
MANUAL TRANSMISSION
6. Install the vehicle speedometer sensor. Tightening torque 7.9—10.7 N.m 80—110 kgf.cm, 69.5—95.4 in.Ibf
7. Connect the vehicle speedometer sensor connector. 8. Add the specified type and amount of transmission
oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.)
9. Connect the negative battery cable. VEHICLE SPEEDOMETER SENSOR INSPECTION 1. Remove the vehicle speedometer sensor.
(Refer to MANUAL TRANSMISSION, VEHICLE SPEEDOMETER SENSOR REMOVAL/ INSTALLATION.)
2. Measure voltage between terminals of the vehicle speedometer sensor while the gear is turning.
Meter needle Action
Moves slightly under 5 V
Speedometer sensor is normal. Inspect wiring harness. (Instrument cluster-Vehicle speedometer sensor)
Does not move Replace vehicle speedometer sensor.
OIL SEAL (M15M-D) REPLACEMENT 1. Drain the transmission oil. 2. Remove the propeller shaft.
(Refer to section L, PROPELLER SHAFT (4x2),PROPELLER SHAFT REMOVAL/ INSTALLATION.)
3. Remove the oil seal using a screwdriver.
4. Apply the specified oil to new oil seal. 5. Install the oil seal until it touches the case using a
suitable piece of pipe.
6. Install the propeller shaft.
(Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/ INSTALLATION.)
7. Add the transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.)
VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the transmission oil. 3. Disconnect the vehicle speedometer sensor
connector. 4. Remove the vehicle speedometer sensor. 5. Apply transmission oil to new O-ring and install it on
new vehicle speedometer sensor.
3. Install the vehicle speedometer sensor.
(Refer to MANUAL TRANSMISSION, VEHICLE SPEEDOMETER SENSOR REMOVAL/ INSTALLATION.)
J1-2
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CONTINUED
MANUAL TRANSMISSION MANUAL TRANSMISSION REMOVAL/INSTALLATION 4x2(M15M-D)
1. Disconnect the negative battery cable. 2. Drain the transmission oil into a container. 3. Remove the propeller shaft.
(Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.) 4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Add the specified type and amount of transmission oil.
(Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) 8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
1 Shift lever knob 12 Speedometer sensor connector 2 Console 13 Back-up light switch connector 3 Dust boot 14 Neutral switch connector (F2 CIS) 4 Change boot upper plate 15 Front pipe bracket
5 Boot 16 Clutch release cylinder
6 Dust boot 7 Gasket
17
Crossmember Removal Note
18 Transmission lower mount8 Wave washer 9 Change bush 10 Change lever
19
Transmission Removal Note Installation Note
11 Change seat
J1-3
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CONTINUED
MANUAL TRANSMISSION
1 Shift lever knob 12 Speedometer sensor connector 2 Console 13 Back-up light switch connector 3 Dust boot 14 Front pipe bracket 4 Change boot upper plate 15 Clutch release cylinder 5 Boot 6 Dust boot
16
Crossmember Removal Note
7 Gasket 17 Dynamic damper 8 Wave washer 18 Transmission lower mount 9 Change bush 10 Change lever
19
Transmission Removal Note & Installation Note
11 Change seat
J1-4
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CONTINUED
MANUAL TRANSMISSION
Crossmember removal note • Securely support the transmission on
a transmission jack, then remove the crossmember.
Transmission removal note • Maintain the stability of the
transmission while removing it.
Transmission installation note Warning • A transmission that is not securely
supported on a transmission jack is dangerous. It can slip or fall, causing serious injury. Never work without the transmission jack until crossmember installation is finished.
1. Place the transmission on a transmission jack.
2. Maintain the stability of the transmission while installing it.
J1-5
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CONTINUED
MANUAL TRANSMISSION4x4(M15MX-D)
1. Disconnect the negative battery cable. 2. Drain the transmission and transfer oil into a container. 3. Remove the front and rear propeller shaft,
(Refer to section L, FRONT PROPELLER SHAFT (4x4), FRONT PROPELLER SHAFT REMOVAL/INSTALLATION.) (Refer to section L, REAR PROPELLER SHAFT (4x4), REAR PROPELLER SHAFT REMOVAL/INSTALLATION.)
4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Add the specified type and amount of transmission and transfer oil.
(Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) (Refer to section J3, TRANSFER, TRANSFER OIL REPLACEMENT.)
8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
1 Shift lever knob 12 Transfer under cover2 Console 13 Speedometer sensor connector 3 Dust boot 14 Back-up light switch connector 4 Change boot upper mount 15 4x4 indicator switch connector 5 Boot 16 Front pipe bracket
6 Dust boot 17 Clutch release cylinder
7 Gasket 8 Wave washer 9 Change bush
18
Crossmember MANUAL TRANSMISSION, MANUAL TRANS-
MISSION REMOVAL/INSTALLATION, 4x2 (M15M-D), Crossmember removal Note
10 Change lever 11 Change seat
J1-6
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CONTINUED
MANUAL TRANSMISSION 19 Transmission lower mount 20
Transmission and transfer Removal Note & Installation Note
Transmission and transfer removal note • Maintain the stability of the transmission and transfer while removing them.
Transmission and transfer installation note
Warning • A transmission and transfer that are not securely
supported on a transmission jack are dangerous. They can slip or fall, causing serious injury. Never work without the transmission jack until crossmember installation is finished.
1. Place the transmission and transfer on a transmission jack. 2. Maintain the stability of the transmission and transfer while
installing them.
J1-7
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CONTINUED
J2–1
MANUAL TRANSMISSION (R15M–D, R15MX–D)
MANUAL TRANSMISSION J2–1. . . . . . . . . . . . . . . . . . TRANSMISSION OIL INSPECTION J2–1. . . . . . . . . TRANSMISSION OIL REPLACEMENT J2–1/2. . . . . . OIL SEAL (R15M–D) REPLACEMENT J2–2. . . . . . VEHICLE SPEEDOMETER SENSOR
REMOVAL/INSTALLATION J2–2. . . . . . . . . . . . . . .
VEHICLE SPEEDOMETER SENSOR INSPECTION...J2–2MANUAL TRANSMISSION
REMOVAL/INSTALLATION J2–3/9. . . . . . . . . . . . . . .
MANUAL TRANSMISSIONTRANSMISSION OIL INSPECTION
1. Remove the filler plug.FILLER PLUG
2. Verify that the oil is at the brim of the filler plug holeas shown. If it is low, add the specified oil from thefiller plug hole.
Specified oilGrade:
API service GL–4 or GL–5Viscosity:
SAE 75W–90 (All season) orSAE 80W–90 (Above 10° C 50°F)
FILLER PLUG HOLE
3. Install a new filler plug.
Tightening torque25—39 N·m 2.6—4.0 kgf·m, 19—28 ft·lbf
TRANSMISSION OIL REPLACEMENT1. Remove drain plugs A and B, and drain the oil into
a container.2. Clean the drain plug A.3. Install the drain plug A with new washer and a new
drain plug B.
Tightening torqueA: 40—58 N·m 4.0—6.0 kgf·m, 29—43 ft·lbfB: 21—31 N·m 2.1—3.2 kgf·m, 16—23 ft·lbf
FILLER PLUG
DRAIN PLUG ADRAIN PLUG B
4. Remove the filler plug and add the specified oilthrough the filler plug port until the level rises to thebottom of the port.
Specified oilGrade:
API service GL–4 or GL–5Viscosity:
SAE 75W–90 (All season) orSAE 80W–90 (Above 10° C 50°F)
Capacity: 2.8 L 3.0 US qt, 2.5 lmp qt (R15M–D)3.2 L 3.4 US qt, 2.8 lmp qt (R15MX–D)
FILLER PLUG HOLE
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MANUAL TRANSMISSION
J2–2
1. Install a new filler plug.
Tightening torque25—39 N·m 2.6—4.0 kgf·m, 19—28 ft·lbf
OIL SEAL (R15M–D) REPLACEMENT1. Drain the transmission oil.2. Remove the propeller shaft.
(Refer to section L, PROPELLER SHAFT (4x2),PROPELLER SHAFT REMOVAL/INSTALLATION.)
3. Remove the oil seal using a screwdriver.
4. Apply the specified oil to the new oil seal.5. Install the oil seal until it touches the case using a
suitable piece of pipe.
PIPE
6. Install the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2),PROPELLER SHAFT REMOVAL/INSTALLATION.)
7. Add the transmission oil.(Refer to MANUAL TRANSMISSION,TRANSMISSION OIL REPLACEMENT.)
VEHICLE SPEEDOMETER SENSORREMOVAL/INSTALLATION(Refer to section J1, MANUAL TRANSMISSION,VEHICLE SPEEDOMETER SENSORREMOVAL/INSTALLATION.)
VEHICLE SPEEDOMETER SENSOR INSPECTION(Refer to section J1, MANUAL TRANSMISSION,VEHICLE SPEEDOMETER SENSOR INSPECTION.)
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ST
MANUAL TRANSMISSION
J2–3
MANUAL TRANSMISSION REMOVAL/INSTALLATION42 (R15M–D)
1. Disconnect the negative battery cable.2. Drain the transmission oil into a container.3. Remove the propeller shaft.
(Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.)4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.)5. Remove in the order indicated in the table.6. Install in the reverse order of removal.7. Add the specified amount and type of transmission oil.
(Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.)8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
R
16—22 1.6—2.3,12—16
N·m kgf·m, ft·lbf
38—46 3.8—4.7,28—33
32—46 3.2—4.7, 24—33
22—28 2.2—2.9, 16—20
7.9—10.7 N·m 80—110 kgf·cm,69.5—95.4 in·lbf
19—25 1.9—2.6, 14—18
16—22 1.6—2.3,12—16
A
A
38—513.8—5.3,28—38
38—513.8—5.3,28—38
69—88 7.0—9.0,51—65
F2
69—88 7.0—9.0,51—65
69—88 7.0—9.0,51—65
7.9—10.7 N·m 80—110 kgf·cm, 69.5—95.4 in·lbf
38—513.8—5.3,28—38
69—88 7.0—9.0,51—65
1 Shift lever knob
2 Console
3 Dust boot
4 Change boot upper plate
5 Boot
6 Dust boot
7 Gasket
8 Wave washer
9 Change bush
10 Change lever
11 Change seat
12 Vehicle speedometer sensor connector
13 Back–up light switch connector
14 Neutral switch connector (F2 CIS)
15 Front pipe bracket
16 Clutch release cylinder
17 Crossmember+ Removal Note
18 Transmission lower mount
19 Transmission+ Removal note+ Installation note
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MANUAL TRANSMISSION G6
1 Shift lever knob 12 Vehicle speedometer sensor connector 2 Console 13 Back-up light switch connector 3 Dust boot 14 Neutral switch connector
4 Change boot upper plate 15 Front pipe bracket5 Boot 16 Clutch release cylinder6 Dust boot 7 Gasket
17
Crossmember Removal Note
8 Wave washer 18 Transmission lower mount 9 Change bush 10 Change lever
19
Transmission Removal note Installation note
11 Change seat
J2-4
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CONTINUED
MANUAL TRANSMISSION
J2–5
WL, WL TURBO
R
7.9—10.7 N·m 80—110 kgf·cm,69.5—95.4 in·lbf
16—22 1.6—2.3,12—16
38—46 3.8—4.7, 28—33
32—46 3.2—4.7, 24—33
N·m kgf·m, ft·lbf
38—51 3.8—5.3, 28—38
16—22 1.6—2.3,12—16
A
A
22—28 2.2—2.9, 16—20
19—25 1.9—2.6, 14—1838—51 3.8—5.3,28—38
1 Shift lever knob
2 Console
3 Dust boot
4 Change boot upper plate
5 Boot
6 Dust boot
7 Gasket
8 Wave washer
9 Change bush
10 Change lever
11 Change seat
12 Vehicle speedometer sensor connector
13 Back-up light switch connector
14 Front pipe bracket
15 Clutch release cylinder
16 Crossmember+ Removal Note
17 Transmission lower mount
18 Transmission+ Removal note+ Installation note
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ST
MANUAL TRANSMISSION
J2–6
Crossmember removal note Securely support the transmission on a
transmission jack, then remove the crossmember.
Transmission removal note
Warning Do not allow the transmission to fall from
the transmission jack.
Maintain the stability of the transmission whileremoving it.
Transmission installation noteWarning A transmission that is not securely
supported on a transmission jack isdangerous. It can slip or fall, causingserious injury. Never work without thetransmission jack until crossmemberinstallation is finished.
1. Place the transmission on a transmission jack.2. Maintain the stability of the transmission while
installing them.
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CONTINUED
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MANUAL TRANSMISSION
J2–7
44 (R15MX–D)
1. Disconnect the negative battery cable.2. Drain the transmission and transfer oil into a container.3. Remove the front and rear propeller shaft.
(Refer to section L, FRONT PROPELLER SHAFT (4x4), FRONT PROPELLER SHAFTREMOVAL/INSTALLATION.)(Refer to section L, REAR PROPELLER SHAFT (4x4), REAR PROPELLER SHAFTREMOVAL/INSTALLATION.)
4. Remove the front pipe. (G6 engine) (Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
5. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.)6. Remove in the order indicated in the table.7. Install in the reverse order of removal.8. Add the specified type and amount of transmission and transfer oil.
(Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) (Refer to section J3, TRANSFER, TRANSFER OIL REPLACEMENT.)
9. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
G67.9—10.7 N·m 80—110 kgf·cm,69.5—95.4 in·lbf
R
19—251.9—2.6,14—18
38—51 3.8—5.3, 28—38
N·m kgf·m, ft·lbf
32—46 3.2—4.7, 24—33
R
44—53 4.4—5.3, 32—39
7.9—10.7 N·m 80—110 kgf·cm,69.5—95.4 in·lbf
37—503.7—5.1,27—36
38—51 3.8—5.3, 28—38
16—221.6—2.3,12—16
69—887.0—9.0,51—65
38—51 3.8—5.3, 28—38
38—51 3.8—5.3, 28—38
A
A
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CONTINUED
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
ST
MANUAL TRANSMISSION
J2–8
1 Shift lever knob
2 Console
3 Dust boot
4 Change boot upper mount
5 Boot
6 Dust boot
7 Gasket
8 Wave washer
9 Change bush
10 Change lever
11 Change seat
12 Transfer under cover
13 Vehicle speedometer sensor connector
14 Back–up light switch connector
15 Neutral switch connector
16 4x4 indicator switch connector
17 Transfer neutral switch connector (RFW model)
18 Front pipe bracket
19 Clutch release cylinder
20 Crossmember+ MANUAL TRANSMISSION, MANUAL
TRANSMISSION REMOVAL/INSTALLATION,42 (R15M–D), Crossmember removal note
21 Transmission lower mount
22 Transmission and transfer+ Removal note+ Installation note
WL, WL TURBO
N·m kgf·m, ft·lbf
38—51 3.8—5.3,28—38
R
7.9—10.7 N·m80—110 kgf·cm,69.5—95.4 in·lbf
R
A
38—51 3.8—5.3, 28—38
32—46 3.2—4.7, 24—33
19—25 1.9—2.6, 14—18
16—22 1.6—2.3,12—16
A 37—50 3.7—5.1,27—36
22—28 2.2—2.9, 16—20
44—53 4.4—5.3, 32—39
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CONTINUED
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
MANUAL TRANSMISSION
J2–9
1 Shift lever knob
2 Console
3 Dust boot
4 Change boot upper mount
5 Boot
6 Dust boot
7 Gasket
8 Wave washer
9 Change bush
10 Change lever
11 Change seat
12 Transfer under cover
13 Vehicle speedometer sensor connector
14 Back–up light switch connector
15 Transfer neutral switch connector (RFW model)
16 4x4 indicator switch connector
17 Front pipe bracket
18 Clutch release cylinder
19 Crossmember+ MANUAL TRANSMISSION, MANUAL
TRANSMISSION REMOVAL/INSTALLATION,42 (R15M–D), Crossmember removal note
20 Transmission lower mount
21 Transmission and transfer+ Removal note+ Installation note
Transmission and transfer removal note
Warning Do not allow the transmission to fall from
the transmission jack.
Maintain the stability of the transmission andtransfer while removing them.
Transmission and transfer installation note
Warning A transmission and transfer that are not
securely supported on a transmission jackare dangerous. They can slip or fall,causing serious injury. Never work withoutthe transmission jack until crossmemberinstallation is finished.
1. Place the transmission and transfer on atransmission jack.
2. Maintain the stability of the transmission andtransfer while installing them.
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TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
TRANSFER TRANSFER ..................................................................J3-1 TRANSFER OIL REPLACEMENT................ J3-1
TRANSFER OIL INSPECTION ...............................J3-1
TRANSFER TRANSFER OIL INSPECTION
1. Remove the filler plug with washer.
2. Verify that the oil is at the brim of the filler plug hole
as shown. If it is low, add the specified oil from the filler plug hole. Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C 50 °F) Capacity: 2.0 L 2.1 USqt,1.8 lmp qt
3. Clean the filler plug. 4. Install the filler plug with new washer.
Tightening torque 40—58 N-m 4.0—6.0 kgf.m, 29—43 ft.lbf
TRANSFER OIL REPLACEMENT 1. Remove the filler plug with washer and drain plug
with washer.
2. Drain the oil into a container. 3. Clean the filler and drain plugs. 4. Install the drain plug with new washer.
Tightening torque 40—58 N.m 4.0—6.0 kgf.m, 29—43 ft.lbf
5. Add the specified oil from filler plug port until the level reaches the brim of filler plug hole. Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C 50 °F) Capacity: 2.0 L 2.1 USqt,1.8lmpqt
6. Install the filler plug with new washer. Tightening torque 40—58 N-m 4.0-6.0 kgf.m, 29—43 ft.lbf
J3-1
CONTINUED
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RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
ST
L–1
PROPELLER SHAFTPROPELLER SHAFT (42) L–1. . . . . . . . . . . . . . . . . .
PROPELLER SHAFT REMOVAL/INSTALLATION L–1. . . . . . . . . . . . . . . . . . . . . . . . . . .
PROPELLER SHAFT INSPECTION L–2. . . . . . . . . . FRONT PROPELLER SHAFT (44) L–2. . . . . . . . . . .
FRONT PROPELLER SHAFT REMOVAL/INSTALLATION L–2. . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT PROPELLER SHAFT INSPECTION L–3. . FRONT PROPELLER SHAFT
DISASSEMBLY/ASSEMBLY L–3/4. . . . . . . . . . . . . . . REAR PROPELLER SHAFT (44) L–5. . . . . . . . . . . .
REAR PROPELLER SHAFT REMOVAL/INSTALLATION L–5. . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR PROPELLER SHAFT INSPECTION L–5. . . .
PROPELLER SHAFT (42)PROPELLER SHAFT REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
50—58 5.0—6.0, 37—43
N·m kgf·m, ft·lbf
37—52 3.7—5.4, 27—39
SST
1 Bolt, nut
2 Nut+ Installation Note
3 Propeller shaft+ Removal Note+ Installation Note
Propeller Shaft Removal Note1. Before removing the propeller shaft, put marks on
the yoke and the companion flange on thepropeller shaft tag side for proper reinstallation.
TAGMARK
2. Remove the propeller shaft from the extensionhousing and immediately install the SST to preventoil leakage.
49 S120 440
WL, F2 CIS, F2 CARB:
WL TURBO, G6:
49 0259 440
Propeller Shaft Installation Note Align the marks made during removal, and install
the propeller shaft. If installing a new propellershaft, align the differential companion flangeprecast marking with the tag on the propeller shaft.
TAGMARK
Nut Installation Note Tighten the center bearing installation nuts with the
vehicle *unloaded.*unloaded...Fuel tank is full; engine coolant and engineoil are at specified levels; spare tire, jack and tools arein designated position.
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PROPELLER SHAFT (42), FRONT PROPELLER SHAFT (44)
L–2
PROPELLER SHAFT INSPECTION1. Measure the propeller shaft runout using a dial
indicator.
Runout0.4 mm 0.016 in max.
2. If the runout is excessive, replace the propellershaft.
3. Move the universal joint in the direction shown, andinspect joint play.
Note Starting torque
0.3—1.1 N·m 3.0—12.0 kgf·cm, 2.7—10.4 in·lbf
4. If there is excessive play or the starting torque isnot within the specification, replace the propellershaft.
FRONT PROPELLER SHAFT (44)FRONT PROPELLER SHAFT REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
28—30 2.8—3.1, 21—22
N·m kgf·m, ft·lbf
1 Bolt, nut
2 Front propeller shaft+ Removal Note+ Installation Note
Front Propeller Shaft Removal Note Before removing the front propeller shaft, put
marks on the yoke and the companion flange onthe propeller shaft tag side for proper reinstallation.
TAGMARK
Front Propeller Shaft Installation Note Align the marks made during removal, and install
the front propeller shaft. If installing a newpropeller shaft, align the precast marking with thetag on the front propeller shaft.
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ST
FRONT PROPELLER SHAFT (44)
L–3
TAGMARK
FRONT PROPELLER SHAFT INSPECTION1. Measure the front propeller shaft runout using a
dial indicator.
Runout0.4 mm 0.016 in max.
2. If the runout is excessive, replace the frontpropeller shaft.
3. Move the universal joint in the direction shown,and inspect the joint play.
Note Starting torque
0.3—0.7 N·m 3.0—8.0 kgf·cm, 2.7—6.9 in·lbf
4. If there is excessive play or the starting torque isnot within the specification, repair the frontpropeller shaft.(Refer to FRONT PROPELLER SHAFT (44),FRONT PROPELLER SHAFTDISASSEMBLY/ASSEMBLY.)
FRONT PROPELLER SHAFTDISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
R
RR
R
1 Snap ring+ Disassembly Note
2 Universal joint yoke
3 Universal joint+ Disassembly Note+ Assembly Note
4 Sliding yoke
5 Propeller shaft
Snap ring Disassembly Note1. Mark the yoke and propeller shaft for proper
reassembly.
MARK
2. Clamp the propeller shaft in a vise.3. Remove the snap ring.
Universal joint Disassembly Note1. Push one bearing cup out of the propeller shaft by
tapping the yoke with a plastic hammer.
YOKE
BEARING CUP
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FRONT PROPELLER SHAFT (44)
L–4
1. Remove the opposite bearing cup in the samemanner.
2. Separate the propeller shaft and yoke.3. Clamp the yoke in a vise.4. Remove the bearing cups and the spider from the
yoke in the same manner as in Steps 1 and 2.
Universal joint Assembly Note1. Verify that the inside of the bearing cup is filled with
1.15—1.45g 0.04—0.05 oz grease. Add thespecified amount of disulphide molybdem greaseas necessary.
2. Set the new spider into the yoke and tap in a newbearing cup until the snap ring groove is exposed.
SPIDER
3. Measure the snap ring clearance, then select andinstall two new snap rings of equal thickness.
Snap ring thicknessesmm in
1.22 0.0480 1.32 0.0520
1.24 0.0488 1.34 0.0528
1.26 0.0496 1.36 0.0536
1.28 0.0504 1.38 0.0543
1.30 0.0512
YOKEBEARING CUP
SNAP RINGCLEARANCE
SPIDER
4. Install the remaining bearing cups and snap ringsas in Steps 1—3.
5. Move the universal joint in the direction shown, andinspect joint play.
Note Starting torque
0.3—0.7 N·m3.0—8.0 kgf·cm, 2.7—6.9 in ·lbf
6. If there is excessive play or the starting torque isnot within the specification, replace the frontpropeller shaft.
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ST
REAR PROPELLER SHAFT (44)
L–5
REAR PROPELLER SHAFT (44)REAR PROPELLER SHAFTREMOVAL/INSTALLATION
1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
50—585.0—6.0, 37—43
37—523.7—5.4, 27—39
N·m kgf·m, ft·lbf
50—585.0—6.0, 37—43
1 Bolt, nut
2 Nut+ PROPELLER SHAFT (42), PROPELLER
SHAFT REMOVAL/INSTALLATION, NutInstallation Note
3 Rear propeller shaft+ Removal Note+ Installation Note
4 Dynamic damper (WL Turbo)
Rear Propeller Shaft Removal Note1. Before removing the rear propeller shaft, put marks
on the yoke and the companion flange on the rearpropeller shaft tag side for proper reinstallation.
TAGMARK
Rear Propeller Shaft Installation Note Align the marks made during removal, and install
the rear propeller shaft. If installing a new propellershaft, align precast marking with the tag on therear propeller shaft.
TAGMARK
REAR PROPELLER SHAFT INSPECTION1. Measure the rear propeller shaft runout using a dial
indicator.
Runout0.4 mm 0.016 in max.
2. If the runout is excessive, replace the rearpropeller shaft.
3. Move the universal joint in the direction shown. Inspect starting torque and joint play.
Note Starting torque
0.3—1.1 N·m 3.0—12.0 kgf·cm, 2.7—10.4 in·lbf
4. If there is excessive play or the starting torque isnot within the specification, replace the rearpropeller shaft.
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M–1
FRONT AND REAR AXLESGENERAL PROCEDURES M– 2. . . . . . . . . . . . . . . . . . FRONT AXLE (42) M– 2. . . . . . . . . . . . . . . . . . . . . . .
WHEEL HUB, STEERING KNUCKLE INSPECTION M– 2. . . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL HUB, STEERING KNUCKLEREMOVAL/INSTALLATION M– 3/5. . . . . . . . . . . . . .
FRONT AXLE (44) M– 5. . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE
INSPECTION M– 5. . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE
REMOVAL/INSTALLATION M– 6/8. . . . . . . . . . . . . . REAR AXLE M– 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR AXLE INSPECTION M– 9. . . . . . . . . . . . . . . . AXLE SHAFT REMOVAL/
INSTALLATION M– 9/11. . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SHAFT M–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SHAFT REMOVAL/INSTALLATION M–12. . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SHAFT DISASSEMBLY/ASSEMBLY M–13/15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTPUT SHAFT (MFW)REMOVAL/INSTALLATION M–16. . . . . . . . . . . . . .
OUTPUT SHAFT DISASSEMBLY/ASSEMBLY M–17/18. . . . . . . . . . . . .
REAR DIFFERENTIAL M–19. . . . . . . . . . . . . . . . . . . . . REAR DIFFERENTIAL OIL INSPECTION M–19. . . . REAR DIFFERENTIAL OIL
REPLACEMENT M–19. . . . . . . . . . . . . . . . . . . . . . . . REAR DIFFERENTIAL REMOVAL/
INSTALLATION M–20. . . . . . . . . . . . . . . . . . . . . . . . . STANDARD DIFFERENTIAL
DISASSEMBLY M–21/23. . . . . . . . . . . . . . . . . . . . . . . . . STANDARD DIFFERENTIAL ASSEMBLY M–24/27. . .
MANUAL FREEEWHEEL (MFW) MECHANISM M–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE INSPECTION M–32. . . . . . . . . . . . . . .
REMOTE FREEWHEEL (RFW) MECHANISM M–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 INDICATOR SWITCH INSPECTION M–32. . . TRANSFER NEUTRAL SWITCH
INSPECTION M–32/33. . . . . . . . . . . . . . . . . . . . . . . . . . RFW SWITCH INSPECTION M–33. . . . . . . . . . . . . . RFW MAIN SWITCH REMOVAL/
INSTALLATION M–33. . . . . . . . . . . . . . . . . . . . . . . . . RFW MAIN SWITCH INSPECTION M–33. . . . . . . . ONE-WAY CHECK VALVE INSPECTION M–34. . . LOCK AND FREE SOLENOID VALVES
INSPECTION M–34. . . . . . . . . . . . . . . . . . . . . . . . . . RFW ACTUATOR INSPECTION M–34. . . . . . . . . . . RFW CONTROL MODULE INSPECTION M–35. . . . RFW CONTROL MODULE
JOINT SHAFT COMPONENTREMOVAL/INSTALLATION M–37. . . . . . . . . . . . . .
JOINT SHAFT COMPONENT DISASSEMBLY M–38/39. . . . . . . . . . . . . . . . . . . . . . . . .
JOINT SHAFT INSPECTION M–39. . . . . . . . . . . . . . JOINT SHAFT COMPONENT ASSEMBLY M–40/42. . . CONTROL BOX REMOVAL/
INSTALLATION M–42. . . . . . . . . . . . . . . . . . . . . . . . . CONTROL BOX DISASSEMBLY/
ASSEMBLY M–43/44. . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT FORK INSPECTION M–44. . . . . . . . . . . . . . .
FRONT DIFFERENTIAL M–45. . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL
INSPECTION M–45. . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL
REPLACEMENT M–45. . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL SEAL
REPLACEMENT M–45. . . . . . . . . . . . . . . . . . . . . . . .
M–46/47FRONT DIFFERENTIAL DISASSEMBLY M–48/50. . . . FRONT DIFFERENTIAL ASSEMBLY M–51/55. . . . . . .
TROUBLESHOOTING M–56. . . . . . . . . . . . . . . . . . . . . . REMOTE FREEWHEEL (RFW) M–56/62. . . . . . . . . . . .
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CONTINUED
REMOVAL/ . . . . . . . . . . . . . . M–35/36INSPECTION
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
FRONT DIFFERENTIAL REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
GENERAL PROCEDURES, FRONT AXLE (42)
M–2
GENERAL PROCEDURESWheel and tire removal/installation The removal and installation procedure for the
wheels and tires are not mentioned in this section.When a wheel is removed, tighten it to thespecified torque.
(Refer to section TD, SUSPENSION, Wheels and Tires.)
Suspension arm removal/installation Tighten any part of the suspension that uses
rubber bushings only after vehicle has beenlowered and unloaded.*
*Unloaded: Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire,jack, and tools are in designated position.
Brake line disconnection/connection
Caution Brake fluid will damage painted surfaces. If
brake fluid gets on a painted surface, wipeit off immediately.
Tighten the brake pipe flare nut using the SST (49 0259 770B). Be sure to modify the brakepipe fIare nut tightening torque to allow use of atorque wrench-SST combination. (Refer to section GI, FUNDAMENTAL PROCEDURES, TORQUE FORMULAS.)
If any brake line has been disconnected any timeduring the procedure, add brake fluid, bleed thebrakes, and inspect leakage after the procedurehas been completed.
Connectors disconnection/connection Disconnect the negative battery cable before doing
any work that requires the handling of connectors.Reconnect the negative battery cable only after thework is completed.
FRONT AXLE (42)WHEEL HUB, STEERING KNUCKLE INSPECTIONWheel Bearing Play Inspection After jacking up the vehicle and supporting it at the
specified places with safety stands, inspect fornoticeable bearing play by holding the top andbottom of the tire.
Wheel bearing axial play0 mm 0 in
Preload Adjustment1. Verify that the tire rotates smoothly when rotated
strongly, and that there is no rough feeling or isabnormal noise from the bearing.
2. Remove the brake caliper component and suspendit by a rope.
3. Remove the hub cap, pull out the cotter pin andremove the set cover.
4. Loosen the locknut to the extent that it can beturned by hand.
5. Attach a pull scale to a hub bolt and measure thefrictional force.
6. Tighten the locknut until the reading reaches thespecified amount.
PreloadFrictional force plus5.9—10.7 N 0.6—1.1 kgf, 1.4—2.4 lbf
7. Install the set cover, and secure with a new cotterpin.
8. Install the hub cap and brake caliper component.
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FRONT AXLE (42)
M–3
1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
108—127 11—13, 80—94
54—68 5.5—7.0, 40—50
30—50 3.0—5.2, 22—50
45—58 4.5—6.0, 33—43
118—156 12—16, 87—11519—25 1.9—2.6,14—18
R
SST
R
SSTR
R
R
R
SST
SST
80—1008.1—10.2,59—73
SST SST
RR
R
R
N·m kgf·m, ft·lbf
R
1 Hub cap
2 Cotter pin
3 Set cover
4 Locknut
5 Washer
6 Brake caliper component+ Removal Note
7 Hub and disc plate component+ Installation Note
8 Dust cover
9 Tie-rod end ball joint+ section N, MANUAL STEERING, STEERING
GEAR AND LINKAGE REMOVAL/INSTALLATION, Tie-rod End Ball Joint Removal Note
10 Knuckle arm
11 Lower arm ball joint+ section R, FRONT SUSPENSION, TORSION
BAR SPRING AND LOWER ARM (42) REMOVAL/INSTALLATION, Lower Arm BallJoint/Knuckle Removal Note
12 Upper arm ball joint+ section R, FRONT SUSPENSION, UPPER
ARM REMOVAL/INSTALLATION, Upper ArmBall Joint/Knuckle Removal Note
13 Steering knuckle
14 Disc plate+ Removal Note
15 Wheel hub+ Removal Note
16 Hub bolt+ Removal Note+ Installation Note
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WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION
PAGES. FROM. MANUAL
FRONT AXLE (42)
M–4
17 Outer bearing inner race
18 Oil seal+ Installation Note
19 Inner bearing inner race
20 Inner bearing outer race+ Removal Note+ Installation Note
21 Outer bearing outer race+ Removal Note+ Installation Note
Brake Caliper Component Removal Note Remove the brake caliper component, and
suspend it by a rope.
Disc Plate, Wheel Hub, Hub Bolt Removal Note
Note The hub bolt does not need to be removed
unless it is being replaced.
1. After putting markings on the disc plate and thewheel hub, remove the bolt and disassemble theplate and hub.
MARK
2. Remove the hub bolt using a press as necessary.
Inner Bearing Outer Race, Outer Bearing OuterRace Removal Note
Note When the inner bearing outer race is removed,
the inner race and oil seal are removedtogether.
Remove the bearing outer race using a suitableround bar and a hammer. For the other side,reverse the wheel hub and remove the outer race.
Outer Bearing Outer Race, Inner Bearing OuterRace Installation Note Install the bearing outer race using the SSTs and a
press. For the other side, reverse the wheel huband install the outer race.
OUTSIDE BEARING
INSIDE BEARING
49 H033 101
49 B025 001
Oil Seal Installation1. After inserting the bearing in the hub, use the SST
to tap in the oil seal until it is flush with the hub endsurface.
2. Apply grease to the oil seal lip.
49 F019 001
Hub Bolt Installation Note Press new hub bolts into the wheel hub using a
press.
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FRONT AXLE (42), FRONT AXLE (44)
M–5
Hub and Disc Plate Component Installation Note1. Apply grease to the areas indicated in the figure.
2. Install the hub and disc plate component, thenadjust the preload. (Refer to FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE INSPECTION, Preload Adjustment.)
FRONT AXLE (44)WHEEL HUB, STEERING KNUCKLE INSPECTIONWheel Bearing Play Inspection(Refer to FRONT AXLE (42), WHEEL HUB,STEERING KNUCKLE INSPECTION, Wheel BearingPlay Inspection.)
Preload Adjustment
Caution When replacing the locknut, tighten it using
the SST and turn the wheel hub a few timesto seat the bearing. Then, perform thepreload adjustment.
1. For RFW model, remove the hub cap and driveshaft end flange. For MFW model, remove thefreewheel hub component.
2. Remove the spacer and set plate.3. Remove the brake caliper component, and
suspend it by a rope.4. Loosen the locknut to the extent that it can be
turned by hand using the SST.
49 S231 635
5. Attach a pull scale to a hub bolt and measure thefrictional force.
6. Tighten the locknut until the reading reaches thespecified amount.
PreloadFrictional force plus5.9—10.7 N 0.6—1.1 kgf, 1.4—2.4 lbf
7. Install the set plate, spacer, freewheel hub or driveshaft end flange, hub cap and brake calipercomponent.
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FRONT AXLE (44)
M–6
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
54—68 5.5—7.0
30—513.0—5.2,22—37
55—675.6—6.9,41—49
40—44 4.0—4.5, 29—32
19—25 1.9—2.6, 14—18
55—80 5.6—8.2, 41—59
SST
SST
R
SST
R
R
R
SST
R
R
RSST
R
SST
SST R
R
118—156 12—16, 87—115
45—58 4.5—6.0, 33—43
SST
R
25—29 2.5—3.0, 19—21
(MFW MODEL)
(RFW MODEL)
SSTR
1 Hub cap
2 Drive shaft end flange
3 Freewheel hub component
4 Spacer
5 Set plate
6 Locknut+ Removal Note+ Installation Note
7 Brake caliper component+ FRONT AXLE (42), WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, BrakeCaliper Component Removal Note.
8 Hub and disc plate component
9 Dust cover
10 Tie-rod end ball joint+ Section N, MANUAL STEERING, STEERIG
GEAR AND LINKAGE REMOVAL/INSTALLATION, Tie-rod End Ball Joint Removal Note
11 Disc plate+ FRONT AXLE (42), WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, Disc PlateRemoval Note
12 Wheel hub+ FRONT AXLE (42), WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, WheelHub Removal Note
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FRONT AXLE (44)
M–7
13 Hub bolt+ FRONT AXLE (42), WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, Hub BoltRemoval Note
+ FRONT AXLE (42), WHEEL HUB, STEERINGKNUCKLE REMOVAL/INSTALLATION, Hub BoltInstallation Note
14 Outer bearing inner race
15 Oil seal+ Installation Note
16 Inner bearing inner race
17 Inner bearing outer race+ FRONT AXLE (42) WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, InnerBearing Outer Race, Outer Bearing Outer RaceRemoval Note
+ Installation Note
18 Outer bearing outer race+ FRONT AXLE (42) WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, InnerBearing Outer Race, Outer Bearing Outer RaceRemoval Note
+ Installation Note
19 Nut+ Section R, FRONT SUSPENSION, TORSION
BAR SPRING AND LOWER ARM (42) REMOVAL/INSTALLATION, Nut Installation Note
20 Shock absorber bolt
21 Upper arm ball joint+ Section R, FRONT SUSPENSION, UPPER
ARM REMOVAL/INSTALLATION, Upper ArmBall Joint/Knuckle Removal Note
22 Steering knuckle component+ Removal Note
23 Lower arm ball joint
24 Oil seal+ Removal Note+ Installation Note
25 Spacer
26 Needle bearing+ Removal Note+ Installation Note
27 Steering knuckle
Locknut Removal Note Remove the locknut using the SST.
49 S231 635
Steering Knuckle Component Removal Note1. Remove the lower arm ball joint from the knuckle
using the SST. (Refer to section R, FRONTSUSPENSION, TORSION BAR SPRING ANDLOWER ARM (42) REMOVAL/INSTALLATION,Lower Arm Ball Joint/Knuckle Removal Note.)
2. Remove the lower arm installation bolt and removethe lower arm with the knuckle.
Oil Seal Removal Note Remove the oil seal using a screwdriver.
Needle Bearing Removal Note Remove the needle bearing using the SST.
49 S231 660
Needle Bearing Installation Note1. Install the needle bearing using the SST and a
press.2. Apply grease to the needle bearing.
49 S033 108
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FRONT AXLE (44)
M–8
Oil Seal Installation Note1. Install the new oil seal using the SST and a press.2. Apply grease to the oil seal lip.
49 S033 107
Outer Bearing Outer Race Installation Note Install the outer bearing outer race using the SST
and press.
49 F027 005
Inner Bearing Outer Race Installation Note Install the inner bearing outer race using the SST
and a press.
49 F027 007
Oil Seal Installation Note Install the new oil seal using the SST and a press.
49 S033 106
Locknut Installation Note1. Install the locknut using the SST.
49 S231 635
2. Adjust the preload. (Refer to FRONT AXLE (44) WHEEL HUB, STEERING KNUCKLE INSPECTION, Preload Adjustment)
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REAR AXLE
M–9
REAR AXLEREAR AXLE INSPECTIONWheel Bearing Play Inspection
1. Jack up the rear end and support it with safetystands.
2. Verify that there is no abnormal noise and that thetire rotates smoothly when forcefully rotated byhand.
3. With a hand on top of the tire, inspect the bearingplay.
Wheel bearing axial play0.05—0.25 mm 0.002—0.010 in
4. If not as specified, adjust the bearing play. (Refer to REAR AXLE, AXLE SHAFTREMOVAL/INSTALLATION, Bearing Inner Race,Bearing Locknut Installation Note, Bearing playadjustment.)
AXLE SHAFT REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
275—313 28—32, 203—231
16—21 N·m1.6—2.2 kgf·cm,12—15 in·lbf
108—127 11—13, 80—94
RSST
SST
R
SST
R
SSTR
*SST
*49 0259 770B
SST
R
SST
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REAR AXLE
M–10
1 Brake drum
2 Parking brake connecting pin
3 Brake pipe
4 Nut
5 Axle shaft and back plate component
6 Shim
7 Bearing locknut+ Removal Note+ Installation Note
8 Lock washer
9 Bearing housing+ Removal Note
10 Bearing inner race+ Installation Note
11 Bearing spacer
12 Oil seal (bearing housing side)+ Installation Note
13 Bearing outer race+ Removal Note+ Installation Note
14 Back plate component
15 Axle shaft
16 Hub bolt
17 Baffle
18 Oil seal (axle casing side)+ Removal Note+ Installation Note
Bearing Locknut Removal Note
Note Be careful when removing or installing the
bearing locknuts for the left wheels becausethey are left threaded (tightened by turningcounterclockwise).
Set the SSTs as shown in the figure, and removethe bearing locknut from the rear axle shaft.
49 0603 635A
49 S120 645A
Bearing Housing Removal Note Remove the bearing and bearing housing using the
SSTs.
49 S026 204
49 S026 205
49 S026 208
Bearing Outer Race Removal Note After removing the bearing inner race and oil seal
from the rear wheel hub, tap lightly using a suitableround bar to force out the outer race.
Oil Seal (Axle Casing Side) Removal Note Remove the oil seal from the axle casing using a
screwdriver.
OIL SEAL
AXLE CASING
Oil Seal (Axle Casing Side) Installation Note1. Use the SST to tap the oil seal in until it is flush
with the end of the axle casing.2. After installation, apply grease to the oil seal lip.
OIL SEAL
AXLE CASING49 H025 001
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REAR AXLE
M–11
Bearing Outer Race, Oil Seal(Bearing Housing Side) Installation Note Press the bearing outer race and the oil seal using
the SSTs.
49 U027 003
49 F027 004
OIL SEAL BEARINGOUTERRACE
Bearing Inner Race, Bearing Locknut InstallationNote
Caution The torque wrench must be attached
perpendicular to the SST.
1. Set the SST and then press the bearing inner racein until 3 to 5 threads of the bearing locknutmounting screw of the axle shaft are visible abovethe top of the bearing outer race.
49 S120 748
2. Remove the SST, and then install the bearinglocknut to the axle shaft.
3. Tighten the bearing locknut using the SST to pressin the bearing inner race.
4. Remove the SST and install the lock washer sothat its tab fits into the groove of the axle shaft.
5. Tighten the bearing locknut to the specified torque.
Bearing locknut tightening torque275—313 N·m
28.0—32.0 kgf·m, 203—231 ft·lbf
49 S120 645A
49 0603 635A
Bearing play adjustment Adjust the bearing play in the axial direction (only
when the bearing is replaced).(1) First insert one side of the rear axle shaft
component and push the end of the shaft to thethrust block, then insert a shim(s) at point A sothat the clearance between the end of the shaftand the thrust block becomes 0.65—0.95 mm0.026—0.037 in .
(2) Next insert the opposite shaft component andpush the end of the shaft to the thrust block.
(3) Use a shim(s) at point A so that the clearancebetween the end of the shaft and the thrust blockbecomes 0.05—0.25 mm 0.002—0.010 in .
Bearing play in axial direction0.05—0.25 mm 0.002—0.010 in
PINION SHAFT
THRUSTBLOCK
SHIMA
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DRIVE SHAFT
M–12
DRIVE SHAFTDRIVE SHAFT REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
R
1 Wheel hub, steering knuckle+ FRONT AXLE (44), WHEEL HUB,
STEERING KNUCKLEREMOVAL/INSTALLATION
2 Drive shaft+ Removal Note+ Installation Note
3 Snap ring
4 Clip+ Installation Note
Drive Shaft Removal Note
Caution Do not damage the dust cover or oil seal.
Remove the drive shaft by prying with a barinserted between the differential casing and thedrive shaft.
Clip Installation NoteLeft side Install a new clip to the output shaft clip groove
with the opening facing upward.
Right side Install a new clip to the clip groove of the drive
shaft end with the opening facing upward.
OPENING
CLIP
28 mm 1.1 in
Drive Shaft Installation Note Be careful not to damage the oil seal with the shaft
spline when installing the drive shaft.
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DRIVE SHAFT
M–13
DRIVE SHAFT DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of removal.
R
R
R
R
R
R
LEFT SIDE
RIGHT SIDE
1 Boot band+ Disassembly Note+ Assembly Note
2 Clip
3 Outer ring+ Disassembly Note+ Assembly Note
4 Snap ring+ Assembly Note
5 Balls+ Disassembly Note+ Assembly Note
6 Inner ring+ Disassembly Note+ Assembly Note
7 Cage+ Disassembly Note+ Assembly Note
8 Boot+ Disassembly Note+ Assembly Note
9 Bell joint component
10 Drive shaft
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DRIVE SHAFT
M–14
Boot Band Disassembly Note
Note The wheel side boot band does not need to be
removed unless replacing it.
1. Pry up the locking clip using a screwdriver andremove the band using pliers.
2. Slide the boot along the shaft to expose the joint.
Outer Ring Disassembly Note
Caution Mark with paint; do not use a punch.
1. Mark the cage and outer ring for proper assembly.2. Remove the clip using a screwdriver.3. Remove the outer ring from the inner ring and the
balls.4. Clean the grease away.
MARKS
Balls, Inner Ring, Cage Disassembly Note
Caution Mark with paint; do not use a punch.
1. Mark the drive shaft and inner ring for properassembly.
MARKS
2. Disassemble the snap ring from the drive shaftusing a snap-ring pliers.
3. Disassemble the balls, inner ring, cage from thedrive shaft as component.
4. Turn the cage by approximately 30 degrees andpull the cage and balls away from the inner ring.
30
Boot Disassembly Note
Note The wheel side boot does not need to be
removed unless it is being replaced.
1. Wrap the shaft splines with tape.2. Remove the boot.
TAPE
Boot Assembly Note
Note The wheel side and differential side boots are
different.
100.5 mm 4.0 in
99.2 mm 3.9 in
WHEEL SIDE DIFFERENTIAL SIDE
1. With the splines of the shaft still wrapped in tapefrom disassembly, assemble the boot.
2. Temporarily assemble the wheel side boot, newboot bands, and differential side boot to the driveshaft.
3. Remove the tape.
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DRIVE SHAFT
M–15
Cage, Inner Ring, Balls, Snap Ring Assembly Note1. Align the marks, and install the balls and cage to
the inner ring in the direction shown in the figure.
Caution Install the cage with the offset facing the
snap ring groove. If incorrectly installed,the drive shaft may become disengaged.
2. Install a new snap ring.
CAGEBALLS
SNAP RING GROOVE
INNER RING
Outer Ring Assembly Note
Note Use the specified grease supplied in the boot
kit.
1. Apply grease to the cage, inner ring, balls, and theouter ring.
Wheel side : 110—130 g 3.8—4.6 ozDifferential side : 95—105 g 3.4—3.7 oz
2. Align the marks, and install the outer ring onto theshaft.
3. Install a new clip.
MARKS
Boot Band Assembly Note
Caution Do not damage the boot. For wheel side, apply grease only when
assembling the boot.
1. Apply grease to the inside of the boot.2. Set the drive shaft to the standard length.
LEFT SIDE
RIGHT SIDE
Standard lengthRight side : 619.0—629.0 mm 24.4—24.7 inLeft side : 551.0—561.0 mm 21.7—22.0 in
3. Release trapped air from inside the boot using ascrewdriver covered with a rag.
4. Set the new boot band to the boot groove.5. Fold the band back and use pliers to pull it tight.6. Lock the end of the band by bending the locking
clips.
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DRIVE SHAFT
M–16
OUTPUT SHAFT (MFW) REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
37—57 3.7—5.5, 27—39
1 Drive shaft+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/
INSTALLATION
2 Bolt
3 Screw
4 Output shaft component+ Removal Note
Output Shaft Component Removal Note Remove the output shaft by prying with a bar
inserted between the bearing housing of the outputshaft and the differential casing.
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DRIVE SHAFT
M–17
OUTPUT SHAFT DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
R
R
R
R
SST
R
1 Clip+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/
INSTALLATION, Clip Assembly Note
2 Output shaft component+ Disassembly Note+ Assembly Note
3 Oil seal+ Assembly Note
4 Bearing+ Disassembly Note+ Assembly Note
5 Output shaft
6 Bearing housing
7 Oil seal+ Assembly Note
8 O-ring
Output Shaft Component Disassembly Note Disassemble the output shaft component using a
press.
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DRIVE SHAFT
M–18
Bearing Disassembly Note Remove the bearing from the output shaft
component using a press.
Oil Seal Assembly Note Use the SST to assemble the new oil seal until it is
flush with the bearing housing end using the SST.
49 M005 796
Bearing Assembly Note
Caution Press the bearing center and shaft center
vertically.
Press the new bearing to the output shaft.
Oil Seal Assembly Note Assemble the new oil seal by lightly tapping it
using a plastic hammer.
Output Shaft Component Assmebly Note Press the output shaft and bearing to the bearing
housing.
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REAR DIFFERENTIAL
M–19
REAR DIFFERENTIALREAR DIFFERENTIAL OIL INSPECTION
Caution Position the vehicle level.
1. Remove the filler plug.2. Verify that the oil is at the brim of the filler plug
hole. If it is low, add the specified oil.
Specified oilType
Standard differential:API service GL–5, SAE 90
LSD:API service GL–6, SAE 90
Capacity42:
1.40 L 1.48 US qt, 1.23 lmp qt44:
1.85 L 1.96 US qt, 1.63 lmp qt
FILLER PLUG
WASHER
3. Install a new washer and the filler plug.
Tightening torque40—53 N·m 4.0—5.5 kgf·m, 29—39 ft·lbf
REAR DIFFERENTIAL OIL REPLACEMENT1. Remove the filler and drain plugs.2. Drain the differential oil into a container.
3. Wipe the plugs clean.4. Install a new washer and the drain plug.
Tightening torque40—53 N·m 4.0—5.5 kgf·m, 29—39 ft·lbf
5. Add the specified oil from the filler plug hole until itreaches the brim of the hole.
Specified oilType
Standard differential:API service GL–5, SAE 90
LSD:API service GL–6, SAE 90
Capacity:42:
1.40 L 1.48 US qt, 1.23 lmp qt44:
1.85 L 1.96 US qt, 1.63 lmp qt
6. Install a new washer and the filler plug.
Tightening torque40—53 N·m 4.0—5.5 kgf·m, 29—39 ft·lbf
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REAR DIFFERENTIAL
M–20
REAR DIFFERENTIAL REMOVAL/INSTALLATION
Caution Clean away the old sealant before applying the new sealant. Install the differential carrier within 10 minutes after applying sealant. Allow the sealant to set at least 30 minutes after installation before filling the differential with the
specified oil.
1. Drain the differential oil. (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL REPLACEMENT.)2. Remove the rear propeller shaft.
(Refer to section L, REAR PROPELLER SHAFT (44), REAR PROPELLER SHAFT REMOVAL/INSTALLATION.)3. Remove in the order indicated in the table.4. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
26—28 2.6—2.9, 19—20
50—58 5.0—6.0, 37—43
1 Axle shaft and back plate component+ REAR AXLE, AXLE SHAFT REMOVAL/
INSTALLATION
2 Differential+ Removal Note
Differential Removal Note To prevent the differential from dropping, leave the
two bolts loosely tightened. Then hit the differentialcarrier using a wooden hammer.
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REAR DIFFERENTIAL
M–21
STANDARD DIFFERENTIAL DISASSEMBLY Disassemble in the order indicated in the table.
SST
SST
SST
SST
SST
1 Differential component+ Disassembly Note
2 Bearing cap+ Disassembly Note
3 Adjusting shim
4 Side bearing cup
5 Side bearing cone+ Disassembly Note
6 Pinion nut+ Disassembly Note
7 Companion flange+ Disassembly Note
8 Oil seal+ Disassembly Note
9 Thrust washer
10 Drive pinion+ Disassembly Note
11 Front bearing cone
12 Collapsible spacer
13 Rear bearing cone+ Disassembly Note
14 Adjusting shim
15 Front bearing cup+ Disassembly Note
16 Oil buffle
17 Rear bearing cup+ Disassembly Note
18 Carrier
19 Hex screw
20 Ring gear
21 Roll pin+ Disassembly Note
22 Pinion shaft
23 Thrust block
24 Pinion gear
25 Pinion gear thrust washer
26 Side gear
27 Side gear thrust washer
28 Case
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REAR DIFFERENTIAL
M–22
Differential Component Disassembly Note Mount a carrier component to the SST or
equivalent.
T57L–500–B
Bearing Cap Disassembly Note Place a mark on one of the bearing caps so that
the left and right bearing caps won’t get mixed up.Use the mark for matching at the time of assembly.
MARK
Side Bearing Cone Disassembly Note
Warning When pulling the side bearing cone, do not
allow differential component to fall. It canstrike legs or feet and may cause seriousinjury.
Caution Mark the left bearing in order to install in
the same position.
Remove the side bearing cone using a press andthe SST.
205–D064D84L–1123–A
Pinion Nut Removal Note Hold the companion frange and remove the pinion
nut.
Companion Flange Disassembly Note Remove the companion flange using universal
puller.
Oil Seal Disassembly Note Pull out the oil seal using the SST.
308–047T77F–1102–A
Drive Pinion Disassembly Note Remove the drive pinion by tapping with a plastic
hammer.
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REAR DIFFERENTIAL
M–23
Rear Bearing Cone Disassembly Note
Note Mark or otherwise distinguish between the front
and rear cones so that they are not mixed up atthe time of reassembly.
Remove the rear bearing cone using the SST.
205–D064D84L–1123–A
Front Bearing Cup, Rear Bearing Cup DisassemblyNote
Note Mark or otherwise distinguish between the front
and rear cups so that they are not mixed up atthe time of reassembly.
Remove the bearing races using the SSTs (308 047 T77F–1102A and 100 001 T50T–100–A).
100–001T50T–100–A
3308–047T77F–1102–A
Roll Pin Disassembly Note
Caution Insert the bar from the knock pin hole at the
opposite side from where the ring gear isinstalled.
Secure the gear case in a vise and remove the rollpin using a small drift.
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Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note
Note • Mark or otherwise distinguish between the front
and rear outer races so that they are not mixed up at the time of reassembly.
• Remove the bearing outer races by using the two grooves on the carrier and tapping the outer races alternately.
Knock Pin Disassembly Note
Caution • Insert the bar from the knock pin hole at the
opposite side from where the ring gear is installed.
• Secure the gear case in a vise and remove the knock pin by using a 4 mm 0.16 in diameter bar.
REAR DIFFERENTIAL
M–24
STANDARD DIFFERENTIAL ASSEMBLY Assemble in the order indicated in the table.
N·m kgf·m, ft·lbf
75—95 7.6—9.7, 55—70
R
SST SST
SST
R
SST
R
RR
SST
R
SST
R
SSTR
130—15013.2—15.3,96—110
298—500 30.3—50.9, 220—368
R
1 Case+ Assembly Note
2 Side gear thrust washer+ Assembly Note
3 Side gear
4 Pinion gear thrust washer
5 Pinion gear
6 Thrust block
7 Pinion shaft
8 Roll pin
9 Ring gear
10 Hex screw
11 Side bearing cone+ Assembly Note
12 Carrier
13 Oil buffle
14 Front bearing cup+ Assembly Note
15 Rear bearing cup+ Assembly Note
16 Adjusting shim+ Assembly Note
17 Rear bearing cone+ Assembly Note
18 Drive pinion+ Assembly Note
19 Collapsible spacer
20 Front bearing cone
21 Thrust washer
22 Oil seal+ Assembly Note
23 Companion flange
24 Pinion nut
25 Side bearing cup+ Assembly Note
26 Adjusting shim+ Assembly Note
27 Bearing cap+ Assembly Note
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REAR DIFFERENTIAL
M–25
Adjusting Shim Assembly NotePinion height Adjustment
1. Assemble the rear bearing cone over the SST andinsert it into the rear bearing cup of the carrier.
2. Assemble the front bearing cone into the frontbearing cup and assemble the SSTs.
205–456
205–110, T76P–4020–A10
205–457
205–105, T76P–4020–A3
205–109, T76P–4020–A9
205–111, T76P–4020–A11
3. Roll the SST component back and forth a fewtimes to seat the bearings while tightening the SSTby hand.
Tightening torque27 N·m 2.8 kgf·m, 20 ft·lbf
4. Center the SST (205–456) into the side bearingbore. Install the bearing caps and tighten the bolt.
Tightening torque75—95 N·m 7.6—9.7 kgf·m, 55—70 ft·lbf
Note There should be drag on the feeler gauge
when it is inserted between the SSTs (205–110, T76P–4020–A10 and 205–456).
5. Insert the thickest feeler gauge possible betweenthe SSTs (205–110, T76P–4020–A10 and205–456).
FEELER GAUGE
205–110T76P–4020–A10
205–456
6. This measurement is the thickness needed for theselective shim if there was no marking on the drivepinion. If the drive pinion is marked with a plus (+)reading, the amount marked should be subtractedfrom the feeler gauge measurement. If the drivepinion is marked with a minus (–) reading, theamount marked should be added to the feelergauge measurement.
Rear Bearing Cone Assembly Note Assemble the selected spacer on the drive pinion
and press the rear bearing inner race until it isfirmly seated on the shaft.
205–090T75L–1165–B
Drive Pinion Assembly NoteDrive pinion preload adjustment
Caution Never loosen pinion nut to decrease drive
pinion preload torque, and never exceedspecified preload torque. If preload torqueis exceeded, a new collapsible spacer mustbe installed and the torque sequencerepeated.
1. Install the drive pinion, collapsible spacer andcompanion flange to the carrier, and tighten thepinion nut until all end play is removed.
2. Continue to tighten in small increments until thespecified preload can be obtained.
Drive pinion preload1.2—1.5 N·m
12.2—15.3 kgf·cm, 10.6—13.2 in·lbf
3. If the specified preload can’t be obtained within thespecified tightening torque range, replace thecollapsible spacer and inspect again.
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REAR DIFFERENTIAL
M–26
Case Assembly Note Assemble the side gears, thrust washer, thrust
block, pinion gears, pinion shaft and knock pin. After assembling the knock pin, make a crimp sothat the pin will not come out of the gear case.
Side Gear Thrust Washer Assembly Note Adjust the backlash of the side gears and pinon
gear as follows.(1) Set a dial gauge to the pinion gear as shown in
the figure.(2) Secure one of the side gears.(3) Move the pinion gear and measure the
backlash at the end of the pinion gear.
Standard backlash0—0.1 mm 0—0.004 in
(4) If the backlash exceeds the standard, use thethrust washers to adjust.
Side Bearing Cone Assembly Note
Caution Bearings should be assembled to the
original positions.
Press the side bearings into the gear case usingthe SST.
205–092T75L–1165–DA
Front Bearing Cup, Rear Bearing Cup AssemblyNote
1. Install the oil baffle in the outer bearing cup bore ofthe carrier.
2. Install the outer bearing cup and inner bearing cupusing the SST.
205–024T76P–4616–A
Oil Seal Assembly Note1. Apply a light coat of oil to the lip of a new oil seal.2. Assemble the new oil seal using the SST.
205–007T56T–4676–B
Side Bearing Cup, Adjusting Shim, Bearing CapAssembly NoteRing gear backlash adjustment
1. Install the gear case component on the carrier.2. Push the gear case component to the left side of
the carrier and measure the clearance between theside bearing and carrier. This measurement is theleft and right total shim thickness.
3. Divide the amount of shim in step 2 appropriatelybetween the right and left side, then install thebearing cap.
4. Adjust the drive pinion, ring gear backlash and theside bearing preload as follows.(1) Mark the ring gear at four points at approx. 90 °
intervals and mount a dial indicator to thecarrier so that the feeler comes in contact at a90° angle with one of the ring gear teeth.
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REAR DIFFERENTIAL
M–27
DIAL INDICATORWITH BRACKETRY
RINGGEAR
5. Inspect the backlash at the three other markedpoints and make sure that the minimum backlashis more than 0.12 mm 0.005 in and difference ofthe maximum and minimum backlash value is lessthan 0.08 mm 0.003 in .
6. If backlash is not as specified, correct the backlashby switching shims from one side of the differentialcase to the other.
7. Using a torque wrench, inspect the total rotatingtorque of the pinion and differential component byrotating the pinion three complete revolutions, andthen reading the rotating torque. The readingsshould not exceed 2.4 N·m 24.0 kgf·cm, 20.8 in·lbf . If the backlash is within specificationbut the rotating torque is to high, the preload maybe adjusted by removing an equal amount of shimsfrom both sides of the differential.
8. Inspect the drive pinion and ring gear toothcontact.(1) Coat both surfaces of 6—8 teeth of the ring
gear uniformly with a thin red lead coating.(2) While moving the ring gear back and forth by
hand, rotate the drive pinion several times andinspect the tooth contact.
(3) If the tooth contact is good, wipe off the redlead coating.
(4) If it is not good, adjust the pinion height, thenadjust the backlash.
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MANUAL FREEWHEEL (MFW) MECHANISMREMOTE FREEWHEEL (RFW) MECHANISM
M–32
MANUAL FREEWHEEL (MFW)MECHANISMON-VEHICLE INSPECTION
1. Jack up the front of the vehicle and support it onsafety stands.
2. Set the select lever in “2H” position.3. Set the freewheel hub control handle to the “FREE”
position, then turn the handle clockwise andcounterclockwise by hand, and inspect that it turnssmoothly.
4. Set the freewheel hub control handle to “LOCK”position and inspect that the wheel turns withconsiderable force applied to make it turn.
5. If not as specified, replace the freewheel hubcomponent as necessary.
REMOTE FREEWHEEL(RFW) MECHANISM44 INDICATOR SWITCH INSPECTION
1. Jack up the vehicle and support it on safety stands.2. Remove the transfer case switch
(44 indicator switch).
3. Inspect for continuity between the terminals asshown using an ohmmeter.
Continuity Switch
Yes Depressed (ON)
No Released (OFF)
4. If not correct, replace the switch.
TRANSFER NEUTRAL SWITCH INSPECTION1. Jack up the vehicle and support it on safety stands.2. Remove the transfer case switch (neutral switch).
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123456567
REMOTE FREEWHEEL (RFW) MECHANISM
M–33
1. Inspect for continuity at the switch using anohmmeter.
Continuity Switch
Yes Depressed (ON)
No Released (OFF)
OFF ON12 mm 0.472 in13 mm 0.512 in
2. If not correct, replace the switch.
RFW SWITCH INSPECTION1. Jack up the vehicle and support it on safety stands.2. Disconnect the RFW switch connector and remove
the switch.
3. Inspect for continuity at the switch using anohmmeter.
Continuity Switch
Yes Depressed (ON)
No Released (OFF)
4. If not correct, replace the switch.
RFW MAIN SWITCH REMOVAL/INSTALLATION1. Remove the meter hood.
(Refer to Section S, DASHBOARD ANDCONSOLE, METER HOODREMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
À
1 RFW main switch
RFW MAIN SWITCH INSPECTION1. Remove the RFW main switch.2. Inspect for continuity between the terminals as
shown using an ohmmeter.: Continuity
SwitchTerminal
SwitchA B D F
OFF
ON
3. If not correct, replace the switch.
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REMOTE FREEWHEEL (RFW) MECHANISM
M–34
ONE–WAY CHECK VALVE INSPECTION1. Remove the one–way check valve.2. Blow through A and inspect that air flows from B.3. Blow through B and inspect that air does not flow
from A.
B A
4. If not correct, replace the one–way check valve.
LOCK AND FREE SOLENOID VALVES INSPECTION1. Disconnect the vacuum hoses and the connector
from each solenoid valve.2. Blow through each valve from port B.3. Inspect that air flows from the air filter.
BA
AIR FILTER
BLOW
4. Connect 12V and a ground to the terminals of eachvalve.
5. Blow through each valve from port B.6. Inspect that air flows from port A.
B A
7. If not correct, replace the solenoid valve(s).
RFW ACTUATOR INSPECTION1. Jack up the vehicle and support it on safety stands.2. Disconnect the vacuum hoses from the actuator.3. Connect a vacuum pump tester to the actuator
(free side) as shown.4. Apply 26.66 kPa 200 mmHg, 7.87 inHg vacuum,
and verify that the rod moves toward the left(driver’s side).
5. Disconnect the vacuum pump tester.6. Connect the vacuum pump tester to the actuator
(lock side) as shown.7. Apply 26.66 kPa 200 mmHg, 7.87 inHg vacuum,
and inspect that the rod moves toward the right(passenger side).
8. If not correct, replace the actuator.
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REMOTE FREEWHEEL (RFW) MECHANISM
M–35
RFW CONTROL MODULE INSPECTION1. Remove the scuff plate. (Refer to section S, TRIM,
SCUFF PLATE REMOVAL/INSTALLATION.)2. Remove the front side trim.
(Refer to section S, TRIM, FRONT SIDE TRIMREMOVAL/INSTALLATION.)
3. Turn the ignition switch on and inspect the RFWcontrol module terminal voltages, referring to theTerminal Voltage Chart.
RFW CONTROL MODULE
4. If not correct, replace the component(s), wiring,and/or RFW control module.
REW CONTROL MODULE REMOVAL/INSPECTION1. Remove the scuff plate. (Refer to section S, TRIM,
SCUFF PLATE REMOVAL/INSTALLATION.)2. Remove the front side trim.
(Refer to section S, TRIM, FRONT SIDE TRIMREMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.4. Install in the reverse order of removal.
1 Connector
2 Nut
3 Bolt
4 RFW control module
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REMOTE FREEWHEEL (RFW) MECHANISM
M–36
Terminal Voltage Chart
RFW CONTROL MODULE TERMINAL
B+: Battery positive voltage
Terminal Signal name Connected to Condition Voltage Inspection point
A Lock solenoid Lock solenoidSolenoid OFF B+ Harness (Lock solenoid—RFW
CM)A Lock solenoid Lock solenoidSolenoid ON Below 0.5 V
CM) Lock solenoid
B Ground Body – Below 0.5 V Harness to ground point
C Free solenoid Free solenoidSolenoid OFF B+ Harness (Free solenoid—RFW
CM)C Free solenoid Free solenoidSolenoid ON Below 0.5 V
CM) Free solenoid
D – – – – –
E 44 indicator 44 indicator 44 indicator light OFF B+ Harness (44 indicatorlight RFW CM)E
light light 44 indicator light ON Below 0.5 Vlight—RFW CM)
44 indicator light
F Lock indicator LOCK Lock indicator light OFF B+ Harness (Lock indicatorlight RFW CM)F
light indicator light Lock indicator light ON Below 0.5 Vlight—RFW CM)
Lock indicator light
H Battery BatteryIgnition swtich ON B+ Harness, Fuse (Battery-IgnitionH Battery BatteryIgnition swtich OFF Below 0.5 V
, ( y gswitch—RFW CM)
I RFW main RFW mainRFW main switchreleased (OFF)
B+ Harness (RFW mainswitch RFW CM)I
switch switch RFW main switchdepreased (ON)
Below 0.5 Vswitch—RFW CM)
RFW main switch
J RFW switch RFW switchRFW switch OFF B+ Harness (RFW switch—RFW CM)J RFW switch RFW switchRFW switch ON Below 0.5 V
( ) RFW switch
K 44 indicator 44 indicator44 indicator switchOFF
B+ Harness (44 indicatorswitch RFW CM)K
switch switch 44 indicator switchON
Below 0.5 Vswitch—RFW CM)
44 indicator switch
L Transfer TransferTransfer neutral switchOFF
B+ Harness (Transfer neutralswitch RFW CM)L
neutral switch neutral switch Transfer neutral switchON
Below 0.5 Vswitch—RFW CM)
Transfer neutral switch
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REMOTE FREEWHEEL (RFW) MECHANISM
M–37
JOINT SHAFT COMPONENT REMOVAL/INSTALLATION1. Drain the front differential oil. (Refer to FRONT DIFFERENTIAL, DIFFERENTIAL OIL REPLACEMENT.)2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
R
23—26 2.3—2.7, 17—19
37—53 3.7—5.5, 27—39
37—53 3.7—5.5, 27—39
SST
1 Drive shaft+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/
INSTALLATION
2 Vacuum hose
3 RFW switch connector
4 Snap pin
5 Joint shaft component, control box component
6 Gear sleeve
7 Output shaft+ Removal Note
Output Shaft Removal Note Remove the output shaft using the SST.
49 0813 215A
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REMOTE FREEWHEEL (RFW) MECHANISM
M–38
JOINT SHAFT COMPONENT DISASSEMBLY Disassemble in the order indicated in the table.
SST
SST
SST
1 Control box
2 Clip
3 Remote freewheel hub+ Disassembly Note
4 Spacer
5 Retaining ring
6 Ball bearing+ Disassembly Note
7 Adjustment shim (s)
8 Dust seal
9 Bearing+ Disassembly Note
10 Oil seal+ Disassembly Note
11 Joint shaft
12 Needle bearing
13 Clip
14 Casing
15 Output shaft and gear sleeve
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REMOTE FREEWHEEL (RFW) MECHANISM
M–39
Remote Free Wheel Hub Disassembly Note Remove the remote free wheel hub using the SST.
49 0710 520
Ball Bearing Disassembly Note1. Remove the ball bearing and the joint shaft using a
press.
2. Remove the ball bearing using a press.
Bearing Disassembly Note Remove the dust seal and bearing using the SST
and a suitable bar.
49 W027 001
Oil Seal Disassembly Note Remove the oil seal using the SST.
49 U027 004
JOINT SHAFT INSPECTION1. Measure the joint shaft runout.
Maximum runout0.03 mm 0.0012 in
2. If not correct, replace the joint shaft.
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REMOTE FREEWHEEL (RFW) MECHANISM
M–40
JOINT SHAFT COMPONENT ASSEMBLY Assemble in the order indicated in the table.
N·m kgf·m , ft·lbf
RSST
R
R
SSTR
R
R
16—22 1.6—2.3, 12—16
SELECTIVE
SELECTIVE
SST
SST
SST
SST
SST
1 Output shaft and gear sleeve
2 Casing
3 Oil seal+ Assembly Note
4 Adjustment shim(s)+ Assembly Note
5 Ball bearing+ Assembly Note
6 Joint shaft+ Assembly Note
7 Bearing+ Assembly Note
8 Retaining ring
9 Spacer+ Assembly Note
10 Remote freewheel hub+ Assembly Note
11 Clip
12 Dust seal+ Assembly Note
13 Needle bearing
14 Clip
15 Control box
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REMOTE FREEWHEEL (RFW) MECHANISM
M–41
Oil Seal Assembly Note1. Apply differential oil to a new oil seal.2. Install the new oil seal using the SST and a press.
49 U027 006
Ajustment Shim(s), Ball Bearing Assembly Note1. Install the removed shim(s) and the ball bearing
using the SST and a press.
49 U027 006
2. Install a new retaining ring.3. Measure the clearance between the ball bearing
and the retaining ring.
4. If not as specified, adjust by adding or removingshims. Use no more than two shims on either side.
Maximum clearance0.15 mm 0.0059 in
Available shim thickness0.15 mm 0.0059 in, 0.30 mm 0.0118 in,0.35 mm 0.0138 in, 0.40 mm 0.0157 in,0.50 mm 0.0197 in
5. Remove the retaining ring.
Joint Shaft Assembly Note Install the joint shaft using the SST and a press.
49 U027 006
Bearing Assembly Note Install the bearing using the SSTs and a press.
49 U027 006
49 U027 005
Spacer, Remote FreeWheel Hub Assembly Note1. Install the removed spacer and the remote
freewheel hub using a suitable pipe and the SSTand a press.
49 U027 005
2. Install a new clip.3. Measure the clearance between the remote
freewheel hub and the clip.
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REMOTE FREEWHEEL (RFW) MECHANISM
M–42
4. If not as specified, adjust by adding or removingspacers. Use no more than two spacers on eitherside.
Maximum clearance0.15 mm 0.0059 in
Available shim thickness0.15 mm 0.0059 in, 0.30 mm 0.0118 in,0.35 mm 0.0138 in, 0.40 mm 0.0157 in,0.50 mm 0.0197 in
Dust Seal Assembly Note1. Install the new dust seal using the SST and a press.
49 M005 796
CONTROL BOX REMOVAL/INSTALLATION1. Drain the front differential oil.
(Refer to FRONT DIFFERENTIAL, FRONT DIFFERENTIAL OIL REPLACEMENT.)
2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
16—221.6—2.3, 12—16
23—26 2.3—2.7, 17—19
Á
Â
À
N·m kgf·m , ft·lbf
1 Vacuum hose
2 RFW switch connector
3 Control box
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REMOTE FREEWHEEL (RFW) MECHANISM
M–43
CONTROL BOX DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
N·m kgf·m , ft·lbf
R
R
R
R
R
R
SST
1 Snap pin
2 Washer
3 RFW actuator
4 RFW switch and washer
5 Spring cap
6 Spring and ball
7 Washer
8 Roll pin+ Disassembly Note+ Assembly Note
9 Change rod
10 Shift fork
11 Boot+ Assembly Note
12 Oil seal+ Assembly Note
13 Control box
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REMOTE FREEWHEEL (RFW) MECHANISM
M–44
Roll Pin Disassembly Note Remove the roll pin as shown in the figure.
Oil Seal Assembly Note Install a new oil seal using the SST and a press.
49 U027 007
Boot Assembly Note Install the boot as shown in the figure.
Roll Pin Assembly Note Install a new roll pin as shown in the figure.
SHIFT FORK INSPECTION1. Measure the clearance between the gear sleeve
and the shift fork.
Standard clearance0.1—0.40 mm 0.0040—0.0157 in
Maximum clearance0.50 mm 0.0197 in
2. Inspect the output shaft and gear sleeve of thesplines for damage and wear.
3. If not correct, replace the output shaft and gearsleeve as necessary.
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FRONT DIFFERENTIAL
M–45
FRONT DIFFERENTIALFRONT DIFFERENTIAL OIL INSPECTION(Refer to REAR DIFFERENTIAL, REARDIFFERENTIAL OIL INSPECTION.)
Specified oilType
Above –18 °C 0 °F: API GL–5, SAE 90Below –18 °C 0 °F: API GL–5, SAE 80
Capacity MFW:1.2 L 1.3 US qt, 1.1 lmp qt RFW: 1.5 L 1.6 US qt, 1.3 lmp qt
FRONT DIFFERENTIAL OIL REPLACEMENT(Refer to REAR DIFFERENTIAL, REARDIFFERENTIAL OIL REPLACEMENT.)
Specified oilType
Above –18 °C 0 °F: API GL–5, SAE 90Below –18 °C 0 °F: API GL–5, SAE 80
Capacity MFW:1.2 L 1.3 US qt, 1.1 lmp qt RFW: 1.5 L 1.6 US qt, 1.3 lmp qt
FRONT DIFFERENTIAL OIL SEAL REPLACEMENT1. Remove the drive shaft.
(Refer to DRIVE SHAFT, DRIVE SHAFTREMOVAL/INSTALLATION, Drive shaft removalNote.)
2. Drain the differential oil.(Refer to REAR DIFFERENTIAL, REARDIFFERENTIAL OIL REPLACEMENT.)
3. Remove the oil seal using a screwdriver.4. Tap in the new oil seal to the differential using the
SST.
49 G030 795
5. Install the drive shaft.(Refer to DRIVE SHAFT, DRIVE SHAFTREMOVAL/INSTALLATION, Drive Shaft InstallationNote.)
6. Add the differential oil to the specified level. (Refer to FRONT DIFFERENTIAL, FRONTDIFFERENTIAL OIL REPLACEMENT.)
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FRONT DIFFERENTIAL
M–46
FRONT DIFFERENTIAL REMOVAL/INSTALLATION1. Drain the differential oil. (Refer to FRONT DIFFERENTIAL, FRONT DIFFERENTIAL OIL REPLACEMENT.)2. Remove the propeller shaft.
(Refer to section L, FRONT PROPELLER SHAFT (44), FRONT PROPELLER SHAFT REMOVAL/INSTALLATION.)3. Remove in the order indicated in the table.4. Install in the reverse order of removal.
95—115 9.5—11.8, 69—85
N·m kgf·m, ft·lbf
63—93 6.4—9.5, 47—68
37—53 3.7—5.5, 27—39
55—80 5.6—8.2, 41—59
MFW
APPLY SCREW LOCK AGENT
1 Drive shaft+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/
INSTALLATION, Drive Shaft Removal Note
2 Front differential component+ Removal Note
3 Differential bracket
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FRONT DIFFERENTIAL
M–47
94.2—115.7 9.5—11.8, 68.8—85.3
N·m kgf·m, ft·lbf
37—53 3.7—5.5, 27—39
62.8—93.1 6.4—9.5, 46.3—68.7
23—26 2.3—2.7, 17—19
94.2—115.7 9.5—11.8, 68.8—85.3
28—30 2.8—3.1, 21—22
RFW
APPLY LOCKING COMPOUND
APPLY SCREWLOCK AGENT
1 Drive shaft+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/
INSTALLATION, Drive Shaft Removal Note
2 Vacuum hose
3 RFW switch component
4 Front differential, joint shaft component+ Removal Note
5 Joint shaft, crossmember
6 Front differential
Front Differential, Joint Shaft Component RemovalNote
1. Set the transmission jack on the differential.2. Remove the bolts and nuts indicated by arrows.
3. Remove the front differential and joint shaftcomponent from the vehicle using the transmissionjack.
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FRONT DIFFERENTIAL
M–48
FRONT DIFFERENTIAL DISASSEMBLY Disassemble in the order indicated in the table.
ÈSST
É
SST
ÆÇ
SST
Å
Ä
SST
À
SSTÃ
Â
Á SST
1 Bolt
2 Differential casing
3 Oil baffle
4 Differential component+ Disassembly Note
5 Lock plate
6 Bearing cap+ Disassembly Note
7 Adjusting screw
8 Side bearing outer race
9 Locknut+ Disassembly Note
10 Washer
11 Companion flange+ Disassembly Note
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FRONT DIFFERENTIAL
M–49
12 Oil seal+ Disassembly Note
13 Drive pinion+ Disassembly Note
14 Front bearing inner race
15 Collapsible spacer
16 Rear bearing inner race+ Disassembly Note
17 Spacer
18 Front bearing outer race+ Disassembly Note
19 Rear Bearing outer race+ Disassembly Note
20 Carrier
21 Bolt
22 Ring gear
23 Knock pin+ Disassembly Note
24 Pinion shaft
25 Pinion gear
26 Thrust washer
27 Side gear
28 Thrust washer
29 Side bearing inner race+ Disassembly Note
30 Gear case
Differential Component Disassembly Note Install the differential component on the SSTs.
49 M005 561
49 0107 680A
Bearing Cap Disassembly Note Place a mark on one of the bearing caps so that
the left and right bearing caps won’t get mixed up.Use the mark for matching at the time of assembly.
MARK
Locknut Disassembly Note Hold the companion flange using the SST and
remove the locknut.
49 S120 710
Companion Frange Disassembly Note Pull the companion flange out using the SST.
49 0839 425C
Oil Seal Disassembly Note Remove the oil seal using a screw driver.
Drive Pinion Disassembly Note Remove the drive pinion by tapping with a plastic
hammer.
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FRONT DIFFERENTIAL
M–50
Rear Bearing Inner Race Disassembly Note
Note Mark or otherwise distinguish between the front
and rear inner races so that they are not mixedup at the time of reassembly.
Remove the rear bearing inner race using the SST.
49 H027 002
Front Bearing Outer Race, Rear Bearing OuterRace Disassembly Note
Note Mark or otherwise distinguish between the front
and rear outer races so that they are not mixedup at the time of reassembly.
Remove the bearing outer races using the twogrooves on the carrier and tapping the outer racesalternately.
Knock Pin Disassembly Note
Caution Insert the bar from the knock pin hole at the
opposite side from where the ring gear isinstalled.
Secure the gear case in a vise and remove theknock pin using a 4 mm 0.16 in diameter bar.
Side Bearing Inner Race Disassembly Note
Caution Mark the left bearing in order to install in
the same position.
Remove the side bearing inner race from the gearcase using the SST.
49 0839 425C
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FRONT DIFFERENTIAL
M–51
FRONT DIFFERENTIAL ASSEMBLY
Caution Clean away the old sealant before applying the new sealant. Install the differential carrier within 10 minutes after applying sealant. Allow the sealant to set at least 30 minutes after installation before filling the differential with the
specified oll.
Assemble in the order indicated in the table.
N·m kgf·m, ft·lbf
R
SST
R
SST
69—83 7.0—8.5, 51—61 SST
SST R
SST R
R
R
SST
184—284 13—29, 95—209
R
SSTRR
SST
18—25 1.8—2.6, 14—18
23—27 2.3—2.7, 17—19
14—51 3.8—5.3, 28—38
SST
1 Gear case+ Assembly Note
2 Thrust washer+ Assembly Note
3 Side gear
4 Thrust washer
5 Pinion gear
6 Pinion shaft
7 Knock pin
8 Ring gear+ Assembly Note
9 Side bearing inner race+ Assembly Note
10 Bolt
11 Carrier
12 Front Bearing outer Race+ Assembly Note
13 Rear bearing outer race+ Assembly Note
14 Spacer+ Assembly Note
15 Rear bearing inner race+ Assembly Note
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FRONT DIFFERENTIAL
M–52
16 Drive pinion+ Assembly Note
17 Collapsible spacer
18 Front bearing inner race
19 Oil seal+ Assembly Note
20 Companion flange
21 Washer
22 Locknut+ Assembly Note
23 Side bearing outer race+ Assembly Note
24 Adjusting screw+ Assembly Note
25 Bearing cap+ Assembly Note
26 Lock plate
27 Baffle plate
28 Differential casing
29 Bolt
Gear Case Assembly Note Assemble the side gears, thrust washer, pinion
gears, pinion shaft and knock pin. After assembling the knock pin, make a crimp sothat the pin will not come out of the gear case.
Thrust Washer Assembly Note1. Set a dial gauge to the pinion gear as shown in the
figure.2. Secure one of the side gears.3. Move the pinion gear and measure the backlash at
the end of the pinion gear.
Standard backlash0—0.1 mm 0—0.004 in
4. If the backlash exceeds the standard, use thethrust washers to adjust.
Ring Gear Assembly Note1. Coat the ring gear and gear case facing surfaces
with locking agent.2. Install the ring gear and tighten the bolt to the
specified torque.
Side Bearing Inner Race Assembly Note
Caution Bearings should be assembled to the
original positions.
Press the side bearings into the gear case usingthe SST.
49 G030 338
Front Bearing Outer Race Assembly Note Press the front bearing outer race into the carrier
using the SST and a press.
49 F027 005
Rear Bearing Outer Race Assembly Note Press the rear bearing outer race into the carrier
using the SST and a press.
49 F027 004
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FRONT DIFFERENTIAL
M–53
Spacer Assembly NotePinion height adjustment
Notes Use the same spacer and nut. Be careful to install collars A and B in the
correct position and facing in the correctdirection.
1. Assemble the spacer, rear bearing inner race andSST (49 8531 568) on to the SST (49 8531 565).Secure the collar with the O-ring. Then install thisto the carrier.
2. Assemble the front bearing inner race, SST (49 8531 567), companion flange, washer and nut to the SST (49 8531 565).
3. Tighten the nut to the extent that the SST (49 8531 565) can be turned by hand.
49 0350 555
49 8531 565
49 8531 568
49 8531 567
SPACER
REAR BEARING
O RING
FRONT BEARING
4. Place the SST on the surface plate and set the dialindicator to zero.
49 0727 570
5. Place the SST (49 0350 555) on top of the SST (49 8531 565), and then set the SST (49 0727 570) on top of the SST (49 0350 555).
6. Place the measuring probe of the dial indicator sothat it contacts the place where the side bearing isinstalled in the carrier. Then measure left and rightside of the lower position.
49 0727 570
49 0350 555
7. Add the two (left and right) values obtained by themeasurements taken in Step 6 and then divide thetotal by 2. From this result, subtract the resultobtained by dividing the number inscribed on theend surface of the drive pinion by 100. (If there isno figure inscribed, use 0.) This is the pinion heightadjustment value.
Note For example, the measured results obtained at
Step 6 are 0.06 mm and 0.04 mm, and thefigure inscribed on the end of the drive pinion is–2:
pinion heightadjustment value
0.06+0.042
– = 0.07 =–2100
Therefore, replace it with a spacer 0.07 mm0.003 in thicker than the currently used one.
Rear Bearing Inner Race Assembly Note
Caution Press in until the force required suddenly
increases. Install the spacer selected for the pinion
height adjustment, confirm that theinstallation direction is correct.
Press the rear bearing inner race in using theSSTs.
49 F401 331SPACER
49 G030 338
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FRONT DIFFERENTIAL
M–54
Drive Pinion Assembly NoteDrive pinion preload adjustment
Caution Do not install the oil seal.
1. Install the drive pinion, spacer, front bearing,collapsible spacer and companion flange to thecarrier, and temporarily tighten the locknut.
2. Adjust the preload of the drive pinon bearing asfollows.(1) Turn the companion flange by hand to seat the
bearing.(2) Use a torque wrench to tighten the locknut
temporarily tightened in Step 1, and confirmthat the specified preload can be obtainedwithin the specified tightening torque range.The torque applied at this time will be usedafter the oil seal is installed.
Locknut tightening torque128—284 N·m 13—29 kgf·m, 95—209 ff·lbf
Drive pinion preload0.9—13.4 N·m 9—14 kgf·cm, 7.9—12.1 in·lbf
49 S120 710
(3) If the specified preload can’t be obtained withinthe specified tightening torque range, replacethe collapsible spacer and inspect again.
(4) Remove the locknut, washer and companionflange.
Oil Seal Assembly Note Apply differential oil to the oil seal lip and press the
oil seal in until it touches the end of the differentialcarrier using the SST.
49 U027 003
Locknut Assembly Note1. Assemble the companion flange and washer.2. Tighten the new locknut using the SST with the
determined torque while performing drive pinionpreload adjustment.
3. Verify that the preload is within the specification.
Preload0.9—1.3 N·m 9—14 kgf·cm, 7.9—12.1 in·lbf
49 S120 710
Side Bearing Outer Race, Adjusting Screw, BearingCap Assembly NoteRing gear backlash adjustment
1. Install the differential gear component to thecarrier. After loosely tightening the bearing outerrace and bearing cap mounting bolts, completelytighten the adjustment screw by hand. Then, whileturning the ring gear, alternately tighten the left andright adjustment screws using the SST.
49 0259 720
2. Adjust the drive pinion, ring gear backlash and theside bearing preload as follows.(1) Mark the ring gear at four points at approx. 90 °
intervals and mount a dial indicator to thecarrier so that the feeler comes in contact at a90° angle with one of the ring gear teeth.
(2) Turn both bearing adjusters equally until thebacklash becomes 0.09—0.11 mm0.0035—0.0043 in using the SST.
49 0259 720
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FRONT DIFFERENTIAL
M–55
(3) Inspect for the backlash at the three othermarked points and make sure that theminimum backlash is more than 0.05 mm0.002 in and difference of the maximum andminimum backlash value is less than 0.07 mm0.0028 in .
(4) After adjusting the backlash, tighten theadjustment screws equally until the distancebetween both pilot sections on the bearingcaps (L) become as specified.
Bearing cap bolt tightening torque38—51 N·m 3.8—5.3 kgf·m, 28—38 ft·lbf
Standard distance185.43—185.50 mm 7.300—7.303 in
3. The inspection and adjustment procedure is asfollows:(1) Coat both surfaces of 6—8 teeth of the ring
gear uniformly with a thin red lead coating.(2) While moving the ring gear back and forth by
hand, rotate the drive pinion several times andinspect the tooth contact.
(3) If the tooth contact is good, wipe off the redlead coating.
(4) If it is not good, adjust the pinion height, thenadjust the backlash.
RED LEAD
Toe and flank contact Replace the spacer with a thinner one, and move thedrive pinion outward.
FLANK CONTACTTOE CONTACT
Heel and face contact Replace the spacer with a thicker one.Bring the drive pinion inward.
FACE CONTACTHEEL CONTACT
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TROUBLESHOOTING
M–56
TROUBLESHOOTINGREMOTE FREEWHEEL (RFW)Foreword Refer to section GI, HOW TO USE THIS MANUAL, TROUBLESHOOTING PROCEDURE and thoroughly read
and understand the basic flow of troubleshooting in order to properly perform the basic procedures.
Precaution This section only mentions unique symptoms of the trouble caused by RFW. Inspect and repair as necessary
for trouble caused by other sources. Inspect the connector and terminal connections when inspecting the wiring harnesses. (The cause of the
malfunction may be a poor connection in the connectors, terminals, or wiring harnesses.)
Diagnostic IndexNo TROUBLESHOOTING ITEM DESCRIPTION
1 No RFW operation from free to lock(RFW indicator light does not illuminate)
Free solenoid valve malfunction RFW indicator light bulb malfunction RFW actuator malfunction RFW switch malfunction Print plate in instrument cluster malfunction METER 15 A fuse malfunction ENGINE 15 A fuse malfunction Transfer neutral switch malfunction 44 indicator switch malfunction RFW control module malfunction Lock solenoid valve malfunction RFW control box malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harness malfunction
2 No RFW operation from lock to free(RFW indicator light does not go off)
Lock solenoid valve malfunction RFW switch malfunction RFW actuator malfunction Print plate in instrument cluster malfunction Engine 15 A fuse malfunction RFW main switch malfunction Transfer neutral switch malfunction 44 indicator switch malfunction RFW control module malfunction Free solenoid valve malfunction RFW control box malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harness malfunction
3 Noise Joint shaft bearing abrasion or damage RFW hub abrasion Joint shaft abrasion
4 Oil leakage RFW control box is poorly installed.
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TROUBLESHOOTING
M–57
Quick Diagnosis ChartPossible factor
Troubleshooting itemR R R Pr M EN Tr 4 R R Lo Fr R O Jo R Jo Con Va R
No RFW operation from free to lock
No RFW operation from lock to free
Noise
Oil leakage
Symptom Troubleshooting
1 NO RFW OPERATION FROM FREE TO LOCK (RFW INDICATOR LIGHT DOES NOT ILLUMINATE)
DESCRIPTION RFW does not change from free to lock.
[TROUBLESHOOTING HINTS]
Transfer neutral switch malfunction 44 indicator switch malfunction RFW control module malfunction Lock solenoid valve malfunction Free solenoid valve malfunction RFW indicator light bulb malfunction RFW control box malfunction
METER 15 A fuse and/of ENGINE 15 A fuse malfunction Print plate in instrument cluster malfunction RFW switch malfunction RFW actuator malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harnesses malfunction
STEP INSPECTION ACTION
1 Disconnect RFW control module connector.Turn ignition (engine) switch on.
Yes Go to Step 6.g ( g )
Measure voltage between RFW control moduleconnector terminal F and ground.Is the voltage greater than 10 V?
No Turn ignition (engine) switch off.Then go to next step.
2 Is the METER 15 A fuse okay? Yes Go to next step.
No Replace 15 A METER fuse.Then go to Step 31.
3 Inspect RFW indicator light bulb. Yes Go to next step.Is it okay? No Replace RFW indicator light bulb.
Then go to Step 31.
4 Measure voltage between instrument cluster Yes Go to next step.connector terminal 1J and ground.Is the voltage greater than 10 V?
No Repair wiring harness between METER 15 A fuseand instrument cluster.Then go to Step 31.
5 Measure voltage between instrument clusterconnector terminal 2H and ground.Is the voltage greater than 10 V?
Yes Repair wiring harness between instrument clusterand RFW control module.Then go to Step 31.
No Replace print plate in instrument cluster.Then go to Step 31.
6 Measure voltage between RFW control module Yes Go to Step 8.connector terminal H and ground.Is the voltage greater than 10 V?
No Turn ignition (engine) switch off.Then go to next step.
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TROUBLESHOOTING
M–58
STEP ACTIONINSPECTION
7 Is the ENG 15 A fuse okay? Yes Repair wiring harness between ENG 15 A fuse andRFW control module.Then go to Step 31.
No Replace the ENG 15 A fuse.Then go to Step 31.
8 Disconnect free solenoid valve connector.Measure voltage between free solenoid valve
Yes Connect free solenoid valve.Then go to next step.
connector terminal A and ground.Is the voltage greater than 10 V?
No Repair wiring harness between ENG 15 A fuse andRFW control module.Then go to Step 31.
9 Measure voltage between free solenoid valve Yes Go to next step.connector terminal B and ground.Is the voltage greater than 10 V?
No Inspect free solenoid valve.Then go to Step 31.
10 Measure voltage between RFW control module Yes Go to next step.connector terminal C and ground.Is the voltage greater than 10 V?
No Repair wiring harness between free solenoid valveand RFW control module.Then go to Step 31.
11 Disconnect lock solenoid valve connector.Measure voltage between lock solenoid valve
Yes Connect lock solenoid valve.Then go to next step.
connector terminal A and ground.Is the voltage greater than 10 V?
No Repair wiring harness between ENG 15 A fuse andRFW control module.Then go to Step 31.
12 Measure voltage between lock solenoid valve Yes Go to next step.connector terminal B and ground.Is the voltage greater than 10 V?
No Inspect lock solenoid valve.Then go to Step 31.
13 Measure voltage between RFW control module Yes Go to next step.connector terminal A and ground.Is the voltage greater than 10 V?
No Repair wiring harness between lock solenoid valveand RFW control module.Then go to Step 31.
14 Turn ignition (engine) switch off. Yes Go to next step.Is there continuity between RFW control moduleconnector terminal B and ground?
No Repair wiring harness between RFW controlmodule and ground.Then go to Step 31.
15 Shift select lever to N position.Is there continuity between RFW control module
Yes Go to Step 19.Is there continuity between RFW control moduleconnector terminal L and ground? No Go to next step.
16 Is there continuity between transfer neutral switchconnector terminal A and ground?
Yes Repair wiring harness between RFW controlmodule and transfer neutral switch.Then go to Step 31.
No Go to next step.
17 Inspect transfer neutral switch. Yes Go to next step.Is it okay? No Replace transfer neutral switch.
Then go to Step 31.
18 Is there continuity between transfer neutral switch Yes Go to next step.connector terminal B and ground? No Repair wiring harness between transfer neutral
switch and ground.Then go to Step 31.
19 Shift select lever to 44 indicator position.Is there continuity between RFW control module
Yes Go to Step 23.Is there continuity between RFW control moduleconnector terminal K and ground? No Go to next step.
20 Is there continuity between 44 indicator switchconnector terminal A and ground?
Yes Repair wiring harness between 44 indicatorswitch and RFW control module.Then go to Step 31.
No Go to next step.
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TROUBLESHOOTING
M–59
STEP ACTIONINSPECTION
21 Inspect 44 indicator switch. Yes Go to next step.Is it okay? No Replace 44 indicator switch.
Then go to Step 31.
22 Is there continuity between 44 indicator switch Yes Go to next step.connector terminal B and ground? No Repair wiring harness between 44 indicator
switch and ground.Then go to Step 31.
23 Shift select lever to 4H position.Is there continuity between RFW control module
Yes Go to Step 27Is there continuity between RFW control moduleconnector terminal J and ground? No Go to next step.
24 Is there continuity between RFW switchconnector terminal A and ground?
Yes Repair wiring harness between RFW controlmodule and RFW switch.Then go to Step 31.
No Go to next step.
25 Inspect RFW switch. Yes Go to next step.Is it okay? No Replace RFW switch.
Then go to Step 31.
26 Is there continuity between RFW switch Yes Go to next step.connector terminal B and ground? No Repair wiring harness between RFW switch and
ground.Then go to Step 31.
27 Inspect one-way check valve. Yes Go to next step.Is it okay? No Replace one-way check valve.
Then go to Step 31.
28 Inspect RFW control box. Yes Go to next step.Is it okay? No Replace RFW control box.
Then go to Step 31.
29 Inspect vacuum in vacuum hoses. Yes Go to next step.Is it okay? No Repair vacuum in vacuum hoses.
Then go to Step 31.
30 Inspect RFW control module. Yes Go to next step.Is it okay? No Repair or replace RFW control module.
Then go to next step.
31 Turn ignition (engine) switch on.Shift select lever from 2H to 4H position.
Yes Troubleshooting completed.Explain repairs to customer.
Does RFW operate from free to lock? No Inspect malfunction symptoms again, then repeatfrom Step 1 if malfunction occurs again.
2 NO RFW OPERATION FROM LOCK TO FREE (RFW INDICATOR LIGHT DOES NOT GO OFF)
DESCRIPTION RFW does not change from lock to free.
[TROUBLESHOOTING HINTS]
RFW main switch malfunction Transfer neutral switch malfunction 44 indicator switch malfunction RFW control module malfunction Free solenoid valve malfunction Lock solenoid valve malfunction RFW control box malfunction
ENGINE 15 A fuse malfunction RFW main switch malfunction RFW actuator malfunction RFW switch malfunction Air leakage from vacuum reservoir or actuator system One-way check valve Print plate in instrument cluster malfunction Related fuses and/or harnesses malfunction
STEP INSPECTION ACTION
1 Disconnect RFW control module connector.Is there continuity between RFW control module
Yes Go to next step.Is there continuity between RFW control moduleconnector terminal F and ground? No Go to Step 3.
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TROUBLESHOOTING
M–60
STEP ACTIONINSPECTION
2 Disconnect instrument cluster connector No.2.Is there continuity between instrument clusterterminal 2H and ground?
Yes Repair wiring harness between RFW control moduleand instrument cluster.Then go to Step 32.
No Inspect for no continuity between Instrument clusterterminal 2H and ground.
3 Turn ignition (engine) switch off.Disconnect RFW control module connector.Turn ignition (engine) switch on
Yes Go to Step 5.
Turn ignition (engine) switch on.Measure voltage between RFW control moduleconnector terminal H and ground.Is the voltage greater than 10 V?
No Turn ignition (engine) switch off.Then go to next step.
4 Is the ENG 15 A fuse okay? Yes Repair wiring harness between ENG 15 A fuse andRFW control module.Then go to Step 32.
No Replace the ENG 15 A fuse.Then go to Step 32.
5 Disconnect free solenoid valve connector.Measure voltage between free solenoid valve
Yes Connect free solenoid valve.Then go to next step.
connector terminal A and ground.Is the voltage greater than 10 V?
No Repair wiring harness between ENG 15 A fuse andRFW control module.Then go to Step 32.
6 Measure voltage between free solenoid valve Yes Go to next step.connector terminal B and ground.Is the voltage greater than 10 V?
No Inspect free solenoid valve.Then go to Step 32.
7 Measure voltage between RFW control module Yes Go to next step.connector terminal C and ground.Is the voltage greater than 10 V?
No Repair wiring harness between free solenoid valveand RFW control module.Then go to Step 32.
8 Disconnect lock solenoid valve connector.Measure voltage between lock solenoid valve
Yes Connect lock solenoid valve.Then go to next step.
connector terminal A and ground.Is the voltage greater than 10 V?
No Repair wiring harness between ENG 15 A fuse andRFW control module.Then go to Step 32.
9 Measure voltage between lock solenoid valve Yes Go next step.connector terminal B and ground.Is the voltage greater than 10 V?
No Inspect lock solenoid valve.Then go to Step 32.
10 Measure voltage between RFW control module Yes Go next step.connector terminal A and ground.Is the voltage greater than 10 V?
No Repair wiring harness between lock solenoid valveand RFW control module.Then go to Step 32.
11 Turn ignition (engine) switch off. Yes Go to next step.Is there continuity between RFW control moduleconnector terminal B and ground?
No Repair wiring harness between RFW control moduleand ground.Then go to Step 32.
12 Shift select lever to N position.Is there continuity between RFW control module
Yes Go to Step 16.Is there continuity between RFW control moduleconnector terminal L and ground? No Go to next step.
13 Is there continuity between transfer neutral switchconnector terminal A and ground?
Yes Repair wiring harness between RFW control moduleand transfer neutral switch.Then go to Step 32.
No Go to next step.
14 Inspect transfer neutral switch. Yes Go to next step.Is it okay? No Replace transfer neutral switch.
Then go to Step 32.
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TROUBLESHOOTING
M–61
STEP ACTIONINSPECTION
15 Is there continuity between transfer neutral switch Yes Go to next step.connector terminal B and ground? No Repair wiring harness between transfer neutral
switch and ground.Then go to Step 32.
16 Shift select lever to 2H position.Is there continuity between RFW control module
Yes Go to Step 20.Is there continuity between RFW control moduleconnector terminal K and ground? No Go to next step.
17 Is there continuity between 44 indicator switchconnector terminal A and ground?
Yes Repair wiring harness between RFW control moduleand 44 indicator switch.Then go to Step 32.
No Go to next step.
18 Inspect 44 indicator switch. Yes Go to next step.Is it okay? No Replace 44 indicator switch.
Then go to Step 32.
19 Is there continuity between 44 indicator switch Yes Go to next step.connector terminal B and ground? No Repair wiring harness between 44 indicator switch
and ground.Then go to Step 32.
20 Shift select lever to 4H position.Is there continuity between RFW control module
Yes Go to Step 28.Is there continuity between RFW control moduleconnector terminal J and ground? No Go to next step.
21 Is there continuity between RFW switchconnector terminal A and ground?
Yes Repair wiring harness between RFW switch.Then go to Step 32.
No Go to next step.
22 Inspect RFW switch. Yes Go to next step.Is it okay? No Replace RFW switch.
Then go to Step 32.
23 Is there continuity between RFW switch Yes Go to next step.connector terminal B and ground? No Repair wiring harness between RFW switch and
ground.Then go to Step 32.
24 Push RFW main switch on.Is there continuity between RFW main switch
Yes Go to Step 28.Is there continuity between RFW main switchconnector terminal I and ground? No Go to next step.
25 Is there continuity between RFW main switchconnector terminal F and ground?
Yes Repair wiring harness between RFW main switchand RFW control module.Then go to Step 32.
No Go to next step.
26 Inspect RFW main switch. Yes Go to next step.Is it okay? No Replace RFW main switch.
27 Is there continuity between RFW main switch Yes Go to next step.connector terminal D and ground? No Repair wiring harness between RFW main switch
and ground.Then go to Step 32.
28 Inspect one-way check valve. Yes Go to next step.Is it okay? No Replace one-way check valve.
Then go to Step 32.
29 Inspect RFW actuator. Yes Go to next step.Is it okay? No Replace RFW actuator.
Then go to Step 32.
30 Inspect vacuum in vacuum hoses. Yes Go to next step.Is it okay? No Repair vacuum in vacuum hoses.
Then go to Step 32.
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TROUBLESHOOTING
M–62
STEP ACTIONINSPECTION
31 Inspect RFW control module. Yes Go to next step.Is it okay? No Repair or replace RFW control module.
Then go to next step.
32 Turn ignition (engine) switch on.Move selector lever from 2H to 4H position.
Yes Troubleshooting completed.Explain repairs to customer.
Does RFW operate from free to lock? No Inspect malfunction symptoms again, then repeatfrom Step 1 if malfunction occurs again.
3 NOISE
DESCRIPTION Noise is heard from front differential.
[TROUBLESHOOTING HINTS]
Joint shaft bearing abrasion or damage RFW hub abrasion
Joint shaft abrasion Conventional front differential parts malfunction
STEP INSPECTION ACTION
1 Inspect joint shaft bearing. Yes Go to next step.Is it okay? No Replace joint shaft bearing.
2 Inspect RFW hub. Yes Go to next step.Is it okay? No Replace RFW hub.
3 Inspect joint shaft. Yes Go to next step.Is it okay? No Replace joint shaft.
4 Malfunction is caused by other than RFW.Inspect conventional front differential parts
Yes Go to next step.Inspect conventional front differential parts.Are they okay? No Replace defective part(s).
5 Has front differential noise stopped? Yes Troubleshooting completed.Explain repairs to customer.
No Inspect malfunction symptoms again, then repeatfrom Step 1 if malfunction occurs again.
4 OIL LEAKAGE
DESCRIPTION The oil leaks from front differential.
[TROUBLESHOOTING HINTS]
Poor installation of the RFW control box Malfunction of conventional front differential parts
STEP INSPECTION ACTION
1 Is RFW control box installed completely? Yes Go to next step.
No Install RFW control box securely.Then go to Step 3.
2 Malfunction is caused by something other thanRFW.
Yes Go to next step.
Inspect conventional front differential parts.Are they okay?
No Replace defective part(s).
3 Is there any oil leakage from front differential? Yes Inspect malfunction symptoms again, then repeatfrom Step 1 if malfunction still occurs.
No Troubleshooting completed.Explain repairs to customer.
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N–1
STEERING SYSTEMGENERAL PROCEDURES N–1. . . . . . . . . . . . . . . . . . . MANUAL STEERING N–1. . . . . . . . . . . . . . . . . . . . . . . .
STEERING WHEEL AND COLUMN INSPECTION N–1/2. . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING WHEEL AND COLUMNREMOVAL/INSTALLATION N–3/4. . . . . . . . . . . . . . . . . STEERING SHAFT INSPECTION N–4. . . . . . . . . . . STEERING GEAR AND LINKAGE
REMOVAL/INSTALLATION N–5/6. . . . . . . . . . . . . . . STEERING GEAR AND LINKAGE
DISASSEMBLY/ASSEMBLY N–7/9. . . . . . . . . . . . . . STEERING GEAR AND LINKAGE
INSPECTION N–9. . . . . . . . . . . . . . . . . . . . . . . . . . . POWER STEERING N–10 . . . . . . . . . . . . . . . . . . . . . . . .
AIR BLEEDING N–10. . . . . . . . . . . . . . . . . . . . . . . . . . . POWER STEERING FLUID INSPECTION N–10/12. . .
STEERING WHEEL AND COLUMN INSPECTION N–12. . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING WHEEL AND COLUMNREMOVAL/INSTALLATION N–12. . . . . . . . . . . . . . .
STEERING SHAFT INSPECTION N–12. . . . . . . . . . . STEERING GEAR AND LINKAGE
REMOVAL/INSTALLATION N–13. . . . . . . . . . . . . . . STEERING GEAR AND LINKAGE
DISASSEMBLY/ASSEMBLY N–14/15. . . . . . . . . . . . . . STEERING GEAR AND LINKAGE
INSPECTION N–15. . . . . . . . . . . . . . . . . . . . . . . . . . . POWER STEERING OIL PUMP
REMOVAL/INSTALLATION N–16/18. . . . . . . . . . . . . . . POWER STEERING OIL PUMP (F2 CIS, F2 CARB,
G6) DISASSEMBLY/ASSEMBLY N–19/20. . . . . . . . . . . POWER STEERING OIL PUMP (WL, WL TURBO)
DISASSEMBLY/ASSEMBLY N–21. . . . . . . . . . . . . .
GENERAL PROCEDURESWheels and tires removal/installation The removal and installation procedures for the
wheels and tires are not mentioned in this section.When a wheel is removed, retighten it to thespecified torque.(Refer to section TD,SUSPENSION, Wheels and Tires.)
Power steering components removal/installation If any power steering fluid line has been
disconnected anytime during the procedure, addATF M–III or equivalent (e.g. Dexron II), bleedthe fluid lines, and inspect for leakage after theprocedure has been completed.
Connectors disconnection/connection Disconnect the negative battery cable before doing
any work that requires handling of connectors.Reconnect the negative battery cable only after thework is completed.
MANUAL STEERINGSTEERING WHEEL AND COLUMN INSPECTIONSteering Wheel Play Inspection If the play exceeds specification, either the steering
joints are worn or the backlash of the steering gearis excessive. With the wheels in the straight-aheadposition, gently turn the steering wheel to the leftand right and verify that the play is withinspecification.
Steering wheel play0—30 mm 0—1.18 in
Steering Wheel Looseness Inspection Move the steering wheel as shown in the figure to
inspect for column bearing wear, steering shaftjoint play, steering wheel looseness, and columnlooseness.
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MANUAL STEERING
N–2
Steering Wheel Effort Inspection1. With the vehicle on a hard, level surface, put the
wheels in the straight-ahead position.2. Remove the air bag module, if equipped.
(Refer to section T, AIR BAG SYSTEM,DRIVER-SIDE AIR BAG MODULEREMOVAL/INSTALLATION.)
3. Measure the steering wheel effort using a torquewrench.
Steering wheel effort4.5 N·m 460 kgf·cm, 399 in·lbf max.
4. If not as specified, inspect the following: rotationstarting torque of pinion, rotation torque of eachball joint, and steering joints.
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MANUAL STEERING
N–3
STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
R
AIR BAG MODEL
40—50 4.0—5.0,29—36
40—50 4.0—5.0, 29—36
16—22 1.6—2.3, 12—16
16—22 1.6—2.3, 12—16
18—24 1.8—2.5, 14—18
20—26 2.0—2.7,15—19
20—26 2.0—2.7, 15—19
1 Horn cap
2 Air bag module (with air bag)+ section T, AIR BAG SYSTEM, DRIVER-SIDE
AIR BAG MODULE REMOVAL/INSTALLATION
3 Locknut
4 Steering wheel+ Removal Note+ Installation Note
5 Column cover
6 Combination switch
7 Steering shaft+ Installation Note
8 Universal joint
9 Boot
10 Intermediate shaft
11 Steering lock component+ Removal Note+ Installation Note
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MANUAL STEERING
N–4
Steering Wheel Removal Note
Caution Do not try to remove the steering wheel by
hitting the shaft with a hammer. The columnwill collapse.
Set the wheels in the straight-ahead position,remove the steering wheel using a suitable puller.
Steering Lock Component Removal Note Use a chisel to make a groove in the heads of the
steering lock mounting bolts. Remove the boltsusing a screwdriver. Remove the steering lockcomponent.
Steering Lock Component Installation Note Install the new steering lock mounting bolts.
Tighten the bolts until the heads break off.
Steering Shaft Installation Note1. Temporarily tighten the bolt A.2. Tighten the nut B to the specified torque.3. Tighten the bolt A to the specified torque.
Tightening torque16—22 N·m 1.6—2.3 kgf·m, 12—16 ft·lbf
A B
Steering Wheel Installation Note1. For vehicles with air bags, adjust the clock spring.
(Refer to section T, CLOCK SPRING, CLOCKSPRING ADJUSTMENT.)
2. Install the steering wheel with the vehicle in thestraight-ahead position.
STEERING SHAFT INSPECTION Inspect the following, and replace the column
component as necessary.1. Needle and ball bearing damage.2. Steering shaft length.
Length816.9—819.9 mm 32.17—32.27 in
3. Dust boot damage.
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MANUAL STEERING
N–5
STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION1. With the wheels in the straight-ahead position, remove in the order indicated in the table.2. Install in the reverse order of removal.
R
SST
N·m kgf·m, ft·lbf
SST
SST
SST
SST
R
R
R
R
45—584.5—6.0,33—43
37—543.7—5.5, 27—39
45—584.5—6.0,33—43
20—262.0—2.7, 15—19
69—787.0—8.0, 51—57
45—584.5—6.0, 33—43
37—543.7—5.5,27—39
45—584.5—6.0, 33—43
79—1578.0—16.0,58—115
1 Cotter pin
2 Nut
3 Ball joint+ Removal Note
4 Locknut
5 Tie rod
6 Center link
7 Idler arm+ Removal Note
8 Bushing
9 Washer
10 Bolt, nut, washer
11 Idler arm bracket
12 Bolt, nut, washer
13 Bolt
14 Steering gear and pitman arm+ Removal Note
15 Dust boot+ Removal Note+ Installation Note
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TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
MANUAL STEERING
N–6
Ball Joint, Idler Arm, Steering Gear and PitmanArm Removal Note Remove the ball joint from the knuckle and center
link, the idler arm from the center link, and steeringgear and pitman arm from the center link using theSST.
49 T028 3A0
Dust Boot Removal Note1. Place the chisel against the boot and hold it at the
angle shown.2. Remove the dust boot by tapping it with a hammer.
Dust Boot Installion Note1. Wipe the grease off the ball joint.2. Put a small amount of lithium-based grease into a
new dust boot.3. Install the dust boot using the SST and a press.
49 1243 785A
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MANUAL STEERING
N–7
STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
R
SST
N·m kgf·m, ft·lbf
R
R
R
SST
R
197—23520.0—24.0, 145—173
128—16613.0—17.0, 95—122
15—211.5—2.2, 11—15
15—241.5—2.5, 11—18
25—342.5—3.5, 25—34
R
1 Nut
2 Pitman arm+ Disassembly Note
3 Clip
4 Dust boot+ Assembly Note
5 Locknut (side cover)+ Disassembly Note
6 Sector shaft+ Disassembly Note+ Assembly Note
7 Side cover
8 Adjusting shim
9 Adjusting screw
10 Oil seal
11 Retaining ring
12 Locknut+ Disassembly Note
13 Oil seal
14 Adjusting nut+ Disassembly Note
15 Bearing
16 Worm ball nut+ Assembly Note
17 Bearing
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MANUAL STEERING
N–8
Pitman Arm Disassembly Note Separate the pitman arm from the steering gear
using the SST.
49 U032 3A0
Locknut (Side Cover), Sector Shaft DisassemblyNote
1. Loosen the locknut.2. Remove the side cover attaching bolts.3. Set the sector shaft in the middle position.4. Tap the sector shaft lower end using a plastic
hammer to loosen the sector shaft.5. Lift and remove the sector shaft with the locknut
and the side cover from the gear housing.
Locknut Disassembly Note Remove the locknut using the SST.
49 U032 201
Adjusting Nut Disassembly Note Remove the adjusting nut using the SST.
49 UB39 585A
Worm Ball Nut Assembly Note1. Inspect the worm ball nut preload using the SST.
49 0180 510B
Worm ball nut preload1.0—1.3 N·m 10—14 kgf·cm, 8.7—12.1 in·lbf
[Without the sector shaft]
2. If not as specified, adjust the preload.(1) Loosen the locknut and turn the adjusting
screw using the SST.
49 U032 201
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MANUAL STEERING
N–9
(2) Tighten the locknut to the specified torqueusing the SST.
Tightening torque128—166 N·m 13—17 kgf·m, 95—122 ft·lbf
49 U032 201
(3) Inspect the worm ball nut preload again.
Sector Shaft Assembly Note1. Set the adjusting screw and shim, in the “T”
groove.2. Measure the clearance in the axial direction.
ADJUSTINGSHIM
3. Adjust the clearance to the specified value if theclearance is more than the specified value.
Clearance0—0.1 mm (0—0.004 in)
Adjusting shim thickness1.97 mm 0.077 in 2.00 mm 0.079 in2.03 mm 0.079 in 2.06 mm 0.081 in2.09 mm 0.082 in
Caution Be careful not to damage the oil seal and
bearing.
4. Assemble the sector shaft in such a way that theteeth of the sector shaft mesh with the center partof the teeth of the worm ball nut.
Dust Boot Assembly Note1. Wipe the grease off the ball joint.2. Put a small amount of lithium-based grease into a
new dust boot.3. Install the dust boot onto the ball joint.4. Set the SST over the boot and install a new clip.
49 U034 209
5. Wipe away excessive grease.
STEERING GEAR AND LINKAGE INSPECTIONSteering Gear Backlash Adjustment
Caution Adjust the backlash while keeping the
steering gear in the center position.Otherwise, the backlash becomesexcessively small and gears may bedamaged.
Turn the adjusting screw to adjust steering gearbacklash.
Backlash0 mm
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N–10
POWER STEERING
AIR BLEEDING1. Inspect the fluid level.
(Refer to POWER STEERING, POWERSTEERING FLUID INSPECTION, Fluid LevelInspection.)
2. Jack up the front of the vehicle and support it onsafety stands.
3. Turn the steering wheel fully to the left and rightseveral times with the engine not running.
4. Reinspect the fluid level. If it has dropped, addfluid.
5. Repeat Steps 3 and 4 until the fluid level stabilizes.6. Lower the vehicle.7. Start the engine and let it idle.8. Turn the steering wheel fully to the left and right
several times.9. Verify that the fluid is not foamy and that the fluid
level has not dropped.10. Add fluid as necessary and repeat Steps 8 and 9.
POWER STEERING FLUID INSPECTIONFluid Level Inspection Inspect the power steering fluid level. Add fluid to
the specified level as necessary.
Fluid specificationATF M–III or equivalent (e.g. Dexron II )
Fluid Leakage Inspection
Caution To prevent damage to the steering system,
do not keep the steering wheel in the fullyturned position for more than 5 seconds.
1. Start the engine and let it idle. Turn the steeringwheel fully to the left and right to apply fluidpressure.
Note The points where fluid leakage may occur are
indicated in the figure.
2. Inspect for fluid leakage.
R.H.D. L.H.D.
F2 CISF2 CARB
WLWL TURBO
WLWL TURBO
G6 G6
F2 CISF2 CARB
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POWER STEERING
N–11
Fluid Pressure Inspection1. Assemble the SSTs as shown in the figure.
49 1232 670A
49 H002 671
2. Mark both hose connections to ensure that thehose is reinstalled in its original position.
3. Disconnect the pressure hose from the oil pump.Attach the SST (49 G032 304).
Tightening torqueG6:
32—47 N·m 3.2—4.8 kgf·m, 24—34 ft·lbfF2 CIS, F2 CARB, WL, WL Turbo:
30—44 N·m 3.0—4.5 kgf·m, 22—32 ft·lbf
4. Connect the SSTs (49 1232 670A and 49 H002 671)to the SST (49 G032 304).
G6
49 B032 304
49 G032 3A4
49 H002 671
F2 CIS, F2 CARB, WL, WL TURBO
5. Bleed the air from the system.6. Open the gauge valve fully. Start the engine and
turn the steering wheel fully left and right to raisethe fluid temperature to 50—60 °C 122—140 °F.
Caution If the valve is left closed for more than 5
seconds, the fluid temperature will increaseexcessively and adversely affect the oilpump.
7. Close the gauge valve completely. Increase theengine speed to 1,000—1,500 rpm and measurethe fluid pressure generated by the oil pump. If thepressure is not within the specification, replace theoil pump component.
Oil pump fluid pressure8.9—9.3 MPa
90—95 kgf/cm 2, 1280—1350 psiTHERMOMETER50—60 °C 122—140 °F
GAUGE
CLOSE VALVECOMPLETELY
Caution If the steering wheel is kept in the fully
turned position for more than 5 seconds,the fluid temperature will rise excessivelyand adversely affect the oil pump.
8. Open the gauge valve fully and increase theengine speed to 1,000—1,500 rpm .
9. Turn the steering wheel fully to left and right andmeasure the fluid pressure generated at the gearhousing. If the pressure is not within thespecification, repair or replace the steering gearcomponent.
Gear housing fluid pressure8.9—9.3 MPa
90—95 kgf/cm 2, 1280—1350 psiTHERMOMETER50—60 °C 122—140 °F
GAUGEOPEN VALVECOMPLETELY
10. Remove the SSTs. Install and tighten the pressurepipe to the specified torque.
Tightening torque30—44 N·m 3.0—4.5 kgf·m, 22—32 ft·lbf
11. Bleed the air from the system.
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POWER STEERING
N–12
Note To determine whether the steering effort is
satisfactory or not, perform the inspection onanother vehicle of the same model and underthe same conditions, and compare the results.
The steering wheel effort varies with conditionsas shown below.1. Road conditions, such as dry or wet, and
asphalt or concrete.2. Tire conditions, such as brand, wear, and
tire pressure.
12. If not as specified, inspect the following points: Air in system Fluid leakage at hose or connectors Function of oil pump and steering gear
STEERING WHEEL AND COLUMNREMOVAL/INSTALLATION(Refer to MANUAL STEERING, STEERING WHEELAND COLUMN REMOVAL/INSTALLATION.)
STEERING SHAFT INSPECTION(Refer to MANUAL STEERING, STEERING SHAFTINSPECTION.)
STEERING WHEEL AND COLUMN INSPECTIONSteering Wheel Play Inspection(Refer to MANUAL STEERING, STEERING WHEELAND COLUMN INSPECTION, Steering Wheel PlayInspection.)
Steering Wheel Looseness Inspection(Refer to MANUAL STEERING, STEERING WHEELAND COLUMN INSPECTION, Steering WheelLooseness Inspection.)
Steering Wheel Effort Inspection1. Inspect the following points:
Tire size and tire pressure Fluid level
2. With the vehicle on a hard, level surface, put thewheels in the straight-ahead position.
3. Start the engine and warm the power steering fluidto 50—60 °C 122—140 °F.
4. Remove the air bag module, if equipped. (Refer to section T, AIR BAG SYSTEM, DRIVER-SIDEAIR BAG MODULE REMOVAL/INSTALLATION.)
5. Measure the steering wheel effort using a torquewrench.
Steering wheel effort7.8 N·m 80 kgf·cm, 69 in·lbf max.
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POWER STEERING
N–13
STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
R
SST
SST
R
R
SST
79—1577.0—16.0, 58—115
37—543.7—5.5, 27—39
45—584.5—6.0, 33—43
69—787.0—8.0, 51—57
45—584.5—6.0, 33—43
20—262.0—2.7, 15—19
37—543.7—5.5, 27—39
32—473.2—4.8, 24—34
24—352.4—3.6, 18—26
R
SST
SST
1 Cotter pin
2 Locknut
3 Ball joint+ MANUAL STEERING, STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION, BallJoint Removal Note
4 Locknut
5 Tie rod
6 Center link
7 Idler arm+ MANUAL STEERING, STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION, IdlerArm Removal Note
8 Bushing
9 Washer
10 Bolt, nut, washer
11 Idler arm bracket
12 Pressure pipe
13 Return pipe
14 Bolt
15 Bolt, nut, washer
16 Steering gear and pitman arm+ MANUAL STEERING, STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION, SteeringGear and Pitman Arm Removal Note
17 Dust boot+ MANUAL STEERING, STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION, DustBoot Disassembly Note
+ MANUAL STEERING, STEERING GEAR ANDLINKAGE REMOVAL/INSTALLATION, DustBoot Assembly Note
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POWER STEERING
N–14
STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
N·m kgf·m, ft·lbf
R
SST
R
R R
R
R
SSTR
R
R
R
R
R
57—645.7—6.5, 42—47
30—443.0—4.5, 22—32
56—635.7—6.5, 42—47
197—23520.0—24.0,145—173
R
1 Nut
2 Pitman arm+ MANUAL STEERING, STEERING GEAR AND
LINKAGE DISASSEMBLY/ASSEMBLY, PitmanArm Disassembly Note
3 Clip
4 Dust boot+ MANUAL STEERING, STEERING GEAR AND
LINKAGE DISASSEMBLY/ASSEMBLY, DustBoot Assembly Note
5 Locknut+ MANUAL STEERING, STEERING GEAR AND
LINKAGE DISASSEMBLY/ASSEMBLY, Locknut(Side Cover), Sector Shaft Disassembly Note
6 Sector shaft+ MANUAL STEERING, STEERING GEAR AND
LINKAGE DISASSEMBLY/ASSEMBLY, Locknut(Side Cover) Sector Shaft Disassembly Note
7 Side cover
8 O-ring
9 Y packing
10 Back up ring
11 Oil seal
12 Back up ring
13 Y packing
14 Dust cover
15 Snap ring
16 Washer
17 Oil seal
18 Valve and piston component+ Assembly Note
19 O-ring
20 Seal ring
21 Gear housing
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POWER STEERING
N–15
Valve and Piston Component Assembly Note
Caution Do not scratch the seal ring and O-ring on
the piston against the entrance to thehousing.
Insert the piston by slightly turning to theleft and right so as not to create flection atthe O-ring and seal ring.
Insert the valve and piston component to the gearhousing.
STEERING GEAR AND LINKAGE INSPECTION(Refer to MANUAL STEERING, STEERING GEARAND LINKAGE INSPECTION, Steering Gear BacklashAdjustment.)
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POWER STEERING
N–16
POWER STEERING OIL PUMP REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.3. For F2 CIS, F2 Carb and G6 engine model, adjust the drive belt.
(Refer to Section B2, DRIVE BELT,DRIVE BELT ADJUSTMENT.)
30—443.0—4.5, 22—32
R
SST
30—393.0—4.0, 22—28
N·m kgf·m, ft·lbf
50—595.0—6.0, 37—43
F2 CIS, F2 CARB
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POWER STEERING
N–17
N·m kgf·m, ft·lbf
19—251.9—2.6, 14—18
32—473.2—4.8, 24—34
32—463.2—4.7, 24—33
50—595.0—6.0, 37—43
SST
CLAMPPOSITION
30 mm1.2 in
G6
1 Drive belt
2 Locknut+ Removal Note
3 Oil pump pulley
4 Pressure pipe (F2 CIS, F2 Carb), pressure hose(G6)
5 Return hose
6 Power steering fluid pressure switch connector(except F2 Carb)
7 Power steering oil pump component
Locknut Removal Note Secure the pulley using the SST and remove the
locknut.
49 G032 354
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POWER STEERING
N–18
N·m kgf·m, ft·lbf
R
R
19—251.9—2.6, 14—18
19—251.9—2.6,14—18
30—443.0—4.5, 22—32
WL, WL TURBO
1 Pressure pipe
2 Return hose
3 Bolt and nut
4 Power steering oil pump
5 O-ring
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POWER STEERING
N–19
POWER STEERING OIL PUMP (F2 CIS, F2 CARB, G6) DISASSEMBLY/ASSEMBLY1. The following procedure is for replacement of the O-rings only. Replace the pump component if other repairs
are necessary.2. Disassemble in the order indicated in the table.3. Assemble in the reverse order of disassembly.
N·m kgf·m, ft·lbf
15—19 1.5—2.0,11—14
22—25 2.2—2.6, 16—18
50—68 5.0—7.0,37—50
9.9—13.7 N·m 100—140 kgf·cm,87—121 in·lbf
R
R
R
R
R
R
R
18—21 1.8—2.2, 14—16
22—25 2.2—2.6, 16—18
7.9—11.7 N·m 80—120 kgf·cm,70—104 in·lbf
F2 CIS
G6
SST
À
F2 CARB
16—23 1.6—2.4, 12—17
1 Power steering oil pump component+ Disassembly Note
2 Pressure switch component
3 O-ring
4 Nut (G6)
5 Connector (G6)
6 Connector bolt
7 O-ring
8 Control valve component
9 Spring
10 Suction pipe
11 O-ring
12 Shaft component
13 Rear body+ Assembly Note
14 O-ring
15 Cam ring+ Assembly Note
16 Rotor
17 Vane+ Assembly Note
18 Pin
19 Side plate+ Assembly Note
20 O-ring
21 Oil seal
22 Front body
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POWER STEERING
N–20
Power Steering Oil Pump Disassembly Note
Caution To secure the oil pump in a vise, use the SST
as shown to prevent damage to the pump.
49 F032 301
Side Plate Assembly Note1. Install a new O-ring and the side plate to the front
body.2. Position the side plate using the rear body.
Vane, Cam Ring Assembly Note1. Install the cam ring with the marks facing the front
body.
2. Install the rotor with the mark facing the rear body.
MARK
3. Install the vanes in the rotor with the rounded edgesoutward.
ROUND EDGE
Rear Body Assembly Note After installing the rear body, manually turn the shaft
to verify that it rotates smoothly.
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POWER STEERING
N–21
POWER STEERING OIL PUMP (WL, WL TURBO) DISASSEMBLY/ASSEMBLY1. The following procedure is for replacement of the O-rings only. Replace the pump component if other repairs
are necessary.2. Disassemble in the order indicated in the table.3. Assemble in the reverse order of disassembly.
R
SST
R
R
R
22—252.2—2.6, 16—18
50—685.0—7.0, 37—50
7.9—11.7 N·m80—120 kgf·cm,69.5—104.1 in·lbf
N·m kgf·m, ft·lbf
1 Power steering oil pump component+ POWER STEERING, POWER STEERING
OIL PUMP (G6) REMOVAL/INSTALLATION, Power SteeringOil Pump Component Disassembly Note
2 Suction pipe
3 O-ring
4 Connector
5 O-ring
6 Control valve
7 Spring
8 Rear body+ POWER STEERING, POWER STEERING
OIL PUMP (G6) REMOVAL/INSTALLATION, Rear BodyAssembly Note
9 O-ring
10 Cam ring+ POWER STEERING POWER STEERING
OIL PUMP (G6) REMOVAL/INSTALLATION, Cam RingAssembly Note
11 Rotor
12 Vane+ POWERSTEERING, POWER STEERING
OIL PUMP (G6) REMOVAL/INSTALLATION, Vane Assembly Note
13 Side plate+ POWER STEERING, POWER STEERING
OIL PUMP (G6) REMOVAL/INSTALLATION, Side PlateAssembly Note
14 O-ring
15 Front body
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POWER STEERING
P–1
BRAKING SYSTEMGENERAL PROCEDURES P– 1. . . . . . . . . . . . . . . . . . . CONVENTIONAL BRAKE SYSTEM P– 2. . . . . . . . . . .
AIR BLEEDING P– 2. . . . . . . . . . . . . . . . . . . . . . . . . . . VACUUM LINE INSPECTION P– 2. . . . . . . . . . . . . . BRAKE PEDAL INSPECTION P– 2. . . . . . . . . . . . . . BRAKE PEDAL REMOVAL/INSTALLATION P– 3. . BRAKE SWITCH INSPECTION P– 4. . . . . . . . . . . . . MASTER CYLINDER REMOVAL/
INSTALLATION P– 4/6. . . . . . . . . . . . . . . . . . . . . . . . . . FLUID LEVEL SENSOR INSPECTION P– 6. . . . . . MASTER CYLINDER DISASSEMBLY/
ASSEMBLY P– 7/8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER BRAKE UNIT INSPECTION P– 8. . . . . . . . POWER BRAKE UNIT REMOVAL/
INSTALLATION P– 9. . . . . . . . . . . . . . . . . . . . . . . . . . VACUUM SWITCH INSPECTION P– 9. . . . . . . . . . . VACUUM SWITCH
REMOVAL/INSTALLATION P–10. . . . . . . . . . . . . . . VACUUM PUMP INSPECTION P–10. . . . . . . . . . . . . VACUUM PUMP REMOVAL/INSTALLATION P–10. LOAD SENSING PROPORTIONING
VALVE INSPECTION P–11. . . . . . . . . . . . . . . . . . . . . LOAD SENSING PROPORTIONING
VALVE ADJUSTMENT P–11. . . . . . . . . . . . . . . . . . .
LOAD SENSING PROPORTIONINGVALVE REMOVAL/INSTALLATION P–11. . . . . . . . .
FRONT BRAKE (DISC) INSPECTION P–12. . . . . . . FRONT BRAKE (DISC) REMOVAL/
INSTALLATION P–13/14. . . . . . . . . . . . . . . . . . . . . . . . . . DISC PAD (FRONT) REPLACEMENT P–14. . . . . . . CALIPER (FRONT) DISASSEMBLY/
ASSEMBLY P–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE (DRUM) INSPECTION P–15. . . . . . . REAR BRAKE (DRUM) REMOVAL/
INSTALLATION P–15. . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE DRUM INSPECTION P–16. . . . . . . . . . . . . . . WHEEL CYLINDER DISASSEMBLY/
ASSEMBLY P–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE SYSTEM P–16. . . . . . . . . . . . . . . . .
PARKING BRAKE (STICK TYPE)INSPECTION P–16. . . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING BRAKE (STICK TYPE)ADJUSTMENT P–16. . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING BRAKE LEVER (STICK TYPE)REMOVAL/INSTALLATION P–17. . . . . . . . . . . . . . .
PARKING BRAKE CABLE (STICK TYPE)REMOVAL/INSTALLATION P–18/19. . . . . . . . . . . . . . .
GENERAL PROCEDURESWheel and tires removal/installation The removal and installation procedures for the
wheels and tires are not mentioned in this section.When a wheel is removed, retighten it to thespecified tightening torque, referring to section TD.
Brake lines disconnection/connection
Caution Brake fluid will damage painted surfaces. If
brake fluid get on a painted surface, wipe itoff immediately.
If any brake line has been disconnected anytimeduring the procedure, add brake fluid, bleed thebrakes, and inspect leakage after the procedurehas been completed.
Fluid specificationSAE J1703 or FMVSS116 DOT–3 or DOT–4
Brake pipe flare nut tightening Tighten the brake pipe flare nut by using the
SST (49 0259 770B). Be sure to modify the brake pipeflare nut tightening torque to allow for use of atorque wrench-SST combination. (Refer to section GI, FUNDAMENTAL PROCEDURES, TORQUE FORMULAS.)
Connectors disconnection Disconnect the negative battery cable before doing
any work that requires handling of connectors.Reconnect the negative battery cable only after thework is completed.
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CONVENTIONAL BRAKE SYSTEM
P–2
CONVENTIONAL BRAKE SYSTEMAIR BLEEDING
Note The reservoir should be kept 3/4 full during
bleeding. The brakes should be bled whenever a brake
line is disconnected. If a hydraulic line isdisconnected at the master cylinder, start at theslave cylinder farthest from the brake mastercylinder, and move to the next farthest slavecylinder until all four cylinders have been bled.If the disconnection point is anywhere exceptthe master cylinder, start at the point closest tothe disconnection, and move to the nextclosest slave cylinder until all four cylindershave been bled.
1. Remove the bleeder cap and attach a vinyl tube tothe bleeder screw.
2. Place the other end of the vinyl tube in a clearfluid-filled container.
3. One person should depress the brake pedal a fewtimes, and then hold it in the depressed position.
4. A second person should loosen the bleeder screw,drain out the fluid and retighten the screw using theSST.
Tightening torqueFront:
9—14 N·m 92—142 kgf·cm, 80—123 in·lbfRear:
5.9—8.8 N·m 60—90 kgf·cm, 53—78 in·lbf
49 0259 770B
5. Repeat steps 3 and 4 until no air bubbles are seen.6. After air bleeding, inspect the following:
(1) brake operation(2) fluid leakage(3) fluid level
VACUUM LINE INSPECTION1. Remove the clamps and the vacuum hose.2. Apply both suction and pressure to the engine-side
hose (Gasoline) or vacuum pump side of the hose(Diesel), and verify that air blows only toward thatside. If air flows in both directions or not at all,replace the vacuum hose.
ENG
CHECK VALVE
BRAKE PEDAL INSPECTIONBrake Pedal Height Inspection Verify that the distance from the center of the
upper surface of the pedal pad to the floor pannelis as specified.
Pedal heightL.H.D.: 214—219 mm 8.43—8.81 inR.H.D.:219—224 mm 8.63—8.81 in
PEDAL HEIGHT
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CONVENTIONAL BRAKE SYSTEM
P–3
Brake Pedal Height Adjustment1. Disconnect the brake switch connector.2. Loosen locknut B and turn switch A until it does not
contact the pedal.3. Loosen locknut D and turn rod C to adjust the height.4. Tighten the bolt with locknut B so that clearance
between the bolt for brake light switch A and pedalstopper is within the specification.
Specification0.1—1.0 mm 0.004—0.039 in
Tightening torque14—17 N·m 140—180 kgf·cm, 122—156 in·lbf
5. Connect the brake switch connector.6. After adjustment, inspect the pedal play and the
brake light operation.
B
DA
C
Brake Pedal Play Inspection1. Depress the pedal a few times to eliminate the
vacuum in the system.2. Remove the snap pin, verify that the holes in the
fork and in the pedal are aligned, and reinstall thepin.
3. Gently depress the pedal by hand until resistanceis felt (approx. 20N 2 kgf, 4.4 lbf ) and inspectthe free play.
Pedal play3—8 mm 0.12—0.31 in
Brake Pedal Play Adjustment1. Remove the snap pin and clevis pin.2. Loosen locknut D and turn rod C to align the holes
in the fork and in the pedal.3. Install the clevis pin and the snap pin.4. Tighten locknut D.
Tightening torque24—34 N·m 2.4—3.5 kgf·m, 18—25 ft·lbf
C
D
5. After adjustment, inspect the pedal height and thebrake light operation.
Pedal-to-floor Clearance Inspection1. Start the engine and verify that the distance from
the floor panel to the pedal pad center is asspecified when the pedal is depressed with a forceof 589 N 60 kgf, 132 lbf .
Clearance105 mm 4.2 in min.
PEDAL-TO-FLOORCLEARANCE
2. If the distance is less than specified, inspect thefollowing:(1) Air in brake system(2) Malfunction of the automatic adjuster(3) Excessive shoe clearance
BRAKE PEDAL REMOVAL/INSTALLATIONR.H.D.
The brake pedal is mounted on the bracketintegrated with the clutch pedal and acceleratorpedal. Refer to section F2, INTAKE AIRSYSTEM, ACCELERATOR PEDALREMOVAL/INSTALLATION for the brake pedal removal/installation.
L.H.D.The brake pedal is mounted on the bracketintegrated with the clutch Pedal. Refer to section H, CLUTCH PEDAL REMOVAL/INSTALLATION for the brake pedal removal/installation.
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CONVENTIONAL BRAKE SYSTEM
P–4
BRAKE SWITCH INSPECTION1. Disconnect the brake switch connector.2. Inspect for continuity between the terminals of the
brake switch connector using the circuit tester.: Continuity
ConditionTerminal
ConditionA B
When the brake pedal isdepressed.
When the brake pedal isnot depressed.
A
B
3. If not as specified, replace the brake switch.
MASTER CYLINDER REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.L.H.D.
SST
R
9.81—15.6 100—160, 87—138
*
12.9—21.5130—220, 113—190
SST
* 49 0259 770B N·m kgf·cm, in·lbf
N·m kgf·cm, in·lbf
*
9.81—15.6 100—160, 87—138
12.9—21.5130—220, 113—190
* 49 0259 770B
SST
SST
R
R.H.D.
1 Brake fluid level sensor connector
2 Brake pipe
3 Bracket (R.H.D.)
4 Master cylinder+ Installation Note
5 O-ring
Master Cylinder Installation Note1. Loosen the adjusting nut of the SST.2. Place the SST on the power brake unit and tighten
the nut and washer.
Tightening torque9.81—15.6 N·m
100—160 kgf·cm, 87—138 in·lbf
3. Apply 66.7 kPa 500 mmHg, 19.7 inHg vacuum tothe power brake unit using a vacuum pump.
49 B043 001
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CONVENTIONAL BRAKE SYSTEM
P–5
4. Turn the adjusting nut of the SST counterclockwiseuntil the gauge rod just contacts the push rod endof the power brake unit. Push lightly on the end ofthe gauge rod to be sure it is seated. Verify thatthere is no gap between the adjusting nut and SSTbody.
5. Remove the SST from the power brake unit.
TOUCHING
TOUCHING
ADJUSTING NUT
49 B043 001
6. Remove the SST from the power brake unit withoutdisturbing the adjusting nut. Set the SST onto themaster cylinder as shown in the figure.
7. Push lightly on the end of the SST gauge rod to besure that it is contacting the bottom of the mastercylinder piston, but do not push so hard that thepiston moves. Note any clearance between theSST body and the adjusting nut: clearance B, orbetween the body and the master cylinder:clearance C. Adjust the push rod as necessary asoutlined in “Adjustment” below.
AdjustmentMeasurement Push rod
Clearance at B Too long
Clearance at C Too short
No clearance at B or C Okay
CLEARANCE (B)
CLEARANCE (C)
49 B043 001
Clearance at B1. Measure and record the height D1 of the gauge
rod.
(D1)
49 B043 001
2. Turn the adjusting nut until the SST body setsclosely on the master cylinder. Turn only enoughfor the body to touch.
3. Measure and record height D2 of the gauge rod.ADJUSTING NUT
(D2)
CLEARANCE (B)
49 B043 001
4. Subtract D1 from D2. Using the SST, turn the nutto shorten the power brake unit push rod anamount equal to the difference.
49 B043 004
49 E043 003A
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CONVENTIONAL BRAKE SYSTEM
P–6
Clearance at C1. Push lightly on the end of the SST gauge rod, and
measure the clearance between the adjusting nutand the SST body.
CLEARANCE (C)
49 B043 001
2. Using the SSTs, turn the nut to lengthen the powerbrake unit push rod an amount equal to theclearance measured at B.
49 B043 004
49 E043 003A
FLUID LEVEL SENSOR INSPECTION1. Disconnect the sensor connector.2. Connect an ohmmeter to the connector.3. Starting with the fluid level above MIN, verify that
there is no continuity.4. Remove the brake fluid and verify that there is
continuity when the level is below MIN.: Continuity
Fl id levelTerminal
Fluid levelA B
Below MIN.
Above MIN.
5. If not as specified, replace the sensor.
B
A
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CONVENTIONAL BRAKE SYSTEM
P–7
MASTER CYLINDER DISASSEMBLY/ASSEMBLY
Caution If the master cylinder body is damaged, replace the unit as a component. When securing the master
cylinder in a vise, tighten only the flange of the master cylinder.
1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
N·m kgf·cm , in·lbf
2.0—2.4 20—25, 18—21
1.0—1.510—15, 8.7—13
À
R
R
R
R
R
R
1 Cap set
2 Screw
3 Reservoir
4 Joint bushing
5 Fluid level sensor
6 Snap ring
7 Spacer
8 Piston guide
9 O-ring
10 Cup
11 Primary piston stopper
12 Primary piston
13 Stop screw+ Assembly Note
14 O-ring
15 Secondary piston
16 Master cylinder body
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CONVENTIONAL BRAKE SYSTEM
P–8
Stop Screw and O-ring Assembly Note1. Install a new O-ring onto the stop screw.2. Push the primary piston component in full.3. Install and tighten the stop screw.
Tightening torque2.0—2.4 N·m 20—25 kgf·cm, 18—21 in·lbf
POWER BRAKE UNIT INSPECTIONPower Brake Unit Function Inspection(Simple method)
Note Replace power brake unit component as
necessary.
Step 11. With the engine stopped, depress the pedal a few
times.2. With the pedal depressed, start the engine.3. If the pedal moves down slightly, immediately after
the engine starts, the unit is operating.
Step 21. Start the engine.2. Stop the engine after it has run for 1 or 2 minutes .3. Depress the pedal with the usual force.4. If the first pedal stroke is long and becomes shorter
with subsequent strokes, the unit is operating.
Note If a problem is found, inspect for damage on
the check valve or vacuum hose, and examinethe installation. Repair as necessary, andinspect it again.
Step 31. Start the engine.2. Depress the pedal with the usual force.3. Stop the engine with the pedal held depressed.4. Hold the pedal down for about 30 seconds .5. If the pedal height does not change, the unit is
operating.
(Inspection using the testers)1. Connect the SSTs, vacuum gauge, and pedal
depression force gauge as shown in the figure.
Note Use commercially available gauges and pedal
depression force gauge. Bleed the air from the SST at gauge A.
VACUUM GAUGE
PEDAL DE-PRESSIONFORCEGAUGE
49 U043 004 49 U043 005
49 U043 006
AA
2. After bleeding the air from the SST, conduct thetest as described in the following steps.
a) Inspection for vacuum lossUnloaded condition
1. Start the engine.2. Stop the engine when the vacuum gauge reading
reaches 66.7 kPa 500 mmHg, 19.7 inHg .3. Observe the vacuum gauge for 15 seconds . If the
gauge shows 63.3—66.7 kPa 475—500 mmHg,18.7—19.7 inHg , the unit is operating.
Loaded condition1. Start the engine.2. Depress the brake pedal with a force of 196 N 20
kgf, 44 lbf .3. With the brake pedal depressed, stop the engine
when the vacuum gauge reading reaches 66.7 kPa500 mmHg, 19.7 inHg .
4. Observe the vacuum gauge for 15 seconds . If thegauge shows 63.3—66.7 kPa 475—500 mmHg,18.7—19.7 inHg , the unit is operating.
b) Inspection for hydraulic pressure1. When the engine is stopped (vacuum 0 kPa 0
mmHg, 0 inHg ) and the fluid pressure is withinthe specification, the unit is operating.
Pedal force Fluid pressure
196 N20 kgf, 44 lbf
790 kPa 8 kgf/cm2, 114 psi min
2. Start the engine. Depress the brake pedal whenthe vacuum reaches 66.7 kPa 500 mmHg, 19.7inHg . If the fluid pressure is within thespecification, the unit is operating.
Pedal force Fluid pressure
196 N20 kgf, 44 lbf
8,240 kPa84 kgf/cm2, 1,200 psi min
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CONVENTIONAL BRAKE SYSTEM
P–9
POWER BRAKE UNIT REMOVAL/INSTALLATION1. Remove the master cylinder. (Refer to
CONVENTIONAL BRAKE SYSTEM, MASTERCYLINDER REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.3. Install in the reverse order of removal.L.H.D.
N·m kgf·m, ft·lbf
19—251.9—2.6, 14—18
24—342.4—3.5, 18—25
R
19—251.9—2.6, 14—18
N·m kgf·m, ft·lbf
24—342.4—3.5, 18—25
R
R.H.D.
1 Vacuum switch connector (Diesel)
2 Vacuum hose
3 Snap pin
4 Clevis pin
5 Nut
6 Power brake unit
7 Gasket
8 Fork
9 Nut
VACUUM SWITCH INSPECTION (DIESEL)1. Remove the vacuum hose from the power brake unit.2. Set the vacuum pump hose (commercially
available on the market) onto the power brake unitas shown.
3. Turn the engine switch on.4. Release the parking brake.5. Apply vacuum to the power brake unit using the
vacuum pump (commercially available on themarket) and verify the operating condition of thebrake light warning light.
Vacuum kPa mmHg, inHg Brake warninglight
Below 10.71.3 8010, 3.20.4 ON
Above 10.71.3 8010, 3.20.4 OFF
6. The vacuum switch is functioning normally if itcorresponds to the above specifications. Replacethe vacuum switch as necessary.
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CONVENTIONAL BRAKE SYSTEM
P–10
VACUUM SWITCH REMOVAL/INSTALLATION(DIESEL)
1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
L.H.D.
N·m kgf·m, ft·lbf20—24 2.0—2.5, 15—18
R.H.D.
N·m kgf·m, ft·lbf20—24 2.0—2.5, 15—18
1 Vacuum switch connector
2 Vacuum switch+ Installation Note
Vacuum Switch Installation Note1. Remove the old sealant.
Caution Do not apply sealant to the tip of the
vacuum switch as a malfunction may occur.2. Apply sealant to the area shown before installation
of the vacuum switch onto the power brake unit,and then tighten it to the specified torque.
Tightening torque20—24 N·m 2.0—2.5 kgf·m, 15—18 ft·lbf
DO NOT APPLYSEALANT ONTHIS AREA
VACUUM PUMP INSPECTION (DIESEL)1. Warm up the engine.2. Disconnect the vacuum hose from the vacuum
pump and connect a vacuum gauge as shown inthe figure, then inspect the vacuum.
Vacuum specification (In 20 seconds)Engine speed 1,500 rpm73.3 kPa 550 mmHg, 21.7 inHg
Maximum vacuumEngine speed 3,000 rpm93.3 kPa 700 mmHg, 27.6 inHg
3. If the pressure is less than the specification,inspect for the following.(1) Malfunction of the vacuum pump(2) Shortage of the lubrication oil pressure
VACUUM PUMP REMOVAL/INSTALLATION(DIESEL)
1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
R
N·m kgf·m, ft·lbf
19—25 1.9—2.6, 14—18
1 Vacuum hose
2 Bolt
3 Vacuum pump
4 O-ring
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CONVENTIONAL BRAKE SYSTEM
P–11
LOAD SENSING PROPORTIONING VALVEINSPECTION
1. Place the vehicle on level ground.2. Inspect the tire inflations and set them to the
recommended pressure as necessary.3. Prepare the vehicle with a person in the driver’s
seat; include the standard vehicle tools, the sparewheel and tire, and a full tank of fuel.
4. Connect pressure gauges (commercially available)to the front and rear calipers.
Note When applying the specified pressure, the brake
pedal must not be “double pumped” or released. Approximately two seconds after setting the front
wheel cylinder fluid pressure, read the rear pres-sure.
5. Bleed the air from the brake system.6. Slowly depress the brake pedal until the front
pressure gauge indicates the specified pressureshown in the table, then note the reading on therear pressure gauge.
kPa kgf/cm2, psiFront pressure Rear pressure
4,900 50, 711 2,550 26, 370
9,810 100, 1,422 3,530 36, 512
REAR PRESSURE FRONT PRESSURE4,900 50, 711 9,810 100, 1,422
kPa kgf/cm 2, psi
LOADED
A PERSON INDRIVER’S SEAT
7. If not as specified, replace and adjust the LSPV.
LOAD SENSING PROPORTIONING VALVEADJUSTMENT
1. Place the unloaded vehicle on level ground.Unloaded condition: Fuel tank is full. Engine
coolant and engine oil are atspecified levels. Spare tire,jack, and tools are indesignated position.
Note A change of 5 mm 0.197 in dimension L
results in a change of 853 kPa 8.7 kgf/cm 2,124 psi for 42 and 1020 kPa 10.4 kgf/cm 2,148 psi for 44.
2. Adjust main spring dimension L between the LSPVand the adjustment link by loosening andrepositioning the LSPV.(1) Decrease dimension L if the fluid pressure is
low.(2) Increase dimension L if the fluid pressure is
high.
Reference valueDimension L
42: 147.5—154.5 mm 5.808—6.082 in44: 175.5—182.5 mm 6.910—7.185 in
ADJUSTMENT LINK
MAIN SPRING
AXLE CASING
BOLT
3. After adjustment, recheck the fluid pressure. If notas specified, replace the LSPV as a component.
LOAD SENSING PROPORTIONING VALVEREMOVAL/INSTALLATION
Caution Do not disassemble the LSPV. Do not move the nut A.
1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
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CONVENTIONAL BRAKE SYSTEM
P–12
3. After installation, adjust the main spring dimension.(Refer to CONVENTIONAL BRAKE SYSTEM,LOAD SENSING PROPORTIONING VALVEADJUSTMENT.)
SST * SST *
A
12.8—21.5 N·m 130—220 kgf·cm, 113—190 in·lbf
19—25 1.9—2.6, 14—18
* 49 0259 770B
12.8—21.5 N·m 130—220 kgf·cm,113—190 in·lbf
19—25 1.9—2.6, 14—18
N·m kgf·m, ft·lbf
1 Brake pipe
2 Nut
3 Bolt
4 Load sensing proportioning valve
FRONT BRAKE (DISC) INSPECTIONDisc Pad Thickness Inspection
1. Jack up the front of the vehicle and support it on safe-ty stands.
2. Remove the wheel and tires.3. Look through the caliper inspection hole and
inspect the remaining thickness of the pads.
Thickness2.0 mm 0.08 in min.
4. Replace the pads as a set (right and left wheels) ifeither is at or less than the minimum thickness.
Disc Plate Thickness Inspection1. Measure the thickness of the disc plate.
Caution When it is necessary to machine the disc
plate, if the disc plate is removed from thevehicle then machined, excessive runoutmay result. Machine the disc plate with itinstalled on the vehicle.
Standard24 mm 0.94 in
Minimum22 mm 0.87 in
Minimum thickness after machining by using abrake lathe on-vehicle22.8 mm 0.90 in
2. If the thickness is not within the specification,replace the disc plate.
Disc Plate Runout Inspection1. Verify that there is no wheel bearing looseness.2. Measure the runout at the outer edge of the
contact surface of the disc pad.
Runout0.05 mm 0.002 in max.
3. If the runout is not within the specification, repair orreplace the disc plate.
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CONVENTIONAL BRAKE SYSTEM
P–13
FRONT BRAKE (DISC) REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not drag.
SST
N·m kgf·m, ft·lbf
22—29 2.2—3.0, 16—29
108—127 10.4—14.0, 80—94
R
R29—34 2.9—3.5, 21—25
1 Brake hose
2 Bolt
3 Guide pin
4 Dust boot
5 Caliper
6 Disc pad+ Installation Note
7 Plate
8 Guide plate
9 Mounting support
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CONVENTIONAL BRAKE SYSTEM
P–14
Disc Pad Installation Note1. Push the piston fully inward using the SST.2. Install the disc pad.
49 0221 600C
DISC PAD (FRONT) REPLACEMENT1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
SST
N·m kgf·m, ft·lbf
29—342.9—3.5, 21—25
R
1 Bolt
2 Caliper
3 Disc pad+ CONVENTIONAL BRAKE SYSTEM, FRONT
BRAKE (DISC) REMOVAL/INSTALLATION,Disc Pad Installation Note
4 Plate
5 Guide plate
CALIPER (FRONT) DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
R
*SST
SST
9—14 92—143, 80–123
*49 0259 770B N·m kgf·cm, in·lbf
1 Piston+ Disassembly Note
2 Dust seal
3 Piston seal+ Disassembly Note
4 Bleeder cap, screw
5 Caliper body
Piston Disassembly Note
Caution Blow the compressed air slowly to prevent
the piston from suddenly popping out.
Place a piece of wood in the caliper, then blowcompressed air through the hole to force the pistonout of the caliper.
WOOD
Piston Seal Disassembly Note Remove the piston seal from the brake caliper
using the SST.
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CONVENTIONAL BRAKE SYSTEM
P–15
REAR BRAKE (DRUM) INSPECTIONBrake Lining Thickness Inspection
1. Remove the brake drum.2. Inspect the remaining thickness of the lining.
Thickness1.0 mm 0.04 in min.
3. Replace both left and right brake shoes if either isat or less than the minimum thickness.
REAR BRAKE (DRUM) REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.3. After installation.
(1) Depress the brake pedal a few times, then verify that the brakes do not drag.(2) Inspect the parking brake lever stroke.
APPLY
N·m kgf·cm, in·lbf
12.8—21.5 130—220, 113—190
9.8—12.7 100—130, 87—112
TO SHADED EREA
SST*
*49 0259 770B
1 Brake drum
2 Hold spring, washer
3 Hold pin
4 Lower return spring
5 Upper return spring
6 Pawl lever spring
7 Pawl lever
8 Adjust strut
9 Brake shoe
10 Parking brake cable
11 Operating lever
12 Brake pipe
13 Wheel cylinder
14 Gasket
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(Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION, Parking Brake Lever Stroke Inspection.)
PAGES. FROM. MANUAL
CONVENTIONAL BRAKE SYSTEM, PARKING BRAKE SYSTEM
P–16
BRAKE DRUM INSPECTION1. Measure the inner diameter of the drum.
Maximum diameter42: 271.5 mm 10.68 in44: 296.5 mm 11.67 in
2. Apply chalk to the inside of the brake drum.3. Inspect for scratches and uneven or abnormal
wear inside the drum as shown in the figure.
4. Repair or replace the drum as necessary. Repair ifthe problem is minor.
5. When repairing or replacing the drum, check thecontact with the shoes.
6. Wipe the chalk off after inspection.
WHEEL CYLINDER DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
N·m kgf·cm , in·lbf * 49 0259 770B
R
R
5.9—8.8 60—90 , 53—78
SST * R
R
1 Dust boot
2 Piston
3 Piston cap
4 Spring
5 Bleeder cap, screw
6 Cylinder body
PARKING BRAKE SYSTEMPARKING BRAKE (STICK TYPE) INSPECTIONParking Brake Lever Stroke Inspection
1. Pull the parking brake lever a few times.2. Verify that the stroke is within the specification
when the parking brake lever is pulled with a forceof 98 N 10 kgf, 22 ibf .
Stroke1—7 notches
3. If not as specified, adjust the parking brake leverstroke.
PARKING BRAKE (STICK TYPE) ADJUSTMENTParking Brake Lever Stroke Adjustment
1. Before adjustment, depress the brake pedalseveral times while the vehicle is moving inreverse.
2. Loosen the locknut A and turn the adjustment nutB so that the stroke is within the above range.
3. After adjustment, tighten the locknut A.
Tightening torque6.9—9.8 N·m 70—100 kgf·cm, 43—86 in·lbf
A
B
4. After adjustment, inspect the following points.(1) Turn the ignition (engine) switch on, pull the
parking brake lever one notch, and verify thatthe brake warning light illuminates.
(2) Verify that the rear brakes do not drag whenthe wheels are turned by hand.
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PARKING BRAKE SYSTEM
P–17
PARKING BRAKE LEVER (STICK TYPE) REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.3. After installation, inspect the parking brake lever stroke.
(Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION.)
N·m kgf·cm, in·lbf
6.9—9.870—100, 43—86
12.8—18.6 130—190, 113—164
1 Clip
2 Joint pin
3 Cable connector
4 Parking brake switch
5 Clip
6 Pin
7 Clip and joint pin
8 Lever
9 Pin and clip
10 Spring
11 Rachet pawl
12 Stopper
13 Fork joint
14 Spring
15 Guide
16 Rod
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PARKING BRAKE SYSTEM
P–18
PARKING BRAKE CABLE (STICK TYPE) REMOVAL/INSTALLATION1. Remove the under guard. (Refer to section F1–F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)2. Remove in the order indicated in the table.3. Install in the reverse order of removal.4. After installation, inspect the parking brake lever stroke.
(Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION.)
4x2
16—22 1.6—2.3, 12—16
16—22 1.6—2.3, 12—16
4x4
N·m kgf·m, ft·lbf
6.9—9.8 N·m 70—100 kgf·cm,43—86 in·lbf
6.9—9.8 N·m 70—100 kgf·cm,43—86 in·lbf
16—22 1.6—2.3,12—16
16—22 1.6—2.3, 12—16
16—22 1.6—2.3, 12—16
16—22 1.6—2.3, 12—16
16—22 1.6—2.3, 12—16
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PARKING BRAKE SYSTEM LHD model with F2 and G6 engine
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CONTINUED
1 Nut
2 Bolt
3 Spring
4 Front brake cable
5 Bolt (44)
6 Bracket (44)
7 Grommet
8 Bolt
9 Spring (44)
10 Clip
11 Rear cable (left)
12 Rear cable (right)
P-19
R–1
SUSPENSIONGENERAL PROCEDURES R–1. . . . . . . . . . . . . . . . . . . WHEEL ALIGNMENT R–1. . . . . . . . . . . . . . . . . . . . . . .
WHEEL ALIGNMENT PREINSPECTION R–1. . . . . FRONT WHEEL ALIGNMENT R– 2/3. . . . . . . . . . . . . .
FRONT SUSPENSION R–3. . . . . . . . . . . . . . . . . . . . . . VEHICLE HEIGHT ADJUSTMENT R–3. . . . . . . . . . FRONT SHOCK ABSORBER REMOVAL/
INSTALLATION R–5. . . . . . . . . . . . . . . . . . . . . . . . . . FRONT SHOCK ABSORBER INSPECTION R–5. . TORSION BAR SPRING AND LOWER ARM
REMOVAL/INSTALLATION (42) R– 6/8. . . . . . . . .
TORSION BAR SPRING AND LOWER ARMREMOVAL/INSTALLATION (44) R– 9/11. . . . . . . . .
LOWER ARM INSPECTION R–11. . . . . . . . . . . . . . . . UPPER ARM REMOVAL/INSTALLATION R–12. . . . UPPER ARM INSPECTION R–13. . . . . . . . . . . . . . . . STABILIZER AND TENSION ROD
REMOVAL/INSTALLATION (42) R–13/14. . . . . . . . . STABILIZER REMOVAL/INSTALLATION (44) R–14.
REAR SUSPENSION R–15. . . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER AND LEAF
SPRING REMOVAL/INSTALLATION R–15. . . . . . .
GENERAL PROCEDURESWheels and tires removal/installation The removal and installation procedures for the
wheels and tires are not mentioned in this section.If a wheel is removed, retighten it to the specifiedtightening torque, referring to section TD.
Suspension arms removal/installation Tighten any part of the suspension that uses
rubber bushings only after the vehicle has beenlowered and unloaded*.* Unloaded condition: Fuel tank is full. Engine
coolant and engine oil are at specified levels.Spare tire, jack, and tools are in designatedposition.
WHEEL ALIGNMENTWHEEL ALIGNMENT PREINSPECTION
1. Inspect the inflation of each tire, and set to therecommended pressure, as necessary.
2. Inspect the front wheel bearing play. Adjust thebearing preload or replace bearing(s) asnecessary. (Refer to section M, FRONT AXLE (42), WHEELHUB, STEERING KNUCKLE INSPECTION orFRONT AXLE (44), WHEEL HUB, STEERINGKNUCKLE INSPECTION.)
3. Inspect the wheel and tire runout at all wheels. (Refer to section TD, SUSPENSION, Wheels and Tires.)
4. Inspect the ball joints and steering linkage forexcessive looseness.
5. Place the vehicle on level ground with no luggageand passenger load.
6. The difference in height between the left and rightsides from the center of the wheel to the fenderbrim must not exceed 10 mm 0.39 in. If notwithin the specification, adjust the vehicle height.(Refer to FRONT SUSPENSION, VEHICLEHEIGHT ADJUSTMENT.)
7. Shake the vehicle to settle the suspension.
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WHEEL ALIGNMENT
R–2
FRONT WHEEL ALIGNMENTSpecifications
ItemSpecification
Item42 44
Total toe in(mm in) 33 0.120.12
Total toe-in(degree) 0° 16’ 16’ 0° 14’ 14’
Front heel alignmentMaximum steering Inner 35° 00’ +2°
–3° 33° 30’ +2°–3°
Front wheel alignment(*1Unloaded
gangle Outer 33° 00’ +2°
–3° 30° 00’ +2°–3°( Unloaded
condition) Camber angle*2 0° 56’ 30’ 1° 06’ 30’
Caster angle*3 1° 37’ 45’ 2° 02’ 45’
Steering axis inclination(reference value)
8° 04’ 10° 15’
*1 Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designatedposition.
*2 Difference between left and right must not exceed 30’.*3 Difference between left and right must not exceed 45’.
Maximum Steering Angle Adjustment1. Loosen the adjusting bolt locknut.2. Turn the adjusting bolt to provide the correct
turning angle.3. After adjustment, tighten the locknut to the
specified torque.
Tightening torque40—58 N·m 4.0—6.0 kgf·m, 29—43 ft·lbf42
ADJUSTING BOLT44
ADJUSTING BOLT
Total Toe-in Adjustment1. Loosen the tie-rod end locknuts.2. Turn the tie rods by the same amount in the
opposite direction.
Note One turn of the tie rod (both sides) changes the
toe-in by about 30 mm 1.18 in. The left and right tie rods are both right
threaded. To increase the toe-in, turn the righttie rod toward the front of the vehicle and theleft tie rod equally toward the rear.
3. Tighten the tie-rod end locknuts.
Tightening torque69—78 N·m 7.0—8.0 kgf·m, 51—57 ft·lbf
TIE ROD
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WHEEL ALIGNMENT, FRONT SUSPENSION
R–3
Caster and Camber Adjustment1. Loosen the upper arm shaft bolt and insert or
remove adjustment shims to provide the correctangle.
No.1—5
FRONT
No.6—11
Adjustment shimNo. Thickness (mm in) No. Thickness (mm in)
1 1.0 0.039 7 1.0 0.039
2 1.6 0.063 8 1.6 0.063
3 2.0 0.079 9 2.0 0.079
4 3.2 0.126 10 3.2 0.126
5 4.0 0.157 11 4.0 0.157
6 0.6 0.024
Note Shims No.1—5 are used on either side. Do not
use more than two. Shims No.6—11 are used at the front and rear
of either sides. Do not use more than one. Camber: A change of shim thickness (at front
and rear) of 1 mm 0.039 in results in achange of about 15’.
Caster: A change of shim thickness (at front orrear only) of 1 mm 0.039 in results in achange of about 30’.
2. After adjustment, tighten the upper arm shaft boltto the specified torque.
Tightening torque94—116 N·m 9.5—11.9 kgf·m, 69—86 ft·lbf
FRONT SUSPENSIONVEHICLE HEIGHT ADJUSTMENT
1. Place the vehicle on level ground.2. Inspect the front and rear tire pressure and adjust it
as necessary.3. Measure the distance from the center of each front
wheel to the fender brim.
Left/right difference10 mm 0.39 in max.
Standard vehicle height (reference value) mm in42
Cab type Vehicle height
Regular Cab, Stretch Cab 427 16.8
Double Cab 422 16.6
44Cab type Tire size Vehicle height
Regular Cab, 205R16 519 20.4g ,Stretch Cab 235/75R15 515 20.3
Double Cab205R16 510 20.1
Double Cab235/75R15 506 19.9
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FRONT SUSPENSION
R–4
1. If the difference between left and right is not withinthe specification, adjust the vehicle height byturning the torsion bar spring anchor bolt.42
ANCHOR BOLT44
ANCHOR BOLT
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FRONT SUSPENSION
R–5
FRONT SHOCK ABSORBER REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
6—8 mm0.24—0.31 in
55—80 5.6—8.2, 41—59
1 Nut+ Installation Note
2 Retainer, bushing
3 Bolt
4 Washer and nut
5 Shock absorber
Nut Installation Note Tighten the nut so that the exposed thread of the
shock absorber piston is 6—8 mm 0.24—0.31 in .
FRONT SHOCK ABSORBER INSPECTION1. Remove the front shock absorber from the vehicle.2. Inspect for damage and oil leakage.3. Inspect the rubber bushing for deterioration and
wear.4. Compress and extend the shock absorber piston at
least three (3) times. Verify that the operationalforce does not change and that there is no unusualnoise.
5. Compress the shock absorber piston and releaseit. Verify that the piston extends fully at a normalspeed.
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FRONT SUSPENSION
R–6
TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2)1. Remove in the order indicated in the table.2. Install in the reverse order of removal.3. Inspect the vehicle height and adjust it as necessary.
N·m kgf·m, ft·lbf
SST
R
APPLY THREADLOCKING COMPOUND
APPLY THREADLOCKING COMPOUND
118—156 12.0—16.0, 87—115
118—156 12.0—16.0, 87—115
1 Cotter pin
2 Nut
3 Lower arm ball joint/Knuckle arm+ Removal Note
4 Bolt, washer, and nut (shock absorber)
5 Anchor bolt+ Removal Note+ Installation Note
6 Anchor swivel
7 Bolt and washer
8 Torsion bar component
9 Anchor arm
10 Torsion bar spring+ Removal Note+ Installation Note
11 Torque plate
12 Lower arm spindle, washer, and nut
13 Rubber bushing+ Removal Note+ Installation Note
14 Tension rod bolt
15 Stabilizer bolt, bushing, retainer, spacer, and nut+ Installation Note
16 Lower arm
17 Bound bumper, washer, and nut
18 Bolts and washer (ball joint)
19 Lower arm ball joint
20 Clip+ Installation Note
21 Lower arm ball joint boot
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FRONT SUSPENSION
R–7
Lower Arm Ball Joint/Knuckle Arm Removal Note Separate the ball joint from the knuckle arm using
the SST.
49 T028 3A0
KNUCKLE
Anchor Bolt Removal Note Mark the anchor bolt and swivel for reference
during installation.
MATCHING MARK
Torsion Bar Spring Removal Note Mark the torsion bar spring and anchor arm and
the torsion bar spring and torque plate forreference during installation.
MATCHING MARK MATCHING MARK
Rubber Bushing Removal Note Remove the rubber bushing from the body using
the SST.
49 UB39 615
Clip Installation Note1. Install the SST to the ball joint stud with the stud
stands straight up.2. Install the clip in the dust boot groove.
49 U034 208
Stabilizer Bolt, Bushing, Retainer, Spacer And NutInstallation Note Tighten the nuts so that 18—21 mm 0.71—0.82 in
of thread is exposed at the end of the bolt.
18—21 mm0.71—0.82 in
Rubber Bushing Installation Note Install a new bushing using the SST.
49 UB39 615
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FRONT SUSPENSION
R–8
Torsion Bar Spring Installation Note1. Before installation, check the identification mark on
the end of the torsion bar spring.
L: Left bar, R: Right bar
2. Align the marks made during removal, and connectthe torsion bar spring to the torque plate.
MATCHING MARK MATCHING MARK
Anchor Bolt Installation Note Install the anchor bolt, and tighten it until the marks
made during removal are aligned.
MATCHING MARK
Note If the anchor bolt was not marked during
removal, install it as follows:(1) Lower the front suspension until the upper
arm contacts the rebound stopper.(2) Install the anchor arm so that the angle A is
34° 4.5°.(3) Install the anchor bolt and tighten it 27.3
turns.
A
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FRONT SUSPENSION
R–9
TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 4)1. Remove the driveshaft snap ring.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.4. Inspect the vehicle height and adjust it as necessary.
SST
R
APPLY THREADLOCKING COMPOUND
R
118—156 12.0—16.0, 87—115 118—156 12.0—16.0, 87—115
1 Cotter pin
2 Nut
3 Lower arm ball joint/Knuckle arm+ FRONT SUSPENSION, TORSION BAR
SPRING AND LOWER ARMREMOVAL/INSTALLATION (42), Lower ArmBall Joint/Knuckle Arm Removal Note
4 Bolt, washer and nut (shock absorber)
5 Anchor bolt and washer+ Installation Note
6 Anchor swivel
7 Bolt and washer
8 Torsion bar spring component
9 Anchor arm+ Removal Note+ Installation Note
10 Torsion bar spring+ Removal Note+ Installation Note
11 Torque plate
12 Lower arm spindle (rear), washer and nut
13 Lower arm spindle (front), washer and nut
14 Stabilizer bolt, bushing, retainer, spacer and nut+ FRONT SUSPENSION, TORSION BAR
SPRING AND LOWER ARMREMOVAL/INSTALLATION (42), StabilizerBolt, Bushing, Retainer, Spacer, And NutInstallation Note
15 Lower arm
16 Bound bumper, washer, and nut
17 Bolt, washer and nut
18 Lower arm ball joint
19 Clip+ FRONT SUSPENSION, TORSION BAR
SPRING AND LOWER ARMREMOVAL/INSTALLATION (42), ClipInstallation Note
20 Lower arm ball joint boot
21 Lower arm bushing+ Removal Note+ Installation Note
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FRONT SUSPENSION
R–10
Anchor Arm Removal Note Mark the anchor arm and body for reference during
installation.
Torsion Bar Spring Removal Note Mark the torsion bar spring and anchor arm and
the torsion bar spring and torque plate forreference during installation.
Lower Arm Bushing Removal Note Remove the lower arm bushing using the SST.
49 U034 2A0
Lower Arm Bushing Installation Note1. Apply soapy water to the new bushing.2. Install the bushing using the SST.
49 U034 2A0
Torsion Bar Spring Installation Note1. Before installation, inspect the identification mark
on the end of the torsion bar spring.
L: Left bar, R: Right bar
2. Align the marks made during removal, and connectthe torsion bar spring to the torque plate.
Anchor Arm Installation Note Align the marks made during removal, and install
the anchor arm onto the torsion bar spring.
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FRONT SUSPENSION
R–11
Anchor Bolt Installation Note Install the anchor bolt, and tighten it until the marks
made during removal are aligned.
Note If the anchor bolt was not marked during
removal, install it at follows:(1) Lower the front suspension until the upper
arm contacts the rebound stopper.(2) Install the anchor arm so that the angle A is
60°4.5°.(3) Install the anchor bolt and tighten it 26.9
turns.
A
LOWER ARM INSPECTION1. Remove the lower arm from the vehicle.2. Inspect for damage, cracks, and bending.3. Check the ball joint rotation torque.
(1) Rotate the ball joint five times.(2) Connect the SST to the ball stud, and measure
the rotation torque using a pull scale.(3) Replace it if not within the specification.
Pull scale reading20—34 N 2.0—3.5 kgf, 4.4—7.7 lbf
49 0180 510B
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FRONT SUSPENSION
R–12
UPPER ARM REMOVAL/INSTALLATION1. Remove in the order indicated in the table.2. Install in the reverse order of removal.3. Inspect the wheel alignment and adjust it as necessary.
R
SST
1 Clip
2 Cotter pin and nut
3 Upper arm ball joint/Knuckle arm+ Removal Note
4 Bolt and washer
5 Adjustment shim+ Removal Note
6 Upper arm component
7 Bolt and washer
8 Upper arm ball joint
9 Clip+ Installation Note
10 Upper arm ball joint boot
Upper Arm Ball Joint/Knuckle Arm Removal Note Separate the upper arm ball joint from the knuckle
arm using the SST.
49 T028 3A0
KNUCKLE
Adjustment Shim Removal Note Note the number, amount and position of the shims
so that they are reinstalled in the correct positions.
Clip Installation Note1. Install the SST to the ball joint stud with the stud
stands straight up.2. Install the clip in the dust boot groove.
49 U034 209
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FRONT SUSPENSION
R–13
UPPER ARM INSPECTION1. Remove the upper arm from the vehicle.2. Inspect for damage, cracks, and bending.3. Check the ball joint rotation torque.
(1) Rotate the ball joint five times.(2) Connect the SST to the ball stud, and measure
the rotation torque using a pull scale.(3) Replace it if not within the specification.
Pull scale reading5.0—24 N 0.5—2.5 kgf, 1.2—5.5 lbf
49 0180 510B
STABILIZER AND TENSION ROD REMOVAL/INSTALLATION (4 2)1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
22—26 2.2—2.7, 16—19
94—127 9.5—13.0, 69—94
94—116 9.5—11.9, 69—86
APPLY THREADLOCKING COMPOUND
1 Nut+ FRONT SUSPENSION, TORSION BAR
SPRING AND LOWER ARMREMOVAL/INSTALLATION (42), StabilizerBolt, Bushing, Retainer, Spacer, And NutInstallation Note
2 Retainer
3 Bolt
4 Bushing, retainer and spacer
5 Bolt
6 Stabilizer bracket
7 Bushing
8 Stabilizer bar
9 Tension rod nut+ Installation Note
10 Bushing and retainer
11 Bolt
12 Tension rod
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FRONT SUSPENSION
R–14
Tension Rod Nut Installation Note Tighten the tension rod nuts so that length L is 98.5
mm 3.88 in .
L
STABILIZER REMOVAL/INSTALLATION (4 4)1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
22—26 2.2—2.7, 16—19
1 Nut+ FRONT SUSPENSION, STABILIZER AND
TENSION ROD REMOVAL/INSTALLATION(42), Nut Installation Note
2 Retainer and bushing
3 Bolt
4 Retainer and bushing
5 Retainer, bushing, and spacer
6 Bolt
7 Stabilizer bracket
8 Bushing
9 Stabilizer bar
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REAR SUSPENSION
R–15
REAR SUSPENSIONREAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION
1. Support the frame with safety stands and place a jack under the differential casing. Remove in the orderindicated in the table. While supporting the differential casing with a jack, raise or lower the jack as necessary.
2. Install in the reverse order of removal.
R
N·m kgf·m, ft·lbf
59—78 6.0—8.0, 44—57
64—78 6.5—8.0, 48—57
78—98 8.0—10.0, 58—72
R
R
20—26 2.0—2.7, 15—19.5 54—73 5.5—7.5, 40—54
APPLY THREAD LOCKINGCOMPOUND
42
1 Nut, washer, retainer, and bushing
2 Nut, washer, retainer, and bushing
3 Shock absorber
4 Nut and washer
5 Nut and washer
6 U-bolt
7 Spring clamp
8 Stopper rubber
9 Bolt and washer
10 Spring pin
11 Nut and washer
12 Shackle pin
13 Shackle plate
14 Leaf spring component
15 Leaf spring bushing+ Removal Note+ Installation Note
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REAR SUSPENSION
R–16
N·m kgf·m, ft·lbf
44
99.1—112 10.1—11.5, 73.1—83.1
APPLY THREADLOCKING COMPOUND
64—78 6.5—8.0, 48—57
78—98 8.0—10.0, 58—72
R
R
20—26 2.0—2.7, 15—19.5
59—78 6.0—8.0, 44—57
1 Bolt and nut
2 Washer, retainer, and bushing
3 Nut, washer, retainer, and bushing
4 Shock absorber
5 Nut and washer
6 Nut and washer
7 U-bolt
8 Set plate
9 Spring clamp
10 Stopper rubber
11 Bolt and washer
12 Spring pin
13 Nut and washer
14 Shackle pin
15 Shackle plate
16 Leaf spring component
17 Leaf spring bushing+ Removal Note+ Installation Note
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REAR SUSPENSION
R–17
Leaf Spring Bushing Removal Note Secure the leaf spring in a vise and remove the
bushing using a chisel.
Leaf Spring Bushing Installation Note Press in the bushing using a suitable pipe.
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S–1
BODYBONNET S– 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BONNET REMOVAL/INSTALLATION S– 2/3. . . . . . . . BONNET ADJUSTMENT S– 3. . . . . . . . . . . . . . . . . .
FRONT FENDER PANEL S– 4. . . . . . . . . . . . . . . . . . . . FRONT FENDER PANEL
REMOVAL/INSTALLATION S– 4. . . . . . . . . . . . . . . DOOR S– 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DOOR REMOVAL/INSTALLATION S– 5. . . FRONT DOOR DISASSEMBLY/ASSEMBLY S– 6. . FRONT DOOR ADJUSTMENT S– 7. . . . . . . . . . . . . REAR DOOR REMOVAL/INSTALLATION S– 7. . . . REAR DOOR DISASSEMBLY/ASSEMBLY S– 8/9. . . REAR DOOR ADJUSTMENT S– 9. . . . . . . . . . . . . . . DOOR LOCK STRIKER
REMOVAL/INSTALLATION S– 9. . . . . . . . . . . . . . . REGULATOR HANDLE REMOVAL S– 9. . . . . . . . . . REGULATOR HANDLE INSTALLATION S– 9. . . . .
POWER WINDOW SYSTEM S–10. . . . . . . . . . . . . . . . . POWER WINDOW MAIN SWITCH
REMOVAL/INSTALLATION S–10. . . . . . . . . . . . . . . POWER WINDOW MAIN SWITCH
INSPECTION S–10/12. . . . . . . . . . . . . . . . . . . . . . . . . . . POWER WINDOW SUBSWITCH
REMOVAL/INSTALLATION S–12. . . . . . . . . . . . . . . POWER WINDOW SUBSWITCH
INSPECTION S–12/13. . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT POWER WINDOW REGULATOR
REMOVAL/INSTALLATION S–13. . . . . . . . . . . . . . . FRONT POWER WINDOW REGULATOR
DISASSEMBLY/ASSEMBLY S–13. . . . . . . . . . . . . . REAR POWER WINDOW REGULATOR
REMOVAL/INSTALLATION S–13/14. . . . . . . . . . . . . . . REAR POWER WINDOW REGULATOR
DISASSEMBLY/ASSEMBLY S–14. . . . . . . . . . . . . . POWER WINDOW MOTOR INSPECTION S–14. . .
POWER DOOR LOCK SYSTEM S–15. . . . . . . . . . . . . . DOOR KEY CYLINDER SWITCH
REMOVAL/INSTALLATION S–15. . . . . . . . . . . . . . . DOOR KEY CYLINDER SWITCH
INSPECTION S–15. . . . . . . . . . . . . . . . . . . . . . . . . . . DOOR LOCK-LINK SWITCH
REMOVAL/INSTALLATION S–15. . . . . . . . . . . . . . . . DOOR LOCK-LINK SWITCH INSPECTION S–15. . . DOOR LOCK ACTUATOR
REMOVAL/INSTALLATION S–15. . . . . . . . . . . . . . . . DOOR LOCK ACTUATOR INSPECTION S–16. . . . . DOOR LOCK TIMER UNIT
REMOVAL/INSTALLATION S–16. . . . . . . . . . . . . . . . DOOR LOCK TIMER UNIT INSPECTION S–17. . . .
FUEL-FILLER LID AND OPENER S–19. . . . . . . . . . . . FUEL-FILLER LID
REMOVAL/INSTALLATION S–19. . . . . . . . . . . . . . . FUEL-FILLER LID ADJUSTMENT S–19. . . . . . . . . .
BUMPER S–19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BUMPER
REMOVAL/INSTALLATION S–19. . . . . . . . . . . . . . . FRONT BUMPER
DISASSEMBLY/ASSEMBLY S–19. . . . . . . . . . . . . . . REAR BUMPER
REMOVAL/INSTALLATION S–20. . . . . . . . . . . . . . . REAR BUMPER DISASSEMBLY/ASSEMBLY S–20/21. .
EXTERIOR ATTACHMENT S–21. . . . . . . . . . . . . . . . . . . RADIATOR GRILLE
REMOVAL/INSTALLATION S–21. . . . . . . . . . . . . . . COWL GRILLE
REMOVAL/INSTALLATION S–21. . . . . . . . . . . . . . . WINDSHIELD GARNISH
REMOVAL/INSTALLATION S–21/22. . . . . . . . . . . . . . . SIDE PROTECTOR REMOVAL S–22. . . . . . . . . . . . . SIDE PROTECTOR INSTALLATION S–22/23. . . . . . . . OVER FENDER
REMOVAL/INSTALLATION S–23. . . . . . . . . . . . . . . TAILGATE
DISASSEMBLY/ASSEMBLY S–23. . . . . . . . . . . . . . TAILGATE ADJUSTMENT S–23. . . . . . . . . . . . . . . . . ROPE HOOK REMOVAL/INSTALLATION S–24. . . .
MOLDING S–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD UPPER MOLDING
REMOVAL S–24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD UPPER MOLDING
INSTALLATION S–24. . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD SIDE MOLDING REMOVAL S–24. . . WINDSHIELD SIDE MOLDING
INSTALLATION S–24. . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BELTLINE MOLDING
REMOVAL/INSTALLATION S–24. . . . . . . . . . . . . . . REAR BELTLINE MOLDING
REMOVAL/INSTALLATION S–25. . . . . . . . . . . . . . . ROOF MOLDING
REMOVAL/INSTALLATION S–25. . . . . . . . . . . . . . . . OUTSIDE MIRROR S–25. . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL OUTSIDE MIRRORREMOVAL/INSTALLATION S–25. . . . . . . . . . . . . . .
POWER OUTSIDE MIRRORREMOVAL/INSTALLATION S–25. . . . . . . . . . . . . . .
POWER OUTSIDE MIRROR INSPECTION S–25/26. . POWER OUTSIDE MIRROR SWITCH
REMOVAL/INSTALLATION S–26. . . . . . . . . . . . . . . POWER OUTSIDE MIRROR SWITCH
INSPECTION S–26. . . . . . . . . . . . . . . . . . . . . . . . . . . REARVIEW MIRROR S–27. . . . . . . . . . . . . . . . . . . . . . . .
REARVIEW MIRRORREMOVAL/INSTALLATION S–27. . . . . . . . . . . . . . .
REAR WINDOW DEFROSTER S–27. . . . . . . . . . . . . . . REAR WINDOW DEFROSTER SWITCH
REMOVAL/INSTALLATION S–27. . . . . . . . . . . . . . . REAR WINDOW DEFROSTER SWITCH
INSPECTION S–27. . . . . . . . . . . . . . . . . . . . . . . . . . . FILAMENT INSPECTION S–27/28. . . . . . . . . . . . . . . . . . FILAMENT REPAIR S–28. . . . . . . . . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER RELAY
REMOVAL/INSTALLATION S–28. . . . . . . . . . . . . . . REAR WINDOW DEFROSTER RELAY
INSPECTION S–28. . . . . . . . . . . . . . . . . . . . . . . . . . . WINDOW GLASS S–29. . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD REMOVAL S–29/30. . . . . . . . . . . . . . . . . . WINDSHIELD INSTALLATION S–30/31. . . . . . . . . . . . . . QUARTER WINDOW GLASS
REMOVAL/INSTALLATION S–32. . . . . . . . . . . . . . . REAR WINDOW GLASS REMOVAL S–33. . . . . . . . REAR WINDOW GLASS INSTALLATION S–33. . . .
DASHBOARD AND CONSOLE S–34. . . . . . . . . . . . . . .
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PAGE 1 OF 2
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
BONNET
S–2
DASHBOARD REMOVAL/INSTALLATION S–34. . . DASHBOARD DISASSEMBLY/ASSEMBLY S–35. . DASHBOARD MEMBER
REMOVAL/INSTALLATION S–36. . . . . . . . . . . . . . . COLUMN COVER
REMOVAL/INSTALLATION S–36. . . . . . . . . . . . . . . FRONT CONSOLE
REMOVAL/INSTALLATION S–36. . . . . . . . . . . . . . . FRONT CONSOLE
DISASSEMBLY/ASSEMBLY S–36. . . . . . . . . . . . . . REAR CONSOLE
REMOVAL/INSTALLATION S–36. . . . . . . . . . . . . . . REAR CONSOLE
DISASSEMBLY/ASSEMBLY S–37. . . . . . . . . . . . . . GLOVE COMPARTMENT
REMOVAL/INSTALLATION S–37. . . . . . . . . . . . . . . METER HOOD
REMOVAL/INSTALLATION S–37. . . . . . . . . . . . . . . TRIM S–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-PILLAR TRIMREMOVAL/INSTALLATION S–38. . . . . . . . . . . . . . .
B-PILLAR TRIMREMOVAL/INSTALLATION S–38. . . . . . . . . . . . . . .
B-PILLAR LOWER TRIMREMOVAL/INSTALLATION S–38. . . . . . . . . . . . . . .
FRONT SIDE TRIMREMOVAL/INSTALLATION S–39. . . . . . . . . . . . . . .
FRONT SCUFF PLATEREMOVAL/INSTALLATION S–39. . . . . . . . . . . . . . .
REAR SCUFF PLATE REMOVAL/INSTALLATION S–39. . . . . . . . . . . . . . .
C-PILLAR TRIM REMOVAL/INSTALLATION S–39. . QUARTER UPPER TRIM
REMOVAL/INSTALLATION S–39/40. . . . . . . . . . . . . . . QUARTER LOWER TRIM
REMOVAL/INSTALLATION S–40. . . . . . . . . . . . . . . BACK UPPER TRIM
REMOVAL/INSTALLATION S–40. . . . . . . . . . . . . . . BACK LOWER TRIM
REMOVAL/INSTALLATION S–40. . . . . . . . . . . . . . . FRONT DOOR TRIM
REMOVAL/INSTALLATION S–41. . . . . . . . . . . . . . . REAR DOOR TRIM
REMOVAL/INSTALLATION S–41. . . . . . . . . . . . . . . HEADLINER S–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLINER REMOVAL/INSTALLATION S–42. . . . . FLOOR COVERING S–42. . . . . . . . . . . . . . . . . . . . . . . . .
FLOOR COVERINGREMOVAL/INSTALLATION S–42/43. . . . . . . . . . . . . . .
SEAT BELT S–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAT BELT REMOVAL/INSTALLATION S–44/45. . . . . . SEAT BELT INSPECTION S–45/46. . . . . . . . . . . . . . . . .
SEAT S–48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT SEAT REMOVAL/INSTALLATION S–48. . . . FRONT SEAT DISASSEMBLY/ASSEMBLY S–49/50. . . CABLE ADJUSTMENT S–51. . . . . . . . . . . . . . . . . . . . REAR SEAT REMOVAL/INSTALLATION S–51/52. . . . . REAR SEAT DISASSEMBLY/ASSEMBLY S–52/53. . . . SEAT WARMER SWITCH REMOVAL S–54. . . . . . . SEAT WARMER SWITCH INSTALLATION S–54. . . SEAT WARMER SWITCH INSPECTION S–54. . . . . SEAT WARMER UNIT INSPECTION S–54. . . . . . . .
BONNET
Warning Removing the bonnet without supporting it
can be dangerous. The bonnet may fall andinjure you. Always perform theseprocedures together with at least anotherperson.
BONNET REMOVAL/INSTALLATION1. Pull out the windshield washer pipe.2. To remove the bonnet hinge, remove the front
fender panel. (Refer to FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.)
3. To remove the bonnet lock, remove the radiatorgrille.
4. Remove in the order indicated in the table.5. Install in the reverse order of removal.6. Adjust the bonnet.
(Refer to BONNET ADJUSTMENT.)
3.0—3.9 30—40,27—34
7.9—10.780—110,69.5—95.4
N·m kgf·cm, in·lbf
AA
Â
ÄÅ
Æ
À
Ã
Á
1 Shroud seal weatherstrip
2 Bonnet
3 Bonnet hinge
4 Bonnet stay
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CONTINUED
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PAGE 2 OF 2
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL
TO. MODEL .INDEXPAGES. FROM. MANUALRANG.DRFT.REPAIR MANUAL
PAGES. FROM. MANUAL
B-PILLAR UPPER TRIM REMOVAL/INSTALLATION S–38. . . . . . . . . . . . . . .
BODY
BUCKLE REMOVAL/INSTALLATION . . . . . . . . . S–46BUCKLE SWITCH INSPECTION . . . . . . . . . . . . S–47
BONNET
S–3
5 Bonnet lock
6 Bonnet release lever
7 Bonnet release cable
BONNET ADJUSTMENT1. Measure the gap and height between the bonnet
and the body.
Clearancea: 2.7—5.3 mm 0.11—0.20 inb: –1.8—0.8 mm –0.07—0.03 in (sec. A—A)c: –2.3—0.8 mm –0.09—0.03 in (sec. B—B)d: –2.3—0.3 mm –0.09—0.01 in (sec. C—C)e: 6.0—10.0 mm 0.24—0.39 inf: 7.0—13.0 mm 0.28—0.51 in
50 2.0
30 1.2
DD
E
E
C C
B B
A A
a
b , c, de
f
SEC. A—ASEC. B—BSEC. C—C
SEC. D—D SEC. E—E
mm in
2. If not as specified, adjust the gap and height.(Refer to Gap Adjustment.) (Refer to Height Adjustment.)
Gap Adjustment1. Loosen the bonnet installation bolts and reposition
the bonnet.
BOLT
2. Tighten the bonnet installation bolts.
Height Adjustment1. Loosen the bonnet lock installation bolts and move
the bonnet lock to reposition the bonnet.
BOLT
2. Tighten the bonnet lock installation bolts.
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CONTINUED
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
FRONT FENDER PANEL
S–4
FRONT FENDER PANELFRONT FENDER PANEL REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove the front side turn light.3. Remove the front bumper.4. Remove the front turn light.5. Remove the front flap.6. Remove in the order indicated in the table.7. Install in the reverse order of removal.
B
A
B
A
6.87—9.80 N·m70—100 kgf·cm,60.8—86.7 in·lbf
1 Mud guard
2 Front fender panel
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CONTINUED
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
DOOR Front Door Harness Removal Note 1. Disconnect the connectors indicated in the table,
if equipped. Connector name Symbol
Driver's side Passenger's side A Door lock-link switch Door lock actuator
B Power window main switch
Power window subswitch
C Power outside mirror ←
D Front power window regulator ←
E Speaker ←
DOOR FRONT DOOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the door screen.
(Refer to FRONT DOOR DISASSEMBLY/ASSEMBLY.)
3. To remove the front door hinge, remove the front fender panel. (Refer to FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.)
4. To remove the checker, remove the speaker. (Refer to section T, AUDIO, SPEAKER REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Adjust the front door.
(Refer to FRONT DOOR ADJUSTMENT.)
1
Front door harness Removal Note
2 Checker pin 3 Front door hinge 4 Front door 5 Checker
2. Disengage the clips.
3. Remove the rubber boot and pull out the door
harness.
S-5
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CONTINUED
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
DOOR
S–6
FRONT DOOR DISASSEMBLY/ASSEMBLY1. Raise the rear edge of the front door glass 80 mm 3.1 in from the fully lowered position.2. Disconnect the negative battery cable.3. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.)4. To remove the inner handle, peel off the door screen partially.5. Disassemble in the order indicated in the table.6. Assemble in the reverse order of disassembly.
N·m kgf·cm, in·lbf
WITHOUT POWER WINDOW SYSTEM AND POWER DOOR LOCK SYSTEM
6.87–9.80 70–100, 60.8–86.7
6.87–9.80 70–100, 60.8–86.7
2.0–2.9 20–30, 18–26
4.3–6.143–63,38–54
WITH POWER WINDOW SYSTEM ANDPOWER DOOR LOCK SYSTEM
8.9–12.790–130, 79–112
6.87–9.8070–100, 60.8–86.7
4.3–6.143–63,38–54
AB
B
DE
H
C
C
D
HE
AJ
IG
F
F
G
J
I
1 Inner handle
2 Door screen
3 Front door glass
4 Glass run channel
5 Front glass guide
6 Rear glass guide
7 Front manual window regulator
8 Front power window regulator
9 Outer handle
10 Retainer
11 Door key cylinder
12 Front door lock (manual)
13 Front door lock (power)
14 Door lock knob
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CONTINUED
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
DOOR
S–7
FRONT DOOR ADJUSTMENT1. Measure the clearance between the door and the
body.
Clearancea: 4.0—6.0 mm 0.16—0.23 inb: –1.5—1.0 mm –0.059—0.039 inc: –2.0—0.5 mm –0.078—0.019 ind: 4.5—8.5 mm 0.18—0.33 ine: 1.2 mm 0.047 inf: 3.5—6.5 mm 0.14—0.25 ing: 2.7 mm 0.11 inh: 5.5 mm 0.22 in
DD
EC
C
AA
BB
F
d
e
b
a
c
(+) (+)
(–)SEC. A—A SEC. B—B SEC. C—C
b
(+) f
g(–) h
SEC. D—D SEC. E—E SEC. F—F
f
a
(–)
E
F
2. If not as specified, loosen the door hingeinstallation bolts or the door lock striker installationscrews, and move them to reposition the door.(Refer to FRONT DOOR REMOVAL/INSTALLATION.)
(Refer to DOOR LOCK STRIKER REMOVAL/INSTALLATION.)
3. Tighten the bolts or the screws.
REAR DOOR REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the door screen.
(Refer to REAR DOOR DISASSEMBLY/ASSEMBLY.)3. To remove the checker, remove the ashtray
bracket. (Refer to REAR DOOR DISASSEMBY/ASSEMBLY.)
4. Remove in the order indicated in the table.5. Install in the reverse order of removal.6. Adjust the rear door.
(Refer to REAR DOOR ADJUSTMENT.)
N·m kgf·m, ft·lbf
22—302.2—3.1, 16—22
8.9—12.7 N·m 90—130 kgf·cm,79—112 in·lbf
1 Connector
2 Checker pin
3 Rear door hinge
4 Rear door
5 Checker
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CONTINUED
PAGES. FROM. MANUAL
DOOR
S–8
REAR DOOR DISASSEMBLY/ASSEMBLY1. Close the rear door glass completely.2. Disconnect the negative battery cable.3. Remove the rear door trim. (Refer to TRIM, REAR DOOR TRIM REMOVAL/INSTALLATION.)4. Disassemble in the order indicated in the table.5. Assemble in the reverse order of disassembly.
WITH POWER WINDOW SYSTEM
6.87—9.80 70—100, 60.8—86.7
E
E
WITHOUT POWER WINDOW SYSTEM
B
D
D
B
C
A
A
C
4.3—6.1 43—63, 38—54
6.87—9.8070—100,60.8—86.7
6.87—9.8070—100, 60.8—86.7
N·m kgf·cm, in·lbf
2.5—3.525—36, 22—31
1 Inner handle
2 Door screen
3 Ashtray bracket
4 Glass hole lid
5 Rear manual window regulator
6 Rear power window regulator
7 Rear door glass+ Removal Note
8 Glass run channel
9 Glass guide
10 Door lock knob
11 Rear door lock
12 Outer handle
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CONTINUED
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
DOOR
S–9
Rear Door Glass Removal Note Draw out the rear door glass through the glass
hole.
REAR DOOR GLASS
REAR DOOR
REAR DOOR ADJUSTMENT1. Measure the clearance between the door and the
body.
Clearancea: 3.5—6.5 mm 0.14—0.25 inb: –1.5—1.0 mm –0.059—0.039 inc: 5.5 mm 0.22 in
D D
A A
E E
B B
a(+)
(–)
(+)
(–)
b b
a
c
a a
b b
(+)
(–)
(+)
(–)
SEC. A–A SEC. B–B SEC. C–C
SEC. D–D SEC. E–E
C
C
2. If not as specified, loosen the door hingeinstallation bolts or the door lock striker installationscrews, and move them to reposition the door.(Refer to REAR DOOR
LOCK STRIKER REMOVAL/INSTALLATION.)
3. Tighten the bolts or screws.
DOOR LOCK STRIKER REMOVAL/INSTALLATION1. Remove the screws.2. Remove the door lock striker.
DOOR LOCKSTRIKER
SCREW 18–261.8–2.7,14–19
N·m kgf·m, ft·lbf
3. Install in the reverse order of removal.
REGULATOR HANDLE REMOVAL1. Remove the regulator handle clip using a rag as
shown.
RAG CLIP
2. Remove the regulator handle.
REGULATOR HANDLE INSTALLATION1. Install the clip in the regulator handle.2. Set the door glass at the fully raised position and
push the regulator handle on as shown.
CLIP FRONT
BACK.TO.CHAPTER.INDEX
CONTINUED
REMOVAL/INSTALLATION.) (Refer to DOOR
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
POWER WINDOW SYSTEM
S–10
POWER WINDOW SYSTEMPOWER WINDOW MAIN SWITCHREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Disengage the clip using a tape-wrapped flathead
screwdriver.3. Pull the switch panel forward, and disengage the
hook.
BODY
CLIP
SWITCH PANEL
BODY
HOOK
4. Disconnect the power window main switchconnector.
5. Remove the screws to remove the power windowmain switch from the switch panel.
POWERWINDOWMAIN SWITCH
SWITCH PANEL
SCREW
6. Install in the reverse order of removal.
POWER WINDOW MAIN SWITCH INSPECTIONRegular Cab, Stretch Cab
1. Remove the switch panel. (Refer to POWERWINDOW MAIN SWITCHREMOVAL/INSTALLATION.)
2. Inspect for continuity between the power windowmain switch terminals using an ohmmeter.
3. When inspecting the driver’s side, connect thebattery positive voltage to terminal F and connectthe ground to terminal D.
4. When inspecting the passenger’s side, turn thepower-cut switch to ON.
Power window switchDriver’s side
: Continuity
Switch Terminalposition F D A (H) B (I)
Manual closeManual close
Off
Auto openManual open
( ): R.H.D.
Passenger’s side: Continuity
Switch Terminalposition F D H (A) I (B)
CloseClose
Off
OpenOpen
( ): R.H.D.
Power-cut switch: Continuity
Switch Terminalposition D A (H) B (I) H (A) I (B)
ON
OFF
( ): R.H.D.
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TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
POWER WINDOW SYSTEM
S–11
5. If not as specified, replace the power window mainswitch.
Double Cab1. Remove the switch panel.
(Refer to POWER WINDOW MAIN SWITCHREMOVAL/INSTALLATION.)
2. Inspect for continuity between the power windowmain switch terminals using an ohmmeter.
3. When inspecting the driver’s side, connect thebattery positive voltage to terminal A (L.H.D.) or F(R.H.D.) and connect the ground to terminal H.
4. When inspecting the passenger’s side and rear,turn the power-cut switch to ON.
Power window switchDriver’s side
: Continuity
Switch Terminalposition A (F) H L (D) J (B)
Manual closeManual close
Off
Auto openManual open
( ): R.H.D.
Passenger’s side: Continuity
Switch Terminalposition A (F) H D (L) B (J)
CloseClose
Off
OpenO en
( ): R.H.D.
Rear left: Continuity
Switch Terminalposition A H K I
CloseClose
Off
OpenO en
( ): R.H.D.
Rear right: Continuity
Switch Terminalposition A H E C
CloseClose
Off
OpenO en
( ): R.H.D.
Power-cut switch: Continuity
TerminalSwitch
position HL(D)
J(B)
D(L)
B(J)
E C K I
ON
OFF( ): R.H.D.
L.H.D.
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CONTINUED
MANUALOPEN
AUTOCIRCUIT
PASSENGER’S SIDE
DRIVER’S SIDE
CLOSE
POWER-CUT SWITCH
AUTOOPEN
A (H) B (I)
H (A) I (B)
F
D
MANUALCLOSE
CLOSE OPEN
H
I
A
BF D
∗ ∗
OPEN
( ) : R.H.D.
RIGHT
E CK ID B
J
H
A
PAS-SENGER’S
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
POWER WINDOW SYSTEM
S–12
R.H.D.
5. If not as specified, replace the power window mainswitch.
POWER WINDOW SUBSWITCHREMOVAL/INSTALLATIONPassenger’s side
1. Disconnect the negative battery cable.2. Disengage the clip using a tape-wrapped flathead
screwdriver.3. Pull the power window subswitch forward, and
disengage the hook.
BODY
CLIP
POWERWINDOWSUBSWITCH
HOOK
BODY
4. Disconnect the power window subswitchconnector.
5. Install in the reverse order of removal.
Rear1. Disconnect the negative battery cable.2. Remove the hook by inserting a tape-wrapped,
flathead screwdriver between the switch and therear door trim.
HOOK
POWER WINDOWSUBSWITCH
3. Disconnect the connector, and remove the powerwindow subswitch.
4. Install in the reverse order of removal.
POWER WINDOW SUBSWITCH INSPECTION1. Remove the power window subswitch. (Refer to
POWER WINDOW SUBSWITCHREMOVAL/INSTALLATION.)
2. Inspect for continuity between the power windowsubswitch terminals using an ohmmeter.
Passenger’s side: Continuity
Switch positionTerminal
Switch positionA B D E F
OffOff
CloseClose
OpenO en
A
BF D
E
CLOSEOPEN
Rear: Continuity
Switch positionTerminal
Switch positionA B D E F
Close
Off
Open
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CONTINUED
A
E C K I
K
L
I
J H F D B
E C AD B
J
H
F
PAS-SENGER’S
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
POWER WINDOW SYSTEM
S–13
ABDF E
OPENCLOSE
A
B
D
F
E
3. If not as specified, replace the power windowsubswitch.
FRONT POWER WINDOW REGULATORREMOVAL/INSTALLATION
1. Raise the rear edge of the front door glass 80 mm3.1 in from the fully lowered position.
2. Disconnect the negative battery cable.3. Remove the front glass guide and the rear glass
guide. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.)
4. Remove in the order indicated in the table.5. Install in the reverse order of removal.
A
8.9—12.790—130, 79—112
D
B
C
CD
B
A
6.87—9.8070—100, 60.8—86.7
N·m kgf·cm, in·lbf
1 Front power window regulator connector
2 Bolt
3 Nut
4 Front power window regulator
FRONT POWER WINDOW REGULATORDISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
3.0—4.9 N·m30—50 kgf·cm, 27—43 in·lbf
1 Bolt
2 Power window motor+ Disassembly Note+ Assembly Note
3 Frame
Power Window Motor Disassembly Note Make marks on the gear and base of the frame
before disassembling the power window motor.
BASE
MARK
GEAR
Power Window Motor Assembly Note Align the marks of the gear and the frame to install
the power window motor.
REAR POWER WINDOW REGULATORREMOVAL/INSTALLATION
1. Raise the rear door glass completely.2. Disconnect the negative battery cable.3. Remove the door screen.(Refer to DOOR, REAR DOOR DISASSEMBLY/ASSEMBLY.)4. Remove in the order indicated in the table.5. Install in the reverse order of removal.
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TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
POWER WINDOW SYSTEM
S–14
A
D
C
A
6.87—9.80 N·m70—100 kgf·cm,60.8—86.7 in·lbf
1 Rear power window regulator connector
2 Bolt
3 Rear power window regulator
REAR POWER WINDOW REGULATORDISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
3.1—4.8 N·m31—49 kgf·cm, 27—42 in·lbf
1 Bolt
2 Power window motor+ Disassembly Note+ Assembly Note
3 Frame
Power Window Motor Disassembly Note Make marks on the gear and base of the frame
before disassembling the power window motor.
MARK
BASE GEAR
Power Window Motor Assembly Note Align the marks of the gear and base of the frame
to install the power window motor.
POWER WINDOW MOTOR INSPECTION1. Remove the power window motor.
(Refer to FRONT POWER WINDOW
POWER WINDOW REGULATORDISASSEMBLY/ASSEMBLY.)
2. Apply battery positive voltage to the power windowmotor terminals and inspect the operation of thepower window motor.
B+: Battery positive voltageConnection
Motor operationB+ GND
Motor operation
A B Up
B A Down
UP DOWN
A
B
A B
3. If not as specified, replace the power windowmotor.
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CONTINUED
REGULATOR DISASSEMBLY/ASSEMBLY.) (Refer to REAR
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
POWER DOOR LOCK SYSTEM POWER DOOR LOCK SYSTEM DOOR LOCK-LINK SWITCH REMOVAL/INSTALLATION
Note • The door lock-link switch is mounted to the
driver-side door lock.
1. Disconnect the negative battery cable. 2. Remove the driver-side door lock.
(Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.)
3. Remove the screws. 4. Remove the door lock-link switch from the front
door lock.
5. Install in the reverse order of removal. DOOR LOCK-LINK SWITCH INSPECTION 1. Disconnect the negative battery cable. 2. Remove the driver-side door screen.
(Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.)
3. Disconnect the door lock-link switch connector. 4. Inspect for continuity between the door lock-link
switch terminals using an ohmmeter.
5. If not as specified, replace the door lock-link
switch. DOOR LOCK ACTUATOR REMOVAL/INSTALLATION Front
Note • The front door lock actuator is mounted to
the passenger-side door lock. 1. Disconnect the negative battery cable. 2. Remove the passenger-side door lock.
(Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.)
3. Remove the screws. 4. Remove the front door lock actuator from the
front door lock.
5. Install in the reverse order of removal.
S-15
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TO. MODEL .INDEX
CONTINUED
POWER DOOR LOCK SYSTEM
5. If not as specified, replace the door lock actuator. DOOR LOCK TIMER UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the flasher unit.
(Refer to section T, EXTERIOR LIGHTING SYSTEM, FLASHER UNIT REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1 Door lock timer unit connector 2 Nut
Rear Note
• The rear door lock actuator is mounted to the rear door lock.
1. Disconnect the negative battery cable. 2. Remove the rear door lock.
(Refer to DOOR, REAR DOOR DISASSEMBLY/ASSEMBLY.)
3. Remove the screws. 4. Disconnect the rod. 5. Remove the rear door lock actuator from the rear
door lock.
6. Install in the reverse order of removal. DOOR LOCK ACTUATOR INSPECTION 1. Disconnect the negative battery cable. 2. Remove the door screen.
(Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) (Refer to DOOR, REAR DOOR DISASSEMBLY/ASSEMBLY.)
3. Disconnect the door lock actuator connector. 4. Apply battery positive voltage to the door lock
actuator terminals and inspect the operation of the door lock actuator.
3 Bracket
B+: Battery positive voltage
4 Door lock timer unit
Terminal A B Actuator operation
GND B+ Lock B+ GND Unlock
S-16
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TO. MODEL .INDEX
CONTINUED
POWER DOOR LOCK SYSTEM
DOOR LOCK TIMER UNIT INSPECTION 1. Remove the flasher unit.
(Refer to section T, EXTERIOR LIGHTING SYSTEM, FLASHER UNIT REMOVAL/INSTALLATION.) 2. Measure the voltage at the door lock timer unit terminals as indicated below. 3. Disconnect the door lock timer unit connector before inspecting for continuity at terminals A, C, D, and H. 4. If not as specified, inspect the parts listed under "Inspection area" and the related wiring harnesses. 5. If the parts and wiring harnesses are okay but the system still does not work properly, replace the door lock
timer unit.
Terminal Voltage List (Reference) B+: Battery positive voltage
Terminal Signal Connection Test condition Voltage (V) /Continuity Inspection area
A GND Body ground Constant: inspect for continuity to ground Yes -
B Power supply D/L 30 A fuse Constant B+ D/L 30 A fuse Door lock-link switch is at lock: inspect for continuity to terminal H No
C Unlock input Door lock-link switch Door lock-link switch is at unlock: inspect
for continuity to terminal H Yes
Door lock-link switch
Door lock-link switch is at lock: inspect for continuity to terminal H Yes
D Lock input Door lock-link switch Door lock-link switch is at unlock: inspect
for continuity to terminal H No
Door lock-link switch
Door lock actuators are locked 0 → B+ → 0 E Lock output Door lock
actuator Other 0 Door lock actuator
Door lock actuators are unlocked 0 → B+ → 0 F Unlock output Door lock
actuator Other 0 Door lock actuator
G - Not used - - -
H GND Terminal A of door lock timer unit
Constant: inspect for continuity to terminal A Yes -
S-17
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TO. MODEL .INDEX
CONTINUED
FUEL-FILLER LID AND OPENER, BUMPER
S–19
FUEL-FILLER LID AND OPENERFUEL-FILLER LID REMOVAL/INSTALLATION
1. Remove as indicated in the table.2. Install in the reverse order of removal.
1 Fuel-filler lid
FUEL-FILLER LID ADJUSTMENT1. Measure the gap and height between the fuel-filler
lid and the body.
Clearancea: 3.5—5.5 mm 0.14—0.21 inb: –0.5—2.0 mm –0.01—0.07 in
12345678
SEC.A–A
A
A
a
b
2. If not as specified, loosen the fuel-filler lidinstallation bolts and reposition the fuel-filler lid.
3. Tighten the fuel-filler lid installation bolts.
BUMPERFRONT BUMPER REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
63—93 6.4—9.5, 47—68
N·m kgf·m, ft·lbf
63—93 6.4—9.5, 47—68
6.87—9.80 N·m70—100 kgf·cm,60.8—86.7 in·lbf
6.87—9.80 N·m70—100 kgf·cm,60.8—86.7 in·lbf
1 Front bumper
2 Front bumper stay
FRONT BUMPER DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
N·m kgf·cm, in·lbf
6.87—9.80 70—100, 60.8—86.7
0.2—0.8 2—9, 2—7
0.2—0.3 2—4, 2—3
1 Front bumper side fascia
2 Front bumper upper fascia
3 Front bumper lower fascia
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TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
BUMPER
S–20
REAR BUMPER REMOVAL/INSTALLATIONWith Step
1. Remove the bolts, then remove the rear bumper.
REAR BUMPERBOLT
N·m kgf·m, ft·lbf
79—1168.0—11.9,58.0—86.0
2. Install in the reverse order of removal.
Without Step1. Disconnect the negative battery cable.2. Disconnect the rear fog light connector.3. Remove in the order indicated in the table.4. Install in the reverse order of removal.
12345678
79—1168.0—11.9,58.0—86.0 16—22
1.6—2.3,12—16
N·m kgf·m, ft·lbf
1 Rear bumper stay
3 Rear bumper fascia
REAR BUMPER DISASSEMBLY/ASSEMBLYWith Step
1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
A
A
A
B
B
B
B
A
N·m kgf·m, ft·lbf
32—463.2—4.7,24—33
6.87—9.80 N·m70—100 kgf·cm,60.8—86.7 in·lbf
6.87—9.80 N·m70—100 kgf·cm,60.8—86.7 in·lbf
0.30—0.78 N·m3.0—8.0 kgf·cm,2.7—6.9 in·lbf
1 Side bumper step+ Removal Note
2 Center bumper step+ Removal Note
3 Rear bumper fascia
4 Rear bumper stay
5 Rear bracket
6 Set plate
Side Bumper Step Removal Note1. Disengage clips A using pliers.2. Pull the side bumper step upward, then remove it.
A A A A
AA
SIDE BUMPER STEP
CLIP A
Center Bumper Step Removal Note1. Remove the screws.2. Disengage clips A using pliers.3. Disengage clips B, then remove the center bumper
step.
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TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
BUMPER, EXTERIOR ATTACHMENT
S–21
A
A A A A
AA
B B B BSCREW SCREW
SCREWSCREW CENTER BUMPER STEP
CLIP B CLIP A
EXTERIOR ATTACHMENTRADIATOR GRILLE REMOVAL/INSTALLATION
1. Pull the radiator grille toward you, then disengageclips A to remove the radiator grille.
A
RADIATOR GRILLE
CLIP
A A A A
AA
A
2. Install in the reverse order of removal.
COWL GRILLE REMOVAL/INSTALLATION1. Remove the windshield wiper arm and blade.
(Refer to section T, WIPER AND WASHER,WIPER ARM AND BLADEREMOVAL/INSTALLATION.)
2. Remove the weatherstrip.3. Remove the screws, then remove the cowl grille.
SCREW
WEATHERSTRIP
COWL GRILLE
4. Install in the reverse order of removal.
WINDSHIELD GARNISH REMOVAL/INSTALLATION1. Remove the screws.2. Pull the windshield garnish upward, then
disengage hook A from the cowl grille.
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TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
EXTERIOR ATTACHMENT
S–22
A
WINDSHIELDGARNISH
HOOK
SCREW
A
COWL GRILLE
1. Install in the reverse order of removal.
SIDE PROTECTOR REMOVAL
Warning Using a razor knife with bare hands can
cause injury. Always wear gloves whenusing a razor knife.
1. Pry the side protector end 20—30 mm 0.8—1.1in using a flathead screwdriver or a razor knife.
2. Pull the side protector, then remove it.
Note The side protector is installed with
double-sided adhesive tape. If the sideprotector is difficult to remove, soften thedouble-sided adhesive tape using a hot airblower.
SIDE PROTECTOR INSTALLATION1. Remove the adhesive remaining on the side
protector (if it will be reused) and the body using arazor knife.
2. Remove any grease or dirt from the adhesionsurface of the side protector (if it will be reused)and the body.
3. Attach double-sided adhesive tape to the sideprotector as shown (if it will be reused).
Clearancea : 0—3.0 mm 0—0.11 inb : 37.5 mm 1.48 inc : 10.0 mm 0.39 ind : 2.0—5.0 mm 0.08—0.19 ine : 25.0 mm 0.98 in
b
a a cc
c a
d d d
c
c
a
a
d d bc a
aa cc c
c ac
e
d
a c
e e
FRONT SIDE PROTECTOR
REAR SIDE PROTECTOR
DOUBLE-SIDED ADHESIVE TAPE
CENTER SIDEPROTECTOR(REGULAR CAB)
CENTER SIDEPROTECTOR(STRETCH CAB)
e
4. Peel off the backing paper from the double-sidedadhesive tape and attach the side protector ontothe body as shown.
Clearancea : 4.8—5.8 mm 0.19—0.22 inb : 5.0—6.0 mm 0.20—0.23 inc : 13.0—14.0 mm 0.51—0.55 ind : 16.5—17.0 mm 0.65—0.66 ine : 12.3—13.3 mm 0.49—0.52 inf : 6.0—8.0 mm 0.24—0.31 in
Regular Cab
b c
a
FRONT SIDE PROTECTOR REAR SIDEPROTECTOR
CENTER SIDE PROTECTOR
SEC. A—A
A
A
f
Stretch Cab
SEC. A—A
b
a
d
FRONT SIDE PROTECTOR REAR SIDEPROTECTOR
CENTER SIDE PROTECTOR
f
A
A
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EXTERIOR ATTACHMENT
S–23
Double Cab
SEC. A—A
b
e
FRONT SIDE PROTECTOR
REAR SIDE PROTECTORf
A
A
5. After installing the side protector to the body, applypressure of 50 N·m 5.0 kgf·m, 37 ft·lbf or morewith a roller, etc.
OVER FENDER REMOVAL/INSTALLATION1. Remove the screws.2. Remove the fasteners.3. Disengage clips A of the over fender using a
fastener remover, then remove the over fender.FRONT
REAR
OVER FENDERFASTENER
SCREW
CLIP
SCREW
FASTENER
OVER FENDER
A
CLIP
A A A
A
A
A
AA
A
A
AA
4. Install in the reverse order of removal.
TAILGATE DISASSEMBLY/ASSEMBLY1. Remove the cover.2. Remove the nuts attaching the tailgate lock.3. Disconnect the rods from the tailgate lock.4. Remove the tailgate lock.
TAILGATE LOCK
NUT
ROD
5. Remove the bolts, then remove the latch guide,latch and rod.
LATCH
BOLT
LATCH GUIDE
ROD
6. Remove the handle.7. Assemble in the reverse order of disassembly.
TAILGATE ADJUSTMENT1. Loosen the bolts.2. Move the striker forward and rearward until the
tailgate will lock properly.3. After the correct adjustment is made, tighten the
bolts securely.
STRIKER
BOLT
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EXTERIOR ATTACHMENT, MOLDING
S–24
ROPE HOOK REMOVAL/INSTALLATION1. Remove the screws and bolts, then remove the
rope hook.
ROPE HOOK
SCREW
BOLT
ROPE HOOK
2. Install in the reverse order of removal.
MOLDINGWINDSHIELD UPPER MOLDING REMOVAL Remove the windshield upper molding from the
windshield. (Refer to WINDOW GLASS,WINDSHIELD REMOVAL.)
WINDSHIELD UPPER MOLDING INSTALLATION Install the windshield upper molding to the
windshield. (Refer to WINDOW GLASS,WINDSHIELD INSTALLATION.)
WINDSHIELD SIDE MOLDING REMOVAL Remove the windshield side molding from the
windshield. (Refer to WINDOW GLASS,WINDSHIELD REMOVAL.)
WINDSHIELD SIDE MOLDING INSTALLATION Install the windshield side molding to the
windshield. (Refer to WINDOW GLASS,WINDSHIELD INSTALLATION.)
FRONT BELTLINE MOLDINGREMOVAL/INSTALLATION
1. Lower the front door glass fully.2. Remove the manual outside mirror or the power
outside mirror.(Refer to OUTSIDE MIRROR, MANUAL
MIRROR, POWER OUTSIDE MIRRORREMOVAL/INSTALLATION.)
3. Pull the rear end of the front beltline molding todisengage the hook.
FRONT BELTLINE MOLDING
HOOK
4. Pull the front beltline molding upward, then removeclips A.
CLIP
A
BELTLINEMOLDING
A A A
5. Install in the reverse order of removal.
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CONTINUED
OUTSIDE MIRROR REMOVAL/INSTALLATION.) (Refer to OUTSIDE
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
MOLDING, OUTSIDE MIRROR
S–25
REAR BELTLINE MOLDINGREMOVAL/INSTALLATION
1. Lower the rear door glass fully.2. Pull the rear end of the rear beltline molding to
disengage the hook.
REAR BELTLINE MOLDING
HOOK
3. Pull the rear beltline molding upward, then removeclips A.
CLIP
A
BELTLINEMOLDING
A A A
4. Install in the reverse order of removal.
ROOF MOLDING REMOVAL/INSTALLATION1. Pull the rear edge of roof molding upward, then
disengage clips A.
A
CLIP
ROOF MOLDINGROOF MOLDING
BODY
AA
A
2. Install in the reverse order of removal.
OUTSIDE MIRRORMANUAL OUTSIDE MIRRORREMOVAL/INSTALLATION
1. Remove the inner garnish.2. Remove the front door trim. (Refer to TRIM,
FRONT DOOR TRIM REMOVAL/INSTALLATION.)3. Remove the screws.4. Remove the manual outside mirror.
MANUAL OUTSIDE MIRROR
SCREW
5. Install in the reverse order of removal.
POWER OUTSIDE MIRRORREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove the inner garnish.3. Remove the front door trim. (Refer to TRIM,
FRONT DOOR TRIM REMOVAL/INSTALLATION.)4. Partially peel off the door screen.5. Disconnect the power outside mirror connector.6. Remove the screws.7. Remove the power outside mirror.
POWER OUTSIDE MIRROR
SCREW
POWER OUTSIDE MIRRORCONNECTOR
8. Install in the reverse order of removal.
POWER OUTSIDE MIRROR INSPECTION1. Disconnect the negative battery cable.2. Remove the inner garnish.3. Remove the front door trim. (Refer to TRIM,
FRONT DOOR TRIM REMOVAL/INSTALLATION.)4. Partially peel off the door screen.5. Disconnect the power outside mirror connector.6. Apply battery positive voltage to the power outside
mirror and inspect the operation of the poweroutside mirror.
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123456567
OUTSIDE MIRROR
S–26
B+: Battery positive voltageConnection Mirror
B+ GND operation
A C Up
C A Down
C D Left
D C Right
*
UP
M
M
A DC
DOWN
RIGHTLEFT
1. If not as specified, replace the power outsidemirror.
POWER OUTSIDE MIRROR SWITCHREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove the fuse block cover.3. Remove the fuse block installation screws, and
push the fuse block into the dashboard.4. Insert your hand into the hole for the fuse block,
and press the hooks of the power outside mirrorswitch.
5. Push the power outside mirror switch out, thenremove it.
6. Disconnect the power outside mirror switchconnector.
POWER OUTSIDEMIRROR SWITCH
POWEROUTSIDEMIRRORSWITCHCONNECTOR
7. Install in the reverse order of removal.
POWER OUTSIDE MIRROR SWITCH INSPECTION1. Remove the power outside mirror switch.
(Refer to POWER OUTSIDE MIRROR SWITCHREMOVAL/INSTALLATION.)
2. Inspect for continuity between the power outsidemirror switch terminals using an ohmmeter.
: Continuity
Switch Terminalposition I L A D C B K
Up
LHDown
LHLeft
Right
Up
RHDown
RHLeft
Right
3. If not as specified, replace the power outside mirrorswitch.
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REARVIEW MIRROR, REAR WINDOW DEFROSTER
S–27
REARVIEW MIRRORREARVIEW MIRROR REMOVAL/INSTALLATIONRegular Cab
Note The rearview mirror is attached to the interior
light. (Refer to section T, INTERIOR LIGHTING SYSTEM, INTERIOR LIGHT REMOVAL/INSTALLATION, Regular Cab.)
Stretch Cab, Double Cab1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
2.0—3.9 20—40, 18—34
N·m kgf·cm, in·lbf
1 Cover
2 Screw
3 Rearview mirror
REAR WINDOW DEFROSTERREAR WINDOW DEFROSTER SWITCHREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove the meter hood.3. Press the hooks of the rear window defroster
switch and push the switch out.
METER HOOD
REAR WINDOWDEFROSTERSWITCH
HOOK
4. Install in the reverse order of removal.
REAR WINDOW DEFROSTER SWITCHINSPECTION
1. Remove the rear window defroster switch.2. Inspect for continuity between the rear window
defroster switch terminals using an ohmmeter.: Continuity : Bulb
Switch Terminal
position A B C D
ON
OFF
D A
C B
C
D B
A
3. If not as specified, replace the rear windowdefroster switch.
FILAMENT INSPECTION1. Turn the ignition switch to ON position.2. Turn the rear window defroster switch on.
Caution Directly touching the rear window defroster
filament with the lead of the circuit testerwill damage it. Wrap aluminum foil aroundthe end of the lead and test the filament bytouching it with the foil.
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REAR WINDOW DEFROSTER
S–28
LEAD OF THE CIRCUIT TESTER
FILAMENT
ALUMINUM FOIL
PUSH
1. Connect the positive () lead of the voltmeter tothe positive side of each filament and the negative() lead to ground.
2. Gradually, slide the positive () lead from thepositive side to the negative side and measure thevoltage. Verify that the voltage decreasesaccordingly.
Measurement place Voltage (Reference value)
(1) (2) Approx. 12 V Approx. 0 V
NEGATIVE SIDE
POSITIVESIDE
(1)(2)
3. If the voltage is not as specified or it changesrapidly, the filament is faulty. Repair the filament.
FILAMENT REPAIR1. Use white gasoline to clean around the damaged
section of the filament.2. Attach tape above and below the damaged section
of the filament.
BROKEN FILAMENT TAPE
SECTION TO BE REPAIRED
3. Using a small brush or marking pen, repair thefilament with silver paint or equivalent.
4. After approximately 2—3 minutes, carefullyremove the tape without disturbing the repairedarea.
Caution Do not use the rear window defroster until
the paint is completely dry. It may causeother malfunctions if it is used before thepaint is dry.
5. Use a hot air blower heated to 150C 302F for30 minutes or let the paint set for 24 hours at25C 77F to allow it to dry completely.
REAR WINDOW DEFROSTER RELAYREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Disconnect the rear window defroster relay
connector.3. Slide the rear window defroster relay upward, then
remove it.
REARWINDOWDEFROSTERRELAY
REAR WINDOW DEFROSTER RELAY CONNECTOR
4. Install in the reverse order of removal.
REAR WINDOW DEFROSTER RELAY INSPECTION1. Remove the rear window defroster relay.
(Refer to REAR WINDOW DEFROSTER RELAY REMOVAL/INSTALLATION.)
2. Inspect for continuity between the rear windowdefroster relay terminals using an ohmmeter.
: Continuity B+: Battery positive voltage
StepTerminal
StepA B C D
1
2 B GND
A
BD
C
A
B
D
C
3. If not as specified, replace the rear windowdefroster relay.
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WINDOW GLASS
S–29
WINDOW GLASSWINDSHIELD REMOVAL
1. Remove the cowl grille.(Refer to EXTERIOR ATTACHMENT, COWL GRILLE REMOVAL/INSTALLATION.)
2. Apply protective tape to the headliner, the bodyand the dashboard.
Warning Using a razor knife with bare hands can
cause injury. Always wear gloves whenusing a razor knife.
Note The windshield upper molding and windshield
side molding are replacement parts.
3. Cut the lip of the windshield upper molding using arazor knife.
WINDSHIELD UPPER MOLDINGPROTECTIVE
TAPE
LIP
R
Not Reusing Windshield
Warning Using a piano wire with bare hands can
cause injury. Always wear gloves whenusing a piano wire.
Note For the areas of the sealant that are difficult to
cut, use a piano wire and follow the proceduresunder “Reusing Windshield”.
1. Use a tool like that shown in the figure, and insertthe blade into the sealant.
2. Pull through the sealant around the edge of theglass.
3. Remove the windshield.4. Remove the spacers from the body.
Reusing Windshield1. Make a hole through the sealant from the inside of
the vehicle using an awl.2. Pass the SST (piano wire) through the hole.
PROTECTIVE TAPE
WINDSHIELD UPPERMOLDING
WINDSHIELDSEALANT
HEADLINERPROTECTIVE TAPE
DAM
R
49 0305 870A
3. Wind each end of the wire around a bar.
Note Use the entire length of piano wire to prevent it
from breaking when cutting through thesealant.
4. Working with another person, saw through thesealant around the edge of the glass, being carefulnot to damage the body.
49 0305 870A
5. Remove the windshield.6. Remove the spacers from the body.7. Remove the spacer and the dam from the glass.
CENTER
DAM
SPACER R
R
8. Remove the windshield upper molding and thewindshield side molding from the windshield.
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WINDOW GLASS
S–30
WINDSHIELD
WINDSHIELD UPPER MOLDING
WINDSHIELD SIDE MOLDING R
R
WINDSHIELD INSTALLATION
Warning Using a razor knife with bare hands can
cause injury. Always wear gloves whenusing a razor knife.
Caution To prevent the sealant from cracking or the
glass from being pushed out by airpressure if a door is closed, open all of thewindows and leave them open until thesealant has hardened.
1. Cut away the old sealant using a razor knife so that1—2 mm 0.04—0.07 in thickness of sealantremains around the circumference of the frame. Ifall the sealant has come off in any one place, applysome primer after degreasing, and allow it 30minutes to dry. Then put on new sealant to createa 2 mm 0.08 in layer.
2. Clean and degrease an approximately 50 mm1.97 in wide strip around the circumference ofthe glass and the bonding area on the body.
3. Align the center mark on the windshield uppermolding with the glass mark.
4. Install the windshield upper molding from thecenter toward both sides.
WINDSHIELD UPPER MOLDING
MARK
GLASS MARK
WINDSHIELD
5. Align the upper edge of the windshield sidemolding with the glass mark.
6. Install the windshield side molding from the upperpart towards the lower part.
GLASS MARK
WINDSHIELDSIDE MOLDINGWINDSHIELD
7. Securely bond a dam along the circumference ofthe glass 8.5 mm 0.33 in from the upper edgeand 14.5 mm 0.57 in from the lower and sideedge.
8. Install the spacer to the glass.
CENTER8.5 0.33
14.5 0.57
DAM
SPACER14.5 0.57
6.0 0.24
14.5 0.57
CERAMICPARTINGLINE
mm in
9. Install spacers into the hole of the body.10. Temporarily install the glass onto the body and
adjust the glass to body clearance.11. Make a mark on the glass directly above the
V-notch of spacers.12. Verify that the gap along the upper edge is
7.5 mm 0.30 in .
SPACER
7.5 0.30
mm in
CENTER MARKINGBODY
13. Remove the windshield.
Caution Keep the area free of dirt and grease, and
do not touch the surface or the primer maynot properly bond to the surface of theglass and body, which may cause leaks tooccur.
14. Use a brush to apply primer to the bonding area ofthe glass and body within the region shown. Useonly glass primer on the glass and body primer onthe body and molding. Allow it to dry forapproximately 30 minutes .
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WINDOW GLASS
S–31
8.5 0.3314.5 0.57
GLASSPRIMER
BODYPRIMER
13.0 0.51
GLASSPRIMER
SIDE
19.00.75
GLASSPRIMER
LOWER
19.0 0.75
16.0 0.63
BODYPRIMER
BODYPRIMER
WINDSHIELDSIDE MOLDING
WINDSHIELDUPPER MOLDING BODY PRIMER mm in
BODYPRIMER
14.5 0.57
UPPER
15. Once the primer is dry, apply a 11.0 mm 0.43 inhigh, 5.0 mm 0.20 in wide bead of sealant alongthe dam around the entire circumference to fill thegap between the dam and the edge of thewindshield.
11.00.43
DAM
5.00.20
mm in
16. Align the glass marks with the V-notches inspacers and install the glass onto the body.
17. Press firmly inward on the glass to compress thesealant.
18. Verify that the gap along the upper and side edgeis 7.5 mm 0.30 in .
19. Adjust the sealant as indicated in the figure.
UPPER
WINDSHIELDBODY
DAM
SEALANT ADJUST SEALANTIN THIS AREA
SIDE
WINDSHIELD
DAM
ADJUST SEALANTIN THIS AREA
BODY
Hardening time of sealant
Temperature Surface hardening time
Time requireduntil car can beput into service
5 °C 41 °F Approx. 1.5 h Approx. 12 h
20 °C 68 °F Approx. 1 h Approx. 4 h
35 °C 95 °F Approx. 10 min Approx. 2 h
20. Use white gasoline to remove any sealant thatoozes out.
21. Install the cowl grille. (Refer to EXTERIOR ATTACHMENT, COWL GRILLE REMOVAL/INSTALLATION.)
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WINDOW GLASS
S–32
QUARTER WINDOW GLASS REMOVAL/INSTALLATIONStretch Cab
1. To remove the quarter window hinge, remove the quarter upper trim. (Refer to TRIM, QUARTER UPPER TRIM REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
1 Hinge cover
2 Quarter window hinge
3 Quarter window lock
4 Quarter window glass
5 Quarter window glass weatherstrip
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WINDOW GLASS
S–33
REAR WINDOW GLASS REMOVAL1. Remove the headliner. (Refer to HEADLINER,
HEADLINER REMOVAL/INSTALLATION.)2. Remove the rear window defroster connector if
equipped.3. While another person presses the rear window
glass, use the SST to push the lip of the rearwindow weatherstrip from the inside.
REAR WINDOW WEATHERSTRIP
LIP49 0259 866A
4. After the top of the rear window weatherstrip isremoved, push the rear window glass outside andremove it with the rear window weatherstripattached.
5. Remove the rear window weatherstrip from therear window glass.
REAR WINDOW GLASS INSTALLATION1. Clean and degrease the body and the rear window
glass.2. Install the rear window weatherstrip to the rear
window glass.REAR WINDOW WEATHERSTRIP
3. Fit the SST into the rear window weatherstrip andcross the ends as shown, leave 200 mm 7.87 in .
49 0259 866A
REAR WINDOW WEATHERSTRIP
200 7.87mm in
4. Apply soapy water as shown.
BODY
REAR WINDOW WEATHERSTRIP
SOAPY WATER
5. Align the rear window glass with the rear windowweatherstrip and body.
6. While another person lightly taps the outside of therear window glass near the rear windowweatherstrip all around its circumference, pull oneend of the SST and install the rear window glass.
49 0259 866A
7. Install the rear window defroster connector ifequipped.
8. Install the headliner. (Refer to HEADLINER, HEADLINER REMOVAL/INSTALLATION.)
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DASHBOARD AND CONSOLE
S–34
DASHBOARD AND CONSOLEDASHBOARD REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove the driver-side air bag module.
(Refer to section T, AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)3. Remove the passenger-side air bag module.
(Refer to section T, AIR BAG SYSTEM, PASSENGER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)4. Remove the steering wheel.
(Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)5. Remove the installation bolts then lower the assembled steering shaft from the dashboard.
(Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)6. Remove the meter hood.7. Remove the instrument cluster.8. Remove the front console. (Refer to FRONT CONSOLE REMOVAL/INSTALLATION.)9. Remove the glove compartment.
10. Remove the bonnet release cable installation nut.11. Remove the A-pillar trims. (Refer to TRIM, A-PILLAR TRIM REMOVAL/INSTALLATION.)12. Disconnect the wires for both the blower unit and the heater unit.
INSTALLATION.)
14. Remove in the order indicated in the table.15. Install in the reverse order of removal.16. Adjust the wires for both the blower unit and the heater unit.
(Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT ADJUSTMENT.)
7.9—11.7 80—120, 70—104
7.9—11.7 80—120, 70—104
7.9—11.7 80—120, 70—104
N·m kgf·cm, in·lbf
1 Bolt 2 Dashboard
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CONTINUED
(Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT REMOVAL.) (Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT
13. Remove the fuse block.
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DASHBOARD AND CONSOLE
S–35
DASHBOARD DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
1 Defroster nozzle
2 Side demister nozzle
3 Center duct
4 Duct
5 Dashboard crash pad
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DASHBOARD AND CONSOLE
S–36
DASHBOARD MEMBER REMOVAL/INSTALLATION1. Remove the dashboard.
(Refer to DASHBOARD REMOVAL/INSTALLATION.)2. Remove the bolts, then remove the dashboard
member.
16—22 1.6—2.3,12—16
BOLT
DASHBOARD MEMBER
N·m kgf·m, ft·lbf
16—22 1.6—2.3,12—16
16—22 1.6—2.3, 12—16
16—22 1.6—2.3, 12—16
3. Install in the reverse order of removal.
COLUMN COVER REMOVAL/INSTALLATION1. Remove the screws, then remove the column
cover.
COLUMNCOVER
SCREW
2. Install in the reverse order of removal.
FRONT CONSOLE REMOVAL/INSTALLATION1. Remove the rear console.2. For manual transaxle vehicle, remove the shift
lever knob.3. Remove the screws, then remove the front
console.
Caution In order to prevent noise caused by
interference with the dashboard, install thescrews to the rear of the front consolebefore installing the front of the frontconsole.
SCREW
FRONT CONSOLE
4. Install in the reverse order of removal.
FRONT CONSOLE DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
1 Screw
2 Front console
3 Boot
4 Set plate
REAR CONSOLE REMOVAL/INSTALLATION1. Remove the screws.2. Pull the rear console upward, then remove it.
SCREW
REAR CONSOLE
3. Install in the reverse order of removal.
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DASHBOARD AND CONSOLE
S–37
REAR CONSOLE DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
1 Screw
2 Console lid outer
3 Console lid inner
4 Rear console
5 Console lid lock
6 Console lid hinge
7 Console lid bracket
GLOVE COMPARTMENT REMOVAL/INSTALLATION1. Open the glove compartment and bend the sides
inward to disengage the pins.2. Pull the glove compartment downward, then
disengage clips A.
PIN
PIN
CLIP
GLOVE COMPARTMENT
A
A
A
3. Install in the reverse order of removal.
METER HOOD REMOVAL/INSTALLATION1. Remove the screws.2. Pull the meter hood toward you, then disengage
clips A and pins B.
PIN
A
CLIP
SCREW
AA
A A
A
A
B
B
B
B
A
3. Disconnect the connectors, then remove the meterhood.
4. Install in the reverse order of removal.
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TRIM
S–38
TRIMA-PILLAR TRIM REMOVAL/INSTALLATION
1. Remove the quarter upper trim. (Regular cab,stretch cab) (Refer to QUARTER UPPER TRIMREMOVAL/INSTALLATION.)
2. Remove the B-pillar upper trim. (Double cab)(Refer to B-PILLAR UPPER TRIMREMOVAL/INSTALLATION.)
3. Pull the A-pillar trim toward you, then disengageclips A and pin B.
4. Pull the A-pillar trim upward, then disengage thehook.
A A
A
A
A
B
A B
CLIP PIN
A-PILLAR TRIM
HOOK
5. Install in the reverse order of removal.
B-PILLAR TRIM REMOVAL/INSTALLATIONRegular Cab
1. Turn over the seaming welt.2. Remove the seat belt upper anchor installation
bolt.3. Remove the back upper trim.4. Pull the B-pillar trim toward you, then disengage
clips A and pins B.5. Remove clip C.6. Remove the seat belt from the B-pillar trim.
A
B
CLIP
PIN
B-PILLAR TRIM
A
A
A
A
B
CLIP C
A
AB
7. Install in the reverse order of removal.
B-PILLAR LOWER TRIM REMOVAL/INSTALLATIONDouble Cab
1. Remove the front scuff plate.2. Remove the rear scuff plate.3. Turn over the seaming welt.4. Pull the B-pillar lower trim indicated by the arrow,
then disengage clips A and pin B.5. Remove the seat belt from B-pillar trim.6. Pull the B-pillar lower trim upward, then disengage
hooks C from the body.
A
B
CLIP
PIN
B-PILLARLOWER TRIM
HOOK
A
A
A
CC
A
B
C
7. Install in the reverse order of removal.
B-PILLAR UPPER TRIM REMOVAL/INSTALLATIONDouble Cab
1. Remove the B-pillar lower trim.(Refer to B-PILLAR LOWER TRIM REMOVAL/INSTALLATION.)
2. Remove the front seat belt upper anchorinstallation bolt.
3. Remove the C-pillar trim. (Refer to C-PILLAR TRIM REMOVAL/INSTALLATION.)
4. Remove the fastener.5. Pull the B-pillar upper trim toward you, then
disengage clips A and pins B from the body.
CLIP
HOOK
B-PILLAR UPPER TRIM
FASTENER
A
B
A A A
A
A
A
B
A
B
6. Install in the reverse order of removal.
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TRIM
S–39
FRONT SIDE TRIM REMOVAL/INSTALLATION1. Remove the scuff plate.2. Loosen the nut.3. Pull the front side trim in the direction indicated by
the arrow, then remove it.
NUT
FRONT SIDE TRIM
4. Install in the reverse order of removal.
FRONT SCUFF PLATE REMOVAL/INSTALLATION1. Remove the screws.2. Pull the front scuff plate upward, then disengage
pin A.
SCREW
FRONT SCUFF PLATE
A
PIN
A
3. Install in the reverse order of removal.
REAR SCUFF PLATE REMOVAL/INSTALLATIONDouble Cab
1. Remove the screw.2. Pull the rear scuff plate upward, then disengage
clips A and pin B.
SCREW
REAR SCUFF PLATE
CLIP PIN
A B
A
AB
3. Install in the reverse order of removal.
C-PILLAR TRIM REMOVAL/INSTALLATIONDouble Cab
1. Turn over the seaming welt.2. Remove the rear seat. (Refer to SEAT, SEAT
REMOVAL/INSTALLATION, Double Cab, Rear.)3. Remove the rear seat belt upper anchor installation
bolt.4. Remove the fasteners.5. Pull the C-pillar trim toward you, then disengage
clips A and pin B.6. Remove the seat belt from C-pillar trim.
CLIP
PIN
C-PILLAR TRIM
FASTENER
A
BA A
A
A
A
B
7. Pull the C-pillar trim upward, then remove it fromthe body.
8. Install in the reverse order of removal.
QUARTER UPPER TRIM REMOVAL/INSTALLATIONStretch Cab
1. Remove the back upper trim.2. Remove the upper anchor of the seat belt.3. Remove the quarter window lock.
(Refer to WINDOW GLASS, QUARTER WINDOW GLASS REMOVAL/INSTALLATION.)
4. Remove the hook.5. Remove the fasteners.6. Pull the quarter upper trim toward you, then
disengage clips A and pins B.
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TRIM
S–40
A
B
AA A
A
A
AA
AA
A
B
B
QUARTER UPPER TRIM
FASTENER
CLIP
PIN
HOOK
7. Install in the reverse order of removal.
QUARTER LOWER TRIM REMOVAL/INSTALLATIONStretch Cab
1. Remove the quarter upper trim. (Refer to QUARTER UPPER TRIMREMOVAL/INSTALLATION.)
2. Remove the back lower trim.3. Remove the fasteners.4. Pull the quarter lower trim toward you, then
disengage clips A and pins B.
FASTENERQUARTER LOWER TRIM
A B
CLIPPIN
A
A
A
A
A
B
B
5. Install in the reverse order of removal.
BACK UPPER TRIM REMOVAL/INSTALLATION1. Pull the back upper trim toward you, then
disengage clips A and pins B.
BACK UPPER TRIM
A
B
CLIPPIN
A
A
A
A
A
A
A
AA
AA
A
B
B
B
A
2. Install in the reverse order of removal.
BACK LOWER TRIM REMOVAL/INSTALLATION1. Remove the fasteners, then remove the back lower
trim.
FASTENER
BACK LOWER TRIM
2. Install in the reverse order of removal.
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TRIM
S–41
FRONT DOOR TRIM REMOVAL/INSTALLATION1. Disconnect the negative battery cable if equipped
with a power window system.2. Remove the regulator handle if equipped.3. Remove the inner garnish.4. Remove the power window switch if equipped.5. Remove the screws and the fastener.6. Pull the front door trim toward you, then disengage
clips A.7. Pull the front door trim upward, then disengage
hook B.
FASTENER FRONT DOOR TRIM
SCREW HOOK
CLIP
A
B
A
A
A AA
A
A
A
A
B
FASTENER FRONT DOOR TRIM
SCREW
HOOK
CLIP
A
B
A
A
A AA
A
A
A
A
B
8. Install in the reverse order of removal.
REAR DOOR TRIM REMOVAL/INSTALLATIONDouble cab
1. Disconnect the negative battery cable if equippedwith power window.
2. Remove the regulator handle if equipped.3. Remove the power window switch if equipped.4. Remove the screws.5. Remove the ashtray.6. Pull the door trim toward you, then disengage clips
A.
ASHTRAY
REAR DOOR TRIM
SCREW
HOOK
CLIP
A
B
INNER HANDLE
A
A
AA
AA
A
A
A
A
B
7. Extract the inner handle from the rear door trim.8. Pull the rear door trim upward, then disengage
hooks B.9. Install in the reverse order of removal.
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TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
HEADLINER, FLOOR COVERING
S–42
HEADLINERHEADLINER REMOVAL/INSTALLATION
1. Remove the A-pillar trims.2. Remove the B-pillar upper trims.
(Refer to TRIM, B-PILLAR UPPER TRIMREMOVAL/INSTALLATION, Double Cab.)
3. Remove the quarter upper trims. (Refer to TRIM, QUARTER UPPER TRIMREMOVAL/INSTALLATION, Stretch Cab.)
4. Remove the C-pillar trims. (Refer to TRIM, C-PILLAR TRIM REMOVAL/INSTALLATION, Double Cab.)
5. Remove the assist handle.6. Remove the rearview mirror.7. Remove the sunvisors and adapters.8. Remove the interior light.
(Refer to section T, INTERIOR LIGHTING SYSTEM, INTERIOR LIGHT REMOVAL/INSTALLATION.)
9. Remove the fasteners, then remove the headliner.
HEADLINER
ASSIST HANDLEFASTENER
SUNVISOR
ADAPTER
10. Remove the headliner from the vehicle through thepassenger-side door.
HEADLINER
11. Install in the reverse order of removal.
FLOOR COVERINGFLOOR COVERING REMOVAL/INSTALLATIONRegular Cab, Stretch Cab
1. Remove the dashboard member. (Refer to DASHBOARD AND CONSOLE, DASHBOARD MEMBER REMOVAL/INSTALLATION.)
2. Remove the quarter lower trims. (Refer to TRIM, QUARTER LOWER TRIMREMOVAL/INSTALLATION, Stretch Cab.)
3. Remove the back lower trim.4. Remove the front seats. (Refer to SEAT, SEAT
REMOVAL/INSTALLATION, Regular Cab.) (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Stretch Cab, Double cab, Front.)
5. Remove the rear seat. (Refer to SEAT, SEAT
cab, Rear.)6. Remove the rear console bracket.7. Remove the lower anchor installation bolts of front
seat belts.8. Remove the front side trims.9. Remove the air outlet ducts.
(Refer to section U, BASIC SYSTEM, AIR OUTLET DUCT REMOVAL/INSTALLATION.)
10. Remove the footrest.11. Remove the fasteners, then remove the floor
covering.
FASTENER
FLOOR COVERING
12. Install in the reverse order of removal.
Double cab1. Remove the dashboard member.
(Refer to DASHBOARD AND CONSOLE, DASHBOARD MEMBER REMOVAL/INSTALLATION.)
2. Remove the B-pillar lower trims. (Refer to TRIM, B-PILLAR LOWER TRIMREMOVAL/INSTALLATION.)
3. Remove the C-pillar trims. (Refer to TRIM,C-PILLAR TRIM REMOVAL/INSTALLATION)
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CONTINUED
REMOVAL/INSTALLATION, Stretch Cab, Double
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
FLOOR COVERING
S–43
4. Remove the front seats and rear seat. (Refer to SEAT, SEAT REMOVAL/INSTALLATION,
REMOVAL/INSTALLATION, Stretch Cab, Double cab, Rear.)5. Remove the rear console bracket.6. Remove the lower anchor installation bolts of front
seat belts and rear seat belts.7. Remove the front side trim.8. Remove the air outlet duct.
(Refer to section U, BASIC SYSTEM, AIR OUTLET DUCT REMOVAL/INSTALLATION.)
9. Remove the footrest.10. Remove the fasteners, then remove the floor
covering.FASTENER
FLOOR COVERING
Type 1
Type 2
FASTENER
FLOOR COVERING
11. Install in the reverse order of removal.
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CONTINUED
Stretch Cab, Double cab, Front.) (Refer to SEAT, SEAT
TO. MODEL .INDEXRANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
SEAT BELT
S–44
SEAT BELTSEAT BELT REMOVAL/INSTALLATION
Caution The ELR has a spring that will unwind if the
retractor’s cover is removed. The springcannot be rewound by hand. If this occurs,the ELR will not work properly. Therefore,do not disassemble the retractor.
Regular CabDriver’s side and passenger’s side
1. Remove the B-pillar trim if equipped with a B-pillartrim. (Refer to TRIM, B-PILLAR TRIMREMOVAL/INSTALLATION, Regular Cab.)
2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
39—78 3.9—8.0, 29—57
39—78 3.9—8.0, 29—57
1 Anchor cover
2 Retractor cover (if equipped)
3 Seat belt
Except driver’s side and passenger’s sideExcept Europe and UK
1. Remove as indicated in the table.2. Install in the reverse order of removal.
39—78 3.9—8.0, 29—57
N·m kgf·m, ft·lbf
1 Seat belt
Stretch CabFront
1. Remove the quarter lower trim. (Refer to TRIM, QUARTER LOWER TRIMREMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
39—78 3.9—8.0, 29—57
39—78 3.9—8.0, 29—57 N·m kgf·m, ft·lbf
1 Anchor cover
2 Seat belt
Rear1. Remove the quarter lower trim.
(Refer to TRIM, QUARTER LOWER TRIMREMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
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SEAT BELT
S–45
39—78 3.9—8.0, 29—57
N·m kgf·m, ft·lbf
39—78 3.9—8.0, 29—57
1 Anchor cover
2 Seat belt
Double CabFront
1. Remove the B-pillar lower trim. (Refer to TRIM, B-PILLAR LOWER TRIMREMOVAL/INSTALLATION, Double Cab.)
2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
39—78 3.9—8.0, 29—57
39—78 3.9—8.0, 29—57
N·m kgf·m, ft·lbf
1 Anchor cover
2 Seat belt
Rear1. Remove the C-pillar trim. (Refer to TRIM,
C-PILLAR TRIM REMOVAL/INSTALLATION.)2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
39—78 3.9—8.0, 29—57
N·m kgf·m, ft·lbf
39—78 3.9—8.0, 29—57
1 Anchor cover
2 Seat belt
SEAT BELT INSPECTIONBelt
1. Inspect the webbing for scars, tears, and wear.2. Inspect the fitting for deformation or damage.3. If a problem is found, replace the seat belt.
ELR1. Verify that the belt can be pulled out smoothly, and
that it moves smoothly when worn.2. Verify that the retractor locks when the belt is
quickly pulled.
3. Remove the retractor.4. Make sure that the seat belt does not lock when
the retractor is tilted slowly up to 15° from themounted position. Make sure that the seat beltlocks when the retractor is tilted 40° or more .
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SEAT BELT
S–46
RETRACTOR
5. If any of the above-mentioned steps are not asspecified, replace the seat belt.
BUCKLE REMOVAL/INSTALLATIONBench SeatDriver’s side and passenger’s side
1. Disconnect the negative battery cable.2. Remove as indicated in the table.3. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
39—78 3.9—8.0, 29—57
1 Buckle
Except driver’s side and passenger’s sideExcept Europe and UK
1. Remove as indicated in the table.2. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
39—78 3.9—8.0, 29—57
1 Buckle
Bucket SeatFront
1. Disconnect the negative battery cable.2. Remove the side cover. (Refer to SEAT, FRONT
SEAT DISASSEMBLY/ASSEMBLY, Bucket Seat.)3. Remove as indicated in the table.4. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
39—78 3.9—8.0, 29—57
1 Front buckle
Stretch CabRear
1. Remove as indicated in the table.2. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
39—78 3.9—8.0, 29—57
1 Rear buckle
Double CabRear
1. Remove the seat cushion. (Refer to SEAT, REARSEAT REMOVAL/INSTALLATION, Double Cab.)
2. Remove as indicated in the table.3. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
39—78 3.9—8.0, 29—57
1 Rear buckle
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SEAT BELT
BUCKLE SWITCH INSPECTION 1. Disconnect the negative battery cable. 2. Disconnect the buckle switch connector. 3. Inspect for continuity between the buckle switch
terminals using an ohmmeter.
4. If not as specified, replace the buckle.
S-47
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SEAT
S–48
SEATFRONT SEAT REMOVAL/INSTALLATIONBench Seat
1. Remove as indicated in the table.2. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
35—63 3.5—6.5, 26—47
35—63 3.5—6.5, 26—47
1 Front seat+ Installation note
Front seat installation note1. To install the seat, tighten the bolts in the order
indicated in the figure.
LEFTSIDE
RIGHTSIDE
FRONT
2. Verify that the seat slider is securely locked inposition before fully tightening the bolts.
3. After installing the seat, slide it forward andbackward and verify that the seat slider securelylocks in position.
Bucket Seat1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
35—63 3.5—6.5, 26—47
35—63 3.5—6.5, 26—47
1 Connector
2 Cover
3 Front seat+ Installation note
Front seat installation note1. To install the seat, tighten the bolts in the order
indicated in the figure.
TUNNELSIDE
DOORSIDE
FRONT
2. Verify that the seat slider is securely locked inposition before fully tightening the bolts.
3. After installing the seat, slide it forward andbackward and verify that the seat slider securelylocks in position.
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SEAT
S–49
FRONT SEAT DISASSEMBLY/ASSEMBLYBench Seat
1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
N·m kgf·m, ft·lbf
32—463.2—4.7, 24—33
A
A
1 Headrest
2 Pole guide
3 Recliner lever
4 Side cover
5 Lower cover
6 Seat back trim
7 Seat back pad
8 Seat back frame
9 Seat cushion trim
10 Seat cushion pad
11 Seat cushion frame
12 Cable
13 Slide adjuster
14 Connecting rod
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SEAT
S–50
Bucket Seat1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.3. When removing the cable (passenger’s seat), adjust the cable. (Refer to CABLE ADJUSTMENT.)
N·m kgf·m, ft·lbf
37—533.7—5.5, 27—39
A
B
39—783.9—8.0, 29—57
C
B
A
C
PASSENGER’S SEAT
39—78 3.9—8.0, 29—57
1 Headrest
2 Recliner lever
3 Side cover
4 Front buckle
5 Spring (stretch cab)
6 Cable (stretch cab)
7 Wire
8 Connecting rod
9 Slide adjuster No.1
10 Slide adjuster No.2
11 Slide adjuster No.3
12 Pole guide
13 Seat back trim
14 Seat back warmer unit (Europe only)
15 Seat back pad
16 Seat cushion trim
17 Seat cushion warmer unit (Europe only)
18 Seat cushion pad
19 Seat cushion frame
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SEAT
S–51
CABLE ADJUSTMENT Verify the slide adjuster slides and locks smoothly
when the slide adjuster lever is operated.
LEVER
LEVER
LOCKSLIDE
REAR SEAT REMOVAL/INSTALLATIONStretch CabSeat back
1. Remove the back upper trim.2. Remove the bolts.3. Lift the seat back up in the direction of the arrow,
then unhook it from the body.
SEAT BACK
BOLT6.87—9.8070—100, 60.8—86.7
N·m kgf·cm, in·lbf
HOOK
HOOK
HOOK
Seat cushion1. Lift up the rear seat cushion.2. Remove the screws.3. Remove the bolts, and then remove the seat
cushion.
SEAT BACK
BOLT16—221.6—2.3, 12—16
N·m kgf·m, ft·lbf
SCREW2.0—2.9 N·m20—30 kgf·cm,18—26 in·lbf
Hinge1. Remove the back lower trim. (Refer to TRIM,
BACK LOWER TRIM REMOVAL/INSTALLATION.)2. Remove the fasteners, and then turn over the floor
covering.3. Remove the bolts, and then remove the hinge.
HINGE
BOLT16—221.6—2.3, 12—16
N·m kgf·m, ft·lbf
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SEAT
S–52
Double Cab1. Remove in the order indicated in the table.2. Install in the reverse order of removal.
N·m kgf·m, ft·lbf
16—221.6—2.3,12—16
35—633.5—6.5,26—47
16—221.6—2.3,12—16
16—221.6—2.3, 12—16
35—633.5—6.5,26—47
PULL
1 Seat cushion
2 Seat back+ Installation note
3 Hinge
4 Striker
Seat back installation note After installing the seat back, verify that it securely
locks to the striker.
REAR SEAT DISASSEMBLY/ASSEMBLYStretch Cab
1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
1 Seat cushion trim
2 Seat cushion pad
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SEAT
S–53
Double Cab1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
1 Headrest
2 Pole guide
3 Seat back trim
4 Seat back pad
5 Rear back catch
6 Side cover
7 Stopper
8 Seat back frame
9 Seat cushion trim
10 Seat cushion pad
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SEAT
S–54
SEAT WARMER SWITCH REMOVAL1. Disconnect the negative battery cable.2. Insert your hand under the dashboard near the
fuse block, grasp the hooks of the seat warmerswitch and pull it forward to remove it.
3. Disconnect the seat warmer switch connector, andthen remove the seat warmer switch.
HOOK
SEAT WARMERSWITCHCONNECTOR
SEAT WARMER SWITCH INSTALLATION1. Connect the seat warmer switch connector.2. Insert the seat warmer switch in the hole to install
it.3. Connect the negative battery cable.
SEAT WARMER SWITCH INSPECTION1. Remove the seat warmer switch.
(Refer to SEAT WARMER SWITCH REMOVAL.)2. Inspect for continuity between the seat warmer
switch terminals using an ohmmeter.
: Continuity : Bulb
Switch positionTerminal
Switch positionD C F
On
Off
FC
D
F
3. If not as specified, replace the seat warmer switch.
SEAT WARMER UNIT INSPECTION1. Remove the front seat. (Refer to FRONT SEAT
REMOVAL/INSTALLATION, Bucket Seat.)2. Inspect seat warmer unit at roor temperature of 20
°C 68 °F.3. Apply battery positive voltage to the seat warmer
unit terminal A, connect the ground to terminal B,and measure the temperature of the thermometalswitch with a thermometer.
A
B
A
B
THERMOMETER
THERMOMETALSWITCH
4. When the temperature of the thermometal switch isapproximately 40 °C 104 °F, inspect theresistance between the seat warmer unit terminalsusing an ohmmeter. Verify that the resistancechanges from approximately 4.8 Ω toapproximately 13.0 Ω.
5. Remove battery positive voltage from seat warmerunit terminals.
6. When the temperature of the thermometal switch isapproximately 30 °C 86 °F, inspect theresistance between the seat warmer unit terminalsusing an ohmmeter. Verify that the resistancechanges from approximately 13.0 Ω toapproximately 4.8 Ω.
7. If any of the above-mentioned steps are not asspecified, replace the seat back pad (with seatwarmer unit) and seat cushion pad (with seatwarmer unit).
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T–1
BODY ELECTRICAL SYSTEM
POWER SYSTEM T– 3. . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE SERVICE CAUTION T– 3. . . . . . . . . . . . . . . . . MAIN FUSE REMOVAL/INSTALLATION T– 3. . . . . IGNITION SWITCH
REMOVAL/INSTALLATION T– 3. . . . . . . . . . . . . . . IGNITION SWITCH INSPECTION T– 3. . . . . . . . . . . KEY REMINDER SWITCH
REMOVAL/INSTALLATION T– 3. . . . . . . . . . . . . . . KEY REMINDER SWITCH INSPECTION T– 4. . . . CIGARETTE LIGHTER
REMOVAL/INSTALLATION T– 4. . . . . . . . . . . . . . . CIGARETTE LIGHTER INSPECTION T– 4. . . . . . .
EXTERIOR LIGHTING SYSTEM T– 5. . . . . . . . . . . . . . FRONT COMBINATION LIGHT
REMOVAL/INSTALLATION T– 5. . . . . . . . . . . . . . . HEADLIGHT AIMING T– 5. . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BULB
REMOVAL/INSTALLATION T– 5/6. . . . . . . . . . . . . . . PARKING LIGHT BULB
REMOVAL/INSTALLATION T– 6. . . . . . . . . . . . . . . FRONT TURN LIGHT
REMOVAL/INSTALLATION T– 6. . . . . . . . . . . . . . . FRONT TURN LIGHT BULB
REMOVAL/INSTALLATION T– 6. . . . . . . . . . . . . . . FRONT SIDE TURN LIGHT
REMOVAL/INSTALLATION T– 6. . . . . . . . . . . . . . . REAR COMBINATION LIGHT
REMOVAL/INSTALLATION T– 7. . . . . . . . . . . . . . . REAR COMBINATION LIGHT BULB
REMOVAL/INSTALLATION T– 7. . . . . . . . . . . . . . . REAR FOG LIGHT
REMOVAL/INSTALLATION T– 7. . . . . . . . . . . . . . . REAR FOG LIGHT BULB
REMOVAL/INSTALLATION T– 7. . . . . . . . . . . . . . . LICENSE PLATE LIGHT
REMOVAL/INSTALLATION T– 8. . . . . . . . . . . . . . . COMBINATION SWITCH
REMOVAL/INSTALLATION T– 8. . . . . . . . . . . . . . . COMBINATION SWITCH
DISASSEMBLY/ASSEMBLY T– 8. . . . . . . . . . . . . . LIGHT SWITCH
REMOVAL/INSTALLATION T– 8. . . . . . . . . . . . . . . LIGHT SWITCH INSPECTION T– 8/9. . . . . . . . . . . . . . HAZARD WARNING SWITCH
REMOVAL/INSTALLATION T– 9. . . . . . . . . . . . . . . HAZARD WARNING
SWITCH INSPECTION T– 9. . . . . . . . . . . . . . . . . . . REAR FOG LIGHT SWITCH REMOVAL T–10. . . . . REAR FOG LIGHT SWITCH
INSTALLATION T–10. . . . . . . . . . . . . . . . . . . . . . . . . . REAR FOG LIGHT SWITCH
INSPECTION T–10. . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT LEVELING SWITCH
REMOVAL T–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT LEVELING SWITCH
INSTALLATION T–10. . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT LEVELING SWITCH
INSPECTION T–10. . . . . . . . . . . . . . . . . . . . . . . . . . . BACK-UP LIGHT SWITCH
REMOVAL/INSTALLATION T–11. . . . . . . . . . . . . . . BACK-UP LIGHT SWITCH INSPECTION T–11. . . .
FLASHER UNIT REMOVAL/INSTALLATION T–11. . . . . . . . . . . . . . .
FLASHER UNIT INSPECTION T–12. . . . . . . . . . . . . . HEADLIGHT LEVELING ACTUATOR
REMOVAL/INSTALLATION T–12. . . . . . . . . . . . . . . HEADLIGHT LEVELING ACTUATOR
INSPECTION T–13. . . . . . . . . . . . . . . . . . . . . . . . . . . REAR FOG LIGHT RELAY
REMOVAL/INSTALLATION T–14. . . . . . . . . . . . . . . REAR FOG LIGHT RELAY INSPECTION T–14. . . . RUNNING LIGHT RELAY
REMOVAL/INSTALLATION T–14. . . . . . . . . . . . . . . RUNNING LIGHT RELAY INSPECTION T–14/15. . . . .
INTERIOR LIGHTING SYSTEM T–16. . . . . . . . . . . . . . . INTERIOR LIGHT
REMOVAL/INSTALLATION T–16. . . . . . . . . . . . . . . INTERIOR LIGHT INSPECTION T–16. . . . . . . . . . . . DOOR SWITCH
REMOVAL/INSTALLATION T–17. . . . . . . . . . . . . . . DOOR SWITCH INSPECTION T–17. . . . . . . . . . . . . . PANEL LIGHT CONTROL SWITCH
REMOVAL/INSTALLATION T–17. . . . . . . . . . . . . . . PANEL LIGHT CONTROL SWITCH
INSPECTION T–18. . . . . . . . . . . . . . . . . . . . . . . . . . . WIPER AND WASHER T–19. . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION T–19. . . . . . . . . . . . . . .
WINDSHIELD WIPER MOTOR INSPECTION T–19. . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION T–19. . . . . . . . . . . . . . .
WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT T–19. . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD WIPER LINKREMOVAL/INSTALLATION T–20. . . . . . . . . . . . . . .
WINDSHIELD WASHER TANK REMOVAL/INSTALLATION T–20. . . . . . . . . . . . . . .
WINDSHIELD WASHER MOTOR REMOVAL/INSTALLATION T–20. . . . . . . . . . . . . . .
WINDSHIELD WASHER MOTOR INSPECTION T–20. . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD WASHER NOZZLE REMOVAL T–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD WASHER NOZZLE INSTALLATION T–20. . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD WASHER NOZZLE ADJUSTMENT T–21. . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD WASHER PIPE REMOVAL/INSTALLATION T–21. . . . . . . . . . . . . . .
WINDSHIELD WIPER AND WASHER SWITCH REMOVAL/INSTALLATION T–21. . . . . . .
WINDSHIELD WIPER AND WASHER SWITCH INSPECTION T–21. . . . . . . . . . . . . . . . . . .
WARNING AND INDICATOR SYSTEM T–22. . . . . . . . INSTRUMENT CLUSTER
REMOVAL/INSTALLATION T–22. . . . . . . . . . . . . . . INSTRUMENT CLUSTER
DISASSEMBLY/ASSEMBLY T–22. . . . . . . . . . . . . . INSTRUMENT CLUSTER INSPECTION T–22/24. . . . . INSTRUMENT CLUSTER REPAIR T–24. . . . . . . . . .
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POWER SYSTEM
T–2
WARNING AND INDICATOR LIGHT BULB REMOVAL/INSTALLATION T–24. . . . . . . . . .
FUEL GAUGE SENDER UNIT INSPECTION T–24/25. . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER TEMPERATURE SENDER UNIT REMOVAL T–25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER TEMPERATURE SENDER UNIT INSTALLATION T–25. . . . . . . . . . . . . . . . . . . . . . . . . .
WATER TEMPERATURE SENDER UNIT INSPECTION T–25. . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PRESSURE SWITCH INSPECTION T–25. . . . . HORN REMOVAL/INSTALLATION T–25. . . . . . . . . . HORN RELAY REMOVAL/INSTALLATION T–25/26. . . HORN RELAY INSPECTION T–26. . . . . . . . . . . . . . . CLOCK REMOVAL/INSTALLATION T–26. . . . . . . . .
AUDIO T–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUDIO UNIT REMOVAL T–26. . . . . . . . . . . . . . . . . . . AUDIO UNIT INSTALLATION T–26. . . . . . . . . . . . . . . SPEAKER REMOVAL/INSTALLATION T–26/27. . . . . . . SPEAKER INSPECTION T–27. . . . . . . . . . . . . . . . . . . ROOF ANTENNA REMOVAL T–27. . . . . . . . . . . . . . . ROOF ANTENNA INSTALLATION T–27. . . . . . . . . . ROOF ANTENNA INSPECTION T–27/28. . . . . . . . . . . . ANTENNA FEEDER
REMOVAL/INSTALLATION T–28. . . . . . . . . . . . . . . ANTENNA FEEDER INSPECTION T–28. . . . . . . . . .
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BODY ELECTRICAL SYSTEM
CONDENSER REMOVAL/INSTALLATION T–28. . .
123456567
POWER SYSTEM
T–3
POWER SYSTEMFUSE SERVICE CAUTION
Caution Determine and correct the cause of the
burnt fuse before replacing it with thespecified type. If the fuse is replaced beforedoing this, it may burn again.
MAIN FUSE REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
G6, WL, WL TURBO, F2 CIS
F2 CARB
1 Nut
2 Bolt
3 Main fuse
IGNITION SWITCH REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the column cover.3. Disconnect the ignition switch connectors.4. Remove the screw to remove the ignition switch.
IGNITIONSWITCH
SCREWIGNITIONSWITCHCONNECTOR
5. Install in the reverse order of removal.
IGNITION SWITCH INSPECTION1. Remove the column cover.2. Disconnect the ignition switch connectors.3. Inspect for continuity between the ignition switch
terminals using an ohmmeter.: Continuity
Ignition key Terminalg yposition 2A 2B 1D 1C 1B 1A
LOCK
ACC
ON
START
2A 2B
1B1C 1D 1A
2B 2A
1C 1A
1D 1B
START
ON ACCLOCK
START
ON ACCLOCK
4. If not as specified, replace the ignition switch.
KEY REMINDER SWITCH REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the column cover.3. Disconnect the key reminder switch connector.4. Remove the key reminder switch.
STEERINGLOCK
KEY REMINDERSWITCH
5. Install in the reverse order of removal.
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POWER SYSTEM
T–4
KEY REMINDER SWITCH INSPECTION1. Remove the column cover.2. Disconnect the key reminder switch connector.3. Inspect for continuity between the key reminder
switch terminals using an ohmmeter.: Continuity
Key positionTerminal
Key positionA B
Inserted
Removed
B A
B
A
4. If not as specified, replace the key reminder switch.
CIGARETTE LIGHTER REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the center panel.3. Remove in the order indicated in the table.4. Install in the reverse order of removal.
1 Cigarette lighter plug
2 Connector
3 Socket+ Removal Note
4 Ring
Socket Removal Note1. Pry up the stopper with a tape-wrapped
screwdriver.2. Pull the socket by prying up the stopper.
CIGARETTE LIGHTER INSPECTION Verify that the cigarette lighter plug will move
normally within 10—20 seconds , after pressingthe plug into the socket. If the plug does not move,replace the cigarette lighter.
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EXTERIOR LIGHTING SYSTEM
T–5
EXTERIOR LIGHTING SYSTEMFRONT COMBINATION LIGHTREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove the radiator grille.
(Refer to section S, EXTERIOR ATTACHMENT, RADIATOR GRILLE REMOVAL/INSTALLATION.)
3. Remove the front turn light. (Refer to FRONTTURN LIGHT REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.5. Install in the reverse order of removal.6. Adjust the headlight aiming.
(Refer to HEADLIGHT AIMING.)
1 Front combination light connector
2 Front combination light+ Removal Note
3 Spring
Front Combination Light Removal NoteRemoval with pliers
Caution When pressing the hook of the adjusting
screws and the screw with the pliers, do notdamage the front combination lightmounting.
1. Press the hook of the adjusting screws and thescrew with the pliers.
2. Pull the front combination light out of the adjustingscrews and the screw.
HOOK
SCREW
ADJUSTING SCREW
FRONT COMBINATION LIGHT MOUNTING
If it is difficult to remove front combination lightwith pliers Remove the adjusting screws and the screw by
loosening them.
SCREW
ADJUSTINGSCREW
ADJUSTINGSCREW
HEADLIGHT AIMING1. Adjust the tire air pressure to the specification.2. Position the unloaded vehicle on a level surface.3. Seat one person in the driver’s seat.4. Start the engine and charge the battery fully.5. Position the vehicle straight ahead and
perpendicularly to a wall.6. Set the headlights 7.6 m 25 ft from the wall.7. While adjusting one headlight, disconnect the
connector of the other.
Caution Always tighten the adjusting screws last.
When loosening the adjusting screws, loosenthe screws first and then tighten them.If the adjusting screws are tightened first,then loosened, they will continue to loosenwhen the vehicle is in motion and maycause the headlights to become misaligned.
8. Adjust the headlights by turning the adjustingscrews as shown in the figure. Loosen the screwsfirst, then tighten them.
UP
DOWN
OUT-WARD
IN-WARD
HEADLIGHT BULB REMOVAL/INSTALLATION
Caution A halogen bulb generates extremely high
heat when it is used. If the surface of thebulb is soiled, excessive heat will build upand the light’s life will be shortened. Whenreplacing the bulb, hold the metal flange,not the glass.
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EXTERIOR LIGHTING SYSTEM
T–6
1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
1 Headlight bulb connector
2 Cover+ Installation Note
3 Headlight bulb
Cover Installation Note Align the TOP mark with top side.
TOP MARK
PARKING LIGHT BULB REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
1 Socket
2 Parking light bulb
FRONT TURN LIGHT REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
1 Screw
2 Front turn light
3 Front turn light connector
FRONT TURN LIGHT BULBREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
1 Socket
2 Front turn light bulb
FRONT SIDE TURN LIGHTREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
FRONT
REAR
1 Front side turn light
2 Front side turn light connector
3 Socket
4 Front side turn light bulb
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EXTERIOR LIGHTING SYSTEM
T–7
REAR COMBINATION LIGHTREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
1 Screw
2 Rear combination light
3 Rear combination light connector
REAR COMBINATION LIGHT BULBREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove the rear combination light.3. Remove in the order indicated in the table.4. Install in the reverse order of removal.
1 Screw
2 Lens+ Removal Note
3 Rear turn light bulb
4 Back-up light bulb
5 Brake light/taillight bulb
Lens Removal Note Push the hook upward with your finger.
HOOK
REAR FOG LIGHT REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
WITHOUT REAR BUMPER
1 Rear fog light connector
2 Nut
3 Spring washer
4 Rear fog light
WITH REAR BUMPER
1 Rear fog light connector
2 Screw
3 Rear fog light
REAR FOG LIGHT BULBREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
1 Screw
2 Lens
3 Rear fog light bulb
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EXTERIOR LIGHTING SYSTEM
T–8
LICENSE PLATE LIGHT REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
1 Screw
2 License plate light
3 License plate light bulb
4 Socket
5 License plate light connector
COMBINATION SWITCH REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. For vehicles without air bag system, remove the
horn cap. For vehicles with air bag system, removethe driver-side air bag module. (Refer to AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)
3. Remove the steering wheel. (Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
4. For vehicles with air bag system, remove the clockspring. (Refer to AIR BAG SYSTEM, CLOCKSPRING REMOVAL/INSTALLATION.)
5. Remove the column cover.6. Remove in the order indicated in the table.7. Install in the reverse order of removal.
1 Screw
2 Combination switch
3 Combination switch connector
COMBINATION SWITCHDISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
1 Screw
2 Windshield wiper and washer switch
3 Light switch
4 Body
LIGHT SWITCH REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the column cover.3. Remove in the order indicated in the table.4. Install in the reverse order of removal.
1 Light switch connector
2 Screw
3 Light switch
LIGHT SWITCH INSPECTIONHeadlight Switch
1. Remove the light switch. (Refer to LIGHT SWITCH REMOVAL/INSTALLATION.)
Note When the flash-to-pass switch is on, the
contact of the low-high switch is at neutral.
2. Inspect for continuity between the light switchterminals using an ohmmeter.
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EXTERIOR LIGHTING SYSTEM
T–9
: ContinuitySwitch position Terminal
Light Dimmer Flash-to-pass
P(B)
D(N)
L(H)
F(J)
H(L)
OFF –Off
OFF –On
TNS –Off
TNS –On
Head LowOff
Head-light
LowOn
lightHigh –
( ): Light switch right side lever
N L H
OFFTNS
LOWHIGHFLASH-TO-PASS
HEAD-LIGHT
(O) (*)
D
H L P
F D
HEAD-LIGHT
OFF
TNS
(J) (N)
(L) (H) (B)
*(M)*
(K)* E
(*) C
(*) A
(*) P
(J)*
(B)*
(*) F
( ): LIGHT SWITCH RIGHT SIDE LEVER
3. If not as specified, replace the light switch.
Turn Switch1. Remove the light switch.
(Refer to LIGHT SWITCH REMOVAL/INSTALLATION.)2. Inspect for continuity between the light switch
terminals using an ohmmeter.: Continuity
Switch positionTerminal
Switch positionC (M) A (K) E (O)
Right
Off
Left( ): Light switch right side lever
N L H
(O) (*)
D
* (M)*(K)* E
(*) C
(*) A
(*) P (J)*
(B)*
(*) F
( ): LIGHT SWITCH RIGHT SIDE LEVER
C
(M)
A E
(O)(K)
3. If not as specified, replace the light switch.
HAZARD WARNING SWITCHREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove the meter hood.
(Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.)
3. Remove as indicated in the table.4. Install in the reverse order of removal.
HOOK
1 Hazard warning switch
HAZARD WARNING SWITCH INSPECTION1. Remove the meter hood.
(Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.)
2. Inspect for continuity between the hazard warningswitch terminals using an ohmmeter.
: Continuity : Bulb
Switch Terminalposition F D B A C I K H J
Off
On
H
K I C A
* J D BFH
K F D
BAJ I
C
C
3. If not as specified, replace the hazard warningswitch.
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EXTERIOR LIGHTING SYSTEM
T–10
REAR FOG LIGHT SWITCH REMOVAL1. Disconnect the negative battery cable.2. Insert your hand under the dashboard near the
fuse block, grasp the hooks of the rear fog lightswitch and pull it forward to remove it.
3. Disconnect the connector to remove the rear foglight switch.
CONNECTOR
REAR FOGLIGHT SWITCH
HOOK
REAR FOG LIGHT SWITCH INSTALLATION1. Connect the rear fog light switch connector.2. Insert the rear fog light switch in the hole to install
it.3. Connect the negative battery cable.
REAR FOG LIGHT SWITCH INSPECTION1. Remove the rear fog light switch. (Refer to REAR
FOG LIGHT SWITCH REMOVAL/INSTALLATION.)2. Inspect for continuity between the rear fog light
switch terminals using an ohmmeter.: Continuity
Switch positionTerminal
Switch positionA D F
Off
Neutral
On
F
A D
F D
A
3. If not as specified, replace the rear fog light switch.
HEADLIGHT LEVELING SWITCH REMOVAL1. Disconnect the negative battery cable.2. Insert your hand under the dashboard near the
fuse block, grasp the hooks of the headlightleveling switch and pull it forward to remove it.
3. Disconnect the connector to remove the headlightleveling switch.
HOOK
CONNECTOR
HEADLIGHT LEVELING SWITCH
HEADLIGHT LEVELING SWITCH INSTALLATION1. Connect the headlight leveling switch connector.2. Insert the headlight leveling switch in the hole to
install it.3. Connect the negative battery cable.
HEADLIGHT LEVELING SWITCH INSPECTION1. Remove the headlight leveling switch.
(Refer to HEADLIGHT LEVELING SWITCHREMOVAL/INSTALLATION.)
2. Inspect for continuity between the headlightleveling switch terminals using an ohmmeter.
: Continuity : Resistance : Bulb
Switch positionTerminal
Switch positionC D A B
00
11
22
33
R1:1600 Ω 2: 560 Ω 3:300 Ω
* * * D
* C A
B
C
B
A
D
0 1 2 3
R1 R2 R3
3. If not as specified, replace the headlight levelingswitch.
R3
R2+R3
R2+ R3R1+
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EXTERIOR LIGHTING SYSTEM
T–11
BACK-UP LIGHT SWITCHREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
R
N·m kgf·m, ft·lbf
25—34 2.5—3.4, 19—24
1 Back-up light switch connector
2 Back-up light switch
3 Gasket
BACK-UP LIGHT SWITCH INSPECTION1. Disconnect the back-up light switch connector.2. Inspect for continuity between the back-up light
switch terminals using an ohmmeter.: Continuity
Shift lever Terminalposition A B
Reverse
Other
A
B
BA
3. If not as specified, replace the back-up light switch.
FLASHER UNIT REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
DRIVER-SIDEFRONT SIDE TRIM
1 Nut
2 Flasher unit
3 Flasher unit connector
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EXTERIOR LIGHTING SYSTEM
T–12
FLASHER UNIT INSPECTION1. Measure the voltage at the flasher unit terminals as indicated below.2. Disconnect the flasher unit connector before inspecting for continuity at terminal C.3. If not as specified, inspect the parts listed under “Inspection area” and the related wiring harnesses.4. If the parts and wiring harnesses are okay but the system still does not work properly, replace the flasher unit.
Terminal Voltage List (Reference)B+: Battery positive voltage
C
A
B
Terminal Signal Connection Test condition Voltage (V)/Continuity
Inspection area
Hazard warning switch onAlternatesB+ and 0
Hazard
A Flasher unit output
Hazard warningswitch Hazard warning
Ignition switch atON position
B+ Hazard warning switch Turn signalout ut switch Hazard warning
switch off Ignition switch atLOCK or ACCposition
0
Turn signallight
Hazard warning switch on B+ HAZARD 10 A
B Power supplyHazard warning
Hazard warning
Ignition switch atON position
B+
HAZARD 10 Afuse
METER 15 AB Power su ly
switch Hazard warningswitch off Ignition switch at
LOCK or ACCposition
0
fuse Hazard warning switch
CFlasher unitground
GNDConstant: inspect for continuity toground
Yes GND
HEADLIGHT LEVELING ACTUATORREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove the radiator grille.
(Refer to section S, EXTERIOR ATTACHMENT, RADIATOR GRILLE REMOVAL/INSTALLATION.)
3. Remove the front turn light. (Refer to FRONT TURN LIGHT REMOVAL/INSTALLATION.)
4. Remove the front combination light. (Refer to FRONT COMBINATION LIGHTREMOVAL/INSTALLATION.)
5. Remove the headlight leveling actuator connectorfrom the bracket.
6. Disconnect the headlight leveling actuatorconnector.
7. Remove the nuts.8. Remove the headlight leveling actuator.
HEADLIGHTLEVELINGACTUATOR
HEADLIGHT LEVELING ACTUATOR CONNECTOR
9. Install in the reverse order of removal.
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EXTERIOR LIGHTING SYSTEM
T–13
HEADLIGHT LEVELING ACTUATOR INSPECTION1. Measure the voltage at the headlight leveling actuator terminals as indicated below.
Note Because the headlight leveling actuator connector is waterproof, it is impossible to measure the voltage at
the headlight leveling actuator terminals. When inspecting, measure the voltage at the terminal of the partwhich is connected to the headlight leveling actuator.
(1) To measure the voltage at the terminal A of the headlight leveling actuator, remove the column cover andmeasure the voltage at the terminal N of the light switch connector.(Refer to LIGHT SWITCH INSPECTION.)
(2) To measure the voltage at the terminal B of the headlight leveling actuator, remove the headlight levelingswitch with the connector connected and measure the voltage at the terminal C of the headlight levelingswitch connector. (Refer to HEADLIGHT LEVELING SWITCH INSPECTION.)
(3) Disconnect the headlight leveling actuator connector before inspecting for continuity at terminal C.2. If not as specified, inspect the parts listed under “Inspection area” and the related wiring harnesses.3. If the parts and wiring harnesses are okay but the system still does not work properly, replace the headlight
leveling actuator.
Terminal Voltage List (Reference)B+: Battery positive voltage
A B C
Terminal Signal Connection Test condition Voltage ( V )/Continuity
Inspection area
A
Headlight leveling Combination
Headlight illuminated B+Combination switchA
gactuator power supply
switchHeadlight unilluminated 0
Combination switch
Headlight levelingswitch at 0
6.2
BHeadlight leveling switch
Headlight HeadlightHeadlight levelingswitch at 1
4.2Headlight leveling switchB leveling switch
position
gleveling switch
gswitch on Headlight leveling
switch at 22.1
Headlight leveling switch
Headlight levelingswitch at 3
0
C
Headlightleveling actuatorground
GNDConstant : inspect for continuityto ground
Yes GND
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EXTERIOR LIGHTING SYSTEM
T–14
REAR FOG LIGHT RELAYREMOVAL/INSTALLATION
Note Because the lock section of the relay is
damaged easily, do not remove the relay fromthe bracket unless replacement is necessary.Always perform an inspection of the rear foglight relay before removal.
1. Disconnect the negative battery cable.2. Disconnect the rear fog light relay connector.3. Remove the rear fog light relay by prying the lock
section of the upper part with a flatheadscrewdriver.
BRACKET
REAR FOGLIGHT RELAY
REAR FOG LIGHTRELAY CONNECTOR
4. Install in the reverse order of removal.
REAR FOG LIGHT RELAY INSPECTION1. Remove the bracket and pull it toward you.2. Inspect for continuity between the rear fog light
relay terminals using an ohmmeter.: Continuity B+: Battery positive voltage
StepTerminal
StepA B C D
1
2 B+ GND
C A
D B
C A
D B
3. If not as specified, replace the rear fog light relay.
RUNNING LIGHT RELAY REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the washer tank from the bracket.3. Remove the running light relay with the cover
attached.
RUNNING LIGHTRELAY WITH COVER
NUT
4. Remove the cover.5. Disconnect the running light relay connector.
COVER
RUNNING LIGHTRELAY
RUNNING LIGHTRELAY CONNECTOR
6. Install in the reverse order of removal.
RUNNING LIGHT RELAY INSPECTION1. Remove the running light relay.
(Refer to RUNNING LIGHT RELAYREMOVAL/INSTALLATION.)
2. Inspect for continuity between the running lightrelay terminals using an ohmmeter.
: Continuity : DiodeTest
condiTerminal
cond -tion A B C D E F
Constant
B C A
F E D
AC
BD
E
F
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EXTERIOR LIGHTING SYSTEM
T–15
3. Connect the terminal A to the positive batteryterminal and the terminal D to the negative batteryterminal.
4. Verify that there is continuity between terminals Aand E, and that there is no continuity betweenterminals B and F.
AC
BD
E
F
B C A
F E D
5. Connect the terminal C to the positive batteryterminal and the terminal D to the negative batteryterminal.
6. Verify that there is no continuity between terminalsB and F, and between terminals A and E.
AC
BD
E
F
B C A
F E D
7. If not as specified, replace the running light relay.
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INTERIOR LIGHTING SYSTEM
T–16
INTERIOR LIGHTING SYSTEMINTERIOR LIGHT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
ALL VEHICLES EXCEPTREGULAR CAB
REGULAR CAB
1 Lens+ Removal Note
2 Interior light bulb
3 Screw
4 Spacer
5 Interior light+ Installation Note
6 Interior light connector
Lens Removal NoteAll vehicles except regular cab
1. Insert a tape-wrapped flathead screwdriver into thelens.
2. Twist the screwdriver to remove the lens.
Regular cab Push the areas indicated by the arrows to pull out
the lens.
Interior Light Installation NoteRegular cab
Note The spacer acts as a ground. If the spacer is
not installed in the position shown in the figure,the interior light may not illuminate.
1. Tighten the screw fully. (More than 4 mm 0.2 inof thread should be exposed.)
2. Install the interior light.
SCREW
SPACERINTERIOR LIGHT
4.0 mm0.2 in
INTERIOR LIGHT INSPECTION1. Remove the interior light.
(Refer to INTERIOR LIGHT REMOVAL/INSTALLATION.)2. Inspect for continuity between the interior light
terminals using an ohmmeter. : Bulb
StepTerminal
StepA B Body GND
ON
DOOR
OFF
ONOFF
DOOR
A
B
A B
3. If not as specified, replace the interior light.
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INTERIOR LIGHTING SYSTEM
T–17
DOOR SWITCH REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
1 Screw
2 Door switch
3 Door switch connector
DOOR SWITCH INSPECTION1. Remove the door switch.2. Inspect for continuity between the door switch
terminals using an ohmmeter.: Continuity
Switch conditionTerminal
Switch conditionA Body GND
Pressed
Released
A A
BODY GND
3. If not as specified, replace the door switch.
PANEL LIGHT CONTROL SWITCHREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove the meter hood.
(Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.)
3. Remove as indicated in the table.4. Install in the reverse order of removal.
HOOK
1 Panel light control switch
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INTERIOR LIGHTING SYSTEM
T–18
PANEL LIGHT CONTROL SWITCH INSPECTION1. Remove the meter hood without disconnecting the panel light control switch connector.
(Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.)2. Measure the voltage at the panel light control switch as indicated below.3. Disconnect the panel light control switch connector before inspecting for continuity at terminal G.4. If not as specified, inspect the parts listed under “Inspection area” and the related wiring harnesses.5. If the parts and wiring harnesses are okay but the system still does not work properly, replace the panel light
control switch.
Terminal Voltage List (Reference)B+: Battery positive voltage
G
H F D B
A
Terminal Signal Connection Test condition Voltage (V)/Continuity
Inspection area
APanel light control output
Each illumination
Inspect using an oscilloscope+ A terminal inspection
— Each illumination
B — Not used — — —
DPower supply
Light switchHeadlight switch at TNS or headlight position
B+ Light switch TAIL 10 A fusesupply
gHeadlight switch at OFF position 0
TAIL 10 A fuse
F — Not used — — —
G
Panel light controlswitchground
GNDConstant: Inspect for continuity toground
Yes GND
H — Not used — — —
A Terminal Inspection1. Measure the wave pattern of the A terminal on the
panel light control switch using an oscilloscope.
PANEL LIGHTCONTROL SWITCH OSCILLOSCOPE
2. Set the headlight switch to either the TNS orheadlight position.
3. Set the panel light control switch to the brightestposition.
4. Verify that the pattern of the screen is as shown inthe figure.
V
0
5. Verify that the pattern on the screen matches thepattern shown in the figure as the panel lightcontrol switch is gradually turned to the darkestposition.
B+
01—3.2 ms
5—15.4 ms
V
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WIPER AND WASHER
T–19
WIPER AND WASHERWINDSHIELD WIPER MOTORREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Disconnect the connector.3. Loosen the bolts.4. Pull the windshield wiper motor forward until the
connection between the windshield wiper motorand windshield wiper link is in the engine room.
5. Pry off the connection between the windshieldwiper motor and windshield wiper link.
6. Remove the windshield wiper motor.
4.0—6.8 40—70, 35—60
WINDSHIELD WIPER MOTOR
CONNECTOR
WINDSHIELDWIPER LINK BOLT
N·m kgf·cm, in·lbf
7. Install in the reverse order of removal.
WINDSHIELD WIPER MOTOR INSPECTION1. Disconnect the windshield wiper motor connector.2. Connect battery positive voltage and inspect the
operation of the windshield wiper motor asindicated below.
Terminal Operation
A High
C Low
A
B
C
D
3. Connect battery positive voltage to terminal C ofthe windshield wiper motor to operate thewindshield wipers at low speed.
4. Disconnect battery positive voltage from terminal Cof the motor while the wipers are operating.
5. Verify that the wipers do not stop in the parkposition.
6. Short between terminal C and B of the motor, andconnect battery positive voltage to terminal D ofthe motor.
7. Verify that the wipers operate at low speed again,then stop in the park position.
8. If not as specified, replace the windshield wipermotor.
WINDSHIELD WIPER ARM AND BLADEREMOVAL/INSTALLATION
1. Remove in the order indicated in the table.2. Install in the reverse order of removal.3. Adjust the windshield wiper arm and blade.
(Refer to WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT.)
16—191.6—2.0,12—14
N·m kgf·m, ft·lbf
1 Cap
2 Nut
3 Windshield wiper arm+ Installation Note
4 Windshield wiper blade
5 Rubber brush
Windshield Wiper Arm Installation Note Clean the windshield wiper arm connector shafts
with a wire brush before installing the windshieldwiper arms.
WINDSHIELD WIPER ARM CONNECTOR SHAFT
WINDSHIELD WIPER ARM AND BLADEADJUSTMENT
1. Operate the windshield wiper motor to set thewindshield wipers in the park position.
2. Align both ends of the wiper blades to the markson the ceramic section.
CERAMIC SECTION
MARK
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WIPER AND WASHER
T–20
WINDSHIELD WIPER LINKREMOVAL/INSTALLATION
1. Remove the windshield wiper arm and blade.(Refer to WINDSHIELD WIPER ARM AND BLADEREMOVAL/INSTALLATION.)
2. Remove the cowl grille.3. Remove the windshield wiper motor.
(Refer to WINDSHIELD WIPER MOTORREMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.5. Install in the reverse order of removal.6. Adjust the windshield wiper arm and blade.
(Refer to WINDSHIELD WIPER ARM AND BLADEADJUSTMENT.)
N·m kgf·cm, in·lbf
6.87—9.80 70—100, 60.8—86.7
1 Bolt
2 Windshield wiper link
WINDSHIELD WASHER TANKREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Disconnect the connector.3. Disconnect the windshield washer pipe from the
windshield washer motor.4. Pull the windshield washer tank up and slide it off
the bracket.
WINDSHIELDWASHER TANK
BRACKET
WINDSHIELDWASHER PIPE
CONNECTOR
5. Install in the reverse order of removal.
WINDSHIELD WASHER MOTORREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove the windshield washer tank.3. Remove in the order indicated in the table.4. Install in the reverse order of removal.
1 Windshield washer motor
2 Grommet
WINDSHIELD WASHER MOTOR INSPECTION1. Disconnect the windshield washer motor
connector.2. Connect battery positive voltage to terminal B and
ground to terminal A of the motor.3. Verify that the windshield washer motor operates.
B
M
A
A
B
4. If the motor does not operate, replace thewindshield washer motor.
WINDSHIELD WASHER NOZZLE REMOVAL1. Disconnect the windshield washer pipe from the
windshield washer nozzle.2. Remove the windshield washer nozzle using a 10
mm 0.4 in deep socket wrench from underneaththe bonnet.
DEEP SOCKET WRENCH WINDSHIELD WASHER NOZZLE
WINDSHIELD WASHER NOZZLE INSTALLATION1. Connect the windshield washer pipe to the
windshield washer nozzle.2. Push the windshield washer nozzle into the
installation hole.3. Adjust the windshield washer nozzle. (Refer to
WINDSHIELD WASHER NOZZLE ADJUSTMENT.)
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123
WIPER AND WASHER
T–21
WINDSHIELD WASHER NOZZLE ADJUSTMENT Insert a needle or equivalent tool into the spray
holes of the windshield washer nozzle and adjustthe nozzle direction as shown.
mm in
MOLDINGEND LINE
WINDSHIELDGLASS END LINE
CENTER
390 15.4320 12.6
1003.9
1003.9
1807.1
27010.6
29011.4
29011.4
WINDSHIELD WASHER PIPEREMOVAL/INSTALLATION
1. Disconnect the windshield washer pipe from thewindshield washer nozzle and the windshieldwasher motor.
2. Remove the clips.3. Remove the windshield washer pipe.
CLIP WINDSHIELDWASHER PIPE
4. Install in the reverse order of removal.
WINDSHIELD WIPER AND WASHER SWITCHREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove the column cover.3. Disconnect the connector.4. Remove the screws.5. Remove the windshield wiper and washer switch.
SCREW
WINDSHIELDWIPER ANDWASHERSWITCH
CONNECTOR
6. Install in the reverse order of removal.
WINDSHIELD WIPER AND WASHER SWITCHINSPECTION
1. Remove the column cover.2. Remove the windshield wiper and washer switch.3. Inspect for continuity between the windshield wiper
and washer switch terminals using an ohmmeter.: Continuity
One-Terminal
Switch positionOne-touch L(F)
G(E)
M(C)
N(D)
C(M)
OFFOff
Wiper
OFFOn
Wiperswitch
INTswitch
LO
HI
Washerswitch
On
( ): Wiper and washer switch left side lever
HI HILO
LO
OFFOFF
INTINT
INTRELAY
WIPERSWITCH
ONE-TOUCH
WASHERSWITCH
(D)
N
L
(F)
M
(C)
G
(E)
C
(M)
0 (*)
* N (*)
L (*)
H (*)
G (*)
*
M * (E) C
* (A)
* (F)
* (J)
H
(J)
* (D)
( ): WIPER AND WASHER SWITCH LEFT SIDE LEVER
4. If not as specified, replace the windshield wiperand washer switch.
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WARNING AND INDICATOR SYSTEM
T–22
WARNING AND INDICATOR SYSTEMINSTRUMENT CLUSTER REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove the meter hood.
(Refer to section S, DASHBOARD AND CONSOLE,METER HOOD REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.4. Install in the reverse order of removal.
1 Screw
2 Instrument cluster connector
3 Instrument cluster
INSTRUMENT CLUSTERDISASSEMBLY/ASSEMBLY
Caution If the print plate on the back of the
instrument cluster is damaged, the systemwill not operate properly and it may becomethe cause of trouble or malfunction.
1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
1 Screw
2 Bulb
3 Alarm
4 Front lens
5 Instrument cluster
INSTRUMENT CLUSTER INSPECTIONSpeedometer
1. Adjust the tire air pressure to the specification.2. Using a speedometer tester, verify that the
speedometer indication is within the allowablerange indicated in the table.
Speedometer tester Allowable range (km/h)pindication (km/h)
Allowable range (km/h)
20 18—22
40 36—44
60 54—66
80 72—88
100 90—110
120 108—132
140 126—154
160 144—176
180 162—198
3. Verify that fluctuation of the speedometer needle iswithin the allowable range.
Needle fluctuation allowable rangeWithin 0.5 km/h
4. If the speedometer needle does not move or if theindication is outside of the allowable range, inspectthe vehicle speedometer sensor and related wiringharness.
5. If the vehicle speedometer sensor and relatedwiring harness are normal, replace the instrumentcluster.
TachometerUsing the SSTs (NGS kit) or a dwell tacho tester
Caution If the engine speed exceeds the allowable
range, the engine could be damaged.Therefore, when inspecting the tachometer,do not allow the engine speed to exceed theallowable range indication on thetachometer.
1. Follow the appropriate procedure for using theSSTs (NGS kit) or dwell tacho tester.
Using the SSTs (NGS kit)(1) Connect the SSTs (NGS kit) to the data link
connector and battery.
DIAGNOSTIC PROGRAM CARD
NGS KIT
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R1
R2
R1
R2
WARNING AND INDICATOR SYSTEM
T–23
(2) Select “VEHICLE & ENGINE SELECTION” andpress TRIGGER. (Select the model andspecifications of the vehicle you are testing.)
(3) Select “PCM-POWERTRAIN CTRL MODULE”and press TRIGGER.
(4) Select “PID/DATA MONITOR AND RECORD”and press TRIGGER.
(5) Select “RPM” and press TRIGGER.(6) Press START.
Using a dwell tacho tester Connect a dwell tacho tester to the terminals K and
B of the PCM connector.
2. Verify that the tachometer indication is within theallowable range indicated in the table.
Dwell tacho tester Allowable range (rpm)indication (rpm)
Allowable range (rpm)
650 583—705
1000 926—1060
2000 1954—2120
3000 2980—3180
4000 4008—4240
3. If the tachometer needle does not move or if theindication is outside of the allowable range, inspectthe PCM and related wiring harness.
4. If the PCM and related wiring harness are normal,replace the instrument cluster.
Fuel Gauge1. Disconnect the fuel gauge sender unit connector.2. Connect the red lead of SST (Fuel And
Thermometer checker) to terminal B of the fuelgauge sender unit connector and black lead toground.
3. Set the resistance of SST (Fuel And Thermometerchecker) to 180 Ω.
*
C B
49 N088 0A0
49 0839 285
4. Turn the ignition switch to ON position.5. Verify that the needle is below E.6. Turn the ignition switch to LOCK position.7. Set the resistance of SST (Fuel And Thermometer
checker) to 10 Ω.8. Turn the ignition switch to ON position.9. Verify that the needle is above F.
10. If the needle does not move or moves irregularly,remove the instrument cluster. (Refer to INSTRUMENT CLUSTERREMOVAL/INSTALLATION.)
11. Measure the resistance between the fuel gaugeterminals using an ohmmeter.
: Resistance
StepTerminal
StepFUEL + FUEL – GND COM
1
2R1, R2: 140—200 Ω
FUEL+
FUEL–
GND
COM
12. Verify that the difference in resistance between R1and R2 is less than 6 Ω.
13. If not as specified, replace the instrument cluster.
Water Temperature Gauge1. Disconnect the water temperature sender unit
connector.2. Turn the ignition switch to ON position.3. Verify that the needle is below C.4. Ground terminal A of the water temperature sender
unit’s vehicle side connector.
A
5. Verify that the needle is above H.6. If the needle does not move or moves irregularly,
remove the instrument cluster.(Refer to INSTRUMENT CLUSTERREMOVAL/INSTALLATION.)
7. Measure the resistance between the watertemperature gauge terminals using an ohmmeter.
: Resistance
StepTerminal
StepTEMP + TEMP – V+ COM
1
2R1, R2: 140—200 Ω
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WARNING AND INDICATOR SYSTEM
T–24
TEMP+
COM
TEMP–V+
8. Verify that the difference in resistance between R1and R2 is less than 6 Ω.
9. If not as specified, replace the instrument cluster.
INSTRUMENT CLUSTER REPAIR
Note The needle of speedometer or tachometer may
continue to rotate clockwise until it rests on themask plate. If a customer complains of thisconcern, repair the needle position accordingto the following steps.
1. Verify the concern.
TACHOMETER SPEEDOMETER
2. Turn the ignition switch to LOCK position.3. Remove the ROOM fuse, then wait for 10 minutes
or more until the power supply in the instrumentcluster is spent.
4. Turn the ignition switch to ON position.5. Verify that the needle returns to zero.
TACHOMETER SPEEDOMETER
6. After the needle returns to zero, install the ROOMfuse with the ignition switch at ON position. If theneedle does not return to zero, remove the frontlens and carefully move the needle to zero byhand. (Refer to INSTRUMENT CLUSTERDISASSEMBLY/ASSEMBLY.)
WARNING AND INDICATOR LIGHT BULBREMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Remove the instrument cluster.
(Refer to INSTRUMENT CLUSTERREMOVAL/INSTALLATION.)
3. Turn the socket counterclockwise to remove thebulb as shown in the figure.
BULB
4. Install in the reverse order of removal.
FUEL GAUGE SENDER UNIT INSPECTION1. For G6, F2 CIS, or F2 Carb engine vehicles, remove
the fuel pump unit. (Refer to section F2, FUELSYSTEM, FUEL TANK REMOVAL/INSTALLATION.) For WL or WL Turboengine vehicles, remove the fuel gauge sender unit.(Refer to section F2, FUEL SYSTEM, FUEL TANKREMOVAL/INSTALLATION.)
2. Using an ohmmeter, measure and verify that theresistance between terminals B and C (WL, WLTurbo) or A and B (G6, F2 CIS, F2 Carb) of the fuelgauge sender unit is as shown in the followingchart while slowly moving the unit arm from emptyto full.
Measuring point Resistance ( Ω)
Full 18.4—26.4
1/2 81.5—93.5
Empty 136—154
253.7 9.988
EMPTY
FULL
1/2
169.7 6.681 *
87.0 3.43 *
B
mm in
C*
* DOUBLE CAB2WD, STRETCHCAB 2WD65.5 2.58
158.1 6.224
WL, WL TURBO
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WARNING AND INDICATOR SYSTEM
T–25
255.7 10.067
EMPTY
FULL
1/2
B
mm in
A
67.5 2.66
160.1 6.303
G6, F2 CIS, F2 CARB
3. If not as specified, replace the fuel gauge senderunit. (Refer to section F2, FUEL SYSTEM, FUEL TANK
FUEL SYSTEM, FUEL PUMP UNIT
FUEL SYSTEM, FUEL PUMP UNITREMOVAL/INSTALLATION.)
WATER TEMPERATURE SENDER UNIT REMOVAL1. Disconnect the negative battery cable.2. Disconnect the connector.3. Remove the water temperature sender unit.
CONNECTOR
WATER TEMPERATURESENDER UNIT
WATER TEMPERATURE SENDER UNITINSTALLATION
1. Apply sealant from the third thread to the topthread.
6—80.24—0.31
THIRD THREAD
mm in
2. Install the water temperature sender unit.
Tightening torque11.8—17.6 N·m
120—180 kgf·cm, 105—156 in·lbf
3. Connect the water temperature sender unitconnector.
4. Connect the negative battery cable.
WATER TEMPERATURE SENDER UNITINSPECTION
1. Remove the water temperature sender unit.2. Place the sender unit in a container of water.3. Heat the water gradually.4. Using an ohmmeter, measure and verify that the
resistance between terminal of the sender unit andthe sender unit body is as shown below.
Water temperature ( °C °F ) Resistance ( Ω)
49.8—50.2 121.7—122.3 189.4—259.6
5. If not as specified, replace the water temperaturesender unit.
OIL PRESSURE SWITCH INSPECTION1. Verify that the oil pressure warning light illuminates
when the ignition switch is turned to ON position.2. Verify that the oil pressure warning light goes off
when the engine is started.3. If the oil pressure warning light does not illuminate
or remains illuminated, inspect the oil pressurewarning light bulb and related wiring harness.
4. If the oil pressure warning light bulb and relatedwiring harness are normal, inspect the oil pressure.(Refer to section D, LUBRICATION SYSTEM, OILPRESSURE INSPECTION.)
5. If the oil pressure is normal, replace the oilpressure switch.
HORN REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Disconnect the horn connector.3. Remove the bolt.4. Remove the horn.
HORN
BOLT
HORN CONNECTOR
5. Install in the reverse order of removal.
HORN RELAY REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the driver-side front side trim.
(Refer to section S, TRIM, FRONT SIDE TRIMREMOVAL/INSTALLATION.)
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CONTINUED
REMOVAL/INSTALLATION.) (Refer to section F2,DISASSEMBLY/ASSEMBLY.) (Refer to section F2,
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WARNING AND INDICATOR SYSTEM, AUDIO
T–26
3. Remove in the order indicated in the table.4. Install in the reverse order of removal.
1 Nut
2 Horn relay connector
3 Horn relay
HORN RELAY INSPECTION1. Remove the horn relay.
(Refer to HORN RELAY REMOVAL/INSTALLATION.)2. Inspect for continuity between the horn relay
terminals using an ohmmeter.: Continuity B+: Battery positive voltage
StepTerminal
StepA B C D
1
2 B+ GND
AD
C B
A
BD
C
3. If not as specified, replace the horn relay.
CLOCK REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the meter hood.
(Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.)
3. Remove the screws and remove the clock.
CLOCK SCREWSCREW
4. Install in the reverse order of removal.
AUDIOAUDIO UNIT REMOVAL
1. Disconnect the negative battery cable.2. With the beveled parts of the SST (Removing tool)
facing inward, insert them into the unit.3. Pull the SST (Removing tool) outward and
rearward to slide out the unit.
49 D066 801A
4. Disconnect the connectors and antenna jack.
AUDIO UNIT INSTALLATION
Caution If the harness or the antenna feeder is
caught between the unit and dashboard, itmay become the cause of trouble ormalfunctions. Make certain that the wiringharness and antenna feeder are not caughtbetween the unit and dashboard.
1. Connect the connectors and antenna jack.2. Insert the unit until each clip clicks.3. Connect the negative battery cable.
SPEAKER REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the front door trim.
(Refer to section S, TRIM, FRONT DOOR TRIMREMOVAL/INSTALLATION.)
Caution When removing or installing a speaker,
touching the radio cone paper could causepoor sound quality. When removing orinstalling a speaker, hold the speaker’sbracket and handle with care.
3. Remove in the order indicated in the table.4. Install in the reverse order of removal.
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123456567
R
123456567
AUDIO
T–27
1 Screw
2 Speaker+ Installation Note
3 Connector
Speaker Installation Note When installing the speakers, position the
speakers so that the terminals face downward.
SPEAKER INSPECTION1. Remove the speaker.
(Refer to SPEAKER REMOVAL/INSTALLATION.)2. Inspect for resistance between the speaker
terminals using an ohmmeter.
: Resistance
Test conditionTerminal
Test conditionA B
ConstantR: 4 Ω
3. Touch the leads of an ohmmeter to the speakerterminals and verify that the speaker clicks.
Range1 Ω
4. If not as specified, replace the speaker.
ROOF ANTENNA REMOVAL1. Disconnect the negative battery cable.2. Remove the driver-side front side trim.
(Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.)
3. Disconnect the connection between the roofantenna and the antenna feeder.
ROOF ANTENNA
ANTENNAFEEDER
4. Remove the screws and pull out the roof antenna.
ROOF ANTENNA
SCREW
ROOF ANTENNA INSTALLATION1. Tape the antenna jack to the antenna drain hose.
2. Pass the roof antenna and antenna drain hosethrough the A-pillar from the hole in the roof.
3. Connect the antenna feeder.4. Install the screws.5. Install the driver-side front side trim.
(Refer to section S, TRIM, FRONT SIDE TRIMREMOVAL/INSTALLATION.)
6. Connect the negative battery cable.
ROOF ANTENNA INSPECTION1. Disconnect the negative battery cable.2. Remove the driver-side front side trim.
(Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.)
3. Disconnect the connection between the roofantenna and the antenna feeeder.
4. Verify that there is no continuity between roofantenna terminals A and B using an ohmmeter.
5. Inspect for continuity between the roof antennaterminals using an ohmmeter.
: Continuity
StepTerminal
StepA B C D
1
2
B
A
C
D
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123456567
AUDIO
T–28
6. If not as specified, replace the roof antenna.
ANTENNA FEEDER REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the driver-side front side trim.
(Refer to section S, TRIM, FRONTSIDE TRIM REMOVAL/INSTALLATION.)
3. Disconnect the connection between the antennafeeder and the roof antenna.
4. Remove in the order indicated in the table.5. Install in the reverse order of removal.
1 Clip
2 Antenna feeder
ANTENNA FEEDER INSPECTION1. Disconnect the negative battery cable.2. Remove the driver-side front side trim.
(Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.)
3. Disconnect the connection between the antennafeeder and the roof antenna.
4. Verify that there is no continuity between theantenna feeder terminals A and B using anohmmeter.
5. Inspect for continuity between the antenna feederterminals using an ohmmeter.
: Continuity
StepTerminal
StepA B C D
1
2
CDB
A
6. If not as specified, replace the antenna feeder.
CONDENSER REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
IGNITIONCOIL
1 Screw
2 Clip
3 Nut
4 Condenser
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U–1
HEATER AND AIRCONDITIONER SYSTEMS
SERVICE WARNINGS U–2. . . . . . . . . . . . . . . . . . . . . . . HANDLING REFRIGERANT U–2. . . . . . . . . . . . . . . . STORING REFRIGERANT U–2. . . . . . . . . . . . . . . . .
SERVICE CAUTIONS U–2. . . . . . . . . . . . . . . . . . . . . . . HANDLING COMPRESSOR OIL U–2. . . . . . . . . . . .
REFRIGERANT SYSTEM SERVICE PROCEDURES U–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANIFOLD GAUGE SET INSTALLATION U–3. . . . RECOVERY U–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING U–3/5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REFILLING U–5/6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REFRIGERANT CHARGE CHECK U–6/7. . . . . . . . . . REFRIGERANT PRESSURE CHECK U–7. . . . . . . PERFORMANCE TEST U–7. . . . . . . . . . . . . . . . . . . .
BASIC SYSTEM U–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . STRUCTURAL VIEW U–8/9. . . . . . . . . . . . . . . . . . . . . . BLOWER UNIT REMOVAL/INSTALLATION U–10. . BLOWER UNIT DISASSEMBLY/ASSEMBLY U–10. COOLING UNIT REMOVAL/INSTALLATION U–10/11. . COOLING UNIT DISASSEMBLY/ASSEMBLY U–12. EVAPORATOR INSPECTION U–13. . . . . . . . . . . . . . HEATER UNIT REMOVAL/INSTALLATION U–13. . . HEATER UNIT DISASSEMBLY/ASSEMBLY U–14. . HEATER CORE INSPECTION U–15. . . . . . . . . . . . . . A/C COMPRESSOR
REMOVAL/INSTALLATION U–15. . . . . . . . . . . . . . . CONDENSER REMOVAL/INSTALLATION U–16. . . CONDENSER INSPECTION U–16. . . . . . . . . . . . . . . RECEIVER/DRIER
REMOVAL/INSTALLATION U–16/17. . . . . . . . . . . . . . . REFRIGERANT LINES
REMOVAL/INSTALLATION U–17/18. . . . . . . . . . . . . . . CONTROL SYSTEM U–19. . . . . . . . . . . . . . . . . . . . . . . .
STRUCTURAL VIEW U–19. . . . . . . . . . . . . . . . . . . . . . MAGNETIC CLUTCH
DISASSEMBLY/ASSEMBLY U–20. . . . . . . . . . . . . . MAGNETIC CLUTCH CLEARANCE
ADJUSTMENT U–20/21. . . . . . . . . . . . . . . . . . . . . . . . . . MAGNETIC CLUTCH INSPECTION U–21. . . . . . . . . A/C RELAY No.1
REMOVAL/INSTALLATION U–21. . . . . . . . . . . . . . . A/C RELAY No.1 INSPECTION U–22. . . . . . . . . . . . . A/C RELAY No.2
REMOVAL/INSTALLATION U–22. . . . . . . . . . . . . . . A/C RELAY No.2 INSPECTION U–22. . . . . . . . . . . . . REFRIGERANT PRESSURE SWITCH
REMOVAL/INSTALLATION U–22. . . . . . . . . . . . . . . REFRIGERANT PRESSURE SWITCH
INSPECTION U–23. . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSWITCH INSPECTION U–23/24. . . . . . . . . . . BLOWER MOTOR
REMOVAL/INSTALLATION U–24. . . . . . . . . . . . . . . BLOWER MOTOR INSPECTION U–24. . . . . . . . . . . RESISTOR REMOVAL/INSTALLATION U–24. . . . . . RESISTOR INSPECTION U–25. . . . . . . . . . . . . . . . . . CLIMATE CONTROL UNIT REMOVAL U–25. . . . . . CLIMATE CONTROL UNIT INSTALLATION U–25. . CLIMATE CONTROL UNIT
DISASSEMBLY/ASSEMBLY U–25/26. . . . . . . . . . . . . . CLIMATE CONTROL UNIT WIRE
ADJUSTMENT U–26/27. . . . . . . . . . . . . . . . . . . . . . . . . . CLIMATE CONTROL UNIT INSPECTION U–27. . . .
TROUBLESHOOTING U–28. . . . . . . . . . . . . . . . . . . . . . . FOREWORD U–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING INDEX U–28. . . . . . . . . . . . . . SYMPTOM TROUBLESHOOTING U–28/39. . . . . . . . . .
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SERVICE WARNINGS, SERVICE CAUTIONS
U–2
SERVICE WARNINGSHANDLING REFRIGERANT Avoid breathing air conditioning refrigerant or
lubricant vapor. Exposure may irritate eyes,nose and throat. If accidental system dischargeoccurs, ventilate work area before resumingservice.
Do not pressure test or leak test R-134a serviceequipment and/or vehicle air conditioningsystem with compressed air. Some mixtures ofair and R-134a have been shown to becombustible at elevated pressures. Thesemixtures, if ignited, may cause injury orproperty damage. Additional health and safetyinformation may be obtained from refrigerantmanufacturers.
Do not allow the refrigerant to leak near fire orany kind of heat. A poisonous gas may begenerated if the refrigerant gas contacts fire orheat such as from cigarettes and heaters.When carrying out any operation that cancause refrigerant leakage, extinguish orremove the above-mentioned heat sources andmaintain adequate ventilation.
Handling liquid refrigerant is dangerous. Adrop of it on the skin can result in localizedfrostbite. When handling the refrigerant, weargloves and safety goggles. If refrigerantsplashes into the eyes, immediately wash themwith clean water and consult a doctor.
STORING REFRIGERANT The refrigerant container is highly pressurized.
If it is subjected to high heat, it could explode,scattering metal fragments and liquidrefrigerant that can seriously injure you. Storethe refrigerant at temperatures below 40 °C104 °F.
SERVICE CAUTIONSHANDLING COMPRESSOR OIL Use FD46XG (G6, WL, WL turbo) or ZXL 100PG
(F2, F2 Cab) compressor oil for this vehicle.Using a PAG oil other than FD46XG (G6, WL,WL turbo) or ZXL 100PG compressor oil candamage the A/C compressor.
Do not spill compressor oil on the vehicle. Adrop of compressor oil on the vehicle surfacecan eat away at the paint. If oil gets on thevehicle, wipe it off immediately.
FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2,F2 Cab) compressor oil (PAG oil) has a highermoisture absorption efficiency than thepreviously used mineral oil. If moisture mixeswith the compressor oil, the refrigerant systemcould be damaged. Therefore, install capsimmediately after using the compressor oil orremoving refrigerant system parts to preventmoisture absorption.
MOISTURE ABSORPTION
FD46XG (G6, WL, WL turbo) or ZXL100PG (F2, F2 Cab) COMPRESSOROIL
MINERAL OIL
TIME
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REFRIGERANT SYSTEM SERVICE PROCEDURES
U–3
REFRIGERANT SYSTEM SERVICEPROCEDURESMANIFOLD GAUGE SET INSTALLATION
1. Fully close the valves of the SST (49 C061 001).2. Connect the SSTs (49 C061 002, 49 C061 003) to
the high- and low-pressure side joints of the SST (49 C061 001).
3. Connect the SSTs (49 C061 006A, 49 C061 007)to the ends of the SSTs (49 C061 002, 49 C061 003).
4. Connect the SSTs (49 C061 006A, 49 C061 007)to the charging valves.
49 C061 001
49 C061 006A
49 C061 002
49 C061 003
49 C061 007CAP
CHARGINGVALVE OFHIGH-PRESSURESIDECHARGING VALVE OF
LOW-PRESSURE SIDE
CAP
RECOVERYConnect an R-134a recovery/recycling/rechargingdevice to the vehicle and follow the devicemanufacturer’s instructions.
CHARGINGCharging Recycled R-134a RefrigerantConnect an R-134a recovery/recycling/rechargingdevice to the vehicle and follow the devicemanufacturer’s instructions.
Charging New R-134a Refrigerant
Caution Do not exceed the specification when
charging the system with refrigerant. Doingso will decrease the efficiency of the airconditioner or damage the refrigerationcycle parts.
1. Install the SSTs (Manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.)
2. Connect the tap pin side of the SST (49 C061 004)to the air purge valve of the SST (49 C061 001).
3. Connect the SST (49 C061 005) to the center jointof the SST (49 C061 001).
4. Connect the SST (49 C061 005) to the vacuumpump.
5. Connect the SST (49 C061 004) to the refrigeranttank.
6. Place the refrigerant tank on the scale.
Regular amount of refrigerant550 g 19.4 oz
49 C061 004
49 C061 001
49 C061 005
TAP PIN SIDE AIR PURGE VALVE
REFRIGERANTTANK
SCALE
VACUUM PUMP
7. Open all the valves of the SST (49 C061 001).
Caution Close the SST (49 C061 001) valve
immediately after stopping the vacuumpump. If the valve is left open, the vacuumpump oil will flow back into the refrigerationcycle and cause a decrease in the efficiencyof the air conditioner.
8. Start the vacuum pump and let it operate for 15 minutes .
49 C061 001
CLOSE
9. Verify that high- and low-pressure side readings ofthe SST (49 C061 001) are at –101 kPa –760 mmHg, –29.9 inHg . Close each valve ofthe SST (49 C061 001).
49 C061 001
10. Stop the vacuum pump and wait for 5 minutes .11. Check the high- and low-pressure side readings of
the SST (49 C061 001). If the reading haschanged, inspect for leakage and then repeat fromstep 7. If the reading has not changed, go to step12.
12. Open the valve of the refrigerant tank.13. Weigh the refrigerant tank.
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REFRIGERANT SYSTEM SERVICE PROCEDURES
U–4
Warning If the refrigerant system is charged with a
large amount of refrigerant when checkingfor gas leakage, and if any leakage shouldoccur, the refrigerant will be released intothe atmosphere. In order to prevent theaccidental release of refrigerant which candestroy the ozone layer in the stratosphere,follow the proper procedures and chargewith only a small amount of refrigerantwhen checking for gas leakage.
If charging the system with refrigerantusing service cans, running the engine withthe high-pressure side valve open isdangerous. Pressure within the servicecans will increase and the cans couldexplode, scattering metal fragments andliquid refrigerant that can seriously injureyou. Therefore, do not open thehigh-pressure side valve while the engine isrunning.
14. Open the high-pressure side valve of the SST (49 C061 001).
49 C061 001
OPEN
15. When the low-pressure side reading increases to0.098 MPa 1.0 kgf/cm 2, 14 psi , close thehigh-pressure side valve of the SST (49 C061 001).
49 C061 001
16. Inspect for leakage from the cooler pipe/hoseconnections using the SST (Gas leak tester). Ifthere is no leakage, go to step 17. If a leakage isfound at a loose joint, tighten the joint and inspectfor leakage again. If there is still leakage at thesame joint, discharge the refrigerant and thenrepair the joint. Repeat the charging procedurefrom step 7. If there is no leakage after tighteningthe joint, go to step 17.
Warning If charging the system with refrigerant
using service cans, running the engine withthe high-pressure side valve open isdangerous. Pressure within the servicecans will increase and the cans couldexplode, scattering metal fragments andliquid refrigerant that can seriously injureyou. Therefore, do not open thehigh-pressure side valve while the engine isrunning.
17. Open the high-pressure side valve of the SST (49 C061 001) and charge with refrigerant until theweight of refrigerant tank has decreased 300 g10.6 oz from the amount in step 13.
49 C061 001
OPEN
18. Close the high-pressure side valve of the SST (49 C061 001).
49 C061 001
Warning If charging the system with refrigerant
using service cans, running the engine withthe high-pressure side valve open isdangerous. Pressure within the servicecans will increase and the cans couldexplode, scattering metal fragments andliquid refrigerant that can seriously injureyou. Therefore, do not open thehigh-pressure side valve while the engine isrunning.
19. Start the engine and actuate the A/C compressor.20. Open the low-pressure side valve of the
SST (49 C061 001) and charge with refrigerant until therefrigerant tank is empty.
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REFRIGERANT SYSTEM SERVICE PROCEDURES
U–5
49 C061 001
OPEN
21. Close the low-pressure side valve of the SST (49 C061 001) and the valve of the refrigerant tank.
22. Stop the engine and A/C compressor.23. Inspect for leakage using the SST (Gas leak
tester). If there is no leakage, go to step 24. Ifleakage is found at a loose joint, tighten the jointand inspect for leakage again. If there is still a leakat the same joint, discharge the refrigerant andthen repair the joint. Repeat the chargingprocedure from step 7. If there is no leakage aftertightening the joint, go to step 24.
24. Disconnect the SSTs (49 C061 006A, 49 C061 007) from the charging valves.
25. Install the caps to the charging valves.
49 0061 00749 C061 006A
CAP
CAP
REFILLING
Caution Do not exceed the specification when
charging the system with refrigerant. Doingso will decrease the efficiency of the airconditioner or damage the refrigerationcycle parts.
1. Install the SSTs (Manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.)
2. Connect the tap pin side of the SST (49 C061 004)to the air purge valve of the SST (49 C061 001).
3. Connect the SST (49 C061 005) to the center jointof the SST (49 C061 001).
4. Connect the SST (49 C061 005) to the vacuumpump.
5. Connect the SST (49 C061 004) to the refrigeranttank.
49 C061 004
49 C061 001
49 C061 005
TAP PIN SIDE AIR PURGE VALVE
REFRIGERANTTANK
VACUUM PUMP
6. Open only the center valve of the SST (49 C061(49 C061 001).
Caution Close the SST (49 C061 001) valve
immediately after stopping the vacuumpump. If the valve is left open, the vacuumpump oil will flow back into the refrigerationcycle and cause a decrease in the efficiencyof the air conditioner.
7. Start the vacuum pump and let it run for 1 minute .
49 C061 001
CLOSE
8. Close the center valve of the SST (49 C061 001).
49 C061 001
9. Stop the vacuum pump.10. Open the valve of the refrigerant tank.
Warning If charging the system with refrigerant
using service cans, running the engine withthe high-pressure side valve open isdangerous. Pressure within the servicecans will increase and the cans couldexplode, scattering metal fragments andliquid refrigerant that can seriously injureyou. Therefore, do not open thehigh-pressure side valve while the engine isrunning.
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REFRIGERANT SYSTEM SERVICE PROCEDURES
U–6
11. Start the engine and actuate the A/C compressor.12. Open the low-pressure side valve of the
SST (49 C061 001).
49 C061 001
OPEN
13. Refer to refrigerant charge check and refill with refrigerant.
SIGHT GLASS
L.H.D.
SIGHT GLASS
R.H.D. (WL, G6, F2 Cab)
SIGHT GLASS
R.H.D. (WL turbo)
14. Close the low-pressure side valve of the SST (49 C061 001) and the valve of the refrigerant tank.
15. Stop the engine and the A/C compressor.16. Disconnect the SSTs (49 C061 006A,
49 C061 007) from the charging valves.17. Install the caps to the charging valves.
CAP
CAP
49 C061 007 49 C061 006A
REFRIGERANT CHARGE CHECK
Caution The FD46XG (G6, WL, WL turbo) or ZXL
100PG (F2, F2 Cab) compressor oil willseparate from refrigerant at hightemperatures of 50 °C 122 °F or more. Ifthis happens, the sight glass will change toa milky-white color, and there is apossibility that you might mistakenlybelieve the refrigerant amount to beinsufficient and recharge with additionalrefrigerant.If the system is overcharged withrefrigerant, the sight glass will becomeclear and give a false indication. You willmistakenly believe that the refrigerantamount is correct. Therefore, when checking the refrigerantamount, verify the refrigerant pressure andcooler pipe temperature in addition to thesight glass condition.
1. Warm up the engine and run it at a constant 1,500 rpm .
2. Set the fan switch at 4th.3. Set the temperature control dial to MAX COLD.4. Close all the doors and windows.5. Check the refrigerant amount condition according
to the following table.
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REFRIGERANT SYSTEM SERVICE PROCEDURES
U–7
Amount Condition ofsight glass
Other conditions
Insufficient
Bubbles
High-pressure side coolerpipe is warm;low-pressure side coolerpipe is cool.
High- and low-pressureside readings are lowerthan normal.
Air cooling ability is low.
CorrectClear
Milky white
High-pressure side coolerpipe is hot; low-pressureside cooler pipe is cold.
High- and low-pressureside readings are normal.
* If sight glass ismilky-white, pour waterinto condenser forapproximately 20seconds to cool it off,then the sight glass willclear.
Over
Clear
High-pressure side coolerpipe is hot; low-pressureside cooler pipe is cold.
High- and low-pressureside reading are higherthan normal.
Air cooling ability is low.
6. If not as specified, troubleshoot the refrigerantsystem. (Refer to TROUBLESHOOTING.)
REFRIGERANT PRESSURE CHECK1. Install the SSTs (Manifold gauge set).
(Refer to MANIFOLD GAUGE SET INSTALLATION.)2. Open the bonnet.3. Close all the doors and windows.4. Warm up the engine and run it at a constant
1,500 rpm .5. Set the fan switch at 4th.6. Set the temperature control dial to MAX COLD.7. Measure the ambient temperature and the high-
and low-pressure side reading of the SST (49 C061 001).
8. Verify that the intersection of the pressure readingof the SST (49 C061 001) and ambienttemperature is in the shaded zone.
PRESSURE READING OF MANIFOLD GAUGE
HIGH-PRESSURE SIDE
LOW-PRESSURE SIDE
AMBIENT TEMPERATURE
2.021, 299
Mpakgf/cm 2, psi
2068
0.22.0, 28
1.515, 213
0.11.0, 14
40104
2577
3086
3595
°C°F
1.010, 142
9. If not as specified, troubleshoot the refrigerantsystem. (Refer to TROUBLESHOOTING.)
PERFORMANCE TEST
Note After servicing the refrigerant system, the test
is performed.
1. Install the SSTs (manifold gauge set).(Refer to MANIFOLD GAUGE SET INSTALLATION.)
2. Open the bonnet.3. Close all the doors and windows.4. Warm up the engine and run it at a constant
1,500 rpm .5. Set the fan switch at 4th.6. Set the temperature control dial to MAX COLD.7. Record center ventilator right side temperature.8. Determine and record ambient temperature.9. Verify that the temperature reading is in the shaded
zone.
AMBIENT TEMPERATURE
2068
40104
2577
3086
3595
°C°F
CENTER VENTILATORTEMPERATURE
°C °F
0 321 342 363 374 395 416 43
10. If the performance is not within the shaded zone,troubleshoot the refrigerant system. (Refer to TROUBLESHOOTING.)
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BASIC SYSTEM
U–8
BASIC SYSTEMSTRUCTURAL VIEW
L.H.D. (G6)
L.H.D. (WL, WL turbo)
RECEIVER/DRIER
CONDENSER
COOLERHOSE(HIGH)
COOLERPIPE(HIGH)
A/CCOMPRESSOR
HEATERHOSE
COOLERPIPE(LOW)
HEATER UNIT
COOLING UNIT
BLOWER UNIT
BLOWER UNIT
COOLING UNIT
HEATER UNIT
HEATERHOSE
COOLERPIPE(LOW)
COOLERPIPE(HIGH)
CONDENSER
RECEIVER/DRIER
A/CCOMPRESSOR
COOLERHOSE(LOW)
L.H.D. (F2, F2 Cab)
BLOWER UNIT
COOLING UNIT
HEATER UNIT
COOLERPIPE(LOW)
COOLERPIPE(HIGH)
HEATERHOSE
A/CCOMPRESSOR
COOLERHOSE(HIGH)
CONDENSER
RECEIVER/DRIER
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BASIC SYSTEM
U–9
COOLING UNIT
SIGHT GLASSCOOLERPIPE(HIGH)
HEATER UNIT
COOLERHOSE (LOW)
CONDENSER
RECEIVER/DRIER
A/CCOMPRESSOR
COOLERHOSE (HIGH)
HEATERHOSE
R.H.D. (WL, WL turbo)
WL turbo
BLOWER UNIT
R.H.D. (G6)
HEATER UNIT
COOLING UNITHEATERHOSE
BLOWER UNIT
COOLERPIPE(HIGH)
COOLERHOSE(LOW)
A/CCOMPRESSOR
CONDENSER
COOLERHOSE (HIGH)
RECEIVER/DRIER
R.H.D. (F2 Cab)
HEATER UNIT
COOLING UNIT
BLOWER UNIT
COOLERPIPE(HIGH)
COOLERHOSE (LOW)
A/CCOMPRESSOR
CONDENSER
RECEIVER/DRIER
HEATERHOSE
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BASIC SYSTEM
U–10
BLOWER UNIT REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the glove compartment.3. Remove the cooling unit.
(Refer to COOLING UNIT REMOVAL/INSTALLATION.)4. Remove the passenger’s side front side trim
(L.H.D. only.)5. Remove as indicated in the table.6. Install in the reverse order of removal.
1 Connector
2 Blower unit
BLOWER UNIT DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
AA
B
B
C
C
L.H.D.
AA
B
B
C
C
R.H.D.
1 Blower motor
2 Resistor
3 Blower harness
4 Polyurethane protector
5 Inlet duct case (front)
6 Inlet duct case (rear)
7 Blower case (upper)
8 Blower case (lower)
9 Air intake door
10 Air intake link
11 Air intake crank
COOLING UNIT REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Discharge the refrigerant from the system.
(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, RECOVERY.)
(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, CHARGING.)
3. Remove the glove compartment.4. Disconnect the air intake wire from the cooling unit.
(Refer to CONTROL SYSTEM, CLIMATECONTROL UNIT WIRE ADJUSTMENT.)
Caution If moisture or foreign material enters the
refrigeration cycle, cooling ability will belowered and abnormal noise will occur.Always immediately plug all open fittingsafter removing any refrigeration cycle partsto keep moisture or foreign material out ofthe cycle.
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BASIC SYSTEM
U–11
5. Remove in the order indicated in the table. Do notallow compressor oil to spill.
6. Install in the reverse order of removal.7. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, PERFORMANCE TEST.)
L.H.D.
R
15—21 N·m1.5—2.2 kgf·m,130.2—190.9 in·lbf R 6.9—9.8 N·m
0.7—1.0 kgf·m,60.8—86.7 in·lbf
9.81—19.61 N·m100—200 kgf·cm,86.8—173.5 in·lbf
20—29 N·m2.0—3.0 kgf·m,15—21 ft·lbf
R
R
R.H.D.
1 Cooler hose (low)+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant LinesRemoval Note
+ REFRIGERANT LINESREMOVAL/INSTALLATION, Refrigerant LinesInstallation Note
2 Cooler pipe (high)+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant LinesRemoval Note
+ REFRIGERANT LINESREMOVAL/INSTALLATION, Refrigerant LinesInstallation Note
3 Connector
4 Cooling unit+ Removal Note+ Installation Note
Cooling Unit Removal Note (R.H.D. only) Turn the cooling unit 90 degrees to the right, and
remove the cooling unit.
Cooling Unit Installation Note When installing a new cooling unit (evaporator),
add FD46XG (G6, WL, WL turbo) or ZXL 100PG(F2, F2 Cab) compressor oil into the refrigerationcycle.
Supplement amount40 ml 40 cc, 1.4 fl oz
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BASIC SYSTEM
U–12
COOLING UNIT DISASSEMBLY/ASSEMBLY
Caution If moisture or foreign material enters the
refrigeration cycle, cooling ability will belowered and abnormal noise will occur.Always immediately plug all open fittingsafter removing any refrigeration cycle partsto keep moisture or foreign material out ofthe cycle.
1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.L.H.D.
R.H.D.
1 Cooler case (upper)
2 Cooler case (lower)
3 Thermoswitch clip
4 Thermoswitch+ Assembly Note
5 Evaporator
6 Expansion valve+ Assembly Note
7 High pressure pipe
Expansion Valve Assembly Note Replace the O-rings at the expansion valve joints
and apply compressor oil to the O-rings andconnect the joints.
Tighten the joint to the specified torque using twoopen-end wrenches.
Assemble the heat-sensing tube as shown in thefigure.
20—24 N·m2.0—2.5 kgf·m,15—18 ft·lbf
11.8—14.7 N·m120—150 kgf·cm,105—130 in·lbf
HEAT-SENSING TUBE
Thermoswitch Assembly Note1. Insert the thermoswitch probe in location as shown
in the figure.
40 mm1.6 in
EVAPORATOR
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BASIC SYSTEM
U–13
EVAPORATOR INSPECTION1. Remove the cooling unit.
(Refer to COOLING UNIT REMOVAL/INSTALLATION.)2. Remove the evaporator from the cooling unit.3. Inspect for cracks, damage, and oil leakage. If any
problems are found, replace the evaporator.4. Inspect for bent fins. If they are bent, use a
flat-head screwdriver to straighten them.
HEATER UNIT REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Drain the engine coolant.
(Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) (With heater core only)
3. Remove the dashboard. (Refer to section S, DASHBOARD AND CONSOLE, DASH BOARD REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.5. Install in the reverse order of removal.
*
* WITH HEATER CORE ONLY
1 Heater hose
2 Heater unit
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BASIC SYSTEM
U–14
HEATER UNIT DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
*
**
* *
*
* WITH HEATER CORE ONLY
1 Heater core
2 Air mix rod
3 Air mix link
4 Air mix crank (1)
5 Air mix crank (2)
6 Air mix shaft
7 Airflow mode main link
8 Airflow mode crank (1)
9 Airflow mode crank (2)
10 Airflow mode crank (3)
11 Airflow mode crank (4)
12 Airflow mode sub link (1)
13 Airflow mode sub link (2)
14 Heater case (1)
15 Heater case (2)
16 Heater case (3)
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BASIC SYSTEM
U–15
HEATER CORE INSPECTION1. Remove the heater unit.
(Refer to HEATER UNIT REMOVAL/INSTALLATION.)2. Remove the heater core from the heater unit.3. Inspect for cracks, damage, and coolant leakage. If
any are found, replace the heater core.4. Inspect for bent fins. If any are bent, use a flathead
screwdriver to straighten them.5. Verify that the heater core inlet and outlet are not
distorted or damaged. Repair with pliers if necessary.
A/C COMPRESSOR REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Discharge the refrigerant from the system.
(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.)
3. Remove the drive belt (P/S + A/C).4. Remove the air cleaner and air hose. (WL turbo
only) (Refer to section F2, INTAKE-AIR SYSTEM,INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
5. Loosen the A/C compressor bolts, then slide theA/C compressor. (WL turbo only)
Caution If moisture or foreign material enters the
refrigeration cycle, cooling ability will belowered and abnormal noise will occur.Always immediately plug all open fittings afterremoving any refrigeration cycle parts to keepmoisture or foreign material out of the cycle.
6. Remove in the order indicated in the table. Do notallow compressor oil to spill.
7. Install in the reverse order of removal.8. Adjust the drive belt (P/S + A/C). (Refer to section
B2, DRIVE BELT, DRIVE BELT ADJUSTMENT.)9. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, PERFORMANCE TEST.)
R
R
15—211.5—2.2,11—15
N·m kgf·m, ft·lbf
24—352.4—3.6,18—26
G6, WL, WL turbo
F2, F2 Cab
N·m kgf·m, ft·lbf
30—393.0—4.0,22—28
R
1 Connector
2 Cooler hose (high)+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant LinesInstallation Note
3 Cooler hose (low)+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant LinesInstallation Note
4 A/C compressor+ Installation Note
A/C Compressor Installation Note Remove the following amount of compressor oil
from the new A/C compressor when replacing theA/C compressor.
Compressor oil to be removed = 180 ml 180 cc, 6.08 fl oz – [compressor oil from oldA/C compressor + 15 ml 15 cc, 0.5 fl oz ]
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BASIC SYSTEM
U–16
CONDENSER REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Discharge the refrigerant from the system.
(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, RECOVERY.) (Refer toREFRIGERANT SYSTEM SERVICEPROCEDURES, CHARGING.)
3. Remove the radiator grille.4. Remove the charge air cooler and air hose. (WL
turbo only)(Refer to section F2, INTAKE-AIR SYSTEM,INTAKE-AIR SYSTEMREMOVAL/INSTALLATION.)
5. Remove the receiver/drier. (Refer to RECEIVER/DRIER REMOVAL/INSTALLATION.)
Caution If moisture or foreign material enters the
refrigeration cycle, cooling ability will belowered and abnormal noise will occur.Always immediately plug all open fittingsafter removing any refrigeration cycle partsto keep moisture or foreign material out ofthe cycle.
6. Remove in the order indicated in the table. Do notallow compressor oil to spill.
7. Install in the reverse order of removal.8. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, PERFORMANCE TEST.)
D
B
C
B
A
D
A
15—21 N·m1.5—2.2 kgf·m,11—15 ft·lbf
C
R
1 Cooler pipe+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant LinesInstallation Note
2 Bonnet lock stay
3 Condenser+ Installation Note
Condenser Installation Note When installing a new condenser, add FD46XG
(G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab)compressor oil into the refrigeration cycle.
Supplemental amount30 ml 30 cc, 1.0 fl oz
CONDENSER INSPECTION1. Inspect for cracks, damage, and oil leakage. If any
problems are found, replace the condenser.2. Inspect for fins clogged by dust. If any are clogged,
remove the dust from the fins.3. Inspect for bent fins. If any are bent, use a flathead
screwdriver to straighten them.
RECEIVER/DRIER REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Discharge the refrigerant from the system. (Refer to
REFRIGERANT SYSTEM SERVICE PROCEDURES,RECOVERY.) (Refer to REFRIGERANT SYSTEMSERVICE PROCEDURES, CHARGING.)
3. Remove the radiator grille.
Caution If moisture or foreign material enters the
refrigeration cycle, cooling ability will belowered and abnormal noise will occur.Always immediately plug all open fittingsafter removing any refrigeration cycle partsto keep moisture or foreign material out ofthe cycle.
4. Remove in the order indicated in the table. Do notallow compressor oil to spill.
5. Install in the reverse order of removal.6. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, PERFORMANCE TEST.)
R
R
6.85—9.80 N·m70—100 kgf·cm, 60.8—86.7 in·lbf
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BASIC SYSTEM
U–17
1 Connector
2 Cooler pipe+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant LinesInstallation Note
3 Condenser+ CONDENSER REMOVAL/INSTALLATION,
Condenser Installation Note
4 Receiver/drier+ Installation Note
Receiver/drier Installation Note When installing a new receiver/drier, add FD46XG
(G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab)compressor oil into the refrigeration cycle.
Supplemental amount35 ml 35 cc, 1.2 fl oz
REFRIGERANT LINES REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Discharge the refrigerant from the system.
(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, RECOVERY.) (Refer toREFRIGERANT SYSTEM SERVICEPROCEDURES, CHARGING.)
Caution If moisture or foreign material enters the
refrigeration cycle, cooling ability will belowered and abnormal noise will occur.Always immediately plug all open fittingsafter removing any refrigeration cycle partsto keep moisture or foreign material out ofthe cycle.
3. Remove the radiator grille.4. Remove the front bumper.
(Refer to section S, BUMPER, FRONT BUMPERREMOVAL/INSTALLATION.)
5. Remove the radiator. (WL turbo only)6. Remove in the order indicated in the table. Do not
allow compressor oil to spill.7. Install in the reverse order of removal.8. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, PERFORMANCE TEST.)
B
A
C E
E
A
B
C
D
DF
F
RR
R
R
B
E
R
A
C
R
B
R
RA
C
D
R
R
AB
L.H.D.
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BASIC SYSTEM
U–18
A: 6.85—9.80 N·m 70—100 kgf·cm, 60.8—86.7 in·lbfB: 15—21 N·m 1.5—2.2 kgf·m, 11—15 ft·lbfC: 20—29 N·m 2.0—3.0 kgf·m, 15—21 ft·lbfD: 9.81—19.61 N·m 100—200 kgf·cm, 86.8—173.5 in·lbfE: 24—35 N·m 2.4—3.6 kgf·m, 18—26 ft·lbf
B
CA
D
B
A
DC
R
R
B
B
E
R RD
C
A
R
R
R.H.D.
1 Cooler hose (low)+ Removal Note+ Refrigerant Lines Removal Note+ Refrigerant Lines Installation Note
2 Cooler hose (high)+ Removal Note+ Refrigerant Lines Installation Note
3 Cooler pipe (high)+ Refrigerant Lines Removal Note+ Refrigerant Lines Installation Note
Cooler Hose Removal NoteWL turbo only Loosen the A/C compressor bolts, then slide the
A/C compressor, and remove the cooler hose boltfrom the A/C compressor.
Refrigerant Lines Removal Note Loosen the nut using two spanners, then remove
the cooler pipe or hose.
Refrigerant Lines Installation Note1. When installing a new cooler pipe or hose, add
FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2Cab) compressor oil into the refrigeration cycle.
Supplemental amountCooler hose (low): 8 ml 8 cc, 0.3 fl ozCooler hose (high): 5 ml 5 cc, 0.2 fl ozCooler pipe: 3 ml 3 cc, 0.1 fl oz
2. Apply compressor oil to the O-rings and connectthe joints.
3. Tighten the joints.(1) Tighten the nut or bolt of the joint by hand.(2) Tighten the joint to the specified torque. If it is a
nut joint, tighten the nut using a spanner andtorque wrench.
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CONTROL SYSTEM
U–19
CONTROL SYSTEMSTRUCTURAL VIEW
L.H.D.
REFRIGERANT PRESSURE SWITCHA/C RELAY No.2*
A/C RELAY No.1 MAGNETIC CLUTCH
CLIMATECONTROL UNIT
RESISTOR
BLOWER MOTOR
THERMOSWITCH
R.H.D.
MAGNETIC CLUTCH
A/C RELAY No.2*
REFRIGERANT PRESSURE SWITCH
A/C RELAY No.1 CLIMATECONTROL UNIT
THERMOSWITCH
RESISTOR
BLOWER MOTOR
* F2 Cab only
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CONTROL SYSTEM
U–20
MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.3. Adjust the magnetic clutch clearance.
(Refer to MAGNETIC CLUTCH CLEARANCE ADJUSTMENT.)
10.1—15.0 N102—153kgf 89—132in·lbf
1 Bolt+ Removal/Installation Note
2 Pressure plate+ Installation Note
3 Shim
4 Snap ring
5 A/C compressor pulley
6 Stator+ Removal Note+ Installation Note
Bolt Removal/Installation Note When removing or installing the bolt, hold the
pressure plate in place as shown in the table.
A/C COMPRESSORBOLT
Stator Removal Note Set a straight-socket (17 mm 0.67 in) on the shaft
of the A/C compressor to protect it. Remove the stator using a pulley puller as shown
in the table.STRAIGHT-SOCKET(17 mm 0.67 in)
Stator Installation Note Install the stator perpendicularly using the SST and
a pulley puller as shown in the table.
49 H061 005
Pressure Plate Installation Note When installing the pressure plate, carry out
magnetic clutch clearance adjustment.
MAGNETIC CLUTCH CLEARANCE ADJUSTMENTG6, WL, WL turbo Only
1. Set the A/C compressor on a level block.2. Turn on the magnetic clutch by connecting the
battery positive voltage to the magnetic clutchconnector terminal and the ground to the A/Ccompressor body.
3. Fix a dial gauge on a magnetic base and set themeasuring probe onto point A on the pressureplate surface.
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CONTROL SYSTEM
U–21
4. Turn off the magnetic clutch by disconnecting theground from the A/C compressor body, thenmeasure the dial gauge readings.
5. Measure the clearance for point B and C on thepressure plate surface by repeating the abovesteps 2 through 4.
Clearance0.35—0.75 mm 0.014—0.029 in
MEASURING POINT
BA
C
6. If the clearance is not as specified, adjust it bychanging the shim.
Note The seven shim sizes from 0.7 mm 0.028 in
to 1.3 mm 0.051 in differ in 0.1 mm 0.004 inincrements.
F2, F2 Cab Only1. Measure the clearance around the entire
circumference between the pressure plate and A/Ccompressor pulley using a thickness gauge.
2. Verify that the clearance is within the specification.
Clearance0.3—0.6 mm 0.01—0.02 in
3. If not within the specification, remove the pressureplate and adjust the clearance by changing theshim (0.1 mm 0.004 in, 0.3 mm 0.012 in, 0.5mm 0.020 in) or the number of shims.
MAGNETIC CLUTCH INSPECTION1. Disconnect the magnetic clutch connector.2. Connect battery positive voltage to terminal A of
magnetic clutch and ground to the A/C compressorbody.
A
A
3. Verify that the magnetic clutch operates.4. If not as specified, replace the stator.
A/C RELAY No.1 REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
1 Connector
2 A/C relay No.1
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CONTROL SYSTEM
U–22
A/C RELAY No.1 INSPECTION1. Remove the A/C relay No.1.2. Inspect for continuity between the A/C relay No.1
terminals using an ohmmeter.: Continuity B+: Battery positive voltage
StepTerminal
StepA B C D
1
2 B+ GND
D
A
B
C
A
B
C
D
3. If not as specified, replace the A/C relay No.1.
A/C RELAY NO.2 REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.
1 Connector
2 A/C relay No.2
A/C RELAY NO.2 INSPECTION1. Remove the A/C relay No.2.2. Inspect for continuity between the A/C relay No.2
terminals using an ohmmeter.: Continuity B+: Battery positive voltage
StepTerminal
StepB D A C
1
2 B+ GND
A B
C D
BD
AC
3. If not as specified, replace the A/C relay No.2.
REFRIGERANT PRESSURE SWITCH REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.2. Discharge the refrigerant from the system.
(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, RECOVERY.) (Refer toREFRIGERANT SYSTEM SERVICEPROCEDURES, CHARGING.)
3. Remove the radiator grille.
Caution If moisture or foreign material enters the
refrigeration cycle, cooling ability will belowered and abnormal noise will occur.Always immediately plug all open fittingsafter removing any refrigeration cycle partsto keep moisture or foreign material out ofthe cycle.
4. Remove as indicated in the table.5. Install in the reverse order of removal.6. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICEPROCEDURES, PERFORMANCE TEST.)
5.9—7.8 N·m 60—80 kgf·cm,53—69 in·lbf
R
À
1 Connector
2 Refrigerant pressure switch+ Installation Note
Refrigerant Pressure Switch Installation Note Apply compressor oil to the O-ring and connect the
joint.
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CONTROL SYSTEM
U–23
REFRIGERANT PRESSURE SWITCH INSPECTION1. Install the SSTs (manifold gauge set).
(Refer to MANIFOLD GAUGE SET INSTALLATION.)2. Disconnect the refrigerant pressure switch
connector.3. Verify the high-pressure side reading of the SST
(Manifold gauge).4. Inspect for continuity between the terminals of the
refrigerant pressure switch using an ohmmeter.
0.18—0.21 1.8—2.2, 26—31
CONTINUITY
NO CONTINUITY
0.4—0.7 4.0—8.0, 57—113
3.0—3.330—34, 427—483
0.02 0.25, 3.56OR LESS
MPa kgf/cm 2 , psi
ABAB
5. If not as specified, replace the refrigerant pressureswitch.
THERMOSWITCH INSPECTIONTo Determine if the Switch is Functioning
1. Remove the glove compartment.2. Start the engine.3. Turn the fan switch on.4. Turn the A/C switch on.5. Connect the positive (+) and negative (–) probes of
the voltmeter to terminal A and terminal B of thethermoswitch respectively. (The wiring harnessconnector must be connected to the thermoswitchconnector.)
6. Inspect the voltage as shown below.
WITH HEATER CORE: Continuity
Magnetic cl tchTerminal
Magnetic clutchA C
On
Off
WITHOUT HEATER CORE: Continuity
Magnetic cl tchTerminal
Magnetic clutchA B
On
Off
A B
WITHOUTHEATER CORE
WITH HEATERCORE
A B C
7. If not as specified, inspect on/off points of thethermoswitch.
To Inspect On/Off Points of the Thermoswitch1. Disconnect the negative battery cable.2. Remove the cooling unit
(Refer to BASIC SYSTEM, COOLING UNITREMOVAL/INSTALLATION.)
3. Remove the thermoswitch. (Refer to BASIC SYSTEM, COOLING UNITDISASSEMBLY/ASSEMBLY.)
4. Connect the negative battery cable.5. Connect the thermoswitch connector to the wiring
harness connector.6. Turn the ignition switch to ON position.7. Turn the A/C switch on.8. Turn the fan switch on.9. Immerse the sensor part of thermoswitch in a
container of ice water.10. Connect the positive (+) and negative (–) probes of
the voltmeter to terminal A and terminal B of thethermoswitch respectively.
11. Inspect the voltage as shown below.
WITH HEATER CORE: Continuity
Water temperat reTerminal
Water temperat ureA C
3°C 37°F or more
1°C 34°F or less
WITHOUT HEATER CORE: Continuity
Temperaturecontrol dial Water temperat re
Terminalcontrol dial
positionWater temperat ure
A B
MAX COLD0—3°C 32—37°F
MAX COLD3°C 37°F or more
1/27—11°C 45—52°F
1/211°C 52°F or more
MAX WARM14—18°C 57—64°F
MAX WARM18°C 64°F or more
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CONTROL SYSTEM
U–24
A B
WITHOUTHEATER CORE
WITH HEATERCORE
A B C
12. If not as specified, replace the thermoswitch.(Refer to BASIC SYSTEM, COOLING UNITDISASSEMBLY/ASSEMBLY.)
BLOWER MOTOR REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the glove compartment.3. Remove as indicated in the table.4. Install in the reverse order of removal.
1 Connector
2 Blower motor
BLOWER MOTOR INSPECTION1. Remove the glove compartment.2. Disconnect the blower motor connector.3. Connect battery positive voltage to terminal B and
ground to terminal A of the blower motor, and verifyits operation.
4. If not as specified, replace the blower motor.
RESISTOR REMOVAL/INSTALLATION1. Disconnect the negative battery cable.2. Remove the glove compartment.3. Remove as indicated in the table.4. Install in the reverse order of removal.
1 Connector
2 Resistor
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CONTROL SYSTEM
U–25
RESISTOR INSPECTION1. Remove the glove compartment.2. Disconnect the resistor connector.3. Verify that the resistance between the terminals of
the resistor is as shown in the table.
Terminal Resistance ( Ω)
1A–1B (2A) R1: 0.43—0.47
1A–1C R2: 1.04—1.16
1C–1D R3: 1.47—1.63
1D 1C 1A 1B 2A
1C 1A
1D 1B
2A
R3 R2 R1
4. If not as specified, replace the resistor.
CLIMATE CONTROL UNIT REMOVAL1. Disconnect the negative battery cable.2. Remove the glove compartment.3. Disconnect the air intake wire from the blower unit.4. Disconnect the air mix wire and airflow mode wire
from the heater unit.5. With the beveled parts of the SST facing inward,
insert them into the climate control unit.6. Pull the SST outward and rearward to slide out the
climate control unit.
49 D066 801A
7. Disconnect the climate control unit connectors.
CLIMATE CONTROL UNIT INSTALLATION1. Connect the climate control unit connectors.2. Insert the climate control unit until each clip clicks.
3. Adjust the wire of the climate control unit. (Refer to CLIMATE CONTROL UNIT WIRE ADJUSTMENT.)
4. Install the glove compartment.5. Connect the negative battery cable.
Climate Control Unit Removal/Installation NoteWith heater core Set the temperature control dial at MAX COLD, the
airflow mode control dial at DEF.
CLIMATE CONTROL UNITDISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.2. Assemble in the reverse order of disassembly.
WITH HEATER CORE
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CONTROL SYSTEM
U–26
WITHOUT HEATER CORE
1 Dial
2 Knob+ Removal Note
3 A/C switch
4 Panel
5 Fan switch
6 Climate control unit harness
7 Illumination bulb
8 A/C amplifer
9 Air mix wire
10 Airflow mode wire
11 Air intake wire
11 Cap
13 Body
Knob Removal Note Use a wire to push the knob from the reverse side
and remove it as shown in the figure.
KNOB
WIRE
CLIMATE CONTROL UNIT WIRE ADJUSTMENTAir Intake Wire
1. Set the air intake lever at FRESH.2. Set the air intake link to FRESH in the direction of
the arrow and insert a screwdriver into the set hole.L.H.D.
AIR INTAKE WIRE
SET HOLE
AIR INTAKE WIRE
SET HOLE
R.H.D.
3. Connect the air intake wire to the air intake link.4. Clamp the air intake wire to wire clamp.5. Verify that the air intake lever moves its full stroke.
Air Mix Wire (With heater core only)1. Set the temperature control dial at MAX COLD.2. Set the air mix link to MAX COLD in the direction of
the arrow and insert a screwdriver into the set hole.
SET HOLE
AIR MIX WIRE
3. Connect the air mix wire to the air mix link.4. Clamp the air mix wire to wire clamp.5. Verify that the temperature control dial moves its
full stroke.
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123456567
123456567
CONTROL SYSTEM
U–27
Airflow Mode Wire1. Set the airflow mode control dial at DEF.2. Set the airflow mode link to DEF in the direction of
the arrow and insert a screwdriver into the set hole.SET HOLE
AIRFLOW MODE WIRE
3. Connect the airflow mode wire to the airflow modelink.
4. Clamp the airflow mode wire to wire clamp.5. Verify that the airflow mode control dial moves its
full stroke.
CLIMATE CONTROL UNIT INSPECTIONA/C Switch
1. Remove the climate control unit. (Refer to CLIMATE CONTROL UNIT REMOVAL.)
2. Inspect for continuity between the A/C switchterminals using an ohmmeter.
: Continuity
Switch Terminalposition A B
OFF
ON
A C B
B AC
3. Connect battery positive voltage to terminal C andground to the terminal A.
4. Turn the A/C switch on.5. Verify that the LED illuminaltes.6. If not as specified, replace the A/C switch.
Fan Switch1. Remove the climate control unit.
(Refer to CLIMATE CONTROL UNIT REMOVAL.)2. Inspect for continuity between the fan switch
terminals using an ohmmeter.: Continuity
Switch Terminalposition A B C D E F
0
1
2
3
4
0
4 3 2 1
F E B C D A
A
D B
CE
F
3. If not as specified, replace the fan switch.
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TROUBLESHOOTING
U–28
TROUBLESHOOTINGFOREWORD Refer to section GI. Thoroughly read and understand the basic flow of troubleshooting in order to properly
perform the procedures. When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. Ifthere is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly andundamaged.
The areas for inspection (steps) are given according to various circuit malfunctions. Use the chart below toverify the symptoms of the trouble in order to diagnose the appropriate area.
TROUBLESHOOTING INDEXNo. Malfunction symptom
1 Insufficient blown air volume and/or no blown air depending on airflow mode.
2 No blown air in any airflow mode.Blown air volume does not change at any fan speed.
3 Airflow mode does not change.
4 Improper air circulation and/or no air circulation.
5 No temperature control.(For climate control unit without variable thermistor only)
6 Air from vent not cold enough.
7 No cool air.
8 Noise while operating A/C system.
SYMPTOM TROUBLESHOOTING1 Insufficient blown air volume and/or no blown air depending on airflow mode.
TROUBLESHOOTING HINTS1 Malfunction in VENT mode system
Steps 1—42 Malfunction in HEAT mode system
Step 53 Malfunction in DEFROSTER mode system
Steps 6—8
STEP INSPECTION ACTION
1 When airflow mode control dial is operated, isappropriate resistance felt and can it be moved
Yes Go to next step.appropriate resistance felt and can it be movedthroughout its full range? No Go to Step 1 of troubleshooting index No. 3.
2 Does air blow out when in VENT mode? Yes Go to Step 5.
No Go to next step.
3 Is vent clogged? Yes Remove obstruction, then go to Step 9.
No Go to next step.
4 Is duct in dashboard properly installed? Yes Inspect duct for clogging, deformity and airleakage, then go to Step 9.
No Install duct securely in the proper position, thengo to Step 9.
5 Does air blow out when in HEAT mode? Yes Go to next step.
No Inspect vent for clogging, then go to Step 9.
6 Does air blow out when in DEFROSTER mode? Yes Operation is okay. Recheck malfunctionsymptoms.
No Go to next step.
7 Is vent clogged? Yes Remove obstruction, then go to Step 9.
No Go to next step.
8 Is defroster duct properly installed? Yes Inspect duct for clogging, deformity, and airleakage, then go to next step.
No Install duct securely in the proper position, thengo to next step.
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CONTROL SYSTEM
U–29
STEP INSPECTION ACTION
9 Does air blow out? Yes Troubleshooting completed. Explain repairs tocustomer.
No Recheck malfunction symptoms, then repeat fromStep 1 if malfunction recurs.
2 No blown air in any airflow mode.Blown air volume does not change at any fan speed.
TROUBLESHOOTING HINTS1 Blower motor, resistor, fan switch malfunction
Step 12 Blower unit malfunction
Steps 2—4
STEP INSPECTION ACTION
1 Inspect the following systems and electrical parts: Yes Go to next step. Blower motor, resistor, fan switch.
Are they okay?No Repair or replace malfunctioning part, then go to
Step 5.
2 Turn ignition switch to ON position.Turn fan switch on
Yes Go to next step.Turn fan switch on.Is noise coming from blower unit? No Go to Step 4.
3 Inspect fan in blower unit. Is fan free of interference from blower unit
case?
Yes Go to next step.
case? Is fan free of foreign material and
obstructions?Is fan okay?
No Remove obstruction, repair or replace fan andblower unit case, then go to Step 5.
4 Is blower unit intake vent clogged? Yes Remove obstruction, then go to next step.
No Inspect if there are any obstructions in passagebetween blower unit and heater unit, then go tonext step.
5 Does air blow out? Yes Troubleshooting completed. Explain repairs tocustomer.
No Recheck malfunction symptoms, then repeat fromStep 1 if malfunction recurs.
3 Airflow mode does not change.
TROUBLESHOOTING HINTS1 Malfunction in heater unit’s airflow mode main link, airflow mode rod, airflow mode cranks, airflow mode sub link, airflow
mode wire or wire clampSteps 1, 2
2 Bevel gear set (2) in climate control unit, airflow mode wire or wire clamp malfunctionStep 3
3 Malfunction in one or more heater unit doorsSteps 4, 5
STEP INSPECTION ACTION
1 Inspect heater unit’s airflow mode main link,airflow mode rod, airflow mode cranks, airflowmode sub links, airflow mode wire and wireclamp. Is there grease on airflow mode main link,
Yes Go to next step.
g ,airflow mode cranks and airflow mode sublinks?
Are airflow mode main link, airflow mode rod,airflow mode cranks, and airflow mode sublinks installed securely and in the properposition?
Is wire clamp free of deformation?Are above items all okay?
No Apply grease or install airflow mode main link,airflow mode rod, airflow mode cranks and airflowmode sub links securely in their proper positions,repair wire clamp, then go to Step 6.
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TROUBLESHOOTING
U–30
STEP INSPECTION ACTION
2 Is airflow mode wire positioned securely and Yes Go to next step.correctly in relation to the heater unit’s airflowmode main link?
No Adjust airflow mode wire or install it correctly, thengo to Step 6.
3 Inspect climate control unit. Is bevel gear set properly engaged?
Yes Go to next step.g y g g
Is airflow mode wire properly installed incorrect direction on bevel gear?
Is wire clamp free of deformation?Are above items okay?
No Properly engage bevel gear set or install airflowmode wire in correct direction, repair or replacewire clamp, then go to Step 6.
4 Is there any foreign material or obstruction in any Yes Remove obstruction, then go to Step 6.of heater unit’s doors? No Go to next step.
5 Are all doors within heater unit securely andproperly positioned?
Yes Inspect each door for cracks or damage, then goto next step.
No Install malfunction doors securely in properposition, then go to next step.
6 Does airflow mode change? Yes Troubleshooting completed. Explain repairs tocustomer.
No Recheck malfunction symptoms, then repeat fromStep 1 if malfunction recurs.
4 Improper air circulation and/or no air circulation.
TROUBLESHOOTING HINTS1 Malfunction in blower unit’s air intake crank, air intake link, air intake wire or wire clamp
Steps 1, 22 Climate control unit air intake wire or wire clamp malfunction
Step 33 Blower unit air intake door malfunction
Steps 4, 5
STEP INSPECTION ACTION
1 Inspect blower unit’s air intake crank, air intakelink and wire clamp. Is there grease on air intake crank and air
Yes Go to next step.
gintake link?
Are air intake crank and air intake link securelyand properly positioned?
Is wire clamp free of deformation?Are above items okay?
No Apply grease or install air intake crank and airintake link properly and securely, repair wireclamp, then go to Step 6.
2 Is air intake wire positioned securely and correctly Yes Go to next step.in relation to the blower unit’s air intake link? No Adjust air intake wire or install securely in correct
position, then go to Step 6.
3 Inspect climate control unit. Is air intake wire properly installed in correct
direction in relation to the air intake lever of
Yes Go to next step.
direction in relation to the air intake lever ofclimate control unit?
Is wire clamp free of deformation?Are above items okay?
No Install air intake wire securely in correct position,repair or replace wire clamp, then go to Step 6.
4 Is there any foreign material or obstruction in Yes Remove obstruction, then go to Step 6.blower unit’s air intake door? No Go to next step.
5 Is blower unit’s air intake door securely andproperly positioned?
Yes Inspect air intake door for cracks or damage, thengo to next step.
No Install air intake door securely in proper position,then go to next step.
6 Does air circulate? Yes Troubleshooting completed. Explain repairs tocustomer.
No Recheck malfunction symptoms, then repeat fromStep 1 if malfunction recurs.
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CONTROL SYSTEM
U–31
5 No temperature control.(Without variable thermistor in climate control unit only)
TROUBLESHOOTING HINTS1 Malfunction in heater unit’s air mix rod, air mix link, air mix cranks, air mix shaft, air mix wire or wire clamp
Steps 2, 32 Bevel gear set (2) in climate control unit, air mix wire or wire clamp malfunction
Step 43 Heater unit air mix door malfunction
Steps 5, 6
STEP INSPECTION ACTION
1 Is coolant sufficiently warmed up? Yes Go to next step.
No Warm engine up, then go to Step 7.
2 Inspect heater unit’s air mix rod, air mix link, airmix cranks, air mix shaft and wire clamp. Is there grease on air mix rod, air mix link and
Yes Go to next step.
g ,air mix cranks?
Are air mix rod, air mix link, air mix cranks, andair mix shaft securely installed in their properpositions?
Is wire clamp free of deformation?Are above items okay?
No Apply grease or install air mix rod, air mix link, airmix cranks, and air mix shaft securely in theirproper positions, repair wire clamp, thengo to Step 7.
3 Is air mix wire securely installed in the correct Yes Go to next step.position in relation to heater unit’s air mix link? No Adjust air mix wire or install securely in correct
position, then go to Step 7.
4 Inspect climate control unit. Is bevel gear set properly engaged?
Yes Go to next step.g y g g
Is air mix wire properly installed in correctposition in relation to bevel gear?
Is wire clamp free of deformation?Are above items okay?
No Properly engage bevel gear set or install air mixwire in correct position, repair or replace wireclamp, then go to Step 7.
5 Is there any foreign material or obstruction in Yes Remove obstruction, then go to Step 7.heater unit’s air mix door? No Go to next step.
6 Is heater unit’s air mix door securely and properlyinstalled?
Yes Inspect door for cracks or damage, then go tonext step.
No Install door securely in proper position, then go tonext step.
7 Does unit operate in every temperature setting? Yes Troubleshooting completed. Explain repairs tocustomer.
No Recheck malfunction symptoms, then repeat fromStep 1 if malfunction recurs.
6 Air from vent not cold enough.
TROUBLESHOOTING HINTS1 Drive belt malfunction
Step 12 Malfunction in blower unit or condenser
Steps 4, 53 Malfunction in receiver/drier or expansion valve (valve closes too much)
Steps 8, 94 Malfunction in refrigerant lines
Steps 10, 115 Malfunction in piping connections
Steps 1, 2, 136 A/C compressor system malfunction, insufficient compressor oil
Steps 15, 167 Compressor oil over-full, malfunction in expansion valve or heater unit air mix link system
Steps 17—20
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TROUBLESHOOTING
U–32
STEP INSPECTION ACTION
1 Inspect drive belt. Yes Go to next step.
+ Section B2, DRIVE BELT, DRIVE BELTINSPECTION
Is it okay?
No Adjust or replace drive belt, then go to Step 21.+ Section B2, DRIVE BELT, DRIVE BELT
ADJUSTMENT
2 Carry out refrigerant system performance test.+ REFRIGERANT SYSTEM SERVICE
PROCEDURES PERFORMANCE TEST
Yes Operation is normal. (Recheck malfunctionsymptoms.)
PROCEDURES, PERFORMANCE TESTIs operation normal? No Go to next step.
3 Are refrigerant’s high-pressure and low-pressure Yes Go to next step.values both high? No Go to Step 6.
4 Is blower unit intake clogged? Yes Remove obstruction, then go to Step 21. (If airdoes not reach evaporator within cooling unit,heat exchange does not occur and refrigerantpressure rises. Therefore, removal of obstructionis necessary.)
No Go to next step.
5 Inspect condenser.+ BASIC SYSTEM, CONDENSER INSPECTIONIs it okay?
Yes Add or subtract refrigerant to make specifiedamount, then go to Step 21. (Excessive amountof refrigerant.)
No Replace condenser, or repair and cleancondenser fins, then go to Step 21.
6 Are refrigerant’s high-pressure and low-pressure Yes Go to next step.values both low? No Go to Step 14.
7 Immediately after A/C compressor operates, doesrefrigerant’s high-pressure value momentarily rise
Yes Go to next step.g g y
to correct value, then fall and stay below it? (Isthere negative pressure on low-pressure side?)
No Go to Step 10.
8 Turn A/C switch off and let air conditioner stop for10 min tes
Yes Go to next step.10 min utes .Start engine.Turn both A/C switch and fan switch on.Does malfunction occur after A/C compressorturns on?
No Start vacuum pump for 30 minutes and replacereceiver/drier, then go to Step 21. (Sincereceiver/drier has become saturated with water,replacement is necessary.)
9 Is expansion valve heat-sensing tube withincooling unit securely installed in proper position?
Yes Replace expansion valve, then go to Step 21.(Since valve closes too much, replacement isnecessary.)
No Install heat-sensing tube securely in properposition, then go to Step 21.
10 Inspect refrigerant lines. Is piping free of damage and cracks? Are piping connections free of oil grime?
(Visual inspection) Are piping connections free of gas leakage? Are piping installation points on condenser free
of gas leakage?
Yes Go to next step.
g g Are piping installation points on receiver/drier
free of gas leakage? Are piping installation points on A/C
compressor free of gas leakage? Are piping installation points on cooling unit
free of gas leakage?*Perform gas leak inspection using gas leaktester.Are above items okay?
No If piping or an A/C component is damaged orcracked, replace it. Then go to Step 21. If there isno damage, go to Step 13.
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CONTROL SYSTEM
U–33
STEP INSPECTION ACTION
11 Are piping connections for evaporator in coolingunit free of gas leakage?
Yes If the A/C compressor is making noise, add 10 ml 10 cc, 0.34 fl oz of compressor oil andverify that malfunction does not occur.Add or subtract refrigerant to make specifiedamount, then go to Step 21.
No If piping is damaged or cracked, replace it. Thengo to Step 21. If there is no damage, go to nextstep.
12 Are piping connections for evaporator in coolingunit loose?
Yes Tighten connections to specified torque. If the A/Ccompressor is making noise, add 10 ml 10 cc,0.34 fl oz of compressor oil and verify thatmalfunction does not occur.Tighten connections to specified torque, add orsubtract refrigerant to make specified amount,then go to Step 21.
No If the A/C compressor is making noise, add 10 ml 10 cc, 0.34 fl oz of compressor oil andverify that malfunction does not occur.Replace O-ring on piping, add or subtractrefrigerant to make specified amount, then go to Step 21.
13 Are piping connections loose? Yes Tighten connections to specified torque. If the A/Ccompressor is making noise, add 10 ml 10 cc,0.34 fl oz of compressor oil and verify thatmalfunction does not occur.Tighten connections to specified torque, add orsubtract refrigerant to make specified amount,then go to Step 21.
No If the A/C compressor is making noise, add 10 ml10 cc, 0.34 fl oz of compressor oil and verifythat malfunction does not occur.Replace O-ring on piping, add or subtractrefrigerant to make specified amount, then go to Step 21.
14 Does refrigerant’s high-pressure value hardly Yes Go to next step. (Pressure hardly increases.)increase? No Go to Step 17.
15 When engine is racing, does high-pressure value Yes Return to Step 3.increase? No Go to next step.
16 After compressor oil is replenished each 10 ml10 cc, 0.34 fl oz , does high-pressure value
Yes Troubleshooting completed. (Explain to customerthat cause was insufficient compressor oil.)
increase? No Replace A/C compressor, then go to Step 21.(Cause is defective A/C compressor.)
17 Is only refrigerant low-pressure value high? Yes Go to Step 20.
No Go to next step.
18 Are heater unit’s air mix rod, air mix link, air mix Yes Go to next step.cranks and air mix shaft securely and properlyinstalled?
No Repair or install air mix rod, air mix link, air mixcranks and air mix shaft securely in properposition, then go to Step 21.
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TROUBLESHOOTING
U–34
STEP INSPECTION ACTION
19 1. Set the fan switch at 4th position.2. Turn the A/C switch on.3. Set to FRESH mode.4. Set the temperature control to MAX COLD.5. Set to VENT mode.6. Run engine at a constant 1,500 rpm for
10 minutes .7. Run engine at idle speed for 1 minute.8. 1 engine speed cycle is defined as going from
idle speed to 4,000 rpm and back to idle speedover a period of 12 seconds . Perform 5 cycles
Yes Go to Step 21.
Perform 5 cycles .9. Run engine at idle speed for 30 seconds .
10. Remove all compressor oil from A/Ccompressor and verify that it is 105 ml 105 cc,3.55 fl oz .
11. If it is more than 105 ml 105 cc, 3.55 fl oz ,put only 105 ml 105 cc, 3.55 fl oz back into A/C compressor.
12. Carry out above steps 1 to 10 again and verifythat compressor oil is 105 ml 105cc, 3.55 floz .
Is there 105 ml 105 cc, 3.55 fl oz ofcompressor oil in A/C compressor?
No Carry out 1 to 10 of step 19 again untilcompressor oil is 105 ml 105 cc, 3.55 fl oz .
20 Is expansion valve heat-sensing tube withincooling unit securely installed in proper position?
Yes Replace expansion valve, then go to next step.(Since valve opens too much, replacement isnecessary.)
No Install heat-sensing tube securely in properposition, then go to next step.
21 Does cool air blow out? (Are results of refrigerantsystem performance test okay?)
Yes Troubleshooting completed. Explain repairs tocustomer.
No Recheck malfunction symptoms, then repeat fromStep 1 if malfunction recurs.
7 No cool air.
TROUBLESHOOTING HINTS1 A/C compressor system malfunction
Step 22 Incorrect amount of refrigerant
Step 33 A/C switch indicator light malfunction
Steps 4—64 A/C relay system malfunction
(WL, WL turbo, F2 Cab) Steps 7, 11—13(G6, F2) Steps 7, 11, 12
5 Refrigerant pressure switch malfunctionStep 8
6 PCM A/C cut-off control system(WL, WL turbo) Steps 9, 26(G6, F2) Step 9
7 PCM (IG1 signal) system malfunctionSteps 10, 25
8 Magnetic clutch system malfunctionStep 14
9 PCM (A/C signal) system malfunction(WL, WL turbo) Steps 15, 20(G6, F2) Steps 15, 19, 20(F2 Cab) Step 15
10 Thermoswitch, A/C switch malfunction(WL, WL turbo, G6, F2) Steps 21—24(F2 Cab) Steps 16—18
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CONTROL SYSTEM
U–35
STEP INSPECTION ACTION
1 Does air blow out? Yes Go to next step.
No Go to Step 1 of troubleshooting indexes 1, 2.
2 Start engine.Turn both A/C switch and fan switch on
Yes Go to Step 1 of troubleshooting index 6.Turn both A/C switch and fan switch on.Does A/C compressor operate? No Go to next step.
3 Inspect refrigerant amount.+ REFRIGERANT SYSTEM SERVICE
Yes Go to next step.+ REFRIGERANT SYSTEM SERVICE
PROCEDURES, PERFORMANCE TESTIs it okay?
No Add or subtract refrigerant to specified level, thengo to Step 27.
4 Does A/C switch indicator light illuminate? Yes Go to Step 7.
No Go to next step*5 Turn ignition switch to ON position.
(With air mix wire) Remove airflow mode wire, airintake wire and air mix wire. Remove climatecontrol unit.(Without air mix wire) Remove airflow mode wire
Yes Go to next step.
(Without air mix wire) Remove airflow mode wireand air intake wire. Remove climate control unit.Remove A/C switch from climate control unit andconnect A/C switch connector.Test voltage at A/C switch terminal C (IG2 signal).Is voltage approximately 12 V ?
No Repair wiring harness between fuse block andA/C switch, then go to Step 27.
*6 Inspect A/C switch.+ CONTROL SYSTEM, CLIMATE CONTROL
UNIT INSPECTION
Yes Inspect wiring harness between A/C switch andresistor, then go to Step 27.
UNIT INSPECTIONIs it okay? No Replace A/C switch, then go to Step 27.
7 Are A/C relay power supply fuses okay? Yes Go to next step.
No Check for a short to ground on blown fuse’scircuit.Repair or replace as necessary.Install appropriate amperage fuse.
*8 Remove radiator grille. Disconnect refrigerantpressure switch connector. When refrigerant
Yes Inspect refrigerant pressure switch, then go to Step 27.
pressure switch connector terminals A and B (onwiring harness side) are shorted, does cool airblow out?
No WL for ISRAEL: Undo short, reconnectrefrigerant pressure switch connector, then go toStep 10.Other models: Undo short, reconnect refrigerantpressure switch connector, then go to next step.
*9 Check the DTC for the PCM ON-BOARDDIAGNOSTIC SYSTEM.Are the following DTCs displayed? DTC 09 (WL or WL turbo) DTC 0120 (F2 or G6)
+ Section F2, ON-BOARD DIAGNOSTICSYSTEM, DIAGNOSTIC TROUBLE CODEINSPECTION
Yes Go to appropriate inspection procedure. (Theengine coolant temperature sensor (DTC 09) orthrottle position sensor (DTC 0120), which sendsthe PCM’s A/C cut off control input signal, may bethe cause of the trouble.)
No Go to next step.
*10 Turn ignition switch to ON position.Does magnetic clutch operate when A/C relay
Yes Go to Step 15.Does magnetic clutch operate when A/C relayconnector terminal B (IG2 signal) is grounded? No Go to next step.
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TROUBLESHOOTING
U–36
STEP INSPECTION ACTION*11 Turn ignition switch to ON position.
Test voltage at the following A/C relay connectorterminals:
Yes Go to next step.
terminals: Terminal A (IG2 signal) Terminal C (A/C control signal)
Is voltage approximately 12 V ?
No Repair wiring harness between fuse block andA/C relay, then go to Step 27.
*12 Test voltage at A/C relay terminal D (A/C controlsignal).
Yes G6 or F2: Go to Step 14.Other models: Go to next step.
Is voltage approximately 12 V ? No Inspect A/C relay, then go to Step 27.*13 Disconnect refrigerant pressure switch connector.
Test voltage at refrigerant pressure switchconnector (on wiring harness side) terminal A
Yes Reconnect refrigerant pressure switch connector,then go to next step.
connector (on wiring harness side) terminal A(A/C control signal).Is voltage approximately 12 V ?
No Repair wiring harness between A/C relay andrefrigerant pressure switch, then go to Step 27.
*14 Test voltage at magnetic clutch connector Yes Inspect magnetic clutch, then go to Step 27.terminal A (A/C control signal).Is voltage approximately 12 V ?
No G6 or F2: Repair wiring harness between A/Crelay and magnetic clutch, then go to Step 27.Other models: Repair wiring harness betweenrefrigerant pressure switch and magnetic clutch,then go to Step 27.
*15 Turn A/C switch off. Remove glove compartment.Turn ignition switch to ON position. Test voltageat the following thermoswitch connector terminal(A/C signal):
Yes F2 Cab: Go to next step.Other models: Go to Step 21.
(A/C signal): Terminal B (with variable thermistor in climate
control unit) Terminal A (without variable thermistor in
climate control unit)Is voltage approximately 12 V ?
No F2 Cab: Repair wiring harness between A/C relayand thermoswitch, then go to Step 27.G6 or F2: Go to Step 19.Other models: Go to Step 20.
*16 Turn ignition switch to LOCK position.Disconnect thermoswitch connector.Start engine.Turn both A/C switch and fan switch on.When following thermoswitch connector terminals(on wiring harness side) are shorted does cool
Yes Undo short, then go to next step.
(on wiring harness side) are shorted, does coolair blow out? Terminal A—C (with variable thermistor in
climate control unit) Terminal B—C (without variable thermistor in
climate control unit)
No Undo short, then go to Step 18.
*17 Turn ignition switch to ON position.Test voltage at the following thermoswitchconnector terminals (IG2 signal): Terminal B (with variable thermistor in climate
Yes Inspect thermoswitch, then go to Step 27.
Terminal B (with variable thermistor in climatecontrol unit)
Terminal A (without variable thermistor inclimate control unit)
Is voltage approximately 12 V ?
No Repair wiring harness between fuse block andthermoswitch, then go to Step 27.
*18 Turn ignition switch to ON position.Turn A/C switch on.Turn fan switch off.Test voltage at A/C switch connector terminal A
Yes Inspect wiring harness between thermoswitchand A/C switch, then go to Step 27.
Test voltage at A/C switch connector terminal A(A/C signal).Is voltage approximately 12 V ?
No Inspect A/C switch, then go to Step 27.
*19 Disconnect refrigerant pressure switch connector.Test voltage at refrigerant pressure switchconnector (on wiring harness side) terminal A
Yes Repair wiring harness between thermoswitch andrefrigerant pressure switch, then go to Step 27.
( g )(A/C control signal). Is voltage approximately 12 V ?
No Go to next step.
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CONTROL SYSTEM
U–37
STEP INSPECTION ACTION*20 Turn ignition switch to ON position.
Test voltage at the following PCM connectorterminals (A/C signal): Terminal G (WL or WL turbo) Terminal Q (G6 or F2)
Yes G6 or F2: Repair wiring harness between PCM andrefrigerant pressure switch, then go to Step 27.Other models: Repair wiring harness betweenPCM and thermoswitch, then go to Step 27.
Terminal Q (G6 or F2)Is voltage approximately 12 V ? No Inspect PCM, then go to Step 27.
*21 Turn ignition switch to LOCK position.Disconnect thermoswitch connector.Start engine.Turn both A/C switch and fan switch on.When following thermoswitch connector terminals(on wiring harness side) are shorted does cool
Yes Undo short, then go to next step.
(on wiring harness side) are shorted, does coolair blow out? Terminal B—C (without variable thermistor in
climate control unit) Terminal A—C (with variable thermistor in
climate control unit)
No Go to Step 23.
22 Turn ignition switch to ON position.Test voltage at the following thermoswitchconnector terminals (IG2 signal):
Yes Inspect thermoswitch, then go to Step 27.
( g ) Terminal A (without variable thermistor in
climate control unit) Terminal B (with variable thermistor in climate
control unit)Is voltage approximately 12 V ?
No Repair wiring harness between fuse block andthermoswitch, then go to Step 27.
*23 Turn ignition switch to ON position.Turn A/C switch on.Turn fan switch off.
Yes Go to next step.
Test voltage at A/C switch connector terminal A(A/C signal).Is voltage approximately 12 V ?
No Inspect A/C switch, then go to Step 27.
*24 Test voltage at thermoswitch connector terminal Yes Go to next step.C (A/C signal).Is voltage approximately 12 V ?
No Repair wiring harness between thermoswitch andA/C switch, go to Step 27.
*25 Test voltage at the following PCM connectorterminals (A/C signal): Terminal L (WL or WL turbo)
Yes WL or WL turbo: Go to next step.Other models: Recheck malfunction symptoms.
Terminal L (WL or WL turbo) Terminal J (G6 or F2)
Is voltage approximately 12 V ?
No Repair wiring harness between A/C relay andPCM, then go to Step 27.
*26 Inspect the following input signal components: Engine coolant temperature sensor and PCM
Yes Recheck malfunction symptoms. Engine coolant temperature sensor and PCM
wiring harness (A/C cut-off control).Are they okay?
No Replace input signal components, then go to nextstep.
27 Does cool air blow out? (Is refrigerant systemperformance test result correct?)
Yes Troubleshooting completed. Explain repairs tocustomer.
No Recheck malfunction symptoms, then repeat fromStep 1 if malfunction recurs.
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TROUBLESHOOTING
U–38
8 Noise while operating A/C system.
TROUBLESHOOTING HINTS1 Magnetic clutch operation noise
Step 32 A/C compressor operation noise
Steps 4—83 A/C compressor slippage noise
Steps 9—114 Hose or refrigerant line interference noise
Step 12
STEP INSPECTION ACTION
1 Is there a squeaking or whirling sound (A/C Yes Go to Step 9.compressor slippage noise)? No Go to next step.
2 Is there a rattling or vibrating sound (interference Yes Go to Step 12.noise)? No Go to next step.
3 Is there a clicking sound (magnetic clutchoperation noise)?
Yes Adjust clearance between magnetic clutchpressure plate and A/C compressor pulley, thengo to Step 13.+ CONTROL SYSTEM, MAGNETIC CLUTCH
CLEARANCE ADJUSTMENT
No Go to next step.
4 Is noise heard continuously for more than 3 Yes Go to next step.seconds after A/C compressor comes on? No Condition is normal. (Noise normally occurs for
2—3 seconds immediately after A/C compressorturns on.)
5 Inspect idle speed.+ Section F2, ENGINE TUNE-UP, IDLE SPEED
ADJUSTMENT
Yes Go to next step.
Is it okay?
No Adjust idle speed, then go to Step 13.
6 Drain compressor oil. Yes Go to next step.Is it contaminated with metal particles? No Replace A/C compressor, then go to Step 13.
7 Is compressor oil whitish and mixed with water? Yes Replace entire A/C system (excluding heater),then go to Step 13.
No Go to next step.
8 Is compressor oil darker than normal andcontaminated with aluminum chips?
Yes Replace A/C compressor and receiver/drier, thengo to Step 13. (Since A/C compressor may beworn and receiver/drier may be clogged,replacement of receiver/drier is necessary.)
No Condition is normal. Recheck malfunctionsymptoms.
9 Inspect drive belt.+ Section B2, DRIVE BELT, DRIVE BELT
INSPECTION
Yes Go to next step.
Is it okay?
No Adjust or replace drive belt, then go to Step 13.
10 Is drive belt worn? Does it have foreign materialimbedded in it, or have oil on it?
Yes Remove obstruction, remove oil, or replace drivebelt, then go to Step 13.
No Go to next step.
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CONTROL SYSTEM
U–39
STEP INSPECTION ACTION
11 Inspect magnetic clutch.+ CONTROL SYSTEM, MAGNETIC CLUTCH
INSPECTION
Yes Replace A/C compressor (excluding pressureplate, A/C compressor pulley, and stator), then goto Step 13.
Is it okay? No Replace magnetic clutch, then go to Step 13.
12 Is noise coming from A/C compressor? Yes Visually inspect A/C compressor, replaceappropriate parts if necessary, then go to nextstep.
No If noise is coming from refrigerant lines, repairany detached or missing clips, tighten loose bolts,then go to next step.
13 Has A/C compressor noise stopped? Yes Troubleshooting completed. Explain repairs tocustomer.
No Recheck malfunction symptoms, then repeat fromStep 1 if malfunction recurs.
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TD–1
TECHNICAL DATATECHNICAL DATA TD– 1. . . . . . . . . . . . . . . . . . . . . . . .
ENGINE TD– 1/3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATION SYSTEM TD– 4. . . . . . . . . . . . . . . . . COOLING SYSTEM TD– 4. . . . . . . . . . . . . . . . . . . . . FUEL AND EMISSION CONTROL
SYSTEMS TD– 5/6. . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE ELECTRICAL SYSTEM TD– 6/10. . . . . . . . . CLUTCH TD–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MANUAL TRANSMISSION TD–10/11. . . . . . . . . . . . . . .
PROPELLER SHAFT TD–11. . . . . . . . . . . . . . . . . . . . FRONT AND REAR AXLES TD–11. . . . . . . . . . . . . . STEERING SYSTEM TD–12. . . . . . . . . . . . . . . . . . . . BRAKING SYSTEM TD–12. . . . . . . . . . . . . . . . . . . . . SUSPENSION TD–13/14. . . . . . . . . . . . . . . . . . . . . . . . . . BODY ELECTRICAL SYSTEM TD–14/15. . . . . . . . . . . HEATER AND AIR
CONDITIONER SYSTEMS TD–15. . . . . . . . . . . . .
TECHNICAL DATAENGINE
ItemEngine
ItemG6
GeneratorNew 10.0—12.0 0.40—0.47
Drive belt deflectionGenerator
Used 12.0—14.0 0.48—0.55Drive belt deflection[Applied pressure
P/SNew 6.6—7.2 0.26—0.28[
98 N 10 kgf, 22 lbf]( i )
P/SUsed 7.2—8.0 0.29—0.31
(mm in)A/C
New 8.5—10.0 0.34—0.39A/C
Used 10.0—11.5 0.40—0.45
GeneratorNew 491—588 50—60, 110—132
GeneratorUsed 393—490 40—50, 88—110
Drive belt tension P/SNew 412—470 42—48, 93—105
(N kgf, lbf)P/S
Used 354—402 36—41, 80—90
A/CNew 557—641 56.7—65.4, 125—143
A/CUsed 471—556 48.0—56.7, 106—124
Compression (kPa kgf/cm2 psi [rpm])Standard 1255 12.8, 182 [270]
Compression (kPa kgf/cm2, psi [rpm])Minimum 882.6 9.0, 128 [270]
Pushing distance of the front oil seal (from the edge of the chain cover) (mm in)
0—0.7 0—0.027
Pushing distance of the rear oil seal (from the edge of the rear cover) (mm in)
0—0.5 0—0.019
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TECHNICAL DATA
TD–2
ItemEngine
ItemWL, WL Turbo
New 7.0—9.0 0.28—0.35
Generator Used 8.0—10.0 0.32—0.39
Limit 16.0 0.63Drive belt deflection [A li d 98 A/C (meas ring
New 5.0—6.2 0.20—0.24[Applied pressure 98N 10 kgf 22 lbf]
A/C (measuringpoint a)
Used 6.0—6.5 0.24—0.25N 10 kgf, 22 lbf]
(mm in)oint a)
Limit 11.3 0.44( )
A/C (meas ringNew 9.5—11.8 0.38—0.46
A/C (measuringpoint b)
Used 11.0—12.5 0.44—0.49oint b)
Limit 18.0 0.71
New 442—637 45—65, 99—143
Generator Used 383—539 39—55, 86—121
Drive belt tension Limit 177 18, 40
(N kgf, lbf) New 403—519 41—53, 91—116
A/C Used 354—431 36—44, 80—96
Limit 181 18.5, 41
Valve clearance [Engine cold] (mm in)IN 0.05—0.15 0.0020—0.0059 (0.100.05 0.00390.0020)
0.15 0.0059 [Engine hot (Reference)]Valve clearance [Engine cold] (mm in)
EX 0.15—0.25 0.0060—0.0098 (0.200.05 0.00790.0020)0.25 0.0098 [Engine hot (Reference)]
Compression (kPa kgf/cm2 psi [rpm])Standard 2,942 30, 427 [200]
Compression (kPa kgf/cm2, psi [rpm])Minimum 2,648 27, 384 [200]
Timing belt deflection [Applied pressure 98 N 10 kgf, 22 lbf]
(mm in)Standard 9.0—10.0 0.36—0.39
Bolt head mark WStandard 101.2—101.8 3.985—4.007
Cylinder head boltBolt head mark W
Minimum 102.5 4.035ylength (mm in)
Bolt head mark NStandard 113.2—113.8 4.457—4.480
Bolt head mark NMinimum 114.5 4.508
Camshaft oil seal tapping amount (mm in) 0.5—1.0 0.02—0.03
Front oil seal tapping amount (mm in) 0—0.4 0—0.01
Rear oil seal tapping amount (mm in) 0—0.5 0—0.01
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TECHNICAL DATA
TD–3
ItemEngine
ItemF2 CARB F2 CIS
GeneratorNew 7.0—8.0 0.28—0.31
Drive belt deflectionGenerator
Used 8.0—9.0 0.32—0.35Drive belt deflection[Applied pressure
P/SNew 5.0—6.0 0.20—0.23[
98 N 10 kgf, 22 lbf]( i )
P/SUsed 5.5—6.5 0.22—0.25
(mm in)A/C
New 10.0—12.0 0.40—0.47A/C
Used 12.0—14.0 0.48—0.55
GeneratorNew 510—588 52—60, 115—132
GeneratorUsed 432—509 44—52, 97—114
Drive belt tension P/SNew 393—490 40—50, 88—110
(N kgf, lbf)P/S
Used 344—441 35—45, 77—99
A/CNew 373—490 38—50, 84—110
A/CUsed 275—372 28—38, 62—83
Compression (kPa kgf/cm2 psi [rpm])Standard 1196 12.2, 173 [300] 1226 12.5, 178 [300]
Compression (kPa kgf/cm2, psi [rpm])Minimum 837 8.54, 121 [300] 858 8.75, 124 [300]
Timing belt deflection New 8.0—9.0 0.32—0.35g[Applied pressure 98 N 10 kgf, 22 lbf] (mm in) Used 9.0—10.0 0.36—0.39
Pushing distance of the front oil seal (from the edge of the chain cover) (mm in)
0 0
Pushing distance of the rear oil seal (from the edge of the rear cover) (mm in)
0—0.5 0—0.019
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TECHNICAL DATA
TD–4
LUBRICATION SYSTEM
ItemEngine
ItemF2 G6 WL WL Turbo
Oil pressure (kPa kgf/cm2, psi [rpm])
295—3923.0—4.0,43—56[3000]
305—4023.1—4.1,45—58[3000]
452—5294.6—5.4,66—76[3000]
402—4804.1—4.9,59—69[3000]
Oil capacitOil replacement 3.9 4.1, 3.4 4.5 4.8, 4.0 5.6 5.9, 4.9
Oil capacity(L US qt lmp qt)
Oil and oil filter replacement 4.2 4.4, 3.7 4.7 5.0, 4.4 6.3 6.7, 5.5(L US qt, lm qt)
Total (dry engine) 4.6 4.9, 4.0 5.5 5.8, 4.8 6.7 7.1, 5.9
Engine oil API service SG API service CD
Above 30C 86F SAE 40 —
0°C—40C 32F—104°F SAE 30 —
–10°C—20C 14F—68°F SAE 20W-20 —
Above –25C –13F SAE 10W-30*, 10W-40, 10W-50 —
Viscosity Above –10C 14F SAE 20W-40, 20W-50 —
Below –20C –4F SAE 5W-20 —
Below 0C 32F SAE 5W-30* —
–15°C—40C 5F—104°F — — SAE 10W-30
Below 10C 50F — — SAE 5W-30 European specification vehicles use only those oils marked with an asterisk
COOLING SYSTEM
ItemEngine
ItemF2 G6 WL WL Turbo
Coolant capacity (L US qt lmp qt)With heater 7.5 7.9, 6.6 9.4 9.9, 8.3
Coolant ca acity (L US qt, lm qt)Without heater 6.9 7.3, 6.1 8.8 9.3, 7.7
Thermostat
Opening temperature (C F)83.5—89.5183—193
Sub:83.5—86.5183—187
Main:86.5—89.5188—193
80—84 176—183
ThermostatFull-open temperature (C F) 100 212 95 203
Full-open lift (mm in)8.5 0.33
min.
Sub: 1.50.06 min. Main: 8.0
0.31 min.
8.5 0.33 min.
Radiator capCap valve opening pressure
(kPa kgf/cm2, psi)
74—1020.75—1.05,10.7—14.9
94—122 0.95—1.25, 13.5—17.7
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TECHNICAL DATA
TD–5
FUEL AND EMISSION CONTROL SYSTEMSCIS vehicles
ItemEngine
ItemG6 F2
Idle speed (rpm) 730—770 (75020) 730—770 (75020)
Injection timing (BTDC °/rpm) 4—6/750 5—7/750
Idle speed*1 (rpm)A/C ON*2 700—800 (75050) 780—880 (83050)
Idle speed 1 (rpm)P/S ON*3 700—800 (75050)
CO concentration Within the regulation
HC concentration Within the regulation
Fuel pressure Hold pressure More than 340 3.5, 50(kPa kgf/cm2, psi) Fuel pump maximum pressure 500—630 5.0—6.5, 72—92
Fuel leakage(drop/2 minutes)
Less than 1
Fuel injector Injection volume(ml cc, fl oz/15 sec.)
55—71 55—71, 1.9—2.3 46—60 46—60, 1.6—2.0
Resistance(Ω) [20°C 68°F]
12—16
Pressure regulator
Fuel pressure (at vacuum ON)(kPa kgf/cm2, psi)
210—250 2.1—2.6, 30—36Pressure regulator
Fuel pressure (at vacuum OFF*4)(kPa kgf/cm2, psi)
270—310 2.7—3.2, 39—45
*1: Excludes temporary idle speed drop just after the loads (A/C, P/S) are turned on.*2: A/C switch and fan switch are turned on.*3: Steering wheel is fully turned.*4: Hot condition at start.
DIESEL vehicles
ItemEngine
ItemWL Turbo WL
Idle speed (rpm)760—800 (78020)*1
700—740 (72020)*2 700—740 (72020)
Injection timing ATDC 10°
Boost relief pressure (kPa kgf/cm2, psi)107—115 1.09—1.18,
15.5—16.8—
Idle-up speedWhen A/C is operated 825—875 (85025)
805—855 (83025)825—875 (85025)*3
Idle u s eed(rpm) When P/S is operated — —
When engine is cold 1200—1500 (1350150)
Injection pump Cam lift (mm in) 2.48 0.098
Injection nozzle
Injection starting pressure(MPa kgf/cm2, psi)
New: 11.4—12.2 116—124, 1650—1760Inspection: More than 10.0 102, 1450
Injection nozzleNozzle leakage
No leakage when pressure of 8.8 MPa 90 kgf/cm2, 1280 psi)is applied.
Diesel smoke (%) Within the regulation*1: General (L.H.D.)*2: Europe and UK*3: Europe
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TECHNICAL DATA
TD–6
CARB vehicles
ItemEngine
ItemF2 CARB
Idle speed (rpm) 800—850 (800 )+50–0
Injection timing (BTDC°) 5—7 (61)
A/C Operated 1400—1600 (1500100)
Idle up speed (rpm)P/S Operated —
Idle-up speed (rpm)D/P Operated 1900—2100 (2000100)
T/P Operated 1050—1250 (1150100)
CO concentration (%) 2.0—2.5 (2.0 )*1, 2.0—3.0 (2.50.5)*2+0.5–0
HC concentration (ppm) —
Fuel pumpDischarge pressure (kPa kgf/cm2, psi) 20—25 0.2—0.25, 2.8—3.6
Fuel umDischarge amount cc cu in min. 1150 70.2
Float level (mm in)H 8—9 0.315—0.354
CarburetorFloat level (mm in)
L 44—45 1.732—1.772
Primary throttle opening angle (°) 48—52 502*1: GULF*2: General
ENGINE ELECTRICAL SYSTEM
ItemEngine
ItemG6
Electrolyte gravity 1.27—1.29
Back-up current *1 (mA) Max. 20
Battery
Test load chart(A)
Battery type 80D26R 195Battery
Slow charge (A)
Battery type (5-hour rate)
80D26R (55) 5.5—6.5
Quick charge(A/30 min.)
Battery type (5-hour rate)
80D26R (55) 35
Rotor resistance (Between slip rings) (Ω) 3.7—4.4
Brush lengthStandard (mm in) 18.5 0.73
Brush lengthMinimum (mm in) 5.0 0.20
Brush spring forceStandard (N kgf, lbf) 4.8—6.0 0.48—0.62, 1.06—1.36
Brush s ring forceMinimum (N kgf, lbf) 2.2 0.22, 0.48
Ignition switchB B+
GeneratorIgnition switchON
Terminal L Approx. 1GeneratorStandard voltage
ONS B+g
(V)Idle
B 14.1—14.7Idle [20C 68F]
Terminal L 13.0—14.0[20 C 68 F]
S 14.1—14.7
Generated current*2 Engine speed (rpm)1000 Approx. 0—43
(Reference) (A)Engine s eed (r m)
2000 Approx. 0—62*1: Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition
switch is at OFF position and the ignition key is removed.*2: Must not be 0 A.
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TECHNICAL DATA
TD–7
ItemEngine
ItemG6
Ignition Resistance Primary coil (Ω) 0.81—0.99gcoil [20C 68F] Secondary coil (kΩ) 10—16
TypeNGK
ZFR5F–11*3, *5, ZFR6F–11*4, *5,BKR5E*3, BKR6E*4
S
Ty eDENSO
KJ16CR11*3, *5, KJ20CR11*4, *5
K16PR–U*3, K20PR–U*4
Sparkplug Plug gap (mm in)
1.0—1.1 0.040—0.043*5, 0.7—0.8 0.028—0.031
Resistance (kΩ)NGK
3 0—7 5Resistance (kΩ)DENSO
3.0—7.5
Tightening torque (N·m kgf·m, ft·lbf) 15—22 1.5—2.3, 11—16
No.1 lead 2.9—7.7
High-Resistance
No.2 lead 4.3—10.8Hightensionl d
Resistance(kΩ ) [20 C 68 F]
No.3 lead 5.4—13.5lead (kΩ ) [20 C 68 F]
No.4 lead 6.6—16.2
Center lead 4.5—11.2
Commutator Standard (mm in) 29.4 1.16diameter Minimum (mm in) 28.8 1.14
Brush lengthStandard (mm in) 12.3 0.48
Brush lengthMinimum (mm in) 7.0 0.28
StarterBrush spring force
Standard (N kgf, lbf) 180—243 18.3—24.8, 40.3—54.5Brush s ring force
Minimum (N kgf, lbf) 57.7 5.88, 12.9
Pinion gap (mm in) 3.0 1.118
No load testVoltage (V) 11.5
No load testCurrent (A) Below 100
*3: Standard plug*4: Cold type plug*5: Europe
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TECHNICAL DATA
TD–8
ItemEngine
ItemF2 CARB F2 CIS
Electrolyte gravity 1.27—1.29
Back-up current *1 (mA) Max. 20
Test load chart Battery type34B19R 110 —
Battery(A)
Battery ty e55D23R 180
BatterySlow charge Battery type 34B19R (27) 3.0—4.0 —g
(A)y y
(5-hour rate) 55D23R (48) 4.5—5.5
Quick charge Battery type 34B19R (27) 20 —g(A/30 min.)
y y(5-hour rate) 55D23R (48) 30
Rotor resistance (Between slip rings) (Ω) 3.7—4.4
Brush lengthStandard (mm in) 18.5 0.73
Brush lengthMinimum (mm in) 5.0 0.20
Brush spring forceStandard (N kgf, lbf) 4.8—6.0 0.48—0.62, 1.06—1.36
Brush s ring forceMinimum (N kgf, lbf) 2.2 0.22, 0.48
Ignition switchB B+
GeneratorIgnition switchON
Terminal L Approx. 1GeneratorStandard voltage
ONS B+g
(V)Idle
B 14.1—14.7Idle [20C 68F]
Terminal L 13.0—14.0[20 C 68 F]
S 14.1—14.7
Generated current*2 Engine speed (rpm)1000 Approx. 0—43
(Reference) (A)Engine s eed (r m)
2000 Approx. 0—62
Ignition Resistance Primary coil (Ω) 1.035—1.265 0.81—0.99gcoil [20C 68F] Secondary coil (kΩ) 10—16
DistributorCentrifugal spark advance °/rpm
0—2/1200, 9—13/2200,19—23/6000
—Distributor
Vacuum spark advance °/kPa mmHg, inHg0—2/20 150, 5.9,
11—15/53.3 400, 15.7—
Type
NGKBKR5E*5
BKR6E*3
BKR7E*4
BPR5ES–11*3
BPR6ES–11*4
Sparkplug
Ty e
DENSOK16PR–U*5
K20PR–U*3
K22PR–U*4
W16EXR–U11*3
W20EXR–U11*4
lugPlug gap (mm in) 0.7—0.8 0.028—0.031 1.0—1.1 0.040—0.043
Resistance (kΩ)NGK
3 0 7 5Resistance (kΩ)DENSO
3.0—7.5
Tightening torque (N·m kgf·m, ft·lbf) 15—22 1.5—2.3, 11—16
No.1 lead 2.75—7.07
High-Resistance
No.2 lead 4.19—10.43Hightensionl d
Resistance(kΩ ) [20 C 68 F]
No.3 lead 4.38—10.88lead (kΩ ) [20 C 68 F]
No.4 lead 5.73—14.08
Center lead 2.00—5.33 3.9—9.9*1: Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition
switch is at OFF position and the ignition key is removed.*2: Must not be 0 A.*3: Standard plug*4: Cold type plug*5: Hot type plug
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TECHNICAL DATA
TD–9
ItemEngine
ItemF2 CARB F2 CIS
Commutator Standard (mm in) 32.0 1.26diameter Minimum (mm in) 31.4 1.24
Brush lengthStandard (mm in) 17.0 0.67
Brush lengthMinimum (mm in) 11.5 0.46
StarterBrush spring force
Standard (N kgf, lbf) 19.2 1.95, 4.25Brush s ring force
Minimum (N kgf, lbf) 8.83 0.90, 1.98
Pinion gap (mm in) 0.5—2.0 0.020—0.078
No load testVoltage (V) 11.5
No load testCurrent (A) Below 60
ItemEngine
ItemWL, WL Turbo
Electrolyte gravity 1.27—1.29
Back-up current *1 (mA) 20 max.
Test load chart75D26L 195
Test load chart(A)
Battery type 75D26R 195(A)
95D31R 250
BatterySlow charge Battery type
75D26L (52) 5.5—6.5Slow charge
(A)Battery type (5-hour rate)
75D26R (52) 5.5—6.5(A) (5-hour rate)
95D31R (64) 6.5—8.0
Quick charge Battery type75D26L (52) 35
Quick charge(A/30 min )
Battery type (5-hour rate)
75D26R (52) 35(A/30 min.) (5-hour rate)
95D31R (64) 40
Rotor resistance (Between slip rings) (Ω) 2.50
Brush lengthStandard (mm in) 17.9 0.70
Brush lengthMinimum (mm in) 5.0 0.20
Brush spring forceStandard (N kgf, lbf) 2.65 0.27, 0.59
Brush s ring forceMinimum (N kgf, lbf) 1.18 0.12, 0.26
B B+
Engine switch TerminalA B+
G
gON
TerminalS 0
GeneratorStandard voltage I 2.0—4.0g
(V) B 14.05—14.85
Idle TerminalA 14.05—14.85
[20C 68F]Terminal
S 7.025—7.425
I 13.00—14.85
Generated current*2 Engine speed 1000
Terminal Bcurrent
Approx. 0—58
(Reference) (A)g
(rpm)2000
Terminal Bcurrent
Approx. 0—74
*1:Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the engineswitch is at OFF position and the engine key is removed.
*2:Must not be 0 A.
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TECHNICAL DATA
TD–10
ItemEngine
ItemWL, WL Turbo
Commutator Standard (mm in) 29.5 1.16diameter Minimum (mm in) 27.3 1.07
Brush lengthStandard (mm in) 17.7 0.70
Brush lengthMinimum (mm in) 8.7 0.34
StarterBrush spring force
Standard (N kgf, lbf) 27.0—33.0 2.75—3.37, 6.05—7.41Brush s ring force
Minimum (N kgf, lbf) —
Pinion gap (mm in) 3.0 0.12
No load testVoltage (V) 11
No load testCurrent (A) Below 130
CLUTCHItem Specification
Clutch pedal
Height (mm in) 241.6—246.6 9.52—9.70
Pedal free play (mm in) 3.0—8.0 0.12—0.31
Clutch disc
Runout limit (mm in) 0.7 0.027 max.
Clutch fluid
Type SAE J1703 or FMVSS116 DOT-3 or DOT-4
MANUAL TRANSMISSIONM15M-D
Item Specification
Type API service GL-4 or GL-5
All-season SAE 75W-90Transmission oil Viscosity Above
10 C 50 FSAE 80W-90
Capacity (L US qt, lmp qt) 2.0 2.1, 1.8
M15MX-DItem Specification
Type API service GL-4 or GL-5
All-season SAE 75W-90Transmission oil Viscosity Above
10 C 50 FSAE 80W-90
Capacity (L US qt, lmp qt) 2.5 2.6, 2.2
Type API service GL-4 or GL-5
All-season SAE 75W-90Transfer oil Viscosity Above
10 C 50 FSAE 80W-90
Capacity (L US qt, lmp qt) 2.0 2.1, 1.8
R15M-DItem Specification
Type API service GL-4 or GL-5
All-season SAE 75W-90Transmission oil Viscosity Above
10 C 50 FSAE 80W-90
Capacity (L US qt, lmp qt) 2.8 3.0, 2.5
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TECHNICAL DATA
TD–11
R15MX-DItem Specification
Type API service GL-4 or GL-5
All-season SAE 75W-90Transmission oil Viscosity Above
10 C 50 FSAE 80W-90
Capacity (L US qt, lmp qt) 3.2 3.4, 2.8
Type API service GL-4 or GL-5
All-season SAE 75W-90Transfer oil Viscosity Above
10 C 50 FSAE 80W-90
Capacity (L US qt, lmp qt) 2.0 2.1, 1.8
PROPELLER SHAFT
Item Propeller shaft (4 2) Front propeller shaft(44)
Rear propeller shaft(44)
Runout limit (mm in) 0.4 0.016 0.4 0.016 0.4 0.016
Starting torque of universal(N·m kgf·cm, in·lbf)
0.3—1.13.0—12.0, 2.7—10.4
0.3—0.7 3.0—8.0, 2.7—6.9
0.3—1.1 3.0—12.0, 2.7—10.4
FRONT AND REAR AXLESItem 42 44
Play (mm in) 0 0
Front axle Wheel bearingPreload
(N·m kgf·cm, in·lbf)0.4—0.7 4.0—8.0, 3.5—6.9
Pull scale reading (N kgf, lbf)
5.9—10.7 0.6—1.1, 1.4—2.4
Rear axle Wheel bearing play (mm in) 0.05—0.25 0.002—0.010
Drive shaft Shaft length Left side 551.0—561.0 21.7—22.0Drive shaft g
(mm in) Right side 619.0—629.0 24.4—24.7
Pinion height (mm in)Front –0.032—0.032 –0.001—0.001
Pinion height (mm in)Rear –0.254—0.254 –0.010—0.010
Backlash of side gear and differential Front 0—0.1 0—0.003gpinion (mm in) Rear —
Drive pinion preload (N·m kgf·cm in·lbf)Front 0.9—1.3 9.0—14.0, 7.9—12.1
Drive inion reload (N·m kgf·cm, in·lbf)Rear 1.8—2.6 18.0—27.0, 15.7—23.4
Backlash of drivepinion and ring
Standard0.09—0.11 0.0036—0.0043 [Front]
0.12—0.20 0.005—0.008 [Rear]inion and ringgear Minimum 0.05 0.002 [Front], 0.12 0.008 [Rear]
Differential(mm in) Allowance variation 0.07 0.003 [Front], 0.08 0.005 [Rear]
DifferentialGrade API service GL-5
ViscosityFront —
Above-18C 0F: SAE 90Below-18C 0F: SAE 80
Standardy
Rear SAE 90
Oil Capacity (L US qt lmp qt)
Front —1.20 1.27, 1.06 [MFW]1.50 1.59, 1.32 [RFW]
(L US qt, lmp qt)Rear 1.40 1.48, 1.23 1.85 1.96, 1.63
Grade API service GL-6
LSD Viscosity SAE 90
Capacity (L US qt, lmp qt) 1.40 1.48, 1.23 1.85 1.96, 1.63
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TECHNICAL DATA
TD–12
STEERING SYSTEM
Item Manual steering Engine speed sensingpower steering
Steering wheelPlay (mm in) 0—30 0—1.18
Steering wheelEffort (N·m kgf·cm, in·lbf) 45 460, 399 max. 7.8 80, 69 max.
Backlash (mm in) 0 0
Steering gearWorm shaft preload (N·m kgf·cm, in·lbf)
1.0—1.3 10—14, 8.7—12.1
0.7—1.2 6.5—12.5, 5.7—10.8
Gear housing pressure(MPa kgf/cm2, psi)
—8.9—9.3
90—95, 1280—1350
OilGrade API service GL-4, SAE 90
ATF M-III or equivalent(e.g. DexronII )
Capacity (L US qt, lmp qt) 0.34 0.36, 0.30 1.1 1.2, 1.0
Power steeringoil pump
Oil pump fluid pressure(MPa kgf/cm2, psi)
—8.9—9.3
90—95, 1280—1350
BRAKING SYSTEM
Item42
44ItemF2, G6 WL, WL Turbo
44
Brake pedal
Brake pedal height (mm in) L.H.D.: 214—219 8.43—8.81R.H.D.: 219—224 8.63—8.81
Brake pedal play (mm in) 3—8 0.12—0.31
Brake pedal-to-floor clearance (mm in) 105 4.2 min.
Power brake unit
Fluid pressure whenpedal depressed at
Power brake unitat 0 kPa 0 mmHg,0 in Hg
790 8, 114 min.
196 N 20 kgf ,44 lbf)(kPa kgf/cm2, psi)
Power brake unit at66.7 kPa 500mmHg, 19.7 in Hg
8,240 84, 1,200 min.
Vacuum pump
Vacuum specification [In 20 seconds] [When engine speed 1,500 rpm]
(kPa mmHg, in Hg)73.3 550, 21.7
Maximum vacuum[When engine speed 3,000 rpm]
(kPa mmHg, in Hg)93.3 700, 27.6
Braking force control device
Type LSPV
Rear fluid pressure when front pressure is4,900 kPa 50 kgf/cm2, 711 psi
(kPa kgf/cm2, psi)2,550 26, 370
Front disc brake
Disc pad thickness limit (mm in) 2.0 0.08
Disc plateThickness limit (mm in) 22 0.87
Disc lateRunout limit (mm in) 0.05 0.002
Rear drum brake
Brake lining thickness limit (mm in) 1.0 0.04
Drum maximum diameter (mm in) 271.5 10.68 296.5 11.67
Parking brake
Parking brake lever stroke[When pulled at 98 N 10 kgf, 22 lbf]
(notches)1—7
Brake fluid
Type SAE J1703 or FMVSS116 DOT-3 or DOT-4
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TECHNICAL DATA
TD–13
SUSPENSIONSuspension
Item 42 44
Total toe-in(mm in) 33 0.120.12
Total toe-in(Degree) 016’ 16’ 014’ 14’
Front wheelli
MaximumInner 3500’ +2
–3 3330’ +2–3
alignment[unloaded*1]
Maximumsteering angle
Outer 3300’ +2–3 3000’ +2
–3Camber angle 056’30’ 1 06’30’
Caster angle*2 137’45’ 202’45’
Exposed thread of shock absorber piston (mm in) 6—8 0.24—0.31
Lower arm ball joint rotation torque(Pull scale reading) (N kgf, lbf) 14—44 0.7—4.5, 1.6—9.9
Upper arm ball joint rotation torque(Pull scale reading) (N kgf, lbf) 3.4—32.5 0.4—3.2, 0.9—7.0
Exposed thread of stabilizer control link bolt (mm in) 18—21 0.71—0.82*1: Fuel tank is full. Engine coolant and engine oil are at specified levels. Spare tire, jack, and tools are in
designated positions.Adjust to the median when carrying out wheel alignment.
*2: Difference between left and right must not exceed 45’.
Wheels and TiresEurope
Item 42 44
SizeFront
195R14C-8PR 205/75R14C 235/75R15 105S 205R16C-8PRSizeRear
195R14C-8PR 205/75R14C 235/75R15 105S 205R16C-8PR
Front
Up to fullpassenger
180 1 8 26200 2.0, 28
180 1 8 26180 1.8, 26
Tire Air pressure
FrontFullloaded
180 1.8, 26220 2.2, 31
180 1.8, 26200 2.0, 28
Air ressure(kPa kgf/cm2, psi)
Rear
Up to fullpassenger 180 1.8, 26 200 2.0, 28 180 1.8, 26 180 1.8, 26
RearFullloaded 450 4.5, 63 250 2.5, 35 450 4.5, 63
Wear limit (mm in) 1.6 0.06
Wh l
Size 145J 145 1/2J 145 1/2J 156 1/2JJ 166JJ
Wheel Offset (mm in) 40 1.57 25 0.98 35 1.38
Pitch circle diameter (mm in) 139.7 5.45
Tightening torque (N·m kgf·cm, in·lbf)
Standard wheel: 89—117 9—12, 65—86Styled wheel (166JJ): 118—147 12—15, 87—108
Wheeland tire Runout limit (mm in)
Horizontal 2.0 0.078and tire Runout limit (mm in)
Vertical 1.5 0.059
Imbalance limit (g oz) 10 0.35 One balance weight: max. 60 g 2.1 oz. If the total weight exceeds 100 g 3.5 oz on one side, rebalance after moving the tire around on the rim. Do not use more than two balance weights on either side of the wheel.
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TECHNICAL DATA
TD–14
GeneralItem 42 44
SizeFront 185R14C- 195R14C- 205R16C- 235/75R15 P235/75R1 P235/75R1SizeRear
185R14C8PR
195R14C8PR
205R16C8PR
235/75R15105S
P235/75R15 105S
P235/75R15 106S
Front
Unloaded(Up tofullpassenger)
180 1.8, 26
180 1.8, 26
180 1.8, 26
Tire Air pressure
Loaded(Fullloaded)
200 2.0, 28
200 2.0, 28
Air ressure(kPa kgf/cm2, psi)
Rear
Unloaded(Up tofullpassenger)
180 1.8, 26
Loaded(Fullloaded)
450 4.5, 63 250 2.5, 35
240 2.4, 34
2602.6, 36
Wear limit (mm in) 1.6 0.06
Wheel
Size 145J145J 1451/2J
166JJ 156 1/2JJ
WheelOffset (mm in) 40 1.57 35 1.38 25 0.98
Pitch circle diameter (mm in) 139.7 5.45
Tightening torque (N·m kgf·cm, in·lbf)
Standard wheel: 89—117 9—12, 65—86Styled wheel (166JJ): 118—147 12—15, 87—108
Wheeland tire Runout limit (mm in)
Horizontal 2.0 0.078and tire Runout limit (mm in)
Vertical 1.5 0.059
Imbalance limit (g oz) 10 0.35 One balance weight: max. 60 g 2.1 oz. If the total weight exceeds 100 g 3.5 oz on one side, rebalance after moving the tire around on the rim. Do not use more than two balance weights on the inner or outer side of the wheel.
BODY ELECTRICAL SYSTEMItem Specification
Headlight High beam/Low beam* 60/552
Parking light 52
Front turn light 212
Exterior light bulb capacity (W)Brake light/taillight 21/52
Exterior light bulb ca acity (W)Rear turn light 212
Back-up light 212
Rear fog light 211
License plate light 52
Interior lightStretch cab, Double cab 101
Interior light bulb capacity (W)Interior light
Regular cab 81
Instrument cluster illumination 3.44
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TECHNICAL DATA
TD–15
Oil pressure warning light 1.41
Generator warning light 1.41
Sedimentor warning light 1.41
Brake system warning light 1.41
Warning and indicator light Rear window defroster indicator light 1.41Warning and indicator light bulb capacity (W) Glow indicator light 1.41
High beam indicator light 1.41
Turn indicator light 1.42
Air bag system warning light 1.41
44 indicator light 1.41
LOCK indicator light 1.41*: Also remains illuminated when high beam turned on.
HEATER AND AIR CONDITIONER SYSTEMS
ItemSpecification
ItemG6, WL F2
Refrigerant Regular amount (g oz) 550 19.4
A/C compressorLubricating oil
Sealed volume (ml cc, fl oz)
180 180, 6.08A/C com ressor
Magnetic clutch clearance(mm in)
0.35—0.75 0.014—0.029 0.3—0.6 0.012—0.023
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SPECIAL TOOLS SPECIAL TOOLS.............................................. ST-1 FRONT AND REAR AXLES ......................... ST-3/5
ENGINE ........................................................ ST-1 STEERING SYSTEM ...................................ST-6 LUBRICATION SYSTEM ............................... ST-1 BRAKING SYSTEM ......................................ST-7 COOLING SYSTEM ...................................... ST-2 SUSPENSION ..............................................ST-7 FUELAND EMISSION BODY ...........................................................ST-7 CONTROL SYSTEMS................................. ST-2 BODY ELECTRICAL SYSTEM .....................ST-8
CLUTCH ....................................................... ST-2 HEATER AND AIR PROPELLER SHAFT .................................... ST-3 CONDITIONER SYSTEMS ......................ST-8
SPECIAL TOOLS ENGINE 49 S013 1A1 Compression gauge set
49 9200 020A Belt tension gauge
49 S011 103 Oil seal installer
49 8010301 Oil seal installer
49 S010 001 Oil seal installer
49 S011 102A Crankshaft lock tool
49 B025 001 Body
49 G033 107A Dust cover installer
49 S120 710 Coupling flange holder
49 P005 204 Oil seal installer
49 H011 101A Crankshaft lock tool
—
LUBRICATION SYSTEM
490187280 Oil pressure gauge
49 G014 001 Oil filter wrench
—
ST-1
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CONTINUED
CONTINUED
SPECIAL TOOLS
COOLING SYSTEM
49 9200 145 Radiator cap tester adapter set
— —
FUEL AND EMISSION CONTROL SYSTEMS
49 8120 215B Pulley puller
49L018901 Injector checker
49H01S9A1A Self-diagnosis checker
49 B019 9A0 System selector
499140074 Cam lift measuring device
49 T088 0A3*1
49 T088 0A5*2 NGS set
Program card
SST No. for Program card varies with language • 49 T088 030E (English & French) • 49 T088 031 E (English & German) • 49 T088 032E (English & Dutch) • 49 T088 033E (English & Swedish) • 49 T088 034C (English & Spanish) • 49 T088 035C (English & Portuguese) • 49 T088 036C (English & Italian)
• 49 T088 037B (English & Danish) • 49 T088 038B (English & Norwegian) • 49 T088 039B (English & Czech) • 49 T088 041 B (English & Greek) • 49 T088 042B (English & Hungarian)
49 T088 043B (English & Polish) • 49 T088 044B (English & Spanish) • 49 T088 045B (English & Portuguese)
*1: Except Europe *2: Europe only
CLUTCH
49 0259 770B Flare nut wrench
49 E011 1A0 Ring gear brake set
49 SE01 310A Clutch disc centering tool
49 1285 071 Needle bearing puller
— —
ST-2
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CONTINUED
SPECIAL TOOLS
PROPELLER SHAFT
49 0259 440 Mainshaft holder
49 S 120 440 Mainshaft holder
—
FRONT AND REAR AXLES
49 T028 3A0 Ball joint puller set
49 T028 303 Body (Part of 49 T028 3A0)
49 T028 304 Attachment (Part of 49 T028 3A0)
49 H033 101 Bearing remover
49 B025 001 Body
49 F019 001 Oil seal installer
49 S231 635 Front hub locknut wrench
49 S231 660 Needle bearing puller
49 S033 108 Bearing installer
49 S033 107 Oil seal installer
49 S033 106 Oil seal installer
49 F027 007 Attachment ∅72
49 F027 005 Attachment ∅62
49 S120 645A Rear shaft holder
49 0603 635A Rear shaft nut wrench
49 S 120 748 Attachment
49 F027 004 Attachment ∅80
49 U027 003 Oil seal installer
ST-3
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CONTINUED
SPECIAL TOOLS 49 H025 001 Bearing installer
49 M005 561 Differential hanger carrier
49 0727 570 Pinion height gauge body
49 8531 565 Drive model pinion
49 0305 555 Gauge block
49 0259 720 Differential side bearing adjust nut wrench
49 0839 425C Bearing puller set
49 F027 005 Attachment ∅62 (Part of 49 F027 0A1)
49 S120 710 Coupling flange holder
49 H027 002 Bearing remover
49 G030 795 Oil seal installer
49 G030 338 Attachment E
49 F401 331 Body (Part of 49 F401 330B)
49 S026 2A1 Rear shaft bearing puller
49 S026 204 Plate (Part of 49 S026 2A1)
49 S026 205 Rod (Part of 49 S026 2A1)
49 S026 208 Attachment (Part of 49 S026 2A1)
49 0710 520 Bearing puller
49 W027 0A0 Oil seal installer set
49 W027 001 Body (Part of 49 W027 0A0)
49 U027 004 Oil seal remover
49 M005 795 Oil seal installer
49 U027 005 Bearing installer
49 U027 006 Bearing installer
ST-4
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SPECIAL TOOLS 49 U027 007 Oil seal installer
49 0813 215A Tubular dowel puller
49 F028 204 Bushing installer
49 M005 796 Body (Part of 49 M005 795)
49 U027 0A0 L.S.D. replacer set
49 UN27 003 Collar A
49 UN27 004 Collar B
49 U027 008 Gauge block
49 F027 009 Attachment ∅68 & ∅77
49 U027 009 Oil seal installer
49 UB71525 Bearing installer
49 U027 010 Bearing installer
49 0107 680A Engine stand
49 U027 011 Shaft (Part of 49 U027 0A0)
49 U027 012 Attachment A (Part of 49 U027 0A0)
49 U027 013 Attachment B (Part of 49 U027 0A0)
49 U027 014 Bolt (Part of 49 U027 0A0)
—
ST-5
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SPECIAL TOOLS STEERING SYSTEM
49 T028 3A0 Ball joint puller set
49 T028 303 Body (Part of 49 T028 3A0)
49 T028 304 Attachment (Part of 49 T028 3A0)
491232670A Power steering gauge set
49 1232 672 Gauge (Part of 49 1232 670A)
49 1232 673 Valve body (Part of 49 1232 670A)
49 H002 671 Adapter
49 0180 510B Preload measuring attachment
49 U032 3A0 Pitman arm puller
49 B032 304 Adapter
491243785A Dust boot installer
49 U034 209 Clip guide
49 U032 201 Locknut wrench
49 G032 354 Adjust wrench
49 G032 3A4 Power steering gauge adapter set
ST-6
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CONTINUED
SPECIAL TOOLS
BRAKING SYSTEM
49 U043 0A0 Oil pressure gauge set
49 U043 004 Oil pressure gauge (Part of 49 U043 0A0)
49 U043 005 Joint (Part of 49 U043 0A0)
49 U043 006 Hose (Part of 49 U043 0A0)
49 0259 770B Flare nut wrench
49 B043 001 Adjust gauge
49 0221 600C Disc brake expand tool
49 E043 003A Turning lock tool
49 0208 701 A Boot air out tool
49 B043 004 Socket wrench
— —
SUSPENSION
49 T028 3A0 Ball joint puller set
49 0180 510B Preload measuring attachment
49 U034 208 Clip guide
49 UB39 615 Bushing puller & installer set
49 U034 2A0 Lower arm bushing puller & installer set
49 U034 209 Clip guide
BODY
49 0305 870A Window tool set
49 0259 866A Window inserting tool
—
ST-7
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SPECIAL TOOLS BODY ELECTRICAL SYSTEM
49 H066 002 Deployment tool
49 D066 002 Adapter harness
49 0839 285 Fuel And Thermometer checker (OLD)
49 N088 0A0 Fuel And Thermometer checker (NEW)
49 D066 801 A Removing tool
49 T088 0A3*1
49 T088 0A5*2 NGS set
Program card
SST No. for Program card varies with language • 49 T088 030E (English & French) • 49 T088 031E (English & German) • 49 T088 032E (English & Dutch) • 49 T088 033E (English & Swedish) • 49 T088 034C (English & Spanish) • 49 T088 035C (English & Portuguese) • 49 T088 036C (English & Italian)
• 49 T088 037B (English & Danish) • 49 T088 038B (English & Norwegian) • 49 T088 039B (English & Czech) • 49 T088 041 B (English & Greek) • 49 T088 042B (English & Hungarian) • 49 T088 043B (English & Polish) • 49 T088 044B (English & Spanish) • 49 T088 045B (English & Portuguese)
*1: Except Europe *2: Europe only
HEATER AND AIR CONDITIONER SYSTEMS
49 C061 0A0A Manifold gauge set (R-134a)
49 C061 012 Anti-back flow valve (R-134a)
49 C061 013 Gas leak tester (R-134a)
49 D066 801A Removing tool
49 H061 005 Attachment
—
ST-8
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